low cost energy efficiency measures...
TRANSCRIPT
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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
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Aux Power Reduction Projects……… 8 Slides
Energy Efficiency Enhancement Projects……… 4 Slides
Renewables based Projects……… 10 Slides
Presentation Outline
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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
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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:
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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
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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
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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
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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
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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
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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
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Aux Power Reduction Projects……… 8 Slides
Energy Efficiency Enhancement Projects……… 4 Slides
Renewables based Projects……… 10 Slides
Presentation Outline
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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
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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
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EIDM
ChemAnalyser
P3E
Low Cost Energy Efficiency Measures – NTPC’s Experience
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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
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Aux Power Reduction Projects……… 8 Slides
Energy Efficiency Enhancement Projects……… 4 Slides
Renewables based Projects……… 10 Slides
Presentation Outline
![Page 17: Low Cost Energy Efficiency Measures –NTPC’sExperiencesteag.in/sites/all/themes/steag/resource/Session3/Tools_for... · NTPC Energy Technology Research Alliance Implementation](https://reader036.vdocuments.us/reader036/viewer/2022081819/5a71d9577f8b9ac0538d35bf/html5/thumbnails/17.jpg)
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
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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
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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
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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
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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
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P&ID:
Low Cost Energy Efficiency Measures – NTPC’s Experience
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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:
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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
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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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Thank Thank YouYou