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TS TIDINGS
KAYAMKULAM CCPP
APRIL 2012
VOLUME : 15.11
HIGHLIGHTS
NORTH CHENNAI TPS II
RINL: TB 4:
APRIL 2012
TS TIDINGS
INSIDE
Feed backs and suggestions from all departments of BHEL for improvement of TS
TIDINGS are welcome and may please be addressed to ADDL. GENERAL MANAGER
(TSX)/BHEL-PSSR/CHENNAI
APRIL 2012
TS TIDINGS
Turbine : Commissioning of all extraction lines NRVs ( Non Return Valves) were
completed.
2 nos. sulphuric dosing pumps were commissioned and trial run done.
UAT 1 3.3 KV bus duct Hipot test and differential relay configuration was
completed.
Feeder E
run and
tracking
conveyor trial
8 hours
trial
Naphtha Lines
completed.
Naphtha drain tank pumps 1 & 2 auto mode commissioning was completed.
Naphtha lines upto HRSG individual rack air blowing was completed for all
six corners.
stage -2
change
run
was
completed in
was
APRIL 2012
TS TIDINGS
Remote commissioning of HRSG Seal air fans 1 & 2 and Augmenting air fans
1 & 2 was completed from PLC and DCS.
LP steam
from
customer header was charged and steam flushing
Deaerator pegging steam line and heating line was carried out,
Steam flushing of BFPs suction, discharge, recirculation and balance leak off
line was carried out.
Trial run of Compressor 1 & 2 for HRSG atomizing air was completed. Air
Blowing upto atomizing air skid and upto HRSG completed.
disc
was
replaced and
the
by customer
of
performance
MRPL:1XFr.5 GTG, 2X28.5 MW STG, 4X270 TPH UTILITY BOILERS, 1X85 TPH
HRSG, ADDITIONAL ORDER: 1XFr.6B GTG, 1X85 TPH HRSG-GT1.
BLT MCC -1, 2, 3 & 4 : CT relay and breaker testing was completed.
isolation
rear bearing
Transformer 2 nos.
vibration
testing carried
APRIL 2012
TS TIDINGS
150 KVA 415 V lighting transformer 2 nos, test was carried out.
Contact
completed.
was
415 V
FBHE-3 BCcompleted.
SH
tube
failure:
Damaged/worn out
tubes
removal
was
ESP & ID fan area MCC HD charged from unit emergency MCC DG.
ID fan A: Lube oil pump A & B trial run completed. Motor no load trial
run completed with channel 2.
11 KV switch gear 2BA panel Hipot test completed. OBA to 2BA Tie Bus
duct Hipot test completed.
Boiler fill pump A coupled trial run and Boiler filling completed with
Boiler filling pump A.
APRIL 2012
TS TIDINGS
Plant Water System : SWBD # OCA ( 3.3 KV panel ) numerical relay testing
completed.
FOPH: LTMCC ODC board CT, PT, breaker testing was completed. ODC
board relay testing & panel relay testing completed. Transformer ODC T01
and T02 testing completed.
Water Supply Transformer ODE T01 & T02 testing was done.
RINL: TB 4:
BFD line : HP heater 1 & outlet line steam blowing was completed.
Blower was started and rolled to 500 rpm on 06.04.12. It was stopped
three times due to turbine front bearing and blower rear bearing vibration
very high.
Turbo blower was run to rated speed on 07/04/12 and surge test was
completed. M/s
MAN DIESEL representative
sent
the test values
to
Germany for validation and clarification.
Lub oil system vapour extraction system was optimized and vacuum in MOT and
bearing pedestals were established.
Blower
suction filter pulsating system compressor 4
completed.
protection
protection
hours
trial run
APRIL 2012
TS TIDINGS
TURBO BLOWER
WAS
RESTARTED AND
72
HOURS
TRIAL
RUN
COMMENCED AT
1800 HRS.
ON
17.04.12
WITH
LP HEATER IN
SERVICE AND COMPLETED ON 20.04.12.
Suction filter on line cleaning system was put in operation on auto mode.
level
and
gland
were
pending
PAPH A : Guide bearing and support bearing lube oil flushing completed.
Air receiver tank flushing completed.
After replacing
completed.
the
new
motor, DC
scanner
fan
done
-
from
hours
Boiler
fill
trial
run
was completed.
TECHNICAL SERVICES / PSSR
APRIL 2012
VALLUR
VALLUR
TS TIDINGS
APRIL 2012
TS TIDINGS
10
APRIL 2012
TS TIDINGS
FEED BACK NO -1
PROJECT: KTPS unit no. 11, (500 MW), KOTHAGUDEM
PROBLEM: VACUUM PUMP no. 2 HIGH CURRENT AND LOW VACUUM PROBLEM
Problem Detail:
One of the vacuum pumps (number 2) in kothagudem 500 MW unit was developing
slightly less vacuum compared to other vacuum pump with same operating condition. Vacuum
pump 1 was developing condenser vacuum of -0.9 ksc, vacuum pump 2 was developing -0.88
ksc at same conditions with one vacuum pump in operation at a time.
Analysis:
As the condenser system is same for both pumps, the problem should be within the
vacuum pump system. Initially to eliminate air ingress problem within pump, flood test
within pump system was carried out and minor ingress points were attended, but no
improvement in the vacuum was achieved. It was suspected that the choking of plate heat
exchanger and cooling water inlet filter. All the pipe lines, seal water filter and plate heat
exchanger were opened and cleaned and no choking was observed.
The problem was referred to the pump vendor and as per their requirement, all the
relevant pump parameters were observed and it was as per attached table 1. Vacuum pump
2 which was developing less vacuum was drawing more current than vacuum pump 1 for the
same load and same operating conditions. It was drawing 270-280 amps current at the
same time other pump is drawing only 205 amps. Pump motor rated current is 210 amps.
Based on the high current data it was suspected to be problem of discharge valve
plate defect. As per recommendation of the vendor, the pump inside was inspected
through inspection cover on both drive end and non drive end. It was observed that valve
plates (part number 5.02) shown in figure 2 were found in damaged condition at both ends
of vacuum pump. The photograph of the damaged component is attached for reference.
Rectification:
The damaged valve plate was replaced with new valve plate. The valve plate is made
from the Teflon sheet locally. Seperator tank was cleaned and the damaged parts of valve
plate were collected from the separator tank.
APRIL 2012
11
TS TIDINGS
Conclusion:
After replacing with new valve plate, the pump is now drawing 205-210 amps, same
as other pump. The performance of both vacuum pumps was same. The parameters after
rectification is given in table 2 for reference. The function of valve plate is to act as non
return valve during parallel operation of vacuum pump. The damaged valve plate was
blocking the exhaust air from the pump and was causing pressurization within vacuum pump.
This resulted in over loading of the pump.
Courtesy:
1. Shri.M V Baskaran, DGM/TSX, BHEL, PSSR, Chennai
2. Shri. R Ganeshram, Engineer/TSX, BHEL, PSSR, Chennai
APRIL 2012
12
TS TIDINGS
Vacuum Pump A
Vacuum Pump B
2BE/-353-OBY4
2BE/-353-OBY4
026919001001
026919001002
2008
2008
Year of Manufacturer
INLET
OUTLET
INLET
OUTLET
31C
32C
31C
32C
37C
39C
37C
40C
60-70
90
-0.8934Bar
-0.8862bar
3.8Kg/cm2
NOT-WORKIN
Cu.m/hr
34cu.m/hr
35C
37C
40C
40C
Atmospheric Temperature
40C
40C
Motor Temperature
66C
50C
205-210A
270-280A
40C
40C
NORMAL mm/sec
NORMAL mm/sec
NOT-WORKING
Mpa
760MM of HG
40C
41C
YES
YES
Vacuum
Pressure (Cooling Water)
Flow Rate (Seal Water) from flow
indicator
Vacuum Pump Body Temperature [1st
Stage]
Vacuum Pump Body Temperature [2nd
Stage]
Motor Current
Separator temperature
Vibration Level
Shut off vacuum at..deg C
Recirculation Pump Body Temperature
Check for Proper Greasing
Check for water Leakage from Body DE
/ NDE
Check for water Leakage from Each
Gland (Average 60 drops / min)
3.8Kg/cm
NDE-NA,DE-130
NDE-NA,DEdrops/min continuous leakage
(DE-130drops/min)
(_____drops/min)
13
APRIL 2012
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APRIL 2012
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Valve Plate
Intersecting
15
APRIL 2012
TS TIDINGS
APRIL 2012
16
TS TIDINGS
Vacuum Pump A
Vacuum Pump B
2BE/-353-OBY4
2BE/-353-OBY4
026919001001
026919001002
2008
2008
Year of Manufacturer
INLET
Cooling Water Temperature(inlet to
& outlet from Heat Exchanger)
Seal Water Temperature(inlet to and
outlet from vacuum pump)
Leakage Rate [From the Rotameter]
OUTLET
OUTLET
32 C
33 C
31 C
32 C
36 C
40C
37 C
40 C
60 70 Kg/hr
-0.8805Bar
-0.8802bar
3.8 Kg/cm2
3.8 Kg/cm2
Vacuum
Pressure (Cooling Water)
Flow Rate (Seal Water) from flow
indicator
Vacuum Pump Body Temperature [1st
Stage]
Vacuum Pump Body Temperature [2nd
Stage]
INLET
NA Cu.m/hr
34.5 Cu.m/hr
40 C
40 C
40 C
40 C
Atmospheric Temperature
37 C
37 C
Motor Temperature
65 C
66 C
205 210 A
205 210 A
40 C
40 C
NORMAL mm/sec
NORMAL mm/sec
NO GAUGE TO
READ Mpa.
NO GAUGE TO READ
Mpa.
40 C
40 C
Motor Current
Separator temperature
Vibration Level
Shut off vacuum at..deg C
Recirculation Pump Body Temperature
Check for Proper Greasing
Check for water Leakage from Body
DE / NDE
Check for water Leakage from Each
Gland (Average 60 drops / min)
YES( Y )
NO
(__)
NDE-NA, DE-130
drops/min.
DE(130 drops/min)
YES(Y)
NO
(__)
NDE-NA, DE-180
drops/min.
DE (180 drops/min)
17
APRIL 2012
TS TIDINGS
18
APRIL 2012
TS TIDINGS
In the turbine bearings it was measured to be varying between +0.006 and -0.006.
Unit was shut down for attending to the problem of over heating of anti surge
controller room due to pressurisation of silencer room. During shut down, the vapour
extraction system of lub oil system was investigated for optimisation.
Oil vapour evacuation system optimisation during shut down:
A Manometer was provided in the Main oil tank for vacuum measurement. It was
reading +10 mm H2O column with one Vapour fan running. During investigation, it was
found that one of the discharge NRV was passing and it was rectified. The vapour fan
discharge line demister drain is connected back to MOT with a siphon. The oil in the
siphon was ensured and no vapour is flowing back to Main oil tank through this drain
line.
The turbine & blower coupling cover is provided with three breathers. As per designer
two breathers on centre line will be sucking air and one breather (3 inch size) in the
drain line will be discharging air during running to avoid heating up of the coupling.
The drawing of coupling cover was attached for reference. These breathers over the
coupling cover were dummied temporarily for observing the performance of Vapour
evacuation system during shut down. After dummying of all the three breathers, MOT
vacuum was (-16) mm H2O with one vapour fan and (-30) mm H2O with 2 vapour fans
in service.
On further study of lub oil system, it was observed that the Over head lub oil tank
was provided with 3 inch diameter vent to atmosphere by inverted 'U' bend pipe. This
vent was temporarily covered for observation. It was found that the vacuum in MOT
improved to (-30) mm H2O with one vapour fan in operation and (-48 )mm H2O with 2
vapour fans in operation.
It is felt that the size of 3 inch vent for Over head tank is more. Referring to a lub
oil scheme of old project (EID Parry, 18.5 MW unit). The drawing of lub oil overhead
tank from schemes of lub oil system (RINL and EID parry) is attached for reference.
Over Head tank at EID Parry project was having one inch vent connected back to
MOT. By this there will not be loss of vacuum in the system. It was suggested to
BHEL/Hyderabad to connect the vent of over head tank to the over flow line which in
turn was connected to Main Oil Tank. By this vacuum in MOT and in the lub oil system
will not be affected and also the dust and contaminants entry through this
atmospheric vent can be avoided.
19
APRIL 2012
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APRIL 2012
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APRIL 2012
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APRIL 2012
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APRIL 2012
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APRIL 2012
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500 MW
RAMAGUNDAM UNIT - 6
TALCHER UNIT - 5
SIPAT UNIT - 5
210 MW
METTUR UNIT 1
26
APRIL 2012
TS TIDINGS
THERMAL
500 MW
250 MW
KOTHAGUDEM UNIT - 10
210 MW
VIJAYAWADA UNITS 1, 2, 3, 4, 5 & 6
MUDDANUR UNITS 2, 3 & 4
RAICHUR UNITS 4 & 5
METTUR UNITS 2 & 4
TUTICORIN UNITS 1,3, 4 & 5
NORTH CHENNAI UNITS 1, 2 & 3
NEYVELI UNITS - 4, 5 & 6
AMARKANTAK UNIT 5
APRIL 2012
27
TS TIDINGS
MW AND ABOVE)
120.00
STATION
North Chennai
Neyveli
Raichur
Tuticorin
Ramagundam
Muddanur
Kothagudam
Vijayawada
VTPS - 7
Mettur
Talcher
Simhadri
Sipat
Amarkantak
Bellary-1
2011-2012
97.88
94.45
84.24
90.35
83.49
92.77
93.71
95.78
98.45
98.42
95.79
101.00
84.73
93.09
--
2012-13
97.40
96.50
73.53
94.82
95.16
91.27
73.81
94.94
91.55
93.89
98.50
95.63
101.68
93.96
81.50
201112
201213
100.00
80.00
60.00
40.00
20.00
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