SGA REDUCTION OF PA & ID FAN LOADING

Transcription

1 SGA REDUCTION OF PA & ID FAN LOADING Project: Reduction of PA and ID fan loading Baseline: 1. PA Fan 1265 KW 2.ID Fan 1844 KW Target: 1. PA Fan 1215 KW 2.ID Fan 1800 KW Resources - Team Members Name Role Dept/Function Manas Tyagi Facilitator Head Operation (CPP) Aadarsh Leader Maintenance (CPP) Atish Member O&E (CPP) Vivek Member O&E (CPP)

2 1.IDENTIFICATION OF PROBLEM

3 1. IDENTIFICATION OF PROBLEM S No LIST OF PROBLEMS IDENTIFIED Area of Work 1 SADC not functioning properly Boiler 2 High PA Header pressure for Mills Boiler 3 High air leakage % in APH Boiler 4 High DP across Fabric filter Boiler 5 Pent house air leakage Boiler 6 Duct air leakage Boiler 7 Damper Problem Boiler 8 Seal trough air ingress Boiler 9 Dog house air ingress Boiler

4 2.SELECTION OF PROBLEM

5 2.1 PROBLEM SELECTION

6 2.2 MILESTONE CHART QUALITY CIRCLE NAME - ELEVATE REGISTATION NO - DEPARTMENT- O&E PROJECT TITLE - Reduction of Fan Loading PROJECT N0-01 MEETING DAY - SATURDAY PROJECT CATEGORY NO - A DATE OF COMPLETION - DATE OF BEGINNING -01/07/14 31/03/2015 MEETING TIME - 16:00hrs TEAM MEMBERS - Aadarsh, Manas, Prakhar,Vivek,Atish SL NO ACTIVITY Jul-14 Aug-14 Sep-14 Oct-14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15 Remarks 1 Definition of problem 2 Analysis of problem 3 Identification of causes 4 Find out the root causes 5 Data analysis 6 Developing solutions 7 Foreseeing possible resistance 8 Trial implimentation and checking performances 9 Regular implimentation Horizontal deployment 10 Follow up and reviews

7 3.DEFINING THE PROBLEM

8 3.1 DEFINING THE PROBLEM 1. High PA Header pressure for Mills : PA pressure > 8.5 Kpa. 2. High air leakage % in APH > 8 %

9 3.2 PROCESS FLOW DIAGRAM

10 3.3 PROBLEM AREA

11 3.4 PROBLEM AREA Original APH had flue gas leakage and erosion which caused damage to Hot end layer. APH Seals were also damaged due to gas erosion. Air leakage % of all the units were on Higher sides

12 4. ANALYSIS OF PROBLEM

13 4.1 (4-W + 1-H Analysis) OBJECTIVE 1. PA fan loading reduction 2. ID fan loading reduction PROJECT - High loading of PA & ID fan GOAL TOOL WHAT WHERE WHEN WHOM HOW Process optimization and improvement in equipment performance QUESTION What is the problem Where is the problem When the problem occurs Whom it is concern How it is affecting ANSWER Fan loading is high In APH and high primary air pressure After six month of annual overhaul O & M 1. Due to higher % of air leakage in APH fan loading increasing.

14 5. IDENTIFICATION OF CAUSES

15 5.1 CAUSE & EFFECT DIAGRAM

16 5.2 CAUSE & EFFECT PRIOTRIZATION S.No Cause Effect level S.No Cause Effect Level 1 Mill Outlet Temperature Low 10 Improper Soot blowing Low 2 Coal quality Low 11 High Bag filter DP HIGH 3 Damper problem Low 12 Inlet guide vane problem Low 4 Motor & Fan efficiency Low 13 Moisture in flue gas, pulsing air Low 5 Air Ingress in APH HIGH 14 SADC Damper Low 6 Duct leakages Low 15 High excess air Low 7 Seal Air fan damper passing Low 16 Higher PA Pressure HIGH 8 Seal trough passing Low 17 Moist. Variation with climate Low 9 High inlet air ambient air temp. Low

17 6. ROOT CAUSE ANALYSIS

18 6.1 HIGH IMPACT ROOT CAUSES Root cause Air Ingress in APH DEFINITION Air Ingress in APH is due to increase in clearance between rotating & stationary part as flue gas side operating in negative pressure & PA FD Side operating in positive pressure High DP of FF High DP in Fabric filter is mainly due to excess flue gas loading due to APH leakages, moisture in flue gas etc. High PA Pressure High PA air pressure operation wrt design increases fan loading 1

19 7. DATA ANALYSIS ON ROOT CAUSE

20 7.1 High Air Ingress in APH seal plates are provided to avoid leakages of gases or air between the sectors while in rotation. The gap adjusted between the seal and sector plate as per the OEM recommendation as follow Radial Seal APH Seals Design Six month after AOH Hot End Cold End Hot End Cold End Inboard to 15 0 to 2 Outboard to 5 9 to 10 Axial Seal to 8 3 to 4 Bypass Seal to 7 9 to 10 APH seals are getting eroded due to high ash in flue gas and the gap between the seals and sector plate found to be in range as follows : The above data reflects that the gap between the seals ( mostly radial) sector plate has increased which resulted into high air leakages.

21 KW % Following graph shows the month wise increase of APH air leakage in unit # 7 APH Air Leakage % Vs Fan Loading PA ID Leakage % 0.0

22 7.2 Higher Primary Air Pressure OEM recommended Primary air pressure =8.5 Kpa Tripping value 5.4 KPA In order to avoid tripping of unit on MFT logic operators use to maintain the primary air pressure more than 8.5 Kpa which is contributing higher loading of PA fan

23 8. DEVELOPMENT OF SOLUTION

24 8.1 IMMEDIATE ACTIONABLES S.No Cause Action Proposed Responsibility Target date Status 1 Air Ingress in APH Rectification of damaged seals. Aadarsh/Indrajeet / Arohi As per AOH Installed 2 High DP of FF Leakage arrest in penthouse & seal trough Aadarsh/Indrajeet / Arohi As per AOH Done 3 High PA Air Header Pressure Operational Control Vivek/ Atish Continuous Daily Monitoring 4 Dampers & IGV s Problem Checking & calibration of links Chandrakant Panda Continuous Done 24

25 8.2 IDEAS/CREATIVE SOLUTIONS S No Idea Area of Work 1 CFD analysis of flue gas duct (uniform distribution of flue gas flow) Boiler 2 Combustion optimization to optimize primary air pressure Boiler 3 Improvement of APH seal ( Online sector plate lifting arrangement N.A so we can put soft touch seal) Boiler 4 Installation of magna drives Boiler 5 SADC correctness Boiler 6 online performance monitoring system Boiler

26 8.3 LIST OF SELECTED SOLUTIONS SL SOLUTIONS 1 Soft touch seal installation 2 PA pressure optimization

27 9. FORSEEING POSSIBLE RESISTANCE

28 FORESEEING PROBABLE RESISTANCE Sl no Probable resistance Resistance possible by whom Solution Responsibility 1 Arrangement of Spares Procurement Approval Evaluation of cost benefit of implementation of APH soft seal Aadarsh/vivek 2 Optimization of pa pressure by operators Operator Data trends to be available for 6 months Atish 3 SOP modification Operator/ Team Leaders SOP was verified and approved by HOD Prakhar

29 10. TRIAL & IMPLEMENTATION

30 11. TRIAL & IMPLEMENTATION Soft Touch Radial Seals shows better overlap with the sector plates and hence ensure proper sealing and reduction in flue gas leakages.

31 KW 2. PA loading reduced after primary air pressure optimization PA pressure Vs Loading Weeks PA Series1

32 11. REGULAR IMPLEMENTATION

33 Regular implementation Installation of seals in all units based on overhauling schedule. Continuous monitoring of PA pressure by the operator on shift basis.

34 INTANGIBLE BENEFITS SELF DEVELOPME NT TEAM SPIRIT KNOWLEDGE SHARING INTANGIBLE BENEFITS SELF MOTIVATION LEADERSHIP COMMUNICATI ON SKILL

35 TANGIBLE BENEFITS BEFORE & AFTER 35

36 TANGIBLE BENEFITS BEFORE & AFTER

37 TANGIBLE BENEFITS Investment Details : For APH Investment on cost of seal per Unit Overall Reduction in Fan loading per unit Payback Month : INR 2.00 Lakhs : 292 KW : 1 months Savings Calculations: Envisaged net saving for all 9 Units (Rs/ Lakhs) : INR 38 lakhs

38 12. FOLLOW UP & REVIEW

39 12. FOLLOW UP & REVIEW 1. Daily monitoring and controlling of operating parameter by the operator. 2. Daily monitoring of performance parameter by the O & E team. 3. Weekly operational review by the operation head. 4. Operational review by the team leader and plant head on monthly basis FLASH REPORT A shift Parameters UoM Std Value U 1 U 2 U 4 U 5 U 6 U7 U 8 U 9 1 Load MW MW MS Pressure Mpa MS Temperature (Turbine inlet) C HRH temperature(turbine inlet) C RH Spray TPH Super Heater Spray TPH Vacuum Kpa Spray as % of MS flow % 2.70% 4.59% 5.02% 3.86% 6.34% 4.69% 5.13% 5.61% 6.14% 9 O2 % % PA header press Kpa Exist Flue Gas Temperature C Make-up water Flow

40 Thank You Queries Please..