May 12

1 MAY 2012 TS TIDINGS
Published by Technical Services / PSSR

For internal circulation
NEYVELI TPS MAY 2012

VOLUME : 15.12
HIGHLIGHTS
CPCL PHASE 3: 22.5 MW UNIT 4:
GT REACHED FULL LOAD.
HRSG ALKALI BOIL OUT WAS CARRIED OUT.
HRSG SAFETY VALVE FLOATING WAS CARRIED OUT.
STEAM BLOWING WAS COMPLETED.
BELLARY 500 MW UNIT 2:
GD TEST OF ESP PASS C AND D COMPLETED.
MRPL GT 1:
GT 1 WAS PUT ON RATCHETING.

--ooOOoo--
TECHNICAL SERVICES / PSSR
INSIDE
1. STATUS OF PROJECTS COMMISSIONED / TO BE COMMISSIONED DURING

2010 - 2013.
2. SERVICE RENDERED TO OTHER REGIONS/SAS/PROJECTS AFTER CONTRACT

CLOSING/CUSTOMER TRAINING.
3. APPRECIATION FROM CUSTOMER FOR SERVICES RENDERED.
4. FEED BACK ON EQUIPMENTS FROM SITES.
5. LET US KNOW.
Feed backs and suggestions from all departments of BHEL for improvement of TS
TIDINGS are welcome and may please be addressed to ADDL. GENERAL MANAGER
(TSX)/BHEL-PSSR/CHENNAI

STATUS OF PROJECTS COMMISSIONED / TO BE COMMISSIONED DURING

2010 – 2013:
BELLARY 500 MW UNIT 2:
Mill – G lube oil flushing was completed. Feeder - F & G calibration was
carried out. Mill E - 8 hrs. coupled trial run was completed
Commissioning of opacity monitoring system was completed.
SAT – 2 bus duct ( 3.3 KV ) HIPOT test was carried out.
Ash handling system : MCC – 2 incomer cable HIPOT test was carried out.
HFO pump – A trial run was carried out.
CWP – C: Protection and interlock checking of motor was completed.

Motor checking and cable HIPOT test completed. Stability test for motor
was carried out.
TDBFP –B : Second LOP motor no load trial run was completed.
Seal air fan – A & B soft starter device (SCHNEIDER Make ) incorporated in
DOL starter, fan was run and established.
2nd incomer of 2HB ( Boiler valves and Damper MCC ) was charged.
MDBFP – C trial run was completed again after interchanging cooling fans of
DE/NDE and balancing. Operating parameters were found to be normal.
Remote operation of breakers from DCS - for boards OCA, OBE, OCF and
2CA completed.
Mill E,F & G : Discharge valves of mill was commissioned.
AOP – 2 motor bearing replacement work was completed.
Extraction NRVs 10 nos. position feed back transmitters zero position

calibration work was completed.
CW forebay make up pump local control panel checking was completed.
SST-02 transformer was charged after completion of cable HV test,

termination, interlock and protection checks.

UAT 01 transformer ( 11 KV/3.3 KV ) protection checking completed and

cooler control cabinet was commissioned. Breaker interlock and protections
demonstrated to customer. UAT 01 transformer bus duct HIPOT test was
carried out. Stability test : Restricted earth fault protection demonstrated
to customer, test charging of transformer was done.
CHP 11 KV second HT cable HIPOT test was carried out.
3 nos. of WSB & LRSB thermal drain valves commissioned.
DM transformer – 2 interlock and protections checking (WT & OT ) PRV

buckholtz ) completed.
Ash handling plant transformer -2 control schemes, interlock and protections

demonstrated to customer.
GD test of ESP C & D pass was completed.
TG MOT oil filling completed after modifications as per BHEL,Hardwar

circular.
Hydrogen drier remote operation demonstrated to customer.
2 BB & 2CB transformers breaker DCS operation completed.
CW – C motor NDE bearing replacement work and alignment work

completed.
PA duct repeat leak test conducted.
TDBFP – B governing rack 5 nos. solenoids remote operation checking

completed.
Remote commissioning of 13 nos. HT breakers of OBD board carried out

jointly with customer.

CPCL PHASE 3 - UNIT 4:
HRSG :
Igniter rod for elevation – 1 was commissioned. Instruments commissioning

was completed upto DCS.
GAS IN was carried out for the first time and hot water rinsing was
completed.
ALKALI BOIL OUT WAS CARRIED OUT ON 14.05.12. Cold rinsing was
carried out for three times after Alkali boil out operation.
DRUM AND SUPERHEATER SAFETY VALVE FLOATING WAS CARRIED

OUT ON 16.05.12.
STEAM BLOWING WAS COMPLETED ON 17.05.12.
Naphtha and Hi-tech Mass flow meters were commissioned upto DCS.
Naphtha pressure control valve for HRSG was commissioned from DCS.
MOVs operation along with interlock protection has been demonstrated to

O & M group of CPCL.
Igniter and flame scanner was commissioned from remote.
Augmenting air fan - 2 for HRSG – 4 hours trial run was completed.
Seal air fan – 1 - 4 hours trial run completed.
GT WAS RESTARTED ON 04.05.12 TO ANALYSE VIBRATION PROBLEM,

SYNCHRONIZED AT 1400 HRS. AND REACHED BASE LOAD OF 22
MW. High vibrations were observed in load gear box high speed end
bearing. GT was shut down FOR FURTHER ANALYSIS.
GT was restarted on 07.05.12 to further analyse the vibration problem and

synchronized through Auto synchronizer of Mark VI. Vibration data was
sent to BHEL/Hyderabad for their analysis.
HP steam flushing was carried out for GT steam injection line.
Master clock system for DCS, SCADA & Mark VI was commissioned.

Spray control valves - 2 nos. and its block valve, Naphtha control valve
for Burners were commissioned from DCS.
GT-4 inlet air filter cleaning system was commissioned.
GT : Control valve for steam injection system was commissioned from DCS.
Control valve for deaerator pegging commissioned from DCS
MRPL:1XFr.5 GTG, 2X28.5 MW STG, 4X270 TPH UTILITY BOILERS, 1X85 TPH
HRSG, ADDITIONAL ORDER: 1XFr.6B GTG, 1X85 TPH HRSG-GT1.
125 V DCDB 1 & 2 & 415 V GT MMC2 – CRM test completed.
6.6 KV bus – B hi-potential test was carried out.
GT frame 5: Skid junction box to field junction box of all instruments

loop checking was completed.
415 V PMCC 3 PT circuits commissioned.
GT Frame -5: GT was put on ratcheting for the first time on 19.05.12.
Frame 5: Ventilation fans for generator compartment B and accessory

compartment B was run for four hours.
125 V DC electrolyte filling completed.
Guillotine damper was commissioned.
NEYVELI TS II EXP CFBC, 2 X 250 MW, UNIT 1:
Unit was boxed up on 20/03/12 due to SH 1.2a in FBHE-2 tube leakage

which is being attended.
FASTBUS transfer panel : FASTBUS transfer system was commissioned by

M/s ABB Engineer.

NEYVELI TS II EXP CFBC, 2 X 250 MW, UNIT 2:
ACW – 2B trial run was completed.
Acid cleaning for fans lube oil system was completed.
NORTH CHENNAI TPS II 2 X 600 MW: UNIT 2 :
Turbine valve MCC # 2 KB and unit Emergency MCC # 2 DG panel 2nd

incomer charged from 2DA.
BOP DCS panel charging completed.
1BA panel (11 KV ) over current relay testing completed.
Vacuum pump Motor A, B, C & D : IR value and winding resistance

testing completed.
11KV unit SWBD - 1BA & 2BA charged from OBA panel.
BCW motor A & B testing was completed.
SADC damper mechanical checking was done.
FD fan – 2A outlet gate & LOP interlock checking completed from DCS.
3.3 KV unit SWBD CT testing completed.
11 KV unit SWBD – 1BA panel hipot test completed.
Unit service transformer – 2 DAT01 was charged.
MDBFP 2A motor testing was carried out.
OBA to 1BA bus duct hipot test completed.
ID fan – 2A LOP interlock checking from remote was completed.
FD fan – 2A: Duct air leak test was completed.
Water system : Transformer ODE T02 protection checking and 11 KV

Transformer cable hipot test completed. 2000 KVA Transformer T02
and PMCC ODE board were charged.
GT HV bushing Tan Delta test was completed.

TG side DCS panels were charged and DPU flashing was completed.
DM plant back wash pump motor B & C trial run was carried out.
DM transfer pump unit 1 motor trial run was completed.
ID fan – 2A channel – 1 high voltage test of cables completed. ID fan 2A

CH 1 reactor testing and source breaker command checking from control
panel was completed. VFD CH-1 Transformer protection checking was
completed.
1 DA-T01 2.5 MVA Dry type transformer testing completed.
Corner – 1 burner tilt, gun assembly, ignitor and scanner dimension and
freeness checking were completed.
OCA 3.3 KV board bus bar HV test completed.
ETDA LT motors ( 2 nos. ) no load trial run was carried out.
Unit service PMCC # 1DA relay testing completed.
RINL:
TB- 4 is in service.
Master and Slave clock system was commissioned.
SG 6 : PA fan B : Stage – II lube oil flushing was completed.
11 KV board incomer, bus coupler feeder interlock and protection checking

was completed.
Mill C, D & E lube oil line hydro test was completed.
Mills A, B, C, D & E lube oil lines acid cleaning was carried out.
ID & FD fan – A & B motor testing was completed.
All LTMCC for SG and TG, HT MCC and CRP panels testing was completed.
1 no. 20 MVA ( SAT 1) transformer testing (ratio, vector, IR values, winding

resistance ) was completed.

ID and FD motor power cable HIPOT test was completed.
Boiler initial filling DM line HIPOT test was completed.
SIMHADRI STAGE II, 2 X 500 MW, UNIT 4:
BOF ( Boiler Outlet Flange ) to ESP C & D pass inlet gates duct ATT (Air
Tightness Test ) was done.
Cold PA duct ATT was done.
Ammonia and Hydrazine dosing skid discharge to CEP discharge header line
flushing was completed.
Boiler was boxed up after safety valve floating.
PA duct and seal air fan piping leak test was done.
Turbine exhaust hood spray line flushing was completed.
Boiler drum S.V.1 internals changed and reassembled.
Hot well cleaning was done and boxed up.
TG was put on barring gear on 16.05.2012.
Unit was synchronized on 23.05.12 and tripped on electrical protection

on 24.05.12.
PA FAN – 4: Lube oil lines acid cleaning was completed.
STERLITE, TUTICORIN, UNIT - 1 :
RAPH – 1 guide bearing and support bearing lube oil flushing is in

progress.

VALLUR 3 X 500 MW, UNIT 1:
PA fan A : Stage 1 lube oil flushing was completed.

Auxiliary Boiler : Boiler feed pump – A trial run was completed. LDO
system oil flushing was completed.
DC-EOP trial run was completed.
DG-DMCW system hydro test was carried out.
PAPH – A : Main motor trial run was completed.
ESP D pass : EERM/CERM motors - 2 hours trial run was completed.
RHS MTM panel termination was completed.
TDBFP – B : Lube oil flushing declared completed. Lube oil system
hydro test completed. Seal steam line card board air blasting was
carried out. Turbine bearing normalization was completed.
PA fan A : Stage II – Lube oil flushing declared completed.
TDBFP A: Tank cleaning work and inspection carried out.
Boiler SADC and burner tilt checking for two corners completed.
HP/LP flash tank connected MOVs commissioning was completed.
VALLUR 3 X 500 MW, UNIT 2

FD fan A : Stage II lube oil flushing was completed.
LDO system hydro test completed.
FD fan – A trial run completed. Impeller assembly checking through blade
pitch actuator was completed.
SAPH A: Guide bearing and support bearing lube oil flushing declared
completed.

SERVICE RENDERED TO OTHER REGIONS/SAS/PROJECTS AFTER CONTRACT

CLOSING/CUSTOMER TRAINING.
--- NIL ---
CUSTOMER TRAINING & TECHNICAL PAPER PRESENTED:
--- NIL ---
APPRECIATION FROM CUSTOMER FOR SERVICES RENDERED :
--- NIL ---

FEED BACK NO.1
PROBLEM: BLADE FAILURES ON AXIAL PROFILE (A.P) FANS
FEED BACK ON BALDE FAILURES IN AXIAL FANS
Axial Reaction fans of Single Stage and Double Stage are supplied as FD Fans and PA
fans applications respectively for many power plants. The blades of these fans are
made of Aluminium material and fixed on fan impeller hub with screws. These blades
are rotating around 90 deg from its axis. This rotation of blades help in lowering and
raising of fan load. The blades are made lighter material (Aluminium) to reduce the
rotating mass of impeller assembly which results in reduced power consumption.
Cases were reported from various sites (Panipat-7, Chabra-1, Suratgarh-6, Paricha-
5, Kahalgaon- 5 and Bhilai-1) that the vibration of fans is high during commissioning
and operation. On physical inspection, the fan blades were found damaged due to
hitting / entrapment of foreign material with blades
Observations has revealed that main cause of damages were hitting/entrapment of
foreign materials( which has come from the suction side like loose bolts, nuts, welding
electrodes left out in the expansion joints and temporary angles/ supports welded in
the silencer/transition ducts etc). Damage of blades results into immediate outage of
fans and causes huge loss to the generation. Cycle time for the manufacture of the
blades is quite long and replacement of blades against damage is putting the
manufacturing Unit in great hardship. Also it is required to replace the entire set
even in one fan blade fails.

Site engineers are advised to follow guidelines/ instructions strictly as indicated in
the fan Operation & maintenance manual . It is mandatory to physically inspect the
fan internal including suction chamber silencer and expansion bellows joints by the
Erection Engineer and Commissioning Engineer in-charge for such activities and remove
the left out items from inside the fan and closing of inspection door before starting
the fan. Similarly the discharge duct upto Airpreheater inlet are to checked and
cleared from all loose items because to avoid carrying of loose items to impeller by
reverse air flow while tripping of one Fan when both fans are service.
COURTESY: FANS DEPT/ M/SBHEL/RANIPET.



FEED BACK NO. 2
PROJECT: RINL TURBO BLOWER #4, VISHAKAPATNAM

PROBLEM: HIGH VIBRATION AND NOISE FROM BEARING HOUSING OF CEP B
AND EXCESSIVE CONTINUOUS LEAKAGE OF CONDENSATE FROM PUMP
GLAND.
Problem detail:
CEP B was commissioned on 08.02.2012. During pump trial run, the vibration and noise
were normal and the vibration reading was as below:
LOCATION HORIZONTAL(mm/s) AXIAL(mm/s)
MNDE 2.9 2.6
MDE 4.3 1.3
PDE 3.5 3.8
High vibration and abnormal sound was observed from bearing housing after around 50
hours of running. Vibration reading was as below:
MNDE 4.5 5.0
MDE 11.3 8.6
PDE 9.8 7.8
Analysis and rectification works:

The following checks and rectification works were carried out in supervision of
technician from BHEL/Hyderabad during resolving the problem:
1. The coupled run out on coupling of the pump and motor (with bush bolt) was
checked. It was 1.7 mm (should be less than 0.03mm).
2. The radial and axial run out on coupling hubs of pump and motor were individually
checked which were within limit.
3. Motor de-coupled trial run was taken again and found the vibration levels were
satisfactory.
4. Pump side coupling hub was changed from another pump and coupled run out was
checked and again it was 2.2 mm in pump side and 0.3mm in motor side. The
coupling bolt holes were found to be having mismatch causing to this coupled run.
The same was corrected.

5. Pump was taken out from foundation by dismantling all the pipe line connecting to
the pump.
6. Motor, motor stand, head gear and pump assembly were dissembled and removed
from the position. It was found that rusty roller element of self-aligning bearing
which may be due to insufficient greasing in shop or dispute bearing supply. This
bearing replaced with new one. Upper shaft of the pump was removed and checked
for its run out and found ok. Clearance of cutless rubber bearing and shaft was
checked and found ok. Shaft was reassembled with head gear.
7. During reassembling of bearing pan with head gear it was found that clearance
between the bearing pan and head gear was 0.55 mm against the drawing value of
0.05mm. It was observed that there were only 3 nos. of fixing bolts(between head
gear and bearing pan) instead of 4 nos. This higher clearance and inadequate bolting
resulted in high vibration of bearing pan along with bearing. Clearance was adjusted
by metal deposition and grinding in the head gear spigot and brought within
allowable limit.
8. The water closing ring (meant for pump gland water supply) was observed to be
having diameter of 92 mm ( Required dimension is 86 mm dia ). The higher diameter
ring was causing excessive continuous leakage of condensate through pump gland.
Water closing ring replaced with new one of correct dimension.
9. Pump was reassembled and placed in position along with head gear, bearing pan,
bearing, motor stand, and motor.
10. Shaft coupled run out was checked and found satisfactory
Pump trial run was taken and all parameters were found within permissible limit. Pump
gland leakage was minimum. Vibration reading recorded as below
Vibration Reading
MNDE 2.7 2.4
MDE 4.1 2.0
PDE 3.1 3.3

The pump was put in continuous service.
Conclusion:
The root cause for the vibration problem is high coupled run out and higher clearance
between bearing pan and head gear. After correction of these, the performance of
the pump was satisfactory. It is to be ensured by manufacturing units for supplying
pump assembly without such deviations to avoid problems at site.
Courtesy:-
1. SHRI DEBASHISH SHETH, SR. ENGINEER/RINL SITE

2. SHRI DEEPAK KUMAR M, AE-II/RINL SITE
3. SHRI ARDHENDU GUIN, AE-II/RINL SITE

Turbo blower
Introduction:
A Turbo blower is a type of machinery comprising a turbine and a blower having
common shaft. The turbine may be driven by gas or steam. The Blower is nothing but
a compressor. A compressor is a device used for pumping compressible fluids. The
basic difference between a compressor and a blower is on the pressure rise in the
system. The Turbo blower is used in steel plants as a part of a blast-furnace system
used as a blast system in steel making. This article describes the blower system used
in a steel plant (RINL,Vizag).
The blower is an axial compressor with 14 blade stages, radial discharge and a
horizontally split casing. It is located in the upstream of the blast furnace. The
compressor supplies hot air (the temperature rise by compression only), at a
temperature of 250 deg C and pressure of 5.75 KSC to blast furnace, which is
required for hot-metal making. The Turbo blower is driven by steam turbine, capacity
control will be done by speed control of the turbine. There is no inlet guide vane
control mechanism.
Constructional features of Blower:

Casing and stator blades:
The compressor casing is made of cast iron with axial inlet nozzle. The axial inlet is
superior to radial inlet. The major advantages are:
• Lower inlet losses resulting in the efficiency benefit of around 0.8%

• Minimised inlet ducting due to close connection to the transition of air intake
filter/silencer.
• Less noise emission at the air intake and minimized noise insulation measures.
The compressor casing and stator blade carrier is made of cast iron (GG 20). The
advantages of using cast iron compared to steel castings are:
• Because of larger thickness of the cast iron casing compared with cast steel,
the damping behavior for noise and vibration is better.

• The elongation factor of cast iron was smaller than cast steel. Nozzle movement
from cold to hot condition is smaller.
• Corrosion resistance of cast iron is better than cast steel.
The discharge nozzle is provided downwards. The casing is supported by pads arranged
at the parting plane. The bearing pedestals are an integral part bolted to the
compressor casing, thus facilitating alignment. The stator blades or rather stator
blade half rings are installed in a separate stator blade carrier which is also
horizontally split and made of grey cast iron.
Rotor:
The rotor blades are forged and milled 13% chrome steel material. The blades are
fixed with parallel rectangular roots fitted in machined grooves of the rotor and kept
in position by retaining rings. The radial final stage is of welded 13% chrome steel
material and is shrink fitted on the rotor shaft. The radial impeller is
thermodynamically low loaded and may be called a rotating diffuser and allows radial
deflection of the discharge flow with minimized losses.
The compressor rotor is a single piece forging and is provided with a balance drum at
its high pressure end to counteract the compression reaction forces. Residual thrust is
taken up in a double acting tilting pad self equalizing thrust bearing. The rotor is
supported in tilting pad type journal bearings. The compressor is equipped with
labyrinth type shaft end seals.
Rotating diffuser:
In every axial flow compressor, the direction of flow has to be changed from axial to
radial with the help of diffuser. The diffuser must simultaneously convert the kinetic
energy into static pressure. The special features of the rotating diffuser are
extremely low aerodynamic loading, robust vanes of airfoil profile and of robust alloy
steel precision casting. The diffuser differs from conventional centrifugal impellers.


Blower name plate details (RINL TB #4)

Vendor’s Name- MAN TURBO AG
Gas handled- AIR
Rated capacity- 502455 M3/Hr
Rated Power- 37215 KW
Hydro test Pr- 9.0 Bar G
Casing Design Pr- 6.0 Bar G
Casing Design Temp- 300 Deg C
TYPE - AG 100/14R
Min operational speed- 3150 rpm
Max continuous speed- 4620 rpm
Trip speed- 4851 rpm
First critical speed- 1815 rpm

Max allowable work Pr- 6.0 Bar G

Min/Max allowable temp- 20/300 Deg C
Air intake system
Atmospheric air is drawn by the compressor from the air intake system. These consist
of filter housing, filter elements and also provided with pulsating cleaning system. A
separate compressor with drier unit supplies air for the pulsating cleaning system. The
cleaning sequence of the filters can be started either manually or on auto mode
sensing the Differential pressure across the filter.
Blow-off valves and interstage outlet valve
Blow-off valves; There are three blow of control valves and one block valve provided
in parallel as shown in the drawing. These valves operate automatically to blow off
process air to the open atmosphere (through the silencer), if there is a risk of
surging. These valves are operated by the hydraulic actuators.
Pnuematically operated Interstage outlet valve also blows off the process air to the
open atmosphere (through the silencer) if there is a risk of surging.
A swing check valve is provided in the discharge line of the blower to prevent process
air entering back to the compressor discharge.
Seal air system
To prevent oil carry over from the bearing pedestal at drive end which is in air flow
path, its labyrinth seals are supplied with pressurized process gas. The pressure at
the seal inlet is maintained around 20 mbar by a pressure control valve. During start
up external instrument air is supplied for sealing through the same control valve.
Check valves are provided in the seal air supply system to prevent process gas
entering instrument air line.
Operation of Turbo blower
The compressor operates as a continuous fluid flow machine according to the dynamic
principle. The mechanical energy supplied by the drive turbine is transmitted to the
compressor stages to the process of air flowing in at the suction region. After a
continuous increase in pressure by the individual compressor stages, the process air
enters the downstream process with the specified discharge pressure at the discharge
nozzle. The discharge-end shut-off valve allows the isolation of the compressor from
the process air system.

Oil system:
The lubricating oil system of the blower is integral part of Steam turbine lub oil
system. Emergency lub oil is supplied from lub oil over head tank during non
availability of power supply. The compressor rotor is provided with jacking oil/ lifting
oil during lower speed operation, supplied from steam turbine oil system. Also, the
control oil for the operation of the antisurge control valves are provided by the steam
turbine oil system.
Control system
The main control system components provided in the blower system are suction flow
measurement, discharge pressure measurement, discharge temperature, discharge flow
to the process and the blow off valves etc., The shaft vibration, bearing metal
temperatures, lub oil pressures and axial shift are also monitored.

Anti-surge control
The compressor is equipped with an anti-surge control system to protect it against

mechanical stress by surging. Anti-surge control system prevents surging of the
compressor by opening the blow off valves, thus returning process gas from the
discharge end to the atmosphere.
TURBO LOG TMR (COWPER FILLING CONTROL) is provided for surge controller and
TURBOLOG COMPACT system is provided for surge detection. The turbolog DSP TMR
(Triple Modular Redundancy) protection and control system extends the capabilities of
a redundant unit that satisfies the highest requirements in terms of error immunity
and ease of maintenance. The failure of one or several components in the TMR system
does not result in any disruption to the current process. A module/card can also be
replaced during operations without giving rise to any disruption (hot-swap capacity).
All TMR-specific functions are essentially components of the operating program and
thus run in the background mode, i.e. out of sight from the user (tracking, mid of
three voting, ...) The user can thus concentrate on the actual operational functions
(open and closed-loop control, protective functions, etc.). A high level of availability
of the system components is achieved, firstly, due to the fact that the components
themselves are exceptionally reliable, and secondly through the triplex redundancy of
all the modules in conjunction with wide-ranging diagnostic facilities.
The system receives the process variables such as speed, pressure, temperature,
switch position, etc. from the three input units and after appropriate preprocessing
(linearisation, filtering, etc. performed directly at the input cards MCAD, MCRTD,
MCMIO, etc.), the data are transmitted via the three DSP buses to the three main
processors (ICUs - industrial controller units). The ICU cards compute the three input
values using various voting/selection criteria (2 out of 3, mid of three, min/max ...)
and determine the values to be used as the actual input values for the calculations
governing the open/closed-loop control or monitoring functions. Normally (i.e. unless
there is an error) the middle of the three error-free input values is used for the
subsequent computation. The calculated output values (e.g. positioning control output
for the live steam valve of a steam turbine or the start-up command for a pump,
etc.) are likewise supplied on the basis of various voting/selection criteria (2 out of 3,
mid of three, min/max ...) to one of the three output cards. The ICU cards
operating in unison with an external voter (incorporated on the termination card, see
diagram) determine which output unit is to be enabled by the 1 out of 3 voter on the
external termination module.

Antisurge control valve with hydraulic actuator


Surge control line and surge safety line
A surge in a compressor is essentially an unstable operating region for the compressor.

When compressor operates at Low flow through compressor stage with higher discharge
pressure, there is a possibility of surge occurrence. There will be a tendency for the gases
to flow back through the compressor (reversal of flow). The flow reversals at rapid cycles
will cause severe stress on rotating components. During surge conditions, abrupt changes in
delivery pressure, delivery temperatures, vibrations levels and compression ratios, which
are harmful for the machine are encountered.
The anti surge controller essentially takes care of surge conditions (i.e) it maintains the
operating point close to Surge Control Line (SCL) – See figures. Whenever the operating
point crosses the SCL and move to the left of SCL in Head vs Q curve, the PI control is
initiated and opens the anti surge valves gradually to recycle the gases . If further, the
operating point moves towards left and crosses the surge safety line, step response is
initiated in the controller and the anti surge block valves are opened fully to bring the

operating point back to the SCL. There will be another line left to this surge safety line
where actual surge occurs.
These curves are drawn at site after carrying out actual surge test. Atleast at three
different speeds actual surge point will be tested and curve is drawn. This curve normally
matches the theoretical surge line. With reference to the drawn surge line, surge safety
line and surge control line is plotted.
Surge counter
Surge counter records arising surges.
Discharge pressure control
During operation of compressor in discharge pressure controller mode, it keeps the process
air pressure in the discharge pipe constant.
Flow control
Flow controller keeps the process gas flow constant.
Turbo Blower is driven by steam turbine. Blower is coupled with turbine by flexible
coupling.

Starting procedure
1. Draining the machine unit

Open the shut-off valve to drain compressor casing. Close the shut-off valves
in the drain pipes after completely draining.
2. Starting up the seal air system
Establish shaft sealing by running seal air system.
3. Starting up the oil system
Establish lubricating and jacking oil system. Over head tank filling have to
ensure. Turbo-blower put on barring gear.
4. Starting normal compressor operation
A) Blow-off valves are 100% open b) Blow-off flap valve is 100% open c)
Interstage blow-off valve open d) stop barring gear operation and load the
machine as per speeding up curve and put the machine as per discharge pressure
control or flow control.

UNITS WHICH HAVE ACHIEVED 100% OA

THERMAL
500 MW
RAMAGUNDAM UNITS – 4, 5, 6 & 7
TALCHER UNIT – 3 & 5
SIMHADRI UNIT - 2
SIPAT UNIT – 5
210 MW
VIJAYAWADA UNITS – 1, 4 & 5
MUDDANUR UNIT – 1 & 3
RAICHUR UNIT – 1 & 6
NORTH CHENNAI UNIT – 1 & 3
NEYVELI UNIT – 5 & 6
AMARKANTAK UNIT – 5
UNITS WHICH HAVE ACHIEVED PLF MORE THAN 100%
500 MW
RAMAGUNDAM UNITS – 4, 6 & 7
SIMHADRIUNIT - 2
SIPAT UNIT - 5
210 MW
VIJAYAWADA UNIT– 5

UNITS WHICH HAVE ACHIEVED PLF BETWEEN 90 & 100%
THERMAL
500 MW
RAMAGUNDAM UNIT – 5
TALCHER UNITS– 1, 2, 3, 4, 5 & 6
SIMHADRI UNIT – 1 & 3
SIPAT UNIT - 4
VTPS UNIT - 7
250 MW
KOTHAGUDEM UNIT - 9 & 10
210 MW
VIJAYAWADA UNITS – 1, 2, 3, 4 & 6
MUDDANUR UNITS – 1, 3 & 4
RAICHUR UNITS – 4, 5, 6 & 7
TUTICORIN UNITS – 1,3, 4 & 5
NORTH CHENNAI UNIT – 1 & 3
NEYVELI UNITS - 4, 5 , 6 & 7
AMARKANTAK UNIT – 5

PERFORMANCE OF BHEL THERMAL SETS IN SR (210 MW AND ABOVE)

FOR THE PERIOD FROM 01/04/2012 TO 31/05/2012 COMPARED WITH THE
CORRESPONDING PERIOD IN THE PREVIOUS YEAR.
( PLF IN PERCENTAGE )
STATION 2011-2012 2012-13

North Chennai 97.88 92.47
Neyveli 94.45 96.68
Raichur 84.24 78.73
Tuticorin 90.35 94.37
Ramagundam 83.49 98.08
Muddanur 92.77 90.63
Kothagudam 93.71 85.75
Vijayawada 95.78 95.75
VTPS - 7 98.45 91.62
Mettur 98.42 73.63
Talcher 95.79 97.00
Simhadri 101.00 97.27
Sipat 84.73 101.6
Amarkantak 93.09 92.89
Bellary-1 -- 85.37
120.00 2011‐12 2012‐13
100.00
80.00
60.00
40.00
20.00
0.00
VTPS ‐ 7
Mettur
Muddanur
Kothagudam
Sipat
Neyveli
Chennai
Amarkantak
Tuticorin
Raichur
Talcher
Ramagundam
Bellary‐1
Vijayawada
Simhadri
North

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1 MAY 2012 TS TIDINGS

Published by Technical Services / PSSR

NEYVELI TPS MAY 2012

CPCL PHASE 3: 22.5 MW UNIT 4:

 GT REACHED FULL LOAD.

 HRSG ALKALI BOIL OUT WAS CARRIED OUT.

 HRSG SAFETY VALVE FLOATING WAS CARRIED OUT.

 STEAM BLOWING WAS COMPLETED.

BELLARY 500 MW UNIT 2:

 GD TEST OF ESP PASS C AND D COMPLETED.

 GT 1 WAS PUT ON RATCHETING.

1. STATUS OF PROJECTS COMMISSIONED / TO BE COMMISSIONED DURING

2. SERVICE RENDERED TO OTHER REGIONS/SAS/PROJECTS AFTER CONTRACT

3. APPRECIATION FROM CUSTOMER FOR SERVICES RENDERED.

4. FEED BACK ON EQUIPMENTS FROM SITES.

TECHNICAL SERVICES / PSSR

STATUS OF PROJECTS COMMISSIONED / TO BE COMMISSIONED DURING

BELLARY 500 MW UNIT 2:

 Commissioning of opacity monitoring system was completed.

 SAT – 2 bus duct ( 3.3 KV ) HIPOT test was carried out.

 HFO pump – A trial run was carried out.

 CWP – C: Protection and interlock checking of motor was completed.

 TDBFP –B : Second LOP motor no load trial run was completed.

 Mill E,F & G : Discharge valves of mill was commissioned.

 AOP – 2 motor bearing replacement work was completed.

 Extraction NRVs 10 nos. position feed back transmitters zero position

 CW forebay make up pump local control panel checking was completed.

 SST-02 transformer was charged after completion of cable HV test,

TECHNICAL SERVICES / PSSR

 UAT 01 transformer ( 11 KV/3.3 KV ) protection checking completed and

 CHP 11 KV second HT cable HIPOT test was carried out.

 3 nos. of WSB & LRSB thermal drain valves commissioned.

 DM transformer – 2 interlock and protections checking (WT & OT ) PRV

 Ash handling plant transformer -2 control schemes, interlock and protections

 GD test of ESP C & D pass was completed.

 TG MOT oil filling completed after modifications as per BHEL,Hardwar

 Hydrogen drier remote operation demonstrated to customer.

 2 BB & 2CB transformers breaker DCS operation completed.

 CW – C motor NDE bearing replacement work and alignment work

 PA duct repeat leak test conducted.

 TDBFP – B governing rack 5 nos. solenoids remote operation checking

 Remote commissioning of 13 nos. HT breakers of OBD board carried out

TECHNICAL SERVICES / PSSR

CPCL PHASE 3 - UNIT 4:

 Igniter rod for elevation – 1 was commissioned. Instruments commissioning

 DRUM AND SUPERHEATER SAFETY VALVE FLOATING WAS CARRIED

 STEAM BLOWING WAS COMPLETED ON 17.05.12.

 MOVs operation along with interlock protection has been demonstrated to

 Igniter and flame scanner was commissioned from remote.

 Seal air fan – 1 - 4 hours trial run completed.

 GT WAS RESTARTED ON 04.05.12 TO ANALYSE VIBRATION PROBLEM,

 GT was restarted on 07.05.12 to further analyse the vibration problem and

 HP steam flushing was carried out for GT steam injection line.

TECHNICAL SERVICES / PSSR

 GT-4 inlet air filter cleaning system was commissioned.

 Control valve for deaerator pegging commissioned from DCS

 125 V DCDB 1 & 2 & 415 V GT MMC2 – CRM test completed.

 6.6 KV bus – B hi-potential test was carried out.

 GT frame 5: Skid junction box to field junction box of all instruments

 415 V PMCC 3 PT circuits commissioned.

 Frame 5: Ventilation fans for generator compartment B and accessory

 125 V DC electrolyte filling completed.

 Guillotine damper was commissioned.

GT REACHED FULL LOAD.

HRSG ALKALI BOIL OUT WAS CARRIED OUT.

HRSG SAFETY VALVE FLOATING WAS CARRIED OUT.

STEAM BLOWING WAS COMPLETED.

GD TEST OF ESP PASS C AND D COMPLETED.

GT 1 WAS PUT ON RATCHETING.

Commissioning of opacity monitoring system was completed.

SAT – 2 bus duct ( 3.3 KV ) HIPOT test was carried out.

HFO pump – A trial run was carried out.

CWP – C: Protection and interlock checking of motor was completed.

TDBFP –B : Second LOP motor no load trial run was completed.

Mill E,F & G : Discharge valves of mill was commissioned.

AOP – 2 motor bearing replacement work was completed.

Extraction NRVs 10 nos. position feed back transmitters zero position

CW forebay make up pump local control panel checking was completed.

SST-02 transformer was charged after completion of cable HV test,

UAT 01 transformer ( 11 KV/3.3 KV ) protection checking completed and

CHP 11 KV second HT cable HIPOT test was carried out.

3 nos. of WSB & LRSB thermal drain valves commissioned.

DM transformer – 2 interlock and protections checking (WT & OT ) PRV

Ash handling plant transformer -2 control schemes, interlock and protections

GD test of ESP C & D pass was completed.

TG MOT oil filling completed after modifications as per BHEL,Hardwar

Hydrogen drier remote operation demonstrated to customer.

2 BB & 2CB transformers breaker DCS operation completed.

CW – C motor NDE bearing replacement work and alignment work

PA duct repeat leak test conducted.

TDBFP – B governing rack 5 nos. solenoids remote operation checking

Remote commissioning of 13 nos. HT breakers of OBD board carried out

Igniter rod for elevation – 1 was commissioned. Instruments commissioning

DRUM AND SUPERHEATER SAFETY VALVE FLOATING WAS CARRIED

STEAM BLOWING WAS COMPLETED ON 17.05.12.

MOVs operation along with interlock protection has been demonstrated to

Igniter and flame scanner was commissioned from remote.

Seal air fan – 1 - 4 hours trial run completed.

GT WAS RESTARTED ON 04.05.12 TO ANALYSE VIBRATION PROBLEM,

GT was restarted on 07.05.12 to further analyse the vibration problem and

HP steam flushing was carried out for GT steam injection line.

GT-4 inlet air filter cleaning system was commissioned.

Control valve for deaerator pegging commissioned from DCS

125 V DCDB 1 & 2 & 415 V GT MMC2 – CRM test completed.

6.6 KV bus – B hi-potential test was carried out.

GT frame 5: Skid junction box to field junction box of all instruments

415 V PMCC 3 PT circuits commissioned.

Frame 5: Ventilation fans for generator compartment B and accessory

125 V DC electrolyte filling completed.

Guillotine damper was commissioned.

Unit was boxed up on 20/03/12 due to SH 1.2a in FBHE-2 tube leakage

FASTBUS transfer panel : FASTBUS transfer system was commissioned by

ACW – 2B trial run was completed.

Acid cleaning for fans lube oil system was completed.

Turbine valve MCC # 2 KB and unit Emergency MCC # 2 DG panel 2nd

BOP DCS panel charging completed.

1BA panel (11 KV ) over current relay testing completed.

Vacuum pump Motor A, B, C & D : IR value and winding resistance

BCW motor A & B testing was completed.

SADC damper mechanical checking was done.

3.3 KV unit SWBD CT testing completed.

11 KV unit SWBD – 1BA panel hipot test completed.

Unit service transformer – 2 DAT01 was charged.

MDBFP 2A motor testing was carried out.

OBA to 1BA bus duct hipot test completed.

ID fan – 2A LOP interlock checking from remote was completed.

FD fan – 2A: Duct air leak test was completed.

Water system : Transformer ODE T02 protection checking and 11 KV

GT HV bushing Tan Delta test was completed.

DM transfer pump unit 1 motor trial run was completed.

ID fan – 2A channel – 1 high voltage test of cables completed. ID fan 2A

1 DA-T01 2.5 MVA Dry type transformer testing completed.

OCA 3.3 KV board bus bar HV test completed.

ETDA LT motors ( 2 nos. ) no load trial run was carried out.

Unit service PMCC # 1DA relay testing completed.

Master and Slave clock system was commissioned.

SG 6 : PA fan B : Stage – II lube oil flushing was completed.

11 KV board incomer, bus coupler feeder interlock and protection checking

Mill C, D & E lube oil line hydro test was completed.

ID & FD fan – A & B motor testing was completed.

1 no. 20 MVA ( SAT 1) transformer testing (ratio, vector, IR values, winding

ID and FD motor power cable HIPOT test was completed.

Boiler initial filling DM line HIPOT test was completed.