POWER PLANT SUMMIT 2008 SMART SOOT BLOWING SYSTEM FOR PERFORMANCE IMPROVEMENT

BY SURYA NARAYANA. S. RAICHUR TPS / KPCL SHAKTINAGAR DATE: 05 to 07.11.2008

PRESENTATION TOPICS
1. BRIEF NOTE ON RAICHUR TPS 2. SMART SOOT BLOWING SYSTEM
-A COMPARISION WITH NORMAL SYSTEM -BACKGROUND OF SMART -SPECIAL FEATURE & BENEFITS OF SMART -LOGICS & OPERATIONAL PHILOSOPHY -PERFORMANCE - CASE STUDY -COST SAVINGS -OBSERVATIONS & PROBLEMS EXPERIENCED -RECOMMENDATIONS

3. CONCLUSION.

DATE OF COMMISSIONING OF 210MW RAICHUR TPS UNITS

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UNIT 1 UNIT 2 UNIT 3 UNIT 4 UNIT 5 UNIT 6 UNIT 7

29.03.1985 02.03.1986 30.03.1991 29.09.1994 31.01.1999 22.07.1999 10.12.2002

I STAGE II STAGE III STAGE IV STAGE V STAGE

RAICHUR TPS PERFORMANCE ( 210MW X 7 UNITS) PARTICULRS UNIT 2003-04 2004-05 2005-06 2006-07 2007-08 RUNNING HRS. HRS 55148 53996 45686 55526 52775 NO. OF TRIPS NO. 90 46 54 54 74 PLANNED OUTAGES HRS. 4385 6529 5450 4536 6172 FORCED OUTAGES HRS. 1954 791 1606 1256 2540 AUX. CONS. % 8.5 8.69 8.63 8.22 8.33 PLF % 88.24 83.33 71.31 89.18 84.22 PAF % 89.69 88.06 88.49 93.39 90.43 SP.FUEL CONS. Kg / Kwh 0.618 0.647 0.659 0.656 0.661 SP. OIL CONS. Ltr / Kwh 0.738 0.605 0.734 0.444 0.712

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MAJOR SOURCES OF COAL SINGERENI COLLIERIES WESTERN COLLIERIES MAHANANDI COLLIERIES

SMART SOOT BLOWING SYSTEM

WHAT IS SMART SOOT BLOWING ? AND HOW IT IS DIFFERENT FROM CONVENTIONAL SOOT BLOWING ?

NORMAL/CONVENTIONAL SOOT BLOWING

SYSTEM CONSISTS OF 56 BLOWERS, ARRANGED IN 4 ELEVATIONS (3 ROWS ABOVE & 1 ROW BELOW THE FIRING ZONE) ALL BLOWERS ARE OPERATED SEQUENTIALLY BLOWERS ARE OPERATED ONCE IN A SHIFT OF 08 HOURS. EACH BLOWER OPERATES 03 TIMES/DAY. REQUIRES 3.3 TONS OF STEAM/ CYCLE.

DISADVANTAGES OF NWBS
SHORT LIVED BENEFITS. NO CONSIDERATION FOR FURNACE CONDITION. NO CONTROL OVER SH & RH SPRAY. NO CONSIDERATION FOR VARIATION IN SLAGGING. NO CONSIDERATION FOR CHANGES IN FUEL, AERODYNAMICS, TILT AND BOILER LOAD. HOW TO OVERCOME THESE PROBLEMS ?

THINK IN THE DIRECTION OF ESTABLISHING AUTOMATIC OPERATION OF WALL BLOWERS ACHIEVING OPTIMUM HEAT ABSORPTION IN THE FURNACE LIMITING SH AND RH SPRAY THEN SMART IS THE SOLUTION !!?

SMART WALL BLOWING SYSTEM IS A SELECTIVE & NEED BASED SOOT BLOWING CORELATED WITH SH SPRAY AND REDUCTION IN ABSORBED HEAT FLUX OPERATION IS BASED ON COMBUSTION REGIME - DEPENDS ON BURNER TILT, EXCESS AIR, MILL COMBINATION, NO. OF MILLS IN SERVICE, ETC. CHANGE OVER TO NORMAL AND BACK TO SMART, AS PER REQUIREMENT IS VERY EASY.

BENEFITS OF SWBS
AVOIDS ACCUMULATION OF DEPOSITS MAINTAINS NET TOTAL FURNACE HEAT ABSORPTION AT OPTIMUM LEVEL. IMPROVES HEAT RATE / CYCLE EFFICIENCY. LOWER PEAK FURNACE GAS TEMPERATURES. REDUCES OPACITY EXCURSION & IMPROVES FLAME STABILITY LOWERS THERMAL NOx DUE TO REDUCED GAS TEMPERATURE. LESS WEAR & TEAR OF EQUIPMENT, STEAM REQUIREMENT, AUX. CONSUMPTION & OPERATIONAL COST.

BACKGROUND
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---- CONTINUED STUDIED THE BEHAVIOUR FOR DIFFERENT COMBUSTION REGIME, MILL COMBINATION, COAL SOURCE, LOAD, ETC., SIMILAR ARRANGEMENTS WERE MADE UNIT-3 BOILER IN 1997 & ERECTED 32 NOs BHEL DEVELOPED HFS, INSTALLED SMART SYSTEM. AUTOMATED & KEPT UNDER R&D FOR 01 YEAR IN THE YEAR 2001. SYSTEM WAS DEDICATED IN JAN 2002.

HEAT FLUX STUDY BY M/S.BHEL IN UNIT 1& 2 BOILERS AT RTPS IN APRIL 1996 RTPS SOUGHT APPROVAL FROM DIRECTOR OF FACTORIES & BOILERS IN JULY 1996 RTPS MADE ARRANGEMENTS FOR HEAT FLUX MEASUREMENTS USING PORTABLE HF PROBES & OPTICAL PYROMETER. STUDY - UNDER DYNAMIC SOOT DEPOSITIONAL CONDITIONS TO VARYING DEGREES

ELECTRONIC LOGIC SYSTEM OF SWBS PROJECT SCHEDULE

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FABRICATION OF HFS 02 MONTHS INSTALLATION OF HFS 15 DAYS ENGINEERING, PROCUREMENT, SOFTWARE CUSTOMIZATION 06 MONTHS ERECTION/INSTALLATION OF CONTROL PANELS & CABLING 02 MONTHS TESTING & DEMO 03 MONTHS ANALYSIS & REPORTING - 01 MONTH FINANCE : BY M/s. BHEL.

HEAT FLUX SENSOR ASSEMBLY

SECTIONAL VIEW OF WATER WALL

INCIDENTAL RADIATION HEAT FLUX

LOAD:170 MW, MILLS:ABCDE, TILT: -9 deg,

ABSORBED HEAT FLUX AT DIFFERENT ELEVATIONS

TYPICAL SH SPRAY TREND CONVENTIONAL vs SWBS

OPERATION PHILOSOPHY
TO MAINTAIN SH SPRAY WITH IN A PRE DEFINED NARROW BAND OF HIGH & LOW SET POINTS.
ON SH SPRAY FLOW CROSSING HSP, SMART SEQUENCE STATS . DEPENDING UPON THE DEPOSITS FORMED, THE ABSORBED HEAT FLUX CHANGES. - ON REDUCTION IN HEAT FLUX BELOW THE SET POINT OF A PARTICULAR SENSOR, THE ADJACENT BLOWERS OPERATE.

---- CONTINUED . THE SEQUENCE CONTINUES TILL SH SPRAY REACHES LOW SET POINT AT WHICH BLOWING STOPS . THE SEQUENCE RESTARTS AGAIN WHEN THE SPRAY REACHES HSP. . SYSTEM CONTINUES IN AUTO TO MAINTAIN SH SPRAY WITHIN A NARROW BAND.

HEAT FLUX SET-POINT CALCULATION

SET-POINT CALCULATION METHODS. BY DYNAMIC SET POINT CALCULATION (THE LAST HEAT FLUX VALUE IS COMPARED WITH SET VALUE BY THE SOFTWARE) OR BY FIXED SET POINT (SYSTEM TAKES USER SET VALUE)

SMART PERFORMANCE AT RAICHUR TPS

OLD & NEW BOILERS

CASE STUDY : U-1 & U-6

REDUCTION IN REHEATER SPRAY

20 15 9 10 5 0 42% Ash 32% Ash 7.3 4.8 17.1

PARAMETERS FOR COST CALCULATION

C onventional blowing

Sm art Blow ing

REDUCTION IN BLOWER OPERATION

DESIGN PARAMETERS

SMART SAVINGS

OBSERVATIONS
AT PART LOAD OPERATIONS OF THE UNIT, REQUIREMENT OF WALL BLOWING COMES DOWN & LESS ECONOMICAL NUMBER OF BLOWER OPERATION ABOVE THE BURNER ZONE IS MORE FAILURE OF HEAT FLUX SENSORS TAKE PLACE MAINLY DURING BOILER START-UP AND SHUT DOWN MORE NUMBER OPERATIONS OF ISOLATION / CONTROL VALVE & DRAIN VALVES

MAJOR PROBLEMS
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AVERAGE FAILURE OF HEAT FLUX SENSORS (HFS) IS 5 TO 8 / YEAR / BOILER REPLACEMENT OF DEFECTIVE HFS NEEDS UNIT SHUT DOWN MORE NUMBER OPERATIONS OF VALVES LEAD TO MORE HEAT LOSS IN THE PIPELINE. PERFORMANCE OF THERMAL DRAIN VALVES IS NOT SATISFACTORY. CONSIDERABLE HEAT LOSS TAKES PLACE THROUGH DRAINS. FREQUENT MAINTENANCE OF VALVES.

BLOWERS ARE GETTING ADVANCED / GETTING RETRACTED IMMEDIATELY WITHOUT BLOWING / REMAINING IN ADVANCED CONDITION WITHOUT RETRACTING AND WITHOUT GIVING ANY ANNUNCIATION

BOILER TUBE FAILURE AT RAICHUR TPS

(DURING 1985 - 20.10.2008)
UNITWISE TUBE FAILURES SINCE COMMISSIONING
40 NO. OF FAILURES 30 20 20 10 0 1 No. of Failures 2 3 4 UNIT 5 6 7 8 9 7 8 5 27

AREA WISE BOILER TUBE FAILURES AT RAICHUR TPS.

ECONOMISER
REHEATERS 14% ECONOMISER 21%

CAUSE WISE BOILER TUBE FAILURES AT RAICHUR TPS.

Material 3% Attch. Weld 5% Blockage 12% Ash 45% Shop/Site Weld 17% Sec. Air 8%

WATER WALL SUPER HEATER REHEATERS

WATER WALL 24%

Ash Steam Sec. Air Shop/Site Weld Blockage Attch. Weld

SUPER HEATER 41%

Steam 10%

Material

RECOMMENDATIONS
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CONCLUSION
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PROVISION OF ADDITIONAL THERMOCOUPLE IN THE SENSOR INTRODUCTION OF ADDITIONAL WALL BLOWERS BELOW GOOSE NECK ELEVATION ON LEFT, RIGHT & FRONT WALL FINE TUNING OF BLOWER OPERATION IN BOTTOM ELEVATION

IMPROVES THE PERFORMANCE OF THE WATER WALL IN THE SOOT BLOWER ZONE. THIS LEADS TO OPTIMUM HEAT ABSORPTION IN THE FURNACE IMPROVES CREEP LIFE OF THE SECONDARY SUPER HEATERS AND REHEATERS MORE BENEFICIAL AT FULL LOAD & WHILE USING POOR QUALITY COAL (HIGH SLAGGING NATURE)

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