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Performance Enhancement of Power Plants

Performance Enhancement of Power Plants. V.S.Amarnath. Typical efficiency Losses per stage. Preview. Present Status: A few facts and Questions Are our evaluation methods and criteria appropriate? Are we achieving our purpose when we overhaul units? What can we do based on these findings.

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Performance Enhancement of Power Plants

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  1. Performance Enhancement of Power Plants V.S.Amarnath

  2. Typical efficiency Losses per stage

  3. Preview • Present Status: A few facts and Questions • Are our evaluation methods and criteria appropriate? • Are we achieving our purpose when we overhaul units? • What can we do based on these findings.

  4. Present status • Most of the 200 MW units are 20+ years old • 100 to 120 MW units are more than 25 years old • Performance evaluation is generally on PLF, not on heat rate. • Outages are based on time schedules not on the needs of the unit

  5. PLF : A good yardstick? • Even Units with good PLF have bad heat rates. • PLF does not reflect the performance of the unit. (Most of the 200-210 Units burn excess of 40 Tonnes per hour).

  6. Heat Rate: A better measure ? • Quantify and assign loss of heat rate • Explore advanced technology to reduce heat rate at least upto design parameters. • Heat Rate should replace PLF as a measure of the performance of a unit.

  7. Overhauls • What is the purpose of an overhaul? • The purpose of an overhaul is to bring the unit back to its rated capacity. • When time schedules dictate the maintenance procedures during an overhaul, much is left undone.

  8. Effective Overhauls • Base overhaul schedules on equipment status. • Bring equipment back to its design value. • Conduct ABC analyses, RLA studies and Root cause analyses. • Base overhauls on the findings of these to increase reliability of the unit.

  9. To get 10% or more from the units • Steam Path Repairs – around 3-4% • Turbine seals – around 3-5% • Reduction of losses on boiler – around 1-4% • Restoring auxiliaries to original rating – around 1-1.5% • Bauman stage modifications on LMZ and Skoda units – around 3-4.5% ** • Base overhauls on the findings of ABC analyses, RLA studies and Root cause analyses to increase reliability of the unit. ** These Figures are based on my experience of 42 years , 60+ overhauls in India, Germany, USA, Malaysia, Iraq, Saudi Arabia, Ireland on turbines ranging from 60 MW to 750 MW

  10. 500 – 1000MW more • If the CEA ensures that all power plants in the country follow these simple steps, we could have anywhere between 500 to 1000 MW of extra power with the existing infrastructure itself !

  11. Thank You • Questions?

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