2017514 ABCOFTHERMALPOWERPLANT

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ABCOFTHERMALPOWERPLANT
THISBLOGISWRITTENFORCONSTRUCTIONSUPERVISORSANDENGINEERSTOGAINPRACTICALKNOWLEDGEONTHERMALPOWER
STATIONBOTHONSUBCRITICALANDSUPERCRITICALTECHNOLOGY.

Friday,9September2016

220VOLTDCSYSTEMBATTERYCHARGER
COMMISSIONINGPARTIIABCOFTHERMALPOWER
PLANT.

COMMISSIONINGPROCEDURE:

TESTINGOFBATTERYCHARGERS:

The insulation value shall be checked with 500 V DC Megger. During this test, all low
voltagecircuits&Relaysetc,shallbebypassed(shorting)

Thepanelshallbeswitchedonatnoload.Forthis,firstmakeinputswitchON&check
thevoltagesatallphasesindicatedbylamps&voltmeterbyselectorswitch.Nowthe
voltage is connected to the primary of the Main transformer which steps the voltage 18
downasrequiredforthespecificDCoutputVoltage&isolatesACInputlinefromBattery
circuits.Thetransformer'ssecondaryisconnectedtotheFullwaverectifierassembly.
BlogArchive
Thebridgeisstandardthreephasefullwavehalfcontrolledsiliconbridge.Thevoltage 2017(4)
controlisaccomplishedbytheapplicationofapositivepulsetothegateterminalsofthe
March(1)
SCRatthedesiredtime.Beforethepulseisapplied,theSCRisopenandnocurrent
CONCLUDINGPARTSTEAMBLOWINGPARTIVABCOFTHE...
flows in the circuit. As soon as SCR is fired, it operates as a standard silicon rectifier
untiltheforwardcurrentisreducedtoalmostzero. January(3)

2016(16)
Checkthenoloadoutputvoltageattheoutputterminals.
Ensuretheoutputvoltageissteadywithoutanytroublefor15minutes. 2015(12)
Checkforannunciationinterlocksetc. 2014(41)
Ifloadisavailable,theequipmentshallbeloadedprogreesivelyuptoratedvalue 2013(116)
Checkforvoltageregulation,freefromoscillation,rippleetc. 2012(12)
Checkfordroppingcharacteristicsathigherloads.
Runtheequipmentfor4hoursandobserveofstabilityandcheckforlocalheating.
Whenunitisloadedtheripplevoltagelevel(peaktopeak)maybeobserved.Followthe Translate
adviceofServiceengineer.
IIFIRSTCHARGINGOFBATTERY: SelectLanguage Poweredby Translate

ThumbrulesaysDCVoltageneededforbaerychargingwillbe2mesthenoofcellsinbaery
bank.Theinialchargingwilltakeapproximately16to24hourssincethebaeriesarealready
chargedandsentasmaintenancefreeones.
kboardisfirmlycoItisofutmostimportancethattheterminalofthebatteryisconnected
to+veloadofchargingsource.Sopolarityshouldbeascertained.
Commencechargingnotlaterthan24hoursafterconnectingallbatterycells.
Givethefirstportionofchargeatarateof100Ampsfor10Hours
DischargeitusingWaterresistanceorhalogenlampsasrecommendedbysupplier
Givethesecondchargingattherateofapproximately20Ampstillthesignsof
completionofchargeobserved.
Selectanyonecell(excepttheendcellorregulatingcell)aspilotcelloutofeveryrack
asgiveninthelayoutofthebatterybank.
Voltageandspecificgravityreadingfrompilotcellswillindicatethestateofchargingof
thewholebatterysystem.Followsuppliersrecommendation
Allcellterminals&connectionsaretobeappliedwithpertroleumjellytoreducecontact
resistance.Noadjustmentshouldbemadewhichwilldisturbcharging.
Whenallthecellshavebeengreasingfreelyandwhenvoltageandspecificgravityof
pilotcellhasbeenconstantover3successivehourreadings,thecellscanbedeemedto Adsense
befullychargedandthechargingmaybeterminated.Thenwipedownoutsideofallcells
andcleanthefloor.
Putthebatterysystemontricklechargingwhenchargingcompletes.
Thetricklechargeshouldbeadjustedtogiveoptimumbatteryvoltageof1.531.67volts
percell.

IIIENERGISINGOFDISTRIBUTIONBOARD:
AboutMe
DebasishGuha
TakefinalI.R.valueoftheboard.Checkea IHAVETHIRTYFIVEYEARSOF
ethiectedwithearththroughwireorstripasshowninthedrawing. EXPERIENCEONBUILDING
EnsurethatalloutgoingcircuitsarelockedinOFFposition. POWERSTATIONSATDIFFERENT
Ensurethatallsafetyprocedureshavebeenobserved. PARTSOFINDIA.DURING
ERECTIONANDCOMMISSIONING
CheckthatpolaritiesofD.Cswitchboardbatterychargerandbatteryarematching.
OFPOWERSTATIONITWASFELT
Closetheincomerswitchofboardtochargeit. THATCONSTRUCTION
SUPERVISORSANDENGINEERS
MeasureD.CVoltageattheInput. KNOWLEDGEABOUTAPOWER PopularPosts
ObserveD.Cboardforanyabnormality. STATIONISVERYLIMITEDTOHIS
Ifboardconditionissatisfactory,checkthatallremoteendfusesofoutgoingcircuitsare OWNFIELD.CONSTRUCTION ID,FD,PAFANSFORBOILERIN
FIELDISUNORGANISEDININDIA. THERMALPOWERPLANTPLAN
removed. ITFELTPRUDENTTOGIVETHEM ANDBRIEFDESCRIPTIONOF
SwitchONoutgoingfeedersonebyone.Recordthefollowingforeachcircuit. KNOWLEDGEOFENTIRE FANS
i.)Polarityatbothendsofcircuit POWERSTATIONINBRIEFSOTHAT TillmylastdispatchIcompleted
thetopicsofBoilerstructure,
ii.)Voltageatbothendsofcircuit. THEYCANUNDERSTANDTHE
BoilerPressureParts,Rotaryair
IVEARTHFAULTRELAYONLOADTEST: LINKOFTHEIRWORKTOSYSTEM.
preheaterasmajorequipment.I
ALSONEWENTRANTSWILLBE
TocarryoutonloadtestfortheBatteryE/Frelay,connectvariableresistanceboxofthe ha...
EQUIPPEDWITHGOOD
rangeof15to150KOhmsbetween+vepoleoftheboardandearth TECHNICALKNOWLEDGE. ERECTIONPLAN
KeepselectivitysettingplugofE/Frelayat3mssetting. ANDSEQUENCE
Viewmycompleteprofile
CutoutresistanceslowlytosimulateanE/Fandobservethecurrentinmilliammeter FORAIR
PREHEATER
whentherelayoperates. PARTV
RecordresistanceandcurrentinmA AirPreheater
Carryoutthistestoneachavailablesettingonrelay. erectionPartVcontinuesAirpre
Whiledoingtestobserveandrecordthedirectionofdeflectionintheammeter.Check heatererectionsequenceand
planisgivenabove.Alsothispr...
whetheritconfirmsthepoleonwhichthefaultissimulated.
Repeatonceaagainonvepoleoftheboard. STEAMBLOWING
Thetestissatisfactoryiftheoperationoftherelayconfirmswiththesetting. PART/IABCOF
THERMALPOWER

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2017514 ABCOFTHERMALPOWERPLANT
THERMALPOWER
PLANT
Note:Electricalcommissioningdemandscoolapproachnotrushedtowardsthejob. Steamblowingof
Anymistakemaycausepermanentdamageandthatwaswitnessedmanyatime. MSlines,
Allinstrumentneedtocalibratedsothatduringdisputeyoucanrely.Thisisalsoa CRH,HRH,SH,RH,HP&LPbypass
pipelinesofturbineiscarriedout
commonproblem. inordertoremoveweldingslag,
Allhandtoolshouldbeinsulatedoneandvaluecheckedbeforeusing. loose...

BOILERFEED
Electricalsignboard/safetysignboardshouldbedisplayed. PUMPERECTION
AND
COMMISSIONING
PARTIIIABCOF
PostedbyDebasishGuhaat11:41 Nocomments: THERMALPOWER
PLANT
Recommend this on Google
PARTIIIContinuationfromPART
IIPlacementofpumppedestal&
groutingwithreadymixgrout.
Wednesday,7September2016 Mountingofpumponthepedes...

ELECTRICALSYSTEMOFA
220VOLTDCSYSTEMBATTERYCHARGERPRE THERMALPLANTABCOF
COMMISSIONINGPARTIABCOFTHERMALPOWER THERMALPOWERPLANT.
Inmyearlierposterectionof
PLANT. heaters,deaeratorswere
discussed.besidethatinTurbine
packagethereareotherauxiliaries
220voltdcsystemwithbatterychargercommissioning bothstat...

TilllastdispatchIhavediscussedaboutthebasicrequirementofelectricalsystemin BOILERFEEDPUMPERECTION
ANDCOMMISSIONINGPARTV
apowerplant.IncontinuationwiththatcommissioningofDC220vsystemwillbe ABCOFTHERMALPOWER
describedbriefly. PLANT
Thesystemconsistof: Oilpipelinesarereassembled
i.BatteryBank afteracidcleaningisover.Oiltank
andduplexfiltersareclean.Oil
ii.BatteryChargerMainandStandby tankisfilledtotherequir...
iii.DCDistributionboard.
ThebatteryisinstalledinthebatteryroomintheHTswitchgearroom.Thisprovidesa BOILERFEEDPUMPERECTION
ANDCOMMISSIONINGPARTVI
220VDCsupplytotherelayandcontrolcircuitsintheGenerator.Generatortransformer ABCOFTHERMALPOWER
andUnittransformerprotectionandcontrolpanels,11KVand3.3KVHTswitchgearand PLANT
4.5 V LT switchgears Unit and station service boards and aux. Control panels. As told FINALCOMMISSIONINGOF
BOILERFEEDPUMP(mdbfp)Till
you earlier 220 volt DC system is backbone of the electrical system .To energise AC mylastdispatchwehave
systemyouneedDCsystem. discussederectionand
BatteryCellsDataSheet(Typical500MWpowerplant commissioningofBoilerFeed
pum...
GuaranteedAHCapacityat10Hrs.discharge
Rate1Volt/Cellat27C990AH ELECTRICALSYSTEMOFA
DesignationKPH990P THERMALPLANTCONCLUDING
PARTABCOFTHERMAL
Recommendedrangeoffloating/trickle POWERPLANT.
Chargingvoltage1.41.42V/Cell EarthpitcheckingEachearth
Recommendedrangeofboostcharging pitischeckedasmentionedinthe
Voltage1.531.67V/Cell standardchecklistofSwitchyard
earthingsystemCheck...
Tricklechargingcurrent1to2MA/AH
Boostchargingcurrent198A 220VOLTDCSYSTEMBATTERY
Opencircuitvoltageofcellwhencompletely CHARGERPRE
COMMISSIONINGPARTIABC
Dischargedat27Cat5hrsdischargerage1.0V OFTHERMALPOWERPLANT.
220voltdcsystemwithbattery
Dimension(mm)522Lx192Wx405H chargercommissioningTilllast
dispatchIhavediscussedabout
Amountofspecificgravityorelectrolyte thebasicrequirementofelectrical
sy...
Percellrequiredforfirstfillingat27C18Lit/cell,1.19+0.01
Specificgravityofcellwhenfullycharged1.19+0.01 GENERATOR
Max.electrolytetemp.thatcellcanwithstand AUXILIARIES
Continuously50C (SEALOIL
SYSTEM)PARTI
Netdrycellweight45Kg ABCOFTHERMAL
Withelectrolyte68Kg POWERPLANT
CellcontainermaterialPolypropylene TilllastdispatchIhaveoutlined
theinstallationofturbineand
Noofcells/Bank169 generatorofthermalpowerplant
brieflywiththehelpofphotos.I
ChargerI&II ha...

InputVoltage415V+10%
OutputVoltage220VDC
FloatVoltage236VDC
BoostVoltage287.3VDC
Rectifiercurrentlimit400A
Batterycurrentlimit198A
Autochargeovercurrent40A
SteadystateoutputvoltageRegulation(For+10%I/P
Voltagevariation+1%
0100%loadvariation
atatime).

Theabovedatawasgivenfromadatasheetofparticularpowerstationbutthismayvary
marginallypowerstationtopowerstationdependingonsystemdesignandintegration
forwhichIamnotexpert.

Precommissioning

Battery,batterychargeranddistributionboardsareinstalledasperdrawing.

Cablingbetweenthebattery/batterychargerandthedistributionboardscompleted.

Basictesting.qualitychecksofcomponentslikeinsulationtesting,continuitytesting,
dimension checking etc are over. Charge the distribution board live at 220 V DC in a
safeandorderlymannerwithoutloadandkeepitchargedfor24hours.

To carry tests and checks to ensure that all the components on the boards are
operatingsatisfactorilyincludingcablestoalltheremotepointsinthe400KVsubstation
andcontrolroom.

ACdistributionboardforinputsupplytobechargedandcommissioned.

Eachmodulewillbecheckedindividually

Eachoutgoingsupplywillbetesteduptothefusesattheremoteend.

BatteryE/FwillbesimulatedforboththepolesandE/Frelaysensitivitywillbe
checked.

Followingserviceswillberequiredduring,testingandprecommissioning

415V,3Phases,50Hzsupply,Adequaterunningwater,Suitablevoltmeter,ammeter,

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2017514 ABCOFTHERMALPOWERPLANT

thermometer and hydrometer,Variable resistance or water load for discharging the
battery.

Electrolyte for cells as per IS266, Pure battery grade distilled water, Variable
resistancebox
of15to150KOhms,1No.500VDCmegger,Multimeter,handtoolsetc.

Standard safety equipment for handling acid and battery . Also fire prevention
equipmentlike
extinguishsers , Exhaust fans to take out fumes if any , etc should be made available.
Different
precautionarysignboardinandaroundthepanelbatteryroometc.

continuedpartIIbatterychargercommissioning.

PostedbyDebasishGuhaat18:36 Nocomments:

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Saturday,20August2016

ELECTRICALSYSTEM220VDCSYSTEMFORMAINPLANT
ABCOFTHERMALPOWERSTATION

220voltDCsystem

The 220V DC system supplies direct current as source of operating power for control,
signaling, relays, tripping and closing of switchgears, emergency motors of most
importantauxiliarysystems.
Undernormalconditionsofstationgeneration,thestoragebatteryunitsarekeptfloating
in DC bus bars by means of the trickle chargers (also known as float chargers). The
tricklechargersofeachbatteryunit,whichisarectifierwithACinput,isnormallymade
to take all DC requirements of the power station without allowing the battery to
discharge.ThisisachievedbymaintainingtheDCoutputvoltageoftricklechargerafew
voltshigherthanthevoltageofthebattery.

A typical 500 MW Main DC Plant is described below. In a power plant Number of DC

system are running parallel in different BOP packages likeAir compressor ,CHP ,AHP
etc. Low voltage DC system is also sunning as per requirement of the system like
FSSS,DCS,ATRS etc. However we are describing only main plant. Switchgear DC
systematswitchyardalsonotconsidered.

MainPlantconsistsof:
i. BatteryBank
ii. BatteryChargerMainandStandby
iii. DCDistributionboard.
ThebatteryisinstalledinthebatteryroomintheHTswitchgearroom.Thisprovidesa220VDC
supplytotherelayandcontrolcircuitsintheGenerator.GeneratortransformerandUnittransformer
protectionandcontrolpanels,11KVand3.3KVHTswitchgearand4.5VLTswitchgearsUnitand
stationserviceboardsandaux.Controlpanels.
BatteryCellsDataSheet
GuaranteedAHCapacityat10Hrs.discharge
Rate1Volt/Cellat27C990AH
DesignationKPH990P
Recommendedrangeoffloating/trickle
Chargingvoltage1.41.42V/Cell

Recommendedrangeofboostcharging
Voltage1.531.67V/Cell
Tricklechargingcurrent1to2MA/AH
Boostchargingcurrent198A
Opencircuitvoltageofcellwhencompletely
Dischargedat27Cat5hrsdischargerage1.0V
Dimension(mm)522Lx192Wx405H
Amountofspecificgravityorelectrolyte
Percellrequiredforfirstfillingat27C18Lit/cell,1.19+0.01
Specificgravityofcellwhenfullycharged1.19+0.01
Max.electrolytetemp.thatcellcanwithstand
Continuously50C
Netdrycellweight45Kg
Withelectrolyte68Kg
CellcontainermaterialPolypropylene
Noofcells/Bank169
ChargerI&II
InputVoltage415V+10%
OutputVoltage220VDC
FloatVoltage236VDC
BoostVoltage287.3VDC
Rectifiercurrentlimit400A
Batterycurrentlimit198A
Autochargeovercurrent40A
SteadystateoutputvoltageRegulation(For+10%I/P
Voltagevariation+1%
0100%loadvariation
atatime).
Above is standard specification of DC voltage system followed by BHEL in 500 MW EPC contract. Cell
voltagesometimeschangedinto2V+/5%insteadof1volt.

FollowinginstallationcheckstobecarriedoutduringerectionoftheDCsystem
1.Roomtobecheckedthoroughlyaboutlevel,acidresistancetilesetc
2.Checkthebatteryaboutdamage,conditionofbatteryi.edryorwait.
3.Ifitisdrythenpreparetheelectrolyteforfilling.
4.CheckallthecableconnectionfrombatterybanktoDCDB
5.ChecktheinstallationofBatterychargerandcabling.
6.Followallsafetyprecautionlistedinsafetymanual
7.Usecalibratedinstrumentsformeasurementsofparameters.
8.Aswewillbehandlingacidsolutionextraprecautionisrequiredforsafehandling.
9.Checktheventilationsystemincludingexhaustfansareworkingproperly.

Continuedpartiiforcommissioningofbatterycharger

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2017514 ABCOFTHERMALPOWERPLANT

PostedbyDebasishGuhaat09:31 Nocomments:

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Saturday,21May2016

ELECTRICALSYSTEMOFATHERMALPLANTCONCLUDING
PARTABCOFTHERMALPOWERPLANT.
Earthpitchecking

Eachearthpitischeckedasmentionedinthestandardchecklistof
Switchyardearthingsystem

Checkthatthedepthoftheearthpitis3.5Mtrincaseofpipe

electrode3Mtrincaseofrodelectrode.

Incase of pipe electrode, earth pit must be having the layers of sand, gravel,
salt,andcoalwiththethicknessasmentionedintheseparatedetail.

Thicknessofthegravelmustbe150mmandthegravelmustbespreadover
theswitchyardarea.

Mainearthingandsubsidiaryconductorsaretobeensuredthat40/50mmdia
rodisusedforthesame.

GENERALCHECKS:

Minimumspacingbetweenelectrodesshallbe6Mtrs.

Earthing conductor shall be laid at least 300 mm below cable trenches and
undergroundserviceducts,pipes,tunnels,railwaytracksetc.,ifcrossed.

Risers of 40/50 mm dia MS rod shall be brought nearby equipment

foundations : 1. 2 Nos. for each equipment earthing. 2. 1 No. for each
structuralearthing.

Risers end near the foundation shall be brought 300 mm above the ground
levelnearfoundation.

Earthing conductors along their run on cable trench ladder columns, beams,
walls, etc. shall be supported by suitable welding/cleat fixation at intervals of
750mm.

Galvanized iron sleeves shall be provided for the passage of the conductors
where ever it passes through the walls. Both ends of the sleeves shall be
sealedtopreventthepassageofwaterthroughthesleeve.

Earthing conductor embedded in concrete shall have approximately 50 mm

concretecover.

Auxiliary mesh of 1500 x 1500 mm size shall be laid at spacing of 300 mm

below operating boxes of circuit breakers, isolatorsmain switches and earth

switches.

AlljointsshallbeweldedasperthedrawingandIScode.

LAs, CVTs, and Earth wire down conductor shall be connected to the main
earthmatthroughrodelectrodes,rodelectrodesshallbemadeoutof40dia
MSrodsatsite.

Lightning Masts down conductor shall be connected to earth mat through 1

NO.pipeelectrode.

Transformer neutral shall be connected to earth mat through 2 nos. pipe

electrodes.

Earth mat shall extend 2 mtrs outside the switch yard fence through rod
electrode.

All equipment shall be earthed to at least two points on opposite side which
shallbeconnectedtodifferentconductorsoftheearthmat.

Testingofearthpits:Earthpitresistanceismeasuredwithearthmeggerand
it should be in the range of 1 to 1.5 ohms. The continuity between two earth
pits connected together is checked using a multimeter and it should show
exactcontinuity.
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2017514 ABCOFTHERMALPOWERPLANT

Earthresistanceofearthmatismeasuredanditshouldbeintherangeof0to
0.05ohms.

Checkoverlappingofjointsareweldedwithnogapbetweentwojoints.

The connection of earthing network is checked according to the layout

drawing.

Wewilldiscuss220VDCSystemasthissystemisrequiredtostartACsystem
breaker.ThereforealittleknowledgeonDCsystemwillhelptounderstandthe
electricalsystem.

continued

PostedbyDebasishGuhaat08:27 Nocomments:

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Wednesday,11May2016

ELECTRICALSYSTEMOFATHERMALPLANTABCOF
THERMALPOWERPLANT.
In my earlier post erection of heaters ,de aerators were discussed . beside
thatinTurbinepackagethereareotherauxiliariesbothstaticandrotarysuch
as different coolers , CEP ( condensate extraction pump ) , vacuum pumps ,
CPU(condensatepolishingunit)etc.ExceptCEPerectionofotherauxiliaries
need not require any special strategy. For CEP erection foundation checking
and canister erection is slightly crtical. CEP is a vertical pump therefore
canister is to be erected before erection of CEP. It is sometimes noticed that
CEP foundation is full of water at bottom most area and prevent canister
erection . It is recommended to repair the foundation so that leakage can be
stoppedordrainingthepitbeforeerection.

Itwasdecidedthatnexttopicswillbesteamblowingaswehavecoveredall
themajorequipment.Howeverireceivedmailsfromyoungengineerstocover

electricalsystemerectionandcommissioning.Iamanelectricalengineerbut
did not work with the system. Therefore what i have seen at site is written
down.Valueadditionistobedonebyindividual.
Earthing system is the mother of electrical system. You can not run an
electricalmachinewithoutearthing.

Theearthingsystemconsistsoffollowing.Earthingisthebasicrequirement
of any Good electrical system. This is essential to protect human lives and
also help us to detect fault in the system . Good earthing provides smooth
electricaloperationandavoidspurioustripping.

i.EarthPit
ii.Subsidiaryconductors

iii.GIFlats

1. EARTH PIT : Each earth pit must be made as per their design
normally that will be either pipe or rod electrode type earth pits. In pipe
electrode earth pit the depth will be 3.5 Mtr . Where as in rod electrode the
depth will be 3 Mtr only. In pipe electrode, the earth pit must be made with
differentlayersofsand,coal,saltandgravelwhereasinrodelectrode,the
rodwillbeinsertedintotheearthsoil.BTGareaearthmatwaslaidafterdoing
thePCCofthearea.Riserswereraisedalongthecolumnfoundationfromtwo
sides.Rodsareweldedatleast250mmoverlapsothatfirmcontactismade.
Special earth pits are made for electronic panels and skids which are
separatedfromelectricalearthing.

2.SUBSIDIARYCONDUCTORS:Theconductorsconnectsbetween
earth pit and various equipments are subsidiary conductors. They are
connectedwithmainearthmatwhichis600mmdepthbymeansofraiser
andwillbeconnectedtoeachearthpitthroughtestlinks.Theotherendofthe
earthpitwillbeconnectedtotheequipment.

3.GIFLATS:Allthetestlinksandequipmentconnectionsoftheswitch
yard are done with GI flats of 75 x 12 mm . Inside the control building, the
earthingconnectionisprovidedby50x6mmGIflats.

Testing
Totesttheindividualearthpitsof400KVswitchyard
Totestthecontinuityoftheearthmat
Tomeasuretheresistanceoftotalearthmat.

TestingEquipment
EarthMeggercalibrated.
Calibrateddigitalmultimeter.
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2017514 ABCOFTHERMALPOWERPLANT
Calibrateddigitalmultimeter.

Stateoftheplant

Erectionof400KVSwitchyardearthingnetworkcompleted.

Testlinksandconnectionstovariousequipmentsdisconnectedfortest.

Clearancefromerectiondepartmentforcarryingoutvarioustestsobtained.

continuedpartii

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Sunday,24April2016

HEATERS,DEAERATORS,PLATETYPEEXCHANGERS,
COOLERSETCPARTII_ABCOFTHERMALPOWERPLANT
PartIihavediscussedabouttheheaters,coolersheatexchangersetc.Inthis
blogIwilldiscussabouttheerectionof
DEAERATOR.

On erection point of view erection of De aerator needs detail planning and

equipmentforerection.Deaeratorconsistof deaeratorandFEEDSTORAGE
TANK. De aerator is in one assembled unit and FST consist of three units pre
fabricatedbut

notassembled.Onceassembleditbecomesaverybigroundshaped
drum/tank.Thereareotheraccessoriesalsolikeplatformarounddeaerator,
saddle at the bottom of FST as such FST rests on it , stand pipes for level
measurement ,misc pipe connection, misc structural items etc. Two dished
ends are welded with respective pieces. This De aerator need to be lifted on
37MfloorCDbaystructure.

Approach to CD can be achieved from end only. If there is one unit then
approachanyoneendwillservethepurpose.Ifthereistwounitthenapproach
will be required from both the sides. If there is 03 units the approach from
middleisrequired.
Minimum crane capacity required is 250 MT with adequate length of boom.
Youmayhavetoremoveafewmemberofroofstructure
toaccommodatetheboomlengthandtheangle.

If you are having luxury 600MT/1200 MT cranes then you place your crane
away from CD bay end but still you may have to remove some of the roof
structureforliftingFSTandDeaerator.
Buthaving600MT/1200MTwillcostyoumore.

A5Telectricwinchand50MpairofrailCR100willberequiredtolayonthe
floorfordraggingofFST.OneendoftheFSTisliftedfirstandplacedonthe
rail then dragged it to its position . Middle piece and de aerators are trial
assembled at he bottom and then dismantled .This is done to avoid any
mismatching during lifting at a height.2nd piece then lifted and locked
temporarilyonthefloor.Deaeratoristhenliftedandplacedonthe2ndpiece
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2017514 ABCOFTHERMALPOWERPLANT
temporarilyonthefloor.Deaeratoristhenliftedandplacedonthe2ndpiece
andboltedsecurely.Assemblywasdraggedintopositionbywinch.Thenthird
pieceswerelifted.

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2017514 ABCOFTHERMALPOWERPLANT
DifferentstagesofFSTerectionshownintheabovepictures.

PostedbyDebasishGuhaat13:45 Nocomments:

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Thursday,21April2016

HEATERS,DEAERATORS,PLATETYPEEXCHANGERS,
COOLERSETC_ABCOFTHERMALPOWERPLANT
I have detailed major equipment of Turbine Package and their method of
erection generally followed in India. There may be some differences during
executiondueprojectspecificsbutbaseisthesame.

AlreadyIhavediscussedmainturbine,GeneratorandMDBFPandTDBFP.
InthisarticleIwillcoverHPHeaters,LPHeaters,Deaerator,PlatetypeHeat
exchangers,coolersetc.

ErectionMethodofstaticequipment.

<Allcoolersareerectedassoonasfoundationisavailable.
Normal foundation checking i.e level ,co ordinate w.r.t. turbine axis is
checkedbeforeplacement.Coolersareplacedaftercheckingtheorientation.
30 mm to 50 mm packer plates are required for placement and subsequent
secondary Grouting. Front piping opens after that as one end is fixed now.
Same method is also followed for other heat exchangers. All the coolers are
comingABbaystructuresi.eTurbinehall.

HPheatersandLPHeaters

< In earlier days and upto 500MW plant all the heaters are erected vertically
withthehelpoftheTGhallEOTcrane.AnerectiondeviceissuppliedwithHP
heatersforerectionasclearancebetweenEOTcranehookbottomand10M
Turbinefloorisminimal.Thereforeerectiondeviceisnecessary.

Highercapacityunitlike660MWandaboveheatersareplacedHorizontallyat
BC bay of 17 M floor. Counter flanges for the connection of pipes to be
checked.

Structuralmembersforverticalheaterserectionaretobechecked,Specially
weldingbetweenthemembers.Ithasbeenexperiencedthatsomeofthe
membersarenotwelded.Thosearetocheckedandweldedbeforeerection.
AlsoLevelandcoordinationaretobecheckedandmarkitinnearestcolumn.
Thiswillhelpduringpipingerectionfordrawingreference.Verticalheatersare
erectedbyEOTcranewithafewpackerplateinthebottom.Asnogroutingis
involvedthereforelevelingandalignmentisdonethroughpackerplateof
differentthickness.Oncealignmentisoverthentheheatislockedwith
temporarystructureandreleaseforpiping.

Heatersrequiretobeerectedhorizontallyrequirespreplanning.Allthe
heatersareerectedonebyone,oneafteranothersidebyside.Thereforepre
planningisrequiredtopushheatersonebyone.Heatersfloorisconcrete
floorthereforeguiderailisamust.Sequentialerectionismustotherwisethere
willnotbeenoughspaceonthefloorforovertaking.Locationofheaterson17
MfloorsuchthatapproachisnotavailablebyEOTCrane.Heatersare
unloadedon17Mflooratdesignatedplace.Draggingonrollersarecarriedout.
Heatersareheavyweightitemsdraggingtobedonethroughparticularplace
otherwiseitcandamagetheconcretefloor.

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2017514 ABCOFTHERMALPOWERPLANT

PictureshowshorizontalheatersandPlatetypeheatexchanger.Erectedand
pipingunderprogressfromoneend.

continuedtoPartII

PostedbyDebasishGuhaat19:37 Nocomments:

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