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PARAMETERS
Unit
STAGE-I
STAGE- II
MW
2X500 MW
4x500 MW
T/HR
336 - DESIGN
370 - WORST
420 - SITE RESTRICTION
44%
44%
Unit Capacity
Coal Consumption /
Unit
Ash
FG flow volume
M 3/SEC
789.00
Gm/Nm3
60
mg/Nm3
56
20.0
Efficiency
99.91
99.939 ( 99.97)
0C
134
140 (125)
336 - DESIGN
370 - WORST
420 - SITE RESTRICTION
PARAMETERS
Unit
Unit Capacity
MW
Coal Consumption /
Unit
FA Evacuation SYSTEM
***
***
T/HR
STAGE-I
STAGE- II
2X500 MW
4x500 MW
336 - DESIGN
336 - DESIGN
370 - WORST
370 - WORST
420 - SITE RESTRICTION 420 - SITE RESTRICTION
Continuous , Vacuum
Continuous , Vacuum Ext
Ext Type
Type
Two Units full collection
with one unit
25 % each unit
transportation
Silo 135 Ton capacity
Buffer Hopper 120 X8 tons
/Silo 750 X2 tons
55 TPH
60 TPH
Next Slide
10
11
During unit startup after a short shutdown , 2-3 passes of ESP are kept in
service to avoid oil soot deposition in all passes .
ESP Fields are charged after sufficient warm up i.e > 110-120 0C inlet /outlet
temp .
SCAPH is kept in service in all cold start-ups & up to sufficiently high load
to ensure better temp at ESP inlet .
FA Evacuation system is kept in service well in advance & mouth chokings
are cleared continuously if any during initial phase .
ESP Auxiliaries are kept in service 24 hrs prior to BLU .
Before planned Unit shutdown all pass rappers are put on continuous mode
for dislodging of ash from collector & emitter electrodes in hot conditions .
All hoppers emptiness ensured before the FA system is taken under
shutdown .
For a short shutdown the Hoppers heaters & shaft /support insulator
heaters are kept ON .
Identified Defects are attended , all fields are charged at charge ratio 1:1
The fields having problem are addressed .
FA system functional /vacuum checks are carried out to bring the system
close to new one .
Next Slide12
STAGE-I
ESP Controllers are up graded recently
by BHEL
VP suction line /ASH LINE modified
(made independent) all 6 VP can be
kept in service
DURING R&M ASH HANDLING
SYSTEM DATA TO BE HOOKED UP
TO PI SYSTEM
BOILER HOPPER DISCONNECTION
FROM ESP SYSTEM UNDER PROGRESS
ESP R&M PLANNED & CONTRACT
AWRADED TO MEET THE STRINGENT
NORMS
STAGE- II
provided
through DCS
ESP OUTLET SIDE GAS SCREEN REMOVED IN
ALL FIELDS OF U 5&6 , UP TO 7TH FIELD IN U
3&4 (balance to be carried out)
VP suction line /ASH LINE modified (made
independent) all 8 VP can be kept in
service
Ash Line made independent , . Additional
water source provided from SW network .
13
CONCLUSION :
The role played by operation engineers in formulating
strategies /practices is very important .
To sustain the overall ESP performance , the operation
support group discusses all the strategies with shift
operation group on General shift days .
After implementation of all best practices as discussed , at
TSTPS the overall performance of ESP & Ash evacuation
system improved indicated by consistency in ESP field
availability .
The PI system has further strengthened in monitoring ,
analyzing and inturn developing the operating personnel to
a larger extent in maintaining
& improving ESP
performance .
14
15
Vacuum Checks .
Shutoff vacuum .
Functional Checks .
Hopper empty vacuum check .
Valve 100 % opening check .
16
Next Slide
18
19
20
250
44.510
39.297
46.099
40.973
218.84
228.75
185.21
147.98
3HNA30CT101.DACA.PV
52.280
3HNA30CT102.DACA.PV
38.108
3HNA30CT103.DACA.PV
54.672
3HNA30CT104.DACA.PV
44.367
4HNA30CT101.DACA.PV
38.025
4HNA30CT102.DACA.PV
36.721
4HNA30CT103.DACA.PV
36.638
4HNA30CT104.DACA.PV
30.518
200
150
100
50
0
2/6/2013 8:28:31 PM
2/7/2013 2:00:00 PM
2.67 days
2/9/2013 12:28:31 PM
21
Next Slide
22
Next Slide
23
Next Slide
24
Improper Evacuation
UNIT#6
600
500
400
300
200
100
0
8/24/2012 9:33:41 AM
ABT.GEN6 Instantaneous MW
Unit#6 TOTAL COAL FLOW
UNIT#6 PASS A VACUUM TX-1
UNIT#6 PASS A VACUUM TX-2
UNIT#6 PASS B VACUUM TX-1
UNIT#6 PASS B VACUUM TX-2
UNIT#6 PASS C VACUUM TX-1
UNIT#6 PASS C VACUUM TX-2
UNIT#6 PASS D VACUUM TX-1
UNIT#6 PASS D VACUUM TX-2
2.00 hours
8/24/2012 11:33:41 AM
\\10.0.120.202\GEN6_MW
356.37
\\10.0.120.202\6HFY00_1P02.SUMMER.PV
420.25
\\10.0.120.202\6PASSA_VAC_TX1
69.336
\\10.0.120.202\6PASSA_VAC_TX2
241.64
\\10.0.120.202\6PASSB_VAC_TX1
212.16
\\10.0.120.202\6PASSB_VAC_TX2
254.28
\\10.0.120.202\6PASSC_VAC_TX1
193.21
\\10.0.120.202\6PASSC_VAC_TX2
293.67
\\10.0.120.202\6PASSD_VAC_TX1
210.25
\\10.0.120.202\6PASSD_VAC_TX2
107.14
Next page
25
2.00 hours
8/29/2012 7:42:54 PM
\\10.0.120.202\GEN4_MW
351.97
\\10.0.120.202\4HFY00_1P02.SUMMER.PV
281.99
\\10.0.120.202\4PASSA_VAC_TX1
191.00
\\10.0.120.202\4PASSA_VAC_TX2
74.000
\\10.0.120.202\4PASSB_VAC_TX1
180.00
\\10.0.120.202\4PASSB_VAC_TX2
277.00
\\10.0.120.202\4PASSC_VAC_TX1
279.00
\\10.0.120.202\4PASSC_VAC_TX2
210.00
\\10.0.120.202\4PASSD_VAC_TX1
0.0000
\\10.0.120.202\4PASSD_VAC_TX2
82.000
26
400
300
200
100
0
11/25/2012 1:03:46.445 AM
ABT.GEN4 Instantaneous MW
Unit#4 TOTAL COAL FLOW
UNIT#4 PASS A VACUUM TX-1
UNIT#4 PASS A VACUUM TX-2
UNIT#4 PASS B VACUUM TX-1
UNIT#4 PASS B VACUUM TX-2
UNIT#4 PASS C VACUUM TX-1
UNIT#4 PASS C VACUUM TX-2
UNIT#4 PASS D VACUUM TX-1
UNIT#4 PASS D VACUUM TX-2
1.33 days
11/26/2012 9:03:46.445 AM
\\10.0.120.202\GEN4_MW
511.03
\\10.0.120.202\4HFY00_1P02.SUMMER.PV
374.15
\\10.0.120.202\4PASSA_VAC_TX1
0.0000
\\10.0.120.202\4PASSA_VAC_TX2
211.00
\\10.0.120.202\4PASSB_VAC_TX1
95.000
\\10.0.120.202\4PASSB_VAC_TX2
222.00
\\10.0.120.202\4PASSC_VAC_TX1
228.00
\\10.0.120.202\4PASSC_VAC_TX2
0.0000
\\10.0.120.202\4PASSD_VAC_TX1
68.000
\\10.0.120.202\4PASSD_VAC_TX2
60.000
\\10.0.120.202\U56_INSTAIR_HDRPR
5.0244
kg/cm2
\\10.0.120.202\U34_INSTAIR_HDRPR
5.6732
kg/cm2
\\10.0.120.202\3LINE1PRESSURE
0.57218
kg/cm2
\\10.0.120.202\3LINE2PRESSURE
0.64831
kg/cm2
0
11/11/2012 12:51:28 AM
Unit#5&6 ESP INST AIR HDR PRESSURE
Unit#3&4 ESP INST AIR HDR PRESSURE
Unit#3 DRY ASH TRANSPORT LINE L1 PRESSURE
Unit#3 DRY ASH TRANSPORT LINE L2 PRESSURE
16.00 hours
11/11/2012 4:51:28 PM
Next Slide
28
\\10.0.120.202\U56_INSTAIR_HDRPR
4.9191
kg/cm2
\\10.0.120.202\U34_INSTAIR_HDRPR
5.0822
kg/cm2
\\10.0.120.202\3LINE1PRESSURE
9.8555E-02
kg/cm2
\\10.0.120.202\3LINE2PRESSURE
1.1154
kg/cm2
Green
Colour IA
pressure
Reduction
Pink
Colour Line
pressure
hunting
0
11/2/2012 4:16:03 PM
Unit#5&6 ESP INST AIR HDR PRESSURE
Unit#3&4 ESP INST AIR HDR PRESSURE
Unit#3 DRY ASH TRANSPORT LINE L1 PRESSURE
Unit#3 DRY ASH TRANSPORT LINE L2 PRESSURE
2.67 days
11/5/2012 8:16:03 AM
Next Slide
29
LINE-2 NO TRANSPORTATION
IA & TR Line Press
4.95
\\10.0.120.202\U56_INSTAIR_HDRPR
4.6036
kg/cm2
\\10.0.120.202\U34_INSTAIR_HDRPR
4.7040
kg/cm2
\\10.0.120.202\3LINE1PRESSURE
0.93655
kg/cm2
\\10.0.120.202\3LINE2PRESSURE
0.47682
kg/cm2
4.5
Line -2
Transportation
stopped
3.5
2.5
1.5
0.5
0
11/22/2012 1:26:28 AM
8.00 hours
11/22/2012 9:26:28 AM
30
2.00 hours
8/29/2012 7:42:54 PM
\\10.0.120.202\GEN4_MW
351.97
\\10.0.120.202\4HFY00_1P02.SUMMER.PV
281.99
\\10.0.120.202\4PASSA_VAC_TX1
191.00
\\10.0.120.202\4PASSA_VAC_TX2
74.000
\\10.0.120.202\4PASSB_VAC_TX1
180.00
\\10.0.120.202\4PASSB_VAC_TX2
277.00
\\10.0.120.202\4PASSC_VAC_TX1
279.00
\\10.0.120.202\4PASSC_VAC_TX2
210.00
\\10.0.120.202\4PASSD_VAC_TX1
0.0000
\\10.0.120.202\4PASSD_VAC_TX2
82.000
Next Slide
31
2.00 hours
8/29/2012 7:42:54 PM
\\10.0.120.202\GEN4_MW
351.97
\\10.0.120.202\4HFY00_1P02.SUMMER.PV
281.99
\\10.0.120.202\4PASSA_VAC_TX1
191.00
\\10.0.120.202\4PASSA_VAC_TX2
74.000
\\10.0.120.202\4PASSB_VAC_TX1
180.00
\\10.0.120.202\4PASSB_VAC_TX2
277.00
\\10.0.120.202\4PASSC_VAC_TX1
279.00
\\10.0.120.202\4PASSC_VAC_TX2
210.00
\\10.0.120.202\4PASSD_VAC_TX1
0.0000
\\10.0.120.202\4PASSD_VAC_TX2
82.000
32
UNIT#3
450
400
350
300
250
200
150
100
50
0
8/25/2012 7:31:50 AM
ABT.GEN3 Instantaneous MW
Unit#3 TOTAL COAL FLOW
UNIT#3 PASS A VACUUM TX-1
UNIT#3 PASS A VACUUM TX-2
UNIT#3 PASS B VACUUM TX-1
UNIT#3 PASS B VACUUM TX-2
UNIT#3 PASS C VACUUM TX-1
UNIT#3 PASS C VACUUM TX-2
UNIT#3 PASS D VACUUM TX-1
UNIT#3 PASS D VACUUM TX-2
8.92 minutes
8/25/2012 7:40:45 AM
\\10.0.120.202\GEN3_MW
332.01
\\10.0.120.202\3HFY00_1P02.SUMMER.PV
375.62
\\10.0.120.202\3PASSA_VAC_TX1
57.098
\\10.0.120.202\3PASSA_VAC_TX2
80.008
\\10.0.120.202\3PASSB_VAC_TX1
100.27
\\10.0.120.202\3PASSB_VAC_TX2
68.107
\\10.0.120.202\3PASSC_VAC_TX1
78.750
\\10.0.120.202\3PASSC_VAC_TX2
60.753
\\10.0.120.202\3PASSD_VAC_TX1
88.000
\\10.0.120.202\3PASSD_VAC_TX2
0.0000
33
\\10.0.120.202\U56_INSTAIR_HDRPR
4.9191
kg/cm2
\\10.0.120.202\U34_INSTAIR_HDRPR
5.0822
kg/cm2
\\10.0.120.202\3LINE1PRESSURE
9.8555E-02
kg/cm2
\\10.0.120.202\3LINE2PRESSURE
1.1154
kg/cm2
IA
Pressure
dropped
IA
Pressure
improved
0
11/2/2012 4:16:03 PM
2.67 days
11/5/2012 8:16:03 AM
34
Next Slide
35
Next Slide
36
Next Slide
37
38
39
40
Next Slide
41
42
43
44
45
Next Slide
46
47
48
49
50
51
52
53
54
Enthalpy Control
55
Logic
Set Value
2/3
2/3
3/8
2/4
2/4
2/4
2/3
470 0 C
4650 C
505 0 C
520 0 C
Closed
56
Stage - I Units
Stage- II Units
Cold
Warm
Hot
Cold
Warm
Hot
Startup Criteria
(Mean Rotor Temp )
< 160 0C
>240 0C
< 430 0C
> 430 0C
> 48 Hrs
0-48 hrs
< 8 Hrs
BLU to Rolling
Parameters
1:20Hrs
80 min
1:15Hrs
75 min
35 min
2:05Hrs
125 min
1:25 Hrs
85 min
35 min
50 min
17 min
07 min
45 min
6-7 min
6-7 min
BLU to synchronisation
2:15 hrs
135 min
1:40 min
100 min
36 min
2:50 Hrs
170 min
1:35 Hrs
95 min
50 min
Best achieved
Parameters BLU to
Synch
2:00
1:48
0:58
3:30
2:10
0:54
2:05 Hrs
125 min
1:20 Hrs
80 Min
30 Min
3:50 Hrs
230 Min
3:20 Hrs
200 Min
30 min
4:20 hrs
3:00 Hrs
1:10 Hrs
6:40 Hrs
5:00 Hrs
300 Min
1:20 Hrs
80 Min
Synchronisation to Full
Load Operation
BLU to Full Load
400 Min
57
drum boiler
Dry Mode Of Operation (> 35%
of load )
58
Next Slide
59
Next Slide
60
Disadvantages
Fire fighting system is additional
No. Of auxiliary drives per mill are
more
High auxiliary power consumption
Prone for explosion
Cumbersome protection &
interlocks ( Purging/steam inerting
Etc)
62
HVDC system
63
CONDITION
If HVDC power flow is more than 1600 MW
and both pose blocked.
If HVDC power flow is more than 1450 & less
than 1600 MW and both pole blocked. OR
HVDC power flow more than 1600 MW and
one pole blocked with remaining pole on
ground return mode.
If HVDC power flow more than 1300 MW and
less than 1450 MW and both pole blocked
.(OR) HVDC power flow more than 1450 MW
and less than 1600 MW and one pole blocked
with remaining pole on ground return mode.
If HVDC power flow is more than 1150 MW
and less than 1300 MW and both pole
blocked. (OR) HVDC power flow is more
than 1300 MW and less than 1450 MW and
one pole blocked with remaining pole on
ground return mode.
If HVDC power flow more than 1000 MW and
less than 1150 MW & both pole blocked. OR)
HVDC power flow more than 1150 MW and
less than 1300 MW and one pole blocked and
remaining pole on ground return mode.
ACTION
Unit # 5 will trip and unit
# 4 & 6 shall be unloaded
by 150 MW each.
Unit # 5 shall trip and
unit # 6 will be unloaded
by 150 MW.
Unit # 4, 5, 6 shall be
unloaded by 150 MW
each.
Unit # 6 shall be
unloaded by 150 MW.
64
dc
xmer
rect
inv
Synch motor
system
85%
84%
83%
82%
80%
5
65
66
67
\\10.0.120.202\4PASSA_BF_DP
I/O Timeout
mmw c
\\10.0.120.202\4PASSB_BF_DP
6.3208
mmw c
\\10.0.120.202\4PASSC_BF_DP
I/O Timeout
mmw c
\\10.0.120.202\4PASSD_BF_DP
249.87
mmw c
\\10.0.120.202\4PASSA_VAC_TX2
\\10.0.120.202\4PASSB_VAC_TX1
\\10.0.120.202\4PASSC_VAC_TX2
\\10.0.120.202\4PASSD_VAC_TX2
300
250
200
150
100
50
0
2/1/2013 12:40:17 PM
1.33 days
2/2/2013 8:40:17 PM
69
Next Slide
70
71
Next Slide
72
73
74
75
U#2
U#3
U#4
U#5
U#6
1ST BOILER
LIGHT UP
02.10.94
22.11.95
11.09.02
05.07.03
18.01.04
27.09.04
SYNCHRONI
SATION
12.02.95
27.03.96
04.01.03
25.10.03
13.05.04
06.02.05
COMMERCI
ALISATION
01.01.97
01.07.97
01.08.03
01.03.04
01.11.04
01.08.05
76