Pf Tpp(Whrs Boe)
2 weeks ago
Designation:
Assistant Manager
Updated:
June 11, 2024
Location:
Madhya Pradesh, India
Organization:
Cement
Job Purpose:
Monitor and supervise the operation of WHRS.
Responsible for safe, continuous and efficient startup and operation of Boiler, Turbine and its auxiliaries in order to keep 100% availability of WHRS.
Collection of data for MIS report as per requirement. Implement & Monitor ABG safety standards & procedures in being followed in WHRS.Job Context & Major Challenges:
The Unit is located in Tonki Village, Tehsil - Manawar, District - Dhar (M.P.). Located at a distance of 139 kms from the city of Indore.
Unit has 2 lines with capacity 6MTPA located at the prime location to capture market of high potential. Total raw material transportation and dispatch is through road transportation with a turnaround of average 600 trucks per day.
Clinker at Dhule and other GUs are being transported from Dhar.
Job Context:
Dhar Cement Works is integrated cement plant equipped with modern technology with an installed capacity of 6 MTPA, cement production capacity of 5.2 MTPA with WHRS for power generation (33 MW) and open cast mines.
Unit has always maintained high level of operational performance and stands tall, as a symbol of ' ̃Sustainable Industrial Development'.
For sustainability units environmental cell monitors air and water quality, audits, and conducts ecological studies and environmental studies of mines and nearby villages.
Waste Heat Recovery System consists of 33 MW MW), condensing type steam turbine with single Injection top Exhaust steam Turbine.Having 2 boiler WHRS type,After Quenching Cooler boiler having steam generation capacity of 50 TPH in final superheater and 25 TPH in HP primary superheater with Working Pressure 18.94 Kg/cm2,LP Boiler of AQC circuit having steam generation of 3.4 TPH with working pressure 7 kg/cm2 and Unit-2 Preheater Boiler type having steam capacity 25.6 TPH with working pressure Kg/CM2 and LP boiler with 11.5 TPH capacity with working pressure 7 kg/cm2.
The auxiliaries system for steam turbine comprises high pressure boiler feed pumps having working pressure 30 Kg/CM2, and Air cooled condensers consisting of total 6 Nos.
of forced draft fans for 1 units having dia. Of fan-9.75 Mtrs, Steam jet air ejectors, gland steam condensers, 01 Nos of Deaerator system etc.The water treatment system consists of R O & D M plant. Waste water will be treated in waste water treatment plant. Auxiliary cooling water system with induced draft cooling towers and raw and fire water system.
The operation of entire WHRS would be a challenge for all engineers with parallel operation of unit without grid (island mode).
Also the Air cooled type condensers is a new technology which needs proper attention for efficient operation as it is changing with the quality of atmosphere air.
system.Major Challenges:
Operation:
'¢ Inspite of availability of grid, maintaining the 100% availability & reliability of boiler TG set in any case by fulfilling IBR statutarty requirements, GPCB norms and WCM & ISO practices for uninterrupted quality power provision to cement plant & keeping minimum Load in the Grid
'¢ Over the years, the Boiler and Turbines componants have started showing deterioration in their performance due to ageing factor. Challenges of best operation & maintanace practices are needed to sustain performance of Boiler-TG set.
'¢ To prepare and provide immediate real time data related to plant performance, budget, flash provision report, power cost budget, etc
Key Result Areas:
KRA (Accountabilities) (Max 1325 Characters)
Supporting Actions (Max 1325 Characters)
- KRA1
- Responsibility of Plant operation:
- Coordinate operational activities for power generation from WHRS in order to supply uninterrupted power to cement manufacturing plant.
- Review operating instructions and tailor them to site specific requirements
- Review of operational strategy and philosophy as per instruction of superior
- Internal Energy audit and cost optimization at plant level
- Forced Outage Analysis per instruction of superior
- Coordinate conduction of Operations Team Review daily Meetings
- Identification of plant abnormality, operational losses & coordinate with maintanace department to resolve issues.
- Interact with service department for daytoday operational work requirement.
- Assist in shutdown plan execution from operational side.
- KRA2
- Plant Performance
- Improved the plant performance in operation and work environment
- Monitor day to day operation of the plant and its deviation from the optimum value.
- Identify factors resulting in low availability, high partial loading and deviation of critica
