RAKESH PANDEY

AGM (OPERATION)
NTPC LTD

i.
ii.
iii.
iv.

Station Heat Rate;

Secondary Fuel Oil Consumption;
Auxiliary Energy Consumption; and
Re-financing of Loan.

i.
ii.
iii.

Force Majeure;
Change in Law: and
Primary Fuel Cost.

Re-Financing of Loans

i.
ii.

Force Majeure;
Change in Law:

A regulatory instrument to reduce specific

energy consumption in energy intensive
industries, with an associated market based
mechanism to enhance the cost effectiveness
through certification of excess energy saving
which can be traded.
A market based mechanism to enhance the
cost effectiveness in improving the energy
efficiency in energy intensive industries thro
certification of energy saving, which can be
traded.

National Mission for Enhanced Energy

Efficiency (NMEEE)
Perform Achieve and Trade

Energy Efficiency in Industry

Market

Energy Efficient Appliances

Energy

Transformation for Energy Efficiency

Efficiency Financing Platform

Funding for ESCO

Framework

for Energy Efficient Economic

Development

Fiscal Instruments for energy efficiency

Regulatory instrument linked with market mechanism

Consultative approach

Unit specific targets

Relative responsibility

Workshops/Seminars/ Visits

Self competing

Ministries/DCs/Associations/FIs/Research Organizations

Outreach/ Capacity Development

Certification of energy saving

Less target for more efficient and more for less efficient

Supports improvement in energy management system

measurement, recording and reporting

Policy
Planning
Equipment regulating standards
EE Standards
Energy Audits
Investment

Policy
Planning
Building Codes and standards
Energy Efficiency measures

Energy Audits
Investment

Strengthening attention to long-term energy

efficiency issues as part of the planning process,
especially in urban and transportation planning
Implementation of mandatory energy efficiency
codes and standards for key types of energyconsuming equipment, motor vehicles, and new
buildings
Facilitation of energy efficient technology
transfer, and adaptation and demonstration of
key technological innovations in new plant in
local markets

Provision of information on the demonstrated

performance and cost effectiveness of energyefficient technologies
Development of voluntary energy efficiency
agreement schemes with industry, and energy
efficiency benchmarking programs
Provision of fiscal or direct incentives for
implementation of new and innovative energy
efficiency schemes
Taxation of energy inputs

Lack of information
Lack of trained personnel or technical or managerial
expertise
Below long-run marginal cost pricing and other price
distortions(in some cases)
Regulatory biases or absence
High transaction costs
High initial capital cost or lack of access to credit
High user discount rates
Mismatch of the incidence of investment costs and energy
savings
Higher perceived risks of the more efficient technology

Sufficient technical capacity to identify,

design, and implement the energy
efficiency option.
Financing must be in place to allow
investment
in
energy
efficiency
improvements.
There must be sufficient incentives for the
energy-using enterprise

Boiler
Turbine
Generator

Furnace
Milling System
Fans for Air Supply
Electrostatic Precipitator
Drum
Water and Steam Circuit in Side Boiler

HPT
IPT
LPT
Condenser
Pump

Requirement of Heat per unit energy

generation
Heat added to Boiler (Kcal)

Heat Rate=

Electrical Energy Sent Out (KWhr)

Improper Fuel Combustion

Problems in Milling System
Heat Losses due to improper Insulation
Leakages in Water and Steam Circuit
Condenser
Pumps
Heaters

Efficiency = Output/ Input

= (Input losses)/ Input.

Types of losses

Exit heat loss

Radiation loss
Condenser loss
Auxiliary power loss.

Heat exchanger

Insulation

Vacuum

Efficient auxiliaries and optimization.

Cycle Efficiency is the efficiency of whole cycle

and can be improved by particular set of steam
condition employed
Turbine Efficiency is the efficiency of turbo
alternator converting the available energy in
the cycle into electrical energy.
Boiler Efficiency is effectiveness of combustion
and heat transfer
Auxiliary Power efficiency depends on the ratio
of Electricity sent out to Electricity Produced.

Should be able to produce at required

parameters over
Compatible with feed water conditions which
changes with turbine loads
Capable of following changes in demand for
steam without excessive pressure swing
Reliable

Feed Water System

Makeup Water System
Condensate System
Steam System
Fuel System

DPNL
SHTR

Platen SHTR

Drum

Reheater
S
C
R
E
E
n
Gooseneck

LTSH

Chimney

Downcomer
waterwall

Fireball

Economiser

ID fan

APH
Bottom Ash

ESP

210 MW Boiler: Water and Steam Circuit

LTSH

Final SH.
Platen SH.
500-540C

330-375C

375C-425C
Economizer
Water Wall
240-310C
310C

Assess Boiler Efficiency by Direct

and Indirect Method
Calculate and Optimize Boiler
Blow Down
Identify and Implement energy
efficiency measures

Where energy gain of the working fluid (Water & Steam)

is compared with the energy content of the boiler
fuel.
Heat Output
Boiler Efficiency=

X 100
Heat Input

Q x ( h g hf )
Boiler Efficiency ( )=
X100
q x GCV

Q : Qty of Stm generated in Kg/Hr

q : Qty of Fuel Used in Kg/Hr
hg: Enthalpy of Saturated Stm in KCal/Kg
of Stm
hf: Enthalpy of Feed Water KCal/Kg of
Water
GCV: Gross calorific Value of Fuel in
Kcal/KG of Fuel

Evaluation is quick
Requires Few parameters for
Computation
Needs Few Instrument for
monitoring

No Clue to the operator

Does not calculate various losses accountable

for low efficiency

The efficiency is the difference between the

losses and the energy input.
Loss Method
Boiler Efficiency ( )= 100% - Losses

Loss of Heat due

Loss of Heat due
combustion air
Loss of Heat due
Loss of Heat due
Loss of Heat due

to Dry Flue gases

to Moisture in Fuel and
to Combustion of Hydrogen
to Radiation
to Unburnt

Ultimate Analysis of Fuel i.e. H2, O2, S, C,

Moisture & Ash Content
%age of O2 or CO2 in Flue Gas
Flue Gas Temperature
Ambient Temperature
Humidity of Air
GCV of Fuel
Percentage of Combustibles in ash
GCV of ash

Excess Air
Air Heater gas Outlet temperature

Lack of Soot Blowing

Deposits on Boiler Heat Transfer Surface
High Excess Air (Causes less heat generation
in Furnace and more in SH)
Higher Elevation burners in service at low
load
Defective baffles and bypass dampers,
causing gas short circuiting
Improper Combustion
Poor Milling Plant Performance
Air recirculation

Moisture in Fuel
Moisture in Combustion
Moisture in Air

High Carbon in Ash

Low Carbon in Ash

Coarse Grinding
Mal adjustment of flame
Unequal loading of different Mills
Incorrect PA air temperature

Exhauster speed too low

Mill Adjustment
Rich Fuel / Air Mixture
Separator ( Classifier) speed too high

Lower Pretreatment Cost

Less make up water consumption
Reduce maintenance downtime
Increased Boiler life
Lower consumption of treatment chemicals

BLOW DOWN CALCULATION

Feed Water TDS x % Make up water
Blow Down(%)=
Max. Permissible TDS in Boiler Water
TDS: Total Dissolved Solids
Blow Down Rate = Boiler Evaporation rate X Blow
Down(%)

Stack Temperature
Feed Water Preheating using Economiser
Combustion Air Preheat
Incomplete Combustion
Excess Air Control
Radiation and Convection Heat Losses

Reduction in Scaling and Soot Losses

VFDs for Fans, Blowers and Pumps
Proper Boiler Scheduling
Milling plant performance
ESP performance

 FOR 200 MW UNITS

INITIAL STEAM PR- 150 Kg/Sq. CM (abs.)

INITIAL STEAM TEMPERATURE - 537 Deg C

REHEAT STEAM TEMPERATURE - 537 Deg C

FOR 500 MW UNITS (SUB CRITICAL UNITS)

INITIAL STEAM PR- 170 Kg/Sq. CM (abs.)

INITIAL STEAM TEMPERATURE - 537 Deg C

REHEAT STEAM TEMPERATURE - 537 Deg C

FOR 660 MW UNITS (SUPER CRITICAL UNITS)

INITIAL STEAM PR- 246 Kg/Sq. CM (abs.)

INITIAL STEAM TEMPERATURE - 537 Deg C

REHEAT STEAM TEMPERATURE - 565 Deg C

output
Efficiency =

Kwh
=

Input
Input
1 Kwh = 3600 K J
output
Efficiency =
x 100 %
Heat Input

Heat rate:
210MW LMW Turbine= 2040 K Cal/kWh
= 42.15%
500 MW = 7940 K Cal/kWh
= 45.3%

Degree of Reaction (R)

Enthalpy Drop in Moving Blade
R=
Enthalpy Drop in Stages

Effect of Load

Throttle Governing
Nozzle Governing
Overload (By Pass) Governing

Terminal Conditions

Effects of Vacuum
Effects of MS and RH Temperature
Effects of MS and RH Pressure
Pressure Drop through Reheaters

Effect of Heater Efficiency

Gland Wear
Feed Pump Power

Internal

Friction in Nozzle, Blades & Disc

Diaphragm gland and blade tip leakage
Partial Admission
Wetness
Exhaust

External

Shaft Gland Leakage

Journal and Thrust Bearing
Governor and Oil Pump

Back Pressure

CW Pumping Power
Leaving Loss
Reduced Condensed Temperature/
Increased Blade steam
Wetness of Steam

Monitoring Steam Traps

Avoiding Steam Leakages
Providing Dry Steam for Processes
Utilising Steam at the lowest Acceptable
Pressure for the process
Proper Utilisation of Directly Injected Steam

Minimizing Heat Transfer Barriers

Proper Air Venting
Condensate Recovery

Financial Reasons
Effluent Restriction
Maximizing Boiler output
Boiler Feed Quality

Insulation of Steam Pipelines and Hot Process

Equipments
Flash Steam Recovery

Data Acquisition System

Distributed Digital Control Monitoring

Information System

Data Acquisitions
Data Monitoring and Status Reporting
Alarm Monitoring & Status Reporting
SOE Recording
Mimics and Guidance's
Long Term data storage Retrieval and
Statistical Analysis
Efficiency Calculations at different points
and overall

Better Human Machine Interface

Online Performance Monitoring
Report Generation
Pre and Post Trip Analysis

Planned maintenance loss

Thermal Efficiency factors
Plant Load Factor
Forced Outages
Plant Availability Factor

Availability and Efficiency has a direct

relationship
Higher availability leads to higher efficiency
Efficient Unit leads to better availability due
to better combustion control conditions,
better fluid dynamic condition and better
heat transfer condition

Performance
Improvement

Efficiency
Improvement

Effective Capacity
Utilisation
Investment Cost
Lower Cost of
Generation

Lower Cost of
Generation
Saving in Resources
Increased Life of
Plant

 10C

increase in stack Temp in 200 MW

unit will lead to

Loss of 6-8 Million Rupees per annum

Increase in cost per kwh by 0.13 to
0.17%
Stack Temperature is more than 200C it
means the scope of cogeneration is
available

Decrease in super heat by 14C Leads to

Loss of 3.5 to 5 Million Rupees per

annum
Increase in Cost of per KWH by
0.075% to 0.1%

If there is no HP Heater it leads to

Loss of 20-25 Million Rupees

per annum
Increase in Cost of per KWH by
0.38% to 0.48%

100 MM increase in Condenser Back Pressure

will lead to

Loss of 53 to 56 Million Rupees

per annum
Increase in Cost of per KWH by
1% to 1.06%

100 K Cal/ kwh increase in heat rate leads to

Loss of 58 to 62 Million Rupees

per annum
Increase in Cost of per KWH by
0.95% to 1.02%

Increase in 1% Excess Air leads to

Loss of 0.5 to 1.0 Million Rupees per

annum
Increase in Cost of per KWH by
0.01% to 0.02% paisa

One percent reduction in PLF leads to

Loss of 62 to 65 Million Rupees

per annum
Increase in Cost of per KWH by
0.95% to 1%

Increase in Make up water by 1% leads to

Loss of 9 to 12 Million Rupees

per annum
Increase in Cost of per KWH by
0.18% to 0.24%

Increase in Sp. Oil Consumption by 1ml/ kwh

leads to

Loss of 30-35 Million Rupees

per annum
Increase in Cost of per KWH by
0.55% to 0.65%

Power Generation= PLF x Capacity x No of

Operation Hours
Quantity of Fuel = Heat Input/ Calorific Value
Heat Output= Steam Quantity x Enthalpy x
Operations/ Annum

Why?
Mother earth has limited resources.
Energy production leads to environmental
degradation.
How?
Changing attitude and practices.
Creating awareness.
Optimisation.
Using energy efficient devices.