THERMAX LTD.

POWER –O&M
ICL BANSWARA
PERFORMANCE REPORT
FY-2017-18

Thermax Power O&M 1

 Index

Content Pages

SAFETY SUMMARY 3

PLANT PERFORMANCE REPORT

4

CHEMICAL CONSUMPTION 5

WATER CONSUMPTION 6

ACHIEVEMENTS 7-8

MAJOR PARAMETER GRAPH 9-13

MAINTENANCE SUMMERY 14

TRIPPING REPORT 15-16

MAJOR SHUTDOWN JOBS

17

KAIZEN AND IMPROVEMENTS 18

MANPOWR DETAIL
Thermax Power O&M
19
2
 Safety Status

Month
T Month Month Month of Month Month of
Month Month of Month of Month of Month Year Till
Parameters ar of of Month Dec of Jan Mar Remarks
of of Jun Sep. Oct. Nov. of Feb date
g May July of Aug.
April
et

Safe Man Hour

∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞

Near miss to Incident

Ratio
0 2.0 2.0 1 1 1 0 0 1 0 0 10
1 1

Number of Fatal
accidents 0 0 0 0 0 0 0 0 0 0 0 0 0
0

Number of Near miss

Identified / Closed 10 2/2 1/1 1/1 1/1 1/1 1/1 0/0 0/0 1/1
0 2/1 1/1 0/0 11/10
%

Number of Audit
points or unsafe
conditions Identified 10 101/63 102/85 103/55 100/55 60/35 101/40 75/50 24/10 54/16 67/16
0 101/64 91/87 979/648
/ Closed
%

Number of Open
points with high
severity 0 1 1 1 1 2 2 2 2 2 4 6 1 4

Number of awards
and appreciation
issued to contractors 2 0 0 0 0 0 0 0 0 0 0 0 0 0

Training Man days

Completed >
0.048 0.151 0.167 0.087 0.169 0.113 0.029 0.098 0.08
2. 0.083 0.27 .021 1.58
5

Number of
Reportable Accident
0. 0 0 0 0 0 0 0 0 0 1
0 0 1
8

Thermax Power O&M 3

 Plant Performance Parameters
TARG
DESC U
ETS
RIPTI NI APR MAY Jun July Aug. Sep. Oct. Nov. Dec. Jan. Feb. Mar. YTD
2017-
ON TS
18
POWER M
GENER W 162150 9409 11992.37 12653.32 12320.90 5717.49 11677.22 12096.82 10592.6 7002.34 10143.17 11102.34 12132.34 126839.98
ATION H

TOTAL
STEAM TP
GENER H
681030 39276 50330 52862 51170 23842 48559 50334 43745 29135 42753 45956 50331 4528292
ATION

AUX.
M
CONSU 20268.7 1210.0
W 1504.6 1523.67 1513.40 874.60 1428.53 1493.02 1323.7 903.28 1214.70 1272.79 1461.91 15724.27
MPTIO 5 7
H
N

AUX.
CONSU
% 12.85 12.55 12.04 12.28 15.30 12.23 12.34 12.5 12.9 11.98 11.46 12.05 12.50
MPTIO 12.5
N

PLF
(DEEME
D/ACT
% 100/95 78.24 83.09 87.87 82.80 69.15 81.09 81.3 78.81 77.57 78.27 82.61 81.53 80.19
UAL)
PAF
(DEEME
D/ACT
% 100/95 76.44 91 99.58 100 51.2 100 100 90.2 57.4 86.8 97.2 98.8 87.3
UAL

Kc
Plant al/
heat K 3150 3207 3239 3160 3088 3027 3007 3079 3080 3069 3224 3362 3212 3143
rate W
Hr

KG
Thermax
Specific
Power
/K
O&M 4
 WTP Chemical Consumption

RO Dossing/CT Dossing/DM NaOCl Sodium Hypo Boiler Boiler Boiler

RO Dossing RO Dossing Plant USE RO Dossing RO Dossing DM Plant Use Chlorite -15% (Kgs) Dossing Dossing Dossing CT Dossing CT Dossing CT Dossing CT Dossing CT Dossing
Maxtreat- Maxtreat- Maxtreat- Maxtreat- Maxtreat-
Maxtreat- Maxtreat- Maxtreat- Maxtreat-
Maxtreat- 9206 NaOH Caustic 3235H Maxtreat- 7700 2515 Scale 652 Non NaCl Sodium
9123 RO 9735 HCl Hydrochloric Acid -33% NaOCl Sodium Hypo 3330 617 Oxidize
9202 ROCC ROCC Soda Flake - Hydrazine 3223 S Corrosion (Mineral) Oxidize Chloride -
Antiscalant SMBS (Kgs) Chlorite -15% (Kgs) Morpholine Biocide
Low pH (Kgs) High pH 96% (Kgs) Hydrate TSP (Kgs) Inhibitor Inhibitor Biocide 15% (Kgs)
(Kgs) (Kgs) (Kgs) (Kgs)
(Kgs) (Kgs) (Kgs) (Kgs) (Kgs)
receivcons recei receive cons cons recei receiv Receiv recei recei cons recei receiv receiv receiv recei receiv
cons. Consumption received cons. Consumption cons. cons. cons. cons. cons. cons. cons.
ed . ved d . . ved ed ed ved ved . ved ed ed ed ved ed
R.O. UF Chlorina
Month Dossi SAC MB Flassin tion
ng g Dossing

April 2.60 0.0 7.00 0.0 2425 0 0.0 0.0 0.0 0.0 195 0 29 0 19.9 0.0 12.300.0 4.95 90.0 42.0 140.056.0 0.0 12.0 0.0 10.0 0.0 400 0

May 2.70 0.0 1.50 0.0 2415 12000 13.0 0.0 8.0 0.0 484 0 42 0 27.0 0.0 17.400.0 6.40 0.0 46.5 0.0 62.0 0.0 12.5 0.0 10.0 0.0 440 0

June 2.40 0.0 4.00 0.0 3275 0 0.0 0.0 0.0 0.0 282 0 28 0 17.4 0.0 18.000.0 7.30 0.0 72.0 140.096.0 0.0 16.0 0.0 11.0 0.0 640 0

July 2.70 0.0 3.50 0.0 3050 0 0.0 0.0 0.0 0.0 325 0 35 0 16.8 0.0 19.300.0 8.80 0.0 72.0 0.0 103.0 0.0 22.0 0.0 16.0 0.0 480 0

August 3.70 0.0 8.00 0.0 1150 0 2.0 0.0 2.0 0.0 345 2500 28 0 21.3 0.0 9.50 0.0 6.20 0.0 39.0 280.061.5 280.012.0 100.05.0 0.0 360 2000

September 3.90 0.0 4.50 0.0 2390 0 0.0 0.0 0.0 0.0 424 0 40 0 22.1 0.0 15.400.0 7.20 0.0 45.0 0.0 60.0 0.0 16.0 0.0 10.0 0.0 520 0

October 4.00 0.0 9.50 0.0 2546 0 0.0 0.0 0.0 0.0 440 0 56 0 24.8 0.0 17.400.0 6.00 0.0 46.0 0.0 62.0 0.0 16.0 0.0 10.0 0.0 480 0

November 4.40 120.08.90 0.0 1743 14000 0.0 0.0 0.0 0.0 413 0 86 1400 18.6 0.0 16.200.0 4.00 0.0 45.0 0.0 58.0 105.016.0 0.0 5.0 0.0 400 0

December 4.40 0.0 8.50 0.0 1546 0 2.0 0.0 2.0 0.0 275 0 179 0 19.6 0.0 10.900.0 4.90 0.0 29.7 0.0 42.0 0.0 5.0 0.0 5.0 0.0 330 0

January 4.5 0 9 0 12.4 1796 850 0 4 0 0 0 479.5 0 83 144 0 16.15 0 12.6 0 4.55 0 48 280 62 280 16 0 10 0 400 1800
February 4.5 0 6 0 30.5 2649 549.1 0 3 0 2 0 414 0 50 10 0 18.12 0 12.4 0 3.15 0 42 0 56 0 19 0 10 0 520 0
March 6.8 0 12.6 0 46 3000 892 0 4 0 4 0 600.5 2500 70 35 1000 22.5 0 13.1 0 3.1 0 46.5 0 62 0 24 0 8 0 800 2000
46.6 120. 83.0 88.9 27985.2291. 26000.28.0 18.0 4677. 5000. 203.0 712.0 2400. 244. 174. 66.590.0 573. 840. 780.5665. 186. 100. 110. 5770. 5800.
0.00 0.00 0.00 0.00 0.00 0.00
TOTAL 0 00 0 0 00 10 00 0 0 00 00 0 0 00 27 50 5 0 70 00 0 00 50 00 00 00 00
CHEMICAL
PRISE RS/KG 300 50 1.7 1.7 1.7 241 340 34 11.25 11.25 260 260 110 121 151 375 203 2.7
CHEMICAL 151. 47574. 3894.8 15901 2283.7 6351 4537 7320 6941 11785 6993 2233
COST 13980 4150 13 5 7 6748 6120 8 5 8010 0.2 0 .5 7.7 5.5 7.5 0 15579
WATER
GENERATIO
N
COST=RS/LIT
ER

Thermax Power O&M 5

 Water consumption

Month Power Generation( MWH) Raw water consumption(M3) DM water Consumption(M3)

April 9409.070 4328.1722 837.40723

May 11992.370 6236.0324 1139.27515
June 12653.320 5440.9276 835.11912
July 12320.9 5051.569 825.5003
August 5717.490 4093.72284 691.81629
September 11677.210 4554.1119 817.4047
October 12968.200 5316.962 881.8376
November 10492.600 4511.818 640.0486
December 7002.340 3851.287 770.2574
January 10143.170 5883.0386 1217.1804
February 11102.340 4996.053 688.34508
March 12132.340 7036.7572 982.71954

Thermax Power O&M 6

 Achievement in FY 17-18
1. Reduced APC from 12.45 % to 11.46 5 in February month with PLF 80.1.it is
lowest in Fy-17-18.
2. Reduced heat rate from targeted 3250 Kcal/kw to 3150 Kcal/kw by reducing heat
losses, venting and leakages.
3. To achieved first time max running load of turbine goes to peak 21 MWH on
25/12/2017 respective of 20 MWH capacity after governor setting change.
4. No any major shutdown taken from CPP site in this year.
5. Optimize running hours of service air compressor from 24 hr to 6 hrs acc. to
requirement and save approximate 2.5 MWH APC per day from Sept-17.
6. Optimize running hours of CHP by increase feeding rate and reduce ideal running
time saving per day 150 KWH APC.
7. By regular following and force to customer replaced the damaged tank by new
acid tank .and stop manual handling of acid.
8. Zero accident and fatality.
9. Convince to customer regarding 5S and TPM activity and also agreed him for
support.
10. Complete every shutdown within the time given by customer and on customer
requirement.
Thermax Power O&M 7
 11. 8 nos of kaizen implemented at site for better O&M.
12. Turbine minor overhauling and generator bearing inspection don during
shutdown 28/11/2017 to 12/12/2017.
13. Plant running in rainy season without load distribution and tripping.
14. AHP probe mode taken in service .
15. To achieve maximum continue running days record of 98 days (23 Aug to 28
Nov 2017).

Thermax Power O&M 8

 Ave. Generation Vs. Heat Rate and Boiler
efficiency
BOILER EFFICIENCY (%) POWER GENERATION (MWH)

PLANT HEAT RATE (KCAL/KWH) 2 per. Mov. Avg. (BOILER EFFICIENCY (%))
100 15000

90 13500

80 12000

70 10500

60 9000

50 7500

40 6000

30 4500

20 3000
78.08

79.71

80.39

82.08

82.34

81.58

82.34

81.67

81.29
10 1500
80.3

80.8

83.1

0 100 0
APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR
YEAR TO MARCH-16

*NOTE – AVG GCV OF FUEL IS KCAL/KG

Thermax Power O&M 9
 Ave. Generation v/s Aux. Power

POWER GENERATION (MWH) AUX CONSUMPTION (%)

16.00
14000
15.00

12000 14.00

13.00
10000
12.00

8000 11.00

10.00
6000
9.00

8.00

127611.350
4000
11992.370

12653.320

11677.210

12968.200

10492.600

10143.170

11102.340

12132.340
9409.070

5717.490

7002.340
12320.9

7.00
2000
6.00

0 5.00

MWH

Thermax Power O&M 10

 Monthly PLF and PAF

PLF (%) PAF (%) DEEMED PAF (%)

120 120

110 110

100 100

90 90

80 80

70 70

60 60

50 50

40 40

30 30

20 20
78.24

83.09

87.87

82.80

69.15

81.09

81.30

78.81

77.57

78.27

82.61

81.53

80.19
10 10

0 0
% %

Thermax Power O&M 11

 Specific Raw and DM water Consumption
Details

SP. RAW WATER CONSUMPTION (LTR/KWH) SP.D.M.WATER CONSUMPTION (LTR/KWH)

0.140
0.95
0.85 0.120

0.75 0.100
0.65
0.080
0.55
0.45 0.060

0.35
0.040
0.25
0.020
0.52

0.41
0.46

0.43

0.72

0.39

0.41

0.43

0.55

0.58

0.45

0.58

0.49
0.15
0.05 0.000
APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEBYEAR
MARTO MARCH-15
LTR/KWH
LTR/KWH

Thermax Power O&M 12

 POWER GENRATION VS SP.STEAM
CONSUMPTION

POWER GENERATION (MWH) SP. STEAM CONSUMPTION

14000 5.00

12000
4.00
10000

8000 3.00

6000
2.00
4000
11677.210

127611.35
11992.37

12653.32

5717.490

12968.20

10492.60

10143.17

11102.34

12132.34
9409.07

12320.9

7002.34
1.00
2000

0 0.00
MWH KG/ KWH

Thermax Power O&M 13

 MAINTENANCE SUMMARY

200 200

180 180

160 160

140 140

120 120
NUMBERS

100 100

80 80

60 60

40 40

20 20
180

180

180

180

180

180

180

180

180

180

180
90
0 0

PLANNED ACTUAL

Thermax Power O&M 14

 Tripping Report

80.00
75.00
70.00
65.00
60.00
55.00
50.00
45.00
40.00
35.00
30.00
25.00
20.00
15.00
10.00 Hrs
5.00 Tripping Reason
0.00
Date

Thermax Power O&M 15

 Plant Tripping Detail

Sr No. Tripping Reason Date Hrs Corrective action

Turbine tripped due to pressure switch malfunctioning or Check pressure switch and reset turbine and after all parameters
1 6/5/2017 0:55
external fault. but boiler running normal normal again synchronized.
Turbine tripped at low pressure & temp. due to both VDCP
2 11/5/2017 4:10 Clear the jam and reset parameter and again taken boiler in line.
jammed and suddenly temp.dropped
Clear all clinkers and check and replaced damaged nozzle and inspect
3 Due to clinker formation 12/5/2017 61:10:00
all other part of boiler .
Due to under voltage jerk during islanding (11.35 kv to 9.94kv) all
4 17/05/2017 0:55 Reset all HT drives and again maintain drum level and reset turbine.
HT drives tripped and drum level at low level.

Due to bed ash cooler cooling water tube leakage furnace draft Isolate bed ash cooler cooling water leakage line and Maintain
5 12/6/2017 4:05
High -high normal draft and taken boiler in line after 2 hr.

Due to PRDS pressure increase turbine exhaust pressure Again maintain vacuum and reset turbine after that plant normal and
6 13/12/2017 12:15
dropped and turbine tripped at low vacuum. synchronized after 35 mins.

Boiler force stop due to LSB-2 tripped at overload but LSB-1 at

manual due to PM work. PA & SA fan tripped. Turbine running Reset PA,SA,ID and maintain normal parameter after that turbine
7 4/1/2018 2:20
at home load for 35 mins but drive(PA,SA,ID) are not start in this rolling at 16:45 hrs
time so that force stopped turbine at (53 kg/cm2 and 423ºc)

Temp. Scanner of TSP was Isolate. Not reset of Turbine due to

Temp. Scanner of Turbine Supervisory Panel was Hanging. So, Command Master Relay trip (86 A & 86 C) Temp. Scanner of TSP was
8 4/3/2018 7:05
Suddenly Tripped Turbine & Generator at 11:05 pm. Isolate, Start ID Fan 1 & 2 , Loop Seal Blower -1 , SA Fan – 1 & 2 & PA
Fan 1 &2 at 5:20 am. Turbine synchronized at 6:10 AM.

Boiler tripped at 12:29 pm due to ID fan hydraulic coupling oil
9 temp switch act HH,and Turbine was manually tripped at Low
temp and pressure (66 kg/cm2) at 13:16 hrs.
Immediate take standby ACW-1 in line. and give permit for check first
one. Normal ID fan,PA fan and start.PA fan start after some time due
20/03/2018 2:05
to thermal overload. All parameter normal and again synchronize
turbine at 15:20 hrs.

Thermax Power O&M 16

 Major shut down works

Sr.
Work Description Month Benefits
No

1.Reduced coal jamming problem in

1. 4 nos. Air blaster erected to coal bunker Aug-17 rainy season.
2.Reduced man hours.
1.Max. Nozzles are eroded and
All 700 Nos furnace wind box nozzles
2. Dec-17 damaged
replaced.
2.Draft fluctuation reduced.
1.For better bed material circulation.
Damaged Cyclone vortex finder replaced
3. Dec-17 2. Full load maintain after that.
by new.
3.ID fan maximum rating reduced.

Turbine Minor overhauling, bearing 1.Reduced vibration.

4. Dec-17
inspection done. 2.Reduced axial displacement

Thermax Power O&M 17

 Site Kaizen and Improvements
Sr.
Job Description Before Remedies Benefits
No
1.Reduced APC up to 3.0 MW per day
1. VFD installed at BFP,SA fan & ACW More Auxiliary consumption 2.Reduced maintenance work.
3.Reduce equipment failure rate.
1.Coal jamming problem in rainy
1.Reduced tripping due to coal
season.
jamming problem in rainy season.
2. Air blaster erected at coal bunkers 2.more manpower engaged during
2.Reduced man hours engaged..
jam.
3.Plant tripped problem.
2 nos of mechanical isolation valve 1.Can not isolate when tube
1.During tube leakage line isolate
3. erected at I/L of both Bed ash puncher during running plant.
without plant tripping or stop.
cooling line. 2.Plant tripped or emergency stop.
1.DCS operator every time
Logic modification for lime stone concentrate on Sox Level every 1.Automatically start/ stop feeding
4. RAV to feed lime automatically time. according to SOX range(
acc. to Sox value. 2.Time consuming and not maintain 2.SOX maintain in limit.
sox acc. To environment norms
1.Distributing Air Compressor load
1. Breaker tripped due to overload.
to both incomers ACB.
Both incomer ACB take in line for 2. All compressor working though
5. 2. Both ACB are healthy and normal
all air compressor. only one breaker.
load distribution.

Thermax Power O&M 18

 MAN POWER DETAILS

TL MAN DAY/MONTH
CONTRACTOR SKILLED MAN DAY/MONTH
900 CONTRACTOR UNSKILLED MAN DAY/MONTH 1200

800
1000
700

600 800

500
600
400

300 400

200
200
755.00

780.00

705.00

769.00

793.00

725.50

731.00

614.00

765.00

801.50

799.00

802.00
100

753
0 0

Thermax Power O&M 19

 Thank You

Thermax Power O&M 20