COMMISSIONING BEST PRACTICES AN EXPERIENCE SHARING

Transcription

1 IPS 2012 Power Plant O&M Event- NTPC Anchored COMMISSIONING BEST PRACTICES AN EXPERIENCE SHARING - Subrata Ghosh - VP(O&M) - Manoranjan Pai Addl VP (Commissioning) (4 X 300 MW Rosa Thermal Power Project)

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4 Recent Achievements Unit-3 Synchronized for the first time on 23rd Dec 11 within 668 days from Boiler Erection start date. Synchronization followed coal firing on same day. Full load achieved within 108 hrs from synchronization without any outage. Commercial Operation declared on 1 st Jan 2012 (24:00hrs) within 9 days from synchronization without any outage.

5 Project Milestone - A Comparison Sl Milestones Unit-1 Unit-2 Unit-3 Date Duration from Boiler Erection Date Duration from Boiler Erection Date Duration from Boiler Erection (Days) (Days) (Days) 1 Start of Boiler Erection 20-Feb Jun Feb Unit 24-Dec Jun Dec Synchroniza tion 3 First Coal Firing 4 First Full Load 30-Dec Jun Dec Feb Jun Dec COD 12-Mar Jun Jan

6 Commissioning strategy Commissioning Management System Incorporating Modifications Learning Implementation High Quality Commissioning Implementing O&M Feedbacks Safety & Quality Practices Adherence to Project Schedule

7 Directing & coordinating commissioning group Punch point resolution Overall commissioning control Defect reporting mechanism Carrying out actual commissioning of systems & equipments under supervision of OEM Apex Committee CPD, Head O&M, SEC Representative, Engineering Head, Corp. Operation representative Coordination Committee R- Power commissioning coordinator, Engineering representative, SEC commissioning coordinator, Corporate Operation Representative Commissioning Group Commissioning management committee R- Power Operation Engineers R- power maintenance Engineers EPC Construction Engineers SEC/ OEM Engineers

8 Role of Apex Committee Provide strategic oversight Managing interface activities Ensuring resource availability Reviewing the planning and issuing guidelines. O&M Head, Construction Head, OEM representative Providing resource & support Formulate strategy Commissioning Group Removal of bottlenecks Review and resolve bottlenecks

9 Role of Coordination Committee To work in coordination with apex committee Planning & execution of all commissioning activities. Preparation of all Commissioning related documents Ensuring resource deployment Reviewing the progress & commissioning work quality Archiving all commissioning documents Comm. Manager, Engineering representative, OEM Planning, organizing and management of all commissioning work Approve commissioning test results Systematic progression of operations Meeting with conveners, EPC & OEM

10 Commissioning Group Responsible for carrying out day to day commissioning Close coordination with OEM, EPC & Associates Owner Group Operation & Commissioning Engineers Owner Group Maintenance Engineers Identify and arrange special T&Ps, spares, services etc. Carrying out all Tests & preparing protocols Getting protocols signed by all EPC construction Engineers OEM Engineers & EPC associates Meeting with conveners, EPC & OEM concerned.

11 Safety and Quality Quality checks and Observation List generation Regular visits with Quality Deptt. Deviations are sent to EPC Interface meeting with EPC and resolution Safety & Quality Commissioning procedures Detailed commissioning procedures Contain details of checklists, protocols, electrical, Instruments and P&ID Safe Commissioning & Implementation of SCC and PTW Issue of safety clearance certificate Coverage under PTW

12 Safety and Quality Local Protection Boxes Fore bay fill test Flushing of CW return line Pre light up GD test APH oil carry over probe ESP ATT with additional blower Citric acid cleaning after acid cleaning N2 capping Mock trial of critical operation LFFD & external flusher with 1 micron filter Drum level & furnace pressure in auto during steam blowing

13 Modifications During Erection Diversion of HPGV Leak Off line from HPH-6 to condenser Provision of manual drain to Atmosphere for MS/CRH/HRH Provision of extra tie rods in CW Pipe lines and additional ARVs Mechanical level indicators for ash hopper Ash Level indications changed from ESP CR to AHP CR Ash Conveying line size changed from 200 mm to 250 mm Provision of bolster in NMEJ

14 Deficiency resolution strategy Involvement of O&M and commissioning ensured in all stages of erection. Deficiencies identified got resolved within time bound schedule. Project director is empowered for deficiency resolution. Intervention of apex committee if deficiency not resolved within 72 hours.

15 O&M Feedback Critical hangers cross checking by expert Deployment of skilled manpower in all areas Repeated ATT of boiler Thorough inspection & identification of other defects in steam blowing Checking of dampers & gates for proper isolation Readiness of mills & feeders before synchronization M/C alignment & lub oil quality cross checking All PC pipe couplings, MDVs & feeder body bolts tightness Provision of Platforms in all working locations All welding joints of furnace, APH body, ducting leakage points Checking before insulation

16 O&M Feedback DP of all lube oil filters monitored and immediate action taken SCAPH testing & charging done and made 100% ready Deployment for recording and analyzing instrument response \ Deployment of skilled manpower in all areas Verifying the logic on offline server as per SAMA Thorough checking of all ESP fields Normalization of field instruments after process establishment Provision of additional air washer tank nozzle Tuning of available auto control loops soon after process stabilization Ensuring sufficient seal water pressure for ash vac p/ps Integration of all the systems/loops Proper anchoring for bottom hopper refractory

17 Learning from other projects & Rosa Stage I Feedback from other projects were studied by a task force consisting of Engineering, Commissioning, Erection and O&M team and a total of 55 modifications were identified and implemented in Rosa. In the second phase, based on Rosa Stage-1 learning a list consolidating all issues/modifications had been prepared by consulting various disciplines involved in Phase I. This list got further refined after discussion with engineering and an action plan was formulated with EPC to implement these modifications. These modifications were made a part of commissioning procedure for Phase II avoiding any chance of non tracking. Status of modification has been reviewed with EPC and O&M on regular basis.

18 Benefits Successful unit commissioning within scheduled time with intensive involvement of O&M. Adopted strategy ensured clear role clarity for sub groups Risk analysis in each activity and maintaining contingency plans for emergencies strengthened confidence in team. Regular brain storming with Engineering department and OEM helped in finding immediate solutions to technical and quality issues faced at site. Planning of resources and material in advance to maintain desired pace of commissioning activities. Strict adherence to Commissioning checklist and 100% implementation of protection system ensured no tripping from synchronization to COD completion.

19 Conclusion Constant construction monitoring ensures freedom from trouble and assurance of quality and maximum output. Monitoring involves setting up of objectives, assessment of critical items, planning and organization, personnel management, contract management and adoption of an appropriate mechanism for reducing time and cost over-runs. Rosa Unit 3 commissioning activities are some examples of objective construction monitoring with an eye to strike a balance between cost over-runs and quality compliance.

20 Thank You Confidential Slide

21 Oil carry over probe Improvement initiative In view of the recent APH fire in one of the power station in country, initiative was taken immediately & APH oil carry over probe was developed & manufactured at site & fitted in all units.

22 Non Metallic Expansion Joints (NMEJ) NMEJ in position Outer fabric cloth. The quality supplied by SEC was also poor as physically observed. Bolster: The NMEJ with this design was procured & fixed. Bolster is place between fabric & inner surface. Problem Frequent failure of NMEJs in stage I APH hot air duct which caused unit tripping. Supplied by SEC. In adequate strength of fabric, improper storage during erection & design deficiency being the main reasons Solution Replaced with better quality & design indigenously with bolster arrangement. Done in all units.

23 Mechanical Indicators provided for effective monitoring of ESP hopper levels to ensure proper evacuation of the hoppers. ESP Hopper Draft line