PROJECT: EID, PARRY, PUDUKKOTTAI, 1 X 18.

55 MW TG

PROBLEM: HIGH MAIN STEAM SILICA PROBLEM DURING RESTART
AFTER OVERHAUL OF FOULED TURBINE


During the month of June 2006, it was reported by customer that the
machine could not be loaded to rated capacity. The operating
parameters of the unit were obtained from the customer and was
examined by us. It was concluded that the main cause could be
due to fouling of turbine blades, which was caused by impure steam.
Based on our advise the unit was shut down and the turbine top casing
was dismantled. Heavy scale deposition on the internals of the
turbine was observed. The scale deposits were removed by alumina
blasting. The damaged components of turbine were sent to
Hyderabad works for rectification and were received & installed in
the turbine. After completion of the above works, turbine top casing
was put back and boxed up. After carrying out oil flushing,
turbine was put on barring gear.

We advised customer for inspection and cleaning of other areas like
boiler, air cooled condenser, etc. The vessels like Boiler drum,
Deaerator, Condensate storage tank were inspected, cleaned and boiler
was flushed.

After completion of assembly of turbine Boiler was restarted on
07/08/06. After nearly 18 hours of venting, the steam through start
up vents, steam purity (Silica 0.02 PPM and Iron Nil PPM) was
achieved. Consistency in steam quality was ensured for 6 hours and
Turbine was rolled, synchronized and loaded to 3 MW on 08/08/2006.
After two hours, load was raised to 5 MW. At this load the Main
steam silica was found increasing. The Turbine was hand tripped, as
the silica level has increased to 0.07 PPM.

Boiler was kept in service and steam was vented out through start
up vents at boiler and turbine end. Even after two days of venting,
the silica level was not dropping below 0.05 PPM. Boiler was boxed up
due to shortage of DM water. When the boiler was restarted after 24
hours of cooling, the main steam silica level has increased to the level
of 0.25 to 0.3 PPM . The silica levels of feed water and drum
saturated steam were well within limit of 0.02 PPM. Drum water (CBD
sample) silica also reduced to the operating level of 0.5 PPM.

This indicated that the contamination had been carried over from
super heater coils. Hence customer was advised to clear the deposits
from super heaters by steam blowing operation. It was decided to
carry out steam blowing by continuous blowing method through ESV.

ESV was dismantled, Steam blow device and temporary piping to
atmosphere were erected. Steam blowing was carried out for three
days (total number of blows - 13 ) and silica was monitored.

After ensuring steam purity ,Turbine was restarted on 22/08/06. When
the deaerator was charged with PRDS steam, Silica level of Feed water
and Steam started increasing .

Further following precautions were taken to ensure that there were no
contamination from other associated system.

1. Deaerator pegging steam line was disconnected and steam blown.

2. CBD vent connection to deaerator was kept isolated and customer
was advised to charge this line only after few weeks of stable
operation of the unit.

3. The condensate of air cooled condenser outlet was left to the
drain till the purity was achieved. On achieving the condensate
purity ( less than 0.03 PPM), the condensate was partially put
back into the feed water circuit and the feed water purity was
monitored. Full recovery of condensate was made after achieving
condensate purity of 0.02 PPM.

4. Condensate purity of turbine exhaust condensate collection tank
was checked before putting it to CST.

5. After achieving condensate purity, turbine load was gradually
raised to maximum load on condensing mode without extraction.
Steam purity was monitored and found to be within limit.

6. Turbine LP extraction was charged and process steam was given.
The purity of condensate return from sugar plant was also
achieved. After achieving purity of condensate , closed loop was
established.

7. Turbine MP Extraction to feed water heater was charged leaving
the condensate from feed water heater outside initially.
Condensate purity was ensured before putting back into closed
loop.

Full load of 18.55 MW with extractions was achieved on 27/08/06. The
inlet steam flow at different extraction flows and load are in line with
design steam map curves. The wheel chamber pressure matches with
the inlet steam flow, as per the design curve. The unit is now
operating at full load.