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Devdeep Bose DGM ( Commng & Testing). COMMISSIONING DEPARTMENT, NTPC-SIPAT. COMMISSIONING DEPARTMENT, NTPC-SIPAT. COMMISSIONING DEPARTMENT, NTPC-SIPAT. COMMISSIONING DEPARTMENT, NTPC-SIPAT. COMMISSIONING DEPARTMENT, NTPC-SIPAT. COMMISSIONING DEPARTMENT, NTPC-SIPAT.

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Presentation Transcript
slide1

Devdeep Bose

DGM ( Commng & Testing)

COMMISSIONING DEPARTMENT, NTPC-SIPAT

slide9

POINTS OF DISCUSSION

    • SUB CRITICAL & SUPER CRITICAL BOILER
    • SIPAT BOILER DESIGN
    • SIPAT TURBINE DESIGN
    • DESIGN PARAMETERS
    • COMMISSIONING
      • PRE COMMISSIONING PROBLEMS
      • POST COMMISSIONING PROBLEM

COMMISSIONING DEPARTMENT, NTPC-SIPAT

slide17

Net Plant Heat Rate = NTRH

= 2207 KCal / KWHR ( at 100% TMCR)

80% TMCR = 2222 Kcal / KWHR

60% TMCR = 2276 Kcal / KWHR

50% TMCR = 2376 Kcal / KWHR

Plant Efficiency at 100% TMCR = 38.96%

80% TMCR = 38.7 %

60% TMCR = 37.78%

50% TMCR = 36.19%

slide18

STEAM GENERATOR

  • Supplier : M/s DOOSAN
  • Erection By : M/s L&T

COMMISSIONING DEPARTMENT, NTPC-SIPAT

slide19

UNDERSTANDING SUPER CRITICAL TECHNOLOGY

  • When Water is heated at constant pressure above the critical pressure, its temperature will never be constant
  • No distinction between the Liquid and Gas, the mass density of the two phases remain same
  • No Stage where the water exist as two phases and require separation : No Drum
  • The actual location of the transition from liquid to steam in a once through super critical boiler is free to move with different condition : Sliding Pressure Operation
  • For changing boiler loads and pressure, the process is able to optimize the amount of liquid and gas regions for effective heat transfer.

COMMISSIONING DEPARTMENT, NTPC-SIPAT

super critical boiler cycle with sh rh regeneration
SUPER CRITICAL BOILER CYCLE WITH SH, RH & Regeneration

TEMP

3

1

568’C

540’C

600

256 Kg/cm2

500

Steam flow :2225 T/Hr

Steam temp : 540 ‘c

Steam Pres : 256 kg/cm2

RH pre : 51.6 Kg/cm2

RH Temp : 568’c

Feed water Temp : 291’c

400

2

300

200

100

5

4

0

ENTROPY

slide21

540°C, 255 Ksc

568°C, 47 Ksc

492°C, 260 Ksc

457°C, 49 Ksc

FUR ROOF I/L HDR

ECO HGR O/L HDR

HRH LINE

MS LINE

411°C, 277Ksc

411°C, 275 Ksc

SEPARATOR

STORAGE TANK

FINAL SH

FINAL RH

LTRH

DIV PANELS SH

PLATEN SH

VERTICAL WW

G

ECO JUNCTION HDR

LPT

IPT

LPT

305°C, 49 Ksc

CONDENSER

HPT

ECONOMISER

ECO I/L

Spiral water walls

FEEDWATER

BWRP

290°C, 302 KSC

FUR LOWER HDR

FRS

slide22

Steam

Partial Steam Generation

Complete or Once-through Generation

Steam

Heat Input

Water

Heat Input

Water

Water

Boiling process in Tubular Geometries

slide23

SIPAT SUPER CRITICAL BOILER

  • BOILER DESIGN PARAMETER
  • DRUM LESS BOILER : START-UP SYSTEM
  • TYPE OF TUBE
    • Vertical
    • Spiral
  • SPIRAL WATER WALL TUBING
    • Advantage
    • Disadvantage over Vertical water wall

COMMISSIONING DEPARTMENT, NTPC-SIPAT

vertical tube furnace
Vertical Tube Furnace
  • To provide sufficient flow per tube, constant pressure furnaces employ vertically oriented tubes.
  • Tubes are appropriately sized and arranged in multiple passes in the lower furnace where the burners are located and the heat input is high.
  • By passing the flow twice through the lower furnace periphery (two passes), the mass flow per tube can be kept high enough to ensure sufficient cooling.
  • In addition, the fluid is mixed between passes to reduce the upset fluid temperature.

COMMISSIONING DEPARTMENT, NTPC-SIPAT

spiral tube furnace
Spiral Tube Furnace
  • The spiral design, on the other hand, utilizes fewer tubes to obtain the desired flow per tube by wrapping them around the furnace to create the enclosure.
  • This also has the benefit of passing all tubes through all heat zones to maintain a nearly even fluid temperature at the outlet of the lower portion of the furnace.
  • Because the tubes are “wrapped” around the furnace to form the enclosure, fabrication and erection are considerably more complicated and costly.

COMMISSIONING DEPARTMENT, NTPC-SIPAT

slide27

SPIRAL WATER WALL

  • ADVANTAGE
  • Benefits from averaging of heat absorption variation : Less tube leakages
  • Simplified inlet header arrangement
  • Use of smooth bore tubing
  • No individual tube orifice
  • Reduced Number of evaporator wall tubes & Ensures minimum water flow
  • Minimizes Peak Tube Metal Temperature
  • Minimizes Tube to Tube Metal Temperature difference
  • DISADVANTAGE
  • Complex wind-box opening
  • Complex water wall support system
  • tube leakage identification : a tough task
  • More the water wall pressure drop : increases Boiler Feed Pump Power
  • Adherence of Ash on the shelf of tube fin
slide29

BOILER OPERATING PARAMETER

COMMISSIONING DEPARTMENT, NTPC-SIPAT

COMMISSIONING DEPARTMENT, NTPC-SIPAT

slide30

Coal Analysis

  • High erosion potential for pulverizer and backpass tube is expected due to high ash content.
  • 2. Combustibility Index is relatively low but combustion characteristic is good owing to high volatile content.

COMMISSIONING DEPARTMENT, NTPC-SIPAT

COMMISSIONING DEPARTMENT, NTPC-SIPAT

slide31

Ash Analysis

  • Lower slagging potential is expected due to low ash fusion temp. and low basic / acid ratio.
  • 2. Lower fouling potential is expected due to low Na2O and CaO content.
slide33

BOILER LOAD CONDITION

  • Constant Pressure Control
  • Above 90% TMCR The MS Pressure remains constant at rated pressure
  • The Load is controlled by throttling the steam flow
  • Below 30% TMCR the MS Pressure remains constant at minimum Pressure
  • Sliding Pressure Control
  • Boiler Operate at Sliding pressure between 30% and 90% TMCR
  • The Steam Pressure And Flow rate is controlled by the load directly

COMMISSIONING DEPARTMENT, NTPC-SIPAT

COMMISSIONING DEPARTMENT, NTPC-SIPAT

slide34

Boiler Load %

60

80

100

40

20

+1

0

-1

Efficiency Change %

-2

-3

-4

CONSTANT PRESSURE Vs VARIABLE PRESSURE BOILER CHARACTERSTIC

Variable Pressure

Constant Pressure

COMMISSIONING DEPARTMENT, NTPC-SIPAT

slide35

Benefits Of Sliding Pressure Operation ( S.P.O)

  • Able to maintain constant first stage turbine temperature
  • Reducing the thermal stresses on the component : Low Maintenance & Higher Availability
  • No additional pressure loss between boiler and turbine.
  • low Boiler Pr. at low loads.

WHY NOT S.P.O. IN NATURAL/CONTROL CIRCULATION BOILERS

  • Circulation Problem : instabilities in circulation system due to steam formation in down comers.
  • Drum Level Control : water surface in drum disturbed.
  • Drum : (most critical thick walled component) under highest thermal stresses

COMMISSIONING DEPARTMENT, NTPC-SIPAT

slide36

STEAM TURBINE K-660-247

  • LMZ (LENINGRADSKY METALLICHESKY ZAVOD)
  • K STANDS FOR KLAPAN LTD.,BULGARIA WHICH SUPPLIES TURBINE,NOZZLES,DIAPHRAGMS, SEALS,BLADES ETC.

COMMISSIONING DEPARTMENT, NTPC-SIPAT

slide37

1.TG DECK IS VIS SUPPORTED AND HAS 26 CONCRETE COLUMNS (T1 – T26).

2.TG HALL IS CONSTITUTED OF 3 MAINS ROWS OF COLUMNS – A,B ,C ROW AND TWO BAYS – AB BAY AND BC BAY. THE WIDTH OF AB BAY IS 36m AND BC BAY IS 12m

3.CONDENSER TUBE BANKS (CW PATH) HAS AN INCLINATION OF 40.

4.THERE ARE TWO MAIN EOT CRANES FOR TG HALL.EACH EOT CRANE IS HAVING A CAPACITY OF 200t FOR MAIN HOIST AND 20t FOR AUXILIARY HOIST. 35.5m IS THE MAXIMUM VERTCAL DISTANCE A HOIST CAN TRAVEL.TANDEM OPERATION OF TWO EOT CRANES ARE ALLOWED.

COMMISSIONING DEPARTMENT, NTPC-SIPAT

condenser
Condenser
  • Design LMZ
  • Design CW Flow 64000 m3/hr
  • Vacuum 77 mm Hg (abs) at 33 0C
  • 89 mm Hg (abs) at 36 0C
  • No. of passes 1
  • Total no. of tubes 22.225 (OD)x0.71 (t) - 29920
  • 22.225 (OD)x1.00 (t) - 2080
  • Tube material ASTM A-249 TP 304
  • Rated TTD 3.40C
  • DT of CW 100C

COMMISSIONING DEPARTMENT, NTPC-SIPAT

condensate extraction pump
Condensate Extraction Pump
  • Design flow rate 238.75 Kg/s
  • Discharge pressure 32.15 Ksc
  • Shut off head 395 m
  • Pump speed 1480 rpm
  • Power input 972.3 KW
  • No. of stages 6
  • Type of first stage impeller double entry
  • Depth 7.43 m

COMMISSIONING DEPARTMENT, NTPC-SIPAT

mdbfp
MDBFP
  • Pump flow 769.950 TPH
  • Suction temp 186.2 0C
  • BP Suction pr. 14.05 ata
  • BFP Suction pr. 21.01 ata
  • BFP Discharge pr. 335.78 ata
  • BFP Discharge temp. 187.9 0C
  • BP Discharge pr. 22.01 ata
  • Shut off head 4830 m
  • BFP Speed 6275 rpm
  • BP Speed 1490 rpm
  • Normal R/C flow 220 TPH
  • HC Rated O/P Speed 6505 rpm
  • Outer casing type barrel
  • No. of stages 7
  • BFP warm up flow 15 TPH

COMMISSIONING DEPARTMENT, NTPC-SIPAT

tdbfp
TDBFP
  • Pump flow 1283.14 TPH
  • Suction temp 186.2 0C
  • BP Suction pr. 14.10 ata
  • BFP Suction pr. 28.24 ata
  • BFP Discharge pr. 335.83 ata
  • BFP Discharge temp. 187.8 0C
  • BP Discharge pr. 29.06 ata
  • Shut off head 4580 m
  • BFP Speed 4678 rpm
  • BP Speed 2098 rpm
  • Normal R/C flow 365 TPH
  • HC Rated O/P Speed 6505 rpm
  • Outer casing type barrel
  • No. of stages 7
  • BFP warm up flow 20 TPH

COMMISSIONING DEPARTMENT, NTPC-SIPAT

drip pump
Drip Pump
  • Design flow rate 324.509 TPH
  • Discharge pressure 43 ata
  • Shut off head 306.7 m
  • Pump speed 1486 rpm
  • Power input 310.1 KW
  • No. of stages 5
  • Type of first stage impeller centrifugal, single entry
  • Depth 1090 mm

COMMISSIONING DEPARTMENT, NTPC-SIPAT

slide51

RATED CONDITIONS

  • LOAD : 660MW
  • BEFORE HP STOP VALVE
      • STEAM PRESSURE : 247KSC
      • STEAM TEMPERATURE : 5370C
      • STEAM FLOW : 2023.75T/HR
  • AFTER HPC
      • STEAM PRESSURE : 48KSC
      • STEAM PRESSURE : 298.710C
  • BEFORE IP STOP VALVE
      • STEAM PRESSURE : 43.2KSC
      • STEAM TEMPERATURE : 5650C
  • STEAM FLOW TO REHEATER : 1681.12T/HR.
  • DESIGN CONDENSER PRESSURE : 0.105KSC (abs.)
  • COOLING WATER FLOW : 64000M3/HR
  • FINAL FEED WATER TEMP. : 286.350C
  • FREQUENCY RANGE : 47.5 – 51.5 Hz

COMMISSIONING DEPARTMENT, NTPC-SIPAT

slide52

STEAM TURBINE

  • Generator rated speed 3000 rpm
  • Generator manufacturer Electrosila
  • No. of bleedings 8
  • Length of the turbine 36.362 m
  • No. of stages
    • HPT 17
    • IPT 11x2
    • LPT-1 5x2
    • LPT-2 5x2
    • Total 59
  • Turbine Governing system
    • Mode of Governing Nozzle
    • Type E/H
    • Control fluid Firequel-L make

Supresta-USA

    • Normal Operating Pr. 50 Ksc
    • Capacity 600 lpm
    • Fluid pump motor rating 200 KW
    • Filter material Ultipor
    • Mesh size 25 µ
turbine protections
Turbine Protections

Turbine protection system consists of Two Independent channels, each operating the corresponding solenoid (220V DC) to trip the Turbine in case of actuation of remote protection

Hydraulic Protection: Apart from the Electrical Trip, Turbine is equipped with the following Hydraulic Protections:

1. Local Manual Trip (1V2)

2. Over speed Trip #1 at 110% of rated speed

3. Over speed Trip #2 at 111% of rated speed

4. Governing oil pressure < 20 Ksc

Contd..

slide54

5.Axial shift Very High (2V3) [-1.7mm, +1.2mm]

6.Turbine bearing vibration : Very High (2V10 including X & Y directions)* >11.2mm/sec (Td=2 sec)

7.Lube oil tank level very Low (2V3)* Td=3sec (Arming with two stop valves open)

8.Lub oil pressure Very Low (2V3) < 0.3 Ksc; Td =3 sec (Arming with two stop valves open)

9.Condenser pressure Very High (2V3) > - 0.7ksc

(Arming with condenser press < 0.15 ksc Abs)

Contd

COMMISSIONING DEPARTMENT, NTPC-SIPAT

slide55

10.M.S. temp Very Low (2V3) < 470 deg C (arming > 512 deg C)*

11.M.S. temp Very High (2V3) > 565 deg C*

12.HRH temp Very Low (2V3) < 500deg C (arming > 535 deg C)*

13.HRH temp Very High (2V3) > 593deg C*

14.HPT outlet temperature Very High (2V4) > 420 deg C

Contd…

COMMISSIONING DEPARTMENT, NTPC-SIPAT

slide56

15.Gen seal oil level of any seal oil tank Very Low (2V3)* < 0 mm;Td=15 sec (Arming with any two stop valves open)

  • 16.All Generator seal oil pumps OFF (3V3)* Td: 9 sec (Arming with any two stop valves open)
  • 17.Generator Stator winding flow Very Low (2v3) < 17.3 m3/hr; Td =120 sec (Arming with any two stop valves open)
  • 18.Generator hot gas coolers flow Very LOW (2V3)* : <180m3/hr; Td=300sec(Arming with any two stop valves open)
  • 19.Generator cooler hot gas temp. Very High(2V4) > 85 deg (Td = 300sec
      • Contd

COMMISSIONING DEPARTMENT, NTPC-SIPAT

slide57

20.MFT operated: (2V3)

21.Deareator level Very High (2V3) > 3400 mm*

22.HP heater level protection operated (2V3)*

23.Generator Electrical protection operated (2V3)

25.Turbine over speed protection operated (114%)

26.Turbine Controller failure protection operated (2V3)

COMMISSIONING DEPARTMENT, NTPC-SIPAT

slide58

COMMISSIONING

OF SIPAT SUPER CRITICAL UNIT

1ST UNIT SYNCHRONIZED AT : 18.02.2011

1ST UNIT FULL LOAD ACHIEVED AT :

2nd UNIT SYNCHRONIZED AT : 03.12.2012

2ND UNIT FULL LOAD ACHIEVED AT : 24.12.2012

COMMISSIONING DEPARTMENT, NTPC-SIPAT

slide59

PRE – COMMISSIONING ACTIVITIES

  • CHEMICAL CLEANING OF BOILER :
  • REQUIRED FOR
  • Maintaining steam quality at the turbine inlet.
  • Minimizing corrosion of the metal surface of boiler.
  • DETERGENT FLUSHING OF PRE-BOILER SYSTEM
      • To remove dirt ,oil ,grease etc., from Condensate ,Feed water, Drip and Extraction steam lines of HP and LP heaters prior to putting these systems in regular service. This is to ensure flow of clean condensate and feed water to the boiler.
  • STEAM BLOWING OF POWER CYCLE PIPING :
    • The purpose of steam line blowing is to remove pipe slag, weld bead deposits and other foreign material from the main and reheat steam systems prior to turbine operation. The cleaning is accomplished by subjecting the piping systems to heating, blowing steam and cooling cycles in sufficient number and duration until clean steam is obtained.
  • SAFETY VALVE FLOATING

COMMISSIONING DEPARTMENT, NTPC-SIPAT

slide60

PRE – COMMISSIONING CHECKS

  • All commissioning procedure should be finalized.
  • P&I Drawings should be finalized and available with site engineer
  • Different systems check list should be finalized with all concerned agencies
  • All Field quality checks should be completed.
  • P&I Checks should be finalized.
  • Start – Up procedure should be finalized

COMMISSIONING DEPARTMENT, NTPC-SIPAT

slide61

COMMISSIONING SEQUENCE OF TG SIDE

  • 1.Commissioning of stator water cooling system for HV testing
  • before generator rotor insertion.
  • Stator water pump trial run.
  • Flushing of the system bypassing winding.
  • Flushing of the system through the winding.
  • 2.Commissioning of MCW,ACW and DMCW system.
  • Trial run of pumps.
  • Flushing of the system.
  • 3.Detergent Flushing of pre boiler system (Feed water ,condensate
  • ,HPH and LPH drip system)
  • Cold water flushing until turbidity comes below 5NTU.
  • Hot water flushing (600C) with 2 hrs circulation of each circuit.
  • Raising water temperature to 600C and addition of Detergent
  • (Coronil 100%)

COMMISSIONING DEPARTMENT, NTPC-SIPAT

slide62

e) Circulation through each circuit for 2 hrs.

  • f) Hot draining of the system
  • g) DM water rinsing of each circuit until conductivity comes below
  • 5µs/cm and oil content BDL.
  • h) Passivation with ammonia and hydrogen peroxide solution at a
  • temperature of 400C.
  • Draining of the system.
  • 4. Lube oil flushing of MDBFP lube oil system.
  • 5.Trial run of MDBFP.
  • 6.Lube oil and seal oil flushing of main TG.
  • 7.CF system flushing.
  • 8.Condenser flood test.
  • 9.Trial run of CEPs
  • 10.Commissioning of generator gas system.
  • 11.Generator ATT.
  • 12.Calibration of HPCVs and IPCVs
  • 13.Putting turbine on barring.
  • 14.Vacuum pumps trial run.

COMMISSIONING DEPARTMENT, NTPC-SIPAT

slide63

15.Commissioning of seal steam system.

16.Commissioning of HP and LPBP system.

17. Vacuum pulling.

18.Lube oil flushing of TDBFP.

19.Steam blowing of TDBFP steam line.

20.Commissioning of TDBFP.

COMMISSIONING DEPARTMENT, NTPC-SIPAT

slide64

MS Line HT

CRH Line HT

HRH Line HT

STATOR COOLING WATER

MS Line Welding Completion ( 30 Pen)

CRH Line Welding Completion ( 12 Pen)

HRH Line Welding Completion (34 Pen)

FUR DRAFT SYSTEM

SEC AIR SYSTEM

MS Line Hanger Erection Cold Setting

CRH Line hangers Cold Setting

HRH Line Hangers Cold Setting

TG ON BARRING

BRP TRIAL RUN

MS Line Insulation

CRH Line Insulation

HRH Line Insulation

TG LUBE OIL / GEN SEAL OIL SYSTEM

POWER CYCLE PIPING STEAM BLOWING

FURNACE READINESS

FUEL OIL SYSTEM READINESS

CHEMICAL CLEANING OF BOILER

AUX PRDS READINESS

UNIT SYNCHRONIZTION

CONDENSER VACCUM SYSTEM

COMPRESSED AIR SYSTEM READINESS

MDBFP Trial

CEP Trial

CW SYSTEM READINESS

GATES, DAMPERS / VALVES

TG :

SG : (13 / 190 )

TG SEAL STEAM SYSTEM

MFT CHECKING

TG CONTROL FLUID SYS

TG GOV SYSTEM

DDCMIS

FSSS READINESS

GEN GAS SYSTEM

slide65

Discussion

Questions Please

Enlighten Us

THANK YOU

slide67

Reduced number of evaporator wall tubes.

Ensures minimum water wall flow.

slide69

Support System for Evaporator Wall

  • Spiral wall  Horizontal and vertical buck stay with tension strip
  • Vertical wall  Horizontal buck stay