mpl’s journey towards acclimatizing with new regime of flexi … · 2020. 10. 30. · tdbfp pid...

Private and Confidential | 1

MPL’s journey towards

“Acclimatizing with new regime of Flexi-Operation”Sub-Title: Changes incorporated in Operating philosophy and Inhouse solutions

Presented By:

Samir PandabEmployee No: 204595

• First Successful venture in PPP model (Tata

Power & DVC)

• Capacity: 2X525 MW. (Greenfield project –

Largest generating Station in ER for Tata

Power)

• Raw material: Coal (BCCL/CCL) & LDO/HFO

and water from DVC Reservoir

• Zero date : 25.10.2007

• COD : U#1 – 01.09.2011

• COD : U#2 – 24.07.2012

• First RO Plant ( for Zero Discharge)

• First NABL Accredited Laboratory in ER.

• BTG : M/s BHEL ; AHP : M/s MBPL; CT : M/s

L&T

Facts & Profile

Maithon Power Limited


Business Environment &

WorkflowCERC, ERLDC

LTOA Customers

DVC150 MW

TPDDL300 MW

WBSEDCL300 MW

TPTCL

KSEBL300 MW

PGCIL 400 kV Network

BCCL/CCL Fuel IOCL/BPCLFuelUnit 1 525 MW Unit 2 525 MW

O&M Associates

IndwellBTG

MBPLAHS

Mc NallyCHP

Maithon Power Limited

TATA POWER 74% DVC 26%

Min

istr

y o

f En

viro

nm

ent

& F

ore

st

Ministry of Power

Go

J, J

SPC

B, C

PC

B

Community

Workforce

Lenders


Future of Thermal Power Plants-May be or may be not??

0

200

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600

0:00 3:00 5:00 7:00 9:00 12:00 15:00 19:00 22:00 0:00

LOAD VS T IME PLOT

0

200

400

600

0:00 3:00 5:00 7:00 9:00 12:00 15:00 19:00 22:00 0:00

LOAD VS T IME PLOT

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600

0:00 3:00 5:00 7:00 9:00 12:00 15:00 19:00 22:00 0:00

LOAD VS T IME PLOT

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400

600

0:00 3:00 5:00 7:00 9:00 12:00 15:00 19:00 22:00 0:00

LOAD VS T IME PLOT

Condition of Base Load operating Thermal power plants over a span of 15 years.

2019

2022 2030

2015

Changing Markets: Increased competition from Units with lower Variable cost and penetration of Renewables with intermittent generation. Results: Load shifting, Seasonal Peakers, Layup.


Why Flexibilization and Change in Approach ??

Electricity at an affordable price having minimal environment footprint has been the focus of our country. Our country has a planto install 175 GW renewable generation capacities by 2022 out of the total installed capacities of 479 GW.

Such a large-scale integration of renewable energy would require balancing by the conventional power generators to manage thevariation in loads. Flexing Thermal (mainly coal based ) units to accommodate Renewable energy would be the major challengefor our country. This integration of renewable power generation with thermal would require “Flexible and Reliable operation ofthe Thermal Generators” at its MTL (Minimum Technical Limit) condition as and when required.

To enable such large-scale integration various initiatives along with “Digitization” measures are being taken up so as to meetthe basic propaganda of “Cheap and Reliable Power”.

This presentation mainly covers the following topics:1. Flexible Operation / Flexibilization:

a) Unit Operation at 55% MCR as per CERC guidelines.b) Frequency response (Primary and Secondary Response and 1% Ramp rate to recover 100% ROE.

2. Digitization and Inhouse Solutions:a) Combustion Optimization using AI/ML in collaboration with TCS.b) Automated Scheduling Software development in MS Excel.c) Integration of Power BI tools in creating app in Google Play for MIS and trend analysis.d) Development of SHR and APC Dashboard.e) Development of Coal Mill operating Window.f) Integration of ADORE and GE APM tools with SAP.


Flexible Operation

MTL Restructure:

Unit Operation at 55% MCR as per CERC guidelines.

Grid Compliance:

Frequency response and 1% Ramp rate to recover 100% ROE (F/D ratio> 75%).

Agenda-1


MTL Restructure:Unit Operation at 55% MCR as per CERC Guidelines

MPL had its Minimum Technical Limit at 680 MW (340 MW for either Units) which was jointly decided by the beneficiaries, ERLDCand MPL till an amendment on Grid Code Regulations was passed by CERC vide Notification No: L-1/18/2010-CERC on06.04.2016 stating:

6.3B : Technical Minimum Schedule for operation of Central Generating Stations and Inter-State Generatingstations. “The technical minimum for operation in respect of a Unit or Units of a Central Generating Stations and Inter-StateGenerating stations shall be 55% of MCR loading or installed capacity of the Unit of a generating station”.

To abide by the Amendment, Minimum Technical Limit for MPL got revised to 577.5 MW which is 55% of 1050 MW.For individual unit MTL is 288.75 MW with normative APC of 6.25%. So, Ex-bus generation stands at 541.4 MW.

Unit operation at such a low load proved cumbersome and we faced numerous constraints which includes:

• Drum Level fluctuations• Poor Flame Intensity• Boiler Metal temperature excursions. LTSH metal temperature> 4600C and Reheater metal temperature >5900C.• Low HRH temperature at IP turbine Inlet < 5300C• Poor Furnace to Windbox DP < 60 mmWC• Inability to perform Soot blowing operation due to poor flame conditions.


Initiatives that were taken to eradicate the Constraintsof running at new MTL condition

Drum Level Fluctuations:

Fluctuations in Drum level were observed at load<320 MW with recirculation valves of both TDBFP’s in CLOSED condition. Toavoid opening of Recirculation valve at load 320 MW and below following changes were incorporated.

1. Drum Level Control Parameter Tuning was done by C&I department to smoothen out the damping effect.• Both TDBFP’s Speed control Gain has been changed to 1.4 from 1.6.• Both TDBFP’s Speed Control Reset has been changed to 2.75 from 3.

• Gain = INPUT/ OUTPUT,

• Where , Input = Speed and Output = Drum Level.

•

• a b

a. Before gain and reset was changed.

b. After gain and reset was changed.

Changes incorporated in both Units

Date Equipment Gain Reset

04-12-2018 TDBFP 1.6 4 to 3.5

06-12-2018 TDBFP 1.6 to 1.4 3.5 to 3.0

11-12-2018 TDBFP 1.4 3 to 2.75

Stepwise reduction of Gain and Reset value of TDBFP Speed controller


2. Dynamic response of TDBFP with respect to Load:

TDBFP PID controller shall acquire dynamic value depending upon the changes in Load. PID controller will act in FAST mode when load is less than 400 MW if any of the recirculation valve of TDBFP’s is NOT CLOSED for either Units.

Unit-1 RESET Value

Load < 400 MW 2.75

Load < 400 MW or Any Recirculation Valve NOT CLOSED

4.00

Load > 400 MW 4.00

Unit-2 RESET Value

Load < 400 MW 3.00

Load < 400 MW or Any Recirculation Valve NOT CLOSED

4.00

Load > 400 MW 4.00

3. Sliding Pressure Curve has been modified and Throttle pressure has been kept higher up to 300 MW.

Old Curve Modified Curve

Load ( MW )Sliding Pressure Set point

( Kg/cm2 )Load ( MW )

Sliding Pressure Set point ( Kg/cm2 )

250 120 250 130

325 140 300 145

350 150 350 150

375 155 375 155

400 160 400 160

Initiatives- Continued


Poor Furnace to Windbox DP:

At load< 320 MW, Furnace to Windbox DP is maintained as low as 60 mmWC whereas as per the curve proposed by OEM it shallbe at 100 mmWC (60.95 % of MCR).

Following actions were taken to improve the Furnace to WB DP:

• Auxiliary air dampers and Fuel dampers were cross checked from local and DCS command in opportunity shutdown.• U-OFA and L-OFA dampers are being kept closed.• Modifications were done in the O2 vs Load curve as has been shown in consultation with ex-BHEL consultants and Boiler experts.

Old Curve Modified Curve

Load (MW) Oxygen Set Point (%) Load (MW) Oxygen Set Point (%)

0 15.4 0 15.4

200 5.4 200 5.4

315 4.2 315 4.5

420 3.56 420 4

500 3.56 450 4

600 3.56 500 3.86

600 3.86



Poor Flame Intensity:

While operating Unit at Load< 300 MW it is observed that furnace conditions deteriorates, and flame intensity as sensed byfireball scanners falls below 50 lumens for each elevations. Often the fireball scanners just shows no flame in certain lowerelevations (AB, BC specifically) as if the flame had extinguished. To improve the flame intensity as well as fire ball stability atlower loads following actions were taken:

• 4 consecutive Mills operation is carried out instead of 5 Mills looking after the specific coal consumption pattern. This enables the heavyloading of the 4 respective mills in service rather than a lean loading of 5 Mills and improves flame stability and intensity. With 4 mills inservice the flame intensity remains in the range of 70-85 Lumens.

• After a rigorous hit and trial method with different Mill combinations it is being concluded that Mill Combination C-D-E-F was found mostsuitable for maintaining flame stability as well as SH/RH steam and metal temperature close to design parameters.


Low HRH Temp and High Reheater metal temp:

Low HRH temp and high reheater metal temp has been one of the prime issue MPL had faced over a long time. Areas whereimprovements were done consists of the following points:

• Gap Mill operation to accommodate a major portion of the furnace volume.• Tier wise soot blowing looking after the DT and DP across the heat transfer elements.

• Introduction of Reheater metal temp bias logic with Burner Tilt in Auto.• Top 6 Mills operation at full load.


Grid Compliance:Primary Frequency Response (RGMO Response)

RGMO influence in MPL is being kept ON as a regular practice to support grid in case of major frequency swings. A maximum of25 MW of RGMO influence on either side is being provided to the governor.

Ramp up-down of both Units of MPL happened to be 50 MW/block (15 mins) as was bilaterally agreed between MPL and ERLDClooking after undue stress in boiler. This happens to be 3.33 MW/min which is too low when compared to the standards set byCERC and CEA of 1% of maximum capacity of the Unit, which in our case stands at 5.25 MW/min.

Target 5.25 MW/min

Actual

Maximum Ramp up rate 3.8MW/min

Maximum Ramp down rate 4.0MW/min

Initiative Points:

• Identification of Load vs Time plot over a span of last 6 months and tracking of SG, Net Export with respect to Time to calculate the actual load ramp rate

• RGMO influence kept ON apart from emergency conditions as per CERC norms.• Tuning of CMC for fast action during load ramp up-down and change in sliding pressure curve to keep machine in throttled

condition.

Data Analysis of the past 6 months data: (Oct-2018 to Mar-2019)


Instances of Load pick up/Load drop during Normal running condition or during Emergency has been captured and mentioned below:

Unit/Date From Load (MW) To Load (MW)Time Taken

(in mins)

Rate of Increase

(MW/min)

Rate of Decrease

(MW/min)

Unit-1 on 14th July-

2019430 460 5 6

Unit-1 on 4th August-

2019320 350 5 6

Unit-1 on 4th August-

2019315 335 3 6.67

Unit-1 on 5th

September-2019345 315 5.5 5.45

Unit-2 on 5th

September-2019470 440 3 10

Unit-2 on 1st

September-2019520 490 4 7.25

Note: All the figures are within acceptable limits

The Results


As per the new CERC norms, from 01.04.2020, MPL was required to comply 1% i.e. 147.66 MW ramp otherwise an amountequivalent to 0.25% of ROE shall be deducted which was quite a big amount of 3.5 crores. Prior to this, the declared ramp was50 MW, so with the new norms it was increasing by almost three folds. After few initial setbacks, the team brainstormed variousstrategies and accordingly SOPs were prepared.

1% Ramp rate to recover 100% ROEBenefits: 3.5 Crore

Some of the key automation introduced in the ABT system were:

• Automatic Calculation of Expected Ramp• Automatic Calculation of Actual Ramp in the block.• Automatic Calculation of Next block SG ramp (To give CDEs expected ramp of the next block during the current block itself).• Automatic Calculation of Current block asking export.• Automatic Calculation of Individual Unit expected generation to achieve the ramp.• Automatic Generation of system Alarm in case of Ramp up/down schedule in the next block, in the current block itself.

Critical Factors for Success:

• Daily tracking and review of achieved and failed ramps and their reasons.• Prepared SOPs of various cases of ramps to make it more process driven.• Entire ABT system was revamped to give real time data guidelines.• C&I department was informed about the parameter deviation during the ramp.• IT department has been asked to revamp the system hardware as per requirement.• Daily review of ramp achievement and the lapses if any along with parameter deviation.


Revamped ABT system via MS Excel tool.


The Results

50.0%57.1%

51.3%

50.0%54.5%

53.8%

56.4%

54.6%

55.4%

55.9% 59.0% 60.5%65.6% 66.5% 69.8% 72.0% 75.2%

75.3%

75.8% 76.7% 77.2%

0.0%

20.0%

40.0%

60.0%

80.0%

100.0%

120.0%

% A

chie

ved

Date

Day wise % %

Cumulative %


Agenda-2

Digitization and In-house

Solutions

Combustion Optimization using AI/ML

Startup Oil Planning Toolkit

Coal Mill Operating Window

Coal Supply Chain

Management

SHR and APC

Dashboard

Integration of Power BI

tools


Combustion Optimization using AI/ML

Plant Twin Process Twin


Integration of Power BI tools in creating app in Google Play

MPL-Flash : An application which is being used for trend analysis and KPI tracking


Coal Supply Chain Management


Coal Supply Chain Management-Continued


Real Time Station Heat Rate Dashboard

Parameters Values UOM

Unit-1 HR PAT cycle 2369 kcal/kwh Unit-1 Unit-2 Unit-1 Unit-2 Unit-1 Unit-2 In Crores Unit-1 Unit-2 In Crores

Unit-2 HR PAT cycle 2370 kcal/kwh MS temp 0.00 0.00 0.00 0.22 kcal/kwh 0.0 0.0 0.000 0.0 1731.4 0.000

Last FY Operational SHR 2353 kcal/kwh HRH temp 0.00 0.00 0.00 0.00 kcal/kwh 0.0 0.0 0.000 0.0 0.0 0.000

Vacuum 0.00 0.00 0.00 0.00 kcal/kwh 0.0 0.0 0.000 0.0 0.0 0.000

SH spray 0.00 9.09 0.00 8.42 kcal/kwh 0.0 70136.3 0.007 0.0 64995.6 0.006

RH spray 0.00 13.44 0.00 7.52 kcal/kwh 0.0 103712.6 0.010 0.0 58030.2 0.006

DM makeup 0.97 0.12 0.65 0.29 kcal/kwh 24.1 954.3 0.000 16.2 2248.4 0.000

Targets Unit-1 Unit-2 UOM DFG without correction 0.00 3.94 0.00 0.47 kcal/kwh 0.0 30442.5 0.003 0.0 3661.2 0.000

TGHR 94.80 2175.48 kcal/kwh DFG with correction 0.00 20.95 0.00 15.68 kcal/kwh 0.0 161688.0 0.016 0.0 120994.7 0.012

Design Unit HR 2234.00 2234.00 kcal/kwh APRDS Flow 0.00 0.05 0.00 0.10 kcal/kwh 0.0 410.3 0.000 0.0 782.6 0.000

Unit HR 110.23 2509.20 kcal/kwh TDBFP Extraction Steam Flow #### -0.82 #### -0.68 kcal/kwh #VALUE! -6334.5 #VALUE! -20.4 -17.0 0.000

Deviation (Controllable+Uncontrollable) -2258.77 139.20 kcal/kwh Total HR Loss without DFG correction #### 25.82 #### 16.35 kcal/kwh #VALUE! 199321.41 #VALUE! -4.23 131432.24 0.013

Boiler Efficiency ( Fixed Value) 86.00 86.70 % Total HR Loss with DFG correction #### 42.83 #### 31.55 kcal/kwh #VALUE! 330566.97 #VALUE! -4.23 247034.42 0.025

Unit-1

Average Coal GCV 3926 Kcal/kg

Average Cost of Coal 4000 Rs/Tonne

Coal Cost 4 Rs/kg

Cost of 1 Kcal 0.001018849 Rs/Kcal

Running Load 525 MW

Generation Capacity of 1 Unit/Day 12.6 MU

PLF 75.01 %

Gen at 100 %/day 9.45126 MU

Gen at 100 %/year 3449.7099 MU

Gen Capacity of 1 Unit/year 3449709900 Kwh

Cost of deviation of HR by 1Kcal/Kwh

for a yearly gen of 1 Unit3514732.45 Rs

35.15 Lakhs

U-1 generation 0.024 Mu's

U-2 generation 7.576 Mu's

SHR Targets

CFT-Derivatives

Current Value Last 24 hrs avg

Cost Calculation and Deviation

0.000

Specific Steam Consumption

Unit-2

2.913

Current Value Last 24 hrs avg

Loss Calculation

UOM

Real Time SHR Dashboard

Parameters affecting HR

0.00

0.00

0.00

0.00

0.00 0.

97

0.00

0.00

0.00

0.00

0.00

0.00

0.00

9.09

13.4

4

0.12

3.94

20.9

5

0.05

-0.8

2M S T E M P H R H T E M P V A C U U M S H S P R A Y R H S P R A Y D M M A K E U P D F G W I T H O U T

C O R R E C T ION

D F G W I T H C O R R E C T ION

A P R D S F L OW T D B F P E X T R A C T IO N S T E A M F L OW

KCAL

/KW

H LO

SS

C U R R E N T V A L U E - S H R

Unit-1 Unit-2

0.00

0.00

0.00

0.00

0.00 0.

65

0.00

0.00

0.00

0.000.22

0.00

0.00

8.42

7.52

0.29 0.47

15.6

8

0.10

-0.6

8M S T E M P H R H T E M P V A C U U M S H S P R A Y R H S P R A Y D M M A K E U P D F G W I T H O U T

C O R R E C T IO N

D F G W I T H C O R R E C T IO N

A P R D S F L OW T D B F P E X T R A C T IO N S T E A M F L OW

KCAL

/KW

H LO

SS

L A S T 2 4 H O UR S A V E R A G E V A L UE

Unit-1 Unit-2

Real time tracking of important KPI’s and parameters affecting SHR and the losses incurred in terms of INR.


APC Dashboard

30-Jun-20 Generation PLF

Unit 1 10.32 81.88%

Unit 2 11.55 91.70%

Station 21.87 86.79% 86.78787879

APC 5.71% 0.66Expected APC as per

PY 2019-20 5.68%

Deviation 0.03%

APC(ABT) 5.49%

APC ( CM) 5.58%

APC dev( MM-ABT) 0.22%

Equipment % of APCActual

MusExpected Mus

APC Tracker FY'21 Check for

Previous data at

Same PLF

Date

25-May-20

5.69%

34%

12%21%

23%

10%

Unit 2

U2 ID Fan

U2 FD Fan

U2 PA Fan

U2 Mill

U2 CEP

0.0

95

0.0

32 0.0

57

0.0

63

0.0

29

0.0

82

0.0

27 0.0

52

0.0

56

0.0

34

U 2 I D F A N

U 2 F D F A N

U 2 P A F A N

U 2 M I L L U 2 C E P

U2 MAJOR CONTRIBUTOR

Actual Mus Expected Mus

28.205%

30.872%

26.000%

27.000%

28.000%

29.000%

30.000%

31.000%

32.000%

U1 U2

Unit 1 vs Unit 2

33%

9%

21%

28%

9%

Unit 1

U1 ID Fan

U1 FD Fan

U1 PA Fan

U1 Mill

U1 CEP

0.0

99

0.0

28

0.0

63

0.0

83

0.0

27

0.0

82

0.0

27 0.0

52

0.0

56

0.0

34

U 1 I D F A N

U 1 F D F A N

U 1 P A F A N

U 1 M I L L U 1 C E P

U1 MAJOR CONTRIBUTOR

Actual Mus Expected Mus

5.71%

5.49%

5.58%

5.35%

5.40%

5.45%

5.50%

5.55%

5.60%

5.65%

5.70%

5.75%

APC APC(ABT) APC ( CM)

APC-CHECKER

0.00% 5.00% 10.00% 15.00% 20.00%

AHP

CHP

RO PLANT

11KV

PWS

ST2 TIE

ST1 TIE

5.30%

2.32%

0.08%

0.00%

18.70%

0.000%

0.000%

ST contribution


Coal Mill operating Window.

Coal Mill operating window determines the safe operating zone of a Mill looking after A/F ratio.


Startup Oil Planning Toolkit

Unit No. 2

Drum Top Metal Temperature (oC)31

HP Turbine Shaft Metal

Temperature (oC)301.92

Type of startup Warm

Process

LDO

consumption

(kL)

HFO

consumption

(MT)

Process

LDO

consumption

(kL)

HFO

consumptio

n (MT)

Dev

from

Plan

consu

mption

(MT)

Boiler Light up and MS Line

Charging17.8 6.0

Boiler Light up and MS

Line Charging12.6 5.1 -6.0

HP/LP Bypass operation 9.0 12.0 HP/LP Bypass operation 10.5 11.9 1.4

Coal Firing ,Steam dumping and

Boiler Pressurising

0.0 2.0

Coal Firing ,Steam

dumping and Boiler

Pressurising

1.6 1.7 1.4

Turbine rolling and synchronization0.0 18.5

Turbine rolling and

synchronization4.2 4.4 -9.9

Unit Stabilization and Load Ramp

up0.0 29.3

Unit Stabilization and

Load Ramp up8.8 9.0 -11.5

Total FO consumption 26.8 67.8 Total FO consumption 37.8 32.2 -24.6

LDO

consumption

(kL)

HFO

consumption

(MT)

Total FO consumption 37.8 32.2

Budgeted Oil Requirement

Starting conditions

Note: Inputs in yellow cells

Actual Oil Consumption

Actual Oil Consumption

0

100

200

300

400

500

600

0 200 400 600 800

Warm Startup - Plan

MS Temperature (deg. C) Drum Metal Temp (top, deg. C)

Provides a comparative analysis of Budgeted oil consumption with Actual oil consumption with respect to the various start-up activities and as per the type of start-up.

Reliability Centered Maintenance (RCM)

RCM way of doing Maintenance


Way Forward-facing the challenges

•After achieving 55% MTL condition we are now moving ahead to 40% MTL operation testing in collaboration with IGEF/Siemens.

•Implementation of Automatic Generation control (AGC) as a part of the Grid compliance and Flexible operation.

•Reduction in Energy Charge Rate (ECR).

•Technology adsorption to sustain in part load operation of Base load plant to part load plant.

Way Forward


Questions, If Any ?


Thank You!Website: www.tatapower.com

Email Id: [email protected]

Contact: (+91) 9031000323

Disclaimer: The contents of this presentation are private & confidential.

Please do not duplicate, circulate or distribute without prior permission.

Private and Confidential |

http://www.tatapower.com/

mailto:[email protected]

mpl’s journey towards acclimatizing with new regime of flexi … · 2020. 10. 30. · tdbfp pid...

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