Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive

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Dev Raj, GM, BHEL, Noida

Improving The Availability of Improving The Availability of Electricity Through Better Techniques of Electricity Through Better Techniques of Predictive/Preventive Maintenance and Predictive/Preventive Maintenance and Modernisation of Thermal Power Plants Modernisation of Thermal Power Plants

Thermal Power India-II (11-12th Dec’2007)

ContentsContents

•Current Scenario

•O&M Improvements

•Maintenance

•Reliability Centered Maintenance

•Drivers of new Technology

•Condition Monitoring

•I.T. in O&M

Current ScenarioCurrent Scenario

Energy Consumption per Capita (KWH)Energy Consumption per Capita (KWH)

India ~ 600

Developed Nations ~ 8000 - 10000

Power GrowthPower Growth

•Installed Capacity at Independence – 1350 MW

•Installed Capacity Current – 1,35,000 MW

•Projected Capacity in 2012 – 2,00,000 MW

•Projected Capacity in 2032 – 8,00,000 MW

Supply of Electric PowerSupply of Electric Power

Availability of Electricity to the Consumer depends upon:

• Installed Capacity• Availability Factor of Installed Units• Plant Load Factor of Thermal Sets• Transmission Losses

If we improve PLF of existing thermal units by 1%, it is equivalent to adding 880MW to the installed capacity

O&M ImprovementO&M Improvement

PERFORMANCE DATA PERFORMANCE DATA –– Thermal SetsThermal Sets

0102030405060708090

70s 80s 90s 2Ks

PLF %OA %

OUTAGESOUTAGES

• FORCED• PLANNED

Improvement AreasImprovement Areas

• Operation• Maintenance• Interval between planned outages• Renovation & Modernisation

WHAT IS MAINTENANCE?WHAT IS MAINTENANCE?

IT IS THE PROCESS OF ENSURING THAT PHYSICAL ASSETS CONTINUE TO DO WHAT THEIR USERS WANT THEM TO DO

Growing Expectations of MaintenanceGrowing Expectations of Maintenance

• First generation (1940s – 1950s) :- Fix it when it broke

• Second generation (1960s – 1970s) :- Higher plant availability- Longer equipment life- Lower costs

• Third generation (1980s – present) :- Higher plant availability and reliability- Greater safety- Better product quality- No damage to the environment- Longer equipment life- Greater cost effectiveness

Growing Expectations of MaintenanceGrowing Expectations of Maintenance

Changing Maintenance TechniquesChanging Maintenance Techniques

• First generation (1940s – 1950s) :- Fix it when it broke

• Second generation (1960s – 1970s) :- Scheduled overhauls- Systems for planning and controlling work- Big, slow computers

• Third generation (1980s – present) :- Condition monitoring- Design for reliability and maintainability- Hazard studies- Small, fast computers- Failure modes and effects analyses- Expert systems- Multi-skilling and teamwork

Changing Maintenance TechniquesChanging Maintenance Techniques

Type of MaintenanceType of Maintenance

• Predictive• Preventive

RReliabilityeliability--CCentered entered MMaintenanceaintenance

It is the process which is used to determine what must be done to ensure that any physical asset continues to do what its users want it to do in its present operating context.

RCM : The seven basic questionsRCM : The seven basic questions

• What are the functions and associated performance standards of the asset in its present operating context?

• In what ways does it fail to fulfill its functions?• What causes each functional failure?• What happens when each failure occurs?• What can be done to predict or prevent each

failure?• What should be done if a suitable proactive

solution cannot be found?

An Old Power Plant Will Have The Same An Old Power Plant Will Have The Same Availability As A New One!!Availability As A New One!!

(If sound O&M practices are in position)

Renovation & ModernisationRenovation & Modernisation

• Extension of plant life• Improvement in PLF and efficiency• Uprating of present unit capacity• New generation C&I• Online Condition Monitoring

Faster way of addition to the generating capacity

Drivers for New Technology

• Present operating condition of Aged Units• ABT/Regulatory Regime• Increased Competition – Merit Order Rating• Environmental Concerns• Scarcity of Resources• Need to cut Input Costs• Demand Growth Outstripping Supply Growth

Technology Frontiers

• Enhanced Condition Monitoring• Introduction of IT

Condition Monitoring

• Vibration Monitoring• Generator Condition Monitoring• On Line Partial Discharge Measurement• Air-gap Flux analyser• Sonic On-Line Tube Leak Detection System• SMART Wall Blowing System• Turbine Stress Evaluators

IT in O&M

• Remote Monitoring• On-line Automation & Diagnostics -PADO• Asset Management System• Documentation System• Networking