Академический Документы
Профессиональный Документы
Культура Документы
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.
A HUMBLE
BEGINING
Foundation Stone Laying
12.11.82
GENERATION (BUs)
20000
19500
19000
18500
18000
17500
17000
16500
16000
19707.7
18305
17820.8
16354
FY 03-04
FY 04-05
FY 05-06
FY 06-07
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
Cost Optimization
A Philosophy
A Business Strategy
Heat
Rate
Boiler/
Turbine
Key Functional
Requirements
Key Generation
Processes
Key Component
Characteristics
RAH Performance
Optimization
Boiler Performance
Optimization
Cost Effective
Generation
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
3%
Stack
Clean-up
Equipment
5%
Auxiliary
Power
10%
Stack
Losses
37%
Electricity
Production
45%
Rejected Heat to
Cooling
Water/ Cooling
Tower
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
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
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.
2nd pass
111
119
113
121
123
115
125
127
117
129
109
133
131
137
135
107
105
BOILER RHS LRSB
580
580
570
570
C15
590
C15
590
560
560
550
550
540
540
A
C14
C
C14
111
119
113
121
115
123
12
5
117
127
12
9
109
133
131
137
135
107
105
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
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
SAPHAO/LAFT
Auxilliary
Power
Reduction
Boiler/
Turbine
Key Functional
Requirements
Key Generation
Processes
Key Component
Characteristics
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
Key Process
Variables
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
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
HT
HT Amp
Amp >> 1800
1800 amps
amps would
would be
be defect.
defect.
Steam-water cycle
CEP
Heaters
BFP
Heaters
Condenser
Turbine
Super
heater
Boiler
CW Pump
Generator
Cooling water
out
GT
GRID
Process
Process map
map validated
validated by
by Champion
Champion &
&
Process
Process owners
owners
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
Other
40.6
2.3
100.0
Percent
APC Share
1500
3
3
NTPC Ltd : Powering Indias Growth
What?
Potential Failure
Result?
Potential
Effects
Why?
Potential Cause
Existing
Controls
Sev
Occ
Det
RPN
How Prevent?
Mitigants
Who?
Responsibility
BFP
High
amp
To be attd.
in O/H
10
300
TMD+Opn*
BFP
High
amp
Continuous
Service
Motor O/H
40
To be attd.in O/H
EMD
BFP
High
amp
To be
attd.in O/H
10
300
TMD+Opn*
BFP
High
amp
To be
attd.in O/H
280
TMD+Opn*
BFP
High
amp
To be
attd.in O/H
120
TMD+Opn*
BFP
High
amp
TMD+Opn*
To be
attd.in O/H
250
High
amp
To be
attd.in O/H
TMD+Opn*
90
High
amp
To be
attd.in O/H
TMD+Opn*
90
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
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.
High
BFP
Impact on conversion
ID Fan
Low
PA Fan
FD Fan
Mill
Difficult
Ease of implementation
Easy
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
After
Before
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
To be
attd.in O/H
120
TMD+O
pn*
90
BFP
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
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
Bottom-line is..