Performance Review of Thermal Power Stations 2005-06 Section-13 PAGE NO 13.

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SECTION-13
STATION HEAT RATE OF COAL/LIGNITE BASED THERMAL POWER STATIONS 13.1 Station Heat Rate (SHR) is an important index for assessing the efficiency of a thermal power station. It should be the endeavour of any station to operate the unit as near their design Heat Rate as possible. Station heat rate improvement also helps in reducing pollution from Thermal Power Stations. In this direction, Performance Evaluation Division of CEA had devised a proforma to monitor various parameters of efficiency of Thermal Power Stations in the country. Data related to Station Heat Rate parameters was received from 57 Thermal Power Stations during 2005-06, which has been compiled, analysed and compared with their design SHR. The analysis of station heat rate so carried out has been highlighted in the Annexure. The analysis of station heat rate parameters has been carried out broadly in two categories of the stations with SHR variation from design: (a) between 0-10% and (b) > 10%. The stations under 0-10% variation category are considered as good performing stations and stations having greater than 10% variation are considered as poorly operating ones. All the stations analysed are using coal as primary fuel and oil as secondary fuel for flame stabilization/starting purposes, where as Neyveli, Kutch and Surat Lignite are lignite based Thermal Power Stations. The analysis has been carried out on the Station basis. The following assumptions have been made for the analysis of station Heat Rate: 1. Analysis of only those power stations has been carried out where data of at least 9 months operation was available. 2. Design station heat rate has been evaluated based on design data of turbine heat rate and boiler efficiency as submitted by TPSs and compared with their Operating station heat rate. 3. The data related to various parameters of station heat rate such as generation, fuel consumption, fuels calorific values, etc. has been taken from TPS authorities / SEBs / utilities on monthly basis. 4. Weighted average of Coal GCV and Oil GCV have been computed yearly for calculating heat rate for the year 13.2.0 METHODS: There are two methods for heat rate evaluation of Thermal Power Stations: Indirect Method and Direct Method.

Performance Review of Thermal Power Stations 2005-06 Section-13 PAGE NO 13. 2

13.2.1

INDIRECT METHOD: Indirect method of Heat Rate Measurement is an instantaneous method which is used for short duration and not possible throughout the year. It is a very complex method and basically a loss based method of measurement of Heat Rate. This method is generally adopted during the Energy Audit Studies. 13.2.2 DIRECT METHOD: Direct Method of Heat Rate Assessment is suitable for long duration in which averaging gives almost actual Heat Rate because Coal consumption measurement is approximately accurate enough if taken over a month/Year. Therefore, this method is employed at almost all stations as per the standard practice. The methodology adopted by us for assessment of station heat rate is based on Direct Method and the same is given in brief as follows: Step 1 All design data such as Turbine Heat Rate, Boiler Efficiency and basic history of Thermal Power Station has been collected from Station authorities and Unit Heat Rate (UHR) is evaluated with respect to unit capacities at 100% PLF. (a) Unit Heat Rate (UHR) = Turbine Heat Rate (Kcal/Kwh) Boiler Efficiency (a) Design Station Heat Rate = UC1XUHR1+UC2 XUHR2+---------------------------------UCn XUHR2 UC1 + UC2 +------- UCn Where, UC1 + UC2 +-------------------------------UCn are Unit Capacities (MW) UHR1+UHR2 +----- ----------------------UHR2 are Unit Heat Rates (Kcal/Kwh) Step 2 Operating parameters such as gross generation, total Coal consumption, Coal average G.C.V, Specific Oil Consumption and Oil GCV have been collected from Thermal Power Station authorities on monthly basis. Thereafter, Operating Station Heat Rate for each month is calculated as under:

Performance Review of Thermal Power Stations 2005-06 Section-13 PAGE NO 13. 3

Station Heat Rate =

Sp. Coal Consumption (Kg/Kwh) x G.C.V of Coal (K.cal/Kg) + Sp. Oil Consumption (ml/Kwh) x G.C.V of Oil (K.cal/litre)

Where, Sp. Coal Consumption = Total coal consumption in a month (Kg) Gross Generation in the month (Kwh) Also weighted Sp. Coal Consumption, weighted Sp. Oil Consumption, weighted GCV of coal and weighted GCV of oil have been computed yearly for calculating yearly SHR. Step3 Operating SHR thus calculated is then compared with respect to design Station Heat Rate and percentage deviation is found to give an idea of performance of the station as a whole as per Step 2. Heat Rate Deviation (%) = (Operating Heat Rate - Design Heat Rate) x100 Design Heat rate 13.3.0 SALIENT FEATURES OF THE GROSS STATION HEAT RATE DATA ANALYSIS: The Operating Heat Rate of Thermal Power Stations during 2005-06, their deviation from the design values and their improvement / deterioration over the preceding year 2004-05 is given in the accompanying Annexure. The main highlights of the outcomes for the year 2005-06 and a comparative analysis with respect to the preceding year are given below: (a) ALL INDIA STATION HEAT RATE Year No. of Capacity Stations ( MW) analyzed Weighted Weighted % % Average average Operating improvement Design Operating SHR / detoriation SHR SHR Deviation (-) in (Kcal/Kwh) (Kcal/Kwh) w.r.t Operating Design Station Heat SHR Rate over preceding year 2397 2788 16 2398 2747 14.57 1.47

200405 2005-

49 57

32222 35480

Performance Review of Thermal Power Stations 2005-06 Section-13 PAGE NO 13. 4

06

The above table and accompanying chart of All India Station Heat Rate indicate that the estimated weighted average operating SHR on All India basis are 2788 Kcal/kwh and 2747 Kcal/kwh for the year 2004-05 and 2005-06 respectively. This analysis indicates that there is an overall improvement of 1.47% in operating SHR during the year 2005-06 over the preceding year. (b) REGION WISE STATION HEAT RATE Region Year Weighte d Average Design SHR (Kcal/K wh) 2430 2418 2443 2423 2357 2359 2376 2435 Weighted % average Operating Operating SHR SHR Deviation (Kcal/Kw w.r.t h) Design SHR 2892 19 2793 15.51 2700 10 2667 10.06 2712 15 2737 16.02 3148 33 2887 18.58 %Improvement / detoriation (-) in Operating Station Heat Rate w.r.t preceding year

Northern Southern Western Eastern

2004-2005 2005-2006 2004-2005 2005-2006 2004-2005 2005-2006 2004-2005 2005-2006

3.42 1.22 (-) 0.92 8.29

The above table indicates that while Northern, Southern and Eastern Regions are showing an improvement of 3.42%, 1.22% and 8.29% in their OPSHR, there is no improvement in operating Station Heat Rate of Western Region during the year 2005-06 over the preceding year 2004-05. Moreover, the Southern Region has achieved the lowest heat rate of 2667 Kcal/kwh among all other regions during 2005-06. (c) The number of efficiently running power stations, whose SHR deviation w.r.t. design heat rate falls in the range of 0-5% & 5-10%, are given in the following table for the year 2004-05 and 2005-06. Sl. Particulars No. 1. Total Stations analyzed 2. No. of Stations in the range of SHR deviation (0-5%) 3. No. of stations in the range of SHR deviation (5-10%) 2004-05 49 4 11 2005-06 57 7 15

Performance Review of Thermal Power Stations 2005-06 Section-13 PAGE NO 13. 5

4. 5.

Total efficient stations in the range of (0-10%) No. of stations with SHR deviation of more than 10%

15 34

22 34

(d) As per the attached Annexure, it is observed that SOUTHERN REPL CESC (2*67.5 MW), DAHANU Private Sector (2*250MW), I B VALLEY (2*210MW), RAYAL SEEMA (2*210MW), K'GUDEM (NEW), Stage-V (Unit 1 & 2: 2*250MW), NORTH CHENNAI (3*210MW) and VIJAYWADA ( 6*210MW) have been assessed as the best stations for the year 2005-06 with SHR deviations of 2.69%, 3.21%, 3.21%, 3.41%, 3.48%, 3.92% & 4.36% respectively with respect to their design Station Heat rate. (e) In all about 34 stations out of analysed 57 stations during 2005-06 are operating at very poor SHR with SHR variation of more than 10% and up to 110 %. These stations need closer monitoring and Energy Audit implementation. (f) While KUTCH LIGNITE 215MW(2x70+1x75) has improved the most during 2005-06 CHANDRAPURA DVC 780MW(3*140+3*120) and PANIPAT

by improving upon its SHR by 12.9% over the preceding year, BOKARO B DVC 630MW(3x210), 1360MW(4*110+2*210+2*250) have also improved their Station Heat Rate during the year 2005-06. However, all these four stations, inspite of some improvement in their SHR over the earlier year, still continue to be amongst the most poorly operating stations with SHR deviation of 17.26%, 40.18%, 40.14% & 26.33% respectively over their design. The other most poorly operating stations during the year 2005-06 are BARAUNI 320MW(Unit Nos.4 to 7: 2x50+2x110), PARICHA 220MW(2x110), AMAR KANTAK EXT. 240MW(Unit Nos. 1 & 2: 2x120), FARIDABAD EXTN.180MW(3x60), SANTALDIH 480MW (4x120), NEYVELI ST- I 600MW(6x50+3x100) and I.P.STATION 247.50MW(Unit Nos. 2 to 5: 3*62.5+1*60) with SHR deviations of 109.81%, 69.96%, 66.71%,49.82%, 48.71%, 45.73% & 41.4% respectively over their design SHR.

Performance Review of Thermal Power Stations 2005-06 Section-13 PAGE NO 13. 6

Operating Station Heat Rate (H.R.) of Thermal Power Stations during 2005 - 06, their deviation from the Design Values, Improvement / Detoriation over 2004 - 05

Sl. No.

Name of Station--No of Units with Installed Capacity (MW)

Installed Capacity (MW)

Design H.R. (Kcal/K wh)

2004 - 05 Operating Heat Rate (Kcal/Kwh)

Generation (MU)

Operating Heat Rate (Kcal/Kwh)

2005-06 % Deviation of Operating H.R. from Design H.R.

% Improvement (+)/ detoriation() in Oprtg. H.R. over preceding year Oprtg. H.R.

1 2 3 4

NORTHERN REGION. DELHI I.P.STATION (Unit Nos. 2 to 5: 3*62.5+1*60) RAJGHAT (2*67.50) Total HARYANA FARIDABAD EXTN. (3*60) PANIPAT (4*110+2*210+2*250) Total PUNJAB GNDTP, BHATINDA (4*110)

247.50 135.00 382.50 180.00 1360.00 1540.00 440.00

2647 2580 2624 2811 2322 2379 2510

3648 3323 4187 3180

984.75 515.47 1500.22 787.31 8135.70 8923.00

3744 3560 3680 4212 2934 3046 2908

41.40 37.95 40.27 49.82 26.33 28.04 15.85

2.61 7.13 0.59 -7.75

2899

2104.15

0.32

Performance Review of Thermal Power Stations 2005-06 Section-13 PAGE NO 13. 7

Sl. No.

Name of Station--No of Units with Installed Capacity (MW)

Installed Capacity (MW)

Design H.R. (Kcal/K wh)

2004 - 05 Operating Heat Rate (Kcal/Kwh)

Generation (MU)

Operating Heat Rate (Kcal/Kwh)

2005-06 % Deviation of Operating H.R. from Design H.R.

% Improvement (+)/ detoriation() in Oprtg. H.R. over preceding year Oprtg. H.R.

6 7 8 9 10 11 12 13

GHTP, LEHRA MOHABAT (2*210) ROPAR (6*210) Total RJASTHAN KOTA (2*110+3*210+1*195) SURATGARH (5*250) Total UTTAR PRADESH H'GANJ B (2*50+4*60+1*110) OBRA (Unit Nos. 1 to 13: 5*50+3*100+5*200) PANKI, (Unit Nos. 3 & 4: 2*110) PARICHA (2*110) Total Total (NORTHERN REGION) WESTERN REGION Chattisgarh

420.00 1260.00 2120.00 1045.00 1250.00 2295.00 450.00 550.00 220.00 220.00 1440.00 7777.50

2238 2277 2318 2418 2260 2332 2831 2701 2528 2529 2689 2418

2380 2583 2631 2445

3145.91 9329.31 14579.37 8294.15 8179.42 16473.58 631.18

2407 2541 2565 2620 2490 2555 3697 3073 3186 4298 3254 2793

7.54 11.55 10.65 8.35 10.15 9.57 30.61 13.77 26.02 69.96 21.03 15.51

1.12 -1.65 -0.41 1.83

3077 3284 4122

5572.90 954.05 763.18 7921.31 49397.48

-0.14 -2.97 4.25

Performance Review of Thermal Power Stations 2005-06 Section-13 PAGE NO 13. 8

Sl. No.

Name of Station--No of Units with Installed Capacity (MW)

Installed Capacity (MW)

Design H.R. (Kcal/K wh)

2004 - 05 Operating Heat Rate (Kcal/Kwh)

Generation (MU)

Operating Heat Rate (Kcal/Kwh)

2005-06 % Deviation of Operating H.R. from Design H.R.

% Improvement (+)/ detoriation() in Oprtg. H.R. over preceding year Oprtg. H.R.

14 15 16 17 18 19 20 21 22 23 24

KORBA EAST (4*50+2*120) KORBA WEST (4*210) Total GUJARAT GANDHI NAGAR (2*120+2*210) KUTCH LIG.(2*70+1*75) SIKKA REP.( 2*120) SURAT LIGNITE, Private Sector (2*125) UKAI ( 2*120+2*200+1*210) WANAKBORI (7*210) Total MADHYA PRADESH AMAR KANTAK EXT. (Unit Nos. 1 & 2: 2*120) SANJAY GANDHI Phase II (2*210) SATPURA (5*62.5+1*200+3*210)

440.00 840.00 1280.00 660.00 215.00 240.00 250.00 850.00 1470.00 3685.00 240.00 420.00 1142.50

2547 2312 2393 2336 2873 2389 2399 2360 2344 2384 2350 2293 2437 2682 2538 3867 3026 2546 2692 2538 3977 2885 3156

3197.59 5746.39 8943.98 5447.00 669.61 1404.66 1874.13 5363.02 3200.32 17958.74 952.57 2791.71 7581.10

2946 2653 2758 2568 3368 2926 2742 2746 2561 2696 3918 2829 3288

15.66 14.74 15.25 9.92 17.26 22.48 14.28 16.32 9.26 13.08 66.71 23.38 34.88 -1.07 1.17 -12.90 -3.33 7.69 1.99 0.90 -1.47 -1.95 4.17

Performance Review of Thermal Power Stations 2005-06 Section-13 PAGE NO 13. 9

Sl. No.

Name of Station--No of Units with Installed Capacity (MW)

Installed Capacity (MW)

Design H.R. (Kcal/K wh)

2004 - 05 Operating Heat Rate (Kcal/Kwh)

Generation (MU)

Operating Heat Rate (Kcal/Kwh)

2005-06 % Deviation of Operating H.R. from Design H.R.

% Improvement (+)/ detoriation() in Oprtg. H.R. over preceding year Oprtg. H.R.

25 26 27 28 29 30 31 32 33

Total MAHARASTRA BHUSAWAL (1*62.5+2*210) CHANDRAPUR (4*210+3*500) DAHANU, Private Sector (2*250) K' KHEDA - II (4*210) KORADI (4*120+1*200+2*210) NASIK (2*140+3*210) PARAS (Unit 2: 1*62.5) PARLI (2*30+3*210) TROMBAY COAL BASED UNIT ONLY, Private Sector (Unit Nos: 1*500) Total Total (WESTERN REGION) SOUTHERN REGION

1802.50 482.50 2340.00 500.00 840.00 1100.00 910.00 62.50 690.00 500.00

2392 2406 2278 2227 2254 2402 2348 2686 2424 2414 2678 2600 2261 2673 2952 2587 3343 2649 2456

11325.37 3381.44 13986.71 4323.07 5187.65 6460.27 5753.08 479.57 5161.98 3408.70

3228 2635 2611 2298 2600 2981 2651 3198 2665 2387

34.92 9.52 14.59 3.21 15.34 24.12 12.91 19.05 9.92 -1.13 -1.60 0.40 1.63 -2.72 0.98 2.47 -4.34 0.60 -2.82

7425.00 14192.5 0

2333 2359

48142.45 86370.55

2634 2737

12.86 16.02

Performance Review of Thermal Power Stations 2005-06 Section-13 PAGE NO 13. 10

Sl. No.

Name of Station--No of Units with Installed Capacity (MW)

Installed Capacity (MW)

Design H.R. (Kcal/K wh)

2004 - 05 Operating Heat Rate (Kcal/Kwh)

Generation (MU)

Operating Heat Rate (Kcal/Kwh)

2005-06 % Deviation of Operating H.R. from Design H.R.

% Improvement (+)/ detoriation() in Oprtg. H.R. over preceding year Oprtg. H.R.

34 35 36 37 38 39

40 41 42 43 44 45

ANDHRA PRADESH K'GUDEM (4*60+4*110) K'GUDEM (NEW), StageV (Unit ! & 2: 2*250) R'GUNDEM - B (1*62.5) RAYAL SEEMA (2*210) VIJAYWADA ( 6*210) Total KARNATAKA TORANGALLU IMP, Private Sector (2*130) Total TAMIL NADU ENNORE (2*60+3*110) METTUR (4*210) NEYVELI ST- I (6*50+3*100) NEYVELI ST- II (7*210) NEYVELI FST EXT (2*210) NORTH CHENNAI (3*210)

680.00 500.00 62.50 420.00 1260.00 2922.50 260.00 260.00 450.00 840.00 600.00 1470.00 420.00 630.00

2465 2234 2616 2250 2301 2327 2220 2220 2507 2386 2739 2601 2434 2348

2594 2723 2293 2443

4732.27 3482.10 68.99 2370.99 8815.75 19470.10 2048.83 2048.83

2660 2312 2822 2327 2402 2441 2382 2382 3309 2537 3992 2878 2770 2440

7.91 3.48 7.88 3.41 4.36 4.88 7.30 7.30 31.99 6.32 45.73 10.65 13.78 3.92

2.54 3.66 1.48 -1.69

3204 2557 3976 2871 2841 2456

600.52 5893.09 3990.19 9174.09 3082.32 4001.13

3.27 -0.79 0.40 0.24 -2.51 -0.65

Performance Review of Thermal Power Stations 2005-06 Section-13 PAGE NO 13. 11

Sl. No.

Name of Station--No of Units with Installed Capacity (MW)

Installed Capacity (MW)

Design H.R. (Kcal/K wh)

2004 - 05 Operating Heat Rate (Kcal/Kwh)

Generation (MU)

Operating Heat Rate (Kcal/Kwh)

2005-06 % Deviation of Operating H.R. from Design H.R.

% Improvement (+)/ detoriation() in Oprtg. H.R. over preceding year Oprtg. H.R.

46

47

48 49 50

51

TUTICORIN (5*210) Total Total (SOUTHERN REGION) EASTERN REGION ASSAM Total BIHAR BARAUNI (Unit Nos.4 to 7: 2*50+2*110) Total JHARKHAND BOKARO B , DVC (3*210) CHANDRAPURA, DVC (3*140+3*120) JOJOBERA IMP TPS, Private Sector (1*67.5+3*120) Total ORISSA I B VALLEY(2*210)

1050.00 5460.00 8642.50

2344 2484 2423

2493

7674.14 34415.48 55934.41

2502 2812 2667

6.72 13.20 10.06

0.34

320.00 320.00 630.00 780.00 427.50 1837.50 420.00

2533 2533 2399 2349 2338 2364 2350

5656

120.95 120.95

5314 5314 3363 3292 2562 3074 2426

109.81 109.81 40.18 40.14 9.60 30.06 3.21

-6.05

3729 3590 2577

2673.95 2034.05 2375.06 7083.06

-9.80 -8.29 -0.57

2441

3094.78

-0.62

Performance Review of Thermal Power Stations 2005-06 Section-13 PAGE NO 13. 12

Sl. No.

Name of Station--No of Units with Installed Capacity (MW)

Installed Capacity (MW)

Design H.R. (Kcal/K wh)

2004 - 05 Operating Heat Rate (Kcal/Kwh)

Generation (MU)

Operating Heat Rate (Kcal/Kwh)

2005-06 % Deviation of Operating H.R. from Design H.R.

% Improvement (+)/ detoriation() in Oprtg. H.R. over preceding year Oprtg. H.R.

52 53 54 55 56 57

Total 420.00 2350 WEST BENGAL BANDEL(4*82.5+1*210) 540.00 2510 BUDGE BUDGE, CESC 500.00 2314 (2*250) D.P.L. 395.00 2700 (2*30+3*75+1*110) SANTALDIH (4*120) 480.00 2298 SOUTHERN REPL, CESC 135.00 2798 (2*67.5) TITAGARH, CESC (4*60) 240.00 2715 Total 2290.00 2494 4867.50 2435 Total (EASTERN REGION) All India 35480.0 2398

3094.78 3097 2472 3441 3516 1795.38 4386.90 1961.86 1108.38 989.97 1830.76 12073.24 22372.03 214074.47

2426 3005 2460 3320 3418 2873 2916 2872 2887 2747

3.21 19.73 6.31 22.98 48.71 2.69 7.39 15.15 18.58 14.57 -2.98 -0.48 -3.52 -2.80