CEA

1. CEA PRESPECTIVE
ON
Energy Efficiency
in
Coal Fired Power Stations
CHANDRA SHEKHAR
DIRECTOR,CEA

2. ALL INDIA PLANT LOAD FACTOR OF COAL BASED
POWER PLANTS (%)
11-12 FO 11.46 pm 5.93 Av. 82.61
12-13 FO 13.59 pm 5.71 AV. 80.69
13-14 FO 17.65 pm 5.01 Av. 77.34

3. GROWTH OF GENERATION GWH
1947 to 2014
4073
5106
9662
16937
32990
47434
66689
102523
104627
156859
245438
287029
395889
517439
624495
789013
876885
912000
967150
0
500000
1000000
1500000
2000000
2500000
generation Gwh

4. Installed Capacity = 255012.8MW
Installed Capacity as on 31-12-14 (Type Wise)
Coal,
153570.9,
60.22%
[CATEGORY
NAME],
[VALUE],
[PERCENTAGE]
Diesel,
1199.75, 0.47%
Nuclear, 4780,
1.87%
Hydro
, 40798.76,
16.00%
[CATEGORY
NAME],
[VALUE],
[PERCENTAGE]

5. Installed Capacity = 243028.95MW
Installed Capacity as on 31.03.2014
(Type Wise)
Hydro
18%
Coal,
130370
.89,
58%
Gas
9%
Diesel
1%
Nuclea
r
2%
R.E.S
12%

6. GENERATION
• Gen. 13-14 -967BU (14-15) upto 31st Dec.793.7BU 722 last year
• Comprises Coal/lignite based 746.1 BU (77.14% of total
Gen.) on 60% Capacity
• Gas = 44.52 BU(4.6% of total Gen.) on 9% Capacity,
• Hydro= 134.84 BU (13.9% of total Gen.) on 17% Capacity
• In 2014-15 upto December,2014
COAL/Lignite 75.28% on 60.22% capacity
Gas 4% on 9% Capacity
Hydro 13.44% on 15.99 % Capacity

7. Power position in the country (2013-14)
COAL ,
746.1, 77%
60% CAP.
GAS ,
44.52,
5%
9%
DIESEL,
1.85, 0%
HYDRO,
134.85, 14%
17%
NUCLEAR,
34.23, 3%
BHUTAN
IMP., 5.6,
1%

8. (in MW)
Capacity addition target during 11th Plan 78,700
Capacity Commissioned during 11th Plan 54,964 MW
43384 MW coal
5156MW gas
5544MW hydro
CAPACITY ADDITION DURING 11TH PLAN
(2007-2012)

9. (in MW)
Capacity addition target during 12th Plan 88,537
Capacity already Commissioned during 12th Plan
(as on 31 Dec., 2014)
Total- 49058.2
42845 COAL
4318.2 GAS
1895.02 Hydro
State 10011.1
Pvt. 29776.5
Central 9270.62
CAPACITY ADDITION DURING 12TH PLAN
(2012-2017)

10. Size Steam Parameter Design
Efficiency
Year
MW ata/C/C (%)
30-50 60/ 482 ~31 1950
60-100 90/ 535 32-33 1960
110 to150 130/ 535/535 35-36 1970
200/210 130,150/535/535 36.3,37.8 1977
250 150/535/535 38.3 1995
500 170/ 538/538 38.5 1984
500 170/535/565 38.7 2010
660 247/535/565 ~39.5 2010
660/800 247/565/593 40.5 2012
Efficiency on HHV basis
Major Unit Sizes and Steam parameters

11. PLF of Power Plants
• PLF 2012-13 2013-14
– State sector – 65.57% 59.13 %
– Central Sector –79.18% 76.11%
– Pvt - 64.12% 68.67%
– ALL INDIA - 69.93% 65.55%
• Loss of Generation due to
– Coal shortage 15.84BU 4.3BU
– Receipt of poor coal quality 16.41 6.75
– Backing Down 23.39 48.95
– Transmission constraints 4.1 0.23
– Gas Shortage 73.09 107.15

12. ALL INDIA Thermal PS last Five Years Efficiency Trend
Capacity Analysed 82973.47 MW (13-14) 73 Stations
Design Efficiency 36.75%
32.54
33.49
33.75
33.84
33.91
31.50
32.00
32.50
33.00
33.50
34.00
34.50
2009-10 2010-11 2011-12 2012-13 2013-14
EFFICIENCY
YEAR
Efficiency
Efficiency

13. BOILER LOSSES to be taken care off seriously of COAL FIRED STATIONS

14. The major factors to be looked into in
TURBINE SIDE LOSSES
• Main steam and reheat steam inlet parameters
(For every 1°drop in Main Steam/ R H temperature than the designed value of 537 °C, causes a
heat loss of approx 0.67 KCal/KWh 1 KG/CM2 drop in Main Steam Pressure at Turbine Inlet than
the design value i.e 150 KG/CM2 causes a heat loss of approx. 1.31 KCal/KWh)
• Turbine exhaust steam parameters
• Reheater and super heater spray
• Passing of high energy draining
• Loading on the turbine
• Boiler loading and boiler performance
• Operations and maintenance constraints
• Condenser performance and cooling water parameters
• Silica deposition and its impact on the turbine efficiency
• Inter stage sealing, balance drum and gland sealing
• Sealing fins clearances
• Nozzle blocks
• Turbine blade erosion
• Functioning of the valves
• Operational status of HP heaters

15. The major TURBINE CYCLE LOSSES
•

16. Major Possibilities for Condenser and
Water pumping and Cooling tower
•

17. Heat rate GAURENTEED BY EQUIPMENT MANUFACTURER

18. PLF% Groupwise 2013-14
Sl. Capacity
Group(MW)
No. of
Units
Cap. in
MW
PLF% in
13-14/12-13/11-12
1 660-800 21 14600 67.92/57.52/44.31
1 450-600 87 45130 67.66/71.97/78.38
2 300-350 26 8020 62.82/70.45/72.26
3 250 51 12830 71.96/77.91/81.75
4 210 143 30030 68.76/76.91/78.67
5 195-200 25 4990 73.23/76.62/74.98
6 100-150 101 12145 46.36/50.23/49.11
7 25-99 85 4880 47.85/54.39/55.46
8 Total 539 132625 65.56/69.93/73.32
* No of units reviewed (Total commissioned – 539/490 Cap.132624 Stations 143

19. VARIOUS FACTOR EFFECTING HEAT RATE
Measurement
System
•COAL CONSUMTION
•GCV CALCULATION
•GROSS & AUX Power
•OIL Consumption
COOLING TOWER
•CT Efficiency
•CW Flow
Partial Load
•Tie up LOSS
•Evacuation LOSS
•Load Throw off/LOSS
BOILER EFFICIENCY
•APH Seal Leakage
•Mill Fineness
•Soot Blowing Loss
•Boiler Blow Down
•H2 in Coal Loss
•Moisture in Coal Loss
•Moisture in Air Loss
•Water Chemistry
•O2 Control
•Flue Gas Exit Temp.
•Dry Flue Gas Loss
•SWAS steam Draining
•Air Ingress
•Insulation Missing
•Attemperation Loss
•Unburnt Loss
TURBINE Heat Rate
•Low Rated MS/RH Temp
& Pressure
•Gland and Drain Valve
Leakages
•HL in Drip System Failure
•Heat Loss in Drip Pump
Failure/NA
•Air Ingress
•High Dissolved O2, D/A
Vent
•HP/IP/LP Cylinder
Efficiency
•Missing Insulation
•TDBFP Efficiency
•HP/LP Heater
Performance
Condenser
•Low Vacuum,
•Tube Cleaning
•Sub cooling
COAL
•H2 in Coal
•Moisture
•Coal Burning
in Yard
•Sulphur in
Coal
•Coal Blending

20. Efforts towards improvement in
Efficiency of Thermal Power
Generation

21. Adoption of Supercritical Technology
• Efficiency gain of about 2 % is possible over sub critical
units
• First Supercritical unit of 660 MW Commissioned in Dec-
2010, 800 MW in July,12
• 33 Units with total capacity 22700 MW operating
• Supercritical to constitute ~40%(~25000MW) coal fired
capacity addition in 12th Plan (2012-17)
• 100% coal fired capacity addition in 13th Plan and
beyond to be supercritical

22. EFFICIENCY IMPROVEMENT THROUGH
RENOVATION AND MODERNISATION Programme
• To restore rated capacity and design parameters such as
Heat Rate, APC, SOC etc..
• To make the operating units well equipped with modified/
augmented latest technology.
• To overcome technological obsolescence and non-availability
of spares.
• To improve the performance parameters in terms of PLF,
Efficiency, Forced Outages, Availability and Reliability.
• To reduce maintenance requirements and enhance the ease
in maintenance.
• Compliance of stringent environmental norms, safety and
other statutory requirements.

23. • Renovation & Modernization of old thermal power stations
is an economical option to supplement capacity addition
programme for increased power availability and Efficiency
• Extension of useful economic life of generating units by
another 15 - 20 years.
• To focus on full load operation of the unit beyond their
original design life.
• Uprating of Generating Unit.
• Improvement beyond design parameters.

24. 24
Drivers for E E R&M
• Availability of Coal, Land & Water is becoming more
difficult for new power projects.
• Coal is an exhaustible natural resource. Hence, its
saving through efficiency enhancement is desirable.
R&M results in lower Specific Coal Consumption.
• R&M is one of the most cost effective measure for
getting additional generation.
• Additional generation from old units becomes
available in very short duration.
( Contd--)

25. • The benefits expected from Comprehensive R&M in a
typical 200/210 MW unit include : -
- Increased output by about 4 - 8%
- Improved Unit Heat Rate by 10 - 15%
- Extended Plant Life by about 15 - 20 years.
• There is a shift from ‘Generation Maximisation’ to
‘Generation Optimisation’ with efficiency enhancement.
Efficiency enhancement of about 8-10% is feasible in the
existing LMZ units.
• Increased emphasis on Environment for clean technology.
The environmental norms are getting more and more
stringent.

26. 26
11th Plan R&M Programme &
Achievements (2007-12 )
Programme
(MW)
Achievement
(MW)
Life Extension
Programme (LEP)
7318
(53 units)
1291
(13 Units)
R&M Programme 18965
(76 units)
14855
(59 units)
Total
26383
(129 units)
16146
(72 units)

27. 27
12th Plan R&M Programme
(20012-17 )
Programme
(MW)
Achievement
(MW)
( 30-09-2014 )
Life Extension
Programme (LEP)
12066
(70 units)
1347.19
( 12 Units )
R&M Programme 17301
(65 units)
1060.5
( 09 units )
Total
29367
(135 units)
2407.69
( 21 units )

28. •Retirement in a systematic manner an ongoing
activity with focus on closing down
•Small and Old units
•Units of non-reheat type
•Units having very low design efficiencies
•Units having very low actual efficiency
RETIREMENT OF POWER PLANTS

29. Present Methodology for Retirement of
units
Units deviating more from design to retire first
Retirement is linked to commissioning of new
units
In case of Gas based , Technology changing
rapidly. Faster retirement could be considered
to keep abreast with technology development

30. RETIREMENTS OF OLD UNITS
• Details of Retirements :
11th Plan - 2398 MW has already been retired
comprising mainly of small size ( <100 MW) ,old and non
reheat units
 12th Plan12-17( Planned)- 4075 MW (< 100 MW coal units,
> 35 years old Gas stations) till date 771 MW
13th Plan (Planned) – about 4000MW

31. Efforts under IGEN Programme
 Mapping of 85 Thermal units done and all the
recommended measure have been implemented
 Guided for adoption of Better O&M Practices
 55 Ebsilon Professional Professional Software
Licenses provided to 15 Utilities
GSECL, HPGCL, PSPCL, MAHAGENCO, CSPGCL, MPPGCL, RRVUNL, NLC,
TANGEDCO, OPGCL, TVNL, DVC, APGENCO, UPRVUNL, and GIPCL

32. TRAINING on USE OF EBSILON
….under IGEN
TRAINING TO 100 ENGINEERS HAS BEEN
IMPARTED ON EBSILON PROFESSIONAL
SOFTWARE
(This training has been imparted by GERMAN and Indian EBSILON EXPERTS)

33. IGEN contd…..
Introduction of Online BPOS and Other Activities
for OLDER TPS for 200MW and Above
 The Boiler Performance Optimization System (BPOS) is
an online computer system which monitors and
optimizes boiler operation. Module for soot blowing
management. In the closed loop mode of operation at
Suratgarh TPS
 INTRODUCTION to energy efficiency through
Efficiency measure and Better Operation and
Maintenance Practices

34. 85 Units MAPPING STUDIES
Capacity
range of
units
No.
of
units
Average
Design
Gross Heat
Rate
(kcal/kWh)
Average
Operating
Gross Heat Rate
(kcal/kWh)
Average
Deviation
(%)
Range of
operating
GHR
(kcal/kWh)
100-110
MW 8 2434.9 3016.8 19.0 2696 - 3601
120-125
MW 9 2395.4 2921.9 18.5 2690 - 3730
140 MW
4 2360.2 2824.1 19.7 2750 - 2905
195-200
MW 5 2399.6 2989.1 24.4 2393 - 3962
210 MW
49 2361.6 2714.4 14.9 2384 - 3064
250 MW
5 2339.1 2687.2 14.9 2546 - 2773
500 MW
5 2254.6 2566.2 13.8 2508 - 2647

35. MAJOR REASONS FOR THE HIGH OPERATING
GROSS HEAT RATE
1. Low combustion efficiency due to improper air-fuel ratio.
2. Poor performance of milling system to meet new demand.
3. Low turbine cylinder efficiency
4. High dry gas losses due to poor heat transfer
5. Poor sealing and heat transfer in air pre-heaters
6. Low condenser vacuum.
7. High air ingress in the boiler and high heat loss due to poor
insulation
8. Improper mill maintenance due to poor spare availability
9. Poor quality of coal
10.High auxiliary power consumption

36. Section wise Unit Heat rate losses in a particular
unit

37. Saving Potential of Coal Based State Power Plants
emerged out through current case studies on 70% plf
0
1
2
3
4
5
6
1 2
0.46
5.07
Case Studies All State Utilities
MilliontonnesofOilequivalent
(MToe)

38. Comparison of average Unit Heat Rate
of different unit sizes
2353.21
2532.30
2311.60
2195.00
2268.60
2633.38
2557.80 2542.80
2343.00
2497.30
1900.00
2000.00
2100.00
2200.00
2300.00
2400.00
2500.00
2600.00
2700.00
120MW 125MW 210MW 250MW 500MW
Load
Average Design Average Operating

39. Variations in Boiler Efficiency
86.03
78.61
86.61
88.93
87.40
81.37
78.12
83.91
88.13
85.70
72.00
74.00
76.00
78.00
80.00
82.00
84.00
86.00
88.00
90.00
120MW 125MW 210MW 250MW 500MW
BoilerEfficiency(%)
LOAD
Design Average Operating Average

40. Parameters 120 MW (2) 125 MW
(1)
210 MW (12) 250 MW
(1)
500 MW (1) Total (toe)
Short Term Potential ( 139317.67 toe)
MS pressure 438.72 0 4449.8 0 63.29 4951.81
MS Temp 41.82 0 1641.34 893.52 0 2576.68
RH Temp 387.78 0 2723.90 186.15 878.63 4176.46
Condenser
Vacuum
839.91 1673.07 50004.95 4573.15 0 57091.08
UBC in Fly Ash 679.07 0 16418.47 0 0 17097.54
UBC in bottom ash 415.49 0 6594.78 404.88 362.99 7778.14
Makeup 0 0 18814.98 0 2498.13 21313.11
Excess air 3615.05 988.22 18846.78 0 882.80 24332.85
Long Term Potential ( 424588.52 toe)
RH Spray 0 915.21 7177.84 0 1556.96 9650.01
SH Spray 10.5 22.59 347.87 0 93.82 474.78
Exit Gas Temp 3002.22 2028.04 32193.89 0 4467.60 41691.95
Change in FW temp 1554.28 0 4867.69 0 6515.25 12937.22
HPT Efficiency 2799.52 4112.85 27154.21 5888.86 4411.76 44367.2
IPT Efficiency 3727.8 769.26 24527.67 749.44 6404.30 36178.47
LPT Efficiency 5052.32 0 197972.48 7491.05 20796.68 231312.53
HPH TTD 3784.42 0 23077.46 851.08 2338.79 30051.75
HPH DCA 0 7.73 2080.06 97.73 0 2185.52
LPH TTD 101.33 0 11784.78 1139.24 308.26 13333.61
LPH DCA 0 0 767.36 0 1638.12 2405.48
Total 563906.18

41. PAT Scheme
• Perform, Achieve and Trade scheme- aim is to
improve Efficiency of the thermal plants both coal &
gas based.
• Total Target Set for thermal power stations= 3.2
MTOE out of total 6.686 MTOE
• Threshold limit to be DC = 30,000 tons of oil
equivalent (TOE) per annum ( all power plants above
11-12 MW will be covered in PAT scheme)
• MOP notified net heat rate reduction targets to 144
Thermal power Stations.
• Stations to achieve the targets within 3 years from
date of notification i.e by 31.3.2015
• Penalty for non achievement

42. Thermal Power Plant Groups under PAT Scheme
Thermal Power Plants
[144 Nos]
Gas [40] Diesel [7]
Coal/Lignite [97]

43. Target Setting for Reduction of NHR
Deviation in Net Station Heat
Rate from Design Net Heat
Rate
Reduction Target for Deviation
in Net Station Heat Rate (%)
Up to 5 % 10 %
More than 5% and Up to 10 % 17 %
More than 10% and Up to 20% 21 %
More Than 20 % 24 %
TARGET SET ARE UNDER NORMALISATION

44. Actual Heat Rate Deviations
S.No. Particulars 2013-14
1. No. of Stations in the range of
SHR deviation(below 5%)
27%
2. No. of Stations in the range of
SHR deviation(5-Below 10%)
32%
3. No. of Stations in the range of
SHR deviation(10-20%)
26%
4. No. of Stations with SHR
deviation of more than 20%
15%
 (ALL INDIA HEAT RATE DEVIATION wrt Design 10.04%
(Huge potential)

46. THANKS
CEA website:
www.cea.nic.in