shes wh san, srafer ah aft Eee 2) Brightening lives, Powering progress aa édt ISSUE SPECIAL: TUBE MILLS -TUBE MI MESSAGE FROM HEAD (TSX) ‘The statements and views expressed in this Magazine are entirely those of authors and not necessarily that of | the Organization Cover photograph: 4 X 125 MW, FR-9E Gas Turbine power plant, ‘Sulaymaniyah (Iraq) [ene OTONEETOEEMESSAGE FROM GM (TSX & SAS).. Dear Colleagues, The fifth issue of Takaniki Darpan is with you with another boquet of articles toenchance our roleas power engineers. As youll know,as power engineers thisis a challanging time for BHEL engineers. The country has an ambitious plan for power addition and SHEL is playing very significant role in country's infrastructure development programme. ‘With pressure on us to increase the number of sets and capacity additon to the national grid every year, we have to be very very careful to see that wedo. ‘not commit any mistake during erection and commissioning. A singlemistake candelayour schedule by months andcan upset the entire planning. In this context, itis important to learn from past mistakes and share our experience with others so that mistakes do not repeat. The publication of this compendium is an effort in that direction to share our experience with ‘others: what good we fave done, what mistakes we have done and what is happening aroundus. ‘With warm regards and best wishes. RL. Ranwas General Manager (TSX & SAS) BHEL, PSWR (HQ) NagpurSTATUS OF THE SITES UNDER COMMISSIONING: 1. NSPCLBHILAI (2x250MW) Unit No.01: A. At present, unitis running at various loads dependingon loadrequirement and coal availability. B. PG Test of TG completed. Unit No. 02: A. Atpresent, unit is running at various loads dependingon loadrequirement and coal availability. B. PG Test preparations under progress. 2. TATATROMBAY (1x250MW) A. PG Test of Boiler, TGand ESP completed and reportaccepted by customer. 3, MAHAGENCO PARAS (1X25OMW AND 1X250MW Extn.) Unit No. 02: A. Synchronisation with coal firing done on 18" Feb 2010. B. Unitachieved full loadon 27" Mar 2010. C. Unitisgeneratingas per load requirement. D. BFP hydraulic coupling bearing temperature rise problem resolved. E, Turbine oil cooler bypassing problem resolved. 4. PARLI (1X250MW AND 1X250MW Extn.) Unit No. 01: A. Unitisrunningsmoothlyatull load with CMC inservice. Unit No. 02: A. Unitachieved full ladon 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 250MW load with CMCin service. 5, 1OCL, BARODA(2x33 MW) Unit No. 01: FSNLachievedon 10.08.2009. Unit synchronised on 08.10.2009. HRSG hydro test completed on 15.10.2009. HRSG ABO achieved on 04.01.2010. Safety valve floating completed on 13.02.2010. Damaged OT! for Generator transformer yet to receive from BHEL, Jhansi. Fullload plannedin May'2010 “TECHNICALSERVICES, BHEL-PSWRGLINPSES OF THE SITES... (EI aAmmong@>Unit No. 02: A. 8. c D. E. F FSNLachievedon 30.03.2010 Unit synchronised on 31.03.2010 P633 Transformer protection relay was not working &send for replacement Unit under shut down forattending the pending works Damaged MDU for Generator transformer yet to receive from BHEL, Jhansi DAVR- Trip Coil yet to Receive FromEDN Bangalore 6. KUTCHLIGNITE(1X77MW) A, B. PG Test preparations underprogress. Pending points are beingattended. 7. SULEMANIYAH, IRAQ (4X123MW, FR9) Unit Nooa: A. B. Unit Synchronised on 26” Feb. 2010. Reliability run test completed successfully on 28° Mar 2010. 8. SLPPMANGROL(2X125MW PHASE II) Unit No. 03: A. 8. Unit achieved full loadon 12” Apr. 2010. Presently, unitis under shutdown dueto PA fan duct joint tear off whichis beingattended. Unit No. 04: A, B. & Unit synchronised on 25" Mar 2010. Achieved full load on 23"Apr 2010. Presently, unitis runningat 120-130 MW. 9, MAHAGENCO BHUSAWAL (2500 MW) A. 8. G HT switchgear panel installation & testing work in progress. \VFD panels & ESP panelsinstallation isin progress. 24VDCDB and UPS system panels installations in progress. 10. MAHAGENCO KHAPERKHEDA (1 X 500 MW) A. >mgon08 Station Transformer-SB was charged on 12/04/10 at 18:38 hrs & kept charged for 24hrs on no-load condition. There was a major fire near the station transformer area on......and the transformer got damaged Restoration workis under progress. \VFD Panels & VFD Transformers have been erected, Dry Type Transformers, LTMSB, ACP & ElectronicControl Panels for ESP have been erected. Soot Blower MCC has been erected Control Panelsof Control Equipment Room like STRP-A/B, GRP & DAVR have been erected. A\l the control panels of Control Equipment Room have been erected except Gravimetric Feeder Panels: 2nos.,Gen. End Winding Vibration Panel. “TECHNICALSERVICES, BHEL-PSWR GLIMPSES OF THESITES.... (EMEG. Cabling of HT SWGRtoMAX DCShas been completed. H. Cabling of MTM 1/C is in progress. MTM pads are being welded by Boiler Mech. JB's have been erected. Cabling of Drum Vents MOV isin progress. Max DCS panels of FOPH/CWPH have beenerected. UPS, ACDB & Batterieshave been erected. 24 DCDB have been erected & Power cabling for one source has been done for all the max DCS panels. rRee 11. NTPCKORBA-7(1X500 MW) A. Boiler lighted up on28” Feb 2010. B. EDTAcleaningcompleted on 31°Mar 2010. C. Detergent flushing of boiler feed system completed on 26" Apr 2010. 12. BORL, Bina Unit No.1: A. All3 fans (ID/SA/PA) Trial run completed. B. MDBFP- 1,2, EXPORTCW-1,3, CTP-1,2 Motors No Load Testing completed. C. Unit-1-STGMCC, Boiler MCCand all MCCs (except ESP MCC) Charged required for Boiler light up. D. AC MOP, AC AP, AC JOP, DC JOP, DC EOP, CEP-1,2, Barring Gear Motor - of STG-1- Commissioned from Electrical side. E. Boiler MOVs Cabling completed, 90% of these commissioned from Electrical side. = STGarea- 3out of 6HT Transformer charged, Testing of 2 nos.in progress. G. Ash Handling MCC, Lime Stone MCC, Pet Coke MCC, ESP MCCs - Erection completed, testing in Progress. H. Conveyor areaCable Tray Fabrication & Erectionin Progress. |. Cooling TowerFan Motors Cabling Completed, Testing in Progress. J, SCAP to 6.6KV boards cabletermination is in progress. K. 2MVAstation Auxiliary transformer (TR-59) has commissioned. L. BARRING GEAR #UNIT-1 ACHIEVED ON 31/03/2010 M, STG-1 COMMISSIONING UNDER PROGRESS Critical issue: Cable schedule for MOVs from Hyderabadis pending. Unit No.2: A. SCAP to 33KV boards loop checkingis progress. B. Cooling tower motors cable laying termination isin progress. Unit No.3: A. 2MvAstation Auxiliary transformer (TR-64) hasbeen charged. B. Cooling tower motors testing has been started. eos “TECHNICALSERVICES, BHEL-PSWR GLIMPSES OF THE SITES... (ENATT OF DUCTING & FURNACE DONE AT NTPC KORBA V.NAVANEETHAKRISHNAN UCM / BHEL Site, NTPC KORBA INTRODUCTION; Boiler furnace is built up at the power plant site with water wall panels supplied from Manufacturing Unit, BHEL TRICHY, by welding with fins / flats and attachments as per the drawing. Also lot of skin casing works are involved with welding and refractory for furnace roof, rear arch enclosure and coutant chambers. And ducts from FD fans, PA fans and ID fans are assembled at site and welded for transportation Of air & flue gas. Prior to application of insulation, all these welding done at site, need checking of soundness by pressurising with air (higher than the normal operating pressure) as per the approved procedure. DESCRIPTIONOF ATT: Air Tightness Test of ducting / furnace is conducted at site after completion of the total enclosure of Boiler pressure parts, completion of skin casing works, completion of all furnace openings & tapping points for instrumentation and erection of wall blowers etc. Furnace manholes, peephole doors, access doors, bottom seal trough and water seal are to be made available before starting the test for achieving the required pressurisation. Completion of air / gas ducting of FD fans, Airheaters, ID fans & ESPs with all instrumentation tapping points, internal & external supports and manhole doors are to be ensured for starting the ATT. The testis conductedin stages, as per the NTPCapproved procedure asindicated below, Stage 1: FD fans discharge ducting upto SAPHs, FD fandisch pressure = 300mmwe Stage 2: Air ducting from SAPHs & windboxes, FD fan disch pressure =300 mmwe ‘Stage 3: Furnace! &II pass, Pressure =75 mmwc(min] Stage 4: Furnace outlet to ESPs inlet, FD fan disch pressure = 300mmwe ‘Stage 5: ESPs outletto ID fans inlet, FD fan disch pressure = 300 mmwe ATTDONE AT KORBA: For ATT of Stage 1, FD fan was run and loaded upto 300-mmwe pressure in the duct, leakages were identified andattended accordingly. The air outlet ducts from SAPHs A & B to Boiler windboxes, are supported from the LHS & RHS Coal bunker support structures, as they are routed outside the Boiler support structures as par drawing. Since NTPC could not provide the coalbunker support structure of LHS, air ducting of SAPH A was erected with temporary supports from Boiler support structure. However, since the temporary supports provided for the LHS zirheater, air outlet ducting was not to be subjected to higher air pressurisation for furnace ATT, otherwise alternative source of air to furnace was required. For BLU, NTPC insisted that furnace ATT (at 75 mmwe) shall be completed, with the existing conditions, It was decided with the existing temporary supports of air ducting of LHS & RHS from Boiler & coal “TECHNICALSERVICES, BHEL-PSWR SITES FEEDBACKS... EREDbunker support structures, to conduct furnace ATT at +75 mmwe air pressure, by admitting air from air compartment of SAPH A to flue gas compartment by removing the radial seal. The air from flue gas ‘compartment of SAPH A will go to furnace in the reverse direction, i.e. instead of Boiler outlet to SAPHA flue gas inlet, air lows to BOILER through fluegas duct. During ATT, airheaters are not inoperation, removal of only segment of Radial seal ofthe SAPH A wassufficient for airflow. Furnace ATT (Stage 2) was conducted successfully with 75 mmweair pressure by runningFD fan. Later on, Stage 3 ATT was conducted by running FD fan & loading upto 300-mmwc pressure, after completion ofthe SAPH A duct supportsand Coal bunkers LHS supportsbyNTPC.. Stage 4 ATT is being conducted by running FD fan & loading upto 300-mmwe pressure, by admitting air to only SAPH A, with Radial seal removed condition. Airis passing through SAPH A air compartmentto flue gas compartment and towards ESPs. This helps to avoid furnace pressurisation unnecessarily, to achieve testing pressure of 300 mmwc of the gasduct from BOF to ESPs inlet. CONCLUSION: NTPC was satisfied with the arrangement of Radial seal removal for conducting furnace ATT, as no compromising of test pressure wasneeded. For conducting Stage 4, if FD fan is used for getting the required 300 mmwc duct pressure in the normal flow path of furnace and outlet to gas duct to ESPs, fan loading will be enormous and furnace also gets pressurised more unnecessarily. Otherwise, separate air blower is to be used to get the required test, pressure of 300 mmwc in the BOF gas duct with additional piping work etc. But avoiding all these, with the removal of one seal strip from SAPH A and running FD fan, the required pressure is achieved in the duct from BOF to ESPsinlet. NTPCis alsosatisfied, as thereis no compromise ontesting parameters. The operation modalities are arrived by BHEL siteteam. eeeCENTRING OF LP TURBINE GLAND BOX IN KWU MACHINE - A CASE STUDY V. Veerapandi Sr. Manager / SAS Email: vpandi@bhelpswr.co.in Introduction: The TG set trouble free run after overhauling is the great relief to customer as well as the work executing agencies. In some of the site, the unit has experienced high shaft vibrations after immediate ‘overhauling which was running normal before overhauling. During the overhauling of equipments, maintaining the acceptable / design values are more important for smooth operation of machine. LP Turbine gland casing centring activity is the last activity to execute in turbine assembly, Itwill play the vital roleintroublefree operation of TGset. One of 500 MW TG set has experienced high shaft & bearing vibrations after overhauling and synchronization of the machine. This article covers observations, analysis of the problem and also suggests remedial measures toavoid recurrence of such a problem. Problem Faced: Machine was taken under shutdown for Generator first inspection and bearing inspection along with casing centring check. After completion of overhauling work, machine was rolled and synchronized to grid. During the process of raising load, bearing No.3 shaft vibration increased and reached above alarm value and machine was immediately hand tripped. Observations made: After hand tripping, the machine didnot come on barring. Shaft Vibration observed (peak peak) 3000 rpm 273 MW Load Just before or peu Cee IY xi XY xy il 37/63 126/89 314/218 335/243 2 61/56 85/85 269/179 421/90 a 55/47 43/40 269/149 700/281 4 92/84 71/65 218/204 441/182Bearings Vibration observed (peak peak) cere 3000 rpm PE ere) Just before iy ny eka Ce x IY xy xy af 17/1s 16/16 16/43 122/118 2 9/7 10/9 17/30 146/153 3 11/14 18/15 54/19 239/191. 4 25/27 19/15 95/61 141/87 So 23/25 33/25 83/87 95/67 6 54/34 35/39 31/51 108/96 Problem Analysis: After completion of overhauling work, machine was synchronized at 07.00 hrs after electrical testing and load was gradually raised to 400 MW. All turbovisory parameters were found normal up to 400 MW load. Due to tripping of three mills, load was dronped from 400 MW to 200 MW at 14.00 hrs, which resulted disturbances in the process parameters. © RH temperature dropped from 520° Cto460 °C © Bypassing of LPH2 andHPHSB. © Nosignificant changes inaxial shift, differential expansion and top/bottom casing temperatures. ‘The machine was stabilised at 300MW and same load was maintained for three hours, during load raising from 300MW at 19.00 hrs, bearing no.3 shaft vibration found to be increasing trend and subsequentty all bearings vibration started increasing and bearing shaft vibration reached to 329 microns and machine was hand tripped immediately. During coasting down time bearing 3 shaft vibration went up to 700 micron and machinedid not comeon barring. JOP pressure and rotor lift on individual bearings were checked and found ok. LP front & rear gland clearances were checked. LP front gland found to be disturbed andthe topclearance observed as 0.20mm. During the overhauling, bearing no.3 was lifted by 0.5mm for the IP/LP rotor alignment correction. ‘Accordingly re-centring of gland casing was carried out by lifting of Gland casing through jack bolt. After centring the gland casing, radial & axial key with proper dimensionas per correction need tobefitted, butit wasnot done properly and key were put with excess clearances and gland casing was also left onjack bolt. (Refer Figure-1 for LP ShaftSeal Assembly / Clearances and Figure 2 for jack bolts setting) The problem was occurred after running the machine for more than 24 hrs. The LP gland casing was got disturbed during jerk on load reduction from 400 MW to 200MW due to tripping of three mills. The gland casing came down due to excess key clearance and rubbing started on rotor and it leads to high shaft vibration. [TECHNICAL SERVICES, BHEL:PSWR sires reeneAcKs.oc IEERemedial Measure Taken: Thefollowing remedial actions were carried out. © LPGland casing re-centringwas done at both sides. © Proper bluecontactwas ensured between key and keys © Newkeys were putas per the design clearances. © Bearing no.3 wasinspected & ensured the healthiness of bearing. Performance of the Machine after corrective action After rectification work, Machine was rolled & synchronized to grid. The shaft & bearings vibrations and Turbovisory parameters are found normal during no load & load operation. Bearings & Shaft Vibration observed (peak peak) Ca 3000 rpm eT) N Bering Vibn (X/Y) Shaft Vibn (X/Y) | Bering Vibn (X/Y) | Shaft Vibn (X/Y) a 15/1. 82/92 17/aa 115/85 Z Us 80/72 10/9 93/88 3 13/13 33/30 17/18 37/38 4 26/23 53/66 19/16 68/63 Sg 26/26 81/79 27/22 85/83 6 38/36 66/70 32/37 7/77 ‘/ 38/43 87/101 27/31 90/105 ‘Suggestion /Recommendations In order to avoid recurrence of such a problem the following are suggested. © Gland casing centring may be carried out after complete assembly of pedestal cover & Gland casing holdingdown bolts are inposition. ‘© Partial weld filling and putting of shim on keys are to be avoided during final assembly. New keys are to befitted with design clearances after centring the gland casing. Toensure proper matching of Gland casing key & keyways by bluecontact. ‘Measurement of gland radial clearances with long feeler gauge to ensure uniform clearances. i bolts of LP gland box to avoid restr Following procedure to be followed for setting of ja nin thermal expansion <> After centring of the LP gland box with the help of jacking bolts in cold condition, keep all the jacking bolts in contact with LP Gland box body. "TECHNICAL SERVICES, BHELPSWR SITES FEEDBACKS... SEConnect all glands sealing piping and complete all connections with LP turbine bellow / turbine bearing pedestal Check the radial clearance of LP gland box with long feeler to ensure thet LP gland box has not been disturbed due to pipe pull /assembly stresses. Dial gauges to be mounted in horizontal and vertical direction on LP giand box. Release the jacking bolts, keep a gap of more than 5 mminall bolts, and ensure from the dial gauge readings that no undue movementis therein LP gland box. Thermal expansion of LP Gland Box in all directionis now ensured during rolling, synchronization and fullloadingofthe machine Runthe machineatfull load under steady state condition for morethan 24hrs, After ensuring all bearing and shaft vibrations are within alarm limits, a clearance of 0.20 mmis to be set between each jacking bolt and LP gland box body. Periodical monitoring of this clearance during operating conditions may be done to ensure that no distortion has taken place in LP giand boxbody. DeTAL a ALLE re y FIGURE 1: LP SHAFT SEALSJacking bolts in transverse direction Jacking bolts in Vertical direction Figure 2:- Jacking bolts provided in Vertical and Lateral direction for Centering of LP gland Conclusion: In KWU machine, the radial clearances of LP Gland casing is very important for smooth operation of the machine and any deviation in these readings may cause rubbing in the LP gland box area which can disturty the vibration pattern of total rotor system. Non-uniform clearance in LP gland boxes may also result in stoppage of barringgear. Though the LP gland casing centring seems to be very simple activity of Turbine assembly, it plays an important role introuble free operation of Turbine. eeeCASE STUDY ON EHTC By: Abhishek Dasgupta Engineer, TSX(C&l) BHEL Bhilai Site OBSERVATION Paras TPS Unit 4, April6,2010. In Unit 4, at around 11:10 hrs, unit was running at 104 MW on load control at 45% position set point to plunger coil. Turbine speed was around 2943 rpm. Gradually turbine started slowing down alongwith grid frequency. Speed reference was tracking actual speed 14.4 rpm ahead of it. As turbine speed went below 2936.4 rpm, suddenly speed reference plummeted to 2883 rpm and after 2 seconds, it came further down to 2805 rpm. Speed controller output went down from 18% to -12% and then after 2seconds itcame down to -61%. Turbine control shifted from load control to speed control. Machine (Turbine) started to unload. Load came down from 104 MW to 85 MW. Load controller output crept to 100%. Machine kept running on speed control. Operator tried to increase speed reference manually but his efforts went in vain, After some time, a5 soon as machine speed went beyond 2940 rpm, machine control jumped from speed control to load control. EHTC opened upto 100%. Load shootup from 85 MW to 148 MW momentarily and then came. back to the load setpoint. Similar phenomenon wes observed at around 15:20 hrs the same day. This time when the machine came back to load control, load jumped from 100 MW to 198 MW. Then machine tripped on generator electrical protection because offield failure. ANALYSIS During rolling and prior to synchronization, speed controller PI remains active. 'SPD_REF_R_L' function block in maxDNA EHTC.4F file passes on speed reference to speed controller by way of accumulating error to speed controller. Speed reference initiation logic becomes clear when 'FRCBIn’ attribute of 'SPD_REF_R_U function block is traced back or ‘followed! in maxDNA. After synchronization, as machine 20s into load control, speed reference tracksactual speed 14.4rpm ahead of itaslongasmachine speedis between 2940 rpm and 3060 rpm with load controller ‘ON’ and load controller being >5% ahead of speed controller. Otherwise, as soon as any of these conditions fail to satisfy, speed reference tracking stops. ‘Speedreference gets frozen at the last reference l.e. 2940-3.6(Dead Band) + 14.4=2950.8rpm. ‘At the same time, another variable, which is created by subtracting 129.6 rpm from current actual speed, comes in queue. Now, ifany of the trip oil pressure switches MAX51CPO11 and MAX51CP012 senses low pressure (<2 kg/sqcm}, 'ATT Turbine Tripped' signal gets generated. Therefore, if speed reference tracking stops, say for speed below 2940 rpm, and ATT Turbine Tripped’ prevail together; the speed reference is further lowered downto 2940 3.6[Dead Band) 129.6=2806.8rpm. This is what happened at Paras that day. Agein, when the speed tracking condition got restored i.e. machine speed went beyond 2940 rpm, speed reference jumped to ActualSpeed+14.4rpm = 2940+.14.4 2954.4rpm. “TECHNICALSERVICES, BHEL-PSWR SITES FEEDBACKS... EERThis caused change over from speed control to load control through the 'MIN' value gate as speed controller output jumped from -61% to +5% andthen+15% andsoon. SUGGESTIONS @ = Thisincident could have been avoided had the pressure switches MAX51CP011 and MAXS51CP012_ behaved properly. © Beyond certain speed, i.e. below 2940 rpm (49 Hz) and above 3060 rpm (51 Hz), speed tracking is, deliberately stopped. This logic is incorporated so that machine does not coast down or speeds up by cumulative action of speed controller. This logic is also in line with maintaining grid frequency within 1 Hz band (2%) around 50 Hz. According to CEA regulations of keeping grid frequency within 1% Le.0.5 Hz around 50 H2 for maintaining power quality, the set values of 2940 rpm and 3050rpm for speed reference tracking, should be kept at 2970 rpm and 3030rpm respectively. © ‘ATT Turbine Tripped' signal is connected to EHTC panel via maxNET. To avoid occurrence such an incident from any spurious signal, ‘ATT Turbine Tripped’ should be connected through hardwire. Moreover, ‘ATT Turbine Tripped’ is generated if ANY of the pressure switches MAXSLCPO11 and MAXS1CPO12 senses pressure low. To have more reliability, another pressure switch may be connected in trip oil circuit and ‘ATT Turbine Tripped' may be generated from 2 out of 3 combinations of those 3 pressure switches. eeeLUB OIL TEMPERATURE AFTER COOLER HIGH ‘S. Mandal $r.DGM (Commissioning) BHEL, Paras Site OBSERVATION: During the rolling and synchronization activity of Paras-II, it was observed that the turbine lub oil temperature after cooler was not stabilizing at 45 °C even after putting the oil temperature control valve into full cooler service position, The oil temperature after cooler increased up to 55 ‘C even after taking both coolerin service and making arrangement for external cooling of the coolers by water jet. The bearing temperature touched maximum to95°Cin bearing-3 by the time unit was synchronized. After synchronization of the unit, the water box of the coolers was inspected for any choking of water flow. Lot of flakes and pebbieswere found into the inlet water box and they were cleaned. During carryingout thecoal OBSERVATIONS: There was no cooling effect from cooling water. The vent water and the outlet water from the cooler were found tobe cold eventhough the oil temperature inside the cooler was 60°C. ing activity afterward, the same problem was faced again. © The butterfly valves at the inlet and outlet was ensured to be open. The water passes inside the coolerwas ensuredtobe inorder. © The water pressure at the inlet to the cooler was increased by running two cooling water booster pumps without anyresult. It was reported that the same problem was faced in PSER with BHEL/Bhopal supplied oil cooler. It might be noted that in Paras-1, the oil cooler was supplied by BHEL/Hardwar. The reason for the problem was short- circuiting the oil flaw inside the cooler from inlet to outlet via the annular area of the cooler tube nest cover and the cooler shell (ref. Fig. -1 below). The matter was reported to BHEL/Bhopal for rectification. A team of technician reported site and rectified the cooler one by one. The matching part of the insert in the tube nest. cover was removed by grinding and material was filled up on the inner edge of it. The inner hole was machined as per the insert ‘outer diameter. Finally, the insert part of the tube nest was welded back on the tube nest cover. The performance of the cooler improved after this and unit run at full load with oll temperature control valve at 10% RRRAs per design there should be a gap (max 1 mm radial) between the lub oil outlet insert outer diameter ( D1) and tube nest outer cover hole inner diameter (D ). As existing (as seen above) there was 12 -15mm annular gap between them. So hot oil was flowing from inlet through the annular gap between the tube nest & cooler outer shell and through the gap between the insert outer diameter & the tube nest outer cover (as shown above) to the outlet bypassing the cooling zone ofthe tube nest. eeeLT POWER SYSTEM THE BACKBONE OF POWER PLANTS PART 2 S.K.Choudhary Manager(Electrical) BHEL, Mangrol Site All types of power plants have redundant emergency electrical systems that are designed to provide backup AC and DC power to emergency safety equipment if normal sources of electrical power are lost. Contrary to the common belief that DC system is meant for a power backup to the AC System, during normal and emergency conditions, the DC system supplies power to operate certain equipment so that even if no AC were available, certain safety-significant equipment would be operable, supplies control powertoimportant loads as breakersand pumps. Normal operation of plants requires a healthy DC system not only as a backup power source, a dependable watchdog but as allifeline on which it isdependent upon for continuous performance and survival in case of interruption. Therefore, this watchdog merits careful attention and surveillance on the part of operation staffand its healthiness isa real plant health parameter. Following pointsare must for having agood DC system backup: 1. Healthy Cells: Cells are tiny power blocks meant for catering to emergency DCrequirements. These are required to be installed on electrically isolated benches in dust free air cooled room. Level and quality of electrolyte in the cells are required to be inspected at regular intervals. interconnecting conductors of the cells carry the rated current of the system. Therefore, tightness of the interconnecting links and adequacy of the conductor cross-section for carrying the rated current has to be ensured at erection stage. 2. Healthy Battery Charger: Battery charger plays an important role of supplying the DC power to connected equipments and charging the batteries during normal operation. Any transient or additional load (in case of AC power failure) is supplied by the battery. Battery charger alarms are required to be attended to with utmost priority to avoid system failure. 3. Healthy Cranking Amperage: It is defined as the highest load current supplied by the battery prior to voltage drop of the DC system to unusable levels. Cranking amperage may be ascertained to the extent possible by switching on highest loads concomitantly. Set and rest voltage values of all the actuating components connected to the DC system must be known in advance to determine the unusable voltage level of the DC system. In none of the load conditions, the system voltage is allowed to attain unusable level. 4. Healthy distribution System: DC distribution board and conductors up to the load terminals are required to be tightened adequately in order to minimize the voltage drop during high current conduction. in order to enhance reliability of the system, ring type or spring loaded press fit type lugs should be used for power as well as control terminals. In case of floating dc system, conductors of both the poles are required to be effectively isolated from earth. Earth fault on either pole of the DC system isan alarming condition and must be rectified on then and there basis. For example, Ina125 V or a220V DC floating system an earth faulton either terminal (Positive or negative), appears to be innocuous but it can bring devastating results as shown inthe following figure:ve terminal Earth. Breaker closing coil It is obvious that in such circumstances, with an earth fault in control circuit, a breaker can close (or trip) bypassing all the system interlocks which may be catastrophic at times. Above holds good for negative terminalearthfaultalso. Post incident analysis of such type of breaker closures quite difficult as sequence of event can detect only ‘opening or closing of the breaker and relevant after effects while cause of the event remain elusive. Therefore, interlocks for closing should be provided at both ends of closing coil which may lessen the probability of such inadvertent operation. Availability of control supply whichis invariably DC in most of the equipments is highly critical and itcan be ensured by having multiple backups in parallel through paralleling diodes. Rating of such diodes should be robust enough to take care of DC system transients as the failed diodes result in paralleling of the sources and fault of one source is reflected in the other, thereby defeating the purpose of having redundant sources. 5. Healthy DC Drives: DC drives connected to the DC system are to be checked for healthiness on regular basis as the components like DC contactors, starting resistors, timers, field trimming resistors and contacts of powerand control circuit get deteriorated with operation hours. eeeTRANSFORMER TRIPPING DURING INTIAL CHARGING BY MAGNETIZING INRUSH Deepak Gehlot Engineer, BHEL Paras Site MagneticIn Rush When a transformer is energized, a transient magnetizing current flows, which may reach instantaneous peaks of 8 to 30 times those of full load. The factors controlling the duration and magnitude of the magnetizing inrushare: i) Size of transformer bank ii) Size of power system iil) Resistance inthe power system from the source to the transformer bank iv) Residual fluxlevel v|_ Type ofiron used for the core and its saturationlevel. There are three conditions which can produce a magnetizing inrush effect i) First Energization ii) Voltagerecovery following external fault clearance ili) Sympatheticinrush due toa parallel transformer beingenergized, Under normal steady state conditions the flux in the core changes from maximum negative value to maximum positive value during one-half of the voltage cycle, i.e. a change of two times maximum. Since fluxcannotinstantly be created or destroyed, transformers are normally designed and.un at values of flux ‘approaching the saturation value an increase of flux to double this value corresponds to relationship, must always be true. Thus, if the transformer is energized at a voltage zero when the flux would normally be at its mavimum negative value, the flux would rise to twice its normal value over the first half cycle of voltage. This initial rise could be further increased if there was any residusl flux in the core at the moment the transformer wasenergized, Since extremesaturation which requiresan extremely high value of magnetizing current. As the flux enters the highly saturated portion of the magnetizing characteristic, the inductance falls and the current rises rapidly. Magnetizing impedance is of the order of 2000% but under heavily saturated conditions, this can reduce to around 40% i.e. an increase in magnetizing current of 50 times normal. This {figure 1 canrepresents to 6 times normal fullload current.Transformer Magnetising Characteristic Twice Norma rermar NotCoae current 3eTwies Normal Fa Fig 1 ‘Analysis of a typical magnitude inrush current wave shows (fundamental = 100%): ‘Component Bc 2"H 3"H 4"H 5"H 6"H 7"H 55% 63% 26.8% 5.1% 4.1% 3.7% 2.4% The ofiset in the waveis only restored tonormal by the circuit losses. The time constantoftthe transient can be quite long, typically 0.1 second fora 100 KVAtransformer and up to 1 second for larger units. Initial rate of decay is high due to the low value of air core reactance. When below saturation level rate of decay is much slower. ‘The magnitude of the inrush current is limited by the air core inductance of the windings under extreme saturation conditions. A transformer with concentric windings will draw a higher magnetizing current when energized from the LV side, since this winding is usually on the inside and has a lower air core inductance. Sandwich windings have approximately equal magnitude currents for both LV and HV. Resistance in thesource will reduce the magnitude current and increase the rate of decay. Effect on Differential Relays Since magnetizing inrush occurs on only one side of the transformer, the effect is similar toa fault condition as far as differential protection is concerned. Although considered usuallyin conjunction with energizing of the transformer, magnetizing current inrush can be caused by any abrupt change in magnetizing voltage. Such transients include the occurrence of a fault, removal of a fault, the change of character of a fault (e.g. from line to ground fault to two phase to ground fault) and out of phase synchronization. Thus, a desensitizing scheme that is effective only when transformer is being energized is not an effective counter technique. “TECHNICALSERVICES, BHEL-PSWR SITES FEEDBACKS... SEEof TPA aaaEse hlnerrerrerccrree) om , AVY lel .." « bee et om oo 7 a oom = —— Sa 4 i 4 a i is i ie e Fig 2: Typical Waveform during Inrush Condition with Harmonic Components The following methods are used to stabilize the relay during magnetizing inrush period. ‘A) Time delayed - acceptable for small transformers or where high-speed operation is not so important. (Note: necessary time delay whenassociated with parallel transformers could be excessive). 8) Harmonic restraint - usual to use 2” H restraint since magnitude inrush current contains pronounced 2"*harmonics. 3H restraint shouldnot be used fortwo reasons: a) Due to delta connections in the main transformer and in the CT circuits (which provide a closed path for third harmonic currents], no third harmonic current would reach the relay, b) CT saturation under internal fault conditions also produces harmonics of which the 3” is the most predominant. Second harmonics are also produced under these conditions (combination of DC offset and fundamental) so excessive saturation of CTs shouldbe avoided. The problem of any restraining tendency due to 2” H currents produced by CTs saturating under heavy internal fault conditions is usually overcome by using high set instantaneous units set at 8-10 x rated current. While the second harmonic produces a useful restraint during external faults, it can produce unwanted restraint for internal faults, due to dc saturation of CTs. Extremely large CTs are required such that they do notsaturate and affect the operating times ofthe differential relay. "TECHNICAL SERVICES, BHELPSWR SITES FEEDBACKS... (ETON©) Gap Detection - Ifthe various current waveforms that occur during magnetizinginrush are analysed, it can be found that the magnetizing currents have a significant period in each cycle where the current is substantially zero. Fault current, on the other hand, passes through zero very quickly, Detection of this zero isconsidered @ suitable Criterion. Thus, a transformer differential relay can be made to restrain if zero is detected in a cycle for more than a certain period (typically 1/4f seconds). With the above principle of detection of magnetizing inrush, fast operation of the relay can be achieved for internal faults and economically designed CTs can be used, without affecting the speed of operation. Effect on Over Current andEarth Fault: ‘As explained above during inrush condition a high current flow this current goes as highas10 times. Thus, it is practice to adoptan instantaneous Over current as calculated by below given Formula. I>>=1.6XI/ sym for Voltage > 5 KV I>>=1.5XIf sym for Voltage <5 KV Where I is Maximum AsymmetricFault Current Further, during Inrush condition there is an unbalance current as shown in figure below. This unbalance flows through the neutral and is detected as earth fault current. In order to avoid Sympathetic Tripping on Earth Fault we can use same strategy as used for Differential Current i.e. increasing Time Delay in Earth Fault tripping / Disable E/f protection during inrush condition. This feature should be limited by using a time limitation, since harmonic restraint can cause trip delays on internal faults with CT saturation. IR+IS+IT=3lo #0 | Fig 3: Currents during Inrush Condition seeTRANSFORMER SPARKING AT SGPP, SULEMANYIAH Deepak Gehlot Engineer, BHEL Paras Site ‘On 30/12/2009, Transformer for GT-4 was Back charged. During Back charging a spark was observed nearV phase. Refer fig. 1 125011250) EL(+)107.05M [@ oF susouct |EL—1—V} aa HEL=1=") Has OUTLET WN fle 2 2/8 (§E2=GT-U}—~_S al [ABI-GT—U] = f Wa (ABo=GT= — | 4 E la |Z x cl -. [ABI=GT=¥] = s 08 [AB2=GT- OF GEN. TRF. gle 3] [ABI-GT-V] BUSDUCT 2/5 8/7 e3 Oe EL(+)100.20M a | r AREA ofS RAIL LEVEL nner er ec | Before Opening 52L breaker, Parametersin MV room were observed. All parameters were found normal. AIILV side Connections were removed and inspected. During inspection, nothing was found in LV bushings. Transformer waslsolated and transformer test were performed. HV MAGNETIC BALANCE: INN Nola Ccis Tia N olen tcl R-N Y-N B-N R-N Y-N B-N 207 158 44.3 206.8 97.8 108. 202.4 418 (158.5HV MAGNETIC CURRENT: anlar IE t ket cae R-Y Y-B B-R RD YD Bd 364.6 364.4 365.1 0.26 0.23 0.28 RATIO CHECK: TAPNO. = RY YB BR RN YN: BN RY Y-B B-R a 355.7, 345.5 356.9 26.72 26.80 27.35 9B 364.6 364.4 365.1 30.90 30.31 30.27 7 364.4 355.2 359.3 32.81 335 33.05 WINGDING RESISTANC! R-N Y-N B-N R-Y Y-B B-R 1 1213 116.52 116.32 3 115.96 113.35, 113.5 4 112.42 111.11 111.83 5 112.13, 109.53 109.87 6 110.48 108.24 108.9 7 109.01 106.82 106.82 8 106.90 105.33 ‘105.27 9B 105.98, 103.84 105.41 19 1.77 1.8 10 108.55 105.32 108.96 11 110.03, 106.7 110.09 12 112.5 108.18 111.41 13 119.22 109.88 113.98 14 116.24 111.39 115.21 as 119.22 112.66 117.86 16 123.55, 114.77 119.17 7 126.68 116.23 123.83 | CTECHNICAL SERVICES, BHELPSWR SITES FEEDBACKS... EENDuring Testing it was observed that AB1-GT-V and AB2-GT-V were isolated refer fig 1 (they were not shorted with each other / nor Connected to earth), Generator transformer wasconnected to UAT through busduct. Sparking can occur, in such a case as main conductor acts as primary of an air core transformer whose secondary (enclosure of the bus duct piece AB1-GT-V and AB2-GT-V) is open. This Situation is similar to that ofa Current transformer whose secondary is open. Fig 2: Showing Path of Current through Earth Under energized condition when the CT's secondary is accidentally open circuited, the current will have only the magnetizing path and the voltage induced across the CT open terminals will be the sameasacross the magnetizing circuit. Under this situation the magnetizing circuit shall carry the same current as caused by theprimary current, whichis very high. :.PeakVoltage developed across the CT open terminals, Vpeak = [35% Zbx Ipin Above explained phenomena resus in development of high voltage which tries to discharge to earth bya spark. Since the UAT charging (inrush) current is there only for small time duration we see onlya sparkand no continuous arcing is observed. Before next charging, the AB1-GT-V and AB2-GT-V were shorted and earthed. During next charging, no sparking was observed, verifying the earlier explain theory. ees‘ion of Plant Efficiency with variation in Stack heat loss Faraz Raza Khan Engineer(TSK) Mangrol Site ExitGas Temperature: The major power loss from the steam generator is the heat of the exit flue gas. Reduction of the exit gas (stack) temperature is typically limited by material selection and concern for dew point and corrosion. By proper evaluation of fuel properties and utilization of Corrosion resistant materials in the final heating surfaces, the stack temperature may be optimized according to each plant. The operating temperature requirements of emissions control equipment such as selective catalytic reduction (SCR) and flue gas desulfurization FGD) systems place additional constraints on the system. Proper arrangement of ‘equipmentand heating surfaces is required to achieve a balance between full load efficiency optimization and desired operating flexibility. While the exit gas temperature limitation will vary for specific plants and fuel ranges, Figure 1 suggests the potential plant efficiency benefit as the design exit gas temperature is modified. 425 F (14°C) reductionin exit gas temperature would improvethe net plant efficiency (HH) by approximately 0.25% points. 38.0 37.5 37.0 Net Plant Efficiency, HHV Basis, % 8 ° 34.0 -50 -40 -30 -20 -10 0 10 20 30 40 50 Change in Boiler Stack Temperature, °F "TECHNICAL SERVICES, BHEL:PSWR sires reeDBACKS.. EERExcess Air and Unburned Carbon: Besides the exit gas temperature, another operating parameter with direct effect on the stack heat lossis the level of excess air used. Flue gas is the mixture and by products of vaporized combustibles and the total air supplied. Therefore, at a given stack temperature, a reduction in air flow rate will reduce the heat carried out through the stack. Ideally, to release the full heating value of the fuel, one would like to supply only that air which is required for full combustion of the fuel i.e., zero percent excess air or an air ratio of 10. Because of heterogeneous mixing of the combustible and oxygen molecules and other fuel and combustion-related conditions, an excess supply of air is providedto promote complete combustion of the fuel. Therefore, the optimal excess air level is 2 compromise between stack heat losses and combustion inefficiency losses as measured by unburned carbon in the ash and further indicated by CO emissions. lustrates this relational balance for a hypothetical unit. Figure: (Optimal Etticiency Stack Heat Losses Heat Loss ‘Combustion Losses (UBC) 0.90 1.00 1.10 1.20 1.30 1.40 1.50 Stoichiometric Air Ratio Optimization of Excess Air and Boiler Efficiency Fig:2 oeHOW SAFE ARE TUBE MILLS FOR OPERAION? MSadagopan St. DGMITSX) BHEL, Paras Site As the leading manufacturer of power equipment, BHEL require to supply equipments of various combinations to meet the requirements of the customer. In boiler, milling plant is one such combination. Many customers use bow! mill of various capacities for coal grinding, but some customers prefer or opt for balltube mill for the same application. Herewe are not going to discuss the merit or demerit of the ball tube mill over other mills. Butthere isa floating opinion that operation of tube mills is tricky from the angle of fire hazard and over filling. Hence thistopicwas thought tobe worth for puttingupsome views for discussion, The basic operational variation ina ball tube millis the availability of pulverised coal stock in the mill at any operational condition. This stock availability gives the flexibility in operation whenever load changes called for. However this stock of pulverised coal if nothandled properly can cause the problem of overfilling and combined with temperature during certain abnormal operational condition may lead to unsafe mill operation. The issue for discussion isthe fire hazard in tube mill andin worst case explosionin the mill. nthe tube mill, pulverised coal is expected to be present in motion only n system flow path onits way to the furnace. Operational experience so far indicated that the following locations in the milling plant were susceptible forfirehazard a) Hotairboxarea b) Feeder ©) Millshell Why are these areas susceptible? Are there any inherent shortcomings in the design, layout of the milling plant? These design and layout areas were revisited earlier and improvements were made. After introducing these changes, betterment in operational and maintenance practices were thought over. Based on these observ: Ins of occurrences, some operational guidelines were introduced. HOT AIR BOX AREA: As far as possible, operation of the mill shall be run with both ends, i.e., both coal elevations of the boiler. However, this may reduce the flexibility of operation at times and hence whenever the requirement of the single end operation of the millis felt, then itis a must that; {i) Collection of coal inthe hotair box of the non-working side is to be avoided by keeping that side air- thro mill damper5% open. (ii) Hot air flow through the bypass duct into the mill is avoided by ensuring full closure of the non- working side bypass damper. For this, bypass air flow measurement and reliable operation of the damper shall be ensured. “TECHNICALSERVICES, BHEL-PSWR ISSUE SPECIAL- TUBE MILLS... IEZZN(iii) Screw conveyer outlet temperature at the non-working end shall be monitored during the operation. Corrective action is needed when this parameter shows an increasing tendency. (iv) With many flange connections in the tube mill layout, any leak area in thecircuit shall be identified andattended to at the first opportunity to avoid hotspots. MILL SHELL: Whenever mill is stopped/tripped to be kept as standby, to avoid smouldering of hot pulverised coal inside themill shell, (i) Barring operation, ie, running the mill onauxiliary motor shall be ensured. Isolation of hot air flow though the mill from any source, shall be ensured. ,, full closure of general shut-off gate During the normal operation of the mill, (i) Whichever side of the mills in service, the corresponding feeder shall be in service. Operation of the mill for longer period without the feeder beingin service shall be avoided. Such an operation of the mill willallow lean mixture in coal pipes with high coal-airtemperature. (ii) Adequate mill level, ie., coal stock, shallalso be ensured. In the absence of the same, over-grinding of pulverised coal in the mill can take place, which can become asource for fire hazard in the mill. During shutdown of the mill, (i) Itis preferable to purge out the mill off pulverised coal. To enable this, a ten minute mill purge can be done maintaining theair flowregime. FEEDER: Feeder is one area where fire hazard is generally not expected. However experience showed that belt damage did occur due tofire. To eliminate this, theguide lines are (i) Adequate sealair pressure to ensure flow from feeder to mill and notvice versashall beensured. To achieve this, any leak from the doors shall be errestedoreliminated. (ii) Feeder operation without clean out conveyer running shall be avoided as this will result in coal accumulation in the conveyer area. (iii) During maintenance of any feeder with single end operation of the mill, positive isolation of the feeder outlet gate on the non-working side shall be ensured and also coal settlement on the outlet gate of the isolated feeder shall be avoided. With any leak of hot air and coal settlement, smouldering of coalcan occur which can lead to belt damage. Steaminerting system -Availability for service at all the timeshall be ensured. With all these operational and maintenance guidelines, safe operation of the tube mill can be done. Only when unwarranted operating condition occurs, mishap takes place. To highlight this, one such incident which led to an explosion in an unexpectedarea of the milling plant isgiven below. “TECHNICALSERVICES, BHEL-PSWR ISSUE SPECIAL TUBE MILLS... ETIEvent Explosionin mill CD during half mill operation Date of occurrence 03/04/2009 Time of occurrence Between 16.25 to 16.35 hrs (approximate) ‘Sequence of events and observation: 1. Mill CDwas taken into service at 09.05 hrs with coal elevation D. Subsequently coal elevation C wasalso taken into service. Till 12.05 hrs, milloperationwas normal. 2. From 12.10 hrs onwards, coal flow disturbance to feeder -D was faced. This was indicated by the increase in screw conveyer outlet temperature. Suspecting choking, at 12.50 hrs, feeder D was taken out of service for work to establish coal flow from bunker. However it appears from air-thro mill low that elevation D was continuously kept in service from 12.10 hrs and an increase in mill outlet temperature were also observed. 3. With coal elevation C in service, bypass air flow of non-working side, i.e., D side was also not completely closed till 15.55 hrs. 4. Meanwhile there was an occurrence of inadvertent operation of feeder outlet gate D during maintenance work at 15.25 hrs, causing pulverised coal leak from the mill to the atmosphere, spreadingin feeder floor. The gate was subsequently closed by the concerned. Feeder D was boxed up, but was not released or taken into service. Explosion sound washeard approximately at 16.29 hrsmore than once. Mill was stopped at 16.40 hrs and elevation C wasisolated. erxnau External inspection showed a) Damage to/snapping of mill inlet duct supports, resulting elevation lowering of the duct. b) Rupture of duct walin common duct below general shut-off gate. c) Damage to metallic expansion joints in the inlet duct to both the sides of the mill by way of elongation. d) C-side screw conveyor bearing housing damage €) Millinternals are tobe observed for any damageafter coolingdown. Analysis and possible cause: 1. Half mill operation was very common and concerned staff was aware of the precautions to be taken as. per guidelines available. 2. However with elevation Cin operation, outlet temperature increase in elevation D showed that outlet gate/s is/are in open condition for long time till the mill stoppage. This indicated that there was an attempt to keep both elevations in service with one feeder tll flow from bunker D was established successfully 3. Millwasinoperation with high noise level, which was an indication fortrouble. 4. An increase in screw conveyer outlet temperature to a level more than 100 deg C called for an immediate action. In addition to that the mill outlet temperature of elevation D was also showing | CTECHNICAL SERVICES, BHEL-PSWR ISSUE SPECIAL TUBE MILLS... EERincrease from the time coal flow disturbance started. 5. Mill outlet temperature of elevation C was also started increasing beyond 100 deg Calong with screw conveyer outlet temperature at around 15.30 hrs. 6. Coal spread in feeder floor and visual observation of coal gushing out from the feeder outlet gate D, with the mill in operation could have contributed to unwanted PF coal settlement in the mixing chamber area. 7. Moreoverescape of reddish sparks was seen at the time of subsequent explosive noise from themixing, chamber area, indicating likelyaccumulation of combustibles in that area. 8, Damage to duct area was due to propagation of pressure wave condition after the occurrence of explosion. Here the following stepsas per guidelines would have avoided the incident 1. Coal elevation D should have been taken out of service once the trouble of coal flow started and feeder was stopped. 2. Withcoal elevation C showing higher temperatures at conveyer outlet and mill outlet, shutdown of the mill would have been the best choice, followed by steam inerting of the mill 3. Positive Isolation of feeder outlet gate and ensuring non operation of the gate during maintenance work would have helped. Communication with clarity between working agencies was needed and ‘would have ensuredthis. CONCLUSION ‘Operation of ball tube mill was not tricky; it required a bit more attentiveness on the user's part and mill parameters are the correct indicators. Ignoring vital information, many times leads to negative result. Hence, tube mill operation is as safe as any other mill, if the guidelines are remembered and followed religiously, teeTSX ACHIEVMENTS 2009-10 TOTALMW COMMISSIONED 1325MW SETS COMMISSIONED IN 2009-10:- 1) BHILAL-2 (250 MW) 2) KUTCH LIGNITE(75 MW) 3) PARLI(250MW) 4) PARAS (250 MW) 5) SULEMANIAH- 1, 2, 3&4 (4X125 MW) PG TEST COMPLETED :- 1) PARAS 1- BOILER & TG PG TEST 2) BIRSINGHPUR5- BOILER, TG & ESP PG TEST 3) HZLZAWAR BOILER, TG&ESP PG TEST 4) TATATROMBAY 8 -BOILER, TG PG TEST & ESPPGT EST 5) BHILAI1- TGPGTEST MMEsprocuredin yr. 2009-10 :- 1) Portable Vibrometer No. 2) Tachometer 5No. 3) Infraredtemperature sensor 10No. 4) Sound level meter No. 5) Microohmmeter No. 6) 10KVmotorised Insulation tester 1No. 7) Relaytest kit 1Set 8) 41/2digit multimeter 5No. 9) Walkie Talkie 40set‘TSX PLANNING 2010-11 © SETSTOBE COMMISSIONED 1) 2) 3) 4) 5) 6) KHAPERKEDA(SOOMW) NTPC KORBA 7 (500 MW) BHUSAWAL 1&2 (2X500 MW) HAZIRA (351 MW) PIPAVAV2 (351 MW) SLPP MANGROL3 & 4(2X 125 MW) © SETSTOBESYNCHRONISED:- 1) 2) 3) 4) 5) 6) 7) 1ocL2(30 Mw) BINA 1,283 (3X33 MW) BHARUCH (33 MW) KONIAMBO (2X 135 MW) FINCHA (2X12 MW) TANDAO(2X 12.5 MW) SHREE MAHESHWAR 1 & 2(10X40MW) © PGTEST TO BE CONDUCTED:- y 2) 3) 4) BHILAI2 NEW PARLI2 PARAS 2 ‘SLPP Mangrol, Unit #3, #4 eee“AND THE LAST PAGE . Dear Friends, ae 2009-2010 was an eventful & successful year for BHELasa whole. At PSWR, we havere- BI stonstcted our wil to excel by attempting all challenging tasks to match the aspirations of our esteemed stakeholders. As an example, we can cite the stupendous task of commissioning both units at SLPR, Mangrol almost simultaneously as well as commissioning of all four Fr-9E gas turbines at Sulaymaniyah against all odds. Our PG test test group once again proved its worth through successful conductance of guarantee tests of ‘maximumno. of ets with bare minimum resources, Friends, never-the-less, let us not be complacent. Tasksahead for the coming years are more challenging & all ofushave to collectivelytake it head on right fromday oneto fulfil ourcommitments toallstakeholders. ‘And in thiscontext, | would like to share one critical view point inthis column. | strongly believe thatin orderto sustain our competitive edge, We all have to think seriously forbuildingup of“Core Competency” at all fields of our Power sector operation. All our esteemed Customers look at BHEL for fast response towards delivery of products/spares, quality execution of projects & trouble shooting assistances. Hence, itis highlyimperative that all our endeavours shall be towards speedy implementation of “Capacity & Capability” building strategies as enshrinedin our corporate objectives. ‘Asapart of Capability augmentation, we need to develop & encourage all our young engineersthrough proper mentoring & adequate training. Towards this, immediate measures shall be to make our existing ‘mentoring system more effective & identification of area specificspecialized training needs for all young Manpower is the biggest asset of this company & therefore all our endeavours shall be to keep the morale ofallindividuals “Very High” through continuous encouragement & welfareschemes. Letall of us work together for bullding up “Core Competency” of all youngengineers to thesatisfaction of all stakeholders, ‘SN Maiti Head, Technical Services, BHEL, PSWR (HQ), Negpur.BHARAT HEAVY ELECTRICALS LIMITED POWER SECTOR WESTERN REGION Shree Mohini Complex, 345, Kingsway, Nagpur-440001, Deion &Pritedat AQUAPRECES Ph 957182062