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Production, Planning & Control in Power Sector
Dev Ashish E002Rajul Garg E013Shweta Gupta E018Sahil Sahni E049Manish Singla E054Varun Malhotra E033
3
India ranked 5th in terms of Power Generation and 6th in Power Consumption
Governed by ministry of power
Expected to grow by 13.2 % in 2012-13
FDI of 100% is allowed in electricity generation
Sector MW % age
State Sector 86,275.40 42.01
Central Sector 62,073.63 30.22
Private Sector 56,991.23 27.75
Total 2,05,340.26
Indian Power Industry
Fuel MW %age
Total Thermal
1,36,436.18 66.44
Hydro 39,291.40 19.13
Nuclear 4,780.00 2.32
RES 24,832.68 12.09
Total 2,05,340.26 100.00
Year Per Capita Consumption
1950 15 KWH/per year
2007 612 KWH/ per year
2012 1000 KWH/ per year
As on 30-06-2012Source:CEA
Power Generation
66%19%
2%12% Total
ThermalHydroNuclearRES
Constitutes about 66% of the power generation in India
Thermal Power producers have less profit margin as compared to hydro power producers because of there large expenditure on fuel(coal, oil and gas)
Indian Thermal Power generation is expected to grow by 14.4 % in 2012-2013
Coal-based power generation would increase by around 19200 mw
Coal Gas Diesel Total
56.8% 9.2% 0.6% 100%
As on 31-07-2012 – Source CMIE, CEA
Thermal Power Generation
Power Generation Process
1. Coal Supply*Coal from the mine is delivered to the coal hopper, where it is crushed to five centimetres (2 inches) in size. *The coal is processed and delivered by a conveyor belt to the generating plant.
2. Pulverizer *The coal is then pulverized, or crushed, to a fine powder, mixed with air and blown into the boiler, or furnace for combustion.
3. Boiler *The coal / air mixture ignites instantly in the boiler.*Intense heat from the burning coal turns the purified water in the boiler tubes into steam, which spins the turbine to create electricity.
4. Precipitator,stack *Burning coal produces carbon dioxide (CO2), sulphur dioxide (SO2) and nitrogen oxides (NOx).*Bottom ash and Fly ash are also produced
Coal Fired Power Plant
Boiler
Diagrammatic Sketch
5. Turbine, generator * Water in the boiler tubes picks up heat from the boiler and turns into steam. Once the steam hits the turbine blades, it causes the turbine to spin rapidly.
6. Condensers and the cooling water system*The cold water is warmed by the steam, which condenses back into pure water and circulates back to the boiler to begin the process of generating electricity again.
7. Water treatment plant: water purification*To reduce corrosion, water must be purified for use in the boiler tubes.
8. Precipitator, Ash systems*Fly ash and bottom ash are removed from the plants and hauled to disposal sites or ash lagoons.
9. Substation, transformer, transmission lines*Once the electricity is generated, transformers increase the voltage so it can be carried across the transmission lines.*Once electricity is delivered to substations in cities and towns, the voltage flowing into the distribution lines is reduced, and then reduced again to distribute electricity to customers.
Players Involved
•Produces Power
•Has state as its beneficiaries based on a predetermined share
Central Generating Unit
(CGU)
•Manages grid operation of its region
•Daily schedule planning for power supply and dispatch
Regional Load Dispatch
Center(RLDC)
•Manages generation & distribution of power in state
• Interacts with RLDC for its share of power from CGU
State Load Dispatch
Center(SLDC)
Central Power Generating Station• Gauges Daily Declared Capacity (DC)
Regional Load Dispatch Center (RLDC)• Receives DC from power plant• Breaks up DC as per SLDC plant wise
share
State Load Dispatch Center (SLDC)• Calculate their respective load
requirement• Conveys their power requirement to
RLDC
Regional Load Dispatch Center (RLDC) • Determines the dispatch schedule for
CPGS• Conveys Dispatch & withdrawal
schedule to respective party
Dispatch Schedule
Demand Forecasting Process
Withdrawal Schedule
• RLDC conveys the Dispatch schedule to power plant & withdrawal schedule to SLDC
• It is a 15 min time slot specifying demand and supply power unit
• For eg : slot 1 can be 200MW. This means the scheduled demand by SLDC is 200 MW for the 15 mins of slot 1 and scheduled supply from CPGS is 200 MW
• Total of 96 slots in a day
Dispatch & Withdrawal Schedule
Tariff mechanism
Capacity charge towards reimbursement of the fixed cost of the plant, linked to the plant's declared capacity to supply MWs
Energy charge to reimburse the fuel cost for scheduled generation
UI charge for deviations from schedule, at a rate dependent on
system conditions.
For any deviation in planned schedule an Unscheduled Interchange (UI) Charge is levied on either parties
If SLDC draws more power than scheduled it has to pay for the excess drawl at a UI rate
The rate is lower if the frequency is high, and higher if the frequency is low
UI Charge
Taken on 21 Aug, 2012 at 20:43
Load Frequency
Load Frequency
Both High and low frequencies are dangerous for machines and power lines
Load Frequency Relationship
Load Frequency
UI Rate increasesIncentive for
Power plant to generate more
Unscheduled Load Management
• Inventory does not comprise semi-finished or finished goods as in case of
most manufacturing plants
• Electricity can not be stored nor is it generated in stages. It is a continuous
non-stop process.
• The place of raw material is taken by the fuel used in generation viz. coal, gas
etc.
• Thermal power generation involves considerable plant and machinery, the
operation and maintenance of which require an inventory of requisite spares
and components to be regularly maintained
• Thus inventory comprises fuel and spares and components, loose tools,
chemicals and consumables
INVENTORY MANAGEMENT
With the introduction of Computerized Stores Accounting System, all information/reports can be generated either item wise or by any required group under the NTPC, Materials codification System (MCS). NTPC has codified the stores & spares under 100 main groups (from 00 to 99)
A) Construction Stores1. Cement2. Steel3. Others (viz. pipe, pipe fitting, cables etc.)
B) O&M Stores1. Coal2. Fuel (Excluding coal)3. Spares (Excluding insurance spares)4. Loose Tools5. Chemical, Gases & Explosives6. Oil & Lubricants7. Stores other than spares (consumables & Gen. Stores)8. Scrap
GROUPING OF ITEMS FOR REPORTING & CONTROL
•Spare parts which are not normally required for routine maintenance but would cause long shut down of vital equipment or entire plant in case of non-availability
Insurance Spares(I)
•Assemblies/sub-assemblies which are replaced as complete units to release defective assemblies for repair in order to cut down on costly idle time of equipment
Unit Assembly (U )
•All spares which require replacement due to wear & tear on their inherently short life
Consumables(C )
IUC Classification
•very tight control and accurate records
•Annual consumption value more than Rs 100000
A Items
•less tightly controlled and good records
•Annual consumption value between Rs 10000 to Rs 100000
B Items
•simplest controls possible and minimal records
•Annual consumption value less than Rs. 10000
C Items
ABC Classification
INVENTORY NORMS FOR STORES & SPARESConstruction store
Cement 2-3 months
Steel 9 months
Others (viz. pipe, pipe fittings, cables) 9 months
Operation and Maintenance StoresCoal 15 days
Fuel (excluding coal) OS shall fix the inventory
Spares (Excluding insurance spares) 18 moths usage indigenous24 month imported
24 month imported
Loose Tools 6 months
Chemical, Gases & Explosives 3 months
Oil & Lubricants 3 months
Consumables & Gen. Stores 6 months
Scrap At least 2 disposals in a year
Maintenance & Protection of Power Plants
• Start-up & shut-down operations more frequent
• Independent management of facilities important
• Preservation of global environment
• Improved generation efficiency
• Enhancing fuel conversion in existing facilities
• Technology to meet the trends
• Life cycle cost minimization
This makes Preventive Maintenance important
Background
Preventive & Predictive Maintenance :
• Non destructive inspection
• Life assessment technology
• Rationalization technology for scheduled inspections
All this improves the efficiency of maintenance
Methodology
• Monitor operation during transition
• Knowledge of deterioration state of equipment
• Regular monitoring of operations
• Performance evaluation for LCC minimization
• Operation Management for efficiency
• Operation data management services
Quantitative State of Facilities
• NDT :– Liquid Penetrant Testing– Magnetic particle testing– Ultrasonic testing
• Problems :– Narrow gap area inspection– Large amount of associated work– Difficulty of life time diagnosis
PM for Boilers
• Prevention of Stress Corrosion Cracking
• Analysis of vibratory response in grouped blades
• Overhauling by removing bucket
• Rationalization technology for scheduled inspection
• Facility Diagnosis Technology (Leak Diagnosis)
• Asset Management Technology (Trend)
PM for Steam Turbines
• Bucket : – Oxidation resistance coating : Ni Based Super alloy– Bucket tip coating for erosion prevention– Low current welding to prevent tip weld build up
• Nozzle : – Welding to cure thermal fatigue cracking– Diffusion Brazing to avoid nozzle deformation
PM for Bucket & Nozzle
• OIL : – Oil level checking. Leakages to be attended.– Oil BDV & acidity checking at regular intervals. If acidity
is between 0.5 to 1mg KOH, oil should be kept under observation.
– BDV, Color and smell of oil are indicative.
• BUSHINGS : – Cleaned and inspected for any cracks.– Note Deposition : Dust, dirt, Salt, chemical, cement, acid
fumes.
PM for Transformers
Condition MonitoringCondition monitoring is the process of monitoring a parameter
of condition in machinery, such that a significant change is indicative of a developing failure.
Fault Diagnosis Fault PredictionAvoid cascading damage to other
machines
Better Spare Management
Enhance machine endurance limit
Lesser Downtime: Increased
Productivity
Greater safety of workforce
Objectives Techniques
Vibration Monitoring
Lubricant Analysis
Noise Analysis
Thermography
DGA
Vibration Analysis•PdM (Predictive Maintenance) technique
• Uses instruments to monitor and analyze machine vibration to determine if the machine is working properly. •Vibration analysis is of the most common techniques used in PdM.
Vibration Spectrum AnalyzerUsed For
Turbines
Generators
Pumps
Motors
Fans
Compressors
Gears• Tooth meshing• Worn teeth• Misalignment• Mechanical looseness
Shaft & Motors• Unbalanced• Bent• Misalignment
Bearings• Damages• Distortion• Lubricant loss
Reasons
Lube Oil Analysis•Performed during routine Preventive Maintenance
• Provides meaningful and accurate information on lubricant and machine condition
OA – 3 Parts
Analysis of Oil Properties
• Moisture• Density• Viscosity• Acidity
Analysis of contaminates
Analysis of wear debris from machines
Contaminated Lube Oil
Measuring moisture content
Thermography•Identification of hot spots•Used for monitoring of switchyard equipment•Routine monitoring of motors/pumps•Monitoring of drain pipes to detect choking•To monitor condition of insulation on pipe and equipments
OA – 3 Parts
The hottest parts are depicted in bright
Yellow Color
Schedules & Standards
Sample Schedules
Vibration Monitoring Daily / Weekly / MonthlyOil Analysis Quarterly
Thermography Quarterly
ISO 17359
Condition monitoring & diagnostics of machine, general guidelines
ISO 13373
Mechanical vibrations and shock vibration monitoring of machines
Standards
Thanks
Power Generation - Video