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
• Evaporation 2,550 Ton/hr
• SH Outlet Press. 253 bar
• SH Outlet Temp. 568
• RH Outlet Temp. 596
• 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
• Evaporation 3,010 Ton/hr
• SH Outlet Press. 275 bar
• SH Outlet Temp. 613
• RH Outlet Temp. 624
• 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
ABOUT DOOSAN POWER SYSTEMS
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
ABOUT DOOSAN POWER SYSTEMS
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
BOILER LIFE MANAGEMENT
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
BOILER LIFE MANAGEMENT
29
BOILER VULNERABLE AREAS AND TYPES OF DAMAGES
Component Type of damage Possible causes
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
BOILER LIFE MANAGEMENT
30
BOILER VULNERABLE AREAS AND TYPES OF DAMAGES
Component Type of damage Possible causes
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
BOILER LIFE MANAGEMENT
31
THE ENGINEERING APPROACH
Require to assess the impact of the past …
… and predict the effects of the future
32
THE ENGINEERING APPROACH
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
THE ENGINEERING APPROACH
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
THE ENGINEERING APPROACH
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
THE ENGINEERING APPROACH
36
THE ENGINEERING APPROACH
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
THE ENGINEERING APPROACH
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
THE ENGINEERING APPROACH
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
ABOUT DOOSAN POWER SYSTEMS
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
ABOUT DOOSAN POWER SYSTEMS
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
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ABOUT DOOSAN POWER SYSTEMS
WHY R&M
R&M MODALITY
CASE STUDY
RECENT R&M PROJECT
CONCLUSION
PROGRAM
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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
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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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THANKS FOR YOUR ATTENTION!
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