World-class O&M know-how
To accomplish their goal of achieving trouble-free operations, Boryeong Unit 3 personnel implemented a wide variety of processes and technologies. As a result, they increased their work efficiency and greatly improved their operational processes.
Improvement of steam turbine bearings. The plant’s turbine bearings had problems with high temperatures and high vibration levels. The staff dealt with these issues by modifying the design of the support of its tilting pad bearings.
Recovery of turbine performance. Another challenge involved improving the performance of the plant’s turbine. Plant personnel recovered 31 MW of output by removing deposits on the turbine nozzle valves. They also improved the steam turbine’s efficiency by reducing internal and other packing steam leakages.
Development of a fault analysis system. The staff tackled problems related to trips in the system by developing a fault analysis system. New methods were developed to automatically track back through the control logic and pinpoint the cause of the trip. In addition, this new system is faster, performing rapid analysis of the trip cause within 10 minutes.
Creation of an accurate calibration system for control modules. Another innovation was the development of an accurate calibration system for control modules, which made it possible to conduct precise inspections of input/output cards.
Development of a high-frequency heater for the generator retaining ring. By creating a special high-frequency heater and a high-frequency welder, plant personnel are now able to apply these to other generators and high-frequency welders. Maintenance hours decreased as a result of maximizing work convenience.
Improving UPS systems. The staff implemented an uninterruptible power supply (UPS) parallel operation system. The plant’s two UPSs operate in parallel to take 50% of the load. If one of the units has problems, the other one takes 100% of the load. In addition, plant personnel installed a UPS surge prevention system on the load side of the UPS.
Establishment of a turbine water induction prevention system. To record and inspect water temperature differences, the staff installed a thermocouple that detects water induction in the upper/lower side of high/intermediate-pressure turbines.
Development of a clinker inspection system within the boiler. The plant personnel’s goal was to prevent boiler damage due to the boiler tube overheating and clinker falling. They implemented a new procedure in which clinker attached to the boiler superheater and reheater is inspected to prevent clinker damage and to maintain optimized operation of the sootblower.
Establishment of a redundant system for the boiler main control facility. The staff installed a new control system, reinforced by the redundant system, for major controllers and input/output signals related to unit trip or load reduction in the boiler.
Development of the e-P&I system application. The Boryeong staff developed the electronic-Piping & Instrumentation system (eP&I system), which is an intelligent software system that can search for facility drawings and all facility information, and then put that information to use for optimizing maintenance activities.
Use of preventive diagnostic systems. The staff also uses a number of remotely operated systems to inspect facilities and promote the use of preventive measures. The diagnosis system for the in/out transformation facility, the insulation diagnosis system, the vibration diagnosis system, and the control module soundness test can predict component failures during operation before they can cause a unit outage.
Creation of a simulation training center. Opened in April 1997, the facility consists of a simulator, a computer room, and a simulator control room. Training includes the following courses: operation practice, simulation, control circuit understanding, and facility operation (plant measurement, installation and operation technology, and application).
Providing online access to operational information. By downloading operating information found on the intranet that interconnects all computers in the company, the staff can collect and analyze real-time operational data for use in preventive maintenance activities (Figure 4).
4. Familiar controls. The standardized plant design also allows operators to quickly become proficient with operating any of the units at the Boryeong plant or at other plants that follow the standardized plant design. Courtesy: KOMIPO
Future directions
Currently, the Boryeong Thermal Power Complex is being reborn as an integrated power generation complex equipped with renewable energy facilities. Its new alternative energy sources include the 525-kW solar photovoltaic system, which in 2008 was installed on the office building of the power plant, and a 2.5-MW hydroelectric power plant that is under construction, and which will use a waterway to transport the necessary water.
Not satisfied to focus only on O&M improvements, Boryeong Thermal Power Complex also is striving to improve its environmental performance. For example, all of Boryeong’s coal-fired power plants are equipped with desulfurization and denitrification facilities. In addition, flyash and desulfurized plaster, by-products of coal-fired generation, are recycled into cement and plasterboard.
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Comments (1)
Do you really mean that the unit war running 3000 day without a single stop? even to for inspection of high pressure vessels?
waiting for your answer.
Editor: The plant operated 3,000 continuous days, not continuously without a shutdown for that period. As long as the plant was synchronized and making power at any time during a day, that day was counted.