NTPC Initiatives on Efficiency & Power Plant Performance

A Maharatna Company

“NTPC Initiatives on Efficiency & Power Plant Performance Improvements”Plant Performance Improvements

D.K.Jain, Director (Technical), NTPC

Presented by

A.K.Mohindru, GM (NETRA), NTPC

2nd Nov. 2011

NTPC IERE Cancun Mexico 1NTPC IERE Cancun Mexico 1

A Maharatna CompanyPresentation Outline...

A. NTPC Profile

B. Efficiency Improvement Efforts at NTPC

• Super Critical Technology• Artificial Intelligence Based Plant Performance

Optimizer• Waste Heat Recovery from Flue gases

C.Advanced NDE Technologies for Plant Performance Improvements

• Institutional Approach• Institutional Approach• Focus Areas

NTPC IERE Cancun Mexico 2

A Maharatna Company

NTPC Profile


A Maharatna CompanyPower Scenario of India

Total Capacity ( as on 31 Aug. 2011 ): 181558 MW

NTPC IERE Cancun Mexico 4NTPC IERE Cancun Mexico 4

A Maharatna CompanyPan India Presence

Geographical spread of generating facilities

KOLDAM(800 MW)KOLDAM(800 MW)

JVs, 3364 Northern,

Eastern 7900

FARIDABAD(430 MW)FARIDABAD(430 MW)

DADRI(817 MW)DADRI(817 MW)

NCTPP(1,820 MW)NCTPP(2,310 MW)

AURAIYAUNCHAHAR(1 050 MW)UNCHAHAR(1 050 MW)

TANDA(440 MW)TANDA(440 MW)

KAHALGAONKAHALGAON

(800 MW)(800 MW)

TAPOVAN VISHNUGAD(520 MW)TAPOVAN VISHNUGAD

(520 MW)

LOHARINAG PALA(600 MW)LOHARINAG PALA

(600 MW)

BTPS(705 MW)BTPS(705 MW)IGSTPP(1,500 MW)IGSTPP(1,500 MW)

5490

NCRSouthern,

4450

Eastern, 7900

RIHAND(3,000 MW)RIHAND(3,000 MW)SINGRAULI

(2,000 MW)SINGRAULI(2,000 MW)

ANTA(413 MW)ANTA(413 MW)

AURAIYA(652 MW)AURAIYA(652 MW)

(1,050 MW)(1,050 MW) KAHALGAON(2,340 MW)KAHALGAON(2,340 MW)

FARAKKA(2,100 MW)FARAKKA(2,100 MW)

KORBAKORBA

VINDHYACHAL(4,260 MW)VINDHYACHAL(4,260 MW)GANDHAR

(648 MW)GANDHAR(648 MW)

BARH3,300 MWBARH3,300 MW

BONGAIGAON(750 MW)BONGAIGAON(750 MW)

( ,500 )( , )

DURGAPUR( )DURGAPUR(120 MW)

ROURKELAROURKELA(120 MW)

NABINAGAR(1,000 MW)NABINAGAR(1,000 MW)

NCR, 4837Western,

8813

4450

KORBA(2,600 MW)KORBA(2,600 MW)KAWAS

(645 MW)KAWAS(645 MW) TALCHER KANIHA

(3,000 MW)TALCHER KANIHA(3,000 MW)

RAMAGUNDAM(2,600 MW)RAMAGUNDAM(2,600 MW) SIMHADRI

(2 000 MW)SIMHADRI(2 000 MW)

TALCHER Thermal(460 MW)TALCHER Thermal(460 MW)

SIPAT2,980 MWSIPAT2,980 MW

MAUDA(1,000 MW)MAUDA(1,000 MW)

RGPPL(1480 MW)RGPPL(1480 MW)

(120 MW)(120 MW)BHILAI574 MWBHILAI574 MW

(120 MW)(120 MW)

No. of plants

Capacity MW

NTPC Owned(2,000 MW)(2,000 MW)

VALLUR(1 500 MW)VALLUR(1 500 MW)

GAS POWER STATIONS

COAL POWER STATIONONGOING HYDRO POWER PROJECTS

ONGOING THERMAL PROJECTS

Coal 15 27535Gas/Liquid fuel 7 3955Sub‐Total 22 31490

Note: Capacity includes capacity under construction; Map not to scale

KAYAMKULAM(350 MW)KAYAMKULAM(350 MW)

(1,500 MW)(1,500 MW) ONGOING THERMAL PROJECTS

Owned by JVsCoal & Gas 6 3364Total 28 34854


ota 8 3 85

A Maharatna CompanyIndia’s Premier Power Utility

NTPC IERE Cancun Mexico 6As on 31.3.2011

A Maharatna Company

NTPC – Performing at global levels

500600700

610

422

Electricity Generation Billion Units

100200300400 333 324

289 276 253 231 224 207

0100

Electricité de France

Korea Electric Power

E.On AG RWE AG Tokyo Electric Power

GDF Suez Enel SpA Comision Federal De Electricidad

Eskom Holdings

NTPC

Highest capacity utilization

60%70%80%

78%67%

61% 60% 59% 58% 57% 56% 55%

#

30%40%50%60%

0%10%20%

NTPC Korea Electric

Taiwan Power

Eskom Holdings

Entergy Corp

Datang International

Huaneng Power

Electricité de France

American Electric


Electric Power

Power Holdings Corp International Power France Electric

Source: International Consultant

Data for year 2009# Including gas based CCPP. However as per CEA norms in NTPC we consider PLF of only coal stations

A Maharatna CompanyCapacity Addition by 2017Long Term Corporate Plan prepared for next 21 years upto 128 GW by 2032 to position NTPC as the World’s largest and best power producer and leader in Green Power

NTPC IERE Cancun Mexico 88NTPC IERE Cancun Mexico

A Maharatna CompanyGlobal Stature

Number 1 independent power producer in Asia in 2010 (by Platts, a division of McGraw-Hill companies)

# 1 in the world in capacity utilization# 1 in the world in capacity utilization# 3 in Asia in electricity output and # 10 in the world# 3 in the world in plant availability

10th l t t i th ld10th largest generator in the world

NTPC IERE Cancun Mexico 99NTPC IERE Cancun Mexico

A Maharatna Company

Super-Critical Technology


A Maharatna Company

Sustainable Power Developer

Implementing high efficiency technology NTPC’s 1st 660 MW unit commissioned (Sipat) & under( p )

Commercial operation 7x660 MW (4,620MW) - under construction 9x660 MW (5,940 MW) - under bidding 9x800 MW (7200 MW) - under bidding

NTPC along-with IGCAR & BHEL developing Advanced Ultra-Super-Critical Technology

Renewable & Nuclear Energy forays

Developing Wind and Solar capacities


p g p Anushakti Vidhyut Nigam Ltd. - A JV company with NPCIL

incorporated; Equity – 49%NTPC& 51% NPCIL

A Maharatna Company

– Supercritical Technology –Approximate Increase in Efficiency

8.0

6.5

8 4.3

5.2

3.2

4

6 3.3

2.8

3.62.7

2

4

538/566

566/566

566/593

600/610

1.7

2.5

1.80.5

1.1

0

300 246 169

538/538

538/566

NTPC IERE Cancun Mexico 12Pressure (Bar)

Base case : 500 MW subcritical unit

A Maharatna CompanyAdvantages of USC parameters

2.5% gain over BarhII

1.4 % gain over BarhII

Efficiency Comparison (Assuming Const. Boiler Efficiency=86%)

Higher efficiency resulting in :

• Fuel Savings 38.93

40.24

41.36

40.00

41.00

42.00

ienc

y

g• Lower APC• Reduced CO2• Lower SOx/NOx

38.05

37.00

38.00

39.00

% P

lant

Effi

cLower SOx/NOx

• Smaller BoP 36.00

Sub critical(170/537/537)

Super critical(247/537/565)

247/565/593 USC(310/600/610)

Major advantage of using USC is improved efficiency

NTPC IERE Cancun Mexico 13(More than 15% gain in efficiency over 200 MW Subcritical plants)

A Maharatna Company

Reduction in APC with Steam Parameters

5 95

6.00

6.00

Base

5.85

5.90

5.955.86

-2.34% 5.79put)

5 70

5.75

5.80(-3.5%)

5.75

-4.09%5.71

-4.83%PC

(% o

f Out

5.60

5.65

5.70

AP

5.55247/537/565 247/565/593 247/600/610 270/600/610 310/600/610

Steam Parameters

Due to improvement in efficiency:• Coal flow, Ash flow, CW flow rate reduce, resulting in lower BOP Aux power


, , , g p• Flue gas flow and Air flow reduce resulting in lower boiler auxiliary power• Feed water flow reduces resulting in lower CEP power

A Maharatna Company

NTPC’s Efficiency Improvement Plans

1st USC unit(270 kg/cm2 / 600°C /

No new

Supercritical Unit(247 kg/cm2 /

565°C/593°C)

620°C)*

39.2 %

41 %

subcritical orders

38.6 %

2009 2012 2017-2020

NTPC IERE Cancun Mexico 15*Under Development with IGCAR/BHEL

A Maharatna CompanyArtificial Intelligence based Plant advisory system

Brief about the system

Real time online operator advisory system based on plant data using Artificial Intelligence techniques for improvement in unit HR

Provide advisory for controllable parameters like O2%, WB to Fur DP, FAD position, Burner tilt, feeder flow while keeping steam temperatures, sprays and metal temperatures within range.

Provide real-time boiler efficiency, TGHR, Unit HR, GCV values on main y, , ,screen.

Online detection and correction of sensor data errors and failures Online detection and correction of sensor data errors and failures.

Online system retraining for any new plant conditions


A Maharatna Company

Artificial Intelligence based Plant advisory system

The power plant process complexity and scope of improvement can be identified by defining various disturbances, Manipulating variables and optimization targets

ANN Learn from these data and once trained can perform prediction for optimization and

Models Inputs and OutputsManipulated Variables

ANN Learn from these data and once trained can perform prediction for optimization and control.

Models Inputs and Outputsp• O2 % Controller• WB Press (Aux air damp)• FAD• Burner Tilt• Feeder speed

Measured Disturbance Optimization Targets Measured Disturbance• Boiler Load• Mill Combination• Ambient Air Temp

•Boiler Efficiency•SH and RH Temp •MS left & right DTAmbient Air Temp

• CW Inlet Temp• PA Hdr Press• MS & RH Temp Unmeasured Disturbance

MS left & right DT•RH left & right DT• RH Spray flow•Metal Acromat


p• Coal Quality• Mill/Burner Wear• Coal Burner Imbalance

temp

A Maharatna Company

Artificial Intelligence based Plant advisory system


A Maharatna Company

Waste Heat Recovery from Flue Gases


A Maharatna Company100TR FGHR-AC Pilot Plant at Ramagundam.

Objecti eObjective:Waste heat from flue gas for 100TR Air Conditioning at Ramagundam

Benefit:• Utilizes Waste heat instead of electrical power/ steam to generate Air

ConditioningConditioning• Green house gas (CFC& HCFC) free Air conditioning.• Auxiliary Power Saving of 0.4 MU per year (266 ton of CO2) y g p y ( 2)

Activities:• Process Design Thermal design of heat exchanger sizing of• Process Design, Thermal design of heat exchanger, sizing of

equipments and C&I aspects carried out in-house


A Maharatna Company

FGHR-AC System at Ramagundam Super Thermal Power Station

P Fl DiProcess Flow Diagram -

ID F

Stack

BoilerESPID Fan

152 oC110 oC

CoolingTower 38 oC

32 oC

Slip Stream Fan

Heat Exchanger

HeatRecovery

Vapor Absorption Machine

Hot water12 oC

Recovery (500 kW th )

Fl P i

DM Water Make up 100 T R

(VAM)90 oC

80 C

7 oC

Flow Control Station

PumpingStation

Chill d t

80 oC

Chilled water

Flue Gas ESP CR, Ash slurry pump house CRHot Water

NTPC IERE Cancun Mexico 21Chilled Water

house CR Hot Water

Cooling Water

A Maharatna Company

Advanced NDE for Plant Performance Improvement


A Maharatna CompanyUltrasonic Phased Array (UT PA) Inspection of Power plant componentsp p p

UT PA for industrial component is analogous to the human• UT PA for industrial component is analogous to the human ultrasound in medical.

• By systematic control of delay in excitation of individual• By systematic control of delay in excitation of individual elements of the probe, we can have beam, which can be steered, skewed apart from focussing at different depths, p g p

• Unlike the conventional ultrasonic testing, the facility to steer the beam within a wide range increases the probability of detection of defects located arbitrarily.

• Ability to raster the beam at different position without physical movement of probes and capability to focus at different depth facilitates internal /volumetric inspection of complicated geometry


complicated geometry.

A Maharatna Company

UT PA

Focussing

Steering

Electronically rasteringy g


A Maharatna CompanyField Testing with Ultrasonic Phased Array

• inspection of installed LP Turbine Blades of a 500 MW unit carried out using UT PA during forced shutdown of the unit (with LP R t d LP i i it lRotor and LP casing in its place.

• Last stage blades were inspected with UT PA for detection of cracks in root regions ofPA for detection of cracks in root regions of blades, which are inside the disk.


A Maharatna CompanyMagnetic Crawler for inspection of W/W Tubes

Developed a system consisting of Developed a system consisting of magnetic crawler and sensor, which can sense any defect, ovality etc causingsense any defect, ovality etc causing distortion in the magnetic field.


A Maharatna CompanyTRANSFORMING LIVES


Documents

NTPC Initiatives on Efficiency & Power Plant Performance