Modern Design and Upgrading of Coal Power Plants in India 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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Modern Design and Upgrading of Coal Power Plants in India Conference 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
BOILER PRESSURE PART DAMAGE MECHANISMComponents Creep Fatigue Erosion Corrosion Over heat Wear
Drum/SeparatorSH/RH Header WW Header Eco. Inlet Header Downcomer/Integral Piping Main Steam Piping Hot Reheat Piping SH/RH Tubing WW Tubing
BOILER LIFE MANAGEMENT
18
THE ENGINEERING APPROACH
Require to assess the impact of the past …
… and predict the effects of the future
Explore and understand original design margins
Understand previous operational history
Develop time histories of temperature behaviour
Enable assessment of operational drift from design intent and available margins
Operation < Design Operation > Design
Operational history
19
THE ENGINEERING APPROACH
Assess damage due to creep – knowledge of materials creep strain behaviour across a range of temperatures
Assess fatigue damage and likely accumulation
Assess ongoing damage due to creep
Assess fatigue damage from future operating regime
From past history:
From future projection:
Assessment of remnant life:
Use cumulative damage techniques and creep/fatigue interaction diagram to assess current and future path
Enables a standard methodology to be used for the formulation of remnant life – recognised by designers and regulatory authorities
20
Specialized NDT and In-Service Inspection Technology
TESTING AND MODERN TOOLS
Visualization Technology
21
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
Computational Fluid Dynamics
Fluent Computational Fluid Dynamics (CFD) code is used in the development and optimization of burner and furnace design
22
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
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
26
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
27
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)
38
BANDEL - UPDATE
Project is more or less on-time, with boiler presently is shutdown for erection.
Relationship with the customer is excellent
39
ABOUT DOOSAN POWER SYSTEMS
WHY R&M
R&M MODALITY
CASE STUDY
RECENT R&M PROJECT
CONCLUSION
PROGRAM
40
AMGEN TORRENT POWER LIMITEDE & F STATION UPRATING
RECENT PROJECT
41
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
42
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
43
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
44
ABOUT DOOSAN POWER SYSTEMS
WHY R&M
R&M MODALITY
CASE STUDY
RECENT R&M PROJECT
CONCLUSION
PROGRAM
45
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
46
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