sustainable performance improvement in thermal power plants · 2019-03-14 · cenpeep sustainable...
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CenPEEP
Sustainable Sustainable Performance ImprovementPerformance Improvement
in Thermal Power Plantsin Thermal Power Plants
Center for Power Efficiency & Environmental Protection (CenPEEP)
Feb 20, 2009
D.K. Agrawal GM (CenPEEP) NTPCM.K.S. Kutty DGM (CenPEEP) NTPC
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CenPEEP
• To meet the Challenges in the Competitive Environment a utility needs to have continued improvement in Operating Efficiency.
• Efficiency Improvement also addresses environmental concerns by reducing GHG emissions.
• It leads to better availability and improved profit margin.
Importance of Performance Improvement
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CenPEEP
• Having the Margins Available Stations can Substantially Contribute to meet the Peaking Requirement.
• Study by CEA on 56 stations covering a capacity of 38600 MW shows operating HR deviations in the range of about 19.3%.
• Substantial Improvement Potential is Available Even in the Best Run Stations (as per CEA study deviation in HR of some of the best operating stations ranges from 2.05% to 3.60%.
Importance of Performance Improvement
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CenPEEP
An average increase of 1% in Efficiency across Indian Power Utilities would result in:
• Coal savings of approx. 11 million tons per annum
• Cost savings worth Rs.16,100 Million ($ 350 Million)
• 3% CO2 reduction per annum (approx.13.5 million tons per annum)
• Higher productivity from the same resources is equivalent to capacity addition
• Lower generation cost per kWh
Impact of Efficiency Improvement Indian Scenario
Installed Capacity (31.12.2008) – 1,47,403 MWThermal – 93393 MW (Coal 77459, Gas 14734, Oil 1200)
Data source:CEA
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CenPEEP
CenPEEP Role CenPEEP Role &&
MethodologyMethodology
Performance Improvement Activities
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CenPEEP
Global ConcernsGlobal Concerns• GHG Emissions / warming• Emissions from coal usage• Sustainable growth
Utility ConcernsUtility Concerns• Efficiency improvement• Availability improvement • O&M costs - Profitability
Center for Power Efficiency & Environmental Protection (CenPEEP)
CenPEEP
Established by NTPC in collaboration with USAID with a mandate to reduce GHG emissions per unit of electricity generated by improving the overall
performance of coal-fired power plants.
The Centre functions as a Resource Centre for acquisition, demonstration & dissemination of state-of-the-art technologies and practices for performance improvement of coal fired power plants for the entire power sector of India.
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CenPEEP
GEPPartners
• USDOE• NETL• EPRI• TVA• GP• Storm Tech.• Structural Int.• Domain Experts
CenPEEP
CenPEEP Partners
Guided byGuided byAdvisory Board & Executive CommitteeAdvisory Board & Executive Committee
Consisting of NTPC, USAID and members from Govt of India, State & Private Power Utilities, industry association, research institutes, etc.
• NTPC• Guj. Gen Co• Maha Gen Co• AP Gen Co• PSEB• UPRVUN• WBPDCL• MPGENCO• IPGCL
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CenPEEP
Training &Technology
Dissemination
TechnologyDemonstration
TechnologySelection &AcquisitionTechnology
Transfer
CenPEEP Approach
State-of-the art technology & practices for GHG reductionStateState--ofof--the art technology & practices for GHG reductionthe art technology & practices for GHG reduction
Knowledge is not enough, implementation brings real benefitKnowledge is not enough, implementation brings real benefit
Sustainability Sustainability through through
Implementation ofImplementation ofSystems & Systems & ProceduresProcedures
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CenPEEPPlant Performance Optimization
Better EfficiencyLower Emissions• Focus on each
sub-system & component
• Health of each component determines health of the equipment
HR
Unit availability
Boiler Turbine
Air Pre Htrs.
Mills & Burners Condenser & CW System
HP& IP Turbine
BFP & HP/LPHeaters
Boiler Pressure parts
Coal handling system Gen; X-mer & switchyardHuman Element
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CenPEEP
Performance EvaluationPerformance Evaluation
Performance Performance OptimisationOptimisation
Recovery of Efficiency LossRecovery of Efficiency Loss
Sustainability through Sustainability through InstitutionalisationInstitutionalisationof Programof Program
Approach for sustainable improvement of Performance of power plants
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CenPEEP
• Performance tests techniques using high accuracy test instruments Boiler efficiency, HP/IP efficiency, Condenser, HP/LP heaters, BFP
• Computational software for tests
• High Velocity Thermocouple (HVT)
• Dirty pilot kit• Helium Leak detection
Condenser air-in-leak detection• Water powered cleaners for Condenser tubes• CW Flow measurement & Cooling Tower
performance optimization
• Eddy current Induction heating
• IR Thermography & Acoustics as diagnostics technologies
Low Cost, High benefit Techniques Demonstrated
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CenPEEPTypical HR Loss Areas
Indian Power Plants
High loss category (20-60 kcal/kWh)Dry Flue Gas Loss Condenser Unaccountable
Medium loss category(10-20 kcal/kWh)• HP/IP Turbine• RH Spray • Cooling TowerLow loss category (<10 kcal/kWh)• Unburnt Loss• MS & HRH Temperature deviations• Feed water Temperature deviations
Typical Break Up of HR Losses
RH Spray,9%
Turbine (HP & IP),19%
Condenser,15%
Dry Flue Gas Loss,
16%
Others,5%Cooling
Tow er,16%
Unaccountables,20%
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CenPEEPThrust Areas - Condenser
Major Concerns• Tube Fouling• Air Ingress• High CW Inlet temperature• High Heat Load
Remedial Measures• Regular & Effective Tube Cleaning• On-line Assessment of Air Ingress• Better Performance of Cooling Tower• Monitoring of High Energy Drains passing
WATER
TUBE
WATER
STE
AM
TUBE
FOULEDSURFACE
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CenPEEPApproach For Condenser Performance Improvement
Say O/H O/H
15 mm HG(~ 30 kcal/kWh)
12 mm HG
30 mm HG (~ 60 kcal/kWh)(no cleaningbetween OH)
MiddleApril Oct Apr Next Yr
Effective Condenser tube cleaningduring opportunity S/D – 12 mm HG
improvement
18 mm HG (~ 36 kcal/kWh)(cleaningbetween OH)
22.5 mm HG10.5 mm HG2nd half average loss
6 mm HG (~12 kcal/kWh)Net Improvement
15 mm HG9 mm HGAverage loss for the year
7.5 mm HG7.5 mm HG 1st half average loss
Without cleaningWith CleaningDescription
3 mm HG
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CenPEEP
Improved Heat Transfer• Clean boiler surface and Air Heater
baskets during Boiler overhauls• Optimized Soot blowing & LRSB
operation• Replacement of AH Baskets, seals &
sector plates• Coal burners & PF pipe orifices• Excess air Optimization• Minimize Tempering Air • Representative Measurements• Reduction in Air Ingress
Thrust Areas - Dry Flue Gas Loss
O2 & temp sensors relocated / increased at many stations for better feedback & control
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CenPEEPMapping of oxygen % in flue gas path
Oxygen in Flue Gas (%) - 200 MW (Aug 08)
0
1
2
3
4
5
6
7
8
Furnace Exit Eco Outlet AH Inlet AH Outlet ID Fan Outlet
Eroded gas ducts, expansion joints & hoppers cause air ingress in boilers
‘What can not be measured can not be saved’
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CenPEEP
• 125 Workshops on Boiler & Turbine Performance Analysis & Improvement; Diagnostics and Knowledge based Maintenance
• 14000 Training man days - Participants from NTPC, DVC, GSCEL, UPRUVNL, TNEB, APGENCO, PSEB, RRUVNL, MSEB, IPGCL etc.
• 319 Demonstrations - Hands-on trainings
• Guidelines on Thrust areas
• Papers at various conferences
• Dissemination of new techniques through ‘Optimisers’
• Customized training programs organized at SEBs as per their needs
Quarterly newsletter
Optimisersavailable on NTPC website
Capability BuildingCapability BuildingNational LevelNational Level
It’s important to capture & share the O&M Expertise & ExperienceIt’s important to capture & share the O&M Expertise & Experience
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CenPEEPPerformance Improvement Potential
Typical Case StudyTypical Case Study
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CenPEEP
Expected kcal/kwh
Actual Kcal/kwh
Total losses Kcal/kwh
Losses Million Rs
1957 2094 137 76.9 ($1.7 million)
Acountable Losses
106 --- 59.5 ($1.3 million)
Unaccoun- table losses
31 --- 17.4 ($0.4 million)
Gross Turbine Cycle Heat Rate (GTCHR)Gross Turbine Cycle Heat Rate (GTCHR)
Case Study - Turbine & AuxiliariesPotential demonstrated in a 210 MW Unit
Glow Sign : Some Utilities have very low losses
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CenPEEP
Accountable Losses Accountable Losses –– 106.2 kcal/106.2 kcal/kwhkwh
Description Loss kcal/kwh
Loss Million Rs
Cond. Vac. 28 15.7
HP Turbine Eff. 19.41 10.9 IP Turbine Eff. 10.74 6.1 HP Heater 5 & 6 30.8 17.3
RH Spray 11.58 6.5
Case Study - Turbine & Auxiliaries Potential demonstrated in a 210 MW Unit
Unaccountable Losses 30.8 kcal/Unaccountable Losses 30.8 kcal/kwhkwhCauses - Passing of High Energy Drains, L.P. Turbine Performance, L.P. Heaters, Uncertainty of Instruments
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CenPEEP
Awards & RecognitionsAwards & Recognitions
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CenPEEP
CTI’s World CTI’s World Climate Climate
Technology Technology Award 2002Award 2002
USEPA USEPA CLIMATE CLIMATE
PROTECTION PROTECTION AWARD 2003AWARD 2003
Awards & RecognitionsAwards & Recognitions
CenPEEP IS A SYMBOL OF SUCCESSFUL INTERNATIONAL COOPERATION FOR GHG REDUCTION
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CenPEEP
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CenPEEP
• High Potential for Efficiency Improvement in Some Plants
• Potential for Efficiency Improvement even in Best Run Plants
• Correct Performance Assessment is an Essential Pre-requisite
• Focus on Individual Equipment Degradations
• High Benefits with limited Investment
• Quantum Improvements Through Replacement & Upgrades
• Sustainable Performance Improvements Through Testing and Establishing Optimum Regimes of Operation
In Conclusion
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CenPEEP
Thanks