Optim

1 |Optimization Of Auxiliary Power Consumption
A REPORT
ON

OPTIMIZATION OF AUXILIARY POWER CONSUMPTION IN
A TYPICAL 300MW COAL-FIRED THERMAL POWER PLANT

BY
Name of the Student ID No.
I.PRANEETH (2011B2A3672H)

AT
JSW ENERGY LTD.
A Practice School I Station of

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI
JUNE, 2013

A REPORT
ON
OPTIMIZATION OF AUXILIARY POWER CONSUMPTION IN A TYPICAL
300MW COAL-FIRED THERMAL POWER PLANT

BY
Name of the Student ID No.
I.PRANEETH (2011B2A3672H)

Prepared in partial fulfillment of the
Practice School-I Course No.
BITS C221/BITS C231/BITS C241/BITS GC221/BITS GC231

AT

JSW ENERGY LTD.
A Practice School- I Station of

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI
JUNE, 2013

BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE
PILANI (RAJASTHAN)
PRACTICE SCHOOL DIVISION

Station: JSW Energy Ltd.
Centre: Vijaynagar Works
Duration: May 22
nd
2013 to July 13
th
2013
Title of the Project: Optimization of Auxiliary Power Consumption in a typical 300MW
Coal based Thermal Power Plant.

ID No: Name of Student Discipline:
2011B2A3672H I.PRANEETH B.E. (Hons.) Electrical &
Electronics Engineering

Name(s) of Expert: Mr. Hanumanth Rao Designation: Shift In-charge
Name of PS Faculty: Mr. V.S.Prasad
Key Words: Auxiliary power, Optimizing techniques, Plant load Factor (PLF) etc.
Project Area (s): Electrical, Power engineering
Abstract: Energy conservation is the burning issue nowadays due to the tremendous scarcity of
electricity across the county. Energy efficiency is a technique which needs to be adopted seriously
for effective energy conservation. Indian power sector is caught between the pressure of adding
new generating capacities to match the rapid growing demand of power to achieve economic
and social development and the environmental challenges.
Therefore by implementing Energy conservation techniques in thermal power plant, we
try to recover the losses which go waste. This report describes basic understanding and
awareness about various types of auxiliaries used in a thermal power plant, their power
consumption and various measures such as installations of VFDs (Variable Frequency Drive) and
other modern techniques to optimize the auxiliary power consumption in a typical 300MW coal
fired thermal power plant using case studies.

Signature of the Student Signature of the Mentor
Date: Date:

Contents
Abstract: ........................................................................................................................................................ 3
Acknowledgement ........................................................................................................................................ 5
PART-I (Orientation Report) .......................................................................................................................... 6
Know your industry (Power Sector) .............................................................................................................. 7
Know Your Organization (JSW Group) .......................................................................................................... 9
Process Mapping ......................................................................................................................................... 17
1. Coal handling plant ............................................................................................................................. 18
2. Fan System .......................................................................................................................................... 21
3. Boiler System ...................................................................................................................................... 22
4. Ash Handling System ........................................................................................................................... 26
5. Turbine-generator system .................................................................................................................. 28
6. Condenser System .............................................................................................................................. 31
7. Cooling Tower System ......................................................................................................................... 33
8. Switchyard ........................................................................................................................................... 35
PART II (Project Report) ........................................................................................................................... 37
What is Auxiliary Power Consumption? ...................................................................................................... 38
Why Focus on Auxiliaries? .......................................................................................................................... 39
Auxiliary Power Consumption in Thermal Power Plant .............................................................................. 40
Types of Auxiliaries ..................................................................................................................................... 41
Auxiliary Power Consumption Calculation .................................................................................................. 45
Energy meter readings of G, GT, ST for 4 consecutive days ....................................................................... 45
Analysis of power consumption of Major and Minor auxiliaries of SBU II Unit, JSW Energy Ltd. ........... 49
Approaches for Optimization of Auxiliary power consumption. ................................................................ 58
CASE STUDY I ............................................................................................................................................. 65
CASE STUDY II .............................................................................................................................................. 67
Suggestions and Improvements .................................................................................................................. 68
Conclusion ................................................................................................................................................... 70
INDEX .......................................................................................................................................................... 71
References .................................................................................................................................................. 72


Acknowledgement

Firstly, I would like to thank Mr. Hanumanth Rao, my mentor, for guiding me
through this project and clearing various apprehensions and conceptual doubts
and providing us with experienced suggestions throughout the program.

I take this opportunity to thank all the staff members of Electrical Maintenance
Department and Operational Support Division for sparing their precious time with
us despite their busy schedule without whom our project would be incomplete.

I also thank the Practice School Division of BITS Pilani for providing me with this
opportunity to gain professional work exposure.

I am hugely indebted to our instructor Mr. V.S Prasad and our co-instructor Mr.
Khemraj for guiding me throughout the training.

I would like to extend special thanks to Mr. Kamalakar, Mr. Venkat, Mr. Bhaskar ,
Mr. Ram Kumar for providing me with the technical data required for the project.


PART-I (Orientation Report)

Know your industry (Power Sector)

The power sector consists of generation, transmission and distribution utilities and is a crucial
component of Indias infrastructure. Indias rapid growth over the past decade has increased
power demand, which is still largely unmet. According to Government of India estimates, the
nations per capita power consumption was pegged at 779 kWh in FY10, far below the world
average of over 2,782 kWh1. However, the government is striving to increase the per capita
consumption to 1,000 KWh per year by the end of 20122 through large sale power projects and
rural electrification programs.

KEY DEVELOPMENTS AND THE CURRENT STATE OF THE INDIAN POWER
SECTOR

Power is considered to be a core industry as it facilitates development across various sectors of
the Indian economy, such as manufacturing, agriculture, commercial enterprises and railways.
Though India currently has the fifth largest electricity generation capacity in the world pegged
at 1, 92,792 MW3, the growth of the economy is expected to boost electricity demand in
coming years4.Exhibits a strong correlation between the GDP growth and increase in power
generation capacity over the last decade.
India saw a total capacity addition of approximately 54,000 MW during the 11th Five
Year plan3, of which approximately 47 per cent was contributed by the central government, 34
per cent from the state government, and a little over 19 per cent from the private sector5.
Some examples of top public sector companies include National Thermal Power Corporation
(NTPC), Damodar Valley Corporation (DVC) and National Hydroelectric Power Corporation
(NHPC). Some key companies in the private sector include Tata Power and Reliance Energy
Limited4.
In India, power is primarily generated from thermal and nuclear fuels, hydro energy and
renewable sources. Exhibits different inputs used for power generation and power
consumption by different sectors. To cope with the demand deficit, the Indian government has
implemented various progressive measures to maximize the countrys power generation
capacity and improve distribution. Some examples of such measures include rural electrification
programmes and ultra mega power projects5. In particular, the inflow of foreign direct
investments is expected to step up capacity addition significantly. The government has allowed
FDI of up to 100 per cent through the automatic route5 in all segments of the power sector
except for nuclear energy4.

Consequently, the sector has drawn about US$ 4.6 billion investment over the past
decade, of which US$ 1.6 billion came in FY12 alone7. In particular, the petroleum and natural
gas segments saw the maximum investments from international companies (US$ 2.7 billion
since 2000) due to the governments New Exploration Licensing Policy (NELP). This jump in
overall investments was facilitated by the planned capacity addition of 76,000 MW and 93,000
MW during the 12th and 13th Five Year plans, respectively4. Further, a statement released by
the Ministry of Power revealed that the power sector is expected to receive investments of
about US$ 300 billion due to large scale expansion plans over the next few years. A large chunk
of investments is expected to come from private investors, who have high confidence in the
sector, as demonstrated by the success of recent IPOs of public sector undertakings under the
Ministry of power.


Know Your Organization (JSW Group)

JSW Group is a part of USD 16.5 billion O. P. Jindal Group. Under the dynamic leadership
of Mr. Sajjan Jindal, JSW Group has grown into a USD 10 billion enterprise with interests across
various core economic sectors Steel, Energy, Cement, Aluminum, Natural Resources,
Maritime Infrastructure and IT.
In a short span of time, JSW has become the largest integrated
steel manufacturer in India. It is striving to become a leading player in every business that it
operates. Its activities have impacted villages and lives of thousands of people associated with
it. JSWs award winning townships and world class infrastructure have set new benchmarks and
won numerous accolades.

Vision
Global recognition for Quality and Efficiency, while nurturing nature and society.

Mission
Supporting the nations growth in power and steel with speed and innovation.

Core Values
Transparency
Strive for Excellence
Dynamism
Passion for Learning

JSWGROUP
JSW Group is one of the Indias largest business conglomerates with their presence in
the following sectors

JSWSteel

JSW steel is the flagship company of the group. JSW steel is the largest
private sector steel manufacturer in terms of installed capacity. JSW steel is one of the
lowest cost steel producers in the world. JSW steel has acquired a controlling stake in
Ispat Industries Ltd. making it Indias largest private sector steel producer with a
combined capacity of 14.3 MTPA.
By 2020, the company aims to provide 34 million tons of
steel annually.

JSW Energy

JSW Energy, is a growing power vertical of the JSW group. The company has
entered in all areas of power business with a operational capacity of 2600 MW and a
generating capacity of 1050 MW in the construction and implementing phase.

JSW Infrastructure

JSW infrastructure is committed to the development of infrastructure for ports,
air ports, ship repair, shipyard, township, roads, rail connectivity, inland waterways.
JSW Infrastructure has following operational units
JSW Jaigarh port , Maharashtra
South West Port, Goa

JSW Cement

JSW Cement, the new diversification foray of JSW group, is presently having 0.7
million ton per annum grinding facility for producing Portland Slag Cement (PSC) and
Ground Granulated Blast Furnace Slag (GGBS).


JSW Energy Ltd.

JSW Energy Limited (JSWEL), the energy vertical of the JSW group established in the
year 1994. The company forayed in all areas of power business with an operational
capacity of 2600 MW and a generating capacity of 1050 in the construction and
implementation phase.

Aiming to generate 11,770 MW, JSW Energy is treading to become one of the
leading private power producers in the country. The company is an early entrant in the
power generation, Power Trading & transmission Business and is exploring
opportunities in the power generation through non-conventional energy sources.

JSW Energy is involved in following power related activities
Power Generation
Power Trading
Power Transmission
Mining
Equipment Manufacturing

Award & Recognitions

1. The SBU #1 (2x 130 MW) at vijayanagar was awarded Meritorious Productivity Award
from CEA, Govt. of India consecutively for 3 years for its excellence in operational
performance parameters.
2. JSW Energy has been awarded NDTV Profit Business Leadership Award in 2010 industry
vertical of POWER.
3. JSW energy has been awarded Best Thermal Power generation Company Award at
Power Line Award 2012 by Power Line Magazine in 2012.


JSW Energy Projects

Operational Generating Capacity

Vijayanagar, Karnataka
SBU I 260 MW (2 x 130) Power Plant

The company owns and operates a 2 x 130 mw dual fuel (coal and gas ) power
plant in vijayanagar, Karnataka. The 260 MW power plant has been operational
since 2000.
The power plant operates on a combustion of coal and gas which is a bby-
product of JSW Steel limited (JSWSL)- Vijayanagar plant.

SBU II 600 MW (2 x 300) Power Plant

The company has commenced commercial operations in both of the 2 x 300 MW
units of the imported coal based power plant in Vijaynagar, Karnataka. The first
Unit was commissioned in April 2009 and commenced commercial operations on
July 1, 2009 and the second unit was commissioned in late July 2009 &
commenced its commercial operation in September 2009.

Barmer, Rajasthan
Phase I 1,080 MW Lignite-Fired Power Plant

RWPL is constructing an 8 x 135 MW lignite fired power plant in the first phase at
Barmer, Rajasthan. The Company has acquired the land of 1,186 acres for the
Project. Today the Company operates 540 MW (4 Units) at Barmer. The Plant will
use lignite from Jalipa and Kapurdi mines, as fuel. For this purpose, the Company
has formed an SPV Barmer Lignite Mining Company Limited, in which 51% shares
are held by Rajasthan State Mining & Minerals Limited and 49% by RWPL. The
company successfully began the production of lignite from its Kapurdi Mines.


Ratnagiri, Maharashtra
1,200 MW Imported Coal- Fired Power Plant

The Company operates 1200 MW (4x300 MW) at Ratnagiri. The project site is
located in close proximity to the sea. A significant volume of the water required
for the project will be satisfied by sea water. The raw water is supplied to the
JSW Energy (Ratnagiri) plant by Maharashtra Industrial Development
Corporation. The plant is running on imported coal.

Projects under Implementation

Kutehr, Himachal Pradesh
240 MW Hydroelectric Power plant

JSWEL is implementing a 240 MW (3 x 80 MW), run-of-the-river, hydroelectric
power project on the upper reaches of river Ravi in the district of Chamba,
Himachal Pradesh. The project involves the construction of a low-sill barrage
across Ravi River to divert water through a 15 km long head race tunnel ending
in a surge shaft to generate an aggregate 240 MW of power in an underground
power house. The Project is scheduled to be commissioned by end of financial
year 2015-16. Environment clearance has been recommended by EAC
For the project in January 2011.

Barmer, Rajasthan
Phase II 270 MW Lignite-Fired Power Plant

RWPL is also planning an additional 2 X 135 MW power plant at Barmer. This
power plant is intended to be on the same parcel of land as the 1,080 MW
Project (Phase I) which is currently under construction. Company is planning to
Sell the entire power generated from this project under short-term power
Arrangements through JSWPTC on merchant basis.


JSW ENERGY OPERATIONS IN INDIA


JSW Power Trading Company Limited (JSWPTC)

JSWPTC, a Wholly Owned Subsidiary Company, is engaged in power trading activities
and has an I category license, the highest Power Trading license category to trade in
power in India.
JSWPTC is one of the top five power trading companies in India, by volume and
has continuously stepped upwards to position itself amongst top Power Trading
Companies during the year ended March 31, 2010. During the FY 2009-10, the JSWPTC
was also nominated as power trading member of Northern Regional Power Committee.

Jaigad Power Transco (JPTL)

JSW Energy had entered into Joint Venture Agreement with Maharashtra State
Electricity Transmission Company Limited (MSETCL) for transmission system / network.
JPTL is 74:26 Joint Venture between the Company and MSETCL.JPTL is implementing
two transmission lines from Jaigad to New Koyna and Jaigad to Karad for evacuation of
power from JSWERL power plant at Jaigad at a total project cost of ` 580 crores. JPTL has
been granted Transmission License from Maharashtra Electricity Regulatory Commission
(MERC).
The company had successfully commissioned a transmission line from Jaigad to New
Koyna and 2nd line from Jaigad to Karad.

Toshiba JSW Turbine & Generator Private Limited

Toshiba JSW Turbine & Generator Private Limited has been incorporated as Joint
Venture Company with a shareholding of 75% by Toshiba Corporation ltd., Japan , 20%
by JSW Energy Ltd. and 5% by JSW Steel Ltd. to design, manufacture, marketing and
maintenance services of mid to large sized Supercritical Steam Turbines & Generators of
size 500 MW to 1000 MW.
This JV is expected to provide advantage in Sourcing critical
equipment for enhancing the generation capacity besides acting
As a catalyst in boosting the power plant equipments manufacturing capacity in
The country. The Company commenced commercial production in February 2012.


Introduction to Thermal Power Plant
Thermal Power Station
A generating station which converts heat energy from coal combustion into electrical energy.

Principle:
A steam power station basically works on the principle of Rankine cycle. Heat produced from
the coal combustion produces steam in the boiler. The steam is then fed into the Turbines and
then it turns the turbine blade which in turn drives the alternator to convert the mechanical
energy of the turbine into electrical energy. After the steam passes through the turbine, the
steam is condensed in a condenser and recycled to where it was heated. To cool this water a
coolant must be used which in turn has to be subjected to heat removal and this is done in the
cooling towers. Generally the coolant will be water. This kind of plants has to be installed at a
place where there is high abundance of water and coal

The various components of a
coal-fired thermal power
plant can be classified into
various systems .The various
systems of power plant are as
follows.


Process Mapping

Explain various processes involved in converting raw material into final product of
the organization?

Start
Coal storage
Pulverization
Boiler
Steam
generation
Turbine
Generator
Transformer
400KV
electricity
Grid
End

1. Coal handling plant

The coal handling plant (CHP) in a thermal power station covers unloading of
coal, its crushing, storage and filling of boiler bunkers. The planning and design of the CHP is
site specific and depends on following factors:
1. Station capacity
2. Coal source and quality
3. Coal transportation mode
Station capacity
Station capacity determines the quantum of coal to be handled by coal handling plant and thus
the capacity of coal unloading system, crushers, coal conveying system etc. Generally for unit
size of 300MW and above, one coal handling plant is provided to cater for two units.

Coal source and quality
Sources of coal for a thermal power station may vary i.e. indigenous run of mine coal,
indigenous washed coal or imported coal. Quality of the coal (GCV, HGI, moisture content etc.)
determines the specification of coal handling equipment apart from the quantity of coal to be
handled.
Sometimes coal blending may also be resorted for environmental reasons. Blending
can be done in many ways. One method is to provide facility in coal handling system to lay
indigenous and imported coal in layers on the belts while conveying coal to bunkers. These coal
layers would get mixed while falling into bunkers. The other method is to stock indigenous and
imported coal in layers in stockyard.

Coal transportation mode
Transportation of coal depends on the location of the power plant with respect to the coal
mines/ coal sources and other site conditions .Various transportation means such as rail or
other captive systems such as merry go round(MGR) , belt conveyors are adopted.


1.1 Description of coal handling plant system

Coal unloading system
The coal received at power
station may be unloaded by
means of wagon tippler or
track hopper or by
combination of both
depending on the type of
coal rakes used for
transportation of coal to the
station.

Coal crushing
Coal unloaded in the wagon
tippler hoppers/track
hoppers is conveyed to crusher house by belt conveyors via pent house and transfer
points depending on the CHP layout. Suspended magnets are placed on conveyors for
removal of tramp iron pieces. Metal detectors are also placed for removal of non-
ferrous materials. In case the sized coal is received , then the coal is directly sent to the
stockyard bypassing the crusher.
The size of
coal received is about 300mm which is sized in crushers to about 20mm. The crushed
coal is either fed to coal bunkers of the boilers or discharged on to conveyors for storage
in coal stockyard through conveyors and transfer points.

Coal stocking and reclaiming at stockyard
Crushed coal is sent to the stockyard when the coal bunkers are full. During stacking
mode, coal is fed from conveyors on boom conveyor and while in reclaim mode, boom
conveyor discharges coal on the yard conveyor for feeding coal to bunkers through
conveyors and transfer points.

DIAGRAM 1: COAL HANDLING SYSTEM

1.2 Coal bunker

Coal brought from stockyard through conveyor belts
is stored in coal bunkers. Each coal bunker supplies
coal to about two pulverization mills. Generally, a
coal bunker has a capacity of 1000 tones.

1.3 Coal feeder

Coal feeder feeds coal from bunker to mill. The coal
is transported using conveyor belts at a precisely
controlled speed. The amount of coal fed into the
mill is regulated using a Variable Frequency Drive (VFD).

1.4 Coal pulverizer (Mill)

Coal is fed into the pulverizer along with air heated to about 650 degrees F from the
boiler. As the coal gets crushed by the rolling action, the hot air dries it and blows the
usable fine coal powder out to be used as fuel. The powdered coal from the pulverizer is
directly blown to a burner in the boiler using various fans.

1.5 Lube oil system

Lube oil system is used for lubrication on gears, thrust bearings and coupling to motor
bearings in a gear box.


2. Fan System
2.1 Primary Air (PA) Fan

These are high pressure fans that generate hot air required for
moving pulverized coal from mill to boiler. Primary air fans usually
provide both hot and cold air which can be tempered before being
introduced into the pulverizers. The cold air is atmospheric air
supplied from the fan discharge. Part of the fan discharge goes
through a section of the air heater or separate air heater which in
turn raises the temperature as required.

2.2 Forced Draft (FD) Fan

Each unit has two forced draft fans. The fans draw warm air
from the top of the boiler house through large sir heaters becoming
the primary and secondary air used for boiler combustion process.
The air heater warms the incoming air by transferring heat energy
from the outgoing gases

2.3 Induced draft (ID) Fan

Induced draft fans exhaust all the gaseous
combustion products, or flue gas, from the boiler by
creating a negative pressure or suction within the furnace.
These are placed at the outlet of the boiler system.


3. Boiler System

A boiler is a closed vessel in which steam is produced from water by combustion of
fuels. The boiler is a rectangular furnace about 50 feet (15 m) on a side and 130 feet
(40 m) tall. Its walls are made of a web of high pressure steel tubes about 2.3 inches
(58 mm) in diameter.
Boilers can be classified into the following two major configurations:
Fire-tube boiler.

In fire tube boilers hot gases are passed through the tubes and water surrounds
these tubes. These are simple, compact and rugged in construction. Depending on
whether the tubes are vertical or horizontal these are further classified as vertical and
horizontal tube boilers. In this since the water volume is more, circulation will be poor.
So they can't meet quickly the changes in steam demand. High pressures of steam are
not possible, maximum pressure that can be attained is about 17.5kg/sq cm.Due to
large quantity of water in the drain it requires more time for steam raising. The steam
attained is generally wet, economical for low pressures. The output of the boiler is also
limited.

Water-tube boiler.

In these boilers water is inside the tubes and hot gases are outside the tubes.
They consists of drums and tubes. They may contain any number of drums. Feed water
enters the boiler to one drum (here it is drum below the boiler).This water circulates
through the tubes connected external to drums. Hot gases which surrounds these tubes
will convert the water in tubes in to steam. This steam is passed through tubes and
collected at the top of the drum since it is of light weight. So the drums store steam and
water (upper drum).The entire steam is collected in one drum and it is taken out from
there. As the movement of water in the water tubes is high, so rate of heat transfer also
becomes high resulting in greater efficiency. They produce high pressure, easily
accessible and can respond quickly to changes in steam demand. These are also
classified as vertical, horizontal and inclined tube depending on the arrangement of the
tubes. These are of less weight and less liable to explosion. Large heating surfaces can
be obtained by use of large number of tubes. We can attain pressure as high as 125
kg/sq. cm and temperatures from 315 to 575 centigrade.


3.1 Boiler operation
Pulverized coal is air-blown into the furnace through burners located at the four
corners, or along one wall, or two opposite walls, and it is ignited to rapidly burn,
forming a large fireball at the center. The thermal radiation of the fireball heats the
water that circulates through the boiler tubes near the boiler perimeter. The water
circulation rate in the boiler is three to four times the throughput. As the water in
the boiler circulates it absorbs heat and changes into steam. It is separated from the
water inside a drum at the top of the furnace. The saturated steam is introduced
into superheat pendant tubes that hang in the hottest part of the combustion gases as
they exit the furnace. Here the steam is superheated to 1,000 F (540 C) to prepare it
for the turbine.
Plants designed for lignite (brown coal) are increasingly used in various locations. Lignite
is a much younger form of coal than black coal. It has a lower energy density than black
coal and requires a much larger furnace for equivalent heat output. Such coals may
contain up to 70% water and ash, yielding lower furnace temperatures and requiring
larger induced-draft fans. The firing systems also differ from black coal and typically
draw hot gas from the furnace-exit level and mix it with the incoming coal in fan-type
mills that inject the pulverized coal and hot gas mixture into the boiler.

3.2 Boiler start-up
Spark plug provides the initial ignition. Light Diesel Oil (LDO) is then fed to the burner
and it catches fire. This is followed by Heavy Furnace Oil (HFO). Once a stable flame is
established the coal/air is blown through the burner where it lights spontaneously. The
oil are then shut off. Burner position, coal flow and air flow are controlled to achieve
desired output of temperature and pressure.

3.3 Boiler drum

Boiler drum stores the water or working fluid required for steam generation. From there
it goes to the inlets of the water walls through which the water rises where it is turned
to steam. The whole process is driven by the principle of natural circulation.


3.4 Boiler furnace

Its the primary part of the boiler where the chemical energy available in the fuel is
converted into thermal energy by combustion.
The corner firing plan and 13 chambers of the furnace is
an essential part of the combustion chamber. The fuel for
combustion is supplied from all 4 corners of the surface hence
the name corner fired furnace. In tangential firing the fuel is
projected horizontally from the corner of the furnace towards
the center. It makes the best use of furnace capacity and
permit reduction in the furnace difficulties in the boiler and
super heating furnaces. Turbulent combustion achieved in
corner fitting of the vortex formation when the 4 jets meet in
the center of the furnace .The 13 chambers are divided
suitably for efficient air supply and level maintenance and Corex gas ejection etc.

From the water-walls inlets the water rises through the water walls of the
furnace where some of it is turned into steam and the mixture of water and steam then
re-enters the steam drum.
The boiler furnace auxiliary equipment includes coal feed nozzles and igniter
guns, soot blowers, water lancing and observation ports (in the furnace walls) for
observation of the furnace interior.
3.5 Air Heater

Its essential as a boiler auxiliary because hot air is necessary for rapid and
efficient combustion in the furnace and also for drying coal in the milling plant. This is
rather different from its original
purpose which was to recover waste
heat from the flue gas. In many of
the present generation of large
boilers 2 sets of air heater are
provided one for normal duty of
preheating air for combustion and
the other for providing higher
temperature to the mills for driving
out wet coal.
The flue gases coming out of the
economizer is used to preheat the air
DIAGRAM 2 :- TANGENTIAL
FIRING
DIAGRAM 3 ROTATING AIR PREHEATER

before supplying it to the combustion chamber. An increase in air temperature of 20
degrees can be achieved by this method. The pre heated air is used for combustion and
also to dry the crushed coal before pulverizing

3.6 Soot Blower

The fuel used in thermal power plants causes soot and this is deposited on
the boiler tubes, economizer tubes, air pre heaters, etc. This drastically reduces the
amount of heat transfer of the heat exchangers. Soot blowers control the formation
of soot and reduce its corrosive effects. The types of soot blowers are fixed type,
which may be further classified into lane type and mass type depending upon the
type of spray and nozzle used. The other type of soot blower is the retractable soot
blower. The advantages are that they are placed far away from the high
temperature zone, they concentrate the cleaning through a single large nozzle
rather than many small nozzles and there is no concern of nozzle arrangement with
respect to the boiler tubes.

DIAGRAM 4 TYPES OF SOOT BLOWERS

4. Ash Handling System

Coal is burnt in the furnace to heat the boiler to produce steam. Burnt coal is called ash.
Some part of the ash falls to the ground and is called bottom ash and the lighter ash particles fly
in the air and are called fly ash.
There are different systems for dealing with bottom ash and fly ash.

Bottom Ash:
The bottom ash falls through the furnace grating and is collected in a hopper. It is then
grinded and crushed to produce find powder ash. The powder ash is then mixed with water to
produce ash slurry.

Fly Ash:
The flue gas exits the furnace and is finally disposed off through the chimney. Before the
chimney a device called the Electrostatic Precipitator is present which is electrically charged.
The fly ash sticks to the screens of the electrostatic precipitator while the rest of the flue
gas escapes through the chimney.
The stuck ash is then scrapped off the screen using an automated scrapper mechanism and
collected in a hopper where it's conveyed to a silo either using air or mechanical conveyor
system. The fly ash is stored because it can be used in the manufacture of cement or fly ash
bricks. Hence its stored in silos and sold to cement plants and not disposed off like bottom ash

4.1 Electrostatic Precipitator (ESP)
An electrostatic
precipitator (ESP), or electrostatic air
cleaner is a particulate collection
device that removes particles from a
flowing gas (such as air) using the force
of an induced electrostatic charge.

In a thermal power
plant, each boiler has three
precipitators which contain high
voltage electrodes which attract the
dust or pulverized fuel ash (PFA) from
DIAGRAM 5 ELECTROSTATIC PRECIPITATOR

the flue gases. At regular intervals the electrodes are scrapped with motor-driven
hammers and the PFA falls into hoppers below.
4.2 Chimney
A chimney is a structure which
provides ventilation for hot flue
gases or smoke from
a boiler, stove, furnace or fireplace to the
outside atmosphere. Chimneys are
typically vertical, or as near as possible to
vertical, to ensure that the gases flow
smoothly, drawing air into
the combustion in what is known as
the stack, or chimney, effect. The space
inside a chimney is called a flue.

Each chimney
consists of flue which can typically serve
two or three boilers i.e. two units.

DIAGRAM 6 CHIMNEY

5. Turbine-generator system

The turbine generator consists of a series of steam turbines interconnected to each
other and a generator on a common shaft. There is a high pressure turbine at one end, followed
by an intermediate pressure turbine, low pressure turbines, and the generator. As steam moves
through the system and loses pressure and thermal energy in it expands in volume, requiring
increasing diameter and longer blades at each succeeding stage to extract the remaining
energy.
Turbine-generator system comprises of following parts
5.1 Superheater

Thermal power plants often have a superheater section in the steam generating
furnace. The steam passes through drying equipment inside the steam drum on to the
superheater, asset of tube in the furnace. Here the steam picks up more energy from
hot flue gases outside the tubing and its temperature is now superheated which is
568C and a pressure of 166 bar is attained. The superheated steam is then piped
through main steam lines to the valves before the high pressure turbine.

5.2 High Pressure (HP) Turbine

High pressure steam at 565C-568C and 156-166
bar pressure obtained from the superheater passes
through the high pressure turbine. The exhaust steam
from this section is sent back to the boiler for reheating
before it is used by the next section of the turbine
system.
The blades in the high pressure turbines
are the smallest of all the turbine blades because the
incoming steam has very high energy and has very low
volume. The blades are fixed to the shaft and as the
steam hits the blades it causes the shaft to rotate.

DIAGRAM 7 HIGH PRESSURE (HP)
TURBINE

5.3 Boiler Reheater

After expanding through the high pressure turbine the exhaust steam is returned to the
boiler at 360C and 40 bar pressure for reheating before it is re-used by the intermediate
pressure (IP) turbine.
The boiler reheater reheats the steam from 360 C back to about 560 C to
extract more energy.
5.4 Intermediate Pressure (IP) Turbine

On leaving the boiler reheater, steam
enters the intermediate pressure turbine at
560C and 40 bar pressure. From here the steam
goes straight to the next section of the turbine
set. The steam has expanded and has less
energy when it enters this section, so here the
turbine blades are bigger than those in the high
pressure turbine. The blades are fixed to the
shaft and as the steam hits the blades the shaft
starts to rotate.

5.5 Low Pressure (LP) Turbine
From The Intermediate
pressure turbines, the steam
continues its expansion in the three
low pressure turbines. The steam
entering the turbine is at 360C and
6.32bar. To get the most work out
of the steam, the exhaust pressure
is kept very low, just 50 millibar
above a complete vacuum.

DIAGRAM 8 INTERMEDIATE PRESSURE (IP)
TURBINE
DIAGRAM 9:- LOW PRESSURE (LP) TURBINE

5.6 Exciter

Exciter is a part of generator that initiates the generator by generating the necessary
electric field for electricity generation.
5.7 Generator

Generator is a device that
converts mechanical energy to electrical
energy. The mechanical energy
because of the rotation of the turbine
leads to the rotation of generator shaft in
the magnetic field as a result of which
electricity is generated.
The electricity
generated is about 20Kv which is
supplied to Generating Transformer (GT)
and Unit Auxiliary Transformers (UAT).

DIAGRAM 10 TURBINE- GENERATOR SYSTEM

6. Condenser System

6.1 Condenser

It is an apparatus used to
condense Vapour in to liquid. The
condenser is made up of thousands of
tubes, the hot steam passes across the
cold surface of the tubes and the steam
is condensed back in to water. In Power
Plant, after passing of steam through
turbine the left out steam is sent back to
the condenser where it converts back to
water and pumped back to the boiler
through low & high pressure feed
heaters.

6.2 Condensate Extraction pump
A Condensate Pump is a specific Type of pump used to pump the water produced in an
condenser. The water is sent back to low pressure feed heaters where the water is heated & sent
back to the boiler.

6.3 Deaerator
A Deaerator Is a device that is widely used for the removal of oxygen and other dissolved
gases from the feed water to steam-generating boilers. In particular, dissolved oxygen in boiler
feed waters will cause serious corrosion damage in steam systems by attaching to the walls of
metal piping and other metallic equipment and forming oxides. From the low pressure feed
heater the water passes through the deaerator before going to the high pressure feed heaters.
In the deaerator, the gases are removed from the water to limit corrosion or rusting of the steel
tubing that carries the water back to the boiler and lines the boiler.
There are two basic types of deaerators. They are
A) Tray-type: - It includes a vertical domed deaeration section mounted on top of a horizontal
cylindrical vessel which serves as the deaerated boiler feed water storage tank.
B) Spray-type: - It consists only of a horizontal cylindrical vessel which serves as both deaeration
section and the boiler feed water storage tank.
DIAGRAM 11 CONDENSER SYSTEM

6.4 Boiler Feed Pump

A Boiler feed water pump is a specific type of pump used to pump feed water in to a steam
boiler. Its a multistage pump provided for pumping feed water to economizer. Generally, three
pumps each of 50 % of total capacity are provided. For rated capacity two pumps will be working
in parallel and third will be in reserve. The major parts include pump barrel, rotor, stator,
mechanical seal and balancing device.
Centrifugal boiler feed water pumps are used in steam power plants. They
are used for feeding water to the boiler, where heat energy will be supplied and feed water will
be changed in steam under pressure.

6.5 Economizer

Absorbs heat from the flue gas and adds it mainly as sensible heat to the feed water. The
temperature of feed water is kept just below saturation in case of non-steaming economizer.
Water from the high pressure feed heaters is heated in the economizer from 252C to 292C
before it continues to the steam drum. Having given up its last heat in the boiler, the flue gases
move on to the air heater. The work in the evaporative section of the plant is reduced by its heat
contribution as well as lowering the temperature of flue gases prior to their entry in the air
heaters.
There Are Two Types of economizer
1. Plain tube type
2. Welded fin tube type

6.6 Steam Drum

The steam drum is simply a huge tank 30.5 meters long that holds both water on its way
into the boiler and steam ready to be superheated. It's vital to keep a level of water in the steam
drum, otherwise the boiler will very quickly overheat. After leaving the economizer, the feed
water reaches the steam drum, which is a cylindrical vessel at the top of the boiler. From here
the water flows by natural circulation through downpipes into the boiler. Saturated steam
collects here ready to go to the super heater. Drum does the important function of separating
steam from a mixture of steam and water.

7. Cooling Tower System

7.1 Cooling towers

Cooling towers are heat removal devices used to transfer process waste heat to the
atmosphere. Cooling may either use the evaporation of water to remove process heat and cool
the working fluid. The main types of cooling towers are natural draft and induced draft cooling
towers. The classification is based on the type of air induction into the tower.
Cooling towers can be classified into two categories on basis of air-to-water flow. They
are
1. Crossflow cooling tower
2. Counter flow cooling tower

1. Crossflow cooling tower:-
Crossflow is a design in which the air flow is directed
perpendicular to the water flow (see
diagram at left). Air flow enters one or
more vertical faces of the cooling
tower to meet the fill material. Water
flows (perpendicular to the air)
through the fill by gravity. The air
continues through the fill and thus past
the water flow into an open plenum
volume. Lastly, a fan forces the air out
into the atmosphere.

Advantages Disadvantages
Gravity water distribution allows
smaller pumps and maintenance
while in use.

More prone to freezing than
counter flow designs.
Typically lower initial and long-term
cost, mostly due to pump
requirements.

Variable flow is useless in some
conditions.

DIAGRAM 12 CROSSFLOW COOLING TOWER

2. Counter flow cooling tower:-

In a counterflow design, the air
flow is directly opposite to the water flow
(see diagram at left). Air flow first enters
an open area beneath the fill media, and
is then drawn up vertically. The water is
sprayed through pressurized nozzles
near the top of the tower, and then flows
downward through the fill, opposite to
the air flow

Advantages Disadvantages
Spray water distribution makes the
tower more freeze-resistant.
Typically higher initial and long-term
cost, primarily due to pump
requirements.

Breakup of water in spray makes
heat transfer more efficient.

Difficult to use variable water flow,
as spray characteristics may be
negatively affected.

.

7.2 Circulating Water Pump

Circulating water pump is a specific type of pump that is used to circulate the water
from the cooling tower to the condenser and back from condenser to cooling tower.

DIAGRAM 13 COUNTER FLOW COOLING TOWER

8. Switchyard

The output voltage generated from the transformer is 20 KV. This voltage is then supplied to Generator
transformer (GT) and to two Unit Auxiliary transformers (UAT).

8.1 Generator Transformer (GT)

Generator Transformer is a step-up transformer which steps up the supplied input voltage of
20KV to 400KV which is then supplied to grid.
The power is supplied through three types of buses.
a. BUS -A
b. BUS -B
c. TRANSFER BUS
There are series of isolators and breakers to control the power supply to these buses.

8.2 Unit Auxiliary Transformers (UAT)
The generated 20KV voltage is supplied as input for two unit auxiliary transformer (UAT-
A) and (UAT-B) which are step down transformers where the voltage is stepped down to 6.6 KV.
This voltage is used for plant internal requirements

8.3 Circuit breakers
They
consists of following parts:
Pole column filled
with SF6 or oil .It consists
of a breaker chamber, two
support isolators,
pneumatic drive rods and
controlled valves. The
pneumatic drive system
incorporates unitized
compressed air system.
DIAGRAM 14 -OIL BREAKER DIAGRAM 15 -SF6 BREAKER


Pneumatic drive system with compressed air unit .It is of two stages, air cooled
reciprocating type and belt driven. An air filter oil water purifier drier and after cooler provides
pure moisture and oil free cool pressurized air to the reservoirs.

8.4 Isolators

These isolators act like switches that regulates the connections to the buses.
The closing and opening time of isolators is within 8 seconds range.
There are 4 isolators in the circuit namely:
a. 89A
b. 89B
c. 89C
d. 89D


PART II (Project Report)


What is Auxiliary Power Consumption?

Auxiliaries are the secondary devices which are essential for the functioning of the core
processes of any power plant. Auxiliary power consumption is the power consumed by these
auxiliaries for carrying out various core processes such as coal pulverization, feeding the boilers,
pump systems, fan systems and other auxiliary processes which help these core processes.
Various elements responsible for the auxiliary power consumption are shown in the figure
below.

Typical elements of auxiliary power consumption

Auxiliary
Power
Consumption
Draft
System(ID,
PA, FD fans)
Feed Water
System(BFP
and CEP)
Cooling
Water
System(CWP
and cooling
towers)
Coal
Handling
Plant(Coal
Mills)
Ash handling
Plant(ESP)
Condensate
System
Others(ACs
and lighting)

Why Focus on Auxiliaries?

In power plants, auxiliaries serve to keep the steam-water cycle safely circulating, and to return
it to its thermodynamic starting point. Without these auxiliary systems, the steam-water cycle
would suffer either an immediate collapse or a dangerous and non-sustainable expansion.
Generally, the plant efficiency ranges from 42% to 46%. Only 46% of the energy present in the
raw material is being converted into electrical energy. For example, if the chemical energy
present in the coal is 100KJ, then only 46KJ of electrical energy is being produced. These
auxiliaries consume the highest quality energy in the plant, i.e, the electrical energy, which
otherwise would have been sent to the grid for consumption. In the above example, out of the
46KJ being generated, only 42KJ is sent to the grid. The remaining 4KJ goes to the auxiliaries.
Reduction in this auxiliary power consumption can save lot of money for the organization as
well as improve the energy efficiency of the plant also.
Auxiliary power consumption is downstream power; efficiency improvements in
Auxiliary loads have a multiplier effect as one moves upstream to the primary energy
Source, within or outside the plant.


Auxiliary Power Consumption in Thermal Power Plant

The auxiliary power
consumption plays a
major role in
enriching the energy
efficiency of the
thermal power plant.
As per the norms APC
should well within the
10%. Since Thermal
power plant is
falls under energy
intensive consumer
category according to
Electricity Act
features,it is paramount importance to analyze the consumption pattern of the plant and work
on various areas so as to boost up the efficiency of cycles and sub-cycle.

Capacity Group in MW Auxiliary Power Consumption in %
500
6.13
250 8.80
210 8.77
195-200 7.67
100-200 10.32
<100 10.31
TABLE 1 CAPACITY WISE APC IN THERMAL POWER PLANT AS PER CEA NORMS

Keeping in view the typical distribution of auxiliary power in a power plant it may be observed
that the total APC may reach up to 12 % depending on the condition of the plant. Therefore
reduction of a minimum amount of 0.5% - 3% may result in huge energy savings and gives rise
to additional output of few MW.


Why the increase in the Plant Auxiliary Power Usage?

The share of total plant auxiliary electrical power in the fleet of fossil-fuel steam plants has
been increasing due to these main factors:
Addition of anti-pollution devices such as precipitators and sulfur dioxide scrubbers
which restrict stack flow and require in-plant electric drive power.
About 40 percent of the cost of building a new coal plant is spent on pollution controls
and they use up about 5 percent of gross power generated.
Additional cooling water pumping demands to meet the environmental discharge rules.
For Pulverized coal plants, the auxiliary power requirements are now in the range of 7-15
percent of a generating units gross power output. Older pulverized coal plants with mechanical
drives fewer anti-pollution devices had auxiliary power requirements of only 5-10 percent.
Increased demand for auxiliary power increases a plants net heat rate and reduces the amount
of salable power.
Types of Auxiliaries

Auxiliaries in a thermal power plant can be classified into
i. Major Auxiliaries
ii. Minor Auxiliaries

Major Auxiliaries

Parts that run on high voltage (6.6 Kv) and consume more power. Various major
auxiliaries in a thermal power plant are :

1. Boiler Feed Pump :
2. CEP( Condensate Extraction Pump)
3. Coal Mills
4. CWP (Circulating Water Pump)
5. PA (Primary Air) Fan
6. FD (Forced Draft) Fan
7. ID (induced Draft) Fan
8. ESP (Elector-Static Precipitator)


Key One Line Diagram of major Auxiliaries

FIGURE 1 KEY ONE LINE DIAGRAM OF SBU II, JSW ENERGY LTD.

Minor Auxiliaries

A line of 6.6 Kv is carried out to UST-1(Unit Service Transformer) where it is stepped down to
415 V which is carried to the minor auxiliaries of the plant.
Minor auxiliaries are the parts that run on low voltage of 415 v and are
essential for running of other auxiliaries of the plant. Minor Auxiliaries are large in number
when compared to the major auxiliaries.

Some of the minor auxiliaries in a thermal power plant are

1. SA (Sealing Air )fan
2. ACWP (Auxiliary Circulating Water Pump)
3. ACW booster
4. Boiler Fill Pump
5. Vacuum Pump
6. MLDB(Main Lighting Distribution Board)
7. Boiler MCC(Motor Control Center)
8. TG(transformer generator) MCC
9. UPS(Utility Power Supply)
10. ACDB (Alternating current Distribution Board)

Since minor auxiliaries
are large in number and dont contribute much to the total auxiliaries power consumption we
limit our scope of research about optimization to the major auxiliaries.


Key One Line Diagram of Minor Auxiliaries

FIGURE 2 KEY ONE LINE DIAGRAM OF MINOR AUXILIARIES OF SBU- II, JSW ENERGY LTD

Auxiliary Power Consumption Calculation

In a thermal power plant , the auxiliary power consumption (APC ) can be calculated by using

APC = G GT + ST

Where APC = Auxiliary Power
consumption
G = power generated by the generator
GT = power generated by the generating transformer
ST = power supplied by the station transformer

Energy meter readings of G, GT, ST for 4 consecutive days

Date Generator(G)
(in KWhr)
Generating
Transformer(GT)
(in KWhr)
Station
Transformer(ST)
(in KWhr)
6
th
July 2013 12113.23 1697074 91337
7
th
July 2013 12125.09 1698741 91445
8
th
July 2013 12138.64 1700647 91568
9
th
July 2013 12152.48 1702602 91694

Multiplication Factor
( M.F)
545454.54/10
6
3636.36363637/10
6
1000/10
6

G
G

6.6KV
GT
UAT
ST
20KV
400KV

DAY 1
Power Generated by Generator (G) for 24 Hrs. = (12125.09-12113.23) x M.F
= 11.86 x (545454.54 / 10
6
)
= 6.469 million units
Power consumed per hour = 6.469/24
= 269 MW
Power Generated by Generating Transformer (GT) for 24 Hrs.
= (1698741-1697074) x M.F
= 1667 x (3636.363637 / 10
6
)
= 6.061million units
= 252 MW
Power Generated by Station Transformer (ST) for 24 Hrs.
= (91445-91337) x M.F
= 108 x (1000 / 10
6
)
= 4.5 MW

APC = G GT + ST
= 269- 252 + 4.5
=21.5 MW
% of APC = 21.5 / 26
= 7.99%


DAY 2
Power Generated by Generator (G) for 24 Hrs. = (12138.64-12125.09) x M.F
= 13.55x (545454.54 / 10
6
)
= 307 MW
= (1700647-1698741) x M.F
= 1906 x (3636.363637 / 10
6
)
= 288 MW
= (91568-91445) x M.F
= 123 x (1000 / 10
6
)
Power consumed per hour =0.123/24
= 5.125 MW

APC = G GT + ST
= 307- 288 + 5.125
=24.125 MW
% of APC = 24.125 / 307
= 7.858%


DAY 3
Power Generated by Generator (G) for 24 Hrs. = (12152.48- 12138.64) x M.F
= 13.84 x (545454.54 / 10
6
)
= 314 MW
= (1702602-1700647) x M.F
= 1955 x (3636.363637 / 10
6
)
= 296 MW
= (91694-91568) x M.F
= 126 x (1000 / 10
6
)
= 5.25 MW

APC = G GT + ST
= 314- 296 + 5.25
=23.25 MW
% of APC = 23.25 / 314
= 7.404%


Analysis of power consumption of Major and Minor auxiliaries of
SBU II Unit, JSW Energy Ltd.

Switch gear readings for three consecutive days

DAY- 1 Major Auxiliaries of Unit- 1A

Auxiliaries Power
factor
()
Operating
Voltage
(KV)
Operating
Current
(amp)
Operating
Power(MW)(P
= 3VI cos)
% contribution
to total Aux.
Power
BFP 1A 0.9 6.6 3.953 35.07%
CEP 1A 0.9 6.6 91.55 0.971 8.6%
ID Fan 1A 0.85 6.6 168.3 1.67 14.8%
FD Fan 1A 0.74 6.6 28.1 0.241 2.1%
PA Fan 1A 0.92 6.6 115.3 1.22 10.8%
COAL MILLS
1A
1B
1C

0.76
0.78
0.74

6.6
6.6
6.6

34.6
36.5
30.7

0.3
0.327
0.268

7.9%
CWP 1A 0.83 6.6 152.9 1.47 13.04%
UST 1A 0.24 6.6 54.93 0.154 1.3%
ESPT 1A 0.67 6.6 38.55 0.304 2.69%
Total Power
consumption
of Unit 1A
(Unit Incomer
1A)

0.86

6.6

1125

11.27


Major Auxiliaries of Unit 1B
Auxiliaries
Power
factor
()
Operating
Voltage
(KV)
Operating
Current
(amp)
Operating
Power(MW)(P=
3VI cos)
%
contritribution
to total Aux.
Power
BFP 1B - - - -
CEP 1B - - - -
ID Fan 1B 0.82 6.6 128.4 1.22 20.7%
FD Fan 1B 0.74 6.6 28.5 0.25 4.25%
PA Fan 1B 0.92 6.6 107.7 1.169 19.9%
COAL MILLS
1D
1E
1F

-
0.76
074

-
6.6
6.6

-
34.93
31.75

-
0.317
0.274

10%
CWP 1B 0.83 6.6 152.3 1.49 25.3%
UST 1B 0.85 6.6 52.19 0.524 8.9%
Total Power
consumption
of Unit 1B
(Unit
Incomer 1B)

0.83

6.6

604.1

5.87


Calculation of Aux. power consumption of Unit 1 of SBU II

Total Auxiliary Power Consumption of unit - 1A and 1B = 11.27 +5.27
= 16.54 MW

Power consumed by the auxiliaries operating under station transformer= 4.5 MW

Total Aux. power = 16.54 + 4.5 = 21.04 MW

Total plant load = 269 MW

% of auxiliary power consumption = 21.04/269

= 7.82%


DAY 2

Major auxiliaries of Unit 1A
Auxiliaries Power
factor
()
Operating
Voltage
(KV)
Operating
Current
(amp)
Operating
Power(MW)(P=
3VI cos)
%
contritribution
to total Aux.
Power
BFP 1A - - - - -
CEP 1A 0.91 6.6 95 1.007 13.86%
ID Fan 1A 0.84 6.6 140.6 1.41 19.41%
FD Fan 1A 0.72 6.6 27.37 0.229 3.15%
PA Fan 1A 0.91 6.6 131.5 1.39 19.13%
COAL MILLS
1A
1B
1C

0.72
0.74
0.73

6.6
6.6
6.6

29.58
29.96
28.46

0.251
0.250
0.254

10.39%
CWP 1A 0.83 6.6 153 1.46 20.1%
UST 1A 0.25 6.6 68 0.201 2.76%
ESPT 1A 0.67 6.6 34.74 0.261 3.59%
Total Power
consumption
of Unit 1A
(Unit
Incomer 1A)

0.86

6.6

1233

7.263

Major auxiliaries of Unit 1B

Auxiliaries Power
factor
()
Operating
Voltage
(KV)
Operating
Current
(amp)
Operating
Power(MW)(P=
3VI cos)
%
contritribution
to total Aux.
Power
BFP 1B 0.89 6.6 503.8 5.25 44.15%
CEP 1B - - - -
ID Fan 1B 0.86 6.6 173.3 1.757 14.77%
FD Fan 1B 0.72 6.6 27.09 0.228 1.91%
PA Fan 1B 0.94 6.6 124.7 1.325 11.14%
COAL MILLS
1D
1E
1F

0.69
0.72
0.74

6.6
6.6
6.6

28.19
27.83
29.55

0.231
0.228
0.239

5.87%
CWP 1B 0.84 6.6 157.1 1.525 12.82%
UST 1B 0.8 6.6 74.22 0.697 5.86%
Total Power
consumption
of Unit 1B
(Unit
Incomer 1B)

6.6

1186

11.89


Minor Auxiliaries of Unit 1A and 1B
Auxiliaries
UST 1A
Operating currents
UST 1B
Operating currents
Boiler Fill Pump 4 -
CCW Pump Motor 264 266
ACW Booster Motor 1
Motor 3
151 153
- -
Vacuum Pump 154 165
SA fan motor 175 0
Feeder for ACDB 0 -
To N/E switch gear 116 -
To Boiler MCC 62 54
To TG MCC 8 40
Stator C/W Pump 52.5 0
Hot Well Makeup Pump 0.6 -
HFO Pump 48 0.4
Diesel Oil Pump 0.1 -
MLDB 44 -
Total USS Incomer 681.3 454

Calculation of Aux. power consumption of Unit 1 of SBU II on Day -2

Total Auxiliary Power Consumption of unit - 1A and 1B = 7.263+11.89 = 19.153MW
Power supplied by station transformer = 5.125 MW
Total Aux. power = 24.278 MW

% of auxiliary power consumption = 24.28/307

= 7.90%


Day 3

Major auxiliaries of Unit 2A
Auxiliaries Power
factor
()
Operating
Voltage
(KV)
Operating
Current
(amp)
Operating
Power(MW)(P=
3VI cos)
%
contritribution
to total Aux.
Power
BFP 2A - - - -
CEP 2A - - - -
ID Fan 2A 0.84 6.6 167.7 1.646 27.14%
FD Fan 2A 0.68 6.6 25.56 0.206 3.3%
PA Fan 2A 0.92 6.6 115.5 1.26 20.78%
COAL MILLS
2A
2B
2C

0.63
0.69
0.74

6.6
6.6
6.6

25.47
26.97
31.97

0.184
0.218
0.284

11.31%
CWP 2A 0.83 6.6 153 1.509 24.88%
UST 2A 0.77 6.6 61.22 0.557 9.18%
ESPT 2A 0.36

6.6 23.45 0.101 1.6%
Total Power
consumption
of Unit 2A
(Unit
Incomer 2A)

0.81

6.6

624.5

6.063


Major auxiliaries of Unit 2B

Auxiliaries Power
factor
()
Operating
Voltage
(KV)
Operating
Current
(amp)
Operating
Power(MW)(P=
3VI cos)
%
contritribution
to total Aux.
Power
BFP 2B 0.9 6.6 430.3 4.52 38.07%
CEP 2B 0.91 6.6 93.4 0.993 8.36%
ID Fan 2B 0.84 6.6 143 1.4 11.79%
FD Fan 2B 0.69 6.6 25.52 0.202 1.7%
PA Fan 2B 0.92 6.6 115.6 1.228 10.34%
COAL MILLS
2D
2E
2F

0.76
0.71
0.68

6.6
6.6
6.6

30.8
28.4
26.62

0.275
0.236
0.210

6.07%
CWP 2B 0.8 6.6 146.42 1.385 11.66%
UST 2B 0.8 6.6 48.62 0.150 1.26%
Circulating
Water
Transformer

0.81

6.6

72.83

0.682

5.74%
Total Power
consumption
of Unit 2B
(Unit
Incomer 2B)

0.86

6.6

1184

11.87


Minor Auxiliaries of both unit -2A and 2B

Calculation of Aux. power consumption of Unit 2 of SBU II on Day -3

Total Auxiliary Power Consumption of unit - 1A and 1B = 6.063 + 11.87 = 17.93MW
Power supplied by the station transformer = 5.25 MW
Total Aux. power = 23.18 MW
% of auxiliary power consumption = 7.38%

Auxiliaries
UST 2A
Operating currents
UST 2B
Operating currents
Boiler Fill Pump 0 0
CCW Pump Motor 260 260
ACW Booster Motor 1
Motor 3
148 -
- 148
Vacuum Pump 168 158
SA fan motor 148 2
Feeder for ACDB 8 9
To N/E switch gear 132 0
To Boiler MCC 52 72
To TG MCC 15 38
Stator C/W Pump - 49.5
Hot Well Makeup Pump - 0
HFO Pump 0.01 0
Diesel Oil Pump - 0
MLDB 3 2
Turbine Lube Oil 9 0
Purifier 0 0
Outgoing to UPS 0 25
Total USS Incomer 615.6 475.2

Approaches for Optimization of Auxiliary power
consumption.

VFD (Variable Frequency Drives)
VFDs are power electronics devices that convert a constant input frequency and
Voltage into variable frequency and voltage output for the motor. A complete VFD
System may consist of all these elements: cabling, an input isolation transformer,
Power factor correction equipment, harmonic filters, the frequency converter itself,
Output filter, and an electric motor.

VFDs are used in applications ranging from small appliances to the largest of power plant mill
drives and compressors. However, about a third of the world's electrical energy is consumed by
electric motors in fixed-speed centrifugal pump, fan and compressor applications and VFDs'
applications is still relatively small. This highlights especially significant energy efficiency
improvement opportunities for retrofitted and new VFD installations.
Variable Frequency Drives work on the concept of affinity laws.

FIGURE 3 VFD SYSTEM

1. Affinity Laws

The affinity laws are used in hydraulics and HVAC to express the relationship between variables
involved in pump or fan performance (such as head, volumetric flow rate, shaft speed) and
power. They apply to pumps, fans, and hydraulic turbines. In these rotary implements, the
affinity laws apply both to centrifugal and axial flows..

Power is proportional to the cube of shaft speed:

According to the law, a small decrease in speed can reduce the power consumption drastically. So, by
varying the speed of the motor according to the load, the excess power consumption is reduced.

2. VFD Internal Design

VFDs are power electronics devices that convert a constant input frequency and voltage into
variable frequency and voltage output for the motor. A complete VFD system may consist of all
these elements: cabling, an input isolation transformer, power factor correction equipment,
harmonic filters, the frequency converter itself, output filter, and an electric motor. The
combination of all the above elements is the physical topology of the AC drive system. The
converter elements power switching function is the motor control platform, which should not
be confused with a low voltage Motor Control Center described elsewhere in this handbook.
The physical topology provides the electrical hardware and the motor control is the
software which performs the power switching routine.


The most common converter topology is composed of three main equipment stages:
A front-end rectifier unit on the 3-phase supply side to convert AC to DC power and to
ensure that harmonics drawn from the network are kept within tolerance.
A DC link composed of one or more capacitors and inductors which filter and smooth the DC
voltage
An inverter unit, using one of the power electronics technologies described in the sections
below, performs the inversion and modulation of the voltage which is applied to the
motor windings.

The effect of these stages on the sinusoidal input AC supply is shown in the figure
below:

3. VFD Energy Efficiency Potential

Many fixed-speed motor load applications that are supplied direct from AC line power can save
energy when they are operated at variable-speed, by means of VFD. Such energy cost savings
are especially pronounced in variable-torque centrifugal fan and pump applications, where the
loads' torque and power vary with the square and cube, respectively, of the speed. This change
gives a large power reduction compared to fixed-speed operation for a relatively small
reduction in speed. For example, at 63% speed a motor load consumes only 25% of its full
speed power. This is in accordance with affinity laws that define the relationship between
various centrifugal load variables.


4. Technical Features of VFD

1. SpeedControlinsteadofthrottling

Of the estimated 65 % of industrial energy used by electric motors, some 20 % is lost by
wasteful flow throttling mechanisms. Additional energy is wasted in inefficient variable
speed coupling methods. VFDs allow application of speed to be controlled without
energy-wasting flow throttling or inefficient hydraulic couplings.
VFD controlled pumps and fans can
respond faster and more reliably than flow throttling valves or dampers. VFDs avoid the
problem of poorly sized control valves which may be unstable for control at less than
10 % opening .Compared to throttling methods, VFDs have lower Inspection &
maintenance costs. Any reduction of speed achieved by using a VFD has major benefits
in reducing pump wear and tear.

2. Improvedmotorefficiency
Another benefit of VFDs is the improved energy performance of the motor itself.
The VFD control allows the motor to operate closer to its best efficiency point.
VFDs can correct for oversized motors by running them at reduced
speed. Compared to other speed control methods, with VFD there is no loss due to
mechanical slip between motor and load.
3. Motor Soft-Starting

VDFs also provide a soft-start when installed in-line with the motor by slowly hiking the
voltage for a smoother startup. Most motors experience start-up in-rush currents that
are 5 to 6 times higher than normal operating currents, which is reduced to 1.5 times
with VFDs, thus reducing wear and tear of the motor. Soft starting is mainly use to limit
large motor starting currents and better management of the power factor.

4. Power Factor Correction

The installation of a VFD helps to improve a motors Power Factor (PF). When installed,
the reactive power that is the source of low power factor circulates mainly between the
DC link and the motor, and therefore cannot affect the input AC electric power supply.
Higher power factor reduces the I
2
R losses in the power transformers and cables.

A VFD equipped motor system will typically have high PF of 0.98
compared to 0.83 for a typical motor. The PF(Power Factor) when using A VFD does not
degrade with the decreased speed, as is the case with typical motors.

5. Slip Compensation

Without a VFD, when the motor load torque is increased, the speed of the motor will
decrease. To compensate for this slip, torque vs. speed curve is modified with use of a
VFD so that the torque increase can be accomplished while maintaining a constant
speed.
This slip compensation is a standard function on most VFD drives and is
especially useful in application which require constant speed but varying torque.

Power Factor Correction

1. Power factor basics

AC Power flow has three components:

Active Power is the power needed for useful work such as turning a lathe, providing
light Or pumping water. It is expressed in Watt or Kilowatt (kW).
Reactive Power is a measure of the stored energy reflected to the source. It is
expressed In var or Kilovar (kVAR).
Apparent Power is the vector sum of both the active and the reactive components.
It is expressed in Volt Amperes or in Kilovolt Amperes (kVA).

2. Power triangle

The relations between the various power components are illustrated in the power triangle
Shown in in the figure. From the figure, it is apparent that the active power component is in
phase with the applied voltage while the reactive component occurs 90 out of phase with the
voltage.

The equation that defines this relationship is:
(KW)^2 + (kVAR) ^2 = (kVA) ^2


Power factor (PF) is, in fact, a measure of efficiency. When the PF reaches unity, it can be said
that the electrical system in the plant is operating at maximum efficiency.

There are two commonly used definitions of power factor:
PF = Cosine of phase displacement between current and voltage.
PF = Cosine of angle between active power and apparent power.

3. Improvement

Some Components like the coal mills, etc. have very low power factor. Power factor can be
improved by either increasing the active power component or reducing there active
component. Of course, increasing the active power component for the sole purpose of power
factor correction would not be economically feasible. Thus, the only practical means for
improving the systems power factor is to reduce the reactive power component. One method
of reducing this component is to provide reactive power locally close to the load. This method
will improve the power factor from the point where the reactive power source is connected. As
an example, consider the load in the figure below.


The total power required is 100kVA of which 80kW is active power and 60kVAR is reactive
Power. If the reactive power is furnished locally, the power system only has to carry 80kVA
(80kW).

4. Problems with capacitor banks:-
When applying power factor correction capacitors, a couple of problems arise.

First, capacitors are a natural low impedance path for harmonic currents and will, therefore,
Absorb these energies. This increase in capacitor current results in higher element temperature
Which reduces the life of the capacitor. Also, because capacitors reduce the network
impedance, Capacitors can actually increase the level of harmonic current on the network.

The second and potentially more serious concern, is network resonance. When capacitors are
Added to the network, they set up a parallel resonance circuit between the capacitors and the
Network inductance. Harmonic current components that are close to the parallel resonance
point are magnified. The magnified current can cause serious problems such as excessive
Voltage distortion, nuisance fuse and breaker operation, overvoltage tripping of drives and
Insulation breakdown within motors, transformers and conductors.

Both risks increase with the size of the capacitor bank. The larger the size of the cap bank,
The higher the risks.
To address this issue, a tuned capacitor bank is one of the solutions that can be used to
suppress a given harmonic order to prevent network resonance.
5. Benefits:-
Power factor improvement allows the use of smaller transformers, switchgear and cables, etc.
as well as reducing power losses and voltage drop in an installation.
A high power factor allows the optimization of the components of an installation. Overrating of
certain equipment can be avoided, but to achieve the best results the correction should be
effected as close to the individual equipment in the building possible.
Losses in cables are proportional to square of the current and power factor improvement
reduced the distribution losses up to 1% from the existing levels.
By improving the power factor of a load supplied from a transformer, the current through the
transformer will be reduced thereby allowing more loads to be added. In practice, it may be
less expensive to improve the power factor, than to replace the transformer by a larger unit.


In order to reduce the Auxiliary Power Consumption the company, JSW Energy Ltd is planning
on implementing various optimization techniques available in the market, such as installing
VFDs at various components .A Comparative study of power consumption of CEP (Condensate
Extraction Pump) and ID (Induced Draft Fan) with and without VFDs is presented as two Case
studies below.

CASE STUDY I

CEP (Condensate Extraction Pump)

Design Data

Flow 795M3/Hr.
Head 335Mtrs = 33.5 Kg/Cm
2

Pump Required Power (795 x 33.5 x 10 x 9.81)/3600 = 715 KW
Pump Efficiency 83.5 %
Pump Input 856 KW
Motor Efficiency 95.36%
Motor Input 897 KW.
Rotation per minute( RPM) 1490

Present Operating Data at 300 MW Unit Load

Flow 790 M3/Hr.
Head 15.4 Kg/Cm
2

Pump Power 980 KW


To keep the pressure 15.4 Kg/Cm
2
, the required speed of the pump
N2 = N1 x (H1/H2)
= 1490 x (15.4/33.5)
= 1070 RPM

{According to pumps Affinity laws: P1/P2 = Q1/Q2 = (H1/ H2)
2
= (N1/N2)
3
}
Net Power Consumption with VFD = (1070 / 1490)
2/3
x 980 = 803 KW
Net power saving due to VFD = 980 803 = 177 KW
Net Money saving per 7500 Hrs. (per annum) = 177 x 7500 x 4 = 5.31 MIR


CASE STUDY II

ID (Induced Draft) Fan

Design Data

Motor power rating 2240KW
Motor speed 740 RPM
Power Factor 0.871
Flow Control Voith Hydraulic Coupling

Operating Data

Motor Speed 563 RPM
Power Consumption 1380 KW

If the Scoop is kept at 100% and with the help of VFD, the Motor is made to run at operating
speed of 563 RPM, the amount of power required :
= (563/740)
3
x 2240
= 986 KW
The Net Power Saving = 1380 986 = 394 KW / hr
Net money saving per annum i.e. 7500 Hr. p.a. = 394 x 7500 x 4 = 11.98 MIR
For two ID Fans, net saving per annum = 2 x 11.98 = 23.96 MIR

These two optimizations can save about 23.96MIR + 5.31MIR = 29.27MIR per annum.

Similarly inspecting and optimization of major power consuming Auxiliaries can help in saving
not just money but also power.


Suggestions and Improvements

1. Coal Handling Plant

Coal conveyers :

i. Idle running of the coal conveyers can be avoided to save the power
consumption. Consumes 15-20% of full load power.
ii. Increasing the rate at which the coal is being filled into the bunkers can
help in saving power consumption.
E.g. The Power consumption for filling of all the three coal bunkers at a
speed of 200 TPH will be more when compared to filling at a rate of
1000TPH and also saving time.

Coal Mills:

To reach the maximum power load, the ideal number of coal mills
required is 4 out of the available 6 depending on the quality of the coal.
But, it is observed that around 5 -6 mills are running to attain the
maximum power load. Hence, any measures taken for reducing the usage
of the extra coal mills can help in saving around 200 KW of power.

2. Cooling towers

Optimizing number of cooling tower fans required to operate based on vacuum
during favorable conditions.
Optimizing cooling tower fan blade angle on a seasonal and load basis.
Forced Draft Cooling tower fans consume large amounts of current, around
1000A. So, instead of using Forced Draft Fans, using natural draft fans can reduce
the power consumption by approximately 2%. This must taken care of during the
designing of the plant.


3. Lighting System

Replacing filament lamps with LED lamps

Though the installation charges are high, payback period is short and has
very low maintenance and high life time.

Installing timers for exhaust fans and other lighting equipment.
All A/C systems set at 24
o
C at is the most energy efficient temperature.


Conclusion

The report reveals that the plant has a considerable ways of saving energy in the
areas of pump units, fan systems, boilers, compressors, lightings, coal handling
plant etc. The total energy savings that can be achieved through these
optimizations prove to be substantial as proved by the case studies shown in the
report. Though the cost of these investments are high, the payback period is
small. The criteria for the implementation of above mentioned measures should
not just be saving energy but also not compromising on the efficiency of the
process. There is a scope of reducing auxiliary power consumption by about 2-
2.5 % in JSW Energy Ltd by taking suitable actions. It is believed that a reduction
of 1% Auxiliary power consumption can save about 22.9 MIR per annum.


INDEX

ACDB Alternating Current Distribution Board
ACWP Auxiliary Circulating Water pump
ACWT Auxiliary Circulating Water Transformer
AHP Ash handling Plant
APC Auxiliary Power Consumption
BFP Boiler Feed Pump
CEP Condensate Extraction Pump
CFL Compact-Fluorescent Lamp
CHP Coal Handling Plant
CRH Cold Re-Heater
CT Cooling Tower
CWP Circulating Water Pump
DCDB Direct Current Distribution Board
DCS Digital Control System
ESP Electro-Static Precipitator
FD Forced Draft
GT Generating Transformer
HP High Pressure
HRH Hot Re-Heater
ID Induced Draft
IP Intermediate Pressure
LED Light Emitting Diode
LP Low Pressure
MCC Motor Control Center
MLDB Main Lighting Distribution Board
PA Primary Air
PCC Power Control Center
SA Sealing Air
SST Station Service Transformer
TG Turbine-Generator
UAT Unit Auxiliary Transformer
UPS Utility Power Supply
UST Unit Service Transformer
VFD Variable Frequency Drive
VSC Variable Speed Control


References

WEBSITES

https://www.jswel.net
https://en.wikipedia.org/
http://economictimes.indiatimes.com/
https://en.wikipedia.org/wiki/Variable-frequency_drive
http://www.cea.nic.in/reports/yearly/
http://www.npti.in/
http://www.Ieeexplore.ieee.org

BOOKS

Schneider electric : Auxiliary Power consumption Reduction in Thermal
power Plant by Ramesh Batia
ABB Handbook of Energy Efficiency For Power Plant Auxiliaries
Increasing efficiency of the conventional auxiliary systems of power plants
by Thomas Schmager, Pasi Mannistro.
Power Plant Engineering by P.K. Nag.
Thermal Engineering by R.S. Khurmi.
Power Plant Engineering by Arora and Domkundavar.
Principle of Power Systems by V.K Mehta.

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