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Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-122 NTPC Ref no SIM/1/TS/2/122

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Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF HP HEATERS SLNO LIST OF CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 PLANT DETAILS OBJECTIVE PROPOSAL SERVICES REQUIRED SAFETY PRECAUTIONS EMERGENCY PROCEDURE STATE OF THE PLANT METHOD COMPLETION CRITERIA

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-122 NTPC Ref no SIM/1/TS/2/122

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Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF HP HEATERS SL.NO 1.0 PLANT DETAILS Regenerative Feed heating system of Simhadri STPP consists of one drain cooler, three LP Heaters one deaerator and four HP Heaters. There are two sets of HP Heater 5A/6A and 5B/6B. Extraction 5A and 5B are taken from IP Turbine casing. Extraction 6A and 6B are taken from CRH. The condensed steam after heating the Feed Water is normally fed to the next lower heater and emergency drains are provided to HP flash tank. The technical data for HP Heaters as follows. 1.1 HP Heater 5A and 5B Type : Shell and Tube Shell side Medium Design Pressure Design Temperature Test Pressure Test Temperature Inlet Temperature Outlet Temperature No. of. Passes No. of . Tubes Surface area Steam & Drain 2.2 and Full Vacuum 224 33 Ambient 412.583 170.2 3 1055 m2 Tube side. Feed Water 320 kg/cm2 224/244 deg C 480 kg/cm2 Ambient 165.5 deg C 203.3 deg C 2 1347

STATUS

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-122 NTPC Ref no SIM/1/TS/2/122

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Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF HP HEATERS SL.NO 1.2 HP Heater 6A and 6B Type : Shell and Tube Shell side Medium Design Pressure Design Temperature Test Pressure Test Temperature Inlet Temperature Outlet Temperature No. of. Passes No. of . Tubes Surface area Steam & Drain 52.4 and Full Vacuum 273 78.6 Ambient 335.25 253.1 3 1269 m2 Tube side. Feed Water 320 kg/cm2 273/293 deg C 480 kg/cm2 Ambient 203.27 deg C 191.927 deg C 2 1347

STATUS

2.0

OBJECTIVE To commission 2 sets of HP Heaters 5A/6A and 5B/6B and make them available for unit operation.

3.0

PROPOSAL Commissioning of two sets of HP Heaters proposed in the following steps.

3.1 3.2 Signatures

Commissioning of HP Heaters 5A and 6A Commissioning of HP Heaters 5B and 6B

NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-122 NTPC Ref no SIM/1/TS/2/122

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Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF HP HEATERS SL.NO 4.0 4.1 4.2 4.3 4.4 4.5 5.0 5.1 5.2 5.3 5.4 5.5 6.0 SERVICES REQUIRED Availability of manpower with required tools for attending any leak. Availability of operating personnel to carryout / coordinate activities. Availability of lighting arrangements and communication facilities in operating floors. Availability of instrument and service air. Availability of LT Power Supply. SAFETY PRECAUTIONS Debris in and around Heaters area shall be removed First aid kit is available near the test area. Approach / staircase / Platform wherever required are made available. Safety appliances like helmet, hand gloves available for operating personnel. Portable fire extinguisher available near test area. EMERGENCY PROCEDURES The test team should be aware of the procedure to be adopted in case of damage to machinery / injury of any personnel connected to the activity. Signatures NTPC

STATUS

BHEL

Station: NTPC - Simhadri Plant Area: TURBINE

BHEL Ref No. PS - DC - 186 500 122 NTPC Ref No. SIM / 1 / TS / 2/122

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Testing Schedule: TESTING SCHEDULE FOR COMMISSIONING OF HP HEATERS STATUS 6.1 The test team should be aware of the procedure to be adopted in case of damage to machinery / injury of any personnel connected to the activity. The test team should be well aware of the procedures to be adopted in case of any abnormality in the activity. STATE OF THE PLANT HP Heaters 5A, 5B, 6A and 6B are erected as per recommended drawing. Detergent flushing of feedwater piping, Heater drain piping are complete and normalised (including erection of control valves) All piping supports are loaded with spring loads to recommended values. HP Heaters Stand Pipe, Level transmitters, Level switches and Level gauge glass are erected. Startup and continuous vent line with orifice are erected. Insulation of HP Heaters, Feed water piping, Extraction steam piping, extraction drain piping, Shell vent piping and heater drain piping are complete.

6.2 7.0 7.1

7.2 7.3 7.4

7.5 7.6

Signature NTPC BHEL

Station: NTPC - Simhadri Plant Area: TURBINE

BHEL Ref No. PS - DC - 186 500 122 NTPC Ref No. SIM / 1 / TS / 2/122

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Testing Schedule: TESTING SCHEDULE FOR COMMISSIONING OF HP HEATERS STATUS 7.7 Commissioning of following valves associated with the system are complete (a) Extraction isolating valves (b) Extraction steam drain valves (c) Heaters start up vent valves (d) Feedwater isolating valves and group bypass valves for the heaters. (e) Heaters drain control valves. Extraction oil relay for QCNRV of extraction piping are set to operate at recommended secondary oil pressure. Simulation checking of all interlocks and protections are complete. Feed water charged to all Heaters and BFP in service All local and remote instrumentation of heaters complete. METHOD Commissioning of HP Heaters 5A and 6A Ensure Feed water charged to HP Heaters 5A and 6A, its bypass isolation closed. Ensure isolating valves of drain control valves are open. Ensure level switches, level transmitters and level gauge glass are charged. Ensure extraction oil relay in governing rack is set to operate at required secondary oil pressure.

7.8 7.9 7.10 7.11 8.0 8.1 8.1.1

8.1.2 8.1.3 8.1.4

Signature NTPC BHEL

Station: NTPC - Simhadri

BHEL Ref No. PS - DC - 186 500 122 NTPC Ref No. SIM / 1 / TS / 2/122

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Plant Area: INSTRUMENT / EQUIPMENT Testing Schedule: ELECTRONIC MODULE OF DDCMIS 8.1.5 Ensure isolating valve in oil line for QCNRV is open and its slide valve in open position. Open shell side start up vent for HP Heater 5A and 6A. Ensure interlock in ATRS for solenoid valve A5 are available and checked. Ensure the following interlock protection for any one of Heaters 5A, 6A level very high. (a) Closure of Extraction steam valves for the HPH bank (HPH 5A and 6A) (b) Opening of extraction line drain valves (c) Bypassing of HPH bank on feed water side (d) Opening of emergency drain control valve to flash tank 8.1.9 8.1.10 8.1.11 8.1.12 Ensure turbine load more than 40% Keep feed water valves on auto. Charge extraction steam to HPH 5A gradually with drain control valve to flash tank (emergency drain) in open position. As the heater shell pressure increases more than deaerator pressure, open drain control valve to deaerator (normal drain). Build up heater level to normal operating level and ensure control valve operation on auto. Observe temperature raise in feed water outlet of heater. Close startup vent of HPH5A and keep continuous operating vent in open condition.

8.1.6 8.1.7 8.1.8

8.1.13

8.1.14 8.1.15

Signature NTPC BHEL

Station: NTPC - Simhadri Plant Area: TURBINE

BHEL Ref No. PS - DC - 186 500 122 NTPC Ref No. SIM / 1 / TS / 2/122

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Testing Schedule: TESTING SCHEDULE FOR COMMISSIONING OF HP HEATERS 8.1.16 Monitor and record the following parameter at various load/full load (a) Extraction pressure (b) Extraction temperature (c) Heater shell pressure (d) Drain temperature (e) Feed water inlet temperature (f) Feed water outlet temperature (g) Heater level (h) Swing check NRV flap positions (i) Heater level control valve positions Charge HPH 6 A with extraction steam gradually. Build up HPH 6A level to normal level with normal level controller. Keep the emergency controller on quto Monitor and record all parameters at various load/full load for HPH 6A as done for HPH 5A. Ensure Heater levels maintained are mentioned in drawing Refer drawing no. 21750100579 Refer drawing no. 21750100580 Refer drawing no. 21750500348 Refer drawing no. 21750500349 in line with the levels HPH 5A HPH 5B HPH 6A HPH 6B

8.1.17 8.1.18 8.1.19

8.1.20

8.2.

Commissioning of HP Heaters 5B and 6B commissioning of HP Heaters 5B and 6B is carried out in the same way as done for HP Heaters 5A and 6A.

Signature NTPC BHEL

Station: NTPC - Simhadri Plant Area: TURBINE

BHEL Ref No. PS - DC - 186 500 122 NTPC Ref No. SIM / 1 / TS / 2/122

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Testing Schedule: TESTING SCHEDULE FOR COMMISSIONING OF HP HEATERS 9.0 9.1 COMPLETION CRITERIA Commissioning of HP Heaters completed by carrying out the proposals given in Section 3.0

Signature NTPC BHEL

TESTING SCHEDULE FOR COMMISSIONING OF HP HEATERS