BHEL

46
BHARAT HEAVY ELECTRICALS LIMITED N.K. BANSAL, AGM (T)

Transcript of BHEL

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

AN

OVERVIEW

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

SOME FACTSTOTAL INSTALLED CAPACITY OF INDIA IS 106254.22 MW

71 % OF THE TOTAL ELECTRIC ENERGY GENERATED BY COAL SETS IN THE COUNTRY WAS CONTRIBUTED BY 210 / 250 / 500 MW RATING BHEL SETS THOUGH THEY FORM 63 % OF TOTAL GENERATING CAPACITY OF THE COUNTRY

MORE THAN 60 % OF THE THERMAL MACHINES OPERATING IN INDIA ARE OF KWU DESIGN.

HIGH RELIABILITY,AVAILABILITY,BETTER HEAT RATE, FASTER START UP AND SHUT DOWN,MAINTENANCE FRIENDLY ENABLES HIGHER ACCEPTABILITY AMONGST MOST CUSTOMERS IN INDIA.

KWU TECHNOLOGY HAS WEATHERED IN INDIAN CONDITIONS AND CUSTOMER HAS SHOWN CONFIDENCE BY PLACING REPEAT ORDERS

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

PLANT LOAD FACTOR

AND

OPERATIONAL AVAILABILITY

OF SOME NTPC MACHINES

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

87.1

87.4

89.0

92.9

94.0

94.1

95.9

84.9

89.2

96.0

93.5

96.9

95.3

PLF

2002-2003

92.7

92.0

93.3

93.8

93.9

94.2

97.8

90.0

91.3

97.3

95.0

98.2

95.6

OA

82.7

89.1

89.1

89.0

94.7

94.2

76.7

82.6

98.2

98.1

97.1

99.3

100.1

PLF

2003-2004

89.8

87.5

91.2

93.5

90.4

93.2

89.5

92.6

91.2

68.4

78.2

93.0

97.3

PLF

2001-2002

86.6

89.6

79.0

95.6

97.5

96.6

91.0

91.9

97.6

87.8

98.7

98.6

96.6

PLFOA

2000-20011999-2000

85.6

83.7

82.4

91.4

93.5

84.4

95.6

92.7

96.5

93.8

83.7

93.1

98.9

86.792.890.288.8UNIT-6

94.289.393.387.1UNIT-5

93.993.784.586.7UNIT-4

89.694.695.993.5UNIT-3

94.291.497.894.0UNIT-2

93.794.197.185.3UNIT-1KORBA

78.890.692.895.8UNIT-7

87.295.792.192.7UNIT-6

SINGRAULI

PLANT/YEAR

98.192.996.797.8UNIT-5

97.468.588.493.4UNIT-4

97.378.298.183.7UNIT-3

98.793.997.793.0UNIT-2

98.297.094.496.5UNIT-1

OAOAOAPLF

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

87.4

85.8

92.3

93.2

88.5

78.4

82.6

80.8

86.6

92.4

85.3

87.4

88.8

PLF

2002-2003

92.8

92.4

93.4

94.3

89.8

87.7

93.6

90.0

95.1

96.5

88.3

90.3

92.0

OA

96.4

99.4

92.7

85.6

91.8

90.1

93.1

95.4

94.4

94.7

87.1

77.7

93.5

OA

99.2

86.6

84.9

89.2

90.8

94.8

95.6

98.4

92.1

-

-

82.3

68.0

OA

69.1

91.5

89.9

91.5

84.6

91.2

90.2

95.7

97.2

-

-

80.8

75.8

PLF

82.5

71.7

90.2

91.4

87.1

94.3

96.7

97.0

96.6

-

-

-

-

PLF

2003-20042001-20022000-20011999-2000

92.881.695.782.3UNIT-4BADARPUR

90.389.376.092.8UNIT-5

91.583.090.489.3UNIT-6

83.786.892.292.2UNIT-5

88.687.985.790.3UNIT-4RAMAGUNDAM

81.389.591.894.6UNIT-4

84.290.791.997.2UNIT-3

86.194.297.196.6UNIT-2

84.388.497.196.3UNIT-1DADRI

91.6---UNIT-2

84.2---UNIT-1SIMHADRI

88.160.084.5-UNIT-7VINDHYACHAL

74.279.088.4-UNIT-8

PLANT/YEAR

PLFPLFOAOA

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

AGE WISE ANALYSIS OF KWU DESIGN TURBINES SUPPLIED BY BHEL

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

AGE-WISE ANALYSIS

0

21 (2 + 2 + 12 + 5)

29 (6 + 3 + 16 + 4)

31 (11 + 5 + 5 + 10)

21 (3 + 8 + 2+ 8)

15 (4 + 3 + 5 + 3)

210 MW(NR + ER + WR + SR)

00> 25 YRS

0020 – 25 YRS

05 (2 + 0 + 3 + 0)

15 – 20 YRS

08 (0 + 1 + 4 + 3)

10 – 15 YRS

4 (0 + 0 + 2 + 2)

2 (0 + 1 + 1 + 0)

5 – 10 YRS

4 (4 + 0 + 0 + 0)

5 (0 + 1+ 2 + 2)

< 5 YRS

250 MW(NR + ER + WR + SR)

500 MW(NR + ER + WR + SR)

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

OPERATIONAL PROBLEMS IN KWU TURBINES

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

A. LP BLADE FAILURE

B. BARRING GEAR STOPPAGE

C. HIGH HP FRONT SHAFT VIBRATION

D. LOW VACUUM DUE TO HIGH AIR INGRESS

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

LP BLADE FAILURE

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

LP BLADE FAILURE :- PROBABLE REASONS

POOR WATER CHEMISTRY

OVERLOADING OF TURBINE

OFF FREQUENCY OPERATION

ALTERATION OF NATURAL FREQUENCY DUE TO EROSION

OF BLADE (OPERATION WITH LOW STEAM PARAMETER &

VWO OPERATION)

LOW VACUUM / HIGH EXHAUST HOOD TEMPERATURE

MECHANICAL RUBBING DUE TO BAD CENTERING

STAGNATION OF WATER IN LP EXTRACTION –1

POOR MACHINING OF BLADE ROOTS / GROOVES

LP WATER INJECTION SYSTEM

POOR MATERIAL OF BLADES

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

LP BLADE FAILURE :- RECOMMENDATIONS / ACTION TAKEN

CONDUCTANCE OF MPI / NFT FOR HEALTHINESS OF LP FREE STANDING BLADES OF 500 / 250 / 210 MW AFTER FIRST 50,000 OPERATING HOURS TO BE CONTINUEDCARE TO BE TAKEN DURING O&M OF THE PLANTAvoid following operation

Off – Frequency operationFull load operation with low vacuumProlonged no load operation Overloading Continuous Valve Wide Open operation

Ensure the proper functioning of following systemsTurbine Drainage SystemLP heaters Drip Cascading auto controls and LP heaters level alarm systemLP exhaust hood spray systemProtection System to avoid incidence of overspeeding, motoring etc.Water chemistry regime

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

ADDITIONAL CHECKS TO BE CARRIED DURING OVERHAULING OF LP MODULE

Centering Check (Record for any rubbing / touching marks at LP casing and LP blade tips)

Replacement of badly eroded LP blades.

Chemical Analysis of salt deposits on LP blades, if any, by customer.

Servicing / inspection of LP exhaust hood spray nozzle to be included in LP module overhaul.

LP BLADE FAILURE :- RECOMMENDATIONS / ACTION TAKEN

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

BARRING GEAR STOPPAGE

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

BARRING GEAR STOPPAGE : PROBABLE REASONS

FAILURE OF LUBRITE PACKERS / KEYS

MAL OPERATION OF GLAND STEAM SYSTEM

CHANGE IN CENTERING OF LP GLAND BOXES

DAMAGE TO HP / IP CASING INSULATION

IMPROPER ROLL CHECK OF HP/IP AND LP CASINGS

POOR BUMP CHECK

POOR LIFT OF JOURNAL IN BEARINGS

HIGH DIFFERENTIAL TEMP. OF TURBINE CASING

POOR SETTING OF OIL CATCHERS/SEALS

FOREIGN MATTER IN STEAM FLOW PATH

INADEQUATE MOTIVE POWER

EXCESSIVE PIPE PULLS

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

BARRING GEAR STOPPAGE : RECOMMENDATIONS / ACTION TAKEN

REFER TROUBLE SHOOTING CHART

INTRODUCTION OF MODIFIED GLAND STEAM SYSTEM

FOR CENTERING & ROLL CHECK OF HP & IP TURBINE WITH TIP TO

TIP GLAND SEALS REF. TECH. CIRCULAR X-74 DATED 6TH NOV’2002

ADJUST POOR BUMP CHECK OR CONSULT BHEL

CHECK ROTOR SYSTEM CAN BE ROTATED EASILY BY HAND

CHECK MACHINE COMES TO AUTO BARRING

CHECK SPEED AT FULL BARRING AND COMPARE WITH PROTOCOLS

ENSURE PROPER INSULATION OF HP & IP CASING

REPLACEMENT OF LUBRITE PACKER WITH HIGH TEMPERATURE

MODIFIED PACKERS

BELLOWS BEING INTRODUCED IN LP FRONT AND REAR GLAND STEAM

SUPPLY AND LEAK OFF LINE

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

HIGH HP FRONT SHAFT VIBRATION

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

HIGH HPF SHAFT VIBRATIONS : PROBABLE REASONS

HIGH COUPLING RUNOUT / SWING CHECK

HIGH SLOW ROLL CHECK VALUE

UNEQUAL / DISTORTED RADIAL CLEARANCE

BAD CENTERING / ROLL CHECK

JAMMED SEAL SEGMENTS

ROTOR UNBALANCE

ANY MAJOR WORK DONE ON LP / GEN ROTORS, WHICH MAY HAVE

CAUSED ROTOR SYSTEM UNBALANCE

BAD BEARINGS

HIGH ROTOR RUN OUT AT JOURNAL / GLANDS

HIGH RUN-OUT / DENT MARKS AT THE LOCATION OF SHAFT

VIBRATION PICK-UP

POOR ALIGNMENT / POOR LOADING OF BEARINGS

OIL WHIRL CONDITIONS

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

ANALYSE THE VIBRATION AND OPERATIONAL DATA

CHECK BEARING ASSEMBLY, ALIGNMENT, COUPLED RUN OUT,

ADJUSTMENT OF STEAM PATH

CROSS MATCHING OF HP / IP / LP ROTOR COUPLING FACES AT BHEL

WORKS

CHANGE IN THE AXIAL POSITION OF SHAFT VIBRATION PICK-UP DUE

TO HIGH SPOTS IN PRESENT LOCATIONS OF PICK UP

SLOW / RATED SPEED BALANCING

ENSURE PROPER FUNCTIONING OF SEAL SEGMENTS

PERIODIC SETTING OF SPRING LOADED TG DECK

INCREASE IN BEARING HEIGHTS, IF OIL WHIRL PRESENT AND

BEARING TEMPERATURE DISTRIBUTIONS NOT OK

HIGH HPF SHAFT VIBRATIONS : RECOMMENDATIONS / ACTION TAKEN

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

LOW VACUUM DUE TO HIGH AIR INGRESS

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

OFF LINE METHOD•Water fill test or vacuum tightness test•Steam pressurization test.

ON LINE METHOD• With the help of Helium Leak Detection Instrument

VARIOUS METHOD OF DETECTING AIR INGRESS

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

WATER FILL TEST : NEW INITIATIVES / GUIDELINES

RECENTLY, BHEL – HARIDWAR HAS ISSUED GUIDELINES MENTIONING

THAT FROM SIMHADRI ONWARDS, ALL CONDENSERS OF 210 / 250 / 500

MW ARE DESIGNED TO WITHSTAND WATER FILL TEST UPTO LP BLADE

TIP. THIS WILL HELP IN DETECTING ALL MOST ALL AIR INGRESS POINT

NO FALL IN WATER LEVEL IN 24 HOURS SHALL INDICATE

SUCCESSFUL COMPLETION OF WATER FILL TEST

IN CASE OF FALL IN LEVEL, HIDDEN AIR INGRESS POINTS NEEDS TO

BE TRACED BY ELIMINATION PROCESS.

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

STEAM PRESSURISATION TEST IS CONDUCTED TO FIND OUT

LEAKAGES IN THOSE AREAS WHICH WILL REMAIN UNDER VACUUM

AND NOT COVERED IN WATER FILL TEST / VACUUM TIGHTNESS TEST.

STEAM PRESSURISATION OF VACUUM SYSTEM IS DONE IN AN

ABSOLUTELY COLD MACHINE AND PIPING SYSTEM.

STEAM PRESSURIZATION TEST INVOLVES FOLLOWING 3 STEPS:

STEP 1 : - CONDUCT WATER FILL TEST AND ENSURE THERE IS NO

FALL IN WATER LEVEL FOR 24 HOURS.

STEP 2 :- PREPARATION OF THERMAL SCHEME OF TURBINE FOR

STEAM PRESSURISATION.

STEP 3 :- CONDUCT STEAM PRESSURISATION OF VACUUM SYSTEM.

STEAM PRESSURIZATION TEST

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

CONDENSER

HELI LEAK DETECTOR

VACUUM PUMP

AIR EXHAUST

STEAM + AIR

SAMPLE LINE

HELIUM LEAK DETECTION TEST : SCHEME FOR DETECTING AIR INGRESS

HELIUM GAS SPRAY ON SUSPECTED AIR INGRESS POINTS

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

COMPARISON OF STEAM PRESSURISATION TEST AND HELIUM LEAK DETECTION TEST

TEDIOUS EXERCISESIMPLE PROCEDURE5.

BULKY AND DELICATE INSTRUMENT

REQUIRE SYSTEM PREPAREDNESS PRIOR TO CONDUCT THE TEST

4.

CAN BE DONE AT LOADCAN BE DONE ONLY WHEN MACHINE IS COLD

2.

CAN DETECT BROAD AIR INGRESS AREA

CAN PINPOINT THE SOURCE OF AIR INGRESS

1.

REQUIRES HELIUM GAS WHICH IS NOT READILY AVAILABLE AT MANY POWER STATIONS

REQUIRE STEAM AND WATER 3.

HELIUM LEAK DETECTION TESTSTEAM PRESSURISATION TESTS.N

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

HIGH AXIAL SHIFT / DIFFERENTIAL EXPANSION

MS / HRH STRAINER CHOKING

OIL STARVATION

OVERSPEEDING OF TURBINE

OTHER PROBLEMS FACED IN KWU MACHINES

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

BHEL’S VIEW ON SPRING LOADED FOUNDATION

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

SPRING LOADED TG DECK : ADVANTAGES

MAJOR CORRECTION IN CATENARY OF MACHINE BY ADJUSTMENT

OF SHIM PROVIDED IN SPRING ASSEMBLY

REDUCTION IN COST OF CIVIL STRUCTURE

BETTER LAYOUT

ISOLATION OF TG DECK AND COLUMN WHICH WILL AVOID

VIBRATION PROBLEM IN TG COLUMN AT ANY TIME

EFFECT OF SETTLEMENT OF FOUNDATION COLUMN CAN BE

MINIMIZED FOR CATENARY DISTURBANCE

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

INCREASE IN ERECTION CYCLE TIME

INCREASE IN OVERHAULING PERIOD

COST OF SPRING ELEMENTS AND ITS INSTALLATION COST

SPRING LOADED TG DECK : DISADVANTAGES

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

USE OF CONVENTIONAL FOUNDATION AS STANDARD PACKAGE

FOR NON-EARTH QUAKE PRONE ZONE.

CUSTOMER WHO OPTS FOR SPRING LOADED TG FOUNDATION

SHOULD BE INFORMED OF INCREASE IN CYCLE TIME FOR

ERECTION AS WELL AS OVERHAULING.

SPRING LOADED TG DECK : BHEL’S RECOMMENDATIONS

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

PRE-OUTAGE SURVEY

FOR

PREDICTIVE MAINTENANCE

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

TO DETERMINE LEVEL OF DEGRADATION IN THE UNIT

TO IDENTIFY AREAS OF DEFICIENCY

TO PLAN THE SCOPE OF WORK FOR NEXT OVERHAUL

TO PLAN THE SPARES REQUIRED IN THE NEXT O/H

TO PLAN THE MOBILISATION OF MAN, MACHINE, TOOLS AND TACKLES

TO PLAN FOR SPECIAL STUDIES TO BE CARRIED OUT IN THE NEXT

SHUTDOWN

AIM OF PRE – OUTAGE SURVEY

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

(A) Engineer from Turbine / Generator Group of PSTS (HQ) {LEADER}

(B) Field Engineering Service Engineer from Steam Turbine /

Turbogenerator Department from BHEL – Haridwar / Hyderabad /

Bhopal

(C) Service Engineer from Regional Service Centre

(D) Engineer from Regional Spare Business Group

(E) Vibration Engineer in case, the machine has some history of

vibration problem

Note:- After the survey, the team may recommend the visit of additional

experts to the site depending upon the problem / investigation

needed by the machine on case to case basis.

TEAM MEMBERS OF PRE – OUTAGE SURVEY

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

CHECKS TO BE CONDUCTED DURING PRE-OUTAGE SURVEY

CHECKS DURING THE RUNNING OF POWER STATION

CHECKS DURING THE SHUTTING DOWN OF THE MACHINE

STUDY OF PAST HISTORY OF THE PLANT

PRESENT AVAILABILITY OF SPARES WITH CUSTOMER

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

OPTIMAL APPROACH

SHORTER MAINTENANCE PERIOD BY ADVANCE PLANNING FOR

SPARE CONSUMPTION

PROVIDES LEAN TIME TO CUSTOMER FOR PROPOSAL

MOVEMENT / SANTIONING OF FUNDS

EDUCATION TO CUSTOMER WRT NEW PRODUCT , NEW

PHILOSOPHY, NEW FAILURES ETC.

PROVIDES FLEXIBILITY TO POST PONE THE SHUTDOWN

DEPENDING UPON CONDITION OF MACHINE

BENEFITS OF PRE – OUTAGE SURVEY FOR CUSTOMER

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

RUN THE COMPONENT.

o FOR HOW LONG ?

o WITH WHAT PRECAUTION ?

REPAIR OF THE COMPONENT

o HELP IN FINALISING SCOPE OF WORK DURING O/H

REPLACEMENT OF THE COMPONENT

o ORDER FOR SPARES WITH OEM TO AVOID DELAYS

DECISIONS OF PRE – OUTAGE SURVEY

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

UPGRADATIONS FOR NEWER GENERATION

OF MACHINES

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

ADVANCED CLASS STEAM TURBINE BLADES FOR IMPROVED EFFICIENCY

TODAY DESIGNER HAS ACCESS TO CALCULATION METHODS, WHICH VERY REALISTICALLY REPRESENT THE FLOW IN A TURBINE. THESE FLOW CALCULATION METHODS ARE USED TO OPTIMISE BLADE DESIGN FROM HP TURBINE THROUGH TO THE LP TURBINE. MOST OPTIMUM TX PROFILE BLADES GIVE HIGHER EFFICIENCY IN TODAY’S STEAM TURBINES. THREE DIMESIONAL BLADES (3DS BLADES) ARE IMPLEMENTED IN HP AND IP TURBINES TO REDUCE SECONDARY FLOW. TWISTED BLADES WITH INTEGRAL SHROUD ARE USED TO REDUCE THE INCIDENCE FLOW LOSSES AND FURTHER INCREASE EFFICIENCY.

IN LP TURBINE FINAL STAGES, CURVED STATIONARY BLADES (BANANA BLADES) ARE IMPLEMENTED TO POSITIVELY INFLUENCE THE DEGREE OF REACTION AND TO PREVENT FLOW SEPARATION AT THE HUB. THE OUTER PORTIONS OF THE FINAL STAGE MOVING BLADES HAVE BACKWARD LEANING PROFILES TO ACHIEVE HIGH PROFILE EFFICIENCIES. THE SIMULATION OF UNSTEADY FLOW IN THE TURBO-MACHINERY IS A CHALLENGING TASK AND CURRENT RESEARCHES ARE DIRECTED AT CFD MODELING TO SIGNIFICANGLY IMPROVE AERODYNAMIC PERFORMANCE OF THE BLADING.

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

HIGH PRESSURE ELECTRO-HYDRAULIC GOVERNING SYSTEM FOR STEAM TURBINES

HIGH PRESSURE ELCTRO HYDAULIC ACTUATION (EHA) SYSTEM COUPLED WITH DIGITAL CONTROL SYSTEM PRESENTS SIGNIFICANT ADVANTAGES OVER THE CONVENTIONAL LOW PRESSURE SYSTEM. IT IS COMPACT IN SIZE, PTOVIDES QUICKER RESPONSE, BETTER SUPERVISION, AND HIGHER LEVEL OF REDUNDANCY AND IS EASIER TO MAINTAIN. HIGH PRESSURE ACTUATION SYSTEM CAN BE APPLIED FOR MAIN, REHEAT AND BYPASS VALVES FOR STEAM TURBINES OF VARIOUS RATINGS. HYDRAULIC ACTUATORS, POWER SUPPLY UNIT, THE ELECTRICAL CONTROLLER AND THE PROTECTION SYSTEM ARE BRIEFLY DESCRIBED IN THIS PAPER.

BHEL HAD ALREADY INTRODUCED HIGH PRESSURE EHA SYSTEM IN HP & LP BYPASS SYSTEM FOR FARIDABAD (NTPC) & DVB COMBINED CYCLE POWER PROJECTS. THIS SYSTEM IS WORKING SATISFACTORILY AT THESE POWER STATIONS. PRESENTLY, BHEL IS IN POSITION TO OFFER HIGH PRESSURE EHA SYSTEM FOR TURBINE BYPASS OPERATION FOR CONVENTIONAL & CCP TURBINES OF ANY RATING. BHEL IS ALSO GEARING ITSELF FOR OFFERING EHA BASED SYSTEM FOR MAIN STEAM TURBINE VALVES.

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

HIGH PRESSURE ELECTRO-HYDRAULIC GOVERNING SYSTEM FOE STEAM TURBINES

THE HIGH-PRESSURE ELECTO-HYDRAULIC GOVERNING SYSTEM ALONGWITH THE DIGITAL CONTROLS OFFER THE FOLLOWING ADVANTAGES:

QUICKER RESPONSE

PRECISE CONTROLAND EASE OF ADJUSTMENT

BETTER SUPERVISION AND HIGHER REDUNDANCY

SIMPLIFIED PLANT LAYOUT DUE TO OVERALL CONPACT SIZE

EASE OF CHANGING CONTROL VALVE SEQUENCE

BETTER INTERCONNECTION WITH OTHER SYSTEMS

CONTROL OIL PIPING REDUCED TO LARGE EXTENT

GOVERNING AND BYPASS RACKS NOT REQUIRED

OPERATION AND MAINTENANCE ARE RELATIVELY EASY

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

STEAM TURBINES WITH SUPER CRITICAL PARAMETERS

MODERN SOCIETY’S CONCERN FOR POLLUTANT EMISSIONS FROM THERMAL POWER PLANT AND EVER INCREASING FUEL COSTS ARE TWO DRIVING FORCES FOR DEVELOPMENT OF MORE EFFICIENT POWER PLANTS. EVERY PERENTAGE POINT INCREASE IN THERMAL EFFICIENCY REDUCES POLLUTANT EMISSIONS BY 2.5% AND ALSO SAVES 2.5% ON FUEL COSTS. POWER GENERATION IN INDIA IS DOMINATED BY SUB-CRITICAL 500MW SETS OPERATING AT 170 ATA / 537 0C / 537 0C AND 210 MW SETS OPERATING AT 150 ATA / 537 0C / 537 0C.

EVERY 50 ATA INCREASE IN MAIN STEAM PRESSURE OR EVERY 22 0C INCREASE IN MAIN AND REHEAT STEAM TEMPERATURE IMPROVES CYCLE EFFICIENCY BY 1%.

Super-critical parameters221.2 BAR (225.6 ATA) PRESSURE AND 374.15 0C TEMPERATURE IS

CALLED CRITICAL POINT OF WATER / STEAM BECAUSE AT THESE PARAMETERS WATER CHANGES TO STEAM PHASE INSTANTANEOUSLY (WITHOUT ANY LATENT HEAT OF EVAPORATION). THE STEAM TURBINES UTILISING MAIN STEAM PRESSURE ABOVE THIS CRITICAL PRESSURE ARE CALLED SUPER-CRITICAL TURBINES.Advantage

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

USE OF SS TUBES IN SURFACE CONDENSER FOR ENHANCED RELIABILITY

FOR CONDENSERS EMPLOYING SWEET WATER I.E. COOLING WATER OTHER THAN SEA WATER OR SALTY WATER (CONTAINING HIGH CHLORIDES), USE OF WELDED SS TUBES IS RECOMMENDED AS THE BEST MATERIAL FOR ITS SUPERIOR QUALITIES OF BETTER EROSION-CORROSION RESISTANCE, HIGHER RELIABILITY, LONGER LIFE AND LOWER CAPITAL AND MAINTENACE COST IN COMPARISON TO NON-FEROUS TUBES LIE ADMIRALTY BRASS, ALUMINIUM BRASS OR CUPRO-NICKEL WHICH WERE CHOSEN AS THE TUBE MATERIALS FOR POWER PLANT CONDENSRES IN THE PAST AS PER TRENDS AND TECHNO-ECONOMICS PREVAILING THEN.

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

TIPS FOR START UP & SHUT DOWN

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

FAST COOLING OF TURBINE TO REDUCE THE COOLING DOWN TIME

ALWAYS KEEP MANUAL VACUUM BREAKER OPEN

WHENEVER MACHINE WAS SHUTDOWN FOR LONG PERIOD, DRAIN

THE HOTWELL

PRIOR TO START OF OIL PUMPS, RAISE THE OIL TEMPERATURE

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)