A STUDY OF ENERGY AUDIT, CONSERVATION Et · PDF filea study of energy audit, conservation et...
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A STUDY OF ENERGY AUDIT, CONSERVATION Et MANAGEMENT MEASURES IN INDIAN THERMAL
POWER STATIONS FOR ENCHANCING POWER GENERATION
THESIS SUBMITTED FOR THE DEGREE OF
DOCTOR OF PHILOSOPHY
By I. P. S. PAUL
Centre of Energy Studies
INDIAN INSTITUTE OF TECHNOLOGY, DELHI April, 1996
CANDIDATE'S DECLARATION
I hereby declare that the work presented in this thesis entitled "A STUDY
OF ENERGY AUDIT, CONSERVATION AND MANAGEMENT MEASURES
IN INDIAN THERMAL POWER STATIONS FOR ENHANCING POWER
GENERATION" in fulfillment of the requirements for the award of the degree
of Doctor of Philosophy, submitted to the Centre for Energy Studies, Indian Institute
of Technology Delhi, is an authentic record of my own research work carried out
by me at CPRI/NPTI/NTPC/IITD during the period from 1989 to 1996 under the
part-time guidance of Prof. S.P. Sabberwal and Prof. S.C. Kaushik, Centre of Energy
Studies, Indian Institute of Technology, Delhi. I further state that while collecting,
compiling and analysing relevant data embodied in the thesis, necessary permission
and cooperation from power stations/concerned authorities was obtained. I am fully
responsible for data collection, measurements during technical visits and experimental
works carried at site/laboratories for Energy Audit and Allied Studies. The matter
embodied in this thesis has not been submitted by me or anybody else for the award
of any other degree to any other university or institute.
I. P. S. PAUL Ph.D. Registation No. 89 RES 008
CERTIFICATE
This is to certify that the thesis entitled 'A STUDY OF ENERGY AUDIT,
CONSERVATION AND MANAGEMENT MEASURES IN INDIAN THERMAL
POWER STATIONS FOR ENHANCING POWER GENERATION' being
submitted by Shri I.P.S. Paul to Indian Institute of Technology, Delhi for award of
the Degree of Doctor of Philosophy is a record of the work undertaken and carried
out by him at CPRI/NPTI/NTPC/IITD under our part-time guidance and occasional
supervision. To the best of our knowledge and belief, the research material contained
in this thesis in present form has not been submitted by him or anybody else in part
or full to any other University or Institute for award of any other degree, as declared
by the candidate.
c- tc6uis Rdti 1,0 Prof S.P.Sabberwal
Prof S.C. Kaushik
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ACKNOWLEDGEMENT
It's my pleasure and privelage to gratefully acknowledge the guidance and
cooperation of my thesis supervisors, Prof.S.P Sabberwal and Prof.S.0 Kaushik of
the Centre for Energy Studies, Delhi for suggesting the most relevant topic of
research. My sincere thanks are for their valuable suggestion, encouragement and
timely help without which it was difficult to complete the studies on part time basis.
I am also thankful to 1.I. T. Delhi and Head, Central of Energy Studies for providing.
all facilities and assistance at all stages.
I am grateful to Shri M.N.God, former Director General, PETS (Now named
NPTI) and Joint Secretary, Ministry of Power, for permission to undertake Ph.D
studies in July '89. Consequent to joining CPRI, in September '92
Dr. M. Ramamoorty, former Director General-CPRI consistently encouraged me to
complete the work as soon as possible. Senior officers of National Power Training
Institute who helped me in various stages were Shri V.S.Lothe, Chief Superintendent,
Nagpur, Shri Prithvipal Singh, Director (Finance & Admn.), Shri A.Arunachalam,
Chief Superintendent Neyveli. At CPRI support of Shri M. K. G Pallai, Director
General, Shri V. Jayachandran, Dr. P.R. Krishna Murthy, Shri. V.B. Ram Mohan
and Shri S. Sridharan Additional Directors is gratefully acknowledged. Deep
apprecation for the help and cooperation of Shri 1. Budding, Shri Mahender Singh
and Smt. V. Bhardwaj is duly acknowledged.
The grateful thanks are also expressed for the kind co-operation of authorities
of Power, Ministry of Power- GOI, NLC, NTPC, APSEB, MPEB, TNEB, CPRI in
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sponsoring Energy audits and permitting use of data/ information collected analysed
and presented in various chapters. 1 am grateful for permitting to undertake technical
study visits in their power stations and numerous suggestions to improve the quality
of research.
Excellent facilities provided by CPRI, NPTI, NTPC, HT, (Delhi) at various
stages of this project while my postings in New Delhi, Durgapur, Neyveli, Nagpur and
Bangalore are gratefully acknowledged. I express sincere gratitude to Shri K.R.
Krishnaswamy, Dr. S. Seetharamu, Shri M. Siddhartha Bhat, Shri R. P. Mandi,
Shri B.B. Gujala for the kind assistance in carrying out various measurements and
laboratory experiments.
The people behind the scene are more vital and among them are my wife
Mrs. Sukhinder Paul, daughter Geetika and many of my collegues in Materials
Technology, High Power Laboratory and Electrical Apparatus Testing Divisions.
I am extremely indebted to them for their kind help and willing support.
Last but not the least, I want to place on record my indebtness to
Prof S. C. Kaushik for his personal guidance, painstaking efforts and deep interest
in thesis. His moral support and effective criticism of the thesis work is worth
appreciation and I wish that every student should get such an able and devoted guide
for the heart breaking thesis work.
I.P.S PAU\-)k\r\L
SUMMARY
The thermal power stations are installed to convert available energy in coal/
lignite/petroletim products into electricity. Besides economy, efficiency and
environment considerations, the energy consumptions in power generation is of
prime significance. The thesis presents some energy auditing studies for savings in
auxiliary power, coal, oil etc. and thereby achieving the main objectives of increased
power generation, improved efficiency and economy in Indian thermal power plants.
The literature survey has revealed that about 70% of India's power
requirements are being met by 329 coal fired thermal power stations having unit
sizes from 30 MW to 500 MW. Consistant developments from operating the plants
based on conventional approaches for effective end use of energy, installing energy
efficient equipment using computer aided designs/ operation/maintenance have taken
place from time to time. However, energy conservation & management measures in
an integrated manner have not been studied for practical applications in actual
operation and maintenance of these plants. Thus this doctorate thesis was under
taken as a project for Indian thermal power stations and the results are for direct
applications in the field. The author had conducted actual field studies/investigations
and gathered relevant data from power stations all over India located particularly in
Madhya Pradesh, Andhra Pradesh & Tamil Nadu and had carried out detailed
energy audit studies in their coal fired thermal power stations. Energy auditing
measurements covered study of thermal plants, process/equipment, oil, coal and
combustion as well as steam/water ciruits, auxiliary power consumption in pumps,
fans, mills, lighting, transformers, and over-all energy management systems. The
collection and analysis of coal and ash samples by laboratory experiments,
measurements at actual plant site(s), compilation of data and parametric readings
alongwith their numerical appreciation by Computer Graphic Software for curve
fittings on PC-AT-486 have been reported and practical/feasible recommendations
for energy saving have been made.
The study of optimum economy and efficiency in energy consumption during
(a) start up (b) normal running and (c) shut down of the typical 210 MW thermal
power plants covered problems leading to delays, and excessive energy
consumption. Remedial measures like standardisation approaches; near elimination of
air leakages in boiler ducts, electrostatic precipitators and air preheater; optimisation
of coal fineness/common auxiliaries, operational ease and monitoring have been
suggested.
Energy analysis for performance evaluation has been stressed by energy
accounting, testing of plant components, consistant monitoring of controllable
parameters. These parameters include flue gas analysis at economiser/air preheater
outlets, humidity of air, coal quantity/quality, unburnt combustibles in fly ash and
flkke gases etc. Significance of accurate instruments, repeatability, proper location
is stressed. A simple energy balance for the 210 MW thermal power plant boiler has
been presented for identifying the energy distribution ratios.
The role of condenser-vacuum, excess air, sliding pressure operation,
renovation and modernisation has also been discussed. The energy efficient
technologies in variable speed (frequency) drives, fluidised bed boilers, tower top
and once through boilers too have been recommended as futuristic technologies for
enhanced power generation.
The main effort in the thesis first of its kind in India has been in conserving
energy at the existing Indian plants by energy auditing, renovations and maintenance
and suggesting practical measures/ techniques for skilled technicians and plant
engineers/managers. It is vital because by using even about one tenth the generation
cost, time/effort and energy, enhanced energy generation is possible by
implementing the aforesaid conservation measures. These measures have found wide
acceptance and appreciation from power station authorities, Central Electricity
Authority and Ministry of Power, Govt. of India.
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CONTENTS
Page No.
Candidates Dec-laration Certificate Acknowledgement Summary Preface Nomenclature List of Tables and Figures
I INDIAN POWER SCENARIO - SURVEY OF STRATEGIES AND ROLE OF ENERGY CONSERVATION IN THERMAL SECTOR 1-10
1.1 Introduction
1.2 Power Generation Resources
1.3 Problems of Power Generation
1.4 Outlook for the Future
1.5 Eighth Plan Proposals for the power sector
1.6 Thermal Power Development
1.7 Energy Conservation Programme in Eighth Plan and its Interface with Thermal Power Generation
1.8 Energy Conservation Programme in Eighth Plan
1.9 Investment in Energy Conservation
1.10 Strengthening infractrusture
1.11 Conclusions
II LITERATURE SURVEY OF SYSTEMATIC APPROCHES FOR ENERGY CONSERVATION IN THERMAL POWER GENERATION 11-27
2.1 Introduction
2.2 Basic principle of organising an energy management programme in TPS
2.3 Organising an energy management programme
2.4 Energy audit related to power plants
2.5 Energy Audit-An Integral step in Management Process
2.6 The energy audit: its role in TPS
2.7 Computer based energy management systems
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2.8 Survey of Energy conservation Technology
2.9 Identification of counter measures
2.10 Review on Energy Conservation in Indian Thermal Power Stations
2.11 Conclusions
III ENERGY AUDIT STUDIES IN A TYPICAL 30 MW THERMAL POWER STATION 28-49
3.1 Introduction
3.2 Energy Audit Studies in a 30 MW Thermal Power Station 3.2.1 Thermal Power Plant Description 3.2.2 The Process and Equipment 3.3 Results of Energy Audit Studies
3.4 Energy Management System
3.5 Conclusions
IV ENERGY AUDIT STUDIES IN A TYPICAL 62.5 MW THERMAL POWER STATION 50-69
4.1
4.2
4.3
The Thermal Power Station Description
The Process and Equipment
Results of Energy Audit Studies
4.4 Energy Management System
4.5 Conclusions
V ENERGY AUDIT STUDIES IN A TYPICAL 110 MW THERMAL POWER STATION 70-101
5.1 The Thermal Power Station Description
5.2 The Process and Equipment
5.3 Results of Energy Audit Studies
5.4 Energy Management System
4.5 Conclusions
VI ENERGY AUDIT STUDIES IN A TYPICAL 120 MW THERMAL POWER STATION 102-120
6.1 The Thermal Power Station Description
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6.2 The Process and Equipment
6.3 Results of Energy Audit Studies
6.4 Energy Management System
6.5 Concusions
VII ENERGY AUDIT STUDIES IN A TYPICAL 210 MW THERMAL POWER STATION
7.1 The Thermal Power Station Description
7.2 The Process and Equipment
7.3 Results of Energy Audit Studies
7.4 Energy Management System
7.5 Conclusions
122-151
VIII, OPTIMUM ECONOMY AND EFFICIENCY IN ENERGY CONSUMPTION DURING START-UP, SHUT DOWN AND NORMAL RUNNING OF 210 MW THERMAL POWER STATIONS
152-171
8.1 Introduction
8.2 Site Trials Analysis of Problem of Delays
8.3 Delay Due to Turbine Expansion and Associated Problems
8.4 Delay Due to Generator Windings Dry Out
8.5 Starting/loading and Stopping of Power Generating Unit with Minimum Number of Auxiliaries
8.6 Standardization Approaches for Minimum Number and Timely Running of Auxiliaries While Start up/Shut down of Unit
8.7 Reduction in Auxiliary Energy Consumption During Normal Load Operation of the Thermal Power Station
8.8 Conclusions
IX PERFORMANCES MONITORING AND ENERGY ANALYSIS FOR ENERGY EFFICIENCY IMPROVEMENT IN THERMAL POWER STATIONS
9.1 Introduction
9.2 Methods of Performance Monitoring
9.3 Boiler & Turbine Tests
172-185
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9.4 Vital Controllable Parameters
9.5 Energy Analysis of Typical 210 MW Plant
9.6 Performance Improvement through Plant Rehabilitation and Modernisation
9.7 Key Role of Parameters Influencing Efficiency
9.8 Optimal Control by Performance Monitoring
9.9 Some Practical Aspects of Monitoring
9.10 Conclusions
X ADDITIONAL ENERGY CONSERVATION BY MEASURES TECHNOLOGICAL OPTIMISATION, ENERGY EFFICIENT EQUIPMENTS, RENOVATION AND MODERISATION AND FUTURISTIC TECHNOLOGIES
10.1 Introduction
10.2 Components Constituting Energy in TPS
10.3 Conservation of Coal/Lignite
10.4 Conservation of Steam
10.5 Sliding Pressure Operation
10.6 Conservation of Furnace Oil
10.7 Role of Excess Air
10.8 Savings Through Auxiliary (Works) Power
10.9 Enhancing Energy Conservation and Efficiency by Renovation & Modernisation in Thermal Power Plants
10.9.1 Investigations & Analysis for poor performance of Indian Thermal Power Stations
10.9.2 Technological necessities of life extension in Indian TPS
10.9.3 Study of major components for residual life assessment
186-215
10.9.4 Futuristic Engineering innovations in uprating and renovating Indian power capacity
10.10 Futuristic Energy Efficient Steam Generation Technologies for Thermal Power Station
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10.10.1 Integrated Coal Gasification Combined Cycle Plants 10.10.2 Futuristic Technologies
10.10.3 Magneto Hydero-Dynamics power generation system
10.10.4 Fluidised Bed Combustion Boiler
10.10.5 Once Through Boilers (OTB)
10.10.6 Tower Types Boilers (TTB)
10.11 Conclusions
XI SUMMARY OF CONCLUSIONS AND RECOMMENDATION 215-219
RELEVANT REFERENCES 220-229
BIODATA 230