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For the first time in India, a 210
MW power unit was commissioned in 27 months setting
an International Record & Desein is proud to be
associated in providing Consultancy on various
packages and furnishing engineering & construction
documentation to achieve the record
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RAICHUR THERMAL POWER STATION
EXTN-UNITS 5 & 6 EACH OF 210 MW CAPACITY
Desein was involved in providing Consultancy to
Karnataka Power Corporation Ltd. for extension Unit #
5&6. This project was funded by various financial
Institutions, Banks & Major equipment supplier, as
such timely completion of the Project was a key factor in
this job since delay in achieving every milestone was
linked with liquidated damages.
The Unit No.5 was scheduled to be commissioned and to be
taken over for commercial operation in 156 weeks (i.e.
36 months) and Unit No.6 in 182 weeks (i.e. 42 months)
from zero date which was reckoned from 2nd September,
1996.
Commissioning & Commercial operation of each Unit
was later preponed by six (6) months as Main Equipment
Supplier agreed to prepone his supplies. Desein took the
challenge in providing engineering & construction
documentation to meet the preponed schedule which resulted
in achieving the target even before the preponed Target
Schedule as shown below:
Zero Date for start of the
Project.................. 2-9-96
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Activity |
Unit # 5
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Unit #
6
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| Mile Stone |
Schedule |
Actual |
Schedule |
Actual |
| Boiler
Erection Start |
30-06-97 |
18-06-97 |
28-12-97 |
24-12-97 |
| Drum Lifting |
26-01-98 |
01-11-97 |
27-07-98 |
30-04-98 |
| Boiler Light
Up |
25-01-99 |
19-11-98 |
26-07-99 |
20-05-98 |
Synchronization
& Commissioning |
24-05-99 |
30-01-99
(27
months) |
22-11-99 |
22-07-99 |
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As indicated above preponed target date of 30 months was
in actual achieved in a record time of 27 months setting
International Utility Record in Commissioning of 210 MW
Coal fired thermal power unit.
STEAM GENERATOR & AUXILIARIES
Steam Generator & other Auxiliaries installed at Raichur
was convensional
two pass, radiant reheat, natural circulation
water cooled welded wall
furnance, single drum, semi outdoor
type unit to use as coal as principal
fuel.
Firing system equipped
with High Energy Arc ignitor system & tilting
nozzle type
corner fired coal burners connected to a master control
lever
which actuate all nozzle to the same degree simultaneously
as a unit, for
stablizing flame as per load requirement
for automatic/ remote operation.
TURBINE GENERATOR & AUXILIARIES
Fully hydrogen cooled generator with brushless
excitation system
excitor
used as advance technology in the TG unit installed.
Two pass type Condensers installed with stainless steel
tube in air zone &
cupro-nickled tubes in water zone for
longer life of tubes.
HP heater and LP heater were provided
of vertical construction for compact
installation and
effective drainage.
INSTRUMENTATION & CONTROL
With increase in Unit size of plants, the number of points
required to be monitored as well as the number and complexity
of the control loops has increased rapidly. This has necessitated
an increase in the instruments and fast dynamic displays
to be provided on the control panel for operator's interactions
which has further resulted in miniaturisation of instruments,
computerised data acquisition system, microprocessor based
distributed Digital Control system for close loop and
open loop control, sequence of event recording with millisecond
resolution, auto start of various drives with group control
system.
In order to meet with the above objectives, Control
Instrumentation (C&I) package for Raichur Unit 5&6 was
provided. Salient features provided under C&I package
are described as follows:
Control
System Equipment
Computerised Digital Distributed Control and management
information system (DDCMIS) Centum-XL have been provided
for modulating control, protection and sequential Control
functions of plant through redundant I/O cards, redundant
32 bit process and state of art Man-machine interface
modules. The system is based on multi loop/ multi function
controller concept.
Complete automation has been provided by integrating
open loop and close loop control functions and by providing
operator guidance message on CRT, complete automatic start-up,
loop up, shut down operation under cold, warm and hot
status of the plant in a prescribed manner thus avoiding
human errors. For sequence of operations stand above SER
system of RIS have been provided.
Turbo Generator supplier
provided control system Procontrol P-B for integral Turbine
Control for ATRS, TSI etc. similarly for integral Steam
Generator control for burner management system Procontrol
P-B have been provided. In addition various fields instruments
of latest design have been used for this project.
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