2.fbc engg
TRANSCRIPT
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Best Practices
Learning and application
In Engineering
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Product profile
Bubbling Fluidized bed combustion (BFBC) boilers
Circulating fluidized bed combustion (CFBC) boilers
Heat recovery Steam Generator (HRSG)
BFBCs for low grade coal as fuels
CFBCs from 75 MW to 250 MW
HRSGs for Frame 5 GT to Frame 9FA GT
Product turnover 5 fold increase to Rs 1000 Cr. in a
span of 4 years
Introduction
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Current practiceAnalysis for improvement for
Ease of manufacture
Comfort for erection
Better performance
Implementation phase (initial)
Continual improvement lead to
Established product with best practices
Approach towards improvement
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Collecting feed back from operational experience of units
Learnings from site action requests and information
obtained during the visit of engineering personnel
Discussion with manufacturing group for ease of
manufacturing and erection
Discussion with erection group before finalisation ofarrangement engineering
Methodology adopted towards improvement
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SH Flow t/h 165
SH Pressure kg/cm2 95
SH Temperature Deg C 540
77 Mw BFBC Power plant - Jindal
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50 MW BFBC Power plant at ACC - Wadi
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SH Flow t/h 75SH Pressure Kg/cm2 65
SH Temperature Deg C 485
BFBC Boiler at PT-IBR Indonesia 3 x 75 TPH
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USAID Test Facility-1986
(90 t/h Hot water)
Combustion Test Rig-1979
0.5 M X 0.5 m
(4,00,000 kcal/h)
FBC Test Facility - 1991
(90 t/h Hot water)
FBC Test Rigs at Trichy
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Municipal Solid WasteShivsankar Ind.,Bangalore
SelCo, Hyderabad
Kiln Char
Sunflag Industries,BandaraWashery Rejects
Tisco, Jamadobha
Fuels Tested
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High Ash coalBellampalli, AP
Mill RejectsParli TPS
Fuels Tested
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Rice HuskRice Mill, Tiruchi
Rice StrawTiruchi
Mustard Crop Residue
Manipal Int., Gurgaon
Biomass Fuels Tested
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Wood ChipsTiruchi
Palm ShellsKerala Electricity Board,
Biomass Fuels Tested
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36
2
26
29
3
1
1
46
6
7
7
9
12
15
Westinghouse-W191
MES-SB30
MES-SB60GE/BHEL-Fr 3
JBE-Fr 5
ALST-MS5001
GE/BHEL-Fr 5
MHI-Fr6
ALST-Fr 6
GE/BHEL-Fr 6
GE/BHEL-Fr 6FA
GE/BHEL Fr 9E
Siemens-V 94.2
GE/BHEL-Fr9FA Fired HRSG Unfired HRSG
3
6
2
26
29
3
1
1
4
6
6
7
79
12
15
Westinghouse-W191
MES-SB30
MES-SB60
GE/BHEL-Fr 3
JBE-Fr 5
ALST-MS5001
GE/BHEL-Fr 5
MHI-Fr6
ALST-Fr 6
GE/BHEL-Fr 6
GE/BHEL-Fr 6FA
GE/BHEL Fr 9E
Siemens-V 94.2GE/BHEL-Fr9FA
Fired HRSG Unfired HRSG
Combined Cycle - 62Cogeneration
Unfired - 9Supplementary Fired - 66Total - 137
ALST-Alsthome Atlantique, France
JBE-John Brown Engg, UK
MHI-Mitsubishi Heavy Industries, Japan
MES-Mitsui Engg & Shipbuilding, Japan
HRSG Experience list
Around 100 HRSGs are
of HARP design
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Two Row Module
Single Row Module
HRSG Module design
improvement
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Module manufacturing Vertical position
For better weld quality
&
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Facility created for largersize HRSG Module
Fabrication vertical
position welding
HRSG Frame assembly
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Standardisation of HRSGs for 9FA GTs
Inlet ductBeam
Bottom brazing
beam
Internal Liner
Inlet duct
HP
IPF
CS
IP LP
Duct
Top brazing beam
Insulation
Main boilerColumn
Modules
HP Drum
IP Drum
LP Drum
HP/IP/LP Drums
Module height
Module width
Heat transfer bundlesdisposition.
Inlet duct configuration
Ducting & Liner system
Insulation system
Structures
Column location and spacing
Floors and stairs
Module support arrangementand hangers
Major components standardised for all 9FA HRSGs
Floor
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CFBC Boiler Design Upgrade
About 50 feedbacks from the operational experience from Surat Lignite(SLPP Phase 1) and BILT Graphics
Learnings from 158 SARs from SLPP I and BILT Graphics incorporated
Discussions with manufacturing and OP & C groups for using ofstandard tooling and materials
Discussions with Erection Group Pre engineering and before
commencement of erection
For 125 MW category
For 250 MW category
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Feedbacks from Operating Units
Lignite Feeder Improvements
Back Sifting of Bed Ash into PA Wind box Back pass Hanger Tube Erosion
FBHE WW Failures - Wall Pitch reduced
AH tube corrosion - Arrangement/Metallurgy
Soot blower at Back pass entry
Welded Flow Orifices for Spray lines
PA and SA ducts NMEJ to MEJ
Cyclone, Feeder Outlet MEJ to NMEJ
Header Connections Changed to avoid Choking
Indigenisation of Refractory, Air-nozzles, Drag Link Chain Feeder, Rotary
Feeder, Vortex Finder
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Backpass Hanger tube Erosion at Entry
o Due to nature of the Duct
connections from the Cyclones
to the common Backpass
preferential gas flow pattern
exists.
o This induces high velocity zones
leading to tube erosion asindicated in the enclosed
transparencies.
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FlueGas
Half Shields
Plan View Convection Backpass Hanger Tubes
CFD Study made and sacrificial Half-shields introduced. Performance
found to be good
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Superheater Header connection change to avoid chocking
Existing Improved
Similar changes in RH and Economiser Headers
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Discussion with Manufacturing Groups
Suggestions Implemented in 125 MW CFBC boilers:
No. ofWW panels reduced from 187 to 148
In-conel attachments in coils replaced by SS Attachments for
easy welding
Combination of T12, T22 & T91 avoided in a single coil to havesingle HT cycle (wherever feasible)
Close pitch drilling of headers eliminated
ID controlled sleeves for coils attachments for easy insertion
Short Radius bends eliminated (Wherever feasible)
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Combustor Panel Openings - improvements
Ease of Panel Manufacture
PresentFuture
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Evaporator circuit close pitch drillingExisting Improved
Similar Improvements made in SH2A, SH2B, RH1, SH3, SH1, Eco, Seal Pot header
connections
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Major issues
Trial assembly of cyclones & match marking at works
Pullout bends of FBHE front panels to be supplied in loose
Erection weld of FBHE coils at about 250 to 300 mm fromwater wall panel
Seal boxes, cyclone, inlet & outlet ducting of cyclone to be fully
welded from inside for better accessibility
Erection Feedbacks Incorporated
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Teething Issues faced and resolved in Giral Phase 1
Leakages of hot ash: Improper seal weldingof pressure parts
were identified and attended to. Procedure evolved and sent toSite to include Protocols for checkingduring erection in Giral II.
Clinker formation at Start-up Burner:ImpingementofHFoilon
burnerthroatcaused clinkers. Resolved bychanging burner tips
with narrower spray angle. HFO was also contaminated withwater - damaged pump barrel, also caused improper combustion
in the burner
Lignite Rotary Air-lock Feeder trips: Frequent feeder trips due to
clutchslipping and resetting of the torquevalue was analysed
andimprovements incorporatedin the clutch assembly and
operating satisfactorily
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Teething Issues faced and resolved Contd.
Foreign material entry into the Lignite feeding system:Foreign
materials like tubes of 2-2.5m longhave found entryinto the
drag chain feedersand damaged theconveyorchain links.
Material hang-up in cyclone: The material buildup in LHS
cyclone was observed on two occassions. After analysis
improvements in operation logics
measurements like seal-pot inlet pressure and
temperature
air injection in cyclone at some critical locations where
material hang up noticed were implemented and the unit
has been in satisfactory operation.
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Limestone size finer:The fines content (
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Issues to be resolved (Customer) - contd.
HFO contaminated with water:The Heavy fuel oil (HFO) used during start-up/load support is contaminated with water and led to improper combustion. The oil pump
barrel got damaged due to water and was replaced. HFO is hence not used in bed lances for
maintaining the load in case of a problem in the Lignite feeding system. Steps taken for reducing
moisture content.
Flue gas analysers :Measurement of CO2 and O2 in order to ensure safe and complete
combustion and SO2 measurement to ensure adequate limestone feeding is yet to beestablished. So far it has been managed with our portable instrument. Presently the instrument
has been calibrated by Vendor and will be observed during operation.
Lignite Drag Chain conveyor trips:Damages of the chain links occurred due to entry offoreign materials. The damaged chain assemblies were stiff. Vendor specialist from UK came to
site, analysed and informed that presence of stagnant wet lignite is the cause. Advised that
lignite is to be drained in case of unit shut down and also lubrication of the chains periodically
to avoid such occurrences. Replaced with new conveyor chain assembly. Failure of Pins noticed
during recent operation, Taken up with Supplier for resolution. Meantime, existing chain
assembly is being replaced with new material supplied for Unit II
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Non Integral FBHE Arrangement 125 MW CFBC design
Integral design Non-integral design
Reduced Shop Weld & Ease of Panel Manufacture
Downcomers (9 nos)
2 nos 457.2 x 40.0
2 nos 355.6 x 30.0
2 nos 141.3 x 16.0
3 nos 219.1 x 22.2
Risers (78 nos)
48 nos 159.0 x 16.0
12 nos 101.6 x 10.0
18 nos 88.9 x 11.13
Supply Pipes (64 nos)
40nos168.3 x 14.27
8 nos 141.6 x 16.0
16 nos 88.9 x 11.13
Downcomers (5 nos)
3 nos 457.2 x 40.0
2 nos 368.0 x 56.0
Risers (58 nos)
58 nos 159.0 x 16.0
Supply Pipes (44 nos)
44 nos 159 x16.0
Use of Standardized
Forged Drum Nozzle
Multi-Cell CLH, Disc Spring & Multi Ball Bearing Supports Eliminated
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Convective Pass Arrangement Reduction in erection joints
10000 x 6800 10871.6 x 6807.2
Section Assy# SL ST
FSH 53 96 203.2
FRH 106 96 101.6
LTSH 106 96 101.6
Eco IV 106 96 101.6Eco III 106 96 101.6
Eco II 106 96 101.6
Eco I 106 96 101.6
Hanger 3x53 203.2
No of Joints 10112 (including FBHE)
Section Assy# SL ST
FSH 55 65/102 180FRH 56 65/96 180
LTSH 110 76 90
Eco IV 110 90 90
Eco III 110 90 90
Eco II 110 90 90
Eco I 110 90 90
Hanger 3x55 180
No of Joints 13252 (including FBHE)
Present Future
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Manufacture & Erection Friendly 125 MW CFB Design Erection
joint reduction
Description Integral design Non integral design Variation
No.of WW headers 251 37 86
No.of WW Panel DUs 297 114 62
Multi cell CLH 36 Nil 100
Convective pass panel bend 1992 Nil 100
No.of joints in
FBHE WW panel 4496 Nil 100
Combustor 2384 2384 No Change
HT coils 13252 10112 24
Others 1027 1027 No Change
Total 21159 13523 36
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Manufacture & Erection Friendly 250 MW CFB Design
Description Proposal
design
Contract
design
Future design
( Suggested)
Variation
Combustor panels 9800 5430 4756 12FBHE RH 1 2500 2160 2160 No Change
Low temperature SH 3000 2880 1440 50
Interstage SH 1 3000 2880 1440 50
Interstage SH 2 3000 2880 1440 50
Steam cooled wall 3300 2700 2560 5
Hanger tubes 4800 3000 2400 20
Final SH 3600 3360 1680 50
Final RH 6000 5760 2880 50
BP Evaporator 5500 5400 3600 33
Economiser 2500 3360 2520 25
Other links 2205 2028 2028 No Change
Total 49205 41838 28904 31
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CFD modeling of ducting for optimisation and for ease of manufacturing.
(Eg. HRSG inlet ducting, Cyclone outlet ducting)
PDMS approach Implemented in Konimabo Nickel CFBC boiler design.
Clashes detected during engineering stage itself.
Modularisation approach To reduce number of erection activities. Care
should be taken for mode of transport
Periodic meeting with site personnel and units concerned apart from pre-
engineering discussion
Interface activities finalisation at 0 date Hyderabad & PEM/Delhi
Importance of proper storage at site and identification of material for easy
retrieval Documentation on lessons learned and documentation for future reference
Enhancing customer awareness on process requirement
Towards bench marking through best practices
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Thank you
Improvement over improvement
Continues with your co-operation ..