Hirakud pWR overview.ppt

Hindalco CPP in Hirakud

1. HIRAKUD POWER

2. CONTENT
•Hirakud Power overview
•Boiler
•CFBC boiler
•Advantages of CFBC.
•Dry ash conveying system
•Interconnection
•Islanding scheme

3. 1 9 5 9
1 9 9 4
2005
WEHAVEACAPTIVETHERMALPOWERPLANTOF
367.5MWCAPACITYOFFOURUNITS
WE ARE THE FIRST CFBC TECHNOLOGY USER IN INDIA
WE HAVE DEPLOYED VARIOUS SYSTEMS THROUGH :
•QMS ( ISO-9001:2000)
•EMS ( ISO-14001:2004)
•OH & S ( OHSAS-18001:1999)
•WORLD CLASS MANUFACTURING (WCM)
WE HAVE MANY ACCOLADES TO OUR CREDIT
•BRITISH SWORD OF HONOUR IN SAFETY
•RAJIV GANDHI ENVIRONMENTAL AWARD
•ENERGY CONSERVATION AWARD FROM CII
2 0 0 6
ABOUT HINDALCO –HIRAKUD POWER

4. BOILERS
BOILERS

5. WHAT IS A BOILER ?
ABOILERGENERATES STEAMATDESIREDRATEATDESIRED
PRESSURE&TEMPERATURE BYBURNINGFUELINITSFURNACE.
WHAT THE IBR SAYS ?
ABOILERISACLOSEDPRESSUREVESSELWITHCAPACITYMORE
THAN22.75LITERSUSEDFORGENERATING STEAMUNDERPRESSURE.IT
INCLUDES ALLMOUNTING FITTEDTOSUCHVESSELSWHICHREMAIN
WHOLLYORPARTLYUNDERPRESSUREWHENSTEAMISSHUT-OFF.

6. CLASSIFICATIONOF BOILERS
FIRE TUBE WATER TUBE
WITH DRUM
(RECIRCULATION)
WITHOUT DRUM
(NO RECIRCULATION)
NATURAL FORCED
ONCE THROUGH
UNIT
BOILERS

7. BOILERS
•P.F. or pulverised fuel boilers
•C.F.B.C. or circulated fluidised
bed combustion boilers

8. PULVERISED FUEL BOILERS

9. CFBC BOILERS

10. BOILERS
HINDALCO-HIRAKUD POWER

11. ```
SUP-2
OUTLET
SUP 3
INLET
SA FAN
ECO 1
INLET
SUP-2
INLET
SUP-3
OUTLET
ECO-1
ECO-1
AIR
HEATER
AIR
HEATER
STEAM
DRUM
ECO 1 OUTLET
CYCLONE
SAND
SILOCOAL
BUNKER
COAL FEEDER
PA FAN
155 TPH BOILER
PROCESS PR0FILE
EVAP
SCREEN
TO ESP
SUP-3
SUP-1
SUP-2
ECO-2
DRG BY K SURESH HINDALCO HIRAKUD POWER
HOT GAS GENERATOR

12. PARTS OF CFB SYSTEM
FURNACE
AIR DISTRIBUTOR
BED ASH DRAIN SYSTEM
SOLID RECYCLE DEVICE

13. Circulating Fluidized Bed Combustion
(CFBC)
•(6–12mmsize)fuelandlimestoneareinjectedintothefurnace
•Theparticlesaresuspendedinastreamofupwardlyflowingair(60-70%ofthe
totalair),whichentersthebottomofthefurnacethroughairdistribution
nozzles.Thebalanceofcombustionairisadmittedabovethebottomofthe
furnaceassecondaryair.
•Whilecombustiontakesplaceat840-900
o
C,thefineparticles(<450microns)
areelutriatedoutofthefurnacewithfluegasvelocityof4-6m/s.Theparticles
arethencollectedbythesolidsseparatorsandcirculatedbackintothefurnace.
Thiscombustionprocessiscalledcirculatingfluidizedbed(CFB).

14. Circulating Fluidized Bed Combustion (CFBC)
•Therearenosteamgenerationstubeimmersedinthebed.
Generationandsuperheatingofsteamtakesplaceinthe
convectionsection,waterwalls,attheexitoftheriser.
•CFBCboilersaregenerallymoreeconomicalthanAFBCboilers
forindustrialapplicationrequiringmorethan75–100T/hrof
steam.

15. COMBUSTION IN CFBC
BOILERS
•For a constant feed water inlet condition
and steam output, the amount of coal
required cannot be reduced below a certain
extent.
•Coal size available can’t be altered.
•In order to tend that minimum coal value,
we must have the best combustion i.e.
optimum air, time, temperature, turbulence.

17. Advantages of Circulating
Fluidized Bed Combustion Boilers

18. Advantages of Circulating Fluidized Bed
Combustion Boilers
HighEfficiency:
FuelFlexibility:Fuelslikewasherrejects,agrowastecanbeburntefficiently.
Boilerscanfirecoalswithashcontentashighas62%andhavingcalorificvalue
aslowas2,500kcal/kg.
PollutionControl;SO
2
formationcanbegreatlyminimizedbyadditionof
limestoneordolomiteforhighsulphurcoals.EliminatesNO
x
formation.
LowCorrosionandErosion:arelessduetolowercombustiontemperature,
softnessofashandlowparticlevelocity(oftheorderof4m/sec).
NoClinkerFormation:temperatureofthefurnaceisintherangeof750–900
o
C.

19. WHY CFB BOILER

20. State of the art
“DENSE PHASE TECHNOLOGY”

21. Typical Operation Cycle
DENSE PHASE
1
System at rest
2
Vessel filling
3
Vessel full
4
System conveying
Level
Probe
Vent
Valve
Air supply
Blow
Valve
MACAWBER BEEKAY PVT. LTD.

22. THE OPERATIONAL PRINCIPLE
Thesystemsnormallyhavedualoperatabilityeitherthroughthetimer
orlevelprobewhichisinstalledinthecollectinghopper.
Assoonastheashlevelreachesafixedlevelinthecollectinghopper,
thelevelprobesensesitspresence,itallowsthesystemtoinitiatea
conveyingcycle.Theinletvalveopenstoallowtheashtogravitate
intotheconveyingvessel,tillitclosesautomatically.Onclosureofthe
valve,theconveyingvesselgetspressurizedandthematerialresistance
helpspressurebuildupwhichconveysthematerialthroughpipeinthe
destinationsilo.Whenconveyingiscompletewhichissensedbythe
controlsystem,airsupplytothesystemisstoppedandsystemisready
forthenextcycle.
Thetotalsystemismadeautomaticbyuseoflevelprobesin
destinationsilo(s)tocontrolthetransferofmaterial.Flexibilityinthe
systemallowstooptfromsingletransferofmaterialfromonepoint
collectiontosinglereceptionhopperoramultipointcollection.The
systemisflexibleenoughandprogrammableandautomatically
operatedthroughaPLCbasedCentralControlPanel.
MACAWBER BEEKAY PVT. LTD.

23. Dense phase systems
•Using positive pressure the system generally utilises a
conveying vessel to collect the material before being
conveyed through the pipeline in batches.
•In dense phase system, a controlled use of air pressure and
volume pushes the batch of material from the vessel in to
pipeline in a plug flow form.

24. Totally enclosed system and devoid of leakages nuisance.
Simplebutruggedequipmentscompletelyfreefromcomplicated
linkagesandprimemovers.
Conveyingpipelinestraveloverheadandsystemsrequireverylittle
spacethusresultinginsavingofpreciousfloorarea,unhindered
movementintheplantandbetterhousekeeping.
Thesystemsnormallydonotrequireexcavation,trenches,
undergroundworkandcivilfoundationsinaproperlylaidoutplant
withadequateheadroomavailability.
ThesystemscanbeinstalledparalleltotheexistingWet/Slurry
DisposalSystemsthroughbifurcatingchutesbelowtheashcollecting
hoppersthusoffergreatflexibilitywithoutdisturbingtheexistingash
disposalfacilities.
EffectiveAshHandlingSystemisonethatdisposesofftheashfrom
collectinghoppersassoonasitisgenerated.Thecollectinghoppers
thusbecomechutesandthereisnotimeforcollecting,de-aerationand
compactiontooccur.TheoperationofDensePhaseisbasedonthis
principle.
ADVANTAGES OF DENSE PHASE CONVEYING
MACAWBER BEEKAY PVT. LTD.

25. ADVANTAGE ENVIRONMENT
•Whenenvironmentalawarenessandprotectionisa
majorindustrialandsocialconcern,DensePhase
pneumaticconveying,bytotallyenclosedhandling
system,isparticularlysuitable.
•Allconventionalproblemsofspillage,dust,
contaminationandstorageareefficientlyand
successfullyeradicated.
•Planthousekeepingisgreatlyimproved.
MACAWBER BEEKAY PVT. LTD.

26. •UNITS
INTERCONNECTION

28. RFW TANK
DEAERATOR
BOILER-3 BOILER-4 BOILER-5
LPH-1 LPH-2 HPH-4 HPH-5
FEED WATER
MAIN STEAM
HCPRDS
CONDENCER MAKE-UP
DEAERATOR LEVEL
CONTROL
CONDENCER
CEP
BFP
EXT-1
EXT-2
EXT-3
EXT-4
EXT-5
TURBINE GENERATOR
100MW
CONDENSATEHOTWELL
LEVEL
CONTROL
TEMP. 232DEGC
PRESSURE 110 KG/CM2
FLOW - 390 T/HR
BOILER
TEMP. 510 +/-5 DEGC
PRESSURE 90 KG/CM2
FLOW 165 T/HR (MAX)
TEMP. 510 +/-5 DEGC
PRESSURE 90 KG/CM2
FLOW 390 T/HR
TEMP. 510 +/-5 DEGC
PRESSURE 86 KG/CM2
FLOW 390 T/HR
TEMP. 45 DEGC
VACUUM --880 G/CM2
INTRODUCTION TO PROCESS
85DECG
125DECG
160DECG
198DECG

29. BOILER BOILER BOILER BOILER BOILER
DEAREATOR
TURBINE
DEAREATOR
TURBINE
CEPCEP BFP BFP
FEED WATER LINE
MAIN STEAM LINE
INTERCONNECTION VALVE
INTERCONNECTION VALVE
CONDENCER CONDENCER
PROCESS FLOW
ANALYSIS
DEAERATOR WATER LINE
DEAERATOR STEAM LINE
BOILER

30. BENEFITS OF INTERCONNECTION
With U-2 & U-3 interconnected total generation with 5 boilers 200MW
Without U-2 & U-3 interconnected total generation with 5 boilers=100+80
Generation Loss in absence of one boiler if not interconnected =200-180
For 1 MWH financial saving = (3.00-1.00)X1000
for 20 MWH financial saving = 20 X 2000
for one day saving = 24 X40000
Considering Approximately 60 days (annual O/H of boilers) interconnection
per year
Total Financial saving annually =60 X 9,60,000= 5 CroreS 76 lacs
.

31. 1.ONE BOILER IS SPARED
A. ONE BOILER CAN BE UNDER MAINTENANCE
B. BOILER-3 CAN BE CONNECTED TO TG -1
2.AUXILLIARY CONSUMPTION OF ONE BOILER IS SAVED.
3. FEED WATER SYSTEM FLEXIBILITY.
OTHER BENEFITS

32. Islanding in power
system of CPP-An over
view

33. •Automatic isolation of CPP and
connected load from the grid
before reaching abnormal
frequency / voltage

34. Thefirstapproachofisolationfromthegridis
calledislandingandisachievedbyrelay-based
isolationincombinationwithloadshedding
systems.Oncethefaultinthegridclears,andthe
gridbecomesstableCPPisagainsynchronized
withgrid.

35. Grid situations which call
for islanding are
•Under voltage in the grid
•Under frequency in the grid
•Over frequency in the grid
•Rate of fall of frequency below a
specified low frequency

36. Criteria for successful
islanding
•Automatic frequency based load
shedding prior to islanding, when the
CPP sent out is less than the
connected load. This will make CPP sent
out little excess of load and prevents
further fall of frequency after
isolation

37. •Spinning reserve during islanding
through HP bypass system. This will
take care of load fluctuation in
islanded condition.
•Change over of turbine from load
mode to frequency / speed mode
immediately after islanding. This
will keep frequency constant even
with small fluctuation of load.

38. •Maintaining stability in auxiliary
system of CPP after islanding with
close monitoring of control system.
•Higher size of captive system is
helpful in successful islanding. As
the size increases the system
inertia (H) increases and frequency
fluctuations are held to minimum.

39. •When the generation is in excess of load
islanding leads to rise in frequency. The
governor maintains the frequency by
switching over to speed mode. HPBP first
opening helps in maintains the steam
pressure leading to a stable system.
•In case of generation is less than the load
frequency/ voltage based load shedding is
assorted just before islanding. This leads
to export power condition and the CPP
isolates from the grid. This eliminates the
chance of frequency fall after islanding.

40. •At Hirakud automatic islanding in
combination load shedding is adopted
for
•Under-frequency
•Under –voltage
•Rate of fall of frequency
•Over Frequency

41. •Firstthereisloadsheddinginsmelterinthe
tuneof10MWpriortoislandingat
predefinedsetpoints(referfollowingtable).
Thisloadsheddinghelpstokeepaspinning
reserveandtakecaresofloadvariation.This
excessgenerationofsteamfor10MWis
accommodatedinHPbypass.Afterfurther
fallofgridparametersislandingtakesplace
asperthefollowingsettingsinexportpower
condition.Immediatelyafterislanding
governorandAVRswitchesovertofrequency
modeandvoltagemoderespectively.

42. Load-
shedding
Islanding
Set
value
DelaySet
value
Delay
Under
Frequency
48.2
Hz
48 Hz
Under voltage124.8
KV
123.6
KV
Rate of
Change of
Frequency
0.4
Hz/s
ec
0.6
Hz/se
c
Over
Frequency
52.1
Hz

43. •Conclusion:The captive power plants does
need connectivity to the grid for reliable
power supply to captive load, but also
needs to insulate themselves from the
system threatening transients in the grid.
So a well designed algorithm for load
shedding, right selection of relays right
setting of the relays are very important.
Numerous field trials are normally
required before the islanding philosophy is
established.

44. •UNITS
INTERCONNECTION

46. RFW TANK
DEAERATOR
BOILER-3 BOILER-4 BOILER-5
LPH-1 LPH-2 HPH-4 HPH-5
FEED WATER
MAIN STEAM
HCPRDS
CONDENCER MAKE-UP
DEAERATOR LEVEL
CONTROL
CONDENCER
CEP
BFP
EXT-1
EXT-2
EXT-3
EXT-4
EXT-5
TURBINE GENERATOR
100MW
CONDENSATEHOTWELL
LEVEL
CONTROL
TEMP. 232DEGC
PRESSURE 110 KG/CM2
FLOW - 390 T/HR
BOILER
TEMP. 510 +/-5 DEGC
PRESSURE 90 KG/CM2
FLOW 165 T/HR (MAX)
TEMP. 510 +/-5 DEGC
PRESSURE 90 KG/CM2
FLOW 390 T/HR
TEMP. 510 +/-5 DEGC
PRESSURE 86 KG/CM2
FLOW 390 T/HR
TEMP. 45 DEGC
VACUUM --880 G/CM2
INTRODUCTION TO PROCESS
85DECG
125DECG
160DECG
198DECG

47. BOILER BOILER BOILER BOILER BOILER
DEAREATOR
TURBINE
DEAREATOR
TURBINE
CEPCEP BFP BFP
FEED WATER LINE
MAIN STEAM LINE
INTERCONNECTION VALVE
INTERCONNECTION VALVE
CONDENCER CONDENCER
PROCESS FLOW
ANALYSIS
DEAERATOR WATER LINE
DEAERATOR STEAM LINE
BOILER

48. BENEFITS OF INTERCONNECTION
With U-2 & U-3 interconnected total generation with 5 boilers 200MW
Without U-2 & U-3 interconnected total generation with 5 boilers=100+80
Generation Loss in absence of one boiler if not interconnected =200-180
For 1 MWH financial saving = (3.00-1.00)X1000
for 20 MWH financial saving = 20 X 2000
for one day saving = 24 X40000
Considering Approximately 60 days (annual O/H of boilers) interconnection
per year
Total Financial saving annually =60 X 9,60,000= 5 CroreS 76 lacs
.

49. 1.ONE BOILER IS SPARED
A. ONE BOILER CAN BE UNDER MAINTENANCE
B. BOILER-3 CAN BE CONNECTED TO TG -1
2.AUXILLIARY CONSUMPTION OF ONE BOILER IS SAVED.
3. FEED WATER SYSTEM FLEXIBILITY.
OTHER BENEFITS