NCPS -DADRI

Presented by J. N. Dubey Sr Supdt ( EEMG)

HEATRATE IMPROVEMENT THE PRESENTATION COVERS

DEFINITION AND TYPES OF HEAT RATE IMPORTANCE OF HEAT RATE IMPROVEMENT CALCULATION OF HEAT RATE CYCLE EFFICIENCY AND HEAT RATE DIFFERENT TYPES OF HEAT LOSSES PARAMETERS AFFECTING HEAT RATE PERFORMANCE OF EQUIPMENTS
CONDENSER PERFORMANCE HP/LP HEATERS PERFORMANCE TURBINE PERFORMANCE COOLING TOWER PERFORMANCE BOILER PERFORMANCE RAPH PERFORMANCE

HEATRATE IMPROVEMENT

HEAT REQUIRED IN KCAL FOR UNIT ( KWH) GENERATION OF ELECTRICITY UNIT OF HEAT RATE KCAL / KWH DESIGN UNIT HEAT RATE : 2274 KCAL/KWH ACTUAL UNIT HEAT RATE : 2400 KCAL/KWH DEVIATION : 126 KCAL/KWH

HEATRATE IMPROVEMENT GROSS UNIT HEAT RATE

The ratio heat input to the boiler including all forms of chemical energy supplied and the gross electrical generation. For most functions (daily/monthly/annual reporting, comparison/ benchmarking of units) unit or plant heat rate is used.

HEATRATE IMPROVEMENT NET UNIT HEAT RATE

A unit heat rate includes all heat input to the boiler. The heat input to the boiler include all forms of chemical energy supplied and the net electrical generation i.e., auxiliary power is to be subtracted from gross electrical energy.

HEATRATE IMPROVEMENT Gross Turbine Cycle Heat Rate (GTCHR)

A Gross Turbine Cycle heat rate includes only heat input to the turbine cycle. GTCHR is the ratio of total heat input to the turbine cycle and the gross generator output.

Turbine Cycle : Starting from ESV to final HP heater outlet It includes HPT , IPT , LPT, condenser, GSC , drain cooler LPH 1, 2, 3 , deaerator,HP heater 5 and HP heater 6

HEATRATE IMPROVEMENT
Boiler
S.H

HPT

IPT

LPT

Ge n

R.H
E C O

Condenser HPH-6
D/ A LPH-3 LPH-2 HPH--5

BF P LPH-1

CE P

DC

GSC

BLOCK DIAGRAM OF THERMAL POWER PLANT CYCLE

HEATRATE IMPROVEMENT
EFFECT OF DEVIATION OF HEAT RATE BY ONE KCAL/ KWH Description Unit value COAL CV KCAL / Kg 3900 COAL COST ( Avg yearly) Rs / Ton 2330 COAL COST Rs / Kg 2.33 Cost of 1 K Cal Rs/ kcal 0.000597436 Generation Capacity of One Unit / day MU 5.04 ( 210x24/1000) PLF % 95 Generation / day considering 95 % PLF MU 4.788 Generation / year considering 95 % PLF MU 1747.62 Generation Capacity of One Unit / year kwh 1747620000

Cost Of Deviation in Heat Rate by 1 kcal / kwh for yearly generation of Lacs one unit

10.44

IMPACT OF PARAMETERS ON HEAT RATE

S No. Parameter Unit Deviation H R Dev ( Kcal/kwh)

1
2 3 4 5 6 7 8 9

HPT efficiency
IPT efficiency LPT efficiency

%
% %

+ 1%
+ 1% + 1%

- 4.5
- 4.5 -11.4

Condenser Back Pressure

M S Pr before ESV M.S.Temp HRH Temp RH Spray DM Make-Up

mm Hg
Kg/cm 2 Deg. C Deg. C T/Hr % MCR

+1mmHgC
+1.0 Kg/cm2 +1.0 Deg C +1.0 Deg C +1 T/H + 1%

+2.0
-1.8 -1.6 -0.68 +0.53 + 20

10

Boiler efficiency
HP Heater -TTD HP Heater - DCA

%
Deg. C Deg. C

+1%
+1.0 Deg C +1.0 Deg C

-26
+1.8 +0.25

11
12

Excess Oxygen
Flue Gas Temp.

%
Deg. C

+ 1%
+1.0 Deg C

+6.6
+1.3

COMPUTATION OF HEAT RATE

DIRECT METHOD
( COAL BASED)

RATIO OF HEAT INPUT TO GROSS GENERATION

COAL CONSUMPTION X COAL GCV HEAT RATE = ---------------------------------------------------------GROSS GENERATION EASY CALCULATION FEW PARAMETERS ANALYSIS OF DEVIATION OF HEAT RATE NOT POSSIBLE UNCERTAINTY IS VERY HIGH

COMPUTATION OF HEAT RATE

LOSS METHOD
( PARAMETERS BASED)

RATIO OF TURBINE CYCLE HEAT RATE TO BOILER EFFICIENCY

TURBINE CYCLE HEAT RATE *100 HEAT RATE = ---------------------------------------------------------BOILER EFFICIENCY

DETAILED ANALYSIS OF DEVIATION OF HEAT RATE POSSIBLE MEASUREMENT OF MANY PARAMETERS IS REQUIRED LONG CALCULATION

COMPUTATION OF HEAT RATE

GROSS TURBINE CYCLE HEAT RATE
TURBINE CYCLE HEAT RATE (KCAL/KWH) =

Qms (Hms - Hfwo) + Qhrh (Hhrh-Hcrh)+Qrh (Hhrh - Hrhs ) ----------------------------------------------------------------------GROSS LOAD

COMPUTATION OF HEAT RATE

HEAT RATE & EFFICIENCY OUT PUT EFFICIENCY = -----------------IN PUT

860 X 100 EFFICIENCY (%) = ------------------HEAT RATE

COMPUTATION OF HEAT RATE

EXAMPLE OF HEAT RATE & EFFICIENCY
DESIGN GROSS TURBINE CYCLE HR = 1985 KCAL / KWH
860 X 100 DESIGN EFFICIENCY OF TURBINE CYCLE =------------ = 43.3 % 1985 ACTUAL GROSS TURBINE CYCLE HR = 2050 KCAL / KWH 860 X 100 ACTUAL EFFICIENCY OF TURBINE CYCLE =------------ = 41.95 % 2050

COMPUTATION OF HEAT RATE

EXAMPLE OF HEAT RATE & EFFICIENCY
DESIGN UNIT HEAT RATE = 2274 KCAL / KWH
860 X 100 DESIGN EFFICIENCY OF UNIT =------------ = 37.8 % 2274 ACTUAL UNIT HEAT RATE = 2400 KCAL / KWH 860 X 100 ACTUAL EFFICIENCY OF UNIT = ------------ = 35.8 % 2400 MAXIMUM LOSS IN CONDENSER APPROXIMATE 58 %

HEAT LOSS
HEAT LOSS DUE TO OPERATING PARAMETERS HEAT LOSS DUE TO EQUIPMENT PERFORMANCE
DRAIN VALVE PASSING /RADIATION LOSS CONTROLABLE HEAT LOSS ACCOUNTABLE UN-CONTROLABLE HEAT LOSS UN ACCOUNTABLE

HEAT LOSS DUE TO OPERATING PARAMETERS

1. LOAD (PARTIAL LOADING) ACCOUNTABLE / CONTROLABLE 2. MS PR. BEFORE ESV ACCOUNTABLE / CONTROLABLE 3. MS TEMP. BEFORE ESV ACCOUNTABLE / CONTROLABLE 4. HRH TEMP. BEFORE IV ACCOUNTABLE / CONTROLABLE 5. RE HEATER SPRAY ACCOUNTABLE / CONTROLABLE 6. COND VACUUM ACCOUNTABLE / CONTROLABLE 7. CW INLET TEMP ACCOUNTABLE / UN-CONTROLABLE 8. CW FLOW ACCOUNTABLE / CONTROLABLE 9. DM MAKE UP ACCOUNTABLE / CONTROLABLE 10. FW TEMP. AT HPH 6 O/L ACCOUNTABLE / CONTROLABLE 11. APH EXIT FLUE GAS TEMP ACCOUNTABLE / CONTROLABLE 12. EXCESS O2 ACCOUNTABLE / CONTROLABLE

HEAT RATE IMPROVEMENT PLAN

PERFORMANCE TESTING TRENDING
TRENDING OF KEY PARAMETERS AND EFFICIENCY TEST RESULTS FOR MONITORING OF RATE OF DETORIATION

MONITORING
BOILER EFFICIENCY TEST TURBINE CYCLE HEAT RATE CONDENSER PERFORMANCE HEATER PERFORMANCE TURBINE EFFICIENCY HELIUM LEAK DETECTION TEST PRESSURE SURVEY OXYGEN SURVEY RAPH PERFORMANCE MILL CLEAN AIR FLOW TEST MILL DIRTY AIR FLOW TEST HOT PA TRAVERSE TEST HIGH VELOCITY THERMOCOUPLE TEST COOLING TOWER PERFORMANCE TEST

REAL TIME HEAT RATE DEVIATION DAILY HEAT RATE DEVIATION REMEDIAL ACTION

ANALYSIS OF TEST RESULT AND REMEDIAL ACTION

DADRI THERMAL PLANT-ON LINE HEAT RATE DEVIATION

DAILY HEAT RATE DEVIATION REPORT

DA E: T 28-May-07
UNIT-1 S No. Parameter (A) Accountable Heat Rate Dev 1 2 3 4 5 Load ( Partial loading) M S Pr before ESV M.S.Temp before ESV HRH Temp before IV Reheater Attemperation Condenser Back Pr (loss due to CW flow , load ,dirty tube and air ingress) C W Inlet Temp. DM Make-Up FW Temp at HPH O/L Dry Flue gas loss (DFG) Effect of coal quality on DFG (a) Oxygen at eco outlet
(b) APH exit flue gas Tem p.(Corr)

UNIT-2 Param eter Value 214.6 150.6 539.4 537.2 4.3 55.1 27.8 0.00 242.0 5.1 0.0 2.35 135.8 18.8 14.5

UNIT-3 Param eter Value 216.3 150.6 538.1 536.6 8.70 60.8 28.1 0.00 244.1 5.81 0.0 2.57 144.9 18.6 19.3

UNIT-4 Parame ter Value 214.6 150.8 538.3 535.4 7.0 67.9 27.8 0.00 242.3 5.73 0.0 2.86 142.9 18.2 16.3

Unit Kcal/kW h Design MW Kg/cm 2 Deg. C Deg. C T/Hr 210.0 150.0 537.0 537.0 0.0 76.0 mm Hg Deg. C % MCR Deg. C % % % Deg. C % % % % Coal % % KL % % Kcal/kW h Kcal/kW h 85.45 90.38 3.54 136.0 10.0 10.0 5.83 12.0 2.26
1.2 Ref .0.8

Param eter Value 211.9 150.9 538.1 538.6 5.8 60.1 27.8 0.000 243.2 4.89 0.0 2.62 127.3 19.4 16.8 5.75 10.18 2.76 0.72 0.0 83.10 88.18

Heat Rate Dev. -2.5 -1.57 -1.78 -1.11 3.19 -2.04 -29.76 3.61 3.1 3.06

Heat Rate Dev. -6.0 -1.01 -3.77 -0.10 2.24 -11.72 -30.08 13.15 4.5 9.04

Heat Rate Dev. -8.18 -1.02 -1.79 0.31 4.48 -2.25 -28.15 3.24 3.3 28.09

Heat Rate Dev. -6.0 -1.38 -2.09 1.14 3.73 13.56 -29.76 5.73 4.3 25.39

6 7 8 9 10

32.0 0.0 247.0 4.77

(c) APH -A Leakage APH -B Leakage 11 W et Flue Gas Loss (a) Moisture in coal (b) % of Hydrogen in 12 13 14 15 Unburnt Carbon loss Startup oil Consumption HPT efficiency IPT efficiency Total (A) (B) Unaccountable H R Deviation

-2.03

5.78 10.18 2.76

-1.21

5.82 10.18 2.76

-0.24

5.82 10.18 2.76

-0.31

-2.24 0.00 10.87 9.99 -9.13 30.1 21.0 2274.0 2295.0

0.76 0.0 84.23 88.01

-1.01 0.00 5.59 10.67 -9.7 22.2 12.5 2274.0 2286.5

0.79 0.0 83.03 88.00

-0.16 0.0 11.27 10.90 19.8 29.1 48.8 2274.0 2322.8

0.69 0.0 84.22 88.32

-2.82 0.00 5.65 9.28 26.4 12.9 39.3 2274.0 2313.3

Total Heat Rate Dev iation ( A+B) Kcal/kW h (C) Design Heat Rate at Full Load Kcal/kW h

(D) Derived Unit Heat Rate (A+B+C) Kcal/kW h

Accountable Heat Rate Deviation

S No. Parameter

1 Load ( Partial loading) 2 M S Pr before ESV 3 M.S.Temp before ESV 4 HRH Temp before IV 5 Reheater Attemperation due to Condenser Back Pr (loss CW flow , load ,dirty tube and air 6 ingress) 7 C W Inlet Temp. 8 DM Make-Up 9 FW Temp at HPH O/L 10 Dry Flue gas loss (DFG) 11 Wet Flue Gas Loss 12 Unburnt Carbon loss 13 Startup oil Consumption 14 HPT efficiency 15 IPT efficiency Total (A)

Unit MW Kg/cm 2 Deg. C Deg. C T/Hr mm Hg Deg. C % MCR Deg. C % % % KL % % Kcal/kWh

DESIGN

Parameter Value

Heat Rate Dev.

210.0 150.0 537.0 537.0 0.0 76.0 32.0 0.0 247.0 4.77 5.83 1.2 85.45 90.38

211.9 150.9 538.1 538.6 5.8 60.1 27.8 0.000 243.2 4.89 5.75 0.72 0.0 83.10 88.18

-2.5 -1.57 -1.78 -1.11 3.19 -2.04 -29.76 3.61 3.1 3.06 -2.03 -2.24 0.00 10.87 9.99 -9.13

Calculation of Unaccountable Heat Rate 1: Calculation of Unit Heat Rate by monthly Turbine Cycle Heat Rate Test and Boiler Efficiency Test Turbine Cycle Heat Rate 2: Unit Heat Rate =--------------------------------- x100 Boiler Efficiency 3: Total HR Deviation = Test Unit HR- Design Unit HR
4: Total HR Deviation = Accountable HR+ Unaccountable HR 5: Unaccountable HR= Total HR Deviation -- Accountable HR

Accountable HR is calculated taking parameters at the time of te

HEAT LOSS DUE TO EQUIPMENT PERFORMANCE

CONDENSER PERFORMANCE

CONDENSER PERFORMANCE
FACTOR AFFECTING CONDENSER BACK PR
1 ) C W inlet temperature 2 ) C W Flow 3 ) Condenser Heat Load 4 ) Air ingress 5 ) Scale inside Tube 6 ) Condenser Tube Choking

COND. BACK PRESSURE ( MM HGC)

100 80 60 40 20 0

EFFECT OF CW TEMP ON BACK PRESSURE

65.6 72.4 79.8 87.9

43.7 48.4 35.6 39.9 32

53.5

59.3

15

17

19

21

23

25

27

29

31

33

35

CW INLET TEMP ( DEG C)

EFFECT OF CW FLOW ON BACK PRESSURE

100
COND. BACK PRESSURE ( MM HGC)

95 90.64 90 85 80 75 70 17000 18000 19000 20000 21000 22000 23000 24000 CW FLOW M3/HR 87.15 84.09 81.45 79.09 76.98 75.04 73.37

81
CONDENSER BACK PR ( MM HGC )

EFFECT OF CONDENSER HEAT LOAD

79.8 78.2

80 79 78 77 76 75 74 73 23
73.8

76

23.5 24 24.5 25 25.5 26 CONDENSER HEAT LOAD ( K CAL/HR)

26.5

CONDENSER PERFORMANCE
EVALUATION OF CONDENSER PERFORMANCE
1: Deviation in condenser back pressure

2: TTD = Terminal Temperature Difference = Tsat- CW outlet Temp where Tsat = Saturation Temp corresponding to back pressure 3: Under cooling = Tsat- Condensate temp in Hot well 4: Air Depression = Tsat T air steam mixure
5: DISSOLVED O2 IN CONDENSATE IN HOT WELL 6 : DIFFERENTIAL PRESSURE OF CW IN/OUTLET

CONDENSER PERFORMANCE Deviation in condenser back pressure

Dev. of test condenser back pressure From expected back pressure

Dev. of corr condenser back pressure From Design back pressure

Primary Method

LMTD Method

LMTD Method

CALCULATION OF EXPECTED SATURATION TEMP AND EXPECTED BACK PRESSURE AT VARIATION OF DIFFERENT OPERATING PARAMETERS
The following equations are used Expected Tsat = CW inlet temp + CW temp rise + TTD ( General Equation) Expected back pressure = Pressure corresponding to Expected saturation temp

1) Expected Tsat (d) = CW inlet temp (d) + CW temp rise (d) + TTD (d)
32 (deg C)+ 10.8 (deg C)+ 3.2 (deg C) = 46 ( deg C)

Expected back pressure (d) = Pressure corresponding to Expected saturation temp (d) = 76 mm HgC = Pd

2) Effect of CW inlet alone Expected Tsat = CW inlet temp (a) + CW temp rise (d) + TTD (d) Expected back pressure = Pressure corresponding to Expected saturation temp = Pcwi Variation due to CW inlet temp = Pd Pcwi Example: C W inlet temperature ( Avg) = 17.7 Deg C Design C W inlet temperature = 32.0 Deg C Expected Tsat = 17.7+10.8+3.2 = 31.7 Deg C Expected back pressure = 35.12 mmHgc Gain due to CW inlet temp = 76-35.12 = 40.88 mm Hgc

3) Effect of CW inlet , CW flow and load

Expected Tsat = CW inlet temp (a) + CW temp rise (a) + TTD (d) = CW outlet temp (a) + TTD (d) Expected back pressure = Pressure corresponding to Expected saturation temp = Pcwif Variation due to CW flow and load = Pcwif Pcwi Example: CW Inlet temp = 17.7 , CW outlet temp =32 Expected Tsat = 32+3.28 = 35.28 Deg C Expected back pressure = 42.83 Deviation due to CW flow and Load= 42.83-35.12 =7.71 mm HGC

Back pr variation due to air and dirty tube ( Bad performance of condenser

Actual condenser back pr = 40.90 mm HgC Expected Back pressure = 42.83 mm HgC = Condenser Back Pressure (a)- Pcwif =40.90-42.83 = -1.93

CALCULATION OF EXPECTED BACK PRESSURE BY LOG MEAN TEMP DIFFERENCE ( LMTD ) METHOD

CONDENSER PERFORMANCE
CALCULATION OF EXPECTED SATURATION TEMP AND EXPECTED BACK PRESSURE BY CHANGE IN LMTD METHOD. DETERMINATION OF CONDENSER DUTY Condenser Duty = (Heat Added MS + Heat Added CRH + Heat added by BFP + Heat added by RH Attemperation) - 860 (Pgen + Pgen losses + Heat Loss rad.)

CONDENSER PERFORMANCE
DETERMINATION OF CONDENSER FLOW:

CW Flow =

Cond Duty ------------------------ m3/hr Cp (Tout Tin) x D

Where: C.W Flow = m3/hr Cond Duty = kcal/hr Cp = 1 kcal/kg o C (Specific heat of water) D = 1000 kg/cubic meter (Density of water) Tout = OC (Average C.W Outlet temp.) Tin = OC (Average C.W Inlet temp.)

CONDENSER PERFORMANCE
Water Velocity in Condenser Tube
C.W Flow Rate x 106 Tube Velocity = ------------------------------------------------------3600 x Tube Area x (Number Tubes Number Plugged) Where: Tube Velocity C.W Flow Rate Tube Area

= m/sec = m3/hr = mm2

CONDENSER PERFORMANCE
Computation of Log Mean Temperature Difference (LMTD): Tout - Tin LMTD = ------------------Tsat Tin Ln ---------Tsat Tout Where: LMTD = 0C Tsat = 0 C (saturation temp corresponding to back pressure)

CONDENSER PERFORMANCE
DETERMINATION OF EXPECTED LMTD FOR DEVIATION FROM DESIGN VALUE
* Correction

for C.W. inlet temperature (ft)

Ft =

Saturation Temp Test - LMTD test ------------------------------------------Saturation Temp Design - LMTD design

CONDENSER PERFORMANCE
Correction for C.W. flow (fw)
1/ 2

Tube velocity test fw = ----------------------Tube velocity design

*Correction for condenser heat load (fq)

Cond. duty design fq = -----------------------Cond. duty test

CONDENSER PERFORMANCE
Expected LMTD LMTD expected = LMTD test x ft x fw x fq oC Determination of Expected Saturation Temperature: (taking into consideration deviation in operating value from design values) [Tin Tout x eZ] Sat. Temp. Expected: = --------------------------- oC [1 - eZ] Where: Tin = Design C.W. inlet temp. Tout = Design C.W. outlet temp. Tout Tin Z = ---------------------Expected LMTD Expected Back Pressure = Derived from steam table corresponding to expected saturation temperature.

ACTION FOR IMPROVING CONDENSER PERFORMANCE 1: REGULAR MONITORING OF CONDENSER PERFORM 2: IDENTIFICATION AND ATTENDING OF HIGH ENERGY DRAIN VALVE PASSING 3:IDENTIFICATION OF AIR INGRESS POINTS BY HELIUM LEAK DETECTION TEST ( WHEN UNIT IS RUNNING) 4: IDENTIFICATION OF AIRINGRESS POINT BY STEAM PRESSURISATION TEST (DURING UNIT OVERHAUL) 5:MAINTAINING PROPER SEAL STEAM PRESSURE AND TEMP 7: PROPER SEALING OF ALL THE VALVE GLANDS IN LINES UNDER VACUUM

ACTION FOR IMPROVING CONDENSER PERFORMANCE 8: PROPER SEALING OF GLANDS OF STANDBY C EP 9:MONITORING SEAL WATER PARAMETERS OF VACUUM PUMP 10: MONITORING OF AIR DEPRESSION 11: JET/CONCO CLEANING OF WATER TUBES 12: PROPER VENTING OF WATER BOX DURING CHARGING OF CONDENSER 13:ENSURE PROPER OPERATION OF HP FLASH BOX SPRAY SYSTEM

CONDENSER PERFORMANCE

IDENTIFICATION OF AIR INGRESS

CONDENSER PERFORMANCE
AIR INGRESS IDENTIFICATION

HELIUM LEAK DETECTION TEST

CONDENSER FLOOD TEST STEAM PRESSURISATION TEST

CONDENSER PERFORMANCE
WORKING PRINCIPLE: The Helium Leak Detection Test is new method based on helium acting as tracer gas that allows an easy and quick location of leaks. The use of helium is advantageous because it is a nontoxic, nonflammable, relatively inexpensive and quickly diffuses through small leaks.

Helium is sprayed at the point where leak is to be checked by means of portable unit which has facility of helium spray. If there is any ingress inside condenser, Helium will also enter with air which is displayed in Heli Test Gen.

CONDENSER PERFORMANCE
PREPARATION FOR TEST:(A)Set up for Helium Spray: 1: Install a gas regulator on Helium gas cylinder. 2: Connect a spray gum through PVC tube. The Portable Leak Detector ( PLI ) may be also used for spraying helium . 3: Adjust helium gas pressure 1.5 to 2.0 Kg / cm 2.
Spray gun

He liu m Cy lin de r

Set up for Helium Spray

CONDENSER PERFORMANCE
Vacuum Pump Exhaust

Set for Helium leak Detection

Connecting pipe

Vacuum Pump

Vacuum pump

Moisture separator Helium leak Detector Water drop separator Silica gel

CONDENSER PERFORMANCE

CONDENSER PERFORMANCE

CONDENSER PERFORMANCE

CONDENSER PERFORMANCE
CONDENSER FLOOD TEST & STEAM PRESSURISATIONTEST Condenser flood test is done by feeling DM water in condenser shell side and water leakage is checked ( if any) Standard procedure should be folllowed for Condenser flood test Steam pressurisation test is done by pressurisation of condenser by steam leakage is checked ( if any) Standard procedure should flow for Condenser steam pressurisation test

LP / HP HEATERS PERFORMANCE

LP/HP HEATERS PERFORMANCE

LP / HP HEATER PERFORMANCE IS MONITORED BY MONITORING FOLLOWING PERFORMANCES INDICES TERMINAL TEMP DIFFERENCE ( TTD) TTD= Ts-FW outlet temp

DRAIN COOLER APPROACH ( DCA) DCA = DRIP TEMP- FW inlet temp TEMP RISE = (FW outlet temp- FW inlet temp )

LP/HP HEATERS PERFORMANCE

TTD HIGH: FOULING IN SIDE TUBE SCALE OUTSIDE OF TUBE AIR BLANKETING MIXING OF WATER THROUGH PARTING PLANE OF WATER BOX ( SHORT CIRCUITING) ONE OR MORE PREVIOUS HEATER/S OUT OF SERVICE HIGH LEVEL OF HEATER ie POOR CASCADING SYSTEM

LP/HP HEATERS PERFORMANCE HIGH DCA

HEATER LEVEL TOO LOW ie POOR CASCADING SYSTEM

LOW TEMP RISE

LOW EXTN STEAM PRESSURE From turbine extration Isolating valve not fully open

FOULING IN SIDE TUBE SCALE OUTSIDE OF TUBE AIR BLANKETING MIXING OF WATER THROUGH PARTING PLANE OF WATER BOX ( SHORT CIRCUITING) ONE OR MORE PREVIOUS HEATER/S OUT OF SERVICE HIGH LEVEL OF HEATER ie POOR CASCADING SYSTEM

TURBINE EFFICIENCY

Used Energy Turbine Efficiency =

Available Energy
hin - hout = hin hisen Where hin = Enthalpy at Cylinder Inlet conditions hout = Enthalpy at Cylinder Outlet conditions hisen = Isentropic Enthalpy

COOLING TOWER PERFORMANCE

Parameters to be Measured
Wet Bulb Temperature (WBT) at Tower inlet

WBT/ DBT for RH Cold Water Temperature

Hot Water Temperature CW Flow to each Tower

Salient Terms Used in CT Testing

Approach
Difference between the Cold Water Temperature at CT outlet and Inlet air Wet Bulb Temperature

Range
Difference between the Hot Water Temperature (inlet to CT) and Cold Water Temperature (outlet of CT) Effectiveness Ratio of Range to Range+Approach

Salient Terms Used in CT Testing

Salient Terms Used in CT Testing

Tower Capability
The most reliable means to assess the cooling tower thermal performance. It is defined as the percentage of water that the tower can cool to the design cold water temperature when the inlet wet-bulb, cooling range, water flow rate at their design value.

Tower Capability
Tower Capability in Percentage = Test Flow Rate Predicted Water

Test flow rate : Measured by 3 port hydraulic pitot

Predicted Water Flow Rate

Calculated from Manufacturer graphs and actual test condition

Tower Capability
Tower Capability in Percentage = Adjusted Test Flow Rate Predicted Water Flow Rate

Adjusted Test Flow Rate

= Measured flow x { Design KW of fans}0.333 { Test KW of Fans }

Predicted Water Flow Rate = Calculated from Manufacturer graphs and actual test conditions i.e. WBT, Range and Cold water temperature.

BOILER PERFORMANCE & APH PERFORMANCE

BOILER PERFORMANCE Dry flue gas loss Loss due to fuel moisture Loss due to fuel hydrogen Loss due to air moisture Loss due to unburnt carbon Radiation loss Other losses like sensible heat loss ONLY TWO LOSSES ie DFG LOSS AND UNBURNT CARBON LOSS ARE CONTROLLABLE

BOILER PERFORMANCE
S.N 1 3 2 Heat Losses (%) Dry Gas Loss Wet flue gas loss % % design
Corrected Test Value

4.77 5.83 1.2

5.30 5.83 0.97

4
5

Loss due to Unburnt Carbon Loss due to moisture in air Radiation & unaccounted Loss

%
%

0.12
%

0.12
0.78 13.0 87.00

Total loss
BOILER EFFICIENCY %

0.78 12.7 87.3

OPTIMISATION OF BOILER EFFICIENCY

HCV

ALL LOSSES
LOSSES (DRY GAS, HYDROGEN FUEL MOISTURE AIR MOISTURE, SENSIBLE HEAT RATE LOSS OF ASH) LOSSES (DRY GAS, AIR MOISTURE ) UNBURNTS LOSS

EFFICIENCY

GAS OUT TEMP

EFFICIENCY

EXCESS AIR

EFFICIENCY

FUEL MOISTURE

LOSS

EFFICIENCY EFFICIENCY

AIR MOISTURE

LOSS

OPTIMISATION OF BOILER EFFICIENCY

H2 IN FUEL H2 LOSS
UNBURNTS EFFICIENCY

UNBURNTS

EFFICIENCY

MILL REJECT RATE

LOSS

EFFICIENCY

FUEL MOISTURE

LOSS

EFFICIENCY EFFICIENCY

MILL REJECT CV

LOSS

BOILER PERFORMANCE
DRY FLUE GAS LOSS HIGH INEFFECTIVE SOOT BLOWING HIGH DRAFT POOR RAPH PERFORMANCE SEAL LEAKAGE IN APH HIGH EXCESS AIR HIGH TEMPERING AIR AIR INGRESS HIGH APH DP

BOILER PERFORMANCE
UNBURNT CARBON LOSS: POOR COAL FINNESS IMPROPER COMBUSTION

Performance Indicators

Air-in-Leakage

Gas Side Efficiency

X - ratio

Gas & Air side pressure drops

AH Performance Monitoring O2 & CO2 in FG at AH Inlet O2 & CO2 in FG at AH Outlet

Temperature of gas entering / leaving air heater

Temperature of air entering / leaving air heater

Diff. Pressure across AH on air & gas side

Air Heater Leakage - Calculation

Empirical relationship using the change in concentration of O2 in the flue gas

=

O2out - O2in * 0.9 * 100 (21- O2out)

Gas Side Efficiency

Ratio of Gas Temperature drop across the air heater, corrected for no leakage, to the temperature head. = (Temp drop / Temperature head) * 100

where Temp drop = Tgas in -Tgas out (no leakage) Temp head = Tgasin - T air in
Gas Side Efficiency = (333.5-150.5) / (333.5-36.1) = 61.5 %

Tgas out (no leakage) = The temperature at which the gas would have left the air heater if there were no AH leakage = AL * Cpa * (Tgas out - Tair in) + Tgas out Cpg * 100

X Ratio Ratio of heat capacity of air passing through the air heater to the heat capacity of flue gas passing through the air heater. = Wair out * Cpa Wgas in * Cpg
Tgas in - Tgas out (no leakage) Tair out - Tair in

Design 0.69 %

X-Ratio depends on
Air infiltration, air & gas mass flow rates X-ratio does not provide a measure of thermal performance of the air heater, but is a measure of the operating conditions.

A low X-ratio indicates either excessive gas weight

through the air heater or that air flow is bypassing the air heater. A lower than design X-ratio leads to a higher than design gas outlet temperature & can be used as an indication of excessive tempering air to the mills or excessive boiler setting infiltration.

Air Ingress Calculations Air ingress quantification is done with the same formulae as those used for calculation of AH leakage

Air ingress = O2out - O2in * 0.9 * 100

(21- O2out) The basis of O2 or CO2 calculation should be the same either wet or dry.

VALVE PASSING
PASSING OF VALVES INCREASES CONDENSER HEAT LOAD INCREASES HEAT RATE HP/LP BY PASS VALVE PASSING EFFECTS ON HEAT RATE

CONCLUDING REMARKS
CONCLUDING REMARKS: FOR IMPROVING HEAT RATE Maintain critical parameter as per rated values. Maintain optimum HP heater level. There is possibility of air ingress in LP heater1 and LP heater -2 as both heaters are running in vacuum even at full load. Air evacuation valve connected to condenser may be kept crack open

CONCLUDING REMARKS
Identify air ingress in vacuum system and get attended Ensure proper sealing of valves which are in vacuum Reduce High energy drain passing Monitor for critical valve (like HP/LP by pass valve) passing Avoid R H spray Minimize system water / steam leakage

CONCLUDING REMARKS
Optimize deaerator vent opening Optimize excess oxygen Optimize tempering air Monitor vacuum pump seal water temp