measures and equipment for optimal efficiency at thermal power...

Measures and Equipment for Optimal Efficiency

at Thermal Power Stations

January 30, 2015 Japan Coal Energy Center (JCOAL)

International Seminar on

"Implementation of PAT Scheme in Thermal Power Stations - Issues and Challenges“

India Habitat Centre

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1. Profile and Activities of Japan Coal Energy Center (JCOAL)

2. O&M Practices and Effective Solutions for BOP Systems, Kyushu Electric Power Co., Inc.

3. Coal Quality Evaluation System（CQES）, Idemitsu Kosan Co., Ltd.

4. Numerical Simulation of Pulverized Coal Combustion, Idemitsu Kosan Co., Ltd.

5. Summary

Overview

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1. Profile and Activities of Japan Coal Energy Center (JCOAL)

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Japan Coal Energy Center (JCOAL)

• Established as a foundation in 1990, with its origin back to 1948

• Covers all coal related issues from upstream to downstream of the coal chain

• Members: 119 incl. major public-listed companies and main players in energy and relevant sectors

• Supervision by METI (Ministry of Economy, Trade and Industry of Japan)

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Exploration

Facilitation and promotion of cleaner utilization of coal

Mining & Preparation

Coal utilization technology development

Upstream Activities CCT Transfer Program on coal preparation Technologies

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CCT transfer project on coal preparation technology Coal preparation technology was set as the main topic of technology

exchange in India considering the importance of high ash coal processing. 1,305 trainees were invited to Japan including 150 Indian experts by the

end of JFY2011 Technology exchange programs dispatching Japanese experts to target

countries were also commenced

Vari-Wave Jig (KCM) Control panel (KCM) Port facilities (Kushiro) Dry separation facility (Nagata Eng.) High efficiency coal preparation plant in Odisha

High efficiency coal preparation plant has been commissioned on July 25th, 2014 in Angul, Odisha using latest vari-wave jig technology with a capacity of 350t/h.

Source: NEDO website

The Project on Efficiency and Environmental Improvement of Coal fired Power Stations

A MOU of Pre-primary Study of Efficiency and Environmental Improvement of Coal-fired Power Stations was signed on April 30, 2010, in the presence of Deputy Chairman, Planning Commission of India, and Minister of Economy, Trade and Industry of Japan. Diagnostic activities for two (2) state owned, one (1) NTPC owned TPS

Durgapur

Unchahar

Badarpur

2010, 2011 Wanakbori

2010 Ramagundam

2011 Kahalgaon

2010, 2011, 2012 Dr. Narla Tata Rao

(Vijayawada)

A MOU for the Project on Efficiency and Environmental Improvement of Coal fired Power Station was signed on June 11, 2012. Diagnostic activities for Durgapur of DVC, Unchahar & Badarpur of NTPC; all of which were referred to in the Joint Statement on the occasion of the 6th Japan-India Energy Dialogue between the Ministry of Economy, Trade and Industry of Japan and the Planning Commission of India on October 10, 2012. CCT workshop in Delhi

2011

2012

Diagnostic activities for two (2) state owned, one (1) NTPC owned TPS R&M Workshop in Delhi

2010

2013

Follow up activities for all TPS are ongoing for all diagnosed TPS. CCT Transfer program for the delegates from India power sector was carried out. CCT workshop in Delhi 6

Typical Example of R & M Proposal

COAL

P Air S Air

Feed Water Heater

SH Steam

RH Steam

Steam Turbine Generator

Cooling Tower

Stack Condenser

ESP IDF

PAF

FDF

Mill

Boiler

Feed Pump

Air Pre-Heater

Fly Ash Bottom Ash

Coal Bunker

Coal Yard

Ash Pond ※

※

Transformer Circuit Breaker

Plan-A:LE Replacement of worn parts only

Plan-B:R&M Replacement of worn parts + Reuse of casing, replacement of HP,IP,LP turbine, D-EHC improvement and ESP rehabilitation

Plan-C:R&M Plan-B+ generator improvement Plan-D:R&M Plan-C+ condenser and feedwater heater improvement

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Mitsubishi Hitachi Power Systems, Nagasaki Works ( 31st Oct. ) J-POWER, Isogo TPS

( 30th Oct., 3rd Dec.)

J-POWER Tachibanawan TPS ( 04th Nov. )

CCT program - Site Visit -

Open-Ended Meeting Embassy of India

Mitsubishi Hitachi Power Systems, Hitachi Works (4th Dec.)

Joban Joint Power Company Nakoso IGCC (5th Dec.)

Chubu Electric Power, Hekinan TPS ( 8th Dec.)

Idemitsu Coal & Environment Research Laboratory, Idemitsu Bulk Terminal ( 26th Sept.) Toshiba Keihin Work ( 25th Sept. )

J-POWER Takasago TPS ( 29 Sept. )

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9 9

Discussion -Topics- Issues around

materialization of R&M Efficiency

Improvement through enhancement of O&M Coal blending as one of

the key measures for domestic coal shortages

Group1 R&M Group2 USC1 Group3 USC2

Possible barriers for Japanese players to work for India power sector

Issues around materialization of Proposed New Project

Technical Target and/or Guideline for

introduction of USC

Road map for high efficiency advanced technology

2. O＆M Practices and Effective Solutions for BOP Systems, Kyushu Electric Power Co., Inc.

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11

Supply Facilities

Hydro142places3,582MWPumpedStorage3places2,300MW ※

Ｃｏａｌ3places2,460MW Thermal9places10,680MW ＬＮＧ2places4,090MW ※

Geothermal6places212MWＯｉｌ5places4,130MW Nuclear2places5,258MW ※

Thetotalofplacesdoesnotmatch, becausetheunit1ofKaritapower

Internalcombustion34places399MWstationiscountedascoalandthe

unit2iscountedasoil.

Wind2places3MW Solar1places3MW

(asofMarch31,2013) Total196places20,137MW

Establishment May1,1951 Paid-inCapital 237.3billionyen #ofShareholders 174,293

#ofSharesIssued andOutstanding 474,183,951

#ofContracts Lighting:7.69million Power:0.93million

#ofEmployees 13,102

IT/telecom

Electricity Sales Volume

Specific-

83.8 billion kWh

Kyushu Electric Power Co., Inc.

Breakdown of Electricity Sales Volume (FY2012)

Domestic Share of Electricity Sales Volume (FY2012)

(Lighting 35.2%)

Other than Specific-scale demand 41.4% (Power

scale demand 58.6% Customers under Liberalization 6.2%) Over 6,000V , 50kW

Tokyo 31.6%

Tohoku 9.1% Kyushu 9.8%

Other 17.9% Domestic Share

of Electricity Sales Volume (10EPCOs)

851.6billion kWh Kansai Chubu 16.6% 14.9%

Consolidated Sales (FY2012) Other 5.6% 1.6%

Energy- related 9.5%

Consolidated Revenue \1,545.9billion Electricity 83.3%

KYUSHU‐EPCO Profiles

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Exchange Program with NTPC In Feb. 2007 The signing ceremony of exchange agreement with NTPC

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In Nov. 2012 ATTEND 5th INDIA POWER AWARD

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J‐COAL Study Diagnosis work NTPC Unchahar PS in FY 2012 Diagnosis Purpose Improving plant efficiency of coal fired thermal power station for effective utilization of coal and reducing environmental load

Schedule Site survey : 2012. 12. 11 – 12. 14 (at Unchahar PS) Presentation : 2013. 3. 11 (at Unchahar PS)

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Maintenance

Preventive Maintenance

Breakdown Maintenance

Time Based Maintenance Condition Based Maintenance

Emergency Maintenance Ordinary Corrective

Categorized Equipment Maintenance Management Periodic Inspection

Aging Equipment Inspection

Maintenance ・High Plant Availability possible through Preventive Maintenance ・Higher economic efficiency requires shift to Condition Based Maintenance Kyushu Electric Power Co., Inc.

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Periodical maintenance Maintaining thermal efficiency

Introduction of high‐ efficiency equipment Improvement of thermal efficiency

Improvement of thermal efficiency

How to Keep High Availability, Efficiencies, Clean ? Improvement Concept of thermal efficiency Grasping periodically the facility performance Economic evaluation

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Sche

dule

d M

aint

enan

ce S

yste

m

Inspection and replacement Annual/Long-term Maintenance program Maintenance Standards Categorize maintenance activities into - TBM (Time-based Maintenance) - CBM (Condition Based Maintenance) - BM(Breakdown Maintenance) based on analysis of past problems and judgment criteria Introduced into Matsuura PS in 2004 and Reihoku PS in 2006 Kyushu Electric Power Co., Inc.

Concept of Equipment Maintenance Management Maintaining power supply Availability

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Plant Life Cycle Maintenance ▽50 ▽Operation Start ▽20∼25 Years

Target of Plant Life Time (50YEARS) Daily maintenance/Periodical maintenance

Replace Plan Initial failure Long Term Maintenance Plan Condition Monitoring R&M LTE Work

Procedure of Long Term Maintenance Plan Select Target Items with O&M conditions Planning of Diagnosis methods ,Sample No(SN) Tools (Online/Offline), Cost, Timing, etc. Data acquisition and analysis of representative point and trends analysis Predict and Judgments for R&M/LTE Work with Experimental Criteria Readjustment of Period of measures, SN Planning of next timing of monitor (Off line) Kyushu Electric Power Co., Inc.

Target items for Overhaul or Replacement Steam Turbine (HP,IP), Cylinders (inner/outer) Major Valves for Steam Turbine (MSV,RSV) FW Heaters Air Pre Heater, Gas Heater (APH/GGH) Electrostatic Precipitator (ESP) Generator (Stator/Rotor) Transformers HV Motors Control Systems

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Seco

ndar

y su

perh

eate

r

Terti

ary

supe

rhea

ter

Bur

ner n

ozzl

e

Boi

ler

Bur

ner n

ozzl

e

Sile

ncer

New soot blower (4 (drum left) + 4 (drum right) = 8)


1. Washing the boiler generating surface 2. Primary superheater soot blow executed (Measure for abrasion due to pressure reduction of injection steam) Soot blower

3. Economizer soot blower newly built 4. Washing the air preheater element and replacing the defective element Induced draft fan

Chimney Electric dust collector

Remarks Polluted by ash, etc. Run soot blower (9 (drum left) + 9 (drum right) = 18) Run/stop soot blower (4 (drum left) + 4 (drum right) = 8)

Quaternary superheater Re- heater

6. Burner nozzle automatic operation 5. Repairing steam leakage of steam type air preheater

Primary superheater Economizer Air preheater

Forced draft fan Steam type air preheater

Improvement typical Measures for Boiler

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Improvement of high‐pressure turbine aged deteriorated part ・Replacing seal fin, etc. ・Removing scale, etc.

Measures for low‐pressure turbine ・Moving blade and stationary blade newly made. Fin installed on moving blade. ・Replacing the diaphram ・Replacing the inner casing

Improvement typical Measures for Turbine Outer casing Inner casing Turbine rotor

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Ope

ratio

n Ho

urs


CEA‐JCOAL Workshop FY2014 Turbine Rotor Replacement timing Mapping of Rotor Replacement timing

Elapsed Years

Op Rate:70% Op Rate:90%

Av.181,600Hr / 26.2yrs 5Years Range Circle

★

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Insu

latio

n St

reng

th(%

)


Sample Chart of Generator Stator Coil Inspection and Replacement timing

Operation Hours

Max. Ave. Min.

Regression lines 99.9% Confidence interval

Temp.Corr Line of Monitoring Start Limit of Operation

Monitoring Period

★

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Inspectionitems

Monthlycheck LubricatetheGrease

Routinecheck Visualinspection,cleaning, windinginsulationmeasurement, etc.

OverHaul CategorizedtoTBM/BDM,Cycles, etc.(on/off-site,Spares, Redundancy,SeverityoftheBD)

Condition Monitoring

Insulationresistancetest, Polarizationindextest,Tanδ test

Whenneeded SupplementaryInsulation, Rewinding


Condition Monitoring for MV Motors • Due to old installation (20 years back), deterioration of insulation is a matter of concern.

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Wea

r le

vel (

degr

ee o

f deg

rada

tion)


Running in Stable operation Advanced stage Time

Temperature diagnosis Vibration diagnosis

Possible to catch abnormalities at early stage Lubricant diagnosis

Condition Monitoring for Rotating Machines Process to Failure of ROTATING MACHINES Failure

3. Coal Quality Evaluation System（CQES）, Idemitsu Kosan Co., Ltd.

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26 PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.

Coal Production & Procurement Transportation Marketing

Boiler Operation

PF boilers CFBC boiler

（Aichi & Tokuyama refineries）（Chiba refinery）

10.6 Million tons （2013） * Idemitsu’s equity Coal mine operation in Australia Acquired coal mine in Indonesia Coal supply from Australia, Indonesia, Russia, China, etc. Idemitsu bulk terminal （Chiba） Shunan bulk terminal Total sales : 14.8 Million tons （2013） Japan : 6.8 Million tons （2013）

Other : 8.0 Million tons （2013）

資料整理番号：14067 Our Coal Business

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資料整理番号：14067 1-11. Coal Analysis Centre

Calorific Value Ultimate Analysis

Ash Fusion Temperature Ash Composition PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.

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資料整理番号：14067 1-12. Coal Quality Evaluation Tests

Ash deposition

<Turbulent flow furnace> <SEM/EDX> PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.

NOx emission

Combustion Furnace Unburned carbon

We have carried out many evaluation tests for various kinds of coals and collected the test results into our database. We can provide technical services by applying these abundant data.

Handling Spontaneous comb.

Durham cone test

Mill Grindability

資料整理番号：14067 1-13. Technical Products

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Dust dispersion inhibitor

Numerical computer simulation

Coal analysis & evaluation tests

Spontaneous combustion simulator

High temperature furnace scope

Ash utilization simulator

Trace element simulator

Coal quality evaluation system

Evaluation tests on handling properties

Spontaneous combustion tester

資料整理番号：14067

PROPERTY OF IDEMITSU KOSAN CO LTD TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO LTD

Bunker

Boiler

SCR

EP

FGD

Mill

Stock Pile

Ash Gypsum

Increase of mill load

Slagging and fouling

Increase NOx emission

Increase dust emission

Decrease De-SOx activity

Decrease gypsum purity

Difficulty of ash utilization

Spontaneous combustion

Dust emission

Excess trace element regulations

Decrease Efficiency

Increase unburned carbon

Coal quality affects the performance of each facility in a coal-fired power plant.

2-1. Coal Quality Impacts on Power Plant

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31 PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.

）

Operating Condition CQES

1. Quick and accurate prediction of plant performance for new coal 2. Prior prediction of problems, which helps to prevent trouble 3. Investigation of optimum blending conditions 4. Abundant technical information （Evaluation technology, Trouble examples, Coal analysis data, etc.）

資料整理番号：14067 2-2. Coal Quality Evaluation System（CQES) Idemitsu developed the computer software which can quantitatively estimate the impacts of coal quality on power plant performance. This system is used in many Japanese and overseas power companies for expanding coal brands. Coal Analysis Data Boiler

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PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.

2-3. Plant Performance（Outline）

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Available

Not available PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.

2-4. Selection of Suitable Blending Ratio

4. Numerical Simulation of Pulverized Coal Combustion, Idemitsu Kosan Co., Ltd.

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We can clearly grasp combustion states in the boiler and investigate its optimum operating conditions, which increase boiler efficiency and reduce NOx emissions. This tool is also useful for the solution of slagging trouble. PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.

Gas velocity Temperature Particle trajectory Oxygen conc. Boiler geometry

3-1. Numerical Simulation 3D simulator optimizes boiler operating conditions without hardware modification.

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Increase in O2 Present Improved 0

FF F E

DE Coal-D CD Coal-C BC BC2 BC1 Coal-B AB Coal-A AA

20 40 60 80 Air Flow Rate（m/s） PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.

Change of damper opening Change of O2 concentration

Increase Improved

O2 conc. （%） 10.0 9.0 8.0 7.0 6.0 5.0 4.0 3.0 2.0 1.0

Present Increase Decrease Increase

Decrease

3-4. Improvement of Boiler Efficiency

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Coal Burner A B C D E Total Present condition 1.3 4.1 5.7 11.0 1.1 5.2 Improved condition 1.7 4.3 1.3 2.3 0.7 2.5

PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.

3-5. Reducing Unburned Carbon

Improved condition OFA Layer Coal-D Burner Layer

O2 conc. （%） 10.0 9.0 8.0 7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.0

Present condition Optimization of Air Damper Settings OFA Layer Coal-D Burner Layer

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Particle Gas Flow Gas Temp. Collision with Boiler Wall

Before （Trouble） OFA Tilt -16 deg.

Improved OFA Tilt +16 deg. PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.

3-6. Solution of Slagging Trouble

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Coal B

Coal A+B

Coal B

Coal A

Coal B

Belt Blending Coal A

In-furnace blending Coal A

In-furnace blending has to choose a suitable blending condition from among many patterns. Boiler performance such as unburned carbon, NOx emission and furnace outlet temperature can be improved compared to the belt blending. PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.

3-7. In-Furnace Blending

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Summary

1. JCOAL is conducting several projects under Indi Japan mutual cooperation in both coal and power sector. Joint declarations at both past and the latest India-Japan Energy Dialogues acknowledged such significance and achievement of the Cooperation.

2. CEA-JCOAL Cooperation provided a good opportunity for materialization of R&M as well as fruitful discussion and information exchange in CCT transfer program.

3. In a targeted long plant life of nearly 50 years, high plant availability possible through preventive maintenance. Higher economic efficiency requires shift to condition based maintenance

4. Idemitsu has been providing technical services to coal users, creating the further demand of coal, and making the most effective use of coal resources.

5. Applying our products and services, we propose optimum coal-blending and boiler-operating conditions which lead to improved efficiency and trouble-free operation in a boiler.

6. We, especially Japanese players in the coal power subsector in India are anxious to work together with our Indian partners toward sustainable development of Indian power sector.

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We look forward to working with you

Website: http://www.jcoal.or.jp/index-en.html Contacts: Mr. K. Murakami ([email protected])

[Contact] Engineering Group International Business Division Kyushu Electric Power Co. Inc. 2-1-82 Watanabe-dori, Chuo-ku, Fukuoka 810-8720 Japan TEL: +81(92)726-1741 FAX: +81(92)716-4428 http://www.kyuden.co.jp/ Kyushu Electric Power Co., Inc.

Coal & Environment Research Laboratory Coal Business Department Idemitsu Kosan Co., Ltd.


http://www.jcoal.or.jp/index-en.html�

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