CCT - Energy Efficient R&M Conference on Clean Coal and Carbon Capture and Storage Technologies A TREC-STEP initiative: 'Developing a Cluster for CCT & CCS for the Indian Thermal Power Sector’ 2-3 Dec 2013, Tiruchirapalli, TN, India Doosan Power Systems India
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CCT - Energy Efficient R&MConference on Clean Coal and Carbon Capture and Storage TechnologiesA TREC-STEP initiative: 'Developing a Cluster for CCT & CCS for the Indian Thermal Power Sector’
2-3 Dec 2013, Tiruchirapalli, TN, India
Doosan Power Systems India
1
ABOUT DOOSAN POWER SYSTEMS
WHY R&M
R&M MODALITY
CASE STUDY
RECENT R&M PROJECT
CONCLUSION
PROGRAM
2
HERITAGE
2011
Acquired by DPS and renamed
Doosan Lentjes
Acquired by Doosan
Acquired by Doosan to become Doosan Babcock Energy
Lentjes GmbH formed
Skoda Energoformed
Skoda daughter
companies privatised
Babcock Power Ltd formed
Ferdinand Lentjes
founded boiler manufacturing
company
Babcock & Wilcox established
Engineering workshop founded
Babcock
Škoda Power
Lentjes
20051928
2004199819931859
200619791891 2009
Doosan Power Systems (DPS) -bringing Babcockand Skoda together
2009
Company becomes Skoda Power
3
ORIGINAL TECHNOLOGY HOLDER
B&W Partnership US B&W B&W Corp.
Doosan Power
Systems India
Doosan Power
Systems
1867 1881
1891 1995
OriginCurrent
Manufacturer
Inve
stm
ent
Acquisition
Period of Investment, Mergers & Acquisitions
Market Area: USA & Cuba
Market Area:Rest of the World
2007
Calcutta office
B&W India
ACC Babcock
1904 1947 1959 1996
India
Mitsui Babcock Energy
MBEL India
Inve
stm
ent
UK B&W
Doosan Heavy
Industries
USA
UK
4
DOOSAN POWER SYSTEMS
Doosan Power Systems Lentjes, Skoda Power, Doosan Babcock
Doosan BabcockDoosan Lentjes
Doosan Skoda Power Doosan Babcock
Boiler & Air Pollution Control Turbo-generators Service
Survey 3 - 9037 HrsNSHEB Surv ey Data First Pi Data Current U2 Data
High Load factor High Load FactorGas and Oil Firing 100% Gas Firing Repowered U1 DataLow start Frequency Low start frequency Medium Load FactorPressure Independent Coincident Pressure 100% Gas Firing
Low Start FrequencyCoincident Pressure
MBEL Acquired Data
4 24 2
223
Oil Gas
Survey 2 Envelope - 65717 Hrs
19%51%
Surv ey 1 Envelope - 34704 Hrs
Total
439
21,32888,130
216
Fuel Mix U1
1980 - 82
Starts
Oil
49%109458
Gas
81%
1983 1984
6829
6621
Boiler Running Hours
2001 20021985 - 1994 1995 1996 - 2000
8052
4837
4200
Total HrsTotal Starts
Hrs Gas Hrs Oil
Starts GasStarts Oil
34
THE ENGINEERING APPROACH
Develop time histories of temperature behaviour
Enable assessment of operational drift from design intent and available margins
Thermal imaging – Quick and safe technique for accurate measurement of surface temperatures
3D Laser Scanning <6mm spot size/ <6mm positional accuracy @50m
360 PV – 360 degree Panoramic Visualisation
TESTING AND MODERN TOOLS
41
Software and Tools group (SWAT) undertake continuous development of a range of in- house tools, which are used for both design and analysis
HAMBE
Calculates the flow, temperature, pressure and composition for the fuel, air and flue gas streams in a utility boiler system for the design load and part loads
BWHOT
System of 13 programs for modeling radiation and heat transfer in a furnace
Recently been extended beyond the furnace exit plane to include the high temperature convective pass
SteamGen
Calculations involve the heat transfer between the gas side and the steam side
Stress Analysis
TESTING AND MODERN TOOLS ( in-house)
42
Prediction of Flow Field, Flame InteractionCoal Burnout, Heat ReleasePollutant Formation (NOx , CO)Fuel and Air Mixing
Sensitivity StudiesAir Staging, Re-burn, SNCR Fuel TypeFuel and Air DistributionFuel Fineness
The commercial Fluent Computational Fluid Dynamics (CFD) code is used in the development and optimization of burner and furnace design
Simulation of Single Burner and Full FurnaceMulti-fuel Combustion Air and Oxyfuel Firing
TESTING AND MODERN TOOLS ( CFD)
43
MULTI FUEL BURNER TEST FACILITY
Full-scale testing and demonstration, contract or third party burners on the 90 MWtMulti-fuel Burner Test Facility (MBTF) in Renfrew, Scotland
Capability to Fire a Wide Range of Fuels
Coals, Bituminous and Low Volatiles8% to 40% Volatiles, Dry Ash FreeUp to 35% Ash, as firedUp to 20% Inherent Moisture, as fired
WBPDCL - BTPS is located at Bandel in Hooghly District in West Bengal, India
BTPS comprises of 4 x 82.5 MWe Coal fired boilers supplied by Babcock & Wilcox
commissioned during 1965 & 1966 and 1 x 210 MWe Coal Fired boiler supplied by ACC Babcock Ltd, with the
backup of Babcock & Wilcox UK commissioned during 1982.
The existing 210 MWe Steam Turbine is of LMZ K-210-130.
HP, IP and LP cylinders of 210 MWe fitted with impulse blading. The HP and IP Cylinders are single flow while LP cylinder is double flow type
The 210 MWe boiler is a Radiant front wall fired two pass parallel backend design with tubular airheater.
Brief description of West Bengal Power Development Corporation Ltd (WBPDCL) -Bandel Thermal Power Station (BTPS)
48
CASE STUDY - BANDEL PJT : BOILER BASIC PARAMETERS(OEM)
Plant BTPS – Unit 5
Year of installation 1982
OEM ACC Babcock
Capacity 1 x 210 MWe
Design Parameters 700 TPH Steam at Final Superheater outletof steam generator 135 kg/cm2 (g) at SH outlet
540 oC at SH outlet540 oC at RH outlet252 oC feed water at Economiser inlet60% MCR to 100% MCR SH control range132 oC flue gas leaving airheater4000 KCal/Kg design coal GCV6 nos Babcock E mills
49
CASE STUDY - BANDEL PJT : SCENARIO PRIOR TO R&M
Deterioration of seals, casings
From 4111 to 3300 kCal/Kg
2092 to 2298 KCal/KWh
From 86.3 to 81.8%
Up by 12%
From 210 to ~185 MWe
Availability down to 71% and PLF
down to 60%
SPM levels are high
Baseline
Increase
Decrease
50
CASE STUDY - BANDEL PJT : KNOWN PROBLEM AREAS
Ash content in Coal has increased and GCV has come down. Resulted in inadequate supply of pulverized coal from the mills. Most of the time it is required to operate all mills, affecting mill maintenance and combustion control system.
Deterioration in many of the pressure parts, airheater, burners, ESPs and auxiliaries
With increase in air-in leakage, draught plant margins are non existent, resulting in limitation on plant output to 185 – 190 MWe.
Plant unit heat rate has deteriorated from the original 2424 to 2872 KCal/KWh and turbine heat rate from the original 2092 to 2298 KCal/KWh.
Boiler efficiency has also gone down to 81.8 % from the original value of 86.3 %.
Emission levels (SPM) have increased considerably.
Performance Data for ’06-’07 indicates Auxiliary Power consumption has gone up by 12%.
Frequent tube failures of economizer bank and other pressure parts lead to lower availability of the boiler. Availability has come down to 71%.
PLF is very low and forced outages are more.
The steam generator has operated for more than 25 years and its performance has degraded.
51
To enhance operating life by further 15 to 20 years
Replacement of various deteriorated pressure parts
Up gradation of coal mill capacity
Reduction in NOx level (fitting of latest design PF burners)
Changing/Replacement of critical components in FD, ID and PA Fans
Opening of site office, Pre-Shut down works (13~18M) (Installation)
Commissioning
PG Test(~27M)
62
BANDEL - UPDATE
Project is more or less on-time, with boiler presently is shutdown for erection.
Relationship with the customer is excellent
63
ABOUT DOOSAN POWER SYSTEMS
WHY R&M
R&M MODALITY
CASE STUDY
RECENT R&M PROJECT
CONCLUSION
PROGRAM
64
AMGEN TORRENT POWER LIMITEDE & F STATION UPRATING
RECENT PROJECT
65
TORRENT THERMAL POWER STATION
‘E’ and ‘F’ stations were manufactured, supplied and erected by M/s BHEL andwere commissioned in 1984 and 1988 respectively. The boiler plant is located atthe north of Ahmadabad, Gujarat, India and owned by Ahmedabad GeneratingCompany (AMGEN)
The exiting steam turbines are of Skoda make having original rated output of110 MWe, rated SH pressure of 130 kg/cm2g and rated SH and RH temperatureof 535 oC
The steam turbine is a 3 casing condensing steam turbine with reheat and eightbleeds of steam for original regenerative system
The original HP turbine has a control stage of 2 numbers Curtis wheel and other 8impulse stages. The original IP turbine has 12 impulse stages. The original LPturbine has 2 x 4 impulse stages
The boilers are BHEL make corner fired units with RH temperature control byburner tilt
The original heat rate of turbine at rated output is 2175 kcal/kWh.
66
TORRENT - BOILER BASIC PARAMETERS
Plant Torrent Thermal Power station – E & F Stations
Year of commissioning 1984 & 1988
OEM M/s BHEL
Capacity 2 x 110 MWe
Design Parameters 375 TPH Steam at Final Superheater outletof steam generator 138 kg/cm2 (a) at SH outlet(original design) 540 oC at SH outlet
540 oC at RH outlet241 oC feed water at Economiser inlet60% TMCR to 100% BMCR SH control range152 oC flue gas leaving airheater4450 KCal/Kg Coal GCV
67
TORRENT PROJECT - OBJECTIVES
Retrofitting existing turbine components with state-of-art efficient turbine components
Modification in boiler reheater surface including replacement of reheater headers to suit requirements of retrofitted turbine
Replacement of existing turbine hydraulic governing system with electro hydraulic turbine control (EHTC)
Overhauling and servicing of turbine valves
RLA and refurbishment of turbine oil system, regenerative system and cooling water system
RLA study of piping valves and castings
Replacement of existing C&I system with state-of-the art DCS
110 MWe 121 MWeUp-rating and modernization
68
TORRENT - BOILER R&M CHALLENGES
R&M on non-OEM designAdditional heating surface shall be supported from roof tubes, local supports to be checked, modified and suitably reinforced
Existing Sootblowersand access openings retained
Enhanced surface addition shall be within original overall RH pressure drop
Entire reheater elements replaced with new elements having extra heating surface (~30% increase) to meet requirement of HBD, within the existing layout
69
ABOUT DOOSAN POWER SYSTEMS
WHY R&M
R&M MODALITY
CASE STUDY
RECENT R&M PROJECT
CONCLUSION
PROGRAM
70
R&M INCREASES LIFE AND ENERGY EFFICIENCYPlant Cycle Efficiency Enhancement
Enhance Efficiency
Increase Capacity
Improve Reliability
Life Extension
Old Plants get a lease of life of at least 15 - 20 yearsHigher cycle efficiency results in lower generation costsLower fuel consumption and hence lower carbon footprintLower emissions
Capacity
Efficiency
Reliability
71
ENERGY EFFICIENT R&M IS ECONOMICALLY VIABLE
New Build
Project Cost(land cost excluded)
EE R&M
(X) INR / MW (0.6 – 0.65 X) INR / MW
Outage More than 50 months project cycle 6 - 8 months
Design Life 20 years 20 years(extended)
Cycle Efficiency(compared with new plant of similar cycle)
100% 100%
Project Risk High Low
Coal Linkage & otherclearances Difficult None
EE R&M is the best available solution for quick increase of reliable power capacity and technically can enhance plant capability as much as a new-build plant in energy efficiency and in design life with optimized CAPEX