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MTPS TANGEDCO IGEN IMPLEMENTATION REPORT M.RAMACHANDRAN SUPERINTENDING ENGINEER ELECTRICAL SYSTEM/ MTPS 1 METTUR DAM

session 2 - 03 (MTPS TANGEDCO IGEN IMPLEMENTATION … 2... · 2018. 2. 22. · ] ( / v } µ ] } v } ( Z W o v ] Ç t ô ð ì Dt h v ] ^ ] Ì t ð y î í ì Dt > } ] } v } ( } Á

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Page 1: session 2 - 03 (MTPS TANGEDCO IGEN IMPLEMENTATION … 2... · 2018. 2. 22. · ] ( / v } µ ] } v } ( Z W o v ] Ç t ô ð ì Dt h v ] ^ ] Ì t ð y î í ì Dt > } ] } v } ( } Á

MTPS TANGEDCO IGEN IMPLEMENTATION REPORT

M.RAMACHANDRANSUPERINTENDING ENGINEER ELECTRICAL SYSTEM/ MTPS 1METTUR DAM

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Brief Introduction of the PlantCapacity – 840 MW Unit Size – 4 X 210 MW

Location of power plant : METTUR THERMAL POWER STATION. Owner : TAMILNADU GENERATION AND DISTRIBUTION CORPORATION

LIMITED.PLF for the station : 92.70 % (IN THE SILVER JUBILEY YEAR 2011-12)UNIT CONTINUOUS RUN :STATION CONTIN. RUN : 71 days

Unit No.

Unit Capacity

(MW)

Year of commissioning

Boiler / Turbine make

1 210 1987 BHEL/LMW2 210 1987 BHEL/LMW3 210 1989 BHEL/LMW4 210 1990 BHEL/LMW

UNIT 1 UNIT 2 UNIT 3 UNIT 4

227 205 272 311

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IGEN Programme and MTPS - I

Under IGEN Phase 2 MTPS Unit 1 was selected as model unitWith the help of M/s STEAG detailed model of

unit 1 was developed.Extensive training was imported to the

engineersField studies were conducted by M/s STEAGUnder the programme, exchange of best O&M

practices, valuable knowledges were shared.

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Works carried out in Unit – 1 of MTPSBoilerCFD analysisR & M of Air Pre Heater (with double sealing )Pent house sealingHigh pressure Jet cleaning

Turbine Condenser tube replacement (top portion only) Condenser tube bullet cleaning Tip Seal Replacement in the HP, IP Turbine diaphragms Monitoring of HP Drains (using Thermal imager)

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Problems Faced in Unit – I of MTPS

• Very high erosion in the flue gas ducts.• High APH outlet temperature• Low outlet temperature of secondary and primary air

of APH outlet• Full ID fan Loading• Low condenser vacuum during summer• Higher steam consumption Almost all the problems have been solved after implementation of IGEN programme. All the above works except Air Pre- Heater Replacement were carried out in the remaining Three units.

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Studies made using EBSILON software

Following studies were made • Air ingress in the flue gas system

– by measuring the O2 value at different locations in the flue gas path. Using This model the above study can be done by measuring temp at different locations of flue gas duct.

• Air pre heater Performance study• Heaters Performance Study • Condenser performance study. • Total cycle analysis. (operating Model analysis)

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Air ingress in the flue gas system

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Air ingress in the flue gas system

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Outcome of Air ingress study in the flue gas system

• High Air ingress noticed in the APH system.

• Air ingress in the Flue gas duct is also more.

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Action Taken

Based on the IGEN knowledge exchange programthe following improvement works was carried out

Modification of APH from 27VIT2000mm to27.5VITM2300mm with double sealing arrangementand increase the heating surface area by 29%.

Computational Fluid dynamics (CFD) modelling wascarried out in the Flue gas path and guide vanes wereerected in the Duct based on the CFD results.

Penthouse sealing was carried out.

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AIR PRE-HEATEREXISTING - Make : BHEL

• TYPE:27 V I T 2000mm• 27 - FEET DIAMETER• V - VERTICAL• I -INVERTED GAS FLOW• T - TRISECTOR• 2000mm -HEATING ELEMENT HEIGHT • 72° PRIMARY AIR FLOW OPENING• Single sealing• 12 sector

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Baskets of APH (old )

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Modified APH Model

27.5 V I T 2300mm – Make GEECO27.5 - FEET DIAMETERV - VERTICALI - INVERTED GAS FLOWT - TRISECTOR2300mm - HEATING ELEMENT HEIGHT 72°C - PRIMARY AIR FLOW OPENING24 Nos - Sectorsealing - Double sealing

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AIR PRE-HEATER WORK CARRIED OUT

Air pre-heater “A & B” replaced with new one– Double sealing – Increase in Height by 300mm from 2000mm to

2300mm.– Increase in Diameter by 344mm from 8676mm to

9030mm.

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PERFORMANCE IMPROVEMENTS

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AIM OF CFD ANALYSIS

»» To find out flow separation andrecirculation as well as flow concentration zonein existing duct arrangement using CFD.

» Pressure drop prediction in the existingsystem.

» To find the mass imbalance in eachpass of the ESP.

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» » Iterative analysis to modify the duct by CFD technique to reduce problematic areas.

» To optimize turbulence (eddy function and formation of recirculation zones)by designing the guide plate to reduced pressure drop.

» To achieve equal flow distribution at each ESP inlet by CFD technique.

» Pressure drop reduction across the system.

AIM OF CFD ANALYSIS

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CFD Modelling

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Flue Gas Duct Photos

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Flue Gas Duct Photos

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Flue Gas Duct Photos

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Flue Gas Duct Photos

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Flue Gas Duct Photos

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PRESENT DUCT CONDITION

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PRESENT DUCT CONDITION

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PRESENT DUCT CONDITION

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PRESENT DUCT CONDITION

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PERFORMANCE IMPROVEMENTS

» From CFD analysis of existing duct itcan be concluded that there was flowseparation, re-circulation & dead zone in thecommon duct which creates the high pressuredrop &mass flow imbalance problem. Theseproblems were optimized by design of properguide vanes.

» In existing duct there is flow imbalanceof ESP A-1 & A-2 and B-1 & B-2 duct pass

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» By designing the optimized guide vane and ductplates using CFD, the flow is nearly uniform withoptimum turbulence & completely avoiding recirculationzone, which result in reduction in pressure drop.

» After modification in ESP inlet & outlet duct ,theflow in A-1 & A-2 and B-1 & B-2 pass of ESP has beenbalanced within 5% of the average flow rate.

» After modification, the pressure drop reductionfrom APH outlet to ESP Inlet & ESP outlet to ID Fan inlet is40 mmWC across the system

PERFORMANCE IMPROVEMENTS

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FLUE GAS LEAKAGES ARRESTING IN PENT HOUSEWORK CARRIED OUT

» Huge quantity of fly ash dumped inpent house area was cleaned totally.

» The pent house was completelywater washes.

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» The area of leakages were identified &arrested by seal plates with proper welding andproviding flexible membrane consist of

Ceramic wool matters, Asbestos blanket Accplazt 55 (Chemical component) SS wire mesh

PENT HOUSE SEALING

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PENT HOUSE SEALING WORK

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PENT HOUSE SEALING WORK

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PENT HOUSE SEALING WORK

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PENT HOUSE SEALING WORK

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PENT HOUSE SEALING WORK

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PENT HOUSE SEALING WORK

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PENT HOUSE SEALING WORK

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PENT HOUSE SEALING WORK

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PENT HOUSE SEALING WORK

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PERFORMANCE IMPROVEMENTS

» » Since the leakage of flue gas has been totally arrested

» Effective turbulence inside the boiler has been enabled

» Clean environment in pent house area was ensured

» Loading of ID fans got reduced considerably

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OVERALL PERFOMANCE IMPROVMENT

SL.NO Description Before COH After COH

1) Induced draft fan scoop

99/100 % 67/67 % ↓

2) Induced draft fan current

141/134 A 102/102 A↓

3) Primary air fan current

100/97 A 95/94 A↓

4) Forced draft fan current

45/42 A 43/44 A↔

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HIGH PRESSURE JET CLEANING IN BOILER PRESSURE PARTS WORK CARRIED OUT.

» High pressure water jet cleaning was carried out in boiler pressure parts area using water jet pump with 200 Ksc.

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PERFORMANCE IMPROVEMENTS

» Heat pickup got increased in waterwall and super heater area .

» Hence the attemperation gotreduced appreciably there by increasing theboiler efficiency .

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PARTIAL REPLACEMENT OF CONDENSER TUBES

Total No. of tubes available: 15620 NosReplaced tubes : 3763 Nos% of tube replacement : 24%Benefit achieved : Around 10 mm of HgReplacement Area : Top portion of condenser

on both left and rightReason for replacement : Scaling

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PERFORMANCE IMPROVEMENTS

» Condenser vacuum improved from670mmHg to 680mmHg at cooling watertemperature of 30°C.

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Over all Improvements Achieved

• APH Leakage reduced to less than 8%.

• APH outlet flue gas temperature reduced by around 150C.

• Around 200C to 250C temperature improvement achieved in Primary and Secondary Air of APH.

• ID fan loading reduced to around 20% to 25% and maintains the same state till date.

• After optimization of flue gas flow in the duct, around 40mmWcpressure drop reduction achieved from APH outlet to ID fan.

• Appreciable improvement in the condenser vacuum.

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Study on reduction of Raw water Consumption

• MTPS has induced draft cooling tower system for cooling water system.

• At present Cycle of concentration is 1.6.• Condenser tube material is cupro-nickel 90/10.• At present Raw water consumption of MTPS for all the four

units is around 5200 M3 per hour.• This corresponds to 6.19 M3 / MW.• Present specific water consumption norms is 3.5 M3/ MW. • To fix the Required COC study was carried out using EBSILON .

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UNIT WISE CONSUMPTION OF COOLING WATER

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FOR ALL THE FOUR UNITS2940/5200

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BY CHANGING COC TO 32940/5200

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• Now based on the above results, discussions aregoing on with the suppliers to raise the COC of thesystem to 3.5 by admitting Sulphuric acid in thecooling water system.

• All calculations such as Sulphuric acid requirement per day, Tank storage capacity Etc. are corresponds to 3.5 COC.

Study on reduction of Raw water Consumption

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STUDY ON HEATING OF CONDENSATE WATER IN THE FLUE GAS DUCT FOR HEAT RECOVERY

• In MTPS long flue gas ducts are available .

• APH outlet temperature is high in the order of 170°c

• It is proposed to heat 10 % of condensate water in the

flue gas duct

• Improvements observed is around 10 kcal/kwhr

71 MTPS

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AFTER DIVERSION OF 10 % CONDENSATE TO HEAT AT FLUE GAS DUCT

72 MTPS

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BEFORE AND AFTER DIVERSION OF 10 % CONDENSATE TO HEAT AT FLUE GAS DUCT

73 MTPS

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Area of attention needed to improve the Heat Rate

Coal yard Management systemProblem faced • FIFO system not followed due to coal demand, Long travel

time of SCR etc.,• Spontaneous combustion in coal yard• Very long period of storage of coal in the coal yard.• Coal received for MTPS-I through wagon from long

distance. Hence deterioration in coal quality is more.

The Targeted Heat rate in the PAT scheme unable to beachieved due to above reasons even though the machines arein good condition.

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THANKS• My sincere thanks to:

» Er. Chandrasekaran, CEA» Er.Vikas Ranjan, BEE» M/s GEZ Germany» Er.Bobin Anto, STEAG» Er. Patnayak, STEAG

»To all the participants of the session.

THANKYOU. M.RAMACHANDRAN

SUPERINTENDING ENGINEERELECTRICL SYSTEMS

METTUR THERMAL POWER STATION-1

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Yearly Rental Application...d p } } u v Ç í î ô d ] v ^ u , Ç v v ] u d ì î ò ì í w w ñ ì ô r ð î ô r ð ð ð ï & w ñ ì ô r ð î ô r ð ð õ ï , fhuwli\ xqghu

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