Published by Technical Services / PSSR

For internal circulation

PARLI TPP

APRIL : 2010
VOLUME : 13.11
HIGHLIGHTS

KAKATIYA 500 MW: UNIT 1

SAFETY VALVE FLOATING WAS COMPLETED.
NALCO UNIT - 10:
UNIT WAS SYNCHRONISED FOR THE FIRST TIME WITH GRID.
NALCO, DAMANJODI UNIT - 5:
UNIT WAS SYNCHRONISED FOR THE FIRST TIME WITH THE
GRID.
RAICHUR UNIT 8:
UNIT WAS SYNCHRONISED FOR THE FIRST TIME WITH THE
GRID.
KUTTIYADI UNIT 1:
UNIT MECHANICAL SPINNING WAS DONE.
KUTTIYADI UNIT 2:
UNIT MECHANICAL SPINNING WAS DONE.

APRIL 2010

TS TIDINGS

INSIDE
1. STATUS OF PROJECTS COMMISSIONED FROM 2002 TO 2009.
2. STATUS OF SETS COMMISSIONED / TO BE COMMISSIONED
DURING 2009 - 2011.
3. SERVICE RENDERED TO OTHER REGIONS/SAS/PROJECTS
AFTER CONTRACT CLOSING/
4.

CUSTOMER TRAINING.

APPRECIATION FROM CUSTOMER FOR SERVICES RENDERED.

5. FEED BACK ON EQUIPMENTS FROM SITES.

6. LET US KNOW -

POWER CABLE INSTALLATION

Feed backs and suggestions from all departments of BHEL for

improvement of TS TIDINGS are
welcome and may please be
addressed to ADDL. GENERAL MANAGER (TSX)/BHEL-PSSR/CHENNAI

TECHNICAL SERVICES / PSSR

APRIL 2010

TS TIDINGS

STATUS OF PROJECTS COMMISSIONED DURING 20022009.

NINL, DUBURI:
BHEL/Trichy suggested for replacing few components of safety
valve. The list was forwarded to customer for placing order.
RAYALASEEMA TPP UNIT 4:
Unit is running around 200 MW.
TG PG test was declared completed on 01.04.2010
BELLARY UNIT 1:
Unit is running around 320 - 500 MW.
Load was reduced on 15.04.2010 due to coal feeding problem.
STATUS OF SETS COMMISSIONED / TO BE COMMISSIONED
DURING 2009 2011:
AMARKANTAK UNIT 5:
Unit is running around 175 to 194 MW.
AHP: Dry Ash system silo civil works is in progress. Clarifier
area: chemical treatment plant building and sump works are in
progress. In wet ash system vacuum pump house building balance
roof works is in progress.
NALCO UNIT 9:
Unit is running around 60 to 120 MW.
DAVR voltage hunting was observed and checking is in progress.
DGM Mills design from BHEL/Hyderabad visited site since
23.04.2010 in connection with the mill modification to resolve the
mill reject issues. Mill A modification was completed and
performance is kept under observation.
TECHNICAL SERVICES / PSSR

APRIL 2010

TS TIDINGS

Unit got tripped at 0135hrs on 29.04.2010 due to station

transformer power failure. Unit was resynchronized at 1145 hrs
on 29.04.2010 and is running at 90 MW load.
NALCO UNIT 10:
Unit was synchronized for the first time with the grid at 0443hrs
on 01.04.2010.
Pending works in TG & Boiler is being attended.
BHUSHAN STEEL AFBC BOILER UNIT 2:
Boiler was lighted up on 01.04.2010, steam blowing was carried
out. Normalisation of piping and Flow nozzle erection were
completed.
Boiler was lighted up again on 21.04.2010 for trial run, but coal
firing could not be established due to feeder problem. Further
after attending the feeder problem Coal firing could not be
established due to bigger coal size. Bunker is being emptied.
BHUSHAN STEEL AFBC BOILER UNIT 3:
Seventy two hours continuous trial operation of the unit was
completed.
Unit is under Shut down from 28.04.2010.
NALCO-DAMANJODI:
TG was rolled to 5000rpm on 02.04.2010

TECHNICAL SERVICES / PSSR

APRIL 2010

TS TIDINGS

Unit was synchronized for the first time successfully at 0912hrs

on 04.04.2010.
Trial run of ID fan B Hydraulic coupling was completed.
Four hours trial run of condensate transfer pumps A & B was
completed.
TG was rolled to rated speed (5300 rpm) again on 14.04.2010,
but could not be synchronized due to HPCV problem.
BHEL/Hyderabad to service the same.
While filling boiler for preservation, tube leakage was observed in
the left side water wall at CD elevation. Stub welding is in
progress.
FD fan A vibration problem was attended by BHEL/Ranipet. Max.
vibration in the fan drive end horizontal side was measured as 36
microns after balancing. FD fan A trial run was completed.
KRL KOCHI:
GT was stopped for attending the vibration problem in load gear
box. Decoupling of the load gear box from the generator side and
turbine side was done. Load gear box alignment with GT &
Generator was completed after moving 5mm towards turbine.
BFP 2 coupled trial run was completed.
SAT -1 control cables loop checking was completed and incipient
fault protection was checked. LV side links were completed and
meggering was carried out.
SAT-1 upstream and downstream interlocks were checked, oil
BDV was checked.
HT 101 : relay testing of balance feeders is in progress.

TECHNICAL SERVICES / PSSR

APRIL 2010

TS TIDINGS

Synchronizer circuit checking in SACP for balance feeders is in

progress.
Feeders remote operation checking for BFP 1, BFP 3 & BFP 4 was
completed.
HIPOT test of Tie 2 transformer 11 kV cable from LIB to
transformer was carried out.
SAT 1 transformer REF protection was checked. SAT -1 was
charged. SAT 1 got tripped on earth fault. On inspection
moisture was observed inside the 33 kV terminal box.
GT three way valve operations were checked.
HIPOT test for 11kV tie 3 transformer cable was carried out
from LIB to transformer.
OLTC of tie 2 transformer was commissioned.
Trial run of BFP 3 was completed.
SAT 2 REF protections was checked.
GT was brought to FSNL at 1230hrs on 27.04.2010.
While closing the tie-1 transformer breaker, generator
transformer tripped on REF protection. Generator transformer
inspection was carried out.
GT REF protection and earthing were tested. After testing GT
was resynchronized with the grid at 1845hrs and loaded to
12MW.
GT got tripped twice due to 33kV GIS wiring mismatch (M/s.
SIEMENS).
33kV GIS section -2 was charged, but all feeders got tripped. It
could be charged only after the 33kV GIS wiring mismatch is
corrected.
TECHNICAL SERVICES / PSSR

APRIL 2010

TS TIDINGS

HRSG leak test was completed upto 15kg/cm2

GT was stopped at 1500hrs on 29.04.2010 due to smoke observed
in B-phase cable of 11kV tie transformer. Shield was found
touching the bottom frame.
Heat sink (HT insulation) was
changed.
Naphtha forwarding pump motor was run for 15 minutes, but the
vibration was found high.
RAICHUR UNIT 8:
Condenser fill test was completed.
Hot-well makeup pump 1 was commissioned.
Turbine and barring gear interlock & protection checks were
demonstrated to customer.
Lube oil flushing of PA fan A and Mill C is in progress.
Condenser Vacuum pulling was completed and steam dumping was
started at 1500hrs on 07.04.2010.
TG was rolled to 3000 rpm for the first time at 0030hrs on
09.04.2010.
SCC and OCC of generator were completed. Over speed oil
injection test was completed.
Unit was synchronized with the grid for the first time at 1245
hrs on 9th April 2010.
OCC test of ESP B pass- 12/14 HVRs was completed. ESP B field
charging and checking are in progress. Lamp load test of seven
nos. of electronic controller for ESP A pass was completed. ESP
A1 pass: two nos. HVR were found having problem and the same
is communicated to BHEL/Jhansi. ESP A2 pass cabling is in
progress (Customer scope).
TECHNICAL SERVICES / PSSR

APRIL 2010

TS TIDINGS

FD fan B was run for 45min.

APH B was run for three hours.
Primary air duct erection work is in progress.
Mill A, Mill B & Mill C were run for one hour and roller setting
was completed.
Lube oil flushing of Mill D was declared completed.
Coal feeder D: clean out conveyer no load trial and belt tracking
were completed.
Feeder outlet gate and mill discharge B & C local operation was
checked.
SGC Condensate and evacuation system checking completed.
KUTTIYADI UNIT 1:
During mechanical spinning, bearing temperature went high; hence
bearing inspection was carried out.
Heavy leakage in the bypass valve was observed when about to
spin. O ring replacement was done.
Governor cards (one analog card and one digital card) were found
defective and replaced.
Balancing was completed on 28/04/2010 successfully, the lower
guide bearing vibration was brought to 120microns and upper guide
bearing vibration was brought to 135microns.
Rotor IR value was found zero, while analyzing it was found that
pole to pole interconnection problem. Insulation sleeve was
changed in rotor coil assembly to solve low IR value.

TECHNICAL SERVICES / PSSR

APRIL 2010

TS TIDINGS

KUTTIYADI UNIT 2:
GRP - Relay testing was completed.
,

Generator bearing was boxed up.

Back charging of GT was completed on 24.04.2010.
Machine was spun and vibration is around 240 microns at LGB and
balancing is in progress

VIJAYAWADA UNIT 7:
Unit is running around full load.
TDBFP A mechanical seal was replaced.
Unit got tripped at 1132 hrs on 11.04.2010 due to accidental
pushing of fire protection push button in local and resynchronized
at 1331 hrs the same day.
ID fan B got tripped on 13.04.2010. BHEL/Bhopal person visited
site for ID FAN B problem, 3 diodes were found faulty in the
exciter and same were replaced with spares. ID Fan B is taken
into service at 0722 hrs on 15.04.2010.
TDBFP A rolling to 3000rpm from auxiliary control valve was
demonstrated to customer.
Unit got tripped at 1816hrs on 21.04.2010 due to differential
protection relay acted on account of external grid disturbance
and resynchronised at 1016hrs on 22.04.2010
Load test of Boiler lift was completed & demonstrated to
customer.
Unit was hand tripped at 1305hr on 27.04.2010 due to boiler
economiser tube leakage.

TECHNICAL SERVICES / PSSR

APRIL 2010

10

TS TIDINGS

Boiler was lighted up at 2130 hrs on 28.04.2010 after attending

the tube leakage. Boiler tripped twice due to low air flow and Reheater protection. Machine was rolled and synchronised in
hydraulic mode at 0810 hrs and demonstrated to customer. Unit
was synchronised at 0910hrs on 28.04.2010.
KAKATIYA UNIT 1:
Trial run of Mill C and Mill D was completed.
Trial run for four nos. lube oil pump motors of TDBFP A & TDBFP
B was completed. TDBFP B vapour extractor fan trial run was
completed. TDBFP B Oil flushing was started. TDBFP A oil
flushing was started on 24.04.2010. TDBFP B lube oil lines hydro
test was completed.
Trial run of feeder B was completed.
Lube oil flushing of Mill F was completed.
Trial run of feeder C was completed.
Generator air leak test was completed.
EHTC has been set right and re-calibrated.
PA fan was run and leak test was carried out for C & D pass
ducting.
Boiler hydro test was carried out at 175kg/cm2.
Boiler was lighted up for safety valve floating. Three nos. RH
safety valves were floated. Four nos. PRDS safety valves were
floated. Two nos. Boiler left side CRH safety valve were floated.
Drum safety valve could not be floated due to vertical expansion
restrictions. Expansion restriction cutting works in progress.

TECHNICAL SERVICES / PSSR

APRIL 2010

11

TS TIDINGS

Safety valve floating is declared completed on 22.04.2010. One

no. SH safety valve and one no. RH safety valves are to be
attended by BHEL/Trichy.
Clean air flow test for Mill C & Mill D was completed.
Trial run of mills E&G was completed.
EID/PARRY:

Unit was running at 11 MW with Naphtha firing.

GT is under shutdown since 12.04.2010.

SERVICES RENDERED TO CUSTOMER /SAS/MUs:

--- NIL --CUSTOMER TRAINING & TECHNICAL PAPER PRESENTED:

--- NIL --APPRECIATION FROM CUSTOMER FOR SERVICES RENDERED :
--- NIL ---

TECHNICAL SERVICES / PSSR

APRIL 2010

12

TS TIDINGS

FEED BACK NO.1

PROJECT

: NALCO CPP UNIT-9 120 MW.

PROBLEMS : HIGH MILL REJECTS AND MORE CURRENT

CONSUPTION IN MILLS
PROBLEMS FACED:
Nalco unit-9 & 10 have been supplied with XRP 803 Bowl mills with
new type of deflector assembly and vane wheel segments for the bowl
bottom air flow arrangement. Drawings old and new deflector
arrangement is enclosed. These mills were in service for last Sept
2009 and found they were rejecting more coal, coal dust
and
consuming more current. This problem got aggravated due to poor mill
reject evacuation and running of mill continuously without doing
periodical maintenance like ring and roller setting due to generation
demand. The mill reject valves were also inaccessible due to piling very
huge amount of rejects. To resolve this, maintenance department, in
line with old mills arrangement, extended the bowl top extension ring
with the hope of reducing the high mill rejects. But in turn the mill
separator body got worn out very fast locally and got punctured in few
places, near the deflector assembly top area all around along with
further increase of rejects along with coal & coal dust.
To overcome the heavy mill reject problem in mills, customer had
carried out modifications in MILL-9A in line with old mills at Nalco.
Later modifications in
Mill-9E existing arrangements were done in
consultation with BHEL Hyderabad mills designs engineer and our site
engineers. The problem , the cause ,the modification , advantages and
disadvantages are listed in the following table.

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APRIL 2010

S.NO

MILL -9A

01

POSITION OF
DEFLECTOR AND
VANE WHEEL
BEFORE
MODIFICATION

02

PROBLEMS
FACED

03

ABNORMALITIES
BEFORE
MODIFICATIONS

TS TIDINGS
MILL-9E

1. HIGH MILL REJECTS

1. HIGH MILL REJECTS

2. SEVERE EROSION OF SEPERATER BODY AND

PUCTURING IN SOME PLACES

2. SEVERE EROSION OF SEPERATER BODY

AND PUCTURING IN SOME PLACES

3. HIGH CURRENT THAT LIMITS FULL

LOADING OF MILLS AND UNITS

3. HIGH CURRENT THAT LIMITS FULL

LOADING OF MILLS AND UNITS

1. MILL REJECT WAS NOT CLEARED PROPERLY

BECAUSE MILL REJECT CONVEYOR SYSTEM
WAS NOT READY AND THE MILL REJECT
VALVES WERE INACCESSIBLE DUE TO
HUGE PILING OF MILL REJECTS
2. DELAYED PERIODICAL MAINTANACE DUE
TO DEMAND FOR GENERATION

3. MILL REJECT WAS NOT CLEARED

PROPERLY BECAUSE MILL REJECT
CONVEYOR SYSTEM WAS NOT READY AND
THE MILL REJECT VALVES WERE
INACCESSIBLE DUE TO HUGE PILING OF
MILL REJECTS
4. DELAYED PERIODICAL MAINTANACE DUE
TO DEMAND FOR GENERATION

REMARKS

14

04

05

06

07

APRIL 2010
POSITION OF
DEFLECTOR,
WHEEL , UPPER
AIR RESTRICTION
RING AFTER
MODIFICATIONS

DEFLECTOR ASSY

MODIFIED LIKE OLD MILLS ARRANGEMENT

NEW ARRANGEMENT WAS REMOVED AND OLD

ARRANGEMENT OF DEFLECTOR LINER PLATES
ALONGWITH NIHARD INSERT S WERE
INSTALLED
UPPER
AIR BOWL UPPER AIR RESTRICTION RING WAS
RESTRICTION
INSTALLED TO MAINTAIN 50-60 MM ANNULAR
RING
GAP.

VANE
ASSY

TS TIDINGS
NEW ARRANGEMENT WITH
MODIFICATIONS

NEW ARRANGEMENT RETAINED AND 7MM

THICK BY 60 MM HT PLATE WELDED ONTO
THIS ALL AROUND TO MAINTAIN 70 MM GAP

REMOVED. INSTEAD WELDING OF RINGS OF

6MM THICK AND HEIGHT 70 MM WAS DONE TO
THE DEFLECTOR ASSY ALL AROUND TO
DIVERT THE AIR TOWARDS BOWL
WHEEL EXISTING VANE WHEELS REMOVED & OLD EXISTING VANE WHEELS WITHOUT OUTER
TYPE VANE WHEEL ASSY WITH OUTER RING RING RETAINED
ERECTED

APRIL 2010

15
08
09

SPRING
COMPRESSION
SET FOR ROLLERS
INVERTED CONE

TS TIDINGS

11 T

11T

REMOVED

REMOVED

10

CENTRE
FEED CARRIED OUT
PIPE
WAS
EXTENSION
BY
50-60MM BEYOND
INNER CONE.

CARRIED OUT

11

ROLLERS

NEW ROLLERS REPLACED

12

CLASSIFIER
POSITION

FOUR-4

GRINDING ROLL WAS FOUND WORN OUT BY 25

MM AT THE CENTER. HENCE TRUNION SHAFT
END CAP POSITION WAS SHIFTED TO 4.
ONE-1

13

PATCH WORK

14

CARRIED OUT I N WORN OUT PORTION OF

LINER AND SEPERATOR BODY
ADVANTAGES OF 1.REJECT REDUCED
MODIFICATIONS

15

DISADVANTAGES
OF
MODIFICATION

16

CONCLUSION

1. NO IMPROVEMENT IN MILL CURRENT

2. LESSER MARGIN FOR MILL LOADING &
ALSO FOR ACHIEVING MILL CAPACITY
WITH SAFE CURRENT MARGIN
THIS OLD DEFLECTOR ASSEBLY IS NOT
SUITABLE. HENCE MILL A IS ALSO TO BE
SUITABLY MODIFIED LIKE MILL E.
MILLS B,C,D MODIFIED LIKE MILL E.

CARRIED OUT I N WORN OUT PORTION OF

LINER AND SEPERATOR BODY
1.REJECT REDUCED
2.CURRENT / POWER REDUCED
3.MILL COULD BE LOADED TO FULL
CAPACITY(PRAMETRES ENCLOSED)
NO DISADVANTAGES

THIS MODIFICATION IS GOOD BECAUSE MILL

REJECT IS LESS AND CONSUME LESS POWER

APRIL 2010

16

TS TIDINGS

MILL PERFORMANCE DATA BEFORE MODIFICATION:

PARAMETER
OBSERVATION-1
Feeder coal flow,
mill air flow
mill o/l temp
mill current
Bowl DP
OBSERVATION-2
Feeder coal flow,
mill air flow
mill o/l temp
mill current
Bowl DP

t/h
t/h
Deg C
Amps
mmwc
t/h
t/h
Deg C
Amps
mmwc

MILL 9A MODIFIED IN MILL 9E MODIFIED WITH

LINE WITH OLD
EXISTING ARRANGEMENT
MILLS
ON 19.4.10
ON 28.04.10
13.5
17.8
84.5
65.9
82
79.5
23.7
34.4
278
581.7
ON 19.04.10
ON 28.04.10
13.5
20.05
83.7
71.03
80
73.98
27.1
33.8
313
556.92

MILL PERFORMANCE DATA AFTER MODIFICATION:

PARAMETER
OBSERVATION-1
Feeder coal flow, t/h
mill air flow t/h
mill o/l temp C
mill current A
Bowl dp mmwc
OBSERVATION-2
Feeder coal flow, t/h
mill air flow t/h
mill o/l temp C
mill current A
Bowl dp mmwc
OBSERVATION-3
Feeder coal flow, t/h
mill air flow t/h
mill o/l temp C
mill current A
Bowl dp mmwc

MILL 9A MODIFIED IN MILL 9E MODIFIED WITH

LINE WITH OLD
EXISTING ARRANGEMENT
MILLS
ON 30.4.10
24.8
23.5
65
65
71.7
68.9
34.4
25.12
206
234
ON 03.5.10
26.97
29.7
65.08
61.4
75.45
68.58
36.17
28.87
229
272.4
ON 04.5.10
25.39
27.59
64.9
64.69
78.41
76.46
36.8
27.55
215.3
307.8

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TS TIDINGS

FEED BACK NO. 2

PROJECT: VIJAYAWADA THERMAL POWER STATION, UNIT 7, 500 MW
PROBLEM: HIGH THRUST BEARING TEMPERATURE IN TDBFP-A

TDBFP A was commissioned on 29.06.2009. Unit reached full load on

08/10/2009 for the first time with both TDBFPs in service .At that
time it was observed that the Active pad top thrust bearing
temperature reached 93deg C. It was found to be increasing with
increase in speed of the pump. At 3000 rpm it was maintaining at
81deg C and steadily increased upto 95-98 deg C at 4800-5000 rpm.
This pump had experienced jamming on 26.10.2009 and its cartridge
had to be withdrawn for servicing the same .Rubbing/Scoring marks
observed on balancing drum were polished. During that time, site along
with BHEL, Hyderabad representatives had also inspected the thrust
bearing, and minor polishing of the babbitt surface was done.
The alarm and Trip values are originally set at 100 and 105 deg C
respectively in MAX DNA. During loading of the pump the Active pad
Top Temperature was seen to increase upto 103-104 degC.
During trial operation of the Unit at Full load from 26.01.2010 to
28.01.2010 the temperature has further raised to 105 deg C. The
following were parameters at full load.
Turbine Load
BFP-A speed
Active pad temperature (Top /Bottom)
Inactive pads temp.(Top/Bottom)
Oil pressure to BFP Thrust bearing
Lo Header pressure
LO supply temperature
Bearing Return oil temp.

:
:
:
:
:
:
:
:

510 MW
5440 rpm
105/84 Deg C
69/69 deg C
0.55KSC
2.7KSC
44 Deg C
65DegC

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APRIL 2010

TS TIDINGS

After discussing with BHEL, Hyderabad, temporarily the alarm and trip
limits were raised by site to 105deg C and 110 deg C respectively as it
was felt that pump could be run in that condition since only one out of
two active pad temperatures was going above alarm limits. (The other
active thrust pad temperature has maintained at temperatures of 75 to
84 deg C in the same operating regime of the pump.).
During continuous operation of the machine after COD, the thrust
bearing temperature increased gradually beyond these limits too and
reached 108Deg C. Hence matter was escalated to BHEL, Hyderabad
for urgent resolution.
On 13.03.2010, BHEL, Hyderabad Engineers visited site after shut
down was taken on pump. The pump thrust bearing was opened and
inspected. Scoring marks and discoloration of the affected pads was
observed. The following corrective actions were taken
A) Since discoloring and high return oil temperature values indicate oil
starvation ,the Orifices kept in the Oil supply lines to NDE Journal
as well as Thrust bearing were removed.
B) Swapping of ACTIVE and INACTIVE PADS was done, since inactive
pads surface was found to be in good condition ,and no spare pads
were immediately available at site.
The pump was boxed up on 17.03.2010 and taken into service.
Following were the parameters observed at full load of turbine after
attending the problem.

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APRIL 2010

Turbine Load
BFP-A speed
Active pad temperature (Top /Bottom)
Inactive pads temp.(Top/Bottom)
Oil pressure to BFP Thrust bearing
Lo Header pressure
LO supply temperature
Bearing Return oil temp.

TS TIDINGS

:
:
:
:
:
:
:
:

500MW
5405rpm
85/69 Deg C
55/56 deg C
2.00KSC
2.1KSC
44 Deg C
55.5DegC

The problem was thus been resolved and pump has been released for
continuous operation. However the difference between Active side top
/Bottom temperatures around 15-20 deg C still remain and needs
BHEL, Hyderabads analysis since this has been a characteristic
behavior of this 500 MW BFP.

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APRIL 2010

TS TIDINGS

POWER CABLE INSTALLATION

Introduction
Regarding the reliability aspects of supply, the so called (n-1)redundancy, realised in the cable route, is often demanded by the
utility. This means a twin system for the overhead line, which,
however, is useful in many cases concerning the loss costs .The
destruction of power poles, for example during the gale-force storms
in France in 1999, leads to a loss of the redundancy of the overhead
line twin system though.
When undergrounding cables, often two parallel systems are laid into
the trench side by side. For the transmission of great power, the
single core cables will not be arranged bundled but in a flat formation
(as in fig. 1b). In order to suppress sheath- or screen-losses by
circulating currents, a cross-bonding of the sheaths/screens is carried
out. The broken line in fig. 1b suggests providing an additional fourth
core instead of a complete second system. This principle was realised
in 1995 for a short 380kVVPE- cable route of a power station. The
copper screens of these cables of only 100 m in length are only oneside bonded. Moreover it was accepted that in the case of failure the
installation of the fourth backup core and the setting-up operation will
take up hours. These disadvantages, which possibly are not acceptable
for a normal power grid operation, are avoided by the installation
concept which will be described in the following.

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APRIL 2010

TS TIDINGS

Installation concept
Fig. 1 explains the advantages of a cable route with only four cores: if
a fast switching of the cores and of their screens is achieved in the
case of failure, the expenses for two cable cores can be saved, while
the reliability of the system remains nearly unchanged. This means
approximately the saving of one third of the total cable costs and
additionally, for a flat arrangement, the saving of one third of the
trench width. In comparison with the single cable system, the
investment cost will increase by less than one third.

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APRIL 2010

TS TIDINGS

The suggested fast-switching principle for the cores is described by

fig. 3. A combination of circuit breakers, realising a single-pole
switching from the troubled to the fourth core, will be needed. For a
switching without interruption, in the 110-kV power grid with an
inductive grounded neutral point, economical disconnecting switches can
be used. In power grids with direct neutral earthing however, circuit
breakers become necessary.
However, this four-core variant may lead to a serious problem: a
cross-bonding of the screens as in a normal three-core cable system,
as shown in fig. 4, can no longer be realised: in the three-core
arrangement the induced longitudinal screen voltages of the three
subsections, see fig. 4b, add up to an insignificant residual voltage Ur,
while the induced longitudinal screen current becomes zero.

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TS TIDINGS

Dividing the cable installation into four sections like in fig. 5 and
cross-bonding cyclically the screens of the four cores (of which just
three are carrying a current: in fig. 5 the first, third and fourth
core), it is true that the longitudinal screen voltage of the three
current-carrying, red marked cores, again, will add to zero (for a
symmetrical arrangement). However, the screen voltage UII (green in
fig. 5), which is induced into the current-less core II in the second
cross-bonding section, would last as a driving voltage in the total
screen path, compare fig. 6.

Cross-bonding is necessary for cables of greater conductor cross

sections (starting at approx. 500 mm2) and especially for flat
formations. Otherwise the screen losses by circulating screen currents
may increase excessively.

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TS TIDINGS

A requirement to implement the suggested solution is an arrangement

of the four cores in a way, that, dependent on the operating situation,
the three current-carrying cores are arranged approximately
symmetrically which leads to an induction of longitudinal screen voltages
of similar values. This is given in fig. 2a in an ideal way, because any
three of the four cores form a symmetrical triangle. Under the
aspects of laying, assembly and repair, in this arrangement the lower
core will be laid into a pipe, which is laid first. The requirement of
similar longitudinal screen voltages holds approximately also for the
arrangements of fig. 2b and 2c, while in the flat arrangement 2c a
balance of the longitudinal voltages can be achieved by a regular
transition of the both inner cores.
For the sake of simplicity a completely symmetrical arrangement
assumed, according to fig. 2a, as well as a current split of the system
according to fig. 5. Therefore, each of the four screen paths will get
induced the voltage UII of the current-less core-sections as a residual
voltage

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It depends on the momentary operating situation, which of the four

cores will remain current-less. In the case of failure, this will
naturally be the damaged core. Still for the same current split (core 2
is current-less), fig. 7 shows the suggested solution to compensate the
residual voltage UII.
First of all the four screens are short-circuited and connected to four
pole switch. In the present example, this switch (KKS) connects to a
compensation cable (KK, green), which being closely arranged beside
the second core is routed back from the end of the cross bonding
section.
Into this compensation cable the longitudinal voltage (- UII) is induced
along the last cross-bonding section IV, so that the total voltage is
reduced to zero in all the four screen paths at the left end of this
cable.
From here, the final problem consists in getting back by means of a
connection cable from the left end of the compensation cable to the
right end of the cross bonding section, i.e. without getting inducing an
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additional longitudinal voltage into this connecting cable. According to

fig. 7 this can be realised by the fact that this cable (NPK = neutral
path cable) changes its place in each third of section IV, in each third
laying close beside one of the three current carrying cores. Similar to
a normal cross-bonding of a three-phase cable, the voltages of the
sections are added up to zero as well, so that one can call this a
neutral path.

The compensation cable and the neutral path cable are exposed to
similar voltage loads like the corrosion protection of the cable. For this
reason, 1 kV-cable can be used, assuming an adequate, normal
overvoltage-protection of the system by arresters.
Since each of the four cable cores could fail or be current-less, one
compensation cable arrangement has to be realised for each of the
four cores according to
fig. 7. This means that one compensation
cable has to be laid alongside each cable core of the last section. The
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required neutral path cable for the three subsections can be realised
by three-core1 kV-cables with a splitting-up of the cores
corresponding to the subsections.
An additional possibility is given by integrating the compensation cable
into the construction of the high voltage cables (High voltage cable
with compensation screen), actually realizable by a second copper
screen which is insulated against the normal cable screen. Under the
aspect of an induced longitudinal voltage of exactly the same value,
this is the perfect solution which saves effort for laying, positioning
and possibly fastening of the additional cables at the same time.
Fig. 8 illustrates the both possibilities a cable core with two parallel
cables (a) and a cable core with one parallel cable (NPK) and one
integrated additional screen as a compensation conductor (b),
respectively.

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Multiple main sections of the cross-bonding system

When the route length is longer than the length of a cross-bonding
main section A (e.g. of 5 km), according to fig. 9 a mirrored
arrangement can be carried out as a continuation into the next main
section B. At the end of this main section B and at the beginning of
the next main section C the screens can be solidly bonded again,
according to fig. 10.
Thus in the distance of to main-sections, for example every 10 km,
two switches for compensation cables must be installed. These switches
have to be provided with energy, and they have to be able to be
triggered from the end of the cable route, e.g. by means of the cable
screens.

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Cable cleats:
Cable Cleats are designed to support and retain cables within the cable
tray system. More importantly, they help prevent damage in short
circuit conditions. Unfortunately, short circuits do happen, and when
they do, they are destructive and dangerous. Cable Cleats are one of
the first lines of defence to help protect the personnel, cables and
cable tray systems.

Figure 1 Trefoil cable

In the event of a short circuit, correctly installed cable cleats can

restrain the cables within the tray, helping avoid cable breaks that can
cause damage to the tray systems and injury to the personnel. Not
only is this a prudent product to install, the National Electrical Code
(NEC) requires adequate cable restraint in article 392.8 (D).
Parallel connected single conductor cables shall be securely bound in
circuit groups to prevent excessive movement due to fault current
magnetic forces. NEC, Article 392.8 (D). The cleats in this catalogue
are covered under IEC Standard 61914. Cable cleats also help avoid
downtime caused by short circuits. They help prevent the need for
expensive repairs and downtime caused by short circuit damages.

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Cable Cleat Selection and Specification Selection and Specification

Step 1: Know the Cables
What type of cable is being used?
Single or Multi-conductor
What is the outside diameter of the cable(s)? What is the cable
arrangement (single conductor cables only)?
Flat or Trefoil
If a ground wire will be installed within the cleat, you will need the
ground wire outside diameter.
Step 2: Know the System
What is the available short circuit current (RMS or ip (peak))? What
type of cable tray is installed?
Step 3: Select the Cable Cleats
Step 4: Select the Mounting Bracket
Mounting brackets are used to attach cable cleats to the rungs of the
ladder type cable trays. Cable tray type will determine the mounting
bracket used.
Step 5: Determine Cleat Spacing for Installation
Cable diameter is equal to the spacing between conductor centres
shown below.Find cable diameter at the top of the table and look down
at the column below it. Find the value equal to or greater than the
available short circuit for your system.

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It is important that the cleats are installed properly to secure cables:

It is not necessary for every cleat to be attached to the tray.
Every other cleat ( ) must be
attached to the tray system to mount cable in tray. Unattached
cleats ( ) provide additional
restraint to keep cables bundled.
The bend radius should be 8 to 12 times the cable diameter.
Cleats should always be installed at the beginning, middle and end
of a bend ( ), and at no time should the distance between cleats
on a bend be more than 0.3M centre to centre.

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TESTED CABLE
SPACING

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FUNCTIONALITY

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AND

RECOMMENDED

CLEAT

What to expect from the tests:

Would realistic tests done on several cable lengths and clamp distances
confirm the theory that the cable must be additionally secured at both
ends to reduce arching and eliminate deformation and stretch marks
on the cable?
Result of the test.
By using a secure plate (rung reinforcing plate) at both ends of the
cable run it confirms:
Less arching on the cable.
Less stretch at terminated ends significant point in regard to
functionality following short circuiting.
No stretch marks on outer cable sheath.
No stretch/deformation of rungs at the end of the cable ladder.
In addition, the tests obtained important data for making the following
recommendation concerning maximum cleat spacing, see table 2.
The tests were carried out without any damage to the cable, even
when using clamps two sizes too large with or without extra rubber
inserts. The test procedure was set up following dialogue with Draka
Norsk Kabel and a Statoil representative.
In order to set realistic maximum test values for the most common
cable cross-sections 150/240/300 mm2, we chose to use a formula
from NEK 606 which gives values as recommended in EN 50368. The
formula states what is maximum short-circuit current for a cable
without the centre core becoming so hot that it weakens the insulation
sheath (250 C).
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PERFORMANCE OF SR UNITS IN APRIL 2010

UNITS WHICH HAVE ACHIEVED 100% OA

THERMAL
500 MW
RAMAGUNDAM UNITS 4, 5 & 6
TALCHER UNITS 1, 2, 3 & 4
SIMHADRI UNIT 1 & 2
SIPAT UNIT - 4
250 MW
KOTHAGUDAM UNIT - 10
210 MW
VIJAYAWADA UNITS - 1, 2 & 5
METTUR UNIT - 1 & 3
TUTICORIN UNITS - 2 & 4
NORTH CHENNAI UNIT - 3
NEYVELI UNIT 4 & 7
UNITS WHICH HAVE ACHIEVED PLF MORE THAN 100%
500 MW
RAMAGUNDAM UNITS 4, 5 & 6
TALCHER UNITS 2, 3, 4 & 5
SIMHADRI UNIT 1 & 2
SIPAT UNIT 4
210 MW
VIJAYAWADA UNIT - 5
TUTICORIN UNIT
- 4 & 5
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UNITS WHICH HAVE ACHIEVED PLF BETWEEN 90 & 100%

THERMAL

500 MW
RAMAGUNDAM UNIT - 7
TALCHER UNIT 1 & 6
SIPAT UNIT - 5
250 MW
KOTHAGUDAM UNIT 9 & 10
210 MW
VIJAYAWADA UNITS 1, 2, 3 & 4
MUDDANUR UNITS 1, 2, 3 & 4
METTUR UNITS - 1, 2, 3 & 4
TUTICORIN UNIT 1 & 2
NORTH CHENNAI UNIT 3
NEYVELI UNITS 4, 5 & 7
125 MW
JSL, DUBURI UNIT 1

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PERFORMANCE OF BHEL THERMAL SETS IN SR (210

MW AND ABOVE)

FOR THE PERIOD FROM 01/04/09 TO 30/04/2010 COMPARED WITH THE

CORRESPONDING PERIOD IN THE PREVIOUS YEAR.
( PLF IN PERCENTAGE )

2010 - 11
74.73
94.54
66.38
96.21
101.30
97.65
95.20
80.97
96.23
100.01
104.11
100.02
2009 - 10

2010 - 11

S
ip
at

2009 - 10
98.51
86.20
92.72
85.52
102.21
100.02
95.47
99.14
99.17
98.56
100.38
-

M
et
tu
r
Ta
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S
im
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i

STATION
North Chennai
Neyveli
Raichur
Tuticorin
Ramagundam
Muddanur
Kothagudam
Vijayawada
Mettur
Talcher
Simhadri
Sipat
120.00

PLF

PLF PERCENTAGE

100.00

80.00

60.00

40.00

20.00

N
ey
ve
li
R
ai
ch
ur
Tu
tic
R
or
am
in
ag
un
da
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M
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da
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K
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da
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V
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w
ad
a

N
or
th

C
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nn
ai

0.00

UNIT

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