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BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

AN OVERVIEW

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

SOME FACTS
TOTAL 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
N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

PLANT LOAD FACTOR AND OPERATIONAL AVAILABILITY OF SOME NTPC MACHINES

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED


PLANT/YEAR 1999-2000 PLF SINGRAULI UNIT-1 UNIT-2 UNIT-3 UNIT-4 UNIT-5 UNIT-6 UNIT-7 KORBA UNIT-1 UNIT-2 UNIT-3 UNIT-4 UNIT-5 UNIT-6
98.9 93.1 83.7 93.8 96.5 92.7 95.6 84.4 93.5 91.4 82.4 83.7 85.6

2000-2001 PLF
96.6 98.6 98.7 87.8 97.6 91.9 91.0 96.6 97.5 95.6 79.0 89.6 86.6

2001-2002 PLF
97.3 93.0 78.2 68.4 91.2 92.6 89.5 93.2 90.4 93.5 91.2 87.5 89.8

2002-2003 PLF
95.3 96.9 93.5 96.0 89.2 84.9 95.9 94.1 94.0 92.9 89.0 87.4 87.1

2003-2004 PLF
100.1 99.3 97.1 98.1 98.2 82.6 76.7 94.2 94.7 89.0 89.1 89.1 82.7

OA
96.5 93.0 83.7 93.4 97.8 92.7 95.8 85.3 94.0 93.5 86.7 87.1 88.8

OA
94.4 97.7 98.1 88.4 96.7 92.1 92.8 97.1 97.8 95.9 84.5 93.3 90.2

OA
97.0 93.9 78.2 68.5 92.9 95.7 90.6 94.1 91.4 94.6 93.7 89.3 92.8

OA
95.6 98.2 95.0 97.3 91.3 90.0 97.8 94.2 93.9 93.8 93.3 92.0 92.7

OA
98.2 98.7 97.3 97.4 98.1 87.2 78.8 93.7 94.2 89.6 93.9 94.2 86.7

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED


PLANT/YEAR VINDHYACHAL UNIT-7 UNIT-8 SIMHADRI UNIT-1 UNIT-2 DADRI UNIT-1 UNIT-2 UNIT-3 UNIT-4 RAMAGUNDAM UNIT-4 UNIT-5 UNIT-6 BADARPUR UNIT-4 UNIT-5
1999-2000 PLF 96.6 97.0 96.7 94.3 87.1 91.4 90.2 71.7 82.5 OA 96.3 96.6 97.2 94.6 90.3 92.2 89.3 82.3 92.8 2000-2001 PLF 75.8 80.8 97.2 95.7 90.2 91.2 84.6 91.5 89.9 91.5 69.1 OA 84.5 88.4 97.1 97.1 91.9 91.8 85.7 92.2 90.4 95.7 76.0 2001-2002 PLF 60.0 79.0 88.4 94.2 90.7 89.5 87.9 86.8 83.0 81.6 89.3 OA 68.0 82.3 92.1 98.4 95.6 94.8 90.8 89.2 84.9 86.6 99.2 2002-2003 PLF 88.8 87.4 85.3 92.4 86.6 80.8 82.6 78.4 88.5 93.2 92.3 85.8 87.4 OA 92.0 90.3 88.3 96.5 95.1 90.0 93.6 87.7 89.8 94.3 93.4 92.4 92.8 2003-2004 PLF 88.1 74.2 84.2 91.6 84.3 86.1 84.2 81.3 88.6 83.7 91.5 92.8 90.3 OA 93.5 77.7 87.1 94.7 94.4 95.4 93.1 90.1 91.8 85.6 92.7 99.4 96.4

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

AGE WISE ANALYSIS OF KWU DESIGN TURBINES SUPPLIED BY BHEL

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

AGE-WISE ANALYSIS
500 MW (NR + ER + WR + SR) 250 MW (NR + ER + WR + SR) 210 MW (NR + ER + WR + SR)

< 5 YRS 5 10 YRS 10 15 YRS 15 20 YRS 20 25 YRS > 25 YRS

5 (0 + 1+ 2 + 2) 2 (0 + 1 + 1 + 0) 8 (0 + 1 + 4 + 3) 5 (2 + 0 + 3 + 0) 0 0

4 (4 + 0 + 0 + 0) 4 (0 + 0 + 2 + 2) 0 0 0 0

15 (4 + 3 + 5 + 3) 21 (3 + 8 + 2+ 8) 31 (11 + 5 + 5 + 10) 29 (6 + 3 + 16 + 4) 21 (2 + 2 + 12 + 5) 0

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

OPERATIONAL PROBLEMS IN KWU TURBINES

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

A. B. C. D.

LP BLADE FAILURE BARRING GEAR STOPPAGE HIGH HP FRONT SHAFT VIBRATION LOW VACUUM DUE TO HIGH AIR INGRESS

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

LP BLADE FAILURE

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

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
N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

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 CONTINUED CARE TO BE TAKEN DURING O&M OF THE PLANT
Avoid following operation Off Frequency operation Full load operation with low vacuum Prolonged no load operation Overloading Continuous Valve Wide Open operation Ensure the proper functioning of following systems Turbine Drainage System LP heaters Drip Cascading auto controls and LP heaters level alarm system LP exhaust hood spray system Protection System to avoid incidence of overspeeding, motoring etc. Water chemistry regime
N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

LP BLADE FAILURE :- RECOMMENDATIONS / ACTION TAKEN


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.

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

BARRING GEAR STOPPAGE

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

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

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

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 NOV2002 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
N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

HIGH HP FRONT SHAFT VIBRATION

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

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
N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

HIGH HPF SHAFT VIBRATIONS : RECOMMENDATIONS / ACTION TAKEN


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
N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

LOW VACUUM DUE TO HIGH AIR INGRESS

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

VARIOUS METHOD OF DETECTING AIR INGRESS

OFF LINE METHOD Water fill test or vacuum tightness test Steam pressurization test. ON LINE METHOD With the help of Helium Leak Detection Instrument

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

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.

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

STEAM PRESSURIZATION TEST


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.
N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

HELIUM LEAK DETECTION TEST : SCHEME FOR DETECTING AIR INGRESS


HELIUM GAS SPRAY ON SUSPECTED AIR INGRESS POINTS

VACUUM PUMP

STEAM + AIR

AIR EXHAUST

CONDENSER
SAMPLE LINE

HELI LEAK DETECTOR

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

COMPARISON OF STEAM PRESSURISATION TEST AND HELIUM LEAK DETECTION TEST


S.N STEAM PRESSURISATION TEST HELIUM LEAK DETECTION TEST

1. 2. 3.

CAN PINPOINT THE SOURCE OF AIR INGRESS CAN BE DONE ONLY WHEN MACHINE IS COLD REQUIRE STEAM AND WATER

CAN DETECT BROAD AIR INGRESS AREA CAN BE DONE AT LOAD REQUIRES HELIUM GAS WHICH IS NOT READILY AVAILABLE AT MANY POWER STATIONS BULKY AND DELICATE INSTRUMENT TEDIOUS EXERCISE

4.

REQUIRE SYSTEM PREPAREDNESS PRIOR TO CONDUCT THE TEST SIMPLE PROCEDURE

5.

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

OTHER PROBLEMS FACED IN KWU MACHINES


HIGH AXIAL SHIFT / DIFFERENTIAL EXPANSION MS / HRH STRAINER CHOKING OIL STARVATION OVERSPEEDING OF TURBINE

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

BHELS VIEW ON SPRING LOADED FOUNDATION

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

SPRING LOADED TG DECK : ADVANTAGES


MAJOR CORRECTION IN CATENARY OF MACHINE BY OF SHIM PROVIDED IN SPRING ASSEMBLY REDUCTION IN COST OF CIVIL STRUCTURE BETTER LAYOUT ISOLATION EFFECT OF OF TG DECK AND OF COLUMN WHICH WILL AVOID BE VIBRATION PROBLEM IN TG COLUMN AT ANY TIME SETTLEMENT FOUNDATION COLUMN CAN MINIMIZED FOR CATENARY DISTURBANCE ADJUSTMENT

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

SPRING LOADED TG DECK : DISADVANTAGES


INCREASE IN ERECTION CYCLE TIME INCREASE IN OVERHAULING PERIOD COST OF SPRING ELEMENTS AND ITS INSTALLATION COST

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

SPRING LOADED TG DECK : BHELS RECOMMENDATIONS


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.

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

PRE-OUTAGE SURVEY FOR PREDICTIVE MAINTENANCE

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

AIM OF PRE OUTAGE SURVEY


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

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

TEAM MEMBERS OF PRE OUTAGE SURVEY


(A) (B) Engineer from Turbine / Generator Group of PSTS (HQ) {LEADER} Field Engineering Service Engineer from Steam Turbine / Turbogenerator Department from BHEL Haridwar / Hyderabad / Bhopal (C) (D) (E) Service Engineer from Regional Service Centre Engineer from Regional Spare Business Group 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.
N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

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

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

BENEFITS OF PRE OUTAGE SURVEY FOR CUSTOMER


OPTIMAL APPROACH SHORTER MAINTENANCE PERIOD BY ADVANCE PLANNING FOR SPARE CONSUMPTION PROVIDES EDUCATION PROVIDES LEAN TO TIME TO CUSTOMER WRT POST NEW PONE FOR PROPOSAL , NEW MOVEMENT / SANTIONING OF FUNDS CUSTOMER TO PRODUCT THE PHILOSOPHY, NEW FAILURES ETC. FLEXIBILITY SHUTDOWN DEPENDING UPON CONDITION OF MACHINE

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

DECISIONS OF PRE OUTAGE SURVEY


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

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

UPGRADATIONS FOR NEWER GENERATION OF MACHINES

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

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 TODAYS 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 TURBOMACHINERY IS A CHALLENGING TASK AND CURRENT RESEARCHES ARE DIRECTED AT CFD MODELING TO SIGNIFICANGLY IMPROVE AERODYNAMIC PERFORMANCE OF THE BLADING.
N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

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.

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

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
N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

STEAM TURBINES WITH SUPER CRITICAL PARAMETERS


Super-critical parameters 221.2 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 MODERN SOCIETYS 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 SUBCRITICAL 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%.

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

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 EROSIONCORROSION RESISTANCE, HIGHER RELIABILITY, LONGER LIFE AND LOWER CAPITAL AND MAINTENACE COST IN COMPARISON TO NONFEROUS TUBES LIE ADMIRALTY BRASS, ALUMINIUM BRASS OR CUPRONICKEL WHICH WERE CHOSEN AS THE TUBE MATERIALS FOR POWER PLANT CONDENSRES IN THE PAST AS PER TRENDS AND TECHNOECONOMICS PREVAILING THEN.

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

TIPS FOR START UP & SHUT DOWN

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

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

N.K. BANSAL, AGM (T)

BHARAT HEAVY ELECTRICALS LIMITED

N.K. BANSAL, AGM (T)

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