ara edt sAfigord es [#8 Bharat Heavy Electricals Limited AKNIK] Diane ” Rottctn 6 —_—— BHEL PSWR DABHOLa@eitel advr Reflection of tha achievements. EDITORIAL COMMITTEE ISSUE NO. 01 MARCH 2009 1 Sh. RLRANWAS INSIDE Sh. SN MAITI Te PAGE EDITOR MESSAGE FROM ED (PSWR) 1 Sh. TLAL MESSAGE FROM GM(TSX&SAS) 2 CONTACTS & FEEDBACKS GLIMPSES OF SITES 3 FEEDBACKS 6 ‘Ms. Neha Baghel Email: nehab@bhelpswr.co.in ee a DABHOL PROJECT Phone: 0712 3048622 Mobile: 08860803261 MESSAGE FROM HEAD (TSX) 37 PUBLISHED BY TSX/PSWR FOR INTERNAL CIRCULATION ONLYMESSAGE from ED (PSWR)....... It gives me great pleasure to bring out the First Edition of “aestteh air’ from Power Sector Western Region. | am confident that this endeavour shall provide a successful platform to share the knowledge and information among all the employees of this region as well as entire BHEL and all the young engineers shall derive maximum benefit out of this publication. | convey my best wishes and success to the entire team for this, publication. With best wishes, Anil Aurangabadkar Executive Director PSWRMESSAGE FROM GM (TSX & SAS). | am very happy to note that BHEL PSWR has brought out the first edition of “warttal afer” in order to share the knowledge and experience of the field engineers with others. For the last few years BHEL PSWR has remained in number one slot with respect to total MWs commissioned in comparison to other regions. Naturally, the field engineers have a vast repertoire of experiences that can be shared and harnessed by others for the benefit of the organization. There is a Chinese saying that a thousand mile journey starts with a single step. I have no doubt in my mind that this small beginning will one day grow into a large collection of feedbacks and knowledge for the benefit of all the power engineers. My best wishes for the success of “warftataxfor’. R. L. Ranwas General Manager(TSX & SAS) PSWRGLIMPSES OF THE SITES .. ‘STATUS OF THE SITES UNDER COMMISSIONING: 1. BHILAITPS Unit No.01: * Synchronized with Coal firing on 05/01/2009. © FullLoad (250 MW) achieved on 18/01/2008. * Commercial Operation of the unit has been declared. © Unitis running at around 200MW Load. Unit No. 02: © Steam blowing activity started on 28/01/09. «Station Transformer charging done on 30/01/09. © Turbine hasbeen put on barring gear on 10” March 2008. 2. TROMBAYTPS © Machine synchronized on 14.01.09, © Machine kept in continuous load operation immediately after first synchronization from 14.01.09 (19.00 Hrs)to 17.01.09 (21.00Hrs).. © Hon. Cabinet Minister of State (Energy), Govt. of India, Shri. Jairam Ramesh and Maharashtra State Energy Minister Shri, Sunil Tatkare inaugurated the plant and declared successful synchronization 0 17.01.09. © Coalfiringhas been done 10” March 2009 3. PARASTPS Unit No.01: © Unitsynchronized on 31/08/2007. © Coal firing achieved on 21/10/2007. © Fullload achieved on 10/03/2008. Trialrun operation completed successfully on 26/12/2008. © Unitisrunningat full load. © PGtest preparation under progress. Unit No. 02: © Boiler hydraulic test completed on 18/02/2009. 4. PARLITPS Unit No. 01: © Unit synchronized on 16/06/2007 © Commissioning of CMC including all major auto loops completed. » ATTof HP/IP stop valves and safety devices demonstrated © ATRS demonstrated and turbine is being rolled in ARTS up to synchronization. ‘(WITECHNICAL SERVICES, BHEL-PSWR GLIMPSES OF THE SITES© BFP autostand by pickup demonstrated © Unitisrunningonfullload Unit No. 02: © Boiler hydraulictest completed on 18/02/2009. © maxDNA Panel erection under progress 5. JPLRAIGARH Unit No. 01: © Unitsynchronized on 02/09/2007. Trial run operation completed on 11/01/2008. PG Test completed on 27/11/2008. ATRS demonstrated. CMCandall the auto loops commissioned and unit is running in CMC. Unitis running atfull load. Unit No. 02: Unit synchronized on 06/03/2008. Trial run operation completed on 15/07/2008. © CMCandall the auto loops commissioned and unit is running in CMC, © Unitis running at full load. Unit No. 03: © Unitsynchronized on 10/02/2008 © Trialrun operation completed on 25/05/2008. © PG Test completed on 19/10/2008. © ATRS demonstrated. ATT of HP/IP stop valve and safety devices demonstrated. © CMCandall the auto loops commissioned and unit is running in CMC. © Unitis runningat full load. Unit No. 04: © Unitsynchronized on 17/06/2008. © Trialrun operation completed on 31/12/2008. ATRS demonstrated ATTof safety devices commissioned. CMCandallthe auto loops commissioned and unit in-operation with CMCin service. Unitis running atfull load. 6. NTPCVINDHYACHAL Unit No. 09: © Optimization of auto loops including CMC completed. © LAN/WAN Network under commissioning. ‘(WITECHNICAL SERVICES, BHEL-PSWR GLIMPSES OF THE SITES ..© Unitisrunningat full load. Unit No. 10: © Optimization of auto loops including CMC completed © LANAWAN Network under commissioning. © Unitisrunningat full load. 7. NTPCRIHAND Unit No. 03: © Preparation of PG test of ESP under progress. Unit No. 04: © PGtest of ESP has been completed on 10" March 2009, 8. BIRSINGHPUR TPS © Unitsynchronized on 18/06/2007. © Trialoperation completed on 03/12/2008. © CMCandall majorauto loops commissioned. © Unitis running at 360-400 MW due to shortage of coal. 9. HZLZAWAR © Unitsynchronized on 22/11/2008. © Coal firing done on 02/12/2008. © Fullloadachieved on 12/12/2008. © Trial operation completed on 15/12/2009. © Unitisrunningat fullload. 10. KUTCH LIGNITE © Boilerlight up achieved on 29/03/2008. © Unit synchronized on 22/10/2008, © SAfan, NMEJand Coal size problem to be attended. 11. SULEMANIYAH Unit No. 01: © Erection of TCC, Mark-VI, GRP, HMI Panels completed and commissioning under progress. © Erection/commissioning of MCC, 125 V Batter charger, 230 V UPS completed. © Erection of GCB, 6.6 kV switchgear, GT/UAT protection panels and auxiliary service boardcompleted. © Erection of IP Bus duct, main GT transformer, UAT transformer under progress. Unit No.02: © Erection of TCC, Mark-VI, GRP, HMI Panels completed and commissioning under progress. © Erection of MCC, 125 V Battery chargers, 230V UPS fire fighting panel completed. See ‘(UITECHNICAL SERVICES, BHEL-PSWR ‘GLIMPSES OF THE SITES =FEEDBACKS .. CLINCKER FORMATION IN BOILERS: TWO CASE STUDIES Background Recently clinker formation problem was reported in some of the recently commissioned 500 MW /250 MW boilers like JPL Raigarh, Bakreshwar, SGTPS Birsinghpur and NTPC Ramagundam. The problem has also been highlighted by Ministy of Energy, Government of India. A detailed joint study of the problem have been conducted at SGTPS Birsinghpur and JPL Raigarh by BHEL Trichy, PSWR and the respective customer. In this article, we look into the basics of Clinker formation in Boilers of 250MW and SOOMW capacity. The recommendations made by BHEL Trichy after looking into the causes of Clinker Formation at 4x250 MWJPL Tamnar and 1x 500MW SGTPS Birsinghpur is also included for information and use. Introduction Ashis the non-combustible mineral residue that remains after the fuel has been thoroughly burnt. During the combustion process, the combustible portion of the fuel is consumed and the non-combustible ash remains in place. As the process continues, the ash residue is subject to certain degree of shrinkage. This shrinkage results in portion of ash fusing together and forming more or less fluid globules or slag and this process is known as slagging. The percentage of shrinkage increases with rise in temperature and is maximum around 1250 Degree Centigrade. Under the proper temperature conditions, the fluid slag globules can solidify and form clinkers in the furnace or deposit on the heating surface of the furnace (Boiler. Due to high presence of Iron and Sulphur in coal, Iron Sulphide formation takes place during combustion. The iron sulphide has low fusion temperature and this leads to formation of globules. Similarly the presence of Aluminum Oxide (A\,0,) also lowers the fusion temperature of ash helping in formation of linkers. The different type of clinker formation such as prorous, black, dark brown or light brown depends on the presence of non-combustible material such as Silica (SiO,), Aluminum Oxide (AI,O,, and Iron Oxide (Fe,0,) contentin coal When molten ash particle, transported by updrafts collides into the furnace wall, a slag deposit is formed Alternatively, ifthe heat transfer surface is covered with a molten sticky slag layer then itis highly probable that ‘dry’ ash particle will also adhere to the surface. Asintered deposit can also form when particles at high temperature impact on heat transfer surfaces. Different approaches can be used to predict the clinker/slagging propensity of a fuel. The common approach is to measure ash deformation temperatures under reducing and oxidising conditions or to use the numerous slagging indices which are available and are based on the acid (Si02, Al203) to base composition (Ca, MgO, K,0, Fe,0, and Na,O) of theash, Case Studies: A) SGTPS, Birsinghpur Unit5, 500 MW The Boiler tripped on 8.3.08 at 04.30 Hrs on flame failure with furnace pressurization beyond 500 mmWC and steam explosion in Bottom Ash Hopper (BAH). Subsequent investigation revealed that the Bottom Ash Hopper was filled with clinkers upto S panel top and seal plate and seal trough of BAH got damaged in front side of BAH. It took almost 4 weeks to bring back the unit. No pressure part was found damaged during the Boiler inspection and hydraulic testing was done after repair in BAH The Boiler is designed for the worst coal with GCV of 3150 Kcal/Kg (ash 45.6%) (MITECHNICAL SERVICES, BHEL-PSWR ‘SITE FEEDBACKS ..‘The followings are the reasons and recommendation: AA) The Probable Reasons: BAH improper evacuation with possibility of more ash collection. © The Bottom Ash Hopper evacuation frequency was inadequate. 6to8 Hrs interval was there during the period 6.3.08 to 8.3.08 instead of 4 Hrs interval between two successive evacuation) © The BAH evacuation effectiveness was not ensured. The view glasses available in the left & right and the openings were closed with dummy plate. It is to be used for ensuring the effective evacuation. © Even though wall soot blowers were commissioned in the end January, 2008, it was put on regular operation from the end February, 2008 after raising the load beyond 400 MW (The load was restricted at 420 MW due to ICT maximum loading). The coal firing is being done since end Sep, 2008 for the last 5 months and the deposit accumulated over the period might have dislodged during the Wall soot blowing time in the March, 08. It could have resulted in accumulation of ash/clinker in BAH, in case of inadequate evacuation. © The unit got tripped twice (3.3.08 &5.3.08) on Flame failure and normally, the tripping had resulted incollection of ash in BAH. Worst of worst coal (higher ash %) usage at Higher load © Inthe end of February, 2008, the load was raised beyond 400 MW © Theground stocks were used till the end of February, 2008 and its likely to have more ash content. © The fresh coal lot from rack was used in Boiler from 28.02.08. The ash content was as high as 52% {Air dried basis) instead of design coal of 44% ash (as received basis) in the sample collected at the time of mishap. Itis likely that the ash collection in BAH was on higher side. © The Mill rejects system is notin service. The hot air is continuously blowing out in the rejects ast is, permanently kept open. Mill rejects sizes were as high as 200 mm and lot of stone & sand were observed in the Mill rejects. It is the indication that the worst coal had been used at the time of mishap. © There were frequent failures of scrapper armin Mill indicating that the worst coal had been used. © The specific coal consumption (ke/Kwhr) was 25% more than the normal, particularly in the month of February, 2008. Itindicates that the worst coal had been fired during the period ineness of Pulverised fuel: ©The continuous hot air blowing out in the Mill reject system might have resulted in recycling of coal within the Mill, leading to more wear out of rollers in the Mill. The Mills were not set at periodic interval for ensuring the Mill Pulverized Fuel (PF) fineness as per requirement. The Mill PF fineness was poor in all Mills. It had resulted in more unburnt higher size particles in BAH. PF sampler supplier visitis being arranged for the proper usage/demo of the equipment for correct sampling Improper air regime: The SADC dampers are to be kept as per remote signal and 100% opening in unwanted elevation will result in reduced atmosphere, an environment for clinkering/slagging. SADC dampers were not checked periodically. Steam Explosion & clinkering The accumulation was more in corner 2 up to bottom of AA elevation. The hot ash/clinker might have slided down and got dropped in the BAH water, resulting in steam explosion, furnace pressurization and damage to front of BAH seal trough. BB) The Recommendations: © The BAH evacuation frequency and complete evacuation are to be ensured. Proper co-ordination is, required between Ash Handling system and UCR. The side view glasses are to be used along with (WITECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS wane | 7front and rear view glasses. Presently side view glasses were dummied asit were broken earlier. © BAH evacuation isto be done after each Wall soot blower cycle. © The BAH capacity is 328 Tonnes. It implies that the interval between the BAH de-ashing should not, be more than 8 Hrs during the worst coal firing at full load. © The fuel flow is to be monitored in line with load as per the predicted curve. Accordingly, more care isto be applied for BAH evacuation. At fullload, the fuel flow should not exceed the BMCR coal flow of 395 TPH, corresponding to the worst coal. The specific coal consumption should not be exceeded than the design value © The wall soot blower cycle is to be done for each shift and the frequency can be reduced after observation. Itis for the improvement of water wall heat pick up and for reducing the SH/RH spray for maintaining the SH/RH steam temperature. © The Mills are to be checked for proper setting & cleanliness of classifier regularly. © The Mill reject system is to be commissioned for all Mill immediately and till such time close monitoringis required for manual opening of reject valve at regular interval. © TheMiilfinenessis to be checked regularly every week for the running Mills. Itshould be more than 70%in -200 mashand less than 2% in+50 mesh. © SADC dampers are to be checked every week for its equal opening percentage in all corners in line with remote signal and faulty dampers are to be attended. © The oxygen percentage is to be kept at 3.57% at Eco outlet for the load more than 300 MW for maintaining proper excess air. » Thenumber of Millsare to be restricted as per the prediction for the better efficiency of Boiler. Conclusion: The clinker samples were investigated at Plant lab in BHEL/Trichy. The report also indicates that the coal is not having clinkering tendency. Due to usage of stocked coal in the yard for longer period might have resulted more slagging in the Water wall and accumulation in BAH during Wall soot blower operation, The unit was started using coal from the rack (not stocked coal). The Unit got tripped at 400 MW on 11.04.08 due to CT failure in the yard. The S panel manhole was opened to check the BAH inside and S Panel slope for accumulation of ash. It was very clean and it indicates that there is no clinkering tendency in the Boiler. 8) Jindal Power Limited, 4x 250MW , Tamnar. Clinker formation was observed in Unit #1 of 4 x 250 MW JPL Tamnar project. The study conducted was for allthe four units. JPLhad provided the following data for all the units © Coal proximate analysis, both as fired and as received for all the units the GCV was in the order of 3200 to 3250 Kcal/Kg which is below the design worst coal © PFfineness isin order © Un-burnt carbon in Bottom ash (below 2%) and Fly ash (below 1%) isin order. © Ash Handling system detail, particularly BAH with BAH operation write up © Wall Soot Blower operation frequency once ina shift © LRSBoperation once in aweek © Goose neck LRSB (65 & 66): In unit 1, 66 (left) is not available : once ina day © Eco hoppers were not being evacuated and the action is being taken to continuously evacuate the same. Itis connected to BAH rear atthe center ©The Coalishaving more sulphur and more iron : The boiler is designed for BMCR steam flow of 825 TPH at rated pressure and temperature TTECHNICALSERMICES, BHEL-PSWR SITE FEEDBACKS ..... | 8Coal Proximate analysis Coal flow in TPH (approx) 250MW_[_262.5M W ‘ASH | Moisture] vm | FC | Gcv | TMCR vo | BMCR Design 39 w__| 22 | 27 | 3600 | 157 165 173 Worst 46 14 as | 22 | 3300 | 170 178 194 Sh spray 41 0 RH spray, a1 0 The Status before Trials: The units are being operated with coal grade of 3250 Kcal/Kg, the worst coal. Falling of burning globules were observed in all the units, either more frequently or less frequently. The globules sizes were in the order of 20 to 30 mm. The units are being operated at 230 to 235 MW with restricted coal flow of 170 tons per hour due to usage of worst coal. The units are being operated at lower Drum pressure with HPCV wide open but with rated steam temperature. The joint observation was made to find out the best suited condition to avoid the clinker formation. In unit 1, the clinker formation was observed as more. The unit 1 was in service for 1.4 years, unit 3 for 1 year, unit 3 for 8 months and unit 4 was in service for the last 4 months. As a result of the trials, the following were concluded Observations: The units are using the coal below the design worst coal of 3300 Kcal/Kg GCV. The coal is having high iron content in ash and high sulphur content. This will result in Iron sulphide formation. As iron sulphide is having low ash fusion temperature, it will from globules, falling down to BAH. Hence, there were small globules falling in all units. The units which are having longer service hours have seasoned coating in water wall and hence the phenomenon was more in Unit 1. The following were done to bring down the flame intensity to el BAH evacuation time was normal (75 mts) © InUnit 4, the distributed firing was tried either with 5 continuous mills (ABCDE) instead of rated 4 or with split mills (AB CD) for TMCR load and found to have effect in reduction of clinkering issue. With Bottom 4 continuous Mills (ABCD) and with the non-working € & EF elevations SADC were opened to 20%, there was reduction in clinkering. © Inunit3, there were 5 Mills (with ABC DE), there was no clinkering. © Inunit4, with 5 mills (split mills ABCEF) and with 4 mills (split ABCD), there was no clinkering © Inunit 4, the WW observation was made effective by raising the Drum pressure through CMC and effective pressure control in auto. It was having effect in reduction in the clinkeringissue. inate burning globules formation and Recommendations: Based on trails, the following are the suggestions to avoid clinkering. 1. The present restriction of 170 tph coal flow to continue till the better quality coal is available. 2. SADC Opening percentage for all successful trails were: AA=50: FAD=10: LOFD/UOFD=50: AAD=25%: and accordingly maintain DP more than 85 mm WCL 3. Split Mills (2+2,3+1) at max of 178 tph Continuous 5 Mills instead of 4 Mills at 250 MW at max 178 tph 5. Continuous 4 Mills with immediate upper non-working and its auxiliary air damper opened at 20%: thatis ABCD Mills with E & EF open at 20% at max of 178 tph coal flow = (WITECHNICAL SERVICES, BHEL-PSWR ‘SITE FEEDBACKS ..The following combinations shall be tried by JPL and feed back given to BHEL. © BCDE Mills with F & FF opento 20% © CDEF mills with B & AB opento 20% The Clinkering observation will be done for all units and feed back may please given to BHEL. After continuous observation / confirmation of clinkering reduction in unit #1, the SADC opening shall be followed in other unit. Final Recommendations: Similar study was also conducted at other sites by BHEL Trichy. Based on the studies conducted at various sites, BHEL Trichy has suggested the following recommendations to be followed by boilers operators and commissioning engineers to avoid clinkering problem: © Regular analysis of coal, ash, unburnt and pulverized coal fineness is to be carried out to detect variations from design conditions and to take corrective measures. Firing of coals worse than the design worst coal and firing of blended coals, unless cleared for firing based on site trials, shall be avoided. When coals are blended, the recommended blend proportion is to be maintained. Mass entry of pyrites, mud, silica etc. along with the coalis to be prevented. * Combustion regime shall be tuned optimally with proper positioning of the air dampers. © Boilers shall be operated at an excess air not less than the recommended value. (Oxygen analyser sto be calibrated periodically. © Properupkeep of tiltmechanism, milling system and SADC. © Split mill operation (skipping an in between coal elevation) and/or operation of an additional mill when firing coals with slagging tendency. Periodic operation of the wall blowers in the furnace to avoid build up of large masses. © Periodical evacuation of ash from bottom ash hopper. Increase in frequency of the ash evacuation when coals worse than considered for design are fired. Ensure total removal of ash from the bottom hoppers. Ensure proper upkeep and adequate spares for ash handling equipments. © Continuous monitoring of bottom ash through observation port in bottom ash hopper and lowermost peephole window in furnace. Any abnormality in ash build up or outage in handling equipments should be intimated at the earliest to shift in charge. Immediate load reduction / stoppage of unit if warranted. ‘(MITECHNICAL SERVICES, BHEL-PSWR ‘SITE FEEDBACKS .. SoeNEW HIGH PRESSURE LP BYPASS SYSTEM BASED ON EHA OPERATION 5. MANDAL Sr. DGM (TSX), PARAS SITE mandal@bhelpswr.co.in Email While commissioning the high pressure (240 bars) LP bypass system, the following problem was faced in respect of spray water injection flow. Unlike the previous version of LPBP system, in the present LPBP system the spray water is modulated by a control valve, based on the LPBP steam flow. The bypass steam flow is indirectly measured in each leg from the pressure after LPBP control valve. The maximum of pressure between two leg of LPBP system is selected and is used in a function generator (given in fig-1) to derive the spray water flow requirement for atemperation of LPBP steam to condenser. There are three nos. of flow transmitters in the spray water line. The actual flow is measured continuously and compared with the required flow (derived from the above curve based on the prevailing steam pressure after control valve). if the actual flow becomes less and remain less for 3.2 seconds, the LPBP will trip on low water flow protection. (CHARACTERISTICS: FOR LP BYPASS SPRAY WATER FLOW Vs PASS sp pengpaapProlect-PARLL 250 MW t F ‘EPARAS 250 MW a iy Lint Finca) FiG-1 (kis Bos” Bem ere SITE FEEDBACKS.During the initial implementation of the scheme, it was observed that there used to be min 15.82 kg/sec of spray water flow (required as per curve generator-see fig-1) even when the pressure after LPBP is 0 kg/cm2 abs. This meant that the spray valve used to remain open to maintain the minimum flow (whenever put on auto) during normal operation of the unit. Hence, the logic was modified so that the spray valve remains closed during normal operation as per the following logic (see fig-2). -hs(LPBP controller o/p)<0%: One LPP stop valve is not closed- &|_, OVERIDE SIGNAL (30%)FOR CLOSING OF SPRAY V/V rel 288g eed: : bgeebs |e Baftes |; Bebaes |£ gh eee [5 a. cree De ue wy cite iow sera ve FIG-2REPORT OF FALIURE OF BOOSTER PUMP COUPLING S. MANDAL Sr. DGM (TSX), PARAS SITE Email: mandal@bhelpswr.co.in BFP-B was running with load at 220 MW. Pump —A was selected as standby. Due to lekage in the feed pump =B suction line, pump ~A was started and loaded for change over. High vibration was observed in pump- A assoonasitwasstarted. Hence, pump~B was taken backinto service and pump~Awas stopped. Next day pump —A was started again and it was observed that the BFP suction pressure was only 5 kg/cm’ as against 23 kg/cm’ in normal operation. During the visual inspection of the pump, it was noticed that the booster pump was not rotating. Hence pump-Awas stopped. OBSERVATIONS 1. Booster pump was decoupled and found that the insulating plate of the coupling got broken (item no 8,9,10,& 11) and all the 12 fixing screws were broken (see enclosed fig.1) Booster pump was found jam Booster pump top casing half was opened. No foreign materials were found Wear ring clerance in location was found to be 0.3 mmatthe top. Pump was removed from location and wear ring clerances were measured. twas 0.55 mm ( diametrically) in NDE end & 0.3 mm at the top of DE end ring. There was no clerance at the bottom of DE end ring. As per BHEL/Hyderabad O & M manual ( ref Drg no-1-189-00-5-5420/00), the min /max clerance at the wear rings (Point D & E) should be 0.62 mm /0.80 mm respectively. 7. NDE side journal bearing was found to have scoring marks on both halves. 8. There were no problems with thrust bearing pad and DE journal bearing. \CTIONS 1. Based on BHEL/Hyderabad recommendation, the clearances of the wear rings were increased to 0.9 mm. by machining. 2. The damaged parts of the coupling were replaced from spare. 3. The NDE end journal bearing was replaced from spare. Pump was assembled and alignment was checked and found o.k. After that, the pump was taken on load and performance was found satisfactory. To avoid the damage of BFP due to prolonged running under such condition, tripping logic as given below has been introduced. © The BFP will trip if the BFP suction pressure does not increase more than 15 kg/cm’ within 15 seconds from main motor ON command. Under cold condition the pressure was found to reach > 15 kg/em2 within 12sec. Cause of failure of coupling was due to jam less clearance of wear ring (the suction strainer disturbance (due to starting after long gap). ig of pump. Site feels that jamming of pump was due to ize was 350 micron) coupled with the thermal Recommendation from BHEL/Hyd. To inspect the BFP-B booster pump and check the wear ring clearances. If found less, it should be increased 100.9 mm at the earliest opportunity. (MITECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS... 13)@ z crcese ‘a he FLEXIBLE COUPLING | #8 * Anal pee I A ghilic: i i sie fi ash | | rile gene A ale CAGE i g iyadeie i Lia 4 asda Fig. 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 heis working as Sr. Deputy General Manager in TSX deptat Paras site. SeeDabhol Power Project History This Power Plant was earlier owned by Dabhol Power Company (DPC), promoted jointly by Enron, Bechtel, General Electric Company of USA and Maharashtra State Electricity Board. Enron was a majority owner of Dabhol Power Company, 2 massive combined-cycle power plant on the western coast of India's Maharashtra state. The construction of Dabhol power plant was started in 1992 and took nine years to commence the operations. The total project cost was $2.9 billions. The percentage of sharing of DPC wasas below: Enron: 65.15%, Bechtel Enterprises: 10%, General Electric:10% and the Maharashtra State Electricity Board 14.85%, General Electric Maharashtra Enea Capital State Electricity 1 Corporation Board i I 1 | a 5 Maharashtra Power Energy Enterprises | | Enron Maw Capital india Darsormect (Mauritius) Company Company Power Mauritius 1 Comeralie 10.00% 65, 19% ae 00% 14.85% Dabhol Power Company The total installed capacity of the project is 2,150 MWs, which is the largest gas-fired power plant in the world. The plant was shut down in June 2001, due to 2 payment and contract dispute between the Maharashtra state government and the plant owners. ‘TECHNICAL SERVICES, BHEL-PSWR ISSUE SPECIAL- DABHOL PROJECT...‘» Development ofthe Dabhol Project Enron began to investigate opportunities in the Indian power sector in 1992, when India first opened its Power sector to private foreign investors. In the month of May, 1992, Enron executives pitched their ideas to the Indian power secretary, who was in the United States to encourage foreign participation in power sector. By June 1992, Enron selected Dabhol as the site for a project and, with General Electric, Enron entered a memorandum of understanding with the Maharashtra State Electricity Board (MSEB) to build ‘the Dabhol project. ‘The operating entity was the Dabhol Power Company, which is a joint venture. During most of the project development period, Enron owned 80% of the project, while General Electric and Bechtel each owned 10%. (In late 1998, MSEB purchased part of Enron's equity stake, which dropped Enron's share to 65.15%.) The parties negotiated the project terms over an 18-month period, which culminated in the Dabhol Power Company and MSEB signing a power purchase agreement in December 1993. Enron also obtained the necessary approvals for the project from the Indian government during this period. Over the next year, Enron developed the project financing, obtaining $635 million in financing, insurance, and loan guarantees from Bank of America, ABN Amro, a group of Indian banks, the U.S. Export- Import Bank, and the Overseas Private Investment Corporation (PIC). Project status- when DPC closed its operation (June 2001): Block- ‘Commissioned and operated for 14000, (670 Mw) EOH Block-I1 ‘Commissioned and 2150 MW | operated for 700 EOH (740 Mw) Block-1ir Under advanced stage ‘of completion (740 Mw) Re-gasification ‘Under Advanced stage Plant of Erection Fuel Jetty | 5 mmpa [Under Advanced stage of completi Breakwater Partially completed Till May 2002, all equipments were preserved and maintained haphazardly by various agencies. In May 2002, M/s Punj Lloyd was engaged by the ‘Lenders’ (M/s ICICI, IDBI, etc) as one single agency for preservation and maintenance of total plant. ‘SPECIAL- DABHOL PROJECT.There are sixgas turbines (Two Frame 9FA and Four Frame 9FA+E) six HRSG and Three steam Turbines. They are grouped in three Blocks. Each block comprises two gas turbine, two HRSG and one steam Turbine. M/s Enron with M/s GE and M/s Bechtel constructed Dabhol Power Station as main contractors. Phase | consisting of one block of two Frame 9FA GTs, two HRSGs and one steam turbine (total 670 MW) was commissioned in May 1999. Block ll & Block! of Phase Il, consisting of Frame 9FA+E GTs, two HRSGs (Total Phase 2X740 MW) was under commissioning when in May 2001 all operations ceased due to arbitration cases between M/s MSEB and Enron. Phase-I:670 MW Block | (2GT-2X215 MW +2 HRSG + 1 ST-1X240 MW) configuration, and 1 Frame 6B gas, turbine for black start. Phase-l: 1480 MW. The 2150 MW (Net capacity) Combined Cycle Plant and 5.0 MTPA integrated LNG (Liquefied Natural Gas ) facilities plant was installed in early 1990 by ENRON Power company USA. © M/s. GE, USA supplied the main equipment of power plant (viz. Gas Turbines, Steam Turbines, Generators, HRSGs and Station C & |.) and M/s Bechtel USA supplied rest of the plant facilities (Project Engineering & Management, BOP supplies, procurement of bought out items, Erection & Commissioning, PG test and handing over the facilities to DPC) including LNG terminal. «The Phase—| was operated on Naphtha till May-2001 as the LNG facilities were not ready and Block=—Il was under commissioning & Testing and Block - Ill was under advanced stage of erection & commissioning. * Since May 2001, both the Phase | & Phase II plant were under shut down and all operation were stopped due to arbitration case between MSEB and Enron over PPA issue. * The plant has been taken over by court on April 2002. M/s Punj Lloyd was appointed for assets preservation and the plantis on preservation since April, 2002, The Dabhol Saga 1991-1992: India opens its power sector to private foreign investors June 1992: MoU signed between Enron and the Maharashtra Govt for Dabhol project. May 1996: Centre extends counter-guarantee for the project. May 1999: 740 MW phase-| starts generation. Oct 2000: MSEB defaults on payments. Jan 2001: Enron invokes Maharashtra Government's guarantee. (MITECHNICALSERVICES, BHEL-PSWR ISSUE SPECIAL- DABHOL PROJECT...April 2001: Enron issues arbitration notices to Centre. June 2001: MSEB terminates PPA with DPC, cites high power tariff. June 2001: Dabhol Power company ceases operation of the Phase-| portion and halts construction on the 90% completed Phase-IIto portion. Feb 2002: IDBI invites Eols for DPC sale. BSES, Tata Power, BG, Shell submit Eols. March 2002: Enron, GE and Bechtel seek $500 mn as minimum bid. Private players drop out. April 2002: Plant taken over by Court April 2003: DPC's Foreign lenders initiate arbitration process in London. October 2003: GE, Bechtel put forward three-pronged strategy to restart plant. July 2005: Special Purpose Vehicle (SPV) formed by Government of India to restart Dabhol Power Project. SPV decided that BHEL would take up the revival work. July 2005: Formation of RGPPL, a joint venture company promoted by NTPC, GAIL, IFS &MSEB. Sep'2005:ICICI awarded the LOA to BHEL for Preliminary study for assessing the requirement for restarting of Dabhol Power Project. '* Sep'2005: Mega Power Project status granted by EGOM for Dabhol Power Project The Plant assets of Dabhol Power Company have been legally transferred to RGPPL. © Feb'2006: RGPPL awarded the LOA to BHEL for Revival & commissioning of Block-ll.e April'2007:RGPPL awarded the LOA to BHEL for Revival & commissioning of Block-| &lll Block-I Configuration Block -I Combined Cycle Module - 670 MW. Gas Naphina LP steam Hot Reheat ISSUE SPECIAL- DABHOL PROJECT...Block-II &lll Configuration ROPPL Glock ll AIM Combined Cycle Module =ax740mw, ra} a Ratnagiri Gas And Power Pvt. Ltd. GE Frame 9FA Gas Turbine JE SPECIAL- DABHOL PROJECT.© LNGTerminal © LNG facility is located on the site adjacent to the power station consist of LNG unloading Jetty, Re-Gasification facility. The re-gasification facility includes three LNG storage tanks of 1.6 lac m? capacity. The facility will be capable of processing SMTPA of LNG. Original provision was made in the 9FA Machine for Naptha to LNG firing ‘* Single Point Mooring (SPM) Fuel unloading system. SPM. single point mooring anchored in the deep sea around 7.8 nautical miles from sea shore, fuel unloading system. 7.7 km long submarine pipe line for transporting liquid fuel , full flow fuel treatment facilities and external liquid fuel storage tank, © JOURNEY FROM DPCTORGPPL ‘© Project Special Purpose Vehicle (SPV) was formed by GOI in July 05 with the aim of settlement for offshore stake holders & proceeding for revival. ‘SPECIAL- DABHOL PROJECT.© SPV consists of NTPC, GAIL, IDBI, ICICI, SBI, Canara Bank & MSEB. Major equity participated by NTPC, GAIL & ICICI bank (each 500 Cr out of total 1765 Cr). Settlements Amounts Debt Principal Otfore clans (Total) Funded Pancpah Funded (Foreign Cuveney Total Project Cost soma wa 2135 6 195 ras 2025.5 0 wm © Ratnagiri Gas and Power Limited (RGPPL), a joint venture company promoted by NTPC and Gall India Ltd, IFS & MSEB as per the restructuring frame work approved by the EGOM on 8th July, After settlement between DPC & Indian Government, the plant assets of Dabhol Power Company have been legally transferred to present owner of RGPPL in September 2005. Shareholders Agreement Name of the company Equity Amount (Rs Crores) Equity(%) NTPC 500 28.33, GAIL 500 28.33, DBI 188 10.65 Icicl 126 744 sBl 153 8.67 Canara Bank 33 1.87 MSEB Holding Co 265 15 ‘(MITECHNICAL SERVICES, BHEL-PSWR- ISSUE SPECIAL- DABHOL PROJECT...Revival Plan oreo © SPV decided that BHEL would take up the main responsibility for revival work and M/s.NTPC had been asked by the Government to take care of O&M of the plant with ICICI as the SPV leader & NTPC as the consultant. The strategy for revival was framed early in Sept' 05. ICICI as the identified customer awarded the contract to BHEL & for execution by SAS, PSWR, Nagpur on 13th Sept 05 for health assessment of main equipments and to suggest possible measures for revival. © RGPPLhas appointed NTPC as owner's consultant for revival and restart of power plant equipment and systems. REVIVALACTIVITIES EXECUTED BY SAS NAGPUR (On 12.09.05 BHEL was awarded the contract for Assessment study of equipment and systems of complete power plant (Block|,II land common BOP systems). After lot of deliberations among BHEL, GE, Bechtel & NTPC, it was decided to carry out assessment of remaining equipments (BOPs) including civil structures & take up activities for Block II (which was in better condition). On 23.02.06, BHEL was awarded the contract for Revival /recommissioning of Block Il + Condition Assessment of BOPS on fast track Basis. (On 13.04.2007, BHEL was awarded the contract for Revival /recommissioning of Block ll. Assessment, revival & restarting of entire block -Contract has been awarded to BHEL under Contract Package -A. Health assessment Study of power Block Completed on December'2005. Revival & Commissioning and operation of Block-ll was awarded to BHEL under contract Package-B. Revival of Block-II was stared on March'2006 and completed on June'2006 Revival & Commissioning and operation of Block-| & II! was awarded to BHEL under contract Package —C. Revival of Block-III was started on May'2007 and completed on November'2007. Block-| revival is under progress, Main scope: A. Assessment study of equipment and systems of complete power plant (Block |,I,IIl and common BOP systems). B. Design basis review of power Block equipments & systems (BOPs) C._ Procurement of Materials/ Equipments including Imports value more than 230 Cr. (MITECHNICALSERVICES, BHEL-PSWR ISSUE SPECIAL- DABHOL PROJECT...D. Overhauling, servicing & commissioning of Block II common BOP systems for start up & full load Operation. Completion of balance erection & commissioning activities. BOPs revival- raw water, Potable water, MU water, condensate, sea water make up, CW, Liquid fuel oil, SWAS, HVAC, fire water, compressors, H2 plant power cycle equipments, ECW,LP Piping, DG set, switchyard, complete plant control, civil structure ete Training of RGPPL's Personnel. (O& Msupport for one month after commissioning. House Keeping & Catering for OEMs. Transportation for OEMs. Customs activities like HSS, mega project registration etc. Inland transportation. Transit Insurance. Importing Spares including HSS~ Independently by Western Region. Procurement of Materials & Services- Single tender basis from OEMS. RBI Approvals, BG,LCrelated issues. Housekeeping & Catering Of Continental ‘Transportation of international Standards Management of the required Work Force. TARGETS ASSIGNED BY GOI: Actual completion © BLOCK—II FULLLOAD -JULY 06 08/06/2006 © BLOCK-III FULLLOAD- MAY 07 22/11/2007 © BLOCK-IFULLLOAD- AUGUST 07 Progress WORK EXECUTED 1) HEALTH ASSESSMENT OF BLOCK-,II & III CONTRACT- (PACKAGE -A) © Boroscopic inspection of Gas Turbine, Steam turbine components and Boiler tubes. * Metallurgical inspection of GT,STG components & Boiler tubes. © Electrical Testing & Bump check of TG Auxiliary system (Lube oil system, Gas system and air system). yrprozzrzr-zoa Boiler support structures & Hangers visual inspection. Visual inspection of Gas Turbine & Steam Turbine components. Gas path Inspection of Gas Turbine GT1B. Inspection of combustion chamber & Measurement of gas bath clearances. STG 1Xseal body inspection. & STG 1X End winding inspection. — ¢ Pee (MITECHNICAL'SERVICES, BHEL-PSWR- ISSUE SPECIAL- DABHOL PROJECT.2) ASSESSMENT OF BOPS , REVIVAL & RESTARTING OF POWER BLOCK-II-CONTRACT-II (PACKAGE-B) © Inspect the inlet air duct, plenum, and bell mouth for cleanliness. © Perform boroscope inspection of the compressor. © Inspect the exhaust duct for cleanliness and readiness for operation. © Operate and check auxiliary lube oil pump for 3 hours. © Operate and check DC emergency lube oil pump for 20 minutes. © Operateand check exhaust frame blowers for 3 hours. © Operate and check compartment pressurization fans for 3 hours. Operate and check fuel gas module vent fans for 3 hours. © Operate and check lube oil mist separator fan for 3 hours. Operate and check generator bearing lift oil pump for 3 hours. Place unit on turning gear as per GE operation and maintenance (0&M) manual prior to startup and check for abnormalities. © Sampleand analyse lube oil, Check gas oil flow divider tubes for carbonization and blockage. Stroke checkall fuel gas and gas oil control valves. Stroke checkall vent valves on fuel gas and gas oil systems. Stroke check and grease the inlet guide vanes. Verify temperature readings for exhaust, generator, wheel space, and lube oil systems. Check battery condition and charge the batteries. Remove, inspect, and clean all flame detectors. Checkall Mark V cards and terminations for loose connections, alarms, forces, and damage. Performairleak test on generator. Load hydrogen in generator. Puff test C02 fire protection system. Steam turbine Inspection © Operate and check auxiliary lube oil pump for 3 hours © Operate and check DC emergency lube oil pump for 20 minutes © Operateand check lube oil mist separator fan for3 hours © Operate and check generator bearing lift oil pump for 3 hours © Place unit on turning gear as per GE O&M manual prior to startup and check for abnormalities © Sample and analyze lube oil. Verify temperature readings for generator and lube oil systems & Check battery condition and Charge the batteries. © Checkall Mark V cards and terminations for loose connections, alarms, forces, and damage © Performairleak test on generator & Load hydrogen in generator © Pufftest C02 fire protection system HRSG 2A & 2B Inspection © Walk down and line up condensate, feed water, heat recovery steam generator (HRSG) and main steam system valves and instrumentation Stroke check all motor-operated and control valves in the condensate, feed water, and main steam systems via DCS (MITECHNICAUISERVICES//BHEL?PSWRITTTI ISSUE SPECIAL- DABHOL PROJECTiee 24© Perform boroscope inspection of HRSG tubes © Inspect burner management system (BMS) PLC for alarms, terminations, and missing components Check BMS control panel indication and lights. Calibrate duct burner oil and gas pressure switches. Wash and prepare chemical injection skid tanks. Replace chemical feed pumps, as required Operate and check chemical injection pump strokes Fill and drain the HRSG until acceptable chemistry achieved Electrical System © Megger and polarization index test generator stator winding & Meggerall power cables and motors © Inspect potential transformer cubicles & Perform visual inspection of neutral earthing resistor © Perform synchronization test on each generator, including backfeed & Perform visual inspection of generatorcircuit breaker local panel © Perform functional generator circuit breaker operation and isolators checks & Perform visual inspection of load commutated inverter (LCI) © Flush LCI cooling water & Inspect water injection pump motor space heater © Stroke check motor-operated valves © Perform visual inspection of all local control panels, terminal boxes, etc, for water intrusion, rodent damage, corrosion, loose terminals, space heater operation, and missing parts © Verifyallrelay settings are correct © Inspectall motor control centers, load centers, switchgear, distribution panels, inverters, etc., forwater intrusion, rodent damage, corrosion, loose terminals, space heater operation, and missing parts BOP Equipments Overhauling, servicing and commissioning of the following BOP Systems for Full load. Checking of integrity of equipment, system, structures, components, valves, specialties, pipe work, supports, healthiness of control system, Hardware & software components & Field Instruments / Actuators/ Analyzers/ Flow devices ete » Rawwater Supply, storage & its treatment System , Potable water system, * Makeup Water DM water system, Condensate storage and transfer system © Sea Water Makeup (Cooling tower makeup) System and associated including chemical dosing system © Circulating (CW) water Blow down system © Circulating Water System (Complete CW pumping system, cooling towers & steam turbine condensers) © Circulating water (chemical dosing) treatment system © Closed cooling water system (of auxiliary cooling) and associated its chemical conditioning skid. © Open cooling water system (of auxiliary cooling) and associated its chemical conditioning skid. © Main steam, Reheat, LP steam & Bypass steam systems (MITECHNICAWISERVICES//BHEL-PSWR ISSUE SPECIAL- DABHOL PROJECT...Feed water system, Condensate System, Condenser Air removal system Chemical Feed System for condensate & feed water, Blow down system for Steam Generator Auxiliary Steam System ,Lube oil storage & Transfer system Liquid Fuel oil booster pumping, storage, purification (treatment) and forwarding (Pumping) system Steam & Water Analysis system HVAC system (s) for main turbine building HVAC system for Miscellaneous buildings Fire water storage and pumping system, Fire detection and protection system Waster water treatment & disposal system. Compressors (service & instrument air) and associated air drier system for main power block and miscellaneous areas. «Hydrogen generation plant & bulk gas storage system © Material Handling Equipments such as Gantry Cranes, EOT cranes, hoist etc. © Hangers & Supports for pipe support system. © Emergecny Diesel Generater Set, Electrical Power Supply (HV/LV) System © Switchyard Equipments including protection and control systems. ‘Complete Plant Control & Instrumentation including local panels field instruments including actuators, analysers, PLCs, UPS, Process connection and piping, instrumentation cables, junction boxes etc. Insulation Insulation work was executed in first time. The scope includes complete supply and application of insulation. Hot Thermal Insulation of the various thicknesses using ROCKLOYD Resin Bonded Rockwool Mattresses for General Piping, Blowdown and Drain Flash Tanks JE SPECIAL- DABHOL PROJECT...Supply & Application of Hot Thermal Insulation of the various pipe dia and various thicknesses using Calcium Silicate Pipe Section /Slabs/ Radial Lags for HRSG piping. 3) REVIVAL & RESTARTING OF POWER BLOCK-1&III CONTRACT-III (PACKAGE-C) GTs &STGs of Block I&II Maintenance & Start Up Support of Two (2) Frame MS9001FA Gas Turbine Generators and One (1) D11. Steam Turbine Generator Each of Blocks | &IIl. GTG- 1A & 3A Inspection and Restart, © Fluid & Consumable Replacements © Top Down Cleaning Effort & Piping Blowouts © Naptha & Distillate System Flush & Functional Checks Fluid Changes © Consumable Replacements © GasTurbine Inspection © Combustion Inspection © Compressor Section Cleaning © HotGas Path & Compressor Section Inspection © GTReassembly © Generator & Auxiliaries Inspection © Auxiliary Systems Inspection © Pre-commissioning © Mechanical, Electrical & Auxiliaries Pre-commissioning © Auxiliary System Flushes and Air Blows © Generator Off-line Protection Check, (MITECHNICAL'SERVICES, BHEL-PSWR- ISSUE SPECIAL- DABHOL PROJECT.GT1A Inspection © LCI Cranking & Permissive Sequence Checks © GTFirst Fire «Heat Soak & FSNL Checks © Operational & Generator Prote © Generator no-loadtests n Test ‘» Commissioning & Fuel Changeover Tests © Integrated Load Tests & Tuning © (DLN) Tuning. '* Operation on Temperature control mode GT3A&3B Generator «Large Gas turbine Generator Dovetail Inspection Recommendation © Collector Sound insulation © OilLeakat Generator Bearing Thermocouple Connection » 324, 7FH2, and 390H Generator Collector Bus Bar Protective Cover Modification GTG- 18 & 3B Inspection and Restart » Fluid & Consumable Replacements '* Top Down Cleaning Effort & Piping Blowouts '» Naphtha & Distillate System Flush & Functional Checks * Fluid Changes » Consumable Replacements * GasTurbine inspection Combustion inspection » Compressor Section Cleaning » Hotgas path & compressor section inspection (Applicable only for GT 1B) © GTReassembiy © Generator & Auxiliaries Inspection © Auxiliary Systems Inspection (MITECHNICAL'SERVICES, BHEL-PSWR- ISSUE SPECIAL- DABHOL PROJECT.GT18 Rotor inspection GT3BRotor inspection Pre-commissioning * Mechanical, Electrical & Auxiliaries Pre-commissioning ‘» Auxiliary System Flushes and Air Blows Generator Off-line Protection Check. GT1A Generator Inspection GIG 1B Generator Inspection Commissioning © LCICranking & Permissive Sequence Checks © GTFirst Fire «Heat Soak & FSNL Checks ‘© Operational & Generator Protection Test © Generator no-loadtests « Naphtha Commissioning & Fuel Changeover Tests, © Integrated Load Tests & Tuning © (DLN) Tuning ‘© Operation on Temperature control mode GT1A&1BandSTG Generator © Large Gas & steam turbine Generator Dovetail Inspection. ‘© Collector Sound insulation * OilLeakat Generator Bearing Thermocouple Connection © 324, 7FH2, and 390H Generator Collector Bus Bar Protective Cover Modification, © GT1AGenerator repaired at BHEL/Hydrabad works. Steam Turbine 1 & 3 Inspection ST1X Generator Inspection © Lagging & Insulation Disassembly © Install scaffolding © Disassemble lagging » Removeinsulation * Steam Valve Inspections © STRotor Alignment Verifications © Steam Turbine Inspections (MITECHNICAWISERVICES//BHEL-PSWR- ISSUE SPECIAL- DABHOL PROJECT...Steam Path Audit Inspection & Cleaning Steam Turbine 3X HP Rotor Assy © Crossover Section © FrontStandard © LPSection © IPSection © HPSection ries © Systems and Auxil STG-3 Re-commissioning © Pre-commissioning © Mechanical, Electrical & Auxiliaries Pre-commissioning © Auxiliary System Flushes and Air Blows © Lube Oil & Hydraulic Oil Flushing © Steam Blows. Commissioning © Steam Turbine Auxiliary Systems © Perform off-line H2 generator tests © Initial Operation Steam Admission & Associated Checks © £X2000 & voltage regulator checks © Synchronize © Synchronous Speed Operations & Associated Checks © Generator Load Tests Black Start Gas Turbine Assembly & Re-commissioning © Inspection, repair/replacement of components, © GTReassembly and Generator & Auxiliaries Inspection © Auxiliary Systems Inspection © Mechanical, Electrical & Auxiliaries Pre-commissioning © Auxiliary System Flushes and Air Blows © Generator Off-line Protection Check. HRSGs Block! 1 Heat Transfer Surfaces: © Replace missing tubes. Plain (unfinned) tubes will be used asa replacement. « _Inspection\repair damaged wraparounds in all modules. © Cleaning of the external surface of tubes with water or compressed air. © Preform hydrostatic test (three pressure levels, RH and FWHTR systems - each shall be tested separately). © Clean the internal surface of the tubes with an alkaline boil out and steam blow-out during recommissioning stage. ©The FWHTR to be completely bypassed (or even blanked) till long term’ recommendations have been (MTECHNICAUISERVICES//BHEL:PSWRITT ISSUE SPECIAL- DABHOL PROJECTiwee 30implemented. 2. Safety Valve Replacement © Missing safety valve to be replaced (IP Drum) 3. ERVs ERV’s to be checked for proper operation and calibration These are usually lifted by setpoint or operator intervention, per unit Feed Water Control Valve To check control valves with the support of OEMs. Attemperator Valve Inspection and Repair, To inspect attemperator valves Checking Pneumatic and Motorized Valves Pneumatic and motorized valves to be stroked via the DCS and local control stations 7 Safety Valve Refurbishment and Resetting-After hydro testing all safety valves to be inspected and resurfaced as required. Steam pressure is required for setting, the safety relief valves is to be reset after the HRSGis up and running, 8 Pipe supports check and adjust Pipe supports to be evaluated and reset prior to commissioning the HRSG. 9. Commissioning-Steam Blow,and Alkaline Boil-out / acid cleaning /steam blow to be carried out during re-commissioning stage. 10 HRSG Hydro and Recertification Hydro test be performed as the first step in the work scope to facilitate identification of pressure parts unable to sustain this pressure. Hydrostatic test pressure to be decided by keeping in view the requirements of the IBR, 11 Casing Seal Replacement/Upgrade Casing seals 14 Stack assistance as required 12 Expansion Joint Replacement 13 Replacement of IP Drum Downcomer Screen 14 Boiler Instrumentation Check and correct ‘* Visual inspection of the local indicator, control unit.Inspection of remote level indicator in control room, Power up and test functionality of probe column to control unit and indicators. ‘© Reinstall /replace insulation and cladding. All gauges & instrumentation should be calibrated © Access individual transmitters and visual inspection Due to long dormant time, these units require complete checkout and calibration by certified technician(s).. © Gauges Pressure and Temperature: Access individual gauges and visually inspect Due to long dormant time, these units require complete checkout. «Thermocouples: Access individual thermocouples and visually inspect. Continuity test to determine failed elements. Insulations 1. Supply & Application of Hot & Cold Thermal insulation. 2. Application of insulation of various pipe dia and various thicknesses using Calcium Silicate Pipe Section /Slabs/ Radial Lags for HRSG piping. 3. Application of Insulation of various pipe dia and various thicknesses using Calcium Silicate Pipe Section /Slabs/ Radial Lags for HRSG piping. (MTECHNICAUISERVICES/)BHEL?PSWROTTT ISSUE SPECIAL- DABHOL PROJECTine 31Key Milestones: Commissioning Block-II - MILESTONE ACTIVITY (GT2AMILESTONE ACTIVITY DATE TIME LOAD ‘SPEED START OF WORK 20/03/2006 HOURS RPM DATE OF COMPLETION OF ALL WORK| 18/04/2006 FIRST TIME M/C PUT ON TURNING 18/04/2006 21:45 0 Ss (CRANKING 27/04/2006 18:10 oO 697, SUCCESSFUL FIRING 28/04/2006 20:40 0 425 FULL SPEED NO LOAD (FSNL) 28/04/2006 20:41 0 3003 (OVERSPEED TEST 30/04/2006 03:30 0 3299) SYNCHRONISATION 30/04/2006 07:55 20MW 3000 WATER INJECTION (05/07/2006 19:00 roomw_ | 3000 BASE LOAD (ON DISTILLATE) 27/05/2006 09:25 235 MW | _3008 FIRST TIME TAKEN ON NAPTHA 30/05/2006 07:40 30MW 3000 BASE LOAD ON NAPTHA, 31/05/2006 00:14 242.2mw | 3024 (GT2B MILESTONE ACTIVITY DATE TIME LOAD ‘SPEED START OF WORK 04/06/2006 RPM DATE OF COMPLETION OF ALL WORK| _ 05/06/2006 FIRST TIME M/C PUT ON TURNING: (05/05/2006 12:30 0 5 RANKING: 05/11/2006 02:18 0 697 ‘SUCCESSFUL FIRING 13/05/2006 21:32 0 425 FULL SPEED NO LOAD 13/05/2006 21:33 0 3003 ‘OVERSPEED TEST 14/05/2006 18:46 0 3299 DUMMY SYNCHRONISATION 14/05/2006 20:33 0 3000 ‘SYNCHRONISATION. 14/05/2006 22:00 20MW 3000 WATER INJECTION 19/05/2006 15:57 roomw | 3000 BASE LOAD (ON DISTILLATE) 28/05/2006 03:30 232.4 3008, FIRST TIME TAKEN ON NAPTHA, (06/01/2006 22:03 30MW 3000 BASE LOAD ON NAPTHA, (06/03/2006 23:34 240.7MW | _3013 ‘ST2X MILESTONE ACTIVITY DATE TIME LOAD SPEED ‘START OF WORK 20/03/2006 RPM DATE OF COMPLETION OF ALL WORK| _ 18/04/2006 FIRST TIME M/C PUT ON TURNING. 20/04/2006 20:00 0 ‘STEAM DUMPING STARTED (03/05/2006 ‘STEAM DUMPING COMPLETED. (06/05/2006 ‘SPEED RAISED TO 800 RPM (07/05/2006 0:57 ‘800 ‘SPEED RAISED TO 2000 RPM (07/05/2006 2000) ‘SPEED RAISED TO 3000 RPM (07/05/2006 3000 FULL SPEED NO LOAD (07/05/2006 3000 ‘OVERSPEED TEST (07/05/2006 2:32 3298, SYNCHRONISATION 07/05/2006 17:36 20 MW. 3016 BASE LOAD (07/05/2006 242.8 Mw] (MITECHNICALSERVICES, BHEL-PSWR ISSUE SPECIAL- DABHOL PROJECT...BLOCK-II (GT2A+GT2B+STG 2X) Trial operation with base load successfully completed on 08/06/2006 BLOCK-III- MILESTONE ACTIVITY GT3A MILESTONE ACTIVITY DATE TIME LOAD ‘SPEED START OF WORK (01.05.2007 0 DATE OF COMPLETION OF ALL WORK 0 FIRST TIME M/C PUT ONTURNING | 05.06.2007 0 5 CRANKING 11.06.2007 0 SUCCESSFUL FIRING 16.06.2007 0 FULL SPEED NO LOAD (FSNU) 16.06.2007 0 2390 (OVERSPEED TEST 16.06.2007 0 3300 SYNCHRONISATION 16.06.2007 1aMW. 2970 BASE LOAD ON LNG (03.11.2007 2iomw__|_2970 GT3B MILESTONE ACTIVITY DATE TIME, LOAD ‘SPEED START OF WORK (01.05.2007 0 DATE OF COMPLETION OF ALL WORK| 19.08.2007 0 FIRST TIME M/C_PUT ON TURNING 19.08.2007 oO 5 CRANKING (05.09.2007 0 SUCCESSFUL FIRING. (05.09.2007 0 FULL SPEED NO LOAD (05.09.2007 0 2995 OVERSPEED TEST (05.09.2007 0 3300 DUMMY SYNCHRONISATION (05.09.2007 0 2965 SYNCHRONISATION 05.09.2007 20MW 2965 BAES LOAD ON LNG 03.11.2007 21omw__| 2965 ST3X MILESTONE ACTIVITY DATE TIME LOAD ‘SPEED START OF WORK (01.05.2007 DATE OF COMPLETION OF ALL WORK| 13.10.2007 FIRST TIME M/C PUTONTURNING | 20.08.2007 iioopm | — ‘SRPM STEAM DUMPING STARTED (09.10.2007 20:30 5 ‘SRPM STEAM DUMPING COMPLITED 14.10.2007 SPEED RAISED TO 800 RPM 16.10.2007 21:30 800 ‘SPEED RAISED TO 2000 RPM 16.10.2007 21:38 1996 SPEED RAISED TO 3000 RPM 16.10.2007 21:48 2997 FULL SPEED NO LOAD 16.10.2007 21:48 3000 OVERSPEED TEST 17.10.2007 4:440M 3335 SYNCHRONISATION 16.10.2007 22:00 20MW 2945 BASE LOAD 03.11.2007 ziomw | 2945 (MITECHNICALISERVICES, BHEL-PSWR ISSUE SPECIAL- DABHOL PROJECT...GT1B MILESTONE ACTIVITY DATE TIME ‘SPEED START OF WORK DATE OF COMPLETION OF ALLWORK| 01.05.2008 FIRST TIME M/C PUTONTURNING | 27.04.2008 2130 Hr 5 RPM CRANKING (08.05.2008 1335 Hr 720 RPM SUCCESSFUL FIRING (08.05.2008 1345 Hr 435 RPM FULL SPEED NO LOAD (08.05.2008 1359 Hr ‘3000 RPM (OVERSPEED TEST (09.05.2008 1820 Hr ‘3150 RPM DUMMY SYNCHRONISATION (09.05.2008 q72inr | 2975 RPM ‘SYNCHRONISATION (09.05.2008 1740 Hr_| 15MW. 72970 RPM BASE LOAD ‘STIX MILESTONE ACTIVITY DATE TIME LOAD ‘SPEED STAR OF WORK = DATE OF COMPLETION OF ALL WORK| 26.05.2008 FIRST TIME M/C PUT ON TURNING 13.05.2008 00.40 Hr 3 RPM STEAM DUMPING STARTED 22.05.2008 00.45 Hr 3 RPM STEAM DUMPING COMPLITED 23.05.2008 2230 Hr 3_RPM SPEED RAISED TO 835RPM 20.05.2008 2205 Hr 834 RPM SPEED RAISED TO 2500 RPM 20.05.2008 2230 Hr 2505 RPM SPEED RAISED TO 3000 RPM 20.05.2008, 2245 Hr 3000 RPM FULL SPEED NO LOAD 20.05.2008, 2245 Hr ‘3000 RPM OVERSPEED TEST 21.05.2008 1120Hr_ | — 3300 RPM ‘SYNCHRONISATION 21.05.2008 2255 Hr_| 10MW. 2982 RPM BASE LOAD ISSUE SPECIAL- DABHOL PROJECT...BLOCK-III (GT3A+GT3B+STG 3X) Trial operation with base load successfully completed on 22/11/2007 BLOCK-1 MILESTONE ACTIVITY GT1A MILESTONE ACTIVITY DATE TIME LOAD SPEED START OF WORK 25.09.2008 DATE OF COMPLETION OF ALL WORK | _17.01.2009 FIRST TIME/MC PUT ON TURNING 12.01.2009 2144 Hr SRPM CRANKING 17.01.2008 1030 Hr 720 RPM SUCCESSFUL FIRING 24.01.2009 1045 Hr 425 RPM FULL SPEED NO LOAD (FSNL) 24.01.2009 1100 Hr 3000 RPM (OVERSPEED TEST 24.01.2009 2030 Hr 3300 RPM SYNCHRONISATION 31.01.2009 16.30Hr_| 20MW 2980 RPM BASE LOAD 19.02.2009 13.05 Hr | 200Mw_ | 3000 RPM GT1B MILESTONE ACTIVITY DATE TIME SPEED START OF WORK (01.05.2007 DATE OF COMPLETION OF ALL WORK | 01.05.2008 FIRST TIME M/C PUT ON TURNING | 27.04.2008 2130 Hr 5 RPM CRANKING (08.05.2008 1335 Hr 720 RPM SUCCESSFUL FIRING (08.05.2008 1345 Hr 435 RPM FULL SPEED NO LOAD 08.05.2008 1359 Hr 3000 RPM (OVERSPEED TEST 09.05.2008. 1820 Hr 3150 RPM DUMMY SYNCHRONISATION (09.05.2008. 1721 Hr 2975 RPM SYNCHRONISATION. (09.05.2008 1740 Hr | 2970 RPM BASE LOAD 14.05.2008 2oomw [3000 RPM ‘STIX MILESTONE ACTIVITY with GT1B]_DATE TIME SPEED STAR OF WORK 01.05.2007 DATE OF COMPLETION OF ALL WORK | 26.05.2008 FIRST TIME M/C PUT ON TURNING 13.05.2008 00.40 Hr 3RPM STEAM DUMPING STARTED 22.05.2008 00.45 Hr 3 RPM STEAM DUMPING COMPLITED. 23.05.2008 2230 Hr = 3 RPM SPEED RAISED TO 835RPM. 20.05.2008 2205 Hr 834 RPM SPEED RAISED TO 2500 RPM 20.05.2008 2230 Hr 2505 RPM SPEED RAISED TO 3000 RPM 20.05.2008 2245 Hr 3000 RPM FULL SPEED NO LOAD 20.05.2008 2245 Hr 3000 RPM OVERSPEED TEST. 21.05.2008 1120 Hr 3300 RPM SYNCHRONISATION. 21.05.2008 2255Hr | — 2982 RPM BASE LOAD (combined GT1A+GT1B+ST1X) Pending (MITECHNICAL'SERVICES, BHEL-PSWR ISSUE SPECIAL- DABHOL PROJECT... (3s)The Project Status As on 19” March 2009 Block-1-Generation:0 MW (Trial operation completed on 16/03/2009) GT1A: 72 hrs Trial operation completed successfully on 16/03/09. Unit under shutdown from 16/03/09 : 17.05 hrs onwards due to non availability of commercial operation Insurance Policy. GT1B: Under Shutdown. The unit was first synchronized on 09/05/2008. Unit is under Shut down from 22/01/2009 due to compressors R3 stage blade crack and Turbine stage 1 & 2 buckets and nozzle damage. STAX: On Turning gear Block- I! -Generation: 308 MW (Trial operation completed on 08/06/2006) GT2A: Not Operational. (Under major break down from 19/01/2008. Rotor repair completed and same rotor is installed in GT 38. RGPPLhas yet to decide about casing repair) GT2B: Running at200MW ST2X: Running at 108 MW Block-Ill-Generation: 326 MW (Trial operation completed on 22/11/2007) GT3A: Not Operational. (Under major breakdown from 08/11/2008. RGPPL has yet to decide about repair). GT3B: Running at 218 MW. DLN Tuningisin progress. ST3X: Running at 108 MW. Mr. V. Veerapandi graduated in Production Engineering from Regional Engineering College at Trichyin the year 1988. Mr. Veerapandi joined BHEL Trichy in the year of 1988 and Transferred to PSWR-SAS Services in 1991. Overhauling, Trouble shooting & Servicing works were carried out in WI. variousranges of Steam Turbines up to SOOMW. Presently as Services In-charge at Dabhol RGPPL site for Revival of RGPPL Dabhol Power Plant. (MITECHNICALSERVICES, BHEL-PSWR ISSUE SPECIAL- DABHOL PROJECT...AND THE LAST PAGE . DearFriends, You have in your hands the first issue of “ware eer’, a compendium of feedbacks brought out by Power Sector Western Region. As we look back, the last few years have been very exciting and challenging for PSWR, both from the point of view of volume and variation. We have been consistently commissioning around 2000MWs per year for the last three years and our region has also earned the reputation of adding maximum “Generating Capacity” with respect to all other regions of Power Sector during the same period. At PSWR, we have been fortunate enough to be associated with some of the very prestigious projects which are trend setters. Whether it is ‘commissioning of India's highest rating nuclear power generating equipment at NPC Tarapur or Negotiations with GE (USA),BECHTEL USA HENRY VOGT& NTPC during finalizing the scope of works for revival of Dabhol Power Project at Ratnagiri, the experience have been highly rewardingand enriching. And we wantto share. In this inaugural issue, we have given details of our experience at Dabhol which has seen many ups and downs in its not very long life of survival and attracted the attention of all “Power Plant Engineers” due to the complexities involved in stabilization of the most “Advanced Class Gas Turbine”. We have also brought out feedbacks on “clinker formation” at some of our boilers, and latest “Low Pressure By Pass (LPBP) system” at Paras which we are sure will be of immense help for others, in commissioning similar products and Systems. \ believe, for this journal to be really meaningful, active participation of you all by sharing rich experiences and valuable suggestions is of paramount importance. Please write to us your opinion about the compendium and suggestions for improvement. Also please share with us technical feedbacks which we will be glad to include in future issues of this publication. With Best Wishes, SNMa Head, Technical Services, BHEL, PSWR (HQ), Nagpur.TA BHARAT HEAVY ELETRICALS LIMITED POWER SECTOR WESTERN REGION Shree Mohini Complex, 345, Kingsway, Nagpur-440001. ese & Pte at AQUA PROCES. 937162862