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Report 85 Pul Coal PDF
Report 85 Pul Coal PDF
FOREWORD
The Power Plant Component of India German Energy Programme (IGEN) is being of Power, Government of India and GTZ, Germany. The overall aim of this programme is
implemented in India with the cooperation of Central Electricity Authority (CEA), Ministry to support and prepare public plant operators for performance reporting as well as implementation of financially attractive and technically viable improvements of power plant net heat rate.
from 100 to 500 MW capacities, were carried out by using a diagnostic tool. This study
Under the IGEN programme, mapping of 85 coal based power generating units, ranging
has been completed during the period 2007-09 covering state owned plants in 14
States, 17 power utilities and 45 thermal power stations. The mapping studies have been done on two conditions namely design parameter as well as on actual operating parameters gathered from different plants for a specific period. The unique feature of this study is that heat rate of the generating unit is not based on the quantification of operating parameters.
coal consumed and energy generated but with the thermo dynamic balancing of actual
The primary purpose of mapping study is to provide a data base and broadly identify areas requiring attention for improving energy efficiency. provides an objective method of setting targets and monitoring progress. The reports Assessment studies and Renovation & Moderation (R&M) measures in some of the plants. The report, also, indicates measures that could be taken up immediately with comparatively smaller expenditure to improve plant performance before going in for regular R&M measures. provide an indication about the necessity and urgency of taking up detailed Residual Life The baseline mapping
The outcome of the study was discussed with the individual State Utilities, who appreciated the recommendations made and findings of the study. Some of the utilities implementing. have already implemented majority of the recommendations and others are in process of
For wider dissemination of the findings of the mapping study, the report is being not carried out. The report highlights the major deviations in operation from design parameters and measures suggested to improve the performance of the plants. to improve the performance of their plants.
uploaded on CEA website for the benefit of power stations where the mapping study was The
power station personnel may implement the recommendations of the mapping studies
Mapping of 85 pulverized coal fired thermal power generating units in different states (Under Indo-German Energy Program (IGEN))
SUMMARY REPORT
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TABLE CONTENTS
SECTIONS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0
PAGE
INTRODUCTION ............................................................................ 5 MAPPING PROCEDURE ................................................................... 6 METHODOLOGY............................................................................ 6 FINDINGS ..................................................................................... 7 ANALYSIS OF OBSERVATIONS ........................................................ 7 SAVINGS POTENTIAL IN COAL CONSUMPTION AND COST .............. 9 REASONS FOR HIGH OPERATING GROSS HEAT RATES ................... 10 MODEL ANALYSIS ....................................................................... 15 RECOMMENDATIONS AS PROPOSED IN THE MAPPING STUDIES ..... 16
10.0 INADEQUACIES IN OPERATION AND MAINTENANCE ..................... 17 11.0 SYSTEM IMPROVEMENTS SUGGESTED .......................................... 19 12.0 CONCLUSION ............................................................................. 21 LIST OF ANNEXURES 1 2A 2B 2C 2D 2E 2F 2G 3A 3B 3C 3D 3E 3F 3G 3H
to CEA Operating Indices for 500 MW units Operating Indices for 250 MW units Operating Indices for 210 MW units Operating Indices for 195-200 MW units Operating Indices for 140 MW units Operating Indices for 120-125 MW units Operating Indices for 100-110 MW units Graph for Operating Gross Heat Rate of 500 MW capacity units (kcal/kWh) Graph for Operating Gross Heat Rate of 250 MW capacity units (kcal/kWh) Graph for Operating Gross Heat Rate of 210 MW capacity units (kcal/kWh) Graph for Operating Gross Heat Rate of 100-125 MW capacity units (kcal/kWh) Graph for Operating Turbine Heat Rate of 500 MW capacity units (kcal/kWh) Graph for Operating Turbine Heat Rate of 250 MW capacity units (kcal/kWh) Graph for Operating Turbine Heat Rate of 210 MW capacity units (kcal/kWh) Graph for Operating Turbine Heat Rate of 100-125 MW capacity units (kcal/kWh)
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3I 3J 3K 3L 3M 3N 3O 3P 4A 4B
Graph for Operating Boiler Efficiency of 500 MW capacity units (%) Graph for Operating Boiler Efficiency of 250 MW capacity units (%) Graph for Operating Boiler Efficiency of 210 MW capacity units (%) Graph for Operating Boiler Efficiency of 100-125 MW capacity units (%) Graph for Operating Auxiliary Consumption of 500 MW capacity units (%) Graph for Operating Auxiliary Consumption of 250 MW capacity units (%) Graph for Operating Auxiliary Consumption of 210 MW capacity units (%) Graph for Operating Auxiliary Consumption of 100-125 MW capacity units (%) Graph for Performance Monitoring Points Graph for Major Loss Area in the Plants
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SUMMARY OF EBSILON MAPPING AND MODEL ANALYSIS OF 85 PULVERIZED COAL FIRED THERMAL POWER GENERATING UNITS IN DIFFERENT STATES 1.0 INTRODUCTION
Technische Zusammenarbeil (GTZ) Gmbh signed an implementation agreement with respect to the Indo-German Energy Programme (IGEN) in the year 2006. Under the IGEN agreement, power plant component is being implemented by the Central Electricity Authority (CEA), in association with the Bureau of Energy thermal power plants. The programme aims to support and prepare power plant operators for performance reporting as well as implementation of financially attractive and technically viable improvements of power plant net heat rate under the provisions of the Energy Conservation Act. The project is being executed under two main sub-components: (i) Mapping studies of thermal power generating units and, (ii) Performance optimization of thermal power stations. Under the first phase of the programme, GTZ provided support to Central Electricity Authority (CEA) for creating data base of the older thermal power plants in India. The scope of the work primarily covers the mapping of 85 thermal power generating units using Ebsilon software. The mapping has been done for two conditions, namely for design parameters and for the actual operating status for the plant parameters gathered from different plant locations. The primary purpose is to provide a database within CEA and broadly identify areas needing attention in the short, medium and long term for improving energy efficiency. The baseline mapping provides an objective method of setting targets and monitoring progress. Efficiency (BEE), for performance optimization and efficiency improvements of
Evonik Energy Services India (EESI) was appointed to carry out the mapping of the 85 power generating units. EESI is a 100% owned subsidiary of Evonik Energy Services GmbH Germany. Evonik, Germany, owns and operates a number of large coal fired power plants with an installed capacity of 11,000 MW in Germany and other countries.
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The identified mapping studies of 85 units ranging in capacity from 100 MW to 500 MW each were completed during the period 2007-09 in 14 Indian States viz Andhra Pradesh, Chhattisgarh, Gujarat, Haryana, Jharkhand, Madhya Pradesh, Karnataka, Maharashtra, Orissa, Punjab, Rajasthan, Tamil Nadu, Uttar Pradesh and West Bengal. These units are part of 45 thermal power stations owned by 17 Power Utilities. The numbers of selected units of different capacities are shown in Table 1 while details of owning utility, name of power station and capacity of unit selected for mapping are depicted in Annexure 1. Table 1 Capacities of Selected Units
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
2.0
MAPPING PROCEDURE
Project teams comprising engineers from CEA and Evonik Energy Services were constituted for groups of units to ensure expert contribution in the mapping studies and in analysis. A nodal officer of the owning utility was nominated at each plant to assist and provide data to the project team. The team visited the unit and discusses and physically checked the condition of the unit. The major observations were discussed and incorporated in the model.
3.0
METHODOLOGY
Design and current operating data for the units were obtained through questionnaires sent by CEA to concerned utilities. Further required data were collected during site visits by Evonik engineers. A design model was then built on the basis of design data obtained from site using Ebsilon software. Actual
IGEN-1/BAC/EBSILON THEROMO DYNAMIC SIMULATION MAPPING PERFORMANCE ANALYSIS-SUMMARY REPORT
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operating parameters were obtained from site and the design model was adjusted to create an operating model based on the current condition of environment and status of the machine. Simulations were then done using the actual coal and the design coal data.
4.0
FINDINGS
The mapping studies revealed that most of the units are being operated under various constraints like poor quality of coal, poor spare and activity planning, turbine and other equipments, Poor condenser vacuum, high consumption, poor housekeeping, operating parameters different steam
from the
rated values and obsolete instrumentation. These have resulted in high heat rates and unreliable plant operations. These observations are analyzed below.
5.0
ANALYSIS OF OBSERVATIONS
The gross heat rate values as well as other operating indices for all the 85 2G.
generating units have been tabulated for different unit sizes in Annexures 2A to Analysis of important power plant performance indicators namely gross heat rate, turbine heat rate, boiler efficiency and auxiliary power consumption has been carried out for the same size of units (100-110 MW, 120-125 MW, 140 MW, 195-200 MW, 210 MW, 250 MW and 500 MW). The comparative unit wise position for the above indices is shown in Annexures 3A to 3P.
5.1
The average design and operating values of gross heat rate as also the percentage deviation for each group size is given in Table 2 below: Table 2 - Gross Heat Rate Deviations
Capacity No. units 8 9 4 5 49 5 5 of Average Design Gross Heat (kcal/kWh) 2413.3 2415.4 2381.7 2385.7 2408.3 2300.6 2254.6 Rate Operating Average Average operating GHR (kcal/kWh) 2696 - 3601 2690 - 3730 2750 - 2905 2393 - 3962 2384 3064 2546 2773 2508 2647 Range of
Gross Heat Rate (kcal/kWh) 2994.4 2894.5 2822.9 2873.6 2765.8 2685.6 2561.3
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Since the operating heat rates recorded were very high in smaller capacity units compared to higher capacity units, this is because of the development metallurgy and in turbine design. Even the variation found higher in 195-200 MW units and most of the unit except one are very old units and these units require the mega R&M and use the latest technology and up gradation replace the obsolete technology. The variations in turbine heat rates are depicted in Table 3 below. and
The tabulation of operating indices for individual units in the above seven capacity ranges in Annexures 2A to 2G indicates that in each category there are a few units which are operating quite close to their design heat rates. For example, in the 210 MW categories, out of the 49 units for which operating data design heat rate. For 500 MW capacity, 4 units out of 5 units mapped have their operating turbine heat rate within 7.5% of design. The analysis brings out, also, that deterioration in the turbine heat rate is the major factor for gross heat rate deterioration. For example, the weighted average deterioration of turbine heat rate came as 10% compared to the average gross heat rate deviation of 18 % is available, there are 17 units for which operating heat rate is within 7.5% of the
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5.2
sizes.
It is seen that boiler efficiencies are close to design values and variation is mainly due to variation from design parameters and combustion problems.
6.0
Substantial savings in coal consumption and operational costs are possible with better maintenance and improvements in heat rate. The potential savings under two assumptions are shown below: Assumption Units operate at an average gross heat rate which deviates only by 7.5 % from the average design heat rate. Table 5 below gives the potential savings in coal consumption and economy in cost if all the units of a particular capacity group operate at an average heat rate which deviates by 7.5% only from the average design heat rate as compared to the situation in which all the units in the group operate at the actual operating heat rate. Assumptions: Average calorific value of coal Price of coal Average plant load factor (2008-09) - Rs 1400/ton - 77.2% - 3626 kcal/kg
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Table 5 Savings with improvement in heat rate to within 7.5% of the average design heat rate
No. of units MW 100-110 120-125 140 195-200 210 250 500 Nos. 8 9 4 5 49 5 5 Heat rate Actual Diff in heat rate kcal/ kWh Savings in Coal ''000 tons/yr saving/unit Sp coal Saving in coal Savings in Money Rs crore/yr Overall cost
Unit size
7.0
It is observed that the heat rate is very high in some units while in others it is only moderately high. Based on observations during site visit and discussions plants, some areas commonly observed to be responsible for high operating gross heat rate are listed below. These observations are not applicable to all the units but are representative of the type of problems encountered. For specific sites, pertaining units , the individual reports may be referred to obtain more details. The simulations have been carried out considering the current condition of unit and its operating environment with the site engineers on the operation and maintenance aspects of the power
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Analysis of observations for different power plants indicates that the major reasons for the high operating gross heat rate are: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Low combustion efficiency lead to high carbon loss. High force outages due to failure of boiler tubes. Poor performance of milling system. Lack of Maintenance planning and spare planning Low turbine cylinder efficiency High dry gas losses due to high unwanted excess air Poor sealing and heat transfer in air pre-heaters Low condenser vacuum. High air ingress in the boiler and high heat loss due to poor insulation Poor Performance of ESP lead to failure of ID fan and low availability. High cooling water inlet temperature due to poor performance of CT Improper mill maintenance due to non availability of grinding media. Non availability of quantity and quality fuel. High auxiliary power consumption due to high heat rate and outages. Obsolete C&I system needs maximum manual controls lead to error. Poor quality critical valves lead to passing and poor control High Boiler corrosion and erosion lead to high force outage Obsolete electrical relays and control lead to more force outage Obsolete governing and excitation system unable to meet the grid
demand variation of load It must be observed that the significance of the above factors differs amongst different capacity ranges, as also, in between units of the same range. In general, the deviations from optimum are less for 250 MW and 500 MW units. One of the major cause for the unreliability is poor Housekeeping and equipment maintenance planning.
7.1
In some of the units, the boiler is being operated without having the feedback based control of was a wide variation of fuel air ratio and quantity of secondary air and primary air .The other major attention is the air fuel velocity is not the same for all the coal burners. The unbalanced flame velocity leads poor flame profile in profile.
IGEN-1/BAC/EBSILON THEROMO DYNAMIC SIMULATION MAPPING PERFORMANCE ANALYSIS-SUMMARY REPORT
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7.2
that
The efficiency of HP, IP and LP turbine cylinders was mapped. It was observed values .This is due to high seal clearances and salt deposits. This has affected the turbine heat rate.
7.3
Soot blowing is provided to clean the boiler tubes from the fire side deposits resulting from combustion of coal. The ineffective soot blowing leads to lower heat transfer to boiler tubes, wastage of thermal energy lead to higher exit flue gas temperatures which affect boiler efficiency adversely. We are not operating LRSB due to the earlier design defects. The modified LRSB and sonic soot blowers shown excellent results to maintain a clean boiler tube surface in second pass effectively.
7.4
Air pre-heater is important equipment which utilizes waste flue gas heat to preheat the cold combustion air. Low temperature inlet hot air to mills affect the coal drying and intern reduce the mill capacity. Worn-out/choked heating elements, Improper seal clearances, damaged sector plates and side sealing plates, air ingress due to damaged expansion bellows improper sealing of inspection holes were observed for the poor air preheater efficiency .This also lead to increase the auxiliary power consumption by more power consumption of ID fan and PA and FD fan due to handling of high qty and leaking tubes were recorded as the major causes unutilized leakage air. In case of tubular air heater improper damaged ferruling
7.5
This act as a major factor for heat rate deterioration in india due to variation in air ingress and cooling water quality and quantity. It was observed that in some units, the condenser vacuum was lower by 3 to 5 percent from its design value. The vacuum in turn depends upon cooling water quantity, temperature and air ingress in the condenser. It was notices that heat rate increase due to low condenser vacuum which is 6 to 10 percent of the design value. Most places we do not have HP/LP by pass system working on auto and have capacity of only 30%
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7.6
The boiler is designed to fully safeguard itself against air ingress from external sources. The air ingress is the cause of over loading of the induced draft fan and also affects the boiler efficiency. It is observed that in many of the old units, particularly those of smaller sizes having refractory insulation, the ingress of air is very high- Oxygen mapping will clearly indicate the air ingress section and take the corrective action accordingly.
7.7
The boiler is designed for almost zero spray at full load with design coal. The spray is very high in some boilers due to poor coal quality. In some boilers we are controlling the reheater temperature by restricting flue gas qty in that section .This affects to divert more gas in superheater coil side and more heat use heavy attemperation in superheater side. pick up. To keep the metal temperature and steam temperature with in limit we As the quantity of coal fired changes and qty of flue gas also changes and changes the flame profile. Due to the above variation heat distribution and heat transfer in different sections of boiler tubes changes and lead to rise in metal temperature. In some boiler we have observed metal oxide formation in reheater and superheater tubes due to overheating and restrict the heat transfer and lead to boiler tube failure.
7.8
The cooling water temperature is high in those units where cooling towers are not well maintained. This results in poor vacuum and high heat rate. The Poor performance of circulating water pumps, choking of tubes due to debris, Non availability of any auto cleaning system also reduces the qty of CW flow and increases the CW outlet temp and poor vacuum. We have observed damaged nozzles of ejectors also leads to cause poor vacuum in condenser. flash tank, expansion bellows and poor gland sealing steam pressure, poor
7.9
In some of the 210 MW units, five mills have to be kept in operation instead of the provision of four mills at full load thus affecting availability of spare mill for maintenance. Most of the time, this problem is due to poor coal quality or poor maintenance of mill itself. Replacements of grinding material on time to get the rated output from mills were not practiced in some stations. Non availability of
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reliable gravimetric feeder further reduces the analysis and preventive action on time
latest units came after 1990 it was observed that copper alloys were not used in
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economical and reliable. So in case of the mega R& M it should be considered on case to case basis.
8.0
MODEL ANALYSIS
The model analysis has been carried out to determine the degradation of performance of important equipment which can affect the overall plant performance and efficiency. HS (Mollier) diagrams has been plotted to assess the current condition of the turbines. Ebsilon software has been used to simulate and frame models with the design and the operating parameters. The software enables assessment of impact of changes in some parameters over those on other related parameters. The thermodynamic cycle analysis balances in totality and we can access the impact quality; change in environmental parameters, cooling water temperature has been assessed. The base model in each case was developed on the basis of design parameters. Thereafter actual operating parameters were obtained from site and put in the sub-profile of the design model to obtain the performance of the unit under current operational conditions and assess the deviations. into account the impact of external factors and current condition of the plant after operation of so many running hours. Most units already crossed more than 100,000 running hours needs immediate attention to retain the following parameters within the best possible limits. In some cases it was already crossing the limits that require immediate R&M. Gross heat rate Turbine heat rate Boiler efficiency Unit efficiency Efficiency of HP turbine Efficiency of IP turbine Efficiency of LP turbine Regenerative heater performance Condenser performance Impact of exit flue gas temperature Coal quality deterioration Deviations in the following can be determined with the help of the model taking of one system gain on the other system. Such changes include deviations in coal
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9.0
Recommendations to improve the performance and efficiency of the plant have been made for each of the units covering maintenance and operational aspects. These recommendations take into account the observations of Evonik experts at site, discussions with project engineers and deviations in operating parameters determined by Ebsilon mapping. The recommendations have been divided into three categories namely: Short term Medium term Long term
The short term recommendations are those which can be implemented immediately at a low cost. These relate to improving vacuum, mill operation, boiler operation, ESP ( better housekeeping, on time deashing to avoid ash carry considered important for improvement of plant efficiency. The medium term recommendations pertain to those works which can be taken up during major shut down or during overhauling. These recommendations relate to attending to coal firing system, air dampers, flue gas system, cooling towers etc and other major defects observed by Evonik engineers. The long term recommendations cover renovation and modernization aspects of the plant considering the available poor quality coal for power generation. Retrofitting the latest technology solutions for energy efficiency and increase in capacity, close loop auto controls to operate the plant with less manpower remotely, high quality material boiler tubes to operate continuously at high metal temperature and reduce the weight due to high stress limits, capsule turbines, EHS system, HP heaters, energy efficient cartridges for BFP, zero leak valves, SWAS system, new design condensers with stainless steel tubes and ATRS and 60% HP/LP bypass valves, vacuum pumps and energy efficient variable pitch axial fans, maintenance free metallic rotary gravimetric feeders grinding material to ensure reliable guaranteed operation. Numerical control Advanced over and electrical maintenance) etc and all other equipment and systems as are
relays, new switch gears Advanced DVRs, energy efficient motors VVF drives, VAM system for HVAC system by utilizing the waste heat after APH. Advanced ESP to meet the environmental STDs. These recommendations, however, will need further detailed studies which could be taken up at the stage of Residual Life Assessment, Renovation and Modernization and Life Extension studies.
IGEN-1/BAC/EBSILON THEROMO DYNAMIC SIMULATION MAPPING PERFORMANCE ANALYSIS-SUMMARY REPORT
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10.2 Turbine
Obsolete and inefficient blades needs replacement can able to generate more power. High Nozzle losses and Poor inlet parameters of the turbine High sealing losses lead to due to poor efficiency and output. Obsolete Governing system and control valves not allow to operate the unit on frequency modulation mode. Obsolete Turbo supervisory system and protection needs replacement. expansion and vibration problems and lub oil leakages High air ingress into system due to pedestal oval and parting plane leakages and poor glands. Gland steam pressure control failure lead to high temperature and damage of oil guards and moisture ingress into lub oil system. Poorly maintained ATRS system more unit trips in emergency. Frequent failure of condenser tubes and in efficient ejectors, stages. Poor maintained deaerator lead to high dissolved oxygen Poor regenerative heaters lead to high DCA and less output. Poor Turbine insulation Poorly maintained lub oil quality and high consumption. Poor steam quality lead to high deposition and pressure drop across the Non working and low capacity Hp/Lp by pass valves on auto leads to Poor gland sealing and Brg housing and pedestal lead to restriction in
High copper carry over lead to copper deposition in Boiler High inlet cooling water temperature due to poor CT
The C&I systems at most of the plants are of older versions which become obsolete needs replacement by new DCS system
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performance, turbine heat rate etc. These figures should be checked with best performance of similar other units in the station.
the design, last months performance, best performance of the unit and Milling system maintenance and air preheater maintenance should be given the top priority based on the performance monitoring parameters and ensure timely replacement of worn out parts to ensure reliable output. Grid monitoring of Oxygen and CO to ensure a complete combustion and control combustion air to limit the dry gas losses. Installation of reliable rotary gravimetric feeders to ensure the coal quantity feed into the mill and indirectly to boiler to get an online assessment of boiler performance. Major maintenance of CW system and cooling towers to achieve quality and quantity of water, a clean condenser tubes to achieve better heat transfer and possible vacuum to gain maximum output. Up gradation of C&I system to replace the obsolete technology and installation of more close loop controls to avoid manual interference. Retrofitting of Electro hydraulic control system with auto starting of turbine system with motorized drains to meet the new grid codes and fast response to variation in demand and auto operation, Shift wise monitoring of operating controllable parameters and merit order operation concept to gain efficiency and availability. The results of monthly performance monitoring of the station should be discussed in a meeting taken by the Head of the plant and remedial action plan including action on urgent financial issues, should be decided in the meeting. Provision of computer software for performance monitoring, maintenance planning and for simulation studies at the plant site may be considered.
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Spare planning and inventory management tools to be incorporated to avoid the delay in maintenance duration and non availability of spares. Annual overhaul of units and auxiliaries should be done regularly based on the performance deterioration. Assessment to be made before and after to access the techno economical gain as far as possible. Activities to be planned as far as possible on account of system demands. Manufacturers maintenance manuals for different equipments and operating guide lines should be available in plant office. Senior officers during their inspections should ascertain that the instructions of the manuals are being followed. Retrofitting energy efficient hydro drive system for conveyors more than75 KW capacity Important work instructions pertaining to particular equipments should be displayed close to the equipment at an appropriate place. CFD modeled ducts to reduce the duct pressure losses and implementing VVF drives to reduce the auxiliary power consumption to be incorporated to update the unit performance to meet the latest demands. Retrofitting dry rotary compressors with HOC (heat of compressor for regeneration) drier in place of old compressors to maintain better instrument air and service air to meet the modern pneumatic instruments. make quality DM water from the deteriorated input water available. Retrofitting the dry bottom ash system with recirculation to reduce the water consumption and utilization of bottom ash. Charging the auxiliary header from CRH at rated load condition to reduce the energy loss of conversion to low pressure steam. refrigeration system in place of HVAC system. Energy efficient lighting system to utilize the latest LEDs to reduce the life cycle cost. One of the major causes for the poor performance is the poor housekeeping which needs immediate attention and close monitoring by top management. It has already proven that this will reduce the maintenance cost and increase the availability. Establishing a separate company at loading point or a centralized location ( coal conditioning company) to condition or blend the coal and supply the proper size coal (1mm to 5mm size) in ensured quality ( without stones and controlled calorific value and ash content) can reduce the losses to minimum and reduce the auxiliary power consumption . They can do the blending and first grinding and separation; This Company can
IGEN-1/BAC/EBSILON THEROMO DYNAMIC SIMULATION MAPPING PERFORMANCE ANALYSIS-SUMMARY REPORT
Utilizing the waste heat to retrofit the VAM ( Vapor absorption machines)
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utilize the low calorific reject coal in the low capacity CFBC/PFBC technology and meet the heat and power requirement for coal conditioning. This will ensure reliability and availability of high capacity most efficient units and reduce the partial and force outage to minimum. Major partial outages were observed due to variation and non availability of coal for bigger capacity high efficiency units. This will reduce the high quality grinding media consumption and outage of high capacity units.
12.0 CONCLUSION
The mapping exercise of the 85 power plants has generated a lot of data and information on the performance of power plants. The reports have been sent to respective plant authorities and presentations have been made before the top managements at the respective utility headquarters. The reports provide an indication about the necessity and urgency of taking up detailed RLA / CA studies and R&M measures in some of the plants. The reports, also, indicate measures that could be taken up immediately with comparatively small expenditure to improve plant performance before going in for regular R&M measures.
The improvement in heat rate of units to within 7.5 per cent of the design heat expected saving of about 6.93 million tons of coal per year for all the 85 units
rate, as is normally accepted after R&M is undertaken for the units, results in for which Ebsilon mapping studies were undertaken. This saving in coal could enable generation of about 9,600 MU per year if used in 500 MW units. It has been observed, also, that in addition to the plant problems explained above, there is need to give attention to improved maintenance practices, manpower planning, training of engineers, installation of, preferably, on-line monitoring system and updating of auto controls and instrumentation. The use of computers for maintaining plant history records should be more extensive. It is necessary to carry out total audit of plant functions covering management issues, delegation of powers and inventory management which are equally important to improve the plant performance. The institutional arrangements require the establishment of an energy efficiency cell at each power plant location. The concept of Model Power Plant has been suggested by CEA to sustain the benefits of the mapping exercise.
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ANNEXURE-1
Report No
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
Power Station
Guru Nanak Dev Thermal Power Station, Bathinda Khapar Kheda Thermal Power Station Kolaghat Thermal Power Station Mettur Thermal Power Station Nasik Thermal Power Station Panipat Thermal Power Station IB Valley Thermal Power Station Guru Hargobind Singh Thermal Power Station, Lehra Mohabbat Neyveli Lignite Corporation Neyveli Lignite Corporation Satpura Thermal Power Station Suratgarh Thermal Power Station Tuticorn Thermal Power Station Chandrapur Thermal Power Station Chandrapur Thermal Power Station Koradi Thermal Power Station Bandel Thermal Power Station Bhusawal Thermal Power Station Korba Thermal Power Station Guru Gobind Singh Thermal Power Station, Ropar Ukai Thermal Power Station North Chennai Thermal Power Station Ukai Thermal Power Station Ukai Thermal Power Station Bokaro Thermal Power Station Wanakbori Thermal Power Station Wanakbori Thermal Power Station Durgapur Thermal Power Station Mejia Thermal Power Station Vijayawada Thermal Power Station Kothagudem Thermal Power Station Korba East Thermal Power Station Anpara Thermal Power Station Anpara Thermal Power Station Obra Thermal Power Station
Unit size
110 210 210 210 210 210 210 210 210 210 210 250 210 500 210 200 210 210 210 210 210 210 200 210 210 210 210 210 210 210 250 120 210 500 200
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PSEB MAHAGENCO WBPDCL TNEB MAHAGENCO HPGCL OPGLC PSEB NLCL NLCL MPPGCL RRVUNL TNEB MAHAGENCO MAHAGENCO MAHAGENCO WBPDCL MAHAGENCO Chhattisgarh SEB PSEB GSECL TNEB GSECL GSECL DVC GSCEL GSCEL DVC DVC APGENCO APGENCO Chhattisgarh SEB UPRVUNL UPRVUNL UPRVUNL
Report No
36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74
Power Station
Vijayawada Thermal Power Station Kothagudem Thermal Power Station Rayalseema Thermal Power Station Bakreswar Thermal Power Station Parli Thermal Power Station Raichur Thermal Power Station Raichur Thermal Power Station Panipat Thermal Power Station Kothagudem Thermal Power Station Obra Thermal Power Station Pariccha Thermal Power Station Pariccha Thermal Power Station Dhuvaran Thermal Power Station Gandhinagar Thermal Power Station Wanakbori Thermal Power Station Tenughat Thermal Power Station Ukai Thermal Power Station Panipat Thermal Power Station Surat Lignite Sikka Thermal Power Station Chandarapura Thermal Power Station Birsinghpur (Sanjay Gandhi) Thermal Power Station T.P.S. Amarkantak Thermal Power Station Santaldih Thermal Power Station Durgapur Thermal Power Station Kothagudem Thermal Power Station Rayalseema Thermal Power Station IB Valley Thermal Power Station Obra Thermal Power Station Panki Thermal Power Station Kota Thermal Power Station Kota Thermal Power Station Paricha Thermal Power Station North Chennai Thermal Power Station Mettur Thermal Power Station Ennore Thermal Power Station Chandrapur Thermal Power Station Koradi Thermal Power Station Guru Nanak Dev Thermal Power Station,
Unit size
210 250 210 210 210 210 210 110 120 110 210 110 140 120 210 210 120 250 125 120 140 210 120 120 140 120 210 210 200 105 110 210 210 210 210 110 500 210 110
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Report No
75 76 77 78 79 80 81 82 83 84 85
Power Station
Vijayawada Thermal Power Station Korba Thermal Power Station Guru Gobind Singh Thermal Power Station, Ropar Ropar Khapar Kheda Thermal Power Station Nashik Thermal Power Station Nashik Thermal Power Station Kota Thermal Power Station Anpara Thermal Power Station Suratgarh Thermal Power Station Chandrapur Thermal Power Station Guru Gobind Singh Thermal Power Station.
Unit size
210 210 210 210 210 140 210 195 500 250 500
Note: Observations/analysis presented in the table are based on the operating parameters as observed at the time of Mapping Studies
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ANNEXURE-2A
Condenser Vacuum (mmHg) Auxiliary Power Cons. (%)
1991
17
1992
16
Design Operating Dev (%) Design Operating Dev (%) Design Operating Dev (%) Design Operating Dev (%) Design Operating Dev (%)
1997
11
1994
14
5 Average Design Values Average Operating Values Average Deviations (%) Minimum of Operating Values Maximum of Operating Values
1994
14
500 481 -3.8% 500 370 26.0% 500 457 -8.6% 500 425 15.0% 500.21 498.51 -0.3% 500.0 446.3 10.7% 370 498.5
2238.0 2508.0 12.1% 2238.0 2646.7 18.3% 2238.0 2563.0 14.5% 2281.0 2590.0 13.5% 2277.9 2523.4 10.8% 2254.6 2566.2 13.8% 2508.0 2646.7
1972.0 2093.0 6.1% 1972.0 2090.9 6.0% 1972.0 2087.0 5.8% 1984.3 2178.6 9.8% 1981.8 2095.7 5.8% 1976.4 2109.1 6.7% 2087.0 2178.6
88.10 83.50 -5.2% 88.10 79.00 -10.3% 88.10 81.40 -7.6% 87.00 84.12 -3.3% 87.00 83.05 -4.5% 87.66 82.21 -6.2% 79.00 84.12
1,524.0 1,455.0 -4.5% 1,524.0 1,137.0 -25.4% 1,524.0 1,207.0 -20.8% 1,507.8 1,315.0 -12.8% 1,509.0 1,550.0 2.7% 1,517.8 1,332.8 -12.2% 1,137.0 1,550.0
537.0 538.0 0.2% 538.0 539.0 0.2% 537.0 537.0 0.0% 538.0 540.0 0.4% 538.0 542.0 0.7% 537.6 539.2 0.3% 537.0 542.0
170.0 165.0 -2.9% 174.0 143.0 -17.8% 170.0 170.0 0.0% 169.0 168.0 -0.6% 173.3 171.3 -1.2% 171.3 163.5 -4.5% 143.0 171.3
670.8 650.0 -3.1% 675.0 651.0 -3.6% 670.8 636.1 -5.2% 760.0 715.0 -5.9% 690.0 670.0 -2.9% 693.3 664.4 -4.1% 636.1 715.0
8.69
7.71
7.81
7.51
7.50
7.84
Total
7.50 8.69
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
BAC/IGEN//EBSILON MAPPING SUMMARY REPORT 25 of 59
ANNEXURE-2B
Load (MW) Condenser Vacuum (mmHg) Auxiliary Power Cons. (%)
SL. NO.
Commiss-
Mode
Efficiency
Design
1 1997 11
250 250 0.0% 250 250 0.0% 250 258 3.2% 250 242.63 -2.9% 250 256 2.4% 250.0 251.3 0.5% 242.63 258.0
2304.6 2698.8 16.9% 2305.0 2771.0 19.8% 2286.2 2667.0 16.7% 2303.1 2751.1 19.4% 2304 2546.1 10.5% 2300.7 2687.2 16.8% 2546.1 2773.0
2004.2 2231.9 11.3% 2004.0 2294.0 14.3% 2005.0 2210.6 10.3% 2004 2284.0 13.9% 2004 2179.2 8.7% 2004.2 2239.9 11.7% 2179.2 2294.0
87.10 82.70 -5.1% 87.12 82.70 -5.1% 87.70 82.90 -5.5% 87.00 83.00 -4.6% 87.00 85.60 -1.6% 87.18 83.38 -4.4% 82.70 85.60
760.0 750.0 -1.3% 760.0 785.0 3.3% 740.0 790.0 6.8% 740.9 790.0 6.6% 740.8 788.0 6.4% 748.3 780.6 4.3% 750.0 790.0
537.0 544.0 1.3% 537.0 530.0 -1.3% 537.0 535.0 -0.4% 537.0 538.0 0.2% 540.0 538.0 -0.4% 537.6 537.0 -0.1% 530.0 544.0
150.0 154.0 2.7% 150.0 144.0 -4.0% 152.0 151.7 -0.2% 147.0 152.0 3.4% 154.1 152.4 -1.1% 150.6 150.8 0.2% 144.0 154.0
700.0 680.0 -2.9% 700.0 680.0 -2.9% 680.0 656.0 -3.5% 665.0 639.0 -3.9% 665.0 654.0 -1.7% 682.0 661.8 -3.0% 639.0 680.0 9.73 9.33 8.54 10.04 9.58
1998
10
2005
1998
10
2000
Average Design Values Average Operating Values Total Average Deviations (%) Minimum of Operating Values Maximum of Operating Values
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
BAC/IGEN//EBSILON MAPPING SUMMARY REPORT 26 of 59
ANNEXURE-2C
Condenser Vacuum (mmHg) Auxiliary Power Cons. (%)
Commiss-
Mode
Efficiency
Design 1 1994 14 Operating Dev (%) Design 2 2007 1 Operating Dev (%) Design 3 1979 29 Operating Dev (%) Design 4 1994 14 Operating Dev (%) Design 5 1995 13 Operating Dev (%) Design 6 1984 24 Operating Dev (%) Design 7 1986 22 Operating Dev (%)
BAC/IGEN//EBSILON MAPPING SUMMARY REPORT
210 210.38 0.2% 210.2 179.44 -14.6% 210 210.3 0.1% 210.4 210 -0.2% 210 214 1.9% 210 207 -1.4% 210 160.4 -23.6%
2270.8 2480.6 9.2% 2270.8 2383.7 5,6% 2397.0 2642.9 10.3% 2331.8 2490.1 6.8% 2332.0 2445.0 4.8% 2333.7 2602.1 11.5% 2333.7 2859.6 22.5%
2007.4 2110.0 5.1% 2007.4 2050.0 2.1% 2062.0 2186.6 6.0% 2007.8 2110.5 5.1% 2007.0 2093.5 4.3% 2007.0 2178.5 8.5% 2007.0 2209.2 10.1%
88.40 85.00 -3.8% 88.40 86.00 -2.7% 86.00 82.80 -3.7% 86.10 84.75 -1.6% 86.10 85.60 -0.6% 86.00 83.70 -2.7% 86.10 77.25 -10.3%
640.0 668.0 4.4% 646.0 556.0 -13.9% 673.0 726.0 7.9% 630.0 635.0 0.8% 630.0 666.0 5.7% 625.0 620.0 -0.8% 630.0 505.0 -19.8%
540.0 538.0 -0.4% 537.0 537.0 0.0% 540.0 535.0 -0.9% 539.0 540.0 0.2% 540.0 540.0 0.0% 535.0 536.0 0.2% 540.0 535.0 -0.9%
147.0 150.0 2.0% 147.0 147.0 0.0% 130.0 130.0 0.0% 150.0 149.0 -0.7% 150.0 149.5 -0.3% 147.0 133.0 -9.5% 150.0 134.6 -10.3%
672.0 660.0 -1.8% 690.0 684.0 -0.9% 710.0 680.0 -4.2% 710.0 695.0 -2.1% 693.0 695.0 0.3% 684.0 631.0 -7.7% 680.0 660.0 -2.9%
27 of 59
9.75
11.29
8.92
8.51
9.70
9.87
10.05
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
ANNEXURE-2C
Load (MW) Condenser Vacuum (mmHg) Auxiliary Cons. (%) Power
1986
22
210.4 175.3 -16.7% 210 192 -8.6% 210.42 219 4.1% 210.36 170.28 -19.1% 210 207.78 -1.1% 210 200 -4.8%
2403.5 3063.6 27.5% 2378.5 2888.6 21.4% 2306.0 2703.0 17.2% 2360.0 2824.3 19.7% 2376.0 2746.2 15.6% 2403.2 2740.0 14.1%
2067.0 2407.0 16.4% 2072.0 2296.4 10.8% 2007.0 2216.5 10.4% 2002.0 2234.8 11.6% 2044.0 2265.5 10.8% 2067.1 2247.0 8.7%
86.00 78.56 -8.7% 87.13 79.50 -8.8% 87.00 82.00 -5.7% 84.85 79.10 -6.8% 86.00 82.50 -4.1% 86.00 82.00 -4.7%
678.0 614.0 -9.4% 645.0 600.0 -7.0% 632.0 656.0 3.8% 630.0 535.0 -15.1% 690.0 708.0 2.6% 678.0 680.0 0.3%
535.0 533.0 -0.4% 540.0 527.0 -2.4% 540.0 515.0 -4.6% 540.0 535.0 -0.9% 540.0 533.0 -1.3% 540.0 527.7 -2.3%
129.0 115.0 -10.9% 137.0 133.0 -2.9% 150.0 146.0 -2.7% 150.0 149.0 -0.7% 135.0 126.0 -6.7% 129.0 124.0 -3.9%
684.0 660.0 -3.5% 680.0 627.0 -7.8% 690.0 670.0 -2.9% 690.0 660.0 -4.3% 690.0 679.0 -1.6% 680.0 644.0 -5.3%
9.50
1982
26
11.19
10
1997
11
9.70
11
1990
18
11.82
12
1985
23
9.11
13
1982
26
9.02
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
28 of 59
ANNEXURE-2C
SL. NO. Year of Commissioning Age 2008 till Mode Load (MW) Gross (kcal/kWh) Heat Rate Turbine (kcal/kWh) Heat Rate Boiler Efficiency (%) Main Steam Condenser Vacuum (mmHg) Auxiliary Cons. (%) Power
Design
14
210 190 -9.5% 210 195.86 -6.7% 210 210 0.0% 210.5 215.26 2.3% 210 206 -1.9% 210 210.78 0.4%
2403.2 2877.0 19.7% 2333.7 2839.1 21.7% 2318.5 2716.3 17.2% 2307.0 2545.4 10.3% 2304.8 2556.5 10.9% 2403.0 2805.0 17.3%
2067 2359.0 14.1% 2007.0 2336.7 16.4% 1994.2 2142.0 7.4% 2007.0 2138.0 6.5% 1995.0 2167.9 8.7% 2067.0 2272.0 9.9%
86.00 82.00 -4.7% 86.10 82.30 -4.4% 86.00 79.00 -8.1% 87.00 84.00 -3.4% 86.60 84.80 -2.1% 86.00 81.00 -5.8%
680.0 651.0 -4.3% 635.0 605.0 -4.7% 635.0 670.0 5.5% 635.0 665.0 4.7% 631.0 632.0 0.2% 646.0 648.0 0.3%
540.0 535.0 -0.9% 535.0 535.0 0.0% 540.0 538.0 -0.4% 540.0 540.3 0.1% 540.0 538.7 -0.2% 535.0 535.0 0.0%
129.0 123.0 -4.7% 147.0 151.0 2.7% 150.0 140.0 -6.7% 147.0 144.9 -1.4% 146.0 143.4 -1.8% 123.0 116.0 -5.7%
680.0 635.0 -6.6% 680.0 640.0 -5.9% 684.0 655.0 -4.2% 684.0 679.0 -0.7% 710.0 661.0 -6.9% 684.0 670.0 -2.0% 9.12 8.29 8.10 8.89 9.32 8.90
1984
24
15
1986
22
16
1989
19
17
1991
19
18
1994
14
19
1982
26
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
29 of 59
ANNEXURE-2C
Year of Board / Place Commissioning Age 2008 till Mode Load (MW) Gross (kcal/kWh) Heat Rate Turbine (kcal/kWh) Heat Rate Boiler Efficiency (%) Main Steam Condenser Vacuum (mmHg) Auxiliary Cons. (%) Power
Design
20
210 200.88 -4.3% 210 210 0.0% 210 194 -7.6% 210 188.9 -10.0% 210.18 200 -4.8% 210 190 -9.5%
2403 2843.7 18.3% 2317.3 2664.0 15.0% 2317.0 2984.0 28.8% 2395.4 2614.5 9.1% 2371.0 2697.0 13.7% 2378.7 2948.4 24.0%
2067 2304.9 11.5% 2007.0 2122.0 5.7% 2007.0 2441.7 21.7% 2060.0 2192.7 6.4% 2040 2222.7 9.0% 2040.0 2324.2 13.9%
86.00 81.05 -5.8% 86.61 79.60 -8.1% 86.60 81.80 -5.5% 86.00 83.90 -2.4% 86.00 82.30 -4.3% 85.80 78.80 -8.2%
652.0 670.0 2.8% 630.0 640.0 1.6% 628.0 611.0 -2.7% 650.0 588.0 -9.5% 652.0 627.0 -3.8% 670.0 578.0 -13.7%
535.0 532.0 -0.6% 540.0 533.0 -1.3% 535.0 533.0 -0.4% 535.0 535.0 0.0% 535.0 535.0 0.0% 535.0 534.0 -0.2%
127.0 119.0 -6.3% 150.0 147.0 -2.0% 150.0 146.0 -2.7% 130.0 130.0 0.0% 130.0 127.5 -1.9% 130.0 130.0 0.0%
684.0 660.0 -3.5% 684.0 660.0 -3.5% 684.0 647.0 -5.4% 680.0 662.0 -2.6% 680.0 666.0 -2.1% 680.0 648.0 -4.7% 9.48 9.92 9.43 9.19 9.70 9.03
1986
22
21
1989
19
22
1990
18
23
1982
26
24
1979
29
25
1981
27
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
30 of 59
ANNEXURE-2C
SL. NO. Year of Commissioning Age 2008 till Mode Load (MW) Gross (kcal/kWh) Heat Rate Turbine (kcal/kWh) Heat Rate Boiler Efficiency (%) Main Steam Condenser Vacuum (mmHg) Auxiliary Cons. (%) Power
Design
26
210 182 -13.3% 210.56 148 -29.7% 210 175 -16.7% 210 210.12 0.1% 210 210.19 0.1% 210 210.39 0.2%
2373.0 2715.0 14.4% 2334.0 2690.0 15.3% 2409.0 2875.1 19.4% 2617.3 2970.4 13.5% 2570.0 2899.9 12.8% 2350.0 2679.5 14.0%
2040.0 2227.0 9.2% 2007.0 2208.0 10.0% 2047.6 2342.9 14.4% 2012.7 2109.8 4.8% 2008.8 2235.1 11.3% 1991.0 2223.0 11.7%
86.00 82.00 -4.7% 86.00 82.10 -4.5% 85.00 81.50 -4.1% 76.90 71.00 -7.7% 78.17 77.10 -1.4% 84.71 83.00 -2.0%
670.0 600.0 -10.4% 635.0 442.0 -30.4% 670.0 650.0 -3.0% 641.9 630.0 -1.8% 657.0 660.0 0.5% 645.0 660.0 2.3%
535.0 533.0 -0.4% 535.0 535.0 0.0% 540.0 525.0 -2.8% 535.0 541.0 1.1% 535.0 535.0 0.0% 535.0 536.0 0.2%
137.0 130.0 -5.1% 150.0 93.8 -37.5% 130.0 108.0 -16.9% 150.0 149.0 -0.7% 150.0 149.0 -0.7% 150.0 148.0 -1.3%
663.0 600.0 -9.5% 690.0 660.0 -4.3% 684.0 650.0 -5.0% 689.0 674.0 -2.2% 684.0 667.0 -2.5% 680.0 655.0 -3.7% 10.40 10.44 10.05 9.00 10.74 12.87
1980
28
27
1993
15
28
1980
28
29
1986
22
30
1993
15
31
1994
14
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
31 of 59
ANNEXURE-2C
SL. NO. Year of Commissioning Age 2008 till Mode Load (MW) Gross (kcal/kWh) Heat Rate Turbine (kcal/kWh) Heat Rate Boiler Efficiency (%) Main Steam Condenser Vacuum (mmHg) Auxiliary Cons. (%) Power
Design
32
210 183 -12.9% 210 210 0.0% 210 210 0.0% 210 210 0.0% 210 210 0.0% 210 210 0.0%
2369.3 2668.7 12.6% 2335.6 2477.0 6.1% 2333.3 2559.0 9.7% 2333.3 2672.1 14.5% 2333.7 2867.1 22.9% 2333.7 2711.4 16.2%
2007.0 2201.8 9.7% 2007.0 2044.8 1.9% 2007.2 2116.1 5.4% 2007.2 2224.7 10.8% 2007.0 2285.0 13.9% 2007.0 2250.4 12.1%
84.70 82.50 -2.6% 85.93 82.55 -3.9% 86.10 82.70 -3.9% 86.10 83.30 -3.3% 86.00 79.69 -7.3% 86.00 83.00 -3.5%
636.0 616.0 -3.1% 635.0 645.0 1.6% 625.0 620.0 -0.8% 625.0 670.0 7.2% 630.0 650.0 3.2% 631.0 658.0 4.3%
535.0 543.0 1.5% 535.0 535.0 0.0% 535.0 535.0 0.0% 535.0 535.0 0.0% 535.0 533.0 -0.4% 535.0 535.0 0.0%
150.0 145.0 -3.3% 150.0 147.0 -2.0% 147.0 140.0 -4.8% 147.0 139.0 -5.4% 147.0 135.0 -8.2% 147.1 147.1 0.0%
680.0 642.0 -5.6% 685.0 655.0 -4.4% 684.0 667.0 -2.5% 684.0 671.0 -1.9% 684.0 660.0 -3.5% 670.0 605.0 -9.7% 9.17 9.50 9.15 9.27 9.00 10.38
1995
13
33
1998
10
34
1985
23
35
1988
20
36
1993
15
37
1989
19
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
32 of 59
ANNEXURE-2C
SL. NO. Year of Commissioning Age 2008 till Mode Load (MW) Gross (kcal/kWh) Heat Rate Turbine (kcal/kWh) Heat Rate Boiler Efficiency (%) Main Steam Condenser Vacuum (mmHg) Auxiliary Cons. (%) Power
Design
38
210 210 0.0% 210 204 -2.9% 210.52 210.36 -0.1% 210 211.8 0.9% 210 210.29 0.1% 210 180 -14.3%
2400 2656.2 10.7% 2395.9 2529.4 5.6% 2312.5 2650.8 14.6% 2312.4 2575.3 11.4% 2378.0 2826.3 18.6% 2318.6 2751.0 18.6%
2062 2147.9 4.3% 2060.0 2152.0 4.5% 2005.8 2232.8 11.3% 2005.8 2086.0 4.0% 2062.0 2259.8 8.4% 1994.0 2160.0 8.3%
85.93 80.86 -5.9% 86.00 85.10 -1.0% 86.73 84.23 -2.9% 86.70 81.00 -6.6% 86.70 80.00 -7.7% 86.00 78.50 -8.7%
650.0 680.0 4.6% 670.0 633.0 -5.5% 640.0 628.0 -1.9% 640.0 627.0 -2.0% 653.0 722.0 10.6% 635.0 526.0 -17.2%
540.0 540.0 0.0% 540.0 540.0 0.0% 539.0 535.0 -0.7% 535.0 540.0 0.9% 535.0 535.0 0.0% 535.0 526.0 -1.7%
136.0 130.0 -4.4% 136.0 132.9 -2.3% 147.0 149.2 1.5% 147.1 152.2 3.5% 130.0 125.0 -3.8% 150.0 124.0 -17.3%
684.0 650.0 -5.0% 700.0 663.0 -5.3% 690.0 680.0 -1.4% 690.0 690.0 0.0% 684.0 640.0 -6.4% 690.0 660.0 -4.3% 9.57 8.07 8.92 9.78 8.66 9.12
1987
21
39
1990
18
40
1994
14
41
1995
13
42
1979
29
43
1996
12
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
33 of 59
ANNEXURE-2C
SL. NO. Year of Commissioning Age 2008 till Mode Load (MW) Gross (kcal/kWh) Heat Rate Turbine (kcal/kWh) Heat Rate Boiler Efficiency (%) Main Steam Condenser Vacuum (mmHg) Auxiliary Cons. (%) Power
Design
44
210.42 184.38 -12.4% 210.36 185.34 -11.9% 210 202 -3.8% 210 210 0.0% 210 200 -4.8%
2333.7 2706.4 16.0% 2333.7 2751.5 17.9% 2333.0 2459.7 5.4% 2303.2 2656.0 15.3% 2397 2747.3 13.6%
2007.0 2192.4 9.2% 2007.0 2261.5 12.7% 2007.0 2090.7 4.2% 1981.2 2238.3 13.0% 2062.2 2211.7 10.0%
86.00 81.00 -5.8% 86.00 82.18 -4.4% 86.00 85.00 -1.2% 86.00 84.27 -2.0% 86.00 80.50 -6.4%
632.0 600.0 -5.1% 630.0 527.0 -16.3% 630.0 570.0 -9.5% 640.0 658.0 2.8% 660.0 644.0 -2.4%
540.0 530.0 -1.9% 540.0 535.0 -0.9% 540.0 563.9 4.4% 537.0 530.0 -1.3% 535.0 535.0 0.0%
150.0 144.0 -4.0% 150.0 122.0 -18.7% 150.0 136.4 -9.0% 150.0 148.1 -1.3% 127.5 101.0 -20.8%
690.0 680.0 -1.4% 690.0 655.0 -5.1% 690.0 632.0 -8.4% 720.0 690.0 -4.2% 684.0 660.0 -3.5% 8.68 8.78 9.27 9.76 9.20
1987
21
45
2006
46
2006
47
2000
48
1982
26
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
34 of 59
ANNEXURE-2C
Load (MW) Condenser Vacuum (mmHg) Auxiliary Cons. (%) Power
SL. NO.
Average Operating Values Average Deviations (%) Minimum of Operating Values Maximum of Operating Values
9.57
8.07 12.87
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
35 of 59
ANNEXURE-2D
Load (MW) 195 211 8.2% 200 194 -3.0% 200.09 180.86 -9.6% 200 100 -50.0% 200.09 145.22 -27.4% 199.0 166.2 -16.4% 100 211.0 Condenser Vacuum (mmHg) 680.0 666.0 -2.1% 690.0 687.0 -0.4% 680.0 659.0 -3.1% 710.0 660.0 -7.0% 690.0 670.0 -2.9% 690.0 668.4 -3.1% 659.0 687.0 8.07 12.59 10.24 11.74 12.59 8.07 8.80 10.00 Auxiliary Power Cons. (%)
SL. NO.
Commiss-
Mode
Heat Rate (kcal/kWh) 2326 2392.6 2.86% 2403.0 2799.7 16.5% 2403 2891.3 20.3% 2395.0 3962.5 64.1% 2400.0 2899.5 20.7% 2399.6 2989.1 24.4% 2392.6 3962.5
Heat Rate (kcal/kWh) 2000.0 2033.7 1.6% 2067.0 2267.2 9.7% 2067.0 2340.8 13.20% 2062.0 2892.5 39.3% 2062 2305.1 11.7% 2051.6 2367.9 15.4% 2033.7 2892.5
Efficiency
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
BAC/IGEN//EBSILON MAPPING SUMMARY REPORT 36 of 59
ANNEXURE-2E
Mode Heat Rate (kcal/kWh) Heat Rate (kcal/kWh) Efficiency Condenser Vacuum (mmHg) Auxiliary Power Cons. (%)
Commiss-
140 112 -20.0% 140 104.23 -25.6% 140.23 104 -25.8% 140 97 -30.7% 140.1 104.3 -25.5% 97.0 112.0
2462.9 2750.0 11.7% 2341.9 2904.8 24.0% 2361.0 2827.6 19.7% 2361 2814.0 19.1% 2381.2 2824.1 18.6% 2750.0 2904.8
2054.0 2242.9 9.2% 2054.0 2325.4 13.2% 2054.0 2298.0 7.7% 2054.0 2252.0 9.6% 2054.0 2279.6 11.0% 2242.9 2325.4
83.40 81.50 -2.3% 86.23 80.00 -7.2% 87.00 81.30 -6.6% 87.0 80.00 -8.5% 86.01 80.70 -6.1% 80.00 81.50
412.0 344.0 -16.5% 395.0 321.0 -18.7% 400.0 315.0 -21.3% 428.4 315.0 -26.5% 408.9 323.8 -20.7% 315.0 344.0
538.0 530.0 -1.5% 540.0 530.0 -1.9% 535.0 520.0 -2.8% 543.0 515.0 -5.2% 539.0 523.8 -2.8% 515.0 530.0
130.0 124.5 -4.2% 130.0 106.0 -18.5% 130.0 120.0 -7.7% 141.0 121.5 -13.9% 132.8 118.0 -11.1% 106.0 124.5
690.0 660.0 -4.3% 690.0 670.0 -2.9% 690.0 670.0 -2.9% 663.0 657.0 -0.9% 683.3 664.3 -2.8% 657.0 670.0
13.70
14.13
14.56
8.91
Note: Observations/analysis presented in the table are based on the operating parameters as observed at the time of Mapping Studies
37 of 59
ANNEXURE-2F
Mode Load Gross Turbine Boiler (%) Main Steam (tph) Flow Temperature (C) (kg/cm2) Pressure Condenser Vacuum (mmHg) Auxiliary Power Cons. (%)
SL. NO.
Commissioning
Year of
(MW)
Efficiency
1974/2000
1978/2000
30
1981
27
1977
31
1988
20
1976
32
1977
31
120 66 -45.0% 120 98 -18.3% 120 114 -5.0% 120 102.9 -14.3% 120 73 -39.2% 120 108 -10.0% 120 78.46 -34.6%
2388.4 2764.1 15.7% 2394.5 2709.7 13.2% 2442.0 2796.0 14.4% 2442 2689.9 10.1% 2442.0 2801.7 14.8% 2346 2862.0 24.4% 2442 3730.0 54.2%
2054.7 2244.3 9.2% 2054.7 2207.9 7.2% 2100 2261.5 7.7% 2100 2187.7 4.1% 2100 2306.9 9.8% 2100 2360.6 14.5% 2100.0 2796.0 33.4%
86.00 81.20 -5.6% 86.00 81.50 -5.2% 85.99 80.88 -5.9% 86.00 81.30 -5.5% 85.50 82.30 -3.7% 89.60 82.50 -7.9% 86.00 75.00 -12.8%
360.0 200.0 -44.4% 362.0 290.0 -19.9% 410.0 410.0 0.0% 362.0 320.0 -11.6% 372.0 246.0 -33.9% 370.0 328.0 -11.4% 403.0 273.0 -32.3%
540.0 532.0 -1.5% 535.0 530.0 -0.9% 537.0 532.0 -0.9% 535.0 530.0 -0.9% 537.0 536.0 -0.2% 537.8 510.0 -5.2% 540.0 523.0 -3.1%
130.4 73.5 -43.6% 130.0 107.0 -17.7% 128.8 126.2 -2.0% 130.0 120.0 -7.7% 127.0 118.0 -7.1% 127.6 106.0 -16.9% 133.0 102.8 -22.7%
690.0 684.1 -0.9% 690.0 676.0 -2.0% 700.0 680.0 -2.9% 690.0 670.0 -2.9% 684.0 664.0 -2.9% 686.0 663.0 -3.4% 686.0 654.0 -4.7%
38 of 59
10.02
13.47
10.36
14.32
13.66
10.54
12.41
1974
34
120.3 70.3 -41.6% 125 128 2.4% 120.6 93.2 -22.8% 66 128.0
2442 3172.4 31.2% 2400.0 2771.0 -15.5% 2395.4 2921.9 18.5% 2689.9 3730.0
2100.0 2478.5 18.2% 2022.0 2162.0 -6.9% 2063.4 2333.9 11.5% 2162.0 2796.0
86.00 78.10 -9.2% 84.30 78.00 7.5% 86.15 80.09 -5.4% 75.00 82.50
344.0 248.0 -27.9% 390.0 391.0 -0.3% 374.8 300.7 -20.2% 200.0 410.0
535.0 505.0 -5.6% 540.0 539.0 0.2% 537.4 526.3 -2.0% 505.0 539.0
130.0 78.8 -39.4% 132.0 145.0 -9.8% 129.9 108.6 -18.6% 73.5 145.0
690.0 660.0 -4.3% 710.0 676.4 4.7% 691.8 669.7 -2.1% 654.0 684.1
13.57
1999
11.50
Total
Average Design Values Average Operating Values Average Deviations (%) Minimum of Operating Values Maximum of Operating Values
12.21
10.02 14.32
Note: Observations/analysis presented in the table are based on the operating parameters as observed at the time of Mapping Studies
39 of 59
ANNEXURE-2G
Condenser (kg/cm2) Pressure Vacuum (mmHg) Auxiliary Power Cons. (%)
100 52 48.0% 105 80 23.8% 110 103.43 6.0% 110 110.19 -0.2% 110 107 2.7% 110 109 0.9% 110 75 31.8% 110 85
2472.0 2924.4 -20.7% 2463.1 3280.7 32.5% 2377.0 2851.3 20.0% 2482.0 3067.5 -23.6% 2460.0 2696.3 -9.6% 2245.6 2883.0 -28.4% 2395.9 3600.8 -50.3% 2418.6 2830.5
2138.0 2310.3 -10.3% 2140 2138 -11.1% 2138.0 2310.3 11.1% 2120.0 2440.0 -9.9% 2120.0 2215.0 -4.7% 2140.0 2372.7 -22.3% 2140.0 2881.4 -28.1% 2140.0 2230.6
86.50 79.00 8.7% 86.90 78.80 9.3% 87.50 81.00 -7.4% 89.48 80.00 10.6% 86.00 82.20 4.4% 86.40 82.30 4.7% 86.70 80.00 7.7% 86.00 78.80
420.0 220.0 47.6% 320.0 258.0 19.4% 326.0 330.0 1.2% 324.0 315.0 2.8% 324.0 315.0 2.8% 365.0 366.0 -0.3% 354.0 285.0 19.5% 325.0 257.0
535.0 525.0 1.9% 535.0 539.0 -0.7% 535.0 515.0 -3.7% 540.0 535.0 0.9% 540.0 533.0 1.3% 540.0 534.0 1.1% 535.0 537.5 -0.5% 540.0 538.0
90.0 68.9 23.4% 130.4 122.6 6.0% 130.0 118.0 -9.2% 129.0 124.5 3.5% 139.0 130.0 6.5% 137.5 127.3 7.4% 128.0 121.0 5.5% 130.0 96.0
700.0 682.0 2.6% 684.0 660.0 3.5% 684.0 638.0 -6.7% 681.2 660.0 3.1% 680.0 660.0 2.9% 684.0 645.0 5.7% 684.0 560.0 18.1% 684.0 638.0
40 of 59
19.76
14.14
15.31
9.60
9.11
9.38
13.04
14.44
SL. NO.
Commissioning
Year of
Load (MW)
Gross
Turbine
Efficiency (%)
Boiler
Average Design Values Average Operating Values Total Average Deviations (%) Minimum of Operating Values Maximum of Operating Values
Note: Observations/analysis presented in the table are based on the operating parameters as observed at the time of Mapping Studies
41 of 59
ANNEXURE-3A
2650
2646.7
2600
2590.0 2563.0
2550
2523.4 2508.0
2500
2450
2400
42 of 59
Note: Observations/analysis presented in the table are based on the operating parameters as observed at the time of Mapping Studies
ANNEXURE-3B
2800
2773.0
2700
2600
2546.1
2500
2400
2300
2200
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
BAC/IGEN//EBSILON MAPPING SUMMARY REPORT 43 of 59
ANNEXURE-3C
2672.1 2529.4
Share of units
- 2500 2500 - 2600 2600 - 2700 2700 - 2800 2800 - 2900 2900 -
ANNEXURE-3D
3730.0 3600.8
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
BAC/IGEN//EBSILON MAPPING SUMMARY REPORT 45 of 59
ANNEXURE-3E
Operating Turbine Heat Rate of 500 MW capacity units (kcal/kWh)
kcal/kWh 2200 2180 2160 2140 2120 2100 2080 2060 2040 2020 2000
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
2178.6
2090.9 2087.0
2093.0
2095.7
46 of 59
ANNEXURE-3F
2300
2294.0
2250
2200
2179.2
2150
2100
2050
2000
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
47 of 59
ANNEXURE-3G
2441.7
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
BAC/IGEN//EBSILON MAPPING SUMMARY REPORT 48 of 59
ANNEXURE-3H
2881.4 2796.0
2187.7
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
49 of 59
ANNEXURE-3I
84
84.12
82
80
79.00
78
76
74
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
50 of 59
ANNEXURE-3J
85.6
84
82.7
82
82.7
82.9
83.0
80
78
76
74
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
51 of 59
ANNEXURE-3K
Share of units
- 78 78 - 80 80 - 82 82 - 84 84 78.6
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
BAC/IGEN//EBSILON MAPPING SUMMARY REPORT 52 of 59
ANNEXURE-3L
82.2
82
82.3
82.3
82.5
81.0
81.2
81.3
81.5
80 78 76 74 72 70
75.0
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
53 of 59
ANNEXURE-3M
8.69
54 of 59
ANNEXURE-3N
10.0
10.04
9.0
8.54
8.0
7.0
6.0
5.0
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
55 of 59
ANNEXURE-3O
Share of units
12.87
8-9 9 - 10 10 - 11 11 - 12 12 -
11.15 9.92
8.66
9.00
9.15
9.32
9.70
ANNEXURE-3P
12.41
12 10 8 6 4 2 0
9.11
9.38
9.60
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
57 of 59
58 of 59
Note: Observations/analysis presented in the table are based on the parameters at the time of Mapping Studies and simulated by model
59 of 59