An Energy & Environment Conscious, Sustainable & Prosperous Organization SESA STERLITE LTD 4X600 MW IPP 1
Jul 13, 2015
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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