Details of ENCON measures recommended during PAT-I & PAT-II by AEA (only those taken which are not
recommended
under PAT-VII)
FORM-2 (PAT-I)-STPS,Suratgarh
S. No. Energy Saving Measures Previous Status Available Current Status
1 Improving compressor performance Loading Pressure:- kg/cm2 Present Loading Pressure:-
Unloading pressure: kg/cm2 Present unloading pressure:
2 Improving pump efficiency by casing/Impeller
Coating of water pumps.
FORM-2 (PAT-II)-STPS-Suratgarh
S. No. Energy Saving Measures Previous Status Available Current Status
1 Reduction in insulation losses Work already in progress and
remaining will be completed in
upcoming annual shutdown
2 Arresting air leakages in APH & flue gas path Total Air leakages were more than
20% in some units. Air ingress from
atmosphere means higher energy
consumption in the FD &ID fan also.
It is necessary to reduce air ingress
across ESP’s to save ID Fan energy.
3 Arresting compressed air leakages No Service air or Instrument air
compressor was getting unloaded
even during low plant load. This
indicates heavy air leakage in the
system. We recommend ultrasonic
leak detection, arresting air leakages
and closing of valves of non operating
units.
4 Operation of Jockey water pump instead of Fire Various tappings such as seal turf of
water hydrant pump after arresting of the leakages bottom ash hoppers/ sealing of ash
slurry pumps/CHP area/Cleaning of
various plant sites has been provided
from the Hydrant line; so; it is very
difficult to maintain the required
water pressure from the Jockey
pump
5 Replacement of inefficient lighting with LED Under implementation and will be
continued in phased manner
6 Impeller trimming ( or new impeller of lesser dia) in Matter shall be taken up with OEM
unit 3/4 DMCW pump
7 Replacement of lighting transformer for Replacement not required as +/- 2.5
maintaining voltage at 220-230 V % and +/-5% taps are available to
maintain the reqd voltage, shall be
taken up during annual shut down of
respective unit
Name of the Power Plant: STPS, Suratgarh
(2) Action taken on the immediate, short term and long term Heat rate improvement measures suggested in the detailed/ mandatory energy audit
report under PAT-VII
(A) IMMEDIATE HEAT RATE IMPROVEMENT MEASURE SUGGESTED BY AEA:-
1 Description Observations by AEA Actions Taken REMARKS (Difficulties faced if
any)
2 Boiler Efficiency Unit-I
The major component of losses is on account of dry flue gas
loss, loss due to hydrogen in fuel, loss due to moisture in fuel.
Higher Dry flue gas loss is primarily due to high FGET
temperature at APH and higher excess air. The design dry flue
gas is 4.56% and present flue gas loss is 5.68%. The deviation is
1.12 % between design and operating.
Excess air (22.09%) is slightly higher than the standard value.
Hence it is recommended to maintain the excess air as per
required.
UNIT-II
The major component of losses is on account of dry flue gas
loss, loss due to hydrogen in fuel, loss due to moisture in fuel.
Dry flue gas is observed on higher side is due to following
reason:-
1. Flue gas temperature leaving air heater
2. Flue gas quantity leaving air heater per unit mass of fuel
burn
Factors affecting flue gas temperature leaving air heater are
overall heat transfer effectiveness of boiler pressure parts and
effectiveness of air heater basket elements.
UNIT-III & IV
The ash analysis shows that the un-burnt carbon in the bottom
ash is 1.07% & in fly ash 0.53% for unit 3. Similarly, for unit 4
the un-burnt carbon in bottom ash is 1.76% and fly ash is
0.50%.
Dry flue gas is observed on higher side is due to following
reason:
1. Flue gas temperature leaving air heater
2. Flue gas quantity leaving air heater per unit mass of fuel
burn
Recommendations for Boiler Efficiency improvement:
Dry Flue gas loss can be reduced by reducing the temperature
differential of flue gas temperature and combustion air
temperature, or in other words reduce flue gas temperature
and increase combustion air temperature. This will be
achieved by optimum performance of air heater and reducing
leakage percentage (though air leakage is within limit). So, it is
recommended to check the internal of APH as the heat
transfer is deteriorated in the next available opportunities in
all the units.
It is also recommended to replace the corroded baskets.
Pressurization test of Boiler up-to ESP inlet at +100mmwc
before shut down to identify leakages and to attend to ensure
zero infiltration of air
Grid measurement at economizer outlet to cross check Oxygen
probe reading
CO monitoring at economizer outlet to optimize excess air.
Monitoring of combustion temperature through pyrometer to
avoid ash fusion and slogging.
3 Air Preheater Performance Recommendation for APH Performance Improvement
It is recommended to adjust the APH sealing system online as
an initial measure. Based on available opportunity RAPH
capital maintenance needs to be carried out to optimize the
leakage from 8 ~ 10%.
Water washing of APH during available opportunities. Ensure
thorough cleaning by continuous washing till inlet & outlet
water PH matches. Dry out the APH after washing by running
ID and FD fans.
4 Mill Performance Recommendations for Improvement of Mill Performance
It is suggested to balance the system resistance of the fuel
lines on clean air.
Suggested to check the coal flow and coal air ratio which will
not only reduce the APC but also give better performance of
mill.
5 ID Fan Performance Observation and Analysis ID Fans:
All the ID Fan are running at low efficiency
The percentage loading in terms of power is higher than the
percentage loading in terms of flow and head.
In available opportunity complete boiler along with flue gas
duct to ID fan inlet should be checked by pressurising the
furnace for detecting air ingress points after removal of
insulation.
Condition based overhauling of motor and fan should be
carried out to improve efficiency
6 Turbine System Observation and Analysis:
Performance Heat rate deviation due to deviation in operating parameter is
shown in above Table
The difference between design and actual turbine heat rate is
found to be in the range of 104 kcal/kWh to 189 kcal/kWh.
The condenser vacuum and final feed water affects mostly for
higher heat rate for unit 3.
However, for unit 5, vacuum and majority of the accountable
parameters are well within the limit but the heat rate is
deteriorated this due to higher feed water flow.
The unaccountable losses are due to losses in high pressure
drain valve, LP Turbine, LP Heaters, gland leakages &
measurement uncertainties.
7 Condensor Performance Observation and Analysis:
The Effectiveness of Condenser of Unit-5 was found to be 64%
against the design 69%, So effectiveness is good.
The effectiveness of unit 3, unit 4 and unit 6 is slightly lower
than the other condenser effectiveness.
TTD of condenser 3 and 4 is higher than the design.
Jet cleaning and/or conco cleaning whenever the plant is in
shut down to remove soluble scale. If the scale is hard and not
soluble acid/chemical cleaning may be used.
In addition, it is recommended to carry out eddy current
testing of 10% tubes for tube thickness survey during each
overhaul. The tubes may be replaced if tube thickness losses
more than 75% of the design thickness.
8 Cooling Tower Observation and Analysis:
Performance The effectiveness of cooling tower is in the range of 44.00% to
62.07%. The unit 3 cooling tower effectiveness is almost
matching with the design effectiveness
Moreover, it is also noted that the water is not properly
distributed across the fills this may be due to fouling or algae
formation across the fills.
Based on the analysis, the range is almost matching with the
design. However, the approach of cooling tower is drastically
increased from the design data. The approach depends on
heat load, air flow and tower size. The load of cooling tower
depends on the water flow and return water temperature. The
approach is affected which may be due to inadequate air flow.
9. Compressor System The pressure setting of the compressor is shown in table 36
and indicates that the loading and unloading difference is
found to be 1.2 kg/cm2.
There is an opportunity to reduce the pressure setting of the
compressor.
10 Insulation survey Major hot spots or higher temperatures has been captured &
presented in report. The areas which needs attention have
been shown in table-37.
9 Energy Saving Measures (a) Reducing the dry flue gas loss of boiler: -
As a measure for controlling excess air, optimum excess level
to be determined based on the CO level, there is a high
possibility of excess air trimming opportunity available. By
optimizing excess air to design a level a 0.55% improvement in
boiler efficiency is achievable. Therefore, it is suggested to
review the O2 trim device set point with incorporating
operator bias feature. Care should be taken such that based
on coal firing rate always minimum air to fuel ratio is
maintained. Above the minimum required unit airflow, the
total unit air/fuel ratio is optimized by the oxygen (O2)
correction controller. The O2 controller acts on the error
between measured flue gas O2 and the O2 set point
programmed as a function of unit steam flow (modified by an
operator adjustable bias).
Dry gas loss can be reduced by reducing the temperature
differential of flue gas temperature and combustion air
temperature, or in other words, reduce flue gas temperature
and increase combustion air temperature. This will be
achieved by the optimum performance of an air heater and
reducing leakage percentage
(b)Optimizing the air compressor pressure:-
As per BEE guidelines, an increase of 5.5 oC in the inlet air
temperature to the second stage results in a 2% increase in
the specific power consumption. Hence due to improper
efficiency of inter stage cooler, the performance of the
compressor may be deteriorated. So, it is recommended
improve the heat exchange in inter stage cooler for
compressor 2 and compressor 3 by proper maintenance of
inter stage cooler.
(c) Improve the condenser back pressure/condenser
vacuum:
All The Units except unit 5 and unit 6 has poor condenser
vacuum. The poor vacuum is impacting the Unit turbine
output. The specific steam consumption increases due to poor
vacuum
Saving Calculation:
Following activities need to be done to improve the unit
vacuum
Condenser tube cleaning there will be an improvement in
condenser vacuum.
Cooling tower frills cleaning/ replacement.
(d) Maintain the Steam Pressure:-
All The Units are maintaining the low steam pressure,
this lower steam pressure indirectly result in higher
steam consumption and higher heat rate. The saving
calculation by maintaining the steam pressure is
provided below
(e) Optimize the Turbine performance:
At present the turbine performance of both the HT and IT
turbine are deteriorated drastically. Hence it is recommended
to improve the turbine performance during next overhauling
by carrying out steam path audit which identify the blade
condition and optimize accordingly.