ENERGY EFFICIENCY MANAGEMENT SYSTEM

Sankar Bandyopadhyay
Email : sankarbando1956@gmail.com
 Presentation Outline
• Cycle efficiency
• Plant optimisation approach
• Typical major loss areas
• Point of relevance
• Use of multiple technology
• Baseline for comparison
• Heat rare assessment
• Primary process indicators
• More parameters
• Methodology for HR Deviation examples
• Typical impact of parameters on HR
• Testing frequency
• Calibration schedule of Instruments
• Accuracy level of instruments
• Test Equipment Matrix
• Heat Balance diagram
• Good Practices
• PDM Technologies
• HR improvement activities
Increase of Cycle Efficiency due to
Steam Parameters
Increase of efficiency [%]

10
6,77
9
5,79
8 5,74
7 4,81
3,74
6 4,26
5 3,44 2,76
3,37
4
2,64
3
2,42 1,47
2 600 / 620
1,78
1
0,75 580 / 600

0 566 / 566
0 538 / 566
300
241 HP / RH outlet temperature [deg. C]
Pressure [bar] 175 538 / 538
 Point of relevance
• Inlet temperature and Pressure ratio are
directly related to cylinder output
• HPC efficiency to be done at VWO condition
• MW output from cylinder is related to tip seal
nozzle, diaphragm, gland seal, surface
roughness of turbine internals etc
• All the inefficiencies in turbine cycle creates
additional thermal load to condenser
 Point of relevance
• Validation of parameters like condenser vaccum
• Validation of assumptions to avoid opinion
formed on symptoms avoiding root cause
• use of fish bone or fault tree method
• Use of first principle thermodynamic software
for scenario and impact analysis and
development of correction curves For HR and
capacity or load
Identification of correlation between primary cause
and secondary effect
 Baseline for Comparison

Design

One baseline that the current performance of the unit could be

compared to is the “design” heat rate. From the point of view of
setting up the tracking system, this is the easiest baseline to obtain.
However, there are several problems with this method:

 The actual initial performance of the unit may have never reached the
design, or even if it did, the performance of some areas may have been
better, while others were worse.

 The “design” heat rate is based on some ambient conditions that vary
during the year. Frequently the design heat rate is calculated at some
design condenser pressure (or inlet water temperature). During some
parts of the year, the condenser pressure should be lower than the
design; therefore the heat rate should be lower than the design.

Over time, as changes are made to the plant, the “original design” may not
represent the “current design” performance of each parameter or the overall
heat rate as after R&M works done
 Baseline for Comparison
Expected” Performance
The last method, and the one that is recommended, is to compare the actual
current performance to an “expected” value. Design heat rate is taken as reference.

 Expected Boiler efficiency: In design, boiler efficiency projections, OEM has generally
considered very high margin of unburnt loss and most of the stations are achieving
unburnt carbon loss much less than the design projections. In order to make it more
realistic, expected boiler efficiency is calculated by considering expected Unburnt loss (%)
, based on best achieved value of the units. Expected Dry Flue gas Loss is also calculated
using expected Unburnt loss.

 Expected Unit Heat rate = Design GTCHR*100/Expected Blr. Effy

 Test Corrected Boiler efficiency of a unit is corrected to design coal and design A/H air inlet
temperature to arrive at test Corrected Boiler Efficiency, which can be compared with
expected boiler efficiency.

 Test corrected gross turbine cycle heat rate of unit is corrected to design cooling water inlet
temperature to arrive at test corrected GTCHR.

 Test corrected Unit Heat rate =

Test Corrected GTCHR*100/ Test Corrected Blr. Effy.

 Difference of Expected Unit Heat rate & test Corrected Unit Heat rate accounts for gap in
performance of the unit.
Heat rate Assessment
 Heat rate Assessment
Definition of Primary Process Indicators
It is the information to be monitored, measured, or tracked that will give an indication that
the process is in trouble and needs corrective action (or that there has been a change in the
process) prior to seeing adverse impacts to a higher indicator, such as a heat rate deviation.

Some indicators are also “parameters” used to calculate heat rate deviations, such as hot
reheat steam temperature. However, most indicators are at a much lower level, such as mill
outlet temperature. Normally, heat rate deviations are not calculated for mill outlet
temperature, even though it affects the thermal performance (and other characteristics) of
the unit. Another example of a primary process indicator is condenser water box differential
pressure. If it increases (due to fouling of the inlet tube sheet, for example), it can reduce
the condenser circulating water flow, resulting in a higher condenser back pressure and a
higher heat rate. Monitoring this differential pressure will immediately show when a change
has occurred, and signal for corrective action to be taken, before it adversely affects the unit
heat rate.

Each system in the power plant (fuel supply, combustion, feed water, condenser, circulating
water, etc.) has multiple Primary Process Indicators that can be used to determine whether
the process is functioning as designed, (or if there has been a change to the process).

There are several available sources that can be used to help develop a list of indicators, such
as original equipment manufacturers manuals, heat rate deviation fault trees, etc. List of
indicators enclosed is considered to be useful in identifying problem in initial stage.
 Some primary process indicators
• Final S/H outlet temp
• Hot reheat outlet temp
• S/H attemperation flow
• R/H attemperation flow
• Final feed water temp at HPH /Eco outlet
• Flue gas temp at APH inlet/outlet
• PA header pressure
• Wind box Pressure
 Some primary process indicators
• Oxygen at APH inlet/outlet
• APH leakage
• Mill outlet temp
• Mill fineness
• Ms pressure
• HPT/IPT Pr Ratio
• Feed water temp at eco outlet
• Bfp balancing leak off pressure
 Some primary process indicators
• Bfp recirculation valve passing
• Condenser Cw flow
• Air in leakage to condenser
• Water box diff pressure
• CT range and approach
• Ct inlet/outlet temp
• Cw inlet temp
• Unit load
 Deviation in chemical parameters
• Boiler PH >9.5
• After cation conductivity0.2
• Condensate DO> 20
• Drum silica> 100
• Ms ACC>0.2
• Feed water DO> 10
Some more parameters to be monitored

HRH pressure
CRH degree of Super heat
1st Stage pressure
Ms Flow
Coal flow
Feed flow
PA flow
PA header pr
Total air flow
Max metal temp at S/H and R/H w.r.to
limit
DP across APH
H2 in coal
TM in coal
 Some more parameters to be
monitored
• ID discharge Pr
• Flue gas temp at APH inlet
• Pri Air temp at APH outlet
• Sec Air outlet temp at ApH outlet
• Hp ext pr
• Hp ext temp
• HP Heater Ext pr and Temp
• Sec air temp to APH outlet
• Pri air to APH outlet
 METHODOLOGY OF HEAT RATE DEVIATION CALCULATION

• Data Collection Methodology

Heat rate deviations are calculated on the basis of

parameter having direct impact on Heat Rate. For

arriving at best possible deviation value, duration of data

collection and frequency of data collection plays vital

role. Heat rate deviation calculation on daily basis should

be based on 24 hrs daily average value. And for daily

heat rate deviation calculation correction for load and

other boundary conditions are to be applied.

METHODOLOGY OF HEAT RATE DEVIATION CALCULATION
Deviation Calculation Methodology
Load
Daily average load based on 24 hr gross energy meter reading is to
be taken for calculation. This average value actual Load is to be
compared with Full load capacity of unit. The difference of Load will
be taken for Heat rate deviation calculation. The heat rate deviation
is to be derived from Load Vs HR deviation curve. Customized/OEM
correction curves are to be used.

Sample Calculation (Column wise w.r.t Daily HR Deviation Report)

Design Full Load = 210 MW

Expected Load = 210 MW
Actual Load = 168 MW
Variance (Exp. Load - Act. Load) = 42 MW

Turbine HR Deviation = 45
kcal/kWh
(From Curve)
Design Boiler  = 86.8 %
HR Deviation = (45/(86.8/100))= 51.8 kcal/kWh
Main Steam Pressure
MS Pressure before ESV – Day average of 24 hr is to be taken for
calculation. This average value of actual pressure will be compared with
expected pressure (Expected pressure = Design pressure) required. The
difference of Pressure will be taken for Heat rate deviation calculation
based on customized correction curves. Customized/OEM correction
curves are to be used.
Sample Calculation (Column wise w.r.t Daily HR Deviation Report)

Design Pressure = 151 kg/cm2 (abs)

Expected Pressure = 151 kg/cm2
(abs)
Actual Pressure = 149 kg/cm2 (abs)

Variance (Exp.Press- Act. Press) = 2 kg/cm2 (abs)

Turbine HR Correction Factor = 0.999 from Curve

Design Turbine HR = 2000 Kcal/kWh
Design Boiler  = 86.8 %

HR Deviation = 2000/(86.8/100)*(1-0.999)= 2.3

kcal/kWh
Main Steam Temperature

Main steam temperature before ESV- Day average of 24 hrs of all the available

temperature points located before ESV is to be taken for calculation. This average

value of actual temperature is to be compared with expected temperature.

(Expected temperature = Design Temperature). The difference will be taken for Heat

rate deviation calculation based on customized correction curves. Customized/OEM

correction curves are to be used.

Sample calculation (Column wise w.r.t Daily HR Deviation Report)

Design M.S Temperature = 537 0C

Expected M.S Temperature = 537 0C

Actual M.S Temperature = 529.5 0C

Variance (Exp. - Act. M.S Temp) = -7.52 0C

Turbine HR Correction Factor = 0.998 From Curve

Design Turbine HR = 2000 Kcal/kWh
Design Boiler  = 86.8 %

HR Deviation = (2000/(86.8/100))*(1-0.998)= 4.6 kcal/kWh

Hot Reheat Temperature

Hot Reheat Temperature before IV- Day average of 24 hrs of all the

available temperature points located before IV is to be taken for

calculation. This average value of actual HRH temperature is to be

compared with expected temperature. (Expected temperature = Design

Temperature). The difference of temperature will be taken for Heat rate

deviation calculation based on customized correction curves.

Customized/OEM correction curves are to be used.

Sample calculation (Column wise w.r.t Daily HR Deviation Report)

Design HRH Temperature = 538 0C

Expected HRH Temperature = 538 0C

Actual Temperature = 530 0C

Variance (Exp - Act HRH Temp) = -8.0 0C

Turbine HR Correction Factor = 0.998 from Curve

Design Turbine HR = 2000 Kcal/kWh
Design Boiler  = 86.8 %
HR Deviation = 2000/(86.8/100)*(1-0.998)= 4.6 kcal/kWh
Superheat Attemperation

S/H attemperation to the boiler – Day average of 24 hrs is to be taken for calculation.

This average value of S/H attemperation to be compared with expected S/H

attemperation. (Expected S/H attemperation = Value corresponding to actual load is to

be derived using Load vs superheat attemperation curve). Load vs superheat

attemperation curve, if not available, may be developed from design data of Boiler. The

difference of average value of day and expected value of S/H attemperation is to be

taken for Heat rate deviation calculation based on customized correction curves.

Customized/OEM correction curves are to be used. Corrections for S/H spray is to be

applied in case tapping of S/H Spray is taken from the location before HP heater.
Sample calculation (Column wise w.r.t Daily HR Deviation Report)
Design S/H Attemperation = 0 t/hr
Expected S/H Attemperation = 16 t/hr
Actual S/H Attemperation = 46 t/hr
Variance (Exp. – Act. Attemp) = -30 t/hr = -5 % of Main Steam Flow
Turbine HR Correction Factor = 0.999 From Curve
Design Turbine HR = 2000 Kcal/kWh
Design Tested Boiler  = 86.8 %

HR Deviation = 2000/(86.8/100)*(1-0.999)= 2.3 kcal/kWh

Reheat Attemperation

R/H attemperation to the boiler – day average of 24 hrs is to be taken for calculation.

This average value of R/H attemperation to be compared with expected R/H

attemperation (Expected R/H attemperation = Value corresponding to actual load is

to be derived using Load vs reheat attemperation curve). Load vs reheat

attemperation curve, if not available, may be developed from design data of Boiler.

The difference of average value of day and expected value of R/H attemperation is to

be taken for Heat rate deviation calculation based on customized correction curves.

Customized/OEM correction curves are to be used.

Sample calculation (Column wise w.r.t Daily HR Deviation Report)

Design R/H Attemperation = 0 t/hr
Expected R/H Attemperation = 6 t/hr
Actual R/H Attemperation = 18 t/hr
Variance (Exp. – Act. Attemp) = -12 t/hr = -2 % of Main
Steam Flow
Turbine HR Correction Factor = 0.9968 (From Curve)
Design Turbine HR = 2000 Kcal/kWh
Design Boiler  = 86.8 %
HR Deviation = 2000/(86.8/100)*(1-0.997)= 7.4 kcal/kWh
Condenser Back Pressure

Condenser backpressure based on 24 hrs averages is to be taken for calculation.

This average value of Condenser backpressure is to be compared with expected

condenser backpressure (Expected condenser back pressure = Design condenser

back pressure corrected for 24 hrs average Load, CW inlet temperature). The

difference of Average value of Day and Expected value of condenser backpressure

is to be taken for Heat rate deviation calculation based on customized correction

curves. Customized/OEM correction curves are to be used.

Sample calculation (Column wise w.r.t Daily HR Deviation Report)
Design Condenser Back Pressure = 76 mm Hg
Expected Condenser Back Pressure = 51 mm Hg
Actual Condenser Back Pressure = 58 mm Hg
Variance (Exp. – Act. Cond. B.P.) = -7 mm Hg

Turbine HR Correction Factor = 0.995(From Curve)

Design Turbine HR = 2000 Kcal/kWh
Design Boiler  = 86.8 %
HR Deviation = 2000/(86.8/100)*(1-0.995)= 11.5 kcal/kWh
CW inlet temperature

CW inlet temperature based on 24 hrs average is to be taken for calculation. This average

value of CW inlet temperature is to be compared with expected CW inlet temperature.

(Expected CW inlet temp= Design CW inlet temperature). Condenser backpressure deviation is

to be calculated due to difference of average value of day and expected value of CW inlet

temperature. Heat rate deviation is to be calculated based on customized correction curves

prepared by station for CW inlet temperature vs Condenser backpressure. Customized/OEM

correction curves are to be used.

Sample calculation (Column wise w.r.t Daily HR Deviation Report)

Design CW Inlet Temperature = 30 0C

Expected CW Inlet Temperature = 30 0C

Actual CW Inlet Temperature = 25 0C

Variance (Exp. – Act. CW Temp) = -5 0C

Change In Back Pressure. = 16.5 mm Hg

Turbine HR Correction Factor = 0.99 (From Curve)
Design Turbine HR = 2000 Kcal/kWh
Design Boiler  = 86.8 %
HR Deviation = (2000/(86.8/100))*(1-0.99) = 23.0 kcal/kWh
DM Makeup Water

Total DM Make up to the boiler in a unit is to be taken for calculation of % D

makeup. This is to be taken from individual flow meter installed in the unit f

make up reading. This average DM make up to condenser to be compared w

0 % DM makeup as PG test is carried out with make up in isolated conditio

For comparing Heat rate loss due to DM make up, it can be divided into 50:

ratio as 50 % steam side leakage and 50 % water leakage of total % of D

makeup. DM make up after boiler light up is to be considered for calculation

case the unit has come after shutdown or tripping.

Heat Value of make up, H (Dev)= 0.5*(H1 - H2) + 0.5* (H3 - H2)
HR (Dev) = MU(Act) *H(Dev)*1000 / (GG)
Where
Daily DM Makeup = MU[Act] tones
MS enthalpy = H1 kcal/kg
Makeup water enthalpy = H2 kcal/kg
Feed water enthalpy = H3 kcal/kg
Gross generation = GG kWh
Heat Rate Deviation = HR (Dev) kcal/kWh
DM MAKE UP WATER

Sample Calculation (Column wise w.r.t Daily HR Deviation Report)

Design DM Make Up = 0 %
Expected DM Make Up = 0 %
Actual DM Make Up-MU (Act) = 100 tones
Variance (Exp. – Act. Makeup) = -100 tones

MS enthalpy H1 = 850
kcal/kg
Makeup water enthalpy H2 = 40
kcal/kg
Feed water enthalpy H3 = 250
kcal/kg
Gross generation GG = 4.032x1000000 kWh
H (Dev) = 0.5*(850-40)+0.5*(250-
40)

HR Deviation =
(100*510*1000)/4.032/1000000
= 12.6 kcal/kWh
Feed Water Temperature

Feed water temperature at top HPH outlet after joining of HPH bypass line, based on daily 24 hrs averages is to be taken

for calculation. This average value of actual Feed water temperature is to be compared with the

expected value of feed water temperature (Expected FW temperature = Feed water temperature

corrected for load, derived from curve between feed water temperature vs load). The difference of

Average value of Day and Expected value of Feed water temperature is to be taken for Heat rate

deviation calculation based on customized correction curves. Customized/OEM correction curves are to

be used.
Sample calculation (Column wise w.r.t Daily HR Deviation Report)
Design FW Temperature = 248 0C

Expected FW Temperature = 236 0C

Actual FW Temperature = 234 0C

Variance (Exp. – Act. FW Temp) = 2 0C

Turbine HR Corr. Factor at 236 0C = 0.996 From

Curve
Turbine HR Corr. Factor at 234 0C = 0.995 From
Curve
Design Turbine HR = 2000
Kcal/kWh
Design Boiler  = 86.8%

HR Deviation = (2000/(86.8/100))*(0.996-.995) = 2.3 kcal/kWhr

 Flue Gas Loss
Calculation of Dry flue gas loss for calculating HR deviations is based on following parameters
AH Exit Temperature

24 hrs Average data is used for computations. It’s important to ensure that the online measurements of
air and flue gas temperatures are representative of average temperatures in the duct. The on line
feedback of flue gas exit temperature after air heaters can be affected by gas stratification and may
require more number of thermocouples than presently installed.

In some layouts, the online thermocouples for flue gas temperature measurement are mounted too close
to air heaters in a cluster and need to be relocated for representative measurement. Similarly the location
and number of temperature sensors on airside at air heater inlet and outlet should be reviewed to obtain
a representative average. In some plants, on line thermocouples for secondary air outlet temperatures at
air heater outlet are mounted too close to the air heater and need to be relocated downstream the ducts
at an appropriate location for representative feedback.

In 500 MW units, the flue gas sampling and temperature measurement should be done in the common
flue gas duct of Primary and Secondary air heater outlet on each side. At present the flue gas temperature
is monitored only at outlet of each air heater and an average value based on assumed proportions of flue
gas flow through primary and secondary air heaters, is used for efficiency computation. A no of
thermocouples should be installed in each common outlet duct for representative on line feedback of
average flue gas temperatures.

24 hrs Average data is used for computations. It’s important to ensure that the online measurement of
flue gas oxygen of zirconia on both sides is representative of average value in the duct. The same can be
confirmed by doing a multi point grid survey. To improve the accuracy of the feedback, two no. zirconia
should be provided in each duct for flue gas oxygen measurement.
Average Air Inlet Temperature to AH

Daily last 24 hrs Average Value shall be used for computations. The reference value shall
be computed based on proportions of actual primary air and secondary air flows through
the air heaters.

Proximate analysis of coal

Last tested proximate analysis shall be used.

Air Heater Leakage

Average air heater leakage value from the last test shall be used. For 500 MW units a
weighted average value of air heater leakage shall be used in proportion to the air flows
through the air heaters.

Unburnt carbon

Unburnt carbon in fly ash and bottom ash value from the last test shall be used.
 Calculations
For arriving at expected value of Dry flue gas loss station is to draw curve of dry flue gas loss Vs load
based on predicted boiler performance given by manufacturer. Two steps are needed :-
Step-1 - Conversion from Proximate Analysis to Ultimate Analysis
Reporting of Proximate Analysis of as fired coal should be on ‘Total Moisture’ basis

- TOTAL MOISTURE = M % (2 stage air drying suggested)

- ASH = A %
- VOLATILE MATTER = VM %
- FIXED CARBON = FC %
-------------------
TOTAL - 100 %

FcDc(T) = Free Carbon On Dry Ash Free Basis = FC/[1-(1.1* A/100)–(M/100)]

VmDf(T) = Volatile Matter On Dry Ash Free Basis = [100 - FcDc(T)]
Cdf(T) = Fixed Carbon On Dry Ash Free Basis = [FcDc(T)+ 0.9*[VmDf(T) – 14 ]
Hdf(T) = Hydrogen On Dry Ash Free Basis = VmDf(T)* [(7.35/VmDf(T) + 10)-
0.013)
Ndf(T) = Nitrogen On Dry Ash Free Basis = [ 2.1 - ( 0.012 * VmDf(T)]
Ca % = Carbon Percentage (Ultimate Value) = Cdf(T) * [ VM+ FC(T)] /[ VmDf(T) +
FcDc(T) ]
H % = Hydrogen Percentage (Ultimate Value) = Hdf(T) * [VM(T)+ FC] / [VmDf(T) + FcDc(T) ]
N % = Nitrogen Percentage (Ultimate Value) = Ndf(T) * [VM(T)+ C(T)] / [ VmDf(T) + FcDc(T) ]
S % = Sulphur Percentage (Ultimate Value) = Assumed As Per Site Reference
Value.
0% = Oxygen % (Ultimate Value) = 100 – M - A – Ca – H – N – S
Step-2 - Reference Primary air Temperature:
Weighted Temp Air In = Tsai*Rsa + Tpai*Rpa
Where
Rsa - Ratio SA flow to Total Air flow = Fsa/Fta
Rpa - Ratio PA flow to Total Air flow = Fpa/Fta
Tpai = Primary air to AH inlet Temp
Tsai = Secondary air to AH in Temp

Step-3 - Calculation of CO2 at AH Outlet

Wet Oout = ((21* L) + 90*Oin)/(L + 90)
Dry Oout = Wet Oout / (1- %Flue Gas Moisture/100)
Where
Oin = % oxygen at AH Inlet from Zirconia Wet Oout
= % oxygen at AH Outlet on wet basis
L = % Average Air Heater Leakage
Dry Oout = % oxygen at AH Outlet on dry basisCO2 % at AH Outlet
CO2 = X – Dry Oout where X - % O2 + CO2 in Flue Gas (Orsat) for station coal

Step-4 - Calculation of Weight of Dry Flue gas loss

Unburnt C in ash (Cash) = Pfa/100*Cfa + Pba/100*Cba
Where
Pfa/Pba - % of ash in flyash and bottom ash respectively
Cfa/Cba - % Unburnt in flyash and bottom ash respectively
C in ash / kg of coal (U) = A/100*Cash/(100-Cash) kg
Where ‘A= ash %
Weight of Dry Flue gas
Weight of dry gas = (Ca+S/2.67-100*U)/(12*CO2out) kg/kg coal
Where
Ca = % Carbon in fuel
S = % Sulfur in fuel
U = Carbon in ash / kg of fuel
CO2 = % Carbon dioxide at AH outlet

Sensible Heat dry gas

(Sh) = Wd*30.6(Tgo-Trai) kJ/kg

Where
Cp = Specific heat of gas kg/kg/C
Tgo = Avg. Flue Gas Temp at AH Out

Dry Gas Loss = Sh*100/(Gcv*4.186) %

Where
Sh = Sensible Heat of dry gas
Gcv = Gross calorific Value of coal
 Sample calculation
Proximate Analysis Of Coal

Moisture (total) = 12.2 %

Ash = 40 %
Volatile Matter = 22.9 %
Fixed Carbon = 24.9 %
Gross Calorific Value (As fired) = 3320 %

Ultimate Analysis by preceding formulae

Carbon - 39.71 %; Sulphur – 0.6 %; Hydrogen – 2.58 %; Moisture 12.2 %; Nitrogen – 0.76
%; Oxygen - 4.14 %; Ash - 40 %; GCV – 3320 kcal/kg

Design Ultimate Analysis - Carbon - 37 %; Sulphur – 0.3 %; Hydrogen – 2.3 %; Moisture

12 %; Nitrogen – 0.8 %; Oxygen – 7.6 %; Ash - 40 %; GCV – 3300kcal/kg
Reference Air Temperature & Gas Temperature

Primary air to AH inlet Tpai = 40 0C

Secondary air to AH inlet Tsai = 34 0C
Weighted Temp Air In Tsai*Rsa + Tpai*Rpa = 36.1 C
Avg. F.G Temp At AH Outlet Tgo = 35 0C

Calculation of CO2 at AH Outlet

Leakage = 10 %
AH Inlet Oin (Wet) = 2.7 %
Moisture in Flue Gas = 10 %
Wet Oout = ((21* L) + 90*Oin)/(L + 90) = 4.5 %
Dry Oout = Wet Oout / (1- %Flue Gas Moisture/100) = 5.0%
CO2 % at AH outlet = 19.3 – 5 = 14.3 %

Carbon in ash
% of Fly Ash Pfa = 80 %
% of Bottom ash Pba = 20 %
% Unburnt in fly ash Cfa = 0.4 % (Last Test value)
% Unburnt in Bottom ash Cba = 1.2 % (Last Test value)
% of Ash in Coal A = 40 %
Unburnt C in ash Cash = Pfa/100*Cfa + Pba/100*Cba =
80/100*0.4+20/100*1.2= 0.56%
C in ash / kg of coal (U) = A/100*Cash/(100-Cash) =
0.002251 kg/kg of coal
Weight of dry gas (Wd)
= (Ca+S/2.67-100*U)/(12*CO2out)= 0.2314 kg/kg of coal

Sensible Heat Dry Gas (Sh)

= Wd*30.6*(Tgo-Trai)=700.09 KJ/kg

Dry Flue Gas Loss (DFG)

= Sh*100/(Gcv*4.186)%=5.038 %
Design Dry Gas Loss = 4.26 %
Expected Dry Gas Loss = 4.26 %
Actual Dry Gas Loss = 5.04 %
Variance (Exp. – Act. DFG) = 0.78 %
Design Turbine HR = 2000 Kcal/kWh
Design Boiler h = 86.8 %

Total HR Deviation = (2000/((86.8-0.78)/100))-2000/(86.8/100))

= 20.9 kcal/kWh

Dry Gas Losses Corrected for Ambient air

And Design Coal = 4.71 %

Impact of Coal on Dry Gas Loss = 5.04 - 4.71 = 0.33 %

HR Deviation = (2000/(86.8-0.33)/100)-
(2000/(86.8/100))
= 8.8 kcal/kWh
Calculation of Wet flue gas loss for calculating HR deviations shall be based on following
parameters
• AH Exit Temperature - Daily 24 hrs Average Value
• Air Inlet Temperature to AH- Daily 24 hrs Average Value
• Proximate analysis of coal from the last test
For arriving at expected value of Wet flue gas loss station is to draw curve of dry flue gas
loss Vs load based on predicted boiler performance given by manufacturer.

Sensible heat of water vapour (Sw) =1.88*(Tgo-25)+2442+4.2*(25-Trai) KJ/kg =2602

KJ/kg

Loss due to moisture in fuel =Sw*M/(Gcv*4.186)=2.284 %

Loss due to Hydrogen in Fuel =9*H*Sw/ (Gcv*4.186) = 4.35 %

Wet Flue Gas Loss = 2.28 + 4.35= 6.64 %

Design Wet Flue Gas loss = 4.82 %

Expected Wet flue gas Loss = 4.82 %
Actual Wet Flue gas Loss = 6.64 %
Variance (Exp. – Act. Wet flue gas loss) = 1.82 %
Design Turbine HR = 2000 Kcal/kWh
Design Boiler h = 86.8 %
HR Deviation = (2000/(86.8-1.82/100) – (2000/(86.8/100))
= 49.3 kcal/kWh
Combustibles In Fly Ash
Last tested value of Combustible in fly ash is to be taken for calculation. The last tested value of
Combustible in fly ash to be compared with PG Test / Best achieved value of Combustible in fly ash
which ever is lower. The difference is to be taken for Heat rate deviation calculations.

Change in Blr Efficiency with Unburnt =0.8* (UBE-UBA) * ASH * 80.77/GCV

UBE - Expected level of unburned carbon expressed as percent by weight of carbon in ash
UBA - Measured value of unburned carbon (%)
ASH - Ash content of coal from proximate analysis (%)
GCV - Gross Calorific value of the as-fired fuel (kcal/kg)

Sample Calculation
Ash % = 40 %
GCV = 3320 Kcal/kg
Expected Unburnt in Fly Ash = 0.5 %
Actual Unburnt in Fly Ash = 0.4 %
Variance (Expected - Actual Unburnt in FA) = -0.1 %
Design Turbine HR = 2000 kcal/kWh
Design Boiler h = 86.8 %
Change in Boiler Efficiency with change in FA Unburnt = -0.062 %

HR Deviation = (2000/((86.8-0.062)/100))-(2000/(86.8/100))
= - 1.6 kcal/kWh
Combustibles In Bottom Ash
Last tested value of Combustible in bottom ash is to be taken for calculation. The last tested
value of Combustible in bottom ash to be compared with PG Test / Best achieved value of
Combustible in bottom ash which ever is lower. The difference is to be taken for Heat rate
deviation calculation.

Change in Blr. Efficiency with change in Bottom ash Unburnt

= 0.2*(UBE-UBA)*ASH*80.77/GCV

UBE - Expected level of unburned carbon expressed as percent by weight of carbon in ash
UBA - Measured value of unburned carbon (%)

ASH - Ash content of coal from proximate analysis (%)

GCV - Gross Calorific value of the as-fired fuel (kcal/kg)

Sample Calculation
Expected Unburnt in Bottom Ash(BA) = 2%
Actual Unburnt in Bottom Ash = 2.5 %
Variance (Expected – Actual Unburnt ) = 0.50 %
Design Turbine HR = 2000 Kcal/kWh
Design Boiler h = 86.8 %
Change in Blr Efficiency with Unburnt = -0.077 %

HR Deviation = (2000/((86.8-0.077)/100))-(2000/(86.8/100))
= 2.1 kcal/kWh
Startup - Oil Consumption
Total oil consumption during startups (Light up to synchronization) and planned shut down is
to be considered for loading in to heat rate deviation.
Sample calculation (Column wise w.r.t Daily HR Deviation Report)
Total Oil Consumption = 10 KL
Day Generation = 4.0 Mus
HR Deviation = 10*10/4
= 25 kcal/kWh
TD BFP Efficiency
Last tested value of TDBFP is to be taken for calculation. Comparison to be done with design
value TDBFP efficiency. The difference between total enthalpy requirement during the test
and Design total enthalpy requirement is to be taken for Heat rate deviation calculation.
Sample calculation (Column wise w.r.t Daily HR Deviation Report)
Design Inlet Steam Enthalpy = 725.3 kcal/kg
Design Exhaust steam Enthalpy = 578.7 kcal/kg
Design Enthalpy drop = 146.6 kcal/kg
Test Inlet Steam Enthalpy = 733.5 kcal/kg
Design Exhaust steam Enthalpy = 578.7 kcal/kg
Enthalpy drop = 155.2 kcal/kg

Addition Heat required by BFP = 8.6 kcal/kg

Additional Heat input = steam flow of TDBFP * 8.6

HR Deviation = 70*1000*8.6/500/1000 = 1.2

kcal/kWh
 Typical Impact of Parameter variation
Parameter variation
200 MW 500 MW

MS Temp by 1 Deg C 0.5 0.5

HRH Temp by 1 Deg C 0.6 0.6

CW inlet temperature by 1 Deg C 6-8 5

Condenser vacuum by 1mmHG 3-4 3-4

Flue gas exit temp by 1 Deg C 1.2 1.2

Eco outlet oxygen by 1% 7-8 7-8

10 T RH Spray 2.5 2.5

FW temp by 1 Deg C 0.9 0.9

1% HPT Eff. 3.5-4 4-4.5

1% IPT Eff. 3.5-4 4-4.5

1% LPT Eff. 9 9

1% Boiler Eff. 25 25
Heat Balance Diagram – VWO Condition (0% MU)

170 811 529.5 MW

1586 537
Impact on MW (For a typical BHEL 500 MW unit)

Parameters Change Impact on MW

MS pressure 1 KSC 2.97
MS temp 10 C 1.1
HRH temp 10 C 5
HPT Eff 1% 1.44
IPT Eff 1% 1.11
LPT Eff 1% 2.26
TDBFP Extn flow 10 Tons 1.05
MS flow 10Tons 3.2
SH Spray 10Tons 0.4
RH Spray 10Tons 1
Cond back pressure 10 mmHg 3.3
Boiler Efficiency 1% 5 1
6
 TESTING FREQUENCY
S.N TEST ON LINE TEST OFF LINE TEST Remarks
FREQUENCY FREQUENCY

1 HP/IP cylinder Efficiency 6 monthly Once in a Year & Pre & Additional Test As per
Post Capital OH requirement
2 Condenser Test Monthly Once in a Year Additional Test As per
requirement
3 HP Heater Performance Monthly Once in a Year Additional Test As per
Test requirement
4 LP Heater Performance Once in a Year - Additional Test As per
Test requirement
4 BFP Performance Test Once in Year Additional Test As per
MDBFP & TDBFP requirement
5 Turbine Pressure Survey - Once in a Year with HP/IP Additional Test As per
efficiency Test requirement
And Pre & Post Capital
O/H
6 Turbine Cycle Heat rate Monthly Once in a Year Additional Test As per
Test requirement
7 Primary Air Flow - - Test As per requirement
Calibration
8 Dirty Air Flow Test - Pre & Post O/H Additional Test As per
requirement
9 APH Performance Test Quarterly Additional Test As per
requirement
10 FG Path Oxygen Mapping - Six Monthly Additional Test As per
And requirement
Pre & Post O/H
11 Boiler Efficiency Test Monthly Pre & Post O/H Additional Test As per
requirement
12 Cooling tower Test Once in a Year Preferably in the period July-Sept Additional Test As per
or Depending Upon Design & actual WBT requirement
Temperature
 To Control
Room

Vibration

flow

Motor Lube Oil

Current

Thermography Performance
Monitoring

One technology is not adequate for diagnostics e.g. DGA for

transformers & vibration for rotating machines Use Of Multiple
Technologies and integration of data is essential
 PdM (Condition Monitoring) Technology presently used

• Visual observations/Operator rounds.

• Thermography : Hot spots, Cold spots (Air ingress
detection)
• Acoustic : partial discharge in transformers ( non
contact), mechanical equipment ( contact method)
• Lube Oil Monitoring.
• Electrical tests (Motor Current Signature analysis)
Broken Rotor Bars
• DGA : oil transformers
• Wear debris analysis ( WDA) : Full spectrum
analysis, particle contents. Viscosity etc, dusty
areas
• Vibration Monitor.
USE OF MULTIPLE TECHNOLOGY ON EACH EQUIPMEMT OR USE OF EACH TECHNOLOGY FOR
MULTIPLE EQUIPMENT ( where ever applicable)
 New techniques

•Laser alignment : For Single & multi-shaft rotating machines exp:

BFP,CEP,Turbine shafts etc.

•Borescope : For internal inspection without Dismantling/opening

machine( like Endoscopy),also called Videoscope.
exp: Boiler pipe header, Motor Internals,Generator
inspection, Turbine internals etc.

•Grease Gun: Based on acoustic. Grease is filled according to ultrasonic

noise generated.
 Thermography (IRT)

• Based on receipt of
infra red rays ( energy).
Different than normal visible range.

• Input infra red energy is Proportional to fourth power of

temperature.

•Rise in temperature is detected as Hot spots.

As per technical journal/ papers temp>5 degree c than
surrounding is termed as “ Hot Spot”.

•Fall in temperature is detected as cold spots

( air ingress in vacuum system)
Areas Where the use of Infrared thermography can Improve
Performance
Mechanical
Electrical
• All types of Valves
• Steam traps •Switchyard/Switchgears
• Bearings •Transformers- Body, OLTC,
• Gear Boxes Bushings, Coolers etc,

• Steam, Air and •Oil level Monitoring

Vacuum Leaks •Batteries
• Air Leaks in •Line Bus-Ducts
Boiler/Turbine ( cold
spot) •Excitation System

• Thermal Insulation •Motor- Bearing, Body,

Coolers
• Coal Yard
 Example: Hot spot

( Mill expansion joints)

Normal temperature of surface is between 57-62 degree c.

Area shown by red arrow is hotter ( 125- 145 degree)
Confirming hot air leakage from this point.

Other applications: Valve passing, C&I cards heating, loose

cable connection, Junction box & lugs tightness. Latest
application: Snick detection during cricket live telecast ( B/W
live image) etc.
 Example: Cold spot

( Mill expansion joints)

Normal Bolt temperature is appx. 45 degree c. Bolts shown

by arrow is cooler by appx. 4-5 degree c ( 40- 41 degree c). Air
ingress was confirmed from these bolts. point.

Application area: LP Turbine & Condenser area , APH,ESP inlet

ducts, O2 probe , Boiler manhole etc.
 Heat rate Improvement
Activities
HP/IP/LP Efficiency
Typical reductions in efficiency as shown in Table
Typical Efficiency Losses HP Efficiency Losses IP Efficiency Losses LP Efficiency Losses

Solid Particle Erosion 0 - 2% 0 - 2% 0 - 0.5%

Blade Deposits 0 - 10% 0 - 5% 0 - 3%

Mechanical Damage 0 - 3% 0 - 2% 0 - 1%

Worn Seals 2 - 12% 1 - 4% 0 - 1%

For a given turbine design, condition of Blade/Vane surface, profile and various type of seals determines
the operating efficiency level of the cylinders. But the non-availability of spare Diaphragms and modules
causes a constraint on the efficiency recovery due to Tip seals wear (Diaphragm type) and seal fin wear,
replacement of which is difficult at site and sending to Works involves the tremendous loss on account of
higher downtime. Wherever possible, concept of modular replacement during planned overhaul is useful.
Steam Path Audits
A very valuable tool to the performance engineer is a steam path audit of the turbine’s steam path. These
audits are performed when the turbine is first opened, before any other work is done. It involves
measuring seal clearances, surface roughness, amount of erosion, mechanical damage, etc. This
information is then fed into a computer program that estimates the heat rate and load penalty of each
non-design seal clearance as well as any other defects. From this information, it is possible to minimize the
cost of the turbine overhaul by only performing the work that is economical.
 Heat rate Improvement
Activities
Infrared Thermography and Ultrasonic Acoustics
Infrared thermography and Ultrasonic acoustics can efficiently identify leaks in many areas.
Both provide accurate detection of fluid leaks that commonly occur at a power plant. When
combined, the effectiveness of these leak detection methods increases dramatically.
Confirming a suspected leak detected with one technology by repeating the detection with a
separate technology is always a best practice.
Infrared Thermography (IR) and Ultrasonic Acoustics can be used to detect leaks on the
following equipment/systems :
Leaking Process Valves
Identifying leaking valves is probably the most effective use of thermography to reduce heat
rate losses and operational problems. Temperature is key to identifying leaking valves. A small
temperature rise can indicate a leak through. Valves and lines going to the condenser, boiler
blow down, miscellaneous drain tank, reclaim tank, drip receiver, and priming for pumps under
vacuum should be checked. All boiler, turbine, stop valve, valve chest, etc., drain lines need to
be checked for leak through. It is to be ensured that valve is totally closed before inspecting.
Steam Traps
IR can identify leaking bypass lines and improper operation. Comparison between like
equipment that is operating the same often confirms problems. Use Ultrasonic Acoustics to
confirm problems.
THANK YOU