Efficiency Improvements Program in Indian State Electricity Board Coal Fired Power Plants Under the Asia Pacific Partnership Program

S. PadmanabanDirector, SARI/E

USAID

Thermal Power India -319-20th Feb., 2009

New Delhi

What is the APP?Through the APP, Australia, Canada, China, India, Japan, Korea, and the United States are working together and with private sector partners to meet goals for energy security, national air pollution reduction, and climate change in ways that promote sustainable economic growth and poverty reduction.

Together, APP Countries account for over half of the world’s GDP, population, energy use, and emissions.

APP Organizational Structure Policy and Implementation Committee

(USA, Chair)

SteelTask Force

Chair(Japan)

Co-Chair (India)

PowerGeneration

AndTransmission

Task Force

Chair(USA)

Co-Chair(China)

AluminiumTask Force

Chair(Australia) Co-Chair

(USA)

Coal MiningTask Force

Chair(USA)

Co-Chair(India)

RenewableEnergy

and DistributedGenerationTask Force

Chair(Korea)

Co-Chair(Australia)

CleanerFossil

EnergyTask Force

Chair(Australia)Co-Chair(China)

CementTask Force

Chair(Japan)

BuildingsAnd

AppliancesTask Force

Chair(Korea)

Co-Chair(USA)

Administrative Support Group(USA)

Why the APP Approach?

Using a sectoral approach that breaks the climate challenge into manageable pieces helps Partners take advantage of readily available opportunities to increase efficiency and reduce emissions.

A sectoral focus enables Partners to lay the foundations for long-term market transformation.

The APP’s programmatic emphasis provides a concrete way for public and private leaders in each of these sectors to focus on real-world priorities.

1960s/70s: construction of 15 thermal power plants and several hydro projects.1980s: moved on to science and technology development in the eighties.1990s: focused on privatization and technology commercialization in the early nineties.1998: GHG emissions reductions in the energy sector - main focus since the sanctions. Today: electricity distribution reform, water-energy, methane-to- markets, municipal services

History of USAID/India’s Energy/Environment Programs

Performance status of Indian Thermal power plants

Highest ever PLF 78.75% achieved in year 2007-08

Few PVT power producers achieved more than 100%

Dahanu TPS - 101.53 %

Sabarmati - 101.42 %

Budge Budge - 100.43 %

Energy loss due to forced outage reduced to 7.71% as against 8.14% during 2006-07

Auxiliary power consumption reduced to 8.17% compared to 8.29% in 2006-07

Overall station heat rate improvement 5.49 %

Excellent achievement by Indian thermal power plants

© Confederation of Indian Industry

Potential available in Indian thermal power plants

8.447.53 Auxiliary power consumption

1.771.20Specific fuel oil consumption

73.7193.18Plant load factor

81.7893.6Operating availability factor %

9.481.03Planned maintenance %

8.744.44Forced outage %

Average of all Indian thermal power

plants

A Best performing unitDescription

Comparison b/n a Best performing unit & average performance

A two-phase combustion optimization and efficiency improvement training is near completion at the Kolaghat coal-fired power plant of the West Bengal Power Development Corporation Limited (WBPDCL), and also at the Ropar coal-fired power plant of the Punjab State Electricity Board (PSEB). One 210-MW unit in each station was been selected for efficiency improvement and greenhouse gas (GHG) emissions reduction.

Objective

Typical Thermal Plant Performance OpportunitiesHigh furnace exit gas temperatures contribute to overheated metals, high de-superheating spray flows, excessive soot blower operation

Coal dribble/spillage due to throats that are too large

Fly ash Carbon losses

High primary airflows contribute to unnecessarily high dry gas losses. Also poor fuel distribution , poor coal fineness & load Control

Bottom ash carbon content; Bottom Ash Hopper - Air In-

leakage

Reduced Lower Furnace Heat AbsorptionIncreased Mass flow through the

precipitator decreases precipitator performance

ID Fan Capacity Limitations (due to high air in-leakage)

Air In-Leakage

Coal Fineness

Identified Testing Locations at RTPS

Ropar TPS, Unit 4 CE Tangentially-fired boiler supplied by Bharat Heavy Electricals Limited (BHEL), with

regenerative air heaters and XRP mills.

Identified Testing Locations at KTPS

KOLAGHAT TPS, Unit 2, 210-MW Associated Babcock Limited (ABL)

front-fired boiler with tubular air heaters and six 8.5E-9 mills

Representatives from the SEB plants visited the United States to observe power plant standards and participate in a demonstration of testing techniques prior to completion of testing in India.

Sites to be visited an toured include the Reid Gardner Power Station (Nevada), Orlando Utilities, Stanton Energy Center & E.ON – U.S.’s Trimble County Station.

The site selected for demonstration of performance testing techniques in the U.S. was the Orlando Utilities Commission, Stanton Energy Center

Phase II, Training in the U.S.

USAID – USDOE and Host Country Contributions

USAID/USDOE State Electric Board

Plants CenPEEP, NTPC

Program Management Formation of an Efficiency

Group within the plant Manpower & Support from the Boiler & Turbine Groups

Technical Assistance & Consulting Services

Creating infrastructure in the designated units for

testing

Local Coordination and Consultancy to the SEB plants

during planning, preparation and implementation

Specialized Diagnostic Testing Equipment

Preparation and plant readiness

Participation in the Testing

In Country & U.S Training Custom duties for the

diagnostic testing equipment

Testing Equipment for Turbine Cycle Heat Rate

Measurements(GTCHR)

Testing & Optimization Demonstration in the Designated

Units in the SEB Plants

Manpower & Support during Testing Turbine Performance Testing

Gross Turbine Cycle Heat Rate (GTCHR) Testing

Center for Power Efficiency & Environmental Protection

Efficiency & Fuel Conservation Heat Rate & GTCHR (Steam Cycle) Challenges

System efficiency issues are impacting coal consumption, efficiency & CO2 production.

Reduced Generation Reduced Load between 50% - 80% MC

Coal Quality Concerns Limited Coal Supply Variations in Fuel GCV from 2,500kcal – 4,000kcal/kg

Coal Blending & Variations from design yield increased levels of CO2 emissions is extremely high considering the carbon content in the coals fired is stable, yet the fuel consumption is nearly twice the design values. Unnecessary supplemental Fuel Consumption impacting heat rate

Major Plant Concerns

Summary & Economic Review of Why this is a “Win-Win” Program

The results achieved has identified and provided the results needed to improve the efficiency opportunities by a minimum of 3 % as well as improve the plants capacity and emission levels.

Both of the Units have greater than 200 kcal/kWhr in measured heat rate opportunities. However, the expected heat rates throughout the Spring, Summer & Fall seasons are expected to increase substantially as ambient temperatures increase and/or extended times between overhauls result in decreased performance.

Each of these plants are now equipped to measure efficiency at the boiler and have attained the knowledge and ability to measure, manage and reduce heat rate and could reduce heat rate on each of these units by at least 100-200kcal/kWhr or 1.5 – 2.5% overall unit efficiency.

It is expected and planned for these plants to continue to utilize performance driven maintenance techniques to improve the plants efficiency and overall reliability.

CO2 Emission Reductions

Considering that each unit had an identified 2% – 3% in efficiency opportunities at the boiler and a additional 2% - 3% in Steam Cycle efficiency, the potential CO2 reduction is ~20,000 tons of CO2

Both plants have multiple units (6 each) and the efficiency improvement practices could easily be replicated and the overall reduction of CO2 could be substantial.

In addition to efficiency improvements were made at both plants and the testing demonstration also helped in overcoming operational constraints that resulted in additional MW generation.

Economic Case Study for (1) 210 MW Unit

Description Variable

Load 210MW(Gross)

Operation 7,000Hrs.

Fuel GCV 3,000kcal/kg

Coal Cost 2,500Rs./Ton

Ash Content 50%

Heat Rate vs. Annual Fuel Cost (Cr.)

Annual Fuel Cost vs. Boiler Efficiency

© Confederation of Indian Industry

USAID/India & USDOE support initiatives of CII-Godrej

GBC for performance improvement in Indian thermal

power plants

20 thermal power plants volunteered

Best practices identified from each power plant & 25

projects shortlised for compilation

Best practices from select international thermal power

plants included

Australia, Germany & Japan

Make Indian thermal power plants world class

Developed manual on “Best practices in Indian thermal Power generating units”

© Confederation of Indian Industry

Power plant summit 2008 –Development of service provider’s network

Power plant summit 2008 – Organised with the

support of USAID/India & USDOE

15 Nos of US based service providers

demonstrated & showcased their services

Over 130 participants from all over India

Future plan – Development of service provider’s

network for Indian thermal power plants

The projected outcome for successful implementation of the

APP Project (INDIA)

Closing

Acknowledgements

The contributions by the National Energy Technology Lab (NETL)/ USDoE, SAIC Inc., Storm Technologies Inc., CII-GBC and CenPEEP, NTPC is gratefully acknowledged.