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  • 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:
  • 2. Schematic of process flow for the solar thermal power plant Process flow diagram
  • 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. Parabolic Trough Solar Field
  • 5. Linear Fresnel Reflector
  • 6. Commissioning Experience Classification of commissioning experience
  • 7. Operational Problems
  • 8. Linear Fresnel Reflector
  • 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. Equipment Problems
  • 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. System Problems
  • 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. 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. HTF Freezing TG TG Schematic of Oil System
  • 16. Pump Seal Failure: February, 2013
  • 17. Dirt/Oil particles collected from the drain point near heat exchanger (March 17, 2013)
  • 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. Summary and Lesson Learnt • System Problem HTF Freezing: Unfreezes only in summer. UPS and Tracker failure: Continuous Power supply
  • 20. Commissioning problems in chronological order
  • 21. THANK YOU
  • 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. 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. Leakages in the superheater – 10/03/2013 Steam Leakage
  • 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. NRV at BFP exit Failure Process flow from Deaerator to Steam generator
  • 27. Leakages in compressed air piping Schematic sketch of compressed air flow
  • 28. Communication problem between level I and level II Control System Hierarchy for the solar thermal power plant
  • 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. Mechanical Seal-Frozen Oil Particles (March 17, 2013)
  • 31. Dirt/Oil particles collected from the basket filter at suction of Main HTF Pumps (March 17, 2013)