National Thermal Power Corporation Limited Kawas Gas Power Project Kawas Gas Power Project A unit of M/s

s National Thermal Power Corporation, ndia Limited! "rief ntroduction# nstalled Capacit$# %&% M' Num(er of Gas Tur(ines and waste heat reco)er$ (oiler# *+ Num(er of ,team Tur(ines# *Confi.uration# - / 0- Gas Tur(ines 1 ,team Tur(ine2 Gas Tur(ine# Ma3e# G4, 5rame# G4 6**74, Model# PG67%74, "ase Load Capacit$ 8 7*% M', Pea3 Load capacit$ 8 77* M' Control ,$stem# ,peedtronic Mar3 9 :peratin. t$pe of fuel# Natural Gas/;istillate 0A<N, NGL, =,;2 :peration Mode# Gas 5uel, Li>uid fuel, Mi? 5uel :peration! ,team Tur(ine# Ma3e# G4C Alstom @ <ateau, Capacit$# 77% M', =P Tur(ine# *7 No, LP Tur(ine# *7 No! ,team Tur(ine Control s$stem# <4C@6-* 0,upplied "$# M/s Ce.elec, 5rance2! 'aste =eat <eco)er$ "oiler# Ma3e# CM ! T$pe# ;ual drum, assisted circulation, )ertical, unfired, dual pressure (oiler! ;i)erter ;amper Ma3e# Metrofle?, T$pe# ,in.le 5lap, Position# =oriAental B 9ertical! At Kawas Gas Power Project, we are stri)in. to reduce num(er of trippin. and unplanned forced outa.es! n this re.ard, we want to (ench mar3 one parameter i!e! CTrippin. of Plant on account of Controls B nstrumentation sectionD! 'e ha)e wor3ed out )arious trippin. at Kawas Gas Power Project and want to share with $ou!

9arious Major and repetiti)e Trippin. at Kawas Gas Power Project on account of Controls B nstrumentations of the plant!
Trippin. Cause/Protection GT trippin. due to Li>uid, Gas Lea3 ;etection! 5E *7@*5E *-@*F 5E *F@*+ 5E *+@*& Total Trips 7<emar3 These were caused due to failure of lea3 detectors, associated electronics components and ca(le (urn! These include spurious B actual trippin.! :ccurred due to malfunction, failure of h$draulic components of di)erter damper! These are all a)oida(le trips! Trippin. of ,team tur(ine due to failure of -+* 9AC GP, s$stem! Trippin. of .as tur(ine on mal operation of fire detection s$stem due to earth fault! These trippin. include spurious trippin.! These trippin. occurred due to failure, malfunctionin. of ser)o )al)es of .as tur(ine due to oil >ualit$!

GT Trippin. due to =<,G ;i)erter ;amper ,T trippin. due to failure of GP, ,$stem GT trippin. due to 4arth 5ault or 5ire Protection s$stem failure! GT trippin. due to Mal 5unction of Gas/Li>uid ,er)o 9al)es!

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Action/ nitiati)es ta3en to a)oid spurious trippin. due to lea3 detection All the ca(le of lea3 detector in tur(ine compartment is replaced with hi.h temperature Teflon coated ca(les! 'ith this modification trippin. due to ca(le (urn is remo)ed and no trippin. after Eear@-**7 is o(ser)ed! ;urin. each o)er hauls the ca(le is me..ered , if re>uire chan.ed! All the Li>uid lea3 detectors are replaced e)er$ ,/; li3e C , =GP B M ! Action/ nitiati)es ta3en to a)oid trippin. due to 4arth fault and 5ire detection s$stem# 5ield wirin. of fire sensors are modified and Humpers located in e?haust compartment for fire sensors were shifted to Marshallin. panel! 'ith this modification, it is possi(le to chec3 indi)idual sensors from LC<! Ca(le in e?haust compartment of fire detection s$stem is replaced in planed ,/; li3e =GP , M and C All the fire sensors after remo)in. from field are thorou.hl$ chec3ed for terminal healthiness, wire cut and insulation resistance! All the fire sensors with low me..er )alues are rejected!

 ,pecial precautions are ta3en durin. connection of fire sensors in field! Hac3et insulation are pro)ided on each core of wire to a)oid earth fault! ,ilicon adhesi)e sealant paste is pro)ided on each fire sensor terminal! This measure remo)e the pro(a(ilit$ of earth fault at termination point due to )i(ration! After installation complete healthiness of s$stem is chec3ed ($ performin. me..erin. from ,peedtronic panel! II@"T B II@9G limit switch ca(le is replaced with hi.h temperature ca(le to eliminate earth fault due to (urnin. of ca(le! All ca(les in tur(ine compartment are replaced with hi.h temperature ca(le ($ pro)idin. additional H" outside tur(ine compartment! 5le?i(le ,, conduits are pro)ided in place of fi? conduit to eliminate ca(le cuts! Action/ nitiati)es ta3en to a)oid trippin. due to 5ailure of 5uel components of Gas tur(ine# 5uel chan.eo)er is carried@out as per de)eloped procedure, where Load is reduced to J* M', G9 is 3ept off, Au?iliar$ =$draulic pump is started! :pportunit$ (ased fuel chan.e o)er is carried from the Local panel in presence of CB representati)e! The schedule fuel chan.eo)er is stopped! Chec3in. of fuel components s$stem ($ alternate methods li3e rotatin. 5low di)ider ($ openin. drain )al)es, Periodic cali(ration of control )al)es! Continuous monitorin. of the lu(e oil >ualit$ ($ testin. in <B; la( and at e?ternal la(s li3e ,=4LL! "etter inline filter 0& Micron A(solute2 is pro)ided in h$draulic s$stem of Gas Control and ,top ratio )al)e! solatin. )al)es are pro)ided in h$draulic s$stem of Gas fuel and Li>uid fuel s$stem! "etter lu(e oil filters are pro)ided in s$stem 0F Micron2! Chan.in. of all line filters durin. shutdowns! :nline filterin. s$stem is (ein. installed! <eplacin. old lu(e oil with new lu(e oil! 5uel chan.e ramp rate modification was proposed and it was accepted ($ :4M! mplementation shall (e carried with mi? fuel firin. s$stem! A)oid fuel chan.eo)er when onl$ one GT is in ser)ice and other is under o)erhaul for eliminatin. pro(a(ilit$ of trippin. of ,T! Additional isolatin. )al)es are pro)ided in h$draulic s$stem (efore ser)o )al)e to facilitate online replacement of ser)o )al)es!

5eed(ac3 5orm Name of the firm# nstalled capacit$# Num(er of Gas tur(ines B ,team tur(ines# Confi.uration# 0- GT 1 7 ,T etc2 Gas Tur(ine Control s$stems# ,team Tur(ine Control ,$stem# =<,G Control ,$stem# PL5 B A)aila(ilit$# T$pe of 5uels#

Gas Tur(ine Trippin. ;ata#

Trippin. Cause, Protection Malfunction of Control ,$stem =uman error while wor3in. in control panel! ,purious Gas/Li>uid Lea3 ;etection Actual Gas/Li>uid Lea3 ;etection Trip on Malfunction of 5ire protection due to 4arth 5ault or other fire s$stem components! Trippin. due to Malfunction of field instruments! 5E *7@*5E *-@*F 5E *F@*+ 5E *+@*& Total Trips <emar3, :(ser)ations and <emedial Measures emplo$ed!

Malfunctionin. of fuel s$stem components li3e ser)o )al)e, L9;T, clutch, flow di)ider etc! 5ailure of Power suppl$! :ther Trips

,team Tur(ine Trippin.#

Trippin. Cause, Protection Trippin. due to control s$stem components failure! 5ield instruments 5ailure/Malfun ction trippin. Trippin. 5ailure of Power ,uppl$! =uman 4rror 5E *7@*5E *-@*F 5E *F@*+ 5E *+@*& Total Trips <emar3, :(ser)ations and <emedial Measures emplo$ed!

Trippin. due to failure of 9i(ration ,$stem components!

:ther Trippin.

"oiler Trippin.
Trippin. Cause, Protection Mal 5unction of instruments! 5ailure of control s$stem 5ailure of Power suppl$! =uman error! 5E *7@*5E *-@*F 5E *F@*+ 5E *+@*& Total Trips <emar3, :(ser)ations and <emedial Measures emplo$ed!

:thers Trippin.