Presentation Title A holistic view of energy efficiency improvement in power generation.

1. Presentation Title • A holistic view of energy efficiency improvement in power generation. • New technology, renovation&modernization and process improvement. By Name: Souvik Dutta Designation: Dy Chief Engineer(Gen) Date:26.08.11

2. New technology, renovation&modernization and process improvement. A holistic view of energy efficiency improvement in power generation.

3. New Technology New Technology New Technology Renovation & Modernization Renovation & Modernization Process Improvement Solutions

4. Solutions Adoption of New Technology in Thermal Power Generation

5. Major Initiatives for higher efficiency…… Adoption Supercritical, Ultra supercritical Technology Adoption of Combined cycle Technology Adoption of Integrated Gasification Combined Cycle (IGCC) Suitable for Indian Coal

6. Adaptation Supercritical / Ultra supercritical Technology Development of Ultra Mega Power Projects (UMPPs) has been identified as a thrust area in order to increase plant efficiency. These are very large sized projects with supercritical technology, approximately 4000 MW each involving an estimated investment of about Rs. 16,000 crore each.

7. Adaptation Supercritical / Ultra supercritical Technology Salient features of the Plant and Choice of Technology • The Ultra Mega Power Projects would use Super Critical Technology with a view to achieve higher levels of fuel efficiency, which results in saving of fuel and lower green- house gas emissions. • Flexibility in unit size subject to adoption of specified minimum Supercritical parameters. • Integrated power project with dedicated captive coal blocks for pithead projects. • Coastal projects to use imported coal.

8. 43% 42% 320/600/620 (800-1000 MW) 280/600/620 (800-1000 MW) 41% 247/565/593 (660/800 MW) Gross Efficiency, GCV Basis 40% 247/537/565 (660 MW) 39% 170/537/537 (500 MW) 38% ‘00 ‘02 Xth Plan XIth Plan ‘12 XIIth Plan ‘17 XIIIth Plan ‘22 ‘07 Solutions Indian Efficiency Roadmap Increasing Unit size & steam parameters Pr/MST/RHT Current scenario

9. Heat rate Improvement Over The Years Indian Efficiency Roadmap Increasing Unit size & steam parameters

10. Parameters for Higher Efficiency……

11. Ultra Mega Power Projects : Indian Scenario Concerns: Viability at agreed upon tariff due to changed scenario of imported coal Projects under process Orissa Integrated Power Ltd Akaltara Power Ltd Coastal Tamil Nadu Power Ltd Coastal Maharashtra Mega Power Ltd Coastal Karnataka Power Ltd Sakhi Gopal Integrated Power Co Ltd Orissa Gogarapalli Integrated Power co Ltd Orissa Tatiya Andhra Mega Power Ltd

12. Ultra Mega Power projects awarded through tariff based competitive bidding route. • Plants have higher operating parameters and increased efficiency levels.

13. WAIGAOQIAO THERMAL POWER STATION P H A S E - I I I : 2 X 1 0 0 0 M W SHANGHAI, CHINA Ultra Supercritical 1000 MW units in China

14. Adoption IGCC (Integrated gasification combined cycle)Technology • An integrated gasification combined cycle (IGCC) is a technology that turns coal into gas—synthesis gas (syngas). • Excess heat from the primary combustion and generation is then passed to a steam cycle, similarly to a combined cycle gas turbine. • This then also results in improved efficiency compared to conventional pulverized coal.( 46% to 52%) • In the IGCC plants, the production of CO2 during the gasification process offers the opportunity for relatively low-cost CO2 capture and storage (CCS), which may give the future IGCC plants some competitive and environmental advantages over super critical plants

15. IGCC (Schematic diagram of the process)

16. IGCC (Schematic diagram of the process)

17. IGCC • Efficiency and reliability improvements are also expected for the IGCC technology. Its efficiency is estimated to grow from 46% in 2010 to 52% in 2020. Some major IGCC plants, worldwide • 580 MW, Kentucky Pioneer Energy, USA • 512 MW, ISAB Energy, Italy • 342 MW, Nippon Oil Corporation Refinery, Japan • 335 MW, Elcogas, Spain • 250 MW, Tampa Electric Company, USA

18. IGCC • India first IGCC power plant is coming up at Vijayawada, foundation for which has been laid. The 125 MW plant will be built in the premises of Vijayawada Thermal Power Plant (VTPS). • BHEL and APGENCO has jointly funded this project. • The main constraint of IGCC technology is cost (+35%), more land requirement and higher auxiliary consumption for producing syn gas.

19. 250 MW IGCC plant: Tampa Electric Company, USA

20. Solutions Renovation and Modernization (R&M) as per CEA guidelines

21. Renovation and Modernization (R&M) as per CEA guidelines • Increase in availability and plant load factor of thermal power stations • Renovation and modernization for achieving higher efficiency levels. • Setting minimum acceptable standards & plan for R&M for projects below standard with clear cost benefit analysis • If economic operation does not appear feasible through R&M, then there may be no alternative to closure of such plants as the last resort. • In cases of plants with poor O&M record a change of management may to be considered so as to improve the efficiency to acceptable standards.

22. NEED FOR R&M – EXISTING UNITS • Improvement in performance parameters – PLF, availability, heat rate/efficiency, auxiliary power consumption, partial loading & forced outage. • Restore derated capacity • Extension of economic life. • Obsolescence & non availability of spares (eg C&I) • Environmental issues/other statutory requirements. • Safety requirements.

23. FUTURE APPROACH TOWARDS R&M NEAR PASTFUTURE In-kind replacement Cost effective technology upgrades Restoration of lost capacity Uprating of capacity Attain design efficiency Improve upon design Efficiency Reactive R&M Pro-active R&M From Time based R&M Condition Monitoring & R&M Optimisation through cost benefit evaluation

24. R&M and Life extension program (LEP) during 11th plan(2007-11)

25. INDIA: Power generation Capacity in MW as on 30th June 2011. Source: CEA website.

26. INDIA: Power generation Capacity (Billion Watts) for Coal/Lignite based plants >25 MW capacity Results of R&M Improvement Trend

27. National Thermal plant performance (Coal lignite based>25 MW) (PLF) Results of R&M Improvement Trend

28. National Thermal plant performance (Coal /lignite based>25 MW) (PAF) Results of R&M Improvement Trend

29. National Thermal plant performance (Coal /Lignite based>25 MW)(Aux%) Results of R&M Improvement Trend

30. Solutions Process Improvement

31. Process parameters to be improved…… • Auxiliary power consumption • Heat rate • Oil figure • Plant load factor • Plant availability factor

32. Reduction of Auxiliary power consumption Sharing of CESC’S experience in reduction of Auxiliary Power consumption

33. Southern Generating Station. CESC Ltd • Commissioning of Variable Frequency Drives for U#2 ID Fans in February 2011 • Objective: To reduce auxiliary power consumption

34. VFD ESSENTIALS • Make: Leader & Harvest Electric Technologies Co. Ltd, China • Indian Partner: Yantra Harvest Energy Pvt. Ltd, Pune • Product : Medium-Voltage VFD • Model: HARSVERT – A06.6/50 • Rated Input Voltage: 6.6 KV • Rated Capacity: 450 KW • Rated Output Current : 50 A • Output Frequency Modulation: 0-50 Hz • Output Voltage Modulation: 0 – 6.6KV • Control Mode: Sinusoidal multi-level Pulse Width Modulation

35. VFD ESSENTIALS Harvest MV Drive consists of • Input Transformer • Power Cell • Control System

36. VFD ESSENTIALS • Multi-winding Phase Shifting Input Transformer (Dry-type) comprising of 18 nos. Secondary (6 Per phase with Phase-shifted at 20,10,0,-10,-20 Degrees for 36-pulse rectification) & 1 no. Auxiliary Winding for Supply to Cooling Fans of Power Cabinet • Primary Winding Rating : 6600V / 49.4 A • Secondary Winding Rating: 710V / 25.5 A • Auxiliary Winding Rating : 380 V/ 12.2 A

37. The Equipment

38. Note: Above Readings are in winter months. Expected AC Load in Summer : 25 KW ID fan reduction in auxiliary power consumption after installation of VFD Payback for two fans:18 to 20 months 36 % savings 50 % savings

39. Forthcoming VFD projects in CESC Ltd in the current financial year. • Southern Generating Station: Installation of four numbers VFD’S for two ID fans & two FD fans of Unit no 1. Project: cost 410 lakhs. • Titagarh Generating Station: Installation of VFD,S for two ID fans in one unit.Project cost: 200 Lakhs

41. Southern Generating Station.CESC Ltd :Micro Hydle project • 45 KW Micro Hydel Project at condenser cooling water outfall (3X15 KW) • Objective: To reduce auxiliary power consumption by extracting power from wasted energy

42. Basic concept

43. Southern Generating Station.45 KW(3x15 KW) Micro Hydel Project ph-1Supplier: Pentaflow Hydro Engineers.Delhi Specifications of the 15KW micro hydle turbine generator set • Rated capacity: 15KW (At Generator output) • Rated net head: 1.8 m • Rated discharge: 1 m3/s • Type of turbine: Propeller 4 blade inverted siphon • Rated turbine speed: 360 rpm • Runner diameter: 1000 mm • Type of generator: Induction • Method of drive: Flat belt • Turbine efficiency: 86%

44. Southern Generating Station. CESC Ltd • Commissioning of phase -1 of the project completed in February 2011 • Average 12-14 KW is being generated from the first 15 KW unit • In subsequent phases another two such sets will be commissioned

45. Auxiliary Energy Saved • Electricity saved each year considering import for 75% time of a day for 350 days in a year • 15 KW X 8400 hrs/year X0.75= 94500 KW-h / Year • This is equivalent to a savings of Rs 435000 / year • With a project cost of Rs 14.3 lakhs/unit payback is approximately3.3 years • In the subsequent years other than minor maintenance costs 100% savings will be achieved • For three such units the projected savings will be approximately Rs 10 lakhs

46. Micro hydle during installation

47. Thank You ! The future of mankind is in our hands. Let us act responsibly to keep the world cleaner for our future generation.