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CenPEEP

CenPEEP

USUS-India 2nd Energy Efficiency Technology Cooperation Conference

Coverage
Energy Efficiency in Power Sector Indian Experience

i. Importance of Efficiency and Availability


ii. CenPEEP iii. System, Practices and New techniques iv. Issues/Challenges and Conclusion

3 Slides 5 Slides 9 Slides 3 Slides

17 Nov, 2009; New Delhi

Centre for Power Efficiency & Environmental Protection (CenPEEP)

CenPEEP

CenPEEP

Plant Performance Indices: Heat Rate (HR)


HR of Coal fired power plant: measure of efficient conversion of chemical energy (fuel) into electrical energy. If a power plant operates at 100% efficiency, the heat rate will be 860 kcal/kWh. Currently, a state-of-art power plant has a design HR of 2100 - 2200 kcal/kWh i.e. about 39 - 41% efficient.
Indian power sector 1% increase in Efficiency would result in
Coal savings of approx. 12 million tons per annum Rupees savings worth Rs.19,000 Million CO2 reduction per annum approx.14 million tons

Efficiency Improvements
Some of the Myths
High PLF & availability translates into Optimum Efficiency Heat rate is the responsibility of Efficiency Management Group at Stations Equipment maintenance to be taken-up based on periodic overhaul schedule Boiler performance degradations has no relation to Turbine Cycle performance Heat rate improvement requires large investment. Results follow immediately after testing is completed.

CenPEEP

CenPEEP

Energy Efficiency Drivers


Reduced GHG Emissions & Conservation of Natural Resources Increased Capacity Reduced Cost of Generation Increased Competitiveness Ease of compliance to New Regulatory Norms Efficiency Monitoring: Early Diagnosis and effective maintenance planning Cost effective solutions for Thermal performance improvement

Coverage
i. Importance of Efficiency and Availability 3 Slides 5 Slides 9 Slides 3 Slides

ii. CenPEEP
iii. System, Practices and New techniques iv. Issues/Challenges and Conclusion

CenPEEP

CenPEEP

Center for Power Efficiency & Environmental Protection (CenPEEP)


Global Concerns GHG Emissions / warming Emissions from coal usage Sustainable growth Utility Concerns Efficiency improvement Availability improvement O&M costs - Profitability

CenPEEP Partners
In 1996, agreed to establish

CenPEEP
Established by NTPC in collaboration with USAID in 1995 to reduce GHG emissions from coal-fired power plants.

NTPC Guj. GenCo Maha GenCo AP GenCo PSEB UPRVUN WBPDCL MPGENCO IPGCL TNEB

CenPEEP
USDOE NETL EPRI TVA USEA General Physics Storm Tech Structural Int. (SI) Domain Experts

To implement Greenhouse Gas Pollution Prevention (GEP) Project

The Centre functions as a Resource Centre for acquisition, demonstration & dissemination of state-of-the-art technologies and practices for performance improvement

Guided by Advisory Board & Executive Committee


Consisting of NTPC, USAID, and representatives from Govt. of India, India, State & private power utilities, industry associations, research institutes, etc.

CenPEEP

CenPEEP

Partnership with US Energy Agency (USEA)


Objectives:
Overhauling and maintenance practices Increasing interval between overhauls Decreasing overhaul duration Sustaining high efficiency Identification of new systems and practices
Australia

CenPEEP Role in Asia Pacific Partnership (APP)

Canada

People People s Republic of China

India

Japan

Republic of Korea

United States of America

APPAPP- Power Generation & Transmission Task Force Force CenPEEP extending support to USDOE / USAID to:
Create sustainable Efficiency Improvement Program at three State utilities (Punjab, West Bengal & Tamil Nadu) Enhance collaboration with U.S. energy efficiency service providers and Indian utilities Facilitate training programs in U.S. institutions / utilities for NTPC/State utility personnel in specialized areas Facilitate exchange visits of U.S. and Indian experts

Methodology: Executive Exchange visits


Visit of senior executives to US Utilities Visit of US experts to India and interaction & dissemination to large audience

CenPEEP

CenPEEP

IndoIndo-Japan Cooperation: Joint Project with JICA


(JICA

- Japan International Cooperation Agency)


i.

Coverage
Importance of Efficiency and Availability 3 Slides 5 Slides 9 Slides 3 Slides

Agreement signed between JICA, MoP & NTPC under Indo Japan Energy Dialogue Project: The study on enhancing efficiency of operating thermal power plants in NTPC India India Duration of Project: January 2009-October 2010 Analysis and evaluation jointly by Japanese experts, NTPCCenPEEP & candidate stations The project involves demonstration of RLA & diagnostic techniques by Japanese service providers Training and exposure to Japanese practices

ii. CenPEEP

iii. System, Practices and New techniques


iv. Issues/Challenges and Conclusion

CenPEEP

CenPEEP

CenPEEP Approach
State-ofState of-the art technology & practices for GHG reduction State-of-the

SubSub-System wise Simplified Performance Testing

Technology Selection & Acquisition Technology Transfer Training & Technology Technology Demonstration Dissemination

Sustainability through Implementation of Systems & Procedures

Approach is to introduce user friendly systems, demonstration, finalization of Procedures / Guidelines & dissemination to all

Whatever is convenient, will only be replicated replicated


Knowledge is not enough, implementation brings real benefit

LowLow-Cost, HighHigh-Benefit Techniques Demonstrated


Performance tests techniques using highaccuracy test instruments Boiler efficiency, HP/IP efficiency, Condenser, HP/LP heaters, BFP

CenPEEP

CenPEEP

Periodic Mapping of Oxygen % in Flue Gas Path


an easy way to quantify increase in Air Ingress

Use of portable DAS High Velocity Thermocouple (HVT) Dirty pitot kit Helium Leak Detector Condenser air-in-leak detection Water-powered cleaners for Condenser tubes CW flow measurement & cooling tower performance optimization IR Thermography & Acoustics as diagnostic techniques Eddy Current Induction heating Eroded gas ducts, expansion joints & hoppers cause air ingress in boilers
Oxygen in Flue Gas (%) - 200 MW (Aug 08)
8 7 6 5 4 3 2 1 0

Furnace Exit

Eco Outlet

AH Inlet

AH Outlet

ID Fan Outlet

Typical HR Loss Areas


Indian Power Plants
High-loss category (20-40 kcal/kWh) Dry Flue Gas Loss Condenser Unaccountable Medium-loss category(10-20 kcal/kWh) HP/IP Turbine RH Spray Cooling Tower Low-loss category (<10 kcal/kWh) Unburnt Loss MS & HRH Temperature deviations Feed water Temperature deviations
Unaccounta bles, 20% RH Spray, 9%

CenPEEP

Widespread Dissemination
130 Workshops on Boiler & Turbine Performance Analysis & Improvement; Programs on Diagnostics and Knowledge based Maintenance 14500 Training man days - Participants from NTPC, DVC, GSCEL, UPRUVNL, TNEB, APGENCO, PSEB, RRUVNL, MSEB, IPGCL etc. 325 Demonstrations - Hands-on trainings Guidelines on Thrust areas like Air Heaters, Boiler Air-in-leakage etc. Papers on Sustainable Heat Rate Improvement of Power Plants and Knowledge based Maintenance at various conferences Customized training programs organized at SEBs as per their needs Supported by 50 US team visits of over 1100 man days

CenPEEP

Typical Break Up of HR Losses


Cooling Tow er, 16% Others, 5% Dry Flue Gas Loss, 16%

Condenser, 15%

Optimisers
available on NTPC website

Turbine (HP & IP), 19%

What can not be measured can not be saved saved

Quarterly newsletter Performance improvement is a race without goal-post It is a continuous process

An Approach for Sustainable Improvement


Efficiency Management System (EMS)

CenPEEP

CenPEEP

Energy & Efficiency Management System (EEMS)


Development & Implementation of EEMS

4. Building diagnostic & analytical capabilities

1. Performance Evaluation

Identification of Heat Rate gaps through monthly performance tests Trending performance indices & analysis of equipment degradations Development of Unit specific HR recovery action plans
Release of Revised EEMS document

Systematic Approach
2. Analysis & Action Plans

Restoration of equipment performance during overhauls Skill / knowledge enhancement through Dissemination workshops

3. Performance Improvement Projects

Equipment Efficiency Computation Program

A uniform, simplified system for plant efficiency monitoring, periodic testing, gap assessment, analysis and corrective actions.

Customized EEMS Document prepared based on learning's at CenPEEP and Heat rate Improvement Guidelines issued earlier

CenPEEP

CenPEEP

High Availability & Reliability


(key to sustained Efficiency improvements) The Road Map

Coverage
i. Importance of Efficiency and Availability 3 Slides 5 Slides 9 Slides 3 Slides

ii. CenPEEP
PdM Improvements Risk Mitigation

iii. System, Practices and New techniques

Availability Improvement Initiatives

iv. Issues/Challenges and Conclusion

Risk Screening

RCM-Living Program

CenPEEP

CenPEEP

Issues & Challenges


Top management support for efficiency improvements Awareness of efficiency impacts Skills, knowledge, advanced tools, Specialized equipments missing with existing service providers Up-gradation of components/spares and reverse engineering capability Limited investment for efficiency restoration: repair / replacement System and planning for efficiency monitoring and restoration Changing established utility practices takes time Quick success stories needed to create momentum
HR gaps wrt design varies from 70 to 100 kcal / kwhr for good plants to 400 kcal for badly run units

Conclusion
CenPEEP the flagship project of USAID, USDOE-NETL, and NTPC - a resource center & Institution for efficiency improvements The CenPEEP-USAID model of acquisition, demonstration, and dissemination of new techniques: proved to be very effective Systems, like Efficiency Management System (EMS), Risk Evaluation, Overhauling Preparedness Index (OPI), and associated practices, etc., introduced in NTPC and found very useful Good potential available for efficiency improvement in existing state utilities and medium to low in central and private utilities; Low hanging fruits with limited investment Correct Performance assessment is an essential pre-requisite; focus to be on individual equipment degradations CenPEEP will continue to play a critical role in performance analysis and diagnostics & introduction of new techniques

CenPEEP

CenPEEP

Conclusion
Existing business environment and constraints provides excellent business opportunities in Indian power sector. The major areas are: Performance diagnostics using state-of-art analysis tools & models Specialized services for repair/maintenance activities for critical equipments including in-situ repairs during overhauls Manufacturing facilities for equipment spares upgradation and reverse engineering Specialized services of remote monitoring and advisory support to the generating stations (i.e., Fleet-Wide Monitoring System) Specialized training in the area of efficiency monitoring Service providers needed to cater to demands of rapid expanding Indian power sector

Awards & Recognitions

CTI CTIs World Climate Technology Award 2002

USEPA CLIMATE PROTECTION AWARD 2003


CenPEEP IS A SYMBOL OF SUCCESSFUL INTERNATIONAL COOPERATION FOR GHG REDUCTION

Awards & Recognitions

CenPEEP

Awards & Recognitions


NTPC NTPC CenPEEP conferred

CenPEEP

International Gold Star Award for Quality 2009 2009


at International Star Quality Convention Geneva

India Power Award 2008 For exemplary work on GHG reduction & environmental protection

CenPEEP

Thank You

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