Maintenance Schedule for 2008-09 and 2009-10: PTPS SR. UNIT NO. - - PowerPoint PPT Presentation

▶
maintenance schedule for 2008 09 and 2009 10 ptps
SMART_READER_LITE
LIVE PREVIEW

Maintenance Schedule for 2008-09 and 2009-10: PTPS SR. UNIT NO. - - PowerPoint PPT Presentation

Aug 18, 2023 313 likes •567 views

Maintenance Schedule for 2008-09 and 2009-10: PTPS SR. UNIT NO. Name of the 2008-09 2009-10 (PROPOSED PERIOD) No. Power Station PERIOD TYPE OF PERIOD TYPE OF OVERHAULING OVERHAULING 1 UNIT- 1 PTPS, Panipat Unit -- ( i) Renovation,

slide-1
SLIDE 1

Maintenance Schedule for 2008-09 and 2009-10: PTPS

SR. No. UNIT NO. Name of the Power Station 2008-09 2009-10 (PROPOSED PERIOD) PERIOD TYPE OF OVERHAULING PERIOD TYPE OF OVERHAULING

1 UNIT- 1 PTPS, Panipat Unit recommissioned on 04.11.2008 (217

days)

(i) Renovation,

Modernization and Upgradation (By BHEL)

  • preventive

maintenance

2 UNIT- 2 PTPS, Panipat 01.03.09 to 15.03.09 (15 days)

Preventive Mtc.

29.01.10 to 15.03.10 (45 days)

Annual Overhauling

3 UNIT- 3 PTPS, Panipat 24.10.08 to 27.11.08 (35 days)

No shut down was availed in 2007-08.

24.10.09 to 07.11.09 (15 days)

preventive maintenance

4 UNIT- 4 PTPS, Panipat 01.04.08 to 18.06.08 (78 days)

Annual Overhauling of 45 days upto 06.05.08 had to be extened upto 18.06.08 due to problem in generator rotor

13.12.09 to 27.12.09 (15 days)

preventive maintenance

5 UNIT- 5 PTPS, Panipat 03-04-08 to 10.04.08 (8 days) Preventive Mtc 01.05.09 to 09.06.09 (40 days)

Upgradation of C&I System. R.L.A will also be carried

  • ut.

6 UNIT- 6 PTPS, Panipat 01.10.08 to 24.10.08 (24 days)

The Annual O/H

24.09.09 to 07.10.09 (15 days)

preventive maintenance

7 UNIT- 7 PTPS, Panipat 09.06.08 to 30.07.08 (51 days)

Annual Overhauling & mandatory inspection. Shut down extended due to problem in Generator Stator.

04.09.09 to 24.09.09 (15 days)

preventive maintenance

8 UNIT- 8 PTPS, Panipat 12.12.08 to 26.12.08 (15 Days)

Preventive Mtc.

16.03.10 to 30.03.10 (15 days)

preventive maintenance

slide-2
SLIDE 2

Maintenance Schedule for 2008-09 and 2009-10: FTPS & DCRTPP

1 UNIT- 1 FTPS, Faridabad 05.11.08 to 25.12.08 (50 days) Capital Overhauling Unit may be phased ouit during 2009-10 (31.03.10) 2. UNIT- 2 FTPS, Faridabad Under Shut down Since 08.09.2008 and phased out during 2008-09 due to uneconomical generation, environment and safety concerns. 3. UNIT- 3 FTPS, Faridabad 31.05.08 to 29.06.08 (30 days) Generator Stator fault & Annual Pre.Mtc. 01.06.09 to 15.07.09 (45 days) Annual Overhauling 4. UNIT- 1 DCRTPP, YamunaNaga r 08.11.09 to 23.11.09 (15 days) preventive maintenance 5. UNIT- 2 DCRTPP, Yamuna Nagar 12.11.08 to 08.12.08 (27 days) for pending works 26.11.09 to 11.12.09 (15 days) preventive maintenance

slide-3
SLIDE 3

Details regarding installation of CTs / PTs of 0.2 class accuracy at PTPS for Special Energy Meters

  • In PTPS-1, the work of installation of interface metering CTs and

PTs on 220 KV Bus-I & II has been completed on 25.12.2008.

  • In Unit-5 and Unit-6, the work of installation of CTs has been
  • completed. The work of installation of PTs is pending for which 9

hours Shut-down on 220 KV Bus-1 is required. The work shall be completed during the earliest available opportunity.

  • The readings from SEMs installed at 220 KV side of Panipat

Thermal Power Station are being taken in compliance to the HERC directives.

slide-4
SLIDE 4

Energy Audit Test of 210 MW Unit-5 of PTPS

Major findings:

  • The Energy Audit Test of Unit-5 was carried out by NTPC from

26.11.2007 to 01.12.2007.

  • There has been a shortfall of about 1.90 % in Unit-5 Boiler

efficiency w.r.t. PG Test Efficiency.

  • The air ingress in ESP & Duct between air heater outlet and ID Fan
  • utlet was very high (about 33.39 %) resulting in high ID fan

loading/& ESP performance.

  • Mill PF fineness: The retention in 50 & 100 mesh is on higher side

and is the main contributor for high un-burnt in bottom ash.

  • There has been a shortfall of 55.91 Kcal/Kwh in TG cycle heat rate

at 100% TMCR load w.r.t. to design values.

  • Both ejectors are in running condition. One of them can be isolated

after rectification of air ingress.

slide-5
SLIDE 5

Energy Audit Test of 210 MW Unit-5 of PTPS

Best Practices Recommendation:

  • Monitoring of critical parameter viz. Flue gas oxygen, Carbon

mono-oxide, Air-heaters differential pressure, super heater spray, main steam temperature/pressure, extraction steam pressure/ temperature, feed water temperature rise across HP/LP Heaters, DM Water Consumption, Condenser vacuum etc.

  • Implementation of Preventive Mtc. Schedule, condition monitoring
  • f auxiliaries to improve reliability and performance.
  • Trip/failure analysis reports prepared by the analysis committee to

be reviewed from time to time. The action taken reports of corrective recommendations of committee should be reviewed from time to time, by higher management to ensure its implementation.

  • To improve House keeping so as to create an ambience for better

working.

  • Training of O&M Engineers to keep them up-dated with best

practices in other Power Stations.

slide-6
SLIDE 6

Energy Audit Test of 210 MW Unit-5 of PTPS

Long term recommendations:-

  • Measurement of furnace temperature and oxygen by high velocity

temperature probe to ensure proper combustion.

  • The Power Station may procure Iso-Kinetic Coal Sampling Device

and clean/dirty air testing kit for regular testing of mills.

  • Multi point oxygen and carbon-mono-oxide probes should be

provided at economizer outlet for proper monitoring of combustion.

  • On-line tube cleaning system to be installed for cleaning of

condenser tubes.

  • On-line energy management system may be installed for close

monitoring of auxiliary power consumption.

  • Feasibility study for replacement of present air conditioning system

with centralized vapour absorption type conditioning Unit common for both unit 5 & 6.

  • Renovation and Modernization of unit after proper residual life and

condition assessment.

slide-7
SLIDE 7

Energy Audit Test of 210 MW Unit-6 of PTPS

Major findings:

  • The Energy Audit Test of Unit-6 was carried out by NTPC from

26.11.2007 to 01.12.2007.

  • There has been a shortfall of about 1.86% in Unit-6 Boiler efficiency

w.r.t. PG Test Efficiency.

  • APH-B Performance has deteriorated considerably and may be due

to damaged heating elements.

  • Mill PF fineness: The retention in 50 & 100 mesh is on higher side

and is the main contributor for high un-burnt in bottom ash.

  • There has been a shortfall of 46.92 Kcal/Kwh in TG cycle heat rate at

100% TMCR load w.r.t. to PG test.

  • CW flow across condenser is less than design flow.
  • Internal inspection/overhauling of ID Fans and rectification of external

air ingress is required.

  • Auxiliary Power could be reduced by stopping one condenser

vacuum pump after attending the air ingress points.

slide-8
SLIDE 8

Energy Audit Test of 210 MW Unit-6 of PTPS

Best Practices Recommendation:

  • Monitoring of critical parameter viz. Flue gas oxygen, Carbon mono-
  • xide, Air-heaters differential pressure, super heater spray, main

steam temperature / pressure, extraction steam pressure / temperature, feed water temperature rise across HP/LP Heaters, DM Water Consumption, Condenser vacuum etc.

  • Trip/failure analysis reports prepared by the analysis committee to

be reviewed from time to time by higher management to ensure its implementation.

  • Implementation of Preventive Mtc. Schedule.
  • Percentage Heat Loss due to devitation in the critical parameter,

which affect heat rate, to be evaluated on a weekly basis. A monthly review of same to be done by the Chief Engineer.

  • Training of O&M Engineers to keep them up-dated with best

practices in other Power Stations.

slide-9
SLIDE 9

Energy Audit Test of 210 MW Unit-6 of PTPS

Long term recommendations:-

  • Measurement of furnace temperature and oxygen by

high velocity temperature probe to ensure proper combustion.

  • The

Power Station may procure Iso-Kinetic Coal Sampling Device and clean/dirty air testing kit for regular testing of mills.

  • Multi

point

  • xygen

and carbon-mono-oxide probes should be provided at economizer outlet for proper monitoring of combustion.

  • On-line tube cleaning system to be installed for cleaning
  • f condenser tubes.
  • The 40 Watt tube lights may be replaced with Energy

Efficient T-5 tubes.

slide-10
SLIDE 10

Benefits achieved after implementation of recommendations of Energy Audit Test of Unit-6

Most of the works as recommended by M/s NTPC during the Energy Audit Test, conducted in Dec., 07 have been carried out in the overhauling of Unit-6 in October, 08. The major improvement in the parameters is as under:

Average value during 3 months before

  • verhauling

Average value during 3 months after

  • verhauling

PLF (%) 97.00 98.59

  • Aux. Consumption (%)

9.43 8.64 Specific Oil Consumption (ml/kWh) 0.88 0.47 Heat Rate (K.Cal/kWh) 2726 2720

Contd...

slide-11
SLIDE 11

Benefits achieved after implementation of recommendations of Energy Audit Test of Unit-6

Parameters Value before O/H

  • n

29.09.08 Value after O/H

  • n

01.11.08 Load (MW) 213 219 Steam flow (T/Hr) 671 665 Drum pressure (Kg/Cm2) 168 167 Condenser vacuum 0.85 0.9 DM consumption (T/day) 270 114 ID Fan loading (Amp.) 115/105/117 (total 337) 109/81/93 (total 283) Feed water temp. at Economiser inlet (ºC) 235.82 238.62 Avg Value gas temp. at AH

  • utlet (ºC)

163 155

slide-12
SLIDE 12

Plant Load Factor (%) of HPGCL Generating Stations upto Jan 09 during 2008-09

Description FTPS HPGCL as a whole Actual PLF (%) with Unit-2 of FTPS in consideration 34.45 71.67 Considering retirement of Unit-2, FTPS, Faridabad on 08.09.08 40.15 72.60

(including DCRTPP)

Excluding UnIt-2, FTPS, Faridabad w.e.f 08.09.08 40.15 74.88

(excluding DCRTPP also)

slide-13
SLIDE 13

Month / Unit wise Plant Load Factor (%) of DCRTPP during FY 2008-09

Month Unit-1 Unit-2 DCRTPP April, 08 68.86

  • 68.86

May, 08 23.88

  • 23.88

June, 08 48.19 82.13 54.61 July, 08 69.99 50.09 60.04 Aug., 08 54.03 74.99 64.51 Sept., 08 39.37 69.90 54.64 Oct.,08 88.95 89.56 89.26 Nov., 08 98.46 37.52 67.99 Dec., 08 99.09 73.43 86.26 Jan., 09 54.38 74.94 64.66 Feb., 09 87.90 69.79 78.84 March, 09 92.14 81.74 86.94 Upto March, 09 68.66 69.53 69.05

Unit-1 synchronized on 13.11.07 and trial operation completed on 14.4.08. Unit-2 synchronized on 29.03.08 and trial operation completed on 24.06.08.

slide-14
SLIDE 14

Region wise details of coal stock position in various Thermal Power Stations of India as monitored by CEA, on daily basis.

Date Northern Region Western Region Southern Region Eastern Region All India (Total) *<7 days **<4 days *<7 days **<4 days *<7 days **<4 days *<7 days **<4 days *<7 days **<4 days 01.01.09 14 8 15 11 5 3 11 7 45 29 15.01.09 12 6 14 10 4 2 10 8 40 26 29.01.09 10 5 14 8 6 1 8 7 38 21 01.02.09 13 6 14 9 5 1 8 8 40 24 15.02.09 10 5 15 10 5 2 10 7 40 24

* critical ** super critical Note: The loss of generation in the country due to shortage of coal in the FY 2008-09 (upto February 10 2009 is 9700 Million Units.

slide-15
SLIDE 15

Details

  • f

coal stock position in Thermal Power Stations of HPGCL

Date Coal stock sufficient for no. of days PTPS Panipat DCRTPP Yamunanagar Position 01.01.0 9 3 Nil Super critical 15.01.0 9 3 Nil Super critical 29.01.0 9 2 3 Super critical 01.02.0 9 1 3 Super critical 15.02.0 9 2 4 Super critical

Note: Loss of generation due to shortage of coal is Nil at HPGCL generating stations.

slide-16
SLIDE 16

Benefits from design change of coal mills in Unit-1 and Unit-2 of PTPS, Panipat.

  • M/s BHEL developed HPMS system for the existing bowl mills

type XRP – 623 of 110 MW Units for improving coal grinding efficiency.

  • In HPMS system, specially developed grinding rolls having

special carbide inserts are provided along with a compatible design of bull ring segments for improved grinding action.

  • The HPMS system was installed and commissioned in coal

mills of Unit-2 during June 08 to August 08.

  • Significant improvement in coal mill reject, outage of coal mills

and guaranteed life of grinding equipment has been achieved.

  • Keeping in view the performance of HPMS system, it is

proposed to replace the conventional milling system with HPMS system in coal mills of 110 MW Units 1, 3 & 4 also.

slide-17
SLIDE 17

Benefits from design change of coal mills in Unit-1 and Unit-2 of PTPS, Panipat – contd.

  • Significant improvement in outage of mills and guaranteed life of

grinding equipment, achieved during six month period as under:

Coal mill outage hours Before HPMS After HPMS coal mill 2A 82.26 20.10 coal mill 2B 71.58 11.11 coal mill 2C 64.28 20.34 coal mill 2D 59.37 21.24 Comparison of guaranteed grinding life of rollers. Conventional milling system HPMS system Grinding rolls 1300 hours with roller adjustment after every 125-150 hrs. 5000 hours with roller adjustment after every 700-750 hrs. Bull ring set 2500 to 2600 hrs. 5000 hrs. Air port ring assembly 7500 hrs. 15000 hrs.

slide-18
SLIDE 18

Benefits from design change of coal mills in Unit-1 and Unit-2 of PTPS, Panipat – contd.

Parameters Six months before installation

  • f

HPMS system Six months after installation of HPMS system

  • Aux. Consumption (%)

11.60 11.46

  • Sp. Oil Consumption

(ml/kWh) 2.73 1.93

  • Sp. Coal Consumption

gm/kWh) 878 870

slide-19
SLIDE 19

Monthly Plant Load Factor (%) of Unit-5 of PTPS since its commissioning during March, 1989 to FY 2008-09

Month 1990-91 1991-92 1992-93 1993-94 1994-95 1995-96 1996-97 1997-98 1998-99 April

  • 34.54

56.90 32.32 83.18 41.20 86.77 91.98 3.08 May

  • 57.33

89.22

  • 90.76

82.66 88.30 11.12 June 26.96 59.76 70.12 11.92 90.51 14.60 44.62 29.28 84.94 July, 40.05 81.17 78.46 62.15 49.26 80.68 82.24 84.64 94.19 Aug 18.52 61.71 85.01 86.46 69.53 61.48 97.40 87.47 80.52 Sept 8.25 88.47 83.25 86.76 88.84 65.17 95.96 70.15 90.76 Oct 60.15 90.36 88.75 83.08 64.11 94.25 96.35 82.92 36.75 Nov 9.180 70.62 89.12 76.20 96.82 90.88 88.81 84.06 91.10 Dec 52.17 92.26 78.52 51.79 96.67 88.74 89.20 96.17 83.61 Jan 74.48 86.74 79.15 92.16 63.08 89.36 81.45 97.98 98.66 Feb 72.02 61.31 68.88 70.83 76.69 95.72 90.39 94.97 85.47 March 67.96 87.10 76.45 95.00 79.65 56.88 80.34 91.07 99.83 During FY 42.97 72.78 78.77 62.44 78.99 64.87 84.7 83.89 71.6

slide-20
SLIDE 20

Monthly Plant Load Factor (%) of Unit-5 of PTPS since its commissioning during March, 1989 to FY 2008-09

Month 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 April 46.80 57.04 98.3 66.55 50.91 77.22 92.29 85.66 72.44 76.34 May 73.03

  • 91.62

18.6 81.3 42.79 95.79 83.18 101.55 93.26 June 87.06 51.18 96.67 90.95 92.32

  • 49.03

99.19 101.86 95.67 July, 88.56 88 83.13 97.07 79.63 89.22 79.24 97.77 100.9 94.65 Aug 97.40 97.7 99.9 100.36 92.4 85.87 89.69 97.2 97.96 98.1 Sept 97.87 100.11 96.8 93.8 98.41 98.81 69.23 95.1 99.87 73.49 Oct 100.10 101.78 100.12 95.87 100.78 100.85 100.1 101.59 93.39 96.22 Nov 92.45 79.5 99.15 98.61 98.4 94.68 97.19 101.69 102.1 102.95 Dec 85.61 96.16 85.47 91.64 93.62 98.61 100.18 102.14 101.6 99.31 Jan 97.13 94.28 93.55 93.77 99.4 96.48 101.71 93.8 92.02 98.44 Feb 89.41

  • 86.11

89.14 99.65 91.22 82.12 91.43 97.46 101.52 March 96.80 93.47 93.33 89.58 85.65 80.93 0.00 50.28 93.38 101.13 During FY 87.75 72.19 93.68 85.44 89.33 79.76 96.69 91.55 96.23 94.27

slide-21
SLIDE 21

Monthly Plant Load Factor (%) of Unit-6 of PTPS since its commissioning during March, 2001 to FY 2008-09

Month 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 April

  • 95.02

29.4 94.75 96.00 26.07 52.9 87.64 May

  • 78.07

25.99 85.22 94.05 67.27 87.43 101.63 June

  • 92.38

78.96 92.06 93.14 98.26 98.83 100.32 July,

  • 96.98

82.55 93.73 64.08 102.5 94.09 92.82 Aug

  • 91.26

89.79 75.82 70.69 103.11 96.62 98.95 Sept 91.93 97.62 95.33 92.29 84.46 101.75 76.31 99.23 Oct 73.98 92.65 99.08 41.4 97.32 98.41 102.38 18.61 Nov 90.78 90.69 96.04 91.7 102.31 99.24 101.45 101.11 Dec 84.11 92.6 87.2 90.26 101.06 102.9 99.16 103.78 Jan 79.32 92.93 97.69 101.13 103.01 102.41 103.7 90.88 Feb 62.39 90.68 99.12 91.37 99.53 95.61 102.57 102.61 March 95.69 95.67 95.76 19.3 0.00 98.42 101.93 103.86 During FY 81.90 92.21 81.38 80.51 74.30 91.4 93.18 91.64

slide-22
SLIDE 22

Monthly Plant Load Factor (%) of Unit-7 of PTPS since its commissioning during Dec., 2004 to FY 2008-09

Month 2004-05 2005-06 2006-07 2007-08 2008-09 April

  • 82.88

96.52 90.72 101.31 May

  • 90.78

72.66 100.83 101.68 June

  • 63.68

85.23 94.36 29.04 July,

  • 70.91

94.41 102.02 4.21 Aug

  • 93.75

101.25 83.95 Sept

  • 101.08

96.57 97.25 Oct

  • 101.36

102.01 102.12 Nov

  • 102.74

101.98 102.33 Dec

  • 81.71

95.47 97.38 Jan 28.97 101.63 98.39 101.90 Feb 64.45 90.71 101.39 101.87 102.53 March 90.68 80.99 53.12 101.19 101.84 During FY 77.17 42.08 90.32 98.91 85.35

slide-23
SLIDE 23

Monthly Plant Load Factor (%) of Unit-8 of PTPS since its commissioning during April, 2005 to FY 2008-09

Month 2005-06 2006-07 2007-08 2008-09

April

53.53 98.16 86.10 101.72

May

77.83 73.43 101.52

June

67.84 92.49 61.47 88.22

July,

73.11 99.48 100.74 89.98

Aug

96.27 96.99 95.10 97.56

Sept

96.19 99.12 95.15 87.86

Oct

97.66 99.00 101.12 98.43

Nov

76.62 50.78 95.77 102.92

Dec

96.22 97.39 102.02 55.54

Jan

90.74 98.81 102.83 103.01

Feb

97.87 86.22 97.85 103.96

March

92.43 101.68 100.09 103.26 During FY 85.32 91.24 86.48 94.41