UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

Welcomes You

SLIDE NO: 1
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

Team Members

 Justin K. Kurian - Sr. Mgr, Group-A (Operation)

 Nishant Bansal -Asstt. Mgr, Group-B (Operation)
 Kushal Rahangdale - Asstt. Mgr, Group-A(Operation)
 Rajeev Dubey - Asstt. Mgr, Group-A(Operation)

SLIDE NO: 2
UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

SLIDE NO: 3
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

Light up to synchronisation time

(Min)

Name of Date
Project As per Actual
Curve

KudgiDeviation: 125 min 360 485 29.11.2018

Sipat Deviation: 290 min 170 460 30.08.2018
Mouda Deviation: 303 min 155 458 30.10.2018
SolapurDeviation: 510 min 150 660 29.09.2018
Time from Aux Boiler Light up to Synch: 1260 min
SLIDE NO: 4
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

Scope of the Discussion

Introduction

Why reduce Cold start up time ?

Why we are taking more time?

Possible solutions to minimise time and energy loss

Optimised Integrated Cold Start-Up curves

SLIDE NO: 5
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

Cold start-up (>72 hrs) of a thermal power plant- very critical activity

Temperature and pressure of all the components

raised up to design parameters from ambient conditions

Time constraint during cold start up to minimize stresses

Cold start-up to be done in energy efficient manner in minimum possible time

Following proper SOPs and LMIs

SLIDE NO: 6
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

LOSS OF DC

MORE AUX BOILER OIL CONSUMPTION

MORE MAIN BOILER OIL CONSUMPTION

HIGH APC

ENERGY AND WATER LOSS

THERMAL EFFICIENCY LOSS

SLIDE NO: 7
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP
Hitachi OEM Cold start up Curve

SLIDE NO: 12
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

Ideal Cold Startup Gantt Chart

SLIDE NO: 10
 SOLAPUR INTEGRATED START UP CURVE UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP
HPT INLET STEAM PRESSURE IPT INLET STEAM PRESSURE FIRING RATE TURBINE SPEED UNIT LOAD
HPT STEAM FLOW IPT STEAM FLOW BRP CIRCULATION FLOW STEAM FLOW HPT INLET STEAM TEMP
IPT INLET STEAM TEMP HFO TEMP SEPARATOR TEMP HPT EXHAUST

DEA IP Ext. Cut in

120 700
HP/LP HP/LP HP/LP
[% of TMCR]

HP/LP
Closed xx% Open Control Closed

CW, ACW, ECW system in service

ID, FD Fans and SCAPH in service

Supply C/O
SH and RH drains controlled closing

Condenser Vacuum Pulling started

Unit Synchronized
LP Heaters 3 & 4 Cut in
HFO Heating Completed
600

Turbine Rolling Started

Boiler Purging Started
DEA pegging started
100
Flow

HP Heaters 7 Cut in
HP Heaters 6 & 8 Cut in
Boiler Filling Started

Boiler Light Up

HP/LP Bypass Closed

Firing

500

105% Load
Full Load
80
Load

400

Wet to Dry
DP to Flow

Steam Temperatures [ o C]
60
Speed

Auxiliary Boiler Light UP

Time from Aux Boiler Light-up to

Aux PRDS Charging started

300
Synch = 760 minutes
HFO Heating started

40
Steam Pressure

200

20
100

0 0
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480 500 520 540 560 580 600 620 640 660 680 700 720 740 760 780 800 820 840 860 880 900 920 940 960 980 100010201040
Time [ minutes]
Prepared By: Sh. Pradeep Kayarkar
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

Aux Boiler light up

time: 07:30 a.m.

Actual time from Aux

Boiler Light-up to
Synch = 1260 minutes

SLIDE NO: 12
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

1. HFO GUN
PROVING WATER VESSEL
DELAY IN ENERGY LOSS
HIGH ISSUES DRAINS
VACUUM FROM SOME
DEARATOR 2. TAKING MILL CONTINOUSLY
PULLING DRAINS TO
PEGGING TIME TO ACHIEVE OPEN
(After BLU) ATMOSPHERE
ROLLING (Loss in Sep. Pr )
PARAMETERS

SLIDE NO: 13
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

Aux Boiler light up

time: 07:30 a.m.

SLIDE NO: 14
UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

SLIDE NO: 15
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

BENEFIT

TIME SAVING OF 5 HOURS FOR DEARATOR PEGGING

SLIDE NO: 16
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

D/A PEGGING : COST BENEFIT ANALYSIS

Case-1: Station LTPRDS already Utilisation of some steam Total DC saving: 13.5*5
Another Unit running charged for keeping D/A hot = 67.5 lakhs

Case-2: Break even time for

Cost of LDO burnt per Total DC saving:
Frequent Aux boiler light up pegging =
hour: 1.93 lakhs 13.5*5 = 67.5 lakhs
especially for D/A pegging 67.5/1.93 = 35 hours

6 MONTHS RSD

SLIDE NO: 17
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

CONVERSION
CONVERSION
HFO LDO
OIL OIL

1 LDO GUNS- QUICK START UP

2 NO REQUIREMENT OF STEAM

3 LOW MAINTENANCE COST

SLIDE NO: 18
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

HFO TO LDO : COST BENEFIT ANALYSIS

Steam consumption in HFO

Cost of HFO- Cost of LDO- heating, tracing & Assuming unit running at
atomising- full load & PRDS charged
Rs. 41231/- per KL Rs. 49622/- per KL from CRH
20 t/h or 5.55 kg/s

Eco inlet Pr & temp: CRH Pr & temp: 60 Heat released from coal
Energy input to
270 kg/cm2, 290˚C, kg/cm2, 340˚C, Change in Enthalpy: assuming 85% boiler
working fluid:
Enthalpy = 1279 Enthalpy = 3015 1736 KJ/Kg efficiency:
1736*5.55 = 9635 KW
KJ/Kg KJ/Kg 11335 KW

SLIDE NO: 19
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

HFO TO LDO : COST BENEFIT ANALYSIS

Coal consumption = (Heat DM water production cost per

So, cost of heating, tracing &
released) / (GCV of design coal year=
LPPF of coal for Solapur: atomising HFO =
in KJ/Kg) = Rs 70 lakh
Rs 7/Kg Rs 5.75 per sec (7*0.822) or
0.822 Kg/s (taking DM water production
Rs 18.1 crores per year.
(GCV = 3300 Kcal/Kg) cost = Rs 40/ton)

Total cost of HFO heating, tracing & Cost of BLUs in year

No. of BLUs in a year = 15
atomising: 1. With LDO = 11 crores approx.
FO consumption for each BLU = 150 KL
18.8 crores per year. 2. With HFO = 28 crores approx.

SLIDE NO: 20
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

Reduction in Min Aux steam temp to 190˚C from 220˚C for Gland
steam charging, talks with Alstom in progress.

Condenser ready for steam dumping from HP & LP Bypass, Boiler

CST pumps & other drains before BLU.

Minimum chance of starvation in RH tubes.

No high energy steam/water dumping to atmosphere.

Saving in oil & coal consumption.

SLIDE NO: 21
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

EXISTING SCHEME
DRAINS TO ADV TANK

Spray from BOILER CST PUMPS

Service water BOILER CST TANK

TO ATMOSPHERE

ADV TANK

CONDENSER
(HOTWELL) BOILER CST LEVEL
CONTROL STATION

SLIDE NO: 22
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

PROPOSED SCHEME
DRAINS TO ADV TANK

BOILER CST PUMPS

Spray from CEP
BOILER CST TANK

TO ATMOSPHERE

DRAIN PUMP
ADV TANK

New Addition
M

CONDENSER
(HOTWELL) BOILER CST LEVEL
CONTROL STATION

SLIDE NO: 23
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

BENEFIT COST

SLIDE NO: 24
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

COST BENEFIT

Description Cost Description Savings

per BLU

Pumps cost HP & LP Bypass Drains 15

Control station MS & HRH Drains 25

Piping including installation HP, LP Heaters & BFPT Drains 15

TOTAL PRDS Drains 25

SLIDE NO: 24
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

Initial Cost

SLIDE NO: 24
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

COST BENEFIT
1. Pumps: 2x3 lakhs = 6 Lakhs
2. Control station = 6 Lakhs
3. Piping including installation = 4 Lakhs
Total cost = 16 Lakhs approx.

SLIDE NO: 24
UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

SLIDE NO: 27
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

COLD START UP FROM Aux BLU TO SYNCH OPTIMISED TO 420 MINUTES FROM 760 MINS
SAVING OF 340 minutes
WITHOUT D/A PEGGING
SOLAPUR INTEGRATED START UP CURVE
HPT INLET STEAM PRESSURE IPT INLET STEAM PRESSURE FIRING RATE TURBINE SPEED STEAM FLOW
BRP CIRCULATION FLOW HPT STEAM ADMISSION FLOW IPT STEAM ADMISSION FLOW UNIT LOAD HPT INLET STEAM TEMP
120 700
[% of TMCR]

Auxiliary Boiler Light UP

CW, ACW, ECW in service

HFO Heating Completed

600
100
Flow
Firing

500

80
Load

400
DEA pegging completed

Auxi PRDS Charging started

Speed

60
HFO Heating started

Steam Temperatures [ o C]
300
Steam Pressure

40

200

20
100

0 0
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480 500 520 540 560 580 600 620 640 660 680 700
Time [ minutes]

SLIDE NO: 28
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

COLD START UP FROM Aux BLU TO SYNCH OPTIMISED TO 160 MINUTES Meeting ideal curve
WITH LDO WITHOUT HFO
SOLAPUR INTEGRATED START UP CURVE
HPT INLET STEAM PRESSURE IPT INLET STEAM PRESSURE FIRING RATE TURBINE SPEED STEAM FLOW
BRP CIRCULATION FLOW HPT STEAM ADMISSION FLOW IPT STEAM ADMISSION FLOW UNIT LOAD HPT INLET STEAM TEMP
120 700
[% of TMCR]

Auxiliary Boiler Lighted Up condition

DEA pegging completed

600
100
Flow

500
80
Main Boiler Light Up
Firing

400

60

Steam Temperatures [ o C]
Speed

300

40
Load

200
Steam Pressure

20
100

0 0
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440
Time [ minutes]

SLIDE NO: 29
 UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

Replacing HFO with LDO • Quick start up of plant and Saving in steam

Vacuum pulling before Boiler Light up • Steam Dumping can be started early

Keeping D/A temp > 100˚C always • Total 5 Hours time saving

Connecting alternate drain from ADV to

CST tank
• DM water wastage can be avoided

SLIDE NO: 30
UDAAN PROFESSIONAL CIRCLE SOLAPUR STPP

SLIDE NO: 31