An Energy & Environment Conscious, Sustainable & Prosperous Organization

SESA STERLITE LTD4X600 MW IPP

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Power Business Overview

Location Capacity

Jharsuguda IPP 4X600 MW

Jharsuguda CPP 9X135 MW

TSPL 3X650 MW

4X600 MW IPP Jharsuguda (Supplied by SEPCO -III)

Boiler Make HBC China

TG DFPS China

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Sesa Sterlite – Power Overview

Contributing to India’s Energy Security

An Energy & Environment Conscious Sustainable Organization

PROJECT - BOILER MODIFICATION FOR RELIABILITY AND STATION HEAT RATE IMPROVEMENT

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4X600 MW INDEPENDENT POWER PLANT

First 600 MW Power Plant of Odisha

ESP – FF Hybrid precipitator maintaining SPM < 50 mg/Nm3

Plant supplied by SEPCO-III China (Boiler- Harbin , Turbine- DFPS)

Plant equipped with modern online performance and combustion Optimisation softwares.

IPP has got accreditation with EnMS 50001:2011 , EMS 14001:2004 , QMS 9001:2008 and OHSAS 18001:2007 to ensure sustainability .

Opportunities identified and executed for efficiency and reliability

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Milestone

Particulars U#1 U#2 U#3 U#4

1st Light up 20-Dec-10 12-Jun-10 20-May-11 19-Feb-12

Date of Synchronization

27-Dec-10 10-Aug-10 9-Jul-11 29-Mar-12

Date of Achieving Full Load

28-Dec-10 14-Oct-10 16-Aug-11 25-April-12

Date of COD 30-Mar-11 9-Nov-10 19-Aug-11 26-Apr-12

MILESTONES OF SSL , JHARSUGUDA

Guaranteed Station Heat Rate achieved in all the Units

Saving Potential in SHR identified in three parameters

High Superheat Spray 150 TPH w.r.t 65 TPH (rated)

High Reheat Spray 33 TPH w.r.t 0 TPH (rated)

Less RH Steam Temperature 525 w.r.t 538 DegC

High metal temperature excursion causing tube failures

Difficult to Control Operating Parameter With Top Mill Operation.

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OPPORTUNITIES IN BOILER

BOILER DETAILS

Boiler Make The China Harbin Boilers co. Ltd

Boiler Type

Subcritical , Reheat, Single Furnace , Single Reheat , Forced Circulation , Balanced Draft , Dry bottom , Tangential corner fired pulverised Fuel Fired

SH Outlet Steam pressure (MPa) 17.5

Design Temp (DegC) 541

Boiler Capacity (TPH) 2060

RH Steam Outlet Pressure (MPa) 3.8

RH Steam Temperature (DegC) 541

Fuel consumption (TPH) 433

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Losses identified at early stage

Initiatives started to counter the problem

Combustion Experts Dr. V T Satyanathan (Ex-BHEL) conducted study

Combustion Experts of Squam Power Plant Technical Consultancy engaged for optimisation

STEAG Germany combustion optimisation software installed

Online trials conducted and detailed study carried out

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CORRECTIVE MEASURES

Trials conducted since 2011 to Dec 2012 mainly focused on

(i) SADC tuning

(ii) Burner Tilts

(iii) OFA damper regulations

(iv) Soot Blowing Optimisation

Trials Conducted but desired result could not be achieved with above Trials.

Conclusion: SSL insisted Sepco-III to study and provide solution.

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ENGAGEMENT OF HBC- OEM

Sepco-III depuetd Combustion expert from Harbin Boiler

Trial Conducted by Harbin Experts from 4-18th December 2012

Operation and combustion expert exercised all the possible combinations

CONCLUSION :

Improvement in performance parameter not achieved

Harbin suspected the variation in fuel was leading to deviations

Harbin referred the problem to design institute for review and solution.

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Review and Proposal

Design institute recommended modification

Harbin proposed modification in three zones of boiler

Reduction of Surface area of LTSH from 12944 to 7696 m2

Reduction of radiation side wall Re-Heater width from 8191 to6268 mm

Increase of Economiser surface from 215000ft2 to 277000 ft2

Boiler efficiency and SHR will remain unaffected.

All the performance test will be carried out after modification.

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Review and Approval of Project

SSL & Ex-BHEL design expert Mr. Sivaraman Krishnamurthy reviewed the proposed modification

Proposal review meeting held at Harbin China in March 2013.

Challenge of pressure part alteration in limited access reviewed

Unit outage for longer time > 60 Days

Directorate of Factories & Boiler reviewed and approved the project

SSL approved the project anticipating long term gain in Conservation of natural resource and reduction in carbon emission.

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REMOVAL OF PRESSURE PART

Material received within 3 months of project approval from China

120 Nos. tube Reheat radiation wall removed from each side

Water wall LTRH headers replaced with new headers

Lower group of LTSH Removed

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Cutting of LTRH

Tube and Header

Removal of LTRH

Header

Economiser Tube

cutting

ERECTION OF PRESSURE PART

Erection methodology was prepared by Harbin & Sepco-III

Job safety analysis carried out in detail

Each lifting tools to be used in project tested before commencement of project

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Steam Cleaning of

Tubes

Erection of

Economiser Coil

Lifting of water wall panel

through bottom ash

hopper

Erection of Pressure Part

Detailed Quality assurance plan to ensure quality work

Radiography conducted in 100% joint in RH and LTSH area

Radiography in 20% joint of Economiser.

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Readiness for

position eco tubeEconomiser coil in

position

PROJECT – Boiler Modification

First modification started in Boiler of Unit#3 w.e.f 12th July 2013

Modification carried out during scheduled annual overhaul of Unit-3

Sepco-III executed the modification project

Material was supplied from China in short duration of 3 months

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Removal of LTRH

Header Fitment of new

LTRH Header

Erection of new

LTRH link pipe

PROJECT – Boiler Modification

Manpower engaged 250

No of Days for project completion - 60

Cost of Project Rs 500 millions INR

No of Welding Joints 3485

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Lifting of Economiser Coil Addition of Economiser bank New Added Economiser bank

Re-Commissioning & Demonstration

Detailed programme prepared for Boiler flushing

Flushing continued for 3 Days to bring the parameters in limits

Post-modification demonstration carried out for

Boiler Efficiency test

Boiler efficiency test at design and worst coal

Demonstration for Zero Reheat spray and rated Super heater spray

Demonstration for top mill and bottom mill operation

Reliability test for design unit load ramp up and ramp down

14 Days reliability run by OEM

All the tests were successfully completed

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Boiler Parameters After Modification

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S.No Parameter Description UOM DesignBefore Modification

After Modification

1 Power Generation MW 600 599 601

2 Coal flow TPH 420 411 383

3 Main Steam Pressure Mpa 16.7 16.37 16.66

4 Main steam Temperature DegC 538 539 539

5 RH steam Temperature DegC 538 536 538

6 RH Steam Pressure MPa 3.8 3.61 3.49

7 SH Spray TPH 65 150 66

8 RH Spray TPH 0 25 0

SH Spray Reduced from 150 TPH to 66 TPH

RH Spray Reduced from 33 TPH to Zero

Top Mills Service operation became normal operation

Improvement in SHR of 14Kcal/KWH achieved

SHR Improvement contributed to saving of 87000 MT of coal per

annum

Reduction in CO2 emission by 2.3 lacs MT emission due to improvement in SHR.

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Result Summary

CALCULATION OF GAIN AFTER MODIFICATION

S.No.IMPROVEMENT AREA

UOMBefore Modification

After Modification

Improvement

Gain in Heat Rate (Kcal/Kwh)

Net Saving in Millions (INR)Per annum

Net Saving of Fuel Per Annum (MT)

1 Av . Power Generation MW 600 600 0 0 0 0

2 Reheat Temperature DegC 525 538 13 6.7 24 10534

3 Reheat Spray % 2.4 0 2.4 7 26 11088

4 SH Spray % 8.6 3.5 5.1 0.12 0.44 190

Total Savings Per unit per Annum (@90% PLF , 3000 Kcal/Kg GCV) 50 21812

Total Saving Per Annum for 4X600 MW 201 87247

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Thank You

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