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Neerja Mathur

Chairperson
Central Electricity Authority &
Ex-Officio Secretary to Govt. of India

New Delhi
January 2014

IGEN-Power Plant optimization

Neerja Mathur
Chairperson

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Major Singh
Member (Planning)
Central Electricity Authority & Ex-Officio
Additional Secretary to Govt. of India

Message
The power sector in India consists of predominantly coal based thermal generation with
a share of about 59% in the total installed capacity. During 12th and 13th Five Year
Plans, substantial capacity addition based on coal is planned. With the increasing gap in
the demand and supply of indigenous coal, the improvement in efficiency in thermal
plants is a focus area of the Government. Further, Government is committed to reduce
Greenhouse gas emissions.
Advent of new technologies as well as up gradation of existing technologies have made
available many new reliable and efficient products and systems which if selected could
help in improving efficiency of power generation.
Indo-German Energy Programme, being implemented by CEA in association with GIZ,
Germany aims towards improvement in availability and energy efficiency of the power
plants.
Mapping of 85 Thermal units has been carried out in Phase-I of the IGEN programme
which brought out saving potential by way of efficiency improvement. These mapping
studies revealed that majority of the units are operating at much higher Heat Rate than
designed.
To make the energy efficiency efforts sustainable in the long run, Under phase II of
IGEN programme,15 Power Utilities were given 40 Ebsilon license along with training to
100 engineers to carry mapping activities and identify the saving potential at their plant.
To make these outcomes of the trainings more visible, a compendium of all the case
studies carried out by various power utilities is being published. This book shall facilitate
the knowledge sharing amongst various power plant utilities on the problems and
remedies for efficiency improvement in thermal power plants.
I appeal that every user and producer of energy must make an effort towards energy
efficiency improvement for his own benefit as well as that of the nation

New Delhi
January 2014

IGEN-Power Plant optimization

Major Singh
Member (Planning)

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Jens Burgtorf
Message

Director, IGEN
GIZ, India

Rapid industrialization, a fast pace of urbanization, and the associated consumerism


are indicative of Indias fast growing economy. But this pace of development has to take
care of other aspects also. Accordingly, the pressure on Indian industry to become
globally competitive while adhering to ecological and social standards is continuously
increasing. This can be achieved by triple bottom-line approach, which takes into
account people, plant and profit.
Energy Efficiency is one of the focus areas for development co-operation to India by
Government of Germany. Germany is committed to reduction in greenhouse gas emission
and environmental protection.
Under Indo-German Bi-lateral Technical Co-operation between the Government of India
and Germany, jointly implemented by Central Electricity Authority and GIZ, the IndoGerman Energy Programme came to existence. The aim of this Programme was
dissemination of knowledge on Energy Efficiency through adequate tools and trainings
with setting up of model examples, in various sectors of economy.
The Power Plant Optimization Component of the IGEN Phase II, provided various
thermal Power Plants with Ebsilon licenses and adequate training to their engineers. This
helped the state utilities to analyse the performance, as well as identify energy efficiency
improvement areas of their power generating units. Also, as a preliminary output of this
Programme, huge saving potentials were identified in these plants. A Case study on areas
of improvement and power plant efficiency analysis to achieve these savings have been
prepared of each plant individually and suggested for implementation by Engineers from
beneficiary utilities.
To share the experiences of different generating units, these case studies on energy
efficiency has been compiled to a consolidated report. It is expected that the
deliberations in this book will help in spreading the ideas of efficiency optimization
and help in identifying further areas of cooperation between Germany and India in this
sector.

New Delhi
January - 2014

IGEN-Power Plant optimization

Jens Burgtorf
Director
IGEN, GIZ
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Table of Contents
CHAPTER 1 ...........................................................................................................................................6
OVERVIEW OF ENERGY SAVING POTENTIAL. ........................................................................6
1.1
INDIAN POWER SECTOR AT A GLANCE ....................................................................................6
1.2
INDO-GERMAN ENERGY PROGRAM .........................................................................................8
1.3
ENERGY SAVING POTENTIAL IN 17 UNITS STUDIED UNDER IGEN PHASE-II ........................10
1.4
ENERGY SAVING POTENTIAL ESTIMATED FOR 85 UNITS MAPPED UNDER IGEN PHASE-I ......11
1.5
COMPARISON OF ENERGY SAVING POTENTIAL AS WORKED OUT IN IGEN PHASE II WITH
PHASE I ..............................................................................................................................................11
1.6
ESTIMATE OF ENERGY SAVING POTENTIAL IN RESPECT OF ALL STATE UTILITIES (COAL
FIRED THERMAL POWER PLANTS) .....................................................................................................13
CHAPTER 2 .........................................................................................................................................15
SUMMARY REPORT OF 17 PULVERIZED COAL FIRED THERMAL POWER
GENERATING UNITS IN DIFFERENT STATES BASED ON EBSILON PROFESSIONAL
ANALYSIS - CASE STUDY ...............................................................................................................15
2.1
METHODOLOGY .....................................................................................................................15
2.2
FINDINGS ...............................................................................................................................15
2.3
ANALYSIS OF KEY PERFORMANCE INDICATORS ....................................................................16
2.3.1 Variations in boiler efficiency...............................................................................................16
2.3.2 Heat rate variations ..............................................................................................................17
2.4
SAVINGS POTENTIAL ..............................................................................................................19
2.5
REASONS FOR HIGH OPERATING GROSS HEAT RATES .............................................................21
2.6
RECOMMENDATIONS AS PROPOSED IN THE CASE STUDIES ....................................................22
2.7
CONCLUSION .........................................................................................................................22
CHAPTER 3 .........................................................................................................................................23
OVERALL PERFORMANCE AND SAVING POTENTIAL OF INDIVIDUAL UNITS............23
3.1
LIST OF UNITS ........................................................................................................................23
3.2
APGENCO - KOTHAGUDEM THERMAL POWER PLANT, UNIT 6 - 120 MW...........................24
3.3
GSECL - SIKKA THERMAL POWER PLANT UNIT 1 - 120 MW .............................................28
3.4
GIPCL- SURAT LIGNITE UNIT 3 - 125 MW ...........................................................................33
3.5
OPGC- IB VALLEY THERMAL POWER PLANT UNIT 2 - 210 MW ..........................................36
3.6
HPGCL- PANIPAT THEMAL POWER PLANT UNIT 6 - 210 MW ..............................................41
3.7
MAHAGENCO- KHAPERKHEDA UNIT 3 - 210 MW .............................................................45
3.8
GSECL- GHANDHINAGAR UNIT 5 - 210 MW ........................................................................49
3.9
GSECL-WANAKBORI UNIT 2 - 210 MW ...............................................................................53
3.10 NLCL- NEYVELI LIGNITE UNIT 2 - 210 MW (NLCL THERMAL POWER STATION 1
EXPANSION) .......................................................................................................................................56
3.11 NLCL- NEYVELI UNIT 7 - 210 MW.......................................................................................60
3.12 TANGEDCO-TUTICORIN UNIT 2 - 210 MW .........................................................................64
3.13 TANGEDCO - TUTICORIN UNIT 4 - 210 MW .......................................................................68
3.14 PSPCL-LEHRA MOHABBAT UNIT 1 - 210 MW .....................................................................72
3.15 TVNL- TENUGHAT UNIT 2 - 210 MW ...................................................................................76
3.16 DVC-DURGAPUR TPS UNIT 4 - 210 MW ..............................................................................80
3.17 RVUNL-SURATGARH UNIT 3 - 250 MW...............................................................................84
3.18 UPRVUNL- ANPARA UNIT 4 - 500 MW ...............................................................................89
ANNEXURE 1: 85 UNITS MAPPED UNDER IGEN PHASE I....................................................................93
ABBREVIATIONS ..............................................................................................................................96
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CHAPTER 1

Overview of Energy Saving Potential


1.1 Indian Power Sector at a Glance
Electricity has been universally recognized as one of the most important inputs for economic
growth and human development. There is a strong two-way relationship between economic
development and energy consumption. On one hand, growth of an economy, with its global
competitiveness, depends on the availability of cost-effective and environmentally benign energy
sources and on the other hand, the level of economic development has been observed to be reliant
on the energy demand.

To achieve both the objectives, the world is moving towards renewable energy sources, but still
the non-renewable energy sources grab the biggest share in catering the need of modernization.
This has also become a matter of great concern as the non-renewable source is limited and hence,
the invention of term sustainable development comes into picture.
Sustainable development is development that meets the needs of the present without
compromising the ability of future generations to meet their own needs.

Fig 1.1: Concept of Sustainable Development


Fig 1.1 shows the concept of Sustainable development. In other words it can be said that
sustainable development is a condition where economic and social development occurs without
damaging the environment. Hence, the sustainable development concept emphasizes on the
optimization of available non-renewable sources and use of renewable energy sources.

Installed generation capacity (As on 30.11.2013)


The Indian Power sector is a giant 232.16 GW power generator, diversified to coal, gas, oil,
nuclear, hydro, and other renewable sources as operating source. In India, Non Renewable Power
Plants constitute 87.3% of the installed capacity, and Renewable Power Plants constitute the
remaining 12.7% of total installed Capacity. Additionally, captive power plants add another
34.44GW to the generation. The contribution of sources to generation has been depicted below in

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Table-1.1 Fig-1.2 shows the contribution of sources in percentage which gives a better
understanding of the scenario.

S. No

Source

1
2
3
4
5
6

Capacity (in MW)

Coal
136448.39
Gas
20380.85
Oil
1199.75
Nuclear
4780
Hydro
39893.4
Other Renewable sources
29462.55
Total
232164.94
Table: 1.1 Total Installed Capacity (source wise)

Coal
Gas
12.69%

Oil

17.18%
58.77%
8.78%

Nuclear
Hydro

2.06%
Other Renewable
sources

0.52%

Note: Captive generation is not included in total

Fig: 1.2 Contributions of sources towards total installed capacity


Out of this 232.16 GW, States alone accounts for 90.59 GW, Central sector 66.99 GW, and
Private sector accounts for 74.58 GW. Table-1.2 and Fig-1.3 shows the total installed capacity of
coal based power plants in India sector wise.

S. No.

Sector

1
2
3

Central
State
Private
Total

Capacity (MW)

Percentage (%)

45435.01
33.29
52828.00
38.71
38185.38
28.00
136448.39
100.00
Table: 1.2 Total Coal based Power Generation (Sector wise)

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Private
28%

Central
33%

State
39%

Total 136.45 GW

Fig1.3 Distribution of Coal Based Power Plants (Sector wise)


Statistics shows that state alone accounts for more than one third of the countrys installation.
Hence, this proves the supremacy of state sector in meeting the requirement of present day
scenario.
2. Indo-German Energy Program
The Indo-German Technical Cooperation in the field of Energy Conservation commenced when
the first Indo-German Energy Efficiency Project was launched in May 1995 by the Energy
Management Centre, a predecessor organization to the Bureau of Energy Efficiency (BEE). With
the success of the project and looking into the need of promoting Energy Efficiency in the
country, a full-fledged Indo-German Energy Program (IGEN) was launched in October 2003.
IGEN was launched in the context of enactment of Energy Conservation Act 2001 and
establishment of Bureau of Energy Efficiency. Out of the two components Energy Efficiency
component and Power Plant Optimization component, the Power Plant Optimization component,
which is being implemented by Central Electricity Authority (CEA) in association with GIZ, aims
at improvements in availability and energy efficiency of power plants.
An average increase of 1% efficiency of thermal power plants results into coal saving of
approximately 11 Million tons per annum. While analyzing the efficiency of conventional power
plants, one has to remember that fuel cost amounts to approximately 75% of the total average
production costs. This fact clearly highlights the necessity of operating the plant at optimum
efficiency. Along with cost effectiveness the reduction in the emission of air pollutants is also
required. The degradation of the plant efficiency is a normal process, but a permanent challenge
to minimize the degradation by measuring performance parameters and taking the corrective
action through the O&M exists. Heat rate deviation occurs due to some or more of the equipment
parameter deviations, process deviations and change in input conditions like atmospheric
temperature, fuel parameters and CW temperature etc. In design, the heat rate is not a static figure
and a constant for the unit and it is dependent on at what load unit is operating.
Indo-German Energy Programme (Phase I)
Recognizing the large potential of energy efficiency in thermal power plant as brought out in para
2 above, the phase-l of the IGEN Project (Power Plant Component) was executed during 2007 to
2009 under two main sub-components:
i) Mapping studies of thermal power generating units
Ii) Performance optimization of Thermal Power Stations.
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In the subcomponent (i), GIZ provided support to CEA for creating data base of the older thermal
power plants in India. The scope of the work primarily covered the mapping by STEAG Energy
Service, of 85 pulverized coal fired thermal generating units using Ebsilon software.
The mapping was done for two conditions, namely for design parameters and for the actual
operating status for the plant parameters gathered from different plant locations. The primary
purpose was to provide a database within CEA and broadly identify areas needing attention in
short, medium and long term for improving energy efficiency. The baseline mapping provides an
objective method of setting targets and monitoring progress.
The mapping study of 85 power generating units undertaken with the help of Ebsilon Software
projected an estimated saving potential of coal to the tune of 6.92 million tonnes per year. As per
Indian quality of coal, the savings would lead to a CO2 emissions reduction up to 10 million
tonnes per year. This reconfirmed the possibility of huge potential in Green House Gas mitigation
and the viability of using Ebsilon software. Mapping exercise introduced power plants to the
versatility of Ebsilon software as a diagnostic tool and enabler for planning for Energy Efficiency
improvement measures in Thermal Power Plants.
Indo-German Energy Programme (Phase II)
To make the energy efficiency efforts sustainable in the long run, phase II (Power Plant
Component) has been launched to build on the achievements of phase I. Phase II aims at
developing replicable Model Power Plants equipped with facilities and resources for continuous
performance monitoring supported by capability to introduce measures for bringing measurable
improvements in the performance of Model Power Plants.
Phase II itself is split in three subcomponents:
a)Support 15 Thermal Power Generation Utilities in various States for their
plant efficiency improvement by using diagnostic tools
b) Introduce the model power plant in four thermal power stations
c) Human resource development to improve knowledge in critical areas
As one of the output of subcomponent (a), phase II, 15 Thermal Power Generation Utilities have
been supplied Ebsilon Software licenses and user staff has been trained in the use of this
software.
As a part of training, Case Studies were required to be developed indicating saving potential and
long and short term Energy Efficiency measures for achieving projected saving. Accordingly, 17
case Studies were developed by trainees from State Utilities pertaining to different units. The
analysis of these 17 units is detailed in Chapter-3. The summarized position of different size of
units considered for case studies are shown in Table 1.3
Total Installed
Capacity (MW)
120
2
240
125
1
125
210
12
2520
250
1
250
500
1
500
Total
17
3635
Table 1.3 Capacities of Selected Units

Capacity (MW)

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Number of Units

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The capacities of these 17 plant sums-up to 3635 MW. On study of these plants, huge range of
savings potential was discovered. These have been taken in detail in chapter-2 and 3.
1.3 Energy Saving Potential in 17 Units Studied Under IGEN Phase-II
The potential improvements have been derived for short term and long term gain of Heat Rate in
17 units studied and the same has been calculated in terms of tonnes of oil equivalent (toe) per
year. The saving potential (toe) has been estimated for each case study shown in Chapter 2. On
the assumption of PLF at 85%, as is normally taken in design phase of the units, total saving
potential has been estimated as 563906.18 toe (short term as 139317.67 and long term as
424588.52 toe) as shown in fig 1.4
Total Short Term Saving Potential
(139317.67 toe)
4951.81

Total Long term Saving potential


(42458284.0552.48toe)
13333.61

2576.68

24332.849

4176.4585

2185.515

9650.01

30051.75

474.78

41691.95
12937.22

21313.11

44367.2

57091.08
231312.53

7778.14

36178.47

17097.54
MS pressure (kg/cm2)

MS Temp (C)

RH Temp (C)

Condenser Vacuum (mmHg)

UBC in Fly Ash (%)

UBC in bottom ash (%)

Makeup (%)

Excess air (%)

RH Spray (t/h)
Exit Gas Temp (C)
HPT Efficiency (%)
LPT Efficiency (%)
HPH DCA (K)
LPH DCA (K)

SH Spray (t/h)
Change in FW temp (C)
IPT Efficiency (%)
HPH TTD (K)
LPH TTD (K)

Fig: 1.4 Short term and Long Term Savings potential with Factors considering 85%PLF
With current all India PLF (70%) the total saving potential for 17 units works out to be 465246.78
toe (Short term117365.47 and long term 347881.32 toe) as shown in fig 1.5. Refer Table 2.7
(chapter 2).
Total Short term Saving Potential
(117365.47 toe)

Total Long term Saving potential


(347881.32 toe)

4076.53

10238.81

2121.97
3536.02
23867.62

22939.35
17551.98

1799.20

1980.99
7700.31
388.00 34392.47
10654.17

46653.83

36763.48
190370.04

29726.24

6405.49
14080.30
MS pressure (kg/cm2)

MS Temp (C)

RH Temp (C)

Condenser Vacuum (mmHg)

UBC in Fly Ash (%)

UBC in bottom ash (%)

Makeup (%)

Excess air (%)

RH Spray (t/h)
Exit Gas Temp (C)
HPT Efficiency (%)
LPT Efficiency (%)
HPH DCA (K)
LPH DCA (K)

SH Spray (t/h)
Change in FW temp (C)
IPT Efficiency (%)
HPH TTD (K)
LPH TTD (K)

Fig. 1.5 Short term and Long Term Savings potential with Factors considering 70%PLF

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On analysis of Fig 1.4 & 1.5, it is observed that the maximum contributing factor towards short
term saving is condenser vacuum and for long term savings is Turbine efficiency. Other major
contributing factors are MS Temp, Unburnt Carbon, Excess air, etc. The detailed analysis of these
parameters affecting individual units under consideration, with recommendations is mentioned in
chapter 3.
1.4 Energy Saving potential estimated for 85 units mapped under IGEN Phase-I

Under IGEN Phase-I, 85 units were mapped during 2007-2009. The details of unit mapped are
indicated in Annexure 1.
After R&M, the operating heat rate is expected to improve with a maximum deviation of 7.5%
from the design. Accordingly, the expected saving was worked out and found to be about 7.04
million tons of coal per year or 2492630 toe (through Ebsilon mapping studies of 85 Thermal
Units). The saving potential in different capacity groups is indicated in table-1.4.
HR
(kcal/kWh)

Weighted
Average of
unit size
(MW)
108.1

120-125

140

Saving potential for all


units mapped
(TOE)

364

Saving
Potential per
unit
(TOE)
27580

120.6

356

30080

270720

140.0

252

24720

98880

195-200

199.0

409

57040

285200

210

49

210.0

173

25460

1247540

250

250.0

162

28380

141900

500

500.0

130

45550

227750

Total

85

17545.2

Unit Size
(MW)

No of
Units

100-110

220640

2492630

Table 1.4 Saving Potential from 85 Units under IGEN I

5. Comparison of Energy Saving potential as Worked out in IGEN Phase II with Phase I
For the purpose of understanding and comparison of trends of the saving potentials worked out in
two phases of IGEN, two approaches are being used:
a) Comparing 17 out of 85 similar units of phase-I with the 17 units of phase-II and
b) Extrapolating the results of 17 units of phase-II to 85 units of Phase-I
The comparison on both approaches has been worked out below. The detailed outcome of each
option could be seen down under.
a) Comparing 17 out of 85 similar units of phase-I with the 17units of phase-II
17 out of 85 units from phase-I, with similar installed capacity to phase-II have been compared
with the results of Case Studies of 17 units now undertaken. The comparative position of saving
potential for 17 units of both phases, assuming PLF 85% is listed below in Table 1.5.

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IGEN

Saving Potential in toe


Short Term
Long Term
Total
249253.90
340384.38
589638.29
139317.67
424588.52
563906.18
Table 1.5 Saving Potential Comparison IGEN I&II

Phase- I
Phase -II

The total savings in toe for these 17 units of both phases comes out to be similar. The mild
deviation, whatsoever, is mainly due for the age and degradation of unit due to time, wear & tear.
The comparison of Saving potentials- short term and Long Term based on Controllable Parameter
is depicted in the PI charts given below:
Total Short term Potential (249253.90 toe)

Total Short Term Potential (139317.67 toe)

2196.27

1199.37
22108.46

4951.81

14173.89

2576.68
4176.4585

24332.849

IGEN I

IGEN II
73106.40

97018.45

21313.11

57091.08

7778.14

4180.70
35270.36

17097.54
MS Temp (C)
Condenser Vacuum (mmHg)
UBC in bottom ash (%)
Excess air (%)

MS pressure (kg/cm2)
RH Temp (C)
UBC in Fly Ash (%)
Makeup (%)

MS Temp (C)
Condenser Vacuum (mmHg)
UBC in bottom ash (%)
Excess air (%)

MS pressure (kg/cm2)
RH Temp (C)
UBC in Fly Ash (%)
Makeup (%)

Fig 1.6 Comparison of Saving potential from Short term measures


Total Long Term potential ( 340384.38 toe)

13333.61
2185.515

12377.31
2471.81

2405.48

1560.40

0.00

0.00

Total Long term potential (424588.52 toe)

43190.52

IGEN I

160431.52

44367.2

IGEN II

54418.05

RH Spray (t/h)
Exit Gas Temp (C)
HPT Efficiency (%)
LPT Efficiency (%)
HPH DCA (K)

40671.42
SH Spray (t/h)
Change in FW temp (C)
IPT Efficiency (%)
HPH TTD (K)
LPH TTD (K)

9650.01
41691.95
12937.22

30051.75

6875.30
18388.05

474.78

231312.53
36178.47

RH Spray (t/h)
Exit Gas Temp (C)
HPT Efficiency (%)
LPT Efficiency (%)
HPH DCA (K)

SH Spray (t/h)
Change in FW temp (C)
IPT Efficiency (%)
HPH TTD (K)
LPH TTD (K)

Fig 1.7 Comparison of Saving potential from Long term measures


It can be observed from Fig 1.6 and 1.7 that the factors contributing are similar for both the
phases of IGEN. The major factor contributing to maximum savings potential for short term is
condenser vacuum and that for long term is LP Turbine efficiency. The detailed analysis and
recommendations is discussed in Chapter 3.
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b) Extrapolating the results of 17 units of phase-II to 85 units of Phase-I

The outcome of the 17 units of Phase-II, were extrapolated to the 85 units of Phase-I, keeping the
PLF same as 85%.
Phase-II
Total MW Studied
3635
Total savings in toe
563906.18
Average savings (toe) per MW
155.13
Phase-I
Total MW mapped

17545.2

Total savings (toe) estimated


Average savings (toe) per MW

2492630 (2.5 Mtoe)


142.06

The average toe per MW calculated from results of both the phases comes to be almost similar.
Extrapolating the result of phase-II to Phase-1
(17545.2*155.13) = 2721786.87
Total savings (toe) for 85 units of phase-I
= 2.7 Mtoe
The total calculated savings in terms of toe, for Phase-I comes to be 2.7 Mtoe against 2.5 Mtoe
actually estimated during execution of Phase-I. The deviation, whatsoever, is mainly due for the
age and degradation of unit due to time, wear & tear.
Hence, from both the exercise, it is evident that savings calculated is almost similar for both the
phases and hence it can be held true for other coal fired state utilities also.

1.6 Estimate of Energy Saving potential in respect of All State Utilities (Coal Fired Thermal
Power Plants)
Perusal of results worked out in para 1.5 above indicates that the range of energy saving potential
as worked out in the two studies is similar. The saving potential worked out in IGEN Phase-II at
70% PLF has been taken as basis, for the purpose of projections of saving potential w.r.t. coal
based thermal power plants under State sector.
Energy saving potential (toe) for Phase-II with 70% PLF works out to be 465246.78 toe. Refer
Table 1.4 for the detailed calculation of savings with 70% PLF (2012-13)
Out of 136448 MW all India installed capacity of coal fired thermal power plants, installed
capacity at State sector is 52828 MW. Assuming that 75% of the coal fired state utilities are
similarly placed as the 17 units studied, the projected saving potential for all coal fired thermal
power plants in State sector with 70% PLF works out to be,
= (75% of 52828)* (Saving based on 70%PLF) / 3635
= {(0.75*52828)*465246.78} / 3635
= 5071125.9 toe
= 5.07Mtoe

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Million tonnes of Oil equivalent


(MToe)

5.07

5
4
3
2

0.46

1
0
1 Studies
Case

2
All State
Utilities

Fig 1.8 Saving Potential of Coal Based State Power Plants


Hence, from the above calculations, a saving potential of 5.07 Mtoe could be achieved for coal
based state utilities of all India. This is huge savings in terms of coal equivalent. Also, this
enormous savings will result in decrease of coal consumption, reduction of CO2 emission,
ultimately leading to the concept of sustainable development.

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Chapter 2

Summary Report of 17 pulverized coal fired thermal power


generating units in different states based on Ebsilon Professional
Analysis - Case Study
1. Methodology
Ebsilon model of the design as well as the operating condition has been created based on the
offline data available at station. The possibility of maintaining the parameters as per the actual
operating condition has been simulated and verified from the plant data. The potential
improvement has been finalized for short term and long term gain of efficiency and it has been
calculated in terms of tonnes of oil equivalent per year.
The model analysis has been carried out to determine the degradation of performance of important
equipment which can affect the overall plant performance and efficiency. Enthalpy drop values
were obtained from the HS (Mollier) diagrams. The model enables assessment of impact of
changes in some parameters over other parameters. Such changes include deviations in coal
quality. Deviations in the following have been determined with the help of the model taking into
account the impact of external factors and current operating conditions of the plant.

Gross heat rate


Turbine heat rate
Boiler efficiency
Unit efficiency
Efficiency of HP turbine
Efficiency of IP turbine
Efficiency of LP turbine
Regenerative heater performance
Condenser performance
Excess O2

2. Findings
The principal challenges of the power supply industry today are security of supply, low cost of
generation of electricity, environmental protection and conservation of available resources. The
controllable losses related to plant parameters not being maintained at their design points based
on actual loads has been computed and the potential improvement in the above areas as a long
term measures have been derived. The controllable losses accounts for losses associated with
equipment degradation and those associated with non-maintenance of design parameters. Since,
Ebsilon uses thermodynamic model of the process, losses of the generator cannot be determined
and the leakages through the steam seal should be considered as boundary condition.
The studies revealed that most of the units are being operated under various constraints like poor
quality of coal, insufficient attention to proper maintenance of boiler, turbine and other
equipment, operating parameters different from the rated values and obsolete instrumentation.

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These have resulted in high heat rates and unreliable plant operations. These observations are
analyzed below.
2.3 Analysis of key Performance Indicators
The gross heat rate values as well as other operating indices for all the 17 generating units have
been tabulated for different unit sizes in Chapter 3. Analysis of important power plant
performance indicators namely gross heat rate, turbine heat rate and boiler efficiency has also
been carried out for the same size of units (120 MW, 125 MW, 210 MW, 250 MW and 500 MW).
The comparative unit wise position for the above indices is shown in Chapter 3.
2.3.1 Variations in boiler efficiency
Table 2.1 and Fig 2.1 depict the variations in boiler efficiency observed in units of different sizes.
Capacity
range of units
(MW)
120
125

No. of
units

210
250
500

12
1
1

Average Design
Boiler Efficiency
(%)
86.03
78.61

2
1

Average
Operating Boiler
Efficiency (%)
81.37
78.12

Average Deviation
(%)
5.41
0.62

86.61
83.91
88.93
88.13
87.40
85.70
Table 2.1 Boiler Efficiency Variations

3.11
0.90
1.95

It is seen that the boiler efficiency is close to design values for 250 and 500 MW units (excluding
125 MW Lignite based Plant), indicating that these units have stabilized. The boiler efficiency has
deteriorated more incase of 120 and 210 MW units, being older units.

88.93
88.13

90.00

Boiler Efficiency (%)

88.00

86.61

86.03

86.00

85.70
83.91

84.00
82.00

87.40

81.37

80.00

78.6178.12

78.00
76.00
74.00
72.00
120MW

125MW

210MW

250MW

500MW

LOAD

Design Average

Operating Average

Fig 2.1 Comparison of average Boiler Efficiency of different unit sizes

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2.3.2 Heat rate variations


The average design and operating values of Turbine heat rate for each group size are depicted in
Table 2.2 and Fig 2.2:

Capacity of
units (MW)

No. of
units

120
125

2
1

210
250
500

12
1
1

Average
Design Turbine
Heat Rate
(kcal/kWh)
2023.94
1990.57

Average
Operating
Turbine Heat
Rate (kcal/kWh)
2133.72
2013.48

Average Deviation
(%)

5.42
1.15

1999.63
2118.42
1953.80
2065.30
1984.80
2142.00
Table 2.2 Turbine Heat Rate Variations

5.94
5.71
7.92

The tabulation of operating indices for individual units in the above five capacity ranges is shown
in Chapter 3. It is observant that, except 125 MW lignite fired unit, TG Heat Rate in all other units
has deteriorated.

2200.00

TG HR (kcl/kWh)

2150.00

2142.00

2133.72

2118.42

2100.00
2050.00

2065.30
2023.94

2000.00

2013.48
1990.57

1999.63

1984.80
1953.80

1950.00
1900.00
1850.00
120MW

125MW

Design Average

210MW

250MW

500MW

LOAD
Operating Average

Fig 2.2 Comparison of average TG Heat Rate of different unit sizes

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The average design and operating values of gross heat rate as also the percentage deviation for
each group size is given in Table 2.2 and Fig 2.3.

Capacity
range of units
(MW)

No.of units

Average
Design Gross Heat
Rate (kcal/kWh)

Average Deviation
(%)

2353.21

Average
Operating Gross
Heat Rate
(kcal/kWh)
2633.38

120

125

2532.30

2557.80

1.01

210

12

2311.60

2542.80

10.00

250

2195.00

2343.00

6.74

500

2268.60

2497.30

10.08

11.91

Table 2.3 - Gross Heat Rate Deviations

Out of 17 units studied, the maximum deviation in operating gross heat rate from the design gross
heat rate has been observed in the case of 120, 210 and 500MW capacity unit whereas it is
comparatively less in 125 and 250 MW unit.

Gross Unit HR (kcal/kWh)

2700.00

2633.38
2557.80

2600.00

2532.30

2500.00
2400.00

2353.21

2542.80

2311.60

2497.30
2343.00

2268.60

2300.00

2195.00

2200.00
2100.00
2000.00
1900.00
120MW

125MW

210MW

250MW

500MW

Load
Average Design

Average Operating

Fig 2.3 Comparison of average Unit Heat Rate of different unit sizes

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The composite effect of TG Heat Rate deviation and boiler efficiency is indicated in table 2.4.
Average Deviation
Unit Heat Rate (%)

5.42

Average
Deviation Boiler
Efficiency (%)
5.41

125

1.15

0.62

1.01

210

5.94

3.11

10.00

250

5.71

0.90

6.74

Capacity range of units


(MW)

Average Deviation
TG Heat Rate (%)

120

500
7.92
1.95
Table 2.4 Average deviation of TG, Unit HR and Boiler Efficiency

11.91

10.08

It is also noticed that deviation in the TG Heat Rate is major contributor in average deviation in
Unit Heat Rate.
2.4 Savings potential
The potential improvements have been derived for short term and long term gain of Heat Rate
and the same has been calculated in terms of tonnes of oil equivalent (toe) per year. The saving
potential (toe) has been estimated for each case study shown in Chapter 3. Total saving potential
of each group size of unit is shown in table 2.5.
Capacity
range of
units
(MW)

No.
of
units

120

86.03

81.37

2353.21

2633.38

2023.94

2133.72

Average Saving
potential (Tonnes
of oil equivalent
per year) per unit
in the unit size
category
Short
Long
Term
Term
3208.92
10016.20

125

78.61

78.12

2532.30

2557.80

1990.57

2013.48

2661.29

7855.88

210

12

86.61

83.91

2311.60

2542.80

1999.63

2118.42

9957.92

27662.61

250

88.93

88.13

2195.00

2343.00

1953.80

2065.30

6057.70

16217.40

500

87.40

85.70

2268.60

2497.30

1984.80

2142.00

4685.84

48531.54

Average Boiler
Efficiency (%)

Average Turbine
Heat Rate
(kcal/kWh)

Average Unit Heat


Rate (kcal/kWh)

Design

Operating

Design

Operating

Design

Operating

Table 2.5 Potential savings


Assumptions:
Plant load factor 85%
Oil GCV 10000 kcal/kg

Table 2.5 depicts average saving potential of each unit. It can be observed from the table that the
125 MW unit has least saving potential as it operates closer to its design parameters. On the other
hand, the 210 MW units have more saving potential. This may be due to non-maintenance of
parameters, degradation of units, leakages, etc. However, the detailed analysis is mentioned in
Chapter 3.
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Short term and long term saving potential for each range of unit with the contributing factors is
represented in Table 2.6 and 2.7 with PLF 85% and 70% respectively.

Parameters

120 MW
(2)

125
MW (1)

210 MW
(12)

250 MW
(1)

500 MW
(1)

Total (toe)

Short Term Potential ( 139317.67 toe)


MS pressure

438.72

4449.8

63.29

4951.81

MS Temp
RH Temp

41.82
387.78

0
0

1641.34
2723.90

893.52
186.15

0
878.63

2576.68
4176.46

Condenser
Vacuum

839.91

1673.07

50004.95

4573.15

57091.08

UBC in Fly Ash


UBC in bottom
ash
Makeup

679.07
415.49

0
0

16418.47
6594.78

0
404.88

0
362.99

17097.54
7778.14

18814.98

2498.13

21313.11

Excess air

3615.05

988.22

18846.78

882.80

24332.85

Long Term Potential ( 424588.52 toe)


915.21
7177.84
0
1556.96
22.59
347.87
0
93.82

RH Spray
SH Spray

0
10.5

9650.01
474.78

Exit Gas Temp

3002.22

2028.04

32193.89

4467.60

41691.95

Change in FW
temp

1554.28

4867.69

6515.25

12937.22

HPT Efficiency

2799.52

4112.85

27154.21

5888.86

4411.76

44367.2

IPT Efficiency

3727.8

769.26

24527.67

749.44

6404.30

36178.47

LPT Efficiency

5052.32

197972.48

7491.05

20796.68

231312.53

HPH TTD
HPH DCA

3784.42
0

0
7.73

23077.46
2080.06

851.08
97.73

2338.79
0

30051.75
2185.52

LPH TTD
LPH DCA

101.33
0

0
0

11784.78
767.36

1139.24
0

308.26
1638.12
Total

13333.61
2405.48
563906.18

Table 2.6 Short & Long Term Potential for energy efficiency based on controllable parameters
based on 85% PLF
Based on the analysis it has been found that the maximum potential is contributed by deterioration
of condenser vacuum which can be attended in short term measure. Other important factors which
are deteriorated in terms of short term measure are like excess air and unburnt carbon in fly ash,
which may be because of bad quality of coal. Similarly the deterioration of turbine efficiency
contributes to maximum saving potential which can be attended as a long term measure. Other
important parameters like exit loss in boiler and HP Heater performance need to be attended in
order to achieve the available potential as a long term plan.

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Parameters

120 MW
(2)

125 MW
(1)

210 MW
(12)

250 MW
(1)

500 MW
(1)

Total (toe)

Short Term Potential ( 117365.47 toe)


MS pressure

361.30

3663.11

52.12

4076.53

MS Temp

34.44

1351.69

735.84

2121.97

RH Temp

319.35

2339.79

153.30

723.58

3536.02

Condenser Vacuum

691.69

1273.07

40922.94

3766.13

46653.83

UBC in Fly Ash

559.24

13521.06

14080.30

UBC in bottom ash

342.17

5430.96

333.43

298.94

6405.49

Makeup

15494.69

2057.29

17551.98

Excess air

2977.11

688.22

18547.02

727.01

22939.35

Long Term Potential (347881.32 toe)


RH Spray

515.21

5902.90

1282.20

7700.31

SH Spray

8.65

15.59

286.49

77.26

388.00

Exit Gas Temp

2472.42

1728.24

26512.61

3679.20

34392.47

Change in FW temp

1279.99

4008.67

5365.50

10654.17

HPT Efficiency

2305.49

3612.85

22362.29

4849.65

3633.21

36763.48

IPT Efficiency

3070.22

569.26

20195.44

617.19

5274.13

29726.24

LPT Efficiency

4160.73

163036.17

6169.10

17004.04

190370.04

HPH TTD

3116.58

18124.09

700.89

1926.06

23867.62

HPH DCA

5.73

1712.99

80.48

1799.20

LPH TTD

83.44

8963.30

938.20

253.86

10238.81

LPH DCA

631.95

1349.04

1980.99

Total

465246.78

Table 2.7 Short & Long Term Potential for energy efficiency based on controllable parameters
based on 70% PLF
With current all India PLF (70%) the total saving potential for 17 units works out to be 465246.78
toe (Short term117365.47 and long term 347881.32 toe) as shown in Table 2.7.
2.5 Reasons for high operating gross heat rates
It is observed that the heat rate deviation is very high in some units while in others it is only
moderately high. Table 2.8 below depicts the maximum and minimum variation among various
ranges of units.
Minimum Heat
Maximum Heat
Capacity range of units
No. of units
Rate Deviation
Rate Deviation
(MW)
(%)
(%)
120
2
10.92
12.7
125
1
1.05
-210
12
3.68
16.51
250
1
2.89
-500
1
10.08
-Table 2.8 Maximum and Minimum variation of Heat rate within range of units
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It is evident from the figure, that the Heat Rate deviation amongst various range units of 210 MW
size is very large.

Based on observations during site visit and discussions with the site engineers on the operation
and maintenance aspects of the power plants, some areas commonly observed to be responsible
for high operating gross heat rate are listed below. These observations are not applicable to all the
units but are representative of the type of problems encountered. For specific sites, the individual
reports may be referred.
Analysis of observations for different power plants indicates that the major reasons for the high
operating gross heat rate are:
1 Un-optimized boiler combustion
2 Low turbine cylinder efficiency
3 Low condenser vacuum.
4 Heater performance
5 High air ingress in the boiler/air heater
6 Inefficient operation of air pre-heaters
7 High super heater and re-heater spray
8 Make Up flow
9 Coal quality not conforming to design coal
10 Inefficient soot blowing of the boiler tubes
6. Recommendations as proposed in the Case Studies
Recommendations to improve the performance and efficiency of the plant have been made for
each of the units covering maintenance and, operational aspects. These recommendations take
into account the observations at site, available information with project engineers and deviations
in operating parameters determined by Ebsilon model. The recommendations have been divided
into two categories namely:
1) Short term and 2) Long Term
The short term recommendations are those which mostly relates to operating practices, can be
implemented immediately at lesser cost, permitting picking up of low hanging fruits.
The long term recommendations cover overhauling and retrofit in the plant. The recommendations
cover energy audit of air flue gas path, replacement of APH blocks, providing oxygen analyzer at
APH outlet, steam path audit for turbines and checking the blade profile, checking and
rectification of heater baffle arrangement, burner management system, auto controls, turbine, ESP
controls and ID fan control improvement. These recommendations, however, will need further
detailed studies which could be taken up at the stage of next annual overhauling or at the time of
Residual Life Assessment studies. The unit wise recommendations for short and long term energy
efficiency are listed in Chapter 3.
7. Conclusion
The case study exercise of the 17 power plants has generated a lot of data and information on the
performance of power plants. It has brought out total saving potential of 563906.18 toe/yr.
Periodical mapping of the units and review of operating practices based on the analysis carried out
with the help of Ebsilon shall provide basis for sustained energy efficiency program in thermal
power plant units.
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CHAPTER 3

Overall Performance and Saving Potential of Individual Units


3.1 List of Units
Under IGEN Phase II, 17 operating Thermal Power Plants of 15 State utilities were identified and
Ebsilon licenses were provided to the utilities with a view of identification of problems to
ultimately improve the efficiency. The list and capacity of all those identified units are mentioned
in Table 3.1.
Sl No

State Board/
Electricity Gen.
Company

Power Station

Kothagudem Thermal Power Plant

Unit size
MW

Unit No

120

APGENCO

2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

GSECL
Sikka Thermal Power Plant
120
GIPCL
Surat Lignite
125
OPGC
IB Valley Thermal Power Plant
210
HPGCL
Panipat Thermal Power Plant
210
MAHAGENCO
Khaperkheda Thermal Power Plant
210
GSECL
Gandhinagar Thermal Power Plant
210
GSECL
Wankbori Thermal Power Plant
210
NLCL
Neyveli lignite
210
NLCL
Neyveli lignite
210
TANGEDCO
Tuticorin Thermal Power Plant
210
TANGEDCO
Tuticorin Thermal Power Plant
210
PSPCL
GHTPP, Lehra Mohabbat TPS
210
TVNL
Thenughat Thermal Power Plant
210
DVC
Durgapur Thermal Power Station
210
RRVUNL
Suratgarh Thermal Power Plant
250
UPRVUNL
Anpara Thermal Power Plant
500
Table 3.1 Description of 17 Generating Units identified under IGEN Phase II

1
3
2
6
3
5
2
2
7
2
4
1
2
4
3
4

With the help of this diagnostic software they were able to identify the areas of concern through
model mapping, as it clearly revealed the deviation of operating parameters with the design
parameters. A detailed analysis of the problems, area of concern and recommendations are
mentioned ahead in this chapter. The recommendations are divided into two categories, i.e. short
term and long term. Short term implies to those recommendations which can be carried out during
the normal operation of the plant, without much cost being incurred. The long term
recommendations on the other hand are those which require availability of equipment for
maintenance, R&M activities, overhauling activities, and moderate cost may also be incurred. The
detailed analyses of individual plants with recommendations are listed ahead.

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3.2 APGENCO - Kothagudem Thermal Power Plant, Unit 6 - 120 MW

Kothagudem Thermal Power Plant is located at Paloncha in Andhra Pradesh, India. The power plant
has an installed capacity of 1,720 MW with 11 units in operation. It is one of the coal based power
plants of APGENCO. The total capacity was commissioned in VI phases from the year 1966 to 2011.
The plant includes units of 60 MW, 120 MW, 250 MW and 500 MW. Under IGEN Phase II, the 6th
unit of this plant of 120 MW was identified and a case study was carried on. This BHEL unit was
commissioned in the year 1974. The R&M of turbine was undertaken by Siemens AG, from the year
2000-2004. The findings of the case study are listed below.
Load

TG Heat
Rate

Unit Heat
Rate

Boiler
Efficiency

Coal
Flow

Condenser
Vacuum

Main Steam
Flow

Temp

Pressure

Units

MW

kcal/kWh

kcal/kWh

t/h

t/h

0C

Kg/cm2

mmHg(a)

Design (A)

120

1955.6

2268.5

86.21

94.11

360

535

130

77.97

Actual (B)

98

2078.7

2516.9

82.71

91.2

302

536

112

68.4

Deviation
(A-B)/A %

18.33

6.3

10.95

4.05

3.09

16.11

0.18

13.85

12.27

Table 3.2 (a) Operating indices of Kothagudem TPP (Unit No 6)


Table 3.2 (a) shows the main operating parameters of Kothagudem TPP (Unit No 6) . It can be
observed from the table that there is quite high variation in parameters, especially in main steam flow
and pressure. These parameters accounts for the loss in efficiency. There are other parameters too that
contribute to the losses. An account of all such parameters contributing to losses, or in other words
contributing to saving potential has been depicted in Fig 3.2 (a) & 3.2 (b) below, for each, short term
and long term, with their estimated savings in toe.

4000

Total Short Term potential interms of tonnes Oil equivalent


(4515.71 toe/yr)
3615.05

3500

Oil in toe/yr

3000
2500
2000
1500
1000
500.37
500

263.58

136.71

0
MS pressure (kg/cm2)

RH Temp (C)

UBC in Fly Ash (%)

Excess air (%)

Controllable Parameters

Fig 3.2 (a) Short Term Saving Potential


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6000

Total Long term Potential interms of tonnes of Oil equivalent


(12812.62 toe/yr)
5052.32

Oil in toe/yr

5000
4000
3002.22

2799.52

3000
2000

1087.24
759.49

1000

101.33

10.5
0

SH Spray (t/h) Exit Gas Temp Change in FW HPT Efficiency LPT Efficiency HPH2 TTD (K) LPH5 TTD (K)
(%)
(%)
(C)
temp (C)

Parameters

Fig 3.2 (b) Long Term Saving Potential


Short term and long term saving potential in toe for deteriorated parameters are shown in Fig 3.2 (a)
& 3.2 (b). The excess air percentage and unburnt carbon in Fly ash percentage are major contributors
towards huge saving potential which can be attended in short term plan. Where as in long term plan,
the Turbine efficiency, exit gas temperature and top heater performance deterioration are the major
factors contributing towards the saving potential. Short term and long term recommendation for
energy efficiency is depicted in Table 3.2 (b).

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Table 3.2 (b) Recommendations for short and long term energy efficiency of Kothagudem TPP
Sl No.

Parameter

Design

Actual

Absolute
Deviation
(%)

A:70.10
B:78.29
C:79.81

A: 6.53

Frequent checking of grinding media


Mill fineness report
Frequent inspection of liner profile &
indicates that intervention Mill fineness shall be improved by ball
replacement, if needed irrespective of
charging periodically and classifier vanes
is required for Mill-A
time based schedule.
adjustment and also Identification of
fineness control
leakage points and rectification.

Observation

Short Term

Long Term

MILL
>75%
fineness (%)

SADC
(mmWC)

Wind box 40
to Furnace
DP>70

42.85

Wind Box to furnace DP


maintaining lower than
design.

Regular maintenance of SADC power


cylinders
Ensuring proper inside flap operation
and condition

Energy Audit of air and flue gas path to


assess the condition of FD, PA and ID
Fans.

Excess Air
(%)

19.38

25.46

31.37

Excess Air is higher than


design.

Regular monitoring of O2 in flue gas and


maintaining secondary air flow
accordingly

Provision of a grid of 4 or 6 oxygen


analyzers at APH Inlet.

APH
2.35
Leakage (%)

8.67

2.68

Very high temperature of Regular checkup of O2 in flue gas in


Replacement of air heater blocks in spite
FG at APH outlet is due to
inlet and out let of air heaters.
of regular scheduled replacement.
partial load operation as
Plugging the failed tubes in the air
well improper heat
heaters regularly.
Provision of a grid of 4 or 6 oxygen
transfer. Improper heat
analyzers at APH outlet.
Improved quality of coal to reduce the
transfer may be due to
erosion of air heater tubes due to high ash
soot deposits or tube
content
blockages.

Turbine
Efficiency
(%)

82.33

7.40

Turbine efficiency is
lower than design.

88.9

Maintaining MS and HRH parameters


near rated values.

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Sl No.

Absolute
Deviation
(%)

Parameter

Design

Actual

Observation

HP Heater
TTD (K)

HPH1:0.17
HPH2:0.24

7.37
7.00

2970
4017

LP Heaters
TTD (K)

LPH1:2.08
LPH2:3.12
LPH3:0.45
LPH4:1.36
LPH5:1.16

0.43
12.45
0.19
1.05
1.79

79.32
28
57.78
31.67
32.52

Heater performance is
deteriorated.

Condenser
TTD (K)

3.8

5.0

31.57

Condenser vacuum is
OLTC should be kept in operation in
Addition of chemicals viz. anti scalant,
within design limit but the
continuous mode,
bio-dispersant, biocides etc. as per the
TTD of condenser is on
chemical analysis of CT water and make Regular cleaning of condenser tubes shall
higher side.
up water.
be carried out.

Heater performance is
deteriorated.

Short Term

Long Term

Heaters should be charged fully instead


of partial charging as per the feed water
temperature before economizer. Due to
poor coal quality the unit operation not
permitting the full charging of HPH.
Drip levels should be maintained
properly.
Maintain drip levels properly.
Temperature gain is not as anticipated
due to very old heaters

Note: Observations/analysis presented in the table is based on the operating parameters as observed at the time of Studies.

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3.3 GSECL - SIKKA Thermal Power Plant Unit 1 - 120 MW

SIKKA Thermal Power Plant is located at Sikka near Jamnagar in Gujarat, India. The power plant
has an installed capacity of 740 MW with 2 units in operation with 120 MW each and 2 X 250 MW
under construction. It is one of the coal based power plants of GSECL. Under IGEN Phase II, the 1st
unit of this plant of 120 MW was identified and a case study was carried on. This BHEL make unit
was commissioned in the year 1989. The findings of the case study are listed below.
Load

TG Heat
Rate

Unit Heat
Rate

Boiler
Efficiency

Coal
Flow

Main Steam
Flow

Temperature

Pressure

Condenser
Vacuum

Units

MW

kcal/kWh

kcal/kWh

t/h

t/h

0C

Kg/cm2

mmHg(a)

Design
(A)
Actual
(B)
Deviation
(A-B)/A
%

120

2092.27

2437.92

85.84

69.5

365.05

537.78

138

76.20

94

2188.74

2749.85

80.03

69.5

289

537

125

80.91

21.67

4.61

12.79

6.77

0.00

20.83

0.15

9.42

6.18

Table 3.3 (a) Operating indices of SIKKA TPP (Unit No 1)


Table 3.3 (a) shows the main operating parameters of Sikka TPP (Unit No 1). It can be observed from
the table that there is quite high variation in parameters, especially in main steam flow, pressure and
boiler efficiency. These parameters accounts for the loss in efficiency and heat rate. There are other
parameters too that contribute to the losses. An account of all such parameters contributing to losses,
or in other words contributing to saving potential has been depicted in Fig 3.3 (a) & 3.3 (b) below, for
each, short term and long term, with their estimated savings in toe.
Total Short Term Potential interms of tonnes of Oil equivalent
(1902.13 toe/yr)
839.91

900
800

Oil in toe/yr

700
600
500
400

415.49
302.01

300

41.82

100
0

178.7

124.2

200

MS pressure
(kg/cm2)

MS Temp (C)

RH Temp (C)

UBC in Fly Ash


Condenser
(%)
Vacuum (mmHg)

UBC in bottom
ash (%)

Controllable Parameters

Fig 3.3 (a) Short Term Saving Potential

IGEN-Power Plant optimization

28 | P a g e

Total Long Term Potential interms of tonnes of Oil equivalent


(7219.77 toe/yr)
4000

3727.8

3500

Oil in toe/yr

3000

2697.18

2500
2000
1500
1000

794.79

500
0
Change in FW temp (C)

IPT Efficiency (%)

HPH6 TTD (K)

Parameters

Fig 3.3 (b) Long Term Saving Potential


Short term and long term saving potential in toe for deteriorated parameters are shown in Fig 3.3 (a)
& 3.3 (b). Condenser vacuum, main steam pressure and unburnt in bottom ash are the major
contributing factors towards huge saving potential which can be attended in short term plan. Whereas
in long term plan the IP turbine efficiency, feed water temperature and top heater performance
deterioration are the major contributing factors towards the saving potential. Short term and long
term recommendation for energy efficiency is depicted in Table 3.3 (b).

IGEN-Power Plant optimization

29 | P a g e

Table 3.3 (b) Recommendations for short and long term energy efficiency of SIKKA TPP
Sl No.

Parameter Design

Actual

Absolute
Deviation
(%)

Observation

Short Term

Long Term

UBC (%)

FA=1
BA=3

FA=1.1
BA=4.86

FA=10
BA=62

UBC in Bottom Ash as well


as Fly Ash is higher than
design.

Checking of Mill fineness and gap Mill Orifice replacement, Maintenance of


setting between the roller and bull
SADC, Clean Air flow Test, Maintenance
ring segment, PA/SA ratio,
of BTD and repairing of Burners.
adjustment of classifier.

Mill
Fineness
(%)

>75%

B=66
D=72

B=12
D=4

Mill rejection is Higher,


Poor Fineness. Abnormal
noise, Bearing Temperature
remains High, PA fan Van
control problem, Oil
leakages.

Regular condition based


Mill grinding roll and bearing
Preventive maintenance and
replacement, Complete mill O/H,
cleaning of classifier based on the
Replacement of venturi and airport
mill capacity degradation, Lub Oil
assembly / inverted cone. Worm gear
cooler Cleaning, Oil replacement,
Worm shaft replacement as per
Grinding roll/BRS wear
requirement, PA fan Van Control
measurement and running hour
replacement, Mill pipe and Critical bend
monitoring , Mill outlet Temp.
replacement
Monitoring.

SADC
(mmWC)

Fuel air damper control and


corner based variation and
mismatch opening of F/A
damper with reference to
control operation.

Fuel air damper control and corner Setting of SADC and damper control.
Servicing, replacement and calibration of
based variation
Power cylinders, Secondary air control
Rectification of damper on
matching with actual by physical
available opportunity.
verification.
Controlling of fuel air damper
based on the flame position.

Excess Air 22.81


(%)

32.07

40.60

No margin available to
maintain the design limits
due to Leakages and Air
ingress.

O2 monitoring before and after


APH, Identifying the duct and
Expansion bellow leakages.

APH
Leakage

Inlet O2
5.1 and

Inlet=20.28 O2 observed higher after


Outlet=80.
APH, PA and SA temp. rise

Inlet O2
4.24 and

Providing O2 mapping point across the


flue gas duct from /APH inlet to ID fan,
Replacement / Repairing of damaged
expansion below and ducts.

Rotor alignment and seal setting


Cleaning of all baskets by water jetting
work during available opportunity.
and replacement of Identified baskets of

IGEN-Power Plant optimization

30 | P a g e

Sl No.

Parameter Design

Actual

Absolute
Deviation
(%)

Observation

(%)

Outlet O2
5.5

outlet O2
9.9

00

lower, variation in PA
header pressure.

Furnace
Leakage

Air ingress was found on


higher side leading to
reduction in furnace draft
operating margin.

Turbine
Efficiency
(%)

HPT=78.1 HPT=83.22 HPT=6.56


IPT=87.6 IPT=76.20 IPT=13.01
LPT=80.13 IPT=88.5
IPT=10.45

Short Term

Long Term

H.E. and C.E., replacement/repairing of


sector plates, complete set of seals
replacements, replacement of rake pins,
maintenance of APH gear box.
Leakage identified in cat house,
pent house, in Corner No.4 inside
of Dog house.
Thermography to identify furnace
wall leakages.

Cylinder efficiency recorded Air cooling arrangement at


on lower side.
Bearing. No. 3.
Excessive leakage observed Oil purifier operation monitoring.
in glands.
Oil quality monitoring.
Turbine oil moisture carry
over found on higher side.
Bearing no.3 temp. remains
high.

IGEN-Power Plant optimization

Platen coil area seal plate, crown plate,


refractory, and skin casing repairing and
replacement in Pent house.
Leakage in Corner No.4 inside of Dog
house was attended by providing
insulation, refractory & Patch work.
Fin welding in furnace wall.
Bottom, LHS & RHS refractory damage
inside of Cat house area to be attended by
cleaning & providing of new refractory.
Skin casing weld crack near SHH-1 header
area, Skin casing found uneven near Drum
area at one place and same was corrected
RLA of Turbine and all its components.
Replacement of new IP rotor with inlet
nozzle.
Complete O/H of Turbine H.P, I.P, L.P,
with sand blasting and cleaning of H.P/I.P
line strainers.

L.P Last diaphragm replacement.


H.P first stage Nozzle replaced.
Complete new sealing system.
Bearing No.3 new replacement.

31 | P a g e

Sl No.

Parameter Design

Actual

Absolute
Deviation
(%)

Observation

Short Term

Long Term

New insulation on Turbine casing and


associated valves and pipings.
8

10

HP Heater
TTD (K),
Outlet
temp(0C)

HPH6
TTD=1
Feed water
outlet
Temp=227.
79

Condenser 76.20
Vacuum
mmHg(a)

BFP power 2.02


comsumpti
on (MW)

HPH6
1680
TTD=17.8
Feed water 7.81
outlet
Temp=210

High TTD noticed and lower H.P.H bypass valve checking.


final feed water temp.
Heater drain to dearator control.

80.9

Low vacuum recorded.

2.89

6.18

43.07

Heater level monitoring.


Heater vent to D/A checking for
passing

Helium leakage test to be


conducted to find out air ingress.
Online Back wash system
operation done when high CW
temp. rise.
Condenser Gravity test on
available opportunity

High power consumption.


Low flow and head.

Mechanical seal leakage.

IGEN-Power Plant optimization

Partition plate checking , attending all


extraction steam valves, feed water inlet
outlet and bypass valve o/h.

Cleaning of condenser by high pressure


water jetting.
Replacement/ Repairing of partition plate.
Water box leakage attaining.
Coating of Water box to avoid corrosion
due to sea water.

CW pump o/h .
NASH (vacuum) pump o/h.
Identified air ingress leakages are attained.
Identified pumps consuming high Replacement of Cartridge of BFP.
power.
Replacement and o/h of all valves.
Energy audit by NPC.
Passing of RC valves.
Replacement of mechanical seal.

32 | P a g e

3.4 GIPCL- Surat Lignite Unit 3 - 125 MW

Surat Lignite Power Station India is located at Village Nani Naroli Tal. Mangrol, Dist. Surat, Gujarat,
India. It has 4 unit of 125MW. The first unit was commissioned in 2000 and the last in 2010. It is
operated by Gujarat Industries Power Company Ltd. (GIPCL). Under IGEN Phase II, the 3rd unit of
this plant of 125 MW was identified and a case study was carried on. This BHEL / Siemens (Boiler/
turbine) unit was commissioned in the year 2010. The findings of the case study are listed below.
Load

TG Heat
Rate

Unit Heat
Rate

Boiler
Efficiency

Lignite
Flow

Condenser
Vacuum

Main Ste am
Flow

Temperatur
e

Pressure

Units

MW

kcal/kWh

kcal/kWh

t/h

t/h

0C

Kg/cm2

mmHg(a)

PGTest (A)

125.33

1993.923

2531.0

78.78

97.79

372.80

528.75

127.926

66.789

Actual (B)

124.96

2013.477

2557.8

78.12

96.12

372.00

535.08

128.42

80.998

Deviation
A-B)/A %

0.30

0.98

1.06

0.84

1.71

0.21

1.20

0.39

21.27

Table 3.4 (a) Operating indices of SLPP (Unit No 3)


Table 3.4(a) shows the main operating parameters of Surat lignite power plant (Unit No 3). The
comparison is based on the results of PG test and the operating condition of the plant during the case
study preparation. It can be observed from the table that there is not much variation in parameters
except the condenser vacuum.
Total Short Term Potential in terms of tonnes of Oil equivalent (2661.29 toe/yr)

1800

1673.07

1600

Oil in toe/yr

1400

988.22

1000
800
600
400
200
0
Condenser Vacuum (mmHg)

Excess air (%)

Controllable Parameters

Fig 3.4(a) Short Term Saving Potential

IGEN-Power Plant optimization

33 | P a g e

Total Long Term Potential in terms of tonnes of oil equivalent (7855.88 toe/yr)

4500

4112.85

4000

Oil in toe/yr

3500
3000
2500

2028.24

2000
1500
1000

915.21

769.26

500

22.59

7.72

0
RH Spray (t/h)

SH Spray (t/h)

Exit Gas Temp


(C)

HPT Efficiency IPT Efficiency (%) HPH6 DCA (K)


(%)

Parameters

Fig 3.4 (b) Long Term Saving Potential


An account of all operating parameters contributing to losses, or in other words contributing to
saving potential has been depicted in Fig 3.4 (a) & 3.4 (b), for each, short term and long term, with
their estimated savings in toe. Condenser vacuum and excess air percentage are the contributing
factors towards saving potential which can be attended in short term plan. Where as in long term plan
the Turbine efficiency, exit gas temperature and spray flow in RH contributes maximum towards the
huge saving potential. Short term and long term recommendation for energy efficiency is depicted in
Table 3.4 (b).

IGEN-Power Plant optimization

34 | P a g e

Table 3.4 (b) Recommendations for short and long term energy efficiency of SLPP
Sr. No. Parameter

PG TEST

Actual

Absolute
Deviation (%)

Observation

Short Term

-----

Long Term

Condenser Pressure 66.789


(mmHg)

80.998

21.27

Condenser Vacuum is on
higher side

UBC in fly ash (%) 0.5475

0.5

8.68

Condenser Tube choke-up & Air ingress was


--identified & attended during AOH-2013, CT Fills
cleaning & inspection
Within Limit

0.99

26.53

Within Limit

UBC in bottom ash 1.3475


(%)
RH Spray (t/h)
0.93

10.37

1015.05

High RH Spray

Problem is being studied, appropriate action will be taken

SH Spray (t/h)

25.94

34.01

31.11

High SH Spray

Problem is being studied appropriate action will be taken

Exit Gas Temp.


(oC)

139.5

155.38

11.38

High exit gas temperature

---

Convective pass tubes


hydro jet cleaning will
be carried out

HPT Efficiency (%) 90.29

80.96

10.33

Deteriorated HPT efficiency

---

IPT Efficiency (%) 88.96

86.7

2.54

Deteriorated IPT efficiency

---

Corrective action will


be taken up in COH
Corrective action will
be taken up in COH

HPH6 DCA (oC)

9.2

10.45

13.59

10

HPH5 DCA (oC)

1.48

7.45

403.38

Awareness is increased for maintaining Heater


level
Awareness is increased for maintaining Heater
level

IGEN-Power Plant optimization

-----

35 | P a g e

3.5 OPGC- IB Valley Thermal Power Plant Unit 2 - 210 MW

Odisha Power Generation Corporation Limited (OPGC) was incorporated on November 14, 1984.
OPGC started as a wholly owned Government Company of the State of Odisha with the main
objective of establishing, operating & maintaining Thermal power generating stations. In pursuit of its
objective, OPGC established Thermal Power Station having two units of 210 MW in the IB valley
area of Jharsuguda District in the State of Odisha. These Units have become operational from 1994 to
1996. Under IGEN Phase II, the 2nd unit of this plant of 210 MW was identified and a case study was
carried on. This BHEL unit was commissioned in the year 1996. The findings of the case study are
listed below.
Main Steam
Load

Unit Heat
TG Heat Rate
Rate

Boiler
Coal
Efficiency Flow

Condenser
Vacuum
Flow

Temperature

Pressure

0C

Kg/cm2

mmHg(a)

Units

MW

kcal/kWh

kcal/kWh

t/h

t/h

Design
(A)

210.06

1991.5

2351.2

84.7

165.3

636.74 535

150

75.98

2194.5

2572.5

85.3

171.2

694

137

97.83

8.67

28.75

Actual
208
(B)
Deviation
A-B)/A % 0.98

535

Table 3.5 (a) Operating indices of IB Valley (Unit No 2)


10.19

9.41

0.71

3.57

8.99

0.00

Table 3.5 (a) shows the main operating parameters of IB valley thermal Power Plant (Unit No 2). It
can be observed from the table that there is quite high variation in parameters, especially in main
steam flow, pressure and condenser vacuum. These parameters accounts for the loss in efficiency and
heat rate. An account of all such parameters contributing to losses, or in other words contributing to
saving potential has been depicted in Fig 3.5 (a) & 3.5 (b) below, for each, short term and long term,
with their estimated savings in toe.
Total Short Term Potential in terms of oil Equivalent (6467.14 toe/yr)
7000.00

6065.44
6000.00

Oil in kl/yr

5000.00
4000.00
3000.00
2000.00

228.92

172.78
0.00
Main steam Pressure (kg/cm2)

Condenser Pressure (mmHg)

Make up (%)

Controllable Parameters

Fig 3.5 (a) Short Term Saving Potential

IGEN-Power Plant optimization

36 | P a g e

Total LongTerm Potential in terms of Oil Equivalent (31233.88 toe/yr)


25000

19073.52

Oil in toe/yr

20000

15000

10000

4817.64

5000

4463.94
2606.31

187.64

66.46

18.37

0
Exit Gas Temp Change in FW HPT Efficiency IPT Efficiency LPT Efficiency HPH6 DCA (K) LPH3 TTD (K)
(%)
(%)
(C)
temp (C)
(%)

Parameters

Fig 3.5 (b) LongTerm Saving Potential

Short term and long term saving potential in toe for deteriorated parameters are shown in Fig 3.5 (a)
& 3.5 (b). Condenser vacuum, main steam pressure and make up flow are the parameters,
contributing towards saving potential which can be attended in short term plan. Whereas in long term
plan the turbine efficiency, exit gas temperature, feed water temperature and top heater performance
deterioration are the factors contributing towards the saving potential. It is found from the analysis
that the deterioration in condenser vacuum and LP turbine efficiency causes more losses. Short term
and long term recommendation for energy efficiency is depicted in Table 3.5 (b).

IGEN-Power Plant optimization

37 | P a g e

Table 3.5 (b) Recommendations for short and long term energy efficiency
Sl No.

Parameter Design

Mill
Fineness
(%)

Actual

Absolute
Deviation
(%)

<75micron (%) AB=76.88 AB=2.51


CD=75.18 CD=0.24
EF=78.44 EF=4.59

75 to 100
micron

AB=12.97 CD=13.97
EF=12.48

100 to 250
micron

AB=8.27
CD=8.86
EF=7.25

Observation

Short Term

Long Term

Passing of IGV, PAD and Regular Preventive

maintenance and cleaning of


Mill explosion.
classifier based on the mill
Variation in Mill Output.
capacity degradation.
Rectification of PA fans IGV
at every available

opportunity.

Replacement of mill liners and


modification in mill for reliability/
monitoring of bypass air and rotation of
mill screw to increase the reliability and
availability of the equipment..
Modification of mill DP and check noise
monitoring system to monitor coal level.
Replacement of IGV & PADs
Retrofitting of variable orifice in order to
balance coal pipe velocity in each corner.

SADC
40/50
position (%)

50/60

25/20

Fuel air damper control


Rectification of damper on
and corner based variation
available opportunity.
Controlling of fuel air
damper based on the flame
position.

Setting of SADC and damper control.


Secondary air control with open feedback
from combustion optimization.

Excess Air
(%)

15.9

7.36

53.71

No margin available to
Attending leakages in
maintain the design limits.
available opportunity.

APH
14.5
Leakage (%)

23.2

60.0

High leakage in air pre


heater

Replacement of ducts and expansion


bellows.
Modification of ESP to improve the dust
collection efficiency.
CO monitoring and maintain O2
measurement grid at I/L & O/L of APH.
Replacement of baskets and sealing
system.
Modified sector plate tracking system.
Modification to 24 element sealing system

IGEN-Power Plant optimization

38 | P a g e

Sl No.

Parameter Design

Actual

Absolute
Deviation
(%)

Observation

Short Term

Long Term

with advanced radial seals.


Proposed to have basket with four sections
to achieve 125 to 130 Deg APH outlet
temperatures.
Modification of GB sealing system.
Reloading and replacement of second pass
duct and its hangers.
5

Air ingress was found on Attending leakages at


higher side leading to
available opportunity.
reduction in operating
margin.
Cylinder efficiency
Utilizing the additional vent
recorded on lower side.
fans for absorbing steam
escape.
Excessive leakage
observed in glands.
Additional centrifuge has
been installed to limit the
Turbine oil moisture carry
turbine oil parameters within
over found on higher side.
limit.
Watching the sealing header
pressure to ensure the
condition of gland seals.

Furnace
(Combustion
Efficiency
%)
Turbine
Efficiency
(%)

98.52

99.53

1.03

HPT=87.1
IPT =90.5
LPT=86.9

HPT=80.5
IPT =82.7
LPT=76.2

HPT=7.58
IPT =8.62
LPT=12.31

HP Heater
TTD (K),
Final Feed
Water
Temp(0C)

HPH6= -0.2
HPH5= -0.2
LPH3= 2.8
HPH6
DCA=6.7
Final feed
Water
Temp=244.8

HPH6= 1.9
HPH5= 2.9
LPH3=
12.1
HPH6
DCA=7.16

HPH6= 850
High drip temperature
HPH5= 1350
noticed.
LPH3= 332.14
HPH6
DCA=6.87

Modified sealing system in pent house and


expansion bellows.
Rectification of hangers and supports.
Retrofitting with modified capsule with
advanced flow nozzles.
The temperature difference between MSV
outlet and control valve is found on higher
side, which needs attention on insulation.
Replacement of damaged seals of HP
Turbine.

Ensure the parting plane


Temperature drop between HPH outlet and
sealing during the available
economizer inlet is found on higher side
opportunity.
which needs replacement of insulation.

IGEN-Power Plant optimization

39 | P a g e

Sl No.

Parameter Design

Actual

Absolute
Deviation
(%)

Observation

Short Term

Long Term

Final feed 0.35


Water
Temp=243.
90C
8

Condenser
vacuum
(mmHg)

Cooling
Tower

75.98

Range=9
Effectiveness
=56.2%

97.83

28.76

Low vacuum recorded.

Helium leakage test to be


conducted to find out air
ingress.
Performance of Vacuum
pump can be checked.

Range=8

11.11

High differential
temperature

Ensure the deck cleaning and Augmentation of cooling tower capacity by


ensure the flow by adjusting
adding cells.
the blade angle.
Monitoring the approach and
do the corrective action
accordingly.

Effectivene 1.78
ss
=55.2%

IGEN-Power Plant optimization

Attending the air ingress by doing the


flood test and re-commissioning the online
cleaning system.
Off line cleaning of the condenser tubes
using brass bullets to ensure continuous
cleaning.

40 | P a g e

3.6 HPGCL- Panipat Themal Power Plant Unit 6 - 210 MW

Panipat Thermal Power Plant is located at Village Assan, Jind road,Panipat. It has a total installed
generation capacity of 1360 MW comprising of 4 units of 110 MW, two units of 210 MW and Two
units of 250 MW. The plant was commissioned as PTPS-1 of 4X110 MW units from 1979 to 1987
and PTPS-2 of 2X210 MW and 2X250 MW from 1989 to 2005. Under IGEN Phase II, the 6th unit of
this plant of 210 MW was identified and a case study was carried on. This BHEL unit was
commissioned in the year 1990. The findings of the case study are listed below.
Load

TG Heat
Rate

Unit Heat
Rate

Boiler
Efficiency

Coal
Flow

Main Steam

Condenser
Vacuum

Flow

Temp

Pressure

Units

MW

kcal/kWh

kcal/kWh

t/h

t/h

0C

Kg/cm2

mmHg(a)

Design (A)

210

1989.8

2277.3

87.3

122.4

635.82

535

150

88.56

Actual (B)

206.4

2182.7

2605.3

83.7

138.7

671.05

543.2

141.3

119.16

Deviation
(A-B)/A %

1.71

9.69

14.40

4.12

13.32

5.54

1.53

5.80

34.55

Table 3.6 (a) Operating indices of Panipat TPP (Unit No 6)


The main operating parameters of Panipat thermal Power Plant unit 6 is shown in Table 3.6(a). There
is deterioration in condenser vacuum, main steam pressure main steam flow and coal flow. These
parameters accounts for the loss in efficiency and heat rate.
Total Short Term Potential in terms of tonnes of Oil equivalent (16474.42 toe/yr)
12000
9713.14

Oil in toe/yr

10000
8000
6000

5191.35

4000
1454.2

2000
115.73
0
MS pressure (kg/cm2)

Condenser Vacuum (mmHg)

UBC in Fly Ash (%)

UBC in bottom ash (%)

Controllable Parameters

Fig 3.6 (a) Short Term Saving Potential

IGEN-Power Plant optimization

41 | P a g e

Total Long Term Potential in terms of Tonnes of Oil equivalent (28221.61 toe/yr)
25000

21034.35

Oil in toe/yr

20000

15000

10000

5000

2223.52
53.85

2223.52

570.74

469.1

1646.53

0
RH Spray (t/h) Change in FW HPT Efficiency LPT Efficiency HPH6 TTD (K) HPH6 DCA (K) LPH3 TTD (K)
(%)
temp (C)
(%)

Parameters

Fig 3.6 (b) Long Term Saving Potential

On account of parameters contributing to losses as shown in Table 3.6(a), or in other words


contributing to saving potential has been depicted in Fig 3.6 (a) & 3.6 (b) below, for each, short term
and long term, with their estimated savings in toe. As per the analysis the deteriorated condenser
vacuum, Unburnt carbon in FA and BA accounts maximum towards the short term savings, whereas
Turbine efficiency (HPT & LPT) and top heater performance deviation from their designed accounts
for the maximum savings in long term. Short term and long term recommendation for energy
efficiency is depicted in Table 3.6 (b).

IGEN-Power Plant optimization

42 | P a g e

Table 3.6 (b) Recommendations for short and long term energy efficiency
Sl No. Parameter Design

FA=2.5
BA=7.0

UBC (%)

Mill
<50micron(%)
Fineness(%)
100micron(%)

200micron(%)

Excess Air
(%)

28.62

Actual

Absolute
Deviation
(%)

FA=4.16
BA=10.72

FA=66.40 The current UBC of the unit is observed to be The total air flow should be
4.16 in FA which is higher than the design
BA=53.14
maintained at optimum level.
range of 2%. This may be due to low excess air
of 9.9 % against design of 28.6 %. (It can be
noted that the excess air calculation is based on
the assumed O2 % as 5.5 % at APH outlet as
the same is not available).

C=1.80
D=1.48
E=1.88
F=2.0
C=11.88
D=9.94
E=17.12
F=18.32
C=18.44
D=11.62
E=29.36
F=28.60
9.99

65.09

APH
7.14
Leakage (%)

20.38

185.43

Exit gas
temp(0C)

139.4

2.52

143

Observation

Short Term

Periodical setting and need


10.72 in BA against the design of 5-6%. Mills
based replacement of the
fineness report indicates that classifier setting
classifiers
for RC feeder E and F is disturbed a lot;
Periodical charging of balls
especially coal passage through 100 and 200
based on mills operating
mesh is exceptionally low.
current.

The current UBC of the unit is observed to be

Long Term

The O2 measurement should


be made available at APH
outlet.
The O2 measurement shall
also be supported with CO
measurement in Flue Gas at
chimney for proper analysis.
Regular mill health can be
monitored with DP
measurement system. The
system is installed but not
available. The same should be
made available.
Periodical replacement of mill
liners as per approved OEM
liner replacement guidelines

Low excess air of 9.9 % against design of 28.6 Identification and rectification A grid of 4 or 6 oxygen

analyzers should be provided


of leakage points.
% is observed. This is due to unavailability of
at APH outlet.
margin with the ID fans. This may be due to the Regular monitoring of O2 in
flue gas and maintain
leakages in various ducts and furnace under
secondary air flow accordingly.
vacuum
As oxygen measurement at APH outlet is not Maintenance and need based Installation of Automatic
replacement of APH seals.
Leakage Control System
available, the value is assumed as 5.5%, the
(ALCS) after feasibility study
same is reflected by trend of low APH outlet
may be explored for online
Flue gas temperatures. Based on the assumed
APH leakage control.
value the analysis shows that the APH leakage
is much higher than design.

IGEN-Power Plant optimization

43 | P a g e

Sl No. Parameter Design

Turbine
Efficiency
(%)

HPT=89.28
IPT =90.56
LPT=89.05

HP and LP
Heaters
TTD/DAC
(K)

HPH6TTD=3.03
HPH5TTD=3.03
LPH3TTD=2.97
HPH6DCA=7

Feed water
temp (0C)

FFWT=241

Condenser
TTD-K
Vacuum
mmHg(a)

TTD=3.1
Vacuum=88.56

Actual

Absolute
Deviation
(%)

HPT=86.21
IPT =92.31
LPT=76.88

HPT=3.44 HPT Cylinder efficiency has slightly degraded


IPT =1.93
from design. This is partially due to Main
LPT=13.67
Steam Pressure being maintained at lower value

HPH6TTD=10.9
7
HPH5TTD=8.13
LPH3TTD=8.88
HPH6DCA=19
FFWT=233.7

262.05
168.32
198.99
171.4
3.03

TTD=14.1
34.55
Vacuum=119.16

Observation

Short Term

Long Term

Proper checking and setting


of Governing characteristics
should be done to put turbine
on normal pressure/ load
controller mode. The same
shall allow the machine to be
operated at rated MS
pressure.
LP Turbine module detailed
analysis is required after
opening it in the next
opportunity.

(140 KSC) against design (150 KSC). It is


observed that turbine is operated with Valve
Wide Open condition at rated load leading to
lower MS pressure.
IP Turbine efficiency is maintaining as per
design.
LP Turbine efficiency is degraded a lot against
design. It is observed especially for LPT stages
up to 3rd extraction. The pressure and
temperature drop is exceptionally low.
Chemical cleaning may be
The TTDs of HP and LP heaters have increased The baffle plates in desuperheating and condensation explored if the scaling on
to unacceptable values.
zone should be checked and
heater tubes is also observed.

repaired/ replaced in next


The DCA value of HPH-6 is also very high
available opportunity.
against design value of 7.0 deg C.

condenser air temperature is observed to be


much lower (45 Deg C) than the saturation
temperature (55 Deg C). This is indicative of
condenser air ingress. The CW flow is
maintaining as per design. The CW temperature
rise is slightly higher than design indicating low
possibility of tube chocking and scaling. The
condenser vacuum is also higher partially to
higher heat loading as steam flow is higher than
design (due to VWO operation)

Poor Condenser vacuum is observed. The

IGEN-Power Plant optimization

Online and offline leakage


detection of the condenser
steam space, Flash tanks and
valves in the lines should be
done.
Tube cleaning can also be
done.

If the normal pressure/ load

controller for turbine can be


put in operation, steam flow
for same load is expected to
be reduced, further improving
condenser vacuum.

44 | P a g e

3.7 MAHAGENCO- Khaperkheda Unit 3 - 210 MW

Kaparkheda Thermal Power Station is located in Nagpur district in the Indian state of Maharashtra.
The power plant is one of the coal based power plants of MAHAGENCO. The coal for the power
plant is sourced from Saoner and Dumri Khurd mines of Western Coalfields Limited. The installed
capacity is 4 X 210 MW. In IGEN Phase II a case study has been prepared for unit 3 for 210 MW.
This BHEL unit was commissioned in the year 2000. The detailed findings are as below.
Load

TG Heat
Rate

Unit Heat
Rate

Boiler
Efficiency

Coal
Flow

Main Steam

Condenser
Vacuum

Flow

Temp

Pressure

Units

MW

kcal/kWh

kcal/kWh

t/h

t/h

0C

Kg/cm2

mmHg(a)

Design (A)

210

1939

2234

86.8

134.4

624

535

149

67

Actual (B)

210

1979.5

2407.1

82.2

179.9

631.5

540

146

71.93

Deviation
(A-B)/A %

0.00

2.09

7.75

5.30

33.85

1.20

0.93

2.01

7.36

Table 3.7 (a) Operating indices of Khaperkheda unit 3

Operating Indices of unit 3 is outlined in table 3.7(a). As can be seen from the table for same
loading condition the condenser vacuum and coal flow is deteriorated much from the
design where as other parameters are close to design limit.

Total Short term Potential in terms of tonnes of Oil equivalent (12647.91 toe/yr)

7000

6013.51
6000

5029.63

Oil in toe/yr

5000
4000
3000
2000

1564.9

1000

39.87
0
MS pressure (kg/cm2)

Condenser Vacuum
(mmHg)

Makeup (%)

Excess air (%)

Controllable Parameters

Fig 3.7 (a) Short Term Saving Potential


IGEN-Power Plant optimization

45 | P a g e

Total Long term potential in terms of tonnes of Oil equivalent (22954.44 toe/yr)
18000
16221.41
16000
14000

Oil in toe/yr

12000
10000
8000
6000
3565.14

4000

2575.35
461.59

87.56

RH Spray (t/h)

SH Spray (t/h)

43.39

0
Exit Gas Temp IPT Efficiency (%) LPT Efficiency (%) HPH5 DCA (K)
(C)

Parameters

Fig 3.7 (b) Long Term Saving Potential


Based on the analysis the short term and long term saving potential is shown in Fig 3.7 (a) & (b). It
has been found that deterioration in condenser vacuum, excess air and makeup flow contributes more
saving potential which can be handled in terms of short term objective whereas as long term
objective, Turbine efficiency (particularly LPT), exit gas temperature and spray flow can be taken
care of, to achieve the saving potential. Short term and long term recommendation for energy
efficiency is depicted in Table 3.7 (b).

IGEN-Power Plant optimization

46 | P a g e

Table 3.7 (b) Recommendations for short and long term energy efficiency
Parameter

Design

Actual

Absolute
Deviation
(%)

Observation

Short Term

Long Term

UBC (%)

FA=1
BA=2

FA=0.8
BA=1.93

FA=20
BA=3.50

No major variation
observed. The UBC in
bottom ash and fly ash are
within the design limit.

Mill (number of Number of mill


mills in
in operation= 4
operation)
Coal
flow=134.4t/h

Sl No.

5 mills are in operation


against the design of 4
number of mill for
generating 210 MW due to
bad coal quality, coal flow
is also more

Number of
mill in
operation=5
Coal
33.85
Flow=179.9
t/h

Excess Air (%) 20

25.19

APH

Leakage=
Leakage =
70.93
3.75%
6.41%
Efficiency=
62%
Efficiency= 16.13
FG temp=1400C 52%
FG
temp=1590C

Turbine
Efficiency (%)

HPT=85
IPT=90.4
LPT=88

HPT=89.76
IPT=85.92
LPT=83.49

Excess air percentage is


high in compared to the
design may be because of
improper heat transfer in
the boiler.

25.95

High flue gas outlet


temperature.

HPT=5.6
IPT=4.96
LPT=5.13

Cylinder efficiency of IP
and LP turbine is observed
in lower side.

IGEN-Power Plant optimization

Monitoring & correcting +50


mesh
Coal fineness.
Feeding better coal out of
available coal

Installation of Multiple O2
sensors in FG path & CO
analyzers at APH inlet

Setting of seals, Identifying air


ingress& attend in overhaul,
Installation of Multiple O2
sensors in FG path

To use raw & imported coal


with blending to optimize to
Design GCV

Identifying air ingress&


attend in overhaul

Replacement of AH baskets
during overhaul 5 years life
extracted

Steam flow path


checking/Casing & gland
centering, roll check. etc
Attending passing High
energy drains.
Checking blades during

47 | P a g e

Sl No.

Parameter

Design

Actual

Absolute
Deviation
(%)

Observation

Short Term

Long Term

overhauling
6

HP Heater

Condenser
67
Vacuum
(mmHg (a))
Cooling Tower Approach
=4.5

HPH5 DCA=5

HPH5
DCA=6.11

22.20

High drip temperature


noticed.

71.93

7.36

Low vacuum is recorded.

Approach
=8.2

82.22

Approach is on higher side, Setting blade angles, Cutting


causing deterioration in
trees for Tech reasons
cooling tower performance.

IGEN-Power Plant optimization

Checking of baffle plate


Putting OLCC in service

Bullet cleaning/Hi pr jetting


during Overhaul
Cleaning C T pond in
overhaul

48 | P a g e

3.8 GSECL- Ghandhinagar Unit 5 - 210 MW

Gandhinagar Thermal Power Station is a coal-fired power station in Gujarat, India. It is located on the
bank of Sabarmati river near Gandhinagar. It is one of the coal based thermal power plant of GSECL.
Toatl installed running capacity of Gandhinagar is 870 MW, having 2 X 120 MW at stage I and 3X
210 MW in Stage-II. In IGEN Phase II a case study has been prepared for unit 5 of 210 MW. This
BHEL unit was commissioned in the year 1998. The detailed findings are as below
Load

TG Heat
Rate

Unit Heat
Rate

Boiler
Efficiency

Coal
Flow

Main Steam

Condenser
Vacuum

Flow

Temp

Pressure

Units

MW

kcal/kWh

kcal/kWh

t/h

t/h

0C

Kg/cm2

mmHg(a)

Design (A)

210.13

1988.8

2319.30

85.75

129.29

632.5

535

150

85.76

Actual (B)

211.33

2190.5

2499.5

87.63

128.67

682.3

534.48

147.7

79.88

Deviation
(A-B)/A %

0.57

10.14

7.77

2.19

0.48

7.89

0.10

1.53

6.86

Table 3.8 (a) Operating indices of Gandhinagar unit 5

Table 3.8 (a) shows the main operating indices of Gandhinagar thermal Power Plant. It can be
observed from the table that there is quite high variation in parameter, especially in main steam flow.
The TG heat Rate is deteriorated around 10.14 % compared to design and unit heat rate deviated
around 7.77%. from design.
Total Short Term Potential in terms of tonnes of Oil equivalent (706.79 toe/yr)

371.37

400
350

Oil in toe/yr

300

252.81

250
200
150
100
50

52.04

30.57

0
MS pressure (kg/cm2)

MS Temp (C)

UBC in bottom ash (%)

Makeup (%)

Controllable Parameters

Fig 3.8 (a) Short Term Saving Potential

IGEN-Power Plant optimization

49 | P a g e

Total Long term Saving potential in terms of tonnes of Oil equivalent (43629.73
toe/yr)
35000

31266.32

30000

Oil in toe/yr

25000
20000
15000
10000

6188.81

5000
370.04

2296.7

1948.26

431.57

311.17

472.85

344.01

0
RH Spray Exit Gas Change in
HPT
LPT
HPH6 TTD HPH6 DCA LPH3 TTD LPH3 DCA
(t/h)
(K)
(K)
(K)
Temp (C) FW temp Efficiency Efficiency
(K)
(%)
(C)
(%)

Parameters

Fig 3.8 (b) Long Term Saving Potential

An account of operating parameters contributing to losses, or in other words contributing to saving


potential has been depicted in Fig 3.8 (a) & 3.8 (b), for each, short term and long term, with their
estimated savings in toe. Form the analysis the short term potential is found to be maximum in UBC
in bottom ash and make up flow. Similarly the long term potential is maximum in case of turbine
efficiency specially LP turbine. Short term and long term recommendation for energy efficiency is
depicted in Table 3.8 (b).

IGEN-Power Plant optimization

50 | P a g e

Table 3.8 (b) Recommendations for short and long term energy efficiency
Sl No. Parameter

Design

Actual

FA=0.91
BA=3.95

Observation

Short Term

Long Term

UBC in FA is Within
limit UBC in BA is
slightly higher

Checking of Mill fineness and


gap setting between the roller
and bull ring segment.

Coal burner maintenance and


replacement is planned during
COH

Mill liners damaged.

Regular Preventive maintenance


and cleaning of classifier based
on the mill capacity degradation.
Rectification of PA fans IGV at
every available opportunity.

Replacement of mill liners, rollers


and pulling segment, orifice.
Monitoring of bypass air and
rotation of mill screw.

25/30

37.5/40

Fuel air damper control


Rectification of damper on
and corner based variation
available opportunity.
Controlling of fuel air damper
based on the flame position.

Complete overhauling of dampers


is planned.

15.86

0.75

No margin available to
maintain the design limits

Attending leakages in available


opportunity.

Replacement / repairing of ducts


and expansion bellows from
furnace up to ID inlet.

18.06
FG temp APH
out= 160.23

108.43

High flue gas outlet


temperature indicates the
improper heat transfer.

Replacement of baskets and seals.


Modified sector plate tracking
system.

Basket cleaning and change of


position of baskets.
Measuring and rectification of
the sealing arrangement.
Attending leakages at available
opportunity.

UBC (%)

FA=1.5
BA=3

Mill Fineness
(%)

Through 200 Within Limit


mesh should In the range of
be more than 75 to 77 %
70%

SADC
Position (%)

40/50

Excess Air
(%)

15.98

APH Leakage 6.44


(%), FG Temp FG temp
APH out (0C) APH out=
148
Furnace
Leakage

Absolute
Deviation
(%)
FA=39.33
BA=31.67

8.26

Air ingress was found on


higher side leading to
reduction in operating
margin of furnace to
Wind box DP.

IGEN-Power Plant optimization

Leakage arresting during COH


including penthouse.

51 | P a g e

Sl No. Parameter

Design

Actual

Absolute
Deviation
(%)

Observation

Turbine
HPT=89.34
Efficiency(%) IPT=92.1
LPT=81.13

HPT=80.99
IPT=92.45
LPT=63.59

HPT=9.3
IPT=0.38
LPT=21.6

Cylinder efficiency
recorded on lower side.

HP Heater
TTD (K)

HPH6TTD
=6.9, DCA=22

DCA=57

High drip temperature


noticed.

HPH6TTD=
-0.02,
DCA=14

IGEN-Power Plant optimization

Short Term

Long Term

Work will be carried out in next


COH
Ensure the parting plane sealing
during the available opportunity.

52 | P a g e

3.9 GSECL-Wanakbori Unit 2 - 210 MW

Wanakbori Thermal Power Station is a coal-fired power station in Gujarat, India. It is located on the
bank of Mahi river in Kheda district. There are seven units of each 210 MW capacity commissioned
from 1982 to 1998. Under IGEN II, a case study has been prepared for unit 2 of 210 MW. This BHEL
unit was commissioned in the year 1983. The detailed analysis is as below.
Load

TG Heat
Rate

Unit Heat
Rate

Boiler
Efficiency

Coal
Flow

Main Steam

Condenser
Vacuum

Flow

Temp

Pressure

t/h

0C

Kg/cm2

mmHg(a)

Units

MW

kcal/kWh

kcal/kWh

t/h

Design (A)

210

2055.9

2316.5

88.75

120.21 670

535

130

75.76

Actual (B)

205

2065

2405

85.86

131.85 640

533

129

75.03

Deviation
(A-B)/A %

2.38

0.44

3.82

3.26

9.68

0.37

0.77

0.96

4.48

Table 3.9 (a) Operating indices of Wanakbori Unit 2


Table 3.9 (a) shows the main operating indices of Wanakbori thermal Power Plant Unit No 2. It can
be observed that there is no major deviation except the coal flow which is quite high as compared to
the designed. The boiler efficiency is also low as compared to the designed value.
Total Short term potential in terms of tonnes of Oil equivalent (2121.11 toe/yr)
1907.67

2000
1800
1600

Oil in toe/yr

1400
1200
1000
800
600
400
200.15
200
13.29
0
MS pressure (kg/cm2)

MS Temp (C)

Makeup (%)

Controllable Parameters

Fig 3.9 (a) Short Term Saving Potential

IGEN-Power Plant optimization

53 | P a g e

Total Long term Potential in terms of tonnes of Oil equivalent (3946.06 toe/yr)
7000

6417.26

6000

Oil in toe/yr

5000
4000
3000
2000
1000

1426.06
230.8

43.78

375.28

609.83

332.28

27.36

0
RH Spray
(t/h)

SH Spray
(t/h)

Exit Gas
Temp (C)

Change in
FW temp
(C)

LPT
Efficiency
(%)

HPH5,6,7
TTD (K)

HPH6 DCA
(K)

LPH4 DCA
(K)

Parameters

Fig 3.9 (a) Long Term Saving Potential


Figure 3.9 (a) &(b) shows the short term and long term saving potential found out based on the
analysis of model and the data collected from site. From the results it is found that the make up flow,
MS temperature, LP turbine efficiency and HP heaters are contributing maximum saving potential,
where as other parameters are boiler exit gas temperatures, SH and RH Spray also contributes
significant saving potential. Short term and long term recommendation for energy efficiency is
depicted in Table 3.9 (b).

IGEN-Power Plant optimization

54 | P a g e

Table 3.9 (b) Recommendations for short and long term energy efficiency
Sl No. Parameter

Design

Actual

Absolute
Deviation
(%)

Observation

Short Term

Long Term

Replacement of mill liners and modification in


mill for reliability/ monitoring of bypass air and
rotation of mill screw.
Modification of mill DP and noise monitoring
system.
Retrofitting of variable orifice in order to
balance coal pipe velocity in each corner.

Mill
Fineness(%)

75% should pass In the range of 66 to


through
70 %
200mesh

Mill fineness is
deteriorated from design
value.

Regular Preventive
maintenance and cleaning of
classifier based on the mill
capacity degradation.

Excess Air
(%)

14.88

14.91

0.02

Excess air is with design


limit but higher fuel flow.

Attending leakages in available Replacement of ducts and expansion bellows.


opportunity.

APH
Leakage(%)

8.12

9.64

18.72

Poor Heat Transfer

Regular Checking of O2 at
APH inlet and outlet.

Replacement of baskets and sealing system.


Modified sector plate tracking system.

Turbine
HPT=81.07
Efficiency(%) IPT=89.63
LPT=77.21

HPT=81.71
IPT=89.80
LPT=76.49

HPT=0.79
IPT=0.19
LPT=0.93

Lower LP Turbine
efficiency

Watching the sealing header


pressure to ensure the
condition of gland seals.

Replacement of damaged seals of LP Turbine.


L.P Last diaphragm replacement.

HP Heater
TTD (K)

HPH7=5
HPH6=18
HPH5=10.6

177
350
112

Deteriorated HP Heater
Performance

H.P.H bypass valve checking


and checking of Heater drain
to dearator control.
Heater level monitoring. And
Heater vent to D/A checking
for passing

Partition plate checking , attending all


extraction steam valves, feed water inlet outlet
and bypass valve o/h.

Within Limit

High pressure water jet


cleaning is being carried out
during the available
opportunity.

Attending the air ingress by doing the Hot well


flood test and replacement of flash tank steam
side expansion bellows. Proposed to conduct
eddy current test to identify the eroded
condenser tubes and replacement.
Proposed to carry out bullet cleaning system.

Final feed
water
temp(0C)
6

HPH7=1.8
HPH6=4
HPH5=5

Final feed water Final feed water


Temp=246.8
Temp=2390

Condenser
75.76
back pressure
(mmHg)

75.03

3.16

0.96

IGEN-Power Plant optimization

55 | P a g e

3.10

NLCL- Neyveli Lignite Unit 2 - 210 MW (NLCL Thermal power Station 1 Expansion)

Neyveli Thermal Power Station is a power plant situated near lignite mines of Neyveli. It consists of
two units capable of producing 420 MW. It is operated by Neyveli Lignite Corporation. 2X 210 MW
has been commissioned in 2002 & 2003. In IGEN Phase- II the case study has been prepared for unit
2. This unit is ANSALDO make and was commissioned in 2003. The detailed analysis is as below.
Load

TG Heat
Rate

Unit Heat
Rate

Boiler
Efficiency

Coal
Flow

Main Steam

Condenser
Vacuum

Flow

Temp

Pressure

t/h

0C

Kg/cm2

mmHg(a)

Units

MW

kcal/kWh

kcal/kWh

t/h

Design (A)

210

1942.9

2124.1

91.64

191.81 603.26 535

150

75.76

Actual (B)

211.6

1994.5

2231.4

89.3

213.94 624

531.3

151

69.14

Deviation
(A-B)/A %

0.76

2.66

5.05

2.55

11.54

0.69

0.67

8.74

3.44

Table 3.10 (a) Operating indices of Neyveli Lignite Unit 2

The operating indices of Neyveli unit 2 are shown in Table 3.10 (a). For same load range the
parameters are nearly to the design value except the coal flow which is may be because
of poor coal quality. As can be seen from table the TG heat rate is deteriorated to 2.66 %
where as the unit heat rate is deteriorated to 5.05%.

Total Short Term Potential in terms of tonnes of Oil equivalent (9142.7toe/yr)


8052.85
8000

Oil in toe/yr

7000
6000
5000
4000
3000
2000
1000

347.13

742.74

0
MS Temp (C)

RH Temp (C)

Excess air (%)

Controllable parameters

Fig 3.10 (a) Short Term Saving Potential

IGEN-Power Plant optimization

56 | P a g e

Total Long Term Potential in terms of tonnes of Oil equivalent (25446.50 toe/yr)

7000

6301.55

6424.3

6198

oil in toe/yr

6000
5000

4278.17

4000
3000
2000

1720.03

1000

126.66

233.61

164.18

LPH4 TTD
(K)

LPH4 DCA
(K)

0
RH Spray
(t/h)

SH Spray
(t/h)

Exit Gas
Temp (C)

HPT
Efficiency
(%)

IPT
Efficiency
(%)

LPT
Efficiency
(%)

Parameters

Fig 3.10 (b) Long Term Saving Potential

Short term and long term saving potential is plotted in figure 3.10 (a) &(b) based on the model
analysis and sample parameter collected during the case study preparation. As can be seen from
figure, the maximum available saving potential is found to be in case of Turbine efficiency, boiler
exit gas temperature, RH Spray flow and Excess air percentage. Short term and long term
recommendation for energy efficiency is depicted in Table 3.10 (b).

IGEN-Power Plant optimization

57 | P a g e

Table 3.10 (b) Recommendations for short and long term energy efficiency
Sl No.

Parameter

Design

Actual

Absolute
Deviation
(%)

UBC(%)

FA=2.04
BA=2.56

FA=1.5
BA=2.5

FA=26.47
BA=2.34

Observation

Short Term

Fly ash and Bottom Ash


After burning grid, speed and air
percentage are within design
flow to ABG.
limit.
Controlling the secondary air and

Long Term

Overhauling of the system to

maintain the availability

territory air to make the fuel air


ratio within limits
2

Mill
Flow(t/h)

Lignite flow
191.81

Lignite flow 11.54


213.94

Performance deterioration
starts after 1800 Running
hours.

APH
Leakage(%)

11.61

4.65

Basket found to be having

Regular replacements of beater


plates and replenishing the wheel
Controlling the feeding rate based
on the mill outlet temp

Material up gradation may help to

improve the wheel life.

Feed control NA
station delta
pressure.

10 to 18 bar -

Every shift steam blowing is done This process to be repeated


during every overhaul to retain
to keep the air heaters clean.
the RAH efficiency.
Baskets were washed and sealing
Advanced air heaters with 24
system improved as a result the
sections will improve the sealing
overall improvement in the boiler
and reduce the leakages
efficiency is 1.76 % on NCV basis
[i.e from 87.11 to 88.87]
The Feed control valves
No action is possible in short term Increasing the Cv [Co-efficient of
delta press. is maintained
velocity] of the temperature
between 10 to 18 bar for
control valves of SH spray
generating adequate
system by replacing the present
attemperator spray water to
under sized valves. The same
maintain SH outlet temp.
flow and pressure comparison
done with existing system in TS2 and performance found as we
recommended.

Turbine exht 318.3


temp(0C)

342

HPT exhaust temperature is No action is possible in short term It will be checked in the overhaul.

59.95

chokes.

7.45

found to be slightly higher

IGEN-Power Plant optimization

58 | P a g e

Sl No.

Actual

Absolute
Deviation
(%)

BFP
4.26
Power(MW)

5.64

32.39

Make Up
flow(t/h)

18

Parameter

Design

Observation

High power consumption

Short Term

Regular auto control and DP

reduction

69 to 90

Variation in condenser

vacuum.

Cooling
tower
Approach
(0C)

4.9

83

Replacement of the SH spray


control valves will bring about
improvements.
Regular monitoring of
recirculation valves by using the
thermography to avoid the
passing and do the rectification
work on time.

Increase in make-up of DM Where ever possible on line

water.

Condenser
75.76
Vacuum(mm
Hg)

Long Term

Deviation in approach

IGEN-Power Plant optimization

Overhauling of high temp drain


leakage arresting utilized. System
valves and check the passing
is isolated and leaks are attended.
Regular vaccum drop test allows Water Jet cleaning. If necessary
acid cleaning.
maximum 2mm/minute and
corrective action taken.
Inspection and maintaining the
better Quality in CW water
Regular inspection and cleaning of
water box in all available
opportunity
Maintain OLTC to ensure the
cleanness

Maintain the better chemical


Regular cleaning of fills cleaning
by water jets and replacement of
parameters on regular basis.
damaged fills during shut down.
Inspection of cooling tower for the
healthiness of nozzles and end
caps.
Checking of cycle of concentrating
in of CW system

59 | P a g e

3.11

NLCL- Neyveli Unit 7 - 210 MW

The Neyveli Thermal Power Station II was built in two stages. At the first stage between March 1986
and March 1988 three units with capacity of 210 MW each were commissioned. Boilers were
supplied by Ganz-Danubius and generators were supplied by Franco Tosi. At the second stage from
March 1991 to June 1993 four units with the same capacity, supplied by Bharat Heavy Electricals
Limited, were added. The unit is located at Neyveli, Tamilnadu. In IGEN phase II case study has
been prepared for unit 7 which is BHEL make and was commissioned in the year 1993. The detailed
analysis is as below.
Load

TG Heat
Rate

Unit Heat
Rate

Boiler
Efficiency

Coal
Flow

Main Steam

Condenser
Vacuum

Flow

Temp

Pressure

t/h

0C

Kg/cm2

mmHg(a)

Units

MW

kcal/kWh

kcal/kWh

t/h

Design (A)

210

2012

2531

79.5

196.59 650.3

535

150

75.98

Actual (B)

210

2083.4

2856

72.9

208.43 661.0

527.96

143.1

76.00

Deviation
(A-B)/A %

0.00

3.55

12.84

8.30

6.02

1.32

4.60

0.03

1.65

Table 3.11 (a) Operating indices of Neyveli Unit 2

Operating Indices of Neyveli unit 7 is shown in Table 3.11 (a). The unit is running with
design load. There is deterioration in boiler efficiency of 8.30 % and the unit heat rate is
deteriorated about to 12.84% compared to design.
Total Short term Potential in terms of tonnes of Oil equivalent (11029.11 toe/yr)
4500
3752.78

4000

3909.15

Oil in toe/yr

3500
3000
2500
2000
1500

1402.6

1000

660.49

781.83

500

516.01
6.25

0
MS pressure
(kg/cm2)

MS Temp (C) RH Temp (C)

Condenser
Vacuum
(mmHg)

UBC in bottom Makeup (%)


ash (%)

Excess air (%)

Controllable Parameters

Fig 3.11 (a) Short Term Saving Potential

IGEN-Power Plant optimization

60 | P a g e

Total Long Term Potential in terms of tonnes of Oil equivalent (46435.88 toe/yr)
35000

29786.78
30000

Oil in toe/yr

25000
20000
15000
10000

6504.83

6135.05
3110.12

5000

301

450.33

147.77

0
RH Spray (t/h) Exit Gas Temp Change in FW HPT Efficiency IPT Efficiency LPT Efficiency HPH7 TTD (K)
(%)
(%)
(%)
(C)
temp (C)

Parameters

Fig 3.11 (b) Long Term Saving Potential

Short term and long term saving potential is plotted in figure 3.11 (a) &(b) based on the model
analysis and sample parameter collected during the case study preparation. As can be seen from
figure, the maximum available saving potential found to be in case of Turbine efficiency, boiler exit
gas temperature, make up flow, Excess air percentage, main steam pressure, main steam and Reheat
temperature. Short term and long term recommendation for energy efficiency is depicted in Table
3.11 (b).

IGEN-Power Plant optimization

61 | P a g e

3.11(b) Recommendations for short and long term energy efficiency


Sl No. Parameter

Design

Actual

Absolute
Deviation
(%)

Observation

Short Term

UBC in bottom ash is


higher

Secondary ait flow to be adjusted After Burning Grates to be


for better combustion.
replaced at regular intervals.
Checking of Mill fineness and gap
setting between the roller and bull
ring segment

UBC (%)

FA=2.04
BA=2.56

FA=0.83
BA=3.88

FA=59.31
BA=51.56

Mill Coal
Flow(t/h)

Coal flow
196.59

Coal flow 208.43

6.02

Excess Air (%) 20

25

25

APH Basket
Outlet temp
choke
146
Outlet temp(0C)

Outlet temp 178

21.92

HP Heater
TTD/DCA(K)

HPH6 TTD=1.5
DCA=4.3

HPH6 TTD=0.1
DCA=6.7

35.82

Long Term

Variation in Mill Output. Mill outlet and inlet temperature to Replacement of mill beater
be maintained by avoiding
wheels at regular intervals
formation and removal of RSD
mouth choke.
Maintaining mill outlet temperature
within limit.
Less margin available to Attending air leakages in the
maintain the design limits
available opportunities.

Overloading of ID fan
Periodical operation of APH soot
and high APH O/L temp.
blowers.
Water washing of APH.
During long period of
By pass valve passing may be
operation, Heat gain
attended.
across HPHs deteriorates.

IGEN-Power Plant optimization

Replacement of ducts and


expansion bellows.
Maintaining O2 measurement at
I/L & O/L of APH.
Ensuring availability of CMC
and auto control of combustion
control.
Replacement of baskets and
sealing system.

Checking and repairing of


partition plate between inlet and
outlet water boxes.
Hp heater FW by pass valve
repair/replacement.

62 | P a g e

Sl No. Parameter

8
7

Observation

Short Term

Long Term

76

Absolute
Deviation
(%)
0.03

Low vacuum recorded.

Regular water box cleaning in


available short shut down.
Conducting regular vacuum drop
test and attending external air
leakages.
Attending high temp.drain valves
passing.
Ensuring online tube cleaning
system availability on day to day
basis.

Identifying air ingress points by


filling the condenser upto the
neck and repairing air ingress
points.
Off line cleaning of the
condenser tubes using high
pressure water jet cleaning.

66.67

High unit make up.

Periodic system make up test is


Repair/Replacement of high and
being conducted to identify and
low pressure atmospheric
attend the causes.
drain/vent valves.
Drain Valve passing may be
checked.
Regular preventive maintenance of Overhauling of all rotating
rotating equipments to ensure
equipments on rotational basis
availability.
to ensure availability and to
reduce auxiliary power
consumption.

Design

Actual

Condenser
Vacuum
(mmHg)

75.98

Make up water
system /flow
(%)

All rotating
equipments

IGEN-Power Plant optimization

63 | P a g e

3.12

TANGEDCO-Tuticorin Unit 2 - 210 MW

Tuticorin Thermal Power Station is situated near newport of Thoothukudi on the sea shore of Bay of
Bengal, Southern India. It has 5 units with a total installed capacity of 1,050 MW commissioned
between the year 1979 to 1991. Under IGEN Phase II, the 2nd unit was identified and a case study was
carried on. This BHEL LMZ unit was commissioned in the year 1980. The detailed analysis is as
below.
Load

TG Heat
Rate

Unit Heat
Rate

Boiler
Efficiency

Coal
Flow

Main Steam

Condenser
Vacuum

Flow

Temp

Pressure

Units

MW

kcal/kWh

kcal/kWh

t/h

t/h

0C

Kg/cm2

mmHg(a)

Design (A)

210

2064.20

2375.30

86.90

89.20

654

535

130

75.76

Actual (B)

209

2191.5

2658.4

82.44

144.5

672.53 532

129

87.3

Deviation
(A-B)/A %

0.48

6.17

11.92

5.13

62.00

2.83

0.77

15.23

0.56

Table 3.12 (a) Operating indices of Tuticorin Unit 2


Table 3.12 (a) shows the main operating parameters of Tuticorin TPP. It can be observed from the
table that there is quite high variation in parameters, especially in main steam flow and condenser
vacuum. These parameters accounts for the loss in efficiency. There are other parameters too that
contribute to the losses.

4000

Total Short Term Potential in terms of tonnes of Oil equivalent


( 6701.85 toe/yr)
3440.05

3500

2777.06

Oil in toe/yr

3000
2500
2000
1500
1000
500

203.28

281.46

MS pressure (kg/cm2)

MS Temp (C)

0
Condenser Vacuum
(mmHg)

Makeup (%)

Controllable Parameters

Fig 3.12 (a) Short Term Saving Potential


IGEN-Power Plant optimization

64 | P a g e

10000

Total Long Term Potential in terms of tonnes of Oil equivalent


( 23891.79 toe/yr)
9144.6

9000

oil in toe/yr

8000
6504.83

7000
6000
5000
4000

2803.33

3000
2000
1000

2519.06

1290.02
531.64 239.24 228.92

4.69

393.65

231.81

Parameters

Fig 3.12 (b) Long Term Saving Potential


An account of all operating parameters contributing to losses, or in other words contributing to
saving potential has been depicted in Fig 3.12 (a) & 3.12 (b), for each, short term and long term, with
their estimated savings in toe. It is observed that apart from others, condenser vacuum and make-up
are the major factors contributing to short term savings and exit gas temperature and LP turbine
efficiency for long term savings. Based on the analysis and observation at site short term and long
term recommendation for energy efficiency is depicted in Table 3.12 (b).

IGEN-Power Plant optimization

65 | P a g e

3.12 (b) Recommendations for short and long term energy efficiency
Sl No. Parameter

High SH &
RH Spray
(t/h)

Design

Actual

RH spray=0
SH Spray=12

RH spray=15
SH Spray=15

Absolute
Deviation
(%)
15
3

Tube analysis was


carried out and found
to be moderately dirty.

Short Term

Excess Air 22 %
and Furnace
Pressure on
+ve side.

APH Outlet Outlet


Outlet
temp=165
sealing temperature temp=132
Leakage=8.12 Leakage=18
4 tier (0C),
end and
Leakage (%)

Furnace
Leakage

18%

18.18

ID fans loaded to the


full capacity and no
margins available to
maintain
optimum
furnace pressure.

25
121.67

Long Term

SH & RH coil alignment and


gap between the furnace
casing and coils may be
checked.

Coal
Coal
Coal
Wear and tear of mill
flow=89.20
flow=144.5 62
order Flow(t/h)
to balance coal pipe velocity and

Observation

Regular condition
internals

based
Retrofitting of variable orifice in
Preventive maintenance and

cleaning of classifier based


in
on the mill fineness.
Attending leakages in flue
gas ducts and second pass of
Boiler during the available
opportunity.

Poor heat transfer in


APH.

Air ingress was found


on higher side leading
to
reduction
in
operating margin.

IGEN-Power Plant optimization

thereby achieving the fuel balance

each corner.
Replacement of ducts and expansion
bellows.
Proposed to reroute the existing flue
gas ducting system leading from APH
outlet to ESP inlet so as to minimize
the ID load.
Replacement of 8 Nos. of ESP fields
and renovation of ESP controller from
Bapcon to Epic III model inorder to
improve the collection efficiency.
APH seals such as radial,
Replacement of existing single
axial and by pass seals are
3 tier APH system
with
being
replaced
during
sacrificing baskets at hot

available opportunity.

Proposed to carry out chemical


cleaning during Capital overhaul.

Attending
leakages
available opportunity.

at

double sealing so as to minimize


the
leakage inside the APH.
Modified sealing system in pent house
and expansion bellows.
Repairing of damaged insulation in rear
arch and in pent house.

66 | P a g e

Sl No. Parameter

Turbine
Cylinder
Efficiency
(%)

Condenser
Vacuum
(mmHg)

Design

HPT=81.8
IPT=89.78
LPT=81.45

75.76

Actual

HPT=81.46
IPT=89.38
LPT=76.32

87.3

Absolute
Deviation
(%)
HPT=0.42
IPT=0.45
LPT=6.30

15.23

Observation

Based
on Ebsilon
power
plant
component software it
is identified that the LP
cylinder efficiency has
reduced by 2 to 3%.
The steam flow at
Turbine stop valve
(Inlet) is found to be
on higher side.
Low vacuum recorded.

IGEN-Power Plant optimization

Short Term

Long Term

High
energy
drains
are periodically inspected
and replaced
during
available shut down.

Proposed
to
carry
out
Capital overhauling of HPT, IPT
and LPT during this year (2013 14).
Replacement of worn out seals
Conducting steam flow path audit.
RLA study of Boiler and Turbine.

High pressure water jet


cleaning is being carried out
during
the
available
opportunity.

Attending the air ingress by doing the


Hot well flood test and replacement of
flash tank steam side expansion
bellows. Proposed to conduct eddy
current test to identify the eroded
condenser tubes and replacement.
Proposed to carry out bullet cleaning
system.

67 | P a g e

3.13

TANGEDCO - Tuticorin Unit 4 - 210 MW

Tuticorin Thermal Power Station is situated near newport of Thoothukudi on the sea shore of Bay of
Bengal, Southern India. It has 5 units with a total installed capacity of 1,050 MW commissioned
between the year 1979 to 1991. Under IGEN Phase II, the 4th unit was identified and a case study was
carried on. This BHEL KWU unit was commissioned in the year 1992. The detailed analysis is as
below.
Load

TG Heat
Rate

Unit Heat
Rate

Boiler
Efficiency

Coal
Flow

Main Steam

Condenser
Vacuum

Flow

Temperature

Pressure

0C

Kg/cm2

mmHg(a)

Units

MW

kcal/kWh

kcal/kWh

t/h

t/h

Design (A)

210

1983.1

2301.0

86.19

115.0

631.28 535

150

65.5

Actual (B)

210

2057.7

2543.6

82.92

149.22 647.48 535

140

82.0

Deviation
(A-B)/A %

0.00

3.76

10.54

3.79

29.76

6.67

25.19

2.57

0.00

Table 3.13 (a) Operating indices of Tuticorin Unit 4


Table 3.13 (a) shows the main operating parameters of Tuticorin TPP. It can be observed from the
table that there is quite high variation in parameters, especially in coal flow, main steam pressure and
condenser vacuum. These parameters accounts for the loss in efficiency. There are other parameters
too that contribute to the losses.
Total Short term Potential in terms of tonnes of Oil equivalent (9448.42 toe/yr)
6000
5160.08

Oil in toe/yr

5000
4000
3000

2195.38

2032.76
2000
1000

60.2
0
MS pressure (kg/cm2)

Condenser Vacuum
(mmHg)

Makeup (%)

Excess air (%)

Controllable Parameters

Fig 3.13 (a) Short Term Saving Potential


IGEN-Power Plant optimization

68 | P a g e

Total long term Potential in terms of tonnes of Oil equivalent (16986.45 toe/yr)
12000

10980.65

Oil in toe/yr

10000
8000
6000
4000
2336.11
2000

1548.02

1016.38
23.45

570.74

263.26

191.55

56.29

0
RH Spray
(t/h)

SH Spray Exit Gas Change in


IPT
LPT
HPH6 TTD HPH6 DCA LPH TTD
(t/h)
(K)
(K)
(K)
Temp (C) FW temp Efficiency Efficiency
(%)
(C)
(%)

Parameters

Fig 3.13 (b) Long Term Saving Potential


An account of all operating parameters contributing to losses, or in other words contributing to
saving potential has been depicted in Fig 3.13 (a) & 3.13 (b), for each, short term and long term, with
their estimated savings in toe. It is observed that condenser vacuum and make-up and MS Pressure
are the factors contributing to short term savings whereas LP turbine efficiency, reheater spray, exit
gas temp and top heater performance are the major factors contributing to long term savings. Based
on the analysis and observation at site short term and long term recommendation for energy
efficiency is depicted in Table 3.13 (b).

IGEN-Power Plant optimization

69 | P a g e

Table 3.13 (b) Recommendations for short and long term energy efficiency
Sl Parameter
No.

Design

Actual

Absolute
Deviation
(%)

Observation

Short Term

Long Term

High SH & RH
Spray (t/h)

RH Spray=0 RH spray=18
SH
SH Spray=19
Spray=14

18 t/h
5 t/h

Tube analysis was


carried
out
and
found
to
be
moderately dirty.

SH & RH coil alignment and


gap between the furnace casing
and coils may be checked.

Proposed to carry out chemical


cleaning
during
Capital
overhaul.

Coal Flow(t/h)

Coal
flow=115

Coal
flow=149.22

29.76

Wear and tear of


mill internals

Regular Preventive maintenance


and cleaning of classifier based
on the mill fineness.

Retrofitting of variable orifice in


order to balance coal pipe
velocity and thereby achieving
the fuel balance in each corner.

Excess Air (%)

15.99

16.07

0.5

ID fans loaded to the


full capacity and no
margins available to
maintain
optimum
furnace pressure.
Furnace Pressure on
+ve side

Attending leakages in flue gas


ducts and second pass of Boiler
during the available opportunity.

Replacement of ducts and


expansion bellows.
Proposed to reroute the existing
flue gas ducting system leading
from APH outlet to ESP inlet so
as to minimize the ID load.
Replacement of 8 Nos. of ESP
fields and renovation of ESP
controller from Bapcon to Epic
III model inorder to improve
the collection efficiency.

APH Leakage (%) 8.44

22

160.66

Poor heat Transfer

Furnace Leakage

Air
ingress
was
found on higher side
leading to reduction
in operating margin.

APH seals such as radial, axial


Replacement of existing single
and by pass seals are being
sealing 3
Heavy leakage
tier APH system with replaced
during
available
4 tier sacrificing baskets at hot opportunity.
end and double sealing so as to minimize the
leakage inside the
APH.
Attending leakages at available
Modified sealing system in pent
opportunity.
house and expansion bellows.
Repairing of damaged insulation
in rear arch and in pent house.

IGEN-Power Plant optimization

70 | P a g e

Sl Parameter
No.

Design

Actual

Absolute
Deviation
(%)

Observation

Turbine Cylinder HPT=86.96 HPT=87.02


HPT=0.07
Based on Ebsilon
IPT=90.89
IPT=90.43
IPT=0.51
Capital Efficiency (%)
LPT=80.66
LPT=7.10
overhauling of HPT, IPT and LPT=86.82
it is identified that
the LP cylinder
efficiency
has
path
reduced by 2 to 3%.

Short Term

Condenser
65.5
Vacuum (mmHg)

82

25.19

Turbine stop valve


(Inlet) is found to be
on higher side.
Low
vacuum
recorded.

IGEN-Power Plant optimization

Long Term

High
energy
drains
power
plant
component software

down.

The

steam flow at RLA

study

High pressure water jet cleaning


is being carried out during the
available opportunity.

are
Proposed to carry out
periodically inspected
and
replaced during available shut
LPT during this year (2013
14).
Replacement of worn out seals
Conducting steam flow
audit.
of
Boiler
Turbine.

and

Attending the air ingress by


doing the Hot well flood test and
replacement of flash tank steam
side
expansion
bellows.
Proposed to conduct eddy
current test to identify the
eroded condenser tubes and
replacement.
Proposed to carry out bullet
cleaning system.

71 | P a g e

3.14

PSPCL-Lehra Mohabbat Unit 1 - 210 MW

Guru Hargobind (Lehra Mohabbat) Coal Power Station India is located at on Bhatinda Barnala Road,
Punjab, India. The plant is 2X210 and 2X 250 MW. The 2X 210 MW units was commissioned in the
year 1998. Under IGEN Phase II, unit 1 of 210 MW was identified and a case study was carried on.
This BHEL Unit was commissioned in the year 1998. The detailed findings are as below.
Load

TG Heat
Rate

Unit Heat
Rate

Boiler
Coal
Efficiency Flow

Main Steam

Condenser
Vacuum

Flow

Temperature

Pressure

0C

Kg/cm2

mmHg(a)

150

75.98

Units

MW

kcal/kWh

kcal/kWh

t/h

t/h

Design (A)

210

1985.5

2238.13

88.67

124.5

627.93 535

Actual (B)

215

2073.9

2320.4

89.38

132.35 673

535

145

105.92

Deviation
(A-B)/A %

2.38

4.45

3.68

0.80

6.31

0.00

3.33

39.41

7.18

Table 3.14 (a) Operating indices of Lehra Mohabbat Unit 1

Operating Indices of Lehra Mohabbat unit 1 is shown in Table 3.14 (a). The unit is running
with 2. 38 % more than design load. The main steam flow and condenser vacuum is higher
than the design.
Total Short Term potential in terms of tonnes of Oil equivalent
( 10699.20 toe/yr)
9810.1

10000
9000
8000

Oil in toe/yr

7000
6000
5000
4000
3000
2000
1000
0

625.5
68.1
MS pressure (kg/cm2)

Condenser Vacuum
(mmHg)

UBC in Fly Ash (%)

195.5
UBC in bottom ash (%)

Controllable Parameters

Fig 3.14 (a) Short Term Saving Potential


IGEN-Power Plant optimization

72 | P a g e

Total Long Term Potential in terms of tonnes of Oil equivalent (9899.70 toe/yr)
5000

4525.8

4500
4000

Oil in toe/yr

3500
2778.1

3000
2500
1970.3

2000
1500
1000

625.5

500
0
RH Spray (t/h)

IPT Efficiency (%)

HPH6 TTD (K)

LPH3 TTD (K)

Parameters

Fig 3.14 (b) Long Term Saving Potential

Short term and long term saving potential is plotted in figure 3.14 (a) &(b) based on the model
analysis and sample parameter collected during the case study preparation. As can be seen from
figure, the maximum available saving potential is found to be in IP turbine efficiency, Heater TTD,
reheater spray flow and condenser vacuum for long term and condenser vacuum and unburnt carbon
for short term. The detailed short term and long term recommendation for energy efficiency is
depicted in Table 3.14(b).

IGEN-Power Plant optimization

73 | P a g e

Table 3.14 (b) Recommendations for short and long term energy efficiency
Sl
No.

Parameter Design

Absolute
Deviation
(%)

Actual

Observation

Short Term

Long Term

Due to maintaining PA header Regular blending of high calorific


pressure on higher side to
coal with uniform distribution in all
meet out the load requirement
units.
with poor quality of coal

Reducing the Boiler loading by


improving the efficiency of
Turbine Modules.
3% reduction in UBC

In the
range of 65
to 70 %

Variation in Mill Output due


to the variation in mill
fineness and moisture content
of coal

Regular Preventive maintenance


and cleaning of classifier based on
the mill capacity degradation,
Monitoring wear rate of grinding
media and maintain the clearances.
Operating the mill within the range
of differential pressure and mill
outlet temperature. Watching the
mill reject and take the corrective
action.

Pitot tube test to determine the


velocity of air fuel mixture may be
carried out, to balance the coal
flow in each of the PC pipe line..
Modification of mill DP and
control the PA header and mill
inlet temperature to maintain better
grinding performance

SADC
30
position(%)

Vary from
20 to 35%

Furnace to wind box DP is on


higher side.

Rectification of damper position


feedback on available opportunity.

Fire ball monitoring system


installation to Controlling of fuel
air damper based on the flame
position.
Setting of SADC and damper
control.
Secondary air control with open
feedback
from
combustion
optimization by installing BPOS.
Increase in boiler efficiency by
0.05 % approx.

Excess
Air(%)

13.5

32.16

There is no margin in ID fan

Attending leakages in available


opportunity.
Carrying out oxygen mapping will
indicate the location of duct

Rectification of ESP leakages


CO monitoring and maintain O2
measurement grid at I/L & O/L of
APH.

UBC(%)

FA=1
BA=4

FA=1.2
BA=4.5

Mill
Fineness
(%)

70% should
pass through
200 mesh

19.9

FA=20
BA=12.50

IGEN-Power Plant optimization

74 | P a g e

Sl Parameter Design
No.

Absolute
Deviation
(%)

Actual

APH
Leakage
(%)

6.47

11.25

73.88

Furnace
Losses

Condenser 75.98
Vacuum
(mmHg)

105.92

39.41

Observation

Short Term

Long Term

erosion.

Installation of Zirconia probes for


oxygen monitoring in flue gases.
10-15 % reduction in ID Fan
loading

Increased losses due to air


in gress due to worn out
seals,
Reduced Heat Pick up
leading to high corrected
flue gas exit temperature.
The outlet temperature
recorded reduced due to
the ingress of cold air
Air ingress was found on
higher side leading to
reduction in operating
margin.

Need to be attended by proper


seal adjustments and better
sealing material.
cleaning of baskets during
available opportunities.

Replacement of baskets and


sealing system.
Modified sector plate tracking
system.
Modification to 24 element sealing
system with advanced radial seals.
Saving as incorporated on the part
of Excess Air

Attending leakages at available


opportunity.

Modified sealing system in pent


house and expansion bellows.
Rectification of hangers and
supports.

Low vacuum recorded.

High pressure water jet cleaning


to be carried out during the
available opportunity.

Attending the air ingress by doing


the Hot well flood test and
replacement of flash tank steam
side expansion bellows. Proposed
to conduct eddy current test to
identify the eroded condenser
tubes and replacement.

IGEN-Power Plant optimization

75 | P a g e

3.15

TVNL- Tenughat Unit 2 - 210 MW

The Tenughat Thermal Power Station is situated near Tenughat Dam in the district of Bokaro. The
project was sanctioned for 3 stages, as stage-I of 2x210 MW, stage-II of 3X210 MW and stage III of
1x500 MW. Tenughat Vidyut Nigam Limited was created as a separate company (Companys Act
1956) in 1987. In IGEN Phase II case study has been prepared for unit 2 of 210 MW. This BHEL unit
was commissioned in the year 1996. The detailed findings are as below.
Load

TG Heat
Rate

Unit Heat
Rate

Boiler
Efficiency

Coal
Flow

Condenser
Vacuum

Main Steam
Flow

Temperature

Pressure

t/h

0C

Kg/cm2

mmHg(a)

Units

MW

kcal/kWh

kcal/kWh

t/h

Design (A)

210

1994

2318.6

86

114.08 635

535

150

75.98

Actual (B)

180

2215.7

2701.5

82.02

115

580

538

129

109.82

Deviation
(A-B)/A %

14.29 11.12

16.51

4.63

0.81

8.66

0.56

14.00

44.53

Table 3.15 (a) Operating indices of Tenughat Unit 2


Main operating parameters are shown in Table 3.15 (a). The unit is running at 180 MW and the cola
flow required for the same is almost close to design value. As shown in table main steam pressure
and condenser vacuum is deteriorated from the design which causes the losses in the performance of
the unit.
Total Short Term Potential in terms of tonnes of Oil equivalent (19021 toe/yr)
12000

10740.64

Oil in toe/yr

10000
8000
6000

4972.44

4000
2000

1829.48

1199.33
279.11

0
MS pressure
(kg/cm2)

RH Temp (C)

Condenser Vacuum UBC in Fly Ash (%) UBC in bottom ash


(mmHg)
(%)

Controllable Parameters

Fig 3.15 (a) Short Term Saving Potential


IGEN-Power Plant optimization

76 | P a g e

Total Long Term Potential in terms of tonnes of Oil equivalent


( 40923.80 toe/yr)
30000

27808.13

Oil in toe/yr

25000
20000
15000
10000
5441.54
3673.04

5000
576.99

1938.94
13.13

1472.03

0
RH Spray (t/h) SH Spray (t/h) Exit Gas Temp Change in FW LPT Efficiency HPH6 TTD (K) LPH3 TTD (K)
(C)
temp (C)
(%)

Parameters

Fig 3.15 (b) Long Term Saving Potential

Short term and long term saving potential is plotted in figure 3.15 (a) &(b) based on the model
analysis and sample parameter collected during the case study preparation. As can be seen from
figure, the maximum available saving potential found to be in case of LP turbine efficiency, Heater
TTD, reheater spray flow, boiler exit gas temperature, feed water temperature, condenser vacuum
and unburnt carbon percentage. Short term and long term recommendation for energy efficiency is
depicted in Table 3.15(b).

IGEN-Power Plant optimization

77 | P a g e

Table 3.15 (b) Recommendations for short and long term energy efficiency
Sl No. Parameter

Design

Actual

Absolute
Deviation
(%)

FA=6.38
BA=11.88

FA=33.19
BA=65

UBC % more in Bottom Ash &


Fly Ash.
(11.88% in BA and 6.38 in FA)

Identification of leakage points and


Stack monitoring with respect to CO
rectification.
should also be done to ascertain the
Use of combustion booster like
proper fuel burning.
thermact may be considered if found
useful on trial basis to reduce the unburnt carbon losses.
A routine check up of un-burnt carbon
in bottom ash and fly ash may be
carried out so as to take corrective
action.

0.81

Passing of IGV, PAD.


Variation in Mill Output.

Regular Preventive maintenance and Replacement of mill liners and


cleaning of classifier based on the
modification in mill for reliability/
mill capacity degradation.
monitoring of bypass air and
rotation of mill screw.
Rectification of PA fans IGV at every
available opportunity.
Modification of mill DP and noise
monitoring system.
Pitot tube testing can find the
Replacement of IGV & PADs
velocity of coal air mixture, this help Major modifications of PA fan
to balance the coal flow in each PC
system with cold PA.
line.
Retrofitting of variable orifice in
order to balance coal pipe velocity in
each corner.

UBC(%)

FA=4.79
BA=7.2

Coal flow
(t/h)

Coal
Coal
flow=114.8 flow=115

Mill
Fineness(%)

Fineness
70% pass
80 to 95%
through 200 passes through
mesh
200 mesh

APH
7
Leakage (%)
Flue gas
Flue gas exit outlet
temp=138
temp(0C)

19.16

173.71

Observation

Short Term

High Flue gas outlet Temperature.

Flue gas outlet 21.01


temp=167

IGEN-Power Plant optimization

Long Term

Replacement of sealing system.


Modified sector plate tracking
system.
Modification to sealing system with
advanced radial seals.
Proposed to have basket with four
sections to achieve 125 to 130 Deg
APH outlet temperatures.
Modification of GB sealing system.

78 | P a g e

Sl No. Parameter

Design

Actual

Absolute
Deviation
(%)

Observation

Short Term

Long Term

Reloading and replacement of


second pass duct and its hangers.
4

Furnace
Combustion Combustion
Leakage/Co efficiency
efficiency
mbustion
96.08
94.08
efficiency(%)

2.08

Air ingress was found on higher


side leading to reduction in
operating margin.

Attending leakages at available


opportunity.

Turbine
Efficiency
(%)

HPT=88
IPT=90
LPT=89

HPT=89
IPT=90
LPT=73.4

HPT=1.14
IPT=0.0
LPT=17.5
3

LP Cylinder efficiency recorded


on lower side.
Excessive leakage observed in
glands.

Watching the sealing header pressure Retrofitting with modifies capsule


to ensure the condition of gland seals.
with advanced flow nozzles.
Maintaining MS and HRH parameters
near rated values.

HP Heater
TTD(K)
Out let
Temp(0C)

HPH6
TTD=-0.27
Heater
outlet
temp=244.8

HPH6
TTD=12.78
Heater outlet
temp=220

Low heater outlet temperature.

Ensure the parting plane sealing


during the available opportunity.

Temperature drop between HPH


outlet and economizer inlet is found
on higher side which needs
replacement of insulation.

Condenser
(mmHg)

75.98

109.82

44.54

Low vacuum recorded.

Helium leakage test to be conducted


to find out air ingress.

Attending the air ingress by doing


the flood test.
Off line cleaning of the condenser
tubes using brass bullets to ensure
continuous cleaning.

BFP(MW)

4.36

5.44

24.77

High power consumption

Regular auto control and DP


reduction

Scoop control modification


Rectification recirculation valve
Modification of cartridge
(0.06% improvement in auxiliary)

CW
Pump(MW)

0.83

1.70

104.82

High power consumption

10.13

IGEN-Power Plant optimization

Modified sealing system in pent


house and expansion bellows.
Rectification of hangers and
supports.

After tube cleaning check tube


thickness
Replacement of plugged tubes.

79 | P a g e

3.16

DVC-Durgapur TPS Unit 4 - 210 MW

Durgapur Thermal power Station (DTPS)Located in Burdwan district of West Bengal, DTPS was set
up in the sixties of last century with two 75 MW units and one 140 MW unit in the first stage.
Another 210 MW unit was added to the plant in the early eighties to augment supplies to the growing
industrial demand. The first 2 units of the Station had to be de-commissioned after a fire accident in
1985. Unit 4 of 210 MW is considered in IGEN Phase II for case study. This BHEL unit was
commissioned in the year 1981. The detailed findings are as below.
Load

TG Heat
Rate

Unit Heat
Rate

Boiler
Efficiency

Coal
Flow

Main Steam

Condenser
Vacuum

Flow

Temperature

Pressure

Units

MW

kcal/kWh

kcal/kWh

t/h

t/h

0C

Kg/cm2

mmHg(a)

Design (A)

210

2046

2348.22

87.13

95

645

540

137

70.6

Actual (B)

211

2192.1

2712.9

83.31

168.8 715.1 535

132.35

81.64

Deviation
(A-B)/A %

0.48

7.14

15.53

4.38

77.68 10.87 0.93

3.39

15.64

Table 3.16 (a) Operating indices of Durgapur TPS 4


Table 3.16 (a) outline the main operating parameters of the unit. The unit is running at 211 MW. As
shown in table main steam pressure and condenser vacuum is deteriorated from the design which
causes the losses in the performance of the unit. The higher coal flow is due to poor coal quality and
lower GCV value.
Total Short Term Potential in terms of tonnes of Oil equivalent (15035.33 toe/yr)

5629.18

6000

Oil in toe /yr

5000
4000

3504.35
2670.73

3000

2228.22

2000
811.07

1000
91.71

100.07

0
MS pressure MS Temp (C)
(kg/cm2)

Condenser
Vacuum
(mmHg)

UBC in Fly Ash UBC in bottom Makeup (%) Excess air (%)
(%)
ash (%)

Controllable Parameters

Fig 3.16 (a) Short Term Saving Potential


IGEN-Power Plant optimization

80 | P a g e

Total Long Term Saving Potential In terms of Oil equivalent (32864.88toe/yr)


30000.00

26952.49

Oil in kl/yr

25000.00
20000.00
15000.00
10000.00
4150.58

5000.00

137.35

48.60

78.18

1255.31

242.37

0.00

Parameter

Fig 3.16 (b) Long Term Saving Potential

Based on the model analysis and sample parameter collected during the case study preparation short
term and long term saving potential is plotted in figure 3.15 (a) &(b). As can be seen from figure, the
maximum available saving potential found to be in case of turbine efficiency, Heater TTD,
condenser vacuum, unburnt carbon percentage makeup flow and excess air percenatge. Short term
and long term recommendation for energy efficiency is depicted in Table 3.16(b).

IGEN-Power Plant optimization

81 | P a g e

Table 3.16 (b) Recommendations for short and long term energy efficiency
Sl No. Parameter

Design

Actual

Absolute
Deviation
(%)

Observation

Short Term

Long Term

BA=1.5
FA=0.5

BA=7.2
FA= 2.3

BA=380
FA= 360

High UBC Percentage in


Fly ash and Bottom Ash

Use of combustion booster like thermact


may be considered if found useful on trial
basis to reduce the un-burnt carbon losses.

Stack monitoring with respect


to CO should also be done to
ascertain the proper fuel
burning.

Mill fineness is less then


design. 6 mills are in
operation compared to 4
mills in design.

Mill fineness shall be improved by ball


charging periodically and classifier vanes
adjustment.

UBC (%)

MILL
>75%
Fineness (%)

In the
range of 68
to 70 %

Identification of leakage points and


rectification.
3

SADC

Excess Air
(%)

Wind box to
Furnace
DP>70
mmWC,
Damper
position
40/50
24.1

Wind Box to furnace


DP 85
mmWC,
Damper
position
30/40
24.9
3.32

All ID fans are fully


loaded, no margin
available

Excess air is with limit but


there is no margin
available for PA fans

Regular maintenance of SADC power


cylinders
Ensuring proper inside flap operation and
condition

Energy Audit of air and flue gas


path to assess the condition of
FD, PA and ID Fans.

Regular monitoring of O2 in flue gas and


maintain secondary air flow accordingly.

A grid of 4 or 6 oxygen
analyzers test point should be
provided.

Identifying and attending leakages across


the furnace.
3) Checking of FD and PA Fan Blade pitch
over the operating range.
5

APH Leakage 7
(%),

46

557

APH outlet O2 % is
measure to be on higher
side of 8.5% and the flue

Regular check up of O2 in flue gas in inlet


and out let of air heaters.
Proper seal setting of the APH to the

IGEN-Power Plant optimization

Replacement of air heater


blocks in spite of regular
scheduled replacement.

82 | P a g e

Sl No. Parameter

Design

Actual

Absolute
Deviation
(%)

Observation

Short Term

Long Term

recommended value to be ensured.


Basket washing and replacement of
damaged baskets of the APH to be done.
Alignment of APH rotor.
Cold end soot blowing to be done as per
recommended schedule.

A grid of 4 or 6 oxygen
analyzers test points should be
provided at APH outlet.

Deteriorated HP and LP
Turbine efficiency

Maintaining MS and HRH parameters near


rated values by ensuring combustion with
proper mill combination.

Steam path audit of the turbine


to be carried out to ensure
silica deposit across the blade.
checking of the blade profile
for any damage.
Replacement of damage
mechanical seals.
Ensuring Diaphragm clearance
as per recommended value

99.11

HPH performance is
deteriorated

Cleaning of the heater coils.


checking and rectification of
heater baffle arrangement.

15.64

Poor condenser vacuum

Drip levels shall be maintained properly.


Ensure the heater vent is in charged
condition.
ensure the heater level transmitter working
properly
Regular cleaning of condenser tubes shall
be carried out.
Blanked tube to be replaced with new
tubes.
Hotwell flood test should be carried out to
ensure no leakage.
Leakage test for all the lines connected to
the condenser to be done.

Flue gas temp Flue gas


(0C)
outlet
temperature
=138

Flue gas
outlet
temperatur
e=167

gas outlet temperature is


1670C

Turbine
Efficiency
(%)

HPT=82
IPT=89.94
LPT=79.92

HPT=76.4
IPT=89.7
LPT=64.8

HPT=6.83
IPT=0.27
LPT=14.41

Heater TTD
(K)

HPH6
TTD=4.5

HPH6
TTD=8.96

Condenser
Vacuum
(mmHg)

70.6

81.64

IGEN-Power Plant optimization

Quality of CW water at
condenser inlet should be
ensured as per the design
requirement by addition of
suitable chemicals on regular
basis.

83 | P a g e

3.17

RVUNL-Suratgarh Unit 3 - 250 MW

Suratgarh Super Thermal Power Station is Rajasthan's first super thermal power station. It is located
27 km away from Suratgarh town in Ganganagar district. The power plant is operated by Rajasthan
Rajya Vidyut Utpadan Nigam Ltd (RVUNL). The power plant has 6 units that can produce 250
megawatts each. The entire plant was commissioned in different phases from 1999 to 2009. Unit 3 is
considered as a case study in IGEN Phase-II. This BHEL unit was commissioned in the year 2002.
The detailed findings are as below.
Load

TG Heat
Rate

Unit Heat
Rate

Boiler
Efficiency

Coal
Flow

Condenser
Vacuum

Main Steam
Flow

Temperature

Pressure

0C

Kg/cm2

mmHg(a)

Units

MW

kcal/kWh

kcal/kWh

t/h

t/h

Design (A)

250

1953.8

2195

88.93

161.4

740.83 537

150

75.98

Actual (B)

250

2065.3

2343

88.13

157

794.23 529

151

88.27

Deviation
(A-B)/A %

5.71

6.74

0.90

2.73

7.21

0.67

16.18

1.49

Table 3.17 (a) Operating indices of Suratgarh Unit 3

Operating Indices of Suratgarh unit 3 is shown in Table 3.17 (a). The unit is running at 250
MW. The main steam flow and condenser vacuum is higher than the design. Also the main
steam temperature is lower than the set point.
Total Short Term Potential in terms of tonnes of oil equivalent ( 6057.70 toe/yr)
5000

4573.15

4500
4000

Oil in toe/yr

3500
3000
2500
2000
1500
1000

893.52

500

404.88

186.15

0
MS Temp (C)

RH Temp (C)

Condenser Vacuum
(mmHg)

UBC in bottom ash (%)

Controllable Parameters

Fig 3.17 (a) Short Term Saving Potential


IGEN-Power Plant optimization

84 | P a g e

Total Long Term Potential in terms of tonnes of Oil equivalent


( 16217.40 toe/yr)
8000

7491.05

7000

Oil in toe/yr

6000

5888.86

5000
4000
3000
2000
749.44

1000

1139.24

851.08
97.73

0
HPT Efficiency IPT Efficiency (%) LPT Efficiency (%) HPH6 TTD (K)
(%)

HPH6 DCA (K)

LPH3 TTD (K)

Parameters

Fig 3.17 (b) Long Term Saving Potential

Short term and long term saving potential is plotted in figure 3.17 (a) & (b) based on the model
analysis and sample parameter collected during the case study preparation. As can be seen from
figure, the maximum available saving potential is found to be in case of turbine efficiency, Heater
TTD, MS & reheater temperature and condenser vacuum. Short term and long term recommendation
for energy efficiency is depicted in Table 3.17(b).

IGEN-Power Plant optimization

85 | P a g e

Table 3.17 (b) Recommendations for short and long term energy efficiency
Sl No. Parameter

UBC (%)

Design

Actual

Absolute
Deviation
(%)

BA=2
FA=1

BA=2.87
FA=0.9

BA=40
FA=10

Due to maintaining PA

Observation

Short Term

Regular blending of high

header pressure on higher


side to meet out the load
requirement with poor
quality of coal

calorific coal with uniform


distribution in all units.

Long Term

Reducing the Boiler loading by


improving the efficiency of Turbine
Modules.
3% reduction in UBC

Mill
Fineness(%)

Fineness>75

NA

Mill explosion and


Variation in Mill Output.

Regular Preventive
maintenance and cleaning of
classifier based on the mill
capacity degradation,
Monitoring wear rate of
grinding media and adequate
ball charging.
To avoid incidence of
explosion in Mills CO
monitoring and Noise level
should be maintained

7-8 kcal gain in heat rate

Pitot tube test to determine the velocity


of air fuel mixture may be carried out, to
balance the coal flow in each of the PC
pipe line..
Modification of mill DP and noise
monitoring system.
1.396 MU generation Loss
Oil reduction 77.13 kl

SADC

Fuel air damper control and

Rectification of damper
position feedback on available
opportunity.

Fire ball monitoring system installation


to Controlling of fuel air damper based
on the flame position.
Setting of SADC and damper control.
Secondary air control with open
feedback from combustion optimization
by installing BPOS.
Increase in boiler efficiency by 0.05 %
approx.

corner based variation

IGEN-Power Plant optimization

86 | P a g e

Sl No. Parameter

Excess Air
(%)

APH outlet
temperature
(0C)

Furnace
Losses

Turbine
Eff.(%)

LP Heater
Extraction
(0C)

Design

11.8

Actual

10.32

Absolute
Deviation
(%)
12.54

Observation

No margin available in ID

fan current limit

APH outlet
Temp= 141

APH outlet
Temp= 130

7.80

Increased losses due to air


in gress due to worn out
seals,
Reduced Heat Pick up
leading to high flue gas exit
temperature.
Air ingress was found on

Short Term

Attending leakages in available


opportunity.
Carrying out oxygen mapping
will indicate the location of
duct erosion.

CO monitoring and maintain O2


measurement grid at I/L & O/L of APH.
Installation of Zirconia probes for
oxygen monitoring in flue gases.
10-15 % reduction in ID Fan loading

need to be attended by proper


seal adjustments and better
sealing material.
cleaning of baskets during
available opportunities.

Replacement of baskets and sealing


system.
Modified sector plate tracking system.
Modification to 24 element sealing
system with advanced radial seals.
Saving as incorporated on the part of
Excess Air

Attending leakages at available

higher side leading to


reduction in operating
margin.
HPT=90.62
IPT=92.84
LPT=88.53

LPH3=191.9
LPH2=108.5

HPT=83.59
IPT=91.74
LPT=85

HPT=7.76
IPT=1.18
LPT=3.99

LPH3=230
LPH2=137

19.85
26.27

Cylinder efficiency
recorded on lower side.
Excessive leakage observed
in glands.
Increased steam flow
requirement resulting in
fully open control valves
with both HP Heaters in
service.
High Drip Flow From
HPH-6
High Extraction
temperature noticed.

Long Term

opportunity.

Arrangement of measurement
of Steam flow to IP Turbine
and gland seals can be made.

IGEN-Power Plant optimization

Modified sealing system in pent house


and expansion bellows.
Rectification of hangers and supports.
Retrofitting with modifies capsule with
advanced flow nozzles.
Modified sealing system in order to
ensure sealing.
Detailed steam path audit during
upcoming capital overhaul can identify
losses due to surface or seals of the
turbine internals Turbines.
Approx 37 Kcal/kwh saving

Condition based Over Hauling of LPT

87 | P a g e

Sl No. Parameter

10

11

Condenser
Vacuum
(mmHg)

Design

Actual

Absolute
Deviation
(%)

75.98

88.27

16.18

Cooling
Tower

BFP(MW)

5.18

Observation

Low vacuum recorded.

High differential

temperature

5.94

14.67

High power consumption

Short Term

Long Term

Helium leakage test to be


conducted to find out air
ingress.
The CW performance test may
be carried out to determine its
flow and current.
Continuous Dozing of
chemicals in CW sump may be
carried out to maintain the
water chemistry and avoid
scaling in tubes

Attending the air ingress by doing the


flood test and re commissioning the
online cleaning system.
Off line cleaning of the condenser tubes
using brass bullets with high pressure
jet.

Monitoring the approach and


do the corrective action
accordingly. Opportunity
Cleaning of nozzles.
Cleaning the surroundings for
better air circulation.

Evaluation of cooling tower


performance and CW Flow
measurement.
Dozing of chemicals and filtration of
scaling sediments.
5 kcal gain

Possible DP reduction.

Deareator pegging from EX-4 instead of


APRDS.
Reduction in BFP current by 5% each
and reduction in heat rate by 30-40 Kcal

IGEN-Power Plant optimization

8 kal heat rate benefit

88 | P a g e

3.18

UPRVUNL- Anpara Unit 4 - 500 MW

The Anpara Power Plant is located near village Anpara on the bank of Rihand reservoir in the district
of Sonebhadra (Uttar Pradesh). The total generating capacity os the plant is 1630 MW which consists
of 3X210 MW and 2X500 MW, commissioned between the years 1987 to 1994. Under IGEn II, the
4th Unit of 500 MW was identified and a case study was carried on. This Toshiba unit was
commissioned in the year 1994. The detailed findings are as below.
Load

TG Heat
Rate

Unit Heat
Rate

Boiler
Efficiency

Coal
Flow

Main Steam
Flow

Temperature

Pressure Vacuum

0C

Kg/cm2 mmHg(a)

Units

MW

kcal/kWh

kcal/kWh

t/h

t/h

Design (A)

500

1984.8

2268.6

87.4

300

1507.43 538

Actual (B)

507

2142

2497.3

85.7

453.4 1550

7.92

10.08

1.95

51.13 2.80

Deviation (A- 1.4


B)/A %

Condenser

169

76.86

540

168

65

0.37

0.59

15.43

Table 3.18 (a) Operating indices of Anpara Unit 4


Table 3.18 (a) outline the main operating parameters of the unit The unit is running at 507 MW. As
shown in table the unit is running with higher coal flow is due to poor coal quality and lower GCV
value. The unit performance deteriorated due to poor coal quality.

3000

Total Short Term potential in terms of tonnes of oil equivalent


( 4685.84 toe/yr)
2498.13

Oil in toe/yr

2500
2000
1500
882.8

878.63

1000

362.99

500
63.29
0
MS pressure
(kg/cm2)

RH Temp (C)

UBC in bottom ash


(%)

Makeup (%)

Excess air (%)

Controllable Parameters

Fig 3.18 (a) Short Term Saving Potential


IGEN-Power Plant optimization

89 | P a g e

Total Long Term Potential in terms of tonnes of Oil equivalent


( 48531.54 toe/yr)

25000

20796.68

Oil in toe/yr

20000

15000

10000

6515.25
4467.6

5000

6404.3
4411.76
2338.79

1556.96

1638.12
308.26

93.82
0
RH Spray
(t/h)

SH Spray
(t/h)

Exit Gas
Temp (C)

Change in
FW temp
(C)

HPT
Efficiency
(%)

IPT
Efficiency
(%)

LPT
HPH6B TTD LPH3 TTD
Efficiency
(K)
(K)
(%)

LPH3 DCA
(K)

Parameters

Fig 3.18 (b) Long Term Saving Potential

Based on the model analysis and sample parameter collected during the case study preparation short
term and long term saving potential is plotted in figure 3.18 (a) &(b). As can be seen from figure
that the maximum available saving potential is found to be in case of turbine efficiency, Heater TTD
RH Spray, Exit gas temperature, change in feed water temperature, unburnt carbon percentage, make
up flow, RH temperature and excess air percentage. Short term and long term recommendation for
energy efficiency is depicted in Table 3.18(b).

IGEN-Power Plant optimization

90 | P a g e

Table 3.18 (b) Recommendations for short and long term energy efficiency
Sl Parameter
No.

Design

Actual

BA=0.7 %
FA=0.3 %

BA=1.09 %
FA=0.23 %

UBC (%)

Mill
70% through Average of 45
Fineness(%) 200 mesh
to 55 %

Excess Air
(%)

15.9

16.22

Absolute
Deviation
(%)
BA=55.71
FA=23.33
-

2.01

Observation
No major variation observed.

Mill current showing very low


of average 145 amp against
normal value of 160 to 165
amp.
It is observed that no proper
ball loading is being done
resulting reduction of coal
fineness and increasing of un
burnt in bottom ash.
Erosion of the coal pipe at
bends and leakage through the
classifier cone.
Erosion of coal burners tip.
Due to improper grinding, coal
feeding in the pulverizer is
higher thus maintaining high
level inside the mill leading to
chocking and frequent tie rod
breakage.
It is increasing also loading on
PA fans and chances of BTL
No margin available to
maintain the design limits

IGEN-Power Plant optimization

Short Term

Long Term

The unburnt in bottom ash is bit


higher and can be maintained by
improving mill fineness
Proper ball loading of required
size & quality should be done in
regular
interval
based on
pulverizer loading.
Coal sampling to be done on
regular basis and required
classifier setting to be done
accordingly to achieve the
required fineness.
Continuous monitoring of mill
level indicator (Both DP &
Noise)
Proper maintenance of mill &
auxiliaries to be ensured during
available shutdown.
Recommended spares as per
OEM for the mills to be used.

Air flow to be optimized at the


design limit.
Any identified leakages in the
furnace , gas duct to be arrested
during available shutdown.
Soot blowing operation to be
optimized based on the furnace

Ceramic lined across the complete


length of the pulverized pipe.
Inner cone of the classifier to be
ceramic lined.

Smart soot blowing system to be


introduced.

91 | P a g e

Sl Parameter
No.

Design

APH
14.52
Leakage (%)

Actual

14.52 ( with
assumption of
O2 % APH
outlet 5.5 )

Absolute
Deviation
(%)

Observation

Seal leakage

Short Term

Turbine
Efficiency
(%)

HPT=84.5
IPT=90.1
LPT=89.4

HP Heater Final feed


outlet
water
temperature Temperature
(0C)
250
TDBFP
7
0
recirculation
valve passing
(t/h)

HPT=82
IPT=85.4
LPT=84.5

HPT=2.96
IPT=5.22
LPT=5.84

Final feed
14
water
Temperature
215
Passing of 200 200 t/h

Cylinder efficiency recorded on


lower side.
Excessive leakage observed in

glands.
Turbine oil moisture carry over

found on higher side.

Two HPH heaters are out of


service because of leakage

Long Term

metal temperature at different


zone.
Replacement of radial sealing
Replacement of baskets.
and proper gap setting with
sector plate.
Rotor alignment to ensure proper
gap setting for axial and
circumferential sealing.
Repair of APH gratings.
Arresting of APH casing
leakages.
Basket water washing and
rotating baskets.
Steam sampling to be taken
Pre and post over hauling steam
periodically and monitor the
path audit to be done and necessary
silica content.
action to be taken during shutdown
to achieve desired parameters.
Testing of oil samples to be done
During capital over hauling gaps
on regular basis.
between turbine blades and casing ,
Oil centrifuging to be done on
rotor and fixed blades to be
regular basis.
checked with necessary adjustment.
Sand blasting to be done.
Mechanical seals to be replaced.
Attending tube bundle leakage.

High power consumption due to Repair of recirculation valve of


passing of recirculation valves
feed line.

IGEN-Power Plant optimization

92 | P a g e

Annexure 1: 85 units Mapped under IGEN Phase I

State Board/
Electricity Gen.
Company
PSEB

2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41

Mahagenco
WBPDCL
TNEB
Mahagenco
HPGCL
OPGLC
PSEB
NLCL
NLCL
MBEB
RSEB
TNEB
Mahagenco
Mahagenco
Mahagenco
WBPDCL
Mahagenco
CSEB
PSEB
GSECL
TNEB
GSECL
GSECL
DVC
GSCEL
GSCEL
DVC
DVC
APGENCO
APGENCO
CSEB
UPRVUNL
UPRVUNL
UPRVUNL
APGENCO
APGENCO
APGENCO
WBPDCL
Mahagenco
KPCL

Sl No.

IGEN-Power Plant optimization

Power Station

Unit size
MW

Unit
No

Gurunanak Dev. Thermal Power Plant,


Bathinda
Khapar Kheda Thermal Power Plant
Kolaghat Thermal Power Plant
Mettur Thermal Power Plant
Nasik Thermal Power Plant
Panipat Thermal Power Plant
IB Valley Thermal Power Plant
Guru Hargobind Thermal Power Plant
Neyveli Lignite Corporation
Neyveli Lignite Corporation
Satpura Thermal Power Plant
Suratgarh Thermal Power Plant
Tuticorn Thermal Power Plant
Chanderpur Thermal Power Plant
Chanderpur Thermal Power Plant
Koradi Thermal Power Plant
Bandel Thermal Power Plant
Bhusawal Thermal Power Plant
Korba Thermal Power Plant
Guru Gobind Singh Thermal Power Plant
Ukai Thermal Power Plant
North Chennai Thermal Power Plant
Ukai Thermal Power Plant
Ukai Thermal Power Plant
Bokaro Thermal Power Plant
Wanakbori Thermal Power Plant
Wanakbori Thermal Power Plant
Durgapur Thermal Power Plant
Meja Thermal Power Plant
Vijayawada Thermal Power Plant
Kothagudem Thermal Power Plant
Korba East Thermal Power Plant
Anpara Thermal Power Plant
Anpara Thermal Power Plant
Obra Thermal Power Plant
Vijayawada Thermal Power Plant
Kothagudem Thermal Power Plant
Rayalseema Thermal Power Plant
Bakreshwar Thermal Power Plant
Parli Thermal Power Plant
Raichur Thermal Power Plant

110

210
210
210
210
210
210
210
210
210
210
250
210
500
210
200
210
210
210
210
210
210
200
210
210
210
210
210
210
210
250
120
210
500
200
210
250
210
210
210
210

1
3
1
3
5
1
1
3
7
7
1
1
6
4
5
5
3
4
6
5
1
4
1
1
4
3
5
4
1
10
6
1
5
13
5
9
1
2
3
3

93 | P a g e

Sl No.

42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85

State Board/
Electricity Gen.
Company
KPCL
HPGCL
APGENCO
UPRVUNL
UPRVUNL
UPRVUNL
GSECL
GEB
GSECL
TVNL
GSECL
HPGCL
GIPCL
GSECL
DVC
MPPGCL
MPPGCL
WBPDCL
DVC
APGENCO
APGENCO
OPGCL
UPRVUNL
UPRVUNL
RVUNL
RVUNL
UPRVUNL
TNEB
TNEB
TNEB
Mahagenco
Mahagenco
PSEB
APGENCO
CSEB
PSEB
PSEB
Mahagenco
Mahagenco
Mahagenco
RUVNL
UPRVUNL
RSEB
Mahagenco

IGEN-Power Plant optimization

Power Station

Raichur Thermal Power Plant


Panipat Thermal Power Plant
Kothagudem Thermal Power Plant
Obra Thermal Power Plant
Paricha Thermal Power Plant
Paricha Thermal Power Plant
Dhuvaran Thermal Power Plant
Gandhinagar Thermal Power Plant
Wanakbori Thermal Power Plant
Tanughat Thermal Power Plant
Ukai Thermal Power Plant
Panipat Thermal Power Plant
Surat Lignite
Sikka Thermal Power Plant
Chandarapura Thermal Power Plant
Sanjay Gandhi Thermal Power Plant
Amarkantak
Santaldhi Thermal Power Plant
Durgapur
Kothagudem Thermal Power Plant
Rayalseema Thermal Power Plant
IB Valley Thermal Power Plant
Obra Thermal Power Plant
Panki Thermal Power Station
Kota Thermal Power Plant
Kota Thermal Power Plant
Paricha Thermal Power Plant
North Chennai Thermal Power Plant
Mettur Thermal Power Plant
Ennore Thermal Power Plant
Chandarpura Thermal Power Plant
Koradi Thermal Power Plant
Bathinda Thermal Power Plant
Vijayawada Thermal Power Plant
Korba Thermal Power Plant
Ropar Thermal Power Plant
Ropar Thermal Power Plant
Kapar Kheda Thermal Power Plant
Nasik Thermal Power Plant
Nasik Thermal Power Plant
Kota Thermal Power Plant
Anpara Thermal Power Plant
Suratgarh Thermal Power Plant
Chanderpur Thermal Power Plant

Unit size
MW

Unit
No

210
110
120
110
210
110
140
120
210
110
120
250
125
120
140
210
120
120
140
120
210
210
200
105
110
210
210
210
210
110
500
210
110
210
210
210
210
210
140
210
195
500
250
500

4
3
8
8
3
1
5
2
1
2
1
8
2
1
3
1
3
1
3
6
3
2
10
4
2
4
4
4
4
5
7
6
1
6
2
2
3
2
1
5
6
4
2
5

94 | P a g e

About CEA
Central Electricity Authority (CEA) is a Statutory Body constituted under the erstwhile Electricity (Supply) Act,
1948, replaced by the Electricity Act, 2003, where similar provisions exist. CEA is responsible for advising the
Ministry of Power in the matter on all technical and economic matters and is also entrusted with a number of
statutory functions. It is responsible for advising Government on national electricity policy, formulation of
short-term and perspective plans for development of the electricity system and co-ordination of activities of the
planning agencies for the optimal utilization of resources to sub serve the interests of the national economy and
to provide reliable and affordable electricity for all consumers. It is entrusted with the tasks of specifying
technical and safety standards for construction of electrical plants, electric lines and connectivity to the grid. It
is also responsible for carrying out studies relating to cost, efficiency, competitiveness related to Power Sector.
It is also mandated to render advice to all State Governments and Regulatory Commissions on all technical
matters relating to generation, transmission and distribution of electricity.

About GIZ
The Services delivered by the Deutsche Gesellschaft fur International Zusammenarbeit (GIZ) GmbH draw on a
wealth of regional and technical expertise and tried and tested management know-how. As a federal enterprise,
we support the German Government in achieving its objective in the field of international cooperation for
sustainable development. We are also engaged in international education work around the globe. GIZ currently
operates in more than 130 countries worldwide. Please visit, www.giz.de
GIZ India
Germany has been cooperating with India by providing expertise through GIZ for more than 50 years. To
address Indias priority of sustainable and inclusive growth, GIZs joint efforts with the partners in India
currently focus on the following Areas:

Energy-renewable energy and energy efficiency


Sustainable Urban and Industrial Development
Natural Resource Management
Biodiversity
Sustainable Economic Development
Social Protection
Financial Systems Development

Steag India
With over 11000 MW of installed capacity, Steag Energy Services are Germany's fifth-largest power producer.
Steag provides a wide range of services internationally. The services include all activities relating to hard coal
fired, gas fired and solar thermal plants. Steag Energy Services (India) Pvt. Ltd. is a wholly owned
subsidiary of Steag Energy Services GmbH providing following services in India.
Energy Technologies Engineering & Consulting Services for setting up of power plants from concept to
commissioning
Plant Services Management of Operation & Maintenance of Power Plant, RLA and R&M studies
System Technologies Online Optimization System for Power Plant, Energy Management System, Online
Diagnostic System, Supply of Simulators and SI System
Training & Advisory Service - Consultancy Services and conducting various programmes / modules to train
the fresh recruited manpower and upgrade of existing manpower using latest techniques and technologies

IGEN-Power Plant optimization

95 | P a g e

Abbreviations
APH
Aux
BFP
BA
CEP
CHP
CO
CO2
CW
DCS
DCA
DM
ESP
EA
FA
FD
FG
FW
GCV
HBD
HGI
HPH
HPT
ID
IGV
IPT
KVA
LPH
LPT
LTSH
LMTD
MCC
mmHg
mmwc
MS Pressure
MS Temperature
MU
Mtoe
PA
PLF
PPD

Air Preheater
Auxiliary
Boiler Feed Pump
Bottom Ash
Condensate Extraction Pump
Coal Handling Plant
Carbon Monoxide
Carbon Dioxide
Cooling Water
Distributed Control System
Drain cooler Approach
Demineralised
Electro-static Precipitator
Excess Air
Fly Ash
Forced Draft
Flue Gas
Feed Water
Gross Calorific Value
Heat Balance Diagram
Hard Groove Index
High Pressure Heater
High Pressure Turbine
Induced Draft
Inlet Guide Vane
Intermediate Pressure Turbine
Kilo Volt Ampere
Low Pressure Heater
Low Pressure Turbine
Low Temperature Super heater
Log Mean temperature difference
Motor Control Centre
Millimeter of mercury
Millimeter of water column
Main steam pressure
Main steam temperature
Million Unit
Million tonne of oil equivalent
Primary Air
Plant Load Factor
Predicted Performance Data

IGEN-Power Plant optimization

96 | P a g e

R&M

Renovation and Modernization

RH
RLA
RPM
RW
SB
SUL
SADC
TM
toe
TTD
UBC
VWO
WW
WB
WBT

Reheater
Residual Life Assessment
Revolution Per Minute
Raw Water
Soot Blower
Sulphur
Secondary air damper control
Total Moisture
Tonnes of Oil Equivalent
Terminal Temperature Difference
Un-burnt Carbon
Valve wide open
Water wall
Windbox
Wet bulb temperature

IGEN-Power Plant optimization

97 | P a g e

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