Reliance Infrastructure Ltd
220 MW Samalkot Combined Cycle Power Plant
Success in Aux Power Reduction
Adarsh Gangrade & Arunkumar Ponugoti 13-05-2010
220 MW Samalkot Combined Cycle Power Plant
SAMALKOT POWER STATION
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220 MW Samalkot Combined Cycle Power Plant
Location Map:
Samalkot
Latitude : 17o 02 18N, Longitude : 82o 08 15E, MSL : 27 Mts Samalkot - 3 KMs, Rajahmundry Airport - 50 KMs, Kakinada Port - 20 KMs Nearest Highway (NH5) - 15 KMs, Samalkot Rly Station 2.5 KMs
SAMALKOT POWER STATION
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220 MW Samalkot Combined Cycle Power Plant
SIGNIFICANT FIVE POINTS OF THE PLANT:
Integrated management System
An integrated Management Systems Certified Plant
RInfra- SPS Management systems Certification Standards Certified under ONE ISO 14001:2004 OHSAS 18001:2007 ISO 9001:2008 ISO 27001: 2005 SA 8000:2001
Integrated Management System (IMS)
18001 Health &Safety
9001 Quality
14001 Environment
IMS
8000 Social Accountability
27001 Inf & Phy Security
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220 MW Samalkot Combined Cycle Power Plant
PLANT DETAILS
COMBINED CYCLE ; 140 MW GT & 80 MW STG STATION CAPACITY: 220 MW COMMISSIONED ON: GAS TURBINE SYNCHRONISED STEAM TURBINE SYNCHRONISED SCHEDULE OF MANDATORY INSPECTION: MAJOR GT INSPECTION AFTER EVERY 32000 EOH MINOR GT INSPECTION AFTER EVERY 8000 EOH GAS TURBINE MAKE: SIEMENS V94.2 OUTPUT 140MW No OF STAGES 4 1st MAJOR OVERHAUL SEPT-OCT 2005 - 35748 EOH 2nd MAJOR OVERHAUL SEPT OCT 2009 71670 EOH 26-01-2002 12-09-2002
STEAM TURBINE MAKE: ANSALDO OUTPUT 80MW No OF STAGES 32 HRSG MAKE: ANSALDO HP/ LP MS PRE: 83 / 5.8 BAR HP/ LP MS FLOW: 230 / 55 T/HR HP/ LP MS TEMP: 528 / 208 DEG C
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Year wise Operating Data
S.No.
1 2 3 4 5 6 7 8
Year
2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10
Station PLF % 56.56 66.55 61.10 45.28 50.55 60.61 52.50 80.86
Availability %
98.83 94.34 98.3 89.39** 97.4 97.4 97.08 90.24**
Aux Load %
2.21 2.69 3.05 3.73 3.53 2.92 3.27 1.97
LESS Natural Gas
**
PLANT MAJOR OVERHAUL DONE
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Plant Data
PLANT DATA YEAR ON YEAR BASIS
120 4 3.5 3 80 2.5
100
PLF , AVAILABILITY %
Present Target Aux Load <1.9 %
60 2 1.5 40 1 20 0.5 0 2002-03 2003-04 2004-05 2005-06 YEARS Availabilty % PLF % Aux Load % New Target 2006-07 2007-08 2008-09 2009-10
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AUXILIARY LOAD %
FACTORS Affecting Aux power consumption
Plant load factor Operation of plant Auxiliaries Service auxiliaries like illumination Unit Start up power reduction ( BFPs at Lower RPM)
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Methods of Aux power Reduction
Installing energy efficiency equipments Optimizing Operation procedures Monitoring of Aux power consumption Knowledge sharing and bench marking
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Significant Energy Conservation Projects
Energy Efficient Projects Implemented
Variable Frequency Drive HP and LP Boiler feed pump and Raw water C E P Destaging CW Pump Corrocoat application Wind Ventilators SWAS water recovering as a Boiler Feed. Cooling Tower Makeup By Pumping Replaced By Gravity Line Cooling tower cell fan FRP Hollow blade placement Energy saver for Lighting systems
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Recent Optimizing Operation Procedures
Deaerator Pressure Reduction from 1.0 to 0.5 bar Air compressor Load pattern optimization from 8 to 6.5 bar
Air dryer optimization of cycle time from 6 to 12 hrs
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HP boiler feed pump- VFD installation
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Energy conservation study on the HRSG High Pressure system
High Pressure Boiler Feed system
Feed station control valve operating at a throttled position of 35 %.
The HP boiler feed water header pressure being 124 bar.
Drum pressure of 75 Bar.
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Feasibility options for energy conservation study revealed opportunities to select from Variable Frequency Drive at Boiler feed pump motor and Destaging of the feed Pump. Hydraulic fluid Coupling with Scoop control Steam turbine driven Boiler feed pump
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Energy Conservation Study of System
An in house technical study was done and following areas identified. Equipment Detailed Study and analysis of existing system
Bearings Journal and Thrust Lube oil system, Shaft driven lube MAIN oil pump Allowable Axial displacement of shaft, balance leak of pressure for water to reach deaerator Min recirculation - to be maintained per manufacturer and Water conditions Coupling Mechanical seals and related cooling system Vibrations of the pump bearing Pump Skid as a whole
Pump
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Energy Conservation Study of System
Bearings
Cooling - fan for winding Vibrations of the Motor bearings Motor Protections Harmonics Control valve type and capacity Control valve Actuator
Motor
Feed control Station
Logics of feed water control study with M/s INVENSYS
Placement of valves at the economizer outlet Position of Check valves Position of isolation valves
Piping
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Energy Conservation Study of System
Deaerator Temperature and Pressure of water at suction to Pump Water and steam cycle PINCH AND APPROACH at Economizer DE SUPERHEATING Steaming at the Economizer possibility Drum and Deaerator capacity
Feed Control system Logics and
Plant load variation study LDC request System Study on past Trip history of the plant Voltage surges and Power / frequency Swing Operational Philosophy
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Typical Pump Curve with Variable speed
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Typical saving in variable speed Application
Variable Speed
Normal Operating Point
Due to Regulatory and Guarantee conditions - OEMs design at 125 % of MCR
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HP Boiler Feed Pump Technical Data
PUMP: Make Head Capacity Stages Lubrication Motor: Make Type Power Supply Speed
: : : : :
: : : : :
M/s Sulzer 1256.5 mwc 276 m3/h 11 Forced
Kirloskar 3 Ph AC Induction Motor 1280 KW 3 Ph/6600 V/50 Hz 2983 rpm
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Reasons for choosing VFD application
Opportunity Type / Technology
Advantage
Disadvantage
Motor heating and insulation Harmonics in Input Line side New Hydraulic system and control to be installed Variable load capability to be checked with system installed Restoration to initial condition
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Variable Frequency Drive Highest Efficiency 96% Variable Load capability Ease of fitment with existing equipment Hydraulic coupling and Scoop Existing technology With low Efficiency at part load. Cost of implementation is lowest.
Pump Destaging
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Implementation after study
Variable frequency drive came out to be best option As the load varies as per request from load dispatch center. Minimum frequency set at 35 HZ as per OEM
Modified Logics configuration with same feed control valve
Operation procedure modification.
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HRSG High pressure system AFTER VFD application
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220 MW Samalkot Combined Cycle Power Plant
HP Boiler feed pump V.F.D
Supplier: Yantra Automation Pvt. Ltd
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Saving in Load by 51% (Part load) 32% (Base load)
Description Discharge Pressure ECO Outlet Press CV Pos Power Before Installation Of VFD 123 bar 118 bar 36 % 1125 kW After Installation Of VFD 42.8 Hz 87 bar 81 bar 72 % 770 kW
Power Saving
Part load: 575 KW & Base load: 355 kW
Saving : 30,17,500 KWH @ 8500 Operating Hours at full load
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LP boiler feed pump- VFD installation
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Energy conservation study on the HRSG Low Pressure system concluded
Low Pressure Boiler Feed system - control valve was operating at a throttled position of 55 %. The LP boiler feed water header pressure being 20 bar with Drum pressure of 5.3 Bar.
Feasibility options after energy conservation study revealed two opportunities to select from Variable Frequency Drive at Boiler feed pump motor and Destaging of the feed Pump.
Variable frequency drive came out to be best option for the plant as load varies as per request from load dispatch center.
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LP Boiler Feed Pump Technical Data
Pump Make Capacity Head Stages Motor
: : : :
Sulzer 68 m3/h 222.5 mwc 05
Make Type Supply Rating Current Speed
: : : : : :
Kirloskar 3 Ph Ac Induction Motor 3 Ph, 415 V, 50 Hz 75 kW 125 A 2970 rpm
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HRSG LOW pressure system before VFD application
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HRSG Low pressure system after VFD application
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LP BFP VFD PANEL and Change over Panel
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Saving in Load by 36% (at Full load operation )
Description
Discharge Pressure ECO Outlet Press CV Pos
Before Installation Of VFD
23. 63 bar 20.27 bar 55 %
After Installation Of VFD 38 Hz 13.6bar 9.9 bar 66 %
Power Power Saving
47.5 kW
30 kW
17.5 kW at Base load
1,48,750 KWH @ 8500 Operating Hours
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Raw water PUMP VFD
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Raw Pump Technical Data
Pump Make Capacity Head Stages Motor Make Type Supply Rating Current Speed : : : : : :
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: : : :
Mather and Platt 470 m3/h 20.12 mwc 01
Crompton greaves 3 Ph Ac Induction Motor 3 Ph, 415 V, 50 Hz 37 kW 63 A 1480 rpm
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Saving in Load by 65%
Description Power Power Saving Before Installation Of VFD 28 kW 18 kW After Installation Of VFD 28 Hz 10 kW
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C.E.P. Destaging
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De staging of Condensate Extraction Pump
Energy conservation study on the HRSG Condensate system concluded Condensate system - control valve was operating at a throttled position of 55 %.
Feasibility options for energy conservation study revealed three opportunities to select from Variable Frequency Drive Destaging of the Pump. Impeller trimming
Destaging came out to be best option for the plant as even though the load varies the requirement at the Dearator level control needs to be maintained. Also trimming option doesnt give flexibility to come back to original condition, if required in future.
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Condensate Extraction Pump
Pump:
Make Type Capacity Head Stages Motor: Make Type Supply Rating Current Speed : : : : : : : : : : : Sulzer Vertical 344 m3/h 204.5 MLC 4 Kirloskar 3 Ph Ac Induction Motor 3 Ph, 6600 V, 50 Hz 270 kW 29 A 1489 rpm
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HRSG Condensate system before Destaging
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CEP Destaging
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Sulzer CEP
3 rd Stage Dummied
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HRSG condensate system after Destaging
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Saving in Load by 26%
Description Discharge Pressure Power Power Saving Before De staging 19.6 bar 246 kW After De staging 14.7 bar 182 kW
Part load: 52 KW & Base load: 64 kW
5,44,000 KWH @ 8500 Operating Hours
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CW Pump Corrocoat
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Circulating water pump
Pump: Make Capacity Head Stages : : : : Mather & Platt (I) Ltd., 8872 m3/h 19.74 MLC Single
Motor:
Make Type Supply Rating Current Speed
: : : : : :
Crompton Greaves 3 Ph Ac Induction Motor 3 Ph, 6600 V, 50 Hz 630 kw 71 A 594 rpm
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Application Of Flu Glide Coating on Circulating Water Pump.
Flu glide Coating is the flake glass filled synthetic polymer type coatings and benefits in:
1.
Reduction in Fluid friction
2.
Reduction in micro turbulence
Increased Efficiency of the pump due to reduction in hydraulic losses.
3.
4.
Reduction in power consumption.
Increased protection against Corrosion & Erosion
5.
6.
Increased life and reliability of the equipment.
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Corrocoat Application
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Saving in Load by 5%
Description
Discharge Pressure
Before Corrocoat
1.3bar
After Corrocoat
1.3 bar
Power
Power Saving
619 kW
36 KW
583 kW
3,06,000 Kwh @ 8500 Operating Hours
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Wind Ventilators
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Wind ventilator
Electrical driven Exhaust fans power consumption of each fan is 4.27KW. As part of energy conservation measure one electrical driven exhaust fan was replaced with Wind ventilator which is driven by natural wind. This has resulted in power saving of 4.27KW. Total 7 fans were replaced with wind Ventilators.
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Ventilation system
Analysis Power Consumption of Exhaust fan Power Consumption wind ventilators 4.27KW Nil
Net Power savings Annual power Saving
(For 7 Fans)
4.27 KW
2,54,065 KWHr @ 8500 Operating Hours
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HRSG Steam and Water Sample Analysis System water recovery and reuse as feed.
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Daily Average Consumption of DM Water was 17 Cu meter / Day
Analyzed the SWAS Sampling System outlet water and found the Water quality is meeting the norms of Boiler Feed Water. Therefore the same water was reused in our system. Over All Achievement - Savings in DM Water make up
- Cycle Chemical parameters maintained within the requirements.
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COOLING TOWER MAKEUP
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COOLING TOWER MAKEUP
INITIAL OPERATION OF THE SYSTEM. Cooling tower basin level was maintained by using pumps which pumped water from clarified water storage tank to basin. This system also supplied water to the Chlorination plant. CT make up pumps - Two no Installed since inception One in service and other stand by. (in summer usage involved two pumps) Design Capacity: : 370 Cu m / Hr Drive Motor Power: 30 KW MODIFIED SYSTEM After a study on cooling tower make up path. A channel system was suggested which ensured water flow to the basin. A diversion channel and road cutting work was done. The control of water is done via VFD controlled Raw water pump that provides input water to Clarified water system.
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Cooling Tower make up
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Cooling Tower make up
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Savings 22.8 KWH
SAVINGS AND PAYBACK PERIOD Project Cost for the implementation: INR 2, 84, 444.00
Saving : 22.8 Kwh
Per annum energy saving: 193800 Kwh (@8500 hr)
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Illumination Energy saver Panel
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Saving in Load by 15%
A survey carried out for reduction in Lighting system. The Energy consumption is 1718 KWh/day. Energy Saver has been installed and commissioned for the Power Block MLDB and BOP MLDB. Total investment, Rs.: 285880 Units / day reduced : 261.3
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Energy saver Panel
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Cooling tower Fan Hollow blade replacement
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Cooling Tower Hollow FRP blade placement
A study on cooling tower was done to evaluate the energy saving options in fans. The system consists of ten induced draught fans .
The study showed following options Hollow fan blade Hub diameter can be reduced as per hollow blade design Increased flow area for air because of aerofoil profile change. Cooling tower nozzles replacement with new higher efficiency Nozzles Blade angle adjusted for the same flow
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Saving in Load by 23%
Average Power Consumption Before Hollow Blade placement : 52 KW Total consumption for 10 motors : 520 KW
Average Power consumption After Hollow Blade placement : 40 KW
Total consumption for 10 motors : 400 KW
12 KW saving per Fan
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Optimizing Operation procedures
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Deaerator Pressure Reduction
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Deaerator is maintained at 1.0 bar(g) pressure by steam extraction from Steam Turbine at 171 deg c & 2.592 tph flow rate. The scope for reduction in deaerator pressure was studied by considering the Mechanical deaeration
process and NPSH requirement for feed pumps. On experimental basis
Deaerator pressure reduced up to 0.5 Bar (g) in steps of 0.1 Bar (g). With this practice found Dissolved oxygen levels, NPSH of pumps are with in limit and observed the increment in Steam Turbine Generation about 200 KW.
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Solubility of Air in water
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HRSG deaerator before pressure reduction.
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Deaerator pressure reduction
Description
Deaerator Pressure
Before Reducing Pressure
1.0 bar 120 deg c 13.12 % 26.8 ppb
After Reducing Pressure 0.53 bar 113 deg c 0.0 % 25.27 ppb
Temp CV Pos ECO inlet Hydrazine
Dissolved O2
Pump suction press
3.66 ppb
2.45 bar
3.63 ppb
2.2 bar
ST generation increased by 200 KW
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HRSG deaerator after pressure reduction.
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Optimization of Compressed air Pressure
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Air Compressors optimization
Air Compressors Installed Capacity - Make : Chicago Pneumatic - Type : Horizontal and Non lubricated - Type of operation : Continuous load (100% and 50%) unload - Free air delivery : 5 M3/min at pressure 9 bar. - Drive Motor Power : 45 KW
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Optimization program
Decreased air leakages from valves and other locations.
Optimization of consumption in auxiliary areas that are intermittently used. ( Fuel oil centrifuge, ETP etc)
Decreased pressure set point with out effecting equipment operation. From 8.0 to 6.5 bar. Load pattern changed from 15 hr full load to 0 hrs full load
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Trend Of Compressor Saving
Decline in Compressor Power consumption
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Hours of loading
800
KWH/ DAY
20 15 10 5 0
715 545 513 490 470
600 400 200 0
29-May-08
12-Jun-08 100% Load
16-Jul-08 50% LoadDate 0% Load
25-Jul-08
13-Oct-08
Power Consumption
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Air Dryer System
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Air Dryer
DESIGN
Type: Dual tower desiccant, Drying mechanism: Blower with Electric heater Flow Rate: 300 Nm3/hr. Pressure: 9.0 kg/cmg Dew Point Temp. : (-) 40DegC Cycle Every 6 hrs One tower is in service and another tower is in regeneration mode.
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Saving in power 56 %
As the Air consumption is optimized to below 50 % of design. ( from 300 to 150 M3/Hr). Margin in dew point is available.
Cycle time is Optimized to 12 Hrs of Adsorption for same Regeneration time. Energy consumption per Day : BEFORE optimization 124 kWh/day Energy consumption per Day : AFTER optimization 54 kWh Saving : 70 KWh/day Annual Saving :5,95,000 kWh.
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PLANT Auxiliary Power Reduction
Before Energy Saving MU / Day Base Load Operation Part Load Operation 98 63 0.1030 0.1026 Present Condition MU / Day 0.0872 0.0773 Saving
Plant Mode of Operation
PLF %
% 15 24
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Combined Cycle Practices
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220 MW Samalkot Combined Cycle Power Plant
FREQUENT CHOKING OF AIR INTAKE FILTERS
BIRD SCREEN PREFILTER COALASCERFILTE R FINEFILTE R
BIRD SCREEN
PREFILTER
COALASCERFILTER
FINEFILTER
COALASCER PAD ROLL
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220 MW Samalkot Combined Cycle Power Plant
AIR INTAKE FILTERS
Air intake filter DP status
5450
14 12
2
3
GT Major Overhaul from
7 8 9
4950 4450 3950
Pre filte r DP
Filter DP in mbar
10 8
2950
Running Hrs.
3450
4.5 mb ar
Fine filter DP 7.5 mbar Total filter DP
`
6 4 2
2450 1950 1450 950 450
0
/0 9 /0 9 /0 9 /0 9 /0 9 /0 9 /0 9 /0 9 /0 9 /0 9 /0 9 /0 9 /0 9 /0 9 /0 9 /1 0 /1 0 /0 5 /0 6 /0 6 /0 7 /0 7 /0 8 /0 8 /0 9 /0 9 /1 0 /1 0 /1 1 /1 1 /1 2 /1 2 /0 1 /0 1 /0 2 /1 0
-50
24
08
23
08
23
07
22
06
21
06
21
05
20
05
20
04
19
03
Day Avg. Pre filter DP
Date
Day Avg.Fine filter DP
Day Avg. Total filter DP
Day Avg. Coalescer Pad
GT Actual Running Hours
14.0 mbar
Coalescer Pad DP 4.5 mbar
1. Additional coaleser pads (100 mm) removed on 15.06.09. 2. Additional coaleser pads (50 mm) provided on 20.06.09. 3. Coalescer pads (50 mm) removed on 12.08.09 & fixed back on 14.08.09. 4. New coaleser pads (50 mm) provided on 28.10.09. 5. Coalescer pads removed on 19.11.09 & new one (50 mm) fixed back on 19.11.09. 6. Coalescer pads removed on 05.12.09 & Old cleaned one (50 mm) fixed on 05.12.09. Coalescer pads again removed on 08.12.09 & new (50mm) fixed on 08.12.09. 7. Coalescer pads removed on 21.12.09 & new one (50 mm) fixed back on 21.12.09. 8. Coalescer pads removed on 30.12.09 & new /old one (50 mm) fixed back on 30.12.09. 9. Coalescer pads removed on 05.01.10 & Old cleaned one (50 mm) fixed on 05.01.10. Coalescer pads removed on 08.01.2010 and no coalescer Pad fixed. 10. Max.Avg.total filter DP went upto 14.0407 mbar , so for all filter replacement on 08.02.10 at 6:00 hrs GT shutdown taken.
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220 MW Samalkot Combined Cycle Power Plant
FREQUENT CHOKING OF AIR INTAKE FILTERS
BIRD SCREEN PREFILTER COALASCERFILTE R FINEFILTE R
BIRD SCREEN
PREFILTER
COALASCERFILTER
FINEFILTER
COALASCER PAD ROLL
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220 MW Samalkot Combined Cycle Power Plant
FREQUENT CHOKING OF AIR INTAKE FILTERS
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MASTER DATA
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Thank you
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