Optimization of Auxiliary Power Consumption in Supercritical Thermal Power Plant Using Six Sigma DMAIC Methodologies
Year: 2026
Type: article
Abstract: Auxiliary Power Consumption (APC) is one of the critical performance indicators in thermal power plants, directly influencing plant efficiency and operational cost. In large supercritical units, auxiliary equipment such as boiler feed pumps, induced draft fans, forced draft fans, cooling water pumps, and coal mills consume significant internal power. This study presents the optimization of auxiliary power consumption in an 800 MW supercritical thermal power plant at Sri Damodaram Sanjeevaiah Thermal Power Station by adopting the Six Sigma DMAIC (Define–Measure–Analyze–Improve–Control) methodology. Operational data for the period 2023–2024 were analyzed to identify major contributors to APC. Key issues such as inefficient pump operation, air ingress in the condenser, suboptimal combustion conditions, and improper operation of auxiliary equipment were identified. Improvement actions including combustion optimization, mill fine tuning, restoration of low-pressure heater-3, modification of high-pressure heater feed outlet temperature, and condenser vacuum improvement were implemented. As a result, APC was reduced from 6.9% to 6.4%, yielding an annual saving of approximately 25 million units (MUs) of electricity. The study demonstrates the effectiveness of Six Sigma techniques in improving energy efficiency and operational performance in large thermal power plants.
Authors: S Lingamaiah, Repana Ramachandra
Institutions: B.E.S.T Innovation University, Sri Krishnadevaraya University
Language: English
Subfield: Energy Engineering and Power Technology
Field: Energy
Domain: Physical Sciences
Open Access status: hybrid
OpenAlex ID: W7203580992