Measures and Equipment for Optimal Efficiency
at Thermal Power Stations
January 30, 2015 Japan Coal Energy Center (JCOAL)
International Seminar on
"Implementation of PAT Scheme in Thermal Power Stations - Issues and Challenges“
India Habitat Centre
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1. Profile and Activities of Japan Coal Energy Center (JCOAL)
2. O&M Practices and Effective Solutions for BOP Systems, Kyushu Electric Power Co., Inc.
3. Coal Quality Evaluation System(CQES), Idemitsu Kosan Co., Ltd.
4. Numerical Simulation of Pulverized Coal Combustion, Idemitsu Kosan Co., Ltd.
5. Summary
Overview
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1. Profile and Activities of Japan Coal Energy Center (JCOAL)
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Japan Coal Energy Center (JCOAL)
• Established as a foundation in 1990, with its origin back to 1948
• Covers all coal related issues from upstream to downstream of the coal chain
• Members: 119 incl. major public-listed companies and main players in energy and relevant sectors
• Supervision by METI (Ministry of Economy, Trade and Industry of Japan)
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Exploration
Facilitation and promotion of cleaner utilization of coal
Mining & Preparation
Coal utilization technology development
Upstream Activities CCT Transfer Program on coal preparation Technologies
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CCT transfer project on coal preparation technology Coal preparation technology was set as the main topic of technology
exchange in India considering the importance of high ash coal processing. 1,305 trainees were invited to Japan including 150 Indian experts by the
end of JFY2011 Technology exchange programs dispatching Japanese experts to target
countries were also commenced
Vari-Wave Jig (KCM) Control panel (KCM) Port facilities (Kushiro) Dry separation facility (Nagata Eng.) High efficiency coal preparation plant in Odisha
High efficiency coal preparation plant has been commissioned on July 25th, 2014 in Angul, Odisha using latest vari-wave jig technology with a capacity of 350t/h.
Source: NEDO website
The Project on Efficiency and Environmental Improvement of Coal fired Power Stations
A MOU of Pre-primary Study of Efficiency and Environmental Improvement of Coal-fired Power Stations was signed on April 30, 2010, in the presence of Deputy Chairman, Planning Commission of India, and Minister of Economy, Trade and Industry of Japan. Diagnostic activities for two (2) state owned, one (1) NTPC owned TPS
Durgapur
Unchahar
Badarpur
2010, 2011 Wanakbori
2010 Ramagundam
2011 Kahalgaon
2010, 2011, 2012 Dr. Narla Tata Rao
(Vijayawada)
A MOU for the Project on Efficiency and Environmental Improvement of Coal fired Power Station was signed on June 11, 2012. Diagnostic activities for Durgapur of DVC, Unchahar & Badarpur of NTPC; all of which were referred to in the Joint Statement on the occasion of the 6th Japan-India Energy Dialogue between the Ministry of Economy, Trade and Industry of Japan and the Planning Commission of India on October 10, 2012. CCT workshop in Delhi
2011
2012
Diagnostic activities for two (2) state owned, one (1) NTPC owned TPS R&M Workshop in Delhi
2010
2013
Follow up activities for all TPS are ongoing for all diagnosed TPS. CCT Transfer program for the delegates from India power sector was carried out. CCT workshop in Delhi 6
Typical Example of R & M Proposal
COAL
P Air S Air
Feed Water Heater
SH Steam
RH Steam
Steam Turbine Generator
Cooling Tower
Stack Condenser
ESP IDF
PAF
FDF
Mill
Boiler
Feed Pump
Air Pre-Heater
Fly Ash Bottom Ash
Coal Bunker
Coal Yard
Ash Pond ※
※
Transformer Circuit Breaker
Plan-A:LE Replacement of worn parts only
Plan-B:R&M Replacement of worn parts + Reuse of casing, replacement of HP,IP,LP turbine, D-EHC improvement and ESP rehabilitation
Plan-C:R&M Plan-B+ generator improvement Plan-D:R&M Plan-C+ condenser and feedwater heater improvement
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Mitsubishi Hitachi Power Systems, Nagasaki Works ( 31st Oct. ) J-POWER, Isogo TPS
( 30th Oct., 3rd Dec.)
J-POWER Tachibanawan TPS ( 04th Nov. )
CCT program - Site Visit -
Open-Ended Meeting Embassy of India
Mitsubishi Hitachi Power Systems, Hitachi Works (4th Dec.)
Joban Joint Power Company Nakoso IGCC (5th Dec.)
Chubu Electric Power, Hekinan TPS ( 8th Dec.)
Idemitsu Coal & Environment Research Laboratory, Idemitsu Bulk Terminal ( 26th Sept.) Toshiba Keihin Work ( 25th Sept. )
J-POWER Takasago TPS ( 29 Sept. )
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9 9
Discussion -Topics- Issues around
materialization of R&M Efficiency
Improvement through enhancement of O&M Coal blending as one of
the key measures for domestic coal shortages
Group1 R&M Group2 USC1 Group3 USC2
Possible barriers for Japanese players to work for India power sector
Issues around materialization of Proposed New Project
Technical Target and/or Guideline for
introduction of USC
Road map for high efficiency advanced technology
2. O&M Practices and Effective Solutions for BOP Systems, Kyushu Electric Power Co., Inc.
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Supply Facilities
Hydro142places3,582MWPumpedStorage3places2,300MW ※
Coal3places2,460MW Thermal9places10,680MW LNG2places4,090MW ※
Geothermal6places212MWOil5places4,130MW Nuclear2places5,258MW ※
Thetotalofplacesdoesnotmatch, becausetheunit1ofKaritapower
Internalcombustion34places399MWstationiscountedascoalandthe
unit2iscountedasoil.
Wind2places3MW Solar1places3MW
(asofMarch31,2013) Total196places20,137MW
Establishment May1,1951 Paid-inCapital 237.3billionyen #ofShareholders 174,293
#ofSharesIssued andOutstanding 474,183,951
#ofContracts Lighting:7.69million Power:0.93million
#ofEmployees 13,102
IT/telecom
Electricity Sales Volume
Specific-
83.8 billion kWh
Kyushu Electric Power Co., Inc.
Breakdown of Electricity Sales Volume (FY2012)
Domestic Share of Electricity Sales Volume (FY2012)
(Lighting 35.2%)
Other than Specific-scale demand 41.4% (Power
scale demand 58.6% Customers under Liberalization 6.2%) Over 6,000V , 50kW
Tokyo 31.6%
Tohoku 9.1% Kyushu 9.8%
Other 17.9% Domestic Share
of Electricity Sales Volume (10EPCOs)
851.6billion kWh Kansai Chubu 16.6% 14.9%
Consolidated Sales (FY2012) Other 5.6% 1.6%
Energy- related 9.5%
Consolidated Revenue \1,545.9billion Electricity 83.3%
KYUSHU‐EPCO Profiles
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Kyushu Electric Power Co., Inc.
Exchange Program with NTPC In Feb. 2007 The signing ceremony of exchange agreement with NTPC
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Kyushu Electric Power Co., Inc.
In Nov. 2012 ATTEND 5th INDIA POWER AWARD
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Kyushu Electric Power Co., Inc.
J‐COAL Study Diagnosis work NTPC Unchahar PS in FY 2012 Diagnosis Purpose Improving plant efficiency of coal fired thermal power station for effective utilization of coal and reducing environmental load
Schedule Site survey : 2012. 12. 11 – 12. 14 (at Unchahar PS) Presentation : 2013. 3. 11 (at Unchahar PS)
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Maintenance
Preventive Maintenance
Breakdown Maintenance
Time Based Maintenance Condition Based Maintenance
Emergency Maintenance Ordinary Corrective
Categorized Equipment Maintenance Management Periodic Inspection
Aging Equipment Inspection
Maintenance ・High Plant Availability possible through Preventive Maintenance ・Higher economic efficiency requires shift to Condition Based Maintenance Kyushu Electric Power Co., Inc.
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Kyushu Electric Power Co., Inc.
Periodical maintenance Maintaining thermal efficiency
Introduction of high‐ efficiency equipment Improvement of thermal efficiency
Improvement of thermal efficiency
How to Keep High Availability, Efficiencies, Clean ? Improvement Concept of thermal efficiency Grasping periodically the facility performance Economic evaluation
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Sche
dule
d M
aint
enan
ce S
yste
m
Inspection and replacement Annual/Long-term Maintenance program Maintenance Standards Categorize maintenance activities into - TBM (Time-based Maintenance) - CBM (Condition Based Maintenance) - BM(Breakdown Maintenance) based on analysis of past problems and judgment criteria Introduced into Matsuura PS in 2004 and Reihoku PS in 2006 Kyushu Electric Power Co., Inc.
Concept of Equipment Maintenance Management Maintaining power supply Availability
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Plant Life Cycle Maintenance ▽50 ▽Operation Start ▽20∼25 Years
Target of Plant Life Time (50YEARS) Daily maintenance/Periodical maintenance
Replace Plan Initial failure Long Term Maintenance Plan Condition Monitoring R&M LTE Work
Procedure of Long Term Maintenance Plan Select Target Items with O&M conditions Planning of Diagnosis methods ,Sample No(SN) Tools (Online/Offline), Cost, Timing, etc. Data acquisition and analysis of representative point and trends analysis Predict and Judgments for R&M/LTE Work with Experimental Criteria Readjustment of Period of measures, SN Planning of next timing of monitor (Off line) Kyushu Electric Power Co., Inc.
Target items for Overhaul or Replacement Steam Turbine (HP,IP), Cylinders (inner/outer) Major Valves for Steam Turbine (MSV,RSV) FW Heaters Air Pre Heater, Gas Heater (APH/GGH) Electrostatic Precipitator (ESP) Generator (Stator/Rotor) Transformers HV Motors Control Systems
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Seco
ndar
y su
perh
eate
r
Terti
ary
supe
rhea
ter
Bur
ner n
ozzl
e
Boi
ler
Bur
ner n
ozzl
e
Sile
ncer
New soot blower (4 (drum left) + 4 (drum right) = 8)
Kyushu Electric Power Co., Inc.
1. Washing the boiler generating surface 2. Primary superheater soot blow executed (Measure for abrasion due to pressure reduction of injection steam) Soot blower
3. Economizer soot blower newly built 4. Washing the air preheater element and replacing the defective element Induced draft fan
Chimney Electric dust collector
Remarks Polluted by ash, etc. Run soot blower (9 (drum left) + 9 (drum right) = 18) Run/stop soot blower (4 (drum left) + 4 (drum right) = 8)
Quaternary superheater Re- heater
6. Burner nozzle automatic operation 5. Repairing steam leakage of steam type air preheater
Primary superheater Economizer Air preheater
Forced draft fan Steam type air preheater
Improvement typical Measures for Boiler
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Kyushu Electric Power Co., Inc.
Improvement of high‐pressure turbine aged deteriorated part ・Replacing seal fin, etc. ・Removing scale, etc.
Measures for low‐pressure turbine ・Moving blade and stationary blade newly made. Fin installed on moving blade. ・Replacing the diaphram ・Replacing the inner casing
Improvement typical Measures for Turbine Outer casing Inner casing Turbine rotor
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Ope
ratio
n Ho
urs
Kyushu Electric Power Co., Inc.
CEA‐JCOAL Workshop FY2014 Turbine Rotor Replacement timing Mapping of Rotor Replacement timing
Elapsed Years
Op Rate:70% Op Rate:90%
Av.181,600Hr / 26.2yrs 5Years Range Circle
★
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Insu
latio
n St
reng
th(%
)
Kyushu Electric Power Co., Inc.
Sample Chart of Generator Stator Coil Inspection and Replacement timing
Operation Hours
Max. Ave. Min.
Regression lines 99.9% Confidence interval
Temp.Corr Line of Monitoring Start Limit of Operation
Monitoring Period
★
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Inspectionitems
Monthlycheck LubricatetheGrease
Routinecheck Visualinspection,cleaning, windinginsulationmeasurement, etc.
OverHaul CategorizedtoTBM/BDM,Cycles, etc.(on/off-site,Spares, Redundancy,SeverityoftheBD)
Condition Monitoring
Insulationresistancetest, Polarizationindextest,Tanδ test
Whenneeded SupplementaryInsulation, Rewinding
Kyushu Electric Power Co., Inc.
Condition Monitoring for MV Motors • Due to old installation (20 years back), deterioration of insulation is a matter of concern.
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Wea
r le
vel (
degr
ee o
f deg
rada
tion)
Kyushu Electric Power Co., Inc.
Running in Stable operation Advanced stage Time
Temperature diagnosis Vibration diagnosis
Possible to catch abnormalities at early stage Lubricant diagnosis
Condition Monitoring for Rotating Machines Process to Failure of ROTATING MACHINES Failure
3. Coal Quality Evaluation System(CQES), Idemitsu Kosan Co., Ltd.
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26 PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.
Coal Production & Procurement Transportation Marketing
Boiler Operation
PF boilers CFBC boiler
(Aichi & Tokuyama refineries) (Chiba refinery)
10.6 Million tons (2013) * Idemitsu’s equity Coal mine operation in Australia Acquired coal mine in Indonesia Coal supply from Australia, Indonesia, Russia, China, etc. Idemitsu bulk terminal (Chiba) Shunan bulk terminal Total sales : 14.8 Million tons (2013) Japan : 6.8 Million tons (2013)
Other : 8.0 Million tons (2013)
資料整理番号:14067 Our Coal Business
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資料整理番号:14067 1-11. Coal Analysis Centre
Calorific Value Ultimate Analysis
Ash Fusion Temperature Ash Composition PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.
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資料整理番号:14067 1-12. Coal Quality Evaluation Tests
Ash deposition
<Turbulent flow furnace> <SEM/EDX> PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.
NOx emission
Combustion Furnace Unburned carbon
We have carried out many evaluation tests for various kinds of coals and collected the test results into our database. We can provide technical services by applying these abundant data.
Handling Spontaneous comb.
Durham cone test
Mill Grindability
資料整理番号:14067 1-13. Technical Products
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Dust dispersion inhibitor
Numerical computer simulation
Coal analysis & evaluation tests
Spontaneous combustion simulator
High temperature furnace scope
Ash utilization simulator
Trace element simulator
Coal quality evaluation system
Evaluation tests on handling properties
Spontaneous combustion tester
資料整理番号:14067
PROPERTY OF IDEMITSU KOSAN CO LTD TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO LTD
Bunker
Boiler
SCR
EP
FGD
Mill
Stock Pile
Ash Gypsum
Increase of mill load
Slagging and fouling
Increase NOx emission
Increase dust emission
Decrease De-SOx activity
Decrease gypsum purity
Difficulty of ash utilization
Spontaneous combustion
Dust emission
Excess trace element regulations
Decrease Efficiency
Increase unburned carbon
Coal quality affects the performance of each facility in a coal-fired power plant.
2-1. Coal Quality Impacts on Power Plant
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31 PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.
)
Operating Condition CQES
1. Quick and accurate prediction of plant performance for new coal 2. Prior prediction of problems, which helps to prevent trouble 3. Investigation of optimum blending conditions 4. Abundant technical information (Evaluation technology, Trouble examples, Coal analysis data, etc.)
資料整理番号:14067 2-2. Coal Quality Evaluation System(CQES) Idemitsu developed the computer software which can quantitatively estimate the impacts of coal quality on power plant performance. This system is used in many Japanese and overseas power companies for expanding coal brands. Coal Analysis Data Boiler
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資料整理番号:14067
PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.
2-3. Plant Performance(Outline)
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資料整理番号:14067
Available
Not available PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.
2-4. Selection of Suitable Blending Ratio
4. Numerical Simulation of Pulverized Coal Combustion, Idemitsu Kosan Co., Ltd.
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資料整理番号:14067
We can clearly grasp combustion states in the boiler and investigate its optimum operating conditions, which increase boiler efficiency and reduce NOx emissions. This tool is also useful for the solution of slagging trouble. PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.
Gas velocity Temperature Particle trajectory Oxygen conc. Boiler geometry
3-1. Numerical Simulation 3D simulator optimizes boiler operating conditions without hardware modification.
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資料整理番号:14067
Increase in O2 Present Improved 0
FF F E
DE Coal-D CD Coal-C BC BC2 BC1 Coal-B AB Coal-A AA
20 40 60 80 Air Flow Rate(m/s) PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.
Change of damper opening Change of O2 concentration
Increase Improved
O2 conc. (%) 10.0 9.0 8.0 7.0 6.0 5.0 4.0 3.0 2.0 1.0
Present Increase Decrease Increase
Decrease
3-4. Improvement of Boiler Efficiency
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資料整理番号:14067
Coal Burner A B C D E Total Present condition 1.3 4.1 5.7 11.0 1.1 5.2 Improved condition 1.7 4.3 1.3 2.3 0.7 2.5
PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.
3-5. Reducing Unburned Carbon
Improved condition OFA Layer Coal-D Burner Layer
O2 conc. (%) 10.0 9.0 8.0 7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.0
Present condition Optimization of Air Damper Settings OFA Layer Coal-D Burner Layer
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資料整理番号:14067
Particle Gas Flow Gas Temp. Collision with Boiler Wall
Before (Trouble) OFA Tilt -16 deg.
Improved OFA Tilt +16 deg. PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.
3-6. Solution of Slagging Trouble
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資料整理番号:14067
Coal B
Coal A+B
Coal B
Coal A
Coal B
Belt Blending Coal A
In-furnace blending Coal A
In-furnace blending has to choose a suitable blending condition from among many patterns. Boiler performance such as unburned carbon, NOx emission and furnace outlet temperature can be improved compared to the belt blending. PROPERTY OF IDEMITSU KOSAN CO., LTD. TO BE REPRODUCED AND USED ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF IDEMITSU KOSAN CO., LTD.
3-7. In-Furnace Blending
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Summary
1. JCOAL is conducting several projects under Indi Japan mutual cooperation in both coal and power sector. Joint declarations at both past and the latest India-Japan Energy Dialogues acknowledged such significance and achievement of the Cooperation.
2. CEA-JCOAL Cooperation provided a good opportunity for materialization of R&M as well as fruitful discussion and information exchange in CCT transfer program.
3. In a targeted long plant life of nearly 50 years, high plant availability possible through preventive maintenance. Higher economic efficiency requires shift to condition based maintenance
4. Idemitsu has been providing technical services to coal users, creating the further demand of coal, and making the most effective use of coal resources.
5. Applying our products and services, we propose optimum coal-blending and boiler-operating conditions which lead to improved efficiency and trouble-free operation in a boiler.
6. We, especially Japanese players in the coal power subsector in India are anxious to work together with our Indian partners toward sustainable development of Indian power sector.
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We look forward to working with you
Website: http://www.jcoal.or.jp/index-en.html Contacts: Mr. K. Murakami ([email protected])
[Contact] Engineering Group International Business Division Kyushu Electric Power Co. Inc. 2-1-82 Watanabe-dori, Chuo-ku, Fukuoka 810-8720 Japan TEL: +81(92)726-1741 FAX: +81(92)716-4428 http://www.kyuden.co.jp/ Kyushu Electric Power Co., Inc.
Coal & Environment Research Laboratory Coal Business Department Idemitsu Kosan Co., Ltd.
Kyushu Electric Power Co., Inc.