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Instructions

This model is meant to calculate the OEE (Overall Equipment Efficiency) of a Boiler primarily based on the Direct Method of Calculation

Working of the Model

1. The Boiler Running-in Data needs to be filled in the Worksheet "Input_Machine_Running_In_Data" after the user has selected the frequecn
for the purpose of referncing and do not hold implications in the efficiency calcultaions.
2. Other details need to filled in the worksheet "Output_OEE_Boiler" where the effectiveness of the Boiler is calculated and the GAP with resp
3. The worksheet "Steam_Table_Lookup" is a look up Table to locate the enthaply values for Feedwater and Steam as per the Temperature a
he Direct Method of Calculation

ter the user has selected the frequecny of calculation of the OEE for the Boiler. The Data has to be filled Datewise. The Dates are used only

er is calculated and the GAP with respect to the Rated Boiler Efficiency is also calculated.
r and Steam as per the Temperature and Pressure measured respectively.
The Dates are used only
Boiler Running-In Data

Instructions: If the Frequency is daily, then the values for Uptime & donwnt
Frequency at which
Fortnightly be picked up from cell Range A6 to F12, similarly if the Frequency is Fortni
OEE is to be analysed
Frequency is Monthly then the values will be picked up from cell Range A6

Uptime Downtime
Date Hours Minutes Date Hours Minutes
7-Nov-10 22 30 7-Nov-10 2 30
6-Nov-10 6-Nov-10
5-Nov-10 6-Nov-10
4-Nov-10 5-Nov-10
3-Nov-10 4-Nov-10
2-Nov-10 3-Nov-10
1-Nov-10 2-Nov-10
31-Oct-10 1-Nov-10
30-Oct-10 31-Oct-10
29-Oct-10 30-Oct-10
28-Oct-10 29-Oct-10
27-Oct-10 28-Oct-10
26-Oct-10 27-Oct-10
25-Oct-10 26-Oct-10
24-Oct-10 25-Oct-10
values for Uptime & donwntime will be picked from cells A6 to F6. If the Frequency is Weekly then the values will
rly if the Frequency is Fortnightly then the values will be picked up from cell Range A6 to F20 and finally if the
icked up from cell Range A6 to F36

Cumulative Numbers
Hours Minutes
Total Uptime 22 30
Total Downtime 2 30
Input Machine Oil Consumption Data

Frequency at which Total Consumption


OEE is to be Fortnightly for the Frequency 1
analysed Selected in Cms

Tank 1

Refill done in Refill done in Consumption in


Date Reading In Cms Date
Ltrs Cms Cms

7-Nov-10 0 10 1 1 7-Nov-10
6-Nov-10 0 0 0 6-Nov-10
5-Nov-10 0 0 0 6-Nov-10
4-Nov-10 0 0 0 5-Nov-10
3-Nov-10 0 0 4-Nov-10
2-Nov-10 0 0 3-Nov-10
1-Nov-10 0 0 2-Nov-10
31-Oct-10 0 0 1-Nov-10
30-Oct-10 0 0 31-Oct-10
29-Oct-10 0 0 30-Oct-10
28-Oct-10 0 0 29-Oct-10
27-Oct-10 0 0 28-Oct-10
26-Oct-10 0 0 27-Oct-10
25-Oct-10 0 0 26-Oct-10
24-Oct-10 0 0 25-Oct-10
23-Oct-10 0 0 24-Oct-10
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
Total Consumption for the
Frequency Selected in 10
Ltrs

Tank 2
Cumulative
Consumption in Consumption of the
Reading In Cms Refill done in Ltrs Refill done in Cms Tanks in Cms
Cms

0 0 1
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
Feedwater Temperature Data

Average Feedwater Temp


Frequency Selected for the OEE Evaluation Fortnightly

Feedwater Temperature in Degree


Celsius

Date
Time 0:00 22:59 21:59 3:00 19:59 5:00 6:00 16:59
7-Nov-10 100 100
6-Nov-10
5-Nov-10
4-Nov-10
3-Nov-10
2-Nov-10
1-Nov-10
31-Oct-10
30-Oct-10
29-Oct-10
28-Oct-10
27-Oct-10
26-Oct-10
25-Oct-10
24-Oct-10
Average Feedwater Temperature

Err:512

Hourly Temperature Record in Degree Celsius


8:00 9:00 13:59 11:00 12:00 10:59 14:00 15:00 7:59
Average Temperature for the Day
17:00 18:00 4:59 20:00 21:00 1:59 23:00 in Celsius
Err:512
Err:512
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
emperature for the Day
in Celsius
Err:512
Err:512
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Output Steam Pressure Data

Average Output Steam Pr


Frequency Selected for the OEE Evaluation Fortnightly

Pressure of the generated Steam in


Bars

Date
Time 0:00 22:59 21:59 3:00 19:59 5:00 6:00 16:59
7-Nov-10 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5
6-Nov-10
5-Nov-10
4-Nov-10
3-Nov-10
2-Nov-10
1-Nov-10
31-Oct-10
30-Oct-10
29-Oct-10
28-Oct-10
27-Oct-10
26-Oct-10
25-Oct-10
24-Oct-10
Average Output Steam Pressure

Err:512

Hourly Pressure Record in Bars


8:00 9:00 13:59 11:00 12:00 10:59 14:00 15:00 7:59
8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5
Average Pressure for the Day in
17:00 18:00 4:59 20:00 21:00 1:59 23:00 Bars
8.5 8.5 8.5 8.5 8.5 8.5 8.5 Err:512
Err:512
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Pressure for the Day in
Bars
Err:512
Err:512
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
OEE Calculations

Input Data

Average Temperature of Feedwater in Degree Celcius Err:512


3
Average pressure of steam in Bar of Kg/cm Err:512
Total amount of Fuel Consumed Err:501

Please enter the Gross Calorific Value of the Fuel Used by the Boiler in Kcal/KG 3200.0000 Kcal/Kg
Please enter the Quantity of steam (in tonnes ) generated during the period in
which the OEE is to be calculated 25.00 Tonnes

Quantity of Steam Generated in Tonnes Per Hour (TPH)

Quantity of Fuel Consumed for Steam Generation in Tonnes Per Hour (TPH) Err:501

Output Parameters

Availability of the Boiler 90.00%


Performance of the Boiler Err:512
Quality of the Output (An Assumption) 100.00%

OEE (Overall Effectiveness of the Boiler) Err:512


Steam Look Up Table

Look Up Values for Feedwater Look Up Values for Steam

Temperature in Enthalpy in Pressure in Bar or Enthalpy in


Enthalpy in KJ/kg
Degree Celcius KCal/kg Kg/cm3 KJ/kg

0.01 0.01 0.0024 0.04 2554


4 16.79 3.9976 0.06 2567
5 21 5.0000 0.08 2577
6 25.21 6.0024 0.1 2585
8 33.61 8.0024 0.2 2610
10 42.01 10.0024 0.3 2625
11 46.19 10.9976 0.4 2637
12 50.4 12.0000 0.5 2646
13 54.59 12.9976 0.6 2653
14 58.8 14.0000 0.7 2660
15 62.99 14.9976 0.8 2666
16 67.17 15.9929 0.9 2671
17 71.36 16.9905 1 2675
18 75.57 17.9929 1.5 2694
19 79.76 18.9905 2 2707
20 83.94 19.9857 3 2725
21 88.13 20.9833 4 2739
22 92.32 21.9810 5 2749
23 96.5 22.9762 6 2757
24 100.7 23.9762 7 2764
25 104.9 24.9762 8 2769
26 109 25.9524 9 2774
27 113.2 26.9524 10 2778
28 117.4 27.9524 20 2800
29 121.6 28.9524 30 2804
30 125.8 29.9524 40 2801
31 130 30.9524 50 2794
32 134.1 31.9286 60 2784
33 138.3 32.9286 70 2772
34 142.5 33.9286 80 2758
35 146.7 34.9286 90 2742
36 150.8 35.9048 100 2725
38 159.2 37.9048 110 2706
40 167.5 39.8810 120 2685
45 188.4 44.8571 130 2662
50 209.3 49.8333 140 2638
55 230.2 54.8095 150 2611
60 251.1 59.7857 160 2581
65 272 64.7619 170 2547
70 293 69.7619 180 2510
75 313.9 74.7381 190 2465
80 334.9 79.7381 200 2411
85 355.9 84.7381 220.9 2099
90 376.9 89.7381
95 398 94.7619
100 419 99.7619
110 461.3 109.8333
120 503.7 119.9286
130 546.3 130.0714
140 589.1 140.2619
150 632.2 150.5238
160 675.5 160.8333
170 719.2 171.2381
180 763.2 181.7143
190 807.6 192.2857
200 852.4 202.9524
210 897.8 213.7619
220 943.6 224.6667
230 990.1 235.7381
240 1037.3 246.9762
250 1085.3 258.4048
260 1134.4 270.0952
270 1184.5 282.0238
280 1236 294.2857
290 1289 306.9048
300 1344 320.0000
320 1461.5 347.9762
340 1594.1 379.5476
360 1760.5 419.1667
374.14 2099.3 499.8333
Enthalpy in
KCal/kg

608.0952
611.1905
613.5714
615.4762
621.4286
625.0000 Temperature of Feedwater in 0c Err:512
627.8571 Pressure of steam in Bar or Kg/cm3 Err:512
630.0000
631.6667 Enthalpy of Feedwater in Kcal/Kg Err:512
633.3333 Enthalpy of Steam in Kcal/Kg Err:512
634.7619
635.9524
636.9048
641.4286
644.5238
648.8095
652.1429
654.5238
656.4286
658.0952
659.2857
660.4762
661.4286
666.6667
667.6190
666.9048
665.2381
662.8571
660.0000
656.6667
652.8571
648.8095
644.2857
639.2857
633.8095
628.0952
621.6667
614.5238
606.4286
597.6190
586.9048
574.0476
499.7619
MATHEMATICAL CALIBERATION CHART OF TANK ( Furna
Dia = 1950 mm Length=5500mm.

Look Up Values for Fuel Quantity DIP versus


QTY
DIP cm. QTY. Ltrs Ltrs/mm.
0 0 1.02
1 10 1.87
2 29 2.41
3 53 2.85
4 81 3.22
5 114 3.55
6 149 3.85
7 188 4.12
8 229 4.38
9 273 4.62
10 319 4.84
11 367 5.05
12 418 5.25
13 470 5.44
14 525 5.63
15 581 5.80
16 639 5.97
17 699 6.13
18 760 6.29
19 823 6.43
20 887 6.58
21 953 6.72
22 1020 6.85
23 1089 6.98
24 1159 7.11
25 1230 7.23
26 1302 7.35
27 1375 7.47
28 1450 7.58
29 1526 7.69
30 1603 7.79
31 1681 7.89
32 1760 7.99
33 1840 8.09
34 1920 8.19
35 2002 8.28
36 2085 8.37
37 2169 8.45
38 2253 8.54
39 2339 8.62
40 2425 8.70
41 2512 8.78
42 2600 8.86
43 2688 8.93
44 2778 9.00
45 2868 9.07
46 2958 9.14
47 3050 9.21
48 3142 9.27
49 3234 9.34
50 3328 9.40
51 3422 9.46
52 3516 9.51
53 3611 9.57
54 3707 9.63
55 3803 9.60
56 3900 9.73
57 3998 9.70
58 4090 9.83
59 4194 9.88
60 4292 9.92
61 4392 9.97
62 4491 10.01
63 4591 10.05
64 4692 10.09
65 4793 10.13
66 4894 10.17
67 4996 10.20
68 5098 10.24
69 5200 10.27
70 5303 10.31
71 5406 10.34
72 5509 10.37
73 5613 10.39
74 5717 10.42
75 5821 10.45
76 5926 10.47
77 6030 10.50
78 6135 10.52
79 6241 10.54
80 6346 10.56
81 6452 10.58
82 6557 10.60
83 6663 10.61
84 6770 10.63
85 6876 10.64
86 6982 10.66
87 7089 10.67
88 7196 10.68
89 7302 10.69
90 7409 10.70
91 7516 10.70
92 7623 10.71
93 7730 10.72
94 7838 10.72
95 7945 10.72
96 8052 10.72
97 8159 10.72
98 8266 10.72
99 8374 10.72
100 8481 10.72
101 8588 10.72
102 8695 10.71
103 8802 10.70
104 8909 10.70
105 9016 10.69
106 9123 10.68
107 9230 10.67
108 9337 10.66
109 9443 10.64
110 9550 10.63
111 9656 10.61
112 9762 10.60
113 9868 10.58
114 9974 10.56
115 10080 10.54
116 10185 10.52
117 10290 10.50
118 10395 10.47
119 10500 10.46
120 10604 10.42
121 10709 10.39
122 10813 10.37
123 10916 10.34
124 11020 10.31
125 11123 10.27
126 11225 10.24
127 11328 10.20
128 11430 10.17
129 11531 10.13
130 11633 10.09
131 11734 10.05
132 11834 10.01
133 11934 9.99
134 12034 9.92
135 12133 9.88
136 12232 9.83
137 12330 9.78
138 12428 9.73
139 12325 9.68
140 12622 9.63
141 12718 9.57
142 12814 9.51
143 12909 9.46
144 13004 9.40
145 13098 9.34
146 13191 9.27
147 13284 9.21
148 13376 9.14
149 13467 9.07
150 13558 9.00
151 13648 8.93
152 13737 8.86
153 13826 8.78
154 13914 8.70
155 14001 8.62
156 14087 8.54
157 14172 8.45
158 14257 8.37
159 14341 8.28
160 14423 8.19
161 14505 8.09
162 14586 7.99
163 14666 7.89
164 14745 7.79
165 14823 7.69
166 14900 7.58
167 14975 7.47
168 15050 7.35
169 15124 7.23
170 15196 7.11
171 15267 6.98
172 15337 6.85
173 15405 6.72
174 15473 6.58
175 15538 6.43
176 15603 6.29
177 15666 6.13
178 15727 5.97
179 15787 5.80
180 15845 5.63
181 15901 5.44
182 15955 5.25
183 16008 5.05
184 16058 4.84
185 16107 4.62
186 16153 4.38
187 16197 4.12
188 16238 3.85
189 16277 3.55
190 16312 3.22
191 16344 2.85
192 16373 2.41
193 16397 1.87
194 16415 1.02
195 16426 0.00
ATICAL CALIBERATION CHART OF TANK ( Furnace Oil)
Capacity =16426 Ltrs.

Look Up Values for Fuel Quantity DIP versus QTY


QTY. Ltrs DIP cm. Ltrs/mm.
0 0 1.02
10 1 1.87
29 2 2.41
53 3 2.85
81 4 3.22
114 5 3.55
149 6 3.85
188 7 4.12
229 8 4.38
273 9 4.62
319 10 4.84
367 11 5.05
418 12 5.25
470 13 5.44
525 14 5.63
581 15 5.80
639 16 5.97
699 17 6.13
760 18 6.29
823 19 6.43
887 20 6.58
953 21 6.72
1020 22 6.85
1089 23 6.98
1159 24 7.11
1230 25 7.23
1302 26 7.35
1375 27 7.47
1450 28 7.58
1526 29 7.69
1603 30 7.79
1681 31 7.89
1760 32 7.99
1840 33 8.09
1920 34 8.19
2002 35 8.28
2085 36 8.37
2169 37 8.45
2253 38 8.54
2339 39 8.62
2425 40 8.70
2512 41 8.78
2600 42 8.86
2688 43 8.93
2778 44 9.00
2868 45 9.07
2958 46 9.14
3050 47 9.21
3142 48 9.27
3234 49 9.34
3328 50 9.40
3422 51 9.46
3516 52 9.51
3611 53 9.57
3707 54 9.63
3803 55 9.60
3900 56 9.73
3998 57 9.70
4090 58 9.83
4194 59 9.88
4292 60 9.92
4392 61 9.97
4491 62 10.01
4591 63 10.05
4692 64 10.09
4793 65 10.13
4894 66 10.17
4996 67 10.20
5098 68 10.24
5200 69 10.27
5303 70 10.31
5406 71 10.34
5509 72 10.37
5613 73 10.39
5717 74 10.42
5821 75 10.45
5926 76 10.47
6030 77 10.50
6135 78 10.52
6241 79 10.54
6346 80 10.56
6452 81 10.58
6557 82 10.60
6663 83 10.61
6770 84 10.63
6876 85 10.64
6982 86 10.66
7089 87 10.67
7196 88 10.68
7302 89 10.69
7409 90 10.70
7516 91 10.70
7623 92 10.71
7730 93 10.72
7838 94 10.72
7945 95 10.72
8052 96 10.72
8159 97 10.72
8266 98 10.72
8374 99 10.72
8481 100 10.72
8588 101 10.72
8695 102 10.71
8802 103 10.70
8909 104 10.70
9016 105 10.69
9123 106 10.68
9230 107 10.67
9337 108 10.66
9443 109 10.64
9550 110 10.63
9656 111 10.61
9762 112 10.60
9868 113 10.58
9974 114 10.56
10080 115 10.54
10185 116 10.52
10290 117 10.50
10395 118 10.47
10500 119 10.46
10604 120 10.42
10709 121 10.39
10813 122 10.37
10916 123 10.34
11020 124 10.31
11123 125 10.27
11225 126 10.24
11328 127 10.20
11430 128 10.17
11531 129 10.13
11633 130 10.09
11734 131 10.05
11834 132 10.01
11934 133 9.99
12034 134 9.92
12133 135 9.88
12232 136 9.83
12330 137 9.78
12428 138 9.73
12325 139 9.68
12622 140 9.63
12718 141 9.57
12814 142 9.51
12909 143 9.46
13004 144 9.40
13098 145 9.34
13191 146 9.27
13284 147 9.21
13376 148 9.14
13467 149 9.07
13558 150 9.00
13648 151 8.93
13737 152 8.86
13826 153 8.78
13914 154 8.70
14001 155 8.62
14087 156 8.54
14172 157 8.45
14257 158 8.37
14341 159 8.28
14423 160 8.19
14505 161 8.09
14586 162 7.99
14666 163 7.89
14745 164 7.79
14823 165 7.69
14900 166 7.58
14975 167 7.47
15050 168 7.35
15124 169 7.23
15196 170 7.11
15267 171 6.98
15337 172 6.85
15405 173 6.72
15473 174 6.58
15538 175 6.43
15603 176 6.29
15666 177 6.13
15727 178 5.97
15787 179 5.80
15845 180 5.63
15901 181 5.44
15955 182 5.25
16008 183 5.05
16058 184 4.84
16107 185 4.62
16153 186 4.38
16197 187 4.12
16238 188 3.85
16277 189 3.55
16312 190 3.22
16344 191 2.85
16373 192 2.41
16397 193 1.87
16415 194 1.02
16426 195 0.00