Operational Best Practices for - IPS 2018indianpowerstations.org/IPS 2013 Presentations/Day... · Inspection During Annual Overhaul , Recommissioning . •Checking for Uniform flue

Operational Best Practices for “ESP Performance Improvement “.

By

Susanta Ghosh AGM(O)I/C & R.N.Das AGM(O) TSTPS-Kaniha .

TSTPS /KANIHA

6X500 MW UNITS , TSTPS , KANIHA

2

2ND LARGEST THERMAL POWER PLANT OF NTPC

Why ESP Performance Monitoring is important ?

• There is a wide gap in ESP design condition & actual operating condition .

• Wide variation in quality of coal fired as coal received from different mines with different qualities .

• Day by day environmental Stringent norms set by regulators , such as – (150 mg/Nm3 → 100 mg/Nm3 → 50 mg/Nm3)

• Annual Overhauling schedule changed to 2 years . • FA Evacuation constraints faced due to restriction in

disposal system /ash dyke . • Dry ash collection from ESP hoppers .

3

ESP DESIGN DETAILS .

4

SL

NO PARAMETERS Unit STAGE-I STAGE- II

1 Unit Capacity MW 2X500 MW 4x500 MW

2 Coal Consumption /

Unit T/HR

336 - DESIGN

370 - WORST

420 - SITE RESTRICTION

336 - DESIGN

370 - WORST


3 Ash % 44% 44%

4 FG flow volume M 3/SEC 789.00 777.0( 533.48 Nm3/sec)

5 Inlet dust burden Gm/Nm3 60 81.303 ( Guran- 63.387)

6 Outlet dust burden mg/Nm3 56 20.0

7 Efficiency % 99.91 99.939 ( 99.97)

8 Gas inlet Temp 0C 134 140 (125)

FA SYSTEM DESIGN DATA .

5

SL

NO PARAMETERS Unit STAGE-I STAGE- II

1 Unit Capacity MW 2X500 MW 4x500 MW

2 Coal Consumption /

Unit T/HR

336 - DESIGN

370 - WORST


336 - DESIGN

370 - WORST


3 FA Evacuation SYSTEM *** Continuous , Vacuum

Ext Type

Continuous , Vacuum Ext

Type

4 Dry ash facility *** 25 % each unit

Silo 135 Ton capacity

Two Units full collection

with one unit

transportation

Buffer Hopper 120 X8 tons

/Silo 750 X2 tons

5

Wetting unit collection

capacity (for each

streams)

T/hr 55 TPH 60 TPH

Operational Best Practices at TSTPS to Enhance ESP Performance.

• Normal operation at various Operating

Conditions .

• Inspection during Annual Overhaul ,

Recommissioning ,Testing , Setting Parameters .

• During Planned Maintenance of ESP passes.

• During Unit Start-up – Shutdown .

6

Normal Operational Strategies For ESP At Various Unit Operating Conditions .

• Monitoring of ESP online Field Parameters .

• Monitoring Effective Evacuation from Eco Hoppers .

• Strategies adopted for Higher Particle Sizing at ESP Inlet due to 1st field out of service .

• Strategies for high coal flow > worst coal firing

• ESP Hopper Effective Evacuation Monitoring through PI system .

• Regular FA system checks for system performance improvement .

• Improvement of Ash Flowability from ESP Hopper .

7

Inspection During Annual Overhaul , Recommissioning .

• Checking for Uniform flue gas distribution across the entire unit by proper inspection & repair of GD screen /Baffels .

• Proper inspection & cleaning of support & shaft system .

• Proper alignment of Emitting electrodes and collecting plates .

• Proper insulation of ESP Hoppers /Casings.

• Checking Proper installation and operation of FA system devices.

• Testing’s Followed by Recommissioning of ESP & FA system

8

Testing’s Followed by Recommissioning of ESP & FA system :

• Support insulator Heater , shaft Insulator heater healthiness checking , effectiveness checking by switching ON for 24 Hrs . Subsequent current measurement .

• After total readiness , continuous rapping for 8 Hrs all GDRM/CREM/EREM , then internal inspection & hopper portion final water wash before box up .

• 24 hrs support /shaft insulator Heater in service before field meggering .

• Each ESP Field Meggering to ensure electrical healthiness . (> 250 MΩ)

• Still air charging & VI characteristic checking for all Fields to identify problems , then subsequent field internal inspection & rectification .

• Inspection of 1st hopper after Furnace pressurisation test is completed .( to remove foreign material if any)

• Air tightness test of ESP up to ESP outlet by pressurizing boiler up to 100 mmwc.

9

Next Slide

Testing’s Followed by Recommissioning of ESP & FA system :

• Hopper Heater current check ,

• Dust level LO/HI indicator operation check .

• P&I check for Rectiformers .

• Gas load testing of Fields to create data base after synchronization .

• Rapper frequency and intensity adjustment later when the unit is brought on-line.

• FA evacuation system Checks .

• Hot tightening of FA evacuation system after one day .

10 Next Slide

During Planned Maintenance of ESP in Operating Units . (ESP Pass isolation for Rectification).

• Whenever number of field goes out of service > 2-3 then planned maintenance of the pass is taken up .

• Effort is put not to loose generation by firing good quality coal to restrict coal flow at 370 T/hr.

• A systematic approach through a standard check list is adopted by operation engineers while ESP pass shutdown activities are carried out .

• This also guides & helps the maintenance personnel for proper & effective inspection & rectification work .

• Still air charging of fields before isolation & after rectification is carried out to ascertain problems /problems are rectified respectively

• Meggering is carried out where problems are not visibly identified .

11 Next Slide

During unit start up – shutdown .

• During unit startup after a short shutdown , 2-3 passes of ESP are kept in service to avoid oil soot deposition in all passes .

• ESP Fields are charged after sufficient warm up i.e > 110-120 0C inlet /outlet temp .

• SCAPH is kept in service in all cold start-ups & up to sufficiently high load to ensure better temp at ESP inlet .

• FA Evacuation system is kept in service well in advance & mouth choking’s are cleared continuously if any during initial phase .

• ESP Auxiliaries are kept in service 24 hrs prior to BLU . • Before planned Unit shutdown all pass rappers are put on continuous mode

for dislodging of ash from collector & emitter electrodes in hot conditions . • All hoppers emptiness ensured before the FA system is taken under

shutdown . • For a short shutdown the Hoppers heaters & shaft /support insulator

heaters are kept ON .

• Identified Defects are attended , all fields are charged at charge ratio 1:1 The fields having problem are addressed .

• FA system functional /vacuum checks are carried out to bring the system close to new one .

12 Next Slide

GIST OF MAJOR MODIFICATIONS CARRIED OUT .

13

STAGE-I STAGE- II

• ESP Controllers are up graded recently

by BHEL

• ESP online parameters data provided

through DCS

• VP suction line /ASH LINE modified

(made independent) all 6 VP can be

kept in service

• ESP OUTLET SIDE GAS SCREEN REMOVED IN

ALL FIELDS OF U 5&6 , UP TO 7TH FIELD IN U

3&4 (balance to be carried out)

• DURING R&M ASH HANDLING

SYSTEM DATA TO BE HOOKED UP

TO PI SYSTEM

• VP suction line /ASH LINE modified (made

independent) all 8 VP can be kept in

service

• BOILER HOPPER DISCONNECTION

FROM ESP SYSTEM UNDER PROGRESS

• Ash Line made independent , . Additional

water source provided from SW network .

• ESP R&M PLANNED & CONTRACT

AWRADED TO MEET THE STRINGENT

NORMS

• Major evacuation monitoring data provided

in PI system .

• ECO HOPPER EFFECTIVE EVACUATION

MONITORED THROUGH PI SYSTEM ( TE

INSTALLED )

CONCLUSION : • The role played by operation engineers in formulating

strategies /practices is very important .

• To sustain the overall ESP performance , the operation support group discusses all the strategies with shift operation group on General shift days .

• After implementation of all best practices as discussed , at TSTPS the overall performance of ESP & Ash evacuation system improved indicated by consistency in ESP field availability .

• The PI system has further strengthened in monitoring , analyzing and inturn developing the operating personnel to a larger extent in maintaining & improving ESP performance .

14

15

Checking Proper installation and operation of FA system devices .

• Vacuum Checks . • Shutoff vacuum .

• Shutoff vacuum with air lock valve close.

• Vacuum with VB open

• Line Vacuum

• Functional Checks .

• Hopper empty vacuum check .

• Valve 100 % opening check .

16

Use of PI system in FA Evacuation Monitoring

• Shut off vacuum Monitoring .

• System Idle time Ineffective evacuation monitoring .

• Deterioration in system performance .

• System Good Performance

• Single Hopper Evacuation for long time.

• IA pressure for 100 % valve opening .

• DA evacuation & transportation system .

• BAG filter DP Monitoring .

17

18 Next Slide

19

Shutoff vacuum check with air intake closed

20

Economiser Hopper Evacuation temp Trend

21

3HNA30CT101.DACA.PV

52.280

3HNA30CT102.DACA.PV

38.108

3HNA30CT103.DACA.PV

54.672

3HNA30CT104.DACA.PV

44.367

4HNA30CT101.DACA.PV

38.025

4HNA30CT102.DACA.PV

36.721

4HNA30CT103.DACA.PV

36.638

4HNA30CT104.DACA.PV

30.518

2/9/2013 12:28:31 PM2/6/2013 8:28:31 PM 2.67 days

Plot-0

0

50

100

150

200

250

300

2/7/2013 2:00:00 PM

44.510

39.297

46.099

40.973

218.84

228.75

185.21

147.98

Improper Evacuation From ESP Hoppers (Idle Time more)

22

Next Slide

Improper Evacuation From ESP Hoppers

23

Next Slide

Improper Evacuation From ESP Hoppers

24

Next Slide

Improper Evacuation

25

\\10.0.120.202\GEN6_MW

356.37

\\10.0.120.202\6HFY00_1P02.SUMMER.PV

420.25

\\10.0.120.202\6PASSA_VAC_TX1

69.336

\\10.0.120.202\6PASSA_VAC_TX2

241.64

\\10.0.120.202\6PASSB_VAC_TX1

212.16

\\10.0.120.202\6PASSB_VAC_TX2

254.28

\\10.0.120.202\6PASSC_VAC_TX1

193.21

\\10.0.120.202\6PASSC_VAC_TX2

293.67

\\10.0.120.202\6PASSD_VAC_TX1

210.25

\\10.0.120.202\6PASSD_VAC_TX2

107.14

ABT.GEN6 Instantaneous MW

Unit#6 TOTAL COAL FLOW

UNIT#6 PASS A VACUUM TX-1


UNIT#6 PASS B VACUUM TX-1


UNIT#6 PASS C VACUUM TX-1


UNIT#6 PASS D VACUUM TX-1


8/24/2012 11:33:41 AM8/24/2012 9:33:41 AM 2.00 hours

UNIT#6

0

100

200

300

400

500

600

Next page

Hopper Evacuation With out proper vacuum

26

\\10.0.120.202\GEN4_MW

351.97

\\10.0.120.202\4HFY00_1P02.SUMMER.PV

281.99

\\10.0.120.202\4PASSA_VAC_TX1

191.00

\\10.0.120.202\4PASSA_VAC_TX2

74.000

\\10.0.120.202\4PASSB_VAC_TX1

180.00

\\10.0.120.202\4PASSB_VAC_TX2

277.00

\\10.0.120.202\4PASSC_VAC_TX1

279.00

\\10.0.120.202\4PASSC_VAC_TX2

210.00

\\10.0.120.202\4PASSD_VAC_TX1

0.0000

\\10.0.120.202\4PASSD_VAC_TX2

82.000











8/29/2012 7:42:54 PM8/29/2012 5:42:54 PM 2.00 hours

UNIT#4

0

50

100

150

200

250

300

350

400

450

500

U-4 A pass Evacuation deterioration VP suction line choking

27

\\10.0.120.202\GEN4_MW

511.03

\\10.0.120.202\4HFY00_1P02.SUMMER.PV

374.15

\\10.0.120.202\4PASSA_VAC_TX1

0.0000

\\10.0.120.202\4PASSA_VAC_TX2

211.00

\\10.0.120.202\4PASSB_VAC_TX1

95.000

\\10.0.120.202\4PASSB_VAC_TX2

222.00

\\10.0.120.202\4PASSC_VAC_TX1

228.00

\\10.0.120.202\4PASSC_VAC_TX2

0.0000

\\10.0.120.202\4PASSD_VAC_TX1

68.000

\\10.0.120.202\4PASSD_VAC_TX2

60.000











11/26/2012 9:03:46.445 AM11/25/2012 1:03:46.445 AM 1.33 days

UNIT#4

0

100

200

300

400

500

600

Indicates Empty Vacuum is increasing , suction line choking , System stopped

Dry ash transportation trend

28

\\10.0.120.202\U56_INSTAIR_HDRPR

5.0244

kg/cm2


5.6732

kg/cm2

\\10.0.120.202\3LINE1PRESSURE

0.57218

kg/cm2


0.64831

kg/cm2

Unit#5&6 ESP INST AIR HDR PRESSURE


Unit#3 DRY ASH TRANSPORT LINE L1 PRESSURE


11/11/2012 4:51:28 PM11/11/2012 12:51:28 AM 16.00 hours

IA & TR Line Press

0

1

2

3

4

5

5.7

Next Slide

Line-2 Choking On 6-11-2012

29


4.9191

kg/cm2


5.0822

kg/cm2


9.8555E-02

kg/cm2


1.1154

kg/cm2





11/5/2012 8:16:03 AM11/2/2012 4:16:03 PM 2.67 days

IA & TR Line Press

0

1

2

3

4

5

6

Pink Colour Line

pressure hunting

Green Colour IA pressure

Reduction

Next Slide

LINE-2 NO TRANSPORTATION

30


4.6036

kg/cm2


4.7040

kg/cm2


0.93655

kg/cm2


0.47682

kg/cm2





11/22/2012 9:26:28 AM11/22/2012 1:26:28 AM 8.00 hours

IA & TR Line Press

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

4.95

Line -2 Transportation

stopped

Single Hopper Evacuation for long time

31

\\10.0.120.202\GEN4_MW

351.97

\\10.0.120.202\4HFY00_1P02.SUMMER.PV

281.99

\\10.0.120.202\4PASSA_VAC_TX1

191.00

\\10.0.120.202\4PASSA_VAC_TX2

74.000

\\10.0.120.202\4PASSB_VAC_TX1

180.00

\\10.0.120.202\4PASSB_VAC_TX2

277.00

\\10.0.120.202\4PASSC_VAC_TX1

279.00

\\10.0.120.202\4PASSC_VAC_TX2

210.00

\\10.0.120.202\4PASSD_VAC_TX1

0.0000

\\10.0.120.202\4PASSD_VAC_TX2

82.000











8/29/2012 7:42:54 PM8/29/2012 5:42:54 PM 2.00 hours

UNIT#4

0

50

100

150

200

250

300

350

400

450

500

Next Slide

Single Hopper Evacuation for long duration

32

\\10.0.120.202\GEN4_MW

351.97

\\10.0.120.202\4HFY00_1P02.SUMMER.PV

281.99

\\10.0.120.202\4PASSA_VAC_TX1

191.00

\\10.0.120.202\4PASSA_VAC_TX2

74.000

\\10.0.120.202\4PASSB_VAC_TX1

180.00

\\10.0.120.202\4PASSB_VAC_TX2

277.00

\\10.0.120.202\4PASSC_VAC_TX1

279.00

\\10.0.120.202\4PASSC_VAC_TX2

210.00

\\10.0.120.202\4PASSD_VAC_TX1

0.0000

\\10.0.120.202\4PASSD_VAC_TX2

82.000











8/29/2012 7:42:54 PM8/29/2012 5:42:54 PM 2.00 hours

UNIT#4

0

50

100

150

200

250

300

350

400

450

500

Shut Off Vacuum Check

33

\\10.0.120.202\GEN3_MW

332.01

\\10.0.120.202\3HFY00_1P02.SUMMER.PV

375.62

\\10.0.120.202\3PASSA_VAC_TX1

57.098

\\10.0.120.202\3PASSA_VAC_TX2

80.008

\\10.0.120.202\3PASSB_VAC_TX1

100.27

\\10.0.120.202\3PASSB_VAC_TX2

68.107

\\10.0.120.202\3PASSC_VAC_TX1

78.750

\\10.0.120.202\3PASSC_VAC_TX2

60.753

\\10.0.120.202\3PASSD_VAC_TX1

88.000

\\10.0.120.202\3PASSD_VAC_TX2

0.0000











8/25/2012 7:40:45 AM8/25/2012 7:31:50 AM 8.92 minutes

UNIT#3

0

50

100

150

200

250

300

350

400

450

Shutoff Vac < 450 mmhg

IA Pressure Low in Unit 5&6

34


4.9191

kg/cm2


5.0822

kg/cm2


9.8555E-02

kg/cm2


1.1154

kg/cm2





11/5/2012 8:16:03 AM11/2/2012 4:16:03 PM 2.67 days

IA & TR Line Press

0

1

2

3

4

5

6

IA Pressure improved

IA Pressure dropped

35 Next Slide

36 Next Slide

37 Next Slide

38

Trends of Proper FA Evacuation

39

Use of TEMPLATE for MHV operation checking

40

Thermostat Location Changed

Old Thermostat Locations New thermostat locations

41

Next Slide

Hopper/Casing manhole air ingress .

HOPPER MANHOLE AIR INGRESS CASING MANHOLE AIR INGRESS

42

GD screen inspection & rectification , placement of flow baffels

43

Ash Build up in Support Insulator Housing of U-3 ESP

44

Hopper /Casing manhole Doors , source of air ingress in ESP ( ESP Pr. test)

45

ESP Field Alignment check Before & After OH

46

Next Slide

ESP Field Misalignment

47

ESP Field Non Rapping side Lower Shock bar Guide Position Check .

48

VI characteristics check for all fields

49

50

Eco hopper TE Fixing

51

52

ADVANTAGES TOWER TYPE BOILER OVER TWO PASS BOILER

53

TOWER TYPE (SINGLE PASS) INVERTED U TYPE (TWO PASS)

Heating surfaces are fully drainable (horizontal).

Restart behavior is excellent.

Heating surfaces are not drainable (vertical). Hence

slow startup and corrosion problem.

Heat exchangers are horizontal and tubes are

exposed to uniform temperature.

Heat exchangers are vertical and exposed to

different gas temperature along the height.

No blockage of ash in the convective heating

surfaces. as pitch of the coils is increasing from the

top to the bottom .

Accumulation of ash on economizer tubes where

the pitch is smaller. Hence local flue gas velocities

increases and erosion occurs.

Pressure parts wear is less due to Impact of ash by

counter action of gravity in the upward gas flow.

In rear pass the ash particles velocity accelerates

due to gravity and increases erosion.

Uniform Flue gas velocity & continuously upward

without any change in direction.

Turbulence created by the change in direction of

flue gas flow generates high local velocities causes

local erosion.

Even flow distribution of flue gas and particulates Thermal expansion of first pass and second pass is

different.

Direct load transmission to the boiler roof and free

expansion

Non-drainable heating surfaces having risk of flow

imbalance.

Spiral WW & Vertical WW Design

54

The Spiral WW Benefits from averaging of lateral

heat absorption variation (each tube forms a part of each furnace wall)

Fewer tubes than the vertical wall unit.

Simplified inlet header arrangement.

Large number of operating units. Use of smooth bore tubing

throughout entire furnace wall system. ( instead of Rifled tube)

No individual tube orifices like drum boilers .

the negative flow characteristics of the spiral furnace .

Vertical tube once through boiler Lower capital costs: Self-supporting tubes, hence

simplifying part of the boiler support system

Elimination of transition headers at spiral/vertical interface

Simpler ash hopper tubing geometry.

Lower operating costs: Lower overall boiler pressure drop,

hence lower auxiliary power load resulting in higher plant output and higher efficiency

‘Positive flow characteristic’ automatically compensates for variations in furnace absorptions .

Simple and economic tube repair Simple start-up system, a start-up

circulation pump is not required Reduced slagging of furnace walls Lower part loads down to 20% are

possible while maintaining high steam temperatures.

Enthalpy Control

55

Special Protections Used

56

DESCRIPTION Logic Set Value

Separator level very high and no

drainage. 2/3 > 12.9 Mtr

Evaporator flow LO-LO (FW flow - SH

spray flow) 2/3 < 420 t/hr

Spiral outlet tube metal temp. HI-HI. 3/8 470 0 C

Evaporator outlet steam temp. HI-HI 2/4 4650 C

ITSH outlet steam temp. very high. 2/4 505 0 C

LTRH outlet steam temp. very high. 2/4 520 0 C

Both the steam valves closed. 2/3 Closed

DETAILS OF UNIT STARTUP PARAMETERS. Stage - I & Stage - II Units

Parameters Stage - I Units Stage- II Units

Cold Warm Hot Cold Warm Hot

Startup Criteria

(Mean Rotor Temp ) < 160 0C

>240 0C

< 430 0C > 430 0C > 48 Hrs 0-48 hrs < 8 Hrs

BLU to Rolling

Parameters

1:20Hrs

80 min

1:15Hrs

75 min 35 min

2:05Hrs

125 min

1:25 Hrs

85 min 35 min

TG set Rolling Time i.e

up to 3000 RPM 50 min 17 min 07 min 45 min 6-7 min 6-7 min

BLU to synchronisation 2:15 hrs

135 min

1:40 min

100 min 36 min

2:50 Hrs

170 min

1:35 Hrs

95 min 50 min

Best achieved

Parameters BLU to

Synch 2:00 1:48 0:58 3:30 2:10 0:54

Synchronisation to Full

Load Operation

2:05 Hrs

125 min

1:20 Hrs

80 Min 30 Min

3:50 Hrs

230 Min

3:20 Hrs

200 Min 30 min

BLU to Full Load 4:20 hrs 3:00 Hrs 1:10 Hrs 6:40 Hrs 400 Min

5:00 Hrs

300 Min

1:20 Hrs

80 Min

57

SDCS ( startup drain control system)

58

Wet Mode of operation like drum boiler

Dry Mode Of Operation (> 35% of load )

59 Next Slide

60 Next Slide

Advantages of Tube Mill

61

Advantages Disadvantages High availability Fire fighting system is additional

Low running maintenance No. Of auxiliary drives per mill are

more Constant capacity and fineness High auxiliary power consumption Hard & abrasive fuel ground

efficiency Prone for explosion

Large reserve capacity of coal Cumbersome protection &

interlocks ( Purging/steam inerting Etc)

Fast response over wide range of load

Increased fineness at low load and hence flame stability

Low air/coal ratio Wide range of coal pulverized Substantial flexibility

62 5

HVDC system

63 5

Special protection Scheme

64

CONDITION ACTION

If HVDC power flow is more than 1600 MW and both pose blocked.

Unit # 5 will trip and unit # 4 & 6 shall be unloaded by 150 MW each.

If HVDC power flow is more than 1450 & less

than 1600 MW and both pole blocked. OR HVDC power flow more than 1600 MW and one pole blocked with remaining pole on ground return mode.

Unit # 5 shall trip and unit # 6 will be unloaded by 150 MW.

If HVDC power flow more than 1300 MW and less than 1450 MW and both pole blocked

.(OR) HVDC power flow more than 1450 MW

and less than 1600 MW and one pole blocked with remaining pole on ground return mode.

Unit # 4, 5, 6 shall be unloaded by 150 MW each.

If HVDC power flow is more than 1150 MW and less than 1300 MW and both pole

blocked. (OR) HVDC power flow is more

than 1300 MW and less than 1450 MW and one pole blocked with remaining pole on ground return mode.

Unit # 4 & 6 shall be unloaded by 150 MW each.

If HVDC power flow more than 1000 MW and less than 1150 MW & both pole blocked. OR) HVDC power flow more than 1150 MW and less than 1300 MW and one pole blocked and remaining pole on ground return mode.

Unit # 6 shall be unloaded by 150 MW.

INTERTRIP SCHEME DUE TO HVDC POLE OUTAGES ( SPS 450) •One Pole Blocked and Ex – Bus Generation > 1750 MW. Tripping of Unit # 6 Instantaneously. •Both Pole Blocked & Ex – Bus Generation > 550 MW

Tripping of Unit # 5 instantaneously

Tripping of Unit # 6 after 1 second time delay

Tripping of Unit 4 after 2 Seconds time delay

•Both Pole Blocked & Ex – Bus Generation > 1100 MW

Tripping of unit # 5 instantaneously. Tripping of Unit # 6 instantaneously. Tripping of Unit # 4 after 2 Seconds time delay. 5

VFD FOR ID FANS

65

Variable frequency drive with load commutated inverter.

xmer rect

dc

inv

3-ph ac

Synch motor

EFFICIENCY OF drive systems.

Fan speed Fluid coupling VFD system

100% 85% 85%

90% 75% 84%

80% 65% 83%

70% 56% 82%

60% 46% 80%

5

ESP 1ST FIELD OUT OF SERVICE

66

2ND LARGEST THERMAL POWER PLANT OF NTPC 67

68 NTPC KANIHA 6X500 MW UNITS

Bag Filter DP Monitoring

69

\\10.0.120.202\4PASSA_BF_DP

I/O Timeout

mmw c

\\10.0.120.202\4PASSB_BF_DP

6.3208

mmw c

\\10.0.120.202\4PASSC_BF_DP

I/O Timeout

mmw c

\\10.0.120.202\4PASSD_BF_DP

249.87

mmw c

\\10.0.120.202\4PASSA_VAC_TX2

\\10.0.120.202\4PASSB_VAC_TX1

\\10.0.120.202\4PASSC_VAC_TX2

\\10.0.120.202\4PASSD_VAC_TX2

Unit#4 PASS A BUFFER HOPPER BAG FILTER DP

Unit#4 PASS B BUFFER HOPPER BAG FILTER DP

Unit#4 PASS C BUFFER HOPPER BAG FILTER DP

Unit#4 PASS D BUFFER HOPPER BAG FILTER DP

2/2/2013 8:40:17 PM2/1/2013 12:40:17 PM 1.33 days

DRY_WET-U#4

0

50

100

150

200

250

300

350

Gas Screen Modification

70

Next Slide

Gas Screen Modification

71

Eco Hopper Temp Element Fixing of Temp element at Eco Hopper Adapter Eco Hopper Temp at DCS system

72

Next Slide

73

74

MEGGERING OF ESP FIELD

75

1ST BOILER LIGHT UP

02.10.94 22.11.95 11.09.02 05.07.03 18.01.04 27.09.04

SYNCHRONISATION

12.02.95 27.03.96 04.01.03 25.10.03 13.05.04 06.02.05

COMMERCIALISATION

01.01.97 01.07.97 01.08.03 01.03.04 01.11.04 01.08.05

U # 2 U # 1 U # 4 U # 6 U # 3 U # 5

TSTPS MILE STONES

76

77

UNIQUE FEATURES OF STAGE – I UNITS

Tower type (single pass) , subcritical once through boiler . Spiral & Vertical Water Wall combination for Evaporator. Enthalpy control for evaporator flow control instead of drum

level control . Sliding pressure operation combined with nozzle governed

turbine . Advantage of quick start up and flexible load variation. Special protections for once through boilers . Double ended Tube Mills for fast load picking up ( Reject

Less Mill ). SDCS ( Startup Drain Control System ) for unit startup & low

load operation . High efficient ESP ( > 99.9 % ). GCB in between generator & GT , thus avoiding the station

XFMR . Concept of ‘Plant Zero discharge’ implemented .

78

UNIQUE FEATURES OF STAGE - II

CENTRALISED CONTROL ROOM FOR ALL 4 UNITS OF STAGE – II

FEEDING THROUGH HVDC LINK TO SOUTHERN GRID .

SPECIAL PROTECTION SCHEME SPS 450/1000

FURNACE DRAFT CONTROL BY VARIABLE FREQUENCY DRIVE FOR

ID FANS . ( 30 % power reduction)

GCB PROVIDED IN BETWEEN GT & GENERTAOR, AVOIDED STATION

XFMR .

VAPOUR ABSORPTION MACHINE FOR AIR CONDITIONING OF

CONTROL TOWER .

MAJOR ESP & ASH HANDLING SYSTEM PROBLEMS EXPERIENCED AT TSTPS .

79

High FG volume loading (777 m3/sec → 1050-1100 m3/sec).

Frequent outage of 1st & 2nd fields .

Failure of Hopper Heaters .(plate type)

Failure of Gas Screens , lower shock bar guide .

Ash Flowability from ESP hoppers .

Ash Buildup in ESP Hopper , Mal Operation of ESP level

probe .

Fluidizing blower outlet temp low .

More evacuation time in B&C pass .

1st hopper evacuation in dry mode .

FA system shutdown / Back log clearing was a problem

Documents

Operational Best Practices for - IPS 2018indianpowerstations.org/IPS 2013 Presentations/Day... · Inspection During Annual Overhaul , Recommissioning . •Checking for Uniform flue