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7/31/2019 CenPEEP Activities
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CenPEEP
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CenPEEP
Center forPower Efficiency
&Environmental Protection
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Centre for Power Efficiency & Environmental
Protection
CenPEEPA Symbol of NTPCs Commitment
for
Sustainable Development
&
Successful International Cooperation forimprovement in the field of power generation
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Centre for Power Efficiency & Environmental
Protection
Formation of
CenPEEP?
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Centre for Power Efficiency & Environmental
Protection
GLOBAL ENVIRONMENTAL CONCERNS
United Nations Framework Convention on
Climate Change (UNFCCC)Kyoto Protocol
Sustainable Development
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Centre for Power Efficiency & Environmental
Protection
In June 1992, the United NationsFramework Convention on ClimateChange (UNFCCC) was signed in Rio
de Janeiro. The climate conventionwas the base for international co-operation within the climate change
area. In the convention the climateproblems & its seriousness was
stressed.
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Centre for Power Efficiency & Environmental
Protection
The conventions overall objective wasthe stabilization of greenhouse gasconcentrations in the atmosphereat a
level that would prevent dangerousinterference with the climate system.
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Centre for Power Efficiency & Environmental
Protection
USA was obligated to a cumulativereduction in its greenhouse gas
emissions to 7% below the 1990levels of the greenhouse gases(including carbon dioxide)
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No Access to state-of-art technologies
(New Technology )
Lack of expertiseand agenciesfor perf. evaluationand gap analysis
Lack of system documentation
Training expertise
Lack of resourcesfor implementation & itssustainability
Local (Indian) Power Plants Challengesfor Efficiency Improvement
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CENTREFOR POWER EFFICIENCYANDENVIRONMENTAL PROTECTION
(CenPEEP)win-win strategy at CenPEEP by achieving synergy between Global
environ-mental concerns and Indian utility needs of ComprehensivePerformance improvement
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CENTREFOR POWER EFFICIENCYANDENVIRONMENTAL PROTECTION
(CenPEEP)
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Training &
Technology
Dissemination
Technology
Demonstration
Technology
Selection &
Acquisition
Technology
Transfer
CenPEEP ModelState-of-the art technology & practices for GHG
reduction from existing coal fired power stations and
new power generation capacities
Sustainabilitythrough
Systems & Procedures
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CENTRE FOR POWER EFFICIENCY ANDENVIRONMENTAL PROTECTION
(CenPEEP)
Green Power through Higher Efficiency
Established in 1994 with support of USAID
Institution set-up to implement Indo-US project ofGreenhouse
Gas Pollution Prevention Project (GEP)
CENPEEP is an example of NTPC's concern for environmentalprotection and commitment to SUSTAINABLE POWERDEVELOPMENT IN INDIA
Window for technology transfer to India from developed
world
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CENTREFOR POWER EFFICIENCYANDENVIRONMENTAL PROTECTION
(CenPEEP)
CenPEEP in collaboration with USAID with a mandate toreduce GHG emissionsper unit of electricity generatedby
improving the overall performance of coal-fired power plants in
India.
The Centre functions as a Resource Centre foracquisition,demonstration anddissemination of state-of-the-art technologies
andpractices for performance improvement of coal fired power
plants for the entire power sector of India.
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Guided byAdvisory Board & Executive Committee
GEP
Partners
NTPC
Guj. Gen Co Maha Gen CO
AP Gen CO
PSEB
UPRVUN
WBPDCL Jharkhand
IPGCL
USDOE
NETL
EPRI
TVA GAI
Southern
Research Structural Int.
Domain Experts
CenPEEP
Members from NTPC, USAID and Govt of India,State & Private Power Utilities, industry, research institutes, etc.
CenPEEP Partnership Greenhouse Gas Pollution Prevention Project
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USDOE : US Dept. Of Energy USAID : US Aid for International Development
NETL : National Energy Technology Laboratory
EPRI : Electric Power Research Institute
TVA : Tennessee Valley Authority GAI : GAI Consultant Inc. Southern Research Structural Int.
Domain Experts
CenPEEP Partnership
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CENTREFOR POWER EFFICIENCYANDENVIRONMENTAL PROTECTION
(CenPEEP)
Tasks CenPEEP assists power station in improving the
performance of operating units.
CenPEEP carried out Performance test to fix base
line performance data wherever performance
Guarantee test data is not available
Establishes System of (POG ) Performance
Optimization Group in all NTPC Station & other
SEBs
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CENTREFOR POWER EFFICIENCYANDENVIRONMENTAL PROTECTION
(CenPEEP)
Project Selection Selection of unit / Station is done based on improvement
potential
willingness on part of the utility to initiate the program
Station need to equip it self with additional off line instruments& skills to conduct a Performance improvement program
Performance testing are carried out at the station by CenPEEP
Performance enhancement potential is worked out in the unit
selected and action plan formulated to enhance the efficiency
level on sustainable basis
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CenPEEP program lead to CO2reduction
Successful replication in SEBs: Maharashtra SEB: reported savings of about 4 million tons
of coal & of 5 million tons of CO2 in two years usingCenPEEP tools
UPRVUNL reported reduction in coal consumption by 2.5%
in one year by implementing learning from CenPEEPawareness Programs
0
0.5
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1.5
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2.5
97-
98
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00
00-
01
01-
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02-
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04-
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07
Year
Cumulativ
eReductioninCO2
Emission
(M
illionTones)
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B. Technology Acquisition
Hands-on trainingin US utility
Demonstration inIndia by US expertsupport
Training in India tolarge number ofengineers
Technical Reports
Technology Acquisition
A. Technology / Practices selection
Technology selection in associationTechnology selection in association
withwithUSDOE / TVA / EPRIUSDOE / TVA / EPRI
CriteriaCriteria Relevance to Problem solution &Relevance to Problem solution &
Success possibility in IndiaSuccess possibility in India
US utility experienceUS utility experience Currently not in use in IndiaCurrently not in use in India
Cost effectivenessCost effectiveness
Possibility of USAID support forPossibility of USAID support for
DemonstrationDemonstration
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DISSEMINATION & TRAINING
Dissemination through:Performance OptimisersWorkshopsSeminars
GuidelinesTechnical documentation5000 man-days training provided to
power station engineersTo increase outreach, establishment of
Regional CenPEEPs at NR & ER
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125 Workshopson Boiler & Turbine Analysis &Performance Improvement; Diagnostics andKnowledge Based Maintenance
14000 Training man days - Participants fromNTPC, DVC, GSCEL, UPRUVNL, TNEB,APGENCO, PSEB, RRUVNL, MSEB, IPGCL etc.
319 Demonstrations - Hands-on training
Guidelineson Thrust areas
Papersat various conferences
Customized training programsorganized at SEBsas per their needs
Widespread
Dissemination
Quarterly newsletter
Optimisersavailable on NTPC website
Supported by 48 US team visits of over 1050 man days
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GHG reduction through Systems of
POG-H & POG-A
Implementation of Optimization program.
Involvement of all concerned at projectlevel
Continued motivation
Performance optimization Group (POG) is
the answer
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Performance Optimisation Group- Heat Rate
(POG-H)
POGs Groups are the forum or structure of
lateral communication: more effective the
communication, more successful is the Program
Performance Optimisation Group- Availability
(POG-A)
Established at all the Stations All relevant executives discuss the performance,
tests and their results
Group defines the action plan for optimisation
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Plant Performance Optimization Approach
Best Efficiency &
Lowest GHG emission
HR
Unit availability
Boiler Turbine
Air Pre Htrs.
Mills & Burners Condenser & CW System
HP& IP Turbine
BFP & HP/LPHeaters
Boiler Pressureparts
Coal handling system Gen; X-mer & switchyard
Human Element
Methodology
Identify major problemareas of degradation
Evaluation of
effectiveness ofimprovement activities
Focus on eachsub-system &component
Health of each
componentdetermineshealth of theequipment
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Boiler Performance OptimizationMill Performance test
Clean air flow test
Dirty air flow test
Air heater Performance tests and gap analysis
Burner to burner PF balance tests
High Volume sampling test HVT
Real time measurements & Balancing of air-fuel ratio
Various test Conducted by CenPEEP
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Turbine
Steam Turbine Efficiency test
Turbine Pressure survey
Condenser Performance Test
Condenser Helium leak detection TestCondenser Water Pressure Cleaner
Feed water heater performance
High Energy Drain Passing
On line CW flow measurement
Cooling Tower Performance tests
Various test Conducted by CenPEEP
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Predictive maintenance System and technologies for diagnostics
Reliability Centered Maintenance
Thermodynamic modeling: A tool for Performance analysis
(PEPSE)-
Thermal audit: Accurate assessment of degradationsRisk evaluation & prioritization
Introducing new overhaul practices
Other Activities By CenPEEP
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29CenPEEP is a resource center for Plant performance optimization, Diagnostics & Solutions
Benefits
Significant GHG reduction
Fuel Savings in power sector
Reliability Improvement
Grass Root Interventions
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LOSSES
IN
POWER STATION
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Concept of loss
A thermal power station consists of Boiler : converts chemical to heat energy.
Turbine : Converts heat to mechanical energy
Generator : Converts mechanical to electricalenergy
Auxiliaries : Electrical to mechanical energy
Any energy conversion associated with
energy loss. This loss may be in the form offriction, heat, magnetic etc.
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BoilerCycle
UnitAuxiliaries
Netelectricoutput
Typical Plant Losses
13%
56% (49%)
8%(3%)
100%
Heatinput 87% 38% 35%
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Boiler loss
A boiler generally encounters followinglosses.
Exit loss or dry flue gas loss.
Wet flue gas loss
Moisture in combustion air
Unburnt gas loss
Combustible in ash
Radiation and unaccounted loss.
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Exit loss or dry flue gas loss Fuel burns in the combustion chamber at very high
temperature. The produced flue gas exchangeheat to super heaters, economizer, air pre heatersand finally comes out at a temperature of about140 deg C.This is in order to strike a balancebetween economy of heat exchange as well as toavoid end corrosion.
The exit flue gas contains mixture of CO2, O2, N2 &CO all at exit temperature and left exhaust to
atmosphere. This resulting a huge heat energy loss.
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Wet flue gas loss
The fuel contains inherent moisture andhydrogen. Combustion of hydrogen producewater. The wet flue gas loss is due to heatabsorption by this moisture/ water forvaporization.
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Moisture in combustion air
The ambient air contains moisture. This
moisture also carries away latent and
sensible heat from the system
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Unburnt gas loss
Though excess air is administered in thecombustion chamber, due to nonhomogeneous mixture and rarifaction in
combustion space, CO gets produce and goesout at exit, taking away the heat value of thegas.
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Combustible in ash loss
The retention time of a coal particle inside thecombustion chamber is in the order of 3 sec. Ifthe particle size is bigger, or the combustionatmosphere is having shortage of oxygen it
does not burnt completely and drops downwith ash particle. Similarly smaller un burntparticle carries away with fly ash.
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Radiation & unaccounted loss
Radiation loss varies with boiler size and load asshown in the figure.
Radiation loss is given by = log10 B = 0.8167 0.4238 log10Cwhere B = radiation and unaccounted loss and C = specific
boiler capacity in kg/s
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Boiler loss calculation- anexample
Fuel firing rate = 5599.17 kg/hr
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Steam generation rate = 21937.5 kg/hr
Steam pressure = 43 kg/cm2(g)
Steam temperature = 377oC
Feed water temperature = 96oC
%CO2 in Flue gas = 14
%CO in flue gas = 0.55
Average flue gas temperature = 190oC
Ambient temperature = 31oC
Humidity in ambient air = 0.0204 kg / kg dry air
Surface temperature of boiler = 70oC
Wind velocity around the boiler = 3.5 m/sTotal surface area of boiler = 90 m
2
GCV of Bottom ash = 800 kCal/kg
GCV of fly ash = 452.5 kCal/kg
Ratio of bottom ash to fly ash = 90:10
Fuel Analysis (in %)
Ash content in fuel = 8.63
Moisture in coal = 31.6
Carbon content = 41.65
Hydrogen content = 2.0413
Nitrogen content = 1.6
Oxygen content = 14.48
GCV of Coal = 3501 kCal/kg
The data collected arefor a boiler using coalas the fuel.
Find out the boilerefficiency by indirectmethod.
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Boiler efficiency by indirect method
Step1 Find theoretical air
requirement
Theoretical air required for
complete combustion
= [(11.43 x C) + {34.5 x (H2O2/8)} + (4.32 x S)] /
100 kg/kg of coal
= [(11.43 x 41.65) + {34.5 x (2.041314.48/8)} +
(4.32 x 0)] / 100
= 4.84 kg / kg of coal
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Step2 Find theoretical CO2 %
% CO2 at theoretical condition( CO2 )t
=Moles of C
Moles of N2 + Moles of C
Where,
Moles of N2 =
4.84 x 77/100 0.016
+ = 0.133228 28
Where moles of C = 0.4165/12 = 0.0347
( CO2 )t =
0.0347
0.1332 + 0.0347
= 20.67
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Step3 To find Excess airsupplied
Actual CO2 measured in flue gas = 14.0%
% Excess air supplied (EA) = 7900 x [ ( CO2)t(CO2)a]
(CO2)a x [100 (CO2)t ]
= 7900 x [20.67 14 ]
14a x [100
20.67]
= 47.44 %
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Step 4 to find actual mass of air supplied
Actual mass of air supplied = {1 + EA/100} x theoretical air
= {1 + 47.44/100} x 4.84
= 7.13 kg/kg of coal
Step5 to find actual mass of dry flue gasMass of dry flue gas consists of Mass of CO2 +Mass of N2 content in the fuel+ Mass
of N2 in the combustion air supplied + Mass of
oxygen in combustion air supplied
Mass of dry flue gas = 0.4165 x 44 7.13 x 77 (7.13-4.84) x 23+ 0.016 + +
12 100 100
= 7.562 kg / kg of coal
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Step
6 to find all losses
1. % Heat loss in dry flue gas (L1) = m x cp x (TfTa )
x 100GCV of fuel
=7.562 x 0.23 x (190
31)
x 1003501
L1 = 7.89 %
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2. % Heat loss due to formation
of water from H2 in fuel (L2)
= 9 x H2 x {584 + Cp (TfTa )}
x 100
GCV of fuel
=
9 x .02041 x {584 + 0.45(190-31)}
x 100
3501L2 = 3.44 %
3. % Heat loss due to moisture in
fuel (L3)
=
M x {584 + Cp ( TfTa )}
X 100
GCV of fuel
=0.316 x {584 + 0.45 ( 190
31) }
x 100
3501
L3 = 5.91 %
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4. % Heat loss due to moisture in
air (L4)
=AAS x humidity x Cp x (TfTa ) x 100
GCV of fuel
=
7.13 x 0.0204 x 0.45 x (190 31) x 100
3501
L4 = 0.29 %
5. % Heat loss due to partial
onversion of C to CO (L5)
=%CO x %C 5744
x x 100
% CO + (% CO2)a GCV of fuel
=
0.55 x 0.4165 5744
x x 1000.55 + 14 3501
L5 = 2.58 %
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6. Heat loss due to radiation andonvection (L6)
= 0.548 x [ (343/55.55)4 (304/55.55)
4] + 1.957 x
(343 - 304)1.25
x sq.rt of [(196.85 x 3.5 + 68.9) /
68.9]
= 633.3 w/m2= 633.3 x 0.86
= 544.64 kCal / m2
otal radiation and convection
oss per hour
= 544.64 x 90
= 49017.6 kCal
% radiation and convection loss = 49017.6 x 100
3501 x 5591.17L6 = 0.25 %
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7. % Heat loss due to unburnt in fly ash
% Ash in coal = 8.63
Ratio of bottom ash to fly ash = 90:10
GCV of fly ash = 452.5 kCal/kg
Amount of fly ash in 1 kg of coal = 0.1 x 0.0863
= 0.00863 kg
Heat loss in fly ash = 0.00863 x 452.5
= 3.905 kCal / kg of coal
% heat loss in fly ash = 3.905 x 100 / 3501
L7 = 0.11 %
8. % Heat loss due to unburnt in fly ash
GCV of bottom ash = 800 kCal/kg
Amount of bottom ash in 1 kg of
oal
= 0.9 x 0.0863
= 0.077 kg
Heat loss in bottom ash = 0.077 x 800
= 62.136 kCal/kg of coal
% Heat loss in bottom ash = 62.136 x 100 / 3501
L8 = 1.77 %
Boiler efficiency by indirect = 100 (L1+ L2+ L3+ L4+ L5+ L6+ L7+ L8)
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y ymethod
( 1 2 3 4 5 6 7 8)
= 100-(7.89 + 3.44+ 5.91+ 0.29+ 2.58+ 0.25+0.11+1.77)
= 100-22.24
= 77.76 %
Summary of Heat Balance for Coal Fired Boiler
Input/Output Parameter kCal / kg of
coal
% loss
Heat Input = 3501 100Losses in boiler
1. Dry flue gas, L1 = 276.23 7.89
2. Loss due to hydrogen in fuel, L2 = 120.43 3.44
3. Loss due to moisture in fuel, L3 = 206.91 5.91
4. Loss due to moisture in air, L4 = 10.15 0.29
5. Partial combustion of C to CO, L5 = 90.32 2.58
6. Surface heat losses, L6 = 8.75 0.25
7. Loss due to Unburnt in fly ash, L7 = 3.85 0.11
8. Loss due to Unburnt in bottom ash,L8
= 61.97 1.77
Boiler Efficiency = 100 (L1 + L2+ L3+ L4+ L5+ L6+ L7+ L8) = 77.76 %
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Boiler Losses Typical values (%)Dry Gas Loss 5.21
Unburnt Loss 0.63
Hydrogen Loss 4.22
Moisture in Fuel Loss 2.00Moisture in Air Loss 0.19
Carbon Monoxide Loss 0.11
Radiation/Unaccounted Loss 1.00
Boiler Efficiency 86.63
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Boiler Efficiency values (%) Tur. HR UHRStage-I 87.58 2021.0 2308
Stage-II 87.77 1947.6 2220
Stage-III 85.14 1944.6 2284
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TURBINE
LOSSES
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A Turbine experiences the
following losses.
1. External Losses
2. Internal Losses
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Turbine External Losses
Shaft gland leakage Losses
Journal & thrust bearing losses
Oil pump losses
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Turbine Internal Losses
Friction lossStationary blades
Moving blades
Eddy Loss
Moving blades
Windage Loss
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Generator Losses
Generator efficiency is very high. Howeverfollowing are the loss component whichare practically insignificant compared to
boiler and turbine loss. Friction & windage loss.
Hysterisis & eddy current loss
Copper loss.
Losses from auxiliary
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Losses from auxiliaryconsumption
Typically auxiliary consumption of a thermalpower station is 8 to 10 % of the normalcontinuous rating.
The major consumption is by electric drivenBFP, ID, FD, Mills and Cooling water pumps.
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Loss estimation method
Direct Loss = Input energy Output energy. In case
of Boiler, input energy is fuel, andmeasurement of fuel with availabletechnology limitation is a major source oferror.
Indirect
Input = Losses + Output. Error in lossmeasurement with available technique is less.Therefore this method is used world wide.
Direct Method of loss
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Direct Method of lossestimation
BoilerFuel Input 100%
+ Air
SteamOut
put
Efficiency = Heat addition to Steam x 100
Gross Heat in Fuel
Flue
Gas
Water
100valuecalorificGrossxratefiringFuel
enthalpy)waterfeedenthalpy(steamxrateflowSteamxEfficiencyBoiler
Indirect Method of loss
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Indirect Method of lossestimation
Boiler Flue gas sample
Steam Output
Efficiency = 100 (1+2+3+4+5+6+7+8) (by Indirect Method)
Air
Fuel Input, 100%
1. Dry Flue gas loss
2. H2 loss
3. Moisture in fuel
4. Moisture in air
5. CO loss
7. Fly ash loss
6. Surface loss
8. Bottom ash loss
Water
Blow down
P f G (T i l H R L )
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Performance Gaps (Typical Heat Rate Losses)
Assessment of the performance gaps is the first step to improvement
Condenser & CTs (31%)
Turbine HP/IP (19%)Dry Flue Gas Loss (16%)
Unaccountables (20%
RHSpray (7%)
Others (7%)
Combustion Optimization
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Combustion Optimization
NON- UNIFORMAir-fuel ratio in Four Corners
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NON UN O
Non optimum
combustion
Higher fuel
consumption
Higher CO2
UNIFORM
Optimum
combustion
Lower fuel
consumption
Lower CO2
Coal Pipes Bad Flame
Good Flame
Steam Condenser Lower Steam Flow
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Steam CondenserLower
Vacuum
Lower Steam Flow
Condensate
Dirty TubesCooling Water
Inlet
Outlet
Non-Optimized condition
Air-in leaks
Lower vacuum
Dirty tubes
Lower generation
(MW)
Higher fuel
consumption
Higher CO2emission
Steam Condenser Higher Steam Flow
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Steam Condenser Higher Steam Flow
Condensate
Clean TubesCooling Water
Inlet
Outlet
More generation
(MW) Low fuel
consumption
Low CO2
emission
Optimized condition
No air-in leaks(High vacuum)
Clean tubes
High
Vacuum
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Condenser Tube Cleaning byWater Powered Cleaners (CONCO)
Water Powered Gun used to push bullets (scrapper)
to clean condenser tubes;
Most effective and low cost technology
Valve Passing
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>150.0C
#3 >#1
Effective method to identify valve leakage & repair.
Losses due to Valves are unaccountable loss
Temperature as per Colour Scale
ESP Performance Enhancement
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ESP Performance Enhancement
Challenges
High ash coals
High ash resistively due
to low sodium andsulpher
Silica & alumina >90%
making flue gas
conditioning difficult.
High flue gas
temperatures reducing
ESP efficiency
Flue gas conditioning by:
Water Fogging(Changing physical
characteristics)
Sodium sulphate dosing
(Changing chemical
characteristics)
Activities
Addressing the ash resistivity
Particulate Collection Enhancement by Water fogging
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Particulate Collection Enhancement by Water fogging
Fog at different water-air Pressure
Significant reduction in particulate emission
Change of Physical Characteristics
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Conclusion
CenPEEP is considered as one of the most successfulbilateral projects of USAID by US administration.
Economic selection and acquisition of state-of-the-arttechnologies
Demonstration & fusion of these technologies withlocal requirements
Wider dissemination with a systems approach.
Best Approach for Environmental Protection
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Thank You
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