Note from the Editors: Renovation and Modernization of thermal power plant is an important and timely issue for discussion. Availability is suffering in many fossil power plants world over and many are contemplating similar efforts as those described in the article below. Perhaps the readers will want to share their experiences.
-----------------------------------------
RENOVATION AND MODERNISATION OF THERMAL POWER PLANTS
N. Ayodhi, Bharat Heavy Electricals Ltd., India
Author Profile Mr Ayodhi is a graduate in Mechanical Engineering has worked in power industry since 1970. He has several years of experience in trouble shooting of operational problems, conducting performance guarantee tests, commissioning of boilers and rendering assistance to utilities during major overhaul. He has conducted plant audit in a number of units in India and abroad. He has been in-charge of engineering and project management aspects and has executed major Renovation & Modernization of five units at Durgapur Projects Limited, India.
Mr Ayodhi is currently working as Deputy General Manager in BHEL and is associated with RLA and R&M jobs. R & M proposal preparation based on performance evaluation study and remaining life assessment study is his present task in addition to special assignments such as training and availability improvement of units. He has published a number of papers in various national and international seminars.
ABSTRACT
The power scenario in India reveals the need to ensure better reliability and improved plant load factor from existing thermal units. Assessment of existing plant is necessary to establish the benchmark and to finalize the scope for renovation and modernization activity. Life assessment based life extension program is a scientific approach to ensure sustained generation from older units. As most of the units have reached their design life, the main concern for any utility will be to ensure sustained generation from such units in a cost effective way.
Steam generator in a thermal power plant is normally designed for specific life. The design life is based on the creep-rupture properties of the steels selected for high temperature sections. From the commencement of regular operation, the degradation starts and assessment of pressure part components is necessary. The periodicity and the extent of assessment depend on the service hours and operating conditions. Review of operational history and failure details helps in deciding the scope. Based on evaluation of test results, run/repair/replacement decision can be taken. In case of turbines it is necessary to ensure the integrity of rotors in addition to heat rate aspects. Associated components like casing, Renovation and Modernization of Plant OMMI (Vol. 1, Issue 2) August 2002 2 control valves and transfer piping are also to be examined. Limitations, if any, in auxiliaries and in balance of plant are also to be studied in detail. By careful assessment and evaluation, life extension program is possible by utilizing the margins built up in design. This paper covers the salient details of Renovation and Modernization of a plant commissioned in the sixties.
INTRODUCTION
3 x 70 MW capacity units commissioned in mid sixties have been performing poorly and continued operation was found to be uneconomical. Preliminary study carried out in selective units formed the basis for broad scope finalization of Renovation & Modernization. Detailed assessment was done by releasing each unit for overhaul in a phased manner and final scope was frozen. Study of each unit in detail was considered necessary since the degradation phenomena of identically designed units is likely to differ depending upon the service conditions to which they have been subjected.
Remaining life estimation forms a part of the study in case of components designed for finite life. Condition assessment was necessary in other areas like rotating equipment to decide replacement/refurbishment requirement. Electrical equipment like HT Motors were mostly considered for rewinding as the design life has exceeded in most of the cases and class B insulation was changed to class F insulation. Detailed tests were carried out in main equipment like generator and transformer for deciding their suitability for the intended service life.
A comprehensive study of Coal Handling System was also carried out to arrive at augmentation requirement. The final scope covered renovation of existing conveyors and crusher system. New wagon tippler along with crusher and conveying system was also considered in addition to stacker re-claimer. The plant was not built with stacker re-claimer system originally. The refurbishment and augmentation of coal handling system was matched with the Renovation & Modernization completion of the units.
Optimum performance of Cooling Tower and cooling water system is vital to achieve heat rate of the machine. Refurbishment of Cooling Water system, heaters and condenser was also covered in addition to gland steam and ejector system. Renovation and Modernization of Plant OMMI (Vol. 1, Issue 2) August 2002 3
Modernization in Control & Instrumentation included the introduction of Teleperm ME (Siemens) system for the distributed controls. Replacement of field equipment along with open/closed loop controls was also included. Burner Management system was also envisaged in boiler package in addition to milling system up-gradation considering the poor calorific value of coal proposed to be used in future.
To meet pollution control requirement, augmentation in dust collection system was taken care by introduction of new electro static precipitator prior to renovation. The units were operated as base load units and planned for operation in the same way after renovation also.
Table below gives the plant details.
Sl No Unit Capacity Boiler & TG Detail. Service Hours Remarks
1 70 MW. Front Wall Fired Boiler (Non Reheat) B & W-USA Turbine- Siemens AG
169966 136351 Boiler Pressure 73.8 Kg/ sqcm (g) & temperature- 500 C Steam Flow-310 Tons/hr Inter-Connection facility available for cross running 2 70 MW Front Wall Fired Boiler(Non Reheat ) B & W-USA Turbine- Siemens AG 147934 188613 Boiler Pressure 73.8 Kg/ sqcm & temperature- 500 C Steam Flow-310 Tons/hr
3 70 MW Tangential Fired Boiler MHI Japan Turbine- Siemens AG 217702 192804 Boiler Pressure 73.8 Kg/ sqcm & temperature- 500 C Steam Flow-310 Tons/hr
During design, the calorific value of coal considered was around 4500 Kcal/Kg. Over a period, deterioration in coal quality started and at the time of renovation the calorific value of coal used was around 3000 Kcal/Kg. Limitation in fuel preparation system and frequent outages were main reasons for low generation.
The details pertaining to the study carried out, findings and major replacements are covered.
TURBINE & AUXLIARIES
Turbine lifetime is mainly determined by the design criteria, material properties and operating conditions. The following are the main components assessed in turbine. Renovation and Modernization of Plant OMMI (Vol. 1, Issue 2) August 2002 4 1. Casing and Valves 2. Turbine Rotors 3. Transfer Piping 4. Coupling Bolts
Details of NDE ( Non-Destructive Examination )
For the casing and valves, Liquid Penetrant Inspection was carried out for detection of surface defects. Magnetic Particle Inspection was employed for detection of surface and subsurface defects particularly for the inner surface of the casing and for butt welds of transfer pipes. The lifetime of piping is limited by the creep property and hence metallurgical examination using replica technique was employed.
Remaining Life Assessment Approach for Turbine Rotors
The HP/IP and LP are solid Rotors. The shafts with low toughness property and having inner cracks are prone for instantaneous failures. Hence special re-qualification procedure developed by Original Equipment Manufacturer was employed.
Ultrasonic inspection technique using straight beam transducer was carried out to detect and size the defects in HP/IP rotor. (Single rotor and no radial bore in HP/IP rotor) The LP rotor was envisaged with radial bores and the same was additionally examined by Eddy current testing as well by UT for detection and sizing the surface breaking defects.
To avoid brittle failure of a rotor, the internal crack like material defect should be lower than the critical crack size. This is dependent on stress and natural toughness. Using finite element program the critical size is evaluated taking into account the centrifugal, thermal and residual stresses. The critical crack size in terms of equivalent flat bottom hole (EFH) is arrived based on the analysis and is compared with the EFH size derived from the test result. The quotient between critical crack size and final defect size produces the safety factor S against brittle fracture. The decision to run/replace was arrived based on safety factor. Renovation and Modernization of Plant OMMI (Vol. 1, Issue 2) August 2002 5
PIPING
Microstructure of piping
The piping from boiler outlet to turbine inlet was checked for service degradation. UT was carried out to ensure the integrity of welds. Replication was done in weld locations covering parent metal, weld and heat affected zone and pipe bends. The spots in the bends covered the tensile portion, middle and compressive portion. Mechanical polishing was adopted and the replication was done using acetate film. The replicas were evaluated and classified according to the guidelines in VGB TW 507. Replacement/re-inspection interval has been fixed depending on the degradation observed in piping.
The Table below gives the major findings and replacements.
Sl. No Description 70 MW 1 Steam transfer pipes Creep cavities found and Replaced (15 MO3 ) 2 HP/IP Casing Refurbished with modified blades (HP casing) 3 LP Casing Refurbished with new blades (all stages) 4 HP/IP Rotor One rotor replaced with new rotor as the re- qualification study indicated low safety factor. Other two rotors refurbished with modified blades. 5 LP Rotor One rotor replaced with new rotor as the re- qualification study indicated low safety factor. Other two rotors refurbished with modified blades. 6 Gland Steam regulation Changed with new system.
TURBINE AUXILIARIES
The auxiliaries like boiler feed pump, condensate extraction pump and heat exchangers were checked. Re-tubing was carried out in case of ejector, heaters and in condenser as per findings. The boiler feed pumps were replaced with new pumps and new automatic re-circulation control valve was envisaged. Refurbishment of existing pumps was not Renovation and Modernization of Plant OMMI (Vol. 1, Issue 2) August 2002 6 attempted due to spares problem for obsolete design. In case of Cooling Water Pumps, it was necessary to carry out reverse engineering for refurbishment of pumps. Such approach was inevitable since new pumps could not be accommodated in the existing layout. The cooling towers and the Cooling Tower fans were refurbished as per the condition assessment study. The Gland Steam Regulation system was replaced with new control valve to ensure proper gland sealing. Group heater protection interlock was envisaged for HP heaters. With the above the heat rate of turbine guaranteed was achieved.
GENERATOR
The degradation of any electrical equipment during service is normal and periodic inspection and diagnostic tests are essential to establish base record and to have trend analysis. The electrical equipment built in late sixties had ground insulation composed of Mica Splitting tapes bonded in thermo-set resin. The following table gives the details of insulation degradation mechanism.
Sl.No Degradation Reason Effect 1 Overheating Overload, failure of cooling system. Insulation to become brittle causing cracks. 2 Ionization Electrical break down of the gas in the voids between the tape layers and in the impregnation. Reduction in dielectric strength. 3 Over Voltage Repeated non-transient over voltage Enhanced ionization causing break down in some weak points. 4 Improper Synchronization Out of phase synchronization and improper adjustment in voltage level. Mechanical damage to coils and coil bracing system. Possibility of cracks developing on the insulation surface. 5 Mechanical damage Excessive vibration and over speed. Hot spots on stator core. Possibility of short circuit between coils due to damage in insulation
The following tests were conducted in the generator.
STATOR
1. Visual inspection for any abnormality on the core, winding and bus bar supports. 2. Hammer test to check the tightness of the slot wedges. 3. DC leakage test up to 6.3 KV Renovation and Modernization of Plant OMMI (Vol. 1, Issue 2) August 2002 7 4. DC winding resistance of the Stator using DLRO (Digital Low Resistance Ohmmeter). 5. Electro Magnetic Core Imperfection Detection (ELCID) test to check the integrity of insulation between stator core laminations using computerized digital equipment. A small fraction of rated excitation is necessary to generate fault currents within the core body. 6. Checking of capacitance & Di-electric loss at voltages from 1KV to 4KV in steps of 1 KV.
ROTOR
UT for detecting any discontinuity or presence of stress corrosion crack in retaining rings. This inspection was carried out across entire circumstances using 2MHz straight search units. The impedance test (At 230 Volts AC) and insulation resistance value has been checked as per normal practice. The electrical fault between winding (inter turn winding fault) if any will display in excessive mechanical vibration. By applying 12 V DC voltage step between one end of the rotor winding and the rotor body, this phenomenon has been checked using digital RSO (Recurrent Surge Oscillograph) test. Based on the above tests the run/ re-insulation/ replacement decision has been arrived. Re wedging and varnishing of insulation were carried out in all units. The end bells in one 70 MW rotor showed discontinuities in UT test and were replaced with new retaining rings. With this the generators were cleared for operation.
BOILER
APPROACH Life assessment was carried out in boiler pressure parts in addition to condition assessment of various auxiliaries.
Arrangement of new Platen Super Heater with increased mass flow rate
(Six coil arrangement changed to four coil arrangement by blanking two stubs in each assembly of inlet and outlet header.)
Renovation and Modernization of Plant OMMI (Vol. 1, Issue 2) August 2002 8 Boiler components can be classified as follows. Low temperature components covering economizer, water walls and low temperature super heater coils. High temperature super heater. Critical piping and headers.
Assessment techniques adopted were based on degradation mechanism and failure history. Low temperature components were checked up for material wastage in addition to Hydrogen damage using attenuation principle of Ultrasonic sound energy waves. Selection of representative location for sampling of tubes and for NDE survey was decided after careful visual inspection.
The high temperature sections covering super heater coils and the headers are susceptible to time dependent degradation mechanism called creep. The weld joints of the header are prone for fatigue damages and the combined effect of creep and fatigue is to be assessed for deciding the usefulness of the component. The ligament sections of the header are prone for cyclic damage and are to be normally inspected using internal inspection equipment for ligament cracks. The super heater coils are to be checked for material wastage as well as presence of oxide scale on the steam side surface for determining the remaining life. The headers and piping are to be examined for service degradation by replication in addition to NDE of welds. The boiler components were examined in line with the above.
Plant audit in running condition is vital to decide the performance capability and to identify system limitation if any in achieving full load. The performance evaluation study should aim in checking
System adequacy like capacity of the ID and FD fans, fuel preparation system and firing system. Possible improvement in efficiency of the steam generator. Modernization of controls and instrumentation to improve the operational flexibility including introduction of burner management system. The above aspects were taken care prior to overhaul. The plant audit and the findings along with the outcome of assessment study formed the basis for scope finalization.
EFFECT ON FUEL CHANGE
Deterioration in coal quality results not only in limiting the milling capacity but also in increasing the possibility of erosion of pressure parts. The effect of high ash content was considered in boiler design review. The details are given below.
Milling system up gradation by replacing with higher capacity mills. High capacity primary air fan for handling the fuel and change of fuel pipe. The burner capacity and heat release aspect. Renovation and Modernization of Plant OMMI (Vol. 1, Issue 2) August 2002 9 Coal characterization for slagging / fouling and its effect on furnace absorption and also heat pick up in super heater. Spray requirement and redesign of de-superheating system. Material up gradation in super heater coils to match the metal temperatures predicted. Reduction in gas velocity by increasing the free gas area wherever replacement has been envisaged. The mechanical design of new equipment with reference to reliable operation. The pre commissioning requirement like chemical cleaning and steam blowing.
The above aspects were considered in various stages of renovation activity. The following Table gives the details of replacement in boiler.
Sl. No. Description Units # 3 & 4 Unit # 5 1. Boiler Drum Cleared for continuous operation Lamination observed and hence re-inspection recommended after 15,000 hours of operation. 2. Water Walls Fully replaced in unit 4 and partial replacement in unit 3. Good condition. 3. Boiler bank tubes Fully replaced since erosion observed in all rows. Bank tubes in good condition and no replacement done. 4. Super Heater coils Outlet section replaced with higher grade material. (T 22) Outlet section replaced with higher grade material. (T 22) 5. Platen Super Heater coils and Headers Mass flow rate increased by reducing no of parallel circuits and full replacement with new coils. Headers retained. Coils in good condition. Super heater outlet header replaced with new header due to sagging. 6. BMS Newly introduced. Newly introduced.
Balance of Plant
The original coal handling system was designed for 500 TPH. The maximum capacity of the system at the time of study was around 250 TPH only. This is because of various constraints in the crusher and in conveying system. The new Coal Handling Plant incorporated was integrated with the existing system. The capacity of the new system envisaged is 2 X 500 TPH. Provision was also made for feeding coal to other units in the plant also. 2 X 35 cubic meter capacity Water Treatment plant was Renovation and Modernization of Plant OMMI (Vol. 1, Issue 2) August 2002 10 also envisaged in the renovation plan. The Controls & Instrumentation system was changed to Programmable Logic Controls (PLC) integrating old plant with new plant.
PLC based new CHP Stacker Reclaimer
The salient milestone details of major activities are given below:
The plant load factor of the units prior to renovation was in the range of 30 to 40 %. The availability of the units after renovation was more than 80 % and the plant load factor was around 65%. Further improvement in plant load factor is possible provided the restrictions in load evacuation in the grid are overcome.
The assessment and renovation activities were carried out successfully, however certain unforeseen problems were experienced during trial run. The details pertaining to the above aspects are discussed.
During reliability run of the unit, frequent failure of the internal lever of the loading arm unit of the mill was experienced. Observation revealed the surface of the failed component to be bright, shiny and crystalline. The failure of the component was brittle in nature. Chemical analysis, tensile test, hardness survey and micro examination of the component were carried out for identifying the root cause of the failure. Though the material composition met with the specification of the material selected, the yield strength and ultimate tensile strength did not meet the specification. Also the failed samples were found to have coarse grain dendritic structure indicating the possibility for brittle failure. The Sl.No Description Unit # 4 Unit # 5 Unit # 3 1. Boiler Hydro 17 th Aug 2000 27 th April 2001 5 th Oct 2001 2. Boiler Light-Up 8 th Nov 2000 7 th June 2001 21 st Oct 2001 3. Synchronization 20 th Jan 2001 5 th Aug 2001 24 th Dec 2001 4. Full Load 28 th April 2001 17 th Oct 2001 30 th Dec 2001 Renovation and Modernization of Plant OMMI (Vol. 1, Issue 2) August 2002 11 analysis confirmed that the structure is in as cast condition which is quite unusual and unlikely for this type of material to achieve the desired strength and ductility. No proper heat treatment was carried out after casting and this resulted in failure. The desired microstructure of this steel testing should be fine grained, pearlite in ferrite matrix necessary for increasing the strength and ductility to avoid such service failure. The material specification for the above component discussed was IS1030 Gr.340. On replacement with better design the failures were eliminated. This feedback was taken care in the mills of the other units well in advance.
CHEMICAL CLEANING
In one of the units, part replacement of water walls was carried out based on the assessment. Sample tube from an un-replaced portion was analyzed for deposit content and for deciding the chemical cleaning requirement. The deposit content was found to be more than 40 milligrams per centimeter square. The solvent selection was done based on the analysis of coupons in the laboratory.
Copper removal and cleaning of the tubes was carried out using hydrochloric acid by circulation method. The effectiveness of the chemical cleaning was confirmed by internal examination of the sample tube from water wall taken after first stage passivation. The presence of magnetite coating was also seen.
When the unit was brought back in service, pinhole leaks from water wall tubes were experienced. The failures were confined to the tubes near the hopper portion and also near the gooseneck. On examination of the failed tubes, lot of internal corrosion was seen on the fireside surface of the tubes. The observations reveal the following.
The sample tube removed for deposit analysis from high heat flux zone did not show any corrosion pitting. But the hopper portion of the tubes that had internal pittings became vulnerable for further corrosion. During the process of chemical cleaning, the corrosion deposits got accumulated in the pitted portion and removal of such deposits could not be done effectively by cold and hot water flushing. When the boiler was brought back in service, numerous failures in water walls were experienced and massive replacement was warranted as corrective measure.
DISCUSSION
Renovation and Modernization job is a complex process as compared to Green field project. Upkeep of plant history is most important for such jobs. Life Extension for another 15 to 20 years is possible even after the units have undergone service period of more than150,000 hours of operation. Cash flow in a phased manner is to be ensured for achieving targets as per plan. Renovation and Modernization of Plant OMMI (Vol. 1, Issue 2) August 2002 12 By careful planning it is possible to complete renovation of the first unit within 18 months from the date of study. Thereafter each unit can be completed in six months interval. NDT Techniques to be adopted are to be carefully planned. Unforeseen requirement at the time of execution if any arises is to be accommodated within the schedule. Retraining of operation and maintenance personal is extremely important. It is preferable to involve the persons right from the construction stage. It is suggested that the operating persons are involved right from commissioning which helps them in building their level of confidence in problem solving. The cost for Renovation and Modernization will range from 30 to 40% of the total cost required to construct a new plant. A collective and coordinated approach among the consultant/customer/executing agency is very much essential for successful completion of R & M activity in time.
REFERENCES
Condition assessment guidelines for Fossil Fuel Power Plant components- EPRI USA. Re-qualification of Turbine components Procedure and Experience by Mr. Michael Siegal / SIEMENS. Renovation, Up-gradation and Modernization of Durgapur Projects Power Station: Life Extension Program First of its kind in INDIA by N.AYODHI and M.K.PAL- Power Gen 2000 (DELHI). Life assessment and Life extension of Thermal Power Plants employing NDT technique - a case study by N. AYODHI EPRI Conference March 2002. VGB TW 507 guidelines for replication.