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CenPEEP Overview & Activity
Importance of Efficiency & Availability
Parameter Impact on Heat Rate
PDM Activities
Efficiency Management System
Methodology & Recognitions
Presentation Coverage
CenPEEP: An institution set up to reduce GHG Emissions
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CenPEEP Overview & Activity
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Protocol of Intent signed in July94 between:NTPC / Ministry of Power & USDOE / USAID-India
CenPEEP inaugurated by US Secretary of Energy.
A joint Indo-US climate change initiative in PowerSector
Centre for Power Efficiency & Environmental Protection
CenPEEP
Project launched in October 1995 with initial end date asMarch 2002; Project extended upto 2005, subsequently
upto 2008; and now upto 2010
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Development of an Institution in power sector in India
CenPEEP GOALS
To reduce GHG emissionfrom coal fired thermal
power plants by performance optimizationin terms
of efficiency, availability & reliability.
Technology acquisitionfor performance
optimization
Institutionalizationof cooperation for technology
transfer.
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Importance Of Efficiency and Availability
New Regulatory Norms
Increased Capacity
Reduced Cost of Generation
Increased Competition
Detect degradation in thermal performance
Develop cost effective solution to correct degradationin thermal performance.
Reduced Environmental Impact- Stack Emissions- Heat Rejected
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Test
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TYPICAL LOSSES
Description Loss (%)
BOILER 11.0
TURBINE CYCLE 44.7
TURBINE-GENERATOR 6.1
STATION AUXILIARIES 2.0
Total 63.8
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Major Factors Contributing to the Losses
Boiler Efficiency Degradation
High Flue Gas Exit Temperature High Unburnt in Bottom/Fly Ash Poor Air Heater Performance Dirty Boiler
High RH/SH Spray
Maintaining Low Parameters
Factors Affecting Performance Degradation
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Major Factors Contributing to the Losses
Poor Condenser Performance Tube Fouling Air Ingress High CW Inlet Temperature
Poor HP / IP /LP Turbine Efficiency
Poor HP Heater Performance
Poor BFP Performance
Passing of High Energy Drain Valves, RH Spray
Valves, BFP Recirculation Valves
Factors Affecting Performance Degradation
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Parameter Impact on Heat Rate
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EFFECT OF CRITICAL PARAMETERSON HEAT RATE
OFF - DESIGN CONDITIONS
Parameter Deviation Effect on Heat
Rate
Main Seam Temp. -5 oC +2.3 Kcal/kwhMain Steam Press. -1 Kg/cm2 +1 Kcal/kwhReheat Temperature -5 oC +2.3 Kcal/kwhReheat Spray +1%
(Throttle
Flow)
+2.4 to 3.6Kcal/kwh
Condenser BackPressure
+1 mmHgA
+2.0 Kcal/kwh
FW Temperature - 1 oC +3.5 Kcal/kwh
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Typical Station Heat Rate Deviations
102.31 kcal/kWh60 - 150 kcal/kWh
30 - 60 kcal/kWh
Unaccountable Losses25 % (~ 30 kcal/kWh)
Accountable Losses75 % (~ 90 kcal/kWh)
25 35 kcal/kWh
75 105 kcal/kWh
Cost Effective Performance Improvement
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Annual Impact of 1 kcal/kWh Improvement
9.95.5200 MW
24.713.5500 MW
RailfedStation
Rs Lacs/Year
PitheadStation
Rs Lacs/Year
UnitCapacity
Does 1 kcal / kwh matters to us?
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Typical Cost Implication of Coal Stations
Cost SavingPer Year
Rs. 6.85 Cr
Coal SavingPer Year
46800 Tons
Impact of HR
Deviation
1 kcal/kWh
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Output Sharing by Turbine CylindersHPT 28%IPT 23%
LPT 49%
Impact of Turbine Efficiency on HR/Output
Description Effect on TurbineCycle HR Effect onKW Effect on output fora 200 MW Unit
1% HPTEfficiency
0.16%
(appr 3 kcal)0.3% 600 kW
1% IPTEfficiency
0.16%
(appr 3 kcal)0.16% 320 kW
1% LPTEfficiency
0.5%
(appr 10 kcal)0.5% 1000 kW
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HP Heaters have direct impact on machine reliabilityand plant Heat Rate / Efficiency.
Heat Rate Loss in a 210 mw Unit in case
HP Heaters not in serviceis about 68 kcal / kWh
Impact of Heater Performance
Annual Impact for one 210 mw Unit
Increase in Coal Consumption 32,100 Tons
Additional Coal Cost (for rail fed) 7.1 Cr
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Effect of Condenser Vacuum on Heat Rate and O&M cost
10 mmHg Improvement in CondenserVacuum Leads to 20 Kcal/kwh Improvement
in Heat Rate for a 210 MW Unit
Annual Impact for one 210 mw Unit
Saving in Coal Consumption 9400 Tons
Saving in Coal Cost (for rail fed) 2.1 Cr
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PDM Activities
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Type of Maintenance Activities
Emergency corrective repairs on critical
equipment Daily/outage scheduled corrective activities
Periodic material replacement Intrusive inspection including open and
inspect.
Non-intrusive inspections, diagnostic tests like Vibration Monitoring, Oil analysis etc
CM
PM
PdM
Forced
Preventive
Predictive
PAM Root Cause Based Maintenance to eliminatethe Maintenance requirement
Proactive
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Predictive Diagnostics Maintenance (PDM)
or Condition Based Maintenance (CBM) isbest strategy and can eliminate PreventiveMaintenance (PM)?
PDM can reduce PM & CM (Breakdown Maint),not eliminate
Economic Mix of all is desirable
PdM CM
PM
PAM
Present
PM
CM
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Preventive Maintenance (PM)
Corrective Maintenance (CM)
Proactive Maintenance (PAM)
Predictive Maintenance (PdM)
Reliability Centered Maintenance (RCM)
Risk Evaluation & Prioritization (REAP)
Knowledge Based MaintenanceRoad-Map
Weare
here(2008) We
werehere
(2003)
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One technology is not adequate fordiagnostics e.g. DGA for transformers &
vibration for rotating machines
MotorCurrent
Lube Oil
Thermography PerformanceMonitoring
Vibration
Pressure
To ControlRoom
Use Of Multiple Technologiesand integration of data is
essential
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Periodic Condition Monitoring Systems
Thermography
Periodic Vibration Monitor Acoustic Leak Detection and Corona detection (air-borne)
Acoustic technology: partial discharge intransformers & for mechanical equipment ( contact
method) Lube Oil Monitoring Electrical tests (Motor Current Monitoring:Broken
Rotor Bars)
DGA in oil for transformers
USE OF MULTIPLE TECHNOLOGY ON EACH EQUIPMEMTUSE OF EACH TECHNOLOGY FOR MULTIPLE EQUIPMENT ( whereever applicable)
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GoalThe goal of RCM is to preserve
equipment functionwith the
required reliability and availabilityat the lowest cost.
MethodologyIdentification of failure modes
and selection of appropriate
task/strategy for its mitigation.
RCM(Reliability Centered Maintenance)
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RCM is based on answers to7 FUNDAMENTAL QUESTIONS
for each Equipment
(and if necessary for the component)
1. What are the functions and associatedperformance standards of the assets in itspresent operating context?
2. In what ways does it fail to fulfill its functions?3. What causes each functional failures?4. What happens when each failure occurs?5. In what way does each failure matter?
6. What can be done to predict and prevent eachfailure?
7. What if a suitable pro-active task can not befound?
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PdM Process: Information to Action
Communication is 70% of the Issue
AcquireData Infer InformationFrom Data
TakeCorrectiveAction
Utilize Field and PersonnelExperience
Utilize Analysis Systems and NeuralNetworks
Maintenance Orders PostMaintenance Tests Operations & Procedures
Adjusted
Maintenance HistoryOperators LogBatch TestsDesign InformationProcess Parameters(Temperature / Pressure / Flow)
Predictive and Condition
monitoring techniquesPerformance
(Oil Analysis/ vibration
/ thermography, acoustics etc.)
NDE Inspection
Visual Inspection
FEED BACK
Technologies are fascinating but they are only tools
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REAP : Risk- evaluation and prioritizationFinancial Risk Optimization (FRO)
FRO is a tool for Prioritization of Maintenance & planEvaluation
A risk prescreening of what needs to be addressed
using five yrs. Historical outage data.
A tool to decide what, when & worth?
Correlates Engineering input to Financial Risk.
The timing of risk critical components
repair/replacement decision.
The value of pursuing the decision timing
considering the constraints of budget etc.
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FRO Implementation Steps
Step 1.1: Screening risk critical equipment: Responsible for Generation Loss.
Step 1.2: Additional Screening for risk critical equipment: Equipment of concern for efficiency Equipment of concern for safety & environment
Finalization of top 20 Risk Critical equipment
Risk Evaluation and Maintenance Prioritization
Maintenance plan Evaluation
Step 2.1:Financial information for FRO
Step 2.2:Determination of probabilities for future.Step 2.3 :Running FRO tools for evaluation of alternate maintenance
plans
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Efficiency Management System
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Performance Evaluation & Action Plan
Performance Optimisation
Recovery of Efficiency Loss
Sustainability through Institutionalisation of Program
An Approach for Sustainable Improvement ofPerformance of Power Plants
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Monitoring of critical parameters and reducingthe deviations
Preparation of daily/monthly Heat Ratedeviation reports
Periodic testing to assess current performancelevel using accurate off-line instruments
Standardization of routine test procedures
Action plan - based on Heat Rate Deviationsand Economic considerations
Evaluation of maintenance and sustainability ofperformance
Methodologyfor Implementation
Station EEMG Structure & Function
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Station -EEMG Structure & Function
( Energy & Efficiency Management Group)
Role & Responsibility of MIS
Management Information Reports Coordination for ORT Coordination with Regional
HQ/REBs Tripping Analysis Coal Stock Survey Oil stock/procurement
Commercial activities,ABT etc
Role & Responsibility of PMG
Parameter monitoring,trending& analysis
Online / Offline Performancetest of system
Daily/Monthly HR Dev. Reports Action plan for corrective
measures
Critical InstrumentPerformance & calibration Implementation of Efficiency
related aspects during O/H Mathmodelling for diagnosis &
analysis Monitoring of APC/Sp.Oil /
Make-up. Monitoring of unit light-ups
PMSGat Region
EEMG Energy & Efficiency Management GroupCEETEM Center for Energy Efficient Technology
& Energy ManagementPMSG Performance Management System GroupSMSG Station Monitoring & Support Group
PMG - Performance Monitoring Group
R i EEMG S & F i
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Region -EEMG Structure & Function
Regional OS
PMSG /
Regional CenPEEPSMSG
ED - Region
Offline performance test(GTCHR, Blr Optimization)
Parameter monitoring ,trending & analysis
Plant Performance Audit
Review of Monthly HRDev. reports
Follow up of action plan Monthly Exception report
on EEMG to CC Training of EEMG Exec.
ManagementInformation Reports
Conducting ORT Fixing PerformanceTargets
Performancemeetings at Station
Coordination onRegulatory Issues
Corporate Centre Structure & Function
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CC - CenPEEPCC - OS
Corporate Centre -Structure & Function
Director(Operation)
Ensure Uniform Practice for performance improvement Developing standardized testing & reporting procedures Providing Guide lines for computation of performance of
equipments & system Providing Software support Technical Support to Regions & Stations Data Bank of Equipment / System / Curves etc. Off line performance testing & combustion optimisation
Performance monitoring ,trending and analysis. Review & Follow up of action Plans Training of Executives Issues to be taken up with Engg. New technique & system Review of Monthly HR Dev. reports Ensuring inclusion of Efficiency related activities in O/H.
Plant Performance audit
PMSG /
Regional CenPEEP
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METHODOLOGY for SUSTAINABILITY
&RECOGNITIONS
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High PLF & Availability translate into OptimumEfficiency
Equipment maintenance to be taken-up based onperiodic overhaul schedule
Boiler performance degradations has no relationto Turbine Cycle performance
Some of the Myths
Impact of Efficiency Improvements
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Win-Win Strategy
Harmony
Global Concerns Utility concerns
Pollution Global Climate
GHG emissions Particulate
emissions Ash pollution
Sustainablegrowth
ProfitabilityPublic
image
EfficiencyAvailabilityO&M costs Industry Norms
CenPEEP
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GEPPartners
NTPCGuj. Gen CoMahaGen COAP Gen COPSEB
UPRVUNWBPDCLJharkhand IPGCL
USDOE NETL EPRI TVA
GAI Southern
Research Structural Int. Others as req.Indian Partners US Partners
CenPEEP
Guided byAdvisory Board & Executive Committee
Consisting of NTPC, USAID and members from Govt of India, State & Private
Power Utilities, industry association, research institutes, etc.
Methodology
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Training &Technology
Dissemination
Technology
Demonstration
TechnologySelection &
Acquisition
TechnologyTransfer
MethodologyIntroduction of Techniques, Systems & Practices for
Performance Optimisationof existing coal fired power
stations and new power generation technologies
Success factors
Sustainabilitythrough
Systems & Procedures
Institutionalization
Thrust on low cost / high benefit technologies for sustainability
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Condenser Tube Cleaning byWater Powered Cleaners
Water Powered Gun used to push bullets
(scrapper) to clean condenser tubes;
Most effective and low cost technology
NON UNIFORMAir-fuel ratio in Four Corners
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NON- UNIFORM Non optimum
combustion
Higher fuelconsumption Higher CO2
UNIFORM Optimum
combustion
Lower fuelconsumption Lower CO2
Coal Pipes Bad Flame
Good Flame
Air-fuel ratio in Four Corners
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>150.0C
#3 >#1
Effective method to identify valve leakage & repair priorities
Valves are unaccountable culprits of efficiency loss
Temperature as per Colour Scale
Pl t P f O ti i ti A h
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Plant Performance Optimization Approach
Best Efficiency &
Lowest GHG emission
Methodology
Identify majorproblem areasof degradation
Evaluation ofeffectiveness ofimprovementactivities
Focus on eachsub-system &component
Health of each
componentdetermineshealth of theequipment
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
HR Improvement Program
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HRIP
Accurate GapAssessment
PIPs
Gap analysis
Action Plans
ResourceMobilizationImplementation
Retrofits
Evaluation &Dissemination
Focus on:1. Evaluation, recovery and controlling degradations in
Individual Equipment
2. Forced outage reduction & availability improvement
HR Improvement Program
NTPC C PEEP C ib i
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NTPC-CenPEEP Contributionfor
GHG Reduction Program
Whole time executives deployed at Corporate & Regional
CenPEEP: 25
Dedicated infrastructure for Corporate & regional ( lab,
library, Conf room, office set-up etc.) Manpower augmentation at Stations to take up CenPEEP
program: 40
Training set-up at NTPC Power Management Institute
Equipment for efficiency and availability improvement atStations: Rs. 100 million ($ 2.5 million)
Equipment at CenPEEP: Rs. 10 million ($ 250,000)
This excludes EPRI membership: $ 940,000
Widespread Dissemination
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125 Workshops on Boiler & TurbinePerformance Analysis & Improvement;
Diagnostics and Knowledge basedMaintenance
14000 Training man days - Participantsfrom NTPC, DVC, GSCEL, UPRUVNL,TNEB, APGENCO, PSEB, RRUVNL, MSEB,IPGCL etc.
319 Demonstrations - Hands-on trainings
Guidelines on Thrust areas
Papers at various conferences Customized training programs organized
at SEBs as 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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CTIs World
ClimateTechnologyAward 2002
USEPA CLIMATEPROTECTION
AWARD 2003
Awards & Recognitions
CenPEEP IS A SYMBOL OF SUCCESSFUL
INTERNATIONAL COOPERATION FOR GHG REDUCTION
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Thank You
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