project report - finalhipc-ye.com/pdf-files/merge24.pdf · all hfo separator started and completed...

PROJECT REPORT - FINAL (Installation & Commissioning)

Harshiyat Power Station (HIPC) Place: Hadramout Investment Power Company Ltd.(HIPC) Al- Harshiyat Power Station 75 MW Power Plant, Mukalla, Yemen.

Engine Model : Wärtsilä18V32. Engine Serial Number: PAAE150665, PAAE150666, PAAE150667, PAAE150668, PAAE150669,

PAAE150670, PAAE167202, PAAE202656’PAAE202657 & PAAE202658. 1 HIPC 23 January 2011

Contents

■ General Information

■ Shipment

■ Technical

■ Installation

● Civil

● Mechanical

● Electrical

■ Pre-commissioning

■ Commissioning 2 HIPC 23 January 2011

General Information Owner :Hadramout Investment Power Company (HIPC). Al-Harshiyat Power Station

75 MW Power Plants Mukalla, Yemen.

Suppliers : Wärtsilä Finland Oy. Tarhaajantie 2,

Fin-65101 Vaasa, Finland.

Engine Model : 10XWärtsilä18V32 Engine Serial Number: PAAE150665, PAAE150666, PAAE150667, PAAE150668, PAAE150669,

PAAE150670, PAAE167202, PAAE202656, PAAE202657 & PAAE202658. Alternator Type : AMG 1120 MR08 DSE Alternator Serial No. : 4602059, 4602060, 4602061, 4602062, 4602063,

4602064, 4605928, 4609026, 4609027 & 4609028.

General Information about Mukalla sites: • Site Location: Al-Harshiyat Power station, Mukalla, Yemen. • Type of Power Plant: Light Fuel Oil (LFO) and Heavy Fuel Oil (HFO) Power Plant. • Capacity of Plant: 75 MW Power Plants. • Owner of the Plant: Hadramout Investment Power Company Ltd (HIPC). • Site Altitude above Main sea level: 220m • Grid Connection: 33/11 kV. • Grid Frequency: 50 Hz. • Rural country side, Sand stone, Hill, Rock and Mount area (Dusty area).

3 HIPC 23 January 2011

Shipment First Shipment:

• Ship arrived at Mukalla sea port on 28.10.09 • Unloading started on 29.10.09

• Unloading completed on 30.10.09.

Second Shipment (Indian Portion): • Ship arrived at Mukalla sea port on 29.11.2009 • Material arrived at site on 13.12.2009.

Main Shipment: • Ship arrived at Mukalla sea port on 28.12.2009 • Unloading started on 29.12.2009. • Unloading completed on 01.01.2010.

Third Shipment (Extended part): • Vessel arrived at Mukalla sea port on 23.05.2010. • Material arrived at site on 25.05.2010.


Shipment

DG unloaded from vessel to Trailer

DG unloaded from vessel to Trailer


Shipment DG unloaded from Trailer to Foundation

Container unloaded from vessel to Trailer


Technical • Mechanical Basic Design received on 08.11.2009. • Electrical basic design received on 08.11.2009. • Mechanical detailed design received on 10.02.2010 • Electrical detailed design received on 10.02.2010.

Installation Civil

• Civil is not Wartsila scope but before placing the DG sets and others equipment to ensure that the foundation

leveling, center line and 0-line are marked as per Wartsila drawing. • Checked all DG sets foundation leveling, center line and 0-line, checked Engine auxiliary module foundation,

Compact booster unit foundation. • Checked Exhaust gas Boiler, Exhaust gas silencer, Auxiliary boiler container, Charge air filter, Cooling water

radiator, Station transformer and Black start container foundation. • Fuel treatment house (Feeder unit, HFO Separator & Oily water treatment unit foundation), Day tanks foundation,

Fire water tank, Treated water tank, and Water treatment unit container foundation checked. • HFO & LFO Storage tank, Unloading station and transfer pump units foundation checked.


Foundation Power House concreting

DG -sets Foundation


Foundation

Stack Foundation Tank Foundation


Mechanical DG-sets Installation

• DG-sets placed on foundation and checked spring location, centre line and 0-line • Engine auxiliary module alignment along with Engine and fixed on foundation with anchor bolts • Compact booster unit alignment with Engine auxiliary module and inter connect the flanges. • Exhaust gas module Installed respect to the DG sets.

DG sets

Engine Auxiliary Module

Compact Booster Unit


DG-sets, EAM, CBU & EGM Installation Compact Booster Unit

DG sets Engine Auxiliary Module

DG sets on Foundation 11 HIPC 23 January 2011

DG-sets, EAM, CBU & EGM Installation EGM Placed on Foundation

Fuel system: ● HFO and LFO unloading pump unit are placed on foundation.

● HFO and LFO Feeder unit has been placed on foundation.

● LFO transfer pump unit has been placed on foundation.

● HFO and LFO Piping (Inside Power house and outside Power house) fabrication, welding, pressure test, pickling and flushing checked with HIPC representative.

● HFO and LFO Storage tank Fabrication, welding and pressure test checked with HIPC representative.

● HFO day tank, buffer tank and LFO day tank fabrication, welding and pressure test checked with HIPC representative.


Fuel oil system

HFO & LFO Storage tank, & Unloading pump units

HFO & LFO transfer pump unit 13 HIPC 23 January 2011

HFO & LFO Feeder Unit

Mechanical Installation

Cooling water system: • Maintenance water tank placed on foundation. • Radiators have been placed on foundation (with legs) including railings. • Cooling water piping (Inside & outside power house) fabrication and welding checked. • Cooling water piping pressure test and flushing checked.

Cooling water Radiator Cooling water Piping 14 HIPC 23 January 2011

Mechanical

Compressed air system: • Starting air Compressor unit and Starting air vessel has been placed on foundation. • Instrument air compressor unit and control air bottle has been placed on foundation. • Starting air and Control air piping fabrication, welding and pressure test checked.


Mechanical

Lubricating oil system: • Lubricating oil unloading pump unit has been placed on foundation. • Lubricating oil transfer pump unit (Stationary) have been placed on foundation. • LO piping (Inside and outside power house) fabrication , welding, pickling & flushing checked. • LO storage tank (Fresh & Used) and service tank fabrication, welding, and pressure test checked.

LO Unloading pump unit LO Transfer pump unit


Mechanical Compressed air system: • Starting air Compressor unit and Starting air vessel has been placed on foundation. • Instrument air compressor unit and control air bottle has been placed on foundation. • Starting air and Control air piping fabrication, welding and pressure test checked.

Starting & Instrument Air compressor unit Starting Air Vessel

Instrument air system Commissioning: Checked all suction/delivery valve in the compressor, air vessel & Dryer. Checked oil level in compressor, power supply in the local panel, checked vessel & dryer drainage solenoid valve functionality, start compressor and fill-up the vessel and checked any leakage. Supply the air in the main distributions line and checked any leakage.


Mechanical

Heat recovery system: • All exhaust gas boiler has been placed on foundation. • Auxiliary boiler container are placed in foundation with feed water tank. • Steam header has been placed on foundation and piping works completed. • Boiler washing water pump and tank has been placed on foundation & piping completed. • Steam and Condensate piping fabrication, welding, pressure test and insulation completed.

Exhaust gas Boiler (EGB) 18 HIPC 23 January 2011

Mechanical Oily water system: Oily water treatment unit has been placed on foundation. Oily water transfer pump unit and feed pump unit has been placed on foundation. Oily water piping fabrication, welding and pressure test completed. Oily water buffer tank fabrication, welding sand blasting, pressure test & painting completed. Sludge loading pump has been placed on foundation and piping works completed. Sludge tank fabrication, welding, sand blasting, pressure test & painting completed.

Oily water treatment unit

Oily water transfer pump 19 HIPC 23 January 2011

Auxiliary system Commissioning

Instrument air system Commissioning: Checked all suction/delivery valve in the compressor, air vessel & Dryer. Checked oil level in compressor, power supply in the local panel, checked vessel & dryer drainage solenoid valve functionality, start compressor and fill-up the vessel and checked any leakage. Supply the air in the main distributions line and checked any leakage.

Instrument Air compressor units 20 HIPC 23 January 2011


Water supply system commissioning: Raw Filling in raw water tank, Control air line blow throwing, Suction & delivery valve checking in raw water booster unit. Multi layer & water softener tank checked, Nacl filling in Nacl Solution tank, Nalco PC- 191 filling in chemical dosing tank. Power supply in the panel board. Checking motor rotation in raw water Booster, treated water booster, RO pump & chemical dosing pump. Started the system and checked as per manufacturer instruction (Pump suction /delivery pressure, air pressure etc). Flow meter and level switch adjusted and successfully commissioning the water treatment system & producing treated water, test the water and found pH value is satisfactory. System run continuously and producing treated water as per boiler & DG sets requirement .

Water Treatment unit



Fuel (LFO) oil system: LFO unloading pump and transfer pump suction and delivery valve checked and kept open position, power supply on in the local panel board, checked motor/pump rotation after that pump started and unloading LFO from tank lorry to LFO storage tank (Flow meter reading checked with HIPC representative) and same procedure LFO transfer from Storage tank to LFO day tank. LFO feeder unit: LFO day tank to Feeder unit and feeder unit to auxiliary boiler day tank and power pouse all valve checked and kept open position. Control air checked, power supply to feeder unit local panel board, checking Motor/pump rotation after that LFO Feeder started and shifting LFO day tank to Auxiliary boiler day tank and also checked all LFO pipe line any leakage. Fuel (HFO) oil system: HFO unloading pump and transfer pump suction and delivery valve checked and kept open position, power supply on in the local panel board, checked motor/pump rotation after that pump started and unloading HFO from tank lorry to HFO storage tank (Flow meter reading checked with HIPC representative) and same procedure HFO transfer from Storage tank to HFO buffer tank. Fuel oil 3-way valve checking and found actuator solenoid valve defective and replaced solenoid valve from extension part. Pre-heating the HFO buffer tank. Separator Commissioning: Checked HFO buffer tank to separator all suction/delivery valve and kept open position, checked instrument air, steam and condensate line and treated water line etc. all HFO separator started and completed commissioning (Separator commission by Westfalia commissioning engineer) . HFO feeder unit: HFO day tank to Feeder unit and power house all valve checked and kept open position. Control air checked, power supply to feeder unit local board, checking Motor/pump rotation, Auto and manual filter checked, Viscometer function checked after that HFO Feeder started and checked main HFO pipe up to CBU.


Auxiliary system Commissioning HFO & LFO Feeder unit

HFO Separators units



Cooling water system: Filling treated water with cooling additives in Maintenance water tank . checked maintenance water transfer pump rotation, mixing water with additives, maintenance water tank to system suction & delivery valve kept open position, after that cooling water filling in the system and checked leakage, water filling radiator also. Radiator fan functionality checking. Expansion vessel checked.

Cooling water Radiator



Compressed air system: Checked all pipe line up to start air vessel & engine auxiliary modules, checked all suction & delivery valves in compressor & air vessel, oil filling in compressor as per manufacture instruction. Power supply in local panel board, compressor rotation checked. Start compressor fill-up the vessel and checked any leakage in compressor to vessel. Supply the air in the main distributions line and checked any leakage.

Starting compressor unit Starting Air Vessel 25 HIPC 23 January 2011


Charge air & Exhaust gas system: Charge air duct and charge air silencer inspect, Charge air filter (dry pack) cleaned, oil filling in charge air filter. Exhaust gas ducting & silencer inspect, water lock inspect.


Mechanical Auxiliary system Auxiliary Boiler Container Exhaust gas Boiler

Black start container

Steam Header Oily water treatment unit


Electrical Wartsila Scope for Electrical system: 1. LV system: Complete 2. MV system: Complete 3. DC system: Complete 4. Control and monitoring system: Complete HV system was in scope of HIPC and it was supplied by M/S MN Dastur, India, Ltd. Installation and erection with commissioning support was covered by M/S HIDELECO Evaluation Delivery and Material Handling:

Delivery Time from Wärtsilä Satisfactory

HV system including Transformer delivery was delayed

Custom Clearance - Satisfactory

Transport to Site- Quite Satisfactory

Storage/ Store Keeping Quite Satisfactory

Material Handling in site Quite Satisfactory and in safe way Erection

Contractor used proper tools

Contractor followed Wartsila’s guide line and safety instruction

Wartsila Supervisory support was well behind to the contractor

HIPC scope

HIPC scope.

Erection failure was minor- in MV panel some analog meters and selector switch were damaged


Electrical - continued Contractor’s skill and competency were well satisfactory Co-ordination among electrical, mechanical and civil was Moderate

Erection Difficulties and suggestion: Cable Ladder Layout- MV panel Doors Less space in Switchgear

In some places, cable ladder routing was so difficult due to less space. Specially in the Auxiliary Module area.

Found couples of MV cubicle doors are misaligned. And lock was not properly operable, specially the breaker doors. Rectified at site.

It was a compact switchgear room including LV, MV and MV (33KV). The space was not sufficient. For better cooling, air flow path and safely operation, a more specious room would be better.

Frequency Converter of Feeder Unit

Three frequency converters for Fuel feeder unit were located in Fuel treatment unit. Due to * heavy high temperature * humidity * Possibility of more dirt in fuel treatment room It would be better to put those frequency converters in a separate cubicle with force ventilation facility. That cubicle would be placed along with BFA902 (LV panel at Fuel treatment house).

Engine hall ventilation unit (Generator side)

Frequency converters were inside the ventilation unit. and there was no maintenance plat form/ ladder around the ventilation unit. It was difficult to work with the Frequency converters.

FC could be relocated in the engine hall just below the louver of ventilation unit/ near by the Neutral cubicle.

BJA panel Sensor/actuator end connections were open, at site they were connected. It should be connected from factory. We have reported this issue in a separate report during installation.


Electrical - continued Pre-Commissioning

Pre-commissioning was performed according to the co-ordination plan with mechanical system requirement and completion There was sufficient man power with satisfactory skill from contractor. Contractor was quite helpful and knowledgeable. The overall pre-commissioning was :

- Well coordinated and planned - Less error found for connection - Quick rectification support whenever modification advised or required

Pre-commissioning Difficulties and Suggestion

LV Power

Delay of 33KV System initiated the difficulty. Had to use black start unit for pre-commissioning support though HIPC arranged small generators. But it was very risky when multiple generators are connected to the LV system and frequent change over required.


Electrical- Continued Pre-Commissioning Sequence-


Electrical- Continued Commissioning

Commissioning was delayed due to 33KV system readiness HIPC connected one temporary 11KV line to the Spare (Factory) Feeders- BAO902

First commissioning was done with this temporary line and its capacity was only 4.5~5.0MW

With this load limit only one engine could be operated

So one by one engine was tested It took too long time HIPC proposed one more 11KV temporary line to BAO904


Electrical - continued

Engine governed by UNIC-C1. the followings are to note for UNIC-C1: a. The hardware configuration was not exact the supplied installation drawings. The Speed control signal from AVR during Sync was connected to different port b. The Base software for UNIC-C1 had very fast PID parameters c. The Speed sensors ( Flywheel) needed to adjust

AVR synchronization

Very stable synchronization obtained

Soft-start

Very stable soft start performed 33 HIPC 23 January 2011

Electrical- Continued Some pictures


Electrical- Continued 35 HIPC 23 January 2011

Electrical- Continued

Overall Evaluation Wartsila Scope: Erection Contractor: HIPC’s Scope:


Engine hall with DG-sets 37 HIPC 23 January 2011

Power House 38 HIPC 23 January 2011

Power House 39 HIPC 23 January 2011

Control Room 40 HIPC 23 January 2011

Electrical Switchgear 41 HIPC 23 January 2011

project report - finalhipc-ye.com/pdf-files/merge24.pdf · all hfo separator started and completed...

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