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Experience in Commissioning of
a 1MWe Solar Thermal Power
Plant in Gurgaon

N.G.R. Kartheek1*, Deepak Yadav 1, Rangan Bane...
Schematic of process flow for the solar thermal
power plant

Process flow diagram
Unique features of the
project
Demonstration of solar thermal
technology for power generation
Combination
of
collector t...
Parabolic Trough Solar Field
Linear Fresnel Reflector
Commissioning Experience

Classification of commissioning experience
Operational Problems
Linear Fresnel Reflector
Receiver tube leakage of the LFR system

Receiver
Tube
leakage

Leakage in the receiver tube
• Operating Pressure: 40 kg/c...
Equipment Problems
Leakages in instrument stub connections on heat
exchanger

Leakage
from
Screwed
connection

Temperature Transmitters showi...
System Problems
HTF Freezing
Ambient Temperature (oC)

15

14

13

12

11

10

Time (hr: min)

Ambient temperature profile at the project ...
HTF Freezing
 Manual Operation
 Temperature gauge readings
at Main HTF Pump discharge
and outlet of solar field
Tempera...
HTF Freezing

TG

TG

Schematic of Oil System
Pump Seal Failure: February, 2013
Dirt/Oil particles collected from the drain
point near heat exchanger (March 17, 2013)
Summary and Lesson Learnt
• Operational Problem – Time consuming, delay in
commissioning
 Leakages in superheater: Torque...
Summary and Lesson Learnt
• System Problem
HTF Freezing: Unfreezes only in summer.
UPS and Tracker failure: Continuous P...
Commissioning problems in chronological order
THANK YOU
Project Objectives
•

1MWe Solar Thermal Power Plant
 Design & Development of a 1 MW plant.
 Generation of Electricity f...
receiver glass window breakage the LFR system

Receiver Window
Glass Breakage

Breakage of the receiver window glass
Inter...
Leakages in the superheater – 10/03/2013

Steam Leakage
Water entry in instrumentation air line
•Compressed air required in the Demineralisation plant (DM) in
mixed bed unit
• No...
NRV at BFP exit Failure

Process flow from Deaerator to Steam generator
Leakages in compressed air piping

Schematic sketch of compressed air flow
Communication problem between level I and level II

Control System Hierarchy for the solar thermal power plant
Steam System valves
•Problem in complete closing of the valve
• Manual closing of Valve – Not possible
• Control Valve in ...
Mechanical Seal-Frozen Oil Particles (March 17, 2013)
Dirt/Oil particles collected from the basket filter at
suction of Main HTF Pumps (March 17, 2013)
339 solar power plant deepak
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339 solar power plant deepak

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Transcript of "339 solar power plant deepak"

  1. 1. Experience in Commissioning of a 1MWe Solar Thermal Power Plant in Gurgaon N.G.R. Kartheek1*, Deepak Yadav 1, Rangan Banerjee1, J.K. Nayak1, Santanu Bandyopadhyay1 Shireesh B. Kedare1 1 Department of energy science and engineering, IIT Bombay Funded by Ministry of New and Renewable Energy Corresponding Author. Tel: +91 22 25764794, E-mail: solarthermaliitb@gmail.com
  2. 2. Schematic of process flow for the solar thermal power plant Process flow diagram
  3. 3. Unique features of the project Demonstration of solar thermal technology for power generation Combination of collector technologies Project Landmarks January 2010 different Direct and indirect steam generation to be demonstrated Simulation package for scale-up January 2011 Test facility for solar thermal applications to facilitate the development of indigenous technology Consortium based approach involving government and industry July 2013
  4. 4. Parabolic Trough Solar Field
  5. 5. Linear Fresnel Reflector
  6. 6. Commissioning Experience Classification of commissioning experience
  7. 7. Operational Problems
  8. 8. Linear Fresnel Reflector
  9. 9. Receiver tube leakage of the LFR system Receiver Tube leakage Leakage in the receiver tube • Operating Pressure: 40 kg/cm2 (g) saturated steam pressure • Hydro test Pressure: 120 kg/cm2 (g) • Leakages were found in 12 welding joints during hot commissioning
  10. 10. Equipment Problems
  11. 11. Leakages in instrument stub connections on heat exchanger Leakage from Screwed connection Temperature Transmitters showing Leakages Temperature Transmitters with sealant • Vapor pressure of Therminol VP 1 at 257 C is 1 bar (a) • Ignition temperature of Therminol VP 1 is 621 C • No screw joints and minimum flanged connections
  12. 12. System Problems
  13. 13. HTF Freezing Ambient Temperature (oC) 15 14 13 12 11 10 Time (hr: min) Ambient temperature profile at the project site on February 24th, 2013 • Crystallization temperature of HTF Therminol VP1 is 12 C 8:30 AM 8:00 AM 7:30 AM 7:00 AM 6:30 AM 6:00 AM 5:30 AM 5:00 AM 4:30 AM 4:00 AM 3:30 AM 3:00 AM 2:30 AM 2:00 AM 1:30 AM 1:00 AM 12:30 AM 12:00 AM 9
  14. 14. HTF Freezing  Manual Operation  Temperature gauge readings at Main HTF Pump discharge and outlet of solar field Temperature of HTF ~350C  Pump at minimum flow rate Schematic of Oil System
  15. 15. HTF Freezing TG TG Schematic of Oil System
  16. 16. Pump Seal Failure: February, 2013
  17. 17. Dirt/Oil particles collected from the drain point near heat exchanger (March 17, 2013)
  18. 18. Summary and Lesson Learnt • Operational Problem – Time consuming, delay in commissioning  Leakages in superheater: Torque spanner  Receiver tube and window glass: Spot Welding, Continuous power  Water Entry in IA line: NRV  Dry run of the BFP: Level Switches • Equipment problems – Good engineering practise  NRV Selection: Horizontal & Vertical line  Instrument Stub: No threaded parts  Compressed air line: No threaded joints  Communication failure: Preconsidered  Steam Valves: Control, Manual handle, Station
  19. 19. Summary and Lesson Learnt • System Problem HTF Freezing: Unfreezes only in summer. UPS and Tracker failure: Continuous Power supply
  20. 20. Commissioning problems in chronological order
  21. 21. THANK YOU
  22. 22. Project Objectives • 1MWe Solar Thermal Power Plant  Design & Development of a 1 MW plant.  Generation of Electricity for supply to the grid. • National Test Facility  Development of facility for component testing and characterization. • Development of Simulation Package  Simulation software for solar thermal power plant scale-up  Compatibility for various solar applications.
  23. 23. receiver glass window breakage the LFR system Receiver Window Glass Breakage Breakage of the receiver window glass Interruption in power supply to the tracking motors, focus shifted partially
  24. 24. Leakages in the superheater – 10/03/2013 Steam Leakage
  25. 25. Water entry in instrumentation air line •Compressed air required in the Demineralisation plant (DM) in mixed bed unit • No NRV in IA line • DM water entered into the airline •4 control valve damaged Dry run of the boiler feed pump • Malfunction of Level transmitter on the Deaerator led to dry of pump
  26. 26. NRV at BFP exit Failure Process flow from Deaerator to Steam generator
  27. 27. Leakages in compressed air piping Schematic sketch of compressed air flow
  28. 28. Communication problem between level I and level II Control System Hierarchy for the solar thermal power plant
  29. 29. Steam System valves •Problem in complete closing of the valve • Manual closing of Valve – Not possible • Control Valve in the Steam Line – Regulate pressure Control Valve without Handle Control Valve with Handle
  30. 30. Mechanical Seal-Frozen Oil Particles (March 17, 2013)
  31. 31. Dirt/Oil particles collected from the basket filter at suction of Main HTF Pumps (March 17, 2013)
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