Boiler Modification for SHR & Reliability Improvement SSL (IPP)
- 1. An Energy & Environment Conscious, Sustainable & Prosperous Organization SESA STERLITE LTD 4X600 MW IPP 1
- 2. 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 2 Sesa Sterlite – Power Overview Contributing to India’s Energy Security An Energy & Environment Conscious Sustainable Organization
- 3. PROJECT - BOILER MODIFICATION FOR RELIABILITY AND STATION HEAT RATE IMPROVEMENT 3
- 4. 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 4
- 5. 5 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
- 6. 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. 6 OPPORTUNITIES IN BOILER
- 7. 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 7
- 8. 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 8 CORRECTIVE MEASURES
- 9. 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. 9
- 10. 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. 10
- 11. 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. 11
- 12. 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. 12
- 13. 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 13 Cutting of LTRH Tube and Header Removal of LTRH Header Economiser Tube cutting
- 14. 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 14 Steam Cleaning of Tubes Erection of Economiser Coil Lifting of water wall panel through bottom ash hopper
- 15. 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. 15 Readiness for position eco tube Economiser coil in position
- 16. 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 16 Removal of LTRH Header Fitment of new LTRH Header Erection of new LTRH link pipe
- 17. 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 17 Lifting of Economiser Coil Addition of Economiser bank New Added Economiser bank
- 18. 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 18
- 19. Boiler Parameters After Modification 19 S.No Parameter Description UOM Design Before Modificatio n After Modificatio n 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
- 20. 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. 20 Result Summary
- 21. CALCULATION OF GAIN AFTER MODIFICATION S.No. IMPROVEMENT AREA UOM Before Modification After Modification Improve ment Gain in Heat Rate (Kcal/K wh) 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 21
- 22. Thank You 22