Paper 3 Operational Best Practices For ESP Performance Improvement

TSTPS /KANIHA
Operational Best Practices for

ESP Performance Improvement .
By
Susanta Ghosh AGM(O)I/C & R.N.Das AGM(O)
TSTPS-Kaniha .
6X500 MW UNITS , TSTPS , KANIHA
2ND LARGEST THERMAL POWER PLANT OF NTPC

2
Why ESP Performance Monitoring is important ?

There is a wide gap in ESP design condition & actual
operating condition .
Wide variation in quality of coal fired as coal
received from different mines with different
qualities .
Day by day environmental Stringent norms set by
regulators , such as
(150 mg/Nm3 100 mg/Nm3 50 mg/Nm3)
Annual Overhauling schedule changed to 2 years .

FA Evacuation constraints faced due to restriction in
disposal system /ash dyke .
Dry ash collection from ESP hoppers .
3
ESP DESIGN DETAILS .

SL
NO
PARAMETERS
Unit
STAGE-I
STAGE- II
MW
2X500 MW
4x500 MW
T/HR
336 - DESIGN
370 - WORST
420 - SITE RESTRICTION
44%
44%
Unit Capacity
Coal Consumption /
Unit
Ash
FG flow volume
M 3/SEC
789.00
777.0( 533.48 Nm3/sec)
Inlet dust burden
Gm/Nm3
60
81.303 ( Guran- 63.387)
Outlet dust burden
mg/Nm3
56
20.0
Efficiency
99.91
99.939 ( 99.97)
Gas inlet Temp
0C
134
140 (125)
336 - DESIGN
370 - WORST
420 - SITE RESTRICTION
FA SYSTEM DESIGN DATA .

SL
NO
PARAMETERS
Unit
Unit Capacity
MW
Coal Consumption /
Unit
FA Evacuation SYSTEM
***
Dry ash facility
***
Wetting unit collection

capacity (for each
T/hr
streams)
T/HR
STAGE-I
STAGE- II
2X500 MW
4x500 MW
336 - DESIGN
336 - DESIGN
370 - WORST
370 - WORST
420 - SITE RESTRICTION 420 - SITE RESTRICTION
Continuous , Vacuum
Continuous , Vacuum Ext
Ext Type
Type
Two Units full collection
with one unit
25 % each unit
transportation
Silo 135 Ton capacity
Buffer Hopper 120 X8 tons
/Silo 750 X2 tons
55 TPH
60 TPH
Operational Best Practices at TSTPS to

Enhance ESP Performance.
Normal operation at various Operating
Conditions .
Inspection during Annual Overhaul ,
Recommissioning ,Testing , Setting Parameters .
During Planned Maintenance of ESP passes.
During Unit Start-up Shutdown .
6
Normal Operational Strategies For ESP

At Various Unit Operating Conditions .
Monitoring of ESP online Field Parameters .
Monitoring Effective Evacuation from Eco Hoppers .
Strategies adopted for Higher Particle Sizing at ESP
Inlet due to 1st field out of service .
Strategies for high coal flow > worst coal firing
ESP Hopper Effective Evacuation Monitoring through PI
system .
Regular FA system checks for system performance
improvement .
Improvement of Ash Flowability from ESP Hopper .
7
Inspection During Annual Overhaul ,

Recommissioning .
Checking for Uniform flue gas distribution across the entire
unit by proper inspection & repair of GD screen /Baffels .
Proper inspection & cleaning of support & shaft system .
Proper alignment of Emitting electrodes and collecting
plates .
Proper insulation of ESP Hoppers /Casings.
Checking Proper installation and operation of FA system
devices.
Testings Followed by Recommissioning of ESP & FA system
Testings Followed by Recommissioning of

ESP & FA system :
Support insulator Heater , shaft Insulator heater healthiness checking ,

effectiveness checking by switching ON for 24 Hrs . Subsequent current
measurement .
After total readiness , continuous rapping for 8 Hrs all GDRM/CREM/EREM ,
then internal inspection & hopper portion final water wash before box up .
24 hrs support /shaft insulator Heater in service before field meggering .
Each ESP Field Meggering to ensure electrical healthiness . (> 250 M)
Still air charging & VI characteristic checking for all Fields to identify
problems , then subsequent field internal inspection & rectification .
Inspection of 1st hopper after Furnace pressurisation test is completed .( to
remove foreign material if any)
Air tightness test of ESP up to ESP outlet by pressurizing boiler up to 100
mmwc.
Next Slide
9
Testings Followed by Recommissioning of

ESP & FA system :
Hopper Heater current check ,

Dust level LO/HI indicator operation check .
P&I check for Rectiformers .
Gas load testing of Fields to create data base after
synchronization .
Rapper frequency and intensity adjustment later when the unit
is brought on-line.
FA evacuation system Checks .
Hot tightening of FA evacuation system after one day .
Next Slide
10
During Planned Maintenance of ESP in Operating Units .

(ESP Pass isolation for Rectification).
Whenever number of field goes out of service > 2-3 then

planned maintenance of the pass is taken up .
Effort is put not to loose generation by firing good quality
coal to restrict coal flow at 370 T/hr.
A systematic approach through a standard check list is
adopted by operation engineers while ESP pass shutdown
activities are carried out .
This also guides & helps the maintenance personnel for
proper & effective inspection & rectification work .
Still air charging of fields
before isolation & after
rectification is carried out to ascertain problems /problems
are rectified respectively
Meggering is carried out where problems are not visibly
identified .
Next Slide
11
During unit start up shutdown .
During unit startup after a short shutdown , 2-3 passes of ESP are kept in
service to avoid oil soot deposition in all passes .
ESP Fields are charged after sufficient warm up i.e > 110-120 0C inlet /outlet
temp .
SCAPH is kept in service in all cold start-ups & up to sufficiently high load
to ensure better temp at ESP inlet .
FA Evacuation system is kept in service well in advance & mouth chokings
are cleared continuously if any during initial phase .
ESP Auxiliaries are kept in service 24 hrs prior to BLU .
Before planned Unit shutdown all pass rappers are put on continuous mode
for dislodging of ash from collector & emitter electrodes in hot conditions .
All hoppers emptiness ensured before the FA system is taken under
shutdown .
For a short shutdown the Hoppers heaters & shaft /support insulator
heaters are kept ON .
Identified Defects are attended , all fields are charged at charge ratio 1:1
The fields having problem are addressed .
FA system functional /vacuum checks are carried out to bring the system
close to new one .
Next Slide12
GIST OF MAJOR MODIFICATIONS CARRIED OUT .
STAGE-I
ESP Controllers are up graded recently
by BHEL
VP suction line /ASH LINE modified
(made independent) all 6 VP can be
kept in service
DURING R&M ASH HANDLING
SYSTEM DATA TO BE HOOKED UP
TO PI SYSTEM
BOILER HOPPER DISCONNECTION
FROM ESP SYSTEM UNDER PROGRESS
ESP R&M PLANNED & CONTRACT
AWRADED TO MEET THE STRINGENT
NORMS
STAGE- II
ESP online parameters data
provided
through DCS
ESP OUTLET SIDE GAS SCREEN REMOVED IN
ALL FIELDS OF U 5&6 , UP TO 7TH FIELD IN U
3&4 (balance to be carried out)
VP suction line /ASH LINE modified (made
independent) all 8 VP can be kept in
service
Ash Line made independent , . Additional
water source provided from SW network .
Major evacuation monitoring data provided

in PI system .
ECO HOPPER EFFECTIVE EVACUATION

MONITORED THROUGH PI SYSTEM ( TE
INSTALLED )
13
CONCLUSION :
The role played by operation engineers in formulating
strategies /practices is very important .
To sustain the overall ESP performance , the operation
support group discusses all the strategies with shift
operation group on General shift days .
After implementation of all best practices as discussed , at
TSTPS the overall performance of ESP & Ash evacuation
system improved indicated by consistency in ESP field
availability .
The PI system has further strengthened in monitoring ,
analyzing and inturn developing the operating personnel to
a larger extent in maintaining
& improving ESP
performance .
14
15
Checking Proper installation and operation of

FA system devices .
Vacuum Checks .
Shutoff vacuum .
Shutoff vacuum with air lock valve close.

Vacuum with VB open
Line Vacuum
Functional Checks .
Hopper empty vacuum check .
Valve 100 % opening check .
16
Use of PI system in FA Evacuation Monitoring

Shut off vacuum Monitoring .
System Idle time Ineffective evacuation
monitoring .
Deterioration in system performance .
System Good Performance
Single Hopper Evacuation for long time.
IA pressure for 100 % valve opening .
DA evacuation & transportation system .
BAG filter DP Monitoring .
17
Next Slide
18
19
Shutoff vacuum check with air intake closed
20
Economiser Hopper Evacuation temp Trend

Plot-0
300
250
44.510
39.297
46.099
40.973
218.84
228.75
185.21
147.98
3HNA30CT101.DACA.PV
52.280
3HNA30CT102.DACA.PV
38.108
3HNA30CT103.DACA.PV
54.672
3HNA30CT104.DACA.PV
44.367
4HNA30CT101.DACA.PV
38.025
4HNA30CT102.DACA.PV
36.721
4HNA30CT103.DACA.PV
36.638
4HNA30CT104.DACA.PV
30.518
200
150
100
50
0
2/6/2013 8:28:31 PM
2/7/2013 2:00:00 PM
2.67 days
2/9/2013 12:28:31 PM
21
Improper Evacuation From ESP Hoppers

(Idle Time more)
Next Slide
22
Next Slide
23
Next Slide
24
Improper Evacuation
UNIT#6
600
500
400
300
200
100
0
8/24/2012 9:33:41 AM
ABT.GEN6 Instantaneous MW
Unit#6 TOTAL COAL FLOW
UNIT#6 PASS A VACUUM TX-1
UNIT#6 PASS B VACUUM TX-1
UNIT#6 PASS C VACUUM TX-1
UNIT#6 PASS D VACUUM TX-1
2.00 hours
8/24/2012 11:33:41 AM
\\10.0.120.202\GEN6_MW
356.37
\\10.0.120.202\6HFY00_1P02.SUMMER.PV
420.25
\\10.0.120.202\6PASSA_VAC_TX1
69.336
\\10.0.120.202\6PASSA_VAC_TX2
241.64
\\10.0.120.202\6PASSB_VAC_TX1
212.16
\\10.0.120.202\6PASSB_VAC_TX2
254.28
\\10.0.120.202\6PASSC_VAC_TX1
193.21
\\10.0.120.202\6PASSC_VAC_TX2
293.67
\\10.0.120.202\6PASSD_VAC_TX1
210.25
\\10.0.120.202\6PASSD_VAC_TX2
107.14
Next page
25
Hopper Evacuation With out proper vacuum

UNIT#4
500
450
400
350
300
250
200
150
100
50
0
8/29/2012 5:42:54 PM
2.00 hours
8/29/2012 7:42:54 PM
\\10.0.120.202\GEN4_MW
351.97
\\10.0.120.202\4HFY00_1P02.SUMMER.PV
281.99
\\10.0.120.202\4PASSA_VAC_TX1
191.00
\\10.0.120.202\4PASSA_VAC_TX2
74.000
\\10.0.120.202\4PASSB_VAC_TX1
180.00
\\10.0.120.202\4PASSB_VAC_TX2
277.00
\\10.0.120.202\4PASSC_VAC_TX1
279.00
\\10.0.120.202\4PASSC_VAC_TX2
210.00
\\10.0.120.202\4PASSD_VAC_TX1
0.0000
\\10.0.120.202\4PASSD_VAC_TX2
82.000
26
U-4 A pass Evacuation deterioration

VP suction line choking
UNIT#4
600
500
400
300
200
100
0
11/25/2012 1:03:46.445 AM
1.33 days
11/26/2012 9:03:46.445 AM
\\10.0.120.202\GEN4_MW
511.03
\\10.0.120.202\4HFY00_1P02.SUMMER.PV
374.15
\\10.0.120.202\4PASSA_VAC_TX1
0.0000
\\10.0.120.202\4PASSA_VAC_TX2
211.00
\\10.0.120.202\4PASSB_VAC_TX1
95.000
\\10.0.120.202\4PASSB_VAC_TX2
222.00
\\10.0.120.202\4PASSC_VAC_TX1
228.00
\\10.0.120.202\4PASSC_VAC_TX2
0.0000
\\10.0.120.202\4PASSD_VAC_TX1
68.000
\\10.0.120.202\4PASSD_VAC_TX2
60.000
Indicates Empty Vacuum is increasing ,

suction line choking , System stopped
27
Dry ash transportation trend

IA & TR Line Press
5.7
\\10.0.120.202\U56_INSTAIR_HDRPR
5.0244
kg/cm2
5.6732
kg/cm2
\\10.0.120.202\3LINE1PRESSURE
0.57218
kg/cm2
0.64831
kg/cm2
0
11/11/2012 12:51:28 AM
Unit#5&6 ESP INST AIR HDR PRESSURE
Unit#3 DRY ASH TRANSPORT LINE L1 PRESSURE
16.00 hours
11/11/2012 4:51:28 PM
Next Slide
28
Line-2 Choking On 6-11-2012

IA & TR Line Press
6
4.9191
kg/cm2
5.0822
kg/cm2
9.8555E-02
kg/cm2
1.1154
kg/cm2
Green
Colour IA
pressure
Reduction
Pink
Colour Line
pressure
hunting
0
11/2/2012 4:16:03 PM
2.67 days
11/5/2012 8:16:03 AM
Next Slide
29
LINE-2 NO TRANSPORTATION
IA & TR Line Press
4.95
4.6036
kg/cm2
4.7040
kg/cm2
0.93655
kg/cm2
0.47682
kg/cm2
4.5
Line -2
Transportation
stopped
3.5
2.5
1.5
0.5
0
11/22/2012 1:26:28 AM
8.00 hours
11/22/2012 9:26:28 AM

30
Single Hopper Evacuation for long time

UNIT#4
500
450
400
350
300
250
200
150
100
50
0
8/29/2012 5:42:54 PM
2.00 hours
8/29/2012 7:42:54 PM
\\10.0.120.202\GEN4_MW
351.97
\\10.0.120.202\4HFY00_1P02.SUMMER.PV
281.99
\\10.0.120.202\4PASSA_VAC_TX1
191.00
\\10.0.120.202\4PASSA_VAC_TX2
74.000
\\10.0.120.202\4PASSB_VAC_TX1
180.00
\\10.0.120.202\4PASSB_VAC_TX2
277.00
\\10.0.120.202\4PASSC_VAC_TX1
279.00
\\10.0.120.202\4PASSC_VAC_TX2
210.00
\\10.0.120.202\4PASSD_VAC_TX1
0.0000
\\10.0.120.202\4PASSD_VAC_TX2
82.000
Next Slide
31
Single Hopper Evacuation for long duration

UNIT#4
500
450
400
350
300
250
200
150
100
50
0
8/29/2012 5:42:54 PM
2.00 hours
8/29/2012 7:42:54 PM
\\10.0.120.202\GEN4_MW
351.97
\\10.0.120.202\4HFY00_1P02.SUMMER.PV
281.99
\\10.0.120.202\4PASSA_VAC_TX1
191.00
\\10.0.120.202\4PASSA_VAC_TX2
74.000
\\10.0.120.202\4PASSB_VAC_TX1
180.00
\\10.0.120.202\4PASSB_VAC_TX2
277.00
\\10.0.120.202\4PASSC_VAC_TX1
279.00
\\10.0.120.202\4PASSC_VAC_TX2
210.00
\\10.0.120.202\4PASSD_VAC_TX1
0.0000
\\10.0.120.202\4PASSD_VAC_TX2
82.000
32
Shut Off Vacuum Check

Shutoff Vac < 450 mmhg
UNIT#3
450
400
350
300
250
200
150
100
50
0
8/25/2012 7:31:50 AM
8.92 minutes
8/25/2012 7:40:45 AM
\\10.0.120.202\GEN3_MW
332.01
\\10.0.120.202\3HFY00_1P02.SUMMER.PV
375.62
\\10.0.120.202\3PASSA_VAC_TX1
57.098
\\10.0.120.202\3PASSA_VAC_TX2
80.008
\\10.0.120.202\3PASSB_VAC_TX1
100.27
\\10.0.120.202\3PASSB_VAC_TX2
68.107
\\10.0.120.202\3PASSC_VAC_TX1
78.750
\\10.0.120.202\3PASSC_VAC_TX2
60.753
\\10.0.120.202\3PASSD_VAC_TX1
88.000
\\10.0.120.202\3PASSD_VAC_TX2
0.0000
33
IA Pressure Low in Unit 5&6

IA & TR Line Press
6
4.9191
kg/cm2
5.0822
kg/cm2
9.8555E-02
kg/cm2
1.1154
kg/cm2
IA
Pressure
dropped
IA
Pressure
improved
0
11/2/2012 4:16:03 PM
2.67 days
11/5/2012 8:16:03 AM

34
Next Slide
35
Next Slide
36
Next Slide
37
38
Trends of Proper FA Evacuation
39
Use of TEMPLATE for MHV operation checking
40
Thermostat Location Changed

Old Thermostat Locations
New thermostat locations
Next Slide
41
Hopper/Casing manhole air ingress .

HOPPER MANHOLE AIR INGRESS
CASING MANHOLE AIR INGRESS
42
GD screen inspection & rectification ,

placement of flow baffels
43
Ash Build up in Support Insulator Housing of U-3 ESP
44
Hopper /Casing manhole Doors , source

of air ingress in ESP ( ESP Pr. test)
45
ESP Field Alignment check Before & After OH
Next Slide
46
ESP Field Misalignment
47
ESP Field Non Rapping side Lower Shock bar

Guide Position Check .
48
VI characteristics check for all fields
49
50
Eco hopper TE Fixing
51
52
ADVANTAGES TOWER TYPE BOILER

OVER TWO PASS BOILER
TOWER TYPE (SINGLE PASS)
INVERTED U TYPE (TWO PASS)
Heating surfaces are fully drainable (horizontal).

Restart behavior is excellent.
Heating surfaces are not drainable (vertical). Hence

slow startup and corrosion problem.
Heat exchangers are horizontal and tubes are

exposed to uniform temperature.
Heat exchangers are vertical and exposed to

different gas temperature along the height.
No blockage of ash in the convective heating
surfaces. as pitch of the coils is increasing from the

top to the bottom .
Pressure parts wear is less due to Impact of ash by

counter action of gravity in the upward gas flow.
Uniform Flue gas velocity & continuously upward

without any change in direction.
Even flow distribution of flue gas and particulates
Accumulation of ash on economizer tubes where

the pitch is smaller. Hence local flue gas velocities
increases and erosion occurs.
In rear pass the ash particles velocity accelerates

due to gravity and increases erosion.
Turbulence created by the change in direction of

flue gas flow generates high local velocities causes
local erosion.
Thermal expansion of first pass and second pass is

different.
Direct load transmission to the boiler roof and free

expansion
Non-drainable heating surfaces having risk of flow

imbalance.
53
Spiral WW & Vertical WW Design

The Spiral WW
Benefits from averaging of lateral
heat absorption variation (each tube
forms a part of each furnace wall)
Fewer tubes than the vertical wall
unit.
Simplified inlet header
arrangement.
Large number of operating units.
Use of smooth bore tubing
throughout entire furnace wall
system. ( instead of Rifled tube)
No individual tube orifices like drum
boilers .
the negative flow characteristics of
the spiral furnace .
Vertical tube once through

boiler
Lower capital costs:
Self-supporting tubes, hence
simplifying part of the boiler
support system
Elimination of transition headers at
spiral/vertical interface
Simpler ash hopper tubing
geometry.
Lower operating costs:
Lower overall boiler pressure drop,
hence lower auxiliary power load
resulting in higher plant output and
higher efficiency
Positive flow characteristic
automatically compensates for
variations in furnace absorptions .
Simple and economic tube repair
Simple start-up system, a start-up
circulation pump is not required
Reduced slagging of furnace walls
Lower part loads down to 20% are
possible while maintaining high
steam temperatures.
54
Enthalpy Control
55
Special Protections Used

DESCRIPTION
Separator level very high and no
drainage.
Evaporator flow LO-LO (FW flow - SH
spray flow)
Spiral outlet tube metal temp. HI-HI.
Evaporator outlet steam temp. HI-HI
ITSH outlet steam temp. very high.
LTRH outlet steam temp. very high.
Both the steam valves closed.
Logic
Set Value
2/3
> 12.9 Mtr
2/3
< 420 t/hr
3/8
2/4
2/4
2/4
2/3
470 0 C
4650 C
505 0 C
520 0 C
Closed
56
DETAILS OF UNIT STARTUP PARAMETERS.

Stage - I & Stage - II Units
Parameters
Stage - I Units
Stage- II Units
Cold
Warm
Hot
Cold
Warm
Hot
Startup Criteria
(Mean Rotor Temp )
< 160 0C
>240 0C
< 430 0C
> 430 0C
> 48 Hrs
0-48 hrs
< 8 Hrs
BLU to Rolling
Parameters
1:20Hrs
80 min
1:15Hrs
75 min
35 min
2:05Hrs
125 min
1:25 Hrs
85 min
35 min
TG set Rolling Time i.e

up to 3000 RPM
50 min
17 min
07 min
45 min
6-7 min
6-7 min
BLU to synchronisation
2:15 hrs
135 min
1:40 min
100 min
36 min
2:50 Hrs
170 min
1:35 Hrs
95 min
50 min
Best achieved
Parameters BLU to
Synch
2:00
1:48
0:58
3:30
2:10
0:54
2:05 Hrs
125 min
1:20 Hrs
80 Min
30 Min
3:50 Hrs
230 Min
3:20 Hrs
200 Min
30 min
4:20 hrs
3:00 Hrs
1:10 Hrs
6:40 Hrs
5:00 Hrs
300 Min
1:20 Hrs
80 Min
Synchronisation to Full
Load Operation
BLU to Full Load
400 Min
57
SDCS ( startup drain control system)

Wet Mode of operation like
drum boiler
Dry Mode Of Operation (> 35%
of load )
58
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59
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60
Advantages of Tube Mill

Advantages
High availability
Low running maintenance
Constant capacity and fineness
Hard & abrasive fuel ground
efficiency
Large reserve capacity of coal
Disadvantages
Fire fighting system is additional
No. Of auxiliary drives per mill are
more
High auxiliary power consumption
Prone for explosion
Cumbersome protection &
interlocks ( Purging/steam inerting
Etc)
Fast response over wide range of

load
Increased fineness at low load
and hence flame stability
Low air/coal ratio
Wide range of coal pulverized
Substantial flexibility
61
62
HVDC system
63
Special protection Scheme

INTERTRIP SCHEME DUE TO HVDC
POLE OUTAGES ( SPS 450)
One Pole Blocked and Ex Bus
Generation > 1750 MW.
Tripping of Unit # 6
Instantaneously.
Both Pole Blocked & Ex Bus
Generation > 550 MW
instantaneously
Tripping of Unit # 6 after 1 second
time delay
Tripping of Unit 4 after 2 Seconds
time delay
Both Pole Blocked & Ex Bus
Generation > 1100 MW
Tripping of unit # 5
instantaneously.
instantaneously.
Tripping of Unit # 4 after 2
Seconds time delay.
CONDITION
If HVDC power flow is more than 1600 MW
and both pose blocked.
If HVDC power flow is more than 1450 & less
than 1600 MW and both pole blocked. OR
HVDC power flow more than 1600 MW and
one pole blocked with remaining pole on
ground return mode.
If HVDC power flow more than 1300 MW and
less than 1450 MW and both pole blocked
.(OR) HVDC power flow more than 1450 MW
and less than 1600 MW and one pole blocked
with remaining pole on ground return mode.
If HVDC power flow is more than 1150 MW
and less than 1300 MW and both pole
blocked. (OR) HVDC power flow is more
than 1300 MW and less than 1450 MW and
one pole blocked with remaining pole on
ground return mode.
If HVDC power flow more than 1000 MW and
less than 1150 MW & both pole blocked. OR)
HVDC power flow more than 1150 MW and
less than 1300 MW and one pole blocked and
remaining pole on ground return mode.
ACTION
Unit # 5 will trip and unit
# 4 & 6 shall be unloaded
by 150 MW each.
Unit # 5 shall trip and
unit # 6 will be unloaded
by 150 MW.
Unit # 4, 5, 6 shall be
unloaded by 150 MW
each.
Unit # 4 & 6 shall be

unloaded by 150 MW
each.
Unit # 6 shall be
unloaded by 150 MW.
64
VFD FOR ID FANS

Variable frequency drive
with load commutated inverter.
3-ph
ac
dc
xmer
rect
inv
EFFICIENCY OF drive systems.

Fan speed
Fluid coupling
VFD
100%
85%
90%
75%
80%
65%
70%
56%
60%
46%
Synch motor
system
85%
84%
83%
82%
80%
5
65
ESP 1ST FIELD OUT OF SERVICE
66
2ND LARGEST THERMAL POWER PLANT OF NTPC
67
NTPC KANIHA 6X500 MW UNITS 68
Bag Filter DP Monitoring

DRY_WET-U#4
350
\\10.0.120.202\4PASSA_BF_DP
I/O Timeout
mmw c
\\10.0.120.202\4PASSB_BF_DP
6.3208
mmw c
\\10.0.120.202\4PASSC_BF_DP
I/O Timeout
mmw c
\\10.0.120.202\4PASSD_BF_DP
249.87
mmw c
\\10.0.120.202\4PASSA_VAC_TX2
\\10.0.120.202\4PASSB_VAC_TX1
\\10.0.120.202\4PASSC_VAC_TX2
\\10.0.120.202\4PASSD_VAC_TX2
300
250
200
150
100
50
0
2/1/2013 12:40:17 PM
1.33 days
2/2/2013 8:40:17 PM
Unit#4 PASS A BUFFER HOPPER BAG FILTER DP

Unit#4 PASS B BUFFER HOPPER BAG FILTER DP
Unit#4 PASS C BUFFER HOPPER BAG FILTER DP
Unit#4 PASS D BUFFER HOPPER BAG FILTER DP
69
Gas Screen Modification
Next Slide
70
Gas Screen Modification
71
Eco Hopper Temp Element

Fixing of Temp element at Eco
Hopper Adapter
Eco Hopper Temp at DCS system
Next Slide
72
73
74
MEGGERING OF ESP FIELD
75
TSTPS MILE STONES

U#1
U#2
U#3
U#4
U#5
U#6
1ST BOILER
LIGHT UP
02.10.94
22.11.95
11.09.02
05.07.03
18.01.04
27.09.04
SYNCHRONI
SATION
12.02.95
27.03.96
04.01.03
25.10.03
13.05.04
06.02.05
COMMERCI
ALISATION
01.01.97
01.07.97
01.08.03
01.03.04
01.11.04
01.08.05
76
UNIQUE FEATURES OF STAGE I UNITS

Tower type (single pass) , subcritical once through boiler .
Spiral & Vertical Water Wall combination for Evaporator.
Enthalpy control for evaporator flow control instead of drum
level control .
Sliding pressure operation combined with nozzle governed
turbine .
Advantage of quick start up and flexible load variation.
Special protections for once through boilers .
Double ended Tube Mills for fast load picking up ( Reject
Less Mill ).
SDCS ( Startup Drain Control System ) for unit startup & low
load operation .
High efficient ESP ( > 99.9 % ).
GCB in between generator & GT , thus avoiding the station
XFMR .
Concept of Plant Zero discharge implemented .
77
UNIQUE FEATURES OF STAGE - II
CENTRALISED CONTROL ROOM FOR ALL 4 UNITS OF STAGE II

FEEDING THROUGH HVDC LINK TO SOUTHERN GRID .
SPECIAL PROTECTION SCHEME SPS 450/1000
FURNACE DRAFT CONTROL BY VARIABLE FREQUENCY DRIVE FOR
ID FANS . ( 30 % power reduction)
GCB PROVIDED IN BETWEEN GT & GENERTAOR, AVOIDED STATION

XFMR .
VAPOUR ABSORPTION MACHINE FOR AIR CONDITIONING OF

CONTROL TOWER .
78
MAJOR ESP & ASH HANDLING SYSTEM

PROBLEMS EXPERIENCED AT TSTPS .
High FG volume loading (777 m3/sec 1050-1100 m3/sec).

Frequent outage of 1st & 2nd fields .
Failure of Hopper Heaters .(plate type)
Failure of Gas Screens , lower shock bar guide .
Ash Flowability from ESP hoppers .
Ash Buildup in ESP Hopper , Mal Operation of ESP level
probe .
Fluidizing blower outlet temp low .
More evacuation time in B&C pass .
1st hopper evacuation in dry mode .
FA system shutdown / Back log clearing was a problem
79

Paper 3 Operational Best Practices For ESP Performance Improvement

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TSTPS /KANIHA

Operational Best Practices for

6X500 MW UNITS , TSTPS , KANIHA

2ND LARGEST THERMAL POWER PLANT OF NTPC

Why ESP Performance Monitoring is important ?

Annual Overhauling schedule changed to 2 years .

ESP DESIGN DETAILS .

777.0( 533.48 Nm3/sec)

Inlet dust burden

81.303 ( Guran- 63.387)

Outlet dust burden

Gas inlet Temp

FA SYSTEM DESIGN DATA .

Dry ash facility

Wetting unit collection

Operational Best Practices at TSTPS to

Normal Operational Strategies For ESP

Inspection During Annual Overhaul ,

Testings Followed by Recommissioning of

Support insulator Heater , shaft Insulator heater healthiness checking ,

Testings Followed by Recommissioning of

Hopper Heater current check ,

During Planned Maintenance of ESP in Operating Units .

Whenever number of field goes out of service > 2-3 then

During unit start up shutdown .

GIST OF MAJOR MODIFICATIONS CARRIED OUT .

ESP online parameters data

Major evacuation monitoring data provided

ECO HOPPER EFFECTIVE EVACUATION

Checking Proper installation and operation of

Shutoff vacuum with air lock valve close.

Use of PI system in FA Evacuation Monitoring

Shutoff vacuum check with air intake closed

Economiser Hopper Evacuation temp Trend

Improper Evacuation From ESP Hoppers

Improper Evacuation From ESP Hoppers

Improper Evacuation From ESP Hoppers

Hopper Evacuation With out proper vacuum

U-4 A pass Evacuation deterioration

Indicates Empty Vacuum is increasing ,

Dry ash transportation trend

Line-2 Choking On 6-11-2012

Unit#5&6 ESP INST AIR HDR PRESSURE

Single Hopper Evacuation for long time

Single Hopper Evacuation for long duration

Shut Off Vacuum Check

IA Pressure Low in Unit 5&6

Unit#5&6 ESP INST AIR HDR PRESSURE

Trends of Proper FA Evacuation

Use of TEMPLATE for MHV operation checking

Thermostat Location Changed

New thermostat locations

Hopper/Casing manhole air ingress .

CASING MANHOLE AIR INGRESS

GD screen inspection & rectification ,

Ash Build up in Support Insulator Housing of U-3 ESP

Hopper /Casing manhole Doors , source

ESP Field Alignment check Before & After OH

ESP Field Misalignment

ESP Field Non Rapping side Lower Shock bar

VI characteristics check for all fields

Eco hopper TE Fixing

ADVANTAGES TOWER TYPE BOILER