assessment of aged power plants to improve the efficiency 2013 presentations/day-1 at... ·...

Promoting the sustainable supply and use of energy for the greatest benefit of all

© World Energy Council 2007

ASSESSMENT OF AGED POWER PLANTS TO

IMPROVE THE EFFICIENCY

NTPC O&M Conference in New Delhi, 13 February 2013

World Energy Council

Asia Region ECUC Team

Hajime Murata

Promoting the sustainable supply and use of energy for the greatest benefit of all © World Energy Council [Date]

World Energy Council (WEC) Asia Region

- WEC is a UK-registered charity headquartered in London.

- WEC Asia Region consists of 13 member countries and regions

China, Hong Kong China, India, Indonesia, Japan, Korea (Rep.),

Nepal, New Zealand, Pakistan, Philippines, Sri Lanka,

Taiwan China, Thailand

- WEC Asia Region established Efficient and Clean Use of Coal

(ECUC) team in 2011.

- The ECUC team visited Suralaya power station Unit 7 in Indonesia from 22 to 25 August 2011. - The ECUC team visited Ramagundam power station Units 3 &

5 from 2 to 6 April 2012.

A Maharatna Company


Ramagundam Power Plants 1/2

Andhra Pladesh

Located in Andhra Pradesh, about 250km Northeast of Hyderabad.

ECUC team visited from 2 to 8 April 2012.

Total Installed Capacity: 2,600MW Commencement

Unit １ 200MW Nov 1983

Unit ２ 200MW May 1984

Unit ３ 200MW Dec 1983

Unit ４ 500MW Jun 1988

Unit ５ 500MW Mar 1989

Unit ６ 500MW Oct 1989

Unit ７ 500MW Aug 2004

・Ramagundam

・Hyderabad

・New Delhi

A Maharatna Company


Ramagundam Power Plants 2/2


Source: Google Map

Jakarta

Suralaya

Location of Suralaya


Suralaya Power Station


Item unit NTPC Ramagundam

Indonesia Power

Unit 3 Unit 5 Suralaya Unit 7

Commencement date -- 01/02/1984 01/09/1989 12/1997

Main steam pressure MPa 14.71 16.67 16.57

Main steam temperature °C 535 537 538

Reheat steam

temperature °C 535 537 538

Boiler type -- B&W design CE design B&W design

Steam production t/h 584 1550 2000

Coal Calorific value

(HHV) Kcal/kg 4300 4300 4225 - 5242

Furnace draft -- Balance type Balance type Balance type

Boiler manufacturer -- ANSALDO BHEL B&W Canada

Turbine rated output MW 200 500 600

Turbine rpm rpm 3000 3000 3000

Turbine manufacturer -- ANSALDO BHEL MHI

Dust collector -- ESP ESP ESP

Specifications


Recent Operating Results

Date -- 2010-2011 2010-2011 2010

Rated output MW 200 500 600

PLF % 87.94 89.54 83.94

Availability factor % 93.27 90.9 94.79

Loading factor % 94.29 98.5 NA

Gross thermal efficiency % 36.32 36.16 35.2

Net thermal efficiency % 33.12 34.39 33.81

Coal consumption ton 902,685 2,302,826 2,201,595

Average coal calorific value Kcal/kg 4,038 4,046 4.833

Specific coal consumption kg/kWh 0.586 0.587 0.50453

Energy generated MWh 1,540.78 3,921,700 4,363,653

Auxiliary power consumed MWh 135,697.20 192,050.50 231,457

Auxiliary power ratio % 8.81 4.9 5.3

Item unit NTPC Ramagundam

Indonesia Power

Unit 3 Unit 5 Suralaya Unit 7


Item unit

Ramagundam Suralaya Unit 7

Unit 3 Unit 5 Comme-

ncement Recent

Comme-

ncement Recent

Comme-

ncement Recent

Date month/year -- 09/‘85 1/‘12 5/‘91 1/‘12 5/‘97 2/‘11

Generator output MW 202 192 502.4 506.4 594.41 604.65

Turbine Heat Rate Kcal/kWh 1966 2003.6 1983.2 2063.8 1868 1862

Efficiency of Boiler % 89.03 87.56 88.22 86.64 86.78 85.65

Gross plant Heat rate Kcal/kWh 2208 2288 2248 2382 2152.5 2175.4

Gross plant efficiency % 38.94 37.58 38.25 36.1 40 39.55

Coal consumption t/h 103 118.4 279.06 320.3 252,80 293.88

Calorific value of coal

(HHV) Kcal/kg 4241 3708 4047 3894 4991.5 5091

Specific fuel consump kg/kWh 0.51 0.615 0.555 0.633 0.43 0.427

Performance Test Results 1/2


Performance Test Results 2/2

Main steam temp. °C 533.3 540.6 537.3 539.8 537.62 536.7

Main steam pressure kg/cm2 149.6 152.03 169.47 170.19 169.60 167.99

Reheat steam temp. °C 534.6 520.0 540 540.9 533.80 539.26

SH spray water flow t/h 46 18.4 62.09 102.9 176.57 260.46

RH spray water flow t/h 0 4.1 6.5 59.2 10.76 17.51

O2 % at eco. outlet % 3.82 2.77 3.59 3.25 2.95 2.53

Gas temp. APH inlet °C 330.4 341.8 364 352 376.88 398.76

Gas temp. APH outlet °C 145.2 165.6 151.9 144.5 131.44 150.79

Condensor vaccum mmHg 86 63.9 70.6 68.7 53.55 57.45

Item unit

Ramagundam Suralaya Unit 7

Unit 3 Unit 5 Comme-

ncement Recent

Comme-

ncement Recent

Comme-

ncement Recent


1) Upgrade Ramagundam Unit 3&5 turbines ; The most

effective retrofitting for improving the plant efficiency

2) Renovate APH

3) Reduce spray water flow

4) Optimize combustion

5) Plan for replacement of the main control system

6) Consider future installment of Flue Gas De-sulphurization

7) Detect and evaluate the malfunctions to maintain the

efficiency of the plants

Recommendations


Turbine Upgrading Experience for Aged Plants

1) Turbine type : TC4F-26 3600rpm 16.57MPa/566degC/538degC

2) Rated output : 250MW

3) Original commercial operation : Since 1970

4) Scope of Upgrading : HIP turbine

5) Completion of Upgrading work : 2011

6) Application technologies for Upgrading :

Updated steam paths for nozzles & blades .

Updated snubber blades .

Updated seal packings .

7) Upgrading Result :

Enhanced heat rate at 250MW : 4.09% relatively between pre &

post

Operating condition after upgrading : Good


Upgraded HIP Turbine of 250MW Unit

HP Section with

updated steam path

IP Section with

updated steam path

Updated seal packing Updated seal packing


Updated Technologies for Turbine Upgrading

Upgraded nozzle with

updated steam path

Upgraded snubber blade rows

with updated steam path

Updated seal packing


- Reduction of coal consumption and CO2 emission by

applying the major recommendations

Ramagundam Unit 3 ; Coal - around 48,000 ton /annum

CO2 - around 79,000 ton /annum

Ramagundam Unit 5 ; Coal - around 105,000 ton /annum


Suralaya Unit 7 ; Coal - around 52,000 ton /annum


- For Ramagundam Unit 3 & 5, approximately 75 to 90 % of the

reduction derives from turbine upgrading.

- The turbine upgrading would increase the output, if the

generator, main transformer and etc. are examined.

- Financial scheme could be applied to the turbine upgrading.

Conclusion

Promoting the sustainable supply and use of energy for the greatest benefit of all

© World Energy Council 2007

Thank you for your kind attention

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