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AN OVERVIEW
SOME FACTS
TOTAL INSTALLED CAPACITY OF INDIA IS 106254.22 MW 71 % OF THE TOTAL ELECTRIC ENERGY GENERATED BY COAL SETS IN THE COUNTRY WAS CONTRIBUTED BY 210 / 250 / 500 MW RATING BHEL SETS THOUGH THEY FORM 63 % OF TOTAL GENERATING CAPACITY OF THE COUNTRY MORE THAN 60 % OF THE THERMAL MACHINES OPERATING IN INDIA ARE OF KWU DESIGN. HIGH RELIABILITY,AVAILABILITY,BETTER HEAT RATE, FASTER START UP AND SHUT DOWN,MAINTENANCE FRIENDLY ENABLES HIGHER ACCEPTABILITY AMONGST MOST CUSTOMERS IN INDIA. KWU TECHNOLOGY HAS WEATHERED IN INDIAN CONDITIONS AND CUSTOMER HAS SHOWN CONFIDENCE BY PLACING REPEAT ORDERS
N.K. BANSAL, AGM (T)
2000-2001 PLF
96.6 98.6 98.7 87.8 97.6 91.9 91.0 96.6 97.5 95.6 79.0 89.6 86.6
2001-2002 PLF
97.3 93.0 78.2 68.4 91.2 92.6 89.5 93.2 90.4 93.5 91.2 87.5 89.8
2002-2003 PLF
95.3 96.9 93.5 96.0 89.2 84.9 95.9 94.1 94.0 92.9 89.0 87.4 87.1
2003-2004 PLF
100.1 99.3 97.1 98.1 98.2 82.6 76.7 94.2 94.7 89.0 89.1 89.1 82.7
OA
96.5 93.0 83.7 93.4 97.8 92.7 95.8 85.3 94.0 93.5 86.7 87.1 88.8
OA
94.4 97.7 98.1 88.4 96.7 92.1 92.8 97.1 97.8 95.9 84.5 93.3 90.2
OA
97.0 93.9 78.2 68.5 92.9 95.7 90.6 94.1 91.4 94.6 93.7 89.3 92.8
OA
95.6 98.2 95.0 97.3 91.3 90.0 97.8 94.2 93.9 93.8 93.3 92.0 92.7
OA
98.2 98.7 97.3 97.4 98.1 87.2 78.8 93.7 94.2 89.6 93.9 94.2 86.7
AGE-WISE ANALYSIS
500 MW (NR + ER + WR + SR) 250 MW (NR + ER + WR + SR) 210 MW (NR + ER + WR + SR)
5 (0 + 1+ 2 + 2) 2 (0 + 1 + 1 + 0) 8 (0 + 1 + 4 + 3) 5 (2 + 0 + 3 + 0) 0 0
4 (4 + 0 + 0 + 0) 4 (0 + 0 + 2 + 2) 0 0 0 0
15 (4 + 3 + 5 + 3) 21 (3 + 8 + 2+ 8) 31 (11 + 5 + 5 + 10) 29 (6 + 3 + 16 + 4) 21 (2 + 2 + 12 + 5) 0
A. B. C. D.
LP BLADE FAILURE BARRING GEAR STOPPAGE HIGH HP FRONT SHAFT VIBRATION LOW VACUUM DUE TO HIGH AIR INGRESS
LP BLADE FAILURE
OFF LINE METHOD Water fill test or vacuum tightness test Steam pressurization test. ON LINE METHOD With the help of Helium Leak Detection Instrument
SUCCESSFUL COMPLETION OF WATER FILL TEST IN CASE OF FALL IN LEVEL, HIDDEN AIR INGRESS POINTS NEEDS TO BE TRACED BY ELIMINATION PROCESS.
VACUUM PUMP
STEAM + AIR
AIR EXHAUST
CONDENSER
SAMPLE LINE
1. 2. 3.
CAN PINPOINT THE SOURCE OF AIR INGRESS CAN BE DONE ONLY WHEN MACHINE IS COLD REQUIRE STEAM AND WATER
CAN DETECT BROAD AIR INGRESS AREA CAN BE DONE AT LOAD REQUIRES HELIUM GAS WHICH IS NOT READILY AVAILABLE AT MANY POWER STATIONS BULKY AND DELICATE INSTRUMENT TEDIOUS EXERCISE
4.
5.
FAST COOLING OF TURBINE TO REDUCE THE COOLING DOWN TIME ALWAYS KEEP MANUAL VACUUM BREAKER OPEN WHENEVER MACHINE WAS SHUTDOWN FOR LONG PERIOD, DRAIN THE HOTWELL PRIOR TO START OF OIL PUMPS, RAISE THE OIL TEMPERATURE