Energy 01 TTPS

ENriched EngineeRing Grub for You
Energy : 01 Power : 01 July 2010
Storage / Preservation Special
< An in-house technical magazine of TTPS > < for local circulation only >
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Energy : 01 Power : 01 July 2010
An in-house technical magazine of TTPS
Grubs:
Chairmans Message Director (Generation)s Message General Manager / HRDs Message Chief Engineers Message SEs Messages EEs Messages Our Energy Er. Krish Store Nicely & Save Wisely 99% is never equal to 100% - Er. Samuel A novel method but NALLA method Er. J.J.Kumar 2 Top reasons for 3 pin Top Er. Sethu Sudden loss of load trip for coal mills Er. Joseph Transformer Storage Tips Improper Contact means NO contact Er. Selvaraj Effective Preservation of Steam Turbine Er. Rajendran Smartness of SMART GRID Er. Balu Energy Generation from control cable Er.Muthukrishnan Concrete steps to preserve Concrete Er. Chandrasekaran Take Care & Save Crore Er. Nagarajan Energy News around us Let it (Light) be LED Er. Kingslin Foreign Material Exclusion Rules for Generator Stator Boiler preservation Er. Saravanan Latest Energy News at TTPS Er. Murugan
< for internal circulation only >
Periodicity of this Magazine
Monthly
Quarterly
Conveniently
1 2 3 4 5-7 8 9 10 11 12 12 13 13 14-15 16 17 18-19 20-21 22 23-24 25 26 27 28
< ENERGY - An in-house technical magazine of TTPS >
C.P.SINGH, I.A.S.,
PRINCIPAL SECRETARY / CHAIRMAN-CUM-MANAGING DIRECTOR, TANGEDCO Limited.
N.P.K.R.R. Maaligai, Electricity Avenue 144, Anna Salai, Chennai-600 002.
< July 2010 > < Energy:01, Power: 01 >
[ P-1 ]
Er. K. BALASUBRAMANIAN, B.E.,F.I.E,

DIRECTOR (GENERATION), TANGEDCO Limited.
10th Floor, Eastern Wing, 144, Anna Salai, Chennai-600 002.
[ P-2 ]
Er. P. BALAKRISHNAN, B.E., M.B.A, M.I.E.,

GENERAL MANAGER / HRD, TAMIL NADU ELECTRICITY BOARD.
10 Floor, Eastern Wing, 144, Anna Salai, Chennai-600 002
th
[ P-3 ]
Er. C. GANESAN, B.E.,

CHIEF ENGINEER, Tuticorin Thermal Power Station, Tuticorin 628004. Tamil Nadu
Off Res Fax
:0461-2352345 :0461-2352332 :0461-2352457
Email: cettps@tnebnet.org
[ P-4 ]
Er. P. Amirtharaj, B.E., Superintending Engineer, Operation / TTPS. CUG Cell No: 9445856878
Er. V. Jeyapaul, B.E., Superintending Engineer, Electrical Systems / TTPS. CUG Cell No: 9445856888
Dream becomes True !!! I was expecting this magazine for a long back, but now my dream has come true. Surely, this magazine will be very useful to all our engineers & staff. The hidden technical treasures among the engineers & staff will definitely improve the performance of the plant and efficiency. Successful
improvements with post-improvement measurements are welcome habits among the field engineers. As I mentioned in the 100th Technical Meeting organized by MRT2 division, release of such a useful technical magazine is one more achievement by the team of engineers who used to share their knowledge for the welfare of TTPS. My heartfelt thanks to Er. A. Krishnavel, AEE/MRT-2 / TTPS for his great effort in releasing this magazine. I wish that the magazine will improve the quality day by day. With warm regards & Wishes, P. Amirtharaj,
23.06.10
One more Excellency!!!

I would like to extend my heartiest greetings to MRT-2 division for having materialized another marvellous idea of preparing technical magazine in addition to their present practice of conducting Technical meetings with the experienced Engineers Specifically, I extend my sincere thanks to Er. A. Krishnavel, Asst. Executive Engineer / MRT-2 and his colleagues / technical forum members for their sincere effort in bringing out this magazine in a pleasant and praiseworthy manner I am so confident that the contents in this first issue will definitely be a great boon to maintenance engineers in saving considerable quantum of time and material for the benefit of TNEB. Best wishes V. Jeyapaul
21.06.2010
[ P-5 ]
Er. U. Rengasamy, M.E., Superintending Engineer, Mechanical - I / TTPS CUG Cell No: 94458566969 My hearty congratulations to all the experienced engineers behind this valuable attempt. This magazine covers all the disciplines of engineering in a power plant. Preservation techniques for Boilers & Turbine rotor are quite useful for the Operation and maintenance personnel of this huge power station of 30+ years old. It is my sincere request to keep this tempo going in the coming years also, with a lot of new articles focusing on improvements and innovative technical ideas. Knowledge is power. The power with this ENERGY will certainly enhance the performance of this plant to a higher level. Best wishes, U.Rengasamy
23.06.2010
Er. K. Hariharasubramanian, B.E.,M.I.E, Superintending Engineer, Mechanical - II / TTPS CUG Cell No: 9445856975 I am pleased to know that a group of experienced and dedicated engineers in TTPS have devised this technical magazine with due importance to Storage & preservation of costly power plant equipments. It is pertinent to note that the MRT wing not only saves the costly equipments of our thermal station, and thereby helps to sustain the power protection to an optimum level; it also saves the priceless value of human lives at times. Hence, the part of MRT on the Power Generation field is inevitable. It is not an over-say that MRT, which conducts periodical technical meetings to explore permanent solutions to challenging problems, plays a vital role in operating our units at full load even after 31 years of valuable service since 1979. I congratulate all the article contributors of this magazine for their open mind in sharing their technical know-how.
With best wishes

K. Hariharasubramanian
23.06.2010
[ P-6 ]
Er. V. Rajendran, B.E., M.I.E, Superintending Engineer, R&M / TTPS CUG Cell No: 9445856970 It gives me pleasure to know that Engineers working in this power station are sharing their knowledge among themselves which may improve the performance of the Station and ultimately the organization. It can be observed from the magazine that notable benefits can be realized in the station through such activities. Any such activity which may enhance the performance of the station/organization deserves recognition. While thanking the organizing committee for given me the opportunity to express my views, I congratulate all the persons responsible for making this magazine a successful one. I hope it will become a more success & meaningful one if the potentials available with the Engineers working in different spheres of the Station are made available for all the sections of the Engineering community. I wish such energetic activities may be carried out enthusiastically in the future so as to renovate the minds of the Engineers which will modernize the station through their skills and put forth our organization ahead of the others in the nation. With best wishes to make this attempt grand success,
V. Rajendran
22.06.2010
Er. R. Narayanasamy, B.E., Superintending Engineer (i/c), Civil / TTPS. CUG Cell No: 9445856963
An organization is rated to be good because of the excellent performance of its present employees. An academic industry is rated to be good when its past engineers perform excellently. TTPS is rated to be an industry of excellence, because, it has moulded and developed a large number of good and responsible engineers. It was a great pleasure to take part in congratulating the technical team of engineers for their excellent effort in sharing their knowledge and in bringing-out this magazine successfully. With warm regards & wishes R.Narayanasamy
23.06.2010
[ P-7 ]
Er. R. Kamaraj, B.E.(Hons.), M.E., Executive Engineer, Instrumentation I / TTPS

CUG Cell No: 9445856881
Er. S. Kaja Mohaideen, B.E., Executive Engineer, Technical Services / TTPS.

CUG Cell No: 9445856965
It is the long felt need of the engineering community of TTPS to have a technical media to share their experience & knowledge. I believe this Technical Magazine - ENERGY - will meet this requirement. The technical challenges faced by O&M engineers and their innovative solutions, need to be recorded for guiding the future engineers. This magazine provides an excellent platform and I am so confident that it will reach the targeted engineers and ultimately benefit TNEB. A clear mental picture is worth pages of explanation. Diagrams are provided in appropriate places, which are more clear and striking and give clear conception of the principles. It has always been a pride and pleasure to be a part knowledge spreading ventures and I appreciate the pains taken by Er. A. Krishnavel and the team of co-authors for creating this excellent magazine. I wish the team a great success and am eagerly looking forward to see many more issues. With warm regards and wishes R.Kamaraj,
16.06.2010
I am glad to note that Er. A.Krishnavel, spreading the spirit of technical interest by organizing weekly meetings, is now bringing out a magazine ENERGY This magazine ENERGY provides a platform for Engineers to share their knowledge and experience gained over the years in the Operation & Maintenance practices. I am sure that this magazine would be more useful to Engineers. A good service initiated by Er. A. Krishnavel, AEE/MRT-2 is highly appreciable. With Best Wishes, S. Kaja Mohaideen
23.06.2010
[ P-8 ]
OUR ENERGY
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We can see this quote in our Switchyard-2 control room. I would say it is truest of all trues. Always, contradiction yields improvements which in turn refine our profession and life. Engineering, the practical application of science to commerce or industry or mankind, always needs some sort of intellectual as well as contradictory thinking towards economical applications. With prevailing power scenario all around the World, the true energy of the engineering community is not just generating electric power; rather it means techno-commercial (social) responsibilities. A technical person should know the commercial impact for every lapse in design, procurement, construction, commissioning, operation & maintenance. Secondly, real energy of an Engineer lies on his effort in accomplishing the reliability of the system that he is going to dedicate for the man kind. Reliability, the quality of being dependable or reliable, is the word mostly being detested by most of us. We felt happy when a system worked yesterday. So. happy when it works today. Thats all. Our goal / ambition in the direction of future are mostly spelled-out as not necessary now-a-days. But, one thing we must remember that in every discipline of engineering, all the moves against reliability concepts have been ended-up with irrecoverable disaster. Encouraging long-term plan is one of the needs of the hour. Nobody can deny that we are surviving now comfortably only because of our predecessors vision and implementations aiming at the future. Many of the utilities which had no reliable long-term plan have experienced great down-falls in their economical status in the recent past. My dear contemporaries, it is the right time to think in a different way, but in an economical way to enhance the performance status of our organisation by adopting the ever green energetic concepts like.. Engineering (design) aiming at long-term Service After Sales (SAS) security Encouraging Life extension plans like retrofitting / refurbishment, before going for a mass replacement Hunting for Technology-based low cost improvements Faith on Standards and technical knowledge Experience cum essentiality based Spares inventory Optimization like Common Spares inventory Preservation of knowledge-base by means of periodical updating.
Er. A. Krishnavel, B.E.(Hons.), M.E.(Distn.). Asst. Executive Engineer / MRT-2 / TTPS < 9443657223 >
< ENERGY - An in-house technical magazine of TTPS > < for internal circulation only > < July 2010 > < Energy:01, Power: 01 >
[ P-9 ]
STORE NICELY & SAVE WISELY OIP BUSHINGS

Bushings should be stored where they will not be subject to mechanical damage. Bushings having exposed paper insulation on the lower end require special protection to prevent moisture contamination. This can be accomplished with a tank or tub filled with oil or with special moisture- proof wrapping. Completely sealed outdoor bushings may be stored out of doors.
in a horizontal position can introduce voids or air bubbles into the filler insulation.
Liquid- and plastic-filled bushings should never be stored in a horizontal position. Storage
The condition of stored bushings should be checked periodically for oil level, mechanical damage, power factor etc. The power factor of a stored bushing should be checked before putting it into service. If the bushings are to be stored outdoors the crates need to be of a weatherproof material or protected with an external covering. The gasket surface and metal parts below the flange shall be covered with polyethylene of vinyl sheets to avoid rusting Knowledge of bushing construction is helpful in developing storage plans. If the bushing has an oil filled condenser the bushing should be stored such that the condenser remains covered. Bushing terminals should be checked to be tight and cap taps should be covered and filled with fluids as required. This is to prevent corrosion and water intrusion during storage. The storage should be arranged such that there must be enough facility for conducting periodical tests In all cases the goal should be to cause no damage to the bushing and keep it in good operating condition
1. Courtesy: O&M Manuals for OIP Bushing M/s TELK, M/s BHEL & M/s ABB 2. FIST Volume 3-2 Testing & Maintenance of HV Bushings 3. The J&P Transformer Book Martin. J. Heathcote
< for internal circulation only > < July 2010 > < Energy:01, Power: 01 >
[ P-10 ]
99% is NEVER EQUAL to 100%

In the beginning of this Millennium, it was decided to replace the inverter transformer for Unit V UPS A. To remove the transformer, large numbers of power and control cables were to be released and to be re-fixed after the replacement. As all the cables were black in colour and without ferrules, anticipating trouble, it A was decided to number all the cables at all the ends. Previous month calendars were torn and numbers were carefully pasted on the cable end and on the fixing side. B After releasing all the cables, the old transformer was extracted and a new one was fixed. All the cables were re-fixed and the system was about to be charged. C Everybody was confident that no cable was wrongly connected. But the Consultant engineer had a doubt. So he first charged the converter for a few seconds, allowing the converter capacitor to be charged up to a voltage and then, switched-off the supply to the converter. Using the voltage available in the capacitor, the inverter was switched on. Immediately, with a Bang the fuses connecting the converter DC to inverter got blown-up. All the power cables were once again checked and above process was repeated. But the Bang and fuse blowing was also continuing. So, the consultant engineer himself checked all the cables throughout the night and found that one pair of very small signal cable, carrying the phase measurement to control card was connected wrongly. It was inadvertently missed while numbering, considering the very small size. After setting that right, the UPS started functioning normally. The above experience taught me a valuable lesson that 99% correct work was not sufficient for perfection.
Er. T. Samuel Sundarraj, M.E., Asst. Executive Engineer / Instn.I / TTPS <9443474079>
[ P-11 ]
A novel method, but NALLA method

Er. J.J.Kumar, B.E., M.I.E.
Asst. Executive Engineer / MPM-2/ TTPS < 9442355546>
During the year 1989, when I was working as an Assistant Engineer in LMHEP/KUTHIRAIKKALMEDU/BHAVANI, I had to maintain 80 Tonne Coles Crane. During that period a major fault occurred in one of the transformers in 400KV SS at Sriperumpudur. A crew from KK Medu was deputed to lift the core from the transformer using this crane. After 2 days, there was a wake-up call at night from CE/Transmission Chennai asking me to bring an 'O' ring for the crane since the crane `had developed a snag due to oil leak through an oil seal. I was assigned to take this spare and I boarded the next available train at Erode to Chennai. When I reached Sriperumpudur along with the service personnel of M/s. Coles Ltd., I was surprised to see that the crane was working smoothly and it had even lifted the core (about 12 Tones) out of the transformer. There was an all round appreciation from our higher officials to the crew about that achievement. After some time when I enquired about the problem and how they managed without the 'O' ring, they said, Sir, we adopted a novel method and solved the problem. We used just a rubber type material i.e. a contraceptive to plug the oil leak. It is not only a novel method, but NALLA method too.
2 TOP REASONS FOR 3 PIN TOP

Er. P. Sethuramalingam, B.E., Assistant Engineer / TS / TTPS < 9443858090 > Even though there is no current flow in normal operations; the earth pin of 3 pin top is designed sturdy & longer than other two pins. Why? It should be longer?: Whenever the 3 pin top is inserted to the supply point, the earth pin contacts (touches) earlier than other two pins. So, the safety of the equipment & operating personal is ensured. It should be sturdy?: To carry large flow of current during the short circuit & insulation failure in the connecting equipment Due to longer & sturdy design of earth pin, the contact area for fault current flow is high and so there will not be any physical damage during fault condition. Courtesy: Hindu Question Corner
[ P-12 ]
SUDDEN LOSS OF LOAD TRIP FOR COAL MILLS

During the year 2003, a new kind of protection was introduced for coal mills in units 4 & 5 by MRT-2 Engineers. Generally in industrial drives, protection against loss of load is not necessary except DC series motor. In Thermal Power Station process, coal mills and feeders are inter-linked. If any one mill gets decoupled and the feeder is R-S Flipflop Mill Motor current low ON DELAY running continuously, then it will create coal choking in the feeding pipes. To clear the 5 seconds S 1 choking, a minimum of one day shut down is 2 seconds 3 required. To avoid this we provided a new trip OFF DELAY Feeder Off ON DELAY logic as shown in the figure for all coal mills in R 5 seconds AND GATE 2 5 To Mill units 4 & 5 in FSSS System. As per this logic, Mill Motor current low Trip mill motor will trip immediately if the mill 4 Feeder Speed >50% decoupled from motor. This logic was derived with no extra cables, sensors, transmitters, switches and any other instruments. It was derived only with the available signal and our creative mind which accounted for a huge cost and time savings.
Er. J.Joseph Chella Durai, A.M.I.E, Asst. Executive Engineer / Instn.-II / TTPS < 9787714581>
TRANSFORMER STORAGE TIPS

Even if the transformer is not required for service for some months, it is desirable that it should be filled with oil as
soon as possible and certainly within 3 months of the original date of draining the oil in the factory. If it is being kept in storage for a period longer than 3 months at some location other than its final position, it should similarly be filled with oil. When oiled cellulose insulation is exposed to atmosphere, the rate of absorption of moisture depends on the relative humidity of the atmosphere, and a general objective of manufacturers of 400 kV transformers is that insulation should not be exposed for more than 24 hours at a humidity of 35 per cent or less. Pro rata this would be 12 hours at 70 per cent relative humidity. During this time the moisture would be absorbed by the outer surfaces of the insulation; increased exposure time causing gradual migration of the moisture into the inner layers. It is relatively easy, if a sufficiently high vacuum is applied, to remove moisture from the outer surfaces of the insulation, even if the outer surface content may be as high as 10 per cent.
Reference: The J&P Transformer Book Martin. J. Heathcote
[ P-13 ]
IMPROPER CONTACT MEANS NO CONTACT

The main auxiliary electrical motors for 210MW Turbo Generator are fed with supply from 6.6kV unit bus. Normally the electric supply to this unit bus is fed by 16MVA, 15.75kV unit auxiliary transformer (UAT). The bus system is made-up of cylindrical aluminium bar supported by insulators The 6.6kV unit bus system is arranged in 4 sections namely 4A, 4B, 5A and 5B in units 4 & 5. The main cylindrical bus is not a continuous one. It has a joint as shown in Fig. A, in each panel to facilitate easy replacement in case of any defect in a particular section of the bus. So, totally, there are three joints per panel (for three phases). The one end of take-off jumper to breaker inlet is connected at the same point where the main bus is joined BEFORE Copper jumper to Breaker (J). This joint is made with 'U' bolt & cylindrical support piece. Due to multiple joints, the tightness of 'U' bolt is not Insulation sleeve effective. Even though tightness was carried out for 27 N-m J with torque wrench spanner as recommended by the OEM, instances of over heating and smoke at joints were noticed when the unit was at full load due to U bolt crack, Main bus extension to improper contact area etc. In such case, the unit load had next breaker panel Main Bus to be reduced to 100MW (partial load) to isolate the faulty U bolt connection OD: 72 mm bus for rectifications like jumper replacement, re-tightness Thickness: 10 mm Fig. A etc. During annual overhaul, the contact resistance at some of the joints were measured as thousands of against the permissible limit of some tens of even though sufficient care was taken in matching and tightness. As the problem caused not only the generation loss but also a concern over the safety of operation / maintenance personnel besides the failure of electrical equipment, the OEM was addressed for technical suggestion to mitigate the problem. But there was no fruitful suggestion from them. Hence, a team of engineers & staff from HT / LT section of EM-III & Sub-division-1 of MRT-2, made an attempt to design & fabricate a suitable jointing piece with minimum modification with out affecting the existing system. The proposed modification in the joint was thoroughly analysed with MRT assistance. Finally, it was decided to modify the joint as shown below (Fig. B) in such a way to increase the contact surface area and there by reducing the contact resistance of joint.
[ P-14 ]
1) To increase the contact area: a) An aluminium spacer curved piece of size 145mm x 65 mm x 18 mm was provided which increased the contact surface of bus bar joint from 3900sq.mm to 9425sq.mm. b) The copper jumper for individual outlet was welded with copper piece of size 60mm x 60 mm x 10 mm there by the contact area was increased by 3500sq.mm 2) To strengthen the connection materials: Two numbers of 12mm cadmium coated hexagonal bolts with 2 Nos plain washer and one number spring washer each with hexagonal nuts were provided in place of 'U' bolts as shown in Fig.B. .
AFTER
60 mm 60 mm
Fig. B
After carrying out the modification during annual over haul period, the contact resistance of the bus bar joints were measured and found to be less than 80 . Moreover, there is no a single incident of over heating / smoke in 6.6kV Bus till date since 2005. Thus by, unit outage / fire accident due to original inferior design of the joint was mitigated. As the work was carried out under direct supervision of department staff with contract labour assistance, the expenditure per panel was just Rs. 4650/- and for 22 panels Rs.102300/-.which is very much economical comparing the Unit outage and safety issues. Tireless Searching for an alternative will always end-up with a good result
Er. P.Selvaraj. B.E.,M.I.E., Asst. Executive Engineer / EM-III / TTPS < 9486453784 >
[ P-15 ]
EFFECTIVE PRESERVATION OF STEAM TURBINE 210 MW Steam Turbine consists of three turbines, namely high pressure turbine (HPT), intermediate pressure turbine (IPT) & low pressure turbine (LPT). LMW sets have HPT-12 stages, IPT-11 stages, LPT 2*4 stages. Whereas, KWU sets have HPT-25 stages, IPT- 2*20 stages & LPT- 2*8 stages. Preservation TIPS: Description Preservative 1. Conduct pre-storing condition assessment Journal and Thrust disc TRB & Varnish 2. There shall not be any dents, cuts, scales, rust, cracks etc. Coupling Black enamel paint 3. Sand blast to remove scales, rust and surface contamination
4. Use Emery stone and metal brush till the surface becomes bright. Rotor surface and Aluminum paint blades 5. Degrease with cotton waste or brush, completely soaked in Radial and Thrust Oil resistant paint suitable degreasing agents. bearing 6. After degreasing, allow the surface to dry in air for about 30 min. Unmachined parts 7. Do not touch by hand the Surfaces prepared for preservation Radial and Thrust Mobilex Grease-2 8. Preservatives shall be applied in closed premises. bearing (or) IOC 9. Preservatives shall be applied not later than 3-5 hours after Machined parts multipurpose grease cleaning and degreasing. 10. Application shall be done at : Temperature - +15C to +50C Relative Humidity - 70% @ 25 C 11. For moderate climatic conditions two coats of preservative is enough, but for tropical climatic conditions the preservation should be done with varnish 4-6 coatings. 12. Anti-corrosive should be applied uniformly without gaps or overflow. 13. Quality of anti-corrosive layer may be checked by visual inspection and defects shall be rectified immediately. 14. Special attention shall be paid to those parts which will ultimately be placed in inaccessible positions. 15. Preservation is valid up to six months, beyond which it is necessary to inspect the preserved parts. 16. Carryout re-preservation if required in the coating damaged area. 17. Do not use Chlorinated agents such as Trichloroethylene & Carbon tetra chloride for Turbine rotor surfaces. 18. The parts conserved by grease should be additionally protected by two layers of paraffin paper. 19. After preservative coatings dry-up completely and then the journals of shafts and thrust discs of rotors are to be wrapped tightly with Aluminum foil (8-10 layers) and finally wrapping with flannel cloth. Er. V. Rajendran. B.E.,MBA., Asst. Executive Engineer / O&E-1 / TTPS <
9486920200 >
[ P-16 ]
SMARTNESS OF SMART GRID

Is electricity a commodity or a premium value-added service? The way this question is answered over the next decade will reshape, perhaps radically, the way electricity is produced, transported and used. That, in turn, will influence the way societies grow and the way people live their day-to-day lives. Recently, the concept known as the smart grid has been gaining momentum. Simply put, a smart grid is the integration of information and communications technology into electric transmission and distribution networks. The smart grid delivers electricity to consumers using two-way digital technology to enable the more efficient management of consumers end uses of electricity as well as the more efficient use of the grid to identify and correct supply demand-imbalances instantaneously and detect faults in a self-healing process that improves service quality, enhances reliability, and reduces costs. Thus, the smart grid concept is not confined to utilities only; it involves every stage of the electricity cycle, from the utility through electricity markets to customers applications. Key characteristics of the smart grid [a] Self-healing: The grid rapidly detects, analyzes, responds, and restores [b] Empowers and incorporates the consumer: Ability to incorporate consumer equipment and behaviour in grid design and operation [c] Tolerant of attack: The grid mitigates and is resilient to physical/cyber-attacks [d] Provides power quality needed by 21st-century users: The grid provides quality power consistent with consumer and industry needs Moreover, Smart grid accommodates a variety of resources, including demand response, combined heat and power, wind, photovoltaic, and end-use efficiency. Fully enables and is supported by competitive electricity markets.
Er.C. Balasubramanian., B.E., Assistant Engineer / CMP / TTPS < 9500555567 >
[ P-17 ]
ENERGY GENERATION FROM CONTROL CABLE

In TTPS, the Units IV & V are having 2 nos. Instrument Air Compressors (IAC) each to meet out the instrument air supply demand. In the past, all these 4 compressors were in continuous service for maintaining the Instrument air pressure. Each Compressor has a prime mover with 135 kW Induction motor. Optimum range of instrument air pressure for each unit was being maintained by loading and unloading operation of two numbers of respective unit IACs. Each unit had its own loading and unloading control circuit responsible for simultaneous loading and unloading of two instrument air compressors of respective units. In the year 2005, there was a suggestion that the demand of instrument air on optimum range for Unit IV & V can be met out from 3 nos. of Instrument Air compressors instead of 4 nos. With TTPSs better performance at heart and towards the move of reduction in auxiliary energy consumption, a team of MRT-2 division Engineers and staff members, who always depend on technical ethics, spirits and values, introduced an electrical circuit modification at the expense of merely 200 mtr. length of multi-core control cables. The modification scheme interconnected the loading / unloading control circuits of Unit IV &V. Modifications towards an Improvement: Normally, the loading/unloading circuit comprising of a set of pressure switches, an electromagnetic contactor and required number of solenoid valves as shown in the fig.A. The pressure switches mounted on Instrument air receiver tank acts in accordance to the loading / unloading pressure settings; thereby the electromagnetic contactor picks up / drops out and extends the electrical supply to the solenoid valves of the running compressors. This in turn will account for the compressors to perform their loading/unloading operations and to maintain the required range of air pressure. Such arrangement in Unit IV and V had been provided unit-wise, for simultaneous loading and unloading operation of compressors. With the application of the multi-core control cable interconnection, the electromagnetic contactors from each unit control circuit was linked together as shown in fig. B and have in tow with the pressure switches of any one of the unit to initiate the simultaneous action of both unit electromagnetic contactors. It ensures simultaneous loading and unloading of both the units running compressors and fulfills the demand of instrument air with optimum range of pressure.
[ P-18 ]
The requirement of continuous service compressors was reduced to three numbers instead of four numbers. Energy saving measurements were done using Power Quality Analyser and realized an annual saving of Rs.11.78 Lakhs worth energy. The cumulative energy savings as on date (20.06.2006 19.06.2010) has been estimated as 4 x 11.78 = 47.12 Lakhs rupees worth energy.
Fig.A
Fig.B
At present scenario of worldwide awareness on climate change for the betterment of mankind, avoiding one number continuous operation of 135 kW motor adds tiny contribution in reduction of green house gases generation which causes global warming. lelqVf<kiz<!l{jz!juk<Kl<!gbqX!kqiqg<gzil<
Er. R. Muthukrishnan. B.E., Asst. Executive Engineer / MRT-2 / TTPS
< 94488356868 >
[ P-19 ]
CONCRETE STEPS TO PRESERVE CONCRETE

Deterioration of Reinforced concrete structures in coastal environment is a challenging problem for a structural engineer. Added to this, the power plant engineer is faced with environmental pollution affecting these structures adversely. Sometimes they may require major repairs within 5 to10 years from the construction. One of the major problems encountered all over the world is corrosion Corrosion : The term corrosion is used to indicate the conversion of metals by natural agencies into various compounds. The term rusting is used to refer corrosion of ferrous metals. Concrete normally provides excellent corrosion protection to embedded reinforcement. The high alkalinity of concrete (pH > 12.5) results in the formation of a protective oxide film on steel bar. However, unless concrete is well compacted and dense, it is susceptible to carbonation and loses its capacity to protect reinforcement. In coastal areas, chlorides can penetrate to depths more than 50mm and reach the steel reinforcement if the concrete is not dense. From engineering stand point, two types of situations are necessary to be considered. The steel reinforcement, being well protected in the alkaline medium in concrete, would take a certain amount of chloride ion to be present so that corrosion can take place. On the other hand, if the passivity is destroyed because of one reason or the other and the pH of concrete is below a certain threshold value, all which is needed for corrosion to take place is oxygen and water, presence of chlorides is not necessary. Concrete construction, in order to be durable, has to ensure that the limiting amount of chloride ions is not exceeded in concrete and also the pH value of concrete is not lowered below the threshold value. Causes of Deterioration in concrete: Design and Construction defects. Poor quality of materials including steel Inadequate supervision Environment & Climatic conditions Inadequate understanding of material behaviour. Typical corrosive actions: Hydration products formed during setting of cement are unstable and susceptible to attack. The deterioration process may be either physical or chemical or combination of both. Some typical physical corrosive actions are due to mechanical wear and tear, action of wave, rain, frost, wind and sandstorm, etc. The external and internal chemical actions involve dissolution or loosening of the concrete in the structure, leading to leaching, due to physical action. It is obvious that in the process, the porous concrete is more prone to chemical corrosive attacks.
[ P-20 ]
Classification of corrosion : The corrosion in concrete may be classified as leaching, swelling and chemical reactions. a) Leaching corrosion: This involves dissolution and leaching of free Ca (OH)2 and is caused by the action of water of low hardness or carbonic acid contents (H2CO3), which is the aqueous solution of CO2 gas. Free carbonic acid transforms calcite (CaCO3) into soluble hydro carbonate which affects the bonding power and the aggregate structure becomes loose. Near the surface of the structure, this reaction may be initiated by the atmospheric CO2 gas. This reaction continues depending upon the availability of free CO2, and is generally perpetual with increased severity. b) Swelling corrosion: This form of corrosion is primarily caused by sulphate ions (SO3 or SO4 ) which may be present in the form of sulphuric acid or its salt such as CaSO4, NaSO4, and MgSO4. The surface of hydrated cement paste is unstable in a sulphate solution and is destroyed by volume increase. A reaction takes place between Ca(OH)2 and sulphate ion to produce gypsum (CaSO4). Its crystallization with two molecules of water is accompanied by swelling. This swelling is advantageous as well as disadvantageous. Initial swelling permits concrete pores to be sealed to increase its resistance to corrosion. However at a later stage increased forces of spalling cause cracking and resulting damage. c) Chemical reactions: In this type of corrosion, the chemical reaction produces salts (chlorides) which are readily soluble or it may produce other compounds, which may increase the solubility of insoluble concrete components, thus weakening the concrete resistance to chemical corrosion. Prevention of Corrosion : Corrosion of reinforcement can be prevented by 1. Keeping the structure clean, 2. Preventing the structure from absorbing moisture, 3. Painting the structure, 4. Protective coatings in the form of bituminous coatings, zinc coatings etc. 5. By providing encasement in the form of jacketing to the concrete structure. Durable Concrete: Durable concrete can be prepared using normal weight aggregates of low permeability, low water / cement ratio, proper reinforcement detailing, and adequate compaction of concrete and with enough curing. Some important aspects like provision of suitable cover, high degree of workmanship, avoiding aggregate with high salt content, water containing salt, avoiding congestion of reinforcement etc., can be seriously considered. Now a- days construction chemicals have arrived in the market to increase the durability, water proof, reduce water content, resist chemical attack etc., and they can be used at construction stage itself to increase the life span of the concrete. . Er. R.K.Chandrasekaran. B.E.(Hons.), Asst. Executive Engineer / CMD-I / TTPS < 9442271729 >
[ P-21 ]
TAKE CARE & SAVE CRORE

The generator rotor is subjected to centrifugal forces, electrical stresses and environment of cooling media. In my view, analysis of some problems faced on the generator rotor such as earth faults, leakage through current carrying bolts & slip rings and vibration have shown that majority of those could be avoided with proper handling and care of the rotor during storage and erection. Due to the special construction features of the rotor like provision of open ventilating canals in rotor slot, exposure of insulation provided in the slot and overhang portion and slip ring assembly to atmospheric condition, an improper storage may lead to deterioration of insulation resistance values of rotor winding, contamination of slip ring surface and ventilating canals due to dust deposit and even blockage of ventilating canals. Some of preservation cum maintenance norms are listed below. 1. Should be kept in the area free from any dripping water, dust and metallic chips. 2. Should always be stored on firm ground with proper supports. 3. Ventilating canals along the length of the rotor and retaining rings should be properly sealed with ready made rubber plugs, seals and adhesive tapes. Avoid using of loose cotton or banian wastes for sealing the canals to avoid any unwanted blockages. 4. Rotor should be covered with polythene sheets and sealed after keeping silicagel bags inside the cover. The silicagel bags should be replaced every fortnight. 5. Dont allow persons having metal things such as pins, nails and even coins near the rotor to avoid intrusion into open canals. Ensure that no tools are kept on the rotor particularly on the ventilating canals or retaining rings. 6. Keep 3 to 4 flood lights around the rotor to keep it in warm condition, to avoid condensation of moisture due to temperature fluctuations throughout the day. 7. Only dry instrument air should be used for rotor purge test and Nitrogen gas should be used for gas tightness test. 8. While lifting the rotor, it must be ensured that proper wooden packers are provided under sling so that sling does not come in direct contact with the rotor body. 9. Rotor must be lifted slowly keeping rotor axis in horizontal direction to avoid any tilting. 10. While lifting and moving the rotor, care must be taken to operate the EOT Er. M. Nagarajan. A.M.I.E, MBA, crane in smooth and micro movements to avoid any jerking on rotor. AEE / CMP / TTPS < 9443002505 >
[ P-22 ]
ENERGY NEWS AROUND US - IPR VIOLATIONS

Business Line, Friday, May 14, 2010 Energy Security Crisis Lack of Spares / Service vendor support for Chinese Power Equipment seen as a big concern Over 30,000 MW of new power capacity coming up using Chinese equipment Spares and service costs also exposed to higher uncertainty The failure to develop a local vendor base could lead to continued dependence on the Chinese for the entire life of the power station Govt.panel recommends order should be placed after factoring in full life-cycle costs The failure to develop a local vendor base could lead to continued dependence on the Chinese for the entire life of the power station Availability of manuals only in Chinese has also been cited as a major impediment. Due to the intellectual property rights violations by Chinese suppliers, support from technological leaders from Europe and the US for upcoming supercritical sets will not be available in case of any technical problem. Of the 49 orders for supercritical sets awarded in the country so far, over half (26) have been secured by Chinese vendors. "Pokhran-like situation" could arise if bilateral relations turned sour in the coming years Orders should be awarded after factoring in the life-cycle costs of Chinese equipment and not just upfront costs
[ P-23 ]
ENERGY NEWS AROUND US FORTHCOMING POWER PROJECTS FOR TNEB

Name Capacity Estimate cost Funding Agency Programme of commissioning
NCTPS-Stage-II Unit-1 NCTPS-Stage-II Unit-2 MTPS Stage-III Bhavani Kattlai Barrage-2 Bhavani Kattlai Barrage-3
1x600MW 1x600MW 1x600MW 2x15MW 2x15MW
Thermal Power Projects Financial tie up is made 2475 crores with REC by M/s. BHEL 2175 crores M/s.REC 3136.68crore M/s.PFC Hydro Power Projects 400.59crore M/s.PFC 396.59crore M/s.PFC Joint Venture Projects
17.05.2011 15.08.2011 25.06.2011 27.10.2010 27.10.2010 Oct.2010-unit-1, Mar.2011-unit-2, Sep.2012-unit-3 Mar 2012 Aug.2012 Mar 2013 Sep 2013
NTPC TNEB Energy Co. Ltd. (NTPC-TNEB joint venture) NLC Tamil Nadu Power Ltd (NLC- TNEB joint venture) Udangudi Power Corporation Limited ETPS Annex
3x500 MW
8000 crore
M/s.REC
2x500MW 2x800MW
4909 crore 9083 crore
M/s.REC Under finalization
Upcoming Projects 1X600 MW Environmental Clearance

Courtesy: www.tneb.in
[ P-24 ]
LET IT (LIGHT) BE LED

Incandescent lamps (light bulbs) create light by running current through a resistive filament, thereby heating the filament to a very high temperature so that it glows and produces visible light. They are highly inefficient, as approximately 98% of the energy input is emitted as heat. A 100 W light bulb produces about 1700 lumens, about 17 lumens/W. Incandescent lamps are relatively inexpensive to produce. The typical lifespan of an AC incandescent lamp is around 1,000 hours. The heat generated by the Incandescent lamps needs additional cooling arrangement in the Air-conditioned control room and the heat damages the lamp holder as well. Whereas, an Light Emitting Diode (LED) lamp gives an output of more than 60 lumens / W. Just recently in February 2010, M/s Cree Inc. demonstrated a white LED with an efficacy of 208 lumens / W. The life span is more than 50 times that of incandescent lamps. Keeping in view of the superiority of LED lamps, a mass of 91 nos. of 220V grade incandescent type indication lamps were studied for their power consumption, failure rate and illumination level. In parallel, relevant laboratory tests Parameter Incandescent LED were also carried-out for various kinds of LED lamps in Power 10.04 W 1.48 W MRT-2 Lab. The results are tabulated in the right side. Relative lux --9.5 times After ensuring the technical advantages of LED Visibility Fair Excellent lamps, as an improvement, failed Incandescent lamps Aesthetic look Fair Excellent were not replaced by incandescent lamps, instead they Watts for 59 nos. 592.36 W 87.32 W were replaced by LED type lamps in a phased manner 5189.073 Units 764.923 Units Energy / year for 59 nos. and the performance is found to be quite satisfactory till Energy @Rs.3 / Unit Rs. 15,567 Rs. 2,295 date. The pay back period is less than a year for the 59 Unit price of LED lamp : Rs.90, No. of LED lamps replaced : 91 nos. of continuously glowing services including fittings.
Pay back period = (91x90) x12 /(15567-2295) = 7.4 months
If we plan for a mass improvement, it will still get reduced. In place of 220V DC indication lamps, if 24 DC LED type lamps are used, energy can be saved 27 times that of incandescent lamps since 24V LED lamp has the power consumption of merely 0.36W. Er. N. Kingslin. D.E.E.E.,
JE / MRT-2 / TTPS < 9488108055 >
[ P-25 ]
FOREIGN MATERIAL EXCLUSION (FME) RULES FOR GENERATOR STATOR

Foreign Material Exclusion (FME), a term originated in the nuclear industry, is the set of procedures geared to minimize the possibility of intrusion into the machine of foreign material before, during, and after the inspection. In principle, the definition of foreign material is anything not normally present during the operation of the generator that may adversely affect its constituent components if left there. For instance, although ambient air is not necessarily considered a foreign material, the water content of the air is. Water definitely is an extraneous element that should be kept from condensing on the machines windings, retaining-rings, and other parts susceptible to mechanical failure from corrosion, or from electric breakdown of the insulation.
Keeping water from condensing onto the machines components can be readily
accomplished by containing both stator and rotor under protective covers (e.g.,tents). It is not uncommon to see a tent with damaged canvas or insufficient retention to the frame allowing rainwater onto the windings, causing unnecessary difficulties later trying to dry the windings to obtain satisfactory insulation (megger) readings.
It is important to perform any scheduled electric tests with dry windings. Otherwise, results obtained will not be
representative of the winding condition under normal operating conditions.

It is also important not to inadvertently contaminate the generator with corrosive liquids such as solvents, certain
oils, and so forth. Sometimes extraneous fluids can be introduced by walking over them and then walking into the machine. Paper, rubber, or cloth booties will go a long way in eliminating the introduction of small pebbles that may be stuck to the sole of the shoe. When pressure is applied to the end-winding by walking over it, a small pebble can puncture the insulation, thus creating a region of electric-field concentration. This is worth avoiding. It is good practice not to step on the bare coils. A cloth will suffice to protect the winding from the shoe. The worst enemies of the windings are any foreign metallic objects. They can become airborne due to the high speed of the cooling gas, and break the insulation when striking it. Courtesy: O&M of Large Turbo-Generators by GEOFF KLEMPNER & ISIDOR KERSZENBAUM
[ P-26 ]
BOILER PRESERVATION
Standby Boiler should be preserved either by Wet Preservation or by Dry preservation to prevent corrosion of Boiler Tubes. In our TTPS, we adopt Wet preservation. Corrosion is caused by simultaneous presence of water and Oxygen. To avoid such circumstances, DM water of pH 9.0 10.0 with Hydrazine (N2H4) is filled to the top of the Boiler and maintained at around 5kg/cm2. Hydrazine of > 50ppm is required for Boiler with more than 4 days of standby condition and >200ppm is required for more than 10 days standby conditions. Regular and continuous monitoring is required for the level of N2H4, copper and iron content in the prescribed Boiler. If there is any drop in the concentration of Hydrazine (Oxygen Scavenger) in the Boiler water, addition of Hydrazine is required. If decomposition of N2H4 is unusually high, cleaning of the Boiler internals should be considered to remove the corrosion deposits. If the Boiler has been under long time preservation using N2H4, care should be taken to drain the Boiler before returning to load, to prevent Ammonia getting into HP and LP heaters causing corrosion of Copper and Nickel tubes. There is always a chance that Oxygen intrusion will occur because of a slight partial vacuum in the Boiler leaking gaskets etc. The Boiler will have to be put under slight excess pressure in order to expel these last remaining traces of oxygen and to prevent intrusion of oxygen from atmosphere. By reducing Oxygen, the protective layer of magnetite in the boiler tubes preserved. Er. A. Saravanan, B.E., M.B.A, Asst. Executive Engineer / TS / TTPS < 9443827167 >
PLEASE DO NOT HESITATE TO PARTICIPATE IN THE TECHNICAL MEETINGS (TM) BEING ORGANISED AT MRT2 LAB & DO UPDATE / UPGRADE YOUR TECHNICAL KNOW-HOW
TM Updates: 113 meetings, 3196 participants Ongoing: Main Tens of Maintenance (MTM) Forthcoming: Technology Alias Technique (TAT)
[ P-27 ]
LATEST ENERGY NEWS AT TTPS

Unit-4 16.01.2010
Er. B. Murugan. B.E.,

AEE / O&E-1 / TTPS < 9442051560 >
Unit-2

09.05.2010 : : : : : : Unit-2, 122 days Unit-5, 159.50 MU, Mar2010 Unit-5, 5.23 MU, 14.04.2010 83.9% (TNERC Norms: 80%) 7.98% (TNERC Norms: 8.5%) 1070 MW, 19.04.2010
Maximum continuous service Maximum Generation in a month Maximum Generation in a day Overall PLF (Jan May2010) Station APC (Jan May2010) Station Maximum MW reached
UNIT 3
Next issue
Special
It would be great if your article contains Strong Technology-base Innovative economical concept Reasonable payback Reliable engineering (design) etc. etc.
(in A4 format)
Please send your articles & feed back to Er. A. Krishnavel, aee1_mrt2_ttps LAN : mrt2lab@ttps.net e-mail: krishna_vel@hotmail.com Cell: 9443657223
Note: The soft copy of this magazine (e-ENERGY) has been published in TTPSs INTRANET (LAN)
[ P-28 ]
Robert
TUTICORIN 9994422806

Energy 01 TTPS

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ENriched EngineeRing Grub for You

Energy : 01 Power : 01 July 2010

Storage / Preservation Special

ENriched EngineeRing Grub for You

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Energy : 01 Power : 01 July 2010

An in-house technical magazine of TTPS

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One more Excellency!!!

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With best wishes

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Er. R. Kamaraj, B.E.(Hons.), M.E., Executive Engineer, Instrumentation I / TTPS

Er. S. Kaja Mohaideen, B.E., Executive Engineer, Technical Services / TTPS.

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< July 2010 > < Energy:01, Power: 01 >

STORE NICELY & SAVE WISELY OIP BUSHINGS

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99% is NEVER EQUAL to 100%

A novel method, but NALLA method

2 TOP REASONS FOR 3 PIN TOP

SUDDEN LOSS OF LOAD TRIP FOR COAL MILLS

TRANSFORMER STORAGE TIPS

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IMPROPER CONTACT MEANS NO CONTACT

SMARTNESS OF SMART GRID

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ENERGY GENERATION FROM CONTROL CABLE

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