8.TPS HR Improvement

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EFFICIENCY IMPROVEMENT

ASPECTS IN THERMAL POWER


STATION

By:
M.V. Pande
Dy.Director
NPTI, Nagpur
WHY ENERGY EFFICIENCY IS IMPORTANT ?

• Depleting fossil fuel


• Optimum plant utilization
• Global warming
• Designated consumer
• Generate more energy with same fuel
EFFICIENCY IMPROVEMENT CAN
GIVE YOU

For an average increase of 1 % in the


Efficiency would result in:-

 Coal savings of approx. 11 million tons per


annum worth Rs.13,000 Million
 CO2 reduction about 13.5 million tons per annum
 Lower generation cost per kWh- as more efficient
the unit works, the more economical it is
MAJOR CAUSE OF INEFFICENCY
IN POWER PLANT
• High Flue gas exit Temp
• Excessive amount of excess air(O2)
• Poor Mill/Burners performance causing
high unburnt carbon in fly and bottom ash
• Poor insulation
• Poor house Keeping
• Poor instrumentation and automation
MAJOR CAUSE OF INEFFICENCY IN
POWER PLANT (Cont…)
• Not running the units on design parameter
• Heaters not in service or poor
performance of regenerative system
• Poor condenser vacuum
• Excessive DM water consumption-
passing and leakages
• Use of Reheat spray to control Reheat
Temperature
• Poor Cylinder Efficiency of turbine
CONTROLLABLE PLANT
PARAMETERS
• M.S. & R.H. Steam Temperatures
• M.S. Steam Pressure
• Condenser Vacuum
• Final Feed Water Temperature
• DP Across Feed Regulation Station
• Auxiliary Power Consumption
• Make Up Water Consumption
HOW TO ACHIEVE ENERGY
EFFICIENCY ?
• Adopt state of the art technologies
• Adopt cutting edge technologies
• Review & Re-engineering of the existing
systems
• Bench Marking
• Energy Auditing
CAN WE IMPROVE EFFICIENCY?
 Yes, provided we shed the myths and
believe in applying result oriented
efforts
 Workout to identify & quantify the
cost of hidden losses
 Bring in requisite operational
behavioral change
SOME OF THE MYTHS
 High PLF & availability translates into
Optimum Efficiency
 Heat rate is the responsibility of Efficiency
Management Group at Stations
 Equipment maintenance to be taken-up
based on periodic overhaul schedule
 Boiler performance degradations has no
relation to Turbine Cycle performance
Some of the Myths contd…
• Design heat rate is the best achievable heat rate
• Efficiency tests are the same as performance
guarantee test
• Heat rate improvement requires large investment.
• Results follow immediately after testing is
completed
• Heat rate is the responsibility of Energy &
Efficiency Management Group (EEMG) at
Stations
• Station instruments are accurate for monitoring
heat rate parameters
Some of the Myths contd…
“Design” is not the best achievable performance

• Predicted performance based on Turbine Heat Balance


Diagrams and Boiler Efficiency at different loads

• ‘Design’ is based on specific ambient conditions that


vary throughout the year

• Actual initial performance could be different from design


or changes might have been made to plant

• Current performance to be compared to an achievable


‘expected’ value to establish efficiency gaps
SYNERGIZE OPERATION
OF UNIT
 Need to clearly understand the relation between
performance & fuel, operation and design
parameters
 Operational behavior and performance
 Impacts of operating efficiency of Boiler, Turbine
and their auxiliaries on Net Unit Heat Rate
 Maximum Achievable Load, Maintenance &
 Availability
SOME CRITICAL FACTORS AFFECTING
BOILER PERFORMANCE
• Fuel:- Heating Value, Moisture Contents, Ash
Composition, Ash Contents,& Volatile Matter.
• Operational Parameter:- Level of Excess Air, &
operating Condition of Burner Tilt Mechanism.
• Design:- Heating input per plan area, Height of Boiler,
Platens & pendants heat transfer Surfaces, Burner &
wind Box design.
BEHAVIOURAL IMPACTS
• Low heat value results in over firing of fuel causing more heat
availability for super heater and re-heater thus more
attempration spray requirement. Hence increase in THR,
overloading of ash handling system, fans and increased soot
blowing

• Moisture content increase causes increase in heat transfer to


S.H, and R.H. Hence again increase in attempration spray and
THR (Turbine Heat Rate)

• Ash composition and contents increases damage to pressure


parts surfaces because of melting behavior of low fusion ash
temperature of blended coal in particular
• In consistency in fired fuel characteristics results in variation in
excess air requirement thereby increasing stack loss and
hence boiler efficiency reduction, overloading of ID Fan and
ultimately unit load limitation

• High heat value causes excessive radiant heat transfer to water


walls thereby leaving lesser heat for super heater and re-heater
• .
BEHAVIOURAL IMPACTS
Normally excess air ranges from 15% to 30% of
stoichiometric air.
• High O2 % and presence of CO at ID Fan outlet are
indicator of air in leakages and improper combustion in
furnace
• Poorly effective damper control also is the cause of
higher SEC of fans both primary and secondary

• The quality and purity of feed water and make up water


is also required to be maintained in a meticulous way by
limiting blow down losses to nearly 1% and by checking
the passing and leakages of valves. However, maximum
3% of flow can be taken as make up for these causes
including soot blowing requirements
• Soot blowing is dependent on ash contents and is unit
specific. Intelligently devised soot blowing can result in
saving the fuel
BEHAVIOURAL IMPACTS
• Cascading effects on efficiency, loading and
availability because of following systems and
equipments performance also needed to be
looked into. The systems are:-
Fuel receiving, preparation and handling systems.
Pulverizing system
Air Heater
Fans
Electrostatic Precipitator
Fly ash handling system
Bottom ash handling system
Waste disposal system
PERFORMANCE IMPACTS ON STEAM
CYCLE , UNIT HEAT RATE & OUTPUT
• Various design & operating parameters of
a unit are responsible for its cycle
performance, heat rate,& out put
CRITICAL FACTORS AFFECTING
CYCLE PERFORMANCE
1. Re-heater & its system pressure drop
2. Extraction line pressure drop
3. Make up
4. Turbine exhaust pressure
5. Air preheat
6. Condensate sub-cooling
7. S/H & R/H spray flows
8. Wet Bulb Temp
9. Top Heaters out of service
10. H.P. heater drain pump
11. Type of BFP drives & method of flow control
RH & ITS SYSTEM PRESSURE DROP….

• Every one 1% decrease in drop can


improve THR and output by 0.1% & 0.3%
respectively
• Normally designed for pressure drop
equivalent to 10% of HP exhaust pressure
EXTRACTION LINE PRESSURE
DROP…
• Permissible pressure drop between stage
pressure & Shell pressure is maximum 6%

• For every 2% increase in this pressure


drop, THR would be poorer by 0.09%
CYCLE MAKE-UP….

• Acceptable value of make up water is 3%


to offset cycle water losses
• For every 1% increase in make up 0.4%
increase in THR & 0.2% reduction on
output is there
EXHAUST PRESSURE…

• Increase & decrease in exhaust pressure


do affect the THR.
• Though no valid thumb rule has been
devised so far, however last stage blade
design & exhaust area of turbine do affect
the impact of changing exhaust pressure.
AIR PRE-HEAT….
• Air preheat of combustion air before entry to
regenerative air heater is done with either with
steam coil air pre - heater or hot water pre
heating coil to maintain Average Cold End
Temperature (ACET) to escape dew point
temperature complications
• Condensate retrieval is necessary to avoid
deterioration to THR depending upon unit load
and combustion pre heating duty
CONDENSATE SUB-COOLING…
• For 30% total flow and 2.5 deg C sub-
cooling ,an increase of 0.001% in THR can
be there for every subsequent 10%
increase in flow
R.H & S.H. SPRAY FLOW…

• Spray water whether drawn from BFP or


after the final heater, it is always less the
generative and less productive as well
• Every 1% spray flow, correction need to
be done in THR & load computed from the
curves supplied with the machine
TOP HEATER OUT OF SERVICE….

• Extraction steam flow meant for top heater


is required to pass through turbine thereby
increasing the output. But at the same
time final feed water tamp. Is lowered
resulting in poor THR
BFP DRIVE SELECTION…

• Though four options are available for


choosing the suitable BFP drive and
control concepts
• Adoption of turbine driven BFP to suit the
design requirements can improve THR by
0.56% and output by 0.58%
PERFORMANCE MONITORING
• Analyze the poor efficiency areas from previous
record
• Go down to specific system and then to
component
• Carry out performance/diagnostic study as
suggested in the Auditing Manual & operating
manual
• Devise a unit specific efficiency control sheet for
few terminal conditions (Act vs Des)
• Monitor once per shift to know the operating
efficiency and check any deterioration
Thank You

mvpngp@yahoo.com

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