NTPC SIMHADRI WELCOMEs

NATIONAL BOILER WORKSHOP-2015

EFFICIENT OPERATION & MAINTENANCE OF BOILERS

By:
M.Sivarama Krishna, GM(O&M)
S.K.PRASAD,Sr.Mgr (O)
CH.PRADEEPKUMAR,Dy.Mgr(O)

FLOW OF PRESENTATION :

Journey of NTPC
Operation Best Practices

Zero Boiler Tube leakage

LATEST Technology adopted
Conclusion

NTPC VISION :

NTPC HAS TO BECOME A 1,28,000 MW COMPANY BY 2032

 INSTALLED CAPACITY :

45,548 MW(Including JVs)

GAS:1000MW

RENEWABLE:100MW

HYDRO:5984 MW

COAL :38,654MW

SUSTAINABLE DEVELOPMENT: A LONG JOURNEY

NTPC GROUP ACCOUNTS FOR 16% OF INDIAS TOTAL

INSTALLED CAPACITY AND 25% OF ALL INDIA
GENERATION AS ON 31.03.2015

FORCED OUTAGE : A MAJOR CHALLENGE

START UP
DEVIATIONS

CHEMICAL
PARAMETER
DEVIATIONS

OVERHEATING
/CORROSION

BTL
FLUE GAS
EROSION

WELD
FAILURES

O & M BEST PRACTICES

TO AVOID STARTUP DEVIATIONS

Standardized all Operation procedures

& reviewed

periodically for improvement.

No SH/RH Spray till Synchronization

Proper choice of Mill/Oil gun elevations during start-up
Maintaining proper Rate of rise of Pressure/Temperature - Avoid
over firing.
Safety valve floating with oil guns only
Passing of SH/RH spray valves attended regularly

O & M BEST PRACTICES

TO AVOID STARTUP DEVIATIONS

SH/RH Spray limiting interlock to limit temp at De-superheater

outlet falling below saturation temp implemented in all units

Monitoring of Economizer outlet temp w.r.t Saturation

temperature at eco I/l pressure during start-up

Drum Level Control

Low range FRS control kept in auto during unit start-up
DP across FRS maintained around 5-10 KSC
CBD is kept open continuously till chemical parameters are achieved
Continuous flow of feed water through economizer during startup is
ensured

O & M BEST PRACTICES

CHEMISTRY IN STARTUPS

Maintaining the chemical regime of boilers

Ensure CPU availability and putting both in service during
start-ups
Frequent sampling of Steam / water at local and SWAS
availability
PH maintained through Ammonia Dozing, Hydrazine is used
optionally to control more O2 in fresh water

Condensate Dumping
Hot draining as per requirements

O & M BEST PRACTICES

WELD JOINT FAILURES
100% Radiography of joints being done during overhauls
Radiography of bends during OH for observing any
blockages or deposits

EROSION
Tube leakage in BTT - Erosion of Burner transition bends
was observed due to Secondary air from wind box Application of plastic refractory over Burner transition tube
bends
Visual Inspection of tubes in Burner zone for signs of
overheating like bulging etc. during OH

O & M BEST PRACTICES

Cutting of Tubes by Grinding machine

HP Jet cleaning boiler surfaces
Use of Beveling machine for chamfering
Plastic Refractory application at suitable locations
Inspection of attemperation spray nozzles
Economizer repair on maintenance beds outside

OPERATION BEST PRACTICES

Monitoring metal temperatures deviations are
discussed in DPM
Monitoring Rate of rise of temp / pressure during
startup & shutdowns thru PI applications
Pressure setting of wall blowers / LRSBs Once in
three months
Operation of LRSBs in the presence of maintenance
Personnel. Incase of any mal-operation, blower can be
retracted immediately without any damage.
Optimization of Wall blower / LRSB Operation
Regular checking of SADC/BT at local and remote
positions. Defects are attended regularly

BOILER TUBE LEAKAGES AT SIMHADRI

Year

Tube Leakage (No) Tube Leakage (%)

2011-12

0.64

2012-13

1.64

2013-14

10

1.37

2014-15

1.03

2015-16

0.00

Previous Financial year

same period

1.10

*No tube leakage in the first three months of the last overhauls

ACTION PLANS FOR ZERO BTL

Area

1.

Cause / Nos

Remedial actions based on past

failures

EROSION

Thickness survey & visual inspection

of all Z-Panel, intersection and all
manhole door tubes.

WELD DEFECT

DP of hand hole door plates welds.

100% radiography of repair joints.

ATTACHMENT
WELD FAILURE

100% fin welding DP at repair joints.

S -Panel

ACTION PLANS FOR ZERO BTL

Area

WATER
WALL &
HANGER
TUBES

Cause / Nos

Remedial actions based on past

failures

EROSION
(SB Steam)

Thickness survey and visual

inspection.
Soot blower alignment checking.
Visual inspection and thickness survey
of burner bends.
Checking of hanger tube shielding and
replacement.

SHORT TERM
OVER HEATING
(Starvation)

Ensuring plugs during tube repair.

Flushing of bottom ring header by
draining at 10 Kg/Cm2.

ATTACH MENT
WELD

100% fin welding DP of repair joints.

Weld failure

To take care while cutting the tube

ACTION PLANS FOR ZERO BTL

Area

Cause / Nos

Remedial actions based on past failures

ROOF
TUBES

EROSION

Penthouse cleaning and seal plate

checking.
Inspection of roof tubes from furnace
side.

PLATEN
SH /
DIVISIONA
L PANEL /
SPACER
TUBES

WELD
FAILURE

100% radiography of repair joints,

Alignment of coils
Radiography& Random DP and
radiography of other joints.

RUBBING
(coil)

Inspection of spacer tubes, girdling

loops and binding loops,
Inspection of tubes near cleats during
every O/H.

ACTION PLANS FOR ZERO BTL

Area
5

REHEATER

Cause / Nos

Remedial actions based on past failures

OVER
-Vertical tubes to be cut by
HEATING
grinding and capping.
(Starvation due to -Steam cleaning of new tubes
blockage.)
before welding.
Monitoring metal temperatures.
Oxide scale measurement.
Visual inspection.
Sponge ball checking of RH tubes for
identifying blockages
Use of Metal caps
WELD
FAILURE

-100% radiography of repair weld Joints

-Random DP / radiography of shop &
erection joints including DMW
-100% DPT & RT in areas of degradation.

ATTACH MENT
WELD FAILURE

- Cleat welding being done..

- Random DP near cleat area.

ACTION PLANS FOR ZERO BTL

Area
6

RH VENT
/ DRAIN
STUB

Cause / Nos
WELD
FAILURE

FLUEGAS
EROSION
7

ECONOM
ISER
WELDFAILURE

Remedial actions based on past

failures
DP of startup vent / drain stubs of
Re heater is being done.

Thickness survey and visual

inspection.
Cassette baffles and shielding
inspection.
100% radiography of repair joints.
Similar erection welds to be
inspected by DP & RT.

ACTION PLANS FOR ZERO BTL

Area

Cause / Nos

Remedial actions based on past

failures

Flue Gas
Erosion

Visual inspection and thickness survey.

Shielding of manhole door bends &
bifurcation tubes.
Refractory application.
Checking of cassette baffles.

LTSH
Modification weld
joint Failure

Random and RT of other welds.

100% radiography of repair welds.

Manhole door
attachment weld
failure

DP at manhole door bends.

Proper clamping of shield.
Visual inspection of fins in LRSB area.

LTSH

OTHER BEST PRACTICES

ENERGY &EFFICIENCY MAPPING OF
a) Draught systems
b) Compressed air systems
c) Milling system
d) CW system
e) Ash handling
f) Coal handling plant.

LATEST TECHNOLOGIES ADOPTED

ASLD(ACOUSTIC STEAM LEAK DETECTORS)

PADO
PI SYSTEM
SCADA
FLAME CAMERAS
ACOUSTIC PYROMETERS

Thank You