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15

SEPTEMBER 2010
FEED BACK NO. 2

TS TIDINGS

PROJECT: SILK ROAD SUGARS, KAKINADA, 1X35MW,FRAME 6B GTG PROBLEM: GAS VALVES INTERSTAGE PRESSURE BETWEEN SRV (STOP RATIO VALVE) AND GCV (GAS CONTROL VALVE) HIGH CAUSING CONTINUOUS VENTING OF GAS AND START PERMISSIVE NOT AVAILABLE. Problem details and analysis: The gas turbine supplied to Silk road sugars, Kakinada is originally for gas fuel only. Due to non availability of gas, GT was commissioned in October 2009 with liquid fuel after carrying out necessary modifications. Customer received gas and GT was commissioned with natural gas in the first week of September 2010. While commissioning the Gas fuel system for the GT, it was observed that while charging the Gas fuel upto Gas valve compartment from the customer Gas filter skid, heavy noise was observed from the Gas skid vent line and confirmed that the gas was coming out from the vent line which is gas valves interstage vent point. Interstage lies between Stop speed ratio valve and Gas control valve and it was suspected that the SRV was passing. It was also noticed that the interstage pressure was showing almost that of the Gas supply pressure but it was building up very slowly. Gas turbine start permissive was also lost due to interstage fuel pressure high. Matter was referred to BHEL, hyderabad and upon their instructions it was decided to carry out air blowing of the line up to the exit point from the Gas fuel skid. This was done to eliminate the foreign particles that might have stuck in the SRV valve seat. The entry point to the Gas fuel skid was dummied and the pipe leading to the GT was disconnected. Instrument air line was connected to one of the pressure gauge point of the system. Air blowing was done by pressurising the line and opening both the valves (SRV and GCV) one by one for depressurisation through the exit point. Air blowing was carried out 10-15 times and observed that rust was coming out of the pipeline. After normalisation once again Gas was charged upto gas fuel skid and same condition which had prevailed earlier was once again observed. It was decided to service the valve. Valve was dismantled, serviced and lapped after getting the valve drawings from BHEL Hyderabad. It was observed that high amount of Rust was accumulated in the valve and casing and was cleaned thoroughly using Diesel. Blue matching was done after lapping and found to be perfect.
TECHNICAL SERVICES / PSSR

16

SEPTEMBER 2010

TS TIDINGS

After assembling back the valve, Gas was once again charged and it was observed that still heavy noise was observed through the vent. Subsequently the impulse pipeline connections and vent connection which was done at BHEL Hyderabad, was verified using the valve drawings. On inspection it was found that the vent line connection was taken from SRV top which is same as that of the supply point and was not matching with the valve drawings. As per the valve vent line has to be taken from the bottom as shown in the figure below which is encircled.

TECHNICAL SERVICES / PSSR

17

SEPTEMBER 2010

TS TIDINGS

TECHNICAL SERVICES / PSSR

18

SEPTEMBER 2010

TS TIDINGS

After correcting the same, Gas was charged and found everything to be normal. Interstage pressure was also reading zero. Gas Turbine was started with gas firing mode. MIXED FUEL OPERATION OF GTG. As both the fuels are available and as per customer need, mixed Fuel firing operation was also established for the GTG, firing with both NAPTHA and GAS. Fuel sroke reference (FSR) for both the fuels will be different. Ie for Liquid fuel, FSR will be termed as FSR1 and for gas fuel it will be FSR2. Mixed fuel operation has been carried out by following steps. 1. Gas turbine was kept under a load of 16 MW which is the minimum load required for the mixed fuel operation. 2. Minimum FSR1 required for mixed fuel operation is 8.5% and Minimum FSR2 required is 17.36%. 3. At 16 MW load, FSR (Combined value of FSR1 and FSR2) with any of the fuel alone was observed to be around 30%. 4. Machine was kept running with Gas, and Distillate selection was made ON from the Graphics page. On selection, Liquid fuel stop valve got opened, Bypass Servo valve current became active, Warren fuel pump clutch got engaged, and FSR2 started reducing after one minute and FSR1 started increasing. When the FSR conditions as said in point no.2 got satisfied, the MIX fuel selection was executed and both the FSRs stayed at that value itself with the mix value percentage. 5. Mix fuel selection was also carried out by keeping the machine running with Naptha and Gas selection was executed. Gas Stop solenoid valve got energized, SRV got opened and FSR1 started decreasing and FSR 2 started increasing. When the FSR conditions were met, the MIX fuel selection was executed. Conclusion: After modifying the tap off point for the interstage impulse and vent line from the valves block assembly to the correct location GT gas firing was successfully carried out.

TECHNICAL SERVICES / PSSR