Performance ImprovementPerformance ImprovementPerformance Improvement Performance Improvement inin

Indian CoalIndian Coal--fired Power Plantsfired Power PlantsIndian CoalIndian Coal--fired Power Plantsfired Power Plants

Thermal Power India – 4India Habitat Centre, New Delhi

28-29 January, 2010

D.K. AgrawalGeneral Manager I/c

Centre for Power Efficiency & Environmental Protection Centre for Power Efficiency & Environmental Protection (CenPEEP)(CenPEEP)

CoverageCoverage

i. Importance of Efficiency and Availability

ii CenPEEP: brief overviewii. CenPEEP: brief overview

iii. CenPEEP: initiatives for Performance Improvement & Emission ReductionEmission Reduction

iv. Opportunities

Indian Power Sector OverviewIndian Power Sector OverviewA M t iAge Matrix

Age of Coal Fired Generating Capacity:MWg g p y> 41 years, 3,001MW,

4%

31-40 years,

6,095 MW, 9%

0-10 years, 17 91421-30 17,914

MW, 25%

11-20 Years

years, 21,468

MW, 30%Years, 23,024

MW, 32%Source: Platts UDI, June 2008Source: Platts UDI, June 2008

Capacity addition target (2007-12): 78,577 MW (Source: The National Electricity Policy, Annual Report 2007-08, Ministry of Power, GOI )

Current energy shortage 9.8%gy g Per capita consumption 704 kWh (2007) Coal to remain mainstay of capacity addition (2007-12: 58,644 MW)

Plant Performance Indices: Heat Rate (HR)Plant Performance Indices: Heat Rate (HR)

HR of Coal fired power plant: measure of efficient conversion of chemical energy (fuel) into electrical energy

Plant Performance Indices: Heat Rate (HR)Plant Performance Indices: Heat Rate (HR)

of chemical energy (fuel) into electrical energy.

If a power plant operates at 100% efficiency, the heat rate will b 860 k l/kWhbe 860 kcal/kWh.

Currently, a state-of-art power plant has a design HR of 2100 y, p p g- 2200 kcal/kWh i.e. about 39 - 41% efficient.

Indian power sectorIndian power sector1% increase in Efficiency would result in• Coal savings of approx. 12 million tons per annumg pp p• Rupees savings worth Rs.19,000 Million per annum• CO2 reduction per annum approx.14 million tons

Energy Efficiency DriversEnergy Efficiency Drivers

R d d GHG E i i & C ti f N t l R

Energy Efficiency DriversEnergy Efficiency Drivers

Reduced GHG Emissions & Conservation of Natural Resources

Increased Capacity

Reduced Cost of Generation

Increased Competitivenessp

Ease of compliance to New Regulatory Norms

Efficiency Monitoring: Early Diagnosis and effective Efficiency Monitoring: Early Diagnosis and effective maintenance planning

Cost effective solutions for Thermal performance improvementCost effective solutions for Thermal performance improvement

Typical HR Loss AreasTypical HR Loss AreasI di P PlI di P PlIndian Power PlantsIndian Power Plants

High-loss category (20-60 kcal/kWh)High loss category (20 60 kcal/kWh) Dry Flue Gas Loss Condenser

Typical Break Up of HR LossesDry Flue

Gas Loss,16%

Others,5%Cooling

UnaccountableMedium-loss category(10-20 kcal/kWh) HP/IP Turbine

Condenser,15%

16%Tow er,

16%

HP/IP Turbine RH Spray Cooling Tower

15%

Unaccountables,20%

Low-loss category (<10 kcal/kWh) Unburnt Loss

MS & HRH T t d i ti

RH Spray,9%

Turbine (HP & IP),19%

20%

MS & HRH Temperature deviations Feed water Temperature deviations

A A ““Win Win –– WinWin”” StrategyStrategy

Gl b l CGl b l C Utility ConcernsUtility Concerns

gygy

Global ConcernsGlobal Concerns• GHG Emissions / warming• Emissions from coal usage

Utility ConcernsUtility Concerns• Efficiency improvement• Availability improvement

• Sustainable growth • O&M costs - Profitability

CenPEEP

Established by NTPC in collaboration with USAID in 1995 to reduce GHG

Th C t f ti R C t f i iti d t ti & di i ti

yemissions from coal-fired power plants.

The Centre functions as a Resource Centre for acquisition, demonstration & disseminationof state-of-the-art technologies and practices for performance improvement

CenPEEP PartnersCenPEEP Partners

In 1995 agreed toIn 1995, agreed to establish

• NTPC• Guj. GenCo• Maha GenCo

• USDOE• NETL

CenPEEP

To implement G h G

• AP GenCo• PSEB• UPRVUN

• EPRI• TVA • USEA

Greenhouse GasPollution

Prevention (GEP) Project

• WBPDCL• MPGENCO• IPGCL

• General Physics• Storm Tech• Structural Int. (SI)

• TNEB • Domain Experts

Guided byGuided byAdvisory Board & Executive CommitteeAdvisory Board & Executive Committee

CenPEEP ApproachCenPEEP Approach

StateState--ofof--the art technology & practices for GHG reductionthe art technology & practices for GHG reductionStateState--ofof--the art technology & practices for GHG reductionthe art technology & practices for GHG reduction

Technology SustainabilitySustainabilitygySelection &Acquisition

Technology

Sustainability Sustainability through through

Implementation ofImplementation ofSystems &Systems &

Training &TechnologyTechnology

TechnologyTransfer

Systems & Systems & ProceduresProcedures

Technology DisseminationDemonstration

Knowledge is not enough, implementation brings real benefitKnowledge is not enough, implementation brings real benefit

SubSub--System wise System wise Simplified Performance Testing Simplified Performance Testing

Approach is to introduce userApproach is to introduce user friendly systems,

demonstration finalization ofdemonstration, finalization of Procedures / Guidelines& dissemination to all& dissemination to all

‘Whatever is convenient, will only be replicated’‘Whatever is convenient, will only be replicated’

LowLow--Cost, HighCost, High--Benefit Benefit Techniques DemonstratedTechniques Demonstrated

Performance tests techniques using high-accuracy test instruments B il ffi i HP/IP ffi i C dBoiler efficiency, HP/IP efficiency, Condenser, HP/LP heaters, BFP

Use of portable DAS High Velocity Thermocouple (HVT) Dirty pitot kit H li L k D t t Helium Leak Detector

Condenser air-in-leak detection

Water-powered cleaners for Condenser tubesWater powered cleaners for Condenser tubes CW flow measurement & cooling tower

performance optimization IR Thermography & Acoustics as diagnostic

techniques Eddy Current Induction heating y g

Periodic Mapping of Oxygen % in Flue Gas Path Periodic Mapping of Oxygen % in Flue Gas Path an easy way to quantify increase in Air Ingressan easy way to quantify increase in Air Ingress

Eroded gas ducts, i j i t &expansion joints &

hoppers cause air ingress in boilers

Oxygen % at various locations in boiler

8

10

• Air ingress can be quantified by the increase in oxygen % in flue gas; 2

4

6O

2 %

• Flue gas Temp.drop from air heater outlet to ID fan discharge also provides an indication.

0Furn Outlet AH Inlet AH Outlet ID outlet

210 MW 210 MW 500 MW 210 MW

An Approach for Sustainable ImprovementAn Approach for Sustainable ImprovementEfficiency Management System (EMS)Efficiency Management System (EMS)Efficiency Management System (EMS)Efficiency Management System (EMS)

1. PerformanceEvaluation

4. Building diagnostic &analytical capabilities

Systematic Approach

2. Analysis & Action Plans3. Performance

Improvement P j tProjects

A uniform, simplified system for plant efficiency monitoring, periodic A uniform, simplified system for plant efficiency monitoring, periodic testing, gap assessment, analysis and corrective actions. testing, gap assessment, analysis and corrective actions.

Energy & Efficiency Management System (EEMS)Energy & Efficiency Management System (EEMS)

Development & Implementation of EEMSp p

• Identification of Heat Rate gaps through monthly performance testsp

• Trending performance indices & analysis of equipment degradationsg

• Development of Unit specific HR recovery action plans

R t ti f i t f d i h l• Restoration of equipment performance during overhauls

• Skill / knowledge enhancement through Dissemination k hworkshops

Customized EEMS Document prepared based on learning's at CenPEEP

High Availability & ReliabilityHigh Availability & Reliability((key to sustained Efficiency improvementskey to sustained Efficiency improvements) ) (( y y py y p ))

Availability Improvement

PdM ImprovementsKBM Road-map

Improvement Initiatives

RCM-Living ProgramRisk Screening• Enables Techno-financial decisions for

• Reduction in routine maintenance work (PM)• Overhauling interval extension: motors,

pumps, valves, etc.

Enables Techno financial decisions for efficiency and maintenance actions

• Useful for risk minimization and providing value for maintenance investments

Widespread DisseminationWidespread Dissemination

130 Workshops on Boiler & Turbine Performance Analysis & Improvement; Programs on Diagnostics and Knowledge based Maintenanceand Knowledge based Maintenance

14500 Training man days - Participants from NTPC, DVC, GSCEL, UPRUVNL, TNEB, APGENCO, PSEB, RRUVNL MSEB IPGCL etcRRUVNL, MSEB, IPGCL etc.

325 Demonstrations - Hands-on trainingsGuidelines on Thrust areas like Air Heaters, ‘Boiler Optimisers

available on NTPC websiteAir-in-leakage’ etc.Papers on Sustainable Heat Rate Improvement of

Power Plants and Knowledge based Maintenance at

available on NTPC website

gvarious conferences

Customized training programs organized at SEBs as per their needs p

Supported by 50 US team visits of over 1100 man days

Quarterly newsletterPerformance improvement is a race without goalPerformance improvement is a race without goal--postpost

It is a continuous processIt is a continuous process

Opportunities for Performance Improvement Opportunities for Performance Improvement

• Performance Assessment, Analyses, and Diagnostics St t f t hi h t t i t t d di ti i t State-of-art high-accuracy test instruments and diagnostic equipment

Use of integrate advanced tools, like modeling software for analysis

Performance guarantee test as third party for new units Performance guarantee test as third party for new units

Assessment of scope of renovation & modernization (R&M), guarantees, etc.

• Service Providers for Specialized Repair/Replacement Areap p p Strong need for good service providers for quality and specialized repair and

overhaul services using state-of-the-art tools and equipments

Unit performance optimization after major boiler repair as specialized services

• Problem Analysis/Availability of Experts Hi h d d t l f l t d bl f iti l i t High demand to solve performance related problems of critical equipments

Problems primarily on account of lack of designer insight, over-dependence upon OEM/foreign supplier/collaborator

International / National RecognitionsInternational / National Recognitions

CTI’s World Climate Technology Award by CTI/IEA-Paris (2002)

International Gold Star for Quality Award by BID International- Madrid (2009)

CTI’s World Climate Technology Award by USEPA Climate Protection Award India Power Award by Council of CTI/IEA-Paris (2002)(2003 )

yPower Utilities, India (2008)

“Small opportunities are often the beginning of great enterprises”