cenpeeppresen_et 2008_ 16 dec08

7/31/2019 CenPEEPPresen_ET 2008_ 16 Dec08

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CenPEEP Overview & Activity

Importance of Efficiency & Availability

Parameter Impact on Heat Rate

PDM Activities

Efficiency Management System

Methodology & Recognitions

Presentation Coverage

CenPEEP: An institution set up to reduce GHG Emissions


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CenPEEP Overview & Activity


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Protocol of Intent signed in July94 between:NTPC / Ministry of Power & USDOE / USAID-India

CenPEEP inaugurated by US Secretary of Energy.

A joint Indo-US climate change initiative in PowerSector

Centre for Power Efficiency & Environmental Protection

CenPEEP

Project launched in October 1995 with initial end date asMarch 2002; Project extended upto 2005, subsequently

upto 2008; and now upto 2010


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Development of an Institution in power sector in India

CenPEEP GOALS

To reduce GHG emissionfrom coal fired thermal

power plants by performance optimizationin terms

of efficiency, availability & reliability.

Technology acquisitionfor performance

optimization

Institutionalizationof cooperation for technology

transfer.


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Importance Of Efficiency and Availability

New Regulatory Norms

Increased Capacity

Reduced Cost of Generation

Increased Competition

Detect degradation in thermal performance

Develop cost effective solution to correct degradationin thermal performance.

Reduced Environmental Impact- Stack Emissions- Heat Rejected


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Test


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TYPICAL LOSSES

Description Loss (%)

BOILER 11.0

TURBINE CYCLE 44.7

TURBINE-GENERATOR 6.1

STATION AUXILIARIES 2.0

Total 63.8


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Major Factors Contributing to the Losses

Boiler Efficiency Degradation

High Flue Gas Exit Temperature High Unburnt in Bottom/Fly Ash Poor Air Heater Performance Dirty Boiler

High RH/SH Spray

Maintaining Low Parameters

Factors Affecting Performance Degradation


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Major Factors Contributing to the Losses

Poor Condenser Performance Tube Fouling Air Ingress High CW Inlet Temperature

Poor HP / IP /LP Turbine Efficiency

Poor HP Heater Performance

Poor BFP Performance

Passing of High Energy Drain Valves, RH Spray

Valves, BFP Recirculation Valves

Factors Affecting Performance Degradation


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Parameter Impact on Heat Rate


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EFFECT OF CRITICAL PARAMETERSON HEAT RATE

OFF - DESIGN CONDITIONS

Parameter Deviation Effect on Heat

Rate

Main Seam Temp. -5 oC +2.3 Kcal/kwhMain Steam Press. -1 Kg/cm2 +1 Kcal/kwhReheat Temperature -5 oC +2.3 Kcal/kwhReheat Spray +1%

(Throttle

Flow)

+2.4 to 3.6Kcal/kwh

Condenser BackPressure

+1 mmHgA

+2.0 Kcal/kwh

FW Temperature - 1 oC +3.5 Kcal/kwh


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Typical Station Heat Rate Deviations

102.31 kcal/kWh60 - 150 kcal/kWh

30 - 60 kcal/kWh

Unaccountable Losses25 % (~ 30 kcal/kWh)

Accountable Losses75 % (~ 90 kcal/kWh)

25 35 kcal/kWh

75 105 kcal/kWh

Cost Effective Performance Improvement


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Annual Impact of 1 kcal/kWh Improvement

9.95.5200 MW

24.713.5500 MW

RailfedStation

Rs Lacs/Year

PitheadStation

Rs Lacs/Year

UnitCapacity

Does 1 kcal / kwh matters to us?


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Typical Cost Implication of Coal Stations

Cost SavingPer Year

Rs. 6.85 Cr

Coal SavingPer Year

46800 Tons

Impact of HR

Deviation

1 kcal/kWh


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Output Sharing by Turbine CylindersHPT 28%IPT 23%

LPT 49%

Impact of Turbine Efficiency on HR/Output

Description Effect on TurbineCycle HR Effect onKW Effect on output fora 200 MW Unit

1% HPTEfficiency

0.16%

(appr 3 kcal)0.3% 600 kW

1% IPTEfficiency

0.16%

(appr 3 kcal)0.16% 320 kW

1% LPTEfficiency

0.5%

(appr 10 kcal)0.5% 1000 kW


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HP Heaters have direct impact on machine reliabilityand plant Heat Rate / Efficiency.

Heat Rate Loss in a 210 mw Unit in case

HP Heaters not in serviceis about 68 kcal / kWh

Impact of Heater Performance

Annual Impact for one 210 mw Unit

Increase in Coal Consumption 32,100 Tons

Additional Coal Cost (for rail fed) 7.1 Cr


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Effect of Condenser Vacuum on Heat Rate and O&M cost

10 mmHg Improvement in CondenserVacuum Leads to 20 Kcal/kwh Improvement

in Heat Rate for a 210 MW Unit

Annual Impact for one 210 mw Unit

Saving in Coal Consumption 9400 Tons

Saving in Coal Cost (for rail fed) 2.1 Cr


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PDM Activities


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Type of Maintenance Activities

Emergency corrective repairs on critical

equipment Daily/outage scheduled corrective activities

Periodic material replacement Intrusive inspection including open and

inspect.

Non-intrusive inspections, diagnostic tests like Vibration Monitoring, Oil analysis etc

CM

PM

PdM

Forced

Preventive

Predictive

PAM Root Cause Based Maintenance to eliminatethe Maintenance requirement

Proactive


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Predictive Diagnostics Maintenance (PDM)

or Condition Based Maintenance (CBM) isbest strategy and can eliminate PreventiveMaintenance (PM)?

PDM can reduce PM & CM (Breakdown Maint),not eliminate

Economic Mix of all is desirable

PdM CM

PM

PAM

Present

PM

CM


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Preventive Maintenance (PM)

Corrective Maintenance (CM)

Proactive Maintenance (PAM)

Predictive Maintenance (PdM)

Reliability Centered Maintenance (RCM)

Risk Evaluation & Prioritization (REAP)

Knowledge Based MaintenanceRoad-Map

Weare

here(2008) We

werehere

(2003)


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One technology is not adequate fordiagnostics e.g. DGA for transformers &

vibration for rotating machines

MotorCurrent

Lube Oil

Thermography PerformanceMonitoring

Vibration

Pressure

To ControlRoom

Use Of Multiple Technologiesand integration of data is

essential


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Periodic Condition Monitoring Systems

Thermography

Periodic Vibration Monitor Acoustic Leak Detection and Corona detection (air-borne)

Acoustic technology: partial discharge intransformers & for mechanical equipment ( contact

method) Lube Oil Monitoring Electrical tests (Motor Current Monitoring:Broken

Rotor Bars)

DGA in oil for transformers

USE OF MULTIPLE TECHNOLOGY ON EACH EQUIPMEMTUSE OF EACH TECHNOLOGY FOR MULTIPLE EQUIPMENT ( whereever applicable)


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GoalThe goal of RCM is to preserve

equipment functionwith the

required reliability and availabilityat the lowest cost.

MethodologyIdentification of failure modes

and selection of appropriate

task/strategy for its mitigation.

RCM(Reliability Centered Maintenance)


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RCM is based on answers to7 FUNDAMENTAL QUESTIONS

for each Equipment

(and if necessary for the component)

1. What are the functions and associatedperformance standards of the assets in itspresent operating context?

2. In what ways does it fail to fulfill its functions?3. What causes each functional failures?4. What happens when each failure occurs?5. In what way does each failure matter?

6. What can be done to predict and prevent eachfailure?

7. What if a suitable pro-active task can not befound?


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PdM Process: Information to Action

Communication is 70% of the Issue

AcquireData Infer InformationFrom Data

TakeCorrectiveAction

Utilize Field and PersonnelExperience

Utilize Analysis Systems and NeuralNetworks

Maintenance Orders PostMaintenance Tests Operations & Procedures

Adjusted

Maintenance HistoryOperators LogBatch TestsDesign InformationProcess Parameters(Temperature / Pressure / Flow)

Predictive and Condition

monitoring techniquesPerformance

(Oil Analysis/ vibration

/ thermography, acoustics etc.)

NDE Inspection

Visual Inspection

FEED BACK

Technologies are fascinating but they are only tools


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REAP : Risk- evaluation and prioritizationFinancial Risk Optimization (FRO)

FRO is a tool for Prioritization of Maintenance & planEvaluation

A risk prescreening of what needs to be addressed

using five yrs. Historical outage data.

A tool to decide what, when & worth?

Correlates Engineering input to Financial Risk.

The timing of risk critical components

repair/replacement decision.

The value of pursuing the decision timing

considering the constraints of budget etc.


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FRO Implementation Steps

Step 1.1: Screening risk critical equipment: Responsible for Generation Loss.

Step 1.2: Additional Screening for risk critical equipment: Equipment of concern for efficiency Equipment of concern for safety & environment

Finalization of top 20 Risk Critical equipment

Risk Evaluation and Maintenance Prioritization

Maintenance plan Evaluation

Step 2.1:Financial information for FRO

Step 2.2:Determination of probabilities for future.Step 2.3 :Running FRO tools for evaluation of alternate maintenance

plans


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Efficiency Management System


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Performance Evaluation & Action Plan

Performance Optimisation

Recovery of Efficiency Loss

Sustainability through Institutionalisation of Program

An Approach for Sustainable Improvement ofPerformance of Power Plants


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Monitoring of critical parameters and reducingthe deviations

Preparation of daily/monthly Heat Ratedeviation reports

Periodic testing to assess current performancelevel using accurate off-line instruments

Standardization of routine test procedures

Action plan - based on Heat Rate Deviationsand Economic considerations

Evaluation of maintenance and sustainability ofperformance

Methodologyfor Implementation

Station EEMG Structure & Function


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Station -EEMG Structure & Function

( Energy & Efficiency Management Group)

Role & Responsibility of MIS

Management Information Reports Coordination for ORT Coordination with Regional

HQ/REBs Tripping Analysis Coal Stock Survey Oil stock/procurement

Commercial activities,ABT etc

Role & Responsibility of PMG

Parameter monitoring,trending& analysis

Online / Offline Performancetest of system

Daily/Monthly HR Dev. Reports Action plan for corrective

measures

Critical InstrumentPerformance & calibration Implementation of Efficiency

related aspects during O/H Mathmodelling for diagnosis &

analysis Monitoring of APC/Sp.Oil /

Make-up. Monitoring of unit light-ups

PMSGat Region

EEMG Energy & Efficiency Management GroupCEETEM Center for Energy Efficient Technology

& Energy ManagementPMSG Performance Management System GroupSMSG Station Monitoring & Support Group

PMG - Performance Monitoring Group

R i EEMG S & F i


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Region -EEMG Structure & Function

Regional OS

PMSG /

Regional CenPEEPSMSG

ED - Region

Offline performance test(GTCHR, Blr Optimization)

Parameter monitoring ,trending & analysis

Plant Performance Audit

Review of Monthly HRDev. reports

Follow up of action plan Monthly Exception report

on EEMG to CC Training of EEMG Exec.

ManagementInformation Reports

Conducting ORT Fixing PerformanceTargets

Performancemeetings at Station

Coordination onRegulatory Issues

Corporate Centre Structure & Function


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CC - CenPEEPCC - OS

Corporate Centre -Structure & Function

Director(Operation)

Ensure Uniform Practice for performance improvement Developing standardized testing & reporting procedures Providing Guide lines for computation of performance of

equipments & system Providing Software support Technical Support to Regions & Stations Data Bank of Equipment / System / Curves etc. Off line performance testing & combustion optimisation

Performance monitoring ,trending and analysis. Review & Follow up of action Plans Training of Executives Issues to be taken up with Engg. New technique & system Review of Monthly HR Dev. reports Ensuring inclusion of Efficiency related activities in O/H.

Plant Performance audit

PMSG /

Regional CenPEEP


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METHODOLOGY for SUSTAINABILITY

&RECOGNITIONS


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High PLF & Availability translate into OptimumEfficiency

Equipment maintenance to be taken-up based onperiodic overhaul schedule

Boiler performance degradations has no relationto Turbine Cycle performance

Some of the Myths

Impact of Efficiency Improvements


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Win-Win Strategy

Harmony

Global Concerns Utility concerns

Pollution Global Climate

GHG emissions Particulate

emissions Ash pollution

Sustainablegrowth

ProfitabilityPublic

image

EfficiencyAvailabilityO&M costs Industry Norms

CenPEEP


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GEPPartners

NTPCGuj. Gen CoMahaGen COAP Gen COPSEB

UPRVUNWBPDCLJharkhand IPGCL

USDOE NETL EPRI TVA

GAI Southern

Research Structural Int. Others as req.Indian Partners US Partners

CenPEEP

Guided byAdvisory Board & Executive Committee

Consisting of NTPC, USAID and members from Govt of India, State & Private

Power Utilities, industry association, research institutes, etc.

Methodology


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Training &Technology

Dissemination

Technology

Demonstration

TechnologySelection &

Acquisition

TechnologyTransfer

MethodologyIntroduction of Techniques, Systems & Practices for

Performance Optimisationof existing coal fired power

stations and new power generation technologies

Success factors

Sustainabilitythrough

Systems & Procedures

Institutionalization

Thrust on low cost / high benefit technologies for sustainability


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Condenser Tube Cleaning byWater Powered Cleaners

Water Powered Gun used to push bullets

(scrapper) to clean condenser tubes;

Most effective and low cost technology

NON UNIFORMAir-fuel ratio in Four Corners


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NON- UNIFORM Non optimum

combustion

Higher fuelconsumption Higher CO2

UNIFORM Optimum

combustion

Lower fuelconsumption Lower CO2

Coal Pipes Bad Flame

Good Flame

Air-fuel ratio in Four Corners


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>150.0C

#3 >#1

Effective method to identify valve leakage & repair priorities

Valves are unaccountable culprits of efficiency loss

Temperature as per Colour Scale

Pl t P f O ti i ti A h


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Plant Performance Optimization Approach

Best Efficiency &

Lowest GHG emission

Methodology

Identify majorproblem areasof degradation

Evaluation ofeffectiveness ofimprovementactivities

Focus on eachsub-system &component

Health of each

componentdetermineshealth of theequipment

HR

Unit availability

Boiler Turbine

Air Pre Htrs.

Mills & Burners Condenser & CW System

HP& IP Turbine

BFP & HP/LPHeaters

Boiler Pressureparts

Coal handling system Gen; X-mer & switchyard

Human Element

HR Improvement Program


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HRIP

Accurate GapAssessment

PIPs

Gap analysis

Action Plans

ResourceMobilizationImplementation

Retrofits

Evaluation &Dissemination

Focus on:1. Evaluation, recovery and controlling degradations in

Individual Equipment

2. Forced outage reduction & availability improvement

HR Improvement Program

NTPC C PEEP C ib i


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NTPC-CenPEEP Contributionfor

GHG Reduction Program

Whole time executives deployed at Corporate & Regional

CenPEEP: 25

Dedicated infrastructure for Corporate & regional ( lab,

library, Conf room, office set-up etc.) Manpower augmentation at Stations to take up CenPEEP

program: 40

Training set-up at NTPC Power Management Institute

Equipment for efficiency and availability improvement atStations: Rs. 100 million ($ 2.5 million)

Equipment at CenPEEP: Rs. 10 million ($ 250,000)

This excludes EPRI membership: $ 940,000

Widespread Dissemination


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125 Workshops on Boiler & TurbinePerformance Analysis & Improvement;

Diagnostics and Knowledge basedMaintenance

14000 Training man days - Participantsfrom NTPC, DVC, GSCEL, UPRUVNL,TNEB, APGENCO, PSEB, RRUVNL, MSEB,IPGCL etc.

319 Demonstrations - Hands-on trainings

Guidelines on Thrust areas

Papers at various conferences Customized training programs organized

at SEBs as per their needs

Widespread Dissemination

Quarterly newsletter

Optimisersavailable on NTPC website

Supported by 48 US team visits of over 1050 man days


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CTIs World

ClimateTechnologyAward 2002

USEPA CLIMATEPROTECTION

AWARD 2003

Awards & Recognitions

CenPEEP IS A SYMBOL OF SUCCESSFUL

INTERNATIONAL COOPERATION FOR GHG REDUCTION


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Thank You

cenpeeppresen_et 2008_ 16 dec08

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