Measures and Equipment for Optimal Efficiency at Thermal Power Stations

Transcription

1 Measures and Equipment for Optimal Efficiency at Thermal Power Stations January 30, 2015 Japan Coal Energy Center (JCOAL) International Seminar on "Implementation of PAT Scheme in Thermal Power Stations - Issues and Challenges India Habitat Centre 1

2 Overview 1. Profile and Activities of Japan Coal Energy Center (JCOAL) 2. O&M Practices and Effective Solutions for BOP Systems, Kyushu Electric Power Co., Inc. 3. Coal Quality Evaluation System(CQES), Idemitsu Kosan Co., Ltd. 4. Numerical Simulation of Pulverized Coal Combustion, Idemitsu Kosan Co., Ltd. 5. Summary 2

3 1. Profile and Activities of Japan Coal Energy Center (JCOAL) 3

4 Japan Coal Energy Center (JCOAL) Established as a foundation in 1990, with its origin back to 1948 Covers all coal related issues from upstream to downstream of the coal chain Members: 119 incl. major public-listed companies and main players in energy and relevant sectors Supervision by METI (Ministry of Economy, Trade and Industry of Japan) Facilitation and promotion of cleaner utilization of coal Mining & Preparation Exploration Coal utilization technology development 4

5 Upstream Activities CCT Transfer Program on coal preparation Technologies CCT transfer project on coal preparation technology Coal preparation technology was set as the main topic of technology exchange in India considering the importance of high ash coal processing. 1,305 trainees were invited to Japan including 150 Indian experts by the end of JFY2011 Technology exchange programs dispatching Japanese experts to target countries were also commenced Vari-Wave Jig (KCM) Control panel (KCM) Port facilities (Kushiro) Dry separation facility (Nagata Eng.) High efficiency coal preparation plant in Odisha High efficiency coal preparation plant has been commissioned on July 25 th, 2014 in Angul, Odisha using latest vari-wave jig technology with a capacity of 350t/h. Source: NEDO website 5

6 The Project on Efficiency and Environmental Improvement of Coal fired Power Stations A MOU of Pre-primary Study of Efficiency and Environmental Improvement of Coal-fired Power Stations was signed on April 30, 2010, in the presence of Deputy Chairman, Planning Commission of India, and Minister of Economy, Trade and Industry of Japan. Diagnostic activities for two (2) state owned, one (1) NTPC owned TPS Diagnostic activities for two (2) state owned, one (1) NTPC owned TPS R&M Workshop in Delhi A MOU for the Project on Efficiency and Environmental Improvement of Coal fired Power Station was signed on June 11, Badarpur Diagnostic activities for Durgapur of DVC, Unchahar & Badarpur of NTPC; all of which were referred to in the Joint Statement on the occasion of the 6 th Japan-India Energy Dialogue between the Ministry of Economy, Trade and Industry of Japan and the Planning Commission of India on October 10, CCT Unchahar 2011 Kahalgaon 2010 Ramagundam Durgapur workshop in Delhi Follow up activities for all TPS are ongoing 2010, 2011, 2012 for all diagnosed TPS. 2010, 2011 Dr. Narla Tata Rao CCT Transfer program for the delegates from Wanakbori (Vijayawada) India power sector was carried out. CCT workshop in Delhi 6

7 Typical Example of R & M Proposal Plan-A:LE Replacement of worn parts only Plan-B:R&M Replacement of worn parts + Reuse of casing, replacement of HP,IP,LP turbine, D- EHC improvement and ESP rehabilitation Coal Bunke r SH Steam RH Steam Circuit Breaker Transformer Steam Turbine Generator Feed Condenser Pump Feed Water Heater Cooling Tower Stack COAL Coal Yard Mill Boile r Bottom Ash Air Pre- Heater PA F FD F P Air S Air ESP Fly Ash IDF Ash Pond Plan-C:R&M Plan-B+ generator improvement Plan-D:R&M Plan-C+ condenser and feedwater heater improvement 7

8 CCT program - Site Visit - Open-Ended Meeting Embassy of India Joban Joint Power Company Nakoso IGCC (5th Dec.) Mitsubishi Hitachi Power Systems, Hitachi Works (4th Dec.) J-POWER Takasago TPS ( 29 Sept. ) Mitsubishi Hitachi Power Systems, Nagasaki Works ( 31st Oct. ) J-POWER Tachibanawan TPS ( 04th Nov. ) Chubu Electric Power, Hekinan TPS ( 8th Dec.) J-POWER, Isogo TPS ( 30th Oct., 3rd Dec.) Idemitsu Coal & Environment Research Laboratory, Idemitsu Bulk Terminal ( 26th Sept.) Toshiba Keihin Work ( 25th Sept. ) 8

9 Discussion -Topics- Group1 R&M Group2 USC1 Group3 USC2 Issues around materialization of R&M Efficiency Improvement through enhancement of O&M Issues around materialization of Proposed New Project Technical Target and/or Guideline for introduction of USC Coal blending as one of the key measures for domestic coal shortages Road map for high efficiency advanced technology Possible barriers for Japanese players to work for India power sector 9

10 2. O&M Practices and Effective Solutions for BOP Systems, Kyushu Electric Power Co., Inc. 10

11 KYUSHU EPCO Profiles Establishment Paid-inCapital May1, billionyen #ofshareholders 174,293 #ofsharesissued andoutstanding #ofcontracts 474,183,951 #ofemployees 13,102 Energyrelated 9.5% IT/telecom Lighting:7.69million Power:0.93million Consolidated Sales (FY2012) Other 5.6% 1.6% Consolidated Revenue \1,545.9billion Electricity 83.3% Supply Facilities Specific- Hydro142places3,582MWPumpedStorage3places2,300MW Coal3places2,460MW Thermal9places10,680MW LNG2places4,090MW Geothermal6places212MWOil5places4,130MW Nuclear2places5,258MW Thetotalofplacesdoesnotmatch, becausetheunit1ofkaritapower Internalcombustion34places399MWstationiscountedascoalandthe unit2iscountedasoil. Wind2places3MW Solar1places3MW Breakdown of Electricity (asofmarch31,2013) Sales Volume (FY2012) Total196places20,137MW scale demand 58.6% (Lighting 35.2%) Electricity Sales Volume 83.8 billion kwh (Power Customers under Liberalization 6.2%) Over 6,000V, 50kW Other than Specific-scale demand 41.4% Domestic Share of Electricity Sales Volume (FY2012) Tohoku 9.1% Kyushu 9.8% Other 17.9% Domestic Share of Electricity Sales Volume (10EPCOs) 851.6billion kwh Kansai Chubu 16.6% 14.9% Tokyo 31.6% Kyushu Electric Power Co., Inc. 11

12 Exchange Program with NTPC In Feb The signing ceremony of exchange agreement with NTPC Kyushu Electric Power Co., Inc. 12

13 In Nov ATTEND 5th INDIA POWER AWARD Kyushu Electric Power Co., Inc. 13

14 J COAL Study Diagnosis work NTPC Unchahar PS in FY 2012 Diagnosis Purpose Improving plant efficiency of coal fired thermal power station for effective utilization of coal and reducing environmental load Schedule Site survey : (at Unchahar PS) Presentation : (at Unchahar PS) Kyushu Electric Power Co., Inc. 14

15 Categorized Equipment Maintenance Management Maintenance Preventive Maintenance Breakdown Maintenance Time Based Maintenance Condition Based Maintenance Emergency Maintenance Ordinary Corrective Maintenance Periodic Inspection Aging Equipment Inspection High Plant Availability possible through Preventive Maintenance Higher economic efficiency requires shift to Condition Based Maintenance Kyushu Electric Power Co., Inc. 15

16 How to Keep High Availability, Efficiencies, Clean? Improvement Concept of thermal efficiency Grasping periodically the facility performance Economic evaluation Periodical maintenance Introduction of highefficiency equipment Maintaining thermal efficiency Improvement of thermal efficiency Improvement of thermal efficiency Kyushu Electric Power Co., Inc. 16

17 Concept of Equipment Maintenance Management Maintaining power supply Availability Inspection and replacement Annual/Long-term Maintenance program Maintenance Standards Categorize maintenance activities into - TBM (Time-based Maintenance) - CBM (Condition Based Maintenance) - BM(Breakdown Maintenance) based on analysis of past problems and judgment criteria Scheduled Maintenance System Introduced into Matsuura PS in 2004 and Reihoku PS in 2006 Kyushu Electric Power Co., Inc. 17

18 Operation Start Initial failure Plant Life Cycle Maintenance Years Target of Plant Life Time (50YEARS) Daily maintenance/periodical maintenance Long Term Maintenance Plan Replace Plan Condition Monitoring R&M LTE Work 50 Procedure of Long Term Maintenance Plan Select Target Items with O&M conditions Planning of Diagnosis methods,sample No(SN) Tools (Online/Offline), Cost, Timing, etc. Data acquisition and analysis of representative point and trends analysis Predict and Judgments for R&M/LTE Work with Experimental Criteria Readjustment of Period of measures, SN Planning of next timing of monitor (Off line) Target items for Overhaul or Replacement Steam Turbine (HP,IP), Cylinders (inner/outer) Major Valves for Steam Turbine (MSV,RSV) FW Heaters Air Pre Heater, Gas Heater (APH/GGH) Electrostatic Precipitator (ESP) Generator (Stator/Rotor) Transformers HV Motors Control Systems Kyushu Electric Power Co., Inc. 18

19 Improvement typical Measures for Boiler Secondary superheater Quaternary superheater Tertiary superheater Reheater 1. Washing the boiler generating surface Primary superheater 2. Primary superheater soot blow executed (Measure for abrasion due to pressure reduction of injection steam) Soot blower 3. Economizer soot blower newly built Economizer 4. Washing the air preheater element and replacing the defective element Burner nozzle Boiler Burner nozzle Air preheater Electric dust collector Induced draft fan Chimney Steam type air preheater Forced draft fan 6. Burner nozzle automatic operation 5. Repairing steam leakage of steam type air preheater Silencer Remarks Polluted by ash, etc. Run soot blower (9 (drum left) + 9 (drum right) = 18) Run/stop soot blower (4 (drum left) + 4 (drum right) = 8) New soot blower (4 (drum left) + 4 (drum right) = 8) Kyushu Electric Power Co., Inc. 19

20 Improvement typical Measures for Turbine Outer casing Inner casing Turbine rotor Improvement of high pressure turbine aged deteriorated part Replacing seal fin, etc. Removing scale, etc. Measures for low pressure turbine Moving blade and stationary blade newly made. Fin installed on moving blade. Replacing the diaphram Replacing the inner casing Kyushu Electric Power Co., Inc. 20

21 CEA JCOAL Workshop FY2014 Turbine Rotor Replacement timing Mapping of Rotor Replacement timing Op Rate:90% Op Rate:70% Operation Hours Av.181,600Hr / 26.2yrs 5Years Range Circle Elapsed Years Kyushu Electric Power Co., Inc. 21

22 Insulation Strength(%) Sample Chart of Generator Stator Coil Inspection and Replacement timing Temp.Corr Regression lines 99.9% Confidence interval Max. Ave. Min. Line of Monitoring Start Monitoring Period Limit of Operation Operation Hours Kyushu Electric Power Co., Inc. 22

23 Condition Monitoring for MV Motors Due to old installation (20 years back), deterioration of insulation is a matter of concern. Inspectionitems Monthlycheck Routinecheck OverHaul Condition Monitoring Whenneeded LubricatetheGrease Visualinspection,cleaning, windinginsulationmeasurement, etc. CategorizedtoTBM/BDM,Cycles, etc.(on/off-site,spares, Redundancy,SeverityoftheBD) Insulationresistancetest, Polarizationindextest,Tanδ test SupplementaryInsulation, Rewinding Kyushu Electric Power Co., Inc. 23

24 Condition Monitoring for Rotating Machines Process to Failure of ROTATING MACHINES Failure Wear level (degree of degradation) Possible to catch abnormalities at early stage Lubricant diagnosis Temperature diagnosis Vibration diagnosis Running in Stable operation Advanced stage Time Kyushu Electric Power Co., Inc. 24

25 3. Coal Quality Evaluation System(CQES), Idemitsu Kosan Co., Ltd. 25

26 Our Coal Business 資料整理番号 :14067 Coal Production & Procurement 10.6 Million tons (2013) * Idemitsu s equity Coal mine operation in Australia Acquired coal mine in Indonesia Coal supply from Australia, Indonesia, Russia, China, etc. Transportation Idemitsu bulk terminal (Chiba) Shunan bulk terminal Marketing Total sales : 14.8 Million tons (2013) Japan : 6.8 Million tons (2013) Other : 8.0 Million tons (2013) Boiler Operation PF boilers CFBC boiler (Aichi & Tokuyama refineries) (Chiba refinery) PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD. 26

27 1-11. Coal Analysis Centre 資料整理番号 :14067 Calorific Value Ultimate Analysis Ash Fusion Temperature Ash Composition PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD. 27

28 1-12. Coal Quality Evaluation Tests 資料整理番号 :14067 We have carried out many evaluation tests for various kinds of coals and collected the test results into our database. We can provide technical services by applying these abundant data. Handling Mill Combustion Furnace Spontaneous comb. Grindability Unburned carbon NOx emission Ash deposition Durham cone test <Turbulent flow furnace> <SEM/EDX> PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD. 28

29 1-13. Technical Products 資料整理番号 :14067 Coal quality evaluation system Numerical computer simulation High temperature furnace scope Coal analysis & evaluation tests Dust dispersion inhibitor Evaluation tests on handling properties Spontaneous combustion simulator Spontaneous combustion tester Ash utilization simulator Trace element simulator 29

30 2-1. Coal Quality Impacts on Power Plant Coal quality affects the performance of each facility in a coal-fired power plant. Decrease Efficiency Bunker Increase unburned carbon Slagging and fouling Increase NOx emission SCR Increase dust emission Decrease De-SOx activity 資料整理番号 :14067 Dust emission Boiler EP Stock Pile FGD Mill Spontaneous combustion Ash Gypsum Increase of mill load Difficulty of ash utilization Decrease gypsum purity Excess trace element regulations 30

31 2-2. Coal Quality Evaluation System(CQES) Idemitsu developed the computer software which can quantitatively estimate the impacts of coal quality on power plant performance. This system is used in many Japanese and overseas power companies for expanding coal brands. ) 資料整理番号 :14067 Coal Analysis Data Boiler Operating Condition CQES 1. Quick and accurate prediction of plant performance for new coal 2. Prior prediction of problems, which helps to prevent trouble 3. Investigation of optimum blending conditions 4. Abundant technical information (Evaluation technology, Trouble examples, Coal analysis data, etc.) PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD. 31

32 2-3. Plant Performance(Outline) 資料整理番号 :14067 PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD. 32

33 2-4. Selection of Suitable Blending Ratio 資料整理番号 :14067 Available Not available PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD. 33

34 4. Numerical Simulation of Pulverized Coal Combustion, Idemitsu Kosan Co., Ltd. 34

35 3-1. Numerical Simulation 3D simulator optimizes boiler operating conditions without hardware modification. 資料整理番号 :14067 Boiler geometry Gas velocity Particle trajectory Temperature Oxygen conc. We can clearly grasp combustion states in the boiler and investigate its optimum operating conditions, which increase boiler efficiency and reduce NOx emissions. This tool is also useful for the solution of slagging trouble. PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD. 35

36 3-4. Improvement of Boiler Efficiency 資料整理番号 :14067 Change of damper opening Change of O2 concentration FF F E DE Coal-D Decrease Increase Improved Present O2 conc. (%) 10.0 CD Coal-C Increase BC BC2 BC1 Coal-B AB Coal-A AA Decrease Increase Air Flow Rate(m/s) Present Increase in O2 PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD. Improved 36

37 3-5. Reducing Unburned Carbon 資料整理番号 :14067 Present condition Improved condition OFA Layer Coal-D Burner Layer Optimization of Air Damper Settings OFA Layer Coal-D Burner Layer O2 conc. (%) Coal Burner A B C D E Total Present condition Improved condition PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD. 37

38 3-6. Solution of Slagging Trouble 資料整理番号 :14067 Gas Temp. Gas Flow Particle Collision with Boiler Wall Before (Trouble) OFA Tilt -16 deg. Improved OFA Tilt +16 deg. PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD. 38

39 3-7. In-Furnace Blending 資料整理番号 :14067 Belt Blending In-furnace blending Coal A Coal A+B Coal A Coal A Coal B Coal B Coal B In-furnace blending has to choose a suitable blending condition from among many patterns. Boiler performance such as unburned carbon, NOx emission and furnace outlet temperature can be improved compared to the belt blending. PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD. 39

40 Summary 1. JCOAL is conducting several projects under Indi Japan mutual cooperation in both coal and power sector. Joint declarations at both past and the latest India-Japan Energy Dialogues acknowledged such significance and achievement of the Cooperation. 2. CEA-JCOAL Cooperation provided a good opportunity for materialization of R&M as well as fruitful discussion and information exchange in CCT transfer program. 3. In a targeted long plant life of nearly 50 years, high plant availability possible through preventive maintenance. Higher economic efficiency requires shift to condition based maintenance 4. Idemitsu has been providing technical services to coal users, creating the further demand of coal, and making the most effective use of coal resources. 5. Applying our products and services, we propose optimum coal-blending and boiler-operating conditions which lead to improved efficiency and troublefree operation in a boiler. 6. We, especially Japanese players in the coal power subsector in India are anxious to work together with our Indian partners toward sustainable development of Indian power sector. 40

41 We look forward to working with you [Contact] Kyushu Electric Power Co., Inc. Engineering Group International Business Division Kyushu Electric Power Co. Inc Watanabe-dori, Chuo-ku, Fukuoka Japan TEL: +81(92) FAX: +81(92) Kyushu Electric Power Co., Inc. Coal & Environment Research Laboratory Coal Business Department Idemitsu Kosan Co., Ltd. Website: Contacts: Mr. K. Murakami 41