Energy Audit & Efficiency

Improvement of Operating
Power Plants

28 July 2015

Dr. Y. P. Abbi
Senior Advisor/Energo Engineering Projects Limited,
Ex- Executive Director/BHEL, Senior Fellow/TERI,
President/Energo
 Energy Efficiency Improvement of
Thermal Power Plants
It is responsibility of Operation & Maintenance
Engineers/Managers of the plant
It involves systematic data collection & analysis
(weekly/fortnigtly); and not once a year by an External
Energy Auditor
Understand the science/technology for each equipment
sub-system of the plant; and keep yourself abreast with
their latest technology development
Planned improvements in stages; dont wait for R&M
Retire old plants with Heat Rate deviation more than
20 %
Energy Efficiency Improvement A
Necessity
Power demand (as on date) is
low (PLF); thus need for
efficiency improvement for
financial sustainability
Energy efficiency improvement
leads to fuel cost saving and
thus plant profitability
It leads to CO2 emission
reduction (a national &
international commitment)
Change Mindset for Energy Efficiency
Improvement
Dont make excuse that coal quality has become
bad
We have to work with the available fuel, and
achieve the best possible results
Blame no more the design defects; it is we who
have to overcome/remove these
Dont be defensive while analyzing results, or
receiving suggestions from external Energy
Auditors
Make PG Test results as the baseline; and make
all efforts to achieve & maintain these
Important that all key instruments used in the
plant are calibrated regularly and at least
conform to prescribe accuracy
Required Accuracy of Instruments
Instrument Accuracy (+/- %)
Thermocouples Temp. Range: 0 to 277 0C 1.1
0
C;
277 to 1260 0C 3/8 %
Pressure Transducers 0.1
Power Meter 0.1
Data Logger 0.03
Power Transducer 0.5
Flue Gas Analyzer 0.5
Ultrasonic Flow Meter 0.5
Anemometer 1.0
Infrared Thermometer 1.0
Lux Meter 1.0
RH Meter 1.0
Calibrated Test Flow Assembly 0.25
LET US CONSIDER THE
PATTERN OF ENERGY
CONSUMPTION & LOSSES
IN A
THERMAL POWER
STATION
Typical Energy Losses in a
Power Plant
Typical Energy Losses in
a Boiler
Typical Energy Losses in Steam Cycle
You cannot Manage
what you cannot
Measure

(Accurately)

- Jack Welch, CEO,

General Electric
 What needs to be measured for
Efficiency Improvement of a
Power Plant ?

Heat rate of the plant

Heat rate of the steam turbine cycle
& Boiler Efficiency
Auxiliary Power Consumption
Net heat rate of the power plant
(Monitored by CEA & BEE under PAT
scheme)
 Heat Rate of Steam cycle and
the
Power Plant
Heat Rate of steam cycle, HRsc = {(Enthalpy
of SH steam) +(Heat added during RH)
(Sensible heat in feed water)} /
(kW electricity generated),
kCal/kWh

Efficiency of steam cycle, sc = 860 /HRsc

Gross Heat Rate of the Power Plant, HRpp =

HRsc / BOILER , kCal / kWh
Gross Calorific value of Fuel = GCV kCal /kg of
fuel
Specific fuel consumption = HRpp / GCV,
Perform Achieve & Trade (PAT)
scheme under Energy Conservation
Act 2001
Applicable for all Designated Consumers (DCs)
Thermal Power Plants are also DCs
Every DC is given a target for reduction in
energy consumption by end of three years
For power plants, the target will be in terms of
reduction of Net Heat Rate of the Plant
Power plants who dont achieve the target will
have to buy Energy Certificates from those
who have achieved more than their targets
 Benefits from Heat Rate
Improvement
Take the case of a typical 210 MW power plant
and assume that it has the following operating
variables:
Heat rate = 2450 kCal/kWh
Plant load factor = 85 %
Coal GCV = 3997 kCal/kg (C = 41.7 %)
Coal cost = INR 2000 /t
CO2 emission per t of coal burnt = (41.07/100)
x (44/12) = 1.5059 t
The coal consumed and its cost, and CO2
emissions per year are as follows:
Specific coal consumption = 2450/3997 =0.613
t/MWh
Electricity produced = 210 x 0.85 x 365
Contd. 1
Coal consumed = 1,563,660 x 0.613
= 958,524 t
Coal cost = INR 958,524 x 2,000
= INR 1,917,048,000
CO2 emissions = 958,524 x 1.5059
= 1,443,441 t
If the energy audit and modifications in O&M
practices yields an improvement of heat rate by just
50 kCal/kWh, the fuel and fuel cost saved per year
would be as follows:
Heat rate (improved to) = 2400 kCal/kWh
Specific coal consumption = 2400/3997
= 0.60045
t/MWh
Contd. 2
Contd. 2
Coal consumed for generating
1,563,660 MWh of electricity = 1,563,660 x 0.60045
= 938,900 tonne
Coal cost = 938,900 x 2000
= 1,877,800,000 INR
CO2 emissions = 938,900 x1.5059
= 1,413,890 t

Thus, coal cost saved in one year = INR (1,917,048,000

1,877,800,000)
= INR 39,248,000
CO2 emissions saved in one year = 1,443,441 - 1,413,890
= 29,551 t

Objectives of an Energy Audit or

Performance Monitoring
To improve Heat Rate and reduce
Auxiliary Power Consumption of
the power plant
To identify energy efficiency
improvement measures
To develop medium-term and
long-term energy conservation
measures, & work out techno-
economics
 Evaluation of efficiency
of Boilers
Standards ASME PTC 4 or BS 2885 or
IS 8753
Applicable for boilers fired with oil,
gas, solid fuels
Two Methods used a) Direct Method,
& b) Indirect Method
Applicable for different firing systems
Stoker, pf, FBC
Applicable for subcritical and
supercritical boilers
 Direct Method
Boiler efficiency = (Heat
output/Heat input) 100
= {Steam flow rate(steam
enthalpyfeed water
enthalpy) 100}/
(Fuel firing rate gross calorific
value)

*Fuel as fired basis only

 Calculation of Boiler
Efficiency
Heat losses (ASME PTC 4)
in the boiler (%)
Dry flue gas losses (sensible heat + un-burnt CO)
Loss due to hydrogen and moisture in the flue gases
Loss due to moisture in air
Un-burnt carbon losses (fly ash and bottom ash)
Loss due to sensible heat in fly ash and bottom ash
Radiation & convection losses from boiler surface
Total losses = Sum of all above
Boiler Efficiency
BOILER = 100 Total losses
 Data required for boiler
efficiency calculations
Ultimate analysis of fuel (C, H, O, N, S, H2O, ash)
GCV of fuel, kCal/kg
O2 in flue gas (% by vol.)
CO in flue gas (% by vol.)
Tg, Flue gas temperature, oC
Ambient air temp., humidity in air
Combustibles (un-burnt) in fly ash & bottom ash
Measurement of temp., press., flow should be
done at multiple points in the duct
Recommended excess air
levels
Fuel/Type of boiler Excess air (%)

Coal
PC 15-20
FBC 20-25
Stoker 25-35
Fuel oil 03-15
Bagasse 25-35
Wood 20-25
Blast furnace gas 15-30
Cold air leakage in an air
heater
F lu e g a s fro m F lu e g a s to ID f a n
e c o n o m ize r

A ir h e a t e r

H o t a ir f o r c o m b u s ti o n A ir f r o m F D f a n s
 Cold air leakage in Air
Heaters
As per ASME PTC 4.1
wAL, % leakage =
{(% O2 in gas leaving the heater - %
O2 in gas entering the heater)/ (21 -
% O2 in gas leaving the heater)}x 90
 Corrected flue gas temperature
leaving the air heater for no leakage

tGONL = {% leakage x CpA x (tGO tAI)/

(100 x CpG)} + tGO

where
CpA = Mean specific heat between
temperature tAI and tGO
CpG = Mean specific heat between
temperature tGO and tGONL
 Case study of Energy
Audit of a 500 MW Boiler
 Case study: Boiler efficiency
evaluation for a 500 MW unit
(Steam parameters- 1700 t/h, 179
ata,540oC/540oC)
Coal properties
Design Actual
C (Wt %) 37.92 44.73
H02.33 01.99
S 00.29 00.37
N00.84 00.62
O06.23 01.83
H2O12.00 14.10
Ash 40.39 36.22
GCV (kCal/kg) 3500 3622
 Measured data for
energy audit
Boiler
O2 in flue gas (%) 4.01
Excess air (%) 23.06
CO (ppm) 9.3
Flue gas temp. (OC) 167.57
Ambient temp. (OC) 23.9
Wet bulb temp. (OC) 18.1
Air heater
O2 (%) in flue gas after eco. 4.01
O2 (%) in flue gas after air heater7.50
 Calculation of boiler
efficiency
Parameter (%) Design Calculated
Dry flue gas loss 5.08 8.89
Heat loss due to CO 0.00 0.00
Heat loss due to moisture in air 0.12 0.12
Heat loss due to moisture and
Hydrogen in fuel 5.95 5.78
Heat loss due to unburnt in bottom ash 0.90 0.07
Heat loss due to unburnt in fly ash 0.00 0.02
Sensible heat in bottom ash 0.38 0.26
Sensible heat in fly ash 0.18 0.33
Surface & unaccounted loss 0.67 0.10
Total heat losses 12.57 15.65
Boiler efficiency 87.4384.35
Analysis of boiler efficiency test
results
Flue gas losses are higher than design
Excess air level is 23.6 % (recommended
value is 20 %)
Flue gas temperature (OC)
Measured 167.57
Corrected after applying
leakage correction
190.0
Design value
146.0
Expected improvement in boiler
efficiency
From To
Flue gas temp. (OC) 190 146
Excess air (%) 23.6 20.0
Boiler efficiency (%) 84.35 87.18*

* This would be very close to the

design value of 87.43%.
Coal and monetary savings potential
through efficiency improvement

Current coal consumption (t/y)

2,632,181
Saving potential through
efficiency improvement (t/y)
74,490
Coal cost (INR/t) 2,000
Monetary savings (INR/y)
148,980,000
Energy Audit of Steam
Turbines
Energy audit of steam turbines
(Data required)
Steam flow, temperature and pressure conditions at the entry
to the HP turbine
Cold reheat steam temperature and pressure
Temperature and pressure of hot reheat steam at the inlet of
IP turbine
Temperature and pressure of IP exhaust steam
LPT exhaust pressure
Extraction temperature and pressure of steam of all the
extractions (6 in case of 500 MW and 5 in case of 210 MW)
Super heater and reheater spray conditions (quantity,
pressure and temperature)
Feed water condition at the economiser inlet (quantity,
pressure and temperature)
Make up water quantity
Coal consumption and power generation
 Analysis of steam
turbine data
TG heat rate (HR)
= (Heat input to turbine)/Power generated

Heat input to turbine = {Heat in main steam + Heat picked up in reheat + Heat in
make-up water + Heat picked up in super heater (SH) spray + Heat in reheater
(RH) spray Heat in feed water}

Heat picked up in reheat = {HRH flow x (Enthalpy of HRH Steam Enthalpy of CRH
steam)}

Heat picked up in SH spray = {SH spray quantity x (Enthalpy of SH spray

Enthalpy of feed water at economiser inlet)}

HRH flow = CRH flow = {MS flow Extraction-6 quantity Gland steam leakages }
Assumed as 1.5% of the MS flow to turbine

Extraction-6 quantity = { FW flow through HPH-6 (enthalpy in enthalpy out)} /

(enthalpy of steam in enthalpy of steam out)

Analysis of steam turbine data

(Contd.)

TG efficiency = 860/TGHR
Plant heat rate = (TGHR/Boiler efficiency)x100
Steam rate (SR) in kgs/kWh is steam input to the
turbine (kgs) to actual power output from the turbine
(kWh)
Specific coal consumption (SCC) in kgs/kWh is overall
plant heat rate (kCal/kWh) to the GCV of coal
(kCal/kg) on as-fired basis.
Cylinder efficiency (HP/IP)= (actual enthalpy drop /
isentropic enthalpy drop)x 100
=(steam inlet enthalpy steam outlet enthalpy)/
(steam inlet enthalpy Isentropic enthalpy)x 100
Audited performance parameters
of a 500 MW steam turbine
Paramet Flow Pressure Temperat Enthalpy Isentropi
ers (t/h) (bar) ure (kCal/kg) c
(OC) enthalpy
(kCal/kg)
Main 1575.97 169.17 535.08 809.11 -
steam

CRH-HPT 1450.00 46.47 343.49 731.05 721.71

exhaust
HRH-IPT 1450.00 42.47 530.09 838.87 -
inlet
IPT - 6.727 268.39 715.03 707.72
exhaust

LPT - 0.096 - 531.02 -

exhaust
 Audited performance parameters
of a 500 MW steam turbine (contd.)
Paramet Flow Pressure Temperat Enthalpy Isentropi
ers (t/h) (bar) ure (kCal/kg) c
(OC) enthalpy
(kCal/kg)
FW at 1580.90 210.02 249.54 259.05 -
eco inlet

SH spray 35.17 195.31 314.50 337.81 -

RH spray 2.49 115.56 183.94 187.65 -

Make-up 9.74 - 25.00 25.04 -

water

- - - - - -
 Audited performance parameters
of a 500 MW steam turbine (contd.)

Coal consumption 286.66

t/h*
Power generation 504.95 MW

* Unit control board value

 Analysis of performance of
steam turbine
Parameter Design@0 Design PG test Audited
% makeup @3% value Performan
water makeup ce
water
TGHR, 1988.10 2023.6 1994.38 2030.74
kCal/kWh

TG 43.26 42.50 43.12 42.35

efficiency,
%
Boiler 87.43 87.43 88.90 84.35
efficiency,
%
Plant HR, 2273.93 2314.54 2243.48 2407.51
kCal/kWh
Analysis of performance of
steam turbine (Contd.)
Parameter Design@0 Design PG test Audited
% makeup @3% value Performan
water makeup ce
water

Overall 37.82 37.16 38.33 35.72

plant
efficiency,
%
Steam - - - 3.12
rate,
kg/kWh
GCV of 3500 3500 - 3622
coal,
kCal/kg
Specific 0.650 0.661 - 0.665
coal
consumpti
on, kg/kWh
Specific - - - 0.568
 Cylinder efficiency of three
turbines
Parameter PG Test Audit
HPT efficiency (%) 87.24 89.32
IPT efficiency (%)91.36 94.42
LPT efficiency (%) 56.33 52.29
Overall efficiency (%)43.12 42.36
 Inference &
Recommendations
SH spray is 2.39%, which is
higher than prescribed limit
Turbine heat rate of 2030.74 (at
0.63% makeup water)is higher
than the design value of 1988.10
Coal consumption as calculated
is higher than UCB value. Thus,
Gravimetric Feeder needs re-
calibration
 Inference & Recommendations
(Contd. 1)
HPT & IPT efficiencies are better than the PG test
level. This leads to lesser enthalpy drop in LP
cylinder, and thus LP cylinder efficiency is lower.
SH spray causes less feed water flow through the
water walls (once-thru boiler) and thus affects its
performance.
RH spray causes less bleed steam flow to the FW
heaters and thus loss of efficiency.
RH spray also lowers the cycle efficiency as the
steam formed by spray water in reheater
bypasses the HP cylinder, and thus affects the
efficiency.
 Inference & Recommendations
(Contd. 2)
Overall performance of turbine can be
improved by reducing the SH and RH sprays
by suitably tilting downwards the burners.
Maintain recommended condensate levels
in FW heaters. With this no heat transfer
areas are immersed in the drain
condensate.
Overall plant efficiency is a function of
efficiencies of both boiler and steam
turbine. In this case, the improving boiler
efficiency can make a major contribution.
Plant Auxiliaries
Performance Data
of
JSW Energy Plants
(compiled by Centre for Science and
Enviroment)
JSW Energy Ltd., Ratnagiri
4 x 300 MW; Sub-critical; Imported coal based; sea
water cooling; Supplied by Shanghai Electric Co.;
Commissioned in 2010 (units # 1,2) & 2011 (units #
3,4)
Sp. Coal consumption = 0.49 kg/kWh
Sp. CO2 emission = 1.03 t CO2/MWh
Plant availability (2011-12) = 89 %
PLF = 71.8 %
APC = 8.53 %
GHR = 2418 kCal/kWh
(12.4 % higher than design)
NHR =2673 kCal/kWh
Not included in PAT scheme
JSW Energy Ltd., Thoranagullu
SBU I: 2 x 130 MW with Corax Gas &
Imported Coal (BHEL) + SBU II: 2 x 300 MW
with Imported Coal (Shanghai Electric)= 860
MW
During 2010-11, 11-12, 12-13
Availability = 91 %
PLF = 96 %
GHR = 2261 kCal/kWh
GHR (design) = 2162 kCal/kWh
APC = 7.46 %
CO2 emission = 0.93 t CO 2/MWh
Continued
Avg. Steam Cycle HR = 1978 kCal/kWh
Design Steam Cycle HR = 1930 kCal/kWh
Boiler efficiency = 88.3 %
Design boiler efficiency = 89.3 %
CWP efficiency
SBU I 68% (Low)
SBU II 87.67 %
PAT Targets (NHR)
SBU I: 2515 to 2503 kCal/kWh
SBU II: 2422 to 2420 kCal/kWh
Rajasthan West Power Plant,
Barmer
2 x 120 MW, High Sulphur Lignite
fired, CFBC boilers
PAT Targets (NHR)
3723 to 3559 kCal/kWh
 Thank you
ypa4@yahoo.co.in
abbi.yashpal@energoindia.com

Books Authored

Y P Abbi & Shashank Jain

Handbook on Energy Audit and Environment Management, published by TERI Press, 2006

Y P Abbi
Energy Audit of Thermal Power, Combined Cycle, and cogeneration Plants, published by TERI Press, 2012

http://bookstore.teriin.org