Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-122
NTPC Ref no SIM/1/TS/2/122
Plant area: TURBINE
TESTING SCHEDULE FOR COMMISSIONING OF
HP HEATERS
SLNO
LIST OF CONTENTS
1.0
PLANT DETAILS
2.0
OBJECTIVE
3.0
PROPOSAL
4.0
SERVICES REQUIRED
5.0
SAFETY PRECAUTIONS
6.0
EMERGENCY PROCEDURE
7.0
STATE OF THE PLANT
8.0
METHOD
9.0
COMPLETION CRITERIA
Sheet 1 of 9
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-122
NTPC Ref no SIM/1/TS/2/122
Sheet 2 of 9
Plant area: TURBINE
TESTING SCHEDULE FOR COMMISSIONING OF
HP HEATERS
SL.NO
1.0
STATUS
PLANT DETAILS
Regenerative Feed heating system of Simhadri STPP consists of
one drain cooler, three LP Heaters one deaerator and four HP
Heaters.
There are two sets of HP Heater 5A/6A and 5B/6B. Extraction 5A
and 5B are taken from IP Turbine casing. Extraction 6A and 6B
are taken from CRH. The condensed steam after heating the
Feed Water is normally fed to the next lower heater and
emergency drains are provided to HP flash tank.
The technical data for HP Heaters as follows.
1.1
HP Heater 5A and 5B
Type
Medium
Design Pressure
Design Temperature
Test Pressure
Test Temperature
Inlet Temperature
Outlet Temperature
No. of. Passes
No. of . Tubes
Surface area
: Shell and Tube
Shell side
Tube side.
Steam & Drain
2.2 and Full
Vacuum
224
33
Ambient
412.583
170.2
3
Feed Water
320 kg/cm2
224/244 deg C
480 kg/cm2
Ambient
165.5 deg C
203.3 deg C
2
1347
1055 m2
Signatures
NTPC
BHEL
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-122
NTPC Ref no SIM/1/TS/2/122
Sheet 3 of 9
Plant area: TURBINE
TESTING SCHEDULE FOR COMMISSIONING OF
HP HEATERS
SL.NO
1.2
STATUS
HP Heater 6A and 6B
Type
Medium
Design Pressure
Design Temperature
Test Pressure
Test Temperature
Inlet Temperature
Outlet Temperature
No. of. Passes
No. of . Tubes
Surface area
2.0
: Shell and Tube
Shell side
Tube side.
Steam & Drain
52.4 and Full
Vacuum
273
78.6
Ambient
335.25
253.1
3
Feed Water
320 kg/cm2
273/293 deg C
480 kg/cm2
Ambient
203.27 deg C
191.927 deg C
2
1347
1269 m2
OBJECTIVE
To commission 2 sets of HP Heaters 5A/6A and 5B/6B and make
them available for unit operation.
3.0
PROPOSAL
Commissioning of two sets of HP Heaters proposed in the
following steps.
3.1
Commissioning of HP Heaters 5A and 6A
3.2
Commissioning of HP Heaters 5B and 6B
Signatures
NTPC
BHEL
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-122
NTPC Ref no SIM/1/TS/2/122
Sheet 4 of 9
Plant area: TURBINE
TESTING SCHEDULE FOR COMMISSIONING OF
HP HEATERS
SL.NO
STATUS
4.0
SERVICES REQUIRED
4.1
Availability of manpower with required tools for attending any
leak.
4.2
Availability of operating personnel to carryout / coordinate
activities.
4.3
Availability of lighting arrangements and communication facilities
in operating floors.
4.4
Availability of instrument and service air.
4.5
Availability of LT Power Supply.
5.0
SAFETY PRECAUTIONS
5.1
Debris in and around Heaters area shall be removed
5.2
First aid kit is available near the test area.
5.3
Approach / staircase / Platform wherever required are made
available.
5.4
Safety appliances like helmet, hand gloves available for operating
personnel.
5.5
Portable fire extinguisher available near test area.
6.0
EMERGENCY PROCEDURES
The test team should be aware of the procedure to be adopted in
case of damage to machinery / injury of any personnel connected
to the activity.
Signatures
NTPC
BHEL
Station: NTPC - Simhadri
BHEL Ref No. PS - DC - 186 – 500 –122
NTPC Ref No. SIM / 1 / TS / 2/122
Sheet 5 of 9
Plant Area: TURBINE
Testing Schedule: TESTING SCHEDULE FOR COMMISSIONING OF HP HEATERS
STATUS
6.1
The test team should be aware of the procedure to be adopted in
case of damage to machinery / injury of any personnel
connected to the activity.
6.2
The test team should be well aware of the procedures to be
adopted in case of any abnormality in the activity.
7.0
STATE OF THE PLANT
7.1
HP Heaters 5A, 5B, 6A and 6B are erected as per recommended
drawing.
7.2
Detergent flushing of feedwater piping, Heater drain piping are
complete and normalised (including erection of control valves)
7.3
All piping supports are loaded with spring loads to recommended
values.
7.4
7.5
7.6
HP Heaters Stand Pipe, Level transmitters, Level switches and
Level gauge glass are erected.
Startup and continuous vent line with orifice are erected.
Insulation of HP Heaters, Feed water piping, Extraction steam
piping, extraction drain piping, Shell vent piping and heater drain
piping are complete.
Signature
NTPC
BHEL
Station: NTPC - Simhadri
BHEL Ref No. PS - DC - 186 – 500 –122
NTPC Ref No. SIM / 1 / TS / 2/122
Sheet 6 of 9
Plant Area: TURBINE
Testing Schedule: TESTING SCHEDULE FOR COMMISSIONING OF HP HEATERS
STATUS
7.7
Commissioning of following valves associated with the system
are complete
(a) Extraction isolating valves
(b) Extraction steam drain valves
(c) Heaters start up vent valves
(d) Feedwater isolating valves and group bypass valves
for the heaters.
(e) Heaters drain control valves.
7.8
Extraction oil relay for QCNRV of extraction piping are set to
operate at recommended secondary oil pressure.
7.9
Simulation checking of all interlocks and protections are
complete.
7.10
Feed water charged to all Heaters and BFP in service
7.11
All local and remote instrumentation of heaters complete.
8.0
METHOD
8.1
Commissioning of HP Heaters 5A and 6A
8.1.1
Ensure Feed water charged to HP Heaters 5A and 6A, its
bypass isolation closed.
8.1.2
Ensure isolating valves of drain control valves are open.
8.1.3
Ensure level switches, level transmitters and level gauge glass
are charged.
8.1.4
Ensure extraction oil relay in governing rack is set to operate at
required secondary oil pressure.
Signature
NTPC
BHEL
Station: NTPC - Simhadri
BHEL Ref No. PS - DC - 186 – 500 –122
NTPC Ref No. SIM / 1 / TS / 2/122
Sheet 7 of 9
Plant Area: INSTRUMENT / EQUIPMENT
Testing Schedule: ELECTRONIC MODULE OF DDCMIS
8.1.5
Ensure isolating valve in oil line for QCNRV is open and its slide
valve in open position.
8.1.6
Open shell side start up vent for HP Heater 5A and 6A.
8.1.7
Ensure interlock in ATRS for solenoid valve A5 are available
and checked.
8.1.8
Ensure the following interlock protection for any one of Heaters
5A, 6A level very high.
(a) Closure of Extraction steam valves for the HPH bank
(HPH 5A and 6A)
(b) Opening of extraction line drain valves
(c) Bypassing of HPH bank on feed water side
(d) Opening of emergency drain control valve to flash tank
8.1.9
Ensure turbine load more than 40%
8.1.10
Keep feed water valves on auto.
8.1.11
Charge extraction steam to HPH 5A gradually with drain control
valve to flash tank (emergency drain) in open position.
8.1.12
As the heater shell pressure increases more than deaerator
pressure, open drain control valve to deaerator (normal drain).
8.1.13
Build up heater level to normal operating level and ensure
control valve operation on auto.
8.1.14
Observe temperature raise in feed water outlet of heater.
8.1.15
Close startup vent of HPH5A and keep continuous operating
vent in open condition.
Signature
NTPC
BHEL
Station: NTPC - Simhadri
BHEL Ref No. PS - DC - 186 – 500 –122
NTPC Ref No. SIM / 1 / TS / 2/122
Sheet 8 of 9
Plant Area: TURBINE
Testing Schedule: TESTING SCHEDULE FOR COMMISSIONING OF HP HEATERS
8.1.16
Monitor and record the following parameter at various load/full
load
(a) Extraction pressure
(b) Extraction temperature
(c) Heater shell pressure
(d) Drain temperature
(e) Feed water inlet temperature
(f) Feed water outlet temperature
(g) Heater level
(h) Swing check NRV flap positions
(i) Heater level control valve positions
8.1.17
Charge HPH 6 A with extraction steam gradually.
8.1.18
Build up HPH 6A level to normal level with normal level
controller. Keep the emergency controller on quto
8.1.19
Monitor and record all parameters at various load/full load for
HPH 6A as done for HPH 5A.
8.1.20
Ensure Heater levels maintained are
mentioned in drawing
Refer drawing no. 2—175—01—00579
Refer drawing no. 2—175—01—00580
Refer drawing no. 2—175—05—00348
Refer drawing no. 2—175—05—00349
8.2.
in line with the levels
HPH 5A
HPH 5B
HPH 6A
HPH 6B
Commissioning of HP Heaters 5B and 6B commissioning of HP
Heaters 5B and 6B is carried out in the same way as done for
HP Heaters 5A and 6A.
Signature
NTPC
BHEL
Station: NTPC - Simhadri
BHEL Ref No. PS - DC - 186 – 500 –122
NTPC Ref No. SIM / 1 / TS / 2/122
Sheet 9 of 9
Plant Area: TURBINE
Testing Schedule: TESTING SCHEDULE FOR COMMISSIONING OF HP HEATERS
9.0
COMPLETION CRITERIA
9.1
Commissioning of HP Heaters completed by carrying out the
proposals given in Section 3.0
Signature
NTPC
BHEL
TESTING SCHEDULE FOR COMMISSIONING OF
HP HEATERS