Documentos de Académico
Documentos de Profesional
Documentos de Cultura
MW
105646.98 87,093.38 17,353.85 1,199.75 37,033.40 4,560.00 16,429.42
Total
1,63,669.80
**include Small Hydro Project, Biomass Gasifier, Biomass Power, Urban & Industrial Waste Power, Wind Energy
Northern
Western Southern Eastern
8.32%
5.04%
Operating2703.9
kcal/kWh
Indian Thermal
APC - Elements
Draft System (ID,FD,PA /SA, HGR Fans
Lighting
APC Break-up
Gross Generation Vs APC Typical APC Breakup
Cooling water system , 1.20% APC, 8.32%
Compressed Air System, 0.04% Feed water System , 3.22% Water treatment System, 0.27% Lighiting , 0.07% Draft System, 2.20%
THERMAL AUXILIARIES
FOR A TYPICAL 210 MW UNIT
LT Motors (415 V)
43 Nos
510 Nos
17.5%
High
Moderate*
Low High*
Moderate to High
*Depends on R & M
Coal Quality
Reduction of 0.2 - 0.3 % in APC with retrofits and system optimisation techniques could be achieved. Major retrofits can result into higher APC reduction
Note,
-
APC is measured only from difference of generated and transmitted power, but no direct measure
Indian Thermal
> S ystem-wise
Opportunities and results
Requirement Analysis
Effectiveness analysis Break-even in terms of power consumption and process gain Multi level / element Control
Corrections due to Performance deterioration Equipment control and retrofits Internals replacement and retrofits Energy Efficient Equipments
Process Upgrades
12 Port LIU
12 Port LIU
12 Port LIU
12 Port LIU
Dept. A
12 Port LIU
Dept. B
12 Port LIU
Dept. C
RS 485-1
RS 485-2
RS 485-1
RS 485-2
RS 485-1
RS 485-2
20
20
20
20
20
20
EM 6400
EM 6400
EM 6400
EM 6400
EM 6400
EM 6400
EM 6400
EM 6400
EM 6400
EM 6400
EM 6400
EM 6400
RS 485 Cable
Fibre patch
6 core Single
Cat6 Cable
BFP scoop operation in three element mode instead of DP mode Avoid Recirculation
Faulty valve
BFP re-circulation through bypass valve leakage was established through study in one of the plant (manual valve closed for 1 hour) and 45 kW (3%) power reduction in BFP was observed Operation of BFP with lower DP (14 bar to 6 bar ) in a 2 x 125 MW plant resulted in to reduction 1.8 MU
Draft System
FD, PA & ID Fans
Arresting Air in-leaks in draft system (by O2 measurement)
Excess Air for combustion - Increase in FD, PA & ID fan power
Excess Air
Flow increase in ID fan
Fuel
Pulverized Coal
Air ingress
Maintain Primary Air to Secondary Air ratio to reduce the PA fan power consumption
15 -40
14% air ingress between APH and ID Fan was indentified in one of the plants and it was rectified to 4% , this resulted in 17% reduction in ID Fan power consumption
Draft System
Elimination of damper/Inlet Guide vane based capacity control with variable speed control system Variable speed drive Variable speed hydraulic coupling Use of energy efficient fans Change of impeller with energy efficient / appropriately sized impeller
Oversize Fan
82%
500
420 Static Pressure System Curves
A
Full open valve
Required Fan
Flow (m3/hr)
Efficiency improvement by replacing fans and impellers of FD, PA and ID Fan results in Energy Saving of 14.5 MU at an investment of Rs. 20 MINR
Optimisation of crusher loading has resulted in reduction 25% of operating time and 16% in energy consumption i.e. 0.5 MU per annum
Coal Milling
Coal Milling/Grinding System
Maintain proper air fuel ratio Periodic testing of coal particle size To minimize fines (less than minimum required size) Optimized Mill parameters Ball loading in Ball/ tube mill Roller pressure with respect to grindability of coal Mill internals replacement with regression analysis of previous and present consumption pattern (including particle distribution)
&
Roller Pressure
Break-even point for replacement must be identified so as to avoid excess energy consumption in coal mill
Replacement Analysis
Grinding Roll Run Hours Vs Specific Power Consumption
10 9.5 9 8.5 8 7.5 7 6.5 6 5.5 5 0 500
y = 2E-07x2 - 0.0004x + 6.9991 R2 = 0.9685 1000 1500 2000 2500 3000 3500 4000 4500 5000
Run Hours
Cooling tower
Nozzles to give better distribution over the fill Follow Manufacturers recommended clearances around cooling towers and relocate or modify structures that interfere with exhaust or air intake Optimize cooling tower fan blade angle on a seasonal and/ or load basis Correct excessive and/ or uneven fan blade tip clearance Replace splash bars with self extinguishing PVC cellular film fills Periodically clean plugged cooling tower distribution nozzles Maintain the Optimum L/G ratio 1.4 to 1.6 ( Rectify distribution problems)
Old cooling water pumps operating at 52% efficiency and developing only 70% of the rated head has been replaced and saved 0.8 MU per annum Detailed study of cooling tower capability, L/G ratio, gas exit velocity, air flow and recirculation to operate 7 CTs instead of 8 CTs has resulted in to energy saving of 0.43 MU per annum
Variable speed drives with feedback control Impeller Trimming to permanently reduce the capacity Proper maintenance
Periodic checking of valves Cavitation Leakage in gland sealing Deposits on impeller/casing
Change the RO discharge Pressure setting with respect to raw water TDS Multiple pumps in parallel operation as per flow requirement
Detailed study of entire system from intake to make-up water has potential in optimisation complete system (intermittent operation of additional pump, avoiding recirculation, installation of VFDs (raw water make-up, cooling tower make-up, ash water make-up, service water make-up, drinking water make-up). Estimated annual savings of these measures is 1.38 MU with investment payback of 20 months
Reduction of generation pressure (identified areas), additional piping to reduce pressure drop, improvement of Volumetric efficiency, separation of cleaning air network with PRV and cleaning nozzles has potential to save 1.2 MU (8 x 120 MW )
Average Efficiency: 50% >Unloading rate > 20% 70% >Unloading rate > 50% Very Bad Efficiency: Unloading rate >70%
Driers Use of heat of compression air dryer instead of electrically heated air dryer User End Open ended usage - use nozzles & pressure regulator
Separation of cleaning air network and reduction of service air generation pressure in a PP resulted in stopping of one air compressor 0.35 MU
Power Distribution
Motors
Loading < 30% - Stat Delta Star connection to minimize motor losses Example: CHP conveyor Motors Energy Efficient Motors
Benefits
reduced kVA drawn , KVAR & current reduction of transformer load reduction of cable losses, reduction of switch gear rating Enhanced life of equipment Fixed capacitor banks (Shunt Connected) at major load ends
Transformers
Optimizing Voltage level of distribution Transformer Loading Optimization Optimum loading 50 to 60% Shifting of loads to under loaded Transformers
15 - 20 years old rewound and under load (<40% loading) motors are Candidates for replacement with Energy Efficient Motors BoP area distribution transformers BoP area, ESP, AHP transformers could be considered for PF Improvement
Conclusion
Yesterday, we operated plant processes, systems and equipments manually Today, we are operating these with localised controls and partial integrated control
Tomorrow, we will have to operate with full integrated and intelligent controls with innovative solutions where we do more than we can imagine today, with less than we used yesterday!
The key to success is changing our behaviour