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At Valuthur CCPP frame 6FA Gas Turbine with Dry Low NOx version
2 was commissioned on 03.01.2003. NOx level of 16 ppm is achieved
in Steady State Premix mode at bas load. DLN-2 version is of first
time use in India.
Each of six combustion chambers is provided with four gas fuel nozzle
namely Primary, Secondary, Tertiary and Quaternary. The start-up
and DLN tuning was carried out by GE specialist utilizing a special DLN
tuning kit. At the upstream of the gas manifold in GT compartment
temporary conical filters were installed in all the four fuel piping.
Differential pressures across the filters were monitored continuously
during start-up and DLN tuning.
During the start-up of turbine the fuel is admitted in the primary
nozzle only upto 80% of speed. At 81% of speed the fuel is admitted
through the tertiary nozzle, with preceding pre fill span of 5 to 10
seconds, in Lean-Lean mode in addition to the diffusion type of firing
in primary nozzle. During this transfer at 81% of speed, the spread
usually goes upto 150 deg.C. from 25 40 deg.C level and settles back
around 30 40 deg.C. before attaining FSNL. Failure of reach FSNL
on account of flame failure of exhaust spread high was noticed on
many occasions.
The split ratio, pre-fill timings and many other
parameters / controls were tried with different combinations and
successful start-up of Gas Turbine to FSNL was established on the
NINTH attempt.
However, on reducing the speed to 99%, Exhaust spread high was
noticed. Unit synchronized while the grid frequency was above 49.5
HZ.
The problem of spread high at lower speed upto 96% was
resolved by readjusting the constants once again and normal operation
in lean-lean mode was established prior to the next synchronization.
Lean-lean mode to piloted premix was carried out around 60% load on