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:

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

Solutions New Technology New Technology Renovation & Modernization New Technology New Technology Renovation & Modernization New Technology Process Improvement

Solutions Adoption of New Technology in Thermal Power Generation

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 green- house 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. 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 green- house 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.

247/537/565 (660 MW) 170/537/537 (500 MW) ‘02 ‘07 ‘22‘17‘12X th Plan XI th Plan XII th Plan XIII th Plan ‘00 247/565/593 (660/800 MW) 280/600/620 ( MW) 320/600/620 ( MW) Gross Efficiency, GCV Basis 38% 39% 43% 42% 41% 40% Solutions Current scenario Indian Efficiency Roadmap Increasing Unit size & steam parameters Indian Efficiency Roadmap Increasing Unit size & steam parameters Pr/MST/RHT

Heat rate Improvement Over The Years Indian Efficiency Roadmap Increasing Unit size & steam parameters Indian Efficiency Roadmap Increasing Unit size & steam parameters

Parameters for Higher Efficiency…… Plant TypeUnit Size (MW) Main Steam Pr (Bar) Main Steam (Temp 0 c) Reheat (Temp 0 c) Notes Sub critical Common practice in India Low Supercritical India’s first supercritical station at Mundra by Adani High Supercritical 660/ Parameters for Mundra Tatapower Ultra Supercritical In operation in Japan/China

Ultra Mega Power Projects : Indian Scenario Projects under process Orissa Integrated Power Ltd Akaltara Power Ltd Coastal Tamil Nadu Power Ltd Coastal Maharashtra Mega Power Ltd Coastal Karnataka Power Ltd Sakhi Gopal Integrated Power Co Ltd Orissa Gogarapalli Integrated Power co Ltd Orissa Tatiya Andhra Mega Power Ltd Concerns: Viability at agreed upon tariff due to changed scenario of imported coal

Name of project & capacity as per LOI Name of successful bidder Date of LOI Levelised Tariff(Rs/Kwh) Mundra Gujrat(5X800 MW) M/S Tatapower Ltd 28/12/ Sasan M.P(6X660 MW) M/S Reliance Power Ltd 01/08/ Krishnapatnam Andhra pradesh(5X800 MW) M/S Reliance Power Ltd 30/11/ Tilya Jharkhand(6X660 MW) M/S Reliance Power Ltd 12/02/ Ultra Mega Power projects awarded through tariff based competitive bidding route. Plants have higher operating parameters and increased efficiency levels.

WAIGAOQIAO THERMAL POWER STATION P H A S E - I I I : 2 X M W SHANGHAI, CHINA Ultra Supercritical 1000 MW units in China

Adoption Technology 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 CO2 during the gasification process offers the opportunity for relatively low-cost CO2 capture and storage (CCS), which may give the future IGCC plants some competitive and environmental advantages over super critical plants 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 CO2 during the gasification process offers the opportunity for relatively low-cost CO2 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 Efficiency and reliability improvements are also expected for the IGCC technology. Its efficiency is estimated to grow from 46% in 2010 to 52% in Efficiency and reliability improvements are also expected for the IGCC technology. Its efficiency is estimated to grow from 46% in 2010 to 52% in Some major IGCC plants, worldwide Some major IGCC plants, worldwide 580 MW, Kentucky Pioneer Energy, USA 580 MW, Kentucky Pioneer Energy, USA 512 MW, ISAB Energy, Italy 512 MW, ISAB Energy, Italy 342 MW, Nippon Oil Corporation Refinery, Japan 342 MW, Nippon Oil Corporation Refinery, Japan 335 MW, Elcogas, Spain 335 MW, Elcogas, Spain 250 MW, Tampa Electric Company, USA 250 MW, Tampa Electric Company, USA Efficiency and reliability improvements are also expected for the IGCC technology. Its efficiency is estimated to grow from 46% in 2010 to 52% in Efficiency and reliability improvements are also expected for the IGCC technology. Its efficiency is estimated to grow from 46% in 2010 to 52% in Some major IGCC plants, worldwide Some major IGCC plants, worldwide 580 MW, Kentucky Pioneer Energy, USA 580 MW, Kentucky Pioneer Energy, USA 512 MW, ISAB Energy, Italy 512 MW, ISAB Energy, Italy 342 MW, Nippon Oil Corporation Refinery, Japan 342 MW, Nippon Oil Corporation Refinery, Japan 335 MW, Elcogas, Spain 335 MW, Elcogas, Spain 250 MW, Tampa Electric Company, USA 250 MW, Tampa Electric Company, USA

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. 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. IGCC

250 MW IGCC plant: Tampa Electric Company, USA

Solutions 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. 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. Renovation and Modernization (R&M) as per CEA guidelines

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. 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. NEED FOR R&M – EXISTING UNITS

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

Sl NoParticularsR&MLEP INumber of thermal power stations 2123 IiNumber of thermal units 7653 Iii Estimated cost in Rs crores ivTotal capacity involved R&M and Life extension program (LEP) during 11 th plan( )

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

INDIA: Power generation Capacity (Billion Watts) for Coal/Lignite based plants >25 MW capacity Improvement Trend Results of R&M

National Thermal plant performance (Coal lignite based>25 MW) (PLF) Improvement Trend Results of R&M

National Thermal plant performance (Coal /lignite based>25 MW) (PAF) Improvement Trend Results of R&M

National Thermal plant performance (Coal /Lignite based>25 MW) (Aux%) Improvement Trend Results of R&M

Solutions Process Improvement Process Improvement

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

Reduction of Auxiliary power consumption Sharing of CESC’S experience in reduction of Auxiliary Power consumption

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

Make: Leader & Harvest Electric Technologies Co. Ltd, China Indian Partner: Yantra Harvest Energy Pvt. Ltd, Pune Product : Medium-Voltage VFD Model: HARSVERT – A06.6/50 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 – 6.6KV Control Mode: Sinusoidal multi-level Pulse Width Modulation Make: Leader & Harvest Electric Technologies Co. Ltd, China Indian Partner: Yantra Harvest Energy Pvt. Ltd, Pune Product : Medium-Voltage VFD Model: HARSVERT – A06.6/50 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 – 6.6KV 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 : 6600V / 49.4 A Secondary Winding Rating: 710V / 25.5 A Auxiliary Winding Rating : 380 V/ 12.2 A VFD ESSENTIALS

The Equipment

Unit LoadParticularsPre-VFD period Post-VFD period Net savings per fan Full load ID fan average load (KW) 370 KW229 KW133.5 KW 75 MW AC load (KW) NIL7.5 KW Part loadID fan average load (KW) 335 KW159 KW168.5 KW MW AC load (KW) NIL7.5 KW ID fan reduction in auxiliary power consumption after installation of VFD Note: Above Readings are in winter months. Expected AC Load in Summer : 25 KW 36 % savings 50 % savings Payback for two fans:18 to 20 months

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 45 KW Micro Hydel Project at condenser cooling water outfall (3X15 KW) Objective: To reduce auxiliary power consumption by extracting power from wasted energy 45 KW Micro Hydel Project at condenser cooling water outfall (3X15 KW) Objective: To reduce auxiliary power consumption by extracting power from wasted energy

Basic concept

Specifications of the 15KW micro hydle turbine generator set Rated capacity: 15KW (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% Specifications of the 15KW micro hydle turbine generator set Rated capacity: 15KW (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. 45 KW(3x15 KW) Micro Hydel Project ph-1 Supplier: Pentaflow Hydro Engineers.Delhi

Southern Generating Station. CESC Ltd Commissioning of phase -1 of the project completed in February 2011 Average KW is being generated from the first 15 KW unit In subsequent phases another two such sets will be commissioned Commissioning of phase -1 of the project completed in February 2011 Average KW is being generated from the first 15 KW unit In subsequent phases another two such sets will be commissioned

Electricity saved each year considering import for 75% time of a day for 350 days in a year 15 KW X 8400 hrs/year X0.75= KW-h / Year This is equivalent to a savings of Rs / year With a project cost of Rs 14.3 lakhs/unit payback is approximately3.3 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 Auxiliary Energy Saved

Micro hydle during installation

Thank You ! The future of mankind is in our hands. Let us act responsibly to keep the world cleaner for our future generation.