Efficiency and turnaround management

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POWEREPC INFRASTRUCTURESOLAR RESOURCES

Venue: Gurgaon Corporate Office P KOTESWARA RAO

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Heat Rate is

The Pulse Ratefor knowing the health of the plant.

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COAL UNLOADER FROM SHIP

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PARAMETER AFFECTED BY

TURBINE HEAT RATE : LOADING FACTOR, AGING

BOILER EFFICNECY :COAL QUALITY

APC : LOADING FACTOR

1. FIRING BOILER RANGE COAL

2. MAINTAINING TG LOADING FACTOR

2 MOST IMPORTANT FACTORS FOR BETTER PERFORMANCE

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LOADING / DISPATCH

RECEIPT

FIRING POINT

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The Performance Ingredients

• Safety• People Management• Performance Monitoring• Condition Monitoring• Planning• The Asset Management• The Turn Around Management• Efficiency workshop

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ZERO TOLERANCE

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CONTRACTS MANAGEMENT

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Plant & ProcessPeople

Failu

res

attr

ibut

ed

to a

nd c

ost o

f los

sC

ost

for

corr

ectio

n

Lloyds Register

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ROLE OF CULTURE

“Culture” that characterizes any group is made of the knowledge, beliefs, customs, and practices shared within the group. These are taken for granted, but they guide attitudes and behaviours, which in turn determine actual outcomes. When a business seeks to improve its performance, it must examine its culture and assess the impact of its practices on the desired results.

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FORCED OUTAGE REDUCTION• Repetitive trips causing short duration outage

• Non repetitive outages of long duration

• Tripping of major auxiliaries leading to unit tripping

• Potential areas of multiple unit trips

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Hea

t Rat

e

No of Years

Inclined Bath Tub curve

Heat Rate Loss Life cycle

Stabilization periodAging –degradation- 0.5 to 0.7% per annum

Heat Rate recouped during major Over hauls

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COAL SAMPLING LOCATION

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• TA Manager • Operations Coordinator • Process Coordinator • Safety Coordinator • Environmental Coordinator • Scheduler • Planner(s) • Contractor Coordinator • Procurement Coordinator • Material Expeditor

THE TURNAROUND TEAM

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Turn Around Process-corporate

• Proven and requiring minimal customization;

• Has intermediate measurable mile-posts

• Scalable to various turnaround types and sizes; and

• Easy-to-use and non-cumbersome, yet provides enough detail and practical aids.

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LONG TERM PLANNING

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Some best practices

ULTRA SONIC PHASED ARRAY in place of RADIOGRAPHY for weld joints-safe, quick by ALSTOM

In-situ metal spray coating on eroded tubes in the boiler

TIER blending of coal

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TOMOGRAPHY

Tomography refers to imaging by sections or sectioning, through the use of any kind of penetrating wave. A device used in tomography is called a tomograph, while the image produced is a tomogram

Sealed source and radio tracer for industrial process tomography.

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Reliability

• “Availability is the probability of a device or system being in the operating or up state at a given period t in the future”.

• A = ( Running Time + Idle Time) / (Total Time in the period ) * 100

• “Reliability is the probability of a device or system performing the purpose adequately for the period of time intended under the operating conditions encountered”.

• R = ( Running Time) / (Running Time + Force outage time) * 100

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ASH UTILISATION REQUISITES

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Monitoring • PADO / Gate cycle / PEPSE• EMS• Energy Audits • Process Deviation Audit• MIS• Reviews• Root cause Analysis• CA &PA• Knowledge sharing

THE EFFICIENCY IMPROVEMENT IN A POWER PLANT IS A CONTINUOUS LIFE TIME ACTIVITY

AND IT CAN BE ACHIEVED WITH EVERY ONE CONTRIBUTING TO IT.

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THANK YOU