Chandrapur Super Thermal Power Station : An ISO 9001, 14001 & OHSAS 18001 Unit

MAHAGENCO
Maharashtra State Power Generation Co Ltd
CHANDRAPUR SUPER THERMAL POWER STATION
(2340 MW)
An ISO 9001, ISO 14001 & OHSAS 18001 Unit
Chandrapur Super Thermal Power Station : An ISO 9001, 14001 & OHSAS 18001 Unit
MAHAGENCO
Maharashtra State Power Generation Co Ltd
Unit-5 Clinker Formation
June-07
C S T P S
A Giant in Generation
MAHAGENCO
Maharashtra State Power Generation Co Ltd
The Event
Set was withdrawn on 12/06/07 at 0937 Hrs due to the formation of clinker in
front & rear side of furnace up to 15 meters.
C S T P S
A Giant in Generation
MAHAGENCO
Maharashtra State Power Generation Co Ltd
The Event
11/06/07: 0830Hrs:- The set was running at an average load of
450MW with all operating parameters normal. Peep holes were
clear.
At 08:30 Hrs RH Metal temp increased to 600
0
C & at 08:47 Hrs coal
mill changed over from 5C to 5A.
Bottom Ash Evacuation started at 0850 Hrs as per regular interval of
2.5 Hrs.
At 0900 Hrs Furnace 9.0 Mtr peep holes on both sides observed
blocked by clinkers.
Bottom Ash Evacuation continued by ground unloading and poking.

C S T P S
A Giant in Generation
MAHAGENCO
Maharashtra State Power Generation Co Ltd
Contd
Clinker removal started by Poking and Water Jetting. Right hand
side clinker removed completely. Load reduction started at 09:35 Hrs
and kept at 400 MW to control ash accumulation.
Load further reduced at 10:00 Hrs to 330MW.
At 10:40 Hrs Load kept at 300MW, simultaneously Left hand side
clinker removal was in progress by poking and jetting.
Unloading of bottom ash on ground was continued.
Total coal flow reduced from 340 to 235 T/Hr.
O2% maintained at more than 5.5%.
Continuous clinkering observed inspite of poking & jetting.
Set withdrawn on 12/06/09 at 0937 Hrs.
C S T P S
A Giant in Generation
MAHAGENCO
Maharashtra State Power Generation Co Ltd
Year Unit-5 Unit-6 Unit-7 Total
1993-94 0.75 * 157.871 * 157.871
1995-96 5.234 * 1.341 * 6.575
1996-97 2.442 * N I L 2.442
1997-98 2.984 * 2.222 * N I L 5.206
1998-99 3.084 0.901 0.252 4.237
1999-00 1.032 * 16.456 *** 6.598 * 24.086
2000-01 5.973 * 5.794 7.708 ** 19.475
2001-02 8.520 5.313 * 25.184 *** 39.017
2002-03 0.100 28.085 ** 3.276 31.461
2003-04 58.149 * 4.222 * 2.990 65.361
2004-05 60.880 * 27.184 * 3.974 92.038
2005-06 1.962 20.322 * 1.306 23.590
2006-07 0.564 9.682 0.499 10.745
2007-08
(till 25-06-07)
136.116 * 34.377 * 0.364 170.857
Total 287.790 313.770 52.151 652.961
Generation Loss (Mus) due to Clinkers problem since
commissioning :
*
: shows no. of event of tripping / outages in that year.
C S T P S
A Giant in Generation
MAHAGENCO
Maharashtra State Power Generation Co Ltd
Coal Bunkered : Quantity Initial Ash Deformation
on 10/06/07 MT Temp (Deg C)
Ballarpur 255 NA
Wani - Rajur (Washed) - 3680 NA
Track Hopper (Ghugus) - 3042 1220
Reclaimed (ordinary)- 305 NA
Coal Bunkered : on 11/06/07

Majari - Chargaon 1923 NA
Wani - Rajur (Washed) - 843 NA
Temperature inside the furnace was of the tune of 1300
O
C as per routine
furnace temp mapping reports, which exceeds IDT of 1220
O
C

C S T P S
A Giant in Generation
MAHAGENCO
Maharashtra State Power Generation Co Ltd
Sketch showing Front & Side view of the Clinker
Side View Front View
C S T P S
A Giant in Generation
MAHAGENCO
Maharashtra State Power Generation Co Ltd
Date Work carried out
Man -
power
Remark
11/06/07
to
12/06/07
1. Clinker removal from all four ash
gates.

2. Clinker removal from 9.0 Mtr
peep holes.
12
nos.

12
nos.
Clinker on RHS at 9.0 Mtr
level and above ash gates
was removed.
LHS clinker removal
continued.
12/06/07
to
14/06/08
1. Breaking of clinker from 9.0 Mtr
peep hole & manhole LHS
continued.
2. Refractory doors of bottom ash
hoppers on both sides opened to
facilitate removal.
3. Three manholes on LHS made by
cutting water-wall tubes.
25nos


6 nos


5 nos
Clinker breaking by water
jetting & spears in progress
on all three fronts from
outside.
Details of Clinker Removal Work :
C S T P S
A Giant in Generation
MAHAGENCO
Maharashtra State Power Generation Co Ltd
Date Work carried out
Man -
power
Remark
Details of Clinker Removal Work :
15/06/07
to
16/06/09
1. Breaking and removal of clinkers
from front, rear wall and LHS water-
wall.
2. Erection of Sky-climbers for
clinker removal
30 nos


10 nos
Sky climber, pneumatic
concrete breaker, spears
utilized and work was in
progress inside the furnace.
Average rate of clinker
removal - 60 to 70 Tons/Day
17/06/07
to
22/06/10
1. Breaking and removal of clinkers
from all three sides of water-wall.
2. Removal of clinker from Bottom
Ash Hopper refractory doors (LHS &
RHS)
40 nos

30 nos

Last piece of clinker was
removed at 3:00 Hrs on
22/06/07 from neck portion
All clinkers from Bottom ash
hopper removed by 15:00
Hrs on 22/06/07
C S T P S
A Giant in Generation
MAHAGENCO
Maharashtra State Power Generation Co Ltd
View of Clinker at Neck
Photograph taken from 9.0 meter peep hole (RHS) after partial removal of clinker
C S T P S
A Giant in Generation
MAHAGENCO
Maharashtra State Power Generation Co Ltd
Clinker Removal in progress
C S T P S
A Giant in Generation
MAHAGENCO
Maharashtra State Power Generation Co Ltd
Clinker Removal in progress
C S T P S
A Giant in Generation
MAHAGENCO
Maharashtra State Power Generation Co Ltd
Observations of Furnace :
Furnace is always bright up to Divisional panel.

Furnace temperatures recorded are always in the range of
1250 to 1350 Deg C. (As per regular furnace temp mappings).

At 9.0 Mtr peep holes, lot of luminous masses like loose sand
clinkers are visible falling continuously.
C S T P S
A Giant in Generation
MAHAGENCO
Maharashtra State Power Generation Co Ltd
Practice Adopted to Avoid Clinkering :
The O2% at economizer outlet increased to 4 4.5%, whenever clinkering
problem sensed (Increased rate of Falling of clinkers seen through 9.0 Mtr peep
holes).
The mill fineness is monitored and maintained at 70% through -200 mesh and
less than 1.5% retained over 50 mesh.
Furnace temp mapping, SADC position & coal air mixture temp is regularly
monitored.
Selective wall soot blowing is carried out as per the furnace temp mapping
report and spray levels.
Coal flow restricted to 340 T/ Hr against design 299 T/Hr.
Bottom Ash Evacuation is carried out after every 2.5 Hrs as against
recommended of once in 8 hrs.
Ground unloading of Bottom Ash is done in the event of poor grinder
discharge.
Regular pressure setting of wall Soot Blowers is done.
Coal Mill Performance is monitored through D.P.T. and C.A.F. Tests.
C S T P S
A Giant in Generation
MAHAGENCO
Maharashtra State Power Generation Co Ltd
Conclusion :
Lower ash fusion temp of the fired coal than furnace temp maximizes
shrinkage rate causing slagging and clinkering in furnace (As indicated in
technical report 2004 by BHEL.
The sand content in coal is primarily the cause for slagging and
clinkering. The sand has Iron impurities to the tune of 15% because of
which ash fusion temperature decreases to 1187
O
C and shrinkage rate
maximized at temp above 1250
O
C (As indicated in technical report
2004 by BHEL).
Firing of lower CV coal than design resulted into more quantity of coal
firing, which in turn increased the furnace ash load and temperature.
C S T P S
A Giant in Generation
MAHAGENCO
Maharashtra State Power Generation Co Ltd
Recommendations :
Use of good quality coal of design CV of 3750 Kcal/Kg and low ash
content.

The coal analysis to be carried out regularly to understand
combustion pattern and to optimize it.

To Ensure the fail safe operation and position indication of Burner
(i.e. matching coal / air bucket position from inside & outside) before
Boiler Light up during Unit Overhaul.
C S T P S
A Giant in Generation
MAHAGENCO
Maharashtra State Power Generation Co Ltd
Thanks