Flexibilization Field Report

Practice Guide to Get Ready

for Flexible Power Plant Operation
Based on results of activities carried out under
the auspices of the Indo-German Energy Forum

December 2022
In co-operation with:
In co-operation with:
 Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

Table of Contents

List of Figures......................................................................................................................... 4
List of Tables .......................................................................................................................... 5
List of Abbreviations.............................................................................................................. 5
1 Background ................................................................................................................. 6
2 Introduction ................................................................................................................. 7
3 Flexibilization Approach .......................................................................................... 11
4 Pre-Test Phase .......................................................................................................... 13
4.1 Information and Data Input ......................................................................................... 13
5 Flexibility Test Runs ................................................................................................. 18
5.1 Test Run Schedule ..................................................................................................... 18
5.2 Test Runs Procedure .................................................................................................. 19
5.2.1 Minimum Load Test Procedure ......................................................................... 21
5.2.2 Ramping Test Procedure .................................................................................. 25
6 Test Run Assessment: Flexibilization Plan ............................................................ 28
6.1 Common Findings ....................................................................................................... 30
6.2 Flexibility Measures .................................................................................................... 33
6.2.1 Mandatory Measures for Minimum Load Operation ......................................... 33
6.2.2 Mandatory Measures for Ramp Rate Improvement .......................................... 35
6.2.3 Further Measures for Flexibility Enhancement ................................................. 36
7 Implementation Recommendation: Deployment ................................................... 40
7.1 Flexibility Checklist ..................................................................................................... 46
8 Useful Publications and Standards ........................................................................ 50
8.1 International Reports and Publications on Best Practices .......................................... 50
8.2 vgbe Standards........................................................................................................... 52
8.3 Relevant Publications in the vgbe Energy Journal ..................................................... 53
9 Maithon Power Limited “Journey towards Flexibilization –
Minimum Power Limit REDEFINED” ....................................................................... 55

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List of Figures1
Figure 1: Test runs at NTPC’s Dadri power plant in June 2018 ............................................... 9
Figure 2: Test runs at Tata Maithon power plant in July 2021 ................................................. 9
Figure 3: Test runs at DVC Andal power plant in March 2022 ................................................. 9
Figure 4: Technical flexibilization procedure .......................................................................... 11
Figure 5: Flexibility skill development program “study, try and apply” and Flexpert logo ....... 12
Figure 6: Principle design of the subcritical 500 MW units ..................................................... 13
Figure 7: Main plant parameters during low load operation (above) and ramp up (below) .... 15
Figure 8: Steam and metal temperatures during ramp up ...................................................... 16
Figure 9: Feed water flow and drum level during ramp up ..................................................... 17
Figure 10: Example of a load profile for minimum load tests ................................................. 19
Figure 11: Example of a load profile for ramping tests ........................................................... 19
Figure 12: Test run approach ................................................................................................. 20
Figure 13: Main plant parameters during a minimum load test .............................................. 28
Figure 14: Main plant parameters during a ramp rate test ..................................................... 29
Figure 15: Potential issues during flexible operation .............................................................. 30
Figure 16: NOx emissions and load during the minimum load tests ....................................... 31
Figure 17: Heat rate relative to load during the test runs ....................................................... 32
Figure 18: Efficiency during the test runs ............................................................................... 33
Figure 19: Overview of a boiler fatigue monitoring system .................................................... 39

1
Pictures and graphs shown in this report were developed in the course of the IGEF project either
from vgbe, Siemens Energy or Steag Energy Services

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 Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

List of Tables
Table 1: Achievements of the IGEF test runs ........................................................................... 7
Table 2: Coal composition during the test runs ........................................................................ 8
Table 3: Study reports issued during the IGEF project ............................................................ 8
Table 4: Example of a test schedule ...................................................................................... 18
Table 5: Detailed test procedure for a minimum load test ...................................................... 24
Table 6: Detailed test procedure for a ramping test ............................................................... 27
Table 7: Issue lists for different plant areas ............................................................................ 43
Table 8: List of critical components ........................................................................................ 44
Table 9: Existing regulations and vgbe standards with respect to condition monitoring ........ 45
Table 10: Flexibility check list for sub-critical Indian power plants ......................................... 49

List of Abbreviations
ACV Auxiliary Control Valve
APH Air Preheater
BFP Boiler Feed Pump
CFMS Coal Flow Measurement System
EOH Equivalent Operating Hours
ESH Equivalent Starting Hours
FD fan Forced Draft Fan
GCV Gross Calorific Value
HP High Pressure
HR Hot Reheat
ID-fan Induced Draft Fan
MCR Maximum Continuous Rating
MDBFP Motor Driven Boiler Feed Pump
MS Main Steam
RH Reheat
SA Secondary Air
SCAPH Steam Coil Air Preheater
SH Superheater
TDBFP Turbo Driven Boiler Feed Pump

Abbreviations referring to companies, institutions and common measurement units (e.g. MW,
min) are not included in this list.

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Practice Guide to Get Ready for Flexible Power Plant Operation

1 Background
To ensure the power supply in the country, India is aiming to double its electricity generation
capacity by 2030. The Indian government has also set ambitious goals for the expansion of
renewables – aiming to install at least 300 GW of solar PV and 140 GW of wind power by
2030. The Indian Prime Minister Modi has announced that India will reach a non-fossil ca-
pacity of 500 GW by 2030. 50% of India’s energy requirements will come from renewable en-
ergy by then. Currently, the renewable capacity excluding hydro power accounts for more
than 115 GW. These developments will mark a huge change in the Indian power system, as
currently around 58% of the installed capacity (407.8 GW in total) comes from conventional
thermal power plants2. While India, on a national level, can rely on solar energy generation
every single day of the year, wind is not always available at peak demand times in the morn-
ing and evening.
As such, flexibilization – which aims at managing the fluctuations in renewable supply by
converting baseload power plants into flexible generating facilities – has become the new
paradigm in thermal power generation. Therefore, it has become a topic of the Indo-German
Energy Forum (IGEF) – a high level platform created to enhance and deepen cooperation
within the energy sector. The IGEF was founded by the German Chancellor and the Indian
Prime Minister at the Hannover Fair in April 2006. It focuses on both promoting private sector
activities and putting in place an enabling environment to further develop the market for
power plant technologies, energy efficiency and renewable energies in India.
A special task force on flexibilization has been created. On the Indian side, National Thermal
Power Corporation Limited (NTPC), the Central Electricity Authority (CEA), the network oper-
ator POSOCO (Power System Operation Corporation Limited) and BHEL (Bharat Heavy
Electricals Limited) are involved in the task force. On the German side, both the Deutsche
Gesellschaft für Internationale Zusammenarbeit GmbH (GIZ) and vgbe have been supporting
the task force on behalf of the Federal Ministry of Economic Affairs and Climate Action
(BMWK). The task force is headed by the Director Operations at NTPC, and the Excellence
Enhancement Center (EEC) holds the secretariat and coordinates the work.
One of the key purposes of the task force was to showcase the technical feasibility of flexible
power plant operation. Therefore, investigations at four Indian power plants were conducted
in the period from January 2017 to July 2022. They included test runs at the Dadri power
plant operated by NTPC, at the Maithon power plant operated by Tata Power and at the An-
dal power plant operated by DVC. Another study was conducted at NTPC’s Simhadri power
plant. The investigations focused on 500 MW subcritical units.

This handbook summarizes the main results and learnings of the studies. It provides an in-
sight into power plant flexibilization which can serve as a blueprint for other Indian plants.

2
Central Electricity Authority (CEA), Installed Capacity in India as of 30 September, 2022:
https://cea.nic.in/installed-capacity-report/?lang=en, retrieved on 31 October, 2022

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2 Introduction
The flexible operation of coal-fired power plants forms an important pillar of India’s energy
transition. Therefore, it is worth reflecting on some important aspects of flexible power plants
that are not only valid for India but also for many countries worldwide.
+ Flexible thermal power plants are key to ensuring sufficient system integration of vari-
able renewable energies such as wind and PV.
+ Flexibility of coal-fired plants contributes to the reduction of CO2 emissions – the de-
crease of full-load operating hours outweighs the effect of lower efficiency at part or
minimum load.
+ The successful deployment of flexibility measures depends on the market design –
the economic viability of the plants has to be ensured, preferably through incentives
for flexible operation.
+ Special focus should also be placed on the further training and skill development of
the power plant personnel.
Flexible operation comprises aspects of low minimum load, fast start-ups and shut-downs
and high ramp rates. The IGEF investigations focused on subcritical coal-fired power plants.
The original design and set up of these plants include some favourable configurations for
flexible operation – e.g. they are equipped with a high number of mills, tilting burners and fre-
quency-driven fans and actuators. The following units were investigated:
− 210 MW and 500 MW (test runs 2018) at Dadri
− 500 MW at Simhadri (no test run)
− 500 MW at Maithon
− 500 MW at Andal

The following results were achieved during the test runs. The ramp rate refers to a% load
change per minute.

Unit capacity 500 MW 500 MW 500 MW

Operator NTPC Tata DVC
Date June 2018 July 2021 April 2022
Minimum Load 40% 36% 32%
Ramp Rate 2.0–3.0%/min 1.5–2.0%/min 2.0%/min

Table 1: Achievements of the IGEF test runs.

Moreover, the results of the investigations at the 210 MW unit at Dadri and at the 500 MW
unit at Simhadri power plants also indicated that a minimum load of 40% should be possible
without major interventions and investments.

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The following table shows examples for the composition of coals which were burned during
the test runs.

Fixed Carbon% 32.8 38.4 36.4

Volatile Matter% 20.4 16.6 22.3
Total Moisture% 8.1 7.4 4.0
Ash% 42.3 37.6 37.3
Gross Calorific Value kcal/kg 3,932.8 4,268.7 4,017.0

Table 2: Coal composition during the test runs.

The following table shows examples for the composition of coals which were burned during
the test runs.

The flexibility studies were conducted by vgbe in co-operation with Steag Energy Services
GmbH and Siemens Energy Global GmbH & Co. KG, both member companies of the vgbe
association. The following reports were developed and published – they served as the basis
for this Flexibility Handbook:

No Title Issued Partner

1 Flexibility Assessment for the NTPC Plants Sept 2017 Steag

Dadri and Simhadri
2 Flexibility Assessment – Implementation Plan for Sept 2018 Siemens
the 500 MW Unit at Dadri Power Plant
- Pre-Test Data Assessment Report Sept 2020 Siemens
Andal Power Plant
- Pre-Test Data Assessment Report Sept 2020 Siemens
Maithon Power Plant
3 Flexibility Assessment and Implementation Plan for Dec 2021 Siemens
the 525 MW Unit 2 at Maithon Power Plant
4 Flexibility Assessment and Implementation Plan for June 2022 Siemens
the 500 MW Unit 2 at Andal Power Plant
Table 3: Study reports issued during the IGEF project.

The following pictures were taken after the successful completion of the test runs.

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 Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

Figure 1: Test runs at NTPC’s Dadri power plant in June 2018.

Figure 2: Test runs at Tata Maithon power plant in July 2021.

Figure 3: Test runs at DVC Andal power plant in March 2022.

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Note of Thanks
On behalf of the Indo-German Task Force Flexibility which was established on request of
Ministry of Power, Govt. of India and the German Ministry in charge of Energy, Govt. of Ger-
many, vgbe expresses its deep gratitude to the power plant teams of Simhadri, Dadri,
Maithon and Andal for the professional and well-organized preparation and execution of the
flexibility investigations and test runs undertaken. We thank the management of NTPC, DVC
and TATA Power for their valuable inputs and highly appreciated support given to the activi-
ties carried out.

All test runs were only possible thanks to the guidance and full support by the Ministry of
Power (MoP), Central Electricity Authority (CEA), Grid Controller of India (Grid India), Bharat
Heavy Electricals Limited (BHEL) and NTPC. We would like to specifically thank Shri Alok
Kumar, Hon’ble Secretary (Power), MoP; Shri V.K. Dewangan, former Additional Secretary,
MoP; Shri Piyush Singh, Joint Secretary (Thermal), MoP and its predecessors Smt. Archana
Agarwal and Shri Aniruddha Kumar; S.K. Kassi, Chief Engineer (Thermal), MoP; Mr. B.C.
Mallick, Chief Engineer (Thermal Renovation & Modernization), CEA and the chair of the
Indo-German Task Force Flexibility, Mr. Ramesh Babu (Director Operations), NTPC and its
predecessors Mr. Prakash Tiwari and Mr. K.K. Sharma. Without their personal involvement,
dedicated support and trust, those test runs would have not been possible.

We would also like to thank Mr. A.K. Sinha (rtd.), NTPC and Mr. Tobias Winter, Director,
Indo-German Energy Forum (IGEF) Support Office for their active support, which was essen-
tial to the smooth execution of the flexibility test runs. We are very grateful to the Excellence
Enhancement Centre (EEC) for the Indian Power Sector and the team led by Director Mr.
Rakesh Chopra for the continuous support to the task force throughout the entire project.
Vgbe and EEC thank their partners and members, Steag and Siemens, for the excellent and
fruitful technical cooperation.

Last but not least, we would like to thank the very many people not mentioned here, who
have contributed their time, knowledge and contacts to make the test runs possible. It was all
of you, who formed part of this exciting journey of demonstrating the technical viability of flex-
ible power plant operation in India.

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 Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

3 Flexibilization Approach
Based on the investigations at the four power plants, a generic procedure for the technical
flexibilization can be deducted. Test runs form a core activity, as they provide insights into
the real performance of the plant with respect to minimum load, start-up time and ramp rates.
The procedure is shown in the following figure.

Figure 4: Technical flexibilization procedure.

The technical flexibilization procedure comprises four steps which are explained in detail in
the following chapters. In brief, these four steps focus on:

(1) Pre-Test Phase: Before the test runs are conducted, the status quo of the plant is an-
alyzed with respect to flexible operation. The assessment of operating data at differ-
ent load conditions is the key activity. Based on this assessment, potential obstacles
and limitations for low load operation, as well as for load ramps, can be identified.

(2) Test runs: The program comprises part-load and minimum-load operation, as well as
ramp-up and ramp-down tests for a set period. The tests follow a defined test sched-
ule that needs to be released by the system operator prior to the test. An experienced
team of operators follows a test procedure that also needs to be prepared in advance.
Health and Safety (HSE) requirements have the highest priority. A defined set of op-
erating data, including the coal composition, is collected during the tests.

(3) Flexibilization plan: The operating test data are analyzed in order to ensure steady,
flexible plant operation. This analysis covers all areas of plant operation: from com-
bustion to water-steam cycle through to flue gas and turbine operation. Based on the
results, measures to enhance and/or to sustain flexible operation are derived. These
measures need to be assessed according to techno-economical evaluation.

(4) Deployment: Finally, the flexibilization plan needs to be implemented. As the

measures will most likely involve a higher level of automated operation of equipment,
sufficient time should be foreseen. This step is not just about technology, it is also
about trust in automated procedures and sequences – and, moreover, in optimized
control logics.

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It might be beneficial to engage an experienced third party at the starting point of the flexibili-
zation activities. This engagement might help to overcome some uncertainties in flexible op-
eration. However, the skill level of Indian power plant personnel is regarded as sufficient to
manage the flexibilization, with only limited requirements for external support.

In this context, it should be noted that the technical flexibilization procedure should be
accompanied by a skill development program. A principle description of such a program is
presented in another report. The following figures provide an overview of the training
program for so-called Flexperts – trainees acquire an understanding of the flexibility
principles and learn how to operate a plant accordingly. The program is divided into three
steps – study, try and apply.

Figure 5: Flexibility skill development program “study, try and apply” and Flexpert logo.

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 Flexibilization Field Report:
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4 Pre-Test Phase
This phase provides transparency about the plant status with respect to flexible plant opera-
tion. At the end of the pre-test phase, a Pre-Test Data Assessment report provides an insight
into the status quo and the potential obstacles and limitations for flexible operation. A quanti-
tative assessment of operating data, as well as qualitative assessments of operating person-
nel’s feedback, form the basis of the report.

4.1 Information and Data Input

Besides the operating data, some general plant information is required to investigate the
plant design. Such information comprises P&IDs and operational manuals for main power
plant areas – boiler, including water-steam-cycle, and turbine. The following design infor-
mation is especially important for the flexibility assessment:
− boiler type, evaporator and combustion design
− the number and arrangement of mills and fans – Induced (ID), Force Draft (FD), Pri-
mary Air (PA), Secondary Air (SA)
− type and number of boiler feed pumps (BFP) – motor-driven (MDBFP), turbo-driven
(TDBFP)
− Air Preheater (APH) design – availability of Steam Coil APH (SCAPH)
− philosophy for unit control – sliding (boiler follow) mode or fixed pressure (turbine fol-
low) mode – and main control loops (e.g. steam temperature and drum level)
The following picture shows the principle design of the subcritical 500 MW units with two-
pass boilers that were investigated in the course of the studies. It is mainly based on a two-
pass boiler manufactured by BHEL and a turbine with KWU/Siemens design.

Figure 6: Principle design of the subcritical 500 MW units.

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 Flexibilization Field Report:
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In order to prepare a pre-test data assessment, operating data at different load points and
during transient operation are required. In steady-state operation, data should be provided
for performance at full load (100% maximum continuous rating (MCR)) and at the lowest op-
erated load in the last couple of months. Transient operation data comprise the following op-
erational situations:
1. Cold start-up to full load (if not available, then warm start-up)

2. Ramp down from full load to low load (lowest operated load in the last couple
of months)
3. Ramp up from low load to full load (lowest operated load in the last months)
The operating data should have a time resolution of less than 1 minute and comprise at least
the following parameters:
− Load
− O2 values and O2 average in excess air
− NOx
− CO
− Main steam pressure
− High pressure (HP) steam temperature
− Reheat (RH) steam temperature
− Superheated (SH) steam temperature
− Flue gas exhaust temperature
− Mill load
− Flame scanner intensity
− Status signal of burner (on/off)
− Drum level
− Metal temperatures
In addition to the operating data, the operating power plant personnel should provide an-
swers to the following questions:
− What prevents you from operating at lower load?
− What do you consider as the main problem during minimum load operation?
− Do you use burner tilt to reduce main steam temperature during ramp up?
− Can flame scanners influence the ability to operate at lower loads?
− How do flame scanners influence the ability to operate at lower loads?
− Do you consider combustion stability / flame stability at minimum load
as a challenge?
− During start-up: At what threshold of coal flow / number of mills in operation, do you
switch off the auxiliary fuel (oil)?

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 Flexibilization Field Report:
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− How do you assess the level of automation at your plant? As this aspect is very im-
portant, a detailed questionnaire will be provided in order to assess the current auto-
mation status in depth.
A Pre-Test Data Assessment Report presents the results of the data analysis and the as-
sessment of the other information. The following figures show results of the data analysis –
here with respect to main plant parameters during steady low load operation and during ramp
up.

− drum level (light

blue): -100 to
10 mm
− el. generation
(pink): 0 to 525
MW
− coal flow (black):
sum of feeder
speed 0 to 320%
− main steam pres-
sure (green):
0 to 200 bar
− main steam flow
(red): 0 to 2000
t/h
− feed water flow
(dark blue):
0 to 2000 t/h
Figure 7: Main plant parameters during low load operation (above) and ramp up (below).
These descriptive diagrams use a uniform scaling from 0 to 100% of the associated meas-
urement range of the operating variable. In this case, the following statement regarding the
drum level was submitted:

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 Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

Drum level was within approximately +/- 40 mm and in the first 50 minutes showed signs of
periodical oscillation. The oscillation implies that control structures are not optimized and/or
not tuned properly. The speed of the load ramp is not that big (less than 1% per minute), and
it is possible to minimize deviations in drum level. Deviations of +/- 40 mm are not considered
a problem, but when increasing the speed of load ramps, it is also assumed that drum level
deviations will increase, which could become a problem.

According conclusions were also provided: For increased speed of load ramps, the drum
level control should be optimized. It looks sufficient for low load operation, but it is yet un-
known how this will change when lowering load further. With faster speed of load ramps, it is
assumed that deviations in drum level will increase. Tuning (and/or structural changes) are
recommended. The correct setting for drum level control is a fast slave controller for flow dif-
ference (between steam and feed water) (integral time approx. 20 seconds), with a slower
master controller for level (about 3 to 5 minutes integral time, gain as much as possible as
long as still stable, derivative action recommended).3

The next figure shows the metal temperature development during load ramps.

− red: max. RH
metal temp.
400 to 600°C
− green: hot RH
steam temp.
400 to 600°C
− brown: average
RH metal temp.
(of 44 measure-
ments)
400 to 600°C
− pink: el. genera-
tion, 0 to 525 MW
− black: burner tilt
position,
0 to 100%
Figure 8: Steam and metal temperatures during ramp up.
The analysis of the findings was as follows: There is a big increase in RH metal temperatures
(both max. and average) at the beginning of the load ramp. At the same time, the hot RH
steam temperature is increasing slightly. The burner tilts are hardly reacting. (They may be in
manual, as they seem to change position in steps.)

3
Pre-Test Data Assessment Report for the Maithon Power Plant, issued by the IGEF team in Septem-
ber 2020

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 Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

This indicates that the burner tilts are not working properly. Either they are in manual, which
shows a lack of confidence in the controls, or they are in automatic and do not react suffi-
ciently.4

The next figure shows a very typical issue that came up during the pre-test phase and which
was verified in the test runs at all three plants.

− black: feed water

flow
0 to 1,500 t/h
− blue: drum level
setpoint and
value
-200 to 200 mm
− pink el. genera-
tion (
0 – 500 MW
Figure 9: Feed water flow and drum level during ramp up.

This figure was generated during the pre-test phase for the Andal power plant (IGEF report
issued in September 2020). It clearly indicates a problem with the control of the drum level
and feed water flow during ramp up. The high fluctuations are caused by a closing or open-
ing of the recirculation line, which is equipped with on/off valves. This is discussed in the next
chapters in more detail.

At all investigated plants, the following common issues could be identified:

− steam temperature control at low load
− drum level control at low load and during load ramps
− flame stability and furnace pressure and windbox delta pressure during load ramps
− low flue gas at low load
These issues will most likely cause problems during flexible operation in any plant. The main
reason is that the control logics are not optimized for lower load and higher ramp rate ranges.
The exact behaviour needs to be investigated during the test runs.

4
Pre-Test Data Assessment Report for the Maithon Power Plant, issued by the IGEF team in Septem-
ber 2020

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5 Flexibility Test Runs

The test runs mark an important step in the technical flexibilization procedure. In the Indian
context, the test runs aim at finding the lowest minimum-load operation, as well as highest
ramp-up and ramp-down rates. Prior to the tests, it is necessary to check whether any existing
control setting might become an obstacle during load reduction. However, no modifications are
permitted that may potentially affect the safety of the boiler during, in-between or after the
tests. The complete boiler and plant protection should be activated. If necessary, the control
systems should be switched to manual mode (e.g. attemperator / steam temperature control).
As safety has highest priority, the test should be interrupted if there is any concern. Preferred
operation procedures should include all expected operating modes of the boiler and the usage
of average coal. Average coal means that the coal should not be of better quality than in usual
daily operation. The tests should reflect the real situation of the plant. Hence, they are con-
ducted by the plant team – in the IGEF project, with support from Indian and German experts.
The tests follow a defined test schedule which needs to be released by the system operator
prior to the test. As this is an important pre-requisite of the test runs, the involvement of relevant
stakeholders such as the system operator or beneficiaries is essential.
Furthermore, a detailed test procedure gives instructions on how the test should be carried
out in detail.

5.1 Test Run Schedule

The duration of a test run, including minimum load and ramping tests, is usually about a
week. The following table shows an example for the program.

Date Weekday Test Target Load

28 March Monday Minimum load test 200 MW (or less)
29 March Tuesday Minimum load test 200 MW (or less)
30 March Wednesday Load ramp test between 200 and 500 MW
31 March Thursday Load ramp test between 200 and 500 MW
1 April Friday Reserve

Table 4: Example of a test schedule.

For each day, a dedicated load profile should be provided by the system operator. The next
two figures show examples of such a profile – for a minimum load test and for a ramping test.

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Practice Guide to Get Ready for Flexible Power Plant Operation

29.03.2022
600

500

400
Load [MW]

300

200

100

0
10:30 11:30 12:30 13:30 14:30 15:30 16:00 16:30 17:30 18:30 19:30
Time (IST)

Figure 10: Example of a load profile for minimum load tests.

30.03.2022
600

500

400
Load [MW]

300

200

100

Time (IST)

Figure 11: Example of a load profile for ramping tests.

5.2 Test Runs Procedure

In both tests – the minimum load and the ramping test – the load will be reduced and respec-
tively increased until an obstacle occurs. The load is changed in pre-defined steps. If an ob-
stacle occurs, there needs to be a discussion about how to overcome it. Possible solutions
range from manual intervention to a changed operation regime (e.g. changing combination of
mills, changing main steam pressure, ...). This principle approach is shown in the next figure.

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 Flexibilization Field Report:
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Figure 12: Test run approach.

Before starting the test, it is recommended to reflect on any potential limitations identified in
the Pre-Test Data Assessment. Mitigation measures should be available to overcome obsta-
cles during the tests. As many issues are related to control logics, which are not optimized
for a wide load range, the most common approach to mitigate this situation is to operate the
plant in manual mode. This was the case in all test runs conducted. Hence, a very experi-
enced operating team is required to manage this complex situation.
During the test process, data needs to be recorded. At least the following parameters should
be included:
− burner tilt positions
− oxygen in flue gas before air preheater
− total air flow
− speed of all boiler feed pumps
− feedwater flow
− position of steam valves (e.g. from extraction and cold reheat) feeding the TDBFP
− unit load
− throttle pressure setpoint
− throttle pressure actual value
− main steam temperatures
− main steam temperature setpoint
− main steam flow
− hot reheat steam temperatures
− hot reheat steam temperature setpoint
− feeder speeds

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− total coal flow

− turbine HP control valve position
− reheat pressure
− drum level
− drum level setpoint
− superheater spray flows
− superheater injection control valve positions
− reheat spray flows
− reheat injection control valve positions
− APH flue gas outlet temperatures
− NOx and CO emissions
− metal temperatures
− raw water flow
− heat rate
− coal composition
The sequence in which mills will be taken into or out of operation should also be clear. The
same is true for fans and pumps. However, alternative sequences can also be tried out dur-
ing the tests.

5.2.1 Minimum Load Test Procedure

The following text refers to a real test procedure that was applied in the IGEF project.
Preparation
− Select coal quality. It is recommended to conduct test with a medium coal quality.
(A good coal quality would increase the probability of successful test completion but
would also raise expectations for all-day operation.)
− Discuss function of existing unit control. Turbine follow mode available? Turbine fol-
low mode stable? Transfer to and from turbine follow mode bumpless?
− Clarify if load setpoint for unit coordinated control can be adjusted below 55% or if it is
limited by the control system. If limited, remove limitation (parameter change in logic,
location to be determined); only necessary for test in unit coordinated control.
− Inform system operator that there is an increased risk of tripping during the tests.
Execution
− Put the unit in actual minimum load (55%), using mills B–E.
− Reduce O2 setpoint by 0.5% for 30 minutes. Check influence on APH temperatures.

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Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

− Put O2 setpoint back to normal.

− Slowly decrease main steam pressure setpoint by 10 bar. It is expected that hot re-
heat steam temperatures will increase. This may also lead to higher APH outlet tem-
peratures. Remain at lower pressure for 30 minutes. Observe APH temperatures.
− Slowly put pressure setpoint back to normal.
− Slowly increase burner tilt position until main steam temperatures or hot reheat steam
temperatures approach alarm limits. (If there are reheat spray injections, they may
come into operation.) Wait for 30 minutes. Observe APH temperatures.
− Slowly put burner tilt position back to normal.
− If positive effects on APH temperatures have occurred, adjust one or several of above
parameters in a way that improves APH temperatures.
− Put SCAPH in operation for increased APH flue gas temperatures.
− Reduce main steam temperature setpoint by 5 K in order to get a higher margin be-
fore reaching material limits.
− Take feed water pump out of operation as early as possible and operate with one
pump. If possible, before reducing load below actual min load.
− Take mill E out of operation. Operate with the minimum number of mills (three) that
are required for this load. Use mills B, C and D.
− Switch to turbine follow mode.
− Put feeders in manual.
− Lower load slowly and in steps by manually reducing feeder speeds. Switch over to
one boiler feed pump as early as possible. Load changes should be around 25 MW
(equaling 5%). This can be achieved by reducing each of the three feeder speeds by
5%, e.g. in the first step from 56% to 51%, in the second step from 51% to 46%. The
third step could be smaller, e.g. from 46% to 43%. After each load reduction, wait
about 30 minutes for stabilization and identify process instabilities. If no instabilities,
reduce load further. The third step should get us to about 210 MW. If not, reduce
feeder speed further.
− If there are instabilities, try to solve them by manual intervention. It might be neces-
sary to temporarily increase load if instabilities are becoming too dangerous for oper-
ation.
− When instabilities cannot be eliminated, go back to last safe load.
− Depending on which instabilities occur, determine whether to maybe change mills,
main steam pressure, burner tilts, etc., and repeat to lower load.
− After reaching 40% (210 MW) or when obstacles cannot be overcome, get back to
288 MW by reversing the last steps in the procedure. Increase feeder speed slowly.
(May not be necessary to wait 30 minutes after each increase. This depends on the
stability. Increase load when it is safe to do so.)

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 Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

− At 288 MW, put unit control back to normal, feeder speeds to auto, start feedwater
pump, and start 4th mill. Exact sequence to be determined during operation.
− Put coal dampers to fully open position, if not yet fully opened.
− If successful, repeat test in coordinated mode of the unit control.
− Put the unit in actual minimum load (55%), using mills B–E.
− Select burner tilt, O2 and main steam pressure as found most suitable in last test.
− Put SCAPH in operation for increased APH flue gas temperatures.
− Reduce main steam temperature setpoint by 5 K to get a higher margin before reach-
ing material limits.
− Take feedwater pump out of operation as early as possible and operate with 1 pump.
If possible, before reducing load below actual min load.
− Take mill E out of operation. Operate with the minimum number of mills (three) that
are required for this load. Use mills B, C and D. (Remain in unit coordinated control).
− Lower load slowly and in steps by adjusting the unit control setpoint. Load changes
should be around 25 MW (equaling 5%). This can be achieved by reducing the load
setpoint from 288 MW to 263 MW to 243 MW to 220 MW to 210 MW, using a slow
slope (e.g. 0.5%/min). After each load reduction, wait about 30 minutes for stabiliza-
tion and identify process instabilities. If no instabilities, reduce load further.
− If there are instabilities, try to solve them by manual intervention. It might be neces-
sary to temporarily increase load if instabilities become too dangerous for operation.
− When instabilities cannot be eliminated, go back to last safe load.
− Depending on which instabilities occur, determine whether to maybe change mills,
main steam pressure, burner tilts, etc., and repeat to lower load.
− After reaching 40% (210 MW) or when obstacles cannot be overcome, get back to
288 MW by reversing the last steps in the procedure. Increase load setpoint slowly.
(May not be necessary to wait half an hour after each increase. This depends on the
stability. Increase load when it is safe to do so.)
− At 288 MW, start feedwater pump and start 4th mill. Exact sequence to be determined
during operation.
− Put coal dampers to fully open position, if not yet fully opened.
− This test may have to be conducted on several days, if obstacles occur. 5

These steps can be further detailed as shown in the following table.

5
Test Procedure for the Maithon Power Plant, issued by the IGEF team in June 2021

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 Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

Time (IST) Load Procedure

11:30 290 MW Reduce O2 setpoint by 0.5% for half an hour
12:00 Put O2 setpoint back to normal
12:00 Slowly decrease main steam pressure setpoint by 10 bar
12:30 Slowly put pressure setpoint back to normal
Slowly increase burner tilt position until main steam temperatures or hot re-
12:30
heat steam temperatures approach alarm limits
13:00 Burner tilt back to normal
If positive effects on APH temperatures have occurred, adjust one or sev-
eral of above parameters in a way that improves APH temperatures.
13:00 Put SCAPH in operation for increased APH flue gas temperatures.
Reduce main steam temperature setpoint by 5 K in order to get a higher
13:15
margin before reaching material limits
Take feedwater pump out of operation as early as possible and operate
13:30
with 1 pump. If possible, before reducing load below actual min load.
Take mill E out of operation. Operate with the minimum number of mills
14:00
(three) that are required for this load. Use mills B, C and D.
14:30 Switch to turbine follow mode
14:30 290 MW Put feeders in manual
15:30 Lower load slowly and in steps by manually reducing feeder speeds
After each load reduction, wait about 30 minutes for stabilization
If no instabilities, reduce load further
When instabilities cannot be eliminated, go back to last safe load
17:30 210 MW Reach 40% load
Slowly reduce damper position of burner with highest load, until it reaches
18:00
average load, or until 30% damper position are reached
Wait for stabilization
If another burner is also high on coal, repeat. Wait for stabilization.
Repeat with other burners until equal coal flow
Slowly open all coal dampers or keep them in actual position, depending
on outcome of the test
18:30 210 MW Slowly increase load to 290 MW
20:30 290 MW 290 MW reached
20:30 If not opened before, put coal dampers to open position
Normalization (not part of the test):
20:30 Put feeders in auto
20:30 Switch to unit coordinated control mode
20:30 Start feedwater pump
21:00 Start 4th mill
21:00 Put SCAPH out of service

Table 5: Detailed test procedure for a minimum load test.

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 Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

This table refers to the load profile given in Figure 10.

5.2.2 Ramping Test Procedure

The following text refers to a real test procedure that was applied in the IGEF project.
Preparation
− Discuss possibilities to improve burner tilt and drum level control. If this is done prior
to the load ramp test, it requires some hot commissioning (drum level approx. ½ day
at full load, and ½ day at low load. Same for burner tilts. Corrections will only be ac-
tive during the hot commissioning and during the load ramp tests.)
− Discuss lowest load that can be achieved with 6 mills (while still maintaining some
margin for the mills to control).
− Discuss target speed of load ramp.
− Discuss, how fast load ramps can be when mills have to be stopped/started.

Execution
Tests without starting/stopping mills:
− Put the unit at full load, operation as usual.
− Put speed of load ramp to 0.5%/min.
− Change load setpoint in one step from 525 MW to 450 MW (operation of (up to) 6
mills is possible at this load setpoint). Will take about 30 minutes to get to 450 MW.
− Wait for stabilization (30 minutes).
− Change load setpoint in one step from 450 MW to 525 MW. (Will take about 30
minutes).
− Wait for stabilization (30 minutes).
− If successful, and all control loops have been stable enough during the ramps: repeat
test with a faster load gradient. The speed of the load ramp should be decided based
on the outcome of the previous test. Preferably 1%/min, if outcome was positive.
− If successful, and all control loops have been stable enough during the ramps: repeat
test with a faster load gradient. The speed of the load ramp should be decided based
on the outcome of the previous test. Preferably 1.5%/min, if outcome was positive.
− Repeat with ever-increasing speeds until alarm limits are approached during one of
the ramps.

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 Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

Tests with starting/stopping mills:

− Put the unit at full load, operation as usual.
− Put speed of load ramp to 1%/min. (Depends also on previous tests. To be discussed
prior to the test.)
− Change load setpoint in one step from 525 MW to 288 MW. Time to reach new load
depends on speed of the load ramp:

Speed of ramp Time to reach load

0.5%/min 90 min

1%/min 45 min

1.5%/min 30 min

2%/min 23 min

− Optionally, instead of lowering load to 288 MW, lower load to below 288 MW, depend-
ing on the outcome of the min load tests.
− During ramp, manually take mills out of operation.
− If problems occur, stop ramp and stabilize.
− After completion of ramp: Wait for stabilization (30 minutes).
− Change load setpoint in 1 step from 288 MW (or lower, whatever actual load is) to
525 MW.
− During ramp, manually start mills.
− If problems occur, stop ramp and stabilize.
− After completion of ramp: Wait for stabilization (30 minutes).
− If successful and all control loops have been stable enough during the ramps, repeat
test with a faster load gradient. To be discussed based on the outcome of the previ-
ous test, how fast the load ramp should be. Consider time for starting and stopping
mills.
− Repeat with ever-increasing speeds until alarm limits are approached during one of
the ramps, or target speed has been reached, or time for starting/stopping mills is not
sufficient any more.
− This test may have to be conducted on several days, if obstacles occur. 6

6
Test Procedure for the Maithon Power Plant, issued by the IGEF team in June 2021

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 Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

Time (IST) Load Procedure

12:30 500 MW
Put speed of load ramp to 0.5%/min
12:30
(or faster, depending on previous tests)
Change load setpoint in one step from 525 MW to 450 MW (operation of
12:30 (up to) 6 mills is possible at this load setpoint). Will take about ½ hour to
get to 450 MW
13:00 430 MW Wait for stabilization (15 minutes)
Change load setpoint in 1 step from 450 MW to 525 MW.
13:15
(Will take about ½ hour.)
13:45 500 MW Wait for stabilization (15 minutes)
If successful, and all control loops have been stable enough during the
ramps: repeat test with a faster load gradient. The speed of the load ramp
14:00
should be decided based on the outcome of the previous test. Preferably
1%/min, if outcome was positive.
14:15 430 MW Wait for stabilization (15 minutes)
14:30 Setpoint to 525 MW
14:45 500 MW Wait for stabilization (15 minutes)
If successful, and all control loops have been stable enough during the
ramps: repeat test with a faster load gradient. The speed of the load ramp
15:15
should be decided based on the outcome of the previous test. Preferably
1.5%/min, if outcome was positive.
15:30 430 MW Wait for stabilization (15 minutes)
15:45 Setpoint to 525 MW
16:00 500 MW Wait for stabilization (15 minutes)
Put speed of load ramp to 1%/min.
16:00 500 MW
(Depends also on previous tests. To be discussed prior to the test.)
16:00 Change load setpoint in one step from 525 MW to 288 MW
During ramp, manually take mills out of operation
If problems occur, stop ramp and stabilize
16:45 290 MW After completion of ramp: Wait for stabilization (30 minutes)
17:15 Change load setpoint in one step from 288 MW to 525 MW
During ramp, manually start mills
If problems occur, stop ramp and stabilize
18:00 500 MW After completion of ramp: Wait for stabilization (30 minutes)

Table 6: Detailed test procedure for a ramping test.

This tables refers to the load profile which is given in Figure 11.

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 Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

6 Test Run Assessment: Flexibilization Plan

The test run assessment is based on the observations and findings during the test runs in
combination with an analysis of the recorded operating data. In general, the assessment is
structured according to the following areas:
− combustion
− steam conditions
− feed water (e.g., drum level)
− mill load
− flue gas conditions
− metal temperatures
− heat rate
− NOx emission
The data are visualized in the same way as in the Pre-Test Data Assessment. The following
figure is taken from a test run assessment providing an overview of the main plant parame-
ters during the minimum load test.

Figure 13: Main plant parameters during a minimum load test.

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 Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

In this example, the following observations were made at 190 MW:

− RH steam temperature low (523°C and decreasing → efficiency loss). However, the
values were not as low as those at other comparable plants.
− FD fan positions 8%, which is not a good range for control.
− Manual drum level control. During minimum load operation, TDBFP A auxiliary control
valve was controlled manually throughout. Drum level setpoint to vary accordingly.
− Flue gas exit temperature at APH outlet decreased to 109.4°C and 112.4°C (below
actual acid dew point).
− Flame intensity at AB2, AB3 and BC2 showing low. Fireball at AB was flickering inter-
mittently.
− Hotwell level remained high >2000 mm Water Column (steam consumption from U1).
− U1 steam flow was increased to 40 t/h at U1 load >500 MW. U1 cold RH bypass mo-
torized valve was opened. Dependency on other unit for steam.
− MDBFP was kept in manual throughout.
− Logic modification required; single fan operation was not possible due to ID fan cur-
rent remaining on higher side and due to flame instability.
− Turbine vibration for HP front bearing (bearing 1) shaft X rose to 116 microns. At 290
MW it is maintained at 100 microns. 7
Such observations were collected for all test situations – also for the ramp test. The next fig-
ure shows an example depicting main parameters for a ramp test.

Figure 14: Main plant parameters during a ramp rate test.

7
Maithon Test Report issued by the IGEF team in June 2021

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 Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

The classification of theses curves was as follows: When ramping up, the unit control gives
priority to building up the pressure. First of all, the increase of fuel leads to a build-up of pres-
sure and only later to more generation (Megawatt). This can be seen in the graph above
whenever the green curve (pressure) increases ahead of the pink curve (MW). This is only
the case in the upward direction. 8

6.1 Common Findings

Based on the results of the test runs in India, it was possible to identify the main areas that
pose problems for flexible operation. They are shown in the following figure.

Figure 15: Potential issues during flexible operation.

Combustion and Boiler

One of the biggest challenges is to ensure flame stability in low load ranges. Besides the
monitoring of important combustion parameters, such as oxygen and CO content, it is essen-
tial that flame scanners operate properly. Ideally, there should be individual flame scanners
for each burner – this is not usually the case in Indian power plants.

The high number of coal mills is an advantage in Indian power plants. This provides flexibil-
ity for load adjustments. A key challenge here is the smooth transition of mills when reducing
or increasing the load. As a general rule, it is better to keep lesser mills running in a higher
operational range than the other way round. This operation mode is more stable – during the
test, at a minimum load of about 35% to 40%, usually three mills were in operation.

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Maithon Test Report issued by the IGEF team in June 2021

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 Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

During fast load changes, high temperature gradients in thick-walled components can cause
thermal stress. Therefore, metal temperatures should be closely monitored to ensure that
critical operating situations can be avoided, e.g., by using burner tilts.

Water-steam cycle
An unstable drum level control was one of the key obstacles during the test runs. Switching
between feed water pumps in low load operation, in particular, caused stability issues. One
reason is that the recirculation valve of the turbo-driven boiler feed pump (TDBFP) is usually
an on-/off-type of valve. The opening and closing of this valve causes significant turbulence
in low load ranges. Therefore, these valves should be substituted by control valves to im-
prove the controllability of the process. Moreover, low steam temperatures also become an
issue at low load – especially in view of the heat rate. This problem can be mitigated by im-
proving the spray controls. Burner tilts can also serve as a measure to increase steam tem-
peratures.

The turbine can also become a problem – although, usually this is not the case. However,
turbine vibration should be closely monitored in order to avoid critical situations.

Flue gas
In low load conditions, low flue gas temperatures can become a major concern if they fall be-
low the flue gas dew point. This can cause significant damage to the air preheater. There-
fore, the flue gas temperatures at the air preheater (APH) outlet need to be monitored and
controlled properly. It is recommended to use the steam coil air preheater (SCAPH) to en-
sure that necessary temperature levels in low load conditions are maintained. Such SCAPH
are usually available in Indian power plants – but are often not in service.

NOx
It can be excepted that NOx decreased with load. This could also be detected during the test
runs (see the following figure).

Figure 16: NOx emissions and load during the minimum load tests.

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 Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

However, the generation of NOx strongly depends on the amount of O2. The major source
of NOx production from nitrogen-bearing fuels is the conversion of fuel bound nitrogen
to NOx during combustion. During combustion, the nitrogen bound in the fuel is released as
a free radical and ultimately forms free N2, or NO. During the release and before the oxida-
tion of the volatiles, nitrogen reacts to form several intermediaries which are then oxidized
into NO. If the volatiles evolve into a reducing atmosphere, the nitrogen evolved can readily
be made to form nitrogen gas, rather than NOx. It can be seen from the test data that NOx in-
creased with the amount of O2 in the flue gas.
This means that the amount of air available at the burners in service is too important and
causes a combustion in an oxidizing environment which releases NOx instead of N2. The NOx
level also depends on the burner constellation.

Heat Rate
The heat rate at various load points during one test run is provided in the next figure. The
data represent stabilized conditions during the test runs. However, the coal quality variation
was very high as a result of blending. Therefore, as an example, the Gross Calorific Value
was in a range of 3,545 kcal/kWh to 5,640 kcal/kWh.

Figure 17: Heat rate relative to load during the test runs.

For these test runs – in addition to the conversion of the heat rate values – the unit efficiency
was calculated based on the heat generated in the superheater and the re-heater. These val-
ues were in the range of 37% at low load and increased to 41% or 42% at high load. These
efficiency values seem to be more conclusive as the data derived from the coal analysis.

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 Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

Figure 18: Efficiency during the test runs.

6.2 Flexibility Measures

Based on the findings, measures to ensure a safe, reliable and steady minimum load opera-
tion, as well as reasonable ramp rates to enhance the dynamic behavior of the plant, were
proposed. Most of the proposed measures were similar in all three test plants. Therefore, it
can be assumed that they also apply to other plants with a similar design. As a result of the
test runs, it is anticipated that the minimum load of such plants is about 40%. This is a level
that can be reached without too much effort. With respect to ramp rates the achievable level
is estimated at about 2% load per minute.

The measures are divided into mandatory and optional categories. The following section dis-
cusses common measures for both categories.

6.2.1 Mandatory Measures for Minimum Load Operation

Thermal Feasibility Study

In order to get transparency about the temperature conditions in the boiler and, thus, about
the stress on important components, a thermal feasibility study of the boiler is recommended.
Such a study would involve the evaluation of process limitations and an assessment of the
impact of low load operation and temperature, as well as the impact of pressure gradients on
the boiler components and equipment. As such, the study would also be essential for en-
hancing the ramp rates of the plant.

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 Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

The thermal feasibility study of the boiler for part load operation should be based on a ther-
mal boiler model that is calibrated with the test data. The calibrated thermal boiler model
should include a thermal evaluation of minimal achievable stable boiler part load for coal
range, a boiler heating surface degradation evaluation, a hardware/software check and a risk
evaluation of boiler components and mitigations. All relevant systems of the boiler (pres-
sure/non-pressure parts, combustion/burner system, flue gas part, I&C etc.) should be exam-
ined with regards to the long-term operation of all relevant new part load cases (incl. power
degradation potential).
Using the test data, a thermal feasibility study of the boiler should be carried out in order to
find and avoid mid and long-term damage/limitations of the boiler systems (design and oper-
ation). Evaluation of process limitations should be carried out. The most commonly used coal
should be analyzed, as well as the potential full range of coal – including coal with maximum
problematic contents such as ash, moisture, sulphur, etc..
Based on the study’s findings, further relevant measures can be defined. These measures
range from advanced (automated) control strategies, including combustion optimization,
ramping and start-up, to the concept of an economizer bypass to increase the APH flue gas
outlet temperatures at low load.

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 Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

Control Optimization and Feedwater Recirculation Valves

Further mandatory measures focus on control optimization.

A) Drum Level Control

The tests showed that drum level controls were not tuned for low load operating
ranges that require auxiliary steam from another unit for TDBFP operation. That is
why it is recommended to upgrade or implement new controls for turbine-driven boiler
feedwater pumps when fed by auxiliary steam from another unit. The current operat-
ing regime is associated with an increased trip risk and requires a lot of operator at-
tention. In this context, the replacement of the feedwater recirculation valves with
modulating type valves will also improve the drum level control. Currently, the open-
ing of the valves causes big disturbances.

Furthermore, an upgrade or implementation of new controls is necessary for the tur-

bine-driven boiler feedwater pumps when fed by auxiliary steam from another unit.
Currently, these controls are not working properly – there is increased trip risk and a
lot of operator attention is required. An automated start and stop sequence of the
BFPs is also required.

B) Flue Gas Temperature Control

The SCAPH should be taken into operation automatically whenever needed. This
would enable the flue gas temperature to be controlled through the use of the steam
APH. This control combined with the upgraded temperature control would prevent
corrosion in the APH.

C) Automated Start and Stop of Mills

Automated start-up and shut-down sequences for the mills are necessary to enhance
the flexible operation.

D) RH Steam Temperature Control

Although the re-heat steam temperature was sufficiently high for the turbine during
the tests, improvement of the heat rate at part load operation is recommended. The
re-heat steam temperature should be controlled by using burner tilts as part of the au-
tomated control. Currently, burner tilts are operated manually and consequently re-
heat steam temperatures are dropping during low load operation. This causes an
avoidable loss of efficiency. The implementation comprises further test runs to investi-
gate the influence of the burner tilts, as well as the design and integration of the logic
for the automated RH steam temperature control.

6.2.2 Mandatory Measures for Ramp Rate Improvement

As already mentioned in the previous chapter, a thermal feasibility study of the boiler will also
be essential for enhancing the ramp rates of the plant. With the help of the model which will
be developed in the course of this study, it will be possible to derive measures to decrease

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 Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

SH and RH metal temperatures in cycling operation regimes, e.g. by effectively applying the
burning tilts. The findings of the thermal feasibility study will also provide the basis for the op-
timization of various controls.

Control Optimization
Further mandatory measures focus on control optimization.

A) Upgrade furnace/windbox delta pressure (dp) control

The setpoint should be given automatically depending on load.

B) Upgrade furnace pressure control

The secondary air control and furnace/windbox dp control should be decoupled. This
will stabilize the furnace pressure and remove oscillations.

C) Change unit control (Coordinated Master Control CMC)

These changes should enable the load to change sooner in the upward direction, and
the pressure later. This would have the following effects:
− better cooling of RH tubes when steam flow increases, less MTM increase
− better drum level stability
− better fuel / air coordination
− better fuel / load coordination
− faster and smoother ramps
It should be noted that ramp rate improvements, as well as stable minimum operation,
strongly depend on a stable and optimized combustion – some control optimization
measures have already been mentioned. Coal flow balancing, which is based on an online
coal flow measurement system and variable orifices, is another promising measure, not only
to enhance flexibility parameters but also to increase efficiency and to reduce NOx emissions.
Although the functioning of such systems could already be demonstrated (see next chapter),
a full-scale test – equipping at least the mills in operation at minimum load with such a sys-
tem – has yet to be carried out. Such a test would provide valuable insights into the effective-
ness of coal flow balancing for the benefit of flexibilization, efficiency and emissions.

6.2.3 Further Measures for Flexibility Enhancement

Control Solutions
If mandatory measures are implemented, some further control upgrades can be implemented
to ensure smooth and efficient plant operation at different load levels as well as with mini-
mum load:

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 Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

A) Unit Control and Automatic Mill Operation (Mill Scheduler)

The main task of the unit control is to provide setpoints for the steam generator and
the turbine that meet specific requirements defined by the operator or load dispatcher.
The two main variables – steam pressure and unit load – have to be controlled by the
slow-acting boiler and the fast-acting turbine. The dynamic behavior of the plant is
replicated using a simplified model of the unit dynamics, which only includes the com-
ponents for boiler dynamics and steam storage.
An additional task of the unit control is to automatically take fans, BFPs and mills into
operation during load ramps, in order to allow smooth and uninterrupted load
changes. A mill scheduler is subordinate to the unit control and switches coal mills
ON / OFF automatically depending on the firing demand and the actual number of fir-
ing devices in service. The center line for the firing devices in service can be speci-
fied. This enables the boiler’s firing balance point to be ascertained, e.g. depending
on the start-up conditions of the boiler (cold, warm or hot start). The system also has
an automatic replacement strategy should one mill not go into service or fail during
service.

B) Main Steam Temperature Control

The current main steam temperature deviations are too large and the high values will
potentially result in higher lifetime consumption of boiler parts. Therefore, the imple-
mentation of a temperature controller is necessary.
The main task of the temperature controller is to achieve stable steam temperatures
so that main steam temperatures can be controlled based on a load-dependent set-
point in all load situations. In normal load operation, setpoint changes occur very
rarely. Disturbances that have to be compensated for quickly - so as to allow the unit
to be operated close to the material limit - represent the most critical situations.
The temperature control concept should be suitable for all boiler types, regardless of
the load, fuel, type of evaporation (drum or Benson-type boiler) or pressure character-
istics, such as fixed or modified sliding-pressure mode. These influences are reflected
in the temperature control parameters but the basic structure is always the same. The
control structure should comprise two main parts:
− The dynamic setpoint calculation
− The subordinated control loop that controls the temperature based on the dynamic
setpoint calculation
The same structure should be applied to different steam temperature control concepts.

Coal Flow Balancing

An online coal flow measurement system (CFMS) provides detailed information about the
coal distribution between mills and coal dust pipes. It also enables combustion optimization
by trimming the air/fuel ratio. Ideally, in addition to the coal flow measurement, controllable
variable orifices should be installed so that coal flow balancing is possible. The main benefits
of such a combined system of online coal flow measurement and variable orifices are:

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 Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

− imbalances occurring during minimum load operation can be detected and

balanced
− air/fuel ratio can be optimized in all load conditions
− inherent storage of mills can be used by increasing primary air flow
− individual burner adjustment is possible
− less CO at boiler walls prevents boiler corrosion
− less NOx emissions and higher efficiency through combustion optimization
Practice shows that a uniform coal flow distribution inside coal dust pipes seldom arises.
Thus, the system must be able to identify and compensate such rope formation – ideally, by
actively manipulating the coal flow via variable orifices.
The effectiveness of CFMS has been demonstrated in various applications, e.g. by Siemens
Energy in power plants in Poland and South Korea, as well as by BMW Steels. The latter ex-
ecuted CFMS tests at one mill at MPL in September 2021. According to BMW Steels’ report,
coal flow balancing was achieved by adjusting temporarily-installed variable orifices. It was
thereby possible to equalize the coal flow in the four pipes to the mill up to a maximum per-
centage deviation of 5.85%. The maximum percentage deviation prior to the balancing was
up to 47.80%.

Condition Monitoring
Condition monitoring systems monitor highly loaded boiler and piping components against
creep and fatigue. Such a system monitors the temperature differences and pressure, and
signals when the allowable limits during load changes have been exceeded. It would be inte-
grated into the existing I&C system and calibrated based on the FEM analysis. It would com-
prise different sub-systems that are explained in the following paragraphs.
The Boiler Fatigue Monitoring System can determine the residual lifetime of highly
stressed components by calculating the creep and low-cycle fatigue of specific components
(in line with EN12952) during real-time operation. Water and steam piping components such
as headers, manifolds, drums, attemperators and piping all have a limited life span. The sys-
tem enables deviations to be detected online and early on, based on real-time signals and
active management of an operating database. The benefits are:
− transparency in operating mode on residual life
− detection of high-wear operating modes
− in-time notification for overhaul and inspection requisite
− enhanced power plant safety and reliability
− utilization of component material reserves
− cost-effective in-service monitoring and analysis

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Figure 19: Overview of a boiler fatigue monitoring system.

The EOH concept provides an overview of the life consumption of standard operating hours
as well as of ESH that reflect load changes and actual stress on the turbine components sub-
jected to ramp up and ramp down. The so-called ESH are calculated from temperature differ-
ences in thick-walled turbine components arising during turbine start-ups, shutdowns and
load changes with distinct steam temperature changes. Hence, the ESH represent the tur-
bine service life expenditure caused by temperature induced stresses.

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7 Implementation Recommendation: Deployment

As a result of the IGEF test runs, NTPC decided to implement a set of flexibility measures in
their Dadri power plant (unit 6). This set comprised the optimization of existing control loops
as well as the introduction of a mill scheduler – a control logic that takes the mill in or out of
operation automatically based on the plant requirements. Furthermore, a controllable recircu-
lation valve was installed in order to ensure smooth control of TDBFP operation at low load.
The according logics were also implemented. In the course of this control optimization pro-
cess, sequences to take in or take out operation main components - such as ID, FD, PA fans
and BFPs - were also automated. These logics did already exist in the MAX DNA system of
BHEL – in many cases these logics had to be modified and/or commissioned.
Building confidence in automated solutions
Gradually, the plant team is learning to trust in the automated solutions key to enhancing the
flexibility of plant. Therefore, it is strongly recommended to foresee enough time in the plan-
ning for the introduction of automated solutions. A good starting point would be an inventory
of the current status of main equipment and control loops with regards to the level of automa-
tion (e.g. from 0 – manual operation to 5 – fully automated operation). Experience shows that
the higher the automation level, the better the flexibility of the plant. Manual interventions
should be reduced to a minimum, especially with respect to fast and efficient start-up.
However, the level of confidence in automated solution needs to be built up. Therefore, a
good compromise should be found according to the plant situation. A no-regret activity is that
every Indian plant check the start and stop sequences of its fans, pumps and mills. These
logics are most likely already existing in the control system and just need to be aligned to the
actual operating procedure.
Due to the high ash content of the Indian coal, it is unlikely that coal-fired power plants can
reduce the minimum load to below 40% without any additional coal treatment. If lower loads
need to be achieved, a concept for homogenization and enhancing coal quality should be de-
veloped. Such a concept could include washing, blending, coal cleaning at site as well as
online coal analysis.
In order to ensure proper combustion control and thereby guarantee a reliable minimum load
operation, proper flame detection – ideally, individual for each burner but not feasible in
many Indian plants – and reliable measurement of O2 and CO are essential.
In any case, a review of all operating procedures is required in order to adapt and modify
them for flexible operation. The following listing provides some practical tips that could be
considered in this context.

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Plant area combustion / mills

Issues − minimum number of mills / burners / burner level ensuring a sufficient
ignition and, respectively, combustion
− minimum coal flow
− air distribution control
− inertia and smooth switch over
Mitigation − Many Indian plants have six or more mills. For minimum load opera-
tion, the boiler will be most likely operated with three mills.
− Optimized combustion control based on the test run experiences in
part load operation; special focus on reaction time and mill switch-
over. Note: It is better running fewer mills at higher load than more
mills at low load – the combustion stability increases.
− Optimized grinding: enables better usage of the fuel – improving the
combustion process, precondition is the use of washed coal, respec-
tively coal without stones, rocks and other hard impurities.
− The control criterion for taking the first mill into operation should be
the temperature inside the respective coal mill (classifier). This tem-
perature should be higher than 70°C in order to avoid water dew point
in the mill and, consequently, to avoid corrosions and blockings inside
the coal mill caused by wet coal dust.

Plant area combustion / burners

Issues − Flame stability (flame pulsation and blow-off)
− Air distribution
Mitigation − Ensure reliable flame detection
− Improve air-fuel ratio
− Increase mixture and swirl
− Ensure equal coal dust distribution to burners
− Reduce cooling air flows
− Improve positioning accuracy of air control flaps
− Use upper burner levels to keep required steam temperatures at low
load, in order to shift heat transfer from the evaporator to the super-
heater / reheater sections

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Plant area Water-steam cycle / chemistry

Issues − Proper water and steam quality at all load conditions in order to avoid
corrosion
− Cycling results during peak demand on condensate supply and oxy-
gen controls
Mitigation − Strict adherence to proven quality standards such as VGB-S-010-T-
00; 2011-12.EN “Feed Water, Boiler Water and Steam Quality for
Power Plants/Industrial Plants”

Plant area Water-steam cycle / evaporator and superheater

Issues − Differences of wall temperatures and material stress
− Avoidance of overheating
Mitigation − Ensure sufficient water / steam flow
− Optimize operation procedures for ramping
− Check for design buffer in minimum feedwater flow, especially in
once-through boilers
− Use circulation mode
− Monitor conditions

Plant area Turbine

Issues − Ventilation (reverse steam flow in the exhaust steam zone)
− Vibration excitation at the last-stage blades
− Water droplet erosion
− Vibration and expansion due to thermal stress (casing, bearings and
shaft)
Mitigation − Implement protective functions in the HP and LP turbine
− Extend vibration monitoring
− Cool blades and casing – for LP a, controlled flow and fast evacuation
via direct link to condenser
− Improve condenser vacuum
− Optimize drainage
− Optimize start-up procedures
− EOH (Equivalent Operating Hours) counter to quantify the lifetime
consumption due to thermal stress
− Improve condition and temperature monitoring

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Plant area Generator

Issues − Thermo-mechanical stress on generator components, especially at
stator windings
Mitigation − Integrate online monitoring and diagnosis: control of the cooling tem-
perature, partial discharge measurement and stator end winding vibra-
tion measurements

Plant area DeNOx

Issues − NH3 slip
− Fouling and corrosion
− Ammonium sulfate formation
Mitigation − Ensure minimum flue gas temperature at all load conditions
(use higher burner level and higher air ratio)
− Improve dosing control
− Enamel coating required at the cold end

Table 7: Issue lists for different plant areas.

Condition monitoring to manage life-time consumption

In order to mitigate negative consequences of flexible operation, condition monitoring sys-
tems are a very useful tool. With their help, it is possible to operate the plant in cycling mode
without compromising the material limits of the plant components. Changing pressure and
temperature-related stresses on the components pose the greatest challenge. This can lead
to increased wear, which is due, in particular, to fatigue damage caused by the cyclical loads.
In the past, the damage mechanism caused by the creep was the main cause of service-life
wear and tear. With flexible operation, the wear and tear caused by fatigue comes into focus.

Moreover, there is also wear and tear due to higher utilization and corrosion caused by
changes in plant chemistry and water excess from increased condensation. The following ta-
ble lists the typical plant equipment most affected by cycling operation.

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Plant equipment with most Primary damage mechanism

significant impacts
Boiler water-walls Fatigue corrosion; corrosion due to oxygen and chemical
deposits (depending on water quality)
Boiler superheaters High temperature differential and hot spots from low steam
flows during start-up, long-term overheating failures
Boiler reheaters High temperature differential and hot spots from low steam
flows during start-up, long-term overheating failures, tube
exfoliation damages IP turbines
Boiler economizer Temperature transient during start-ups
Boiler headers Fatigue due to temperature ranges and rates, thermal dif-
ferentials tube to headers; cracking in dissimilar metal
welds, headers and valves
Drum Thermo-mechanical stress at drum walls
LP turbine Blade erosion
Turbine shell and rotor clear- Non-uniform temperatures result in rotor bow and loss of
ances desired clearance and possible rotor rubs with resulting
steam seal damages
Feed water heaters High ramp rates during starts; not designed for rapid ther-
mal changes
Air heaters Cold end basket corrosion when at low loads and start up,
acid and water dew point
Fuel system / pulverizers Cycling of the mills occurs from even load following opera-
tion as iron wear rates increase from low coal flow during
turn down to minimum

Table 8: List of critical components.

A thermal feasibility study of the boiler would set the baseline for the assessment of proper
temperature conditions in the boiler and the stress on the listed components (except the tur-
bine parts). This study provides transparency about the limitations and set points (e.g., for
metal temperatures) for efficient, dynamic but gentle operation. In order to ensure strict com-
pliance with these values, the instrumentation for relevant combustion-related measurements
needs to work properly. Furthermore, we recommended implementing condition monitoring
systems to monitor the lifetime consumption. Hence, the Dadri team decided to integrate a
Boiler Fatigue Monitoring System and EOH counter for the turbine.
The following table provides an overview of helpful (European) regulations and vgbe stand-
ards with regards to inspections, testing and calculating the operational lifespan of equip-
ment.

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Pipeline Header / drum Injection cooler

Calcula- − VGB-S-109 − VGB-S-109 − VGB-S-109
tion/ de- − VGB-R 507 section − VGB-S-013 − VGB-S-013
sign 4.3.2 with references − EN 12952-3 − VGB-S-540
to: FDBR Guide- − EN 13445-3 (A1 item − EN 13480-3
line “Design of power 19) − EN 13445-3
piping” and VDI man- − TRD series 300*, 508* − TRD series 300*,
ual Energy Technolo- − AD 2000 series B/S 508*
gies − Finite elements − AD 2000 series B/S
− VGB-S-013 (boiler in- method − Finite elements
terior) method
− VGB-S-503
− VGB-R 510
− EN 13480-3
− TRD series 300*, 508*
− AD 2000 series B/S
− AD 2000 series HP
100R (replacement for
TRR 100)
− Finite elements
method
Extended − VGB-R 508 − VGB-S-013 − VGB-R 540
inspection − VGB-R 510 − DIN EN 13445-5 − DIN EN 12952-6
− EN 13480-5 − DIN EN 12952-6
Diagnostic − VGB-S-509 (periodic − TRD series 500* − TRD series 500*
test inspection) in conjunc- − VGB-S-509 (periodic − VGB-R 540 in con-
tion with VGB-R 510 inspection) in conjunc- junction with
− VGB-S-517 tion with VGB-R 510 VGB-R 509
− (microstructure rating − VGB-TW507 − VGB-S-517
charts) − (microstructure rating − (microstructure rating
charts) charts)
Diagnostic − TRD 508*/EN 12952-4 − TRD 508*/EN 12952-4 − TRD 508*/EN12952-4
lifetime − TRD series 300* / EN − TRD series 300* / EN − TRD series 300*
calculation 12952-3 12952-3 − EN 12952-3
− Force/displacement − DIN EN 13445-3 A1 − Finite elements
transducer with diag- (Appendix M) method
nostic system by the − Finite elements
manufacture method
− Finite elements
method

Table 9: Existing regulations and vgbe standards with respect to condition monitoring.

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Need for preservation or lay-up procedures

Preservation or lay-up procedures are another important aspect. Boiler tube failures and
other corrosion fatigue effects can be reduced by defining lay-up procedures, depending on
the duration of the plant being off-line. For implementing suitable preservation procedures to
protect equipment, the vgbe standards “Preservation of Power Plants” and “Preservation of
Steam Turbo-Generator Set” could serve as a guideline.
Flexible operation with cycling, part load and minimum load operation should be considered
in the design of the flue gas equipment. The flue gas treatment needs to comply with envi-
ronmental norms at all potential load conditions. Cycling load operation has an impact on
DeNOx and DeSOx systems – e.g. pumping operation scheme and dosing control.

7.1 Flexibility Checklist

The following table includes a summary of the most important elements in the flexibilization
process of a typical sub-critical Indian power plant. For each equipment and control loop, op-
erational procedures should be reviewed and extended for a wider load range. In a continu-
ous improvement process the effect of these measures should be monitored and further ac-
tions might be taken to further optimize.

Designation Optimized load Autom. Level: Remark

range 0 none – 5 fully
Equipment
Mills − Define optimized mill se-
quence for ramp-up and
ramp down
− Define optimized mill config-
uration for minimum load
− Ensure automated start-up
and shut-down of mills
− Consider a mill scheduler for
automated ramp-up and ram-
down of mills
ID fan(s) − Optimize load range of fans
− Ensure automated start-up
and shut-down of fans
− Ensure optimized switch-
over from or to one-fan oper-
ation (in case there are > 1
fan)
− Consider automated fan con-
trol and switch over
FD fan(s) see ID fan
PA fan(s) see ID fan

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Designation Optimized load Autom. Level: Remark

range 0 none – 5 fully
SA fan(s) see ID fan
MDBFP(s) − Optimize load range of
pumps
− Ensure automated start-up
and shut-down of fans
− Ensure optimized switch-
over from or to one-pump op-
eration
− Consider automated pump
control and switch over
TDBFP(s) see MDBFP
− Ensure that the recirculation
valve is a controllable one –
optimize the control in low
load range, e.g. even con-
sider automated control
APH Critical equipment in low load
operation – ensure flue gas tem-
peratures above acid dew point
SCAPH − Keep this equipment in
“ready-to-operate” state –
beneficial to ensure flue gas
temperature level above acid
dew point
− Automated start-up and stop
are desirable
Burners Burner tilts are a key lever for
steam temperature control (esp.
in low load)

Control loops
Drum level − MDBFP and TDBFP need to
be optimized for the full load
range (see above)
− Optimized control parameter
for the full load range – con-
sider automated control
− Include feed-forward control
to ensure higher dynamics

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Designation Optimized load Autom. Level: Remark

range 0 none – 5 fully
Main steam temp. − Optimized control parameter
for the full load range – con-
sider automated control
− Use burner tilts for control
− Include feed-forward control
to ensure higher dynamics
RH steam temp. See main steam temp.
Flue gas temp. Consider SCAPH operation to
maintain temperatures above
acid dewpoint
SH RH metal temp. − Use burner tilts for control
− Adjust set points according
to the results of the thermal
feasibility study for the boiler
Windbox dp and fur- − Use automated set points
nace pressure − Decouple (secondary) air
control and furnace/windbox
dp control
Unit Control − Significant influence on the
dynamic behavior of the
plant – can be enhanced by
integrating a simplified model
of the unit dynamics that only
includes the components for
boiler dynamics and steam
storage
− Integration of advanced solu-
tion such as condensate
throttling improves the flexi-
bility of the plant
Others
Start-up sequence Full range − Decrease of start-up time re-
quires optimized procedures
for all steps (start of fans,
pumps, mills etc.)
− The higher the automation
level, the faster the start-up

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Designation Optimized load Autom. Level: Remark

range 0 none – 5 fully
Instrumentation Full range n.a. − Reliable measurements in
(e.g. for RH metal the full range are essential –
temp., O2, NOx and quality and quantity of exist-
CO, windbox dp, fur- ing instrumentation should
nace pressure, be checked
flame scanners, − If necessary, a substitu-
steam temp. and tion/modernization of instru-
pressures, flue gas mentation should be consid-
temp.) ered
Condition Monitoring − Provide important infor-
Systems such as mation about the equipment
Boiler Fatigue Moni- status with respect to the op-
toring System, EOH
erational lifespan
counter for the tur-
bine, vibration moni- − Not directly required for flexi-
toring ble operation but very benefi-
cial to mitigate
Table 10: Flexibility check list for sub-critical Indian power plants.

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8 Useful Publications and Standards

8.1 International Reports and Publications on Best Practices

1) Nepper-Rasmussen B. C. et al., Development and Role of Flexibility in the Danish
Power System, 2021
The study presents the development of flexibility options in the Danish Power System
from 2000 to 2020. It reflects the lessons learnt gathered over the past two decades
and puts a special focus on the Combined Heat and Power (CHP) concept which is
very common in Denmark.
2) Sinha, Anjan: The Recipe Book for the Flexibilization of Coal Based Power Plants,
Indo-German Energy Forum, 2020
This book presents best practices and operating procedures for the flexible operation
of coal fired power plants in India. It is based on the review of published international
literature, inputs from pilot studies carried out in Indian power stations (including the
test run activities under the auspices of the Indo-German Energy Forum with VGB in-
volvement) and experts’ interviews. It was compiled by Mr. Anjan Sinha, a highly
acknowledged Indian expert on this subject who worked for NTPC for many years.
3) Storm, Stephen: High-Level Flexibility Assessment and Benchmarking Tool, Electric
Power Research Institute, Report 3002019900, 2020
This publication introduces flexibility templates to support power plant operators in
complex flexibility assessments. By using theses templates, it is possible to identify
design limitations and operating gaps, as well as areas for improvement. The tem-
plates are applicable to both subcritical and supercritical steam generators with a ca-
pacity of more than 100 MW. The publication also provides recommendations on miti-
gation measures to prevent costly equipment damage due to flexible operation.

4) Wiatros-Motyka, Malgorzata: Power Plant Design and Management for Unit Cycling,
Report from IEA Clean Coal Centre CCC/295, 2019
In this study, different modes of cyclic operation of coal-fired plants and strategies for
managing the negative impacts are identified. Options include new operating prac-
tices, use of advanced materials, suitable design features, power plant preservation
during standby and installation of improved control systems. Such measures can im-
prove unit heat rates and reduce the number of forced outages in existing fossil fuel-
fired plants, as well as in new builds. This study also identifies potential trade-offs as-
sociated with technology selection for enhanced flexibility. Examples from Germany,
India, Poland and USA are given.

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5) Central Electricity Authority: Flexible Operation of Thermal Power Plants for Integra-
tion of Renewable Generation, CEA-Report, 2019
This is an official Government of India report which reflects on the implications of
large-scale renewable generation integration and the need for flexible operation of
other types of generating units, especially coal-fired power plants. Flexibilization
measures, implementation strategies and pilot projects are described. It presents a
preliminary estimate of the capital investment & increase in operational expenditure
for flexible operation. Furthermore, it sets out a road map for the cost-effective and
flexible operation of various sizes of thermal units.

6) vgbe’s Flexibility Toolbox: Compilation of Measures for the Flexible Operation of

Coal-Fired Power Plants, VGB-B-033, March 2018
The Flexibility Toolbox supports operators of coal-fired power plants in switching from
base-load to flexible operation. It contains information on technologies, further training
courses and management topics. The Toolbox offers 40 different measures to in-
crease flexibility through retrofits or technical interventions. The measures concen-
trate on combustion, water-steam cycle, turbine, control technology and auxiliary sys-
tems.

7) IEA: Status of Power System Transformation: Advanced Power Plant Flexibility 2018,
IEA Report, 2018
The Status of Power System Transformation 2018 report was jointly prepared by the
International Energy Agency (IEA) and the US National Renewable Energy Labora-
tory (NREL). The report presents the findings of the Advanced Power Plant Flexibility
(APPF) Campaign, which was supported by two Clean Energy Ministerial initiatives:
the 21st Century Power Partnership (21CPP) and the Multilateral Wind and Solar
Working Group.
This report provides a comprehensive overview of how power plants can contribute to
making power systems more flexible, as well as offering a range of guidance on strat-
egies to promote cost-effective and system-appropriate power plant flexibility
measures. Based on a wealth of real-life case studies and data, it provides a refer-
ence source for the technical capabilities of power plants in a diverse set of country
contexts.
8) Clean Energy Ministerial: Thermal Power Plant Flexibility, Publication of the Clean
Energy Ministerial, 2018
This report examines the situation in China both today and in the future, with detailed
analyses of the power system using a power system model developed by the China
National Renewable Energy Centre (CNREC), combined with expertise on thermal
power plants from the Electric Power Planning Engineering Institute (EPPEI). In the
analyses, experiences from Denmark and the Nordic power market are used in a Chi-
nese context to provide insight into how to incentivize flexibility in the Chinese power
system.

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9) Agora Energiewende: Flexibility in thermal power plants, Study by Prognos AG and

Fichtner GmbH & Co. KG, 2017
This study provides a broad analysis of possible flexibility measures for thermal
power generation, focusing on coal power plants. The first part of the study analyzes
major challenges with regards to the integration of large shares of renewables. The
second part describes in detail current technical characteristics related to the flexibility
of thermal power plants. The third part analyzes some retrofit measures to increase
the flexibility of coal power plants, including their technical and economic parameters.
Fourth, findings regarding challenges and opportunities are discussed and put into
perspective by spotlighting the situation in South Africa and Poland, two countries
with large coal power generation shares.

8.2 vgbe Standards

The most relevant documents are the vgbe standards which provide detailed information on
important aspects of flexible operation.
1) Feed Water, Boiler Water and Steam Quality for Power Plants / Industrial Plants,
VGB-S-010-T-00;2011-12.EN
2) Preservation of Steam Turbo-Generator Sets, VGB-S-036-00-2017-04-EN
3) Preservation of Power Plants, VGB-S-116-00-2016-04-EN
4) Condition Monitoring and Inspection of Components of Steam Boiler Plants, Pressure
Vessel Installations and High-Pressure Water and Steam Pipes, VGB-S-506-R-
00;2012-03.EN
5) Cooling Water Guideline, VGB-R 455e
6) Recommendations for the operation and monitoring of boiler circulating pumps –
Based on extensive follow-up examinations relating to the damage event in 2014;
VGB-TW-530, 2019
7) Material specification for components under pressure in fossil-fired power plants,
VGB-S-109-00-2012-08-EN, 2012
8) Construction and installation supervision in the manufacture and assembly of water-
tube boilers and associated systems in thermal power plants, VGB-S-013-00-2017-
04-EN, 2017
9) VGB-Standard for the Internal Pipework of Turbine Systems, VGB-S-503-00-2017-06-
EN, 2017
10) Herstellung und Bauüberwachung von Rohrleitungsanlagen in Wärmekraftwerken
(German only), VGB-R 508
11) Guidelines for rating the microstructural composition and creep rupture damage of
creep-resistant steel for high pressure pipelines and boiler components and their weld
connections, VGB-S-517-00-2014-11-EN, 2014

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8.3 Relevant Publications in the

vgbe Energy Journal (formerly VGB POWERTECH Journal)
1) Heim, S., Komogowski, L.; Methods for the flexibilization of thermal power plants:
A literature review, VGB POWERTECH Journal, 6/2021
2) Aydt, M. Bader, J. Bareiß, R. Mohrmann, I. Pfaff, S. Prost, R. Uttich and H. Wels,
Flexibilisation – Analysis of the effects by evaluation of the VGB database KISSY,
VGB POWERTECH Journal, 1-2/2021
3) Trzeszczyynski, J., Trzeszczyynska, E.; Diagnostics as a source of knowledge and
strategy of coal-fired power units operated in a flexible mode; VGB POWERTECH
Journal, 9/2020
4) Scharfetter, C. and Abel-Günther, K.; Steam turbines: Old iron or innovative compo-
nent for the energy turnaround? VGB POWERTECH Journal, 6/2020
5) Richter, M., Oeljeklaus, G. and Görner, K.; Dynamic simulation of flexibility measures
for coal-fired power plants, VGB POWERTECH Journal, 4/2020
6) Garmatter, H., Marks, E., Kostenko, Y., Veltmann, D. and Scharf, R.; Simulation of
hot standby mode for flexible steam turbine operation in combined cycle power
plants, VGB POWERTECH Journal, 10/2019
7) Hoppe, T., Braune, J. and Nielsen, L.; Dynamic System Simulation for New Energy
Markets – Optimization of a Coal Fired Power Plant Start-up Procedure, VGB
POWERTECH Journal, 9/2019
8) Pieper, C. and Beckmann, M.; Transformation of the German energy system, VGB
POWERTECH Journal, 8/2019
9) Dinkel, K. and Peterseim, J.; Battery augmented biomass and waste power plants – A
new approach to provide grid services, VGB POWERTECH Journal, 1-2/2019
10) Moxham, B.; Converting coal to biomass: Making the energy transition feasible, VGB
POWERTECH Journal, 6/2018
11) Bolhar-Nordenkampf, M., Kokko, A. and Kinni, J.; Multifuel CFB solutions – Producing
power in a flexible environment, VGB POWERTECH Journal, 4/2018
12) Ke, Z., Lin, L., Schröder, H.-C. und Guoqing, F.; Plasma ignition system for oil free
power plant Zetes in Turkey and its advantages for the changed circumstance of en-
ergy market, VGB POWERTECH Journal, 7/2017
13) Heddoun, H.and Richard, J.-M.; Last stage blade trailing edge erosion feedback in
EDF LP turbines with flexible operation, VGB POWERTECH Journal, 3/2017
14) Biesinger, F. et.al; Steam turbines subject to flexible operation, VGB POWERTECH
Journal, 11/2016
15) Baca, M., Joswig, A.; Extended requirements on turbo-generators due to changed op-
erational regimes, VGB POWERTECH Journal, 6/2016

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16) Michels, B. and Kotzan, H.: Retrofit of an ECO bypass to reduce minimum load of a
750 MW hard coal-fired power plant, VGB POWERTECH Journal, 4/2015
17) Heinzel, T.; Meiser, A.; Stamatelopoulos, G.-N. and Buck, P.: Implementation of Sin-
gle Coal Mill Operation in the Power Plant Bexbach and Heilbronn Unit 7, VGB
POWERTECH Journal, 11/2012

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9 Maithon Power Limited “Journey towards Flexibilization –

Minimum Power Limit REDEFINED”
A team of Maithon Power Limited (MPL) contributed to the IGEF workshop in Kolkata on
22 November 2022 with the following presentation. It reflects MPL’s perspective on the
the IGEF flexibility project.

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Practice Guide to Get Ready for Flexible Power Plant Operation

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Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

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Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

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Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

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Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

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Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

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Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

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Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

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Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

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Flexibilization Field Report:
Practice Guide to Get Ready for Flexible Power Plant Operation

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