TG PG Test Procedure PDF

Download as pdf or txt
Download as pdf or txt
You are on page 1of 129
At a glance
Powered by AI
The document outlines the test procedure for performance guarantee tests of the turbine cycle and auxiliary power consumption for a 2x600MW power plant. It details objectives, parameters being tested, test setup, instrumentation, data collection and analysis procedures.

The objectives are to carry out performance tests as per contract documents, prove heat rate and output of the turbine cycle, and prove guaranteed auxiliary power consumption and other contractual parameters related to the turbine and its auxiliaries.

The parameters guaranteed under liquidated damages are turbine cycle heat rate at different loads, continuous turbine output, condenser pressure, CW pumping power, and total auxiliary power consumption.

BHEL/ POWER SECTOR-EASTERN REGION(HQ)/TECHNICAL SERVICES

ट�जी और सहायक पॉवर उपभोग हे तु �नष्पाद गारं ट� पर��ण प्र�क


(संशोधन-00)

PERFORMANCE GUARANTEE TEST PROCEDURE


FOR TG CYCLE & AUXILIARY POWER CONSUMPTION
(REV-00)

प�रयोजना नाम: �संगरे नी को�लयर�ज ट� पी एस।

भारत हे वी इलेिक्ट्र �ल�मटे ड प�रयोजना स्था: बी एच ई एल साइट कायार्ल


(भारत सरकार का उपक्) (2X600 मेगावाट), �संगरे नी ट�पीपी, पगडपललट (गांव),
पावर सेक्ट:पूव� �ेत:: कोलकाता जयपुर (मंडल) िजला: अ�दलाबाद, आंध प्रद-504216.

Project name: SINGARENI COLLIERIES TPS


Bharat Heavy Electricals Limited
(A GOVERNMENT OF INDIA UNDERTAKING) Project location: BHEL SITE OFFICE (2X600 MW),
Power Sector: Eastern Region: Kolkata SINGARENI TPP, PEGADAPALLI (VILLAGE), JAIPUR
(MONDAL) DIST. ADILABAD, ANDHRA PRADESH-
504216.

भारत हे वीइलेिक्ट्रकल्स�ल�
पावर सेक्ट:पूव� �ेत, कोलकाता,प्लॉटसंड़ीज- 9/1, सेक्ट-II,
Signature Not Rकरुणामय,
Digitally signed
by PVerified
SEN
सॉल्टलेकसीट,कोलकाता-700 091.रिजकायार ्लयःबीएचईए, �सर�फोटर13:45:26
, नयी�दल्ल-
Date: 2016.08.10
़ IST -110 049
Reason: CAT II
Location:
Bharat Heavy Electricals LimitedNTPCEOC
POWER SECTOR-EASTERN REGION (HQ), DJ-9/1, SECTOR-II KARUNAMAYEE
SALT LAKE CITY, KOLKATA-700091,PHONE: 033 2321 1958.Registered Office: BHEL
House, Siri Fort, New Delhi - 110 049.

STG PG TEST PROCEDURE FOR MAITHON POWER LIMITED 2X525MW MAITHON RIGHT BANK TPP Page 1/41
Comments on the document is attached
please.
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

INDEX 

 
TITLE 
TITLE  PAGE NO 
NO. 
 

1.0  OBJECTIVE   4 

2.0  TEST CODE   6 

      3.0  TEST SCHEMATIC  6 

4.0  SELECTION OF MEASURING INSTRUMENTS   6 

     5.0  ADVANCE PLANNING FOR THE TEST   7 

6.0  PREPARING THE TG CYCLE FOR THE TEST  7‐8 

7.0  PRETEST SHUT DOWN ACTIVITIES BY BHEL  8 

8.0.  INSTALLATION OF TEST INSTRUMENTS  8‐9 

9.0  GENERAL GUIDELINES  9‐10 

10.0  INSTRUMENTS CALIBRATION AND CORRECTION  10 

11.0  ITEMS ESSENTIAL FOR AGREEMENT  10 

12.0  NUMBER OF TEST RUNS  10 

13.0  FREQUENCY OF OBSERVATION  10 

14.0  RECORDING OF READINGS  11 

15.0  DURATION OF TESTS  11 

16.0  ACTIVITIES BEFORE OFFICIAL TEST  11 

17.0  POST TEST ACTIVITIES  12 

18.0  AGEING  12 

19.0  ANNEXURE  ( 1 TO 25 )  13‐129 

3 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

 
1.0 OBJECTIVE  
 
 To carry out the performance guarantee tests in line with the contract document 
 To prove “HEAT RATE” and output of the turbine cycle 
 To prove guaranteed Auxiliary power consumption and other contractual guarantees related to Turbine and 
its auxiliaries. 

2.0 GUARANTEED PARAMETERS UNDER LIQUIDATED DAMAGES (Category‐I) 
 

Sr. no.  Guaranteed Parameters  Guaranteed figures 

(i)  Turbine cycle Heat Rate in Kcal/Kwhr under rated steam conditions at  1927.1 Kcal/Kwhr 


design condenser pressure with zero make up at 600 MW unit load. 
(HBD. NO. PE‐DC‐381‐100‐N151) 
(ii)  Turbine cycle Heat Rate in Kcal/Kwhr under rated steam conditions at   1975.7 Kcal/Kwhr 
design condenser pressure with zero make up at 480 MW unit load. 
(HBD. NO. PE‐DC‐381‐100‐N152) 
(iii)  Continuous TG output of 600 MW under rated steam conditions at  600MW 
worst condenser pressure with 3% make up. 
(HBD. NO. PE‐DC‐381‐100‐N161) 
(iv)  Condenser pressure in mm Hg(abs) measured at300mm above the top  77mmHg(abs) 
row of condenser tubes under VWO condition, 3% make up, design CW  Refer to annexure‐21 
temperature and CW flow. 
(v)  CW pumping power in KW for design CW flow and the pressure drop in 1037 KW (per unit 
CW side by measure bunker for terminal points. (Power consumption  basis) 
shall be computed based on overall efficiency of 83.1 of CW pump and  Refer to annexure‐22 
drive set. 
(vi)  The  total  unit  auxiliary  power  consumption  for  all  the  Turbine  19,659 (Per unit) KW
Generator  Auxiliaries,  steam  generator  auxiliaries,  ESP  and  turbine   
cycle  and  other  common  auxiliaries  required  for  continuous  unit  Refer to annexure‐18  
operation  at  100%  TMCR  (600MW  unit  load)  under  rated  steam 
conditions  at  worst  condenser  pressure  with  3%  make‐up  and  with 
ambient air temperature of  270C and RH of 60% shall be guaranteed. 
(vii)  The  total  unit  auxiliary  power  consumption  for  all  the  Turbine  15,301 (Per Unit) KW
Generator  Auxiliaries,  steam  generator  auxiliaries,  ESP  and  turbine   
cycle equipment and other common auxiliaries required for continuous  Refer to annexure‐18 
unit  operation  at  80  %  TMCR(480MW  unit  load)  under  rated  steam 
conditions  at  worst  condenser  pressure  with  3%  make‐up  and  with 
ambient air temperature of 270C and RH of 60% shall be guaranteed. 
 

2.1 Demonstration parameters / capabilities for Turbine Generator 

Sr. no.  TURBINE GENERATOR SET CAPABILITY Value/Remarks 

(i)  The  steam  turbine  generator  unit  shall  be  capable  of  delivering  the  As per HBD No. PE‐DC‐
output at generator terminals corresponding to VWO condition under  381‐100‐N167 
rated conditions at design condenser pressure 0% make‐up. 
(ii)  The  steam  turbine  generator  unit  shall  be  capable  of  maximum  600 MW 
continuous  output  at  generator  terminals  corresponding  to  all  HP  HBD no. PE‐DC‐381‐100‐
heaters  out  of  operation,  under  rated  steam  conditions  at  a  design  N170 
condenser pressure and 3% make up.  Refer to annexure‐16 
 

4 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

2.2 Demonstration parameters / Turbine Auxiliaries – 

Sr.  STEAM CONDENSING PLANT  Remarks


no. 
1. Life  of  sponge  rubber  balls  and  number  of  balls  lost  during  1000hrs of  plant  Refer to annexure‐23
operation  shall  be  as  indicated:  Life  of  sponge  ball  =  3  Weeks.  Balls  lost  during 
1000 Hrs of plant operation less than or equal to 10% 
Sr.  FEED WATER HEATERS & DEAERATORS Remarks
no.   
1. The Dissolved Oxygen content in feed water at De‐aerator effluent at De‐aerator   Refer to annexure‐19
outlet without chemical dosing at all loads shall not exceed 0.005cc/litre. 
2. Difference  between  the  saturation  temperature  of  the  steam  entering  the  De‐ Refer to annexure‐20
aerator and temperature of the feed water leaving De‐aerator. 
Sr.  Condensate extraction pumps  Remarks
no. 
1.  Each  CEP  set  shall  be  capable  of  delivering  flow  &  total  dynamic  head  Refer to annexure‐24
corresponding to run out point as specified. 

2.  The vibration, noise level and parallel operation of any two of three pumps shall 
be demonstrated. 
Sr.  Boiler feed pumps  Remarks
no.   
1.  Each  BFP  set  shall  be  capable  of  delivery  flow  and  total  dynamic  head  Refer to annexure‐25
corresponding to run out point. 
2.  The vibration level and parallel operation of any two of the three pumps shall be 
demonstrated‐ Noise level‐85 db (With acoustic enclosure) 
3.  Cold/Hot start ups of the unit using TDBFP with motive steam from auxiliary steam 
header. 
Sr.  Noise  Remarks
no. 
1.   
Noise level measurement shall be carried out using applicable and internationally 
 
acceptable  standards.  The  measurement  shall  be  carried  out  with  a  calibrated 
 
integrating Sound level meter meeting the requirement of IEC 651 or BS:5969 or 
 
IS:9779.  The  steam  turbine  generator  unit  shall  perform  continuously  without 
 
exceeding the level of noise 90 db (A) for TG set and 85 db (A) for auxiliaries over 
 
the  entire  range  of  output  and  operating  frequency.  During  HPLP  bypass 
‐‐ 
operation, sound level may go to 110 db (A)for short duration. 
Sound pressure shall be measured all around the equipment at a distance of 1.0m 
horizontally from the nearest Surface of the machine and at a height of 1.5m from 
the floor level in elevation. 
A  minimum  of  6  points  around  each  equipment  shall  be  covered  for 
Measurement.  Additional  measurement  Points  shall  be  considered  based  on  the 
Applicable  standards  and  the  size  of  the  equipment.  The  measurement  shall  be 
done  with  slow  response  on  the  A‐weighting  scale.  The  average  of  A‐weighted 
sound  pressure  level  measurements  expressed  in  decibels  to  a  Reference  of 
0.0002  microbars  shall  not  exceed  the  guaranteed  value.  Corrections  for 
background noise shall be considered in line with the Applicable standards. All the 
necessary  Data  for  determining  these  corrections,  In  line  with  the  applicable 
standards, shall be collected during the tests. 
 

5 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

2.0   TEST CODE 

 Performance guarantee Test for heat rate & output will be carried out in line with contract test code ASME‐PTC‐6. 

3.0 TEST SCHEMATIC 

The approved test scheme titled “PERFORMANCE GUARANTEE TEST INSTRUMENTATAION SCHEME” of Drawing no. 
PG‐DG‐381‐100‐N121 shall be used. Refer Annexure‐11 

 
4.0 SELECTION OF MEASURING INSTRUMENTS 

 The instruments meeting accuracy/uncertainty requirements, as specified in ASME‐PTC‐6shall be selected and shall 
be as per the TG PG test instrumentation schematic drawing no PE‐DG‐381‐100‐N121 Rev04.The brief detail of 
instruments to be used during the PG test is provided in the following table. Refer Annexure‐11 for TG‐PG test 
instrumentation list. 

Sl  Parameter  Range Instruments Accuracy/Uncertain


No  ty 
1  Mass flow  ‐‐ Nozzle/orifice  As per Performance 
supplied byBHEL  test code 

2  Differential pressure across the  Various ranges upto  DP Transmitter Accuracy +/‐ 0.05 % 


flow orifice/ nozzle.  0‐2.5 Kg/cm2  or better. 
3  Pressure  various  ranges  up  to  Pressure  Accuracy  +/‐ 0.1 %
0‐250 kg/cm2    transmitters 
4  Temperature   0‐350 0 C  Platinum resistance  Uncertainty ±0.55 0C
thermometer  

5  Temperature  0‐650 0 C K type  Uncertainty ±0.55 0C


thermocouple  
6  Generator power  ‐‐ Digital power  Uncertainty +/‐ 0.1 %
Analyser 
7  Auxiliary power measurement  0‐1A Power transducer Uncertainty +/‐ 0.1 %
0‐125V 
0‐190.5W 
8  LT  drives  power  consumption  0‐440 Volt Digital‐Multimeter Accuracy 1% 
(voltage), Clamp‐on 
measurement  0‐400 A 
meter(Amp) & Power 
factor meter (pf)/three 
phase power tong 
tester.
8  Secondary measurement for  ‐‐ Data logger Accuracy +/‐ 0.03 %
Voltage (PT, DPT, TC & Power 
Transducer), Resistance (RTD). 

9  Atmospheric pressure  0‐780mmHG Barometer or abs   Accuracy +/‐ 0.1 % or 


pressure  better 
transmitter  
10  Ambient temp.  0‐350degC RTD connected to  Uncertainty ±0.55 0C
data‐logger 

 
 
 
 
 

6 of 129
                                                                                                                                                           
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

5.0   ADVANCE PLANNING FOR THE TEST  
 
        During  the  commissioning/erection  period  of  the  unit  every  effort  shall  be  made  to  ensure  the  provision  of  all 
test‐tapping points as per test scheme.  
        Any missing tapping points or practical difficulty to make availability of tapping points and point of measurement  
due to unavoidable reasons will be mutually discussed between BHEL and Customer at site and agreed upon  prior  
to start of final test . Effort had been made to keep PG test tapings points separate from the normal operational 
measurement  points,  however  in  case  of  practical  difficulties  and  extreme  emergency,  things  will  be  discussed 
with customer and agreed upon for taking measurement through existing operational points at the time of test.  
5.1  All  tapping  points  will  be  checked  by  BHEL  during  commissioning  stage  that  no  pipeline  or  installation  etc. 
interferes with approach to the tapping points as far as possible. The temperature elements are of 300‐400 mm 
length  and  enough  space  should  be  made  available,  so  that  the  test  temperature  elements  can  be  inserted 
without any difficulty. In case of any obstruction, an alternate/operational test stub is to be used as far as possible. 

 5.2  Welded type thermo‐wells shall be used by BHEL for all critical lines (High temperature / pressure). These thermo‐
wells will remain permanently installed on the pipelines. Screwed type thermo‐wells (Low pressure / temperature) 
shall  be  used  for  temperature  measurement  and  may  be  installed  in  the  unit  just  prior  to  the  test.  For  these 
thermo‐wells, matching stub with suitable plug will be provided in the erection stage itself.  

5.3  All  pressure  tapping  are  supplied  with  single  or  double  root  valves  depending  upon  the  pressure  rating  of  the 
pipelines. In case some of the pressure tapings are found not available, the same will be provided or alternatively. 
Either  a  'T‐off  shall  be  taken  from  the  process  tapping  point  or  process  point  itself  shall  be  used  after  mutual 
agreement. Impulse pipe of suitable size and strength shall be laid during pre‐test preparation stage. The pressure 
lines will be rigid enough to withstand any type of vibrations. 

5.4   Test CTs and PTs of 0.2 accuracy class are to be provided by the BUS duct supplier. The installation and/or test 
data for ratio and phase angle errors at different VA burdens and power factors shall be provided by the Customer 
for  accurate  power  calculations.  Additionally,  test certificates giving  the  above  information  as  submitted  by  the 
Generator bus duct supplier shall also be arranged for BHEL use. 

5.5  CT terminals should be provided with termination arrangement for shorting/opening links. Effects of connecting 
leads  shall  be  neutralised  in  power  calculations  by  measuring  voltage  drop  across  Pt  terminals  in  bus  duct  and 
measuring point. 

6.0      PREPARING THE TG CYCLE FOR THE TEST   

 Efforts are to be made by BHEL to ensure that all the TG systems /equipment are brought into service at the time 
of trial operation. The unit readiness for conducting the PG test is to be ensured as per the checklist given below. 

6.1  Ensure that all the heaters are in normal operation and drips of these heaters are cascading properly as per the   
cycle. It is to be checked that there is no bypassing of the drips either to condenser or to de‐aerator and this is to 
be ensured for sufficient time before actual commencement of the test.  

6.3 Check that there should not be any tube leakage in the heaters. 

6.3  If required, ensure the cleanliness of condenser tubes and get the same cleaned, if called for, during the shutdown 
prior to the test. 

6.4 Ensure that pressures of main steam, CRH, HRH and extractions to various heaters and condenser back pressure for 
full  load  are  near  to  their  expected  values.  Ensure  that  all  test  flow  elements  are  available  at  site  with  all  their 
matching flanges and fasteners. 
 
6.5 Ensure that the pressure drop of cooling water across the inlet and outlet of the condenser is within design figure 
and there is no tube leakage in condenser. Conductivity and oxygen content at condenser hot‐well should also be 
within the prescribed limit. 
 

6.6 Ensure that requisite tapings are available in flow element to be used for condensate flow measurement. 
 

7 of 129
                                                                                                                                                           
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

 
6.7  Ensure  the  cleanliness  of  the  E.S.V  strainers.  In  case  of  the  excessive  pressure  drop  across  it,  the  same  shall  be 
cleaned. 
 
6.8 System tightness check to be carried out during commissioning of the machine i.e. de‐aerator level drop 
test  may  be  done  for  around    two  hours  by  keeping  the  interconnection  with  other  units  (if  any)  on 
steam and feed side  isolated and also by closing the make‐up inlet and by keeping the CBD, EBD isolated. 
The de‐aerator level is to be raised to the maximum permissible before this exercise. Fall in de‐aerator 
level i.e. system losses are then to be observed. The problem, if any, is to be identified and rectified and 
the  efforts  shall  be  made  to  bring  down  the  system  leakages  to  minimum.  (Ref  drawing/  calculation 
procedure for de‐aerator level drop, which is enclosed).
When the system is properly isolated for a performance test, the unaccounted leakage shall not exceed 
0.1% of design throttle flow at full load. To achieve the above value of unaccounted leakages, BHEL shall 
prepare  the  unit  during  pre‐test  available  shutdown.  However,  during  the  test,  if  it  is  found  that  the 
unaccounted  leakage  is  more  than  0.1%  of  design  throttle  flow  at  that  load,  the  heat  rate  will  be 
increased by an amount equal to half the difference between actual unaccounted for leakage expressed 
as  percentage    of  design  throttle  flow  at  that  load  and  0.1%  (allowed  by  the  code).  However,  if  the 
unaccounted  leakage  during  the  test  shall  be  more  than  0.5%  of  design  throttle  flow  at  that  load  and 
appreciable leakage is visible in boiler area, mutual agreement shall be made regarding consideration of 
excess leakage in the calculation of test result. 
 
6.9 Ensure the proper tightness of the valves for passing etc. 
 
6.10 Ensure the best availability of all test tapings points as per test scheme. 
 

7.0      PRE‐TEST SHUTDOWN ACTIVITIES BY BHEL 

             After  the  unit  is  ensured  ready  for  the  test,  a  suitable  shutdown  shall  have  to  be  agreed  between  BHEL  and   
Customer. BHEL shall supply the calibrated test instruments prior to the start of the shutdown. Major activities to 
be carried out during this shut down shall be as follows. 

7.1  Mounting/Installing screwed type thermo‐wells, provision for 'T'‐offs, laying‐out of impulse pipelines etc. 

7.2  Providing any additional test tapping points if found necessary/applicable. 

7.3  Necessary  arrangement/rectifications  for  meeting  the  system  isolation  i.e  required  defective/passing  valves 
identified during the joint inspection to be attended.  

7.4   Mounting of temperature elements in identified hot areas and laying‐out their cables. 

7.5  Laying‐out impulse pipeline (if not already laid) from the root valves in hot zones and terminating with pressure 
transmitter isolating valves. Their root valves to be kept open. 

7.6   If required, Condenser tube cleaning and condenser air tightness checks to be carried out   and any leakages to be 
got attended. 

8.0      INSTALLATION OF TEST INSTRUMENTS  

8.1      Flow measuring devices 

             The flow assembly with matching flanges is supplied during commissioning stage. Flow measuring devices is to be 
mounted by replacing the spool piece provided in condensate line preferably during the planned shutdown for PG 
test so that these are used for minimum duration prior to the test. However the actual mounting may vary from 
site to site as per availability of material. The actual drawing with calibration certificate will be furnished before 
PG test. A typical installation sketch for DP transmitters for measuring assemblies is enclosed. Installation sketch 
of  flow  assembly  as  per  requirement  shall  be  arranged  by  BHEL  prior  to  pre‐test  shutdown.  It  is  preferable  to 
check the impulse pipeline connections after installation for  any leakage/chocking etc. by pressurizing the system 

8 of 129
                                                                                                                                                           
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

by running condensate pump to the extent possible during the unit shutdown itself. Problem noticed if any has to 
be attended during the shutdown itself. 

8.2      Temperature measuring instruments 

              K‐Type  Thermocouple  and  platinum  resistance  thermometer  elements  will  be  used  for  temperature 
measurements. After connecting extension leads (Chromel‐Alumal compensating cable for TCs and copper cable 
for  PRTs),  these  elements  shall  be  mounted  into  thermo‐wells  as  per  instrument  allocation  list  and  PG  test 
scheme. The connection to measuring instruments to be made as per the sketch enclosed. Thermocouple wire is 
to  be  connected  such  that  Chromel  portion  of  the  extension  lead  is  connected  to  Chromel  part  and  Alumel 
portion to Alumel part of the sensor. To identify this, a positive sign has been marked on each Chromel terminal. 
The  reference  junction  temperature  for  thermocouples  will  be  maintained  at  zero  degree  by  using  ice  box  or 
through  electronic  zero  degree  reference  junction  compensator.  The  mV  output  from  the  thermocouples  and 
Ohms output from PRTs shall be measured with precision data logger. 

8.3  Pressure measuring instruments  

             Impulse  pipelines  (of  appropriate  length)  with  isolation  valves  are  to  be  laid  for  mounting  the  pressure 
transmitters. Impulse pipeline for the vacuum (negative pressure) measurement points should be laid such that 
transmitter  is  mounted  above  the  tapping  point.  Thus  these  lines  should  be  laid  with  upward  slope.  All  the 
impulse lines should be rigid enough to avoid any vibration in the instrument. For water height correction, the 
vertical distance from the centre of the transmitter to the tapping points is to be measured for each tag number 
and joint protocol by BHEL and Customer to be signed prior to test. The vertical distance above the tapping point 
is to be taken as positive whereas same below the tapping is to be taken as negative for pressure correction. The 
impulse pipelines are to be purged/ flushed sufficiently and steam to be allowed to condense before mounting 
the  transmitters.  A  transmitter  will  be  charged  only  before  use  otherwise  it  should  be  kept  isolated  to  avoid 
exposure to vacuum in case the unit trips.  

8.4  Power measuring Instruments  

           CTs and PTs for PG test use should be identified well in advance and locations of their terminals in panels checked 
for the connection of the power meters referring the generator schematic drawings. The lead resistance voltage 
drop  in  the  circuit  of  PTs  shall  be  measured  if  required  along  with  customer  and  protocol  for  the  same  to  be 
made  during  the  PG  test.  The  digital  power  meter  will  be  connected  to  the  identified  CTs  and  PTs  terminals 
preferably in three‐phase four‐wire mode.  

 8.5      Level measurement  

            Level  measurement  in  5  minutes  of  interval  are  to  be  recorded  for    all  the  storage  tanks    by  means  of  digital 
recording system (MAX /DAS panel) available at site with metric scales.  A sample data sheet for readings to be 
recorded is enclosed herewith.  

8.6     Secondary measurement by data acquisition system 

            Data  acquisition  system  is  based  on  a  digital  processor.  It  is  interfaced  with  computer  that  utilizes  software  to 
activate the logger to view and analyse the collected data. Data acquisition system consists of many components 
that are integrated to sense electrical parameter sent by the transducers (RTD, TC, Pressure transmitter & Power 
transducer) mounted in the field.  
 
9.0       GENERAL GUIDELINES 

9.1  All  electrical  instruments  should  be  placed  away  from  any  magnetic  field.  Their  proper  levelling  should  also  be 
ensured.  

9.2         The  tips  of  thermocouples  and  PRTs should  always touch  the bottom  of  the  thermo  wells.  If  felt  necessary, the 
adjustable mounting coupling can be removed and in that case the element should be properly pressed downward 
and tied with a piece of wire. Stub projections and sensor stems, which are protruding out of thermo‐well, should 
be covered with asbestos rope providing thermal insulation. 

9.3     All the instruments should be stored in clean dry place nearer to unit under test preferably at turbine floor level. 

9 of 129
                                                                                                                                                           
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

9.4     At least two tags (including Tag No./service etc.) should be provided each at the instrument end near tapping points 
and Data‐logger end.          
9.5   All the pressure transmitters should be mounted in vertical position. 
9.6   Depending  upon  the  likelihood  of  completion  of  the  above  activities,  date  of  conductance  of  final  test  will  be 
jointly agreed with the customer under mutually agreed deviations, if any. 
 

10.0     INSTRUMENTS CALIBRATION AND CORRECTION  
10.1   All the test instruments and other applicable instruments shall be duly calibrated at NABL accredited BICC (BHEL 
Instruments Calibration  Centre)  at Noida  or  any  other  NABL  accredited  lab. Calibration  of  Pressure  transmitters, 
RTD, TC sensors may also be carried out at site/HQ by BHEL engineer/NABL agency before conductance of the test 
in  presence  of  customer  representative  (if  felt  necessary).  In  general  the  validity  of  calibration  for  all  PG  Test 
sensors (RTD, TC, PT, Transducer & Power meter) will be of two years from the date of calibration. 

 10.2    All Copy of valid calibration certificate (on the day of installation) will be handed over to customer suitably before 
the start of test. 

10.3   Pressure transmitters' readings shall be additionally corrected for water column height corrections by measuring 
the difference in levels between centre of the transmitter and the corresponding tapping point‐(Height correction).  

Note: Calibration validity for all the PG test instruments will be ensured on the day of installation for conductance of TG 
cycle PG test. 

11.0    ITEMS ESSENTIAL FOR AGREEMENT  

11.1   Nomination of test coordinating Engineer from customer side. 

11.2   All the test instruments shall be transported to site as per the proposed date.  

11.3   Means for obtaining steady operating parameters at their specified values. 

11.4   Provision of a separate room of adequate size on the turbine floor for storing the test instruments and materials 
for use during the test under lock and key shall be in the scope of the customer. 

11.5    Deployment of round the clock proper security personnel from the time of installation of sensors till removal of all 
equipment/sensors, if not in the scope of BHEL. 

11.6   Provision of illumination by Customer at all measuring junctions and working places. 

11.7    Provision of T&P by Customer like UPS power supply of 15 Ampere to at‐least five locations under TG area for Data‐
loggers station, Compressed air etc. 

12.0    NUMBER OF TEST RUNS  
 
In addition to trial run and Preliminary test, Duplicate heat rate tests will be performed at 600MW and 480 MW unit 
loads to prove the heat rate. The test result of the duplicate test runs shall agree within +/‐ 0.25%. If they differ more 
than 0.25%, a third test shall be run at the same test points. Corrected results of any one of the three tests runs, which 
deviate from the corrected average heat rate of all the three by more than 0.25%, shall be eliminated. Otherwise, the 
results of all the three test runs shall be acceptable. 
 
Further one test shall be carried out to prove unit output and condenser back pressure/CW pumping power at VWO 
condition as stipulated under category‐1 and demonstration tests category. 
 
13.0   FREQUENCY OF OBSERVATION 
 
It will be carried out meeting the requirements of clause no. 3.9.1, ASME PTC‐6 which is as follows: 
 

For  Heat  rate  tests  and  Output  Tests,  the  readings  for  pressures,  flows,  temperatures  and  Generator  Power  shall  be 
recorded  in  the  data‐logger  at  an  interval  of  minimum  30  seconds.  In  case,  Digital  power  meter  for  measurement  of 
Generator Power not hooked up with Data‐logger, measurement shall be recorded with the help of manual reading of the 
Digital Power meter at an interval of one minute. Other parameters at the interval of 5 minutes shall be taken either from 
DCS or by manual recording. 

10 of 129
                                                                                                                                                           
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

 
            14.0   RECORDING OF READINGS 
 
14.1    Data  logger  will  be used  to  record  the  test  readings  at  an  interval  of  minimum 30  seconds  in raw  values  for  the            
following: 
 
 Sl.  Parameter Unit   
No. 
1  Pressure /DP transmitter output Volt   
2  PRT output   Ohms
3  TC output  mV  
4  Power transducer output  Volt 
5  Power meter output  Watt  

14.2   Recording will be done for every 5 Minute during the test through MAX/DAS system or manually for the following 
data    

A   De‐aerator level                                       mm 
B   Hot‐well level                                            mm   
C   CST Level                                                    mm 
D   Boiler drum level                                      mm 
E   Generator Hydrogen Pressure          ata 
F   Frequency                            Hz 
 
15.0   DURATION OF TESTS 
 
As  per  ASME  PTC‐6,  Tests  shall  be  normally  carried  out  at  a  steady  state  run  of  two  our  duration.  However, 
duration will be mutually decided depending upon the conditions prevailing during conductance of PG tests.Any 
deviations  of  parameters  from  the  rated  conditions  shall  be  corrected  with  the  help  of  correction  curves.  The 
applicable correction curves as per the “Method of Computation of Heat Rate” for heat rate correction & Output 
correction are enclosed as per annexure‐14. 
 
16.0 ACTIVITIES BEFORE OFFICIAL TEST  

16.1  The  completion  of  test  preparation,  mounting  of  instruments,  isolation  of  thermal  cycle  and  briefing  of  the  local 
observers.   

16.2   The load is brought to rated capacity with rated parameters for taking a set of trial readings of all instruments. 

16.3   The readings of the mock test to be analysed for their correctness, if they are correct, final test can be started. 

16.4   The following operations shall not take place during the test, for which the isolation is carried out.  

 Continuous Blow Down  
 Dusting of the Associated Boiler Unit  
 Steam Supply to Fuel atomisation, if any 
 Fuel Heating and SCAPH, if any 
 Soot blowing 
 Water and steam sampling 
 Any other flow from the system which affects the Heat Rate 
 
 
  16.5  The system is isolated so that no unaccounted steam goes out or comes into cycle. The makeup quantity shall be 
measured / estimated by noting down the level drop in de‐aerator/hot‐well and also taking into consideration the 
various storage tanks' levels at periodic intervals of the test. 
 
  16.6   Any  other  unaccounted  losses  like  high  gland  leakage  from  CEP,  if  exists,  shall  be  measured/estimated  for  their 
quantity. 
 
  16.7 Sensitivity of the condenser hot well level control shall be reduced or preferably the level controlled be on manual 
mode to avoid excessive fluctuation in the condensate flow to de‐aerator.   

11 of 129
                                                                                                                                                           
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

 
  16.8   PRDS  control  valve  spindle  cooling  water,  atmospheric  valve  gland  sealing  water  flow  shall  be  adjusted  for 
minimum flow.  
 
  16.9    Proper sealing water supply to vacuum system especially to atmospheric valve seals shall be ensured. 
 
  16.10   All means shall be put to maintain the parameters constant through out the test.  

17.0    POST TEST ACTIVITIES  
 
17.1  All  the  test  readings  of  average  value  shall  be  jointly  signed  &  one  copy  will  be  handed  over  to 
site/customer/consultant  after  completion  of  all  tests.  One  set  of  average  readings  signed  by  customer  shall  be 
retained by BHEL for calculation of test results and submission of test reports. 
 
17.2    A shut down of the unit is to be arranged for a minimum period of 5 days for dismantling of all the test instruments 
and flow measuring assemblies, if called for.  
 
18.0    AGEING 
 
Ageing  allowance  will  be  given  during  evaluation  of  PG  test  results  and  hence  guaranteed  heat  rates  shall  be 
increased by the amount calculated as per the formula given in cl. No. 3.07, sub‐sesction‐3 of ASME‐PTC‐6 report 
1985  (Reaffirmed  1991).  Period  of  ageing  shall  be  considered  from  the  date  of  successful  completion  of  initial 
operation to the date of conductance of PG test, irrespective of the reasons for delay in conducting the PG test 
attributable to employer or contractor. 
In calculating the above factor any period(s) during which the turbine has not been in operation at a stretch for 
more than a week shall not be considered. 
 

********************************************** 

12 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

19.0  Annexure:  
 
 List of Annexure 
ANNEX. 
TITLE  Page no 
NO 
1  Details of welded type test thermo‐well pocket (with plug)  14 
2  Details of screwed type test thermo‐well  15 
3  Details of pressure stub  16 
4  Diagram for connection between pressure source and transmitter  17 
5  Diagram for connection between vacuum source and transmitter  18 
Diagram for connection between flow orifice to differential 
6  19 
pressure transmitter 
7  Temperature measurement lay out scheme for RTD  20 
8  Temperature measurement lay out scheme for T/C  21 
9  Pressure measurement lay out scheme for PT   22 
Typical connections for measuring Electrical power output by the 
10  three wattmeter method  23 

11  PG test instrumentation scheme & list  24‐33 


12  Computation procedure for De‐aerator level drop  34 
13  Computation procedure for hot well level drop  35 
14  Method for computation of heat rate  36‐47 
15  Correction curves   48‐70 
16  Heat balance diagram  71‐76 
17  System check list  77 
18  Auxiliary power consumption test procedure  78‐80 

19  DISSOLVED OXYGEN CONTENT AT DEAERATOR OUTLE  81 


DIFFERENCE BETWEEN THE SATURATION TEMPERATURE OF THE 
20  STEAM ENTERING THE DE‐AERATOR AND  82 
THE TEMPERARTURE OF THE FEED WATER LEAVING DE AERATO
21  Condenser Back Pressure test procedure  83‐99 
22  TEST PROCEDURE FOR CW PUMPING POWER  100‐105 
TEST PROCEDURE FOR CONDENSER ON LOAD TUBE CLEANING 
23  106‐110 
SYSTEM 

24  PG TEST PROCEDURE FOR CONDENSATE EXTRACTION PUMP  111‐118 

25  PG TEST PROCEDURE FOR BOILER  FEED  PUMP  119‐129 

13 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

  ANNEXURE –1 

 
 Details of welded type test thermo‐well pocket (with plug): 
 

1. M‐type of stub and thermowell to be used for main steam, CRH,HRH, bled steam (To HPH‐5 & DEA) 
feed water lines, HPH drains, HPT rear (1st leak  off) HPT front (2nd leak off), IPT front (1st leak off). 
2. N‐type of stub to be used on condensate, cooling water and law pressure/temp steam pipe lines 
(Bled steam to LPHs, Ejectors, GSC, LPH drain lines, IP rear leak off, mixture of leak offs to EXT‐4, 
cross over pipe lines, exhaust hood, BFP suction line, sealing steam to glands. ) 
3. M‐type of stub to be provided with welded thermowell . 
4. ‘X’ to be fixed based on pipe wall thickness. 

14 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

ANNEXURE – 2 
 
 
 
 Details of screwed type test thermo‐well: 
 

PIPE DIA ‘U’

100‐180 120
180‐260 160
260‐360 200
360‐500 250
Above 500 320

Working Pressure 180 Kg/cm2 
Working  550 Deg C 
Temperature 
Test Pressure 360 Kg/cm2 
 

Note: 

1. All dimensions are in MM. 
2. Material AISI 316 SS. 
3. ‘U’ to be decided based on Pipe Diameter. 
4. To be I.B.R. Approved. 
5. Each thermowell to be provided with 2MM TH. Annealed copper washer & 
M20X1.5 Carbon steel Bolt. 

15 of 129
                                                                                                                                                            
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

ANNEX
XURE – 3

 
 
 
 Deetails of prressure stub:  

 
Note: 
 
1. This stub is to
o be used for a
all the pressu re test tappin
ng coming und
der performannce test schem
me. 
2. For pressure above 40ata, two root valvve to be used.
3. For pressure below 40ata, one root valvve to be used.
4. Impulse pipe material same or equivalenntas the stub material. 
 
 
 
 
 
 

16 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

ANNEXURE – 4 
 
 
 Diagram for connection between pressure source and transmitter: 
 

  Note: 

  I.
II.
Gauge may be above, below or level with pressure tap. 
Gauge must not be subjected to vacuum. 
III. Shut valve immediately if turbine is tripped out or before shut down. 
IV. Impulse/Connecting pipe shall not be less than 3/8 inch (10mm) inside diameter and ½ inch 
(13mm) nominal outside diameter or equivalent tubing. 
V. For pressure greater than 40kg/cm2 use 3mm wall thick impulse pipe. 
VI. For pressure less than 40kg/cm2 use 2.5mm wall thick impulse pipe.  

17 of 129
                                                                                                                                                            
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

ANNEX
XURE – 5

 

 Diagrram for co
onnection
n between
n vacuum source an
nd transm
mitter: 
 
 

18 of 129
                                                                                                                                                            
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

 
ANNE
EXURE–6

 
 
 Diaagram  fo
or  connecction  bettween  flo
ow  orificce  to  diffferential  pressure

traansmitter 
 
 
ASME P
PTC 6  
 
 

 
 
 
 
 
 
 
 
 
 
 
 
 

19 of 129
                                                                                                                                                            
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

 
ANNE
EXURE–7

 
 
 
 Temperaturre measurrement layy out sche
eme for RT
TD 
 

20 of 129
                                                                                                                                                            
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

ANNEXURE –8

                                                                                                                                       

 Tem
mperature
e measure
ement lay  out schem
me for T/C

 
 

21 of 129
                                                                                                                                                            
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

ANNEXURE –9

 
 
 
 
 Presssure meassurement lay out sccheme forr PT 
 

22 of 129
                                                                                                                                                            
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

ANNEXURE 10

 
 
 Typiccal connecctions for measurin
ng Electriccal power output byy the thre
ee 
wattmmeter me ethod 
 

 
 

23 of 129
                                                                                                                                                            
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

 
ANN
NEXURE – 11
  PG test instru
umenta
ation sch
heme 
 

 
Instrum
mentatiion list ffor 2X60
00MW Singareeni TPS 
 

   
 

24 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

25 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

TG PG test instrumentation list for 2x600MW Singareni TPS 

TEMPERATURE MEASUREMENT  
*APPROXIMATE 
 
S. No  Tag No  Service  VALUES AT 100% 
Inst. 
LOAD (In deg c) 
1  TW01  SH Spray Comm. Header   T/C   ‐  
2  TW02   SH Spray Comm. Header   T/C  ‐  
3  TW03   HPT inlet bef. Strainer (L)  T/C   537 
4  TW04   HPT inlet bef. Strainer (L)  T/C  537 
5  TW05   HPT inlet bef. Strainer (R)   T/C   537 
6  TW06   HPT inlet bef. Strainer (R)   T/C  537 
7  TW07   Extraction 7 to HPH 7 (TE)  T/C  391.3 
8  TW08   Extraction 7 to HPH 7 (TE)  T/C  391.3 
9  TW09   Extraction 7 to HPH 7A (HE)  T/C  389.1 
10  TW10   Extraction 7 to HPH 7A (HE)  T/C  389.1 
11  TW11   Extraction 7 to HPH 7B (HE)  T/C  389.1 
12  TW12   Extraction 7 to HPH 7B (HE)  T/C  389.1 
13  TW13   HPT Exhaust steam   PRT  332.7 
14  TW14   HPT Exhaust steam   PRT  332.7 
15  TW15   CRH steam after HPBP  PRT  332.7 
16  TW16   CRH steam after HPBP  PRT  332.7 
17  TW17   CRH Before spray (L)  PRT  332.7 
18  TW18   CRH Before spray (R)  PRT  332.7 
19  TW19   Downstream of HPBP  T/C   ‐  
20  TW20   Downstream of HPBP  T/C  ‐  
21  TW21   Extraction 6 to HPH 6A (HE)  PRT  330.6 
22  TW22   Extraction 6 to HPH 6A (HE)  PRT  330.6 
23  TW23   Extraction 6 to HPH 6B (HE)  PRT  330.6 
24  TW24   Extraction 6 to HPH 6B (HE)  PRT  330.6 
25  TW25   Steam to PRDS hdr.  T/C  ‐ 
26  TW26   Steam to PRDS hdr.  T/C  ‐ 
27  TW27   HRH bef. Strainer (L)  T/C   565.0 
28  TW28   HRH bef. Strainer (L)  T/C  565.0 
29  TW29   HRH bef. Strainer (R)  T/C   565.0 
30  TW30   HRH bef. Strainer (R)  T/C  565.0 
31  TW31   Extraction 5 to HPH 5 (TE)  T/C   463.4 
32  TW32   Extraction 5 to HPH 5(TE)  T/C  463.4 
33  TW33   Extraction 5 to HPH 5A (HE)  T/C   462.9 
34  TW34   Extraction 5 to HPH 5A (HE)  T/C  462.9 
35  TW35   Extraction 5 to HPH 5B (HE)  T/C  462.9 
36  TW36   Extraction 5 to HPH 5B (HE)  T/C  462.9 
37  TW37   IPT Exhaust steam (L)  PRT   328.2 
38  TW38   IPT Exhaust steam (L)  PRT  328.2 
39  TW39   IPT Exhaust steam (R)  PRT  328.2 
40  TW40   IPT Exhaust steam (R)  PRT  328.2 
41  TW41   LPT I/L steam common header (R)  PRT  328.2 
42  TW42   LPT I/L steam common header (R)  PRT  328.2 
43  TW43  LPT I/L steam common header (L)  PRT  328.2 
0
* APPROXIMATE VALUES AT 100% LOAD (In  C) ARE GIVEN FOR REFERENCE ONLY. 

26 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

TG PG test instrumentation list for 2x600MW Singareni TPS 

TEMPERATURE MEASUREMENT  
*APPROXIMATE 
Sl. 
Tag No  Service  Inst.  VALUES AT 100% 
No 
LOAD (In deg c) 
44  TW44  LPT I/L steam common header (L)  PRT  328.2 
45  TW45   Extrn.4 to Deaerator (TE) PRT  328.2
46  TW46   Extrn.4 to Deaerator (DE) PRT  327.5
47  TW47   Extrn.4 to Deaerator (DE) PRT  327.5
48  TW48   TDBFP‐A steam inlet PRT  327.2
49  TW49   TDBFP‐B steam inlet PRT  327.2
50  TW50   FW BFP A discharge PRT  167.3
51  TW51  FW BFP B discharge PRT  167.3
52  TW52   RH spray comm. Header PRT  ‐ 
53  TW53   RH spray comm. Header PRT ‐ 
54  TW54   FW inlet to HPH 5A PRT 167.3
55  TW55   FW inlet to HPH 5A PRT 167.3
56  TW56   FW inlet to HPH 5B PRT 167.3
57  TW57   FW inlet to HPH 5B PRT 167.3
58  TW58   FW HPH 5A outlet  PRT 207.5
59  TW59   FW HPH 5A outlet  PRT 207.5
60  TW60   FW HPH 5B outlet  PRT 207.5
61  TW61   FW HPH 5B outlet  PRT 207.5
62  TW62   FW HPH 6A inlet  PRT  207.5
63  TW63   FW HPH 6A inlet  PRT  207.5
64  TW64   FW HPH 6B inlet  PRT  207.5
65  TW65   FW HPH 6B inlet  PRT  207.5
66  TW66   FW HPH 6A outlet  PRT  250.8
67  TW67   FW HPH 6A outlet  PRT  250.8
68  TW68   FW HPH 6B outlet  PRT  250.8
69  TW69   FW HPH 6B outlet  PRT  250.8
70  TW70   FW HPH 7A inlet  PRT  250.8
71    TW71 '   FW HPH 7A inlet  PRT  250.8
72  TW72   FW HPH 7B inlet  PRT  250.8
73  TW73   FW HPH 7B inlet  PRT  250.8
74  TW74   FW HPH 7A outlet  PRT  278.0
75  TW75  FW HPH 7A outlet  PRT  278.0
76  TW76  FW HPH 7B outlet  PRT  278.0
77  TW77  FW HPH 7B outlet  PRT  278.0
78  TW78  FW before economiser PRT  278.0
79  TW79  FW before economiser PRT  278.0
80  TW80  HPH 7A Drain to HPH 6A PRT  255.6
81  TW81  HPH 7A Drain to HPH 6A PRT  255.6
82  TW82  HPH 7B Drain to HPH 6B PRT  255.6
83  TW83  HPH 7B Drain to HPH 6B PRT  255.6
84  TW84  HPH 6A Drain to HPH 5A PRT  212.3
85  TW85  HPH 6A Drain to HPH 5A PRT  212.3
86  TW86  HPH 6B Drain to HPH 5B  PRT  212.3
87  TW87  HPH 6B Drain to HPH 5B PRT  212.3
88  TW88  HPH 5A drain to DEA (HE)  PRT  172.2
89  TW89  HPH 5A drain to DEA (HE)  PRT  172.2
90  TW90  HPH 5B drain to DEA (HE)  PRT  172.2
91  TW91  HPH 5B drain to DEA (HE)  PRT  172.2
92  TW92  CRH bef. Mixing to Extraction 4 PRT 332.7
93  TW93  CRH after spray (R) PRT  ‐ 
94  TW94  CRH after spray (R) PRT  ‐ 
95  TW95  CRH after spray (L) PRT  ‐ 
* APPROXIMATE VALUES AT 100% LOAD (In 0C) ARE GIVEN FOR REFERENCE ONLY. 

27 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

TG PG test instrumentation list for 2x600MW Singareni TPS 

TEMPERATURE MEASUREMENT  
*APPROXIMATE 
Sl. 
Tag No  Service  Inst.  VALUES AT 100% 
No 
LOAD (In deg c) 
96  TW96  CRH after spray (L) PRT  ‐ 
97  TW97  TDBFP A exhaust steam to condenser‐A PRT  0.9635
98  TW98  TDBFP B exhaust steam to condenser‐B PRT  0.9635
99  TW99  TDBFP‐B steam inlet PRT  327.2
100  TW100  TDBFP‐B steam inlet PRT  327.2
101  TW101  TDBFP‐A steam inlet PRT  327.2
102  TW102  TDBFP‐A steam inlet PRT  327.2
103  TP01   CEP inlet from condenser‐A hot‐well PRT  46.4
104  TP02   CEP inlet from condenser‐A hot‐well PRT  46.4
105  TP03   CEP inlet from condenser‐B hot‐well PRT  46.4
106  TP04   CEP inlet from condenser‐B hot‐well PRT  46.4
107  TP05   GSC drain to Flash Tank PRT  ‐ 
108  TP06   Main condensate inlet GSC  PRT  46.6
109  TP07   Main condensate outlet. GSC  PRT  47 
110  TP08   Gland steam to GSC  PRT  ‐ 
111  TP09   Main condensate inlet DC  PRT  47 
112  TP10   Main condensate inlet DC  PRT  47 
113  TP11  Main condensate inlet LPH 1A PRT 49.9
114  TP12  Main condensate outlet LPH 1A PRT  71.6
115  TP13  Main condensate outlet LPH 1B PRT  71.6
116  TP14  Main cond. O/L LPH1A&B common header PRT  71.6
117  TP15  Main condensate inlet LPH 2 PRT 71.6
118  TP16  Main condensate outlet LPH 2  PRT  94.7 
119  TP17  Main condensate inlet LPH 3  PRT  94.7 
120  TP18  Main condensate outlet LPH 3  PRT   123.6 
121  TP19  Main condensate outlet LPH 3  PRT   123.6 
122  TP20  Main cond. aft LPH3 aft mixing   PRT   123.6 
123  TP21  Main cond. to Dea. after flow element  PRT  123.6 
124  TP22  Main condensate to Dea. After  NRV  PRT  123.6 
125  TP23  Main condensate to Dea. After  NRV  PRT  123.6 
126  TP24  Extraction 3 to LPH 3 (TE) from LPT‐A  PRT  209.2 
127  TP25  Extraction 3 to LPH 3  (HE)  PRT  208.9 
128  TP26  Extraction 3 to LPH 3  (HE)  PRT  208.9 
129  TP27  Extraction 2 to LPH 2 (TE) PRT  118.6 
130  TP28  Extraction 2 to LPH 2  (HE) PRT  118.3 
131  TP29  Extraction 2 to LPH 2  (HE) PRT  118.3 
132  TP30  LPH 3 drain to LPH 2 near LPH3   PRT  99.5 
133  TP31  LPH 2 drain to LPH 1A&B near LPH2   PRT  76.4 
134  TP32  LPH 1A drain to DC   PRT  74.4 
135  TP33  LPH 1B drain to DC   PRT  74.4 
136  TP34  DC drain to CFT   PRT  51.8 
137  TP35  CW inlet to COND‐A  (L)  PRT  ‐ 
138  TP36  CW inlet to COND‐A  (L)  PRT  ‐ 
139  TP37  CW inlet to COND‐A  (R)  PRT  ‐ 
140  TP38  CW inlet to COND‐A  (R)  PRT  ‐ 
141  TP39  CW inlet to COND‐B  (L)  PRT  ‐ 
142  TP40  CW inlet to COND‐B  (L)  PRT  ‐ 
143  TP41  CW inlet to COND‐B  (R)  PRT  ‐ 
144  TP42  CW inlet to COND‐B  (R)  PRT  ‐ 
* APPROXIMATE VALUES AT 100% LOAD (In 0C) ARE GIVEN FOR REFERENCE ONLY. 

28 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

TG PG test instrumentation list for 2x600MW Singareni TPS 

TEMPERATURE MEASUREMENT  
*APPROXIMATE 
Sl. 
Tag No  Service  Inst.  VALUES AT 100% 
No 
LOAD (In deg c) 
145  TP43  CW outletto COND‐A (L)  PRT  ‐ 
146  TP44  CW outlet to COND‐A  (L)  PRT  ‐ 
147  TP45  CW outlet to COND‐A  (L)  PRT  ‐ 
148  TP46  CW outletto COND‐A  (L)  PRT  ‐ 
149  TP47  CW outlet to COND‐A  (L)  PRT  ‐ 
150  TP48  CW outlet to COND‐A  (L)  PRT  ‐ 
151  TP49  CW outlet to COND‐A  (R)  PRT  ‐ 
152  TP50  CW outlet to COND‐A  (R)  PRT  ‐ 
153  TP51  CW outlet to COND‐A  (R)  PRT  ‐ 
154  TP52  CW outlet to COND‐A  (R)  PRT  ‐ 
155  TP53  CW outlet to COND‐A  (R)  PRT  ‐ 
156  TP54  CW outlet to COND‐A  (R)  PRT  ‐ 
157  TP55  CW outletto COND‐B (L)  PRT  ‐ 
158  TP56  CW outlet to COND‐B  (L)  PRT  ‐ 
159  TP57  CW outlet to COND‐B  (L)  PRT  ‐ 
160  TP58  CW outletto COND‐B  (L)  PRT  ‐ 
161  TP59  CW outlet to COND‐B  (L)  PRT  ‐ 
162  TP60  CW outlet to COND‐B  (L)  PRT  ‐ 
163  TP61  CW outlet to COND‐B  (R)  PRT  ‐ 
164  TP62  CW outlet to COND‐B  (R)  PRT  ‐ 
165  TP63  CW outlet to COND‐B  (R)  PRT  ‐ 
166  TP64  CW outlet to COND‐B  (R)  PRT  ‐ 
167  TP65  CW outlet to COND‐B  (R)  PRT  ‐ 
168  TP66  CW outlet to COND‐B  (R)  PRT  ‐ 
169  TP67  Vacuum pump  Suction L of COND‐A    PRT  ‐ 
170  TP68  Vacuum pump  Suction R of COND‐A    PRT  ‐ 
171  TP69  Vacuum pump  Suction L of COND‐B    PRT  ‐ 
172  TP70  Vacuum pump  Suction R of COND‐B    PRT  ‐ 
173  TP71  Vacuum Pump  SucCommhdr of COND‐A    PRT  ‐ 
174  TP72  Vacuum Pump  SucCommhdr of COND‐B    PRT  ‐ 
175  TP73  LPBP to COND‐A    PRT  ‐ 
176  TP74  LPBP to COND‐B  PRT  ‐ 
177  TP75  TDBFP B booster pump suction  PRT  163.8 
178  TP76  TDBFP B booster pump suction  PRT  163.8 
179  TP77  TDBFP A booster pump suction  PRT  163.8 
180  TP78  TDBFP A booster pump suction  PRT  163.8 
181  TP79  Extraction 3 to LPH 3 (TE) from LPT‐B  PRT  209.2 
182  TP80  Extraction 2 to LPH 2 (TE) from LPT‐B  PRT  118.6 
183  TP81  LPH 2 drain to LPH 1A near LPH 1A  PRT  76.4 
184  TP82  LPH 2 drain to LPH 1B near LPH 1B  PRT  76.4 
185  TP83  Main condensate inlet LPH 1B  PRT  49.9 
186  TP84  DC drain to CFT   PRT  51.8 
187  TP85  Main condensate outlet LPH 2  PRT  94.7 
188  TP86  Main condensate inlet LPH 3  PRT  94.7 
189  TP87  LPH 3 drain to LPH 2 near LPH2  PRT  99.5 
190  TP88  Main condensate inlet LPH 2  PRT  71.6 
191  TP89  Main cond. to Dea. after flow element  PRT  123.6 
* APPROXIMATE VALUES AT 100% LOAD (In deg c) ARE GIVEN FOR REFERENCE ONLY. 

29 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

TG PG test instrumentation list for 2x600MW Singareni 1X600 MW TPS 

PRESSURE MEASUREMENT  

* APPROXIMATE 
S. No   Tag No   Service    Range (in kg/cm2)   VALUES AT 100% 
LOAD (in kg/cm2) 
1  PD01   MS to HPT bef. Strainer R   0‐250   170 
2  PD02   MS to HPT bef. Strainer L   0‐250   170 
3  PD03   HPT 1 st stage   0‐250   ‐ 
4  PD04   Extraction 7 to HPH 7 (TE)  0‐100  65.54 
5  PD05   Extraction 7 to HPH 7A (HE)  0‐100  62.59 
6  PD06  Extraction 7 to HPH 7B (HE)  0‐100  62.59 
7  PD07  HPT Exhaust  (TE)  0‐60   43.03 
8  PD08   CRH steam   0‐60   43.03 
9  PD09   CRH before spray L   0‐60   43.03 
10  PD10   CRH before spray R  0‐60   43.03 
11  PD11   PRDS steam   0‐60   ‐ 
12  PD12   Extraction 6 to HPH 6A (HE)  0‐60   40.88
13  PD13   Extraction 6 to HPH 6B (HE)  0‐60   40.88
14  PD14   HRH to IPT L before strainer  0‐40  38.72
15  PD15   HRH to IPT R before strainer  0‐40  38.72
16  PD16   IPT Inlet L   0‐40  38.72
17  PD17   IPT Inlet R   0‐40  38.72
18  PD18   Extraction 5 to HPH 5 (TE)  0‐25   19.36 
19  PD19   Extraction 5 to HPH 5 (TE)  0‐25   19.36 
20  PD20   Extraction 5 to HPH 5A  (HE)  0‐25   18.39 
21  PD21   Extraction 5 to HPH 5B  (HE)  0‐25   18.39 
22  PD22   FW BFP A discharge   0‐250   205.02 
23  PD23   FW BFP B discharge   0‐250   205.02 
24  PD24   RH Spray common header   0‐250   ‐ 
25  PD25   SH Spray common  header   0‐250   ‐ 
26  PD26   FW HPH 5A inlet   0‐250   205.02 
27  PD27   FW HPH 5B inlet   0‐250   205.02 
28  PD28   FW HPH 5A outlet   0‐250   ‐ 
29  PD29   FW HPH 5B outlet   0‐250   ‐ 
30  PD30   FW HPH 6A outlet   0‐250   ‐ 
29  PD31   FW HPH 6B outlet   0‐250   ‐ 
30  PD32   FW HPH 7A outlet   0‐250   202.02 
31  PD33  FW HPH 7B outlet   0‐250   202.02 
32  PD34  HPH‐7A drain to HPH‐6A   0‐100  ‐ 
33  PD35  HPH‐7B drain to HPH‐6B  0‐100  ‐ 
34  PD36  HPH‐6A drain to HPH‐5A   0‐60  ‐ 
35  PD37  HPH‐6B drain to HPH‐5B   0‐60  ‐ 
36  PD38  HPH‐5A drain to Deaerator  0‐25  ‐ 
37  PD39  HPH‐5B drain to Deaerator  0‐25  ‐ 
 
* APPROXIMATE VALUES AT 100% LOAD (In Kg/cm2) ARE GIVEN FOR REFERENCE ONLY. 

30 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

TG PG test instrumentation list for 2x600MW Singareni 1X600 MW TPS 

PRESSURE MEASUREMENT 
* APPROXIMATE 
Range(in  VALUES AT 100% 
S. No  Tag No  Service  kg/cm2)  LOAD (in kg/cm2) 
38  PA01  CW DP L ‐ COND‐A    0‐1  ‐ 
39  PA02  CW DP R ‐ COND‐A    0‐1  ‐ 
40  PA03   CW DP L ‐ COND‐B  0‐1  ‐ 
41  PA04   CW DP R ‐ COND‐B  0‐1  ‐ 
42  PA05   IPT exhaust L  0‐10  7.7 
43  PA06   IPT exhaust R  0‐10  7.7 
44  PA07   LPT inlet steam to common header(L)  0‐10  7.7 
45  PA08   LPT inlet steam to common header(R)  0‐10  7.7 
d (R)
46  PA09   Extraction 3 to LPH 3 (TE) from LPT‐A  0‐4  2.597 
47  PA10   Extraction 3 to LPH 3 (HE)   0‐4  2.468 
48  PA11   Extrn.4 to deaerator (TE) 0‐10  7.7 
49  PA12  Extrn.4 to deaerator (DE)  0‐10  7.08 
50  PA13   Extraction 2 to LPH 2 (HE)   0‐780 mmHg  0.944 
51  PA14   TDBFP‐A steam inlet  0‐10  6.78 
52  PA15   TDBFP‐B steam I/L  0‐10  6.78 
53  PA16   Extraction 2 to LPH 2 (TE)  from LPT‐A  0‐780 mmHg  0.944 
54  PA17   Gland steam to GSC   0‐780 mmHg  ‐ 
55  PA18   Main condensate inlet GSC   0‐25  21.99 
56  PA19   Main condensate inlet DC   0‐25  ‐ 
57  PA20   MC to Deaerator after Flow Element   0‐10  ‐ 
58  PA21   Deaerator shell pressure   0‐10  ‐ 
59  PA22   TDBFP B booster pump suction  0‐10  6.93 
60  PA23   TDBFP A booster pump suction  0‐10  6.93 
61  PA24  TDBFP A exhaust steam to Cond. A  0‐780 mmHg  0.106 
62  PA25  TDBFP B exhaust steam to Cond. B  0‐780 mmHg  0.106 
63  PA 26  CW I/L  pressure (L) Condenser‐A  0‐10  ‐ 
64  PA27  CW O/L pressure (L) Condenser‐A  0‐10 ‐ 
65  PA 28  CW I/L  pressure (R) Condenser‐A  0‐10 ‐ 
66  PA29  CW O/L pressure (R) Condenser‐A  0‐10 ‐ 
67  PA30  CW I/L  pressure (L) Condenser‐B  0‐10 ‐ 
68  PA31  CW O/L pressure (L) Condenser‐B  0‐10 ‐ 
69  PA32  CW I/L  pressure (R) Condenser‐B  0‐10 ‐ 
70  PA33  CW O/L pressure (R) Condenser‐B  0‐10 ‐ 
71  PA34  Condenser vacuum  L COND‐A  0‐780 mm Hg  0.1047 
72  PA35  Condenser vacuum  L COND‐A  0‐780 mmHg  0.1047 
73  PA36  Condenser vacuum  L COND‐A  0‐780 mmHg  0.1047 
74  PA37  Condenser vacuum  L COND‐A  0‐780 mmHg  0.1047 
75  PA38  Condenser vacuum  R COND‐A  0‐780 mmHg  0.1047 
* APPROXIMATE VALUES AT 100% LOAD (In Kg/cm2) ARE GIVEN FOR REFERENCE ONLY 

31 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

TG PG test instrumentation list for 2x600MW Singareni 1X600 MW TPS 

PRESSURE MEASUREMENT 
* APPROXIMATE 
Range(in  VALUES AT 100% 
S. No  Tag No  Service  kg/cm2)  LOAD (in kg/cm2) 
76  PA39  Condenser vacuum  R COND‐A  0‐780 mmHg  0.1047 
77  PA40  Condenser vacuum  R COND‐A  0‐780 mmHg  0.1047 
78  PA41  Condenser vacuum  R COND‐A  0‐780 mmHg  0.1047 
79  PA42  Condenser vacuum  L COND‐B  0‐780 mmHg  0.1047 
80  PA43  Condenser vacuum  L COND‐B  0‐780 mmHg  0.1047 
81  PA44  Condenser vacuum  L COND‐B  0‐780 mmHg  0.1047 
82  PA45  Condenser vacuum  L COND‐B  0‐780 mmHg  0.1047 
83  PA46  Condenser vacuum  R COND‐B  0‐780 mmHg  0.1047 
84  PA47  Condenser vacuum  R COND‐B  0‐780 mmHg  0.1047 
85  PA48  Condenser vacuum  R COND‐B  0‐780 mmHg  0.1047 
86  PA49  Condenser vacuum  R COND‐B  0‐780 mmHg  0.1047 
87  PA50  CEP I/L from Condenser‐A Hot‐well  0‐780 mmHg  ‐ 
88  PA51  CEP I/L from Condenser‐A Hot‐well  0‐780 mmHg  ‐ 
89  PA52  CEP I/L from Condenser‐B Hot‐well  0‐780 mmHg  ‐ 
90  PA53  CEP I/L from Condenser‐B Hot‐well  0‐780 mmHg  ‐ 
91  PA54  LPBP to COND‐A    0‐60  ‐ 
92  PA55  LPBP to COND‐B  0‐60  ‐ 

93  PA56  Extraction 3 to LPH 3 (TE) from LPT‐B 0‐4  2.597 

94  PA57  Extraction 2 to LPH 2 (TE) from LPT‐B 0‐780 mmHg  0.994 

95  PA58  Extraction 1 to LPH 1B  0‐780 mmHg  0.402 

96  PA59  Extraction 1 to LPH 1A  0‐780 mmHg  0.402 

97  PA60  TDBFP‐A steam inlet  0‐10  6.78 

98  PA61  TDBFP‐B steam inlet  0‐10  6.78 

 
* APPROXIMATE VALUES AT 100% LOAD (In Kg/cm2) ARE GIVEN FOR REFERENCE ONLY 

32 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

TG PG test instrumentation list for 2x600MW Singareni TPS 

FLOW MEASUREMENT 

S.No  Tag No  Service  Range(in kg/cm2) 

1  FP01A   Condensate flow to deaerator  0‐2.5  


    2  FP01B   Condensate flow to deaerator  0‐2.5  
3  FP02   Steam flow to TDBFP A   0‐0.5  
4  FP03   Steam flow to TDBFP B  0‐0.5  
5  FP04   SH Spray  L  0‐0.5  
6  FP05   SH Spray  R  0‐0.5  
7  FP06   RH Spray  L  0‐0.5  
8  FP07   RH Spray  R  0‐0.5  
9  FP08  Auxiliary steam   0‐0.5  
10  FP09   Makeup from DM System to COND‐A  0‐0.5  
11  FP10  Makeup from DM System to COND‐B  0‐0.5  
Note ‐ FP02 TO FP09: PROCESS NOZZLE WITH PGT INSTRUMENTS. 
LEVEL MEASUREMENT 
S.No  Tag No  Service  Remarks  
1  Lvl1   Deaerator  Readings will be taken from DCS
2  Lvl 2   Hot well COND‐A  Readings will be taken from DCS 
3  Lvl 2   Hot well COND‐B  Readings will be taken from DCS 
POWER MEASUREMENT 
S.No  Tag No  Service  100% Value in MW  
1  PWM  POWER MEASUREMENT   600 
 

33 of 129
                                                                                                                                                            
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

ANNE
EXURE – 12 

CA
ALCULATIION PROCCEDURE FO
OR DEAER
RATOR LEV
VEL DROP

 

L’ = L + 2(2/3) H 
 
H mean = ((h1+h2)/2   ‐ D//2 
                     
D/2) 2 – (h meann) 2     
Slant Heiight(S) = 2 ( D
            L’ x S x h x  x 60   
Qm = ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ 
                 t x 1000 
Where: 

h = h1 –– h2 

h1 = Startt reading of le
evel from botttom of tank in
n m = H1 + D/2 + y 
h2 = End reading of levvel from bottoom of tank in m
m = H2 + D/2 + y 
+

H1 = Start Gauge level reading from
m NWL in m 

H2 = End Gauge level rreading from N
NWL 
H = Lengtth of Dished e
end of Tank inn m 

   = Density of fluid in
n Kg/m3 
t    = Time of measurem
ment in min
y   =   Heiight of NWL frrom Tank cen tre line in m.

Qm = Rate of Level dro
op/ rise in T/H r. 
 

For 2x6000MW Singaareni TPS 

60 mm
L= 4566 D= 3600 mm
m
F= 4761
10 mm y= 457 mm
H= 975 mm

34 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

ANNEXURE – 13

CALCULATION PROCEDURE FOR HOTWELL LEVEL DROP  
 

For levels in straight portion of tank 
Qm = (W1 – W2) x 60   in T/Hr 
  1000x  t 

Where: 

W1  =  Start Weight of condensate corresponding to H1 in T                                                                                                    
=  W x L x H1 x d 

W2  =  End Weight of condensate corresponding to H2 in T 

       =   W x L x H2 x d 
  d   =   Density of condensate in  Hotwell in Kg/m3  
H1   =  Start Gauge level reading from NWL in m 
H2   =  End Gauge level reading from NWL in m 

t      =  Time of measurement in min 
Qm = Rate of Level drop/ rise in T/Hr 
For 2x600MW Singareni TPS 

  L            =    12700 mm 

  W          =    6968 mm 

35 of 129
                                                                                                                                                            
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

  

 
 
    ANN
NEXUR
RE – 1
14 
  METH
HOD FO
OR COM
MPUTAT
TION O
OF  
H
HEAT RA
ATE 
 
 

 
36 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

37 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

38 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

DOCUMENT TITLE: DOCUMENT NUMBER:


METHOD FOR COMPUTATION OF HEAT RATE PE-DC-381-100-N122 REV 04
PROJECT TITLE: 2X600 MW SINGERENI TPP AT ADILABAD PAGE 2 OF 10

1.0 HEAT AND MASS BALANCE ACROSS HP HEATERS:

Steam extractions to HP heaters is to be evaluated from thermal balance of the heaters. Feed water Mffw going to the economizer
comprises of the feed water quantities Ma and Mb coming from HP heater trains A and B respectively.
The heat and mass balance equations at this point are:

Ma+Mb = Mffw (A)

Ma.H6a + Mb.H6b = Mffw.H14 (B)

From these two equations, the value of Ma and Mb can be evaluated in terms of Mffw.

1.1 HEAT BALANCE ACROSS HPH-7A:

Ma.(H6a-H5a) = Za.(H12a-H7a) (C)

1.2 HEAT BALANCE ACROSS HPH-7B:

Mb.(H6b-H5b) = Zb.(H12b-H7b) (D)

1.3 HEAT BALANCE ACROSS HPH-6A:

Ma.(H5a-H4a) = Za.(H7a-H8a)+Ya.(H11a-H8a) (E)

1.4 HEAT BALANCE ACROSS HPH-6B:

Mb.(H5b-H4b) = Zb.(H7b-H8b)+Yb.(H11b-H8b) (F)

1.5 HEAT BALANCE ACROSS HPH-5A:

Ma.(H4a-H3a) = (Ya+Za).(H8a-H9a)+Xa.(H10a-H9a) (G)

39 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

DOCUMENT TITLE: DOCUMENT NUMBER:


METHOD FOR COMPUTATION OF HEAT RATE PE-DC-381-100-N122 REV 04
PROJECT TITLE: 2X600 MW SINGERENI TPP AT ADILABAD PAGE 3 OF 10

1.6 HEAT BALANCE ACROSS HPH-5B:

Mb.(H4b-H3b) = (Yb+Zb).(H8b-H9b)+Xb.(H10b-H9b) (H)

Putting the values of Ma and Mb in terms of Mffw, we can calculate the values of Za, Zb, Ya, Yb, Xa & Xb in terms of Mffw.

2.0 HEAT AND MASS BALANCE ACROSS THE DEAERATOR:

M2.H2 = (Xa+Ya+Za).H9a+(Xb+Yb+Zb).H9b+W.H1+M1.H13 (I)

M2 = M1+W+Xa+Xb+Ya+Yb+Za+Zb± Mdea (J)

From the equations (I) and (J), the value of M2 can be calculated in terms of Mffw.

3.0 FINAL FEED WATER FLOW:

Mffw = M2 –Mshs-Mrhs (K)

Mshs = 0, when spray is taken from HPH outlet.

In the above equation,Mshs and Mrhs is measured and M2 is calculated in terms of Mffw.
Hence, the value of Mffw can be calculated.

NOTE:
1. When there is an increase in the level of Deaerator, -ve sign shall be used for Mdea.
2. When there is a decrease in the level of Deaerator, +ve sign shall be used for Mdea.
3. When there is an increase in the level of Boiler Drum, -ve sign shall be used for Mdrum.
4. When there is a decrease in the level of Boiler Drum, +ve sign shall be used for Mdrum.

4.0 SUM OF STORAGES [Msto] INCREASES OR DECREASES FOR THE FOLLOWING TANKS:
a) Hotwell Storage
b) Drum Storage

40 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

DOCUMENT TITLE: DOCUMENT NUMBER:


METHOD FOR COMPUTATION OF HEAT RATE PE-DC-381-100-N122 REV 04
PROJECT TITLE: 2X600 MW SINGERENI TPP AT ADILABAD PAGE 4 OF 10

c) Condensate Make up storage


d) Deaerator Storage
NOTE:

For the above storages if there is a net increase in the level, +ve sign is to be taken for Msto and if there is a net decrease in level, -ve
sign is to be used for Msto to arrive at the Total Cycle Losses to be reflected in the main steam flow [Mms].

Mms = Mffw ± Msto ± mdrum + Mshs (L)

Mshs = 0, when spray is taken from HPH outlet.

Reheat Steam Flow, Mrh = Mms-Za-Zb-Ya-Yb-Md+Mrhs (M)

5.0 SYMBOLS:

M1 = Mass flow measured from flow measuring device FP01 [Condensate flow to deaerator]  (Kg/hr)

Md = Gland leakages A, B and C from HP turbine to be computed  (Kg/hr)

Msto = Total increase/decrease of storage in system [from level gauges] during test  (Kg/hr)

Mdea = Change in deaerator storage during the test  (Kg/hr)

Mdrum = Change in drum level during test  (Kg/hr)

W = Extraction steam flow to deaerator [Calculated from thermal balance]  (Kg/hr)

Xa = Extraction flow to HPH-5A [Calculated from thermal balance]  (Kg/hr)

Xb = Extraction flow to HPH-5B [Calculated from thermal balance]  (Kg/hr)

Ya = Extraction flow to HPH-6A [Calculated from thermal balance]  (Kg/hr)

41 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

DOCUMENT TITLE: DOCUMENT NUMBER:


METHOD FOR COMPUTATION OF HEAT RATE PE-DC-381-100-N122 REV 04
PROJECT TITLE: 2X600 MW SINGERENI TPP AT ADILABAD PAGE 5 OF 10

Yb = Extraction flow to HPH-6B [Calculated from thermal balance]  (Kg/hr)

Za = Extraction flow to HPH-7A [Calculated from thermal balance]  (Kg/hr)

Zb = Extraction flow to HPH-7B [Calculated from thermal balance]  (Kg/hr)

H1 = Enthalpy of steam entering deaerator based on measurements PA12 & TW46, TW47  (Kcal/kg)

H2 = Enthalpy of feed water at deaerator outlet based on measurements (PA22, TP75 & TP76) and (PA23, TP77 & TP78)  (Kcal/kg)

H3a = Enthalpy of feed water at HPH-5A inlet based on measurements PD26, TW54 & TW55  (Kcal/kg)

H3b = Enthalpy of feed water at HPH-5B inlet based on measurements PD27, TW56 & TW57  (Kcal/kg)

H4a = Enthalpy of feed water at HPH-5A outlet based on measurements PD28, TW58, TW59, TW62 & TW63  (Kcal/kg)

H4b = Enthalpy of feed water at HPH-5B outlet based on measurements PD29, TW60, TW61, TW64 & TW65  (Kcal/kg)

H5a = Enthalpy of feed water at HPH-6A outlet based on measurements PD30, TW66, TW67, TW70 & TW71  (Kcal/kg)

H5b = Enthalpy of feed water at HPH-6B outlet based on measurements PD31, TW68, TW69, TW72 & TW73 (Kcal/kg)

H6a = Enthalpy of feed water at HPH-7A outlet based on measurements PD32, TW74 & TW75  (Kcal/kg)

H6b = Enthalpy of feed water at HPH-7B outlet based on measurements PD33, TW76 & TW77  (Kcal/kg)

H7a = Enthalpy of HPH-7A drain based on measurements PD34, TW80 & TW81  (Kcal/kg)

H7b = Enthalpy of HPH-7B drain based on measurements PD35, TW82 & TW83  (Kcal/kg)

H8a = Enthalpy of HPH-6A drain based on measurements PD36, TW84 & TW85  (Kcal/kg)

H8b = Enthalpy of HPH-6B drain based on measurements PD37, TW86 & TW87  (Kcal/kg)

42 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

DOCUMENT TITLE: DOCUMENT NUMBER:


METHOD FOR COMPUTATION OF HEAT RATE PE-DC-381-100-N122 REV 04
PROJECT TITLE: 2X600 MW SINGERENI TPP AT ADILABAD PAGE 6 OF 10

H9a = Enthalpy of HPH-5A drain based on measurements PD38, TW88 & TW89  (Kcal/kg)

H9b = Enthalpy of HPH-5B drain based on measurements PD39, TW90 & TW91  (Kcal/kg)
H10a = Enthalpy of extraction steam entering HPH-5A based on measurements PD20, TW33 & TW34  (Kcal/kg)

H10b = Enthalpy of extraction steam entering HPH-5B based on measurements PD21, TW35 & TW36 (Kcal/kg)

H11a = Enthalpy of extraction steam entering HPH-6A based on measurements PD12, TW21 & TW22  (Kcal/kg)

H11b = Enthalpy of extraction steam entering HPH-6B based on measurements PD13, TW23 & TW24  (Kcal/kg)

H12a = Enthalpy of extraction steam entering HPH-7A based on measurements PD05, TW09 & TW10  (Kcal/kg)

H12b = Enthalpy of extraction steam entering HPH-7B based on measurements PD06, TW11 & TW12  (Kcal/kg)

H13 = Enthalpy of condensate entering deaerator based on measurements PA20, TP22 & TP23  (Kcal/kg)

Ta = calculated on the basis of PD07 and Enthalpy correspondinmg to PD01, PD02 and TW03 to TW06…………..………….(Deg C)

6.0 HEAT RATE:

Mms[Hms-Hffw] + Mrh[Hrho-Hrhi] + Mshs[Hffw-Hshs]+ Mrhs[Hrhi-Hrhs]


HR = Pnet (N)

HR = Heat Rate (Kcal/KW.Hr)

Mms = Main steam flow at HPT inlet [As calculated]  (Kg/Hr)

Mrh = Reheat steam flow at IPT inlet [As calculated]  (Kg/Hr)

Mshs = Superheater attemperation flow measured from plant flow measuring device FP04 & FP05  (Kg/Hr)

43 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

DOCUMENT TITLE: DOCUMENT NUMBER:


METHOD FOR COMPUTATION OF HEAT RATE PE-DC-381-100-N122 REV 04
PROJECT TITLE: 2X600 MW SINGERENI TPP AT ADILABAD PAGE 7 OF 10

Mrhs = Reheater attemperation flow measured from Plant Flow measuring device FP06 & FP07 (Kg/Hr)

Hms = Enthalpy of steam before ESV based on measurements PD01 to PD02 & TW03 to TW06 (Kcal/Kg)

Hffw = Enthalpy of final feed water after HP heaters based on measurements PD32, PD33 & TW78, TW79 (Kcal/Kg)

Hrho = Enthalpy of Hot Reheat steam before IV based on measurements PD14 to PD15 & TW27 to TW30  (Kcal/Kg)

Hrhi = Enthalpy of Cold Reheat steam based on measurements PD07 & TW13 to TW14  (Kcal/Kg)

Hshs = Enthalpy of superheater attemperation based on measurements PD25 & TW01, TW02  (Kcal/Kg)

Hrhs = Enthalpy of Reheater attemperation based on measurements PD24, TW52 & TW53  (Kcal/Kg)

Pnet = Pgen-Paux (kW)

Pgen = Power measured at Generator Terminals (kW)

Paux = Power required for Turbine Integral Auxiliaries (150KW) (kW)

NOTE:

When SH spray is tapped from downstream of HP heaters then Hshs = Hffw and accordingly SH term becomes redundant in the HR
(Eq. N) calculation.

7.0 COMPUTATION OF TOTAL GLAND LEAKAGES:

Steam leakage through the glands A, B and C is calculated using the formula given below:
2 2
[P1 – P2 ]
G=KX 
[P1.V1]

44 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

DOCUMENT TITLE: DOCUMENT NUMBER:


METHOD FOR COMPUTATION OF HEAT RATE PE-DC-381-100-N122 REV 04
PROJECT TITLE: 2X600 MW SINGERENI TPP AT ADILABAD PAGE 8 OF 10

G = Steam Leakage through the Glands (T/Hr)

P1 = Pressure before the Glands (Ata)

P2 = Pressure after the Glands (Ata)


3
V1 = Specific volume at inlet conditions to the Glands (m /kg)

Data for guarantee case is given below [Refer HBD No. PE-DC-381-100-N151, REV 00]

PARAMETER HPT INLET END HPT OUTLET END

G 2.522 3.33
P1 43.03 43.03
P2 7.71 7.71
V1 *0.0791496 **0.0602803

* Based on 43.03 Ata and 810.7 Kcal/kg.


** Based on 43.03 Ata and 333.0°C.
For design case P1, P2 and V1 and G are known and hence K can be evaluated.

K values calculated for the design case are as given below:

A) For Gland Leakage from HPT inlet end K = 0.1099435


B) For Gland Leakage from HPT outlet end K = 0.126687

For test case, by putting this value of K and the test values of P1, P2 and V1 the computation of G can be done.

For the test case, the values of P1, P2 and V1 are determined as given below:

FOR HPT INLET END:


P1 is based on measurements PD07

45 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

DOCUMENT TITLE: DOCUMENT NUMBER:


METHOD FOR COMPUTATION OF HEAT RATE PE-DC-381-100-N122 REV 04
PROJECT TITLE: 2X600 MW SINGERENI TPP AT ADILABAD PAGE 9 OF 10

P2 is based on measurements PA05 to PA06


V1 is based on measurements PD07 and Ta
Ta is calculated on the basis of PD07 and Enthalpy correspondinmg to PD01, PD02 and TW03 to TW06.

FOR HPT OUTLET END:


P1 is based on measurements PD07
P2 is based on measurements PA05 and PA06
V1 is based on measurements PD07 and TW13, TW14

8.0 NOTE:

1.0 The Heat Rate is guaranteed with 0% makeup and hence no makeup will be supplied to the condenser during the PG test. Under
these conditions the storage in the deaerator feed storage tank and Hotwell are utilized towards the leakages losses and the
measured Heat Rate shall be corrected using the correction curves viz. change in Heat Rate vs. change in storage of feed water
storage tank and change in Heat Rate vs change in Hotwell Level.

9.0 GUARANTEE CONDITION:

1. Turbine Cycle Heat Rate at 100% LOAD = 1927.1 Kcal/KWHr


(Refer HBD Nos. PE-DC-381-100-N151 REV00 Titled “600MW, 0%MU, 77mm Hg a Back Pr.” )

Turbine Cycle Heat Rate at 80% LOAD = 1975.7 Kcal/KWHr


(Refer HBD Nos. PE-DC-381-100-N152 REV00 Titled “480MW, 0%MU, 77mm Hg a Back Pr.” )

2. If the test is carried out later than three (3) months, after the date of commissioning, due to any reason whatsoever, Aeging shall be
applicable inline with the clause 2.05.04 (i) sub section-V, Part-A page 44 of 48 of the tender specification and S.No 11 of
Amendment-1 to technical specification.

46 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

DOCUMENT TITLE: DOCUMENT NUMBER:


METHOD FOR COMPUTATION OF HEAT RATE PE-DC-381-100-N122 REV 04
PROJECT TITLE: 2X600 MW SINGERENI TPP AT ADILABAD PAGE 10 OF 10

10.0 LIST OF CORRECTION CURVES:

HEAT RATE CORRECTION CURVES:

1. Throttle Steam Pressure


2. Main Steam Temperature
3. Reheat Steam Temperature
4. Condenser Back Pressure
5. Change in Deaerator Level
6. Change in Hot Well Level
7. Power Factor
8. Frequency
9. Generator Hydrogen Pressure
10. Generator Voltage
11. SuperHeater Spray (Applicable only when SH spray is taken after BFP discharge)

OUTPUT CORRECTION CURVES:


1. Throttle Steam Pressure
2. Main Steam Temperature
3. Reheat Steam Temperature
4. Condenser Back Pressure
5. Change in Deaerator Level
6. Power Factor
7. Frequency
8. Generator Hydrogen Pressure
9. Generator Voltage
10. Change in Hot Well Level
11. SuperHeater Spray (Applicable only when SH spray is taken after BFP discharge)

47 of 129
                                                                                                                                                            
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

 
 
 
 
 
 
 
 
 
ANNE
A EXUREE – 15
 
CORREC
C CTION C
CURVES
   

 
 
 
 
 
 
 
 
 
 

48 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

49 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

2X600 MW SINGERENI TPP AT ADILABAD
LIST OF CORRECTION CURVES
Slon. DOCUMENT TITLE  DRAWING No. REV. NO.

1 HEAT RATE CORRECTION CURVE FOR THROTTLE STEAM PRESSURE PE‐DC‐324‐100‐N221 00

2 HEAT CORRECTION CURVE FOR MAIN STEAM TEMP PE‐DC‐324‐100‐N222 00

3 HEAT RATE CORRECTION CURVE FOR REHEAT STEAM TEMP.  PE‐DC‐324‐100‐N223 00

4 HEAT RATE CORRECTION CURVE FOR CONDENSER PRESSURE. PE‐DC‐324‐100‐N224 01

5 HEAT RATE CORRECTION CURVE FOR CHANGE IN DEA. LEVEL  PE‐DC‐324‐100‐N225 00

6 HEAT RATE CORRECTION CURVE FOR GENERATOR VOLTAGE.  PE‐DC‐324‐100‐N226 01

7 HEAT RATE CORRECTION CURVE FOR FREQUENCY.  PE‐DC‐324‐100‐N227 01

8 HEAT RATE CORRECTION CURVE FOR POWER FACTOR  PE‐DC‐324‐100‐N228 01

9 HEAT RATE CORRECTION CURVE FOR GEN. HYDROGEN PRESSURE PE‐DC‐324‐100‐N229 01

10 OUTPUT CORRECTION CURVE FOR MAIN STEAM PRESSURE  PE‐DC‐324‐100‐N230 00

11 OUTPUT CORRECTION CURVE FOR MAIN STEAM TEMP.  PE‐DC‐324‐100‐N231 00

12 OUTPUT CORRECTION CURVE FOR REHEAT STEAM TEMP.  PE‐DC‐324‐100‐N232 00

13 OUTPUT CORRECTION CURVE FOR CONDENSER PRESSURE  PE‐DC‐324‐100‐N233 01

14 OUTPUT CORRECTION CURVE FOR GENERATOR VOLTAGE  PE‐DC‐324‐100‐N234 00

15 OUTPUT CORRECTION CURVE FOR FREQUENCY  PE‐DC‐324‐100‐N235 00

16 OUTPUT CORRECTION CURVE FOR POWER FACTOR  PE‐DC‐324‐100‐N236 00

17 OUTPUT CORRECTION CURVE FOR GENERATOR HYDROGEN PRESSURE PE‐DC‐324‐100‐N237 01

18 OUTPUT CORRECTION CURVE FOR CHANGE IN DEA. LEVEL  PE‐DC‐324‐100‐N239 00

19 OUTPUT CORRECTION CURVE FOR CHANGE IN HOT‐WELL LEVEL PE‐DC‐324‐100‐N241 01

20 HEAT RATE CORRECTION CURVE FOR CHANGE IN HOTWELL LEVEL PE‐DC‐324‐100‐N245 00

50 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

51 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

52 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

53 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

0.1047 ATA

01

54 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

55 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

2X600MW SINGERENI TPP AT ADILABAD

GUARANTEED VOLTAGE : 21.0 KV

HEAT RATE CORRECTION FACTOR Vs. GENERATOR VOLTAGE

1.001

100%
80%
HEAT RATECORRECTION FACTOR

0.999
19.500 20.000 20.500 21.000 21.500 22.000 22.500

GENERATOR VOLTAGE < kV>

1. Correction curves for operating conditions deviating from guarantee conditions.


2. To obtain the corrected value multiply the measured value by the correction factor. REV-01

Doc. No.: PE-DC-381-100-N226 PREP: AKS


BHEL PEM
DEPARTMENT: MSE CHECKED: AKS

NOIDA APPD. : AK

56 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

2X600MW SINGERENI TPP AT ADILABAD

HEAT RATE CORRECTION CURVE FOR FREQUENCY


GUARANTEED FREQUENCY = 50 Hz

1.00025

1.00020

1.00015

1.00010

1.00005

1.00000

0.99995
HEAT RATE CORRECTION FACTOR

0.99990

0.99985

0.99980
100%MCR
0.99975

0.99970
80%MCR
0.99965

0.99960

0.99955

0.99950

0.99945

0.99940

0.99935

0.99930

0.99925
47 47.5 48 48.5 49 49.5 50 50.5 51 51.5 52

FREQUENCY (Hz)

REV-01
1. Correction curves for operating conditions deviating from guarantee conditions.
2. To obtain the corrected value multiply the measured value by the correction factor.

Doc. No.: PE-DC-381-100-N227 PREP: AKS

DEPARTMENT: MSE CHECKED:AKS


BHEL PEM
NOIDA APPD. : AK

57 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

2X600MW SINGERENI TPP AT ADILABAD

GUARANTEED POWER FACTOR : 0.85

HEAT RATE CORRECTION FACTOR Vs. POWER FACTOR

1.0036

1.0031

1.0026

1.0021
HEAT RATE CORRECTION FACTOR

1.0016

100%

1.0011
80%

1.0006

1.0001

0.9996

0.9991

0.9986
0.80 0.85 0.90 0.95 1.00

POWER FACTOR

REV-01
1. Correction curves for operating conditions deviating from guarantee conditions.
2. To obtain the corrected value multiply the measured value by the correction factor.

Doc. No.: PE-DC-381-100-N228 PREP: AKS


BHEL PEM
DEPARTMENT: MSE CHECKED: AKS

NOIDA APPD. : AK

58 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

2X600MW SINGERENI TPP AT ADILABAD

GUARANTEED GEN HYDROGEN PR = 5.0 BAR(g)

HEAT RATE CORRECTION FACTOR Vs. GEN. HYDROGEN PR.

1.00016

1.00012

100%
HEAT RATE CORRECTION FACTOR

80%
1.00008

1.00004

0.99996
4.250 4.450 4.650 4.850 5.050 5.250

GEN. HYDROGEN PR. <BAR(g)>

1. Correction curves for operating conditions deviating from guarantee conditions.


2. To obtain the corrected value multiply the measured value by the correction factor. REV-01

Doc. No.: PE-DC-381-100-N229 PREP: AKS


BHEL PEM
DEPARTMENT: MSE CHECKED: AKS

NOIDA APPD. : AK

59 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

60 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

61 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

62 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

0.1047 ATA

REV-01

63 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

VOLTAGE CORRECTION CURVES FOR 600 MW GENERATOR


(THDF 115/67 + BRUSHLESS EXCITATION)
(RATED VALUES : 600 MW / 21.0 KV / 0.85 PF / 5.0 BAR(g) H2 PR. / 50 HZ)

250

200

150

100
CORRECTION (KW)

21.000 KV
50 21.525 KV
22.050 KV
0 20.475 KV
19.950 KV

-50

-100

-150

-200
0 0.25 0.5 0.75 1
MW LOAD (P.U.)

REV. NO. 00
DATE: 17.11.2009
PE-DC-381-100-N234 PREPARED BY: A.K. GOYAL CURVE NO.: TG:THDF 115/67:026

64 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

FREQUENCY CORRECTION CURVES FOR 600 MW GENERATOR


(THDF 115/67 + BRUSHLESS EXCITATION)
(RATED VALUES : 600 MW / 21.0 KV / 0.85 PF / 5.0 BAR(g) H2 PR. / 50 HZ)

400

350

300

250

200 50.0 HZ
CORRECTION (KW)

50.5 HZ
150 51.0 HZ
51.5 HZ
100 49.5 HZ
48.0 HZ
50 47.5 HZ

-50

-100

-150
0 0.25 0.5 0.75 1
MW LOAD (P.U.)

REV. NO. 00
DATE: 17.11.2009
PE-DC-381-100-N235 PREPARED BY: A.K. GOYAL CURVE NO.: TG:THDF 115/67:027

65 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

P.F. CORRECTION CURVES FOR 600 MW GENERATOR


(THDF 115/67 + BRUSHLESS EXCITATION)
(RATED VALUES : 600 MW / 21.0 KV / 0.85 PF / 5.0 BAR(g) H2 PR. / 50 HZ)

1000

500

0
CORRECTION (KW)

0.85 P.F.
-500
0.90 P.F.
0.95 P.F.
1.00 P.F.
-1000
0.80 P.F.

-1500

-2000

-2500
0 0.25 0.5 0.75 1
MW LOAD (P.U.)

REV. NO. 00
DATE: 17.11.2009
PE-DC-381-100-N236 PREPARED BY: A.K. GOYAL CURVE NO.: TG:THDF 115/67:028

66 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

HYDROGEN PRESSURE CORRECTION CURVES FOR 600 MW GENERATOR


(THDF 115/67 + BRUSHLESS EXCITATION)
(RATED VALUES : 600 MW / 21.0 KV / 0.85 PF / 5.0 BAR(g) H2 PR. / 50 HZ)

50

30

10
CORRECTION (KW)

5.00 bar(g)
-10 4.75 bar(g)
4.50 bar(g)

-30

-50

-70
0 0.25 0.5 0.75 1
MW LOAD (P.U.)

REV. NO.:00
DATE: 17.11.2009
PE-DC-381-100-N237 PREPARED BY: A.K. GOYAL CURVE NO.: TG:THDF 115/67:029

67 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

2X600 MW SINGARENI TPP AT ADILABAD

RATED VALUE OF DEA. LEVEL DROP = 0%

CHANGE IN DEA. LEVEL VS OUTPUT CORRECTION CURVE.

1.00700

1.00600

1.00500
OUTPUT CORRECTION FACTOR.

1.00400

1.00300

1.00200

1.00100

1.00000

0.99900
0.00 1.00 2.00 3.00 4.00 5.00

DROP IN DEA. LEVEL (% OF MS FLOW)

1. Correction curves for operating conditions deviating from guarantee conditions.


2. To obtain the corrected value multiply the measured value by the correction factor.
3. This curve is applicable for load conditon of 600MW & 480MW.

Doc. No.: PE-DC-381-100-N239 PREP: VJ

DEPARTMENT: MSE CHECKED: AKS


BHEL PEM
NOIDA APPD. : AK

68 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

2X600MW SINGERENI TPP AT ADILABAD


REV-01

RATED VALUE OF BLOW DOWN = 3%


RATED VALUE OF BACK PR. = 0.1047 ATA

OUTPUT CORRECTION CURVE Vs CHANGE IN HOTWELL LEVEL

1.004

1.002

1.000
OUTPUT CORRECTION FACTOR.

0.998

0.996

0.994

0.992

0.990
-3 -2 -1 0 1 2 3 4 5

CHANGE IN HOTWELL LEVEL<%OF MS FLOW>

1. Correction curves for operating conditions deviating from guarantee conditions.


2. To obtain the corrected value multiply the measured value by the correction factor.
3. This curve is applicable for load conditon of 600MW & 480MW.

Doc. No.: PE-DC-381-100-N241 PREP: AKS

DEPARTMENT: MSE CHECKED: AKS


BHEL PEM
NOIDA APPD. : AK

69 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

2X600 MW SINGARENI TPP AT ADILABAD

HEAT RATE CORRECTION CURVE FOR CHANGE IN HOTWELL LEVEL

HEAT RATE vs CHANGE IN HOTWELL LEVEL

1.013
HEAT RATE CORRECTION FACTOR

1.008

1.003

0.998

0.993

0.988
-3 -2 -1 0 1 2 3

CHANGE IN HOTWELL LEVEL (% OF MS FLOW)

1. Correction curves for operating conditions deviating from guarantee conditions.


2. To obtain the corrected value multiply the measured value by the correction factor.
3. This curve is applicable for load conditons of 600MW, 480MW and 360MW.

DR.No:PE-DC-381-100-N245 PREP: VJ

DEPARTMENT: MSE CHECKED: AKS


BHEL PEM
NOIDA APPD. : AK

70 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

 
ANNEXURE – 16 

HEAT BALANCE DIAGRAM 

 
Sr. no.  Document title  Drawing No.  Page No. 
 

1  600MW, 0 % MU, 77 mmHg (A) BACK PR.  PE-DC-381-100-N151   72   

 
2 480MW, 0 % MU, 77 mmHg (A) BACK PR. PE-DC-381-100-N152 73   

 
3 600MW, 3 % MU, 89 mmHg (A) BACK PR. PE-DC-381-100-N161 74   

 
PE-DC-381-100-N167
4 VWO, 0% MU, 77 mmHg(A) BACK PR. 75 
 

 
600MW, 3 % MU, 77 mmHg (A) BACK PR
5 PE-DC-381-100-N170 76 
(All HP Heaters out of service)  

71 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

l'ID.DD 1110.7
11195.SIB ~ 5!7. D 7.;o I '!WI. a
12BS.BI~ ~ 328.2

~'·~·
C B B C C B B C C B B C

K
E
85.511 1152.2 G
IIB.UB! ~!Ill.!

~.OS 172M
157. 11119 • !IS!. 7

0.1Dil7 I 515.8
~----r---~~1'----,~----~ mo.~s 1 o.Si!llll5
~.os T727.~ !II. 72 T8!11.8
t-='O.:;::DDD::..::M-o(.M
15'53.11117 I !IS!. 7 l!ilill.lllll I 5115. D
ISI.!B I 11011.3
102.1~ ~--~
7. 7D I '!WI.B
170.157 ~ 328.2
J 78.790 M
J
CDN

~a 2.5V7 laea.~

-- 87.1&55 ~ 208.2
o.s.
52.817
18118.2
~ 118.8
0.1102 I m. 5
5!.1l5B ~ D. 9870
0.218 81.5
H~-o_.a_la
___£-~'B1_.a______~

80.535 M B I

--
N~

~
~i
BDD.S H

Ill~
+--Cir--t!2l= K E M

-~ c
~ ... NQ ll171J.8119M
•Ill
Ill:::
G!r:
ilil 'Ill' lii!i si si " 52.0 H C F H
-r- C> -r- - r- '"'"' 0.101n 1118.3
li! ,. li! ,. li! li! li! i ~ ~ ~ I!B5. 7BD I 118.1&

-
1:1
'Hi
.,_
--.
- 'I_· :..... "' 'li "' "l 'I_· "' 'I_·:. I i
ell!!
21.111 I ~7.0
~Pr ~h"\-....L..-=."".j...l
W1
~ I!B5.7BD 1118.8

Loy--~ "::r----'
r-®r--®
., ...
~~

,..::N
N
CDUI
"""" .... II! II!
~~ sisi Ifill! ~;i
-lisi-
NN ;;u;
-f- -- - f- -- -- - f-
.!!! oil o!!J oil! olil olil
·~
ill
~ ~ Iii ~ ~ ~ Ci
TURBINE GROSS OUTPUT - 609.376 ""' 2X600 JIW S/NGARENI TPP AT ADILAIWJ
LESS ~ LIISSES
LESS GENERIITIII LIISSES
• 1.444 MV
• 7,7fli! Mil
Tli INTEGR#IL MDI JREAk-I.P
AT
IKCrUKG BiARAT HEAVY ELECTRICALS LTD
LESS PII\IER REiliiiRED Fml • 11.1:111 MV

Tli INTEliiW. -
IIIL VN'IUI EXIWJSTEII = 0.7:1 Ill
Cf" PUll' I Cf" VN'IIJR EXIWJS1ER • 1011.0 Ill
TIH °C lXI
rad&1 PRD..ECT ENGINEERING MANAGEI£NT
NEW DELHI
TURBINE NET OUTPUT =600.00 NW CIIICILATDE PUIIP
GEJD#ITIII NJX p[]\IER IIEQIIT
• 0.7!5 KV
• 43.5 K\1
M.. PIR55 .. TIH REP
HICD
VJ
"ICS 600M\v' 0/::MU 77 MMHG(A) B. PR
I£AT RATE • 1927.1 ICCALII<WHR GSC ElCHAUSlER • S.O Ill H.. ENTIRPY .. KCAL/KG
PPD AIC JCB NC 381
T•• TEit'EIIA1UIE ••' C DRG NC REV02
"TE lJ0512 PE - DC - 381 - lOD-Nl:!l

72 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

170.111 I 810.7 110.111 I 810.7


11165.11115 ,153'1.0 11165.111111 ,153'1.0 8.31 I M.l

~o.ao
1018. '15"1 ' !211. 1
:0:
c B B c c B B c c B B c
1!!1
d :0: :0: :0: :0: :0: :0: :0: :0: :0: :0: :0: :0: :0: :0:
!MID. ISO Ill
K E ! ~ I
r-.
~ !I 1!1 ~ i .....__.... Iiid 111 ! i i !
--~
d d ...: ...: d d d d d d d d d
1~.7
52.88
.. G
1111••12 ,1382.5
91!1.11111
118.057
I '72111.0
' 925.8
!!!
.;
rc r-....
...... ~
..
r---
0.0111 M B 0.10117 I 582.2
918.1112 1 o.B!BI
,. '1''72111.0
12111. '1'!11 1 925.8
"" 31.50
12111. '1'!11
'1'880.1
I 511i. 0
0.0111 M
M

15.81
80.1121
,__,
I 810.8

J 8.91 111lB.I
199.BBS ' !211.7
•o
83.122"
~~ J
-f-o
:;!
&lc 2.1!111 I 11110.1
r;;~ -r 52.9U '210.1
.nil o.8n TM.Z

/\!~
91.018 -rua.7
oil 0.,.7 I 629.6
I 91.2a .D.BBI5

.... o• .... -., ...... ND


"!I u R.l27 M
BDB.I H
B I

~~ ~~ ~g
-f-o
~i
- 1-- -f-o
i~ i~
-1-o ~~
.... if!"! li!~
..~ ..... ..~ I ..Iii ..... .... .. l2l= K E M

~~
- 1-

-~
u;i i
ID

. .;
I!::::
:o;
I
~ ~&I
!!l!ii
• •
IDD

!!!i
- I- - I-
ID~
~!!i .;I
"!
~
- ;_ N II
.,
i! .
-
:o; ~~
Iii- 0"I! illi
- I-
~~
cl! !Iii
- I- ~~
... c ll13l.l9l M
~
C F H

-ill
- I-
il
"' I~ "'
-
5
"' I!~ 5!
I
il - .."'
1

- 1::-
.."'
-
-
I- ''""
:::: ~ • ..~
o.to•7
lll8.3
( ~ 1115.111 I Ill··

i~ "' "' I
~ "' ~ !~ ~i
,_
~ 1:::
!!l "'
1:::
!!l
.
"' ....."' !!l
::"'
I 1
!!i cl 211.,. I •1.1

tB1 ~ \B9
1- .;

-~
~
;;;r
~
.; 1115.111 llli.B
"'
I"'
_I]
I'
n r-® ~
.....
~~
Cl Cl o• ....ill ill IDO
"!~ .... .. ...
-~~1-
~!! 1-1!~ Iii Iii
- ~ -~ -r -~ -~
r::;::
- 1- -aili
~

.~
..ill .!I
~
.Iii
ii
•i!
fli
•!ii
ai
.i
~ ~ ·~c5
.i

2X600 JIW SINGARENI TPP AT ADILABAJJ


T\RBll£ GROSS DJTPUT • 489.175 NY
AT Ioc
lLSS I£CH UISSES
LESS liDIERl'lllll UISSES
lLSS I'INEII IIEilUIIIEII Fill
• 1.444 IN
• 6.SIII IN
• 11.1111 IN
TG IIITEGIW. AIJX MEAIC-IP
DIL VN'OJft EICIWJSTEII • 0.7'5 ~~~~
TIH
KCRLIKG
[)(J

PREP
ra;;r VJ
BHI\R,t,T l£,t,VY ELECTRICH...S LTD
PROJECT ENGII£ERING H,t,NIIGEHENT
1£'tt' DELHI

TG INT£&11111.. AIJX CF Pill' ' CF VN'OJft EICIWJSTEII • IIIOJI KW


• D.7l! ICV
M•• lll95 •• T/H 480M\v' 0/::MU 77 MMHG(A) B. PR
TURBINE NET IIJTPUT =
480.00 NV
Clllcu..ATING Pill'
GENERATIII AIJX PIIWER IIEGMT • 43.5 ICV H•• ENTHALPY •• KCRLIKG
CIICD
APPD
I'IICS
AIC JDB NI 3BI
HE,t,T RATE • 1975.7 ICCAL/ICVItl GSC EKHNJSTER • S.O ICV
T•• TEII'ERRTLfiE ..• c DATE 2JO!i 1 DRG NI PE - DC - 3Bl - 100-NC!I! REV Dl

73 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

74 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

170.00 I BID. 7
1111.17.111111 .L 597.0 a.u I "1'111.1
l!lili.IDD ,L !121.1

c a ®® ®® ®® ®® I C

K
E !!! !! !! !!!
g g - d d

0.1047 I m.~
Ulli.518 I 0.112U
~-~ Tm.1 ...,. ~-~~ Ta.1
1BIII.2ili 1 !11!111.8 1BII1.2ili 1 585.0

t-='D.:,:DDD:....M:........,o{M
211.~1 la.a
IDB. 732 ,L '183.2
8.11 I "1'111.1
182.188 ' !12'7. 8

J 111.1.128" J

2.731 IBIB.O
72.133 '201.8

··~
58.11211
1111.17.8
'118.2
D.Ull I 822.2
57.781 ... 0.811i7
0.228 82.8
~~~-~_.72B
____.LL82
__.a______J

"!Iii 81.107 "

--
B I
"'"'
,..:,.:
ii::: lllg ~Jl____:'·a H
-f-4
..... ...
~~
Iii!
"RI
IB-
"!"!
liB
lillil
. .; ~~ ~~
NO
Iii Iii
NO
~~
c ~u..,:::::;o::l::..2.:.:."--<c
K E M
f "

.!!
-r- - - OUI - - OUI -r- - - -= "' o. 1047 I u.s
~~ ~ ~
I-!I
I-
!I ,!1 1
!I Iii :: ~ '.~~.BBB ! U.U

.. : : :
~----~~~!----------~~· ~ -~~ -a-;
ll: : ll:
~~ .. to@~.:
..... "'"'
!!!:f
..
ID

~~

D
NN
'r-----'
NN
-- ......

-lid -~~- -!Iiiii- -llilli- -Iiif--


NN ~
f--
... - r- - f-- --
•iD .ill .~ •!! .Iii ,ji ,ji
'Iiig
! ~ § p! !!! !! !!
2X600 JIW SINGARENI TPP AT ADILABAD
1~.
AT
TIH

H•• HASS •• T/H PREP


;~ VJ
BHo\RIIT HEIIVY ELECTRICIILS LTD
PROJECT ENGJitEERING MIINIIGEMENT
NEY DELHI

H•• ENTIR..f'Y •• KCAL/KG CH<D IlkS IV\J D OXMU 77 MMHG(A) B. PR


IIPPD Ilk Jill NJ 381
T•• TEftRAT\IIE ••• C
llo'ITE 23.0 5.12 DRG NJ PE - DC - 381 - IDD-N16 7 REV 01

75 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

no.oo I 8to. 1
160U.025 t 537.0 8.51 I 7U7.6
IU12.623 t 335.0
C B 8 c C B 8 C C B B C

600.150 HH

I -~-
61l. 70 1758.2 --]'
0.000 • U00.3
,-----~-----U-U.-85---~~~-5-.-9--------------------~~
10.000 • ~6.2
0.1047 I 57U.2
1212. YY9 I 0. 92YI
f--"0,_,.0""00"--"-M---to{ 8 uu. as f 735.9 UO.U7 f 858.2
t587.99o 1 ~8.2 1587.990 1 565.o
10.000 M
E

2t.9a I a12.6
0.000 tY71.1
8.51 7Y7.6
177.8Y5 t 335.0
J

2.859 I 691.1
0 77.626 • 21U.5
men
::r~ I 6Y9.9
"'
1/lO . 1.087
61.573 • 122.6
-f-
O.Y27 I 623.9
6l.Y88 • 0.9885
I 63.5
I® o.239
0.368 • 63.5

68.612 M B l

~ ~·'"
00 00 00
00
- f-
00
- ....
,,... ,,... I 0
,,... I 0 NO
"'
~ci ~d 0 ~d 0 "' "' C 712 H C F K
~~
0 0
~~ ~~ ~~ Iii Iii
- f- - f-
c:i
- f-
c:i
-- -- -f- - - z: :I: 7 I Y6.3
"'
_:; I ::"' I ::"' 1::"' "'
_:; 1 ~ ffi::; ~!530.m !US.U
N '
ru ru c:i ~ I Y6.9
~
ID '
•N •N !ij
't_20.18
~~ ~ "' ~ "' li~ ~ !530. 77U I U6.5
cir- cir-
1"-
'
.-® "-r@
"'"' ........ ..., "' r-

I!!"'"'I!!
CD

§§ ~~ vi vi gi gi
-- -- - -
....
- -
....
- f-
l!e I
CD
ID I
CD
ID I ....
ID
,..:
....
c:i
0
c:i
0 "'"'c:i
"' "'
2X600 MW SINGARENI TPP AT ADILABAD
AT IKCRL/KG
T/H I °C (XJ BHARAT HEAVY ELECTRICALS LTD
PROJECT ENGINEERING MANAGEMENT
NEIJ DELHI
M.. MRSSENSTA~M .. T/H PREP VJ 600MVI 3%MU 77 MM Hg BACK PR.
H•• ENTHRLPIE •• KCRL/KG CHKD AKS ALL HP HEATERS OUT OF SERVICE
APPD AK JOB NO 381
76 of 129 T.. TEHPEAATUA .. 'C DATE 23 05.1 2 DRG NO PE - DC - 381 - 100-N170 01
REV
                                                                                                                                                           
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

             ANNEXURE – 17 
System check list‐ 

 
 

Ensure  the  plant  is  able  to  operate  without  any  constraints  at  full  load  for  a  minimum  of  4  hrs  with  following 
conditions. 

1. Plant to run at rated steam parameters.  
2. All equipment which are needed for proper functioning of TG to be in service.  
3. De‐aerator level drop test to be carried out & effort to be made to keep leakage level at lowest.  
4. All HP & LP Heaters to be in normal operation and drips of these heaters to be cascaded properly without any 
bypassing to HP/LP flash tank of condenser. 
5. All connections to and from external sources like plant PRDS header, make up, dozing, steam for external use, 
boiler drains and blow‐down , external spray to flash tanks ,valves etc. to be cut off/minimised.  
6. Alternate lines which are not designed for normal use like CRH pegging to De‐ aerator/BFPT, auxiliary pegging 
to de‐aerator/BFPT, De‐aerator initial heating system & fill lines, HPH6 drain to de‐aerator, etc should not be 
charged.  
7. System would be tight as per Design Heat Balance Diagram.  
8. Any equipment required from boiler side should be available so to get the steady required steam parameter.  
9. Sealing line for CEP & Vacuum Pumps to be connected from CEP discharge and supply from DM MU to this line 
to be closed.  
10. Turbine/ Boiler controls should be fine tuned, so that tests can be done at stable conditions.  
 

 
 
 

77 of 129
                                                                                                                                                           
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

ANNEXURE – 18 
 

Auxiliary Power Consumption Test Procedure 
 

OBJECTIVE: 

To prove total auxiliary power consumption of the applicable HT and LT drives as per contract guarantee schedule at 
following TMCR conditions.   

Sr. no.  Parameter  Guarantee Value 

I)  The  total  auxiliary  power  consumption  for  all  the  Turbine  Generator  At 100% TMCR   
Auxiliaries, steam generator auxiliaries, ESP and turbine cycle and other  19,659 (Per unit) KW 
common  auxiliaries  required  for  continuous  unit  operation  at  100%   
TMCR  (600MW  unit  load)  under  rated  steam  conditions  at  worst   
condenser  pressure  with  3%  make‐up  and  with  ambient  air 
temperature of  27deg c and RH of 60% shall be guaranteed. 
II)  The  total  auxiliary  power  consumption  for  all  the  Turbine  Generator  At 80% TMCR   
Auxiliaries,  steam  generator  auxiliaries,  ESP  and  turbine  cycle  15,301 (Per Unit) KW 
equipment and other common auxiliaries required for continuous unit   
operation  at  80  %(480MW  unit  load)  TMCR  under  rated  steam   
conditions,  and  at  worst  condenser  pressure  of  with  3%  make‐up  and 
with  ambient  air  temperature  of  27deg  c  and  RH  of  60%  shall  be 
guaranteed. 
 
 

a. The power consumption (HT/LT) of SG & ESP auxiliaires will be measured separately during Boiler PG & ESP PG 
test. 
b. The power consumption of TG auxiliaries and other continuously operating equipment will be measured during 
TG PG test.  
c. Total auxiliary power consumption will be calculated after completion of Boiler, ESP and TG PG tests.  
 

PREPARING THE MACHINE FOR 600MW FOR CONDUCTANCE OF PG TEST 

Turbine–Generator and associated equipment will be raised to the rated load of 600 MW. The auxiliary power 
consumption test is to be conducted during main PG test at 600 MW as per the guarantee clause mentioned  
above.  
 

GENERAL GUIDE LINES 

a. All HT power will be measured through power transducers/ power meter. Output of the power transducers (if 
used) will be connected to data logger. 
b. It will be ensured that the power transducers are connected in the correct phase sequence.  
c. All  LT  power  will  be  measured  through  use  of  digital  multi‐meter  (voltage),  Clamp‐on  meter  (Amp.)  &  Power 
factor meter (pf) / three phase power tong tester.   
d. For measurement of Transformer losses, shop test results shall be used. 
e. Shop test results /type test/rated power/ data sheet, if required  for computation of Aux. Power consumption 
due to non availability of specific drive,  shall be made available during PG test and will be used for calculation of 
total power, if called for. 

78 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

 
 
LIST OF INSTRUMENTS AND ITS ACCURACY 

a. All the identified CTs and PTs used in the existing panel of each HT drives will be connected to power transducers 
and hooked on to the main data logger for recording.  
b. Power  transducers  using input : 110V, (0‐1A)for an  output  of (4‐20)mA,  with  an  uncertainty  equal  to or  better 
than+/‐0.1%. 
c. 3.5  digit  Digital  multi‐meter  (voltage),  Clamp‐on  meter  (Amp)  &  Power  factor  meter  (pf)  /  Three  phase  power 
tong tester will be usedfor measurement of power for LT drives and data will be recordedmanually. 
d. All valid calibration certificatesshall be furnished at the time of the test. 
 

LIST OF AUXILIARIES CONSIDERED FOR AUXILIARY POWER CONSUMPTION  

2X600MWSingareniTPP(Rev02) 

(I)  UNIT AUXILIARIES  POWER  POWER 


  CONSUMPTION  CONSUMPTION 
(KW)  (KW) 
(INDICATIVE  (INDICATIVE 
BREAKUP) BREAKUP)
600MW load  480MW load
   
a)  Unit oil purifier 
b)  Unit control oil purifier. 
85  85 
c)  Electric oil heater for lube oil. 
d)  Feed and discharge pumps of oil purification system. 

e)  Condenser air evacuation pumps. 
f)  Condenser tube cleaning systems pumps. 
g)  Condensate extraction pumps. 
1700  1648 
h)  Drip Pumps (Not envisaged) 
i)  Hydrazine dosing pumps. 
j)  Ammonia dosing pumps. 
k)  Oil purifiers of 2x 50% TDBFPs, and their feed and discharge pumps.
l)  Lube oil pumps of 2x 50% TDBFPs, and their electrical oil heater for lube oil. 
m)  Auxiliary oil pumps for MDBFP.  250  250 
n)  Oil pumps for HP‐LP bypass system. 

o)  Motor driven boiler feed pump 
(for this purpose only 15% of the deemed power consumed by the MDBFP  1421  0 
is considered at 100% TMCR only) 
P  Mills/PA Fans/FD Fans/ID Fans/Air heaters/Coal Feeders/Seal Air Fans/Lube 
 to  oil pumps for Fans/Fuel oil pressurizing pump/Boiler water circulation 
aa)  pump/Scanner air fans/Air heater and mill system/Electrostatic 
  Precipitators(corona only)  11970  9430 
 

AA  Total for (I) 15426  11413

79 of 129
                                                                                                                                                           
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

(II)  Common auxiliaries (Power consumption indicated is per unit basis) POWER  POWER 


  CONSUMPTION  CONSUMPTION 
  (KW)  (KW) 
(INDICATIVE  (INDICATIVE 
BREAKUP) BREAKUP)
600MW load  480MW load
ab)  DM  Cooling  (Normally  working)  water  pumps to  supply  cooling  water 
  on  the  primary  (DM)  side  of  the  plate  type  heat  exchangers  in  the 
  closed loop Equipment cooling (Unit auxiliaries) water system. 
   
ac)  Auxiliary  Cooling  (normally  working)  water  pumps  to  supply  cooling 
  water  on  the  secondary  side  of  the  plate  type  heat  exchangers  in  the  850  850 
  closed loop Equipment cooling (unit auxiliary) water system. 
   
ad)  Power consumption of any other continuously operating auxiliary for 
  unit operation at different guarantee point loads (Condensate transfer 
  pump) 
 
Air Conditioning (Main control room ESP control room) & Ventilation 
ae) 
System. 
 
773  773 
af)  Mill Reject System 
 

Total for (II)  1623  1623 

TOTAL GUARANTEED AUXILIARY POWER CONSUMPTION PER UNIT (Pu)                   
17049  13036 
(Total for (I)+ Total for (II)) 

(III)  Transformers (Power consumption indicated is per unit basis) POWER  POWER 


  CONSUMPTION  CONSUMPTION 
  (KW)  (KW) 
(INDICATIVE  (INDICATIVE 
BREAKUP) BREAKUP)
  Transformer losses (GT/ST/UT/UAT/MSST/LT) 2610  2265

BB TOTAL GUARANTEED LOSSES PER UNIT TRANSFORMER (TL) 2610  2265

 
Notes: 
 

1. The auxiliary power consumption break‐up given above is for indicative purpose & total value as indicated in 
guarantee schedule is guaranteed.  
2. Auxiliary power consumption for common steam generator and auxiliaries corresponds to design coal & 27 0C 
ambient, 60%c RH design coal with moisture. 
3. Auxiliary power consumption for common station auxiliaries has been proportionately considered for single 
unit. 
4. ‘TL’ losses of transformers under bidder’s scope. Total power ‘Pa’ as arrived is as follows 
 
Pa (KW) = PU + TL = 17049 + 2610 = 19659 KW (for 100% Load) 
Pa (KW) = PU + TL = 13036 + 2265 = 15301 KW (for 800% Load) 
Pa (KW) = Guaranteed Auxiliary Power Consumption 
PU (KW) = Power consumed by auxiliaries of unit under test 
TL   (KW) = Losses of the transformer supplied by the bidder. 
 

5. Transformer losses are at actual loading of transformer at TMCR load. 
 
 

6. Normal operation of transformers without outage is considered.   
 

80 of 129
                                                                                                                                                           
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

 
Annexure‐19 
 

DISSOLVED OXYGEN CONTENT AT DEAERATOR OUTLET 

The dissolved oxgen content in feed water at Deaerator outlet shall be measure in the power plant laboratory 
by the Indigo‐Carmine method or ASTM D‐888 reference method‐A. 

Deaerator  is considered to be performing satisfactorily if the measured value is less than 0.005 cc/litre at al 
loads and without chemical dosing. 

This test shall be carried out before PG test or along with PG test. 

BHEL shall ensure protocol with Customer at site. 

BHEL                                                                                                                                                       CUSTOMER 

81 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

Annexure‐20 
 
 
DIFFERENCE BETWEEN THE SATURATION TEMPERATURE OF THE STEAM ENTERING THE DE‐AERATOR AND 
THE TEMPERARTURE OF THE FEED WATER LEAVING DE‐AERATOR 

Difference between the saturation temperature of the steam entering the De‐aerator and temperature of the 
feed water leaving De‐aerator shall be evaluated /measured and it shall be 1.11 deg.C. 

This test shall be done along with PG test. 

BHEL shall ensure protocol with Customer at site. 

BHEL                                                                                                                                                       CUSTOMER 

82 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

 
ANNEXURE – 21 
 

  Condenser Back Pressure test 
  procedure 
   

83 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

2X600 MW SCCL STPP

THE SINGARENI COLLIERIES COMPANY LTD.


POWER PROJECT DIVISION

CONDENSER BACK PRESSURE TEST PROCEDURE


(PROCEDURE NO: HXE - PT - CONDR - 073- 00)

HEAT EXCHANGER ENGINEERING


HARDWAR

84 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

HXE-PT-CONDR-073-00
Rev. No. : 00
Dated : 11/06/2016
Page 1 of 15
HEAT EXCHANGER ENGG
BHEL, HARDWAR

PROCEDURE FOR BACK PRESSURE DEMONSTRATION TEST ON STEAM


SURFACE CONDENSER

(PROCEDURE NO: HXE-PT-CONDR-073-00)

1.0: SCOPE:

The purpose of this write-up is to provide detailed procedure for demonstrating the
performance of steam surface condenser with regard to the following:

1.1 : The absolute back pressure of 77 mmHg(a) achieved by the equipment 300
mm above the top rows of condenser tubes when turbine operation
corresponds to VWO conditions, at 3% make-up, at design inlet cooling water
temperature of 33oC, at design circulating water flow rate and tube cleanliness
factor of 0.9.

2.0: COMPARISON:

The condenser is said to have fulfilled its design requirement when the measured
back pressure when corrected for differences in measured and designed values of
C.W. quantity, heat rejected in condenser, C.W. inlet temperature and cooling
surface area is found to be equal or less than the designed back pressure of 77
mmHg(a).

Worked By : Checked By : Approved By :

Deepak Kr. Yadav Deepak Kr. Yadav Naveen Prakash

85 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

HXE-PT-CONDR-073-00
Rev. No. : 00
Dated : 11/06/2016
Page 2 of 15
3.0: DESCRIPTION AND DEFINITION OF BASIC TERMS

Term Symbol Description Unit

Condenser
Rate at which heat is rejected to
Load H Kcal / hr
circulating water in condenser
Inlet Steam Saturation temperature of steam
o
Temperature ts corresponding to back pressure Ps C
(measured in mm HgC)
Inlet Temperature of cooling water o
tw1 C
Temperature measured at condenser inlet

Outlet Temperature of cooling water o


tw2 C
Temperature measured at condenser outlet

Temperature Increase of cooling water temperature


tw o
C
rise from inlet to outlet.

Cooling water Quantity of cooling water circulating


Qw m3/hr
flow through condenser per unit time

Specific heat Cp Specific heat of cooling water kcal/kg-oC

4.0: COMPLIANCE TO STANDARD:

The procedure is guided by recommendations of ASME-PTC 12.2 for steam surface


condenser.

5.0: MEASUREMENT:

The test scheme and mounting of instruments is as per approved PG Test


instrumentation scheme and approved write-up on Performance Guarantee test for
TG Package.

Worked By : Checked By : Approved By :

Deepak Kr. Yadav Deepak Kr. Yadav Naveen Prakash

86 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

HXE-PT-CONDR-073-00
Rev. No. : 00
Dated : 11/06/2016
Page 3 of 15
5.1 : Condenser Back Pressure:

12 Nos. (6 nos on each condenser) measurement points will be located 300 mm


above top row of tubes. These are fitted with ASME basket to ensure static pressure
measurement. These shall be uniformly located so as to cover total area above
tubes.

5.2 : Circulating Water Temperature:

5.2.1 : Inlet Temperature:

For PG Test measurement purpose of inlet temperature eight nos. (Four nos for
each condenser) test points, two nos. on each condenser inlet nozzle will be
provided.

5.2.2 : Outlet Temperature:

For PG Test purpose outlet temperature will be measured by providing six nos.
symmetrically spaced measurement points on each outlet pipe at least five meters
away from condenser nozzle. The points may be provided after bends and the
length of insertion of each point will be different to obtain bulk mean temperatures.

5.2.3 : Correction:

All temperatures will be measured with the help of RTDs in conjunction with digital
multimeters. Test data-logger can also be used with prior agreement. The following
corrections shall be applied to the measured values for arriving at the test values:
- PRT/ RTD, Instrument calibrations.
- Lead wire resistance, if applicable.

Worked By : Checked By : Approved By :

Deepak Kr. Yadav Deepak Kr. Yadav Naveen Prakash

87 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

HXE-PT-CONDR-073-00
Rev. No. : 00
Dated : 11/06/2016
Page 4 of 15
5.3 : Circulating Water Flow:

No direct method shall be employed for measurement of C.W. quantity flowing


through condenser. The same shall be computed from heat rejected to condenser
obtained from test heat rate calculations. Hence condenser test shall be conducted
in conjunction with turbine test. Details are as per Annexure-3.

5.4 : Cleanliness Factor:

Prior to test, physical/chemical cleaning of the tubes and water boxes shall be done
to obtain the desired tube cleanliness. After cleaning, the following cleanliness factor
will be considered for computation of results:

Titanium Tubes: 0.9

5.5 : Specific Heat:

Specific heat of water which is used in condensers at Singreni will be taken as 1.0
Kcal/Kg C.

6.0 : CONDITIONS FOR TEST:

6.1 : General Condition:

During condenser demonstration test, the air leakage into the vacuum systems
should not exceed 16 kg/hr. Air shall be measured by the flow device provided on
the air evacuating device.

Worked By : Checked By : Approved By :

Deepak Kr. Yadav Deepak Kr. Yadav Naveen Prakash

88 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

HXE-PT-CONDR-073-00
Rev. No. : 00
Dated : 11/06/2016
Page 5 of 15
6.2 : Machine Load:

Demonstration of Condenser Back Pressure will be carried out in conjunction with


turbine test. The machine load shall be kept corresponding to VWO condition of
Turbine with 3% make-up.

6.3 : Make-Up:

Condensate make-up of approx. 3% will be added to condenser during the test. This
shall be accounted for by opening the CBD during the test with quantity of blow
down set at 3% of condensate flow. Level of hot well and De-aerator shall be
maintained by adding make-up. Any other method can also be decided during test.

6.4 : Leakage/By-pass of Drains/Steams:

Prior to test, it will be ensured that drain flow to condenser (direct or through flash
boxes) will be strictly as per the design load regimes. Any bypass of drains /steam to
condenser must be identified and isolated.

6.5 : Allowable Deviations:


Testing shall be performed under conditions of inlet-water temperature, heat load,
and cooling-water flow within the limits as specified in Table 3.1 of ASME PTC 12.2.

Testing Parameters Deviations from specified conditions

Inlet Water Temperature +/- 10 oF

Heat Load +/- 5%

Cooling Water Flow +/- 5%

Worked By : Checked By : Approved By :

Deepak Kr. Yadav Deepak Kr. Yadav Naveen Prakash

89 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

HXE-PT-CONDR-073-00
Rev. No. : 00
Dated : 11/06/2016
Page 6 of 15

7.0 : INSTRUMENTS AND THEIR ACCURACIES (PRESSURE / TEMPERATURE


GAUGE):

The accuracy of various gauges shall generally conform to the recommendations of


ASME PTC 12.2 for steam surface condensers (refer enclosed Annexure - 1) or as
agreed between SCCLPPD and BHEL.

8.0 : FREQUENCY AND DURATION OF MEASUREMENT:

In case the readings are recorded through PG. Test data-logger, the frequency of
recording shall be governed by the data-logger characteristics. However for manual
recordings, the frequency of readings shall be 5 min. both for back pressure
readings and C W inlet/outlet readings. For condenser calculations, one hour data
will be considered from minimum test duration of two hour period during steady state
condition.

9.0 : COMPUTATION OF RESULTS:

9.1 : Heat rejected to condenser will be calculated based on the uncorrected and
actual heat rate of the Turbine Generator package at the time of test. Heat
rejected to condenser will be the difference of Heat supplied to the Turbine less
the Turbine output (Generator output corrected for mechanical / electrical
losses and turbine losses). Enclosed Annexure - 3 gives detailed relationship
for computation of condenser heat load.

9.2 : Computation of circulating water quantity / velocity will be done based on


circulating water temperature measurements, heat load on condenser as per
item 9.1 above and actual total tube sectional area per pass. Details of
calculations will also be as per Annexure - 3.
Worked By : Checked By : Approved By :

Deepak Kr. Yadav Deepak Kr. Yadav Naveen Prakash

90 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

HXE-PT-CONDR-073-00
Rev. No. : 00
Dated : 11/06/2016
Page 7 of 15

9.3 : The next step determines the actual (test) log mean temperature difference.
Annexure - 4 gives the procedure for calculation of the same. The test LMTD
corresponds to measured back pressure, C.W. velocity, actual surface area
and C.W. inlet temperature. Hence, it shall be corrected for designed C.W. inlet
temperature, velocity, surface area and heat rejected as identified in Annexure-
2. The corrected condenser back pressure will be computed from corrected
test LMTD as per Annexure-5. Correction curves for the above varying
parameters are enclosed as Annexure-6, 7 & 8.

9.4 : The corrected back pressure will be compared with the design back pressure
for the purpose of final evaluation.



Worked By : Checked By : Approved By :

Deepak Kr. Yadav Deepak Kr. Yadav Naveen Prakash

91 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

HXE-PT-CONDR-073-00
Rev. No. : 00
Dated : 11/06/2016
Page 8 of 15

ANNEXURE – 1

INSTRUMENT LIST FOR SURFACE CONDENSER TEST

SL MEASUREMENT NOMINAL TYPE OF RANGE OF ACCURACY OF


REMARKS
NO PARAMETERS VALUE INSTRUMENT INSTRUMENT INSTRUMENT

Absolute
Manometer/
60-89 U-tube 0-780 +0.10 With vernier
01 Back Pressure
mmHgC Manometer/ mmHgC mmHgC attachment
Pressure
Transmitter

C.W. inlet RTD / Glass


02 15 -40oC 0 -50 oC +/-0.1 oC
temperature thermometers

C.W. outlet RTD / Glass


03 25 -46oC 0 -50 oC +/-0.1 oC
temperature thermometers

Fortins With vernier


Atmospheric 700 –760 0-760 +0.25
04 Barometer attachment
Pressure mmHgC mmHgC mmHgC
(Site Lab.) and scale

Worked By : Checked By : Approved By :

Deepak Kr. Yadav Deepak Kr. Yadav Naveen Prakash

92 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

HXE-PT-CONDR-073-00
Rev. No. : 00
Dated : 11/06/2016
Page 9 of 15

ANNEXURE-2

GUARANTEE DATA

Sl Guarantee
Symbol Description Unit
No. Data
01 - Design, Mfg and Testing Code - HEI
6
02 Hlg Heat Load kcal/hr 325.93 x 10
03 Qg Cooling Water Flow per condenser 31650 31650
o
04 tw1d Cooling Water Inlet Temperature C 33.0
05 Psg Back Pressure mmHgC 77.0
06 L Effective Tube Length mm 13000
07 N Number of Tubes no. 17266
08 do x t Tube outside dia. x thickness mm x mm 28.575X0.7112
Dissolved Oxygen in
09 - cc/l 0.015
hotwell condensate

Worked By : Checked By : Approved By :

Deepak Kr. Yadav Deepak Kr. Yadav Naveen Prakash

93 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

HXE-PT-CONDR-073-00
Rev. No. : 00
Dated : 11/06/2016
Page 10 of 15
ANNEXURE – 3

MAIN CALCULATION

Station: 2X 600 MW SCCL STPP Date:

Unit: Duration :

Symbol Description Derivation Units Value

o
tw1m Mean C W in temp (tw11 + tw12) / 2 C
o
tw2m Mean C W out temp (tw21 + tw22) / 2 C

tw Mean C W temp rise (tw2m – tw1m) o


C

 Density of water - kg/m3 1000

Cp Specific Heat of water - kcal/kg 1

Ha Heat added in the cycle HR x Pg kcal/hr

To Output of Turbine (Pg / g + 1500) kcal/hr


x 859.846

Hr Heat rejected to condenser* (Ha – To)/2 kcal/hr

Qw C W flow rate Hr / (tw x  x Cp) m3/hr

Aw C W flow area 0.785 x di2 x N / p m2

V C W velocity Qw / Aw x 3600 m/sec.

A Condensing surface area  x do x L x N m2

LEGEND :
tw11: C W Inlet temp – 1st half Pg : Generator output, KW
tw12 nd
: C W Inlet temp – 2 half g : Generator efficiency
tw21: C W Outlet temp – 1st half di : tube inside dia., mm
nd
tw22: C W Outlet temp – 2 half p : number of C W passes
HR : Cycle Heat Rate
‘*” : Heat rejection to condenser is for one condenser.
Worked By : Checked By : Approved By :

Deepak Kr. Yadav Deepak Kr. Yadav Naveen Prakash

94 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

HXE-PT-CONDR-073-00
Rev. No. : 00
Dated : 11/06/2016
Page 11 of 15

ANNEXURE – 4

TEST LMTD COMPUTATION

Symbol Description Derivation Units Value

Pa Measured condenser - ata


Pressure
o
ts Saturation temperature Corres to Ps C

 LMTD tw/ln[(ts–tw1m)/ts–tw2m)] oC

Worked By : Checked By : Approved By :

Deepak Kr. Yadav Deepak Kr. Yadav Naveen Prakash

95 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

HXE-PT-CONDR-073-00
Rev. No. : 00
Dated : 11/06/2016
Page 12 of 15

ANNEXURE – 5

CORRECTION OF LMTD AND BACK PRESSURE

Symbol Description Derivation Units Value

ft C W inlet temp correction Annexure – 6 -


factor
-
fv C W Velocity correction Annexure – 7
factor

fh Heat load correction Annexure – 8 -


factor

c Corrected LMTD  x ft x fv x fh o
C

X Exponential exp (twd / c ) -

twd Design C W Temp. rise hlg/ (Qg x  x Cp) o


C

tsc Corrected steam temp. tw1d + X x twd /(X – 1) o


C

Psc Test condenser pressure Saturation pressure mmHgC


corrected to design point corresponding to tsc

Worked By : Checked By : Approved By :

Deepak Kr. Yadav Deepak Kr. Yadav Naveen Prakash

96 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

HXE-PT-CONDR-073-00
Rev. No. : 00
Dated : 11/06/2016
Page 13 of 15

Worked By : Checked By : Approved By :

Deepak Kr. Yadav Deepak Kr. Yadav Naveen Prakash

97 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

HXE-PT-CONDR-073-00
Rev. No. : 00
Dated : 11/06/2016
Page 14 of 15

Worked By : Checked By : Approved By :

Deepak Kr. Yadav Deepak Kr. Yadav Naveen Prakash

98 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

HXE-PT-CONDR-073-00
Rev. No. : 00
Dated : 11/06/2016
Page 15 of 15

Worked By : Checked By : Approved By :

Deepak Kr. Yadav Deepak Kr. Yadav Naveen Prakash

99 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

 
ANNEXURE – 22 
PROJECT: 2X600 MW SCCL ADILABAD TPP

TEST PROCEDURE FOR CW PUMPING


POWER 

100 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

PROJECT: 2X600 MW SCCL ADILABAD TPP

TEST PROCEDURE FOR CW PUMPING POWER

101 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

2 X 600 MW SCCL ADIALABD TPP

Procedure For Measurement Of Equivalent CW Pumping Power: for Pressure Drop In CW


system Between BHEL Terminal Points.

1.0 This procedure covers the calculation of equivalent CW pumping power for Design flow through
condenser corresponding to pressure drop in CW system within BHEL Terminal points (Refer Section
VI, Part A, Functional Guarantees & Liquidated Damages, Cl.1.01.01 (iv) of technical specification).

The total pressure drop within BHEL Terminal points constitutes of pressure drop through following:

 Condenser
 Balls collecting strainer of Condenser on Load Tube cleaning System
 Piping and fittings

2.0 The equivalent pumping power thus can be obtained from the pressure drops measured in these
components for the CW flow through them, using following calculations.

The formula used for calculating the Test CW pumping power (Ptest) with reference to design
conditions, within BHEL terminal points is as follows:

Ptest = Qdesign * DPcorrected


-----------------------
367.2 * o
Where:
Qdesign = Design Condenser CW flow = 28000 m3/hr

o = Overall efficiency of CW pump & Drive Set


= 0.83 (as per Section VI, Part A, Functional Guarantees & Liquidated Damages,
Cl.1.01.01 (iv), of technical specification)

DPcorrected = Test pressure drop corrected for design conditions

= ( Qdesign / Qtest )1.75 * DPtest * ( Ctd / Ctt )


Here;
Qtest = Test flow through condenser as computed.
(VWO, 3% Make-Up condition)

DPtest = Test CW side pressure drop within BHEL terminal points measured across Pressure
Test points.

Ctd = Design temperature correction factor for friction loss as per HEI (Ref Annexure-I)

Ctt = Test temperature correction factor for friction loss as per HEI (Ref Annexure-I)

102 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

3.0 The pressure drop for Condenser, Balls Collecting Strainer, piping and fittings within BHEL terminal
points can be measured directly at site across the Pressure Test Points (PTP’s) (viz. the pressure
drop measured across pressure test points shall include the pressure drop of condenser, COLTCS,
piping and fittings within BHEL terminal points) and tabulated in the log sheet attached as Annexure
II. The PTP’s shall be calibrated before the test in an approved reputed test lab. The calibration
certificate in original shall be submitted to customer before start of the PG Test for their acceptance.

4.0 The design CW pressure drop within BHEL terminal points is 6 MWC at design CW flow (viz.
condenser – 4.10, Ball strainer – 0.15 MWC and Piping and fittings – 1.75 MWC)

The Condenser On Load Tube Cleaning System should be in clean condition for the purpose of test
and this is to be ensured after backwashing the strainer.

103 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

HXE-PT-CONDR-074-00
Rev. No. : 00
Dated : 11/06/2016
Page 3 of 3

ANNEXURE-1

Worked By : Checked By : Approved By :

DK Yadav DK Yadav N Prakash

104 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

Annexure II

Log sheet for CW Pumping Power Test


Project: 2X600 MW SCCL ADILABAD TPP

Pressure at PTP provided Pressure at PTP provided at Flow as calculated Differential pressure between
S.No. at BHEL’s supply Terminal BHEL’s return Terminal Qtest BHEL terminal points, DPtest DPcorrected
Point Point
(1) (2) (3) (4) (5) = (3) - (2)

105 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

 
ANNEXURE – 23 
PROJECT: 2X600 MW SCCL ADILABAD TPP

TEST PROCEDURE FOR CONDENSER ON


LOAD TUBE CLEANING SYSTEM 

106 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

9661-110-27PE-PVM-W-004, Rev-00

107 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

108 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

109 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

110 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

ANNEXURE – 24 
PROJECT: 2X600 MW SCCL ADILABAD TPP

PG TEST PROCEDURE FOR CONDENSATE


EXTRACTION PUMP 

111 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

112 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

FP 12947
PRODUCT STANDARD
Rev No. 05
TD-106-1

PUMPS Rev No. 00


Form No.

HYDERABAD
HYDERABAD Page 2 of 6

SINGARENI THERMAL POWER PROJECT (2X600MW)

PROCEDURE FOR PERFORMANCE GUARANTEE TEST OF CEPs AT SITE


The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED,
It must not be used directly or indirectly in any way detrimental to the interest of the company.

1.0.0 OBJECT OF TEST :


The site performance guarantee tests shall cover the following tests on CEPs against
“Guarantees under category-III”.
1.1.0 Each CEP shall be capable of delivery flow and total dynamic head corresponding to
to Run out point.
1.2.0 The vibration, Noise level and parallel operation of any two of the three pumps shall be
demonstrated ,
COPYRIGHT AND CONFIDENTIAL

2.0.0 GUARANTEE PARAMETERS:


SI.NO CONDITION FLOW DYNAMIC TEMP SPEED
cubic HEAD °C RPM
M/hr MLC
01 RUN OUT CONDITION 975 190 46.4 1485

3.0.0 TEST SCHEME :


The Schematic arrangement for conducting the test is indicated in sheet-6.
4.0.0 TEST MEASUREMENT:
4.1.0 FLOW:
Suction flow shall be measured using the plant flow orifice. Differential pressure across flow
nozzle shall be measured using differential pressure transmitter of accuracy 0.25% and flow
shall be calculated based on the calibration data of flow orifice.
4.2.0 HEAD :
Head shall be measured by pressure transmitters having an accuracy of ±0.10%.

Revisions : Prepared : Approved : Date :


FP10495
Ref. Doc

07.06.16
Refer to record of revisions : (ROHIT P) (SRINIVAS P)

113 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

FP 12947
PRODUCT STANDARD
Rev No. 5
TD-106-2

Rev No.00
PUMPS
Form No.
HYDERABAD
HYDERABAD Page 3 of 6
4.4.0 Temperature:
Temperature shall be measured using platinum RTDs.

4.5.0 Speed:
Speed shall be measured using digital, Non-contact type optical speed indictor
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED .

having an accuracy of 1 RPM/STROBOSCOPE.


It must not be used directly or indirectly in any way detrimental to the interest of the company.

4.5.0 Vibration:
Vibration of CEP shall be measured at BEP condition using portable vibration meter.

4.6.0 Noise level:

Noise level shall be measured at BEP condition at a distance of 1.0m from the outer most surface of
CEP and 1.5m above floor level, using portable noise level meter. Correction for back ground noise
shall be applied in line with HIS.

4.7.0 List of instruments:


COPYRIGHT AND CONFIDENTIAL

The list of instruments required for the PG tests are indicated in sheet-6.

4.8.0 Calibration of instruments:

All Instruments used for Pumps PG test will be calibrated at BHEL(R & D) prior to the PG test,
and calibration certificates shall be furnished to NTPC.

4.9.0 Data logging:

Primary sensors of flow, pressure and temperature will be connected to a data logger
And recorded for evaluation.

5.0.0 PERFORMANCE AT RUN OUT CONDITION:

The pump flow will be adjusted to the Run out condition, and measurements will be made for all
parameters. Various parameters will be logged at interval of 1 minute. 15 sets of reading will be
recorded continuously. Average of at least 10 sets of consistent data shall be considered for
evaluating the performance guarantee data.

Run out condition: - Test will be conducted at 3 flow point. i.e Run out point, +5% and -10% of Run
out condition flow.

Curve for flow vs head will be plotted after applying speed and temperature correction. Guarantee
parameters will be read from this curve.

114 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

FP 12947
PRODUCT STANDARD
Rev No. 5
TD-106-2

Rev No.00
PUMPS
Form No.

HYDERABAD Page 4 of 6

6.0.0 PARALLEL OPERATION :

Parallel operation of any two CEPs will be demonstrated at best efficiency point. 15 sets
of flow reading will be recorded continuously at 1 minute intervals.
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED .
It must not be used directly or indirectly in any way detrimental to the interest of the company.

Average of at least 10 consistent readings will be considered for evaluating the performance
guarantee data.

Test will be conducted at 1 flow point i.e at BFP point (615 Cu.m/hr).

7.0.0 ACCEPTANCE CRITERIA FOR TESTS :

7.1.0 Capability at Run out condition :

Total dynamic head of CEP at Run out condition shall not be less than the guaranteed
dynamic head of CEP at relevant operating condition flow.
COPYRIGHT AND CONFIDENTIAL

7.2.0 Parallel operation: variation in flow between the pumps shall not exceed 5%.

7.3.0 Vibrations: Vibration shall not exceed 7.0 mm/sec (rms.)

7.4.0 Noise Level: Noise level shall not exceed 85 dBA.

7.5.0 Sample calculations :

7.5.1 Flow calculations :

(a) Correction for temperature :


Q1 = Q/WT

Where ,Q = Measured flow in T / Hr, Q1 = corrected flow in Cu.M/Hr


WT = Sp.Weight at test temperature

(b) Correction for speed :


QS = Q1 (NS /NT)

Where ,QS = Flow in Cu.M/Hr at specified speed


NS = Specified speed
NT = Test speed

115 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

FP 12947
PRODUCT STANDARD
Rev No. 5
TD-106-2

Rev No.00
PUMPS
Form No.

HYDERABAD Page 5 of 6

7.5.2 Head calculations :

(a) Correction for temperature :


H = ( P2- P1) X10/WT
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED .
It must not be used directly or indirectly in any way detrimental to the interest of the company.

Where, P2 = CEP disch. Pr.in kg/sq.cm


P1 = CEP suct. Pr. in kg/sq.cm
H = Dynamic head of CEP in MLC at test speed

(b) Correction for speed :


HS = H X SQUARE (NS /NT)

Where ,HS = Dynamic head of CEP in MLC at specified speed


COPYRIGHT AND CONFIDENTIAL

116 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

117 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

REV DATE ALTERED: AS KALYAN


450
01 27-07-2012 APPROVED: M M RAO
M IN. RE CIRC FLOW
400
THE NPSHR VALUE IS UPDATED TO SECOND DECIMAL PLACE

350

A
Head (m)

300

D FLOW HEAD ACT. TEMP (deg. SP. WT SPEED


REF HEAD (mlc) EFFIC (%) POWER (KW) NPSHR (mlc)
(cu.m/hr) (mlc) C) (kg/m3) (RPM)
250

C E A 900 290 290 49.2 988.4 80.5 873 1485 3.35


200 B B 975 190 267 46.4 989.6 79.2 885 1485 3.54

C 715 240 329 46.4 989.6 80.5 787 1485 2.89


150
D 825 290 309 49.2 988.3 81.1 845 1485 3.16

100 E 1015 215 252 59.7 983.3 78.2 877 1485 3.65
1200

A - Design condition
1000 51.5 HZ
A
POWER (KW)

B - Runout Condition
D
800 B E 50 HZ C - Best Efficiency Point
C 47.5 HZ D - HPH out Condition
600
E - Maximum Capability condition

400

200
90.0 5.5
90 18
A A NOTE :
80.0 5
80 16 1. SHUT OFF HEAD AT 50Hz = 367 mlc.

2. INPUT POWERS AT B , C , D & E ARE CALCULATED


70.0 4.5
70 14
Efficiency (%)

BASED ON ACTUAL HEADS GENERATED AT 50 Hz.


60.0 4
60 12
Efficiency (%)

B
50.0
50 A E 10 3.5 NPSH (R) m Digitally signed
Signature Not Verified
NPSH (R) m

by Sign Sunil
Jumde
NTPC DRAWING NO: 9661-110-02HY-PVM-N-002, REV-01
40.0
40
C D 8 3 Date: 2012.08.03
14:41:13 IST
JOB NO. : 381 M/s The Singareni Colliries Company
C CUSTOMER:
Reason: CAT IV
Limited (SCCL)
30.0
30 A 6 2.5 STATUS: CONTRACT Location:
NTPCEOC
CONSULTANT: M/s NTPC Ltd.
51.5 HZ B DRG./REF.NO. (INTERNAL)
20
20.0 4 2 SCCL COAL BASED THERMAL POWER
50 HZ FP12910 PROJECT:
PLANT (2X600MW)

10 2
PUMPS ENGINEERING NAME SIGN DATE
10.0 1.5
BHARAT HEAVY ELECTRICALS PRPD. AS Kalyan -- 05-05-2012
CHKD. M M RAO -- 05-05-2012
0 0 LTD. HYDERABAD APPD. B RAJKUMAR -- 05-05-2012
0.0 1
00 200
100 400
200 600
300 400800 5001000 600 1200 700 1400 800 1600 900 1800
1000 2000
1100 1200 TITLE: DRG. NO. HY-DG-4-FP12910
Flow (m3/ h) REV 01
Flow (m3/ h) ESTIMATED PERFORMANCE CURVES OF CEP
SHEET NO: 1 NO. OF SHEETS: 1

118 of 129
 
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

ANNEXURE – 25 
PROJECT: 2X600 MW SCCL ADILABAD TPP

PG TEST PROCEDURE FOR BOILER FEED


PUMP 

119 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

120 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

FP 12948
PRODUCT STANDARD
Rev No. 05
TD-106-1

PUMPS Rev No.00


Form No.

HYDERABAD
HYDERABAD Page 2 of 6

SINGARENI THERMAL POWER PROJECT (2X600MW)


PROCEDURE FOR PERFORMANCE GUARANTEE TEST OF BFP SETS AT SITE

1.0.0 OBJECT OF TEST :


The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED,

The site performance guarantee tests shall cover the following tests on BFP sets
It must not be used directly or indirectly in any way detrimental to the interest of the company.

against “Guarantees under category –III”.


1.1.0 Each BFP set shall be capable of delivery flow and total dynamic head corresponding
to Run out point.
1.2.0 The vibration, Noise level and parallel operation of any two of the three pumps shall
be demonstrated
2.0.0 GUARANTEE PARAMETERS:
2.1.0 Run-out condition:
COPYRIGHT AND CONFIDENTIAL

SI.NO EQUIPMENT FLOW TOTAL DYNAMIC TEMP BP/ BFP


Cubic m/hr HEAD (BP+BFP) °C SPEED
m/c rpm
01 MD BFP SET 1350 2025 148.7 1495 / 5630

02 TD BFP SET 1350 2025 148.7 1475 / 5635

3.0.0 TEST SCHEME:


The Schematic arrangement for conducting the test is indicated in sheet-6.

4.0.0 TEST MEASUREMENTS:

4.1.0 FLOW:

Suction flow shall be measured using the plant flow nozzle. Differential pressure across flow
nozzle shall be measured using differential pressure transmitter of accuracy 0.25% and flow shall
be calculated based on the calibration data of flow nozzle.

4.2.0 HEAD :
Head shall be measured by pressure transmitters having an accuracy of ±0.10%.

4.3.0 Temperature:

Temperature shall be measured using platinum RTDs.

Revisions : Prepared : Approved : Date :


FP10
Ref.
Doc

495

Refer to record of revisions : (ROHIT.P) (P.SRINIVAS) 07.06.16

121 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

FP 12948
PRODUCT STANDARD
Rev No. 5
TD-106-2
Rev No.00
PUMPS
Form No. HYDERABAD
HYDERABAD Page 3 of 6

4.4.0 Speed

TD Booster pump speed,MD Booster pump speed and MD BFP Speed shall be measured using
digital,non-contact type optical speed indicator having an accuracy of 1 RPM/STROBOSCOPE.
TD BFP Speed will be derived from measured TD BP Speed, using gear box gear ratio.
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED .
It must not be used directly or indirectly in any way detrimental to the interest of the company.

4.5.0 Vibration:

Vibration of BFP at BEP point shall be measured using portable vibration meter.

4.6.0 Noise level:

Noise level shall be measured at a distance of 1.0m from the outer most surface of BFP and
1.5m above floor level, using portable noise level meter. Correction for back ground noise shall
be applied in line with HIS.

4.7.0 List of instruments:

The list of instruments required for the PG tests are indicated in sheet-6.
COPYRIGHT AND CONFIDENTIAL

4.8.0 Calibration of instruments:

All Instruments used for Pumps PG test will be calibrated at BHEL(R & D) prior to the PG test,
& calibration certificates shall be furnished to NTPC.

4.9.0 Data logging:

Primary sensors of flow, pressure and temperature will be connected to data logger
And recorded for evalution.

5.0.0 PERFORMANCE AT RUN OUT CONDITION:


The pumps flow and pressure will be adjusted to the RUN out condition, and measurement will
be made for all parameters. The inter stage and kicker-stage lines will be closed during the test
.Various parameters of Booster pump & BFP will be logged at interval of 1minute. 15 sets of
reading will be recorded continuously.
Average of at least 10 sets of consistent data shall be considers for evaluating the performance
guarantee data.

Run out condition :- Test will be conducted at 3 flow points.i.e Run out point,+5% and (-)10% of
Run out condition flow.

Curve for flow vs. head will be plotted after applying speed and temperature Correction,
Guarantee parameters will be read from this curve.

Total dynamic head of BFP set is the sum of Booster pump head and BFP head at guaranteed
flow.

122 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

FP 12948
Rev No. 5
TD-106-2

PRODUCT STANDARD
Rev No.00
Form No.
PUMPS
HYDERABAD
Page 4 of 6

6.0.0 PARALLEL OPERATION:

Parallel operation of two TD BFP sets will be demonstrated at Best efficiency point.
The inter-stage and kicker-stage lines shall be closed during the test. 15 sets of reading will be
recorded continuously at 1 minute intervals.

Average of at least 10 consistent reading will be considered for evaluating the performance
guarantee data.

Test will be conducted at 1 flow point i.e at BEP point (855 Cu. m/hr).
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED .

7.0.0 ACCEPTANCE CRITERIA FOR TESTS:


It must not be used directly or indirectly in any way detrimental to the interest of the company.

7.1.0 Capability at Run out Condition:

Total dynamic head of BFP set at Run out condition read from the site tested curve shall not be
less than the guarantee dynamic head of BFP set at relevant operating condition flow.

7.2.0 Parallel operation of BFP sets:


COPYRIGHT AND CONFIDENTIAL

The variation in flow between the pumps shall not exceed 5%.

7.2.0 Vibrations:

Vibration will be measured and the same shall not exceed 7.0 mm/sec (rms.)

7.3.0 Noise Level:

Noise level shall not exceed 85 dBA.

7.4.0 Sample calculations:

7.4.1 Flow calculations:

(a) Correction for temperature:


Q1 = Q/WT1

Where, Q = Measured flow in T/Hr


Q1 = Corrected flow in Cu.M/Hr
WT1 = sp. Weight at BFP suction temperature

(b) correction for speed :


QS = Q1 (NS / NT)

Where, QS = flow in Cu.M/Hr at specified speed


NS = specified speed
NT = Test speed

123 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

FP 12948
PRODUCT STANDARD
Rev No. 5
TD-106-2

Rev No.00
PUMPS
Form No.

HYDERABAD Page 5 of 6

7.4.2 Head calculations for BP

(a) correction for temperature


HBP = (P2- P1) X 10/ WT1
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED .
It must not be used directly or indirectly in any way detrimental to the interest of the company.

Where, P2 = BP Disch./BFP Suction Pr.in kg/Sq.cm


P1 = Booster pump suction Pr.in kg/Sq.cm
HBP = Dynamic head of BP in MLC at test speed

(b) correction for speed


HBPs = HBP X SQUARE (NS /NT)

Where, HBPs = Dynamic head of BP in MLC at specified speed

7.4.3 Head calculations for BFP


(a) correction for temperature
HBFP = (P3 –P2) X 10/WT2
COPYRIGHT AND CONFIDENTIAL

P3 = BFP discharge pressure in kg/sq.cm


P2 = BFP Suction / BP Disch . Pr.in kg/sq.cm
WT2 = SP.Weight at BFP Disch.Temperature.
HBFP = Dynamic head of BFP in MLC at test speed

(b) correction for speed

HBFPs = HBFP X SQUARE(NS / NT)


Where ,HBFPs = Dynamic head of BFP in MLC at specified speed

124 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

125 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

Rev-02 Rev-01

3100 Test code updated. NPSHR values revised as per


MIN RC FLOW
9661-110-03HY-PVM-N-008, pump frame

2800 and test code indicated.

2500
D FLOW HEAD EFFICIENCY POWER SPEED NPSHR
E REF
(m3/hr) (mlc)
SP. GR.
(%) (KW) (RPM) (mlc)
F
ead (m)

2200
A 1220 2127 0.903 80.2 7957 5710 68.5
A B 1350 1840 0.918 77.9 7972 5630 87.8
Head

C 1055 2048 0.904 81.2 6551 5430 54.9


C D 1165 2409 0.904 80.7 8562 5910 62.9
1900 B E 1195 2365 0.904 80.5 8643 5905 65.8
F 1165 2339 0.903 80.7 8304 5845 62.9
1600

1300 A- DESIGN POINT


B- RUNOUT POINT
C- BEST EFFICIENCY POINT
1000 D- EMERGENCY POINT
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
E- U/F CASE 1
Flow (m3/h) F- U/F CASE 2
10000
D E
8000
F A B
ER (KW)

6000 C
POWER

4000 NOTE :
1. DISCHARGE FLOW AT THE DESIGN CONDITION
2000 IS WITH INTER STAGE CLOSED.
2. MIN. RC FLOW INDICATED IS FOR BFP OPERATION. THIS IS
INDICATED ONLY FOR THE PURPOSE OF CALCULATING
0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
BFP SET SHUT OFF PRESSURES AT RC FLOW.
Flow (m3/h) 3. HYDRAULIC COUPLING MAXIMUM OUTPUT SPEED = 6010 RPM

90

A
80 100

70 B

60 75 PUMP FRAME MODEL: FK4E36


iency (%)

F E TEST CODE: ANSI/ HI 14.6-2011


Digitally signed
Efficienc

50 A Signature Not
by PVerified
D R SEN
NPSH (R) m

NTPC
Date: DRAWING NO: 9661-110-03HY-PVM-N-001
2013.04.17
40 C 50
JOB NO. : 381
14:04:55 IST M/s The Singareni Colliries Company Limited
Reason: CAT IV
CUSTOMER:
Location: (SCCL)
30 STATUS: CONTRACT
NTPCEOC
CONSULTANT: M/s NTPC
DRG./REF.NO. (INTERNAL)
20 25 SCCL COAL BASED THERMAL POWER PLANT
FP12880 PROJECT:
(2X600MW)

10
PUMPS ENGINEERING NAME SIGN DATE
PRPD. AS Kalyan -- 13-08-2012
BHARAT HEAVY ELECTRICALS LTD.
CHKD. M M RAO -- 13-08-2012
0 0 HYDERABAD APPD. B RAJKUMAR -- 13-08-2012
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 TITLE: DRG. NO. HY-DG-4-FP12880
Flow (m3/h) ESTIMATED PERFORMANCE CURVES OF MD REV 02
BOILER FEED PUMP SHEET NO: 1 NO. OF SHEETS: 1

126 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

Rev-03 Rev-02 Rev-01


260
Test code updated. Test code updated. Pump frame and test code are

MIN. RE CIRC. FLOW


240

220

C
200 D E 51.5 HZ
Head (m)

F A B
180
50 HZ

160 47.5 HZ
FLOW EFFICIENC POWER SPEED NPSHR
REF HEAD (mlc) SP. GR.
(m3/hr) Y (%) (KW) (RPM) (mlc)
140
A 1220 193 0.9030 82.3 704 1495 5.75

120 B 1350 185 0.9180 81.5 766 1495 6.64

C 1055 202 0.9040 81.8 641 1495 4.79


100
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 D 1165 196 0.9040 82.3 683 1495 5.41
E 1195 195 0.9040 82.3 697 1495 5.60
Flow (m3/h) F 1165 196 0.9030 82.2 683 1495 5.41

900
51.5 HZ
800
E A- DESIGN POINT
700 D B 50 HZ
POWER (KW)

B- RUNOUT POINT
A
600
C F 47.5 HZ C- BEST EFFICIENCY POINT
D- EMERGENCY POINT
500
E- U/F CASE 1
POW

400 F- U/F CASE 2


300
200
NOTE :
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
Flow (m3/h) 1. DISCHARGE FLOW AT THE DESIGN CONDITION
IS WITH INTER STAGE CLOSED.
90 9
A 2. MIN. RC FLOW INDICATED IS FOR BFP OPERATION. THIS IS
INDICATED ONLY FOR THE PURPOSE OF CALCULATING
80 8 BFP SET SHUT OFF PRESSURES AT RC FLOW.

70 B 7

60 A 6 PUMP FRAME MODEL: FA1B75


E
Efficiency (%)

F TEST CODE: ANSI/ HI 14.6-2011


50 C D 5
NPSH (R) m

NTPCDigitally
DRAWING signed
NO: 9661-110-03HY-PVM-N-002
Signature Not
by PVerified
R SEN
40 4 JOB NO. : 381 Date: 2013.04.25 M/s The Singareni Colliries Company Limited
51.5 HZ CUSTOMER:
19:25:04 IST (SCCL)
50 HZ STATUS: CONTRACT Reason: CAT IV
30 3
N

47.5 HZ Location:
CONSULTANT: M/s NTPC
DRG./REF.NO. (INTERNAL) NTPCEOC
20 2 SCCL COAL BASED THERMAL POWER PLANT
FP12881 PROJECT:
(2X600MW)
10 1 PUMPS ENGINEERING NAME SIGN DATE
PRPD. AS Kalyan -- 13-08-2012
BHARAT HEAVY ELECTRICALS LTD.
CHKD. M M RAO -- 13-08-2012
0 0 HYDERABAD APPD. B RAJKUMAR -- 13-08-2012
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
TITLE: DRG. NO. HY-DG-4-FP12881
Flow (m3/h) ESTIMATED PERFORMANCE CURVES OF MD REV 03
BOOSTER PUMP SHEET NO: 1 NO. OF SHEETS: 1

127 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

Rev-02 Rev-01
3400
Test code updated. NPSHR values revised as per
9661-110-03HY-PVM-N-008, pump frame
3100
and test code indicated
MIN RC FLOW
2800

2500
D
Head (m)

2200

C A
H

1900 B
FLOW EFFICIENCY POWER SPEED NPSHR
1600 REF HEAD (mlc) SP. GR.
(m3/hr) (%) (KW) (RPM) (mlc)
A 1220 2127 0.903 80.2 7956 5710 68.5
1300 B 1350 1846 0.918 77.9 7999 5635 87.8
C 1055 2068 0.904 81.2 6615 5450 54.9
D 1165 2394 0.904 80.7 8507 5895 62.9
1000
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
Flow (m3/h)
10000 A- DESIGN POINT
B- RUNOUT POINT
D B C- BEST EFFICIENCY POINT
8000
A D- EMERGENCY POINT
(KW)
POWER (KW

6000
C
4000 NOTE :
1. DISCHARGE FLOW AT THE DESIGN CONDITION
2000 IS WITH INTER STAGE CLOSED.
2. MIN. RC FLOW INDICATED IS FOR BFP OPERATION. THIS IS
INDICATED ONLY FOR THE PURPOSE OF CALCULATING
0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
BFP SET SHUT OFF PRESSURES AT RC FLOW.
Flow (m3/h) 3. DRIVE TURBINE TRIP SPEED= 6281 RPM

90

80
A 100

B
70
Efficiency (%)

60 75 PUMP FRAME MODEL: FK4E36

50 A TEST CODE: ANSI/ HI 14.6-2011


NPSH (R) m

D NTPC DRAWING NO: 9661-110-03HY-PVM-N-003


Digitally signed
40 C 50 Signature Not
JOB NO. : 381 by PVerified
R SEN M/s The Singareni Colliries Company Limited
CUSTOMER:
Date: 2013.04.17 (SCCL)
30 STATUS: CONTRACT 17:18:25 IST
CONSULTANT: M/s NTPC
DRG./REF.NO. (INTERNAL)Reason: CAT IV
20 25
Location: SCCL COAL BASED THERMAL POWER PLANT
FP12882 NTPCEOC PROJECT:
(2X600MW)

10
PUMPS ENGINEERING NAME SIGN DATE
PRPD. AS Kalyan -- 13-08-2012
BHARAT HEAVY ELECTRICALS LTD.
CHKD. M M RAO -- 13-08-2012
0 0 HYDERABAD APPD. B RAJKUMAR -- 13-08-2012
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 TITLE: DRG. NO. HY-DG-4-FP12882
Flow (m3/h) ESTIMATED PERFORMANCE CURVES OF TD REV 02
BOILER FEED PUMP SHEET NO: 1 NO. OF SHEETS: 1

128 of 129
PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

Rev-03 Rev-02 Rev-01


Test code updated Test code updated. Pump frame and test code are indicated
300
280

260
MIN. RE CIRC. FLOW
250 T-TRIP(BP) 1645RPM
240
480 m3/hr for
Condition - A
220
200 C D
A
200 167.8889645
Head(m)
(m)

150
B A B
Head

180
C
FLOW EFFICIEN POWER SPEED NPSHR
160
100 REF HEAD (mlc) SP. GR.
(m3/hr) CY (%) (KW) (RPM) (mlc)

140 A 1220 193 0.9030 82.3 704 1495 5.75


50 B 1350 179 0.9180 81.5 741 1475 6.59
120
C 1055 182 0.9040 81.8 578 1427 4.61
100
0 D 1165 211 0.9040 82.3 735 1543 5.54
00 100 200200 300
400 400 600500 600
800 7001000800 1200
900 10001400
1100 1200
1600 13001800
1400 1500
2000

Flow
Flow(m3/h)
(m3/h)
800
900 A- DESIGN POINT
B- RUNOUT POINT
800
700 A B C- BEST EFFICIENCY POINT
C D D- EMERGENCY POINT
700
A
(KW)

600
600
NOTE :
(KW)

500
B C
POWER

500 1. DISCHARGE FLOW AT THE DESIGN CONDITION


400
POWER

400 IS WITH INTER STAGE CLOSED.


300 2. MIN. RC FLOW INDICATED IS FOR BFP OPERATION. THIS IS
300
INDICATED ONLY FOR THE PURPOSE OF CALCULATING
200 BFP SET SHUT OFF PRESSURES AT RC FLOW.
00 100 200200 300
400 400 600500 600
800 7001000800 1200
900 10001400
1100 1200
1600 13001800
1400 1500
2000
Flow (m3/h)
Flow (m3/h)

90
90 9
18
A A
80
80 8
16

70 7
70
B 14
Efficiency (%)
(%

PUMP FRAME MODEL: FA1B75


60
60 A 6
12
Efficiency (%)

D TEST CODE: ANSI/ HI 14.6-2011


50 C 5 Digitally
SignatureNTPC
Not signed
by PVerified
50 10 DRAWING NO: 9661-110-03HY-PVM-N-004
(R) m
m

R SEN
NPSH(R)

JOB NO. : 381 Date: 2013.04.25 M/s The Singareni Colliries Company Limited
40
40 84 CUSTOMER:
19:23:06 IST
C (SCCL)
NPSH

STATUS: CONTRACT Reason: CAT IV


Location:
30
30 A 63 DRG./REF.NO. (INTERNAL)
CONSULTANT:
NTPCEOC
M/s NTPC
B SCCL COAL BASED THERMAL POWER PLANT
20
20 42 FP12883 PROJECT:
(2X600MW)
10 PUMPS ENGINEERING NAME SIGN DATE
10 21
PRPD. AS Kalyan -- 13-08-2012
BHARAT HEAVY ELECTRICALS
CHKD. M M RAO -- 13-08-2012
00 LTD. HYDERABAD
00 APPD. B RAJKUMAR -- 13-08-2012
00 100 200200 300
400 400600500 600
800 7001000800 900
1200 1000
14001100 1200
1600 1300
18001400 2000
1500 TITLE: DRG. NO. HY-DG-4-FP12883
Flow (m3/h)
Flow (m3/h) ESTIMATED PERFORMANCE CURVES OF TD REV 03
BOOSTER PUMP SHEET NO: 1 NO. OF SHEETS: 1

129 of 129

You might also like