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Power Plant Optimization Component under IGEN Programme – Review & Progress Achieved

Power Plant Optimization Component under IGEN Programme – Review & Progress Achieved. K.K.Chakarvarti Manager- Power Plant Component IGEN, GTZ. Introduction.

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Power Plant Optimization Component under IGEN Programme – Review & Progress Achieved

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  1. Power Plant Optimization Component under IGEN Programme – Review & Progress Achieved K.K.Chakarvarti Manager- Power Plant Component IGEN, GTZ

  2. Introduction • India has an installed power generating capacity of 143,061 MW (as on March 31, 2008) of which the thermal power stations share is 91,906 MW (64%).

  3. Total Installed Capacity- 1,43,061 MW (as on March 31, 2008 )

  4. Introduction-Contd. • The contribution of energy generated by thermal stations was 559 billion kWh, which is about 80% of electricity generated (704.5 billion kWh) in 2007-08. • There has been significant improvement in the plant load factor of thermal stations, which improved from 52.4% in 1985-86 to 78.6 in 2007-08, registering a remarkable improvement of 50 % during the period. • Since the major power generation contribution is from thermal sector, an average increase of 1% in the thermal power plant efficiency would result in: a. Coal savings of approx. 11 million tons per annum for nation (approx) worth 200 Million Euro b. 3% CO2 reduction per annum (approx.13.5 million tons per annum)

  5. ALL INDIA PLANT LOAD FACTOR (%) OF COAL FIRED THERMAL POWER STATIONS

  6. INDIAN SCENARIO: DESIGN HEAT RATE TRENDS*

  7. EFFECT OF CRITICAL PARAMETERS ON HEAT RATE

  8. Policy initiatives of Government of India to improve the power sector efficiency • Power sector reforms • Promotion of clean coal technologies, • Energy Conservation Act 2001 • Electricity Act 2003 • National Electricity Policy, 2005 • Adoption of Super Critical Technology for 660/ 800 MW units for Ultra mega Projects (4000 MW each) and • Increased emphasis on environmental considerations

  9. Barrier to Efficiency Improvement in Power Sector – Indian Scenario • Emphasis on plant load factor instead of ‘efficient generation’. • Degradation of equipment resulting in loss of capacity. • Delayed overhauls (Seasonal Constraints) • Financial constraints lead to inadequate maintenance • Lack of awareness on efficiency related issues • Inadequate monitoring system for parameters

  10. The Indo German Energy Programme (IGEN) • The Ministry of Power, Government of India and GTZ (Deutsche Gesellschaft für Technische Zusammenarbeit (GTZ) GmbH) signed an ‘implementation agreement’ with respect to the Indo-German Energy Programme in 2006. • The Indo German Energy Programme (IGEN) is performing research work and performance assessment in support of the implementation of the Energy Conservation Act 2001 in cooperation with the Ministry of Power and its statutory bodies Bureau of Energy Efficiency (BEE), and Central Electricity Authority (CEA). • Under the IGEN agreement, CEA has been entrusted with the task of ensuring performance optimisation and efficiency of thermal power plants.

  11. The Indo German Energy Programme (IGEN) • The overall aim of this measure under Indo Germany Energy programme is to support and prepare public and private power plant operators for performance reporting as well as implementation of financially attractive and technically viable improvements of power plant net heat rate under the provisions of the Energy Conservation Act. • The project is being executed under two main sub-components: • 1. Mapping Studies of thermal power generating units • 2. Performance Optimisation of Thermal Power Stations

  12. Mapping Studies of Indian Thermal Power Stations(Sub Component-I) • GTZ has provided support to CEA in creating a database of the older thermal power plants in India. • The scope of the work primarily covers the mapping of the 85 thermal power generating units by using Ebsilon software. • The mapping is done for two-condition design status and the actual operating status based on plant parameters gathered from different plant locations. • Its primary purpose is to provide a baseline mapping for creating a database within CEA and identify areas both short and long term, needing attention in order to improve energy efficiency. • The baseline map would permit an objective method of setting targets and monitoring progress.

  13. MAPPING STUDIES - PROGRESS ACHIEVED Mapping studies of 55 Thermal power generating units of the 14 Indian States viz. Andhra Pradesh Chhattisgarh, Gujarat, Haryana, Jharkhand, Karnataka, Madhya Pradesh, Maharashtra, Orissa, Punjab, Rajasthan, Tamil Nadu, Uttar Pradesh & West Bengal have been completed.

  14. The total installed capacity of above 55 coal fired thermal generating units, covered under the mapping study is 11245 MW, which is about 15% of the installed capacity of coal fired generating units (76300 MW) in the country. • The mapping studies carried out by using Ebsilon Software have brought out the deviations between design and operating parameters such as gross heat rate, turbine heat rate, boiler efficiency , specific coal consumption of the power generating units .

  15. Salient features of outcome of Mapping Studies of twenty-six nos. of 210 MW units 1. The mapped thermal generating units were characterized by a wide band of energy performance 2. Few of them were very closed to their designed energy performance, but majority of them had deviated from their designed performance by a bigger margin 3. Operating Gross Heat Rate was found to be varying from 2477 to 3084 kCal/kWh against their design values of 2321 and 2444 kCal/kWh respectively, exhibiting deviation band width of 156 kCal/kWh (6.3%) to 640 kCal/kWh (20.7%)

  16. 4. For an average designed Gross Heat Rate of 2384 kCal/kWh for these 26 units of 210 MW capacities, the heat rate has increased by an average value of 385 kCal/kWh, registering an average increase of 16% from their design performance.

  17. 5. The mapping studies have proved that older units having better operation and maintenance practices can still demonstrate higher performance than comparatively younger units. 27 % of 210 MW power generating units, having age more than 25 years have shown better performance than 54 %of 210 MW units in the age group of 14-25 years Average Gross Heat Rate by age group (210 MW) (as observed through Mapping Studies)

  18. 2500 2407 2400 2300 2200 2100 2045 2000 1900 • The operating gross heat rate of turbines was found to be the major contributor in the deterioration in the energy performance of 210 MW units. The turbine gross heat rate varied from 2045 to 2407 kcal/kWh indicating a wide difference of 362 kCal/kWh in the operating performance of 210 MW turbine units, which is about 60% of the total deviation (607kCal/kWh) observed for 210 MW generating units. • Turbine Heat Rate of 210 MW capacity units (kcal/kWh)(as observed through Mapping Studies)

  19. 2,900 2,850 12 units One unit 2,800 13 units 2,750 kcal/kWh 2,700 2,650 2,600 2,550 2,500 2,450 2,400 Franco-Tosi KWU LMZ 2,783 2,739 2,806 Total average Average Gross Heat Rate by Turbine Type (210 MW)(as observed through Mapping Studies)

  20. 3,000 4 units 2,900 one unit 2,800 21 units kcal/kWh 2,700 2,600 2,500 2,400 ABL BHEL Transelectro 2,906 2,745 2,783 Total average Average Gross Heat Rate by Boiler Type (210 MW)(as observed through Mapping Studies)

  21. 86.00 84.20 84.00 82.00 82.00 80.00 78.00 77.25 76.00 74.00 Boiler Efficiency of 210 MW capacity units (%)(as observed through Mapping Studies)

  22. 12.5 11.82 11.5 10.5 9.5 8.5 8.07 7.5 6.5 Percentage of Auxiliary Consumption of 210 MW capacity units (%)

  23. Performance Optimisation of Thermal Power Stations under IGEN Programme (Sub Component II) • The overall aim of this measure is to support and prepare public and private power plant operators for performance reporting as well as implementation of financially attractive and technically viable improvements of power plant net heat rate under the provisions of the Energy Conservation Act. • This phase has been initiated with effect from 15th January, 2008 and is expected to be completed by 15th January, 2010. The following 5 outputs are planned:

  24. Performance Optimisation of Thermal Power Stations under IGEN Programme (Sub Component II) Contd… 1.Technical assistance for conduct of high quality energy audits 2. Technical assistance in the establishment of energy management system in the power plants 3. Annual statistics of validated impact of energy conservation in power plants 4. Familiarization and interchange of best practices with power plant operators in Germany or Europe 5. Development of electronic data base to analyze the findings of all energy audit reports carried out in power plants and assessment of impacts with respect to energy conservation and efficiency.

  25. PERFORMANCE OPTIMISATION OF THERMAL POWER STATIONS - PROGRESS ACHIVED • The following progress has been achieved in the past 6 months since the initiation of the activities with effect from 15th January, 2008. • Output – 1 • Technical Assistance for Conduct of High Quality Energy Audits • 1. 1 Survey of best practices on power plant performance monitoring in Germany / Europe, data generation and its analysis, software and analytical tools used, on line as well as mobile measuring instruments, newest trend in power plant performance optimization, etc. • -- (Draft Prepared)

  26. 1.2. Organization of 20 workshops and 20 seminars to disseminate findings across India --- (Schedule finalized, conduct of workshops and seminars is commencing from August 2008) 1.3 Development of standard procedure for energy auditing of power plants and its finalization --- (Under preparation, expected to be completed by Sep 2008) 1.5 Undertake statistical analysis of 100 energy audit reports prepared by accredited energy auditors for assessment of their quality and findings ---- (Received 25 reports from power stations and are being evaluated for statistical analysis on the qualitative assessment such as areas covered, quality of reports, probing skills, report structure etc.)

  27. Output – 2 • Technical Assistance in the Establishment of energy management system in the power plants • 2.1 Development of a model organizational structure for establishing Energy Management Cells, employing certified Energy Manager, based on the outcome of the survey of all public and private power plants • --- (40 TPS have submitted information till date and is under analysis) • Miscellaneous: • To support energy managers, energy auditors and other energy professionals engaged in the energy efficiency improvement in the power plants, a new home page on "Power Plant Optimization" – Component has been established w.e.f May, 2008 in www.energymanagertraining.com . This section has recorded about 5800 visitors.

  28. Outcome Expected from IGEN The following outcomes are expected of the programme: a. Assistance in the improved efficiency of thermal power plants b. Establishment of mapped power plants data bank c. Establishment of Energy Efficiency cell at Power Plants d. Capacity building of the power plant professional on power plant optimization e. Standard Prescribed format for submitting Energy Audit Reports.

  29. CONCLUSIONS • The increasing preference for commercial energy has led to a sharp increase in the demand for electricity and fossil fuels. • Use of Fossil Fuels result in emission of huge quantity of carbon dioxide causing serious environmental damages. • There is a considerable potential for reducing energy consumption by adopting energy efficiency measures in thermal power stations of our country. • Energy efficiency will not only reduce the need to create new capacity requiring high investment, but also result in substantial environmental benefits. • With the enactment of the Indian Energy Conservation Act, 2001, an institutional framework is now available for promoting energy efficiency in all sectors of the economy • Efficient use of energy and its conservation will succeed as a program if there is a strong institutional set up in the country and opinion leaders and captains of industry take lead in implementing the best practices supporting the conservation programme

  30. ENERGY IS LIFE JOIN HANDS IN CONSERVING IT

  31. ANNEXURE-I List of Generating Units Covered under Mapping Studies

  32. ANNEXURE-I Contd… List of States and Generating Units Covered under Mapping Studies

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