Boiler Modification for SHR & Reliability Improvement SSL (IPP)

1. An Energy & Environment
Conscious, Sustainable &
Prosperous Organization
SESA STERLITE LTD
4X600 MW IPP
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2. Power Business Overview
Location Capacity
Jharsuguda IPP 4X600 MW
Jharsuguda CPP 9X135 MW
TSPL 3X650 MW
4X600 MW IPP Jharsuguda (Supplied by SEPCO -III)
Boiler Make HBC China
TG DFPS China
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Sesa Sterlite – Power Overview
Contributing to India’s Energy
Security
An Energy & Environment Conscious Sustainable Organization

3. PROJECT - BOILER MODIFICATION FOR RELIABILITY AND
STATION HEAT RATE IMPROVEMENT
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4. 4X600 MW INDEPENDENT POWER PLANT
 First 600 MW Power Plant of Odisha
 ESP – FF Hybrid precipitator maintaining SPM < 50 mg/Nm3
 Plant supplied by SEPCO-III China (Boiler- Harbin , Turbine- DFPS)
 Plant equipped with modern online performance and combustion
Optimisation softwares.
 IPP has got accreditation with EnMS 50001:2011 , EMS 14001:2004 ,
QMS 9001:2008 and OHSAS 18001:2007 to ensure sustainability .
 Opportunities identified and executed for efficiency and reliability
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5. 5
Milestone
Particulars U#1 U#2 U#3 U#4
1st Light up 20-Dec-10 12-Jun-10 20-May-11 19-Feb-12
Date of
Synchronization
27-Dec-10 10-Aug-10 9-Jul-11 29-Mar-12
Date of Achieving
Full Load
28-Dec-10 14-Oct-10 16-Aug-11 25-April-12
Date of COD 30-Mar-11 9-Nov-10 19-Aug-11 26-Apr-12
MILESTONES OF SSL , JHARSUGUDA

6.  Guaranteed Station Heat Rate achieved in all the Units
 Saving Potential in SHR identified in three parameters
 High Superheat Spray 150 TPH w.r.t 65 TPH (rated)
 High Reheat Spray 33 TPH w.r.t 0 TPH (rated)
 Less RH Steam Temperature 525 w.r.t 538 DegC
 High metal temperature excursion causing tube failures
 Difficult to Control Operating Parameter With Top Mill
Operation.
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OPPORTUNITIES IN BOILER

7. BOILER DETAILS
Boiler Make The China Harbin Boilers co. Ltd
Boiler Type
Subcritical , Reheat, Single Furnace ,
Single Reheat , Forced Circulation ,
Balanced Draft , Dry bottom ,
Tangential corner fired pulverised Fuel
Fired
SH Outlet Steam pressure (MPa) 17.5
Design Temp (DegC) 541
Boiler Capacity (TPH) 2060
RH Steam Outlet Pressure (MPa) 3.8
RH Steam Temperature (DegC) 541
Fuel consumption (TPH) 433
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8.  Losses identified at early stage
 Initiatives started to counter the problem
 Combustion Experts Dr. V T Satyanathan (Ex-BHEL) conducted study
 Combustion Experts of Squam Power Plant Technical Consultancy
engaged for optimisation
 STEAG Germany combustion optimisation software installed
 Online trials conducted and detailed study carried out
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CORRECTIVE MEASURES

9.  Trials conducted since 2011 to Dec 2012 mainly focused on
 (i) SADC tuning
 (ii) Burner Tilts
 (iii) OFA damper regulations
 (iv) Soot Blowing Optimisation
 Trials Conducted but desired result could not be achieved with
above Trials.
 Conclusion: SSL insisted Sepco-III to study and provide solution.
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10. ENGAGEMENT OF HBC- OEM
 Sepco-III depuetd Combustion expert from Harbin Boiler
 Trial Conducted by Harbin Experts from 4-18th December 2012
 Operation and combustion expert exercised all the possible
combinations
 CONCLUSION :
 Improvement in performance parameter not achieved
 Harbin suspected the variation in fuel was leading to deviations
 Harbin referred the problem to design institute for review and solution.
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11. Review and Proposal
 Design institute recommended modification
 Harbin proposed modification in three zones of boiler
 Reduction of Surface area of LTSH from 12944 to 7696 m2
 Reduction of radiation side wall Re-Heater width from 8191 to6268
mm
 Increase of Economiser surface from 215000ft2 to 277000 ft2
 Boiler efficiency and SHR will remain unaffected.
 All the performance test will be carried out after modification.
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12. Review and Approval of Project
 SSL & Ex-BHEL design expert Mr. Sivaraman Krishnamurthy
reviewed the proposed modification
 Proposal review meeting held at Harbin China in March 2013.
 Challenge of pressure part alteration in limited access reviewed
 Unit outage for longer time > 60 Days
 Directorate of Factories & Boiler reviewed and approved the
project
 SSL approved the project anticipating long term gain in
Conservation of natural resource and reduction in carbon
emission.
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13. REMOVAL OF PRESSURE PART
 Material received within 3 months of project approval from China
 120 Nos. tube Reheat radiation wall removed from each side
 Water wall LTRH headers replaced with new headers
 Lower group of LTSH Removed
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Cutting of LTRH
Tube and Header
Removal of LTRH
Header
Economiser Tube
cutting

14. ERECTION OF PRESSURE PART
 Erection methodology was prepared by Harbin & Sepco-III
 Job safety analysis carried out in detail
 Each lifting tools to be used in project tested before
commencement of project
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Steam Cleaning of
Tubes
Erection of
Economiser Coil
Lifting of water wall panel
through bottom ash
hopper

15. Erection of Pressure Part
 Detailed Quality assurance plan to ensure quality work
 Radiography conducted in 100% joint in RH and LTSH area
 Radiography in 20% joint of Economiser.
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Readiness for
position eco tube
Economiser coil in
position

16. PROJECT – Boiler Modification
 First modification started in Boiler of Unit#3 w.e.f 12th July 2013
 Modification carried out during scheduled annual overhaul of Unit-3
 Sepco-III executed the modification project
 Material was supplied from China in short duration of 3 months
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Removal of LTRH
Header Fitment of new
LTRH Header
Erection of new
LTRH link pipe

17. PROJECT – Boiler Modification
 Manpower engaged 250
 No of Days for project completion - 60
 Cost of Project Rs 500 millions INR
 No of Welding Joints 3485
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Lifting of Economiser Coil Addition of Economiser bank New Added Economiser bank

18. Re-Commissioning & Demonstration
 Detailed programme prepared for Boiler flushing
 Flushing continued for 3 Days to bring the parameters in limits
 Post-modification demonstration carried out for
 Boiler Efficiency test
 Boiler efficiency test at design and worst coal
 Demonstration for Zero Reheat spray and rated Super heater spray
 Demonstration for top mill and bottom mill operation
 Reliability test for design unit load ramp up and ramp down
 14 Days reliability run by OEM
All the tests were successfully completed
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19. Boiler Parameters After Modification
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S.No Parameter Description UOM Design
Before
Modificatio
n
After
Modificatio
n
1 Power Generation MW 600 599 601
2 Coal flow TPH 420 411 383
3 Main Steam Pressure Mpa 16.7 16.37 16.66
4 Main steam Temperature DegC 538 539 539
5 RH steam Temperature DegC 538 536 538
6 RH Steam Pressure MPa 3.8 3.61 3.49
7 SH Spray TPH 65 150 66
8 RH Spray TPH 0 25 0

20.  SH Spray Reduced from 150 TPH to 66 TPH
 RH Spray Reduced from 33 TPH to Zero
 Top Mills Service operation became normal operation
 Improvement in SHR of 14Kcal/KWH achieved
 SHR Improvement contributed to saving of 87000 MT of coal per
annum
 Reduction in CO2 emission by 2.3 lacs MT emission due to
improvement in SHR.
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Result Summary

21. CALCULATION OF GAIN AFTER MODIFICATION
S.No.
IMPROVEMENT
AREA
UOM
Before
Modification
After
Modification
Improve
ment
Gain in
Heat
Rate
(Kcal/K
wh)
Net Saving
in Millions
(INR)Per
annum
Net
Saving
of Fuel
Per
Annum
(MT)
1 Av . Power Generation MW 600 600 0 0 0 0
2 Reheat Temperature DegC 525 538 13 6.7 24 10534
3 Reheat Spray % 2.4 0 2.4 7 26 11088
4 SH Spray % 8.6 3.5 5.1 0.12 0.44 190
Total Savings Per unit per Annum (@90% PLF , 3000 Kcal/Kg GCV) 50 21812
Total Saving Per Annum for 4X600 MW 201 87247
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22. Thank You
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