Installation & Commissioning Report · Pre-commissioning Commissioning. General Information Owner :Hadramout Investment Power Company (HIPC). Al-Harshiyat Power Station 75 MW Power

Installation & Commissioning Report

Mukalla Iron & Steel Plant

1 © Wärtsilä 23 January 2011

Place: Hadramout Investment Power Company (HIPC).Al-Harshiyat Power Station75 MW Power PlantsMukalla,Yemen.

Engine Model : Wärtsilä18V32.Engine Serial Number: PAAE150665, PAAE150666, PAAE1 50667, PAAE150668, PAAE150669,

PAAE150670, PAAE167202, PAAE202656’PAAE202657 & PAA E202658.

Contents

■ General Information

■ Shipment

■ Technical

■ Installation

● Civil

● Mechanical


● Electrical

■ Pre-commissioning

■ Commissioning

General Information

Owner :Hadramout Investment Power Company (HIPC).Al-Harshiyat Power Station75 MW Power PlantsMukalla,Yemen.

Suppliers : Wärtsilä Finland Oy.Tarhaajantie 2, Fin-65101 Vaasa,Finland.

Engine Model : 10XWärtsilä18V32Engine Serial Number: PAAE150665, PAAE150666, PAAE150667, PAAE150668, PAAE150669,

PAAE150670, PAAE167202, PAAE202656, PAAE202657 & PAAE202658.


PAAE150670, PAAE167202, PAAE202656, PAAE202657 & PAAE202658.Alternator Type : AMG 1120 MR08 DSEAlternator 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).

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):


• Material arrived at site on 13.12.2009.

Main Shipment:


Shipment Shipment


• 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.

DG unloaded from vessel to Tailor

Shipment


DG unloaded from vessel to Tailor

Shipment

DG unloaded from Tailor to Foundation


Container unloaded from vessel to Tailor

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.

.

Power House concreting

Foundation


DG –sets Foundation

Foundation

Stack Foundation


Tank Foundation

Mechanical

• 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 Installation

10 © Wartsila 23 January 2011

Compact Booster Unit

Engine Auxiliary Module

DG sets

Compact Booster UnitEngine Auxiliary ModuleDG sets

DG-sets, EAM, CBU & EGM Installation


DG sets on Foundation

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 customer representative.

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

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

Fuel oil system

HFO & LFO transfer pump unit HFO & LFO Feeder Unit

HFO & LFO Storage tank, & Unloading pump units


HFO & LFO transfer pump unit HFO & LFO Feeder Unit

Mechanical Installation

Cooling water system:• Maintenance water tank placed on foundation.• Radiators has 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 © Wärtsilä 23 January 201114 © Wärtsilä 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.


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.

Mechanical

LO Unloading pump unitLO 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.

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.

Mechanical


Exhaust gas Boiler (EGB)

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.

Mechanical

Oily water treatment unit


Oily water transfer pump

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.

Auxiliary system Commissioning

Instrument Air compressor units



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. Start 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 customer 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 customer 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.


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.


HFO & LFO Feeder unit

23 © Wärtsilä 23 January 201123 © Wärtsilä 23 January 201123 © Wärtsilä 23 January 2011

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



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

Black start container

Exhaust gas Boiler


Steam HeaderOily water treatment unit

Electrical

Wartsila Scope for Electrical system:

1. LV system: Complete2. MV system: Complete3. DC system: Complete4. Control and monitoring system: Complete

HV system was in scope of Customer. And it was supplied by M/S MN Dashtur, 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 customer scope


� HV system including Transformer delivery was delayed customer scope

� Custom Clearance – Moderate It was in customer scope.

� Transport to Site- Quite Satisfactory

� Storage/ Store Keeping Quite Satisfactory

� Material Handling in siteQuite 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

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

MV panel Doors we found couple of MV cubicle doors are misaligned. And lock was not properly operable. Specially the breaker doors. Rectified at site.

Less space in Switchgear 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 roomIt would be better to put those frequency converter 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 bellow the louver of ventilation unit/ near by the Neutral cubicle.

BJA panelSensor/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.


Pre-Commissioning

� Pre-commissioning was performed according to the co-ordination plan with mechanical system requirement and completion

� We got sufficient man power with satisfactory skill from contractor. Contractor was quite helpful and knowledgeable.

� The over all 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 This was quite enough cited issue ever for this project. Delay of 33KV System initiated the difficulty. We had to use our black start unit for pre-commissioning support though customer arranged small


We had to use our black start unit for pre-commissioning support though customer 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-



� 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



Some pictures





Overall Evaluation

Wartsila Scope:

Erection Contractor:

�

�


Customer’s Scope

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Engine hall with DG-sets


Power House


Power House


Control Room


Electrical Switchgear


Documents

Installation & Commissioning Report · Pre-commissioning Commissioning. General Information Owner :Hadramout Investment Power Company (HIPC). Al-Harshiyat Power Station 75 MW Power