S Banerjee Thermal Power Plant Performance Improvement Using Quality Initiatives 1.unlocked

Thermal Power Plant Performance
Improvement using Quality Initiatives
NTPC Ltd : Powering Indias Growth

Outline
NTPC Ltd.'s overview
Vindhyachal Super Thermal Power Plants Overview
Six Sigma
Why is six sigma needed for Indian Power Sector
Boiler Performance Optimization using Six Sigma
Reduction in Auxilliary Power Consumption using six sigma.





A HUMBLE
BEGINING
Foundation Stone Laying

12.11.82
The first signboard comes up

5.08.82


Powering Peoples Progress (Generation)
20000
GENERATION (BUs)
19500
19000 19707.7
18500
18000 18305
17500 17820.8
17000
16500 16354
16000
FY 03-04 FY 04-05 FY 05-06 FY 06-07

Continuous Improvement in Process & Efficiency (PLF %)

100
PLF (%)
95 92.46 92.73
90.01
90
85 82.38
80
FY 03-04 FY 04-05 FY 05-06 FY 06-07
PLF


PLANT PERFORMANCE IMPROVEMENT USING QUALITY INITIATIVES
Improvement in Performance Parameters

Improvement in business processes (systems)
Cost Optimization
MUDA (Waste) Reduction
Development of World-class spare parts & service providers

WHAT IS THIS SIX SIGMA ?
A Philosophy Disciplined & structured data

driven problem solving
approach.
All about reducing deviations

(mistakes) in all that we do.
A Business Strategy Good quality reduces cost

Heat
Rate Boiler/
Cost Effective
Generation
Turbine
Cost Effective Generation depends broadly on :-
Unit Heat Rate RAH Seals/
Boiler Performance
Optimization
House Pent House/ Basket
ESP
Optimization
of
1) Optimizing Heat Rate
RAH Performance
Eff./ Seals
House
Optimization
Quality of House
2) Reducing
#1 Auxilliary
QualityPower Consumption
of House
Quality of
#2
3) Reducing operation & maintenance (O&M) costs Quality
.
#3
#4
Key Functional Key Generation Key Component Key Process

Requirements Processes Characteristics Variables

Team Vindhyachal receiving National Quality
Thermal PowerAward from H.E.
Plant Performance
Improvement
President of India for PIP on CW using
duct painting in Quality
stage I Initiatives
units
Process
Sweet fruits limitations
Six Sigma
Methodology
Bulk of fruits Problem of erosion in radiant super heater placed

Process characterization in water wall soot blower area of stage I, 6 x 210
MW units.
and optimization including PDCA
Problem of vibration in the cooling fan NDE
Low hanging fruits bearing of ID fans in stage I.
Simple QC tools
Problem of damage of rapping motor shaft in ESP
of Stage I.
Logic and intuition
Problem of ingress of dust in the PA fan bearing of
Quick hits-Kaizen stage I.
Brainstorming etc
Platform on safety v/v floor is in unsafe condition
NTPC Ltd
in :stage
Powering
I. (5S) Indias Growth


3% 5% 10% 37% 45%

Stack Auxiliary Stack Electricity Rejected Heat to
Clean-up Power Losses Production Cooling
Equipment Water/ Cooling
Tower

PAPH B
PAPH
FLUE GAS FLOW DIAGRAM O/L TEMP
145 0C
H E
D SAPH B
L P O E C
I R SAPH B
F H L R C O
V E O/L TEMP
U S A I O N 160 0C
I H Z 549 N. O 365
R S 960 T 846 E 750 M
N I E O 1
944 A I SAPH A
A O 964 N 810 N 606 & 379 O/L TEMP
T T S
C R N 2 164 0C
E A E
E H A S
R L R SAPH A
S L H
S
H 3 SAPH B
O/L TEMP
145 0C PAPH A

Problems Faced
More convective flow less retention of heat in 1st pass.

Less heat absorption in 1st pass due to Slagging.
Less heat absorption in super heater and re heater area
due to dirtiness in the area ,clinkering formation in radiant
zone.
Improper secondary damper position.
Poor performance of air preheater and its air ingress.

2nd pass LRSB ARE DIVIDED INTO

111 119
A- S/H Right R/H Left

113 121
123
B- S/H R/H Right And 2nd Pass
115 125 127
117
C-2nd Pass Only
129 D- S/H Right And R/H Left

109
133 131
107
105 137 135
BOILER RHS LRSB LRSBs : Long Range Retractable Soot Blowers

Box plot showing the best results for the LRSB A

Individual Value Plot of C15 vs C14 Boxplot of C15 by C14
590 590
580 580
570 570
C15
C15
560 560
550 550
540 540
A B C D A B C D
C14 C14

111 119 Boiler RHS Red

Coloured LRSBs were
121
113 selected based on
123
results of Analysis of
115
12 127 Variance (ANOVA)
117
5
12
109 9
133 131
107
105 137 135
BOILER RHS LRSB LRSBs : Long Range Retractable Soot Blowers

120 112
122 114
Red Coloured
128 12 LRSBS are
6 116
124 in Reheater Area
118
130
132 134
110
136 138 108
106
BOILER LHS LRSB LRSBs : Long Range Retractable Soot Blowers

Box and Individual plot

Boxplot of SAPBox
HAO/LBPlot
EF, SAPHAO/LAFT Individual
Individual ValuePlotof SAPHAValue
O/LBEF, SAPlot
PHAO/LAFT
170 170
165 165
160 160
Data
Data
155 155
150 150
145 145
140 140
SAPHAO/LBEF SAPHAO/LAFT SAPHAO/LBEF SAPHAO/LAFT


Auxilliary
Power
Boiler/
Cost Effective
Reduction
Generation
Turbine
House Unit Heat Rate FD/ PA/ ID
Boiler Performance
Optimization
Cost Effective Generation depends broadly on :-TIGs/ Hot
Fans/Mills
of
PA Fan Performance
Optimization
House Air Lkg/
Quality
1) Optimizing Heat of
Rate
Optimization
Impeller
House
#1 Quality of House
2) Reducing Auxilliary Power Consumption
Quality of
#2
Quality
# 3
3) Reducing operation & maintenance (O&M) costs.
#4
Key Functional Key Generation Key Component Key Process

Requirements Processes Characteristics Variables

Project CTQs Auxiliary

AuxiliaryPower
PowerConsumption
Consumption
Big
BigYY reduction
reduction
Project
ProjectYY11 BFP
BFPpower
powerconsumption
consumption
Project
ProjectYY22 ID
IDFan
Fanpower
powerconsumption
consumption
Process
Processdrill
drilldown
down Project
ProjectYY33 PA
PAFan
Fanpower
powerconsumption
consumption
Project
ProjectYY44 FD
FDFan
Fan power
powerconsumption
consumption
Project
ProjectYY55 Mill
Millpower
powerconsumption
consumption
Project
ProjectYY66 CW
CWPump
Pumppower
powerconsumption
consumption
Project
ProjectYY77 CEP
CEPpower
powerconsumption
consumption

High Level Process Map
S I P O C
Supplier Input Process Output Customer
Key Questions
What is included/excluded in the
PA fans Bowl Mills Stack out scope of this project?
Includes:
Unit
Unit HT
HT System
System
FD fans Boiler ESP ID Fans Excludes:

LT
LT System
System &
& Offsite
Offsite Load
Load
Flue gas path What is the Unit, Opportunity,

Defect?
HT
HT Amp
Amp >> 1800
1800 amps
amps would
would be
be defect.
defect.
Has this process map been

validated by key people?
Steam-water cycle
Process
Process map
map validated
validated by
by Champion
Champion &
&
CEP Heaters BFP Heaters Process
Process owners
owners
Super Boiler
Condenser Turbine heater High level process
map done
CW Pump Generator GT GRID
Cooling water
out NTPC Ltd : Powering Indias Growth
Identify Sources of Variation

Pareto Chart For APC
2000
100
1500
80
APC Share
Percent
60
1000
40
500
20
0 0
Equipments BFP CW ID Fan PA Fan FD Fan Mill Other
Count 654.3 331.6 287.3 183.7 174.3 127.7 40.6
Percent 36.4 18.4 16.0 10.2 9.7 7.1 2.3
Cum % 36.4 54.8 70.8 81.0 90.6 97.7 100.0

Identify Major Sources of Variation
3
3
Potential Failure Modes Effect Analysis - BFP
When? What? Result? Why? Existing Sev Occ Det RPN How Prevent? Who?
Process Potential Failure Potential Potential Cause Controls Mitigants Responsibility
Step Effects
BFP Passing from 5F1,5F2 & High Worn out seat To be attd. 6 10 5 300 1) L/S Adjust. on closing TMD+Opn*
C/V amp & others in O/H 2) Manual Tight., if possible
BFP Reduced Motor Efficiency High Continuous Motor O/H 2 4 5 40 To be attd.in O/H EMD
amp Service
BFP Passing from R/C V/V High Worn out seat To be 6 10 5 300 1) L/S Adjust. on closing TMD+Opn*
& D/V NRV not holding amp & others attd.in O/H 2) Manual Tight., if possible
BFP Passing from 421 V/V High Worn out seat To be 7 8 5 280 1) L/S Adjust. on closing TMD+Opn*
(Manual+Motorised) amp & others attd.in O/H 2) Manual Tight., if possible
BFP Passing from 605,607 & High Worn out seat To be 4 6 5 120 1) L/S Adjust. on closing TMD+Opn*
C/V V/V amp & others attd.in O/H 2) Manual Tight., if possible
BFP Passing / Opening from High Worn out seat 1) L/S Adjust. on closing TMD+Opn*
514 A & B V/Vs amp &/or Passing To be 5 10 5 250 2) Manual Tight., if possible
from 5A1,5A2, attd.in O/H
140/6 C/V
BFP Passing from 29/14 High Worn out seat To be 1) L/S Adjust. on closing TMD+Opn*
Spray V/Vs amp & others attd.in O/H 3 6 5 90 2) Manual Tight., if possible
BFP Passing from 3rd stage High Worn out seat To be 1) L/S Adjust. on closing TMD+Opn*
V/V (S/B BFP) amp & others of S/B attd.in O/H 3 6 5 90 2) Manual Tight., if possible
BFP 3) Change the BFP conbin.
BFP Low Pump High Worn out Pump O/H 5 10 5 250 1) Combination Change TMD
Efficiency amp cartridge (AC / BC)
2) To be attd.in O/H
BFP Higher DP across FRS High Slightly higher Regularly 5 10 5 250 Experiment regularly to Operation
amp NTPC Ltd : Powering Indias Growth
flow require. optimize DP +
C&I*+TMD
Decide Focus Area ?

High Priority / Focus
BFP
ID Fan
Impact on conversion
PA Fan
FD Fan
Mill
Low
Difficult Easy
Ease of implementation

Control Summary
Control/Response
Control/ResponsePlan
PlanHighlights
Highlights Benefits
Benefitsof
ofProject
Project
When HT equip. amp goes up steeply, Direct Saving.

all associated V/Vs being checked. Conservation of Coal.
Lesser Environmental Pollution.
PA Fans being regularly checked for hot Better CSR Practices & other intangible
air leakage. benefits.
Boiler & ESP man/peep holes being Communication

Communication&&Translation
Translation
checked regularly for any passing.
Informed to operational staff.
Future control plan prepared for arresting Communicate project results with
APC further. operating staff and process owner.
Communicate results to HOD

Control Charts of APC Before & After Project

Before
After

FMEA Analysis for Current Window of Opportunity
When? What? Result? Why? Existing Sev Occ Det RPN How Prevent? Who? Sev Occ Det New
Process Potential Failure Potential Potential Cause Controls Mitigants Responsibility RPN
Step Effects
Passing from High Worn out To be 6 10 5 300 1) Change V/Vs TMD 6 10 5 300
BFP
5F1,5F2 & C/V amp seat & others attd.in O/H 2) L/S Adjust. on +Opn*
closing
BFP Passing from High Worn out seat To be 4 6 5 120 1) L/S Adjust. on closing TMD+O 3 6 5 90
607 &C/V amp & others attd.in O/H 2) Manual Tightening pn*
BFP D/V NRV +3rd High Worn out To be 6 10 5 300 1) L/S Adjust. on TMD+O 6 10 5 300
stage spray amp seat & others attd.in O/H closing pn*
v/vs not
holding
2) Manual Tightening
BFP Higher DP High Slightly Regularly 5 10 5 250 Experiment regularly Opn,C&I 5 10 5 250
across FRS amp higher flow to optimize DP TMD
require.
PA TIGs in Open/ High Improper As and Mill labours to be discouraged Opn.

from keeping it in open condi.
Fan Struck up Curre Practices by when 3 10 5 150 2 10 5 100
& Struck up condition to be att
Condition nt Mill area lab. needed on pri & Mois. draining
PA Hot Air High Aging/ Imp. During To be attended at first BMD

Maint./ Opportunity
Fan Leakage Curre 4 10 5 200 opportunity. R/P 3 10 5 150
Expansions
nt
Mill Improper Higher Maintenance Roller 1) By effectively screening BMD Mill
Rollers Setting Amps Fault/Foreign Setting foreign material CHP
3 9 5 135 3 9 5 135
Material 2) During Opportunity
ID Various Higher Mech During 1) Regular Checking BMD

Damage/Expansio
Fan Leakages Amps Opportunity 5 10 5 250 2) To be attd.in O/H R/P+P/P 3 10 5 150
n/ Maintenance
Prac or in O/H 3) During Opportunity
ID Peepholes/ Higher Mech Regular 1) Regular Checking BMD+

Fan Manholes Amps NTPCOpportunity
Damage/Expa Ltd
Checking/:orPowering
4 10 5 India
200 s2) Growth
To be attd.in O/H Opn. 3 10 5 150
Passing nsion in O/H 3) During Opportunity
Bottom-line is..


S Banerjee Thermal Power Plant Performance Improvement Using Quality Initiatives 1.unlocked

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Thermal Power Plant Performance

Improvement using Quality Initiatives

NTPC Ltd : Powering Indias Growth

NTPC Ltd.'s overview

Vindhyachal Super Thermal Power Plants Overview

Why is six sigma needed for Indian Power Sector

Boiler Performance Optimization using Six Sigma

Reduction in Auxilliary Power Consumption using six sigma.

NTPC Ltd : Powering Indias Growth

NTPC Ltd : Powering Indias Growth

NTPC Ltd : Powering Indias Growth

NTPC Ltd : Powering Indias Growth

NTPC Ltd : Powering Indias Growth

Foundation Stone Laying

The first signboard comes up

NTPC Ltd : Powering Indias Growth

NTPC Ltd : Powering Indias Growth

Powering Peoples Progress (Generation)

NTPC Ltd : Powering Indias Growth

Continuous Improvement in Process & Efficiency (PLF %)

NTPC Ltd : Powering Indias Growth

NTPC Ltd : Powering Indias Growth

PLANT PERFORMANCE IMPROVEMENT USING QUALITY INITIATIVES

Improvement in Performance Parameters

NTPC Ltd : Powering Indias Growth

WHAT IS THIS SIX SIGMA ?

A Philosophy Disciplined & structured data

All about reducing deviations

A Business Strategy Good quality reduces cost

NTPC Ltd : Powering Indias Growth

Key Functional Key Generation Key Component Key Process

NTPC Ltd : Powering Indias Growth

Bulk of fruits Problem of erosion in radiant super heater placed

NTPC Ltd : Powering Indias Growth

NTPC Ltd : Powering Indias Growth

3% 5% 10% 37% 45%

NTPC Ltd : Powering Indias Growth

NTPC Ltd : Powering Indias Growth

More convective flow less retention of heat in 1st pass.

NTPC Ltd : Powering Indias Growth

2nd pass LRSB ARE DIVIDED INTO

A- S/H Right R/H Left

129 D- S/H Right And R/H Left

105 137 135

BOILER RHS LRSB LRSBs : Long Range Retractable Soot Blowers

NTPC Ltd : Powering Indias Growth

Box plot showing the best results for the LRSB A

NTPC Ltd : Powering Indias Growth

111 119 Boiler RHS Red

105 137 135

BOILER RHS LRSB LRSBs : Long Range Retractable Soot Blowers

NTPC Ltd : Powering Indias Growth

BOILER LHS LRSB LRSBs : Long Range Retractable Soot Blowers

NTPC Ltd : Powering Indias Growth

Box and Individual plot

NTPC Ltd : Powering Indias Growth

NTPC Ltd : Powering Indias Growth

Key Functional Key Generation Key Component Key Process

NTPC Ltd : Powering Indias Growth

Project CTQs Auxiliary

NTPC Ltd : Powering Indias Growth

FD fans Boiler ESP ID Fans Excludes:

Flue gas path What is the Unit, Opportunity,