e-Compendium GETS 2014

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I am pleased to learn that NTPC is organizing the maiden Global Energy Technology Summit (GETS – 2014) wherein technology experts from all over the World will be sharing their knowledge on the latest technology trends to address the evolving and future challenges of the power industry. The challenge before our nation is to provide power to all at an affordable cost with minimum possible environmental impact.

During the XII Plan (2012-2017), the country has a target for adding more than 88,000 MW of capacity. Out of this, 26,182 MW is supposed to be added by the central sector.

Further, due to efforts made by NTPC in the Bulk Tendering and also because of the initiatives taken by the Government, international players have set-up shops and manufacturing units in India. Now, with the ‘Make in India’ initiative of the Hon’ble Prime Minister, many more players are expected to come in the country. Thus, the country’s generation capacity will be augmented by using different types of equipment manufactured by agencies from different countries of the world with different design and technology.

In view of the above, it is important for us, as a country, to have open deliberations on the type of technology suitable to our country. It is also needed that the required benchmarks on technical parameters for equipment to be manufactured or imported into India are laid down taking into consideration their performance in the Indian conditions, especially with Indian coal.

NTPC being a pioneer power generator in the country having an installed capacity of 43,128 MW and generating over 25% of India’s power, thought it necessary to be a catalyst for initiating national and international debate on the above issues. To make Global Energy Technology Summit 2014 (GETS – 2014) a memorable event, it has been synchronized with the raising day of NTPC starting November 7th, 2014 which will be a regular annual event from now on.

I wish all success to GETS – 2014.

MESSAGE

(ARUP ROY CHOUDHURY)

Dr. Arup Roy ChoudhuryPh.D., IITD.

Chairman & Managing DirectorNTPC Limited

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It is indeed a great pleasure to know that NTPC has taken an initiative to organise the first-ever “Global Energy Technology Summit”, GETS-2014 to mark the celebration of its 39th raising day on 7th November, 2014 and making it a regular annual event.

The idea behind hosting this Summit is to share the heads & hearts with the who’s who in the power sector worldwide and getting acquainted with the problems or issues confronting the power sector companies in various parts of the world and India in particular. I am hopeful that GETS-2014 will not only throw light on new emerging technologies in power generation, environmental concerns, etc. but will also deliberate the challenges to make them commercially viable and affordable.

This Summit will also provide an opportunity to all participants and stake-holders to put forth their view points and exhibit their capabilities before a galaxy of professionals & intellectuals in the field of energy & power generation.

My best wishes for the success of GETS-2014.

MESSAGE

(I. J. Kapoor)

Inderjit Kapoor Director (Commercial) NTPC Limited

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It is a matter of great pride that NTPC Ltd., is organising its First International Technical Summit titled “Global Energy Technology Summit’ GETS 2014 from 7th to 9th Nov. 2014 in New Delhi/Noida focussing on emerging new technologies in the Power Sector synchronising with its Foundation Day, i.e. 7th November for the inauguration of the Summit.

NTPC is considered the leader & trendsetter in Indian Power scene and in keeping with its position, it seeks to play an active role as facilitator in the creation of a formal knowledge-sharing platform by organising GETS 2014, which from this year onward will be a regular international event. This event will connect Technology leaders, OEMs, Research institutes, Utilities, Consultants, Experts and other innovative people around the globe together to share their experiences, explore and delve upon new technologies aimed at providing greener, cleaner, efficient and affordable power to all. This is indeed the need of the hour, and particularly for India when it is poised for rapid capacity additions.

Beginning with grand inauguration on 7th November, the following two days are devoted to meticulously planned technical sessions with focus on contemporary themes like Environment protection, Energy efficiency & conservation, Renewable energy, Reliability & safety and Automation etc., related to Power Generation, Transmission and Distribution. On the sidelines of the technical sessions, parallel exhibition stalls are showcasing the latest technologies and products by Technology leaders, OEMs, EPC contractors, Consultants, Utilities and Research organisations which, I am sure, will evoke keen interest among delegates and authors for one-to-one interaction relating to their respective domain.

At the end, I take this opportunity to sincerely appreciate all participants and delegates from different parts of India and abroad as well as the organisers from NTPC for the great effort and enthusiasm shown by them and wish GETS-2014 to be a great success.

MESSAGE

(A.K. JHA)

A. K. Jha Director (Technical) NTPC Limited

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I am profoundly happy to learn that NTPC Ltd., is organising an international energy Summit (GETS-2014) to mark the occasion of its Raising day falling on 7th November, 2014. It is indeed a great and commendable endeavour on the part of members of NTPC family!

Through GETS 2014, the world at large, particularly those connected with technology development and deployment in the field of power generation and distribution, will come together at the premises of NTPC. This will lead to an intensive interaction on the various aspects of technology development and deployment and discussions with the specialists in various fields for deploying more efficient & greener technologies for meeting the energy needs of the nation.

I am sure that through this intensive knowledge sharing, the participants will gain a significant insight into the latest technology trends and carry back with them a great experience of the Summit.

In today’s world, knowledge and expertise know no boundaries and closer interactions on advanced technologies and innovations achieved elsewhere between industry representatives and technology leaders of the world would definitely lead to a sea change in the attitude and morale of not only Indian power professionals and industry experts but also of their counterparts abroad.

I wish the Summit a grand success.

MESSAGE

U. P. PANI Director (Human Resources) NTPC Limited

(U.P. Pani)

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It gives me a sense of great satisfaction and pride that NTPC Ltd., is holding its first-ever Global Energy Technology Summit – 2014 with its gala-opening coinciding with the Foundation Day of NTPC on 7th November, 2014 – a glorious tribute to the grand occasion! The Summit aims at bringing diverse technological knowledge, expertise and experience of engineers, scientists and technologists of India and the World together to be showcased into well thought-out technical sessions and exhibitions, concerning global and domestic energy scene.

We are all aware that speed & quality are the two most important aspects in the construction of power projects whether using conventional fossil- fuel sources or renewable sources – to address the ever-increasing gap of demand & supply of sustainable and affordable power. I am sure this summit will not only enable Indian power professionals getting enriched by the practices, methods and technologies followed abroad but also will hold out an Indian perspective of the issues concerned with power project construction, generation and distribution in the sub-continent to the delegates & specialists from various corners of the World.

I extend my heartiest welcome to all invitees, delegates, authors and exhibitors to the Summit and also the best wishes to the organisers in their endeavour to hold such a mega event.

MESSAGE

( S.C. PANDEY )

S.C. PANDEY Director (Projects) NTPC Limited

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I am extremely happy to learn that this year NTPC Ltd., is commemorating its 39th Raising Day on 7th November, 2014 in a very special way by holding the opening ceremony of GETS – Global Energy Technology Summit, 2014, bringing the eminent technologists, engineers & specialists associated with power generation & distribution under one roof.

It is indeed very heartening to see that when India is passing through a transformation on all fronts in its journey towards development and rapid infra-structure creation, holding such events makes great sense, as energy & power are the backbone of a country”s growth, industrialization & prosperity.

New capacity addition with most modern power generation technology and greater emphasis on renewables at affordable cost without affecting the ecological balance, will hold the key to future energy model.

GETS 2014 forum - I am sure will be the most informative as well as an enjoyable event for all, and it will also act as a starting ground for future collaboration and co-operation in common areas of Technologies Innovations, and R&D amongst scientific & industrial communities.

Wish GETS - 2014 a great success.

MESSAGE

(K. Biswal)

K. BISWAL Director (Finance) NTPC Limited

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NTPC Ltd., is celebrating its 39th foundation day on 7th November, 2014 and to mark this occasion as an unforgettable event, it is decided to organise the Global Energy Technology Summit, GETS-2014 raising its curtain on the same day.

I am extremely delighted to note that NTPC Ltd., truly living upto its stature of 5th largest power utility in the world and 2nd in Asia, is playing host to the above international event GETS-2014-first of its kind in NTPC, first of its kind in India. It goes without saying, holding an event of such a big magnitude takes months of painstaking effort on the part of everybody including authors, participating companies, organisers and all those who worked behind the scene.

Developing countries like India, with burgeoning population and with vast land mass need a huge fleet of operating power plants from all types of fuel sources with special focus & attention towards greater exploitation of renewables in the back-drop of carbon-constrained world. Maintaining operational efficiency & sustained plant-loading of the existing fleet of power stations and new capacity addition with advanced-technology based super-critical/ultra super-critical units as well as quantum increase in power production from naturally-endowed, country-specific renewable resources are the need of the hour to meet the challenge of supply-demand gap.

I am sure that GETS-2014 will be the true confluence of knowledge and experience of power professionals and technologists from all over the world and will carry forward the spirit of exploring & breaking new frontiers of technology to GETS-2015.

I wish all the success to Global Energy Technology Summit, GETS-2014.

MESSAGE

(KAUSHAL KISHORE SHARMA)

Kaushal Kishore Sharma Director (Operations) NTPC Limited

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I am glad to know that NTPC has taken initiative in organizing the Global Energy Technology Summit (GETS 2014) with the theme “Emerging Technologies for Future”. This is yet another significant landmark in NTPC’s efforts to update the Indian Power Sector with latest technological advancements.

I believe that for accelerated and sustainable growth of any sector, new and emerging technologies prove to be a key success factor. Therefore, in order to ensure sustainable growth of the Indian Power Sector in general and NTPC in particular, emphasis is required for acceptance of advanced and best technologies in the field.

I am sure that sharing of views & experience on emerging technologies by the eminent experts and world technology leaders during the Summit will go a long way in building up the required knowledge base for finding the most optimum energy solution for the country and will benefit the Power Sector immensely in terms of cost, efficiency & environmental care.

I wish the event a great success.

MESSAGE

(M.R.P. Rao)

M.R.P. Rao Chief Vigilance Officer NTPC Limited

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Today, power sector growth is being fuelled by demands of restless young India. Needless to say, to meet this burgeoning electricity capacity demand, challenges like managing GHG emissions, fuel supply and sourcing constraints, availability of land and water, protection of local environment etc., will only stiffen over time.

In pursuit of accomplishing the ambitious growth plans, NTPC is organizing the first Global Energy Technology Summit GETS-2014. GETS will continue to be an annual event from now onwards and shall contribute to knowledge enhancement about the latest and state of the art technologies all over the world.

I am sure that the delegates to the conference will find it exciting to have a first hand glimpse of panorama of new products, innovations and benchmarked technologies showcased and deliberated in the Summit. I also expect this Summit to stimulate the global scientific and industrial community to assess the business opportunity that lies in India and create manufacturing facilities for manufacture of advanced equipment and systems releated to power industry in India.

I am confident that this Summit will help disseminate and assimilate knowledge for mutual benefit of the end users and technology leaders. The feedback and expectations from end users shall, in turn, enrich the technology leaders, aiding further innovations for technological advancements in power sector.

I would like to appreciate and acknowledge the untiring efforts put in by Team NTPC in organizing the Summit.

I wish GETS-2014 a grand success.

MESSAGE

(A.K. GUPTA)

A. K. Gupta Executive Director (Engg.) & Chairman-Organising Committee-GETS-2014 NTPC Limited

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“The best way to predict the future is to invent it” – Alan Kay

The adage may sound to be a pompous overstatement. But, as long as we do not violate too many of Newton’s laws, we can probably make new technology shape up our future as we want it. In simple words, we should choose what we want and then make it happen. This has been the conviction behind organizing GETS 2014 wherein the global fraternity of Power Professionals will assemble together to apply their collective wisdom, to deliberate and to decide what we want and how to make that happen.

Global Energy Technology Summit has been initiated by NTPC as an annual event, to be held every year from the 7th to 9th November, with an objective to identify and assess emerging new technologies of power generation for the future and to accelerate their adoption and assimilation. The theme of this year’s Summit is aptly christened as “Emerging Technologies for the Future”. GETS 2014 shall focus inter alia on technologies for improving efficiency, diversifying sources of power, reducing emissions, promoting automation, improving reliability, conserving scarce resources and accelerating the pace of project execution.

We are thankful to the authors for their enthusiastic response which has resulted in submission of more than 160 high quality national and international technical papers. Due to time constraints, it has not been possible to provide a slot for presentation to all the papers. However, we are extremely grateful to the authors for their valuable contributions and have decided to publish all the papers on GETS website and also publish them in book form as a compendium of abstracts.

I am sure, with the marvellous contributions from the revered authors and untiring efforts put in by the technical and the organizing teams of GETS 2014, GETS will be a truly sought after event year on year.

(Arun Kumar Sinha)

P R E F A C E

Arun Kumar Sinha GM & Head (PE-Mech.) Leader - Technical Team GETS-2014 NTPC Limited

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Contents

GETS Themes

Efficiency….The Wannabe

Efficiency…By Design 17-39

Speedy and Quality Executions 40-46

Environment….A Pledge to Defend

Towards Green 49-64

Optimising Resources 65-85

Energy Conservation 86-94

Diversity of Energy Sources….For Sustainability 97-126

Reliability, Safety & Security….A Must 129-151

Automation…. For the Paradigm Shift

Automation for Optimised Operations 155-181

Advanced Computations and software tools 182-194

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Emerging Technologies for FutureNTPC‘s‘Global Energy Technology Summit’ GETS 2014 showcased state of art technologies from the technology leaders in the Power and Energy industry to power professionals worldwide. The global energy industry never stands still. Acquiring pre-emptive knowledge about emerging technologies is the best way to ensure that we have a say in the making of our future. The summit had about 175 technical papers from all around the world. The response of authors was overwhelming. Due to paucity of time, only 55 papers could be presented.

This compendium gives an abstract page of all the technical papers. This compendium is available online,’’e-Compendium“and from the hyperlinked title the technical papers can be assessed online.

Efficiency….The WannabeThe Ever Wannabe

In the current scenario of ever increasing environmental concerns and shrinking fossil fuel resources, efficiency improvement cannot be ignored. Efficient generation of power is of interest to any thermal power utility as cost of fuel is the major chunk of total operating cost. To set the tone for the deliberations, the first session of GETS 2014 is “Efficiency”.

The session on efficiency shall cover recent developments on efficiency improvement technologies including new cycles, Supercritical/ Ultra-Supercritical/ Advanced Ultra-Supercritical, Innovative design of Steam Generators to improve efficiency through reduction of exit flue gas temperature, improved combustion, minimizing excess air quantity etc. or any other technology, Means to improve efficiencies of Turbines & Auxiliaries. Case studies, practical design implementation strategies, new materials or any other topics related to efficiency improvement have been covered.

Speedy & Quality Executions

Today, the impetus is on Innovation, speed and quality and to fulfil the un-satiated demand for quality infrastructure and accelerate Industrial Development. The world is looking towards its technocrats for construction methodologies that are faster, cleaner, leaner and greener.

This session on” Speedy & Quality Executions” shall cover emerging ground-breaking techniques having potential to significantly compress the project gestation period in the areas of Construction Management, Advanced Construction Techniques, Construction Automation, Modern Construction Materials & Equipment, etc. for power plants.

Environment….A Pledge to DefendTowards Green

Power plants can be said to be a century old whereas the green dimension essentially started in the post war period. Such recentness of things and the way these dimensions evolved to circumscribe and transform the whole act of putting and operating power stations is amazing. While we were still struggling with local pollution a paradigm shift took us to global pollution. Global warming link with anthropogenic emissions emerged on the horizon almost suddenly.

Early dust nuisance from stacks prompted use of cyclone filters and ESPs. Post war heavy industrialization in Japan flagged the case for local pollution. European laws followed, with other countries also taking up environmental laws. Local pollution issues soon got reinforced with global warming as impact on green cover got established. The term GREEN entered out lexicon with new overtones to its meaning.

The session “Towards Green” delineates the technologies, which can potentially enable a powerful march towards a green future. It covers papers which help mitigate local or global pollution. The section covers subjects which deal with efficiency increase as a way towards green or on the other hand directly impact reduction of other pollutants through environmental control devices like ESPs. The section is an attempt to provide a 3600 subject coverage..

GETS Themes

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Energy Conservation

The promise of the future lies in our ability to reduce energy consumption through using less energy. In the current scenario of ever increasing environmental concerns and shrinking fossil fuel resources, energy conservation is need of hour. Accordingly, to set the tone for the deliberations, a session titled “Energy Conservation” has been scheduled.

This session on Energy Conservation shall cover recent developments like demand side response, energy efficient drives, Plasma ignition for low grade coal, LED lighting etc.

Optimising Resources

Higher growth aspirations, in the backdrop of shrinking land, water, and coal availability and their increasing cost, necessitates optimal utilization of these resources. This session shall cover technologies that can help reduce the ecological footprint by minimizing the consumption rates.The latest developments in the field of Air-cooled condensers, GIS, Pipe conveying, mechanised coal-blending system with auto sampling, steep angle conveying, dry/bottomash utilisation and handling, desalination and wastewater utilisation are some of the technologies covered by various authors in this session. The topics of Innovative compact plant layouts and R & M of plant assets have also been included.

Diversity of Energy Sources….For SustainabilityWith depleting reserves of fossil fuel like coal, oil and gas and the apprehensions of Nuclear Generation, Energy from Renewable sources like Solar, Wind, Biomass, Small Hydro etc. are inevitable, which are perennial in nature and can be effectively harnessed at any place ,any time depending on Technology or a combination of technologies selected.

Earlier Renewables were used for power generation in remote areas where conventional power was techno commercially not feasible to reach. However, as Renewables do not have any harmful impact on Environment and hence now a days very much sought after for capacity addition in the grid by most of the developed and developing nations.

Improvements in efficiency, low cost storage and integration with different conventional and other renewable sources make the renewable generation cost effective, increase reliability and ease despatch ability issues. The papers in the session on Diversity of Fuel – Renewables have been selected based on their innovative approach for making the Renewable Power Generation so cost effective that this is available to common consumers at grid parity in the near future and can be traded in the power market without any subsidy or based on pre-decided preferential tariff.

Reliability, Safety & Security

Reliability of power is the key for a quality service from a power generator. State of art technologies displaying maintenance free equipment, online diagnostics & health monitoring, reliability analysis and other technologies for reliable systems are covered through the various papers on this topic. The gamut of technology covered includes Nano technology, Microgrids, Smart substations and Cyber physical systems.

Apart from reliability, safety of personnel & equipment is a critical success factor for all industries and safety engineering based on international standards plays a major role in this important area. Security of critical infrastructure is also an area of prime concern these days & latest state of the art technological solutions (perimeter intrusion detection, CCTV, access control system, command & control centre) are being deployed to address the same. This is not confined alone to physical security; cyber security has also gained prominence in view of recent incidents of intrusions in vital installations, worldwide. A paper on Cyber security by team members of IEC 62443-2-4 standard on Industrial Automation & Control systems is also included.

The papers in this session on Reliability, Safety & Security dwell on the latest practices and technologies being deployed in this niche area and will certainly enhance the perspective of the reader.

AutomationAutomation for Optimised Operations

Integration of power plant operations and power plant business has become a reality by adoption of latest technologies in power plant automation. Today’s automation technologies and solutions have integrated the operations of varied power plant processes, from fuel

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supply, power generation, plant performance, emission monitoring & grid connections. This plenary session is devoted to such cutting edge automation technologies for reliable and optimised plant operations.

The session on Automation shall share the experiences of authors on Power Plant automation and control solutions, DDCMIS systems, SCADA, Smart Grid, application of Nano-Technology, robotics and state of the art communication technologies. The papers in the session on Automation for Optimised Operations have been selected based on their innovative application of available state of the art technologies, experiences gained in use of innovative technologies and the future developments in power plant automation in making the power generation business more simple, sustainable and profitable.

Advanced Computations and software tools

The advancement of computational technology in hardware, software and database management has made it possible to analyse large input data to gain understanding and insight into complex processes, which were otherwise not possible through manual analysis. Today, advance computation technology is being used in all phases of power plant, from designing to operation and maintenance for optimal utilization of resources.

The session on “Computational and Software Tools” shall cover applications of advance computing technologies in power plant process improvement. The session will deliberate recent developments, and applications of computation software for piping design, and CFD modelling to get insight into the possible causes and solutions for complex processes. Other papers are on FEM application for RLA, development of real time operator advisory, incipient fault detection and predictive monitoring for efficient plant operation using Artificial intelligence methods like ANN, Pattern recognition, Fuzzy and Genetic Algorithm etc..

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Abstarct:

Coal blending ratio is normally decided on the basis of experimental findings on boiler behaviour, slagging behaviour etc. But of late the cost of high CV coal has enhanced and consumers are not ready to purchase power generated from high cost blending.

High moisture steam coal contributes around 47% of the total recoverable steam coal reserve. Demand of this high moisture coal for power generation is very low because of transportation cost and its adverse effects on heatrate and auxiliary power consumption. But in reality landed cost of this coal is much less than landed cost of high CV coal. Drying of this coal can improve the quality, but this will enhance the cost of generation. A judicial blending of high moisture coal with low moisture domestic coal may address the issues.

Considering the inevitability of using high moisture coal in future plants, this paper has comes out with a study on blending domestic coal with high moisture Indonesian coal to offset the adverse effect. Standard flame temperature model, based on first principle, has been suitably modified to study the flame temperature and flue gas temperature trends at different blending ratio. The available knowledge on slagging behaviour of blended coal through different research paper is used to predict the slagging in the furnace. Blending experience and performance data of Simhadri 500 MW unit of NTPC is used for validating the study. The result shows that the model can be used for optimising blending ratio.

Author(s)

Mr. Pradip Chanda

E mail : [email protected], [email protected]

The Author is currently working as Additional General Manager in Power Management Institute of NTPC. He obtained his B.E (Electrical) from Calcutta University in 1980 and started his career as thermal power plant commissioning engineer in NTPC. He has worked as Operation in-charge of 200 and 500 MW unit and plant efficiency department for more than 18 years. He received his M.Tech from IIT, Delhi in 2003. His area of interest is power station system controls, mathematical modelling and simulation of thermal processes.

HIGH MOISTURE COAL – EFFECT OF BLENDING ON BOILER PERFORMANCE

EFFICIENCY

21 #

18

Abstarct:

In order to achieve higher efficiencies and reduce emissions of environmentally damaging gases, new super critical power generation technology requires higher pressure and higher temperature parameters for its Turbine Heat cycle. The present study deals with the requirement of mechanical properties, creep resistant properties of various candidate materials at high pressure and high temperature, Welding techniques to be followed and the challenges involved in Welding of these materials in ultra-super Critical Power Plants. The P91 steels are high strength alloys that normally transform completely to martensite during cooling. P92 has creep strength approximately 30-40% higher than P91 in the temperature range 593oC to 621oC, however P92 is still a code case with ASME albeit used in recent European, Chinese and American ultra-super critical power plants in temperature range near or beyond 600 oC for Main steam& Hot reheat line owing to definite advantage of less pipe wall thickness. Also challenges involved in selection of consumable, welding technique and pre and post weld heat treatment for P92/ T92 need to be addressed with seriousness to avoid delta ferrite formation and formation of intermetallic lave phase due to presence of excessive tungsten as explained in this paper. Further, use of P36 material and its welding requirements have been investigated w.r.t. the conventional use of SA106Gr.B or Gr.C material for Boiler feed pump discharge feed water piping system, recognizing the higher tensile strength of WB-36. However, WB36 is preferred for application below 350oC as WB36 shows a certain sensitivity to temper embrittlement, owing to the fact that its most critical ageing temperature has been proved to be 350oC as per manufacturer’s report.

Author(s)

Rakesh Kumar DGM ( PE-Mech) – NTPC

An Engineering Professional with over 21 years’ experience in Project Engineering, Operation and Maintenance in Power Plant industry.

Graduated (B.E. -Mechanical) from BIT Sindri, Dhanbad, Jharkhand in the year 1991 and Post graduated (M. Tech.- Power generation technology) from IIT Delhi in the year 2002.

Knowledge of National and International Standards (IBR, IS, ASME, ASTM, AWWA etc.) for Design Engineering and Testing of Power cycle Piping, Boiler, Auxiliaries like heat exchangers, Air pre heaters, Fans and Design of Insulation. Knowledge and experience of Maintenance and Operation of Power Plant.

Presented and published many technical papers in national and International seminars on various aspects of power industry. Attended various National and International seminar and workshop on boiler maintenance, equipment design, Welding research, Materials for boiler pressure parts and piping in super critical power plants etc.

Vineet Kumar, Assistant Manager (PE-Mech) – NTPC

An Engineering Professional with over 04 years experience in Project Engineering, Power Plant industry. Post Graduate in Thermal Engineering from NIT Kurukshetra. Knowledge of IBR, ASME, ASTM, IS Standards for High Energy Pipe design and Pipe flexibility Analysis softwares like CAESAR – II, etc.

WELDING TECHNIQUES INVOLVED IN SUPER CRITICAL POWER PLANTS FOR HIGH PRESSURE / HIGH TEMPERATURE PIPING

EFFICIENCY

59#

19

Abstarct:

It is known that air preheater plays an important role in improving the boiler efficiency. Efficent air preheater is having significant effect on heat rate and fan loading. Lot of technical papers are available emphasizing the cost saving by reducing the fuel consumption and reducing the fan loading. Under performing air preheater sometimes brings down boiler MW output also. Air preheater is an easily approachable equipment for Renovation and Modernization to increase the boiler efficency.

A typical way of approaching the problem is to conduct a site assessment study to understand the current operating conditions of the equipment. Based on the assessment report, recommendation is made for modifications for potential improvements. Predicted performance was calculated considering the improvements. On further discussion with the Customer, the scope is finalised and the guarantee parameters was fixed.

This paper present a case study where modifications were implemented and the results are achieved to the desired values.

Author(s)

Mr. V. Rajagopal

E-mail : [email protected], [email protected]

The Author is a Post Graduate Engineer has a long experience with Air Preheaters, since 1975. He is involved in the selection, design and field engineering of air preheaters with main focus on up gradation and solving the problems in air preheaters. He has conducted various workshops and seminars for engineers in India and abroad. A visionary with a clear business acumen.

BOILER EFFICIENCY IMPROVEMENT THROUGH AIR PREHEATER

EFFICIENCY

78#

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Abstarct:

Power plants have long cooled their turbine condensers with splash fill and asbestos cement sheet cooling towers. When plastic film media becameavailable there was a rush to adopt the higher efficiency fill, and to refitexisting towers with the new media. With the unpredictability of nature,large flow make-up water sources proved to be too unstable with impurities, andmuch of this modern fill has gone though periods of plugging and malfunction.Now industry is looking backwards to see what was good about splash fill, andhow can it be further adapted to do a job needed in the 21st century.

With this as a background, we have surveyed the major categories of splashfill, including V Bar and laths, hanging grids, mesh fill, Trickle blocks, andTurbo-splash.

Author(s)

Mr. Satendra Rawat MM Aqua Technologies Limited, India E-mail : [email protected]

SURVEY OF SPLASH FILL TO INVESTIGATE NEW USES FOR EXISTING TECHNOLOGY

EFFICIENCY

88 #

21

Abstarct:

ABB’s carbon-in-ash instrument is a measurement system designed to perform online analysis of the unburned carbon content in boiler fly ash. Unlike other instruments currently on the market that provide only intermittent results, sometimes taking up to 12 minutes,ABB’s CIA instrument delivers continuous “true” real-time feedback to the boiler control system for closed loop control strategies, improving combustion efficiencies within power plants. Its unique patented non-extractive monitoring system incorporates advanced microwave technology for reliable and accurate measurement of unburned carbon in boiler fly ash. A simple design with minimal moving part, provides fast installation and less maintenance. In addition, the ABB carbon-in-ash instrument measures the quality (%) and the quantity (g/m3) of the ash produced in a power generation facility.

This real time solution with designed to the measuring the location at Boiler back-pass will improve Boiler safety, efficiency and environmental healthy perspectives. Good quality ash may be sold as a profitable by-product to the construction industry, instead of having to pay for its disposal in costly landfills

The instrument is designed for easy installation and minimal maintenance. Other benefits include:

• patented non-extractive online measurement

• highly accurate measurements in real-time

• in-situ measurement methodology

• potential reduction of unburned carbon-in-ash by 1-5 %

Author(s)

Mr. Balakrishnan C.

E-mail :[email protected]

The Author has 11 years experience in combustion and fuel firing equipements manufactring, development and field installation at thermal power industries. At present he is working in ABB and holding the position of “combusttion instrument specialist” and resposible for combustion instruments engineerng and doing sales support.

CARBON-IN-ASH INSTRUMENTREAL-TIME MONITORING OF UNBURNED CARBON-IN-ASH

EFFICIENCY

92 #

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Abstarct:

The first experience in India with R&M/LE measures on large Steam Power Plants (>200 MW) however showed some difficulties in the execution. As a result of this the market seems to be concerned whether a Restoration-to-name-plate-rating via repair or component replacement is the right solution or whether a Modernization with state of the art materials and technology which will improve the performance in terms of heat rate, output, reliability, availability, etc. will be the right solution.

This paper addresses features and benefits of both solutions Repair/Replacement “In-Kind” and Modernization and in addition the combination of both methods.

Repair features such as: • In-situ assessment, (NDT, etc.) • Remaining Lifetime Assessment • In-situ repair • Replacement of component “In-Kind”, with full interchangeability for the fleet

Modernization features such as:

• 3DS-Blades, • High end (Advance) Seals • Inner Casings and Rotors optimization • Valve and Electro-Hydraulic-Governor solutions

The presentation concludes with operational experience.

Author(s)

Thorsten Strunk Sales and Marketing Manager - Steam Plant Modernization Siemens AG Power Generation Services - Power and Gas [email protected]

Satbir Singh Malik Head - Customer Support Siemens Ltd India Power Generation Services - Power & Gas [email protected]

SIEMENS INNOVATIVE REPAIR/ REPLACEMENT AND EFFICIENCY IMPROVEMENT SOLUTION OF STEAM TURBINES

EFFICIENCY

101 #

23

Abstarct:

In view of high investment requirement in green field power stations, shortfall/ challenges in coal allocations, resource constraints and environmental concerns, there is an urgent need for efficient utilisation of existing generating capacity as well and to avoid capacity degradation.

The tariff regulations notified by CERC for next tariff control period (FY 2015-19) are expected to benefit the distribution utilities and consumers by way focusing on efficient power generation resulting in lower tariffs.

The demographics of thermal generating units reveal the following population of generating Steam Turbine sets are operating well beyond their original useful lifetime:

• 200/ 210 MW operating over 25 years – 68 units

• 500 MW operating over 25 years – 14 units

With adoption of efficient generating equipment by means of Steam Turbine R&M/ Retrofit the potential of efficiency improvement would result in an annual coal consumption reduction of about 12.5 million tonnes per annum, and also help the utility to generate and evacuate efficient power under merit order dispatch with minimal tariff shock.

This paper intends to assess the various options of enhancing efficiency of thermal power plants, review global practice & available technology and to recommend strategies for adopting enhanced efficiency for operating thermal power assets in India.

Author(s)

Mr. Chinmoy MOHANTY, Head of Tendering, Steam Turbine Execution Centre, ALSTOM INDIA LTD, Noida E-mail : [email protected]

Mr. Pradeep AGARWAL, Managing Director, Steam Turbine Execution Centre, ALSTOM INDIA LTD, Noida

Mr. Puneet BHATLA, Technical Director, ALSTOM INDIA LTD, Noida

Mr. Mahesh KENDHE, Head – ILCM, ALSTOM INDIA LTD, Noida

ENHANCING EFFICIENCY IN OPERATING ASSETS

EFFICIENCY

114 #

24

Abstarct:

After more than 10 year operation, Siemens steam turbines have become the reference for large scale coal fired power plant applications with ultra-supercritical steam conditions. Over the years the efficiency of such plants has been continuously increased by higher steam parameters.

This paper will give an overview to the turbine module selection and the experience of Siemens steam turbines for applications at a power output range from 600 to 1000 MW. Furthermore, an outlook on future capabilities with respect to efficiency and operational flexibility will be given.

Author(s)

Mr. Stefan Brueck, Siemens AG, Germany E-mail : [email protected]

Mr. Rainer Quinkertz, Siemens AG, Germany E-mail : [email protected]

SIEMENS USC STEAM TURBINES - EXPERIENCE AND FURTHER DEVELOPMENTS

EFFICIENCY

118 #

25

Abstarct:

With the ever increasing concerns to reduce power plant emissions including greenhouse gases and to reduce plant operating cost, fossil fired power plants have been moving to higher steam parameters like ultra-supercritical (USC) conditions to improve the system efficiency. Original equipment manufacturers (OEMs’) are constantly striving to develop new technologies for improvement of turbine efficiency. Performance improvement in turbine cycles can be optimized via a variety of system parameters. However, isolated attempts at optimization could have impacts that positively or negatively affect the global cycle performance. This article seeks to demonstrate the influence of such parameters and the impacts on the global performance and expected future developments.

Author(s)

Mr. Mahendra Singh Mehra Alstom Bharat Forge Power Limited, IHDP, Sector 127, Noida E-mail :[email protected]

The Author has done Post graduate in Thermal engineering from IIT Delhi and has more than ten years of experience in steam turbine design and power cycle optimization. Mahendra holds six patents on his name related to cycle performance improvement and has been actively involved in development of new products and cost competitive exercises.

OPTIMIZATION OF THE POWER CYCLE FOR IMPROVED OPERATING EFFICIENCY

EFFICIENCY

123 #

26

Abstarct:

Coal based Thermal Power Plants in India approximately contributes to 65% of total Electricity generated. At the same time, these plants have adverse effect on the environment due to emission of Carbon (mono & di) oxides.

Due to the above stated reason, Environmental bodies are encouraging technologies that reduce the pollution and can at the same time meet the stringent environmental norms. There are clean technologies such as Solar Energy, Hydro Energy, Wind Energy etc for power generation but that comes with higher capital investment and of course these plants cannot come up at any location. For these sought of plants the location need to be strategically thought of, which in turn becomes a constraint.

We all are aware that Technology, day by day, is getting advanced and it is evident from how technology changed from Sub Critical to Super Critical and then to Ultra Super Critical. Now technology is further heading towards “Advanced – Ultra Super Critical (A-USC)”.

With A-USC technology, there can be improvement in the system efficiency and economics of power generation and at the same time reduce the emission levels.

This technology comes with a price as the selection of right material is a challenge.

This paper describes about the A-USC technology, its effect on system efficiency and economics.

Author(s)

Mr. Rajendra Tekade

Project Engineer, Lauren Bharat Engineering Pvt. Ltd., Mumbai.

The Author is having 14 years of experience in Engineering of Thermal Power Plants. Was part of Engineering team for India’s first Solar Thermal Power Plant at Rajasthan.

E-Mail : [email protected]

EFFICIENCY GAIN THROUGH ADVANCED ULTRA SUPER CRITICAL TECHNOLOGY

EFFICIENCY

130#

27

Abstarct:

Most of the Concentrated Solar Power (CSP) plants with steam turbines are equipped with a cooling system tocondense the steam leaving the steam turbine. Different types of coolingsystems are used at power plants, including recirculating wet cooling and drycooling. Both these systems have some demerits such as with dry cooling system the turbine efficiency decreases with increase in ambient dry bulb temperature.In case of recirculating wet cooling with increased ambient dry bulbtemperature, though the turbine efficiency is better compared to dry cooling,it needed considerable makeup water. CSP plants with Hybrid cooling can generate high electrical power output during periods of high ambient airdry-bulb temperatures and minimize plant water consumption.

This paper describes Hybrid coolingsystem for CSP plants. . Hybrid cooling system makes use of both wet anddry cooling methodologies. In this parallel cooling system, the dry cooling unitis the primary heat rejection system and is used for majority of the timeduring operation.

Author(s)

Mr. Amar Chougale, Lauren Bharat Engg. Pvt. Ltd., India E-mail : [email protected]

Mr. Sivapathasekaran M, Lauren Bharat Engineering Private Limited, India E-mail : [email protected]

HYBRID COOLING SYSTEM FOR CSP PLANT

EFFICIENCY

136 #

28

Abstarct:

This technical paper will focused on the concept of Advanced Energy Auditing/Performance testing of the existing power plant and extends its purview and implementation on the Pre Energy auditing of plant under commissioning.

The conventional performance testing performs within the test boundary and calculates the energy transfer by measuring the process parameters. The primary focus is on the measurement and their location to get all the information about the plant performance. With this methodology the actual picture of design and implemented engineering, and improvement via reverse engineering to increase overall plant performance will remain unclear.

The advanced performance testing will widen the area of performance testing. It will consider the whole plant as an energy transfer/storage device and do analysis by dividing it into the multiple components of individual identity. The further scope of this method is to relate the performance and impact of process variation of one equipment with others. The conventional performance testing will be a part of the advance performance testing in addition there is analysis of control system strategy, equipment size, and pipe sizes, reverse engineering, and closed cycle system analysis using conventional and advance statistical analysis method.

The advantages of this new method of energy auditing will be:

1. Divide the whole plant into components and give details of their contribution in efficiency/heat rate.

2. Reverse engineering will helps to find the niche areas of the design.

3. Better understanding of the plant control system with process variance.

The implementation of the new method of energy auditing will not be complicated considering the plant operation is already optimized. The main consideration will be on the system itself. Therefore, it can easily work in parallel with the other activities.

Author(s)

Mr. LokeshChourasia Email: [email protected]

Working as a Sr. Process Engineer with Lauren Bharat Engg Pvt. Ltd. Over 11 years of experience in Conventional and CSP Solar Power plants in Design, Operation, Commissioning, Startup, and Performance testing. The area of interest is Process engineering, New technology development, Impelmentation, and Energy conservation. The project experienced in 25MW to 500MW Power plants.

NEW METHODOLOGY OF PERFORMANCE TESTING IN SIMPLE CYCLE AND COMBINED CYCLE POWER PLANT

EFFICIENCY

137 #

29

Abstarct:

With government authorities of India directing mines to wash coal to lower the ash content and increase the gross calorific value (GCV), reserves of high ash, low GCV washery rejects will remain behind at the site. The only technology capable of effectively burning this opportunity fuel economically is a circulating fluidized-bed (CFB) boiler. In India, two-stage internal recirculating (IR) CFB technology has been supplied and serviced for 18 CFB units to date using washery rejects as fuel for subcritical applications. Globally, CFB technology has gained recognition as being a viable technology for larger utility boilers as CFBs have now been successfully operated in commercial boilers as large as 600 MW. At this scale, CFB technology has transitioned from subcritical to supercritical circulation, and typically incorporate an additional fluidized-bed heat exchanger coupled with the lower furnace. This combines the benefits of a CFB, fuel flexibility and low emission without additional equipment, with the plant efficiency benefits of supercritical technology. By installing mine-mouth supercritical CFB power plants, fuel transportation costs are minimized. In addition, a reliable supply of washery rejects is available to keep the unit consistently supplied with fuel for generating electricity to the grid. The result is an efficient, economical and environmentally responsible way of disposing of waste coal.

Author(s)

Mr. Scott Anderson (Email: [email protected])

Master Degree in Mechanical Engineering from Youngstown State University and Master Degree in Nuclear Engineering from Pennsylvania State University. Presently working in New Product Development for Babcock and Wilcox (B&W), primarly involved with product design, research, and testing of CFB technology. Previous work has been with B&W peforming saftey analysis on the mPower SMR design as well as thermohydraulics on B&W supercritical and subcritical designs.

Mr.Raju Nair (Email: [email protected])

Bachelor of Technology in Chemical Engineering from University of Calicut and Post Graduate Diploma in Business Management from Narsee Monjee Institute of Management Studies (NMIMS) Mumbai. Presently working as Manager-Performance Engineering, Thermax Babcock & Wilcox Energy Solutions Pvt. Ltd., leading process engineering design of super-critical/sub-critical Pulverised Fuel fired Utility range of boilers. Previously worked on process & detailed engineering of AFBCs, Travelling Grates, Oil&Gas units and many Retrofit Jobs in industrial range of boilers.

Mr.C R Subramaniam (Email: [email protected])

Graduate in Mechanical Engineering from MS University. Post graduation specialization in the field of Computational Engineering from School Advanced Engineering and Information Technology, IIT Madras. Currently pursuing his Research Work in Indian coal Combustion at IIT Bombay. Presently working as Manager(Process Engg.),Thermax Ltd ,Pune mainly involving Design of Circulating Fluidized Bed Combustion Boilers, Pulverised Fuel fired boilers, BTG cycle Integration.

Efficient Combustion of Waste Fuel with Supercritical CFB Technology

EFFICIENCY

144 #

30

Abstarct:

Strong thermoacoustic vibration has been occurred in oil fired utility boiler due to the effect of large temperature differential in burner/furnace system. Simple tube models were used for thermoacoustic vibration which simply predicted vibration by only using two differential conditions, cold and hot. In this study, transfer matrix method was applied to improve the accuracy of the analysis. It consists of transfer matrices which are several changes in cross sectional areas, temperature gradients and flame models. Thermoacoustic vibration is evaluated by complex frequencies of global matrix which is the combination of transfer matrices. Several cases were calculated by using transfer matrix model of burner/furnace system. As a result, transfer matrix model has proved more accurate result compare to the result of previous tube models. To validate transfer matrix method, test in actual oil-fired boilers was performed.

Author(s)

Mr.Sungjong Ahn is a junior engineer in Doosan Heavy Industries. He is responsible for noise and vibration of component of Boiler, HRSG (Heat Recovery Steam Generator), Gas Turbine in Structure and Vibration Research Team. Mr. Ahn has developed evaluation method of Boiler noise.He has a B.S. degree (Mechanical Engineering) and an M.S. degree (Acoustics and Vibration) [email: [email protected]]

Mr.Jinwoong Ha is a senior engineer in Doosan Heavy Industries. He is responsible for Rotordynamic of Steam turbine, Gas turbine and Generator in Structure and Vibration Research Team. He has developed advanced rotordynamic method and his experience background span more than 10 years of rotordynamic. He received his B.S. degree (Mechanical Engineering) and M.S. degree (Vibration) [email: [email protected]]

Mr.YounghoJu is a senior engineer in Doosan Heavy Industries. He is responsible for vibration of Steam turbine, Boiler in Structure and Vibration Research Team. He has developed LSB of Steam turbine and his experience background span more than 15 years of component of steam turbine and boiler. He received his B.S. degree (Mechanical Engineering) and an M.S. degree (Vibration) [email: [email protected]]

Mr.Cheolhong Kim is a principal engineer in Doosan Heavy Industries. He is head manager of Structure and Vibration Research Team. He has developed LSB of Steam turbine and his experience background span more than 20 years of component of steam turbine and boiler. He has a B.S. degree (Mechanical Engineering), M.S. degree (Vibration) and Ph. D (Nonlinear Vibration) [email: [email protected]]

ANALYSIS AND VERIFICATION OF THERMOACOUSTIC VIBRATION IN OIL-FIRED BOILER FOR LARGE THERMAL POWER PLANT

EFFICIENCY

148 #

31

Abstarct:

Taean 300MW class IGCC project using clean coal technology was launched at the end of 2006. The plant has been constructed in Taean, Korea and will be commissioned in 2016. This plant is composed of the main four blocks: Air separation, dry-feed gasification, gas treating and power block. The target of plant net efficiency is 42% based on HHV using the bituminous coal, while NOx and SOx emissions are less than 30ppm and 15ppmrespectively.

In this project, Doosan Heavy Industries and Construction has done basic & detail engineering and construction work about gasification and gas treating block. In addition, Doosan has manufactured a gasifier and syngas cooler which are the key equipment in the gasification plant. Doosan has also developed the engineering tool, named DIGITs consists of equipment modeling, basic design, process simulation and engineering database part. As the results of the DIGITs simulation, the optimum operation conditions to maximize the performance of gasification plant are derived. So in this paper, various simulation results using DIGITs, as well as engineering and construction work done in the project were introduced.

Author(s)

Mr. Bongkeun Kim, Lead Research Engineer, Coal Conversion System Development Team, Corporate R&D Institute, Doosan Heavy Industries & Construction [email protected]

Mr. Youseok Kim, Senior Research Engineer, Coal Conversion System Development Team, Corporate R&D Institute, Doosan Heavy Industries & Construction [email protected]

Mr. Jeongseok Yoo, Principal Research Engineer, Team Leader Coal Conversion System Development Team, Corporate R&D Institute, Doosan Heavy Industries & Construction [email protected]

Mr. Sangjo Lee, General Manager, Coal Gasification Engineering & Technology Team, Boiler Business Group, Doosan Heavy Industries & Construction [email protected]

STATUS OF ENGINEERING DEVELOPMENT AND CONSTRUCTION FOR GASIFICATION PLANT IN TAEAN 300MW IGCC

EFFICIENCY

153 #

32

Abstarct:

In recent Korean power market, the cogeneration power plants which supply heat and power have been increased significantly in connection with new city construction. The large apartment complex in a new city is a best place to construct the CHPP for maximum fuel efficiency. The application of the clutched steam turbine is the key technology for a flexible operation of CHPP in variable demands of heat and power. When the heat (steam) demand is increased for residence buildings, low pressure turbine is disconnected by a clutch in the power system. On the other hand, low pressure turbine is clutched for an additional power generation in the peak seasons. Doosan has developed and supplied a 60Hz, 200MW clutched steam turbine to Sejong new city in Korea and successfully commissioned in December 2013 with the Doosan’s own technology although Doosan has not experienced in this kind of steam turbine. This paper introduces Doosan’s technology and experience of design, installation and operation of the clutched steam turbine for CHPP.

Author(s)

Mr. Seong Heon Yang, Ph.D. ([email protected]) Chief Engineer, Turbine/Generator Business Group

CURRENT WORK:

• Rotordynamic Design in a Steam Turbine • Bearing Basic Design in a Steam Turbine • Vibration Diagnosis in a High Speed Rotating Machinery • Starting & Loading Design in a Steam Turbine • Commissioning Operation of Steam Turbine • Performance Testing and Evaluation

EXPERIENCE: • Main Research Work

- Development of Anti-spragging Tilting Pad Journal Bearing, Bearing Design S/W, Vibration Diagnosis Technology, Rotor Dynamic Design Technology

• Main Design Work

- Boryeng #1/2 Retrofit Turbine (500MW) - Cirebon/Gheco-one New Turbine (700MW) - Eraring #1/2/3/4 Retrofit Turbine (750MW) - Marafig #5/6 New Turbine (270MW) - Rabigh II New Turbine (660MW) - Sejong/YanjuClutched Steam Turbine for CHPP (300MW)

• Award

- CEO Award (Youngwang #5/6 Nuclear Steam Turbine Commissioning, 2002) - CEO Award (Boryeng #1/2 Retrofit Turbine Design, 2007) - CEO Award (High Vibration Settlement of Younghung #1/2 Remedy Turbine, 2010) - 2011 Best Paper Award (2011 Power-Gen International) - CEO Award (Clutched Steam Turbine Design and Operation, 2013) - Biographical Record in the Marquis Who’s Who in the World, 2014

SUCCESSFUL DESIGN AND OPERATION OF A CLUTCHED STEAM TURBINE

EFFICIENCY

154 #

33

Abstarct:

The feasibility study for the life extension and performance improvement of the supercritical 500MW coal-fired thermal power plants that were operating over 20 years in South Korea was carried out. The purpose of feasibility study is to find the optimal thermal condition for performance improvement in the case of 10% uprating and the combustion of low grade coal.

‘4’ cases studies were carried out to find the optimal thermal condition and it was described that 593/593oC steam condition was the best cost-effective solution and plant efficiency could be increased from original by +2%.

It was revealed that the all convective tubes such as superheater, reheater and economizer tubes, PA/ID fans, HIP steam turbine, LP rotor, high temperature piping and high pressure heaters should be replaced in the case of 593/593oC steam condition.

Author(s)

Mr.Yongkeun Chung ([email protected])

Joined Doosan Heavy Industries & Constructions (DHI) in 1991 and are working at Service Engineering Team. Carrying out power plant optimization business as mechanical engineer.

Ms. Samyi Cha ([email protected])

Joined Doosan Heavy Industries & Constructions (DHI) in 2010 and are working at Service Engineering Team. Carrying out power plant optimization business as mechanical engineer.

Mr. Kiwan Kwon ([email protected])

Joined Doosan Heavy Industries & Constructions (DHI) in 2013 and are working at Service Engineering Team. Carrying out power plant optimization business as mechanical engineer.

THE STUDY FOR LIFE EXTENSION AND UPGRADE OF SUPERCRITICAL 500MW COAL-FIRED POWER PLANT IN S. KOREA

EFFICIENCY

156 #

34

Abstarct:

Worldwide demand for electricity is rapidly increasing. Concerns about fuel consumption and resulting CO2 emissions have stimulated the construction of more efficient fossil fuel power plants. The higher steam temperatures and pressures needed to achieve this increase in thermal efficiency require materials with improved capabilities, particularly Creep-Rupture Strength. One Creep-Strength Enhanced Ferritic (CSEF) steel alloy which is playing a significant role in new plant construction is ASTM A335 P92. Wyman-Gordon has provided P92 boiler piping for Ultra Supercritical (USC) plants in the U.S., Europe and throughout China where it has been installed in 181 units at 91 power plants. This paper will present a capabilityoverview of the alloy.

Author(s)

Dr. Ian Dempsterearned a Bachelor’s degree and Doctorate in Metallurgy from the University of Strathclyde, Glasgow, U.K. in 1979 and 1982 respectively. He has 31 years’ experience in the metalsindustry related to nickel base alloys used in high temperature applications,ferritic alloys used in the power generation industry and titanium base alloys used in high temperature gas turbine and space satellite applications. He has worked on process, property and microstructure development of these alloys. R&D activities have been in forging, extrusion and heat treatment processing of nickel, and titanium development alloys and the study of creep strength enhanced ferritic steels. [email protected]

Leon G. Klingensmithis the Chief Metallurgist (Ret.) of Wyman-Gordon Forgings, Inc. He has served in various manufacturing and sales management positions during his 48-year career in the metals industry. He also participatedin various ASME and EPRI study groups dealingwith Creep-Strength Enhanced Ferriticsteels.Klingensmith graduatedfrom the Pennsylvania State University with a B.S. in Metallurgy and completed additionalcourse work at Stanford University and the University of California. He has presented papers to more than 20 ASM International chapters throughout the United States and at international PowerGen-related technicalconferences in the United States, Europe and Asia. [email protected]

P92 – THE PREFERRED HIGH PERFORMANCE ALLOY FOR USC POWER PLANT APPLICATION

EFFICIENCY

158 #

35

Abstarct:

Permanently increasing electricity consumption predominantly driven by Malaysia’s rapid advances in industrialization along with stringent environmental requirements are demanding the implementation of power plants which are characterized by highest efficiencies, lowest emissions, highest flexibility, and excellent economics.

In response to this globally world-wide visible market needs Siemens started in the year 2000 the development of the SGT5-8000H gas turbine, the largest exclusively air-cooled heavy duty gas turbine currently in commercial operation. This gas turbine reduces the annual CO2 emissions by approximately 43.000 tons which is an equivalent to the CO2 emissions of 10.000 mid-range automobiles running 20.000 km pa

In this paper market-driven design features of the Prai Power Plant are illustrated in response to the Malaysian energy market requirements, which stands as example for many other Asian countries facing similar boundary conditions.

Author(s)

Mr. Stefan Eichner, Senior Sales Manager South Asia, Siemens AG E-mail :[email protected]

PRAI POWER PLANT – MALAYSIA SETS A NEW TREND REGARDING EFFICIENCY AND EMISSIONS IN SOUTH EAST ASIA

EFFICIENCY

172 #

36

Abstarct:

Since the implementation of vertical roller mill for coal grinding the design concept of the gearboxes to drive the mill changed totally. Based on the experience for large vertical mill applications the gearbox supplier introduced the bevel-planetary gear arrangement also for coal grinding. But the focus lies not in increasing drive power but in improving efficiency, reliability and simplification of maintenance.

The following paper describes the design concept of the initial and the state-of-the-art gearbox design. It point out the latest design improvements based on recent redesign work of individual western gearbox suppliers. Benefits of the actual design are stated together with a comparison of both gear units.

A case study describing the replacement project located in Poland (Europe) closes the theoretical discussion about the different gear designs and shows customer benefit and satisfaction.

Author(s)

Mr. Martin Baechler, Product Manager, FLSmidth MAAG Gear Switzerland, E-mail : [email protected]

Mr. Tomasz Wroblewski, Engineering Office Manager , FLSmidth MAAG Gear Poland, E-mail : [email protected]

Mr. Lukasz Orlowski, Designer Engineering, FLSmidth MAAG Gear Poland, E-mail : [email protected]

Mr. Rethinakumar Ganesan, Head of MAAG Gear India Operation, FLSmidth MAAG Gear India, E-mail : [email protected]

ENERGY EFFICIENT DRIVE FOR COAL GRINDING MILLS

EFFICIENCY

182 #

37

Abstract:

Fossil fuels represent the major share of power generation, with growth to more than two-thirds of the electricity generated in future. India is significant for this global growth in fossil power generation. Demands on scarce resources and impacts to the environment will be coincident with this increase. To address such demands, improvements in generation efficiency are a “no-regrets” action which reduces demands and the potential impacts. In case of steam power plant, this will include improved combustion, advanced controls, reduction in emissions, reduction in auxiliary power demands, improved steam turbine aerodynamics, as well as increases to the underlying thermodynamic cycle by increases in steam temperature and pressure. Today, new units are mostly supercritical (SC) and USC, and the future outlook is to plants with AUSC conditions. While there is no specific defenition of USC or AUSC, Alstom defines USC as today’s state-of-the-art steam conditions of 600-625oC and AUSC as beyond these steam conditions, requiring the application of nickel alloys, which would , due to increased strength, allow a significant jump in steam conditions, with a target of 700-760oC. This translates to a significant plant efficiency benefit (7-10%) over today’s plants, for an incremental investment in application of these new materials & new fabrication techniques.

Alstom is a leader in advancing USC and AUSC steam power plant technology and is a founding member of the European EMAX and the USA USC Materials Consortia. Alstom has on-going developments for the boiler, steam turbine components and in field testing through test loops in operating utility boilers. Through these programs, Alstom has gained considerable know-how and experience in materials properties, welding, fabrication design, design rules / industry code standards and is ready to progress to full scale demonstration. This paper presents some of the work done so far and what remains to be done, to commercialize AUSC plants in a global market.

Author(s)

Mr. John Marion Director of Technology and R&D, ALSTOM Power’s Boiler Business, Windsor, U. S. A. E-mail : [email protected]

Mr. Samar Sen Boiler Technology Development Specialist, Steam Boilers, Alstom India Ltd., Noida, India E-mail : [email protected]

STATE-OF-THE ART ULTRA SUPERCRITICAL AND READINESS FOR ADVANCED ULTRA-SUPERCRITICAL (AUSC) STEAM POWER PLANTS

EFFICIENCY

185 #

38

Abstract:

With the ever increasing concerns to reduce power plant emissions including greenhouse gases and to reduce operating cost, fossil fired power plants have been moving to higher steam parameters like ultra-supercritical (USC) conditions. Also, original equipment manufacturers (OEMs’) are carrying research to develop new technologies for improvement of turbine efficiency. The efforts to improve performance include research and development on steam turbine are on sealing and blading technologies, which holds the key for better steam path efficiencies. Also, efforts are being made to optimize LSB design and diffuser designs for optimizing exhaust loss curves for wide range of operation .This paper focuses on above new technologies and other new research being developed by Alstom and ABFPL to address key issues on performance

Author(s)

Mr. Michael Sell Alstom Power, Brown Boveri Str. 7. Baden CH5401 Switzerland E-mail :[email protected]

The Author has Studied Aeronautical engineering at Masters and Doctoral level at Imperial college London. After which he took a postdoctoral research role in the area of steam turbine aerodynamics, at the ETH, Zürich, working wth Professor Gyarmathy. In 2001 he moved to Alstom, progressing through various roles to be currently directior, R&D execution for Large Steam Turbines.

Mr. Mahendra Singh Mehra, Alstom Bharat Forge Power Limited, IHDP, Sector 127, Noida E-mail :[email protected]

The Author has done Post graduate in Thermal engineering from IIT Delhi and has more than ten years of experience in steam turbine design and power cycle optimization. Mahendra holds six patents on his name related to cycle performance improvement and has been actively involved in development of new products and cost competitive exercises.

Mr. Abhishek Verma, Alstom Bharat Forge Power Limited, IHDP, Sector 127, Noida E-mail :[email protected]

The Author has done B. Tech. in Mechanical Engineering and has more than 15 years of experience, including 12 years experience in Power Sector. Capital cost optimization & cycle performance improvement is core area of strength & interest.

RECENT ADVANCEMENT IN STEAM TURBINE FOR HIGHER EFFICIENCY

EFFICIENCY

199 #

39

Abstarct:

Advanced Ultra-supercritical (AUSC) coal-fired power plants will utilize steam pressures and temperatures that are too high for traditional ferritic steels and hence will require austenitic alloys. Older nickel-base superalloys such as 263 and 617, developed for aircraft engine applications were initially evaluated under the European collaborative AD700 project, beginning in 1998. Their limitations led to the development of a new age-hardened alloy, INCONEL® alloy 740H. The alloy possesses exceptional fireside corrosion resistance and creep rupture strength at temperatures up to 800°C. This paper presents the latest data on microstructure stability, heavy section welding and manufacture of components, including forged fittings.

Author(s)

John J. de Barbadillo received his BS, MS and PhD degrees from Lehigh University in Metallurgy and Materials Science. He has been employed by Inco Ltd R&D Center in Suffern NY and then at the Inco Alloys/Special Metals plant in Huntington WV. Dr. de Barbadillo is a Fellow of ASM and currently holds the position of Manager, Product and Process [email protected]

Brian A. Baker is a Product Development and Application Engineer with 24 years of experience working in the areas of high temperature corrosion and product development with Special Metals. He has numerous publications, patents and associated new products and [email protected]

Ronald D. Gollihue is an American Welding Society Certified Welding Inspector and Certified Welding Educator. He has been in the welding industry for 25 years. For the past 14 years he has been a Welding Project Specialist for Special Metals Research and Technology group overseeing the day-to-day functions of the Welding Development Laboratory in Huntington [email protected]

Shailesh J. Patel is Vice President, Research and Development, PCC Forged Products Division. Dr. Patel is a graduate of Leeds and Birmingham Universities and has worked at Inco Alloys/Special Metals plants inHereford England and Huntington WV, USA with experience in R&D and [email protected]

INCONEL® ALLOY 740H - AN ALLOY DESIGNED FOR ADVANCED ULTRA-SUPERCRITICAL APPLICATIONS

EFFICIENCY

210 #

40

Abstract:

As per the 12th Five Year Plan, the target is to reach 79690 MW. And with the release of coal block by the Government of India to the private and public sector, the future of thermal power generation is very bright. Therefore expansion of existing sites or setting up new generation capacities is on high. But the cost of the land has increased tremendously in last decade. Considering this problem, the need for a Wagon Shifter is very indispensable.

The main aim of manufacturing the wagon shifter-pusher is to reduce the space requirements in out-haul side of wagon tippler station and minimizing the unloading time .To form an empty rake at outhaul side in any plant or port, around 800 meters free rail track consisting of 58 wagons of is required. This space puts a severe constraint on plant layout as land availability for power plants or any industrial application is not only becoming difficult but also becoming very expensive.

As a result all the power generation companies have to design their plant layout with minimum land requirement. To deal with this problem, the need for Wagon Shifter cum Pusher has become vital to reduce the land requirement thus increasing the plant capacity and efficiency

Author(s)

ROHIT DUTTA MEDHI

Assistant Manager Business Development Bulk Material Handling, Power BU Larsen & Toubro Ltd. [email protected]

SRINIVAS CHANDRASHEKAR

Manager Business Development Bulk Material Handling, Power BU Larsen & Toubro Ltd. [email protected]

WAGON SHIFTER & PUSHER AND ITS ADVANTAGES TO THE POWER INDUSTRIES

SPEEDY & QUALITY EXECUTIONS

48#

41

Abstract:

Pre-award activities forms a big part of total timeline of power plant construction in which Land acquisition time plays a major role. Delays in acquisition significantly escalate the project construction time &cost.Land Acquisition has been categorized as “Top Risk” under the Enterprise Risk Management Framework of NTPC. Reducing the footprint of a power plant while ensuring maintainabili, affordability & sustainability is one of the biggest challenge. Technology up-gradation and optimized layouts are the only solution to convert this challenge into opportunity.

Eight projects entailing an investment of Rs 165,000 Crore were shelved owing to land acquisition issues in 2011-12 in India. The end of 119 years old Land Acquisition Act, 1894 & birth of New RFCT & LARR act 2013, was supposed to mark a new era in the developmental history of India. The Act was formed to remove historical injustice through a series of changes in acquisition process. But it lost balance between Industry & Farmers by increasing the acquisition time from 36 to 51 months. The research analyses this long time, consent clause, non-applicability of urgency clause, absence of ROW clause, Social Impact Assessment, numerous public hearings etc.

This paper compares the land requirement of NTPC Thermal Power Plants with Indian private sector, Indian state sector & International Power Plants. The paper flows through the saga of NTPC journey wherein company reduced land requirement from more than 2 Acre/MW in Singrauli to less than 0.7 Acre/MW by Technological advances. The paper investigates the Technologies adopted by NTPC in last four decades & their contribution in optimizing Land. This Paper also unveils the road ahead for NTPC to further optimize its land requirement for speedy construction to become technological leader in global energy market.

Author(s)

Shailendra Bhardwaj -

With more than Eleven years of experience in Power Sector, Sh. Bhardwaj is a Mechanical Engineer (BE - Hons.) by profession. He is currently Dy. Manager in New Project Group at NTPC Ltd. He Worked in Reliance Industries Ltd, Jamnagar & DCM Shriram Industries Ltd, Kota before joining NTPC.

Sh. Bhardwaj, an upholder of professionalism, is PGDBA from Symbiosis, Pune, Certified Welding Inspector from WRI, BHEL, Trichy, Certified Boiler Operation Engineer, Accredited Energy Auditor, Chartered Engineer and IRCA UK Certified QMS Lead Auditor. Currently he is pursuing Diploma in Training & Development from ISTD, Delhi. ([email protected], [email protected])

AkhileshPoddar -

AkhileshPoddar is a graduate in Civil Engineering with Post Graduation in Transportation Engineering. He is working with NTPC from last eight years with role to identify new sites for thermal plants and to develop layout and infrastructure facilities for thermal power plants. Apart from the professional life, Sh. Poddar is a marathon runner and has zeal to challenge himself every time both in professional as well in personnel life. ([email protected])

LAND ACQUISITION & PLANT LAYOUT: CONVERTING CHALLENGE INTO OPPORTUNITY THROUGH TECHNOLOGICAL ADVANCES

SPEEDY & QUALITY EXECUTIONS

49#

42

Abstract:

In the 11th Five Year Plan there has been an addition of 52063 MW in India’s Power Generation. And in the current 12th Five Year Plan, the target is to reach to 79690 MW. And in India power is mostly generated through coal. With the plan to release of coal blocks by the Government Of India to the private sector and the public sector enterprise, Coal India, the future of thermal power generation is very bright. Many companies are adding new capacities by expanding their existing site or by setting up new generation capacities in greenfield location.

In this situation, it is very essential for all power generationcompanies to complete the project in the shortest period of time to avail themaximum benefit. And that can be achieved through

• Reduce Engineering Time

• Reduce Construction Time

• Reduce Interface

• Reduce Unforeseen Work

If we follow to the above mentioned methods then surely we can complete our project in time without any unnecessary delay resulting in huge cost and time saving.

Author(s)

BARATHKUMAR Deputy General Manager Business Development Bulk Material Handling, Power BU [email protected] Larsen & Toubro Ltd.

DEBASISH TAPADAR Joint General Manager Business Development Bulk Material Handling, Power BU [email protected] Larsen & Toubro Ltd.

HOW TO COMPLETE A CHP PROJECT IN 24 MONTHS?

SPEEDY & QUALITY EXECUTIONS

65#

43

Abstract:

Last year NTPC awarded the contract to Design , Engineering, supply , packing , forwarding, transportation, unloading, storage , Installation and commissioning of 50 Mw Grid connected solar PV based power project at Ganeshpura village of Rajgarh district of Madhya Pradesh on turnkey basis to TATA Power solar.

This project was largest in the terms of capacity for any solar project to be completed by both the company. The paper provides the detail of innovative ideas used to overcome all challenges faced to complete the project within stipulated timeline and also complying with the technical requirement.

Author(s)

Rajnish Chaudhary

BE (Electrical) having more than 20 years of work experience in various industries likeFertilizer, Refinery & petrochemicals, Telecom, Solar & solar solutions.

For last seven year involved in Design and Engineering of solar cell manufacturing plant as well as large scale ground mount solar power projects across India.

NTPC 50MW PROJECT CHALLENGES AND WAY FORWARD

SPEEDY & QUALITY EXECUTIONS

87#

44

Abstract:

For long tunnel structures such as Head Race Tunnels (HRT) in hydropower projects, tunnel excavation by TBM (Tunnel Boring Machine) is frequently envisaged as it provides considerable time savings compared to conventional tunnel excavation. TBM monthly advance rates in excess of 300m are frequently achieved. However, it must not be forgotten that when using a TBM the key advantage of conventional excavation techniques, the flexibility to deal with unexpected situations, is considerable reduced.

Risk and risk management considerations for TBM tunnelling operations have to start during the early project phases such as when alignment studies and geotechnical investigation programs are been carried out. Tunnel boring machines for long tunnels are commonly “custom built” to meet the specific requirements of the project. Uncertainties with regard to the actual encountered geotechnical conditions will inevitably lead to time delays and to an increase in construction costs.

The contractual framework needs to be balanced to allow for a fair sharing and distribution of risks and responsibilities.

In case of an unexpected event during tunnel excavation there is always an initial phase of “chaos” before an organised response can take place. With an optimised site organisation this period can be minimized and any remedial / recovery measures can be decided on quickly.

This paper attempts give a critical look at risk and risk management techniques and requirements in TBM tunnelling operations, particularly in the Himalayan Mountains, starting from early project phases such as geological investigations carrying on into the actual project construction phase.

Author(s)

MILLEN Bernard, Geologist, Project Manager, GEOCONSULT ZT GmbH

BRANDL Johann, Geotechnical Engineer, Project Director, GEOCONSULT ZT GmbH

DENMAN David, Engineer, TBM Expert, GEOCONSULT ZT GmbH

RISK AND RISK MANAGEMENT IN TBM TUNNELLING

SPEEDY & QUALITY EXECUTIONS

142#

45

Abstract:

Tunnel boring machines are commonly used these days to drill hydraulic tunnels in varying and often very complex geological conditions, for long straight lines where the objective is a rapid construction rate. These machines, which first appeared in the 1960s, have undergone significant technical developments over the past two decades, which have allowed the pushing back of their application limits and the diversification of their conditions of use.

The aim of these adaptations is to mitigate the geotechnical and geological risks inherent in very long underground tunnels. Some principles are set out in the document, which looks back at the development of the first tunnel boring machines to excavate hard rock and cites a few recent developments available on the new machines. This will be illustrated using recent examples where a tunnel boring machine has been used to carry out construction work for EDF, as well as major projects worldwide.

Tunnel boring machine technique is very wide-ranging and each machine has its own specificities, as each type of terrain and underground work project is unique. This article cannot therefore describe the specificities of these machines in detail and only general notions and remarks are included.

Only the so-called “hard rock” tunnel boring machines are described, because it is very generally this type of machine which is implemented in the case of hydraulic tunnels.

Author(s)

François LAIGE EDF-CIH – Hydro Engineering Center – Underground Works Expert.

Michel AYOUB EDF-CIH – Hydro Engineering Center – Project Manager

Rémi COURTIAL EDF-CIH – Hydro Engineering Center – Project Manager

SPEEDY EXECUTION OF TUNNELS BY TUNNEL BORING MACHINE

SPEEDY & QUALITY EXECUTIONS

155#

46

Abstract:

The importance of executing projects on time and with the required quality cannot be overemphasized. This paper highlights the advanced methods and tools used during the execution of the turnkey Tower Boiler project for the 600 MW lignite power plant in Sostanj (Slovenia).

Boilers are one of the main components of a coal fired power plant. These are complex products, and Sostanj Tower Boiler has over 33,500 tons and 79,000 components. Due to this complexity, all large scale projects are vulnerable and can face significant issues such as delays or quality problems during execution unless the right planning and controls are in place.

The Sostanj 6 Tower Boiler, expected to go into commercial operation in February 2015, has been successfully executed in time with state of the art quality standards. Based on the acquired experience of many decades executing projects, a series of processes and tools have been implemented by Alstom Boiler Deutschland on this project in order to improve project execution and address the aforementioned challenges.

This paper will describe the following main processes and tools:

- Aspects of the comprehensive Project Management process during execution - An integrated tracking management system for steel structure. - A material management system - A very detailed construction planning tool - Advance construction methods - Strong EHS rules on site

Author(s)

Heinz Lorey Director of Sales and Tendering, Alstom Boiler Deutschland, Stuttgart [email protected]

Joerg Blaurock Director of Project Execution and Managing Director Alstom Boiler Deutschland, Stuttgart [email protected]

Cristian Casanova Project Manager, Alstom Boiler Deutschland, Stuttgart [email protected]

SPEEDY & QUALITY POWER PROJECT EXECUTION

THE SOSTANJ 6 TOWER BOILER CASE

SPEEDY & QUALITY EXECUTIONS

184#

47

48

49

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Abstract:

Raw water received by NTPC- Faridabad is worst water among all NTPC stations. This partly treated or untreated sewage water is aerated and chemically treated with Biocides and coagulants for removal of suspended impurities. The filtered water is than used as make up water for Cooling tower ( CW system) and for production of DM water. The objective of the current study was to utilize micronutrients like nitrate, phosphate and other dissolved & suspended impurities present in wastewater for algal growth resulting in decrease of concentrations of the micronutrients and dissolved & suspended solids present in water. Microalgae culture was inoculated in two algae ponds of areas measuring 50m2+20m2. Micro-algae from the ponds was used as inoculums to treat different raw water samples. Suspended and dissolved chemical impurities in water were analysed in water before and after inoculums of microalgae. The analysis results showed dramatic reduction of suspended and dissolved impurities varying from 24% to 85%. Microalgae has very strong potential to treat raw water received at NTPC-Badarpur and Faridabad to reduce suspended & dissolved solids and saving of bulk chemical consumption by 30-50%.

Author(s)

Mr. K K Sharma E mail :[email protected]

I did my post graduation in chemistry from Delhi university in 1989 and joined NTPC as Vth batch ET (Chem) in March 1993.I was posted from 1994 to 2009 at NTPC-Badarpur and thereafter at NTPC- Faridabad since April’2009. I have worked in DM plant operation & Coal at Badarpur and as Head(chemistry ) at NTPC Faridabad since Feb’2011

MICROALGAE THE NEXT FRONTIER TO TREAT WASTE WATER

44#

50

TOWARDS GREEN

Abstract:

With sustainable development becoming a buzz word in socio-economic settings the world over, the call for cleaner energy is gaining louder, day by day. At the forefront of the targeted sector lies the global power industry. The opportunities thrown forward by intensive Green Supply Chain Management (GSCM) practices for State owned power companies (SOPCs) call for a comprehensive study about the possibilities that can be explored regarding making existing supply chains greener. The significance of the study manifests itself in the fact that the power utilities of the state need to have a consolidated analysis of their supply chains, which can throw opportunities of prospective gains – both commercial and environmental. A study on GSCM practices prevalent in SOPCs, along with the areas where improvisation/modernization can be done, will help the SOPCs’ managements indecisively dealing with the problems of losses and inefficiencies in a number of operational domains, simultaneously attending to environmental concerns, as well.

Author(s)

Ms. Sheetal Soda E-mail: [email protected] Research Scholar, Department of Industrial and Production Engineering, Dr. B.R. Ambedkar National Institute of Technology, Jalandhar,Punjab

Dr. Anish Sachdeva E-mail: [email protected] Associate Professor, Department of Industrial and Production Engineering, Dr. B.R. Ambedkar National Institute of Technology, Jalandhar,Punjab

Dr. R.K.Garg E-mail: [email protected] Professor, Department of Industrial and Production Engineering, Dr. B.R. Ambedkar National Institute of Technology, Jalandhar,Punjab

OPTIMIZING ORGANIZATIONAL GAINS BY REINFORCING GREEN SUPPLY CHAIN MANAGEMENT (GSCM) MEASURES IN POWER COMPANIES

(SPECIAL REFERENCE TO PUNJAB)

70#

51

Abstract:

The world’s climate is changing adversely, and these changes have a massive impact on our planet. Groundwater levels in India are threatened by increase in the population and climatic shifts and it will decrease drastically in the future. The scarcity of fresh water source and the need for additional water supplies remains critical and will exponentially grow in the future. Our planet utilizes solar desalination evaporation process to produce precipitation, which is the primary source of fresh water on the Earth. The concept of Solar Sea Water Desalination (SWD) is a replication of above mentioned natural evaporation process on a smaller and economical scale. Conventional desalination plants use electrical power & fossil fuels for operation. The Concentrated Solar Thermal (CST) technology replaces these conventional energy inputs with solar energy, which eliminates the emission of harmful green-house gases. The intensive energy needed for desalination is another indirect hurtful effect of same on environment. CST offers a reasonable option of cogeneration of electricity with desalination. CST based technology uses Multi-Stage Flash (MSF), Multi-Effect Distillation (MED) & Thermal Vapor Compression (TVC) method for water desalination which can cut down the high fuel requirement in these plants. Although the negative impacts from usage of fossil fuels can be mitigated using CST, the adverse effects of desalination like high concentrate brine disposal on environment has to be considered. In this paper, the negative effects of solar seawater desalination system on coastal environment and preventive measures are explained.

Author(s)

Abdul Hanif Khan Email :- [email protected] Head – CSP Initiatives, W & RE IC, L&T Construction

Devang Chauhan Email: [email protected] Senior Engineer, CSP Initiatives, W & RE IC, L&T Construction

Renjith Kurian Email :- [email protected] Senior Engineer, CSP Initiatives, W & RE IC, L&T Construction

TOWARDS GREEN

SOLAR SEA WATER DESALINATION AND ENVIRONMENT

105#

52

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Abstract:

Power plants are the largest industrial consumers of water in India and water availability poses a major challenge to growth of the industry.

Opportunities for reuse of wastewater exist both within the power plant and from outside the power plant. Municipal sewage (from outside) has been successfully treated and used by power plants for both critical applications like boilers and non-critical applications including washing, etc. Wastewater streams from within the plant including cooling water blowdown, boiler blowdown, demineralization / reverse osmosis reject and ash pond wastewater have been successfully treated and reused back in the process.

Technical feasibility of various schemes of wastewater reuse have been established globally. Treatment schemes, especially those including membrane based systems have been used in some cases in India as well. Financial viability of these schemes depend on the judicious use of water treatment chemicals, ultrafiltration and reverse osmosis membrane based systems and innovative separation technologies such as electrodialysis reversal (EDR).

One of the core problems concerning wastewater reuse of high TDS streams is disposal of the ultimate reject streams. The goal of wastewater reuse schemes should be to reduce the ultimate reject stream as much as possible and ensure highest possible recovery from wastewater streams. Other objectives of power plant operators would include asset protection, financial viability, ease of operation and long-term sustainability.

The paper plans to highlight issues in reuse of various wastewater streams and proposes integrated chemical and membrane based solutions that could be deployed to achieve the reuse objectives.

Author(s)

Anand Krishnamurthy E-mail: [email protected]

Anand Krishnamurthy is the Marketing Leader for GE Water India. Anand has diverse experience in water, wastewater and infrastructure sectors, in marketing, product development, market research, strategy and consulting roles.

WASTE WATER RE-USE IN POWER PLANTS

132#

53

TOWARDS GREEN

Abstract:

Coal is the main source of fossil fuel and worldwide almost 75% of the electricity is generated using coal as the primary fuel. With the rapid industrial development, the power generation demand increases sharply and use of more coal will be necessitated. Thermal powe r plants uses different qualities of coal, different combustion technologies and operating conditions. The use of coal will increase the emissions of greenhouse gases and other pollutants. Main emission from the coal and lignite based power plants are particulates, SOx and NOx. In india. The levels of particulates at source is governed by Central Pollution Control Board (CPCB) guidelines whereas SO2 and NOx are monitored based on Ambient Air Qaulity Standards released by Ministry OF Environment and Forest (MOEF) during November 2009. Environment regulation to control SO2 emissions are already adopeted in over 30 countries. The SO2 emisson regulation in India is currently based on the stack height. The concentrations of SO2 emitted from the coal combustion are considered generally proportional to the sulphur content in the coal. Many power plants owners have chosen to use imported low sulphur coal in order to achieve required ambient air quality standard. However, where SO2 emission is higher in cluster of power plants, MOEF gives project clearance with FGD system on case to case basis. It is learent that in India, the emission regulation to limit SOx and NOx will be introduced shortly.

There are established technologies available to control the emissions of SO2, NOx and particulates. This paper discusses the growth of the Indian power sector, needs for technology to limit gaseous pollutents emissions, FGD technologies available, FGD plants inIndia and suitable FGD technology for Indian power scenario.

Author(s)

Shri M. Sataymoorthy, General Manager- Engineering - Graduate with Honours in Mechanical Engineering – joined BHEL, Tiruchirapalli in 1978. Sponsored by BHEL for post graduation in Fluid Machinery and was working in Fans Engineering till 1990. Headed the Defence Projects Group involved in indigenous development of missile launchers for more than 10 years. Was in-chage of Fans Engineering and Water Treatment groups. Currently heading the engineering groups of boiler auxiliaries at Ranipet since 2012 Email:[email protected]

Shri K.Rajavel, Additional General Manager - Flue Gas Desulphurization(FGD). –A Mechnical Engineering graduate - Joined BHEL, Tiruchy in 1975 and worked in FES. Since 1985, at Ranipet - worked in ESP proposals, contracts, Erection, FES over 23 years and presented paper on performance test. Since 2008, leading FGD group and involved in proposals, Contract and E&C.Involving IIT-Chennai, completed many Reasearch Projects in FGD and Gas cleaning system of IGCC. Involved in developing SCR for Denox control through slip stream demo plant. Email:[email protected]

Shri Manoj Kumar Thakur-Senior Process Engineer – Flue Gas Desulphurization system. A Chemical Engineering graduate from NITK joined BHEL in 2008. He has got 6 years plus of experience in FGD process selection, basic engineering, proposal,erection & commissioning of seawater FGD system. Involved in developing technology for simultaneous removal of Sox-Nox using EBT through a joint project with BARC, Mumbai - Email: [email protected]

EMERGING FLUE GAS DESULPHURIZATION (FGD) TECHNOLOGIES FOR THERMAL POWER PLANTS IN INDIA

140#

54

TOWARDS GREEN

Abstract:

Electrostatic precipitators (ESP) are widely used to capture fly ash generated due to combustion of coal in thermal power plants. The basic principle used for fly ash collection is electrical charging of ash particle and subsequent collection and removal of ash from ESP. ESP performance is primarily affected by fly ash characteristics – e.g. resistivity or chemical composition, ash content in coal, ESP inlet temperature, moisture content in flue gas, condition of ESP internals, functioning of Rapping mechanism, presence of back corona etc. Presence of one or multiple reasons may severely affect ESP performance and may also lead to higher energy consumption with deterioration in ESP collection efficiency and sometime results in exceeding the prescribed emission norms. All the changes mentioned above in ESP behavior are reflected in V-I characteristics. All modern controllers are equipped with capabilities to draw V-I characteristic in automated manner. In case it not possible to draw V-I curves in auto mode, same can be drawn in manual mode also. V-I curve can be effectively used to diagnose mechanical and electrical issues related to ESP field. This paper explains use of V-I curve approach to identify the probable causes for many ESP related problems and its conformation by internal ESP inspection during overhauling or shutdown.

Author(s)

Mr. Tushar Kumar B.Sc.(Engg.)- Electrical Engg., M.E. (Control & Instrumentation), MBA ( Finance) DGM (Environment Management), NTPCEOC, Sector 24, NOIDA E-mail: [email protected]

Have experience in power plant Operations and Commissioning. Presently working in Environment Management group and have keen interest in air pollution control systems and measurement technologies.

ESP Performance enhancement through V-I curve analysis

141#

55

TOWARDS GREEN

Abstract:

Concerns regarding the potential global environmental impacts of fossil fuels used in power generation and other energy supplies are increasing worldwide. Biomass co-firing in existing coal-fired boilers has emerged as a prospective option for voluntary reduction in CO2 emissions to mitigate the global warming problem. Co-firing is defined as supplementing a primary fuel with a secondary fuel. Biomass can serve as a supplement for coal combustion and has been successfully employed by various electric utility companies. Coal co-firing was successful with up to a 20% biomass mix.Every ton of biomass co-fired directly reduces fossil CO2 emissions by over 1 ton.Currently the most popular option for co-firing applications is direct co-firing, where biomass and coal are utilized together in the same boiler. This is mainly due to relatively low investment cost of turning an existing coal power plant into a co-firing plant. There are many successful co-firing systems, however there are various constraints that may be encountered. Most of them originate from fuel properties.

In the 1990s, many power plants demonstrated this option in Europe, Japan and United States, and then proceeded to use it commercially. In recent years with the need to reduce greenhouse gas emissions and meet Kyoto requirements in some countries, there is renewed interest in biomass co-firing on the basis that biomass is “CO2-neutral”.

The aim of this paper is to give an overview of the process& constraints associated with co-firing systems & its applicability to utility boilers in NTPC & India.

Author(s)

Mr. Somnath Bhattacharjee E-Mail : [email protected]; [email protected]

The author of this paper has around 26 years of experience in O&M of power stations. He is an MBA with specialization in Finance and has done M.Tech. in Power Generation Technology from IIT Delhi in year 2007. He has presented papers and case studies at national and international conferences. He has presented paper in Seventh Asian Computational Fluid Dynamics (ACFD7) Conference held at Indian Institute of Science (IISc), Bangalore from 26th to 30th November 2007 & 3rd International Congress on Computational Mechanics & Simulation (ICCMS 09) at IIT Bombay from 1st to 3rd December, 09. His paper on “Recovery of Waste Heat from boiler Flue Gas by using Kalina Cycle” was presented at International Conclave on Climate Change at ESCI Hyderabad from 12th to 14th Oct.’11..

CO-FIRING OF COAL & BIOMASS WASTE IN A CONVENTIONAL PF-FIRED POWER STATION-ISSUES & CHALLENGES

146#

56

TOWARDS GREEN

Abstract:

It is easier to describe pollution than to define it. Environmental pollution may be described as the unfavourable alteration of our surroundings which occur mainly due to rapid industrialization which ultimately results in deterioration of quality of air. All of us are aware that utilization of coal as a fuel and its incomplete combustion leads to emission of soot sulphur and other compounds into the atmosphere. In this paper we will be discussing about the statutory emission requirements specified by pollution control authorities for the past twenty five years and how the particulate matter collector viz. Electrostatic precipitator (ESP) is being designed to address the issue. The challenge is that how to augment the existing equipment to the present emission norms as prescribed by statutory authorities and also taking into account of future requirements. This paper also explains possible augmentation strategies of existing pollution control equipment with case studies for various projects. For reducing the emission with constraints of space, options like ammonia flue gas conditioning (AFGCS) are also being considered.

All over the world PM10 and PM2.5 is talked about and in other countries already this is addressed by enforcing authorities. Days are not far off that this requirement will be mandatory in our country also. Details with respect to future technologies like agglomeration of fine particles and also combination of ESP and Fabric Filter to address PM2.5 are also be presented.

Author(s)

Shri. M. Sataymoorthy, General Manager- Engineering - Graduate with Honours in Mechanical Engineering – joined BHEL, Tiruchirapalli in 1978. Sponsored by BHEL for post graduation in Fluid Machinery and was working in Fans Engineering till 1990. Headed the Defence Projects Group involved in indigenous development of missile launchers for more than 10 years. Was in-charge of Fans Engineering and Water Treatment groups. Currently heading the engineering groups of boiler auxiliaries at Ranipet since 2012 Email:[email protected]

Shri.S.S Mani, Additional General Manager –Air Quality Control Systems (AQCS) - Graduate in Civil Engineering from NIT, Tiruchy. Joined BHEL Ranipet in the year 1981. Working inProduct Engg group of AQCStill 2009. Presently headingthe department. Planned organised for design, supply and succeesful commissioning of more than 170 retrofit ESPs apart from green field ESPs in India. Submitted a paper in the recent ICESP XIII conference at Bangalore in 2013. Email:[email protected]

Shri.C.Ganesh, Senior Manager– Air Quality Control Systems (AQCS) –Joined BHEL in 1982 and has worked in operations before joining product Engg group of AQCS in the year 1992. Presently heading product Engg group of AQCS. Successfully commissioned Fabric filter at Romania and Koniambo and also AFGC system in 120MW plant in India.- Email: [email protected]

Shri.M.Ravichandran,Manager– Air Quality Control Systems (AQCS) - Engineering graduate AMIE (Mech) joined BHEL in 1982. Working in Electrostatic precipitator design proposals & contract engineering for 24 years for different application viz. coal fired boilers, biomass fired boilers, recovery boiler, steel & cement plants. Submitted a paper in the recent ICESP XIII conference at Bangalore in 2013- Email: [email protected]

AUGMENTATION OF POLLUTION CONTROL EQUIPMENT TO MEET THE PRESENT EMISSION NORMS AND ALSO FUTURE REQUIREMENTS

147#

57

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Abstract:

Doosan has combined its OEM strength in Circulating Fluidised Bed (CFB) design with its supercritical coal fired boiler technology to develop its new Ultra-Supercritical (USC) Circulating Fluidised Bed boiler design. Doosan has observed changes in the world coal market and the drive to utilise lower quality fuel to drive down the cost of electricity. Pulverised coal boiler designs have been the technology of choice however development of a design that has much greater fuel flexibility at no extra capital cost needed another solution. Doosan Lentjes which introduced the first utility scale CFB in the world, has combined it’s CFB combustor design and unique ash flow control technology with Doosan Babcock’s patented PosiflowTM low mass flux vertical tube furnace technology to deliver a leading edge USC CFB boiler design. Doosan is developing a 600MWe class USC CFB boiler concept for demonstration incorporating the proven aspects of both Doosan Lentjes and Doosan Babcock OEM boiler technologies. The result is expected to deliver a utility boiler with the efficiency, performance and reliability of PC boiler technology coupled with the fuel flexibility and smaller plant size of the USC CFB. This paper presents the USC CFB development story and the boiler concept that will offer India the opportunity to access lower generation costs and greater environmental sustainability.

Author(s)

GerdHeiermann– [email protected]

Over 35 years of experience in different leading functions in the international power plant industry with deep exposure to CFB-technologies and USC/SC utility size boiler design of major OEM’s. Held positions as Technical Director Engineering and Project Director with global players in the power industry.Currently responsible at Doosan Lentjes for the development and introduction of USC/SC Boiler Technologies with focus on CFBC.

Douglas Spalding– [email protected]

With a degree in Aeronautical Engineering Douglas has held a broad range of roles across the energy sector for almost 30 years. Starting inRolls Royce gas turbine development, then leading a thermal engineering and turbo-machinery R&D team at the UK’s National Engineering Laboratory and then moved to Doosan Babcock in 1998. Within Doosan, Douglas identified the emergence of the carbon market and its impact on coal fired power plant, secured a lead position on UK DeNOx retrofits, developed Doosan opportunities in HRSG flexibility and now heads up product planning and marketing in the Doosan Boiler R&D centre.

ACHIEVING LOWER COST GENERATION AND ENVIRONMENTAL SUSTAINABILITY THROUGH ADOPTION OF USC CFB TECHNOLOGY

151#

58

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Abstract:

Electrostatic precipitators (ESPs) have been used to collect particulate emissions from coal fired boilers for many years. To produce lowest cost electricity with the lowest possible emissions, coal fired boilers today need to have flexibility to burn a variety of coals and at the same time achieve very low emissions consistently. To meet these challenges, the size, cost and arrangement of ESPs becomes very large and hence power plants are now considering use of Fabric Filters as an alternative to ESPs. While Fabric Filters have been used to collect particulate emissions from coal fired boilers for many years, designing the filters to meet the required emissions from large 800 to 1100 MWe boiler systems is more challenging than for smaller units (100 to 600 MWe).

This paper provides insights on key issues that need to be considered while designing and evaluating high ratio fabric filters for large coal fired boiler installations. Advantages of using tall bag designs of up to 12 m length are elaborated and compared with other conventional designs. Various aspects of fabric filter design especially in taller bag designs like flow patterns and loading into the bag nests of various compartments are evaluated and discussed. Once the dust is collected on the filter bags, incorporation of a very efficient cleaning system in the filters to clean the bags while keeping the system pressure drop as low as possible, and limiting the emissions within the guaranteed limits, is also discussed.

Author(s)

Mr. Peter Wieslander Principal Research Engineer with Alstom Power Sweden AB, Vaxjo, Sweden [email protected]

Mr. Ajay Vajpeyi Process Engineering Manager based out of Kolkata, India [email protected]

Mr. Venkatesh Rao Global Product Manager based out of Kolkata, India [email protected]

FABRIC FILTER SOLUTIONS FOR LARGE COAL FIRED POWER PLANTS

206#

59

Abstract:

The NID System is an advanced multi-pollutant control dry scrubbing process that was developed by Alstom in the late 1980’s, with commercial units in operation since 1996. The system allows for SO2 removal rates greater than 98% while operating with high sulphur fuels that would be beyond the capabilities of traditional SDA (spray dryer) dry scrubber systems. Continuous innovation and improvement of this dry scrubbing system has allowed it to be applied to the ever tightening environmental emissions limits for pulverized coal boilers in the US and elsewhere.

Brayton Point Unit 3 is a 697MW(gross) PC boiler operating in Massachusetts, USA. The NID system supplied was designed to meet 98% removal with an inlet SO2 concentration of 2,830 mg/Nm3 dry (2.5 lb/MMBtu) along with additional requirements for Mercury, SO3, and Total Particulate control.

This paper provides an overview of the NID system and highlights the start-up, operations, and performance of the Brayton Point NID DFGD System after almost two years of operational experience.

Author(s)

Mr. Jiangtian Zhang Unit Technology Manager with Alstom Technical Service (Shanghai) Co., Ltd, Beijing, China [email protected]

Mr. Travis Reynolds Senior Process Engineer ECS with Alstom Power Inc, Knoxville, USA [email protected]

Mr. Paulo E Souza-De-Oliveira Product Manager ECS with Alstom Power Inc, Knoxville, USA [email protected]

TOWARDS GREEN

MODULAR DESIGN NID SYSTEM FOR MULTI-POLLUTANT CONTROL AND BRAYTON POINT NID OPERATIONAL EXPERIENCE

207#

60

TOWARDS GREEN

Abstract:

Coal stored in the open has become a silent killer. Open coal stockpiles are the largest source of hydrochloric acid, mercury and arsenic, resulting in 115,000 premature deaths and 20Mn asthma cases in one year. Coal dust is a health, safety and operational concern. 2-4% of stored coal can be lost from open stockpiles due to wind and spontaneous combustion.

With bigger plants, stockpiles get larger and thus the need to protect the environment from Coal and Coal from Environment. Different options of Cover are available, from sheds to concrete/steel domes to aluminum domes. The choice of cover is dependent on land availability, layout, stacking/reclaim systems, site, type of coal, etc. The covered stockpile system should be chosen considering these factors.

The Aluminum Dome technology has made 300m diameter domes and larger possible, thereby presenting the opportunity to store thousands of tons of coal in a very small foot print. Majority of plants worldwide utilize aluminum dome and circular stacker reclaimer to achieve the most operationally efficient and environmentally sound storage solution.

Aluminium Domes is the first choice due to: - Corrosion and maintenance free - Light weight for safe & fast erection - 50 -100 yr life

Coal Domes can achieve the triple objective of Protecting Life, Coal and Profits. Domes not only contain the health hazards of coal dust, also protect the Coal from the elements of environment and thereby protect the profits of the power producer, while helping to keep our planet cleaner and greener.

Author(s)

Kari Kauppi E-mail: [email protected]

Mr. Kauppi, based on Los Angeles, is responsible for the global business development in bulk material storage for CST Covers Ind., a global leader in clear-span all-aluminum covers and structures. He has a degree in Mechanical Engineering and has over 30 years of experience in equipment design, plant operations and business development in various industries.

COAL DOMES TO PROTECT LIFE, COAL AND PROFITS

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Abstract:

The United States Department of Energy(U.S. DOE) Office of Fossil Energy and the Ohio Coal Development Office (OCDO) have been the primary supporters of a U.S. effort to develop the materials technology necessary to build and operate an Advanced-UltraSuperCritical (A-USC) steam boiler and turbine with steam temperatures up to 760°C (1400°F). The program is made-up of two consortia representing the U.S. boiler and steam turbine manufacturers (Alstom, Babcock& Wilcox, Foster Wheeler, Riley Power, and GE Energy) and national laboratories (Oak Ridge National Laboratory and the National Energy TechnologyLaboratory) led by the Energy Industries of Ohio (EIO) with the Electric PowerResearch Institute (EPRI) serving as the program technical lead. Over 10 years, the program has conducted extensive laboratory testing, shop fabrication studies, field corrosion tests, and design studies. Based on the successful development and deployment of materials as part of this program, the Coal Utilization Research Council (CURC) and EPRI roadmap have identified the need for further development of A-USC technology as the cornerstone of a host of fossil energy systems and CO2 reduction strategies. This paper will present some of the key consortium successes and ongoing materials research in light of the next steps being developed to realize A-USC technology in the U.S. Key results include ASME Boiler and Pressure Vessel Code acceptance of Inconel 740/740H (CC2702), the operation of the world’s first 760°C (1400°F) steam corrosion test loop, and significant strides in turbine casting and forging activities. How utilization of materials designed for 760°C (1400°F) can have advantages at 700°C (1300°F) will also be highlighted.

Author(s)

Robert M. Purgert, President, Energy Industries of Ohio E-mail: [email protected]

Robert Purgert, President of Energy Industries of Ohio, is a native Ohioan who began his career at Wright Patterson Air Force Base negotiating and administering contracts for the Air Force Materials Laboratory. He returned to his hometown of Cleveland and headed the Procurement Operations Branch at NASA-Glenn Research Center. During his tenure he was responsible for overseeing contracting policy and procedures for energy, propulsion and space launch vehicle programs.

Mr. Purgert joined the private sector where he worked at area defense contractors. These included Cleveland Pneumatic Landing Gear, Physics International Co., and Thompson Casting Company. At Thompson he was responsible for developing a new advanced squeeze casting process for Metal Matrix Composites (MMC’s). The process called “Metal Compression Forming” was named one of R&D Magazines “Top 100” new technologies. He was also recognized as a recipient of Ohio’s Emerging Technology Award along with Oak Ridge National Laboratory. He holds a patent for lightweight metallic foams and has published a number of technical articles to include “The need for Government/Industry Partnerships”. He has participated at many international conferences to include India’s Indira Gandhi Centre for Atomic Research, US AIDs Pace Workshop and the previous NTPC conferences.

Mr. Purgert’s other experiences include testifying before Congress and he was a driving force for creating Energy Industries of Ohio to aid Ohio’s basic energy intensive industries and power generation sector. His organization continues to work with these industries and also the base-load power generation sector by overseeing major programs for clean coal technologies and next generation nuclear systems.

CURRENT STATUS OF THE U.S. DOE/OCDO A-USC MATERIALS TECHNOLOGY RESEARCH AND DEVELOPMENT PROGRAM

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TOWARDS GREEN

Abstract:

Introducing advanced boiler design in thermal power stations of today is becoming mandatory. It is necessary not only from an economic perspective but also from an environmental perspective.

The increase in plant efficiency is mainly achieved by increasing the steam parameters. Additional performance are achieved by a thorough 360° approach including Double Reheat, Fuel Flexibility, Tangential Firing, Full Air Fuel Ratio Control, Effective Air Preheater Design, Single Flue Gas Train, Compactness and much more.

USC design features which have enabled high plant efficiencies are outlined. The paper is empowered by boiler type comparison and analysis of operational flexibility, material selection, controlled safety valve and multi fuel concepts in ultra supercritical boilers.

Danish power plants are in this sense design and performance wise understood to define the elite. These plants are designed and supplied by Burmeister & Wain Energy (BWE) which over decades has build knowledge and experience to design boilers with unmatched efficiency and reliability.

BWE has furthermore been a member of the European COMTES700 initiative on advanced USC technology. Highlights are touched in view to see synergistic possibilities with the similar Indian program.

Author(s)

Flemming Skogaard Nielsen, Vice Precident Engineering, [email protected]

Born 1965, B. Sc. Energy Engineering at Helsingør Teknikum 1989, Employeed at BWE A/S 1989, Pressure Part Engineer 1989, Project Manager Avedøre Unit 2 400 MWe USC Boiler 1995, Project Manager Amager Unit 1 Multi Fuel Utility Boiler 2005, Department Manager Boiler Design 2006, Engineering Manager Porto Tolle 3.660 MW USC Boiler 2008, Vice President Engineering Division 2009

Carsten Søgaard, Sales & Proposal Manager, [email protected]

Born 1971, M.Sc. Energy Engineering at Technical University of Denmark 1999, Established Energy Consult 2001, Ph.D. work at Technical University of Denmark from 1999-2003. Energy Specialist at CP Kelco ApS 2004-2007, Consultant at Energy Consult 2007-2009, Project Engineer at BWE A/S 2009, Project Manager at BWE A/S 2010, Sales & Proposal Manager at BWE A/S 2014.

ADVANCED BOILER DESIGN

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Abstract:

Power Generators pledging its concern to the protection of environment and having environment protection on its agenda in the process of generating green power using inferior quality of fuel are adopting CFBC(Circulating Fluidized Bed Combustion) technology for its boilers.

CFBC is a class of Fluidized Bed Combustion (FBC) technology. FBC initially used in the chemical and process industries was applied to the electricity industry because of its perceived advantages over competing combustion technologies.

Generators in India adopted this technology for generating power up to 250MW unit size. Generators who have taken care of fuel quality at design stage and precautions during erection have achieved encouraging performance levels.

This paper presents the green power technology, CFBC. Advantages of CFBC over conventional Pulverized Combustion technology, its inherent nature in protecting the environment and the economy of having such technology keeping green power generation at the helm are indicated. Experience of NTPC in operating these boilers as consultant is also discussed.

At the end, this paper advocates the use of such green power technologies and stresses the need to encourage them by the government by relaxing the norms or laying down separate norms in respect of Auxiliary Power Consumption, reimbursement of complete fuel additive charges if necessary

Author(s)

Dr Srikrishna, S. E-mail: [email protected]

Author has joined NTPC in 1986 as ET after completing his batchler degree in Mechnical Engineering from NIT Kurukshetra (Earlier known as RECK). Completed his M.Tech(Industrial Engg) and Ph.D in the area of Reliability Centered Maintenance(RCM) from IIT Delhi to enhance his knowledge base. After working about 10 years in operation and 2 years in operation and efficiency department of Badarpur Thermal Power Station, he has opted to be part of 12 member team selected and posted for executing first O&M assignment of NTPC at Surat Lignite Power Plant(SLPP) of Gujarat Industries Power Company Limited(GIPCL) in 1998. At SLPP he has been exposed to the work areas of maintenance planning, Commercial other than operation and Operation & Efficiency. After completion of O&M assignment at SLPP in 2006, he is posted at Consultancy Wing Engineering department. Since then he is working with mechnical engineering group and involved in engineering of Harduaganj(2x250MW), Parichha(2x250MW), Bhawana(1500MW) CCPP and Singareni(2x600MW) projects. In addition to this he has also involved in engineering coordination of Anpara-D(2x500MW) project coming up on abandoned ash dyke.

TOWARDS GREEN

CFBC-GREEN POWER TECHNOLOGY

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TOWARDS GREEN

Abstract:

In thermal power stations, an electrostatic precipitator (ESP) is generally installed to process the exhaust gas generated from the coal fired boiler. Planning an ESP system is undertaken by taking into consideration flow gas conditions, dust properties (including the dust resistivity) in the gas, user’s requirements, etc. Among these, when the dust resistivity is high in the conventional type ESP technology, a larger footprint is required for the dust collection area by its collection principles, resulting in an enlarged ESP facility. In order to solve this problem, Hitachi, Ltd. has developed a moving electrode electrostatic precipitator (MEEP) which is configured differently from the conventional type ESP in terms of different mechanisms, enabling a high collection performance with compact configuration. The MEEP technology can be applied not only to new installations but also to retrofit implementations aimed at improving precipitation performance.

The MEEP technology has been supplied in many and various applications, receiving a high reputation from users. With environmental regulations becoming more stringent, business in overseas has been increasing.

By taking the opportunity on this occasion, an instruction will be made on the MEEP technology as to its great efficiency compared with the existing conventional type ESP regardless of new installations or existing ESP facilities. This technology would be highly significant in planning an environmental control project.

Author(s)

Takamasa Kojo Assistant manager Project Planning and Development Department Air Quality Development Systems Division Industrial Machinery Systems & Air Quality Development Systems Division Hitachi Plant Construction, Ltd. E-mail : [email protected]

MOVING ELECTRODE ELECTROSTATIC PRECIPITATOR

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Abstract:

Most mechanical draft cooling towers used around the world operate by using standard mechanical air moving equipment such as an axial fan, a gear box, a drive shaft and a motor. As presented in CTI Journal, Vol. 34, No . 1, a low-speed motor directly coupled to an axial fan can present benefits to the cooling tower industry [3]. This paper describes low-speed motor experiences of one European cooling tower manufacturer.

Author(s)

Martin Kubíček Jan Holl

Martin Kubicek is a Head of Asia Commercial Department of M/s FANS, a.s., based in Prague, Czech Republic. He has been in the cooling tower industry since 2008. In 2004 he graduate d as Mechanical Engineer at Brno University of Technology and till 2008 he was working on his PhD degree at the same university and University of Malta. He began his career as a trainee in FANS, a.s. company and since that time he is working as a member of commercial team. Since 2009, when subsidiary of ANS, a.s. in India named FAN S ASIA Pvt. Ltd. Has been established ,he has been spending most of his time ma inly in India to understand local market and client’s requirement. As of now, he is looking forward to his first child, which should come early next year.

email : [email protected]

LOW SPEED MOTOR EXPERIENCE USED IN COOLING TOWER INDUSTRY

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Abstract:

With the limited economic perspective of alternative energy and the hesitance to nuclear power, we believe that coal based power generation will maintain its prominent position for years to come.

Nowadays we are technically capable of designing totally enclosed storage and handling systems for storing huge quantities of bulk solids to meet the high demand for energy and mineral resources.

The configurations have not changed however the storage capacity per unit as well as the infeed and outfeed rates have increased strongly during the last decade. On top of that the operating flexibility has been optimized by applying advanced automatic control and monitoring systems.

There is a growing number of reasons why organizations which handle and store large quantities of bulk solids should care about environmental issues. Not only employees, as internal stakeholders, are affected by pollution in the work environment, but also external stakeholders such as communities are affected by local pollution. Government regulators, investors, environmental activist groups etc. will increasingly put pressure on these organizations to look for new creative and cost-efficient ways to manage and minimize environmental impacts.

Following this approach it often appears that the additional investment for an enclosed storage facility will have a payback period within approx. the first 10 years of operation!

Finally the totally enclosed storage systems are also made possible by the application of the Dutch Eurosilo® concept. This proven concept meets the requirements of Environmental Protection Agencies worldwide. The latest developments will be shown.

Author(s)

Jaap P.J. Ruijgrok M.Sc.(Mech.Eng),Managing Director, ESI Eurosilo B.V., [email protected] is involved in bulk solids handling since 1981 and he held several positions within ESI Eurosilo.Since 2007 he is working as Managing Director and majority shareholder of ESI Eurosilo BV.

Richard Spaargaren, M.Sc.(Mech.Eng),, Sales Manager, ESI Eurosilo B.V., [email protected] started his career within ESI Eurosilo in 2001 and as a sales manager he globalized the application of enclosed bulk systems worldwide.

Mini P.S. Puri, Advisor India, ESI Eurosilo B.V., [email protected] introduced new concepts and technologies to help make the Indian industry globally competitive and environmentally friendly like, Rotary Blowers for FGDs, Virtual Reality & Simulation, CAD, CAM & Automation, Selective Electro-Chemical Platting etc.

FUTURE PROOF SOLUTION FOR LARGE COAL SILOS

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Abstract:

Contrary to popular perception, it is not the shortage of generating capacity but the lack of demand by Discoms, which inter-alia, is a major cause of power shortage at consumer end. Clubbing of consumers demand with intermediaries i.e. distribution agencies and their inefficient management has resulted into the continuous losses to them in a few Indian states. In many cases, distribution agencies are unwilling to purchase power, as they have to sell it at lower prices to the consumers, resulting into losses. The paper discuss the model, where the consumers will be able to purchase the power directly from the power producing companies and will make direct payment to them. This will let the DISCOMs free from the potentially loss making commitments. Their responsibilities will be to ensure the accessibility of power to the end consumer and maintain and manage the grid and possibly metering and billing systems. As a result of direct linkage between the service provision and revenue generation, the sustainable model is expected to fill the gap by more than 291.5 BU every year which is equal to approximately full annual energy consumption of 81M average size urban households. In addition frustration caused by frequent power cuts is also expected to save significant number of human hours. It will contribute in enhancing GDP by ensuring continuous supply if manufacturers and consumers. The paper will discuss the details to implement the model for ensuring the above benefits.

Author(s)

SonalKulshreshtha GreenSync Solutions Pvt Ltd India [email protected]

+919450080811

IMPROVING POWER GENERATION EFFICIENCIES AND POWER AVAILABILITY THROUGH ALTERNATIVE DELIVERY MODELS

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Abstract:

Power is one of the important infrastructure needs for the development of our country. With ever increasing demand for power, many new thermal power stations are being set-up. Besides coal, water is another critical resource for the generation of power. To meet the demand of water, Thermal power stations are looking for alternative sources. Desalination water and sewage water are some of the alternative sources available. Out of these, sewage water is one of the cheapest and reliable options available. With the availability of modern sewage treatment technologies, it is very easy to treat the sewage to required quality. Mahagenco, a state owned power generation company of Maharashtra, has taken initiative to set an example for reuse of treated sewage in power plants.

One of the power power plants of Mahagenco, Koradi Thermal Power Station (KTPS), is a coal based power plant with installed capacity of 1100 MW and is located near Nagpur. When Mahagenco wanted to expand the power plant capacity by 1980 MW to meet energy needs of the state, they could not find the water source to meet their needs. As a solution, Mahagenco has explored use of sewage generated from Nagpur city as its alternative source of water to meet its expansion plans. Accordingly, Mahagenco made an agreement with Nagpur Municipal Corporation to treat 130 MLD sewage and use the treated sewage in their power plant. It is one of the best examples of sustainable water reuse model in India. Sewage treatment reduces the pollution in the city and the treated water solves the water problems of Mahagenco’s new power plant. Besides, it saves valuable drinking water for use in the city of Nagpur. Additionally, Nagpur city is getting revenue from Mahagenco to the tune of Rs. 15 Cr per year for providing land and raw sewage.

Author(s)

Y.V.V. Satyanarayana, [email protected]

Author has 24 years of experience in the filed of water and wastewater treatment and recycle. He has graduated in Civil Engineering and Post Graduated in Environmental Engineering. He worked in various organisations like NEERI, Ion Exchange (India) Ltd., etc. Presently he is in the position of Director in SFC Environmental Technologies Pvt. Ltd., Navi Mumbai.

RE-USE OF TREATED SEWAGE IN THERMAL POWER STATIONS

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Abstract:

As an alternative option to the conventional Wet Bottom Ash Systems (WBAS), the MAC® system is a technology for the dry extraction of bottom ash from pulverized coal-fired (PCF) boilers of any size and burning any type of coal. The MAC® dry bottom ash system offers zero water consumption and reduces the intrinsic heat losses associated with conventional WBAS. All conveyors in the MAC® system are based on the damage-tolerant Superbelt® design, which offers unique features of, high temperature and impact load resistance and high tensile strength, preventing sudden system failures or forced boiler shutdowns that may be associated with bottom ash handling systems

One of the most important effects related to the use of the dry bottom ash technology is its impact on boiler efficiency. To prove this, and in compliance with ASME PTC 4-2013, evaluations on boiler efficiency increases associated with the installation of the MAC® system were carried out. Continuous development of Magaldi technology in dry bottom ash (from now on B.A.) extraction from PCF boilers has resulted in a significant reduction in the amount of air required to cool bottom ash leading to a twofold advantage: the application of the MAC® system to large low-rank coal fired boilers and increased boiler efficiency.

Author(s)

Mr. Fulvio Bassetti, email:[email protected]

Master Degree in Mechanical Engineering. Working for 21 years in Magaldi Group (Italy); since 2009, Technical Director, Process Dept. Author of technical articles on high temperature Bulk Materials Handling published in relevant international journals and conference proceedings (Power Gen, IEA, VGB). Member of European Power Plant Suppliers Association (EPPSA) and ASME PTC 4 – Fired Steam Generators committee.

Mr. Debasish Chakraberty, email:[email protected]

Degree in engineering with almost 20 years of working experience in Magaldi dry bottom ash handling system for both PF and CFBC boilers.

Mr. Lorenzo Lepore, email: [email protected]

Master Degree in Mechanical Engineering. Formerly researcher at CSM (Italy), since 2008 works for the Magaldi Group as Process Engineer for the Dry Bottom Ash extraction systems from both PC and FBC boilers.

DEVELOPMENT OF MAGALDI DRY BOTTOM ASH HANDLING SYSTEM

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Abstract:

In present days due to increase in cost of generation as fuel cost is high and revised tariff norms, being world’s one of the most efficient power generation company, NTPC is facing problem to sustain growth rate. To restrict cost of generation, economical design will help in reducing capital cost and hence in cost of power generation. With latest development in conveying technology, optimum cost economic design for in-plant coal handling plant can be done.

This presentation will cover following specific topic:

1. Optimisation of belt width:

It is possible to select lower belt width for same material to transport by increasing belt speed, using optimum troughing angle and using unequal idler roll.

2. Route optimisation:

Horizontal Adaptability: Most efficient way to transport material from one point to next is as directly as possible. However, conveying in straight line is not possible due to obstruction by other facilities. BY using horizontal curves in conventional trough conveyor, obstruction can be avoided without introducing transfer point.

Vertical conveying system: Long conveying distance can be reduced using steep and vertical conveying technology like sandwich conveyor, pocket belt conveyor which can transport material even at an angle 90o.

3. Coal transportation from mine to plant by conveying system

For pit head power plant which have its dedicated mines and located near the mine, instead of MGR system, conventional trough belt conveyor system with crushing and coal washing facilities at mine end can be planned. Hence no crushing and unloading facilities at plant end is required. Moreover, conveying capacity of coal handling plant and capacity of ash handling system shall be reduced. Moreover, land requirements for main plant and ash dyke can also be reduced.

Author(s)

Dipankar Halder (BE.Mechanical -1999) Sr.Manager PE-Mech/MH NTPC Ltd Email : [email protected]

Smruti Ranjan Pattnaik (B.Tech. Mechanical-2008) Dy. Manager PE-Mech/MH NTPC Ltd Email : [email protected]

OPTIMISATION OF COAL HANDLING SYSTEM USING LATEST TECHNOLOGY ON BELT CONVEYOR SYSTEM

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Abstract:

The largest operating cost of any coal fired power plant is the fuel itself, i.e. coal. Considering today’s complex coal market, power plants need to be ready for coals that they have never seen before and which may not conform to the initial design considerations of the plant. Lower grade coals can lead to higher fuel consumption. Coals with high iron (Fe) or Silicon (Si) content can result in fouling and slagging of the boilers, which in turn can cause unplanned outages further increasing the amount of coal burned to come back online.

In the light of all these possible situations, an effective blending process basis online, real-time analysis of coal using PGNAA technology can lead to increased efficiency using lesser amount of fuel which translates to cost savings from the reduced coal consumption.

On-line coal analyzers have been in use in coal mines, washeries, and coal-fired power plants for over twenty years. These analyzers provide minute-by-minute analysis of SiO2, Al2O3, Fe2O3, CaO, TiO2, K2O, and Na2O in the ash. In addition the can also report the Gross Calorific value of the coals passing through the analysis zone. Using these results as the process control parameters, power plants can improve their operating efficiency, reduce outages and optimize coal consumption by enabling better blending practices.

For more than 2 decades Thermo Fisher Scientific has been offering online Elemental Analyzers with PGNAA technology allowing personnel of coal mines and power plants to make proactive process decisions to minimize variations in coal quality.

Author(s)

Name: Ankush Koul Designation: Applications and Product Specialist – Coal and Cement E-mail ID: [email protected]

Ankush has over 6 years’ experience in various industrial sectors having handled roles in Sales, Marketing and Product management of increasing responsibility over the years

In his current role as Application and product Expert for PGNAA technology applications in Coal and Cement Markets, he has over a year’s worth of hands on experience in these sectors. With this background, he is conversant with the attributes of these sectors specifically related to Coal Handling Plants with a profound understanding of the problems faced related to Coal Quality and has successfully proposed solutions to mitigate and possibly eliminate these.

EFFECTIVE AND ECONOMIC COAL BLENDING

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Abstract:

Traditionally, conveying bulk materials are associated with dust generation and spillage. Pipe conveyors come across as an environment friendly mode of conveying bulk materials which envelop the bulk material within & negotiate horizontal and vertical curves. They are quite useful for in-plant conveying and conveying over long distances crossing forests, water bodies, human settlements, roads, highways and railway tracks addressing the environmental & statutory requirements. This has helped in putting up projects in eco-sensitive zones. By combining multiple conventional conveyors into a single pipe conveyor layout permitting, systems now have higher reliability and availability with a smaller team to operate and maintain. Pipe conveyors have found their use in Thermal Power Plants, Mines, Ports, Cement Plants, Fertilizer plants, Alumina plants, Iron Ore and Steel plants, Captive Jetties etc. The pipe conveyors designed so far have been as short as 60 meters to as long as 8200 meters and for varying capacity of materials of different bulk densities, size & moisture content. Presently, the limitations are the available belt widths in the market, which limit the maximum lump size and capacity of conveying. With advancement in belt technology, this will also be overcome in future.

Author(s)

Dharmavir Jha FLSmidth Private Limited India [email protected] 919940637841

PIPE CONVEYOR TECHNOLOGY & FLSMIDTH’S EXPERIENCE IN INDIA

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Abstract:

With changing Power Plant needs on reducing the pollutants and emphasis on conservation of resources like water, United Conveyor Corporation USA (Technical Collaborator of L&T) has been developing and implementing various state of art technologies in various Power Plants worldwide to meet their requirements.

Multiple factors influence a plants decision to convert from wet to dry system. Utility companies still using ash ponds to accumulate Bottom Ah and Fly Ash have some important decisions to make in the coming years. They will need to explore various options available and upcoming developments in ash handling technologies to handle this problem. This paper will discuss various ash conveying options available to power plants seeking to get rid of storing ash in ash ponds. These technologies include Continuous Dewatering Systems, VAX and PAX systems for Dry Bottom Ash Handling etc.

Author(s)

Ashwani Perswal is a Program Manager in United Conveyor Corporation, USA (Technical Collaborator of L&T ).

ADVANCEMENT IN ASH HANDLING SYSTEM TECHNOLOGIES

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Abstract:

Membrane Bio Reactor ( MBR ) is the combination of a membrane process like micro filtration or Ultra filtration with a suspended growth bio reactor and is being widely used for industrial/municipal waste water treatment. Recent technical innovation and significant membrane cost reduction have enabled MBRs to become an attractive recycling option of waste water treatment.This case study describes the design and operation of MBR system of treating sewage for generation of DM water requirement at Pragati Power Corporation Ltd, Bawana near Delhi

Author(s)

Name : Dr. Abhay Kumar Sahay E-mail: [email protected]/[email protected] Phone number/Mobile No.: 0120-2405265/9650991789 Project : CC-OS Area of Specialization( Current) :Power Plant Chemistry a) Water treatment , b) Cycle Chemistry and c) C W System Work experience :Departments worked in : 1.NTPC Korba : From 1989 to 1996 2.CC-OS( Chem) : From 1996 on wards

Recycling Sewage to Demineralized water generation -A successful Case study

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Abstract:

Thermal power plants need three important inputs viz. Water, coal and land. Water being the most important input is scarce and also needed for sustaining life in the earth. The problem of finding water for industrial use is very difficult nowadays. Looking at the water map of India whole of western India (Rajasthan, Gujrat, Punjab, Haryana etc), parts of central India comes under water scarce area. Whatever water available shall be used for human consumption and cannot afford to be used for industrial use like in power plants. As the availability of water is becoming scarcer day by day it is becoming essential that power plants utilize water judiciously.

Huge quantity of water needs to be circulated for taking away the heat of the steam in the condenser and make up water is added to compensate for evaporation, drift and blow-down. More than 80% of the water requirement for the power plant is used for make-up to the cooling tower. In order to minimize this water requirement, alternate technology of Air Cooled Condenser is being used in many plants across the world. This paper includes the various options, specifications, layout requirements and cost and maintenance aspects for use of Air Cooled Condenser in thermal power stations.

Author(s)

Arnada Samal NTPC Ltd India [email protected] 919650991288

USE AIR COOLED CONDENSER AND CONSERVE WATER

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Abstract:

EDI is an electrically-driven membranes process which combines the technologies of electro-dialysis and mixed-bed ion exchange. EDI has succeeded over other processes is the ability for it to continuously remove ionic species particularly weakly-ionized species. EDI, as a membrane demineralization process routinely reduces CO2 levels by over 99% in most applications. The performance that EDI has demonstrated in removing difficult ions, gives good potential for future growth of EDI. EDI’s performance in removing these impurities will thus assuredly lead to greater use of EDI in the production of ultra pure water.

Present paper deals with results obtained during one month trial of 1M3 EDI module at NETRA, NTPC to compare the efficacy of Elecrodeionization (EDI) System with conventional Ion Exchange Resin based MB De-mineralizer. Study revealed that quality obtained by EDI is at par or even better in comparison to resin based Demineralization plant. The Total organic carbon reduction ability of EDI has also been discussed in the paper. Its advantages like environment friendly technology, consistent output quality, cost, storage, safety, space requirements along with mechanism etc have also been dealt. Paper also mentions EDI potential for different applications at plant.

Key words: Electro-deionization, self regeneration, Total organic carbon

Author(s)

Dr. Rakesh K Sharma, Ph.D. (Chem.) DGM, NETRA, NTPC Ld. [email protected]

Five years O&M (Chemistry) of thermal power plants, 17 year experience in Water Treatment Technologies, Boiler Chemistry, Resin Condition Monitoring, Fly ash based value added products. 28 Nos. of National & International publications. One Patent granted and another filed.

R. Nagarajan (M.Sc Chemistry); Dy. Manager (NETRA), [email protected]

Analytical and Research experience of 25 Years in the field of water chemistry, ion exchange resins, FRF reconditioning, Corrosion and scale problems of boiler and condenser, post operational acid cleaning of boiler and condenser scale cleaning.

G K Nayak, M Sc Chemistry, MBA-HRD; AGM, NETRA; [email protected]

Looking after corrosion and resin labs at NETRA. Have 30 years experience in power plant chemistry, water treatment, introducing advance SWAS lab, coal and oil lab and overall managerial and administrative function of both Chemistry and Business Excellence department. He is a trained Six Sigma ‘Black Belt’ holder from GE and also acted as an assessor of NTPC Business Excellence model.

ELECTRO-DEIONIZATION SYSTEM AS A VIABLE ALTERNATIVE FOR DEMINERALIZATION

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Abstract:

Electrical networks are constantly expanding and switchgear manufacturers need to adapt their design to provide optimized solutions to achieve this evolution. One of the key concern is land scarcity and space restriction that users are facing when expanding the network. Substations are getting closer to urban areas or even included in the cities areas, as a consequence land-acquisition becomes a serious issue.

Gas-insulated substations can be an appropriate answer to these challenges, especially when considering new technological breakthrough in the GIS design.

As an example, thanks to the integration of single-break technology, circuit-breakers are becoming much more compact than previous generation (double break). Based on latest self-blast and double-motion principle, these new single-chamber breakers are rated 63 kA up to 550kV. Compared to previous circuit-breaker generation, this means a 50 % size reduction.

Due to the small size of these new breakers, compact bay-arrangement become possible allowing for complete bay assembling at workshop and reduced building size on-site.

At 800 kV level, existing GIS are based on technologies from the years 1990’s. Consequently dimensions are quite big and 800 kV are mostly installed outdoor.

The main objective of the recent development of new 800 kV GIS was to develop a compact GIS to make possible installation in a small-size building. This most compact arrangement was achieved using double chamber vertical type breaker, whenever most of existing circuit-breakers are four-chambers horizontal type arrangement.

Thanks to the genuine positionning of the two chammbers in a Z-type lay-out, the new 800 kV GIS is not higher than existing 550 kV GIS delivered today.

Another challenge is the design of compact disconnectors, considering the behaviour towards VFTO. At 800 kV level, specific performances are required to meet the bus charging capacitive switching requirements. Many studies, calculation and tests were performed to establish new criteria definition. As a result, a new compact disconnector could be designed.

New GIS for both 420 kV and 800 kV levels are smaller than previous generation and square meters comparison versus AIS is 1 to 10.

Author(s)

Yves DOIN, Director-R&D, GIS PL, ALSTOM GRID, 1 avenue Paul Doumer – BP 601 – 73106, Aix-les-Bains Cedex Aix les Bains, FRANCE

NEW 765 KV GIS TECHNOLOGIES FOR IMPROVED SUB-STATION LAYOUTS AND LAND OPTIMIZATION

128#

78

OPTIMIZING RESOURCES

Abstract:

Generator circuit breakers, located between the generator and the step-up transformer, are widely used nowadays for generator ratings ranging from 50 MVA to 1400 MVA. They have proved to be an economical and efficient solution for the protection of generators and transformers. A summary of the numerous general advantages of having a generator circuit breaker is presented hereunder. To select a generator circuit breaker, two main performance parameters have to be taken into account. One key performance parameter is the capability of breaking a short-circuit current. To do so, the design of the interrupting chamber, heart of the generator circuit breaker, is a crucial factor. Thanks to their high voltage derived technology, it is possible to interrupt short-circuit currents of at least 160 kA with the use of a spring operating mechanism. Therefore, the improvement on reliability and availability of the generator circuit breakers using spring mechanisms is now accessible for power plants up to 1400MVA.The other key performance parameter is the nominal current to be carried continuously with a limited busbar temperature and within a maximum ambient temperature. To increase the nominal current keeping the mandatory generator circuit breaker reliability, ALSTOM T&D has chosen to use very simple and long-time proven cooling system solutions. These solutions, which are using long life and reliable fans to cool down the SF6 gas with full redundancy, have been designed to reach the customer requirements for operation, maintenance and cost efficiency.

Author(s)

Parthsarathi HARICHANDAN Alstom Grid India [email protected] +91 9500028412

William BOISSY ALSTOM GRID France [email protected] 0033608861675

ADVANTAGE OF GCB SCHEME OF A POWER PLANT

157#

79

OPTIMIZING RESOURCES

Abstract:

Water has become a scarce commodity nowadays. This is mainly due to scanty rainfall in the recent decades, across the country, resulting in low recharge of natural water resources. Many of the power plants in India are dependent on natural water resources like rivers and lakes. All the power plants need water treatment plants to cater to boiler feed make-up, cooling water, service and potable water requirements. Conservation of water in every possible way is necessary due to its increasing scarcity. Optimized use of all the resources like raw water, space, power, chemicals along with minimum waste generation is necessary while treating water for use in power plant for sustained development.

Author(s)

Shri. M. Natarajan, Additional General Manager, New Products - Water treatment.- Joined BHEL in 1979 at Tiruchy and has worked in various disciplines.. He has an experience of over 2 decades in water treatment and is one of the resource persons in preparation of the Road map for Desalination & water purification activities to Government of India. He has presented more than 10 papers in various National Conferences on desalination and Water treatment. He has vast experience in design, procurement, erection, commissioning and O&M of various membrane based water treatment systems. Email: [email protected]

Shri S.A.Vijayakumar, Senior Manager, New Products – Water treatment. - Joined BHEL in 1981 at Tiruchy and worked in various disciplines. He has got hands on experience(4years) in O & M of Sea Water Desalination Plant. He is involved in erection, commissioning and field engineering services of different membrane based water treatment plants. He has completed many Research Projects and filed Two Patents. Email:[email protected]

Shri I.M. Ramalingeswara Rao- Deputy Manager, New Products – Water treatment. – A Mechanical Engineering graduate from JNTU, Hyderabad. He has got 10 years plus experience in process selection, basic engineering, proposal, contract engineering, commissioning of various membrane based water treatment systems and Contract coordination for various water treatment system projects. Email:[email protected]

Shri S. Srivatsan Senior Product Engineer, New Products – Water treatment.A Mechanical Engineering post graduate from BITS-Pilani. He has got 5 years plus of experience in process selection, basic engineering, proposal, contract engineering of membrane based water treatment systems. He is also involved in technology transfer and knowledge management of Water treatment systems.Email:[email protected]

MEMBRANE BASED TECHNOLOGY IN WATER TREATMENT PLANTS FOR POWER PLANT

160#

80

OPTIMIZING RESOURCES

Abstract:

India has been heavily reliant on coal for bulk of its electricity needs. Going by the recommendations of the 12th and 13th 5-year Plans, this dependence looks likely to continue well into the future. An addition of 14,000 MW of coal plants has been planned every year, on an average. This paper cautions that focusing heavily on baseload, coal plants will lead to inefficiency and inflexibility. Power demand is increasingly following a cyclical pattern, characterized by sharp peaks during certain hours and marked troughs during off-peak hours and night. If capacity of baseload plants exceeds a certain threshold in the system, they will run at sub-optimal loads during off-peak hours. This leads to a significant drop in their efficiency. Many of the coal plants are already operating at a lower-than-normative annual plant-load factor (PLF). A major reason for this is the reduced evacuation of power during off-peak hours and night.

The problem will be exacerbated by the planned addition of renewable energy into the grid, in line with our “National Action Plan to Mitigate Climate Change”. The intermittency and unpredictability of renewable energy generation will add to the problem of variability.

This paper presents a case for changing the traditional mix and pruning down the baseload coal plants to about 80% of the planned capacity, replacing the balance 20% with flexible peaking plants. The benefits of this optimized or hybrid systems are clearly visible and quantifiable such as

a) As the burden on investment will be lower by nearly MINR 350,000 (approx. MEUR 4375),

b) The land requirement will be lower by 14,000 acres.

c) The avoided water consumption will be nearly 500 million cu.m/year. CO2 emissions will be reduced by 13 million tons/year

Author(s)

Kenneth Engblom is Marketing Director of Wartsilä Power Plants. Wärtsilä Corporation is a world wide provider of Marine and Power Plants solutions with an annual net-sales of around 5 Billion Euro.

Kenneth graduated from Helsinki University of Technology, Finland with a Master degree in Mechanical Engineering. He joined Wärtsilä 1996 and have since that had various managerial positions in R&D, Project Management and Sales. During extended times of his career Kenneth has been stationed in Finland, India, US and Australia. In his current position as Marketing Director, Kenneth is leading the Marketing activities in Wärtsilä Power Plants globally.

VALUE OF FLEXIBILITY IN OVERALL ELECTRICITY GENERATION MIX IN INDIA

162#

81

OPTIMIZING RESOURCES

Abstract:

With increasing Coal demand for power generation and uncertainty in domestic coal supplies coupled with infrastructure constraints in transportation ,Independent power Plant, Captive Power plant owners look for alternate fuel source. In this context ,Petcoke a product of delayed coking refinery by product which is rich is Carbon and heat value is looked up as alternate fuel . On the other hand, the coal beneficiation plants located at mine mouth which generates coal waste which are rich in ash content, low heat value needs a sustainable combustion solution to disposal efficiently. CFB technology which has matured now as Clean combustion Technology with Multi fuel firing capability has emerged as a best technology solution for above said fuels .The inherent nature of particle recirculation and high turbulence in CFB enhances Carbon combustion efficiency upto 97.5 % for above said fuels and also capable for reducing airborne emissions like SOx,NOx. Thermax has played major role in technological advancement of Internal recirculation CFB (IRCFB) technology in India first at a Chemical Complex in U.P. India and perfected the system to suit Indian fuel Conditions and later played major role in establishing Petcoke as a fuel for steam generation starting from lab scale studies to scaleup upto 150MWe. Thermax has supplied and has successful operating experience using IRCFB firing 100% Petcoke, Coal wastes (known as Washery Rejects). This paper will provide insights to the challenges and design considerations of CFB for such fuels.

Author(s)

C R Subramaniam (Email: [email protected])

Graduate in Mechanical Engineering from MS University. Post graduation specialization in the field of Computational Engineering from School Advanced Engineering and Information Technology, IIT Madras. Currently pursuing his Research Work in Indian coal Combustion at IIT Bombay. Presently working as Manager (Process Engg Utility Boiler.), Thermax Ltd , Pune mainly involving Design of Circulating Fluidized Bed Combustion Boilers, Pulverised Fuel fired boilers, BTG cycle Integration

Shekhar Kashalikar Mechanical engineer with experience in Power & Heating field for past 25 years . Presently he is Head- Strategic Business Unit - Solid fuel & Utility Boilers at Thermax Ltd.,Pune.

Abhay R Patil Post graduate in Structural Engineering with 25 years of experience in design of various types of Boilers like CFB,HRSG,AFB,Travelling Grate. Presently he is Head of Engineering of Solid Fuel and Utility Boilers Strategic Business Unit in Thermax Ltd.,Pune.

POWER GENERATION USING PETCOKE: CFB BOILER TECHNOLOGY SOLUTION

174#

82

OPTIMIZING RESOURCES

Abstract:

The basic requirement for Power Plants is the reliable and steady generation of electricity. Especially in India the demand increases from year to year and is hence of highest importance. Malfunction even in minor components can cause breakdowns, which consequently affect inhabitants or the productivity of connected industries.

The Main Cooling Water circuit belongs to the most important systems of any power station, as it is a direct part of the production and a failure can cause tremendous technical, economical or environmental problems. Hydraulic Actuators for Butterfly Valves operate here similar to brakes of a car. If one can’t decelerate, one will cause an accident. Therefore there is very little difference, whether the engine or the brakes fail – the outcome will be similar and will certainly affect more than only the brake. The same counts for Hydraulic Actuators, which prevent in emergency cases from damages to pumps, overall system and even affects to industries and inhabitants.

VAG seriously heard the concerns of power plant operators, looked into the matter and came up with a reliable system. In case of pump failures, or other unexpected scenarios the hydraulic actuators of VAG operate instantly and reliable. They are a smart combination of non-return and isolation valves in just a single one.

This paper informs about risks, which caused problems to Power Plants earlier. We show possibilities to ensure a safe and reliable function and highlight developments for valves and their actuators. We are going to raise the awareness for the importance of valves with Hydraulic Actuators, making the plant safer, more reliable and energy efficient. These valves do not just protect a pump, increase the plants overall safety and reliability but also reduce resistances which keep the plants own energy consumption at a minimum.

Author(s)

Andreas Schmidt graduated in Mechanical Engineering from the University of Applied Science in Frankfurt am Main (Germany). He works in the Valve Industry since 2008, when he started with Areva Nuclear Power. His responsibility included the development of a new design specification for safety related actuators for industrial valves in the primary circuit of Nuclear Power Staions. Since 2010, Andreas is part of VAG Armaturen GmbH and part of the specialized Power Station department. Andreas has international experience with VAG in more than 12 countries, worked on fourcontinents and even lived on three continents. Andreas also acts as an internal Trainer for ourInternational Conferences.

Contact Information:

Mr.AndreasSchmidt(KeyAccountManagerPowerPlants):[email protected] Mr.SrinivasanNT(VicePresident Powerat VAGIndia):[email protected]

INCREASING THE SAFETY, RELIABILITY AND EFFICIENCY OF POWER PLANTS BY USING MODERN SOLUTIONS FOR PUMP PROTECTION IN WATER SYSTEMS

181#

83

OPTIMIZING RESOURCES

Abstract:

• Concept of Submerged Centrifugal Pump(SCF)

• Why SCF Pump sets?

• Design Features of Submerged Centrifugal Pump

• Salient Features SCF Motors

• Advantages of SCF Pump Sets

• Various Innovative Installations of SCF Pump sets

• Comparison of SCF & VT Pumps

• Comparison of SCF &HSC Pumps

Author(s)

A J Patel Director - Technical M/s. Aqua Machineries Pvt. Ltd

EFFECTIVE PUMPING SOLUTIONS TO DEPLETING SOURCES

183#

84

Abstract:

The flue gas emitted from coal fired power plants contains significant amount of water vapour, sensible and latent heat. Recovery and utilisation of thermal energy and water from the flue gas of a coal fired power plant is a challenging task for the researchers. Technical challenges are many in the attempts to reduce the flue gas temperature from the normal ESP outlet temperature of 136 °C to the temperature below the water dew point which is of around 45 ° C. This paper explores the available technologies and challenges to recover heat and water from the flue gas. Energy and water recovery potential from the flue gas of a 210 MWe coal fired power plant is also estimated in this work. The estimate indicates thermal energy potential up to 42.6 MWth and water recovery up to 5.5 lakhs litres/day when the flue gas with 5.76 % of water vapour by weight is cooled from 136 °C to 35.9 °C.

Author(s)

Dr.R.Senthil Murugan, Senior Engineer, R&D, Bharat Heavy Electricals Ltd., Trichy. Email ID: [email protected]

Mr.R.Dhanuskodi, Deputy General Manager, R&D, Bharat Heavy Electricals Ltd., Trichy. Email ID : [email protected]

Mr.R.Kaliappan, Additional General Manager, R&D, Bharat Heavy Electricals Ltd., Trichy. Email ID: [email protected]

Mr. S.Sundararajan, General Manager, Product Engineering (Fossil boiler), Bharat Heavy Electricals Ltd.,Trichy. Email ID:[email protected]

Mr. M.Muthukrishnan, General Manager, R&D and Coal Research, Bharat Heavy Electricals Ltd., Trichy. Email ID:[email protected]

HEAT AND WATER RECOVERY FROM FLUE GAS OF COAL FIRED THERMAL POWER PLANTS-TECHNIQUES, CHALLENGES AND ESTIMATE

187#

OPTIMIZING RESOURCES

85

Abstract:

The efficiency of a wet cooling tower relates directly to the unit efficiency of a thermal power plant. Many existing power plants utilize cooling towers with splash fills due to the perception that all film fills, regardless of design, will foul. Therefore splash fills are used which require tall fill sections in order to achieve the required thermal duty. Pumping water to reach such heights requires greater energy consumption for pumping power than if properly selected anti-fouling film fills were selected.

In an attempt to utilize more efficient film fills, many cooling towers were installed with high efficiency cross-fluted fills which were not well suited for the poor water and atmospheric conditions found at the plant site. As a consequence, these fills have fouled creating a very serious reduction in cooling tower efficiency which causes an increase in plant heat rate.

This paper will address the issue of improving plant efficiency by the installation of fills that will improve the cooling tower cooling efficiency while maintaining cleanliness. The real value of a degree of the cooling tower return water temperature will be described in detail.

Author(s)

Richard Aull, P.E., Director of Application Engineering, Brentwood Industries

Rich Aull is the Director of Application Engineering of the Cooling Tower Group at Brentwood Industries with 35 years’ experience in the cooling tower industry. With Brentwood since 1993, he is responsible for all aspects of application engineering, including software development and new product development.

Rich is active in the Cooling Technology Institute (CTI), as the Software Publishing Task Group Chair, and Vice Chair of the Multi-Agency committee. He has published technical papers and conducted seminars on a variety of cooling tower topics for the Cooling Technology Institute, Electric Power Research Institute and American Society of Mechanical Engineers.

Rich received his B.S. & M.S. Degrees in Mechanical Engineering from the New Jersey Institute of Technology and is a registered Professional Engineer in the States of New Jersey & Pennsylvania.

Email: [email protected]

Improving Plant Efficiency by Use of Modern Anti-Fouling Fills

200#

OPTIMIZING RESOURCES

86

ENERGY CONSERVATION

Abstract:

Glass Fibre Reinforced Plastic (GRP) composites are being encouraged as the materials of 21st century because of their superior corrosion resistance, excellent thermo-mechanical properties and high strength-to-weight ratio. For last 25 years the use of GRP pipes for Power Plant applications have increased multifold due to its enhanced performance, serviceability and durability over conventional materials.

The right selection of pipe material will be vital in ensuring the long-term performance, safety and high operational availability of the power plants through their lifetime. Capital and operating costs of pipelines can be brought down with selection of suitable combination of diameter, pressure class & stiffness class from among different resin based GRP pipes and it will also enable a faster execution and efficient operation of plant. The lightweight property, makes it easier to handle by installers without the use of heavy lifting equipment.

In this paper benefits of GRP over the conventional pipe material has been focused upon and finally a sincere attempt has been made to describe the recommendations pertaining to GRP pipes based on recent experiences in power sector.

The underlying objective in adoption of GRP pipes has been to achieve overall cost & operational efficiency over the conventional metallic counterparts.

Author(s)

Pramod Chandra Nath, DGM ( PE-Mech) – NTPC

An Engineering Professional having 18 years of experience in Project Engineering in Power Plant industry. Graduated (B.E. -Mechanical) from Utkal University in the year 1995 and joined NTPC Ltd. in 1996.

Navneet Kumar, DGM ( PE-Mech)-NTPC

An Engineering Professional having 18 years of experience in Project Engineering in Power Plant industry. Graduated (B.E. -Mechanical) from Bihar University in the year 1996 and joined NTPC Ltd. in 1997.

Nipun Pharlia, Manager (PE-Mech) – NTPC

An Engineering Professional having 18 years of experience in Power Sector. Graduated (B.E.-Mechanical) from Bangalore University in the year 1996 followed by M.Tech (Energy & Environment Engg.) and Post graduate Diploma in Business Administration..

USE OF GRP PIPES FOR POWER PLANTS TO ACHIEVE COST & OPERATIONAL EFFICIENCY

75 #

87

Abstract:

Most of the electricity is generated by coal, natural gas, petroleum and other fossil fuels. The limited resources shall increase the cost of electricity. Nearly 70 percent of electricity consumed by industry is used for millions of motors worldwide. So, to improve efficiency of motor and related system is the most efficient energy-saving concern. Considering energy-saving effect difference between high-rating and low-rating induction motors, two solutions, enhance motor efficiency itself and improve related system efficiency, has been recommended correspondingly. In the same time, experience of SEMC has been introduced for instance.

Author(s)

Mr. Minglun Sun

A brief introduction of the author: Mr. Minglun Sun, born at 1965, Graduated from Shanghai Jiaotong University at 1985 and get the Bachelor degree. Deputy General Manager and Chief engineer of Shanghai Electric Machinery Co., Ltd.(SEC), Senior engineer, Specialist of asychronous motor engineering and applying. E-mail: [email protected].

ENERGY CONSERVATION

APPLICATION OF HIGH-EFFICIENCY MOTOR AND ENERGY-SAVING SYSTEM

90#

88

ENERGY CONSERVATION

Abstract:

This paper discusses Variable Frequency drives & energy efficiency along with some case studies and issues arising out of drive application in industrial installations. Effect of using an AC drive on the motor and installation –solutions , IEC/NEMA standards for inverter duty motors , Input supply voltage and current harmonics-solutions & IEEE-519 Standard has also been deliberated.

Author(s)

Mr. Ganesh Iyer

The author is presently working as General Manager- Applications Specialist with Danfoss Industries Private Limited since 2006. He has over 30 years of design and application experience in the field of drives, control systems & harmonic mitigation solutions & has published several technical papers in trade magazines representing various segments- Energy, Sugar, Sugar co-generation, mining & power. .

He is an alumnus of Indian Institute of Technology-Mumbai, having completed post-graduation with specialization in Power Electronics and Control Systems.

He can be contacted at [email protected]& +919920373263

ENERGY EFFICIENT AC DRIVES-INPUT & OUTPUT ISSUES

107#

89

ENERGY CONSERVATION

Abstract:

Isgec Heavy Engineering Limited, with technology license from Foster Wheeler, North America offers Supercritical Pressure Boilers using Benson Vertical Tube (BVT) design for once through evaporator. This has several advantages over conventional spiral wall design. These advantages include ease of fabrication, construction & maintenance apart from enabling the use of conventional buck stay & self-support design for the furnace walls. In terms of operational performance, the vertical tube design with lower mass flux has inherently lower pressure drop & hence lesser auxiliary power for Boiler Feed Water Pump, and ensures natural circulation characteristics which help in minimizing temperature differential between different tubes in the furnace. The vertical tubes help in minimizing the tendency of furnace deposit accumulating over the furnace walls, which is a big advantage when the boiler has to fire different types of coal. The paper brings out these benefits in Supercritical Boilers, and also covers an overview of the world’s first and largest Pulverized Coal fired Supercritical Boiler with Opposed wall firing, using the BVT feature designed, supplied & successfully commissioned in 2011 by Foster Wheeler in North America.

Author(s)

Krishnamurthy Viswanathan Email I’d: [email protected]

Brief Profile of Author:

Mr. Krishnamurthy Viswanathan is Head, Engineering (Utility Boilers) at ISGEC Heavy Engineering Ltd., Noida.

He has more than 35 years of experience in design and engineering of various types of boilers for applications in the industrial and power sectors. He has extensive knowledge of different boiler technologies in Pulverised coal fired boilers with regard to corner firing and wall firing, as well as spiral wall evaporator and vertical wall evaporator for once-through supercritical pressure boilers. In the past, he has worked with organizations such as BHEL, Thermax and Alstom.

Mr. Viswanathan is a Mechanical Engineering graduate from Madurai Kamaraj University and has a master’s degree in Design and Production of Thermal Power Equipment from University of Madras. He also holds a PG Diploma in Operations Management from IGNOU.

BENSON VERTICAL TUBE EVAPORATOR FOR SUPERCRITICAL PRESSURE ONCE THROUGH BOILERS

117#

90

ENERGY CONSERVATION

Abstract:

Coal based power plants dominate power production in India and would continue to do so in the foreseeable future. Efficiency of coal usage within a power plant can be significantly improved by usage of coal flow aids and methods to control combustion and material handling losses.

The flow characteristics of a particular coal will vary according to the surface moisture, fines content, and equipment design. Typically, coal will tend to agglomerate as the surface moisture increases. Flow interruptions caused by bridging and plugging can occur in the funnel section of storage bunkers and feeder inlet piping. These problems can result in lost production, reduced load, or unscheduled downtime. Specially formulated coal flow aids improve the flow of wet coal throughout coal handling systems and reduces the tendency of wet coal to agglomerate, thus reducing the potential for system pluggage.

Auto-oxidation of coal in stockpile, reclaim operations, conveyor belts, galleys and bunkers decreases the quality of coal and could be a potential safety hazard. Material handling losses during transfer and transportation additionally contribute to environmental pollution. Specially formulated chemicals like wetting agents, foaming agents, sprayed binding agents, foamed binding agents and crusting agents can provide protection against auto-oxidation and material handlings losses, thus improving plant efficiency.

This presentation proposes to discuss the impact of coal flow, auto-oxidation and material handling losses on plant efficiency and suggests mitigation measures, with background principles and case studies to overcome the issues.

Author(s)

Anand Krishnamurthy

Anand Krishnamurthy is the Marketing Leader for GE Water India. Anand has diverse experience in water, wastewater and infrastructure sectors, in marketing, product development, market research, strategy and consulting roles.

Narain Madhavan

Narain Madhavan is a Lead Product Manager with GE Water India. Narain has more than 10 years of experience in the water and chemicals industry and has been with GE Water in multiple roles across Technology and Product Management.

[email protected], [email protected]

EFFICIENCY IMPROVEMENT BY IMPROVING COAL FLOW AND MINIMIZING MATERIAL HANDLING LOSSES

133 #

91

ENERGY CONSERVATION

Abstract:

Tremendous quantity of oil is used for igniting pulverized coal(PC) boilers and its stabilizing combustion at low loads as well as various fuel system and boiler operational conditions. The scarcity of oil resources makes the oil price ten folds of that of coal. Oil burden has been one of the top priorities power plant operators deal with. Technologies have been developed to reduce oil consumption and further, ideally, eliminate the oil consumption for boiler ignition and combustion stabilization purposes. Plasma ignition and combustion stabilization uses coal but not oil to serve exact the same ignition functions plus extra benefits, such as simultaneously running ESP system and less NOx generation. As the plasma ignition is stably gaining acceptances for PC boilers burning typical coals, the plasma ignition technology faces challenges to raise the technical sophistication to a new height to effectively handle low grade coals, which has been increasingly used in many countries where using low grade coals has become the consequence of broader coal applications outside of power generation, shrinking supply of the better grade coals, and gradually increased coal prices, etc.. Related ignition issues are discussed, including straightly use the same coal boiler burns but not specially prepared ignition coal, longer plasma electrode service span and plasma arc stability as well as broader power adjustment range etc.. With proper handling on these related issues, the advanced plasma ignition system would be used reliably and productively at the PC power plants burning the low grade coals and significantly improve their operational productivity by virtually eliminated all the fuel oil consumption and related expenses.

Author(s)

Michael Hong: VP, Magtech, USA, BS/MS/MBA in the USA, Rich and long work experiences in combustion management with orientation to both energy saving and environmental protection in fossil power industry. Contact info [email protected]

Fei Liu: Senior Engineer, Inventor, President of Nanjing Chuangneng Power Technology & Development Co., Ltd.. Researcher and supplier of combustion management, optimization, and innovation products and systems. Contact info: [email protected]

Yongming Hua: Professor, Dept., of Thermal Power Eng, School of Energy and Environment Protection, Southeast University, Focus on combustion management and optimization as well as green energy and their utilization. Contact info: [email protected]

Jun Li: Senior Engineer, Deputy GM, Jiangsu Jingjiang Power Plant, Jiangsu Guoxin Investment Group, Years of career in technical, operational, and management positions in thermal power plants

PLASMA IGNITION AND COMBUSTION STABILIZATION TECHNOLOGY FOR LOW GRADE COALS

139 #

92

ENERGY CONSERVATION

Abstract:

In Utilities around the world, cost benefit analysis of various Demand Response (DR) implementations has underscored the fact that these demand side infrastructure can bring in much better return on investment with far less capital outlay and faster deployment cycle, while achieving the same target objectives that can be met by conventional supply side infrastructure, that is generation assets and transmission corridors. In some application areas like spinning reserves, DR provides a much cheaper alternative to maintaining expensive reserves. There is reason to believe, response performance of DR is comparable if not better than conventional reserves. When it comes to de-congesting a transmission corridor, DR perhaps is the only short term solution. Add to this the growing realisation of reducing reliance on fossil fuels. DR can very well form a part of the renewable purchase specifications drawn up under the aegis of the National Action Plan for Climate Change (NAPCC). Even without this, DR’s recent use in balancing renewables makes a valuable contribution towards the same objectives. To harness the immense possibilities there are certain technology choices that are important in order to draw up a successful road map for DR implementation.

The purpose of this paper is to examine the various opportunities of applying DR, their respective business cases and the general technological requirements that would be important in successful implementation.

Author(s)

Himadri Endow ([email protected]) holds a B.Sc. (Hons) in Phy and B.Tech&M.Tech degrees in E&C from University of Calcutta. He has been serving the IT, Industrial Auto and T&D market sector for over 31 years in various capacities. Among his professional activities, he has led delivery of many global SCADA/EMS/DMS projs, been involved in managing R&D as well as design/development/management/marketing of many technologies, real time control products/systems & embedded systems. He has served the Govt. of India in senior positions before joining Alstom T&D, in 1990. An IEEE member and member of the global expert Grp within ALSTOM Grid, he has written on Smart Grids in international journals and serves as guest lecturer at prestigious Tech/Mgmt Institutes. He has led Smart Grid activities at Alstom Grid in India/East Asia/Middle East regions and is currently responsible for India & South Asia.

Mark Triplett ([email protected]) is a graduate of the Military Academy at West Point (USA) and holds a Master’s in Business Administration from San Diego National University. He is a certified PMP from Project Management Inst. (USA). Mark is the Managing Director of the Demand Response Management System activity at Alstom Grid and former President of UISOL Software. Mark has responsibility for the DRMS product line, market & commercial strategy, product direction, and global sales. He has over 20 years of experience in business operations/sales/consulting/proj management in the areas of DR software development, utility consulting, enterprise app integration, and telecom network management. In 2001 Mark and his team at Vitria Tech, had created the first DR automation solution. Mark had led the start-up of UISOL Software, creating the first commercial DRMS (DRBizNet), for ISO/Wholesale Market Operators in 2008. UISOL was acquired by Alstom in 2011 and continues to operate as a BU within Alstom Grid’s Network Management Systems (NMS) group.

ADVANCED DEMAND RESPONSE MANAGEMENT SYSTEM OPPORTUNITIES & TECHNOLOGY CHOICE FOR ELECTRIC UTILITIES

161 #

93

ENERGY CONSERVATION

Abstract:

Power generation and Industrial facilities commonly utilize Electrostatic Precipitators (ESP) for collection of filterable particulate matter from process flue gas streams. While this method of particulate collection offers a very low pressure drop and low auxiliary power consumption by FD and ID fans, the conventional power systems used to energize the ESP’s have very low power factors. Replacing conventional power systems in existing ESP’s with Switch Mode Power Supplies (SMPS) having higher power conversion efficiency can reduce the auxiliary power usage of the ESP. For new applications, the SMPS can be operated in maximum power mode to significantly increase power input to a single ESP bus section thereby reducing the number of power systems required while maintaining the high power factor. This paper will illustrate how SMPS technology can be utilized to minimize auxiliary power usage on new and old ESP’s as well as allow ESP manufacturers to produce smaller ESP’s to meet target emission rates.

Author(s)

Jason Horn – Director, Environmental Controls for Stock Equipment Company

Jason Horn is the Director of Environmental Controls for Stock Equipment Company in Chagrin Falls, Ohio. He began his career in the power industry in 2005 as a corporate air emissions control engineer with American Electric Power. Since joining Stock Equipment in 2007, Jason has held various positions of increasing responsibility within the environmental controls product line. He currently serves as the secretary for the Worldwide Pollution Control Association and holds a Bachelor of Science degree in electrical engineering from Ohio Northern University.

PRECIPITATOR AUXILIARY POWER SAVINGS USING SWITCH MODE POWER SUPPLIES

232#

94

ENERGY CONSERVATION

Abstract:

LED luminaries are most energy efficient solution that offers savings up to 60% in overall consideration. For retrofit also the ROI can be less than one year. COB technology has given better solution for industrial applications with higher lumen output and reliability. Branded players can offer total product basket with LED solution and also able to provide in-house testing facility to verify the performance of luminaries.

Total Solution – Lighting design shall be considered along with electrical design right from first stage itself this provides total cost effective solution and design optimisation.

• Selection of LED Luminaire - preferably COB for Well Glass, High Bay and Flood Lights.

• Automation for street light with On/Off or dimming solution, based on usage and no. of fittings.

• Use of optimisation sensors for parking area, corridors and wash rooms

• Get specially designed Luminaire with exact wattage based on required Lux levels.

• Design the Lighting system and get the total load to calculate Transformer Load and cable sizes.

Overall it’s a Win-Win solution for the industry and the environment. Save money save environment

Author(s)

SwaroopBolar Deputy General Manager All India Sales Head Luminaire Email :- [email protected]

SanjaykumarBahirgonde Sr. Manager (Sales & Business Development for Industry) Email :[email protected]

ENERGY EFFICIENT LIGHTING SOLUTION - INDUSTRY

234 #

95

96

97

DIVERSITY OF ENERGY SOURCES

Abstract:

Bharat Heavy Electricals Limited has established Solar cell and PV module manufacturing facilities at its Electronics Division, Bangalore wherein it manufactures 156-mm crystalline silicon solar cells with power output of 4.3 to 4.4 watts and solar cell conversion efficiency up to 18.4%. Photovoltaic modules are constructed with 60 or 72 solar cells which are interconnected in series configuration and yield a power output of 250 / 300 watt. PV modules are interconnected in series (PV array) – parallel configuration in the case of a grid interactive power plant to obtain the required voltage and power output for the power plant. In order to make the solar energy affordable and reliable, BHEL is engaged in various in-house developments and continuous process and product improvements in cell and module manufacturing.

Author(s)

S. Ravi BHEL-EDN, Bangalore [email protected] Design and development of Solar Cells and PV Modules and Capacity Expansion

Silika Mahapatra BHEL-EDN, Bangalore [email protected]

Pratha Jhawar BHEL-EDN, Bangalore [email protected]

Felix Menezes BHEL-EDN, Bangalore [email protected]

Sandeep Chandril BHEL-EDN, Bangalore [email protected]

MANUFACTURING TECHNOLOGIES FOR HIGH EFFICIENCY CRYSTALLINE SILICON SOLAR CELLS AND PV MODULES

13#

98

Abstract:

India is abundant in Solar and Wind resource. If judicially and optimally tapped, the resource can be converted into Electrical Energy for supplementing the power scarce nation on a huge scale. Presently, almost 87% of electricity is generated by fossil fuel (coal/Gas) fired and other non-renewable power stations. Balance 13% power is fed by renewable resources such as Solar, Wind, etc.Fossil fuel fired power stations are Base load power stations by virtue of constant controlled output and high level of predictability. On the contrary, renewable energy resources such as Solar and Wind are highly unpredictable. With accelerated depletion of Coal and Gas, compounded with increased climate change threat due to high carbon emission, the share of Solar and Wind energy is bound to increase dramatically. However, the low level of predictability of Solar and Wind resources may lead to Grid Destabilization and Under-utilization.

In order to overcome or at least mitigate above threat, innovative solutions are being invented and gradually getting mature to provide stable and predictable output from Large MW Utility scale Solar and Wind Power plants through high Capacity, quick charge & long discharge Energy Storage batteries. The paper deals with various aspects of Technological developments in such utility scale storage solutions, their impact on grid discipline, economics and present impediments/challenges with such solution.

Author(s)

SUDHIR PATHAK

The Author is presently working as Asst Vice President ( Electrical System Design) with Welspun Energy ltd, Largest Solar Power Developer in India. B.Tech. (Electrical Engg) from I.I.T. BHU, Varanasi in 1994, has worked with NTPC for 18+ years in Engineering, Erection, Testing, commissioning, maintenance, 3 years with Welspun and now with Welpsun Energy Ltd While in Welspun, the author has one patent filed on his name.Being leader in Renewable space, we are in continous process of acquiring , understanding latest & future technology, innovating procesess for improving system reliability, optimisation and quality.

RENEWABLE ENERGY: FUTURE BASE LOAD STATION

14#

DIVERSITY OF ENERGY SOURCES

99

Abstract:

Reliability of a Solar P V plant is the hallmark of a stable grid operation, customer satisfaction and a profitable business for the plant owner. This can be achieved by a) Reduction of equipment break downs using Reliability Centred Maintenance (RCM) techniques b)Plant performance monitoring and efficiency analysis and c)Identification and managing the operational risks in a holistic way. Once a P V Plant enters post commissioning stabilization stage, our endeavour should be to establish a robust maintenance process to ensure a high degree of plant availability and reliability for trouble free, efficient operation. RCM involves minimizing equipment failures by detailed analysis of various failure modes, their effects and implementing a combination of plant parameter monitoring, along with an optimized set of predictive and preventive maintenance processes. To enhance the effectiveness, the RCM analysis has to cover the systems and equipments beyond plant boundary (eg.: power evacuation system, plant communication system etc.) which have direct impact on reliable plant operation. RCM benefits are a)Improved plant reliability and higher production level b)Cost reduction through elimination of redundant / superfluous maintenance activities c)Focus on ‘vital few’ critical equipments and their maintenance activities d)Maintaining a lean inventory system. The real life case studies from NTPC’s 5 MW P V Plant at Port Blair (A&N) are explained here, which can be gainfully replicated in other P V plants to improve their performance.

Author(s)

I R Bhat AGM(Projects) Renewable Energy Projects Office Belgaum Karnataka e-mail: [email protected]

RELIABILITY ENHANCEMENT OF SOLAR PV PLANTS THROUGH RCM PROCESS DURING POST COMMISSIONING STABILIZATION PERIOD

17#

DIVERSITY OF ENERGY SOURCES

100

Abstract:

Maintaining Ecology ensures perfection in future of production of energy and life. A fish ladder(fishway/fish pass/ fish step) is a structure on or around artificial and natural barriers(dams etc.)to allow fish to pass around the barriers by swimming and leaping up a series of relatively low steps(ladder)into the waters on the other side.According to Probability distribution theory and theory of motion,fish swimming behavior determines fish thrust in fish ladder structure used in hydro power plants. Fish species distribution in the Himalayan streams depends on the flow rate, nature and substratum, water temperature, and the availability of food.It was recognized long ago that obstructions in rivers such as dams affect fish populations.Many design factors are looked at by engineers when designing and placing a structure.Sehgal identified several zones on the basis of the dominant fish species and the hydrographical features.Menon related the distribution of Himalayan fish to morphological characteristics.According to practical use and other technicalities,fishways is helping the ecology to restore,although,fish ladder does not ensure good life for fish/ hydro power plants Literature is scanty to identify and establish the concept of fish friendly technical designs in case of fish ladder. This paper uses some mathematical inputs behind technical need of fish ladder.

Author(s)

Dr.Suparna Mukhopadhyay

1.Mechanical Engineer (Ph.D in mechanical engg from Jadavpur university)

2.Presently posted in P&S Department,TSTPS

FISH LADDER- A TECHNICAL NEED OR ECOLOGICAL FALLACY IN CASE OF HYDRO POWER PLANTS (HPP)

19#

DIVERSITY OF ENERGY SOURCES

101

Abstract:

Renewable energy sources (RES), such as wind and solar, have vast potential to provide energy security and sustainability with very little greenhouse gas emissions linked with power generation. However, due to their inherent variable and intermittent nature, delivering reliable and quality power on demand is extremely challenging. This is due the fact that the wind does not always blow, and the sun does not always shine at times when consumer needs power. On the other hand, occasionally, the demand for power can be low when renewable energy sources are at their peak. In order to mitigate the negative impacts linked with variability and intermittency, RES need the support of other balancing systems to firm up their output. Energy storage is one such option to smoothen the fluctuations arising out of variability. Energy storage in electric grids is also used for grid stability; flatten loads to reduce peak congestion, and to provide ancillary services. This paper gives an overview of wind and solar photovoltaic (PV) energy conversion systems and few energy storage methods capable of integration with renewable energy systems.

Author(s)

Dr. K.V. Vidyanandan, Member, IEEE, Additional General Manager, Power Management Institute, NTPC Ltd., Noida, India.

Dr. K. V. Vidyanandan received the M. Tech. (Power Generation Technology) and Ph. D. (Electrical Engineering) from the Indian Institute of Technology (IIT), Delhi, India. He is a Faculty Member at the Power Management Institute (PMI), NTPC Ltd., NOIDA. Before joining PMI, he has worked at Farakka, Korba and Singrauli super thermal power stations of NTPC Ltd. His research interests include Wind and Solar PV Energy Systems, Energy Storage, Microgrids, and Frequency Regulation.

e-mail: [email protected]

ROLE OF ENERGY STORAGE IN THE GRID INTEGRATION OF WIND AND SOLAR PV ENERGY SYSTEMS

25#

DIVERSITY OF ENERGY SOURCES

102

Abstract:

Energy consumption in India is increasing rapidly and this increasing energy demand requires addition of more and more power plants on short time periods. In the present situation among various energy sources based on fossil fuels and renewables, solar energy looks most viable due to various good reasons such as low LCOE, faster execution, no distribution losses, minimum statutory approvals etc. Roof top solar PV power plants for captive energy consumption, especially for industrial customers have been found very much beneficial in order to reduce grid consumption dependence. Today, solar PV systems are known for the fastest executed power plant of any kind. The fast execution of a solar power plant is mainly contributed to the technological improvements taken place in the recent years such as string inverters, standardization of mounting structures for various roofs. Implementation of string inverters in the roof top solar power plants has improved the project execution times, plant up-time and energy yield due to eliminated losses of transformers. In the current scenario, roof top solar PV systems have already achieved grid parity in many geographical locations / customers. Lower LCOE, achieved grid parity, faster execution and no ground space requirement makes roof top solar power plants very attractive. However, there are various challenges associated with roof top solar PV power plants, such as DG interface, plant monitoring, multiple inverter options, maintenance, restricted space etc., which needs to be addressed to make solar power sustainable, affordable and reliable. In the present paper all these aspects and their importance in Indian scenario are discussed in detail.

Author(s)

Bhaskar S Kamath E-mail: [email protected]

Bhaskar S. Kamath, presently heads roof top engineering at Tata Power Solar (TPS) and has a professional experience of 22 years. He has a 12 year experience in the field of renewables, especially solar, and has designed systems for varied utilities, including oil & gas, telecom, hybrid solutions, micro grid, village electrifications, gas pipelines, VSAT’s etc. In his role, he is actively engaged with solar field for bringing down cost of energy using innovative solutions. He is managing team of 6 smart engineers at his work place dedicated for rooftop engineering for better, smart and sustainable solar.

Dinesh Kumar E-mail: [email protected]

Dinesh Kumar, presently working at Tata Power Solar as a part of rooftop Project Engineering Team. He is involved in design and engineering of rooftop solar systems. He is passionately working in the field of renewables for past 4 years. Actively engaged in developing new BoS technologies for rooftop solar such as optimizers, DG fuel saver.

OPERATIONAL AND ECONOMIC BENEFITS OF ROOF TOP SOLAR PHOTOVOLTAIC POWER PLANTS

28#

DIVERSITY OF ENERGY SOURCES

103

Abstract:

Recently MNRE has launched a programme on “Development of Solar Cities” which aims at a minimum 10 % reduction in projected demand of conventional energy by the end of year 2019. In support of this, the objective of this paper is to estimate the roof top solar potential of Indian Solar Cities. Global Horizontal Irradiance of all the selected solar cities from NASA, NREL and Meteonorm database has been presented. In a solar PV system, the cost of the modules still comprises around 53% of total system cost. Moreover, it is difficult to get suitable land in city areas for installation of the PV modules. Hence for the development of a sustainable solar city, it is worth to consider all the possible designs aspects aiming to generate larger energy over lesser area. Different roof top PV system designs are possible depending on the module structure/ table arrangements. Electricity generation potential of a system for a particular location is highly dependent on the tilt and tracking arrangements. Generation potential of PV system for all the possible designs for a selected solar city- Delhi is estimated using Meteonorm database and PVSyst simulation software. High gain in the specific yield is observed when a system is designed with tracking. The direct rooftop area required for different designs to meet the 10% energy demand of city is also calculated. Solar city design is a new phase of sustainable development with wide scope which could reduce the energy demand of a city in a large scale in the near future.

Author(s)

Name: Mayank Thapliyal Email ID: [email protected] Education: M-Tech, Center for Energy Studies, Indian Institue of Technology Delhi Working as Engineer at Lahmeyer International (India) Pvt. Ltd.

SOLAR POTENTIAL OF INDIAN SOLAR CITY

31#

DIVERSITY OF ENERGY SOURCES

104

Abstract:

In Today’s generation, the natural resources such as water, minerals, air and soil are being depleted and polluted due to population growth, which results in ecological imbalance.

This paper describes the various smart methods which could be implemented and also some of the methods which had been implemented already in utility photo-voltaic (PV) solar power plants for sustainability of natural resources.

The various methods include Contour Following Structures, Seasonal Tilt Structures, Driven pile foundations for solar structures, Composite buildings, Innovative construction material use, Smart building orientation and sizing, Smart Rooftop solar plant installation and Rain Water Harvesting systems.

Aforementioned methods are described in the paper by considering some case studies, which shall explain the actual picture of the methods implemented.

Author(s)

Rams Thallur, PE(CA, USA), M.ASCE, (MICE) Sr. Engineering Manager, Head – Civil & Structural (Solar Projects) L & T Construction, Chennai (E-mail id: [email protected])

Santhanalakshmi. S Asst. Engineering Manager, Solar EDRC – Water & Renewable Energy IC L & T Construction, Chennai (E-mail id: [email protected])

Santhosh.B.R Senior Design Engineer, Solar EDRC – Water & Renewable Energy IC L & T Construction, Chennai (E-mail id: [email protected])

SUSTAINABLE GREEN DESIGN OF PHOTO-VOLTAIC SOLAR POWER PLANTS

32#

DIVERSITY OF ENERGY SOURCES

105

Abstract:

In recent years India has implemented approximately grid connected solar power project of the cumulative capacity of around 3000 MW. Still the solar power segment of the country is dealing with the lot of difficulties viz. unavailability of measured solar radiation data, long term operating history of solar PV technology in Indian climatic conditions, lack of domestic manufacturing of solar PV modules, concentrating collectors and receivers, inverters, etc. which makes impact on the bankability of the solar power project. Due to intermittence of the nature of solar irradiance and variability of available solar radiation databases there is significant uncertainty in the energy yield estimation and hence the financial feasibility of the solar power projects.

This study presents the overview of GHI and DNI databases available in context of India for 23 representative locations covering its all major climatic zones. All solar radiation databases have been compiled on a common typical meteorological year (TMY) format and statistically evaluated. Further using all databases the energy yield estimation of a MW scale grid connected solar PV power project has been carried out for multiple locations using PVsyst computer software. Similarly for Concentrating Solar Power (CSP) technology the energy yield estimation has been carried our using SAM computer software for selected locations through all DNI databases.

Significant variation has been observed in the energy generation pattern of solar PV and CSP projects when multiple databases are used. The deviation of capacity utilization factor and unit cost of electricity for solar PV power projects has been received from 0.6% to 26%; however for CSP projects it has been received from 1.5% to 40%. From this exercise it has also been observed that the ISHRAE weather database is not suitable evaluation of solar power projects.

Author(s)

Dr.IshanPurohit

A combination of Academic, Research and Industrial exposure in the area of renewable energy (Solar), Dr.IshanPurohit is working as General Manager- Renewables at Lahmeyer International India since last five years. Working in the area of renewable energy since last 14 years; his profile comprises Owner’s & Lender’s Engineering services of around 5000 MW renewable energy projects. He has earlier worked with TERI, IIT Delhi and other prestigious institutions. Being doctorate in the dimension of Solar Energy; he has published more than 100 research papers/ articles in international/national journals/ conferences & magazines. He is Visiting Faculty at TERI University, NPTI and several other institutions of well repute and contributing toward teaching and research guidance of Master and Doctoral students.

Dr.GunjanPurohit

Dr. Gunjan Purohit working as Assistant Professor (Physics) at Department of Physics, H N B Garhwal (Central) University, Dehradun, India. His core area of research comprises Laser and Opto-Electronics, High Temperature Plasma (Cross Focussing) and Solar Energy. He is Principal Investigator of seveal research projects funded by DST, UCOST, MNRE etc. He has contributed more than 50 research papers in International and National journals.

IMPACT ASSESSMENT OF SOLAR RADIATION DATABASES ON TECHNO-ECONOMIC FEASIBILITY OF SOLAR POWER PROJECTS IN INDIA

33#

DIVERSITY OF ENERGY SOURCES

106

Abstract:

Exceeding more than 20 GW installed capacity; wind power generation is commercialized renewable energy segment in India. Recently due to several initiatives taken by Government of India and several State Governments, grid connected solar power (especially solar PV) has made significant progress in the country. Being a renewable energy resource wind and solar both resources are intermittent in the nature. In addition both sources are dilute source of energy hence require large area for collection which causes large land requirement in wind and solar power projects.

In the present study an approach has been developed towards large scale grid connected wind solar hybrid power projects which shares the common power evacuation facilities, infrastructure and land. The study find after shading analysis that enough solar PV system can be installed within the land area in a wind farm. The sharing of infrastructure could enable in reduction of cost of generation from the combined system by about Rs. 0.28 per kWh.

Author(s)

Mr.Alok Kumar Jindal

Mr.Alok Kumar Jindal, at present is working as Deputy General Manager-Renewables at Lahmeyer International India Private Limited since January 2014 and before that he has been working at The Energy and Resources Institute as Fellow in Renewable Energy. A Master of Technology in Energy Studies from IIT Delhi, he brings with him a lot of knowledge in the field of energy and environment technologies and has experience in design and evaluation of over 1000 MW Wind Power Projects as well as the solar power projects both grid connected as well as off-grid.

Dr.IshanPurohit

A combination of Academic, Research and Industrial exposure in the area of renewable energy (Solar), Dr.IshanPurohit is working as General Manager- Renewables at Lahmeyer International India since last five years. Working in the area of renewable energy since last 14 years; his profile comprises Owner’s & Lender’s Engineering services of around 5000 MW renewable energy projects. He has earlier worked with TERI, IIT Delhi and other prestigious institutions. Being doctorate in the dimension of Solar Energy; he has published more than 100 research papers/ articles in international/national journals/ conferences & magazines. He is Visiting Faculty at TERI University, NPTI and several other institutions of well repute and contributing toward teaching and research guidance of Master and Doctoral students.

TECHNO-ECONOMIC ASPECTS OF LARGE SCALE GRID CONNECTED WIND-SOLAR HYBRID POWER PROJECTS IN INDIA

35#

DIVERSITY OF ENERGY SOURCES

107

Abstract:

Solar PV is the only scalable renewable energy solution that can meet the country’s increasing energy requirements and can electrify rural households.

We believe that rather than isolated solutions, an integrated approach is required to secure the country’s heavily intertwined energy, water and food requirements in the coming decades. Solar highway over canals and agricultural fields will generate GWs of clean energy, conserve millions of cubic metre of surface water and increase thousands of tonnes of food production providing social & economic development at the bottom of the pyramid.

The solar power system built over the raw water reservoir not only conserves land space but also helps in water conservation and environmental benefits while generating clean, renewable and more affordable electricity. In addition to power generation, the system helps significantly to reduce algae growth and evaporation loss in the reservoir due to shade created by solar panels. Calculations indicate that this system shades the water and can reduce evaporation by up to 27%. In view of that, it would be beneficial to install SPV plant at the area available over the water body. To the best of our knowledge this would be the first of its kind in India. Increasingly in India land availability for power plant is becoming a major hurdle and one of the main root causes of delay

Author(s)

ArunavUppal, B.Tech (Mechanical), professional in Engineering and Development of solar power projects. He started his career in Reliance industries Limited, Solar group. In past 7 years he has enriched his knowledge and gained experience in solar power technology while working with esteemed organizations: Tata Power Solar, LancoSolar, PunjLlyod& Reliance. Currently associated with Tata Power Solar, he is looking after the development of various critical projects.

SOLAR ENERGY SOLUTION ON UNUSED WATERBODY: SUBSTITUTE FOR LAND REQUIREMENTS OF SOLAR POWER PLANT

38#

DIVERSITY OF ENERGY SOURCES

108

Abstract:

Depleting fossil fuel resources and externalities costs of producing energy from fossil fuel have made the uptake of renewable energy a necessity. However, there are certain barriers to the acceptability of renewable energy worldwide. One of the major barriers to adoption of renewable energy on a large scale is its high initial cost which puts upward pressure on the overall price of renewable energy which in turn makes it unaffordable. Thus, there is an urgent need for suitable strategies for making renewable energy affordable on a large scale. The government of a country should take the responsibility to devise strategies and implement those strategies through policy actions, regulations and necessary financial and non-financial arrangements. These strategies should be technology specific, spatial in nature, and should consider existing country-level or province-level strategies and policies before being finalized. Moreover, strategies for making renewable energy options affordable should lay down the role of relevant government departments, private entities and other relevant stakeholders. Some of these strategies are creating level playing field for renewable energy technologies vis-à-vis conventional energy technologies, encouraging private participation in promotion of renewable energy in rural areas, developing domestic manufacturing sector for renewable energy technologies, providing subsidies and tax benefits, promotion of off-grid systems etc. In this paper, we will discuss these strategies and their role in making renewable energy technologies affordable. Further, global experience suggests that there are certain policies and programs that have been adopted by various governments to bring the cost of renewable energy technologies on par with the conventional energy technologies. In the end, we will highlight few such policies that have been adopted by different countries across the globe for making renewable energy options affordable.

Author(s)

Debarshi Gupta, Research Associate, World Institute of Sustainable Energy, Pune Mr.Debarshi Gupta has been working in the renewable energy sector for more than three years. He completed his post graduation in economics with specializations in econometrics and financial economics in the year 2009 from university of Calcutta. In the year 2011, he joined World Institute of Sustainable Energy as a research associate in the Centre for Renewable Regulation and Policy. In WISE, he has participated in various projects in the fields of renewable energy regulation and policy and acquired expertise in electricity tariff computation, renewable energy promotional policy study and analysis, data analysis etc. Few of the projects in which he has worked over three years are “Strengthening South-South Cooperation to Increase Affordability of Sustainable Energy Options in Asia and the Pacific”, “Policies to promote renewable energy technologies in the Asia-Pacific region”, “Risk of coal based electricity generation “, “Creation of a legal, policy and regulatory framework for accelerated RE development in Bihar etc.

STRATEGIES TO MAKE RENEWABLE ENERGY AFFORDABLE

39#

DIVERSITY OF ENERGY SOURCES

109

Abstract:

Renewable energy sources are to play a crucial role for sustainable growth and the energy security of the country. The stability of output, efficiency, cost of generation, land utilization etc. are few major factors which play a major role in deciding the proportions of renewable energy mix in the grid. Hybrid solar thermal installations have the potential to overcome these challenges. They promise a higher efficiency, a stable output and no separate requirement for heat storage. The efficiency of the hybrid plant is dependent on the type of integration and the efficiency of main cycle to which the integration is done. Different methods of such integration in a coal fired power plant higlighting their advantages and constraints are brought in this paper. The options are compared w.r.t the achievable efficiencies in case of integration in a typical 210 MW coal based unit with main steam parameters 150 kg/cm2 and 537 deg C. The optimum solution for retrofit and green field projects are discussed.

Keywords: Renewable, Solar thermal, Clean energy, Hybrid, Efficiency

Author(s)

Neeraj Goswami

Graduate in Mechanical Engineering with M.Tech from IIT Delhi. 11 years of experience in NTPC in powerplant design and maintenance. Presently involved with design and installation of Solar thermal related applications at NTPC- NETRA. E-mail : [email protected]

Rajulin Dhas.K

Graduate in Mechanical Engineering from College of Engineering, Guindy and currently working at NTPC Engineering Office, Noida. 3 years of experience in system and process engineering of thermal power plant cycles. E-mail : [email protected]

SOLAR THERMAL INTEGRATION WITH CONVENTIONAL COAL BASED POWER PLANT

43#

DIVERSITY OF ENERGY SOURCES

110

Abstract:

India’s renewable energy capacity (excluding large hydro) has reached about 29.9 GW, of which 68.9% comes from wind, while solar PV contributes only around 4.5% of the renewable energy installed capacity in India. Wind farms are preferred in areas where average wind speed is above 4.5m/s.Wind energy potential is mainly concentrated in the western and southern part of the country due to the better wind regimes. In India the wind generation period is also limited to a few months during the stronger south west monsoon from April to September and weaker north east monsoon from October to December. For the remaining period of the year evacuation facility which is idle .The area utilized by a wind mill is approximately 20% including area for maintenance owing to the huge inter machine spacing. This unoccupied land is often left unutilized. There is good prospective for installation of solar power plants in these areas. Incidentally the existing wind farms in India also have good solar irradiation which is an added advantage. Even though both wind and solar are of variable nature, generation from solar can be predicted to a greater extent and it is always high during daytime whereas for wind the generation is equally shared, if not it is more during night time. The integration of these two energy sources allows improving the overall system utilization and reliability of the energy supply.

This paper aims to analyse the case if solar was to be installed in an existing wind farm and bring out how the existing resources and infrastructure can be utilized in a better manner. It will also indicate the reduction of additional infrastructure that would be required if both solar and wind farms was to be set up separately.

Author(s)

Kailash Chandra Pandey Engineering Manager Solar EDRC Water & Renewable Energy IC L&T Construction [email protected]

OPTIMAL UTILISATION OF WIND POWER AND SOLAR POWER FOR IMPROVED GRID MANAGEMENT IN TAMIL NADU– A CASE STUDY

47#

DIVERSITY OF ENERGY SOURCES

111

Abstract:

Energy self-sufficiency and high agricultural productivity are essential to guarantee unabated progress of a country with a burgeoning population.

Even with adequate water and nutrient supply, agricultural productivity is dependent on three limiting factors – light intensity, carbon dioxide concentration and temperature. Several crops exhibit saturation of photosynthesis rate beyond certain level of irradiation and any excess radiation will not contribute much to increase the photosynthesis rate, instead causes excessive transpiration.

India is a power deficit country and much emphasis is given to increasing the power generation from renewable energy sources, mainly solar PV, to meet the power demand. Currently, PV power generation plants are installed on wastelands, located very remotely from load-centres and evacuation points resulting in heavy infrastructure requirement and high transmission losses.

Co-existence of solar PV power plants on cultivated farm-lands can give twofold benefits from the same piece of land. An appropriately designed solar array layout can supply adequate amount of radiation for highest productivity, reduce transpiration and retain moisture in soil, while utilizing the remaining radiation for electricity generation. India has around 60.5% of its land area under cultivation; about 395 million acres which can support up to 56TW PV installation. Agricultural lands are also situated closer to the load centres and have better grid connectivity; and can also consume part of the generated energy for agricultural needs or in micro/community grids. This paper intends to bring out the technical benefits and challenges of a solar PV plant co-existing on agricultural land through a case-study.

Author(s)

Anish Kalathil: [email protected]

A Post Graduate in Electrical Engineering from University of Mumbai, with specialisation in Power Systems, he works at the Solar Business of L&T Construction’s Water and Renewable Energy IC. He has five year’s experience in the field of solar photovoltaic power plant engineering.

Aparna Sankar: [email protected]

After completing Post-Graduate degree in Renewable Energy Engineering and Management from TERI University, she joined the Solar Business of L&T Construction’s Water and Renewable Energy IC. She is passionate about developing innovative solutions for harnessing the benefits of solar energy.

SOLAR CO-EXISTENCE: PV ON FARM LAND

55#

DIVERSITY OF ENERGY SOURCES

112

Abstract:

In some of the Thermal Power Stations of NTPC having open cooling water (CW) cycle, hydro potential in CW discharge channel has been identified as a potential source of renewable energy which can be harnessed by constructing small hydro projects. The cooling water is drawn from Rihand Reservoir through an approach channel upto the CWPH forbay and pumped to the condensers. After utilisation water is discharged into the CW discharge channel which carries water to a distance of 6 km to affect sufficient cooling before it joins back to Rihand reservoir. The Hydro Project is located near the outfall of the discharge channel. The installed capacity of the project is 2x4.0MW with a design discharge of 85cumec & rated head of 14.0m, this will generate 56.64M.U. annually at PLF of 81%.

The water of discharge channel is diverted through spillway and 600m long diversion channel constructed on the left bank of discharge channel to facilitate the construction of Power House and for spilling of water when the Power House is closed or partially operated. The spillway is designed for full supply discharge of 85m3/s at FRL i.e.273.50m with a free board of 1.5m. Power Intake, two penstocks of about 35.0m long and 3.5m diameter are envisaged for feeding the water to machines. PH of 27.31m X 25.20m is under construction to house two tubular horizontal S-type machines of 4.0MW each. Gates are provided at the end of draft tube for dewatering of draft tube during maintenance. About 2050m long tail race channel downstream of Power House is constructed to carry water back to the reservoir.

NTPC is in the process of implementing several programmes for energy conservation & the Singrauli Small HPP has been conceived as an energy conservation option to harness the available hydro potential which was otherwise going waste.

Author(s)

Sh N.K. Jain is a graduate in civil engineeringfrom NIT Calicut, Kerala. He has more than 25 years of experience in the field of planning & design of Hydro Power Projects. He is presently working in the capacity of additional General Manager in NTPC Ltd. Prior to joiningNTPC in Dec’07, he was serving in NHPC, a premier organisation in the field of hydro power development, for a period of 18 years.

Mail id: [email protected]

Shri SubhrajitDas is a Graduate in Civil Engineering from University of Sambalpur, Orissa, a post Graduate in Structural Engineering from IIT Delhi and Masters in Business Administration from FMS, Delhi University. He has more than 10 years of experience in the field of Planning and Design of Hydro Power Projects. Presently he is working as a Manager in NTPC Ltd.

Mail id: [email protected]

SINGRAULI SMALL HYDRO POWER PROJECT 2X4 MW (UNDER IMPLEMENTATION) – A CASE STUDY

60#

DIVERSITY OF ENERGY SOURCES

113

Abstract:

Solar energy holds a significant promise to provide clean and green energy. However, due to time variable demands and time variable supply, solar energy resource is not fully satisfying. To meet the world’s ever-growing energy demands in an environmentally responsible and sustainable manner we need to effectively capture, convert and store this tremendous natural resource.

While we continue to build cheaper and more efficient solar panels, it is storage that needs a breakthrough so that solar energy can be used when the sun is not shining. The difficulty is that electricity is hard to store. Batteries cannot efficiently store energy on a large scale. Thermal energy storage can play a vital role in increasing the effective use of energy equipment and can be applied to balance the possible mismatch between the supply of, and demand for energy.

Molten salts can be used as likely ideal candidates as storage media with increased storage temperatures close to 500 0C and extremely low vapour pressures. Initial assessment results show that molten nitrate salts can be extremely potential medium for heat transfer and storage in concentrated solar power plants. One of the most promising salt which is a binary salt consisting of 60 % NaNO3 and 40 % KNO3 has been used successfully as a thermal energy collection and storage fluid. It can be used over an operative temperature range of 260 – 550 0C.

A study has been done to design a solar thermal plant using heat storage for electricity production independent of weather conditions or to continue to produce electricity even after the sun goes down. The paper focuses on the key findings of using storage system in solar thermal plant.

Author(s)

ASHISH JAIN

Mr Jain is currently working as Deputy General Manager (Electrical) in ONGC. He has over 24 years of experience in various facets of oil and gas industry. He holds a Bachelors degree in Electrical Engineering and a Masters in Marketing Management. He is a life member of Institution of Engineers and Indian Institute of Plant Engineers. He has had experience of working at Mumbai High, Uran Complex, Tripura Asset and Corporate Office. Currently he is posted in the Business Development and Joint Venture Group of ONGC. Mr Jain is recipient of Young Executive of the Year award by CMD ONGC and best Technical Paper award by erstwhile Director (Technical), ONGC.

E-mail: jain_ashish[at]ongc.co.in

STORING THE SUN – KEY TO SUSTAINABLE ENERGY

63#

DIVERSITY OF ENERGY SOURCES

114

Abstract:

Theoretically very high conversion efficiency, approaching 100% is a possibility in fuel cells which avoid Carnot thermal cycle limitations involving non-isothermal conditions. A great deal of research has been made towards establishing the factors or parameters that affect the performance of the cells. The kinetics of the chemical reaction in a fuel cell increases with the increase in operating temperature which is sometimes achieved by pressurizing the electrolyte (liquid) hence higher current density.Concentration of electrolyte also should be chosen in a such a manner so as to give optimum result.Also, fuel mixture ratio (say CO/CO2) or fuel flow rate and oxidiser flow rate should be such as to give the best results.

In the present paper, practical data relating to electrodes (Cathode/Anode), electrolyte, catalyst, working temperature, pressure, specific power, stack efficiency, overall system efficiency, number of installations, normal power output, peak power output, fuel consumption, emissions, maximum hours logged in a single plant & total hours logged in for different plants for various types of Fuel cells e.g. PEFC, PAFC, AFC, MCFC and the latest SOFC, have been reported.

In the context of developing countries like India, which has already set a massive capacity addition target for its renewable electric power generation from Solar & Wind sources recently, Fuel cell based power generation could join in probably as an important contributor in a modest way (if not big) the distributed energy revolution as has been witnessed in US, Europe, Japan etc. already. Coal Bed Methane (estimated reserve being about 400 billion cubic metre), conventional natural gas after priority use, LPG, bio gas & waste gas can be the practical fuel sources in coming decades for both industrial & domestic scale fuel cells. Fuel cell based power generation of either PAFC (PC-25 series), MCFC hot module and SOFC recent modules hold out big promise. Huge Bio-mass resource, bio-gas plants and controlled pyrolysis can make FC based power generation programme successful on a sustainable basis in both stand-alone as well as utility set-up.Fuel cells could also be thought of supplementing electrical power in peak-hours, through thermal re-generation (utilising waste heat) in off-peak hours.

Co-marketing agreement between large scale Power Utilities & Fuel cell manufacturers is also a viable & win-win proposition on which the business models of some utility companies & Fuel cell manufactures of US are being based presently in certain cases. Same is worth trying in India too.

Author(s)

Mr. S. Chakrabarti is a Graduate in Mechanical Engineering with distinction from Bengal Engineering College (University of Calcutta) and has done Master of Technology in Energy Studies from I.I.T. Delhi and thereafter M.B.A. in Finance from IGNOU, New Delhi. An avid learner to the core, he has written many scholarly articles and has also presented papers in various National & international fora such as CHEMCON at Indian

Institute of Chemical Technology, IIT s, World Energy Congress Meet-2004 at Sydney, Confederation of Indian Industries seminars, International Conference on Metals etc. Mr.Chakrabarti joined N.T.P.C Ltd in 1982 immediately after graduation and has over of 30 years of rich &checkered experience in the field of Project Engineering & execution of Large Thermal Power Projects including 500 MW, 660 MW and 800 MW units in N.T.P.C. Ltd. Currently he is working as General Manager (Mechanical) in the core Project Engineering Division .Being a specialist of Direct Energy Conversion technology, he keeps keen interest in supplementing conventional power source with Green Power as well and also play important role directly or indirectly in promoting Green Power.

FUEL CELL – A VIABLE ALTERNATIVE FOR POWER GENERATION

IN DEVELOPING COUNTRIES

67#

DIVERSITY OF ENERGY SOURCES

115

Abstract:

Recent concerns about climate change and sustainable development have induced great interest in renewable energy as an alternative source of power. In line with its commitment for sustainable development, the Government of India has mandated all power generators and consumers to fulfil a certain percentage of their energy requirements through renewable sources. Solar energy is one such source of green energy with PV and solar thermal, both being viable technologies. Through the course of this paper, we have compared stand alone PVs with integrated solar generation systems with the help of a case study about NTPC Faridabad. The study has considered the following aspects: Capital Cost requirements, Land and water requirements, Efficiency, Maintenance cost and Waste management.

The average DNI available at Faridabad is 5.48 kWh/m2/day and land available is 24acres. Standalone PV system analysis is based on 5Mw PV plant as per land requirement of 4acres/MW .We have considered the integration of the solar thermal system with the LP cycle of the existing steam turbine installed at Faridabad. For LP cycle integration we found that Parabolic Trough Collector (PTC) type solar thermal system is best suited. Following table summarises our observations:

The study illustrates that even though as on date the cost of solar thermal is higher than solar PV, its effective annual generation is also higher. Even considering factors like waste management and maintenance cost, this case study suggests that PTC type integrated thermal power generation system is more suited for the land available at NTPC Faridabad than standalone solar PV system.

Author(s)

Maya Ramachandran, BTech(Instrumentation&Control),Manager(C&I), NTPC Faridabad, [email protected]

Vishnu Chand, BE( Electronics and Communication), Dy Manager(Opn),NTPC Faridabad, [email protected]

Pankaj Arora, BTech (Electronics and Communication), Asst Manager (Opn), NTPC Faridabad, [email protected]

Parameter Solar PV Solar PTC

Annual generation 7.409 MU 9.17 MU

Capital cost 6.12Cr/MW 7.92Cr/MW

Water requirements 5m3/day 173.056m3/day(167.056 in closed cycle)

Maintenance cost Higher Lesser

Waste management More expensive and difficult Negligible

INTEGRATED SOLAR THERMAL PLANTS VS SOLAR PV AT NTPC-A COMPARATIVE STUDY

79#

DIVERSITY OF ENERGY SOURCES

116

Abstract:

Photovoltaic cells are made from ‘P’-Type and ‘N’ type silicon which is sand witched by a junction. ’ P’ Silicon are rich in + holes and ‘N’ type silicon is rich in electrons. Charge is built up across PV cell as electrons and holes combined at the junction. Approximately 0.58 v DC is developed as a result of static charge. Solar energy radiation in the form of infra red and visual light, is emitted by sun. Out of this, visual light is in the band width of 300 nm to 780 nm. When visual light from 400 nm to 500 nm falls on solar PV cell electrons gain energy and jump from ‘N’ type silicon to’ P’ type silicon with a velocity of 6.22x10 5 m/s and 2.96 x105 m/s and if impedance is applied then electric current shall flow. This is called photo electric effect. 70 PV cells are soldered together to make one panel. Each panel will generate 35 volt dc and 245 watts of power. One string comprised of 48 panels and will generate 11.760 kw of power. These strings of panels are connected with inverters. The role of inverter is to convert AC power into DC power and regulate it’s impedance to generate maximum amount of power. Modern inverters have the features of synchronisation with AC power system. Out put of inverters is stepped up from 345 volt ac to 33 KV power systems. From 33KV switch gear it is pumped to grid for commercial generation

Author(s)

S.O.KATIYAR, AGM, EMD FGPS NTPC FARIDABAD

I DID BE ELECTRICAL FROM MREC JAIPUR IN 1977 AND DID MBA IN FINANCE. WORKED IN NTPC KORBA, DADRI AND FARIDABAD AT VARIOUS POSITIONS.

POWER GENERATION BASED ON PHOTO VOLTAIC TECHNOLOGY AT 5MW SOLAR PLANT

94#

DIVERSITY OF ENERGY SOURCES

117

Abstract:

Ever increasing energy demand, fast depletion of fossil fuels, along with environmental concerns has already made path for emergence of Solar Energy and Solar PV plants are being installed in large scale. However, large Solar PV installations are essentially land intensive which will always be a premium commodity. In the direction of conserving the precious land & water, installing Solar PV system on water bodies like lake, reservoir, canal etc is also an emerging option and becoming attractive particularly when big generating companies like NTPC etc. are having large reservoirs at many stations. Apart from land conservation, Floating PV installations have many other benefits like increase in performance of solar PV panels due to cooling effect, water conservation, reduction in algae growth, quicker installation etc. This paper gives more insight about the Floating PV technology, present status & various available options and NTPC’s plan to assess and promote this platform for increasing its renewable energy portfolio.

Author(s)

SoumenSardar received B.Tech (E&ECE) and M.Tech (Automation & Computer Vision) degrees both from IIT Kharagpur in 2004. He joined NTPC in 2005 and is presently working as a Scientist at NETRA, focusing on the outdoor & indoor evaluation of various PV technologies. E mail id: [email protected]

Vishal Singh, Dy. Manager, NETRA, received B.Tech in Electrical Engineering from MNIT, Jaipur, in 2007. He is presently working in areas like Electrical aspects of Solar PV systems, Renewable integration/retrofits, Storage, VFDs etc. E-mail id: [email protected]

J. S. Chandok joined NTPC in 1991. He did his M.Tech (Gold Medalist) from IIT Delhi in 2004. Over the years he has worked in various positions at NTPC such as Boiler C&I Maintenance at Korba,, Project Engineering (C&I) at EOC Noida. Presently working as AGM at NETRA and looking after various areas like Artificial intelligence, Pattern Recognition, Solar PV, Smart grid, Expert Systems. E mail id: [email protected]

FLOATING SOLAR PHOTOVOLTAIC SYSTEM: AN EMERGING TECHNOLOGY FOR CLEAN ENERGY DEPLOYMENT

96#

DIVERSITY OF ENERGY SOURCES

118

Abstract:

The world’s climate is changing adversely, and these changes have a massive impact on our planet. Groundwater levels in India are threatened by increase in the population and climatic shifts and it will decrease drastically in the future. The scarcity of fresh water source and the need for additional water supplies remains critical and will exponentially grow in the future. Our planet utilizes solar desalination evaporation process to produce precipitation, which is the primary source of fresh water on the Earth. The concept of Solar Sea Water Desalination (SWD) is a replication of above mentioned natural evaporation process on a smaller and economical scale. Conventional desalination plants use electrical power & fossil fuels for operation. The Concentrated Solar Thermal (CST) technology replaces these conventional energy inputs with solar energy, which eliminates the emission of harmful green-house gases. The intensive energy needed for desalination is another indirect hurtful effect of same on environment. CST offers a reasonable option of cogeneration of electricity with desalination. CST based technology uses Multi-Stage Flash (MSF), Multi-Effect Distillation (MED) & Thermal Vapor Compression (TVC) method for water desalination which can cut down the high fuel requirement in these plants. Although the negative impacts from usage of fossil fuels can be mitigated using CST, the adverse effects of desalination like high concentrate brine disposal on environment has to be considered. In this paper, the negative effects of solar seawater desalination system on coastal environment and preventive measures are explained.

Author(s)

Abdul Hanif Khan, Head – CSP Initiatives, W & RE IC, L&T Construction

Email :- [email protected]

Devang Chauhan, Senior Engineer, CSP Initiatives, W & RE IC, L&T Construction

Email :- [email protected]

Renjith Kurian, Senior Engineer, CSP Initiatives, W & RE IC, L&T Construction

Email :- [email protected]

SOLAR SEA WATER DESALINATION AND ENVIRONMENT

105#

DIVERSITY OF ENERGY SOURCES

119

Abstract:

Majority of electricity in India is produced using fuels like Coal, Gas and Biomass based power plants. Major parts of India experiences load shedding during which high costly fuel like Naptha and Furnace Oil are used. As on today a lot of power plants are running on with coal reserves less than 15 days. This is leading to operation of plants on part load basis thus poor operating efficiency. Integration of these conventional power plants with solar thermal power can increase output of existing power plant by making them work at full load without added emissions by different possible schemes, making the plants more efficient than existing situation. Also the integration of solar can help reduction of fuel consumption and decrease in emissions that are polluting the environment. In this paper various schemes of boosting power output by addition of solar with conventional power and the concept of Integrated Solar Combined Cycle Power plants will be discussed.

Author(s)

Gantasala Balaji, M. E. Manufacturing Systems, Assistant Manager - Mechanical,

CSP Intiatives, Solar Business, Larsen & Toubro Limited

[email protected]

Abdul Hanif Khan, M. Tech Construction Manmagement,

Head – CSP Initiatives, Solar Business, Larsen & Toubro Limited.

[email protected]

SOLAR THERMAL POWER PLANTS – EFFICIENCY BOOSTER FOR CONVENTIONAL POWER PLANTS

106#

DIVERSITY OF ENERGY SOURCES

120

Abstract:

In view of the increasing power crisis, increasing cost of coal , inadequate availability of gas etc , the issue which obviously crops up :“Can we seriously think to aggressively pursue our venture for increased renewable energy ? “ The initiatives in Germany for solar power has been an eye opener. Moreover due to tremendous thrust on R&D in solar energy area across the world , the cost of solar power has been steadily reducing. It has already reached grid parity in some part of the world & is expected that within few years it will reach grid parity in India as well.

Govt. of India has taken up an ambitious plan for adding 20000 MW by 2022 in JNNSM plan . NTPC has also started its venture for solar power & taken its capacity to 95 MW . As a part of the plan , 5 MWp Solar PV plant has been installed & commissioned at Dadri.

While carrying out the execution of this project at Dadri , there has been lot of learning which the present study tries to capture . The study not only highlight about the problems faced at site during execution , but it aims to reflect to the perceived problems in the whole process from concept to commissioning . Based on the learning of the recent trend in the solar power sector across globe , the present study also aims to reflect the following ;

i) Framework for increasing generation at Dadri by increasing capacity of PV modules for maximum utilization of existing AC side of plant .

ii) Analysis of the existing process for faster execution of project .

Author(s)

Name: Goutam Deb

Organization: NTPC Ltd. ; Designation : Additional General Manager ( Mech. Erection) Academic Qualification : B.E.(Mech. Engg.) ; M.Tech (Industrial Mgmt.) ; MBA(Fin. & HR).

Professional experience :

i) Presently working as AGM, ME at NTPC Unchahar for the execution of 500MW coal fired power plant .

ii) 20 years of experience in project management area in the execution of power project of 500 MW units at NTPC Farakka, NTPC Kahalgaon, NTPC Dadri & NTPC Unchahar

iii) Experience of execution of 1st solar power project (5MWp) at NTPC Dadri

iv) 6 years of experience in O&M of thermal power plant in the area of Boiler maintenance.

Email : [email protected]

INSTALLATION OF 5MWP SOLAR POWER PLANT AT NTPC, DADRI : LEARNINGS & SOME THOUGHTS FOR SHAPING FUTURE ROAD MAP

110#

DIVERSITY OF ENERGY SOURCES

121

Abstract:

This technical paper will focused on the implementation of concept of hybridization of existing/future Coal and Combined cycle power plant with solar thermal augmentation. The objective of Hybridization is to replace and save a substantial amount of conventional fuel energy with addition of steam and hot water to the closed cycle system. This will leads to an increase in overall efficiency and will increase overall plant load factor which suffers mainly due to insufficient supply of fuel. Overall the report will give the technical feasibility of hybridized CSP Plant.

To understand the feasibility of hybridization, a detail analysis was done on the existing combined cycle and coal power plant hybridization with Solar CSP Parabolic Trough technology. The methodology is to add steam/hot water from the solar field to the Rankine cycle without doing major changes in the present system. The multiple location of steam/water addition is analysed and feasible location is recommended in the paper.

The result of this study will show the scope of considerable amount of Natural Gas/ Coal saving with the Hybridization. Considering the current market price of fossil fuel, the overall impact of the implementation of the study will be huge with the replacement of part of high pressure steam and all low pressure steam from existing boiler system with the Solar steam addition.

Author(s)

Lokesh Chourasia

Working as a Sr. Process Engineer with Lauren Bharat Engg Pvt. Ltd. Over 11 years of experience in Conventional and CSP Solar Power plants in Design, Operation, Commissioning, Startup, and Performance testing. The area of interest is Process engineering, New technology development, Impelmentation, and Energy conservation. The project experienced in 25MW to 500MW Power plants. Email: [email protected]

Amit Gawade

Working as a Mechanical Engineer with Lauren Bharat EnggPvt. Ltd. Over 5 years of experience with more than 3 years in Concentrated Solar Power, Parabolic trough Plants. Specialized in Solar Field design, Optimization & System Advisor Model. Executed project includes GGEL 50MW CSP in Rajasthan India. Current Project includes 25MW CSP Project with Thermal Energy Storage, Gujarat, India. Email: [email protected]

HYBRIDIZATION OF COAL/COMBINED CYCLE THERMAL POWER PLANT WITH CSP- PARABOLIC TROUGH TECHNOLOGY

125#

DIVERSITY OF ENERGY SOURCES

122

Abstract:

Water is one of the basic needs for living. There is continuous rise in water demand because of economic development. Growth in population also contributes in increased water requirement. Many parts on the earth have scarcity of fresh water. Water is available on Earth in plenty as sea water but cannot be utilised without treatment. Desalination has become very essential process to meet the requirement of fresh water for today’s living. Most of the desalination plants require steam as medium. There are multiple options for steam generation. But due to rapid increase in cost of coal and fuel oil, an alternate option needs to be thought of for steam generation. Now-a-days there is rapid increase in usage of SOLAR ENERGY for various applications. Here too SOLAR ENERGY can be a good alternative for steam generation necessary for desalination process. This way there will be saving in the depleting resources like coal, oil etc. and will add in reducing the environmental pollution. This paper describes Concentrating Solar Power (CSP) technologies for steam generation using solar energy and using this steam with conventional desalination techniques such as Multistage Flash Distillation (MFD) or Multistage Effect Distillation (MED).

Author(s)

Abantika Gupta

Working as a Process Engineer with Lauren Bharat Engineering Pvt. Ltd for more than two years, presently involved in process designing of concentrated solar power plant. Also having design experience of Water Treatment Plant & Thermal Power Plant for around seven years. Email: [email protected]

Amar Chougale

Working as a Mechanical Engineer with Lauren Bharat Engineering Pvt. Ltd. Over 2 years of experience in CSP Solar Power plants in Design, Commissioning, Start-up, and Performance testing. Worked on GGEL 50MW CSP in Rajasthan India. Current Project includes 25MW CSP Project with Thermal Energy Storage, Gujarat, India. Email:[email protected]

CSP TECHNOLOGIES FOR DESALINATION OF SEAWATER

129#

DIVERSITY OF ENERGY SOURCES

123

Abstract:

The firing or co-firing of biomass in existing pulverised coal boilers is an attractive option, environmentally, commercially and technically, for the production of renewable electricity, and the combination of biomass firing or co-firing with carbon dioxide capture and storage offers one of the few options for the extraction of CO2 from the atmosphere in sizeable volumes. Biomass firing and co-firing with coal have, to date, been associated with retrofitting biomass handling and combustion technology to existing coal-fired power plants. Doosan Babcock is a market leader in the implementation of biomass firing and co-firing projects at existing pulverised coal power plants. To date the conversion projects have involved three principal technical approaches, viz:

• Pre-mixing of biomass, in pelletised, granular and coarse dust forms, with coal and processing the mixed fuel through existing coal handling, milling and firing systems, without significant physical plant modification

• Installation of dedicated mills for biomass and direct injection of the biomass particles into the existing coal firing system

• Installation of dedicated mills and modification of the firing system to enable combustion of processed biomass pellets at levels up to 100%

Doosan’s experience in biomass co-firing and conversions on coal fired power plant in Europe and North America is summarised in this paper.

Author(s)

Dr W R Livingston is at Doosan Babcock R&D. He is a Chemistry graduate (Heriot-Watt University, Edinburgh) and has a PhD in Chemistry from the University of Birmingham. After five years post-doctoral research at the University of Birmingham and Imperial College in London, he joined Babcock Energy Ltd. as a Senior Development Engineer in 1985. He has major research interests and experience in all fuel and chemistry-related aspects of the development, design and operation of fossil fuel-fired boilers and has particular interests in the characteristics and behaviour of fuel ashes and boiler tube corrosion processes, and in the combustion and co-firing of non-conventional fuels, including waste materials and biomass.

For the past 15 years, Dr Livingston has been involved in both research and development activities on biomass firing and co-firing, and in a number of implementation projects on the firing and co-firing of a wide range of biomass materials in coal-fired power stations in Britain, and more recently in North America. Dr Livingston has been the UK representative on the IEA Bioenergy Task 32 (Biomass Combustion and co-firing) Committee for several years.

Email : [email protected]

RECENT EXPERIENCE OF THE CONVERSION OF COAL-FIRED UTILITY BOILERS TO THE FIRING AND CO-FIRING OF BIOMASS

152#

DIVERSITY OF ENERGY SOURCES

124

Abstract:

The theoretical limit of extraction of freely flowing wind kinetic energy into useful mechanical energy of wind turbine exists and in this paper an attempt has been made to explain what is commonly known as Betz’ limit. Wind velocity mapping and theoretically approximated wind velocity distribution function as a variable of time of the year are the two most important externally controlled parameters while rotor diameter & its aerodynamic design along with the right selection of the rated wind speed for the machine are being the most important designer controlled factors in estimating the exploitation potential. India ranking 5th in the world in terms of total installed wind power capacity, has considerable coast line making it very much amenable to exploiting both on-shore & off-shore wind energy further in the country with the advent of much improved blade & foundation designs concepts.

Author(s)

Mr. S. Chakrabarti

Mr.Chakrabarti is a Graduate in Mechanical Engineering with distinction from Bengal Engineering College (University of Calcutta) and has done Master of Technology in Energy Studies from I.I.T. Delhi and thereafter M.B.A. in Finance from IGNOU, New Delhi. An avid learner to the core ,he has written many scholarly articles and has also presented papers in various National & international fora such as CHEMCON at Indian Institute of Chemical Technology, IIT s ,World Energy Congress Meet-2004 at Sydney, Confederation of Indian Industries seminars, International Conference on Metals etc. Mr.Chakrabarti joined N.T.P.C Ltd in 1982 immediately after graduation and has over of 30 years of rich &checkered experience in the field of Project Engineering & execution of Large Thermal Power Projects including 500 MW, 660 MW and 800 MW units in N.T.P.C. Ltd. Currently he is working as General Manager (Mechanical) in the core Project Engineering Division. Being a specialist of Direct Energy Conversion technology, he keeps keen interest in supplementing conventional power source with Green Power as well and also play important role directly or indirectly in promoting Green Power.

THEORETICAL ESTIMATION OF WIND POWER POTENTIAL AND PROSPECTS OF WIND POWER EXPLOITATION IN INDIA

165#

DIVERSITY OF ENERGY SOURCES

125

Abstract:

In earlier days, hydro turbines were designed and recommended to operate mostly at peak loads only. Part load operation was quite restricted due to design limitations. Turbines were subjected to heavy vibrations, pulsation and cavitation at part load operation due to rapid fall in efficiency. In the present scenario of resource constraints, shortage of electricity and rising generation costs, clients are demanding optimum performance of hydro turbines at wider range of head and output.

With latest technological advancement, modern design tools and sophisticated laboratory techniques it is quite possible to offer optimum turbine performance (output and efficiency) for wide range of operation (peak loads as well as part load) for new and refurbishment projects.Alstom has developed individually tailor made client service package ranging from technical support, client help line, personnel training, maintenance engineering, condition monitoring to full reliability package, total operation and maintenance with enhanced performance to offer full justification to client’s investment paybacks.

This could be possible only with Alstom’s well established reengineering, repair processes and continuous R &D programs.

Our presentation outlines Alstom systematic approach to offer superior performance at peak and part loads for aging hydro plants using state of art technologies.

Author(s)

C K Jain Head of product engineering development Alstom India Limited Vadodara - [email protected] Author has more than 34 years of experince in hydro turbine engineering. Specially for the Hydro projects located in Himalayn region

Pierre Yves Lowys is expert for hydraulic turbine behaviour Alstom Hydro France - [email protected] Pierre-Yves has more than 17 years of practice in design, research and development of hydraulic equipments, and has experience in testing, diagnostic and feedback of all kinds of turbines for more than 30 projects wordwide.

REFURBISHMENT TO GAIN HIGHER PERFORMANCE FOR AGE OLD HYDRO PROJECTS

197#

DIVERSITY OF ENERGY SOURCES

126

Abstract:

The integration of photovoltaic (PV) solar sites and other distributed energy resources (DERs) into utility control systems is an increasingly important topic as the penetration levels of these resources continue to increase. The evolving regulatory and operational landscape between DER operators and regional utilities is creating opportunities for DERs to be used in grid support activities. The inherently fast acting characteristics of inverters make them especially suited for short-duration sourcing and sinking of reactive power. This paper discusses how to address the communications integration and activation of adaptive control strategies for these DER sites. An integrated control solution needs to address methods of collecting wide-area power system state information in such a way that the feedback is available for potential control strategies. Network topology, communications protocols, time coherence, and data update rates are considered. Additionally, PV sites can operate in a number of different control modes based on grid conditions and available solar radiation. These modes can include power factor matching, power factor correction, voltage support, and net metering, among others. This paper presents an overview of the control and monitoring infrastructure necessary to support emerging PV control methodologies.

Author(s)

Michael Mills-Price is the technology development lead for the solar energy business unit at Advanced Energy Industries, Inc.

Michael Rourkeis a principal automation engineer with Schweitzer Engineering Laboratories, Inc.

Darrin Kite is an associate automation engineer with Schweitzer Engineering Laboratories, Inc. The authors can be contacted at [email protected].

ADAPTIVE CONTROL STRATEGIES AND COMMUNICATIONS FOR UTILITY INTEGRATION OF PHOTOVOLTAIC SOLAR SITES

214#

DIVERSITY OF ENERGY SOURCES

127

128

129

RELIABILITY, SAFETY & SECURITY

Abstract:

With increasing economic pressure on power plants it becomes more and more important to ensure that the operation follows the best practice and that the available knowledge and experience is shared and available at any time. In the past solutions for performance monitoring have been developed and widely implemented in many power plants. These solutions are valuable and helpful tools that provide insight into the thermodynamic processes of the plant and use KPIs for an early detection of changes. However, it requires some engineering knowledge and experience to use this information to identify faults or to derive the best possible corrective action. The next generation of IT solutions supports the operators in these engineering tasks. Predictive analytics allow deriving quantitative models of the plant behavior from power plant data. Such models enable the operator to make a reasoned estimation of the trends of key parameters of the plant and their cost implications. They are complemented by decision support systems which uses plant data together with a-priori knowledge about the plant to identify the root causes of increased losses and to propose corrective action. In this paper concepts and solution are presented that implement these approaches for the operation of power plant. It is shown how this leads to the automation of knowledge in the plant and ensures continuous best practice operation. Operational experiences with such solution are presented.

Authors(s)

Lea Boche ([email protected])

Additional General Manager Product Development

Dr. Peter Deeskow ([email protected])

Head of Product Development

Vedika Agrawal ([email protected])

Manager Simulator Group

PREDICTIVE ANALYTICS AND DECISION SUPPORT FOR IMPROVED PLANT EFFICIENCY

10#

130

Abstract:

Reliability of a Solar P V plant is the hallmark of a stable grid operation, customer satisfaction and a profitable business for the plant owner. This can be achieved by a) Reduction of equipment break downs using Reliability Centred Maintenance (RCM) techniques b) Plant performance monitoring and efficiency analysis and c) Identification and managing the operational risks in a holistic way. Once a P V Plant enters post commissioning stabilization stage, our endeavour should be to establish a robust maintenance process to ensure a high degree of plant availability and reliability for trouble free, efficient operation. RCM involves minimizing equipment failures by detailed analysis of various failure modes, their effects and implementing a combination of plant parameter monitoring, along with an optimized set of predictive and preventive maintenance processes. To enhance the effectiveness, the RCM analysis has to cover the systems and equipments beyond plant boundary (eg.: power evacuation system, plant communication system etc.) which have direct impact on reliable plant operation. RCM benefits are a)Improved plant reliability and higher production level b)Cost reduction through elimination of redundant / superfluous maintenance activities c)Focus on ‘vital few’ critical equipments and their maintenance activities d)Maintaining a lean inventory system. The real life case studies from NTPC’s 5 MW P V Plant at Port Blair (A&N) are explained here, which can be gainfully replicated in other P V plants to improve their performance.

Author:

I R Bhat AGM(Projects) Renewable Energy Projects Office| Belgaum Karnataka| e-mail: [email protected]

RELIABILITY ENHANCEMENT OF SOLAR PV PLANTS THROUGH RCM PROCESS DURING POST COMMISSIONING STABILIZATION PERIOD

17#

RELIABILITY, SAFETY & SECURITY

131

Abstract:

The electrical consumption of electrical machines represents 66 % of the global world industrial electrical power consumption. Based on this fact, we are aware that all what can be realized in order to improve the machines efficiency and power factor will contribute to the sustainable development.

Jeumont electric is involved in the design and manufacturing of electrical machines and has accompanied or anticipated technical improvements for more than one century .

The purpose of the paper is to show how design and manufacturing tools can meet the today environmental challenges.

Author:

Lodewijk (Ludwig) Fostier

Born in Lessines (Belgium) December 11, 1956. Graduate of

“La Faculté Polytechnique de Mons (Belgium)”, High school leading to the diploma of Civilian Engineer in Electromechanics in June 1978.

Worked as assistant in the Laboratory of Electrotechnics of this university during 4 years studying the behavior of induction motors fed by inverters.

Since 1982, employed by the JEUMONT-SCHNEIDER designing large electrical machines and special devices for nuclear power plants. Involved in the design of special electrical machines (asynchronous and synchronous) in the design office for several purposes: petrochemical plants, classical power plants and nuclear power plants.

In 2008, become the Design Office manager of JEUMONT ELECTRIC. In addition, teach Electrotechnics and the induction motor design in two French high schools.

ELECTRICAL ROTATING MACHINES IMPROVEMENTS

(IMPACT OF DESIGN TOOLS, MANUFACTURING METHODS AND MATERIAL QUALIFICATION ON SUSTAINABLE DEVELOPMENT)

18#

RELIABILITY, SAFETY & SECURITY

132

Abstract:

Electrical power system consists of various components like a generator, transmission lines and transformers. A transformer and its maintenance over the years at site will play a crucial role in the reliability of the power system.

The key to successful maintenance of transformer is preventing moisture ingress within the insulation material. Slightest infusion of water requires to be removed to avoid deterioration of cellulose. Online dehydration systems are equipments which cater to this requirement of keeping moisture in the insulation at minimum levels.

Various drying methods like conventional drying and LFH have been tried for extraction of moisture from a transformer, but there is a cost to all in terms of either time, money or convenience. However, online drying systems are slowly establishing themselves as a reliable source of moisture removal equipments that achieve desired results without any adverse effect on the insulation. An upside to online drying systems is effectiveness in moisture removal from not only oil, but from the innermost layers of transformer insulation.

Versatility of the equipment for usage in any rating of transformer has urged utilities and industries to start using the equipment in not only the existing transformers requiring refurbishment, but also in new units that are consciously maintained to achieve the highest level of reliability.

Author:

Ranjan Joseph – Siemens Transformer Works, India

Author is responsible for Sales and Business Development of Transformer Lifecycle Management services and products at Siemens’ Transformer Works in Mumbai Worked as assistant in the Laboratory of Electrotechnics of this university during 4 years studying the behavior of induction motors fed by inverters.

ONLINE DRYING SYSTEMS FOR INCREASING TRANSFORMER RELIABILITY

69#

RELIABILITY, SAFETY & SECURITY

133

Abstract:

A combination of population growth, continual improvement in living standards and increased industrial activities has drastically broadened the gap between demand and supply in the energy sector. Although the total generation capacity of our country has registered about 80-90 fold growth in generation since independence. It is well accepted that to meet the requirement, we need to install new power generating units.Moreover, availability / augmentation of power generation capacity of the old power plants by judicious renovation and modernization can significantly contribute to achieve the target. Renovation and modernization of existing power plants is economical as compared to setting up a greenfield project and is a more viable option. This involves less gestation period and low cost.

Key Assets are those that when they fail they shut the plant down, cause extensive property damage, or endanger the health and safety of the staff and public. Critical Piping (Steam Piping mainly from Boiler O/L Nozzles to Turbine I/L Nozzles) is one of the key assets in a power plant which plays a important role in operation of plant. The failure of Critical piping requires a long lead time to put it back in operation resulting in huge losses to power unit. To ensure the availability of the generating plants, R&M of these piping systems need to be done. Before carrying out the R&M activity for Piping system, RLA (Residual Life assessment) is to be carried out to access the condition of Piping system. Various NDT techniques like Advanced UT testing (TOFD, Linear / Annular Focused Phased array), Stress analysis for the hanger and support design check, FEA based analysis to establish the remaining life of the piping system etc. are emerging out to assess the health of the system.

Authors:

Rakesh Kumar, DGM ( PE-Mech) – NTPC An Engineering Professional with over 21 years’ experience in Project Engineering, Operation and Maintenance in Power Plant industry. Graduated (B.E. -Mechanical) from BIT Sindri, Dhanbad, Jharkhand in the year 1991 and Post graduated (M. Tech.- Power generation technology) from IIT Delhi in the year 2002.

Knowledge of National and International Standards (IBR, IS, ASME, ASTM, AWWA etc.) for Design Engineering and Testing of Power cycle Piping, Boiler, Auxiliaries like heat exchangers, Air pre heaters, Fans and Design of Insulation. Knowledge and experience of Maintenance and Operation of Power Plant.

Presented and published many technical papers in national and International seminars on various aspects of power industry.

Utsav Agarwal, Manager ( PE-Mech)-NTPC An Engineering Professional with over 09 years’ experience in Commissioning , Operation & Project Engineering, Power Plant industry. Graduate in Mechanical Engineering from NIT Calicut.

Vineet Kumar, Assistant Manager (PE-Mech) – NTPC An Engineering Professional with over 04 years experience in Project Engineering, Power Plant industry. Post Graduate in Thermal Engineering from NIT Kurukshetra. Knowledge of IBR, ASME, ASTM, IS Standards for High Energy Pipe design and Pipe flexibility Analysis softwares like CAESAR – II, etc.

GUIDELINES FOR RLA OF CRITICAL PIPING SYSTEM IN AGING PLANTS

74#

RELIABILITY, SAFETY & SECURITY

134

Abstract:

NTPC Faridabad gets natural gas from GAIL. The gas passes through gas conditioning skids prior to entering into Gas Turbine System for combustion. Two critical systems namely emergency Gas Shutoff Valve (GSV) and Gas pressure regulating station (PRS) form major parts of the common gas skid system.

In past we had three major failures which led to shutdown of entire power station. These were failures of control power supply, pressure Controller and control relay which drives the GSV solenoid. Although the system is fail safe by design, all the failing elements were non redundant. C&I team carried out modifications in-house for eliminating such failures and overall improvement of the system. These are as follows:

1. Emergency Gas shut off Valve (GSV):

1A. Failure of continuously energized single relay driving the solenoid valve. This issue was addressed by installing an additional relay parallel to the existing one, so if one fails it shall not close the GSV.

1B. Failure of continuously energized Solenoid valve.

Issue resolved by installing an additional solenoid valve at the exhaust port of the existing solenoid. The solenoid is such that when energized, it will close the exhaust port of the existing solenoid. The solenoid shall be operated through the contacts of the additional relay

2. Gas pressure regulating station (PRS):

2A. Failure of the common Pressure controller causing closure of all four control valves.

Circuit modified such that the existing main pressure controller operates two selected main control valves. An additional pressure controller has also been installed to operate the remaining two control valves on fall of pressure (by 1ksc) in case main controller fails.

3. Single Source of Control Power Supply: Its failure shall lead to closing of GSV & PRS both.

Second source of Power Supply provided and control supply made redundant.

Author:

Tapeshwar Dayal: B.Tech in Elect. Engg. from IIT, BHU (Formerly IT BHU) Varanasi. Started his career at SAIL, Bokaro as ET in 1985 and worked there for two years. Joined NTPC in 1987 and has worked in plant operation and Controls & Instrumentation deptt in various capacities at Rihand and Faridabad. Currently posted as Additional GM & Head of C&I deptt. at NTPC Faridabad.

He may be reached at [email protected] and Mobile no. 9650994326.

IMPROVING THE RELIABILITY OF COMMON GAS CONDITIONING SKID

77#

RELIABILITY, SAFETY & SECURITY

135

Abstract:

Rolling bearings are vital components in all industrial equipment including powerplant machinery. Bearing problems can cause costly downtime, equipment damage, breakdowns, and reduced reliability. Bearing failures also result in noisy atmosphere and loss of significant investments in heavy units. This paper intends to apprise typical bearing types, components of rolling bearings, assemblies used especially in powerplants, operational problems and counter measures, precautions to prevent failures. Basic concepts related to bearings like basic load ratings, types of loads, types of bearing arrangements, thermal clearances, fitting clearances are discussed. Topics like bearing handling methods, lubrication methods& selection, mounting and dismounting, analysis of damaged bearings, replacement criterion etc...Running problems like vibration, uneven noise, overheating etc…their causes like dust, dirt, preload, contamination, external heating, and fit used in assembly are also covered. Latest technologies like sensor technology(condition monitoring), profiled rollers, insulation coatings, alternate materials, Integrated maintenance systems of reputed bearing manufacturers like SKF,NTN,TIMKEN,FAG enable plant maintenance engineers to effectively increase machine uptime ,increase efficiency of running equipment and increase operation reliability.

Author:

Srinivasarao Perumalla, Mech.Maintenance Engineer, Thermal powerplant E-mail: [email protected]

I am a post graduate of IIT Delhi, Mechanical engineering Department (dec2002).After my PG I worked as a lecturer in my hometown for a stint of 3 years. I joined NSPCL as ET in 2006 and since then I have been working in Turbine and Auxiliaries Maintenance. My vision is to become a technology specialist in Powerplants and expand my interest in steel, ports, heavy Engineering etc. Industries.

BEARING MAINTENANCE PRACTICES -A NEW PERSPECTIVE

80#

RELIABILITY, SAFETY & SECURITY

136

Abstract:

The capital cost of modern gas-fired and combined cycle plants has been reduced by the widespread use of large air – cooled turbine generators. However problems have recently been experienced in some of the stator windings in such generators. These problems include deterioration and failure of the insulation in the stator slot due to coil vibration. This has occurred in both conventional and global VPI stators. In addition, some machines have seen problems with partial discharge in the end winding and lead area due to insufficient spacing between high voltage components. This paper presents example of these problems and discusses some repair alternatives

Author:

S.O.Katiyar AGM EMD FGPS NTPC Faridabad

I did BE Electrical from MREC Jaipur in 1977 and did MBA in Finance. Worked in NTPC Korba, Dadri and Faridabad at various positions.

ROOT CAUSE ANALYSIS OF FGPS GAS TURBINE GENERATOR FAILURES

81#

RELIABILITY, SAFETY & SECURITY

137

Abstract:

Microgrid is an integrated system that contains Distributed energy resources (DER), Advanced control systems, Load management, Energy storage (ES) and Communication infrastructure. Microgrid plays a critical role to pave the way for full-fledged smart grid as well as smart cities. This technical paper describes in detail technicalities of Microgrid with various models and application areas. The major feature of Microgrid is that it can operate in parallel with grid as well as in isolation mode to enable continuous quality power during power shortage and peak demand time. The paper discuses about the integration of distributed energy resources i.e. renewable energy sources like solar, wind along with conventional energy sources like diesel generator, advanced control systems to control source as well as loads and energy storage for power and energy applications. Energy storage systems used for different applications like during renewable intermittency as well as backup for critical loads are detailed out. Microgrid offers benefits to user and utility company during critical situations like blackout and support for ancillary services.

The Microgrid models starting from simple solar diesel hybrid system for diesel abatement, solar along with battery system to full-fledged campus level microgrid are explained with the help of three case studies. The paper includes practical load test data of a Diesel Generator (DG) that shows its efficient loading range and explains the role of Microgrid in increasing the penetration of renewables and minimizing the diesel consumption. Further full-fledged Microgrid functionalities like diesel generator parallel operation with utility, capacity management, peak shaving, storm anticipation, load shedding/adding, renewable metering/control operation are elaborated with an example of a campus scale pilot project at Larsen & Toubro (L&T), Chennai.

Author:

Harshitha S Kumar heads the Microgrid and Roof top PV Systems business segment in Renewable Energy Business of Larsen & Toubro- Construction. Under her leadership some of the major achievements include the World’s largest single roof top power plant of 7.52 MWp capacity in India, Intersolar awards for projects in 2013. Before joining the Solar business team, she was part of L&T Corporate Strategy and had worked deeply along with top management consultants McKinsey & Co and Bain & Co. She had worked with various businesses in infrastructure, hydrocarbon and manufacturing sectors on various aspects such as strategy development & implementation, performance improvement, organization design and M&A screening. She was also closely involved in formulating and implementing Corporate Strategy for L&T including portfolio decision and organizational restructuring.

Earlier she was part of the Power Transmission & Distribution business of L&T Construction wherein she worked across functions including Project Management, Operational improvement initiatives, Strategic planning and Perspective plan development for the business unit. Harshitha has an MBA (PGDM) from S P Jain Institute of Management and Research and also an M.Tech degree from IIT Madras. Email id:[email protected].

ROLE OF SMART MICROGRID IN POWER RELIABILITY AND STABILITY

91#

RELIABILITY, SAFETY & SECURITY

138

Abstract:

In the electrical power industry one of the first applications of nanotechnology led to a new corona resistance enamel wire for inverter fed motors. At Siemens Energy a research program had been started to utilize nanotechnology to improve the electrical properties of high voltage insulation systems for turbine generators. Inorganic particles with a size of ten to fifty nanometers have been added to stator winding insulation systems. Subsequently, the erosion and treeing behaviour has been studied. The outcome of this fundamental research work is a new, more efficient nano particle based ground wall insulation for large generators with important improvements in electrical characteristics.

This paper shows that with the application of specially treated spherical SiO2 nano particles as part of the well-proved epoxy-mica ground wall insulation, the electrical properties of the insulation systems can be improved significantly. Resistivity to partial discharge erosion and electrical treeing is greatly increased and results in longer lifetime until electrical breakdown.

As a first step, basic investigations on epoxy-mica nanocomposites were carried out on plate shaped specimens with standardized electrode configuration for screening tests on material properties. In the second step of development, the influence of nanoparticles on the electrical treeing process as a pre-break mechanism was examined. In the third step, the new nanocomposite insulation system was tested at originally manufactured mica fibre glass taped tube-like specimens and small stator winding bars prepared by the same manufacturing process as the original stator winding coils. Compared to the established reference insulation system, the new nano particle based high voltage insulation system shows a flatter electrical lifetime curve resulting in tremendous improvement in the lifetime at rated and operational electrical stresses. This will lead to a more efficient insulation system, which improves the specific power output and lifetime of existing (after rewind) and new Siemens generators in the near future.

Authors:

Jürgen R. Weidner

Siemens AG, Energy Sector, Mülheim a.d. Ruhr, Germany

[email protected]

Dr. Friedhelm Pohlmann

Siemens AG, Energy Sector, Mülheim a.d. Ruhr, Germany

[email protected]

Dr. Jaap van Kampen

Siemens AG, Energy Sector, Mülheim a.d. Ruhr, Germany

[email protected]

NANOTECHNOLOGY IN HIGH VOLTAGE INSULATION SYSTEMS FOR TURBINE GENERATORS – FIRST RESULTS

100#

RELIABILITY, SAFETY & SECURITY

139

Abstract:

Bushing failures are one of the major root causes for transformer failures. The condition of a bushing depends on a variety of factors:

- Technology of the bushing

- Operating conditions

- Age of the bushing , Etc

The condition of a bushing is often not linearly related to those factors. They are influencing each other which often makes it difficult to exactly predict the condition of the bushing. This paper shall present a method how to assess the condition of a bushing fleet, to determine the risk for the assets and how to reduce it depending on a variety of influencing factors.

In a first step an overview of the installed base is needed. This overview shall help to cluster the bushing fleet and later on to set up a replacement schedule. The clusters can be made based on:

- Bushing technology

- Age of bushing

- Voltage and current level

- Serial number of bushings, Etc.

Practically there are two ways of determining if a bushing shall be replaced or not:

1) Based on technology and age: There are empirical values for each technology about the expected life time. Since generally the life time of a bushing is shorter than the life time of a transformer, many utilities change the bushings during an overhaul of the transformer without assessing the physical condition of the bushings.

2) Based on physical measurements: There is a variety of measurements which helps to indicate the condition of the bushing (partial discharge, power factor, capacitance, dissolved gas analysis, etc.). Based on the results of the measurements, a replacement program can be developed.

For setting up a replacement schedule not only the likelihood of a failure needs to be considered. The consequences of a failure also have a major impact on the priority. Furthermore there is an opportunity by choosing the right design of the bushing to fully or partially standardize the bushing fleet. This leads to further benefits like lower costs for storage and restocking of spare parts.

Further, this paper will also address the today’s latest state of the art technologies of high voltage condenser type bushings for various high voltage transformer applications.

Author:

Mr. Bruno Schnider obtained his Bachelor’s degree in Mechanical Engineering from the polytechnic institute of Lucerne in 1996. Following a few years of mechanical engineering, he joined Pfisterer Sefag in Switzerland as International Project Manager for HV transmission lines.

Before joining ABB Micafil in Zürich beginning of this year, being responsible for Sales and Marketing of RIP HV condenser bushings in reassigned areas, he worked as Sales and Project Manager for Pfisterer Ixosil in Switzerland in the field of HV cable systems for three years.

INCREASING TRANSFORMER RELIABILITY BY PROACTIVE MANAGEMENT OF BUSHING FLEET AND LATEST STATE OF THE ART CONDENSER BUSHING TECHNOLOGIES

145#

RELIABILITY, SAFETY & SECURITY

140

Abstract:

During construction and initial reservoir impounding, performance of an earth and rock-fill dam is required to be closely and frequently monitored for safety of the dam. During construction stage, rate of construction of earth and rockfill dam has to be manoeuvred i.e. increased or decreased on the basis of the instrumentation results to achieve safe construction. Similarly, during initial reservoir impounding, instrumentation results are of paramount importance and have a consequential impact on the decisions regarding future rate of filling, to enable safe impounding of dam. Koldam Hydro Electric Power Project is located on Satluj River in Bilaspur district of Himachal Pradesh in India. The project envisages utilization of a drop in head of about 140m by constructing a 167m high (from the deepest foundation level) rockfill dam and a dam toe surface power house with an installed capacity of 800 MW. Earth and Rockfill dam of Kol Dam HEPP has an elaborate monitoring instruments network for monitoring the health of the various structures viz. earth and rock-fill dam, spillway, galleries and foundations. Around 500 electronic and mechanical instruments have been installed and the performance of these structures is being monitored through this monitoring network. In the present paper, instrument network of only earth and rock-fill dam has been presented. Koldam HEPP is in final stages of construction and first stage of initial impounding has already been completed in the month of March-April 2014. Analyses of the data of monitoring instruments obtained during first stage of reservoir impounding and associated safety aspects have been discussed in the paper.

Authors:

Atul Nayak, Manager, NTPC Ltd., Engineering Office Complex, A-8A, Sector-24,

Noida – 201301, India, email: [email protected]

Dr. Anubhav, Sr. Manager, NTPC Ltd., Engineering Office Complex, A-8A, Sector-24,

Noida – 201301, India, email: [email protected]

Madhukar Aggarwal, Add. General Manager, NTPC Ltd., Engineering Office Complex,

A-8A, Sector-24, Noida – 201301, India, email: [email protected]

ENSURING SAFE AND RELIABLE PERFORMANCE OF EARTH AND ROCK-FILL DAM OF KOLDAM HEPP THROUGH INSTRUMENTATION

163#

RELIABILITY, SAFETY & SECURITY

141

Abstract:

Benefits & Features of Variable Speed Direct Hydraulic Drives in CHP

• The continuous and new developments of Large Hydraulic Drive Systems for tough applications addressing the needs of complete system engineering, flexibility & optimized selection – Leads to Process optimization.

• Overview on maximizing Machine Up-time – Leads to operational Reliability

Authors:

Mr. Peter Nilsson – Industry Sector Manager – Asia Pacific

An Industrial Global Professional in the Bosch Rexroth BMH Team, with a rich experience of nearly 24 years, and is based in Mellansel, Sweden.

Mr. Nilsson has Spearheaded the business development team of Hagglunds for certain European & Middle East Countries.

Now Mr. Nilsson has reached a new height within Bosch Rexroth and is responsible for all business related activities for Large Hydraulic Drives for Asia Pacific Countries.

e-mail : [email protected]

Dan Murphy – Sr. Project Management

A Mechanical Engineering Graduate having more than 30 years of experience in the Bulk Material Handling Industry, based in Australia.

Mr. Murphy was instrumental in developing BMH business in Hagglunds, Australia and has handled critical Mining & Material Handling projects starting from complete system engineering to successful Commissioning of the Project.

Currently he is engaged in the Global BMH team of Bosch Rexroth.

e-mail : [email protected]

RELIABILITY AND OPTIMIZATION IN VARIABLE SPEED DRIVE SYSTEMS

175#

RELIABILITY, SAFETY & SECURITY

142

Abstract:

Power Plant maintenance is often annual cycle. With the requirement of consistently having higher PLF, it is evident now to rethink on maintenance strategies. Conventional maintenance practices needs to be modernized to take advantage of automation. Work identification is no more part of operator’s field round and nor a choice for plant manager. Efforts for reduction in maintenance costs needs scientific evaluation of observed anomalies for risk mitigation. This paper talks about the various aspects of technology challenges of effective asset management for lifecycle maintenance and outlines creating the framework for automated maintenance management practices. Such approach is highly beneficial in increasing the plant availability, safety and profitability while reducing the surprises and insurance premiums.

Author:

Mr. Pankajkumar Sharma

Software & Services Leader

GE India Industrial Private Ltd. (Div. Bently Nevada),

E-mail: [email protected]

Phone : +91-9987003861

Pankajkumar Sharma is Software & Services Leader for GE – Measurement & Control. He is responsible for promoting GE’s “Industrial Internet” solutions. He graduated in Mechanical Engineering from M S University of Vadodara in 1998. Initial 5 years, he worked with IPCL-Dahej (now Reliance group of companies) in maintenance and condition monitoring of rotating/reciprocating machines. Since 2003, he is working with GE and led Machinery Diagnostics Services of Bently NevadaTM for India region. Under his leadership, GE India successfully completed “Vibration Analysis Domain Expert Development Program” for ONGC and started 24x7 Remote Monitoring & Diagnostics centre. He has published number of technical papers and articles in Orbit, ISA conferences and NSRD.

PLANT ASSET MAINTENANCE MANAGEMENT - PARADIGM SHIFT THROUGH AUTOMATION

189#

RELIABILITY, SAFETY & SECURITY

143

Abstract:

Super critical Power Plants (SCPP) run at different operating conditions often based on 660MW, 800MW (Europe, North America and India) to 1000MW (China, Malaysia) output requirements. In the United States gas fired SCPP plants have also been designed at below 500MW. Clean and cost effective SCPP plants require “whistle clean” conditions, low emissions, low noise, higher velocities and flow rates. Majority of the Specification packages for Valves are developed by experienced Piping Engineers, assigned to EPCs and the Valve section comprises a relatively small element where references to Industrial standards like ASME B16.34 or ANSI B31.1 are made for design and stress parameters. The specific valve data sheets then provide some more information as to design conditions and fail safe modes for the specific valves. With the advent of SCPP requirements, the current specifications make it somewhat enigmatic for Valve Designers and manufacturers to address the concerns of the Power Plant Designers and engineers in terms of pressure drops, velocities and sound levels without knowing several other parameters that are intrinsic to valve design, sizing and optimization. This paper presents some parameters for consideration as well as some specific suggestions for understanding the design characteristics of High Pressure, High Temperature Applications in operating both Base Load and Peaking Power Plants.

Author:

Rana Bose, PEng is President of RBose and Associates Inc., a Montreal, Canada based high-level Engineering and Management Mentoring organization with over 30 years’ experience in Valves, Aerospace, Metallurgy, Surface treatment Technology, Lean Process Optimization and Technology Acquisition.

SUPERCRITICAL POWER PLANTS AND THE NEED FOR INTEGRATED VALVE SPECIFICATIONS

190#

RELIABILITY, SAFETY & SECURITY

144

Abstract:

Combustion process in a thermal power plant is associated with a considerable amount of risk, which necessitates the requirement of fail-safe Boiler Protection System (BPS). Since Boiler OEM/supplier is the best agency to determine the safety requirements for their boiler, it is an industry practice to procure BPS from the Boiler supplier in new power plants. However, due to ageing of plants with passage of time and obsolescence in the electronic industry, R&M of control system including BPS has become the need of the hour.

In the absence of support of Boiler OEM for R&M, it is important to establish that BPS, comprising of new hardware/ software components implementing latest concepts of safety logic, ensures safety of boiler in all regimes of operation.

To establish an affirmative and deterministic requirements of the safety system, guidance is drawn from the internationally accepted Performance based standards IEC 61508 (Functional safety of Electrical/ Electronic/ Programmable Electronic safety-related systems) & IEC 61511 (“Functional safety: Safety Instrumented Systems for the Process industry sector”) and Boiler and Combustion Systems Hazards Code – NFPA 85.

IEC 61508/61511 adopt a risk-based approach and guide in determining the safety integrity requirements for safety functions to be implemented. Safety availability is expressed in terms of a quantitative measure - Safety Integrity Level (SIL), which is defined as “average probability of a safety instrumented system performing satisfactorily the required safety functions under all the stated conditions within a stated period of time”.

An in-depth study of Safety Standards, Practices adopted by reputed international OEMs and the experience gained by the industry over years has been done to establish various requirements including SIL for Boiler Protection System to be employed for R&M of BPS.

Authors:

Alok Kumar Sinha, AGM(PE-C&I), M.Tech(Instrumentation) 15 years of experience in O&M in Thermal Power Station, 5 years of experience in Project Engineering, E-mail ID: [email protected]

Shalini Shankar, Manager(PE-C&I), B.Tech(Electronics & Telecommunication) 2 years of experience in O&M in Thermal Power Station, 10 years of experience in Project Engineering, E-mail ID: [email protected]

Alka Upadhyay, Dy. Manager(PE-C&I), B.E( Instrumentation)| 6 years of experience in Project Engineering, E-mail ID: [email protected]

SAFETY REQUIREMENTS FOR R&M OF BOILER PROTECTION SYSTEM

191#

RELIABILITY, SAFETY & SECURITY

145

Abstract:

Continuous energy supply plays a vital role in today’s global economy and in the daily lives of citizens around the world. Over the past years power utilities have increasingly become strategic targets for physical and cyber attacks from internal and external aggressors. Failure of individual sites poses a threat to power grid stability resulting in potential blackouts for large geographical areas.

With the Command and control system, centralize and process all security and safety related information providing decision making support during an emergency and provide situational awareness of the site at any point of time.

Authors:

Ralph Mueller [email protected]

Mr. Ralph Mueller carries rich experience in system design, engineering and implementation of complex transmission systems and telecommunication networks. He specializes in Physical security & Communication Solutions for Energy Market & Smart Grid Communication Solutions”. He is currently based at Siemens AG, Germany

Ajay Gupta [email protected]

Mr. Ajay Gupta, a renowned veteran in the field of Enterprise Security. He is heading the Enterprise Security & Services division for Siemens India. His expertise lies in Strategy and Innovative Solutions, Enterprise wide Solutions, Security Automation, Identity Management, Surveillance , Biometrics, Physical and Logical Access Convergence solutions. Prior to joining Security automation field he has been involved in Power plant automation for more than 14 years and was involved in C&I of power plants.

Denzil.D [email protected]

Denzil D carries a rich experience in Fire, Security and Building management system working in various fields of design, pre-sales and direct sale activities providing solution for large security system projects for Power plants, Oil & Gas sector, Container terminals and Port environments.

TECHNOLOGY ORIENTED SECURITY SYSTEM FOR POWER UTILITIES

196#

RELIABILITY, SAFETY & SECURITY

146

Abstract:

This paper sketches out a few of the more important concerns that electricity suppliers should account for when planning substation upgrades. The focus is on how best to increase the reliability, availability, and maintainability of power substation automation networks within the context of the IEC 61850 vision, to give electricity suppliers a clear idea of the design procedures, device tolerances, and hardware and software features they should expect from the engineers and manufacturers who design and build their networking and computing devices.

Authors:

Dennis Lin Manager

Jun Chuang Business Development Manager

Larry Wang Project Supervisor

Kyle Pearson Technical Writer

MAKING SMART SUBSTATIONS EVEN SMARTER

201#

RELIABILITY, SAFETY & SECURITY

147

Abstract:

Cyber physical systems are interconnected intelligent nodes collaborating with each other, often controlling physical systems around them. Smart Grid, Intelligent Vehicles, Smart factories etc. are some examples of Cyber-Physical Systems. Cyber-Physical Systems can potentially give us insights and help us solve problems that were traditionally considered impossible. This paper provides an overview of cyber-physical systems in various contexts and how they can potentially be applied for a smarter grid. The complex and massive scale of these cyber physical systems makes it very difficult to implement and test these systems. The session also discusses some efficient approaches to designing and testing these cyber physical systems.

Author:

Raviteja Chivukula is a Technical Marketing Engineer with National Instruments. A graduate in Electrical Engineering & VLSI from IIT Madras, he has worked with NI in various roles and has been actively involved in configuring, building systems and consulting in the fields of Power electronics, Robotics, Control systems, Motion control, SDR and Wireless test systems. His former research areas include Unmanned Aerial Vehicles and Laser based sensing systems. He is passionate about teaching and is a visiting faculty at PSG College of Technology – Coimbatore, where he teaches an interdisciplinary course on System Design to undergraduate students from EEE, ECE, EIE and ME departments.

E-Mail ID: [email protected]

POWER OF INTERCONNECTED INTELLIGENT SYSTEMS – CHALLENGES IN DESIGNING & TESTING CYBER-PHYSICAL SYSTEMS

208#

RELIABILITY, SAFETY & SECURITY

148

Abstract:

Cyber Security has gained a huge importance in the last few years specially towards Industrial control systems (ICS) and specially critical infrastructure. The Mindset of Air-GAP and not connecting to the internet at all for ICS and Critical Infrastructure does not guarantee to any organization that it is secured and that no cyber crime can be committed against the organization. Stuxnet a present live example..

Cyber space is gaining importance and it is a fact that borders are no longer physical but CYBER BORDERS with nations trying to take control over each other’s Cyber Borders. It is also believed that the First Online Cyber killing could happen this year end as cyber criminals, APT Actors, state sponsored cyber terrorists exploit internet technologies to target victims. Europol said it expected ‘ injury and possible deaths” caused by computer attacks on critical infrastructure.

With a global manufacturing base and where technology changes rapidly and organizations optimizing costs state sponsored or back doors for unknown vulnerabilities being present knowingly or unknowingly is a growing threat. This paper would highlight processes on using modern day technologies which would help organizations to be proactive in terms of security. It would cover aspects of how fuzzing can be used to determine Zero Day or Unknown Vulnerabilities like Stuxnet or Heartbleed and ways to create quick patches so as to be able to mitigate them and create a stronger robust network.

Authors:

Mohit Rampal- Is a MS from BITS Pilani and in the IT, Telecom and Infrastrucutre

Security for over 20+ years. Is a CISSP and has been instrumental in rolling out large projects in PKI, Defense , Real Time Gross Settlement, Cheque Truncation and many more

Email: [email protected]

Shubika Soni holds an MBA from AMITY and has been in the IT, Telecom and Infrastrucutre for over 4 years. Had worked with organisations like Nortel, Avaya and Juniper.

Email: [email protected]

CYBER SECURITY FOR CRITICAL INFRASTRUCTURE

211#

RELIABILITY, SAFETY & SECURITY

149

Abstract:

Cyber security is becoming a very important concern for the whole community & the industry in particular. Until many years ago, the automation industry was kept out of the cyber threats loop, but with the connectivity of the automation systems to the business or enterprise network, these systems also have become vulnerable to cyber threats. To add to this, open architecture & commercial off the shelf (COTS) products in HMI have acted as catalysts to this changing scenario. The recent incidents comprising industrial control systems in various parts of the world destroys the myth that there cannot be comprises in the core DCS controls.

This paper discusses the various methods & means of improving the cyber security status of any industrial installation with distributed control systems or programmable logic controllers (PLC)s. The main components of an IACS cyber security program are presented along with its importance in the overall security scenario. The standards related to cyber security are briefly touched and the areas addressed by these standards are described. In the end, issues of concern are raised along with suggestions to overcome these bottlenecks.

Authors:

Ragnar Schierholz

As the Head of Cyber Security for the Process Automation division, Ragnar Schierholz is responsible for all cyber security aspects in products, projects and services of the ABB division Process Automation. In this role he is a member of the global Cyber Security Team at ABB. Ragnar is a member of various standardization bodies on cyber security for industrial control systems, such as the ISA 99 committee or the IEC TC 65 WG10 and a recognized member of the international industrial control system security community. Ragnar received a Master’s degree in Computer Science from the Western Michigan University in Kalamazoo nd a parallel Master’s degree in Management Information Systems from the University of Paderborn, Germany. Subsequently he earned a PhD degree in Management Information Systems from the University of St.Gallen, Switzerland.

R. Sarangapani

R. Sarangapani is an Additional General Manager in Project Engineering-C&I Dept of NTPC Ltd. in its engineering office, based in Noida. He has been involved in the engineering of many thermal power plants as well as factory testing of many DCS systems/simulators R. Sarangapani is also a team member of the IEC 62443-2-4 standardization team.

DEFENCE IN DEPTH: A MULTI LAYERED APPROACH TO CYBER SECURITY OF IACS

212#

RELIABILITY, SAFETY & SECURITY

150

Abstract:

Reliability of power is the key for a quality service. Wind or solar power generators are remote by nature. You need to monitor and provide service to these renewable energy plants wherever these are located in order increase the efficiency (against initial cost). It is becoming increasingly important for investors and owners of renewable power to monitor and manage Equipment’s in order to improve productivity, reduce maintenance costs and thus ensure that the reliability issues are overcome. In this paper I will share my experience of a applying a holistic approach for remote monitoring and management of a Solar PV Plant with the help of state of art technologies for online diagnostics & monitoring.

Author:

Sarala M Naidu, [email protected]

Sarala M is a Technical Speaclist working in ABB R & D, Bangalore, in the areas of distribution control system automations since 2004. She has done her Bachelor of Engineering in Electrical & Electronics and Master Degree in Computer Science. She is working in the Automation projects for Solar PV and Microgrids with focus on Cyber security and remote monitoring aspects, recently. She is an active participant in local and international Technical Conferences and has authored multiple papers on feasiblities, challenges and approaches of state of art technologies for the Industrial automation scenarios.

REMOTE MANAGEMENT OF GRID CONNECTED SOLAR PV PLANT

220#

RELIABILITY, SAFETY & SECURITY

151

Abstract:

Microgrids is be one of the new trends in the field of Energy. But just as with the main electrical grid, it is important to remember security first. As the reliance on modern communication technology increases (cloud computing, wireless, etc.), power systems are vulnerable to cyber-attacks and hackers. In this paper an overview of the cyber vulnerabilities and an approach for a defense-in-depth at the control system level to support secure microgrid in the utilities, is presented.

Author:

Sarala M Naidu, [email protected]

Sarala M is a Technical Speaclist working in ABB R & D, Bangalore, in the areas of distribution control system automations since 2004. She has done her Bachelor of Engineering in Electrical & Electronics and Master Degree in Computer Science. She is working in the Automation projects for Solar PV and Microgrids with focus on Cyber security and remote monitoring aspects, recently. She is an active participant in local and international Technical Conferences and has authored multiple papers on feasiblities, challenges and approaches of state of art technologies for the Industrial automation scenarios.

PAVING THE WAY TO SMART CYBER SECURITY IN MICROGRIDS

221#

RELIABILITY, SAFETY & SECURITY

152

153

154

155

Abstract:

The constant increase in the share of renewable energies in electricity generation forces coal-fired power plants into operating regimes they originally were not designed for. Instead of working in a largely plannable and thus stable base load operation, power plants now have to feed electricity into the grid with a more flexible mode of operation at precisely the point in time when the renewable energies cannot do it. This compensation for the fluctuating renewable power suppliers not only leads to higher wear of technical components, but also makes totally new demands on the operation of the tried and tested power plants that have been reliable so far. These challenges include increasing the efficiency, reacting to load changes faster and more flexibly, and decreasing minimum loads by stabilizing the combustion, among other things. The better coal-fired power plants master these and other challenges and in addition are able to detect operating problems early on, the more efficiently and flexibly can they follow the peak loads of the renewable energies. The continuous optimization of the combustion by means of an intelligent, self-learning process control (advanced process control) is one contribution to meeting these challenges. It can be supported by an improved process monitoring using specialized sensors. The results that can be achieved by using software solutions in this context are highly convincing.

Author(s)

1) Peter Deeskow ([email protected])

Head, Product Development, System Technologies, STEAG Energy Services Germany

2) Dirk Tiedtke ([email protected])

Head of PiT Group, Tech. Dept., Powitec De, Germany

3) Raja Badsha ([email protected])

DGM, C&I, STEAG Energy Services India

4) Sai Prem Kumar Ayyagari ([email protected])

Formerly Sr. Manager, C&I, STEAG Energy Services India

CASE STUDIES FOR ADVANCED COMBUSTION OPTIMIZATION FOR COAL FIRED POWER PLANTS

11#

AUTOMATION FOR OPTIMISED OPERATIONS

156

Abstract:

Supercritical technology assumes significant importance today in Indian Power Generation sector, especially from the efficiency and environment point of view. Going forward, a significant majority of the new Coal fired plants will adopt this technology.

Background: Supercritical plants deserve different treatment in designing the control systems due the fast response required for its Boiler Closed loop controls. The three major considerations are:

• Fast response time of the DCS to take care of the complex once thru operation of the Boiler

• Safe operation of the process involving high pressure and temperature

• Tight integration to minimize interface time among various control systems

Description: The present paper describes the philosophy adopted and the experience of implementation and operation of a Unified DCS for 2x700 MW Supercritical plant and thereby, how the optimised performance is achieved.

Three major design criteria discussed in this paper are:

• A unified System Architecture for DCS, involving same platform for Boiler, Turbine and Station Control

• Adopting the Functional Grouping in line with BTG OEM’s plant control philosophy

• Using a plant Simulator to conduct an extensive hardware and software FAT to minimize commissioning time

The experience during commissioning is shared with description of critical activities and the reduction achieved in commissioning time / efforts.

A summary of cost-benefit study of the project was done and synopsis is provided to capture the benefits accrued in areas of Hardware, Software, Engineering Resources and commissioning time.

Finally, an excerpt from an interview with the customer is shared where he expressed his views and experience.

Author(s)

Hiranmoy Mukhopadhyay, an engineer by profession has more than 15 years experience in the Control & Automation Industry. Presently heads the Power Generation Vertical for Control & Automation division of L&T. He can be reached at [email protected]

Sharad Agrawal, an engineer by profession has more than 12 years experience in the Control & Automation Industry and presently heads the Engineering of Power Generation Projects for Control & Automation division of L&T. He can be reached at [email protected]

SUPERCRITICAL PLANT DCS: ACHIEVING OPTIMUM PERFORMANCE

46#

AUTOMATION FOR OPTIMISED OPERATIONS

157

Abstract:

The very existence of the smart Grid concept is based on real time data connectivity of the generation systems, the grid, the distribution system and the user. Communications standards are evolving and there is lot of work going on for the unified architecture. The participation of various stakeholders in the future energy systems through standard communication standards is being deliberated and discussed. The two radical standards IEC 61850 and the OPC, are being seen as the most promising for future smart Grid concept. The technical paper examines the various aspects, data models and integration considerations of IEC 61850 with OPC for achieving data integration for the upcoming smart energy systems. The authors have put forward the real examples of data integration of IEC 61850 with OPC DA 2.0 in different projects. The authors have also put forward the integration study of OPC UA with IEC 61850 which shall prove to be an enabler for new vistas for smart systems having multi-agent systems with hierarchical controls, diagnosis and monitoring. OPC UA which can run on multiple systems with remote access across the cloud and supporting complex data structures can be integrated with IEC 61850 to actualize the Smart Electrical Systems.

Author(s)

Saroj Chelluri is presently working as Additional General Manager in Project engineering division of NTPC Limited. She has about 28 years of experience in Electrical design department of NTPC Ltd. She has been involved extensively in electrical systems automation, design of Protection and Controls for auxiliary power supply systems in power plants, including concept designs, preparation of technical specifications, tender engineering, detail engineering, testing, and execution. She has introduced the numerical relay technology and SCADA systems on IEC 61850 in the medium- and low-voltage system automation designs, a first in India. She has authored international papers titled ‘Integration Considerations for Large-Scale IEC 61850 Systems’ presented at Western Power Delivery Conference conducted by Washington State University at Seattle, USA and “Edifying the Smart Future of power Utilities by analysing the benefits of Generation side Virtual Power Plant” presented at the ISA meet at Charlotte, NC, USA and technical paper titled ‘GOOSE Controls for a 3x 800 MW Power Plant’ at POWID organised by Washington State University, Seattle , USA. Saroj is an active council member of ISA Delhi chapter and is holding ‘Membership Chair’. She can be reached at [email protected].

R. Sarangapani works for the largest Power Generation Company In India NTPC Ltd. and serving as Additional General Manager (Engineering). In a career spanning 23 years in the Power Sector, he has mainly worked in the Engineering of Coal fired power Plants from Concept to commissioning. His areas of work broadly include Engineering & Design of Power Plant Control & Automation Systems - For coal fired stations, Engineering of solutions for Renovation & Modernisation of Coal Fired Power Plant I&C Systems, Engineering Management & Project Administration for Power Plant Projects, Business Planning, Monitoring & staffing functions etc. His areas of specialization include Engineering of Thermal Power Station Control & Instrumentation Systems including Plant wide IT integration systems and Renovation & modernisation solutions for such systems, Engineering of Training Simulators for Fossil Power Plants and Engineering of Performance Analysis Diagnosis & Optimisation (PADO) systems for Power Plants. He can be reached at [email protected].

OPC INTEGRATION WITH IEC 61850 FOR POWERING SMART POWER SYSTEMS

58#

AUTOMATION FOR OPTIMISED OPERATIONS

158

Abstract:

Need for efficient stockyard operations and control on coal quality have increased rapidly over the years. The use of advanced automation has become a key success factor in order to establish an efficient, high-quality, stable and competitive supply chain of a thermal power plant. Dry bulk handling equipments like Stacker & Reclaimer, Train/Truck Loading Stations and Ship loader/unloaders can go totally unmanned thereby unleashing the full potential of these equipments. Such a system delivers the capital efficient tonnage. Benefits include:

• Increased throughput

• Maximised output by increasing utilisation

• Utilising excess capacity

• Lower cost tonnes

• Higher returns

• Capital efficient volume growth

This advanced automation technology deploys a 3D laser scanning and RTK-GPS combined with high-level language algorithms. It allows optimization up to an extent that only one operator, placed in a central control room can handle the operations of a complete stockyard. The ROI of such installations were found to be less than 2 years and clients have experienced a significant reduction in maintenance, more homogeneous flow rates, up to 15% higher efficiency, increased quality prediction and of course, reduced operating costs. As a welcome side effect, the high precision stacking was found to lower environmental impact.

The integration of sampling equipments to the above material handling system would be the next wisest decision. Such a sampling system needs to be built on certain basic design principles: (1) Should provide true representative samples, (2) Should be able to provide quality advice of the product, (3) Shall support control over blending, feeding & loading of the product, (4) To provide value addition in business decisions

Author(s)

Senthil Kumaar T is currently working as Manager, Sales & Marketing with FLSmidth Pvt Ltd and is looking after Electrical & Automation project sales in the Material Handling and Mineral Processing sectors. He has about 15 years fo experience in the automation field.

Email Id - [email protected]

Krishnakanth G is currently working as Dy Manager, Sales & Marketing with FLSmidth Pvt Ltd and is looking after sales of Quality & Process Control products in Cement & Mineral sectors. He has about 15 years fo experience in the automation field.

Email Id - [email protected]

ADVANCED AUTOMATION FOR UNMANNED STOCKYARD OPERATIONS & COAL QUALITY

73#

AUTOMATION FOR OPTIMISED OPERATIONS

159

Abstract:

At NTPC Faridabad the ST MMI system (WSPOSE 3.55) was commissioned in the year 2000. By 2012, the components of ST MMI system became obsolete and spare were no more available. It also had the following problems & limitations:

i) The Servers & Workstations had slow CPU with limited memory.

ii) System had problems of recurring communication break between WSPOSE panel and Servers, debugging error etc.

iii) It had non redundant network switch and dependency on physical Functional key Board (FKB) which became obsolete.

It was desired to have a cost effective solution which would eliminate the said problems and retain most of the existing features/ graphics. It was tried to develop server and operating terminals and site C&I was almost successful except few problems such as debugging errors associated with analogue points. Those problems were related with non-compatibility/non-availability of few proprietary software. With these experience site approached the system supplier to jointly develop a solution on similar platform. Initially they were reluctant citing obsolescence of product and non-availability of experts but later on they agreed. Many technical discussions were held with the system supplier and finally a solution was found with new version of existing system. The necessary hardware & software were purchased and the new system with following features has been successfully commissioned:

i) Servers & Workstation: Advanced WSPOSE4.00 platform, latest hardware and software.

ii) Replacement of old rack power supply by a new power supply module which is compact, preset and occupies less space. Communication card & processor card at WSPOSE panel also replaced. System was tested and found successful without any communication break and without debugging errors.

iii) Network redundancy in new system provided.

iv) The software based FKB has been configured to replace the old one. Now all operation; possible through FKB, can be executed through mouse.

v) Additional improvements: No MO-SCSI drive, additional space of the large hard disk is enough for archiving.

Author(s)

Tapeshwar Dayal: B.Tech in Elect. Engg. from IIT, BHU (Formerly IT BHU) Varanasi. Started his career at SAIL, Bokaro as ET in 1985 and worked there for two years. Joined NTPC in 1987 and has worked in plant operation and Controls & Instrumentation deptt in various capacities at Rihand and Faridabad. Currently posted as Additional GM & Head of C&I deptt. at NTPC Faridabad.

He may be reached at [email protected] and Mobile no. 9650994326

UPGRADATION OF STEAM TURBINE MAN MACHINE INTERFACE (STMMI) SYSTEM

83#

AUTOMATION FOR OPTIMISED OPERATIONS

160

Abstract:

Most DDCMIS today requires separate servers or workstations to support different applications. Some systems run one application per server to avoid the risk of vulnerabilities in one application affecting the availability of another application on the same server. The applications are tightly coupled with the hardware. At times, this results in underutilized hardware resources, inflexible and difficult to maintain systems.

Virtualization can help resolves these issue by allowing a single server to simultaneously run multiple operating systems and applications. These solutions can help Automation Industry to reduce PC hardware requirements and minimize the frequency and impact of operating system and hardware changes while simplifying overall system management, improving availability, reliability and disaster recovery. Improved hardware reliability along with virtualization helps build high availability solutions too.

Virtualization can also be used to address issues of hardware obsolescence and software obsolescence where in support for hardware/software may not last for more than 5 years practically.

Conclusion:

In general paradigm shift in the IT industry towards virtualization needs to be extended to DDCMIS offered to get the power and advantage of latest technologies.

Virtualization is penetrating into process automation solutions faster than you think!

Author(s)

1) Prakash D DGM-BHEL Electonics Division, Bangalore

2) Manohar Salimat C AGM-BHEL Electonics Division, Bangalore

3) Anubhav Dwivedi Deputy Manager,PE - C&I| EOC-NTPC

VIRTUALIZATION IN PROCESS CONTROL SYSTEM – POSSIBILITIES AND OPPORTUNITIES

85#

AUTOMATION FOR OPTIMISED OPERATIONS

161

Abstract:

Distributed Control Systems (DCS) are extensively used in power plants for end-to-end plant requirements including control, protections, operation, monitoring, alarms, event analysis, trends and reports. The basic reliability of such a system is an unspoken faith for operation and maintenance executives. This paper discusses network hardening activities, which were necessitated by unique multiple-unit trip incidents involving complete and simultaneous failure of DCS of two interconnected units in a simultaneous manner.

The initiating cause of the DCS failure was a network storm that got initiated in one of the two redundant networks due to an inadvertent loop of five Ethernet switches by design. The paper provides details of comprehensive design validation tests for DCS networks (integrated network tests) carried out by NTPC on an innovative basis to confirm the sturdiness of the upgraded processor firmware and its hardened network against overloads or storms. It also provide details of network hardening measures such as Storm control settings, Multicast/Broadcast filtering in network switches, Loop detection mechanism such as RSTP for removal of inadvertent loop in DCS network, standard procedure for periodic network audits and online network maintenance practices to ensure optimum network performance which is prerequisite for safe and proper functioning of DCS. The paper also brings comparison of network architecture and network settings adopted by different DCS vendors in power plants.

It is emphasized as conclusion that the dual exercise of strengthening processors and networks independently will eliminate all vulnerabilities of any DCS, and safeguard against a complete DCS failure event with a bullet-proof two-tier security

Author(s)

Rajat Roy is presently working as DGM-O&M in NTPC Dadri plant. He joined NTPC in 1995. He can be reached at [email protected].

K. Anoop is presently working as Sr. Manager-O&M in NTPC Rihand Plant. He joined NTPC in 2002. He can be contacted at [email protected].

Amit Kumar Singh is presently working as Deputy Manager in Project Engineering-Control & Instrumentation Department, Engineering Division of NTPC Limited. He joined NTPC in 2008. He can be reached at [email protected]

STRENGTHENING DCS NETWORKS

93#

AUTOMATION FOR OPTIMISED OPERATIONS

162

Abstract:

As there is no energy reserve in the Once Through System, the control system must match exactly and continuously feed water flow and boiler firing rate (both fuel and air). Transient mismatches can be severe, tending to burn out conditions in case of feed water starvation and tending towards positive pressure effects in case of excess feed water. Hence, the feed water control loop needs to be designed to control operation more tightly and to hit and maintain the set points so that the steady state and stable operation, can be achieved without oscillation. This paper analyzes certain issues encountered with feed water control loops in super critical boilers and recommends control tuning to improve boiler dynamics.

Author(s)

Ashok Kumar Panda has done B.E. in Electronics and Telecommunication Engineering from NIT, Silchar and M.Tech from IIT, Delhi. He is presently working in Tata Power as Head, Control & Instrumentation in Core Technology & Diagnostics department. Earlier to Tatapower, he has worked in Lanco EPC division (2008-2012) as HOD, C&I engineering. He had joined NTPC in 1991 as EET and left NTPC at 2008 as Chief Design Engineer in C&I engineering department. Email id: [email protected]

Kumar V Ghate has graduated in Instrumentation from M.I.T, Chennai. He joined Tata Power in, year .1981 and presently working as Head, Instrumentation Maintenance Department in CGPL, Mundra (5x800MW). He has experience in erection, commissioning and maintenance of 500 / 800 MW plants, in Tata Power. He has visited NTPC plants to fine tune the critical control loops. Email id: [email protected]

Kalyan Kumar Panda is Mechanical Engineering graduate from B.E. College, Shibpore and post graduate from IIT, Kharagpur. He joined NTPC as 4th Batch Executive Trainee in the year 1979 and has worked at various levels in Operation and Maintenance departments in different NTPC plants. He was serving as General Manager and Station In-Charge of Kahalgaon plant before leaving NTPC. He joined Lanco in 2007 as Chief Operating Officer and was In-Charge for Engineering, Quality & Knowledge Management. Presently he is working in Tata Power as Vice President & Chief, Core Technology and Diagnostics. In the current role, he is responsible for support to the Operating Stations for operational excellence and technology solutions for critical issues. He has presented technical papers in various forums like Engineering Council, CEA, NTPC O&M Summit, STEAG International Seminar etc. Email id: [email protected].

STUDY AND DESIGN OF FEED WATER CONTROL LOOP FOR SUPER CRITICAL BOILER

102#

AUTOMATION FOR OPTIMISED OPERATIONS

163

Abstract:

The global regulatory focus on reduction of SO2 emissions has led to the adoption of range of Flue Gas Desulfurization (FGD) techniques among others to control them. Protecting the environment from harmful emissions of power plants requires CEMS to be accurate and reliable in long-term operation. The most common sample conditioning systems use Thermoelectric (Peltier) coolers to chill the sample and remove the moisture in the liquid phase. However, it has been shown that accuracy suffers when monitoring SO2 or NO2 as a portion of the sample is lost while the water is condensed. Secondly, such systems have reliability problems as the wet and dirty samples foul sampling lines and cooler elements, making it difficult to achieve good measurements. In this paper, real world experience with sample conditioning systems using Nafion membrane technology is presented that demonstrates their ability to preserve the composition of the gas in hot, wet, and dirty samples and guarantee accurate results over a long service life. This experience provides power plants and refineries the confidence to deploy an effective alternative that both improve measurement accuracy and analyzer reliability.

Author(s)

Gene Bohensky

Gene Bohensky has a BS in Cermanic Engineering from Rutgers University in NJ, USA. He is currently the OEM Sales Manager at Perma Pure, LLC. Email: [email protected]

Harshad Waknis

Harshad has a B.E in Mechanical Engineering from the University of Pune (India) and a Master of Engineering Management Degree from Dartmouth College (USA). He is currently part of the Halma Graduate Leadership Development Programme. Email: [email protected]

IMPROVED CEMS ACCURACY AND RELIABILITY WITH SAMPLE CONDITIONING SYSTEMS USING NAFION TECHNOLOGY

112#

AUTOMATION FOR OPTIMISED OPERATIONS

164

Abstract:

Managing single power stations or entire fleets today requires strong focus on operational efficiency, in particular efficient operation in the control room itself. And there are good reasons why this gains attention again:

The ability to accelerate information handling and decision making, to prevent maloperation and to enable fast and sound troubleshooting is of primary significance when it is required to maintain and even further increase plant availability and profitability under today’s regimes of high-stress, fast-ramp and load change operations.

The suppliers to the power generation industry, especially the manufacturers of power plant control technology, are faced with the demand to provide solutions to these particular challenges. And these challenges even multiply when it comes to the merging of control rooms into single centralized control rooms for entire fleets.

We will use real world examples to describe Siemens’ approach to cope with this:

Clear and easy to understand display of information and advanced alarm management are just examples of what is needed to allow operators mastering the amount of information at maximum efficiency.

Author(s)

Hans-Christian Ostertag, Siemens AG

Head of Market Requirements and Sales Support

Product Management Instrumentation & Controls

Siemens AG

ADVANCED OPERATION TODAY: HOW THE USER INTERFACE BOOSTS OPERATOR EFFICIENCY

119#

AUTOMATION FOR OPTIMISED OPERATIONS

165

Abstract:

Electrostatic Precipitator (ESP) is one of the important pollution control equipment used in thermal power plants for removing particulate matter in flue gas. It is an Electrical Equipment powered by High Voltage Rectifiers (HVR) with suitable ratings depending on the size of ESP. The HVRs are normally placed in ESP rooftop and Power Modules called Electronic Control Panel (EC) are placed in ESP Control Room. For a typical plant, the distance between them is ranging from 200m to 500m. Signals like ESP Current, ESP Voltage and HVR alarms from HVR are interfaced to EC through signal cables, which will run into a maximum of 100KM for typical 96 Field ESP. Similarly, other inputs/outputs like Hopper Heater Status, ALI Status are Rapper Motor control from ESP Fields also consume kilometres of signal cable for interface. Traditionally, such signals are directly interfaced to controllers consuming huge amount of cables. With advancement in wireless communication protocols standards, signal cables are being replaced by cable-less communication by converting signals into communication packets saving huge cost without compromising on reliability and functionality of process. This paper discusses on how a Wireless standard is chosen for ESP application from varieties of Wireless communication standards available. Three widely used Wireless communication standards namely, Bluetooth, Wi-Fi and Zigbee, are compared for suitability for ESP application. ZIGBEE Wireless communication standard was adopted and implemented due to its versatility in meeting reliability requirement and easy implementation methods. This paper also discusses a ZIGBEE PROFILE created for ESP Controllers enabling direct third party support. Operational advantageous and cost savings due to cable elimination and erection and commissioning are also presented for a typical ESP installation.

Author(s)

K.P.Manimala [email protected] has obtained her BE(ECE) followed by ME(Applied Electronics) from College of Engg Guindy, Chennai. She joined BHEL in 1992 as Engineer Trainee. At present she is SDGM and heading Embedded Systems at BHEL, Ranipet. She has vast experience in developing Embedded Electronic controller for Electrostatic Precipitator including single point control monitoring system like Integrated Operated System (IOS) and SCADA based Man Machine Interface (MMI)

V.S.Suresh Kumar [email protected] joined BHEL in 1996 after obtaining his BE(ECE) from College of Engg Guindy, Chennai and ME(Avionics) from Madras Institute of Tech, Chennai. At present, he is Sr.Manager working in Embedded Systems at BHEL, Ranipet. He has vast experience in developing Embedded Electronic controllers for Electrostatic Precipitator including various Communication protocol interfaces for ESP Controllers.

Vivek Philip John, Engineer / BHEL Ranipet. [email protected]. Author has graduated in Electronics and Communication Engineering from Govt. College of Engineering, Kannur in 2010. Joined BHEL in February 2011 as Engineer Trainee. Since then he was involved in development of embedded controllers for ESP control system.

WIRELESS TECHNOLOGY IN ELECTROSTATIC PRECIPITATOR – A METHOD TO OPTIMIZE RESOURCES

131#

AUTOMATION FOR OPTIMISED OPERATIONS

166

Abstract:

For substations above 220 kV including that of HVDC Bi-pole, the grid in India has seen over nine fold addition in terms of MVA/MW capacity in 26 years since the end of the 7th plan period. At the end of the current 12th plan, the capacity of AC substations is projected to be 6,69,801 MVA with another 22,500 MVA coming from HVDC Bi-pole stations [1]. In terms of CAGR this translates into a growth of 8.56% till the end of the 12th plan. With a massive plan of integrating and evacuating renewable energies, this growth in capacity is set to rise during the 13th plan ending in 2022.The demands and expectations of a substation’s operation is continually evolving with the complex flows and the security needs that have come to characterise the modern grid. The evolution of standards have helped to ease many issues relating to engineering, safety, security, self-healing based availability, refurbishments and life-cycle costs. In adopting these standards, the future full digital substation should ideally adapt legacy multi-generational devices. It should be able to build on them to provide new generation technologies required to optimally manage the substation assets as well as play a focal part in supervision and control of the complex grid flows. This article looks at the choices available to the utilities to migrate from conventional technologies and harness the full power of the digital substation, the business case for doing so, and ending with a few case histories.

Author(s)

1. Himadri Endow ([email protected]) holds a B.Sc. (Hons) in Phy and B.Tech & M.Tech in E&C from University of Calcutta. He has been serving the IT, Industrial Auto and T&D market sector for over 32 years in various capacities. Among his professional activities, he has led delivery of many global SCADA/EMS/DMS projs, been involved in managing R&D as well as design/development/management/marketing of many technologies, real time control products/systems & embedded systems. He has served the Govt. of India in senior position before joining Alstom T&D, in 1990. An IEEE member and member of global expert Grp within Alstom Grid, he has written on Smart Grids in international journals and also serves as guest lecturer at prestigious Tech/Management Institutes. He has led Smart Grid activities at Alstom Grid in India/East-Asia/Middle-East regions and is currently responsible for India & South Asia.

2. Ritesh Bharat ([email protected]) obtained B.E (Electrical) in 1994 from National Institute of Technology, Bhopal. He is presently working as DGM & Head of Protection Apps at Alstom Grid Substation Auto Solutions group in India. He started his career as a Proj Engineer at a Waste Heat Recovery Boiler & Thermal Power Plant in Chhattisgarh. He then joined Alstom P&C div and commissioned many protection schemes in India/China/Thailand/Iran/Qatar. In 2003, he migrated to Australia & New Zealand to work for a Consulting firm providing design services to EHV clients. Ritesh has presented technical papers on protection algorithms, NCITs and super conductors in national & international forums.

3. Purshottam Kalky ([email protected]) obtained a B.E (Electrical) in 2003 from Delhi College of Engineering. He started his career as engineer in Desein Pvt Ltd before moving to Alstom in 2005. He currently works as a Senior Manager and involved in the design of substations upto 1200 kV. A member of IEEE & CIGRE he has been associated in the design of India’s first 765 kV substation at NTPC Sipat.

SUBSTATION AUTOMATION – THE PUSH FROM CONVENTIONAL TO FULL DIGITAL TECHNOLOGIES – BENEFITS & CHOICE BEFORE UTILITIES

134#

AUTOMATION FOR OPTIMISED OPERATIONS

167

Abstract:

Why optimize boiler combustion.??

To lower the Green House Gases (GHG) Emissions, specifically targeting the SOx, NOx and CO2 reduction & better boiler efficiency and Heat Rate, this directly translates in an economic benefit attached to the Fuel Savings. Faster Dispatch Rate – With Less Equipment Stress

The Boiler Optimization Functions allow the adaptive approach that overcomes barriers to successful advanced process control in boiler optimization by accounting for unique behaviors in the basic automation, as well as in advanced schemes for boiler operation. It allows the plant’s advanced control system, which is sometimes referred to as a combustion optimization system, to compensate for changes in the way pulverized coal is introduced into a coal-fired boiler and to accordingly control the changing effects in the boiler. Performance Diagnosis Analysis and Optimization (PADO) brings in the capability of building Offline and Online models using Thermodynamics first principle based models. It incorporates numerous capabilities to provide essential services for several levels of the power generating enterprise, including:

• Automated revenue calculations & Real-time plant-level cost information for the power trading floor

• Intelligent data filtering to turn data into meaningful information and Automated report generation and distribution throughout the enterprise.

Techniques such as modeling (both empirical- and first principle-based); optimization through the use of linear programming and non-linear programming techniques; soft sensors; model predictive control; neural nets; and fuzzy logic which are components of Advance Process Controls (APC) have been effective in the power industry. APC with PADO enables power plants to leverage the best technologies used for process controls and performance optimization.

Author(s)

Tandon Oberoi is working as a Technical Sales Consultant with Schneider Electric/Invensys and takes care of technologies for Design, Simulation and Optimization software portfolio for India region. Has about 10 years of experience in Power and Hydrocarbons Simulation operations and simulations. He can be reached at [email protected].

ADVANCE PROCESS CONTROLS WITH PERFORMANCE DIAGNOSIS ANALYSIS & OPTIMIZATION

135#

AUTOMATION FOR OPTIMISED OPERATIONS

168

Abstract:

The success of IEC 61850 so far can be attributed to the goals set by the standard namely- interoperability, free configuration and long term stability. When IEC 61850 standard was introduced in 2003, the focus has been on commercial implementation towards IEC 61850-8-1 station bus. IEC 61850-9-2 process bus was not much talked about mainly due to non-availability of supporting devices in the market. In 2004 UCA International Users Group came out with Implementation guideline for digital interface to Instrument Transformers using IEC 61850-9-2. The main purpose of this guideline is to speed up the implementation of process bus standard using interfaces (Merging Unit) to non-conventional Instrument Transformers. This guideline is popularly known as IEC 61850-9-2LE (LE stands for Light Edition).

Today most of the major manufactures have IEDs and merging units ready to support process bus implementation using IEC 61850-9-2 in substations. It is now time for power utilities to benefit from process bus technology. Utilities who have already implemented station bus based on IEC 61850-8-1 standard, to reap full benefits of the standard it is obvious for them to implement process bus based on IEC 61850-9-2 and for those utilities who have not implemented station bus it is time to start implementing both.

This paper discusses process bus concepts, process bus solution in general, specific process bus solution that can be implemented without changing the classical protection philosophies that are followed by the utilities and the solution for fully digital substation using IEC 61850-9-2. This paper further discusses the approach for implementation of process bus for new and existing installations and concludes with benefits of process bus implementation.

Author(s)

Girish MV ([email protected]) graduated in Electrical Engineering. He has more than 19 years of experience in design, engineering and commissioning of Control, Protection and Automation systems for transmission and distribution substations. He has been with ABB since 2004, prior to that he worked with GE and he was instrumental in designing some of their first substation protection and control systems in India. He is presently working as Assistant Vice President -Technology - Substation Automation Systems of ABB India. Prior to that he worked with ABB R&D center as Technical Product Manager. He was a team member who designed and engineered the first IEC 61850 based Substation Automation System in India for 400kV/220kV Powergrid, Maharanibagh substations in 2005. In 2009, he was involved in testing products using IEC 61850-9-2LE process bus technology in UCA accredited lab of ABB Switzerland. He is a member of the National Study Committee B5 (Protection and Substation Automation) of CIGRE in India

Bhargav NV ([email protected]) graduated in Electrical Engineering. He has 7 years of experience in engineering and commissioning of Substation Automation Systems and development of Substation Automation products for transmission and distribution substations. He has been with ABB since 2007. He was recently involved in testing of products using process bus technology at ABB R&D center. He is currently working in engineering department of Substation Automation Systems of ABB India.

MOVING TOWARDS PROCESS BUS IN SUBSTATIONS

138#

AUTOMATION FOR OPTIMISED OPERATIONS

169

Abstract:

The control of Boiler, Turbine and Generator (BTG), that is, major equipment in Power Plant was operated separately by different and separate control systems which were supplied by different manufacturer till now, but this paper describes development and site validation of Integrated Monitoring and Control System (IMCS) based on common platform, which can monitor and control BTG overall.

The different control system was applied at Power plant till now because characteristics such as response time and redundancy conditions depending on BTG were different, but this paper shows that IMCS based on common platform was developed to be suitable for all BTG with different characteristic. IMCS was designed to be flexible system architecture capable of installing single, dual redundancy or triple redundancy conditions, response time, data loss-free communication and changing of response time setting, etc., so differentiated with existing controller.

And IMCS implemented by design guide shows that module test and combined function test were successful, such as test of loopback, Dual and Triple modular redundancy test, etc., so that function, performance and fault tolerance were satisfactory. Finally, installation and commissioning test at 500MW thermal power plant in Korea shows that SAT and 240-hours reliability operation test were successful and tuning stability performance on output fluctuation was improved.

Author(s)

Yunjae Choi ([email protected])

Senior Engineer, Control System Research Team,

Corporate R&D Institute, Doosan Heavy Industries & Construction

Seungmin Kim (Seungmin.Kim @doosan.com)

Principal Engineer, Control System Research Team,

Corporate R&D Institute, Doosan Heavy Industries & Construction

Simkyun Yook ([email protected])

Control System Research Team Leader,

Corporate R&D Institute, Doosan Heavy Industries & Construction

A STUDY AND VALIDATION OF IMCS WITH COMMON PLATFORM FOR BTG IN POWER PLANT

143#

AUTOMATION FOR OPTIMISED OPERATIONS

170

Abstract:

GUARDIAN control system for power plants was developed under five-year localization development project funded by Korea government. It consists of control subsystems for boiler, turbine and generator, which are based on a single platform for enhanced maintenance and efficient operation. Each controller’s network is provided with dual and triple modular redundancy for safety and flexibility. Special I/O modules are provided for signals from turbine and generator, where very fast and independent process is required. The system was installed at a 500MW thermal power plant in Taean, Korea, and has been in commercial operation since 2012.

Author(s)

Jayhyuk Choi ([email protected]) is a Research Engineer of Doosan Heavy Industires. He received his B.S. and M.S. degrees in Aerospace Engineering from KAIST (Korea Advanced Institute of Science and Technology), Daejeon, Korea, in 2010 and 2012, respectively. His current research interests include control logic standardization and fast start optimizer for large steam turbines.

Hyunwoo Son ([email protected]) is a Research Engineer of Doosan Heavy Industires. He received his B.S. degree in Electrical Engineering from Kyungpook National University, Daegu, Korea, in 2007, and his M.S. degrees in Mechanical Engineering from KAIST, Daejeon, Korea, in 2009. His current research interests include control logic basic design for small steam turbines and and fast start optimizer for large steam turbines

Seongjin Hong ([email protected]) is a Senior Research Engineer of Doosan Heavy Industires. He received his B.S. and M.S. Degrees in Mechanical Engineering from Pusan National University, Busan, Korea, in 1997 and 1999, respectively. His current research interests include control system for large gas turbine.

Sungho Kim ([email protected]) is a Principal Research Engineer of Doosan Heavy Industries. He received his B.S. and M.S. Degree in Mechanical Engineering from Yeungnam University, Kyoungsan, Korea, in 1991, and from Kyungpook University, Daegu, Korea, in 1995, respectively. He is currently leading the Process Control Research Team, Corporate R&D Institute.

DEVELOPMENT AND IMPLICATION OF TURBINE CONTROL SYSTEM GUARDIAN-T FOR LARGE THERMAL POWER PLANT

149#

AUTOMATION FOR OPTIMISED OPERATIONS

171

Abstract:

Ethernet communications, which was proven and widely accepted in domestic and industrial applications, has started taking root in substation and power-plant environment in last decade. IEC61850 implementation by IED vendors has dramatically changed the concept of protection, control and monitoring of substations, with its goals of promoting interoperability and long term stability, and its extensive modelling of power system components. Another innovation of the standard is IEC 61850-9-2, which facilitates digitization at the primary equipment level. With both IEC61850-8-1 and IEC61850-9-2, comes the possibility of less complex, reliable, easy to maintain and safe substation environment, combined with operational efficiency. Wide Area Monitoring based on IEEE C37.118-2 is also getting attention in grid utilities, particularly in complex grids and where, end users who have had to face power blackouts. Vendors and customers have started exploring the possibility to integrate WAMS based Special Protection and Control systems with the Substation Automation System. Such integration contributes to a more reliable, self-healing and pro-active grid environment.

This paper explores the possibilities of above mentioned communication technologies, in the context of power plants and substations.

Author(s)

1. Abraham VARGHESE ([email protected])

Abraham Varghese is currently the Head of Product Applications for Substation Automation Solutions (SAS) business in ALSTOM GRID, with responsibility for worldwide application support on the full portfolio of substation protection IEDs. He is based in ALSTOM GRID’s Centre of Excellence for Protection in Stafford, U.K. for the past seven years. During his tenure at Stafford, he contributed to a number of developments in the domain of Digital Substations, in particular the MiCOM relays with IEC 61850-9-2LE interface and the Analogue Merging Unit.

Abraham has been active in power system protection domain for more than two decades across various functions - Business Development, Subject Matter Expert (Automation), Engineering and Services. He holds a Ph. D. in Electrical Engineering from the Univ. of Illinois at Urbana-Champaign, U.S.A., and is a Senior Member of the IEEE, U.S.A. Abraham is also active in CIGRE Committee B5, and is the lead for the annual APPS (Analysis & Protection of Power Systems) training program held at ALSTOM GRID, Stafford

2. Sukumaran SUNISH ([email protected])

Sunish – An engineering graduate with a domain experience of more than 15 years. He has a total of more than 10 years of association with Alstom. His areas of expertise in the Substation Automation are Testing & Commissioning, Product Application Support, Design Engineering, Product Marketing etc. He has done paper presentation at various forums such as GRIDTECH, GETCO, DOBLE etc. Presently, he is heading Supra Regional Application activity, under the umbrella of Global Product Application.

MODERN COMMUNICATION TECHNOLOGIES AND POWER PLANT EFFICIENCY

159#

AUTOMATION FOR OPTIMISED OPERATIONS

172

Abstract:

Over the years, process control technologies for Power Plant applications have controlled different sections and applications, discretely. In recent years, with the advancement of technology, DCS systems are evolving towards integrated architecture – resulting in new applications, greater operational efficiency, advanced diagnostics features, and next-generation optimization tools and techniques.

Wireless is another indispensable technology which finds multiple applications in next generation power plants. It offers process improvement opportunities by making possible measurement and control, hitherto deterred by remote locations, physical obstructions and barriers, and high cost of engineering and integrating technology. Application of wireless at power plants can reduce installation and maintenance costs and improve predictive intelligence.

This paper will elucidate the latest trends in DCS technology, Wireless and Predictive technology which will form the automation solution for next generation power station.

Author(s)

Suhas Bhide,

Director, Wireless

Emerson Process Management India

[email protected]

Manoj Dubey

Assistant Director, Power and Water Solutions.

Emerson Process Management India

[email protected]

AUTOMATION SOLUTIONS FOR NEXT GENERATION POWER STATIONS

164#

AUTOMATION FOR OPTIMISED OPERATIONS

173

Abstract:

Today, and over the next few decades, electricity generation represents the largest driver of demand for energy. The fundamental problem with electricity generation is that demand for electricity does not remain constant and fluctuations in load occur which leads to not all generation capacity being fully utilized all of the time.

This paper examines a concept called Real Time Performance Management, which address broader paradigm of excellence and can be primarily categorized under three disciplines:

• Discipline of Engagement to assess business units, assets, costs, and processes according to real-time and predictive metrics - Performance Excellence

• Discipline of Integrity to control variations in asset performances and processes enabling continuous cost & energy improvements - Operational Excellence

• Discipline of Institutionalization of value chains & operating models for productive turnarounds against deviations or non-conformities - Process Excellence

A substantial gap exists between the actual and potential performance in the Power Sector. Variation of performance due to Technology/mode of operation is attributed around at 20-25% and Human factors/management makes up the remaining 75-80%. A unified approach bridging the gap across process, production & business control can help substantially improve net fuel efficiency, curtail O&M cost , better start-up & synchronize time, and efficient emission management.

As technology increases in complexity and management requirements become more challenging, it becomes important to have a flexible framework to help process the data, analyze it, visualize it, and make it available in the best form for end users according to their roles. Real Time Performance Management concepts lay guidelines to enabling that vision”

Author(s)

Mr. Asish Adhikari –Director, Industry Solutions, Schneider-Electric

E: [email protected]; [email protected]

Asish is currently the Global Director of Industry Solutions. Primary responsibilities include directions for industry solutions, extending product portfolio thru M & A, proliferation into specific regions focusing on product mix revenue, leveraging direct & indirect sales channel. Asish has around 18 years of expereince in the field of Manufacturing Operations Management and Consultancy. Asish holds a bachletor degree in Chemical Engineering.

REAL TIME PERFORMANCE MANAGEMENT [RTPM] FRAMEWORK CONCEPTS FOR POWER GENERATION INDUSTRY

168#

AUTOMATION FOR OPTIMISED OPERATIONS

174

Abstract:

Power Utility Industry is of utmost importance to the development of the Indian economy and to meet the infrastructure growth plans of the new populist government. The last ten years, have seen an unprecedented growth of power capacity in India, with several new large size super-critical power stations being set-up across the nation.

Several of these new power stations have adopted the supercritical power plant technology, with higher efficiencies and lower greenhouse gas emissions to meet the growing demands for power whilst reducing the impact on the environment.

Utilizing the state of the art new Automation solutions, the power plants are able to achieve higher levels of automation with inherent high reliability and availability of the units with the latest control systems. In addition to this utilizing Operator training simulator the plant operators can achieve higher level of operations utilizing the simulator acorss the plant life cycle from design all the way to commissioning and then training of their personell.

Author(s)

Rahul Nargotra – Director Power Industry Asia Pacific – Schneider Electric

Having graduated from India in 1994, Rahul worked in different organizations from engineering, project management, site commissioning and Sales and Marketing for Power Projects in the Asia Pacific region. 20years of experience in the Utilities Industries across Asia Pacific regions with special exposure to China, South Korea and Indian power markets.

Excellent exposure to the Asia Pacific Regional Markets for Product Promotional campaigns and Product Sales for the power automation Industry. Supported and organized several Product Launches, branding and large theme seminars and presentations across the region, on regional and country basis. Technical Presentations and system demonstrations. He spent two years in China from 2006 to 2008, based out of Nanjing to get a great exposure of the large China Power Automation industry.

Email: [email protected]

Mr. Kuldip Pahuja – Sales manager India –Schneider Electric

Email: [email protected]

ACHIEVING OPERATIONAL EXCELLENCE BY INNOVATIVE AUTOMATION AND OPTIMIZATION SOLUTIONS FOR POWER PLANTS

177#

AUTOMATION FOR OPTIMISED OPERATIONS

175

Abstract:

Complete control over coal handling, active blending and homogenization can significantly cutoff losses caused by unstable coal quality and subsequent problems with boiler operation and performance. Enelex is a solution partner in online coal ash analysis, moisture and calorific value, sampling equipment, safety systems, thermal monitoring and boiler operation monitoring. The company has long-term experience in design of turnkey customized Coal Quality Management Systems and has successful projects within Europe and Asia, nowadays starting activities in South Africa and India.

The procedure for coal quality management does not only check the coal quality, it also gives the operator the opportunity to affect the coal quality during the process which means the intended coal quality can be reached smoothly, during normal operation and without extra costs.

Coal Quality Management System has to receive the information on expected input material parameters to prepare the plans, usually the average parameters of coal received. The more detailed information is provided, the more exact are the plans. It has to be mentioned that properly designed system should be able to handle the coal quality even in case the coal quality expectations are not correct. Other input information utilized is the feedback data from the laboratory analysis of the coal. The data from the laboratory usually don’t come on time to be used as an input for operational management but it is always used to verify the online measurement and system maintenance as well.

Author(s)

Viktor Valenta, [email protected]

Education: Machinery Engineering and Automation, Degree in Computer Technologies

Professional: Since 2004 design and testing of on-line ashmeters, thermal monitoring systems and oxygen analyzers in Enelex company, present position: Director Technical Responsibility for product innovation, technical participation on development of Coal Quality Management systems and application of on-line coal analysis

Speaker at conferences:

• Southern African Coal Processing Society Conference, Secunda, South Africa, July 23-25, 2013

• NTPC O&M Conference „Indian Power Stations“ – 2014, New Delhi, India, Feb 13-15, 2014

ONLINE PROCESS OPTIMIZATION OF COAL HANDLING PLANT

178#

AUTOMATION FOR OPTIMISED OPERATIONS

176

Abstract:

Arrival of new technologies in any area, always brings good things and new features to life. However it also brings in, the issue of obsolescence of the existing technologies. The introduction of computers into power plant controls have exposed most of our power plants to this risk of either hardware or software obsolescence. The recent announcement of Microsoft for discontinuing support for Windows XP operating system has created a new risk of obsolescence for all DCS systems presently operating on Windows XP OS. Dealing with DCS system obsolescence is becoming a major challenge for NTPC. While the wholesale replacement of obsolete DCS system should be the last resort for dealing with system obsolescence, virtualisation could be a cost-effective alternate solution. Virtualisation will allow us to retain DCS systems that still provide business benefits. Operation and maintenance staff will see no difference between legacy system and the new systems built on virtualisation technology. The concept of Virtualisation has been implemented successfully in the 660 MW simulators at PMI by creating a virtual Windows XP environment on Windows 8 operating system. The Yokogawa Centum CS3000 which can be installed only on Windows XP is currently running on Windows 8 machine. The virtualisation software used for the purpose is VMWare. This paper discusses the advantages and issues faced during the virtualisation process in addition to the generic concept of virtualisation. Virtualisation can also be tried as a solution to overcome the risk of obsolescence faced by NTPC plants on DCS systems based on other Windows Operating System like Windows NT, Windows 2000 etc , before jumping on to the rip and replace solution. Presently we have proven the virtualisation solution only on TCP / IP based networks and usage of this solution on proprietary protocol based networks is yet to be proven. This paper also discusses the various options, opportunities, challenges and limitations of this concept.

Author(s)

Kasa Venkateswara Prasad completed his BE in Electronics and communication from Vinayaka Missions Engineering College, Salem and MS(Electronics and Control) from BITS, Pilani. He joined NTPC as a 18th batch EET. He is presently working as a Sr. Faculty Member in Power Management Institute, and he has also worked in TSTPS commissioning and maintenance at 6x500 MW and can be contacted at [email protected].

9650997388 (M)

Vikash Kumar Malhotra has completed his B.E. (Electrical) from NIT-Jaipur and PGDBM from IIM-Lucknow. He is presently working as a Sr. Faculty Member in Power Management Institute, Noida. He can be contacted at [email protected], 9650992433 (M)

Rahul Sahu has completed B.E (Elex. & Instr.) from S.G.S.I.T.S, Indore. He is presently working as a faculty member in Power Management Institute, Noida. He can be contacted at [email protected], 9650998206 (M)

VIRTUALISATION: A STRATEGY TO MANAGE CONTROL SYSTEM OBSOLESCENCE (A CASE STUDY OF 660 MW SIMULATOR)

186#

AUTOMATION FOR OPTIMISED OPERATIONS

177

Abstract:

To minimize controllable losses tied to feedwater heater performance by gaining additional insight into the basic feedwater heater and power cycle operations; associated performance indicators and the positive or negative impact of level control on overall plant efficiency as related to net unit heat rate and cost containment.

Author(s)

DONALD HITE

BUSINESS DEV. MGR. - POWER INDUSTRY

Magnetrol International, Inc.

Donald Hite has 30 years of instrumentation background and experience acquired through past employment with the U.S. Air Force, Honeywell, Thermo Scientific and his most recent ten years Magnetrol International and Orion Instruments. He provides technical expertise and training to customers on the best practices for optimizing critical power plant applications using advanced radar technologies. As a complement to his studies in Computer Science at the University of Southern Mississippi, Donald is a certified Master Instructor who has designed and conducted technical training courses on Inertial and Radar Navigation Systems; Level Measurement and Control Technologies; Data Acquisition and Management Processes; and Heat Rate and Feedwater Heater Level Control for clients worldwide.

HEAT RATE AND FEEDWATER LEVEL CONTROL

194#

AUTOMATION FOR OPTIMISED OPERATIONS

178

Abstract:

Unit Control or Coordinated Master Control (CMC) Scheme in Coal/Fossil Fired Power Plants synchronizes the boiler and turbine operation to meet the load demand set by the Operator or by Automatic Dispatch Centre (ADC). It continuously coordinates with thermal limitation and capabilities of Boiler and Turbine to achieve desired load at optimum heat rate with minimal operator intervention. CMC mode comes into action when all the lower level controls in Turbine and Boiler are in Auto. Since water & steam characteristics vary to a large extent during operation of super critical units, the boiler response/dynamics becomes a complex multi-variable function. In super critical boiler, during implementation of Unit control, various aspects & response of boiler and turbine to be taken care, to ensure optimized and sustained operation of the Unit. The major aspects are:

• Wet to Dry Mode Transition -Transfer from wet to dry has to be smooth as it may lead to high temperature in boiler tubes in upper evaporator zone and which in turn may lead to tube failures, toggling between Dry to Wet mode of operation, which may lead to high separator storage tank level.

• Fuel to FW Ratio Control - Fuel to FW ratio shall be optimal and any change in ratio beyond the permissible range will lead to either lower flow through evaporator tubes or lower steam temperatures at SH outlet.

• FW Flow Control - Control of feed water flow during change over from DP to Flow control, Recirculation valve opening/closing of MDBFP, MDBFP to TDBFP changeover. Further it is also to be ensured that sufficient operating margin is maintained in changeover of DP to Flow control and Wet to Dry mode transition in Boiler.

• HP Bypass Control - Selection of Fixed position control and Pressure control, Pressure ramp control during unit start-up/stabilization and large load throw-off.

Author(s)

Bhupesh Kumar Gupta is presently working as Manager in Project Engineering-Control & Instrumentation Department, Engineering Division of NTPC Limited. He joined NTPC in 2004. He can be reached at [email protected].

Ashish Kumar Sahu is presently working as Deputy Manager in Project Engineering-Control & Instrumentation Department, Engineering Division of NTPC Limited. He joined NTPC in 2008. He can be contacted at [email protected].

Tarun Garg is presently working as Deputy Manager in Project Engineering-Control & Instrumentation Department, Engineering Division of NTPC Limited. He joined NTPC in 2008. He can be reached at [email protected].

Bottlenecks in Implementation of Unit Control for Super Critical Units

195#

AUTOMATION FOR OPTIMISED OPERATIONS

179

Abstract:

Economic Load dispatch ELD referred Merit order rating is old problem but still extensively researched by technical community. IPP with multiple units using ELD tools since long time are mostly lost in time with old rigid assumptions which cannot meet demand dictated by current scenarios lime fuel supply issues and power system operator reducing control time scale.

In this paper we propose a computational tool that helps IPP with load dispatch among units capable to catch up with demand set by power system operator. Business environment development adds constraints to load dispatch like fuel supply, Right time load dispatch as computational platform that helps to manage fuel constraints and equipment constraints. Right time load dispatch integrated with business system can be powerful tool more for fuel management team than power plant operation team.

Investment on analytical computational tools which can do online and offline analysis help to decide in right time to carry out load dispatch to clusterd units in networked region or multiple units in station. This tool can help IPPs to leverage data to increase MW generated with lower marginal cost per MW.

Author(s)

Sudershan S

Performance Optimization-Power & Water Solutions- Emerson Process Management Pte Ltd,Singapore. Working With Emerson Process Manamement ,Power and Water Solutions in area of Power plant process optimization. Started working experinece in NTPC Ltd till 2007 ,currently works from Singapore and leads optimization of power plant in Asia Pacific region (email:[email protected])

SK Marrtinluthur

Performance Optimization-Power & Water Solutions Emerson Process Management India Ltd, Noida. Working with Emerson process management,Pwoer and Water solutions,India. Leads role of model b ased performnce analysis and power plant optimization. (email: [email protected]

RIGHT TIME LOAD DISPATCH

204#

AUTOMATION FOR OPTIMISED OPERATIONS

180

Abstract:

Large substations often have complex and dynamic topologies. The voltage available on either side of an open breaker may originate from a number of sources. This has led to the development of centralized systems to carry out synchronism-check functions to synchronize all breakers within the substation. Such a system uses the status of breakers and disconnects to identify a voltage source for each side of the breaker that is to be synchronized. Custom logic is required to accommodate the topology of a particular substation. In the past, these systems have been realized using custom hardware or programmable logic controllers (PLCs) and significant amounts of wiring. This paper describes in detail a synchrophasor-based approach that provides a significant reduction in the effort and cost required to design, build, and test a centralized synchronizing system. Phasor measurement and control units (PMCUs) transmit voltage phasors and breaker and disconnect status to a central controller. The central controller time-aligns the data and selects the correct voltages to use for synchronizing according to the present status of the breakers and disconnects. Once the appropriate checks of the voltages are made, a close command is sent from the central controller to the PMCU responsible for the breaker that is to be closed. A primary objective is to reduce the requirement for custom logic as much as possible. The design relies heavily on using the program organizational units (POUs) described in IEC 61131. These can be developed, tested, write-protected by passwords, and easily reused in subsequent projects.

The synchrophasor-based approach proposed in this paper is also applicable when synchronizing two power sources. This usually entails controlling voltage magnitude and frequency in one island, whereas synchronism check does not carry out voltage or frequency control. The scheme described in this paper is applicable to synchronism check and can be extended to support synchronizing two islands.

Author(s)

Dale Finney is a senior power engineer with Schweitzer Engineering Laboratories, Inc.

Mangapathirao (Venkat) Mynam is a senior research engineer with Schweitzer Engineering Laboratories, Inc.

Marcos Donolo is a lead research engineer with Schweitzer Engineering Laboratories, Inc.

Amy Sinclair is a field application engineer with Schweitzer Engineering Laboratories, Inc.

The authors can be contacted at [email protected].

DESIGN OF A CENTRALIZED SUBSTATION SYNCHRONIZING SYSTEM

213#

AUTOMATION FOR OPTIMISED OPERATIONS

181

Abstract:

The communications standard IEC 61850-5 identifies fast messages that perform high-speed automation, protection, and interlocking to meet or exceed a transmission time of 3 milliseconds as Type 1A, Performance Class P2/P3. Modern microprocessor-based devices and Ethernet networks routinely meet this requirement when everything is working as expected. One of the most important acceptance criteria (and perhaps least understood) is the maximum transmission time when unexpected things do happen and messages are delayed. Because not all paths in an Ethernet network perform the same, this paper introduces path performance classifications that illustrate the minimum and maximum transfer times between two devices.

The telecommunications performance standard IEC 60834-1 is commonly used to evaluate point-to-point high-speed automation and interlocking. It describes the overall operating time between the instant of the change of state at the command input on the source device and the instant of the change of state at the command output on the destination device. This includes propagation time and any additional delays. IEC 60834-1 further defines transmission dependability as the ability to receive each command message within the fixed actual transmission time defined by the application, in this case 3 milliseconds.

IEC 61850-5 specifically states that testing and verification of the complete transfer time must be performed during site acceptance testing using the physical devices and network equipment. Methods to test and validate message transmission during normal Ethernet packet delivery as well as during path failure are introduced in this paper based on both Rapid Spanning Tree Protocol (RSTP) and Parallel Redundancy Protocol (PRP).

Author(s)

Saroj Chelluri is working as Additional general manager in the project engineering division of NTPC Limited.

David Dolezilek is a research and development technology director with Schweitzer Engineering Laboratories, Inc.

Jason Dearien is a senior software engineer with Schweitzer Engineering Laboratories, Inc.

Amandeep Kalra is an automation engineer with Schweitzer Engineering Laboratories, Inc.

The authors can be contacted at [email protected].

DESIGN AND VALIDATION PRACTICES FOR ETHERNET NETWORKS TO SUPPORT AUTOMATION AND CONTROL APPLICATIONS

215#

AUTOMATION FOR OPTIMISED OPERATIONS

182

ADVANCED COMPUTATIONS AND SOFTWARE TOOLS

Abstarct:

Modern process industries and power plants have an extensive electrical distribution system to provide reliable power to equipment. Nowadays generally paralleling of transformers is done to reduce electrical losses, improve power quality and increase reliability which results in higher fault levels and withstand capacity (> 150 kA).

When a low voltage circuit breaker interrupts a fault current in the electrical circuit, an arc is established between the contacts of the breaker which must be extinguished efficiently. Behavior of this arc is governed by the interaction of Electric, Magnetic, Thermal and Flow field.

Experimental study for any changes in design to enhance the interruption capability becomes tedious and so an approach of modeling the phenomenon in CAE domain has become a topic of interest. The commercial CFD tool FLUENT is used for simulation of arcing phenomena in LV circuit breaker. CFD helps us in the visualization of the temperature, pressure and flow field, which otherwise is very difficult due to highly irradiating nature of arc.

This paper focuses on the CFD study of an arc behavior which is greatly influenced by peripheral ablative materials controlling movement and temperature of the arc, arc chamber geometry by optimizing de-ion plate profile and its orientation and venting arrangements by effective deionization, filtering to achieve optimized exit clearances. Increase in the arc voltage plays a major role in the arc quenching and hence detailed arc root phenomena are modeled.

Author(s)

Amol Kale M.Tech (Mechanical), Manager - Technology Upgradation Switchgear Design & Development Center Electrical & Automation, Larsen & Toubro Ltd., Mumbai Mail : [email protected]

Abhimanyu Singh B.E. (Mechanical), Assistant Manager - Technology Upgradation Switchgear Design & Development Center Electrical & Automation, Larsen & Toubro Ltd., Mumbai Mail : [email protected]

CFD ANALYSIS TO STUDY ARC BEHAVIOUR IN LOW VOLTAGE SWITCHGEAR FOR EFFICIENT ARC QUENCHING

30#

183

Abstarct:

Innovation in critical technology, efficiency improvement designs, new materials, etc. is a focus for every power & energy company. However, in order to remain competitive, Total Cost of Ownership (TCO) plays a key role over the entire Plant Life Cycle and hence efficient plant engineering, process optimization, concurrent workflows, managing complex data and extracting intelligent information becomes critical.

Increase in complexity of plants, volume & redundancy of engineering data (especially in power plants) demands for a process driven integrated technology which would enhance engineering efficiency across the plant life cycle from planning, through design, engineering & construction and up to maintenance phases.

iPIM is slated to bring a paradigm shift to help power plant owners and designers to do its project planning, cost estimation and coordinated design by working on an integrated database of Intelligent Objects. iPIM with its technology platform CADISON helps in developing a 3D model with engineering attributes providing intelligence across every phase and creating standard BTG & balance of plant (BOP) packages improving reusability, standardization and harmonization of engineering data.

Author(s)

Mr.Ajit Joshi (President - Neilsoft Limited),Mr.Ajit is a global business leader with an international career spanning over 23 years in the field of Engineering, CAX, PLM and Manufacturing IT solutions. He has worked with leading software product development as well as IT and Engineering services companies in key leadership roles, working closely with customers as well as teams, across North America, Europe and Asia. Ajit has extensive global experience in the areas of business management, customer relationship management, business development, marketing, sales, operations, strategy planning, global delivery, quality and R & D. (Email : [email protected])

Mr.Praveen Kapse (Global Marketing Manager- Neilsoft Limited),Mr. Praveen Kapse specializes in global marketing of design engineering services and solutions. He has 14 years of rich experience in strategic marketing, global market analysis, in depth research and knowledge in various engineering areas like design, plant engineering, CAD software solutions for various industries. Praveen has global experience in the areas of Go To Market strategies, Business development, Marketing for engineering products and solutions. (Email : [email protected]

INTELLIGENT PLANT INFORMATION MODELLING (IPIM)-A FUTURISTIC TECHNOLOGY IMPROVING ENGINERING EFFICIENCY OF PLANTS BY 30%

ADVANCED COMPUTATIONS AND SOFTWARE TOOLS

41#

184

Abstarct:

Pneumatic Conveying of solid particles plays an important role in coal and ash handling units of thermal power plants and depending on the application, it could have high or low loading of solids. Information about flow regimes and pressure drop is very crucial in designing and operating these transport units. CFD combined with Discrete Element Model can be used to model these processes as well as equipment.

In case of dilute phase, particle-particle interactions are usually negligible and are, hence, neglected while modeling. In case of dense phase, DEM can be used to take into account these interactions and increase the accuracy of predictions. With DEM, all forces related to particle-particle, particle-fluid, and particle-wall are modeled in detail. Effect and variation in these forces as regimes change is also taken into account.

Regimes, such as slug flow, which is characterized by very less presence of air and wherein solids move in a fashion similar to a moving fixed bed, can also be simulated using this method. In this case, interactions between fluid-particle can be neglected. Current work deals with this particular regime of interest wherein a transient simulation has been run for sufficient amount of time to predict phase transition to slug flow.

Author(s)

Mr. Vinod Dhiman, currently employed as Sr.Technology Specialist with ANSYS Software Pvt. Ltd., India holds an M.Sc.(Engg.) from Indian Institute of Science, Bangalore where his work dealt with interface tracking algorithm applied to Stefan’s Problem. In his current role, he primarily works with Steel Industry, Oil and Gas, and Energy Industries, providing them engineering support while using ANSYS tools to tackle challenges faced in design, troubleshooting, and retrofitting of processes and equipment.

Prior to ANSYS, he worked with GE Aviation, India as Technologist in Advanced Cobustors Group where he worked on various projects related to processes in aircraft engine combustors, including multiphase and reacting flows.

NUMERICAL SIMULATION OF HORIZONTAL PNEUMATIC CONVEYING USING CFD-DEM

ADVANCED COMPUTATIONS AND SOFTWARE TOOLS

53#

185

Abstarct:

Tubular components are used in different industries such as thermal power plants, nuclear power plant, chemical and process industries etc. For safe and efficient operation, it is important to ensure the structural integrity of these components under various types of operational transients. Structural integrity evaluation of these tubes requires crack initiation toughness as well as ductile fracture resistance data of these components. In this work, the fracture behavior of these tubes has been evaluated using axially-cracked non-standard specimens directly machined from thin-walled Zirconium alloy tubes. Two types of loading mandrels, viz., conical mandrel with 4 degree taper angle and two semi-cylindrical split mandrels, have been used to open the axial crack in the tubular specimen. The crack extension was measured with the help of a non-contact optical system in case of comical mandrel test setup and load-normalization technique in case of semi-cylindrical mandrel test setup. Specimens with different initial crack lengths were tested and the load-displacement data were obtained from the experiments. It was observed that for a given value of applied displacement, specimens with smaller initial crack lengths absorb more energy due to extensive plastic deformation. The plastic energy absorbed vs. crack extension data was however observed to be nearly independent of the initial values of crack length. This may be attributed to the dependence of ductile crack growth on formation of an intense localized plastic deformation zone ahead of the crack-tip, which is independent of the remaining ligament. Finite element analysis of the specimen along with the loading set-up has been carried out in order to predict the load-deformation behavior of the specimens. The size of effective remaining ligament ahead of crack tip has been evaluated from finite element analysis and this data has been used in subsequent evaluation of fracture resistance behavior of tubular specimens. This research will be useful for remaining life assessment and integrity assessment of thin-walled tubular components of thermal and nuclear power plants.

Author(s)

Dr. M.K. Samalis a senior scientist at Reactor Safety Division of Bhabha Atomic Research Centre (BARC) and faculty at Homi Bhabha National Istitute (HBNI), Mumbai, India. He has more than 18 years of research and teaching experience. He received his Ph.D. from University of Stuttgart, Germany and has carried out post-doctoral research work at Ohio State University, USA. His teaching and research interests include finite element analysis, material modeling, smart structures and damage mechanics. He has successfully implemented the online damage monitoring system at various chemical process and thermal power plants of India. He is associated with various research and development projects and the Indo-German bilateral project with University of Stuttgart, Germany. He has more than 165 publications including 59 papers in various international journals. (email: [email protected]; [email protected])

BEHAVIOUR OF TUBULAR POWER PLANT COMPONENTS FOR REMAINING LIFE ASSESSMENT

54#

ADVANCED COMPUTATIONS AND SOFTWARE TOOLS

186

Abstarct:

Creep and fatigue are the two primary and dominant damage mechanisms of critical high temperature power plant components, such as boilers and high energy pipings. Creep damage at highly-stressed locations near the shell-nozzle junctions, discontinuities and pipe-bends can limit their useful service lives due to extensive cavitation and grain-boundary cracking. To evaluate the exhaustion of useful creep and fatigue life, an on-line finite element method based program has been employed for thermo-mechanical stress analysis of such components in NTPC thermal power plants. The three-dimensional finite element models of the components have been developed for estimating the damages due to fluctuating power plant transients and the load ramps during start-ups and shut-downs.

The structural stress response obtained from the module is used for computing creep and fatigue damages. A case study of damage assessment for the final super-heater header of a 210 MW NTPC unit has been detailed in this work. From analysis of the accumulated creep and fatigue damage data, it was observed that the ASME design life has been exhausted for a set of stub-header weld joints. The identified locations were taken for in-situ metallurgical inspection for ensuring its structural integrity. The detailed in-situ metallographic studies have been done as per the statutory requirement IBR Act 391A of 1998 during a surveillance programme.

It is observed that the shell-nozzle junction has manifested creep cavitation and is in the zone of secondary creep damage process. The stage of creep cavitation as per Neubauer’s cavitation model has assisted in finalising an inspection schedule. The finite element analysis based assessment along with in-situ quantitative metallographic evaluation has established a reliable methodology to address the remaining life assessment of such critical high temperature components, which is essential for operational safety, reliability and economic plant operation.

Author(s)

Mr. R. Dagais working in the field of mechanical metallurgy for the past 26 years including failure analysis and life estimation of power plant components. He is also involved in finite element analysis and modeling. (email: [email protected])

Dr. M.K. Samal is a senior scientist at Reactor Safety Division of Bhabha Atomic Research Centre (BARC) and faculty at Homi Bhabha National Istitute (HBNI), Mumbai, India. He has more than 18 years of research and teaching experience. He received his Ph.D. from University of Stuttgart, Germany and has carried out post-doctoral research work at Ohio State University, USA. His teaching and research interests include finite element analysis, material modeling, smart structures and damage mechanics. He has successfully implemented the online damage monitoring system at various chemical process and thermal power plants of India. He is associated with various research and development projects and the Indo-German bilateral project with University of Stuttgart, Germany. He has more than 165 publications including 59 papers in various international journals. (email: [email protected]; [email protected] )

STRUCTURAL INTEGRITY ASSESSMENT OF SUPERHEATER HEADER BY FE ANALYSIS AND QUANTITATIVE METALLOGRAPHY

56#

ADVANCED COMPUTATIONS AND SOFTWARE TOOLS

187

Abstarct:

Cyber physical systems are interconnected intelligent nodes collaborating with each other, often controlling physical systems around them. Smart Grid, Intelligent Vehicles, Smart factories etc. are some examples of Cyber-Physical Systems. Cyber-Physical Systems can potentially give us insights and help us solve problems that were traditionally considered impossible. This paper provides an overview of cyber-physical systems in various contexts and how they can potentially be applied for a smarter grid. The complex and massive scale of these cyber physical systems makes it very difficult to implement and test these systems. The session also discusses some efficient approaches to designing and testing these cyber physical systems.

Author(s)

Raviteja Chivukula is a Technical Marketing Engineer with National Instruments. A graduate in Electrical Engineering & VLSI from IIT Madras, he has worked with NI in various roles and has been actively involved in configuring, building systems and consulting in the fields of Power electronics, Robotics, Control systems, Motion control, SDR and Wireless test systems. His former research areas include Unmanned Aerial Vehicles and Laser based sensing systems. He is passionate about teaching and is a visiting faculty at PSG College of Technology – Coimbatore, where he teaches an interdisciplinary course on System Design to undergraduate students from EEE, ECE, EIE and ME departments. (E-Mail ID – [email protected])

POWER OF INTERCONNECTED INTELLIGENT SYSTEMS – CHALLENGES IN DESIGNING & TESTING CYBER-PHYSICAL SYSTEMS

66#

ADVANCED COMPUTATIONS AND SOFTWARE TOOLS

188

Abstarct:

Efficient operation of fossil fuel power plant is becoming very important with present PAT regime and stringent environmental norm, Improvement in power plant efficiency requires understanding of power plant processes, which are very dynamic, non-linear and complex. Computational tools like Computational Fluid dynamics (CFD) and Artificial Intelligence (AI) model the complex processes and provide diagnostic and advisories which helps in process improvement. CFD simulation and its visual parametric output of a given power plant process/domain provides insight into process inefficiencies whereby modifications can be simulated and its effect on parameters can be predicted beforehand. Further, the plant operator has to maintain the plant parameters on a real time basis for optimum efficiency, real time process analysis and improvement becomes important. It requires huge process data to be evaluated in real time and search for optimal solutions to provide advisory to operator. Artificial Intelligence methods like ANN, Pattern recognition, Fuzzy and Genetic Algorithm etc. are being used for real time plant optimization, incipient fault detection and diagnostic. The papers cover various case studies and technical solutions taken up in NETRA, R&D wing of NTPC Limited using CFD and AI.

Key words: Power plant, modelling, CFD, Artificial Intelligence

Author(s)

SujayKarmakar, AGM (NETRA), M. Tech, IIT Delhi, Email: [email protected] Mob: 9650992481

Presently working as AGM (NETRA). Heading Combustion and CFD Modeling group. Joined NTPC in 1991. His experience includes commissioning, operation & efficiency of multi-fuel combined cycle power plant, IGCC technology and process improvement using CFD modeling

J. S. Chandok joined NTPC in 1991. He did his M.Tech (Gold Medalist) from IIT Delhi in 2004. Over the years he has worked in various positions at NTPC such as Boiler C&I Maintenance at Korba,, Project Engineering (C&I) at EOC Noida. Presently working as AGM at NETRA and looking after various areas like Artificial intelligence, Pattern Recognition, Solar PV, Smart grid, Expert Systems. E mail id: [email protected]

COMPUTATION SCIENCE AND ITS APPLICATION FOR POWER PLANT PROCESS IMPROVEMENT IN NTPC

71#

ADVANCED COMPUTATIONS AND SOFTWARE TOOLS

189

Abstarct:

In this paper we use the large signal Francis turbine model to predict the speed performance for a given governor control philosophy. Further, we investigate the impact of governor tuning parameters on the speed performance. The correct choice of penstock, governor and turbine-generator models helps predict the time domain speed response to a good approximation. This can help in reducing the time and the number of trials required in tuning the governor. Our simulation results closely tally with the real time data obtained from various hydro plants operating under different conditions. Further, speed performances of governors in other hydro plants tuned using this method have been presented.

Author(s)

Biswajit Dutta is with Bharat Heavy Electricals, Bangalore as Sr. Engineer in Hydro Controls Engg. Dept ([email protected])

Sailesh Thota is with Bharat Heavy Electricals, Bangalore as Engineer in Hydro Controls Engg. Dept ([email protected] )

Jayateerth Agarkhed is with Bharat Heavy Electricals, Bangalore as Additional General Manager in Hydro Controls Engg. Dept ([email protected])

PERFORMANCE PREDICTION OF SPEED CONTROL LOOP FOR FRANCIS TURBINES BASED ON LARGE SIGNAL MODEL

76#

ADVANCED COMPUTATIONS AND SOFTWARE TOOLS

190

Abstarct:

Given the pace and scale of research and development in scientific and engineering areas, High Performance Computing (HPC) has become a key enabling technology to have faster, better, more economic and safer solutions or insights. Areas such as life sciences, nuclear research, atmospheric sciences, materials science, structural mechanics etc. are witnessing progressively higher reliance on HPC.

Similarly, in energy sector, with the ever-growing complexity and size of power plant systems, modelling and simulation for the design, operations and management of these systems, HPC is required to meet the nature and of demand of huge computational power.

Also, by collecting and analyzing key performance and sensor data of power plants, it is possible to understand patterns that lead to equipment failures. This can lead to very advanced Condition Based Maintenance schemes that allow maintenance activities to be focused on those tasks that yield the greatest return. Such a case is potentially a good candidate for application of Predictive Analysis using Big Data and parallel programming technologies such as Map Reduce. Similarly, various data mining techniques will also be required to get real time plant advisory and incipient fault diagnostic.

In this paper we aim to bring out the significance of Big Data, Analytics & High Performance Computing technologies in various applications for power plants.

Author(s)

Harmeet Singh Sawhney Senior Manager, NETRA, NTPC Limited, Greater Noida

Sandeep Agrawal Technical Officer, HPC Solutions Group, C-DAC Pune

J S Chandok Additional General Manager, NETRA, NTPC Limited, Greater Noida

PrashantDinde Sr. Technical Officer, HPC Solutions Group, C-DAC Pune

Sanjay Wandhekar Associate Director, C-DAC Pune

EXPLORATION OF APPLICATIONS OF HPC, BIG DATA AND ANALYTICS FOR POWER PLANTS

89#

ADVANCED COMPUTATIONS AND SOFTWARE TOOLS

191

Abstarct:

In the power plant industry, dynamic simulation tools are becoming more important because of the growing need to evaluate dynamic behavior. The aim of this study is to investigate the use of a dynamic simulation tool to predict the dynamic behavior of a HRSG (Heat Recovery Steam Generator) model. This paper reports a dynamic simulation model of a HRSG and its application for the start-up procedure. An existing HRSG model was built using an in-house dynamic simulation tool named ASIMPLE (Analysis and Simulation for Plant Engineering). ASIMPLE has been in development by Doosan since 2010 for the purpose of dynamic simulation and analysis of power plant. A numerical calculation of dynamic behavior for the HRSG model during start-up was performed by ASIMPLE. The results showed satisfactory agreement with the real operational data. These results show that ASIMPLE is a reliable tool to predict the dynamic behavior and the start-up procedure for a HRSG.

Author(s)

Mr. Kim Hyo Jun (Email : [email protected])

Kim Hyo Jun received M.S. in mechanical engineering from Korea University. Since joining DOOSAN in 2009, he has been working in system engineering team. Currently his work is focused on the dynamic analysis for a power plant.

Mr. JeongKwang Hun (Email : [email protected])

JeongKwang Hun completed his M.S. course in mechanical engineering at Seoul National University in 2007. Since joining DOOSAN in 2007, he has been working in system engineering team and is in charge of dynamic analysis for a power plant.

Mr. Lee Ki Hyun (Email : [email protected])

Lee Ki Hyun received M.S. in mechanical engineering from Korea University in 1994.Since joining DOOSAN in 2000, he has been working on system engineering team. He has 20 years of experience in dynamic simulation of boiler and HRSG.

Mr. Roh Kyung Bong (Email : [email protected])

Roh Kyung Bong received B.S. in computer science from KyungnamUniversity. Since joining DOOSAN in 2004, he has been working on system engineering team.

Ms. JEON Woo Won (Email : [email protected])

JEON Woo Won received B.S. in control engineering from Changwon University. Since joining DOOSAN in 2008, she has been working on system engineering team.

NUMERICAL AND EXPERIMENTAL INVESTIGATION ON HEAT RECOVERY STEAM GENERATOR DURING START-UP PROCEDURE USING ASIMPLE

150#

ADVANCED COMPUTATIONS AND SOFTWARE TOOLS

192

Abstarct:

This paper proposed an algorithm for bearing fault diagnosis of induction motor based on down-sampling of the acquired vibration signal, feature extraction and support vector machine. The key factor in the bearing fault diagnosis is the feature selection and their classification. A vibration signal recorded at high sampling frequency is down-sampled and this down-sampled data is used for feature extraction. The diagnosable features from statistical time domain and wavelet domain are selected and given to a multiclass SVM based classifier for classification. The method is tested on vibration data of3 HP squirrel cage Induction motor with different bearing abnormalities. Experimental results show that the algorithm gives good results for bearing fault diagnosis of rotating electrical machines.

Author(s)

Hariom Vishwakarma, recieved his B.E in Electrical Engg. from Govt. Engg. College Rewa (M.P) in 2008 and M.Tech in Measurement & Intrumentattion from IIT Roorkee in 2010. He is currently working in O&M deparment, NTPC Ltd in MSTPP Mouda, Nagpur.His area of interest are Condition monittoring, Signal Processing, Expert system,Machine Learning etc. (Email.: [email protected])

Bhaskar Maheshwari, recieved his B.Tech in Mechanical Engg. from NIT Kurukshetra (HR.) in 2010.He is presently working in O&M deparment, NTPC Ltd in MSTPP Mouda, Nagpur. (Email.: [email protected])

Yougal Deep Dhiman, recieved his B.Tech in Mechanical Engg. from NIT Hamirpur (H.P.) in 2011.He is currently working in O&M deparment, NTPC Ltd in MSTPP Mouda Nagpur. (Email.: [email protected])

BEARING FAULT CLASSIFICATION USING VIBRATION SIGNAL FOR INDUCTION MOTOR

171#

ADVANCED COMPUTATIONS AND SOFTWARE TOOLS

193

Abstarct:

With the advantage of Sensors, Computing and Storage capacity, power plants are equipped with advanced DCS (distributed control systems) to capture signals for various parameters and events during operation of power plant. With DCS facility high frequency signal capturing not only become easier but cost effective. Every moment a large amount of data is being captured and stored in databases. The captured data contains rich information. Unless the data is converted into usable information and knowledge, information in the data is just a piece of data. Manual interpretation of this high frequency data is a Herculean task. Computational Intelligence (CI) also known as Machine Learning (ML) techniques, is in simple a gamut of techniques (viz. Artificial Neural Networks, Fuzzy Logic, Evolutionary Computing etc.) that can help in learning from data and convert data into usable information and knowledge. With the knowledge acquired from the data power plant performance can be optimized with solutions, in a cost effective way with shorter turnaround time. Currently, BHEL has adapted CI techniques and started its journey in solutions for power plant issues and problems. In this paper various solutions for power plant problems including predicting unburned carbon in ash, NOx prediction, monitoring and predicting when the PA-Fan would land into stall zone etc. would be discussed and also methods to improve the overall performance of thermal power plants.

Author(s)

J.Krishnaiah is currently Manager at Coal Research Centre at BHEL Trichy. He has earned his PhD and Masters in Manufacturing Systems Engineering from IIT Kharagpur and Bachelor’s degree in Mechanical Engineering from JNTU, Anantapur. (email: [email protected])

K.S. Madhavan is currently Sr. Deputy General Manager at the Corporate R&D, Bharat Heavy Electricals Limited. He holds a Ph.D. in Computer Science, a Master’s degree in Management and a Bachelor’s degree in Electrical Engineering from IIT Madras. (email: [email protected])

R.Dhanuskodi is currently Dy. General Manager, R&D, BHEL, Trichy. He has completed BE in mechanical engineering and M.Tech in Energy Engineering in from the Regional Engineering College Tiruchirappalli (present NITT), and is presently carrying out his Doctoral program at NIT, Trichy. (email: [email protected])

S. Arumugamis currently AGM/COAL RESEARCH, BHEL Trichy. He has obtained B.E (Hon’s) in Mechanical Engineering from P.S.G College of Technology Coimbatore and Master’s Degree in “Design and Production of Thermal Power Equipment” from REC Trichy . (email: [email protected])

COMPUTATIONAL INTELLIGENCE BASED SOLUTIONS FOR THERMAL POWER-PLANT PERFORMANCE IMPROVEMENT

179#

ADVANCED COMPUTATIONS AND SOFTWARE TOOLS

194

Abstarct:

Software systems have been developed for Automation of Power Piping Engineering, using current 3D Plant Design Technologies. Most of the processes involved in Power piping Engineering have been automated, by using PDMS (a 3D plant design package as nodal software). The use of Plant Design software has been extended to a level of detail engineering, by doing extensive customization. Hence, apart from Layout Engineering using 3D modeling, generation of detail engineered drawings/documents for shop/site is also enabled.

Modeling of Pipes and Hangers in 3D environment forms the base for all further Engineering processes. Piping layout drawing can be generated and dimensioned as an in-built feature of the software. BHEL has done extensive customization in PDMS by creating databases, programs and symbols, to enable the following Engineering processes

• P&ID creation and valve schedule generation using AVEVA-P&ID software • 3D pipe routing and Layout drawing generation • Pressure loss calculation - 3D piping model as input • Interface for direct input transfer from PDMS model to Stress analysis s/w CAESAR-II • Input data generation from 3D piping model for Insulation calculations(in-house) • Creation of hanger arrangement in 3D with minimal inputs. • Piping detail Engineering and generation of shop/site isometrics and related documents like IBR calculation sheets/forms, Erection welding schedule, data for ERP system (SAP) • Interface for data generation from 3D hanger model to Hanger Detail Engineering s/w

The intended benefits are

• Interference free layout / minimizes costly rework – 3D view and auto-clash checking • Error free drawings / documents -as generated directly from 3D. • Minimizes conversion errors- interface data generation/transfer through programs • Cycle time reduction and uniformity in design/drafting- Automation

Author(s)

Mr C.Vaithianathan is presently working for BHEL-Piping Centre, Chennai (India) as Additional GM in Engg.Department and heading Piping Layouts& Stress Analysis, Engineering Automation and Research & Product development groups. He is a member of piping product Committee and Convener of Piping Technical committee in BHEL. Also member of corporate level Engineering Automation group and chairman of Corporate Plant design expert group in BHEL. He joined BHEL in 1985, worked in various Boiler/Power plant projects and gained design experience in Boiler Pressure parts, Piping and in CAD systems& programming. He did his Bachelor of Engineering Degree in Mechanical and Production discipline from Annamalai University (India) in 1985. His schoolings were done in N.L.C campus schools, Neyveli (India). (Email: [email protected]).

AUTOMATION OF POWER PLANT PIPING ENGINEERING- USING 3D PLANT DESIGN TECHNOLOGIES

209#

ADVANCED COMPUTATIONS AND SOFTWARE TOOLS

195

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