Evonik Thermal Analysis For MAHAGENCO Turbines

Mrs. Remich/ Mr.
Nietzschmann, Germany
Dr. Verghese, India
15.05.2008
The Importance of Sound
Simulation, Analytics and
Operation Support Systems
for the Implementation of
Efficiency Enhancement
Measures
Seite | 2 15.05.2008 | A. Nietzschmann, C. Remich, Dr. Verghese
A sound simulation, diligent analytics and
reliable operation support systems for the
Implementation of Efficiency Enhancement
Measures (Retrofits) are mandatory for a
sustainable, economical and environment-
friendly operation of power plants
Efficiency Enhancement Measures are
exemplarily shown by Evoniks steam turbine
retrofits
Evoniks approach and methodology will be
presented and is adaptable to other projects
and clients
Introduction
Seite | 3 13.05.2008 | Dr. Verghese, A. Nietzschmann, C. Remich
1. Energy Enhancement Projects of ESS,
India
2. Reasons for Retrofits and Applicable
Measures
3. Evaluation Process for Retrofits
4. Sustainable Operation Management
with Operation Support Systems
Energy Enhancement Projects of
ESS, India
GTZ funded program
Ebsilon Mapping of 85 old units of sizes 100 to 500 MW belonging to the
Electricity Boards for CEA
KfWfunded program
Basic Findings for Improving Efficiency and Reliability of 200/210 MW
Power Units in partnership with Vattenfall, Europe
World Bank projects:
Consultancy services for Energy Efficiency, Renovation & Modernization
of 210 MW Unit #5 at Bandel TPS - under Coal Fired Power Station
Rehabilitation Project
Consultancy Services to design Renovation & Modernisation scheme to
improve the Energy Efficiency, Upgrade Capacity and Residual Life of
Koradi TPS, Unit 6 (210 MW)
Review of O&M and Management Practice of MAHAGENCO & WBPDCL
for Koradi & Bandel Rehabilitation Projects
Energy Enhancement Projects of
ESS, India
PSEB
Owners Engineering Services, R & M works unit 3 &4, 110 MW, GNDTP,
Bathinda
RLA/CA/LE Studies and Performance Testing of 2 x 210MW units at Ropar
CSEB
RLA/CA/LE Studies and Performance Testing for 4 x 210 MW units of the
Hasdeo TPS at Korba West
R&M Consultancy Services towards preparation of techno-commercial
specification, evaluation of bids and detailed engineering of 4 x 210 MW
units at Korba West TPS
Residual Life Assessment and Steam Path Audit studies:
2 x 210 MW GGSSTPS at Ropar for PSEB
200 MW Unit #2 RamagundamTPS of NTPC
About 130 units of LMZ/KWU turbine types
Installed between 1977 and 1982
Operation hours accumulated varies between 150,000 to 200,000
hours
Plant Load Factor varying from 62 % to 90 %
Results of 26 units of 210 MW size which were mapped show a
wide range of performance parameters
Basic Data of old 210 MW in India
Observed Operating Capacity of
210 MW capacity units
Operating Capacity of 210 MW capacity units (MW)
170.0
175.2
190.0 195.9
207.8
219.0
210.8
0.5
50.5
100.5
150.5
200.5
250.5
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Observed Gross Heat Rate of
Power Plants (kcal/kWh)
Gross Heat Rate of 210 MW capacity units (kcal/kWh)
2,877
2,839
2,824
2,747
2,643
3,064
2,477
2,952
2,300
2,400
2,500
2,600
2,700
2,800
2,900
3,000
3,100
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Observed Boiler Efficiency (%)
Boiler Efficiency of 210 MW capacity units (%)
79.10
82.00
77.25
84.20
74.00
76.00
78.00
80.00
82.00
84.00
86.00
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Observed Turbine Heat rate
(kcal/kWh)
Turbine Heat Rate of 210 MW capacity units (kcal/kWh)
2407
2359
2337
2266
2234
2045
1900
2000
2100
2200
2300
2400
2500
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Observed Auxiliary Power
Consumption (%)
Percentage of Auxilary Consumption of 210 MW capacity units (%)
8.68
11.82
8.07
8.9
9.11
9.32
11.19
6.5
7.5
8.5
9.5
10.5
11.5
12.5
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Dr. Jacob T Verghese, Managing Director
Evonik Energy Services India Pvt Ltd
15.05.2008
Analysis of Nasik Unit III-
210 MW Thermal Power
Plant
Unit Capacity : 210 MW
Unit No : 3
Year (age) : 1979 (29 years)
Boiler Make : BHEL
Turbine Make : BHEL
Owner : Mahagenco
Introduction to the unit
Output : 210.80 MW
Gross heat rate : 2371.8 kcal/kWh
Turbine heat rate : 2040 kcal/kWh
Boiler efficiency : 86%
Unit efficiency : 33.6 %
Coal consumption : 0.47 kg/kWh
GCV of the coal : 5000 kcal/kg
Design Details
Design Model
Operating Model with
Actual GCV
Output : 209.7 MW Gross heat rate : 2675.8 kcal/kWh
Boiler efficiency : 81.9% Unit efficiency : 32.1 %
Turbine heat rate : 2192.4 kcal/kWh
Operating Model with
Design GCV
Output : 209.7 MW Gross heat rate : 2650.6 kcal/kWh
Boiler efficiency : 82.7% Unit efficiency : 32.4 %
Turbine heat rate : 2192.2 kcal/kWh
R & M Activities for
Boiler
Boiler water wall, superheater, economiser, safety and
critical valves
Low NO
x
burners and secondary air control
Ducts, expansion joints, insulation & cladding
Milling system up gradation with raw coal feeders to meet
current firing demand of available coal quality
Air preheaters and ESP (Electrostatic precipitator)
Fans -FD, ID and PA
Boiler soot blowers, CO monitoring, SWAS, performance
monitoring & control
Ash handling system
Coal handling system
Compressed air system
Impact of Rehabilitation on
Boiler
Improvement in Boiler Efficiency (%)
81.9
86
79 80 81 82 83 84 85 86 87
Before
After R&M
R & M Activities for
Turbine
Components included for R & M are:
LP Turbine and HP turbine retrofitting
Turbine gland sealings
Regenerative heaters
Condenser retubing & online cleaning system
Boiler feed pumps with energy efficient cartridges and auto
scoop controls
Turbine stress evaluator, ATRS, EHS control
Modified HP/LP bypass valves & other critical valves
Objective:
To Improve the heat rate and reduce the losses
To improve the turbine controls
Impact of Rehabilitation on
Turbine
Improvement in Turbine Efficiency (%)
75
89
60
85
90
80
50 60 70 80 90 100
HP
IP
LP
After R & M
Before R & M
Installation of smart transmitters and prime measuring elements,
localized cabinets meeting IP 56 protection standards, thermo couples
with compensating cables
New DCS system including monitoring, diagnosis, boiler protection
Replacement of cables-on need basis and wirings, dampers and actuators
Replacement of flow elements, scanners, igniters, level transmitters
Partial retrofit of electrical system
Modern O&M organisation & procedures to reduce cost
LAN system and local server with firewalls to transmit and receive data to
expert centres
Objective:
To improve reliability and achieve smooth & efficient operation
Improved control for load change in response to load demand.
Adaptable for on line efficiency monitoring and optimization
R & M Activities of
I & C and Electrical Systems
Improvement in power generation
Increase overall efficiency
Improve the unit availability
Increase the period between overhaul
Reduce the O & M costs
Extension of equipment life time up to 20-25
years
Reduction in auxiliary power consumption
Summary of benefits
of R & M activities
Options for R & M
Option A
1
Option B Option C
Essential R & M Include
Option A and
Include
Option B and
DCS system with
Prime measuring
elements
LP turbine retrofit Generator
modification
Total APH
modification
HP and IP turbine
retrofit
Parameter Option A
1
Option B Option C
Load, MW 210 215 220
Heat rate,
kcal/kWh
2543 2456 2402
Capital Rs
Million
3625 4630 5099
Features of options
Salient features of financial options
Par ticular s Units Option A
1
Option B Option C
Capacity MW 210 215 220
Capital Costs Rs Million 3625 4630 5099
Capital Cost/MW Rs Million 17.26 21.54 23.18
Shut Down Duration Months 5 6 7
Plant Load Factor (Zeroth Year) % 45.21 42.50 35.42
Plant Load Factor (First Year) % 77.5 85 85
Heat Rate kcal/kWh 2543 2456 2402
Gross calorific value of coal kcal/kg 3800 3800 3800
Aux consumption in zeroth Year % 8.75 8.5 8.5
Specific Consumption of Oil ml/kWh 2.00 1.00 1.00
19.81% 21.85% 21.25% FIRR
Sensitivity Analysis of options
Financial cost
Particulars Option A1 Option B Option C
FIRR - Base Case 19.81% 21.85% 21.25%
FIRR 21.42% 23.66% 23.03%
Change in FIRR in absolute terms 1.60% 1.81% 1.78%
Change in FIRR in relative terms (%) 7.48% 7.66% 7.73%
FIRR 18.41% 20.28% 19.70%
Change in FIRR in absolute terms -1.40% -1.57% -1.55%
Change in FIRR in relative terms (%)
-7.60% -7.75% -7.84%
(-ve is adverse)
A. Impact of changes in Capital Cost - Reduction by 10%
B Impact of changes in Capital Cost - Increase by 10%
Sensitivity Analysis of Options
Power Tariff
FIRR - Base Case 19.81% 21.85% 21.25%
FIRR 16.63% 18.81% 18.37%
Change in FIRR in relative terms (%) -19.15% -16.14% -15.66%
FIRR 22.45% 24.45% 23.72%
11.75% 10.64% 10.41%
A. Impact of changes in Power tariff - Reduction by 10%
B.Impact of changes in power tariff-Increaseby 10%
Power Tariff
FIRR - Base Case 19.81% 21.85% 21.25%
FIRR 16.63% 18.81% 18.37%
FIRR 22.45% 24.45% 23.72%
11.75% 10.64% 10.41%
A. Impact of changes in Power tariff - Reduction by 10%
B.Impact of changes in power tariff-Increaseby 10%
Shut Down Period
FIRR - Base Case 19.81% 21.85% 21.25%
FIRR 19.62% 21.60% 20.98%
-0.99% -1.15% -1.28%
(-ve is adverse)
Impact of increase in Shut Down Duration by 10%
FIRR Sensitivity to 10% Adverse Variation in Selected Factors
19.8%
21.8%
21.2%
18.4%
19.7%
18.4%
19.6%
21.6%
21.0%
20.3%
16.6%
18.8%
0%
5%
10%
15%
20%
25%
Option A1 Option B Option C
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R
R
FIRR Increase in Capital Cost Reduction in Power Tariff Increase in Shut Down Duration
India
Measures
Reasons for Retrofits and
Applicable Measures
Steam Turbine Retrofit
Measures:
Objectives:
Improvement of Turbine
Efficiency due to new parts as
well as new design
improvement of unit efficiency
increase of power output at constant
fuel input with low specific costs
reduction of specific CO2-emissions
reduction of maintenance costs
Requirements
for Evoniks Retrofit:
short schedule of project
realization during a normal long-time
shut-down (maintenance) of the unit
short payback-time
success of measure
State of Turbine:
old design, means effficiency
is not state of the art, but
remaining life time sufficient
for further operation or
life time extension of parts
possible by overhaul
Potential Measures on Steam Turbines
HP- and IP-cylinders
further use of outer casing mostly possible
replacement of inner casing and modification to state-of-the-art 3D-blading
-
i,HP
88% ;
i,IP
92% (150 MW / 300 MW)
- if necessary upgrade of process-parameters (residual life time!)
- sliding-instead of constant-pressure operation
(only HP; depending on boiler)
replacement of shaft
drop-in or complete module replacement
Applicable Measures
Potential Measures on Steam-Turbines
LP-cylinder
modification to state-of-the-art 3D-blading
lowering of condenser vacuum by condenser optimization
duration of measures
from order approx. 16-24 months (depending on type and manufacturer)
Applicable Measures
India
Measures
Evaluation Process for Retrofits
Decades of experience
and striking new grounds in the energy field
Kln-Godorf
211 MW
2004
Termopaipa
165 MW
1999
Infracor
600 MW
Iskenderun
1.320 MW
2003
Mindanao
232 MW
.
2006
Walsum
750 MW
COD 2010
Walsum
600 MW
Weiher
724 MW
Fenne
502 MW
Lnen
500 MW
Voerde
2.234 MW
Bergkamen
747 MW
Herne
950 MW
Bexbach
773 MW
Leuna
158 MW
1996
COD =Commercial Operation Date
Evaluation Process for Steam Turbine Retrofits
Measurement of the units
characteristics like turbine
and plant efficiency on a
time to time basis
(report / units history)
Evaluation Process for Steam Turbine Retrofits
Simulation of a reference
heat and mass balance of
the units actual state of
the water-steam cycle by
utilization of Evoniks
simulation software
Ebsilon
Professional
real model of the unit
compiled with Evonik ES Programme EbsilonProfessional
Evaluation process for steam turbine retrofits
increased power output = improved plant efficiency
Calculate the improvement of
the cycle with state-of-the-art
turbine efficiencies
(manufacturers figures)
Calculate the improved plant
efficiency
150 MW
157 MW
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Wrap up: Evaluation process for steam
turbine retrofits
Measurement of the unit on a time
to time basis reports
Economic evaluation on basis of
expected costs, schedule of power
plant and remaining operating
hours
Realization of Retrofit during
planned outage
Acceptance test after Retrofit to
confirm guarantee values
(mostly turbine efficiency)
executed by EES/supplier
What is necessary to carry out Retrofits
successfully :
large amount of experience in retrofit-
projects
(very different engineered units)
good knowledge of necessary scope of
measures, used materials and worked out
concepts
reliable planning / scheduling
wide-spread expertise of thermodynamic
simulation, engineering and testing services
India
Measures
Performance Analysis Diagnostics
and Optimization Package
In 2002, BHEL placed its first order for a complete
Diagnostic and Optimisation System(PADO) based
on STEAG/KETEK SR Systems for the 2 x 500
MW units of NTPC at Simhadri
After the successful installation and trial use, BHEL
have placed a further order for 14 units of 500 MW
unit size at:
Ramagundam, Sipat, Vindhyachal, Rihand,
Kahalgaon and Talcher Power Stations
Main Features
Complete Plant Optimisation based on
validated 5-minute calculations
Controllable losses identified and highlighted
in terms of Rs/hour
Soot Blowing Optimisation
Set Point Optimization
Root Cause Diagnosis
Boiler Life Time Monitoring
Overview
Boiler
Turbine
Condenser
Trending
Signing of Framework
Agreement for PADO
PADO
Performance, Anal ysis, Di agnostic, Optimization
Summary Sheet
Particulars Units
Option A1
Option B Option C
Capacity MW 210 215 220
Capital Costs Rs Million 3625.24 4630.06 5099.23
Capital Cost/MW Rs Million 17.26 21.54 23.18
Residual Plant Life Years 15 15 15
Project Duration Months 24 24 24
Shut Down Duration Months 5 6 7
Plant Load Factor (Zeroth Year) % 45.21 42.50 35.42
Plant Load Factor (First Year) % 77.5 85 85
Plant Load Factor (annual reduction of PLF) 0.2 0.1 0.1
Heat Rate kcal/kWh 2543 2456 2402
Heat Rate after first major overhaul after 5 years kcal/kWh 2555.72 2468.28 2414.01
Heat Rate after second major overhaul after 10 years kcal/kWh 2568.49 2480.62 2426.08
Heat Rate Escalation Factor % 0.3 0.2 0.2
Gross calorific Value of coal kcal/kg 3800 3800 3800
Aux Consumption Zeroth Year % 8.75 8.5 8.5
Aux consumption after first major overhaul after 5 years % 8.78 8.53 8.53
Aux consumption after second major overhaul after 10 years % 8.81 8.56 8.56
Annual increase in Aux Consumption 0.2 0.15 0.15
Specific Consumption of Oil ml/kWh 2 1 1
Specific Consumption of Oil annual Escalation factor % 1 1 1
Dismantling, erection and commissioning %age of Equipment cost % 18.5 18.5 18.5
Option A
1 -
Summary
Boiler
Renovation of essential pressure parts replacement
depending up on equipment history & analysis
Rectification and retrofitting milling system
Installation of CO monitoring and combustion control
Renovation of ducts & insulation systems
Air preheater rectification
Dry ash handling system & Systems required for
environmental compliance
Rectification of boiler auxiliaries and water system
Option A
1 -
Summary
Turbine
Renovation of HP, LP and IP turbine of old technology
Retrofitting of modified regenerative heaters
Improvement in HP, LP bypass system
Retrofitting of TSI and EHS system
Rectification of hangers and supports
Rectification of critical valves
Rectification of turbine auxiliaries
Condenser retubing and on-line cleaning system
Rectification of cooling towers and CW system
Option A
1 -
Summary
Electrical and I & C System
Renovation of control and instrumentation system
Replacement of transmitters and prime measuring
instruments
Online monitoring and optimization system
Retrofitting of switchgears,isolators and LT and HT
panels
Modification of switchyard
Retrofitting new protection system
Retrofitting of seal oil system, generator rotor,
hydrogen dryer
Implementation of energy management system
Retrofitting of electrical system for auxiliaries
Summary Sheet
Option A1 Option B Option C
FIRR 19.81% 21.85% 21.25%
Sensitivity Analysis basis FIRR (above)
A. Impact of changes in Capital Cost
Reduction in Capital Cost % 10% 10% 10%
FIRR 21.42% 23.66% 23.03%
Change in FIRR in absolute terms (-ve is adverse) 1.60% 1.81% 1.78%
Increase in Capital Cost % 10% 10% 10%
FIRR 18.41% 20.28% 19.70%
Change in FIRR in absolute terms (-ve is adverse) -1.40% -1.57% -1.55%
B. Impact of changes in Power Tariff
Reduction in Power Tariff % 10% 10% 10%
FIRR 16.63% 18.81% 18.37%
Increase in Power Tariff % 10% 10% 10%
FIRR 22.45% 24.45% 23.72%
Change in FIRR in absolute terms (-ve is adverse) 2.64% 2.60% 2.47%
C. Impact of increase in Shut Down Duration
Increase in Shut Down Duration % 10% 10% 10%
FIRR 19.62% 21.60% 20.98%

Evonik Thermal Analysis For MAHAGENCO Turbines

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