Energy Audit Report by CPRI

No.: CPRI/ECDD/ EA/76/10

Report Submitted to JOJOBERA TPS, TATA POWER JAMSHEDPUR on ENERGY AUDIT AT JOJOBERA TPS UNIT 3, 120 MW (Po No 5300076114 )

Submitted by

DECEMBER 2010 Volume 1 (Boiler, Turbine & Overall Unit) ENERGY CONSERVATION & DEVELOPMENT DIVISION Central Power Research Institute, Prof. Sir C.V. Raman Road, P.B. No 8066, Sadashivanagar, Bangalore – 560 080 E-mail: [email protected] Web-site: http://www.cpri.in

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CPRI Report – TPC-G

Project Summary 01

Title:

02 03

Work Order No. Sponsoring agency:

04

Contact Person (sponsorer):

05

Contact Person (TPC-G):

06

Project implementing agency:

07

Contact Person (project implementing agency):

M. Siddhartha Bhatt, Additional Director (EC & DD) Central Power Research Institute, P.B. No. 8066, Sir C.V.Raman Road, Sadashivanagar Sub-P.O., Bangalore-560080 Tel: 080-23604682, 23604736 FAX: 080-23604682/23601213 E-mail:[email protected]; [email protected]. in

08

Energy audit team : (At site)

M. Siddhartha Bhatt, Additional Director Rajashekar P. Mandi, Engineering Officer N. Rajkumar, Engineering Officer

09

Objectives:

10

Scope of work:

Energy Audit & Performance Test of 1 x 120 MW Unit at Jojobera Power Plant, Jamshedpur- Unit No. 3 PO No. 5300076114 dt. 16.04.2010 TATA POWER, The Tata Power Company Ltd Jamshedpur 831 016 India Tel 91 657 2276875, 6511543 Fax 91 657 2276875, 2278352. Registered Office Bombay House 24 Homi Mody Street Mumbai 400 001 Mr. U. S. Bapat, Vice President Operation (ER) The Tata Power Company Ltd, Jamshedpur 831 016 India Tel 91 657 2276875, 6511543 Fax 91 657 2276875, 2278352. Registered Office Bombay House, 24 Homi Mody Street Mumbai 400 001 Mr. P.K. Bandhu, Manager Operations, The Tata Power Company Limited Jojobera Power Plant, Jamshedpur 831 016 Mob. 09204858087 Central Power Research Institute, P.B. No. 8066, Sir C.V.Raman Road, Sadashivanagar Sub-P.O., Bangalore-560080 Tel:080-23604682, 23604736 FAX: 080-23604682, 23601213

Energy Audit and performance test for TPC-G’s thermal power stations and suggestions for their improvements 1: To assess the achievable station heat rate and improvements 1

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in auxiliary consumption and specific oil consumption.

2: Suggest measures to improve performance parameters (SHR, auxiliary consumption and specific oil consumption) over a period of time. 3: Preparation and submission of report. 11

Report No.:

12

Power station:

EC&DD/EA/76/2010 Jojobera TPS, Tata Power Jamshedpur

13

Date of issue of report:

14

Signature of Energy Audit Team Leader:

15

Signature of the Division Head:

October 25th 2010/ December 21 2010

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EXECUTIVE SUMMARY This study presents the results of the tests on major equipment (boiler, turbine, generator, heat exchangers, condenser, auxiliaries, etc.) of Unit No. 3 at TPC-G, Jojobera. The gross overall efficiency of the Unit 3 TG set is 33.4 % against the design efficiency of 38.2 %. The gross overall TG heat rate (TG HR) is 2577.1 kcal/kWh at the test load of 100 % and representative GCV as compared to the design heat rate of 2253.7 kcal/kWh. The TG heat rate considers the boiler, turbine and generator efficiencies. The deviation in the test TG heat rate from the design value is as follows: Unit 3 Test UHR DHR Dev due to Boiler Dev due to Turbine Dev due to Generator Test efficiency Design efficiency Overall difference Overall difference

2577.07 2253.7 48.1 274.8 0.5 33.4 38.2 4.8 323.4

kcal/kWh kcal/kWh kcal/kWh kcal/kWh kcal/kWh % % % kcal/kWh

The deviation in the test TG heat rate is 323.4 kcal/kWh which can be attributed to 48.1 kcal/kWh due to the boiler, 274.8 due to the turbine and 0.5 kcal/kWh due to the generator. Hence the turbine is the component leading to maximum losses.

Unit 3 Test UHR Test Efficiency HR-Seasonal dev HR-Cycling dev HR-Dev DM HR-Dev-rejects HR-Dev-MS& RH pipe Annual unit HR Annual Efficiency

2577.07 33.4 0 26.00 29.49 8.04 2.7 2643.3 32.5

3

kcal/kWh % kcal/kWh kcal/kWh kcal/kWh kcal/kWh kcal/kWh kcal/kWh %

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The annual unit heat rate (UHR) of the unit considering all factors such as load factor, DM water make up to account for steam for non-motive applications, rejects, energy consumption in hot, warm and cold starts; seasonal variations is 2643.3 kcal/kWh for Unit 3. Since during the test coal of representative GCV is fired, the heat rate also accounts for quality of coal fired. Hence the UHR adequately represents the annual heat consumption in the unit. Immediate measures include operational optimization of parameters such as combustion optimization, mill fineness optimization, coal flow equalization, etc. Fine tuning of parameters, parameter setting and parameter trending, reduction of steam and air leaks, etc., would help in operational optimization. Procurement of combustion optimizer, field instruments for performance monitoring and condition monitoring is required. Cleaning of internals of pressure parts, condenser, feed heaters and coolers is also envisaged as an immediate measure. The steam path audits of turbines are required in view of the turbine internal losses. Medium term measures include smart soot blowing system, VFDs for pumps and fans, heat recovery devices and heaters; energy efficient BFPs, CEPs and CWPs, etc.. Long term measures include IP & LP turbine retrofits & up gradation of DCS. The suggested measures for energy efficiency are given under the summary of recommendations. The recommendations have been classified under immediate, medium and long term measures based on their investment criteria and time period required for implementation. The savings are as follows: Sl. No.

Type of measure

Investment (Rs. in lakhs)

Pay back period (months)+

562

Reduction in test heat rate (kcal/kWh)* 10

01

Immediate measures

02

Medium term measures

440

10

52

03

Long term measures

3600

25

58

48

* As compared to present test annual UHR + Benefits include life extension The total investment is Rs. 0.38 Crores/MW for all the measures.

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SUMMARY OF RECOMMENDATIONS Immediate term measures Sl. No.

01

02

03

04

05

06

07

Recommendations

Retrofitting of VFDs for emergency lift pumps, seal air fans, fire fighting pump. TGA analysis of coals fired into the boiler can help to optimize combustion controls. Continuous monitoring system for CO in the furnace and flue gas ducting Boiler performance optimization using Air/combustion/mill/exit gas/ash optimizer from STORM TECH/ Bacharach/ KENT/ABB/Pegasus/GE Gas proportioning dampers, flue gas, primary and secondary air dampers should be retrofitted with cold hardened material (medium alloy steel or high carbon steel) with in built hard overlay of tungsten carbide. During overhaul all the gas flow guide vanes, direction vanes, diversion baffles are to be inspected. Materials of diversion baffles must use alloy steel with overlay of hard materials like silicon carbide or tungsten carbide. Drain, drip valves and extraction NRVs: replace damaged valve stem by stellited seats, valve plug

Anticipated reduction in heat rate, kcal/kWh*

Time Anticipated investment, frame for Rs. implement (lakhs)# ation, months

Process improvement

30.0

6

Process improvement

30.0

6

Process improvement

22.0

4

Process improvement

50.0

5

Process improvement

-

4

Process improvement

5.0

4

Process improvement

30.0

6

5

Pay back period, months +

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08

09 10

11

12

13

14

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with Inconel 750, plug by Nitronic 60. Temperature sensors with indicators may be installed for energy monitoring of passing of high energy drains. Chemical cleaning of boiler Retrofitting of coal feeder drive motor with VFD for smooth control and invocation of oil guns. Installation of D-Scall meter (scale control device) at the inlet of coolers with severe scaling intensity Additional 6 nos wall soot blowers for the Divisional panel/sonic soot blowers Energy efficiency parameters of the boiler, turbine and generator side like condenser vacuum, MS & RH temperatures and pressures, mill fineness, furnace exit gas temperature (FEGT), O2 in flue gas before and after APH, etc., may be specially recorded in EXCEL sheets for analysis, trending study and sharing with O & M and management for energy control The daily, weekly, monthly and annual averaging of KPI ( UR, SOC, SFC, AP, etc.) as well as machine related parameters must be made on EXCEL available for sharing with the O & M and management. Monthly efficiency tests on boiler, turbine, feed water heater, condensers, may be conducted by procurement of instruments for field tests


Process improvement

-

2

Process improvement Process improvement

20.0

2

10.0

6

Process improvement

30.0

6

Process improvement

36.0

4

Process improvement

-

-

Process improvement

-

-

Process improvement

50.0

-

6

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16 17

18

19

20

21

22

23

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Online performance analysis software Energy management system for online performance index generation Ultimate analysis mapping of coal from different mines and sources at least once a month Replacement of conventional auxiliary motor relays with numerical relays Modification of ID fan blading with aerodynamic profile with hard weld overlay Replacement of selected old brass impellers of pumps with SS 304 impellers. CCTVs for monitoring of leaks & video cameras or capture of maintenance and operations knowledge Repair of boiler lifts

24

turbo vaned flywheeling eco ventilators

25

Review of present overhaul pattern of one COH in 2 years Kaizen for maintenance

26 27

28

Passively

powered

While procuring replacement spares, material up gradation and new technology options must be kept in mind instead of old time tested spares. Vendor development in critical areas: HVOF coating, Martensitic steel materials, Reverse engineering, Computational fluid dynamics (CFD) solutions, Computational electromagnetics (E-MAG)


10

30.0

36

Process improvement

30.0

-

Process improvement

20.0

-

Process improvement

30.0

Process improvement

50.0

4

Process improvement

50.0

4

Process improvement

15.0

4


20.0

4

4.0

4

Process improvement

-

-


-

-

-

-

-

-

Process improvement

7

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29

30

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Erosion and solutions, corrosion resistant materials, software resources, etc. Conduct of steam path audits before and after a COH Ready rekoner books on O & M Development of maintenance standards


Process improvement

-

Process improvement 31 Process improvement 10 562 *As compared to present test annual UHR + Benefits of life extension also. # Routine maintenance related costs are not indicated as they are maintenance. $ Cost proportioned to unit

8

-

-

a part of

48

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SUMMARY OF RECOMMENDATIONS Medium term measures Sl. No .

01 02 03

04

Recommendations

Energy efficient BFP cartridges Energy efficient CEPs and CWPs Improvements in the mills: Strain gauge under the bearing supports for on-line weight of the mill; dynamic classifier; noise level monitoring; steam supply system for quenching; coal mill performance evaluation one in a month using isokinetic sampler.

Smart system.

soot

Anticipated reduction in heat rate, kcal/kWh* Process improvement Process improvement Process improvement

blower

Process improvement Total 10 *As compared to present test annual UHR + Benefits of life extension also.

9

Time Anticipated investment, frame for Rs. (lakhs) implement ation, months 100 12 200

8

40

6

100

12

440

-


52

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SUMMARY OF RECOMMENDATIONS

Long term measures Sl. No.

Recommendations

Anticipated reduction in heat rate, kcal/kWh*

01

IPT retrofit excluding 10 casing- 3 d blading 02 LPT retrofit- 3 d blading 10 03 Upgrading of DCS, data Process storage and data improvement highway including FSSS, field instruments, alarms and MIS Total 25 *As compared to present test annual UHR + Benefits of life extension also.

10

Time Anticipated investment, frame for Rs. (lakhs) implement ation, months 1500 12 1500 600

12 12

3600

-


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CONTENT (Volume 1) 1.0 INTRODUCTION Energy audit 1.1 1.2 Scope of the energy audit 1.3 Period of the experimental work 1.4 Design rating of major equipment 1.5 Age and service period 1.6 Current level of performance measured 2.0 BOILERS AND ASSOCIATED EQUIPMENT 2.1 Coal analysis and boiler efficiency tests 2.2 Boiler – Temperature & pressure survey 2.3 Boiler and Associated Systems-Component wise analysis of Performance; equipment assessment for damage, restriction, de-rating and loss 3.0 TURBINE GENERATOR 3.1 Turbine Efficiency Tests 3.2 Turbine – Temperature and pressure survey 3.3 Turbine & associated systems–Component wise analysis of performance; equipment assessment for damage, restriction, de-rating and loss 4.0 CONDENSER & COOLING TOWER-ANALYSIS OF PERFORMANCE

Page Nos. 1

4

13

17

5.0 STEAM AUDIT AND STEAM UTILIZATION SYSTEM- ANALYSIS OF PERFORMANCE; EQUIPMENT ASSESSMENT FOR DAMAGE, RESTRICTION, DE-RATING AND LOSS 6.0 CAPACITY ADEQUACY ANALYSIS OF AUXILIARY EQUIPMENTS

18

7.0 FORCED OUTAGE & START UP ANALYSIS

19

8.0 OPERATION & MAINTENANCE PRACTICES

20

8.1

Operational practices

8.2

Maintenance practices 8.2.1

Day to day maintenance

8.2.2

Annual and capital overhauls

9.0 OVERALL SYSTEM

28

9.1

Test heat rate at 100 % load

9.2

Heat consumption due to steam lost to non-motive applications represented by DM make up Heat consumption due to cycling/abnormal operationstart up and shut down

9.3

19

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9.4 9.5 9.6 9.7 9.8

9.9


Additional heat consumption due to year round variations in environmental and fuel parameters from test values Accounting of mill rejects Accounting of heat loss in piping in-between boiler and turbine Overall annual unit heat rate assessment Categorization of remedies for improvement of the parameters 9.8.1 Immediate heat rate improvement (over a 12 month period) 9.8.2 Medium term heat rate improvement (over 2-3 year period) 9.8.3 Long term heat rate improvement (over 5 year period and further) Degradation of unit heat rates 9.9.1

9.10

Degradation of the commercial unit heat rate (UHR) as computed by the station Trajectories and projections

10.0 CONCLUSIONS

37

Annexure – 1: Figures Annexure – 2: Tables Annexure – 3: Procedures Annexure – 4: Documents

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Abbreviations/Nomenclature ABT AC AFB AHP AOH AP APH ARW AVF BDV BFP BTL C C&I CA CC CEP CHP COH CT CW DA DC DCS DIM DM DT ECO ERP ESP ESV FDF FO F/O GCR GCV H HCV HGI HP HPT HT HV HVOF IBR

Availability based tariff Alternating current As fired basis Ash handling plant Annual overhaul Auxiliary power ( MW or MWh for a time period) Air pre-heater Aerial ropeway Availability factor (%) Breakdown voltage Boiler feed pump Boiler tube leakage Capacity of the unit or station (design or operating, MW) Control and instrumentation Chemical Analysis Carrying capacity Condensate extraction pump Coal handling plant Capital overhaul Current transformers Cooling water Deposit analysis Direct current Distributed control system Dimensional measurement De-mineralized Destructive test Economizer Enterprise resource package Electrostatic precipitator Emergency stop valve Forced draft fan Furnace oil Forced outage Generation control room Gross calorific value (kcal/kg or MJ/kg) Time period block (hours) Higher calorific or heating value (kcal/kg or MJ/kg)=GCV Hardgrove Index of coal High pressure High pressure turbine High tension ( 6.6 kV and above) High voltage High velocity oxyfuel flame Indian Boiler Regulation 14

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ID IDF IED IP IPT KPI LDO LE LP LPT LT Max. MCCB MCR Min. MIS MOD MS NDT NF NRV O&M OD OEM p P PADO PAF PC PLF PT R&M RH RLA RR SAIDI SAIFI SEC SFC SH SHR SOC SPM SR SSC ST T TDBFP

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Inside diameter Induced draft fan Intelligent electronic device Intermediate pressure Intermediate pressure turbine Key performance indicators Light diesel oil Life extension Low pressure Low pressure turbine Low tension (415 V) Maximum Moulded case circuit breaker Maximum continuous rating of the unit Minimum Management information system Merit order dispatch Main steam Non-destructive test Natural frequency Non return valve Operation and maintenance Outer diameter Original equipment manufacturer Pressure (kPa or MPa) Power output (MW) Performance analysis, diagnostics and optimization Primary air fan Personal computer Plant load factor (%) Potential transformers Renovation and modernization Reheat Remaining life assessment Railway receipt System average interruption duration index System average interruption frequency index Specific energy consumption (kWh/t) Specific coal consumption (kg/kWh = t/MWh) Superheater Station heat rate ((kcal/kWh) Secondary specific fuel oil consumption (ml/kWh) Suspended particulate matter Steaming rate (t of steam /t of coal) Specific steam consumption (kcal/kWh=t/MWh) Station transformer Temperature (0C) Turbine driven boiler feed pump 15

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UAT UHR v VI WTP Greek letters α δ ∆ η Subscripts a av A B BA e f G in m max min O ref S T Units of power inputs/outputs MW MWm MWt


Unit auxiliary transformer Unit heat rate (kcal/kWh) Velocity (m/s) Visual inspection Water treatment plant Excess air factor (dimensionless: 1.0-3.0) Leakage rate (dimensionless: 0 to 1.0), deviation in heat rate Difference Efficiency (dimensionless or %) Ambient Average Auxiliary Boiler Bottom ash Electric Flame Generator Input Mechanical Maximum Minimum Gross overall Reference Steam Turbine

Electrical power Mechanical shaft power output rate Rate of energy change in water or steam (heat input/output rate)

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1.0 INTRODUCTION The objective of the study is the independent assessment of achievable performance parameters for Tata Power’s thermal power station (Unit No. 3) and suggestions for its improvements. The overall study report is in two volumes: Volume 1 covers Boilers, turbines, heat exchangers, etc., and overall systems Volume 2 covers Unit & station auxiliaries and generator. In this Volume the fuel systems and overall systems are discussed. This section introduces the power plant and defines the scope of work. The Tata Power Jojobera had established coal fired thermal power station of 67.5 MW (Unit 1) and 4 units of 120 MW. The present station capacity is 547.5 MW. Unit 3 is presently under study. Unit 3 of 120 MW has multi-fuel firing capability and consists of BHEL corner fired boilers with BHEL turbines supplied by BHEL. The energy audit study is carried out for the Unit 3.

1.1 Energy audit An energy audit is basically a technique used to establish the patterns of energy use, identifying how and where losses are occurring and suggest measures for enhancing energy efficiency with the economic implications.

1.2 Scope of the energy audit An energy audit is carried out at TPC-G TPS, for energy accounting of coal, fuel oil, power and auxiliary power leading to suggestions on measures for energy efficiency improvement. The scope of the Energy Audit presented is as follows: 1: To assess through tests of individual equipment, the achievable unit heat rate, loadability, capacity adequacy and improvements in auxiliary consumption and specific oil consumption 2: To quantify the performance of various sub-systems through an energy balance and energy efficiency of boiler, turbine, major auxiliaries, heat exchangers, etc.

3: Suggest measures to improve performance parameters (UHR, auxiliary consumption and specific oil consumption) over a period of time 4: Preparation and submission of report

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The energy audit covers the major equipment, auxiliaries and includes fact finding, assessment of equipment and loss levels, performance measurement, analysis, suggestions for improvement of performance parameters over a period of time, maintenance improvements, operational improvements & strategic planning. The detailed scope of work is as per the PO No. 5300076114 dt 16.04.2010.

1.3 Period of the experimental work The energy audit field work was carried out as per scope during August 2010.

1.4 Design rating of major equipment The details of the boiler & its auxiliaries and turbine & its auxiliaries are given in Table 1 to 6 (see Annex 2). Sl. No. 01 02 03 04 05

Particulars Fuel type Unit capacity Steam to fuel ratio SSC DHR

Unit No. MW t/t t/MWh Kcal/kWh

3 Coal 120 4.31 2.960 2253.47

1.5 Age and service period The capacity and age of the Unit is given in Table 7 (Annex 2).

1.6 Current level of performance measured by TPC-G The unit performance indices are as follows: Plant load factor Plant availability factor Gross overall efficiency Unit heat rate Specific fuel consumption Specific fuel oil consumption Auxiliary energy consumption Figures 1-6 (see Annex 1) give the monthly variation of the KPI for Unit 3 for the past 3 years.

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Figures 7-11 (Annex 1) give the sensitivity of the KPI to PLF. It can be seen that there is reasonable correlation with the data (R2=around 0.6). However, there is opportunity to improve the quality of the data acquisition and measurement.

1.6.1 Routine measurements of critical parameters and its documentation Routine measurement of critical parameters is being done at present through the DCS. The majority of the parameters except those which require manual measurements like mill fineness, unburnts in ash, etc., are available on the DCS but special recording of the critical parameters on daily average, weekly average, monthly average , yearly average or trends of these is not available for sharing with the O & M and management of the TPS for energy control. Recommendation: Parameters which have a bearing on energy efficiency of the boiler, turbine and generator side like condenser vacuum, MS & RH temperatures and pressures, mill fineness, furnace exit gas temperature (FEGT), O2 in flue gas before and after APH, etc., may be specially recorded in EXCEL sheets for analysis, trending study and sharing with O & M and management for energy control. Recommendation: A water monitoring software package is to be in place. The package must have capability to draw inputs from the various field instruments (which will act like IEDs) and make an on-line continuous data base grid of the information for generation various types of information such as consumption per unit per shift, consumption during cycling operations, operator wise consumption, etc., to enable the performance optimization group to take control action on the areas of wastage and excessive consumption. Consumption and production should be separately monitored. At present only gross data is being recorded and is not useful for energy control.

1.6.2 Trends and comparisons At preset, the bare machine variables and KPI data are available but the majority of data is not available for energy control. The important KPI are presently being analyzed on a daily, weekly and monthly basis. Recommendation: The daily, weekly, monthly and annual averaging of KPI (UHR, SOC, SFC, AP,etc.) as well as machine related parameters must be made on EXCEL available for sharing with the O & M and management. The same must be made available on EXCEL sheet for analysis and in graphical form for trend analysis.

1.6.3 Efficiency & performance test results At present efficiency and performance tests are not being done in the units as a part of the in-house energy efficiency program. This would give valuable data such as

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effects of moisture and coal quality on the boiler efficiency, etc. Also efficiency tests on boilers for different sources of coals are not presently available. Also efficiency tests on boilers for different sources of coals are not available. Performance tests on turbines, condenses, feed water heaters, generator, etc., and evaluation of AP are not being practiced. Valuable information can be generated from these. Recommendation: Monthly efficiency tests on boiler, turbine, feed water heater, condensers, may be conducted for 2 hours duration at the maximum load and the data may be archived for further analysis and future archiving. This will be useful for observing the seasonal trends as well as sensitivity to GCV and moisture content.

1.6.4 Detailed analysis Detailed analysis of root causes for failures is being done to the extent required or replacement and further operation. Detailed analysis of performance is done at a macro level covering the KPI. At a micro level or parameter level, detailed root cause analysis is not being done at present. Detailed analysis is being done for the following: • Events •

Failures

•

Performance parameter variations

2. BOILERS AND ASSOCIATED EQUIPMENT The boiler (BHEL) is of the sub-critical cycle, π type, two pass, tangentially fired, tilting injection, balanced draught, natural circulation, radiant, reheat, wet bottom with direct fired pulverized coal with XRP 783 Raymond bowl mills. The furnace is of the membrane type wall construction. The outer side of the combustion chamber, pent house and all the equipment are insulated with lightly bonded wool mattresses. In the top deck, deck below drum, rear arch deck and at buck stay portions pour able insulation is applied.

2.1 Coal analysis and boiler efficiency tests Coal and ash samples were collected during the tests. The results of the coal analysis from CPRI laboratories are given in Table 8 (see Annex 2). The results of the unburnts analysis of bottom ash and fly are given in Table 9 (see Annex 2). The results of the flue gas analysis are given in Table 10 (see Annex 2). CPRI observations: The GCV of coal during the test is the representative coal used by the TPS. The boiler has been tested in this coal condition.

Boiler efficiency test results

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The results of the boiler efficiency are given in Table 11 (see Annex 2). The measured boiler skin temperature is given in Table 12 (see Annex 2). The performance of the tubular air pre-heaters are given in Table 13 (see Annex 2). The observations and recommendations regarding the boiler performance are as follows: i.

Boiler efficiency of the unit at a GCV of 4623 kcal/kg is 85.31 % .

ii.

O2 in flue gas is in the range of after APH.

iii.

The CO content measured in flue gas was 274-442 ppm. The measured CO is on the higher side indicating incomplete combustion.

iv.

Unburnt losses in bottom ash and fly ash are high. Unburnts in bottom ash is 5.6 % and 1.9 % in fly ash.

v.

The wet flue gas loss is 4.81 % against the design value of 6.14 %.

vi.

The maximum skin temperature is as high as 185 ºC which is high at certain zones. Loss due to convection and radiation loss is 1.56 % compared to design value of 1.21 %. The average overall surface temperature measured is 72.7 ºC. The surface temperature should be 10 ºC above the ambient temperature. Recommendation: The flexible insulation of the boiler needs to be replaced at hot spots. Partial need based insulation replacement is recommended.

3.72-4.96 % before APH and 5.15-8.98 %

The site observations along with recommendations are as follows: Recommendation: Some measures for the boiler involving operational optimization through balanced flows are as follows: Sl. No. 01

02 03 04

Parameter Coal flow balance between pipes in an elevation

Optimal values To within ±10 % of the mean value. Earlier practice was use of static devices such as Ni-hard flow equalization nozzles. Present practice is to use a variable air jet at a pressure of 110-120 kPa and at an angle of 45° across the pulverized coal flow pipe passage to introduce dynamic flow resistance which can be controlled for flow equalization. primary air Primary air to different mills within ±5% of the mean. Coal Fineness 70 % of the mass passing 75 µm size with a deviation of ±5% of the mean fineness. Minimum coal 0.8-1 m/s line velocity 5

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05


Mill outlet temperature Secondary Air balanced at wind boxes Furnace Oxygen

> 85 °C while the operating values are in the range 88-96 °C. To within ± 5 % of the mean value. SADC (secondary air damper control) must be on auto for the unit. 2.5 % to 3.0 % and with less than 5 % leakage between Furnace Exit and Economizer and less than 10 % leakage at APH. O2 control in the furnace is in place. The operating furnace O2 is 3.7-4.9 %. Oxygen after < 4.2 % as per design and the operating APH O2 is 5.6 % Bottom ash < 4 % as per design and the operating value is 0.1 to 0.2 %. Fly ash < 1 % as per design and the operating value is 1.9 % Carbon < 100 ppm as per design and the operating monoxide value is 272 ppm to 442 ppm.

06

07

08 09 10 11

2.2 Boiler – Temperature & pressure survey Table 14 gives the flue gas temperature survey and Table 15 gives the flue gas pressure survey. From the above named Table 14 (see Annex 2), it is seen that the operating temperature profile is deviating from the design value. The operating flue gas temperature before APH is 384 °C against the design value of 298 °C and after the APH it is 154 °C against the design value of 139.0 °C .

2.3 Boiler and associated systems -component wise analysis of performance; equipment assessment for damage, restriction, de-rating and loss Heating surfaces: Water wall, economizer, super heaters, reheater, air pre-heaters, etc. Table 16 (Annex 2) gives the specific heating surfaces. The furnace volume is undersized by 16 % for the present coal while the EPRS is OK. The SH is OK and the RH is also OK. The ECO and APH are is also OK. The performance of the economizer is given in Table 17 and the performance of the water walls is given in Table 18. The observations regarding the heating surfaces are as follows:

i.

It is seen that the furnace gas tightness is OK.

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ii.

The performance of ECO is OK. The design flue gas velocity at ECO is expected to be in the range of 8.5 to 9.5 m/s. Due to ash accumulation and fouling, the velocities increase to nearly 12 m/s or more resulting in enhanced erosion rates. To reduce erosion, close monitoring of flue gas velocity is needed. Also suitably designed cassette baffles of ceramic/steel with hard overlay may be introduced for reduction of erosion. Recommendation: During a shut down, before cleaning and clearing of the debris a clean air velocity test may be conducted to confirm the velocity profile in the ECO in the running condition. After clearing of all debris and fouling, the same may be repeated and it may be ensured that the velocities are within 8.5 to 9.5 m/s. Gas velocity at the gap between the ECO coil bundle and the boiler furnace wall must be minimized by frequent cleaning of debris. Ceramic/hard coated steel cassette baffles may be introduced for reduction of erosion. Material up gradation must also be considered. Partial replacement of ECO coils is recommended.

iii.

The APHs are tubular shell and tube type with two secondary APH and one primary APH.

iv.

Air leakage occurs in the APH because of the pressure difference between the high pressure air and the low pressure exiting flue gases. The air leaks into the flue gas stream and exits to the stack resulting in energy loss of hot air, pressure loss of hot air and additional load on the ID fan. The flue gas temperature at the APH outlet increases on account of this besides resulting in reduced boiler efficiency and increased auxiliary power to the fans. The LHS side leakage of Secondary APH is 9.3 % and for RHS it is 21.3 % which is on the high side, against the design value of 7.7 %. The leakage of primary APH is 19.8 % compared to the design value of 16.3 %. Air leakage in APH is from two sources: Punctured tubes at the centre of the nest Punctured tubes at the sides (edge of the APH) and the boiler.

v.

The erosive nature of Indian coals giving rise to wear and erosion of high severity is also a cause for the tube punctures. Besides, the cold end corrosion of heat exchanger materials leads to tubes being eaten away due to the combined effects of wear and corrosion. APH leaks reduce boiler efficiency by as much as 1 %. Recommendation: The measures for the APH are as follows: Clean air velocity tests to understand the air velocities in the gap between the APH and boiler water wall surfaces. Installation of ceramic cassette baffles for alteration of the flue gas flow to avoid direct impingement on the tubes and reduction of the flow velocities.

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Application of sacrificial weld overlays of hard materials like tungsten carbide over tube surfaces prone to high velocity flue gas flow.

Furnace combustion, thermal sealing and control: combustion equipment, Ducts, heat leakage, insulation, refractory, pent house sealing & Furnace bottom sealing, etc.

The observations regarding the furnace are as follows: i.

One of the objectives of achieving good combustion and efficiency is making heat flux distribution even with symmetric fireball. It must be noted that uneven heat flux distribution gives rise to reduced heat transfer and tube failures.

ii.

Particle size distribution and percentage of volatiles in coal affects combustion efficiency and combustion characteristics. Combustion reactivity of coal determined by percentage volatiles. De-volatilization of coal 60-100 ms while char combustion 1-2 s. Recommendation: TGA analysis of coals fired into the boiler can help to optimize combustion controls.

iii.

Long term erosion is an effect for consideration in this boiler. main factors affecting erosion in the boiler are: Flue gas velocity Composition and percentage of mineral content Changes in the flue gas direction Arrangement of pressure parts Flue gas temperatures

iv.

The boiler efficiency is affected by some of the design parameters like: Boiler volume Gas temperature entering the first pendent at the goose neck level. Furnace exit gas temperature Location and number of soot blowers Burner input, clearance, mouth design and tilting mechanism Heat input available at the primary combustion zone (burner elevations). In all the above design parameters, the boiler is satisfactory and appropriate except for water wall under sizing for high ash coals.

v.

Erosion could be combated by measures such as: Reduction of gas velocity in second pass In-line arrangement for all 2nd pass heat transfer surfaces 8

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Refractory/steel with hard facing liner shielding of faces prone to erosion Cassette baffles of 2nd pass heat exchangers vi.

Flue gas temperature at boiler outlet (APH outlet) is dependent on: Furnace heat absorption rate and slagging cum fouling behavior APH leakage (from air side to the flue gas side) Excess air factor of the flue gas which is dependent on gas tightness and air tightness in the boiler APH effectiveness Burner tilting mechanism and their response Ambient air conditions Fuel quality

vii.

The high flue gas temperature at the boiler out can be controlled by: Furnace cleaning through smart soot blower system Water washing of APH during an outage Optimizing of primary and secondary A/F ratios

viii.

FEGT (furnace exit gas temperature) measurement and High quality visible flame safe scanner system are already available and the performance is good.

ix.

The present soot blowing system is time based and open looped. This can be converted into a closed loop system by installation of smart soot blowing system or intelligent soot blowing system the heart of which is the furnace cleanliness probe. This is nothing but a heat flux sensor which gives a measure of the fouling through a deposition probe which gives the degree of fouling or slagging and heat flux through a chordal thermocouple which measures the furnace inner skin temperature. Such heat flux sensors are incorporated in boiler water wall sections. Based on the output of the sensors the soot blowing interval is decided automatically through a logic based system incorporated into the plant DCS. If the cleanliness value falls below a certain value it signals for a soot blowing cycle. The benefits of the smart soot blowing system are an increased level of furnace heat absorption (by around 10 %), a lower exit flue gas temperature (around 10 ºC) and reduction in soot blowing frequency and auxiliary steam (around 5 %) in the long term. Recommendation: To maintain a high level of cleanliness in the furnace, the present soot blower system needs to be converted into smart soot blower system.

x.

Oxygen measurement: The measurement process needs to be strengthened by more probes forming a grid. The O2 measurement may also be introduced after the APH.

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xi.


Recommendation: On-line CO measurement is presently not in service. Continuous monitoring of CO before APH may be introduced for combustion optimization using multi-grid measurement with 4 sensors.

Furnace and piping: Flow control and sealing: Ducts, dampers, valves, wind box, etc.; supports and fixtures The observations regarding the furnace flow systems are as follows: i.

Recommendation: Periodic cleaning of ash and debris collection in fan duct during any available outage.

ii.

Recommendation: During overhaul all the gas flow guide vanes, direction vanes, diversion baffles for flow diversions are to be inspected and need to be replaced. Materials of diversion baffles must be alloy steel with overlay of hard materials like silicon carbide or tungsten carbide.

iii.

Valves: Recommendation: In the case of badly damaged internals, it is recommended to replace valves by new valves with stem by stellited seats, valve plug with Inconel 750 (ASTM A45; Rockwell hardness 35), plug by Nitronic 60 (ASTM A479 with hard facing).

iv.

Downstream side of high energy drains: Recommendation: Temperature sensors with indicators may be installed for energy monitoring of passing.

Coal/oil circuit: pipes, feeders, burners etc. The observations regarding the coal and oil circuits are as follows: i.

Recommendation: Replacement of VFDs.

drives of coal feeders with

ii.

Recommendation: Retrofitting of fuel oil pump motor with VFD for smooth control and invocation of oil guns.

Boiler auxiliaries: ID Fan, FD fans, PA fans, mills, etc. The observations regarding the boiler auxiliaries are as follows: The performance of the ID fan is affected by: Increased clearance between fan impeller blades & casing Deterioration in blade profile, surface finish of blades Increased air heater pressure drop and choking 10

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Excess air flow through the system Leakage seal passing Flue gas duct choking causing reduced cross section area ID fan capacity drop occurs due to wear and erosion of internals and results in reduced efficiency as well. The damaged components are impeller, casing, scroll and inlet damper. The options for improved performance are: a. Brazed Tungsten Carbide cladding b. Chrome Carbide weld overlay c. Hard alloy steel i.

The ID fans generally have high erosive deterioration tendencies. Recommendation: Modification of ID fan impeller blades & casing through material upgradation such as either upgraded material or conventional material with chrome carbide weld overlay to fill the damaged portions, so that its performance will not deteriorate over a period 5 to 6 years.

ii.

The velocities of coal and flue gas also get altered due to high flow rates which results in increased wear and erosion by 3 to 4 time (as erosion rate is directly proportional to ~ v3). Change over to superior grade wear resistant materials (medium alloy steels with hard weld overlays) is imminent. Control of heat and air leaks is also equally important in system performance restoration.

iii.

Energy efficient variable frequency drives: The traditional speed changing devices like gear boxes, belt drives, chain drives have low efficiencies of the order of 85-92 % whereas the present voltage sensing technology gives efficiencies as high as 94-96 % Recommendation: Replacement of the following drives with VFDs: Emergency lift pumps, oil handling pumps, seal air fans, hydrogen cooler booster pump, fire fighting pump & compressed air system.

iv.

Energy Efficiency pumps: Replacement of pumps of brass impellers with SS impellers can give an improvement in 8-10 % points improvement in the composite pump-motor efficiency. Recommendation: Replacement of selected old brass impellers of pumps with SS 304 impellers.

v.

Mill controls: Recommendation: Replacement of analog controls of mills by digital controls.

vi.

Mill safety: Recommendation: Replacement of present mill vents with expansion vents to handle explosions due to combustion of volatiles in the system.

vii.

The recommended measures for the mills are as follows: Sl. No.

System/parameter Optimization

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01

02 03

04

05


Classifier setting

Frequent classifier settings and cleaning to ensure the fineness and ensuring that the coal air mixture temperature and velocity are as per design. Alternatively, backward curved exhausters with wear resistant, dust deflectors at the mill outlet can improve the mill performance as well as increase its wear resistance. Spring load and roll Constant adjustment of spring load setting clearance and roll clearance setting Classifiers Simple classifiers result in collar formation in rolls which acts as a funnel in passing heavier particles back to the mill. Extension of centre feed pipe can avoid this problem. Dynamic classifier where the segregation of coal particles is done with the help of active powered fan. Mill internal Maintain mill internals. Replacement of mill clearances internals on performance basis rather than on hours basis is already in place. Condition based maintenance for the mills in practice at the TPS. Rotating vane Rotating vane assembly in place of assembly stationary vane assembly.

Recommendations: For improving the mills, in the medium term, some additional measures are: Strain gauge under the bearing supports of the mill for on-line weight of the mill to indicate the status of the loading of the mill. This practice is used in International practices to know the level of loading rather than other indirect parameters such as mill current and mill differential pressure. Retrofitting of mill with dynamic classifier Monitoring of noise level inside the mill to assess the loading level especially when the service air lines are choked. Sonic sound detection may also be used for mills for mill condition monitoring. Modification of explosion vents to handle mill related explosions. Steam supply system for quenching of mill fires. Coal mill performance evaluation one in a month using isokinetic

sampler.

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The condition assessment of steam generator components is given in Table 19. The leakages in boilers are given in Table 20.

3.TURBINE- GENERATOR The steam turbine is of the KWU (Siemens) design, three cylinder, throttle governing, multi stage, reaction, tandem compound, single flow HP, double flow IP and double flow LP with six uncontrolled extractions.

3.1 Turbine efficiency tests Turbine efficiency test results The results of the efficiency tests and heat rate of the turbines are presented in Table 21. The loss of work in the turbines is given in Table 22. The observations regarding the turbine performance are as follows: i.

The turbine efficiency is 39.67 % and specific steam consumption is 3.25 t/MWh against the design value of 44.46 % and 2.96 t/MWh.

ii.

The turbine internal losses as indicated in Table 22 above are around 6.76 MWm. The total loss of work in the turbine is 7.12 MWm. These losses are due to the turbine internals not converting the thermal energy in the steam to mechanical work (turbine irreversibility) as per the design.

iii.

Internal leaks in the turbine circuit result in loss of auxiliary power and loss of work in steam. BFP recirculation valve passing of 10 t/h could lead to loss of 75 kW. Similarly, SH, RH spray valves, HP vent valves passing lead to losses.

iv.

Sliding pressure operation: The provision is presently in use and may be continued.

v.

ATRS: Recommendation: Provision for rolling of the turbine through ATRS may be implemented. Turbine rolling must only be through ATRS.

3.2. Turbine – Temperature and pressure survey The steam temperature survey is given in Table 23. The steam pressure survey is given in Table 24. The MS entrance pressure is lower by 0.8 MPa against the design of 12.70 MPa. The MS temperature is 4 ˚C less than design. The CRH temperature is higher by 10 °C. The HRH is on par with the design.

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3.3 Turbine & associated systems–Component wise analysis of performance; equipment assessment for damage, restriction, de-rating and loss Steam flow path system The observations regarding the steam flow path are as follows: i.

The rated MS and RH temperatures are normal.

ii.

The HRH temperatures are almost on par with the design. The HRH and CRH pressures are lower the design by 0.8 MPa. The CRH temperature is higher by 10 °C.

iii.

The LPT exit temperature is 55.7 °C as compared to the design value of 46.4 °C. The condenser vacuum is 12.0 kPa against the design value of 10.6 kPa. The cold end is optimized. However, the TTD across the condenser is 2.4 °C against the design value of 3.4 °C.

iv.

Steam path audit: The deterioration in the operating heat rate is mainly because of the steam turbine internal losses. The energy losses are in the blading and steam paths of the turbine. Recommendation: During the next capital overhaul steam path audit may be conducted to quantify deterioration in heat rate at every stage of the turbine and for initiating corrective action.

LPT and IPT retrofits: The earlier concept of R & M was generally thought of as replacing highly stressed components and deformed members to increase the plant availability and continue plant operation beyond the service life. In the light of the above analysis, recommendations are given which are of ‘replace’ philosophy. The investment for this activity has its own justification that investment is relatively low and keeps the system running in the present healthy and safe condition till a new technology is infused enhancing the efficiency as well as health and life. The present day concept of R & M is to make full use of state-of-the-art technology available to meet the long term objectives set for the exercise, viz., improvement in availability, continuous operation and efficiency of the plant and to extend the life of the plant by 20 years. To meet these objectives of the R & M it is necessary to harness the up-to-date technology of the turbines rather than to stop at simple replacement of damaged components or conventional re-blading. Considering the large improvement potential to the gross overall efficiency it is economically beneficial to go in for the new design high efficiency turbines rather than simple re-blading or replacement of stressed/damaged components of the old turbine. In this light the recommendation for R & M and life extension of the turbine is as given below.

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Recommendation for turbines: Considering the above facts the present steam turbine IP & LP cylinders may be replaced with standard 3-d stage specific bladed turbines with 3-d modeled exhaust diffuser, improved tip to tip sealing, modified exhaust hood spray and a turbine supervisory system. The standard added features of the retrofitted turbines are as follows: •

Modification in location of exhaust hood spray such that the excessive ventilation heating (during low load operation and load rejection) is not experienced in the LPT on the generator side.

•

Endoscopes for examination of blading without opening of the casing.

•

The expected life of the turbine is 15 years or 100,000 hours. The time for replacement of the turbine is around 3 months. The efficiency is expected to result in reduction in heat rate by around 10 kcal/kWh for IPT and 10 kcal/kWh for the LPT for identical inlet conditions and exhaust condition.

Feed Heaters, turbine side lines, valves, pumps and heat exchangers The performance of the feed water is indicated in Table 25 (see Annex 2). The observations regarding the feed water heaters are as follows:

i.

The TTD of HPH-6 is 13.6 ºC against the design value of 0.9 ºC. Recommendation: Cleaning of tube nest of HPH 6 to improve the performance.

ii.

The TTD of HPH-5 is 11.7 ºC against the design value of 1.4 ºC. Higher TTD indicates poor heat transfer. Recommendation: Cleaning of tube nest of HPH 6 to improve the performance.

iii.

The TTD across LP heater 3 is -3.0 ºC against design value of 3.7 ºC. This gives good performance of the heater but indicates that the energy conversion in the steam turbine LP module is not as per the design.

iv.

The TTD across LP heater 2 is -6.8 ºC against the design value of 12.2 ºC. This indicates that the extraction steam is entering at a higher degree of superheat than the design value. This again points out the poor performance of the turbine.

The reasons for the sub-optimal performance of HP feed water heaters are: Air blanketing and improper venting in HP heaters due to isolation of vent air line Air blanketing and improper venting in LP heaters at sub-atmospheric pressure

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Steam side contamination due to presence of oxygen above 100 ppb resulting in exfoliation of tube material in the formation of scale layer. The recommendations for the feed water heaters are: Regular venting of air lines in HPH. HPH & LPH feed water outlet temperatures to be maintained. Reduction in permissible oxygen in steam to below 100 ppb. i.

Valves: Valves bodies and seat damage may be ascertained during an internal inspection for suspected of passing. Normally, the seats/discs of new valves are hard faced with Cobalt Carbide or Nickel Molly alloy. The stems are of 18/10 Class 300 - SS or ASTM A 453 GR 660. Recommendation: In the case of badly damaged internals, it is recommended to replace valve stem by stellited seats, valve plug with Inconel 750 (ASTM A45; Rockwell hardness 35), plug by Nitronic 60 (ASTM A479 with hard facing). The following valves are recommended for inspection: PRDS pressure control valves, HPT control valves, BFP recirculation valves, drain valves & auxiliary steam valves.

ii.

Extraction & NRVs: Recommendation: Need based Replacement of major extraction & NRVs with valves of better materials such as valve stem by stellited seats, valve plug with Inconel 750 (ASTM A45; Rockwell hardness 35), plug by Nitronic 60 (ASTM A479 with hard facing). Valves for HPH drip to deaerator, drain of HP, Auxiliary steam, drain valve, etc. , may be considered for improvement.

iii.

Deaerator: The deaerator temperature and pressure are below their design values and boiling is affected because of feed being sub-cooled. Recommendation: Oxygen measurement must be introduced in the deaerator.

iv.

Heat recovery devices: Gland steam condenser, stack steam condenser and vent steam condensers: The performance of these is normal.

v.

Coolers and secondary heat exchangers: Recommendation: Installation of D-Scall meter (scale control device) at the inlet of coolers with severe scaling intensity.

vi.

BFP Lube oil cooler & BFP scoop oil cooler: These are shell and type heat exchangers and operation is normal.

vii.

Feed water pumps: Recommendation: Replacement of cartridges of feed pumps with energy efficient cartridges with efficiencies (pump+ motor) of around 70-80 %.

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viii.

CW and condensate extraction pumps: Recommendation: Replacement of CW pumps and CEPs with energy efficient pumps of composite efficiency (pump+ motor) of at least 60 %. The pumps may be modified to antifriction bearings.

ix.

Other turbine side pumps: Recommendation: Replacement of turbine side pumps like sump pump, drip pump, etc. of bronze, brass impellers with pumps of SS impellers which have 8-10 % points higher composite pumpmotor efficiency. SS impeller pumps are inherently higher in efficiency than bronze, brass or non-ferrous impeller pumps.

The condition assessment of steam cycle components is given in Table 26.

4. CONDENSER, COOLING TOWER- ANALYSIS OF PERFORMANCE; EQUIPMENT ASSESSMENT FOR DAMAGE, RESTRICTION, DE-RATING AND LOSS The surface condensers are able to meet the unit requirements. Table 27 gives the performance of the condenser. The performance of the condenser is almost on par with the design. The TTD of the condenser is on par with the design 3.4 0C. The condenser vacuum is 12.0 kPa against the design of 10.6 kPa

Cooling tower - 3 Cooling tower is of counter flow with 4 cells. During study period all the 4 fans were in service. Table 28 gives the performance of cooling towers. The observations are i. LHS side heavy bush growth obstruction the air flow to cells 3A, 3B and 3C. ii. Water spillage from raiser duct was observed. iii. Drift eliminators are blocked with heavy algae. iv. In few locations fill material is damaged and water is flowing through this damaged area without splashing. v. Inspection door topside and movable door gap leads to fresh air entry into fan suction. vi. The operating range varies from 6.9 to 7.0 ˚C against design value of 10.0 ˚C. vii. The operating approach varies from 9.0 to 9.3 ˚C against design value of 4.2 ˚C. viii. The operating effectiveness varies from 42.4 to 43.8 % against design value of 70.4 %. Recommendation: 17

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i.


The cooling water quality to be monitored and controlled to avoid algae growth. The damaged fills need to be replaced. The cooling water to each cell need to be equalized to improve the performance. The bushes near the cooling tower need to be cleared off to have resistance free air entry to CT.

ii. iii. iv.

5. STEAM AUDIT AND STEAM UTILIZATION SYSTEMANALYSIS OF PERFORMANCE; EQUIPMENT ASSESSMENT FOR DAMAGE, RESTRICTION, DE-RATING AND LOSS In this unit, steam related losses are quite low (1 % of the main steam flow). The unit has steam vacuum pumps and oil heating /tracing by steam. It is assumed that all the steam out of the boiler goes to the turbine. But in practice a certain percentage of steam is lost from the boiler side as auxiliary steam. The auxiliary steam consumption is around 3-8 t/h. The auxiliary steam is taken from the CRH line through auxiliary steam station after pressure reduction and de-superheating. The DM water consumption is normally designed at 1-3 % of the main steam flow and the operating values are normally supposed to be in the range of 1-3 %. In this unit the DM make up is well within limits. The recommendations for auxiliary steam are as follows: Sl. No. 01

System/parameter Particulars

02

Valves

03

Steam leaks

04

Make up

Blow down

Optimization of blow down (CBD+IBD) based on judicious setting of purity. Check for passing of CBD and IBD valves and high energy drains on the turbine side is in place and can be further strengthen by use of local temperature sensor to check for passing. Arresting of steam leaks from soot blower and auxiliary steam lines typically at flanges, valve stems, etc. must be done proactively. Monitoring of make-up water to control excessive steam consumption through actual flow measurement of make up.

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05

Steam loss

06

Insulation

07

Cycling operations


Steam loss in areas outside the unit area such as oil tank heating, oil line tracing, may be curtailed by plugging uncontrolled losses. Steam losses are seen at a number of locations in the oil plant. Insulation of steam lines by 50 mm unbonded, felted, inorganic based mineral/rock/slag wool of thermal conductivity followed by MS pipe skin cladding. The insulation is damaged at many locations in the boiler gallery and at the oil plant. Steam loss during cycling and abnormal operation must be regulated.

6. CAPACITY ADEQUACY ANALYSIS OF AUXILIARY EQUIPMENTS Capacity limitation is characterized by the load factor of the auxiliary at the operating unit load. When the actual load factor of the auxiliary is higher than the expected load factor (at that plant load) it leads to capacity limitations at higher loads. When designing the auxiliary motors, they are provided with 20 % margin (10 % in pressure and 10 % in flow). The design load factor of auxiliary motors is 100 % at 100 % MCR rating of the unit, except in the case of FD fans which is set at 30 %. The present limiting unit capacity is arrived at without considering the margins. The capacity adequacy analysis was carried out for each of the major HT auxiliary equipments. The Load factor of the auxiliary motor at 99.28 % MCR (test load) are worked out and given in Table 29 (see Annex 2). It can be seen from the Table that at the operating unit load of 100 % PL of the unit, the auxiliaries CEPs pose capacity limitation as these are getting loaded to almost 95 % of their power rating. At 100 % MCR , i.e., 120 MW, in the case of CE pumps there is capacity limitation of 10 % and there are no margins. There is no capacity limitation on any other auxiliaries.

7. FORCED OUTAGE & START UP ANALYSIS The tripping reports for the Unit for the past 2 years is given in Annex 4:A4-1. The average rates are as follows: •

BTL: 0-1/year

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•

No of trippings/year: 6/year

•

Mean time between failure (days): 61 days

•

Average time per outage: 3.5 hours/outage

The number of forced outages are showing a decreasing trend from over 8 outages/year to 5/year over the years. It is seen that the average time taken for hot warm and cold starts is as follows: Average time from Boiler light up to 100 % Load (h) Unit no. Unit 3

Hot start 2.0

Warm start 36.0

Cold start 72.0

8. OPERATION & MAINTENANCE PRACTICES 8.1 Operational practices The review of the operating procedures is given in Table 30. The recommendations regarding operation practices are as follows: i.

Run the unit as close to the design parameters as possible. The heat rate will be minimum when the unit parameter deviation is minimum. For every deviation of operating parameter there will be increase in heat rate. Focus areas are O2 in flue gas and mill fineness.

ii.

The operation criterion is based on running of the unit. The unit is automated to a good extent to enable efficient operation. With the aid of a few operator aids for start up and optimal operation the unit can perform efficiently.

iii.

The operation must consider the various inputs from Performance optimization group and Chemists for process optimization.

iv.

The operation practices must be aligned to operation of the units steadily without tripping with the maximum availability and minimum no of outages.

v.

The ISO objectives and engineering declarations must be focused on operation considerations such as minimizing the number of trippings, minimizing resource consumption for restarts.

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vi.

Maintaining 100 % availability of all feed water heaters and heat recovery condensers.

vii.

All OEM manuals must be thoroughly studied and don’ts must be carefully understood and observed. This will avoid long term damage to asset equipment and irreversible degradation of heat rate which will be costly to reverse.

viii.

Keep target parameters and maintain un-burnts in bottom ash and unburnts in fly ash, make up water %, etc., within limits. The combustion limits are as follows: o Bottom ash limits 4 %, o Fly ash < 1 %. o Optimal CO: 100 ppm

In addition to the above, installation of software packages for unit management such as the following will aid in the operations: o On line maintenance schedule package o Enterprise resource planning o Spares inventory management o Condition monitoring through vibration analysis o Asset management package The TPC-G has installed SAP ERP package for their material management, preventive maintenance, finance and HR activities. Above objectives may be achieved by developing following system: A close monitoring and reporting system. An efficient system of review which ensures timely attention to the maintenance requirement. Training and capacity building for improved knowledge of operational practices to operation staff. Efficiency up keep of instruments, auto control loops, annunciation system, protections & interlocks. Good house keeping and working environment. Training for O & M staff.

Operational aids: Sl. System No. 01 Multi media annunciation 02 On-line software

Particulars To aid in quick decision making of deviated parameters Parameter trending on-line and indication of deviations from the design.

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03

ATRS

04

Expert systems For decision support during abnormal operations and emergencies Simulator To simulate new and unusual situations

05

Turbine rolling must be only through ATRS

Measurement of losses through Chemist: Periodic (daily) measurement once in a shift are being taken for unburnts in bottom ash, unburnts in fly ash, CO in flue gas, mill fineness, mill rejects, etc. These are useful aids for operational optimization. This input is presently available but not being used for process optimization. Recommendation: The data recorded in each shift by the Chemists may be integrated by Performance Optimization Group into online optimization of the boiler and turbine, mill operating parameters to improve the unit performance through minimization of losses on account of these. Presently unburnts report on daily basis, coal mill fineness weekly, and CO measurement is on need basis. When the parameters are out of good range these must be addressed through parameter defect card system. Closed circuit TVs: Recommendation: CCTVs may be installed in boiler elevations AB, CD, EF, etc., on all corners. The viewing must be in control room and in Station Head’s office. In all around 8-10 CCTVs/unit may be installed for monitoring the boilers for coal leaks, steam leaks, oil leaks etc. Also CCTVs may be used for conveyor monitoring. Performance trending as an operational guideline: Recommendation: The process of performance trending presently using off line data and gradually using on line data, can be taken up for operational optimization, the aid of TGA of fired coal, stress evaluation, etc., can also be used as guidelines. The performance trending software capability can be strengthened by procurement of standard software (typically PADO, Ebsilon, Pro-engineer, Steam Master, IPSEPro, etc.,) having flexibility of downloading into a standard data base such as EXCEL. Ready rekoner books for data: Recommendation: Ready rekoner books of 100-150 pages need to be brought out by the TPS for each unit for all major operating parameters in sufficient copies and distributed to operation and maintenance staff. Capture and dissemination of operational knowledge: Knowledge capture, recording, transferring are the most important aspects for operational processes. Multimedia based knowledge management system is of great help in this context. The system requires a well documentation, recording & multimedia support which can yield most cost effective training results for the operations sections. Development of a knowledge centre will be a good move for long term benefits of the TPS. Recommendation: Setting up of infrastructure for capture of operational knowledge including simulating faults through video recording and replay on LCD screen. Video and LCD projectors may be procured for specific purpose of

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operational capture, documentation and transfer among the operators. The areas of knowledge capture in operations are as follows: • • • • •

Cold start boiler side activities venting / draining and other activities) Cold start turbine side activities Auxiliary preparation an manual operation Oil gun preparation Auxiliary changeover (with dos & don’ts)

TGA analysis of the coal as an operational aid: (Thermo gravimetric analysis) TGA analysis of coal is a good operational aid. The combustion characteristics are not dependent on the GCV alone but on the percentage of volatiles. If the volatiles are too low in the coal then even though GCV is high its combustion characteristics are retarded and maintaining the fireball is problematic. On the other hand, if the volatile content is too high then pre-combustion occurs before entering the furnace in the coal pipe itself if the coal air mixture temperature is around 90 °C. This information can also be used to ascertain that the flame temperature is appropriate for a given coal. This analysis must be done before the coal goes to the bunker so that the operator is well aware of the combustion characteristic during the shift. It is clarified here that obtaining a TGA after the combustion is over is only of academic interest and does not provide the operator with any inputs for operational optimization. This will be useful when there is over 3 days coal stocks if coal yard coal is taken. If bunker coal is used then it needs to be around 6 hours in advance.

Energy management systems: On line energy monitoring systems which includes software and sensors can be useful for measurement of electrical energy, measurement and monitoring of performance of auxiliaries in terms of efficiency as well as specific energy consumption. Other benefits include energy balancing, data trending and online feedback on performance deterioration of major and selected minor auxiliaries. Quantification of losses and establishment of baselines are possible. Recommendation: Energy management system is a useful tool for monitoring and control of auxiliary power of in-plant and outlying major auxiliaries.

8.2 Maintenance practices Some of the best practices followed are as follows: i. ii. iii.

iv.

Valve Wide Open Operation of Turbine to eliminate throttling noises. Energy conservation measures. Cross Functional Teams for improvement of plant performance viz., Heat rate, auxiliary consumption, occurrence analysis, resource conservation (water, steam etc). Bench mark outage time.

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Corporate Social Responsibility Institutionalization of Business Excellence Model.

8.2.1 Day to day maintenance i.

Water/steam leaks: Drain water leakages are seen at few places. These must be minimized.

ii.

Valves: In-between two overhauls, boiler and turbine side valves some times develop gland leaks or stem leaks.

8.2.2 Annual and capital overhauls Unit No. 3

Age

Expected No. of AOH

Actual No. of AOH

Expected No. of COH

Actual No. of COH

9

7

7

2

2

The Unit which has undergone 9 years of service has undergone 7 annual overhaul (AOH) and 2 capital overhauls (COH) against their designated 7 AOH and 2 COH. Overhauls are a part of the asset management process and their optimization is required. The general practice is to go in for AOH every year for a period of 24-26 days and COH once in four years. Other patterns of overhauls are also being followed such as a long AOH once bi-annually, or short AOH once every 8 moths, etc. Normally, overhauls must be scheduled and done as per schedules and must not be delayed by over 2 months. The maintenance planning must be oriented to achieve the COH & AOH as per schedule. Recommendation: The overhaul pattern may be reviewed and the optimal pattern may be established as there is scope for further optimization. The overhauls must be so organized that the asset management is optimized (asset value is preserved) and the TPS gets maximum benefit in terms of restoration of UHR from the overhaul and also prevention of leaks and damage in-between overhauls. The major works undertaken during the COH are the overhauling of the turbine modules and partial replacement of pressure parts like ECO, LTSH, water wall tubes, etc.

8.2.4 Recommended maintenance practices KAIZEN for maintenance: KAIZEN is a Japanese word which means gradual, orderly and continuous improvement with minimal investment. Kaizen is ongoing process focusing on elimination of waste in all systems of an organization. Kaizen has two elements viz., improvement\change for betterment and continuity. The three functions -Maintenance, Innovation and KAIZEN should occur in an organization simultaneously as follows:

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i.

ii. iii.

iv.


Maintenance refers to smooth functioning of current status, setting up of procedures and implementation of standards. Usually Artisans and technicians of the organization are responsible for maintenance. Innovation are a break through routine and run of the mill activities such as buying new machines, major renovation of machines, etc Kaizen is an intermittent function involving small steps but with continuous betterment. The actual working is expected from workers (technicians and Artisans) and lower management (Supervisors) but mandate and encouragement of upper management (Station head and General Managers) with facilitation from middle management (Executives and Superintendents) is essential. It is believed in Japanese management that managers should spend

50 % of their time in making improvements. Recommendation: KAIZEN is recommended for identifying wastes and long term sustainability of the organization. Maintenance procedure documentation: Work instructions for maintenance are well documented. The maintenance procedures and data recording on routine maintenance, AOH and COH along with breakdown maintenance procedures are in order and well maintained. The quality of the documents is good but can be improved and made more systematic over the next two years with very little effort. Also the formats can be standardized for all plant equipment or class of equipment. Capture and dissemination of tacit maintenance knowledge: Knowledge capture, recording, transferring are also important for maintenance processes. Recommendation: Setting up of Multimedia based knowledge management infrastructure for capture of maintenance knowledge through video recording and replay on LCD screen. Video and LCD projectors may be procured for specific purpose of operational capture, documentation and transfer among the operators. The areas for knowledge capture are: Maintenance side (Mechanical) • Valve maintenance (Gland replacement, overhaul, quality checks) • Coal mill maintenance • Coal mill lube oil system maintenance • Pump maintenance • Boiler tube leakages ( Reason-wise programs) • Lubricant replacement Maintenance side (Electrical) • Motor testing & Quality checks • Zirconia O2 sensor calibration • Meter replacement • Relay testing • Charging procedure of Transformer Maintenance side (control & instrumentation)

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• • • • •


Valve, Damper, IGV : Actuators’ maintenance (I/P convertor, positioner feedback transmitter checks) Primary Sensor Checks (Temp. RTD,T/C, Level etc.), site Instruments checks (Press. gauges, Temp. gauges, switches, etc.) Analyzers Operation checks (O2,CO, Opacity,etc. ) Transmitters, Converters operation checks (pressure, temp., flow, level, etc) Control circuit & electronic cards checks. Indicators, Recorders, meters operation checks.

Standardization of routine maintenance processes: Maintenance work should governed by ‘maintenance standards’ and these are to be developed by the managers with involvement of workers and (a) include industry and operating experience with reference to national and international standards (b) provide guidance for more definitive documents which govern maintenance activities. At present only work plans are documented through Enterprise Process manual (SAP) but not standardized. Recommendation: The development and implementation of the standards must be made mandatory for all major maintenance works. Measurement of maintenance performance: being measured through SAP ERP.

Maintenance data is presently

Material up gradation considerations during procurement of spares: Recommendation: While procuring replacement spares, material up gradation and new technology options such as bimetal extrusions, coated tubes, internally ribbed tubes, etc., must be kept in mind instead of old time tested spares. Vendor development in critical areas: Recommendation: The boiler and turbine maintenance must initiate vendor development either through Vendor-TPS meet or other mechanisms for identification of competent vendors in the areas of: • HVOF coating • Martensitic steel materials • Reverse engineering for problematic or obsolete components with difficult to get or spares • Computational fluid dynamics (CFD) solutions to hydrodynamic and heat transfer related re-engineering problems. • Computational electromagnetics (E-MAG) solutions to electrical machine design and re-engineering problems. • Erosion and corrosion resistant materials • Software resources Innovative maintenance practices: The innovative maintenance practices must be documented and shared to all concerned.

Maintenance budgeting: The budgeting process is based on historical trends of previous budget along with a cost index for price rise.

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Long term rate contracts for better inventory management: Recommendation: For many items long term rate contract (3-5 years) with price escalation formulae can be entered into by one TPS to minimize inventory levels. These contracts may also be made applicable to other TATA stations (as per terms of contract with the vendor) so that the duplication or efforts of processing can be eliminated at other stations. Long term contracting having the following features shall strengthen the inventory management system leading to a win-win situation: • Assured business-committed yearly quantities • Minimum inflation risks: Price variation (on both sides) with clauses linked to basic raw material /key ingredient cost based on national /market /international /exchange prices can be fixed. • Penalty for delay and incentive for early supply against pre-defined delivery periods. • Timely payment with cash discount for early payment and interest for delay payment. • Well defined contract termination applicable to both parties clarifying notice period and amount. • In case contract is with authorized dealer/stockist, backing of OEM/OES for quality and quantity assurance. • Exclusively defined taxes and levies, so as to get free float. Role of cleanliness as a maintenance procedure: It is now recognized that cleanliness of each and every equipment plays a far more serious role than envisage earlier. Though thorough cleaning of equipment either with water or air may temporarily hamper other maintenance jobs, it is now recognized that cleanliness plays a vital role in the long run in the form of secondary damage control. Pipe conveyors are being used to prevent fall out of coal from conveyors. Recommendation: Air washer units (5 nos/unit) are installed for improvement in dust cleanliness. Passively powered turbo vaned flywheeling eco ventilators with no electrical consumption may be used for expelling the air from the turbine halls.

Condition monitoring group: Successful condition monitoring can bring down maintenance costs by making a distinction between defective equipment and excluding good equipment for maintenance. It also helps in identifying equipment when they enter the danger zone well before they reach damage zone. Recommendation: For realization of benefits of condition monitoring in terms of quick identification of abnormal operation and danger zone well before it reaches the damage zone or catastrophic zone, the following measures are required: Step 1: A policy for organized online condition monitoring may be evolved. A condition monitoring group which is a nuclear group for monitoring HT auxiliaries once monthly and other auxiliaries as and when required, must be in place.

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Step 2: Cost economical condition monitoring of the station hardware/ equipment may be divided into four categories: On-line monitoring and tripping on parameters outside safe range. On-line monitoring with annunciation on parameters outside safe range. Off-line daily monitoring. Off-line weekly/monthly monitoring. Recommendation: For on-line and continuous monitoring equipment SMS alert systems may be installed to be activated only if the parameter goes out of range. Step 3: Presently the condition monitoring group is entering the scene only when high level of vibrations are sensed in any auxiliary such as ID fan, cooling water pump, PA fan, etc. Recommendation: It is recommended to have a round the clock condition monitoring group with the job responsibility of monitoring the condition of equipment like vibrations, temperature rise, leakage levels, oil depletion, loss of lubricant, leakage, etc., and recommend to the Maintenance Sections which equipment needs to be attended to and give advance warning of the path to failure well before it happens. Step 4: Recommendation: The group must be treated as an operations group and must not be burdened with responsibilities that will not give them time for real full time field monitoring. The complete condition assessment responsibility must be theirs.

Operational optimization and performance monitoring through performance monitoring group: Operational optimization means operating the unit at the optimal parameters. While the parameters directly affect the efficiency, the sensitivity of other parameters is indirect and low. The operating philosophy is to maintaining the parameters to as near the design set point parameter as possible. Parameters such as burner tilts, minimization of RH spray, coal air mixture temperature, oxygen in flue gas, etc., need to be brought as near the design as practically possible. Recommendation: Monthly performance tests are to be conducted on the boiler and turbine, Tri-monthly mill performance tests. Also performance tests are to be conducted on heaters, condensers, cooling towers, etc., Field instruments are also to be available with POG for conduct of tests. Boiler performance optimization: Since boiler is the weakest in terms of energy efficiency boiler performance optimization is required. Recommendation: Boiler performance optimization using Air/combustion/mill/exit gas/ash optimizer from STORT TECH/Bacharach/KENT/ABB/Pegasus/GE, etc.

9. OVERALL SYSTEM 9.1 Test heat rate at 100 % load The gross and net overall parameters are given in Tables 31 (Annex 2). deviation in efficiency and heat rate from design is given in Table 32 & 33.

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The basis for computing the difference in heat rate is by keeping all variables at their design value and varying only the variable accounting for the increase in heat rate. By this process simulation the difference in heat rate is arrived at.

Unit 3 Test UHR DHR Dev due to Boiler Dev due to Turbine Dev due to Generator Test efficiency Design efficiency Overall difference Overall difference

2577.07 2253.7 48.1 274.8 0.5 33.4 38.2 4.8 323.4

kcal/kWh kcal/kWh kcal/kWh kcal/kWh kcal/kWh % % % kcal/kWh

The observations regarding the overall system are as follows: i. ii. iii.

The overall design gross efficiency is 38.2 % and the overall operating gross efficiency is 33.4 % at 100 % MCR. The design TG heat rate is 2253.71 kcal/kWh. The operating TG heat rate (test) is 2577.10 kcal/kWh at the tested load of 100 % MCR. The deviation of the design TG heat rate from the operating Test TG heat rate is 323.4 kcal/kWh which is attributed to 48.1 kcal/kWh due to boiler, 274.8 kcal/kWh due to turbine and 0.5 kcal/kWh due to the generator. Thus, boiler is the equipment with maximum deviations.

9.2 Heat consumption due to steam lost to non-motive applications represented by DM make up This heat loss is represented by the DM water make up which represents the steam lost from the process. Normal DM water make up is around 3 % of the main steam flow. The annual heat consumption for DM water make up (Q) in Mcal/h, is given by, Q (Mcal/h) = {10-3[DM water make up (%) * Main steam flow at 100 % load (kg/h)*(hsteam-hwater) (kcal/kg)/(boiler efficiency=0.86)] } The power generated (considering 100 % PLF) (E) in MW is given by, P (MW)= Unit capacity x 1.0

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The heat rate component due to cycling and abnormal operations is given by, Annual heat rate component due to DM water make up = HRsteam = [Q/P]

9.3 Heat consumption due to cycling/abnormal operationstart up and shut down This heat consumption can be computed based on the number of hot, warm and cold starts. The heat consumption (Mcal) for any type of start as a function of the average resource (coal, fuel oil and DM water) consumption (averaged over an year) for that start is given by: Heat Consumption/start (Mcal)= 10-3{[Raw coal consumption (kg) * weighted average GCV of raw coal (kcal/kg)] + [FO Consumption (m3) * density (kg/m3) * GCV of FO (kcal/kg)]+ [LDO Consumption (m3) * density (kg/m3) * GCV of LDO (kcal/kg)] + [DM water consumption (m3) * density (kg/m3) *(hsteam-hwater) (kcal/kg)/(boiler efficiency=0.86)] } The annual heat consumption for cycling operations (Qc) in Mcal/year, is given by, Q (Mcal/year) = {[Qhot start (Mcal) x number of hot starts/year]+ [Qwarm start (Mcal) x number of warm starts/year]+ [Qcold start (Mcal) x number of cold starts/year]} The annual energy generated (considering 100 % PLF) (E) in MWh is given by, E (MWh/year)= Energy generated = Unit capacity x 8760 x 0.8 The heat rate component due to cycling and abnormal operations is given by, Annual heat rate component due to cycling and abnormal operations = HRcycling = [Qc/E]

9.4 Additional heat consumption due to year round variations in environmental and fuel parameters from test values This is the algebraic sum of the difference between the test heat rate of the station in the month of CPRI test and the individual test heat rates or every month over the year. In case, in the month of test, the heat rate is the highest or higher than the standard deviation, seasonal variation is taken as zero. HR

seasonal variation

= ∆UHR

test month and other months

9.5 Accounting of mill rejects This is taken as,

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HR reject= {(Reject production (% of coal through mill)) * weighted average GCV of Raw coal (kcal/kg)* SFC (kg/kWh))}

9.6 Accounting of heat loss in piping in-between boiler and turbine This is taken as, HR MS, RH piping = {π* (Running length of piping (m)) * (diameter of piping coal (m))* (convective and radiative heat transfer rate (natural convection) (kcal/hm2°C))* (∆Tpipe ( °C )}/E The actual formulae are worked out in EXCEL sheets.

9.7 Overall annual unit heat rate assessment 9.7.1 Computation of annual unit heat rate In the present study the annual heat rate is computed as follows: Test heat rate based on actual performance test under conditions of zero make up and zero auxiliary steam consumption. Heat consumption translated into a heat rate component due to steam consumption for non-motive applications which is reflected in terms of DM water make up. Heat consumption translated into a heat rate component due to cycling or abnormal operations like hot, warm and cold starts. Heat consumption translated into heat rate components due to deviation in test parameters all though the year (positive and negative deviations). Energy components to account for reject coal at the mill. This is because the coal entering the bunker is considered as entering coal and GCV of the bunkered coal is taken. The component due to mill ejects is to be subtracted. The unit heat consumption is computed considering all the above which portrays the realistic heat consumption vis-à-vis the energy generated. The heat rate credit is added algebraically to the unit heat rate in computing the annual unit rate assessment.

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The annual heat rate therefore considers the seasonal variations, the cycling heat requirements (due to hot/warm/cold starts), the energy components in rejects and the heat lost in MS & RH piping. The basic data on DM water, rejects, resource consumption in various types of starts, heat losses in piping between boiler and turbine and calculations of the heat rate component based on these are given in Annex 3 in the form or reproduction of the original EXCEL sheets. Unit 3 Test UHR Test Efficiency HR-Seasonal dev HR-Cycling dev HR-Dev DM HR-Dev-rejects HR-Dev-MS& RH pipe Annual unit HR Annual Efficiency

2577.07 33.4 0 26.00 29.49 8.04 2.7 2643.3 32.5

kcal/kWh % kcal/kWh kcal/kWh kcal/kWh kcal/kWh kcal/kWh kcal/kWh %

The following is to be noted from the above annual UHR components: i.

In the cyclic deviations the hot/warm/cold starts is taken as 5/3/2 and the energy components are taken as 1/2/3 kcal/kWh for each type of start. The total deviation due to starts is quite low and well within limits and there is no possibility for reducing this further.

ii.

The loss due to rejects is also within limits as rejects are only 0.2 % of the total coal and well within the 1 % limit. Hence no further optimization is possible on this count.

iii.

The loss due to DM make up is also well within limits. The DM make up is 1.0 % of the MS flow and much lower than the limit of 3 % and hence no further optimization is possible.

9.8 Categorization of remedies for improvement of the parameters 9.8.1 Immediate heat rate improvement (over a 12 month period) The immediate objective of the heat rate improvement program of the Station is to contain the degradation trend and keep the performance parameters steady over the whole year. Some of the measures to be achieved are as following: i.

Operational optimization of parameters. Presently there is no online performance software for tracking and optimization of operational parameters. The same may be installed and used.

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ii.

Proactive round the clock involvement of Performance Optimization Group and Condition Monitoring Group in control of plant parameters. Field instruments for performance monitoring may be procured and tests may be conducted on the unit. Monthly performance tests are recommended to reconcile the values of heat rates to be declared.

iii.

Replacement of selected old brass impeller pumps with SS impellers.

iv.

Maintaining 100 % availability of all feed water heaters and heat recovery condensers.

v.

Cleaning of feed water heat tube nests and heat exchangers; and replacement of self cleaning strainers.

vi.

Modification of ID fan blading with aerodynamic profile and with hard weld overlays.

vii.

Passively powered eco ventilators.

viii.

Retrofitting of VFDs for selected pumps.

The immediately achievable TG heat rate reduction for this unit is 10 kcal/kWh. 9.8.2 Medium term heat rate improvement (over 2-3 year period) The medium term measures are as the following: i.

Furnace exit gas temperature and viewing from the control room.

CCTVs for boiler firing elevation

ii.

Smart soot blower system for steam economy.

iii.

Furnace skin insulation replacement.

iv.

Energy efficient pumps especially BFPs, CWPs and CEPs.

v.

Improvements in milling systems

The TG heat rate reduction achievable under medium term scenario for this unit is 10 kcal/kWh. 9.8.3 Long term heat rate improvement (over 5 year period and further) In the long term scenario of 5 years and over future the heat rate can be brought down through extensive R & M of the units. The major replacements already done and proposed are given above under the section on major replacements done and proposed.

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The major R & M works envisaged for long term improvement are as follows: i.

IP and LP turbine retrofits with 3-d blading.

ii.

Partial replacement of superheater coils.

iii.

Up gradation of the existing DCS with additional capacity of data storage, engineering station, work station and data highway including FSSS, alarms and MIS.

It is mentioned here that since long term measures are cost intensive, all easier avenues of operational optimization, good housekeeping and wastage reduction must be used to the optimal extent. The TG heat rate reduction achievable under long term scenario for this unit is 25 kcal/kWh.

9.9 Degradation of unit heat rates 9.9.1 Degradation of the commercial unit heat rate (UHR) as computed by the station The comparative chart of the degradation of the UHR with the commercial heat rate as declared by the TPS is as follows: Comparison of TG HR as per std degradation rates and actual values reported by TPS Year FY

Design Heat Rate (DHR) (kcal/kWh)

2253.7 2009-10 2253.7 2008-09 2253.7 2007-08 2253.7 2006-07 Degradation rate at Degradation rate at

Years

% Degraded Heat Rate at 0.4 %

10.0 4.0 9 3.6 8 3.2 7 2.8 2009-10 kcal/kWh/year % 2009-10 degradation/year

34

% % Degraded degradation Heat of actual Rate at heat rate 0.7 % 7.0 17.50 6.3 15.01 5.6 18.74 4.9 10.97 39.43 1.75

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Comparison of CPRI TG test HR as per std degradation rates and actual values Year FY


Years

20092253.7 10 Degradation rate at

2009-10

Degradation rate at

2009-10

% Degraded HR at 0.4%

% % Degraded degradation HR at of actual 0.7% TG HR

4.0

10

7.0

kcal/kWh % degradation/year

14.35 32.34 1.43

Comparison of CPRI test annual UHR with std degradation rates Year FY


Years

20092253.7 10 Degradation rate at

2009-10

Degradation rate at

2009-10

% Degraded HR at 0.4%

10

4.0 kcal/kWh % degradation/year

% % Degraded degradation HR at of actual U 0.7% HR 7.0

17.29 38.96 1.73

The degradation of the station commercially declared UHR is 17.50 % over design UHR. The degradation rate is 1.75 %/year which works out to 39.43 kcal/kWh per year.

9.10 Trajectories and projections The trajectories are given on the following basis:

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Experimental test annual UHR (snap shot test UHR + factors to account for annual effects) + [degradation rate based on 0.4 %/year of DHR] + [improvements due to short term, medium term and long term measures] FY

2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016

UHR achieved by TPC-G kcal/kWh 2539 2501 2676 2592 2648

Test UHR with degradation kcal/kWh

Test UHR with degradation + improvements kcal/kWh

2643 2652 2661 2670 2679 2688

2633 2642 2651 2645 2654 2663

Figure: Trajectories based on test annual UHR-coal firing for Unit 3 of TPC-G

Annual UHR -coal (kcal/kWh)

2680 2650 2620 2590 2560 2530

TPC-G achieved Test UHR + degradation Test UHR+ degradation+improvements

2500 2006 2008 2010 2012 2014 2016 2018 FY

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10.CONCLUSIONS The main conclusions of the study are as follows: i. The gross overall efficiency of the Unit 3 TG set is 33.4 % against the design efficiency of 38.2 %. The gross overall TG heat rate (TG HR) is 2577.1 kcal/kWh at the test load of 100 % as compared to the design heat rate of 2253.7 kcal/kWh. ii. The deviation in the test TG heat rate is 323.4 kcal/kWh which can be attributed to 48.1 kcal/kWh due to the boiler, 274.8 due to the turbine and 0.5 kcal/kWh due to the generator. Hence the turbine is the component leading to maximum losses. iii. The annual unit heat rate (UHR) considering all factors such as PLF, DM make up, rejects, energy consumption in starts, etc. is 2643.3 kcal/kWh for Unit 3. This annual UHR represents the annual heat consumption of the unit considering all annual realistic factors. iv. Immediate measures include operational optimization of parameters such as mill fineness optimization, coal flow equalization, etc. Fine tuning of parameters, parameter setting and parameter trending, reduction of steam and air leaks, etc., would help in operational optimization. Procurement of field instruments for performance monitoring and condition monitoring is required. Cleaning of internals of pressure parts, condenser, feed heaters and coolers is also envisaged as an immediate measure. v. Medium term measures include smart soot blowing system, insulation, VFDs for pumps and fans, heat recovery devices and heaters; energy efficient BFPs, CEPs and CWPs, furnace exit gas temperature measurement, etc.. vi. Long term measures include waste heat recovery boiler, IP & LP turbine retrofits with 3-d blading & up gradation of DCS. vii. The investment in immediate, medium term and long term measures works out to Rs. 562, 440 & 3600 lakhs respectively. The total cost is Rs. 0.38 crores/MW. viii. The degradation of the station commercially declared UHR is 17.50 % over design UHR. The degradation rate is 1.75 %/year which works out to 39.43 kcal/kWh per year. ix. Trajectories of unit heat rate is provided on the basis of test snapshot heat rate with factors for annual effects and annual degradation rate of 0.4% of DHR. About 9 kcal/kWh/year degradation in UHR is predicted based on the

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test snap shot and improvements due to short, medium and long term measures. ****************

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Annex 1


Annex– 1 (Figures, Graphs & Photographs)

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Annex 1


A 1-1: UNIT PERFORMANCE

Plant load factor v/s years 100 90 80

PLF (%)

70 60

2008 2009 2010

50 40 30 20 10 0 APR MAY JUN

JUL AUG SEP OCT NOV DEC JAN FEB MAR Months

Availabilty factor v/s Years 120

Availabilty factor

100 80 2008 2009 2010

60 40 20 0 APR MAY JUN

JUL AUG SEP OCT NOV DEC JAN FEB MAR Months

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Annex 1


Auxiliary consumption (%) v/s Years

Auxiliary consumption (%)

14 12 10 2008 2009 2010

8 6 4 2 0 APR MAY JUN

JUL

AUG SEP OCT NOV DEC JAN FEB MAR Months

Specific coal consumption (kg/kWh)

Specific coal consumption (kg/kWh) v/s Years 0.88 0.86 0.84 0.82 0.8

2008

0.78

2009

0.76

2010

0.74 0.72 0.7 0.68 APR

JUN

AUG

OCT Months

3

DEC

FEB

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Specific fuel oil consumpton (ml/kWh)

Specific fuel oil consumption (ml/kWh) v/s Years 14.0 12.0 10.0 2008 2009 2010

8.0 6.0 4.0 2.0 0.0 APR

JUN

AUG

OCT

DEC

FEB

Months

UHR (kcal/kWh) v/s Years 3100 3000 UHR (kcal/kWh)

2900 2800 2008 2009 2010

2700 2600 2500 2400 2300 2200 APR

JUN

AUG

OCT Months

4

DEC

FEB

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Annex 1


2

y = -0.0155x + 2.782x - 24.199 2 R = 0.9471

Availiablity factor v/s PLF 120.00

Avaliablity factor

100.00 80.00 60.00 40.00 20.00 0.00 0

10

20

30

40

50

60

70

80

90

100

PLF (% )

y = -0.004x + 10.674 2

R = 0.0191

Auxiliary consumption v/s PLF 14 12

PLF(%)

10 8 6 4 2 0 0

10

20

30

40

50

60

70

Auxiliary consumption (% )

5

80

90

100

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2

y = 3E-06x - 0.0011x + 0.8549 2

R = 0.2252 Specific coal consumption v/s PLF Sp. coal consumoption (kg/kWh)

0.88 0.86 0.84 0.82 0.80 0.78 0.76 0.74 0

10

20

30

40

50 60 PLF (% )

70

80

90

100

2

y = 0.0029x - 0.4844x + 20.926 2 R = 0.9307 Specific fuel oil consumption v/s PLF Sp. fuel oil consumption (ml/kWh)

14 12 10 8 6 4 2 0 0

10

20

30

40

50 PLF (% )

6

60

70

80

90

100

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2

y = 0.0368x - 8.1995x + 3054.1 2

UHR v/s PLF

R = 0.3977

3000 2950 2900

PLF (%)

2850 2800 2750 2700 2650 2600 2550 2500 0

10

20

30

40

50

60

UHR (kcal/kWh)

7

70

80

90

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Annex – 2 (Tables and Charts)

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Table 1: Design rating of major equipment (100 % MCR) Sl. No.

Particular of equipments

Units

Unit 3

Steaming rate

t/h

352.2

Boiler efficiency

%

87.03

MW

120

t/MWh

2.935

Turbine efficiency

%

44.46

Turbine heat rate

kcal/kWh

1934.53

Boiler

01

Turbine

02 Electrical output rate Specific steam consumption

Turbo Generator

03

Turbo generator efficiency

%

43.85

Turbo generator heat rate

kcal/kWh

1961.4

MW

120

%

98.63

Generator

04 Electrical output rate

Generator efficiency at unity power factor

Table 2: Design rating of the TPC-G Unit No. 3 (100 % MCR) Sl. No.

Particular

Units

Unit 3

01

Unit installed capacity

MW

120

02

Unit de-rated Capacity (present)

MW

120

03

Gross over unit efficiency

%

38.16

04

Unit design heat rate

kcal/kWh

2253.47

05

Station capacity (present)

MW

547.5

06

Station heat rate

kcal/kWh

NA

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Table 3: Details of the boiler and its auxiliaries-1. Sl. 01

Details

Particulars

No.

Type

Outdoor, two pass, pie type, radiant, Natural circulation, balanced draft, dry bottom ash, single drum, corner fired fusion welded water walls.

02

No. of turbine

03

Fuel used

04

05

boilers

per 1

Primary

Coal / Oil

Secondary

HFO

Fuel firing equipment Type of fuel firing Type of coal mills No. of coal mills Type of coal burners Load per coal burner No. of coal burners No. of coal elevations Type of oil burners No. of oil elevations No. of oil burners

Direct corner firing XRP 783 Raymond Bowl mill, 36.5 t/h per mill, 442 kW motor 5/3 (total/ service) Coal Tilting Tangential Burners 8.33 % MCR per burner, 9.125 t/h 20/12 (total/service) 5 HFO, BHEL make 3 12

Soot blowers

Wall Blowers, Long Retractable Soot Blowers

Furnace zone

40 Nos., Wall blower, Medium used Steam

Platen, Convection and 20, Long retract, Medium used – Steam Reheater and ECO zone 06

Steaming capacity

352.2 t/h

07

Steam pressure SH outlet

130.7

Drum pressure Reheater outlet

140.8 kgf/cm2 28.78 kgf/cm2

Steam temperature SH outlet

540 °C

Reheater outlet

540 °C

08

09

Heater types

3

Vol. 1



Economiser

Plain tube

Superheaters

Low temp super heater, Platen super heater, Spaced Final super heater

Air heater type Desuperheating

Tubular Pri- 3 blocks, Sec- 6 blocks Spray

10

Boiler efficiency

87.03% (design)

11

Boiler aux. (Fans)

12

ID fans FD fans PA fans

NDZV 26 SIDOR BHEL AP1 17/11, BHEL AP2 17/12, BHEL

Auxiliary steam

Gland steam, oil heating, fuel oil atomization at burners, soot blowers, steam tracing lines of fuel oil lines

4

Vol. 1



Table 4: Details of the boiler and its auxiliaries-2. SL. 1.0

Description Steam Generator Nos Make

Units 1 BHEL

Type

Pulverized fuel fired, Corner fired, single

Circulation Draft Furnace bottom Max. continuous rating: 100% BMCR 100 % TMCR

1.1

Pressure at Super heater outlet Temperature at SH outlet at RH outlet Flue gas temp at Air-heater outlet Guaranteed Boiler efficiency at GCV Air Pre-heaters

t/h t/h

drum Natural Balanced Wet 390.0 352.2

kg/cm2 °C °C °C

130.7 540 540 139

%

87.03

Type Nos

1.2

Tubular PAPH – 1 No. SAPH – 2 Nos.

Milling Plant Mills Type

Raymound bowl mill XRP 783

Nos. Working / Standby Capacity per mill PA fans Nos Type

1.3

Unit-3

t/h

3/2 36.5 2 AP 2 17/12

Capacity

m3/s

44.26

Pressure

mmWC

1179

Motor rating

kW

675

Speed Draft Plant ID fans Type Nos: Working/Standby

rpm

1480

Capacity

m3/s

127.6

Pressure Drive : Fixed / Variable speed

mmWC

360 Fixed

NDZV 26 Sidor 2 / Nil

5

Vol. 1



Electric capacity Speed FD fans Type Nos.

kW rpm

680 740

Capacity

m3/s

75.83

Pressure Electric rating Speed

mmWC kW rpm

487 480 1480

API-17/11 2

Heat Balance 100 % BMCR

100 % TMCR

60% TMCR

%

4.23

4.19

3.49

3.53

H2O & H2 in Fuel

%

6.15

6.14

6.06

6.07

H2O in Air

%

0.13

0.13

0.10

0.10

Unburnt Carbon

%

1.10

1.10

1.10

1.10

Radiation & Unaccounted

%

1.18

1.21

1.36

1.12

Manufacturers Margin

%

0.20

0.2

0.20

0.20

Total Losses

%

12.99

12.97

12.31

12.12

EFFICIENCY

%

87.01

87.03

87.69

87.88

Losses

unit

Dry Gas

6

100 % TMCR with HPH out

Vol. 1


Description


Design Fuel Composition Unit Value

Proximate Analysis Fixed Carbon Volatile Matter Moisture Ash Grindability Index Higher Heating Value Size Of Coal to Mill

% % % % HGI kcal/kg mm

21.2 21.8 12 45 55 3350 25

% % % % % % %

35.11 2.36 0.6 0.64 4.29 12 45

Ultimate Analysis Carbon Hydrogen Sulphur Nitrogen Oxygen Moisture Ash

Fuel Burning Equipment Type Make & Nos Capacity Disposition

Furnace Volume Heating Surface Area Water Walls Low Temp Super Heater Platen Super Heater Final Super Heater Reheater Economiser Secondary Air Heater Primary Air Heater

Oil Burner BHEL:12 22.5 % SGMCR Corner

2663 m³

1871m² 3046 m² 513 m² 352 m² 1470 m² 4607 m² 21370 m² 11575 m²

7

Vol. 1


Predicted Performance Description Flow


Unit 100% BMCR

100% TMCR

60% 100% TMCR TMCR with HPH out

t/h t/h

390 320

352.2 301.8

212.6 185.1

333.7 316.7

t/h t/h t/h

401.7 0 0

352.2 0 2.3

212.6 3.9 2.2

343.7 6.8 3.3

Air Heater Outlet- Primary Air Heater Outlet- Secondary Tempering Air

t/h t/h t/h

135 299.1 17

125.6 257.6 21.3

90.9 141.2 4.9

144.6 273 4.2

Total Combustion Air(including Leak) Fuel

t/h

491.4

448.4

277.3

462.1

Coal(HHV-3350 kcal/kg)

t/h

90.4

81.8

51.1

83.6

t/h t/h t/h t/h

167.2 373.8 167.2 373.8

158.9 330.6 158.9 330.7

117.1 188.1 117.1 188.1

173.3 335.2 173.3 335.2

ºC ºC ºC ºC ºC ºC ºC ºC

337 424 424 522 522 540 334 540

336 426 426 528 521 540 333 540

331 419 407 535 525 540 322 540

336 438 423 530 520 540 344 540

ºC ºC

235 287

234 286

212 268

188 260

ºC ºC ºC

33 277 274

33 274 273

33 244 246

33 250 250

ºC ºC ºC ºC ºC

981 1082 981 981 765

973 1070 973 973 754

891 1012 891 891 671

969 1070 969 969 755

Steam Superheater Outlet Reheater Outlet

Water Feed Water SH Spray Stage-1 Stage-2

Air

Gas PAH SAH PAH SAH

Outlet Inlet Outlet Outlet

Temperature Steam Saturation Temp in Drum LTSH outlet Platen SH inlet Platen SH outlet Final SH inlet Final SH outlet RH inlet RH outlet

Water Economiser inlet Economiser outlet

Air Ambient AH outlet(Primary) AH outlet(Secondary)

Gas Leaving Furnace Entering Platen SH Leaving Platen SH Entering Reheater Leaving Reheater

8

Vol. 1


Entering LTSH Leaving LTSH Entering Economiser Entering Airheater Leaving Air Heater At Stack Entrance


ºC ºC ºC ºC ºC ºC

664 464 464 305 140 136

642 456 456 298 139 136

566 412 412 262 122 122

644 460 460 285 121 121

Pressure (Steam & Water) Superheater MSSV outlet

kgf/cm²

131

130.7

128

131

LTSH outlet

kgf/cm²

140

138.3

131

138

Drum

kgf/cm²

143

140.8

132

140

Economiser Valve Inlet

kgf/cm²

146

143.5

134

143

Reheater Outlet

kgf/cm²

30.2

28.78

17.4

30.1

Reheater inlet

kgf/cm²

31.7

30.15

18.2

31.5

Superheater System

kgf/cm²

12.2

10.1

3.99

9.14

Reheater System

kgf/cm²

1.5

1.37

0.82

1.37

Economiser System

kgf/cm²

2.84

2.64

2.23

2.6

mmWC mmWC mmWC mmWC mmWC mmWC

285 882 862 750 639 260

244 834 815 716 606 239

149 757 749 693 587 227

256 870 851 728 618 247

mmWC mmWC mmWC mmWC mmWC

-17 300 274 141 100

-14 259 238 134 100

-5 156 148 112 100

-15 271 248 136 100

mmWC mmWC mmWC mmWC mmWC mmWC mmWC mmWC mmWC

-4 -4 -5 -11 -23 -47 -127 -178 20

-4 -4 -5 -10 -20 -40 -109 -154 16

-4 -4 -5 -6 -10 -18 -60 -88 6

-4 -4 -5 -10 -21 -43 -112 -159 18

Pressure Drop

Pressure & Drafts (Air & Gas) Primary Air PA Fan Inlet PA Fan outlet Airheater Inlet Airheater Outlet Mill Inlet Mill Outlet

Secondary Air FD Fan Inlet FD Fan Outlet Airheater Inlet Airheater Outlet Windbox Pressure(at inlet)

Gas Furnace SH Platen inlet Reheater Inlet LTSH inlet Economiser Inlet Airheater Inlet ESP Inlet ID Fan Inlet ID Fan Outlet

9

Vol. 1



O2, CO2 (Dry Volume), Excess Air O2 in Gas at Economiser outlet CO2 in Gas at Eco outlet Excess Air in Gas at Eco outlet

% % %

3.56 15.5 20

3.56 15.5 20

3.56 15.5 20

3.56 15.5 20

Heat Balance Losses (As per ASME PTC 4.1) Dry Gas H2O and H2 in Fuel H2O in Air Unburnt Carbon Radiation and unaccounted Manufacture's Margin Total Loss Efficiency (Bases on HHV) Material Boiler Drum Water Wall Tubes Inlet of All Super Heaters and Reheaters Just Before the outlet of Super Heaters & Reheater Outlet of Super heaters and Reheaters Soot Blowers Wall Blowers LRSB(For SHs, RH And Eco)

% % % % % % % %

4.23 4.19 3.49 6.15 6.14 6.06 0.13 0.13 0.1 1.10 1.1 1.1 1.18 1.21 1.36 0.20 0.2 0.2 12.99 12.97 12.31 87.01 87.03 87.69

3.53 6.07 0.1 1.1 1.12 0.2 12.12 87.88

SA270 GR70 SA210 Gr.C P11,T11 1.25 Cr,1Mo (Medium Alloys) P22,T22

2.25 Cr,1 Mo (High Alloys)

P91, T91 12% Cr

40 Nos 20 Nos

MILL AND BURNER PERFORMANCE 100% BMCR Mill Type No. of Mill in operation Nos. Mill Loading % Air Flow per Mill t/h Air Temperature at Mill Inlet °C Mil Outlet Temperature °C Fineness % (thro' 200 mesh) % Burner Tilt Degree Burner Elevation in operation

3 83 51 251 70 -19 C, D, E

10

100% 60% TMCR TMCR XRP-783 3 2 74.8 70 48.95 48 242 234 66-90 70 70 0 17 C, D, E C&D

100% TMCR (HPH Out) 3 78 50 244 70 -5 C, D, E

Vol. 1



MILLS Type

Bowl Mill - XRP 783

Make & Nos Capacity

BHEL: 3 36.5 t/h

Motor kW System FD Fan Make Type Capacity Specific Weight Total Head Speed Design Air Temp

300 Pressurized Booster Cold PA 2 Nos BHEL AP1 17/11 - Axial Flow 75.83 m³/s 1.04 kg/m³ 487 mmWC 1480 rpm 50 °C

Control Fan Reserve Flow Pressure FDF MOTOR Make Rating Current Insulation Class

Blade Pitch 34.90% 64.88% BHEL 480 kW 52 A F

PA Fan Make Type Capacity Specific Weight

2 Nos BHEL AP2 17/12 – Axial Flow 44.26 m³/s 1.11 kg/m³

Total Head Speed Design Air Temp Control Fan Reserve Flow Pressure PAF MOTOR Make Rating Current Insulation Class

1179 mmWC 1480 rpm 50 °C Blade Pitch 47.60% 97.40% BHEL 675 kW 71 Amps F

11

Vol. 1



ID Fan Make Type Orientation Capacity

2 Nos BHEL NDZV 26 SIDOR 45°C Inclined Suction 127.6 m³/ s

Specific Weight Total Head Speed

0.768 kg/m³ 360 mmWC Variable

Design Air Temp

163 °C

Control Fan Reserve Flow Pressure IDF MOTOR Make Rating Current Speed Insulation Class ID FAN HYDRAULIC Make Rotation

IGV and Scoop 42.30% 81.80% BHEL 680 kW 79 A 740 rpm F COUPLING Voith CCW viewed in the direction of the power flow.

Scoop Tube Stoke

242 mm

Motor Speed Sleep Turbo Coupling Speed Regulating Range Oil Tank Capacity

740 rpm 3.10% 717 rpm 05:01 650 litre

12

Vol. 1



Table 5: Details of the turbine and its auxiliaries-1. Sl.

Particulars

Details- Unit 3

Type

BHEL design, Three cylinder, throttle governing, multi stage, reaction,

No. 01

tandem compound, single flow with six uncontrolled extractions 02

Electrical capacity

03

Steam flow

120 MW

Turbine inlet 04

05

06

07

355.6 t/h

Steam paths in the turbine HP turbine

Single flow, 25 reaction stages

IP turbine

Single flow, 19 reaction stages/flow

LP turbine

Double flow, stages/flow

Steam temperature HP turbine inlet

540 °C

IP turbine inlet

540 °C

LP turbine outlet

46.4 °C

Steam pressure HP turbine inlet

127.0 Kg/cm2

IP turbine inlet

28.80 Kg/cm2

IP turbine outlet

4.16 Kg/cm2

Turbine outlet

0.1060 Kg/cm2

Feed water heaters HP

2

LP

3

Deaerator (open feed heater)

1

Heat recovery devices

Yes

Gland steam condenser

Yes

Stack steam condenser Yes (condenser flash tank) Vent steam condenser

Yes

08

Turbine-generator Efficiency

44.46 %

09

Turbine-generator heat rate

1934.53 kcal/kWh

10

Turbine efficiency

43.85%

11

Turbine heat rate

1961.40 kcal/kWh 13

2x9

reaction

Vol. 1

12

13



Condenser type

Shell and tube surface type

Condenser vacuum

10.60 kPa

Turbine auxiliary pumps Boiler feed pump

Scoop coupling, MDBFP – 3

Nos.,

1515

kW

kW,

2/1

(installed/operating) – 3/2 Condensate ext. pump

Direct

coupling,

250

(installed/operating)

Manufacturers Name Type Model No No of Steam Turbine Efficiency HP Cylinder IP Cylinder LP Cylinder

Bharat Heavy Electricals Limited 2 Casing , Reheat, Condensing, Tandem K-30-16 + N-30- 2*3.2 Two(HP+IP) + Two (LP) Design 88% 95% 72%

DESIGN AND PERFORMANCE DATA Max. Continuous Rating at Generator terminal at 3 % make-up and design condenser cooling water inlet temperature Turbine Rated speed Throttle Steam at HP strainer Inlet

120 MW 3000 rpm

Pressure Temperature Flow CRH Steam

126kgf/ cm² 535 °C 352.251 t/h

Pressure Temperature Flow HRH Steam

32.070 kgf/cm² 335.2 °C 301.775 t/h

Pressure Temperature Flow LP Turbine Inlet

28.8 kgf/cm² 535 °C 301.775 t/h

Pressure Temperature

5.1624 kgf/cm² 285.3 °C 14

Vol. 1



Flow LP Turbine Outlet/ Condenser Inlet

285.05 t/h

Pressure Temperature

0.1033 kgf/cm² 46.6 °C at 0.9324 dryness factor 249.33 t/h 0.03

Flow Max. Make-Up to Turbine Cycle (at condenser hotwell) Steam pressure drop in the reheat circuit (HP outlet to IP inlet) Feed water Temperature Operating Frequency Range for Turbine 7 Auxiliaries Steam Turbine Swallowing Capacity with turbine control valve in wide open (VWO) condition

3.27 kgf/cm² 233.6 °C 47.5-51.5 370.329 t/h

Max. allowable turbine exhaust pressure at MCR

0.3 kgf/cm²

Min. allowable turbine exhaust pressure at MCR No Load Steam flow through HP Turbine IP/ LP Turbine Shaft Vibration at each bearing house (peak to peak) Critical speed HP/ IP Turbine LP Turbine Critical Speed of turbine and generator rotor together assembled Turning Gear Speed Is turbine is designed for full arc admission during startup Max. allowable temperature at LP turbine exhaust hood Is exhaust hood spray system included Coasting Down time (min) after turbine trip

0.05 kgf/cm²

With Vacuum Without Vacuum GOVERNING SYSTEM Mode of Governing Type of Governing Dead Bank of the Governor Percentage regulation and its range of adjustability Emergency Stop Valve Opening through full travel For closing through full travel On load throw off Temporary speed rise (TSR) Permanent Speed rise Range of adjustability of speeder reference 15

40 t/h 5 t/h 100 microns 2400 rpm 1900 rpm 1140, 1440, 1900, 2160 rpm 50 rpm Yes 90 °C Yes To turning gear speed/ To stand still 28/ 33 18 / 23 Throttle Governing Electro Hydraulic 0.0006 3.5-6 ; 2-10

5-15 sec. 0.1 +/ - 0.01 sec. Full Load 50 % Load 8% 7% 5 % 2.5 % 0- 110 %

Vol. 1



MATERIAL OF CONSTRUCTION Turbine casing HP outer casing/ barrel casing HP inner casing IP casing LP outer casing LP inner casing & LP blade carriers 4L, 4R LP blade carriers(1L, 1L, 3L, 1R, 2R, 3R) between blade carriers & diffusers Turbine Shaft HP/ IP rotor shaft LP rotor shaft Turbine disc (if shrunk on) Moving Blades HP Turbine 1st stage HP Turbine other stages IP Turbine stages LP Turbine stages LP Turbine last stage Fixed Blades HP Turbine 1st stage HP Turbine other stages IP Turbine stages LP Turbine stages LP Turbine last stage Casing Joints Bolts HP/ IP Turbine casing LP Turbine casing Shaft Coupling

Cast Steel GS22 MO4 GS 17 CrMo V 511 Not Applicable IS-2062 & IS 960 GS 22 Mo4 IS 2062 & DIN 17155 HII 30 Cr MoNi V 511 26 Ni Cr Mo V 115 Not applicable X 22 Cr Mo V 121 X 22 Cr Mo V 121 X 22 Cr Mo V 121 X 20 Cr 13 X 5 Cr Ni 134/ X 7 Cr Al 13 X X X X X

22 22 22 20 20

Cr Cr Cr Cr Cr

Mo V 121 Mo V 121 Mo V 121 13 13

21 Cr Mo V 57 Carbon steel (P8.8) Rigid (integral), same as rotor material ASTM 533 GR 70

IP-LP cross around piping CONSTRUCTION FEATURE & OTHER DATA Number of Cylinder No. of bearings including thrust bearing of turbine No. of Stages HP- No. of Impulse stages HP- No. of Reaction stages IP- No. of Impulse stages IP- No. of Reaction stages LP- No. of Impulse stages 16

2 3 Nil 25 Nil 19 Nil

Vol. 1



LP- No. of Reaction stages First stage diameter Length of last LP blades Tip diameter of last LP blade Max. Peripheral velocity of last LP blade Annulus area of last stage Method of moisture removal at last stage Type of blade protection against moisture erosion No. of low pressure stages protection against moisture erosion Type of joint to the condenser Type of anti friction material used in bearings Type of thrust bearing Type of turbine shaft HP/ IP Turbine shaft LP turbine shaft Method of turbine shaft quenching HP/ IP rotor LP rotor Type of shaft coupling between HP/ IP IP/ LP LP/ Generator Manufacturer Type Orientation To Condenser Tube Axis Number No of Pass Hot well Water Box

BHEL,Hydrabad Bottom Mounted Perpendicular to Turbine Rotor Axis 1 2 Divided Divided

SHELL SIDE DESIGN CONDITION Steam From Turbine(3% make-up & 34 C CWDT) Quantity 257.953 t / h Pressure .106 kgf/cm² Temperature 46.6 ºC Enthalpy 578.4 kcal/kg Steam from HP & LP Bypass (during bypass operation) Quantity 329.89 t/h

Pressure Temperature Enthalpy

.12 kgf/cm² 49 ºC 818.7 kcal/kg 17

2x9 625 mm 560 mm 2270 mm 356.6 m/ sec. 2 x 3.2 m² None Based on erosion index or coating not required None Welded ORGOV- 738 Tilting pad No Bore type No Bore type Oil/ Mist Not applicable Not applicable Rigid Rigid

Vol. 1



Drain from Feed Cycle at Turbine VWO Condition Quantity 37.847 t / h Pressure .3393 kgf/cm² Temperature 53.5 ºC Enthalpy 53.5 kcal/kg Condensate Make-up at turbine VWO condition Quantity 11.11 Temperature Ambient

Other Steam/Drains through flash box or directly to condenser at turbine VWO Source DC/GSC/ GS Excess Quantity in t/h 37.847/0.154/1.239 Pressure in kgf// cm² 0.3393/0.98/Temperature in ºC 53.5/99.9/Enthalpy in Kcal/Kg 53.5/100/730.8 Design heat load corresponding to turbine 145.23 Gcal/h VWO condition with 5% margin Design Back Pressure 0.106 kgf/cm² Condensate Temp at Hotwell outlet 46.6 ºC Temp of air vapour mixture at air cooler section 42.43 ºC Volume of condensate stored at normal level to low level 15.76 m³(3 min.capacity) Cooling Water Design Parameter Flow Quantity Inlet/Outlet Temperature Cleanliness Factor Velocity of water in tubes Cooling surface Condenser Tube In Condenser Section Outer diameter Inner diameter Number In Air Cooler Section Outer diameter Inner diameter Number Effective Condenser tube length Method for securing tube to tube sheet Exit end of tube protrude beyond face

16000 m³/h 34/43.077 ºC 85% 1.96 m/s 7774 m²

22 mm 18 BWG 14000 22 mm 22 BWG 1200 7400 mm Roller Expansion 3 mm each side

18

Vol. 1


Material of Construction Shell Condenser Neck Water Box Tube Sheet Tube in Condensing Zone Tube in Air Cooling Zone Tube Support Plate


SA516 Gr70 SA516 Gr70 SA516 Gr70 SA516 Gr70 SB111UNS70600 (C-Ni 90/10) SA249TP304 SA516 Gr70

Vacuum Pump GENERAL Manufacturer Model no. Number Stage of Pump Standard condition for Air Suction Ejector Coupling DESIGN DATA Guaranteed capacity of pump Speed of Pump Volume of Surface condenser, turbine steam space and piping Motor Rating Motor Current Guaranteed Vibration Level Guaranteed noise level at 1.0 m COOLING WATER Quality Design temperature Design pressure MATERIAL OF CONSTRUCTION Casing Shaft Impeller

Nash Korea Ltd. AT 2006 E 1+1 2 HEI Not provided Flexible 15 scfm 490 rpm 450 m³ 93 kW 191.6 A 7 mm/sec 85 dBA Passivated DM water 39 °C 10 kgf/cm² Cast Iron JIS G4051 S45C (CS) Nodular Iron

VACUUM PUMP RECIRCULATION PUMP Quantity 13 m³/h Head 22 m Motor Rating/ current 3.5 kW/ 7.5 Amps

19

Vol. 1



Cooling Tower Supplier Type No. of Cell DESIGN DATA Water Flow

BDWT, Chennai Induced Draft, Counter Flow 6 18000 m³/h/ tower

Hot water temperature

43°C

Cold water temperature

33 °C

Wet bulb temperature

28.8 °C

Range Approach Evaporation Loss Drift Loss

REDUCTION GEAR BOX Manufacture Model no. Type Quantity Reduction Ratio Type of Gears No. of Stages Nominal KW Rating Transmission Efficiency

10 °C 4.2 °c 289.8 t/h 1.8 t/h

Flender (Kharagpur) Kens 200 Bevel-helical 6 12.5:1 Bevel- Helical and Spur 2 45 97.50%

FAN Manufacture

Parag Fans, Indore

No. of Fans per Cell

1

No of Fans per Tower No of Blades per Fan

6 4

Max. Discharge through Fan Static Head at Max. Discharge Speed Motor Make Capacity/ Current/ Speed BUTTERFLY VALVE Purpose Manufacturer

1789369.2 m³/h 6.8 mWC 116 rpm ABB 45 kW/ 1500 rpm

Hot water line isolation/ cell Durga Engineering Co. 20

Vol. 1



700 mm ø 6 Manual m³/h m³/h

Size No. of Valves per Tower Method of operation Max. Flow Normal flow CONSTRUCTION FEATURE Fills Fills Height Surface area per fills Basin Size Volume of water per basin No of Heaters HP Heaters Deaerator LP Heaters HP Heater-6

HP Heater-5

Deaerator

LP Heater-3

PVC Fills 1.5 m 412771.52 m2 16.8 x 16.8 4572.3 m3 6 2 1 3 Extraction Pressure Ex. Temp Drip Temp FW inlet temp FW outlet temp FW Flow FW pressure Steam flow Extraction Pressure Ex. Temp Drip Temp FW inlet temp FW outlet temp FW Flow FW pressure Steam flow Extraction Pressure Ex. Temp FW inlet temp FW outlet temp FW Flow FW pressure Steam flow Extraction Pressure Ex. Temp Drip Temp Cond inlet temp Cond outlet temp Cond Flow 21

29.5 340 192 185 233.6 355.6 156 33.32 10.6 398 158 152 185 355.6 156 17.873 3.8 281 119.5 149.6 355.6 3.8 14.687 1.187 195 98 92 119.5 289.3

Vol. 1


LP Heater-2


Cond pressure Steam flow Extraction Pressure Ex. Temp Drip Temp Cond inlet temp Cond outlet temp Cond Flow Cond pressure Steam flow

20 13.68 0.17 105 74 68 92 289.3 20 11.68

Ex Enthalpy kcal/kg Drip Temp Cond inlet temp Cond outlet temp Cond Flow Cond pressure Steam flow

609.9 71 50 68 289.3 20 9.5

LP Heater-1

H. P. HEATERS GENERAL Manufacturer Tube Supplier Type

H.P.- 5

H. P.- 6

BHEL Vallinox, France Shell/ removable

BHEL Vallinox, France Shell/removable

Number of closed feed water heater 1 per STG unit Orientation Vertical Tube Type U- Tube No. of Tube Passes 2 DESIGN DATA

1 Vertical U-Tube 2

Shell side data Unit Extraction Steam: Flow Inlet temperature Shell inlet pressure

t/h ºC

19.201 400.1

36.633 334.4

kgf/cm²

12.098

31.702

t/h ºC

H.P.H.- 6 36.633 193.5 NA

NA

55.834

36.633

Drain Entering: Source Flow Temperature Other drain entering Drain Leaving: Flow

t/h

22

Vol. 1


Temperature Design Pressure Design Vacuum Test Pressure /Temperature


ºC

159.9

193.5

kgf/cm² 16 0/ Full Vacuum kgf/cm² 24/ 410 57/ 360

Fouling Resistance Tube Data Sheet Feed Water Flow Inlet Temperature Outlet Temperature

t/h ºC ºC

Inlet pressure

kgf/ cm²

Design/ Test Pressure Design temperature Fouling Resistance Feed water velocity through tubes at average operating temp. De superheating Section: LMTD Transfer Rate

kgf/ cm² ºC h.m².ºC/ kcal

Pressure drop Heat transfer surface Condensing Section: LMTD Transfer Rate Heat transfer surface Drain Cooling Section: LMTD Transfer Rate Heat transfer surface Whether heater is design for additional load during abnormal condition

38

As per HEI 381.439 153.5 187

187 235.3

~ 166

~ 165

264/ 396 210/ 230 As per HEI

250/ 270

m/ s

2.1313

2.2413

ºC kcal/h.m².ºC

95.1 483.1

51.5 722.4

kgf/ cm² m²

0.27 40.7

0.35 50.65

ºC kcal/h.m².ºC m²

13.23 2693 275.1

17.49 2796 333

ºC kcal/h.m².ºC m²

15.01 1865 56.2

19.65 1761.8 48

Yes

CONSTRUCTIONAL FEATURE Shell OD/ Thick/ L Tube Number OD/ Length Gauge

mm

1032/ 16/ 10280

mm BWG

490 15.875/ 9600 14/ 15

MATERIAL OF CONSTRUCTION Shell

SA 516 Gr 70 23

1050/ 25/ 11250

Vol. 1



Shell cover Tube

SA 516 Gr 70 SA 213 T304

Deaerater Type of Deaerating Feed water Heater Manufacturer DESIGN DATA Feed water flow Temperature of Deaerated Water Condensate Inflow Temperature of Condensate Inflow Heating Steam Quantity Heating Steam Pressure Heating Steam Temperature Steam/ Flashed drains into Deaerator: From HP Heater From CBD Steam/ Flashed drains into Feed Water Storage Tank Deaerating Heater Operating Pressure Pegging Steam pressure at low load/ part load Pegging Steam Temperature at low load/ part load Load Range as percent of TG MCR for pegging steam Whether heating steam rakes are provided in deaerating feed water storage tank Is a separate, initial heating steam rake provided Deaerator Design Pressure/ Temperature Deaerator Feed water storage tank design Pressure/ Temperature Water storage capacity provided in feed water storage tank upto normal water level Sprayer Assembly Detail Number of sprayer assembly Spray assembly type Manufacturer of Sprayer assembly Condensate flow through each sprayer assembly Pressure drop under design condensate flow Tray Detail Thickness No. of horizontal Trays in one Stack and no. of Stacks Total No. Trays 24

Spray Tray type BHEL,Hyderabad 381.439 t/h 150.7 °C 309.673 t/h 120.1 °C 15.931 t/h 4.94 kgf/ cm² 284.1 °C Flow/ Temperature 55.834 t/h / 159.9 °C 12.24 t/h / 170 °C Nil 4.94 kgf/ cm² 3.0 kgf/ cm² 200 to 330 °C

< 60 % Yes Yes 6 kgf/ cm² & FV/ 350 °C 6 kgf/ cm² & FV/ 230 °C 60 m³

22 Spring Loaded BHEL , Hyderabad 14.076 t/h 0.32 kgf/ cm² 1.6 mm 20 and 8 160

Vol. 1



MATERIAL OF CONSTRUCTION Deaerator shell Feed water storage tank shell & dished end Sprayer Tray

L.P. HEATERS

Units

1

Carbon Steel SA 516 Gr 70 SS TP 304 SS 304

LPH-1

LPH-2

LPH-3

GENERAL

1.1

Manufacturer

BHEL

1.2

Tube Supplier

Vallinox, France

1.3

Type

Bundle, Shell

Numberof closedfeed water heater per STG 1.4

unit

1

1

1

1.5

Orientation

Horizontal

Vertical

Vertical

1.6

Tube Type

1.7

No. of Tube Passes

U- Tube 2

2

DESIGN DATA

2.1

Shell side data

2

2

Extraction Steam:

2.1.1

Flow

t/h

10.583

12.523

14.74

Inlet temperature

ºC

71.5

110.6

199.4

Shell inlet pressure

kgf/ cm²

0.3393

0.8853

2.2526

L.P.H.- 2

L.P.H.-3

--

Drain Entering:

Source 2.1.2

Flow

t/h

27.264

14.74

--

Temperature

ºC

74.6

98.8

--

NA

NA

NA

Other drain 2.1.3

entering

Drain Leaving: Flow

t/h

37.847

27.264

14.74

2.1.4

Temperature

ºC

71.5

74.6

98.8

2.1.5

Design Pressure

kgf/ cm²

4

4

4

2.1.6

Design Vacuum

2.1.7

Test Pressure/

0/ Full Vacuum kgf/ cm² 25

6.0/ 150

Vol. 1


Temperature

2.1.8


ºC

Fouling Resistance h.m².ºC/ kcal

2.2

As per HEI

Tube Data Sheet

2.2.1

Feed Water Flow

t/h

309.673

2.2.2

Inlet Temperature

ºC

49.5

68.3

92.4

2.2.3

Outlet Temperature

ºC

68.3

92.4

120.1

2.2.4

Inlet pressure

kgf/ cm²

~ 9.0

~ 8.2

~ 7.6

Design/ Test 2.2.5

Pressure

kgf/ cm²

24/ 36

2.2.6

Design temperature

ºC

15

2.2.7

Fouling Resistance h.m².ºC/ kcal

As per HEI

Feed water velocity through tubes at average 2.2.8

operating temp.

m/ s

1.6

1.63

1.65

NA

NA

NA

De superheating Section

2.3

LMTD

ºC

Transfer Rate

kcal/h.m².ºC

Pressure drop

kgf/ cm²

Heat transfer surface

m²

Condensing Section LMTD

ºC

9.78

10.9

11.97

Transfer Rate

kcal/h.m².ºC

2419

2751

3073

m²

245

230

224.7

LMTD

ºC

--

13.78

15.2

Transfer Rate

kcal/h.m².ºC

--

1634

1439

Heat transfer 2.4

surface Drain Cooling Section

2.5

26

Vol. 1



Heat transfer m²

surface

--

Whether heater is design for

25.5

16.7

Yes

additional load 2.6

during abnormal condition

3

CONSTRUCTIONAL FEATURE

3.1

Shell OD/ Thick/ L

878/ 14/

878/ 14/

878/ 14/

8860

9700

9000

3.2

Tube Number

350

350

350

3.2.2

OD/ Length

mm

15.875/ 7500

15.875/ 8600

15.875/ 7900

3.2.3

Gauge

BWG

3.2.1

4

mm

20

MATERIAL OF CONSTRUCTION

4.1

Shell

SA 516 Gr 70

4.2

Shell cover

SA 516 Gr 70

4.3

Tube

SA 213 TP 304

Condensate Extraction Pump GENERAL Manufacturer

BHEL, Hyderabad

Model No.

EN7H32

No. of Pump

1+1 Vertical, BowlType, MultiStage, Canister

Type of Pump

Stages

7 Double suction at 1st stage

Type of suction Type of Coupling

Flexible, Spacer type

Mechanical

Type of seal

Michell ( Tilting pad type) between Pump & Motor)

Type of thrust bearing

Flexible

Type of shaft DESIGN DATA

Design Capacity per Pump

360 m3/h

Run-out Flow per Pump

396 m3/h 27

Vol. 1



100 m3 h

Minimum Flow per Pump

5.401 mlc st

Suction pressure at design capacity at 1 stage Design pressure at Design Capacity

180.401 mlc

Total Head at design capacity

175 mlc

Shut off Head

218 mlc

NPSH available (minimum)

4.233 mlc

Rated Speed

1478 rpm

Pump Efficiency at design point

81%

Pump Power required at design point

210 kW

Drive Motor Rating/ Current

250 kW/ 27.5 A

Critical speed

3714 rpm

Max. Vibration level

10 mm/ sec

LIQUID DATA Liquid Handled

Condensate 25- 85 °C

Temperature range Specific Gravity at design temp. of 46.6 °C

PH

0.999

8.8 to 9.2

COOLINGWATER REQUIREMENT 0.60 m3/h

Flow per Pump Inlet temperature

39 °C

Quality

D. M. Water

10 °C

Temperature rise across H.E

Supply Pressure

4.8- 5.0 kgf/cm2

Design Pressure

10 kgf/cm2

MATERIALOF CONSTRUCTION Bowl or Casing

BS 1452 GR 260 (IS:210, Gr: FG

Diffuser & Guide vane

Part of Bowl

-

Impeller All Stage

BS 1504 425 C11

Shaft Sleeves

BS 970 431 S29 (T)

Lower Pump Shaft & Upper Pump shaft

BS 970 420 S29R (Forging)

28

260)

Vol. 1



BOILER FEED PUMP

UNIT

MAIN

BOOSTER PUMP

PUMP 1

DESCRIPTION

1.1 Make 1.2 Number of Set 1.3 Pump Model

KSB, Pune 3 3 WK 150/ 2 CHTC 4/ 12 Multistage, Multistage RingSection BarrelCasing Common Elec. Motor directly driving Booster pump & Main Pump through variable speed hydraulic gear coupling

1.4 Type of Pump 1.5 Type of Drive

2

DESIGN & PERFORMANCE DATA

2.1

Inlet Flow

t/h / m3/ h

2.2

Outlet Flow

t/h/ m3/ h

2.3

Minimum Recirculation Flow at design speed (Main Pump3950rpm

2.4 2.5

Booster pump-1487 rpm)

t/h/ m3/ h

Total Dynamic Head at rated Speed & capacity

mlc

2.7

Max. Shut off Head NPSH required at Booster Pump Efficiency at rated point Hot n as per HIS

2.8 2.9

Power Input to Pump Max. Vibration Level

2.6

215.2/ 235 215.2/

215.2/ 235 215.2/

235

235

59.53/

91.6/

65

100

1990

mlc

83

mlc

3.85

%

69

75.1

kW

51 <2.8 for 192 to 235 m3/ h.

1515 <2.8 for 192 to 235 m3/ h.

mm/ s

29

2442

Vol. 1



< 4.5 for 65 to 192 m3/ h. & 235 to 258.5 m3/ h. <6.5 for 258.5 to 270 m3/ h. 2.1

Max. Noise Level dBA

77 + 3 dBA

< 4.5 for 65 to 192 m3/ hr. & 235 to 270 m3/ h.

89 + 3 dBA & with Noise Hood < 85 dBA

3 CONSTRUCTION FEATURE OF B.F.P. 3.1 Casing Type

Ring Section

Outer : Barrel Inner : Ring

3.2 Impeller Arrangement

Tandem

Tandem

3.3 Number of Stage 3.4 Journal bearing, Type

2 ANTIFRICTION NDE : Deep grove ball Brg.6410C3 DE : Cylindrical Roller Brg. NU410C3 --

12 Plain Bearing C. Steel + White

3.6 Coupling Type

Flexible Membrane, TSKS0075-0178-1450, Triveni Flexibox

Flexible Membrane, TSKS-09300177-2100, Triveni Flexibox

3.7 Type of Axial Balancing Device

Through Balancing Holes in the impeller & wearing ring on both Double Piston side of impeller + Thrust Bearing Diffuser Diffuser

3.5 Thrust Bearing

3.8

Pump designed with diffuser or volute

3.9

BFP Suction Strainer: Type

Simplex

Back washing facility

No

Filtration Ring

150 micron 30

Metal LGSn 80 Segmental Tilting Pad Type Double Acting

Vol. 1


Min. running clearance ( Radial)


0.175

4 MATERIAL OF CONSTRUCTION 4.1 Inner Casing

CA6NM

4.2 Outer Casing 4.3 Impeller 4.4 Diffuser 4.5 Casing Wearing Ring: Material Hardness Impeller Wearing Ring: 4.6 Material Hardness 4.7 Shaft

BHN

BHN

4.8 Shaft Sleeves 4.9 Stuffing Box 4.1 4.1 4.1 5

Balancing Device Pressure bolting studs Nuts LUBE OIL SYSTEM FOR BFP

Pump Speed Motor Rating of Pumps Lube Oil Cooler type TYPE OF COUPLING

NA CA6NM CA6NM

CA6NM ASTM A105/ SS Cladding CA6NM CA6NM

Chrome Hard 400 Min. 350

Chrome Hard 400 Min. 350

1.4024.19 Man. 250 ASTM A276 Type 410 (Forged) CHR.PLATED AISI 316 CA6NM

1.4024.19 Man. 250 ASTM A182 Gr.F6NM (Forged) CHR.PLATED AISI 316 CA6NM ASTM A182 Gr.F6A EN24 V/ T EN24 V/ T

EN24 V/ T EN24 V/ T

5.1 Type of Pump 5.2 Number of Pump 5.3 5.4 5.5 6

0.15

rpm kW

Oil from lube oil system of Hydraulic Coupling will be supplied to Main Pump Bearing 1 MOP + 1 AOP MOP- 3847 AOP- 1485 AOP- 5.5 KW/ 11 A Shell & Tube type Type : Flexible Membrane Make : Triveni Flexibox Model : TLPW-1850- 0133x001 Type : Flexible Membrane Make : Triveni

6.1 Between Motor & Hydraulic Coupling

6.2 Between Hydraulic Coupling & BFP 31

Vol. 1



Flexibox Model : TSKS-0930- 0177-2100 Type : Flexible Membrane Make : Triveni Flexibox Model : TSKS-0075- 0178-1450

6.3 Between Motor & Booster Pump

7 RECIRCULATION VALVE 7.1 Manufacturer 7.2 Capacity

t/h/ m3 /h

MIL Controls Ltd. 91.6/ 100

Table 6: Design parameters at various load conditions for the Unit Sl. No.

Temperature, Pressure, Flow points Descriptions

100 % BMCR

100 % TMCR

60 % TMCR

at various 100 % TMCR with HPH out

01

Steaming rate of the boiler, t/h

02

Pressure at SH. Outlet , kgf/cm

03

Temp. at SH. Outlet , °C

04

Pressure at RH. Inlet , kgf/cm

05

Temp. at RH. Inlet , °C

2

2

2

390.0

352.2

212.6

333.7

131.0

130.7

127.6

131.0

540.0

540.0

540.0

540.0

31.65

30.15

18.20

31.47

334.0

333.0

322.0

344.0

30.15

28.78

17.38

30.10

06

Pressure at RH. Outlet , kgf/cm

07

Temp. at RH. Outlet , °C

540.0

540.0

540.0

540.0

08

Feed water temp. , °C

235.0

234.0

212.0

188.0

09

Ambient air temp. , °C

33.0

33.0

33.0

33.0

10

Combustion air temp. secondary, °C

274.0

273.0

246.0

250.0

11

Fuel quantity, t/h

90.4

81.8

51.1

83.6

12

Air quantity, t/h

491.4

444.8

277.3

462.1

32

Vol. 1



Table 7: Capacity and age of units

No of Units

Unit Capacity (MW)

Derated Capacity (MW)

Date of commissioning

1

2

3

Unit-3

120

120

Age (years)

Make Boiler

Turbine

4

5

6

7

27 Aug 2001

BHEL

BHEL

9

Table 8: Results of proximate & ultimate analysis of raw coal samples collected during Unit heat rate test Particulars

SL. No.

Unit

Design

Analyzed value

kcal/kg

3350.0

4623

01

Gross calorific value

02

Carbon in fuel

%

35.11

47.22

03

Hydrogen in fuel

%

2.36

3.20

04

Sulphur in fuel

%

0.60

0.60

05

Oxygen in fuel

%

4.29

6.55

06

Ash in fuel

%

45.00

38.93

07

Moisture in fuel

%

12.00

6.60

Table 9: Results of unburnts analysis of bottom ash and fly ash samples collected during Unit heat rate test Particulars

SL. No.

Unit

Analyzed Value

01

Bottom ash

%

5.60

02

Fly ash

%

1.90

Table 10: Flue gas analysis Sl. No.

Particular

O2, %

1

Before SAPH-LHS

2

After SAPH-LHS

3

Before SAPH-RHS

4

After SAPH-RHS

6.16

5

Before PAPH

4.96

6

After PAPH

8.98

3.97, 4.06 5.15 3.80, 3.72

33

Vol. 1



Table 11: Boiler thermal performance by losses method Sl. No.

Particulars

Design,

Operating,

%

%

1.1

Loss due to sens. Heat in dry FG

5.77

1.2

Loss due to unburnt CO in flue gas

0.17

1 Dry flue gas loss

4.19

5.94

2.1

Loss due to moisture in fuel

0.90

2.2

Loss due to hydrogen in fuel

3.91

2 Wet flue gas loss

6.14

4.81

3 Loss due to moisture in comb. Air

0.13

0.16

4.1

Loss due to bottom ash

0.76

4.2

Loss due to fly ash

1.03

4.3

Loss due to sens. Heat of bottom ash

0.37

4.4

Loss due to sens. Heat of fly ash

0.16

4 Losses due to ash

1.10

2.32

5 Loss due to radiation

0.50

6 Loss due to convection

1.06

7 Un-accounted losses

1.21

Manufacturing margin

0.20

8 Heat equivalent of auxiliary power

--

-0.11

Heat loss due to puffing in furnace first 9 pass

--

0.00

12.97

14.69

10 Total losses 11 Thermal efficiency

Correction factor to account for annual 12 average station GCV 13 Corrected test boiler efficiency

34

87.03

85.31

--

--

87.03

85.31

Vol. 1



Table 12: Boiler skin temperature measurement

104.5 63.1 77 324.4 59.9 60.4 330 195.1 73.1 65 64.3 64.9 40.4 42.8

42.1 40.9 40.8 38.6

40.2 38.6

36.7 34.6

36.4 33.5 43 41.3

38 40.3

64.2 113.4 99.2 67 58.2

59.1 96 74.8 80 138 80.7 87.2 56.5 113.7 65.4 63.4 50.8 54.5 55.8 56.2

57.1 67.8 64.7

58.1 66 63.7 64.1 67.8

59.9 62.1 56.4 158.9 81 193 118.6 179 96.4 120.7 71.8 59.1 59.8 59.4 56.4 54.2

52 59 60.1

60.3 66.1

81.2 57.8 55.6 92 52.8

52.2 58.6 57.5 58.1 69.8 64.80

60.8 66 96.8 72.8 68.5

61.5 68.4 73.8 68.7 83

58.1 62.8 90.7 77.8 70.4

53.9 77.9 70.4 68.3 84.2

54.9 66.8 72.1

52.5 72.4 63.7 75 146 86.40 69.1 75.9 97.80

Drum level 197 50.1 67.6 120.7 127 235 70.3 305 329.4 Front 39.2 86.3 65.7 80.8 38.5 40.7 37.7 38.1 Rear 36 62.2 74.9 74.2 35.1 40.5 38.2 40.2 1 Level down 60.2 69.5 90 69.8 74.5 78.2 98.2 49.3 51.2 54.5 58.3 51.6 52.1 41.4 44.6 Rear 62.2 52.4 71.1 59.4 70.2 67 66.8 60.3

66.2 77.2 59.9 83.5 55

57.3 66.8

43.1 329.8 280.6

50.7 331.1 138.5

45.1 97.3 139

77.4 41

93.9

48.6

78.9 35.9

61.1 38.9

62.2 39.6

53.1 75.6 51.6 51.2 47.8

70.7 68.7 58.3 49.3 46.30

50.7 60.7 120.5 51.4 48.5

72.7 73.8

55.1 71.7

64.8 62.3

62.4 56.1 60.2 65.4 54.2

56.4 120 56.8 64.6 60.8

76 78.2 71.8 60.2 64.4

64.2 70.1 68.4 59.6

Rear 59.6 52.8 54.56 66.1 64.7 65

55.4 68.1

60.8 62.6

69 76.1

57.9 44 61.2 99.6 54.2 61.9

57.4 62.8 185 66.1 70 67.1

56.4 61.1 197.2 107.1 70.5 62.8

52.5 53.4 122.1 48.5 68.5 62.3

66.8 50.6

74.9 64.8

75.6 54.1

73.4 77

1 Level down 59.8 49.8 58.1 59.8 50.8

1 Level Down 59.6 57.1 73.6 60.7 119.2 60.5 106.3 111 54.5 62.5 Rear side 66 65.4 68.4 91.2 106 71.1 1 Level Down 35

Vol. 1


60.4 68.4 69 53.7 57.3 60 76.6

66.4 67.5 87.8 54.4 55.6 61.2 75.1

58.6 63.2

59.1 58.5 53.4 73.3

61.2 69.3 63.4 62.4 72.7 141.9 55.6 57.3 54.4 53.7 61.9 58.4 60.1 60.5 64.6 69.8

60.6 63.2 65.1 75 61.8 170 127 115.8 186.8 106 70.4 61.4 160.9 58.4 59.1 56.1 56.8 59 64.2 64.7 67

73.7 62.9 63.8 64.3

70.7 65.2

86.6 81.5

78.8 76.5 68.3 71.6

70.3 66.1

74.8 67.5 58.7 55.5 193.6 191 193 100.8 170.6 108 165 94.4 65.8 61.3 61.8 64.1 68.5 71.1 63.1 61.4

64.1 63.6 59.3 58.4

65.9 65.9

64 57.3 71 73.8 122.6 77 75.6 74.5 106.8 101 125 162.3 82.7 67.5 64.8 67 60.7 73.2 62.9 64.2 67.3 66.8

61.4 55.8 59.8 62.5

63.5 61.5

56.1 85.4

56.1 67.8 57.2 61.9

61.3 61.4


60.5 65.7 131.00 101.4 62.6 57.3

67.8 113 178 55.9 58 47.5

67.4 75.1 110 49.5 59.4 58.9

Rear side 63.3 62.6 59.1 70.4 62.3 62.5 1 Level Down (1st left 1st Right) 67.8 56.3 55.1 116.8 61.2 69.4 57.3 90.2 75.8 54.3 62 54.6 69.1 68.4

front side 77.3 64.8 65.9 114.1 70.9 73.2 63 72.5 Rear side 63.7 63.5 113 140.4 71 69.2 67.6 66.9 (2nd left 2nd Right) 56.7 65.3 68.1 58.2 65.2 55.25 71.2 58.6 146.3 69.4 56.1 54.2 64.2 60.7 Rear side 65.7 71.7 61.6 65.4 64.6 70.1 72.1 69.2 1 Level down (1st left 1st Right) 61.4 55.3 57.3 64.7 136 140.5 132.2 120 98.5 70.3 52.1 55.6 86.8 58.6 front side 58.9 72.9 67.8 56.5 60.5 58.6 52.5 69.6 Rear side 56.9 67.3 53.2 117.2 67.5 64.5 56.2 62.3 (2nd left 2nd Right) 36

57.9 66.9 107.6 48.3 56.6 62.1

60.5 70.4 87.3 48.6 49.3 61.1

61.2 64 53.3 49.7 67.3 58.1

68.8

64.2

63.5

67.6 107.9 56.4 59.5

62.9 125.9 57.4 57.9

77.2 123.5 61.9 54.3

113.6 73.6

94.2 85

110.2 95

122.3 75.5

178.3 115.3

105.2 77.7

57.8 127.1 168.8.2 62

87.8 123.4 85 49.5

65.6 143 98.5 68.5

59.3

57.3

56.7

76.3 90.2 155 70.5 70.6

68.5 57.8 152.7 52.4 75.9

54.3 56.1 146.8 160.8 68.9

65.6 82.5

109.4 101.8

107.7 107.8

104.1 61.6

96.9 64.2

98.8 68.5

Vol. 1


64 57.9 153.5 70.1 78.8

60.9 56.4 161 72.1 72.9

75.6 74.2

65.6 66.6 68.3 63.3

69.4 84.5 99.7 64.7 58.4

76.3 61.5 99.7 61.6 56.4

61.3 62.3 53.4 48.9 114 128.3 65.9 198.1 74.4 75.2 68.4 64.6

93.1 83.1 67.3 54.8 98.5 129.3 76.5 63.9 60.6

62.9 63.1 66.6 171.1 185 63.9 63 67.4 62.3

59.3 69.3 64.4

86.5 61.3 175.4 112 61.4 62.4

64.2 71.1

66 121

64.1 57.2 58.9 58.2

74.5 56.9 56.8 55 60.1 65.2 64.1 80.1

59 56.8 44.8 71.9

57.7 63.9

60.4 57.3 59.2 55.8

60.1 65.7

66.3 67.5

63.6 63.4 60.4 64.3

66.1 65.8

74.4 62.5 63.8 52.1 44

50.7 70.2 59.5 50.6 50.1

60.8 64.2 80.3 54.7

57.7 66 64.1 80.1

98.8 88.4 82.5

75.4 62.5 99.2 71.4

57.9 70.6


54.8 60.7 177.6 190.2 64.3

56 67.2 83 59.3 94.2 101.5 58.9 60.4 70.6 64.4 Rear side 60.2 68.7 63.3 68.1 59.8 55.8 59.3 58.3 1 Level Down (1st left 1st Right) 75.6 56.7 59.4 73.5 60.8 61.6 130.5 91.4 105.9 54.6 65.1 66.2 76.8 69.7 1st Front side 62.3 69.2 121 116.5 66.1 94.9 56.2 71.9 60.6 65.5 1st Rear side 82.6 71.6 63.7 110.3 72.8 62.1 66.2 68.5 (2nd left 2nd Right) 53.8 55.8 60.3 54.7 53 55 79.7 61.1 56.5 49.2 61.4 64.2 49.7 69 2nd Front side 59.7 57.3 56.4 53.8 69.7 64.3 65.8 54.9 2nd Rear side 63.5 70.2 75.3 69 66.9 68.4 70.2 64.6 1 Level Down 56.9 51.1 49.2 48.3 55.9 48.1 60.1 66.6 45 58.1 75.5 54.3 62.4 64 Front side 58.5 56.2 52.8 53.8 61.5 58.2 99.2 55.6 Rear side 37

67.8 137.7 178.1 56.4 70.4

67.5 181.20 157.2 70.1 58.9

67.3 100 140.4 60.3 67.6

74 56.3

66.4 60.6

76.6

63.8 72 111.5 68.7 70.2

56.9 74.5 150.2 71.3

57.8 90.2 174.9 68.9

107 61.2

105.5 66.4

78 65.6

115.2 70.5

94.9 65.8

107.2 65.8

58.5 84.7 61.2 66.9 50.2

58.8 55.2 60 54.3 51.2

62.9 56.3 54.2 58.9

65.9 69.5

66.8 66.3

64.2 65.6

64.5

64.4

64.4

114.5 53.8 44 58.6 41.7

72.5 57.4 64 59 45

72 76.9 63.8 60.2 49.2

42.5 56.4

99.8 58.1

75.4 78.1

Vol. 1


72.9 68.5 59.7 105.5 72.8 96.2 61.8 77.6 69.4

62.6 61.1 75.5

51.5 55.1 67.9 68.9

54.3 46.3 44.6 68.9

55.5 50.9 53.5 53 44.7 73.8 72.3 66.2

122.4 41.6 84 92.60 61.4 45.1 46.6 48.6 53.5 65.8

58.2 53.6 42.4 40.3

45.1 60.4

70.3 55 57.8 100 46.4 44.3

62 54.2 115 112 45 81.3

56.3 83.6 96.2 60.8 56.4

58.7 77.3 124 63.2 75.6 49.4

62.4 56.8 55.8 78.1 101.9 88.8 72.5 153.6 62.5 55.3 57 60.9 61.4 61.2 57.5 69.4 103.2 120 80.5 101.7 62.2 65.1 60.1 64

51 53 109.4 47.3 43.1 41.5

46 49.2 112 48.2 50.1 50.1

40.5 40.7 45.6 54.5 93 147.6 59.4 96 41.8 46 52.2 46.4

47.5

46 43.8 50.1 41.5

47.3 46.1

45.2 35.4

38.7 40.4 59.1 54.2

39.2 45.3


59.1 69.2 76.1

53.4 69.3 62.3 64.2 74.9 73.2 80.1 131 72.7 1 Level Down 49.7 51.7 62.9 71.8 59.4 48.3 75.6 44.3 50.9 54.3 52.2 Front side 79.3 113 85 62 42.8 53.8 42.5 Rear side 56 54.7 54.8 54.5 79.6 49.9 40.3 39.9 1 Level Down 61.3 61.7 70.4 118.1 60.6 62.9 108 109 110.6 64.5 46 61 86.4 55.6 69.1 54.2 54.2 Front side 66.1 66.7 67.5 74.8 129.7 117 128 72.8 55.8 64.5 56.8 60.6 Rear side 60.1 64.7 59.1 58.7 121.4 61.2 57.1 63 64.1 62.6 72.3 60.2 1 Level Down 38.9 48.8 46.1 43.4 38.9 41.3 43 42.4 40.8 85 105 103.8 47.2 55.4 44.6 44.5 48.3 38.9 Front side 53.4 42.5 52 47.7 44.3 55.8 44.6 48.2 Rear side 47.4 54.8 42.5 50.8 38.9 36.6 41.2 42.8 Average – 72.7

38

99.2 64.3

103.2 59.8

95.6 56.4

111.9 47.5 51.2 55.4

64.1 41.9 48.4 56

46.4 43.7 60.5

51.3

58.4

61

52.7

52.8

66.1

60.1 46.7 105.9 102.7 70.7 56

77.6 53 86 100.8 67.3 57.1

59.9 58.3 120 92.8 72.3 64

87.1 55.3

90.3 47.4

90.6 46.3

121.4 57.8

75.4 74.2

85.4 61.5

42.1 48.1 48.2 108.9 55.8 40.4

47.3 45.6 128.3 105.4 44.3

40 46.4 130.3 92 46.1

48.9 56.1

43.9 84.1

50.2 49.9

37.8 36.2

46.3 38.4

42.8 37.5

Vol. 1



Table 13: Thermal Performance of air pre-heaters Sl. Particular No. Oxygen in flue gas 1 Before APH 2 After APH Flue gas temp 3 Before APH 4 After APH ∆T 5 Air temperature 6 After APH 7 Before APH ∆T 8 Air flow 9 Total [a] Leakage 10 APH in-leakage [a] 11 APH in-leakage Thermal load

Operating (SAPH) LHS RHS

Unit

Design

% %

3.6 4.56

4.0 5.2

3.9 6.2

ºC ºC ºC

298.0 139.0 159.0

379.4 153.2 226.2

399.9 155.0 244.9

ºC ºC ºC

273.0 33.0 240.0

285.9 35.6 250.3

286.0 35.6 250.4

t/h

257.6

134.6

126.5

t/h %

19.7 7.65

12.5 9.32

26.9 21.26

12 Thermal load MWt 17.8 9.7 9.1 [a] Total air flow and APH in-leakage in design column indicates for both the APH ∆T - Differential temperature

39

Vol. 1


Sl. Particular No. Oxygen in flue gas 1

Before APH

2 After APH Flue gas temp


Unit

Design

Operating PAPH

%

3.6

4.0

%

5.56

9.0

3

Before APH

ºC

298.0

373.5

4

After APH

ºC

139.0

152.8

∆T 5 Air temperature

ºC

159.0

220.7

6

After APH

ºC

274.0

308.4

7

Before APH

ºC

33.0

35.6

∆T 8 Air flow

ºC

241.0

272.8

9 Total Leakage

t/h

125.6

179.2

APH in-leakage

t/h

20.5

35.5

11 APH in-leakage Thermal load

%

16.29

19.79

MWt

8.7

14.2

10

12 Thermal load ∆T - Differential temperature

40

Vol. 1



Table 14: Flue gas temperature survey in boiler Sl.

Particular

Unit

Design

Operating

No.

Furnace outlet

0

973.0

--

02

SH Platen outlet

0

973.0

--

03

Reheater outlet

0

754.0

--

LTSH inlet

0

642.0

670.3

05

LTSH outlet

0

456.0

496.7

06

Economiser inlet

0

456.0

496.7

Airheater inlet

0

298.0

384.2

Airheater outlet

0

139.0

153.7

01

04

07 08

C C C C

C C C C

Table 15: Flue gas pressure survey in boiler Sl. No.

Particular

Unit

Design

Operating

01

Furnace

mmWc

-4.0

-7.6

02

SH Platen inlet

mmWc

-4.0

-7.6

03

Reheater inlet

mmWc

-5.0

-5.6

04

LTSH inlet

mmWc

-10.0

-10.5

05

Economizer inlet

mmWc

-20.0

-14.7

06

Air pre heater inlet

mmWc

-40.0

--

07

ESP inlet

mmWc

-109.0

-104.8

08

ID fan inlet

mmWc

-154.0

-176.9

09

ID fan outlet

mmWc

+16.0

-1.2

Table 16: Specific heating surfaces (Calculated) Sl.No. 1 2 3 4 5

6 7

Particulars

Unit

Specific furnace volume Specific Effective Projected Radiant Surface area Specific super heater area

3

m /MW

22.19

m2/MW

15.59

2

32.59

2

12.25

2

38.39

2

274.54

2

64.78

m /MW

Specific reheater area

m /MW

Specific economizer area

m /MW

Specific air preheater area

m /MW

Specific condenser area

m /MW

41

3

Vol. 1



Table 17: Performance of economizer SL. No.

Particulars

Unit

Design

Operating

01

Feed water temp. before economizer

ºC

234.0

224.2

02

Feed water temp. after economizer

ºC

286.0

291.6

03

Feed water flow through economizer

t/h

352.2

387.6

04

Thermal Load (Water side)

MWt

41.0

58.2

Table 18: Performance of water walls SL. No.

Particulars

Unit

Design

Operating

kgf/cm2

140.8

135.9

01

Boiler drum pressure

02

Saturation temp. at drum pressure

ºC

337.2

334.4

03

Water temp. at outlet of economizer

ºC

286.0

291.6

04

Degree of sub-cooling of water entering water walls

ºC

51.2

42.8

05

Evaporative water wall load

MWt

103.2

115.8

06

Sub-cooled water wall load

MWt

29.4

26.9

07

Total thermal load

MWt

132.6

142.7

42

Vol. 1



Table 19: Condition assessment of steam generator components Sl. No. Particular Observation 01 Boiler 1.1 Furnace and water walls Tubes panel flatness OK Tube swelling OK Damage from falling slag No Condition of ash hopper OK refractories Furnace fire ball symmetry Coal flow equalization to be done Condition of fire ball Not uniform Water wall deposit Internal deposits suspected Gas side corrosion Not observed Erosion from soot blowers Not Observed Furnace gas tightness OK 1.2 Ring header Presence of debris & corrosion Minor debris; corrosion absent 1.3 Economizer Alignment of assemblies Distorted/deteriorated tubes to replaced Condition of welds, attachments, OK supports, spacers, shields baffles Ash erosion No Condition of anti erosion devices OK 1.4 Super heaters Alignment of assemblies OK Condition of welds, attachments, OK supports, spacers, shields baffles Ash erosion No Condition of anti erosion devices OK Steam erosion Not observed LTSH OK Rear RH tubes OK 1.5 Soot blowers Condition of wall soot blowers OK & in service Condition of long retractory soot OK & in service blowers Manual/automation of soot Remote blowers 1.6 Coal burners Condition of coal burners OK Burner tilting mechanism Operative in gang operation 1.7 Condition cladding

of

Insulation, lagging and cladding insulation and OK

43

be

Vol. 1

1.8

1.9

02 2.1

2.2

03 3.1

04 4.1

05 5.1



Valves and dampers Boilers stop valves OK Safety valves (drum S/H, R/H) OK Attemperator/spray valves OK Isolation valves Not passing Drain valves All dampers OK Pent house General cleanliness (ash Clean accumulation) Integrity of header/drum OK supporting arrangement/ attachment welds Gas tightness OK Corrosion of pent house casing No Piping Steam generator integral piping Condition of fixed & variable OK supports Deformation of pipes Not observed Saddle weld for cracking Not observed Steam generator hanging system and structure Condition of beams, supports, Not observed washer springs fittings etc. Deformation, cracks and loss of Not observed strength due to corrosion of various structural members Corrosion of hanger tie rods Not observed Ducts Air/gas ducts Air/gas tightness Leakage observed Expansion joints OK No leakage seen Dampers Ok Duct supports and hangers OK Corrosion of dampers/stiffness/ Not observed baffle plates etc. Corrosion of ducts work Not observed downstream of air heaters General condition of wind box OK Air Pre-heater Basket including any low Cold end elements eroded. Corrosion temperature corrosion not observed. Axial and Radial seals Deteriorated Sector plates Deteriorated Expansion joints OK PF piping Pulverized fuel piping for erosion OK 44

Vol. 1



Table 20: Leakages in the boiler and associated equipment

Particulars

SL. No.

Gradating A –E

01

Coal leaks from adjoining bunker conveyors

B

02

Coal leaks from coal pipes

B

03

Coal leaks from mill area including reject gates

B

04

Steam leaks from main piping (valve passing, drain leaks, safety valve opening)

A

05

Steam leaks from auxiliary steam lines (soot blowing lines, oil heating/atomizing lines, sampling lines, spray lines, etc.)

B

06

Hot air leaks (wind box area, air ducts, APH, etc.)

B

07

Flue gas leaks (boiler puffing, flue duct leaks, etc.)

A

08

Heat leaks (boiler skin insulation, duct insulation, main pipe insulation, auxiliary piping insulation, insulation of valve bodies, etc.)

B

09

DM water leaks

A

10

Soft water leaks

A

11

Overall cleanliness gradation

B

Scale of cleanliness: A: no B: insignificant leaks leaks

C: significant leaks

45

D: major leaks

E: excessive leaks

Vol. 1



Table 21: Performance of steam turbine Sl.

Unit

Particular

No.

Design

Operating

(MCR)

01

Plant load

MW

120.00

119.14

02

Main steam flow

t/h

355.6

387.4

03

Specific Steam consumption (SSC)

t/MWh

2.96

3.25

04

Turbine efficiency

%

44.46

39.67

05

Turbine heat rate

kcal/kWh

1934.53

2167.97

06

Turbine heat rate

kJ/kWh

8098.04

9075.22

Table 22: Losses in the turbine-condenser system Unit

Sl.No.

Particular

01

Poor main steam temperature and pressure than

Operating

design

MWm

0.05

Poor re-heat steam temperature and pressure than design

MWm

0.14

03

Loss due to re-heat spray

MWm

0.04

04

Higher than design absolute pressure at the condenser

MWm

0.13

02

5.1 Loss in turbine internals – HPT

MWm

0.0

5.2 Loss in turbine internals – IPT

MWm

1.65

5.3 Loss in turbine internals – LPT

MWm

5.11

5.0

Deterioration in turbine performance due to irreversibility

MWm

6.76

06

Loss of thermal energy in condensate sub cooling

MWm

0.00

07

Total loss of work in the turbine-condenser

MWm

7.12

46

Vol. 1



Table 23: Steam temperature survey in turbine

SL. No.

Particulars

01

MS temperature at HPT inlet

02 03 04 05

06 07 08 09

10

Unit

Design (MCR)

Operating

0

535.0

531.2

CRH temperature

0

342.0

352.0

HRH temperature

0

535.0

534.0

HPH-6 Extraction

0

340.0

336.5

HPH-5 Extraction

0

398.0

411.9

Deaerator Extraction

0

281.0

299.1

LPH-3 Extraction

0

195.0

238.3

LPH-2 Extraction

0

105.0

196.7

LPH-1 Extraction

0

NA

NA

Exhaust hood temp

0

46.4

55.7

C

C C C

C

C C C

C

C

Table 24: Steam pressure survey in turbine

SL. No.

Particulars

Unit

Design (MCR)

Operating

01

MS pressure at HPT inlet

kgf/cm2

127.0

119.2

02

CRH pressure

kgf/cm2

32.0

32.9

HRH pressure

kgf/cm

2

28.8

30.3

2

29.5

32.3

03

04

HPH-6 Extraction

kgf/cm

05

HPH-5 Extraction

kgf/cm2

06 07

08

Deaerator Extraction LPH-3 Extraction

LPH-2 Extraction

09

LPH-1 Extraction

10

Condenser vaccum

10.6

12.6

kgf/cm

2

3.8

6.0

kgf/cm

2

1.19

2.1

kgf/cm

2

0.17

0.7

kgf/cm

2

NA

NA

10.6

12.0

kPa

47

Table 25: Feed heater data for UNIT – 3

Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Particular FW inlet temperature FW outlet temperature Specific heat capacity of FW FW flow Ext. steam pressure Ext. steam temperature Ext. steam sat. temperature Ext. steam enthalpy Drain temperature Enthalpy of sub cooled liquid Heat gained by Feed water Heat released by Ext. Steam Steam flow through the heater TTD DCA Degree of subcooling of drain Steam flow through the heater

Unit o

C C kJ/kgo K kg/s kgf/cm2 o C o C kJ/kg o C kJ/kg kWthermal kj/kg kg/s o C o C o C t/h o

HPH – 6 Design Operating 185.00 178.40 233.60 224.10 4.58 4.54 98.78 109.35 29.50 32.30 340.00 336.50 234.50 237.73 3111.25 3101.09 192.00 190.10 816.72 808.32 22010.5 22684.4 2294.5 2292.8 9.6 9.9 0.9 13.6 7.0 11.7 42.5 47.6 34.53 35.62

HPH – 5 Design Operating 152.00 158.80 185.00 178.40 4.39 4.39 98.78 109.35 10.60 12.60 398.00 411.90 186.40 190.11 3259.89 3287.87 158.00 164.80 666.57 696.19 14303.8 9400.7 2593.3 2591.7 5.5 3.6 1.4 11.7 6.0 6.0 28.4 25.3 19.86 13.06

Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Particular FW inlet temperature FW outlet temperature Specific heat capacity of FW FW flow Ext. steam pressure Ext. steam temperature Ext. steam sat. temperature Ext. steam enthalpy Drain temperature Enthalpy of sub cooled liquid Heat gained by Feed water Heat released by Ext. Steam Steam flow through the heater TTD DCA Degree of subcooling of drain Steam flow through the heater

Unit o

C C kJ/kgo K kg/s kgf/cm2 o C o C kJ/kg o C kJ/kg kWthermal kj/kg kg/s o C o C o C t/h o

LPH – 3 Design Operating 92.00 96.80 119.50 124.90 4.21 4.22 80.36 89.14 1.19 2.10 195.00 238.30 123.24 121.90 2865.02 2949.73 98.00 102.00 411.22 428.03 9305.6 10566.3 2453.8 2521.7 3.8 4.2 3.7 -3.0 6.0 5.2 25.2 19.9 13.65 15.08

LPH – 2 Design Operating 68.00 70.20 92.00 96.80 4.20 4.20 80.36 89.14 0.17 0.70 105.00 196.70 104.20 90.03 2694.88 2871.21 74.00 79.40 310.54 333.21 8095.9 9953.6 2384.3 2538.0 3.4 3.9 12.2 -6.8 6.0 9.2 30.2 10.6 12.22 14.12

LPH – 1 Design Operating 50.00 55.20 68.00 70.20 4.21 4.21 80.36 89.14 -0.10

2553.04 71.00 246.00 6089.9 2307.0 2.6

21.0 9.50

79.40 5626.1

24.2

Vol. 1



Table 26: Condition assessment of steam cycle components Sl. No.

Particular

Remark/observations

01 1.1

Turbine Piping MS & RH steam piping Cross over piping HP/LP turbine bypass Exhaust hood Cladding of piping

OK OK OK OK OK

1.2

1.3

1.4 02

03

04

Valves Emergency stop valves OK Control valves OK Extraction valves OK NR valves OK Main steam flow paths & sealing passages Inlet nozzle chambers OK Diaphragms OK Stationary and moving blades OK Inter blade clearances OK HP, IP & LP sealing at inlet and exit side OK Governing system Speed governor OK Condenser Shell OK Tubes OK Water box Minor leakage observed Expansion joint with LPT casing OK Feed water heaters HP regenerative feed water heaters Cleaning of tube nest required LP regenerative feed water heaters OK Deaerator OK Heat recovery devices Gland steam condenser OK Vent steam condenser OK Stack steam condenser OK

48

Vol. 1



Table 27: Thermal performance of Condenser Sl.

Particulars

Unit

Design

Operating

No.

01

Temperature at LPT exhaust

0

C

46.4

55.7

02

Condenser absolute pressure

kPa

10.6

12.0

03

Saturation condenser

0

46.4

49.4

Condensate depression

0

0.0

-6.3

TTD across condenser

0

3.4

2.4

CW inlet temperature

0

34.0

37.3

07

CW outlet temperature

0

43.0

47.0

08

Rise

0

C

9.0

9.7

Vacuum loss due to the higher cooling water inlet temperature

kPa

--

--

Vacuum loss due to lower cooling water flow

kPa

--

--

kPa

--

1.4

04

05 06

in

temperature

in C

circulating

C

C C C

water

temperature

09 10 11

Vacuum loss due to dirty tubes, lowered area of condenser, inleakage of cooling water, air ingress in condenser and inadequate capacity of air removing vacuum pump.

Table 28: Performance of cooling tower – 3 Particular

Unit

Design

Trial-1

Trial-2

Trial-3

Cooling water inlet temperature

o

43.0

42.5

42.6

42.7

Cooling water outlet temperature

o

33.0

35.7

35.7

35.7

Inlet dry bulb temperature

o

NA

31.8

31.4

31.1

Inlet wet bulb temperature

o

28.8

26.3

26.6

26.7

Range

o

10.0

6.9

6.9

7.0

Approach Effectiveness

o

4.2 70.4

9.3 42.4

9.1 43.0

9.0 43.8

C

C C

C

C

C %

49

Vol. 1



Table 29: Capacity adequacy of auxiliaries of Unit 3 at test load of 119.14 MW (99.28 % of MCR) Unit 3 : Load: 119.14 MW Rating, kW

Operating power, kW

Load factor at test load

Load factor at 100 % MCR

BFP 3A

2000

1450.48

0.73

0.74

BFP 3B

2000

1449.27

0.72

0.74

BFP 3C

2000

1072.87

0.54

0.55

CEP 3A

250

233.31

0.93

0.95

CEP 3B

250

224.93

0.90

0.92

ID fan 3A

680

493.92

0.73

0.74

ID fan 3B

680

418.83

0.62

0.63

FD fan 3A

480

284.09

0.59

0.60

FD fan 3B

480

289.22

0.60

0.61

PA fan 3A

675

306.33

0.45

0.46

PA fan 3B

675

295.48

0.44

0.45

Mill 3A

300

225.28

0.75

0.76

Mill 3B

300

171.63

0.57

0.58

Mill 3D

300

274.99

0.92

0.93

Mill 3E

300

254.62

0.85

0.86

CWP 3A

765

575.60

0.75

0.77

CWP 3B

765

525.26

0.69

0.70

Air Compressor 3C

754

598.93

0.79

0.81

Equipment

50

Vol. 1



Table 30: Review of operation procedures of Unit 3 Sl. No. 01

02

Procedure

CPRI remarks

Pre-operation procedures

OK

Clean up

OK

Chemical cleaning

OK

Blowing steam lines

OK

Setting safety valves

OK

Cold start up

OK

Pre-light up

OK

Initial firing

OK

Light off

OK

03

Hot start up

OK

04

Warm start up

OK

Normal operation

OK

05

Increasing load

OK

Decreasing load

OK

06

Normal shut down

OK

07

Emergency procedures

OK

08

Procedures adopted optimization

for

51

operational

OK

Vol. 1



Table 31: Gross efficiency, heat rate and specific fuel consumption

Sl. No. 01 02

Particular

Unit Efficiency

Design efficiency

overall

Operating efficiency

overall

Gross

%

38.16

%

33.37

kcal/kWh kJ/kWh

2253.47 9433.11

Heat rate 03

Design unit heat rate

04

Operating unit heat kcal/kWh 2577.07 rate kJ/kWh 10787.72 Specific Fuel Consumption (SFC) at test coal

05

Design SFC

kg/kWh

0.48

06

Operating SFC

kg/kWh

0.55

Table 32: The deviations in gross overall efficiency from design

Operating

Particular

Sl. No.

Difference in components efficiency from design (% points) 01

Boiler

1.72

02

Turbine

4.79

03

Generator

0.02

04

Auxiliary steam

Considered separately

05

Auxiliary power


Deviation in gross overall efficiency (% points) 06

Boiler related losses

0.71

07

Turbine related losses

4.07

08

Auxiliary steam related losses

09

Generator related losses

0.01

10

Total deviation from design efficiency

4.79


52

Vol. 1



Table 33: Causes for deviation of gross heat rate from design

Sl. No. 01 02

Particular

(kcal/kWh) Difference in the boiler efficiency from the design efficiency given by the manufacturer

04

48.10

Difference in the turbine efficiency from the design efficiency given by the manufacturer

03

Value

275.01

Difference in generator efficiency from the design efficiency given by the manufacturer Due to steam consumption in the boiler, turbine and auxiliary steam requirements such as blow down, gland steam, vent steam, stack steam, loss through steam traps, steam tracing and fuel oil tank heating, giving rise to proportional make up Total difference in gross heat rate

53

0.49 Considered separately 323.6

Vol. 1



Annex – 3 (Procedures, Calculations & Spread sheets)

1

Vol. 1



A 3-1: Efficiency, specific fuel consumption and heat rate Q

η

Boiler

η Turbine =

=

Steam from boiler

Q

Fuel in to boiler

PMechanical from turbine Q steam to turbine

η Auxiliary steam =

QSteam to turbine QSteam from boiler

PElectrical from generater η Generater = PMechanical to generator

PElectrical sent out to generator PAuxiliary power = PElectrical generated

η Net overall = η BoilerηTurbineη Auxiliary steamηGeneratorη Auxiliary power 2

Vol. 1



η Gross overall = η BoilerηTurbineη Auxiliary steamηGenerator The detailed formulae are given as follows:

The overall performance of the composite unit can be estimated by using the individual component performance as inputs. Efficiency is the ratio of the rate of energy output to the rate of energy input to the system under consideration. The performance indices are defined as: i.

η

o, g

Gross overall efficiency (ηo,g)

=

P =η η η η Q

(1)

O

B

S

T

G

I

ii.

Net overall efficiency (ηo,n)

( − ) η = P P =η η Q O

A

o ,n

O,g

(2)

A

I

Where PA is the auxiliary electrical power. The component efficiencies are defined as follows: iii.

Boiler (ηB)

ηB) is the ratio of the rate of energy output of steam produced Boiler efficiency (η at the boiler outlet to the rate of the energy input in raw coal at the mill inlet.

η

B

=

Q Q

B,s

(3)

I

Where QB,s is the rate of energy flow in steam produced by the boiler (in case of steam generation) . iv.

Turbine efficiency (ηT)

Turbine efficiency (η ηT) is the ratio of the rate of energy output at the shaft to the net rate of energy in steam supplied from the boiler to the turbine.

3

Vol. 1

η

T

=



P Q

T

(4)

T ,s

Where QT,s is the rate of energy flow in steam drawn by the turbine (in case of steam turbine). PT is the rate of mechanical energy output of the turbine. v. Generator efficiency (ηG) ηG) is the ratio of the rate of electrical energy output at the Generator efficiency (η generator terminal to the rate of energy output at the turbo-generator shaft.

η

G

=

P P

O

(5)

M

Where PM is the mechanical shaft output of the turbine (gas turbine or steam turbine). vi. Auxiliary power efficiency (ηA) Auxiliary power efficiency (η ηA) is the ratio of the rate of energy output exported from the station to the corresponding rate of energy output at the generator terminal.

η

A

=

P −P P O

(6)

A

O

vii.

Auxiliary steam efficiency (ηS)

Auxiliary steam efficiency (η ηS) is the ratio of the rate of energy output in steam supplied to the turbine to the rate of energy output produced at the boiler outlet. This efficiency is included to take into account any auxiliary steam consumption and differences between the steam output of the boiler and that of the turbine.

η

S

=

Q Q

T ,s

(7)

B ,s

This refers to the usage of auxiliary steam in between the boiler outlet and the turbine inlet. 4

Vol. 1


Specific fuel consumption (SFC)

viii.

SFC =


3.6 m P

f

(8)

O

Where mf is the rate of primary fuel consumption ix.

HR =

Unit heat rate (UHR) 3600

η

(9)

o, g

The HR is with reference to gross overall efficiency (gross heat rate). x.

Turbine heat rate (THR)

3600

HR =

η

(10)

T

The THR is the turbine efficiency (turbine heat rate). xi.

η

is

=

Turbine isentropic efficiency (ηis,T)

∑m ∆h ∑m ∆h s

u

s

is

(11)

where ∆his is the isentropic enthalpy change (flow weighted) across the turbine and ∆hu is the net useful enthalpy change (flow weighted) across the turbine (the enthalpy change which has been converted into work plus the enthalpy change which has led to heat transfer from the turbine skin). Isentropic efficiency refers to the fraction of enthalpy difference that is convertible into work.

5

Vol. 1



Procedure for efficiency testing of boilers Efficiency tests were performed on the unit as per BIS 8753:1977.

Conditions maintained for boiler efficiency tests The following conditions are maintained: i.

Unit must run on3/4th of the test load (TMCR) or more for the last 12 hours

ii.

Unit must run at near test load(rated load) (TMCR) for the last 2 hours

iii.

Setting period before the test: 60 minutes

iv.

Test period: 120 minutes (load to be held constant)

v.

Further run on period after test: 15 minutes

vi.

Coal from the same source must be used for the past 24 hours

vii.

Bunker level at the time of start of test: Full or near to full

viii.

Steam output variation during the test: less than 3% of the value test value

ix.

Steam pressure variation during the test: less than 6% of the test value

x.

Intermittent blow down must be reduced to nil

xi.

CBD & MS attemperation flow must be kept constant.

xii.

Drum, de-aerator and hot well levels must be maintained steady

xiii.

All HP and LP heaters must be in service

xiv.

Wherever possible all re-circulation flows HP/LP heater bypass, HP/LP turbine bypass and valve passing must be reduced to nil

xv.

Steam/water lines to service/station requirements, drains on valves and heaters, auxiliary requirement

xvi.

Fuel oil must not be used during the test

xvii.

A fuel soot blowing cycle must be carried out before the test

xviii.

Wherever possible all maintenance, mill rejection, etc. must be stopped during the test

xix.

All unit auxiliaries must be measured before and after the test.

xx.

Operators both at the local site and at the control room must be informed in advice.

6

Vol. 1



Duration of the test: Two hours excluding one hour stabilization period prior to the test.

Data collection during the test: Readings were taken from the control room instruments at regular interval of fifteen minutes. The readings were taken half an hour before the start of the test followed by every fifteen minutes till the completion of the test.

Samples collected during the tests 1.

Raw coal to be collected about 500 gm of 2 samples of which one sample to be analyzed for proximate and CV analysis. Another sample to be handed over to CPRI.

Period of collection: to be collected after one hour from the start of the test.

2.

Pulverized coal for sieve analysis- from each mill in service from all 4 corners to constituting a total weight of about 200 gm sieve analysis of these samples to be carried out.

Period of collection: to be collected after one hour from the start of the test.

3.

Fly ash and bottom ash to be collected during the cycle followed by the test and unburnt test to be carried out.

Period of collection: to be collected during the cycle immediately followed by the test. 4.

Orsat analysis of flue gas at before and after the APH in both LHS and RHS. Percentage of CO2, O2 and CO to be analyzed.

Period of collection: to be collected half an hour after the start of the test and the

7

Vol. 1



second sample to be collected after one and half an hour from the start of the test.

Procedure for efficiency testing of turbines Conditions maintained for turbine efficiency test The following conditions are maintained: (1)

Unit must run on 3/4th of the test load or more for the last 12 hour

(2)

Unit must run at near test load (rated load) for the last 2 hours

(3)

Settling period before the test: 60 Minutes

(4)

Test period : 120 Minutes (load to be held constant)

(5)

Further run on period after test : 15 Minutes

(6)

Coal from the same source must be used for the past 24 hours

(7)

Bunker level at the time of start of test;

(8)

Steam output variations during the test: less than 3% of the test value

(9)

Steam pressure variations during the test: less than 6% of the test value

(10)

Intermittent blow down must be reduced to nil

(11)

CBD & MS attemperation flow must be kept constant

(12)

Drum, de-aerator and hot well levels must be maintained steady

(13)

All HP and LP heaters must be in service

(14)

Wherever possible all re-circulation flows. HP/LP heater bypass. HP/LP turbine bypass and valve passing must be reduced to nil

(15)

Isolation of the following is required: large volume storage tanks, by pass systems, auxiliary steam lines, drain lines on stop, interceptor and control valves; interconnecting lines to other units, steam coil APH,DM water equipment, soot blowers, heater shell drains, heater drain bypass, steam/water lines and turbine washing lines

(16)

All Unit auxiliaries must be kept in constant condition during the test

(17)

Bunker level must be measured before and after the test

(18)

Operators both at the control room must be informed in advance

8

Vol. 1



Duration of the test: Two hours excluding one hour stabilization period prior to the test

Data requirement: Readings were taken from the control room instruments at regular interval of fifteen minutes. The readings were taken half an hour before the start of the test followed by every fifteen minutes till the completion of the test.

9

Vol. 1



Boiler efficiency calculation Sl. No.

Particular

Unit

Unit # 3

kcal/kg

4623

1

Gross calorific value of fuel (HCV)

2

% of Carbon in fuel

%

47.22

3

% of Sulphur in fuel

%

0.60

4

% of moisture in fuel

%

6.60

5

% of ash in fuel

%

38.93

6

% of Hydrogen in fuel

%

3.20

7

% of Oxygen in fuel

%

6.55

8

% of UB in bottom ash

%

5.60

9

% of UB in fly ash

%

1.90

Bottom ash temp.

o

900.00

11

Fly ash temp.

o

C

153.67

12

Sp. Heat of bottom ash

kJ/kgK

1.05

13

Sp. Heat of fly ash

kJ/kgK

0.84

14

CO in flue gas

ppm

350.00

15

% O2 in flue gas after APH

%

6.76

FG temp. at APH outlet

o

153.67

17

Ambient air temperature

o

C

35.61

18

Humidity fraction of ambient air

kg/kg

0.0206

19

Mill input shaft power

kW

926.51

20

PA Fan input shaft power

kW

601.82

21

FD Fan input shaft power

kW

573.32

22

Avg. furnace skin temperature

23

Furnace outer surface area

24

Calorific value of CO

25 26

10

16

27 28

C

C

o

C

72.70

m2

1629.50

kJ/kg

10092.40

% O2 in flue gas before APH

%

4.14

% O2 in furnace

%

4.14

Leaking FG temp. at first pass

o

C

0.00

--

0.00

FG puffing factor in first pass

10

Vol. 1



Boiler efficiency calculation (Contd…) Sl. No.

Particular

Unit

Unit # 3

29

Gross calorific value of fuel (HCV)

kJ/kg

19351.88

30

Net calorific value of fuel (LCV)

kJ/kg

18648.63

31

CO2 in flue gas (Computed from O2)

%

12.58

32

Mass of air required for combustion

kg/kg

6.84

33

Heat loss due to unburnt CO

kJ/kg

33.62

34

Excess air factor at furnace

--

1.25

35

Excess air factor at APH inlet

--

1.25

36

Heat loss due to puffing in furnace first pass

kJ/kg

0.00

37

Loss due to bottom ash

%

0.76

38

Loss due to fly ash

%

1.03

39

Loss due to sens. Heat of bottom ash

%

0.37

40

Loss due to sens. Heat of fly ash

%

0.16

41

Loss due to unburnt CO in flue gas

%

0.17

42

Loss due to sens. Heat in dry FG

%

5.77

43

Loss due to moisture in fuel

%

0.90

44

Loss due to hydrogen in fuel

%

3.91

45

Loss due to moisture in comb. Air

%

0.16

46

Loss due to convection

%

1.06

47

Loss due to radiation

%

0.50

48

Heat equivalent of auxiliary power

%

-0.11

49

Heat loss due to puffing in furnace first pass

%

0.00

50

Total losses

%

14.69

51

Thermal efficiency

%

85.31

Correction factor to account for 52

annual average station GCV

53

Corrected test boiler efficiency

0.00

11

%

85.31

Vol. 1



Turbine efficiency calculation Sl. No.

Particular

Unit

Unit # 3

1

MS flow into turbine

t/h

387.35

2

HRH flow

t/h

355.34

3

RH spray

t/h

1.10

4

Plant load

MW

119.14

5

Enthalpy of MS

kJ/kg

3437.63

6

Enthalpy of HRH

kJ/kg

3533.54

7

Enthalpy of CRH

kJ/kg

3133.24

8

Enthalpy of RH spray

kJ/kg

710.10

9

Enthalpy of FW at oulet of final feed heater

kJ/kg

981.28

10

Generator efficiency

%

98.61

11

Generator efficiency

fraction

0.99

12

THR

__

2.52

13

Turbine heat rate

kJ/kWh

9075.22

14

Turbine heat rate

kcal/kWh

2167.97

15

Turbine efficiency

%

39.67

16

Specific steam consumption

t/MWh

3.25

12

Vol. 1



Overall efficiency calculation Sl. No.

Particular

Unit

Unit # 3

1

Boiler efficiency (Operating)

%

85.31

2

Turbine efficiency (Operating)

%

39.67

3

Generator efficiency (Operating)

%

98.61

4

Auxiliary power (Operating)

MW

0.0

5

HCV of fuel

kcal/kg

4723

6

MS flow to turbine (Operating)

t/h

387.35

7

Auxiliary steam flow (Operating)

t/h

0

8

RH spray (Operating)

t/h

1.10

9

Cont. blow down (Operating)

t/h

0.0

10

Intermittent blow down (Operating)

t/h

0.0

11

MS enthalpy (operating)

kJ/kg

3437.63

12

RH spray enthalpy (operating)

kJ/kg

710.10

13

Aux. Stm. Enthalpy (Operating)

kJ/kg

3076.4

14

Blowdwon enthalpy (Operating)

kJ/kg

0.0

15

Gross overall efficiency (Operating)

%

33.37

16

Plant load (Operating)

MW

119.14

17

Net overall efficiency (Operating)

%

33.37

18

Gross heat rate (Operating)

kcal/kWh

2577.07

kJ/kWh

10787.72

kcal/kWh

2577.07

kJ/kWh

10787.72

19

Net heat rate (Operating)

20

Operating gross SFC

kg/kWh

0.55

21

Operating net SFC

kg/kWh

0.55

22

Plant load (Design)

MW

120

23

Boiler efficiency (Design)

%

87.03

24

Turbine efficiency (Design)

%

44.46

25

Generator efficiency (Design)

%

98.63

26

Auxiliary power (Design)

MW

0.00

27

Aux. Power efficiency (Design)

%

1

28

MS flow to turbine (Design)

t/h

355.6

29

Aux. Steam flow (Design)

t/h

0

30

Aux. Steam efficiency (Design)

%

1.00

13

Vol. 1



Overall efficiency calculation (Contd…) 31

Aux. power efficiency (Operating)

%

1.00

32

Aux. Steam efficiency (Operating)

%

1.00

33

Gross overall efficiency (Design)

%

38.16

34

Net overall efficiency (Design)

%

38.16

35

Gross heat rate (Design)

kcal/kWh

2253.47

kJ/kWh

9433.11

kcal/kWh

2253.47

kJ/kWh

9433.11

36

Net heat rate (Design)

37

Design gross SFC

kg/kWh

0.48

38

Design net SFC

kg/kWh

0.48

Difference in efficiencies 39

Boiler

% pts

1.72

40

Turbine

% pts

4.79

41

Generator

% pts

0.02

42

Aux. Power

% pts

0.00

43

Aux. Steam

% pts

0.00

Deviation in net overall efficiencies (%pts) 44

Boiler related loss

% pts

0.71

45

Turbine related loss

% pts

4.07

46

Generator related loss

% pts

0.01

47

Aux. Power related loss

% pts

0.00

48

Aux. Steam related loss

% pts

0.00

49

Total dev. From design efficiency

% pts

4.79

SFC at various points in the circuit 50 51 52 53

SFC to produce unit electrical energy exported

t/MWh(net elec.)

0.55

SFC to produce unit electrical energy at the generator terminal

t/MWh(gross elec.)

0.55

SFC to produce unit mechanical

t/MWh

energy at turbine shaft

(mech.)

0.54

t/MWh (thermal)

0.21

SFC to produce unit energy in flue gas in furnace

14

Vol. 1



Overall efficiency calculation (Contd…) Saving in fuel 54

Saving in fuel

t/h

8.16

55

Saving in fuel

%

12.56

Deviation in gross overall efficiencies (%pts) 56

Boiler related loss

% pts

0.71

57

Turbine related loss

% pts

4.07

58

Generator related loss

% pts

0.01

59

Aux. Power related loss

% pts

0.00

60

Aux. Steam related loss

% pts

0.00

61

Total dev. From design efficiency

% pts

4.79

15

Vol. 1



Annex – 4 (Documents Copied)

1

Vol. 1



A 4-1: TRIPPING DATA.

Sl Date of No. outage

1

2

3

23.05.08

27.05.08

03.06.08

Date of Time syn

10:01

07:38

16:46

23.05.08

27.05.08

03.06.08

Duration Time (Hrs)

11:41

1.67

10:16

2.63

19:03

2.25

4

15.06.08

10:57

15.06.08

13:26

1.5

5

03.08.08

23:34

04.08.08

18:17

18.75

FaultInt/ext

Reason for shut down / Tripping

Energy lost (MWH)

Tripped

Boiler tripped on RH protection

200.4

Tripped

Boiler tripped on RH protection

315.6

Tripped

Generator tripped on reverse power

270

Tripped

Turbine tripped on condenser vacuum very low

180

Condenser Planned water box

6

22.08.08

09:50

22.08.08

13:02

3.2

Tripped

7

17.09.08

22:18

18.09.08

01:16

3

Tripped

8

28.09.08

16:35

28.09.08

18:12

1.63

Tripped

9

30.09.08

13:31

30.09.08

15:04

1.55

2

Tripped

cleaning Generator tripped on Class-A protection Flame Failure Flame Failure Condenser Pressure very high

2250

384

360 195.6

186

Vol. 1

10

11


25.11.08

17.02.09

14:16

16:32

25.11.08

17.02.09


14:38

0.37

18:08

1.6

44.4

Tripped

Boiler tripped on Flame failure

192

38.15

Total Time

Sl Date of No. outage

Tripped

Human error, during change over of Bus configuration for export.

4578

Time

Date of syn

Time

Duration (Hrs)

FaultInt/ext

Reason for shut down / Tripping

Energy lost (MWH)

170.4

1

09.06.09

13:15

09.06.09

14:50

1.42

Tripped

Over speed

2

01.08.09

04:05

01.08.09

07:06

3

Tripped

Boiler tripped on Flame Failure

3

11.08.09

07:51

11.08.09

10:24

2.55

4

09.09.09

03:03

09.09.09

07:05

4

5

03.12.09

05:22

03.12.09

07:50

2.5

6

23.12.09

18:09

13.47

Total Time

3

Boiler tripped on Flame Failure Turbine Tripped on Tripped Lub oil Pressure Very Low Boiler tripped Tripped on RH Protection Planned Desynchronised Tripped

360

306

480

300

1616.4

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66

TATA POWER COMPANY LIMITED JOJOBERA THERMAL POWER STATION JOJOBERA, JHARKHAND

Proposal for PC-Based Progress 3 Engineering cum Diagnostic Station and 800xA Human Machine Interface for 2 x 120 MW Units ABB OFFER NO: E.UAPS.RE.8.0052. R1 DATED 04. 05.2009 ENQUIRY REF : Site Visit of our Representative

TECHNO -COMMERCIAL PROPOSAL

ABB LIMITED PS – POWER GENERATION PLOT NO. 5 & 6, PHASE II, PEENYA INDUSTRIAL AREA BANGALORE – 560 058

ABB

Customer Project Offer No Enquiry ref

TPC Ltd, Jojobera Thermal Power Station Proposal for Progress3, and 800xA HMI E.UAPS.RE.8.0052. R1 dated 04.5.200 9 Site Visit of our Representative

ABB

1.0 Preface 2 x 120 MW TPC, Jojobera Thermal Power Station has Procontrol P13 make control system of ABB design with WSPose in units 2,3 as HMI. This system is utilized for realizing various functions required for control; monitoring and operation of the FSSS and ATRS of 120 MW power generating Unit # 2,3. The existing Procontrol system is provided with One Diagnostic station and Logic development station for each unit. The existing system in each unit is using 2 IPBs. Due to the age of the installed system and difficulty in maintenance and operation of the old hardware, there is a requirement to upgrade the control system HMI. The requirement is for HMI system that is Windows 2003/XP based compatible with the existing ABB make Procontrol System with no loss/degradation in functionality/performance. ABB offers tailor made solutions for upgrading/refurbishing the existing systems at minimum costs and without compromising on the system performance. The interface for P13 is an original ABB design hardware developed for Procontrol P13. This hardware is utilized as the interface for the HMI developed by ABB for its Procontrol P13/42 and Advant series of DCS. The 800xA is a truly “open” HMI system based on standard PC hardware, based on industry standard software like Windows 200X/XP and MS Excel/ODBC/DDE/OPC etc. The diagnostic station present at the plant is PRAUT microcomputer based SK06, which is used for the logic development and monitoring of the system. Due to shortcomings of SK06, the plant can face problem whenever there arises a need in modification of the program or forcing of signals is to be done under the certain conditions, when SK06 is connected to a particular 70PR03/70PR05. Also it is not possible with SK06 to do subsequent operation w ith different participants. This offer gives a detailed description of the upgrade for the existing Diagnostic Station

to

Progress 3 and HMI to ABB’ latest state of the art solution -800xA. The offer is divided into two phases, in the first phase we propose to upgrade the Engineering Station and in the second Phase, the existing HMI to 800xA. Both the activities will be carried out in parallel.

2.0 Procontrol P13 – Upgradation of Engineering cum Diagnostic Station: 2.1Technical Proposal: Progress 3, is based on Windows XP Operating station platform and compatible with the existing Procontrol P13 system with no loss/degradation in functionality/performance.

Techno-Commercial Proposal Techno-Commercial Proposal Preliminary Draft- For Discussion Only-Confidential

Page 2 of 36

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © Copyright 2008 ABB. All rights reserved.



ABB

Based on the initial discussions at ABB Bangalore, ABB had proposed to introduce 6 number of 70BK03 modules to access data from the TMR local panels into Progress3. However, based on site visit and discussions at site, it is proposed to extend the existing IPB (One Number) to all the TMR panels. This will have the following advantages. Access of Trend Data from the signals. Separate FKB signals will not be required. Trip Conditions (22 signals) from each of the TMR channels shall be connected to the new HMI System to help trip analysis. This will help in root cause analysis for the trip conditions. Internal Signals of BK and PR modules will also be available for analysis into Progress3. However, the existing TMR Configuration, its functionality and the communication from TMR panels to common panel will be retained as existing. The existing TMR panels communicate with the IPB by means of communication through 70BK03 modules. The schematic below shows the existing configuration.

Fig-01: Existing Configuration Techno-Commercial Proposal Techno-Commercial Proposal Preliminary Draft- For Discussion Only-Confidential

Page 3 of 36




ABB

For the TMR configuration of EHTC and Turbine Protection, it is proposed to extend the IPB to the se local Buses for better data aquisison. In order to extend the IPB, ABB will introduce 2 BK02 (One for Turbine Protection and One for EHTC) and One 70FA01 box with FK coupler cards for each TMR panel. Please refer below schematic. Progress 3 Computer will placed near the diagnostic panels within a distance of 2mtrs.

Connection to the control system The Procontrol P13 Progress 3 is connected to the platform via one or more 70BK03 modules. The process of up gradation will include the replacement of existing PC for diagnostic Station. The connection to IPB will be through 70BK03C module installed in the existing diagnostic panel. The Progress 3 computer will be connected to the 70BK03C module over serial (RS232) communication. The Progress 3 computer will be communicating through 70BK03C in the diagnostic panel to the IPBs and hence to the different stations on the IPBs.


Page 4 of 36




ABB

The Proposed configuration is shown in the above drawing. In the present case in a 70BK03 will be placed in the existing diagnostic station where the progress 3 computer will be connected to the 70BK03. The system will be communicating through the 70 BK02 modules in the diagnostic station to the IPBs and to the local stations.

2.2 Attractive Features: Procontrol Progress 3 is a Programming documentation and service tool. It has been specifically designed to enable upgrade or replacement of older generation of Procontrol Engineering. The system runs on Microsoft Windows 2000/XP Professional Personal Computers or Notebooks. It is controlled interactively on monitor with aid of state of the art user-friendly graphical interface windows techniques. 1) Single Point Uploading: The instruction codes can be read and loaded to the EEPROMs of the 70PR05 processors of all the P13 stations from single point i.e Progress 3 engineering station. This eases the conventional process of program loading by connecting to the processors individually. 2) Easy Code Transfer: The ease of code transfer from existing EPROMs and graphical documentation of the codes makes it an ideal choice for Procontrol Processor Upgrades. Additional import functions allow the as built documentation of existing application programs generated by older Procontrol P13 tool generations.

3) Over all Administration and Addressing: Progress 3 provides all the facilities the user needs to Engineer, Commission and service the Procontrol P13 Platform. This includes the administration of: Techno-Commercial Proposal Techno-Commercial Proposal Preliminary Draft- For Discussion Only-Confidential

Page 5 of 36




ABB

Ø Projects Ø Intra Plant busses Ø Local busses Ø Bus Couplers Ø Stations, racks, devices Ø Signals Ø Documentation Structure Ø Load Modules Ø Parameters Ø Test sets Also the addressing includes of: Ø Devices Ø Signals Ø Parameters Ø Service RAM 4) Online Functions: These mainly include: Ø Debugging with Function Block diagram. Ø Ø Ø Ø Ø Ø

Recording of Signals Forcing of Signals Loading of Parameters Loading of Programs Reading of EPROM data Disturbance bit display


Page 6 of 36




ABB

5) Print Functions: This includes printing of: Ø Functional block diagram Ø Ø Ø Ø Ø

Signals Hex-code Intra Plant Bus Listing Local Bus Listing Parameter Listing

Ø

Racks with module occupation.

6) Spare Inventory Minimization With the implementation of PC based Progress 3, Procontrol modules like 70SK30, 70SK31, 70SK32, 70SK33, 70SK34, 70SK35, 70SK36, 70SK37 modules are not required and hence bringing down the inventory and spare requirement for these modules. Note: The above features are the software features of Progress 3 software. The complete use of the functionality and the features will depend on the existing Procontrol P13 system, its interface to the existing P13 and available engineering backups.


Page 7 of 36




ABB

2.3 Development of Functional Block Diagram As the logic back-up available with M/s Tata Power is in the form of hex -code, the logic for each controller will be developed in the form of functional block diagram from the existing hardcopy documentation available at Plant. From the available document we find that there is 28 redundant pair of controllers and 18 non redundant Controllers. There is approximately 85 drive control modules (AS04 modules) installed in the Plant. The Process of development of a Function Block diagram will involve the following steps. Development of signal list from the existing documents. Creation of Function Block diagram from the existing documents in the Function Block editor of Progress 3. Comparison of the target code generated with the one existing in the Controller in the form of Hex Code. Correction if any. Commissioning the Function Block diagram.

3.0 Upgradation of the WS Pose HMI System to ABB 800xA HMI As per ABB’s standard policy and in order to bring your plant to the current technology level from time to time and market trends, ABB is committed towards providing you with the best solutions based on the technological upgrades and continuous enhancements, globally over the years. It is our endeavor to inform and provide you the opportunities for implementing state of the art technology as a step towards protection of your investment and prolonging plant & system life. Upgrades of the Procontrol P13/42 system with the latest HMI Operator system have been carried out at a number of other installations by ABB. ABB’s latest generation of Human System Interface, the 800xA (Process Portal A), combines the comprehensive process know-how and installation experience with advanced software functionality.


Page 8 of 36




ABB

Based on Windows 2003/XP platform, the 800xA unified user interface provides a consistent method for accessing enterprise wide data in real-time for managerial decisions as well as for launching multiple applications from any connected workstation in your plant or office. The software, 800xA is a truly “open” HMI system based on standard PC hardware and works on industry standard software like Windows 200X/XP and MS Excel/ODBC/DDE/OPC etc. The seamless integration of ABB’s Procontrol P13 Platform in to the world of Industrial IT allows you to increase your overall efficiency and to achieve greater asset optimization by making real-time data available across the entire enterprise. 800xA Process Portal provides flexible opera tion with a high level of scalability in order to respond to changing operation and production needs.

3.1 Proposal It is proposed an two 800xA servers with 100% data handling capacity will be installed to achieve data concentration from the local P13/42 IPB for the HMI system. With our 800xA and P13 Connect solution, we provide the possibility for step wise, continuous migration solutions to the latest automation technology. This unique ABB approach ensures investment protection by preventing equipment obsolescence through out the plants life. The modifications in the 800xA application program are limited to the interconnection functionality to the new 800xA. A modification of the Procontrol P13 application programming to change the functionality of the plant control is neither envisaged nor required. A sample overview of the new operator station system is shown below.


Page 9 of 36




ABB

Fig 01: Procontrol P13/42 configuration with 800xA

3.2 Details of the Installation process: The installation process is a detailed operation involving a high level of design, engineering and planning in order to achieve the required level of reliability and functionality. In order to achieve this, the following procedure is followed as a standard: 1.

Data collection of existing HMI : This step involves the process of collecting data and details of the existing configuration and various other aspects like the Mimics, trends, logs, reports etc. This step also involves the handover of critical data like the VPC command structures; partitioning diagrams and the engineering database dump from the EDS/ OWS, Performance calculation details etc by the customer to ABB.

2.

Design and Engineering of the New HMI package: In this step, the New HMI package configuration and functionalities are built in line with the existing plant operation philosophy and system configuration. Many improvements in the mimic layout and look and feel can be integrated during this procedure with the involvement of the plant engineers with ABB engineers during this stage. The new Mimic layouts, trend configurations, log and report configurations are carried out in this step. Configuration and migration of the existing engineering and configuration data is also carried out.


Page 10 of 36




ABB

Fig:02 3. Installation of New HMI software server: As the first step, the data acquisition server is loaded and initialized with the new HMI software. The newly installed server is then connected to the P13/42 IPB using the spare set of tapping from the FA coupler box. This server is assigned the last available address on the IPB. Please refer figure below for details of the retrofit. This step is carried out online during plant operation with out any hindrance to normal control and operations of the plant. Once the parallel data acquisition server is put online, the acquisition of data on this server and its associated client is monitored. Commands are given from this operator station and checked on the Diagnostic station by calling the telegram address for that command. These commands will not have any effect on the normal plant operation or DCS functioning as the addresses used will be un-used in the P13 logics. Hence these commands can only be read by the Diagnostic station and will not be read by the P13 controllers. This monitoring process is carried on till each of the tags configured have been physically verified for correctness of configurations. Refer fig:03


Page 11 of 36




ABB

4. Hot commissioning of the installed server: This step is carried out during any available plant shutdown, which could be of a very small duration to enable on-line HOT testing of the commands from the new HMI stations. In this step, one of the existing servers is shutdown and brought offline. Now, the new HMI server is assigned the address of this existing server, which has been brought offline, and normal operation is resorted to from this new Server client setup. As all the data acquisition tags and command tags including feedbacks have already been tested using parallel server and the Diagnostic station, in step # 3, this step will involve actual operation of only the required drives and valves etc in order to HOT commission the new HMI system.


Page 12 of 36




ABB

3.3 Highlights of 800xA HMI System IMPORTANT TECHNICAL ASPECTS: 1) P13 interface with OperateIT: The P13 interface represents the linking element between the process visualization software and the P13 bus through PIF Board. The PIF board serves to connect to the P13 bus directly. In turn, the P13 interface accesses the PIF board, which is mounted directly in the PCI slots instead of the conventional ISA slots that are obsolete. Interfacing of Operate IT with ABB make Procontrol P13 system is done by the PIF card, which communicates directly with the P13 without any third party communication device in between. Hence the hardware reliability is maintained. Following are some of the advantages of the PIF card:


Page 13 of 36




ABB

Advantages: Interface 800xA directly with P13 without any third party interface between P13 & 800xA. Interface mounts directly in PCI slots, which eliminates the hardware obsolesce problem as in traditional ISA slots. Control program to watch several Statistical values concerning P13 Interface Interface device driver diagnosis tool in Windows NT to check the status, interrupt used and I/O port address area reserved by the device driver.

Typical layout of the interface card: 2) Drive Control with 800xA: The control functions can be easily and efficiently designed using the Functional Unit libraries included in 800xA, which reflect power plant standards and practice. These libraries include standard basic function blocks for analog and binary functions. Furthermore, proven solutions for handling drives, pumps, controllers etc. have also been programmed into function blocks and are offered with the 800xA shown in table 1. Furthermore, to increase engineering efficiency and quality on a functional level, a library of Functional Units is offered with the 800xA. A Functional Unit serves as an entity, keeping all the components for a specific solution such as a drive, across the control system. Accordingly, and as shown in figure 1, each Functional Unit consists of: 1) process I/O functions 2) application macro communication over the Control Bus, HMI presentation data (faceplate and object display attributes)


Page 14 of 36




ABB

ProcontrolP13 Examples of Functional Units 1. Two-state drive control 2. Servo drive control 3. Solenoid valve control 4. Analog drive control 5. Incremental drive control 6. Binary control logic 7. Group logic control 8. Group control 9. Selector (2, 3, 4) 10. Manual station 11. Set point integrator 12. Analog input 13. Digital input Note: The above features are the software features of P13 connect software. The complete use of the functionality and the features will depend on the existing Procontrol P13 system, its limitations and available engineering backups.

Attractive features and Benefits: Existing PRAUT ,PMS, POSE, WS -Pose operator stations are based on general purpose computing platforms, which became obsolete much faster than the basic control system. Replacing these operator stations provides attractive features and benefits:

Data Integration:

Using the 800xA Servers and through Fiber Optic Communication all real time data including process graphic, trends, logs, alarms etc for individual, multiple units can be made available at a single place.

PC based operator stations

Open the Procontrol P13 system to the new industrial standards and improve its connectivity as a result of the OPC technology used in the P13 Connect design.

Ease of use

800xA and P13 Connect, is a dedicated power plant operator station solution designed to increase power plant operation efficiency and reduce engineering effort.


Page 15 of 36




ABB

Information transmission security

Redundant Interface design and high coupler performance allow safe bi-directional transmission of any signal without loss of information.

Full compatibility

As the original Procontrol P13 equipment supplier, and based on our large experience and reference in hundreds of power plants world wide, we guarantee the full compatibility of the new 800xA with the Procontrol P13 automation solution.

On-line retrofit

As the original Procontrol P13 equipment designers, and based on our large experience a high degree of Design and Engineering reliability has been built into the retrofit solution for P13/42 systems. Due to this, it is possible to perform a really “On-line” retrofit solution even in a critical application such as a power plant control system. This provides an opportunity to upgrade/retrofit the P13 systems without the requirement of an actual plant shutdown. A plant shutdown would be required only for a few days for the purpose of “HOT” testing of the critical drives etc.

Investment protection

With our OperateIT and P13 Connect solution, we provide the possibility for stepwise, continuous migration solutions to the latest automation technology. This unique ABB approach ensures investment protection by preventing equipment obsolescence through out the plant life.

Real time information

OperateIT and P13 Connect ensure real time access to all information available within the control system wherever the information is needed. ABB’s Aspect Object Technology ensures easy configuration and access to the required information. ASPECT OBJECT: Special tool with 800xA Def: An aspect is a description of some properties of a real world entity. The properties described could be mechanical layout, how the object is controlled, a live video image, name of the object etc. Using Aspect Object property in 800xA one can access various real world entities with a single click of the mouse. With the click of a mouse we can access all relevant information concerned to an object as shown in the fig below .


Page 16 of 36




ABB

Aspect Object “ ...one integrated thing that hides all the differences"

Aspects Process IFS Graphics

Real Object

Operator Interaction

ABB Object

Maintenance record Operator interaction

Control Control MS Word Builder Control Data sheet

Simulation Model iGES ElMaster Simulation Model Electrical diagram

AutoCad MS Excel P&I Diagram

ABB Automation

Aspect Systems

P&ILoop Diagram spec

OIT Overview 000907 Page 10

The enabling technology for this data access, storage, and management is ABB’s patented Aspect Object framework. Aspect Objects relate all of your plant data, the Aspects, to specific plant assets, the Objects. The headache of locating information spread between different people, locations, computers, and applications is over. Aspect Object navigation presents the entire production facility in a consistent, easy to view fashion. This allows a single window environment to include smart field devices, asset optimization functions, information management, batch management, safety systems, and MES (Manufacturing Execution Systems) applications.

Figure 1 More examples of Aspects of an Object


Page 17 of 36




ABB

800xA OPC Client Connection The 800xA OPC Client Connection is intended for use with third party clients. In an ABB Industrial IT installation, the connectivity packages are used to integrate the operator workplaces, etc. with the Industrial IT controllers. All run-time data, and some configuration data in the system is available for other clients via OPC. The 800xA System acts as an OPC-Server for OPC-DA and OPCHDA. The 800xA System acts as an OPC-Server for OPC-DA (1.0, 2.0), OPC-HDA (1.20), and OPC -AE (1.1). Several OPC-Clients can be connected simultaneously to the system to exchange data.

Operations The Operator Workplace is built on Operate IT process portal technology and it is the 800xA System Operator Interface. The key functions provided are: presentation of process graphics, execution of process faceplates, presentation of trends, and presentation of alarms. Two types of Operator Workplace clients exist: §

Operator Workplace - Client. Techno-Commercial Proposal Techno-Commercial Proposal Preliminary Draft- For Discussion Only-Confidential

Page 18 of 36




§

ABB

Operator Workplace - Remote Client.

Features: §

Personalized workplaces for focused information access

§

Intuitive and flexible navigation for fast information access

§

Integrated data for informed decision-making

§

Comprehensive operator functionality for reliable control

Operator Workplace Client The Operator Workplace provides efficient control and supervision of different kinds of processes in integrated systems. The Operator Workplace uses client/server capabilities allowing both client and server applications to run in one PC for a small configuration, or to run in a configuration with one server and up to thirty client workplaces. Functional overview: §

Graphics displays, with support for ActiveX components to include any third party graphical component.

§

Faceplates for process objects.

§

Alarm and Event management and presentation.

§

Operator History, including trend presentation and Alarm and Event history.

§

Excel based reporting (scheduled and on demand).

§

System Status Viewer.

§

Topology Status Viewer.

The Operator Workplace provides a number of configurable options that allow a user to tailor the workplace to suit their needs, be they a senior or junior operator, an engineer, a maintenance technician, a manager supervisor or a system administrator.

Faceplates

Faceplates are designed mainly for operator use, to monitor and effect control of a process. Each object can have up to three different sized faceplates, depending on the needs of the object and the user (see Figure 2 Faceplates.) The Operator Workplace provides a flexible faceplate framework, making the creation and the customization of the product-supplied faceplates straightforward and intuitive. The faceplate framework is composed of five main areas. Techno-Commercial Proposal Techno-Commercial Proposal Preliminary Draft- For Discussion Only-Confidential

Page 19 of 36



1.


ABB

At the top of the faceplate is the header area. This includes the object name and description, as well as alarm state indication, acknowledgement button, and object in-use (or locked) indication.

2. Below the header area is the status area. This includes object state indication (e.g., manual mode) and link buttons to other aspects (e.g., operator note). 3. At the bottom of the faceplate are the faceplate size selection buttons (for reduced, normal, and expanded size faceplates). 4. Above the faceplate size selection buttons is the control button area. The configuration of the status and button areas is done through simple fill-in-the blanks configuration and provides the ability to link in button and status indicators. 5. Between the status and button area is a faceplate element area. This is a free-form graphic that is configured in the same way as any process graphic.

Figure 2 Faceplates

Quad Display

It is possible to divide the display area in four smaller areas where each area can hold an individual display to get a better overview of a process. The content of each mall area can be maximized to


Page 20 of 36




ABB

cover the whole display area and will return to the original quarter area again when minimized. See Figure 7A.

Figure 7A Operator Workplace Quad Display layout

Navigation

The Operator Workplace supports the ability to right click on any object to view and select available actions or display call-ups from a context menu. For a given user, the context menu is the same, no matter where the object is displayed. The configuration of an object in and of itself automatically defines the possible selections available within the context menu. The context menu is filterable based upon the user log-in, such that an engineer might have access to certain actions that are configuration-related, while an operator would not have access to them. The context menu also contains a reference list of other graphics or displays in which the same object is used, allowing the Techno-Commercial Proposal Techno-Commercial Proposal Preliminary Draft- For Discussion Only-Confidential

Page 21 of 36




ABB

user to quickly navigate to them. This reference list is provided automatically without requiring the user to do any manual mapping. Within the tool collection of the application bar, a number of navigational buttons and pull down menus are available to provide quick access to displays and information. Object and aspect history lists as well as back and forward buttons allow an operator to view and recall past selections quickly. Associated displays of a selected object or aspect can be quickly called up using short cut buttons that are automatically enabled when the object or aspect is selected.

Alarm List

The Alarm List displays all events matching the configured alarm filter. All, or a subset of an event’s attributes, along with the current value for that objects can be displayed. Viewing the alarms is very flexible. Use the default sort order or adjust the sorting by double clicking on the headers. Adjust the layout by drag & drop columns to suit your needs. Return to the default layout by just clicking on the reset button.

Figure 3 Alarm list Acknowledge of individual alarms, selected multiple alarms, or an entire page of alarms can be performed from the Alarm List. The colors and blinking of alarms are configurable. It is also possible to define what columns to present, the time format, and the sorting order of the list.

Event List

The Event List displays all events matching the configured event filter. The event list functionality is the same as for alarm list, except acknowledge.


Page 22 of 36




ABB

Trend Display

Trend displays are some of the most important tools associated with operating and analyzing industrial process. The Operator Workplace addresses this need by presenting the operator wing an extensive set of trending features and functions.

Figure 4 Trend Display

Operator Workplace - Remote Client (Optional package, not quoted)

The Terminal Service concept enables remote access to an 800xA system from a standard PC without ABB-specific software installed. The remote client provides operation capabilities and access to historical information. Configuration capabilities are limited on the remote client. The same security concept utilized for a rich client will be used for the remote client, making it possible to define those actions that are permitted from a remote client. The Remote Clients adhere to the access control concept generally supported by Operator Workplace Clients. The following functions are remote client enabled: Plant Explorer navigation Operation graphics, alarm&event, trend, history logging, system status, and faceplates Information Manager Techno-Commercial Proposal Techno-Commercial Proposal Preliminary Draft- For Discussion Only-Confidential

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ABB

Batch client A third party solution from Citrix is used to implement remote clients. Ci trix Metaframe Presentation Server© software must be installed on an Application Server running an Operator Workplace rich client to enable access from remote clients.

Audit Trail

The Security and Access Control System allows audit of operator actions and security. The system supports logging of security violations, configuration changes, and operator actions to the process. The audit logs can be viewed in the alarm and event list. This makes it possible to see the effect of an operation. The audit log contains the following information: Date and time for the operation Node from which the operation was performed User name of the individual performing the operation Type of operation Object, property or aspect affected by the operation Additional information from the involved aspect system

Figure 5A An Example of an Audit List Some more features and benefits are: PC system based on Windows /200x/XP Power plant specific look and feel Platform for process and information management software with easy access to process data. Techno-Commercial Proposal Techno-Commercial Proposal Preliminary Draft- For Discussion Only-Confidential

Page 24 of 36




ABB

Replacement /Up gradation needs minimal Engineering. Easy maintenance and availability of spare parts Use of latest computing and information technology Mouse only operation and multi screening Full graphics 1280 x 1024 pixels process presentation Process operation from any of the operator stations using face plates for interaction Display of sequence and interlocking control conditions Advanced alarm and event handling, using priorities and configurable filters Trend recording and real-time monitoring Excel® based reports (standard and user definable). Configurable history for events, analog values and reports Open for user applications due to international standards Comprehensive set of application packages Engineering support for Procontrol P13/42


Page 25 of 36




ABB

5.0 Replacement of Critical Modules. Based on the site visit and discussion, it is proposed that the following critical modules whose malfunctioning may cause Unit Tripping will be replaced with imported modules of ABB. This replacement is to be done in each of the TMR Channels It is also proposed to replace some of the existing modules of the Turbine Protection Panel (CJJ32) and EHTC Common (CJJ31) with ABB manufactured modules. The list of these modules is enclosed below. Sl No

Modules

CJJ31

CJJ32

1

70EB01

10

2 3

70EB02 70AB01

5 30

4 5

70AB02 70BK03

CJJ21

CJJ22

CJJ23

8

8

8

4 3

4 3

4 3

In TMR panels EB01 will be replaced at locations, EA10, EA11, FA01, FA02, FA10, FA11, GA10 and GA11. Similarly, AB02 will be replaced at locations FA34, FA35, GA34 and GA35. The Quantity mentioned above is for One Unit only. As discussed, the Unit rate of the above modules are given in the Commercial Section of this offer, so that the modules can be procured and replaced by M/s TPC as per their requirement and suitability.

6.0 Major Considerations and Assumptions of the Offer 1.

The offer covers only signals available in the present system and available in the IPB.

2. Availability of existing documentation with logics for P13 system with M/s Tata Power 3. The specification of the server will be strictly in accordance with the ABB’s recommended hardware for 800xA systems. 4. The modifications in the 800xA application program are limited to the interconnection functionality to the new 800xA. 5. There is space in the TMR Panels to keep BK03 modules. 6. A modification of the Procontrol P13 application programming to change the functionality of the plant control is not included and not required .


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ABB

7.0 Duration of the Project Commissioning of Engineering Station will require at most 15 days for commissioning at site. The system can be commissioned online, however for downloading to the controller, it is recommended to have shutdown. That limits the actual Plant outage required to be maximum 4 days. A detailed Activity schedule will be submitted after the award of Offer. The 800xA HMI system will need a max. Of 15 days for installation, testing and commissioning at site, after the material has reached the site and design and engineering has been done in our office. Please also refer to the upgradation procedure mentioned in the beginning of the proposal. This limits the Commissioning time by checking the input signals in the IPB during online running of the Plant. Commissioning is only limited to the outputs from the system.

8.0 Scope of the offer: The scope of this offer for one unit is as detailed in sections below. 8.1 Scope of supply: Progress 3 and Extension of IPB Sl. No. Item description 1

Workstation for Progress 3 EWS 1.6 GHz or better , 512 MB RAM, 80 GB HDD , CD R/W/DVD Combo drive.

Qty/Unit

Total Qty UOM

1

2

No

2

Interface of Progress 3 with Procontrol Station -Latest 70BK03C-E/R1/R3 communication

1

2

No

3

EPROM Programmer

1

2

No

4

1

2

No

5

Progress 3 Tool (Engineering / Maintenance) SW - Package including license: Hex-editor, monitoring function including CD ROM 1No with Manual and Hard Lock Dongle-1No 70BK02 Modules

6

12

Nos.

6

70FA01 with 2 Numbers 70FK01

3

6

Nos.

7

IPB Cable

1

1

Lot


Page 27 of 36




ABB

HMI Upgrade Item description

No. A

2.

Qty/ Unit

Server Workstation for 800xA : Xeon Dual/Quad core 1.6GHz, 1x 73GB SAS /80GB SATA HDD, 2 GB RAM,20" TFT Monitor, Std Keyboard, Mouse, Win 2003 Server. (Make: DELL/HP/IBM/Equiv) Operator Workstation for 800xA

2

4

Nos.

4

8

Nos.

4

8

Nos.

1

2

Lot

Switch, LAN cable, redundant Networking within the distance of 100 mtrs.

1

2

Lot

A4 Color Laser printer for Reports Dot matrix printer for Alarms

1 1

2 2

No No

1

2

No

4

P13 interface cards (PIF03) for HMI server (PCI slot compatible) with connecting cable

7

800xA software for Server Workstation with license for 2000 tags and 300 history points, license dongle and media box Communication Setup

7 8 9

UOM

Procontrol P13/42 Upgradation

P4 Dual/Quad core 1.6GHz, 1x 73GB SAS /80GB SATA HDD, 1GB RAM,20" TFT Monitor, Std Keyboard, Mouse, Win XP. (Make: DELL/HP/ IBM/Equiv)

6

Total Qty

Rev Drive for external data storage. Note: This offer quantity is for two units only 8.2 Exclusions: Scope of Supply: 1)

Power Cables.

2) UPS and associated Power supply equipment 3) Furniture


Page 28 of 36




ABB

8.3 Scope of Work: Our process of up gradation will include: Progress 3: Installation of software in the Progress 3 PC. Establishment of communication with 70BK03. Uploading the 70PR02, 70PR03 data through EPROM Programmer and uploading the BK02 and FV01 data in the Progress 3. Modification in Hex Editor and downloading. Uploading the 70PR05b data in the Progress 3. Modification in Hex Editor and downloading and any simulation in the controller. Taking back up, Design, Engineering and Up gradation of the existing database to ABB’s make Progress 3. Preparation of Function Block Diagram based on the latest Hardcopy available in the Plant and Signal List available in the Plant. 800xA HMI Upgradation: ABB’s scope is limited to the data and tags available in the present system. Any modification for any new tag in the control system is not considered. Supply, Design, Engineering, Supervision of installation, commissioning & Testing of the system Engineering, Software Development, Assembling, Testing of the System. Supervision on Pre-Commissioning activities and commissioning of the supplied system.

8.4 Exclusions: Scope of Work All Products and services are excluded which are not specifically mentioned. Power cable lying. Any civil or erection work. Changes and Modification in Cabinets, dismantling and mounting of racks, IO cards etc. Providing any features which are not available in offered package.


Page 29 of 36




ABB

Any logics or schemes that is non existent and not operational in the present system as on date. Any interface with the SOE(70EB10) system Notes: 1. 2. 3.

One 230VAC/110VAC UPS Power Supply is to be provided by M/s Tata Power for the 800xA server and operator work stations and Progress 3 PC. Furniture for the computers to be provided by M/s Tata Power . FBD Hard Copy and updated documentation must be provided by M/s Tata Power


Page 30 of 36




ABB

9.0 COMMERCIAL PROPOSAL Price Schedule: 800xA HMI Upgradation Sl. No.

Description

Qty

Total Basic Price(Ex-works) in Indian rupees Rs. 21,600,000/(Rupees Twenty One Million and Six Hundred Thousand

1

Price for Design, Engineering, Supply of 800xA HMI 1 Unit System as per above mentioned scope of Supply.

2

Rs. 40,500,000/Price for Design, Engineering, Supply of 800xA HMI 2 (Rupees Forty Million and Five System as per above mentioned scope of Supply. Units Hundred Thousand Only)

Only)

Progress 3

1

Price for Design, Engineering, Supervision of Installation, implementation, testing, Commissioning, 1 Unit and Supply of Progress 3 System as per above

Rs. 7,470,000/(Rupees Seven Million Four Hundred and Seventy

mentioned scope of supply.

2

Thousand Only)

Price for Design, Engineering, Supervision of Installation, implementation, te sting, Commissioning, 2 and Supply of Progress 3 System as per above Units mentioned scope of supply.

Rs. 14,670,000/(Rupees Fourteen Million Six Hundred and Seventy Thousand Only)

Engineering Services on Procontrol P13( To be ordered with Progress 3) 1 Num

Rs 150,000/(Rupees One Hundred and Fifty Thousand Only)

1

Development of Function Block Diagram per Controller

2

Development of Function Block Diagram per Drive Rs. 50,000/1 Num Control Module (Rupees Fifty Thousand Only)

Note: for number of Controllers, see their relevant technical section. The Quantity is based on site feedback. For Critical Modules , please check the relevant portion.


Page 31 of 36




ABB

9.3 Unit price for Critical Modules Sl No

Modules

1

70EB01 B-E

2 3

70EB02C -ES 70AB01C-ES

4 5

70AB02B-E 70BK03C -E/R3

Unit Rate of Modules (INR) 58,000/65,000/87,000/110,000/450,000/-

10.0 GENERAL TERMS AND CONDITIONS Your Acceptance of our offer should be communicated through a written purchase order specifying the following terms and conditions as an explicit acceptance of it. IMPORTANT NOTICE “This Budgetary offer No E.UAPS.RE.8.00 52.R1 dated 04.05.200 9 is preliminary and not final and as such non binding. It is tendered for discussion only, does not constitute a term to contract and ABB can, without notice, mak e any changes in ABB’s own discussion.”

Prices

The quoted prices are net & firm and on DELIVERY, EX WORKS PEENYA – BANGALORE. Our scope is based on the above mentioned items in scope of supply and services only.

Excise Duty

The offered prices are exclusive of all taxes and excise duties,

Sales Tax And Other

levies, cess & octroi, Service Tax etc. which have to be borne by you at actual as per the prevailing rates at the time of delivery and

Levies

service. Present prevailing rate, ED on hardware (including CESS) is 8.24%, ED on Software in CD-ROM (including CESS) is 8.24%, Sale Tax is 2% and Service Tax (Including CESS) 10.3%. You shall furnish necessary declaration forms wherever applicable. In case of any statutory variations in terms of variations of rates / tariff / classification of Excise Duty, Sales Tax or any other tax / duty / levy for both self - manufactured and bought-out items if become livable by Central / State / Local authorities shall be paid / Techno-Commercial Proposal Techno-Commercial Proposal Preliminary Draft- For Discussion Only-Confidential

Page 32 of 36




ABB

reimbursed at actual on demand by concerned authorities at applicable rates at the time of dispatch / levy within the contractual delivery period. If the cost of the bidder / contractor for the performance of the contract are increased or decreased by levy of a new tax on the final equipment, by a new act of Central / State / Local authorities and which are not in force as on date of offer, such liability / benefit shall be to Owner’s account.

Terms of Payment

FOR SUPPLY: 30% payment as interest free advance along with Purchase Order Balance 70% payment through bank against dispatch documents. The bank Charges will be at individuals account. FOR E &C:

50 % against site mobilization. Balance 50 % against job completion.

LD Clause

Not Applicable.

Delivery

All items as per the B.O.M shall be supplied within 20 weeks on receipt of technically and commercially clear order. The above delivery reckons the availability of frozen engineering information within 30 days of receipt of technically / commercially clears order.

Packaging Handling

and

Extra at 1%

Freight and

The prices quoted do not include cost towards freight and transit insurance.

Insurance Note

Freight charges and insurance will be in your scope. We shall intimate you the dispatch details to enable you to arrange insurance. If you do not arrange the insurance, goods will be dispatched to you at your risk.

Warranty

The warranty of the supplied system is limited against manufacturing defects for the hardware items supplied as per the bill of material for a period of 18 months from date of dispatch Or 12 months from the date of Techno-Commercial Proposal Techno-Commercial Proposal Preliminary Draft- For Discussion Only-Confidential

Page 33 of 36




ABB

commissioning, whichever is earlier. The warranty period shall expire prematurely if the customer or a third party undertakes inappropriate modifications or repairs to the Supply or if the customer, in the event of a defect, does not immediately take all appropriate steps to mitigate the damage and give ABB the opportunity to remedy such defect.

Validity of offer

Unless otherwise specified in writing, this quotation will expire thirty (30) days from the date of offer. Change in Scope This quotation is based on our understanding of the enquiry. If subsequent to of Supply. the tender evaluation and placement of order, changes in the specification alter the quoted scope of supply and services, we reserve the right to renegotiate the contract price. In case the quantities would increase or decrease during the execution of the Works, the Contract price will be adjusted on the basis of the prices valid at that time. Routine Progress, Visits for the above by customer's engineers will not be subject to an Witness Testing additional charge provided such visits do not affect the agreed production & Inspection. program. Also the charges for travel, lodging, boarding of customers’ / Purchaser’s persons shall not be in ABB scope. Test Certificates Internal Testing Certificates will be provided. Exclusion of Exclusion of Consequential Losses and Limitation of Liability: Consequential Notwithstanding anything contained in the conditions to the contrary, the damages & Supplier shall not be liable for any special, indirect or consequential damages Limitation of or losses, such as, but not limited to, loss of revenue, loss of use, loss of liability production, loss of data, loss of con tracts, costs of capital or costs connected with interruption of opera tion. The total liability of the supplier, irrespective of whatever legal reason, shall be limited to the 1% value of the contract price. Erection and Commissioning:

Our scope of job will be completed in all respects within 15 days from the clearance and availability of the control room and Shutdown. In case of extended stay of our commissioning engineers at site for reasons not attributed to ABB, Per Day charges will be applicable extra.

Service Charge

Extra Man day @ Rs. 25,000/- for Commissioning and Service, in case the reason of delay of commissioning is not attributed to ABB. Techno-Commercial Proposal Techno-Commercial Proposal Preliminary Draft- For Discussion Only-Confidential

Page 34 of 36




ABB

Force Majeure is herein defines as any cause which is beyond the control of the contractor or owner as the case may be, which they could not foresee, or with a reasonable amount of diligence could not be foreseen, and which substantially affects the performance of the contract such as:

Force Majeure

a) Natural phenomena including but not limited to floods, droughts, earthquakes and epidemics. b) Act of Government, domestic or foreign including but not limited to war, declared or undeclared priorities, quarantines, embargoes. c) Riots and Civil commotion. d) Transportation delay due to above force Majeure clause (a), (b) and (c) of above.

Scope of Supply &

The scope of our supply shall be limited to the items mentioned in the

Works

Bill of Material. The scope of our works shall be limited to the Supervision of installation and commissioning of the items mentioned in the Bill of Material.

End Statement

User

ABB Will provide an end user statement once the order is finalized. The same needs to be signed and attached along with the Purchase Order.

ARBITRATION & All disputes and differences arising out of or connected with the JURISDICTION execution of the contract/ order, failing amicable settlement on mutual terms shall be referred to arbitration in line with the provision of the Indian arbitration act in force. In the event of dispute the jurisdiction for settlement of the same.


Page 35 of 36




ABB

Procontrol P13 HMI/EWS Year

End User

Plant

Country

IPGCL

IPGCL

INDIA

Ref. 1

Power MW

Retrofit

Existing

Technology

R

Pose90

AS160 OS

2

2006

REL

Dahanu

INDIA

250

R

PMS

800xA

3

2006

REL

Dahanu

INDIA

250

R

PMS

800xA

4

2007

TNEB

TTPS

INDIA

210

R

Pose90/SK06

800xA/Progress3

5

2007

NTPC

TSTPS

INDIA

500

R

Sk06

Progress 3

6

2007

TVNL

TVNL

INDIA

210

R

Sk06

Progress 3

7

2008

APGENCO

Pochampadu

INDIA

3x9

R

Desk Operation

800xA/Progress 3

8

2008/ UE

AGBP

NEEPCO

INDIA

R

Pose90

800xA

9

2008

GSECL

WTPS

INDIA

210

R

WS Pose

800xA/Progress 3

10

2008/ UE

RRVUNL

KTPS

INDIA

210

R

Pose90

800xA/Progress 3

11

2008

REL

DTPS

INDIA

250

R

SK06

Progress 3

12

2008/ UE

MSPGCL

KTPS

INDIA

210

R

SK06

Progress 3

13

2008/ UE

MSPGCL

CSTPS

INDIA

210

R

SK06

Progress 3

14

2009

PSEB

Ropar

INDIA

210

R

70PR03

70PR05

15

2009

APGENCO

Rayelseema

INDIA

210

R

70PR03

70PR05

UC: Under Execution


Page 36 of 36



QUOTATION FOR PROCONTROL P13 SPARES ABB OFFER NO:E.UAPS.RE.10.024.R0 DATED 8.2.2010

COMMERCIAL PROPOSAL

ABB LIMITED PS – POWER GENERATION PLOT NO. 5 & 6, PHASE II, PEENYA INDUSTRIAL AREA BANGALORE – 560 058

ABB


Tata Power Jojobera Quotation for Procontrol P13 Spare E.UAPS.RE.10.024.R0 Dated 8.2.2010 Your Discussion with our Representative

ABB

Commercial Offer Price Offer: Sl. No.

Item Description

Unit Price (INR)

Total Price (INR)

2

2,250,000* /-

4,500,000 /-

2

165,000 /-

330,000/-

1

535,000 /-

535,000 /-

Qty.

1. 800xA HMI Cold Standby Server consisting of: a) PC for HMI Server with Quad-Core Intel(R) Xeon processor, 2x6MB Cache, Integrated Dual Broadcom Gigabit Network Card, 3X146GB 3.5-inch 15K RPM SAS Hard Drive, 1.44MB 3.5" Floppy Drive, USB Keyboard, USB Mouse, 16x SATA DVD + / - RW Drive, UltraSharp(TM) 20" Flat Panel LCD Monitor – 1 no b) PIF cards installed in the server – 2 nos c) Dongle – 1 no

PC for HMI Client with: Intel(R) Core(TM)2 Duo processor, 2.83GHz, 1066MHz FSB, 3MB cache, Broadcom 5754 Gigabit 2. NIC, 1GB (2x512MB) 667MHz NECC Dual Channel DDR2 SDRAM Memory, 1.44MB 3.5 " Floppy Drive, USB Keyboard, USB Mouse, UltraSharp(TM) 20 " Flat Panel LCD monitor, 146GB SAS HDD (15k RPM) 3. 70BK03C-E - Interface to local bus module

Total in INR: Rupees Five Million Three Hundred and Sixty Five Thousand Only

5,365,000 /-

* The price quoted includes the services required for installation of cold standby server. No software or licenses have been considered.

Commercial Proposal Commercial Proposal

Page 2 of 4



ABB

GENERAL TERMS AND CONDITIONS Your Acceptance of our offer should be communicated through a written purchase order specifying the following terms and conditions as an explicit acceptance of same. Prices

The quoted prices are net & firm and on DELIVERY, EX WORKS PEENYA – BANGALORE.

Excise Duty Sales Tax And Other Levies

The offered prices are exclusive of all taxes and excise duties, levies, cess & octroi, Service Tax etc. which have to be borne by you at actual as per the prevailing rates at the time of delivery and service. Present prevailing rate, ED is 8.24%, Sales Tax is 2%. You shall furnish necessary declaration forms wherever applicable.

Terms of Payment

100% payment against dispatch documents.

Delivery

Delivery time for supply of the modules is about 16 weeks from the date of receipt of the technically and commercially clear/firm order.

Packaging and Handling

Included.

Freight

The prices quoted do not include cost towards freight and transit insurance. The material will be dispatched on Freight at actual shall be applicable and insurance will be in your scope.

Note

We shall intimate you the dispatch details to enable you to arrange insurance. If you do not arrange the insurance, goods will be dispatched to you at your risk.

Warranty

12 months from the date of dispatch. The warranty period shall expire prematurely if the customer or a third party undertakes inappropriate modifications or repairs to the Supply or if the customer, in the event of a defect, does not immediately take all appropriate steps to mitigate the damage and give ABB the opportunity to remedy such defect. The above prices are valid for a period of 30 days from the date of offer.

Validity LD Clause Exclusion of Consequenti al damages & Limitation of liability

Not Applicable. Exclusion of Consequential Losses and Limitation of Liability: Notwithstanding anything contained in the conditions to the contrary, the Supplier shall not be liable for any special, indirect or consequential damages or losses, such as, but not limited to, loss of revenue, loss of use, loss of production, loss of data, loss of contracts, costs of capital or costs connected with interruption of operation.


Page 3 of 4


Force Majeure


ABB

Force Majeure is herein defines as any cause which is beyond the control of the contractor or owner as the case may be, which they could not foresee, or with a reasonable amount of diligence could not be foreseen, and which substantially affects the performance of the contract such as: a) Natural phenomena including but not limited to floods, droughts, earthquakes and epidemics. b) Act of Government, domestic or foreign including but not limited to war, declared or undeclared priorities, quarantines, embargoes. c) Riots and Civil commotion. Transportation delay due to above force Majeure clause (a), (b) and (c) of above


Page 4 of 4


PROPOSAL FOR PROCONTROL P 13 SPARES ABB OFFER NO: E.UAPS.RE.9.0257.R1 DATED 25.11.2009 Ref: Email Dated 23.11.2009

TECHNO-COMMERCIAL PROPOSAL ABB LIMITED PS – POWER GENERATION PLOT NO. 5 & 6, PHASE II, PEENYA INDUSTRIAL AREA BANGALORE – 560 058

ABB


Tata Power , Jojobera Quotation for Procontrol P 13 Spare E.UAPS.RE.9.0257.R1 dated 25/11/2009 Email dated 23/11/2009

ABB

Commercial Offer Price Offer: Sl. No. 1

Item

Item Description

70PR05b HESG332204R0001

Programmable Processor

3

Unit Price (INR) 580,500/-

2

BK02C-E HESG332209R0001

Bus Coupler

2

445,500/-

891,000/-

3

BT01cHESG447024R0001

Bus Isolating Amplifier Module

2

180,000 /-

360,000/-

4

70FA01BHESG223140R0001

Bus access coupler

1

180,000/-

180,000/-

5

70FK01BHESG447016R0001

IPB Coupling module

10

90,500/-

905,000/-

6

FV01B-E HESG332164R0001

IPB Bus traffic Director

2

490,500 /-

981,000/-

Firmware Upgradation of

35

32,000/-

1,120,000/-

7

Qty

Total Price 1,741,500/-

*

70Pr05a to I/latest version Total in INR: Rupees Six Million One Hundred and Seventy Eight Thousand and Five hundred only

6,178,500 /-

* We will require 2 days service for the same considering plant is under shutdown.

Techno-Commercial Proposal Commercial Proposal

Page 2 of 4



ABB

GENERAL TERMS AND CONDITIONS Your Acceptance of our offer should be communicated through a written purchase order specifying the following terms and conditions as an explicit acceptance of same. Prices

The quoted prices are net & firm and on DELIVERY, EX WORKS PEENYA – BANGALORE.

Excise Duty Sales Tax And Other Levies

The offered prices are exclusive of all taxes and excise duties, levies, cess & octroi, Service Tax etc. which have to be borne by you at actual as per the prevailing rates at the time of delivery and service. Present prevailing rate, ED is 8.24%, Sales Tax is 2%. You shall furnish necessary declaration forms wherever applicable.

Terms of Payment

100% payment through bank against dispatch documents.

Delivery

Delivery time for supply of the modules is about 16 weeks from the date of receipt of the technically and commercially clear/firm order.

Packaging and Handling

Included.

Freight

The prices quoted do not include cost towards freight and transit insurance. The material will be dispatched on Freight at actual shall be applicable and insurance will be in your scope.

Note

We shall intimate you the dispatch details to enable you to arrange insurance. If you do not arrange the insurance, goods will be dispatched to you at your risk.

Warranty

The warranty of the supplied system is limited against manufacturing defects for the hardware items supplied as per the bill of material for a period of 12 months from date of dispatch. The warranty period shall expire prematurely if the customer or a third party undertakes inappropriate modifications or repairs to the Supply or if the customer, in the event of a defect, does not immediately take all appropriate steps to mitigate the damage and give ABB the opportunity to remedy such defect.

The above prices are valid till 11.12.2009. Prices will be having upward price revision in the next financial year. Not Applicable as this is a spare offer. LD Clause Exclusion of Exclusion of Consequential Losses and Limitation of Liability: Consequenti Notwithstanding anything contained in the conditions to the contrary, the al damages & Supplier shall not be liable for any special, indirect or consequential damages Limitation of or losses, such as, but not limited to, loss of revenue, loss of use, loss of production, loss of data, loss of contracts, costs of capital or costs connected liability with interruption of operation. Validity


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Force Majeure


ABB

Force Majeure is herein defines as any cause which is beyond the control of the contractor or owner as the case may be, which they could not foresee, or with a reasonable amount of diligence could not be foreseen, and which substantially affects the performance of the contract such as: a) Natural phenomena including but not limited to floods, droughts, earthquakes and epidemics. b) Act of Government, domestic or foreign including but not limited to war, declared or undeclared priorities, quarantines, embargoes. c) Riots and Civil commotion. Transportation delay due to above force Majeure clause (a), (b) and (c) of above


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ABB wins ‘Best Power Plant Upgrade’ award at Asian Power Awards 2010

ABB wins ‘Best Power Plant Upgrade’ award at Asian Power Awards 2010 2010-11-16 ABB' s project was recognized as the ‘Best Power Plant Upgrade in Asia’ at the Asian Power Awards 2010 held in Singapore. ABB received this award for an upgrade project executed for Tata Power in Jojobera, Jharkhand - a state in eastern India.

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ABB upgraded the control system for a 2 X 120 MW coal based thermal power plant of Tata Power. Tata Power, erstwhile known as Tata Electric, pioneered the generation of electricity in India nine decades ago. Today, it is the country' s largest private power utility.

The power plant feeds the steel plant at Tisco Jamshedpur, Jharkhand and is very critical to the operations of the large steel plant. The plant was facing a problem of availability of the control system affecting the availability of power supply to steel plant. ABB conducted a survey and analyzed that upgrading the system would significantly improve the reliability and availability of the control system. Thus the customer will be able to achieve the objective at a fraction of the cost of a new system. ABB’s scope included upgrade of Procontrol P13 control and existing HMI (Human Machine Interface) system, supply of new engineering and diagnostic tool - Progress3 for the Procontrol P13 system and supply of critical spare parts. The State of the Art HMI system improves the plant operations and the Function Chart Builder facility of the Progress3 will facilitate on-line functional logic monitoring and simulation features for the Procontrol P13 System. The upgrade was completed within a short plant maintenance period.

Rekha Subramaniam, the local Business Unit manager for Power Generation in India receiving the award on behalf of ABB.

Contact us Page information: Rajeev Kishore Anshuman N

Contact us General information: Contact ABB

ABB’s solution benefitted the customer in: - Eliminating unscheduled outages. Increased plant stability and uninterrupted power generation. - Increased reliability for turbine and boiler protection system - Increased operational flexibility with a new state of the art operator interface allowing efficient monitoring and Plant Operations - Reduced maintenance costs - Improved diagnostics and added Simulation facility for plant availability - Extended life of the plant with latest technology at fraction of costs

This upgrade is in line with ABB’s ‘evolution without obsolescence’ policy aimed at supporting customers in maximizing the return on asset investments while keeping abreast of latest technology. The Procontrol P13 platform has large installed base of distributed control systems (DCS) in power generation worldwide.

http://preview.inside.abb.com/cawp/seitp202/B24909EAC16B6A7F482577DC0029AA2... 12/13/2010

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