AES OPGC India AES Corporation 2/ Team Team Name :- Efficiency improvement Team Team Sponsor :- Venkatachalam Kupusami Team Members :- Amalendu Nanda Manoj Ku. Jit Madhumita Soren Manoj Ku. Pradhan Deepak Ranjan Tripathy Tarini Patnaik Amrit Bal Facilitator Sukanta Mohapatra AES Corporation 3/ Team Charter (problem or issue ) Background OPGC I station which is now 16 years old requires system modifications, which is being carried out in the form of DCS up gradation, excitation system control up gradation and coal feeder up gradation etc. for sustainability and reduction of forced outages on account of control system related issues. OPGC team on a sustainable basis has taken steps on energy management front. We wanted to focus on the areas where we can benefit from performance or efficiency improvement with minimum investment. Team decided to list out the energy losses and rectify the same with an objective to enhance the station performance. Basically, we thought of improving efficiency through loss Reduction wherever possible by process optimisation, adherence to standard checklist, carrying out small modifications, controlled use of equipment wherever possible for cost optimisation and better resource utilisation. AES Corporation 4/ Team Charter (Risks of not doing this project) Steam Loss of 18142 T /Y Bloated Budgeted Station oil consumption by 88 KL per year. Increased Auxiliary power consumption 148982 kWhr Deteriorating Station performance Higher Maintenance Cost Underutilized Resources Unscrupulous expenditure Low Maintenance effectiveness ratio Low Availability / Reliability of equipments AES Corporation 5/ Team Charter ( Goal & Objective ) Goal Objective Take out one out of two service Air Ejector from Unit-1 Increasing the steam turbine output. Check & Rectify Steam Traps in : Boiler Area. Turbine Area. Maximum utilization of heat. Maintain less Oil Pressure while taking Oil Guns Reduce Oil Consumption BFP recirculation valve passing Auxiliary power consumption Modification of Circuit to run One HFO Pump Lesser Auxiliary Power Consumption AES Corporation 6/ Findings (Approach method, Tools ) The Team used the PDCA approach, with the following APEX Tools utilized: Brainstorming Check sheets Data Gathering by samples FIRE GAP Analysis Gantt Chart Implementation Plan 5W2H AES Corporation 7/ Conducting Brainstorming Sessions Identify and brief a leader or facilitator ( Amalendu Nanda was identified as Leader) Introduce the brainstorming session The Leader welcomed participants and described the purpose of the session, roles and responsibilities, and the facilities. The Leader used a structured approach and allowed every person in the group to give their ideas as their turns came up in the rotation or to pass until the next round. Identified Focus Areas Performance or efficiency improvement with minimum investment. Energy losses listing & rectification. Future Impetus Improving efficiency through loss reduction by Process optimisation Adherence to standard checklist Carrying out small modifications Controlled use of equipment Position/Role Name Knowledge Area/Expertise Team Lead Amalendu Nanda Operation & efficiency Knowledge Mgr. Manoj Ku. Jit Operation Knowledge Mgr. Madhumita Soren Performance & efficiency Knowledge Mgr. Manoj Ku. Pradhan Mechanical Maintenance Knowledge Mgr. Deepak Ranjan Tripathy Head WTP Brainstorming AES Corporation 8/ Alternatives discussed Take out one service Air Ejector from Unit-1 Check & Rectify Steam Traps in :Boiler Area & Turbine Area. Maintain less Oil Pressure while taking Oil Guns BFP recirculation valve passing Modification of Circuit to run One HFO Pump Condenser and Cooling Tower Performance Improvement Optimization of soot blowing process Unit 1- Performance evaluation to be done by reducing excess air to boiler Mill ball feeding based on requirement Boiler Flue gas duct & APH duct leakage to be reduced. Heater Performance enhancement Identified Projects (For this Year) Take out one service Air Ejector from Unit-1 Check & Rectify Steam Traps in :Boiler Area & Turbine Area Maintain less Oil Pressure while taking Oil Guns BFP recirculation valve passing Modification of Circuit to run One HFO Pump Rest Projects will be taken up in subsequent years. Identified projects scored over the rest on grounds of low investment higher returns. Brainstorming AES Corporation 9/ Organizational Scope Operation and Maintenance teams are involved in the project. Team Activity Scope Sl No. Project Activities 01 Discussion on the project regarding its feasibility with different concerned parties, Proposed modification. 02 Study of all the points one by one through field survey 03 Work on every points simultaneously for completion of project in time 04 Carry out modification as per requirement 05 Required spare to be ordered for modification 06 Project completion and trial implementation Brainstorming AES Corporation 10/ Gap Analysis Current State Two Main air ejectors are used for air extraction and creating vacuum in the condenser in Unit-1. Steam required for one Main Ejectors is 1TPH. 60% of steam traps are passing causing steam loss. Maintaining 6.5ksc of oil pressure while taking Oil Guns. Oil flow of 1.4KL per gun. Pneumatic recirculation valve of BFP -2B is passing 30T. Drawing extra current of 10Amp. Two HFO pumps are kept in service during normal conditions even when oil guns are not in service. Gap Identification & rectification of air ingress points. Improve the capacity of the Main air ejector . Checking of Steam Trap. Replacement of defective Steam Traps Maintaining lower oil pressure for reduced oil flow per gun. Servicing / Replacing of the Recirculation Valve that is passing. Necessary modification to be done for interconnecting both Unit-1 & 2 HFO Stations Future State Running with one Air Ejector in Unit-1 . Utilize 1TPH steam for increasing the steam turbine output. All the Steam traps in service for retaining steam within the process for maximum utilization of heat. Maintain the Oil Pressure at 6 ksc while taking Oil Guns. Oil flow of 1.3KL per gun. Passing proof recirculation valve will reduce the current run by the BFP. Reduction in Auxiliary power consumption by 101.737KWH One HFO pump in service. AES Corporation 11/ 5W2H ( Air Ejector ) Type 5W2H Question Subject Matter What? What will be done? Take out one service Air Ejector from Unit-1. Identification & rectification of air ingress points. Purpose Why? Why will it be done? Increase the steam turbine output. Location Where? Where will it be done? Turbine Area Unit-1 Sequence When? When does it need to be done? Are there time constraints, deadlines? People Who? Who will do it? M.K.Pradhan, A.P.Nanda, M.K.Jit Method How? How will it be done? How will the tasks be approached and managed? 1. Carryout required trouble shooting operation and carryout modification in the system to improve the capacity of the Main air ejector so that vacuum can be sustained with single service air ejector. 2. Take out one service Air Ejector from Unit-1. Cost How Much? How much will it cost? How much investment is required? No significant investment as the job would be performed by in-house expertise and material requirement is also not significant. How much return is expected? Revenue from extra generation = 2299500*0.41= 9,42,795 INR Start Date End Date 25/09/2010 30/12/2010 5W2H AES Corporation 12/ 5W2H ( Steam Traps ) Type 5W2H Question Subject Matter What? What will be done? Checking/Replacement of defective Steam Traps Purpose Why? Why will it be done? 60% of steam traps are passing causing steam loss. Steam loss due to defective traps = 0.1*21*365*24*0.85*0.6 = 9381.96 T/ Yr Location Where? Where will it be done? Turbine Side, Deaerator Floor, PRDS Floor , Mill Area Sequence When? When does it need to be done? Are there time constraints, deadlines? People Who? Who will do it? M.K.Jit , Madhumita Soren Method How? How will it be done? How will the tasks be approached and managed? Checking of Steam Trap has been done by Visual inspection, Checking by Ultra probe, Temperature checking Replacement of 12 defective Steam Traps Cost How Much? How much will it cost? How much investment is required? Cost of 12 traps = 12X5000 = 60,000INR How much return is expected? Revenue from extra generation = 2814600*0.41=11,53,986 INR Start Date End Date 02/11/2010 30/12/2010 5W2H AES Corporation 13/ 5W2H (Optimising Oil Pressure ) Type 5W2H Question Subject Matter What? What will be done? Reducing oil consumption by optimizing oil Pressure while unit is on oil support Purpose Why? Why will it be done? Reducing oil pressure reduces oil flow through the oil guns, thus reducing the oil consumption. Location Where? Where will it be done? Oil fired boilers use oil guns for start-up, warm-up, and load carrying. Sequence When? When does it need to be done? Are there time constraints, deadlines? People Who? Who will do it? Sudhakar Swain, Madhumita Soren Method How? How will it be done? How will the tasks be approached and managed? Maintain the Oil Pressure at 6 ksc instead of 6.5ksc while taking Oil Guns. This will reduces the oil flow by 0.1 KL per gun from 1.4KL per gun to 1.3 KL per Gun. Cost How Much? How much will it cost? How much investment is required? NIL How much return is expected? Benefit of Rs 37,00,000 is expected Start Date End Date 01/09/2010 30/12/2010 5W2H AES Corporation 14/ 5W2H (BFP recirculation valve passing ) Type 5W2H Question Subject Matter What? What will be done? Prevent BFP recirculation valve passing Purpose Why? Why will it be done? Reduction of auxiliary consumption Location Where? Where will it be done? BFP 2B (Unit 2 boiler feed pump) Sequence When? When does it need to be done? Are there time constraints, deadlines? People Who? Who will do it? A.P.Nanda, Amrit Bal Method How? How will it be done? 30T of passing through recirculation valve of BFP-2B. BFP 2B (Unit 2 boiler feed pump) is drawing extra current of 10Amp. Passing is prevented, then there is a auxiliary saving potential . Cost How Much? How much will it cost? How much investment is required? Recirculation valve spare 3,00,000INR How much return is expected? Savings potentials per year = 101.73X24X365X0.85X (2/3) X1.3 = 6, 56,484 INR Start Date End Date 02/11/2010 30/12/2010 5W2H AES Corporation 15/ 5W2H (Using One HFO Pump ) Type 5W2H Question Subject Matter What? What will be done? Running of single HFO pump instead of two during normal operating condition of both Units. Purpose Why? Why will it be done? Lesser Auxiliary Power Consumption Location Where? Where will it be done? Unit-1 & 2 HFO Stations Sequence When? When does it need to be done? Are there time constraints, deadlines? People Who? Who will do it? Sudhakar Swain, A.P.Nanda Method How? How will it be done? How will the tasks be approached and managed? 1.Stopping of One HFO Pump. 2. Necessary modification to be done for interconnecting both Unit-1 & 2 HFO Stations Cost How Much? How much will it cost? How much investment is required? Material cost: INR 10,000 How much return is expected? Annual Savings (in Rs) = Rs 1, 95,033 Start Date End Date Completed ( 30/07/2010) ( Under Trial Observation) 5W2H AES Corporation 16/ Findings (Issues and Root Causes) 1. Unit-1: One of the Main air ejectors to be taken out of service Two Main air ejectors are in service in Unit-1 due to inadequacy in the performance of single Main air ejector. Though several attempts have been made to keep one Main air ejector in service, we have not been able to succeed, so far. Team would like to carryout required trouble shooting operation and carryout modification in the system to improve the capacity of the Main air ejector so that vacuum can be sustained with single service air ejector. APEX tool will be used in performing this task. Steam required for one Main Ejectors is 1TPH. If we can take out one ejector then we would be able to utilize 1TPH steam for increasing the steam turbine output. 2. Steam Trap: The function of a steam trap is to discharge condensate, air and other incondensable gases from a steam system while not permitting the escape of live steam. The steam trap is an essential part of any steam system. It is the important link between good steam and condensate management, retaining steam within the process for maximum utilization of heat, but releasing condensate and incondensable gases at the appropriate time. At OPGC, Thermostatic Type of Steam Traps are used and are operated by changes in fluid temperature. In total 21 nos. of trap (10 nos in Unit 1 & 11nos in Unit 2) are in service. Defective stream traps have been identified by taking temperature measurement across each trap. It is observed that 60% of steam traps are passing causing steam loss. AES Corporation 17/ Findings (Issues and Root Causes) 3. Oil Gun flow optimisation : In coal fired boilers the oil guns are used for start-up and warm-up purpose. Oil fired boilers use them for start-up, warm-up, and load carrying. These oil guns are designed with a capacity of around thirty percent of boiler maximum continuous rating. Oil guns are used during initial start up of unit for light- up of the boiler, for taking coal mill into service when adjacent mills are not in operation and as a flame stabilization fuel. In present practice, we are maintaining 6.5ksc of oil pressure while taking Oil Guns. This caters to oil flow of 1.4KL per gun. We are planning to maintain the Oil Pressure at 6 ksc while taking Oil Guns. This will reduces the oil flow by 0.1 KL per gun. 4. BFP Recirculation: It has been seen that there is nearly 30T of passing through recirculation valve of BFP-2B. As a result BFP 2B (Unit 2 boiler feed pump) is drawing extra current of 10Amp. If passing is prevented, then there is a saving potential . 5. Using One HFO Pump Currently, two HFO pumps are kept in service. There is a plan to keep one HFO pump in service after doing suitable modification in the circuit. AES Corporation 18/ Solution Implementation (Addressing Issues ) Running with one Air Ejector in Unit-1 (Currently two ejectors are in service in Unit-1) : Identification & rectification of air ingress points. Checking/Replacement of defective Steam Traps in : Boiler Area. Turbine Area. Reduce Oil Consumption by Optimising Oil Pressure. Reducing oil pressure reduces oil flow through the oil guns, thus reducing the oil consumption. Reducing Auxiliary Power consumption Rectify recirculation valve passing of BFP and CEP. Checking of individual pumps for Recirculation valve passing and taking steps to rectify Stopping of One HFO Pump Necessary modification to be done for interconnecting both Unit-1 & 2 HFO Stations AES Corporation 19/ Solution Implementation (Solution superseded any other solutions) Other ways of Improving Efficiency were as follows Condenser and Cooling Tower Performance Improvement Optimization of soot blowing process Unit 1- Performance evaluation to be done by reducing excess air to boiler Mill ball feeding based on requirement Boiler Flue gas duct & APH duct leakage to be reduced. Heater Performance enhancement But these efficiency improvement measures superseded all other possible measures in terms of Financial returns and appreciable impact on KPIs Increasing the steam turbine output.- Steam required for one Main Ejectors is 1TPH. If we can take out one ejector then we would be able to utilize 1TPH steam for increasing the steam turbine output. Maximum utilization of heat- Defective stream traps have been identified by taking temperature measurement across each trap. It is observed that 60% of steam traps are passing causing steam loss. Reduce Oil Consumption - In present practice, we are maintaining 6.5ksc of oil pressure while taking Oil Guns. This caters to oil flow of 1.4KL per gun. We are planning to maintain the Oil Pressure at 6 ksc while taking Oil Guns. This will reduces the oil flow by 0.1 KL per gun. Auxiliary power consumption - It has been seen that there is nearly 30T of passing through recirculation valve of BFP-2B. As a result BFP 2B (Unit 2 boiler feed pump) is drawing extra current of 10Amp. If passing is prevented, then there is a saving potential. Lesser Power Consumption - Modification of process/ control Circuit to run One HFO Pump AES Corporation 20/ Solution Implementation (Implementation plan) Activity/Milestone Start Date End Date Collect information of the feasibility of the project. 25/06/2010 30/06/2010 Finalization of the project plan and submission for approval 02/07/2010 15/07/2010 Discussion strategy for carrying out all the jobs simultaneously 20/07/2010 25/07/2010 Necessary Modifications 27/07/2010 30/12/2010 Offer to be asked from different parties for the required spares. ( Procurement of steam traps, Recirculation valve spare ) 02/10/2010 24/11/2010 Completion of the project & report finalization after 15 days trial 05/12/2010 20/12/2010 Necessary Modifications Start Date End Date Take out one service Air Ejector from Unit-1 25/09/2010 30/12/2010 Check & Rectify Steam Traps in : Boiler Area. Turbine Area. 02/11/2010 30/12/2010 Maintain less Oil Pressure while taking Oil Guns 01/09/2010 30/12/2010 BFP recirculation valve passing 02/11/2010 30/12/2010 Modification of Circuit to run One HFO Pump Completed ( 30/07/2010) ( Under Trial Observation) AES Corporation 21/ Results: Business impact in Performance The Following Issues were addressed - Steam Loss of 18142 T /Y Bloated Budgeted Station oil consumption by 88 KL per year. Increased Auxiliary power consumption 148982 kWhr Forced outages ( Trips ) Deteriorating Station performance Higher Maintenance Cost Underutilized Resources Unscrupulous expenditure Maintenance effectiveness ratio Availability ,Reliability of equipments AES Corporation 22/ Results: Business financial benefits Air Ejector Cost savings: For 210 MW Generation steam flow requirement is 680T So, 1 T of steam flow will generate 0.3MW. So, Generation improvement per year by running 1 ejector = (210/680*365*24*0.85) = 2299.5MW=2299500 KWhr Revenue from extra generation = 2299500*0.41= 9,42,795 INR = $ 20951. Investment: No significant investment as the job would be performed by in-house expertise and material requirement is also not significant. Steam Traps Cost savings: Steam loss due to defective traps = 0.1*21*365*24*0.85*0.6 = 9381.96 T/ Yr For 210 MW Generation steam flow requirement is 680T So, 1 T of steam flow will generate 0.3MW. So, Generation improvement per year by replacing defective traps = (210/680*9382) = 2814.6MW=2814600KWhr. Revenue from extra generation = 2814600*0.41=11,53,986 INR = $ 25644 Investment: No significant investment as the job would be performed by in-house expertise Material replacement 12 number of traps to be replaced Cost of 12 traps = 12X5000 = 60,000INR = ($1333 ) AES Corporation 23/ Results: Business financial benefits Oil Gun flow optimisation : Cost Benefit Budgeted Station oil consumption is 1230KL per year. If we reduced the flow from 1.4KL per gun to 1.3 KL per gun, then the consumption would be reduced to 1142 KL per year. Thus a benefit of Rs 37,00,000 ($ 82222 ) is expected. Investment: No significant investment as the job would be performed by in-house expertise Material cost: Nil BFP Recirculation: Cost Benefit: If passing is prevented, then there is a saving potential of Auxiliary power consumption = 1.732 x 6.6 x 10 x 0.89 = 101.737KWH Savings per year = 101.73X24X365X0.85X (2/3) X1.3 = 6, 56,484 INR ($ 14589 ) Note: BFP recirculation valve passing checks to be carried out for Unit-1 Investment: Manpower cost: In-house manpower Material cost: Recirculation valve spare 3,00,000INR ($6667) AES Corporation 24/ Results: Business financial benefits Using One HFO Pump Cost Benefit: Power of Drive Motor for HFO is 22KW (for calculation we will consider 20KW) Total working hours = Total hours of Operation Average hours when both the Pumps are needed = (331 * 24) (500) = 7444 hrs Annual Savings (in Rs) = (20 x 7444) x 1.31 = Rs 1, 95,033 ($ 4334 ) Investment: Manpower cost: In-house manpower Material cost: INR 10,000 ($ 222 ) AES Corporation 25/ Results: Business financial benefits Investment Cost of 12 traps $ 1333 Material cost: Recirculation valve spare $ 6667 Material cost for Modification in Circuit for running 1 HFO Pump $ 222 Total Cost:- $8222 Cost Savings Air Ejector :- $ 20951 Steam Traps :- $ 25644 Oil Guns :- $ 82222 BFP Recirculation:- $ 14589 HFO Pump :- $ 4334 Total Annual Benefits:- $ 147740 Pay Back Period :- less than a 1 Month NPV :- $ 20704209 AES Corporation 26/ Knowledge Learned as a team OPGC team believed that If a team is to reach its potential, each player must be willing to subordinate his personal goals to the good of the team. Responsibility Sharing for Timely Execution It was decided to distribute responsibilities among the team members for early completion of project. Clear Communication & Proper Record Keeping Communication guidelines were formulated and it was decided to keep all the finding of jobs carried out in the APEX folder kept inside common OPERATION folder. Minutes or notes were posted from team meetings or projects. Safety our way of Life The team ensured the safety of employees in the work place during the project implentation.Safety talks, auditing ,supervision were effective. AES Corporation 27/ Conclusion Coming together is a beginning. Keeping together is progress. Working together is success.