Bench Marking Utility Systems

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Utility benchmarking

Besides their interdependence theonly other external inputs requiredfor their generation are:

- the fuel and- raw water(The air and the chemical additivesare ignored for this presentation)


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It is not correct to benchmark utilityoperations performance based on the

generation costs as the input costs of fueland water vary widely from site to site.It is also not possible to compare the specificconsumption of various utilities for unit generation of any one utility.You need one index to compare the utilitygeneration at one site to the generation at another site.


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GENERATION, RECIEPT AND DISTRIBUTION OF UTILITIES AT CPP AND UTILITY PLANT

PARTICULARS POWER NAT.GAS FUELS R. W. OTHER UTL C.W. RETN COND. STEAM INST.AIR PLANT AIR E.UNITS KWH KSM^3 MT M^3 M^3 M^3 M^3 MT NM^3 NM^3 M^3

GENERATION: 128420033 0 0 0 3581258 41712120 0 380253 13604255 18151455 793754PURCHASE FROM OUTSIDE 421390 24558 20554 2318688 140484 0 163051 0 0 0 0FROM - STG 17055000 0 0 0 0 0 0 51372 0 0 0Receipts from Plants 0 10002 0 0 0 0 47901 157101 0 1718558 0

TOTAL 145896423 34560 20554 2318688 3721742 41712120 210952 588726 13604255 19870013 793754

DISTRIBUTION:EXPORT 158400 0 0 0 0 0 0 0 0 0 0

TOTAL CONSUM. IN PLANTS125825897 6563 0 62999 1534822 34498032 156345 371846 12377375 5195214 614234POWER 906771 10663 10699 0 2569 5422637 54607 105979 305357 651114 0

COOLING WATER 8580297 0 0 0 367169 0 0 0 0 0 87595RAW WATER 374590 0 9 43890 0 0

OTHER UTILITIES 4991755 0 0 2211799 1445515 302221 0 54477 340426 84681 69358RETURN CONDENSATE 35611 0 0 0 1059 321829 0 0 66508 6985 22567

STEAM 274135 17334 9846 0 367244 71118 0 54936 360259 166156 0INSTRUMENT AIR 282657 0 0 0 776 492535 0 0 71330 13631464 0

PLANT AIR 3620548 0 0 0 1099 580061 0 0 76279 0 0EFFL. TREATMENT PLANT845762 0 0 0 1488 23688 0 1488 6720 134400 0

TOTAL 145896423 34560 20554 2318688 3721742 41712120 210952 588726 13604255 19870013 793754


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Utility benchmarkingUtilitygenerated

Following utilities are requiredFuel Water P ower Steam IA N2 CW

P ower Yes Yes Yes Yes Yes No Yes

Steam Yes Yes Yes Yes Yes No Yes

IA No No Yes No Yes No Yes

N2 No No Yes No Yes No Yes

CW No Yes Yes No Yes No No


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Though each utility depends on otherutilities for their generation, ultimatelyspecific consumption of all these can beconverted to the consumption of theirexternal input utilities, namely fuel and

water.


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INPUT TO UTILITY GENERATING CENTRE, Haz ira OUTPUT FROM UTILITY GENERATING CENTRE, HDec '2001 (TO MANUFACTURING PLANTS / LOSSES)

Actual Consumption Actual ConsumptionRaw Water Fuel Raw Water Fuel

GEB Power (KWH) m3 MMKCal GEB Power (KWH) m3 MMKCal421390 0 1391 421390 0 1391

Raw Water (m3) m3 MMKCal Generated Power (KWH) m3 MMKCal2274798 2274798 1333 126172377 89607 226101

Fuel (MMKCal) m3 MMKCal Raw Water (m3) m3 MMKCal451088 0 451088 62999 62999 37

Filter Water (m3) m3 MMKCal776334 809367 1226

Service Water (m3) m3 MMKCal263830 275169 702

Cooling Water (m3) m3 MMKCal

34516391 322141 13446

Fuel Energy Input DM Water (m3) m3 MMKCalHP Nat Gas (KSm3) MMKCal 319043 374233 139424558 209971

LP Nat Gas (KSm3) MMKCal3439 29407

BFW (m3) m3 MMKCalHSD (MT) MMKCal 176192 136698 1519715 159

SHP (MT) m3 MMKCalNaphtha (MT) MMKCal 179525 158495 15743116517 170125

HP (MT) m3 MMKCalC9 (MT) MMKCal 20942 18425 17522

762 7849MP (MT) m3 MMKCal

C6-C8 Raf (MT) MMKCal 24945 21788 188031864 19199

LP (MT) m3 MMKCalHCR (MT) MMKCal -9783 -8523 -70921396 14379

IA (Nm3) m3 MMKCalRLDO (MT) MMKCal 12382758 11453 52790 0

451088 PA (Nm3) m3 MMKCal5302881 2688 1972

TOTAL 2274798 453812 2274541 453408

U T I L I T Y G E N E R A T I N G

C E N T R E


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Utility Benchmarking

An iterative procedure helps to work out the specific consumption of fuel andwater.The table next shows the specificconsumption of water and fuel for the

secondary utilities for two sites for twomonths prepared from such an iterativeprocedure.


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Utility BenchmarkingData for two sites Set 2

U tility U nit Site 1 Site 2P

ower Kcal/kwh 2346 1792C Water Kcal/m3 573 390

SHP

steam

Kcal/kg 880 877

Inst Air Kcal/NM3 413 426

Nitrogen Kcal/NM3 1199 NA


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By using this method it is possible tobenchmark different sites on their utilitygeneration performance in the area of energyconservation.

This method also bring into focus thenecessary changes required in design andoperational practices to improve the energyconsumption.


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Besides benchmarking with others,

with this method, each site canimprove on their own performance.This method can be extended to

process plants as well to monitorthe fuel and water consumption perunit of product.


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The second concept is useful forpower plant operations where thefuel consumption is the highest.


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Utility BenchmarkingThere are lot of variables that govern the fuelrequirement of steam and power generation

P ower and steam are produced throughvariety of equipments - GT, STG, boilers andHRSGs.

i. Fuel boiler steam STG powerii. Fuel GT poweriii. Fuel HRSG steam STG power


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Utility BenchmarkingHeat rate of one machine is different fromother machine.Steam is let down through control valves at

one site but at another site it is takenthrough extraction from a steam turbine.Steam turbine is used to eliminate steamletdown but steam is condensed in surface

condensers.O ne site uses boilers for steam generationwhile another site uses supplementary firingin HRSG for meeting the steam demand.


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GT

STG

Boiler

HRSG

GT Power

STG Power

Extraction steamdelivered to the grid

SHP steam deliveredto the grid

Condensate

Fuel

DM

Water


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Utility BenchmarkingSeveral efficiency parameters are used tomonitor improvements. For example, we haveGT - o/c heat rateHRSG - thermal efficiencyGT/HRSG - Cogen efficiencyBoilers -thermal efficiency

STG - cycle efficiencyThese parameters do not adequately reflect the combined effect of all the conservationefforts .


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A combined parameter called fuelefficiency improvement index has beendeveloped for this purpose.First the fuel efficiency of the C PP isworked out as below:CPP fuel efficiency = A / B where

A = P ower + Steam delivered to thegrid in kcal unitsB = Fuel burnt in kcal units


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Fuel efficiency improvement index isthen = C / D where

C = Fuel efficiency for the current periodD = Fuel efficiency for the referenceperiod


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By monitoring the fuel efficiencyimprovement index we are able to track theprogress made by each C PP on their energyconservation programs.The same is used tobenchmark the site C PP operations.

The above method is independent of theconfiguration and design of the C PP systemsand focuses on the improvements made byeach site.


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Utility BenchmarkingO bservations

The best site in terms of high fuel

efficiency is site 4 but it ranks no.3in terms of ongoing improvements.The site which has a very poor fuel

efficiency is trying its level best onimprovements and is ranked no.1in its conservation efforts.


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Thanks for yourlistening.

Bench Marking Utility Systems

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