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Unit #3
50.64 36.78 5.45 56.49 56 11
Unit #4
46.48 34.10 56.61 52.73 42 54
Station
48.14 35.18 36.15 54.23 47 97
00-01 01-02 02-03 03-04 04-05
Unit #3 00-01: Total forced outage was 1210.92 hrs out of which outage due to tube leakage was 909.36 hrs. 01-02: Poor availability due to forced outage of 645 hrs. (606 hrs. for Boiler tube leakage) and 2678 hrs. for RLA/refurbishment & Capital O/H (from 10.12.01 to 02.06.02). 02-03: Poor availability due to RLA/Refurbishment & Capital O/H and forced outage from 26.07.02 to 30.04.03 caused by Generator Rotor Earth Fault 03-04: Total outage was 1935 hrs mainly due to Rotor E/F and Boiler Tube Leakage.
04-05: Total outage was 1849 hrs mainly due to Boiler Tube Leakage and O/H from 01.12.04 to 26.12.04. From the above details it is evident that the performance of the Unit was poor during the years 01-02 & 02-03 due to RLA/Refurbishment & Capital O/H and Generator Rotor E/F. In other periods outage was mainly due to Boiler Tube leakage. In general the Unit is presently capable of generating at 56% PLF. For further improvement, R&M/LU action has been taken up so that it can generate at about 70% PLF. Unit #4 00-01: Total outage was 2535 hrs. - tube leakage for 831 hrs, planned outage 474 hrs for renewal of Boiler steaming license, Fire hazards in burner floor 254 hrs and CM & CHP problems due to poor quality of Coal supply 159 hrs. 01-02: Total outage 4830 hrs. mainly due to Capital O/H (01.07.01 to 30.11.01) - 3650 hrs, Boiler tube leakage 565 hrs. and 2678 hrs. for RLA/Refurbishment & Capital O/H (from 10.12.01 to 02.06.02). 02-03: Total outage was 1953 hrs out of which 759 hrs for hooking up Addl. ESP. 03-04: Total outage was 2120 hrs mainly due to Boiler Tube leakage 920 hrs., Condenser tube & Generator H2 cooler gas lkg.- 441 hrs. 04-05: Total outage was 3551 hrs mainly due to Boiler Tube Leakage 1011 hrs, Annual O/H (20.06.04-23.07.04) & Gen Seal Oil Sys. trouble - (30.07.04 18.08.04). Unit #4 is running at an average PLF of 50%. Different actions on Short- term, Medium- term & Long- term basis, as recommended by NTPC-DVC Peer group, have been taken to improve the performance. Also RLA & Capital O/H of this unit has been scheduled in 05-06.
Performance The station performance is gradually improving and presently operating at above 80% PLF.
Performance
PLF (%)
The performance of CTPS Units #4, #5 & #6 has been very poor since inception. Unit #4 The main reason for poor performance of U #4 was the failure of TurboGenerator (high vibration of TG Bearing No. #3) on 3rd June, 01.After O/H of TG and its auxiliaries Unit was synchronized on 23.04.03. Unit suffered forced outage on 29.05.03 due to a devastating fire that broke out in 3.3 KV Cable gallery. Prior to fire incidence during the operating period in Apr.-May03 unit average load was 42.96 MW (PLF 35.8%). Also, during operation continuous oil support was unavoidable due to inherent problem of ABL Boiler right from its commissioning. Since then unit remained under shut down. Unit #5 Unit operation was found to be uneconomical due to very high specific oil consumption, poor performance of cooling tower, coal mills and frequent boiler tube leakage. (PLF: 01-02, 29.36%, 02-03, 16.4% & in 03-04, 9.34%). Unit was last in operation on
23.11.03 and gone under S/D due to Boiler tube leakage and Generator Seal leakage. Later unit was kept available but not brought back to bar as per management decision because of uneconomic generation of the unit since very beginning owing to high SOC. Unit #6 Since commissioning the unit could not be operated at rated capacity. Unit suffered forced outage in July 95 due to bursting of 3.3 KV Switch gear resulting in severe damage of all switch gears along with Bus bars, internal wiring, Protection relays and other accessories. After complete rehabilitation work, unit couldnt be stabilized and kept in continuous service in spite of repeated efforts mainly due to high turbine (IP Rotor vertical) eccentricity, high vibration in TG Bearing #3 & #5, erratic performance of coal mills, BFPs etc. Unit was last de-synchronized on 06.06.02 due to boiler tube leakage along with above problem. In view of prolonged S/D of the Unit #4, #5 & #6 and uncertainty about their restoration and rehabilitation, the manpower, earlier engaged for O&M of above three units, had subsequently be reduced to bare minimum skeleton level as required for operation of safety measures. For economical operation and improvement of station generation several action has been initiated. DVC has given stress to run U #1, #2 & #3 at present. Performance of these three units has shown gradual improvement (Annual PLF considering these three units was 27.76 %, 34.22 % & 55.43% during 02-03, 03-04 & 04-05 respectively). SOC has been subsequently brought down from 16.435 ml/kWh in 03-04 to 2.61 ml/kWh in 04-05 which is close to National average for such old units. A comprehensive R&M program will be taken up during 06-07 for these Units for Life Extension and Uprating the capacity. Also it has been decided in the recent meeting with M/s. BHEL, Bhopal and NTPC to carry out Thermal Performance Test (TPT) of Unit # 6 after extensive overhauling of Boiler with its accessories, TG and auxiliaries etc. as per the scope of work of NTPC, based on which decision for revival of U #4, #5 & #6 will be taken.
Serves as standby source of power in case of system exigencies. Provides reactive power to the system for voltage regulation, in case it functions as synchronous condenser. Regarded as quick peaking source as Unit takes 16 Minutes for start up, synchronization and loading. Requires less manpower, cost beneficial and short gestation period. Plant is dependent on costly principal fuel, but it stands justified in choice between costly power and no power, in case of exigencies.
GT No. I & III have been under shut-down due to forced outage since 20.7.99 & 14.5.96 respectively. In order to revive the same, BHEL Gas Turbine Services (BGGTS) were entrusted with the work of major inspection towards overhauling. It was detected that major components in the critical zones including turbine rotor and stator portion have sustained extensive damage, in both the Units. Due to nature and extent of damage in both the units being same, the possibility of cannibalization of either one to revive the other thus stands ruled out. Action has been taken to re-commissioning the Units on Renovation by procuring Spares GT No. II is available for generation. However, it has not been synchronized since 3rd November 03. In general Gas Turbine is being run only on advise of CLD to meet the system demand that too in extreme urgency as the cost of generated power from GT is unacceptably high. To keep the Unit healthy for meeting up the power demand at the time of requirement during extreme emergency condition, it has been decided to run this Unit at full speed no load (FSNL) for one hour at an interval of one month.
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