Power & Blowing Stations O & M Challenges in Power & Blowing Stations

Power & Blowing Stations of SAIL Main Objectives:- Supply uninterrupted cold blast to all the blast furnaces, as per their requirement . Supply process steam at require temperature and pressure. Generate power to cater to category-I loads of Rourkela Steel Plant Maximize MVAR generation for improving drawl power factor. To maximize utilization of the waste gases (BF Gas & CO gas) arising out of the steel making process. To maximize power generation opportunity from other avenues available in the steel making process. (TRTG & BPTG)

INSTALLED CAPTIVE CAPACITY POWER STEAM GENERATORS CAPACITY (MW) BOILERS CAPACITY (Tons/hr) AVG.(DAY) Steam Usage   Process (%) Power (%) OWN BSP PP-I TG-0,1&2:12MW,TG-3:15MW 51 Blr 1- 6:150 T/hr 900 400 66 34 DSP OPP TA-1,2,3&4 :5 MW 20 Blr 1- 7: 68 T/hr 476 221 75 25 RSP CPP-I TA-2,3,4,6 :25 MW 100 Blr1,2 :90T; 3,4:112T/hr; 5,6:150T/hr 704 198 33 67 ISP Power House NIL - Blr 9,10 & 11: 54T/hr; A,B: 90T/hr 288 36 --- ISP New P&BS STG 1,2 &3:18 MW, TRTG:14,BPTG:8.2 76 Blr-1,2,3:200 T/hr 600 278 49 RSP New P&BS STG 1,2 : 18MW, TRTG:14MW, BPTG:6.5MW 56.5 Blr-1,2 &3:100 T/hr 300 195 BSP New P&BS STG-25MW,TRTG-14MW, BPTG-4MW 43 Blr-1,2&3:150T/hr 450 CFP U-1: 4.2 MW 4.2

TOTAL SAIL LOAD [MW] (including VISP, SSP & CFP) 1206 INSTALLED CAPTIVE CAPACITY POWER STEAM GENERATORS CAPACITY (MW) BOILERS CAPACITY (Tons/hr) AVG.(DAY) Steam Usage   Process (%) Power (%) JV NSPCL BSP PP-2 TG-1,2: 30MW, TG-3 :14 MW 74 Blr 1, 2, 3: 150 T/hr 450 312 32 68 NSPCL BSP PP-3 * U-1,U-2 : 250 MW 500 Blr-1,2 :780 T/hr 1560 1494 100 NSPCL DSP CPP U-1,U-2: 60 MW 120 Blr 1,2 : 260 T/hr 520 498 NSPCL RSP CPP-2 U-1,U-2 :60 MW Blr 1,2 : 280 T/hr 560 533 BPSCL Bokaro (TPP,CPP & Blr-9) TG-1 :12MW, TG-2,3 : 55MW, TG-6,7,8 : 60MW; TG-9:36MW 338 Blr1-5:220T/hr,Blr 6-8: 260T/hr; Blr9:300T/hr 2180 1261 52 48 OWN 350.7 3268 1328 1152 5270 4098 TOTAL 1503 8538 5426 * TOTAL SAIL LOAD [MW] (including VISP, SSP & CFP) 1206

Power sourced by all SAIL plants during the year   Captive-OWN Captive-JV Grid Import JV Wheeling Power Exchange MW 116 617 424 27 23 % 9.6 51.1 35.2 2.3 1.9

CONTRACT DEMAND with GRID DSP BSL ISP BSP RSP VISP SSP CFP SAIL TOTAL MVA 100 220 8 152 200 150 27 84 43.0 984 Supply Voltage level 220KV 33KV 110KV 230KV   SUPPLY UTILITY DVC CSPDCL WESCO MESCOM TANGEDCO MSEDCL

CAPTIVE POWER PLANT -I The plant and equipment's High Pressure Boilers – 1 to 6. Turbo Blowers – 1 to 5 Turbo Alternator – 2,3,4 & 6 Medium Pressure Boilers– 1,2 & 3 Coal Handling Plant – Old (150 Tons/Hr. and New. Water treatment Plant – 1 & 2 Cooling Water pump House and cooling Towers. Ash Slurry Pump house and Ash handling system. Electrical Distribution system at 33 KV, 6.6 KV & 415V.

CAPTIVE POWER PLANT -I Fuels Used Coal – Boilers are designed for coal CV of 5600 Kcal/Kg. Present availability of coal CV varies from 1500 – 3500 Kcal/Kg. with Ash content maximum up to 46%. Presently coal is supplied from Mahanadi Coal Fields and Eastern Coal Fields. (This variation in coal CV affected the performance of CPP-I to a great extent. Blast Furnace Gas – calorific Value – 900 Kcal/Kg. Mixed gas – Calorific Value – 4000 Kcal/Kg. Furnace Oil – Calorific Value - 9800 Kcal/Kg. CAPTIVE POWER PLANT -I

CAPTIVE POWER PLANT -I Maximum consumption of BF gas in Boilers HP Boiler # 3 & 4 – 8X11000 Nm3 ( each Boiler have 8 burners) HP Boiler # 5 & 6 – 5 X 22000 Nm3 ( each Boiler have 5 burners) Maximum consumption of CO gas in HP Boiler # 1 & 2 – 1X2000 Nm3 ( each Boiler have 1 burners) HP Boiler # 3 & 4 – 4X3000 Nm3 ( each Boiler have 4 burners) HP Boiler # 5 & 6 – 2X1000 Nm3 ( each Boiler have 2 burners) MP Boiler # 1 & 2 – 2000 Nm3 ( each Boiler have 4 burners) MP Boiler # 3 – 4X2000 Nm3 ( each Boiler have 4 burners) Coal consumption rate of each feeder of HP Boiler # 1 & 2 is 2 T/hr. (12 nos of Coal Feeders in each Boilers).Average consumption of coal in AFBC boilers is 18 T/hr/ Boiler. Coal consumption rate of each Coal Mill of HP Boiler # 5 & 6 is 8 T/hr. ( 3nos of Coal Mills in each Boiler). Average consumption of coal in PF boilers is 20 Tons / Hr / Boiler.

CAPTIVE POWER PLANT -I Coal consumption rate of MP Boiler # 1 & 2 is 12 T/hr. Average consumption of coal in MP Boiler# 1 & 2 boilers is 8 T/hr/per Boiler. Coal consumption rate of MP Boiler # 3 is 12 T/hr. Average consumption of coal in MP Boiler# 3 is 10 T/hr/per Boiler. Average Steam Generation from HP Boiler 1 & 2 – 80 T/ Hr. Average Steam Generation from HP Boiler 3 & 4 – 90 T/Hr. Average Steam Generation from HP Boiler 5 & 6 – 95 T/Hr. Average Steam Generation from MP Boiler 1 & 2 – 35 T/ Hr/Boiler Average Steam Generation MP Boiler # 3 – 45T/Hr.

CAPTIVE POWER PLANT -I HP Boiler # 1, 2, 3 & 4 Commissioned in the year 1959-60.The technology was supplied by M/S BABCOCK with rated capacity of125 T/Hr. These were Grate firing , Multiple fuel ( Coal, BF gas, Mixed Gas, Furnace oil) boilers. HP Boiler # 1& 2 renovated in the year 1994-95 by M/S BHEL to AFBC boilers& Capacity rerated to 95 T/Hr.Coal Firing in HP Boiler # 3 & 4 was stopped. HP Boiler # 5 & 6 Commissioned in the year 65-66. During the expansion of CPP-I. The technology was supplied by M/S BABCOCK with rated capacity of 125 T/Hr. These are pulverized fuel firing( 3 no’s of Ball Mills) with multiple fuel ( Coal, BF gas, Mixed Gas, Furnace oil) firing facility. Steam Pressure and temperature of all the HP Boilers – 59 Kg/cm2, 485oC. MP Boiler # 1 & 2 Commissioned on 1978. Technology supplier –IJT. Technology adopted – Stoker Fired. Fuel – Coal ( Size minus 25 mm). Capacity – 60 T/Hr. Steam Pressure and temperature – 18 Kg/cm2, 350oC. MP Boiler # 3. Commissioned on 1998. Technology supplier –IJT. Technology adopted – CFBC ( Circulating Fluidized Bed Boiler).Fuel – Coal ( Size minus 6 mm). Capacity – 60 T/Hr. Steam Pressure and temperature – 18 Kg/cm2, 350oC.

Turbo-Blowers D – Delivery M - Manifold M BF # 1 BF # 4 M D D M D M D 5 6 4 3 2 1

Turbo-Blowers CAPACITY TB# 1 TB# 2 TB# 3 TB# 4 TB# 5 SUCTION VOLUME 163000 Nm3 / Hr. 133000 Nm3 / Hr. 165000 Nm3 / Hr. DISCHARGE PRESSURE 2.3 Kg/cm2 1.73 Kg/cm2 RPM 4055 3560 STEAM CONSUMPTION 48.75 T/Hr. 27.35 T/Hr. BHP 11.7 Mw 6.71 Mw

CLOCK WISE FROM GENERATOR REAR RATING TA-2 TA-3 TA-4 TA-6 MVA 31.2 MW 25 MVAR 17 VLOTAGE 6.6 KV CURRENT 2730 RPM 3000 POWER FACTOR 0.8 TYPE OF EXCITATION STATIC BRUSH LESS EXCITATION VOLTAGE 167 V 150 V EXCITATION CURRENT 340A 608A DIRECTION OF ROTATION CLOCK WISE FROM GENERATOR REAR GENERATOR TRANSFORMER TRANSFORMER 2 3 TRANSFORMER 31 TRANSFORMER 33 GOVERNING SYSTEM SR-4 SR-3 WOODWARD

POWER AND BLOWING STATION (NEW) SCHEMATIC DIAGRAM OF BOILER AND MAIN STEAM HEADER 100 TPH BLR # 1 FROM FEED LINE HEADER MAIN STEAM BUS #! 1 BLR # 2 FROM FEED LINE HEADER BLR # 3 FROM FEED LINE HEADER MAIN STEAM BUS # 2 FROM WHRB MIN 20 TPH MAX 50 TPH

POWER AND BLOWING STATION (NEW) SCHEMATIC OF MAIN STEAM BUS DISTRIBUTION SYSTEM STEAM TO T.B # 1 STEAM TO T.B # 2 MAIN STEAM HEADERS STEAM TO T.B # 3 STEAM TO STG # 1 STEAM TO STG # 2 STEAM TO 11 ATA PRDS STEAM TO 25 ATA PRDS

POWER AND BLOWING STATION (NEW) DETAILS OF TURBO BLOWER : TURBINE MAJOR PARAMETER DESCRIPTION TYPE NK 50 / 71 – 3 OF BHEL MAKE IMPULSE REACTION TURBINE 13 STAGES TURBINE SPEED SPEED RANGE TURBINE TRIP SPEED 4782 RPM . 3964 TO 5840 RPM 6104 RPM . INLET PRESSURE EXHAUST PRESSURE 60 KG / SQ CM ( A ) 0.09 KG / SQ CM ( A) TURBINE INLET TEMPERATURE 485 DEG CELCIUS

POWER AND BLOWING STATION (NEW) BLOWER DETAILS : MAJOR PARAMETER DESCRIPTION TYPE MAN , AXIAL FLOW WITH LAST STAGE RADIAL NO OF STAGES 17 + 1 SUCTION PRESSURE AT INLET 0 . 976 KG/SQ CM ( ABS) DISCHARGE VOLUME DISCHARGE PRESSURE 165000 N CU. MTR /HR ( GUARANTEED) 210000 N CU MTR / HR ( MAX) 4.5 KG/SQ CM TO 6.21 KG/SQ CM (ABS)

POWER AND BLOWING STATION (NEW) STG DETAILS : MAJOR PARAMETER DESCRIPTION MAKE SHIN NIPPON TYPE MULTI STAGE ( 14 ) , SINGLE FLOW EXTRACTION CUM CONDENSING TURBINE RATED POWER 18 MW STEAM PRESSURE AT INLET STEAM TEMPERATURE 58 ATA 485 DEG CELCIUS GENERATOR TDPS 18 MW, 11 KV, 1500 rpm, pf-0.8 BRUSHLESS EXCITATION EXTRACTION AT 11 ATA .

POWER AND BLOWING STATION (NEW) TRTG DETAILS : MAJOR PARAMETER DESCRIPTION MAKE MES TYPE MULTI STAGE ( 14 ) , SINGLE FLOW EXTRACTION CUM CONDENSING TURBINE RATED POWER 20 MW BLAST FURNACE GAS PRESSURE AT INLET GAS TEMPERATURE 58 ATA 485 DEG CELCIUS GENERATOR BHEL 22.5 MW, 11 KV, 3000 rpm, pf-0.8 BRUSHLESS EXCITATION PRESSURE DROP

POWER AND BLOWING STATION (NEW) BPTG DETAILS : MAJOR PARAMETER DESCRIPTION MAKE SHIN NIPPON TYPE MULTI STAGE ( 14 ) , SINGLE FLOW EXTRACTION CUM CONDENSING TURBINE RATED POWER 6.5 MW STEAM PRESSURE AT INLET STEAM TEMPERATURE 66 ATA 485 DEG CELCIUS GENERATOR TDPS 6.5 MW, 11 KV, 1500 rpm, pf-0.8 BRUSHLESS EXCITATION EXTRACTION AT 11 ATA .

Challenges in O & M Common Steam Bus System. Common auxiliaries. Aged equipment's in all old plants. Challenges in O & M

Challenges in O & M Fuel Control to Boilers are difficult. Fluctuations in BF gas Pressure, Volume & CV affects performance and reliability. Cascade operation of TA’s having different governing systems add to the complexities during isolation. Challenges in O & M

Too many equipment’s of different make & capacity add pressure to budget allocation. Leads to high inventory, complexities in maintenance planning. Availability of shutdown of equipment’s become difficult because of common equipment and the process requirements. The operation & maintenance is largely labour intensive due to large no of equipments of different type and make. Auxiliary consumption is very high. Challenges in O & M

Non availability of waste gas during BF shutdowns affect boiler performance. Frequent starting and stopping of machines reduces the life of machines. Partial loading of turbines also makes the operation uneconomical. Poor techno economical performance of old machines increases the cost of production. Because of the complex system, huge manpower requirements the generation cost is very high. Thus perceived to be uneconomical. Challenges in O & M

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