EEC Workshop - 29th

August , New Delhi

Performance enhancement of
old thermal power stations
using software tools

Dr. J T Verghese
Managing Director
STEAG Energy Services, India

STEAG Energy Services India

Business Lines
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STEAG Energy Services India offers services in the field of:

Engineering Consulting Services
Diagnostic Study and Testing
Energy Audit
Renovation & Modernization Consultancy
Operation and Maintenance
Information Technology for Power Plants
New Technologies for Power Plants
Advisory
2

STEAG Energy Services India

Offices / O & M Sites

Bathinda
Noida

New Delhi

Ahmedabad
Hazira
Haldia
Jharsuguda
Hyderabad

Corporate & Registered Offices of STEAG India

Bangalore
Chennai

Regional Offices of STEAG India

O & M Sites of STEAG India

Major Clients

Many4 more

O & M Projects
Duration
S. No.

1.

Type

CCPP

Capacity

156 MW

Location

Hazira

Owner

GSEG

Scope

O&M

From

To

2001

2010

2.

CCPP

30 MW

Gandhar

ONGC

O&M

2005

2007

3.

CCPP

116 MW

Haldia

HPL

O&M

2006

2012

4.

WHRP

30 MW

Goa

Videocon O & M Advisory 2006

2011

5.

Coal

4 X 600 MW Jharsuguda

Sterlite
Energy

O&M

2010

2017

Hazira

GSEG

O&M

2011

2015

Bathinda

HMEL

O&M

2011

2015

6.

CCPP

507 MW
(156 MW +
351 MW)

7.

CCPP

165 MW

4 X 600 MW Coal Based Power Plant

at Jharsuguda, Orrisa - India

CCPP Hazira, Gujarat - India

R & M and LE
Mapping
Mapping using
using Ebsilon
Ebsilon Software
Software
to
to check
check the
the potential
potential for
for
efficiency
efficiency improvement
improvement

R&M
R&M Measures
Measures should
should
include
include online
online software
software
tools
tools to
to optimize
optimize efficiency
efficiency

Tendering
Tendering and
and
award
award of
of contract
contract
for
for R&M
R&M

RLA
RLA Studies
Studies &
&
Performance
Performance
Evaluation
Evaluation Tests
Tests

Techno-economic
Techno-economic
Analysis
Analysis of
of R&M
R&M
Measures
Measures

Preparation
Preparation of
of technical
technical
and
and commercial
commercial
specification
specification for
for R&M
R&M

How to Improve Efficiency

First Step: low hanging fruits

Improve efficiency by improving operation and
maintenance by the normal methods:

Maintenance Planning
Training
Standard Operating
Procedures
Improve maintenance methods

How to Improve Efficiency

Next Steps
Audit or map the plant using offline modeling tool to detect causes
for sub-optimal operations

Provide online systems for

optimization of resources
fault detection and prediction
lifetime monitoring for better planning of inspections and
maintenance and calculation of life-time consumption

Provide customized systems for maintenance planning

Audit or map the plant using off line

modelling

Summary of the mapping exercise conducted

jointly by CEA and Steag under the Indo
German Efficiency Program

Mapping of 85 power plants - EBSILON

Design Model

Performance as per design documents

Analysis
1.

Output

210 MW

2.

Gross Heat Rate

2305.16 kcal/kWh

3.

Coal Consumption

110 t/h

4.

Boiler Efficiency

86

5.

Turbine Cycle Heat Rate

1982.72 kcal/kWh

6.

Unit Efficiency

37.3%
10

EBSILON Running Model

Simulated Performance as per operating GCV

Analysis
1.

Output

210 MW

2.

Gross Heat Rate

2664.22 kcal/kWh

3.

Coal Consumption

166 t/h

4.

Boiler Efficiency

79.6%

5.

Turbine Cycle Heat Rate

2122.50 kcal/kWh

6.

Unit Efficiency

32.3%
11

85 Units Mapped Size-wise

Capacity (MW)
100
105
110
120
125
140
195
200
210
250
500
Total

Number of Units
1
1
6
8
1
4
1
4
49
5
5
85
12

Analysis of 16 Units Under 16 Years of

Age with Reaction Type Turbine
Including Indicative Saving of Coal
Analysis of 16 units under 16 years of age
with reaction type turbine
Indicative saving of coal
1200
th tons of consumed coal
per year
potentially
conserved coal

best

1000

800

600

If all the units would have the same gross heat rate as
the most efficient unit, 8.6% of the coal, altogether
1,256,650 tons, approx. Rs 113.1 crores would be
saved by the 15 less efficient units each year.
Assumptions: all the units work at a PLF of 80%, use coal with
4000 kcal/kg calorific value and 1ton coal costs Rs 900

400

200

13

Analysis of 16 Units Under 16 Years of

Age with Reaction Type Turbine

Analysis of 16 units under 16 years of age

with reaction type turbine
Indicative additional capacity
1600
1400
1200 per year
million units
1000
800

additional capacity
million units/ year

If all the units would have the same capacity

as the unit with the highest capacity, the
overall output would be by 9.7% or 2,173
million units higher each year.
Assumption: all the units work at a PLF of 80%

600
400
200
0

14

Analysis of 16 Units Above 16 Years of

Age with Reaction Type Turbine

Analysis of 16 units above 15 years of age

with reaction type turbine
Indicative saving of coal
1,200
th tons of consumed coalpotentially
per yearconserved coal

best

1,000

800

600

If all the units would have the same gross heat rate as
the most efficient unit, 7.3% of the coal, 1,122,600
tons, approx. Rs 101 crore would be saved by the
15 less efficient units each year.
Assumptions: all the units work at a PLF of 80%, use coal with
4000 kcal/kg calorific value and 1ton coal costs Rs 900

400

200

U16

U15

U14

U13

U12

U11

U10

U9

U8

U7

U6

U5

U4

U3

U2

U1

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Analysis of 16 Units Above 15 Years of

Age with Reaction Type Turbine

Analysis of 16 units above 15 years of age

with reaction type turbine
Indicative additional capacity
1600
1400

million units
1200per year
1000
800

If all the units would have the same capacity

as the unit with the highest capacity, the
overall output would be by 8.1% or 1,807
million units higher each year.

additional capacity
million units/ year

Assumption: all the units work at a PLF of 80%

600
400
200
0

16

Analysis of 17 Units Above 15 Years of

Age with Impulse Type Turbine
Analysis of 17 units above 15 years of age
with impulse type turbine
Indicative saving of coal
1,200
th tons of consumed coal per
year conserved coal
potentially
best
If all the units would have the same gross heat rate as the most efficient unit, 7.3%
1,000
of the coal, 1,122,600 tons, approx. Rs 128.8 crore would be saved by the 15
less efficient units each year
Assumptions: all the units work at a PLF of 80%, use coal with 4000 kcal/kg calorific value and

800

600

If all the
units would have the same gross heat rate as
1ton coal costs Rs 900
the most efficient unit, 7.3% of the coal, 1,122,600
tons, approx. Rs 128.8 crore would be saved by
the 15 less efficient units each year
Assumptions: all the units work at a PLF of 80%, use coal with
4000 kcal/kg calorific value and 1ton coal costs Rs 900

400

200

U17

U16

U15

U14

U13

U12

U11

U10

U9

U8

U7

U6

U5

U4

U3

U2

U1

17

Analysis of 17 Units Above 15 Years of

Age with Impulsive Type Turbine

Analysis of 17 units above 15 years of age

with impulse type turbine
Indicative additional capacity

1600
1400
additional capacity

million units
per year
1200

real

If all the units would have the same capacity

as the unit with the highest capacity, the
overall output would be by 7.1% or 1,655
million units higher each year.

1000
800

Assumption: all the units work at a PLF of 80%

600
400
200

U17

U16

U15

U14

U13

U12

U11

U10

U9

U8

U7

U6

U5

U4

U3

U2

U1

18

Auxiliary Consumption of 210 MW

Capacity Units

Auxiliary Consumption of 210 MW capacity units (%)

13
Auxiliary consumption (%)
12

11

10

19

Generally Observed Problems

Systems

Observations

Maintenance planning and

management

Needs to be upgraded

Online monitoring

Not provided

DCS

Only some units have been

provided

Documentation

Needs improvement

Operating instruction and manual

Needs to be updated

20

Online systems

Provide Online systems for:

optimization of
processes

fault detection and

prediction system

life time monitoring for

better planning of
inspections and
maintenance and
calculation of life time
consumption.
21

Why to use the software tools ?

DCS has the information needed to do the calculation of

efficiencies and heat rates it gives performance
calculation, trending and values of parameters
But what are the limitations ?
1.DCS does not give the system wise efficiencies so you
do not know where the losses occur
2.Data from I/O points e.g. Temperature, pressure mass
flow could be wrong because of sensor errors, bad
connectors etc. That makes calculation erroneous.
3.DCS does not give advice what to do

22

Online Tool:
Optimization Sequence

1. All relevant data from DCS which goes into

calculation need to be validated i.e. all
implausible values have to be replaced by
plausible values
2. All calculations must be done every 5 minutes
(not only once a day) since the quality of coal and
combustion process is changing. Threfore the
state of heating surfaces must be monitored
constantly.
3. Results are presented in a user friendly manner:
Status of the subsystems is indicated by green,
yellow, red and losses expressed in money
terms.
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PADO Screens

24/09/2008 ES-

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PADO Screens
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PADO Controllable Losses (1)

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PADO Set Point Optimization (1)

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Modules of the On Line systems

28

Advantages of the Online Tool

Improving the quality of measurements by

data validation
Evaluation of boiler, turbines, condenser and
other components
Optimization of unit operation (sootblowing,
setpoints)
Calculation of what-if scenarios
Generation of daily and monthly reports

Enhance the efficiency of the power plant!

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