Optimization of Compressed Air in Thermal Power Plant - A Novel Approach

OPTIMIZATION OF COMPRESSED
AIR IN THERMAL POWER PLANT

– A NOVEL APPROACH
Group Members
- RD katre (Sr. GM)
- Vishal laddha(Mgr)
INTRODUCTION
Approxima
tely 10%
gets to the
point of
use!!
• APC considered as one of the major performance indices.

• Generally, 6-10% of total generated power is consumed in the power plant itself for
running various auxiliaries and processes.
• Air compressors accounts for significant amount of electricity ranges from 2 to 5 % of
total auxiliary power consumption of the plant.
• . Only 10 – 20% of energy reaches the point of end-use, and balance converted to
unusable heat energy and to a lesser extent lost in form of friction, misuse and noise.
Designed requirement of air in 4X250 Mw in OPJSTPP
1.REQUIREMENT OF AIR IN BOILER:

REQUIREMENT OF SERVICE AIR FOR FOUR BOILER =4X1640 Nm3/hr=6560Nm3/HR
REQUIREMENT OF INSTRUMENT AIR FOR FOUR BOILER =4X720 Nm3/hr=2880Nm3/hr
TOTAL REQUIREMENT OF AIR IN BOILER=9440Nm3/hr
2.REQUIREMENT OF AIR IN TURBINE:

TOTAL REQUIREMENT OF INSTRUMENT AIR IN TURBINE=1870 Nm3/hr
3.TOTAL REQUIREMNET OF AIR IN ASH PLANT & ESP=500 Nm3/hr
4.TOTAL REQUIREMNET OF AIR IN DM PLANT=300 Nm3/hr
TOTAL REQUIREMENT OF INSTRUMENT AIR IN PLANT=5550 Nm3/hr

TOTAL REQUIREMENT OF SERVICE AIR IN PLANT =6560 Nm3/hr
TOTAL REQUIREMENT OF AIR IN PLANT=12110 Nm3/hr

Add safety margin 20%, Capacity Requirement =14532 Nm3/hr
CONFIGURATION OF COMPRESSED AIR SYSTEM
Corner- 1 2 3 4
UNIT#2,3,4
Unit#1
One centrifugal compressor capacity=7620Nm3/hr

JOURNEY TOWARDS SUCCESS
STEP1- CONTROL SYSTEM OPTIMIZATION (BY REDUCING THRESHOLD LIMIT VALUE)

• One centrifugal compressor at full load and another on partial load was the normal
plant operation
• Partial loaded compressors bypass valve was getting open at 71 Amp minimum limits to
meet out demand.
• Threshold limit optimized to 67 Amp gradually so that inlet valve position reduced for
same discharge quantity and subsequently reduction in power consumption.
ENERGY MANAGEMENT SYSTEM DATA BEFORE CONTROL SYSTEM OPTIMIZATION

REDUCED THRESHOLD LIMIT VALUE (CONCERNED WITH OEM/IR TEAM)
AIR COMPRESSOR 01 AIR COMPRESSOR 02 AIR COMPRESSOR 03
ACTIVE IMPORT
Day CURREN POWER( ACTIVE CURRE POWER CURRE POWER
T(A) KW) ENERGY(MWH) NT(A) (KW) ENERGY(MWH) NT(A) (KW) ENERGY(MWH)
Avg Avg Readin Consu Avg Avg Readin Consu Avg Avg Readin Consu
Value Value g mption Value Value g mption Value Value g mption
1-Apr 74.7 766.9 1280.6 18.4 76.8 797.4 25945 19.2 0 0 21901.8 0
2-Apr 74.7 772.8 1299.2 18.5 76.7 804 25964.3 19.3 0 0 21901.8 0
3-Apr 74.7 774.4 1317.7 18.6 79.3 833.5 25984.3 20 0 0 21901.8 0
4-Apr 74.6 774.5 1336.3 18.6 79.1 831.6 26004.3 20 0 0 21901.8 0
5-Apr 74.7 775.3 1354.9 18.6 78.9 828.5 26024.2 19.9 0 0 21901.8 0
6-Apr 74.7 773.5 1373.5 18.6 79.4 832.2 26044.2 20 0 0 21901.8 0
7-Apr 74.7 776.6 1392.1 18.6 78 820.5 26063.9 19.7 0 0 21901.8 0
8-Apr 74.7 775.2 1410.7 18.6 78.8 827.5 26083.7 19.9 0 0 21901.8 0
9-Apr 72.4 752.4 1428.7 18 79.7 838.5 26103.9 20.1 3.4 35.9 21902.6 0.8
10-Apr 74.7 774.2 1447.4 18.7 79.7 837.2 26124 20.2 0 0 21902.6 0
11-Apr 74.7 776.2 1466 18.6 80.1 843.7 26144.3 20.3 0 0 21902.6 0
12-Apr 74.6 775.2 1484.6 18.6 78.5 827.7 26164.2 19.9 0 0 21902.6 0
13-Apr 74.8 781.2 1502.6 18 79 834.9 26183.5 19.3 0 0 21902.6 0
14-Apr 75.2 785.8 1521.5 18.9 79 834.2 26203.5 20 0 0 21902.6 0
15-Apr 75.3 783.9 1540.3 18.8 79.6 840.6 26223.7 20.2 0 0 21902.6 0
16-Apr 75.3 783.9 1559.1 18.8 53.1 559.7 26237.2 13.5 27.1 283 21909.4 6.8
17-Apr 75.3 782.1 1577.8 18.7 0 0 26237.2 0 79.7 833.5 21929.4 20
18-Apr 75.3 782.6 1596.6 18.8 0 0 26237.2 0 79.4 832 21949.4 20
19-Apr
20-Apr
75.3
75.3
782.4 1615.4 18.8
782.7 1634.2 18.8
REDUCED TLV
0
0
0
0
26237.2
26237.2
0
0
79.2
81.6
830.8 21969.3 19.9
857.3 21989.9 20.6
21-Apr 75.3 783.6 1653 18.8 0 0 26237.2 0 82.6 868.4 22010.7 20.8
22-Apr 72.4 749.5 1671 18 0 0 26237.2 0 80.8 848.2 22031.1 20.4
23-Apr 70.2 723.8 1688.3 17.4 0 0 26237.2 0 79.4 830.7 22051 19.9
24-Apr 70.2 723.2 1705.7 17.4 0 0 26237.2 0 78.5 818 22070.7 19.6
25-Apr 70.2 725.3 1723.1 17.4 0 0 26237.2 0 78.3 820 22090.4 19.7
26-Apr 70.9 732.8 1740.7 17.6 12.4 130.4 26240.4 3.2 66.1 691.1 22107 16.6
27-Apr 71.1 735.8 1758.3 17.7 0 0 26240.4 0 78.1 817.4 22126.6 19.6
28-Apr 70.7 734.1 1775.9 17.6 0 0 26240.4 0 76.8 803.9 22145.9 19.3
29-Apr 70.8 734.7 1793.6 17.6 0 0 26240.4 0 76.1 795 22164.9 19.1
30-Apr 17.4 180.3 1798 4.4 54.3 569.1 26254 13.6 78.4 820.5 22184.7 19.7
AFTER REDUCING TLV FROM 71 TO 67 (CONCERNED WITH IR TEAM)
STEP2- COMPRESSED AIR LEAKAGE IDENTIFICATION AND ARRESTING AT
DIFFERENT LOCATION OF PLANT-AHP, BOILER,TG,DM PLANT IN ALL
STEP3- STUDY OF CONSUMPTION PATTERN AND IGNITOR ROD DATASHEET

STUDY
• Measurement is the first step in any conservation activity.

• Compressed air is ancillary system in power generation plants, its instrumentation and
control is also undermined compared to main plant.
• All compressors discharge, instrument and service air header flow meters were made
ready. Also, there was no flow meter installed in the header of igniter cooling and L.D.O.
atomization air.
• Measured and calculated Consumption pattern
Total air flow-8530m3/hr
Service air line flow-1250m3/hr
Instrument air line flow-4645m3/hr
Igniter cooling and cleaning line flow-2550m3/hr
Igniter cooling air consumption was about31% in total compressed air

IGNITOR ROD DATASHEET STUDY
SPARK ROD PART No.
Type & Model No Flexible / CBLS . 1000.025
Operating Temp. 540C AT TIP,150 C AT CABLE END
Tube SS.304
Flex Section SS.316
Pin/ Socket BRASS/55-316
Insulation Of wire TEFLON
Insulation Of Socket CERAMIC
Spark Tip 185 MM
Type & Model SEMI CONDUCTIVE TYPE &157.900.003
Operating Voltage 2000
Tip Life 106 sparks
Material SPECIAL ALLOY
Casting SS.316
Tip SPECIAL ALLOY
Coating SEMI CONDUCTIVE
Fig. 2 HEA igniter arrangement

01-HEA RETRACTOR 8 INCH STROKE 02-HEA FLEX SPARK ROD W/O TIP,
03-HEA SPARK TIP 04-HEA EXCITOR,
05-HEA FLEX CABLE ASSEMBLY 06-SS HOSE, 07-AIR SET W/MB
Utility of ignitor cooling air
INSIDE FURNACE
INSIDE FURNACE
IGNITOR ROD
GUIDE PIPE IGNITOR COOLING AIR LINE
AIR PRESSURE OPTIMIZATION
STEP4 –IGNITOR COOLING LINE AND AIR PRESSURE OPTIMIZATION
EXHAUSTIVE QUALITATIVE AND QUANTITATIVE EFFORTS WERE CARRIED OUT
After optimization of air pressure at igniter cooling and cleaning line

air flow is
•Total air flow-7410m3/hr
•Service air line flow-1250m3/hr
•Instrument air line flow-4645m3/hr
•Igniter cooling and atomizing line flow-1415m3/hr.
Sl. no. DESC. FLOW BEFORE FLOW AFTER SAVING IN
REGULATION OF IGNITER REGULATION OF FLOW(M3/HR)
COOLING LINE(6.5KG/CM2) IGNITER COOLING
LINE (2.5KG/CM2)
1 IGNITER & 2550 M3/HR 1415 M3/HR 1135M3/HR
ATOMISING AIR LINE
FLOW
FROM THE ABOVE CALCULATION IT IS FOUND THAT 1/3 (APPROXIMATE 2550M3/HR)

OF TOTAL FLOW CONSUMED IN IGNITOR COOLING LINE FOR ALL UNITS.
STEP5-CONTINEOUSLY MONITORING TEMP OF IGNITOR ROD
TIMELY INSPECTION OF IGNITOR TIP IN ALL UNIT’S AT ALL CORNER’S
Location Pressure Spark Tip Spark Rod

( Kg/cm2) (Deg. (Deg. Celsius)
Celsius)
EF elevation, 7.0 117 49
EF elevation 2.2 134 68
• With a planned and close observation at ignitor cooling line ,which is at pressure
7kg/cm2,grdually reduced this pressure day by day till 2.2kg/cm2
• Repeated spark checks were carried out for around 4 months at regular intervals,
• The conditions at the spark tip and spark rod were monitored and thus pressure was
optimized.
• After confirming the experiment in one unit, it is implemented in all the remaining units.
This need not required any additional instruments but, only pressure gauge in all corners.
EMS DATA AFTER AIR PRESSURE OPTIMIZATION OF IGNITOR AIR
COOLING LINE
JOURNEY STARTED WITH 39.5MWH/DAY AND

WE HAVE REACHED ABOVE 28.91MWH/DAY
ENERGY ECONOMICS
SR.NO. NAME OF BEFORE AFTER TOTAL DATE OF

ACTIVITY CONSUMPTION CONSUMPTION SAVINGS IMPLEMENTATION
1 CONTROL SYSTEM 39.62MWH 37.02MWH 2.6MWH 22/04/2013

OPTIMIZATION
2 IGNITER AIR 37.02MWH 28.91 MWH 8.11MWH 20/10/2013

COOLING LINE
PRESSURE
OPTIMIZATION
TOTAL MWH SAVING PER DAY=39.62-28.91=10.71MWH/DAY
TOTAL MWH SAVING PER YEAR=10.71*365 =3909MWH
SO TOTAL KWH SAVING PER YEAR=3909*1000 =3909000KWH
TOTAL MONITORY SAVINGS PER YEAR=3909000*3=1.172Cr

STILL JOURNEY IS CONT…
FUTURE PLANS
1. WE WILL PROVIDE A BUTTER FLY VALVE AT ALL THE FOUR CORNERS OF
IGNITER COOLING AIR LINE , IN EMERGENCY OR IN BLACK OUT CONDITION
THIS BUTTERFLY VALVE WILL CLOSE , -PO NO.-410000007268,TARGET DATE-
25/03/2014
2. WE WILL ALSO PROVIDE BUTTERFLY VALVE FOR AHP INLET AIR LINE , AT THE
TIME OF EMERGENCY THIS WILL CLOSE,PO NO. 410000007267,TARGET DATE-
15/03/2014
1. OPTIMIZATION AIR FOR FEEDER MANUAL VIEW GLASS AIR PURGING LINE
CONT………….
“Gentle footprints today will ensure a path for tomorrow”

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OPTIMIZATION OF COMPRESSED

AIR IN THERMAL POWER PLANT

• APC considered as one of the major performance indices.

1.REQUIREMENT OF AIR IN BOILER:

TOTAL REQUIREMENT OF AIR IN BOILER=9440Nm3/hr

2.REQUIREMENT OF AIR IN TURBINE:

TOTAL REQUIREMENT OF INSTRUMENT AIR IN PLANT=5550 Nm3/hr

TOTAL REQUIREMENT OF AIR IN PLANT=12110 Nm3/hr

One centrifugal compressor capacity=7620Nm3/hr

STEP1- CONTROL SYSTEM OPTIMIZATION (BY REDUCING THRESHOLD LIMIT VALUE)

ENERGY MANAGEMENT SYSTEM DATA BEFORE CONTROL SYSTEM OPTIMIZATION

STEP3- STUDY OF CONSUMPTION PATTERN AND IGNITOR ROD DATASHEET

• Measurement is the first step in any conservation activity.

Igniter cooling air consumption was about31% in total compressed air

Fig. 2 HEA igniter arrangement

After optimization of air pressure at igniter cooling and cleaning line

FROM THE ABOVE CALCULATION IT IS FOUND THAT 1/3 (APPROXIMATE 2550M3/HR)

TIMELY INSPECTION OF IGNITOR TIP IN ALL UNIT’S AT ALL CORNER’S

Location Pressure Spark Tip Spark Rod

JOURNEY STARTED WITH 39.5MWH/DAY AND

SR.NO. NAME OF BEFORE AFTER TOTAL DATE OF

1 CONTROL SYSTEM 39.62MWH 37.02MWH 2.6MWH 22/04/2013

2 IGNITER AIR 37.02MWH 28.91 MWH 8.11MWH 20/10/2013

TOTAL MWH SAVING PER DAY=39.62-28.91=10.71MWH/DAY

TOTAL MWH SAVING PER YEAR=10.71*365 =3909MWH

SO TOTAL KWH SAVING PER YEAR=3909*1000 =3909000KWH

TOTAL MONITORY SAVINGS PER YEAR=3909000*3=1.172Cr

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