PRESENTATION ON (site name)

OPERATION 2014-15
presented by
(J.SENTHIL KUMAR)

HODs MEET 2015

AP-TG REGION

VENUE:
DATE:

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

INTRODUCTION
Plant capacity and type (35 MW &
CPP)
Plant location : GUMMIDIPOONDI
Plant commissioned on (12.06.2013)
Plant O&M commenced on (MARCH
2013)

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

PLANT DETAILS
Sl.
No.
1
2
3

DESCRIPTION
NO. OF BOILER AVAILABLE IN EACH
TYPE
EACH BOILER MAKE
EACH BOILER CAPACITY

BLR MS PARAMETERS

5
6
7

PREDOMINANT FUEL USED

TG MAKE (If available)
TG CAPACITY (If available)

TG MS PARAMETERS(If available)

WTP MAKE

10

RO-DM CAPACITY

11

COOLING TOWER MAKE

12

COOLING TOWER TYPE

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

DATA
1
GB ENGINEERING
150 TPH
PRE:95 Kg/Sq.cm /
TEMP:525 5 C
COAL
SIEMENS
35 MW
PRE:89 Kg/Sq.cm /
TEMP:520 C

PLANT DETAILS (contd)

Sl.
No.

DESCRIPTION

13

CHP MAKE

14

CHP CAPACITY

15

AHP MAKE

16

AHP CAPACITY

17

ASH SILO CAP (in hrs & tons)

18

PROCESS PLANT PRODUCT

150 TPH

19

PROCESS PLANT MAX POWER/STEAM

OR BOTH
REQUIRMENT/HR

20

PROCESS PLANT PRODUCTION CAP(If

more than one mention each)

21
10/24/16

DATA

DG SET CAPACITY
MANKIND IS IN PURSUIT OF TRUTH,
LET US WORK TOWARDS THIS

625 KVA
4

PLANT AVAILABILITY FACTOR

(in %)
120.0

100.0

80.0

60.0

40.0

20.0

0.0

APR'14 MAY'14 JUN'14 JUL'14 AUG'14 SEP'14 OCT'14 NOV'14 DEC'14 JAN'15 FEB'15 MAR'15

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

PLANT LOAD FACTOR (in %)

120.0

100.0

80.0

60.0

40.0

20.0

0.0

APR'14 MAY'14 JUN'14 JUL'14 AUG'14 SEP'14 OCT'14 NOV'14 DEC'14 JAN'15 FEB'15 MAR'15

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

POWER GENERATION (in

MW)
30000
25000
20000
15000
10000
5000
0
-5000
-10000
-15000
10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

AUXILIARY CONSUMPTION
(in %)
14
12
10
8
6
4
2
0

APR'14 MAY'14 JUN'14

JUL'14 AUG'14 SEP'14 OCT'14 NOV'14 DEC'14 JAN'15 FEB'15 MAR'15

-2
-4

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

FUEL GCV
(bunker coal - as fired basis)
5000

4000

3000

2000

1000

APR'14 MAY'14 JUN'14 JUL'14 AUG'14 SEP'14 OCT'14 NOV'14 DEC'14 JAN'15 FEB'15 MAR'15

-1000

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

BOILER-1 EFFICIENCY (in %)

100

80

60

40

20

APR'14 MAY'14 JUN'14 JUL'14 AUG'14 SEP'14 OCT'14 NOV'14 DEC'14 JAN'15 FEB'15 MAR'15

-20

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

10

TURBINE-1 HEAT RATE

(kcal/kwhr)
3000

2500

2000

1500

1000

500

APR'14 MAY'14 JUN'14 JUL'14 AUG'14 SEP'14 OCT'14 NOV'14 DEC'14 JAN'15 FEB'15 MAR'15

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

11

UNIT-1 GROSS PLANT HEAT RATE

(kcal/kwhr)
4000
3500
3000
2500
2000
1500
1000
500
0

APR'14 MAY'14 JUN'14 JUL'14 AUG'14 SEP'14 OCT'14 NOV'14 DEC'14 JAN'15 FEB'15 MAR'15

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

12

NO. OF TRIPS/OUTAGES
MONT
H
APR14
(1 Trip)

TRIP DESCRIPTION

DURAT
ION

REASON FOR TRIP

1. BOILER &
TURBINE GOT TRIP.

1.5 hrs

UAT transformer
synchronising time
tie incomer tripped.

1. BOILER &
TURBINE GOT TRIP.
MAY14
(5
Trips)

JUNE1

10/24/16
4 (6

Trips)

2 hrs

REMEDIAL
ACTION TOOK

DT LT INCOMER-3 & WTP LT

INCOMER BREAKER UNDER
VOLTAGE OPERATED DUE TO
SETTINGS CHANGED
EB FLUXIVATION(230 KV EB
SIDE ONE FEEDER TRIPPED
SAME TIME)
ID-1,PA-1 &2 TRIPPED DUE
TO OVER CURRENT (110 KV
LINE EB DISTURBANCE )
INFORMED TO EB
STATION INCOMER L31
ALARM CAME

2. BOILER &
TURBINE GOT TRIP.

1.30 hrs

3. BOILER &
TURBINE GOT TRIP.

3.35 hrs

PA-2 TRIPPED DUE TO

MOTOR DE TEMPERATURE
HIGH,

RTD CHECKED

4. BOILER &
TURBINE GOT TRIP.

18.30 hrs

UPS-1 & 2 FAILED .SO DCS

SYSTEM OFF AND PLANT
TRIPPED

CARD REPLACED

5. BOILER &
TURBINE GOT TRIP.

2.45 hrs

UPS-1&2 SYNCHRONISED

UPS-2 CHECKED

01.10 hrs

GENERATOR TRIPPED DUE TO

OVER CURRENT

INFORMED TO EB

1. BOILER &
TURBINE GOT TRIP.

13

OPERATION CHALLENGES
SL.NO

CHALLENGES

WATER WALL
REAR SIDE
TUBE FAILURE & FEEDING HAS
ERROSION
STOPPED,
FAILURE TUBE
REPLACEMENT,
ERRODED
TUBES
BUTTERING
WORK DONE &
AIR FLOW TO
FURNACE HAS
CONTROLLED.

IN KICK OFF
ZONE 1 MTR
LENGTH TUBE
THICKNESS
FOUND LESS.

BED ASH
NEW BELLOW
COOLER NOT IN ORDER WAS
SERVICE.
PLACED.
MANKIND IS IN PURSUIT OF TRUTH,
CONVEYING
SS
LET US WORK TOWARDS THIS

BOTH SIDE NOT

IN SERVICE.

10/24/16

ACTION TOOK

PRESENT
STATUS

14

OPERATION CASE STUDIES

1) WATER WALL TUBE ERROSION & FAILURE:
DUE TO HIGH VELOCITY OF COMBUSTION AIR &
WHILE CIRCULATING THE BED DENSITY PARTICLES
FALLING FROM TOP & IRON % CONTENT IN COAL.
2) BED ASH COOLER SERVICE:
CONVEYING SS BELLOW GOT DAMAGED & BED
MATERIAL NOT SHIFTED PROPERLY FROM FURNACE
TO BED ASH COOLER.
3) HOME LOAD NOT IN SERVICE:
WHILE EB FAILURE PLANT GOT TRIP BECAUSE TG NOT
WITH STAND IN HOME LOAD. UAT NOT YET PROPERLY
COMMISSIONED.
10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

15

REPORTS SYSTEM
Write various kinds of report you generate such
as daily, weekly, monthly, etc
1) WE ARE GENERATING DAILY, MONTHLY, SHUT
DOWN & ANNUAL REPORTS.
2) IN THIS REPORTS WE ARE MAINTAINING
PLANT PERFORMANCE
(BOILER,TURBINE),PLF,EFFICIENCY,HEAT
RATE(PLANT,TURBINE)PM,VIBRATION READINGS
FOR ALL EQUP, WATER QUALITY REPORTS, CHP
REPORTS, MECHANICAL, ELECTRICAL,
INSTRUMETATION REPORTS.
10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

16

NEW IMPLEMENTATIONS/SYSTEMS
ADAPTED IN THE YEAR
1)

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

17

OPPORTUNITIES FOR IMPROVEMENT

IN OPEARATION
SL.NO

OFIOPERATION

ACTION TOOK

AUTO
COMBUSTION
TO BE TAKEN.

LOGIC TO BE
CHECK

START UP
BURNER
LOGICS TO BE
SIMPLIFIED.

EMRV TAKEN IN
TO SERVICE.

WHILE EB
FAILURE PLANT
COMES TO
HOME LOAD

WHILE EB
FAILURE TO

10/24/16

PRESENT
STATUS

UAT NOT YET

COMMISSIONED

18

NEXT YEAR PLANS

1) BED ASH COOLER MODIFICATION WORK.
2) DAMAGED AIR NOZZLES REPLACEMENT
WORK.
3) DAMAGED ACC FAN BLADES
REPLACEMENT
4) AUTO COMBUSTION TAKEN IN TO
OPERATION.
5)WATER WALL METAL SPRAYING FOR
AVOIDING TUBE EROSION AND TUBE FILURE.
6)
10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

19

RELATION WITH CLIENT OPERATION

TEAM
1) WE ARE MAINTANING GOOD RELATION
SHIP WITH CLIENT OPERATION TEAM.
2) DAILY THEY CONDUCTING MEETING AND
WE DICUSSING ABOUT PLANT
PERFORMANCE AND HOW TO IMPROVE THE
PLANT AVAILABILITY & OPERATION.
3) OUR OPERATION TEAM GIVEN SOME
GOOD SUJECTIONS TO CLIENT FOR BOILER
& TURBINE OPERATION AND SAME THEY
ALSO ACCEPTED.
10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

20

SAFETY AT WORK
MONTH

INCIDENTS

REMEDIAL ACTION
TAKEN

NIL

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

21

TRAININGS FOR THE YEAR

10/24/16

MONTH

TOPIC/S

GIVEN BY

NO.OF
PARTICIPA
NTS

JAN15

Work permit
system,
Conveyor
belt safety

T.Saravanan
,
A.Kumar

53

FEB15

Safety
measures
near
rotating
parts,
Cleanliness,
Emergency
planning

T.Saravanan

48

MAR15

CPR, Safety
Belt

T.Saravanan

75

APR15

Fire fighting
training,

Usha fire &

safety,

73

TRAININGS FOR THE YEAR

10/24/16

MONTH

TOPIC/S

GIVEN BY

NO.OF
PARTICIPA
NTS

MAY15

First aid,
Hot, Height
work permit

T.Saravanan

89

JUN15

Fire Fighting
pumps,
Emergency
planningSiren
use,EOT
Crane
operation

T.Saravanan

92

JUL15

Structure
use for first
aid , 5S

T.Saravanan

79

AUG15

Safety
Rules, Fire

T.Saravanan

122

TRAININGS FOR THE YEAR

10/24/16

MONTH

TOPIC/S

GIVEN BY

NO.OF
PARTICIPA
NTS

SEP15

Coal yard,
conveyor
safety

T.Saravanan

67

OCT15

Close call,
Case
Studies

T.Saravanan
, A.Kumar

43

NOV15

CHP Safety
Inter Logs,
Personal
Safety

T.Saravanan

65

DEC15

Shutdown
jobs-Unsafe
act

T.Saravanan
, A.Kumar

24

MY TEAM INCLUSIVE OF.

DESIGNATI
ON

ORG.
CHART

ACTUAL

SHORT

EXCESS

OPERATION
INCHARGE

NILL

NILL

SHIFT
INCHARGE

NILL

NILL

DCS
OPERATOR

BOILER
FIELD
OPERATOR

NILL

TURBINE
FIELD
OPERATOR

NILL

NILL

CHP/AHP
OPERATOR

NILL

NILL

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

25

MY TEAM IS SUPPORTIVE IN ACHIEVING BEST

OPERATION PRACTICES BECAUSE

1) EVERY MONTH WE ARE ACHIEVING

TRAGETED PLF.
2) WE ARE OPERATING THE PLANT
WITHOUT ANY OPERATION RELATED
PROBLEMS.
3) WE ARE GIVING GOOD
PERFORMANCE AND MAX. PLANT
AVAILABILITY.
4)
10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

26

OPPORTUNITIES FOR IMPROVEMENT

IN MY TEAM
SL.NO

OFI-TEAM

TRAINING
CLASS TO BE
CONDUCTED.

SEMINAR CLASS
TO BE
CONDUCTED.

INTER
RELATIONSHIP
& DISCUSSION
DEVELOPMENT
WITH OTHER
SITE TECH
PERSON

10/24/16

ACTION TOOK

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

PRESENT
STATUS

27

OUR REQUIREMENTS
1)

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

28

QUESTIONS?

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

29

THANK YOU

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

30