1 jsw energy limited of 149 rwpl mopr – july - 14
TRANSCRIPT
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1JSW Energy Limited of 149RWPL MOPR – JULY - 14
INNOVATION AND BEST PRACTICES
July ’15
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2JSW Energy Limited of 149RWPL MOPR – JULY - 14RWPL- Barmer
Contents
APC Reduction Initiatives
Heat Rate Improvement Initiatives
O&M Practices
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3JSW Energy Limited of 149RWPL MOPR – JULY - 14RWPL- Barmer
APC Reduction Initiatives
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4JSW Energy Limited of 149RWPL MOPR – JULY - 14RWPL- Barmer
Running 3 CW Pump for four units
Original Scheme: Four CW Pumps are to be kept in operation for condenser cooling and auxiliary cooling water requirements of four units in the plant.
Observations: In normal running with four CW Pumps in operation, Discharge pressure : 0.21-0.23 MPa. Cooling water range : 7.5°C around Subcooling: Upto 2°C intermittently specially in winter season
Analysis & Trial Run: Flow through the CW Pumps reduced by throttling the valves at the condenser inlet. Once the valves were closed up to 70 %, one out of the three pumps was stopped. The three pumps were operating at a discharge pressure of 0.18-.19 MPa. Increase in the cooling water range across the condenser from 7.6 °C to 9.5 °C. However no effect on vacuum and other parameters were observed. Improvement in Cold water temperature with reduction in water loading in Cooling tower.
Result: Energy Saving of 4600 kWh per hour with eight units in operation. Two standby CW Pumps instead of one for four units.
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5JSW Energy Limited of 149RWPL MOPR – JULY - 14RWPL- Barmer
Running 2 ACW Pump for four units
Original Scheme: One ACW Pump (motor rating 180 kW, capacity 1400 m³/hr) is being provided for each unit for auxiliary cooling water.
Observations & Modification: Rerouting the ACW water to Plate Heat Exchanger from Generator Air cooler return (instead
of ACW Pump discharge as per original scheme). Common discharge header of ACW Pump of two units. Successful trial conducted in unit #7 & #8
Sketch: ACW System Modification
Result: Energy Saving of 160 kWh per hour. Increase in redundancy of the system. Change in logics of Standby pumps of ACW system accordingly.
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6JSW Energy Limited of 149RWPL MOPR – JULY - 14RWPL- Barmer
VFD Installation in LP Drip Pump
LP drip pump was operating with discharge control valve opening of 30 to 40%.
One stage of LP drip pump was removed and achieved a benefit of `9.2kwh per hour.
In other pump, a VFD was installed and achieved saving of 18.2 Kwh per hour per Unit.
Benefits:-
Net power saving of 18.2 Kwh per hour per LP Drip pump achieved.
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7JSW Energy Limited of 149RWPL MOPR – JULY - 14RWPL- Barmer
Optimization of ESP
Earlier the ESP operation was on manual mode and KV and mA remains same across the
load variation as well as SPM variation.
ESP operation put on Opacity control mode.
Benefits :
Reduction in ESP power consumption by putting ESP in Opacity control mode for controlling
the SPM under limit.
Reduction in ESP power consumption from 400 KW to 100 KW per unit.
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8JSW Energy Limited of 149RWPL MOPR – JULY - 14RWPL- Barmer
Heat Rate Improvement
Initiatives
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9JSW Energy Limited of 149RWPL MOPR – JULY - 14RWPL- Barmer
De-superheating water sourcing
De-superheating water sourcing after HPH-1 boiler feed water instead of HPH-2 inlet,
The De-superheating water temperature shall be 240 Deg C instead of 165 Deg C.
Benefits:-
Improvement in cycle efficiency by way of regenerative feed water heating and
ultimate reduction in heat rate by 2 kcal/kwh.
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10JSW Energy Limited of 149RWPL MOPR – JULY - 14RWPL- Barmer
O & M Practices
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11JSW Energy Limited of 149RWPL MOPR – JULY - 14RWPL- Barmer
Online Performance Monitoring System
Online real time Performance Monitoring System developed in house: Turbine Heat Rate Boiler Efficiency Heaters Performance Heat rate deviation Economizer Steaming Turbine Cylinder Efficiency Cooling Tower Performance
MS Excel with inbuilt steam table synchronized with DCS data
Benefits: Availability of real time performance of the system
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12JSW Energy Limited of 149RWPL MOPR – JULY - 14RWPL- Barmer
Regular monitoring of APC and GAP Analysis
Major equipment / system Auxiliary Power Consumption being monitored:
Boiler Fans Boiler Feed Pump Condensate Extraction Pump Cooling Tower ESP CW Pump BOP System: Lignite Handling system, Ash handling system, Main Air compressors etc
Benefits: Equipment/system unit wise comparison available on specific power basis. Identification of high energy consuming equipment on daily basis.
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13JSW Energy Limited of 149RWPL MOPR – JULY - 14RWPL- Barmer
In House Helium Leak detection System
Helium Leak detector system procurement from M/s Agilent Technologies, USA along with the Helium gas
Identifying air ingress across Condenser and other negative pressure areas Air ingress zones in VAM system
Benifits: Vacuum Improvement in the system System used in running units, hence problem identified prior to shutdown
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14JSW Energy Limited of 149RWPL MOPR – JULY - 14RWPL- Barmer
APH Bypass Arrangement
APH Bypass Arrangement made to avoid Sulphur corrosion
Both Primary Air and Secondary Air by-pass arrangements have been provided.
Benefits : -
APH tube life enhancement.
Faster cooling of boiler
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15JSW Energy Limited of 149RWPL MOPR – JULY - 14RWPL- Barmer
LOTO-Lock out and Tag out
Adopted Lock Out and Tag out system in isolation of equipment / system.
Fool proof method which enhance safety performance.
Benefits:-
Improved Safety performance.
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16JSW Energy Limited of 149RWPL MOPR – JULY - 14RWPL- Barmer
Furnace Water Wall Corner Refractory Modification
OEM design Breaker at the Furnace water wall corners are eliminated.
Three tubes at each corner on all the water wall throughout the height are covered with Refractory
A case of confidence on experience than struggling with original design.
Benefits:
The elimination of frequent corner tubes failures.
Elimination of casting of intricate corner breaker.
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17JSW Energy Limited of 149RWPL MOPR – JULY - 14RWPL- Barmer
Reduction in Bed Ash Conveying Pipe Line Erosion
The bed ash conveying pipe line are getting eroded very fast.
Many modification in the system and operation philosophy
D- pump operation changed from time mode to level probe mode
Conveying time optimization 300 sec to 150sec
Discharge conveying pressure cut off 0.5Ksc to 1.4Ksc to ensure the dense conveying.
The 90º composite elbow has been changed to Drum type (Damru Bends).
Pipe line thickness survey to identify the erosion points.
Ensured dense phase conveying
Benefits :
The life of the conveying pipe lines improved.
Improvement in ambient air quality.
Reduction in dumper unloading.
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18JSW Energy Limited of 149RWPL MOPR – JULY - 14RWPL- Barmer
Keeping HP heater 2 in service while boiler lit up
Keeping HPH-2 in service during any kind of Unit lit up (Cold, Warm, Hot or Very Hot Start Up) after
HP Bypass in service and HP bypass pressure more than 0.1 MPa
Benefits :
Increase in Economizer I/L FW temp by 40-60 Deg C (i.e. from 70-80 Deg C to 120 - 140 Deg C).
Increased life of ECO tubes due to Reduction in Cold-end Corrosion of ECONOMISER
Increased life of APH Tubes due to reduction in Cold End Corrosion of APH tubes due to increased
Flue Gas temp at APH I/L.
Reduction in Oil consumption during lit up..
Energy Saving of 18.6 GCal per lit up.
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19JSW Energy Limited of 149RWPL MOPR – JULY - 14RWPL- Barmer
Link Canal Height increase at Mohangarh Pump House
In Mohangarh Pump House earlier sump level was maintaining 3.5 - 4.5 meter.
For utilizing main Canal head, link canal side wall height increased by 1m.
Now Sump level maintaining between 4.5 - 5.5 meter sump level resulted in increased
pump suction head.
Benefits :
Reduction in frequent operation of Link Canal Gate.
Increase in station water delivery by 30-40 m3/hr.
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20JSW Energy Limited of 149RWPL MOPR – JULY - 14RWPL- Barmer
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21JSW Energy Limited of 149RWPL MOPR – JULY - 14RWPL- Barmer
THANK YOU