Issues and challenges in coal fired generation in - mec

Report
Set up as the Central Electricity Board in 1949,
National Electricity Board until !990 and since
then as Tenaga Nasional Berhad (TNB), it is the
largest electricity utility in Malaysia and a
leading utility company in Asia.
• Core business: Generation, Transmission and
Distribution of electricity
• No. of Employees: more than 34,900
• Almost RM 99 billion in assets
• Total installed capacity more than 20,000 MW
Electricity Industry in Malaysia
Energy Demand in Malaysia
Introduction to TNB Janamanjung (TNBJ)
(A wholly owned subsidiary of Tenaga Nasional Berhad)
Current Plant Configuration
- 3 x 700 MW Coal Fired
Current Net Capacity
- 2100 MW
Commissioned in 2003
Extension: 1 X 1000MW USC Boiler
by March 2015
Current manpower: 525
3
TNBJ’s location in Peninsular Malaysia
TNBJ
Main Plant (Unit 1, 2 & 3)
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
•
•
•
Type of Plant
Net Capacity
Plant Configuration
Boiler Capacity
-
Pulverised Coal Firing
2,100 MW
3 x 700 MW
3 x 2390 t/hr of steam
([email protected])
Interconnection
- 500 kV, double circuit line
Current coal sources: Kalimantan (Indonesia), Newcastle
(Australia) & South Africa procured through TNB Fuel (TNB
subsidiary)
Coal stockyard design for 1.5 months supply
Estimated annual consumption 6 million tones
New Plant - Unit 4
Plant Capacity
1000 MW (Nominal)
Technology
Pulverized Coal Combustion;
Supercritical Plant
1. BACKGROUND
–Build,
Project
Overview
Project
Concept
Own and
Operate (BOO)
Project Start Date
31 March 2011
Scheduled Completion
Date for EPC Contract
31 March 2015
Emission Standards
World Bank Requirements &
Malaysian DOE Standards
New Plant - Unit 4
EPC Contract
Alstom n CMC Consortium
•
Owner’s Engineer
1. BACKGROUND
Tokyo Electric Power
Services Co. Ltd and
– •Project
Overview
Minconsult
Sdn. Bhd. Joint
Venture
1. BACKGROUND – Satellite View
2. TECHNOLOGY – Comparison
M 1/2/3
M4
Temperature
566 oC
600 oC
Pressure
165 bar
270 bar
Efficiency
34 -37%
38-42%
Salient Features
Reduced CO2 emission
Boiler Material – Final
Superheater
Boiler Feed pump
Rotor type
IPB Type
Stringent water regime
Total reduction = 60gCO2/kWh
Up to Alloy Steel
(T91/T92)
Stainless Steel (304H)
3 x 50 % Motor driven
2 x 50% Turbine driven +
1 x 30% motor driven (startup/back-up)
Solid monobloc forging
Welded rotor (HP/IP/LP)
Natural Cool
Forced Cool
Uses Boiler Drum, can
do Blowdown
Once-through Boiler, uses
Condensate Polishing Plant
1. BACKGROUND – Key Dates
2. TECHNOLOGY – Ultra-supercritical boiler
• Supercritical technology is considered as a fully proven
technology
• The reference plant for the ultra-supercritical plant in US and
China
2. TECHNOLOGY – Advantage of Ultra-supercritical
• Low Environmental Emissions
• Operate at higher efficiencies of average ~ 40% (Consume
less coal and therefore produce fewer emissions per kWh
output)
• Reduction of 158,000 metric ton/annum of CO2 emission in
comparison to a similar conventional power plant.
Environmental
Designs and Standards
Parameters
M 1/2/3
DOEGas
MalaysiaEmission
World Bank
Flue
Design
Nitrogen Oxide
(NO2)
1700 mg/Nm3
max
Sulfur Dioxide
(SO2)
3500 mg/Nm3
Flue
Gas
max
650 mg/Nm3
max.
650 mg/Nm3
max.
M4
510 mg/Nm3
max.
750mg/Nm3
750mg/Nm3
200 mg/Nm3
Emission
Limits/Design
for
max.
max.
max.
Manjung
1,2 & 3 comply
with World
Bank
400 mg/Nm3
50mg/Nm3
50mg/Nm3
Guideline
max
max.
max.
Particulates/Dust
50mg/Nm3
max.
Carbon Monoxide
(CO)
NA
200mg/Nm3
max.
200mg/Nm3
max.
200mg/Nm3
max.
Opacity
40%
20%
20%
20%
TNBJ’s 5-Year Plant Performance
Unplanned Outage Rate (%)
18.00
16.00
14.00
12.00
10.00
8.00
6.00
4.00
2.00
0.00
FY2008
FY2009
FY2010
FY2011
FY2012
TNBJ’s 5-Year Plant Performance
Sales
Sales (GWh)
TNBJ’s 5-Year Plant Performance
Units Sold, GWh
16290.33
14109.51
14045.12
12334.36
10342.38
FY 08/09
FY 09/10
FY 10/11
FY 11/12
FY 12/13
TNBJ’s 5-Year Plant Performance
Plant Output Factor (%)
86.23
88.52
FY 09/10
FY 10/11
96.85
98.17
FY 11/12
FY 12/13
69.94
FY 08/09
16
Risk
• TNB’s definition of risk: Anything that has the
potential to prevent the organisation from
achieving its objectives.
• TNBJ has identified 7 specific risks:
Specific Risk ID
Specific Risk
GEN-JAN-0001
Low Plant Reliability
GEN-JAN-0004
Breach of plant security
GEN-JAN-0014
Breach of Legal and Regulatory requirements.
GEN-JAN-0024
Fire or explosion
GEN-JAN-0025
Accidents leading to fatalities /
injuries or property damage
GEN-JAN-0029
Corruption/ fraud
GEN-JAN-0031
Low Plant Efficiency
Common Systems Risk Profile
No
Description of
Shared Critical
System
Likelihood
of Failure
Impact of
Failure
Gross
Risk
Rating
Likely
Catastrophic
High
Unavailability / Contaminated Demin
Moderate Catastrophic
water to the plant.
Common storage for all unit generators Moderate Catastrophic
High
Description of Impact on System
Failure
1 Coal Delivery System Unavailability of coal to all boilers.
2 Water Treatment
Plant
3 Hydrogen Storage
4 Distillate Storage &
Supply System
Common storage for all units.
Used for light up and combustion
support.
5 Raw & Service Water Unavailability of Demin Water to
Supply
boilers.
High
Unlikely Catastrophic High
Unlikely Catastrophic
High
Issues & Challenges
1)
2)
3)
4)
5)
Coal spontaneous combustion
Boiler tube leak
Strain on plant (higher demand and low cost)
Ensuring variance of coal (prevent over reliance)
Decrease in supply of good coal, more
competition
6) Tighter Environmental Regulations
7) Public perception; easy scapegoat
1) Coal spontaneous combustion
Coal is susceptible to spontaneous
combustion.
Preventive measures
o Compacting coal piles to reduce the amount of air
within the pile.
o Minimizing coal storage times, First In First Out (FIFO)
o Continuous monitoring for hot spots. When a hotspot is
detected, the ignited coal should be removed.
o Regular & disciplined housekeeping
2) Boiler Tube Leak
Tube overheating
Clinker formation
Preventive measures
•
•
•
•
•
•
•
•
Uncompromising Sootblowing activities.
Adhering plant operating limits
Replacement of component based on life assessment study.
Condition monitoring of boiler tube during overhaul.
Low coal quality
Differing operational regime for new coal
Ageing plant
Over heating of boiler tubes
3) Strain on Plant (higher demand and low cost)
Coal plant required to run constantly
on full load due to:
• High demand of electricity
• High merit order, high load factor.
• Cheaper to burn coal than gas
• Low coal CV (require more coal
per MW) – strain on coal delivery
system
Preventive Measures
• Spare must be readily
available.
• Long term agreement with
Service Providers.
4) Varieties of coal
• Different types of coal used, each with different properties
and characteristics.
• Each trial burn has its own risk.
• Boiler needs to be tuned according to type of coal
• Overheating, emission control
Preventive measures
o Alert to what type coal is being sent to
boiler.
o More attention on coal milling operation.
o Daily discussion on coaling activities during
Production Meeting
5) Decrease in supply of good coal,
more competition
Preventive measures
• Increase in maintenance frequency of critical
equipment eg mills
• Support from OEM on boiler tuning
• Engage Technical Service Advisor
6) Tighter Environmental Regulations
•
•
•
•
Investment for compliance
Bag filters
FGD
Improved boiler design and
technologies
7) Public perception
•
•
Long outstanding perception
of coal is dirty
Conveniently blamed by
public
Preventive Measures
•
•
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Improve awareness and Educate the public
Improve relations/buy in with public esp
surrounding communities
CSR program with communities
CSR Activities by TNBJ
Program Penanaman Bakau bersama Komuniti di Daerah Manjung melibatkan murid-murid
sekolah dan penduduk kampung . Program ini diadakan untuk mendidik para peserta
kepentingan dan sumbangan pokok bakau dalam kehidupan kini.
Program Sambutan Perayaan Deepavali di Rumah Anak-anak Yatim Seri Manjung diadakan
untuk meraikan anak-anak yatim sempena perayaan Deepavali. Persatuan dan kesatuan di
TNB Janamanjung turut serta dalam program ini.
Program Sambutan Perayaan Tahun Baru Cina di Rumah Orang-orang Tua dan Kg KDSK Seri
Manjung untuk meraikan orang-orang tua dengan pemberian limau mandarin, angpau dan
jamuan makan tengah hari.
Program Kayuhan Hijau bersama DOE Negeri Perak diadakan sempena Minggu Alam Sekitar
Malaysia. Warga kerja TNB Janamanjung turut terlibat dalam kayuhan ini yang bermula di
UniKL dan berakhir di Marina Island.
Program Back to School
Di Pasaraya Giant Seri Manjung diadakan untuk membantu meringankan beban keluarga
kurang berkemampuan untuk persediaan persekolahan anak-anak mereka. Sepasang baju
sekolah dan keperluan pembelajaran disumbangkan. Beberapa buah keluarga kurang
berkemampuan di sekitar kawasan Seri Manjung terlibat dalam program ini.
Program ‘Confirm A’ Untuk Pelajar Tahun 6 di sekitar Daerah Manjung telah diadakan dengan
kerjasama diantara TNB Janamanjung Sdn. Bhd. dan Uniten. Program ini membolehkan pelajar
Tahun 6 membuat latihan UPSR melalui laman sesawang yang direka khas oleh Professor Dr.
Azree dari Uniten.
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OTHER ACTIVITIES
Majlis Sumbangan kepada Akaun Amanah CSR telah diadakan di SUK, Ipoh Perak. Akaun
Amanah CSR ini ditubuhkan untuk kerajaan Negeri Perak melaksanakan aktiviti CSR di
seluruh Negeri Perak.
36
Awards Received by TNBJ
ASEAN Coal Awards – 25th September 2013
Organized by ASEAN Centre for Energy to
promote coal and Clean Coal Technology (CCT)
TNB Janamanjung is the sole representative for Malaysia and
won 2 categories :
1. Corporate Social Responsibility (CSR) : “TNBJ’s CSR –
Station in Harmony with Community”
2. Special Project :
“TNBJ Quality Journey to PAS55 Certification”
Human Resource Minister Award 2013
Human Resource Minister Award 2013
– Large Employers (Service)
13th December 2013
TNBJ Won Bronze For Product Excellence Award
In Global CSR Summit & Awards 2014 In Bali, Indonesia
3rd April 2014
Thank You

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