Power Plant Optimization Component

1
Power Plant Optimization Component under IGEN
Programme Review Progress Achieved
K.K.Chakarvarti Manager- Power Plant
Component IGEN, GTZ
2
Introduction

• India has an installed power generating capacity
  of 143,061 MW (as on March 31, 2008) of which
  the thermal power stations share is 91,906 MW
  (64).

3
Total Installed Capacity- 1,43,061 MW (as
on March 31, 2008 )
4
Introduction-Contd.

• The contribution of energy generated by thermal
  stations was 559 billion kWh, which is about 80
  of electricity generated (704.5 billion kWh) in
  2007-08.
• There has been significant improvement in the
  plant load factor of thermal stations, which
  improved from 52.4 in 1985-86 to 78.6 in
  2007-08, registering a remarkable improvement of
  50 during the period.
• Since the major power generation contribution is
  from thermal sector, an average increase of 1
  in the thermal power plant efficiency would
  result in
• a. Coal savings of approx. 11 million tons per
  annum for nation (approx) worth 200 Million
  Euro
• b. 3 CO2 reduction per annum (approx.13.5
  million tons per annum)

5
ALL INDIA PLANT LOAD FACTOR () OF COAL FIRED
THERMAL POWER STATIONS
6
INDIAN SCENARIO DESIGN HEAT RATE TRENDS
PERIOD STEAM PRESSURE TEMPERATURE UNIT SIZE (MW) TURBINE Heat Rate (Kcal/kWh) Unit Heat Rate (Kcal/kWh)
1951-60 60 kg/cm2, 482oC 30 57.5 2470
1961-75 70 kg/cm2, 496oC to 90 ata 538oC 60 100 2370
1961-75 130 ata 535/535oC 110 120 2170 2060 2552-2423
1977-82 130 ata 535/535oC 210 (Russian) 2060 2423
1983 150 ata 535/535oC 210 (Siemens) 2024 2335
1984 170 ata 535/535oC 500 1950 (TDBFP) 2294
1990 150 ata 535/535oC 170 ata 538/538 oC 210/ 250 250/ 500 1950 (MDBFP) 1950 (TDBFP) 2294 2294
Above are best design values (design rates of individual unit varies based on reference ambient, coal quality, design and supply dates) Above are best design values (design rates of individual unit varies based on reference ambient, coal quality, design and supply dates) Above are best design values (design rates of individual unit varies based on reference ambient, coal quality, design and supply dates) Above are best design values (design rates of individual unit varies based on reference ambient, coal quality, design and supply dates) Above are best design values (design rates of individual unit varies based on reference ambient, coal quality, design and supply dates)
7
EFFECT OF CRITICAL PARAMETERS ON HEAT RATE
Variation Impact (kCal/kWh) Impact (kCal/kWh)
Variation 200 MW Unit 500 MW Unit
SH Spray 20 T/hr 0.30 0.81
RH Spray 20 T/hr 12.00 4.76
MS Pr. 10 kg 12.00 7.30
MS Temp. 10oC 6.00 6.20
RH Steam 10oC 6.00 5.55
Load 10 MW 12.00 4.36
Cond. Back Pr. 5 mm Hg 8.00 6.70
FW Temp. 10oC 8.00 10
8
Policy initiatives of Government of India to
improve the power sector efficiency

• Power sector reforms
• Promotion of clean coal technologies,
• Energy Conservation Act 2001
• Electricity Act 2003
• National Electricity Policy, 2005
• Adoption of Super Critical Technology for 660/
  800 MW units for Ultra mega Projects (4000 MW
  each) and
• Increased emphasis on environmental
  considerations

9
Barrier to Efficiency Improvement in Power Sector
Indian Scenario

• Emphasis on plant load factor instead of
  efficient generation.
• Degradation of equipment resulting in loss of
  capacity.
• Delayed overhauls (Seasonal Constraints)
• Financial constraints lead to inadequate
  maintenance
• Lack of awareness on efficiency related issues
• Inadequate monitoring system for parameters

10
The Indo German Energy Programme (IGEN)

• The Ministry of Power, Government of India and
  GTZ (Deutsche Gesellschaft für Technische
  Zusammenarbeit (GTZ) GmbH) signed an
  implementation agreement with respect to the
  Indo-German Energy Programme in 2006.
• The Indo German Energy Programme (IGEN) is
  performing research work and performance
  assessment in support of the implementation of
  the Energy Conservation Act 2001 in cooperation
  with the Ministry of Power and its statutory
  bodies Bureau of Energy Efficiency (BEE), and
  Central Electricity Authority (CEA).
• Under the IGEN agreement, CEA has been entrusted
  with the task of ensuring performance
  optimisation and efficiency of thermal power
  plants.

11
The Indo German Energy Programme (IGEN)

• The overall aim of this measure under Indo
  Germany Energy programme is to support and
  prepare public and private power plant operators
  for performance reporting as well as
  implementation of financially attractive and
  technically viable improvements of power plant
  net heat rate under the provisions of the Energy
  Conservation Act.
• The project is being executed under two main
  sub-components
• 1. Mapping Studies of thermal power generating
  units
• 2. Performance Optimisation of Thermal Power
  Stations

12
Mapping Studies of Indian Thermal Power
Stations(Sub Component-I)

• GTZ has provided support to CEA in creating a
  database of the older thermal power plants in
  India.
• The scope of the work primarily covers the
  mapping of the 85 thermal power generating units
  by using Ebsilon software.
• The mapping is done for two-condition design
  status and the actual operating status based on
  plant parameters gathered from different plant
  locations.
• Its primary purpose is to provide a baseline
  mapping for creating a database within CEA and
  identify areas both short and long term, needing
  attention in order to improve energy efficiency.
• The baseline map would permit an objective
  method of setting targets and monitoring
  progress.

13
MAPPING STUDIES - PROGRESS ACHIEVED
Mapping studies of 55 Thermal power generating
units of the 14 Indian States viz. Andhra Pradesh
Chhattisgarh, Gujarat, Haryana, Jharkhand,
Karnataka, Madhya Pradesh, Maharashtra, Orissa,
Punjab, Rajasthan, Tamil Nadu, Uttar Pradesh
West Bengal have been completed.
CAPACITY WISE PLANTS COVERED (Nos)
210 MW 35
200 MW 3
250 MW 4
500 MW 2
110 MW 3
120 MW 5
125 MW 1
100 MW 1
140 MW 1
TOTAL 55
14

• The total installed capacity of above 55 coal
  fired thermal generating units, covered under
  the mapping study is 11245 MW, which is about
  15 of the installed capacity of coal fired
  generating units (76300 MW) in the country.
• The mapping studies carried out by using Ebsilon
  Software have brought out the deviations between
  design and operating parameters such as gross
  heat rate, turbine heat rate, boiler efficiency ,
  specific coal consumption of the power
  generating units .

15
(No Transcript)
16
Salient features of outcome of Mapping Studies of
twenty-six nos. of 210 MW units
1. The mapped thermal generating units were
characterized by a wide band of energy
performance 2. Few of them were very closed to
their designed energy performance, but majority
of them had deviated from their designed
performance by a bigger margin 3. Operating
Gross Heat Rate was found to be varying from 2477
to 3084 kCal/kWh against their design values of
2321 and 2444 kCal/kWh respectively, exhibiting
deviation band width of 156 kCal/kWh (6.3) to
640 kCal/kWh (20.7)
17
4. For an average designed Gross Heat Rate of
2384 kCal/kWh for these 26 units of 210 MW
capacities, the heat rate has increased by an
average value of 385 kCal/kWh, registering an
average increase of 16 from their design
performance.
18
5. The mapping studies have proved that older
units having better operation and maintenance
practices can still demonstrate higher
performance than comparatively younger units.
27 of 210 MW power generating units, having
age more than 25 years have shown better
performance than 54 of 210 MW units in the age
group of 14-25 years
Average Gross Heat Rate by age group (210 MW)
(as observed through Mapping Studies)
19

• The operating gross heat rate of turbines was
  found to be the major contributor in the
  deterioration in the energy performance of 210 MW
  units. The turbine gross heat rate varied from
  2045 to 2407 kcal/kWh indicating a wide
  difference of 362 kCal/kWh in the operating
  performance of 210 MW turbine units, which is
  about 60 of the total deviation (607kCal/kWh)
  observed for 210 MW generating units.
• Turbine Heat Rate of 210 MW capacity units
  (kcal/kWh)(as observed through Mapping Studies)

20
Average Gross Heat Rate by Turbine Type (210
MW) (as observed through Mapping Studies)
21
Average Gross Heat Rate by Boiler Type (210 MW)
(as observed through Mapping Studies)
22
Boiler Efficiency of 210 MW capacity units
()(as observed through Mapping Studies)
23
Percentage of Auxiliary Consumption of 210 MW
capacity units ()
24
Performance Optimisation of Thermal Power
Stations under IGEN Programme (Sub Component II)

• The overall aim of this measure is to support
  and prepare public and private power plant
  operators for performance reporting as well as
  implementation of financially attractive and
  technically viable improvements of power plant
  net heat rate under the provisions of the Energy
  Conservation Act.
• This phase has been initiated with effect from
  15th January, 2008 and is expected to be
  completed by 15th January, 2010. The following 5
  outputs are planned

25
Performance Optimisation of Thermal Power
Stations under IGEN Programme (Sub Component II)
Contd
1. Technical assistance for conduct of high
quality energy audits 2. Technical assistance in
the establishment of energy management system in
the power plants 3. Annual statistics of
validated impact of energy conservation in power
plants 4. Familiarization and interchange of
best practices with power plant operators in
Germany or Europe 5. Development of electronic
data base to analyze the findings of all energy
audit reports carried out in power plants and
assessment of impacts with respect to energy
conservation and efficiency.
26
PERFORMANCE OPTIMISATION OF THERMAL POWER
STATIONS - PROGRESS ACHIVED

• The following progress has been achieved in the
  past 6 months since the initiation of the
  activities with effect from 15th January, 2008.
• Output 1
• Technical Assistance for Conduct of High
  Quality Energy Audits
• 1. 1 Survey of best practices on power plant
  performance monitoring in Germany / Europe, data
  generation and its analysis, software and
  analytical tools used, on line as well as mobile
  measuring instruments, newest trend in power
  plant performance optimization, etc.
• -- (Draft Prepared)

27
1.2. Organization of 20 workshops and 20
seminars to disseminate findings across India
--- (Schedule finalized, conduct of workshops
and seminars is commencing from August
2008) 1.3 Development of standard procedure for
energy auditing of power plants and its
finalization --- (Under preparation, expected to
be completed by Sep 2008) 1.5 Undertake
statistical analysis of 100 energy audit reports
prepared by accredited energy auditors for
assessment of their quality and findings ----
(Received 25 reports from power stations and are
being evaluated for statistical analysis on the
qualitative assessment such as areas covered,
quality of reports, probing skills, report
structure etc.)
28
(No Transcript)
29

• Output 2
• Technical Assistance in the Establishment of
  energy management system in the power plants
• 2.1 Development of a model organizational
  structure for establishing Energy Management
  Cells, employing certified Energy Manager, based
  on the outcome of the survey of all public and
  private power plants
• --- (40 TPS have submitted information till date
  and is under analysis)
• Miscellaneous
• To support energy managers, energy auditors and
  other energy professionals engaged in the energy
  efficiency improvement in the power plants, a new
  home page on "Power Plant Optimization"
  Component has been established w.e.f May, 2008 in
  www.energymanagertraining.com . This section has
  recorded about 5800 visitors.

30
(No Transcript)
31
(No Transcript)
32
Outcome Expected from IGEN
The following outcomes are expected of the
programme a. Assistance in the improved
efficiency of thermal power plants b.
Establishment of mapped power plants data
bank c. Establishment of Energy Efficiency cell
at Power Plants d. Capacity building of the
power plant professional on power plant
optimization e. Standard Prescribed format
for submitting Energy Audit Reports.
33
CONCLUSIONS

• The increasing preference for commercial energy
  has led to a sharp increase in the demand for
  electricity and fossil fuels.
• Use of Fossil Fuels result in emission of huge
  quantity of carbon dioxide causing serious
  environmental damages.
• There is a considerable potential for reducing
  energy consumption by adopting energy efficiency
  measures in thermal power stations of our
  country.
• Energy efficiency will not only reduce the need
  to create new capacity requiring high investment,
  but also result in substantial environmental
  benefits.
• With the enactment of the Indian Energy
  Conservation Act, 2001, an institutional
  framework is now available for promoting energy
  efficiency in all sectors of the economy
• Efficient use of energy and its conservation will
  succeed as a program if there is a strong
  institutional set up in the country and opinion
  leaders and captains of industry take lead in
  implementing the best practices supporting the
  conservation programme

34
ENERGY IS LIFE
JOIN
HANDS
IN
CONSERVING IT
35
ANNEXURE-I
List of Generating Units Covered under Mapping
Studies
Sl No Plant Unit Number STATE Capacity
1 Bhatinda Unit 2 Punjab State Electricity Board 110 MW
2 Khaparkheda Unit 1 Maharashtra State Power Generation Co Ltd 210 MW
3 Kolaghat Unit 3 Maharashtra State Power Generation Co Ltd 210 MW
4 Mettur Unit 1 Tamilnadu Electricity Board 210 MW
5 Nasik Unit 3 Maharashtra State Power Generation Co Ltd 210 MW
6 Panipat Unit 5 Haryana Power Generation Co. Ltd 210 MW
7 IB Valley Unit 1 Orissa Power Generation Co. Ltd 210 MW
8 Lehra Mahaba Unit 1 Punjab State Electricity Board 210 MW
9 Neyveli Unit 3 Neyveli Lignite Co 210 MW
10 Neyveli Unit 7 Neyveli Lignite Co 210 MW
36
Sl No Plant Unit Number STATE Capacity
11 Satpura Unit 7 Madhya Pradesh Electricity Board 210 MW
12 Suratgarh Unit 1 Rajasthan State Electricity Board 250 MW
13 Tuticorin Unit 1 Tamilnadu Electricity Board 210 MW
14 Chandrapur Unit 6 Maharashtra State Power Generation Co Ltd 500 MW
15 Chandrapur Unit 4 Maharashtra State Power Generation Co Ltd 210 MW
16 Koradi Unit 5 Maharashtra State Power Generation Co Ltd 200 MW
17 Bandel Unit 5 West Bengal Power Development Co Ltd 210 MW
18 Bhusawal Unit 3 Maharashtra State Power Generation Co Ltd 210 MW
19 Korba,West Unit 4 Chhattisgarh State Electricity Board 210 MW
20 Ropar Unit 6 Punjab State Electricity Board 210 MW
37
Sl No Plant Unit Number STATE Capacity
21 Ukai Unit 5 Gujarat State Electricity Co Ltd 210 MW
22 North Chennai Unit 1 Tamilnadu Electricity Board 210 MW
23 Gandhinagar Unit 3 Gujarat State Electricity Co Ltd 210 MW
24 Ukai Unit 4 Gujarat State Electricity Co Ltd 200 MW
25 Bokaro Unit 1 Damodar Valley Corporation 210 MW
26 Wanakbori Unit 4 Gujarat State Electricity Co Ltd 210 MW
27 Wanakbori Unit 3 Gujarat State Electricity Co Ltd 210 MW
28 Durgapur Unit 4 Damodar Valley Corporation 210 MW
29 Mejia Unit 1 Damodar Valley Corporation 210 MW
30 Vijayawada Unit 1 Andhra Pradesh Generation Co ltd 210 MW
38
Sl No Plant Unit Number STATE Capacity
31 Kothagudem Unit 10 Andhra Pradesh Generation Co ltd 250 MW
32 Korba,East Unit 6 Chhattisgarh State Electricity Board 120 MW
33 Anpara A Unit 1 Uttar Pradesh Rajya Vidyut Utpadan Nigam Ltd 210 MW
34 Anpara B Unit 5 Uttar Pradesh Rajya Vidyut Utpadan Nigam Ltd 500 MW
35 Obra B Unit 13 Uttar Pradesh Rajya Vidyut Utpadan Nigam Ltd 200 MW
36 Vijayawada Unit 5 Andhra Pradesh Generation Co ltd 210 MW
37 Kothagudem Unit 9 Andhra Pradesh Generation Co ltd 250 MW
38 Rayalseema Unit 1 Andhra Pradesh Generation Co ltd 210 MW
39 Bakreswar Unit 2 West Bengal Power Development Co Ltd 210 MW
40 Parli Unit 3 Maharashtra State Power Generation Co Ltd 210 MW
39
Sl No Plant Unit Number STATE Capacity
41 Raichur Unit 3 Karnataka Power Co Ltd 210 MW
42 Raichur Unit 4 Karnataka Power Co Ltd 210 MW
43 Panipat Unit 3 Haryana Power Generation Co. Ltd 110 MW
44 Kothagudem Unit 8 Andhra Pradesh Generation Co ltd 120 MW
45 Obra A Unit 8 Uttar Pradesh Rajya Vidyut Utpadan Nigam Ltd 100 MW
46 Paricha Unit 3 Uttar Pradesh Rajya Vidyut Utpadan Nigam Ltd 210 MW
47 Paricha Unit 1 Uttar Pradesh Rajya Vidyut Utpadan Nigam Ltd 110 MW
48 Dhuvaran Unit 5 Gujarat State Electricity Co Ltd 140 MW
49 Gandhinagar Unit 2 Gujarat State Electricity Co Ltd 120 MW
50 Wanakbori Unit 1 Gujarat State Electricity Co Ltd 210 MW
40
Sl No Plant Unit Number STATE Capacity
51 Tenughat Unit 2 Tenughat Vidyut Nigam Ltd 210 MW
52 Ukai Unit 1 Gujarat State Electricity Co Ltd 120 MW
53 Panipat Unit 8 Haryana Power Generation Co. Ltd 250 MW
54 Surat Lignite Unit 2 Gujarat Industries Power Company Ltd. 125 MW
55 Sikka Unit 1 Gujarat State Electricity Co Ltd 120 MW
41
ANNEXURE-I Contd
List of States and Generating Units Covered under
Mapping Studies
STATES PLANTS COVERED (Nos)
PUNJAB 3
MAHARASHTRA 8
GUJARAT 11
RAJASTHAN 1
UTTAR PRADESH 6
HARAYANA 3
ANDHRA PRADESH 6
TAMIL NADU 5
KARNATAKA 2
ORISSA 1
DVC 3
WEST BENGAL 2
MADHYAPRADESH 1
CHHATTISGARH 2
JHARKHAND 1
TOTAL 55