International Journal For Multidisciplinary Research

E-ISSN: 2582-2160   •   Impact Factor: 9.24

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Volume 8 Issue 4
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Optimization of Auxiliary Power Consumption in Supercritical Thermal Power Plant Using Six Sigma DMAIC Methodologies

Author(s) Mr. S Lingamaiah, Dr. Repana Ramachandra
Country India
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.
Keywords Auxiliary Power Consumption, Six Sigma, DMAIC, Supercritical Power Plant, Energy Efficiency, Thermal Power Plant Optimization.
Field Engineering
Published In Volume 8, Issue 4, July-August 2026
Published On 2026-08-16
DOI https://doi.org/10.36948/ijfmr.2026.v08i04.85875
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E-ISSN 2582-2160
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CrossRef DOI prefix of IJFMR is 10.36948/ijfmr

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