BTL

Unit Trip date

No

Synchro
Date

1
2

26-04-2010 01-05-2010
11:53
05:15

BTL
Area

Outage
Cost
(crores)

6.36
2.42

113.37

34.01

6.65

130

05-05-2010 06-05-2010
Bottom
03:01
17:58
ring header

38.95

11.69

90

16-06-2010 22-06-2010
02:42
12:48

LTSH

154.10

46.23

54.45

165

8.82

4
5
6

03-07-2010 06-07-2010
07:13
01:33

Econo miser

66.33

19.9

11.5

149

16-07-2010 21-07-2010
18:10
04:23

LTSH

106.22

31.87

10

118.8

20-01-2011 23-01-2011
22:48
08:12

LTSH

57.40

17.22

110.5

4.12
5.97
3.45

FIN YR TOTAL

Mid RH

SD Oil Start Up
Outage hrs MU Lost
(kL) Oil (kL)

536.37

160.91 91.60 763.30

31.14

BTL
Unit
No

Trip
date

Synchro
Date

BTL
Area

08-05-2011 13-05-2011
23:26
05:25

LTSH

13-06-2011 16-06-2011
13:17
01:09

26-06-2011 01-07-2011
20:41
08:14

Water
Wall
Water
Wall

01-08-2011 05-08-2011
17:09
05:41

21-11-2011 25-11-2011
23:19
14:21
FIN YR TOTAL

Outage MU
hrs
Lost

SD Start Outage
Oil Up Oil Cost
(kL) (kL) (crores)

122

5.73

54.45

3.29

107.55 32.265 1.65 117.15

5.98

LTSH

84.53

25.36 1.65

99

4.74

LTSH

87.03

26.11 16.5

126

5.07

101.98 30.595 1.65

59.87

17.96

3.3

440.97 132.29 24.75 518.60

24.82

BTL
Unit
No

Trip
date

Synchro
Date

BTL
Area

Outage
hrs

MU
Lost

SD Oil Start Up
(kL) Oil (kL)

Outage
Cost
(crores)

18-04-2012 22-04-2012
Near IK 36 85.65
23:51
13:30

25.695

37.95

110.55

5.10

25-04-2012 27-04-2012
Water Wall 53.62
10:29
16:06

16.085

6.6

97

3.25

28-04-2012 03-05-2012
21:30
02:44

LTSH

101.23

30.37

6.6

112.6

5.72

03-05-2012 06-05-2012
12:43
13:52

LTSH

73.15

21.945

6.6

80.85

4.14

313.65

94.09

57.75

401.00

18.21

FIN YR TOTAL

FIN YR

NO OF BTL

TOTAL
OUTAGE
HRS

2010 11

536.37

2011 12

440.97

2012 13
(Till Date)

313.65

TOTAL

15

1290.99

TOTAL OUTAGE
COST

31.14
CRORES
24.82
CRORES
18.21
CRORES
74.17
CRORES

BTL
Unit Trip date
No

Synchro Date BTL Area

Outage Cost
(crores)

Preceding Trip
date

SD Cause

Outage hrs

Day
Difference

26-04-2010 01-05-2010
11:53
05:15

Mid RH

6.36

25-03-2010
23:03

Mid RH Tube
leakage

136.92

32

05-05-2010 06-05-2010
03:01
17:58

Bottom
ring
header

2.42

03-03-2010
19:13

Furnace Clinker
Formation

216.58

62

16-06-2010 22-06-2010
02:42
12:48

8.82

03-06-2010
10:47

Replacement of
40116 Isolator
contactor

4.95

13

03-07-2010 06-07-2010 Economise

07:13
01:33
r

4.12

13-05-2010
23:00

Furnace
pressure LL

6.58

50

16-07-2010 21-07-2010
18:10
04:23

LTSH

5.97

10-07-2010
13:28

Coal Shortage

30.32

20-01-2011 23-01-2011
22:48
08:12

LTSH

3.45

15-12-2010
13:38

DCS Power
Supply failure

63.93

36

1
2

LTSH

BTL
Unit
No
1

Trip date

Synchro
Date

BTL
Area

08-05-2011 13-05-2011
LTSH
23:26
05:25

13-06-2011 16-06-2011 Water

13:17
01:09
Wall

Outage
Preceding Trip
Cost
date
(crores)
5.73

3.29

26-06-2011 01-07-2011 Water

20:41
08:14
Wall

5.98

SD Cause

Outage
Day
hrs Difference

01-05-2011
00:54

Condenser
Tube Cleaning

80.82

22-05-2011
04:04

Low system
Demand

24.079

23-05-2011
14:14

Drum level
sensor malfunction

6.417

25-05-2011
21:59

1SB - 1PAB 6.6kV

Breaker Earth Fault
tripping

5.783

19

18-06-2011
19:04

DCS Communication
failure

4.95

21-06-2011
10:45

415 V Bus
failure

8
5
16
26

01-08-2011 05-08-2011
LTSH
17:09
05:41

4.74

16-07-2011
20:05

Furnace pressure
LL

6.583

21-11-2011 25-11-2011
LTSH
23:19
14:21

5.07

27-10-2011
09:37

Coal Shortage

144.4

8
22
21

BTL
Unit
No

Trip
date

Synchro
Date

BTL
Area

Outage
Preceding
Cost
Trip date
(crores)

18-04-2012 22-04-2012 Near

23:51
13:30
IK 36

25-04-2012 27-04-2012 Water

3.25
10:29
16:06
Wall

28-04-2012 03-05-2012
LTSH
21:30
02:44

5.72

03-05-2012 06-05-2012
LTSH
12:43
13:52

4.14

5.10

SD
Cause

Outage
Day
hrs Difference

FICF
16-04-2012
pressure 3.23
09:58
low
Exciter
10-03-2012
Brush
60.73
09:33
failure
Aux
25-04-2012
power
3.25
15:54
failure
BTL
25-04-2012
Water 53.62
10:29
Wall

46
3
8

MAKING BTL ZERO!!

REPLACEMENT OF WEAKENED TUBES / JOINTS AT
THE EARLIEST OPPORTUNITY, i.e. WHEN UNIT TRIPS
DUE TO SOME OTHER REASON
REGULAR MONITORING OF METAL TEMPERATURE
EXCURSION
REGULAR MONITORING OF METAL TEMPERATURE
AT LEAKAGE PRONE AREAS e.g. NEAR
SOOTBLOWERS

 THIS CALLS FOR AN ONLINE BOILER METAL

TEMPERATURE MONITORING SYSTEM THAT
WOULD ENABLE
24 X 7 BOILER TUBE METAL TEMPERATURE PROFILING
IDENTIFICATION OF TUBES ON THE VERGE OF
LEAKAGE.

ASLDs HELP ONLY AFTER THE TUBE LEAKAGE HAS

OCCURRED

To lower fuel cost, we change coal source

frequently resulting in frequent changes in
fuel quality. Differences in fuel cause
combustion changes that affect slagging
and soot deposition in the furnace.

The conventional sootblowing techniques relies

on employment of a large number of smaller
sootblowing systems, activated by the personal
discretion of the control engineer rather than
activation based on measurements.
The problems associated with a fixed schedule
blowing system:
1) Excessive blowing wastes steam
2) Insufficient blowing decreases efficiency
3) Unbalanced blowing may cause opacity
spikes.

Fouling and slagging in the furnace as well as in the

convective heat exchanger zone leads to a reduction
in boiler efficiency and reduction in availability such
as:
1) Increase of furnace backend temperature
2) Increase of attemperation rate
3) Damages in the hopper area and the wet/dry
bottom ash system as a result of big slag formations
falling down from the furnace walls or/and
superheater.
4) Unplanned boiler shut downs
5) Overcleaning damages tubes, affecting unit
availability

FOULING IN FURNACE AREA

ACCUMULATION OF COARSE ASH &

SLAG AT Bottom ash Hopper

Therefore the solution is to blow appropriate

sections of the furnace as needed.

THIS CALLS FOR INTELLIGENT OR

SMART SOOTBLOWING SYSTEM

SMART SOOTBLOWING LOGIC

source: EPRI

BENEFITS OF SMART SOOTBLOWING

Reduction of tube erosion

Reduction of usage of water
Reduction of attemperation spray rates
(extension of tube lifetime)
Reduction of backend temperatures.