Coal Audit

CPRI   is  in the area of energy efficiency in the generation sector through energy audit, performance evaluation, component testing for a number of years. CPRI has specialized in energy audits of hydro and coal fired thermal power plants of the complete range of ratings from as low as 20 MW to 500 MW. It also plans to take up supercritical units of 660 MW and above. CPRI has a track record of conducting over energy audits in thermal (coal, gas and nuclear) thermal stations and hydro power stations besides a number of R & M studies.

Energy Efficiency & Renewable Energy Division (ERED) of CPRI has taken up a prestigious consultancy work for Maharashtra Energy Regulatory Commission for benchmarking of the unit heat rates and station heat rates of coal fired units of MSPGCL (Maharashtra State Power Generating Company Ltd.), thermal stations through conducting performance tests on coal fired thermal power plants, computing the present performance indices and suggesting performance norms for the immediate term, medium term and long term. The performance indices cover unit heat rates (UHR), station heat rates (SHR), specific oil consumption (SOC), auxiliary power (AP), etc. for 32 units (ranging between 30 MW to 500 MW) of MSPGCL spread over different geographic regions of Maharashtra. The consultancy work was awarded by the Maharashtra Electricity Regulatory Commission (MERC), Mumbai.

The scope of activities which is based on a comprehensive scope of work and terms of reference given by MERC, involves an in-depth look at the processes and procedures of the seven TPS- Koradi, Khaperkheda, Chandrapur, Nashik, Bhusawal, Paras & Parli in complete transparency. The primary processes of receipt, handling and management of fuels (imported, indigenous and washed coals, fuel oils) and water (DM, soft, potable and raw) which are accounting for major cost components of the stations have been analyzed and technologies for supply chain optimization and raw material management have been proposed.

The principles of accounting of coal quantity and its heating values at various points; and computation of station heat rate have been reviewed in depth and procedures and instrumentation have been suggested to answer to the observations of MERC –'the coal consumption should be dependent on the unit heat rate and not vice versa'. The suggestions also encompass the break-up of the accountability and responsibility for coal from the mine to the station entrance, from the tipplers to the bunkers and from the mills to the furnace.

In preference over analog, stand alone, incompatible measuring equipment, the change over to digital instrumentation and tracking devices which can be seamlessly integrated into a central server and which have provision for downloading data into a data base has been advocated. Need for technical auditing of Information and communication system for obtaining a holistic picture of its structure and efficacy on one hand and the change over to Intelligent electronic devices (IEDs) preferred instrumentation systems has been highlighted.

The study encompasses capture and dissemination of tacit operational knowledge, maintenance knowledge and forced outage knowledge which is essential for progress in performance. It assesses and validates the internal knowledge sharing processes. It reviews the maintenance philosophy, maintenance organization structure, tooling techniques, maintenance performance mapping, maintenance delivery system, maintenance planning, standardization of procedure, benchmarking of timing of outages caused by BTL (boiler tube leaks), etc. Performance orientation linked with knowledge based maintenance, condition based guidelines, component reliability and risk evaluation procedures are part of the study. The benefits of 5 year rolling plans for pressure parts replacements (like ECO coils, primary SH coils, WW tubes, etc.), heat exchanger replacements (like lube oil coolers, feed water heaters, vent condensers, etc.), thermal skin insulation replacement, 20 %/year painting and upkeep plan have been brought out.

The study points out that R & M must be a continuous activity and the plans must not be equipment centric but must be aligned with benefits of improvements in unit heat rate and/or other unit performance parameters.

The stress on performance optimization, cleanliness and leakage control being a round the clock activity with ISO objective focus to achieve the required results is a part of the study.

On the financial side, a critical re-look through audits for the simplification and modification of administrative and accounting processes to bring down the lead times for the procurement cycle (which has an impact on inventory carrying costs and overall business cycle) is studied. Analysis of decision making processes is also a part of the study.

Coming to HRD, the study revisits job functions, both operation and maintenance, re-orientation towards performance and accountability at all levels, job rotation system, alternative ways of augmenting the shortage of manpower, reward of invention talent, support of quality circles, mid career educational intervention, reduction of attrition rate, etc., are studied. A critical review of training needs in the present day context such as operational optimization, maintenance methodologies, regulatory requirements, etc., is undertaken.

The performance tests give the Test TG heat rate (UHR) (boiler, turbine & generator only) at 80 % load against the Design heat rate (DHR). The Test station Overall Station heat rate (considering besides the boiler and turbo generator other factors such as DM water make up; rejects; consumptions due to hot, warm and cold starts; heat in MS & RH pipelines, seasonal deviations (if any) at 80 % load which accounts for all the coal at the bunker. The life time degradation rates are computed. The capacity adequacy is also checked.

The tests include total electrical system audit including transformer load management, power factor management and load balancing. The performance evaluation of auxiliary equipment like boiler feed pumps, condensate extraction pumps, induced daft fans, forced draft fans, primary air fans, mills, etc. Energy efficiency also covers the common station auxiliaries like coal handling plant, ash handling plant, DM plant, circulating water system, air compressors, etc. Suggestions for improving the energy efficiency of these equipments with techno-economic feasibility study are also proposed.

Suggestions for measures to improve the KPI (key performance indices) like station heat rate, auxiliary power consumption and specific oil consumption with time bound action plans are given. Objective oriented Monsoon management plan is required to be in place for maintaining the KPI within regulatory limits as the deviations in station load, monthly SOC and monthly PLF are predominant during monsoon seasons.

The study benchmarks the performance, identifies undone works which were historically ignored but which are of current importance and proposes changes leading to reliability, transparency and cleanliness in an environment of competitive cutting edge power generation. In short the study encompasses the business process re-engineering for enhancing station performance to maintain market leadership. If the existing plant processes and procedures are made more effective, the improvement of performance will be a natural consequence.

Gujarat wants cut in solar power tariff for existing Solar Plants

Gujarat, home to half of India’s solar power-plant capacity, is seeking to have a cut on the rate it pays to solar project developers, keeping in view the owners’ excessive and unwanted profits in the current scenario. The state government has approached the Gujarat Electricity Regulatory Commission (GERC) with a petition, seeking a reduction in the solar power tariff, quoting the unwanted and windfall gains to the solar project developers.

The Gujarat Urja Vikas Nigam Limited (GUVNL) had signed a 25-year PPA ( Power purchase agreements ) for 971.5 MW of solar power with 88 developers including Adani Enterprises Ltd., Moser Baer India Ltd., Tata Power Co., and Welspun Energy Ltd. since 2010. For the first 12 years the developers were offered Rs. 15 per unit and Rs 5 per unit for the next 13 years. Currently, a levelised tariff of Rs. 12.54 per unit is being received by the project developers.

According to GUVNL’s filed petition, a reasonable and carefully judged consequent tariff would be about 9 rupees per unit, less than the average levelised current tariff of Rs. 12.54 for the 25 years. The petition filed mentions that the increased tariff of Rs 3.54 per unit is a direct burden on consumers and is an unjustified source of gain to project developers.

“The current outgo (on buying solar power) is quite high, and having a levelised tariff will help them in managing cash flows better”, a GUVNL official stated. The first hearing on whether regulators will accept a case based on the filed petition will be held on July 23. Meanwhile, the project developers are pretending to be anonymous to the entire happenings. A project developer says that they are just waiting to see whether GERC admits GUVNL’s petition or not.

The Football that Generates Energy

Imagine being able to play football and capture the energy generated when kicking the ball at the same time. This is exactly what Uncharted Play, a for-profit social enterprise in the United States, has designed. An electricity generating football, known as the Soccket, turns the energy from a kick-about into usable power.

Co-founders of Uncharted Play, Jessica O. Matthews and Julia Silverman first came up with the idea of developing the energy harnessing football in 2008. After receiving their final funding from a Kickstarter campaign in March 2013, they are now ready to share it with the world.

According to the World Bank Institute, 20 per cent of the world’s populations are without reliable access to electricity. Almost all of these 1.4 billion people are living in the developing world. “The Soccket is one way to fight energy poverty and encourage people to play at the same time,” says Victor Angel, Vice President for Product Development at Uncharted Play. Angel and his team are working together with NGOs in developing countries like Nigeria, Brazil and South Africa, and hope to provide disadvantaged communities with both power and a football to play with.

Simon Trace, CEO at the sustainable development corporation, Practical Action thinks the Soccket is a fun and interesting piece of technology. “Although it probably won’t provide a huge amount of energy for very many people, the idea of bringing attention to the energy crisis through things like the Soccket is excellent,” he says.

How does it work?

Embedded in the centre of the ball is a gyroscopic mechanism similar to a swinging pendulum. As the Soccket is in motion, the moving weight is constantly being pulled down by gravity. This then generates kinetic energy, which is converted into electrical energy and stored inside the ball. This energy can later be accessed through an external plug as a power source. Apart from the energy harnessing mechanism inside the ball, the internal shell is made up of high-density foam known as Polyurethane, which makes it airless, thereby preventing it from going flat. The stored energy can power an LED lamp for up to three hours after 30 minutes of play, and has enough power to charge a phone or battery.

Over the past two years the team at Uncharted Play have gone through various steps to improve the ball. “We shrunk the internal mechanism to be the size of a fist,” says Angel. “One of the most challenging components was to find an ideal weight and density of the external shell as it needs to be as light as a regular soccer ball, but at the same time deflation proof, durable and water resistant.” Now, the Soccket only weighs about 30 grams more than an average football.

In the form of a “buy one-give one” model, the Soccket will be sold in western markets (for around £65 including the LED lamp). The profits will then be used to distribute the balls at little or no cost in developing countries like Mexico and Nigeria through development organizations such as Children International. Apart from its power-generating properties, the Soccket is also being used in educational programmes. NGOs such as InstitutoPromundo in Brazil use the ball to explain concepts of energy conservation to communities in urban shantytowns known as favelas.

The team at Uncharted Play is working on creating more innovative technologies in the near future. “We are currently developing portable flashlights which will allow people to share the power of one Soccket.” They are also looking into making it more sustainable by using biodegradable materials to make the external shell of the ball.

                                         Karnataka for FY 2013-14

• Key Highlights:-

 1.    The Honorable Karnataka Electricity Regulatory Commission vide its notification dated 21.06.2013, has notified the pooled cost of power purchase at Rs. 3.07 per unit from 01.04.2013 to 31.03.2014, subject to truing up as per actual.
 2.    Earlier, vide its notification dated 27.06.2012, the Hon’ble Commission had notified the APPC at Rs. 2.60 / unit for FY ending March 2013. As per the finalized accounts, the same is trued up to Rs. 2.65 / unit.
 3.    To the extent of power purchased under APPC in FY 2012-13, the difference of Rs. 0.05 / unit shall be paid in 3 equal instalments to RE Generators.
 4.    Similarly the difference of Rs. 0.47 / unit on account of the APPC continued at Rs. 2.60 per unit until 21.06.2013 as an interim measure shall also be paid in 3 equal instalments.   

• How it has been determined?

Here the ‘Pooled Cost of Power Purchase’ is the weighted average pooled price at which the State distribution licensees or ESCOMs put together have purchased the electricity including cost of self-generation, if any, in the previous year from all the energy suppliers long-term and short-term, but excluding those based on renewable energy sources, as the case may be.

•  What will be the impact of this rate?

The current rise in APPC makes investment in Renewable energy projects under APPC + REC mode very attractive with a minimum return of Rs. 12.37 per unit for Solar & Rs.4.57 per unit for Non – Solar projects in the State.

•   Impact of the order on REC based projects in the state:-

 1.    With the increase in APPC the Karnataka state becomes one of the most favourable states for investment on REC mode. However, only projects that sell power to ESCOMs at APPC can be benefited as the state still lacks clear options for Renewable Energy Captive Power Projects to participate in the REC market.
 2.    Even in the recent tariff orders for all ESCOMs for FY 2013-14, the Hon’ble KERC has continued to extend the concessional wheeling charges as 5% of total energy injected, and will be deducted in kind for Non-Solar; whereas, it is free- wheeling for Solar Power Projects in order to promote Non-Conventional Energy generation within the state.
 3.    Currently, KERC has not declared any provision for Renewable Energy Generators to pay the actual Wheeling Charges and Losses, as paid by Conventional Power Generators.
 4.    The REC are issued by Central Agency guided under the principles of Hon’ble CERC and since RECs cannot be availed by any Captive RE generator availing concessional wheeling, all Captive RE generators in the state of Karnataka remain ineligible to participate in the REC market.