1 may 2010 ts tidings - bhel - pssr · pdf fileboiler pg test was successfully completed....

1 MAY 2010 TS TIDINGS

TECHNICAL SERVICES / PSSR

ALMATTI DAM MAY : 2010 VOLUME : 13.12

Published by Technical Services / PSSR For internal circulation

H I G H L I G H T

VIJAYAWADA UNIT 7

ESP PG TEST WAS DECLARED COMPLETED. BOILER PG TEST WAS SUCCESSFULLY COMPLETED.

KUTTIYADI UNIT – 1:

UNIT WAS SYNCHRONISED TO GRID FOR THE FIRST TIME.

KRL KOCHI: HRSG

ALKALI BOIL OUT COMPLETED. STEAM BLOWING COMPLETED. SAFETY VALVE FLOATING COMPLETED.



INSIDE

1. STATUS OF PROJECTS COMMISSIONED FROM 2002 TO 2009.

2. STATUS OF SETS COMMISSIONED / TO BE COMMISSIONED DURING 2009 - 2011.

3. SERVICE RENDERED TO OTHER REGIONS/SAS/PROJECTS

AFTER CONTRACT CLOSING/ CUSTOMER TRAINING.

4. APPRECIATION FROM CUSTOMER FOR SERVICES RENDERED.

5. FEED BACK ON EQUIPMENTS FROM SITES.

6. LET US KNOW - DIGITAL PROTECTION, CONTROL & MONITORING IN MV SWITCHGEARS Feed backs and suggestions from all departments of BHEL for improvement of TS TIDINGS are welcome and may please be addressed to ADDL. GENERAL MANAGER (TSX)/BHEL-PSSR/CHENNAI



STATUS OF PROJECTS COMMISSIONED DURING 2002 – 2009:

NINL, DUBURI :

BHEL/Trichy has suggested for replacing few components of safety valve. The list was forwarded to customer for placing order.

BELLARY UNIT – 1 :

Unit is running around 415 – 450 MW.

Load reduction is due to CW pump problem. Only two CW pumps are available for service.

Unit was shut down on 18.05.2010 due to evacuation problem. Unit was synchronized on 19.05.2010 and loaded to 415 MW.

Unit load was reduced to around 240 MW from 25/05/2010 to 27/05/2010 due to coal feeding problem.

STATUS OF SETS COMMISSIONED / TO BE COMMISSIONED DURING 2009 – 2011 :

AMARKANTAK – UNIT 5 :

Unit is running at 160 - 180 MW.

Station Transformer 5A: Pending points are being attended.

Ash handling system: Vacuum pump house balance civil works, dry ash system silo civil works and recovery water system (chemical house & pump house area) civil works are in progress.

CHP: PLC commissioning is in progress. DE and DS system mechanical erection and attending to punch points are in progress.

Chlorination system: Fixing of caustic soda tower is in progress.



NALCO - UNIT 9 :

Unit is running at 90 - 120 MW.

When the unit was running at 100 MW, it got tripped on 16.05.2010 due to low vacuum protection and resynchronized on 17.05.2010.

Modification work of all the mills was completed.

Commissioning of SOx, NOx and O2 analyser was completed.

Unit got tripped on 27.05.2010 due to grid disturbance. TG came to rest with all oil pumps in service but did not come to barring gear. Problem was identified as no lift in generator rear bearing and Unit is under shut down for normalization of barring gear and to attend to shut down works.

Preparation for ESP PG test (ash evacuation, B pass field checking) is in progress.

NALCO – UNIT 10 :

APH A : First stage lube oil flushing of guide bearing was completed.

PA fan 10B oil flushing was completed. IGV calibration completed. PA fan 10B motor trial run was completed.

PA fan 10A lub oil pump motors trial run completed.

Duct leak test from APH to ESP was carried out.

ID fan – A motor trial run was completed.

Pending works of Boiler and TG are being done.

BFP 10 A motor trial run was completed. Hydraulic coupling trial run completed.

Turbine stop and control valves ATT checking was completed.



Hot air shut off Damper modifications for Mills in progress in the presence of BHEL,Ranipet representative.

BHUSHAN STEEL – AFBC BOILER UNIT 2 :

72 hours continuous trial operation of the unit was completed. Unit is in service with 60 - 65 TPH steam generation.

Unit was under shut down from 06.05.2010 to 16.05.2010 due to economizer tube leak.

Presently unit is in service with 65 TPH steam flow.

BHUSHAN STEEL – AFBC BOILER UNIT 3 :

Unit is under shut down since 28.04.2010 due to clinker formation.

NALCO – DAMANJODI :

While filling boiler for preservation, tube leakage was observed in the left side of water wall at CD elevation and was attended.

Steam blowing of HFO return lines, SCAPH lines and atomizing lines was completed.

FD fan A trial run was completed.

PA fan - B - Trial run of lube oil pumps motor was completed.

PA fan - A & B – Main motors cable termination was completed.

Calibration of instruments of BFP hydraulic coupling , PA fan - A & B lube oil skid instruments were completed.

TG aux MCC was charged.

HP dosing motors - 1 & 2 trial run was completed.



ID fan – B trial run was completed and inlet IGV was commissioned.

Steam blowing of 6 ata, 11ata and HPBP system spray lines was completed.

KRL KOCHI :

GT was synchronized on 02.05.10 and tripped on the same day due to cable fault.

Tie-2 Transformer stability test was carried out.

GT was restarted and synchronized on 14.05.2010.

Station Auxiliary Transformer (SAT) – 2 was charged on 15.05.2010 for the first time.

HRSG alkali boil out was completed.

LP dosing pumps coupled run was completed.

HRSG safety valve floating in the presence of Boiler Inspector was completed.

Steam blowing was completed.

Maximum load reached was 30 MW. GT is running at 20 MW.

HRSG balance instruments commissioning was in progress.

PLC to DCS tags address checking was in progress.

BFP 4 trial run was completed.

RAICHUR – UNIT 8 :

Super heater / Reheater spray control station hydraulic test / steam flushing completed.

Coal feeder - B & C outlet gate was commissioned from remote.

Mill discharge valve – B & C local operation was completed.

Mill – E motor trial run was completed.



Spring compression setting and classifier operation checking for Mill – D & E were completed.

Cooling water line flushing for lube oil coolers was completed for PA fan – A &B, FD fan – B and ID fan – B.

Trial run of ID fan – B motor was completed with channel – 1. 8 hrs. trial run of ID fan – B was completed with VFD channel – 1. ID fan – B VFD channel – 2 hunting problem was resolved and run on local/remote mode individually and with both channels in parallel.

PA fan – A & B blade pitch control were calibrated from remote.

Mill – D: HAD & CAD was calibrated from remote.

ESP GD test was declared completed and MOM was made with customer.

CERM coupled trial run was completed (All the 14 nos.)

BFP C recirculation valve was commissioned. BFP – C scoop was commissioned. BFP C trial run was completed.

Mill – E trial run and roller setting was completed.

SH and RH spray block valve was commissioned from remote

BFP – A lube oil flushing was declared completed and oil was drained.

Seal air fan – A and B trial run was completed after changing the Over load relay (OLR). Seal air lines blowing was completed.

PA fan B was commissioned and trial run along with duct leak test was completed.

Wall blowers commissioning was in progress.

ESP - A pass fields charging was in progress.

Furnace leak test was carried out and leakages are being attended.



Commissioning of gates/MOV and dampers are in progress.

RAYALASEEMA TPP - UNIT 5 :

ID fan – 5B lube oil flushing was completed.

APH water washing pump – 2 was commissioned.

Steam blowing was completed for LDO headers and all four corners including atomizing lines, SCAPH lines of both A & B passes, HFO headers and all twelve corners including atomizing lines were completed.

APH – B guide bearing lube oil flushing was completed.

KUTTIYADI UNIT 1 :

SCC & OCC tests were successfully carried out.

Unit was synchronized to grid for the first time on 08.05.2010 and reached a load of 30.5 MW.

Load throw off test was conducted at 12.5% load. Auto synchronizer was made through and put into service.

KUTTIYADI UNIT 2:

Machine was spun and balancing was completed.

Generator dry out was completed.

SCC tests were successfully carried out. While doing OCC vibration was found increasing beyond 250 microns. Balancing was done.

During OCC test, bolt of the balancing weight sheared and hit on the winding. Repair works of the winding was in progress.



VIJAYAWADA UNIT 7:

Unit is running around full load.

ESP PG test was declared completed and MOM was made with the customer.

Boiler PG test was completed successfully and MOM was signed.

KAKATIYA UNIT 1 :

Coupled trial run of Mill – G was carried out.

Calibration of Feeder – E & F was completed.

Air leak test of Mills - E, F & G was completed.

Tracking and trial run of Feeder – F was completed.

TDBFP A – Lube oil flushing was declared completed.

Unit was synchronized on 09.05.2010 and loaded to 80 MW.

Generator partial discharge monitoring system was commissioned.

TG was rolled to 3000 rpm on 12.05.2010.

TDBFP B – Governing checks, protection and interlock checks were completed.

Unit got tripped on 14.05.2010 while changing from LDO to HFO at CD elevation and unit was brought back on the same day.

HFO firing was established in all the elevations.

TDBFP – A: ACV Erection was completed.

TDBFP – B: Drive turbine solo run to 5400 rpm on 15.05.2010 and actual over-speed test was conducted.

Unit was shut down on 16.05.2010 due to non-availability of fuel oil and again synchronized on 25.05.2010.

UTs commissioning was completed and were kept in service.



Unit is under planned shut down from 30.05.2010 due to ash handling problem (customer scope).

EID / PARRY :

GT is under shut down since 12.04.2010.

SERVICES RENDERED TO CUSTOMER /SAS/MUs:

--- NIL ---

CUSTOMER TRAINING & TECHNICAL PAPER PRESENTED: Presentation was made to Neyveli customer Engineers at Neyveli site on ‘Commissioning activities in the Turbine area’ on 24/04/2010 by Shri. M V Baskaran, Senior Manager/Technical services. Around twenty customer executives including GM/Projects, Neyveli attended the programme.

--- NIL ---

APPRECIATION FROM CUSTOMER FOR SERVICES RENDERED :

--- NIL ---

PROBLEM: HYDROMOTOR NOT ABLE TO ROTATE TURBINE

PROJECT: NALCO CCP – UNIT – 10. 120 MW

INTRODUCTION The turning gear for 120 MW design of steam turbine is a hydromotor with

over running clutch, which is assembled at factory, at the front end of the front

bearing pedestal of the HP cylinder. The hydromotor uses high pressure shaft lift oil,

when turbine is in lifted condition, to rotate the turbine shaft system at slow speed

before start up, and after shut down for cooling down, as required for safe operation

of the turbine.

PROBLEM At Nalco unit 10 the hydromotor was assembled with steam turbine with all fittings

and connections as in Unit 9, but when the Turning Gear Solenoid valve was opened, to

operate with shaft lift oil arrangement, the hydro motor was not able to rotate the

turbine shaft system.

ANALYSIS To analyze the causes for this fault, the following checks were carried out:

1. After dismantling the hydromotor from the HP front pedestal the Hydro motor

was checked with compressed service air for free rotation. It was found

rotating freely.

HYDROMOTOR

2. The rotor lift at all the bearings was rechecked and found to be normal

between 0.05 to 0.1 mm. The turbine was rotating freely with manual barring.

3. The over running clutch direction was confirmed as OK . (In unit 9 it was

reversed and was corrected at site).

4. When the hydromotor solenoid valve was opened pressure dropped from 150

KSC to 135 KSC in jacking lift oil pressure. The pressure recovered to 150 KSC

when the solenoid valve was closed.

As a first step, to determine where this pressure drop was occurring, a dummy was

provided in the Hydro-motor inlet after the solenoid block. Then when the hydromotor

inlet solenoid valve was opened, pressure drop was observed exactly as before.

Therefore it could be concluded that this drop was occurring in the solenoid block.

Further checks were done to locate the loss as follows:

1. Leakage of the ‘O’ ring between solenoid and block was suspected, but that had

already been attended and checks ensured it was OK, with oil pressure and

after dismantling the block.

2. Excess oil flow was observed from bearing lubricating line of over-running

clutch when jacking oil alone was in service. (See fig 6.)

3. By running the jacking oil pump with heated oil in MOT, it was found that the

lube oil supply line coming into the FBP is getting hot, so it was suspected that

jacking oil is entering the lube supply line of clutch and hydro-motor.

4. On checking the schematic of oil lines in drawing it was seen that an NRV inside

the block in the lube oil path to hydromotor is meant to allow the hydro-motor

to be lubricated by lub oil when solenoid valve is closed. No oil should go to lub

oil from jacking oil because the NRV blocks this. Normally this NRV will be

provided in the block which is connected to turning solenoid valve. Here it was

suspected to be missed. See figure and pics below for details.

Fig 1. LIFTING OIL SCHEME : DRG NO. 2-131-00-62253

Fig 2. SOLENOID AND SOLENOID BLOCK ARRANGEMENT

Fig 3. SCHEMATIC REPRESENTATION OF SOLENOID AND BLOCK

• Orifices are supplied separately for fitting in unions at locations shown in figure above.

Fig 4. ACTUAL ARRANGEMENT IN FRONT BEARING PEDESTAL

So the solenoid valve block, jacking oil , lub oil and drain connection unions for

the hydromotor motor were dismantled. There was no NRV inside the block at

the location as indicated in the schematic drawing no. 2-131-00-62253. Fig 3 shows internal details.

This was reported to BHEL/Hyderabad. Immediately, a new spring loaded NRV

was supplied to site which was then assembled in the block. In addition 2 and

2.5 mm orifices which were supplied with the material for hydromotor were

also assembled in the union assemblies as indicated in Fig 3 & 4 above.

Summary of hydromotor checks:

1. Hydromotor freeness can be checked with compressed air. The

hydromotor can rotate either way depending on which side air is given.

2. The clutch assembly is to be ensured as in Fig 5 . The 20 bar lift setting

for the clutch is done with high pressure gauge mounted as shown. This

gauge is removed after the pressure setting is done and the pressure

tapping point is plugged for regular use. See pictures below for details.

Fig 5. CLUTCH LIFT SETTING ARRANAGEMENT

Fig 6: CROSS SECTIONAL VIEW O

F O

VER T\RUNNING CLUTCH ASSEMBLY

CL

UT

CH

LIF

T S

ET

TIN

G

3. The correctness of over running clutch direction is to be confirmed by

rotating the splined gear shaft as follows: with turbine at rest, without

hydromotor assembled, the splined shaft will rotate clockwise because

the clutch permits this rotation. Anticlockwise rotation causes

engagement and the clutch will not rotate. Turbine is meant to rotate

anticlockwise when viewed from FBP towards generator.

4. Orifices of 2 mm and 2.5 mm are to be assembled in the union connectors

in the lines to lub oil & hydromotor inlet as shown in Fig 3.

5. Healthiness of solenoid is to be established by checking oil entry and cut-

off to the hydromotor when open and close commands are given. The

solenoid feeds jacking oil only in the forward direction.

6. The manual isolation valve in the solenoid block must be checked to verify

that it is isolating completely for maintenance and safety.

Note: At the time of manual barring for alignment of turbine, JOP is

in service. To prevent accidental rotation of the turbine with bearing

covers open and no lub oil, a temporary dummy was provided (see pics in

fig 7 below) in the hydromotor inlet. (The solenoid is energized to close

and is normally open without electric supply !)

Fig 7:DUMMY IN JACKING OIL SUPPLY FOR HYDROMOTOR AND ISOLATION VALVE

CONCLUSION

After above checks were completed and the turning gear system was

assembled, the turbine rotated freely without any manual assistance as soon as

solenoid was operated. This time, and during repeated trials later also, the drop

in lift oil pressure was only 2 ksc .



FEED BACK NO. 2

Project: KUTTIYADI Additional Extension Scheme 2X50 MW HEP, KSEB Problem: High Vibration at Generator UGB(Upper guide bearing) and LGB(Lower guide bearing) during spinning to rated speed.

Turbine Details Type : Vertical Pelton, 4 Jets Rated Speed : 500 rpm No of Buckets : 21 Nos Rated Head : 625 m Rated Discharge : 10.2 m3 Rated O/P : 51.5 MW Mfg : BHEL/Bhopal Generator Details Frame Size : HGT 420/164-12D Rated Power : 50MW /55.56 MVA MCR : 55/61.11 Rated Volts : 11kV±5 % P.F : 0.9 Lag Rated Frequency : 50 3 % Runaway Speed : 940 rpm No of Poles : 12 Any D.O.R : CW viewed from Top. Unit # 1 Balancing work.

Unit # 1 was started on 18.04.2009 after increasing the bearing clearance in the Upper Guide Bearing from 0.34 mm to 0.40 mm as per instruction from BHEL/ Bhopal, because during first spinning of the



machine upper guide bearing metal temperature raised to 72°C. There are two non contact eddy current vibration pickups available in both upper guide bearing and lower guide bearing for measurement of shaft vibration. One probe measurement was taken for each bearing. Optical probe for measurement of speed and phase angle is located near Lower guide bearing vibration probe. Reflecting tape is placed on rotor in the pole 1 centre line which was taken as reference point.

During first running, shaft vibration in the upper guide bearing at 500 rpm was 248 µm and in the lower guide bearing it was 195 µm. As per the O&M manual of BHEL/ Bhopal allowable limit of shaft displacement (pk- pk) is 60 to 80 % of diametral clearance of the guide bearing. During running it was observed that optical probe was not working some time found that oil film formed on the optical probe head that was cleaned and relocated near upper guide bearing at the same angle. Every time during starting the machine the vibration value is 250 µm in the upper guide bearing and 200 µm in the lower guide bearing, these values were stabilized to 175 µm and 160 µm in the upper and lower guide bearing correspondingly after 60 minutes of continuous running. It was decided to do balancing to bring down vibration to below 150 microns.

Location of Vibration Pickup and Optical Probe. Number indicates the Pole

DOR

1

4

7

10



In the trial-1, 10 kg of balancing weight was added in the UGB at 60 deg from the reference mark in the direction of rotation (DOR). The machine was spun the vibration in the UGB increased to 305 µm and in the LGB decreased to 170 µm.

In the trial-2, 27.6 kg of balancing weight added in upper guide

bearing area at the location of 100 deg against direction of rotation from the reference. Vibration in the UGB raised to 380µm and 400 µm in LGB. All the weights were removed and machine was spun without any weights vibration in UGB is 381 µm and LGB is 300 µm immediately attaining rated speed and after 30 minutes vibration values stabilized at 230 µm in UGB and 200 µm in LGB.

In trial-3, 10.350 kg of balancing weight added in both UGB and

LGB at the location of 60 deg in the DOR. The vibration is reduced to 160 microns immediately after attaining the rated speed in the LGB and vibration in the UGB is 308 microns.

In trial-4 LGB balance weight was shifted to 45 deg in the DOR.

The vibration in UGB again increased to 380 microns and in LGB vibration decreased to 140 microns. The top bracket vibration also measured in the radial direction and the value is 180 microns.

In trial -5 UGB balancing weight was removed and LGB balancing

weight kept at the same location. The vibration in UGB reached 393microns and 180 microns immediately after attaining the rated speed and stabilized to 250 microns and 120 microns in Upper and lower guide bearing correspondingly. In the top brackets 3 radial arm jacks were found loose and same were tightened.



In trial -6, 20.6 kg balancing weight added in the UGB at 100 deg from the reference in the direction of location and LGB weight remain same. The machine was spun and vibration in the LGB considerably reduced 75 microns and the UGB shaft vibration is 294 microns.

In trial- 7, further 20 kg of balancing weight added in the

previous trial location in the UGB. The vibration in the UGB reduced to 91 microns but at the same time vibration in LGB increased to 315 microns.

In trial-8, 10.3 kg of balancing weight was removed from the

UGB. The vibration in UGB was 100 microns and LGB vibration reduced to 197 microns.

In trial -9, 5 kg of balancing weight added at reference point in

the LGB fan. The shaft vibration in the UGB 145 microns and in the LGB 150 microns and the above values stabilized to 130 micron and 145 micron in Upper and lower guide bearing correspondingly.

The top bracket vibration also reduced to 6 microns (over all).

The shaft vibration characteristic was measured during OCC &

SCC Test. During SCC test while raising the current vibration in UGB was decreased by around 20 microns at the same time LGB was increased by around 20 microns. The final vibration values at rated current were 117 micron in UGB and 161 micron in LGB.

During OCC test also the above same characteristic was observed.

The vibration at rated voltage was 115 micron in UGB and 161 micron in LGB.



The vibration characteristic of the m/c was observed during load throw off at 25% and 50 % load. During 25 % load throw off speed of the machine went up to 570 rpm and vibration level increased to 305 microns in LGB and decreased to 92 microns in UGB from normal working level. The deflector closing time was adjusted to 2 seconds then load throw off at 50 % load was done, this time speed went up to 546 rpm vibration level raised to 235 micron in the LGB and not much change in the UGB from the normal working level

Vibration summary during SCC/OCC/LOADING/LOAD THROW OFF

Sl No Speed UGB LGB rpm Vibration Vibration

Current/ Voltage/

load Micron Micron Remarks

Vibration Readings During SCC Test on 05.05.2010 1 503 20 A 140 146 No load current

2 503 1500 A 125 154 50 % current

3 504 2927 A 117 154 Rated Current

4 523 20 A 124 161 No load Current Vibration Readings During OCC Test on 06.05.2010

5 400 131 108 Unit Started 6 510 132 140 No Load Voltage

7 506 50 V 131 151 No Load Voltage

8 504 5041 V 123 144 45 % Voltage 9 507 11020 V 125 167 Rated Voltage 10 500 11020 V 116 157 Rated Voltage

11 500 11020 V 115 161 Rated Voltage

Trial



Vibration Readings During Loading on 08.05.2010

12 495 5 MW 116 176 Unit Synchronized 13 496.4 16 MW 109 176 14 496.7 20 MW 103 168 15 496 22 MW 107 172 16 496.4 27 MW 117 167 17 496.6 26 MW 106 173 18 495.6 22 MW 107 169 19 497.1 25 MW 107 171 20 497.1 27.5 MW 104 174 21 495 27.5 MW 113 183 In Control Room 22 496.7 25 MW 112 171 23 497 20 MW 107 171 24 497.2 15 MW 121 174 25 497.2 12.4 MW 121 172 26 497.6 10 MW 113 174 27 504 0 MW 130 160 Vibration Readings During Load Throwoff 28 495.8 12.5 MW 120 174 25 % load 29 579 92 305 25 %Load throw off 30 546 110 230 50 % Load throw off 31 496.3 25 MW 103 167 50 % load 32 552 98 255 50 % Load throw off



DIGITAL PROTECTION, CONTROL & MONITORING IN MV SWITCHGEARS

INTRODUCTION :

The fast innovation in digital & communication technology has opened a vast area for the development in protection and substation automation. Electromechanical and static relays have been superseded by intelligent electronic devices (IEDs) with numerous add-on functions. These compact multifunctional IEDs not only cost less but also save additional space and assembled cost compared to traditional relays. Above all, they are nearly maintenance free. Modern IEDs can further store information and communicate with operators and higher level control systems. Protective relays have migrated from formerly stand-alone devices meant for dedicated function to coordinated or integrated components of an overall substation automation system.

CONVENTIONAL APPROACH :

Dedicated devices for each of the protection, control & monitoring functions are employed at each level. Protection devices exclusively relays, act on the proper circuit breaker as soon as an electrical fault has been detected in the system. Controlling devices act on primary devices on local command or operator interface command or SCADA command.

For monitoring, primary device information, distributed control system (DCS) equipment status are viewed and all important measurement & information is retrieved at a central point. Complete separation is there between protection, control & monitoring. Although still used widely, the major drawback of this approach is –

• There’s no communication between protective relays.



• Innumerous wiring is required to be made between various equipments for interlocking.

• More manpower to be employed - Maintenance, Substation operator & expert for fault detection & analysis.

• Size of panels is very big.

• Specific protective relays for each protection function resulting in large number of relays in each panel.

The only advantage of this approach is low initial cost of installation.

LATEST TRENDS :

With the powerful treatment of information using microprocessors and development of communication, substation engineers have realized that the protection, control & monitoring can now be talked & implemented together using the IEDs. The development in communication & microprocessor technologies has resulted in devices which are having



communication facilities on one hand & numerical multi-functions on the other. Now different functions are combined in one functional device giving reduction in overall hardware cost, space & wiring. With enhanced memory of these IEDs, service interruptions can be minimized with practically no loss of information (battery back up). Large quantity of data can be exchanged between equipments at very high transfer speed. Protection, control & monitoring now in substation need not be handled separately any more.

DIGITAL CONTROL & PROTECTION SYSTEM :

IEDs are coming with RS232 serial interfaces for setting and the retrieval of stored data through local PC connected to this port, while wired RS485 or optical fiber interfaces allows connection to substation control systems or remote terminal units (RTUs). This allows additional automation for complete substation not only locally but through remotely located control rooms also. Further, it permits an access to all information available in the substation from a remote point.



The substation control system basically consist of a central computer with human machine interface (HMI) and decentralize feeder dedicated bay-units. Communication takes place via a substation LAN using proprietary / open protocols. The SCADA connection is provided by an RTU / data concentrator The communication of intelligent electronic devices (IEDs) begin with the introduction of various proprietary communication protocol like profibus, K Bus , SPA bus etc by the ace IEDs manufacturers. Their proprietary protocol makes it difficult to transfer data from IEDs to the RTU / plant SCADA system. Also with earlier technology, it was impossible to have communication amongst IEDs. To make the system more useful, Data concentrator (DC) was introduced. This data concentrator polls the data from the individual IEDs, displays them on the substation HMI for control & monitoring of substation and transfers the data to the upper level system i.e. plant SCADA. With this, all the data for communicating with upper level system are available at a central point as DC can take data from various IEDs of different make also as long as they are compatible with it. EVOLUTION OF UNIVERSAL PROTOCOL : The major disadvantage of proprietary protocol device, though very powerful with its manufacturer, is the lack of interoperability i.e. IED’s from two different manufacturers on proprietary protocol can not communicate or exchange information / data with each other where by eliminating the possibility of expansion with different makes. These increased the dependency on single vendor who took advantage.



To overcome the disadvantage some open protocols like Modbus, IEC-60870-5-103, DNP, LON etc. were formulated. These protocols allowed interoperability partially but not to the full extent. Though interoperability is provided, but practical problem still persist that the coordination amongst IEDs from different manufacturers for integration makes it difficult for commissioning engineer to implement. The reason being that the manufacturer do not divulge the details for sharing of private parts of the data of IEDs. These drawbacks calls for standard ensuring essential feature such as interoperability among different IEDs manufacturer, free allocation of function, capability to follow the fast changing communication technologies and ease of engineering & maintenance. All these needs were merged into new international standard called IEC:61850 “Communication network & system in substation.



Some of the advantages of IEC-61850 are listed below:- - Exchange of information independent of manufacturer for

configuration of the automation system.

- Although each IEC:61850-compliant IED may be configured using its dedicated tool only, all these IED-tools have to be compliant with IEC:61850. That means the reading, handling and writing of configuration files has to be in accordance with Substation Configuration description Language (SCL) of IEC:61850 as regards the standardized data model, the data access (services) and all communication connections. Common and standard data models, communication connections etc. allows the system integrator to use understandable data from all devices (irrespective of the supplier of the device) to integrate the complete system and to assure data consistency.

- All functions performed in the substation are covered in the general scope of the standard.

- Data in an IED is referred by its power system tag in IEC:61850. These tags are well defined and have to be common across the vendors. Common naming for common understanding.

- For all substation equipments like circuit breaker, transformer etc., IEC:61850 provides standardized information model globally.

- It is highly flexible & scalable.

- Reduces operation engineering & maintenance cost.

- It is a seamless solution for cross application requirement.

- IEC:61850 provides requisite openness for future high efficiency data transfer.

- There is no restriction imposed by the standard as far as system architecture is concerned.



- The standard accepts any system philosophy, from a distributed architecture to a centralized configuration and allows a free allocation of various functions.

The IEC:61850 communication standard provides means to integrate communication, information & applications into a coherent flexible & very powerful framework for substation automation.



UNITS WHICH HAVE ACHIEVED 100% OA THERMAL

500 MW

RAMAGUNDAM UNITS – 4, 5, 6 & 7

TALCHER UNITS – 2, 4, 5 & 6 SIPAT UNIT - 4

VTPS – 7

210 MW

VIJAYAWADA UNIT - 3 & 5 MUDDANUR UNIT - 3 METTUR UNIT - 3 TUTICORIN UNIT - 2

NORTH CHENNAI UNIT – 2 & 3 NEYVELI UNIT – 4

UNITS WHICH HAVE ACHIEVED PLF MORE THAN 100%

500 MW

RAMAGUNDAM UNIT – 5 & 7 TALCHER UNITS – 2, 4, 5 & 6

PERFORMANCE OF SR UNITS IN MAY 2010



UNITS WHICH HAVE ACHIEVED PLF BETWEEN 90 & 100%

THERMAL 500 MW

RAMAGUNDAM UNIT – 4 & 6

TALCHER UNIT – 1

SIMHADRI UNIT – 1 & 2

SIPAT UNIT – 4 & 5

VTPS - 7

250 MW

KOTHAGUDAM UNIT – 9 & 10

210 MW

VIJAYAWADA UNITS – 2, 3 & 5

MUDDANUR UNIT – 2 & 3

METTUR UNIT - 3

TUTICORIN UNIT – 2 & 4

NORTH CHENNAI UNIT – 2 & 3

NEYVELI UNIT – 4

125 MW

JSL, DUBURI UNIT – 2



PERFORMANCE OF BHEL THERMAL SETS IN SR (210 MW AND ABOVE) FOR THE PERIOD FROM 01/04/2010 TO 31/05/2010 COMPARED WITH THE CORRESPONDING PERIOD IN THE PREVIOUS YEAR. ( PLF IN PERCENTAGE )

PLF

0.00

20.00

40.00

60.00

80.00

100.00

120.00

North C

henn

ai

Neyve

li

Raichu

r

Tutic

orin

Ramag

unda

m

Mud

danu

r

Kothag

udam

Vijaya

wada

VTPS -

7

Mettur

Talch

er

Simha

dri

Sipat

UNIT

PLF

PER

CENT

AGE

2009 - 10 2010 - 11

STATION 2009 - 10 2010 - 11 North Chennai 91.94 68.98

Neyveli 88.87 86.63 Raichur 90.39 59.75 Tuticorin 76.35 89.49

Ramagundam 98.29 100.80 Muddanur 93.18 93.71

Kothagudam 95.02 94.87 Vijayawada 97.72 79.21 VTPS - 7 - 97.53 Mettur 95.71 90.66 Talcher 97.10 97.81 Simhadri 101.13 98.72 Sipat 70.43 98.63

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