Energy Audit of Rajiv Gandhi Thermal Power Plant Hisar
Vikas Duhan 1,
1 2
Research Scholar, Dept. of EE, G.T.C.
Bahadurgarh, Haryana, India
Email: vduhan90@gmail.com
Abstract- This paper presents Energy Audit of
Thermal Power plat with the required demand of electricity
is growing fast due to economic growth and increase in
population. With the consideration of environmental issues
and sustainable development in energy, ideally, renewable
energy such as wind, solar, and tidal wave should be only
resources to be explored. Since the growth in demand is also
a heavy factor in energy equations, then the renewable
energy alone is not able to generate enough electricity to fill
the gap within a short time of period. Power plants are one
of the most suitable choices for environmental enhancement
and higher efficiency. However, there has been an issue of
whether or not to adopt this technology in the INDIA
because it is not clear whether the dynamic response and
performance for plants can satisfy the Gird Code
requirement. This thesis reports a study of dynamic
responses of power plants through mathematical modeling,
identification, and simulation. It also presents a new control
strategy based on an alternative configuration of generalized
predictive control for enhancement of the plant responses.
In the process of modeling development, Genetic Algorithms
are used for parameter identification and model response
optimization. The model has also been verified for certain
operation conditions with the different sets of data obtained
from 600MW power plant.
Index Terms- Generator, Turbine , Boiler, Condenser, Cooling
Tower, Furnace, Transformer, Coal, Oil, Water, Grinder,
Chimney, Fans, Bus-bar, Insulator, Relay, Conductor .Circuit
Breaker, Super heater, Air pre-heater, Economiser, Ash
Handling Plant.
INTRODUCTION
To meet the growing demand for energy in industries,
one of the aims is to identify the technical support in improving
their energy performance through comprehensive energy audits,
implementation assistance, technology audits, and capacity
building. Energy audits help in identifying energy conservation
opportunities in all the energy consuming sectors. While these
do not provide the final answer to the problem, but do help to
identify the existing potential for energy conservation, and
induces the organizations/individuals to concentrate their efforts
in this area in a focused manner.[1]
In the present scenario of rapidly growing demand of energy in
transportation, agriculture, domestic and industrial sectors, the
auditing of energy has become essential for over coming the
mounting problems of the world wide crisis and environmental
degradation. There are two factors contributing to the increase in
the energy consumption, one is more than 20% increase in
world’s population and another one is worldwide improvement
in standard of living of human being. The industrial sector
consumes about 50% of total generated energy. Therefore
improving energy efficiency is the main focus of Energy
Auditing.[2]
The energy audit evaluates the efficiency of all process
equipment/systems that use energy. The energy auditor starts at
the utility meters, locating all energy sources coming into a
© JRPS International Journal for Research Publication & Seminar Vol 05 Issue 02 March -July 2014
Jitender Singh2
Assistant Professor, Dept. of EE, G.T.C
Bahadurgarh, Haryana, India
Email: Jeetboora@yahoo.co.in
facility. The auditor then identifies energy streams for each fuel,
quantifies those energy streams into discrete functions, evaluates
the efficiency of each of those functions, and identifies energy
and cost savings opportunities.[2]
AUDIT OF THERMAL POWER PLANT
Energy audit is a technical survey of a plant in
which the machine wise, section wise, department wise
pattern of energy is balance the total energy input in
relation to production mode. It consists of activities that
seek to identify conservation opportunities preliminary to
the development of an energy savings program.[3]
Energy audit methodology is a systematic approach to
reduce energy consumption. It converts all forms of
energy and energy costs of the system. Aim of the energy
audit is to reduce the energy cost per unit of
production.[3]
The current paper audit of thermal Power Station Hisar, a
bunching of two individual units with total installed
capacity of 1200 MW is located about 30 KM in the West
of Hisar village Khedar on Chandigarh-Hisar National
Highway and is surrounded by cultivated green fields. In
addition, 989 acres of saline waste land is earmarked for
disposal of ash. The plant is equipped with a huge
residential colony to ensure availability of staff and
officers round the clock. The current chapter includes the
study carried out in unit no.2 of Rajiv Gandhi thermal
power plant Hisar. This unit is of 600MW installed
capacity. In this efficiency of boiler, turbine & generator,
condenser & heater are calculated & compared at
different loads. After comparing the efficiencies of
various sub-units of plant, we find out the losses & also
know about the overall efficiency of plant. In this case
study the reading of various sub units are taken from the
control panel, installed in control room.[4]
Problem Formulation
In RGTPP, Hisar 600 MW units is consideration
for energy audit and efficiencies of main sub-units as like
boiler, turbine and generator, condenser & heater are
calculated and compared at different loads which
highlights in RGTPP 600 MW units energy efficiency has
to be improved to survive in global market.[4]
Brief Information of the Plant-
Installed 2 X 600 MW
Capacity
 Available 989 acres Sr. no Parameter Indian coal
Land
1 Moisture 5.98
Location Khedar, Hisar

EPC M/s Reliance Energy Ltd, 2 Ash 38.63

Contractor
3 Volatile matter 20.67
EPC Cost Rs 3775.428 crore (total estimated
cost Rs.4512 crore) 4 Fixed carbon 34.69
Administrat 31.12.2005

ive
approval A boiler is an enclosed vessel that provides a means for
Project M/s Desein was appointed Project combustion heat to be transferred into water until it becomes
heated water or steam. The hot water or steam under pressure is
Consultanc Consultant and CEA were engaged
then usable for transferring the heat to a process. Water is a
as Review Consultants useful and cheap medium for transferring heat to a process.
y
When water is boiled into steam its volume increases about
Coal M/s Mahanadi Coalfields Ltd., Orissa 1,600 times, producing a force that is almost as explosive as
Sources gunpowder. This causes the boiler to be extremely dangerous
equipment that must be treated with utmost care. The process of
Equity State Govt. is contributing 20% equity heating a liquid until it reaches its gaseous state is called
for the project vide letter dated evaporation.[5]
contributio
10.10.2002. Balance 80%
n Since the products of flue gases directly contact the stock, type
Has been arranged through PFC. of fuel chosen is of importance. For example, some materials
Issue of Issued to M/s REL vide letter dated 29.01.2007 will not tolerate sulphur in the fuel. Also use of solid fuels will
generate particulate matter, which will interfere the stock place
LOI inside the furnace. Hence, vast majority of the furnaces use
liquid fuel, gaseous fuel or electricity as energy input. Melting
furnaces for steel, cast iron use electricity in induction and arc
furnaces. Non-ferrous melting utilizes oil as fuel.[6]
Performance of Rajiv Gandhi Thermal
Power Plant during last four year Cooling towers are a very important part of many chemical
plants. The primary task of a cooling tower is to reject heat into
OIL COAL the atmosphere. They represent a relatively inexpensive and
GENERAT AUXILIARY CONSUM CONSU dependable means of removing low-grade heat from cooling
YEAR P L F (%) water. The make-up water source is used to replenish water lost
ION (MU) CONS. (%) PTION MPTION to evaporation. Hot water from heat exchangers is sent to the
(ml/kwh) (kg/kwh) cooling tower. The water exits the cooling tower and is sent
back to the exchangers or to other units for further cooling.[6]
2010-
24689 26 9.98 24.065 0.952
2011 Data Analysis
2011- In this step, the data, which is collected from Power Plant Unit
55582 54 6.37 2.695 0.756 No.2 & at different output load, is analyzed. Firstly from the
2012 data of Thermal Power Plant running at the load of 600MW or
2012- full output load given in Table is considered for the analysis
49929 48 5.93 1.1069 0.736 purpose. [8]
2013 Enthalpy (KJ/Kg) = Cp T
2013- Energy (MW) = Flow (Kg/Sec.) x Enthalpy /1000
43819 48 5.83 0.604 0.738 Temperature is taken in degree Kelvin.
2014 The value of enthalpy and energy is given below:- Pressure =
177 Kg/cm2
Temperature = 544 ºC = 817 K
Flow=1782 T/Hr. = 1887×1000/3600
= 524.16Kg/sec
Enthalpy (Cp T) =4.2 × 817 = 3431.4 KJ/Kg
Energy =524.16 × 3431.4/1000 = 1798.62 MW [8]

The typical proximate analysis of various coal

Data Analysis of plant at 600 MW
Boiler Section

© JRPS International Journal for Research Publication & Seminar Vol 05 Issue 02 March -July 2014
 Inlet in Boiler [8] T [7] – T [22]
= 218-190
At (40) Coal = 440T/hr = 440 × 1000/3600 = 122.22 Kg. /Sec. 340-190
Calorific Value = (C.V) of Coal = 3400 K Cal/Kg, = 0.186
HPH6 Effectiveness = T [24] – T [23]
(i) Energy = 3400× 122.22 × 4.2/1000 = 1745.30 MW T [05] – T [23]
(ii) At (2) Energy = 1217.12MW = 250-218
(iii) At (24) Energy = 1206.90 MW 370-218
= 0.210
Outlet from Boiler [8] HPH7 Effectiveness = T [25] – T [24]
T [03] – T [24]
= 290-250
(iv) At (1) Energy = 1798.62 MW
540-250
(v) At(3)Energy =1780.33MW
= 0.137
(vi) Flue Gases (These are not taken in consideration)
Total Inlet = (i) + (ii) + (iii) = 1745.30+1206.90+1217.12 =
4169. 32 MW Overall Unit Efficiency [8]
Total Outlet = (iv) + (v) + (vi) = 1798.62 + 1780.33 + 0 =
3578.95 MW Fuel burnt (Coal) = 440T/ Hr = 122.22 Kg/Sec
Loss in Boiler = Inlet – Outlet= 4169. 32 – 3578.95 = 590.37 C.V = 3400 K Cal/kg = 3400 × 4.2 = 14280 KW
MW Heat Input = 14280×22.22/1000 = 1745.30 MW
Efficiency of Boiler = 3578.95 x 100/4169.32 = 85.84 %
Efficiency = Output of Station x 100
Section Turbine & Generator [8] Input of Station

i) HPT Inlet (1) = 1798.62 MW = 600 x 100

Outlet (2) + (5) = 1217.12 + 149.28 = 1366.40 MW
Net Energy at HPT = 1798.62 – 1366.40 = 432.22 MW 1745.30

ii) IPT Inlet (3) = 1780.33 MW

Outlet (4) + (7) = 1387.22+87.25 = 1474.47 MW = 34.37%
Net Energy at IPT = 1780.33 – 1474.47 = 305.86 MW

iii) LPT Inlet (4) = 1387.22MW

Outlet (9) + (11) + (13) = 274.61+260.23 +248.60 = 783.44 MW
Net Energy at LPT = 1387.22 – 783.44 = 603.78 MW Modeling
Net Input at Turbine (HPT, IPT & LPT) = 432.22 + 305.86 +
783.44 = 1521.52 MW
Efficiency of Turbo Generator = 600 × 100/ 1521.52 = 39.43 % This includes the ability to give the required MW response to
the load request, keeping continuous optimal operation, and
minimizing the fluctuations in the boiler variables which are the
Section Condenser [8] main reason for reducing the life of the equipments. However, to
achieve those operating objectives, power plant still need more
Condenser Efficiency = Actual Cooling Water Temp rise advanced control with higher automation and more flexibility
Max Possible Temp. Rise = which require learning and adopting one of these advanced
Water Outlet Temp.[42]-Water temp. at Inlet [41] * 100 technologies in this study.[5]
Exhaust Steam Temp. [15] – Water temp. at Inlet [41]
Power plant is a complex process which embeds
= (55 – 45) x100 highly nonlinear features. For physical or mathematical models,
( 64 – 45) a care should be taken in choosing the simulation tool that has
= 52.63 % the necessary programming language for solving the model
equations or optimization problem of parameter identification
Section Heaters (LP & HP) [8] procedure. The published work in the last two decades for power
plant simulations has shown more advanced simulation
technologies than the past one. Those tools offer graphical or
LPH1 Effectiveness = T [18] – T [17] blocks presentation for the power plant systems which is
T [13] – T [17] composed from mathematical operations, integrators,
= 80 – 50 differentiators, transfer functions in s-domain and so on. It
248-50 therefore has the advantage of easier modification even for the
= 0.151 people who are not the main model frame builders. Also, they
LPH2 Effectiveness = T [19] – T [18] can be easily understood and adapted with other objects. The
T [11] – T [18] graphical simulation also offers the ability to access any variable
= 120 – 80 in the plant without much effort. Some packages that are
385-80 commonly used for this area of research are[5]
= 0.131
LPH3 Effectiveness = T [20] – T [19]
T [9] – T [19]
= 180-120
Boiler Model
458-120
= 0.177
HPH5 Effectiveness = T [23] – T [22] The major boiler model are shown in Fig . The unit of this
power plant is 600MW power plant process. Choosing 600MW

© JRPS International Journal for Research Publication & Seminar Vol 05 Issue 02 March -July 2014
capacity boiler is mainly because the data for such a power are shown by the result. The related data for this model is given
station for model validation could be obtained. The hot water by-
from the feed water heater is heated in the economizer before it
is introduced to the superheating stages through the water wall. i) The input applied voltage is 570 v and various current source
The super heater consists of three sections which are low is 50,90,120,160,200,240,280,320,360,400.
temperature super heater, platen super heater, and final stage ii) Voltage source are 64,130,180,222,250,270,280,286,290,294
super heater. The main steam boiler is 16000000 and transport and % armature currents is 85,110,210,310,410 for the reference
delay is applied whose initial input is zero and time delay 1 and resistance is 0.07.
initial buffer size is 1024 applied to pressure sensor is 0.000001
to scope 2 are shown in model. There are two main function are fan speed model
used in this model are step function and ramp function and one
error format in the array for expansion value is 0.04 applied for %Ise (A) 50 90 120 160 200 240 280 320 360 400
the result output.[5] %Voc (V) 64 130 180 222 250 270 280 286 290 294
%Sketch the speed - load characteristics of the series fan
connected to
%570 V main by calculating the speed and load values at
armature currents
%of 85, 110, 210, 310, 410 A.
Ise=[74 110 190 310 420]
Vm=570;
R=0.07;
n=1100;
Ea = Vm - (R*Ise)
Is=[50 90 120 160 200 240 280 320 360 400];
Vo=[64 130 180 222 250 270 280 286 290 294];
Eo=interp1(Is,Vo,Ise)
N=n*Ea./Eo
T=(60/(2*pi)).*Ea.*Ise./N
plot(T,N);

Fig(1) Boiler model

Fan Model

The major fan model are shown in given program to find out the
curve between speed and load according to fan in and fan out

© JRPS International Journal for Research Publication & Seminar Vol 05 Issue 02 March -July 2014
 RESULT AND DISCUSSION

The efficiencies of typical 600 MW Plant at

load & parameters are compared as follows-

Sr. No. Description 600MW

1 Boiler Efficiency 85.84%

Turbine &
2 Generator 39.43%
Efficiency
Fig(2) Boiler model scope
Condenser
3 52.63%
Efficiency

Heater LPH1
4 0.151
Effectiveness

Heater LPH2
5 0.131
Effectiveness

Heater LPH3
6 0.177
Effectiveness

Heater HPH5
7 0.186
Effectiveness

Heater HPH6 Fig(3) Boiler model scope 1

8 0.210
Effectiveness

Heater HPH7
9 0.137
Effectiveness

Overall Plant
10 34.37%
Efficiency

Coal
11 440 T/Hr
Consumption

Fig(5) Boiler Model scope 2

© JRPS International Journal for Research Publication & Seminar Vol 05 Issue 02 March -July 2014
 CONCLUSION
From the analysis part of this work, it is concluded that the
overall plant efficiency varies with the variation or small change
in the output loads. From the experimental work done in above
steps shows that as the output load is lower the efficiency of
total unit is low. Output Load of the plant always depends upon
the requirements for consumption of energy. As the energy
consumption decreases, Plant has to be starting to run at lower
load and the overall performance is also lower, because energy
cannot be stored. On the other hand if the Plant or Unit can run
at Full Output Load or 600 MW load the performance is higher.
During the study of plant following main reasons found for
energy losses which should be improved and results to increase
overall plant efficiency.
1 .Equipment inefficiency.
2. High slop generation/reprocessing rate.
3. High pressure drops in steam/feed/product lines.
4. Heat loses due to poor insulation.
5. Frequent shut-downs/start-up etc.
6. Energy loss from hot surface of heaters.
7. Energy loss from steam lines.
8. Energy loss from electrical systems.[7]
Conclusion for improvement of efficiency
There are various methods to improvement in the efficiency of
thermal power plant are given below.
1. By using the boiler model and fan model we can improve the
efficiency of thermal power plant around 1- 2 %.
2. To reduce the corruption in oil transport system we can
improve the efficiency of thermal power plant.
3. Using high Calorific Value of the coal and increasing the
oxygen content of the coal we can improve the efficiency of
thermal power plant around 1-2 %.
4. Plant should run at higher load also increased in the
efficiency of thermal power plant.
5. Reduce air, water, steam, flue gas leakage from the power
plant and increased in the efficiency of thermal power plant.
© JRPS International Journal for Research Publication & Seminar Vol 05 Issue 02 March -July 2014
Fig(6) Fan Model
REFERENCES
[1].Rajan G.G (2001), “Optimizing Energy efficiency in
industries by Energy Loss Control-models”,
[2] Rask, E Lo, K.L. & Song E, Z. M.(1969), “Tube Failures
Occurring in the primary super heaters and re heaters and in the
economizers of coal fired boilers”, Energy Conservation in Coal
fired boilers , Vol.12, 1969, Page No. 185.
[3] “Energy managements” Hand book by C.Turner, Jhon
Willey, and sons publication.
[4] Dognlin, Chen James, D & Varies B.de (2001), “Review of
current combustion, technologies for burning pulverized coal”,
Energy conservation in coal fired boilers Vol.48, Page No. 121-
131.
[5] Adams, J., Clark, D.R., Louis, J.R., & Spanbauer, J.P. 1965.
Mathematical modeling of once-through boiler dynamics. IEEE
Transactions on Power Apparatus and Systems, PAS.Vol.84,
issue (2), pp 146-156.
[6] “ASHRAE Handbook”, NPC Case Studies in 2013.
[7] M. & Lewis, W “Coal ash deposits in coal fired boilers”
Energy conservation of coal fired boilers, Vol. 13, , Page No.
170-180.
[8] P.K.Nag, R. K Rajput “Power Plant Engineering” Tata
McGraw-Hill Publishing Company Limited ” New Delhi. 3 rd
Edition.
BIOGRAPHIES
Vikas Duhan is a research student. His interested area broadly
within Electric Power System. He received his B.Tech from Jind
Institute of Engineering & Technology, Jind. Affiliated to
Kurukshetra University, Kurukshetra, India and presently
pursuing his M.Tech (Power System) from School of PG
Engineering A unit of Ganga Technical Campus Approved by
AICTE, New Delhi & Affiliated to Maharishi Dayanand
University, Rohtak, Haryana, India
Jitender Singh is an Assistant Professor in School of PG
Engineering A unit of Ganga Technical Campus Approved by
AICTE, New Delhi & Affiliated to Maharishi Dayanand
University, Rohtak, Haryana, India. He received his B.Tech in
2007 and M.Tech in 2011. His areas of interest are power
system Controls and Smart grid.