A REPORT ON CYCLE TIME REDUCTION AT 2 X 250MW REL DAHANU UNIT 1 DURING OVERHAULING OF TURBINE. V. Veerapandi Sr. Manager/Ser Email-vpandi@bhelpswr.co.in Introduction: REL Dahanu TPS with an installed capacity of 500 MW KWU Design has 2 x 250 MW units, situated at Dahanu (MS). TG sets are manufactured by BHEL/Haridwar and it was installed and Erected by BHEL(PSW). Unit #1,250 MW was commissioned on 31"December 1994, REL, Dahanu awarded the Unit-1 COH to BHEL-PSWRSAS Nagpur with the short time schedule of 15 days from barring gear stopping to barring gear start. Unit-1 was withdrawn on 2" August 2006 for capital overhaul of HPT,LPTand Generator along with MPI,NFT of LP Turbine blades. Benchmark on record minimum dur: of LP Turbine Blades. n of HPT, LPT and Generator capital overhaul along with MPILNFT New maintenance strategies and technologies were emerging in the industry for cycle time reduction However, with strategic planning, meticulous monitoring and dedicated efforts, the capital overhaul of HPT, LPT & Generator along with MPI,NFT of LP Turbine Blades were accomplished in record lowest time inindia. (/UTECHNICAL SERVICES, BHEL-PswR SITE FEEDBACKS... HS!Review by Site and follow-up from HQ Site reviewsall activities minutely Time taking processes, idle times between activities, delay in arranging spares and mobilization of experts from units ete. are identified well in advance. HQ was involved in reviewing processes and all important issues and HQ inputs were duly incorporated on activity planning at site. Reduction in overhauling duration to the target schedule is attributed to meticulously planning and follow-up of critical activities, which is accomplished in a shortest duration Strategic Planning Time taking processes of all activities were reviewed before start of work. Idle times between activities, delay in procurement and mobilization etc, were identified. The motive was to reduce duration of HPT, LPT. and Generator overhauling. Reduction in overhauling duration to the target schedule is attributed to strategic planning and follow-up of critical activities. List out the History of past problems & Pre-overhaul survey record. Analyze Present running behavior. Input from Manufacturing Units's (MU's) and utilities and Timely arrange experts service from Mu's Milestone based review and scheduling of sequential and parallel activities. Mobilization of resources 3 days before start of Overhaul Identification ofidle time detailed planningin advance to shorten theidle time. All the anticipated spares required for completion of the overhauling work arranged at T.G. Floor before start of the work. Use of latest technology like induction heating for dismantling and assembly of turbine. Unit de-synchronization at 480°C of HP shaft (HPS) temperature by decreasing the load before shut down. Barring gear and Turbine oil pump stop at 125°C HP Shaft temperature. Toinitiate overhauling activities as soon as machine comes to barring gear. Decoupling of Generator rotor from turbine rotor and put back turbine rotor in barring. Start dismantling of generator and O/H activitiesthereatter. Generator work started within 36 hrs of De-synchronisation (0000 hrs : De-synchronisation (HP shaft temp at 480 DegC) 17.5 hrs: Barring gear stop (HP shaft temp at 400 Deg C) 17.5hrs.to20.5 hrs ‘Stop AOP and lub oil to bearing no 5,6,7 blanked and bearing no. 4is minimized. [MITECHNICAUSERVICES, BHEL-PSWR SITE FEEDBACKS... 60)Procedure for decoupling of LP-Generator in hot coni Note: Decoupling LP-Gen coupling Hand barring will continue during this period 20.5 hrs B/G re-started with this practice Generator rotor thread out work starts within 36 hrs of de-synchronization. jons Turbineison Turning Gear. JOPin service, AOP in service. Loosening of pedestal cover bolts, removal of vibration probes. Close turning gear valve to reduce the speed, Simultaneously loosen and remove pedestal cover bolts. When Turbine speed becomes zero, stop AOP while JOP is continuously kept in service and continue Hand Barring. Remove pedestal 4 cover. Close Lubricating oil throttle valve to the minimum possible. ‘Simultaneously blank lub oil supply to bearing 5,6 and 7 by putting gasket in lub oil supply line. (parallel, by 3 gangs). Keep watch on bearing 1,2 and 3 metal temperature and simultaneously do hand barring, Put tin sheet/polythene to cover on bearing 4. Start EOP and continue hand Barring, Loosen LP-Generator coupling bolts and decouple LP-generator by continuing hand barring. Shift generator rotor away from turbine. Stop EOP and Adjust bearing 4 lubricating oil throttle valve to normal Put pedestal cover back andstart EOP & barring gear. Dismantling & prepare for generator rotor thread out. Atthe time of rotor thread out, stop turning gear again and stop EOP. Remove pedestal 4 cover. After shifting of generator coupling from pedestal 4, put pedestal 4 cover back ‘Turbine on Barring gear with AOP in service till HP shaft temp comes to 125 degC Jacking oil pumpis keptin service throughout. [MITECHNICAUSERVICES, BHEL-PSWR SITE FEEDBACKS nn. [S17Milestone Activities of U-1,Dahanu TPS Capital Over Haul. SI.No| Activities Completion Dates 1. | Machine taken shutdown on 02.08.06 00.00 hrs 2. | Generator Rotor threaded out 03.08.06 20.00 hrs 3. | Barring gear stoppedon 06.08.06 10.00hrs 4, | Liftingof LP outer cover 06.08.06 11.00 hrs 5. | LProllcheck completed 06.08.08 12.00hrs 6. | LPRotorliftedon 07.08.06 05.00 hrs 7. | HPBreechnutopened 08.08.06 12.00 hrs 8. | HPModuleliftedon 08.08.06 19.00 hrs 9. | LProtorblades MPI completed 09.08.09 10.00 hrs 10. | LProtorblades NFT started 09.08.06 14.00 hrs 11. | Generator Rotor threaded in 10.08.06 17.00hrs 12. | H.P. Module dismantled 10.08.06 24,00 hrs 13. | LProtor blades NFT completed 11.08.06 02.00 hrs 14. | HPinnercasing boxed up 13.08.06 03.00 hrs 15. | LPinner-inner &inner-outer boxed up 14.08.06 06.00 hrs 16. | HPModule boxed up after inspection 14.08.06 23.00hrs 17. | HPModule lifted & placed on pedestal 15.08.06 00.22 hrs 18. | Alignmentstarton 15.08.06 10.00hrs 19. | Breech nutcentering & hot tightening 15/08/06 23.00 hrs 20. | Alignment Completed 16.08.06 03.00hrs 21. | LP/IPCoupling &CRO Completed 16.08.06 15.00hrs 22. | LPouterfinal boxed up 17.08.06 22.00hrs 23, | RotorZero-Positionon 18.08.06 20.00hrs 24, | Generator boxed up 18.08.06 16.00hrs 25. | Oilflushingstart on 19.08.06 06.00hrs 26, _| Machine put on Barring gear 19.08.06 20.00 hrs 27. | Machine Synchronized 20.08.06 21.46.hrs (MITECHNICAL'SERVICES, BHEL-PSWR SITE FEEDBACKS .... [18]Activities carried out before Barring gear stopping © Gene Rotor threaded out. © Wedge tightns checking. © ELCID test © Generator rotor RSO test © Stator overhang NFT. 2" Day © LP Rotor sand blast cleaning completed. © HP Breech nuts and all pipe line opening completed. «LP Free standing blades removal 4" Day HP module made vertcl. HP inner casing lifted from outer casing Generator rotor threaded in. Ist Day Barring gear stopped. © HPIRLP roll check carried out. © HP/IP Bump check © LP Turbine dismantled & rotor lifted. © LProtor sand blast cleaning started. 3 Day © HP module lifted from pedestal + LP Free standing fas blades MPI « Generator rotor CC bolt rectification & Air leak test completed. 5° Day HP rotor taken out HP rotor inspection + LP Free standing blades NFT started. «Generator assembly started. SITE FEEDBACKS vow EST6" Day 7° Day © LP Free standing ‘© HP inner casing blades NFT. boxed up. © HP inner casing « LP Free standing ovality check blades NFT. © HP new rotor placed in zero * LProtor placed in zero position. «LP final steam position © HP steam flow flow path path measurement measurement done. done. 8" _Day 9” Day © HP inner casing assembled into the outer casing, LP Turbine boxed © HP Module lifted from service bay and placed on pedestal. up «HP inlet inserts, © HP inner inner lock ring boxed up. tightened. LPinner outer © Breech nuts boxed up. aligning started 10” Day 11" Day © HP/IP,IP/LP © HP/IP,IP/LP alignment coupling © HP breech nuts hot tightened. © HPT swing check © LP/Generator © Generator air alignment tightness test © Generator air © IP.CV Cover tightness machining © Exciter assy © HP/IPIP/LP © CRH flange coupling tightening [MITECHNICAUSERVICES, BHEL-PSWR SITE FEEDBACKS... [7200]12" Day HP/IP coupling reaming Generator air tightness test Exciter assy HPIP & LP Turbine roll check « LP outer boxed up. «Bearings boxed up. Conclusion 13" Day © C&l work completed, up. © Oil flushing © HP turbine insulation. * Machine put on barring gear. na benchmark on record minimum duration in KWU design TG set overhaul could be achieved. It was the determination, commitment, monitoring and follow-up of associated activities that ascertained to achieve a challenging target. Working out activities well in advance with subcontractor agencies/ partners and round the clock execution of job with new strategies helped to meet schedule deadlines. Mr. V. Veerapandi graduated in Production Engineering from Regional Engineering College at Trichy in the year 1988. Mr. Veerapandi joined BHEL Trichy in the year of 1988 and was transferred to PSWR-SAS Services in 1991. Since then he is responsible for Overhauling, Trouble shooting and Servicing works of Steam Turbines of various ranges up to SOOMW eee ‘GMIVECHNICAU'SERVICES, BHEL-PSWR SITE FEEDBACKS... [/20)"ISSUE SPECIAL-CFBC BOILERS . CIRCULATING FLUIDISED BED COMBUSTION (CFBC) BOILER BY: V GOVINDAN, SR. DGM (TSX) BHEL, KUTCH SITE Circulating Fluidized Bed Combustion (CFBC) technology has evolved from conventional bubbling bed combustion as a means to overcome some of the drawbacks associated with conventional bubbling bed combustion (see Figure 1). Circulating Bed Boiler Design At high fluidizing gas velocities in which a fast recycling bed of fine material is superimposed on a bubbling bed of larger particles, the combustion temperature is controlled by rate of recycling of fine material. Hot fine material is separated from the flue gas by a cyclone and is partially cooled in a separate low velocity fluidized bed heat exchanger, where the heat is given up to the steam. The cooler fine material is then recycled to the dense bed. (MITECHNICALSERVICES; BHEL-PSWR ISSUE SPECIAL- CFBC BOILERS nv. | 22