18th Unit Level Professional circle convention

NTPC TANDA

PRESENTATION SYNOPSIS
NAME OF THE PROJECT Tanda Thermal Power Station

NAME OF PC PRAYAS

AREA OF FUNCTIONING OPERATION+ EEMG

DATE OF FORMATION OF PC 2013

NUMBER OF PC MEMBERS 04

NAME/ DESIG. OF PC LEADER Ritu Singh

( Sr MANAGER)

DETAILS OF etails of member 1.RITU SINGH (EEMG)

making the presentation
TOPIC OF THE PRESENTATION
2.ROHIT KANSAY (EEMG)
3.RISHI KUMAR (OPERATION)
4 .PRAVEEN Kr DUBEY (OPERATION)
System Analysis for Optimization
ECR Tool

Number of meetings in calendar year

2018

Numbers of projects implemented

18th Unit Level Professional circle convention

 NTPC TANDA
ACTIVITY SUMMARY REPORT
(For Period Jan.18 to Dec.’18)

Name of Professional Circle : PRAYAS Project: TTPS

Name of Coordinator: Mr. Amitabh Bhaumik Department: OPERATION

DATE THEME/TOPIC SPEAKER Name & NO. SYNOPSIS OF

OF MEMBER PRESENTATION
S. No PRESENT
1 10/01/2018 Ways to increase 06 Heat Rate
plant efficiency Improvement
2 20/01/2018 Optimization of plant 05
parameters
3 05/02/2018 Discussion on 05
Thermal loss
analysis tool
4 25/02/2018 Understanding 03
system characteristic
curves
5 18/03/2018 Basic of ECR tool 03
and its features
6 04/04/2018 Discussion on trade 03
off questions (Daily
Activities)
7 17/04/2018 Discussion on daily 03
varying demand for
better efficient
operation
8 03/05/2018 Study of CW pumps 03
stopping in low
load/winter weather
9 22/05/2018 CW pumps vs CW 03
CT Fans
10 05/06/2018 Understanding and 03
need of APC
integration in system
process decision
11 17/06/2018 Savings estimations 03
12 29/06/2018 Study of Equipment/ 03
system curves
13 14/07/2018 Study of previous 03
tool TLA
14 27/07/2018 Issue in continuous 03
monitoring of online
parameters and its
limitations
15 08/08/2018 Study of approach 03
for optimization by
CenPEEP
16 21/08/2018 Optimization by 03
use of ECR tools

23 16/11/2018 Update on savings 03

24 25/11/2018 Cost benefit analysis 03

25 01/12/2018 Discussion with 05

HOD

26 12/12/2018 Preparing executive 03

summary

27 20/12/2018 Making presentation 03

Abstract :

We know that over the period of time actual characteristic curves of equipment
changes. In NTPC tanda, Each unit have different Condenser loss curve with
respect to load (MW) despite of same make machine. Similar is the case with
mills with each showing specific behavior. There is also limitation on
continuous online measurement due to maintenance problem, quality of
measurement instrument specially in PSU, frequent malfunctioning of
instruments. There is a need for real-time system analysis which uses less
number of online parameters without compromising desired accuracy level.
This purpose is served by ECR ( Energy charge rate) tool.

Introduction :

NTPC Tanda has 4X110 MW Unit located in Dist. Ambedkar nagar. ECR
(Energy charge rate) tool is developed to tackle trade off/optimization problem
so that objectivity can be brought in decision making.

Certain Trade off Questions like

- How many CW pump to be kept in service while not losing enough on

Condenser vacuum loss

- Which one should turn off first CW pump or CT fan in winter Season to save
APC

requires system analysis. Most of it is found that certain decisions regarding

above questions are just conventions followed in a particular plant without any
Study on the impact.

ECR tool Quantifying the Impact of a deliberate action on complete system.

For example, some time Engineer want to know about the monitory impact of
some Actions like RH temp increased by increasing FD fan air flow when
furnace scanner indicates deterioration of flame on burner tilt upward
movement .

ECR tool aim to provide real time feedback to the operator in monetary
terms .

It analyze the system holistically , also provide expected value as per design
data , present data which is easily understandable to operation engineer, less
prone to instrument measurement errors as curves are used for predicted HR
losses. Curves are Derived to meet the desired accuracy level from Actual HR
data.

ECR tool uses excel VBA scripts and PI data ( OSIsoft system ) in Excel .

Problem Statement :

Factors affecting the optimization is readily available in literature. In most of

the Studies on optimization involves changes in various listed factors to see the
impact. The Feedback is crucial to know the impact. Optimizations in an
isolated system may not result the optimization in whole interlinking system.
Complete system analysis is required.

Feedback should be accurate up to desired accuracy level, less prone to

instrumentation measurement errors, preferably real time and easily
understandable.

Solution :

Attempt have been made to relook ECR and break into constituent which can be
used for optimization

ECR = { [HR /(1-APC) ]/GCV } * landed price of coal ------ (1)

Where

ECR = Energy charge Rate

APC= Auxiliary power consumption

GCV= Gross calorific value of coal

HR= Heat rate

Heat rate is calculated through parametric method. It means HR can be

rewritten as summation of -

HR actual= HR design + HR losses. ------(2)

 Typical HR loss calculations to arrive Unit Heat rate at NTPC tanda is
shown as below

Thus , Using (1) and (2) ,ECR can be rewritten as

ECR actual =ECRdesign+ ECR1 (due to MS press HR loss) +ECR2 (due to MS

temp HR loss) +.... so on ------(3)

For calculating HR loss in ECR tool , Curves have been derived at required
accuracy by plotting historical data or original curves provided by
Manufacturer.

Derived Curves accurately predict HR loss within a derived accuracy level in a

given practical operating range. For example , HR losses due to Condenser
vacuum as predict by Curve is tested within -.960 ksc to -.860 ksc vacuum.
ECR loss due to APC is applicable for APC from 10% to 14 % and HR varies
from 2650 to 2800 kcal/kwh for a given unit. It is crucial to quantify the
percentage error in results due to curve.

Snap shot of ECR tool at NTPC Tanda

Only controllable ECR losses are given way in the Excel based application.
ECR losses due to Turbine efficiency ,Radiation losses, Wet flue gas losses,
Loss due to moisture in fuel and air are ignored as either they are constant or
uncontrollable by Control room engineers.
Benefit:

1. Real time results , tackle trade off and bring objectivity

2. Quick decision making

3. Expected parameters for operators at different loads for better understanding

4. Use of curves limits impact of instrumentation errors if done through online

calculations using various parameters such as in case of dry flue gas loss
calculations.

5. Active Involvement of control room engineer. They can do experiments and

see the results. They do not have to wait for instructions from higher ups or wait
for Energy efficiency calculations to be done by specialized person every time.

6. Cost effective as simple excel and VBA scripts are used. PI process books
are difficult to handle .

Conclusion :

Optimizations can be easily done by bring removing complexity and bring

objectivity in the system. System analysis providing Real-time results prevent
experimentation biasness and take care of complex interdependent system.

In most of the situation, Instrumentation measurement error cannot be ignored

as there are maintenance issues or quality of measurement instruments are not
good which make it unreliable for continuous measurement.

Thus It is always better to practically varies the known factors which influence
the system to see the results. Thus real-time feedback system is crucial for
optimization in such scenario.
References :

1. Power Plant performance by A.B. Gill

2. CenPEEP manual on Energy and efficiency management system by NTPC

3. https://www.excel-easy.com/vba.html