activities adopted for performance improvement · 3-tier checklist system for monitoring equipment...
TRANSCRIPT
Activities adopted for Performance Improvement
3 x 250 MW Thermal Power PlantISO 9001:2008, ISO 14001:2004 & OHSAS 18001:2007 certified
Budge Budge Generating Station
Agenda
Brief introduction of CESC Limited & BBGS
Performance parameters & Trends
Activities undertaken for improvement
Awards & Accolades
About CESC Limited & BBGS……
New Cossipore 1949100 MW
Titagarh 1983-84240 MW
Southern 1990-91135 MW
Budge Budge 1997,1999 & 2010
750 MW
• a RP-Sanjeev Goenka group Company in the business of generation & distribution of electricity since 1899
• Total licensed area : 567 sq kms, in & around Kolkata
• Consumer base : over 2.5 million
• Total Generation capacity : 1,225 MW
CESC Limited
Major Landmarks Unit - 1 Unit - 2 Unit - 3
Trial synchronization 16.09.97 06.03.99 12.07.09
Commercial generation 07.10.97 01.07.99 28.02.10
Full load generation 26.02.98 09.08.99 29.09.09
BBGS is the latest, largest & most modern power plant of CESC
ISO 14001:2004ISO 9001:2008 OHSAS 18001:2007
Performance parameters ……
70
75
80
85
90
95
100
105
75.0
9
75.8
4 79.8
5
86.3
8
99.6
1
99.7
7
100.
43
100.
53
93.7
5
82.7
8
90.1
6
Plant Load Factor (%)
Plant Load Factor (%) and Generation (Mu)
3000
3500
4000
4500
5000
5500
6000
6500
3,28
9
3,32
2
3,50
7 3,78
4
4,36
3
4,37
0
4,41
1
4,40
3
4,28
6
5,43
9
5,94
0
Generation (Mu)
Activities – to improve PLF
Export during night lean periods due to trading opportunity in power as per Indian Electricity Act, 2003
5% overloading of machines with the concurrence of OEM keeping all parameters within limits
Ensuring reliability of Units
00-0
1
01-0
2
02-0
3
03-0
4
04-0
5
05-0
6
06-0
7
07-0
8
08-0
9
09-1
0
10-1
1
11-1
270
75
80
85
90
95
100
105
0
100
200
300
400
500
600
70074
.04
75.0
9
75.8
4 79.8
5
86.3
8
99.6
1
99.7
7
100.
43
100.
53
93.7
5
82.7
8
90.1
6
0 0 0 7.5
160
418458 441
301
159107 126
PLF % Export (Mu)
PLF (%) vis-à-vis Export (Mu)
00-0
1
01-0
2
02-0
3
03-0
4
04-0
5
05-0
6
06-0
7
07-0
8
08-0
9
09-1
0
10-1
1
11-1
280
85
90
95
100
92.7
1
93.0
9
94.6
6
91.7
4
92.7
4
97.4
7
97.0
4
97.3
9
97.5
4
94.6
1
91.8
9 95.2
Plant Availability Factor (%)
Activities – to improve PAF
Reduction of Annual overhauling period● Annual overhaul period from 28 days to 12 days
● Use of sky climbers
● Replacement of wind-box internals which were earlier repaired
● Engagement of multiple contractors 24x7 hrs
● TG major overhauling every 6 years
● Ancillary plants overhaul throughout the year
Activities – to improve PAF
Improved Maintenance Practices● Daily maintenance planning meetings for planned jobs
● CFT for condition based monitoring & predictive maintenance
● Renewal of Boiler back-pass tubes in a planned manner to reduce
Boiler tube leakages
● Proactive identification of Boiler tube leakages vide Acoustic Tube
leak Detection System
Activities – to improve PAF
Improved Operational Practices● 3-tier checklist system for monitoring equipment health
● Strict parameter deviation monitoring by operation personnel
● Installation of ELC machines for online oil conditioning
● Installation of chute vibrators to prevent chute chokage during
monsoon
● Forced air cooling of Turbine to reduce downtime
● Standard operating procedures
00-0
1
01-0
2
02-0
3
03-0
4
04-0
5
05-0
6
06-0
7
07-0
8
08-0
9
09-1
0
10-1
1
11-1
27.60
8.10
8.60
9.10
9.60 9.33 9.189.39
9.048.69
8.328.13 8.03 8.00
8.268.62
8.25
00-0
1
01-0
2
02-0
3
03-0
4
04-0
5
05-0
6
06-0
7
07-0
8
08-0
9
09-1
0
10-1
1
11-1
270
75
80
85
90
95
100
74.04 75.09 75.8479.85
86.38
99.61 99.77 100.43 100.53
93.75
82.78
90.16
Specific Energy Consumption (%) vis-à-vis PLF (%)
Activities – to improve Specific Energy consumption
● dP across feed control station has been reduced from original
8 Kg/cm2 to 1.8 Kg/cm2 thus minimizing throttling loss
● Optimizing number of CW Pump operation depending on
seasonal temperature, maintaining design vacuum
● Modification of Furnace draft control logic related to ID Fan
vane and scoop control by making the vane operation band
dynamic with respect to the scoop position
● Optimizing Compressor loading / unloading
Activities – to improve Specific Energy consumption
● Stage blinding in Condensate Extraction Pump
● Use of dual speed CT fan motors to allow running at lower
speed during winter
● Intermittent operation of ISS hopper drains thus reducing
running hrs of Intake pump
● Timer circuit has been incorporated to control outdoor
lighting and use of energy efficient lights at control room
Activities – to improve Specific Energy consumption
● Use of energy efficient motors
● Installation of Energy monitoring system to monitor energy
consumption of electrical boards and HT drives and thus
enabling to take corrective measures proactively
Future Plans● Installation of VVVF drives for PA fans
● Use of LED lamps
00-0
1
01-0
2
02-0
3
03-0
4
04-0
5
05-0
6
06-0
7
07-0
8
08-0
9
09-1
0
10-1
1
11-1
20.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
0.74
0.61
0.60
0.30
0.23
0.12 0.13
0.13 0.15
0.33
0.88
0.39
Higher oil consumption is due to trial synchronization and stabilization of Unit-3
Specific Oil consumption (ml/Kwh)
Activities – to improve Specific Oil consumption
● Higher reliability & lesser Outages
● Trial of Oil guns without oil consumption
● To check sequence of operation
● To ensure scavenge takes place thus clearing the oil tips
00-0
1
01-0
2
02-0
3
03-0
4
04-0
5
05-0
6
06-0
7
07-0
8
08-0
9
09-1
0
10-1
1
11-1
21.50
1.70
1.90
2.10
2.30
2.50
2.70
2.90
2.67
2.28
2.24 2.
35
2.47
2.11
1.85 1.
89
1.87 1.90
2.10 2.
15
Specific Water Consumption (l/Kwh)
Activities – to improve Specific Water consumption
● Increase of the cycle of concentration of CTCW system by
dosing corrosion inhibitors / anti-scalant special chemicals
and monitoring Calcium hardness level, thus decreasing CT
blow-down
● Changing the mode of operation of ISS hopper blow-down
from continuous to intermittent, thereby reducing the
Intake water consumption
● All Volatile chemical treatment in power cycle water
thereby avoiding Boiler blow-down
● Utilization of CTCW blow-down as station service water
● Diversion of ACF backwash effluent to Holding pond for
recycling
● Recirculation of station effluent from holding pond to raw
water treatment plant
Activities – to improve Specific Water consumption
Original Scheme
Cooling Water Forebay
Cooling Water Pumps
Condenser
Turbine
Cooling Tower
Hot Water
Cold Water
River Hoogli
Holding PondRaw Water Treatment
Plant
Station Services
CT Make-up
Canteen
Mun
icip
al D
rain
DM Plant
Fish Pond
Revised SchemeDischarge outside Plant
Modifications done
Sludge Pit
CT
Blo
wd
ow
n
Pump House
Control of Plant effluentWe are a Zero Effluent discharge Station
Bottom Ash Zero Discharge System
Click to edit Master text stylesSecond level
Third levelFourth level
Fifth level
Click to edit Master text stylesSecond level
Third levelFourth level
Fifth level
0 - discharge system
0 - discharge system schematic
CDM Projects
Reduction of Boiler Efficiency Loss due to blow down by achieving All Volatile Treatment (AVT)/ Zero Solid Treatment
Modification of Furnace draft control logic related to ID Fan vane and scoop control
Globally FIRST Thermal Power plant to register 2 of our Energy saving projects with UNFCCC
00-0
1
01-0
2
02-0
3
03-0
4
04-0
5
05-0
6
06-0
7
07-0
8
08-0
9
09-1
0
10-1
1
11-1
20
20
40
60
80
100
120
140
160
141
129
119
110
67
58
46
34
50 48 48 43
Suspended Particulate Matter (mg/Nm3)
Monitoring & Control SPM & RPM
Sl Systems implemented
1 Ammonia Dosing System
2 Water Fogging System
3 DE & DS System
4 Dry Fog System
5 Water Sprinkler System
Major Initiatives Towards
Ammonia Dosing Ammonia Dosing
Online SPM Online Stack
Category Uses of ash
1 Bricks / Blocks / Tiles / Cement
2 Roads & Embankments
3 Structural filling
4 Land filling
Barge Silos HCSS
Intiatives towards 100% Ash utilisation
Awards & Accolades ……
Environment Excellence award – 2004 & 2006
National Award for utilization of Fly ash, from Ministry of Power, Ministry of Environment & Forests and Department of Science & Technology in 2005
National Award for Excellence in Energy Management from CII in 2005
National Award for Excellence in Water Management from CII in 2005
Gold award for Excellence in Environmental Management from Greentech Foundations in 2005, 2006 & 2007
National Award from CEA in 2009-10 for meritorious performance amongst Thermal Power Plants in Environmental Management
Awarded by CEA for achieving highest Plant Load Factor in the country in 2005-06
Award for Innovative Environmental Project (Dry Fog system at Wagon Tippler & Secondary Crusher House) from CII in 2012
Silver award for Best Environmental practices from CII for the year 2009 -2010
Good Green Governance award from Srishti Publications in 2011
Asian Power Award for Best Environmental Management amongst all Power plants of Asia in 2010
Thank You