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PRESENTATION ON ESSENTIAL REQUIREMENTS

FOR

ENERGY AUDITS

IN

THERMAL POWER STATIONS

BY
H.S.Bedi
Sr. Vice President (Power)
Energo Engineering Projects Ltd.
A-57/4, Okhla Industrial Area,
Phase – II, New Delhi - 110020
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“You cannot Manage what you
cannot Measure”

(Accurately)

- Jack Welch, CEO, General Electric

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PATTERN OF ENERGY CONSUMPTION

IN

THERMAL POWER STATION


TYPICAL PLANT LOSSES
4
ECONOMIC ASPECTS OF INEFFICIENT

MACHINES (200 MW)

SHORT FALL LOSS IN


CRORES PER
ANNUM

TURBINE CYCLE HEAT RATE 1.0 % 5.0

BOILER EFFICIENCY 1.0% 1.75

AUX. POWER CONSUMPTION 5.0 % 1.25

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REQUIREMENT – 1

1.1 ACCURACY OF COLLECTED DATA

– Collected data has to be most accurate & doubtless.

– Use calibrated and accurate instruments better conforming to ASME-PTC

standards

– 1.0% Error in data means unreliability and 25000 tons of coal loss/annum for

200 MW Unit or approx Rs. 5 crores / year based on assumption that

•TG cycle heat rate is taken as 2000 kcal / kwh

•Coal CV is taken as 4000 kcal / kg

•Price of coal taken as Rs. 2000 / ton

– Loss increases with machine size


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1.2 EFFECT OF INSTRUMENTATION ON ACCURACY

A. Plant on-line instruments with few audit instruments Accuracy


around 3.0%.
B. Accurate calibrated instruments as per ASME-PTC-6 for steam
turbine& ASME-PTC-4-1 for Boilers.
Accuracy around 0.5 %

1.3 EFFECT OF PROCEDURE ON ACCURACY OTHER THAN


ASME-PTC-6 for steam turbines and ASME – PTC-4.1 for boiler

– Error in Boiler Energy Audit – around 2.0%


– Error in steam turbine Energy Audit – around 3.0%

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1.4 TOTAL ERROR BECAUSE OF

INSTRUMENTATION & PROCEDURE

INACCURACY 6.0%

NOTE:
DIFFERENCE IN COST OF ENERGY AUDIT
BETWEEN AUDIT BY ACCURATE INSTRUMENTS
AS PER ASME AND NORMAL INSTRUMENTS IS 12
TO 14 LACS AS AGAINST 6 TO 8 LACS.
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EFFECT OF INSTRUMENT INACCURACY ON
HP/IP Turbine Efficiency

Main Steam HPT Exhaust


Pressure Temp Pressure Temp
HPT Kg/cm2 Deg C Kg/cm2 Deg C
Efficiency
1 1 1 1
0.6 % 0.6 % 2.0 % 0.7 %

IPT Inlet IPT Exhaust


Pressure Temp Pressure Temp
IPT Kg/cm2 Deg C Kg/cm2 Deg C
Efficiency
1 1 1 1
1.2 % 0.3 % 6.0 % 0.4 %

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EFFECT ON HEAT RATE FOR PARAMETER
DEVIATION (500MW UNIT)
DEVIATION IN PARAMETER EFFECT ON HEAT
RATE (KCAL/KWH)

1. HPT inlet press. by 5.0 ata 6.25


2. HPT inlet temperature by 10.0deg C 6.0
3. IPT inlet temperature by 10.0deg C 5.6
4. Condenser pressure by 10.0 mm of 9.0
Hg
5. RH spray water quantity by 1.0% 4.0
6. HPT Cylinder efficiency by 1.0% 3.5
7. IPT Cylinder efficiency by 1.0% 4.0
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REQUIRED ACCURACY AND CALIBRATION OF THE INSTRUMENTS

The proposed instruments should have following level of accuracy.

i. Thermocouples and PRTs – ASME special class ‘A’ i.e ½ DIN tolerance
ii. Pressure and differential pressure - 0.1%
transmitters better than
iii. Power Meter for generator & - 0.1%
Unit Aux Power measurement
iv Data Logger - 0.03%
v Power transducers / Load Analyser - 0.5%
vi Flue gas analyser - 0.5%
vii Ultrasonic flow meters - 0.5%
viii Anemometer - 1.0%
ix Infrared Thermometer - 1.0%
x Lux meter - 1.0%
xi RH meter - 1.0%

These should be duly calibrated from NABL accredited lab.


The above accuracies for S.No. I to V are as per ASME specified for
Performance Evaluation of Thermal Power Plants.
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REQUIREMENT – II
PROPER SCHEMES FOR ENERGY AUDIT

FG
Expansion
Bellow

Economizer

HVS
APH

Sampling
Locations
APH

FG

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Annexure - I
BOILER EFFICIENCY AND APH TEST SCHEME &
INSTRUMENTATION DIAGRAM

1. Grid measurement for gas composition and gas temp. at air pre
heater inlet / outlet.
W/6 W/3 W/3 W/6
T1 T2 T3

D/6
N11 N21 N31

D/3 DEPTH
N12 N22 N32

D/3
N13 N23 N33

D/6

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14
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ENERGY AUDIT SCHEME FOR 210 LMW STEAM TURBINE

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REQUIREMENT - III

FREQUENCY OF READINGS FOR ACCURATE DATA COLLECTION

TURBINE CYCLE AUDIT

Pressure - 5 Minutes
Temperature - 5 Minutes
Flow - 1 Minute
Power - 1 Minute
Levels - 10 Minutes

BOILER UNIT AUDIT

Temperature - 15 to 30 Minutes
Flue Gas Composition - ½ to one hour

DURATION OF AUDIT TEST

Turbine Cycle - 2 Hrs


Boiler Unit - 4 Hrs
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REQUIREMENT – 4
SCOPE OF WORK (SPEC) FOR ENERGY AUDIT OF A
TYPICAL THERMAL POWER PLANT UNITS
A. BOILER
• Boiler efficiency by heat loss method as per ASME PTC-4-1
guidelines and give break up of losses
• Furnace air ingress at different levels upto I.D.Fans
• Air heater performance
 Gas side efficiency
 Air side and gas side pressure drop across APH
 Air leakage across APH
 X – ratio i.e heat capacity of air to gas capacity.
• Aux power consumption and combined efficiency of fan and motors
of ID, FD & PA fans.
• 18
Aux power consumption of coal mills, feeders vs loading.
B. TURBINE
1. Turbine cycle heat rate as per ASME-PTC-6 methodology and
instrumentation
2. HP and IP cylinders efficiency
3. Turbine pressure survey
4. TTD & DCA of HP / LP heaters Pressure drop across heaters
5. Condenser performance i.e
 Condenser back pressure after duly considering the effect of
present C.W inlet temp, C.W flow, heat load on condenser
and air ingress to condenser vis-à-vis design conditions
 C.W side pressure drop in condenser
1. Cycle losses
2. Performance of turbine glands
3. Ejector performance
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C. ELECTRICAL SYSTEM

1 Motors • Assessment of Loading condition of HT


and LT motors of Boiler area, Turbine area
and Balance of Plant area.
• Assessment of operating parameters like
load variation, Power factor of HT and LT
motors consuming power more than 50
KW.

2 Capacitors • Assessment of health of capacitors.

3 Plant Lighting system • Lighting load survey and Assessment of


installed load efficacy (I.L.E) and I.L.E
ratio at various areas of plant.

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D. Pump performance for BFPs, CEPs, Aux C.W.P & C.W.P and

pumps consuming power more than 50 KW etc.

• Check Performance of the pumps by comparing the corrected

measured flow at operating speed to design speed with that of

the expected flow derived from the characteristic curves against

the corrected total dynamic head at design speed.

• Determine Pump efficiency as the ratio of power input to the

pump shaft to hydraulic power.

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E Insulation Audit:
A. Walk through survey of Boiler, Turbine and associated steam
piping to identify the damaged and Hot spot area.
B. Surface temperature measurement at the damaged and Hot
spot area by infrared temperature indicator.
C. Estimation of heat loss in the hot spots and damaged
insulation area.

F Balance Of Plant
(i) Compressed air system:
• Free Air Delivery i.e. Capacity evaluation of the Plant and
Instrument air compressors.
• Checking volumetric efficiency of compressors.
• Assessment of compressed air leakage quantity.
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(ii) Air conditioning system:
• Performance evaluation of AC Plant w.r.t net cooling /
refrigeration capacity along with heat load of Air handling unit and
energy requirements.
(iii) Ash Plant
• Performance of ash Slurry pumps through power measurement
and flow measurement.
• Ash water ratio assessment and recommendations for
optimization in water and power consumption.
(iv) Cooling Tower Performance
It shall include establishment of
• Liquid/Gas ratio
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Cooling tower effectiveness, approach and range
(V) Coal Handling Plant

Input Power measurement of all the key equipment of the CHP area

like: Paddle feeders, Conveyors, Stacker & Re-claimer, Wagon

Tipplers, Crushers,

NOTE:
• ENERGY CONSERVATION MEASURES TO BE SUGGESTED

IN ALL THE ABOVE AREAS OF AUDIT.


• ENERGY AUDIT PROCEDURE TO BE SUBMITTED ALONG

WITH AUDIT MEASUREMENT SCHEMES AND APPROVED


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1.0 USEFULNESS OF ENERGY AUDIT IN
THERMAL POWER STATION
• Identifies wastage areas of fuel, power and water utilization.
• Reduction in cost of generation by implementing findings of EA.
• Increases power generation by efficient utilization of steam in turbine
cycle and reduction in Aux Power Consumption.
• Maintenance planning and availability improvement.
• Provides guidance in loading sequences of the units.
• Identification and rectification of errors in on-line instruments.
• Leads to reduction in green house gases.
• Utilizes specialized services of experienced engineers.
• Training of O&M staff for efficient control of unit operation.
• Improves competitiveness by reducing unit generation.
• Creates bench mark for all equipments and systems.
• Fulfills bureau of energy efficiency mandatory requirement of Energy
Audit.
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METHODS / OBSERVATIONS FOR SAVINGS ENERGY IN
POWER PLANT

1) Operation of machine at very low turbine I/L parameters.

2) Operation of turbine at lower loads.

3) HP and IP turbine cylinder efficiencies are very low.

4) Main steam and HRH inlet temperature to turbine very low.

5) RH pressure drop high.

6) High quantity of SH Spray and its tapings before HPH-5


resulting in loss of heat because of changed cycle.

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METHODS / OBSERVATIONS FOR SAVINGS ENERGY IN
POWER PLANT

7) HP heater no. 5 out of service.

8) Turbine cycle not operating as per design scheme i.e.


Ejector and Deaerator pegging steam from PRDS
header as against normal source from deaerator &
extraction steam respectively.
9) Passing of turbine cycle drain valves.
10) Make up quantity to cycle is very high which indicates
excessive system steam (heat) loss.
11) TTD & DCA of heaters high.
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METHODS / OBSERVATIONS FOR SAVINGS ENERGY IN
POWER PLANT

12) Condenser air ingress and dirty tubes.


13) Under loading of motors
14) Excessive air leakage in compressed air system
15) Faulty insulation
16) Drain valves passing
17) Air ingress to Boiler furnace
18) FAD of compressors low

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Thanks…
Energo Engineering Projects Ltd.
A-57/4, Okhla Industrial Area, Phase – II

Phone: +91 - 11 - 26385323/ 28/ 29/ 38


Fax: +91 – 11 – 26385333
E-mail: energo@del3.vsnl.net.in
energo@energo.co.in
Web: www.energoindia.com
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