Commissioning of Steam Turbine Generator Control system

1) When did you work on this project?

Ans: @@@@@@@@@

2) Your position and responsibility in the project:

Ans: Electrical Commissioning Engineer (to carry out commissioning of all
electrical equipments of Steam turbines Generators

3) The location where the project was carried out

LAYYAH co-generation power plant, District LAYYAH Punjab Pakistan

4) The name of the organization:

Ans: THAL Industries Corporation Limited
Background:
5) Describe the project briefly:
This was a project of coal fired and Baggas base Small power plant to fulfil the electrical energy
requirements of local area of about 6,291 km² with population of 1,824,230.this project was
proposed with Steam Turbines Generators capacity of 26MW with 21MW contract of energy supply
to area and national grid. This plant was designed by a local firm USMAN Engineering private limited
in 18 months.

5) What were the objectives of the project?

Environmental protection

Energy efficiency

power export

6) Describe the nature of the area where the project was carried out

8) Organizational chart (you may attach an image, pdf etc)

9) Statement of your duties/responsibilities in the project. You may add more

I was the member of commissioning team which was consisting of 7 members.

My duties which I performed are listed
 Installation of all control switches board panels.
 Commissioning of all control panels from field terminations to CCR(Central control
room)
 Settings and Programming of Generator protection relays related to generation
system.
 Testing and calibration of Generator protection relays related to generation
system.
10) How you applied your engineering knowledge and skill

Name courses whose content was utilized in the project both directly and indirectly. If
you name academic courses, make sure that they are in your transcripts. If you have
undergone other training courses you can also state them here:

(a) Academic courses: ( YOU HAVE TO SELECT)

(b) Training courses: ( YOU HAVE TO SELECT)

(c) Which engineering manuals or standards did you refer to during the project?
 Sequence Diagrams of Switch board Control Panels.
 Data sheets of all equipments used in Control Panels.
 Installation instruction provided by contractors.
 Manufacturers Designers reference handbooks of all equipments.
 ANSI /IEEE Standard C37.2 Standard for Electrical Power System.

11) How did you prepare for the project? (eg. I met with my supervisor and discussed....
I prepared a project schedule ...etc)

When I was nominated in the commissioning team I was so excited to work on this
project because it was a different type of project where I have to learn many new things
and face the difficult challenges. So I started studying the technical articles related to
commissioning of power plants. I start collecting the standards of IEEE for
commissioning of Steam power plants.

12) The tasks assigned to you and how you went about accomplishing them. Please
include at least 4 tasks and sub tasks. Explain how each task was carried out.

Following tasks were assigned to me.

Erection, commissioning, Programming and testing of listed Generators switchboard

control panels

a- Generator excitation control panel(Provided By ABB India)

b- Steam turbine speed control panel (Provided By TRIVENI India)
c- Generators protections relays Panel( By USMAN Engineering Pakistan)
d- Generators Synchronization and load sharing Panel( By USMAN Engineering
Pakistan)

Task-1

Erection, installation and layouts:

In the erection of above listed switchboard panels I was assigned a sub task to draw a
layout and Sequence arrangement of panel’s. Which I designed in CorelDraw and its
design is attached.
Task-2

Commissioning:

I prepare a control cable schedule for termination of control signals between Machines
field and central control room as per provided sequence diagrams of panels by vendors.
This schedule was calculated with reference to signals type, length of cable, route of
cables etc. i.e.4 core 4mm² flexible armored cables was selected for Current transforms
Secondary signals where total length of cable was 80m from Current transformer to
Protection Relay Panel.

Task-3

Settings and Programming of Protections Relays:

Following Protections were set and programmed through protection unit interfacing
software (Utility software 3) provided by vender (DEIF Denmark)

Attachment Task-3

Task-4

Testing and calibration of Protections Relays:

Attachments testing reports

13) Technical difficulties/problems you encountered during the project and how you
solved them by applying engineering principles/knowledge. Below is an example of how
this question might be answered (note that this is just an example)

Ans:
This was the project of some different type where supply of equipments and control
panels was from different vendors across different countries and commissioning staff
from these vendors was also involved for commissioning supervisory of project. It was
very difficult and challenging for commissioning team to coordinate and interconnect the
control panels with each other. These control panels were designed as to use them as
universal control system not specially designed for this project. Sequence diagram and
drawings of these control panels were not designed to coordinate with each other

Solutions:

These matters were forwarded to the concern vendors of supplied equipments. They
make some amendments in their design, in sequence diagram and drawings with
suggestions to make changes on site in the control panels to coordinate with each
other. So many of control signals and there works of operations were modified as per
plant requirement. Such as power transducer was added in control panels to provide
load signal to WOODWARD 505 turbine speed control unit.

14) Strategies devised by you including any original or creative design work. Here you
can be creative and develop a practical case.

Ans: will provide you an attachment.

15) How you worked with other team members.

Ans:

1- Maintaining good communication skills with team members

2- Always setting up a good examples with co-workers and team members
3- Creating the good working relations
4- Assigns correct job to the correct person.
5- Managing the conflicts with team members

16) Briefly state how you observed the following in your projects:

(a) Safety of workers and property:

Ans:
1- All personal protective equipments were provided to workers.
2- Safety rules and regulations were strictly obeyed during the project.
3- Always taking reasonable steps to ensure the health and safety of themselves
and others by safety department and management.
4- Ensuring that their work doesn’t harm any of workers in plant.

(b) Environmental sustainability:

1- Integrated green thinking into our way of working on project.

2- Maximize the resource conservation
3- Utilize the energy in an efficient and smart manners
4- Leads to environmental as well as economic sustainability.

(c)Professional and ethical conduct:

1. honesty
 2. trustworthiness

3. loyalty

4. respect for others

5. adherence to the law

6. doing good and avoiding harm to others

7. Accountability.

17) Your view of the overall project

(a) What did you learn from the project?

Ans:
This was a great time for me whom I spend in this project; this project had taught me
lot of skills and builds my career in a new way. Following are some lesson that i learn
in this project, This was the first time for me to generator start-up by the vendor and the
one that would conclude our functional testing. It also included the load bank testing,
alarm verification, and operational testing that included the ATSs. I felt comfortable
sharing this test with him so that on the next time out, he would remember me and have
a better understanding of any load bank testing that was required.

(b) What was your contribution to the success of the project?

Ans :

I play a key role in the project that was the very crucial and important than all
others tasks. In execution phase, major job was erection testing & commissioning of
the machinery in a time bound manner without compromising on quality which i
perform very well as per the overall commissioning reports of the project.

(c)How you achieved project goals:

In following successful steps I achieved my projects goals;

1- My communication with all my co workers was open, honest and respectful.
2- Me and my team understand the goals and were committed to attaining them.
3- Creativity, innovations and different viewpoints were accepted with open mind.
4- With coordination of team members we make quality decisions together.

18) Additional information

(a) Two engineering Formulas that you used in your project and what they were used to
calculate:

1.
Ans:

V3ϕ = √3I(Rc cos ϕ + Xc sin ϕ)L/1000

This formula was used to calculate cable length and sizes which were used in
control panels,
Where
 V3ϕ is the three phase voltage drop (V)

II is the nominal full load or starting current as applicable (A)

Rc is the ac resistance of the cable (Ω/km)

Xc is the ac reactance of the cable (Ω/km)

Cosϕ is the load power factor (pu)

L is the length of the cable (m)

2.
Ans:

Turn Ratio (a) = Np / Ns = vp / vs = ip / is

Np = Number of turns on primary side

Ns = Number of turns on secondary side
vp = Volts on primary side
vs = Volts on secondary side
ip = amps on primary side
is = amps on secondary side

this formula was used during secondary injection test of the Protections Relays to
calculate the CT/PT RATIO Test.

(b) Any other additional data you deem important (can be graphical results, pictures of
CAD models, circuits etc)