1. Experience in Commissioning of
a 1MWe Solar Thermal Power
Plant in Gurgaon
N.G.R. Kartheek1*, Deepak Yadav 1, Rangan Banerjee1, J.K. Nayak1, Santanu Bandyopadhyay1
Shireesh B. Kedare1
1
Department of energy science and engineering,
IIT Bombay
Funded by
Ministry of New and Renewable Energy
Corresponding Author. Tel: +91 22 25764794, E-mail: solarthermaliitb@gmail.com

2. Schematic of process flow for the solar thermal
power plant
Process flow diagram

3. Unique features of the
project
Demonstration of solar thermal
technology for power generation
Combination
of
collector technologies
Project Landmarks
January 2010
different
Direct and indirect steam
generation to be demonstrated
Simulation package for scale-up
January 2011
Test facility for solar thermal
applications to facilitate the
development
of
indigenous
technology
Consortium based approach
involving
government
and
industry
July 2013

4. Parabolic Trough Solar Field

5. Linear Fresnel Reflector

7. Commissioning Experience
Classification of commissioning experience

8. Operational Problems

9. Linear Fresnel Reflector

10. Receiver tube leakage of the LFR system
Receiver
Tube
leakage
Leakage in the receiver tube
• Operating Pressure: 40 kg/cm2 (g) saturated steam pressure
• Hydro test Pressure: 120 kg/cm2 (g)
• Leakages were found in 12 welding joints during hot commissioning

11. Equipment Problems

12. Leakages in instrument stub connections on heat
exchanger
Leakage
from
Screwed
connection
Temperature Transmitters showing
Leakages
Temperature Transmitters with sealant
• Vapor pressure of Therminol VP 1 at 257 C is 1 bar (a)
• Ignition temperature of Therminol VP 1 is 621 C
• No screw joints and minimum flanged connections

13. System Problems

14. HTF Freezing
Ambient Temperature (oC)
15
14
13
12
11
10
Time (hr: min)
Ambient temperature profile at the project site on February 24th, 2013
• Crystallization temperature of HTF Therminol VP1 is 12 C
8:30 AM
8:00 AM
7:30 AM
7:00 AM
6:30 AM
6:00 AM
5:30 AM
5:00 AM
4:30 AM
4:00 AM
3:30 AM
3:00 AM
2:30 AM
2:00 AM
1:30 AM
1:00 AM
12:30 AM
12:00 AM
9

15. HTF Freezing
 Manual Operation
 Temperature gauge readings
at Main HTF Pump discharge
and outlet of solar field
Temperature of HTF ~350C
 Pump at minimum flow rate
Schematic of Oil System

16. HTF Freezing
TG
TG
Schematic of Oil System

17. Pump Seal Failure: February, 2013

18. Dirt/Oil particles collected from the drain
point near heat exchanger (March 17, 2013)

19. Summary and Lesson Learnt
• Operational Problem – Time consuming, delay in
commissioning
 Leakages in superheater: Torque spanner
 Receiver tube and window glass: Spot Welding, Continuous
power
 Water Entry in IA line: NRV
 Dry run of the BFP: Level Switches
• Equipment problems – Good engineering practise
 NRV Selection: Horizontal & Vertical line
 Instrument Stub: No threaded parts
 Compressed air line: No threaded joints
 Communication failure: Preconsidered
 Steam Valves: Control, Manual handle, Station

20. Summary and Lesson Learnt
• System Problem
HTF Freezing: Unfreezes only in summer.
UPS and Tracker failure: Continuous Power
supply

21. Commissioning problems in chronological order

22. THANK YOU

23. Project Objectives
•
1MWe Solar Thermal Power Plant
 Design & Development of a 1 MW plant.
 Generation of Electricity for supply to the grid.
•
National Test Facility
 Development of facility for component testing and
characterization.
•
Development of Simulation Package
 Simulation software for solar thermal power plant scale-up
 Compatibility for various solar applications.

24. receiver glass window breakage the LFR system
Receiver Window
Glass Breakage
Breakage of the receiver window glass
Interruption in power supply to the tracking motors, focus shifted partially

25. Leakages in the superheater – 10/03/2013
Steam Leakage

26. Water entry in instrumentation air line
•Compressed air required in the Demineralisation plant (DM) in
mixed bed unit
• No NRV in IA line
• DM water entered into the airline
•4 control valve damaged
Dry run of the boiler feed pump
• Malfunction of Level transmitter on the Deaerator led to dry of
pump

27. NRV at BFP exit Failure
Process flow from Deaerator to Steam generator

28. Leakages in compressed air piping
Schematic sketch of compressed air flow

29. Communication problem between level I and level II
Control System Hierarchy for the solar thermal power plant

30. Steam System valves
•Problem in complete closing of the valve
• Manual closing of Valve – Not possible
• Control Valve in the Steam Line – Regulate pressure
Control Valve without Handle
Control Valve with Handle

31. Mechanical Seal-Frozen Oil Particles (March 17, 2013)

32. Dirt/Oil particles collected from the basket filter at
suction of Main HTF Pumps (March 17, 2013)