IPS – 2012 Power Plant O&M Event- NTPC

Anchored

COMMISSIONING BEST PRACTICES

– AN EXPERIENCE SHARING

- Subrata Ghosh - VP(O&M)

- Manoranjan Pai – Addl VP (Commissioning)

(4 X 300 MW Rosa Thermal Power Project)

Recent Achievements

Unit-3

Synchronized for the first time on 23rd Dec 11 within 668

days from Boiler Erection start date.

Synchronization followed coal firing on same day.

Full load achieved within 108 hrs from synchronization

without any outage.

Commercial Operation declared on 1st Jan 2012 (24:00hrs)

within 9 days from synchronization without any outage.

5

Project Milestone - A Comparison

Sl Milestones Unit-1 Unit-2 Unit-3 Date Duration

from

Boiler

Erection

Date Duration

from

Boiler

Erection

Date Duration

from

Boiler

Erection

(Days) (Days) (Days)

1 Start of

Boiler

Erection

20-Feb-08 0 20-Jun-08 0 23-Feb-10 0

2 Unit

Synchroniza

tion

24-Dec-09 673 15-Jun-10 725 23-Dec-11 668

3 First Coal

Firing

30-Dec-09 679 16-Jun-10 726 23-Dec-11 668

4 First Full

Load

10-Feb-10 721 26-Jun-10 736 28-Dec-11 673

5 COD 12-Mar-10 751 30-Jun-10 740 01-Jan-12 677

Learning

Implementation

Incorporating

Modifications

Implementing

O&M Feedbacks

Safety

& Quality Practices

Adherence to

Project

Schedule

Commissioning

Management

System

High

Quality

Commissioning

Commissioning strategy

Coordination Committee

R- Power commissioning

coordinator,

Engineering representative,

SEC commissioning

coordinator,

Corporate Operation

Representative

Overall

commissioning

control

Directing &

coordinating

commissioning

group

Punch point

resolution

Carrying out actual

commissioning of

systems &

equipments under

supervision of

OEM

EPC

Construction

Engineers

Commissioning

management

committee

Commissioning

Group

SEC/ OEM

Engineers

R- power

maintenance

Engineers

R- Power

Operation

Engineers

Defect

reporting

mechanism

Apex Committee

CPD, Head O&M, SEC

Representative, Engineering

Head, Corp. Operation

representative

Role of Apex Committee

Formulate strategy

Providing resource & support

O&M Head, Construction Head,

OEM representative

Commissioning Group

Review and resolve bottlenecks

Provide strategic oversight

Managing interface activities

Ensuring resource availability

Reviewing the planning and issuing

guidelines.

Removal of bottlenecks

Role of Coordination Committee

Approve commissioning test

results

Planning, organizing and management

of all commissioning work

Comm. Manager, Engineering

representative, OEM

Systematic progression of

operations

Meeting with conveners,

EPC & OEM

To work in coordination with apex

committee

Planning & execution of all

commissioning activities.

Preparation of all Commissioning

related documents

Ensuring resource deployment

Reviewing the progress &

commissioning work quality

Archiving all commissioning

documents

Commissioning Group

EPC construction Engineers

Owner Group Maintenance

Engineers

Owner Group Operation &

Commissioning Engineers

OEM Engineers & EPC associates

Meeting with conveners,

EPC & OEM

Responsible for carrying out day to

day commissioning

Close coordination with OEM, EPC &

Associates

Identify and arrange special T&Ps,

spares, services etc.

Carrying out all Tests & preparing

protocols

Getting protocols signed by all

concerned.

Safety and Quality

Safe Commissioning &

Implementation of SCC and PTW

Issue of safety clearance certificate

Coverage under PTW

Commissioning procedures

Detailed commissioning procedures

Contain details of checklists,

protocols, electrical, Instruments and P&ID

Quality checks and

Observation List generation

Regular visits with Quality Deptt.

Deviations are sent to EPC

Interface meeting with EPC and resolution

Safety

& Quality

Safety and Quality

Mock trial of critical operation

N2 capping

Citric acid cleaning after acid

cleaning

LFFD & external flusher

with 1 micron filter

Drum level & furnace pressure

in auto

during steam blowing

Local Protection Boxes

Pre light up GD test

Flushing of CW return line

APH oil carry over probe

ESP ATT with additional blower

Fore bay fill test

Modifications During Erection

Ash Conveying line size changed

from 200 mm to 250 mm

Ash Level indications changed

from ESP CR to AHP CR

Mechanical level indicators for

ash hopper

Provision of bolster in NMEJ

Diversion of HPGV Leak Off line from

HPH-6 to condenser

Provision of manual drain to

Atmosphere for MS/CRH/HRH

Provision of extra tie rods in CW Pipe

lines and additional ARVs

Deficiency resolution strategy

Involvement of O&M and commissioning ensured in all

stages of erection.

Deficiencies identified got resolved within time bound

schedule.

Project director is empowered for deficiency resolution.

Intervention of apex committee if deficiency not resolved

within 72 hours.

O&M Feedback

Provision of Platforms in all

working locations

Checking of dampers & gates

for proper isolation

Repeated ATT of boiler

M/C alignment & lub oil quality cross

checking

Critical hangers cross checking

by expert

All PC pipe couplings, MDVs &

feeder body bolts tightness

Readiness of mills & feeders

before synchronization

Thorough inspection & identification

of other defects in steam blowing

Deployment of skilled manpower

in all areas

All welding joints of furnace, APH

body, ducting leakage points

Checking before insulation

O&M Feedback

DP of all lube oil filters monitored

and immediate action taken

Normalization of field instruments

after process establishment

Verifying the logic on offline server

as per SAMA

Tuning of available auto control loops

soon after process stabilization

SCAPH testing & charging done

and made 100% ready

Ensuring sufficient seal water

pressure for ash vac p/ps

Provision of additional air washer

tank nozzle

Thorough checking of all ESP fields

Deployment of skilled manpower

in all areas

Deployment for recording and

analyzing instrument response

\

Proper anchoring for bottom

hopper refractory Integration of all the systems/loops

Learning from other projects & Rosa Stage I

Feedback from other projects were studied by a task force

consisting of Engineering, Commissioning, Erection and O&M team

and a total of 55 modifications were identified and implemented in

Rosa.

In the second phase, based on Rosa Stage-1 learning a list

consolidating all issues/modifications had been prepared by

consulting various disciplines involved in Phase – I . This list got

further refined after discussion with engineering and an action plan

was formulated with EPC to implement these modifications. These

modifications were made a part of commissioning procedure for

Phase II avoiding any chance of non tracking. Status of modification

has been reviewed with EPC and O&M on regular basis.

Benefits

Successful unit commissioning within scheduled time with

intensive involvement of O&M .

Adopted strategy ensured clear role clarity for sub groups

Risk analysis in each activity and maintaining contingency

plans for emergencies strengthened confidence in team.

Regular brain storming with Engineering department and

OEM helped in finding immediate solutions to technical and

quality issues faced at site.

Planning of resources and material in advance to maintain

desired pace of commissioning activities.

Strict adherence to Commissioning checklist and 100%

implementation of protection system ensured no tripping

from synchronization to COD completion.

Conclusion

Constant construction monitoring ensures freedom from trouble

and assurance of quality and maximum output. Monitoring involves

setting up of objectives, assessment of critical items, planning and

organization, personnel management, contract management and

adoption of an appropriate mechanism for reducing time and cost

over-runs. Rosa Unit 3 commissioning activities are some

examples of objective construction monitoring with an eye to strike

a balance between cost over-runs and quality compliance.

Confidential Slide

Thank You

Oil carry over probe

Improvement initiative

In view of the recent APH fire in one of the power station in country,

initiative was taken immediately & APH oil carry over probe was

developed & manufactured at site & fitted in all units.

Non Metallic Expansion Joints (NMEJ)

Problem

Frequent failure of NMEJs in stage “I” APH hot air duct which caused unit

tripping. Supplied by SEC. In adequate strength of fabric, improper storage

during erection & design deficiency being the main reasons

Solution

Replaced with better quality & design indigenously with bolster

arrangement. Done in all units.

NMEJ in position

Outer fabric cloth. The

quality supplied by SEC

was also poor as

physically observed.

Bolster: The NMEJ with this

design was procured & fixed.

Bolster is place between fabric &

inner surface.

Mechanical Indicators provided for effective monitoring of ESP hopper levels to ensure proper evacuation of the hoppers.

ESP Hopper

Draft

line