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APP 4APP 4thth Peer Review in Australia Peer Review in Australia“Brown Coal Best Practice Workshop”“Brown Coal Best Practice Workshop”

Summary of the ActivitiesSummary of the Activities

27 June, 2008

The Federation of Electric Power Companies of Japan

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The Federation of Electric Power Companies

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1. 1. Overview of the 4Overview of the 4thth Peer Review in Australia Peer Review in Australia Thanks to the Federal Government of Australia, Victoria

Government, Loy Yang Power, International Power Hazelwood, True Energy Yallourn, and related organizations, the 4th Peer Review in Australia has been very successful in terms of gaining invaluable experience in Brown Coal Technologies.

Japan’s delegates are really appreciative of the efforts and the amount of work to organise such a huge international event.

Safety procedures are very well established and performed rigorously throughout the activities.

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1-1. 1-1. Japan’s involvement in the 4Japan’s involvement in the 4thth Peer Review Peer Review

May - June 2008: Preparation for the Peer Review in Australia based on the US Peer Review

19 June 2008: Internal Peer Review meeting and discussion using the pieces of information available at that stage

23 – 27 June, 2008: Peer Review Activities including Checklist Exercises at Loy Yang: 26th June: Peer Review at Loy Yang 26 – 27th June: Site Visits to Yallourn and Hazelwood

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1-2. 1-2. Background of the Peer Review (1)Background of the Peer Review (1)- Comparison of thermal efficiencies -- Comparison of thermal efficiencies -

20

30

40

0 20 40Year since commissioning

The

rmal

Effi

cien

cy (%)

Current value

Y-P/S Y-P/S （（ Oil, Oil, TEPCOTEPCO ））

A-P/S A-P/S （（ Coal, X-Coal, X-CountryCountry ））

35.535.5 （（ DesignDesign））

（％）

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1-3. 1-3. Background of the Peer Review (2)Background of the Peer Review (2)- Importance of the O&M practices- Importance of the O&M practices - -

To organise and analyse the historical maintenance information

To collect the information supplied by OEM systematically

To utilise the operating information To integrate the above information and to

identify the optimum replacement of components from long term perspectives

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The first priority should be placed on reinforcement of O&M aspects, not on the major investments.

To monitor and analyze the operation data To investigate the maintenance history since

commissioning To integrate the operation and maintenance

assessments and to keep the O&M program updated continuously

1-3. 1-3. Background of the Peer ReviewBackground of the Peer Review- Shared perception -- Shared perception -

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2-1. 2-1. What is the Efficiency Checklist? What is the Efficiency Checklist? Peer Review Activities started in April 2007 and

some items were developed. “Green Hand Book” (Instructions for O&M

technologies for the coal fired power plants) ‘The Efficiency Checklist For The Coal-fired

Power Plants’Practical tool to put those listed items into practice was required.

‘Efficiency Review Sheet’

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2-2. 2-2. The ‘Checklist’ and the ‘Review Sheet’The ‘Checklist’ and the ‘Review Sheet’

One item on the ‘Efficiency Checklist’ corresponds to one ‘Review Sheet’.

Efficiency Checklist

Review Sheet

APP Peer Review Activities

The Procedure for Reviewing Efficiency Based on ‘The Efficiency Checklist For The Coal-fired Power Plants’

18th January 2008

The Federation of Electric Power

Companies of Japan

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2-3. 2-3. Steps of the Peer ReviewSteps of the Peer Review

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3-1. 3-1. Findings – Loy Yang – Boiler Group (1)Findings – Loy Yang – Boiler Group (1) Overall Power Plant is well maintained! Safety awareness (protection, signs) is well established! Operators and engineers were highly experienced. Gland leaks from the valves – SH spray water valves

(SH3A-2, SH4A-4)

Hot spots on the AH casing – potential leakage AH bypass dampers – not fully closed

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3-2. 3-2. Findings – Loy Yang – Boiler Group (2)Findings – Loy Yang – Boiler Group (2) Ash hopper – air ingress due to the loss of water seal

SH/ RH spray flows – need to be monitored PF leakage on Unit2

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3-3. 3-3. Findings – Loy Yang – Boiler Group (3)Findings – Loy Yang – Boiler Group (3) ECA dampers – air ingress House keeping – important Operation side – Excess air 2.15 ICMS project – Smart system is a very good program that includes

replacements of dampers, sensors and actuators. Few energy efficiency measures may be taken up to reduce the amount of

fuel, ultimately reducing emission of CO2 and dust.

In 1980s, there was an upgrade of DCS from analog (pneumatic (1960s technology)) to digital (Bailey N90) for MS and RH temperature control. However this system didn’t work appropriate, because local system didn’t follow demand of DCS. Operator controlled it manually and set steam temperature lower in order to have a margin for hunting or overshooting. It takes several months to modify spray valve and local control, even though many tuning were performed. Yallourn has experienced the same situation when upgrading DCS. Suggestion/ When DCS upgraded, not only the upgrade of DCS but also local control systems and hardware is crucial (i.e. Valves and Dampers) in order to respond to high speed demand, especially that is related to the plant efficiency./ If DCS control system and local control systems don’t match well, plant efficiently may not be improved.

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3-4. 3-4. Findings – Loy Yang – Auxiliary GroupFindings – Loy Yang – Auxiliary Group Plant was well maintained. – bunkers, ducts, casings,

housekeeping, etc. Bunker area is a little bit dusty. AH outlet temperature is about180 deg.C/ AH air leakage

is about 20% – the volume of AH elements might be increased and radial gap may be reduced.

Unexpected unit trip may be an issue. – BFP BP bearing etc.

Oxygen Treatment – pH might potentially be low, which may lead to corrosion of LP heater drain lines.

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3-5. 3-5. Findings – Loy Yang – Turbine Group (1)Findings – Loy Yang – Turbine Group (1) Upgrades and efficiency improvements are very

positive indications. (e.g. HP, IP turbine. Condenser titanium tube. Turbine MSV, CV, Bypass valve)

Engineers are very positive to adapt them, but daily O&M activities can be more focused on.

Improvement in daily performance management is recommended. (Please refer to the “Green Handbook.”)– 2.4 Performance management – 2.5 Example of operation and performance management.

ICMS project is under progress. It’s a good opportunity to introduce the comprehensive performance management system.

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3-5. 3-5. Findings – Loy Yang – Turbine Group (2)Findings – Loy Yang – Turbine Group (2) Steam leakage Ground leakage of level control valve for LP3 HTR. Steam leakage from level gauge and related valve of HP

HTR.

Steam leakage from the boiler feed pump and piping. HP Heater level control : Level indication is zero on almost

all the HP Heaters.

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3-6. 3-6. Findings – Loy Yang – Turbine Group (3)Findings – Loy Yang – Turbine Group (3) Condenser pressure:

– Periodical condenser inspection or on-line cleaning systems are recommended.

– Unit 3 Condenser pressure: (design condition: 10kPa: actual condition: 11kPa) (1kPaA - change in heat rate is ca. 0.5%)

Equivalent GHG of LYA in 2006 : 19,362,812 ton-CO2 19,362,812 ton-CO2 / 4 unit * 0.5% = 24,000 ton-CO2 abatement

Deviation of TCV opening.– All control valves expected to be the same openings; 30 to

35%, while actual openings are 30 to 50%. Replacement of LP turbine last stage blade is to be

considered.– Replacement of HP and IP have been planned, but the LP last

stage replacement has not yet been planned.

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4-1. 4-1. Related Activities of the Peer ReviewRelated Activities of the Peer Review

Findings at the Yallourn Power Station Positive efficiency management attitude Improved forced outage rate from 12 to 4% Alliance for O&M with SILCA and RTL Sophisticated mining with GPS for dozers DCS upgraded (ABB infi90) and the

integrated control room Tag system for the permit of maintenance

work Good housekeeping

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4-2. 4-2. Conclusion of the Brown Coal Peer ReviewConclusion of the Brown Coal Peer Review Brown coal technologies including coal drying

and CO2 capture are very impressive and their progresses are really beneficial.

Efficiency improvement at the brown coal sites is 1.5 times more effective than at black coal power stations: 1.2t/MWh:0.8t/MWh ~ 1.5

While pre-combustion and post-combustion technologies are very effective, O&M management is also imperative in reducing GHG Emission, whatever the business drivers may be.