Kalyani Gerdau_6 MW

M/S KALYANI GERDAU STEELS LTD 1 X 6MW BLAST FURNACE GAS BASED POWER PLANT

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BIDDER'S SIGNATURE:------ II.8.1 AVANT-GARDE

Sl.No. 8.0 GUARANTEE SCHEDULE Unit Remarks

8.01 Steam parameters and flow conditions with 10 TPH Extraction

a Steam pressure at the inlet of turbine stop valve ata 64

b Deg.C 480

c Exhaust parameters ata 0.22

d Normal steam flow condition

- Inlet flow at turbine ESV TPH 34.36

8.02 Guarantee parameters

a Net Power output at generator terminals kW 6000

b Power consumption of auxiliary equipment kW

c Auxilary cooling water flow Cu.M/Hr

d Deg.C Stator 85

e Turbine cycle heat rate kcal / kw h 3860

f Vibration limits mm/sec

g Noise level at 1 mtr. distance dB(A) As per OSHA

Steam temperature at the inlet of turbine stop valve

Maximum temperature rise in the generator windings

above max. inlet temperature of cooling air of 400c


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BIDDER'S SIGNATURE:------ II.8.2 AVANT-GARDE

Sl.No. 8.0 GUARANTEE SCHEDULE Unit Remarks

8.01 Steam parameters and flow conditions without Extraction

a Steam pressure at the inlet of turbine stop valve ata 64

b Deg.C 480

c Exhaust parameters ata 0.22

d Normal steam flow condition

- Inlet flow at turbine ESV TPH 26.91

8.02 Guarantee parameters

a Net Power output at generator terminals kW 6000

b Power consumption of auxiliary equipment kW

c Auxilary cooling water flow Cu.M/Hr

d Deg.C Stator 85

e Turbine cycle heat rate kcal / kw h 3025

f Vibration limits mm/sec

g Noise level at 1 mtr. distance dB(A) As per OSHA

Steam temperature at the inlet of turbine stop valve

Maximum temperature rise in the generator windings

above max. inlet temperature of cooling air of 400c


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Submitted by Arani Power Systems,Updated on 26-12-2009

II.3.3 AVANT-GARDE

Sl.N. Description Unit Requirement Acceptance

3.1 Design Input

3.1.1 Number of Turbogenerator No. 1.0 Yes

3.1.2 MW 6.0 Yes

3.1.3 kg/cm2(a) 64 Yes

3.1.4 °C 480 Yes

3.1.5 °C 130 Yes

3.1.6 Yes

3.1.7 Process returen condensate quantity kg/hr Nil Yes

3.1.8 Exhaust steam pressure kg/cm2(a) 0.22 Yes

3.1.9 Cooling system Air cooled Yes

3.1.10 Economic steam rate % load 80 to 100 Yes

3.1.11 % MCR 15 Yes

3.1.12 As per OSHA

3.1.13 Generator Rating MVA 7.5

3.1.14 Power factor (Lagging) 0.8 Yes

3.1.15 Generation Voltage KV 6.6 ± 10% Yes

3.0 TURBOGENERATOR DESIGN INPUT AND MINIMUM REQUIRMENTS.

Turbogenerator Capacity (at 100% MCR)

Steam pressure at the inlet of turbine ESV

Steam temp. at the inlet of turbine ESV.

Deaerator outlet Temeprature / BFP discharge feed water temperature.

Process steam requirements at process point VD (Approx. 200m form turbine)

10000kg/hr, 14 ata, 225°C

Minimum expected load at which TG is expected to operate

Maximum noise pressure level at 1.0mts distance from any equipment

Bidder to indicate the

value.


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II.3.4 AVANT-GARDE


3.1.16 System Frequency Hz 50 ± 5% Yes

3.1.17 °C 30 Yes

3.1.18 °C 50 Yes

3.2 Steam Turbine

3.2.1 34.36 TPH

3.2.2

3.2.3

3.2.3 Type of Deaerator considered

3.2.4 Turbine casing hydraulic test pressure Yes

3.2.5 Turbine Exhaust Orientation Down ward Yes

3.3 Gland Sealing System

3.3.1 Type of gland packing

3.3.2 Gland packing material

3.3.3 Gland steam condenser Yes

3.3.4 2x100% Yes

Ambient temperature for performance design.

Ambient temperature for electrical design.

Inlet steam quantity at the inlet of Turbine ESV

TG vendor to furnish the

details along with HMBD.

Bleed steam quantity, pressure and temperature for Deaerator.



3.18 tph,5.98 ata,222.7 ºC

Bleed steam quantity, pressure and temperature for Process requirement.



10 tph,14 ata,225 ºC

Fixed pressure type

Constant Pr. Deareator

1.5 times design pr.

Labyrinth type sealed with

steam.

Labyrinth type sealed with steam.

13 Chromium, Stainless steel

13 Chromium, Stainless steel

Condensate cooled

AC motor driven exhauster for gland steam condenser


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II.3.5 AVANT-GARDE


3.3.5 Design standard for GVC HEI

3.3.6 Shell material SA 106 Gr. B

3.3.7 Tube material Yes

3.3.8 Tube size OD x THK Ok

3.3.9 Water velocity through the tubes m/s not less than 1 Yes

3.3.10 Fouling resistance 0.0002 Yes

3.3.11 mm 3.0 Yes

3.3.12 Tube side pressure drop kg/Sq.cm 0.5 Yes

3.4 Gear Box

3.4.1 Type Double helical Double helical

3.4.2 Service factor Min. 1.3 1.3

3.4.3 Gear Box noise level As per OSHA Yes

3.5 Oil System

3.5.1 No. of Oil coolers Nos Yes

3.5.2 No. of Oil filters Nos Yes

3.5.3 Tube side fouling factor for oil coolers m²h°C/kcal 0.0002 Yes

3.5.4 Water velocity in oil coolers m/s >1.0 Yes

3.5.5 Oil cooler tube material Stainless steel Yes

HEI / ASME SecVIII Div.1

SA 106 Gr.B /SA 515

Gr.70

SA 213 TP 304

19.05 / 18 BWG

Hr.sq.m.deg.C/kcal

Corrosion allowance for the components other than the tubes

2 X 100 % (1W+1S)

2 X 100 % (1W+1S)


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II.3.6 AVANT-GARDE


3.5.6 Oil cooler shell and tube sheet material IS2062 Yes

3.5.7 Plugging margin for oil cooler % 20 Yes

3.5.8 mm 3.0 Yes

3.5.9 % 2.0 Yes

3.5.10 Minimum filter grade for lube oil Microns 40 Yes

3.5.11 Minimum filter grade for control oil Microns 10 Yes

3.5.12 Microns 10 Not applicable

3.5.13 Oil piping material up to filter Carbon Steel Yes

3.5.14 Stainless Steel Yes

3.5.15 Return oil piping material Carbon Steel Yes

3.5.16 Oil reservoir material IS2062 Yes

3.5.17 Corrosion allowance for the reservoir mm 3.0 Yes

3.5.18 Overhead emergency oil tank material Stainless steel Yes

3.5.19 Settling oil tank capacity m³ Min. 3.0 Yes

3.5.20 Capacity of oil transfer pump m³/hr Min.1.0 Yes

3.5.21 Settling oil tank material IS2062 Yes

3.6 Insulation

Corrosion allowance for the components other than the tubes

Capacity of oil purifier with respect to normal rate of flow through the reservoir

Minimum filter grade for the common filter if used for both control and lube oil circuits.

Oil piping material including valves (all wetted parts) from filter to bearings


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II.3.7 AVANT-GARDE


3.6.1 Bounded Mineral Wool IS 8183 Yes

3.6.2 Hexagonal wire netting IS 3150 Yes

3.6.3 Cladding Aluminium Yes

3.7 Electrical system

3.7.1 Generation Voltage

3.7.2 Generator phase rotation Clock Wise Clock Wise

3.7.3 Generator winding connection Star Star

3.7.4 Short circuit ratio > 0.5 0.5

3.7.5 Sec. 3.0 3

3.7.6 %

3.7.7 % 10.0

3.7.8 Secs 15.0

3.7.9 Stator winding insulation Class-F Class-F

3.7.10 Rotor winding insulator Class-F Class-F

3.7.11 Yes

3.7.12 Enslosure for alternator and exciter IP-54

3.7.13 Terminal box Yes

6.6 kV,3 phase

6.6 kV,3 phase

Three phase short circuit withstand time

Saturated rated direct axis sub-transient reactance

Between 12% to 18%

As per TDPS generator specs

Maximum continuous negative sequence current


Negative sequence withstand underfault


Temperature rise of stator and rotor at maximum continuous rating at 0.8 pf at working voltage and frequency stipulated.

Limited to class-B

IP-54 for Generator & Exciter

Suitable for cables


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II.3.8 AVANT-GARDE


3.7.14 Excitation type

3.7.15 Auxiliary Voltage Yes

3.7.16 Control supply

3.7.17 Voltage variation % ± 10 ± 10

3.7.18 Frequency variation % ± 5 ± 5

3.7.19 % ± 10 Yes

3.7.20 System fault level at 6.6 kV System kA 31.5 Yes

3.7.21 Fault duration for 6.6 kV System Sec 3.0 Yes

3.7.22 Sec Yes

3.7.23 Fault duration for 6.6kV Cables Sec 3.0 Yes

3.7.24 Earthing system of 6.6kV Yes

3.7.25

a) Winding Nos. 2 per phase

b) Stator core Nos. 4.0 Yes

c) Bearing Nos. Yes

d) Air Cooler Cold & Hot air circuits Nos. Yes

e) Exciter Field Nos. 2.0 Yes

3.7.26 AVR PANEL

Brush less with PMG

Brushless Excitation

415 V, 3 phase, 4 wire

230 V, 1phase, AC and 110V

DC

231 V, 1phase, AC and 110V DC

Combined voltage and frequency variation

Fault level & duration for 415V switch gear

50kA & 1 Second

NGR groundedRTDs quantity

12 (4 Nos. per

phase)

4 (2 Nos. per bearing)

4 (2 Nos. per bearing)


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II.3.9 AVANT-GARDE


a) AVR Type Digital Digital

b) No. of Channels of AVR

3.8.27 LAVT Panel

a) Enclosure IP 52 IP 52

Two Auto & One manual

Two auto & One Manual


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II.3.10 AVANT-GARDE


b) No. of PTs (Dual Core) Nos

As per SLD

Yes

c) Excitation PT No. Yes

d) No. of LAs & SCs Nos Yes

e) Terminal Arrangement Yes

3.7.28 NGR

a) Enclosure IP 52 Yes

b) Metering CTs Nos

As per SLD

Yes

c) Protection CTs Nos Yes

d) Differential CTs Nos. Yes

e) Neutral link No Yes

f) Terminal Arrangment Yes

g) Resistors Yes

3.7.29 Protection, Metering & Control Panel

a) Enclosure IP 42 Yes

b) Protection relay with RS 485 interface. Yes

c) Additional discrete relay Yes

Suitable for Cables

Suitable for Cables

Shall be stainless steel edge wound

type.

Microprocessor based multi -

functional relay with

standby relay.

As per SLD and

specification


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II.3.11 AVANT-GARDE


d) Panel indicating meters Yes

e) Energy Mesurement Yes

f) Transducer (4-20mA). Yes

3.7.30 LT Cables

a) PVC Cable Yes

b) Control Cables Yes

3.7.31 Motors

a) Degree of Protection IP 55 Yes

b) Voltage Yes

c) Type Yes

d) Insulation Class F Yes

e) Starting Yes

f) Duty Continuous Yes

g) Cooling TEFC Yes

h) Terminal Box Yes

3.7.32 DC Motor

As per SLD and

specification

1.1 kV Grade, Al. conductor

1.1 kV copper conductor, 2.5

Sq.mm

415 Volts + 10%

Energy efficient

VFD / DOL / S/D

Rotatable 4 in to 90 Deg.


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II.3.12 AVANT-GARDE


a) Protection IP 54 Yes

b) Terminal Box Yes

c) Starter No. Yes

d) Insulation Class F Yes

3.7.33 HT Cable

a) Type Yes

b) Conductor Aluminium Yes

c) Rating A Yes

4 Deg. in to 90 Deg.

One No. with two stage resistors.

6.6 kV XLPE (UE)

As specified in SLD

Kalyani Gerdau_6 MW

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