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INFRA DAHANU
THERMAL POWER STATION
(250 X 2 MW UNIT)
2
Annua
l
kcal/
avera
kg 3966 3652 3608 3422 3170 3235 3642 3354 3170
ge
GCV
3
Total
heat Mcal 599. 515.5
to /h 611.7 527.34 536 533.4 531.42 527.5 1215.9
4 5
boiler
4
Total
fuel
quanti
t/h 162 179.9 155.1 107.2 120 104.2 105.5 147.3 347.4
ty
5 Restri
ction
on %
BMCR less No No No Yes No Yes Yes No No
to
GCV
Effect of GCV on loading rate or steaming rate of the
boiler:
810
800
Steaming rate, t/h
790
780
770
760
750
740
80 82 84 86 88 90
Boiler efficiency, %
Variation of coal consumption with boiler efficiency
at a constant boiler steaming rate and constant
GCV
164
162
Coal consumption, t/h
160
158
156
154
152
150
80 82 84 86 88 90
Boiler efficiency, %
Dependence of unit loading (MW) on the coal quality
280
260
250
240
230
3300 3500 3700 3900 4100 4300 4500
Coal GCV (kcal/kg)
Study of operational parameters
The operational parameters of the boiler be
classified into two types:
Continuous normal and continuous overload
parameters with no time restriction on them.
Overload parameters with restriction on a
single excursion as well as total time in the life
of the unit.
There are two types of parameters in a boiler:
Quantity parameters (like flow, current, etc.)
which are directly plant load dependent
Quality parameters (like temperature, voltage,
pressure, etc.) which are designed to be plant load
independent for the load range 60 % UMCR
through maximum load.
Study of operational parameters
On scrutiny of the data it is seen that the DTPS
has not exceeded any parameter beyond the
values set by the OEM and they have set
alarms and trippings for parameters well within
the limits set by OEM for asset management
and asset preservation. It is ensured that
restricted time overload parameters are never
reached control action in the form of alarms
and tripping is designed to be activated well
before they are reached. All control loops are in
action and continuous recording of all data is
available including water chemistry data.
Heat loading rate (Million kcal/h) in the boiler
640
620
Heat loading rate (106 kcal/h)
600
580 design
Operating
560
Linear (design)
540 Linear (Operating)
520
500
480
235 240 245 250 255 260 265 270 275
Plant load (MW)
DTPS boilers are designed for BMCR of 805 t/h & design
steam flow at 250 MW is 746 t/h. As per the study it
is seen, DTPS has ensured that boilers are operated
well within BMCR design limit. Steam flow from the
boiler is being monitored on real time basis through
DCS and the limit of < 775 t/h- priority 1 Alarms are
configured in HMI Also daily/monthly/yearly basis
deviation report is reviewed and all parameters are
being recorded and ensured to be within limits.
Better quality of coal (Blend Indian washed coal with
imported coal) which is higher than the design GCV
by 600-800 kcal/kg also contributes in maintaining
high steaming rate of the boiler besides the high
boiler efficiency.
In conclusion, it can be said that the DTPS has been able
to maintain steaming rates below the BMCR levels
prescribed by OEM while simultaneously not
overloading any parameter beyond OEM limits
through:
High boiler efficiency (85.35 %)
High GCV of coal (600-800 kcal/kg above the design value)
Minimizing auxiliary steam requirements
TURBINES
The terminology to designate capacity of turbines is as
follows:
TMCR refers to steam demand for 100 % UMCR
VWO (valve wide open) condition of the turbine
refers to steam demand when the turbine valves are
fully opened. These are normally 5 % over and
above the 100 % UMCR capacity. Hence turbines
have operating margins of 5 % above the 100 %
UMCR capacity.
The turbines are sized such that they shall
be capable of operating continuously with
valves wide open (VWO) at rated main steam
and reheat steam parameters. The total
steam flow to turbine is the steam flow at HP
turbine stop valve inlet plus external steam
supplied to the turbine cycle such as gland
steam, stack steam, etc.
Sl. Unit particulars- TMC
No. Steam turbine UNITS R VWO MARGIN Design
Dahanu 250 MW
1 Units 1 & 2 MW 250 262.82 1.05 Seimens
Paras 250 MW Unit 3
2 MW 250 264.78 1.06 Seimens
Parli 250 MW Unit 6
3 MW 250 264.78 1.06 Seimens
Tata Trombay Unit 8
4 MW 250 264.78 1.06 Seimens
Nasik 210 MW Unit 5
5 MW 210 213.30 1.02 Russian
Chandrapur 210 MW
6 Unit 3 MW 210 215.80 1.03 Russian
Bhusawal 210 MW
7 Unit 3 MW 210 215.00 1.02 Russian
Koradi 210 MW Unit 7
8 MW 210 215.80 1.03 Russian
Khaperkheda 210
9 MW Unit No 4 MW 210 221.70 1.06 Seimens
Chandrapur 500 MW
10 Unit 7 MW 500 524.40 1.05 Siemens
TURBINES
However, it is common experience that most Siemens
turbines have continuous overload margins up to
8 %, that is, 210 MW operate at up to 227 MW.
Siemens turbines normally have a built in margin of
15 % in torque. It has been clarified from turbine
specialists that turbines have margins up to 15 % in
power output without any harmful effect provided
efficiency and steam cleanliness is maintained.
Since turbines are constant speed machines with
load directly proportional to the transmitted torque,
the heat generation in the journal bearings is
second order dependent on load while the heat
generation in thrust bearings is directly proportional
to load. If the turbine efficiency is maintained very
near the design value, then the heat generation in
the thrust bearings can be kept well within OEM
limits even with high load ability.
Sl. Unit particulars TMC
No. - Steam turbine UNITS R VWO MARGIN
Hitachi
1 MW 210 222.00 1.06
Mitsubishi
2 MW 210 222.00 1.06
Siemens
3 MW 210 221.70 1.06
Russian
4 MW 210 215.60 1.03
TURBINES
Apart from maintaining the load ability of turbines, DTPS
has made provisions to supply the required steam
through:
minimized auxiliary steam flow (by cutting down on
tracing steam for HFO and introducing zero steam leak
policy)
minimized DM water consumption (by cutting down steam
lost to the atmosphere)
minimized auxiliary steam consumption in the turbine
itself (for gland sealing steam, stack steam and vent
steam) to ensure that most steam goes into the turbine
and turbine load ability further improves.
DTPS has ensured turbine load ability of more than 100%
TMCR by some additional measures such as the following:
Good condenser vacuum due to open cycle operation of
condenser cooling & by use of sea water for condenser
cooling. Rated parameters of equipments are never
violated & regular monitoring of same through deviation
report thereby preventing parameter excursions and loss
of value of the asset. Maintaining very good quality of
process chemistry parameters of steam and water
Program of routine, preventive, predictive maintenance
and planned AOH. Continuous monitoring of process
cycle efficiency on line & off line. Simulator training for
operators using the customized 250 MW simulator.
Variation of steam input with turbine heat rate
at constant power output
Steam input to turbine,
765
760
755
t/h
750
745
740
735
1920 1940 1960 1980 2000
Turbine heat rate, kcal/kWh
Variation of power output with turbine heat
rate at constant steam input to turbine
264
Power output, MW
262
260
258
256
254
1920 1940 1960 1980 2000
Turbine heat rate, kcal/kWh
TURBINES
In conclusion it can be said that the DTPS
has be able to maintain good load ability on
the machine within the OEM margins and
without exceeding any OEM parameter
limits by:
Maintaining high turbine efficiency (turbine
heat rate deviates from design by only 4.4
kcal/kWh)
Strictly maintaining water quality
parameters as per OEM guidelines
Minimizing auxiliary stack, vent and gland
sealing steam requirements in the turbine.
TURBINES
All turbine related flow, pressure (except for variable
pressure operation), temperature, vibration and position
parameters are archived for past two years in EXCEL files.
In additional the water chemistry parameters such as
electrical conductivity, pH, silica and chlorides have been
archived for the last 2 years on daily average as well as
hourly basis for 2009 and 2010. Figures 77-91 give the
turbine steam, oil and metal parameters including
mechanical parameters such as vibration, axial shift, etc.,
over the past one year on a daily average basis for Unit 1.
Similar data is also studied for Unit 2. The hourly average
is also archived and studied for both Units 1 & 2 for 2
years (2009 & 2010). On scrutiny of the data it is seen
that the DTPS has not exceeded any parameter beyond
the values set by the OEM and they have set alarms and
trippings for parameters well within the limits set by OEM
for asset management and asset preservation. Restricted
time overload parameters are never reached to preserve
the value of the asset. Very good water chemistry
parameters are being maintained.
The parameters which have most critical effect on the life
of the turbine are:
Main steam and reheat temperature
Main steam pressure
MW at MARGIN
Sl. Unit particulars- MVA pf = MW at pf=0.85
No. Generator rating 0.85 pf=0.99 to 0.99
Dahanu 250 MW
1 Units 1 & 2 294.0 250 291.18 1.16
Paras 250 MW Unit 3
2 294.1 250 291.18 1.16
Parli 250 MW Unit 6
3 294.1 250 291.18 1.16
Tata Trombay Unit 8
4 294.1 250 291.18 1.16
Nasik 210 MW Unit 5
5 247.0 210 244.59 1.16
Chandrapur 210 MW
6 Unit 3 247.0 210 244.59 1.16
Bhusawal 210 MW
7 Unit 3 247.0 210 244.59 1.16
Koradi 210 MW Unit 7
8 247.0 210 244.59 1.16
Khaperkheda 210 MW
9 Unit No 4 247.0 210 244.59 1.16
Chandrapur 500 MW
10 Unit 7 588.0 500 582.35 1.16
The schedule of tolerances in the generator must be as per IS
4722: 2001 and the operating specifications including
combinations of parameters at any given output must be
according to IS 5422: 1996 (reconfirmed 2002).
Sl. No. Particulars of continuous Designed value
parameters
01 Maximum temperature of stator core 105 0 C
02 Maximum temperature of stator 105 0 C
windings
03 Maximum temperature of stator 115 0C
windings
04 Maximum temperature of cold gas 45 0C
05 Maximum temperature of hot gas 75 0C
06 Maximum temperature of inlet water 38 0C
07 H2 gas pressure 3 bar
08 Voltage variation 5%
09 Unbalanced load 8%
10 Unsymmetric short circuit current 10
(I2t)
11 Frequency 5%
Sl. Factors Description
No.
Power frequency
1 % frequency No effect
drop (-0.5 Hz)
1.06
Generator active power output (p.u.)
1.04
1.02
1
0.98
0.96
0.94
0.92
0.9
0.88
0.86
0.84 0.89 0.94 0.99 1.04 1.09 1.14
Terminal voltage of generator (p.u.)
Figure :Variation of permissible stator current (% of MCR)
y = -14.713x 2 + 28.461x - 12.707
R2 = 0.9971
1.04
Generator stator current (p.u.)
0.96
0.92
0.88
0.84
0.8
0.84 0.89 0.94 0.99 1.04 1.09 1.14
Terminal voltage of generator (p.u.)
Figure :Variation of permissible stator current occurance time
(min)
y = 745704e-8.6624x
R2 = 0.6521
60
Permissible safe time (min)
50
40
30
20
10
0
1 1.2 1.4 1.6 1.8 2
Stator current of generator (p.u.)
Figure :Variation of permissible rotor current occurance time
(min)
y = 63.296e-1.7162x
R2 = 0.8686
10
Permissible safe time (min)
0
1 1.2 1.4 1.6 1.8 2
Rotor current of generator (p.u.)
GENERATOR
TRANSFORMERS
Generator transformer are rated by
apparent power (MVA) and not by real
power (MW). Generator transformers are
normally rated at 7.1-10 % higher than the
generator 100 % MCR MVA rating at the
designed power factor. Generator
transformers are designed for continuous
operation at any tap at rated 315 MVA with
voltage variation of 10 % of rated tap
voltage; and capable of delivering rated
current at a voltage equal to 105 % of rated
voltage without exceeding specified
temperature rise giving a continuous
overload capacity of 5 %.
If the power factor is improved
from 0.85 to near 1.0 then a 15
% margins will be available to
the station in the form of active
power (MW) capacity. Thus,
generator transformers have a
margin of around 7-10 % with
an additional margin if the
power factor is increased from
0.85 to 0.99 as the capacity is
controlled by the MVA rating
and not the MW rating.
Sl. Unit particulars-Generator MVA of MVA
No. transformer Units Gen of GT MARGIN
Dahanu 250 MW Units 1 &
1 2 MVA 294.1 315 1.07
2 Paras 250 MW Unit 3 MVA 294.1 315 1.07
3 Parli 250 MW Unit 6 MVA 294.1 315 1.07
4 Tata Trombay Unit 8 MVA 294.1 315 1.07
5 Nasik 210 MW Unit 5 MVA 247.0 250 1.01
Chandrapur 210 MW Unit 3
6 MVA 247.0 250 1.01
7 Bhusawal 210 MW Unit 3 MVA 247.0 250 1.01
8 Koradi 210 MW Unit 7 MVA 247.0 250 1.01
Khaperkheda 210 MW Unit
9 No 4 MVA 247.0 250 1.01
Remaining
Life
(h, years)
<45
> 45 =45
poor Normal Good
0.016000
0.014000
0.012000
Normal Distribution
0.010000
0.008000
0.006000
0.004000
0.002000
0.000000
0 20 40 60 80 100 120
Plant Load Factor, %
There are 66 units in India which have
achieved average plant loads of 100-110 %
and there are 14 stations which have
achieved annual station loads in excess of
100 % during 2007-2008. The maximum
average plant load is 110.69 % which is in
conformation with the OEM design margins.
[Ref: Performance review of 2007-08 of
CEA]
There are 9 units and 3 stations in India which
have clocked a PLF of over 100 % with the
maximum being 104.14 % in 2007-2008.
[Ref: Performance review of 2007-08 of
CEA]
Sector wise private sector units have clocked a
PLF of 91 % as compared to Central sector
of 87 %.[Ref: Performance review of 2007-
08 of CEA]
Study of current
operating levels
In the case of boilers the R-Infra have utilized the margin of
BMCR of up to 8 %. They have used the margin steam
meant for auxiliary steam use and for DM make up for
generation by minimizing/optimizing the margin steam
usage. Further, they have maintained a coal GCV of
around 4000 to 4200 kcal/kg (20-23 % higher than the
design GCV) thereby proving advantage of optimization
of the boiler capacity which has a design GCV of 3400
kcal/kg. The additional 600 kcal/kg has been taken
advantage to load the boiler to obtain steaming rates
near but below the BMCR ratings. Scrutiny of records
(hourly and daily data for the past 2 years) indicates that
BMCR ratings have not been exceeded. This has been
possible by maintaining a high boiler efficiency which
ensure that coal, air, flue gas flow rates are reduced and
heat release rates in the boiler are minimized. If the
boiler efficiency is decreased additional quantity of fuel
would have to be fired causing a higher heat release rate
in the boiler which would lead to parameters exceeding
the design values and therefore imposing restriction on
loadability. Thus, it can be said that the high boiler
efficiency is a major factor responsible for the high boiler
loadability.
Study of current
operating levels
On the turbine side the capability of the turbine has been well
utilized. By periodically overhauling the turbines and
utilizing the margin steam for the turbine (the auxiliary
steam for turbine gland sealing steam, stack steam, vent
steam, etc.), they have been able to generate almost
268.7 MW without exceeding the parameters at any point
of time and without crossing the OEM VWO margins. In
other words, the high turbine efficiency is responsible for
maintaining a high turbine loadability well within the
VWO margins and parameters below their OEM limits. In
addition to this maintaining of very good water chemistry
has contributed to the loadability. It is generally
accepted that the Siemens turbines can easily be loaded
continuously up to 10 % without any adverse impact on
the life provided their efficiency very near the design
value. If the efficiency of the turbine drops then the heat
losses in the turbine decrease and their loadability would
come down because the parameters (like main steam
flow, HRH flow, CRH flow and condensate flow) would
exceed their OEM prescribed levels.
Study of current
operating levels
On the generator side the margin power factor
(from the design value of 0.85 to unity) through
implementing a high power factor of 0.99 on
the 33 kV distribution side of the energy supply
has been made full use of to get maximum
active power while minimizing the heat
generation from the reactive power
component. The loading is within the OEM
margins and the parameters are within OEM
limits. The same is the case of the generating
transformer. Besides the high efficiency of the
generator and generator transformer have
contributed to low heat generation. If the
generator efficiency had decreased, then the
present level of loadability would not have been
possible.
Figure : Maximum continous overload rating
of the units
320
310
300
Plant load (MW)
107
y = -0.0003x 2 + 1.2457x - 1292.4
106
R2 = 0.6528
Loading rate (% of MCR)
105
104
103
102
101
100
2220 2240 2260 2280 2300 2320 2340 2360 2380
Unit Heat rate (kcal/kWh)
y = -0.2221x + 609.83
Annual Loading rate ( % of MCR) for the period 1995-2010
R2 = 0.7339
110
Annual Loading rate (% of MCR)
105
100
95
90
85
80
2240 2260 2280 2300 2320 2340 2360 2380
Unit Heat rate (kcal/kWh)
Study of current
operating levels
We are also of the conclusion that the operation
regime of quality parameters (temperatures,
pressures, voltages, etc.) as well as quantity
parameters (flows & currents) have been
restricted to the limits imposed by the OEM for
all parameters and overshooting of critical
parameters is not seen. The DTPS has
introduced continuous monitoring of
parameters through DCS as well as condition
monitoring of selected parameter. The
continuous safe overloading margins provided
by the OEM have been made use of to operate
the plant up to a load of 268 MW without
violating either the OEM margins or the OEM
limits of parameters.
Thus after a thorough scrutiny of the data
sheets, daily and hourly readings for the
past two years, physical inspection of
equipment, study of name plate ratings
and efficiency tests on equipment we have
come to the following conclusions:
The parameter limits set by the OEM for all
equipment have been maintained by
setting the alarms and trip setting below
these values. Parameter monitoring and
condition monitoring have been installed.
This has led to asset preservation and
management.
The margins provided by the OEM for the
boiler, turbine and generator have not
been crossed but been made use of by
measures to ensure that loadability is
high.
On the boiler side DTPS have minimized
DM water make up and auxiliary steam
besides firing coal with around 600
kcal/kg higher than the design coal
thereby maintaining good boiler
loadabiliy within the BMCR limits. A high
boiler efficiency is being maintained. If
the boiler efficiency drops down then the
heat load in the boiler will increase and it
will not be possible to sustain the
required steaming rate. High boiler
efficiency thus enables loading of the
unit to 268.7 MW without crossing the
100 % BMCR limit or any parameters
exceeding.
On the turbine side they have
maintained very good water chemistry
regime, regularly overhauled turbines
and minimized auxiliary steam to the
turbine (gland steam, stack steam, etc.)
thereby maintaining good turbine
loadability well within the 100 % VWO
limits given by OEM. If the turbine
efficiency decreases, the present loading
rate will not be possible to be maintained
in the turbine and the load will have to
be decreased.
On the generator side they have taken
advantage of the high power factor of
0.99 against the generator design
power factor of 0.85, and the high
generator efficiency to get an increase
in loadability by around 8 % but within
the OEM limit of 291 MVA without any
parameters crossing the OEM limits.
Combining all these factors R-Infra has
been able to load the unit to 268.7 MW
against the design value of 250 MW.
Maintaining this load is not harming the
life of the unit as the DTPS has ensured
boiler operation is within 100 % BMCR
limits, turbine operation is within 100 %
VWO limits and generator operation is
within the capability curve. Further, all
parameters are kept within OEM
recommended limits.
The plant capacity is 250 MW and
the present continuous load limit
of 268 MW is well within the
frame work of the OEM margins
and parameter limits. There is
no evidence to show that the
parameters have been exceeded
in any equipment.
The present unit loadability of 268 MW achieved
because of the high boiler, turbine and
generator efficiencies (low unit heat rate); coal
quality of around 4,000 kcal/kg, prudent use of
margin steam in the boiler and turbine
(through zero leak policy), proactive control of
water chemistry regime and margin power
factor of near unity. All design margins
provided by the OEM have been utilized without
parameters shooting beyond the safe levels
and minimizing cycling excursions. If coal GCV,
boiler efficiency, turbine efficiency, generator
efficiency and power factor decrease, then it
will not be possible to maintain the loadability
of the units to 268 MW. There is an inverse
relationship between unit heat rate and unit
loadability as explained earlier in the text.
The issue of continuous operation of
the unit 7 % higher than the 100 %
UMCR (at 260 to 268 MW) was
discussed with OEM and other units.
They have opinioned that the
sustainability of the 265-268 MW may
not be of a permanent nature and
both availability and loadability are
bound to drop in due course of a few
years. A large number of factors are
responsible for this loadability and
any let up in any side may affect
loading. Loadability is linked to heat
rate and if heat rate increases
implying that losses in the boiler,
turbine and generator increase then
the loadability will not be sustainable.
Also, the PG tests indicate the OEM
assurance is for 250 MW which is
identical to several units installed in
India by the OEM and no capacity
upgrades have been added since
inception. Moreover, the margins are
not uniform in boiler, turbine and
generator and limitations may be
created in any one equipment.
Further, the original design considers
a margin as envisaged by the CEA grid
code 2005 and up-rating of the unit
could affect this margin. Considering
all the above factors we are of the
opinion that the rating can be
maintained at 250 MW.
Heat rate
The gross overall efficiency of the Unit 1 TG set is 37.8 % against
the design efficiency of 38.5 %. The gross overall TG heat rate
(TG HR) is 2275.34 kcal/kWh at the test load of 265.5 as
compared to the design heat rate of 2230.60 kcal/kWh.
The deviation in the test TG heat rate is 44.2 kcal/kWh which can be
attributed to boiler side as 39.8 kcal/kWh and due to the
turbine side it is 4.4 kcal/kWh. On the generator side the
deviation is 0 kcal/kWh.
The annual unit heat rate (UHR) of the unit considering all factors is
2292.7 kcal/kWh for Unit 1.
The average degradation of SHR corresponds to a degradation
rate of 0.18 % of design HR/year. The degradation of
SHR has averaged 0.18 %/year over the past few years.
The CPRI test TG HR is showing a degradation rate of
0.13 %/year. The degradation is 2.0 % of the DHR.