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PROJECT: PROBLEM:

EID PARRY, PUDUKKOTTAI - 1x18.55 MW TG POOR VACUUM DURING INITIAL COMMISSIONING

STG supplied by BHEL, Hyderabad at EID, Parry, Pudukkottai is having air cooled condenser, which is supplied by M/s Paharpur Cooling

Towers. Air evacuation system consists of one starting ejector and two main ejectors. Vacuum pulling was carried out on 19/03/06. Even after admission of turbine sealing steam, maximum vacuum of 0.5 kg/cm2 could only be achieved. Two minor leakages were identified at turbine side and nothing was reported from air-cooled condenser side. But the air flow from main ejector exhaust was more than 60 kg/hr. Motive steam supply pressure at ejector inlet was 5.5 kg/cm2, against design pressure of 8 kg/cm2. The steam supply line is of 2 inch size. It was decided to increase to 3 inch size. After increasing the line size, rated steam pressure at ejector inlet was maintained. The leakages at turbine side were arrested. Vacuum of 0.8 kg/cm2 was achieved. However the air exhaust remained high (above 55 kg/cm2).

With condenser vacuum of 0.8 kg/cm2 it was decided to roll the machine. While rolling to first warming up speed of 1000 RPM, vacuum has fallen to 0.78 kg/cm2 and stabilised. After two hours of warming up, speed was raised to second warming up speed of 4000 RPM. While holding at 4000 RPM, vacuum started deteriorating and within 20 minutes, the vacuum dropped to trip level of 0.55 kg/cm2 and unit tripped. The air evacuation system and condenser were studied. The following are the observations made: 1. There are 6 cooling fans in total to cover all the segments of condensor. The air evacuation lines for the main ejectors are from the condensor drawn from all segments. All the cooling fans are necessarily to be run enabling steam entered to get condensed at all sections. The speed of fan can be adjusted, as they are variable frequency driven. Earlier they were running only three fans. It was decided to start all the fans. 2. The air evacuation line for the starting ejector is drawn from the condensate collecting tank (Hotwell). Condensate collecting tank is connected to the turbine exhaust with an isolation valve, which was open. This has caused the exhaust steam to directly flow in to the condensate tank, thereby heating the condensate. After rolling to

4000 RPM, the condensate temperature was 65 deg C. This high condensate temperature influenced poor performance of the main ejectors. Also, the starting ejector removing only the exhaust steam directly bypassing condensor. Hence it was decided to keep the valve in the line between turbine exhaust and condensate tank closed, before rolling. 3. Also, as the temperature of condensate was high, it was decided to replace the total DM water in the condensate tank with fresh water. The schematic arrangement of condensor and air evacuation system are as shown in the enclosed figure. After carrying out the above changes in the operation of condenser and air evacuation system, unit was rolled to rated speed of 5650 RPM. It was running at rated speed for electrical tests for more than 12 hours, without disturbance in the vacuum. Subsequently, the machine was loaded upto 2 MW. Vacuum dropped upto 0.77 kg/cm2 on loading the machine. Further for improving the vacuum, air ingress in the air-cooled condenser is to be identified and arrested, which is planned by customer in the shutdown in first week of April 2006.

EID PARRY CONDENSOR AND AIR EVACUATION SYSTEM

A IR C O O L E DC O N D E N S O R

COOLING FANS

TURBINE CCT/HOTWELL

STARTING E J E C T O R

C E P THIS VALVE CLOSED

MAIN EJECTOR

T OG S C