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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 BombayFunded by
Ministry of New and Renewable EnergyCorresponding Author. Tel: +91 22 25764794, E-mail: [email protected]
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 different collector technologies
Direct and indirect steam generation to be demonstrated
Simulation package for scale-up
Test facility for solar thermal applications to facilitate the development of indigenous technology
Consortium based approach involving government and industry
Project Landmarks
January 2010
January 2011
July 2013
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
• 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
Leakage in the receiver tube
Equipment Problems
Leakages in instrument stub connections on heat exchanger
Temperature Transmitters showing Leakages
Leakage from Screwed connection
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
System Problems
HTF Freezing
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Ambient temperature profile at the project site on February 24th, 2013
• Crystallization temperature of HTF Therminol VP1 is 12°C
HTF Freezing Manual Operation Temperature gauge readings at Main HTF Pump discharge and outlet of solar fieldTemperature of HTF ~350C Pump at minimum flow rate
Schematic of Oil System
HTF Freezing
Schematic of Oil System
TG
TG
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 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
Summary and Lesson Learnt
• System Problem HTF Freezing: Unfreezes only in summer.UPS and Tracker failure: Continuous Power
supply
Commissioning problems in chronological order
THANK YOU
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.
receiver glass window breakage the LFR system
Breakage of the receiver window glass
Receiver Window Glass Breakage
Interruption in power supply to the tracking motors, focus shifted partially
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 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
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 the Steam Line – Regulate pressure
Control Valve with HandleControl Valve without Handle
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)
