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

2. 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)

3. 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

4. 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

5. 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

6. 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

7. 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.

8. 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 – Kcal/Kg.
Furnace Oil – Calorific Value Kcal/Kg.
CAPTIVE POWER PLANT -I

9. 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 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.

10. 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.

11. CAPTIVE POWER PLANT -I HP Boiler # 1, 2, 3 & 4
Commissioned in the year 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 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 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 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 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.

12. Turbo-Blowers D – Delivery M - Manifold M BF # 1 BF # 4 M D D M D M D5 6 4 3 2 1

13. Turbo-Blowers CAPACITY TB# 1 TB# 2 TB# 3 TB# 4 TB# 5 SUCTION VOLUME
Nm3 / Hr.
133000
Nm3 / Hr.
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

14. 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

15. 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

16. 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

17. 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

18. 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
KG/SQ CM ( ABS)
DISCHARGE VOLUME
DISCHARGE PRESSURE
N CU. MTR /HR ( GUARANTEED)
N CU MTR / HR ( MAX)
4.5 KG/SQ CM TO 6.21 KG/SQ CM (ABS)

19. 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 .

20. 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

21. 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 .

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

23. 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

24. 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

25. 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

26. Thank You