CALCULATION OF BOILER EFFICIENCY

The roe of effcency montorng es n maxmzng generaton from the therma power pants. It
enhances energy effcency of the power pant. Presenty about 65% of the tota power s generated
by therma power pants. In order to keep maxmum output from a gven nput, the unts must run at
the maxmum possbe effcency. Power pant performance at varous steps heps n mprovng the
power generaton capacty.
BOILER EFFICIENCY s defned as the heat added to work n fud expressed as a percentage of heat n
the fue beng burnt. Boer effcency depends soey on the boers abty to burn the fue and
transfer the resutng heat to water and steam. The pressure and temperature of steam, athough
profoundy aterng cyce effcency & turbne effcency. Have no effect on boer effcency.
In DIRECT METHOD boer effcency can be cacuated as foows:
Effcency = |(enthapy of steam-enthapy of feed water) xsteam fow|/(quantty of coaxC.V)
Agan, enthapy of steam can be cacuated as the summaton of the enthapy n the man steam ne
and the enthapy gan n the reheater part of the boer.
OBSERVATION:
UNIT#3 (TOTAL CAPACITY=120 MW)
Load on 14/7/05 s 87.5 MW
Tota oad consumpton: 55.7 TPH
Load from IB Vaey : 15.1 TPH
Load from Mddng : 40.6 TPH
C.V of IB Vaey coa : 2944 KCa/Kg
C.V of Mddng coa : 4375 KCa/Kg
Man steam temperature: 533.48 C
Man steam pressure : 120.65 Kg/cm
2
Man steam fow : 262.2 TPH
Pressure of the boer(drum):130.8 Kg/cm
2
Temperature at the economzer net: 210.18
o
C
Reheater:
Inet temperature: 258
o
C
Inet pressure : 28.3 Kg/cm
2
Outet temperature: 537.48
o
C
Outet pressure : 23.3 Kg/cm
2
CALCULATION:
Enthapy of man steam at 533.48
o
C & 120.65Kg/cm
2
pressure s
hsteam =823.01KCa/Kg
Enthapy of steam at reheater net (at 2588 C & 28.3 Kg/cm2) s
hrh/=692.7KCa/Kg
Enthapy of steam at reheater outet (at 537.48 C & 23.3 Kg/cm2) s
hrho/=847.5KCa/Kg
Tota gan n enthapy n reheater = hrho/- hrh/
= 847.5KCa/Kg-692.7KCa/Kg
=154.8KCa/Kg
Enthapy of man steam (tota)= 823.01KCa/Kg+154.8KCa/Kg
=977.81KCa/Kg
Tota energy nput to the boer=(15.13 2944+40.63 4375)x103 KCa/Hr
=(44454.4+177625)x103 KCa/Hr
=222079x 103 KCa/Hr
Enthapy of feed water s cacuated as:
h=hf-Cp t
where,
h: Enthapy of feed water
hf: Enthapy at 130.8 Kg /cm2
Cp=1KCa/Kg
t=|sat. temp at 130.8Kg/cm2- economzer net temp|= 329.84-210.1
o
C
=119.748
o
C
h= 364-119.74
=244.26KCa/Kg
Boer Effcency= {(823.01KCa/Kg+154.8KCa/Kg-244.26KCa/Kg)x262.2x103 KCa/Hr } /
222079x 103 KCa/Hr
=86.61%
CALCULATION OF EFFICIENCY OF AIR PREHEATER
Ar preheaters are empoyed as therma energy recovery system n steam power pants.
The ob|ectve s to extract the maxmum possbe amount of therma energy from the outgong
fue gas, whch woud otherwse be carred away to the atmosphere.
The extracted therma energy s utzed to heat up the Secondary Ar & a part of the
Prmary Ar. Hot Prmary Ar removes the surface mosture from the coa n the puvrerser &
therefore reduces the heat requred by coa to reach ts gnton temperature n the furnace. Aso
hot Secondary Ar asssts n effectve combuston & to mantan the furnace temperature.
Hence, the effcency wth whch heat s transferred from fue gases to the ar devered by
ID & FD fans s an mportant crtera for effcent operaton of the power pant. To cacuate the
effectveness of Ar Preheaters, the foowng observatons are recorded whch forms the bass for
subsequent cacuatons.
Observa!"#s: $
The following observations pertain to Unit #3
1. Generaton 100.1 MW
2. Coa Consumpton 60 Tons / Hour
3. Tota (Prmary + Secondary) ar fow 400 Tons / Hour
4. Prmary (Hot + Cod) ar fow 171 Tons / Hour
5. Fue gas net temperature (common to a heaters) 310.6 Deg. C
6. Hot Prmary Ar fow 65 % of tota PA
7. Data regardng ar preheaters
Heater
Ar I/L temp.
(Deg. C)
Ar O/L temp.
(Deg. C)
Fue gas O/L temp.
(Deg. C)
Prmary Ar Heater ( PAH ) 40.0 280.3 130.2
Secondary Ar Heater A ( SAHA ) 33.0 289.1 168.6
Secondary Ar Heater B ( SAHB ) 33.2 292.2 168.0
Ca%&'%a!"#s: $
Flue gas temperature differences: -
At PAH => ( 310.6 - 130.2 ) Deg. C = 180.4 Deg. C
At SAHA => ( 310.6 - 168.6 ) Deg. C = 142.0 Deg. C
At SAHB => ( 310.6 - 168.0 ) Deg. C = 142.6 Deg. C
Average fue gas temperature dfference = T
()
= ( 180.4 + 142.0 + 142.6 ) / 3 = 155 Deg. C
Air temperature differences :-
At PAH => ( 280.3 - 40 ) Deg. C = 240.3 Deg. C
At SAHA => ( 289.1 - 33 ) Deg. C = 256.1 Deg. C
At SAHB => ( 292.2 - 33.2 ) Deg. C = 259.0 Deg. C
Average ar temperature dfference = T
a!r
* ( 240.3 + 256.1 + 259.0 ) / 3 = 251.8 Deg. C
Secondary Ar fow = ( 400 - 171 ) Tons / Hour = 229 TPH
Hot Prmary Ar fow = 65 % of tota PA fow = 0.65 X 171 TPH = 111.15 TPH
Snce the tota secondary ar & 65 % of prmary ar passes through ar heaters, so tota ar fow
through ar heaters = m
a
= ( 229 + 111.15 ) TPH = 340.15 TPH
The coa has 45 % ash content, 20 % of the tota ash generated s consdered as bottom ash
whch s not carred by fue gases. So fue gas fow through a the ar heaters,
m
fg
= tota ar fow + coa consumpton - bottom ash generaton
= 400 + 60 - ( 60 X 0.45 X 0.2 ) TPH = 454.6 TPH
So, heat reeased by fue gas at the heaters = m
fg
x T
fg
x S
fg


=
454.6 X 155 X 1.01 X 1000 K| /Hr
= 71161.63 X 1000 K| / Hr
where, ( S
fg
= specfc heat of fue gas = 1.01 K| / Kg / Deg. C )
Heat ganed by ar n the heaters = m
a
x T
ar
x S
ar

= 340.15 X 251.8 X 0.79 X 1000 K| / Hr
= 67663.32 X 1000 K| / Hr
where, ( S
ar
= specfc heat of ar = 0.79 K| / Kg / Deg. C )
So, E((!&!e#&+ "( A!r Heaers
* , Heat ganed by ar n the heaters / heat reeased by fue gas at the heaters ) X 100 %
= ( 67663.32 / 71167.63 ) X 100 %
= -../06 %
CALCULATION OF H.P. CYLIN1ER EFFICIENCY
C+%!#2er e((!&!e#&+: The cynder effcency s defned as the rato of heat drop n a cynder to
the sentropc heat drop n that cynder.
In dea case the expanson of steam n a cynder (say H.P. cynder) shoud be sentropc.
But due to frcton, wndage or other sources of oss, the expanson dffers from sentropc
expanson.

S"3 &+%!#2er e((!&!e#&+* A&'a% hea 2r"4 !# &+%!#2er 5 1// %


Ise#r"4!& hea 2r"4 !# &+%!#2er
Typca vaue of effcency of HP cynder = 8-%
Ca'ses "( H.P. &+%!#2er e((!&!e#&+ var!a!"#:
) Short bades, partcuary at eary stages
) Consequent hgh tp osses
) Damage of tp seas & nterstage gands
v) Increased roughness of bade surface
Determination of H.P. cylinder efficiency: -
Observa!"#:
Data coected on: 13.07.2005
Unt No.: 3
Load on Machne = 100 MW
Frequency = 49.91 Hz.
Steam Temperature at H.P. net = 535
o
C
Steam Pressure at H.P. net = 122 kg/cm
2
Steam Temperature at H.P. outet = 328
o
C
Steam Pressure at H.P. outet = 27.9 kg/cm
2
Enthalpy of steam at corresponding temperature and pressure: -
H3 = Enthapy of steam at H.P. net at 535
o
C & 122 kg/cm
2
= 821.98 kca/kg
H4 = Enthapy of steam at C.R.H. at 328
o
C & 29.9 kg/cm
2
= 733.62 kca/kg
H4s = Enthapy of steam at C.R.H. at 27.9 kg/cm
2
durng sentropc expanson=719.07
kca/kg
Ca%&'%a!"#:
Effectve heat drop = (H3-H4)
= (821.98-733.62) kca/kg
= 102.91 kca/kg
Isentropc heat drop = (H3-H4s)
= (821.98-719.07) kca/kg
H.P. &+%!#2er e((!&!e#&+ * ,E((e&!ve hea 2r"467 ,Ise#r"4!& hea 2r"46 5 1//%
* ,88.8671/9.-16 5 1//%
* 8..86 %
CALCULATION OF CON1ENSER : COOLIN; TO<ER EFFICIENCY
CON1ENSER:
The condenser s bascay a heat exchanger where the steam, whch was used to rotate the turbne,
s condensed to water and recrcuated n the boer turbne crcut to compete the cosed Rankne
Cyce. The heat reeased by steam whe the coong water from the coong tower absorbs
condensng.
The condenser here s doube pass, counter fow heat exchanger. Smpy for a counter fow heat
exchanger; the effectveness or the effcency s gven by,
= |{Ch(Th1-Th2)}/{Cmn(Th1-Tc1)}|= |{Cc (Tc1-Tc2)}/{Cmn(Th1-Tc1)}|
Where,
Th1, Th2: Temp of the steam at net and steam after condensng at outet.
Tc1, Tc2: Temp of coong water at net & outet.
Cc:Mass fow rate3 Cp of coong water.
Ch: Mass fow rate of steam3 Cp.
Cmn: smaer of Cc & Ch.
OBSERVATION:
On 12/7/05 on a generaton of 94.5 MW,
Coong water
Fow rate: 26000m3/Hr
Temperature
PASS A PASS B
INLET OUTLET INLET OUTLET
37 44.5 37 45.3
Condenser vaccum: -0.88Kg/cm2
Hotwe temperature: 508 C
Fow rate: 282 TPH
Condenser Inet Temp: 56.68 C
CALCULATIONS:
Th1

Ch2 Th2
Ch1
= |{Ch(Th1-Th2)}/{Cmn(Th1-Tc1)}|= |{Cc (Tc2-Tc1)}/{Cmn(Th1-Tc1)}|
Now,
Cc: Mass fow ratexCp of coong water = 26000 TPH Cp
Ch: Mass fow rate of steamxCp. =; (as phase change takes pace)
Cmn= Cc
= (Tc2-Tc1) / (Th1-Tc1)
= (44.5-37) / (56.6-37)
=0.39
39%
COOLIN; TO<ER:
The coong tower from condenser needs to be cooed and ths s done n a coong tower. Here, used
s a wet nduced draft-coong tower.
The coong tower works on prncpe of adabatc humdfcaton. Here the coong water fows n
opposte drecton to atmospherc ar. Some water evaporates drawng ts atent heat from water thus
coong t .The ar gets humdfed and eaves from top of the coong tower.
Coong tower parameters are desgnated as:
Range
Approach
Effectveness of coong tower effcency.
OBSERVATION:
On 11/7/05 on 94.5 MW generaton,
Coong water net temperature: 44.58 C
Coong water outet temperature: 378 C
Ar net temperature: 328 C
Humdty: 87%
WBT correspondng to net ar condton (from psychometrc chart): 298 C
CALCULATIONS:
AIR OUT
(3)
5

AIR IN (1)
COOLE1 <ATER (4)
Effectveness=(Tw4-Tw3)/(Tw4-Twb1)=(44.5-37)/(44.5-29)=0.48==8%
Fow of water =18000TPH of whch evaporaton oss s 289.9 TPH, drft oss s 1.8 TPH whch s
repenshed by make up water suppy.
CALCULATION OF IP CYLIN1ER EFFICIENCY
Ideay the expanson n Turbne shoud be sentropc. So, n the T- dagram the process shoud
have foowed the straght vertca path 1-2-3. But due to osses n the turbne (due to frcton, etc.)
the process foowed s non-sentropc and hence s represented by the curve 1-2-3 n the T-
It can be noted that,
h2<h2 h3<h3

s2<s2 s3<s3
So t s cear, that the work done n actua expanson process s ess than that done n sentropc
process. Hence, the effcency of the turbne can be cacuated as foows:

turb*Actua expanson work done n turbne/Isentropc work (theoretca)
Now,
Let, >= Man steam fow rate
> =HP6 extracton
>"=HP5 extracton
Steam fow rate at IPT entry, m1=m-m
Aso, steam fow after HPH5 extracton (.e. after pont 2/2 n the T- dagram),
>2 = >1->"= > -( > + > ")
Therefore, actua work done n the turbne,

<=>1(h2-h1)+>2(h3-h2)
= <1+<2
And, Isentropc work,

I=>1(h2-h1)+>2(h3-h2)
= I1+I2

turb= <7I
OBSERVATION ,1ATE1: 1=7/07/.6
LOAD=100.2MW
MAIN STEAM FLOW=302.1TPH
POINT
TE?PERATURE ,8 C6
PRESSURE ,@)7&>96
IPT Inet 524 25.5
IPT Outet 289 4.36
HPH5 Extracton 395 10.4
USEFUL 1ATA:
FULL LOAD EXTRACTION FLOW FOR:
HPH5 19.201TPH
HPH6 36.633TPH
TE?PERATURE
,8 C6
PRESSURE
,@)7&>96
ENTHALPY
,@&a%7@)6
ENTROPY
,@&a%7@)@6
524 25.5 839.52 1.76546
10.4 769.3 "
4.36 713.36 "
395 10.4 777.09 1.77732
289 4.36 727.03 1.79038
CALCULATIONS:
h1=839.52 KCa/Kg h2=777.09 KCa/Kg
h2=769.30 KCa/Kg h3=727.03KCa/Kg
h3=713.36 KCa/Kg
>=(36.6634 120)x100.2 TPH= 30.588555 TPH
>"=(19.2014 120)x100.2 TPH=16.0328 TPH
>1=(302.1-30.588555) TPH=271.511445 TPH
>2=(271.511445-16.0328) TPH=255.478645 TPH
I=|271.511445(839.52-769.3)+255.478645(769.3-713.36)|x103 =33357.009063 103 KCa/Hr
<=|271.511445(839.52-777.09)+255.478645(777.09-727.03)|x103
=29739.723 103 KCa/Hr
=<4 I
=(29739.724 33357.00906)x100
= 8-%
PERFOR?ANCE CRITEIA OF ELECTROSTATIC PRECIPITATORS
: ITS EFFICIENCY CALCULATION
The methods used for the remova of dust from gases are many but for power appcatons they are
mted to two types, the mechanca coector, whch by centrfuga acton causes the dust partces
to eave the gas stream by nerta and the eectrostatc precptator, whch uses eectrc forces to
remove the dust from the gas stream.
If gravty setters and centrfuga separators are devces that drves the partces aganst a sod wa
& f nether can functon effectvey (at an ndustra scae) for partces beow about 5 dameters,
then for wa coecton devces to work on smaer partces they must exert forces that are more
powerfu than gravty or centrfuga forces.
The ESP s very much ke a gravty setter or a centrfuga separator, but the e%e&r"sa!& ("r&es
drves the partces to the wa.
The prncpes on whch an ESP operates are that the dust-aden gases pass nto a chamber where
the ndvdua partces of dust are gven an eectrc charge by absorpton of free ons from a hgh
votage D.C Ionzng fed. Eectrc forces cause a stream of on to pass from the dscharge eectrodes
to the coectng eectrodes and the partces of dust entraned n the gas are defected out of the gas
stream nto the coectng surfaces where they are retaned, ether by eectrca or moecuar
attracton. An ntermttent bow usuay referred as Rappng removes them. Ths causes the dust
partces to drop n the dust hoppers stuated beow the coectng eectrodes.

CORONA 1ISCHAR;E

;AS FLO<


1ISCHAR;E ELECTRO1E
COLLECTIN; ELECTRO1E
FI;: SECTIONAL PLAN SHO<IN; TYPICAL ARRAN;E?ENT OF PRCIPITATOR ELECTRO1ES
There are four dfferent stages of n the process:
1. Ionzaton of gases and chargng of dust partces.
2. Mgraton of the partce to the coector.
3. Deposton of charged partces on the coectng surface.
4. Dsodgng of partces from the coectng surface.
In ESPs the resstng force s the Stokes vscous drag force, but the force movng the partce
towards the wa s eectrostatc. Ths force s practcay proportona to the partce dameter
squared, and thus the rato of drvng force to resstng force s proportona to the dameter.
Thus t s harder for an ESP to coect sma partces than arger ones.
COLLECTIN; EFFICIENCY:
Usuay coectng effcency shoud be gven by the rato of the dfference n dust
concentraton to the net dust concentraton.
= {(C-Co)/C}x100 (1)
where,
: Effcency n percentage.
C: Inet dust concentraton.
Co: Outet dust concentraton.
But, the 1e's&h A A#2ers"# eB# s the most wdey used smpe eqn for desgnng, anayss
& comparson of the ESP. the Deutsch - Anderson eqn s gven by:
=100x{1-e(-k)}
where,
k = Cmx(A/D)= Cm{L/(RxV)}
D: Voume of the gas passng through ESP.
L: Effectve ESP ength.
R: Spacng of the eectrode.
<m: Apparent mgraton veocty (drft veocty).
V: Gas veocty.
A: Coectng area.
PERFOR?ANCE CRITERIA :
The performance crtera of the ESP as coected on 11/07/05-15/07/05 are gven beow.
A. Chara&er!s!&s O( 1's:
i. Par!&%e S!Ee 1!sr!b'!"#: The sze dstrbuton of the fy ash enterng the net of
the ESP pays a ma|or roe n ts performance. The partce sze dstrbuton s gven n the
tabe beow:
?ICRON SIFE PERCENTA;E 1ISTRIBUTION BY
<EI;HT
10 32
10-20 24
20-30 14
30-40 10
Over 40 20
ii. 1's L"a2!#): Inet dust concentraton s 95.88gm/Nm3
iii. Che>!&a% C">4"s!!"#: Chemca composton of the fy ash produced from ths
pant s gven beow:
CHE?ICALS AVERA;E
% Lo 1.8
% SO2 58.4
% A2SO3 29.6
% Fe2O3 3.2
% CaO 3.0
% MgO 1.2
% SO3 0.45
% Aka as Na2O 0.18
% SO2+A2O3+Fe2O3 91.5
iv. E%e&r!&a% Res!s!v!+: For temperature beow 1608 C, the resstvty s domnated
by surface conducton over the fy ash partces, whch n turn s greaty nfuenced
by chemca composton. (.e. H2O, SO3 etc.). At hgher temperature, or n a
perfecty dry atmosphere the fy ash behaves as a sem nsuator. Here the
operatng temperature s 150
o
C.
B. Chara&er!s!&s O( ;ases:
For an ESP desgned for hgher coecton effcency, t s of ma|or mportance to have a
good fue gas dstrbuton nsde the chamber. Ths ensures the effectve utzaton of the
coectng area provded n the precptator.
Ths s obtaned by provdng the defecton pates on the prmary and the secondary screens.
i. ;as e>4era're: 143
o
C
ii. ?"!s're C"#e#: 4%
iii. ;as F%"C Rae: 115.9 m
3
/sec
iv. Press're 1r"4: 13.0Kg/cm
2
SPECIFICATION OF THE ELECTROSTATIC PRECIPITATOR:
ESP SIFE: 2P, 1C, 27GP(400mmx48x73), 5F (53 14.6)
;AS VOLU?E: 844736m
3
/Hr
OPERATIN; TE?PERATURE: 150
o
C
NU?BER OF PRECIPITATORS7BOILER: 2
NU?BER OFCHA?BERS: 1
NU?BER OF ;AS PASSEN;ERS FOR ESP: 27
COLLECTIN; SURFACE HEI;HT: 14.62m
COLLECTIN; SURFACE SPACIN;: 400mm
COLLECTIN; SURFACE LEN;TH: 4.45x5
NU?BER OF FIEL1S PER ESP: 5
SET DUANTITY7SIFES: 5NO, 1000Ma, and 105kv
INLET 1UST CONCENTRATION: 117.5gm/Nm
3
OUTLET 1UST CONCENTRATION: 50mg/Nm
3
CALCULATION:
Drft veocty, Cm=|Dx 0xE2{ 4 ( +2)}|/
={20x10(-6)x8.85x10(-12)
x(105x1000)2x.75}/{1.8x10(-5)
=/./818 >7se&
where,
D=20
0=8.853 10(-12) C/V.m
E=105KV
{ 4 ( +2)}=0.75, 5 6
=1.8x10(-5) Kg/m.s
K=(CmxL)/(RxV)
=(0.0813x4.45x5)/{400x10(-3)x0.741}
=6.1
where,
L=4.45x5m
R=400mm
V=0.741m/sec
={1-e(-k)} 100 G(r"> 1e's&h A A#2ers"# eB#H
=0.99776 100
*--.006%
CALCULATION OF L.P. CYLIN1ER EFFICIENCY
The roe of effcency montorng es n maxmzng generaton from the therma power pants. It
ncreases the energy effcency of the power pant.
Turbne effcency: The cynder effcency s defned as the rato of heat drop n a cynder to the
sentropc heat drop n that cynder.
In dea case the expanson of steam n a cynder (say H.P. cynder) shoud be sentropc. But due
to frcton, wndage or other sources of oss, the expanson dffers from sentropc expanson.
So t s cear, that the work done n actua expanson process s ess than that done n sentropc
process. Hence, the effcency of the turbne can be cacuated as foows:

turbne*Actua expanson work done n turbne/Isentropc work (theoretca)
E5ra&!"# Sea> S+se>
In order to ncrease the cyce effcency, the condensate & feed water s preheated by beed
steam from turbne.
Heatng s carred out n sx stages n three LP heaters, a deaerator & two HP heaters.
OBSERVATION:
?a!# Sea> F%"C Rae: 285.05 TPH
LAO1
,?<6
EITRACTION STEA? FLO< ,TPH6
LPH$1 LPH$9 LPH$8
120 10.583 12.523 14.74
87.5 7.717 9.13154 10.75
POINT TE?PERATURE
,8 C6
PRESSURE
,@)7&>96
ENTHALPY
,@Ca%7@)6
ENTROPY
,@Ca%7@).@6
1RYNESS
FRACTION
LPT net 285.3 5.1624 724.3095 1.767 1
LPH3
extracton
199.4 2.2526 685.27 - 1
LPH2
extracton
110.6 0.8853 644.694 - 1
LPH1
extracton
71.5 0.3393 627.9 - 1
LPT outet 46.6 0.1033 578.648 - 0.9324
LPH3
extracton
- 2.2526 674.24375 1.767 1
LPH2
extracton
- 0.8853 637.6 " 1
LPH1
extracton
- 0.3393 599.9756 " 0.95
LPT outet - 0.1033 560.143 " 0.9
NOTE: In the above tabe the dryness fracton of the extracted steam s taken to be 1, as the LPH
extracton steam quaty was not obtanabe. It can be assumed to be one wth margna errors,
because t w be greater than 0.95.
CALCULATION:
Now, man steam fow rate = 285.05 TPH
Actua work done=|285.05x(724.3095-685.27)+(285.05-10.75)x
(685.27-644.694)+(285.05-10.75-9.1314)x(644.694-627.9)+ (285.05-10.75-9.1314-
7.717)x(627.9-578.648)|x103 KCa/Hr
=8-38-1.=.=.51/J8 @Ca%7Hr
Isentropc work done=|285.05x(724.3095-674.24375)+
(285.05-10.75)x(674.24375-637.6)+ (285.05-10.75-9.1314)x
(637.6-599.9756)+ (285.05-10.75-9.1314-7.717)x
(599.9756-560.143)|x103 KCa/Hr
===3..=.888651/J8 @Ca%7Hr
The effcency of the LP turbne = LPT
=Actua work done 4 sentropc work done
=8-38-1.=.=.51/J87==3 ..=.888651/J8
*88.=1%