Reflection of the achievements..

EDITORIAL COMMITTEE ISSUE NO. 06 AUG 2010

Sh. R L RANWAS Sh. S N MAITI

INSIDE TITLE PAGE 1 2 6

EDITOR Sh. TARSEM LAL

MESSAGE FROM GM(TSX&SAS) GLIMPSES OF SITES CONTACTS & FEEDBACKS ISSUE SPECIAL ALL VOLATILE TREATMENT OF BOILER Mr. Dinesh Jawade Email: djawade@bhelpswr.co.in MESSAGE FROM GM (TSX) Phone: 0712 3048660 Mobile: 09423680639 37 FEEDBACKS 13

The statements and views expressed in this Magazine are entirely those of authors and not necessarily that of the Organization.

Cover photograph: Power Plant, NTPC, Korba

PUBLISHED BY TSX/PSWR FOR INTERNAL CIRCULATION ONLY

MESSAGE FROM GM (TSX & SAS).......

Dear Colleagues,

I am very much delighted to present you the sixth issue of Takniki Darpan, the technical magazine published by PSWR, Nagpur. So far, we have covered variety of topics starting from tube mill, CFBC boilers to renewable energy and many more to come in the forthcoming issues. Sharing of experiences and knowledge by means of various feedbacks will not only avoid recurring problems but also expand the knowledge base of every engineer working in power plant, which will result in time saving. However, in spite of knowing all these, we are not sharing the feedbacks amongst us as there was no proper forum available. Routinely, we face many problems and also resolve them at site level, but the same is not communicated to others. I request each individual to spare fifteen minute time daily and make a habit to record these problems in daily diary which will become consolidated feedback from each individual. And now, these feedbacks can be shared to the larger section of the engineers through Takniki Darpan. Hence, once again I request you to generously share the feedbacks, even if it is very small in nature, so that everybody in BHEL will get benefited.

With warm regards and best wishes.

R. L. Ranwas General Manager (TSX & SAS) BHEL, PSWR (HQ) Nagpur

TECHNICAL SERVICES, BHEL-PSWR

GLIMPSES OF THE SITES

STATUS OF THE SITES UNDER COMMISSIONING: 1. NSPCL BHILAI (2 x 250MW ) Unit No.01: A. At present, unit is running at various loads depending on load requirement and coal availability. B. PG Test of TG completed. Unit No. 02: A. At present, unit is running at various loads depending on load requirement and coal availability. B. PG Test of TG completed on 05/08/2010. 2. TATA TROMBAY (1 x 250MW) A. PG Test of Boiler, TG and ESP completed. B. At present, unit is running at various loads depending on load requirement and coal availability. 3. MAHAGENCO PARAS (1 X 250MW AND 1 X 250MW Extn.) Unit No. 02: A. Synchronisation with coal firing done on 18 Feb 2010. B. Unit achieved full load on 27th Mar 2010. C. Unit is generating around 200 MW load. D. BFP hydraulic coupling bearing temperature rise problem resolved. E. Turbine oil cooler bypassing problem resolved. F. Unit is under trial operation. 4. PARLI (1 X 250MW AND 1 X 250MW Extn.) Unit No. 01: A. Unit is running smoothly at full load with CMC in service. Unit No. 02: A. Unit achieved full load on 10 Feb. 2010. B. Major pending points like commissioning of STLD system, UCP, Sensors of smart wall blowers, Auto-synchronizer, LSR, all printers, ATRS completed during the shutdown. C. Unit running at 250 MW load with CMC in service. D. Trial operation, Completed on 30 July,2010.
TECHNICAL SERVICES, BHEL-PSWR GLIMPSES OF THE SITES
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E. PG test preparation under progress. 5. IOCL, BARODA (2X33 MW) Unit No. 01: A. FSNL achieved on 10.08.2009. B. Unit synchronised on 08.10.2009. C. HRSG hydro test completed on 15.10.2009. D. HRSG ABO achieved on 04.01.2010. E. Safety valve floating completed on 13.02.2010. F. Full load achieved on 30/03/2010. Unit No. 02: A. FSNL achieved on 30.03.2010. B. Unit synchronised on 31.03.2010. C. Unit under shut down for attending the pending works. 6. KUTCH LIGNITE (1 X 77MW) A. PG Test preparations under progress. B. Pending points are being attended. 7. SULEMANIYAH, IRAQ (4 X123MW, FR9) Unit No 04: A. Unit Synchronised on 26 Feb. 2010. B. Reliability run test completed successfully on 28th Mar. 2010. C. Representatives of PSWR visited to attend pending points. 8. SLPP MANGROL (2 X 125MW PHASE II) Unit No. 03: A. Unit achieved full load on 12 Apr. 2010. B. Unit in running at 100 to 125 MW load. Unit No. 04: A. Unit synchronised on 25 Mar 2010. B. Achieved full load on 23 Apr 2010. C. Presently, unit is running at 120 -130 MW.
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9. MAHAGENCO BHUSAWAL (2 X 500 MW) Unit No.4 : A. Drainable hydro test completed on 31/03/2010. B. Stator lifting and placement completed on 27.07.2010. TG alignment in progress C. Station transformer is ready for charging. D. ESP/VFD area tray work and cabling in progress E. Installation of SPBD and Tie bus duct under progress F. Installation of DCS panel in control room completed. Milestones Planned: G. Start up power commissioning by 20.08.2010. Critical Pending Issues: H. SPBD Materials from BHEL Rudrapur. I. TG packages from Hardwar. J. Critical customer inputs like, AC PCR, AC VFD CR, FOPH to boiler pipe rack, Boiler o/L to ESP duct foundations, ACW/CW pump house building, Boiler to TG cable tray interconnections, PCR to ID fan area pipe rack with trays etc. 10. MAHAGENCO KHAPERKHEDA (1 X 500 MW) A. Station Transformer-5B was charged on 12/04/10 at 18:38 hrs & kept charged for 24 hrs on no-load condition. B. VFD Panels & VFD Transformers have been erected. C. Dry Type Transformers, LTMSB, ACP & Electronic Control Panels for ESP have been erected. D. Soot Blower MCC has been erected. E. Control Panels of Control Equipment Room like STRP-A/B, GRP & DAVR have been erected. F. All the control panels of Control Equipment Room have been erected except Gravimetric Feeder Panels- 2 nos., Gen. End Winding Vibration Panel. G. Cabling of HT SWGR to MAX DCS has been completed. H. Cabling of MTM T/C is in progress. MTM pads are being welded by Boiler Mech. JB's have been erected. I. Cabling of Drum Vents MOVs is in progress. J. Max DCS panels of FOPH/CWPH have been erected. K. UPS, ACDB & Batteries have been erected. L. 24 V DCDB have been erected & Power cabling for one source has been done for all the max DCS panels. M. Lub oil flushing of ID, FD & APH completed.

TECHNICAL SERVICES, BHEL-PSWR

GLIMPSES OF THE SITES

11. NTPC KORBA-7 (1 X 500 MW) A. Boiler lighted up on 28 Feb 2010. B. EDTA cleaning completed on 31 Mar 2010. C. Detergent flushing of boiler feed system completed on 26th Apr. 2010. D. Steam blowing completed 4th Aug., 2010. 12. BORL, Bina Unit No. 1: A. Rolling of the turbine achieved on 09/07/2010. B. Dynamic testing of Generator completed on 09/07/2010. C. Electrical overspeed of turbine demonstrated. D. Major problem with Generator Transformer attended. E. Dead bus synchronization of the Unit achieved on 29/07/2010. F. Turbine rolling problem has been attended. G. Coal Firing of Unit 1 planned by end August, 2010. Unit No. 2: A. Turbovisory work completed. B. All turbine auxiliaries remote trial with interlocks completed. C. Turbine put on barring gear on 31/07/2010. D. Dead Bus synchronisationcompleted on 15 Aug. 2010. Critical Issues : 1. Instrumentation cables from BHEL, Hyderabad. Unit No. 3: A. 2 MVA station Auxiliary transformer (TR-64) has been charged. B. Cooling tower motors testing has started.
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TECHNICAL SERVICES, BHEL-PSWR

GLIMPSES OF THE SITES

ISSUE SPECIAL ALL VOLATILE TREATMENT OF BOILER BOILER OPERATION WITH AVT & CWT
Sh. V. NAVANEETHAKRISHNAN UCM / BHEL Site, NTPC KORBA INTRODUCTION: Modern thermal power plants, stressing on higher availability, higher reliability, optimal operation & maintenance costs, enhanced life of boiler pressure parts and ease of operation, advocate for stringent boiler water chemistry during operation. Also the feed water chemistry maintained during the plant operation determines the amount & type of deposits inside the boiler tubes, which determines the post operational chemical cleaning and the intervals of cleaning. These necessitated the discontinuance of coordinated phosphate treatment for Boiler water chemistry and advent of All Volatile Treatment of Boiler water for sub-critical & super critical cycles plant operation. Also combined water treatment (CWT), a philosophy of treating the condensate with CPU and boiler water with oxygen dosing, is also emerging as an improved method for better life cycles of all pressure parts in the plant. Research and studies are continuing regarding the influence of water chemistry over the deposits and life of pressure parts of thermal power plants all over the world. BHEL has supplied first time units operating on Oxygenated Water Treatment mode (2 X 250 MW) to NSPCL, BHILAI. PROJECT DESCRIPTION: BHEL has executed 2 X 250 MW power project at BHILAI for NSPCL, a joint venture power utility of SAIL and NTPC on EPC basis except CHP and Switch yard. Salient features of the Boiler and Plant are, Type: Fuel: Raw water: PT Plant: DM water: Feed water: CW system: Natural Circulation, Radiant Reheat, Tangential firing, Single Drum, Dry bottom & Balance draft furnace Pulverised coal Chlorination treatment Chlorination, Liquid Alum & Poly Aluminium Chloride treatment in Clarifuculator RO plant Liquid ammonia and Oxygen treatment with Condensate Polishing Unit Chlorination, Sulphuric acid and Scale-inhibitor dosing

DMCW system: Caustic Lye treatment Potable water:Hypochlorite treatment BOPs: AHP: : ETP & STP: MRS: PLCs linkage with main Control Room by Optical Fibre Cabling Dry fly-ash handling with pressurized air conveying Furnace bottom with HP water seal & wet ash handling system Ash water recovery system and plant waste water treatment Pneumatic pressurized conveying system
ISSUE SPECIAL - ALL VOLATILE TREATMENT OF BOILER

TECHNICAL SERVICES, BHEL-PSWR

DESCRIPTION OF AVT & CWT: All Volatile Treatment is the method that keeps dissolved oxygen close to zero and suppresses corrosion of tubes. Removal of dissolved oxygen in the boiler feedwater is done by dosing hydrazine at the CEP discharge and by deaeration before the suction of BFPs. For maintaining pH of Boiler water, ammonia is dosed in the condensate discharge, contrast to the conventional phosphate dosing in the boiler drum. Combined water treatment is the process of dosing ammonia to maintain boiler water pH and dosing of oxygen in very small quantity (5 ppb to 20 ppb approx. & 50 ppb max. in a week) to achieve Hematite layer inside the tubes. For Boiler operation with AVT / CWT, high purity of condensate, feedwater & Boiler water, for which CPU is provided in the scheme. CWT adopted for thermal power plant gives hematite layer inside the tubes, which is flat and dense, compared to the conventional magnetite layer which is undulated. And the solubility of hematite is extremely small compared to magnetite, which contains relatively large magnetic particle causing undulation scale formation on the surface of the metal. Also during Boiler operation with CWT, the scale generating speed on tubes comes down to half of other treatments, which results in lesser post operational chemical cleaning activities. However for operating the unit on CWT, high purity of water to be maintained which involves stringent measures and close monitoring of SWAS parameters along with the operation of CPU. The operation loss of thermal plant on account of tube failures, chemical cleaning etc are reduced to the tune of 20 to 95 % by adopting CWT. Controlling the drum silica is done by the operation of CPU in the CEP discharge line. If the CPU is not ready / commissioned, Boiler water silica levels are controlled by the operation of CBD from Drum, leading to wastage of boiler water and additional make-up of DM water. In the absence of CPU in service in the condensate line for controlling silica, lot of DM water about 200 M /Day is being used as make up to the system due to operation of drum CBD, in BHILAI units. Also liquid ammonia being dosed in the system for maintaining the pH of water. However for units designed for Oxygenerated treatment in feed system, Hydrazine dosing is not recommended for removing dissolved oxygen. Only ammonia dosing for pH correction and Deaeration are recommended for unit operation which is called AVT (O), being followed in BHILAI.
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THE PARAMETERS TO BE MAINTAINED IN UNIT: Following are the parameters to be monitored and maintained during unit operation with AVT (O), I Demineralized water (at DM Plant outlet)

Parameters 1. Specific conductivity (micromhos/cm) 2. Specific conductivity (micromhos/cm) at storage tank outlet (including CO2) 3. Silica (as SiO2, ppm) 4. Na + K , ppb, max 5. TOC (ppb, max) 6. Oxygen
TECHNICAL SERVICES, BHEL-PSWR

Values 0.15 (Max) 1.0 (Max) 0.02 (Max) 5 (Max) 300 (Max) Saturated
ISSUE SPECIAL - ALL VOLATILE TREATMENT OF BOILER

II Feed water quality- AVT (O) 1. conductivity (micromhos/cm) after cation exchanger 2. Specific conductivity (micromhos/cm) 3. pH at 25 deg C 4. Silica (as SiO2, ppm) 5. Iron as Fe, ppb 6. Oxygen (ppb) 7. Chloride (as Cl, ppb) 8. Sulphate (as SO4, ppb) III Boiler water quality - AVT (O) 1. pH at 25 deg C 2. Cation conductivity (micromhos/cm) 3. Silica (as SiO2, ppm) 4. Chloride (as Cl, ppb) 5. Sulphate (as SO4, ppb) 6. Oxygen (as O, ppb) (Note: as measured at downcomer) IV Saturated steam quality- AVT (O) 1. Conductivity (micromhos/cm) after cation exchanger 2. Silica (as SiO2, ppb) 3. Sodium (as Na, ppb) V Superheated steam quality- AVT (O) 1. Conductivity (micromhos/cm) after cation exchanger 2. Sodium (as Na, ppb) 3. Silica (as SiO2, ppb) 4. Iron as Fe, ppb 5. Chloride (as Cl, ppb) 6. Sulphate (as SO4, ppb) VI Condensate quality Hotwell outlet 1. Cation conductivity (micromhos/cm) 2. Silica (as SiO2, ppb) 3. Oxygen (ppb) 4. pH 5. Iron (as Fe, ppb)
TECHNICAL SERVICES, BHEL-PSWR

0.20 (Max) 4.0 - 11.0 9.2 - 9.6 0.02 (Max) 20 (Max) 10 (Max) 3 (Max) 2 (Max) > 8.5 1.5 (Max) 0.13 (Max) 30 (Max) 30 (MAX) NIL 0.20 (Max) 20 (Max) 5 (Max) 0.20 (Max) 5 (Max) 20 (Max) 20 (Max) 3 (Max) 2 (Max) 0.20 (Max) 20 (Max) 10 (Max) 9.0- 9.6 20 (Max)

ISSUE SPECIAL - ALL VOLATILE TREATMENT OF BOILER

ANALYSIS OF SAMPLES OF UNIT OPERATION: Following pictorials illustrate the Fe pick up by the feed water at various locations of the Regenerative cycle in the powerplant operation. It is clear that without CPU, the Fe concentration in the operating system sample is more at all locations, from CEP Dischrge to turbine inlet. AVT with & without CPU

AVT with & without CPU II

TECHNICAL SERVICES, BHEL-PSWR

ISSUE SPECIAL - ALL VOLATILE TREATMENT OF BOILER

LIMITS OF DRUM PRESSURE: Following graphs depict the limits of drum pressures during unit operation with respect to the silica, chlorides and sulphate values from the samples of Boiler water.

Control of Silica in Boiler Water under AVT (O)

TECHNICAL SERVICES, BHEL-PSWR

ISSUE SPECIAL - ALL VOLATILE TREATMENT OF BOILER

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Control of Sulphate in Boiler water under AVT (O)

Control of Chloride in Boiler water under AVT (O)

TECHNICAL SERVICES, BHEL-PSWR

ISSUE SPECIAL - ALL VOLATILE TREATMENT OF BOILER

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CONCLUSION: Thermal power plants operating on Supercritical cycles and Once through Boilers are generally operating on AVT mode / Oxygenerated treatment, as the Turbine operating parameters need strict control on steam purity for safety of turbine blades and boiler tubes. However plants operating on subcritical cycles also can operate with AVT / Oxygenerated modes that provide high steam purity for better operating conditions like lower silica levels and lower deposits in tubes. But the operation and monitoring of Steam and water samples at all locations in the Regenerative cycle to be done religiously for achieving the results.

Mr. V. Navaneethakrishnan has joined in BHEL Trichy in May 1982 as Chargeman in QC department of Boiler and auxiliaries with DME. He has completed AMIE (I) in 1983 in mechanical branch and joined as Engineer in PSWR in Jan 1989 at KHAPERKHEDA Turnkey project as Boiler Commissioning Engineer. He has completed MBA (HR) from IGNOU New Delhi in 1993 and now presently working as UCM at 1 X 500 MW NTPC Korba unit 7

TECHNICAL SERVICES, BHEL-PSWR

ISSUE SPECIAL - ALL VOLATILE TREATMENT OF BOILER

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FEEDBACKS Tata Power Trombay U#8 1 X 250 MW FLUE GAS DESULPHURISATION PLANT
Shri. V.K. Jhade Manager, Khaperkheda

TECHNICAL SERVICES, BHEL-PSWR

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TECHNICAL SERVICES, BHEL-PSWR

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3. Equipment for FGD: Type 1) 2) 3) 4) 5) 6) 7) 8) 9) BOOSTER FAN BUF Control oil pump BUF Seal air fan Sea water/booster pump Aeration fan GGH GGH seal air fan GGH SOOT blower GGH H.P & L.P. Pump Working+ Standby one two one+one two+one two one one one one+one one+one

10) Seal air fan for inlet damper

Equipment Details 1. Booster fan Capacity Efficiency Power consumption 2. Sea Water pump Capacity Head Efficiency Power consumption Sea water consumption Scrubbing Mixing & aeration Service water consumption
TECHNICAL SERVICES, BHEL-PSWR

626890 m3/hr 80% 1125 kW 3600 x 2 m3/hr 14 m 85% 320 kW 7200 m /hr 6200 m3/hr 20 m3 /hr
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4. OPERATIONAL PARAMETERS OF FGD BOOST UP FAN FAN BRG. TEMPERATURE BEARING ROOM TEMP HYDRAULIC ACTUATING ROOM TEMP DE BRG. 1&2 TEMPERATURE NDE BRG. 1&2 TEMPERATURE MOTOR BRG. TEMPERATURE MOTOR WDG. PHASE 1,2,3 TEMP FAN HOUSING VIBRATION MOTOR I/B & O/B BRG. VIBRATION BUF LO PRESSURE BUF RUNNING & SEAL AIR PRESSURE BUF CURRENT SEA WATER BOOSTER PUMP:PUMP DE BRG. VIBRATION PUMP NDE BRG. VIBRATION MOTOR I/B BRG. VIBRATION MOTOR O/B BRG. VIBRATION PUMP DE BRG. TEMPERATURE PUMP NDE BRG. TEMPERATURE MOTOR I/B BRG. TEMPERATURE MOTOR O/B BRG. TEMPERATURE MOTOR WDG. TEMPERATURE PUMP RUNNING & DV CLOSED SCAVENGING LOW LEAKAGE FAN SWBP CURRENT SWBP FLOW EACH NORMAL 45 45 50 45 45 50 60 0.5 1 5 3 75 NORMAL ALARM 3.2 2.74 4 3.5 45 46 45 46 70 OPEN 50 20 3600 <3000 <2000 >90 >4.4 >4.4 >4.4 >4.4 >80 >80 >80 >80 >105 TRIP >8.8 >8.8 >8.8 >8.8 >90 >90 >90 >90 >110 TRIP >100 DEGC AMPERE M3/HR. >10S ALARM >80.0 >80 >80 >80 >80 >80 >105 >9.6 >9.6 <2.50 <2 TRIP >90 >90 >90 >90 >90 >90 >110 >12.6 >12.6 <1.50 <2 UNIT DEG C DEG C DEG C DEG C DEG C DEG C DEG C mm/S mm/S Bar KPA AMPERE UNIT mm/s mm/s mm/s mm/s DEG C DEG C DEG C DEG C DEG C TIME DELAY >10S >10S >10S >10S >10S >10S >5S >5S >5S >30S. >10S TIME DELAY >10 S >10 S >10 S >10 S >10 S >10 S >10 S >10 S >10 S >30 S >4 HRS.

TECHNICAL SERVICES, BHEL-PSWR

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LOGISTICS SEAL AIR FAN:-- I/L DAMPER CLOSED, I/L DAMPER SEAL AIR VALVE OPEN, ALL SEAL AIR FAN STOPPED.:--- AUTO START. I/L DAMPER OPEN & I/L DAMPER OF SEAL AIR FAN CLOSED & FAN RUNNING <3 S----- FAN STOP. QUENCHING PUMP:- BLOWER O/L AIR TEMPERATURE >50 DEG C, AUTO PUMP A START COMMAND OR >60S, PUMP B START. BLOWER O/L AIR TEMPERATURE <45 DEG C AUTO STOP COMMAND. AERATION BLOWER PARAMETERS TO BE MONITORED FROM LOCAL. GGH ROTATION:GGH LP SOOT BLOWING SEQUENCE.:1. Direction ------- Clockwise o.k. 2. Inverter#1------ Current (Amps) Frequency/Speed. High Speed 18 51.2 Hz/3 RPM. Low Speed 13.6 13 Hz/0.75 RPM. 3. Inverter#2------- Current (Amps) Frequency/Speed. High speed 14.7 51.2 Hz/3 RPM. Low Speed 13.6 12.8 Hz/0.75 RPM. 1. Service water pressure at inlet header: - 2.3 Bar. 2. LP wash Pump discharge at inlet of lance: - 6Bar. 3. Dwell time for LP wash: - 80Sec. 4. Fluid on position: - 1069mm. 5. Full length of travel: - 3807mm. 6. Stepping Distance covered: - 45mm. 7. Acid time:- 300sec. 8. GGH Speed: - 0.75 RPM. NOTE:- SOOT BLOWING SEQUENCE IS SAME. Manual operation for GGH both Jet Blowers done. Advance position--- anticlockwise, Retract positionclockwise GGH MONITORING PARAMETERS GENERAL DATA Gas Reheater Size:- 26.5 GVN 600 Element Details:- 600mm Decarburised Steel, HS8e, 0.75mm thick + 0.3mm enamel Flow Arrangement:- Untreated Gas Down/Treated Gas Up. Sealing Surface Top Sector Plate: Fixed clearances from Rotor Axial Seal Plates: Fixed clearances from Rotor Bottom Sector Plate: Fixed clearances from Rotor Rotor Seals set to suit rotor thermal deformation. Drive Motors Drive 'A': 15kW Electric motor with inverter drive Drive 'B': 15kW Electric motor with inverter drive Reduction Gear:Helical Gear Unit Ratio: 486.219/1 (Electric Drives) 379.405/1 (Air Drive) Couplings:- Pinflex PF2BB6
TECHNICAL SERVICES, BHEL-PSWR SITES FEEDBACKS

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Rotor Speed:- Normal Speed 3.0 R.P.M. Nominal Slow Speed:- 0.5 R.P.M. Nominal Bearing Lubrication:- Oil bath for both rotor bearings. Top Steady Bearing 15 litres. (approx.) Bottom Support Bearing 30 litres. (approx.) Grade ISO VG 1000 Synthetic (Mobil SHC639 or equivalent) Gearbox Lubrication:- Oil bath for both Primary and Secondary Units. Cleaning Devices:- Two-off fully retractable Jetblowers. Location - One in each untreated gas duct. Medium - UTG Inlet:- Steam / HP / LP Water UTG Outlet:- Steam / HP Water STEAM :Available steam supply pressure:20.6 bar g. Operating pressure :8 bar g. No. of Nozzles :- 6 Operating flow :- quantity per lance 3600 kg/hr Rotor speed - 3.00 R.P.M. Frequency :- Every 8 hours initially. Final frequency to be determined by operator experience at site

HP WASHING:- Hot End Cleaning Device (Untreated Gas Inlet Duct) Cold End Cleaning Device (Untreated Gas Outlet Duct) - On Load Cleaning Medium :- Cold Water. Pressure at Inlet Flange :100bar g. No. of Nozzles :- 6 Water Consumption/Lance 5.7 m3/hr Rotor speed :- 0.5 R.P.M. Frequency :- When normal sootblowing cannot maintain pressure drop below 1.5 times clean rotor value. LP WASHING:- Hot End Cleaning Device (Untreated Gas Inlet Duct) Off Load Cleaning Medium :- Cold Water. Pressure at Inlet Flange - 5 bar g. No. of Nozzles :- 6 Radial Coverage :- 3098 mm (approx.) 3 Water Consumption/Lance :- 39.6 m /hr Rotor speed :- 0.5 R.P.M. Frequency :- As found necessary with boiler off load.
TECHNICAL SERVICES, BHEL-PSWR SITES FEEDBACKS

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RATING ARE AS:- DESIGN/MAX/50%TMCR MAX/50%TMCR MIN.

Rotation Speed rpm:- 3.00 /3.00/ 3.00/ 3.00 Flow Quantities per Boiler (kg/hour) Untreated Gas In 808690/808690/491200/491200 Untreated Gas Out 824818/824130/503226/503746 Treated Gas In 817491/817919/503830/497030 Treated Gas Out 832951/832951/513294/506408 Treated Gas Recycled Purge 18801/18319/11994/12052 Treated Gas Recycled Scavenge 12788/12154/9618/9752 Total Stack Flowrate 801362/802478/491682/484604 Leakage per Boiler (as % of Untreated Gas Inlet Flow) Untreated to Treated Gas Leakage 0.46 /0.44 /0.49 /0.51 Temperatures (C):Untreated Gas In 135.0/ 155.0/ 123.0 /123.0 Untreated Gas Out 79.3/ 97.0/ 80.4/ 74.1 Treated Gas In 30.0/ 46.4/ 45.8/ 33.6 Treated Gas Out 85.2/ 103.9/ 87.8 /82.8 Pressures (mm Wg):Untreated Gas Side Pressure Drop 55.5/ 59.1/ 39.0/ 38.6 Clean Plate Treated Gas Side Pressure Drop 47.2/ 50.5/ 34.9/ 33.6 Clean Plate Untreated to Treated Gas Differential Hot End:- 285.0/ 285.0/ 190.0/ 190.0 Untreated to Treated Gas Differential Cold End:- 182.2/ 175.3/ 116.2/ 117.8 Treated Gas Composition (% by volume):Nitrogen 71.946/ 71.946/ 72.298/ 76.028 Oxygen 4.400/ 4.400/ 5.860/ 6.170 Carbon Dioxide 13.400/ 13.400/ 12.080/ 12.710 Sulphur Dioxide 0.004/ 0.004/ 0.002/ 0.002 Water Vapour 10.250/ 10.250/ 9.760/ 5.090 Density at NTP kg/m:- 1.3076/ 1.3076 /1.3029/ 1.3288
TECHNICAL SERVICES, BHEL-PSWR

RATING ARE AS:- DESIGN/MAX/50%TMCR MAX/50%TMCR MIN.

Rotation Speed rpm:- 3.00 /3.00/ 3.00/ 3.01 Flow Quantities per Boiler (kg/hour) Untreated Gas In 808690/808690/491200/491201 Untreated Gas Out 824818/824130/503226/503747 Treated Gas In 817491/817919/503830/497031 Treated Gas Out 832951/832951/513294/506409 Treated Gas Recycled Purge 18801/18319/11994/12053 Treated Gas Recycled Scavenge 12788/12154/9618 /9753 Total Stack Flowrate 801362/802478/491682/484605 Leakage per Boiler (as % of Untreated Gas Inlet Flow) Untreated to Treated Gas Leakage 0.46/ 0.44/ 0.49/0.52 Temperatures (C):Untreated Gas In 135.0/ 155.0/ 123.0 /123.1 Untreated Gas Out 79.3/ 97.0/ 80.4/ 74.2 Treated Gas In 30.0/ 46.4/ 45.8/ 33.7 Treated Gas Out 85.2/ 103.9/ 87.8 /82.9 Pressures (mm Wg):Untreated Gas Side Pressure Drop 55.5/ 59.1/ 39.0/ 38.7 Clean Plate Treated Gas Side Pressure Drop 47.2/ 50.5/ 34.9/ 33.7 Clean Plate Untreated to Treated Gas Differential Hot End:- 285.0/ 285.0/ 190.0/ 190.1 Untreated to Treated Gas Differential Cold End:- 182.2/ 175.3/ 116.2/ 117.9 Treated Gas Composition (% by volume):Nitrogen 71.946/ 71.946/ 72.298/ 76.029 Oxygen 4.400/ 4.400/ 5.860/ 6.171 Carbon Dioxide 13.400/ 13.400/ 12.080/ 12.711 Sulphur Dioxide 0.004/ 0.004/ 0.002/ 0.003 Water Vapour 10.250/ 10.250/ 9.760/ 5.091 Density at NTP kg/m:- 1.3076/ 1.3076 /1.3029/ 1.3289
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5.

Permissive and protection Tank oil level Tank oil temperature Control oil pressure Lube oil pressure Bearing temperature Control blade adjustment Impeller blade position Discharge damper/ate Fan motor Protections Fan bearing temperature Fan vibration Delta P across oil filter Lube oil pressure low Control oil pressure low Oil level in the tank low FGD First up sequence Boiler air flow should not be ID fans should run 2/3 Sea water pump should run FGD inlet temperature GGH should run Sea water flow BUF not trip FGD not trip GGH First up. Electrical no fault Low speed should not trip Inlet/Top/Bottom temperature should be low Alarm >95deg Celsius >4.5mm/s >5 bar <4 bar <14 bar <50%

Start permissive of booster fan >50% >25 deg Celsius >20 bar >4 bar <95 deg Celsius manual close close on Trip >105deg Celsius 9mm/s

<560 T/hr

< 180 deg Celsius > 6600 m /hr

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TECHNICAL SERVICES, BHEL-PSWR

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Booster fan first up sequence Motor NDE,DE Vib not high Fan housing vibration not high Lube oil pressure not low Outlet damper open Inlet damper open Seal pressure not < 4 bar Motor bearing temperature not high Booster fan bearing temperature not high FGD PG TEST FGD PG test was carried out after completion of Boiler and TG PG test. FGD PG Test was delayed due to non availability of CW Pump as well as low suction pressure and insufficient water flow through FGD booster pumps. (Sea water flow at Booster pump inlet is 5800m3/hr against design rated flow is 7200m3/hr) Booster pump inlet connection is given at condenser CW outlet pipe. With mutual agreement between BHEL and TATA POWER, FGD PG Test carried out as it is condition at unit full load 250 MW. FGD PG test carried out on 25/03/10 from 1500 hrs to 1800 hrs at unit full load 250MW. SO2 measured at inlet of FGD is 50.7ppm and at FGD outlet 4.4ppm. As per test reading FGD SO2 removal efficiency is more than 90% as design guaranty value is 90%.

Mr. VIRENDRA KUMAR JHADE obtained B.E. Degree in Mechanical Engineering from Government College of Engineering and Technology, Raipur (Ravishankar University). He joined BHEL Power sector western region as Engineer Trainee in 1997. He has worked in Technical services department in the area of Boiler commissioning. He has wide experience in various types and capacity of boiler commissioning like CFBC, AFBC, PURVERISED FUEL FIRED, STROKER BOILER etc. He is working as MANAGER, Technical Services, Boiler commissioning department.

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GENERATOR AIR LEAK TEST

OBSERVATIONS:

Shri. S. Mandal AGM (TSX), Paras Site

During first synchronization of Paras-II, the air leak test value could not be achieved to below < 0.3 2 2 kg/cm in 24 hrs with test air pressure of 4.0 kg/cm . Subsequent to the synchronization, the air leak test was repeated and some more leakages were found in the end seal area (along the bolts) and in some pipe 2 weld joints. Even after attending those, the leak test value could not be brought down below 0.24 kg/cm in 24 hrs. It was a constant drop of 0.02 kg/cm2 per hr. ACTIONS: Following operation points were also scrutinized but did not result any improvement in the leak test value: Seal oil DP- The DP was reduced from 1.7 kg/cm2 to 1.3 kg/cm2 without any result. Generator gas temperature variation during day and night- Even after taking temperature correction, the result was not within the permissible limit ( max 0.05 kg/cm2) After lot of brain storming, it was found out that there was air leakage in the diode wheel area. This meant that the leakage was from the CC (current carrying) bolts of exciter. Considering that it was a new generator, any leakage in the CC bolt area was not anticipated . The matter was referred to BHEL/Hardwar for necessary action. BHEL/Hardwar technician team with required spares ( O-ring and adhesive), visited site and replaced the damaged /under size O-rings below the seal plate and around the CC bolts mating surface with seal plate to attend to the problem.

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FRF AND LUB OIL MIX UP

OBSERVATION:

Shri. S. Mandal AGM (TSX), Paras Site

Before start of control fluid flushing, air leak test of control fluid lines was done. For conducting the air leak test, other than many dummies, one dummy was put in the drain line of the governing rack (ref fig-1 below). Lub oil system flushing was completed and system was in service with fresh oil. Oil accumulation in the governing rack header was noticed. ACTION: Since the FRF system was not started, the source of oil was lub oil only. After careful tracing, it was confirmed that the oil was coming from the vent line of the primary oil line. As per the scheme, in case of FRF as control fluid and lub oil for turbine bearings, the primary oil line vent in the governing rack is connected into a separate header which was terminated to the lub oil drain header. In this case, it was observed that there was an extra vent line (see fig-1 & 2 below) other than the designed one. This vent was connected back in the governing rack header.

Fig -1

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Fig -2

The extra drain was cut at both ends and dummied. Thus a great trouble of mix up of lub oil with FRF was avoided

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IP CASING TOP BOTTOM DIFFERENTIAL TEMPERATURE

OBSERVATION: Shri. S. Mandal AGM (TSX), Paras Site

During checking of HPT and IPT casing top and bottom temperature thermocouple, following observations were made. HPT top thermocouple depth (L & R )- 100 mm HPT bottom thermocouple depth ( L & R ) 100mm IPT top thermocouple insertion depth (D), ( L & R ) - 20 mm /20 mm IPT bottom thermocouple insertion depth( D), (L & R ) - 35 mm/35mm ACTION : As per the drawing (0-10601-18000), the depth of IPT top and bottom thermocouple depth from casing surface is to be same. As per the above data, the depth from the outer surface of the casing to the bottom of the hole was 35 mm in case of the bottom temperature thermocouple and the same for top temperature one was 20 mm. Since there was variation observed in the measured values of IPT top bottom thermocouple depth, the matter was referred to BHEL/Hardwar. As advised by Hardwar, the top side hole depth was increased by 15 mm to make it equal to that of the bottom ones.

Four thermocouples( two at top & two at bottom)

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TECHNICAL SERVICES, BHEL-PSWR

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WATER ACCUMULATION IN THE GLAND STEAM LEAK OFF LINE TO GSC

Shri. S. Mandal AGM (TSX), Paras Site OBSERVATION: During first synchronization of Paras-II, the gland steam leak off line to GSC and GSC vapour lines were not fully ready (ref fig-1). So as a alternative, system lineup was made as per the enclosed valve position. Vacuum was pulled and dumping activity started. After completion of dumping, before start of rolling, it was noticed that there was no steam coming out of the leak off line exhaust. ACTION: The gland steam supply valve to the GSC (MAW80AA001) was opened and lot of water gushed out from the U-loop drain. The piping was laid as per the scheme ( 2-13100-29121) and in the scheme, the U-loop drain was envisaged after the isolating valve(MAW80AA001). This layout defeats the draining of condensation under the above mentioned line up. The matter was referred to BHEL/Hardwar for changing the U-loop position from downstream of isolating valve to upstream position. Such layout was already envisaged in 500MW set ( as enclosed). With the concurrence of Hardwar, the U-loop position was changed.

Scheme as was given in the drawing

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Mr. S. Mandal graduated in Mechanical Engineering from Jadavpur University, Kolkata in 1984. Mr. Mandal joined BHEL in 1984 as engineer trainee and was posted in TSX dept. He has 24 years of rich experience in Steam and Gas Turbine commissioning. At present he is working as Additional General Manager in TSX dept at Paras site.

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REPORT ON EBFP FAILURE

DESCRIPTION:

Shri. Preetham V. Engineer (TSX), Mangrol Site

The EBFP is provided in CFBC boiler for the purpose of maintaining the drum level in case of emergency during boiler operation. The pump provided is driven by a diesel engine, which can be run through a remote command from the control room. The main purpose of the pump is to avoid starvation of water in the boiler tubes in case of an emergency i.e. blackout condition. START PERMISSIVES: The pump does not have any start permissive. START CONDITIONS: 1. Combustor lower temp. greater than 450 0C AND all BFP's off for more than 5 seconds. 2. Combustor lower temp. greater than 450 0C AND black out condition with no delay. 3. Boiler Protection-1 acted and combustor lower temp. greater than 450 0C and all BFP's off for more than 5 seconds OR Black out condition with no delay. The EBFP has no direct tripping command from control room all the tripping to this pump are from local panel of this pump. The conditions in which the pump will trip are as below :1. Lube oil header pressure very LOW. 2. Deaerator level very LOW. 3. Engine local panel tripping incorporated for engine safety. 4. Bearing temperature very HIGH (Gearbox bearings at 1100C, Pump bearings at 900C) not in service due to customer requirement. CHRONOLOGICAL ORDER OF EVENTS ON 02/06/2010 UNIT #4 SLPP MANGROL: 14:58 15:21 15:22 15:33 15:40 Unit #4 tripped on drum level very high. BFP- A tripped on suction pressure low, the deaerator level observed at this time was (-) 1230 mmWc. EBFP got start command from control room. EBFP started (Fig. 1). EBFP tripped. Engine was tried to start from local panel. Since deaerator level, lube oil pressure and bearing temperature were normal, it resulted in burning of one of the terminals of the battery bank. Pump and engine were decoupled and found that pump was seized.

17:45

OBSERVATIONS: 1. The EBFP was run on auto mode as soon as the running BFP in the unit tripped. 2. There was no flow observed in the feed control station of the boiler. 3. The mechanical seal of the pump has got damaged.
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4. The pump discharge pressure was decreasing gradually, when the pump was running in minimum re-circulation. 5. The suction pressure of the pump decreased to 0.46 kg/cm2 when the deaerator level was (-) 758mmWc (Fig. 2 in increasing trend) whereas the tripping of the pump is at (-) 1600mmWc. 6. There may be some vapour formation in the deaerator as pegging of deaerator was cut off and water temp and pressure in the deaerator was gradually coming down. 7. May be the balance leak off does not provide any circulation when the pump is not in service, which may lead to uneven expansion in the pump impeller and casing. 8. The suction strainer of the pump was cleaned on 31/05/2010 and pump was run for 5 mins on 01/06/2010. Later on inspection of suction strainer, it was found clean and had no damage. ACTION SUGGESTED: 1. The pump should be tripped on low suction pressure also. 2. The pump may be provided with a warm up line from the feed water line, which would keep the pump ready for running any time. In existing units (1&2), the EBFP's have warm up line with a motorised isolation valve.

Fig. 1
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Fig. 2

Mr. Preetham completed his B.E. in Mechanical from National Institute of Technology Karnataka, Surathkal in May 2005. He completed a project on Low temperature Rankine Cycle in 2005. Mr. Preetham Joined BHEL on 13th july 2005. Since 2006, he is working as a Boiler Commissioning Engineer. Worked in Dabhol project in 2006, later in MPPGCL Birsinghpur 500MW till 2009 and presently working in SLPP Mangrol 2x125MW CFBC.

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FEED BACK ON LP TURBINE INNER-INNER COMPENSATOR BELLOWS FAILURE AT KSTPS UNIT-1, 200 MW TG SET NTPC KORBA
V.Veerapandi Sr.Manager/ Ser BHEL-PSWR Nagpur E-mail :vpandi@bhelpswr.co.in INTRODUCTION: NTPC KSTPS 200 MW KWU design Unit-1 TG set was commissioned on 28/02/1983. The machine had completed around 1,95,925 running hours till this shut down. Unit was withdrawn on 02/04/10 due to LP inner-inner compensator bellow failure. The major activity of LPT rotor replacement and LP casing compensator replacement were carried out during this overhauling. This article covers observations, action taken and sequential procedure for LP casing inner-inner to inner outer compensator bellows replacement . OBSERVATIONS DURING LOAD: Heavy abnormal sound was observed from LP Turbine during machine was on full load. IPT exhaust steam temperature observed as 2900C. IPT exhaust steam pressure observed as 5.0 Kg/cm 0 LPH2 outlet temperature observed as 80 C. The heavy sound on LP Turbine and low pressure in IP exhaust line clearly indicates the bellow failure in LP inner-inner compensator. The Failure was occurred in the month of December 2009 and BHEL advised NTPC to replace the compensator immediately to avoid major damages. Due to non availability of spares at site, NTPC run the machine with bellow failure condition for four months. OBSERVATIONS AFTER DISMANTLING OF LP TURBINE: The following observations were made after dismantling of LP Turbine. th th Deep dent / bend and cut marks was observed on the leading edge of all the blades of 6 & 7 stages of Moving & Guide blades at both Turbine & Generator sides Last stage (8th ) blades leading edge around 100-150 mm in length at both sides found heavy erosion marks and light dent marks. Dent and bend marks on Moving & Guide blades

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COMPENSATOR BELLOWS AND THEIR SUPPORTS LP inner-inner to inner outer compensator bellows at right side found missing and the broken bellow pieces are passed through extraction line. Broken pieces of inner-inner to inner outer compensator bellow were found in between inner-inner and inner outer casing and LP Heater No.2 inlet line.

COMPENSATOR BELLOW FAILURE ANALYSIS LP inner-inner casing bottom half was removed after cutting of both side inlet pipes. Inlet steam pipes and their supports were thoroughly inspected. During inspection of right side inner compensator, a long crack was observed from the longitudinal weld joint of bellow protection pipe. The inlet steam flow was directly hit on the compensator bellow through the cracked portion of protection pipe and it lead to failure of bellow. ACTIONS TAKEN: Damaged LP Rotor was replaced by new rotor . MPI & NFT of last stage free standing blades. LP inner-inner to inner outer compensator bellows (Dn 800) on left & right sides (2 Nos) were replaced. LPH3 ( A3) bellow ( 1 No.) was replaced. COMPENSATOR BELLOW REPLACEMENT PROCEDURE : 1. Removal of outer protection cover of outer compensator bellow between Girder & inner outer casing on both side. 2. Cutting /Grinding of outer protection cover support ring on both sides. 3. Cutting/ Grinding of flange weld joint with the inner-inner compensator on both sides.
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4. Cutting and pushing the inner protection pipe of outer compensators towards Girder side of the steam inlet pipes at both end to facilitate the outer compensator removal . 5. Cutting and taking out of outer compensator (Dn 800) bellow (between Girder & inner outer casing ) on both sides. 6. Cutting of lip joint between inner-inner casing and the inner-compensator on both sides. 7. Pushing the inner-inner compensator (Dn 800) towards outer compensator bellow end on both side to facilitate lifting of inner-inner bottom casing. 8. Recording the axial & radial position of inner-inner casing. 9. Recording of elevation readings of the inner-inner casing at the four palm. 10. Removal of eccentric bushes & axial keys of the inner-inner casing. 11. Cutting of A3 (LPH3) compensator (Dn 400) joint between inner-inner casing & inner outer casing connected to A3 Extraction pipe line below the inner-outer casing 12. Removal of bottom half of inner-inner casing. 13. Placement of both side inner-inner compensator bellow into the outer casing steam inlet pipes after edge preparation at both sides. 14. Placement of inner-inner casing bottom half in position. Assembly of eccentric bushes & axial keys and align the inner casing by radial /axial direction w.r.t original reference. 15. Alignment and preparation of the lip joints on both sides. 16. Placement of T/H of inner- inner casing & inner outer casing and tightening of the alternate bolts after properly locking the inner-inner casing w.r.t inner-outer casing. (This is to be done to eliminate any distortion during the welding of pipes). 17. Placement of inner protection pipe (new one) of outer compensator bellow and pushing towards girder end to facilitate final placement of outer compensator. 18. Placement of outer compensator in position at both sides, align the outer compensator with innerinner compensator & steam inlet pipe at both sides with proper welding gap. 19. Welding of inner compensator at both sides at a time with two welder. 20. Welding of outer compensator at both sides at a time with two welder. 21. Alignment and welding of inner protection pipe of outer compensator. 22. Preparation and welding of the joints of the inner compensators with the flanges in the steam inlet pipes of outer casing on both sides. 23. Fitting ,alignment and welding of support ring of outer protection cover on both sides. 24. Assembly of outer protection covers of outer compensator bellow. 25. Taking out top halves of inner-outer and inner-inner casings after completion of welding. 26. All butt joint root welding by TIG (TGS1CM) and Arc welding by E7018. Radiography to be conducted in all butt joint and 100% DPT for all other joints.
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LP INNER INNER & INNER-OUTER COMPENSATOR ARRANGEMENT (RIGHT SIDE)

Protection cover Support ring

LP Inner -outer casing

Outer protection cover Inner protection pipe Inner protectio n pipe

LP Inner-Inner casing

STEAM FLOW

Inner-inner compensator Lip Joint

Outer compensator

Erection Joint

Erection joint

Flange connected to outer casing A3 compensator

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Inner-inner compensator placement

Inner-inner Bottom half placement

Inner inner Bellow Fit up

Rotor placement

PARAMETERS AFTER RECTIFICATION : 1. IPT exhaust steam temperature 2. IPT exhaust steam pressure 3. LPH2 outlet temperature

- 316 C. 2 - 7.0 Kg/Cm . 0 - 85 C.

CONCLUSION: The replacement of inner compensator bellows at both side and LPH3 (A3) compensator bellows by lifting of inner casing bottom half, LP turbine overhauling work along with LP rotor replacement including honing /reaming of IP/LP & LP/Generator coupling were carried out within the contract schedule period of 20 days. BHEL-PSWR SAS has adopted innovative techniques, strategies to meet the scheduled deadlines. Mr. V. Veerapandi graduated in Production Engineering from Regional Engineering College at Trichy in the year 1988. Mr. Veerapandi joined BHEL Trichy in the year of 1988 and was transferred to PSWRSAS Services in 1991. Since then he is responsible for Overhauling, Trouble shooting and Servicing works of Steam Turbines of various ranges up to 500MW .
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AND THE LAST PAGE

Dear Friends,
This is a special issue on latest techniques to be adopted for boiler water treatment. As you are aware, within next two to three years all our commissioning engineers shall be handling super critical units where all drum type steam generators shall be replaced with once thru boilers. Quality of feed water requirement for all once thru boilers shall be most stringent & require a totally different approach for online treatment. All volatile treatment (AVT) which is a must for all once thru boilers shall not be able to take care of residual hardness present in feed water since boiler water pH will be maintained by Ammonia solutions instead of conventional coordinated phosphate treatment. Hence for taking care of all residual hardness, commissioning of condensate polishing unit is must right from initial stages for safe & reliable operation of the plant. Apart from AVT treatment ,there is a totally new concept of Oxygenated treatment(AVTO) of feed water cycle where O2 is injected into the feed cycle for transformation of scale from magnetite to hematite & protective hematite layer thus formed reduces the rate of scale formations by almost 50%. It is also claimed that Oxygenated treatment reduces the frequency of post operation chemical cleaning considerably. Is not it thrilling? All along, we have concentrated on removal of oxygen from feed cycle to minimize corrosion. Hence we all must try to understand the chemistry of oxygenated treatment. This new technique of boiler water treatment is envisaged in NSPCL Bhilai drum type boilers. Therefore understanding of the entire operation philosophy & all sorts of post operational feed backs shall be very much useful to all of you. Overall we are in receipt of lot of feed backs from all our site engineers in different areas of operations. Due to space constraint all feed backs /write ups are not included in this issue. However, we assure you that all valuable feed backs shall be published in the next issue of Takniki Darpan. I would once again emphasize that the future of BHEL lies on quick adoption of latest technologies & exploring the alternatives by out of box thinking with respect to time cycle reduction in all our processes. This is possible by improving Core Competencies of each & every individual in all fields of operation. With best wishes to all of you,

S N Maiti General Manager (TSX), BHEL, PSWR (HQ), Nagpur.

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BHARAT HEAVY ELECTRICALS LIMITED

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