TSTPS /KANIHA

Operational Best Practices for

“ESP Performance Improvement “.

By
Susanta Ghosh AGM(O)I/C & R.N.Das AGM(O)
TSTPS-Kaniha .
6X500 MW UNITS , TSTPS , KANIHA

2ND LARGEST THERMAL POWER PLANT OF NTPC

2
 Why ESP Performance Monitoring is important ?
• There is a wide gap in ESP design condition & actual
operating condition .
• Wide variation in quality of coal fired as coal
received from different mines with different
qualities .
• Day by day environmental Stringent norms set by
regulators , such as
– (150 mg/Nm3 → 100 mg/Nm3 → 50 mg/Nm3)
• Annual Overhauling schedule changed to 2 years .
• FA Evacuation constraints faced due to restriction in
disposal system /ash dyke .
• Dry ash collection from ESP hoppers .
3
 ESP DESIGN DETAILS .
SL
PARAMETERS Unit STAGE-I STAGE- II
NO
1 Unit Capacity MW 2X500 MW 4x500 MW

336 - DESIGN 336 - DESIGN

Coal Consumption /
2 T/HR 370 - WORST 370 - WORST
Unit
420 - SITE RESTRICTION 420 - SITE RESTRICTION

3 Ash % 44% 44%

4 FG flow volume M 3/SEC 789.00 777.0( 533.48 Nm3/sec)

5 Inlet dust burden Gm/Nm3 60 81.303 ( Guran- 63.387)

6 Outlet dust burden mg/Nm3 56 20.0

7 Efficiency % 99.91 99.939 ( 99.97)

0C
8 Gas inlet Temp 134 140 (125)
4
 FA SYSTEM DESIGN DATA .
SL
PARAMETERS Unit STAGE-I STAGE- II
NO

1 Unit Capacity MW 2X500 MW 4x500 MW

336 - DESIGN 336 - DESIGN
Coal Consumption /
2 T/HR 370 - WORST 370 - WORST
Unit
420 - SITE RESTRICTION 420 - SITE RESTRICTION
Continuous , Vacuum Continuous , Vacuum Ext
3 FA Evacuation SYSTEM ***
Ext Type Type
Two Units full collection
with one unit
25 % each unit
4 Dry ash facility *** transportation
Silo 135 Ton capacity
Buffer Hopper 120 X8 tons
/Silo 750 X2 tons
Wetting unit collection
5 capacity (for each T/hr 55 TPH 60 TPH
streams)

5
 Operational Best Practices at TSTPS to
Enhance ESP Performance.
• Normal operation at various Operating
Conditions .

• Inspection during Annual Overhaul ,

Recommissioning ,Testing , Setting Parameters .

• During Planned Maintenance of ESP passes.

• During Unit Start-up – Shutdown .

6
 Normal Operational Strategies For ESP
At Various Unit Operating Conditions .
• Monitoring of ESP online Field Parameters .
• Monitoring Effective Evacuation from Eco Hoppers .
• Strategies adopted for Higher Particle Sizing at ESP
Inlet due to 1st field out of service .
• Strategies for high coal flow > worst coal firing
• ESP Hopper Effective Evacuation Monitoring through PI
system .
• Regular FA system checks for system performance
improvement .
• Improvement of Ash Flowability from ESP Hopper .
7
 Inspection During Annual Overhaul ,
Recommissioning .
• Checking for Uniform flue gas distribution across the entire
unit by proper inspection & repair of GD screen /Baffels .
• Proper inspection & cleaning of support & shaft system .
• Proper alignment of Emitting electrodes and collecting
plates .
• Proper insulation of ESP Hoppers /Casings.
• Checking Proper installation and operation of FA system
devices.
• Testing’s Followed by Recommissioning of ESP & FA system

8
 Testing’s Followed by Recommissioning of
ESP & FA system :
• Support insulator Heater , shaft Insulator heater healthiness checking ,
effectiveness checking by switching ON for 24 Hrs . Subsequent current
measurement .
• After total readiness , continuous rapping for 8 Hrs all GDRM/CREM/EREM ,
then internal inspection & hopper portion final water wash before box up .
• 24 hrs support /shaft insulator Heater in service before field meggering .
• Each ESP Field Meggering to ensure electrical healthiness . (> 250 MΩ)
• Still air charging & VI characteristic checking for all Fields to identify
problems , then subsequent field internal inspection & rectification .
• Inspection of 1st hopper after Furnace pressurisation test is completed .( to
remove foreign material if any)
• Air tightness test of ESP up to ESP outlet by pressurizing boiler up to 100
mmwc.

Next Slide
9
 Testing’s Followed by Recommissioning of
ESP & FA system :
• Hopper Heater current check ,
• Dust level LO/HI indicator operation check .
• P&I check for Rectiformers .
• Gas load testing of Fields to create data base after
synchronization .
• Rapper frequency and intensity adjustment later when the unit
is brought on-line.
• FA evacuation system Checks .
• Hot tightening of FA evacuation system after one day .

Next Slide
10
During Planned Maintenance of ESP in Operating Units .
(ESP Pass isolation for Rectification).

• Whenever number of field goes out of service > 2-3 then

planned maintenance of the pass is taken up .
• Effort is put not to loose generation by firing good quality
coal to restrict coal flow at 370 T/hr.
• A systematic approach through a standard check list is
adopted by operation engineers while ESP pass shutdown
activities are carried out .
• This also guides & helps the maintenance personnel for
proper & effective inspection & rectification work .
• Still air charging of fields before isolation & after
rectification is carried out to ascertain problems /problems
are rectified respectively
• Meggering is carried out where problems are not visibly
identified .
Next Slide
11
 During unit start up – shutdown .
• During unit startup after a short shutdown , 2-3 passes of ESP are kept in
service to avoid oil soot deposition in all passes .
• ESP Fields are charged after sufficient warm up i.e > 110-120 0C inlet /outlet
temp .
• SCAPH is kept in service in all cold start-ups & up to sufficiently high load
to ensure better temp at ESP inlet .
• FA Evacuation system is kept in service well in advance & mouth choking’s
are cleared continuously if any during initial phase .
• ESP Auxiliaries are kept in service 24 hrs prior to BLU .
• Before planned Unit shutdown all pass rappers are put on continuous mode
for dislodging of ash from collector & emitter electrodes in hot conditions .
• All hoppers emptiness ensured before the FA system is taken under
shutdown .
• For a short shutdown the Hoppers heaters & shaft /support insulator
heaters are kept ON .
• Identified Defects are attended , all fields are charged at charge ratio 1:1
The fields having problem are addressed .
• FA system functional /vacuum checks are carried out to bring the system
close to new one .
Next Slide12
GIST OF MAJOR MODIFICATIONS CARRIED OUT .
STAGE-I STAGE- II
• ESP Controllers are up graded recently • ESP online parameters data provided
by BHEL through DCS
• VP suction line /ASH LINE modified • ESP OUTLET SIDE GAS SCREEN REMOVED IN
(made independent) all 6 VP can be ALL FIELDS OF U 5&6 , UP TO 7TH FIELD IN U
kept in service 3&4 (balance to be carried out)
• DURING R&M ASH HANDLING • VP suction line /ASH LINE modified (made
SYSTEM DATA TO BE HOOKED UP independent) all 8 VP can be kept in
TO PI SYSTEM service
• BOILER HOPPER DISCONNECTION • Ash Line made independent , . Additional
FROM ESP SYSTEM UNDER PROGRESS water source provided from SW network .
• ESP R&M PLANNED & CONTRACT
• Major evacuation monitoring data provided
AWRADED TO MEET THE STRINGENT
in PI system .
NORMS
• ECO HOPPER EFFECTIVE EVACUATION
MONITORED THROUGH PI SYSTEM ( TE
INSTALLED )

13
 CONCLUSION :
• The role played by operation engineers in formulating
strategies /practices is very important .
• To sustain the overall ESP performance , the operation
support group discusses all the strategies with shift
operation group on General shift days .
• After implementation of all best practices as discussed , at
TSTPS the overall performance of ESP & Ash evacuation
system improved indicated by consistency in ESP field
availability .
• The PI system has further strengthened in monitoring ,
analyzing and inturn developing the operating personnel to
a larger extent in maintaining & improving ESP
performance . 14
15
 Checking Proper installation and operation of
FA system devices .

• Vacuum Checks .
• Shutoff vacuum .
• Shutoff vacuum with air lock valve close.
• Vacuum with VB open
• Line Vacuum
• Functional Checks .
• Hopper empty vacuum check .
• Valve 100 % opening check .

16
 Use of PI system in FA Evacuation Monitoring

• Shut off vacuum Monitoring .

• System Idle time Ineffective evacuation
monitoring .
• Deterioration in system performance .
• System Good Performance
• Single Hopper Evacuation for long time.
• IA pressure for 100 % valve opening .
• DA evacuation & transportation system .
• BAG filter DP Monitoring .
17
 18
Next Slide
19
Shutoff vacuum check with air intake closed

20
 Economiser Hopper Evacuation temp Trend
Plot-0 44.510
39.297
300 46.099 3HNA30CT101.DACA.PV
40.973 52.280
218.84 3HNA30CT102.DACA.PV
250 228.75 38.108
185.21 3HNA30CT103.DACA.PV
147.98 54.672
3HNA30CT104.DACA.PV
200 44.367
4HNA30CT101.DACA.PV
38.025
4HNA30CT102.DACA.PV
150 36.721
4HNA30CT103.DACA.PV
36.638
4HNA30CT104.DACA.PV
100
30.518

50

0
2/6/2013 8:28:31 PM 2/7/2013 2:00:00 PM 2.67 days 2/9/2013 12:28:31 PM
21
Improper Evacuation From ESP Hoppers
(Idle Time more)

Next Slide
22
Improper Evacuation From ESP Hoppers

Next Slide

23
Improper Evacuation From ESP Hoppers

Next Slide

24
 Improper Evacuation
UNIT#6

600 \\10.0.120.202\GEN6_MW
356.37
500 \\10.0.120.202\6HFY00_1P02.SUMMER.PV
420.25
\\10.0.120.202\6PASSA_VAC_TX1
400
69.336
\\10.0.120.202\6PASSA_VAC_TX2
300 241.64
\\10.0.120.202\6PASSB_VAC_TX1
212.16
200
\\10.0.120.202\6PASSB_VAC_TX2
254.28
100 \\10.0.120.202\6PASSC_VAC_TX1
193.21
0 \\10.0.120.202\6PASSC_VAC_TX2
8/24/2012 9:33:41 AM 2.00 hours 8/24/2012 11:33:41 AM 293.67
ABT.GEN6 Instantaneous MW \\10.0.120.202\6PASSD_VAC_TX1
Unit#6 TOTAL COAL FLOW 210.25
UNIT#6 PASS A VACUUM TX-1 \\10.0.120.202\6PASSD_VAC_TX2
UNIT#6 PASS A VACUUM TX-2 107.14
UNIT#6 PASS B VACUUM TX-1
UNIT#6 PASS B VACUUM TX-2
UNIT#6 PASS C VACUUM TX-1
UNIT#6 PASS C VACUUM TX-2
UNIT#6 PASS D VACUUM TX-1
Next page
UNIT#6 PASS D VACUUM TX-2
25
 Hopper Evacuation With out proper vacuum
UNIT#4

500 \\10.0.120.202\GEN4_MW
450 351.97
\\10.0.120.202\4HFY00_1P02.SUMMER.PV
400
281.99
350 \\10.0.120.202\4PASSA_VAC_TX1
191.00
300
\\10.0.120.202\4PASSA_VAC_TX2
250 74.000
\\10.0.120.202\4PASSB_VAC_TX1
200
180.00
150 \\10.0.120.202\4PASSB_VAC_TX2
277.00
100
\\10.0.120.202\4PASSC_VAC_TX1
50 279.00
0 \\10.0.120.202\4PASSC_VAC_TX2
8/29/2012 5:42:54 PM 2.00 hours 8/29/2012 7:42:54 PM 210.00
ABT.GEN4 Instantaneous MW \\10.0.120.202\4PASSD_VAC_TX1
Unit#4 TOTAL COAL FLOW 0.0000
UNIT#4 PASS A VACUUM TX-1 \\10.0.120.202\4PASSD_VAC_TX2
UNIT#4 PASS A VACUUM TX-2 82.000
UNIT#4 PASS B VACUUM TX-1
UNIT#4 PASS B VACUUM TX-2
UNIT#4 PASS C VACUUM TX-1
UNIT#4 PASS C VACUUM TX-2
UNIT#4 PASS D VACUUM TX-1
UNIT#4 PASS D VACUUM TX-2

26
 U-4 A pass Evacuation deterioration
VP suction line choking
UNIT#4

600 \\10.0.120.202\GEN4_MW
511.03
500 \\10.0.120.202\4HFY00_1P02.SUMMER.PV
374.15
\\10.0.120.202\4PASSA_VAC_TX1
400
0.0000
\\10.0.120.202\4PASSA_VAC_TX2
300 211.00
\\10.0.120.202\4PASSB_VAC_TX1
95.000
200
\\10.0.120.202\4PASSB_VAC_TX2
222.00
100 \\10.0.120.202\4PASSC_VAC_TX1
228.00
0 \\10.0.120.202\4PASSC_VAC_TX2
11/25/2012 1:03:46.445 AM 1.33 days 11/26/2012 9:03:46.445 AM 0.0000
ABT.GEN4 Instantaneous MW \\10.0.120.202\4PASSD_VAC_TX1
Unit#4 TOTAL COAL FLOW 68.000
UNIT#4 PASS A VACUUM TX-1 \\10.0.120.202\4PASSD_VAC_TX2
UNIT#4 PASS A VACUUM TX-2 60.000
UNIT#4 PASS B VACUUM TX-1
UNIT#4 PASS B VACUUM TX-2
UNIT#4 PASS C VACUUM TX-1
Indicates Empty Vacuum is increasing ,
UNIT#4 PASS C VACUUM TX-2 suction line choking , System stopped
UNIT#4 PASS D VACUUM TX-1
UNIT#4 PASS D VACUUM TX-2 27
 Dry ash transportation trend
IA & TR Line Press

5.7 \\10.0.120.202\U56_INSTAIR_HDRPR
5.0244
kg/cm2
5
\\10.0.120.202\U34_INSTAIR_HDRPR
5.6732
kg/cm2
\\10.0.120.202\3LINE1PRESSURE
4 0.57218
kg/cm2
\\10.0.120.202\3LINE2PRESSURE
0.64831
3 kg/cm2

0
11/11/2012 12:51:28 AM 16.00 hours 11/11/2012 4:51:28 PM
Unit#5&6 ESP INST AIR HDR PRESSURE
Unit#3&4 ESP INST AIR HDR PRESSURE
Unit#3 DRY ASH TRANSPORT LINE L1 PRESSURE
Next Slide
Unit#3 DRY ASH TRANSPORT LINE L2 PRESSURE

28
 Line-2 Choking On 6-11-2012
IA & TR Line Press

6 \\10.0.120.202\U56_INSTAIR_HDRPR
4.9191
kg/cm2
\\10.0.120.202\U34_INSTAIR_HDRPR
5
5.0822
kg/cm2
\\10.0.120.202\3LINE1PRESSURE
9.8555E-02
4
Green kg/cm2
\\10.0.120.202\3LINE2PRESSURE

Colour IA 1.1154
kg/cm2
3
pressure
Reduction
2

Pink
1
Colour Line
pressure
0
hunting
11/2/2012 4:16:03 PM 2.67 days 11/5/2012 8:16:03 AM
Unit#5&6 ESP INST AIR HDR PRESSURE
Unit#3&4 ESP INST AIR HDR PRESSURE
Unit#3 DRY ASH TRANSPORT LINE L1 PRESSURE Next Slide
Unit#3 DRY ASH TRANSPORT LINE L2 PRESSURE

29
 LINE-2 NO TRANSPORTATION
IA & TR Line Press

4.95 \\10.0.120.202\U56_INSTAIR_HDRPR
4.6036
4.5 kg/cm2
\\10.0.120.202\U34_INSTAIR_HDRPR
4 4.7040
kg/cm2
\\10.0.120.202\3LINE1PRESSURE
3.5
Line -2 0.93655
kg/cm2
3 Transportation \\10.0.120.202\3LINE2PRESSURE

stopped 0.47682
kg/cm2
2.5

1.5

0.5

0
11/22/2012 1:26:28 AM 8.00 hours 11/22/2012 9:26:28 AM
Unit#5&6 ESP INST AIR HDR PRESSURE
Unit#3&4 ESP INST AIR HDR PRESSURE
Unit#3 DRY ASH TRANSPORT LINE L1 PRESSURE
Unit#3 DRY ASH TRANSPORT LINE L2 PRESSURE

30
 Single Hopper Evacuation for long time
UNIT#4

500 \\10.0.120.202\GEN4_MW
450 351.97
\\10.0.120.202\4HFY00_1P02.SUMMER.PV
400
281.99
350 \\10.0.120.202\4PASSA_VAC_TX1
191.00
300
\\10.0.120.202\4PASSA_VAC_TX2
250 74.000
\\10.0.120.202\4PASSB_VAC_TX1
200
180.00
150 \\10.0.120.202\4PASSB_VAC_TX2
277.00
100
\\10.0.120.202\4PASSC_VAC_TX1
50 279.00
0 \\10.0.120.202\4PASSC_VAC_TX2
8/29/2012 5:42:54 PM 2.00 hours 8/29/2012 7:42:54 PM 210.00
ABT.GEN4 Instantaneous MW \\10.0.120.202\4PASSD_VAC_TX1
Unit#4 TOTAL COAL FLOW 0.0000
UNIT#4 PASS A VACUUM TX-1 \\10.0.120.202\4PASSD_VAC_TX2
UNIT#4 PASS A VACUUM TX-2 82.000
UNIT#4 PASS B VACUUM TX-1
UNIT#4 PASS B VACUUM TX-2
UNIT#4 PASS C VACUUM TX-1
UNIT#4 PASS C VACUUM TX-2
UNIT#4 PASS D VACUUM TX-1 Next Slide
UNIT#4 PASS D VACUUM TX-2
31
 Single Hopper Evacuation for long duration
UNIT#4

500 \\10.0.120.202\GEN4_MW
450 351.97
\\10.0.120.202\4HFY00_1P02.SUMMER.PV
400
281.99
350 \\10.0.120.202\4PASSA_VAC_TX1
191.00
300
\\10.0.120.202\4PASSA_VAC_TX2
250 74.000
\\10.0.120.202\4PASSB_VAC_TX1
200
180.00
150 \\10.0.120.202\4PASSB_VAC_TX2
277.00
100
\\10.0.120.202\4PASSC_VAC_TX1
50 279.00
0 \\10.0.120.202\4PASSC_VAC_TX2
8/29/2012 5:42:54 PM 2.00 hours 8/29/2012 7:42:54 PM 210.00
ABT.GEN4 Instantaneous MW \\10.0.120.202\4PASSD_VAC_TX1
Unit#4 TOTAL COAL FLOW 0.0000
UNIT#4 PASS A VACUUM TX-1 \\10.0.120.202\4PASSD_VAC_TX2
UNIT#4 PASS A VACUUM TX-2 82.000
UNIT#4 PASS B VACUUM TX-1
UNIT#4 PASS B VACUUM TX-2
UNIT#4 PASS C VACUUM TX-1
UNIT#4 PASS C VACUUM TX-2
UNIT#4 PASS D VACUUM TX-1
UNIT#4 PASS D VACUUM TX-2
32
 Shut Off Vacuum Check
UNIT#3 Shutoff Vac < 450 mmhg
450 \\10.0.120.202\GEN3_MW
400 332.01
\\10.0.120.202\3HFY00_1P02.SUMMER.PV
350 375.62
\\10.0.120.202\3PASSA_VAC_TX1
300
57.098
250 \\10.0.120.202\3PASSA_VAC_TX2
80.008
200 \\10.0.120.202\3PASSB_VAC_TX1
100.27
150
\\10.0.120.202\3PASSB_VAC_TX2
100 68.107
\\10.0.120.202\3PASSC_VAC_TX1
50 78.750
0 \\10.0.120.202\3PASSC_VAC_TX2
8/25/2012 7:31:50 AM 8.92 minutes 8/25/2012 7:40:45 AM 60.753
ABT.GEN3 Instantaneous MW \\10.0.120.202\3PASSD_VAC_TX1
Unit#3 TOTAL COAL FLOW 88.000
UNIT#3 PASS A VACUUM TX-1 \\10.0.120.202\3PASSD_VAC_TX2
UNIT#3 PASS A VACUUM TX-2 0.0000
UNIT#3 PASS B VACUUM TX-1
UNIT#3 PASS B VACUUM TX-2
UNIT#3 PASS C VACUUM TX-1
UNIT#3 PASS C VACUUM TX-2
UNIT#3 PASS D VACUUM TX-1
UNIT#3 PASS D VACUUM TX-2
33
 IA Pressure Low in Unit 5&6
IA & TR Line Press

6 \\10.0.120.202\U56_INSTAIR_HDRPR
4.9191
kg/cm2
\\10.0.120.202\U34_INSTAIR_HDRPR
5
5.0822
kg/cm2
\\10.0.120.202\3LINE1PRESSURE
9.8555E-02
4
kg/cm2
\\10.0.120.202\3LINE2PRESSURE
1.1154
IA kg/cm2
3
Pressure
dropped
2

IA
Pressure
1
improved
0
11/2/2012 4:16:03 PM 2.67 days 11/5/2012 8:16:03 AM
Unit#5&6 ESP INST AIR HDR PRESSURE
Unit#3&4 ESP INST AIR HDR PRESSURE
Unit#3 DRY ASH TRANSPORT LINE L1 PRESSURE
Unit#3 DRY ASH TRANSPORT LINE L2 PRESSURE

34
Next Slide
35
Next Slide
36
Next Slide
37
38
Trends of Proper FA Evacuation

39
Use of TEMPLATE for MHV operation checking

40
 Thermostat Location Changed
Old Thermostat Locations New thermostat locations

Next Slide
41
Hopper/Casing manhole air ingress .
HOPPER MANHOLE AIR INGRESS CASING MANHOLE AIR INGRESS

42
GD screen inspection & rectification ,
placement of flow baffels

43
Ash Build up in Support Insulator Housing of U-3 ESP

44
Hopper /Casing manhole Doors , source
of air ingress in ESP ( ESP Pr. test)

45
ESP Field Alignment check Before & After OH

Next Slide
46
ESP Field Misalignment

47
ESP Field Non Rapping side Lower Shock bar
Guide Position Check .

48
VI characteristics check for all fields

49
50
Eco hopper TE Fixing

51
52
 ADVANTAGES TOWER TYPE BOILER
OVER TWO PASS BOILER
TOWER TYPE (SINGLE PASS) INVERTED U TYPE (TWO PASS)
 Heating surfaces are fully drainable (horizontal).  Heating surfaces are not drainable (vertical). Hence
Restart behavior is excellent. slow startup and corrosion problem.

 Heat exchangers are horizontal and tubes are  Heat exchangers are vertical and exposed to
exposed to uniform temperature. different gas temperature along the height.
 No blockage of ash in the convective heating  Accumulation of ash on economizer tubes where
surfaces. as pitch of the coils is increasing from the the pitch is smaller. Hence local flue gas velocities
top to the bottom . increases and erosion occurs.
 Pressure parts wear is less due to Impact of ash by  In rear pass the ash particles velocity accelerates
counter action of gravity in the upward gas flow. due to gravity and increases erosion.
 Turbulence created by the change in direction of
 Uniform Flue gas velocity & continuously upward
flue gas flow generates high local velocities causes
without any change in direction.
local erosion.
 Thermal expansion of first pass and second pass is
 Even flow distribution of flue gas and particulates
different.
 Direct load transmission to the boiler roof and free  Non-drainable heating surfaces having risk of flow
expansion imbalance.
53
 Spiral WW & Vertical WW Design
The Spiral WW Vertical tube once through
 Benefits from averaging of lateral boiler
heat absorption variation (each tube Lower capital costs:
forms a part of each furnace wall)  Self-supporting tubes, hence
 Fewer tubes than the vertical wall simplifying part of the boiler
unit. support system
 Simplified inlet header  Elimination of transition headers at
arrangement. spiral/vertical interface
 Large number of operating units.  Simpler ash hopper tubing
 Use of smooth bore tubing geometry.
throughout entire furnace wall Lower operating costs:
system. ( instead of Rifled tube)  Lower overall boiler pressure drop,
 No individual tube orifices like drum hence lower auxiliary power load
boilers . resulting in higher plant output and
 the negative flow characteristics of higher efficiency
the spiral furnace .  ‘Positive flow characteristic’
automatically compensates for
variations in furnace absorptions .
 Simple and economic tube repair
 Simple start-up system, a start-up
circulation pump is not required
 Reduced slagging of furnace walls
 Lower part loads down to 20% are
possible while maintaining high
steam temperatures. 54
Enthalpy Control

55
 Special Protections Used
DESCRIPTION Logic Set Value
Separator level very high and no
2/3 > 12.9 Mtr
drainage.
Evaporator flow LO-LO (FW flow - SH
2/3 < 420 t/hr
spray flow)
Spiral outlet tube metal temp. HI-HI. 3/8 470 0 C
Evaporator outlet steam temp. HI-HI 2/4 4650 C
ITSH outlet steam temp. very high. 2/4 505 0 C
LTRH outlet steam temp. very high. 2/4 520 0 C
Both the steam valves closed. 2/3 Closed

56
 DETAILS OF UNIT STARTUP PARAMETERS.
Stage - I & Stage - II Units
Stage - I Units Stage- II Units
Parameters
Cold Warm Hot Cold Warm Hot
Startup Criteria >240 0C
(Mean Rotor Temp )
< 160 0C > 430 0C > 48 Hrs 0-48 hrs < 8 Hrs
< 430 0C
BLU to Rolling 1:20Hrs 1:15Hrs 2:05Hrs 1:25 Hrs
Parameters
35 min 35 min
80 min 75 min 125 min 85 min
TG set Rolling Time i.e
up to 3000 RPM
50 min 17 min 07 min 45 min 6-7 min 6-7 min

2:15 hrs 1:40 min 2:50 Hrs 1:35 Hrs

BLU to synchronisation 36 min 50 min
135 min 100 min 170 min 95 min
Best achieved
Parameters BLU to 2:00 1:48 0:58 3:30 2:10 0:54
Synch
Synchronisation to Full 2:05 Hrs 1:20 Hrs 3:50 Hrs 3:20 Hrs
Load Operation
30 Min 30 min
125 min 80 Min 230 Min 200 Min
6:40 Hrs 5:00 Hrs 1:20 Hrs
BLU to Full Load 4:20 hrs 3:00 Hrs 1:10 Hrs
400 Min 300 Min 80 Min

57
SDCS ( startup drain control system)
 Wet Mode of operation like
drum boiler
 Dry Mode Of Operation (> 35%
of load )

58
Next Slide 59
Next Slide
60
 Advantages of Tube Mill
Advantages Disadvantages
 High availability  Fire fighting system is additional
 No. Of auxiliary drives per mill are
 Low running maintenance
more
 Constant capacity and fineness  High auxiliary power consumption
 Hard & abrasive fuel ground
 Prone for explosion
efficiency
 Cumbersome protection &
 Large reserve capacity of coal interlocks ( Purging/steam inerting
Etc)
 Fast response over wide range of
load
 Increased fineness at low load
and hence flame stability
 Low air/coal ratio
 Wide range of coal pulverized
 Substantial flexibility
61
5
62
HVDC system

5 63
 Special protection Scheme
INTERTRIP SCHEME DUE TO HVDC CONDITION ACTION
POLE OUTAGES ( SPS 450) Unit # 5 will trip and unit
If HVDC power flow is more than 1600 MW
•One Pole Blocked and Ex – Bus # 4 & 6 shall be unloaded
and both pose blocked.
by 150 MW each.
Generation > 1750 MW.
If HVDC power flow is more than 1450 & less
Tripping of Unit # 6
than 1600 MW and both pole blocked. OR Unit # 5 shall trip and
Instantaneously. HVDC power flow more than 1600 MW and unit # 6 will be unloaded
•Both Pole Blocked & Ex – Bus one pole blocked with remaining pole on by 150 MW.
Generation > 550 MW ground return mode.
Tripping of Unit # 5 If HVDC power flow more than 1300 MW and
instantaneously less than 1450 MW and both pole blocked Unit # 4, 5, 6 shall be
Tripping of Unit # 6 after 1 second .(OR) HVDC power flow more than 1450 MW unloaded by 150 MW
time delay and less than 1600 MW and one pole blocked each.
Tripping of Unit 4 after 2 Seconds with remaining pole on ground return mode.
time delay If HVDC power flow is more than 1150 MW
and less than 1300 MW and both pole
•Both Pole Blocked & Ex – Bus Unit # 4 & 6 shall be
blocked. (OR) HVDC power flow is more
Generation > 1100 MW unloaded by 150 MW
than 1300 MW and less than 1450 MW and
Tripping of unit # 5 each.
one pole blocked with remaining pole on
instantaneously. ground return mode.
Tripping of Unit # 6 If HVDC power flow more than 1000 MW and
instantaneously. less than 1150 MW & both pole blocked. OR)
Unit # 6 shall be
Tripping of Unit # 4 after 2 HVDC power flow more than 1150 MW and
unloaded by 150 MW.
Seconds time delay. less than 1300 MW and one pole blocked and
remaining pole on ground return mode. 5 64
 VFD FOR ID FANS
Variable frequency drive
with load commutated inverter.

3-ph dc
ac xmer rect inv Synch motor
EFFICIENCY OF drive systems.
Fan speed Fluid coupling VFD system
100% 85% 85%
90% 75% 84%
80% 65% 83%
70% 56% 82%
60% 46% 80%
5 65
ESP 1ST FIELD OUT OF SERVICE

66
2ND LARGEST THERMAL POWER PLANT OF NTPC
67
NTPC KANIHA 6X500 MW UNITS 68
 Bag Filter DP Monitoring
DRY_WET-U#4

350 \\10.0.120.202\4PASSA_BF_DP
I/O Timeout
mmw c
300
\\10.0.120.202\4PASSB_BF_DP
6.3208
mmw c
250
\\10.0.120.202\4PASSC_BF_DP
I/O Timeout
200 mmw c
\\10.0.120.202\4PASSD_BF_DP
249.87
150 mmw c
\\10.0.120.202\4PASSA_VAC_TX2
\\10.0.120.202\4PASSB_VAC_TX1
100 \\10.0.120.202\4PASSC_VAC_TX2
\\10.0.120.202\4PASSD_VAC_TX2

50

0
2/1/2013 12:40:17 PM 1.33 days 2/2/2013 8:40:17 PM
Unit#4 PASS A BUFFER HOPPER BAG FILTER DP
Unit#4 PASS B BUFFER HOPPER BAG FILTER DP
Unit#4 PASS C BUFFER HOPPER BAG FILTER DP
Unit#4 PASS D BUFFER HOPPER BAG FILTER DP

69
Gas Screen Modification

Next Slide
70
Gas Screen Modification

71
 Eco Hopper Temp Element
Fixing of Temp element at Eco
Hopper Adapter Eco Hopper Temp at DCS system

Next Slide
72
73
74
MEGGERING OF ESP FIELD

75
 TSTPS MILE STONES

U#1 U#2 U#3 U#4 U#5 U#6

1ST BOILER
LIGHT UP
02.10.94 22.11.95 11.09.02 05.07.03 18.01.04 27.09.04

SYNCHRONI
SATION
12.02.95 27.03.96 04.01.03 25.10.03 13.05.04 06.02.05

COMMERCI
ALISATION
01.01.97 01.07.97 01.08.03 01.03.04 01.11.04 01.08.05

76
 UNIQUE FEATURES OF STAGE – I UNITS
 Tower type (single pass) , subcritical once through boiler .
 Spiral & Vertical Water Wall combination for Evaporator.
 Enthalpy control for evaporator flow control instead of drum
level control .
 Sliding pressure operation combined with nozzle governed
turbine .
 Advantage of quick start up and flexible load variation.
 Special protections for once through boilers .
 Double ended Tube Mills for fast load picking up ( Reject
Less Mill ).
 SDCS ( Startup Drain Control System ) for unit startup & low
load operation .
 High efficient ESP ( > 99.9 % ).
 GCB in between generator & GT , thus avoiding the station
XFMR .
 Concept of ‘Plant Zero discharge’ implemented . 77
 UNIQUE FEATURES OF STAGE - II

 CENTRALISED CONTROL ROOM FOR ALL 4 UNITS OF STAGE – II

 FEEDING THROUGH HVDC LINK TO SOUTHERN GRID .
 SPECIAL PROTECTION SCHEME SPS 450/1000
 FURNACE DRAFT CONTROL BY VARIABLE FREQUENCY DRIVE FOR
ID FANS . ( 30 % power reduction)
 GCB PROVIDED IN BETWEEN GT & GENERTAOR, AVOIDED STATION
XFMR .
 VAPOUR ABSORPTION MACHINE FOR AIR CONDITIONING OF
CONTROL TOWER .
78
 MAJOR ESP & ASH HANDLING SYSTEM
PROBLEMS EXPERIENCED AT TSTPS .
 High FG volume loading (777 m3/sec → 1050-1100 m3/sec).
 Frequent outage of 1st & 2nd fields .
 Failure of Hopper Heaters .(plate type)
 Failure of Gas Screens , lower shock bar guide .
 Ash Flowability from ESP hoppers .
 Ash Buildup in ESP Hopper , Mal Operation of ESP level
probe .
 Fluidizing blower outlet temp low .
 More evacuation time in B&C pass .
 1st hopper evacuation in dry mode .
 FA system shutdown / Back log clearing was a problem 79