- •5.3 Test Instructions
- •Table of Allowable Rapid Fluctuations of Certain Key Measurements.
- •5.5.6 Data Verification
- •5.6 Results
- •5.7 Analysis
- •5.7.1 Method of Trending Results
- •5.8 Report
- •HP / IP Turbine Efficiency Test
- •Typical Control Room Data Sheet
- •Point ID
- •Condenser
- •Annexure - I
- •CONDENSER DESIGN DATA
- •Annexure - II
- •TEST READINGS
- •Annexure - III
- •TYPICAL CONTROL ROOM READINGS
- •UNITS
- •kcal/hr
- •3.0 Working And Test Set Up
- •TEST ENGINEER (TE):-----------------------------------------
- •ENGINEERING REVIEW
- •PERSONNEL REQUIRED
- •TEST CREW ORIENTATION
- •REFERENCE DRAWINGS
- •LEAK DETECTOR OPERATION
- •TEST LOG
- •ACCESSIBILITY
- •CONTROL ROOM / UNIT DATA
- •LIST OF INSTRUMENTS & ACCESSORIES REQUIRED FOR AIR-IN-LEAK TEST
- •L. P. Turbine
- •*Total time from leak sensing by instrument to retrieval to zero (0)
- •Unit
- •LOW FEED WATER TEMPERATURE
- •EXCESSIVE MAKEUP
- •HIGH WATER LEVEL
- •EXCESSIVE NUMBER OF TUBES PLUGGED
- •HIGH DRAIN COOLER APPROACH TEMPERATURE (DCA)
- •DRAIN COOLER INLET NOT SUBMERGED
- •IMPROPER SETTING
- •EXCESSIVE TUBE BUNDLE PRESSURE DROP
- •HP Heater Test Data
- •Control Room Readings
- •FAULT TREE
- •LP Heater Test Data
- •Control Room Readings
- •FAULT TREE
- •LOW FEED WATER TEMPERATURE
- •EXCESSIVE MAKEUP
- •WORN VENT
- •HIGH WATER LEVEL
- •TUBE LEAKES
- •HEADER PARTITION LEAKS
- •EXCESSIVE NUMBER OF TUBES PLUGGED
- •HIGH DRAIN COOLER APPROACH TEMPERATURE (DCA)
- •DRAIN COOLER INLET NOT SUBMERGED
- •IMPROPER SETTING
- •EXCESSIVE TUBE BUNDLE PRESSURE DROP
- •EXCESSIVE NUMBER OF TUBES PLUGGED
- •Unit
- •BFP Test Data
- •Typical Control Room Readings
- •Boiler Feed Pump A / B / C
- •Typical DAS Readings
- •Description
- •CONTENTS
- •1.0 Introduction
- •3.1 Process Description
- •4 References
- •4.1 ASME Performance Test Code 4.2 – 1969, Coal Pulverizers
- •5 Prerequisites
- •(A clean air test is performed with the primary air to the mill at full load normal conditions with the mill out of service (normal primary airflow, no fuel flow)).
- •Avg. Velocity
- •6.4 Isokinetic Coal Sampling
- •4.5.2 Unburned in Flyash at Economizer Outlet
- •Summary
- •Dry Gas Loss
- •Gas Temp Leaving AH - Corr. to Design Ambient
- •OBJECTIVE : Determine the amount of Power being consumed by the primary plant equipment.
- •TEST ENGINEER (TE):
- •REFERENCE: ASME PTC 19.6-1955 and TVA Proc. No. TS/PERF/RTST/FOS/16.0
- •BILL OF MATERIALS
- •BILL OF MATERIALS
- •Note: Quantities to be decided as per the requirement
- •2.4 PORTABLE DATA ACQUISITION SYSTEM
- •BILL OF MATERIAL
- •Acquisition
- •EQUIPMENT: Thermocouple wire for flue gas temperature measurement
- •2.9 HIGH VELOCITY THERMOCOUPLE (HVT) PROBE
- •2.11 HIGH VOLUME FLYASH SAMPLER
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Centre For Power Efficiency And Environmental |
Procedure Number |
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NTPC |
Protection, NOIDA |
CENPEEP/EFF/TP/301 |
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TITLE |
Rev. 1/EMS |
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CENPEEP |
Routine Turbine Efficiency Test |
Issue Date: 20/04/2000 |
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Page: 7 |
OF 16 |
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NOTE: Changes in feedwater heater operation affect the extraction flow from the turbine, which directly affects the stage pressures both at the extraction where the change occurs and all extractions above and below this point.
If normal conditions cannot be obtained, station may prepare an appropriate alternate test plan. A test should not be canceled because of abnormal unit operation.
5.3.4.6No Auxiliary Steam Cross Tie to Other Units.
5.3.4.7No Soot Blowing.
5.3.4.8Ensure no Spray Attemperation.
5.3.4.9Other aspects as given in sample Check Sheet enclosed.
CAUTION: Care must be exercised when operating at full load with reduced pressure. The steam generator manufacturer should be consulted prior to operation at VWO (Value Wide Open) with reduced main steam pressure. Operating in this mode could result in steaming in the economizer and can upset the circulation in natural circulation steam generators. In addition, the latent heat of vaporization is greater at lower pressures, requiring more heat release in the furnace, which may worsen the problem.
5.3.4.10 Verifying Steady State Operations
The Test Engineer is responsible for ensuring that the unit has reached steady state before beginning a test run. Generally, the specifications listed in ASME PTC 6-1976-Steam Turbines, Table 3.1 are followed, but the Test Engineer may, at his own discretion, make this determination. The Test Engineer should include a statement in the test log describing the circumstances requiring the ASME specifications.
Certain permissible rapid fluctuations in steady state conditions are allowed. A rapid fluctuation is one whose frequency is twice the frequency of the readings. See table below:
Table of Allowable Rapid Fluctuations of Certain Key Measurements.
Measurement |
Permissible Rapid Fluctuation |
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Centre For Power Efficiency And Environmental |
Procedure Number |
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NTPC |
Protection, NOIDA |
CENPEEP/EFF/TP/301 |
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TITLE |
Rev. 1/EMS |
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CENPEEP |
Routine Turbine Efficiency Test |
Issue Date: 20/04/2000 |
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Page: 8 |
OF 16 |
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Main Steam Pressure |
+/- 0.25 percent of the absolute pressure or |
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0.3 kg/cm2, whichever is larger. |
Main & Reheat Steam Temperature |
+/-2.0 o C where superheat is 15 to 28o C; |
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+/- 3.0o C where superheat is greater than 28o C. |
Main Steam or Feed Water Flow |
Refer to ASME PTC 6-1996, |
Gross Generator Output |
+/- 0.25 percent. |
Turbine Speed |
+/- 1.0 percent. |
HP Turbine Exhaust Temperature |
+/- 3.0o C. |
Condenser Pressure |
+/- 0.0015 kg/cm2 or +/- 1.0 percent of the |
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absolute pressure, whichever is large |
Makeup |
+/- 0.25 percent. |
Measurement |
Permissible Rapid Fluctuation |
Hotwell and DA Storage Tank Level |
+/- 1.0 percent |
Firing Rate/Feeder Speed |
+/- 1.0 percent |
Furnace Exit O2 |
+/- 0.25 percent |
Note: The unit should be operated at steady state through the test run .Upsets such as soot blowing and sluicing should be avoided. However, should any operation become necessary during the course of the test which will upset steady state operation, the Test Engineer will, at his discretion, decide whether to continue data collection or to abort test
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5.4Installation of Test Equipment
The turbine test equipment can be divided into three major systems: Instrumentation, Network Equipment and the Control/Data Acquisition System. The instrumentation that must be installed for the turbine test consists of RTDs, Pressure Transmitters and Pressure Transmitter Power Supply equipment.
5.4.1RTD Installation and Removal
Installation
5.4.1.1Locate thermowell
5.4.1.2Using gloves, remove thermowell cap
5.4.1.3Ensure thermowell is clean, remove debris if necessary
5.4.1.4Ensure thermowell is polished
5.4.1.5Insert RTD, making sure good contact with bottom of well
5.4.1.6Secure RTD such that it is held firmly against bottom during use
5.4.1.7Position the cable and cable leader such that the point of the RTD shaft and cable leader meet is not stressed
5.4.1.8Insulate RTD such that the shaft of the RTD is not exposed to ambient temperature atmosphere
5.4.1.9All RTDs installed
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Centre For Power Efficiency And Environmental |
Procedure Number |
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NTPC |
Protection, NOIDA |
CENPEEP/EFF/TP/301 |
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|
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|
TITLE |
Rev. 1/EMS |
|
CENPEEP |
Routine Turbine Efficiency Test |
Issue Date: 20/04/2000 |
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Page: 9 |
OF 16 |
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Removal
5.4.1.10Disconnect the cable from RTD leader
5.4.1.11Remove any securing devices, and temporary test insulation
5.4.1.12Using gloves, carefully remove RTD from thermowell
5.4.1.13Replace thermowell cap
5.4.1.14All RTDs removed
5.4.2Pressure Transmitter Installation and Removal
Installation
5.4.2.1Identify tap-in location
5.4.2.2Verify that sense line is isolated from system pressure
5.4.2.3Vent sense line if possible
5.4.2.4Remove plug/cap at tap-in location
5.4.2.5Attach pressure transmitter capillary tube to tap-in
5.4.2.6Ensure all connections are tight
5.4.2.7Slowly open sense line isolation valve
5.4.2.8Vent transmitter, using vent plug, until all the air is removed from sense line and capillary tube
5.4.2.9Check for leaks
5.4.2.10Attach test cable to pressure transmitter leader such that leader is not stressed
5.4.2.11All pressure transmitters installed
Removal
5.4.2.12Verify sense line is isolated
5.4.2.13Vent transmitter and leave vent open
5.4.2.14Disconnect pressure transmitter capillary tubing from tap-in location
5.4.2.15Replace cap/plug
5.4.2.16Slowly open sense line isolation valve and check for leaks
5.4.2.17All pressure transmitters removed
5.4.3Transmitter Power Supply Setup
5.4.3.1Choose a location for the power supply that is central to the transmitter it will deny access to the other plant equipment, and is isolated from harsh environments
5.4.3.2Locate nearest plant power outlet
5.4.3.3Run extension cords to transmitter
5.4.3.4Identify power supply inlet and outlet side
5.4.3.5Connect cable from pressure transmitter to inlet side of power supply
5.4.3.6Connect cable from power supply outlet to data acquisition module
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Centre For Power Efficiency And Environmental |
Procedure Number |
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NTPC |
Protection, NOIDA |
CENPEEP/EFF/TP/301 |
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|
TITLE |
Rev. 1/EMS |
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CENPEEP |
Routine Turbine Efficiency Test |
Issue Date: 20/04/2000 |
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Page: 10 |
OF 16 |
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5.4.3.7When all transmitters using the power supply are connected, energize the power supply
5.4.3.8Request Test Engineer to perform a scan to ensure pressure transmitters functioning properly
5.4.3.9Troubleshoot network if necessary
5.4.3.10 All transmitters functioning normally
5.4.4Data Acquisition System Module Setup
5.4.4.1Identify modules required for station
5.4.4.2Choose a location for the power supply that is central to the transmitters it will service, out of high traffic areas, doesn’t deny access to other plant equipment, and is isolated from harsh environments
5.4.4.3Identify first module (# of module)
5.4.4.4Connect remaining in ascending channel order
5.4.4.5Label modules with masking tape, identifying which channels are associated with module
5.4.4.6Set dip switch for modules
5.4.4.7Locate nearest plant power supply suitable for the modules power supply
5.4.4.8Run extension cords from plant outlet to power supply
5.4.4.9Connect network communication cable to A/D module
5.4.4.10Energize the A/Ds power
Caution: Do not energize the A/Ds until entire network is connected. Do not make any connections to the data acquisition modules once power has been applied, although measurement inputs such as RTDs and transmitters can be connected while module is energized.
5.4.5Computer Link to Data Acquisition System
5.4.5.1 Connect computer to gateway interface (7011) or to the first station
provided it starts with measurement processor (A/D 7017,7221,7320, or7321) using RS-232 cable.
5.4.5.2Run communications cable making sure cable is out of high traffic areas, does not deny access to other plant equipment, 3 to 4 meters above floor and isolated from harsh environments.
5.4.5.3After computer is linked to the first station, the first station is linked to the second station, the second to the third, and so on until all stations are linked.
5.4.5.4Connect a 24 volt DC power supply to the gateway interface and each measurement processor (A/D)
5.4.5.5Verify that the system is networking (communicating)
5.4.5.6Request Test Engineer to run a test scan to ensure system is functioning properly