![Page 1: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/1.jpg)
WELCOME
Dev Raj, GM, BHEL, Noida
Improving The Availability of Improving The Availability of Electricity Through Better Techniques of Electricity Through Better Techniques of Predictive/Preventive Maintenance and Predictive/Preventive Maintenance and Modernisation of Thermal Power Plants Modernisation of Thermal Power Plants
Thermal Power India-II (11-12th Dec’2007)
![Page 2: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/2.jpg)
ContentsContents
•Current Scenario
•O&M Improvements
•Maintenance
•Reliability Centered Maintenance
•Drivers of new Technology
•Condition Monitoring
•I.T. in O&M
![Page 3: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/3.jpg)
Current ScenarioCurrent Scenario
Energy Consumption per Capita (KWH)Energy Consumption per Capita (KWH)
India ~ 600
Developed Nations ~ 8000 - 10000
![Page 4: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/4.jpg)
Power GrowthPower Growth
•Installed Capacity at Independence – 1350 MW
•Installed Capacity Current – 1,35,000 MW
•Projected Capacity in 2012 – 2,00,000 MW
•Projected Capacity in 2032 – 8,00,000 MW
![Page 5: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/5.jpg)
Supply of Electric PowerSupply of Electric Power
Availability of Electricity to the Consumer depends upon:
• Installed Capacity• Availability Factor of Installed Units• Plant Load Factor of Thermal Sets• Transmission Losses
![Page 6: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/6.jpg)
If we improve PLF of existing thermal units by 1%, it is equivalent to adding 880MW to the installed capacity
![Page 7: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/7.jpg)
O&M ImprovementO&M Improvement
PERFORMANCE DATA PERFORMANCE DATA –– Thermal SetsThermal Sets
0102030405060708090
70s 80s 90s 2Ks
PLF %OA %
![Page 8: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/8.jpg)
OUTAGESOUTAGES
• FORCED• PLANNED
![Page 9: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/9.jpg)
Improvement AreasImprovement Areas
• Operation• Maintenance• Interval between planned outages• Renovation & Modernisation
![Page 10: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/10.jpg)
WHAT IS MAINTENANCE?WHAT IS MAINTENANCE?
IT IS THE PROCESS OF ENSURING THAT PHYSICAL ASSETS CONTINUE TO DO WHAT THEIR USERS WANT THEM TO DO
![Page 11: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/11.jpg)
Growing Expectations of MaintenanceGrowing Expectations of Maintenance
• First generation (1940s – 1950s) :- Fix it when it broke
• Second generation (1960s – 1970s) :- Higher plant availability- Longer equipment life- Lower costs
• Third generation (1980s – present) :- Higher plant availability and reliability- Greater safety- Better product quality- No damage to the environment- Longer equipment life- Greater cost effectiveness
![Page 12: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/12.jpg)
Growing Expectations of MaintenanceGrowing Expectations of Maintenance
![Page 13: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/13.jpg)
Changing Maintenance TechniquesChanging Maintenance Techniques
• First generation (1940s – 1950s) :- Fix it when it broke
• Second generation (1960s – 1970s) :- Scheduled overhauls- Systems for planning and controlling work- Big, slow computers
• Third generation (1980s – present) :- Condition monitoring- Design for reliability and maintainability- Hazard studies- Small, fast computers- Failure modes and effects analyses- Expert systems- Multi-skilling and teamwork
![Page 14: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/14.jpg)
Changing Maintenance TechniquesChanging Maintenance Techniques
![Page 15: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/15.jpg)
Type of MaintenanceType of Maintenance
• Predictive• Preventive
![Page 16: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/16.jpg)
RReliabilityeliability--CCentered entered MMaintenanceaintenance
It is the process which is used to determine what must be done to ensure that any physical asset continues to do what its users want it to do in its present operating context.
![Page 17: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/17.jpg)
RCM : The seven basic questionsRCM : The seven basic questions
• What are the functions and associated performance standards of the asset in its present operating context?
• In what ways does it fail to fulfill its functions?• What causes each functional failure?• What happens when each failure occurs?• What can be done to predict or prevent each
failure?• What should be done if a suitable proactive
solution cannot be found?
![Page 18: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/18.jpg)
An Old Power Plant Will Have The Same An Old Power Plant Will Have The Same Availability As A New One!!Availability As A New One!!
(If sound O&M practices are in position)
![Page 19: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/19.jpg)
Renovation & ModernisationRenovation & Modernisation
• Extension of plant life• Improvement in PLF and efficiency• Uprating of present unit capacity• New generation C&I• Online Condition Monitoring
Faster way of addition to the generating capacity
![Page 20: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/20.jpg)
Drivers for New Technology
• Present operating condition of Aged Units• ABT/Regulatory Regime• Increased Competition – Merit Order Rating• Environmental Concerns• Scarcity of Resources• Need to cut Input Costs• Demand Growth Outstripping Supply Growth
![Page 21: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/21.jpg)
Technology Frontiers
• Enhanced Condition Monitoring• Introduction of IT
![Page 22: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/22.jpg)
Condition Monitoring
• Vibration Monitoring• Generator Condition Monitoring• On Line Partial Discharge Measurement• Air-gap Flux analyser• Sonic On-Line Tube Leak Detection System• SMART Wall Blowing System• Turbine Stress Evaluators
![Page 23: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/23.jpg)
IT in O&M
• Remote Monitoring• On-line Automation & Diagnostics -PADO• Asset Management System• Documentation System• Networking
![Page 24: Thermal Power India-IIindiacore.com/bulletin/papers-tpi2/dev-raj-preventive...Dev Raj, GM, BHEL, Noida Improving The Availability of Electricity Through Better Techniques of Predictive/Preventive](https://reader031.vdocument.in/reader031/viewer/2022011812/5e27d98fc6b4ff62a403b2f4/html5/thumbnails/24.jpg)