CCT - Energy Efficient R&M boiler manufacturing company Babcock & Wilcox established Engineering...

CCT - Energy Efficient R&MConference on Clean Coal and Carbon Capture and Storage TechnologiesA TREC-STEP initiative: 'Developing a Cluster for CCT & CCS for the Indian Thermal Power Sector’

2-3 Dec 2013, Tiruchirapalli, TN, India

Doosan Power Systems India

1

ABOUT DOOSAN POWER SYSTEMS

WHY R&M

R&M MODALITY

CASE STUDY

RECENT R&M PROJECT

CONCLUSION

PROGRAM

2

HERITAGE

2011

Acquired by DPS and renamed

Doosan Lentjes

Acquired by Doosan

Acquired by Doosan to become Doosan Babcock Energy

Lentjes GmbH formed

Skoda Energoformed

Skoda daughter

companies privatised

Babcock Power Ltd formed

Ferdinand Lentjes

founded boiler manufacturing

company

Babcock & Wilcox established

Engineering workshop founded

Babcock

Škoda Power

Lentjes

20051928

2004199819931859

200619791891 2009

Doosan Power Systems (DPS) -bringing Babcockand Skoda together

2009

Company becomes Skoda Power

3

ORIGINAL TECHNOLOGY HOLDER

B&W Partnership US B&W B&W Corp.

Doosan Power

Systems India

Doosan Power

Systems

1867 1881

1891 1995

OriginCurrent

Manufacturer

Inve

stm

ent

Acquisition

Period of Investment, Mergers & Acquisitions

Market Area: USA & Cuba

Market Area:Rest of the World

2007

Calcutta office

B&W India

ACC Babcock

1904 1947 1959 1996

India

Mitsui Babcock Energy

MBEL India

Inve

stm

ent

UK B&W

Doosan Heavy

Industries

USA

UK

4

DOOSAN POWER SYSTEMS

Doosan Power Systems Lentjes, Skoda Power, Doosan Babcock

Doosan BabcockDoosan Lentjes

Doosan Skoda Power Doosan Babcock

Boiler & Air Pollution Control Turbo-generators Service

Doosan Heavy Industries & Construction

5

PRODUCT LINE

Boiler

• Pressure Part• Non-Pressure Part• Mill• Burner• Structural Steel• DCS / APH

AQCS

BOP

• FGD• SCR• ESP• Ash Handling

System

• Condenser• Heater• Dearator

P.P Non-P.P Pulverizer BurnerStructural

Steel

APH

Condenser Heater Dearator

FGD SCR ESP AHS

DCS

6

SUPPLY CAPABILITY

Design and Engineering, Manufacturing, Erection, Commissioning and Training.

After Service and Retrofits forBoiler Island, DCS, SCR, FGD, ESP etc.,

Scope

Subcritical and Supercritical for Utility & Industrial plant

Unit Type

Coal (Bituminous, Sub-Bituminous,

Anthracite, Lignite)Oil, Gas & Biomass

Fuel

7

WORLDWIDE INSTALLATIONS

Subcritical boilers 123,086 MWeSupercritical boilers 44,145 MWeTurbines 55,500 MWeCFB 21,528 MWth

WtE plants 9,073,600 t/aWet FGD 77,400MWeCFB FGD 38 million m³/h

Total worldwide references

8

RECENT SUCCESS

• Mundra / Coal(800MW x 5unit)

•Sipat / Coal(660MW x 3unit)

• Raipur / Coal(685MW x 2unit)

• Kudgi & Lara/ Coal(800MW x 5 unit)

India

• Younghung #5~6(870MW x 2unit)

• Shin-Poryong #1,2(1000MW x 2unit)

South Korea• Al-Khalij / Oil (350MW x 4unit)

• Tripoli West / Oil(350MW x 4unit)

Libya

• Ain Sokhna / Gas(650MW x 2unit)

Egypt

• Rabigh PP2 / Oil(700MW x 4unit)

• Marafiq #5,6 / Oil(275MW x 2unit)

Saudi Arabia

• Hsinta #1,2 / Coal(500MW x 2unit)

Taiwan

• Nueva Ventanas / Coal(240MW x 1unit)

• Angamos / Coal(240MW x 2unit)

• Campiche / Coal(240MW x 1unit)

Chile• Cebu CFB / Coal

(100MW x 2unit)

Philippines• Cirebon / Coal

(700MW x 2unit)

Indonesia

• Gheco-one / Coal(700MW x 1unit)

• Glow CFB / Coal(115MW x 2unit)

Thailand

• Mong Duong II / Coal(600MW x 2unit)

Vietnam

USA• Trimble,2 / Coal(815MW x 1unit)

• Pecem & Itaqui / Coal(350MW x 4unit)

Brazil

9

2 x 685 MWe

• Evaporation 2,126 Ton/hr

• SH Outlet Press 256 bar

• SH Outlet Temp. 570

• RH Outlet Temp. 597

• Indian Bituminous coal 41 – 45% ash

• Client GMR Energy

• Contract Award Jan. 2010

Supercritical firing high ash coal

RECENT INDIAN PROJECTS – RAIPUR

10

RECENT INDIAN PROJECTS – NTPC KUDGI & LARA

5 x 800 MWe


• SH Outlet Press. 253 bar



• Indian coal (High Ash) 35 ~ 45% Ash

• Client NTPC

• Contract Award Feb. 2012

Supercritical Once-thru firing high ash coal

11

RECENT KOREAN PROJECT – SHINBORYEONG

2 x 1,000 MWe


• SH Outlet Press. 275 bar



• Sub-bituminous coal

• Client KOMIPO

• Contract Award Mar. 2012

Ultra Supercritical Once-thru TypeInternationally traded coals

12

MANUFACTURING CAPABILITY

DPS DHIDOOSAN VINA

Changwon, Korea(Capacity : 5,500MWe /year)

Chennai, India(Capacity : 2,200MWe /year)

Vina, Vietnam(Capacity : 2,000MWe /year)

> 10 GWe / YEAR

13

INDIAN PROJECT REFERENCES

UK B&W year book 1927

Since 1960 : • 63 coal utility boiler references (7 under construction) ~13 GWe• plus many 100’s industrial boilers

14

GENERAL VIEW OF DPSI SHOP

Engineering and Manufacturing unit at Chennai, India

15

DPSI – STRONG INDIAN CREDENTIALS

Significant part of an established global company

Wide range of products well suited for the Indian market

Financially strong

Long history in India

Success and failures along the way

Over 13 GWe of utility reference plant

Strong Engineering and Manufacturing base in Chennai and Delhi

150+ Engineers, supporting DPS’s global business

Local knowledge, experience and capabilities, operating globally, with global technical resources and backup

16


WHY R&M

R&M MODALITY

CASE STUDY

RECENT R&M PROJECT

CONCLUSION

PROGRAM

17

CCT OPTIONS

Boiler

SteamTurbine

New installationsRunning installations

Advanced Supercritical Units:

High Cycle Efficiency

CCT: Efficiency Improvement

R&M of existing units

18

CO2 ABATEMENT FROM FOSSIL FUELS

CO2Reduction

ASC

Carbon Capture & Storage (CCS)

Possible Now

Long Term

Time

Medium Term20252015

95%

AGING FLEETS

R&M

USC

ASC – 600 ºC/600 ºC, 290 bar

USC – 700 ºC/700 ºC, 345 bar

Baseline

30%

60%

19

CO2 ABATEMENT FOR COAL FIRED PLANTS

Retrofitting carbon abatement features to existing coal-fired power plants

rather than replacing with new-build ‘green-field plants:

Minimises overall expenditure

Extends plant life by 20 years or more

Maximises the use of existing infrastructure

Reduces planning consents

Doing so will lead to Environmental benefits being realised faster and

more widely

20

IBR MANDATE

AGINGOF

BOILERS

IBRREGULATION

391[A]

“…. prescribes RLA after 100,000 hours of operation for boilers with steam temperature over 400 0C; for others, after 25

years. Thereafter, every 5 years…”

21

R&M OF EXISTING UNITS

Existing Installations

Scope for Improvement BTG R&M

Boiler

Turbine Generator

22


WHY R&M

R&M MODALITY

CASE STUDY

RECENT R&M PROJECT

CONCLUSION

PROGRAM

23

R&M OF BOILERS AND AUXILIARIES

R&M - A Global perspective based on DPS’s Expertise and Experience

Renovation & Maintenance through Framework Alliances

R&M methodologyBoiler Life ManagementEngineering ApproachModern ToolsTesting

24

R&M THROUGH FRAMEWORK ALLIANCES

The Alliance

Customer benefits

Long Term (7-10 years) agreements for fleet wide maintenance

For Ex. DPS is engaged in Framework alliances with major utilities such as British Energy, Scottish Power and RWE

Access to staff & labour resources to meet known long term requirements & response to events

Preferred access to OEM competence and Technology & Engineering resource focused on plant life extension and reliability

Incentive for high performance via agreed KPI

Agreed mechanism for rate increases

Reduced risk through gain / pain share and capped price works packages

Continuous improvement plan with incentive to deliver

25

R&M METHODOLOGY

Phase I:Plant Condition Assessment

Phase II:Post Assessment Analysis & Boiler redesign

Phase III:Refurbishment

26

BOILER LIFE MANAGEMENT

Typical Issues;

Plant operating beyond design life

Changing modes of operation

Requirement for more operational flexibility

Alternative fuel sources

Material degradation – corrosion

Erosion

27

BOILER PRESSURE PART DAMAGE MECHANISMComponents Creep Fatigue Erosion Corrosion Over heat Wear

Drum/SeparatorSH/RH Header WW Header Eco. Inlet Header Downcomer/Integral Piping Main Steam Piping Hot Reheat Piping SH/RH Tubing WW Tubing


28

BOILER VULNERABLE AREAS AND TYPES OF DAMAGES

Component Type of damage Possible causes

Drums and headers

Metal loss Corrosion, oxidation, acid attacks, oxygen pitting

Cracks at weld joints, distortion, ligament cracks (in high temperature headers)

Mechanical/ thermal stresses

Metallurgical (for high temperature headers)

Creep, fatigue

Drums with expanded tubes

Seat weepage Caustic embrittlementLigament cracks

Residual stresses from tube expansion


29



Superheater/ reheater tubes

Metallurgical Creep, fatigue

Metal loss Erosion, corrosion

Cracks, deformation Mechanical/ thermal stresses

Furnace, boiler bank and economiser tubes

Metal loss Corrosion, oxidation, acid attacks, oxygen pitting, erosion

Spray attemperator

Cracks, deformation Thermal stresses


30



Piping Metallurgical (in HT piping)

Creep, fatigue

Cracks, deformation (including in hangers and supports)

Mechanical/ thermal stresses

Metal loss (LT piping) Corrosion, cavitation, erosion due to solid particles, water droplets in steam pipes

Air preheaters

Metal loss Acid dew point corrosion, ash erosion

Ducts, casings, structure etc.

Metal loss Erosion, corrosion, thermal/ mechanical fatigue

Deformation Mechanical/ thermal stresses


31

THE ENGINEERING APPROACH

Require to assess the impact of the past …

… and predict the effects of the future

32


Explore and understand original design margins

Path Stage Header Description No. off

Design P Bar g

Calc P Bar

g

TempDeg C

BodyMaterial

Branch Material

Body fMPa

Basis of Design

Shtr Inlet Primary Superheater Inlet 1 193.5 193.5 363 TS12A

CML 125.36

Yield

1st Stage Superheater

Primary Shtr Outlet Stub 68 193.5 180 506 CRM2 CRM2 89.54 Srt

Primary Shtr Outlet Manifold 4 193.5 193.5 501 CML CML 92.62 Srt

1st Stage Attemperator body 4 193.5 193.5 487 CML - - YieldSecondary Shtr Inlet Manifold 4 193.5 178 432 CS CS 77.96 YieldSecondary Shtr Inlet Stub 68 193.5 178 432 CS CML 77.96 Yield

2nd Stage Superheater

Secondary Shtr Outlet Stub 68 193.5 178 514 CML CRM2 75.16 Srt

Secondary Shtr Outlet Manifold 4 193.5 178 510 CML CML 81.34 Srt

2nd Stage Attemperator Body 4 193.5 178 510 CML - - Srt

Tertiary Shtr Inlet Manifold 4 193.5 193.5 499 CML CML 92.71 YieldTertiary Superheater Inlet Stub 4 193.5 193.5 499 CML CRM2 92.71 Yield

Final Shtr Tertiary Superheater Outlet 3 193.5 177.5 552 CRM2 - 47.08 Srt

Reheater Reheater Inlet 3 51.02 51.02 385 CS CS 92.87 YieldReheater Inlet Stub 68 51.02 51.02 385 CS CS 92.87 Yield

Reheater Outlet Stubs 68 51.02 40.5 588 CRM2 CRM2 42.92 Srt

Reheater Outlet 3 51.02 40.5 550 CRM2 - 48.46 Srt

33


Understand previous operational history

%

1724 564

5061 225

1360 8

401 9

1353

3413

3527

7298

8060

8152

8745

7526

7337

5712

4835

100908070605040302010

No

50 11 35 9 16 33 9 1 22 23 47 12 31 21 7 4 13 9 23 33

5040302010

Unit 1 Surv ey PeriodsUnit 2 Surv ey Periods

Survey 3 - 9037 HrsNSHEB Surv ey Data First Pi Data Current U2 Data

High Load factor High Load FactorGas and Oil Firing 100% Gas Firing Repowered U1 DataLow start Frequency Low start frequency Medium Load FactorPressure Independent Coincident Pressure 100% Gas Firing

Low Start FrequencyCoincident Pressure

MBEL Acquired Data

4 24 2

223

Oil Gas

Survey 2 Envelope - 65717 Hrs

19%51%

Surv ey 1 Envelope - 34704 Hrs

Total

439

21,32888,130

216

Fuel Mix U1

1980 - 82

Starts

Oil

49%109458

Gas

81%

1983 1984

6829

6621

Boiler Running Hours

2001 20021985 - 1994 1995 1996 - 2000

8052

4837

4200

Total HrsTotal Starts

Hrs Gas Hrs Oil

Starts GasStarts Oil

34


Develop time histories of temperature behaviour

Enable assessment of operational drift from design intent and available margins

Operation < Design

Operation > Design

35

Fatigue

Pressure cycles increased

Propensity for thermal fatigue

Locally – Header Body thermal shock

Globally – Racking tube ties/ buckstays/ tube stubs

Elements – tube ties and attachments

Creep

Basically an On-load issue – fatigue interaction effects

High temperatures under pressure at RTS for short periods

Short term overheating


36


From past history:

Assess damage due to creep – knowledge of materials creep strain behaviour across a range of temperatures

Assess fatigue damage and likely accumulation

From future projection:

Assess ongoing damage due to creep

Assess fatigue damage from future operating regime

37

Assessment of remnant life:

Use cumulative damage techniques and creep/fatigue interaction diagram to assess current and future path

Enables a standard methodology to be used for the formulation of remnant life – recognised by designers and regulatory authorities

Basic requirements: time, temperature and stress


38

Engineering assessment provides an indication of future fragilities

Inspection and monitoring required to confirm predicted behaviour

Develop plans for mitigation or replacement of components

Use latest alloy and design technology to engineer replacement parts for future operating scenarios

Develop instrumentation scheme

Inspect selected areas

Review metallurgical condition via sampling/ replication

Utilise measurement tools to review tube life


39

Specialized NDT and In-Service Inspection Technology

Ultrasonics, TOFT, Phased Arrays, Multimode Ultrasonics

Automated NDT systems

Austenitic weld inspection

Computer modeling of inspection capability

Qualification of procedures, equipment & personnel

Risk based inspection

Non-invasive inspection

Pre-service and in-service inspection

Leak detection, Acoustic Emission

TESTING AND MODERN TOOLS

40

Inspection & Visualization TechnologySpecialist NDT Smart Scan

Thermal imaging – Quick and safe technique for accurate measurement of surface temperatures

3D Laser Scanning <6mm spot size/ <6mm positional accuracy @50m

360 PV – 360 degree Panoramic Visualisation

TESTING AND MODERN TOOLS

41

Software and Tools group (SWAT) undertake continuous development of a range of in- house tools, which are used for both design and analysis

HAMBE

Calculates the flow, temperature, pressure and composition for the fuel, air and flue gas streams in a utility boiler system for the design load and part loads

BWHOT

System of 13 programs for modeling radiation and heat transfer in a furnace

Recently been extended beyond the furnace exit plane to include the high temperature convective pass

SteamGen

Calculations involve the heat transfer between the gas side and the steam side

Stress Analysis

TESTING AND MODERN TOOLS ( in-house)

42

Prediction of Flow Field, Flame InteractionCoal Burnout, Heat ReleasePollutant Formation (NOx , CO)Fuel and Air Mixing

Sensitivity StudiesAir Staging, Re-burn, SNCR Fuel TypeFuel and Air DistributionFuel Fineness

The commercial Fluent Computational Fluid Dynamics (CFD) code is used in the development and optimization of burner and furnace design

Simulation of Single Burner and Full FurnaceMulti-fuel Combustion Air and Oxyfuel Firing

TESTING AND MODERN TOOLS ( CFD)

43

MULTI FUEL BURNER TEST FACILITY

Full-scale testing and demonstration, contract or third party burners on the 90 MWtMulti-fuel Burner Test Facility (MBTF) in Renfrew, Scotland

Capability to Fire a Wide Range of Fuels

Coals, Bituminous and Low Volatiles8% to 40% Volatiles, Dry Ash FreeUp to 35% Ash, as firedUp to 20% Inherent Moisture, as fired

Heavy Fuel OilNatural Gas

Two Stage Combustion

Oxyfuel Conversion

Biomass firing capability

Combustion Chamber : 17m Long, 5.5m Wide, 5.5m High Horizontal, Water-Jacketed

44

LABORATORY SUPPORT SERVICES

ChemistryFuelsMechanical TestingNDTMetallurgy & WeldingInstrument CalibrationEmissions

45


WHY R&M

R&M MODALITY

CASE STUDY

RECENT R&M PROJECT

CONCLUSION

PROGRAM

46

CASE STUDY

BANDEL THERMAL POWER STATIONUNIT 5 EER&M

47

CASE STUDY - BANDEL PJT THERMAL POWER STATION

WBPDCL - BTPS is located at Bandel in Hooghly District in West Bengal, India

BTPS comprises of 4 x 82.5 MWe Coal fired boilers supplied by Babcock & Wilcox

commissioned during 1965 & 1966 and 1 x 210 MWe Coal Fired boiler supplied by ACC Babcock Ltd, with the

backup of Babcock & Wilcox UK commissioned during 1982.

The existing 210 MWe Steam Turbine is of LMZ K-210-130.

HP, IP and LP cylinders of 210 MWe fitted with impulse blading. The HP and IP Cylinders are single flow while LP cylinder is double flow type

The 210 MWe boiler is a Radiant front wall fired two pass parallel backend design with tubular airheater.

Brief description of West Bengal Power Development Corporation Ltd (WBPDCL) -Bandel Thermal Power Station (BTPS)

48

CASE STUDY - BANDEL PJT : BOILER BASIC PARAMETERS(OEM)

Plant BTPS – Unit 5

Year of installation 1982

OEM ACC Babcock

Capacity 1 x 210 MWe

Design Parameters 700 TPH Steam at Final Superheater outletof steam generator 135 kg/cm2 (g) at SH outlet

540 oC at SH outlet540 oC at RH outlet252 oC feed water at Economiser inlet60% MCR to 100% MCR SH control range132 oC flue gas leaving airheater4000 KCal/Kg design coal GCV6 nos Babcock E mills

49

CASE STUDY - BANDEL PJT : SCENARIO PRIOR TO R&M

Deterioration of seals, casings

From 4111 to 3300 kCal/Kg

2092 to 2298 KCal/KWh

From 86.3 to 81.8%

Up by 12%

From 210 to ~185 MWe

Availability down to 71% and PLF

down to 60%

SPM levels are high

Baseline

Increase

Decrease

50

CASE STUDY - BANDEL PJT : KNOWN PROBLEM AREAS

Ash content in Coal has increased and GCV has come down. Resulted in inadequate supply of pulverized coal from the mills. Most of the time it is required to operate all mills, affecting mill maintenance and combustion control system.

Deterioration in many of the pressure parts, airheater, burners, ESPs and auxiliaries

With increase in air-in leakage, draught plant margins are non existent, resulting in limitation on plant output to 185 – 190 MWe.

Plant unit heat rate has deteriorated from the original 2424 to 2872 KCal/KWh and turbine heat rate from the original 2092 to 2298 KCal/KWh.

Boiler efficiency has also gone down to 81.8 % from the original value of 86.3 %.

Emission levels (SPM) have increased considerably.

Performance Data for ’06-’07 indicates Auxiliary Power consumption has gone up by 12%.

Frequent tube failures of economizer bank and other pressure parts lead to lower availability of the boiler. Availability has come down to 71%.

PLF is very low and forced outages are more.

The steam generator has operated for more than 25 years and its performance has degraded.

51

To enhance operating life by further 15 to 20 years

Replacement of various deteriorated pressure parts

Up gradation of coal mill capacity

Reduction in NOx level (fitting of latest design PF burners)

Changing/Replacement of critical components in FD, ID and PA Fans

Improve boiler efficiency (lowering backend temperature)

Reduction in outlet dust burden

Modernize steam turbine to achieve 215 MWe

Reduce Auxiliary power consumption.

Improve plant heat rate

On the whole the project aims at Energy Efficiency R & M of Unit – 5 (210 MW)

CASE STUDY - BANDEL PJT : R&M OBJECTIVES

52

Item Client requirements Guarantee by Doosan

Unit Capacity Increase from 210 MWe to 215 MWe

215 MWe

PLF 80% from present level of approx. 60% avg.

PLF as per grid requirement

Gross Unit Heat Rate

2456 kCal/KWh from present levels of ~3000 kCal/KWh

2345 kCal/KWh

Auxiliary Power Consumption

13.5 MW for key auxiliaries 13 MW for key auxiliaries

Fuel diet Designed for worst coal with Calorific Value of 3300 kCal/kg

Designed for worst coal with Calorific Value of 3300

kCal/kgParticulate Emission

90 mg/Nm3 90 mg/Nm3

Life Extension Minimum 15 years Minimum 15 years

CASE STUDY - BANDEL PJT : CONTRACTUAL GUARANTEES

53

• Platen superheater upgrade

• Additional reheater surface

• Economiser modification

• Burner panel modification

• Final SH and Pendant RH

replacement

HEATING SURFACES

Before After

Before After

CASE STUDY - BANDEL PJT : MODIFICATIONS

54

CASE STUDY - BANDEL PJT : PPA, PRE & POST R&M

55

• Low NOx Axial Swirl Burner

• Developed in 1980s• Over 2700 burners installed• 40 - 70% NOx reductions

BURNER

• Enhanced mill throughput• Dynamic classifiers• PF piping & VARBs

MILLING SYSTEM

CASE STUDY - BANDEL PJT : TECHNOLOGY UPGRADES

56

• New ID and PA fans• FD fan refurbishment• New lube oil skids• Replacement of control

dampers

FANS

• Additional field• SPM level within 90mg/Nm3• Automatic rapping system• New TR sets

ESP

MODIFICATIONS

57

• Additional block• Modular construction• Inlet ferrulesAIRHEATER

CASE STUDY - BANDEL PJT : OTHER MODS

58

• Seals• Expansion joints• Refractory & insulation• Aerofoils & Venturi• Ash handling system• Electricals• Fire fighting system• Dosing and sampling system• Misc civil works

MISC. SCOPE

CASE STUDY - BANDEL PJT : MISCELLANEOUS

59

BANDEL : BOILER PROJECT SCOPE SUMMARY

Lower SPM / NOx Emission &Boiler Performance Improvement;

Enhanced life from modern replaced equipment.

Typical Drum-type Boiler

Major Pressure PartsReplacement for Life extension, reliability and performance improvement

DCS Modernization Renewal of Field Instruments

Environment Equip. RetrofitESP

Low-NOx Burner

New sootblowers, replacement/refurbishment of valves and actuators

Milling Plant upgrade, New PA Fans, PF Piping and Gravimetric Feeders

New ID Fan, Seal Air and Core Air Fans, refurbished FD

Fans, Flues and Ducts & Dampers

Airheater refurbishment and surface addition for reduced flue gas losses

60

BANDEL: TURBO GENERATOR PROJECT SCOPE SUMMARY

Improved Heat Rate and capacities allowing for quick pay-back of project and reduction in carbon footprint.

Advanced Seals

Entropy/Velocity Distribution

Generator & Aux. Replacement

Efficiency & hence turbine heat rate improvement is the key to the EER&M:Approx. 5% improvement over original LMZ turbine design

State-of-art Turbine Technologies

Advanced Blade Technology

Integral Covered Bucket Design

HP, IP, LP Turbine ReplacementTG Lube oil system upgradeElectro hydraulic governors

New ESVs, IVs and CVsDrains & extraction system

refurbishmentCondenser retubing, New CEPs,Energy Efficient BFP cartridges

Drip Pump Refurbishment,HP/LP heater tube nest replacement,

Deaerator tower replacement,Renew HP/LP Bypass Valves

Misc. Valves, actuatorsRenewal of Hangers and supports of

critical piping + InsulationTurbo-visory system, Field Instruments

61

BANDEL: PROJECT MILESTONES OF BANDEL R&M PROJECT

2012 2013 20143 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 10 111 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 32 32

Detailed Engineering(~12M)

Completion of Material Order

(~10M)

Shut-down(19M~24M)

Warranty

Reliability Test(25M)Manufacturing

(~17M)

Delivery(12~18M)

Opening of site office, Pre-Shut down works (13~18M) (Installation)

Commissioning

PG Test(~27M)

62

BANDEL - UPDATE

Project is more or less on-time, with boiler presently is shutdown for erection.

Relationship with the customer is excellent

63


WHY R&M

R&M MODALITY

CASE STUDY

RECENT R&M PROJECT

CONCLUSION

PROGRAM

64

AMGEN TORRENT POWER LIMITEDE & F STATION UPRATING

RECENT PROJECT

65

TORRENT THERMAL POWER STATION

‘E’ and ‘F’ stations were manufactured, supplied and erected by M/s BHEL andwere commissioned in 1984 and 1988 respectively. The boiler plant is located atthe north of Ahmadabad, Gujarat, India and owned by Ahmedabad GeneratingCompany (AMGEN)

The exiting steam turbines are of Skoda make having original rated output of110 MWe, rated SH pressure of 130 kg/cm2g and rated SH and RH temperatureof 535 oC

The steam turbine is a 3 casing condensing steam turbine with reheat and eightbleeds of steam for original regenerative system

The original HP turbine has a control stage of 2 numbers Curtis wheel and other 8impulse stages. The original IP turbine has 12 impulse stages. The original LPturbine has 2 x 4 impulse stages

The boilers are BHEL make corner fired units with RH temperature control byburner tilt

The original heat rate of turbine at rated output is 2175 kcal/kWh.

66

TORRENT - BOILER BASIC PARAMETERS

Plant Torrent Thermal Power station – E & F Stations

Year of commissioning 1984 & 1988

OEM M/s BHEL

Capacity 2 x 110 MWe

Design Parameters 375 TPH Steam at Final Superheater outletof steam generator 138 kg/cm2 (a) at SH outlet(original design) 540 oC at SH outlet

540 oC at RH outlet241 oC feed water at Economiser inlet60% TMCR to 100% BMCR SH control range152 oC flue gas leaving airheater4450 KCal/Kg Coal GCV

67

TORRENT PROJECT - OBJECTIVES

Retrofitting existing turbine components with state-of-art efficient turbine components

Modification in boiler reheater surface including replacement of reheater headers to suit requirements of retrofitted turbine

Replacement of existing turbine hydraulic governing system with electro hydraulic turbine control (EHTC)

Overhauling and servicing of turbine valves

RLA and refurbishment of turbine oil system, regenerative system and cooling water system

RLA study of piping valves and castings

Replacement of existing C&I system with state-of-the art DCS

110 MWe 121 MWeUp-rating and modernization

68

TORRENT - BOILER R&M CHALLENGES

R&M on non-OEM designAdditional heating surface shall be supported from roof tubes, local supports to be checked, modified and suitably reinforced

Existing Sootblowersand access openings retained

Enhanced surface addition shall be within original overall RH pressure drop

Entire reheater elements replaced with new elements having extra heating surface (~30% increase) to meet requirement of HBD, within the existing layout

69


WHY R&M

R&M MODALITY

CASE STUDY

RECENT R&M PROJECT

CONCLUSION

PROGRAM

70

R&M INCREASES LIFE AND ENERGY EFFICIENCYPlant Cycle Efficiency Enhancement

Enhance Efficiency

Increase Capacity

Improve Reliability

Life Extension

Old Plants get a lease of life of at least 15 - 20 yearsHigher cycle efficiency results in lower generation costsLower fuel consumption and hence lower carbon footprintLower emissions

Capacity

Efficiency

Reliability

71

ENERGY EFFICIENT R&M IS ECONOMICALLY VIABLE

New Build

Project Cost(land cost excluded)

EE R&M

(X) INR / MW (0.6 – 0.65 X) INR / MW

Outage More than 50 months project cycle 6 - 8 months

Design Life 20 years 20 years(extended)

Cycle Efficiency(compared with new plant of similar cycle)

100% 100%

Project Risk High Low

Coal Linkage & otherclearances Difficult None

EE R&M is the best available solution for quick increase of reliable power capacity and technically can enhance plant capability as much as a new-build plant in energy efficiency and in design life with optimized CAPEX

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CCT - Energy Efficient R&M boiler manufacturing company Babcock & Wilcox established Engineering...

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