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Centre For Power Efficiency And Environmental |
Procedure Number |
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NTPC |
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Protection, NOIDA |
CENPEEP/EFF/TP/401 |
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TITLE |
Routine Station Auxiliary |
Rev. 2 /EMS |
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Issue Date: 20/04/2000 |
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CENPEEP |
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Power Survey |
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Page: 1 |
Of 8 |
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INITIATION CONDITION: |
Semi-Annually |
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OBJECTIVE : Determine the amount of Power being consumed by the primary plant equipment.
UNIT # |
DATE |
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ROUTING |
START: |
Date/Time |
FINISH: |
Date/Time |
TEST ENGINEER (TE):
REFERENCE: ASME PTC 19.6-1955 and TVA Proc. No. TS/PERF/RTST/FOS/16.0
_________________________________________________________________________________
Instruction: Steps should be performed in the sequence given. Document the completion of each step by placing “check” in the “CK” column. Document missed Targets in the “Comments” column. Take corrective action on missed Targets.
NO. |
WHO |
WHAT |
HOW |
INDICATOR |
TARGET |
COMM |
OK |
The Station Auxiliary Power Survey (Service Survey) can provide an indication of equipment condition, in addition to determining net unit generation. If data is obtained at approximately the same Load & operating parameter, trends can be established to detect changes in power consumption. Significant changes will prompt to further
investigations to determine why the component is performing in an |
unexpected manner. |
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01 |
TE |
Make appropriate |
Notify Shift Supervisor |
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notification |
of the date and time of |
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the test to request steady |
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operation of all pertinent |
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equipment through the |
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test period |
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Notify Unit Operator of |
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locations where test |
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equipment will be |
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installed. |
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Notify maintenance so |
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that no required |
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equipment will be |
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requested out of service |
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during the test. |
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02 |
TE |
Have necessary test |
Have all kWh meters |
Potential and |
Operable |
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equipment installed |
installed on the correct |
indicating |
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unit |
lights |
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03 |
TE |
Conduct any training |
Walk-thru a practice test |
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necessary for data |
run, instructing data |
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taker(s) to |
takers as necessary |
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successfully perform |
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their tasks |
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Centre For Power Efficiency And Environmental |
Procedure Number |
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NTPC |
Protection, NOIDA |
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CENPEEP/EFF/TP/401 |
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TITLE |
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Rev. 2 /EMS |
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Routine Station Auxiliary |
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Issue Date: 20/04/2000 |
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CENPEEP |
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Power Survey |
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Page: 2 |
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Of 8 |
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CMC – Coordinated Master Control |
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NO. |
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WHO |
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WHAT |
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INDICATOR |
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TARGET |
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COMM |
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OK |
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04 |
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TE |
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Conduct a pre-test |
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Briefly review data |
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meeting including |
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taker(s) responsibilities. |
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the Unit Operator |
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(UO) on the |
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respective unit. |
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05 |
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Ask the Unit Operator to |
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notify you immediately if |
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unit operating conditions |
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change. |
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NOTE |
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to maintain the continuity of the performance trends, the target load conditions should closely match |
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those of previous tests performed. |
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06 |
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TE/UO |
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Verify Unit Load |
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CMC status ( if unit is |
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AUTO control |
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Not lit |
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Control (CMC) and |
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equipped with CMC) |
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Button |
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steady. |
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07 |
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Unit has remained |
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constant at target load for |
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20 minutes. (Through |
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CMC or manual control) |
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08 |
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TE |
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Conduct station |
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Take data utilizing the |
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Service Survey Test |
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data sheets (Appendix A) |
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or similar |
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NOTE: Test data should span a 24 hour period. If unit conditions do not allow those, extrapolations can be made.
09 |
TE/UO |
Return unit to |
Notify UO that testing is |
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normal |
complete |
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UO returns CMC controls |
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to normal if desired. |
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Notify Shift Supervisor |
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that testing is complete |
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Ensure that all test |
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equipment is removed. |
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Notify Unit Operator that |
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all test equipment has |
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been removed. |
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Notify Shift Supervisor |
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that all test equipment has |
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been removed. |
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10 |
TE |
Calculate Results |
Calculate TOTAL |
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STATION SERVICE |
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usage using Appendix B |
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Calculate PULVERIZER |
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kWh PER TON, using |
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Appendix B. |
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Centre For Power Efficiency And Environmental |
Procedure Number |
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NTPC |
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Protection, NOIDA |
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CENPEEP/EFF/TP/401 |
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TITLE |
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Rev. 2 /EMS |
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Routine Station Auxiliary |
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Issue Date: 20/04/2000 |
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CENPEEP |
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Power Survey |
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Page: 3 |
Of 8 |
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11 |
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TE |
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Analyze Results |
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Plot TOTAL STATION |
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SERVICE Usage and |
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PULVERIZER kWh PER |
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TON on control charts or |
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time line graphs showing |
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historical and expected |
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data. |
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TREND OTHER |
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EQUIPMENT AS |
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DESIRED |
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Look for gaps, adverse |
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trends, sudden changes |
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etc. |
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Identify areas for possible |
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improvement. |
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12 |
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TE |
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Issue Report |
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Narrative describing any |
Issued < 30 |
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unusual findings |
days |
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Copy of Plots |
Issued < 30 |
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days |
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Data listed in tabular |
Issued < 30 |
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form. |
days |
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Equipment: |
kWh Energy Meter of Class + 0.2% |
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Centre For Power Efficiency And Environmental |
Procedure Number |
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NTPC |
Protection, NOIDA |
CENPEEP/EFF/TP/401 |
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TITLE |
Rev. 2 /EMS |
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Routine Station Auxiliary |
Issue Date: 20/04/2000 |
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CENPEEP |
Power Survey |
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Page: 4 |
Of 8 |
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Appendix A
NO. |
EQUIPMENT |
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TIME |
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READING |
TIME |
READING |
METER |
DIFFERENCE |
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NAME |
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BEGAN |
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END |
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CONSTANT |
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Base Time – |
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Begin & End |
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01 |
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Station Load |
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02 |
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Generator Load |
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03 |
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Common Station |
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Service |
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04 |
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Unit Station |
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Service |
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COMMON STATION SERVICE BOARD A * |
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05 |
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Cond. Circ. Water |
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Pump A |
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06 |
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Stat. Serv. & Inst. |
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Air Comp. A |
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07 |
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CT Pump / CWPP |
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COMMON STATION SERVICE BOARD B * |
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08 |
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Cond. Circ. Water |
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Pump B |
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09 |
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Soot Blower B |
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10 |
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CT Pump |
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UNIT STATION SERVICE BOARD A* |
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11 |
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Boiler feedwater |
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Pump A |
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12 |
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FD Fan A |
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13 |
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PA Fan |
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14 |
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ID Fan A |
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15 |
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Fly Ash Water |
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Pump A |
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16 |
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Bottom Ash Water |
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Pump A |
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UNIT STATION SERVICE BOARD B* |
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17 |
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Boiler feedwater |
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Pump A |
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18 |
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FD Fan B |
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19 |
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P A Fan |
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20 |
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ID Fan B |
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21 |
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Fly Ash Water |
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Pump B |
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22 |
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Bottom Ash Water |
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Pump B |
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Centre For Power Efficiency And Environmental |
Procedure Number |
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NTPC |
Protection, NOIDA |
CENPEEP/EFF/TP/401 |
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TITLE |
Rev. 2 /EMS |
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Routine Station Auxiliary |
Issue Date: 20/04/2000 |
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CENPEEP |
Power Survey |
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Page: 5 |
Of 8 |
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APPENDIX A (cont.)
DATA SHEET (cont.)
PULVERIZERS
23Pulverizer A
24Pulverizer B
25Pulverizer C
26Pulverizer D
27Pulverizer E
28Pulverizer F
* Note: Auxiliaries can be selected as per the station systems
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PULVERIZER FEEDER COUNTER |
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Begin |
End |
Difference |
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Time |
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A |
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B |
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C |
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D |
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E |
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F |
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Tons per Feedwater Count-______________ |
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•If Coal Scales are available and in service, data can be taken to determine an average for each count.
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Centre For Power Efficiency And Environmental |
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Procedure Number |
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NTPC |
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Protection, NOIDA |
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CENPEEP/EFF/TP/401 |
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TITLE |
Routine Station Auxiliary |
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Rev. 2 /EMS |
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Issue Date: 20/04/2000 |
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CENPEEP |
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Power Survey |
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Page: 6 |
Of 8 |
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APPENDIX – B |
Calculations |
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UNIT _______________ |
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kWh Per Day |
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kW |
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Unit Gross Load |
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Unit Station Service |
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Common Station Service |
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PULVERISZERS |
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Feeder |
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Tons Per Count |
Tons Per |
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kWh Per |
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kWh Per |
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% Unit Gross Generation |
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Counts |
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Ton |
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Pulv. A |
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Pulv. B |
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Pulv. C |
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Pulv. D |
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Pulv. E |
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Pulv. F |
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Totals |
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METERED UNIT STATION SERVICE |
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Auxiliary |
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kWh/day |
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Percent of Unit Gross Generation |
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Boiler Feedwater Pump A |
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Boiler Feedwater Pump B |
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FD Fan A |
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FD Fan B |
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ID Fan A |
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ID Fan A |
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Hotwell Pump A |
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Hotwell Pump B |
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Fly Ash Slurry Pump A |
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Fly Ash Slurry Pump B |
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Bottom Ash Slurry Pump A |
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Bottom Ash Slurry Pump B |
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TOTAL CONSUMPTION |
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Centre For Power Efficiency And Environmental |
Procedure Number |
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NTPC |
Protection, NOIDA |
CENPEEP/EFF/TP/401 |
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TITLE |
Rev. 2 /EMS |
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Routine Station Auxiliary |
Issue Date: 20/04/2000 |
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CENPEEP |
Power Survey |
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Page: 7 |
Of 8 |
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APPENDIX B |
(cont.) |
CALCULATIONS (cont.) |
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COMMON STATION SERVICE |
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kWh/day |
Percent of Common Station Service Use |
Condenser Circ. Water Pump A
Condenser Circ. Water Pump B
Station Serv. Air Compressor
A,B,C
TOTAL METERED
PRORATE THE COMMONSTATION SERVICE (CSS):
PCSS = [ ( Unit MW/Plant MW) * ( CSS “A” – Unit Loads on CSS “A” +CSS “B” – Unit Loads on CSS “B”)] / Time in Hours
PCSS = ________________________________________
TOTAL PRORATED COMMON STATION SERVICE (TPCSS) :
TPCSS = Metered CSS Total (dedicated to the unit only) + PCSS
TPCSS = ___________________________________
TOTAL STATION SERVICE (TSS)
TSS = Unit SS “A” + Unit SS “B” + TPCSS
TSS = _________________________________________
Percentage of TSS to the Unit Load, |
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% TSS = |
TSS |
x 100 |
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--------------------------- |
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Unit Power
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Centre For Power Efficiency And Environmental |
Procedure Number |
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NTPC |
Protection, NOIDA |
CENPEEP/EFF/TP/401 |
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TITLE |
Rev. 2 /EMS |
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Routine Station Auxiliary |
Issue Date: 20/04/2000 |
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CENPEEP |
Power Survey |
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Page: 8 |
Of 8 |
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D.Analysis:
•Trend Total Station Service (TSS)
•Plot TSS as percentage of unit generation
•Look for deviations
•In case of deviations perform the root cause analysis by observing deviations down the line from common bus to the individual auxiliary level
•Perform analysis on the deviated auxiliary
•Make action plan for correctives
•Repeat the survey after doing the needful to confirm the status
• Refer Fault tree for root cause analysis. Ref: Figure E – 7, Volume I
(For Internal circulation only)
TECHNICAL
SPECIFICATIONS
FOR
PERFORMANCE TEST
EQUIPMENT
Procedure No.: CENPEEP/EFF/INST/501 |
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Rev No. |
: 01/EMS |
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Issue Date |
: April 20, |
2000 |
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CENPEEP |
Centre for Power Efficiency & Environmental Protection |
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National Thermal Power Corporation Ltd. |
A-8A, Sector-24, NOIDA, (U.P.) 201301 India Tel: 011-8-4525197, Fax: 011-8-4538874 email: cenpeep@ntpcrd.ernet.in
2.1 PRESSURE TRANSMITTER RANGE 0 TO 60 KG/SQCM (GAUGE)
1)Smart microprocessor based, analog output, pressure transmitter with digital communication capability shall be furnished with suitable two valve manifolds.
2)Pressure transmitter shall be constructed to withstand 150% of the upper range limit of the transmitter without loss of accuracy as specified.
3)The transmitter shall be of two-wire type with an output signal range 4 to 20 MA DC and shall be based on state of the art, field proven technology. The transmitter shall be microprocessor based with digital communication capability and with local LCD indication for output indication.
4)The electronic transmitter shall meet or exceed the following requirements. PERFORMANCE SPECIFICATIONS:
A)Accuracy: +/-0.075% of span or better including hysterisis, linearity and repeatability of pressure sensor for span from 1:1 to 10:1 of URL.
B)It shall have 12 point calibration (six rising and six falling) the calibration shall be as per BS6447 (or equivalent), calibration data is to be supplied for each transmitter.
C)Stability: +/-0.1% of URL for 6 months.
D)Operating temp range:
i)for sensor – 0 to 85 oC.
ii)for electronics and housing – 0 to 80 oC.
E)Temp variation effect: max. Of 0.015% per 3 oC with respect to the calibration temp.
F)Power supply range: 12V to 45 V DC.
G)Humidity range: 0 to 95 %
5)Transmitters shall be able to drive an output impedance of 500 OHMS minimum.
6)Transmitters shall be provided with test point connection and output terminals physically separated from other electronics so that transmitter electronics as not exposed during testing and terminations.
7)Transmitter measuring element assembly shall have SS316 diaphragms, stainless steel body and high tensile carbon steel bolts.
8)Transmitters shall be provided with suitable drain and vent points for the measuring element either on the instrument body or on the manifold.
Section: 2.1 Page 1/6
9)Transmitters shall be provided with IP-55 dust tight and weather proof housing with durable corrosion resistant coating.
10)All connections for electric wiring shall be provided with threaded holes or knockouts for electrical conduit connections not smaller than ½ inch nominal size.
11)Accessories :
a)each transmitter shall be provided with manifolds as per the following specification:
1)type: two valve/ (three valve for DP transmitters)
2)material: SS 316
3)inlet/outlet: 1/2 inch NPT (F)
4)test and drain connections: ¼ inch NPT(F) with drain plug.
5)body and bonnet: SS 316
6)gland packing of PTFE/ABS rings suitable for the pressure and temperature rating of 400kg/sqcm at 260 oC
7)the process connection to the transmitters shall be through Swagelok type compression fittings both at the transmitter end and the process end. The compression fittings shall be suitable for S.S. capillary specified below:
b)- 1) S.S. capillary for connecting the process pipe to the transmitter inlet port. Capillary size: 3 MM O.D. & 1 MM I.D. length – 1.5 meters.
- 2) compression fittings for the capillary connections on the transmitter end & the processor end.
-3) the fittings should be of ‘Swagelok’ type S.S. compression fitting with ½ inch
&¼ inch male thread connection for process end & transmitter end respectively and compression end size suitable for 3MM capillary.
c)each transmitter shall be provided with a two meter long shielded signal cable
(Beldon E-88761-E-108998 series or equivalent) of minimum 16 AWG conductor size and suitable for 200 oC temperature. The cable shall have teflon insulation for individual cores and overall teflon insulation. This signal cable shall be provided with suitable lugs for screwed terminations at both ends (transmitter and D.A.S. I/O termination unit). Also suitable gland for connections at transmitter end are to be provided with signal cables.
d)Hand held communication unit suitable for pressure and differential pressure transmitters: total quantity 1 no.
e)Shielded extension cable of following length (as specified in C above) are to be
supplied: 20 meter length - meter length – (quantities as per the requirement) 12) Transmitter shall be equipped with all accessories for specified service conditions. Note:
1.Other ranges to have same specifications as above for gauge/absolute pressure transmitters.
2.Manifold is optional
Section: 2.1 Page 2/6
3.Quantities of extension cables can be decided on the basis of plant layout requirements and location of test stations
Section: 2.1 Page 3/6
Technical Data Sheet: Pressure Transmitter: Range 0 to 60 kg/cm2
The following data shall be furnished for the equipment model quoted.
Sl.No. |
NTPC Requirements |
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Vendor Compliance |
Remarks / |
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Deviations |
1. |
Manufacturer’s Name |
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2. |
Model No. |
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3. |
Ordering Code |
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4. |
Smart Range Pressure transmitter with |
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microprocessor, analog output with digital |
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communication capability with suitable two |
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valve manifolds |
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5. |
Upper Range limit of 150% without loss of |
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accuracy as specified |
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6. |
a) |
Two wire type with an output signal range |
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4 - 20 mA DC with state of art and field |
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proven technology. |
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b) |
Microprocessor based with digital |
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communication capability and with local |
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LCD indication for output |
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7. |
Performance Specifications: |
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a) Accuracy: + / - 0.075% of span or better |
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including hysteresis, linearity, and |
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repeatability of pressure sensor for span |
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from 1:1 to 10:1 of URL |
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b) |
12 point calibration data sheet as per |
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BS 6447 (or equivalent) to be supplied |
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for each transmitter. (six rising or six |
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falling) |
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c) Stability: + / - 0.1% of URL for 6 months |
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d) |
Operating temperature |
range: |
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(iii) for sensor – 0 to 85 oC |
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(iv) for electronics and housing – |
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0 to 80 oC |
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e) |
Temp. variation effect: Max. of 0.015% |
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per 3 oC with respect to the calibration |
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temperature. |
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f) |
Power Supply Range: 12V to 45V DC |
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g) |
Humidity range to 0 to 95%` |
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8. |
Output impedance of 500 Ohms minimum |
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Sl.No. |
NTPC Requirements |
|
Vendor Compliance |
Remarks / |
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Section: 2.1 Page 4/6
Deviations
9.Test point connection and output terminals physically separated from other electronics so that transmitter electronics is not exposed during testing and terminations
10.Element measurement assembly shall have
SS 316 diaphragms, stainless steel body and high tensile carbon steel bolts
11.Suitable drain and vent points for measuring element
12.IP 55 dust tight and weather proof housing with durable corrosion resistant coating
.
13.Connections for electric wiring with threaded holes or knock outs for electrical conduct connections not smaller than ½ inch nominal size
14.a) Accessories: Manifolds as per the following specifications:
b)Type: Two valve
c)Material : SS 316
d)Inlet/Outlet: ½ inch NPT(F)
e)Test and drain connections: ¼ inch NPT(F) with plug
f)Body and bonnet: SS 316
g)Gland packing of PTFE/ABS rings
suitable for the pressure and temperature rating of 400 kg/cm2 at 260 oC
h)SS Capillary for connecting the process pipe to the transmitter inlet port.
Capillary size: 3 mm O.D & 1 mm I.D
Length – 1.5 meters
i)Compression fittings for the capillary connections on the transmitter end and the process end
iii)The fittings should be ‘Swagelok’ type S.S compression fitting with ½ inch
Section: 2.1 Page 5/6
and ¼ inch male thread connection for process end and transmitter end respectively
i)To be provided with meter long Shielded signal cable (Beldon E-88761- E-108998 series or equivalent) of
minimum 16 AWG conductor size and suitable for 200 temperature and overall teflon insulation. Signal cable shall be provided with suitable lugs for screwed terminations at both ends.
(j Hand held communication unit suitable for pressure and differential
pressure transmitters: total quantity 1 no.
(k Shielded extension cable of following length (as specified in C above) are to be supplied : 20 meter length &
50 meter length
15.Equipped with all accessories for specified service conditions
16.Documents: Operation & Maintenance manual (2 sets)
Note: A) Data sheets to be submitted along with the offer clearly indicating deviations, if any.
B)Detailed Quality Plan & Type test report after ordering to be submitted for approval
C)Test & Guarantee Certificate to be submitted before the dispatch clearance
Maintenance: After sales maintenance support to be available in India through authorized representative or directly.
Section: 2.1 Page 6/6