1b.promotion of energy conservation in indian thermal power

8/7/2019 1B.Promotion of Energy Conservation in Indian Thermal Power

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Energy Conservation Act and Energy AuditEnergy Conservation Act and Energy Audit

ATAR SINGHATAR SINGH

DEPUTY DIRECTOR, NPTIDEPUTY DIRECTOR, NPTI


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India has an installed power generating capacity of 143,061 MW (as on

March 31, 2008) of which the thermal power stations share is 91,906

MW (64%).

IntroductionIntroduction


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Energy consumption in India is low, though efficiency of use is reasonable

Per capita energy consumption is 530 kgoe; world average is 1770 Energy intensity of Indian economy was 0.18 kgoe/$-GDP(PPP) in 2004;

compared to 0.14 in Japan and 0.19 in the EU

Energy demand is increasing due to rising incomes, acceleratedindustrialization, urbanization and population growth 2003-04 : 572 Mtoe

2016-17 : 842-916 Mtoe 2026-27 : 1406-1561 Mtoe

Meeting the increasing demand only through increases in supply may leadto: Reduced energy security due to volatility in availability and prices of

imported fuels Adverse environmental impacts Strain on balance of payments

Energy conservation and energy-efficiency are an essential part of nationalenergy strategy

Energy Use in India


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The contribution of energy generated by thermal stations was 559

billion kWh, which is about 80% of electricity generated (704.5 billion

kWh) in 2007-08.

There has been significant improvement in the plant load factor of

thermal stations, which improved from 52.4% in 1985-86 to 78.6 in

2007-08, registering a remarkable improvement of 50 % during the

period.

Since the major power generation contribution is from thermal sector,

an average increase of 1% in the thermal power plant efficiency would

result in:

a. Coal savings of approx. 11 million tons per annum for nation

(approx) worth 200 Million Euro

b. 3% CO2 reduction per annum (approx.13.5 million tons per annum)

Indian Thermal Power StationsIndian Thermal Power Stations


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ALL INDIA PLANT LOAD FACTOR (%) OFCOAL FIRED THERMAL POWER STATIONS

57

.1

77

.03

78.61

74

.3

53

.2

74

.8

72

.772

.2

69

.969

67

.3

64

.664

.7

64

.4

63

60

61

55.3

53

.9

56

.5

55

56

.5

52

.4

48

53

58

63

68

73

78

1985-86

1986-87

1987-88

1988-89

1989-90

1990-91

1991-92

1992-93

1993-94

1994-95

1995-96

1996-97

1997-98

1998-99

1999-2000

2000-01

2000-02

2002-03

2003-04

2004-05

2005-06

2006-07

2007-08

YEARS

PLF(%)


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INDIAN SCENARIO: DESIGN HEAT RATEINDIAN SCENARIO: DESIGN HEAT RATE

TRENDS*TRENDS*

PERIOD STEAMPRESSURE&

TEMPERATURE

UNIT SIZE

(MW)

TURBINE

Heat Rate

(Kcal/kWh)

Unit Heat Rate

(Kcal/kWh)

1951-60 60 kg/cm2, 482oC 30 57.5 2470

1961-75 70 kg/cm2, 496oC to

90 ata 538oC

60 100 2370

1961-75 130 ata 535/535oC 110 120 2170 2060 2552-2423

1977-82 130 ata 535/535oC 210 (Russian) 2060 2423

1983+ 150 ata 535/535oC 210(Siemens)

2024 2335

1984+ 170 ata 535/535oC 500 1950 (TDBFP) 2294

1990+ 150 ata 535/535oC

170 ata 538/538 oC

210/ 250

250/ 500

1950 (MDBFP)

1950 (TDBFP)

2294

2294

*Above are best design values (design rates of individual unit varies based on

reference ambient, coal quality, design and supply dates)


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EFFECT OF CRITICAL PARAMETERS ONEFFECT OF CRITICAL PARAMETERS ON

HEAT RATEHEAT RATE

Variation Impact (kCal /kWh)

200 MW Unit 500 MW Unit

SH Spray 20 T/hr 0.30 0.81

RH Spray 20 T/hr 12.00 4.76MS Pr. 10 kg 12.00 7.30

MS Temp. 10oC 6.00 6.20

RH Steam 10oC 6.00 5.55

Load 10 MW 12.00 4.36

Cond. Back Pr. 5 mm Hg 8.00 6.70

FW Temp. 10oC 8.00 10


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Power sector reforms

Promotion of clean coal technologies,

Energy Conservation Act 2001

Electricity Act 2003

National Electricity Policy, 2005

Adoption of Super Critical Technology for 660/ 800 MW units for Ultramega Projects (4000 MW each) and

Increased emphasis on environmental considerations

Policy initiatives of Government of India to improve thePolicy initiatives of Government of India to improve the

power sector efficiencypower sector efficiency


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Emphasis on plant load factor instead of efficient generation.

Degradation of equipment resulting in loss of capacity.

Delayed overhauls (Seasonal Constraints)

Financial constraints lead to inadequate maintenance

Lack of awareness on efficiency related issues

Inadequate monitoring system for parameters

Barrier to Efficiency Improvement in Power Sector Barrier to Efficiency Improvement in Power Sector

Indian ScenarioIndian Scenario


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Enacted in October 2001Enacted in October 2001Become effective from 1st March 2002Become effective from 1st March 2002

Bureau of Energy Efficiency (BEE) operationalized fromBureau of Energy Efficiency (BEE) operationalized from

11stst March 2002.March 2002.

MISSION OF BEEMISSION OF BEE

Develop policy and strategies with a thrust on self regulationDevelop policy and strategies with a thrust on self regulationand market principles, within the overall framework of theand market principles, within the overall framework of the

EC Act with the primary objective of reducing energy EC Act with the primary objective of reducing energy

intensity of the Indian economy.intensity of the Indian economy.


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DESIGNATED CONSUMERSDESIGNATED CONSUMERS( Energy Intensive Industries and other Establishments)( Energy Intensive Industries and other Establishments)

(A programme to initially focus on energy policy issues of energy(A programme to initially focus on energy policy issues of energyefficiency improvement in organized sectors such as energy intensiveefficiency improvement in organized sectors such as energy intensiveindustries and commercial sector through establishment of energyindustries and commercial sector through establishment of energymanagement system, capacity building of energy professionals,management system, capacity building of energy professionals,implementation of energy audits, establishments of specific energyimplementation of energy audits, establishments of specific energyconsumption norms and support to consumers on providingconsumption norms and support to consumers on providinginformation on authentic energy data )information on authentic energy data )

Schedule to EC Act provides list of 15 energy intensive industries and otherSchedule to EC Act provides list of 15 energy intensive industries and otherestablishments to be notified as designated consumers (DC). DCs toestablishments to be notified as designated consumers (DC). DCs to

Appoint or designate energy managersAppoint or designate energy managers

Get energy audits conducted by accredited energy auditorsGet energy audits conducted by accredited energy auditors

Implement techno-economic viable recommendationsImplement techno-economic viable recommendations

Comply with norms of specific energy consumption fixedComply with norms of specific energy consumption fixed

Submit report on steps takenSubmit report on steps taken


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1) Criteria for Notification for a Industry as Designated Consumer

Thermal Power Stations- 30,000 metric tonne of oil equivalent (MTOE) per yearand above

2) Fertilizer- 30,000 metric tonne of oil equivalent (MTOE) per year and above

3) Cement- 30,000 metric tonne of oil equivalent (MTOE) per year and above

4) Iron & Steel- 30,000 metric tonne of oil equivalent (MTOE) per year and above

5) Chlor-Alkali- 12,000metric tonne of oil equivalent (MTOE) per year and above

6) Aluminium- 7,500 metric tonne of oil equivalent (MTOE) per year and above

7)Railways- One traction substation in each Zonal Railway , Production units andWorkshops of Indian Railways having total annual energy consumption of 30,000

MTOE or more under Ministry of Railways

8) Textile-3,000 metric tonne of oil equivalent (MTOE) per year and above

9) Pulp & Paper-30,000 metric tonne of oil equivalent (MTOE) per year and above


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The Ministry of Power, Government of India and GTZ (Deutsche

Gesellschaft fr Technische Zusammenarbeit (GTZ) GmbH) signed an

implementation agreement with respect to the Indo-German Energy

Programme in 2006.

The Indo German Energy Programme (IGEN) is performing researchwork and performance assessment in support of the implementation of

the Energy Conservation Act 2001 in cooperation with the Ministry of

Power and its statutory bodies Bureau of Energy Efficiency (BEE), and

Central Electricity Authority (CEA).

Under the IGEN agreement, CEA has been entrusted with the task of

ensuring performance optimisation and efficiency of thermal power

plants.

The Indo German Energy Programme (IGEN)The Indo German Energy Programme (IGEN)


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The overall aim of this measure under Indo Germany Energy

programme is to support and prepare public and private 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:

1. Mapping Studies of thermal power generating units

2. Performance Optimisation of Thermal Power Stations

The Indo German Energy Programme (IGEN)The Indo German Energy Programme (IGEN)


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GTZ has provided support to CEA in creating a database of the older

thermal power plants in India.

The scope of the work primarily covers the mapping of the 85 thermal

power generating units by using Ebsilon software.

The mapping is done for two-condition design status and the actual

operating status based on plant parameters gathered from different plant

locations.

Its primary purpose is to provide a baseline mapping for creating a

databasewithin CEA and identify areas both short and long term, needing

attention in order to improve energy efficiency.

The baseline map would permit an objective method of setting targets

and monitoring progress.

Mapping Studies of Indian Thermal Power StationsMapping Studies of Indian Thermal Power Stations

(Sub Component-I)(Sub Component-I)


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Mapping studies of 65 Thermal power generating units of the 14 Indian

States viz.

Andhra Pradesh, Chhattisgarh, Gujarat, Haryana, Jharkhand,Karnataka, Madhya Pradesh, Maharashtra, Orissa, Punjab, Rajasthan,

Tamil Nadu, Uttar Pradesh & West Bengal have been completed.

The mapping studies carried out by using Ebsilon Software have

brought out the deviations between design and operating parameters

such as gross heat rate, turbine heat rate, boiler efficiency , specific

coal consumption of the power generating units .

MAPPING STUDIES - PROGRESS ACHIEVEDMAPPING STUDIES - PROGRESS ACHIEVED


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1. The mapped thermal generating units were characterized by a wide

band of energy performance

2. Few of them were very closed to their designed energy performance,

but majority of them had deviated from their designed performance by

a bigger margin

3. Operating Gross Heat Rate was found to be varying from 2477 to 3084

kCal/kWh against their design values of 2321 and 2444 kCal/kWh

respectively, exhibiting deviation band width of 156 kCal/kWh (6.3%) to

640 kCal/kWh (20.7%)

Salient features of outcome of Mapping Studies ofSalient features of outcome of Mapping Studies of

twenty-six nos. of 210 MW unitstwenty-six nos. of 210 MW units


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4. For an average designed Gross Heat Rate of 2384 kCal/kWh for these

26 units of 210 MW capacities, the heat rate has increased by an average

value of 385 kCal /kWh, registering an average increase of 16% from theirdesign performance.


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5. The mapping studies have proved that older units having better

operation and maintenance practices can still demonstrate higher

performance than comparatively younger units. 27 % of 210 MW power

generating units, having age more than 25 years have shown better

performance than 54 %of 210 MW units in the age group of 14-25 years

Average Gross Heat Rate byage group (210 MW)

(as observed through Mapping Studies)


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6. The operating gross heat rate of turbines was found to be the major

contributor in the deterioration in the energy performance of 210 MW

units. The turbine gross heat rate varied from 2045 to 2407 kcal/kWh

indicating a wide difference of 362 kCal/kWh in the operating

performance of 210 MW turbine units, which is about 60% of the total

deviation (607kCal/kWh) observed for 210 MW generating units.

Turbine Heat Rate of 210 MW capacity units (kcal/kWh)


2407

2045

1900

2000

2100

2200

2300

2400

2500

A G H t R t b T bi T


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Average Gross Heat Rate by Turbine Type(210 MW)


12 units

13 units

One unit

2,400

2,450

2,500

2,550

2,600

2,650

2,700

2,750

2,800

2,850

2,900

kca

l/kW

h

Total average 2,783 2,739 2,806

Franco-Tosi KWU LMZ


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Average Gross Heat Rate by Boiler Type (210 MW)(as observed through Mapping Studies)

one unit

21 units

4 units

2,400

2,500

2,600

2,700

2,800

2,900

3,000

kca

l/kWh

Total average 2,906 2,745 2,783

ABL BHEL Transelectro


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Boiler Efficiency of 210 MW capacity units (%)


84.20

77.25

82.00

74.00

76.00

78.00

80.00

82.00

84.00

86.00


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Percentage of Auxiliary Consumption of 210MW capacity units (%)

11.82

8.07

6.5

7.5

8.5

9.5

10.5

11.5

12.5


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The overall aim of this measure is to support and prepare public and

private 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 theEnergy Conservation Act.

This phase has been initiated with effect from 15th January, 2008 and is

expected to be completed by 15th January, 2010. The following 5

outputs are planned:

Performance Optimisation of Thermal Power StationsPerformance Optimisation of Thermal Power Stations

under IGEN Programmeunder IGEN Programme

(Sub Component II)(Sub Component II)


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1. Capacity building of power plant personnel and Technical assistance

for conduct of high quality energy audits

2. Technical assistance in the establishment of energy management

system in the power plants

3. Annual statistics of validated impact of energy conservation in power

plants

4. Familiarization and interchange of best practices with power plant

operators in Germany or Europe

5. Development of electronic data base to analyze the findings of all

energy audit reports carried out in power plants and assessment of

impacts with respect to energy conservation and efficiency.

Performance Optimisation of Thermal Power StationsPerformance Optimisation of Thermal Power Stations

under IGEN Programmeunder IGEN Programme

(Sub Component II) Contd(Sub Component II) Contd


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The following progress has been achieved in the past 6 months since theinitiation of the activities with effect from 15th January, 2008.

Output 1

Technical Assistance for Conduct of High Quality Energy Audits

1. 1 Survey of best practices on power plant performance monitoring in

Germany / Europe, data generation and its analysis, software and

analytical tools used, on line as well as mobile measuring instruments,

newest trend in power plant performance optimization, etc.

-- (completed)

PERFORMANCE OPTIMISATION OF THERMAL POWERPERFORMANCE OPTIMISATION OF THERMAL POWER

STATIONS - PROGRESS ACHIVEDSTATIONS - PROGRESS ACHIVED


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1.2. Organization of 20 workshops and 20 seminars to disseminate findings

across India

--- Workshops & Seminars across the country in progress.

1.3 Development of standard procedure for energy auditing of power

plants and its finalization

--- Application of guidelines for energy auditing of thermal power

plants manual prepared

1.5 Undertake statistical analysis of 100 energy audit reports prepared by

accredited energy auditors for assessment of their quality and findings

---- (Received 25 reports from power stations and evaluated for

statistical analysis on the qualitative assessment such as areas

covered, quality of reports, probing skills, report structure etc.)

O t t 2


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Output 2

Technical Assistance in the Establishment of energy management system in

the power plants

2.1 Development of a model organizational structure for establishing Energy

Management Cells, employing certified Energy Manager, based on the outcome

of the survey of all public and private power plants

--- in progress

2.2 Discuss with public & private power plants owner findings in workshops and

present a common most preffered energy conservation studies plan and delivery

mechanism

Miscellaneous:

To promote energy efficiency improvement in the power plants, a new home page on

"Power Plant Optimization" Component has been established w.e.f May, 2008 in

www.energymanagertraining.com .


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The following outcomes are expected of the programme:

a. Assistance in the improved efficiency of thermal power plants

b. Establishment of mapped power plants data bank

c. Establishment of Energy Efficiency cell at Power Plants

d. Capacity building of the power plant professional on power plant

optimization

e. Standard Prescribed format for submitting Energy Audit Reports.

Outcome Expected from IGENOutcome Expected from IGEN


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CONCLUSIONSCONCLUSIONS

The increasing preference for commercial energy has led to aThe increasing preference for commercial energy has led to asharp increase in the demand for electricity and fossil fuels.sharp increase in the demand for electricity and fossil fuels. Use of Fossil Fuels result in emission of huge quantity ofUse of Fossil Fuels result in emission of huge quantity of

carbon dioxide causing serious environmental damages.carbon dioxide causing serious environmental damages. There is a considerable potential for reducing energyThere is a considerable potential for reducing energy

consumption by adopting energy efficiency measures inconsumption by adopting energy efficiency measures inthermal power stations of our country.thermal power stations of our country.

Energy efficiency will not only reduce the need to create newEnergy efficiency will not only reduce the need to create newcapacity requiring high investment, but also result incapacity requiring high investment, but also result insubstantial environmental benefitssubstantial environmental benefits..

With the enactment of the Indian Energy Conservation Act,With the enactment of the Indian Energy Conservation Act,2001, an institutional framework is now available for2001, an institutional framework is now available forpromoting energy efficiency in all sectors of the economypromoting energy efficiency in all sectors of the economy

Efficient use of energy and its conservation will succeed as aEfficient use of energy and its conservation will succeed as aprogram if there is a strong institutional set up in the countryprogram if there is a strong institutional set up in the countryand opinion leaders and captains of industry take lead inand opinion leaders and captains of industry take lead inimplementing the best practices supporting the conservationimplementing the best practices supporting the conservationprogrammeprogramme


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1b.promotion of energy conservation in indian thermal power

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