Dr. J T VergheseManaging DirectorSTEAG Energy Services, India

Performance enhancement of old thermal power stations

using software tools

EEC Workshop - 29th August , New Delhi

STEAG Energy Services India Business Lines

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STEAG Energy Services India offers services in the field of:

Engineering Consulting Services

Diagnostic Study and Testing

Energy Audit

Renovation & Modernization Consultancy

Operation and Maintenance

Information Technology for Power Plants

New Technologies for Power Plants

Advisory

STEAG Energy Services India Offices / O & M Sites

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Hazira

New Delhi

Haldia

Bangalore

Hyderabad

Ahmedabad

Jharsuguda

Chennai

Noida

Corporate & Registered Offices of STEAG India

Regional Offices of STEAG India

O & M Sites of STEAG India

Bathinda

Major Clients

4Many more

O & M Projects

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CCPP Hazira, Gujarat - India

4 X 600 MW Coal Based Power Plant at Jharsuguda, Orrisa - India

S. No. Type Capacity Location Owner Scope

Duration

From To

1. CCPP 156 MW Hazira GSEG O & M 2001 2010

2. CCPP 30 MW Gandhar ONGC O & M 2005 2007

3. CCPP 116 MW Haldia HPL O & M 2006 2012

4. WHRP 30 MW Goa Videocon O & M Advisory 2006 2011

5. Coal 4 X 600 MW JharsugudaSterlite Energy O & M 2010 2017

6. CCPP507 MW

(156 MW + 351 MW)

Hazira GSEG O & M 2011 2015

7. CCPP 165 MW Bathinda HMEL O & M 2011 2015

R & M and LE

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Mapping using Ebsilon Software to check the potential for efficiency improvement

Mapping using Ebsilon Software to check the potential for efficiency improvement

RLA Studies & Performance

Evaluation Tests

RLA Studies & Performance

Evaluation Tests

Techno-economic Analysis of R&M

Measures

Techno-economic Analysis of R&M

Measures

R&M Measures should include online software

tools to optimize efficiency

R&M Measures should include online software

tools to optimize efficiency

Preparation of technical and commercial

specification for R&M

Preparation of technical and commercial

specification for R&M

Tendering and award of contract

for R&M

Tendering and award of contract

for R&M

How to Improve Efficiency

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First Step: low hanging fruits

Improve efficiency by improving operation and maintenance by the normal methods:

● Maintenance Planning● Training● Standard Operating

Procedures● Improve maintenance methods

How to Improve Efficiency

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Next Steps

• Audit or “map the plant using offline modeling tool to detect causes for sub-optimal operations

• Provide online systems for

• optimization of resources• fault detection and prediction• lifetime monitoring for better planning of inspections and

maintenance and calculation of life-time consumption

• Provide customized systems for maintenance planning

Audit or “map“ the plant using off line modelling

Summary of the mapping exercise conducted jointly by CEA and Steag under the Indo

German Efficiency Program

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Mapping of 85 power plants - EBSILON Design Model

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Performance as per design documents

1. Output 210 MW

2. Gross Heat Rate 2305.16 kcal/kWh

3. Coal Consumption 110 t/h

4. Boiler Efficiency 86

5. Turbine Cycle Heat Rate 1982.72 kcal/kWh

6. Unit Efficiency 37.3%

Analysis

EBSILON Running Model

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Simulated Performance as per operating GCV

1. Output 210 MW

2. Gross Heat Rate 2664.22 kcal/kWh

3. Coal Consumption 166 t/h

4. Boiler Efficiency 79.6%

5. Turbine Cycle Heat Rate 2122.50 kcal/kWh

6. Unit Efficiency 32.3%

Analysis

85 Units Mapped – Size-wise

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Capacity (MW) Number of Units

100 1105 1110 6120 8125 1140 4195 1200 4210 49250 5500 5

Total 85

Analysis of 16 Units Under 16 Years of Age with Reaction Type Turbine Including Indicative Saving of Coal

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0

200

400

600

800

1000

1200

Analysis of 16 units under 16 years of age with reaction type turbineIndicative saving of coal

potentially conserved coal bestth tons of consumed coal per year

If all the units would have the same gross heat rate as the most efficient unit, 8.6% of the coal, altogether 1,256,650 tons, approx. Rs 113.1 crores would be saved by the 15 less efficient units each year.Assumptions: all the units work at a PLF of 80%, use coal with 4000 kcal/kg calorific value and 1ton coal costs Rs 900

Analysis of 16 Units Under 16 Years of Age with Reaction Type Turbine

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0

200

400

600

800

1000

1200

1400

1600

Analysis of 16 units under 16 years of age with reaction type turbine

Indicative additional capacity

additional capacitymillion units/ yearmillion units per year

If all the units would have the same capacity as the unit with the highest capacity, the overall output would be by 9.7% or 2,173 million units higher each year.Assumption: all the units work at a PLF of 80%

Analysis of 16 Units Above 16 Years of Age with Reaction Type Turbine

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U1

U2

U3

U4

U5

U6

U7

U8

U9

U10

U11

U12

U13

U14

U15

U16

0

200

400

600

800

1,000

1,200

Analysis of 16 units above 15 years of age with reaction type turbineIndicative saving of coal

potentially conserved coal bestth tons of consumed coal per year

If all the units would have the same gross heat rate as the most efficient unit, 7.3% of the coal, 1,122,600 tons, approx. Rs 101 crore would be saved by the 15 less efficient units each year.Assumptions: all the units work at a PLF of 80%, use coal with 4000 kcal/kg calorific value and 1ton coal costs Rs 900

Analysis of 16 Units Above 15 Years of Age with Reaction Type Turbine

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0

200

400

600

800

1000

1200

1400

1600

Analysis of 16 units above 15 years of age with reaction type turbine

Indicative additional capacity

additional capacitymillion units/ year

million units per year

If all the units would have the same capacity as the unit with the highest capacity, the overall output would be by 8.1% or 1,807 million units higher each year.Assumption: all the units work at a PLF of 80%

Analysis of 17 Units Above 15 Years of Age with Impulse Type Turbine

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If all the units would have the same gross heat rate as the most efficient unit, 7.3% of the coal, 1,122,600 tons, approx. Rs 128.8 crore would be saved by the 15 less efficient units each year Assumptions: all the units work at a PLF of 80%, use coal with 4000 kcal/kg calorific value and 1ton coal costs Rs 900

U1

U2

U3

U4

U5

U6

U7

U8

U9

U10

U11

U12

U13

U14

U15

U16

U17

0

200

400

600

800

1,000

1,200

Analysis of 17 units above 15 years of age with impulse type turbineIndicative saving of coal

potentially conserved coal bestth tons of consumed coal per year

If all the units would have the same gross heat rate as the most efficient unit, 7.3% of the coal, 1,122,600 tons, approx. Rs 128.8 crore would be saved by the 15 less efficient units each year Assumptions: all the units work at a PLF of 80%, use coal with 4000 kcal/kg calorific value and 1ton coal costs Rs 900

Analysis of 17 Units Above 15 Years of Age with Impulsive Type Turbine

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U1

U2

U3

U4

U5

U6

U7

U8

U9

U10

U11

U12

U13

U14

U15

U16

U17

0

200

400

600

800

1000

1200

1400

1600

Analysis of 17 units above 15 years of age with impulse type turbine

Indicative additional capacity

additional capacity realmillion units per year

If all the units would have the same capacity as the unit with the highest capacity, the overall output would be by 7.1% or 1,655 million units higher each year.Assumption: all the units work at a PLF of 80%

Auxiliary Consumption of 210 MW Capacity Units

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7

8

9

10

11

12

13

Auxiliary Consumption of 210 MW capacity units (%)

Auxiliary consumption (%)

Generally Observed Problems

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Systems Observations

Maintenance planning and management

Needs to be upgraded

Online monitoring Not provided

DCS Only some units have been provided

Documentation Needs improvement

Operating instruction and manual Needs to be updated

Online systems

– Provide Online systems for:● optimization of

processes● fault detection and

prediction system ● life time monitoring for

better planning of inspections and maintenance and calculation of life time consumption.

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Why to use the software tools ?

DCS has the information needed to do the calculation of efficiencies and heat rates – it gives performance calculation, trending and values of parameters

But what are the limitations ?

1.DCS does not give the system wise efficiencies so you do not know where the losses occur

2.Data from I/O points e.g. Temperature, pressure mass flow could be wrong because of sensor errors, bad connectors etc. That makes calculation erroneous.

3.DCS does not give advice what to do

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Online Tool: Optimization Sequence

1. All relevant data from DCS which goes into calculation need to be validated i.e. all implausible values have to be replaced by plausible values

2. All calculations must be done every 5 minutes (not only once a day) since the quality of coal and combustion process is changing. Threfore the state of heating surfaces must be monitored constantly.

3. Results are presented in a user friendly manner:Status of the subsystems is indicated by green, yellow, red and losses expressed in money terms.

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PADO Screens

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PADO Screens

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PADO Controllable Losses (1)

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PADO Set Point Optimization (1)

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Modules of the On Line systems

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Advantages of the Online Tool

– Improving the quality of measurements by data validation

– Evaluation of boiler, turbines, condenser and other components

– Optimization of unit operation (sootblowing, setpoints)

– Calculation of what-if scenarios– Generation of daily and monthly reports

– Enhance the efficiency of the power plant!

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