Installation & Commissioning Report - Hipc-ye
Installation & Commissioning ReportMukalla Iron & Steel PlantPlace: Hadramout Investment Power Company (HIPC).Al-Harshiyat Power Station75 MW Power PlantsMukalla,Yemen.Engine Model: Wärtsilä18V32.Engine Serial Number: PAAE150665, PAAE150666, PAAE150667, PAAE150668, PAAE150669,PAAE150670, PAAE167202, PAAE202656’PAAE202657 & PAAE202658.1 Wärtsilä 23 January 2011
Contents General Information Shipment Technical Installation Civil Mechanical Electrical Pre-commissioning Commissioning2 Wärtsilä 23 January 2011
General InformationOwner :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.Alternator Type: AMG 1120 MR08 DSEAlternator Serial No. : 4602059, 4602060, 4602061, 4602062, 4602063,4602064, 4605928, 4609026, 4609027 & 4609028. 3General 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: 220mGrid Connection: 33/11 kV.Grid Frequency: 50 Hz.Rural country side, Sand stone, Hill, Rock and Mount area (Dusty area). Wärtsilä 23 January 2011
ShipmentFirst 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):4 Vessel arrived at Mukalla sea port on 23.05.2010. Material arrived at site on 25.05.2010. Wärtsilä 23 January 2011
ShipmentDG unloaded from vessel to TailorDG unloaded from vessel to Tailor5 Wärtsilä 23 January 2011
ShipmentDG unloaded from Tailor to FoundationContainer unloaded from vessel to Tailor6 Wärtsilä 23 January 2011
Technical Mechanical Basic Design received on 08.11.2009.Electrical basic design received on 08.11.2009.Mechanical detailed design received on 10.02.2010Electrical detailed design received on 10.02.2010.InstallationCivil Civil is not Wartsila scope but before placing the DG sets and others equipment to ensure that the foundationleveling, 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 waterradiator , 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.7 Wärtsilä 23 January 2011
FoundationPower House concretingDG –sets Foundation8 Wärtsilä 23 January 2011
FoundationStack FoundationTank Foundation9 Wärtsilä 23 January 2011
MechanicalDG-sets Installation DG-sets placed on foundation and checked spring location, centre line and 0-lineEngine auxiliary module alignment along with Engine and fixed on foundation with anchor boltsCompact booster unit alignment with Engine auxiliary module and inter connect the flanges.Exhaust gas module Installed respect to the DG sets.DG setsEngine Auxiliary ModuleCompact BoosterUnit10 Wartsila 23 January 2011
DG-sets, EAM, CBU & EGM InstallationDG setsEngine Auxiliary ModuleDG sets on Foundation11 Wärtsilä 23 January 2011Compact Booster Unit
DG-sets, EAM, CBU & EGM InstallationEGM Placed on FoundationFuel 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, pressuretest, pickling and flushing checked with customer representative. HFO and LFO Storage tank Fabrication, welding and pressure test checked with customerrepresentative. HFO day tank, buffer tank and LFO day tank fabrication, welding and pressure test checked withcustomer representative.12 Wärtsilä 23 January 2011
Fuel oil systemHFO & LFO Storage tank, & Unloading pump unitsHFO & LFO transfer pump unit13 Wärtsilä 23 January 2011HFO & LFO Feeder Unit
Mechanical InstallationCooling 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 Radiator14 Wärtsilä 23 January 2011Cooling water Piping
MechanicalCompressed 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.15 Wärtsilä 23 January 2011
MechanicalLubricating 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 unitLO Transfer pump unit16 Wärtsilä 23 January 2011
MechanicalCompressed 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 unitStarting Air VesselInstrument air system Commissioning: Checked all suction/delivery valve in the compressor, airvessel & 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 anyleakage. Supply the air in the main distributions line and checked any leakage.17 Wärtsilä 23 January 2011
MechanicalHeat 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 Wärtsilä 23 January 2011
MechanicalOily 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 unitOily water transfer pump19 Wärtsilä 23 January 2011
Auxiliary system CommissioningInstrument air system Commissioning:Checked all suction/delivery valve in the compressor, air vessel & Dryer. Checked oil level incompressor, power supply in the local panel, checked vessel & dryer drainage solenoid valvefunctionality, start compressor and fill-up the vessel and checked any leakage. Supply the air in themain distributions line and checked any leakage.Instrument Air compressor units20 Wärtsilä 23 January 2011
Auxiliary system CommissioningWater supply system commissioning:Raw Filling in raw water tank, Control air line blow throwing, Suction & delivery valve checking in rawwater booster unit. Multi layer & water softener tank checked, Nacl filling in Nacl Solution tank, NalcoPC- 191 filling in chemical dosing tank. Power supply in the panel board. Checking motor rotation in rawwater Booster, treated water booster, RO pump & chemical dosing pump. Start the system and checkedas per manufacturer instruction (Pump suction /delivery pressure, air pressure etc). Flow meter and levelswitch 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 wateras per boiler & DG sets requirement .Water Treatment unit21 Wärtsilä 23 January 2011
Auxiliary system CommissioningFuel (LFO) oil system: LFO unloading pump and transfer pump suction and delivery valve checked andkept open position, power supply on in the local panel board, checked motor/pump rotation after thatpump started and unloading LFO from tank lorry to LFO storage tank (Flow meter reading checked withcustomer 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 powerpouse all valve checked and kept open position. Control air checked, power supply to feeder unit localpanel board, checking Motor/pump rotation after that LFO Feeder started and shifting LFO day tank toAuxiliary 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 andkept open position, power supply on in the local panel board, checked motor/pump rotation after thatpump started and unloading HFO from tank lorry to HFO storage tank (Flow meter reading checked withcustomer representative) and same procedure HFO transfer from Storage tank to HFO buffer tank. Fueloil 3-way valve checking and found actuator solenoid valve defective and replaced solenoid valve fromextension part. Pre-heating the HFO buffer tank.Separator Commissioning: Checked HFO buffer tank to separator all suction/delivery valve and keptopen position, checked instrument air, steam and condensate line and treated water line etc.all HFO separator started and completed commissioning (Separator commission by Westfaliacommissioning engineer) .HFO feeder unit:HFO day tank to Feeder unit and power house all valve checked and kept open position. Control airchecked, power supply to feeder unit local board, checking Motor/pump rotation, Auto and manual filterchecked, Viscometer function checked after that HFO Feeder started and checked main HFO pipe up toCBU.22 Wärtsilä 23 January 2011
Auxiliary system CommissioningHFO & LFO Feeder unitHFO Separators units23 Wärtsilä 23 January 2011
Auxiliary system CommissioningCooling water system:Filling treated water with cooling additives in Maintenance water tank . checked maintenance watertransfer 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 Radiator24 Wärtsilä 23 January 2011
Auxiliary system CommissioningCompressed air system:Checked all pipe line up to start air vessel & engine auxiliary modules, checked all suction & deliveryvalves in compressor & air vessel, oil filling in compressor as per manufacture instruction. Powersupply in local panel board, compressor rotation checked. Start compressor fill-up the vessel andchecked any leakage in compressor to vessel. Supply the air in the main distributions line andchecked any leakage.Starting compressor unit25 Wärtsilä 23 January 2011Starting Air Vessel
Auxiliary system CommissioningCharge 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.26 Wärtsilä 23 January 2011
Mechanical Auxiliary systemAuxiliary Boiler ContainerExhaust gas BoilerBlack start containerSteam Header27 Wärtsilä 23 January 2011Oily water treatment unit
ElectricalWartsila Scope for Electrical system:1.2.3.4.LV system:MV system:DC system:Control and monitoring system:CompleteCompleteCompleteCompleteHV 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 HIDELECOEvaluationDelivery and Material Handling: Delivery Time from Wärtsilä HV system including Transformer delivery was delayedcustomer scope Custom Clearance –ModerateIt was in customer scope. Transport to Site-Quite Satisfactory Storage/ Store Keeping Quite Satisfactory Material Handling in siteQuite Satisfactory and in safe waySatisfactoryErection28 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 Wärtsilä 23 January 2011
Electrical - continued Contractor’s skill and competency were well satisfactory Co-ordination among electrical, mechanical and civil was ModerateErection Difficulties and suggestion:Cable Ladder Layout-In some places, cable ladder routing was so difficult due to lessspace. Specially in the Auxiliary Module area.MV panel Doorswe found couple of MV cubicle doors are misaligned. And lock wasnot properly operable. Specially the breaker doors. Rectified at site.Less space in SwitchgearIt was a compact switchgear room including LV, MV and MV (33KV). The space was notsufficient. For better cooling, air flow path and safely operation, a more specious room wouldbe better.Frequency Converter of Feeder UnitThree 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 ventilationfacility. 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 workwith the Frequency converters.FC could be relocated in the engine hall just bellow the louver of ventilation unit/ near by theNeutral cubicle.BJA panelSensor/actuator end connections were open, at site they were connected. It should be connectedfrom factory. We have reported this issue in a separate report during installation.29 Wärtsilä 23 January 2011
Electrical - continuedPre-Commissioning Pre-commissioning was performed according to the co-ordination plan with mechanical system requirement andcompletion We got sufficient man power with satisfactory skill from contractor. Contractor was quite helpful andknowledgeable. The over all pre-commissioning was :- Well coordinated and planned- Less error found for connection- quick rectification support whenever modification advised or requiredPre-commissioning Difficulties and SuggestionLV PowerThis 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 smallgenerators. But it was very risky when multiple generators are connected to the LV system and frequentchange over required.30 Wärtsilä 23 January 2011
Electrical- ContinuedPre-Commissioning Sequence-31 Wärtsilä 23 January 2011
Electrical - continued Engine governed by UNIC-C1. the followings are to note for UNIC-C1:a.b.c.The hardware configuration was not exact the supplied installation drawings. The Speed control signalfrom AVR during Sync was connected to different portThe Base software for UNIC-C1 had very fast PID parametersThe Speed sensors ( Flywheel) needed to adjust AVR synchronizationVery stable synchronization obtained Soft-startVery stable soft start performed33 Wärtsilä 23 January 2011
Electrical- ContinuedSome pictures34 Wärtsilä 23 January 2011
Electrical- Continued35 Wärtsilä 23 January 2011
Electrical- ContinuedOverall EvaluationWartsila Scope: Erection Contractor: Customer’s Scope 36 Wärtsilä 23 January 2011
Engine hall with DG-sets37 Wärtsilä 23 January 2011
Power House38 Wärtsilä 23 January 2011
Power House39 Wärtsilä 23 January 2011
Control Room40 Wärtsilä 23 January 2011
Electrical Switchgear41 Wärtsilä 23 January 2011
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
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