Energy Audit and Energy Efficiency improvement of Thermal Power Plant

Presentation by Group#B3 Anusha Kolli Sumit Kumar Vijay Sandeep Gurnani Abhinav Agarwal Mukund Chandak

Abraham Lincoln (1809-1865)

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Contents
Introduction Energy audit methodology Measurements performed Identify all opportunities where energy can be saved Cost analysis Final recommendation Prioritizing

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Energy Audit

An energy audit is an inspection, The energy audit evaluates the survey and analysis of energy flows for efficiency of all building and process energy conservation in a building, systems that use energy. The energy process or system to reduce the auditor starts at the utility meters, amount of energy input into the system locating all energy sources coming into without negatively affecting the a facility. The auditor then identifies outputs(s). energy streams for each fuel, quantifies those energy streams into discrete functions, evaluates the efficiency of each of those functions, and identifies energy and cost savings opportunities.

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Flow chart of Energy Audit process

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Energy audit methodology

Historical review Pre planned walkthrough sheet Make a detailed list of data requirements Compute the mass and energy flow Energy conservation opportunities Energy saving options Cost analysis Final recommendation Prioritizing

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Energy consuming parts of a typical thermal power plant

Boiler Condenser Cooling water from sea Chimney Generator Steam Line Turbine

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Typical Plant Losses

Typical Boiler Losses

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Typical Cycle Losses

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Energy Audit of Boilers

Performance of Boiler and APH be established by measuring exit flue gas Temperature Heat loss due to heat in dry flue gas. Heat loss due to moisture in as fired fuel. Heat loss due to moisture from burning of hydrogen in fuel Heat loss due to moisture in air. Heat loss due to surface radiation and convection. Heat loss due to formation of carbon monoxide. Heat loss due to combustibles in bottom and fly ash Recommendations: Analyze Flue Gas for Proper Air/Fuel Ratio Install Economizer to Preheat Boiler Feed Water Direct Warmest Air to Combustion Intake Replace Obsolete Burners With More Efficient Ones

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Methods to improve boiler efficiency

Increasing boiler efficiencies by 1 to 3 percent equivalent to savings of $600,000 to $1,700,000 per 450 MW boiler. Optimizing fuel/air ratio Installing economizer Reducing scale and deposits Reducing blow down Operating at peak efficiency Preheating combustion air Switching from steam to air atomization

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 Optimizing fuel/air ratio:

- If the fuel is too much as compared to the air, incomplete combustion occurs. This will give rise to carbon soot deposits inside the combustion chamber or even over the boiler tubes - When there is more air than is required for combustion, the extra air becomes heated up and is finally discharged out to the atmosphere thereby wasting heat. N0x formation may also take place - However, there are reasons for putting in some extra air for combustion - to compensate for imperfect burner fuel-air mixing conditions, air density changes, control system "slop", burner maintenance, fuel composition and viscosity variation, and imperfect atomizing steam or air controls for burners.

Installing Economizer:
- This is only appropriate if there are insufficient heat transfer surfaces in the boiler. The economizer tubes may contain either circulating boiler water or circulating feed water. Because the temperature of the exhaust gases can be quite high, the economizer tubes may be fitted with safety valves to avoid over-pressure damage. Also temperature control of feed water is required to prevent pump airlock. To avoid corrosion, careful design is needed to ensure that the exhaust flue gas temperature does not drop below the dew point.

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 Reducing scale and deposits:

- For any boiler operation, this is a must. The safety of the boiler is at stake. Any - scale or deposits will lead to reduced heat transfer that will eventually lead to - overheating, reduction of mechanical strength of the steel and finally to bursting

Reducing blow down:

- Blow down of boiler water is discharging hot water into the drains. - However, blow down is necessary to maintain the boiler water concentration of - dissolved solids that are necessary for conditioning the boiler water. The - dissolved solids are necessary for preventing boiler corrosion and scaling. - As steam is generated from the evaporation of water, the remaining water - in the boiler becomes more and more concentrated. This must be drained away - during blowdown.

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 Operating at peak efficiency:

- When operating two or more boilers, improved efficiency can sometimes be obtained by unequal sharing of the load so that the combined load operates at peak efficiency

Preheating combustion air:

- Any heat loss from the skin of the boiler to the boiler room can be utilized back for combustion - By preheating the intake air the combustion in the furnace becomes more efficient

Switching from steam to air atomization:

- For burners with steam atomization, switching to air atomization will naturally - result in less steam consumption overall and better boiler efficiencies. This is - only applicable for heavy fuel oil burners

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Energy Audit of steam Turbine cycles and its auxiliaries

Turbine cycle heat rate HP and IP cylinders efficiency Turbine pressure survey TTD & DCA of HP / LP heaters performance Condenser performance i.e
- Condenser back pressure after duly considering the effect of present C.W inlet temp. C.W flow, heat load on condenser and air ingress to condenser vis--vis design conditions - C.W side pressure drop in condenser

Cycle losses Performance of turbine glands Ejector performance

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Energy Audit of steam turbine

Performance parameters need to be determined are (according to ASME PTC 6) heat rate (b) generator output (c) steam flow, (d) steam rate (e) feed water flow

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Energy Audit of CHP

Major equipment:
- Crushers - Conveyors - Feeders - Tipplers - Stacker-Reclaimers

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 Measurement and Observation to be made

- Drive speed, belt speed, roller conditions, belt conditions and belt loading with respect to design - Power consumption of equipments (load and no-load conditions) - Loss of energy in the coal in stock yard due to spontaneous combustion - Equipments operations and throughout comparison with design conditions

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Data collection of CHP

Design details of overall CHP
- Capacity, specific power consumption etc.

Process flow diagram Track hoppers

- Number, length, capacity, power, layout etc.

Paddle feeders
- Number, capacity, travel, speed, power

Wagon tippler
- Number, type, capacity, maximum weight, time cycle, motor rating

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 Crushers
- Number, type, capacity, coal size at inlet and outlet, motor rating, power consumption, number of vibrating feeders

Coal Design parameters and sizes Belt Conveyors

- Capacity , number, speed, width, motor rating power consumption

Stacker Reclaimer
- Quantity, capacity, travel speed. Number of buckets and length of boom, motor rating

Other Equipments Vibrating feeders, dust suppression system pumps , belt feeders, dust extraction fans etc

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Energy conservation possibilities

Performance improvement options:
- Possibilities in Improving the throughput this is a major energy saving area which offers substantial saving at minimum investment. - Reducing the idling time. - Increasing the loading. - Modifications and changes in coal feeding circuits. - Need for automation and controls. - Identification of combination of various least power consuming equipments and recommending merit order operation. - Use of natural daylight through conveyor galleries and use of fire resistant translucent sheet.

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 Sequence of coal handling operations like receipt, unloading, stacking and reclaiming and the selection of machinery is to be made in such a way that all the handling operations are accomplished without the use of semi mechanized means like bulldozers which are more energy intensive equipments. However Principal of FIRST IN FIRST OUT is to be adopted for coal receipt & consumption and at any time coal need not to be stocked in yard for more than incubation period (duration between coal mined and getting self ignited)

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Ash Handling Plant

Major Energy Consumers

Ash water pumps Ash slurry series pumps The contribution of wet ash handling plant in auxiliary power consumption varies between 1.5 to 2%
Major Objectives in AHP

Evaluation of ash water ratio Analysis of higher consumption of water if any Comparison of the ash water ratio with design value, P.G. Test value and previous energy audit values Equipment's performance
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Data collection of AHP

Line diagram Detailed Specification pertaining to
- Type - Handling capacity - Percentage ash collection rates - Fly ash and bottom ash extraction capacities - Operating hours

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 PG test values/design values of

- Coal parameters - Ash generation - Ash to water ratio - Slurry velocities - No.of pumps involved

Energy consumption details Water consumption details Performance characteristic curves of all pumps

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Operating parameters of AHP

Water supply rate Water velocity Discharge Head Valve position Temperature Operating hours and schedule Pressure drop in system Pump/motor speed Load of the plant Discharge throttle valve position Flow control frequency % loading of pump on flow and head % loading on motor

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 While conducting the energy audit of the pumping, the following aspects need to be explored in detail for Optimization / improving the ash to water ratios
- Possibilities of reducing the operating hours of the AHP - Adequacy of pipe sizes - Improvement of pumping systems and drives. - Use of energy efficient pumps - Replacement of inefficient pumps - Use of high efficiency motors - High Performance Lubricants: The low temperature fluidity and high temperature stability of high performance lubricants can increase energy efficiency by reducing frictional losses. - Booster pump application

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Electrical Systems
Transformers: Assessment of the health & Transformer load loss of GT, UAT, Station Service transformers etc Identification of possible Energy conservation options in this area Motors: Assessment of Loading condition of HT and LT motors of Boiler area, Turbine area and Balance of Plant area Assessment of operating parameters like load variation, Power factor, of HT and LT motors consuming power more than 50 KW Identification of possible Energy conservation options in this area (with latest techniques) Recommendations: Replace Over-Size Motors and Pumps with Optimum Size Utilize Energy-Efficient Belts and Other Improved Mechanisms Use Most Efficient Type of Electric Motor

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Plant Lighting system: Lighting load survey and Assessment of installed load efficacy (I.L.E) and I.L.E ratio at various areas of plant Assessment of present lighting controls Identification of Energy Conservation Opportunities Recommendations:
Utilize Higher Efficiency Lamps and/or Ballasts Install Occupancy Sensors Make a Practice of Turning Off Lights When Not Needed Air Conditioning System: Performance evaluation of AC Plant w.r.t net cooling / refrigeration capacity along with heat load of Air handling unit and energy requirements at the operating conditions vis--vis design condition to be determined.

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Energy Audit of BoP

Compressed Air system: Free Air Delivery i.e. Capacity evaluation of the Plant and Instrument air compressors Checking volumetric efficiency of compressors Assessment of compressed air leakage quantity Assessment of Energy performance of the air compressors/ specific power consumption Study of the compressed air network and suggest suitable energy saving options Recommendations:

Install Compressor Air Intakes in Coolest locations Reduce the Pressure of Compressed Air to the Minimum Required Eliminate Leaks in Inert Gas and Compressed Air Lines/Valves

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Ash Plant: Performance of ash Slurry pumps through power measurement and flow measurement Ash water ratio assessment and recommendations for optimization in water and power consumption Cooling Tower Performance: It shall include establishment of Liquid/Gas ratio Fan efficiency as the ratio of shaft power developed and the work done by the fan Cooling Tower Effectiveness, approach and range. Cooling capacity. Coal Handling Plant: Input Power measurement of all the key equipment of the CHP area like: Paddle feeders, Conveyors, Stacker & Re-claimer, Wagon Tipplers, Crushers, Establishment of specific energy performance indicators.

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Instrumentation and control

Evaluate the instrumentation available in the plant and identify the locations here online measurements are necessary for efficiency calculations however unavailable Recommendation regarding type of instrument, installation details, make etc. Measuring instrumentation at coal handling plant, ash handling system, Raw water and waste water system

Thermal Insulation including radiation losses:

Heat loss calculation Insulation of Boiler, Air and Flue gas path and Steam piping Surface temperature measurement at the damaged and Hot spot area by infrared temperature indicator. Estimation of Heat loss in the hot spots and damaged insulation area

DM Plant
Capacity utilization and power consumption of all major drives. Performance evaluation of pumps.

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Cooling water system

Assessment of cooling tower capacity and efficiency / effectiveness Evaluate circulating water pump flow rate, head developed, pressure of pumping system and power consumption Assessment of condenser heat load, deviation indicated in respect of the CW pump performance Water circulation, condenser efficiency, and turbine heat rate Assessment of Vacuum system and fan performance

Fire Fighting system

Input Power measurement of all the key equipment of the Fire system like hydrant, spray (Electric & Diesel),Jockey Pump, Booster Pump Establishment of specific energy performance indicators

APC & performance

Evaluation of unit auxiliary power consumption & performance including specific energy Consumption ( SEC) of critical drives where output parameters is available on line, cooling water pumps, CHP (including Performance of Locomotives, Loaders, Dozers, Proclaim and tipplers), AHP, FOPH, WTP and Cooling Towers using power analyzers.
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Water system
Water consumption in a coal based thermal power plant
Area Quantity with ash water recycling (m3/hr) 4180 3270 260 640 130 476 1334 10090 Consumption (m3 /MW) 2.0 1.5 0.13 0.32 0.065 0.37 0.66 5.0 %

Ash handling Cooling towers DM water Drinking water (colony +plant) Coal handling Fire fighting Others total

41.4 30.4 2.6 6.3 1.3 4.7 13.2 100

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 A thermal power plant of 210 MW capacity recycles approximately 2000 m3/hr ash water. Reducing water consumption from 5.86 liter/kWh to 4.9 liter/kWh results in reduction of 16 percent in water consumption and savings of Rs.15.8 million/annum in water bill By systematic water audit and quantifying water flows at each pumping station, one can carry out water balance with a reasonable accuracy. Based on water audit studies in a number of thermal power stations, some of the measures can be taken which will give major savings both in terms of water and Energy

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Measures
Optimizing ash water ratio Recycling ash water from ash dyke Increasing cycles of concentration (COC) Reducing drinking water consumption Reducing leaks and over flows Installation of effluent treatment plant

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Optimizing ash water ratio

In wet ash handling power plants, about 50-60 percent of water is consumed just for ash handling. Typical design ash water ratios are around 1:5 for fly ash and 1:8 for bottom ash. However, the actual combined ash water ratios are around 1:20. For every percent reduction of ash water ratio, there is a saving potential of 60 m3/hr of water. In addition to water savings, the associated auxiliary power consumption reduction would be 0.2 MU/annum for every ash water ratio reduction After initiating water conservation measures, many thermal power plants have brought down their ash water ratios to a reasonable level to 1:10 to 1:12.

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Recycling ash water from ash dyke

About 60 percent of water is consumed for ash handling purpose alone. The ash slurry is sent to ash dykes, which are normally located about 1415 km away from the main power plant. After the ash gets settled in the ash dyke, the clear water can be recycled. This water can be re-used for ash handling purpose after minor treatment (if necessary). A thermal power plant of 210 MW capacity recycles approximately 2000 m3/hr ash water. By reducing water consumption from 5.86 liter/kWh to 4.9 liter/kWh results in reduction of 16 percent in water consumption and savings of Rs. 15.8 million/annum in water bill (@ Rs. 1/kL of raw water).

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Increasing cycles of concentration (COC)

The maximum water loss in the thermal power plants is in the cooling towers, in the form of evaporation. We need around 180 m3/hr cooling water flow to the condenser to generate 1 MW. Expected evaporation ratio for every 1 MW of power generation is 2.6 m3/hr. For a 210 MW power plant, the expected evaporation loss would be 550 m3/hr. To compensate this evaporation loss, the blow down losses and drift need to provide make up water Normally the cooling towers are designed for a COC(ratio of dissolved solids in circulating water to make up water) of around 3. To keep COC of 3, we need to provide a blow down of around 275 m3/hr, for a 210 MW power plant. By increasing COC, the blow down quantity can be reduced. By external water treatment and adding water treatment chemicals, COC of even 10 can be reached. By increasing COC from 3 to 10, we can reduce the blow down quantity drastically from 275 m3/hr to30 m3/hr, which is a savings of 88 percent.

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Reducing leaks and over flows

Lot of water leaks from Valves, Flanges, Taps, Fire fighting hoses, under ground fire fighting lines, cooling tower basin, gardening hoses etc takes place Overflows from cooling towers of AC plants, Air washers, and Overhead tanks due to non-functioning of float systems are also there Huge water leaks from the condenser pipe ducts are noticed. By bringing underground fire fighting lines to over ground, attending various water leaks, providing ball and cock float systems for overhead tanks and smaller cooling towers, 3-5 percent water consumption can easily be reduced.

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Installation of effluent treatment plant

A typical thermal power plant will have a 3-4 main drains. All this drain water gets collected and finally goes out of the plant boundary. The measured drain quantities alone are found to be in the range of 8001000 m3/hr. By installing effluent water treatment plants and recycling this water for the ash handling purpose, 80-90 percent of this water can be saved.
Potential

Based on the water flows measurements in different thermal power stations and comparing them with design values and practically achievable figures, savings worth Rs. 3.3 crore/annum, equivalent to 40 percent water use reduction have been identified Since there is a close nexus between water and energy, energy savings to the tune of 3.57 MU/annum is also identified .
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Total Electrical System Audit Including Lighting

Assessment of the loading pattern of installed transformer to identify measures for reduction of losses Power consumption by each AC system by using power measurement analyzers including Cooling effect and humidity Performance of air compressors by using power measurement analyzers Electrical parameters like current, voltage, power factor and power by using power measurement analyzers Assessment of health of capacitors and adequacy of the existing VAR compensation system HT/LT motor consuming power more than 50 KW need to be checked for measuring electrical parameters and performance Lighting of Main plant including office building lux measurement and power consumption (day/night phase wise) Distribution losses Harmonic analysis Identification of Energy Conservation opportunities

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Cost Analysis of Heat Exchanger

Cost of Heat Exchanger, Pump, Piping ,Insulation and Storage Tank: Rs 1,65,000(Approximate) COP of Refrigerator increases by roughly 15%.Savings:308 units per month Savings from Water Heaters : 2928 units(Replacing 9 geysers)

Total Monthly Savings:3236 units Total Monthly Savings in Rupees: Rs 18,768

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Cost analysis

S.No

Recommended measure Electricity saved per month

Savings in Rs per month

Capital investment

Pay back period

Use solar water heater instead of geyser Use automatic washing machine instead of manual

3600Kwh

20,880

7,80,000

3 years

48Kwh

278.4

10,075

3.1years

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Final recommendation
Heat Exchanger must be implemented, as its payback period is least and effectiveness highest. Solar Water Heaters are generally efficient but water temperatures would slightly decrease in the rainy season. Automatic washing machines saves more energy and its payback period is also less. In the long run they are more efficient than manual machines. The total amount of electricity that can be saved=6884 Kwh per month. Roughly Rs40,000

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References
Energy Audit done Energo Engg Projects Ltd at Kolaghat unit ASME standards (PTC) Wikipedia www.google.com www.sciencedirect.com www.googlesholar.com www.cea.nic.in www.actsys.com www.indiapower.org www.iea-estap.org http://www.reduct.com/news/BoilerEfficiency1.htm
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THANK YOU

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