APGENCO

GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
Agenda
Briefly about APGENCO
Objectives of IGEN in APGENCO
EBSILON software training & utilization in APGENCO
Methodology & Faults diagnosed as a result of mapping Exercise
Measurement of Long term & Short term Potential and saving accrued
as a result of mapping exercise
Important points of Case study report / UNIT-6 /120 MW
Short term and long term recommendations and action plan
Support and Guidance required on mapping exercise of Boiler
components in 500 MW units of APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
1.I nstalled Capacity 8924.9 MW
2.Third Largest Power Utility in I ndia.
3.APGENCO's Hydel I nstalled Capacity is the Highest
in I ndia (3829.4)
4.APGENCO record daily generation - 157.735 MU on
24.09.2013, highest since inception
BRI EFLY ABOUT APGENCO
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
Station wise installation capacities
1. Dr.NTTPS : 6x210 + 1X500 : 1760 MW
2. RTPP: 5x210 : 1050 MW
3.Kothagudem-O&M : 4x60+4x120: 720 MW
4. Kothagudem-V&VI : 2x250 + 1x500 : 1000MW
5.KTPP: 1x500 : 500MW
6. Ramagundam-TPS : 1x62.5 : 62.5 MW
TOTAL THERMAL : 5092.5 MW
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
Installation capacity
1. APGENCO Hydro 3829.4
2. APGENCO Wind + Solar 3.0
APGENCO Total 8924.9
Machkund (APGENCO Share) : 120 MW
Tungabhadra (APGENCO Share):72 MW
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
THERMAL
HYDRO
SOLAR+WIND
SHARED
0
1000
2000
3000
4000
5000
6000
GENERATION
THERMAL
HYDRO
SOLAR+WIND
SHARED
APGENCO POWER GENERATI ON PATTERN
ACIEVEMENTS & PLANNING NEW
INSTALLATION OF NEW PLANTS
APGENCO Thermal Power Stations generated 37934
MU during 2012-13 and achieved 85% PLF against All
India Average PLF of 69.9%.
MD of APGENCO selected as CEO of the Year (State
Thermal) 2013 based on its excellent performance in
thermal power generation.
APGENCO is planning to add 4520 MW Thermal
capacity by installing four 800 MW Units, one each at
Vijayawada, Kothagudem, Krishnapatnam &
Bhoopalapally and 2x660 MW Units at Ramagundam
to meet future power requirements of the State.
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
Objectives of IGEN in APGENCO
1. Mapping of thermal plants in APGENCO,
2. Training on EBSILON Software:
As the part of implementation of IGEN-Phase-II
program, ten Engineers from APGENCO power
stations were trained up in Ebsilon software at
M/s Steag Energy services, New Delhi during
May and December of 2012 .
3. Software license: M/s Steag Energy Services
issued 4 licenses for utilization of Ebsilon
software in APGENCO power stations.
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
1. After completion of training, the personnel of M/ s
Steag Energy services Visited Kothagudem TPS of
APGENCO during J uly,2012 and March,2013 for
development of data base of performance optimization
using Ebsilon software as well as to extend support in
preparation of case study report.
2.Mapping exercise carried out for 120 MW, 250 MW,
500 MW thermal power plants by various participants
from APGENCO under the guidance of M/ s Steag Energy
services.
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
EBSI LON SOFTWARE SUPPORT
3. Difficulties in 120 MW Plant: Even though the plant is
very old and most of the design data is not available,
mapping carried out with the help of EBSI LON software
by using characteristic curves.
4.I MPORTANT OBSERVATI ON:
I dentified certainproblems where there are
mismatches of the design data with the plant. EBSI LON
pinpointed wrong instrumentation data.
EBSI LON SOFTWARE SUPPORT
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
1.Calculated heat rate and efficiency with all the
components available in 120 MW unit of Kothagudem
TPS in mapping exercise
2.Observed huge variation of heat rate, coal consumption
during mapping with HP heaters and without HP heaters.
3.Case Study of 120 MW / UNI T-6 of Kothagudem
TPS have been prepared by mapping more than 50
parameters of design and actual operation to find the
influence of operating parameters.
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
METHODOLOGY &FAULTS DI AGNOSED AS A
RESULT OF MAPPI NG EXERCI SE
METHODOLOGY
4.The possibility of maintaining the parameters
as per the actual operating condition has been
simulated and verified from the plant data.
5.The potential improvement has been finalized
for short term and long term gain of efficiency
and it has been calculated in terms of tonnes of
oil equivalent per year.
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
Andhra Pradesh Power Generation Corporation
KOTHAGUDEM THERMAL POWER STATION
Overview of the Plant :
The Power Plant has 8-Units, (4X60, 4X120 MW) commissioned as shown
below:
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
1.Performance evaluated in the design model
of the unit 6 for 100 % design condition.
2.The Design parameters have been
considered from the HBD and boiler PPD.
3.A model has been simulated using the data
after overhauling for analyzing the plant and
equipment performance.
120 MW UNIT-6/ KTPS-B Station
Methodology adopted in Design modeling
120 MW UNIT-6/ KTPS-B Station
Overall Performance Design condition
FI G-1: DESI GN EBSI LON MODEL OF 120 MW/ UNI T-6/ KTPS
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
GOVERNMENT OF INDIA
MINISTRY OF POWER
FI G-2: FULL LOAD MODEL OF 120 MW/ UNI T-6 AFTER OVERHAUL
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
FI G-3: OPERATI NG MODEL OF 120 MW/ UNI T-6 AT 98 MW
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
The saving short term potentials worked out for Kothagudem
Thermal Power Plant Unit 6 are indicated below.
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
The saving long term potentials worked out for Kothagudem
Thermal Power Plant Unit 6 are indicated below.
1 MWh = 0.086 toe (therefore 1 toe = 11630.0 kWh)
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
The unit capital overhauling was
carried out in October 2012. The
data after overhauling was taken
on 28th December 2012 for
model simulation.
120 MW UNIT-6 Modeling with data
after capital overhaul
ACHIEVEMENT TILL TO DATE
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
Boiler Aux & Turbine Aux Analysis:
Observations:
BOI LER& AUX
1. Most of the components of Boiler were replaced in 2001 during R&M in view of
deteriorated coal quality to 3030 kcal/kg from original design of 4300 kcal/kg***.
Also, heat rate of the unit was maintaining very high.
2. The Boiler auxiliaries were not upgraded suitably. Tube & Ball mill capacity was
upgraded from 29t/h to 32t/h only by liner plates modification in mills.
3. The capacity of existing ball mills, vapour fans and ID fans is not suitable for
continuous rated generation with available coal in the range of 3000 kcal/kg.
TURBI NE& AUX
1. Turbine rotors were also upgraded to reaction turbine from impulse turbines.
2. The governing system of turbine is obsolete and based on Hydraulic system only.
2. Due to capacity restriction from mills, vapour fans and ID fans Unit is operated
with VWO condition at lower load than design.
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
GOVERNMENT OF INDIA
MINISTRY OF POWER
Flue gas profile
The Air heater is a tubular type
having design flue gas outlet
temperature of 150
0
C and measured
is 178
0
C. There is 28
0
C deviation in
exit gas temperature which leads to
33.60 kcal/ kWh heat rate deviation.
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
Observation
APH inlet oxygen measurement online system
is available but single probe is there.
APH outlet oxygen measurement is done by the
chemist on need basis.
Very high temperature of flue gas at APH outlet
is due to partial load operation as well improper
heat transfer. Improper heat transfer may be
due to soot deposits or tube blockages.
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
HP HEATER ANALYSI S OF OPERATI NG CONDI TI ON
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
GOVERNMENT OF INDIA
MINISTRY OF POWER
HP Heater performance
As per the simulation study, the TTD of the HP heaters are
deteriorated much in compared to the design.
Because of deteriorated TTD of HPH2 (7.13K) heat rate
deviation is found to be 12.17 kcal/kWh.
Observation:
High value of TTDs for HPHs is a result of partial charging of
HPHs. HPHs are kept partial charged (steam side) even at rated
load conditions to avoid very high APH flue gas outlet
temperature. Isolating HPH completely is also not possible as it
leads to very high cold reheat (CRH) pressure.
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
Condenser Analysis of Operating Condition
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
1.Modelling of 500 MW units in APGENCO is
under process and further support/training
from CEA/Steag is here by requested .
2.Modelling of specifically boiler and
associated components has not been carried
out using EBSILON software.
Training shall be conducted for analysis of
boiler components.
REQUIREMENT OF MODELLING
SUPPORT
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
For each power station of
APGENCO, a dedicated license
with laptop is required for better
utilization and analysis of power
station critical parameters.
REQUIREMENT OF Dedicated licenses
with laptop
Advantages observed during modelling of Power
plant with the help of EBSI LON SOFTWARE
1) Eventhough the plant is very old and most of the design data is
not available, mapping carried out with the help of EBSI LON
software by using characteristic curves.
2) I dentifiedcertain problems where there are mismatches of the
design data with the plant. EBSI LON pinpointed wrong
instrumentation data.
3) Calculatedheat rate and efficiency with all the components
available in 120 MW unit of KothagudemTPS. Performance and
efficiency can be evaluated if performance of the any of the
component suspected deteriorated for ex: HP heaters or
condenser,Air heaters andequavalent loss of fuel or coal
consumption can be calculated.
4) Thepotential improvement can be calculated for short term
and long term gain of efficiency in terms of tonnes of oil
equivalent per year.
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
Salient features of EBSILON Model of 9
th
Unit/ 250 MW/ KTPS-Vth stage
1.Ebsilon mapping model is developed.
2.Total plant and Sub systems like Condenser,
Heaters,Turbine& air heaters, UBC analysis
carried out. The efficiency and heat rate are
found satisfactory.
3.How ever, observed certain minor level of heat
loss in HP heaters and condenser and equavalent
fuel loss is calculated using the EBSILON
software.
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER
Thank you
APGENCO
GOVERNMENT OF INDIA
MINISTRY OF POWER