An Introduction of PAT Cycle for

Combined Cycle Power Plants

For

TO R R E N T P O W E R LT D

By

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EFFITECH SOLUTIONS LLP

Who We Are- Effitech Solutions LLP
An early stage Startup- focusing primarily on Energy Management,
Services Offered
Energy Auditing, Training and Development, and Solar PV EPC.
• Energy Auditing
Core Team Details
• PAT cycle Consultancy
➢Mr. Lokesh Chourasia, BEE Certified Accredited Energy Auditor,
• Water Audit
BE Mechanical, MS Thermal Engineering, Ex NTPC, Reliance,
AREVA employee • Process Audit
➢Mr. Srinivas, BEE Certified Energy Auditor, BE Mechanical, More • Carbon Foot Print
than 15 years experience in Power and Steel Industry
• Solar EPC Services
➢Mr. Ravinder Singh, BE Electrical, More than 20 years
experience in Power Industry • Stack Monitoring Testing
➢Mr. Nitesh, BE Computer science, MS Computer Science, Data • Sustainability Services
Analyst

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 Introduction: Lokesh Chourasia
▪BE Mechanical , MS Mechanical (Thermal Engineering)
▪Worked previously with NTPC Ltd., AREVA Solar, McHale
Performance, and Reliance Power.
▪A BEE Certified Accredited Energy Auditor.
▪Have more than 19 Years of Industry experience primarily in
O&M, Plant Performance, and Energy Audit of Power Plants
▪Completed More than 100 energy audits, 40 Baseline
verification audits, and more than 20 M&V Audits in Power
Plant, Iron & Steel, Refineries, and Petrochemical Plants.

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 Introduction to PAT
❖India has committed to reduce the emission intensity by 45% by 2030
below 2005 level.
❖Perform, Achieve and Trade (PAT) is a part of National Mission of
Energy Efficiency.
❖The threshold limit yearly 30000 tones of oil equivalent (toe) is the cut-
off limit criterion for any unit in the Power sector to be identified as
designated consumer (DC)under PAT
❖1 Tons of Oil Equivalent is 10 Millions of kCal, Which is equivalent to
2.0 Tonne of NonCoking Coal of 5000 kCal/kg GCV.

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 PAT Cycle Concept and Timeline
Baseline Assessment
Year 2 Year 3 M&V Audit
Audit Year

PAT Cycle Baseline Years Assessment Year

PAT Cycle I 2007-08,2008-09,2009-10 2010-11
PAT Cycle II 2015-16, 2016-17, 2017-18 2018-19
PAT Cycle III 2016-17, 2017-18, 2018-19 2019-20
PAT Cycle IV 2017-18, 2018-19, 2019-20 2020-21
PAT Cycle V 2018-19, 2019-20, 2020-21 2021-22
PAT Cycle VI 2019-20, 2020-21, 2021-22 2022-23
PAT Cycle 2021-22, 2022-23, 2023-24 2024-25
VII and VII a

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 Ecerts Concept and Calculation
Getting Ecerts
𝑁𝑜𝑡𝑖𝑓𝑖𝑒𝑑 𝑇𝑎𝑟𝑔𝑒𝑡 𝐻𝑅 − 𝐺𝑡𝐺 𝐻𝑅 𝐴𝑐ℎ𝑖𝑒𝑣𝑒𝑑 𝑤𝑖𝑡ℎ 𝑁𝑜𝑟𝑚𝑎𝑙𝑖𝑧𝑎𝑡𝑖𝑜𝑛 ∗ 𝑁𝑜𝑡𝑖𝑓𝑖𝑒𝑑 𝑁𝑒𝑡 𝐺𝑒𝑛𝑒𝑟𝑎𝑡𝑖𝑜𝑛
𝑁𝑜 𝑜𝑓 𝐸𝑐𝑒𝑟𝑡𝑠 =
10

❖Overachievers will be rewarded

with Ecerts and Underachievers will
be panelized
❖1 Ecert = 1 TOE

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 Target Notification: Torrent power
Ltd
Name, Address and State Registration Net Heat Net Product Net Heat Rate
No. Rate Output (Million (kcal/kWh)
(kcal/kWh) Units)

19 Sugen Mega Power Project, TPP0189GJ 1596.99 5871 1592.71

Torrent Power Ltd,

20 UNOSUGEN Power Project, Torrent TPP0190GJ 1585.23 1964 1585.23

Power Ltd

Dgen Power Project Not received any target. But has to fulfil all the
compliances other than MnV Audit

Sugen Target improvement is .27% Whereas, the UnoSugen has to

maintain its Net heat rate
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 Proforma Important Tabs
Instruction Sheet : Source of documents for Form Sh

General Information: Details about DC, PAT Cycle selection, and details of Energy Manager

Form-1 : Final Outcome based on Data provided in Form Sh. Non Editable

Form Sh: Most important tab. All data should be filled in Form Sh, All calculations will be
based on Form Sh only

Summary Sheet : Major calculation and summary linked to Form Sh. Non Editable

Normalization Tabs : Non Editable

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Proforma Form Sh
Proforma has 2 Sections for All data
1. Assessment Year
2. Baseline Year : Approved by the BEE

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Form Sh: Data needed to enter in the
Proforma
• Design Data of each unit
• Yearly generation, Aux Power Consumption, Fuel consumption, Gross Heat Rate
• Annual PLF
• Fuel Composition, NCV
• Loss of PLF due to non-availability of fuel/schedule/backing down/any external
factor/Unforeseen factors
• Startup and Stoppages due external factor/Unforeseen factors
• Energy saving investment and yearly saving

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 Form Sh: Tentative Source Document
Section In
Details Data Source
Proforma
4 Plant Capacity (MW) and unit wise design details Design OEM Data
6 Load Vs Heat Rate curve and coefficients Plot curve based on HBD Diagram
Unit wise Operating Data include Operating Load, Loading Monthly and Yearly Generation
6 Factor, Gross Generation, and Heat Rate of Each Unit Report
Details of Electricity Generated and Auxiliary Power
9 Consumption
iii Electricity Consumption-Colony/Construction Logbook
iv Auxiliary Power Consumption SLDC Report, CEA report
Fuel Composition Report from
10 Unit wise Fuel Analysis Details
Supplier
12.1 Loss of PLF due to any external factors
Each Unit Average Operating Load (MW) and hours caused
by low ULF due to Fuel Unavailability, Scheduling, and Block wise Generation report
Backing Down
12.2 Each Unit Reserve Shutdown hours, Forced Outage, and Report submitted to SLDC or CERC or
Planned Outage Annual Gen Report
12.4 Start and Stop due to Shutdown Shut down report, Annual Report

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 Proforma Form Sh:Load Vs Heat
Rate
In Section 5 of The Form Sh includes

❖ Design Details of each unit including Boiler and Turbine Heat Rate Will be Gated from OEM Document.

❖Turbine Heat Rate Vs Load Curve equation, Can plot from HBD diagram at various unit loads

Heat Rate Vs Load

Turbine Heat Rate Vs Load Curve is important
2300.00
2250.00
in estimating the performance of the plant in
2200.00
2150.00
Part Load operation. It is one of the most
2100.00
2050.00
important plot in the proforma
2000.00 y = 0.0129x2 - 6.5892x + 2788.4
1950.00 R² = 0.9969
1900.00
0 50 100 150 200 250 300

OEM Curve or HBD data curve Constant 1 Constant 2 Constant 3

y=ax2-bx+c R2 a b c
1947 0.997 0.0129 6.5892 2788.40

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 Form Sh: Operating load and
loading factor
Section 6 of Form Sh Operating Load and
Operating Load of each unit calculated as Loading Factor
𝐺𝑒𝑛𝑒𝑟𝑎𝑡𝑖𝑜𝑛∗1000
𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝐿𝑜𝑎𝑑 = Shows How Close
𝑅𝑢𝑛𝑛𝑖𝑛𝑔 𝐻𝑜𝑢𝑟𝑠

Loading Factor of each unit Calculated as

Station is operating
𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝐿𝑜𝑎𝑑
at rated Capacity
𝐿𝑜𝑎𝑑𝑖𝑛𝑔 𝐹𝑎𝑐𝑡𝑜𝑟 = 𝑈𝑛𝑖𝑡 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦

Unit Capacity Running hours Generation Operating load Loading factor

Hours MU MW %
Unit 1 200 5910.42 923.35 156.22 78.11%
Unit 2 210 6140.73 938.48 152.83 72.78%
Unit 3 210 6788.95 1091.06 160.71 76.53%
Unit 4 210 5998.72 955.85 159.34 75.88%
Station 830 3908.745 629.11 75.80%

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Form Sh: Gross Heat Rate Calculation
for Units
Section 6 of Form Sh

Gross Heat Rate is the most important factor in estimating the plant performance.
A Plant has to Consider All the Fuel Used inside the GtG boundry during the AY

𝐹𝑢𝑒𝑙 𝐶𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 ∗ 𝐹𝑢𝑒𝑙 𝑁𝐶𝑉 ∗ 1000

𝐻𝑒𝑎𝑡 𝑅𝑎𝑡𝑒 =
𝑈𝑛𝑖𝑡 𝐺𝑒𝑛𝑒𝑟𝑎𝑡𝑖𝑜𝑛
Coal Consumption Heat rate
Heat rate,
Unit unit Generation Ton
kCal/kWh
3650.86
1 923.35 787073 3126.6
2 938.48 799965 3127.5
3 1091.1 933180 3133.3
4 955.85 817535 3136.1

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Form Sh: Auxiliary Power
Consumption (APC)
Section 9 of Form Sh

❖ APC is an important factor in estimating the Net plant performance.

❖ An APC is used in calculation of Net Heat Rate of the Plant
❖ APC of whole plant is considered.
❖ APC must not include power consumption in Colony and Construction
❖ APC Value to be entered in MU. Proforma will convert it into % APC

Station Station Generation Gross Heat rate, APC % APC Net Heat Rate
kCal/kWh
MU kCal/kWh MU %
1 923.35 3126.6 100 10.83% 3506.34
2 938.48 3127.5 100 10.66% 3500.49
3 1091.1 3133.3 100 9.17% 3449.44
4 955.85 3136.1 100 10.46% 3502.53

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Form Sh: Unit wise Fuel Analysis
Details
Section 10 of Form Sh

❖ Natural Gas is a primary fuel of Gas based power plants

(Weighted Average) Operating

Sr No Element Units Design Fuel
value ❖ All the values
i Methane (CH4) % should be on
iii Ethane (C2H6) % Weighted Average
iv Propane (C3H8) % only
v Other Hydro Carbons (C4+) %

vi Hydrogen %

vii Nitrogen %

Relative density (Specific

x kg/NM3
Gravity)

xi GCV kcal/NM3

Xii NCV kcal/NM3

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Form Sh: Loss of PLF due to low
operating load
Section 12.1 of Form Sh Loss of PLF is
Primary Considered Low PLF due to below external factors important factor in
1. Fuel Unavailability : Plant not have sufficient fuel to calculation of
operate unit at full load normalization due to
2. Backing Down : When the unit is available to operate at PLF and APC
100% But Grid ask them to reduce load

Unit Average MW caused by low ULF due to Fuel Unavailability Average MW caused by low ULF due to backing down

Yearly Average MW Operating Hours Yearly Average MW Operating Hours

Unit 1 175.86 1593.47 181.00 1604.20

Unit 2 184.15 1582.97 193.52 1885.20
Unit 3 178.80 1866.77 190.87 1565.70
Unit 4 175.91 1301.52 188.99 1817.40

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 Form Sh: Loss of PLF due to Outages
Section 12.2 of Form Sh The Outage hours are
Primary Considered Outages due to important in estimating the
1. Reserve ShutDown : Plant is Ready to be Availability Factor of the
operated but do not have PPA or Grid Demand plant which is used in
2. Forced Outage : Unit has to shutdown due to calculation of normalization
any external reason due to low PLF and APC
Running Reserve
Forced Outage Planned Unavailability Total Running Hours
Unit Capacity hours Shutdown
MW Hours Hours Hours Hours Hours
Unit 1 200 5910.42 0 2144.05 705.53 8760.00
Unit 2 210 6140.73 0 1910.35 708.92 8760.00
Unit 3 210 6788.95 534.58 1021.77 414.70 8760.00
Unit 4 210 5998.72 265.18 2496.75 0.00 8760.65

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 Normalization: External Factor
Why: Due to fuel non-availability, Grid Disturbance, or any other factor plant may opt
to reduce the load on turbine leading to low efficiency of units and Station
The Generating Companies have no control over the External Factors
External Factors Considered in Section 12.1, 12.2, 12.4, and 12.4.1 in Form Sh
Impact of External Factor Benefits is considered in two ways in proforma

1. Benefit of External factor in PLF and APC Normalization

2. Benefit of Electrical Energy and Thermal Energy
Consumption during shut down in NF 6 Other Factors

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 List of Normalizations
Section 13 of Form Sh

(ii) NF-2 PLF and APC-Document Available for Normalisation

NF-3 Gas Fuel Mix Document Available for Normalisation : When Mixing multiple fuel including
(vi)
Natural Gas, Naphatha, or any other fuel
(vii) NF-4 Gas OC Cycle Document Available for Normalisation: Plant which can be operated on OC

NF-5 Gas Quality-Document Available for Normalisation : For sudden change in Gas
(viii)
quality
(ix) NF-6 Others Factors-Document Available for Normalisation
G.3(iii)Normalisation
NF-7 Fuel Mix for TPP- Document Available for Normalization
G.3.1 PLF and APC Normalisation E2.3 kcal/kwh -2648.37
G.3.2 Gas Fuel Mix Normalisation E.5.2 kcal/kwh 0.00
G.3.3 Gas OC Cycle Normalisation E.6.2 kcal/kwh 0.00
G.3.4 Gas Quality Normalisation E7.2 kcal/kwh 0.00
G.3.5 Others Normalisation E.4.2 kcal/kwh 10.88
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 Normalizations: NF-2 PLF and APC

Why : APC of the plant does not reduce proportionally with the
reduction in Unit load
Following Factors used in estimation of PLF and APC Normalizations
1. Plant is operating at part load due to External Factor
2. Plant is shut down due to external factor
Documents Needed :
▪ Heat Rate Vs Load Curve for all the units
▪ SLDC record of Generation, Backing down, and Scheduling

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Normalizations NF-6 Others Factors-
Details :
❖Other Factors primarily includes plant energy consumption in
start-up, Shutdown Thermal and Electric Energy consumption
❖It is included in section 12.4B an 12.6 in Form Sh
Documents Needed :
▪ Logbook Record of each day,
▪ Must have Data filled in Baseline Year as well

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 Why Some Plants Do Not Receive
Normalization
❖Improper Documents
For Example: Not having NABL, 3rd Party certificate will not give Coal
Quality Normalization
❖Unavailability of Load Vs Heat Rate Curve : Will not give APC vs PLF
Normalization
❖Incorrect Calculations of Outage Hours and Running hours
❖Do not have proper record of station energy consumption during
shutdown due to external factor
❖DC did not provided the same data for the baseline years

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 PAT Cycle Timeline and Activities
Activity
Activity Timeline Description Tentative dates Where
By
Form 1, Action plan/Form 3 Yearly submission of Form 1 within 3 30 June (Every
3 Months DC SDA/BEE
submission months from last financial year Year)
Within 18 months MEA should be done by AEA, who issue 18 Months from
Mandatory Energy Audit AEA DC
from Notification Form 2 after completion of MEA Notification
Monitoring and Verification 4 Months after Within 4 month from conclusion of
31st July 2020 EmAEA DC
Audit completion of AY target year
Form A, Form B along with 4 Months after Within 4 month from conclusion of DC and
31st July 2020 SDA/BEE
others documents completion of AY target year EmAEA
Submission of Form A, Form B Within 45 days of the last date of
45 Days 15th Sept 2020 SDA BEE
with SDA comments submission of Form A

Recommendation of Escerts to Within two months from the date of the

Two Months 15th Nov 2020 BEE MoP
MoP, GOI receipt of the comments from SDA

Within 45 days from the date of the Issuance of

Issuance of Escerts by MoP 45 Days 31st Dec 2020 MoP
recommendation of Escerts from BEE Escerts by MoP
After 1 month from the Completion of
Form D Submission One Month DC SDA/BE
Trading

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What to Do to Achieve target
Understand the Proforma and Calculations

Understand the Energy Consumption in GtG boundry

Mandatory Audit of the Plant

Get Recommendations which can help in meet the target

Implement the Encon measures as action plan

Yearly check the progress

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 Compliances to meet
•Appoint or designate certified energy manager
•Submit annual energy consumption return
•Keep and submit documents as needed, backup of All the data
•Get energy audit conducted by an accredited energy auditor
•Implement techno Economic viable recommandations
•Comply with energy consumption norms and standards

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 Responsibility of Plant Energy Manager
•The Plant energy manager will be the person who had passed BEE
certification exam
•The Energy manager will be in charge of all the energy
conservation activities inside the plant.
•Energy Manager will be responsible for Authenticity of the data.
•The energy manager will communicate with the BEE on the behalf
of plant.
•Energy Manager will reply the any query from BEE and will attend
BEE seminars, and training.

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M&V Audit

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 Introduction: M&V Audit
❖ Monitoring and Verification Audit (M&V) done after completion of
assessment year of the PAT Cycle
❖ M&V Audit should be completed within 4 months of completion of
Assessment Year
❖Every Year BEE publish list of Agencies (EmAEA) who can do M&V Audit of
different sectors
❖DC Select any designated agency in that particular sector
❖ Assessment Year Performance will be compared with the Baseline Year
Performance
❖EmAEA submit report to BEE at the end of M&V with the recommendations of
ECerts

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 Purpose and Objective of M&V
Audit
❖ Estimate the Performance of the DC in PAT Cycle
❖ Check the details filled by DC in the proforma is correct and
matches with the authentic source of document.
❖ Check Whether DC has met the PAT Targets.
❖ AEA opinion on entitlement or requirement of energy saving
certificates (Ecerts) for the plant.
❖ Evaluate every energy saving activity undertaken by DC in
PAT Cycle. verify the plant has achieved the target with the
help of Encon Activities.

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 Approach and Methodology of
M&V Audit
Approach
1. Receive Work Order from DC
2. Form a Team of AEA, Sector Expert, CEA, and Engineer for M&V Audit of Plant
2. Communicate to BEE and DC about the M&V Audit visit
Methodology
1. Initial meeting with the plant team
2. Walk through of the Plant
3. Collect Filled Proforma with details about products, production, various sources of energy
utilization in the plant and their consumption details for the baseline and assessment year.
4. Verify source details of all collected data .
5. Verify the Encon Implemented and Amount of energy saved during the PAT Cycle.
6. Check Third party Lab Analysis report, Calibration reports.
7. Sign the MoM and Take supporting of all verified documents.

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Boundary for Combined Cycle Power
Plant

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 Steps of M&V Audit Proforma
Verification
Select the Proper PAT Cycle in General Instruction sheet

Check Form Sh Whether the Baseline Data is filled by the BEE and Locked

If DC was in previous PAT cycle then verify the baseline data with the previous PAT Cycle M&V Data

If it’s a New DC then verify the Baseline Data with source documents

Verify the GtG Energy Balance, Mass Balance, and Other Calculations

Check the Plant Heat Rate with and without Normalizations

Finalize the Proforma and Estimate the Ecerts

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What Happens After M&V Field Visit?
❖AEA will prepare the Report and Submit it along with Form
A, Form B, and other Annexures to BEE in PATNet Portal
❖BEE will check the Proforma and Report
❖BEE will send comments to DC if they are not satisfied with
the source documents
❖BEE will go with Check Verification if they have further
Doubt
❖Ecerts will be issued only after approval of report
❖DC is continued in PAT Cycle and have to meet compliances.

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List of Forms to be Submitted
Form A
Form A detail includes
❖Form A must be signed by Plant
❖Ecerts Finalized designated Energy Manager/ Plant
❖Encon Implemented during PAT Head
Cycle
❖Annual Saving in TOE

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 List of Forms to be Submitted
Form B
Form B includes
following details
❖ The Ecerts Finalized by
EmAEA
❖It clearly mention the
number of Ecerts to be
Issued or purchased
❖It must be signed by an
AEA

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 Latest Development in PAT
• New “Carbon Credit Trading Scheme (CCTS), 2023” Notification came in June 2023. The
major update includes
•SEC (TOE/Tonne) Will be Replaced with SGE (Specific GHG Emissions) tCO2eq/ Ton of
equivalent product
•The ECERTs will be replaced with Carbon Credit Certificates
• Yearly “Annual Energy Consumption and GHG Emissions” data needs to be submitted.
•Total GHG Emissions include Direct Emissions and Indirect Emissions
•Specific GHG Emission for Power Plant will be “t CO2eq/MWh”
•Direct GHG emissions are emissions from sources that are owned or controlled by the
Plant/DC.
•Indirect GHG emissions are emissions that are a consequence of the activities of the
Plant/DC, but occur at sources owned or controlled by another entity.

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 Conclusion
❖This Presentation includes basic details of PAT Introduction,
M&V Audit, and Latest Development.
❖Most Important Parameters in M&V Audit is
❖ Heat Rate Calculation
❖ Heat Rate Vs Load Curve
❖ Source Documents

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Questions ??

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 Thankyou

Any further Queries regarding proforma

or Energy Audit for Power Plant and Iron
& Steel Sector can be sent directly to me
at

Ph: 9702769326
Email : lokeshchourasia1@gmail.com

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