low cost energy efficiency measures...

NTPC Energy Technology Research Alliance

Implementation of PAT Scheme in Thermal Power Stations - Issue & Challenges

Low Cost Energy Efficiency Measures – NTPC’s Experience

At

India Habitat Centre

Presented For

30th Jan’2015

Aux Power Reduction Projects……… 8 Slides

Energy Efficiency Enhancement Projects……… 4 Slides

Renewables based Projects……… 10 Slides

Presentation Outline

Low Cost Energy Efficiency Measures – NTPC’s Experience

Back Ground:A typical 210 MW unit consumes coal equivalent of 550 MW and reject 350 MW – 125 MW in Chimney & 225 MW in Cooling TowerThere is large potential to capture & utilize this low grade energy

Project: Low Grade Flue Gas based Air Conditioning

Status: Implemented at NTPC Ramagundam Coal Station – Oct’13

Unit Size MWe

Heat Recovery (140-110C)

(MWth)

Eqv. Air Conditionin

g (TR)110 4.8 960210 7.9 1600500 17.6 3520

Cooling Water

Chilled Water

Flue Gas

Hot Water

4

Stack

BoilerESPID Fan

Slip Stream`

Fan (VFD)

Flue Gas Heat

ExchangerHeat

Recovery (500 kW th )

Pumps

DM Water Make up

Vapor Absorption Machine(VAM)

100 TR

Hot water

150 oC110 oC

12 oC90 oC

80 oC

7 oC

ESP &

ASPH CR

Steam heat ex standby

Cooling Tower

40 T/hr

32 oC

pump

Pumps

38 oC

Low Cost Energy Efficiency Measures – NTPC’s Experience

Process Flow Diagram:

5

Benefits:APC Saving: ~ 0.4 MU/YrCO2 avoided: ~ 312 Tons/YrGreen House Gas (CFC & HCFC) free A/C system Huge scale-up potential

Methodology:Waste heat is used to generate hot water which drives a Li-Br based Vapor Absorption machine (VAM)Chilled water generated from VAM is distributed to different locations (ESP Control rooms) for Air conditioning.

Low Cost Energy Efficiency Measures – NTPC’s Experience

Low Cost Energy Efficiency Measures – NTPC’s Experience

Project: Low Grade Flue Gas based Desalination

Status: In Tendering, at NTPC Simhadri, completion by Mar’16

Methodology:Waste heat is used to generate hot water (~90C)Hot water is flashed to produce Low Pressure Steam (~0.32 ata)LP Steam is used to drive a Multi Effect Distillation System and produce sweet water from sea water

Low Cost Energy Efficiency Measures – NTPC’s Experience

Salient Details:Plant Capacity: 120 TPDGain Output Ratio (GOR) ≥ 6

Benefits:Energy Saving: ~ 16 GJ/YrNo need of Sweet water - DM Water directly from Sea WaterOperating temperature below solubility temperature - No chemicals

Benefits:Korba (U #5,6)

4-5 deg C increase in PAPH air outlet tempTanda (U #1,2,3,4)

50 kW/Fan ID Fan power saving in Tanda50 mmWC pressure drop reductionNo duct repair work done in next overhaul

Vindhychal (U #2,5)13 mmWC Pressure drop reduction35 kW/Fan ID Fan power savingNo duct repair work done in next overhaulDecreased ESP pass flow variation 23% to 5%

CFD Results for Tanda 110 MW unitVSTPP U#5 FG flow at different ESP passes

291269

286 296287

371358

306

250270290310330350370390

ESP_OUT-A ESP_OUT-B ESP_OUT-C ESP_OUT-DESP Pass

Flow

in T

/hr Before

After

Non uniform flow in ESP passes

Status: Implemented at Korba, Tanda & Vindhyachal

Low Cost Energy Efficiency Measures – NTPC’s Experience

Project: CFD modeling for Duct for reduction of Aux Power & Erosion

Low Cost Energy Efficiency Measures – NTPC’s Experience

Description:Motor up-gradation (18 No's) for VFD operation with in-house developed refurbishing technique.VFD panel with bypass contactor arrangement. Closed Loop CT Fan’s speed control – based on Condenser heat load & Ambient condition.Remote Operating Work Station (OWS) at CCR with Fibre Optic communication.

Project: Up-gradation of motors winding & VFD retrofitting in Cooling Tower Fan

Status: Implemented at NTPC Dadri Gas Station – Dec’13

Benefits :APC saving: ~ 1.14 MU/YrCO2 avoided: ~ 436 Tons/YrIntelligent Control of CT fans.Smooth fan start - Low stress of gear box, bearings.Enables overload operation of motor.

Motor Insulation SchemeMotor Insulation Scheme

Key features:Enhanced thermal & di-electric capability.RTDs embedded in stator slots for temp feed back.All CT-1 motors (18 Nos) refurbished at Dadri electrical workshop.

Low Cost Energy Efficiency Measures – NTPC’s Experience

Aux Power Reduction Projects……… 8 Slides

Energy Efficiency Enhancement Projects……… 4 Slides

Renewables based Projects……… 10 Slides

Presentation Outline

Low Cost Energy Efficiency Measures – NTPC’s Experience

Project: NTPC e-Power Plant Solution (NePPS)

Status: Implemented at NTPC Talcher Kaniha & Simhadri

Salient DetailsAimed towards (i) Process Optimization and Performance improvement & (ii) Early Warning and DiagnosticArtificial Intelligence based system - ANN, Genetic Algorithm (GA), Pattern Recognition, Fuzzy rule base Fleet wide performance monitoring with access from plant, region and CorporateDeveloped in ‘Service Oriented Architecture’ (SOA)

Performance

Improvement

DVR

GA Optimizer

Real time Data setFor self learning

NN Inputs(Controllable & Uncontrollable)

Inputs to be optimized

Obj Fun(Blr Effi)

Inputs

Constraints

Real time Operator Advisory

+ DCSSet Point

PID control loop

Set point correction

Energy  Intensification  and  Diagnostic  Model  (EIDM): Artificial Intelligence (AI) based modeling and optimization software for real time operator advisory. Have features of Retraining 

Low Cost Energy Efficiency Measures – NTPC’s Experience

EIDM

ChemAnalyser

P3E

Low Cost Energy Efficiency Measures – NTPC’s Experience

WB Pr: 87 # 78 mmwcBurner Tilt: 60 # 64

WB Pr: 85 # 91.1 mmwcWB Pr: 75 # 99 mmwcBurner Tilt : 72.7 # 69

O2% : 3.2 # 2.9

Burner Tilt : 70 # 62.5O2% : 2.84 # 2.69

Energy Intensification and Diagnostic Model (EIDM) Testing and Results

Low Cost Energy Efficiency Measures – NTPC’s Experience

Aux Power Reduction Projects……… 8 Slides

Energy Efficiency Enhancement Projects……… 4 Slides

Renewables based Projects……… 10 Slides

Presentation Outline

Steam Separator

Pump

Steam to VAM

Solar Paraboloid Dish

Solar BlockFresnel Paraboloid

Solar DishSteam Separator

Air Conditioning Block

Li-Br Double effect VAMChilled Water Tank

Condensate from VAM

Project: Solar Thermal HVAC System

Status: Implemented at NETRA – June’12

8 Bar, 1730 C

1 Bar, 650 C

9 Bar, 650 C

8 Bar, 1730 C

Low Cost Energy Efficiency Measures – NTPC’s Experience

18

Mode of Operation:Mode-1, Working dayMode-2, Weekend & HolidayMode-3, Lean Solar period

Low Cost Energy Efficiency Measures – NTPC’s Experience

Benefits:APC Saving: ~ 0.1 MUs/YrCO2 avoided: ~ 90 Tons/YrLow Carbon, Green House Gas (CFC & HCFC) free A/C system Capable of operating in both Cooling as well as Heating Mode

Low Cost Energy Efficiency Measures – NTPC’s Experience

Project: Solar Thermal Hybrid Plant

Status: NIT by Feb’15

Salient Merit (vis-à-vis Stand Alone Solar Thermal Plant)Higher Thermal Efficiency: 24.39% against 16-18% of stand aloneLow Capital Cost: No separate turbine block, No additional DM PlantLow Operational Cost: No TG auxiliaries -Lo APC & DM makeupNo daily start-stop: Independent of solar radiation.Higher CUF: No daily TG rolling, Lower start-up time.No Thermal Energy Storage: Not required for hybrid operationReduction in CO2 Emission: 4060 Tons /year (approx)

Technology:Solar: Single / Two Axis Tracking, Concentrated Solar Thermal Power Generation & Evacuation: Thru existing Turbo-Generator & Switch Yard

Integration Configuration

FW 200 Bar / 200 C / 600 TPH

NTPC’s Existing System

Proposed System

Control Valve: Used to regulate the flow of feed water in solar heat exchanger according to varying Solar Radiation with a view to maintain required temperature at HPH-6 outlet

From HPH-5 To Economizer

Solar Field

Steam 40 Bar / 350 C

FW 170 Bar / 247 C / 600 TPH

Steam Separator

Solar Heat Exchanger

Pump

Saturated Steam

Control Valve

Drain To HPH - 5

From HP Turbine

200 C / 200 TPH

Wet Steam

64.2 Bar, 280 C

Process Patent Filed

HPH-6

FW 200 Bar / 200 C / 400 TPH

Condensate, 250 C

280 C

65 Bar, 280 C 70 Bar

247

C /

200

TPH

Low Cost Energy Efficiency Measures – NTPC’s Experience

Project: Solar Thermal Cooking System

Status: Under Execution at NTPC Dadri, completion by July’15

Salient DetailsAll mode of cooking possible i.e Boiling (100C), Frying (220C) and Baking (270C)All weather solution – thru integrated LPG fired Thermic Fluid HeaterQuick Start Up – Sp. heat of Thermic Fluid is 0.58 vis-a-avis 1 of waterThermal Energy StorageNo steam – no scale – no chemicalDelinked Solar & Cooking Block

Solar Block

(2 No of Two Axis Tracking, Paraboloid 

Solar Dish)

Cooking Block

(2 No each of Boiling Vessel. Frying Pan & 

Tawa)

Balance of Plant

(LPG Fired TF Heater, Expansion Tank, Pumps, 

PLC etc)

Block Diagram

P&ID:

Low Cost Energy Efficiency Measures – NTPC’s Experience

0

50,000

100,000

150,000

200,000

250,000

JanFe

bM

ar Apr

May Jun JulAu

gSe

pt OctNo

v De

c

Energy (kcal/day)

Solar Energy

Cooking  Energy Required / Day: 2.15 Lac Kcal

1.75 Lac Kcal/Day Solar Cooking System for Main Plant Canteen

(at the 500 W/sq.mtr DNI)

69 75

93

83 91

77

0 0

73

89

67

81

24 9

0

7

2

13

96 93

17

4

23

12

0

20

40

60

80

100

LPG Cylinde

rs / M

onth

Consp 24 9 0 7 2 13 96 93 17 4 23 12

Saving 69 75 93 83 91 77 0 0 73 89 67 81

Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov  Dec

LPG cylinder consp:Present: 1095/YrWith STCS: 400/YrCO2 avoidance: 40 T/Yr

Low Cost Energy Efficiency Measures – NTPC’s Experience

Benefits:

Key FeaturesWeb based Remote MonitoringSeasonal tiltString MonitoringPipework for panel cleaning

Salient DetailsInstalled Capacity:110 kWpCollector Area:1,560 Sq.m

BenefitsEstimated Generation: 0.17 MUs / YrCO2 avoidance: 163 Tons / Yr

Project: Remotely monitored 110 kWp Solar PV Rooftop as R&D test bed

Status: Implemented at EOC Annexe Noida – Oct’14

Low Cost Energy Efficiency Measures – NTPC’s Experience

Project: Integration of rooftop PV with existing 24 V DC battery charger

Status: Under installation at NTPC Unchahar

Low Cost Energy Efficiency Measures – NTPC’s Experience

Configuration: Solar PV DC system installed on TG roof & integrated to existing DC battery charger system feeding DDCMIS load.

PV Panels

Charge Controller

LOAD (DDCIM

S)

Present Charger

3 Phase, 415V AC 24V

DC BUS

Interconnection Point

At TG Roof

Battery

Benefit:APC Saving: ~ 30,000 Units/YrCO2 avoidance: ~ 24 Tons/Yr

Salient DetailsSolar Block : 16 kWpSize of Charger : 400 AExisting charger efficiency : 70%

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