ENERGY AUDIT AT R-
INFRA DAHANU
THERMAL POWER STATION
(250 X 2 MW UNIT)
CENTRAL POWER RESEARCH
INSTITUTE, BANGALORE-560080
MERC CONTRACT TO CPRI
INVESTIGATION INTO PERFORMANCE
OF DTPS R-INF
PERIOD: 2 MONTHS FROM 22.01.2010
TOR: RATING OF THE UNITS
PERMISSIBLILITY OF MW OVERLOADING OF
THE UNIT ABOVE THE MCR VALUE
DE-RATING/UP-RATING OF THE UNITS
FACT FINDING OF UNIT CAPACITY &
HISTORY
TESTS ON UNITS & CONSTRAINTS
DESIGN CAPACITY/
RATING OF DTPS
INSTALLED DURING BSES PERIOD 1995
TAKEN OVER BY R-INFRA IN 2003
NO MAJOR CHANGE IN HARDWARE SINCE
IDENTICAL TO OVER 25 250 MW UNITS INSTALLED
ALL OVER INDIA INCLUDING PARLI, PARAS & TATA
TROMBAY.
SAME DESIGN REPLICATED IN ALL UNITS. THEY ARE
OF STAND 250 MW DESIGN OF BHEL
PG TEST, INSTALLATION MANUALS, NAME PLATES,
CAPACITY TESTS OF EQUIPMENT AND C & I
INDICATE UNITS ARE OF 250 MW CAPACITY.
Margins provided by OEM
Continuous peak plant load duty (over
and above the 100 % unit MCR rating)
is denoted equipment wise as follows:
Boilers: BMCR (boiler MCR) rating
Turbines: VWO (valve wide open)
rating
Generators: MVA (apparent power)
rating
Generating transformers: MVA
(apparent power) rating
Margins over 250 MW
DTPS units have operating margins of:
8 % steam flow in the boiler side (BMCR flow)
5 % power output on the turbine side (VWO
flow)
16 % on the generator side (capability curve)
23 % on the generator transformer side.
These margins are provided in all 250 BHEL
supplied units including those at Paras Unit 3,
Parli Unit 6 and Tata Trombay Unit 8 as
elaborated in the text. MARGINS CAN BE FULLY
USED CONTINUOUSLY PROVIDED PARAMETERS
ARE NOT EXCEEDED. OEM HAS IMPOSED
RESTRICTIONS ONLY ON OPERATING
PARAMETERS OF INDIVIDUAL EQUIPMENT AND
NOT ON MW MARGINS
BOILER MARGINS
Sl. No. Unit particulars-boiler UNITS NCR BMCR MARGIN Design
Dahanu 250 MW
1 Units 1 & 2 t/h 746.60 805 1.08 CE/BHEL
Paras 250 MW Unit 3 1.10
2 t/h 736.20 810 CE/BHEL
Parli 250 MW Unit 6 1.10
3 t/h 738.21 810 CE/BHEL
Tata Trombay Unit 8 1.10
4 t/h 736.20 810 CE/BHEL
Nasik 210 MW Unit 5 1.07
5 t/h 652 700 CE/BHEL
Chandrapur 210 MW
6 Unit 3 t/h 652 700 1.07 CE/BHEL
Bhusawal 210 MW
7 Unit 3 t/h 654 700 1.07 CE/BHEL
Koradi 210 MW Unit 7 1.07
8 t/h 652 700 CE/BHEL
Khaperkheda 210 MW
9 Unit No 4 t/h 624.23 690 1.11 CE/BHEL
Chandrapur 500 MW
10 Unit 7 t/h 1540 1670 1.08 CE/BHEL
INSTALLATIONS at SL. Nos.5-10 are old
Plant load (active power or MW) dependent
and plant load independent parameters:
Majority of the quality parameters like
temperature, pressure (except for variable
pressure operation), voltage, etc., are designed
by the OEM to be nearly constant and first
order load independent for the load range of 60
% UMCR to through maximum load and
changes are only second order.
However, the quantity parameters like flow,
current, etc. are directly proportional to active
power (MW) or plant load or machine loading.
As energy efficiency increases these quantities
decrease in magnitude for a given output.
OEM DEFINITION OF:
CONTINUOUS PEAK
LIMITED TIME PEAK PARAMETERS
Continuous peak parameter:
purposefully set for achieving the
maximum performance or output from
the machine.
Peak parameters for limited periods:
time limits in s /min /h in one excursion
as well as total time in the lifetime of the
equipment. Occurs because of system
operational transients or constraints or
faults or system mismatch.
Sl. Partic Units Dahan Paras Parli 250 Nasik Chandr Bhusawa Koradi Khaper Chandra
No. ulars u 250 250 MW MW Unit 210 MW apur l 210 MW 210 kheda pur 500
at 100 MW 6 Unit 5 210 Unit 3 MW 210 MW Unit
% MW Unit 7 MW 7
BMCR Unit 3 Unit No
condit 4
ions
1
Desig
kcal/
n coal
kg 3700 3400 3400 5000 4445 5100 5000 3500 3500
GCV
2
Annua
l
kcal/
avera
kg 3966 3652 3608 3422 3170 3235 3642 3354 3170
ge
GCV
3
Total
heat Mcal 599. 515.5
to /h 611.7 527.34 536 533.4 531.42 527.5 1215.9
4 5
boiler
4
Total
fuel
quanti
t/h 162 179.9 155.1 107.2 120 104.2 105.5 147.3 347.4
ty
5 Restri
ction
on %
BMCR less No No No Yes No Yes Yes No No
to
GCV
Variation of Steaming rate with boiler efficiency at
constant coal consumption and constant GCV
810
800
Steaming rate, t/h
790
780
770
760
750
740
80 82 84 86 88 90
Boiler efficiency, %
SIMULATED FROM ACTUAL DATA
Variation of coal consumption with boiler efficiency
at a constant boiler steaming rate and constant
GCV
164
162
Coal consumption, t/h
160
158
156
154
152
150
80 82 84 86 88 90
Boiler efficiency, %
SIMULATED FROM ACTUAL DATA
Dependence of unit loading (MW) on the coal quality
280
y = -4E-05x 2 + 0.351x - 465.57
270 R2 = 0.7627
Unit load (MW)
260
250
240
230
3300 3500 3700 3900 4100 4300 4500
Coal GCV (kcal/kg)
SIMULATED FROM ACTUAL DATA
Heat loading rate (Million kcal/h) in the boiler
640
620
Heat loading rate (106 kcal/h)
600
580 design
Operating
560
Linear (design)
540 Linear (Operating)
520
500
480
235 240 245 250 255 260 265 270 275
Plant load (MW)
SIMULATED FROM ACTUAL DATA
TURBINE MARGINS
Sl. Unit particulars- TMC
No. Steam turbine UNITS R VWO MARGIN Design
Dahanu 250 MW
1 Units 1 & 2 MW 250 262.82 1.05 Seimens
Paras 250 MW Unit 3
2 MW 250 264.78 1.06 Seimens
Parli 250 MW Unit 6
3 MW 250 264.78 1.06 Seimens
Tata Trombay Unit 8
4 MW 250 264.78 1.06 Seimens
Nasik 210 MW Unit 5
5 MW 210 213.30 1.02 Russian
Chandrapur 210 MW
6 Unit 3 MW 210 215.80 1.03 Russian
Bhusawal 210 MW
7 Unit 3 MW 210 215.00 1.02 Russian
Koradi 210 MW Unit 7
8 MW 210 215.80 1.03 Russian
Khaperkheda 210
9 MW Unit No 4 MW 210 221.70 1.06 Seimens
Chandrapur 500 MW
10 Unit 7 MW 500 524.40 1.05 Siemens
TURBINE MARGINS
Sl. Unit particulars TMC
No. - Steam turbine UNITS R VWO MARGIN
Hitachi
1 MW 210 222.00 1.06
Mitsubishi
2 MW 210 222.00 1.06
Siemens
3 MW 210 221.70 1.06
Russian
4 MW 210 215.60 1.03
Variation of steam input with turbine heat rate
at constant power output
VWO: 800 t/h
Steam input to turbine,
765
760
755
t/h
750
745
740
735
1920 1940 1960 1980 2000
Turbine heat rate, kcal/kWh
SIMULATED FROM ACTUAL DATA
Variation of power output with turbine heat
rate at constant steam input to turbine
VWO: 800 t/h
264
Power output, MW
262
260
258
256
254
1920 1940 1960 1980 2000
Turbine heat rate, kcal/kWh
SIMULATED FROM ACTUAL DATA
TURBINES
DTPS has be able to maintain good MW load ability
on the machine within the OEM margins and
without exceeding any OEM parameter limits
by:
Maintaining high turbine
efficiency (turbine heat rate
deviates from design by only 4.4
kcal/kWh)
Strictly maintaining water
quality parameters as per OEM
guidelines
Minimizing auxiliary stack, vent
and gland sealing steam
requirements in the turbine.
MW at MARGIN
Sl. Unit particulars- MVA pf = MW at pf=0.85
No. Generator rating 0.85 pf=0.99 to 0.99
Dahanu 250 MW
1 Units 1 & 2 294.0 250 291.18 1.16
Paras 250 MW Unit 3
2 294.1 250 291.18 1.16
Parli 250 MW Unit 6
3 294.1 250 291.18 1.16
Tata Trombay Unit 8
4 294.1 250 291.18 1.16
Nasik 210 MW Unit 5
5 247.0 210 244.59 1.16
Chandrapur 210 MW
6 Unit 3 247.0 210 244.59 1.16
Bhusawal 210 MW
7 Unit 3 247.0 210 244.59 1.16
Koradi 210 MW Unit 7
8 247.0 210 244.59 1.16
Khaperkheda 210 MW
9 Unit No 4 247.0 210 244.59 1.16
Chandrapur 500 MW
10 Unit 7 588.0 500 582.35 1.16
TESTS ON UNITS
Maximum load- 265.5 MW: 2292.7kcal/kWh
100 % UMCR- 252 MW: 2299.13 kcal/kWh
F-GRADE LOAD- 2326.2 kcal/kWh
MAXIMUM LOAD REACHED WAS 240 MW
Design: 2230.60 kcal/kWh
Achieved: 2293 kcal/kWh
EVEN AT 268 MW NO PARAMETER HAS
EXCEEDED OEM LIMITS ; DTPS CONTROL
SET POINTS ARE BELOW OEM LIMITS
Loadability
Combining all the margins provided by the OEM,
R-Infra has been able to load the unit to 268 MW
against the design value of 250 MW.
Maintaining this load is not harming the life of the
unit as the DTPS has ensured that all parameters
are kept within OEM limits.
High loadability is made possible by high energy
efficiency or low unit heat rate which enables the
parameters not to exceed their limits.
OEM MANUALS DO NOT SPECIFIC ANY UPPER
LIMITS ON MW LOADING OR MW OVERLOADING
ABOVE 100 % UMCR RATING, OEM MANUAL
SPECIFIES CONTINUOUS AND LIMITED TIME
LIMITS ON OPERATING PARAMETERS OF B,
T,G,GT, ETC.
Remaining life
Units 1 & 2 have been commissioned in Jan
and March 1995 and have completed 15 years
of service and nearly 1,20,000 operating
hours.
Acceleration of life expenditure takes place
due to parameter excursions into the limited-
time-overload-regime for long periods, due to
frequent cyclic loading, due to frequent
transients with high ramping rates. Scrutiny
of operation and parameters indicates that the
DTPS has avoided operation in these life
limiting regimes thereby preserving the
longevity of their assets. The cyclic operations
are far lower than their design values.
We are here
Remaining
Life
(h, years)
Ө
<45
Ө > 45˚ Ө=45˚ ˚
poor Normal Good
Real time years
Remaining life
Considering a total engineering life of 35
years of service or 3,00,000 operating hours
the physical (actual) life expenditure of both
units is expected to be 40 %. Except for
generator, where the life expenditure is 50 %
(remaining life= 50 % or 14 years), the
remaining life of other components matches
roughly with the physical life expenditure.
This indicates that acceleration of life has not
taken place. The low degradation rate
coupled with the high loading on the plant
also leads to the conclusion that the
equipment are healthy and factors in the
nature of non-repairable damage are not
present. UNHEALTHY EQUIPMENT CANNOT
BE LOADED AT ALL
Degradation
The CPRI test TG HR is showing a
degradation rate of 0.13 %/year.
The degradation is 2.0 % of the
DHR
LOW LEVEL OF DEGRADATION
INDICATES THAT THE EQUIPMENT
ARE HEALTHY AND NO NEGATIVE
EFFECTS OF MW LOADING
BEYOND 100 % UMCR
Up-rating/de-rating
The maximum load on Unit 1 was 268.7 MW and
on Unit 2 was 266.0 MW in 2009 & in 2010. Up-
rating or de-rating of the unit has been studied
and it is concluded that the unit capacity is 250
MW and the present maximum plant loading of
268 MW is sustainable only because of high
boiler, turbine and generator efficiency; and
external factors like coal quality being 600
kcal/kg higher and high power factor of 0.99.
The sustainability may not be long lasting.
The PG test by OEM is for 250 MW, these units are
identical to several 250 MW units, grid code
2005 stipulates a margin over the 100 % UMCR
rating. Considering these facts it is concluded
that the up-rating of 250 MW to 260 or 265 MW
may not be sustainable in terms of availability
as well as loadability in the future.
CONCLUSIONS
SCRUTINY OF RECORDS INDICATES UNIT CAPACITY IS
250 MW IDENTIAL TO OTHER 250 MW UNITS SUPPLIED
BY BHEL.
OEM MARGINS IN BOILER, TURBINE, GENERATOR AND
GENERATOR TR HAVE BEEN FULLY MADE USE OF TO
ACHIEVE LOADABILITY OF 268 MW WELL WITHIN OEM
PARAMTER LIMITS.
OEM MARGINS CAN BE FULLY USED CONTINUOUSLY
PROVIDED PARAMETERS ARE NOT EXCEEDED. OEM HAS
IMPOSED RESTRICTIONS ONLY ON OPERATING
PARAMETERS OF INDIVIDUAL EQUIPMENT AND NOT ON
MW MARGINS. OEM PARAMTERS ARE NOT EXCEEDED BY
DTPS.
TESTS INDICATE ANNUAL UHR OF:
265.5 MW - 2293 kcal/kWh
100 % UMCR- 252 MW: 2299.13 kcal/kWh
F-GRADE LOAD- 2326.2 kcal/kWh
MAXIMUM LOAD REACHED WAS 240 MW
Design: 2230.60 kcal/kWh
Achieved STATION DATA : 2293 kcal/kWh
CONCLUSIONS
UPRATING OF THE UNIT HAS BEEN STUDIED.
SINCE THE UNIT IS OF 250 MW STANDARD
DESIGN OF BHEL, THE MARGINS ARE BEING
UTILIZED BY ENERGY EFFICIENCY
IMPROVEMENTS, HIGHER GCV OF COAL AND
HIGH POWER FACTOR. THESE CIRCUMSTANCES
MAY NOT BE SUSTAINABLE ALL THROUGH THE
LIFE OF THE UNIT.
GENERATORS AND GTS ARE QUITE HEALTHY
AND NORMAL. REMAINING LIFE IS ALSO GOOD.
NO IMMEDIATE RISK FOR 16-20 khours AS PER
THE RLA REPORTS OF ABB & ERDA.
CONSIDERING THE CRITICALITY OF LOAD
HANDLED BY DTPS AND CONSIDERING THAT
THERE ARE NO SPARES WITH OTHER MEMBERS
OF MAHARASHTRA GRID FOR 250 MW THESE
CAN BE CONSIDERED.
