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KTPS, Koradi. Physical Performance 2008-09. Action Plan: CHP (357.84 Mus). It is observed that the breakdown in the CHP is mainly due to lack of manpower at the various spots in need . Action Plan: CHP. Revamping of critical auxiliaries will increase the unloading and feeding capacity .
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KTPS, Koradi Physical Performance 2008-09
Action Plan:CHP (357.84 Mus) It is observed that the breakdown in the CHP is mainly due to lack of manpower at the various spots in need.
Action Plan:CHP Revamping of critical auxiliaries will increase the unloading and feeding capacity.
Action Plan:ESP / AHP /Bag filters (90 Mus) It is observed that the Loss in 2008-09 was mainly due to load restriction by damaged bags of Unit 6 to keep emissions minimum with in the limit. The replacement of Bags done in Jan 2009 with higher grade material for the expected life of 4 years Therefore this loss is not expected in 2009-10. However the life of the bags will exponentially reduced due to very low load operation, as bag pulsating frequency increases in low load condition inducing vibration in the bag and higher Auxiliary consumption.
Action Plan:Generator H2 Leakage (42.424 Mus) It is observed that the Loss in 2008-09 was predominantly in Stage – I Units No. 3 and 4. The vibration of Generator rotor, surface roughness of the generator collar and Compressibility of the seal bearing gasket are the root cause of H2 leakage. Retention strength of seal gasket losses in case of higher vibration. LP rotor blading and balancing done in unit - 3. Now the vibrations are reduce from 150 micron to below 25 micron. Unit - 4 Generator rotor trim balancing done. The vibration levels are also reduces to acceptable level. Therefore this loss is not expected in 2009-10.
Action Plan:Pressure Part Leakage (15.263 Mus) It is observed that the Loss in 2008-09 was predominantly in Units No. 3 for Bottom ring header water wall tube stub joint. The stub joints of unit 2, 3 and 4 are also checked and attended. The stub joints of unit 1 will be attended in AOH Aug 2009. Therefore this loss is not expected in 2009-10.
Action Plan:Condenser vacuum (15.06 Mus) It is observed that the Loss in 2008-09 was predominantly in Units No. 2 due to heavy scaling inside the tubes. The acid cleaning followed by high pressure hydro-jetting is planned to remove scaling. It will be ensured that the jet pressure will be more than 1000 Kg/Cm2 for effective cleaning. Therefore this loss is expected to minimize in 2009-10.
Action Plan:Condenser Tube Leakage (11.06 Mus) It is observed that the Loss in 2008-09 was predominantly in Units No. 2 probably due to thinning of the tubes. Eddy current test will be carried out during the overhaul of stage – I units to access the present condition by M/s CPRI. The order is already placed for test of 12000 tubes and will be operated during 2009. The decision of replacement will be done on the basis of Eddy current test to avoid failures in future. Therefore this loss is expected to minimize in 2009-10.
Success story:Boiler Tube Leakage (-33.847 Mus) Replacement of U3 – Primary super heater top bank tubes with higher grade material (T22 in place of Medium carbon steel). Replacement of Pendent re-heater coil. Therefore this loss is expected to minimize further in 2009-10.
Success story:Governing Problem (-29.047 Mus) Off line testing of speed governor for its characteristics of displacement verses speed and healthiness on special test rig design and develop in-house. Offline Testing of overspend governor assembly on special test rig design and develop in-house. This ensures the reliable working during the actual operation. It reduces the time and oil consumption for over speed test and governor setting. The reliability will further increase after replacement with modified governor supplied by M/s BHEL. Therefore this loss is expected to maintain to minimum in 2009-10.
Success story:TG Brg. vibrations (-19.532 Mus) This is predominant in Unit 1 and 3. Unit - 3 vibrations reduced from 150 micron to below 25 microns after LP rotor blading and balancing. For Unit – 1, Turbine casing Key restoration, casing pull correction will be done in AOH Jul-Aug 09. New nozzle ring for HP and IP will be retrofitted (BHEL supplied) for improvement in Heat Rate and Loading capability of the machine. Therefore this loss is expected to minimize further in 2009-10.
Reasons for higher Aux. consumption generation • Partial loading due to CHP constraints. • Discom supply & transformer losses included in Aux. Cons as per HO from Jan - 09. • U2 partial loading due to ID fan 2B vibration problem. • U6 loading restrictions due to damaged filter bags till OH in March-09. • U5 loading restrictions due to ID fan erosion & 13 bladed impeller as against 19 bladed impeller.
Reasons for less Availability • Partial loading due to CHP constraints. • Deteriorated condition of Air Pre-heaters of Stage – I Units. • Loading restriction due to damaged bag filters of Unit – 6. These are now replaced and there is no load restriction.
Reasons for higher Heat Rate • Less availability (Partial Load) of the units) due to CHP. • U5 & U6 Partial Loading due to Bag Filter damaged bags till OH . • 120 nos. of outages & their start ups (110 in 2007-08). • Increased Sp. Oil cons. to 6.97 ml/kwh (2.96 in 2007-08). • Actual coal CV considered & no adjustment during 2008-09. • Deteriorated condition of APH of Stg. – I Units.
