O M CHALLENGES IN RENOVATION JOB OF WAGON

O & M CHALLENGES IN RENOVATION JOB OF WAGON TIPPLER Presented by: P. K. Samantaray, Sr. Manager & M. Prasad, Manager Under the Guidance of: Sri R. Kumar, CEO Sri A. K. Singh, GM (Maintenance)

BPSCL – An Overview Ø Bokaro Power Supply Company (P) Ltd. is a Joint Venture Company of SAIL and DVC, each have 50% equity holding. Ø Objective of BPSCL is to supply process steam to Bokaro Steel Plant (SAIL) at 100 ata, 39 ata and 8 -12 ata: 500 -550 Tph and Power as per Annual target. Ø BPSCL also supplies Sodium Cationated water: 300 Tph Ø BPSCL has an aggregate installed capacity to generate 338 MW of Power and 2180 TPH of steam. Ø Manpower strength in BPSCL is 247 (Executive-173, Non. Executive-74) as on 01. 07. 2019

CAPACITY - Boiler TPP CPP UNIT #9 BOILER CAPACITY (T/Hr) VINTAGE Particulars 1 220 45 Years 2 220 45 Years 3 220 43 Years 4 220 39 Years Multi-fuel fired Boilers – Max. 75% generation by pulverized coal and rest by Blast Furnace & Coke Oven gas, supplied from BSL/SAIL. 5 220 37 Years TOTAL 1100 6 260 32 Years 7 260 29 Years 8 260 28 Years TOTAL 780 9 300 04 Years Make Karsyn Kotelshchik, Russia Tπ-156 Installed in the 1 st phase Installed in the 2 nd phase Rafaco, Poland OPG-260 Pulverized coal fired boiler Alstom, India Pulverized coal fired boilers PCSM 006071 TOTAL 2180

CAPACITY TURBINE TPP CPP UNIT #9 CAPACITY (MW) VINTAGE 1 12 (BPTG) 31. 12. 1974 2 55 13. 07. 1972 3 55 13. 10. 1973 TOTAL 122 6 60 25. 01. 1986 7 60 16. 09. 1988 8 60 31. 03. 1989 TOTAL 180 9 36(BPTG) TOTAL 338 02. 09. 2014 Particulars Make Back Pressure TG Kaluga Elektrosila, Russia P-12 -90 -37 Condensing type LMZ, Elektrosila, Russia K-50 -90 -4 Condensing type Zamech, Dolmel, Poland, 9 K-66 Back Pressure TG Skoda, Czech Rep. Brush, UK PCSM-006071

Challenges in the O&M of BPSCL Ø Profound dependence of TPP boilers on BF & CO gases from BSL/SAIL. Ø Incomplete Combustion due to inconsistent and inadequate supply of BF & CO gases. Ø Utilization of Fly ash. Ø The poor health of only Wagon Tippler. Ø Obsolete technology of TPP Boilers.

Requirement of the Job Ø Sever cracks were developed at various civil structures. Ø Frequency of breakdowns increased significantly affecting the avg. detention time. Ø Capital repair of the wagon tippler was long time due. Ø Aging of the tippler structures. Ø Risk of total collapse of tippler requiring very high restoration time.

Details of Wagon Tippler Make HEC, Ranchi Year of Installation 1970 Type & Capacity Rotary, 1000 TPH Angle of Rotation 170 ° RPM 14 Gearbox Reduction Rating 51. 1 Motor Rating 30 KW, 415 V, Duty 40%

CHALLENGES IN RENOVATION JOB OF WAGON TIPPLER Ø Complete dependence of BSL for Power & process steam requirement Ø Threat of drawing power by BSL from DVC exceeding the contract demand of 220 MVA. Ø Coal unloading through manual means was not adequate to cater daily coal feeding requirement (5000 MT approx. ). Ø No prior experience/ expertise was available with BPSCL in such renovation job.

Strategies Adopted for Renovation Ø Identification and completion of all pre-shutdown jobs. Ø To make all necessary contracts/work orders in place. Ø Identification and arrangements of all required spares. Ø To plan round the clock working during shutdown period and maximizing the manpower engagement. Ø To build healthy coal stock level

PRE-SHUTDOWN ACTIVITIES Ø Planning of various jobs. Ø Execution of jobs before the actual shut-down. Ø Activities were mainly in-house fabrication jobs. Ø Dismantling of some of the supplied spares for easy handling during erection. Ø Pre-alignment and assembly of some of the spare parts to save time during erection work. Ø Transfer of required co-ordinates of wagon tippler. Ø Resource and material mobilization at site.

JOB SEQUENCE Ø Ø Ø Duration: From 22/05/2018 to 05/06/2018 (15 days). Dismantling of complete wagon tippler. Removal of worn-out foundation frames by breaking RCC foundations. Erection & alignment of base/foundation frames by level re-transfer followed by casting of base frame by CED. Erection of rotor (Inhaul side) followed by 1 st bottom frame. Erection & alignment of middle rotor with 1 st rotor along with erection of pipe frames. Erection & alignment of 2 nd bottom frame followed by last rotor (outhaul side) along with erection of balance pipe frames. Erection and alignment of gearbox foundation frame followed by casting of the foundation by CED Erection of both cradle assemblies after welding of bottom frames with rotors. Erection of both tippler platforms followed by fixing of stay pipes and arms. Erection of top beams and complete welding of different associated structures. Removal of all locking structures, fixing and welding of checkered plate and complete welding, painting followed by trial run of the tippler.

Gantt Chart

SCENARIO during Shutdown Ø Schedule of shutdown planned for 28 days Ø Coal stock as on 22. 05. 2018 i. e. at start of the shutdown: 68, 201 MT Ø Coal stock as on 05. 06. 2018 i. e. at end of the shutdown: 34, 313 MT Ø Number of wagons unloaded manually during shutdown period: 461 wagons Ø Average generation level during shutdown period: Steam: 1152 TPH (Min. – 1099 TPH, Max. – 1231 TPH) Power: 139. 7 MW (Min. – 127 MW, Max. – 159. 64 MW)

CONCLUSION Ø With better co-ordination among all involved agencies, whole pre and post shutdown activities were completed safely in 15 days. Ø Use of high early strength and self-compacting concrete mortar cum chemicals helped in reducing the overall job time. Ø Total cost involved: Rs. 34, 39, 429/* Mechanical jobs: Rs. 17, 83, 550/- (excluding cost of spares) * For civil jobs: Rs. 16, 55, 879/- (including cost of materials) Demurrage charges incurred: Rs. 11, 83, 350/-

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