O & M Challenges in Power & Blowing Stations

1. 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)

4. TOTAL SAIL LOAD [MW] (including VISP, SSP & CFP)1206

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 – 4000 Kcal/Kg. • Furnace Oil – Calorific Value - 9800 Kcal/Kg.

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 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.

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 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.

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

13. Turbo-Blowers

15. 100 TPH BLR # 1 MAIN STEAM BUS #! 1 FROM FEED LINE HEADER POWER AND BLOWING STATION (NEW) BLR # 2 FROM FEED LINE HEADER SCHEMATIC DIAGRAM OF BOILER AND MAIN STEAM 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

18. POWER AND BLOWING STATION (NEW) BLOWER DETAILS :

19. POWER AND BLOWING STATION (NEW) STG DETAILS :

20. POWER AND BLOWING STATION (NEW) TRTG DETAILS :

21. POWER AND BLOWING STATION (NEW) BPTG DETAILS :

22. Challenges in O & M

23. Challenges in O & M

24. Challenges in O & M

25. Challenges in O & M

26. Thank You