Energy Conservation and Energy Auditing of Thermal Power Plant

In accordance with Energy Conservation Act, 2001, the Thermal Power Generating Stations have been notified as the Designated Consumers (DCs) by the government and accordingly it has become mandatory to carry out energy audit on a regular basis and report the energy conservation measures adopted to Bureau of Energy Efficiency (BEE). CEA in Click to edit Master subtitle style cooperation with GTZ under Indo-German Energy program has prepared initial guidelines for energy auditing of Power Plants to provide common basis for such energy audits. These should be used for improving the energy efficiency of power plants in the country.
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(Deutsche

The Indo German Energy The Ministry of Power, Government of India and GTZ Programme (IGEN)
Gesellschaft (GTZ) fr GmbH) signed an

Technische

Zusammenarbeit

implementation agreement with respect to the Indo-German Energy Programme in 2006.

The Indo German Energy Programme (IGEN) is research work and performance

performing

assessment in support of the implementation of the Energy Conservation Act 2001 in cooperation with the Ministry of Power and its statutory bodies Central been Bureau of Energy Efficiency (BEE), and Electricity Authority (CEA).

Under

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the

IGEN

agreement,

CEA

has

The

The Indo German Energy Programmemeasure under (IGEN) overall aim of this

Indo

Germany Energy for performance

programme is to support and reporting financially as well as and plant

prepare public and private power plant operators implementation of attractive

technically viable improvements of power Conservation

net heat rate under the provisions of the Energy Act.

The project is being executed under two main

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sub-components:

The

following

Outcome Expected from IGEN

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
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Power Scenario in India

Economic growth in India, being dependent on power sector, has necessitated an enormous growth in electricity demand over the last three decades. In 1947, the total generation capacity was 1360 MW, in 1991 it grew to 65000 MW and as on date (CEA report 10th August 2011) the installed capacity has grown to 1,81,558 MW of which thermal capacity being 118409 MW. Many ultra mega projects using supercritical boilers are in various stages of erection/commissioning. The following is the break up of installed capacity as on 10/8/2011. Coal = 99503 MW Gas = 17706 MW Diesel = 1200 MW Thermal total = 118409 MW (65 % of total installed capacity) Nuclear = 4780 MW , Hydro = 38206 MW 7/18/12

Energy Conservation and Energy Auditing of Thermal Power Plant

Improving the energy efficiency in power plants can be achieved by : 1) Improving energy efficiency in existing plants. 2) Higher size units 3) Technology adoption 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 3% CO2 reduction per annum Higher productivity from the same resource is equivalent to capacity addition.

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b.

c.

d.

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Energy Conservation and Energy Auditing of Thermal Power Plant

Following systems in Thermal Power Stations are covered for energy auditing. 1. Coal handling plant 2. Boiler 3. Thermal Insulation 4. Ash handling 5. Water pumping 6. Fans 7. Turbine 8. Condenser cooling 9. Compressor air system 10. Motors 11. Air Conditioning 12. Lighting
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Energy Performance Assessment of the Boiler

Performance of the boiler, like efficiency and evaporation rate reduces with time, due to poor combustion, heat transfer fouling and poor operation and maintenance. Deterioration of fuel quality and water quality also leads to poor performance of boiler. Efficiency testing helps us to find how far the efficiency has drifted away from the best efficiency. Any observed abnormal deviations Click to edit could therefore Master subtitle style to pin point the be investigated problem area for necessary corrective action. Hence it is necessary to find out the current level of efficiency for performance evaluation, which is prerequisite for energy conservation action in power plant. Focus should be 7/18/12

Boiler
The boiler of a thermal power plant is used at high pressure and temperature required for the steam turbine that drives the electrical generator. The boiler has furnace, steam drum, superheater coils, reheaters coils, economiser and airheaters. The air and flue gas path equipment include forced draught fans (FD). Induced draft fans (ID), Click to edit Master furnace, airpreheaters (APH),subtitle style fly ash collectors (electrostatic precipitators, bag filters) and the flue gas stack. Brief schematic diagram of a typical coal fired sub critical boiler is given in the following figure.
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SCHEMATIC DIAGRAM OF BOILER

v v v v v

Water cycle Fuel cycle Air & flue gas cycle Steam cycle Ash/ rejects cycle

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BOILER SPECIFICATION FOR 210 MW KWU UNIT

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FACTORS AFFECTING PERFORMANCE OF COMBUSTION

SURFACE CONTACT AREA OF FUEL WITH AIR AIR-FUEL RATIO RETENTION TIME COMBUSTION CHAMBER TEMPERATURE TURBULANCE IN COMBUSTION CHAMBER REMOVAL OF PRODUCTS OF COMBUSTION

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COMBUSTION
TIME
SUFFICIENT RETENTION TIME MUST BE ALLOWED FOR THE FUEL TO STAY INSIDE THE FURNACE TO COMPLETE COMBUSTION. TIME REQUIRED/AVAILABLE DEPENDS FUEL TYPE,QUALITY,SIZEFURNACE SIZE, VELOCITY, DRAUGHT EFFECTS THERMAL DIFFUSION OF REACTING MOLECULES DUE TO INCREASED VELOCITY OF MOLECULES WITH INCREASE IN TEMPERATURE INFLUENCE THE RATE OF REACTION

TEMPERATURE

FACTORS AFFECTING TEMPERATURE

HEAT ABSORBED BY FURNACE HEAT ABSORBED BY REACTANTS TO BRING THEM TO IGNITION TEMPERATURE HEAT ABSORBED BY NITROGEN IN AIR
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COMBUSTION

TURBULANCE

MECHANICAL AGITATION OF REACTANTS TO BRING THEM INTO PHYSICAL CONTACT REQUIREMENT IS MORE AT FINAL STAGE OF COMBUSTION LESSER THE TURBULANCE MORE CARBON LOSS DEPENDS

WIND BOX TO FURNACE DIFF.PR.IN CORNER FIRED BOILERS TERTIARY AIR IN WALL FIRED BOILERS

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Boiler Efficiency Test

Purpose of Test : The purpose of the test is
to calculate actual performance and efficiency of the boiler and compare it with design values or norms. It is an indicator for tracking day to day and season to season variation in efficiency and energy efficiency improvements.

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Boiler Efficiency

By boiler efficiency is meant the measure of

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There are two methods of determining boiler efficiency 1. Direct method 2. Indirect or losses method The direct method : This method is straight forward and consists of measuring the heat supplied to the boiler and heat added to the steam in the boiler in a given time. Efficiency ( for non reheat unit) = (Enthalpy of steam Enthalpy of feed water)* Steam Flow (Quantity of coal * CV) = WS{ Cp(T-To) + L + (To t)} Mf* CV WS = Steam flow rate Cp = Specific heat of steam T 7/18/12 H Steam temperature To = Saturation = S.

Boiler Efficiency Calculation Methods

The trouble with this method is that several of these quantities are difficult to measure particularly coal quantity, the steam quantity and CV of coal. The error in measurement results in an overall tolerance of about + 1.5 % . However this method of efficiency determination is gaining popularity of late and used more frequently because of simplicity and advances being made in measurement techniques. In indirect method, the efficiency is calculated by determining the losses in the boiler. For this, chemical analysis of the fuel and the flue gas analysis are the basis of calculation. Efficiency = 100 % - Losses 7/18/12

Boiler Efficiency Methods

Boiler Efficiency Methods Thus if losses are known, the efficiency can be derived.
An important advantage of this method is that the errors in measurement do not make significant changes in efficiency. Thus if boiler efficiency is 90 % an error of 1% in direct method will result significant changes in efficiency.

90+ 0.9 = 89.1 to 90.9 In indirect method, 1 % error in measurement of losses will result in Efficiency = 100 (10+0.1) = 90 + 0.1 = 89.9 to 90.1 Clearly, the tolerance is narrow in losses method. However because of advancement in instrumentation and easiness the direct method is also becoming popular nowadays.
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LOSSES ENCOUNTERED IN BOILER

CONTROLLABLE

COMBUSTIBLE IN ASH LOSS DRY GAS LOSS CO IN FLUE GAS MILL REJECTS LOSS LOSSES DUE TO POOR INSULATION MOISTURE IN FUEL HYDROGEN IN FUEL AIR MOISTURE SENSIBLE HEAT IN ASH

UN CONTROLLABLE

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Controllable Variables Affecting Boiler Performance

Super heater Steam Outlet Temperature Reheater Steam Outlet Temperature Air Heater Leakage Super heater spray Reheater Spray High Primary airflows Coal Mill Reject High Carbon Content in Fly Ash High Carbon Content in Bottom Ash Exit Gas Temperature

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Controllable Variables Affecting Boiler Performance

Economizer Exit Gas Temperature Air heater Exit gas Temperature Boiler air in leakage Auxiliary Power Consumption of Fans, Mills and Soot Blowers Excess Oxygen in Flue Gas Cycle Losses due to Leaking Vent and Drain Valves Soot Blowing Optimization Mill Air In Leakage on Suction Mills Steam Purity Problems
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AREAS/EQUIPMENT CONTRIBUTING TO VARIOUS LOSSES IN A BOILER

COMBUSTION IN FURNACE AIRHEATER PERFORMANCE MILL PERFORMANCE FANS PERFORMANCE WATER LOSSES

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TYPICAL BOILER LOSSES

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FACTORS WHICH EFFECT BOILER EFFICIENCY(Boiler Losses) Loss due to the heat carried away by hot flue gases. (a) Dry flue gas loss, and (b) Wet flue gas loss(loss due to moisture in fuel and due to moisture formed by combustion of H2 in fuel) Moisture in combustion air loss Unburnt carbon loss Carbon in ash loss Unburnt gas loss Due to incomplete combustion of carbon Excess air loss. Radiation loss and unaccounted losses. Blow- down and leakages. Dry Flue gas Losses : This is the heat loss in in the dry 7/18/12 component of the gases, as these are discharged from

Boiler Losses
Wet Flue Gas Loss : Due to moisture in fuel : Moisture that enters the combustion chamber as part of fuel/air causes a heat loss because it must be heated from its initial temperature to boiling point, then evaporated and finally superheated to leave boiler at the same temperature as flue gases. (assume latent heat of evaporation as 2257 KJ / Kg at atmospheric pressure). Radiation and Unaccounted Losses : It includes heat carried Click to in ash, heat loss in bottom hopper and seal away edit Master subtitle style water, loss from boiler casing to surrounding, losses due to unburnt volatile matter etc. Radiation loss depends on the effectiveness of the boiler casing insulation. Blow down and make up : Cause two fold losses By way of heat loss with blow down and subsequent heating of make up water.
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Boiler Efficiency Typical Example

Maintaining efficiency : The best way to analyze the problem of maintaining efficiency is to examine the major losses in efficiency, what effects them, and what can be done to control them. A typical heat balance for a pulverized coal fired utility boiler would be : Dry gas loss 5.16 % Loss due to hydrogen and moisture in the fuel 4.36 % Loss due to unburned combustible 0.50 % Loss due Click to edit Master subtitle style to radiation 0.30 % Loss due to moisture in air 0.13 % Manufacturers margin and unaccounted loss 1.50 % Overall efficiency 88.05 % Minor losses are usually lumped into one percentage figure 7/18/12

Boiler Efficiency
Monitoring Efficiency : Continuous monitoring of
flue temperature and flue gas oxygen content by regularly calibrated recorder or indicator and by periodic checks on combustibles in the refuse will indicate if original efficiencies are being maintained. If conditions vary from the established performance base, corrective adjustments or maintenance steps should be taken. High exit-gas temperatures and high draft losses Click with normalto edit Master subtitle style excess air indicates dirty heat absorbing surfaces and need for soot blowing. High excess air normally increases exit gas temperatures and draft losses and indicate the need for adjustment to the fuel-air ratio. The high excess air may, however, be caused by excessive casing leaks, cooling air, or air heater leaks. 7/18/12 High combustible in the refuse indicates a need for

Boiler Efficiency
m m m m m

Boiler efficiency varies with type of fuel. Oil / Coal being best and lowest with gas. Coal properties directly affect the efficiency of the boiler Moisture in coal decreases boiler efficiency. Efficiency of boiler will change if the fuel fired is not as per the design (High FGET in Tatas unit 5 boiler is due to high moisture and high volatile matters in coal).

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Boiler Losses

STACK LOSS Heat carried

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Boiler Losses
HEAT CARRIED AWAY BY MOISTURE Heat absorbed by the moisture in flue gases constitutes a loss because, water vapour is not condensed in the boiler and thus substantial amount of latent heat (Approx..540 Kcal / kg at atmospheric pressure) is lost. There are two sources of moisture in flue gases viz. Moisture in fuel. Combustion product of hydrogen content in fuel. Click to edit Master subtitle style SOURCE OF MOISTURE IN FLUE GASES Moisture in fuels such as coal and gas. Fuels containing high hydrogen Such as natural gas generate Large amount of water vapour When burned. 2H2 + O2 2H2O i.e . 1 kg of hydrogen, when burnt, produces 9kg of water vapour . 7/18/12

INCOMPLETE

COMBUSTION

Incomplete combustion means partial burning of fuel. Part of the fuel may remain unburned or carbon in fuel may burn partially to form carbon monoxide. Causes of incomplete combustion are: Inadequate air. Improper distribution of air. Fuel not properly pulverized or atomized. Low furnace temperatures. Moisture in fuel. Low secondary air temperatures.
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WHY INCOMPLETE COMBUSTION IS A LOSS Unburned fuel is obviously a loss because it releases no energy, but is paid for. Partially burned carbon releases much less energy than when burnt fully. 2C + O2 2CO + 4,400 BTU. C + O2 CO2 + 14,600 BTU. As is evident partial burning of carbon generates carbon monoxide, a toxic gas and releases much less heat and 7/18/12 thus constitutes a huge loss.

Boiler Losses
Loss due to excess air : Quantity of air supplied over and above the minimum required amount of theoretically determined air (stoichometric) is called excess air. Certain quantity of excess air needs to be supplied, because it is practically not possible for every molecule of fuel to come in contact with every molecule of oxygen supplied in the limited time the mixture remainsstyleboiler with no excess Click to edit Master subtitle in air, resulting in improper combustion and consequent losses. However, too much excess air increases the amount of flue gases. Since, the temperature of exit gas temperature is nearly constant , increase in flue gas flow means increase in stack loss.
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LOSS DUE TO HIGH EXCESS OXYGEN

MONETORY LOSS / DAY IN Rs.THOUSANDS

6 0 5 0 4 0 3 0 2 0 1 0 0

1 2 3 4 5 INCREASE OF EXCESS OXYGEN % 1% INCREASE IN EXCESS OXYGEN WILL LEAD TO AN ANNUAL LOSS OF
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LOSS DUE TO HIGH F.G. TEMP.AT A.H. OUTLET 5 INCREASE IN 0 F.G.TEMP. AT 4 5 A.H. OUTLET 4 BY 100C 0 3 WILL LEAD TO 5 AN ANNUAL 3 LOSS OF 0 2 Rs.1CRORE 5 FOR A 210 MW 2 0 UNIT 1 5 1 0 5 0 5 1 1 INCREASE IN A.H. OUTLET 0 5 TEMP 0C 2 0

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MO NIT ORY LOS S PER DAY IN Rs. THO USA NDS

Boiler Performance Monitoring

Flue Gas Exit Temperature (FGET)
Reasons Water wall , superheater & Reheater surfaces slagging m Fouling in air preheater m Low coal mill outlet temperature m High moisture and volatile matter in coal m Low Coal calorific value m Air leak in furnace 7/18/12 m High excess air
m

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Boiler Performance Monitoring

Excess air & Air flow (Actionable)

m

m m

Excess air set point changed with load changes. Carbon in ash monitored daily. Secondary air dampers, Fuel 7/18/12

COMPUTATION OF BOILER LOSSES Dry Gas Loss HEAT CARRIED AWAY

BY DRY FLUE GAS SH WHERE
D

= W D *C P *(T G - T A ) Kcal/ Kgf

W D WEIGHT OF DRY FLUE GAS Kgm/ Kgf CP SPECIFIC HEAT OF DRY FLUE GAS Kcal/ Kgm 0 C 0 T G GAS TEMPERATURE AT AIR HEATER OUTLET C TA AMBIENT TEMPERATU RE 0 C

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COMPUTATION OF BOILER LOSSES

1. Dry flue gas loss:

Where C%BA % of carbon in bottom ash C%FA - % of carbon in fly ash Bash Bottom ash qunatiity in kg Fash Fly 7/18/12 ash quantity in kg

FGT flue gas temperature at APH outlet in 0 C ABT Ambient temperature in C Cp= specific heat of fuel in Kcal/kg C = 0.23

COMPUTATION OF BOILER LOSSES

2. Loss due to unburnt carbon in ash:
Loss due to unburnt carbon in ash, Luca = Calorific value of carbon in kcal / kg [ (C % FA FAsh) + (C % BA BAsh)] GCV of fuel, GCV

3. Loss due to moisture in fuel:

4. Loss due to hydrogen in fuel:

Where H2 kg of H2 in 1 kg of fuel
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COMPUTATION OF BOILER LOSSES

5. Loss due to moisture in air:

Where AAS=Actual mass of air supplied Humidity = humidity of air in kg/kg of dry air

6. Loss due to CO in flue gas:

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TYPICAL BOILER HEAT BALANCE

5.5% 4.2%

Heat loss due to dry flue gas

Dry Flue Gas Loss

Heat loss due to wet flue gas Heat loss due to moisture in fuel Heat loss due to moisture in air Heat loss due to unburnts in residue Heat loss due to radiation & other unaccounted loss

Heat 100% from Fuel BOILER

1% 0.3% 1% 1% 87%

Boiler Efficiency (Heat in Steam)

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EXPLORATION OF ENERGY CONSERVATION OPPORTUNITIES Boilers:

Steam and water parameters ( flow, pressure and temperature )

Air and gas parameters ( flow, pressure and temperature ) Burners operation Primary and secondary air ratios and temperatures Air infiltration in to boilers Air infiltration to flue gases Unburnt loss reduction Combustion control boiler excess air, O2 Measurement inaccuracy Dry flue gas loss Insulation Water quality, Blow down and its control
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EXPLORATION OF ENERGY CONSERVATION OPPORTUNITIES

Coal quality and performance of coal mills Super heater and reheater performance Super heater temperature, slagging of furnace water walls and tubes Fouling on the pendant and horizontal convection tubes, soot blowers performance Boiler control systems Limitation on Performance of associated equipments (pumps, fans, heaters, soot blowers, mills, etc) affecting boiler loading and efficiency Loading on ID, FD and PA fans Operation of dampers /inlet guide vanes / speed controllers of fans Fouling of boiler heating surfaces Installation of energy saving retrofits DM water consumption

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