22 Tips - How to Reduce Auxiliary Power Consumption of 500/600/660/800 MW Sets ?

22 Tips - How to reduce Auxiliary Power Consumption of 500/600/660/800 MW Sets ?

Auxiliary Power Consumption (electrical energy needed to run the Unit at variable loads)

1.    Conduct Energy Audit of the Units/Plant every year by an efficient Energy Auditor

2.    Implement all the recommendations of the said Energy Auditor for the Units/Plant

3.    Identify and plug all energy loss points of the Units/Plant to the extent possible

4.    Improve Unit overall efficiency (36% for sub-critical & 42% for super-critical)

5.    Improve Unit Heat Rate (close to 2300/2000 kCal/kWh for sub-critical/super-critical)

6.    Maintain Unit PLF close to 90% (for 330 days in a year/nearly 8000 running hours)

7.  Reduce Specific Coal Consumption (0.5 - 0.6 kg/kWh) by sustained optimization of combustion in the boiler using suitably blended coal (60% ‘F’ Grade + 40% ‘D’ Grade)

8.   Reduce Specific Oil Consumption in the steaming Boiler (close to 1.0 ml/kWh)

9.   Reduce DM Make-up Water Consumption in the steaming Boiler (close to 1.0%)

10. Carry out routine/preventive/annual/capital maintenance of all load bearing equipments including their prime movers of the Unit as per recommendations of respective OEMs 

11. Maintain desired voltage/frequency level for the auxiliaries when the Unit is in Bus

12. Keep Unit Transformers in service when the Unit is in Bus beyond 10% rated load 

 

13. Use combination of Steam Turbine Driven (2x50% running at 100% rated load) & Electric Motor Driven (1x50% kept as standby) Boiler Feed Pumps for running Unit

14. Or use Motor Driven Boiler Feed Pumps with Multi-Stage Variable Speed Drive (with planetary gears) Vorecon (3 x 50% E-motor + Vorecon) for running Unit

15. Use VFD for the prime movers of all other load bearing equipments for the running Unit

16. Keep all standby load bearing equipments of the Unit in switched off/standby mode 

17. Maintain desired Condenser Vacuum (around 76 - 80 mm of Hg) in the running Unit

18. Maintain optimum back end temperature (around 130⁰C - 140⁰C) in the steaming boiler

19. Maintain unburnt carbon in fly/bottom ash of the steaming boiler on lower side (~1%)

20. Run the Unit at Base Load (100% Rated Load) on 24x7 basis

21. Maintain ash evacuation/disposal of the steaming boiler in dry mode except exigency

22. Maintain optimum illumination level in the Plant (use energy efficient lamps)

Posted on 14 May, 2013