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    Precommissioning Load Trial

    Uploaded by

    yinkaakins2001
    The document provides information on pre-commissioning and commissioning activities for a steam turbine. Pre-commissioning includes steam blowing of pipes to remove particles, condenser testing including leak and vacuum drop tests, checking bearing clearances and dumps, setting throttle valves and safety trips. Commissioning includes load trials to check performance and satisfy customer requirements. Key steps involve starting the barring gear, warming up steam pipes, verifying overspeed trips, monitoring vibration and temperature levels under solo run and load run tests.

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    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd

    Precommissioning Load Trial

    Uploaded by

    yinkaakins2001
    630 views47 pages
    The document provides information on pre-commissioning and commissioning activities for a steam turbine. Pre-commissioning includes steam blowing of pipes to remove particles, condenser testing including leak and vacuum drop tests, checking bearing clearances and dumps, setting throttle valves and safety trips. Commissioning includes load trials to check performance and satisfy customer requirements. Key steps involve starting the barring gear, warming up steam pipes, verifying overspeed trips, monitoring vibration and temperature levels under solo run and load run tests.

    Original Description:

    Step by step guide to pre-commissioning activities for 6.6 MW steam turbine for power generation

    Copyright

    © © All Rights Reserved

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    The document provides information on pre-commissioning and commissioning activities for a steam turbine. Pre-commissioning includes steam blowing of pipes to remove particles, condenser testing including leak and vacuum drop tests, checking bearing clearances and dumps, setting throttle valves and safety trips. Commissioning includes load trials to check performance and satisfy customer requirements. Key steps involve starting the barring gear, warming up steam pipes, verifying overspeed trips, monitoring vibration and temperature levels under solo run and load run tests.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    630 views47 pages

    Precommissioning Load Trial

    Uploaded by

    yinkaakins2001
    The document provides information on pre-commissioning and commissioning activities for a steam turbine. Pre-commissioning includes steam blowing of pipes to remove particles, condenser testing including leak and vacuum drop tests, checking bearing clearances and dumps, setting throttle valves and safety trips. Commissioning includes load trials to check performance and satisfy customer requirements. Key steps involve starting the barring gear, warming up steam pipes, verifying overspeed trips, monitoring vibration and temperature levels under solo run and load run tests.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 47

    BY:

    NAGESH H

    PRE COMMISSIONING : The activities carried out before


    passing steam to the turbine is called pre commissioning.
    COMMISSIONING: The activities carried out to ensure
    turbine performance is as per design is known as commissioning.

    SUBBURAJ PAPER PVT LTD


    TECHNICAL DATA

    PRE COMMISSIONING
    STEAM BLOWING
    CONDENSER TEST
    BEARING CLEARANCE, FLOAT, DUMP OF ROTOR,GEAR

    AND PINION
    THROTTLE VALVE SETTING
    ALL SAFETY TRIP FUNCTIONING AND RESPONSE OF SEV

    STEAM BLOWING
    The purpose of blowing the steam lines prior to starting

    up a new unit is to remove any foreign particle remaining


    in steam inlet pipeline.
    The principle behind steam blowing is thermal cycling i.e
    heating of pipe lines by blowing steam & cooling. This
    will tend to break mill scale / weld slag away from the
    pipe wall due to difference in co-efficient of thermal
    expansion.

    EQUIPMENTS
    Temporary piping
    Temporary piping support
    Silencer
    Target plate

    PROCEDURE FOR STEAM BLOWING.


    Disconnect steam inlet pipe
    from turbine emergency stop
    valve
    2. Arrange for target plate of
    mirror finished aluminum of
    thickness 10 to 12 mm to be
    fitted at 1 meter away in the
    temporary blowing line. which
    is placed in the main steam line
    by making a fixture
    3. During the blowing down
    process open all the drain lines
    from boiler to inlet pipe flange
    4. Steam blows should be carried
    out by fully opening the
    isolating valve.
    1.

    TARGET
    PLATE

    STEAM INLET

    SUPPORTING PLATE

    PROCEDURE FOR STEAM BLOWING


    5.

    6.
    7.

    8.

    Bring the boiler press. up to 70 to 80% of


    working press. & temp., blow down the
    steam line until press. drops to 20 to 30%
    of working press./temp. recommended
    by boiler manufacturer and then allow
    the line to get cooled(~40C ) and then
    hammer the steam pipe line near joints .
    Repeat this procedure for three times.
    Now place the target plate in the fixture
    & blow down the steam line and allow it
    to cool.
    This cycle is repeated till we get
    acceptance value , In each cycle continue
    hammering and Stamp the cycle no. on
    the receiving face of the target plate.

    ACCEPTANCE CRITERIA
    Indentation is acceptable when there are no more than 2 dents of
    0.2mm in a 50X50 mm section of target plate.

    PRECAUTIONS
    1.
    2.

    3.

    Check that all pipes are supported properly during blow down.
    Necessary safety precautions must be taken such as fencing of the area
    and providing ear protection against the inevitable noise generated
    during blow down process.
    No one should move around the blowing area

    CONDENSER MASS FLUSHING


    Dummy
    flange

    Objective: To clean the cooling water inlet and


    outlet pipe lines of condenser from cooling pond
    to cooling tower.

    To cooling
    tower at 12 m
    height

    condenser

    Dummy
    flange

    Drain

    2 to 2.5
    kg/sq .cm

    Procedure:
    Place the dummy flanges in cooling water inlet
    and outlet line of the condenser.
    Prepare a temporary pipe line for flushing
    Pump the water from cooling pond till water
    flows out on top of cooling tower and then
    switch off the pump.
    Drain the water .
    Repeat this procedure until the water is clean.

    Chemically treated
    water from cooling
    pond

    CONDENSER TESTS
    1.WATER LEAK TEST:

    EXHAUST
    STEAM

    Pipe line is made from DM water pump to


    condenser shell.
    Fill the condenser with DM water up to the
    bottom of exhaust casing until water leaks
    from the exhaust thermo well of turbine.

    COOLING WATER
    OUTLET

    Ensure that all the pipe lines are filled with


    water which are connected in the vacuum
    system.
    Hold the water up to one hr and observe any
    leakage from the flange and welded joints.
    Ensure that
    system
    HOTWELL

    COOLING WATER INLET

    there is no leakage in the

    Drain the water completely from the system


    after the completion of test

    CONDENSER TESTS
    EXHAUST
    STEAM

    2. VACUUM DROP TEST


    Isolate the turbine from condenser by
    providing a ms plate of approximate 10 to
    15 mm thickness between condenser
    flange and bellow flange provided at
    turbine exhaust flange along with turbine .

    COOLING WATER
    OUTLET

    Fill the condenser hot well


    level

    to normal

    Start hogger ejector and create vacuum to


    the designed value of 0.1 ATA and close
    the hogger ejector
    Check the rate of vacuum drop
    HOTWELL

    COOLING WATER INLET

    Drop in vacuum should not exceed 0.01


    kg/sq.cm in 30 minutes.

    BEARING CLEARENCE
    Place the bottom bearing shells and load the
    rotor on bearings.
    Place a lead wire of 0.7mm thick with a coat
    of grease circumferentially around the top
    half of the journal.
    Place the top half of bearing shell with its
    bearing cap and tighten it.
    Remove the crushed lead wire and measure
    the thickness of the crushed lead wire which
    gives the existing bearing diametrical clearance
    DESCRIPTION

    OBSERVED(mm)

    REQUIRED(mm)

    Rotor fore

    0.21

    0.18-0.23

    Rotor after

    0.21

    0.22-0.26

    Pinion fore

    0.37

    0.37-0.42

    Pinion after

    0.37

    0.37-0.42

    Gear fore

    0.27

    0.25-0.30

    Gear after

    0.26

    0.25-0.30

    Dump check is done to ensure


    minimum clearance b/w rotor &
    nozzle chest and diaphragm nozzle.
    Place the rotor on journal bearing.
    Assemble the top bearing shells
    into the bottom bearings and place
    the bearing cap.
    Insert the active thrust pad into its
    position.

    Dial
    indicator
    position

    Description (Dump) Observed

    Required

    Rotor

    0.72

    0.7-0.8

    Gear

    0.65

    0.40-0.75

    To check the float of the

    rotor ,the same procedure


    has to be followed but the
    rotor movement is
    restricted by using non
    active thrust pad.
    Description Observed

    Require
    d

    Rotor

    0.30035

    0.35

    THROTTLE VALVE LIFT

    MAX.LIFT

    First valve is adjusted by feeler


    gauge and other two valves are
    set by vernier caliper

    PRESSURE SETTING
    Control oil pressure

    14kg/sq.cm

    Bearing oil pressure

    1.9 kg/sq.cm

    Accumulator pre-charge pressure

    12kg/sq.cm

    (80% of control oil pressure)


    Trip circuit oil pressure

    1.5 kg/sq.cm

    VERIFY ALL INTERLOCKS AND ALARMS

    CHECK ALL SAFETY TRIPS

    MANUAL TRIP

    ITEM

    SETTING
    VALUE

    SET
    VALUE

    TRIP PR.

    0.5-0.8

    0.8

    RESET PR.

    0.8-1.2

    SOLENOID
    TRIP

    0.5

    L P TRIP

    LP TRIP

    OVER SPEED TRIP

    0.9
    0.5

    ENSURE THAT SEV AND TV CLOSES


    IN ALL TRIPPING
    SOLENOID
    TRIP

    VIBRATION PROBE SETTING

    PROBES HAS TO BE SET


    FOR 9 to 12VOLTS

    1.TURBINE FORE
    2.TURBINE AFTER
    3.PINION FORE
    4.PINION AFTER
    5.GEAR FORE
    6.GEAR AFTER

    7.ALTERATOR FORE
    8.ALTERNATOR AFTER
    9.AXIAL

    COMMISSIONING AND LOAD TRIAL


    OBJECTIVES:

    To check various pressure settings with in the lube oil and control oil

    system
    To check vibration level with in limits
    Governor take over
    To check the over speed trip and electrical trips are functioning correctly
    To prove performance of machine and to satisfy customer

    COMMISSIONING PROCEDURE FOR SOLO RUN


    TEST AND LOAD RUN TEST
    Start AOP
    Open all drains of steam in turbine
    SEV drain
    Nozzle chest drain
    Wheel case drain
    Casing drain
    Throttle valve drain

    Check oil level in oil tank through oil level gauge and temperature of
    the oil should be minimum 35deg c
    Ensure that cooling water to oil cooler, condenser,GVC is flowing

    Start the motor driven barring gear. An interlock ensures that the baring gear
    can not be started before bearing oil pressure is established i.e 1.5kg/sq.cm
    Run barring gear for a period of 12 hours, if turbine is started first time for
    an SCG 3 turbine.
    Check the vibration level are with in limits
    Allow sealing steam for laby packing's

    START EJECTOR SYSTEM

    VAPOUR FROM
    CONDENSER
    BASIC PRINCIPLE

    MOTIVE STEAM
    HOGGER

    Entrapped gases
    COOLING WATER INLET
    AND OUTLET

    MOTIVE STEAM

    START MOTOR DRIVEN CEP

    Balancin
    g leak
    of
    DISCHARG
    E
    BLO
    DELIVERY

    Suction from hot


    well

    SUCTION

    P=6kg/cm sq

    To ejector
    tubes

    RESET ALL SAFETY TRIPS


    Solenoid trip

    PUSH TO TRIP

    Manual trip
    LP trip

    PULL TO
    RESET

    SOLENOID TRIP
    L P TRIP
    CONTROL OIL LINES
    DRAIN LINE

    MANUAL TRIP

    Crack open the steam supply isolating valve and warm up the
    steam pipe line to turbine SEV
    Reasons for warm up :
    To avoid uneven expansion of pipe line, rotor and casing
    To avoid water hammering effect
    Start GVC blower
    Initially lift the HP actuator lever
    Gradually open the SEV, which should be sufficient for
    warming nozzles and casing.
    After few minutes, when the turbine warmed through and all
    water has been expelled, then partially close the turbine drains

    TURBINE START UP CURVE TO BE FOLLOWED

    1st cs-2600 rpm


    Sudden jump 2300-2900

    CHECK FOR OVER SPEED TRIP AND SET ELECTRICAL TRIP

    SET OVER SPEED TRIP WITH IN THE RANGE OF 110-115% OF


    RATED SPEED
    7829rpm
    Remove material on
    this opposite face if os
    trip is less

    TO INCREASE TRIP SPEED

    Valve

    TURBINE START UP CURVE TO BE FOLLOWED

    TURBINE START UP CURVE TO BE FOLLOWED

    CHECK FOR VIBRATION LEVELS AND TEMPARATURE

    VIBRATION READINGS IN SOLO RUN TEST


    ITEM

    POSITION

    READINGS
    MILS/PP

    ROTOR
    FORE BRG

    0.8

    0.7

    ROTOR
    AFTER BRG

    0.73

    0.42

    PINION
    FORE BRG

    1.75

    1.48

    PINION
    AFTER BRG

    0.74

    0.46

    GEAR FORE
    BRG

    0.25

    0.27

    GEAR
    AFTER

    0.33

    0.42

    X (TOP)

    5.3

    Y (BOTTOM)

    4.2

    BRG
    AXIAL

    LOAD CURVE DURING STABLE OPERATION

    VIBRATION READINGS WITH LOAD RUN TEST


    ITEM

    POSITION

    READINGS
    MILS/PP

    ROTOR FORE BRG

    0.8

    0.64

    ROTOR AFTER
    BRG

    0.51

    0.4

    PINION FORE BRG

    1.8

    1.5

    PINION AFTER
    BRG

    0.68

    0.43

    GEAR FORE BRG

    0.28

    0.38

    0.37

    0.58

    5.3

    DRIVEN MACHINE
    FORE BRG

    0.9

    1.63

    DRIVEN MACHINE
    AFTER BRG

    0.69

    0.55

    GEAR AFTER BRG


    AXIAL

    LOAD TRIAL(PARAMETERS)
    SPEED

    RPM

    LOAD
    STEAM INLET

    MW
    PRESSURE
    TEMP.

    STEAM FLOW

    kg/Sq.cm
    C
    TPH

    WHEEL CASE PR.


    EXTRACTION

    EXHAUST
    PRESSURE
    HOT WELL TEMP
    COOLING WATER

    EJECTOR

    OIL PRESSURE

    BRG TEMP. C

    kg/Sq.cm
    PR.
    TEMP
    FLOW
    PRE.
    TEMP

    kg/Sq.cm
    C
    TPH
    kg/Sq.cm
    C
    C

    1.5
    33.8
    436
    14.3
    4
    0.75
    203
    3.3
    -0.83
    84
    45

    INLET PR
    kg/Sq.cm
    INLET TEMP
    C
    OUT LET PR. kg/Sq.cm
    OUT LET TEMP
    C
    STEAM INLET PR. kg/Sq.cm
    INLET TEMP
    C
    VACCUM PR. kg/Sq.cm
    LUBE OIL
    kg/Sq.cm
    CONTROL OIL kg/Sq.cm
    D.P ACROSS FILTER kg/Sq.cm

    1.6
    19
    1.3
    28
    10
    330
    -0.85
    2.1
    14
    0.1

    ROTOR

    65.8
    82.1
    69.1
    56.6
    51.2
    46.2
    65
    67
    45
    32

    FORE
    AFTER
    FORE
    AFTER
    FORE
    AFTER
    DE
    NDE

    PINION
    GEAR
    ALTERNATER
    COOLER OIL TEMP.

    6822

    INLET
    OUT LET

    C
    C

    COMPARISION OF SPECIFIC STEAM


    CONSUMPTION
    OF MACHINE AT SITE WITH RESPECT TO
    PERFORMANCE CURVE

    ACTUAL STEAM CONSUMPTION


    PARAMETERS

    Inlet steam
    pressure.

    Kg/sq.C
    m

    Inlet steam
    temperature

    Exhaust steam
    pressure

    Kg/sq.C
    m

    Turbine speed

    Rpm

    Electrical load

    Mw

    Total power consumption

    Kwh

    Total steam consumption

    Kg

    PROJECTED
    VALUES

    AVERAGE
    VALUE

    Correction factors

    SL
    NO

    UNITS

    Inlet steam
    pressure
    Inlet steam
    temperature
    Exhaust steam
    pressure
    Turbine speed
    Age factor

    STEAM CONSUMPTION*CORRECTION FACTORS(A,B,C,D)*AGE FACTOR

    SSC =
    SSC =

    POWER GENERATION

    Kg/kwh

    Example: FR 1

    ACTUAL STEAM CONSUMPTION


    Sl
    no

    parameters

    Projected
    values

    Average
    value

    units

    Inlet steam pressure.

    66

    57

    Kg/sq.Cm

    Inlet steam temperature

    490

    502

    Degc

    Exhaust steam pressure

    1.54

    0.8

    Kg/sq.Cm

    Turbine speed

    7055

    6693

    Electrical load

    15

    12.5

    Total power consumption

    25000

    Kwh

    Total steam consumption

    165000

    Kg

    SSC =

    Correction factors
    Inlet steam
    pressure

    0.9

    Inlet steam
    temperature

    1.0

    Rpm

    Exhaust steam
    pressure

    1.0

    Mw

    Turbine speed

    0.965

    Age factor

    1.0

    STEAM CONSUMPTION*CORRECTION FACTORS(A,B,C,D)*AGE FACTOR


    POWER GENERATION

    ACTUAL SSC = 5.73 kg/kWH at average load of 12.5 mw


    PROJECTED SSC = 6.17 kg/kWH at average load of 12.5 mw

    PROBLEM FACED IN SITE


    SITE:SUBBURAJ PAPERS
    Dump was found 0.37 instead of 0.75
    Cause: High points in the nozzle chest seam welding.
    Corrective action: The seam welding in the nozzle chest was blue matched with the shrouding of
    moving blade and some high point was found in welding. welding high points were corrected by
    filing and finally dump was achieved.
    CEP was consuming more than rated current
    Cause: Misalignment of pump and motor

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