WELCOME

TO

CUSTOMER
OFFICIALS
R.K. BALU DGM/FES
RENOVATION & MODERNISATION (R & M)
OF
BOILER & ITS AUXILIARIES

R.K. BALU DGM/FES

 Need for R&M

9 Installation Cost per MW is High for New Units

9 Gestation period is high for New Units

9 Boiler components are Designed for a Life of 25-30 years

9 Pressure Parts Failures due to

ƒ Service related damages like Oxidation, Corrosion,

Erosion and Creep Fatigue

ƒ Abnormal operating conditions like

- More no. of Start- ups & Shutdowns
- Lack of proper maintenance
- Operating at high temp. regions

R.K. BALU DGM/FES

 Need for R&M (Contd.)

9 Deterioration in Coal quality with Lower Calorific value and

Higher ash content Resulting in

ƒ Reduced Availability Boiler and its Auxiliaries

ƒ Limitation of Milling System
ƒ Erosion of Pressure parts, Gas Ducts, AH, ID Fans
Leading to Unforeseen forced outages

9 Reduced load Operation & Poor Availability leading to Low

PLF of units

R.K. BALU DGM/FES

 OBJECTIVES OF R&M
R&M programmes basically aim at achieving :
9 Reduced Forced outages to improve Availability and Reliability of Boiler
9 Capacity augmentation / regain of lost capacity
9 Enhanced operational Efficiency
9 Improved Equipment Performance
9 State-of-the-art upgrades
9 Reduced support fuel requirement
9 Wear life improvements of Rotary parts Particularly Mill, ID Fan & AH
9 Meeting latest environmental standards and Pollution Control Norms
9 Energy conservation
9 Increased operational Safety
9 Lesser maintenance requirement & time

R.K. BALU DGM/FES

R&M PROGRAM OF BHEL FOCUSSES ON

) Reduced Forced outages to improve

Availability and Reliability of Boiler

) Capacity augmentation / regain of lost capacity

) State of the Art Improvements

R.K. BALU DGM/FES

AVAILABILITY & RELIABILITY IMPROVEMENTS

) Even at lesser loads targeted PLF can be achieved if

the Unit Availability is increased

) Can be achieved by
ƒ Reducing Pr.parts failures
ƒ Minimising Air ingress into the system
ƒ Increasing the availability of Auxiliaries

) Cost effective proposal resulting in

major saving for the Customer

R.K. BALU DGM/FES

 LOST CAPACITY RESTORATION

) Improving the Performance of the Unit from

present operating level of 75-80% to 100%

) Major problem is Deteriorated Coal quality

) Fuel preparation system Up-gradations

) Expenditure will be more

) Direct benefit in terms of MW increase

R.K. BALU DGM/FES

STATE - OF - THE - ART IMPROVEMENTS

) BHEL’s In - house R&D efforts to suit Indian

Coal conditions

) Can be retrofitted in Older design units

) Units can be run at optimum Efficiency level

) Operation cost will come down

) Higher Safety for Equipment & Man power

R.K. BALU DGM/FES

 METHOD OF APPROACH

Method of approach & Technology adopted by BHEL are :

) Plant Evaluation

) Thermal Performance Assessment of the unit.

) Residual life assessment of Pressure parts

) Preparation of R&M packages for Replacement, repairs,
modification and upgrades

) Preparation of cost benefits and execution time

) Execution of R & M program

) Evaluate the Performance feedback of the modifications

after R&M

R.K. BALU DGM/FES

 PLANT EVALUATION
Plant Evaluation mainly focus in the review of the operational history of
the Boiler, with reference to :

) Number of start-up & shutdown (Unit trip data analysis )

) Operation regimes maintained in the Boiler

) Preservation method adopted during major outage periods

) Duration and extent of parameter escalation mainly with
respect to steam temp.

) Operating history and failure statistics

) Generic problems experienced by the Customer

R.K. BALU DGM/FES

 THERMAL PERFORMANCE EVALUATION

) Thermal performance test is conducted to assess the

present performance of the unit & its limitation to achieve
rated parameters

The following tests normally conducted

) The as-run readings at maximum available load to
evaluate the present performance
) The unit operation will be tuned to optimum possible
running condition and then data collected

) Unit performance at part load (60% MCR)

R.K. BALU DGM/FES

THERMAL PERFORMANCE EVALUATION (Contd.)
) The data collected is analysed for total thermal performance

behaviour of the Boiler

Possible ways of improving the PLF/efficiency of the unit like :

ƒ Need for changing surface areas
ƒ Identifying Air ingress points etc
ƒ Augmenting Fuel firing system capacity reduction of gas
velocity / temp for minimising erosion potential
ƒ Adequacy of ESP & ID fans are decided

R.K. BALU DGM/FES

 RESIDUAL LIFE ASSESSMENT STUDY
RLA study conducted basically to find out :
) The present condition of the Boiler pressure parts
) To determine the remaining left out life
of the pressure parts

R.K. BALU DGM/FES

 WHERE RLA FIGURES IN

LIFE EXTENSION PROGRAMME (LEP)

PLANT EVALUATION PERFORMANCE

DATA COLLECTION EVALUATION RLA

PROBLEM AREA
IDENTIFICATION

VARIOUS PROPOSALS
FOR LIFE EXTENSION

F DONE IN PHASED
E FULL OUT
E
D
B
A
C
K

PERFORMANCE EVALUATION

R.K. BALU DGM/FES

 PREPARATION OF R & M PACKAGE

) Analysis for finding the root cause of problems and arrive

at feasible technical solution
) Identifying the problem areas affecting the Unit
performance

) Composite package for Revamp, Retrofit & Modernisation

of Boiler will be worked out

) The final recommendation will include :

Pressure parts replacements
ƒ Fuel firing capability improvements
ƒ Need for acid cleaning
ƒ ESP improvement
ƒ State-of-the-art upgrades etc.
ƒ Cost benefit analysis & Pay back period
R.K. BALU DGM/FES
 BHEL’S EXPERIENCE IN R&M

BHEL’s R&M program mainly concentrate in improvements / up--

-gradation of :

) Pressure parts improvement

) Firing system improvements/upgrades

) Milling system improvements

) Boiler Auxiliaries improvements

) Measures for Pollution Controls

) Controls and Instrumentation updates

R.K. BALU DGM/FES

 PRESSURE PART IMPROVEMENTS

) Redesign of 2nd pass for lower Gas velocity (10m/s) to

minimise Erosion potential
) Cassette / baffles, shields for LTSH, Eco & WW screen bends
for erosion protection
) Modified arrangements for alignment of superheater in
furnace
) Additional flexible loops (bends) introduced in SH outlet
headers to improve flexibility
) Binder coil / spacer coils redesigned
) LTSH supply tubes and SH screen tubes eliminated by
redesigning the 2nd pass
) Improved WW bottom hopper sealing arrangement to
minimise air ingress
) Forced drain system for Soot blower piping
R.K. BALU DGM/FES
 FIRING SYSTEM IMPROVEMENTS

) Ceramic lined PF bends for fuel piping for better wear life
and less maintenance.

) Wide range coal nozzles for better flame stability

) High energy arc ignitors for oil consumption reduction

) Air cooled non-retractable oil guns.

) Volumetric belt feeder in place of rotary feeder to improve

availability

R.K. BALU DGM/FES

 MILLING SYSTEM IMPROVEMENTS

) For Bowl mills, state-of-the-art improvements for better

wear life and increased fineness, like mechanical face seal
assembly, stationary vane wheel assembly, ceramic lined classifier
cones etc.

) For Drum mills, modified liners and ball charge for increase in mill
output as well as for increased wear life

) Increased down spout size from bunker to feeder to mill for lesser
chance of choking

) Larger size mills in place of old mills for getting more coal output

R.K. BALU DGM/FES

 BOILER AUXILIARIES & OTHER SYSTEM IMPROVEMENTS

AIRHEATERS
) Extended tube design for tubular air-heaters for avoiding entry
erosion and air leakage
) Increased thickness tubes for tubular air-heater for better wear life
) Corten steel tubes for bottom air heaters to avoid cold end
corrosion
) Automatic leakage control system and infra red fire detection for
regenerative air-heaters
DUCTS AND DAMPERS
9 Guillotine gates for complete isolation for PA fans, ID fans and ESP
ducting
9 Louvre dampers with special sealing for open / close dampers
9 Biplane dampers for complete isolation
9 Ceramic tile lining at some portion of duct (ESP inlet) for erosion
protection
9 Redesigned ducting for lesser velocity to minimise ash erosion
9 Acoustic insulation for ducts
9 Silencers at Fan inlets
R.K. BALU DGM/FES
 BOILER AUXILIARIES & OTHER SYSTEM IMPROVEMENTS
FANS
) Variable frequency drive for reduced power consumption
) Simply supported type PA fans with sleeve bearings
) Replaceable liners for ID application
) Third PA fan for transporting increased coal output from mills
) Third ID fan for improving draft in furnace

ELECTROSTATIC PRECIPITATORS
9 Augmentation of ESP to achieve collection efficiencies up to
99.98% to meet reduced particulate emission rqte.
9 Better material (904L) for ESP emitting electrode to avoid
stress corrosion cracking
9 Micro processor based controls (like BAPCON, RAPCON,
COMCON) for better ESP management and collection
efficiency
9 Pulsed on/off control for reduced power consumption
R.K. BALU DGM/FES
 POLLUTION CONTROL FEATURES
The Pollution control has become stringent world over and also
in India. BHEL is offering as a retrofit for old boilers for the
following system

) Emission level up to 50 mg/Nm3 can be achieved with

BHEL ESP’s and retrofits are made for old Boilers.
Layout constraints are also resolved by innovative way
of positioning the additional ESP fields/ESP’s.

) For reducing NOx emission, the following new system /

concepts

ƒ Over fire air systems

ƒ Concentric firing system
R.K. BALU DGM/FES
 CONTROLS & INSTRUMENTATION UPDATES

) Measures to avoid spurious tripping by

ƒ 2/3 logic for furnace pressure and drum level
ƒ Visible light flame scanner for better viewing
) Micro processor based controls for Burner Management
System (BMS)

) Secondary Air Damper Control system (SADC) for better

combustion and flame stability

) Conductivity type Electrostatic water level indicator for

proper level indication and control

) Acoustic steam leak detection system for early detection of

tube leaks and to avoid secondary damages

) On-line condition monitoring system for Oxygen / Vibration /

Water chemistry / Pollution

) Boiler performance Optimisation System

R.K. BALU DGM/FES
 CONTROLS & INSTRUMENTATION UPDATES (Contd.)
) Most of the above design features are available as standard retrofit
package - as component improvement or as system improvements

) All the above retrofits are implemented in number of Power Stations in

India and Abroad

) During the past 10 years, BHEL has successfully handled, a massive

Renovation and Modernisation (Phase I & II) programme launched by
Government of India, to upgrade operating thermal power stations run by
state electricity boards

) With this background experience of R & M and also the design update and
technology improvement, BHEL has also very successfully carried out
rehabilitation of a number of boilers supplied by other manufacturers in
India and Abroad

) In 1990, BHEL has obtained a prestigious overseas order from

TNB/Malaysia for the rehabilitation and incorporating gas firing for 12 units
located at 3 places in Malaysia. This contract has been successfully
completed to the entire satisfaction of the owner and a rigorous
Performance guarantee test carried out
R.K. BALU DGM/FES
 BHEL’S EXPERIENCE ON STATE-OF-THE-ART DESIGN
IMPROVEMENTS

Old Design

) 100lb Volumetric Rotary feeder for feeding raw coal into the Mill

) Feeder speed control by PIV

) Boiler load demand signal actuate PIV for more coal into Mill and
Boiler

) Hinge gate mechanism controls the volume of coal fed into the Mill

R.K. BALU DGM/FES

 PROBLEM FACED

) Coal flow largely depends upon

ƒ Raw coal size
ƒ Presence of foreign material
ƒ Bulk density of coal
ƒ Effective operation of hinge gate

) Shear key & Shear pin failures

) Coal flow is very much erratic

) Low rangeability & variation in output

) Problem with Hinge gate mechanism

) Wear out of PIV gears & chain leading to ineffective

speed control
R.K. BALU DGM/FES
 MODIFICATION IMPLEMENTED

) BHEL’s Belt type Gravimetric feeder

) Existing R.C.Feeder is of short centred type

) BHEL developed short-centred Volumetric Belt feeder with

ƒ 24” Down spout piping
ƒ Eddy current clutch drive
ƒ Coal on belt monitor
ƒ Belt motion monitor

) Robust construction as per NFPA

) Feeder speed control by variation of field voltage to eddy

current drive

) Bunker emptying can be done by reverse rotation of feeder

R.K. BALU DGM/FES
 PERFORMANCE AFTER RETROFIT

) These feeders are running continuously for the past 2 years without
any of the problems
) Uninterrupted coal flow to the feeder and the pulveriser ensured
) Shear key and shear pin failures eliminated.
) Controlled coal flow through the belt type feeder improved the
rangeability and linearity of coal flow with ref.to speed variation
) Eddy current clutch drive of the new feeder provides accurate &
reliable feedback signals for faster response of load change
) Bunker emptying chute in feeder also helps in mtc. of the bunker
during rainy season
) Coal on belt and belt motor monitor doubly ensures the NO-coal Flow
condition and gives immediate signal to the operator
) Higher availability of the unit and better satisfaction levels

R.K. BALU DGM/FES

 BHEL's Experience in Renovation & Modernisation
1.Domestic Projects
(During the period 1990 to 1999)

SL. Name of the Name of the Power Nature of Work Carried out Remarks
No Customer Station and Capacity

01 Neyveli Lignite 4 x 50 MW Unit nos.2, 3, 4 Unit loaded to

Corpn.Ltd & 5 Boilers of Russian 235 t/hr (design
(NLC) make 220 t/hr)
Complete pressure parts replacement (waterwalls),
Exit gas
economizer, downcomer, SH headers, DESH, entire MS
temperture
piping etc. about 350 tons).
reduced from
•All valves reconditioning/replacement
190oC to 140oC
•All non-pressure part renovation
•Measures for performance uprating/low capacity
•Measures for performance uprating/low capacity
restoration.

02 Steel Authority Bokaro Steel plant 3x220 Boiler loaded to

of India Ltd. t/hr Units nos. 3, 4 & 5 full capacity
(SAIL) Boilers of Russion make
Pressure part replacement in water wall, screen SH,
Conv.SH, (Platen SH, redesigned with material upgrades)
•Burner performance uprating
•APH (tubular) performance improvement
•Other non-pressure parts renovation
•Metal temperature scanner system introduction

03 Bihar State Unit nos. 1-4 & 5-6 Work under

Electricity 8x50 MW boilers progress
Board
Replacement of complete downcomer pipes
(BSEB)
•Replacement of waterwall tubes - partial
•Replacement of superheater - modified design
•Replacement of economizer blocks - modified
R.K.•Replacement
BALU DGM/FESof main steam piping
•Replacement of airheater blocks
SL. Name of the Name of the Power Nature of Work Carried out Remarks
No. Customer Station and Capacity

04 APSEB Kothagudem TPS About 50oC gas

2 x 110 MW Units Nos.7 & temperature
8 reduction
achieved.

•Exit gas temperature reduction by second pass pressure

parts redesign and replacement.
05 RSEB Kota TPS Full parameters
2 x 110 MW achieved since
Unit nos. 1 & 2 1995

•Lost capacity restoration with fuel system upgrades

•HEA ignitor introduction in place of eddy plate ignitor.

06 TNEB Ennore Work under

2x110 MW progress
Unitnos. 3 & 4

•Complete pressure part re-engineering (tangent tube

waterwall to membrane tube waterwall)
•Performance uprating (lost capacity restoration).

R.K. BALU DGM/FES

SL. Name of the Name of the Power Station Nature of Work Carried out Remarks
No. Customer and Capacity

07 SAIL Bhilai Steel Plant 2x150 t/hr

Non pressure part renovation

•Total downcomer/upriser replacement
•DESH replacement
•SH headers replacement

08 APSEB Kothagudem Work under

2x110 MW progress
Unit nos. 5 & 6

•Complete pressure part re-engineering

(tangent tube waterwall to membrane
tube waterwall

•Performance uprating (lost capacity restoration)

•Non pressure part renovation

09 HSEB Panipat TPS Work under

4x110 MW progress
Unit nos.1,2

•Milling system capacity upgradation

10 UPSEB Obra Unit no.11 200 MW Lost capacity of
boiler restored.

•Mill capacity upgradation

R.K. •3rd PA
BALU fan introduction
DGM/FES
•Airpreheater sector widening from 52o to 70o
SL. Name of the Name of the Power Station Nature of Work Carried out Remarks
No. Customer and Capacity

11 SPC, Kota 2x90 t/hr boilers Capacity

enhancement by
more than 15%
carried out
successfully.
•Lost capacity enhancement
•Higher size mill replacement
•Performance review for low-grade coal

12 Gujarat Narmada 3 x 180 t/hr VU 40 boilers Fuel conversion

Valley Fertiliser implemented and
Corporation successfully tested
Bharuch Fuel conversion - additional gas firing facility at full load. Forced
•Forced drain system for soot blowers (State-of-the-art drain system for
improvement) soot blowers
supplied and
commissioned.

13 IOC Mathura 3 x 150 t/hr VU 40 boilers Conversion

completed and
performance
proved

•Conversion of boiler for 100% natural gas firing

14 IOC, Haldia 3 x 125 t/hr boilers Burner retrofit

completed and
working.
Low-NOx burner retrofit

R.K. BALU DGM/FES

 2.OVERSEAS PROJECTS
SL. Name of the Name of the Power Station Nature of Work Carried out Remarks
No. Customer and Capacity

01 Tenga Nasional i) TJPS Stage I More than

Berhad Malaysia 2 x 60 MW Guaranteed
ii) TJPS Stage II Rehabilitation of boilers Efficiency
2 x 60 MW •Rehabilitation of turbine and generator auxiliaries achieved.
iii) TJPS Stage III •Replacement of total station controls and instrumentation
3 x 120 MW with microprocessor based system.
•Life assessment and extension survey
•Incorporation of natural gas firing facility in three 120 MW
boilers

02 Tenaga Nasional SIPS - do -

Berhad, Malaysia 2 x 120 MW
Rehabilitation of boilers.
•Rehabilitation of turbine and generator auxiliaries
•Replacement of total station controls and instrumentation
with microprocessor-based system
•Life assessment and extension survey
•Incorporation of natural gas firing facility in three 120 MW
boilers.

03 Tenaga Prai - do -
Nasional Berhad, 3x120 MW
Malaysia

•Rehabilitation of boilers
•Rehabilitation of turbine and generator auxiliaries
•Replacement of total station controls and instrumentation
R.K. BALU
with DGM/FES
microprocessor - based system
•Life assessment and extension survey
SL Name of the Name of the Power Nature of Work Carried out Remarks
. Customer Station and Capacity
No
04 General Tripoli West TPS
Electric 60 MW boiler (Stein
Company, Industrie, France, make)
Libya
Replacement of all bowed waterwalls
•Replacement of superheaters, superheater
supports
•Revamping of burners
•Revamping of ducts and insulation

05 General Bengazi
Electric 8 x 160 t/hr boilers
Company, (Babcock Company
Libya make)

•Replacement if waterwalls
•Replacement of refractory & insulation
•Replacement of burners
•Replacement of expansion bellows
•Servicing of soot blowers, valves, fuel
pumping and heating station.
•Servicing of fans
•Replacement of APH elements and servicing
•Renovation of controls and instrumentation
•Chemical cleaning.

R.K. BALU DGM/FES

SL Name of the Name of the Power Nature of Work Carried out Remarks
. Customer Station and Capacity
No
.

06 General Zuera Desalination

Electric Plant
Company 2x90 t/hr boilers
Libya (IDRO, TERMICI,
Italy, make) Replacement of waterwalls, bank tubes
•Replacement of insulation
•Replacement of economizer
•Servicing of valves , soot blowers
•Servicing of burners
•Servicing of fans
•Revamping of controls and instrumentation

07 General Dhama TPS

Electric 3x120 t/hr boilers
Company (Babcock, Germany,
Libya make)
Replacement of waterwalls,
•Replacement of soot blowers
•Replacement of refractory and insulation
•Revamping of burners
•Servicing of valves
•Revamping of fuel system equipment
•Servicing of fans
•Servicing of airpreheaters and element
replacement
•Chemical cleaning

R.K. BALU DGM/FES

SL. Name of the Name of the Power Nature of Work Carried out Remarks
No. Customer Station and Capacity

8 Bangladesh Siddhirganj
Power 1 x 50 MW (225 t/hr boilers)
Development (CE, USA, make)
Board,
Bangladesh Replacement of complete furnace walls
•Replacement of complete bank tubes
•Replacement of superheater - partly
•Replacement of side waterwall headers
•Replacement of damaged burners
•Servicing of entire boiler including fan, APH, safety
valves and other valves.
•Replacement of APH seals
•Replacement of refractory & insulation
•Replacement of water level indicator
•Replacement of part-duct and expansion joints
•Servicing of controls and instrumentation
•Chemical cleaning

R.K. BALU DGM/FES

THANK YOU ALL

R.K. BALU DGM/FES