s banerjee thermal power plant performance improvement using quality initiatives (1)

Thermal Power Plant Performance Improvement using Quality Initiatives

NTPC Ltd : Powering IndiaNTPC Ltd : Powering Indias Growths Growth



NTPC Ltd.'s overview

Vindhyachal Super Thermal Power Plants Overview

Six Sigma

Why is six sigma needed for Indian Power Sector

Boiler Performance Optimization using Six Sigma

Reduction in Auxilliary Power Consumption using six sigma.

OutlineOutline



A HUMBLE BEGINING

Foundation Stone Laying12.11.82

The first signboard comes up 5.08.82



Powering PeoplePowering Peoples Progresss Progress (Generation)

G

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(

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)

17820.8

16354

19707.7

18305

160001650017000175001800018500190001950020000

FY 03-04 FY 04-05 FY 05-06 FY 06-07



Continuous Improvement in Process & EfficiencyContinuous Improvement in Process & Efficiency (PLF %)

92.46 92.73

82.38

90.01

80

85

90

95

100

FY 03-04 FY 04-05 FY 05-06 FY 06-07

PLF

P

L

F

(

%

)



PLANT PERFORMANCE IMPROVEMENT USING QUALITY INITIATIVESPLANT PERFORMANCE IMPROVEMENT USING QUALITY INITIATIVES

Improvement in Performance Parameters

Improvement in business processes (systems)

Cost Optimization

MUDA (Waste) Reduction

Development of World-class spare parts & service providers



WHAT IS THIS SIX SIGMA ?WHAT IS THIS SIX SIGMA ?

A Philosophy

A Business Strategy

Disciplined & structured data Disciplined & structured data driven problem solving driven problem solving approach.approach.

All about reducing deviations All about reducing deviations (mistakes) in all that we do.(mistakes) in all that we do.

Good quality reduces costGood quality reduces cost



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House of

Quality

# 1

Heat Rate

Key Functional Requirements

Key Component Characteristics

Key Generation Processes

Key Process Variables

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House of

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# 2

Boiler/ Turbine

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House of

Quality

# 3

RAH Seals/ Pent House/

ESP

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House of

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# 4

Basket Eff./ Seals

Cost Effective Generation depends broadly on :Cost Effective Generation depends broadly on :--

1) Optimizing Heat Rate

2) Reducing Auxilliary Power Consumption

3) Reducing operation & maintenance (O&M) costs.



Logic and intuitionLogic and intuitionQuick hits-KaizenBrainstorming etc

Low hanging fruitsLow hanging fruitsSimple QC tools

Bulk of fruitsBulk of fruitsProcess characterizationand optimization including PDCA

Process Process limitationslimitationsSweet fruitsSweet fruits

Six Sigma Methodology

Problem of erosion in radiant super heater placed in water wall soot blower area of stage I, 6 x 210 MW units.

Problem of vibration in the cooling fan NDE bearing of ID fans in stage I.

Problem of damage of rapping motor shaft in ESP of Stage I.

Problem of ingress of dust in the PA fan bearing of stage I.

Platform on safety v/v floor is in unsafe condition in stage I. (5S)

Team Vindhyachal receiving National Quality Award from H.E. President of India for PIP on CW duct painting in stage I units



3%Stack

Clean-upEquipment

5%Auxiliary

Power

10%Stack Losses

37%ElectricityProduction

45%Rejected Heat to

Cooling Water/ Cooling

Tower



FLUE GAS FLOW DIAGRAMFLUE GAS FLOW DIAGRAM

DDIIVVIISSIIOONNAALL

FFUURRNNAACCEE

RREEHHEEAATTEERR

HHOORRIIZZOONNTTAAL L SSHH

EECCOON.N.11&&22

EECCOONNOOMMIISSEERR

33

PAPH BPAPH B

SAPH BSAPH B

SAPH ASAPH A

PAPH APAPH A

960960

964964

846846

944944

750750

810810

549549

606606

365365

379379

LLHHSS

RRHHSS

PAPHPAPHO/L TEMPO/L TEMP145 145 00CC

SAPH BSAPH BO/L TEMPO/L TEMP160 160 00CC

SAPH ASAPH AO/L TEMPO/L TEMP164 164 00CC

SAPH BSAPH BO/L TEMPO/L TEMP145 145 00CC

PPLLAATTEENN

SSHH



Problems FacedProblems Faced

More convective flow less retention of heat in 1st pass. Less heat absorption in 1st pass due to Slagging. Less heat absorption in super heater and re heater area

due to dirtiness in the area ,clinkering formation in radiant zone.

Improper secondary damper position. Poor performance of air preheater and its air ingress.



BOILER RHS LRSB

LRSB ARE DIVIDED INTO

A- S/H Right R/H Left

B- S/H R/H Right And 2nd Pass

C-2nd Pass Only

D- S/H Right And R/H Left

125 127

129

131133

137 135

119

121

123

105

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109

117

115

113

1112nd pass

LRSBs : Long Range Retractable Soot Blowers



C14

C

1

5

DCBA

590

580

570

560

550

540

Individual Value Plot of C15 vs C14

C14

C

1

5

DCBA

590

580

570

560

550

540

Boxplot of C15 by C14

Box plot showing the best results for the LRSB A



BOILER RHS LRSB

125

127

129

131133

137 135

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123

105

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117

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113

111 Boiler RHS Red Coloured LRSBs were

selected based on results of Analysis of

Variance (ANOVA)




BOILER LHS LRSB

106

108110

136 138

132 134

130

128 126

120

124

122

112

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116

118

Red Coloured LRSBS are

in Reheater Area




Box and Individual plot

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SAPHA O/L AFTSAPHA O/L BEF

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165

160

155

150

145

140

Boxplot of SAPHA O/L BEF, SAPHA O/L AFT

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SAPHA O/L AFTSAPHA O/L BEF

170

165

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155

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145

140

Individual Value Plot of SAPHA O/L BEF, SAPHA O/L AFTBox Plot Individual Value Plot



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House of

Quality

# 1

Auxilliary Power

Reduction

Key Functional Requirements

Key Component Characteristics

Key Generation Processes

Key Process Variables

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House of

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# 2

Boiler/ Turbine

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House of

Quality

# 3

FD/ PA/ ID Fans/Mills

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House of

Quality

# 4

TIGs/ Hot Air Lkg/ Impeller

Cost Effective Generation depends broadly on :Cost Effective Generation depends broadly on :--

1) Optimizing Heat Rate

2) Reducing Auxilliary Power Consumption

3) Reducing operation & maintenance (O&M) costs.



Big YBig Y Auxiliary Power Consumption reductionAuxiliary Power Consumption

reduction

Process drill downProcess drill down

BFP power consumptionBFP power consumption

Project Y 2Project Y 2 ID Fan power consumptionID Fan power consumption

Project Y 3Project Y 3 PA Fan power consumptionPA Fan power consumption

Project Y 4Project Y 4 FD Fan power consumptionFD Fan power consumption

Project CTQProject CTQss

Project Y 5Project Y 5 Mill power consumptionMill power consumption

Project Y 1Project Y 1

Project Y 6Project Y 6 CW Pump power consumptionCW Pump power consumption

Project Y 7Project Y 7 CEP power consumptionCEP power consumption



Key QuestionsWhat is included/excluded in the scope of this project?Includes:

Excludes:

What is the Unit, Opportunity, Defect?

Has this process map been validated by key people?

High level process map done

HT Amp > 1800 amps would be defect.HT Amp > 1800 amps would be defect.

Unit HT SystemUnit HT System

LT System & Offsite LoadLT System & Offsite Load

Process map validated by Champion &Process owners

Process map validated by Champion &Process owners

Supplier

SS IIInput

PPProcess

OOOutput

CCCustomer

High Level Process Map

PA fans

FD fans

Bowl Mills

ID FansESP

CEP BFPHeaters

BoilerSuper heaterTurbineCondenser

Generator GT GRID

Heaters

Steam-water cycle

Stack out

Flue gas path

CW Pump

Cooling water out

Boiler



Identify Sources of VariationIdentify Sources of VariationA

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EquipmentsCount

36.4 18.4 16.0 10.2 9.7 7.1 2.3Cum % 36.4 54.8

654.3

70.8 81.0 90.6 97.7 100.0

331.6 287.3 183.7 174.3 127.7 40.6Percent

OtherMillFD FanPA FanID FanCWBFP

2000

1500

1000

500

0

100

80

60

40

20

0

Pareto Chart For APC



Identify Major Sources of VariationIdentify Major Sources of Variation

3333



Potential Failure Modes Effect Analysis - BFPWhen?Process

Step

What?Potential Failure

Result?Potential Effects

Why?Potential Cause

Existing Controls

Sev Occ Det RPN How Prevent?Mitigants

Who?Responsibility

BFP Passing from 5F1,5F2 & C/V

High amp

Worn out seat & others

To be attd. in O/H

6 10 5 300 1) L/S Adjust. on closing2) Manual Tight., if possible

TMD+Opn*

BFP Reduced Motor Efficiency High amp

Continuous Service

Motor O/H 2 4 5 40 To be attd.in O/H EMD

BFP Passing from R/C V/V& D/V NRV not holding

High amp


To be attd.in O/H


TMD+Opn*

BFP Passing from 421 V/V (Manual+Motorised)

High amp


To be attd.in O/H


TMD+Opn*

BFP Passing from 605,607 & C/V V/V

High amp


To be attd.in O/H


TMD+Opn*

BFP Passing / Opening from 514 A & B V/Vs

High amp

Worn out seat &/or Passing

from 5A1,5A2, 140/6 C/V

To be attd.in O/H

5 10 5 2501) L/S Adjust. on closing

2) Manual Tight., if possibleTMD+Opn*

BFP Passing from 29/14 Spray V/Vs

High amp


To be attd.in O/H 3 6 5 90

1) L/S Adjust. on closing2) Manual Tight., if possible

TMD+Opn*

BFP Passing from 3rd stage V/V (S/B BFP)

High amp

Worn out seat & others of S/B

BFP

To be attd.in O/H 3 6 5 90

1) L/S Adjust. on closing2) Manual Tight., if possible 3) Change the BFP conbin.

TMD+Opn*

BFP Low PumpEfficiency

High amp

Worn out cartridge

Pump O/H 5 10 5 250 1) Combination Change (AC / BC)

2) To be attd.in O/H

TMD

BFP Higher DP across FRS High amp

Slightly higher flow require.

Regularly 5 10 5 250 Experiment regularly to optimize DP

Operation +

C&I*+TMD



Decide Focus Area ?Decide Focus Area ?Priority / Focus

Ease of implementationDifficult Easy

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Low

High

BFP

ID Fan

FD FanMill

PA Fan



Informed to operational staff.Communicate project results with operating staff and process owner.Communicate results to HOD

Control/Response Plan HighlightsControl/Response Plan Highlights Benefits of Project Benefits of Project

Communication & TranslationCommunication & Translation

Control SummaryControl Summary

When HT equip. amp goes up steeply,all associated V/Vs being checked.

PA Fans being regularly checked for hot air leakage.

Boiler & ESP man/peep holes being checked regularly for any passing.

Future control plan prepared for arresting APC further.

Direct Saving.Conservation of Coal.Lesser Environmental Pollution.Better CSR Practices & other intangible benefits.



Control Charts of APC Before & After ProjectControl Charts of APC Before & After Project

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FMEA Analysis for Current Window of Opportunity FMEA Analysis for Current Window of Opportunity When?Process

Step

What?Potential Failure

Result?Potential Effects

Why?Potential Cause

Existing Controls

Sev Occ Det RPN How Prevent?Mitigants

Who?Responsibility

Sev Occ Det New RPN

BFP Passing from 5F1,5F2 & C/VHigh amp


To be attd.in O/H

6 10 5 300 1) Change V/Vs2) L/S Adjust. on

closing

TMD+Opn*

6 10 5 300

BFP Passing from 607 &C/V

High amp


To be attd.in O/H

4 6 5 120 1) L/S Adjust. on closing2) Manual Tightening

TMD+Opn*

3 6 5 90

BFP D/V NRV +3rdstage spray

v/vs not holding

High amp


To be attd.in O/H

6 10 5 300 1) L/S Adjust. on closing

2) Manual Tightening

TMD+Opn*

6 10 5 300

BFP Higher DP across FRS

High amp

Slightly higher flow

require.

Regularly 5 10 5 250 Experiment regularly to optimize DP

Opn,C&I TMD

5 10 5 250

PA Fan

TIGs in Open/ Struck up Condition

High Curre

nt

Improper Practices by Mill area lab.

As and when

needed3 10 5 150

Mill labours to be discouraged from keeping it in open condi. & Struck up condition to be att

on pri & Mois. draining

Opn.2 10 5 100

PA Fan

Hot Air Leakage

High Curre

nt

Aging/ Imp. Maint./

Expansions

During Opportunity 4 10 5 200

To be attended at first opportunity.

BMD R/P 3 10 5 150

Mill Improper Rollers Setting

Higher Amps

Maintenance Fault/Foreign

Material

Roller Setting 3 9 5 135

1) By effectively screening foreign material

2) During Opportunity

BMD Mill CHP 3 9 5 135

ID Fan

Various Leakages

Higher Amps

Mech Damage/Expansio

n/ Maintenance Prac

During Opportunity

or in O/H5 10 5 250

1) Regular Checking 2) To be attd.in O/H


BMD R/P+P/P 3 10 5 150

ID Fan

Peepholes/ Manholes Passing

Higher Amps

Mech Damage/Expa

nsion

Regular Checking/

Opportunity or in O/H

4 10 5 2001) Regular Checking 2) To be attd.in O/H


BMD+ Opn. 3 10 5 150



BottomBottom--line isline is....

s banerjee thermal power plant performance improvement using quality initiatives (1)

Documents

powering indiantpc

quality initiativesntpc

good quality

auxilliary power consumption

sigma reduction

structured data driven

deviations mistakes

business strategy