The document discusses operations and maintenance (O&M) practices at thermal power stations to improve efficiency. It provides examples from Kyushu Electric Power Co., which has implemented preventative and condition-based maintenance programs. Key measures taken by Kyushu include periodic inspections and replacements, improving boiler components like soot blowers and burners, and rehabilitating turbines by replacing aged parts to maintain efficiency over the plant lifetime.

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. 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
Overview
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)
4
Exploration
Facilitation and promotion of cleaner
utilization of coal
Mining & Preparation
Coal utilization technology development

5. Upstream Activities
CCT Transfer Program on coal preparation Technologies
5
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 25th, 2014 in
Angul, Odisha using latest vari-wave jig technology with a capacity of 350t/h.
Source: NEDO website

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
Durgapur
Unchahar
Badarpur
2010, 2011
Wanakbori
2010
Ramagundam
2011
Kahalgaon
2010, 2011, 2012
Dr. Narla Tata Rao
(Vijayawada)
A MOU for the Project on Efficiency and
Environmental Improvement
of Coal fired Power Station
was signed on June 11, 2012.
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 6th Japan-India Energy Dialogue
between the Ministry of Economy, Trade and
Industry of Japan and the Planning
Commission of India on October 10, 2012. CCT
workshop in Delhi
2011
2012
Diagnostic activities for two (2) state owned,
one (1) NTPC owned TPS
R&M Workshop in Delhi
2010
2013
Follow up activities for all TPS are ongoing
for all diagnosed TPS.
CCT Transfer program for the delegates from
India power sector was carried out.
CCT workshop in Delhi 6

7. Typical Example of R & M Proposal
COAL
P Air S Air
Feed Water Heater
SH Steam
RH
Steam
Steam Turbine
Generator
Cooling Tower
Stack
Condenser
ESP
IDF
PA
F
FD
F
Mill
Boile
r
Feed
Pump
Air Pre-
Heater
Fly Ash
Bottom Ash
Coal
Bunke
r
Coal Yard
Ash Pond※
※
Transformer
Circuit Breaker
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
Plan-C:R&M
Plan-B+ generator
improvement
Plan-D:R&M
Plan-C+ condenser
and feedwater heater
improvement
7

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

9. 99
Discussion -Topics-
Issues around
materialization of
R&M
Efficiency
Improvement through
enhancement of O&M
Coal blending as one of
the key measures for
domestic coal
shortages
Group1 R&M Group2 USC1 Group3 USC2
Possible barriers for Japanese players to work for India power sector
Issues around materialization of Proposed New
Project
Technical Target and/or Guideline for
introduction of USC
Road map for high
efficiency advanced
technology

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

11. 11
Supply
Facilities
Hydro142places3,582MWPumpedStorage3places2,300MW
※
Ｃｏａｌ3places2,460MW
Thermal9places10,680MW
ＬＮＧ2places4,090MW
※
Geothermal6places212MWＯｉｌ5places4,130MW
Nuclear2places5,258MW
※
Thetotalofplacesdoesnotmatch,
becausetheunit1ofKaritapower
Internalcombustion34places399MWstationiscountedascoalandthe
unit2iscountedasoil.
Wind2places3MW
Solar1places3MW
(asofMarch31,2013)
Total196places20,137MW
Establishment May1,1951
Paid-inCapital 237.3billionyen
#ofShareholders 174,293
#ofSharesIssued
andOutstanding
474,183,951
#ofContracts
Lighting:7.69million
Power:0.93million
#ofEmployees 13,102
IT/telecom
Electricity Sales
VolumeSpecific-
83.8 billion kWh
Kyushu Electric Power Co., Inc.
Breakdown of Electricity Sales Volume
(FY2012)
Domestic Share of Electricity Sales Volume
(FY2012)
(Lighting
35.2%)
Other than
Specific-scale
demand
41.4%
(Power
scale
demand
58.6%
Customers under Liberalization 6.2%)
Over 6,000V , 50kW
Tokyo
31.6%
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%
Consolidated Sales (FY2012)
Other
5.6% 1.6%
Energy-
related
9.5%
Consolidated
Revenue
1,545.9billion
Electricity
83.3%
KYUSHU‐EPCO Profiles

12. 12
Kyushu Electric Power Co., Inc.
Exchange Program with NTPC
In Feb. 2007
The signing ceremony of exchange agreement with NTPC

13. 13
Kyushu Electric Power Co., Inc.
In Nov. 2012
ATTEND 5th INDIA POWER AWARD

14. 14
Kyushu Electric Power Co., Inc.
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 : 2012. 12. 11 – 12. 14 (at Unchahar PS)
Presentation : 2013. 3. 11 (at Unchahar PS)

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

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

17. 17
ScheduledMaintenanceSystem
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
Introduced into Matsuura PS in 2004 and Reihoku PS in 2006
Kyushu Electric Power Co., Inc.
Concept of Equipment Maintenance Management
Maintaining power supply Availability

18. 18
Plant Life Cycle Maintenance
▽50▽Operation Start ▽20∼25 Years
Target of Plant Life Time (50YEARS)
Daily maintenance/Periodical maintenance
Replace PlanInitial failure Long Term Maintenance Plan
Condition Monitoring
R&M LTE Work
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)
Kyushu Electric Power Co., Inc.
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

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

20. 20
Kyushu Electric Power Co., Inc.
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
Improvement typical Measures for Turbine
Outer casing
Inner casing
Turbine rotor

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

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

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

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

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

26. 26PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.
Coal
Production
&
Procurement
Transportation
Marketing
Boiler
Operation
PF boilers
CFBC boiler
（Aichi & Tokuyama refineries）
（Chiba refinery）
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.
Idemitsu bulk terminal （Chiba）
Shunan bulk terminal
Total sales : 14.8 Million tons （2013）
Japan : 6.8 Million tons （2013）
Other : 8.0 Million tons （2013）
資料整理番号：14067
Our Coal Business

27. 27
資料整理番号：14067
1-11. Coal Analysis Centre
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.

28. 28
資料整理番号：14067
1-12. Coal Quality Evaluation Tests
Ash deposition
<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.
NOx emission
Combustion Furnace
Unburned carbon
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
Spontaneous comb.
Durham cone test
Mill
Grindability

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

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

31. 31PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.
）
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.）
資料整理番号：140672-2. 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.
Coal
Analysis
Data
Boiler

32. 32
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.
2-3. Plant Performance（Outline）

33. 33
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.
2-4. Selection of Suitable Blending Ratio

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

35. 35
資料整理番号：14067
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.
Gas velocity TemperatureParticle trajectory Oxygen conc.Boiler geometry
3-1. Numerical Simulation
3D simulator optimizes boiler operating conditions
without hardware modification.

36. 36
資料整理番号：14067
Increase in O2
Present Improved
0
FF
F
E
DE
Coal-D
CD
Coal-C
BC
BC2
BC1
Coal-B
AB
Coal-A
AA
20 40 60 80
Air Flow Rate（m/s）
PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.
Change of damper opening Change of O2 concentration
Increase
Improved
O2 conc.
（%）
10.0
9.0
8.0
7.0
6.0
5.0
4.0
3.0
2.0
1.0
Present
Increase
Decrease
Increase
Decrease
3-4. Improvement of Boiler Efficiency

37. 37
資料整理番号：14067
Coal Burner A B C D E Total
Present condition 1.3 4.1 5.7 11.0 1.1 5.2
Improved condition 1.7 4.3 1.3 2.3 0.7 2.5
PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.
3-5. Reducing Unburned Carbon
Improved condition
OFA Layer
Coal-D Burner Layer
O2 conc.
（%）
10.0
9.0
8.0
7.0
6.0
5.0
4.0
3.0
2.0
1.0
0.0
Present condition
Optimization of
Air Damper Settings
OFA Layer
Coal-D Burner Layer

38. 38
資料整理番号：14067
ParticleGas FlowGas Temp. 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.
3-6. Solution of Slagging Trouble

39. 39
資料整理番号：14067
Coal B
Coal A+B
Coal B
Coal A
Coal B
Belt Blending
Coal A
In-furnace blending
Coal A
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.
3-7. In-Furnace Blending

40. 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 trouble-
free 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.

41. 41
We look forward to working with you
Website:
http://www.jcoal.or.jp/index-en.html
Contacts:
Mr. K. Murakami (kzmurakami@jcoal.or.jp)
[Contact]
Engineering Group
International Business Division
Kyushu Electric Power Co. Inc.
2-1-82 Watanabe-dori, Chuo-ku, Fukuoka 810-8720 Japan
TEL: +81(92)726-1741 FAX: +81(92)716-4428
http://www.kyuden.co.jp/
Kyushu Electric Power Co., Inc.
Coal & Environment Research Laboratory
Coal Business Department
Idemitsu Kosan Co., Ltd.
Kyushu Electric Power Co., Inc.