Beruflich Dokumente
Kultur Dokumente
Chairperson
Central Electricity Authority &
Ex-Officio Secretary to Govt. of India
New Delhi
January 2014
Neerja Mathur
Chairperson
2|Page
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
Major Singh
Member (Planning)
3|Page
Jens Burgtorf
Message
Director, IGEN
GIZ, India
New Delhi
January - 2014
Jens Burgtorf
Director
IGEN, GIZ
4|Page
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
IGEN-Power Plant optimization
5|Page
CHAPTER 1
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.
6|Page
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
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%
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)
7|Page
Private
28%
Central
33%
State
39%
Total 136.45 GW
8|Page
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)
Number of Units
9|Page
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
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)
Makeup (%)
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)
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)
Makeup (%)
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
10 | P a g e
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
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
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.
11 | P a g e
IGEN
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)
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 (%)
13333.61
2185.515
12377.31
2471.81
2405.48
1560.40
0.00
0.00
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)
12 | P a g e
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
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
13 | P a g e
5.07
5
4
3
2
0.46
1
0
1 Studies
Case
2
All State
Utilities
14 | P a g e
Chapter 2
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.
15 | P a g e
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
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
16 | P a g e
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
17 | P a g e
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
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.
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
18 | P a g e
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
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)
Design
Operating
Design
Operating
Design
Operating
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.
IGEN-Power Plant optimization
19 | P a g e
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)
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
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
RH Spray
SH Spray
0
10.5
9650.01
474.78
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.
20 | P a g e
Parameters
120 MW
(2)
125 MW
(1)
210 MW
(12)
250 MW
(1)
500 MW
(1)
Total (toe)
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
559.24
13521.06
14080.30
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
515.21
5902.90
1282.20
7700.31
SH Spray
8.65
15.59
286.49
77.26
388.00
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
IGEN-Power Plant optimization
21 | P a g e
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.
IGEN-Power Plant optimization
22 | P a g e
CHAPTER 3
State Board/
Electricity Gen.
Company
Power Station
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.
23 | P a g e
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
4000
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)
Controllable Parameters
24 | P a g e
6000
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
25 | P a g e
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
Observation
Short Term
Long Term
MILL
>75%
fineness (%)
SADC
(mmWC)
Wind box 40
to Furnace
DP>70
42.85
Excess Air
(%)
19.38
25.46
31.37
APH
2.35
Leakage (%)
8.67
2.68
Turbine
Efficiency
(%)
82.33
7.40
Turbine efficiency is
lower than design.
88.9
26 | P a g e
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
Note: Observations/analysis presented in the table is based on the operating parameters as observed at the time of Studies.
27 | P a g e
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
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 bottom
ash (%)
Controllable Parameters
28 | P a g e
3727.8
3500
Oil in toe/yr
3000
2697.18
2500
2000
1500
1000
794.79
500
0
Change in FW temp (C)
Parameters
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
Mill
Fineness
(%)
>75%
B=66
D=72
B=12
D=4
SADC
(mmWC)
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.
32.07
40.60
No margin available to
maintain the design limits
due to Leakages and Air
ingress.
APH
Leakage
Inlet O2
5.1 and
Inlet O2
4.24 and
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
Turbine
Efficiency
(%)
Short Term
Long Term
31 | P a g e
Sl No.
Parameter Design
Actual
Absolute
Deviation
(%)
Observation
Short Term
Long Term
10
HP Heater
TTD (K),
Outlet
temp(0C)
HPH6
TTD=1
Feed water
outlet
Temp=227.
79
Condenser 76.20
Vacuum
mmHg(a)
HPH6
1680
TTD=17.8
Feed water 7.81
outlet
Temp=210
80.9
2.89
6.18
43.07
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
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
1800
1673.07
1600
Oil in toe/yr
1400
988.22
1000
800
600
400
200
0
Condenser Vacuum (mmHg)
Controllable Parameters
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)
Parameters
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
80.998
21.27
Condenser Vacuum is on
higher side
0.5
8.68
0.99
26.53
Within Limit
10.37
1015.05
High RH Spray
SH Spray (t/h)
25.94
34.01
31.11
High SH Spray
139.5
155.38
11.38
---
80.96
10.33
---
86.7
2.54
---
9.2
10.45
13.59
10
1.48
7.45
403.38
-----
35 | P a g e
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
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)
Make up (%)
Controllable Parameters
36 | P a g e
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
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).
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
(%)
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
opportunity.
SADC
40/50
position (%)
50/60
25/20
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
38 | P a g e
Sl No.
Parameter Design
Actual
Absolute
Deviation
(%)
Observation
Short Term
Long Term
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
39 | P a g e
Sl No.
Parameter Design
Actual
Absolute
Deviation
(%)
Observation
Short Term
Long Term
Condenser
vacuum
(mmHg)
Cooling
Tower
75.98
Range=9
Effectiveness
=56.2%
97.83
28.76
Range=8
11.11
High differential
temperature
Effectivene 1.78
ss
=55.2%
40 | P a g e
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
Oil in toe/yr
10000
8000
6000
5191.35
4000
1454.2
2000
115.73
0
MS pressure (kg/cm2)
Controllable Parameters
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
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
Long Term
Low excess air of 9.9 % against design of 28.6 Identification and rectification A grid of 4 or 6 oxygen
43 | P a g e
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
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
44 | P a g e
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
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 (%)
Controllable Parameters
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
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.
Sl No.
Number of
mill in
operation=5
Coal
33.85
Flow=179.9
t/h
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
25.95
HPT=5.6
IPT=4.96
LPT=5.13
Cylinder efficiency of IP
and LP turbine is observed
in lower side.
Installation of Multiple O2
sensors in FG path & CO
analyzers at APH inlet
Replacement of AH baskets
during overhaul 5 years life
extracted
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
71.93
7.36
Approach
=8.2
82.22
48 | P a g e
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) 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)
Makeup (%)
Controllable Parameters
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
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
25/30
37.5/40
15.86
0.75
No margin available to
maintain the design limits
18.06
FG temp APH
out= 160.23
108.43
UBC (%)
FA=1.5
BA=3
Mill Fineness
(%)
SADC
Position (%)
40/50
Excess Air
(%)
15.98
Absolute
Deviation
(%)
FA=39.33
BA=31.67
8.26
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
HPH6TTD=
-0.02,
DCA=14
Short Term
Long Term
52 | P a g e
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
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
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
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
Mill
Fineness(%)
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
APH
Leakage(%)
8.12
9.64
18.72
Regular Checking of O2 at
APH inlet and outlet.
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
HP Heater
TTD (K)
HPH7=5
HPH6=18
HPH5=10.6
177
350
112
Deteriorated HP Heater
Performance
Within Limit
Final feed
water
temp(0C)
6
HPH7=1.8
HPH6=4
HPH5=5
Condenser
75.76
back pressure
(mmHg)
75.03
3.16
0.96
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
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
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%.
Oil in toe/yr
7000
6000
5000
4000
3000
2000
1000
347.13
742.74
0
MS Temp (C)
RH Temp (C)
Controllable parameters
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
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).
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
Long Term
Mill
Flow(t/h)
Lignite flow
191.81
Performance deterioration
starts after 1800 Running
hours.
APH
Leakage(%)
11.61
4.65
Feed control NA
station delta
pressure.
10 to 18 bar -
342
HPT exhaust temperature is No action is possible in short term It will be checked in the overhaul.
59.95
chokes.
7.45
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
Short Term
reduction
69 to 90
Variation in condenser
vacuum.
Cooling
tower
Approach
(0C)
4.9
83
water.
Condenser
75.76
Vacuum(mm
Hg)
Long Term
Deviation in approach
59 | P a g e
3.11
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
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)
Condenser
Vacuum
(mmHg)
Controllable Parameters
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
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).
61 | P a g e
Design
Actual
Absolute
Deviation
(%)
Observation
Short Term
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
6.02
25
25
APH Basket
Outlet temp
choke
146
Outlet temp(0C)
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.
62 | P a g e
Sl No. Parameter
8
7
Observation
Short Term
Long Term
76
Absolute
Deviation
(%)
0.03
66.67
Design
Actual
Condenser
Vacuum
(mmHg)
75.98
Make up water
system /flow
(%)
All rotating
equipments
63 | P a g e
3.12
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
4000
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
64 | P a g e
10000
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
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
Short Term
Excess Air 22 %
and Furnace
Pressure on
+ve side.
Furnace
Leakage
18%
18.18
25
121.67
Long Term
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
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.
Attending
leakages
available opportunity.
at
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.
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.
67 | P a g e
3.13
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
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
Oil in toe/yr
5000
4000
3000
2195.38
2032.76
2000
1000
60.2
0
MS pressure (kg/cm2)
Condenser Vacuum
(mmHg)
Makeup (%)
Controllable Parameters
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)
Parameters
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
Coal Flow(t/h)
Coal
flow=115
Coal
flow=149.22
29.76
15.99
16.07
0.5
22
160.66
Furnace Leakage
Air
ingress
was
found on higher side
leading to reduction
in operating margin.
70 | P a g e
Sl Parameter
No.
Design
Actual
Absolute
Deviation
(%)
Observation
Short Term
Condenser
65.5
Vacuum (mmHg)
82
25.19
Long Term
High
energy
drains
power
plant
component software
down.
The
study
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
71 | P a g e
3.14
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
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)
195.5
UBC in bottom ash (%)
Controllable Parameters
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)
Parameters
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).
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
In the
range of 65
to 70 %
SADC
30
position(%)
Vary from
20 to 35%
Excess
Air(%)
13.5
32.16
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
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.
75 | P a g e
3.15
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
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)
Controllable Parameters
76 | P a g e
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
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).
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
0.81
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
Long Term
78 | P a g e
Sl No. Parameter
Design
Actual
Absolute
Deviation
(%)
Observation
Short Term
Long Term
Furnace
Combustion Combustion
Leakage/Co efficiency
efficiency
mbustion
96.08
94.08
efficiency(%)
2.08
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
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
Condenser
(mmHg)
75.98
109.82
44.54
BFP(MW)
4.36
5.44
24.77
CW
Pump(MW)
0.83
1.70
104.82
10.13
79 | P a g e
3.16
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
132.35
81.64
Deviation
(A-B)/A %
0.48
7.14
15.53
4.38
3.39
15.64
5629.18
6000
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
80 | P a g e
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
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).
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
UBC (%)
MILL
>75%
Fineness (%)
In the
range of 68
to 70 %
SADC
Excess Air
(%)
Wind box to
Furnace
DP>70
mmWC,
Damper
position
40/50
24.1
A grid of 4 or 6 oxygen
analyzers test point should be
provided.
APH Leakage 7
(%),
46
557
APH outlet O2 % is
measure to be on higher
side of 8.5% and the flue
82 | P a g e
Sl No. Parameter
Design
Actual
Absolute
Deviation
(%)
Observation
Short Term
Long Term
A grid of 4 or 6 oxygen
analyzers test points should be
provided at APH outlet.
Deteriorated HP and LP
Turbine efficiency
99.11
HPH performance is
deteriorated
15.64
Flue gas
outlet
temperatur
e=167
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
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
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
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)
Controllable Parameters
84 | P a g e
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)
(%)
Parameters
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).
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
Long Term
Mill
Fineness(%)
Fineness>75
NA
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
SADC
Rectification of damper
position feedback on available
opportunity.
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
APH outlet
Temp= 141
APH outlet
Temp= 130
7.80
Short Term
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.
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
High differential
temperature
5.94
14.67
Short Term
Long Term
Possible DP reduction.
88 | P a g e
3.18
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
Condenser
169
76.86
540
168
65
0.37
0.59
15.43
3000
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)
Makeup (%)
Controllable Parameters
89 | P a g e
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
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).
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.
Short Term
Long Term
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
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
glands.
Turbine oil moisture carry over
Long Term
92 | P a g e
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.
Power Station
Unit size
MW
Unit
No
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
Power Station
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:
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
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
96 | P a g e
R&M
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
97 | P a g e