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IN
BY
H.S.Bedi
Sr. Vice President (Power)
Energo Engineering Projects Ltd.
A-57/4, Okhla Industrial Area,
Phase – II, New Delhi - 110020
“You cannot Manage what you
cannot Measure”
(Accurately)
IN
Contd
…
1.0 USEFULNESS OF ENERGY AUDIT IN
THERMAL POWER STATION
• Provides guidance in Loading Sequences of
the Units.
• Identification and Rectification of errors in on-
line Instruments.
• Leads to reduction in Green House Gases.
• Utilizes specialized services of experienced
Engineers.
• Training of O&M staff for Efficient Control of
Unit Operation.
Contd
…
1.0 USEFULNESS OF ENERGY AUDIT IN
THERMAL POWER STATION
Contd….
IMPORTANCE OF ACCURACY IN ENERGY
AUDITS
NOTE:
TG CYCLE HEAT RATE IS TAKEN AS 2000 KCAL /
KWh
COAL CV IS TAKEN AS 4000 KCAL / Kg
PRICE OF COAL TAKEN AS Rs. 2000 / TON
LOSS INCREASES WITH MACHINE SIZE
Impact of Turbine Efficiency on
HR/Output
HPT 28%
IPT 23%
LPT 49%
HP/IP Turbine Efficiency
Instrument Inaccuracy / lack of corrections
10 MM HG IMPROVEMENT IN
CONDENSER VACUUM
LEADS TO 20 Kcal/kwh (1%)
IMPROVEMENT IN HEAT RATE FOR A
210 MW UNIT
EFFECT ON HEAT RATE FOR PARAMETER
DEVIATION (500MW UNIT)
CALIBRATION LAB
• Govt. Accredited i.e. NABL Labs
TEST SCHEME
• To be Furnished And Approved Sample enclosed
HEAT LOSS METHOD
BOILER EFFICIENCY = 100 - % AGE LOSSES
1. Heat Loss in Dry flue gas
a. Hg = 0.24 wg (Tg – Ta) as percentage of heat input
G.C.V
a. Hg = K (Tg – Ta) /1.8 K=0.32 for fuel oil
% CO2 in flue gas K=0.35 for Bituminous coal
2. Heat loss due to evaporation of moisture & H2 in fuel
Hm = Wm+9H (100 – Tf) + 540 – 4.6 (Tg -100) %of heat input
G.C.V
3. Heat loss due to moisture in air
Ha = 0.26 Wma (Tg – Ta) % of heat input
G.C.V
4. Heat loss due to Incomplete combustion to Co
Hco = 2414 C x CO x 1 as % of heat input
CO+CO2 G.C.V
5. Heat loss due to unburnt carbon “C”
Hc = Wc x 7831 as % of heat input
G.C.V
6. Heat loss due to Blow Down
Hbd = Wb (hbw – hw) as % of heat input
G.C.V
7. Heat loss due to Radiation
In above
Wg =Wt of dry flue gas
W..G = [44.01 *CO2 + 32*O2 28.02 * N2 + 28.01*CO]*[Cb + 12.01 * S/32.07]
12.01 * (CO2 + CO)
Tg = Tempt. Of flue gas at exit of Boiler
Ta = Tempt. Of air at inlet (ambient)
Tf = Tempt. Of fuel inlet
hbw-hw = Heat in blow down
Wm = Weight of moisture
Wma = Wt of waterin Kg/Kg of air X Wt of air in Kg supplied / Kg of fuel
Wc = Weight of unburnt “C”
Wb = Wt of water blow down
Economizer
HVS
APH
Sampling
Locations
APH
FG
Annexure - I
BOILER EFFICIENCY AND APH TEST SCHEME &
INSTRUMENTATION DIAGRAM
1.Grid measurement for gas composition and gas temp. at air pre heater
inlet / outlet.
W/6 W/3 W/3 W/6
T1 T2 T3
D/6
N11 N21 N31
D/3 DEPTH
N12 N22 N32
D/3
N13 N23 N33
D/6
D = Duct Depth (Internal)
W = Duct Width (Internal)
Tx = Traverse (x) (Pockets)
x =1 to 5 (Width wise)
Nxy = Nodexy
(Sketch for one half of flue gas duct cross - section)
Grid measurement for gas sampling and temperature measurement at 3 to 5 locations on
APH inlet & at 3 to 5 locations on APH outlet ducting as close to APH as possible shall be
taken provided test pockets are available for inserting sampling probes. Flue gas sampling
and temperature measuring probe shall be inserted at each location and traversed to collect
data at these points in each location. This shall eliminate effect of gas stratification.
Air temperature at inlet and outlet of APH shall be measured at two points each in case
spare pockets are available.
Ambient temperature, barometric pressure & RH is measured near F.D. fans.
Note1 : WBPDCL to provide the test pockets in each of the Air and Gas path for
inserting test instrument.
Measured flow Q M3 / HR
Suction pressure Ps kg / m2
Discharge Pressure PD kg / cm2
Test speed Nrpm
Liquid temp. T°C
Specific weight of liquid W kg / M3
Total dynamic head at test speed N
H = (PD – PS) X 10 / W MLC
CONCLUSION
Pressure - 5 Minutes
Temperature - 5 Minutes
Flow - 1 Minute
Power - 1 Minute
Levels - 10 Minutes
Temperature - 15 to 30 Minutes
Flue Gas Composition - ½ to one hour
Thermodynamically
F Balance Of Plant
(i) Compressed air system:
•Free Air Delivery i.e. Capacity evaluation of the Plant and Instrument
air compressors.
•Checking volumetric efficiency of compressors.
•Assessment of compressed air leakage quantity.
•Assessment of Energy performance of the air compressors/ specific
power consumption.
•Study of the compressed air network and suggest suitable energy
saving options.
(ii) Air conditioning system:
•Performance evaluation of AC Plant w.r.t net cooling / refrigeration
capacity along with heat load of Air handling unit and energy
requirements at the operating conditions vis-à-vis design condition to be
determined.
(iii) Ash Plant
•Performance of ash Slurry pumps through power measurement and flow
measurement.
•Ash water ratio assessment and recommendations for optimization in
water and power consumption.
(iv) Cooling Tower Performance
•It shall include establishment of
•Liquid/Gas ratio
•Fan efficiency as the ratio of shaft power developed and the work done
by the fan
•Cooling Tower Effectiveness, approach and range.
•Cooling capacity.
V Coal Handling Plant
Input Power measurement of all the key equipment of the CHP area
like: Paddle feeders, Conveyors, Stacker & Re-claimer, Wagon
Tipplers, Crushers,
Establishment of specific energy performance indicators.
Contd….
METHODS / OBSERVATION FOR SAVINGS ENERGY IN
POWER PLANT