Power Plant Engineering 1.58] INDIAN ENERGY SCENARIO Economic growth in India, being dependent on the power sector, has necessitated an enormous growth in clectricity demand over the last two decades. In 1947, the total power generation capacity was only 1360 MW, and by 1991 it grew to 65,000 MW, of which 69% (45,000 MW) was generated in thermal plants. Hydro developments, as stated are not so environmentally benign as was earlier believed. They can cause conflict over usage of lands and the damage to ecology. The total Indian hydro-potential, as assessed by the Central Electricity Authority, is 84,000 MW. The installed capacit 18,443 MW (March, 1991) compared to 200 kW in 1897 (Darjecling) and 508 MW at the time of independence. Most of the turbomachinery have been indigenously produced by the Bharat Heavy Electricals Ltd., the largest unit being 165 MW. However, the pace of hydro development has considerably slowed down recently for many reasons, and the focus is more on mini or small hydel plants in the mountainous regions. Tentatively, in the order of 26,000 MW of hydro capacity would be added by 2002 during the 9th five-year plan, as envisaged. Nuclear power promotion has all but ceased in many areas of the world as a consequence of growing public concern regarding safety and regulatory hurdles. Nonetheless, in India, there appears to be a comparatively energetic nuclear programme. Presently, in India, about 2.3% of generating capacity is nuclear based. This corresponds to about 1500 MW of the installed capacity comprising 8 units. An additional 1320 MW is under construction, based on 220 MW units, and should be on line by 1997. According to the development plan, the total installed capacity by 2002 will be 5700 MW, including the first Indian 500 MW PHWR unit in Rajasthan. It is anticipated that following on the tail of the natural uranium fuelled reactor programme, a fast breeder programme using plutonium will be established, followed by a thorium based programme, thereby taking advantage of a large indigenous resource of thorium. The state-of-the-art technology for the renewable energy utilization (i.e. solar, wind, biomass, tidal. OTEC, etc.) is such that it will hardly make any contribution to the total energy production. However, construction of a 100 MW ocean thermal energy conversion (OTEC) project has commenced in 1994, 40 km offshore from Kulasenkharapatnam in Tamil Nadu. Coal-fired power plants are now getting maximum attention, since coal is abundantly available and the implementation time is relatively short. Tentatively, the additional thermal power generation capacity during the 8th Plan is 28,000 MW and during the 9th Plan (by 2002) further 32,000 MW has been added as shown in Table 1.2. It has been planned to generate an additional 73,000 MW of power by the end of the 11th Plan (2007-2012) which excludes the proposed eight ultra megapower projects with a capacity of 4000 MW each (i.e. 105,000 MW total). The per capita energy consumption will be still 600 MW in India, while it is 12000 MW in China (in 2006).Introduction: Economics of Power Generation 3] Table 1.2 Indian generation capacity (in MW) 1991 8th Plan 9th Plan 10th Plan _—‘Total (1997) (2002) (2007) (2007) Thermal 45.000 28,000" 32,000 58,000 —1,63,000 (69.3%) Hydro 18,443 8,680 26,000 23,000 76,123 (28.5%) Nuclear 1,500 1,320 2,880 5,700 (2.2%) Addition 38,000 61,000 81,000 Total 65,000 1,03,000 1,64,000 2,45,000 ® includes 7500 MW of gas-based combined cycle plant. As in other parts of the world, natural gas-based combined cycle power plant is gaining prominence. Consequently, the 8th Plan envisages installation of 7500 MW capacity, using indigenous gas reserves. Table 1.3 gives the growth pattern in unit sizes and steam parameters in coal-based power plants. In the 70s, the focus was on 100 and 200 MW units, while in the 80s it was on 210 and S00 MW units. Consideration is now being given to increasing the size of future units to 660,800 and 1000 MW to reduce installation cost per kW. Table 1.3 Growth pattern in unit sizes and steam parameters Unit Collaboration Steam Station No. of size parameters first units (MW) installed till March, 1991 10-15. 27.5 bar 400°C 1947-50 NA. 30-37.5 59 bar, 482°C 1951-60 62 60-100 72.4-91 bar, 1961-76 56 496-535°C 100 USSR 91 bar, 535°C Patratu Dec. 71 79 200 LMW, USSR 132 bar, Obra Dec. 77 12 535°C/535°C (UPSEB) 210 KWU, Siemens 152 bar, Korba March 83 89 535°C/535°C (NTPC) 500 KWU, Siemens 172 bar, — Trombay-5_Dec. 84 13 538°C/538°C (Tata) With the liberalization of Indian economy, the power sector has been made open to the private sector, and it is expected that the rate of growth of generation capacity will be faster than that envisaged in the five-year plans (Table 1.2).3) Power Plant Engineering nun Gunviauan Ayouerq pajeny 0D pazuaaing wapowW vT'T “Bra uraysis dnuea]> wopsnquios-1s0d (0 a8 aera ts mene setae eres Uypuey or yse AU ‘Aseutig €) qorwiauad wIEDIg (s)ury yep fe posiog Sy Jeaowas 70S twarsks uo1ss9.Auo9 19M0g (s)dumnd aresuapuoy — (saieay s1empaa4 (samor Suyjoo warsks s97em Sunejnost) | ‘saurqiny, / ad ansasoy /. nds / ee aqtd sansy, O2P TS ot Wireps5; > 809 jes PL OF 9 kn vipaoyas to) | Repu Burpeoqun ures ways funpuey je0 (spiopoagIntroduction: Economics of Power Generation 3) 6 COAL-FUELLED ELECTRICITY GENERATING UNIT Figure 1.14 depicts a modem pulverized coal-fired electricity generation facility that uses the most commonly employed Rankine-based thermodynamic cycle. Steam at the desired pressure, temperature and mass flow is produced in a steam generator and expanded through a turbine generator. The exhaust steam is then condensed in a condenser and the condensed liquid is used again in the steam generator. Coal is delivered to the facility by railway wagons, barges or trucks. The coal handling system unloads the coal, stocks, reclaims, crushes and conveys it to storage silos. Coal from the silos is then pulverized to a fine powder and blown into the steam generator, where it is mixed with air and combusted to release energy for the generation of steam. The steam generator produces, superheats and reheats steam as it proceeds through the cycle. The steam turbine generator converts the thermal energy (enthalpy rise) of the superheated and reheated steam to electrical energy. Steam exhausted from the turbine is condensed to liquid in the condenser. The condensate pumps feed the water through the |.p. regenerative feedwater heaters to a deaerator. Boiler feed pumps move the deacrated liquid through the h.p. feedwater heaters back to the steam generator. Forced draught (or draft) fans supply combustion air to the steam generator and the primary air fans transport pulverized coal into the burners. Induced draught fans remove the flue gases from the furnace and exhaust them through the stack into the atmosphere. Cooling water for the condenser is supplied by the circulating water system, which takes the heat removed from the condenser and rejects it to cooling towers or another heat sink such as a cooling lake, river or sea. Combustion gases coming out of the steam generator require additional treatment for removal of flyash particulates, sulphur dioxide and nitrogen oxides before the gases are released through the exhaust stack. PETIA A power station supplies the following loads to the consumers: —_— Time in hours 0-6 6-10 10-12. 12-16 16-20 20-22 22-24 Load in MW 30 70 90 60 100 80 60 (a) Draw the load curve and estimate the load factor of the plant. (b) What is the load factor of'a standby equipment of 30 MW capacity if it takes up all loads above 70 MW? What is its use factor? Solution (a) The load curve is drawn in Fig.E1.1. Energy generated = area under the load curve =30x6+70xX4+90x2+60x4+ 100x4 +80 2+ 602Power Plant Engineering 100 90 80 70 60 50 40 Load, MW 30 20 10 0 0 2.4 6 8 10 12 14 16 18 20.22 24 Time, hours Fig, E1.1 = 180 + 280 + 180 + 240 + 400 + 160 + 120 = 1560 MWh 1560 MWh 24h Average load = = 65 MW averageload _ 65 Load factor = “peak load =T00 = 0.65 Ans. ‘) If the load above 70 MW is supplied by a standby unit of 30 MW capacity, the energy generated by it =20x2+30x4+10x2 = 40 + 120+ 20 = 180 MWh Time during which the standby unit remains in operation =2+4+2=8h Average load = 180 MWh/8h = 22.5 MW Load factor = 22.5/30 = 0.75 Ans. energy generated Use factot =} —————— plant capacity x operating hours 180 x10? kWh = OR 0.75 Ans. 30x10 kwxsh ° > 4%Introduction: Economics of Power Generation Bs) The peak load on a power plant is 60 MW. The loads having maximum demands of 30 MW, 20 MW, 10 MW and 14 MW are connected to the power plant. The capacity of the power plant is 80 MW and the annual load factor is 0.50. Estimate (a) the average load on the power plant, (b) the energy supplied per year, (c) the demand factor, (d) the diversity factor. Solution _ average load (a) Load factor = “peak load Toad average load 60 MW Average load = 30 MW Ans. (b) Energy supplied per year = average load x 8760 h = 30 x 8760 MWh = 262.8 x 10°kWh Ans. 0.5= maximum demand _ 60 (c) Demand factor = Connected load 30420410414 mie = 0.811 Ans. 74 sum of individual maximum demands simultaneous maximum demand _ 30+20+10414_74 60 ~ 60 = 1.233 Ans, (d) Diversi ity factor A thermal power plant of 210 MW capacity has the maximum load of 160 MW. Its annual load factor is 0.6. The coal consumption is | kg per kWh of energy generated and the cost of coal is Rs 450.00 per tonne. Calculate (a) the annual revenue eared if energy is sold at Re 1 per kWh and (b) the capacity factor of the plant. Solution. Annual load factor = (average load)/(peak load) Average load = 0.6 x 160 = 96 MW Energy generated per year = 96 x 8760 MWh = 840,960 x 10° kWh Coal required per year = 840,960 x 10° kg = 840,960 tonnes Cost of coal per year = 840,960 x 450 = Rs 378.432 x 10° Cost of energy sold = Rs 840,960 x 10° = Rs 840.96 x 10°26] Power Plant Engineering (a) Revenue earned by the power plant per year = Rs 840.96 x 10° ~ Rs 378.432 x 10° = Rs 462.528 x 10° = Rs 46.25 crore Ans. (a) average load _ 96 MW. capacity of plant ~ 210 MW = 0.457 Ans. (b) (b) Capacity factor = A power plant has the following annual factors: load factor = 0.75, capacity factor = 0.60, use factor = 0.65. Maximum demand is 60 MW. Estimate (a) the annual energy production, (b) the reserve capacity over and above the peak load, and (c) the hours during which the plant is not in service per year. Solution __ average load ~ peak load Average load = 0.75 x 60 = 45 MW. Annual energy production = 45,000 x 8760 = 394,200,000 kWh =394.2x10°kWh Ans. average load plant capacity Plant capacity = 45/0.6 = 75 MW Reserve capacity over and above the peak load =75-60=15MW Ans. energy generated per year plant capacity x hours in operation 394.2 x 10° kWh 75 x10° kW x 0.65 Hours not in service in a year = 8760 — 8086 = 674 hrs Ans. (a) Load factor (b) Capacity factor = (c) Use factor = Hours in operation = = 8086 hrs It is proposed to supply a load with a maximum demand of 500 MW and load factor of 70%. Choice is to be made from a nuclear power plant, a hydraulic power plant and a steam power plant. Calculate the overall cost per kWh in case of each scheme as given below: Cost Steam Hydroelectric Nuclear power plant powerplant —_ power plant . Capital cost per Rs 3 crore Rs4crore Rs S crore MW installed . Interest 6% 5% 5% . Depreciation 6% 4% 5% . Operating cost 30 paise 5 paise 15 paise (including fuel) per kWh . Transmission and 2 paise 3 paise 2 paise distribution cost per kWhIntroduction: Economics of Power Generation Solution (a) Steam power plant: Capital cost = Rs 3 x 500 crore = Rs 1500 x 10° Interest = 0.06 x 1500 x 10 = Rs 90 x 10” Depreciation = 0.06 x 1500 x 10” = Rs 90 x 10” Annual fixed cost (interest + depreciation) = Rs 180 x 10” Energy generated per year = average load x 8760 = Load factor x maximum demand x 8760 .7 x 500 x 10° x 8760 = 306.6 x 10’ kWh Running cost/kWh = (operating cost / kWh) + (transmission and distribution cost/kWh) : =30+2=32 paise Overall cost/kWh = fixed cost/kWh + running cos/kWh __Rs 180x107 ~ 306.6 x10" kWh = 0.59 +0.32=0.91 or 91 paise + 0.32 (b) Hydroelectric power plant: Capital cost = Rs 4 x 500 crore = Rs 2000 x 107 Interest = 0.05 x 2000 x 10 = Rs 100 x 10” Depreciation = 0.04 x 2000 x 10” = Rs 80 x 10” Annual fixed cost = interest + depreciation = Rs 180 x 10” 180x107 _ nee 306.6 x10" Running cosvkWh = 5 + 3 = 8 paise Overall cosvkWh = 0.59 + 0.08 = Re 0.67 (c) Nuclear power plant: Capital cost = Rs 5 x 500 crore = Rs 2500 x 10” Interest = 0.05 x 2500 x 10” = Rs 125 x 10” Depreciation = 0.05 x 2500 x 107 = Rs 125 x 10” Annual fixed cost = Rs 250 x 107 Rs 250x107 306.610” kWh Running cost/kWh = 15 + 2 = 17 paise Overall cost/kWh = 0.82 + 0.17 = Re 0.99 Therefore, the overall cosv/kWh is minimum in case of hydroclectric power plant. Fixed cos/kWh Fixed cos/kWh =[28] Power Plant Engineering eeu eg A power plant of 210 MW installed capacity has the following particulars: Capital cost = Rs 18,000/kW installed Interest and depreciation = 12% Annual load factor = 60% Annual capacity factor = 54% Annual running charges = Rs 200 x 10° Energy consumed by power plant auxiliaries = 6% Calculate (a) the cost of power generation per kWh, and (b) the reserve capacity Solution Load factor average load 7 capacity of the plant Capacity factor — maximum demand average load 0.60 __210MW 054 ~ maximum demand Maximum demand = (210 x 0.54)/0.60 = 189 MW Reserve capacity = 210 - 189 = 21 MW Ans. (b) Average load = load factor x maximum demand = 0.6 x 189 = 113.4 MW Energy produced per year = 113.4x 10° x 8760 = 993.384 x 10° kWh Net energy delivered = 0.94 x 993.384 x 10° = 933.781 x 10° kWh Annual interest and depreciation (fixed cost) = 0.12 x 18000 x 210 x 10° = Rs 453.6 x 10° Total annual cost = fixed cost + running cost = 453.6 x 10° + 200 x 10° = Rs 653.6 x 10° Rs 653.6 x 10° 933.781 x 10° kWh =Rs 0.70 or 70 paise Ans. (a) Cost of power generation = The incremental fuel costs for two generating units a and b of a power plant are given by the following relations, dF JAP, = 0.065 P, + 25 dF,/dP, = 0.08 P, + 20 where F is the fuel cost in rupees per hour and P is the power output in MW. Estimate (a) the economic loading of the two units when the total load supplied by the power plants is 200 MW, (b) the loss in fuel cost per hour if the load is equally shared by both units.Introduction: Economics of Power Generation Solution (a) The given data are P,+ Py =200 ql) The condition for economic loading demands equal incremental heat rates of the two units which leads to dF,/dP, = dF/dP, 0.065 P, + 25 = 0.08 P, + 20 (2) Solving Eq. (1) and (2), we get P,=75.86MW and = Py = 124.14 MW (b) If the load is equally shared by the units, ie. P= Py = 100 MW, then the increase in cost of fuel for unit a is given by dF, 100 jn” = J (0.065 P, +25) dP, 2 75.86 Pp 100 = [ooss $+ 257,| = 741.47 75.86 i.e., Rs 741.47 per hour. The increase in cost for unit is 100 = J (0.08, +20) dP, 124.14 Pp 100 = [aoe +20 a] =~ 699.23 2 124.14 that is, the cost of fuel for unit b decreases by Rs 699.23 per hour. Therefore, the net increase in fuel cost due to departure from economic distribution of load = 741.47 ~ 699.23 = Rs 42.24 perhour — Ans. Calculate the cost of generation per kWh for a power station having the following data: Installed capacity of the plant = 200 MW Capital cost = Rs 400 crores Rate of interest and depreciation = 12% Annual cost of fuel, salaries and taxation = Rs 5 crores Load factor = 50% Also estimate the saving in cost per kWh if the annual load factor is raised to 60%. Solution Assuming the maximum demand equal to the capacity of the power plant, average load Load factor = ———————————_ maximum demandPower Plant Engineering = average load 200 Average load = 200 x 0.5 = 100 MW Energy generated per year = 100 x 10° x 8760 = 87.6 x 107 kWh 0.5 Interest and depreciation (fixed cost) ; = 0.12 x 400 x 10” = Rs 48 x 10” Total annual cost = 48 x 107 + 5 x 107 = Rs 53 x 10” Rs 53x10" t Wh = > = Rs 0.6 i . Cost per kWh 37610" kWh 30.61 or 61 paise Ans. When the load factor is raised to 60%, Average load = 0.60 x 200 = 120 MW Energy produced per year = 120 x 10° x 8760 = 105.12 x 10 kWh Total annual cost will remain the same. Rs 53x10" 10812107 =Re0.50 or 50 paise Cost per kWh = Saving in cost per kWh = 61 ~ 50 = II paise Ans. A 300 MW thermal power station is to supply power to a system having maximum and minimum demand of 240 MW and 180 MW respectively ina year. Assuming the load duration curve to be a straight line, estimate the (a) load factor, (b) capacity factor. Solution The load duration curve is shown in Figure E1.9. Energy supplied per year = (180 MW x 8760 h) + 5040- 180) MW x 8760 h = 210 x 8760 MWh = 183.96 x 10” kWh 183.96 x10” kWh ats Average load = 8760h =210'°10°kW _ __averageload — _ 210 MW _ Load factor = Thaximum demand 240 MW 0.875 Ans. Capacity factor = NEL Le 0.70 A apacity factor = 3503769 = 9 ins.