CEP Samalkot
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Success in
Aux Power Reduction
Adarsh Gangrade & Arunkumar Ponugoti
13-05-2010
Reliance Infrastructure Ltd220 MW Samalkot Combined Cycle Power Plant
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SAMALKOT POWER STATION
220 MW Samalkot Combined Cycle Power Plant
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Samalkot
Location Map:
Latitude : 17o 02 18N, Longitude : 82o 08 15E, MSL : 27 Mts
Samalkot - 3 KMs, Rajahmundry Airport - 50 KMs, Kakinada Port - 20 KMs
Nearest Highway (NH5) - 15 KMs, Samalkot Rly Station 2.5 KMs
SAMALKOT POWER STATION
220 MW Samalkot Combined Cycle Power Plant
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An integrated Management Systems Certified Plant
220 MW Samalkot Combined Cycle Power Plant
8000Social
Accountability
14001
Environment
27001Inf & PhySecurity
9001Quality
RInfra- SPSManagement systems
Certification
Integrated ManagementSystem (IMS)
18001Health &Safety
IMS
SIGNIFICANT FIVE POINTS OF THE PLANT: Integrated management System
Standards Certified under ONE
ISO 14001:2004
OHSAS 18001:2007
ISO 9001:2008
ISO 27001: 2005
SA 8000:2001
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PLANT DETAILS
220 MW Samalkot Combined Cycle Power Plant
COMBINED CYCLE ; 140 MW GT & 80 MW STG
STATION CAPACITY: 220 MW
COMMISSIONED ON: GAS TURBINE SYNCHRONISED 26-01-2002
STEAM TURBINE SYNCHRONISED 12-09-2002
SCHEDULE OF MANDATORY INSPECTION:
MAJOR GT INSPECTION AFTER EVERY 32000 EOH
MINOR GT INSPECTION AFTER EVERY 8000 EOH
GAS TURBINE STEAM TURBINE
MAKE: SIEMENS V94.2
OUTPUT 140MW
No OF STAGES 41st MAJOR OVERHAUL
SEPT-OCT 2005 - 35748 EOH
2nd MAJOR OVERHAUL
SEPTOCT 2009 71670 EOH
MAKE: ANSALDO
OUTPUT 80MW
No OF STAGES 32
HRSG
MAKE: ANSALDO
HP/ LP MS PRE: 83 / 5.8 BAR
HP/ LP MS FLOW: 230 / 55 T/HR
HP/ LP MS TEMP: 528 / 208 DEG C
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Year wise Operating Data
S.No. YearStation
PLF %Availability % Aux Load %
LESS
Natural
Gas
1 2002-03 56.56 98.83 2.21
2 2003-04 66.55 94.34 2.69
3 2004-05 61.10 98.3 3.05
4 2005-06 45.28 89.39** 3.73
5 2006-07 50.55 97.4 3.53
6 2007-08 60.61 97.4 2.92
7 2008-09 52.50 97.08 3.27
8 2009-10 80.86 90.24** 1.97
** PLANT MAJOR OVERHAUL DONE
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Plant Data
PLANT DATA YEAR ON YEAR BASIS
0
20
40
60
80
100
120
2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10
YEARS
PLF,AVAILABILITY%
0
0.5
1
1.5
2
2.5
3
3.5
4
AUXILIARYLOAD
Availabilty % PLF % Aux Load % New Target
Present Target Aux Load
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FACTORS Affecting Aux power consumption
Plant load factor
Operation of plant Auxiliaries
Service auxiliaries like illumination
Unit Start up power reduction ( BFPs at Lower RPM)
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Methods of Aux power Reduction
Installing energy efficiency equipments
Optimizing Operation procedures
Monitoring of Aux power consumption
Knowledge sharing and bench marking
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Significant Energy ConservationProjects
Energy Efficient Projects Implemented
Variable Frequency Drive HP and LP Boiler feed pump and Raw water
C E P Destaging
CW Pump Corrocoat application
Wind Ventilators
SWAS water recovering as a Boiler Feed.
Cooling Tower Makeup By Pumping Replaced By Gravity Line
Cooling tower cell fan FRP Hollow blade placement
Energy saver for Lighting systems
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Recent Optimizing Operation Procedures
Deaerator Pressure Reduction from 1.0 to 0.5 bar
Air compressor Load pattern optimizationfrom 8 to 6.5 bar
Air dryer optimization of cycle time from 6 to 12 hrs
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HP boiler feed pump- VFD installation
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Energy conservation study on the HRSG High Pressure system
High Pressure Boiler Feed system
Feed station control valve operating at a throttled position of 35 %.
The HP boiler feed water header pressure being 124 bar.
Drum pressure of 75 Bar.
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Feasibility options for energy conservation studyrevealed opportunities to select from
Variable Frequency Drive at Boiler feed pump motor and
Destaging of the feed Pump.
Hydraulic fluid Coupling with Scoop control
Steam turbine driven Boiler feed pump
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Energy Conservation Study of System An in house technical study was done and following areas identified.
Equipment Detailed Study and analysis of existing system
Pump
Bearings Journal and Thrust
Lube oil system, Shaft driven lube MAIN oil pump
Allowable Axial displacement of shaft, balance leak ofpressure for water to reach deaerator
Min recirculation - to be maintained per manufacturerand Water conditions
Coupling Mechanical seals and related cooling system
Vibrations of the pump bearing
Pump Skid as a whole
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Energy Conservation Study of System
Motor
Bearings
Cooling - fan for winding
Vibrations of the Motor bearings
Motor Protections
Harmonics
FeedcontrolStation
Control valve type and capacity
Control valve Actuator
Logics of feed water control study with M/s INVENSYS
Piping
Placement of valves at the economizer outlet Position of Check valves
Position of isolation valves
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Energy Conservation Study of System
Water and steam
cycle
Deaerator
Temperature and Pressure of water at suction to Pump
PINCH AND APPROACH at Economizer
DE SUPERHEATING
Steaming at the Economizer possibility
Drum and Deaerator capacity
System
Feed Control system Logics and
Plant load variation study LDC requestStudy on past Trip history of the plantVoltage surgesand Power / frequency Swing
Operational Philosophy
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Typical Pump Curve with Variable speed
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Typical saving in variable speed Application
Variable Speed
Due to Regulatory and Guarantee conditions - OEMs design at 125 % of MCR
Normal Operating Point
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HP Boiler Feed Pump Technical Data
PUMP:
Make : M/s Sulzer
Head : 1256.5 mwc
Capacity : 276 m3/h
Stages : 11
Lubrication : Forced
Motor:
Make : Kirloskar
Type : 3 Ph AC Induction Motor
Power : 1280 KW
Supply : 3 Ph/6600 V/50 Hz
Speed : 2983 rpm
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Reasons for choosing VFD application
Opportunity Type /Technology
Advantage Disadvantage
Variable Frequency Drive Highest Efficiency 96%
Variable Loadcapability
Ease of fitment withexisting equipment
Motor heating andinsulation
Harmonics in Input
Line side
Hydraulic coupling andScoop
Existing technology
With low Efficiency atpart load.
New Hydraulic systemand control to beinstalled
Pump Destaging Cost of implementationis lowest.
Variable load capabilityto be checked with
system installed
Restoration to initialcondition
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Implementation after study
Variable frequency drive came out to be best option
As the load varies as per request from load dispatch center.
Minimum frequency set at 35 HZ as per OEM
Modified Logics configuration with same feed control valve
Operation procedure modification.
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HRSG High pressure system AFTER VFD application
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220 MW S lk t C bi d C l P Pl t
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HP Boiler feed pump V.F.D
Supplier: Yantra Automation Pvt. Ltd
220 MW Samalkot Combined Cycle Power Plant
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Saving in Load by 51% (Part load) 32% (Base load)
DescriptionBefore Installation
Of VFD
After Installation
Of VFD 42.8 Hz
Discharge Pressure 123 bar 87 bar
ECO Outlet Press 118 bar 81 bar
CV Pos 36 % 72 %
Power 1125 kW 770 kW
Power Saving Part load: 575 KW & Base load: 355 kW
Saving : 30,17,500 KWH @ 8500 Operating Hours at full load
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LP boiler feed pump- VFD installation
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Energy conservation study on the HRSG Low Pressure system concluded
Low Pressure Boiler Feed system - control valve was operating at athrottled position of 55 %. The LP boiler feed water header pressurebeing 20 bar with Drum pressure of 5.3 Bar.
Feasibility options after energy conservation study revealed twoopportunities to select from
Variable Frequency Drive at Boiler feed pump motor and
Destaging of the feed Pump.
Variable frequency drive came out to be best option for the plant asload varies as per request from load dispatch center.
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LP Boiler Feed Pump Technical Data Pump
Make : Sulzer
Capacity : 68 m3/h
Head : 222.5 mwc
Stages : 05
Motor
Make : Kirloskar
Type : 3 Ph Ac Induction MotorSupply : 3 Ph, 415 V, 50 Hz
Rating : 75 kW
Current : 125 A
Speed : 2970 rpm
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HRSG LOW pressure system before VFD application
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HRSG Low pressure system after VFD application
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LP BFP VFD PANEL and Change over Panel
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Saving in Load by 36% (at Full load operation )
DescriptionBefore Installation
Of VFD
After Installation
Of VFD 38 Hz
Discharge Pressure 23. 63 bar 13.6bar
ECO Outlet Press 20.27 bar 9.9 bar
CV Pos 55 % 66 %
Power 47.5 kW 30 kW
Power Saving 17.5 kW at Base load
1,48,750 KWH @ 8500 Operating Hours
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Raw water PUMP VFD
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Raw Pump Technical Data
PumpMake : Mather and PlattCapacity : 470 m3/hHead : 20.12 mwcStages : 01
MotorMake : Crompton greavesType : 3 Ph Ac Induction MotorSupply : 3 Ph, 415 V, 50 HzRating : 37 kWCurrent : 63 ASpeed : 1480 rpm
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Saving in Load by 65%
DescriptionBefore Installation
Of VFD
After Installation
Of VFD 28 Hz
Power 28 kW 10 kW
Power Saving 18 kW
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C.E.P. Destaging
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De staging of Condensate Extraction Pump
Energy conservation study on the HRSG Condensate system concluded Condensate system - control valve was operating at a throttled position
of 55 %.
Feasibility options for energy conservation study revealed three
opportunities to select from
Variable Frequency Drive
Destaging of the Pump.
Impeller trimming
Destaging came out to be best option for the plant as even though theload varies the requirement at the Dearator level control needs to bemaintained. Also trimming option doesnt give flexibility to come back
to original condition, if required in future.
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Condensate Extraction Pump Pump:
Make : Sulzer
Type : Vertical
Capacity : 344 m3/hHead : 204.5 MLC
Stages : 4
Motor:
Make : Kirloskar
Type : 3 Ph Ac Induction MotorSupply : 3 Ph, 6600 V, 50 Hz
Rating : 270 kW
Current : 29 A
Speed : 1489 rpm
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HRSG Condensate system before Destaging
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CEP Destaging
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Sulzer CEP
3 rd Stage Dummied
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HRSG condensate system after Destaging
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Saving in Load by 26%
Description Before De staging After De staging
Discharge Pressure 19.6 bar 14.7 bar
Power 246 kW 182 kW
Power Saving Part load: 52 KW & Base load: 64 kW
5,44,000 KWH @ 8500 Operating Hours
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CW Pump Corrocoat
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Circulating water pump Pump:
Make : Mather & Platt (I) Ltd.,
Capacity : 8872 m3/h
Head : 19.74 MLCStages : Single
Motor:
Make : Crompton Greaves
Type : 3 Ph Ac Induction Motor
Supply : 3 Ph, 6600 V, 50 Hz
Rating : 630 kw
Current : 71 A
Speed : 594 rpm
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Application Of Flu Glide Coating on Circulating Water Pump.
Flu glide Coating is the flake glass filled synthetic polymer type coatings andbenefits in:
1. Reduction in Fluid friction
2. Reduction in micro turbulence
3. Increased Efficiency of the pump due to reduction in hydraulic losses.
4. Reduction in power consumption.
5. Increased protection against Corrosion & Erosion
6. Increased life and reliability of the equipment.
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Corrocoat Application
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Saving in Load by 5%
Description Before Corrocoat After Corrocoat
Discharge Pressure 1.3bar 1.3 bar
Power 619 kW 583 kW
Power Saving 36 KW
3,06,000 Kwh @ 8500 Operating Hours
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Wind Ventilators
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Wind ventilator
Electrical driven Exhaust fans power consumption of each fan is4.27KW.
As part of energy conservation measure one electrical driven exhaust fan
was replaced with Wind ventilator which is driven by natural wind.
This has resulted in power saving of 4.27KW.
Total 7 fans were replaced with wind Ventilators.
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Ventilation system
Analysis
Power Consumption of
Exhaust fan4.27KW
Power Consumption wind
ventilatorsNil
Net Power savings 4.27 KW
Annual power Saving
(For 7 Fans)
2,54,065 KWHr @ 8500Operating Hours
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HRSGSteam and Water Sample Analysis System
water recovery and reuse as feed.
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Daily Average Consumption of DM Water was 17 Cu meter / Day
Analyzed the SWAS Sampling System outlet water and found the Waterquality is meeting the norms of Boiler Feed Water. Therefore the same
water was reused in our system.
Over All Achievement
Savings in DM Water make up
Cycle Chemical parameters maintained within the requirements.
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COOLING TOWER MAKEUP
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COOLING TOWER MAKEUP
INITIAL OPERATION OF THE SYSTEM. Cooling tower basin level was maintained by using pumps which
pumped water from clarified water storage tank to basin. This systemalso supplied water to the Chlorination plant.
CT make up pumps - Two no Installed since inception One inservice and other stand by. (in summer usage involved two pumps)
Design Capacity: : 370 Cu m / Hr
Drive Motor Power: 30 KW
MODIFIED SYSTEM
After a study on cooling tower make up path.
A channel system was suggested which ensured water flow to the
basin. A diversion channel and road cutting work was done.
The control of water is done via VFD controlled Raw water pump thatprovides input water to Clarified water system.
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Cooling Tower make up
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Cooling Tower make up
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Savings 22.8 KWH
SAVINGS AND PAYBACK PERIOD
Project Cost for the implementation: INR 2, 84, 444.00
Saving : 22.8 Kwh
Per annum energy saving: 193800 Kwh (@8500 hr)
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Illumination Energy saver Panel
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Saving in Load by 15%
A survey carried out for reduction in Lighting system.The Energy consumption is 1718 KWh/day.
Energy Saver has been installed and commissioned for
the Power Block MLDB and BOP MLDB.
Total investment, Rs.: 285880
Units / day reduced : 261.3
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Energy saver Panel
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Cooling tower Fan Hollow blade replacement
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Cooling Tower Hollow FRP blade placement
A study on cooling tower was done to evaluate the energysaving options in fans.
The system consists of ten induced draught fans .
The study showed following options
Hollow fan blade
Hub diameter can be reduced as per hollow blade design
Increased flow area for air because of aerofoil profile change.
Cooling tower nozzles replacement with new higher efficiencyNozzles
Blade angle adjusted for the same flow
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Saving in Load by 23%
Average Power Consumption Before Hollow Blade placement : 52 KW
Total consumption for 10 motors : 520 KW
Average Power consumption After Hollow Blade placement : 40 KW
Total consumption for 10 motors : 400 KW
12 KW saving per Fan
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Optimizing Operation procedures
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Deaerator Pressure Reduction
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Deaerator is maintained at 1.0 bar(g) pressure by steam extraction from
Steam Turbine at 171 deg c & 2.592 tph flow rate. The scope for reduction
in deaerator pressure was studied by considering the Mechanical deaeration
process and NPSH requirement for feed pumps. On experimental basis
Deaerator pressure reduced up to 0.5 Bar (g) in steps of 0.1 Bar (g).
With this practice found Dissolved oxygen levels, NPSH of pumps are with
in limit and observed the increment in Steam Turbine Generation about 200
KW.
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Solubility of Air in water
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HRSG deaerator before pressure reduction.
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Deaerator pressure reduction
Description Before ReducingPressure
After Reducing Pressure
Deaerator Pressure 1.0 bar 0.53 bar
Temp 120 deg c 113 deg c
CV Pos 13.12 % 0.0 %
ECO inlet Hydrazine 26.8 ppb 25.27 ppb
Dissolved O2 3.66 ppb 3.63 ppb
Pump suction press 2.45 bar 2.2 bar
ST generation increased by 200 KW
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HRSG deaerator after pressure reduction.
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Optimization of Compressed air Pressure
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Optimization program
Decreased air leakages from valves and other locations.
Optimization of consumption in auxiliary areas that are intermittently
used. ( Fuel oil centrifuge, ETP etc)
Decreased pressure set point with out effecting equipment operation.From 8.0 to 6.5 bar.
Load pattern changed from 15 hr full load to 0 hrs full load
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Trend Of Compressor Saving
Decline in Compressor Power consumption
715545 513 490 470
0
5
10
15
20
25
29-May-08 12-Jun-08 16-Jul-08 25-Jul-08 13-Oct-08Date
Hoursofload
ing
0
200
400
600
800
KWH/DAY
100% Load 50% Load 0% Load Power Consumption
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Air Dryer System
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Air Dryer
DESIGN Type: Dual tower desiccant,
Drying mechanism: Blower with Electric heater
Flow Rate: 300 Nm3/hr.
Pressure: 9.0 kg/cmg Dew Point Temp. : (-) 40DegC
Cycle Every 6 hrs One tower is in service and another tower is inregeneration mode.
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Saving in power 56 %
As the Air consumption is optimized to below 50 % of design. ( from300 to 150 M3/Hr).
Margin in dew point is available.
Cycle time is Optimized to 12 Hrs of Adsorption for sameRegeneration time.
Energy consumption per Day : BEFORE optimization 124 kWh/day
Energy consumption per Day : AFTER optimization 54 kWh
Saving : 70 KWh/day
Annual Saving :5,95,000 kWh.
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PLANT Auxiliary Power Reduction
Plant Mode of Operation PLF %
Before EnergySaving
PresentCondition
Saving
MU / Day MU / Day
%Base Load Operation 98 0.1030 0.0872 15
Part Load Operation 63 0.1026 0.0773 24
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Combined Cycle Practices
90
FREQUENT CHOKING OF AIR220 MW Samalkot Combined Cycle Power Plant
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INTAKE FILTERSBIRD
SCREEN
PREFILTER COALASCERFILTE
R
FINEFILTE
R
BIRD SCREEN PREFILTER COALASCERFILTER FINEFILTER
COALASCER PAD
ROLL
AIR INTAKE FILTERS
220 MW Samalkot Combined Cycle Power Plant
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Air intake filter DP status
0
2
4
6
8
10
12
14
24/05/
09
08/06/09
23/06/09
08/07/
09
23/07/
09
07/08/09
22/08/09
06/09/
09
21/09/
09
06/10/09
21/10/09
05/11/09
20/11/09
05/12/09
20/12/09
04/01/10
19/01/10
03/02/10
Date
FilterDPinmbar
-50
450
950
1450
1950
2450
2950
3450
3950
4450
4950
5450
RunningHrs.
Day Avg. Pre filter DP Day Avg.Fine filter DP Day Avg. Total filter DP Day Avg. Coalescer Pad GT Ac tual Running Hours
1 2 3 GT Major
Overhaul from
4 5 6 7
8 9
`
1. Additional coaleser pads (100 mm) removed on 15.06.09. 2. Additional coaleser pads (50 mm) provided on20.06.09. 3. Coalescer pads (50 mm) removed on 12.08.09 & fixed back on 14.08.09. 4. New coaleser pads(50 mm) provided on 28.10.09. 5. Coalescer pads removed on 19.11.09 & new one (50 mm) fixed back on19.11.09. 6. Coalescer pads removed on 05.12.09 & Old cleaned one (50 mm) fixed on 05.12.09.Coalescer pads again removed on 08.12.09 & new (50mm) fixed on 08.12.09. 7. Coalescer pads removedon 21.12.09 & new one (50 mm) fixed back on 21.12.09. 8. Coalescer pads removed on 30.12.09 & new/old one (50 mm) fixed back on 30.12.09. 9. Coalescer pads removed on 05.01.10 & Old cleaned one (50mm) fixed on 05.01.10. Coalescer pads removed on 08.01.2010 and no coalescer Pad fixed. 10.Max.Avg.total filter DP went upto 14.0407 mbar , so for all filter replacement on 08.02.10 at 6:00 hrs GT
shutdown taken.
Prefilte
rDP
4.5mbar
FinefilterDP
7.5 mbar
Total filterDP
14.0 mbar
Coalescer
Pad DP4.5 mbar
FREQUENT CHOKING OF AIR220 MW Samalkot Combined Cycle Power Plant
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INTAKE FILTERSBIRD
SCREEN
PREFILTER COALASCERFILTE
R
FINEFILTE
R
BIRD SCREEN PREFILTER COALASCERFILTER FINEFILTER
COALASCER PAD
ROLL
FREQUENT CHOKING OF AIR220 MW Samalkot Combined Cycle Power Plant
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INTAKE FILTERS
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8/6/2019 CEP Samalkot
95/96
confidential
MASTER DATA
95
http://master%20data%20report.xls/http://master%20data%20report.xls/http://master%20data%20report.xls/ -
8/6/2019 CEP Samalkot
96/96
Thank you