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Boiler Monitoring
Boiler Monitoring
AN APPROACH AT
GMR Warora Energy.
Presented By: Sambai Raja P
Pradeep Sahu
Murali Ravi Shanker
Date: 08.12.2015
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Vision
Mission
By 2020,GMR Energy wants to be the most profitable and one of the leading
integrated Energy companies in India and derive value by
• Diversifying strategically across Energy value chain
• Being a preferred employer
• Being socially responsible
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Boiler Performance Monitoring – An Approach At GMR Warora Energy
CONTENTS
1. INTRODUCTION
3. CONTROL MEASURES
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Introduction
GMR Warora Energy is a part of the GMR Group, which is one of the largest diversified
Infrastructure Conglomerates in India which operates 600 MW (2X300 MW) coal based power
plant located in Warora, Maharashtra.
GMR Energy is fully tied up under long term PPA for 200 MW each with Dadar & Nagar Haveli
Power Distribution Corporation Limited (DNHPDCL), Maharashtra State Electricity Distribution
Company Limited (MSEDCL) and 150 MW with Tamil Nadu Generation and Distribution
Corporation (TANGEDCO).
ISO 9001, ISO 14001, ISO 50001 energy management system (EnMS),OHSAS 18001(BVQI)
certified plant & 5s implementation unit.
Operation of GMR is driven by customer-focused approach to meet obvious requirement of
reliable and economical power. For which multi-prong strategies are adopted at GMR. One of
such strategy is Boiler performance monitoring and continual improvement in its
performance.
The paper discusses the approach adopted at GMR for monitoring of Boiler performance and
various strategies adopted for continual improvement in boiler efficiency.
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Approach at GMR Warora Energy
The basic approach adopted for improvement in boiler performance at GMR Warora
is,
Control.
Measures
&
Monitor
CA/PA Control
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Measures & Monitoring
At GMR boiler efficiency is monitored
1) Online
2) Offline
Online Monitoring:
At GMR Units are equipped with DDC
system for monitoring and control of
process.
The system has in-built software for plant
performance monitoring, which also
calculates boiler efficiency.
By providing various coal parameters,
boiler efficiency is calculated which helps
the operator for monitoring.
So operator can take action immediately
whenever there is deviation in efficiency.
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Measures & Monitoring
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Measures & Monitoring
Offline Monitoring:
At GMR software package is developed in
house.
This package calculates boiler efficiency as
per BS –2885.
In this package after computing the various
process parameters and Ultimate analysis of
coal, Boiler efficiency and various losses are
calculated.
This package also compares losses against
design losses.
The package is made available to operators
who can monitor and control parameter
affecting boiler efficiency.
The front end of the model is shown below.
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Measures & Monitoring
IN HOUSE SOFTWARE FOR OFFLINE MONITORING
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Measures & Monitoring
Shift Basis:
In the every shift desk engineers are calculating boiler efficiency with the help of package
and comparing it with online efficiency.
Daily basis:
With the help of above model on daily basis various prominent losses like dry flue gas loss,
un-burnt carbon loss, wet flue gas loss, are calculated and compared with design losses.
Various control charts used for monitoring are as shown in figures.
Mill Performance:
• Mill Performance again depends on various factors such as roller wear, Air flow ratio, Liner
Condition inside the mill, etc. These factors will again tend to affect boiler efficiency
Cleanliness Performance:
• Heat transfer within the boiler mainly depends on the cleanliness of the boiler from fireside
as well as from internal. So good condition of soot blowing equipment's and their regular
usage as well as good boiler water chemical parameters ensure the surface cleanliness.
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Corrective And Preventive Actions (CA/ PA)
All these regular monitoring and control actions help to maintain losses at
acceptable level. But to find permanent solution for recurring problems suitable
corrective and preventive actions are initiated.
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Benefits & Conclusion:
The Boiler Performance Monitoring provided our plant O & M personnel a tool to
Thus by monitoring & control it enhanced the boiler performance and as a benefit
it tremendously helped in cost saving of fuel, O&M cost & Plant Availability Factor
(PAF).
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Snapshots
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Snapshots
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Snapshots
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Snapshots
Air Heater Performance
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Thank You
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Boiler Performance Monitoring – An Approach At GMR Warora Energy
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Boiler Performance Monitoring – An Approach At GMR Warora Energy
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Boiler Performance Monitoring – An Approach At GMR Warora Energy
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