Presentation Title A holistic view of energy efficiency

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

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

Solutions New Technology Renovation & Modernization Process Improvemen t

Solutions y hnolog ec New T neration f e ption o Ado ower G P hermal in T

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

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.

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 greenhouse 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.

Solutions s ter e ram 43% ap a dm am p a o y R & ste nc cie t size i Eff Uni Pr/MST/RHT ian ing Ind as 280/600/620 cre In (800 -1000 MW) Gross Efficiency, GCV Basis 42% 41% 320/600/620 (800 -1000 MW) 247/565/593 40% 247/537/565 (660/800 MW) (660 MW) 39% 170/537 (500 MW) Current scenario 38% ‘ 00 ‘ 02 Xth Plan ‘ 07 XIth Plan ‘ 12 XIIth Plan ‘ 17 XIIIth Plan ‘ 22

Heat rate Improvement Over The Years ters ap ame adm m par y Ro c stea icien size & Eff dian ng Unit In asi ncre I

Parameters for Higher Efficiency…… Plant Type Unit Size (MW) Main Steam Pr (Bar) Main Steam (Temp 0 c) Reheat (Temp 0 c) Notes Sub critical 500 170 537 Common practice in India Low Supercritical 660 247 537 565 India’s first supercritical station at Mundra by Adani High Supercritical 660/800 247 -280 565 593 Parameters for Mundra Tatapower Ultra Supercritical 1000 295 600 In operation in Japan/China

Ultra Mega Power Projects : Indian Scenario Awarded Projects Sasan power Ltd Jharkhand integrated power Ltd IPP: Adani Power, Mundra Coastal Gujrat Power Ltd power Ltd Coastal Andhra Power Ltd Concerns: Viability at agreed upon tariff due to changed scenario of imported coal Projects under process Orissa Integrated Power Ltd Akaltara Power Ltd Coastal Karnataka Power Ltd Coastal Tamil Nadu Power Ltd Tatiya Andhra Mega Power Ltd Sakhi Gopal Integrated Power Co Ltd Orissa Gogarapalli Integrated Power co Ltd Orissa Coastal Maharashtra Mega Power Ltd

Awarded UMPP Projects Ultra Mega Power projects awarded through tariff based competitive bidding route. Plants have higher operating parameters and increased efficiency levels. Name of project Name of Date of LOI Levelised & capacity as per successful Tariff(Rs/Kwh) LOI bidder Mundra Gujrat(5 X 800 MW) M/S Tatapower Ltd 28/12/06 2. 26 Sasan M. P(6 X 660 MW) M/S Reliance Power Ltd 01/08/07 1. 19 Krishnapatnam Andhra pradesh(5 X 800 MW) M/S Reliance Power Ltd 30/11/07 2. 33 Tilya Jharkhand(6 X 660 MW) M/S Reliance Power Ltd 12/02/09 1. 77

Ultra Supercritical 1000 MW units in China WAIGAOQIAO THERMAL POWER STATION PHASE-III: 2 X 1000 MW SHANGHAI, CHINA

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 CO 2 during the gasification process offers the opportunity for relatively low-cost CO 2 capture and storage (CCS), which may give the future IGCC plants some competitive and environmental advantages over super critical plants

IGCC (Schematic diagram of the process)

IGCC (Schematic diagram of the process)

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

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.

250 MW IGCC plant: Tampa Electric Company, USA

Solutions d tion an (R&M) as a Renov nization Moder A guidelines per CE

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.

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.

FUTURE APPROACH TOWARDS R&M NEAR PAST In-kind replacement Restoration of lost capacity FUTURE Cost effective technology upgrades 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

R&M and Life extension program (LEP) during 11 th plan(2007 -11) Sl No Particulars R&M LEP I Number of thermal power stations 21 23 Ii Number of thermal units 76 53 Iii Estimated cost in Rs crores 4487 12433 iv Total capacity involved 18965 7318

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

INDIA: Power generation Capacity (Billion Watts) for Coal/Lignite based plants >25 MW capacity Results of R&M nd e re nt T Imp em rov

National Thermal plant performance (Coal lignite based>25 MW) (PLF) Results of R&M nd Imp e vem ro re nt T

National Thermal plant performance (Coal /lignite based>25 MW) (PAF) Results of R&M nd e re nt T Imp m ove r

National Thermal plant performance (Coal /Lignite based>25 MW) (Aux%) Results of R&M Imp rov em ent Tre nd

Solutions cess I Pro ment mprove

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

Reduction of Auxiliary power consumption S CESC’uction of f n aring o e in red Sh c umptio s n experiery Power con Auxilia

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

VFD ESSENTIALS Make: Leader & Harvest Electric Technologies Co. Ltd, China Indian Partner: Yantra Harvest Energy Pvt. Ltd, Pune Product : Medium-Voltage VFD Model: HARSVERT – A 06. 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. 6 KV Control Mode: Sinusoidal multi-level Pulse Width Modulation

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

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 : 6600 V / 49. 4 A Secondary Winding Rating: 710 V / 25. 5 A Auxiliary Winding Rating : 380 V/ 12. 2 A

The Equipment

ID fan reduction in auxiliary power consumption after installation of VFD Unit Load Particulars Pre-VFD period Post-VFD period ID 370 KW Paybackfan two fans: 18 to 229 KW for 20 average months (KW) load Full load Net savings per fan 133. 5 KW 75 MW AC load (KW) NIL 7. 5 KW 36 % savings Part load ID fan average load (KW) 335 KW 159 KW 168. 5 KW NIL 7. 5 KW 50 -55 MW AC load (KW) Note: Above Readings are in winter months. Expected AC Load in Summer : 25 KW 50 % savings

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

Southern Generating Station. CESC Ltd : Micro Hydle project er t condens ject a Hydel Pro icro KW) by 45 KW M fall (3 X 15 sumption out ater er con cooling w iliary pow aux To reduce asted energy : Objective mw power fro extracting

Basic concept

Southern Generating Station. 45 KW(3 x 15 KW) Micro Hydel Project ph-1 Supplier: Pentaflow Hydro Engineers. Delhi Specifications of the 15 KW micro hydle turbine generator set • Rated capacity: 15 KW (At Generator output) • Rated net head: 1. 8 m • Rated discharge: 1 m 3/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%

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

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 X 0. 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 approximately 3. 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

Micro hydle during installation

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