Transcript
PC-
TEAM AMIT NAYAK
PRAVEEN PRAJAPATI RAVI PAL SINGH
SHAHNAWAZ AKHTAR KHAN
CO ORDINATOR SHRI D. N. TIWARI AGM MAINTENANCE
NTPC TANDA
Sl. No DATE THEME/TOPIC SPEAKER Name & NO. OF
MEMBER PRESENT
SYNOPSIS OF
PRESENTATION
1
2-JULY-
2012 Sacrificial anode AMIT NAYAK
O&M
executives; 12 nos
Knowledge sharing:
Condenser Tube
leakages – causes &
remedies
2
8-AUG-
2012 Condensate System RAVI PAL SINGH
Operation Group-C
executives; 20 nos
Knowledge sharing:
Condensate System
Emergency handling
3
6-SEP-
2012 APH Performance PRAVEEN PRAJAPATI
O&M
executives; 12 nos
Knowledge sharing:
APH Performance and
Leakage Control
4 3- OCT-
2012
Compressed Air
System
SHAHNAWAZ
AKHTAR KHAN
O&M
executives; 15 nos
Knowledge sharing:
Compressed Air System
performance
5 4-JAN-
2013 Rotary Parts PRAVEEN PRAJAPATI
NRHQ, GM-OS and
senior executives of
NTPC stations of
Northern Region; 35
nos
Outages and O&M
Practices @ NTPC
Tanda
KNOWLEDGE SHARING BY ShARP
NEED OF HOUR “AIR COOLED CONDENSER TO
CURTAIL POWER PLANT THIRST’’
LAYOUT
• WHY AIR COOLED CONDENSER • WATER USED IN THERMAL POWER PLANTS • FUTURE WATER DEMAND • WATER CONSERVATION IN POWER PLANTS • AIR COOLED CONDENSER • STATIONS RUNNING ON AIR COOLED CONDENSER • RESEARCH AND FINDINGS • VENDORS • FUTURE SCOPE • MAJOR IMPACT USING AIR COOLED CONDENSER • CONCLUSION
WHY AIR COOLED CONDENSER
WHY AIR COOLED CONDENSER CONTD...
Source: 2nd water council, worldwatercouncil.org
WHY AIR COOLED CONDENSER CONTD...
WHY AIR COOLED CONDENSER CONTD...
Water energy nexus
It’s been said,
we’re going to
run out of fresh water,
before we run out of OIL.
Water Use in Thermal Power Plants
POWER PLANT TYPE Range
m3/MW
Gas based power plants 1.7 - 2.0
200 MW coal based thermal power plants 4.5 - 5.0
500 MW coal based thermal power plants 3.5 - 4.5
200 MW coal based power plants with ash water recycling 3.5 - 4.0
660 MW coal based super thermal power plants with ash
water recycling 3.0 - 4.0
110 MW coal based old power plants 7.0 - 8.0
Source: Report on minimization of water requirement in coal based thermal power stations by CEA : January’ 2012
Water Use in Thermal Power Plants
• Cooling Water (CW)
• Make-up Water
• Demineralised Water (DM water)
• Ash Handling Water
• Service Water
• Fire Water
• Potable Water
Water use for specific purposes (2x500 MW)
Cooling tower make up
DM water make up
Potable & service water
Clarifier sludge etc.
Coal dust suppression
AREA CONSUMPTION m3/h WATER USE (%)
Cooling tower make up 3450 86.25
DM water make up 120 3
Potable & service water 250 6.25
Clarifier sludge etc. 110 2.75
Coal dust suppression 70 1.75
TOTAL 4000 100
Ash disposal* 1300 32.5
*To be tapped from CW system as blow down water and as such not considered in consumptive water.
Water Use in Thermal Power Plants
Source: Report on minimization of water requirement in coal based thermal power stations by CEA : January’ 2012
Future water demand
0
20
40
60
80
100
120
140
2010 2025 2050
STANDING SUB COMMITTEE, MOWR
NCIWRD
Wat
er D
eman
d (
BC
M)
Source: Water Use and Efficiency in Thermal Power Plants : FICCI – HSBC Knowledge Initiative
Water Stress in INDIA
• Lots of Power Projects are getting delayed due to land acquisition problems.
• Barren or arid Land for setting power plants can be a solution.
Water conservation in thermal power plants
• Increasing cycles of concentration
• Optimising ash-water ratio
• Recycling ash water from the ash dyke
• Using air cooled condensers
• Reducing leaks and over flows
• Wastewater recycling
Wuxiang, China 2x600 MW Coal Fired Power Plant
Rio Bravo, Mexico — ACC for 3x515 MW Combined Cycle Power Plant
Types of AIR COOLED CONDENSER
Types of AIR COOLED CONDENSER
Hybrid Cooling System
Types of AIR COOLED CONDENSER
AIR COOLED CONDENSER
Finned tubes
• Steel tube
• Aluminium fins
• Aluminium coated on tube air side
Source: M/s SPX Air cooled Condenser Brochure
Routine maintenance of
DCS using jet
AIR COOLED CONDENSER
STATIONS RUNNING ON AIR COOLED CONDENSER Power Plants
• 2X350MW Ind Barath Power India Ltd. Orissa.
• 135 MW KSK Energy, Rajasthan.
• 81.5 MW Sarda Energy, Siltara plant.
Captive Power Plants
• Birla White
• Jaypee Group
• J.K. Laxmi
• Shree Cements
• Ultratech Cements.
GLOBAL STATIONS RUNNING ON AIR COOLED CONDENSER
RESEARCH
AND
FINDINGS
ASSUMPTIONS
• Capital cost : 5 crore/MW
• Auxiliary power consumption : 6.5 % with IDCT
: 6.0% with NDCT
• O&M cost : 13 lakh/MW/year
• Unit heat rate : 2425 kcal/kWh
For 2X500 MW PLANT
Findings Sl no
Description
Wet Cooling System (NDCT)
Direct Dry Cooling System (ACC)
Indirect Dry Cooling System (ACC)
1 Condenser Pressure 0.1019 Ksc .1835 Ksc .2243 Ksc 2 Gross unit output, MW 500 466.72 465.11 3 Capital cost Crore 2500 2601.5 2675.5 4 Crore/MW 5 5.57 5.75
5 Auxiliary power
consumption, % of gross
output 6 6.64 6.12 6 Gross heat rate, kcal/kWh 2425 2597.9 2606.9 7 O&M cost lakh/MW 13 12.08 12.13
8
First year tariff
Fixed charges Rs/kWh 1.59 1.75 1.79
Variable charges
Rs/kWh 0.71 0.77 0.77
Total Rs/kWh 2.31 2.52 2.56 9 Difference in tariff Rs/kWh Base 0.21 0.25
10
Levelised tariff
Fixed charges Rs/kWh 1.42 1.53 1.56
Variable charges
Rs/kWh 1.21 1.3 1.3
Total Rs/kWh 2.63 2.83 2.86 11 Difference in tariff Rs/kWh Base 0.21 0.23
Source: Report on minimization of water requirement in coal based thermal power stations by CEA : January’ 2012
Findings
Description
Difference in Levelised Tariff(Rs/Kwh)
Wet Cooling
System
Direct Dry Cooling
System
Indirect dry cooling
system
Condenser Back
Pressure .1835 Ksc .2243 Ksc
Plant at load
Centre
Base(NDCT) 0.31 0.34
Base (IDCT) 0.32 0.34
Plant at pit-head Base(NDCT) 0.21 0.23
Base (IDCT) 0.21 0.24
CW Water & Treatment Cost @ NTPC Tanda
DESCRIPTION Consumption
(Kg/Day) Matl
Cost(Rs/KG) Total Annual
Cost
Manpower Cost(Per Month)
Annual ManpowerCost
POLY ALUMINIUM CHLORIDE 500.00 6.75 1231875.00 24000.00 2,88,000.00
SCALE INHIBITOR 84.00 70.00 206955.00
35000.00 4,20,000.00 CORROSION INHIBITOR 84.00 60.00 206955.00
BIO DISPERSANT 24.00 40.00 59130.00
CLO2 8.00 55.00 19710.00
CHLORINE DOSING 400.00 11.00 985500.00 30000.00 3,60,000.00
SUB TOATAL 2710125.00 10,68,000.00
TOTAL TREATMENT COST 37,78,125.00
WATER COST PAID TO IRRIGATION DEPT
2,64,00,000.00
TOTAL COST OF CW WATER 3,01,78,125.00
ANNUAL LDO CONSUMTION .54 ml per unit 1,449.36
TOTAL COST OF LDO Rs 40000 per kl 5,79,74,400.00
@ NTPC Tanda
TOTAL COST OF CW WATER : 3,01,78,125.00 TOTAL COST OF LDO : 5,79,74,400.00 (in Rs. Per annum)
LAND SAVING WITHOUT RESERVOIR
MW STEAM FLOW TPH ACRE m2 ACC m2
LAND SAVING % LAND SAVING
500 1568.00 14.00 56000.00 9910.00 46090.00 82.30
660 2250.00 18.00 72000.00 14016.00 57984.00 80.53
800 2400.00 22.50 90000.00 15336.00 74664.00 82.96
WITH RESERVOIR
MW STEAM FLOW TPH ACRE m2 ACC m2
LAND SAVING % LAND SAVING
500 1568.00 34.00 136000.00 9910.00 126090.00 92.71
660 2250.00 44.00 176000.00 14016.00 161984.00 92.04
800 2400.00 55.00 220000.00 15336.00 204664.00 93.03
SOURCE: REVIEW OF LAND REQUIREMENTFOR THERMAL POWER STATIONS-CEA, SEPT 2010
VENDORS
• M/S SPX, NORTH CAROLINA,USA
• M/S THERMAX, PUNE.
• M/S GEA ENERGY TECHNOLOGY, BHOPAL DIVISION
• M/S ENERGO
• M/S CLASSIK COOLING TOWERS, COIMBATORE
• M/S PRECESION COOLING SYSTEM, CHENNAI
Design parameters
DESIGN REQUIREMENTS VALUE UNIT
EXHAUST STEAM FLOW 100 t/hr
EXHAUST STEAM PRESSURE 0.1835 Ksc
EXHAUST STEAM QUALITY 92 %
AIR INLET TEMPERATURE 30 C
BAROMETRIC PRESSURE 101.3 kPa
TEHRMAL PERFORMANCE VALUE UNIT CONDENSING TEMPERATURE 58 C
HEAT LOAD 60.4 MW
ARRANGMENT VALUE UNIT NUMBER OF FAN MODULES
REQUIRED 4 NUMBER OF A-FRAMES
REQUIRED 1
PLOT AREA 585 m2
ACC WIDTH 12.3 m
ACC LENGTH 47.6 m
INLET HEIGHT 9.2 m
FAN DETAILS VALUE UNIT
FAN DIAMETER 32 ft
FAN SHAFT POWER (TOTAL) 765 kW
FAN SHAFT POWER (PER FAN) 191.2 kW Source : GEA energy technology
FURTHER SCOPE OF AIR COOLED CONDENSER • Utilisation of hot air discharge in air-flue gas
cycle of boiler.
• Natural draught cooling towers in place of forced draught fans to reduce APC in dry cooling system.
MAJOR IMPACT USING AIR COOLED CONDENSER
Systems Wet Cooling System Dry Cooling System
Major Equipments Cooling tower and surface condenser Air Cooled Condenser
Availability of coolant Water at what cost / Is it available ? Air is free
Plant location Should be near water source to reduce
cost Water source is not criteria
Maintenance cost High 25% of that for wet cooling
system
Effluent treatment Necessary Not required
Fouling and scaling Major concern Not a concern
Cleaning Frequent tube side cleaning is
necessary
Occasional fin cleaning is
required
Total plant set up Involves intake water, pumping system
and storage facility No such infrastructure required
Area for complete
system More Less
Annual Energy
Consumption High Low
CONCLUSION • Exponentially rising demand of power • In future there may be a situation in which water sources may not
cope up with this requirement. • Norms of the regulatory authorities regarding usage of natural
resources will be further tightened, which will curtail the freedom of usage of water in power plant.
• By employing air cooled system, which eliminate dependencies on water for CW, locating stations in water scarce regions will be more possible.
• Although dry cooling systems are costly technologies on techno-economic considerations, but foreseeing the future, it is the need of hour to employ dry cooling system, which offers possible solution for power plant installation eliminating the above mentioned challenges.
It’s a thirsty world...
Industry is thirsty…
Agriculture is thirsty…
We are thirsty…
REFRENCES • Mr. Romit Sen, Senior Assistant Director, FICCI Water Mission: FICCI – HSBC, Knowledge
Initiative on Water Use and Efficiency in Thermal Power Plants. • The Integrated Energy Policy, Govt. of India • www.indiapower.org - accessed on June 30, 2011 • The Bulletin on Energy Efficiency, 2006, Volume 7, Issue 3 • Report of the Steering Committee on Water Resources for XI Five Year Plan • Phansalkar Sanjiv and Verma Shilp; India's Water Future 2050: Potential Deviations from
Business • International Journal of Rural Management (2007) 3: 14 • Technical EIA Guidance Manual for Thermal Power Plants, MoEF, 2009 • Report on minimization of water requirement in coal based thermal power stations:
central electricity authority, New Delhi, January’ 2012 • C. P. Kumar Scientist ’F’, National Institute of Hydrology, Roorkee: Water Status and
Problems in India • Audrey Maheu, McGill University: Energy choices and their impacts on demand for water
resources: An assessment of current and projected water consumption In global energy production
• Anna Delgado Martin, Massachusetts of Technology: Water Footprint of Electric Power Generation: Modelling its uses and Analyzing options for a water-scarce future
Thank you
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