best o & m practices at 2 x125 mw akarimota thermal power...
TRANSCRIPT
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Best O & M practices at 2 X125 MW Best O & M practices at 2 X125 MW AkarimotaAkarimota Thermal Power StationThermal Power Station
By: Shri. By: Shri. JanardanJanardan N. Dave: GM (Power)N. Dave: GM (Power)-- Corporate OfficeCorporate OfficeShri. Dinesh S. Shri. Dinesh S. MakwanaMakwana: I/C GM (PP): I/C GM (PP)--ATPSATPSShri. Shri. HirenHiren S. S. SilajiyaSilajiya (EE(EE--Power)Power)--Corporate OfficeCorporate Office
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Background
•GMDC is mainly a mining company. It started itsmining business in the year 1963.
• In the year 1994, it had been decided to invest inlignite based 2 x 125 KW Akrimota Thermal PowerStation in Kutch.
•The investment decision was taken for forwardintegration and value addition in the wake of powershortage. The other objective was also to avail taxbenefits for depreciation.
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Background
The project got clearance from CEA in the year 1999. The estimated cost of the project was Rs. 1357.11 Cr (Revised).
26 vendors were engaged to execute the power project including MNCs like Alsthom, Germany and Ansaldo, Italy.
Total strength of manpower sanctioned for the power project is 216, out of which 168 are technical personnel.
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Background
The plant is using CFBC Boilers which can firelignite and is environment friendly.
The lignite is supplied from nearest Panandhro,Umasar & Matano Madh mines of GMDC andwater is taken from 1.4 KM sea-water intake channelfrom Kori Creek.
GMDC has a Power Purchase Agreement with M/sGUVNL to supply the entire power to the grid.
The plant started commercial generation fromMarch, 2006
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PerformanceFINANCIAL YEAR GENERATION (MU) PLF
%INCOME
Rs/CrEXP.Rs/Cr
LOSS/PROFITRs/Cr
2005 – 06 175 8.01 13.26 233.65 - 220.39
2006 – 07 377 17.25 122.53 266.86 -144.27
2007 – 08 1009 45.95 161.54 243.82 - 82.28
2008 – 09 1105 50.49 186.86 235.80 - 48.96
2009 – 10 1393 63.65 273.42 229.80 + 43.62
2010 – 11 1171 53.45 243.25 212.20 + 31.15
2011 – 12 870.9 39.66 142.64 204.49 -61.85
2012 – 13 921.6 42.08 178.55 196.40 -17.85
2013 – 14 985.4 45.00 175.77 186.21 -10.44
2014-15 1358.8 62.04 238.80 222.20 +16.60
2015-16 1427.4 65.00 258.18 252.43 +5.75
2016-17 1392.9 63.60 309.07 309.02 +0.05
2017-18 1360.1 62.11 270.49 256.38 +14.11
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Cost AnalysisFINANCIAL YEAR UNITS SOLD (MU) COST PER
UNIT (Rs.)REVENUE EARNED/
UNIT(Rs.)
DIFFERENCE(±)
2007 – 08 848 2.86 1.87 - 0.99
2008 – 09 928 2.53 1.97 - 0.56
2009 – 10 1193 1.92 2.25 + 0.33
2010 – 11 992 2.13 2.45 + 0.32
2011 – 12 733.036 2.35 1.64 -0.71
2012 – 13 774.974 2.13 1.94 -0.19
2013 – 14 859.041 1.89 1.78 -0.11
2014-15 1176.896 1.64 1.76 +0.12
2015-16 1234.287 1.77 1.81 +0.04
2016-17 1177.148 2.22 2.22 +0.0004
2017-18 1158.521 1.88 1.99 +0.10
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Best Performance
Highest Daily Generation 03-12-2008 6.08 MU PLF – 101.3%
Highest Monthly Generation March - 2018 155.2 MU PLF – 83.4%
Highest Quarterly Generation Q4:2017-18 446.2 MU PLF – 82.64%
Highest Yearly Generation FY 2015 - 16 1427 MU PLF – 65.0%
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Technical Analysis
It has been observed that ATPS achieved more than 100% daily PLFand 83% Monthly PLF several times, efforts are in place for continuebetter performance on sustainable basis.
This inconsistent achievement of good PLF & better performance ismainly owing to ATPS boilers.
CAUSE EFFECT REMARKS
Explosion of Lignite Feeder Severe Eliminated
Omega Panel Tube Leakage Severe Eliminated
Loop Seal Bellow Leakage Severe Eliminated
Boiler Tube Leakage Severe Reduces with plasma coating
Plate Heat Exchanger Failure Moderate Eliminated
N/A of Lignite Feeder Partial Loading Maintenance Activities Reviewed
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Gujarat Mineral Development Corporation Limited (GMDC) isoperating 2x125 MW CFBC Boilers at Village Nani Chher,Taluka Lakhpat, District Kutchchh. The salient features ofBoilers,
Boiler:Supplier : M/a AlstomCapacity : 405 TPHPressure : 138 Kg/Cm2Temperature: 535 +/- 5 Dec CType : Circulating Fluidized Boiler, Top supported.Auxiliaries : 2 PA fans, 2 SA Fans, 2 ID Fans, 2 Ash coolerfans, 3 Fluidizing air fans
Brief of ATPS CFBC Boiler
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Turbine:
Supplier : M/s. ANSALDOType : ReactionType of Governing : Electro HydraulicNo. of Cylinder :02Speed : 3000 rpm.Main steam Parameter (HP inlet):Pressure :132.6 kg/cm2Temp :535 Degree CIP Inlet :Pressure :31.93 kg/cm2Temp :535 Degree CNo of stages : Control stage +22/16/7.
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CombustorLoop-Seal
CFBC-BOILER
CYCLONE
GAS
SH-3
RH-1
ECO
SH-4 Omega PanelTAPH
BURNERS
BED ASH
DRUM
SH-5RH-2 Omega Panel
ESP
CHIMNEY
FLY ASH
COAL+ LIME
AIR
BACK PASS
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DRUM
SH-5
RH-1
Condenser
CRH
FromBFP
BOILER
SH-4
RH-2
TURBINEG
IP TURBINE
SH-3
LIGNITE ENTRY
BED ASH
AIR
ECO
Con. Water to Boiler
Electricity Generation from Lignite
Sea water o/l Sea water inlet
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Cyclone -A
Boiler Combustion & Cyclone Area
Boiler Drum
Combustor
Cyclone - B
Flue Gas Direction
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EROSION PRONE ZONE
SS 310 Shield on Pull out bend at RTZ
level
Elevation At gravimetric feeder floor.
Boiler Combustor (Inside View)
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Troubleshooting carried out a ATPS
Shield condition• Initially there was shield on water wall tube in furnace
RTZ area. • However shield and tube erosion has been observed in
RTZ area which led to boiler tube leakages.• We have modified RTZ area shield and replaced with
refractory application. • It improves the condition and reduce the boiler tube
leakages. • Additional hanger tube shields reconditioning has been
carried out.
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Furnace RTZ area
Troubleshooting carried out a ATPS
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Troubleshooting carried out a ATPS
Recovering of L-valves• Previously we were facing problems of L-valves choking.
• It restricts the bed material draining and increase the
furnace bed pressure.
• We have carried out modification in L-valves.
• L-valve sleeve has been modified and extended inside the
furnace (500 mm) to avoid choking from big material like,
refractory piece, clinker piece, etc.
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L-valve Modified Sleeve Sleeve inside Furnace
Troubleshooting carried out a ATPS
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Troubleshooting carried out a ATPS
Rectifying of primary air leakages• We have arrested primary air leakage which resulted in
increased PA flow and improve the fluidization and
combustion efficiency.
• It also helps in reducing auxiliary power consumption.
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Troubleshooting carried out a ATPS
Recovery of Draglink chain conveyor• We were facing generation loss due to tripping of lignite
draglink feeder.
• We have carried out overhauling of draglink with replacement of
chain sprocket, guide plates, liner plates and links.
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Troubleshooting carried out a ATPS
Recovery of damaged refractory lining• Refractory condition is very important part in CFBC
boiler. We have carried out damaged refractory recovering in the following area.
• Both Ash coolers, • Loop seal, • Furnace inside, • Cyclone-1A ,• Cyclone -1B area
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Recovery of Damaged Refractory
Troubleshooting carried out a ATPS
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ModificationIn Refractory for
Prevention of water wall tube
erosion
Omega Panel
Refractory Sealing box
(Inside Combustor)
Sealing Rope
Pressure Plate
Combustor water wall
tubes
Combustor water wall Erosion
adjacent refractory seal box in each
omega panel
BEFORE AFTER
REFRACTORY MODIFICATION
SicromalPlate
OMEGA PANEL– sealing rope arrangement and sincromal plate
Troubleshooting carried out a ATPS
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Recovering of all the sealing air connection• Sealing air line bellow found damaged condition same
was removed from its position and Non- metallic bellow replaced with metallic bellow.
Troubleshooting carried out a ATPS
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Cleaning of expansion joints underneath PA wind box.
• We are carrying out cleaning of expansion joint underneath PA win box in ever shutdown for proper expansion to avoid any potential damage.
Troubleshooting carried out a ATPS
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Rectifying of L-valve supports• We have carried out L-valve bellow replacement and
provide the supports to avoid deformation of L-valve bellow and to prevent it from damage.
Troubleshooting carried out a ATPS
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Recovering of damaged fluidizing nozzles• Fluidizing nozzles is very important for proper fluidization in
CFBC boiler.• We are carrying out nozzle mapping to check for damaged
nozzles. • After mapping result we have carried out damaged fluidizing
nozzles replacement. • We are also arranging PA nozzles holes in cross direction to
avoid damage of other nozzle from high velocity jet of air.
Troubleshooting carried out a ATPS
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Furnace nozzles
Troubleshooting carried out a ATPS
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Vortex condition• Previously cyclone vortex deformation and ditched
from its position has been observed.
• Vortex damage leads to unit shutdown and huge generation loss.
• We have restrict the cyclone inlet temperature to avoid damage cyclone vortex.
• We have also carried out strengthening and provide support and refractory to vortex.
Troubleshooting carried out a ATPS
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Cyclone vortex strengthening
Troubleshooting carried out a ATPS
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Photo graph shows deposition between two tubes
Sequence of work execution.1. Cutting of tubes.2. Hydro jet cleaning with 400 bar.3. New tube installation.
TAPH tube replacement work
Troubleshooting carried out a ATPS
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FURNACE RTZ AREA PLASMA COATING WORK IN U#1 & 2
Before-Eroded tubes in RTZ area After-Plasma coating of 500
microns.
Troubleshooting carried out a ATPS
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PASS”B” outlet
PASS”B” InletPASS”A”
Intlet
PASS”A” outlet
Troubleshooting carried out a ATPS
Condenser cleaning work :
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Pneumatic de-chocking tool Hydro-jet machine
Gauge showing pressure of 500 bar for hydro-jet machine.
Troubleshooting carried out a ATPS
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Condenser chocked & de-chocked tubes.
CONDENSER DETAIL :-• Condenser having around 9600 tubes.•Condenser chocked tube status(2741 Nos.)• Pass A inlet 1060 nos. & outlet 1021 Nos.• Pass B inlet 442 Nos. & outlet 218 Nos.• At present 1304 nos. of tubes de-chocking & 1350 nos. hydro-jetting done rest in progress.
Troubleshooting carried out a ATPS
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0
50
100
150
200
250
300
350
Load (MW) Vacuum (mbar) Total Air Flow (kg/s)Parameter
Unit-1 performance improvement
Before AOH
After AOH
Performance improvement after troubleshooting in Unit-1.
Parameters Before AOH After AOH % Improvement
Load (MW) 84 112 33.33
Vacuum (mbar) 302 137 54.64
Total Air Flow (kg/s) 113 133 17.70
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Performance improvement after troubleshooting in Unit-2.
Parameters Before AOH After AOH % Improvement
Load (MW) 94 110 17.02
Vacuum (mbar) 296 95 67.91
Total Air Flow (kg/s) 115 126 9.57
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A) Measures on Boiler Pressure Parts :
Combustor waterwall tube thickness survey
Inspection of SH-4 & RH-2 Omega tubes for any localized erosion.
Combustor intermediate wall tubes inspection at front an rear wall corners.
Above refractory transition zone shield inspection and replacement.
Inspection of corner tubes adjacent to cyclone entry
Roof tubes adjacent to cyclone entry gets inspected through thickness survey
This being pressurized boiler all the fins are inspected thoroughly and any
punctured/wear/tear is observed , shall be attended.
Second Pass hanger tubes and front wall tube thickness survey.
Second pass hanger tues and front wall tubes shield inspection and replacement.
Best Practice adopted to avoid unforeseen outage
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B) Measures towards Refractory :
Physical inspection of cyclone refractory based on which future course of action takes place.
Thermography of cyclones to ensure internal condition of the overall refractory .
Based on thermography and visual inspection corrective measures is outlined.
Examination of vortex and corrective measures.
Inspection of all the eight loop seal bellows , inspection cyclone down comer to loop seal entry and return leg to combustor as damage of refractory in this area cusses deformation and oxidation of parent material.
Best Practice adopted to avoid unforeseen outage
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Thank You