“Economizer Modification–A focused perspective PC_B… · Transforming lives RAMAGUNDAM...
Transcript of “Economizer Modification–A focused perspective PC_B… · Transforming lives RAMAGUNDAM...
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Transforming lives
RAMAGUNDAM
“Economizer Modification–A focused perspective(A Case Study on Project Management)
A Team effort by
Balaram Reddy TSatish Chandra VNaresh Raju PPavan M
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Presentation Outline …
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Present scenario at NTPC
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PLF trend over the years…
Source: NTPC Annual Report 2015
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Ramagundam PLF
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“My flight should fly”
- Sh. Aditya Ghosh, CEO, Indigo
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Boiler
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Boiler Efficiency Losses
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First time in India by handling 1200MT in a running plant
Economiser modification at U#6
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Reduction in Flue gas Exit temperature
Improvement in Boiler EfficiencyReduction in Flue gas velocity thereby erosion
reduction in economizer
SH spray reduction
Environmental benefits
Improvement in ESP collection efficiency.Emission reduction (CO/CO2 / SOx / Nox)
Targeted Benefits
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Project Approvals
Corporate Centre OEM Statutory Bodies Budget
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Project PlanningContract Awarding
Preparatory works
Interim Change of plans
Safety plans
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Logistics PlanningMaterial Procurement In house designAlternate vendor
development Awarding of Service contract Split contracts Additional resources
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In House Design of Hanger Bends
Designed with the help of NETRA, Exactly suitable at site
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Contract Awarding
Works divided among two agencies on 50-50% basis
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Preparation
Best Man power chosen, to avoid re-work
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Eco coil shifting
Shifted from stores 1 week before OH
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Eco coil shortening
Shortening works started 15 days before OH
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Interim Change of Plans
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Coil Removal
Per day coil removal raised to 43 against 24
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Coil Placement
Removed 20 sets and inserted 15 sets.
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Safety Plans
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Safety PlansWorkers safety training T&P Testing Safety monitoring Safe material handling
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Time
Actual coil placement completed in 15 days against 25 days planned
RAMAGUNDAM
SYNCHRONISATION
BOILER SAFETY VALVE FLOATING
BOILER LIGHT UP
BOILER HYDRO TEST
RESTORATION
RADIOGRAPHY
WELDING WORKS
COIL INSERTION
COIL REMOVAL
PREPARATORY WORKS FOR COIL REMOVAL
ACTIVITY Vs. DAY WISE PLAN
MILE STONE CHART NTPC
9
TARGET
STARTED ON 22.07.2016
3 12 3315 18 216
END DATE 22.08.2016
24 27 30
ACTUAL
ECONOMISER MODIFICATION WORKS IN U#6 OH
34 & 35 DAYS
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Performance Achievement
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Benefits achieved Flue Gas exit temperature reduction: 15 deg.C Heat Rate Improved by 15 K.cal/Kw.Hr Boiler efficiency improved by 0.75% Annual coal consumption reduced by 16000MTPAT benefits SH attemperation reduction APC reduction Variable Cost Reduction
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APC REDUCTION
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Benefits in Physical parameters
Description
Before modif. HT Surface
( 12833sq.M) in economiser
After modif. HT Surface
( 16426sq.M) in economiser
Feed water Eco. i/l Temp
254 254
Feed water Eco. o/l Temp
317 321
FGT at Eco i/l 438/477 442/484FGT at Eco o/l 375 333
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Monetary Benefits Cost of the project:
Material cost: Rs 8.5 Cr ( 2existing +1 new bank)Services cost: Rs 1.5 CrTotal cost incurred Rs10Cr
Monetary Benefits achieved:
Benefit due to coal saving: Rs 4.8 Cr.Energy Certificates earning in PAT cycle-II(PAY BACK PERIOD: 10 Months)
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Performance 1 Reduction in Flue Gas Exit
temperature 15 deg C
2 Corresponding Heatrate reduction 15 kCal/kWhr
3 Per annum Energy savings 59130 Million Kcal
4 Energy equivalent of coal 15561 MT of coal
5 Saving in Rs Cr / year 4.67 Rs Cr
6 Pay back in years (incl two existing banks) 2.4 Years
7 Pay back in years (additional bank) 10.0 Months
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Towards Environment Gains Emission reduction of CO2 by 19650MT Reduction in CO, SOx, Nox Enhanced ESP efficiency thereby reduction in SPM Future FGD investment cost reduction Reduction in ash handling
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Replication of the project
R&M Budget Proposal i/p for Implementation at other units-4 & 5 of NTPC-Ramagundam
A detailed study report beingsent to CC for the projectimplementation at similar units of NTPC
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Installing VFD Motors in ID, FD, PA Fans
R&M of Air Pre Heaters
LP Coil Pre Heating
Energy efficient equipments – IE coded motors for CT
Installation of FGD
Our other smart ideas
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The difference between what we do and what we are capable of doing would suffice to solve most of the problems.