COMMISSIONING EXPERIENCE AND LEARNING

NTPC VINDHYACHAL STG-III (2X500MW)

PAPER PREPARED BY
S.S SEN DGM (COMMSG) S.K ROY SR SUPDT. (COMMSG) SATYA NARAYAN ENGR. MD. AKHTAR ENGR.

INFERIOR QUALITY OF TEMPORARY PIPING BEING USED DURING CHEMICAL CLEANING/STEAM

BLOWING ACTIVITIES.

All temporary piping should be identified with tag nos, similar to other pr. parts with separate PGMA, DU etc. Proper drawing with quality plan support details drains vents and location of isolating valve should be clearly mentioned. Temporary piping drawings should be duly approved by corporate engg. And CQA. The hydro test/NDT requirements should be clearly mentioned in the drawings. The first isolating valve must be located nearest to the junction with permanent system.

INADEQUATE CAPACITY OF SUCTION LINES OF ACID INJECTION PUMPS USED DURING CHEMICAL
CLEANING PROCESS.

As per scheme three acid injection pumps (3X50%) were designed to take suction from a common header having 80 Nb dia. and discharging into a common header having the the same dia. During mock trial it was observed that while running two pumps at a time one pump was getting starved, Consequently pump was getting hot and its gland was getting damaged with in few minutes. One additional suction line was drawn directly from mixing tank and acid storage tanks and thus problem of pump starvation was solved.

Insufficient gap between RH coil bottom and rear arch tube in unit #9

As per drawing clearance between RH coils bottom and rear arch is 350mm.But on measurement the value of clearance in some of the coils was in the range of 250mm approximately. Later BHEL revised the minimum clearance as 285mm.Revision was accepted by the site and modification was carried out. To obtain minimum 285mm clearance gap between the tubes of coil at the bottom was reduced to 15mm, Which is as per drawing. In this exercise 2 to 7 loops of different panels were shortened and available clearance between the tubes is shifted to clearance between coil bottom and arch. Out of 74 ,51 coils were modified and 186 circuit loops shortened involving 372 butt joints.

LTSH UPPER BANK COIL-MISALIGNMENT IN

ALMOST ALL THE COILS IN FRONT SIDE IN UNIT#10

Uneven gap between the coils in front side ,the problem has been referred to BHEL trichy response awaited.

PROBLEM OF OFFSET AND ORIENTATION IN NMEJ OF UNIT#9

It was observed that offset of NMEJ was in reverse direction at
around 6 no. of locations e. g wind box (L&R), ECO outlet (L&R), hot SA duct (L&R). Later on all the above NMEJ were attended in situ.

PROBLEM OF PA FAN BLADE PITCH GETTING FULLY CLOSED IF FEEDBACK BECOMES BAD

As per logic implemented PA fan blade pitch gets fully closed if feedback gets disturbed due to any reason. It has been decided to modify this logic and the blade pitch in this situation will remain stay put.

COAL MILL FINENESS POOR IN (+50)

It was observed that coal mill fineness was poor in chemical analysis. later on spring compression was set at 10.5 tonnes against 8.5 tonnes and classifier setting was changed from 4 to 6 on its scale.

PROBLEM OF VALVES PASSING LIKE CBD,EBD,IBD, SH &RH SPRAY

It was observed that these valves are passing heavily after few months of operation, on inspection it was found that their seats were in badly damaged condition. Later on these valves were attended for passing by lapping.

HIGH VIBRATION (AXIAL &RADIAL) IN PA FAN-9A

PA Fan-9A fan DE brg. was having high axial and radial vibration of the order of 8-9 mm/sec. During recent overhaul its rotor assembly was dismantled and it was observed that there was loose rust (around 500 grams) inside the rotor assembly. After removal of loose rust the fan brg. vibration came down to normal level (2-3 mm/sec). It is suspected that due to improper storage of the fan rotor during erection stage, there was ingress of moisture inside the rotor causing formation of rust. These loose rust particles were creating unbalance during frequency change.

PROBLEM OF HIGH METAL TEMP OF RH OUTLET COILS

It has been observed that few no of RH outlet coils e. g coil no 66&70. are maintaining high metal temp of the order of 580-590 deg C. Total 71 nos. of TCs are provided.55 nos. outside the gas path, 06 nos. at the outlet front header,06 nos. at the outlet rear header Assembly no. 18,38 and 58 have 11TCs full depth measurement. As per experience of unit no.-9,.Assembly no. 66&70 are experiencing higher metal temp. than assembly no. 38 and 58.in which full depth TCs are installed. Hence thermocouples from assembly no. 58 be shifted to assembly no. 56 and thermocouples from assembly no.-38 be shifted to assembly no. Also additional thermocouples should be installed.

EXPERIENCES AND FEEDBACKS

No provision of approach/platform for valves/dampers of air and FG circuits of APHs. ( especially FD and DDs of APH).

No clearance of boiler pressure parts insulation before completion of fin welding.

HFO/LDO lines to be air and steam charged before oil charging & hot tightening of all flanged section bolts. Location of boiler side cable trays beneath the HFO/LDO station. The boiler area main cable route to be shifted in LHS of boiler to avoid fire hazard due to HFO/LDO lkg.

Proper checking of blade pitch mechanism locking during commissioning stage itself.

Provision of SS lines in mill lub oil return in place of MS linelub oil supply lines for upper and lower radial bearing are of SS make but the return line and excess discharge line are of MS make lub oil picks up mechanical impurities during the return cycle and welding& fit up, acid pickling , and lub oil flushing of these lines takes lot of time. the cycle time of the above activities can be reduced by using the SS lines.
Acoustic steam leak detector to be installed in boiler for quick identification of BTL. Flame monitoring camera yet not cleared from corporate engg. Provision of ladders inside the wind box for checking of SADs.

The very first requirement of commissioning e. g platform proper approach, boiler lift and area lighting gets satisfied at the tag end of commissioning.

NEED TO REVIEW TWO STAGE HYDRO TEST (DRAINABLE/ NON DRAINABLE) OF BOILER. After completion of stage-I hydro test of boiler a lot of cutting & welding is done for completion of balance work on pressure parts.