Compliance TO NTPC Comments

Document: FAT PROCEDURE FOR PADO

Project: NORTH KARANPURA (3X660 MW)
REF: CC405:30112 DTD 21-05-2020
Document No : 4410-001-405-PVI-Y-223

Sl.No NTPC Comment BHEL Compliance

1 Performance document has been commented with ACC performance will be
issues related to air cooled demonstrated inline with the
condenser. The same to be incorporated in this previous FATs as per enclosed
document also. “Annexure-
How performance of ACC will be demonstrated in 1(ManualCalculation.xlsx)”
FAT ?
Please incorporate the same suitably.

Digitally signed
Signature Not Verified
by kailash
Date: 2020.09.01
12:13:18 IST
Reason: CAT I
Location:
NTPCEOC

01_Compliance to NTPC comments.doc Page 1 of 1

PADO:FAT PROCEDURE
North Karanpura STPP (Stage-I), 3 X660 MW

FACTORY ACCEPTANCE TEST

PROCEDURE
OF PADO
FOR
NORTH KARANPURA SUPER THERMAL
POWER PROJECT
STAGE I (3 X 660 MW)

Bharat Heavy Electricals Limited.

Mysore Road, Bangalore
This document contains proprietary information of. Bharat Heavy Electricals Limited and is tendered subject to the
condition that the information be retained in confidence.
Revision History

Release Prepared Approved

Rev. Reason Nature of Reviewed
Date by by
no. Changes by

00 20.01.2017 Initial Abhishek Sai

Amit Joel
Submission Anand Kumar

01 13.11.2019 Modified as per transmittal Ref: Minor Ashvini N Ramesh

CC405:15485 dtd 16.04.2017 Amit Joel
Sukhadeve Kumar
02 11.08.2020 Modified as per transmittal Minor Ashvini N Ramesh
Ref:CC405:30112dtd21.05.2020 Amit Joel
Sukhadeve Kumar

4410-001-405-PVI-Y-223-R02 Page 2 of 10
 Test Setup for North Karanpura II PADO FAT

PADO Ethernet
PADO WORK
SERVER Switch
STATION

PADO Server:

• Function:
This node is used as PADO Server.

• All PADO modules loaded:

- SRx (Visualisation)
- SRv (Data Validation)
- SR4/SR-EPOS (Performance Analysis &Monitoring)
- BCM (Boiler Cleaning Management)
- MT (Metal Temperature Calculation)
- What-IF(offline)
- SR1 (Boiler Stress Condition Analyzer)
- SPO (Set Point / Emission Optimization)
- FT (Diagnostics &Water Chemistry)
- MOR (Merit Order Rating)

PADO Workstation:

• Function:
This node is used as Workstation for PADO server.
• Software modules loaded:
PADO Visualization Screens.

4410-001-405-PVI-Y-223-R02 Page 3 of 10
 • Objective: Verification of the SR4/ SR:EPOS scope of supply and
functionality

Sl. Description Test Procedure Expected System Remarks

No. Results Results
1.0.0 Performance Analysis &Monitoring
Visualization screens :
1.Performance
Summary. 2.Boiler.3
BPOS Backward
calculations.4.Metal
Temperature for
FSH.5.Metal
Temperature for FRH.
6.Turbine cycle.
7.Turbines.8.Condenser.
09.HP Heaters.10.LP
Heaters. 11. Fans.
12.AH-A.13.AH-B.
14.Set Point
Basic screens enabled
Optimization.
for Plant overview,
15.Soot Blowing
Boiler, 28 screens
Optimization.
Turbine cycle, available.
16.Auxillary Power
Air / flue gas,
Consumption.
Condenser
17.Energy Consumption
Index. 18.Specific
Energy Consumption.
19.Station Auxiliaries.
20.Mill Optimization
21.MILL -A Overview.
22.MILL -B Overview.
23.MILL -C Overview.
24.MILL -D Overview.
25.MILL -E Overview.
26.MILL -F Overview.
27.MILL -G Overview.
28.MILL -H Overview

Calculated results will be Please refer

1.0.1 Unit Heat Rate (Gross) shown in screen. Note 1 given
below
Calculated results will be Please refer
1.0.2 Unit Heat Rate (Net) shown in screen. Note 1 given
below
Calculated results will be Please refer
1.0.3 TG Heat Rate (Gross) shown in screen. Note 1 given
below
Calculated results will be Please refer
1.0.4 TG Heat Rate (Net) shown in screen. Note 1 given
below
2.0.0 Plant And Equipment Efficiencies Calculation
Unit efficiency net Calculated results will be Please refer
shown in screen. Note 1 given
below
2.0.1 Boiler Efficiency by Calculated results will be Please refer
Heat Loss Method (BS shown in Note 1 given
EN 12952) below
4410-001-405-PVI-Y-223-R02 Page 4 of 10
2.0.2 Air Heater Calculated results will be Please refer
- Leakages and shown in screen. Note 1 given
Monetary below. Changes
Losses in X-Ratio and
- Efficiency Efficiency can
- X-Ratio be seen in
visualization.
2.0.3 Turbine HP/IP/LP Calculated results will be Please refer
Efficiency shown in screen. Note 1 given
below
2.0.4 LP/HP Heater TTD Calculated results will be
and DCA. shown in screen. Please refer
Note 1 given
below

2.0.5 Condenser Efficiency Calculated results will be Please refer

shown in screen. Note 1 given
below
2.0.6 Boiler Feed Pump and Calculated results will be Please refer
Condensate Extraction shown in screen. Note 1 given
Pumps Efficiencies below
2.0.7 Fan Efficiencies- Calculated results will be Please refer
FDF,PAF,IDF shown in screen. Note 1 given
below
2.0.8 ESP- Collection Calculated results will be Please refer
Efficiency, Opacity shown in screen. Note 1 given
below
2.0.9 Heating Surface Calculated results will be Please refer
Evaluation shown in screen. Note 1 given
below
2.0.10 Generator Efficiency Calculated Generator Value can be
efficiency will be shown seen in
in screen. Visualization.
2.0.11 Emission Monitoring Emission parameters Value can be
like CO2 etc. are seen in
calculated. Visualization
2.0.12 Coal Mill evaluation Parameters like Mill
capacity, Power
Value can be
consumption etc., are
seen in
calculated as part of
Visualization
Coal Mill evaluation will
be shown.
3.0.0 Controllable Losses Calculation
3.0.1 Evaluation of steam Screen showing Screen provided
cycle parameters controllable Losses will with controllable
(controllable losses) be shown. Losses
•Throttle temperature
•Throttle pressure
•Reheat temperature
•Reheat pressure drop
•Condenser pressure
•SH spray flow
•RH spray flow
•Final feed water
temperature
•Make up flow to
Hotwell

4410-001-405-PVI-Y-223-R02 Page 5 of 10
4.0.0 What If Analysis Sample test case like
available with the
scenarios as per MS Temp
attached Annexure-4 Feed Water I/L Temp
will be demonstrated.

5.0.0 Boiler Cleaning Soot Blowing Colour changes See Note 2

Management requirement as per of heating
Time based and Surface and SB
Heating surface status can be
efficiency / fouling seen in
settings Visualization

Note 1: Excel Sheet with calculation formulasshall be prepared for checking the results. In this
sheet the expected value will be calculated based on measurement data during FAT. This will be
compared with calculated results of PADO.During Test some input values will be changed and
corresponding changes will be shown in Excel sheet and PADO Screens and values will be
compared, the excel sheet has been attached as Annexure-1.

Note 2.: To demonstrate the functionality of soot blowing module the efficiencies of heating
surfaces must be changed over the time like they change on site i.e. slow decreasing trend and
rapid increase after soot blowing. Such trends for all heating surfaces must be available for the
BCM module. All parameters for BCM like time periods for soot blowing and limits for efficiencies
must be set corresponding to the trends with these artificial efficiencies trends. Preparation of
such data or collecting the data is practically difficult. Hence this feature will be demonstrated with
other site data.
However, Actual functioning with site specific settings shall be demonstrated at site.

4410-001-405-PVI-Y-223-R02 Page 6 of 10
 • Objective: Verification of the topology of the unit model
6.0.0 Graphical Modeling Tool
Sr. Description Test Procedure Expected System Remarks
No. Results Results
6.0.1 Topology of unit Topology of the Topology of
thermodynamic model Plant can be seen in the plant has
the Graphical been taken
Toolkit. General care.
functionality of
Graphical modeling
tool (e.g.
modification of unit
model, modification
of component
characteristics etc.)
will be
demonstrated.

6.0.2 Site dependent Implementation of System shows

Components base parameters the same no.
related to the plant of components
topology will be as exists in
shown. the Plant data.

• Objective: Verification of the SRopt scope of supply and functionality

7.0.0 Set Point Optimization
Sl. No. Description Test Procedure Expected System Remarks
Results Results

7.0.1 Set point parameters: Functionalities will be Actual Unit

•Set point parameters not demonstrated Heat Rate will
with optimized Heat due to non - be optimized
Rate will be displayed. availability of at the lowest
operating data, level of NOx
Testing will be done
at site during
commissioning.

• Objective : Verification of the SRmt scope of supply and functionality

8.0.0 Metal Temperature Calculation
Sl. No. Description Test Procedure Expected System Remarks
Results Results
8.0.1 Metal Temperature Calculated results will Screen shows
Calculation be shown in screen. measured &
calculated
values.

4410-001-405-PVI-Y-223-R02 Page 7 of 10
 • Objective: Verification of the SR1 scope of supply and functionality

9.0.0 Boiler Stress

Condition Analyzer
Sl. No. Description Test Procedure Expected System Remarks
Results Results
9.0.1 System functionalities of Status LTC &SR1 Status screen
SR1 visualization cockpit visualizations available with
available will be shown results.
9.0.2 Overview screen Overview screen will Overview
installed be shown. screen
available.
9.0.3 Basic calculation results Display on Overview Lifetime
on contributions to Visualization will be consumptions
lifetime consumption shown. are displayed
in the
overview
screen.
9.0.4 Creep and fatigue Display on Overview Creep and Sample Creep and
Visualization will be fatigue for the Fatigue calculations
shown. relevant are as per
components Annexure - 2
generated and
shown on
screen.
Note 3:

a. Creep & Fatigue value for one component will be calculated by excel sheet with formulas
(Annex-2).

b. Impact of cyclic loading will be demonstrated by two calculation with data stored in SR1
archive .One data set will show moderate load changes and the other will have significant load
changes as it is a case during flexibilisation of unit operation. Comparison of these two cases will
show the effect on the fatigue.

• Objective: Verification of the SRv scope of supply & functionality

10.0 Data Validation
Sl. Description Test Procedure Expected Results System Remarks
No. Results
10.0.1 Range check as part A specific tag like RH Color of RH temp. Tag
of the data temp. Range will be will be changed to
preparation package shown on the boiler violet. However data
for relevant data screen. A value reconciliation shall
installed higher/lower than the replace the bad
range will be forced. measurement.
10.0.2 First Principle based Sample tags like one Validated results value
Data Reconciliation out of 4 tags will be close to the
BOIL_M_T_MS1, other three tags.
BOIL_M_T_MS2,
BOIL_M_T_MS3,
BOIL_M_T_MS4, will
be changed from
current values.

4410-001-405-PVI-Y-223-R02 Page 8 of 10
 Objective :SRx (general data server module)
11.0.0 SRxVis (Visualization)
11.0.1 System files for the visualization module SRxVis installed and operating
Menu “File”
11.0.2 New Chart, New Process graphic, new data table, Open, open and move
to time, save, save as, save all, workspace, print, print preview, page
setup, setting, set graphics, recent file and exit.
Menu “Edit”
11.0.3 (Diagram) Cut, Copy, Paste, Delete, undo and redo.
Menu “View”
11.0.4 simple menu, status bar, tool bar, tabs, view time bar, view log.

11.0.5 Move have several option like previous time frame, previous time interval
etc.
Menu "Diagrams"
11.0.6 Chronology, cumulative frequency, xy diagram, time interval, use as X
axis, highlight selected tag, filter selected tags, filter selected tags, show
all tags, show/hide selected tags
11.0.7 Inserting title, insert tags, insert user defined formula
11.0.8 Copy tag-name, copy with option, copy bitmap, copy chart, duplicate
chart, global chart setting, properties.

Menu "Parameter"
11.0.9 Parameter editor
Menu "Process sheets"
11.0.10
Accessing all visualization sheet as mentioned in serial no "1.0.0
Menu "MP checklists
11.0.11 Measurement verification list - it list out all measurement values and their
status.
Menu "Documentation"
11.0.12
SRxParameter Editor, SRx Vis user interface - this is the link of help
documents.
Menu "Windows"
11.0.13 Close, close all, close all srx details, cascade, tile vertical, tile horizontal,
arrange icons.
Menu "Help"
11.0.14 Help and about SR: SUITE- gives the detail of SR suite version.

4410-001-405-PVI-Y-223-R02 Page 9 of 10
 • Objective: Verification of SR::FT – Water Chemistry Management and
Diagnostic.
12.0.0 SR::FT
Sl. No. Description Test Procedure System Results Remarks

12.0.1 Fault Tree Sample Fault Trees will be Some false fault will
shown with explanation of be generated to
functionality explain its
functionality.

• Objective: SR::MOR – Merit Order Rating

13.0.0 Merit Order

Rating
Sl. No. Description Test Procedure System Results Remarks

13.0.1 MOR MOR screen will be shown Functionality will be

with all its functionality. shown based on test
input values.
Different behavior of units
will be simulated. Test will
be done as per constraint Set Points(MW) for
defined in SDD, Every unit individual unit will be
will have different generated
constraints. Set Point (MW)
for the committed load will
be given.
Appropriate
Provision for incorporating behavior/Functionalities
off design to be demonstrated.
conditions(parameter
deviation & equipment
constraints) in the Net
TGHR & Boiler Eff will be
shown.

4410-001-405-PVI-Y-223-R02 Page 10 of 10