Maintenance Schedule for 2008-09 and 2009-10: PTPS SR. UNIT NO. Name of the 2008-09 2009-10 (PROPOSED PERIOD) No. Power Station PERIOD TYPE OF PERIOD TYPE OF OVERHAULING OVERHAULING 1 UNIT- 1 PTPS, Panipat Unit -- ( i) Renovation, preventive Modernization and maintenance recommissioned on Upgradation 04.11.2008 (217 (By BHEL) days) 2 UNIT- 2 PTPS, Panipat 01.03.09 to Preventive Mtc. 29.01.10 to 15.03.10 Annual Overhauling 15.03.09 (15 days) (45 days) 3 UNIT- 3 PTPS, Panipat 24.10.08 to No shut down was 24.10.09 to 07.11.09 preventive availed in 2007-08. maintenance 27.11.08 (35 days) (15 days) 4 UNIT- 4 PTPS, Panipat 01.04.08 to Annual Overhauling of 45 13.12.09 to 27.12.09 preventive days upto 06.05.08 had to maintenance 18.06.08 (78 days) (15 days) be extened upto 18.06.08 due to problem in generator rotor 5 UNIT- 5 PTPS, Panipat 03-04-08 to Preventive Mtc 01.05.09 to 09.06.09 Upgradation of C&I System. R.L.A 10.04.08 (8 days) (40 days) will also be carried out. 6 UNIT- 6 PTPS, Panipat 01.10.08 to The Annual O/H 24.09.09 to 07.10.09 preventive maintenance 24.10.08 (24 days) (15 days) 7 UNIT- 7 PTPS, Panipat 09.06.08 to Annual Overhauling & 04.09.09 to 24.09.09 preventive mandatory inspection. maintenance 30.07.08 (51 days) (15 days) Shut down extended due to problem in Generator Stator. 8 UNIT- 8 PTPS, Panipat 12.12.08 to Preventive Mtc. 16.03.10 to 30.03.10 preventive maintenance 26.12.08 (15 Days) (15 days)
Maintenance Schedule for 2008-09 and 2009-10: FTPS & DCRTPP 1 UNIT- 1 FTPS, 05.11.08 to Capital Unit may be phased ouit during Faridabad 25.12.08 Overhauling 2009-10 (31.03.10) (50 days) 2. UNIT- 2 FTPS, Under Shut down Since 08.09.2008 and phased out during 2008-09 due to Faridabad uneconomical generation, environment and safety concerns. 3. UNIT- 3 FTPS, 31.05.08 to Generator Stator 01.06.09 to Annual Faridabad 29.06.08 fault & Annual 15.07.09 (45 Overhauling (30 days) Pre.Mtc. days) 4. UNIT- 1 DCRTPP, 08.11.09 to 23.11.09 preventive YamunaNaga (15 days) maintenance r 5. UNIT- 2 DCRTPP, 12.11.08 to for pending works 26.11.09 to 11.12.09 preventive Yamuna 08.12.08 (15 days) maintenance Nagar (27 days)
Details regarding installation of CTs / PTs of 0.2 class accuracy at PTPS for Special Energy Meters • In PTPS-1, the work of installation of interface metering CTs and PTs on 220 KV Bus-I & II has been completed on 25.12.2008. • In Unit-5 and Unit-6, the work of installation of CTs has been completed. The work of installation of PTs is pending for which 9 hours Shut-down on 220 KV Bus-1 is required. The work shall be completed during the earliest available opportunity. • The readings from SEMs installed at 220 KV side of Panipat Thermal Power Station are being taken in compliance to the HERC directives.
Energy Audit Test of 210 MW Unit-5 of PTPS Major findings: • The Energy Audit Test of Unit-5 was carried out by NTPC from 26.11.2007 to 01.12.2007. • There has been a shortfall of about 1.90 % in Unit-5 Boiler efficiency w.r.t. PG Test Efficiency. • The air ingress in ESP & Duct between air heater outlet and ID Fan outlet was very high (about 33.39 %) resulting in high ID fan loading/& ESP performance. • Mill PF fineness: The retention in 50 & 100 mesh is on higher side and is the main contributor for high un-burnt in bottom ash. • There has been a shortfall of 55.91 Kcal/Kwh in TG cycle heat rate at 100% TMCR load w.r.t. to design values. • Both ejectors are in running condition. One of them can be isolated after rectification of air ingress.
Energy Audit Test of 210 MW Unit-5 of PTPS Best Practices Recommendation: • Monitoring of critical parameter viz. Flue gas oxygen, Carbon mono-oxide, Air-heaters differential pressure, super heater spray, main steam temperature/pressure, extraction steam pressure/ temperature, feed water temperature rise across HP/LP Heaters, DM Water Consumption, Condenser vacuum etc. • Implementation of Preventive Mtc. Schedule, condition monitoring of auxiliaries to improve reliability and performance. • Trip/failure analysis reports prepared by the analysis committee to be reviewed from time to time. The action taken reports of corrective recommendations of committee should be reviewed from time to time, by higher management to ensure its implementation. • To improve House keeping so as to create an ambience for better working. • Training of O&M Engineers to keep them up-dated with best practices in other Power Stations.
Energy Audit Test of 210 MW Unit-5 of PTPS Long term recommendations:- • Measurement of furnace temperature and oxygen by high velocity temperature probe to ensure proper combustion. • The Power Station may procure Iso-Kinetic Coal Sampling Device and clean/dirty air testing kit for regular testing of mills. • Multi point oxygen and carbon-mono-oxide probes should be provided at economizer outlet for proper monitoring of combustion. • On-line tube cleaning system to be installed for cleaning of condenser tubes. • On-line energy management system may be installed for close monitoring of auxiliary power consumption. • Feasibility study for replacement of present air conditioning system with centralized vapour absorption type conditioning Unit common for both unit 5 & 6. • Renovation and Modernization of unit after proper residual life and condition assessment.
Energy Audit Test of 210 MW Unit-6 of PTPS Major findings: • The Energy Audit Test of Unit-6 was carried out by NTPC from 26.11.2007 to 01.12.2007. • There has been a shortfall of about 1.86% in Unit-6 Boiler efficiency w.r.t. PG Test Efficiency. • APH-B Performance has deteriorated considerably and may be due to damaged heating elements. • Mill PF fineness: The retention in 50 & 100 mesh is on higher side and is the main contributor for high un-burnt in bottom ash. • There has been a shortfall of 46.92 Kcal/Kwh in TG cycle heat rate at 100% TMCR load w.r.t. to PG test. • CW flow across condenser is less than design flow. • Internal inspection/overhauling of ID Fans and rectification of external air ingress is required. • Auxiliary Power could be reduced by stopping one condenser vacuum pump after attending the air ingress points.
Energy Audit Test of 210 MW Unit-6 of PTPS Best Practices Recommendation : • Monitoring of critical parameter viz. Flue gas oxygen, Carbon mono- oxide, Air-heaters differential pressure, super heater spray, main steam temperature / pressure, extraction steam pressure / temperature, feed water temperature rise across HP/LP Heaters, DM Water Consumption, Condenser vacuum etc. • Trip/failure analysis reports prepared by the analysis committee to be reviewed from time to time by higher management to ensure its implementation. • Implementation of Preventive Mtc. Schedule. • Percentage Heat Loss due to devitation in the critical parameter, which affect heat rate, to be evaluated on a weekly basis. A monthly review of same to be done by the Chief Engineer. • Training of O&M Engineers to keep them up-dated with best practices in other Power Stations.
Energy Audit Test of 210 MW Unit-6 of PTPS Long term recommendations:- • Measurement of furnace temperature and oxygen by high velocity temperature probe to ensure proper combustion. • The Power Station may procure Iso-Kinetic Coal Sampling Device and clean/dirty air testing kit for regular testing of mills. • Multi point oxygen and carbon-mono-oxide probes should be provided at economizer outlet for proper monitoring of combustion. • On-line tube cleaning system to be installed for cleaning of condenser tubes. • The 40 Watt tube lights may be replaced with Energy Efficient T-5 tubes.
Benefits achieved after implementation of recommendations of Energy Audit Test of Unit-6 Most of the works as recommended by M/s NTPC during the Energy Audit Test, conducted in Dec., 07 have been carried out in the overhauling of Unit-6 in October, 08. The major improvement in the parameters is as under: Average value during Average value during 3 months before 3 months after overhauling overhauling PLF (%) 97.00 98.59 Aux. Consumption (%) 9.43 8.64 Specific Oil Consumption 0.88 0.47 (ml/kWh) Heat Rate (K.Cal/kWh) 2726 2720 Contd...
Benefits achieved after implementation of recommendations of Energy Audit Test of Unit-6 Parameters Value before O/H on Value after O/H on 29.09.08 01.11.08 Load (MW) 213 219 Steam flow (T/Hr) 671 665 Drum pressure (Kg/Cm2) 168 167 Condenser vacuum 0.85 0.9 DM consumption (T/day) 270 114 ID Fan loading (Amp.) 115/105/117 109/81/93 (total 337) (total 283) Feed water temp. at 235.82 238.62 Economiser inlet (ºC) Avg Value gas temp. at AH 163 155 outlet (ºC)
Plant Load Factor (%) of HPGCL Generating Stations upto Jan 09 during 2008-09 Description FTPS HPGCL as a whole Actual PLF (%) with Unit-2 of 34.45 71.67 FTPS in consideration Considering retirement of 40.15 72.60 Unit-2, FTPS, Faridabad on (including DCRTPP) 08.09.08 Excluding UnIt-2, FTPS, 40.15 74.88 Faridabad w.e.f 08.09.08 (excluding DCRTPP also)
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