Presentation Title A holistic view of energy efficiency improvement in power generation. New technology, renovation & modernization and process improvement

Presentation Title A holistic view of energy

efficiency improvement in power generation.

New technology, renovation & modernization and process improvement.

ByName: Souvik DuttaDesignation: Dy Chief Engineer(Gen)Date:26.08.11

New technology, renovation & modernization and process improvement.

A holistic view of energy efficiency improvement in power generation.

SolutionsSolutions

New New Technology Technology

Renovation & Modernization

New New Technology Technology

Renovation & Modernization

New Technology

Process Improvement

SolutionsSolutions

Adoption of New Technology

in Thermal Power GenerationAdoption of New Technology

in Thermal Power Generation

Major Initiatives for higher efficiency……

Adoption SAdoption Supercritical, upercritical, Ultra supercritical Ultra supercritical TechnologyTechnology

Adoption SAdoption Supercritical, upercritical, Ultra supercritical Ultra supercritical TechnologyTechnology

Adoption of Combined Adoption of Combined cycle Technologycycle Technology

Adoption of Combined Adoption of Combined cycle Technologycycle Technology

Adoption of Adoption of Integrated Integrated Gasification Combined Gasification Combined Cycle (IGCC) Suitable Cycle (IGCC) Suitable for Indian Coalfor Indian Coal

Adoption of Adoption of Integrated Integrated Gasification Combined Gasification Combined Cycle (IGCC) Suitable Cycle (IGCC) Suitable for Indian Coalfor Indian Coal

Adaptation Adaptation Supercritical / Ultra supercritical TechnologySupercritical / Ultra supercritical Technology

Development of Ultra Mega Power Development of Ultra Mega Power Projects (UMPPs) has been Projects (UMPPs) has been identified as a thrust area in order identified as a thrust area in order to increase plant efficiency.to increase plant efficiency.

Development of Ultra Mega Power Development of Ultra Mega Power Projects (UMPPs) has been Projects (UMPPs) has been identified as a thrust area in order identified as a thrust area in order to increase plant efficiency.to increase plant efficiency.

These are very large sized projects with These are very large sized projects with supercritical technology, approximately supercritical technology, approximately 4000 MW each involving an estimated 4000 MW each involving an estimated investment of about Rs. 16,000 crore investment of about Rs. 16,000 crore each.each.

These are very large sized projects with These are very large sized projects with supercritical technology, approximately supercritical technology, approximately 4000 MW each involving an estimated 4000 MW each involving an estimated investment of about Rs. 16,000 crore investment of about Rs. 16,000 crore each.each.

Adaptation Adaptation Supercritical / Ultra supercritical TechnologySupercritical / Ultra supercritical Technology

Salient features of the Plant and Choice of TechnologySalient features of the Plant and Choice of Technology

• The Ultra Mega Power Projects would use Super Critical Technology with a view to achieve higher levels of fuel efficiency, which results in saving of fuel and lower green- house gas emissions.• Flexibility in unit size subject to adoption of specified minimum Supercritical parameters.• Integrated power project with dedicated captive coal blocks for pithead projects.• Coastal projects to use imported coal.

Salient features of the Plant and Choice of TechnologySalient features of the Plant and Choice of Technology

• The Ultra Mega Power Projects would use Super Critical Technology with a view to achieve higher levels of fuel efficiency, which results in saving of fuel and lower green- house gas emissions.• Flexibility in unit size subject to adoption of specified minimum Supercritical parameters.• Integrated power project with dedicated captive coal blocks for pithead projects.• Coastal projects to use imported coal.

247/537/565

(660 MW)

170/537/537

(500 MW)

‘02 ‘07 ‘22‘17‘12Xth Plan

XIth Plan

XIIth Plan

XIIIth Plan

‘00

247/565/593

(660/800 MW)

280/600/620

(800-1000 MW)

320/600/620

(800-1000 MW)

Gro

ss E

ffic

ien

cy, G

CV

Bas

is

38%

39%

43%

42%

41%

40%

Solutions

Current scenario

Indian Efficiency Roadmap

Increasing Unit size & steam parameters



Pr/MST/RHT

0

2

4

6

8

10

12

14

200 LMZ (1978) 200 KWU (1979) 500 KWU (1982) 500 KWU Mod(1998)

500 High RH(2006)

660 SC 660/800 SC

Heat

Rat

e Im

prov

emen

t (%

)

P = 170 ataMST = 537RHT = 537

P = 170 ataMST = 537RHT = 565

P = 247 ataMST = 537RHT = 565

P = 247 ataMST = 565RHT = 593

P = 170 ataMST = 537RHT = 537

P = 130 ataMST = 537RHT = 537

P = 150 ataMST = 537RHT = 537

Heat rate Improvement Over The Years





Parameters for Higher Efficiency……

Plant Type Unit Size(MW)

Main Steam Pr (Bar)

Main Steam (Temp 0c)

Reheat (Temp 0c)

Notes

Sub critical 500 170 537 537 Common practice in India

Low Supercritical

660 247 537 565 India’s first supercritical

station at Mundra by Adani

High Supercritical

660/800 247-280 565 593 Parameters for Mundra Tatapower

Ultra Supercritical

1000 295 600 600 In operation in Japan/China

Ultra Mega Power Projects : Indian Scenario

Sasan power Ltd

Jharkhand integrated power Ltd

Coastal Gujrat Power

Ltd power Ltd

Coastal Andhra

Power Ltd

Awarded Projects

Projects under process

Orissa Integrated Power Ltd

Akaltara Power Ltd

Coastal Tamil Nadu Power Ltd

Coastal Maharashtra Mega Power

Ltd

Coastal Karnataka Power Ltd

Sakhi Gopal Integrated Power Co Ltd Orissa

Gogarapalli Integrated

Power co Ltd Orissa

Tatiya Andhra

Mega Power Ltd

Concerns: Viability at agreed upon Concerns: Viability at agreed upon tariff due to changed scenario of tariff due to changed scenario of imported coalimported coal

IPP:Adani Power,Mundra

Name of project & capacity as per LOI

Name of successful bidder

Date of LOI Levelised Tariff(Rs/Kwh)

Mundra Gujrat(5X800 MW)

M/S Tatapower Ltd 28/12/06 2.26

Sasan M.P(6X660 MW)

M/S Reliance Power Ltd 01/08/07 1.19

Krishnapatnam Andhra pradesh(5X800 MW)


Tilya Jharkhand(6X660 MW)


Ultra Mega Power projects awarded through tariff based competitive bidding route.

Plants have higher operating parameters and increased efficiency levels.

Awarded UMPP Projects

WAIGAOQIAO THERMAL

POWER STATION

P H A S E - I I I : 2 X 1 0 0 0 M W

SHANGHAI, CHINA

Ultra Supercritical 1000 MW units in China

Adoption Adoption IGCC (Integrated gasification combined cycle) TechnologyTechnology

An integrated gasification combined cycle (IGCC) is a technology that turns coal into gas—synthesis gas (syngas).

Excess heat from the primary combustion and generation is then passed to a steam cycle, similarly to a combined cycle gas turbine.

This then also results in improved efficiency compared to conventional pulverized coal.( 46% to 52%)

In the IGCC plants, the production of CO2 during the gasification process offers the opportunity for relatively low-cost CO2 capture and storage (CCS), which may give the future IGCC plants some competitive and environmental advantages over super critical plants

An integrated gasification combined cycle (IGCC) is a technology that turns coal into gas—synthesis gas (syngas).

Excess heat from the primary combustion and generation is then passed to a steam cycle, similarly to a combined cycle gas turbine.

This then also results in improved efficiency compared to conventional pulverized coal.( 46% to 52%)

In the IGCC plants, the production of CO2 during the gasification process offers the opportunity for relatively low-cost CO2 capture and storage (CCS), which may give the future IGCC plants some competitive and environmental advantages over super critical plants

IGCC (Schematic diagram of the process)

IGCC (Schematic diagram of the process)

NITROGEN

LOCKHOPPERPRESSURISATION

COAL

BUFFER / WEIGHINGHOPPER

COOLED GAS

CLEANEDGAS

DUST

FILTER

COMBUSTOR

COMP

RESS

ORAI

R

TURBINE

EXHAUST GASES

WATER PUMP

CONDENSER

ALTERNATOR

TURBINE

BOILE

R

STEAM

STEAMTURBINE

HEAT

RECOVERYGAS

TURBINECLEANINGGASIFIERDRYER

COAL

DRIED

COAL DRYING

AND GAS COOLING

CYCLONE

AIR

AIR

HOT GASASH/ CHAR

CO2

TO STACK STEAM

ASH/ CHAR

NITROGEN

LOCKHOPPERPRESSURISATION

COAL

BUFFER / WEIGHINGHOPPER

COOLED GAS

CLEANEDGAS

DUST

FILTER

COMBUSTOR

COMP

RESS

ORAI

R

TURBINE

EXHAUST GASES

WATER PUMP

CONDENSER

ALTERNATOR

TURBINE

BOILE

R

STEAM

STEAMTURBINE

HEAT

RECOVERYGAS

TURBINECLEANINGGASIFIERDRYER

COAL

DRIED

COAL DRYING

AND GAS COOLING

CYCLONE

AIR

AIR

HOT GASASH/ CHAR

CO2

TO STACK STEAM

ASH/ CHAR

IGCC

Efficiency and reliability improvements are also expected for Efficiency and reliability improvements are also expected for the IGCC technology. Its efficiency is estimated to grow from the IGCC technology. Its efficiency is estimated to grow from

46% in 2010 to 52% in 2020. 46% in 2010 to 52% in 2020.

Some major IGCC plants, worldwideSome major IGCC plants, worldwide

580 MW, Kentucky Pioneer Energy, USA580 MW, Kentucky Pioneer Energy, USA

512 MW, ISAB Energy, Italy512 MW, ISAB Energy, Italy

342 MW, Nippon Oil Corporation Refinery, Japan342 MW, Nippon Oil Corporation Refinery, Japan

335 MW, Elcogas, Spain335 MW, Elcogas, Spain

250 MW, Tampa Electric Company, USA250 MW, Tampa Electric Company, USA

Efficiency and reliability improvements are also expected for Efficiency and reliability improvements are also expected for the IGCC technology. Its efficiency is estimated to grow from the IGCC technology. Its efficiency is estimated to grow from

46% in 2010 to 52% in 2020. 46% in 2010 to 52% in 2020.

Some major IGCC plants, worldwideSome major IGCC plants, worldwide

580 MW, Kentucky Pioneer Energy, USA580 MW, Kentucky Pioneer Energy, USA

512 MW, ISAB Energy, Italy512 MW, ISAB Energy, Italy

342 MW, Nippon Oil Corporation Refinery, Japan342 MW, Nippon Oil Corporation Refinery, Japan

335 MW, Elcogas, Spain335 MW, Elcogas, Spain

250 MW, Tampa Electric Company, USA250 MW, Tampa Electric Company, USA

India first IGCC power plant is coming up at Vijayawada, foundation for which has been laid. The 125 MW plant will be built in the premises of Vijayawada Thermal Power Plant (VTPS).

BHEL and APGENCO has jointly funded this project.

The main constraint of IGCC technology is cost (+35%), more land requirement and higher auxiliary consumption for producing syn gas.

India first IGCC power plant is coming up at Vijayawada, foundation for which has been laid. The 125 MW plant will be built in the premises of Vijayawada Thermal Power Plant (VTPS).

BHEL and APGENCO has jointly funded this project.

The main constraint of IGCC technology is cost (+35%), more land requirement and higher auxiliary consumption for producing syn gas.

IGCC

250 MW IGCC plant: Tampa Electric Company, USA

Solutions

Renovation and

Modernization (R&M) as

per CEA guidelines Renovation and

Modernization (R&M) as

per CEA guidelines

Increase in availability and plant load factor of thermal power stations

Renovation and modernization for achieving higher efficiency levels.

Setting minimum acceptable standards & plan for R&M for projects below

standard with clear cost benefit analysis

If economic operation does not appear feasible through R&M, then there may be no alternative to closure of such plants as the last resort.

In cases of plants with poor O&M record a change of management may to be considered so as to improve the efficiency to acceptable standards.

Increase in availability and plant load factor of thermal power stations

Renovation and modernization for achieving higher efficiency levels.

Setting minimum acceptable standards & plan for R&M for projects below

standard with clear cost benefit analysis

If economic operation does not appear feasible through R&M, then there may be no alternative to closure of such plants as the last resort.

In cases of plants with poor O&M record a change of management may to be considered so as to improve the efficiency to acceptable standards.

Renovation and Modernization (R&M) as per CEA guidelines

Improvement in performance parameters – PLF,

availability, heat rate/efficiency, auxiliary power

consumption, partial loading & forced outage.

Restore derated capacity

Extension of economic life.

Obsolescence & non availability of spares (eg C&I)

Environmental issues/other statutory requirements.

Safety requirements.

Improvement in performance parameters – PLF,

availability, heat rate/efficiency, auxiliary power

consumption, partial loading & forced outage.

Restore derated capacity

Extension of economic life.

Obsolescence & non availability of spares (eg C&I)

Environmental issues/other statutory requirements.

Safety requirements.

NEED FOR R&M – EXISTING UNITS

FUTURE APPROACH TOWARDS R&M

NEAR PAST FUTUREIn-kind replacement Cost effective technology upgrades

Restoration of lost capacity Uprating of capacity

Attain design efficiency Improve upon design Efficiency

Reactive R&M Pro-active R&M

From Time based R&M Condition Monitoring & R&M

Optimisation through cost

benefit evaluation

NEAR PAST FUTUREIn-kind replacement Cost effective technology upgrades

Restoration of lost capacity Uprating of capacity

Attain design efficiency Improve upon design Efficiency

Reactive R&M Pro-active R&M

From Time based R&M Condition Monitoring & R&M

Optimisation through cost

benefit evaluation

Sl No Particulars R&M LEP

I Number of thermal power

stations

21 23

Ii Number of thermal units

76 53

Iii Estimated cost in Rs crores

4487 12433

iv Total capacity involved

18965 7318

R&M and Life extension program (LEP) during 11th plan(2007-11)

INDIA: Power generation Capacity in MW as on 30th June 2011. Source: CEA website.

0

20000

40000

60000

80000

100000

120000

140000

160000

180000

MW

Coal Gas Diesel Neuclear Hydro Renewable Total Captive

Source of power

Capacity in MW as on 30th June 2011. Source: CEA website.

54.66%

10%

2.7%

10.43%

21.53%

0.68%

11.02%

96.74 Billion watts

176.99 Billion watts

58.59 60.65 61.15 62.7265.93

67.7869.89

70.5674.91

80.44

96.74

0

10

20

30

40

50

60

70

80

90

100

2000-2001

2001-2002

2002-2003

2003-2004

2004-2005

2005-2006

2006-2007

2007-2008

2008-2009

2009-2010

Jun-11

INDIA: Power generation Capacity (Billion Watts) for Coal/Lignite based plants >25 MW capacity

Improvement Trend

Results of R&M

National Thermal plant performance (Coal lignite based>25 MW) (PLF)

68.7

4 69.9

7

72.3

4

72.9

6

74.8

4

73.7

1

77.0

3

78.7

5

77.2

2

77.6

8

62

64

66

68

70

72

74

76

78

80

PLF %

2000

-200

1

2001

-200

2

2002

-200

3

2003

-200

4

2004

-200

5

2005

-200

6

2006

-200

7

2007

-200

8

2008

-200

9

2009

-201

0

Year

Improvement Trend

Results of R&M

National Thermal plant performance (Coal /lignite based>25 MW) (PAF)

79

.84

79

.91

81

.83

81

.93

82

.93

81

.78

83

.72

84

.76

85

.05

85

.1

84

.24

77

78

79

80

81

82

83

84

85

86

PAF %

20

00

-20

01

20

01

-20

02

20

02

-20

03

20

03

-20

04

20

04

-20

05

20

05

-20

06

20

06

-20

07

20

07

-20

08

20

08

-20

09

20

09

-20

10

20

10

-20

11

Year

79

.84

79

.91

81

.83

81

.93

82

.93

81

.78

83

.72

84

.76

85

.05

85

.1

84

.24

77

78

79

80

81

82

83

84

85

86

PAF %

20

00

-20

01

20

01

-20

02

20

02

-20

03

20

03

-20

04

20

04

-20

05

20

05

-20

06

20

06

-20

07

20

07

-20

08

20

08

-20

09

20

09

-20

10

20

10

-20

11

Year

Improvement Trend

Results of R&M

National Thermal plant performance (Coal /Lignite based>25 MW) (Aux%)

9.0

1

8.7

2

8.5

3

9.0

5

8.5

7

8.4

4

8.2

9

8.1

7

8.3

3

8.3

4

7.6

7.8

8

8.2

8.4

8.6

8.8

9

9.2

Aux %

20

00

-20

01

20

01

-20

02

20

02

-20

03

20

03

-20

04

20

04

-20

05

20

05

-20

06

20

06

-20

07

20

07

-20

08

20

08

-20

09

20

09

-20

10

Year

9.0

1

8.7

2

8.5

3

9.0

5

8.5

7

8.4

4

8.2

9

8.1

7

8.3

3

8.3

4

7.6

7.8

8

8.2

8.4

8.6

8.8

9

9.2

Aux %

20

00

-20

01

20

01

-20

02

20

02

-20

03

20

03

-20

04

20

04

-20

05

20

05

-20

06

20

06

-20

07

20

07

-20

08

20

08

-20

09

20

09

-20

10

Year

Improvement Trend

Results of R&M

Solutions

Process Improvement Process Improvement

Process parameters to be improved……

Auxiliary power consumption

Heat rate

Oil figure

Plant load factor

Plant availability factor

Auxiliary power consumption

Heat rate

Oil figure

Plant load factor

Plant availability factor

Reduction of Auxiliary power consumption

Sharing of CESC’S

experience in reduction of

Auxiliary Power consumption Sharing of CESC’S

experience in reduction of

Auxiliary Power consumption

Southern Generating Station. CESC Ltd

Commissioning of Variable Frequency Drives for U#2 ID Fans in February 2011

Objective: To reduce auxiliary power consumption

Commissioning of Variable Frequency Drives for U#2 ID Fans in February 2011


Make: Leader & Harvest Electric Technologies Co. Ltd, China

Indian Partner: Yantra Harvest Energy Pvt. Ltd, Pune

Product : Medium-Voltage VFD

Model: HARSVERT – A06.6/50

Rated Input Voltage: 6.6 KV

Rated Capacity: 450 KW

Rated Output Current : 50 A

Output Frequency Modulation: 0-50 Hz

Output Voltage Modulation: 0 – 6.6KV

Control Mode: Sinusoidal multi-level Pulse Width Modulation

Make: Leader & Harvest Electric Technologies Co. Ltd, China

Indian Partner: Yantra Harvest Energy Pvt. Ltd, Pune

Product : Medium-Voltage VFD

Model: HARSVERT – A06.6/50

Rated Input Voltage: 6.6 KV

Rated Capacity: 450 KW

Rated Output Current : 50 A

Output Frequency Modulation: 0-50 Hz

Output Voltage Modulation: 0 – 6.6KV

Control Mode: Sinusoidal multi-level Pulse Width Modulation

VFD ESSENTIALS

Harvest MV Drive consists of

Input Transformer

Power Cell

Control System

VFD ESSENTIALS

Multi-winding Phase Shifting Input Transformer (Dry-type) Multi-winding Phase Shifting Input Transformer (Dry-type) comprising of 18 nos. Secondary (6 Per phase with Phase-comprising of 18 nos. Secondary (6 Per phase with Phase-shifted at 20,10,0,-10,-20 Degrees for 36-pulse rectification) & 1 shifted at 20,10,0,-10,-20 Degrees for 36-pulse rectification) & 1 no. Auxiliary Winding for Supply to Cooling Fans of Power no. Auxiliary Winding for Supply to Cooling Fans of Power CabinetCabinet

Primary Winding Rating : 6600V / 49.4 APrimary Winding Rating : 6600V / 49.4 A

Secondary Winding Rating: 710V / 25.5 ASecondary Winding Rating: 710V / 25.5 A

Auxiliary Winding Rating : 380 V/ 12.2 AAuxiliary Winding Rating : 380 V/ 12.2 A

VFD ESSENTIALS

The Equipment

Unit Load Particulars Pre-VFD period

Post-VFD period

Net savings per fan

Full load ID fan average load (KW)

370 KW 229 KW 133.5 KW

75 MW AC load (KW)

NIL 7.5 KW

Part load ID fan average load (KW)

335 KW 159 KW 168.5 KW

50-55 MW AC load

(KW)

NIL 7.5 KW

ID fan reduction in auxiliary power consumption after installation of VFD

Note: Above Readings are in winter months. Expected AC Load in Summer : 25 KW

36 % savings36 % savings

50 % savings50 % savings

Payback for two fans:18 to 20 months

Forthcoming VFD projects in CESC Ltd in the current financial year.

Southern Generating Station:

Installation of four numbers VFD’S for two ID fans & two FD fans of Unit no 1. Project: cost 410 lakhs.

Titagarh Generating Station:

Installation of VFD,S for two ID fans in one unit.Project

cost: 200 Lakhs

Southern Generating Station.CESC Ltd :Micro Hydle project

45 KW Micro Hydel Project at condenser

cooling water outfall (3X15 KW)


by extracting power from wasted energy

45 KW Micro Hydel Project at condenser

cooling water outfall (3X15 KW)


by extracting power from wasted energy

Basic concept

Specifications of the 15KW micro hydle turbine generator set• Rated capacity: 15KW (At Generator output)• Rated net head: 1.8 m• Rated discharge: 1 m3/s • Type of turbine: Propeller 4 blade inverted siphon • Rated turbine speed: 360 rpm• Runner diameter: 1000 mm• Type of generator: Induction• Method of drive: Flat belt• Turbine efficiency: 86%

Specifications of the 15KW micro hydle turbine generator set• Rated capacity: 15KW (At Generator output)• Rated net head: 1.8 m• Rated discharge: 1 m3/s • Type of turbine: Propeller 4 blade inverted siphon • Rated turbine speed: 360 rpm• Runner diameter: 1000 mm• Type of generator: Induction• Method of drive: Flat belt• Turbine efficiency: 86%

Southern Generating Station.45 KW(3x15 KW) Micro Hydel Project ph-1Supplier: Pentaflow Hydro Engineers.Delhi

Southern Generating Station. CESC Ltd

Commissioning of phase -1 of the project completed in February 2011

Average 12-14 KW is being generated from

the first 15 KW unit

In subsequent phases another two such sets will be commissioned

Commissioning of phase -1 of the project completed in February 2011

Average 12-14 KW is being generated from

the first 15 KW unit

In subsequent phases another two such sets will be commissioned

Electricity saved each year considering import for 75% time of a day for 350 days in a year

15 KW X 8400 hrs/year X0.75= 94500 KW-h / Year

This is equivalent to a savings of Rs 435000 / year

With a project cost of Rs 14.3 lakhs/unit payback is approximately3.3 years

In the subsequent years other than minor maintenance costs 100% savings will be achieved

For three such units the projected savings will be approximately Rs 10 lakhs

Auxiliary Energy Saved

Micro hydle during installation

Thank You !

The future of mankind is in our

hands. Let us act responsibly

to keep the world cleaner for

our future generation.

The future of mankind is in our

hands. Let us act responsibly

to keep the world cleaner for

our future generation.

Documents

Presentation Title A holistic view of energy efficiency improvement in power generation. New technology, renovation & modernization and process improvement