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Aux Power Optimisation

The document discusses auxiliary power consumption in coal-fired power plants. It provides breakdowns of typical auxiliary power loads and how consumption can be optimized. Reducing auxiliary power usage is an important way to improve net unit heat rate and thermal efficiency. Key areas for optimization include fans, pulverizers, electrostatic precipitators, and reducing degradation of equipment performance over time. Regular monitoring of individual drive power consumption allows tracking changes from overhaul to overhaul.

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jp mishra
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958 views18 pages

Aux Power Optimisation

The document discusses auxiliary power consumption in coal-fired power plants. It provides breakdowns of typical auxiliary power loads and how consumption can be optimized. Reducing auxiliary power usage is an important way to improve net unit heat rate and thermal efficiency. Key areas for optimization include fans, pulverizers, electrostatic precipitators, and reducing degradation of equipment performance over time. Regular monitoring of individual drive power consumption allows tracking changes from overhaul to overhaul.

Uploaded by

jp mishra
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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AUXILIARY POWER

OPTIMIZATION
Heat Input into a Large Coal Fuelled
Power Plant- Sub Critical design.
3%
Stack 5% 10% 37%
Clean-up Auxiliary Stack Electricity 45%
Equipment Power Losses Production Rejected Heat to
Cooling Water/ Cooling Tower
Power Plant –Fossil fuels
• Fossil fueled fired generating stations have very precise
definition of Thermal efficiency.
• It is the ratio of heat equivalent of Fuel fired to the heat
equivalent of electricity sent to transmission network.
• Auxiliary power consumption has two components.
• Unit auxiliary power consumption & station auxiliary
powerconsumption.
Power plant cycle efficiency
• Role of Steam Generator is to generate steam which is
used to convert heat energy into kinetic energy.
• Conversion cost includes usage of steam produced for
internal consumption such as SCAPH , TDBFP, Air
Condtioning based on VAS
• Aux. power consumption would depend on coal quality
and on type of cycle.
• Why not use better coal, which would lower
auxiliary power consumption and an optimum
performance can be sustained with less expenditure
on O&M Cost.
The definition of net unit heat rate, expressed in terms of its
component parts, provides a set of potential heat rate
improvement options. Reducing auxiliary power use is an
important option for improving net unit heat rate.
The breakdown of auxiliary power loads for a large coal-fired power plant is
presented in the Table .
Auxiliary power use in coal-fired power plants by technology:
Power plant cycle efficiency
• Gross boiler efficiency at any point of operation can be
improved by consuming more electricity through Mills &
fans.
• When we are using low cost INFERIOR COAL, we
consume more auxiliary power consumption to improve
operating efficiency.
• Usage of an additional pulverizer to handle poor coal
results in increased power consumption, however,
corresponding improvement in Gross boiler efficiency may
not be achieved.
IMPORTANCE OF AUXILIARY POWER
CONSUMPTION
• DEGRADATION OF EQUIPMENT PERFORMANCE CAN BE
READILY GUAGED FROM POWER CONSUMPTION .
• UNIT OR BOILER POWER CONSUMPTION IS MONITORED AS
% OF GENERATION WHICH IS JUST A GROSS INDEX.
• POWER CONSUMPTION GUARANTEE ON BOILER COVERS
ALL MAJOR DRIVES.
• POWER CONSUMPTION SHOULD BE MEASURED
TOGETHER IN A TYPICAL BOILER EFFICIENCY TEST.
Change in plant Conditions with time increases
Auxiliary power
• Air in leakage to boiler gas enclosure
• Fouling of Boiler heating Surface –higher dry gas loss would
increase power consumption
• Higher draft loss due to air ingress and ash deposition
• Air heater leakage / Air ingress after APH’s
• Deterioration of Turbine Steam Path Condition.
• Condenser pressure/ condenser cleanliness- air ingress
and extent of tube pluggage
• Steam and water leaks from drains and vents.
NET HEAT RATE
• NET HEAT RATE MONITORING WOULD COVER
IMPACT OF AUX. POWER CONSUMPTION OF DIFFERENT
DRIVES
• NET HEAT RATE MONITORING CAN BE ADOPTED FOR
INERNAL PROCESSESS.
• THIS WOULD CALL FOR INDIVIDUAL MONITORING OF
DRIVES USING ACCURATE ENERGY METERS .
• SUCH A SYSTEM IS BEING INTRODUCED AS A RETROFIT IN
ALL OLD PLANTS IN NTPC & CONSUMPTION LEVELS ARE
BEING TRACKED FROM OVERHAUL TO OVERHAUL.
MAJOR DRIVES
DRIVES ARE LISTED FOR A TYPICAL 600MW UNIT ARE-
• ID FAN
• FD FAN
• PA FAN
• CEP
• MILL
• TG DMCW
• CW PUMP
• ACW PUMP
• MDBFP
Fans' Aux Power on Different Oxygen Levels
Data From Boiler Optimization Tests
2500 5200
1214 11 16 23 18 15 14
2000 5100

Power (kW)
A u x P ow e r

Total F a n
5000
1500
(kW)

4900
1000
4800
500 4700
0 4600
2.2 2.7 3.2 3.7 4.2 4.7

Flue Gas Oxygen Eco Outlet Left From DAS (%)


FD Fans PAFans ID Fans Fans' Aux.Power
ID FANS POWER CONSUMPTIONS
MEASURED ID FANS POWER CONSUMPTION IS GENERALLY
HIGH FOR FOLLOWING DEVIATIONS-
•HIGHER FLUE GAS VOLUME
•HIGH AIR HEATER LEAKAGE.
•HIGH ESP LEAKAGE.
•HIGHER FLUE GAS TEMPERATURE.
•HIGHER PRESSURE DROP ACROSSCHIMNEY.

•IMPELLER EROSION REFLECTS DEGRADATION


PRIMARY AIR FANS
• PA FANS DESIGNED FOR HIGH MARGINS TO HANDLE
HIGH MOISTURE COAL AND INCREASED PRESSURE DROP
ACROSS AIR HEATER .
• INCREASED PA FLOWS TO MILL COULD IMPROVE BOILER
LOADING BUT IT IS AT COST OF INCREASED UNBURNT LOSS
& HIGHER POWER CONSUMPTION.
FD FANS
• FD FANS POWER CONSUMPTION DEPENDS ON
EXCESS AIR LEVEL AND WIND BOX PRESSURE
SETTING
• HIGH PA LOADING RESULTS IN REDUCTION OF
FD FANS POWER
• POTENTIAL FOR FANS’ POWER CONSUMPTION
OPTIMIZATION IS MAXIMUM.
PULVERIZERS
• PULVERIZER POWER CONSUMPTION HAS MANY TRADE
OFFS,SUCH AS MILL FINENESS, MILL OUTPUT & PA FLOW.
• REGULAR PERFORMANCE TESTING OF MILLS SHOULD
ENABLE THE ESTABLISHMENT OF BASE LINE DATA FOR
MILLS.
• COAL AND HGI DATA ARE TAKEN TO CORRECT FOR ANY
DEVIATION.
ELECTOSTATIC PRECPITATOR
• IT'S AUXILIARY POWER CONSUMPTION IS DEPENDENT ON ASH
CHARACTERISTICS AND OF COURSE ON BOILER OPERATING REGIME.
• PULSE ENERGISATION SYSTEM HAS RESULTED IN MAJOR SAVINGS OF INPUT.
• EFFECTIVE RAPPING SHOULD HELP.
• UPGRADATION HAS BEEN UNDERTAKEN IN ALL UNITS TO REDUCE POWER
INPUT.
• CORRECTION METHDOLOGY FOR ESP IS VERY DIFFICULT TO WORK.

• IT IS REGULATED BY ASH RESISITIVITY WHICH IS COTROLLED BY GAS


EXIT TEMPERATURE AND COAL MOISTURE.

• EFFECTIVENESS OF RAPPING SYSTEM SHOULD HELP TO REDUCE THE


OPERATING POWER CONSUMPTION.

• SWITCHING OFF FIRST FIELD IS PRACTICSED AT SOME STATIONS WHICH IS


DEBATABLE.
CONCLUSION
AUXILIARY POWER CONSUMPTION AUDITS HAVE A
TREMENDOUS PAY BACK AND INCREASE AWARENESS
REGARDING EQUIPMENT PERFORMANCE.

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