BHARAT HEAVY ELECTRICALS LIMITED

TECHNICAL OFFER
SUNFLAG IRON & STEEL CO LTD – 1 X 42 MW STG AT
BHANDARA, NAGPUR, MAHARASHTRA
CONSULTANT: FICHTNER CONSULTING ENGINEERS (INDIA) PVT. LTD.
ENQUIRY SPECIFICATION NO: 1110166-ME-SPC-120-002 REVA

MARCH’ 2011
  
   
 
Sunflag Iron & Steel Ltd.  
Nagpur 
 
1 x 42 MW STG (Technical Offer) 
Consultant: Fichtner Consulting Engineers (India) Private Ltd. 
Tender Specification no. 1110166‐ME‐SPC‐120‐002 REV A 
 
 

Technical Offer - Index

1.0) Section - I : Overall Scope, Terminal Points and Exclusions

2.0) Section – II : Technical write-ups

3.0) Section – III : HMBD (Heat and Mass balance diagram)

4.0) Section – IV : Comments, Clarifications and Deviations

5.0) Section – V : Vendor List

Bharat Heavy Electricals Ltd., Industry Sector, New Delhi – 110 003
  
   
 
Sunflag Iron & Steel Ltd.  
Nagpur 
 
1 x 42 MW STG (Technical Offer) 
Consultant: Fichtner Consulting Engineers (India) Private Ltd. 
Tender Specification no. 1110166‐ME‐SPC‐120‐002 REV A 
 
 

SECTION – 1

Overall Scope, Terminal Points and Exclusions

Bharat Heavy Electricals Ltd., Industry Sector, New Delhi – 110 003
 SUN FLAG – 1 X 42 MW TECHNICAL OFFER  

A. SCOPE OF SUPPLY - MAJOR EQUIPMENT *

1. STEAM TURBINE

2. OIL SUPPLY SYSTEM.

3. SURFACE CONDENSER.

4. STEAM JET AIR EJECTOR.

5. GLAND STEAM CONDENSER.

6. FEEDWATER HEATERS (LPH- 1No)

7. DEAERATOR

8. LUBE OIL COOLERS – 2X100%

9. GENERATOR & AUXILIARIES

10. GENERATOR AIR COOLERS

11. INTEGRAL INSTRUMENTATION

12. BALANCE OF PLANT – MECHANICAL

B. LIST OF TERMINAL POINTS

C. LIST OF EXCLUSION

NOTE: DETAILED SCOPE OF SUPPLY ENCLOSED.

1. PG test code is as per IEC 953 part II.

2. Hot well storage capacity is 2 minutes.
3. All sub vendor items shall be as per BHEL vendor list only.
4. Deaerator storage capacity is 10 min from NL to LL level.
5. Condenser design is as per HEI.
6. QAPs shall be as per BHEL standard only.

BHARAT HEAVY ELECTRICALS LIMITED, INDUSTRY SECTOR, NEW DELHI-3

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1.0 Scope of Supply - Steam Turbine

1.1.1. Steam Turbine
1.1.2. Emergency Trip Cum Stop Valve
1.1.3. Blanket Plate for Steam Blowing
1.1.4. Turbine Steam Governing Valves
1.1.5. Steam Strainer Built into Stop Valve
1.1.6. Reduction Gearbox between Turbine & Generator
1.1.7. Coupling and Coupling Guard between Turbine & Gearbox
1.1.8. Coupling and Coupling Guard between Gearbox & Generator
1.1.9. Manual Barring Device
1.1.10. Turning Device -Electric
1.1.11. Solenoid Valve for Remote Tripping
1.1.12. Turbine Sole Plate / Gear Box Base Plate
1.1.13. Foundation Bolts
1.1.14. Shaft Grounding Device
1.1.15. Gland Sealing System (automatic) including inlet and dump control valve
1.1.16. Mating Flanges for Turbine Inlet & Extraction Flanges
1.1.17. Gland Steam Leak off piping
1.1.18. Special Tools for Maintenance
1.1.19. Prime Coat of Paint
1.1.20. O & M Manuals -6 sets
1.1.21. Turbine Drain Water Piping within TG Block
1.1.22. Turbine Insulation ( Mineral Wool spray with CAT-9 cement layer )
1.1.23. QCNRV in Extraction Line Other than in LPH line
1.1.24. SCNRV in extraction line to Deaerator
1.1.25. Bolt Heating equipment (Electric)
1.1.26. Vacuum Breaker Valve
1.1.27. Turbine Enclosure
1.1.28. Exhaust hood spray system (Automatic)

BHARAT HEAVY ELECTRICALS LIMITED, INDUSTRY SECTOR, NEW DELHI-3

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2.0 Scope of Supply - Oil Supply System

1.1 Main Oil Tank (Carbon Steel Matl)Including
- Drain & Maintenance Openings
- Level Indicator
- Level Signalisation High/Low
- Connection for Purifier
1.1.1 Main Oil Pump with AC motor

1.1.2 Auxiliary Oil Pump with AC Motor

1.1.3 Emergency Oil Pump with DC Motor(DCSC loose supply)

1.1.4 Jacking oil Pump with 1AC + 1DC Motor(DCSC loose supply)

1.1.5 Duplex Filter with paper cartridge for Lube Oil

1.1.6 Trans-flow Valves for Duplex Oil Filters

1.1.7 2x100 % oil cooler with Change Over Device for Oil Coolers

1.1.8 Oil Mist Fan with AC Motor (2 x 100%)

1.1.9 Pressure Throttles for Bearings

1.1.10 Complete Lube Oil Piping (Stainless Steel Material After Filter Outlet)

1.1.11 Complete Control Oil Piping ( Stainless Steel Material )

1.1.12 Overhead Lube oil tank with complete Piping ( Stainless Steel material)

1.1.13 Oil Accumulators ( as required)

1.1.14 Oil Centrifuge (2400 LPH).

1.1.15 Governing Console Consisting of

− Duplex Filter for Control Oil
− Main Trip Solenoid Valve
− Electric-Hydraulic Converter
− Local Gauge Board with Control Oil System Instruments
− Solenoid Valve for Opening / Closing of ESV
- Other hydraulic components

BHARAT HEAVY ELECTRICALS LIMITED, INDUSTRY SECTOR, NEW DELHI-3

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SCOPE OF SUPPLY – TG INTEGRAL PIPING

1. Turbine Drain Water Piping within TG Block
2. Gland Sealing Steam Piping from a Point within TG Block
3. Gland Steam Leak-off line to Gland Steam Condenser
4. GSC Exhausters Exhaust Piping
5. Balance Piston Leak-Off Steam Piping
6. Condensate drains piping from SJAE and GSC condensers to Surface condenser.
7. Exhaust hood spray piping from CEP discharge to turbine.
8. Drain & Vent piping as applicable
9. Airside inter-connection piping between condenser and ejector.
10. Supports for all the above piping as required
11. Insulation for all the above piping as required

3.0 SURFACE CONDENSER :

3.1. Two pass divided water box circular Condenser.

3.2. Carbon steel dome, shell, hot well, water box etc. and welded SS tubes.

3.3. Standpipes for mounting instruments

3.4. Sacrificial anodes inside water box for cathodic protection

3.5. Primer coating on outer surfaces and epoxy coating on waterbox internals.

3.6. Accessories ( rupture disc, water expansion relief valve, vent and drain valves ).

3.7. Tubing of Condenser shall be done at site by erection agency. Shell-baffle-tubesheet

sub-assembly shall be dispatched as a single piece. Hotwell, waterbox, tubes, standpipes,
surgepipe etc. will be sent loose from BHEL works.

BHARAT HEAVY ELECTRICALS LIMITED, INDUSTRY SECTOR, NEW DELHI-3

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4.0 STEAM JET AIR EJECTOR :

4.1. 2 x 100% running ejector inter and after condensers and 1x100% starting ejector
with silencer.

4.2. Nozzle and diffusers for ejectors.

4.3. Inter and after condensers with carbon steel shell, tube sheet, water box & stainless
steel (SA249 TP304) tubes

4.4. Primer coating on outer surfaces

4.5. Steam and Air pipes

4.6. Accessories ( water expansion relief valve, vent and drain valves ).

5.0 GLAND STEAM CONDENSER :

5.1 GSC with 2 x 100% Ejector

5.2 Carbon steel shell, waterbox and stainless steel (SA249 TP304) tubes

5.3 Accessories ( tube side relief valves, vent and drain valves ).

5.4 Primer coating on outer surfaces

6.0 FEEDWATER HEATERS (Horizontally mounted) :

(LPH- 1No):
6.1 LP Heater with welded stainless steel tubes (SA688 TP304). Heater shall be oriented
Horizontally.

6.2 Accessories (shell side safety relief valve, tube side relief valves, vent and drain
valves).

6.3 Standpipes for mounting instruments.

BHARAT HEAVY ELECTRICALS LIMITED, INDUSTRY SECTOR, NEW DELHI-3

 SUN FLAG – 1 X 42 MW TECHNICAL OFFER  

7.0 DEAERATOR :

7.1 Spray-cum-tray Deaerator with feed storage tank

7.2 Standpipes for mounting instruments

7.3 Accessories ( safety relief valves, vent and drain valves, isolation valves ).

7.4 Primer coating on outer surfaces

8.0 ST OIL COOLER:

8.1 Vertical 2 x 100% capacity ST Oil Cooler.

8.2 Coolers with carbon steel shell, waterbox etc. and welded SS tubes.

8.3 Manually operated 3-way change over valve.

8.4 Primer coating on outer surfaces

8.5 Accessories ( vent and drain valves ).

BHARAT HEAVY ELECTRICALS LIMITED, INDUSTRY SECTOR, NEW DELHI-3

 SUN FLAG – 1 X 42 MW TECHNICAL OFFER  

9.0 GENERATOR AND AUXILIARIES.

1. Indoor mounted closed circuit air cooled Generator (VPI) consisting of

• Stator with output leads (3 phase +3 neutral) taken out from the bottom of the m/c.
• Rotor suitable for Overhang BLE
• Bearings, base frame, built in RTDs, space heaters
• Bottom mounted Air to water coolers with (n) cooler elements.
• Arrangement to attenuate noise level to 85 dBA at 1 m

2. Over hang Brush-less Exciter & PMG with portable stroboscope.

3. Digital Automatic Voltage Regulator with Two auto built-in manual channel

4. Neutral Grounding Resistor to limit the fault current to 100A for 30 sec with motorized off-load
isolator.(Ref: DWG.NO. 20-1110166-E-208)

5. Generator simplex vertical control, metering & synchronizing panel with auto-synchroniser and
multifunctional microprocessor based numerical relay panel for Gen. Protection only.1No.
redundant Generator Protection Relay.

6. Interconnecting control cables for connection between generator and generator control and relay
panels (Length considered is 100m. Unit rates applicable beyond this length).

10.0 GENERATOR AIR COOLERS.

10.1 Pit mounted STG Air Cooler

10.2 High fin welded SS tubes with Cu- fins , Carbon steel frames.

10.3 Accessories ( CW inlet/outlet valves, vent and drain valves ).

10.4 Primer coating on outer surfaces

BHARAT HEAVY ELECTRICALS LIMITED, INDUSTRY SECTOR, NEW DELHI-3

 SUN FLAG – 1 X 42 MW TECHNICAL OFFER  

11.0 Scope of Supply- Control, Protection and Supervisory System

1.) A Turbine Control Panel/Cabinet(TCP) housing the Electronic Governor and TSI monitoring
Rack shall be in BHEL’s scope.

2.) Interlocks and protections for the Steam Turbine & Auxiliaries are to be realized in DCS,
which is in Customer’s scope.
3.) All Closed Loop Controls will be realized in Customer’s DCS.

4.) All the control and signal cabling from Field instruments to Field Junction Boxes including
Field junction box are in BHEL scope.

5.) All the primary field instruments and final control elements in STG integral portion are in
BHEL Hyd’s scope.

6.) The bearing metal temperature monitoring is considered in customer DCS. The bearing
RTD’s shall be wired to customer DCS.

7.) Independent electronic over speed protection( 2 out of 3 logic) system is in BHEL scope.

The C&I Scope of ST & Auxiliaries is given below

11.2 A Turbine control Panel housing:-
11.1.1 Electronic Governor (WW505) for control of
- Turbine Speed
- Load
- Inlet Steam Pressure
11.1.2 Electronic Over speed Protection Device (2/3 Logic)

11.1.3 Dual channel Turbine shaft Vibration and Axial Displacement monitoring system
(TSI rack BNC 3500 or Equivalent ) which includes proximity type probes,
proximeters and extension cables and monitors for the following
- Shaft Vibrations at Turbine Front bearing
- Shaft Vibrations at Turbine Rear bearing
- Shaft Vibrations at Generator Front bearing
- Shaft Vibrations at Generator Rear bearing
- Shaft Vibrations at Gearbox High speed Shaft
- Shaft Vibrations at Gearbox Low speed Shaft

BHARAT HEAVY ELECTRICALS LIMITED, INDUSTRY SECTOR, NEW DELHI-3

 SUN FLAG – 1 X 42 MW TECHNICAL OFFER  

- Turbine Axial displacement

- Key Phasor

11.2 THE FOLLOWINGS ARE ENVISAGED IN DCS OF CUSTOMER

11.2B Primary instruments to realise the Turbine Auxiliaries Interlock and Protections for
the following drives , to be realised in DCS ( in Customer’s scope)
- Auxiliary Oil Pump
- Main oil pump
- Jacking oil Pump
- Emergency Lube Oil Pump
- Oil Vapour Extraction Fan
- Turning Gear
- Condensate Extraction Pumps
- Exhaust hood spray solenoid
11.2B Closed Loop Controls for the following to be realized in Customer DCS-
- Gland Steam Header Pressure
- Condenser Hot-well Level
- LPH & Deaerator Level control

11.2C Bearing metal temperature monitoring in DCS of customer for:

- Turbine Front Journal Bearing Temperatures
- Turbine Rear Journal Bearing Temperatures
- Turbine Thrust Bearing Temperatures (Active & Non active)
- Gear Box Bearings Temperatures
- Generator Front Journal Bearing Temperatures
- Generator Rear Journal Bearing Temperatures

11.3. Field Instruments (for STG integral portion)

11.3.1 Bearing Thermo elements (RTD’s) for monitoring bearing metal temperatures of
the following in Customer DCS
- Turbine Front Journal Bearing Temperatures
- Turbine Rear Journal Bearing Temperatures
- Turbine Thrust Bearing Temperatures (Active & Non active)
- Gear Box Bearings Temperatures

BHARAT HEAVY ELECTRICALS LIMITED, INDUSTRY SECTOR, NEW DELHI-3

 SUN FLAG – 1 X 42 MW TECHNICAL OFFER  

- Generator Front & Rear Journal Bearing Temperatures

11.3.2 Local Pressure Gauges with in battery limit

11.3.3 Local Temperature Gauges with in battery limit

11.3.4 Flow Elements

− Flow Orifice in Condensate line

11.3.5 Level Gauges

- Main Oil Tank
- Over Head Oil Tank
- Surface Condenser Hot-well
- Gland Steam Condenser
- Deaerator
- LP heater

11.3.6 Instruments Mounted On Local Gauge Rack

- Main Steam Pressure
- Main Steam Temperature
- Wheel Chamber Pressure
- Gland Steam Pressure
- Gland Steam Temperature
- Extraction-I Pressure
- Extraction-II Pressure
- Extraction-I Temperature
- Extraction-II Temperature
- Lube Oil Header Pressure
- Control Oil Pressure
- Exhaust Steam Pressure
- Exhaust Steam Temperature
11.3.7 Instruments Mounted On Local Gauge Rack of Governing Rack
- Control Oil Pressure

BHARAT HEAVY ELECTRICALS LIMITED, INDUSTRY SECTOR, NEW DELHI-3

 SUN FLAG – 1 X 42 MW TECHNICAL OFFER  

- Start-Up Oil to ESV Pressure

- Trip Oil to ESV Pressure
- HP Secondary Oil to HP Governing Valve Pressure
- Trip Oil Header Pressure

11.3.8 Primary instruments required for Alarms, Trips, Interlocks and

Annunciation ( Realised in DCS in Customer's scope) with in battery
limits.

11.3.9 Transmitters / Temperature Elements /Primary Sensors required for

Remote Indication and Control with in battery limits.

11.4 Control Valves for the followings-

− Condenser Hot-well Make-up
− Condensate Minimum Re-circulation
− Hot Well Level
− Sealing Steam to Gland Steam Header (Gland Sealing System)
− Dump Steam from Gland Steam Header (Gland Sealing System)
− LP Heater level.
− Deaerator Level control

11.5 I/P Converters /Air filter regulators as required

11.6 SJAE Rotameters
11.7 Field junction boxes.
11.8 Control & Instrument cables ( screen and extension) from field instruments to
Field junction boxes, including Field Junction Box

11.9 GI instrument air supply lines.

11.10 Impulse line along with fittings (same as that of parent line material) for
instruments in pressure parts.

BHARAT HEAVY ELECTRICALS LIMITED, INDUSTRY SECTOR, NEW DELHI-3

 SUN FLAG – 1 X 42 MW TECHNICAL OFFER  

12 BALANCE OF PLANT - MECHANICAL.

1. Condensate extraction pumps – 2x100 %.

2. Condensate piping up to deaerator inlet.
3. Condensate minimum recirculation piping.
4. Instrument air piping from terminal point to consumption points in STG hall.
5. Extraction steam piping for LPH and deaerator along with MOVs.
6. Excess condensate dump piping up to terminal point.
7. Insulation for piping in scope.

BHARAT HEAVY ELECTRICALS LIMITED, INDUSTRY SECTOR, NEW DELHI-3

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B. List of Terminal points (Mechanical)

1. Main Steam Piping: At inlet of Turbine ESV.

2. Condensate: At the inlet of deaerator.
3. Auxiliary Steam: At one point in TG hall( at 16 ata, 300 deg C)
4. Cooling Water: - At inlet and outlet flanges of condenser.
5. Auxiliary Cooling water: At inlet and outlet flanges of oil cooler and air cooler.
6. Initial heating steam to deaerator: At deaerator nozzle.
7. DM Make-up Water: At condenser nozzle.
8. Excess condensate dump: At outlet of excess dump control valve.
9. Feed water: At De-aerator Outlet flange(Total FW piping excluded from BHEL scope)
10. De-aerator over flow & Normal drain to CST/DM Tank : At deaerator nozzle.
11. CBD vent to deaerator: At nozzle/flange on De-aerator
12. All Vents: At safe height
13. All Drains: At suitable point in TG hall.
14. Instrument air: At one Point in TG hall.
15. Excess Condensate to DM/CST Tank:- At one point in TG hall.

List of Terminal points (Electrical)

1. Generator Power: At Generator terminals.
2. 415 V LT Power: At consumption points.
3. DC power: At consumption point. (DCSC Loose supply)
4. UPS power : At Consumption Points

List of Terminal points (C&I)

1. Control and Signal Cables: At field junction boxes
2. I/Os of Governor & TSI Racks to DCS: At Terminal Boxes of the individual
instruments

BHARAT HEAVY ELECTRICALS LIMITED, INDUSTRY SECTOR, NEW DELHI-3

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C. List of Exclusions
MECHANICAL
1. Main Steam Supply Line up to ESV of Turbine
2. Total Feed Water Piping system and boiler feed pumps.
3. Deaerator structure.
4. Deaerator over flow/drain piping
5. CW and Auxiliary CW piping beyond Terminal Points
6. Butterfly valves and RE joints.
7. CW & ACW Pumps
8. HP & LP dosing system
9. Supports and operating platform with ladders for Deareator.
10. Blow down tanks
11. Condensate Storage tank/DM Water Storage tanks
12. AC & Ventilation
13. Fire fighting
14. DM plant
15. DM Make-up water piping up to terminal point
16. Stairs and Rails, Access Ladders, Platforms
17. All Chequered Plates and Frames, Embedments in Foundation
18. Civil & Structural Engineering design and construction works
19. All Civil, Carpenter and Concrete Works
20. Approvals From Statutory Authorities (Erection Agency scope)
21. Initial Oil Filling (Erection Agency scope)
22. Grouting Material Supply and Application (Erection Agency scope)
23. EOT Crane.
24. Roots valves and thermowells for instrumentation on the piping which is not in BHEL
scope.
25. Layout engineering except layout of BHEL supplied equipments and Piping in
BHEL scope.

26. Any other Equipment not Specifically mentioned in scope of Supply

BHARAT HEAVY ELECTRICALS LIMITED, INDUSTRY SECTOR, NEW DELHI-3

 SUN FLAG – 1 X 42 MW TECHNICAL OFFER  

LIST OF EXCLUSION ELECTRICAL

1. Out door switchyard and associated cabling.
2. All HT /LT Switchgear.
3. 415V PCC /STG MCC.
4. Power system stabilizer.
5. Busducts with CTs, PTs, LASP, & NGT.
6. UPS system including cabling up to terminal point
7. Cable glands, lugs, cable termination kits, JBs and other accessories.
8. Cable trays, conduits, and cable trays support structures.
9. Equipment support structures.
10. All HT Power Cables.
11. Load sharing module.
12. All AC/DC ,UPS, LT415 V power & control cables ,cable Trays & accessories
13. Local Control station (Push button Station), starters and JBs for motors and for Turbine
Auxiliaries.
14. All other power cables except as mentioned in Scope
15. All distribution boards for LT,HT ,UPS etc
16. Complete above & below ground earthing
17. Master Clock System
18. Interconnecting cables between Purchaser’s equipment and Bidder’s equipment.
19. All civil works including preparation for cable trenches/cable racks/cable trays/laying of
cables beyond battery limits

20. Chequered Plates/RCC Blocks above Trenches.

21. Termination of cables including terminating accessories at Purchaser’s equipment
22. Fire proof sealing of cable opening
23. Generator Transformers & Aux. Transformers
24. Transformer Rails
25. Laboratory equipment
26. System Studies
27. Plant illumination

BHARAT HEAVY ELECTRICALS LIMITED, INDUSTRY SECTOR, NEW DELHI-3

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28. Telecommunication & Public address system

29. Lightning Protection
30. CO2 Fire extinguishing Equipment for Generator.
31. PC, Printer & software for hooking up with generator digital relays.
32. AC & DC auxiliary power supplies required for generator and auxiliaries.
33. All other power cables & control cables except those included in scope.
34. All civil works of generator including concrete wall for air cooler ducting.
35. All motors and motor control panels.
36. System studies if any.
37. Relay test kit
38. All Transformers
39. All Circuit breakers including GCB.
40. Battery and battery charger.
41. Any other item not specifically mentioned above.

List of Exclusion of Control & Instrumentation

1. DCS
2. SOE
3. Signal Conditioning for DAS/DCS
4. Cables beyond local junction boxes
5. Engineering station with laser printer.
6. Standalone local control system for chemical dosing.
7. Support of I&C spares for 15 years.
8. Interconnecting cables between purchaser’s equipment.
9. Clock System
10. Laboratory Equipment & Laboratory Instruments
11. Analysers
12. Flow Elements except as mentioned in Scope.
13. Laboratory Instruments
14. Termination of cables including terminating accessories at purchaser’s equipment.
15. Any other item not specifically mentioned in scope.

BHARAT HEAVY ELECTRICALS LIMITED, INDUSTRY SECTOR, NEW DELHI-3

  
   
 
Sunflag Iron & Steel Ltd.  
Nagpur 
 
1 x 42 MW STG (Technical Offer) 
Consultant: Fichtner Consulting Engineers (India) Private Ltd. 
Tender Specification no. 1110166‐ME‐SPC‐120‐002 REV A 
 
 

SECTION – 2

Technical write-ups
Steam Turbine, Heat Exchanger & Generator

Bharat Heavy Electricals Ltd., Industry Sector, New Delhi – 110 003
  
   
 
Sunflag Iron & Steel Ltd.  
Nagpur 
 
1 x 42 MW STG (Technical Offer) 
Consultant: Fichtner Consulting Engineers (India) Private Ltd. 
Tender Specification no. 1110166‐ME‐SPC‐120‐002 REV A 
 
 
1. Write‐up : Steam Turbine 
2. Write‐up: Turbine Balding 
3. Write‐up: Turbine outer casing 
4. Write‐up: Turbine guide blade 
5. Write‐up: Steam quality 
6. Write‐up: Turbine Steam purity 
7. Write‐up: Lube oil system 
8. Write‐up: Steam turbine maximum operating condition 
9. Tools and tackles 
10. Write‐up: Generator 
11. Write‐up: Generator tests 
12. Write‐up: Exciter 
13. Write‐up: Exciter tests 
14. Load time curve 
15. Capability curves 
16. Saturation curves 
17. Layout of Generator 
18. Write‐up: Surface Condenser 
19. Write‐up: Spray cum tray type Deaerator 
20.  Write‐up: Air Ejector system 
21. Write‐up: Oil Cooler 
22. Write‐up: Air Coolers for Generators 
23. Write‐up: Gland Steam Condenser 
24. Write‐up: LP Heater 
25. Recommended spares.  

Bharat Heavy Electricals Ltd., Industry Sector, New Delhi – 110 003
 110

Turbine Type HNK

General Description

Design: Turbine casing and guides blade carrier

Steam flow through the turbine is in the axial direction. After leaving the body of the emergency
stop valve, the live steam enters the valve chest with the control valves, which forms an integral
castings with the upper half of the outer casing. The valve chest is designed as a transverse tube
with opening at both ends for assembly.

The turbine casing is divided into an admission and an exhaust section. Depending on the initial
steam conditions, the admission sections of comparable size are designed with castings of
different wall thickness. The admission section will be completed by an exhaust section of
adequate size. The overall length is adjusted by cylindrical or conical spacer rings. The turbine
casing is horizontally split. The upper and lower casing halves are flanged and assembled by
bolts.

The turbines are equipped with either a nozzle block or a steam chamber.

The nozzle block is designed as half shell and is kinematically supported by the outer casing. In
the regulating stage, the corresponding lower half in the outer casing is designed as a simple
blinding shield in order to avoid excessive windage losses. The nozzle groups are inserted in to
the nozzle block. The nozzle block is connected with the steam chamber by L-ring seals in the
same manner as the inner casing with the control valves. The nozzle block serves also has guide
for the balancing – piston gland.
With the type range HNK, the steam chamber used in the type of turbines is axially split. In its
upper half it accommodates the nozzle group. The bottom half of the regulating stage is equipped
with a windage shell. The front part of the steam chamber carries the sealing strips of the
compensating piston gland.

BHARAT HEAVY ELECTRICALS LIMITED.

 110

Turbine Type HNK

The guide blade carriers are inserted with a lathe-turned circumfrential groove into corresponding
webs of the outer casing. They are positioned in the lateral direction by eccentric guide pins and
adjusted to the correct height by shims.

Bearing:

By its brackets, the outer casing is supported on the two bearing pedestals independently from the
bearing housings. The vertical position of the outer casing is determined by adjustable
positioning elements located between the brackets and the supporting plan of the pedestals. The
clearance left between the under side of the assembly-bolt head and the bracket allows for both
axial and lateral expansion of the outer casing with respect to the pedestal. The central position is
ensured by guide ways in the bottom half of the casing. They leave the casing free to expand also
in the vertical direction.

The fixed reference position of the casing is at the rear- end support brackets. The casing is thus
to yield to thermal expansion by moving forward on special slide elements between the front-end
brackets and the front bearing pedestal. The turbine rotor is supported in the bearing housings
and is radially independent from the outer casing. The radial journal bearings are of the multi-
wedge type. Two or four oil wedges uniformly spaced on the circumference hold the rotor in a
stable position. The bearings are babbitt-lined.

The correct axial position of the turbine rotor is ensured by a thrust bearing incorporated in the
front bearing housing. It is intended also for taking up the residual axial thrust. For this reason it
is designed as double-acting bearing of the segment type. The tiltable bearing segments are like
wise babbitt-lined. The heated rotor expands in the direction towards exhaust hood. As the
turbine casing with its fixed reference at the rear pedestal expand into the opposite direction, the

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Turbine Type HNK

resulting differential expansion will be only small on condition that rotor and casing are heating to
approximately the same temperature.

Turbine rotor and blading

The turbine rotor is integral with the disc of the control stage wheel and is forged from a solid
blank. Except for the control stage, the blading is of the reaction type. The running blades have
their roots, shaft and shrouding milled from the same solid forging. Only exception to this rule
are the twisted blades of the low-pressure end rows. Because of the wide spacing and thin shaft
section it is impossible to design them with integrally milled shrouding . The running blades in
the drum stages have roots of the inverted-T type. The roots of the control-stage blades are
forked. . But occasionally the last row of low-pressure blades, depending on the centrifugal stress
to which they are subjected, may be designed with forked roots, too.

The guide blades are manufactured from drawn bar material and have pronged roots. The guide
blades tips are fitted with riveted shroud strips.

Blade Tip Sealing and Shaft Glands

Radial steps machined on the circumfrential surfaces of both the stationery and moving blades
rows together with oppositely situated sealing strips in the guide blades carrier and on the turbine
rotor or forming efficient labyrinth seals.

The points at which the shaft passes through the casing are like wise sealed by labyrinth glands
with caulked-in seal strips. The shells of these glands are mounted in the outer casing in manner,
which leaves them free to follow thermal expansion. In the central portion of the gland, leak
stem is drawn of to a region of lower pressure. This limits the amount of leak steam discharged

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Turbine Type HNK

into the atmosphere. Turbines are designed for live steam supply at this point in order to
maintain an adequate vacuum.

Governors and controls

An emergency stop valve provided at the entrance of the turbine gives the initial steam access to
the admission chest. During normal operation, the stop valve is held open by oil pressure against
the contracting force of a compression spring. In an emergency, pressure in the trip-oil circuit is
suddenly relived and stop valve will close immediately. The control valves of turbine regulates
the steam throughout to the amount, which is requiring to obtaining the desire output and / or
speed. They are hydraulically activated by servo-oil. The control valves are adjustably
suspended from a wall beam. By means of two spindles and via lever system, the beam can be
moved by the actuator, which is mounted, on the steam chest.

The control element serving as transmitter for the control impulses to the governor system is
incorporated in the front bearing pedestal.

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 201

Turbine Blading

General

The turbine blades convert the thermal energy of the steam into mechanical power. The blading is thus
of primary importance of the efficiency and operational reliability of the machine, and no effort is spared
in determining the most favorable profile and in providing for the necessary mechanical strength,
accuracy of manufacture and surface quality. Particular importance is attached to ensure freedom from
resonance. The natural frequency of the rotor blades (without shrouding) is tuned against the rotational
frequency already in the design stage, and a close check is conducted when the blading has been
installed, the fit of the blades being then carefully checked as well.

Blades without shrouding are employed for rotors whose blades are shaped from the solid rotor material
by electro-chemcial machining (Fig. 2). All the inserted blades of the regulating and reaction stages are
designed with inegrally milled shrouds.

Fig 1 Fig 2
Section of a blade Rotor section with blades produced by
electro-chemical machining

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 201

Turbine Blading

Frequency turning is not required for rotor blades with shrouds (Fig.4) since the shrouds are located close
together and thus produce an effective damping effect which prevents vibration of detrimental amplitude.
The twisted low pressure blades have a small cross-sectional area and a large tip spacing and are
therefore without integrally milled shrouds. For damping blade vibration, they are provided with
damping wires of steel or titanium. Stainless steel is employed for the entire blading.

Regulating stage

Turbines designed for regulating the steam flow through nozzle groups are provided with a regulating
stage, which takes the from of impulse blading permitting partial admission.

The regulating stage is omitted in the case of turbines with throttle control, the steam being admitted
direct with full admission to the first expansion stage through the control valves.

Reaction stages

The stages following the regulating stage are designed for 50% reaction. The guide blades and rotor
blades have the same profile and blade angle.

Rotor blades

The inverted T-root rotor blades with shrouding (Fig.4) are milled from solid material and are bottom
caulked with brass after insertion in the shaft groove. Th roots are so designed that after assembly the
specified blade spacing is obtained without the need of fitting spacers. A locking blade, which is secured
to the rotor by means of threaded dowels, closes off the blading gate without forming a gap.

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Turbine Blading

Fig. 3
Two forms of blades for the regulating stage
Blade root with single fork
Blade root with multiple fork

Fig. 4 Rotor blade

Guide blades
The guide blades are manufactured from drawn bar material. They have a pronged root, the correct
interblade spacing being obtained by means of spacers fitted in the blade groove. The shrouding is
riveted and combines several guide blades into a group (Fig.5).

BHARAT HEAVY ELECTRICALS LIMITED.

 201

Turbine Blading

Low-pressure stages

The last stages of the I.p. turbine are combined in groups with standard-size blades. The sizes of these
blades are so selected that a permissible axial velocity in the end stage and thus an economical leaving
loss is obtained for any volume flow. The difference between the circumterential velocity at the blade
root and tip is quite considerable and is taken into account by twisting the blade along its length. The
rotor-blade roots, takethe form of fork-shape or T-shape, are inserted in te radial grooves of the rotor and
are secured by taper dowels or bottom-caulking. The trailing edges are machined to a thin profile to
avoid any stall patches and the formation of large water drops. The axial clearance from the last row of
rotor blades is kept large to facilitate atomizing of water drops released from the leaving edges and to
provide for a sufficiently long acceleration path for any droplets remaining. The impact velocity of the
water drops impinging on the leading edges of the blades is thus reduced.

Fig. 5
Group of guide blades

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Turbine Blading

Tip sealing

In the case of turbines with 50% reaction component, a pressure gradient is produced both at the guide
and rotor blades. The pressure difference generates a flow in the gap between the stationary and rotating
components and losses are thus caused. To keep these leakage losses low effective blade-up sealing has
to be provided. Cylindrical blades (guide and rotor blades) are therefore provided with continuous with
continuous shrouding strips with radial recesses which form an effective labyrinth seal together with the
sealing strips (Fig.8).

The shroud strip of rotor blades is formed by abutting strip sections which are milled from the solid

Fig. 6 Fig. 7
together with the blades. The guides are fitted with riveted shroud strips.
L.P. stage with T-root blades L.P. stage with fork-root blades

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Turbine Blading

The shroud strips which are caulked into the guideblade carrier or shaft opposite to the shrouds are made
of stainless steel. They are designed to accommodate the maximum pressure difference occurring. On
the other had, the heat produced in the event of contact occurring at the sealing tips and transferred to the
guid-blade carrier of shaft remains low enough to prevent deformation of these components.

Fig 8
Segment of fixed blades

The sealing strips can be replaced easily. Replacement of sealing strips which may have worn out as a
result of rubbing and correction of the clearances may be carried out during a routine inspection with-out
great difficulty.

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 202

TURBINE

Turbine Casings: Outer Casing

The following subassemblies are accommodated in the outer casing: Inner casing, nozzle housing, guide-
vane carrier or steam chest- depending on the type of turbine and searing glands.

The outer casing is composed of a front, intermediate, and rear section. Those sections are either
integrally cast (HP plus LP casings), welded together, or assembled by screws. The two last mentioned
designs offer the possibility of employing different materials for the individual sections. In addition, the
outer casing is divided up into several portions which can be designed for diverse pressures. In each
portion, the pressure compartment is limited by webs into which the guide-vane carriers of varying length
and by a conformable design of the blading, it becomes possible to adapt the steam pressure in the
individual compartments to a given set of live-and exhaust-steam conditions and thus to meet the
requirements with regard to extraction pressures.

1. Bore for control valve spindle

2. Buttress lug for guide-vane carrier position
fixing dev.
3. Exhaust section
4. Web carrying rear sealing gland
5. Ledge supporting rear bearing housing
6. Rear casing guide
7. Hole for flange screws
8. Web accomodating guide-vane carrier
9. Front casing bracket
10. Web carrying front sealing gland
11. Live-steam intake
12. Control-valve seats

Fig-1
Turbine Casing : Outer Casing

The outer casing is axially split. Its top part with its brackets on the casing supports, while the bottom
part is assembled to the top part at the flanged joint by screws and studs.

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Turbine

Turbine casings: guide blade carrier

The guide blade carrier accommodates the guide vanes (1) of the turbine blading. It is inserted with is
latheturned circumferential groove (3) into a corresponding supporting web of the outer casing. The web
is used also for axial positioning. The guide blade carriers are adjusted to the correct height by shims of
appropriate thickness which are placed upon the mounting lugs (4). Eccentric guide pins projecting from
the lower half of the outer casing permit the alignment in radial direction and serve also from locking the
carrier against rotation.

1 Guide blade
2 Drilled hole for joint assembly bolt
3 Lathe turned circumferential groove
4 Face of mounting lug for carrying adjustment shims

Fig. 1.
Guide blade carrier

BHARAT HEAVY ELECTRICALS LIMITED.

 210

Steam Quality

Introduction

The build up of deposits in turbines due to impurities in the steam can cause both thermodynamic
and mechanical problems which can develop in to blade failure if chlorides are present. This
means that it is essential to eliminate chlorine and its compounds. E.g. MgCl2, NaCl, From the
steam. It has been shown beyond doubt that even a quantity of 0. 0025% Cl is dangerous for all
the high-temperature steels used in blade manufacture. The corrosion attack of the aggressive
deposits affects primarily the alternating bending strength of the blade materials in the region of
initial steam wetness.

Guide values

The VGB guidelines for feedwater and boiler water are recommended as the basis for the
requirements concerning steam purity[see Fig 1to 5]

Although it is basically high desirable for these guide values to be attained, it is not always
economically feasible to do so. This is especially true when commissioning new plant and also
during all start- ups and shut-downs.

When assessing the cost of water treatment, however, the cost of possible turbine outages and
repairs resulting from steam-impurity damage should always be offset against it.

In order to avoid any misunderstandings we should emphasize that the guide value for steam
purity given in the following tables are only a starting point they provide no guarantee of the
complete elimination of turbine deposits.

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 210

Steam Quality

If there is any possibility of improving the steam purity above the given guide values we strongly
advise that it be taken.

It is also advisable to provide continuous monitoring of the water/steam system by chart recorder
measuring the electrical conductivity of the main steam and turbine condensate after a strongly
acid cation exchanger.

BHARAT HEAVY ELECTRICALS LIMITED.

 210

Steam Quality

Boiler type Units Drum-type and natural Once through boiler

circulation boilers
Working pressure Bar <0.5 <64 <64
(gauge)
General requirement -- -- clear and colourless

Hardness mval/kg <0.03 <0.02 Not detectable

Oxygen O2 mg/kg <0.10 <0.02 <0.02

Carbondioxide CO2
Combined mg/kg <25 <25 not detectable
free mg/kg not detectable not detectable not detectable

Total Iron Fe mg/kg -- <0.05 <0.02

Total Copper Cu mg/kg -- <0.01 <0.003

pH at 25°C necessary to -- 9.0 – 9.5 volatile

low for feed pumps and -- >9 >9 alkalizing agents only.
feed heaters

Silicic acid Sio 2 mg/kg Only guide values <0.20 in continuous

for builder water operation.
applicable
Conductivity at 25°C
locally in flow of uS/cm Only guide values <0.20 in continuous
continuous sampling for builder water operation.
point after strongly acid applicable
cation exchanger
(applicable to CO2 free
water only).
Potassium permanga- mg/kg If possible <10 if possible <10 If possible >5
nate consumption.
Oil mg/kg <3 <1 <0.5

Figure 1.
Guide values for fed water (working pressure <64 bar (guage))

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Steam Quality

If there is a sudden rise in the salt content saturated steam mg/kg flushing should be carried out
without delay in order to remove any chlorides deposited on the blades. (See also Flushing
instruction for Industrial Steam Turbines).

Working pressure Bar (gauge) 0.5 20 40 <64

p value (1) mval/kg 1.5 1-12 1-6 1-3

Silicic acid Sio2 mg/kg -- <(70+7xp) <(30+3xp) <10

Phosphate PO4 mg/kg 10-15 10-20 <15 <15

Conductivity at 25°C
measured after u5/cm <5000 <10000 <5000 <2500
neutralization with HCL
against phenolpthalein.

1. When using demineralised feed water the p value can be llimited to 0.1 – 1.0 mvl/kg.

Figure 2

Guide values for boiler water (working pressure <64 bar (gauge))

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 210

Steam Quality

Working pressure Once through Natural-circulation boilers

Boilers and injection
Water for de- 64 bar* 80 bar / and above
Superheaters

General requirements clear and colourless

Conductivity at 25°C
Locally in –flow at a
Continuous sampling <0.2 refer to the guide values for boiler water
Point after a strongly
Acid action exchanger without alkalinization (neutral method): < 0.15
(only applicable to CO2
free water u5/cm)
pH at 25°C >9 >9 >9
volatile alkalizing volatile alkalizing agents
agents only only if possible

without alkalinization (neutral method): 6.5 to 7.5

Oxygen O2 mg/kg <0.020 <0.020

Without alkalinization (neutral method): <0.050

Total iron (Fe) mg/kg <0.020 <0.030 <0.020

Total copper (Cu) mg/kg <0.003 <0.005 <0.003

Silicic acid (SiO2) mg/kg <0.020 ref to the guide values for boiler water

Totoal carbon dioxide (CO2) not detectable <25 not detectable

mg/kg

Hardness mval/kg not detectable 0.010 if de-mineralised not detectable

Water is not used

KmnO4 consumption mg/kg if possible <5 if possible <10 if possible <5

Oil mg/kg <0.3 <0.5

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 210

Steam Quality

• With localized heat generation rates 230 kw/m2 the use of the guide values for 30 bar working
pressure and above is recommended for all working pressures.

Figure 3

Feed water for water-tube boilers in continuous operation, measured at

the boiler inlet ((working presure ≥ = 64 bar (gauge)).

Note:

With localized heat generation rates 230 kw/m2 the use of the guide values for 160 bar working
pressure is recommended for al working pressures (except Sio2).

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 210

Steam Quality

Working pressure bar (gauge) 64 80 110 125 >160

Conductivity at 25°C locally

in flow at continuous sampling
point u5 /cm . <2500 <300 <50

ρ value mval/kg 0.1-1.0 <0.3 <0.1

ρH value at 25°C 10-11 9-10.5 9-10

silicic acid (SIO2) mg/kg <8 <4 <1.8 <1.2 <0.3

With phosphate dosings:

Phosphate (PO4 “”) mg/kg <15 2-6

Figure 4

Boiler water for water-tube boilers in continuous operation

(working pressure ≥= 64 bar (gauge))

Note:

When operating without alkalinization (neutral method), or when alkalizing exclusively with volatile
agents, only the conductivity values should be followed while maintaining the feed water values given
in fig. 3 with a ρH value 6.5:

64 – 125 bar (gauge) working pressure 50 5/cm

125 bar (gauge) working pressure 20 5 /cm

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 210

Steam Quality

if demineralised feed water is used for 64 (gauge) working pressure the alkalization recommended from
80/110 bar (gauge) working pressure is sufficient. However the relevant guide values for conductivity
and phosphate content must also be adhered to.

Note:
In the working pressure range 80 bar (gauge) it is usually impossible to attain a steam conductivity 0.2
S/cm if the maximum conductivity of the boiler water given in figure 4 is utilized to the full. In such
cases check whether operation of the turbine can tolerate a higher steam conductivity; if not the
conductivity of the boiler water must be reduced from that given in figure 4 (special arrangements
between turbine and boiler suppliers).

Conductivity at 25°C locally in-flow at a

Continuous sampling point after a strongly uS/cm <-0.2
Acid cation exchanger (only applies to CO2 - free water)
Silicic acid (SIO2) mg/kg < 0.02
Total iron (Fe) ) mg/kg < 0.02
Total copper (Cu) ) mg/kg < 0.003
Sodium and potassium mg/kg < 0.02

Figure - 5
Steam for turbines in continuous operation
(Working pressure <= 64 bar (gauge))
References :
Recommendations for avoiding damage to steam turbines (internal fouling):
VGB-Dampflechnik. 2nd edition 1974.

BHARAT HEAVY ELECTRICALS LIMITED.

 211

Operation

Steam purity

The deposits which occur in a turbine due to impure steam can lead to thermodynamic and
mechanical inefficiencies and, in the presence of chlorides, also to blade breakages. The steam must
therefore be free from chlorine and chlorine compounds (MgCl2;NaCl, etc.). It has been found that
Cl content as small as 0.0025% has a detrimental effect on all the high temperature steel grades used
for the manufacture of blades. The corrosion stressing caused by active deposits is worst when the
steam is slightly saturated and adversely affects the fatigue strength of the blade material.

Recommended values of steam purity for continuously operating turbines are given by “Society of
the Operators of Large Boilers in Germany”. The values are amended from time to time in
accordance with appropriate advances in technology.

These recommended values (see table below) are the ultimate values which should be aimed for, but
in many cases these cannot be attained with an economical outlay. This is particularly applicable to
the commissioning of new plant but is also valid for starting-up and shutting-down operation.

In industrial power station, which nearly always have a make-up water requirements greater than
50%, the conductivity of live steam only reaches value of 1.S/cm (mho/cm) despite considerable
expenditure on water treatment. This expenditure, however, should be seen in the light of the costs
involved when a turbine fails due to impure steam conditions and must be repaired.

It should be noted in this connection, to avoid confusion, that even if the recommended values are
rigidly adhered to, it is not possible to completely eliminate deposits in the turbine. Amongst other
factors the proportions of the impurities play an important part, although this is not yet fully
understood. In cases where the steam purity of a plant can be raised above the recommended value,
every effort should be made to do so. It is also strongly recommended that recording instrument

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 211

Operation

should be used to continuously monitor the electrical conductivity of the live steam and turbine
condensate following a strongly acid cation exchange unit. In the event of serious contamination
saturated steam should immediately.

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 211

Operation

Recommended Values for Live Steam Condensate

Quantity Unit Continuous operation * Starting up**

Conductivity at 20°C

Circulation boiler u S/cm 0.3 1.0

Once through boiler 0.2 0.5
Silicic acid(SiO2) mg/kg 0.02 0.05
Total (Fe) mg/kg 0.02 0.05
Copper (Cu) mg/kg 0.003 0.01
Sodium + Potassium mg/kg 0.01 0.02

• VGB recommended values February 1962

** There should be a discernible tendency for this to fall. When commissioning new plant
recommended values for continuous operation should be reached after 2 to 3 days and with
starting up operations after 2 to 3 hours.

BHARAT HEAVY ELECTRICALS LIMITED.

 401A

Lube Oil System

General

A satisfactory and continuous supply of oil is essential for the safe and reliable running of a
turbine and its driven equipment. The oil supply system should ensure the operational safety of
bearings. The system is of the closed circuit type, i.e.; a definite amount of oil quantity, which is
previously determined, is continuously recirculated.

Apart from this, the oil supply system has to ensure the oil required for the governing system and
the safety devices of the turbine at an increased pressure. For this, same oil is used whose
pressure on leaving the pump equals first the control oil pressure of governing system and then
the lower bearing oil pressure.

The oil supply system includes the following equipment:

¾ The oil tank from which the pumps draw in the oil and to which the oil is returned after
passing through the governing system and the bearings.

¾ The main oil pump (4220), driven by A.C. motor delivers the oil and raises its pressure to the
necessary control oil pressure.

¾ The A.C driven Auxiliary oil pumps (4230) has been designed as full duty pump also so as to
work as standby to main oil pump.

¾ The DC motor driven Emergency oil pump (4240) supplies oil to the turbine bearings during
coasting down period of the turbine.

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 401A

Lube Oil System

¾ The oil coolers (4440A & 4440B) in which the heat absorbed in turbine oil system is
dissipated.

¾ The adjustable orifice (A0 01) in which the heat absorbed in turbine oil system is dissipated.

¾ The adjustable oil throttle (A0 02), provided between oil cooler and duplex filter maintains the
oil pressure in the lube oil heater pressure to the required bearing oil pressure.

¾ The adjustable bearing oil throttles (A0 03 to A0 09), which permit to adjust the oil quantity,
required for the relevant bearings.

¾ Duplex type oil filters (4510A & 4510B) to clean the oil from possible contamination.

¾ The oil vapor extraction fan (4330) to remove oil vapors from oil tank.

Oil Tank (4310)

The oil tank serves for storing the oil volume required for governing and lubricating systems. It
allows oil to be filtered through strainers mounted in the oil tank and the impurities are deposited
at the bottom of the tank along with the oil sludge. A gradient is provided at the bottom of the
tank to enable the impurities to be collected for easy drain off. Besides strainers, baffle plates are
also provided to give a longer path for the returning oil by allowing it to remain longer time in the
tank so that the entrapped air is effectively released. The oil level in the tank can be indicated by a
float cylinder for direct indication on the operating floor. The oil tank is further provided with
necessary connections for oil centrifuge.

BHARAT HEAVY ELECTRICALS LIMITED.

 401A

Lube Oil System

Oil Cooler

The heat absorbed by the oil in the bearings and elsewhere in the oil system is dissipated in the oil
cooler which is of shell and tube design.

The system consists of two oil coolers each of 100% capacity. A change over device (double 3 way
transflow valve arrangement) is provided for switching over to standby oil cooler whenever it is
necessary to take the main cooler for maintenance. . The change over device is so designed that
under any circumstances both the coolers are not allowed to be shutdown. Whenever feasible, the
switching over to the standby oil cooler is to be carried out during the standstill condition of the
turbine. If it proves unavoidable that the switching be made in the course of turbine operation, it
should be done with utmost care before switching over to another oil cooler, this must be generously
vented and the bearing oil pressure must be observed during a considerable period afterwards.

Oil Filters

The duplex type of oil filter having replaceable paper cartridges with filtration of 10 microns are
provided. This is in addition to the oil strainer arrangement provided in the oil tank. A changeover
device is also fitted for switching over to standby oil filter in case of choking of the working filter.
The change over device is so designed that under any circumstances both the filters are not allowed
to be shutdown. A differential pressure switch (DIPSH) set at 1.0Kg/cms is provided to annunciate
high differential pressure.

BHARAT HEAVY ELECTRICALS LIMITED.

 401A

Lube Oil System

Overhead Oil Tank

In addition an Overhead oil tank is provided for supplying oil to the turbine bearings when the other
oil pumps are not in operation during turbine trip condition.

Instrumentation

Several local and remote panel mounted instruments are provided in the system to ensure monitoring
of oil supply system. The instrumentation shall be as per lube oil scheme, and instrument data
sheets.

BHARAT HEAVY ELECTRICALS LIMITED.

 701
Steam Turbine
Maximum Operating Conditions

Maximum Operating Conditions For Live Steam Inlet Pressure and Temperature.

The turbine offered can be operated at the extreme operating conditions as laid down in the
recommendations of the International Electro Technical Commission.

Clause 19 of the IEC Publication No.45-1970 reads as follows:

Limitation of variation from rated steam pressure and temperature. The turbine shall be capable
of accepting variations from the rated conditions within the limits stated below:

a) Pressure:

The average pressure as the turbine inlet over any twelve months of operation shall not
exceed the rated pressure. In maintaining this average, the pressure shall not exceed 110%
of the rated pressure, except that swings to 120% of the rated pressure shall be admissible,
provided the aggregate duration of such swings over any twelve months of operation shall
not exceed 12 hrs. The re-heater safety valves shall be set so that the turbine exhaust
pressure before the re-heater cannot exceed 120% of the pressure at this point when the
machine is operating at rated power output.

b) Temperature:

For rated steam temperature upto and including 565°C (1050°F), the permissible variations
are as stated in the succeeding paragraphs. For specified temperatures in excess of 565°C
(1050°F), the permissible variations should be the subject special agreement.

BHARAT HEAVY ELECTRICALS LIMITED.

 701
Steam Turbine
Maximum Operating Conditions

The average steam temperature at any inlet to the turbine over any twelve months of operation shall
not exceed the rated temperature. In maintaining this average, the temperature shall not normally
exceed the rated temperature by more than 8.3°C (15°F). If, exceptionally, the temperature exceeds
the rated temperature by more than 8.3°C (15°F) the instantaneous value 14°C (25°F) in excess of the
rated temperature, provided that the total operating time between these two limits does not exceed
400 hours during any twelve months operating period. Operation between limits of 14°C (25°F and
28°C (50°F) in excess of the rated temperature, may be permitted, provided that the total operating
time between these two limits does not exceed 80 hours during any twelve months operating period.
In no case shall the temperature exceed the rated temperature by more than 28°C (50°F)

Should steam be supplied to any terminal point on the turbine through two or more parallel pipes, the
steam temperature in any of these pipes should not differ from that in any other by more than 17°C
(30°F) except that during fluctuations not exceeding 15 min. in duration, a temperature difference not
exceeding 28°C (50°F) shall be admissible. The steam temperature in the hottest pipe shall not
exceed the limits given in the preceding paragraph.

Note: For turbines operating with nominally saturated steam, limits should be given for the
moisture content at the inlet points to the turbine.

By the period of operation, in paragraphs a) and b), is meant the period the machine is
connected to the load system.

BHARAT HEAVY ELECTRICALS LIMITED.

 ANNEXURE-III 702

SPECIAL TOOLS AND TACKLES

Sl. Usage
No. Description

01. Hook spanners Tripping device

02. Hook spanner Servomotor
03. Spanner Stop valve assembly
04. Pin spanner Over speed governor
05. Adjusting screw Over speed governor
06. Ring spanner Turbine casing
07. Single ended open jaw spanner Stop valve
08. Double ended open jaw spanner Stop valve
09. Single ended box spanners Bearing housing
10. Eye bolts Bearing housing
11. Assembly fixture Governing valves
12. Bush Governing valves
13. Assembly fixture Lower part of casing
14. Lifting equipment Rotor
15. Transport fixtures Turbine casing
16. Spanners Extraction stop valve

BHARAT HEAVY ELECTRICALS LIMITED.

 713
List of Tools in
Standard Tool Box

S.NO. Description Specification Quantity

1. Single ended ring spanner Size AF 30 mm IS 4509 1 No.
2. Single ended ring spanner 36mm IS 4509 1 No.
3. Single ended ring spanner 41mm IS 4509 1 No.
4. Single ended ring spanner 46mm IS 4509 1 No.
5. Single ended ring spanner 50mm IS 4509 1 No.
6. Single ended ring spanner 55mm IS 4509 1 No.
7. Single ended ring spanner 60mm IS 4509 1 No.
8. Double ended open jaw spanner size 10 x 11 mm IS 2028 1 No.
9. Double ended open jaw spanner 12 x 13 mm IS 2028 1 No.
10. Double ended open jaw spanner 13 x 15 mm IS 2028 1 No.
11. Double ended open jaw spanner 17 x 19 mm IS 2028 1 No.
12. Double ended open jaw spanner 22 x 24 mm IS 2028 1 No.
13. Double ended open jaw spanner 27 x 30 mm IS 2028 1 No.
14. Double ended open jaw spanner 32 x 36 mm IS 2028 1 No.
15. Double ended open jaw spanner 36 x 41 mm IS 2028 1 No.
Single ended (Black Finish) open jaw spanner IS 2028 1 No.
16.
Size AF 46 mm
17. Single ended (Black Finish) open jaw spanner 50 mm IS 2028 1 No.
18. Single ended (Black Finish) open jaw spanner 55 mm IS 2028 1 No.
19. Single ended (Black Finish) open jaw spanner 60 mm IS 2028 1 No.
20. Single ended (Black Finish) open jaw spanner 75 mm IS 2028 1 No.
21. Single ended (Black Finish) open jaw spanner 80 mm IS 2028 1 No.
22. Allen key Size AF 2 mm IS 3082 1 No.

BHARAT HEAVY ELECTRICALS LIMITED.

 713
List of Tools in
Standard Tool Box

S.NO. Description Specification Quantity

23. Allen Key 2.5 mm IS 3082 1 No.
24. Allen Key 3mm IS 3082 1 No.
25. Allen Key 4 mm IS 3082 1 No.
26. Allen Key 5 mm IS 3082 1 No.
27. Allen Key 6 mm IS 3082 1 No.
28. Allen Key 8 mm IS 3082 1 No.
29. Allen Key 10 mm IS 3082 1 No.
30. Allen Key 12 mm IS 3082 1 No.
31. Allen Key Size AF 14 mm IS 3082 1 No.
32. Allen Key 17 mm IS 3082 1 No.
33. Allen Key Size AF 22 mm IS 3082 1 No.
Engineers screw driver with plastic handle IS 844 Part III 1 No.
34.
Size 2.4 x 10 x 200 mm
Electrician screw driver with plastic handle 1No.
35.
Size 2.4 x 10 x 200 mm
36. Eye bolt M10 IS 4190 1 No.
37. Eye bolt M12 IS 4190 1 No.
38. Eye bolt M16 IS 4190 1 No.
39. Eye bolt M20 IS 4190 1 No.
40. Single ended box spanner IS 2030 1 No.
41. Tommy bar for above IS 2030 1 No.

BHARAT HEAVY ELECTRICALS LIMITED.

 SCHEDULE OF TESTS ON EMDM060O
B.L. EXCITER & PMG AT WORKS REV. No. 00
Sheet 1 of 1
HYDERABAD

TESTS TO BE CONDUCTED ON B.L. EXCITER

1. Over-speed test on rotor before assembly at 120% of rated speed for 2 minutes along
with generator.

2. Open circuit characteristics.

3. Load magnetization characteristics.

4. Measurement of D.C resistance of Armature windings and Main pole winding.

5. Measurement of IR value and High voltage test.

TESTS TO BE CONDUCTED ON PILOT EXCITER

1. Measurement of output voltage at rated speed.

2. Checking of phase sequence and measurement of frequency.

3. Measurement of load circuit characteristic .

4. Measurement of D.C resistances of stator winding.

5. Measurement of I.R value and high voltage tests.

Note :
The exciter will be mounted on the overhang of the generator rotor shaft but electrically
not connected to the generator rotor. The rotor shaft will be driven by a test pit DC
drive motor. The exciter is excited from separate D.C. source and output will be taken
through sliprings to a water load (resistance.) .The PMG output will be fed to a 3 phase
resistance load.

ELECTRICAL MACHINES ENGINEERING

 TECHNICAL DESCRIPTION EMDM031
REV. No. 00
OF Sheet 1 of 1
HYDERABAD
BRUSHLESS EXCITER FOR 2 POLE TGs

1.0 INTRODUCTION : The field winding comprises of concentric coils

suitably insulated and mounted on the salient
The brushless excitation system consists of mainly poles in the stator.
A.C. exciter, Rotating rectifier wheels, Permanent
magnet generator and Automatic voltage regulation 4.0 ROTATING RECTIFIER WHEELS -
equipment. The system operates with a high degree of
reliability and requires minimum maintenance. The diodes are mounted on heat sinks made
of cast Aluminium and they are housed an the
2.0 GENERAL ARRANGEMENT : same A.C. exciter rotor on a carrier ring. Both
fuses and diodes are mounted radially to
The A.C. Exciter comprises a revolving armature and ensure that the rectifying junctions are held
a stationary yoke with field windings. The alternating under compression during rotation. Adequate
voltage generated by the A.C. exciter is rectified by cooling of the diodes is achieved by means
the rotating diodes and the rectified voltage is fed to of integral fins on the heat sinks. Sufficient
the field winding of the generator. Electrical margins are provided in the rating of the
connections are made by leads running along the diodes to increase the reliability. The number
surface of the rotor of the A.C exciter . The D.C. and rating of the diode bridges are so chosen
output of the rectifier wheels is connected to the field as to ensure satisfactory operation of the
winding of the generator by suitable insulated leads generator at rated load even if one complete
taken through the rotor shaft. The field excitation for bridge is faulty but without field forcing facility.
the a.c. exciter is controlled by the Automatic Voltage Snubber circuits with capacitors and resistors
Regulator( A.V.R) as per the requirements of the are housed in the carrier ring and are
generator voltage and load. For increased reliability of connected in parallel with each rectifying
the excitation system, the power supply to the A.V.R. bridge to damp the over-voltage spikes arising
is taken from a Permanent Magnet Generator(P.M.G.) out of commutation and hole storage effects.
directly coupled to the main exciter. The A.C. exciter Supervision of the healthiness of the rectifiers
and the P.M.G. are mounted on a common bed plate is done by checking the fuse indicators by
and enclosed by a suitable cover. The A.C. exciter , means of a Stroboscope.
P.M.G. and rotating rectifier wheels are cooled by air.
5.0 PERMANENT MAGNET GENERATOR
3.0 A.C. EXCITER:
For increased reliability of power supply to
The A.C. exciter comprises mainly of a rotating the A.V.R., a P.M.G. is provided and it is
armature and a stationary field. The armature consists driven by the rotor of the generator. The rotor
of a core made of low-loss electrical sheet steel. The consists of permanent magnets and the stator
laminations are thinly insulated and baked to give a is wound with a three phase uniformly
durable insulation. The armature winding is a three- distributed winding. It generates a power
phase winding laid in the slots and insulated for Class supply of 220V, 3 phase.
'F'. The finished armature is balanced and tested for
over-speed capability at 120% of the rated speed for 2
minutes.

ELECTRICAL MACHINES ENGINEERING

 SCHEDULE OF TESTS ON EMDM059
REV. No. 00
Sheet 1 of 1
HYDERABAD
GENERATORS AT WORKS

1. Overspeed test of rotor before assembly at 120% rated speed for 2 mts.

2. Mechanical run and measurement of vibrations at rated speed.

3. Measurement of mech losses, short circuit characteristic upto 100% In & losses.

4. Measurement of mech losses, open circuit characteristic upto 120% En & losses.

5. Measurement of shaft voltage.

6. Checking of phase sequence.

7. Measurement of rotor impedance (rotor inside stator).

8 Measurement of insulation resistance of stator and rotor windings before and after
High Voltage test (m/c at rest).

9. High voltage test of stator and rotor windings (m/c at rest).

10. Measurement of Polarisation Index of stator winding.

11. Measurement of d.c.resistances of Stator and Rotor Windings in cold condition.

12. Measurement of d.c. resistances and insulation resistance of RTDs.

13. Determination of efficiency by separation of losses method.

14. Measurement of Capacitance and tan  of stator winding.

Note :

Generator will be assembled separately with out coolers & enclosure (if any),
on a test foundation frame driven by D.C drive motor & excited using test pit
slip rings (in case of Brushless Excitation System) fed from a D.C source.

ELECTRICAL MACHINES ENGINEERING

 TECHNICAL DESCRIPTION EMDM027
REV. No. 00
OF Sheet 1 of 2
AIR COOLED 2-POLE TGs

1.0 INTRODUCTION : non-magnetic through type insulated clamping

bolts which are so arranged as to ensure a
The synchronous generator is of two pole, 3-phase uniform clamping pressure especially within the
air cooled type and is designed for continuous teeth area and at the same time providing for
operation at its rated output. The constructional uniform intensive cooling of the stator core ends.
features ensure reliability, easy maintenance and
economical operation. 2.3 STATOR WINDING:

2.0 STATOR: The stator winding is of short chorded pitch, double

layer lap-bar type construction. The stator bars are
2.1 STATOR FRAME: composed of varnished and glass covered copper
strips. The strips are stacked to form a Roebel bar
The stator frame is of welded steel construction and with 360 deg. transposition in order to reduce eddy
supports the laminated core and the winding. The current losses. The stator after placement of coils in
welded circular ribs as well as the axial stiffeners the slots is impregnated in VPI system and hot
provide the required rigidity for the stator frame. cured thereafter to form a consolidated mass.
This ensures excellent electrical and
2.2 STATOR CORE: mechanical properties of stator winding. To
prevent corona discharges, the bars are wrapped
The stator core is stacked from thin cold rolled with conductive polyester fleece during insulation
non-oriented electromagnetic sheet steel of bar stage. The overhang of the winding is
punchings having low loss factor and high supported with resin absorbent glass mats and
permeability and is suspended in the stator frame tyings which ensure a very rigid support after resin
from the insulated guide bars. The laminations are absorption and hot curing. Six terminals are
slotted, deburred and varnished with high quality brought out of the stator end cover at exciter end.
synthetic varnish. The core is divided into packets
of required dimensions and these packets are 3.0 ROTOR
separated by radial ducts to provide adequate
passage for the flow of coolant. These ducts are 3.1 ROTOR SHAFT:
formed by insulated thick stamping steel
laminations on which ventilating spacers are spot The rotor shaft is a single piece, solid forging of
welded. Glass laminate sheets are placed special Alloy steel manufactured by vacuum
adjacent to each thick lamination sheet of every casting by reputed shops under strict inspection
packet to provide additional insulation. For reducing and control. To ensure that only high quality
the stray load losses, the air gap is enlarged at forgings are used, strength tests, material analysis,
both ends of the core by means of stepped end and ultrasonic tests are carried out during
packets which are glued together to prevent manufacture. Radial slots are milled axially on the
vibration during operation. During the assembly of rotor body to accommodate the field windings.
the core, the laminations are pressed together The slots are distributed over the
under heat using a hydraulic press to ensure a rigid circumference so that two solid poles are
and consolidated core and is firmly held together obtained. After completion, the rotor is balanced
by means of clamping fingers, end plates and thoroughly and subjected to an over-speed test at
120% of the rated speed for 2 minutes.

ELECTRICAL MACHINES ENGINEERING

 TECHNICAL DESCRIPTION EMDM027
REV. No. 00
OF Sheet 2 of 2
AIR COOLED 2-POLE TGs

3.2 ROTOR WINDINGS: 4.0 BEARINGS:

The rotor winding consists of several coils The generator rotor is supported on two journal
made of high conductivity silver bearing bearings. The bearings are lined with babbitt
electrolytic copper conductors ensuring high material to reduce the wear and damages to
thermal stability. Each coil consists of several the journal. To eliminate shaft currents, one
series connected turns comprising two half turns bearing is insulated. The bearing temperature
each of which is connected by brazing in the is supervised by a thermo-element arranged
end winding portions. Slots are punched in the in the lower half of the bearings, so that the
coils to provide ventilation paths. The measuring point is located directly below and
individual turns of the coil are insulated against nearer the babbitt. Each bearing is provided
each other by epoxy glass laminates. L-shaped with facilities for fitting vibration pick-ups for
slot troughs of epoxy glass cloth with Nomex vibration supervision. The oil supply for the
filler are used as slot insulation. The wedges are bearings is provided from the turbine oil system.
made of well conducting material and short-
circuited at their ends through the retaining 5.0 VENTILATION:
rings which are silver plated at the contact
surfaces to act as an effective damper winding. The turbogenerator is designed with closed
circuit forced air cooling system . Radial type
3.3 RETAINING RINGS: of ventilation system is employed in the stator
and rotor. The cooling air is passed through
The centrifugal forces of the rotor end windings the various ventilation paths and the hot air
are taken up by single-piece retaining rings. The flows out of the stator frame and is cooled in
retaining rings are forged out of non-magnetic water-air heat exchangers. The air is
steel in order to reduce stray losses and are circulated by the axial fans in the machine.
cold worked to have high mechanical strength.
The forgings are subjected to mechanical 6.0 TEMPERATURE_MEASUREMENTS:
tests and non-destructive tests to ensure
soundness and high quality. The retaining rings The temperature at different points in the stator
are shrink fitted on the rotor barrel on one side, winding, cold air region, hot air region and the
and on the hubs on the other side. Each retaining generator and exciter bearing metal are
ring is secured axially by a snap ring. They are measured by means of resistance temperature
insulated from the rotor winding by high quality detectors (R.T.D.s) of Platinum Pt 100 type,
insulation of sufficient thickness. placed at a number of suitable places. These
R.T.D.s would be connected to a temperature
3.4 FANS: scanner provided in the generator control panel.

The cooling air is circulated by two axial flow fans

located on either side of the rotor barrel. The fan
blades have threaded roots for being screwed into
the rotor shaft. The blades are die forged from
aluminium alloy. Each blade is secured at its root by
grub screws against loosening.

ELECTRICAL MACHINES ENGINEERING

 HEAT EXCHANGERS SURFACE CONDENSER
(ROUND)

1.0 Introduction:

The condenser is Surface type, fabricated construction and single shell. The condenser is
mounted on saddles. An expansion bellow or a set of springs at the supports is provided to take
care of thermal expansion in vertical direction. The condenser is rigidly connected to the
exhausthood of the turbine.

On the water side the condenser is divided vertically into two independent water paths. This
arrangement facilitates the operation of one half of the condenser when the other half is under
maintenance for a very short duration.

The condenser is provided with integral air cooling zone from where air and non condensable
gases are continuously drawn out with the help of air evacuation system.

2.0 Operation:

The main functions of the condenser are

i) To condense the stern exhausted from the turbine to enable recycling of

Condensate.

ii) To maintain vacuum such that the heat drop to be utilised in the turbine is
optimum.

iii) To maintain the temperature of the condensate at the saturated level to remove the
dissolved gases.

iv) To prevent the under cooling of the condensate to minimise thermal losses.

v) To facilitate the extraction of air and other gases to maintain high level of
performance.

vi) To receive sub atmospheric drains eg. drains from steam jet air ejectors, LP Heaters
and drain coolers etc.

Condensation takes place on the outer surfaces of tubes through which the cooling water is
circulated. The tubes are arranged in bundles which are separated by adequate wide lanes. The
selective layout of tubes in the condenser, ensures efficient heat transfer from steam to cooling
water, keeping the resistance to steam flow to barest minimum.

Bharat Heavy Electricals Ltd,Hyderabad-500032 Page 1/5

 HEAT EXCHANGERS SURFACE CONDENSER
(ROUND)

3.0 Design & Construction:

The surface condenser is designed to HEI standard wherever applicable with suitable
cleanliness factor or fouling factor based on cooling water quality, tube material and cooling
water velocity. The condenser is designed for proper distribution of steam. Adequate attention
is paid to avoid sub coo!ing of condensate and also stagnant air pockets.

4.0 The main parts of the condenser are:

a) Shell

h) Water box

c) Tubes

d) Tube plates

c) Support plates

f) Super structure

g) Hotwell

h) Supports.

4.1 Shell:

The condenser shell is of carbon steel, cylindrical shape and fabricated construction. It is
welded to the front and rear tube plates.

The steam flow in condenser shell is guided with properly located baffles to have effective
condensation with minimum subcooling and efficient removal of air and non-condensables,
The steam space is divided transversly support plates. Necessary connections on the condenser
shell are provided for make up, drains, vent and instruments etc. The shell is protected against
overpressure by rupture disc or atm.relief valve or Burshing diaphragm.

4.2 Water Box:

The condenser water box is of carbon steel construction cylindrical in shape and closed by a
flat cover. It is divided vertically into two segments with two cooling water inlet and outlet
connections. Water box is designed for even distribution of water. The water box covers are
provided with hinge arrangement to facilitate repair and replacement of tubes. Inspection holes
are provided for routine maintenance and visual inspection. Water boxes and end covers are

Bharat Heavy Electricals Ltd,Hyderabad-500032 Page 2/5

 HEAT EXCHANGERS SURFACE CONDENSER
(ROUND)

lined with rubber lining/ FRP lining to protect against sea water corrosion in case of sea water
supply. Some times NF cladded CS or SS cladded CS plates are also used depending on
customers requirement.

4.3 Tubes:

The condenser is provided with tubes. The tubes are secured to tube plates by roller expansion
which provide good sealing arrangement against penetration of circulating water into steam
space. The tubes are arranged in such a way to facilitate self draining of tubes during shut
down.

The cooling water flows inside the tubes and steam flows over the tubes. These tubes provide
the necessary heat transfer surface. Each tube is tested in conformance to material specification
and subjected to a hydraulic test pressure of 70 atg. at suppliers works.

4.4 Tube Plates:

The tube plates are generally of carbon steel and welded to the shell. The holes are drilled to a
close tolerance and the tubes are roller expanded into the tube plates. Some times NF cladded
CS or SS cladded CS plates are also used depending on tube side flow medium or customers
preference. Solid NF or SS tube plates are also considered depending on customer requirement.

4.5 Support Plates:

The support plates are of carbon steel material and welded to the shell. The tubes are supported
on support plates at regular intervals along its length which help in arresting vibration induced
by running TG and consequently the tube damage.

4.6 Superstructure:

The function of superstructure is to enable even distribution of steam to tube bundle. It also
houses steam dumping device if it is envisaged in the system. The superstructure is made of
carbon steel plates and strengchened from inside or outside by plate/flats/rods/langles/channals
to retain its shape against atm. relief pressure.

4.7 Hotwell:

The condenser hot well is of carbon steel material and semicircular or rectangular shape. It is
welded at the bottom of the shell and it has adequate storage capacity of water. It may be
divided vertically into two sections. One or more condensate extraction connections are
provided in the hotwell

4.8 Supports:

Bharat Heavy Electricals Ltd,Hyderabad-500032 Page 3/5

 HEAT EXCHANGERS SURFACE CONDENSER
(ROUND)

The condenser is fixed with saddles and rested on foundation block. In case of spring mounted
condenser, springs are located under each support plate. These springs take the weight of the
condenser and its tubes and transfer to foundations. During operation the weight of circulating
water and of condensate along with thrust of springs is transferred to turbine foundation.

5.0 Qaulity Control:

Very high standard of quality is maintained during design and construction to ensure reliability
of the condenser during operation. The welding procedures and welders are qualified before
starting of manufacture. Similarly the expansion of tubes into tube sheets are optirnised before
the manufacture commences. All welding is carried out by qualified, welders using qualified
welding procedures. The tubes are expanded into tube plates by torque controlled expanders
operating under predetermined parameters. The water boxes arc hydraulically tested. Shell
side water will be filled upto 1 meter above the top row of tubes and will be checked for any
leakage,

6.0 Despatch:

All the parts are, thoroughly drained and dried. The parts are then cleaned and external
surfaces of the equipment are painted. Interior surfaces of water box and its covers are coated
with rust preventive. All the openings are properly blanked before despatch. The condenser
will be despatched with all internals except hotwell, standpipe, surge pipe, instruments and
valves, which shall be sent separately.

Bharat Heavy Electricals Ltd,Hyderabad-500032 Page 4/5

 HEAT EXCHANGERS SURFACE CONDENSER
(ROUND)

Bharat Heavy Electricals Ltd,Hyderabad-500032 Page 5/5

 HEAT EXCHANGERS SPARY CUM TRAY TYPE
DEAERATOR

1. Introduction

The deaerator is provided to remove the dissolved corrosive gases from the feed water
which goes to the boiler. It prevents internal corrosion of boiler tubes. The oxygen is
reduced to 0.005 cc/litre and carbondioxide is reduced to untraceable limits.

It is a direct contact type heater and is located between LP Heaters and Boiler feed pump
in regenerative cycle. The steam from a suitable turbines stage is drawn to heat the
condensate which is broken in fine particles for effective heating and mass transfer of non
condensable gases.

The deaerator consists of integral vent condenser, one deaerating header and one feed
storage tank.

2. Flow Arrangement

The condensate to be deaerated enters the deaerating chamber at the top and is sprayed by
variable orifice spray valves. The water then falls through perforated tray stack or spill or
spill over track by gravity allowing for mass transfer and additional heat transfer time. The
condensate is divided into fine droplets and comes in the intimate contact with the steam
resulting in release of non condensable gases which are carried by the steam moving
upwards.

The condensate after leaving deaerating heater enters the feed storage tank from where it
goes out to boiler feed pumps. The steam flows counter to condensate flow. It enters the
feed storage tank first and then goes into deaerating heater, where it gets condensed. Some
steam along with non condensable gases go out of the equipment.

3. Design and Construction

The deaerator removes the non condensable gases by heating the condensate, which
reduces the solubility of non condensables and then allow for the mass transfer time to
reduce non condensable further. The steam flowing upwards provided the atmosphere for
the mass transfer and the condensate droplets while carrying away non condensable gases.
The trays divide the condensate into fine droplets so that heating and mass transfer is
achieved quickly. Steam admittance in storage tank provides steam blanket over stored

Bharat Heavy Electricals Ltd., Hyderabad - 500032 page:1/4

 HEAT EXCHANGERS SPARY CUM TRAY TYPE
DEAERATOR

condensate and thus eliminates sub cooling of condensate and reabsorption of gases by the
condensate.

Vortex breaker is provided at feed water outlet to prevent forming of vortices and
consequent possible damage of boiler feed pumps.

The deaerator and the feed water storage tank are designed and constructed to International
Standards like HEI, TEMA, ASME Section VIII Division 1 etc. The deaerating header is
mounted on the feed storage tank for simplified layout and compact arrangement.

4. Deaerating Header

The main parts of the deaerating header are:

shell:

The shell of the deaerating header is fabricated from boiler quality steel plates, and is
closed with dished ends. The shell is mounted directly either vertically or horizontally over
the feed storage tank.
It houses stainless steel trays. The distribution chamber is located at the top in which
stainless steel spray valves are provided for spraying condensate. It is provided with
connections such as condensate inlet, inspection opening steam + air outlet etc.

Spray valves and trays:

The spray valves are made out of SS304 with a spring loaded conical disk moving in a
case. The variable opening is controlled by the flow.

The tray design is of two type i.e. perforated trays and spill over trays. Perforated trays
have no. of small size holes through which condesate falls down and annular and central
opening for adequate flow velocities of steam + non condenables and pressure
equalisation. The perforated trays are independently supported by rigid supports. In case of
spill over trays a series of channel type SS 304 trays are arranged such that condensate
spill over from one layer of trays to another Spill over trays are rigidly supported one over
the other. They are proven for load throw off and HP/LP bypass operation.

Bharat Heavy Electricals Ltd., Hyderabad - 500032 page:2/4

 HEAT EXCHANGERS SPARY CUM TRAY TYPE
DEAERATOR

Feed water storage tank:

The shell of the storage tank is fabricated from boiler quality steel plates. The two ends of
the tank are closed with dished ends. Various connection like condensate outlet, steam
inlet, drain outlet, HP drips,relief valves,inspection opening, thermometer pockets, level
gauges, high and low level
alarms, manholes etc., are provided. An access ladder is provided inside the tank which
will be helpful for cleaning and inspection purposes. The tank is supported at either ends
by a fixed and a roller support.

5. Quality Control

The deaerator is manufactured after establishing the process of manufacture thoroughly.

The welders and the welding procedure are qualified before starting the manufacture. All
welding is carried out by qualified welders using qualified welding procedures.

Completed storage tank and deaerating header are subjected to hydraulic test to a pressure
equal to 1.5 times the design pressure.

6. Despatch

All parts are thoroughly drained & dried. The parts are then cleaned and external surface
of the equipments are painted. Generally header assembly is despatched in
assembled condition after proper hydro test at works. Whenever FST is to be despatched
in a single piece it is hydro tested at works. In case of FST is to be despatched in parts due
to transport limitation and site handling facilities, the final assembly is done at site and
then hydro tested. Tank internals are generally coated with washable temporary rust
preventive and external surfaces is coated with paint. All the nozzle openings are properly
blanked.

Bharat Heavy Electricals Ltd., Hyderabad - 500032 page:3/4

 HEAT EXCHANGERS SPARY CUM TRAY TYPE
DEAERATOR

Bharat Heavy Electricals Ltd., Hyderabad - 500032 page:4/4

 HEAT EXCHANGERS AIR EJECTOR SYSTEM

1.0 Introduction:

The air ejector system is used to extract the non condensable gases from the condenser and
thereby creating vacuum in the system. It consists of one Hogging ejector and two main
ejectors. Each consists of first stage and second stage ejector, inter and after condenser.
To create vacuum during starting condition, Hogging ejector is used to extract the non
condensable gases from the system. When the vacuum in the condenser reaches 500-
55Omm of Hg column and after stabilization of main ejector, hogging ejector is switched
off. Out of the two main ejectors one is for normal operation, while the other one serves as
stand by.

2.0 Hogging ejector:

The hogging ejector serves to evacuate the condenser and related pipe at the time of
starting the turbo-set. The starting ejector consists mainly of the steam chamber nozzle,
diffuser and mixing chamber. The motive steam with the same parameter as that of main
ejector attains a great velocity by passing through nozzle. All the air in the system,
therefore rushes into the mixing chamber. This air along with the working steam is again
compressed in the diffuser, and then let out to the atmosphere.

A pressure gauge, silencer, vacuum gauge and valves are mounted on hogging ejector.

3.0 Main ejector:

The main ejector is of two stage single element design each with its inter and after
condenser. The main ejector maintain vacuum in the condenser by continuously suck-ing
in steam air mixture during operation.

The working steam is expanded to a very low pressure in a suitably formed nozzles of the
first stage ejector and resulting high velocity of the steam sucks in steam air mixture from
the condenser. The steam air mixture along with the working steam is compressed in first
stage diffuser and introduced into the inter condenser where most of the steam is
condensed. The coolant for the condensers of the ejector is the main condensate pumped
by condensate pump. In this way the heat of the steam is utilized in raising the
temperature of the condensate. When the condensate quantities are very low cooling water
will be used as coolant in inter and after condensers. the condensate of the working steam
is drained off to the main condenser, through a steam trap.

Bharat Heavy Electricals Ltd,Hyderabad-500032 Page - 1/5

 HEAT EXCHANGERS AIR EJECTOR SYSTEM

The non condensed portion of the steam and air from inter condenser is sucked in bv the
second stage ejector using same parameters of working steam and expanded in a nozzle, as
in the 1st stage. The steam air mixture together with the working steam is then compressed
to above atmosphere pressure in second stage diffuser and introduced in after condenser,
where all the steam is condensed and air is extracted through an outlet branch. The
condensate of the working steam is drained off to main condenser through a steam trap.

4.0 The main parts of the ejector air.

1. Suction chamber

2. Shell

3. Water chambers

4. Tubes

5 . Air measuring device

4.1 Suction chamber:

The suction chamber has been divided into parts. all the compression stages consisting of
nozzle and diffuser are amounted inside this chamber. The convergent divergent nozzle
has been designed to accelerate the steam flow and thereby reduce the pressure of steam in
the 1st stage suction chamber. the low pressure in suction chamber sucks the non
condensable gases from condenser. The steam and air vapour mixture enters the diffuser
and while passing through the diffuser, the kinetic head is converted to pressure head.
Nozzle is fabricated from stainless steel and diffuser from carbon steel material.

4.2 Shell:

Usually this is fabricated from carbon steel. It is divided into two parts as inter and after
condenser. Condensate from condenser or cooling water first enters the inter condenser,
and then after condenser. It houses the necessary connection such as steam inlet, drain
outlet, air suction outlet (for inter condenser) relief valve etc.

Bharat Heavy Electricals Ltd,Hyderabad-500032 Page - 2/5

 HEAT EXCHANGERS AIR EJECTOR SYSTEM

4.3 Water chamber:

This is usually of carbon steel material and divided into different zones in such a manner
that cold condensate or cooling water first flows through the inter condenser and there after
through after condenser.

Condensate or cooling water inlet and outlet connection are provided in the water box.

Whenever cooling water is used for cooling metallurgy of water chambers may be similar
to that of main condenser depending on customers requirement.

4.4 Tubes:

The tubes are straight and roller expanded in tube sheets. the condensate flows inside the
tubes. Steam and air mixture flows over the tubes. These tubes provided the necessary
heat transfer surface. Each tube is tested for conformance to material specification and
subjected to a hydraulic test pressure of 70 atg at suppliers works. All the tubes are heat
treated throughout their length for better grain structure and long tubelife.

4.5 Air measuring device:

The air flow meter, for measurement of dry air discharge from condenser is fitted at the air
exit of the ejector.

The design of this device is such that it enables the measurement of dry air discharge while
the condenser and ejector air in operation.

5.0 Quality control:

The steam jet air ejectors are manufactured after establishing the procedure of manufacturing.
Welders and welding procedure are qualified before manufacture. Expansion of tubes into tube
plates are optimized before the manufacture commences. All welding is carried out by qualified
welders using qualified welding procedure. The tubes are expanded into the tube plates by torque
controlled expanders operating under predetermined parameters.

Performance tests for main ejectors are carried out at shop with dry air and air vapour mixture
under various operating conditions. Completed ejector inter and after condensers are subjected to
hydraulic test to one and half times the design pressure. Starting ejectors are performance tested at
site only.

Bharat Heavy Electricals Ltd,Hyderabad-500032 Page - 3/5

 HEAT EXCHANGERS AIR EJECTOR SYSTEM

6.0 Despatch:

All parts are thoroughly drained and dried. Subsequently thoroughly cleaned and painted. All the
openings are properly blanked before despatch.

Bharat Heavy Electricals Ltd,Hyderabad-500032 Page - 4/5

 HEAT EXCHANGERS AIR EJECTOR SYSTEM

Bharat Heavy Electricals Ltd,Hyderabad-500032 Page - 5/5

 HEAT EXCHANGERS OIL COOLER

A) Introduction:

The function of TG set oil cooler is to cool the hot bearing lubrication oil before returning it to
the bearing thus preventing over-heating and damage to the bearings.

Lubricating oil while passing through the TG set bearings absorbs large amount of heat
generating from bearing friction as well as conducted through turbine shaft. In order to remove
the absorbed heat, hot oil is passed through oil coolers wherein the heat from oil is transferred to
cooling water.

It is usual to provide two coolers of 100% capacity such that any one cooler may be taken out of a
service for cleaning / repairs without necessitating shut down of TG set. A transflow type change
over device interposed between the coolers ensures uninterrupted supply of lubrication oil to the
bearings during the change over.

B) Design and Construction

Generally oil coolers for TG sets are of the shell & tube type , Vertically mounted construction.
The shell side embodies an arrangement of alternate disc & doughnut baffles or segmented
baffles. Cooling water is arranged to flow through the tubes in 4 passes and oil is arranged to flow
over the tubes in single pass. The tube bundle and shell can be withdrawn independently for
inspection & cleaning and to effect any repairs.

The inlet/outlet water box is provided at the bottom & reverse end water box at the top. The water
boxes can be turned relative to the oil connections to suit the associated pipe work. It has adequate
venting & fluid draining facilities.

It is usual to design/operate oil side at a higher pressure than water side to avoid any ingress of
water into the oil.

The oil cooler consists of 3 main parts.

1. Shell
2. Water boxes
3. Tubenest.

1. Shell:

The cylindrical shell is made of carbon steel plates with two main flanges welded at both
the ends. Bottom flange is bolted to inlet/outlet water box flange and the top flange is

Bharat Heavy Electricals Ltd., Hyderabad - 500032 page: /4

HEPE008.DOC
 HEAT EXCHANGERS OIL COOLER

bolted with stuffing box type gland. Two flanged branches are provided on shell for oil
entry & exit.

The exterior of shell also carries lifting lug for lifting the complete cooler or only shell as
required.

2. Water boxes:

Both inlet/outlet and reverse end water boxes are made of carbon steel plates and are of
adequate proportions to minimize pressure drop & turbulence.

The inlet/outlet and reverse end water boxes are divided internally by partition plates to
suit the number of passes.

In case seawater is used as coolant these water boxes can be lined with neoprene rubber,
fibreglass or other corrosion resistant materials.

3) Tubenest

Tubenest consists of mainly 2 tube plates, tubes & baffle plates. Tubes are rollers
expanded in tubeplate holes. The entire tubenest is covered with a thin carbon steel sheath
to form a tight shell over the tubenest in the case of disc & doughnut baffled tubenests.

a) Tubeplates:

Normally tube plates are made of carbon steel material. In special cases nonferrous
materials like Naval brass, Muntz metal etc. can be used. Both tube plates are drilled to
receive tubes & bolts securing waterboxes.

The tubeholes are internally reamed to a finish for rollers expanding of the tubes in the
tubeplates.

b) Tubes:

Normally tubes used are of Admiralty mixture brass materials. Other materials like
aluminium brass, cupronickel, stainless steel etc. may be used depending on the quality of
cooling water employed. It is usual to use pl R Kqintubes in oil coolers. Some times to
make design compact lowfin tubes are also employed.

c) Baffles:
Bharat Heavy Electricals Ltd., Hyderabad - 500032 page: /4

HEPE008.DOC
 HEAT EXCHANGERS OIL COOLER

Baffles of disc and doughnut type are used within the tubenest. The baffles are made of
carbon steel material and are required in position by spacer tubes.

C) Special Features:

1) Thermal Expansion:

Longitudinal expansion of tubes due to rise in temperature during operation is

accommodated by the action of stuffing box type gland between shell and the reverse end
tube plate, the gland is a synthetic rubber ring housed under compression in the shell bore.

In the remote event of leakage from this gland, oil cannot leak into the water circuit, or
water into the oil circuit as the reverse end water box has a separate gasket joint. General
practice is to arrange for the oil circuit pressure always to exceed the water circuit
pressure, so that if a leak occurs the oil circuit will remain free of water.

2) Sheathing on tubenest: (in case of disc & doughnut baffled tubenest)

In a conventional design of shell and tube oilcooler with a removable tube bundle
arrangement, the doughnut baffles extend upto shell inside diameter with a specified
assembly clearance between shell ID and doughnut baffle OD. If this clearance is
perfectly achieved during manufacture, then by passing of oil across the gap can be catered
for in the design of oil cooler, but in actual manufacture control of these clearances is
difficult during various forming operations. In a fabricated shell, the ovality of rolled shell
results in large by pass clearances which in turn will adversely affect the performance of
cooler.

To overcome the above problem, entire tubenest is covered with a thin carbon steel sheath
to form an inner shell. Since the sheath thickness is very small it can be pressed over
doughnut baffles, to obtain a tight joint. The covered tubenest is inserted in the main shell
with a branch into branch arrangement of shell side to separate out inlet & outlet zones.

D) Quality Control

The oil coolers are manufactured after establishing the complete manufacturing procedure. A
mock up test is carried out to prove tube to tube sheet joint before the actual job is taken up. The
tubes are expanded in the tubeplates by torque controlled expanders operating under
predetermined parameters. All welding is done by qualified welders using qualified welding
procedures.

Completed oil cooler is hydro tested both on oil & waterside at one & half times the design
pressure. Oil side of cooler is specifically tested with oil to avoid corrosion effect.
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HEPE008.DOC
 HEAT EXCHANGERS OIL COOLER

E) Despatch:

All parts are thoroughly drained & dried. Subsequently the equipment openings are closed by
metallic covers and then thoroughly cleaned & painted before despatch.

Bharat Heavy Electricals Ltd., Hyderabad - 500032 page: /4

HEPE008.DOC
 HEAT EXCHANGERS OIL COOLER

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HEPE008.DOC
 HEAT EXCHANGERS AIR COOLERS FOR
GENERATOR

1.0 Introduction

The function of air coolers is to remove the heat absorbed by air in the electric machine casing. This is
necessary to prevent overheating of electric machine windings and damage to that equipment.

Air coolers are used for cooling of TG set generator, GT set generators, BFP motors, synchronous
condensers etc. Air is circulated by the rotor fans of generator/motor is a closed system, the heat absorbed
by the air being removed in the air coolers mounted in the basement/by the side/on top of/in the stator
casing of generator or motor by the circulating cooling water.

Air coolers consists of a set of standard finned tubed cooler elements and are selected/ designed depending
on heat load, circulating air quality, cooling water inlet temperature & fouling considerations.

2.0 Design & Construction:

Generally Air Cooler elements consists of several rows of high finned tubes fitted in two tube plates and
enclosed in a framework with inlet/outlet & reverse and water boxes at two ends of each element.
Circulating air passes over the finned tubes thereby giving its heat to the cooling water flowling through
the tubes. The finned tube side of elements is kept open on two side for air flow. Cooling water is arranged
to flow through the tubes in two or more passes. Complete air cooler element can be withdrawn from its
mounting for inspection/cleaning/repairs etc. It is possible to remove inlet/outlet and reverse end water
boxes for cleaning/plugging of any one element in position by reducing load on generator/motor.

An additional spare cooler element can be provided in the air duct for base mounted and side mounted
designs by using flapper closing arrangements on air side. This is done on special requirements of
customers.

Two cooling water headers with isolation valves are provided for CW inlet and outlet for a set of air cooler
elements.

Air cooler elements consists of 4 main parts.

1) High finned tubes.

2) Tube plates.
3) Frame.
4) Waterboxes.

3.1 High Finned Tubes:

Normally tubes used are admiralty brass with copper fins. Other materials like aluminium brass,
cupronickel, with copper fins may be used depending on the quality of cooling water flowing through
tubes. Sometimes stainless steel tubes with A1. fins or brass tubes with copper wire winding are also used
for special applications.

3.2 Tube Plates:

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HEPE010.DOC
 HEAT EXCHANGERS AIR COOLERS FOR
GENERATOR

Usually tube plates are of carbon steel material. In special cases nonferrous materials like Naval brass,
Muntzmetal and stainless steel etc. can be used. Both tube plates are drilled to receive tubes and bolts
securing waterboxes.

The tubeholes are internally reamed to a finish suitable for roller expanding of the tubes in the tubeplates.

3.3 Frame:

Frame is a rectangular structure of CS plates, angles, channels etc. to enclose a set of finned tubes. It is
open on two sides and closed on two sides. Open side allows the air to flow over tubes. It gives rigidity to a
budle of tubes for mounting with electrical machine. Frame is bolted on two ends to the tube plates and
also houses tube supporting arrangement.

3.4 Waterboxes:

Both inlet/outlet and reverse and waterboxes are made of carbon steel plates and are of adequate
proportions. The inlet/outlet & reverse end boxes are divided internally by partition plates to suit the no.of
passes. They are bolted to front & rear end tube plates.

In case of sea water supply, these waterboxes can be lined with neoprene rubber, fibre glass or other
corrosion resistant materials.

On special requirements, they can be made out of nonferrous materials, NF cladded CS,SS cladded CS or
SS.

4.0 Quality Control:

The air coolers are manufactured after establishing the complete manufacturing procedure. A mockup test
is carried out to prove tube to tubesheet joint before the actual job is taken up. The tubes are expanded in
the tubeplates by torque controlled expanders operating under predetermined parameters. All welding is
done by using qualified welding procedures.

Completed air cooler elements are hydrotested on tube side at one & half times the design pressure.

5.0 Despatch:

All parts are thoroughly drained & dried. Subsequently the equipment openings are closed by metallic
covers & then thoroughly cleaned & painted before despatch.

Bharat Heavy Electricals Ltd., Hyderabad - 500032 page: /4

HEPE010.DOC
 HEAT EXCHANGERS GLAND STEAM
CONDENSER

1.0 Introduction:

The gland steam condenser is used to condense the gland steam extracted from turbine glands, in a
regenerative cycle. This besides condensing the gland steam, heat the condensate from the
condenser. In case of very low condensate flows or non condensing sets, GSC steam will be
cooled by condensate. The condensate or cooling water passes through the tubes and steam/drain
passes over the tubes. The gland steam condenser is of surface type, horizontal / vertical mounting
type.

2.0 Flow arrangement

The steam and air mixture enters the shell side of the gland steam condenser and loses its latent
heat to condensate or cooling water flowing through the tubes. Segmental baffles are provided to
regulate the steam flow for efficient heat transfer and prevention of the main condensate flowing
from one end to and leaving out from the other end. Usually condensate after passing through the
gland steam condenser enters the low pressure heater. A motor driven fan or ejector is used to
suck the non condensable air from the shell side of the condenser.

3.0 Design & Construction

The gland steam condenser is of surface type and it is sized for reliable operation at different
loads. Adequate attention is paid for removing the air which is coming along with gland leakage
steam from turbine, under all load conditions. The gland steam condenser is designed and
constructed to HEI, BEAMA & ASME Section -VIII standards.

The salient features of the gland steam condenser are described below.

3.1 Shell

The shell is fabricated from boiler quality plates and is welded to tube plates at both ends. It
houses the necessary connections for the steam inlet, drain outlet air exhaust.

3.2 Water box

This is fabricated from carbon steel and closed by a cover, condensate inlet and outlet connection
are provided to front and rear water box respectively. In case cooling water supply of GSC, the
metallurgy of water boxes may be same as main condenser or ejector condenser based on
customer requirements.

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HEPE011.DOC
 HEAT EXCHANGERS GLAND STEAM
CONDENSER

3.3 Tubes

The tubes are straight and ends are roller expanded into tube sheets. These tubes provide
necessary heat transfer surface. Each tube is tested to conform to material specification and
subjected to a hydraulic test pressure of 70 atg. at suppliers works. All the tubes are heat treated
throughout their length for better grain structure and long tube life.

3.4 Baffles

Number of segmental baffles of mild steel are provided to guide the steam and condensate flow
for efficient heat transfer and also to support the tubes at regular intervals for vibration free
performance. The holes are drilled to a close tolerance and the tubes are roller expanded into the
tube sheets.

Impingement baffles:- Impingement baffle is provided at steam inlet to protect the tubes from
erosion.

4.0 Quality Control

The gland steam condenser is manufactured after establishing the procedure of manufacturing
thoroughly. Welders and welding procedure are qualified before manufacture. Similarly the
expansion of tubes into tube plates are optimised before the manufacture commences. All
welding is carried out by qualified welders using qualified welding procedure. The tubes are
expanded into the tube plates by torque controlled expander under predetermined parameters.
Completed gland steam condenser is subjected to hydraulic test to a pressure equal to one and half
times the design pressure.

5.0 Despatch

All parts are thoroughly drained and dried, subsequently thoroughly cleaned and painted. All the
openings are properly blanked before despatch.

Bharat Heavy Electricals Ltd., Hyderabad - 500032 page: /2

HEPE011.DOC
 HEAT EXCHANGERS L.P.HEATER

1.0 Introduction:

The low pressure heaters are used to heat the condensate from the condenser, by extraction steam
from turbine in a regenerative heat cycle. This, besides resulting an improvement in the thermal
efficiency, removes moisture from the low pressure stage of the turbine thereby reducing the
problem of blade corrosion in the turbine. The condensate passes through the ‘U’ tubes and
steam/drain passes over the tubes.

The L.P. Heaters are of surface type with either horizontal or vertical mounting.

2.0 Flow Arrangement:

The steam enters the shell side of the heater and loses its latent heat to condensate flowing through
the tubes. Segmental baffles are provided to regulate the steam flow for efficient heat transfer and
prevention of tube vibration. Flow of condensate is counter to steam/drain flow. Condensate after
leaving the heaters goes to deaerator. L.P.Heaters are designed with condensing zone or
condensing with drain cooling zone.

3.0 Design and Construction:

The low pressure heaters are ‘U’ tube type and sized to give reliable operation at different loads.
Besides thermal performances, the heaters are checked for vibration, thermal stresses etc,.
Adequate attention is paid for venting and drainage of heaters under all operating conditions.

The heaters are designed and constructed to HEI and ASME Section - VIII standards.

The salient features of the heaters are as follows:

3.1 Shell:

The shell is fabricated from boiler quality plates and is closed with a dished end. It houses the
necessary connections for the steam inlet, drain outlet, level gauge, low and high level alarms,
relief valves, space for flashing of the drain coming from higher stages.

3.2 Tubes:

The tubes are ‘U’ shaped and the ends are roller expanded into tube sheets. These tubes are
provided for necessary heat transfer surface. The ‘U’ tubes are free to expand independently and
therefore, expansion bellows are not required.

Bharat Heavy Electricals Ltd., Hyderabad - 500032 page:1 /4

HEPE013.DOC
 HEAT EXCHANGERS L.P.HEATER

Each tube is tested for conformance to material specification and subjected to a hydraulic test
pressure of 70 atg. at suppliers works. All the tubes are heat treated through out their length for
better grain structure and long tube life besides making them suitable for bending and expanding.

3.3 Water Chamber:

This is fabricated from boiler quality steel plate and closed by a dished end. It is provided with
condensate inlet and outlet Connections.

3.4 Baffles:

Series of segmental baffles of mild steel are provided to guide the steam and condensate flow for
efficient heat transfer and also to support the tubes at regular intervals for vibration free
performance. The holes are drilled to very close tolerances to reduce the amplitude of vibrations.

3.5 Tube Plate:

Tube plate is of carbon steel material. Tube holes are drilled to a close tolerance and the tubes are
roller expansed into the tube plates.

3.6 Impingement Baffles:

Impingement baffles are provided at steam inlet to protect the tubes from erosion, suitable carbon
steel dispersers are fitted at the inlet connection of drain coming from higher stage heaters.

4.0 Quality Control:

The heaters are manufactured after establishing the procedure of manufacturing thoroughly.
Welders and welding procedure are qualified before manufacture.

Similarly the expansion of tubes into tube plates are optimised before the manufacture
commences. All welding is carried out by qualified welders using qualified welding procedure.
The tubes are expanded into the tube plate by torque controlled expanders operating under
predetermined parameters. Completed L.P.Heaters are subjected to hydraulic test to a pressure
equal to 1.5 times the design pressure.

5.0 Despatch:

All parts are thoroughly drained and dried. Subsequently thoroughly cleaned and painted. All the
openings are properly blanked before despatch.

Bharat Heavy Electricals Ltd., Hyderabad - 500032 page:2 /4

HEPE013.DOC
Recommended SPARES

Sr.No Item Quantity

1 Steam Turbine
a) Front Journal Bearing 1 No
b) Rear Journal Bearing 1 No
c) Thrust Journal Bearing 1 Set
d) Labyrinth fins for Steam Glands 1 Set
e) Gaskets 1 Set
f) Steam Strainer Element 1 No
2 Generator
a) Generator Bearing shell 2 Nos
b) Insulation of bearing 1 Set
c) Bearing sealing ring 1 Set
d) Duplex RTDs for Gen. bearing. 2 Nos
e) Diodes Assembly 2 Nos
f) Gen. Earthing brushes 4 Nos
g) Generator space heater 1 Nos
  
   
 
Sunflag Iron & Steel Ltd.  
Nagpur 
 
1 x 42 MW STG (Technical Offer) 
Consultant: Fichtner Consulting Engineers (India) Private Ltd. 
Tender Specification no. 1110166‐ME‐SPC‐120‐002 REV A 
 
 

SECTION – 3

HMBD (Heat & Mass Balance Diagram)

Bharat Heavy Electricals Ltd., Industry Sector, New Delhi – 110 003
  
   
 
Sunflag Iron & Steel Ltd.  
Nagpur 
 
1 x 42 MW STG (Technical Offer) 
Consultant: Fichtner Consulting Engineers (India) Private Ltd. 
Tender Specification no. 1110166‐ME‐SPC‐120‐002 REV A 
 
 

SECTION – 4

Comments, clarifications & Deviations to tender specification

Bharat Heavy Electricals Ltd., Industry Sector, New Delhi – 110 003
 DOC. No.
BHEL TECHNICAL PROPOSAL HEE-TEND-001
Page 1 of 2
HYDERABAD

LIST OF DEVIATIONS / CLARIFICATIONS

PROJECT : 1X42MW SUNFLAG IRON & STEEL CO. LTD.

CONSULTANT : FICHTNER CONSULTING ENGINEERS INDIA PVT.

Spec. No. : 1110166-ME-SPC-120-002, Rev. A

Sl
Clause No. Customer Requirements Deviation / clarification
No.
1. Cl. No.-3.1.1.1.10, Gland steam condenser with As condenser is provided with
Page 7 of 53, Sec-1 2x100% motor driven vapour 2x100% SJAE hence we propose
& extraction fans. GSC with ejector instead of fan
Cl. No.-4.1.5, and motor.
Page 8 of 16, Sec-2.1
&
Cl. No.-3.2.2,
Page 16 of 16, Sec-2.1
2. Cl. No.-9.0.0, QAP BHEL standard QAP will be
Page 22 of 53, Sec-1 followed.

3. Cl. No.-15.0.0, DRAWING / INFORMATION Only GA drawing will be

Page 35 of 53, Sec-1 TO BE SUBMITTED ALONG submitted to the
WITH TENDER customer/consultant at contract
stage for information.
4. Cl. No.-2.0.0, CODES AND STANDARDS Condenser and Steam Jet Air
Page 3 of 8, Sec-2.2 Ejector will be designed and
& manufactured as per HEI latest
Sl. No.-1.10.0, addition and BHEL standard
Page 7 of 8, Sec-2.2 only.

Department Prepared by Checked by Approved by Date Rev

Heat Exchangers JHA KISHORE S.SRIKANTH 21.02.2011 00
Engg.
 DOC. No.
BHEL TECHNICAL PROPOSAL HEE-TEND-001
Page 2 of 2
HYDERABAD

5. Cl. No.-3.1.0, The condenser hot well shall be Condenser Hotwell storage
Page 4 of 8, Sec-2.2 sized for five (5) minute storage capacity will be 3 minute as per
& capacity (between normal and BHEL standard practice.
Sl. No.-1.11.0, low-low level)
Page 7 of 8, Sec-2.2
Maximum oxygen content of Maximum oxygen content of
condensate leaving the condenser condensate leaving the condenser
shall be 0.015 cc/lit will be 0.03 cc/lit as per HEI.

Extra tube thickness shall be We confirm that the

provided in the impingement reinforcement provided in the
zone. condenser dome and the pipes
provided at the top of the tubes
avoid the steam from directly
contacting the tubes, hence higher
thickness tubes / impingement
guards/baffles or alternative
arrangement are not required.
6. Cl. No.-4.3.0, Hot well shall be divided Hotwell will be undivided.
Page 5 of 8, Sec-2.2 longitudinally with a vertical
divider

7. Sl. No.-1.8.2 to 1.8.5, Material of construction for Material of construction for tubes
Page 7 of 8, Sec-2.2 condenser:- is welded SS.
Material of construction of shell,
water boxes, channel, tubesheet
and hotwell of condenser will be
of IS2062 Gr.B instead of SA516
Gr.70. This is as per our standard
practice and is also in line with
material provided in 37.2MW
APGCL Lakwa Condenser.
8. Sl. No.-4.3.0, Material of construction for oil The MOC for oil cooler is welded
Page 11 of 16, Sec-2.1 cooler. SS.

9. Sl. No.-2.4.4, Material of construction for Inter Material of construction for Inter
Page 8 of 8, Sec-2.2 and after condenser tubes : SS and after condenser tubes will be
316 L stainless steel SA249 TP 304 as
per BHEL standard practice.
10. Cl. No.-2.0.0, CODES AND STANDARDS: Feed water heaters will be
Page 3 of 5, Sec-2.4 designed and constructed as per
HEI and ASME Sec-VIII Div. I
only.
Department Prepared by Checked by Approved by Date Rev
Heat Exchangers JHA KISHORE S.SRIKANTH 21.02.2011 00
Engg.
 DOC. No.
BHEL TECHNICAL PROPOSAL HEE-TEND-001
Page 3 of 2
HYDERABAD

Clarification
1. Cl. No. 4.1.0. The Condenser shell shall be of The Condenser shell shall be of
Page No.-4 of 8, Sec-2.2 mild steel welded construction carbon steel (IS2062 Gr.B)
welded construction.
2. Cl. No. 4.1.0. The condenser water boxes The condenser water boxes will
Page No.-4 of 8, Sec-2.2 shall be of fabricated and be of fabricated and welded
welded mild steel construction. carbon steel (IS2062 Gr.B)
construction.
3. Cl. No. 4.0.0. LP Heaters shall have LP Heater will have only
Page No.-4 of 5, Sec-2.4 provision of integral condensing and drain cooling
desuperheating, condensing zones as per code.
and drain cooling zones.
4. Sl. No. 1.4.0. Material of construction of tube for LP Heater will be welded
Page No.-5 of 5, Sec-2.4 stainless steel U-tube type (SA688 TP304).

Department Prepared by Checked by Approved by Date Rev

Heat Exchangers JHA KISHORE S.SRIKANTH 21.02.2011 00
Engg.
 DEVIATIONS / CLARIFICATIONS EMDM075
Rev. No. 00
AGAINST TENDER SPECIFICATIONS Sheet 1 OF 2
Customer: SUNFLAG IRON & STEEL CO. LTD.
HYDERABAD
Sl.No
Clause/ ITEM CLARIFICATIONS/DEVIATIONS
Page No.
SECTION 3.2 :: DETAILED TECHNICAL SPECIFICATION - ELECTRICAL
1. --- SCOPE OF SUPPLY Generator scope of supply will be as per our scope
document EMDM014
2. 3.2/ 5 of 11 The following minimum instruments shall As per our standard design philosophy we are providing
be provided for Generator: temperature detectors in the Generator as follows:
• Temperature detectors (atleast Stator winding (Min. 2/Phase): (12 + 1 spare) x 2 nos. -
12) for stator winding uniformly simplex type
distributed along the Stator core: 3x2 nos.-simplex type
circumference of stator and Stator teeth : 4x2 nos-simplex type
located at the hottest possible Cold air inlet region : 2 nos. – duplex type
zones. Hot air outlet region : 2 nos. – duplex type
• Temperature detectors (atleast Bearings: 1 in each bearing – duplex type
12) for stator core out of which 6
nos. to be located at the end
zones.
• Detectors for monitoring the
temperature of cooling medium
at the outlet of the winding
• Detectors (atleast 2) for air
cooler to measure inlet & outlet
gas temperature
• Temperature detectors (atleast 2)
for bearing
• Vibration monitoring system
3. 4.1.0 / 6 of 11 Current transformers for metering & The Generator will be provided with six nos. of copper
protection functions shall be located in terminals enclosed with epoxy glass sleeves / tubes and
the Generator bushing. these terminals are assembled in stator frame with
suitable rubber gaskets to provide necessary seal
adequate for air cooled Turbo Generators.
Phase side CTs will be provided on the run of the phase
side busduct. Phase side PTs will be provided in the
LAVT cubicle. Neutral side CTs shall be provided in the
Neutral side run of busduct.
4. 4.3.0 / 8 of 11 Power system stabilizer Power system stabilizer (PSS) is not envisaged for this
size and rating as per our design standard.
5. 5.1.0 / 8 of 11 The following riutine electrical tests shall
be carried out on each genaerator as a
minimim: Since these are type tests, results of tests done on similar
• Equivlaent heat runs to generator will be furnished during detailed engineering
determine temperature rises stage.
comprising an open circuit run
followed by a short circuit run at
The rated stator current.
• Calculation of temp. rise of
stator and rotor.
• Retardation test to establish
GD^2

6. ANNEXU Short circuit ratio>0.5 As per latest revision of IEC-60034-3 (2007), the
RE. 3.2.1/ minimum value of SCR specified is 0.35. However,
13.0 BHEL proposed Generator is having SCR of 0.47 on
52.5 MVA base which is adequate for Generators
equipped with microprocessor based AVR.
SECTION 3.3 DETAILED TECHNICAL SPECIFICATION-ELECTRICAL (Busduct, SPVT & NEUTRAL Grounding resistor)
7. 2.0.0 / 3 of 9 11 kV motor operated on load isolator for Motor operated off-load isolator shall be provided.
NGR
 8. 4.4.0 / 6 of 9
The resistor enclosure protection shall be NGR cubicle enclosure will be IP 32.
IP 54
SECTION-3.4 Generator Control & Relay panel (GCP & GRP)
9. 4.0 / 3 of 7 Control panel shall be mosaic grid type Generator control and relay panel will be simplex vertical
type with CRCA sheet.
10. 4.1.0 / 5 of 7 Additional generator protective
monitoring equipment shall be provided • Bearing metal temperature measurement is
to protect against the following: through RTDs and hooked upto temp. scanner.
• High bearing temperatures
• Over speed conditions • Over speed and Excessive vibration
• Excessive vibrations measurement in part of Turbine control panel.
• Generator overheating • Generator overheating can be realized through
RTDs and same is hooked upto temperature
scanner.

11. 4.1.0 / 6 of 7 Generator differential protection The offered generator stator is with bar type construction
including inter turn fault protection(87G) with one turn in each bar. Hence there is no chance of
• Inter-turn fault protection (87 TG) inter turn fault. However if there is any phase to phase
• Excitation transformer over fault, it can be detected by differential relay.
current protection. • Inter-turn fault protection (87 TG) is not
applicable.

• Excitation transformer is not applicable.

• Time graded IDMT type back non-
directional over current protection in • Generator Transformer is not generator scope of
all phases on HV side of Generator supply and hence 51 GT protection is not
transformer(51 GT) provided.
12. 3.3.0( 25), sec Fire proof cables We offer PVC type cables instead of fire proof.
1.0 page 13 of
This is as per our standard practice followed for all the
53
STG sets of this size and rating.
13. SLD / DWG. AVR-1 & AVR-2 One (1) NO. AVR is provided with Two Auto and built
NO 20-
in manual channel and potential free contacts for DCS
1110166-E-
208 communication.
14. Datasheet CO2 equipment for Generator The offered Generator is with Global VPI system, in
which the insulating material does not propagate the fire
and acts as fire retardant. Hence CO2 fire extinguishing
system is not required and hence not offered.
15. ----- TESTS Generator and BL Exciter will be tested separately at
works without their auxiliaries and controls. List of tests
to be carried out at works on Generator and Exciter are as
per EMDM 059 & EMDM 060o enclosed. For type tests,
results of tests done on similar generator will be
furnished during detailed engineering stage. The
auxiliaries, which are bought out items, are tested at our
vendor works for which test certificates will be
furnished.
16. --- List of Approved vendors We are enclosing our list of vendors who are reputed and
established vendors. BHEL to source items as per
attached BHEL approved vendor list.
 DEVIATIONS/ COMMENTS ON SPECIFICATION DOC NO:- TC-1112021-DV;
(STG & Auxiliaries) REV : 00

Project : SUNFLAG ; 1 x 42 MW STG Page 1 of 6

Hyderabad CONSULTANT : FICHTNER Consulting Engineers (India) Pvt. Limited, Mumbai

LIST OF DEVIATIONS
SL Reference Clause Deviation Reason for Deviation
No
1. Clause 4.3.0 of 1110166-ME- Main Oil Pump offered is A/C motor driven instead Main Oil Pump offered is A/C motor driven
SPC-120-002,Rev-A; Sec 2.0 of main turbine shaft/ gearbox driven. (along with a Overhead Oil Tank) as per latest
page 10 of 16 standard BHEL design practice, to increase the
reliability and maintainability of the Main Oil
Pump. BHEL has supplied more than 500 sets
with this design.
2. Section 4.0 Control & Scope of C&I will be as per BHEL's scope of ----
instrumentation supply.

FORMAT NO. PREPARED BY: CHECKED BY: APPROVED BY:

TAM-9119-00
STEAM & GAS TURBINES AND COMPRESSORS

S.DAS UPK UPK

FORMAT REV: 00 DEPT. : T & C ENGINEERING DEPT. CODE : 415
Dt 28.02.11 Dt. 28.02.11 Dt. 28.02.11
Z:\TENDER\DEV&COM\SUNFLAG-1X42MW-DV.DOC
 DEVIATIONS/ COMMENTS ON SPECIFICATION DOC NO:- TC-1112021-DV;
(STG & Auxiliaries) REV : 00

Project : SUNFLAG ; 1 x 42 MW STG Page 2 of 6

Hyderabad CONSULTANT : FICHTNER Consulting Engineers (India) Pvt. Limited, Mumbai

LIST OF COMMENTS
SL Reference Clause Comment
No
1. Clause 2.0.0 of 1110166-ME- The PG test code will be as per IEC 60953 Part II /DIN1943 which is most relevant for Industrial STG
SPC-120-002,Rev-A; Sec 2.0 sets. Please note that PTC 6 is generally used for large condensing steam turbines.
page 3 of 16
2. Clause 3.0.0 of 1110166-ME- Design back pressure of 76 mm Hg ( abs ) will maintained at guarantee point, but in all other operation
SPC-120-002,Rev-A; Sec 2.0 back pressure will vary as per condenser heat load.

Over pressurization ( Under VWO ) is allowed as per IEC 45 only.

The number of startups and startup procedure will be as per BHEL startup curve only.

Variable pressure operation is not standard feature with industrial Turbo generator and hence it is not
envisaged for the offered turbine. Generally variable pressure operation is applicable to combined
cycle power plant.

No separate flash tank is required. All drains are connected to condenser through surge pipe.

Over speeding during full load will be restricted to less than 110% of rated speed.

3. Clause 4.1.1 of 1110166-ME- Boroscope opening is not applicable for Steam turbine.
SPC-120-002,Rev-A; Sec 2.0
page 6 of 16 Casing metal temperature monitoring is not applicable for these range of Steam Turbines , hence
supervisory thermocouples will not be provided.

FORMAT NO: TAM-9119-00

FORMAT REV: 00
STEAM & GAS TURBINES AND COMPRESSORS DEPT. : T & C ENGINEERING DEPT. CODE : 415
Z:\TENDER\DEV&COM\SUNFLAG-1X42MW-DV.DOC
 DEVIATIONS/ COMMENTS ON SPECIFICATION DOC NO:- TC-1112021-DV;
(STG & Auxiliaries) REV : 00

Project : SUNFLAG ; 1 x 42 MW STG Page 3 of 6

Hyderabad CONSULTANT : FICHTNER Consulting Engineers (India) Pvt. Limited, Mumbai

LIST OF COMMENTS
SL Reference Clause Comment
No
4. Clause 4.1.2 of 1110166-ME- The blade design details are proprietary in nature, hence will not be provided.
SPC-120-002,Rev-A; Sec 2.0
page 7 of 16
5. Clause 4.1.3 of 1110166-ME- Static balancing is not applicable and hence not done.
SPC-120-002,Rev-A; Sec 2.0 Dynamic balancing is done up to rated speed.
page 7 of 16 Bearing housing vibration measurement is not considered as per BHEL design and only relative shaft
vibration measurements are considered for alarm and trip.
6. Clause 4.1.9 of 1110166-ME- ST is insulated with mineral wool spray with CAT-9 cement layer as final coat.
SPC-120-002,Rev-A; Sec 2.0
page 9 of 16
7. Clause 4.2.0 of 1110166-ME- Gear Box will be designed as per AGMA standard as API 613 is applicable for Refinery service.
SPC-120-002,Rev-A; Sec 2.0
page 10 of 16
8. Clause 4.3.0 of 1110166-ME- Oil strainer is not required for main oil tank as strainers are provided at the inlet of individual pump
SPC-120-002,Rev-A; Sec 2.0 suctions.
page 10 of 16 The main oil tank is sized for 12 recirculations per hour (5 min retention time) , which is adequate.

9. Clause 4.3.0 of 1110166-ME- As per BHEL design, the lube oil purifier is sized for 1% of normal oil flow through lube oil circuit.
SPC-120-002,Rev-A; Sec 2.0
page 10 of 16 Only normal sight glasses are provided in oil return lines as per BHEL design.
10. Clause 4.4.0 of 1110166-ME- Speed Changer and Load limit device is part of the supplied governor, hence separate device is not
SPC-120-002,Rev-A; Sec 2.0 envisaged.
page 12 of 16

FORMAT NO: TAM-9119-00

FORMAT REV: 00
STEAM & GAS TURBINES AND COMPRESSORS DEPT. : T & C ENGINEERING DEPT. CODE : 415
Z:\TENDER\DEV&COM\SUNFLAG-1X42MW-DV.DOC
 DEVIATIONS/ COMMENTS ON SPECIFICATION DOC NO:- TC-1112021-DV;
(STG & Auxiliaries) REV : 00

Project : SUNFLAG ; 1 x 42 MW STG Page 4 of 6

Hyderabad CONSULTANT : FICHTNER Consulting Engineers (India) Pvt. Limited, Mumbai

LIST OF COMMENTS
SL Reference Clause Comment
No
11. Clause 4.4.4 of 1110166-ME- Please note that WW505 Governor is considered , which is non-redundent.
SPC-120-002,Rev-A; Sec 2.0
page 13 of 16 Magnetic Speed pick up probe is considered.

Independent 2/3 Electronic over speed protection is considered in scope. This is in addition to over
speed protection thro Electronic Governor.
12. Clause 5.0.0 of 1110166-ME- Heat Stability test for the rotor is not required and hence not done.
SPC-120-002,Rev-A; Sec 2.0
page 13 of 16 Boro-scope testing is not applicable for Steam turbine.
13. Clause 2.1.1, Section 4.0, Triple redundant sensors are considered for turbine protection for critical trips as per BHEL design.
Control & Instrumentation
Dual redundant sensors are considered for other closed/open loop controls.

PLC/DCS are excluded from BHEL scope and same shall be considered by customer. Self diagnostics
and troubleshooting features shall be part of customer DCS.

Maintenance platforms, access ladders are excluded from BHEL scope as the same are part of
civil/erection agency.
14. Clause 4.3.0 of 1110166-ME- Turbine auto start/shut down system(ATRS) is not considered for this size and rating of turbine as
SPC-120-002,Rev-A; Sec 4.0 BHEL design. The same is applicable for larger sets of 70-80 MW and above rating.
page 8 of 28

FORMAT NO: TAM-9119-00

FORMAT REV: 00
STEAM & GAS TURBINES AND COMPRESSORS DEPT. : T & C ENGINEERING DEPT. CODE : 415
Z:\TENDER\DEV&COM\SUNFLAG-1X42MW-DV.DOC
 DEVIATIONS/ COMMENTS ON SPECIFICATION DOC NO:- TC-1112021-DV;
(STG & Auxiliaries) REV : 00

Project : SUNFLAG ; 1 x 42 MW STG Page 5 of 6

Hyderabad CONSULTANT : FICHTNER Consulting Engineers (India) Pvt. Limited, Mumbai

LIST OF COMMENTS
SL Reference Clause Comment
No
15. Clause 4.4.0 of 1110166-ME- Trips will not be provided for the following:
SPC-120-002,Rev-A; Sec 4.0 [c] Bearing metal temperature – High (HH trip only provided)
page 9 of 28 [e] Bearing oil temperature high – Indication only
16. The following are being provided as a part of TSI for the turbine of this size and rating as per
Clause 4.5.0 of 1110166-ME- standard design practice of BHEL: -
SPC-120-002,Rev-A; Sec 4.0 - Relative shaft vibration
page 9 of 28
- Axial shaft position of rotor
- Key phasor
Turbine Speed can be monitored in DCS.
Bearing temperature monitoring is not part of TSI. Only bearing RTD’s will be provided which is
directly connected to DCS for monitoring. Local gauge will be provided for bearing oil
temperature.
Make up control valve shall be supplied loose by BHEL.
Make up control and Condensate excess return control is not in BHEL’s scope.
17. General Only the components like foundation bolts & nuts, Packing plates, Sole plates required for anchoring &
erection of the TG Set and its auxiliaries will be supplied by BHEL. All other embedded parts like pipe
sleeves, plates for pipe supports, corner angles etc. (which are generally required during the casting of
the TG Deck) will not be supplied.
The details of plate inserts on TG deck will be furnished by BHEL and these shall be arranged by civil
contractor as per BHEL’s standard practice.

FORMAT NO: TAM-9119-00

FORMAT REV: 00
STEAM & GAS TURBINES AND COMPRESSORS DEPT. : T & C ENGINEERING DEPT. CODE : 415
Z:\TENDER\DEV&COM\SUNFLAG-1X42MW-DV.DOC
 DEVIATIONS/ COMMENTS ON SPECIFICATION DOC NO:- TC-1112021-DV;
(STG & Auxiliaries) REV : 00

Project : SUNFLAG ; 1 x 42 MW STG Page 6 of 6

Hyderabad CONSULTANT : FICHTNER Consulting Engineers (India) Pvt. Limited, Mumbai

LIST OF COMMENTS
SL Reference Clause Comment
No
18. General The sub-vendors shall be as per BHEL approved vendor list, which can be discussed and finalized
during first kick-off meeting.
19. General The List of Documents and Documentation Schedule shall be mutually agreed and settled during the
first kick-off meeting.
20. General Configuration PC along with configuration software for configuring the TSI system is not envisaged
in scope of supply. As this is required only during commissioning, necessary PC/lap top (with
commissioning software) will be brought by the commissioning engineer and will be taken back after
commissioning

FORMAT NO: TAM-9119-00

FORMAT REV: 00
STEAM & GAS TURBINES AND COMPRESSORS DEPT. : T & C ENGINEERING DEPT. CODE : 415
Z:\TENDER\DEV&COM\SUNFLAG-1X42MW-DV.DOC
  
   
 
Sunflag Iron & Steel Ltd.  
Nagpur 
 
1 x 42 MW STG (Technical Offer) 
Consultant: Fichtner Consulting Engineers (India) Private Ltd. 
Tender Specification no. 1110166‐ME‐SPC‐120‐002 REV A 
 
 

SECTION – 5

Vendor List

Bharat Heavy Electricals Ltd., Industry Sector, New Delhi – 110 003
 List of steam turbine subvendors

Sl.
Item Descripti
No. on Supplier Name
1 GEAR BOX M/s FLENDER - GRAFFENSTADEN,
GREATER THAN 15 M/s VOITH TURBO BHS - GETRIEBE GMBH,
MW
M/s RENK AKTIENGESELLSCHAFT -
M/s SEISA GEAR LTD
M/s TRIVENI ENGG & IND LTD
M/s MAAG GEAR AG.,
M/s WINERGY DRIVE SYSTEMS INDIA PVT. LTD.
M/s LUFKIN INDUSTRIES, INC.
2 GEAR COUPLINGS M/s FLENDER - GRAFFENSTADEN,
M/s VOITH TURBO BHS - GETRIEBE GMBH,
M/s RENK AKTIENGESELLSCHAFT -
M/s MAAG GEAR AG.,
M/s LUFKIN INDUSTRIES, INC.
3 LUBE OIL PUMPS M/s KSB PUMPS LIMITED,
AND EMERGENCY
OIL PUMPS
(HORIZONTAL & M/s SULZER PUMPS INDIA LTD.,
CENTRIFUGAL) M/s KIRLOSKAR EBARA PUMPS LIMITED,
4 JACKING OIL M/s DENISON HYDRAULICS INDIA LTD.,
PUMPS (GEAR /
VANE TYPE ) &
TRANSFER OIL M/s DYNAMATIC TECHNOLOGIES LIMITED
PUMP M/s TUSHACO PUMPS PVT. LTD.,
5 OIL PURIFICATION M/s WESTFALIA SEPARATOR(I) P. LTD,
UNIT M/s ALFA-LAVAL (INDIA)LIMITED,
6 CONDENSATE M/s KSB PUMPS LIMITED,
EXTRACTION M/s SULZER PUMPS INDIA LTD.,
PUMPS
M/s KIRLOSKAR EBARA PUMPS LIMITED,
7 A. C. MOTOR (LT) M/s CROMPTON GREAVES LTD. SECBAD
M/s SIEMENS INDIA LTD, SECBAD.
M/s KIRLOSKAR ELECTRIC CO,
M/s ABB LIMITED, HYD
M/s BHARAT BIJLEE LIMITED, SEC'BAD
8 D.C. MOTOR M/s CROMPTON GREAVES LTD. SECBAD
M/s KIRLOSKAR ELECTRIC CO,
9 QUICK CLOSING M/s BHARAT HEAVY ELECTRICALS LTD.,
EXTRACTION NON-
RETURN VALVES
10 I/H CONVERTORS M/s VOITH TURBO GMBH & CO. KG.,
11 CONDUCTIVITY M/s EMERSON PROCESS MANAGEMENT (I) PVT. LTD.,
AND PH M/s ABB LIMITED, HYD
MONITORING
M/s BETA INSTRUMENTS,
SYSTEM AND DO2
ANALYSER M/s FORBES MARSHALL LTD.,
M/s INSTRUMENTATION LIMITED,
M/s UPTRON INDIA LIMITED,
12 CONTROL CABLES M/s UNIVERSAL CABLES LTD, HYD
M/s RADIANT CABLES PVT. LTD., HYD
M/s POLYCAB INDUSTRIES PVT.LTD.,SEC'BAD
M/s CORDS CABLE INDUSTRIES LTD., N DELHI
M/s KEI INDUSTRIES LIMITED,
 M/s DELTON CABLES LIMITED, NEW DELHI
M/s ELKAY TELELINKS LTD., FARIDABAD
M/s CONTEMP INSTRUMENTATION P LTD
M/s FORT GLOSTER INDUSTRIES LTD.,
13 ELECTRONIC M/s WOODWARD GOVERNOR INDIA PVT.LTD.
GOVERNOR ( M/s BHARAT HEAVY ELECTRICALS
MICROPROCESSO
M/s TRI-SEN LIMITED,
R BASED )
M/s VOSPER THORNYCROFT CONTROLS-
14 ELECTRO M/s EMERSON PROCESS MANAGEMENT (I) PVT. LTD.,
PNEUMATIC M/s ABB LIMITED, HYD
CONVERTORS, ( I/P
M/s MTL INSTRUMENTS LIMITED,
CONVERTORS)
M/s SHREYAS INSTRUMENTS PRIVATE LTD.,
15 FLOW NOZZLES M/s MICRO PRECISION PRODUCTS (P) LTD.
M/s INSTRUMENTATION LTD,
M/s GENERAL INSTRUMENTS CONSORTIUM
16 FLOW ORIFICES M/s MICRO PRECISION PRODUCTS (P) LTD.
M/s INSTRUMENTATION LTD,
M/s PRECISION ENGINEERING INDS.,
M/s GENERAL INSTRUMENTS CONSORTIUM
17 LEVEL M/s CHEMTROLS INDUSTRIES LTD.,
TRANSMITTER ( M/s DRESSER VALVE INDIA PVT.LTD.,
ELECTRONIC -
M/s FISHER SANMAR LIMITED,
SMART )
18 PR. & DIFF. PR. M/s EMERSON PROCESS MANAGEMENT (I) PVT. LTD.,
TRANSMITTERS ( M/s ABB LIMITED, HYD
ELECTRONIC -
M/s FUJI ELECTRIC SYSTEMS CO. LTD.,
SMART )
M/s YOKOGAWA INDIA LIMITED.,
M/s HONEYWELL AUTOMATION INDIA LIMITED
19 TURBO M/s SHINKAWA ELECTRIC CO LTD.,
SUPERVISORY
INSTRUMENTS FOR
VIBRATION, M/s MECHANALYSIS (INDIA) LTD.,
ECCENTRICITY, M/s VIBROMETER,
AXIAL M/s BENTLY NEVADA LLC,
DISPLACEMENT

Note: The above list is not to be used for scope clarity

All the other items shall be procured from BHEL standard vendors list
 RECOMMENDED SUPPLIERS FOR
Sht. 1 of 1
GENERATOR AUXILIARIES
HYDERABAD
Customer: SUNFLAG IRON & STEEL CO. LTD.
S.No ITEM NAME OF THE SUPPLIER

1. AVR for Brushless Excitation 1. M/s BHEL, India.

System
2 Generator Control, 1. M/s Areva, Chennai, India
Protection & Syn. Panels with 2. M/s ABB, Bangalore, India
protective relays 3. M/s Siemens, India
4. M/s Easun Engg. with Beck–With,USA relays, India.
5. M/s Schneider Electricals, India
3 Cables 1. M/s Universal Cable Ltd. Satna, India
2. M/s Nicco, Hyderabad, India
3. M/s Radiant Cables, Hyderabad, India
4. M/s Delton cables, India
5. M/s KEI, Hyderabad, India
6. M/s Thermo Pads Pvt Ltd, Hyderabad, India
7. M/s Cords cable Industries Pvt Ltd, Delhi
8. M/s Polycab Industries (P) Pvt, Hyderabad, India
9. M/s Goyolene Fibres (I) Pvt Ltd, Hyderabad, India
10. M/s LAPP cables, B’lore, India