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

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

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

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 Role CenPEEP Role &&

MethodologyMethodology

Performance Improvement Activities

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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.

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

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

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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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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• 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

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%

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

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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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

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’

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

CenPEEPPerformance Improvement Potential

Typical Case StudyTypical Case Study

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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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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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Awards & RecognitionsAwards & Recognitions

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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

CenPEEP

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

CenPEEP

Thanks