BHEL-ELECTRONICS DIVISION
Case study of
Optimisation Efforts
at
NTPC Ramagundam Unit # 7
-A V Seshagiri Rao- NTPC
-Biswanath Mahapatra-BHEL
BHEL-ELECTRONICS DIVISION
NTPC-Vision
A world class integrated power major,
powering India's growth, with increasing global
presence
BHEL-ELECTRONICS DIVISION
31704 MW
BHEL-ELECTRONICS DIVISION
NTPC Ramagundam Performance 1998-to 2010
86.21
90.22
89.25
86.14
91.52
88.54
90.51
86.45
88.90
90.14
94.4594.81
89.36
90.76
90.03
88.21
92.71
90.98 91.04 90.9590.57
91.49
93.52 93.65
80
82
84
86
88
90
92
94
96
1998-99 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10
P.L.F. (%)
AVAILABILITY (%)
Installed Capacity : 2600 MW
(3*200+4*500)
BHEL-ELECTRONICS DIVISION
U-7 performance
86.81
79.59
98.3994.65
101.19
93.64
80.41
99.15
92.77
98.65
0.00
20.00
40.00
60.00
80.00
100.00
120.00
2005-06 2006-07 2007-08 2008-09 2009-10
PLF
Availability
BHEL-ELECTRONICS DIVISION
PADO (Performance analysis, Diagnostics and
Optimisation)
Installed in Unit 7 in Oct 2008
BHEL-ELECTRONICS DIVISION
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.
BHEL-ELECTRONICS DIVISION
BHEL-ELECTRONICS DIVISION
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
BHEL-ELECTRONICS DIVISION
PADO SYSTEM NETWORK CONFIGURATION FOR RAMAGUNDAM UNIT #7
BHEL-ELECTRONICS DIVISION
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
BHEL-ELECTRONICS DIVISION
Case study :
Soot Blowing Optimisation
BHEL-ELECTRONICS DIVISION
General Soot Blowing Practice
Time based
•Regular intervals
Parameter based
• Metal temperature
criteria
•Spray
•Flue gas exit
temperature
•Coal quality
•Slagging tendency
•Mill combination
BHEL-ELECTRONICS DIVISION
PADO Results
•Neural technology
•Heating Surfaces Heat Transfer efficiency
•Boiler gas Path temperatures
•Fire Ball Height
•Relationship Drawing
BHEL-ELECTRONICS DIVISION
BHEL-ELECTRONICS DIVISION
16
Comparison of PADO results with Actual Boiler – 15th Sept 2009
Tune
settings
25 Sept
2009Observe Results –
05th Sept 2009
Operate &
confidence Building
– 15th Oct 2009
Design Of
Experiments
BHEL-ELECTRONICS DIVISION
17
7 Months Period
01-11-2008 to 30-05-2009
With
01-11-2009 to 30-05-2010
Data Comparison
BHEL-ELECTRONICS DIVISION
Results comparison
Parameter Before PADO1.11.08 – 30.5.09
After PADO
1.11.09 – 30.5.10
Improvement
Unit Operating
Hours above 490
MW
4697 4844
Total soot blowing
steam consumption8923 5918 33.68 %
Soot Blowing Steam
Kg/MW3.853 2.393 37.89 %
BHEL-ELECTRONICS DIVISION
Results Comparison
No. Of Times
Wall Blowers
Operation
Before PADO
1.11.08 – 30.5.09
After PADO
1.11.09 –30.5.10
Improvement
Cleaning Of wall
Blowers AB
Groups
710 391 44.93 %
Cleaning Of wall
Blowers C Group542 205 66.73 %
Cleaning Of wall
Blowers D Group531 216 61.04 %
BHEL-ELECTRONICS DIVISION
Results comparison
No. Of Times
LRSB Operation
Before PADO
1.11.08 – 30.5.09
After PADO
1.11.09 – 30.5.10
Deviation
Div. Pnl 20 42 104 %
Platen SH 40 65 62.5 %
RH 38 57 50 %
LTSH 22 32 45.5 %
Eco 21 29 38.1 %
BHEL-ELECTRONICS DIVISION
Results comparison
Parameter Before PADO1.11.2008 – 30.5.2009
After PADO
1.11.2009 – 30.5.2010
RH Metal temp Above 590
Deg in Hrs.52 41
RH Metal temp Above
594Deg in Hrs.22 21
RH Metal temp Above 598
Deg in Hrs.8 10
RH spray 30 T/Hr 34 T/hr
Heat Rate 2349 2336
BHEL-ELECTRONICS DIVISION
Before Implementation of SBO Module
BHEL-ELECTRONICS DIVISION
After Implementation of SBO Module
BHEL-ELECTRONICS DIVISION
24
Coal flow Vs SAPH Outlet Temperatures
BHEL-ELECTRONICS DIVISION
25
Coal flow Vs PAPH Outlet Temperatures
BHEL-ELECTRONICS DIVISION
26
Coal flow Vs FEGT
BHEL-ELECTRONICS DIVISION
27
Coal Flow Vs RH Metal temperature
BHEL-ELECTRONICS DIVISION
28
HRH temp Vs IPT Overall Efficiency
BHEL-ELECTRONICS DIVISION
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
BHEL-ELECTRONICS DIVISION
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
BHEL-ELECTRONICS DIVISION
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
BHEL-ELECTRONICS DIVISION