By: Baboo Ram Ex.

Executive Director BHEL Power Sector

PRESENTATION NAME

 Pre-commissioning means preparation for commissioning. commissioning of various equipments and systems are pre-commissioning for commissioning of the power plant. It is a pre-requisite for commissioning.

 Commissioning means to put the equipment into operation as envisaged. For a thermal power plant commissioning means to set up and optimise all its equipments and systems to get output, efficiency, auxiliary power consumption and emission on sustained basis as envisaged to drive the benefit. For super critical and ultra supercritical plant commissioning would mean higher efficiency of the plant with lower emission level and lower auxiliary power consumption(as compared to sub critical plants ) on sustained basis in order to drive the benefit of elevated steam parameters.

Out put Heat Rate ( Efficiency ) Auxiliary power consumption Emission level Sustained generation

 Material
Infrastructure Expertise

ANNEX-1

 36 units UMPP
32units SCPP

27960MW
21540MW

FURNACE WALL DESIGN

The furnace walls are exposed to the greatest heat flux of all heat absorbing surface. This is because of the intense radiant heat from the fireball. For any given furnace size, the spiral wall unit in which the tube is wrapped around the unit has fever tubes then vertical wall unit.

Lower pressure drop means lower feed-pump power and lower. through-life energy consumption Other advantages include better turn-down, simpler construction and improved availability.

SPIRAL & VERTICAL WATER WALL CONFIGURATION

Optimized Rifled Tube

Steam Temperature H-IP Combined Type

600C / 600C to 620C

Main steam inlet flange elbow

9Cr-1Mo steel

Protection of No.s 1,2 journal thrust bearing

Overlay coating

Cooling structure with main steam leading pipe Nozzle box

Rotor cooling for IP section (Protection of aged bending)

No.1 IP internal casing

12Cr cast steel

IP

12Cr cast steel

HP HP internal casing

12Cr cast steel

Main steam Inlet short pipe

9Cr-1Mo steel

Reheat steam inlet short pipes

9Cr-1Mo steel

Main steam stop valves

12Cr cast steel

12Cr cast steel

Control valves

Combined reheat steam valves

12Cr cast steel

HIP Rotor

12Cr steel

660MW Steam turbine : Cross section View

TECHNOLOGY ISSUES

OTHER ISSUES

Water-wall Cracking
Higher metal temperatures and the use of low alloy steel. Thermal fatigue cracking is caused by the combined action of elevated metal temperatures and thermal cycling. Growth of internal tube deposits, high heat flux, deterioration of fluid-side cooling or external fireside coatings. Slagging and shedding, Soot blowing, water cleaning or other factors may cause thermal cycling

Negative Flow Characteristic

A high mass flux design. If the furnace heat flux distribution is non-uniform due to slagging.

INCREASE IN HEAT ABSORPTION IS A REDUCTION IN TUBE FLOW

A FLOW RESPONSE CALCULATED FOR VARIOUS HEAT ABSORPTIONS FOR A BOILER WALL CIRCUIT WITH A HIGH MASS FLUX

Slagging
Slagging refers to deposition of solid layers on the boiler tube, formed by sintering. Slagging is quite hard to remove and also (although it is sintered material) the slagging material is usually still a good insulator.

Due to Spiral tube configuration. Inclination of the tubes is thought to increase the propensity of slag and clinker. The higher fireside metal temperatures of supercritical boilers may also contribute to increased slagging.

Welding of Special Materials

Welding of dis-similar pieces i.e. two pieces fabricated out of different materials is a difficult process. The difficulty increases when the metals, out of which the pieces to be welded are fabricated, are newly developed and not conventional.

Tube Spacing to Handle Indian Coal

Indian coal has high ash content and lower calorific value as compared to coals available in other countries such as Australia and South Africa. The designs of supercritical boilers developed by foreign manufacturers are based on the superior type of coals. The tubing has to ensure that steam parameters required for the supercritical steam cycle are maintained and have to be adopted to suit Indian coals.

Height of Structure
Convenient and economical height of the boiler structure. The height of the boiler governed, however, by design considerations. The height of the (Chimney) is governed by environmental considerations.

Transportation of Major Equipment

Imported equipment unloading facilities at port and project site. Load bearing capacity of bridges involved (rail or road). Limited heavy equipment carriers Needs to develop approach road to the project site.

Skilled Manpower
Shortage of enough experience and skill available for the erection and commissioning of a 660 MW/ 800 MW.

OPERATION & MAINTENANCE ISSUES

INDIAN AMBIENT CONDITIONS AND INDIAN COALS

G coal is available for thermal power plants. The quality of coal available from domestic sources compares very unfavorably with the quality of coals imported from other countries such as Australia, Indonesia or South Africa.

Problems associated with Indian coal are: Indian coal typically has higher moisture content. This can lead to lower boiler efficiencies than with imported coal. Low volatile matter in Indian coal leads to high-un-burnt carbon loses. Low boiler efficiency due to low CV and high ash content in Indian coals High ash and coal handling costs and milling power lead to high auxiliary power consumption High ash and high silica in the coal leads to higher erosion. Though lower flue gas velocities and provision of shielding plates can reduce erosion, it leads to higher capital costs for the boiler. Indian ambient condition High ambient temperature leads to higher cooling water temperature reducing the achievable condenser vacuum to a maximum of 0.13 bars. This in turn leads to higher steam consumption and a poorer turbine heat rate. High relative humidity leads to more losses in cooling tower

OPERATION & MAINTENANCE ISSUES

AVAILABILITY OF CONTRACTOR FOR MAINTENANCE Specific skills for maintenance. Important to provide extensive training to the plant personnel using similar facilities abroad and also using training simulators.

Chemical Cleaning Oil flushing Steam blowing Restoration of system Barring gear Vacuum system check Commissioning of gland sealing system Commissioning of HP/LP bypass system

Steam dumping

 Control gear setting Checking of turbine and generator protection

Rolling and synchronizing

Loading and trial run Performance guarantee test

OBJECTIVE The objective of this procedure is to chemically clean and passivate the internal surfaces of the steam generating portion (water touched surfaces) and heating surfaces (Economizer) using specified chemicals employing a single step process. This will render the above mentioned surfaces free of mill scale, and other deposits and form uniform & smooth protective layer of magnetite. With this protective layer, the generating surfaces are rendered passive to generate adequate negative potential under the operating pH to resist corrosion.

 Iron concentration in three consecutive samples show equilibrium status.

When the iron concentration in the cleaning solution is constant, it indicates that all the oxides have been dissolved. However, a minimum EDTA(Ethelene Diamine Tetra Acid ) contact period of 6 hours from the time of attaining the required temperature (110 deg. C) shall be allowed.
Completion of pickling process once the EDTA strength and iron concentration level out and reach equilibrium. The system shall be allowed to cool with the ID & FD fans in operation. Open the drum air vents when the pressure reaches to 1 kg / sq.cm.

When the temperature comes down to 95 deg. C, the system shall be drained completely in hot condition to the effluent pit by opening all the drain valves .

 The drum surface shall be visually inspected for uniform smooth coating of protective layer. The low point header will be inspected and loose debris if any, will be removed

 Hot DM water flushings shall be drained into plant normal drain. The organic spent EDTA chemical solution after the cleaning process is drained into a pit. The pH of the effluent will be in the range of 8.5 to 9.0 and hence no treatment for pH adjustment is required as it would meet the pH requirement for disposal. Compressed air shall be used to destroy the residual Hydrazine & organics and the effluent shall be disposed after aeration for 10 days. (The organic chemical is completely bio-degradable).

 Lubricating oil system Seal oil system

Jacking oil system

Governing oil/ control fluid system

To clean and remove any foreign material from the oil system

 Completion of oil piping Installation of temporary piping after proper cleaning Cleaning of main oil tank and bearing pedestal Oil throttles in the bearing supply lines must be removed and dummy

provided
Duplex filter element in oil supply line to thrust bearing should be removed initially however it may be installed during final stage of flushing

Flushing devices are installed in the bearing pedestal to bypass the

bearings MOP must be removed and flushing device installed

 Jacking oil system is isolated and it should be flushed separately.

Turning gear nozzle box is removed and replaced with flushing

device. Suitable oil heating arrangement must be available to raise the oil temperature to around 75 C. Oil cooling arrangement should also be there to cool the oil for giving thermal shocks. Arrangement for analysis of oil sample should be available.

 Use of cotton waste is prohibited for cleaning the oil system. Markin cloth to

be used. For checking the direction of rotation of the oil pumps oil must be filled in the oil tank Provision must be made for stopping the oil pumps from local as well as from UCB Fire fighting arrangement must be available during flushing Arrangement for cleaning the spilled oil should be available before starting the oil flushing. Motor current of the oil pumps specially the auxiliary oil pump should not exceed the rated value.

 Oil flushing is considered complete when there is no mechanical impurities and traces of moisture as catched from oil sample. Duplex filter remains clean after 24 hours of flushing. Particle count is also some time used to declare completion of oil flushing.

Recommendation of turbine supplier should be a guiding factor.

After oil flushing the system is restored to original position.

All the temporary piping and flushing devices are removed.

All the orifices/ restrictions are restored. All instrumentation pressure, temperature ,flow devices etc. are normalized. Blanks installed during flushing are removed. Main oil tank is drained , oil tank cleaned and recharged with fresh oil . Bearing pedestals are cleaned before boxing up Coolers are normalized

 The function of barring gear is to rotate the shaft at low speed to remove the temporary bend during start up and after shut down to prevent hogging. Barring gear are :

Electric motor operated

Hydro motor operated Hydraulic barring gear All turbines have manual barring gear provision

Alignment of rotor train completed Rotors coupled Oil flushing completed Instrumentation inside the bearing pedestals completed. Bearing pedestals boxed up Generator work is completed and generator boxed up. Exciter is coupled. Insulation of generator bearing is checked before generator bearing

pedestal box up.

Condenser floated and joint between turbine and condenser made.

 Lube oil and seal oil system commissioned

Jacking oil pumps are available All the turbovisory , local and control room instrumentation are installed, calibrated and available for monitoring Interlock and protection for oil tank, oil pump and barring are tested and available Dc emergency power as well as DG set are commissioned and are available Shaft lift is checked in all the journals and is ok Direction of rotation of the shaft is checked.

ESTABLISH THE LUBE OIL SYSTEM ENSURE LUBE OIL TEMPERATURE AFTER OIL COOLER IS >35 C ENSURE PRESSURE IN ALL BEARING OIL SUPPLY LINE AND FLOW IS SITE GLASSES ENSURE PRESSURE IN SEAL OIL SUPPLY LINE AND FLOW IN SITE GLASSES. ENSURE DIFFERENTIAL PRESSURE REGULATOR IS FUNCTIONING. DC SEAL AND DC LUBE OIL PUMPS ARE ON AUTO START MODE AN CASE OF AC FAILURE SWITCH ON THE SUPPLY TO SUPPLY TO TURBOVISORY.

START JACKING OIL PUMP AND CHECK THE JACKING OIL PRESSURE AN ALL THE BEARINGS . TURN THE SHAFT MANUALLY WITH THE HELP OF MANUAL BARRING GEAR AND CHECK THE FREENESS OF THE SHAFT

MOTIVE OIL CAN BE ALLOWED TO ENTER BARRING GEAR WHEEL CHAMBER BY OPENING THE ELECTRICALLY OPERATED MOTIVE OIL VALVE
JACKING OIL PUMP IS KEPT RUNNING AS LONG AS SHAFT IS TURNING.

 ANY ABNORMAL IS NOISE IN THE TURBINE GLANDS OR BEARINGS.

RETURN OIL FLOW FROM THE BEARINGS AND TEMPERATURE OF OIL.

TURBOVISORY READINGS.
GENERATOR SEAL OIL TEMPERATURE AND LINER METAL TEMPERATURE. COSTING DOWN TIME FROM FULL BARRING SPEED TO ZERO

 MAIN STEAM COLD REHEAT

HOT REHEAT
HP BYPASS LP BY PASS AUXILIARY STEAM AND PRDS HEADER GLAND SEALING OTHER SMALL BORE LINES

The objective of steam blowing is to remove scales, loose material, iron cuttings etc, that might have been entrapped in Super Heaters, Steam piping, reheaters during manufacture, storage, erection at site. Failure to remove the debris may result in damage to turbine blades. Valves etc.

 The steam blowing is done in four stages. Viz Stage 1(1a,1b) Stage 2 (2a & 2b), Stage 3 (3a & 3b) & stage 4. Loop pipes from ESV and IV to turbine are to be taken care for cleanliness before erection and not to be steam blown. Steam blowing is carried out by adopting puffing method for stages 1a, 2a 2b,&3a,3b. in which, boiler pressure is raised to 40 Kg/cm2 and released through a quick opening valve and steam blowing done till the Drum pressure drops from 40 Kg/cm2 to 20 Kg/cm2 Steam blowing for stages 1b & 4 are carried out by continuous method. Steam blowing by continuous method shall be done at 4050% of normal operating pressure of the respective system for period of 20 to 30 minutes. Blowing repeated after a time gap of 2 Hrs.

 Stage1a: SH, MSL, ESV, temporary line from ESV to EOTV and EOTV to exhaust with temporary piping will be concluded by observing the indents on the target plate. Stage1b:SH,MSL,Aux PRDS, Atomizing Steam lines & FO heating/tracing lines. Stage 2a SH, MSL, ESV, temporary lines from ESV to EOTV, EOTV to CRH line, CRH lines up to boiler end with temporary exhaust pipe. Tap off lines from CRH for deaerator, , auxiliary PRDS, HP heater 6a & 6b, gland sealing, etc. shall be remain closed/isolated. Stage 2a end point will be concluded by observing the indents on the target plate . Stage 2b : 2a plus HP bypass inter connection, hand operated valve mounted in place of HP bypass valve and CRH lines up to Boiler end with temporary exhaust piping. In this stage 6 to 8 blows will be given through HP bypass to ensure cleanliness of the limb. Boiler MS stop valve will be used for stage 2b. EOTV will be kept closed. Manually Operated Isolation Valves in HP bypass lines will be kept opened fully. Stage 3a : 2a plus reheater, HRHL, IV and temporary pipe. CRH line along with attemperator shall be welded with reheater before start of stage 3a. LP bypass lines shall be blanked during stage 3a. Stage 3a end point will be concluded by observing the indents on target plates .

Stage-3b: Stage 3a plus LP Bypass lines. Stage-4 : 4a) APRDS to Gland seal steam 4b) CRH to turbine extraction line (HPHS &LPHS). 4c) CRH to Extraction 4 to Deaerator 4d) CRH to Deaerator / FST 4e) CRH to HP Heaters.

4f) CRH steam line to Turbine gland sealing line

4g) CRH to APRDS

 BLANKING DEVICES ARE INSTALLED IN TURBINE MAIN TOP AND CONTROL VALVES AND SIMILARLY IN ESV

TARGET PLATE IS INSTALLED BEFORE THE STEAM EXHAUST.

TEMOPORARY PIPING ARE ERECTED FROM MAIN STOP VALVE TO OUTSIDE BUILDING TEMPORARY PIPING ARE ERECTED FROM ESV TO OUT SIDE BUILDING ARRANGEMENTS ARE MADE TO BLOW COLD REHEAT PIPE LINE TOWARDS BOILER END LOOPS ARE ERECTED TO BLOW HP BYPASS AND LP BY PASS

TEMPORARY ARRANGEMENTS ARE MADE TO BLOW GLAND SEALING AND

OTHER SMALL BORE LINES

 The purpose of steam blowing of all critical piping, the steam blowing valve will be opened at 40 kg/Sq.Cm. and closed at 20 kg/sq.cm drum pressure. All the steam lines are purged as per various stages and it is a standard practice to limit number of blows per day to( 8-10) with an interval of 1-1 hours.

Blowing is carried out during the day and system is left cooling during night
While blowing stage 3a, suitable dummies will be put at LPBP outlet temporary line. Required flange provisions are made in these temporary lines for installation of dummies.

 All instruments coming in the steam flow are isolated or removed Temporary pipings are properly supported and insulated Steam exhaust is led to outside building to a safer place so as not to cause damage to equipment or person Steam blowing should be done preferably during day time due to noise pollution

Sufficient quantity of dm water is stored

 Steam blowing is considered complete when target plate remains clean (2-3) small dots in three consecutive steam blows after overnight cooling.

for stages 1, 2a, & 3a Disturbance factor value at selected locations should be greater than unity.
More than 5 (five) pitting and shall not have any deformed edges. Besides, there shall be no pitting in the rim zone, i.e., area other than central zone Gland steam and other small bore pipings are blown for 1-2 hours and blowing is terminated on visual operation

Disturbance Factor

Qb2 x Vb Q2 MCR x VMCR

Qb QMCR Vb VMCR Qb Where Qb

Steam flow during blowing Steam flow at MCR Sp. Volume of steam during blowing Sp. Volume of steam at MCR Sonic Velocity During blowing x Area x 1 Vb

St. flow in kg/sec KP Vb g Area Vb K P Vb g =M/sec = Sq.M = Cu.m/Kg = Constant = 1.3 = Pressure at the exit pipe = Kg/Sq.m = Sp. Volume =Cu.M/Kg = Acceleration due to gravity = M/Sec2

Sonic Velocity =

 After steam blowing the system is restored to original position.

All the temporary pipings and temporary supports are removed.

All the orifices/ restrictions are restored. All instrumentation pressure, temperature ,flow devices etc. are

normalized
Blanking arrangements are removed and valves restored . Blanks installed during steam blowing for system isolation are

removed and system normalized.

Remote trip from UCB Manual trip from local Low vacuum trip Low vacuum trip -hydraulic Low lube oil pressure Axial shift Over speed striker 1 and 2 Fire protection channel -1 Fire protection channel-2 MOT low level Low lub oil pressure Boiler fire out Main steam temperature low Generator protection

 Steam dumping is carried out before steam admission to turbine During steam dumping operation, quality of steam is improved by turbine supplier

HP/LP by pass system is used for steam dumping

Turbine is kept on barring gear

Full vacuum is raised

 Max flow is stabilized through HP/LP by pass with rated steam parameter. Steam dumping is carried out till quality of condensate at CEP discharge is same as inlet to hot well make up.

After steam dumping hot well, deaerator & Boiler drum are drained, clean and inspected before recharging.

 GE,s Super Critical/ Ultra Super Critical Steam Turbine. Recommended procedure for commissioning of large steam turbine by BHEL. Analysis of Supercritical technology in Indian Environment and Utilizing Indian coal by Prof: M M Hasan, Mechanical Engineering dept (Jamia Islamiya New Delhi) STEAM TURBINE DESIGN CONSIDERATIONS FOR SUPERCRITICAL CYCLES, Presented by Bechtel Power Corporation, Frederick. Bituminous coal fired large SC Power Plants for the European Market presented by Mr.K. Busekrus(HITACHI) ON 2007 Supercritical technology in Indian presented by NTPC Ltd.

S. No. 1.

Name/Location UMPP, Mundra

No of units 5

Capacity (MW) 800

Utility M/S. Tata power Ltd

2.
3. 4. 5. 6. 7.

UMPP, Sasan
UMPP, Krishnapatnam UMPP, Tilaiya UMPP, Orissa UMPP, Chatisgarh UMPP, Tamilnadu

6
5 5 5 5 5

660
800 800 800 800 800

M/S. Reliance Power Ltd

M/S. Reliance Power Ltd M/S. Reliance Power Ltd -

S. No. 1.

Name/Location Hissar

No of units 2

Capacity (MW) 660

Utility M/S. HPGCL

2. 3.
4. 5. 6. 7. 8.

Jhajjar Talvandi Sabo

Mundra, Kutch Meja-IV, Uttar Pradesh Sipat-I, Bilaspur New Nabinnagar, Bihar Krishnapatnam

2 2
2 2 3 3 3

660 660
660 660 660 660 800

M/S. HPGCL M/S. PSEB

M/S. Adani Power Ltd M/S NTPC Ltd Joint venture M/S NTPC Ltd M/S NTPC Ltd Joint venture M/S. APGENCO

S. No. 9. 10. 11. 12.

Name/Location Solapur Thermal Power Station, Maharashtra Barh Super Thermal Power Station Raghunathpur-II, West Bengal Gidderbaha Station-1, Punjab

No of units 2 3 2 2

Capacity (MW) 660 660 660 660

Utility M/S. NTPC Ltd M/S. NTPC Ltd. M/S. DVC M/S. PSEB

13.
14.

Shahpur Thermal Power Company Ltd

Jewargi Power Company of Karnataka Ltd

2
2

660
660

M/S STPCL
M/S Power Company of Karnataka Ltd.

S. No. 1. 2.

Name/Location Dhenknal, Orissa Pussurar Region, Raigarh Chhatisgarh Chutru Region of Jharkhand

No of units 2 3

Capacity (MW) 660 660

Utility M/S. Lenco Infratech M/S. Infrastructure Leasing & Financial Service Ltd. M/S. Infrastructure Leasing & Financial Service Ltd.

3.

660

4.

Gondia, Maharashtra

660

M/S. Adani Power Maharashtra Private Ltd

M/S. Infrastructure Leasing & Financial Service Ltd. M/S Ahtena Chhatisgarh Power Private Ltd.

5.

Chandil Region of Jharkhand Bade Dumarpali, Raigarh Chhatisgarh

660

6.

660

S. No.

Name/Location

No of units

Capacity (MW)

Utility

7.
8. 9. 10.

East Godavari, Kakinda

Sinnar, Nasik (Maharashtra) Nagapattinam, Tamilnadu Nandgaon pet, Amravati (Maharashtra)

2
2 2 4

660
660 660 660

M/S. Spectrum Power Generation Ltd

M/S. Fama Power Company Ltd M/S. PEL Power Ltd. M/S. Sophia Power Private Ltd.

11.
12.

Tamnar Raigarh, Chhatisgarh

Tamnar Raigarh, Chhatisgarh

2
2

660
660

M/S. Opelina Finance & Investment Ltd

M/S Jindal Power Ltd

S. No. 13. 14.

Name/Location Lathur, Maharashtra Machillipatnam, Andhra Pradesh

No of units 2 2

Capacity (MW) 660 660

Utility M/S. Amravati Thermal Power Ltd. M/S. Thermal Powertech Corporation(I) Ltd

15.

Gopuvanipalem, Krishna (Andhra pradesh)

Simar Thermal Power Plant, Junagarh (Guj.)

660

M/S. Nagarjuna Construction Company Ltd.

M/S. JSW Energy Ltd.

16.

800

17.

Salaboni Thermal Power Ltd, Paschim Midnapore

Manappad Tuticorin, Tamilnadu

800

M/S. JSW Energy Ltd.

18.

660

M/S Ind-Bharat Power (Madras) Ltd

S. No.

Name/Location

No of units

Capacity (MW)

Utility

19.
20.

Mundra, Kutch, Gujrat

Sompeta, Dirkakulam (Andhra Pradesh) Central India Power, Phase-II, Maharashtra Tanda Expansion, Uttar Pradesh Katwa, West Bengal Bakreshwar Extesion Project

3
3

660
660

M/S. Adani Power Ltd.

M/S. Nagarjuna Construction Company Ltd. M/S. Central India Power company Private Ltd. M/S. NTPC Ltd M/S. WPDCL M/S. WPDCL

21.

668

22. 23. 24.

2 2 1

660 660 660

S. No.

Name/Location

No of units

Capacity (MW)

Utility

25.
26. 27. 28. 29. 30. 31.

Koradi Extension Project Maharashtra

East Coast, Andhra Pradesh NSL Power, Tamilnadu Marakanam, Tamilnadu Darlipali, Orissa Lara, Chhatisgarh Kudgi, Karnataka

2
2 2 4 4 5 3

660
660 660 800 800 800 660

M/S. Mahagenco
M/S. East Coast Energy M/S. NSL Power Private Ltd M/S. NTPC Ltd M/S. NTPC Ltd M/S. NTPC Ltd M/S. NTPC Ltd. JV with M/S. PCKL