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Constraints For Achieving Full Load

The document outlines constraints and liabilities across multiple units that limit achieving full load operation. Key issues include: 1) Limitations across units 1-7 in ESP performance, ID fan capacity, turbine vibrations, mill operations, condenser vacuum pressure and cooling tower effectiveness that restrict increasing load. 2) Offsite issues like unavailable pumps and fans, leaking lines and poor vacuum across shared systems like the cooling towers for units 1, 2 and 7 further constrain operations. 3) Individual units have unique constraints such as high motor currents, failed protections, refractory damage and component failures that restrict their maximum loads.

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Eswar Kalyan
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44 views

Constraints For Achieving Full Load

The document outlines constraints and liabilities across multiple units that limit achieving full load operation. Key issues include: 1) Limitations across units 1-7 in ESP performance, ID fan capacity, turbine vibrations, mill operations, condenser vacuum pressure and cooling tower effectiveness that restrict increasing load. 2) Offsite issues like unavailable pumps and fans, leaking lines and poor vacuum across shared systems like the cooling towers for units 1, 2 and 7 further constrain operations. 3) Individual units have unique constraints such as high motor currents, failed protections, refractory damage and component failures that restrict their maximum loads.

Uploaded by

Eswar Kalyan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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No Margin - Unitwise Liabilities / Constraints for achieving

Full Load

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Unit-1

1. Full load not coming with 4 ESP passes in service.

2. Mill E taking high current 34A at coal flow 27TPH, Full load in 4 mill
operation is a problem.

3. MOT cooler-A water side passing, cooler choke.

_____________________________________________________________

ST-I OFFSITE

1. IAC C,D & E and PAC A Not available.

2. Only 5 CT pumps can be run, Cooling Tower overflowing with 6 CT pumps


in service.

_____________________________________________________________

Unit-2

1. Full load not coming with 4 ESP passes in service.

2. No margin in ID Fan due to air ingress in ESP, Flue gas ducts & Furnace.
Air Flow cannot be increased beyond 620 T/hr.

3. O2 Tx RHS deviation high limiting fuel feeding margin (O2 > 2.5% to be
maintained).

4. HRH temp L & R deviation high (7-10 deg C). HRH L maintaining Lower
than HRH R.

5. DFA

a. Y Stream Hoppers ash accumulation is higher

b. Y Stream ME suction gets frequently choked.


c. Z2 Air washer line leakage on frequent basis.

_____________________________________________________________

Unit-3

1. ID Fan-3B IGV not loading beyond 108A (Overload at 118A) thereby


limitation in increasing air flow.

2. Full load not achieving with 04 ESP passes (after commissioning of ESP
pass-E).

3. Turbine shaft Vibration 1X and 2X maintaining in alarm range.

_________________________________________________________________

ST-2 OFFSITE

1. CT-6B fans-3,5,7,9,11 are out due to odd side header problem.

2. CT-4A fans-5,6,7,8,9 R & M work in progress.

3. TWS-2,4 & 6 getting frequently out.

4. BATP-4B & 6B frequently getting choked when taken in service for


bottom ash operation.

5. IAC-2 & PAC-4 LP O/L air temperature maintaining high.(>160 c)

6. ST-2 DFA line vacuum very poor while running in dry mode.

7. TAC-B abnormal sound

__________________________________________________________________

UNIT-4

1. ID fans current running very high.(>390 Amp)

2. TDBFP-4B mechanical overspeed trip protection not working.

3. TDBFP-4B LOT moisture content always remain high due to sludge


formation taking place.
4. ESP performance poor due to high flue gas o/l temperature at APH
outlet.

5. BAHs refractory badly damaged due to which hopper getting choked


many times.

6. Both TDBFP efficiency poor and RPM high.

7. Poor condenser vacuum due to CT performance.

8. Control fluid oil continuous foaming taking place and FRF tank level
showing erratic in UCB.

9. FRF tank both heaters coil burnt.

10. Many high energy drain valves to FT-5 & 6 passing.

11. Condensate DO running high.

12. Turbine trip oil pressure maintaining low.(6.2 ksc)

__________________________________________________________

Unit-5

1. Both C.G efficiency poor.

2. Mill A and H fineness poor and developing clinker when raising load.

3. Mill J not avl. From long time. Under permit for GRS/BRS.

4. Mill F having abnormal sound.

5. I.D fans getting overloaded with coal flow above 380 TPH for maintaining

design O2 .

__________________________________________________________

Unit-6
1. Less margin available with combination of ID fan A & B as compared to
ID-A & C

2. ID fan A & B motor winding temperature maintaining high around 130


degree C @ 379 Amp.

3. Poor condenser vacuum as CW inlet temp maintaining high (33 degree C)


from design value of 27 degree.

4. At higher load & Due to poor vacuum, BFP got over speed to maintain
drum level hence to avoid over speeding load reduced.

5. RH metal temperature excursion occurring frequently whenever


continuous mill or upper mill or seven mills are taken in service.

__________________________________________________________________

UNIT-7

1. Turbine valve wide open capacity is 517MW only during PG test.


2. HPCV-1,2 not opening more than-75%/85%,due to this full load cannot
be achieved.
3. Frequent pressurization happens at full load with higher throttle
pressure as CMC tuning is not proper.
4. IN CMC mode throttle pressure not getting maintained.
5. During summertime when vacuum was poor we need to put throttle pr
setpoint more than design value to achieve full load and HPCV gets fully
opened and if cmc responds poorly to coal quality changes
uncontrollable pressure rise in drum happens which is not
desirable,even if the pressure rise is within the permissible drum
pressure limits,The BFP cannot cater to that high pressure and drum
level cannot be maintained by BFPS will cause unit to trip.
6. During summertime Mill labyrinth seal leakage are restricting mill
capacity by brg temp increasing and requiring us to take extra mill,which
is causing an increase in APC.
7. Both CT effectiveness poor, EPRI recommendations / findings are as
follows
● channeling of water rather than droplets.
● damaged nozzles are the main culprit.
● biofouling in cold water basin found.
● splash trays installation poor alignment.
● residual chlorine is not being present in the water.
● CT sludge pumps are not available.

__________________________________________________________________

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