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Thermal Power Plant Performance

Improvement using Quality Initiatives

NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

Outline
NTPC Ltd.'s overview
Vindhyachal Super Thermal Power Plants Overview
Six Sigma
Why is six sigma needed for Indian Power Sector
Boiler Performance Optimization using Six Sigma
Reduction in Auxilliary Power Consumption using six sigma.

NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

A HUMBLE
BEGINING
Foundation Stone Laying
12.11.82

The first signboard comes up


5.08.82
NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

GENERATION (BUs)

Powering Peoples Progress (Generation)

20000
19500
19000
18500
18000
17500
17000
16500
16000

19707.7
18305
17820.8
16354
FY 03-04

FY 04-05

FY 05-06

NTPC Ltd : Powering Indias Growth

FY 06-07

Thermal Power Plant Performance


Improvement using Quality Initiatives

Continuous Improvement in Process & Efficiency (PLF %)

PLF (%)

100

95

92.46

92.73

FY 05-06

FY 06-07

90.01
90

85

82.38

80
FY 03-04

FY 04-05

PLF
NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

PLANT PERFORMANCE IMPROVEMENT USING QUALITY INITIATIVES

Improvement in Performance Parameters

Improvement in business processes (systems)

Cost Optimization

MUDA (Waste) Reduction

Development of World-class spare parts & service providers

NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

WHAT IS THIS SIX SIGMA ?


Disciplined & structured data
driven problem solving
approach.

A Philosophy

All about reducing deviations


(mistakes) in all that we do.

A Business Strategy

Good quality reduces cost

NTPC Ltd : Powering Indias Growth

Heat
Rate

Boiler/
Turbine

Key Functional
Requirements

Key Generation
Processes

Key Component
Characteristics

NTPC Ltd : Powering Indias Growth

RAH Performance
Optimization

Boiler Performance
Optimization

Cost Effective Generation depends


broadly on :RAH Seals/
Pent House/
House
Basket
ESP
Eff./ Seals
of
1) Optimizing
Heat
Rate
House
Quality
House
of
2) Reducing
Auxilliary
of
QualityPower Consumption
House
#1
Quality
of
#2
Quality
3) Reducing operation & maintenance (O&M) costs
.
#3
#4
Unit Heat Rate
Optimization

Cost Effective
Generation

Thermal Power Plant Performance


Improvement using Quality Initiatives

Key Process
Variables

Thermal
PowerAward
Plant Performance
Team Vindhyachal receiving National
Quality
from H.E.
Improvement
using
President of India for PIP on CW
duct painting
in Quality
stage I Initiatives
units

Sweet fruits
Six Sigma
Methodology

Process
limitations

Bulk of fruits
Problem of erosion in radiant super heater placed
Process characterization
in water wall soot blower area of stage I, 6 x 210
MW units.
and optimization including PDCA
Low hanging fruits
Simple QC tools
Logic and intuition
Quick hits-Kaizen
Brainstorming etc

Problem of vibration in the cooling fan NDE


bearing of ID fans in stage I.
Problem of damage of rapping motor shaft in ESP
of Stage I.
Problem of ingress of dust in the PA fan bearing of
stage I.
Platform on safety v/v floor is in unsafe condition
NTPC Ltd
Powering
in :stage
I. (5S) Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

3%
Stack
Clean-up
Equipment

5%
Auxiliary
Power

10%
Stack
Losses

37%
Electricity
Production

NTPC Ltd : Powering Indias Growth

45%
Rejected Heat to
Cooling
Water/ Cooling
Tower

Thermal Power Plant Performance


Improvement using Quality Initiatives
PAPH B
PAPH
O/L TEMP
145 0C

FLUE GAS FLOW DIAGRAM

F
U
R
N
A
C
E

L
H
S

R
H
S

D
P
I
L
V
A
I
S 960 T
E
I
O 964 N
N
S
A
H
L

H
O
E
R
R
C
E
I
O
H
Z 549 N.
846 E 750
O
1
A
944
810 N 606 &
T
T
2
E
A
R
L
S
H

E
C
O
N
O 365
M
I
379
S
E
R
3

NTPC Ltd : Powering Indias Growth

SAPH B
O/L TEMP
145 0C

SAPH B
SAPH B
O/L TEMP
160 0C

SAPH A
O/L TEMP
164 0C

SAPH A

PAPH A

Thermal Power Plant Performance


Improvement using Quality Initiatives

Problems Faced
More convective flow less retention of heat in 1st pass.
Less heat absorption in 1st pass due to Slagging.
Less heat absorption in super heater and re heater area
due to dirtiness in the area ,clinkering formation in radiant
zone.
Improper secondary damper position.
Poor performance of air preheater and its air ingress.

NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

2nd pass
111

119

113

121

A- S/H Right R/H Left


B- S/H R/H Right And 2nd Pass

123
115

LRSB ARE DIVIDED INTO

125

127

C-2nd Pass Only

117

129

D- S/H Right And R/H Left

109
133

131

137

135

107
105
BOILER RHS LRSB

LRSBs : Long Range Retractable Soot Blowers


NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

Box plot showing the best results for the LRSB A


Individual Value Plot of C15 vs C14

Boxplot of C15 by C14

580

580

570

570
C15

590

C15

590

560

560

550

550

540

540
A

C14

C
C14

NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

111

119

113

121

115

123

12
5

117

127

Boiler RHS Red


Coloured LRSBs were
selected based on
results of Analysis of
Variance (ANOVA)

12
9

109
133

131

137

135

107
105

BOILER RHS LRSB

LRSBs : Long Range Retractable Soot Blowers

NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

128

12
6

120

112

122

114

Red Coloured
LRSBS are
in Reheater Area

116
124
118

130
132
136

134
138

108

110

106

BOILER LHS LRSB

LRSBs : Long Range Retractable Soot Blowers


NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

Box and Individual plot


Individual
Individual V
aluePlotof SAPHAValue
O/LBEF, SAPlot
PHAO/LAFT

170

170

165

165

160

160
Data

Data

Boxplot of SAPBox
HAO/LBPlot
EF, SAPHAO/LAFT

155

155

150

150

145

145

140

140

SAPHAO/LBEF

SAPHAO/LAFT

SAPHAO/LBEF

NTPC Ltd : Powering Indias Growth

SAPHAO/LAFT

Thermal Power Plant Performance


Improvement using Quality Initiatives

NTPC Ltd : Powering Indias Growth

Auxilliary
Power
Reduction

Unit Heat Rate


Optimization

Boiler/
Turbine

Key Functional
Requirements

Key Generation
Processes

Key Component
Characteristics

NTPC Ltd : Powering Indias Growth

PA Fan Performance
Optimization

FD/ PA/ ID
House
Cost
Effective Generation depends
broadly on :-TIGs/ Hot
Fans/Mills
of
Air Lkg/
House
Quality
Impeller
1)
Optimizing Heat of
Rate
House
Quality
House
of
#1
2) Reducing Auxilliary Power Consumption
of
Quality
#2
Quality
#
3
3) Reducing operation & maintenance (O&M) costs.
#4
Boiler Performance
Optimization

Cost Effective
Generation

Thermal Power Plant Performance


Improvement using Quality Initiatives

Key Process
Variables

Thermal Power Plant Performance


Improvement using Quality Initiatives

Project CTQs

Process
Processdrill
drilldown
down

Big
BigYY

Auxiliary
AuxiliaryPower
PowerConsumption
Consumption
reduction
reduction

Project
ProjectYY11

BFP
BFPpower
powerconsumption
consumption

Project
ProjectYY22

ID
IDFan
Fanpower
powerconsumption
consumption

Project
ProjectYY33

PA
PAFan
Fanpower
powerconsumption
consumption

Project
ProjectYY44

FD
FDFan
Fan power
powerconsumption
consumption

Project
ProjectYY55

Mill
Millpower
powerconsumption
consumption

Project
ProjectYY66

CW
CWPump
Pumppower
powerconsumption
consumption

Project
ProjectYY77

CEP
CEPpower
powerconsumption
consumption

NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

High Level Process Map

Supplier

Input

Process

Output

Customer

PA fans

Bowl Mills

Stack out

Key Questions
What is included/excluded in the
scope of this project?
Includes:
Unit
Unit HT
HT System
System

FD fans

ID Fans

ESP

Boiler

Excludes:

LT
LT System
System &
& Offsite
Offsite Load
Load

What is the Unit, Opportunity,


Defect?

Flue gas path

HT
HT Amp
Amp >> 1800
1800 amps
amps would
would be
be defect.
defect.

Has this process map been


validated by key people?

Steam-water cycle

CEP

Heaters

BFP

Heaters

Condenser

Turbine

Super
heater

Boiler

CW Pump

Generator

Cooling water
out

GT

GRID

NTPC Ltd : Powering Indias Growth

Process
Process map
map validated
validated by
by Champion
Champion &
&
Process
Process owners
owners

High level process


map done

Thermal Power Plant Performance


Improvement using Quality Initiatives

Identify Sources of Variation


Pareto Chart For APC
2000
100
80
60

1000

40
500
20
0
Equipments
Count
Percent
Cum %

BFP
654.3
36.4
36.4

CW
331.6
18.4
54.8

ID Fan
287.3
16.0
70.8

PA Fan FD Fan
183.7
174.3
10.2
9.7
81.0
90.6

Mill
127.7
7.1
97.7

NTPC Ltd : Powering Indias Growth

Other
40.6
2.3
100.0

Percent

APC Share

1500

Thermal Power Plant Performance


Improvement using Quality Initiatives

Identify Major Sources of Variation

3
3
NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

Potential Failure Modes Effect Analysis - BFP


When?
Process
Step

What?
Potential Failure

Result?
Potential
Effects

Why?
Potential Cause

Existing
Controls

Sev

Occ

Det

RPN

How Prevent?
Mitigants

Who?
Responsibility

BFP

Passing from 5F1,5F2 &


C/V

High
amp

Worn out seat


& others

To be attd.
in O/H

10

300

1) L/S Adjust. on closing


2) Manual Tight., if possible

TMD+Opn*

BFP

Reduced Motor Efficiency

High
amp

Continuous
Service

Motor O/H

40

To be attd.in O/H

EMD

BFP

Passing from R/C V/V


& D/V NRV not holding

High
amp

Worn out seat


& others

To be
attd.in O/H

10

300

1) L/S Adjust. on closing


2) Manual Tight., if possible

TMD+Opn*

BFP

Passing from 421 V/V


(Manual+Motorised)

High
amp

Worn out seat


& others

To be
attd.in O/H

280

1) L/S Adjust. on closing


2) Manual Tight., if possible

TMD+Opn*

BFP

Passing from 605,607 &


C/V V/V

High
amp

Worn out seat


& others

To be
attd.in O/H

120

1) L/S Adjust. on closing


2) Manual Tight., if possible

TMD+Opn*

BFP

Passing / Opening from


514 A & B V/Vs

High
amp

Worn out seat


&/or Passing
from 5A1,5A2,
140/6 C/V

TMD+Opn*

To be
attd.in O/H

250

1) L/S Adjust. on closing


2) Manual Tight., if possible

Passing from 29/14


Spray V/Vs

High
amp

Worn out seat


& others

To be
attd.in O/H

TMD+Opn*

90

1) L/S Adjust. on closing


2) Manual Tight., if possible

Passing from 3rd stage


V/V
(S/B BFP)

High
amp

Worn out seat


& others of S/B
BFP

To be
attd.in O/H

TMD+Opn*

90

1) L/S Adjust. on closing


2) Manual Tight., if possible
3) Change the BFP conbin.

BFP

Low Pump
Efficiency

High
amp

Worn out
cartridge

Pump O/H

10

250

1) Combination Change
(AC / BC)
2) To be attd.in O/H

TMD

BFP

Higher DP across FRS

High
amp

Slightly higher

Regularly

10

250

Experiment regularly to
optimize DP

Operation
+
C&I*+TMD

BFP

BFP

10

NTPC
Ltd : Powering Indias Growth
flow require.

Thermal Power Plant Performance


Improvement using Quality Initiatives

Decide Focus Area ?


Priority / Focus

High

BFP
Impact on conversion

ID Fan

Low

PA Fan
FD Fan
Mill

Difficult

Ease of implementation

NTPC Ltd : Powering Indias Growth

Easy

Thermal Power Plant Performance


Improvement using Quality Initiatives

Control Summary
Control/Response
Control/ResponsePlan
PlanHighlights
Highlights
When HT equip. amp goes up steeply,
all associated V/Vs being checked.
PA Fans being regularly checked for hot
air leakage.
Boiler & ESP man/peep holes being
checked regularly for any passing.
Future control plan prepared for arresting
APC further.

Benefits
Benefitsof
ofProject
Project
Direct Saving.
Conservation of Coal.
Lesser Environmental Pollution.
Better CSR Practices & other intangible
benefits.
Communication
Communication&&Translation
Translation
Informed to operational staff.
Communicate project results with
operating staff and process owner.
Communicate results to HOD

NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

After

Before

Control Charts of APC Before & After Project

NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

FMEA Analysis for Current Window of Opportunity


When?
Process
Step

What?
Potential Failure

Result?
Potential
Effects

Why?
Potential Cause

Existing
Controls

Sev

Occ

Det

RPN

How Prevent?
Mitigants

Who?

Sev

Occ

Det

New
RPN

Responsibility

Passing from
5F1,5F2 & C/V

High
amp

Worn out
seat & others

To be
attd.in O/H

10

300

1) Change V/Vs
2) L/S Adjust. on
closing

TMD
+Opn*

10

300

BFP

Passing from
607 &C/V

High
amp

Worn out seat


& others

To be
attd.in O/H

120

1) L/S Adjust. on closing


2) Manual Tightening

TMD+O
pn*

90

BFP

D/V NRV +3rd


stage spray
v/vs not
holding

High
amp

Worn out
seat & others

To be
attd.in O/H

10

300

1) L/S Adjust. on
closing
2) Manual Tightening

TMD+O
pn*

10

300

BFP

Higher DP
across FRS

High
amp

Slightly
higher flow
require.

Regularly

10

250

Experiment regularly
to optimize DP

Opn,C&I
TMD

10

250

PA
Fan

TIGs in Open/
Struck up
Condition

High
Curre
nt

Improper
Practices by
Mill area lab.

As and
when
needed

Mill labours to be discouraged


from keeping it in open condi.
& Struck up condition to be att
on pri & Mois. draining

Opn.
2

10

100

PA
Fan

Hot Air
Leakage

High
Curre
nt

Aging/ Imp.
Maint./
Expansions

During
Opportunity

200

To be attended at first
opportunity.

BMD
R/P

10

150

Mill

Improper
Rollers Setting

Higher
Amps

Maintenance
Fault/Foreign
Material

Roller
Setting

1) By effectively screening
foreign material

BMD Mill
CHP

135

BFP

ID
Fan

Various
Leakages

Higher
Amps

Mech
Damage/Expansio
n/ Maintenance
Prac

During
Opportunity
or in O/H

ID
Fan

Peepholes/
Manholes
Passing

Higher
Amps

Mech
Damage/Expa
nsion

10

10

150

135

10

250

2) During Opportunity
1) Regular Checking
2) To be attd.in O/H
3) During Opportunity

BMD
R/P+P/P

10

150

Regular

1) Regular Checking

BMD+
Opn.

10

150

in O/H

3) During Opportunity

Checking/
NTPCOpportunity
Ltd
:orPowering
s2) Growth
To be attd.in O/H
4
10
5 India
200

Thermal Power Plant Performance


Improvement using Quality Initiatives

Bottom-line is..

NTPC Ltd : Powering Indias Growth

Thermal Power Plant Performance


Improvement using Quality Initiatives

NTPC Ltd : Powering Indias Growth

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