PROJECT

Type 11/100 220

1.1 TECHNICAL PARTICULARS

General Rated Turbine Data and Limit Values Oil Supply System Governing Equipment Seal Steam and Drain Equipment Auxiliary and Safety Equipment Metering Equipment Rated Data of Condensing Plant Motor List Weights of Some Heavy Components

TECHNICAL PARTICULARS

General

Type of Turbine 11/100 220

AEG Impulse Type

Double-casing Condensing Turbine

Unit 3 Unit 4 Unit 5

Rated Turbine Data

Output, economical 80,000 kW max. 100,000 kW

Live steam pressure, normal 1200 psig (84.4 atg) max. cont. 1250 psig (87.9 atg) max. short-time 1380 psig (97 atg)

Live steam temperature, normal 950 °F (510 °C) Max. cont. 970 °F (521 °C) Max. short-time 986 °F (530 °C) Max. short-time 1009°F (543 °C)

1) 1380 psig (97 atg) are permissible for a maximum of 12 hours per year.

2) The max. short-time live steam temperature of 986 °F (530 °C) is permissible for a maximum of 400 hours per year and

3) 1009 °F (543 °C) are permissible for a maximum of 80 hours per year with the duration of an operation limited to 15 minutes at one time.

941 °F (505 °C)

The pressure in stage 1 should not exceed 1132 psia (79.6 ata)

Steam flow at 80 MW, Casing I (H.P.) 642,920 lbs/h (291.6 t/h) 1200 psig (84.4 atg), 950 °F (510 °C) Casing II (L.P.) 527,560 lbs/h (239.3 t/h)

Max. steam flow Casing I (H.P.) 821,640 lbs/h (372.7 t/h) Casing II (L.P.) 736,740 lbs/h (334.2 t/h)

No-load steam flow (generator excited) approx. 20,720 lbs/h (9.4 t/h) Condenser pressure norm. 1.82 in. Hg (0.063 ata) max. 3.51 in. Hg (0.1213 ata) Condensate flow norm. 477,740 lbs/h (216.7 t/h) max. 667,120 lbs/h (302.6 t/h)

C.W.

temperature norm. 75 °F (24 °C) max. 90 °F (32 °C)

C.W.

flow 40,330 imp. gal/min (11,000 m³/h)

THREE-PHASE SYNCHRONOUS GENERATOR

WITH HYDROGEN COOLING

Type FKWS 3742 p

AEG - TELEFUNKEN

CONTENTS

1. TECHNICAL PARTICULARS

General Rated Data Electrical Data Mechanical Data Cooler Data Gas and Oil supply System Auxiliary, Measuring and Safety Equipment Control Room Equipment Tables Curve Sheets Oil specification

1.1. General

Generator type FKWS 3742p

Year of Manufacture Unit 3 : 1966 Unit 4 : 1966 Unit 5 : 1967

Stator Nos. Unit 3 : G 8133 Unit 4 : G 8134 Unit 5 : G 8152

Rotor Nos. Unit 3 : I 8133 Unit 4 : I 8134 Unit 5 : I 8152

Main exciter Type ECT 84/31/8 Unit 3 : No. 704 384 Unit 4 : No. 704 385 Unit 5 : No. 710 468

Amplidyne Type GQC 4546sp1 Unit 3 : No. 338 990 402 Unit 4 : No. 338 990 401 Unit 5 : No. 344 426 501

Base exciter Type 245 sond. Unit 3 : No. 705 805 Unit 4 : No. 705 806 Unit 5 : No. 710 454

Gear unit Type DSF 20 x Unit 3 : 5671 Unit 4 : 5672 Unit 5 : 5779

Voltage regulator Type TSA 2

Field rheostat R 250

Hydrogen cooler Type V 15 x 9 – 3021/2 KF 30 203 No. T 850 429

BOILER TECHNICAL SPECIFICATIONS:

1. Type and model number Boilers 1 & 2 I.C.A.L. 100 MW rating Contract No.10931 Boilers 3, 4 & 5 Mitchell Eng. 100 MW rating Contract No. 7298

2. Steam pressure Superheater outlet 1271 P.S.I.

3. Steam temperature Superheater outlet 965ºF {518,3ºC}

4. Feed water temperature Economizer inlet 405ºF {207,2ºC}

5. Burner type (P.F.) Boilers 1 & 2 hand tilting, corner mounted Boilers 3, 4 & 5 stationery type, sidewall mounted.

6. Flame type Pulverized fuel (profile) flame thrower

7. Method of lowering temperature Attemperator

8. Heat efficiency Thermal efficiency ±85%

9. Hot air temperature Air at air heater outlet 503ºF (261,7ºC)

10. Method layout Rotary air heater, gas heated

11. Method of ash removal Wet ash removal(hydrovacs and sluice nozzles)

12. Method of blowing ash Wet ash removal

13. Exhaust gas temperature Gas leaving the air heater 269ºF (131,7ºC)

14. Operating level height 35 feet

15. Outside dimensions – Boiler & 300 ft long x 150 ft wide x 150 ft high Turbine House

16. Country of manufacture England

17. Number of Units Five (4)

TURBINE TECHNICAL SPECIFICATIONS

1. Type and model number Double casing condensing turbine type 11/100220 AEG impulse type

2. Inlet steam flow (80 MW) Casing I (H.P.) 642920 lbs/hr (373472kg/hr) Casing II (L.P.)527560 lbs/hr (334881 kg/hr)

3. Inlet steam temperature 510ºC

4. R.P.M. 3000 R.P.M.

5. Power output (maximum), heat rate, 100MW continuous maximum rating steam rate

6. Exhaust steam pressure At 100 MW 1,91 ins Hg 0,066 ata

7. Exhaust steam flow Through the condenser

8. Relative internal efficiency 31,1%

9. Heat consumption rate ± 21 M Joules

10. Steam consumption rate 113 kg /sec

11. Number of return stages 6

12. Extraction pressure at each return stage See chart below

13. Temperature flow volume See chart below

14. Process steam extraction press. See chart below temperature and volume

1. Outside dimensions H.P. Turbine rotor 10514 kg. 1338 dia. 5205mm long

2. L.P. Turbine rotor 20200 kg. 2520 dia. 5915mm long
15. Country of manufacture Germany A.E.G.

The turbine is equipped with 6 non-regulated extraction points for feed water heating:

After Pressure Temperature Flow at 80 MW Extr. Stage

Psia (ata) ºF (ºC) lbs/h (t/h) I H.P. 9 236,1 (16,6) 577 (303) 31,090 (14,1) II H.P. 11 139,4 (9,8) 471 (244) 29,320 (13,3) III H.P. 13 76,8 (5,4) 379 (193) 30,200 (13,7)

Extr. Wetness % IV H.P. 15 38,4 (2,7) 0,57 20,060 (9,1)

1. V L.P. 1 16,1 (1,13) 4,22 23,150 (10,5)

2. VI L.P. 2 6,3 (0,44) 6,85 28,880 (13,1)

III GENERATOR TECHNICAL SPECIFICATIONS

1. Type and model Three phase synchronous generator with hydrogen number cooling. Type FKWS 3742 P

2. Electric resistance Resistances at 20ºC Stator No. 8133 Phase U1 X1 0,00240 ohm Phase U2 X2 0,00238 ohm Phase Y1 Y1 0,00235 ohm Phase V2 Y2 0,00237 ohm Phase W1 Z1 0,00239 ohm Phase W2 Z2 0,00238 ohm

Field winding, slip ring to slip ring Rotor No. 8133 0,119 ohm

Main Exciter No. 704 384 Field Winding I K 5,02 ohm Compoles GH 0,00098 ohm

Amplidyne

No. 338 890 402 Main field ia – ka 28,1 ohm Control field ib – kb 13,2 ohm Diff. field ic – kc 43,0 ohm

Base Exciter No. 705,805 Field winding CO 16,9 ohm

Field Currents For max. output at 30 psig H 2 pressure approx. 1700 A

1. Output voltage 10,5 kV ± 5% speed 3000 R.P.M.

2. output amperage 6,11 KA 50 Hz

3. Type of cooling Hydrogen H2 cooler type 4 x V15 x 9-2950/2 KF 30203

4. Country of Germany A.E.G.

Electric motor type and power

Number of units per turbine

IX CONTROL SYSTEM

1. Method of control

2. Instrumentation types

X ASH REMOVAL SYSTEM

1. Boiler ash removal method:

1. Ash Removal Equipment Specifications: Type and model

2. Capacity Country of origin
2. Method of ash removal used by the original plant

XI ELECTRICAL SYSTEM:

1. Voltage steps for plant electricity usage:

2. Principal transformer Specifications: Type and model Steps Number of units

3. Plant use transformer specifications: Number of units

Hawker Siddeley D160L. 25HP 2920 RPM 380V 34 amps

4 total

Pneumatic Kent, Bailey, Hannemann

Wet ashing – Hydrovacs and sluice nozzles

Spargo Ash Pump 12” dia. Frame 50

RPM 700, 55m head, 700m³/ hour (water) South Africa No major alterations carried out.

10,5 kV to 6,6 kV Unit transformer 3 phase oil cooled 10 000 KVA 10,5 to 6,6 5

20 Auxiliary transformers 4. Other major electrical equipment specifications:

AEG Electrostatic Precipitator One high voltage transformer Two low voltage transformers TECHNICAL DATA Total weight – 4550 lbs Connection Voltage – 380V single phase Oil Weight – 2410 lbs Frequency – 50 C.P.S. Oil Quantity – 275 gal Input – 41,3 KVA

A.C. Current – 109 amps The no-load R.M.S. value of the Rated High Voltage – 78 kV (peak) H.V. transformer is 55 kV Rated output current – 500 MA And the peak value 55x2=76kV Losses - Approx. 3,6 KW with 380 volt primary voltage.

XII OPERATING INDICES:

Boiler heat efficiency On gross calorific value of fuel 89,3% On net calorific value of fuel 92,6%

Turbine heat consumption rate 510 ºC live steam temp. at turbine combined stop and emergency valves

Steam consumption rate The guaranteed weighted steam consumption including steam to condensate and feed heaters and de-aerator but excluding steam to other auxiliaries and assuming that no water is being circulated between the condenser and the reserve feed tank is:-

Weighted steam consumption As defined by B.S. 132:1951:

3x1 + 4x2 + 3x3 10 …….8.1199 lbs/kWh

consumption at test

loads of 60 MW ……..8.003 lbs/kWh 80 MW ….. 8.047 lbs/kWh 100 MW ….. 8.334 lbs/kWh

Standard coal consumption rate per kWhr 50 ton per hour at 100 MW.

Plant (500 mw) electricity usage rate ± 35 MW.

POWER STATION – EXISTING DATA

PRESENT CONDITION OF PLANT

At present the plant consists of four 100 MW rated steam turbine generator units complete with boiler plant and auxiliary equipment. The units are in a ‘moth-balled’ condition.

AGE

DATE FIRST UNIT COMMISSIONED : 31/03/1963 DATE LAST UNIT COMMISSIONED : DECEMBER 1968

COAL

ANNUAL CONSUMPTION: WHEN GENERATING 1,9 MILLION TONES STOCKPILE VOLUME: WHEN GENERATING 220 000 M3 SILOS/STAITHES: (2) CAPACITY 28 000 TONS BOILER BUNKERS: (15) CAPACITY 500 TONS EACH ASH CONTENT: 20 %

MILLING PLANT

MANUFACTURERS: BOILERS 1, 2 &4 PHI ENGINEERING BOILERS 3 MITCHELL ENGINEERING

MILLS -3 PER BOILER TYPE: BOILERS 1, 2 & TRACK AND TYRE MILLS

BOILER 3 TUBE MILLS

OUTPUT: 22,7 TON PER HOUR, PER MILL (MAX. RATING 25 TONS PER HOUR)

BOILERS

MANUFACTURER: BOILERS 1 & 2 I. C. A. L.

BOILERS 3 & 4 MITCHELL ENGINEERING TYPE: P.F. FIRED, WATER TUBE BOILERS

RATING: 900 000 LBS PER HOUR CONTINUOUS MAXIMUM RATING, AT 1250 PSIG. AND 965 ºF

BURNERS (PER BOILER) 12 UNITS

TURBINES

MANUFACTURER: AEG

TYPE: TURBINE 1 & 2 11/100120

3, 4 & 5 11/100220 RATING 100 MW CONTINUOUS

TURBINE RUNNING HOURS SINCE COMMISSIONING

TURBINE NO 1 155993 HRS 17,80742 YEARS TURBINE NO 2 163585 HRS 18,674086 YEARS TURBINE NO 3 154811 HRS 17,672488 YEARS TURBINE NO 4 144552 HRS 16,501369 YEARS TURBINE NO 5 144826 HRS 16,532648 YEARS

TURBINE G/O HOURS

TURBINE NO 1 16423 HRS 1,8747716 YEARS TURBINE NO 2 9681 HRS 1,1051369 YEARS TURBINE NO 3 32483 HRS 3,7081049 YEARS TURBINE NO 4 6751 HRS 0,770662 YEARS TURBINE NO 5 5727 HRS 0,6537671 YEARS

BOILER RUNNING HOURS SINCE COMMISSIONING

BOILER NO 1 158083 HRS 18,046004 YEARS BOILER NO 2 160604 HRS 18,333789 YEARS BOILER NO 3 152525 HRS 17,411529 YEARS BOILER NO 4 144615 HRS 16,508561 YEARS BOILER NO 5 SOLD

BOILER G/O HOURS

BOILER NO 1 13748 HRS 1,5694063 YEARS BOILER NO 2 22535 HRS 2,5724885 YEARS BOILER NO 3 32483 HRS 3,7081049 YEARS BOILER NO 4 6751 HRS 0,770662 YEARS BOILER NO 5 SOLD

INFORMATION FROM PERFORMANCE MONITORING 31/01/1991 TYPE: WET SYSTEM (HYDROVAC ASHING SYSTEM)

PRECIPITATORS

MANUFACTURER: BRAND ENGINEERING (PTY) LTD TYPE: ELECTROSTATIC 5 FIELDS UNITS 1 & 2

3 FIELDS UNITS 3, 4 & 5

GENERATOR TRANSFORMERS

MANUFACTURER: 1 & 2 AEG

3, 4 & 5 OERLIKON RATE CAPACITY: 110 000 KVA TERMINAL VOLTAGE: 10,5/275KV

COOLING SYSTEM

WET SYSTEM THROUGHOUT

COOLING TOWERS (4)

TYPE: NATURAL DRAUGHT, CONCRETE HEIGHT: 93,4 METRES

CHIMNEYS (2)

HEIGHT: 119,48 METRES TYPE: SINGLE FLUE - CONCRETE

MOTHBALLING DATES

UNIT NO 1 08\01\1987 UNIT NO 2 14\09\1988 UNIT NO 3 18\10\1989 UNIT NO 4 10\09\1990 UNIT NO 5 05\11\1990

RUNNING PARTICULARS AT SITE - ESTIMATED BOILERS

Pounds per hour evaporation 720,000 830,000 900,000 corresponding 113,6kg/hr to 100 MW 80% rating M.C.R. Temperatures Water from economizer (inlet 405 ºF)……………….ºF 535 535 537 Steam at superheater inlet……………………………ºF 580 584 588 Primary superheater outlet ….……………………….ºF 833 849 857 Secondary superheater inlet….………………………ºF 805 806 807 Superheater outlet ……………………………………ºF 965 965 965 Air at airheater (minimum)…………………… …….ºF 90 90 90 Air at airheater outlet………………………….......... ºF 491 503 504 Gas leaving furnace………………………………….ºF 2018 2088 2130 Gas at superheater inlet ……………………………..ºF 1972 2042 2084 Gas at superheater inter-stage …. …………………ºF 1725 1782 1824 Gas leaving superheater ………………………..........ºF 1059 1081 1111 Gas at economizer inlet …………………… ……….ºF 1059 1081 1111 Gas leaving economizer (Blr.1………………………ºF 813 825 838 (Blr. 2…………...................ºF Gas leaving airheater (minimum) … ……………......ºF 260 269 280

Pressures

Steam in saturated steam drum lb/ sq. in………… 1337 1365 1385

Steam drum (Cont.)

Total discharge capacity saturated steam ……………………………………..940,000 lb/hr.

Superheater

Type ………HOPKINSON’S “HYLIF TORSION BAR………...............3 Bore ………………………………………………………………………2½ ins.

Total area …………………………………………………………………….. 6.85 sq. in.

Total discharge capacity superheater steam………………………………….. 291,000 lb/hr

(The contractor should note the special requirements of the South African regulations with regard to safety valve areas.)

SAFETY VALVE BLOW-OFF PRESSSURES

DRUM SUPERHEATER NO. OPEN CLOSE NO. OPEN CLOSE

RUNNING PARTICULARS AT SITE (CONT.) BOILERS

Pounds per hour evaporation 830,000 900,000 720,000 corresponding to 100 MW rating

B. Th. U. absorbed

Per sq. ft. boiler surface ………….per hour 89,800 103,900 112,900

Per sq. ft. superheater surface ……per hour 5,560 6,440 7,265

Per sq. ft. economizer surface (Blr. 1) per hour 2,170 2,488 3,265

Per sq. ft. airheater surface …………per hour 542 623 676

B. Th. U released per cu.ft. of combustion chamber volume …… per hour 14,530 16,810 18,210

Velocities (average)

Water through economizer tubes (Blr. 1) f.p.s. 2,2 2,5 2,7 (Blr. 2) f.p.s. 3,7 4,3 4,7

Steam through pipes connecting drum to superheater ………………......f.p.s. 43,2 49,8 54,0

Steam through primary S/H tubes …………………………………..f.p.s. 56,2 63,5 70

Steam through secondary S/H tubes …………………………….. f.p.s. 103,9 117,0 120,6

Air through airheater ……………… f.p.s. 20,6 23,8 25,8

Estimated heat losses

Drygas………………………………………… 4,11 4,23 4,55

H2 plus H2o in fuel ........................................ 3,75 3,79 3,79

Unburned combustible………………………… 1,91 1,98 2,03

0,63 0,70 0,73Radiation …Unaccounted

Total heat loss ……………………………. 10,40 10,70 10,90