TURBINE HEAT RATE CALCULATION

DESCRIPTION UNIT

STEAM
Steam Temp at TG inlet Deg.C 512.354
Steam Pressure at TG inlet Kg/cm2 83.918
Steam flow TPH 3748.965
LOAD MW 936
HP HEATER
Feed water temp at outlet Deg.C 201.7685
Heat rate 2448.9

Sp steam consumption 4.005

Enthalphy of steam 817.8

Enthalphy of feed water 206.4

TURBINE HEAT RATE 2448.947

 SITAPURAM POWER LIMITED (43MW)

Heat Rate of TG sets :

PARAMETERS Sitapuram power limited

Type of TG Unit TG -Design
Actual
Power Output MW 43.0

Turbine inlet steam parameters

Inlet steam flow with full process steam : TPH 169.8
Enthalpy of Inlet steam to turbine. : Kcal/Kg 816.7

Extraction 1
Steam Flow TPH 14.4
Internal use in HP Heater TPH 14.4
Enthalpy of steam Kcal/kg 726.2

Extraction 2
Steam Flow TPH 6.5
Internal use in Deaerator TPH 6.5
Enthalpy of steam Kcal/kg 673.8

Extraction 3
Steam Flow TPH 2.1
Internal use in LP Heater TPH 2.1
Enthalpy of steam Kcal/kg 685.6

Feed water addition

FW flow TPH 15.4
Enthalpy Kcal/Kg 35.0

Condensate return
Condensate return Flow TPH 0
Enthalpy of Condensate Kcal/kg 0

Feed water inlet temperature degC 205

Turbine Heat Rate Kcal/kwh 2428

Boiler efficiency 84.8%

Station Heat Rate Kcal/Kwh 2863
Enthalpy for ready referency :

Pressure Enthalpy Kca/Kg

107 822.5
93.1 826
90 818
67 806
65 807.5
61 814.4
60 806

49.5 787
42 766
54
30 770
36 771
27.5 778.2
25.7 752.6
20 765
18.5 738.9
16.3 730.1
16 736.7
12.7 752
15.5 741.7
16 730.3
15 737.8
18.2 733.2
Sitapuram power limited
TG -Actual

#DIV/0!

#DIV/0!
Enthalpy for ready referency :

Pressure Temp Enthalpy Kca/Kg Pressure

107 530 822.5 12
93.1 530 826 12
90 515 818 11.15
67 485 806 7
65 485 807.5 5
61 495 814.4 5.5
60 480 806 4
3.5
49.5 442 787 4.6
42 400 766 3.91
54 440 3.2
30 410 770 6.6
36 405 771 6.5
27.5 410 778.2 1.01
25.7 361.3 752.6 11.3
20 380 765 8.3
18.5 329 738.9 3.8
16.3 331 730.1 2.3
16 323 736.7 2
12.7 348 752 0.75
15.5 331 741.7 0.96
16 310 730.3
15 323 737.8
18.2 318 733.2
Temp Enthalpy Kca/Kg
265.5 709
300 727.5
285 720.3
234.5 697.4
195 670
210 686
227 696.7
174 670
227 696
200 683.3
182 675.3
208 684.2
227 694
101.6 639.6
294 725
236 697
174 670.4
174 672.6
249 709.1
95.5 637.7
129 653
 Turbine heat rate calculation as per ageing
05.03.2013

Sl No Description Heat rate

1 Turbine Heat rate as per design 2400.00 Kcal/kwh
2 Turbine Heat rate as per PG test 2428.39 Kcal/kwh

Turbine Ageing calculation at full load

Major TG overruling done on NOV 2010 27 months/ till date

Ageing factor calculaton 1.68%

Turbine heat rate as per ageing for 27 months 2467.73 Kcal/kwh

05.03.2013
 SITAPURAM POWER LIMITED (43MW)

Turbine Heat Rate & Station Heat Rate : AT 21.5 MW LOAD

PARAMETERS Sitapuram power limited

Type of TG Unit TG -Design
Actual
Power Output MW 21.5

Turbine inlet steam parameters

Inlet steam flow with full process steam : TPH 80.9
Enthalpy of Inlet steam to turbine. : Kcal/Kg 816.7

Extraction 1
Steam Flow TPH 9.5
Internal use in HP Heater TPH 9.5
Enthalpy of steam Kcal/kg 716.6

Extraction 2
Steam Flow TPH 4.9
Internal use in Deaerator TPH 4.9
Enthalpy of steam Kcal/kg 666.7

Extraction 3
Steam Flow TPH 1.1
Internal use in LP Heater TPH 1.1
Enthalpy of steam Kcal/kg 682.6

Feed water addition

FW flow TPH 7.1
Enthalpy Kcal/Kg 30.9

Condensate return
Condensate return Flow TPH 0
Enthalpy of Condensate Kcal/kg 0

Feed water inlet temperature degC 138.6

Turbine Heat Rate Kcal/kwh 2562

Boiler efficiency 84.5%

Station Heat Rate Kcal/Kwh 3032
Enthalpy for ready referency :

Pressure Enthalpy Kca/Kg

107 822.5
93.1 826
90 818
67 806
65 807.5
61 814.4
60 806

49.5 787
42 766
54
30 770
36 771
27.5 778.2
25.7 752.6
20 765
18.5 738.9
16.3 730.1
16 736.7
12.7 752
15.5 741.7
16 730.3
15 737.8
18.2 733.2
Sitapuram power limited
TG -Actual

Sl NO Particular
1) Coal consumption /Day
AT 21.5 MW Load

2) CHP SHOULD BE RUN LESS THEN

#DIV/0!

#DIV/0!
Enthalpy for ready referency :

Pressure Enthalpy Kca/Kg

107 822.5
93.1 826
90 818
67 806
65 807.5
61 814.4
60 806

49.5 787
42 766
54
30 770
36 771
27.5 778.2
25.7 752.6
20 765
18.5 738.9
16.3 730.1
16 736.7
12.7 752
15.5 741.7
16 730.3
15 737.8
18.2 733.2
418 T/Day

6.0. Hrs
Pressure Temp Enthalpy Kca/Kg
12 265.5 709
12 300 727.5
11.15 285 720.3
7 234.5 697.4
5 195 670
5.5 210 686
4 227 696.7
3.5 174 670
4.6 227 696
3.91 200 683.3
3.2 182 675.3
6.6 208 684.2
6.5 227 694
1.01 101.6 639.6
11.3 294 725
8.3 236 697
3.8 174 670.4
2.3 174 672.6
2 249 709.1
0.75 95.5 637.7
0.96 129 653
 WITHOUT HP HEATER STEAM CONSUMPTION

TPH K.CAL/KG TOTAL K.CAL 161.58

I/L 169.409 816.7 138356.3303 131962.4
HPH 14.411 726.2 10465.2682
DEA 11.323 673.8 7629.4374
LPH 14.583 685.6 9998.1048 17627.54
COND 129.121 555.8 71765.4518 81797.09
POWER 43MW 99858.2622
38498.0681 32537.76
K.Cal/Kwh 895.30
1 KWHR = 860.4 K.CAL
AM CONSUMPTION

WITOUT HPH STEAM CONSUMPTION

135.674 6.553 3642.157 84.701

WITOUT HPH STEAM TO CONDENSER
 Heat Loss Method -
Sr No Description
1 Proximate Analysis (ADB)
Total Moisture
Inherent Moisture
Ash
Volatile Matter
Fixed Carbon
Gross Calorific Value
2 Proximate Analysis (ARB)
K=(100-TM)/(100-IM)
Ash
Volatile Matter
Fixed Carbon
Gross Calorific Value
3 Ultimate Analysis
Sulphur
C=(1.0.01*Z)*Cp+(0.05*A)-(0.5*S)
Z=TM+1.1*A+0.1*S
Cp=(0.0015782*Qp)-(0.2226*Vp)+37.69
Qp=(100*Q*4.186)/(100-Z)
Vp=100*(v-(0.1*A)-(0.1*S))/(100-Z)
H2 =(1-0.01*Z)*Hp+(0.01*A)-(0.015*S)
Hp=(0.0001707*Qp)+0.0653*Vp)-2.92
N=(2.1-(0.012*VM))
O=100-(C+H+S+N+A+TM)
4 Boiler Operating Parameters
APH flue gas temp O/L
Ambient temp
Bed Temp
O2
CO2
N2
CO
Weighted avg of LOI
5 Boiler Efficiency By Heat Loss Method
Unburnt carbon loss
Sensible Heat Loss due to Fly Ash
Bed ash
Loss due to moisture in combustion air
Loss due to moisture and H2 in fuel
Dry flue gas loss
Readition loss
ESP ash LOI
`
BOILER EFFICIENCY CALCULATION

Unit

% 8.68
% 3.36
% 44.52
% 25.59
% 26.53
kcal/kg 2895

0.94
% 42.07
% 24.18
% 25.07
kcal/kg 2736

% 0.35
32.67
54.99
67.98
25442.42
44.30
% 2.36
4.3
% 1.81
% 20.75

o
C 141.000
o
C 36
o
C 830.000
% 3.2
% 15.26
% 81.54
% 0.00
%

4.00
0.302
0.390
0.067
6.85
4.10
0.35
0.35
16.41
83.59
 (43MW) SITAPURAM POWER LIMITED (DONDAPADU)

Boiler Performance Evaluation

Sl.No Description Unit Value

1 Coal firing rate Kg/hr 38700

2 Steam generation rate Kg/hr 180000
3 Steam pressure kg/cm2 88
4 Steam temperature C 515
5 Feed water temperature C 206
6 O2 in flue gas by volume % 2.6
6 CO in flue gas by volume %
7 CO2 in flue gas by volume % 18.3
8 Average flue gas temperature C 140
9 Specific heat of flue gas -
10 Ambient temperature C 43
11 Humidity in ambient air kg/kg dry air 60
12 Surface temperature of boiler C 45
13 Wind velocity around the boiler m/s 3
14 Total surface area of boiler m2 4192

Ultimate analysis of coal (in %)

15 Ash content in coal %
16 Moisture in coal %
17 carbon content %
18 Hydrogen content %
19 Sulphur content %
20 Oxygen content %
21 Nitrogen content %
22 GCV of coal kCal/kg
23 Bottom ash %
24 Fly ash %
25 GCV of fly ash kCal/kg
26 GCV of bottom ash kCal/kg
Boiler efficiency by Indirect method

To find theoretical air requirement

1 Theoretical air required for complete combustion kg/kg of coal 0.00

Theoretical CO2
Moles of C - 0.00
2
Moles of N2 - 0.14
CO2 theoretical % 0.00
3 Excess air supplied % -79.00
4 Actual mass of air supplied /kg of fuel (AAS) kg/kg of fuel 0.00
5 Mass of dry flue gas kg/kg of fuel 7.13

Various losses in boiler

1 Heat loss in dry flue gas (L1) % #DIV/0!

Heat loss due to evaporation of water due to H 2 in

2 % #DIV/0!
fuel (L2)

3 Heat loss due to moisture in fuel (L3) % #DIV/0!

4 Heat loss due to moisture in air (L4) % #DIV/0!

Heat loss due to partial combustion of C to CO
5 % #DIV/0!
(L5)
Radiation and convection losses ( standard 0.5 to
6 % 0.5
1%) L6
7 Loss due to unburnt in fly ash (L7) % #DIV/0!

8 Loss due to unburnt in bottom ash (L8) % #DIV/0!

Boiler efficiency by Indirect method % #DIV/0!

Note :Field marked in yellow colur needs to be filled only

ADU)

38.7

18.3
 BOILER-EFFICIENCY CALCULATION
Heat Loss Method - ASME PTC 4.1
Sr No Description Unit
1 Proximate Analysis (ADB)
Total Moisture % 9.03
Inherent Moisture % 2.05
Ash % 45.20
Volatile Matter % 23.55
Fixed Carbon % 29.20
Gross Calorific Value kcal/kg 3446
2 Proximate Analysis (ARB)
K=(100-TM)/(100-IM) 0.93
Ash % 41.98
Volatile Matter % 21.87
Fixed Carbon % 27.12
Gross Calorific Value kcal/kg 3200
3 Ultimate Analysis
Sulphur % 0.35
C=(1.0.01*Z)*Cp+(0.05*A)-(0.5*S) 36.15
Z=TM+1.1*A+0.1*S 55.24
Cp=(0.0015782*Qp)-(0.2226*Vp)+37.69 76.16
Qp=(100*Q*4.186)/(100-Z) 29932.07
Vp=100*(v-(0.1*A)-(0.1*S))/(100-Z) 39.41
H2 =(1-0.01*Z)*Hp+(0.01*A)-(0.015*S) % 2.55
Hp=(0.0001707*Qp)+0.0653*Vp)-2.92 4.8
N=(2.1-(0.012*VM)) % 1.84
O=100-(C+H+S+N+A+TM) % 17.14
4 Boiler Operating Parameters
APH flue gas temp O/L o
C 132.386
Ambient temp o
C 38
Bed Temp o
C 871.551
O2 % 3.914
CO2 % 14.65
N2 % 81.44
CO % 0.00
Weighted avg of LOI % 5.89
5 Boiler Efficiency By Heat Loss Method
Unburnt carbon loss 5.63
Sensible Heat Loss due to Fly Ash 0.232
Bed ash 0.410
Loss due to moisture in combustion air 0.057
Loss due to moisture and H2 in fuel 6.19
Dry flue gas loss 3.90
Readition loss 0.35
Total losses 16.77
Efficiency % 83.23
ESP EFFICIENCY

ESP IN LET DUST CONCENTRATION (Gram/Nm3)

ESP OUT LET DUST CONCENTRATION(mg/NM3)

FICIENCY

ONCENTRATION (Gram/Nm3) 43 43000

CONCENTRATION(mg/NM3) 76.8

ESP EFFICIENCY 99.82

 ECONOMIZER EFFICIENCY
STEP-1
HEAT OF FLUE GASES
M-air MASS OF AIR SUPPLIED 120000 kg
M-feedd MASS OF FEED WATER 90000 kg
CP Sp heat of FLUE GAS 0.278 Kcal/kg Oc
Delta air Temp of air delivered to the boiler 155 Degree
Delta F Eco I/L flue gas temp 476 Degree
5 Delta fw Feed water temp at eco I/L 207 Degree
Delta fhp Feed water temp hp heter I/L 163 Degree

3960000

STEP-2
HEAT ABSORBED BY BFW IN THE ECONOMISER

10708560
ECONOMIZER EFFICIENCY

36.98 %
 FLUDIZING AIR VELOCITY

Air velocity = Total air supplied/ furnace area

Furnace area
Area 5132X8923

Total area 45.792836 Sq mtr

Toatal air flow = 120 TPH

AIR VELOCITY 2.62 M/sec

GAS DENSITY

Gas Density = (273X1.293)/(273+gas temp)

Gas temp= 125

352.989
413
Gas Density 0.855 Kg/m3

FLUID VELOCITY IN PIPE

FLOW(TPH) 180
PIPE DIA(mm) 250
AREA 62500
FLOW (lit/min) 3000

VELOCITY 1.019 M/Sec

ELOCITY

.
PIPE
 COOLING TOWER EFFICIENCY

Sum temp:
Wet bulb temp
I/L Temp of CT
O/L Temp of CT
Approach

Range
Effectiveness
R EFFICIENCY

33
27
44
33
6

11
65
 CONDENSER EFFICIENCY

T1 = In let Temp of cooling Tower

T2 = Out let Temp of cooling Tower

T3 = Corressponding temp to vacuum in the condenser

Efficiency 115.56
35
45.4

44
 CONDENSER EFFICIENCY

I/L Temp of Condenser 35

O/L Temp of condenser 45.4

Saturation temp corresponding to pressure 44

Delta T 10.4
Efficiancy 1.1556
 14.7M3 DM PLANT AND 15.0 M3 RO PLANT

Clarified Water Storage Tank

SWST

MGF

MGF: Multigrade Filter 3" FM with Strainer

SWST: Service Water Storage Tank UF FFT

UF FFT: Ultra Filteration Fast Flushing Tank

UF PST: Ultra Filteration Product Storage Tank Tank
DWST: Degassifier Water Storage Tank
SAC: Strong Acid Cation UV Filteration
SBA: Strong Base Anion
MB: Mixed Bed
DM WST: Demineralised Water Storage Tank

DM WST
1

MB SBA SAC

DM WST
2

MGF BACK WASH

UV FAST FLUSH
NEUTRALISATION TANK
RO BACKWASH

MB REGEN WATER

SBA REGEN WATER GUARD POND

SAC REGEN WATER In plant gardening

CT BLOW DOWN
ND 15.0 M3 RO PLANT

COOLING TOWER

To Toilets and P&V makeup

Design OBR= Out put Between Regeneration -295/r

Out put Between Regeneration -295/regene

1" FM with Strainer
SWST

DM Plant Out Put =100%

UF FFT

UF PST Design
At present

RO PLANT OUT PUT=

RO Plant

DWST
To Zuari Cements Ltd.
 DM PLANT

BR= Out put Between Regeneration -295/regeneration

ut put Between Regeneration -295/regeneration

M Plant Out Put =100%

RO PLANT

15 M3
12 M3

O PLANT OUT PUT= 80.00 %

 Boiler blow down calculation

1) Feed water TDS

2) % of make up water
3) Max permissiable TDS in boiler water
ulation

2
0.62
70