BHEL-ELECTRONICS DIVISION

Case study of

Optimisation Efforts

at

NTPC Ramagundam Unit # 7

-A V Seshagiri Rao- NTPC

-Biswanath Mahapatra-BHEL

BHEL-ELECTRONICS DIVISION

NTPC-Vision

A world class integrated power major,

powering India's growth, with increasing global

presence

BHEL-ELECTRONICS DIVISION

31704 MW

BHEL-ELECTRONICS DIVISION

NTPC Ramagundam Performance 1998-to 2010

86.21

90.22

89.25

86.14

91.52

88.54

90.51

86.45

88.90

90.14

94.4594.81

89.36

90.76

90.03

88.21

92.71

90.98 91.04 90.9590.57

91.49

93.52 93.65

80

82

84

86

88

90

92

94

96

1998-99 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10

P.L.F. (%)

AVAILABILITY (%)

Installed Capacity : 2600 MW

(3*200+4*500)

BHEL-ELECTRONICS DIVISION

U-7 performance

86.81

79.59

98.3994.65

101.19

93.64

80.41

99.15

92.77

98.65

0.00

20.00

40.00

60.00

80.00

100.00

120.00

2005-06 2006-07 2007-08 2008-09 2009-10

PLF

Availability

BHEL-ELECTRONICS DIVISION

PADO (Performance analysis, Diagnostics and

Optimisation)

Installed in Unit 7 in Oct 2008

BHEL-ELECTRONICS DIVISION

WHAT IS PADO?

• PADO is a software based optimisation and diagnostics

system based on client-server architecture.

• It’s a package rich in intensive information which aids

plant operator to run the plant with most optimum

efficiency , availability and maintainability.

• Massive Computation Engine for monitoring and

analysis of Performance Parameters of Power Plant.

BHEL-ELECTRONICS DIVISION

BHEL-ELECTRONICS DIVISION

PADO MODULES

•PERFORMANCE ANALYSIS & MONITORING

MODULE

•SYSTEM & PERFORMANCE OPTIMISATION

•BPOS(BOILER PERFORMANCE OPTIMISATION

SYSTEM)

•CONTROL LOOP OPTIMISATION

•BOILER STRESS CONDITION ANALYSER

•SYSTEM & PERFORMANCE DIAGNOSIS MODULE

•INTELLIGENT WATER & STEAM CHEM. MGT

BHEL-ELECTRONICS DIVISION

PADO SYSTEM NETWORK CONFIGURATION FOR RAMAGUNDAM UNIT #7

BHEL-ELECTRONICS DIVISION

Optimisation Package

Various features are as follows :

•Boiler related calculations :

Efficiency , Environmental Parameters, RLA , Metal temperatures Monitoring, APHs , Mills and Soot Blowing Analysis

•Turbine related calculations :

Heat rate. Cylinders efficiency , Heaters efficiency Condenser efficiency and CEP efficiency

•Energy Conservation :

Aux power consumption and Specific Power Consumption

BHEL-ELECTRONICS DIVISION

Case study :

Soot Blowing Optimisation

BHEL-ELECTRONICS DIVISION

General Soot Blowing Practice

Time based

•Regular intervals

Parameter based

• Metal temperature

criteria

•Spray

•Flue gas exit

temperature

•Coal quality

•Slagging tendency

•Mill combination

BHEL-ELECTRONICS DIVISION

PADO Results

•Neural technology

•Heating Surfaces Heat Transfer efficiency

•Boiler gas Path temperatures

•Fire Ball Height

•Relationship Drawing

BHEL-ELECTRONICS DIVISION

BHEL-ELECTRONICS DIVISION

16

Comparison of PADO results with Actual Boiler – 15th Sept 2009

Tune

settings

25 Sept

2009Observe Results –

05th Sept 2009

Operate &

confidence Building

– 15th Oct 2009

Design Of

Experiments

BHEL-ELECTRONICS DIVISION

17

7 Months Period

01-11-2008 to 30-05-2009

With

01-11-2009 to 30-05-2010

Data Comparison

BHEL-ELECTRONICS DIVISION

Results comparison

Parameter Before PADO1.11.08 – 30.5.09

After PADO

1.11.09 – 30.5.10

Improvement

Unit Operating

Hours above 490

MW

4697 4844

Total soot blowing

steam consumption8923 5918 33.68 %

Soot Blowing Steam

Kg/MW3.853 2.393 37.89 %

BHEL-ELECTRONICS DIVISION

Results Comparison

No. Of Times

Wall Blowers

Operation

Before PADO

1.11.08 – 30.5.09

After PADO

1.11.09 –30.5.10

Improvement

Cleaning Of wall

Blowers AB

Groups

710 391 44.93 %

Cleaning Of wall

Blowers C Group542 205 66.73 %

Cleaning Of wall

Blowers D Group531 216 61.04 %

BHEL-ELECTRONICS DIVISION

Results comparison

No. Of Times

LRSB Operation

Before PADO

1.11.08 – 30.5.09

After PADO

1.11.09 – 30.5.10

Deviation

Div. Pnl 20 42 104 %

Platen SH 40 65 62.5 %

RH 38 57 50 %

LTSH 22 32 45.5 %

Eco 21 29 38.1 %

BHEL-ELECTRONICS DIVISION

Results comparison

Parameter Before PADO1.11.2008 – 30.5.2009

After PADO

1.11.2009 – 30.5.2010

RH Metal temp Above 590

Deg in Hrs.52 41

RH Metal temp Above

594Deg in Hrs.22 21

RH Metal temp Above 598

Deg in Hrs.8 10

RH spray 30 T/Hr 34 T/hr

Heat Rate 2349 2336

BHEL-ELECTRONICS DIVISION

Before Implementation of SBO Module

BHEL-ELECTRONICS DIVISION

After Implementation of SBO Module

BHEL-ELECTRONICS DIVISION

24

Coal flow Vs SAPH Outlet Temperatures

BHEL-ELECTRONICS DIVISION

25

Coal flow Vs PAPH Outlet Temperatures

BHEL-ELECTRONICS DIVISION

26

Coal flow Vs FEGT

BHEL-ELECTRONICS DIVISION

27

Coal Flow Vs RH Metal temperature

BHEL-ELECTRONICS DIVISION

28

HRH temp Vs IPT Overall Efficiency

BHEL-ELECTRONICS DIVISION

29

Value Addition

- 40% Reduction in Wall Blowing

– Tube erosion will reduce –

• No Tube leakage Since Nov 2008

– Reduction in Steam consumption

– Excellent Data Reconciliation

– Easy Evaluation of Results

– Design of Experiments – made easy

– Further scope of improvement is visible

BHEL-ELECTRONICS DIVISION

BHEL EXPERIENCE IN PADO

•Commissioned : 12 units of 500MW sets viz; Simhadri

Stg.I , Ramagundam St.III , Rihand Stg.II , Vindhyachal

Stg. III , Talcher Stg. II & Bellary Unit # 1

•Under commissioning : 5 units of 500MW sets

•Under execution :

500MW sets : 32 units

195MW sets : 2 units

250MW sets : 7 units

600MW sets: 4 units

660 MW supercritical sets : 2 units

BHEL-ELECTRONICS DIVISION

BHEL EXPERIENCE IN PADO

•BHEL has executed PADO for the plants where

complete DCS platform ( SG , TG and Stn C&I ) has

been supplied by BHEL

•BHEL has also integrated and supplied PADO for the

plants where part of the DCS has been supplied by

other vendors

BHEL-ELECTRONICS DIVISION