Case study of Optimisation Efforts at NTPC Ramagundam Unit # 7

Transcription

1 Case study of Optimisation Efforts at NTPC Ramagundam Unit # 7 -A V Seshagiri Rao- NTPC -Biswanath Mahapatra-BHEL

2 NTPC-Vision A world class integrated power major, powering India's growth, with increasing global presence

3 31704 MW

4 NTPC Ramagundam Performance 1998-to Installed Capacity : 2600 MW (3*200+4*500) P.L.F. (%) AVAILABILITY (%)

5 U-7 performance PLF Availability

6 PADO (Performance analysis, Diagnostics and Optimisation) Installed in Unit 7 in Oct 2008

7 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.

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9 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

10 PADO SYSTEM NETWORK CONFIGURATION FOR RAMAGUNDAM UNIT #7

11 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

12 Case study : Soot Blowing Optimisation

13 General Soot Blowing Practice Time based Regular intervals Parameter based Metal temperature criteria Spray Flue gas exit temperature Coal quality Slagging tendency Mill combination

14 PADO Results Neural technology Heating Surfaces Heat Transfer efficiency Boiler gas Path temperatures Fire Ball Height Relationship Drawing

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16 Operate & confidence Building 15 th Oct 2009 Comparison of PADO results with Actual Boiler 15 th Sept 2009 Design Of Experiments Observe Results 05 th Sept 2009 Tune settings 25 Sept

17 Data Comparison 7 Months Period to With to

18 Results comparison Parameter Before PADO After PADO Improvement Unit Operating Hours above 490 MW Total soot blowing steam consumption % Soot Blowing Steam Kg/MW %

19 Results Comparison No. Of Times Wall Blowers Operation Before PADO After PADO Improvement Cleaning Of wall Blowers AB Groups Cleaning Of wall Blowers C Group % % Cleaning Of wall Blowers D Group %

20 Results comparison No. Of Times LRSB Operation Before PADO After PADO Deviation Div. Pnl % Platen SH % RH % LTSH % Eco %

21 Results comparison Parameter Before PADO After PADO RH Metal temp Above 590 Deg in Hrs. RH Metal temp Above 594Deg in Hrs. RH Metal temp Above 598 Deg in Hrs RH spray 30 T/Hr 34 T/hr Heat Rate

22 Before Implementation of SBO Module

23 After Implementation of SBO Module

24 Coal flow Vs SAPH Outlet Temperatures 24

25 Coal flow Vs PAPH Outlet Temperatures 25

26 Coal flow Vs FEGT 26

27 Coal Flow Vs RH Metal temperature 27

28 HRH temp Vs IPT Overall Efficiency 28

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 29

30 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

31 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

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