Sipat # 5 COD

NTPC Ltd(Corporate Operation services)

Date: 03-12-08

Sub : Report on Sipat - II : For commissioning of unit # 5

1. LHS milling system

2. PA fan # B , FD fan # B & ID fan # B trial run

3. TDBFP # A & B trial run

4. ESP passes C & D readiness

5. Mill rejects handling system

6. Erection of FG I/L duct for ESP C & D passes

7. ESP C & D pass fly ash handling system

8. Wall blowers and LRSBs commissioning

9. Condensate polishing unit

10. CPU regeneration system

11. Boiler lift

Put up for kind persual.

AGM(OS)

The undersigned was on tour from 27/11/08 to 29/11/08 stationed at Sipat STPP to review the unit # 5 commissioning activities . BLU of Unit # 5 has been planed on 12-12-08 to achive full load generation and subsequent activities . The erection completion and commissioning of the following systems is pending (Detailed list of pending activities has been enclosed).

Asok kumar Das Sr Manager (OS)

Annexure

NTPC - Sipat stage II (2*500MW) - Status of unit # 5 as on 30th Nov-08

Milestones achieved

Target for BLU to achieve 500 MW 12th Dec-08

System /Equipments ready

Sl No Area Equipments1 Mills Mill A- D proven , Mill # E ready for operation2 Fans FD fan # A , ID fan # A & PA fan # A3 APHs Pri APH # A , Both Sec APH 4 ESP pass Pass # A & B 5 SADC & burner tilt Remote operation ready6 Safety valves & ERVs7 Cooling system ACW(A/B/C) , SGECW(A/B), TGECW(A/B/C)8 LPHs LPH 1/2/39 Safety valves

10 Ash handling sy BA sy( A,B grinder ) , FA for ESP pass A, B11 CW & CT sy

Status of balance system/ Equipments

SL NO Equipment Present status Tar date

1

LHS millsMill # F 5th Dec-08Mill # G 10th Dec-08Mill # H 15th Dec-08Mill # J Sole plates erected 20th Dec-08Mill # K No erection activity started 20th Dec-08

2

Feeders for LHS mill Mill # F Erection not started 7th Dec-08Mill # G Erection not started 10th Dec-08Mill # H Erection not started 14th Dec-08Mill # J Erection not started 20th Dec-08Mill # K Erection not started 20th Dec-08

3

Coal pipings for LHS mills Mill # F 120/ 126 pipes completed 10th Dec-08Mill # G 111/122 pipes complted 10th Dec-08Mill # H 92/117 pipes complted 10th Dec-08

Mill # J 15th Dec-08

Mill # K 15th Dec-08

4

Bunkers for LHS mills Mill # F Loading clearance givenMill # G Ready for inspectionMill # H Ring beams / plan bracings erection in progress 5th Dec-08Mill # J SS cone welding in progress in feeder floor 15th Dec-08

1. Test synchronised with oil on 13.08.08 2. Coal firing on 10.11.08 3. 200 MW achieved on 12.11.08

1. Erection completed upto MDV, 2. Rollers / LO piping / Motor alignment / tray works / cabling balance

73 /114 pipes complted, front required from mill side

71/116 pipes complted, front required from mill side

4

Mill # K SS cone welding in progress at zero meter 20th Dec-08


5

Fans

FD fan # B trial 7th Dec-08

PA fan # B trial 7th Dec-08

ID fan # B trial 14th Dec-08

Pri APH # B

6

Balance DuctingDuct ready , ATT is to be done 15 nos NMEJs to be fixed

Balance external ducting (BOF to ESP)

ESP # C pass 10th Dec-08

ESP # D pass 20th Dec-08

7

Pending InsulationsPA fan # A Dish duct partially pending

FD fan # A Dish duct lower plane pending

LHS air duct Cold + hot duct pending

FD fan # B Disc duct pending

ESP D pass BOF to ESP + ESP + ESP to ID fan

8

BFPs

TDBFP # A pump trial Put on barring on 14-11-08

2nd Dec-08Solo run & pump trial pending

TDBFP # B pump trial 15th Dec-08

9

ESP

# C pass ATT done , O/L duct & gates readyField charging on 05-12-08

# D passATT done , O/L duct & gates readyField charging on 20-12-08

10 Wall blowers (88 nos)

11

Spray SH spray Remote commissioning done

RH spray

12 CPU # 5

13 CPU regeneration PLC commissioning in progress 4 th Dec-0814 Mill reject handling sy Pyrite hopper of RHS mills erected

1. Motor trial run taken 2. LO flushing started on 20/11 & comp by 30/11 3. Blade fixing pending

Blade fixing , motor trial , LO lines flushing pending

1. Motor alignment in progress , LO pump trial done 2. LO flushing in progress since 27/11 3. Power cabling from VFD Xfmr to SWGR prnding , motor trial

1. LO line flushing , motor trial run , completed 2. Air motor trial run , soot blower & dampers commissioning pending

LHS PA cold and hot air duct

O/L duct completed , I/L duct erection in progress

Insulation material problem

LO flusing started on 27/11/08 , compl by 07/12/08

Instrumentation , putting on barring , solo run & pump trial pending

Erection completed , dry run and commissioning of remote operation pending

Line erection done / steam blowing done / Flow measurement element to be installed.

1. Vessels erection done , pipings erection in progress 2. Instrumentation and commissioning pending

Exp by 30-12-08


15

Ash handling sy

BA system

ESP passes ESP A & B pass commissioned

#C pass

Ash evacuation pipings erection in progressVacuum pump , collecting tower erected

#D pass

Ash handling series Series A & B ready

Series # A Water trial completed

Series # B Motor trial done , pump trial pending

16 Boiler lift Not installed

Grinder A,B ready with disposal line , Grinder C,D installed & to be commissioned , disposal line of grinder C & D erection in progress (Tar 30.11.08)

ECO & APH ash evacuation

ECO & APH of LHS completed , RHS of APH in progrss

Instrumentation ,Commissioning of MHV's,vacuum pump pending1. Erection of ash evacution pipings & valves ,collecting tower and Vacuum pump pending 2. Instrumentation ,Commissioning of MHV's,vacuum pump pending

Asok Kumar Das SR Manager(OS)

Sipat unit # 5 Turbine bearing temp and vibrationUnit # 5 unit # 4

Load 210 MW Load 282 MW Load 500 MW Load 500 MW

Brg no Axis

1 X 19.89 86.6578.84

19.1 74.779

18.8 6179

12.6 6372

Y 15.33 117.79 13.8 106 14.5 92 17 29

2 X 8.35 7274.7

12.9 72.575

11.09 7375

8 8074

Y 12.5 158.04 10.4 164 15.52 151 9.8 24

3 X 16.74 75.0188.4

18.7 25.7888

17.16 5371

11 3390

Y 23.05 98.7 20.7 83.9 26.68 92 14 26

4 X 35.7 59.8188.45

33.3 55.288

22.8 6089

24 8090

Y 38.01 38.64 36.6 43.9 37.8 45 27 83

5 X 66.28 46.7776.11

50.67 52.677

49.18 5877

31 7874

Y 8.86 73.03 14.2 67.2 20.28 73 56 128

6 X 24.41 18.2876.96

24.8 25.477

20.8 3578

18 5877

Y 21.87 35.34 26.3 36.1 24.47 48 17 65

7 X 25.82 87.0663.49

22.07 73.464

25 7164

15 9771

Y 30.29 58.07 25.03 56.5 24.6 59 19 90

Brg vibn

Shaft vibn

Max brg temp

Brg vibn

Shaft vibn

Max brg temp

Brg vibn

Shaft vibn

Max brg temp

Brg vibn

Shaft vibn

Max brg

temp

Status of Auto Loop of Sipat # 5ABB station C&I system

Sl No Description Status Remarks

1 Furnace draft Yes Auto

2 Drum level low Yes Proven in auto

3 Drum level high Yes Auto

4 PA header pr Yes Auto

5 Hotwell level control Auto

6 D/A level Yes Auto

7 D/A pressure Yes Man

8 GSC min R/C Yes Proven in auto

9 CEP R/C Yes Proven in auto

10 LPH level Yes Auto

11 HPH level Yes for HPH 6B/5B HPH 6A/5A not avl

12 TG/SG ECW DP Yes Manual

13 Mill air flow Yes Mill A to H Mill J & K not ready

14 Mills outlet temp Yes Mill A to H Mill J & K not ready

15 Air flow master Yes Proven in auto

16 Fuel flow master Yes Proven in auto

17 SH spray Yes Auto

18 RH spray Yes Proven in auto

19 Boiler follow mode Yes Proven in auto

20 CMC Yes Proven in auto

Readiness from C & I side ID fan kept in

manual due to single channel operation

Normal M/U ready

Put in auto for 1hr 30 mins

BHEL C&I system

1 Yes Auto

2 Turbine lub oil temp Yes Auto

3 Primary water temp Yes Auto

4 Cold gas temp Yes Auto

5 Control fluid temp No Man

6 HPBH & LPBP Yes Proven in auto

7 Turbine EHC Yes Auto

8 TDBFP-A seal /Leak steam pr Yes Auto9 Fuel oil pressure Yes Proven in auto

10 Atomising steam pressure Yes Proven in auto11 SADC Yes Auto

12 Aux PRDS MS & CRH No Man

Seal steam / Leak steam system

MS PRDS not charged

NTPC Ltd(Corporate Operation services)

Date 23-12-08

Sub : Report on Sipat - II : For commissioning of unit # 5

1. LHS milling system

3. TDBFP # B

4. ESP pass "D" readiness

5. Mill rejects handling system

6. ESP D pass fly ash handling system

7. Wall blowers and LRSBs commissioning

8. Pending insulation of air + FG duct + ESP , FW pipes + HPHs' drips , SH & RH spray lines

8. Ash slurry series A & B

9. Condensate polishing unit

9. Coal tranportation thro' MGR

11. Boiler lift


AGM(OS)

The undersigned was on tour from19/12/08 to 22/12/08 stationed at Sipat STPP for unit # 5 commissioning activities .Unit is presently running at 300 MW load with 5 mills (RHS).COD of Unit # 5 has been planed on 31-12-08 . The erection completion and commissioning of the following systems is pending (Detailed list of pending activities has been enclosed).

Asok kumar Das Sr Manager (OS)

NTPC - Sipat stage II (2*500MW) - Status of unit # 5 as on 22 th Dec-08

Milestones achieved

COD 31st Dec-08

System /Equipments ready

Sl No Area Equipments1 Mills Mill A- E proven

2 Fans

3 APHs Both Pri APH , Both Sec APH 4 ESP pass Pass # A, B ,C5 SADC & burner tilt Remote operation ready6 Safety valves & ERVs7 Cooling system ACW(A/B/C) , SGECW(A/B), TGECW(A/B/C)8 LPHs LPH 1/2/39 Ash handling sy BA sy( All 4 grinder ) , FA for ESP pass A, B & C Series # C & D

10 BFPs MDBFP & TDBFP A

10 CW & CT sy11 CPU regeneration

Status of balance system/ Equipments


1

LHS mills

Mill # F 26th Dec-08

Mill # G 25th Dec-08

Mill # H 25th Dec-08

Mill # J Erection completed upto MDH 25th Dec-08Mill # K Erection completed upto MDH 25th Dec-08

2

Feeders for LHS mill Mill # F Feeder calibration done Mill # G Feeder calibration done

Mill # H 25th Dec-08

Mill # J 25th Dec-08Mill # K 25th Dec-08

1. Test synchronised with oil on 13.08.08 2. Coal firing on 10.11.08

Both ID fans , FD fans and PA fans (ID fan # B ch -2 not available/VFD xfrm damaged / being shifted from KhSTPP)

1. Mill bearing (lower) damaged during trial run ( After 15 mins running) 2. mill dry run and CAF test pending1.Mill boxed up ,LO flushing completed. 2.Motor alignment & cabling in progress 3. motor trial exp on 24-12 / mill dry run / CAF test pending1. Mill boxed up .Motor trial done. LO flushing in progress 3. Mill dry run & CAF pending

Feeder / outlet pipe / gate erection done . Feed pipe / bunker outlet gate erection / feeder calibration pending


3 Coal pipings for LHS mills : Coal pulling done & supports in progress

4

Bunkers for LHS mills Mill # F Loading clearance givenMill # G Loading clearance given on 01-12-08Mill # H Loading clearance given on 10-12-09Mill # J SS cone erected & welding in progress 25th Dec-08Mill # K SS cone erected & welding in progress 25th Dec-08

6

Balance Ducting

13/ 15 nos NMEJs to be fixed

Balance external ducting (BOF to ESP)ESP # C pass

ESP # D pass 25th Dec-08

7

Pending Insulations

Boiler

PA fan # A Dish duct partially pending

FD fan # A Dish duct lower plane pending

LHS air duct Cold + hot duct pending

FD fan # B Disc duct pending

ESP D pass BOF to ESP + ESP + ESP to ID fan

TDBFP # A BP + MP (suction & discharge line : partially)

SH spray Line & spray station

RH spray Line & spray station

HPHs FW lines + drip lines

8

BFPs

TDBFP # B pump trial 30th Dec-08

9

ESP

# C pass To be taken in service after rectification of fields.

23-12-0830 % insulation pending

# D passATT done , O/L duct & gates ready

30-12-08Field charging / insulation pending

10 Wall blowers (88 nos) Erection completed . Dru run of 46 nos done

11

Spray SH spray Put on auto

RH spray

12 CPU # 5

13 CPU regeneration PLC commissioning

PA Duct NMEJs LHS

C pass charged.30 % Insulation pending

1. 2/2 boxex erected 2. 2nos NMEJ erection , welding of duct /ATT/ insulation balance

Corners firing zone (high density insulations to be put)

Insulation material received / work in progress

Steam blowing of line , LO flusing completed , steam piping / feed water piping in progress

Pump alignment , Instrumentation , putting on barring , solo run & pump trial pending

One line each stream ready for manual operation

1. Vessels erection done , pipings erection in progress( resin transfer line , DM water line pending) 2. Instrumentation and commissioning pending

Exp by 30-12-08


14 SWAS Pipings in progress / Instrument cabling , Instrumentations and commissioning pending


15 Mill reject handling sy

16

Ash handling syBA systemBA piping 4 MS lines ready

Clinker grinder & flap gate All 4 commissioned

Completed

ESP passes ESP A & B pass commissioned

#C pass

#D pass

Ash handling series Series C & D ready

Series # A Erection done / Motor & pump trila pending

Series # B

A/B ADL

17 LHS tripper

18 MGR

19 Boiler lift Not installed

Pyrite hopper of RHS mills erected / for LHS mills pending

ECO & APH ash evacuation

Ash evacuation pipings erection in progress(Laterals 250 NB, strainers , pipes of sizes 150 NB, 200 NB , 25 NB urgently required)

Vacuum pump commissioned, collecting tower erected

Instrumentation ,Commissioning of MHV's,vacuum pump pending1. Erection of ash evacution pipings & valves ,collecting tower and Vacuum pump pending 2. Instrumentation ,Commissioning of MHV's,vacuum pump pending

Motor trial done , pump B1 trial done . Trial for PP B2 & B3 pending

B line completed ; A > 10 joints pending for rail culverts

27A - Fire has damaged the belt. Belt restoration work to start on 22.12.08. Empty rack run done upto SILO. Delay in awarding in contracts for loading in SILO from Coal India end.

Asok Kumar Das SR Manager(OS)

Sipat # 5 Observation prior to full load operation

Sl No Area

1 24 meter cable gallery 2 8.5 meter LPHs + BFP exhaust area 3 Boiler "0" meter Full of debris + scrap + construction eqpts

4 Mills area 5 ESP area drains around incomplete 6 PA fan area Drains in front of PA fans incomplte

78 ESP control room Approach to the stair case incomplte

Lot of opennings in the control room9 Generator seal oil system Full of debris

10 Oil station tray Full of debris 11 Boiler different floor Debris + scrap

Drains not complete + complete drains are full of debris

Approach road inbetween PA fans and ESP incomplete

Sipat # 5 : Activity chart towards full load

Date Time Activity Remarks 17-12-08 15:58 BLU18-12-08 18:41 Syn19-12-08 15:54 unit triped "Generator inter turn protection" /Bus duct PT loose 19-12-09 16:19 BLU19-12-10 Syn20-12-08 15:57 Unit triped

Sipat # 5 : Problems faced in the Journey towards full load

Sl No Equipment Problem faced Solution / Action taken

1 CW pp # 4 P/S module replaced

2 TDBFP # A Attended

3 ID fan B Ch 2 VFD Xfrm burnt VFD Xfrm being shifted from KhSTPP # 7

4 Mill # F Brg replaced

5 Mill # D Pulley replaced + belt replaced

6 Mill # E Coal dust lkg from mill top Tightened

7 TDBFP # A Diaphragm replaced

8 Mill # B Feeder tripping w/o alarm

9 Sec APH # B

10 Generator bus duct PT PT loose / tightened

11 UAT # 5B Syn permissive not coming

12 Mill # G Vibration high Roller setting done

13 Wall blowers Gasket replaced with original one

14 PA fan A I/O card problem Replaced

15 TDBFP # A Replaced

16 MS silica high (35 ppb ) CPU not available

Triped (first out S1 & S2 energised)

Oil lkg from from BP(NDE) return oil line & MP(NDE) RTD

Bearing damaged during mill trial ( lower brg)

Feeder beld damaged , Idler pulley damaged

Diaphragm dameged ( Unit triped on Cond vac low)

Fault in the Control supply (Neutral to ground )

Rotor stoppage alarm not coming

Unit triped on generator interturn protection

Staem line safety valve flange gasket leakage (twice)

BP suction strainer gasket ruptured

Sipat # 5 COD

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