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EEMG Manual PDF
EEMG Manual PDF
DRAFT MANUAL
i
PREFACE
Our mission is to “make available reliable and quality power in
increasingly large quantities at competitive prices.” Thus we must
strive to produce electricity at the lowest cost. Efficiency
improvement has a direct bearing on the cost of electricity. Hence
we must run the plant at its best achievable efficiency all the time.
It may be mentioned here that the document for Gas Turbine and
WHRB will be issued separately.
i
ACKNOWLEDGEMENTS
i
Table of Contents
1 Introduction
1.1 Objective
2 Definitions
3 Heat Rate Assessment
3.1 Monitoring Primary Process Indicators
3.2 Heat Rate Deviation Trending
3.3 Parameters To Be Tracked
3.3.1 Turbine Cycle
3.3.2 Boiler Cycle
3.3.3 Auxiliary & Station Power
3.3.4 Unaccountable losses
4 Baseline For Comparison With Actual Performance
4.1 Design
4.2 Performance Guarantee Test
4.3 Historical Operating or Test Data
4.4 Benchmarking Similar Units
4.5 Current Expected
5 Methodology for Heat Rate deviation calculation
5.1 Data Collection Methodology
5.2 Deviation Calculation Methodology
5.3 Monthly Heat Rate Deviation
6 Periodic Testing with On-Line Instrument
6.1 Introduction
6.2 Type Of Tests
6.3 Testing Frequency
7 Instrumentation
7.1 Pressure Transmitters
7.2 Temperature
7.3 Flow
7.4 Gas Analyzers
7.5 Energy Meters
7.6 Additional Equipment
8 Typical Test Procedures
8.1 HP/IP Turbine Efficiency Test
8.2 Turbine Cycle Heat Rate Test
8.3 HP Heater Performance Test
8.4 Condenser Performance Test
8.5 Cooling Tower Performance Test
8.6 Mill Dirty Air Flow Test
8.7 Air Heater Performance Test
8.8 Boiler Efficiency Test
i
9 Heat Rate Action Plan
9.1 Preparation of action Plan
9.2 Calculation of Unit & Station HR
9.3 Review of Plan
9.4 Annual Targeting
10 Reporting System & Formats
10.1 Information Flow
11 EEMG Structure & Responsibility
11.1 Setup - Station
11.2 Setup - Region
11.3 Setup - Corporate
12 Tools
12.1 Introduction
12.2 Comprehensive Thermal Kit
12.3 Thermodynamic Model of the Plant
13 Fault trees
ii
1. INTRODUCTION
Efficient operation of generating power plants has always been
important to utilities. The heat rate of a conventional Coal fired
power plant is a measure of how efficiently it converts the chemical
energy contained in the fuel into electrical energy. This conversion
is accomplished in four major steps. First, the chemical energy in
the fuel is converted into thermal energy, then the thermal energy
is converted into kinetic energy, then the kinetic energy is
converted in mechanical energy, and last the mechanical energy is
converted to electrical energy. In each of these sub-processes,
some energy is lost to the environment. Some of the fuel is not
burned completely, some of the thermal energy is lost out the stack
and rejected to the cooling water, some of the kinetic and
mechanical energy produces heat instead of electricity, and last,
some of the electricity that is produced is used by these sub-
processes. The heat rate of a power plant is the amount of
chemical energy that must be supplied to produce one unit of
electrical energy.
1-1
equipment may be run, the initial steam temperature may
not be continuously maintained as high as it should be, etc.
1.1 OBJECTIVE
The amount of money spent for fuel will be reduced. This lowers
the cost of producing the electricity.
1-2
2. DEFINITION
The purpose of this section is to clearly define the terms used in
this document along with the general terms, which are specific to
performance monitoring of equipment and system. This is to have
clarity and same understanding of the terminology used across the
organization.
2.1.1 Unit Heat Rate - A “unit” heat rate includes all heat input to
the boiler. The heat input to the boiler should include 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 should be used.
2.1.2 Net Unit Heat Rate - A “unit” heat rate includes all heat
input to the boiler. The heat input to the boiler should include all
forms of chemical energy supplied and the “net” electrical
generation i.e., auxiliary power is to be subtracted from gross
electrical energy.
2.1.3 Actual Unit Heat Rate - The true heat rate of a unit is
usually calculated from the amount of fuel (all fuel, coal, oil, gas,
etc.) burned during the period, the gross calorific value of the fuel,
and the generation for the period. The integrated readings of fuel
burned and generation are (i.e. daily, weekly, or monthly) used to
calculate the actual heat rate. Actual heat rate includes fuel
burned during startups, and includes the negative net generation
during off-line periods.
2.1.4 Design Unit Heat Rate - The heat rate on a unit varies with
both load and ambient conditions (air and cooling water
temperature). However, one “design” heat rate number is
frequently published for a unit. It is the heat rate the designer
anticipates will occur at the design condenser pressure and a
certain load. Whenever it is given, the unit condition should also
be specified (such as “maximum continuous rating” (MCR) or the
load when the turbine valves are wide open (VWO), etc.).
2-1
2.1.5 Reference Unit Heat Rate - This is the heat rate the unit is
capable of obtaining, based on the initial design configuration. It
is usually derived from the turbo generator and boiler performance
guarantee or acceptance test results.
2.1.6 Expected Unit Heat Rate - The heat rate that the unit
should be capable of obtaining based on the present design
configuration. It is calculated by adjusting the reference heat rate
for the effects of permanent modifications to the unit.
2.1.8 Target Unit Heat Rate - The heat rate i.e. set as a goal.
This is usually based on historical performance along with
anticipated changes resulting from improvement activities and
uncorrected degradation.
2-2
2.9 Continuous monitoring – monitoring conducted on a
uniform continuous basis, using automated data collection
2.17 HP-IP turbine shaft leakage –the steam leakage from the
HP turbine to the IP turbine through the shaft seals of a combined
HP-IP element.
2-3
2.22 Performance parameters – those variables in a cycle, which
can be measured or calculated which are indicative of the level of
performance of a component or system
2.25 Single valve (full arc control) – the operation by which the
steam flow into a turbine is governed by opening all control valves
simultaneously
2.26 Steam path audit – an audit of the turbine steam path that
is used to quantify associated performance losses for each
nonstandard condition. These performance losses are determined
by taking detailed physical measurements of the steam path
during a turbine outage.
2.30 Main steam flow – S/H steam flow at the HP turbine inlet
2-4
2.33 Turbine exhaust pressure – the LP turbine exit pressure
measured at the exhaust flange. It may not be the same as the
condenser backpressure.
2.34 Valve point – the valve position just before the succeeding
valve starts to open
2.38 Air Pre heater leakage - Air Pre heater leakage (%) is
defined as the weight of air passing from the airside to the gas side
of the air heater. This index is an indicator of the condition of the
air heater’s seals for specific configuration.
2.39 Air Pre heater Gas side Efficiency - Air Pre heater Gas side
Efficiency is defined as the ratio of the temperature drop, corrected
for leakage, to the temperature head, expressed as a percentage.
2-5
3. HEAT RATE ASSESMENT
3.1.1 Purpose
3-1
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 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 if 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.
a) Steam Temperatures:
3-2
ii. Hot Reheat outlet temperature(s) (H)
iii.∆T across attemperation station when the steam
Temperature is below set point (H)
b) Attemperation Flows
i. Reheat (H)
ii. Superheat (H)
c) FW temperature at economizer outlet (M)
d) Water/Steam temperature rise across each sections (M)
(Econ , WW, Primary SH, Final SH, Reheater, etc.)
e) Pressure Drop
i. Economizer (L)
ii. Economizer outlet – Final SH outlet
(Once through units) (M)
3-3
i) Ratio of total primary air flow to total secondary air flow (M)
3.1.4.4 Pulverizer
3.1.4.5 Turbine
a) MS pressure (H)
b) Pressure ratio
i. HPT - First Stage / HPT exhaust (H)
ii. IP - inlet / outlet (H)
iii. LP - inlet / last extraction (M)
c) Ratio of corrected first stage pressure to corrected flow (H)
d) Section efficiencies * (M)
3.1.4.8 Condenser
3-4
a) Condenser CW Flow (H)
b) Air In leakage (H)
c) Water box Differential Pressure (H)
d) Terminal Temperature Difference (M)
e) Temperature Rise (M)
f) Deviation from expected Condenser Back Pressure (H)
g) Pressure drop across trash rack/traveling water screens (M)
h) Condensate sub cooling (L)
i) Air steam mixture sub cooling (L)
j) Tube Cleanliness factor (M)
a) Range (H)
b) Approach (H)
c) CW Flow (H)
d) WBT at Tower inlet (M)
e) CT inlet temperature [H]
f) CT outlet temperature [H]
g) CT fan power [M]
3.1.4.10 Other
3-5
3.2 HEAT RATE DEVIATION TRENDING
By calculating actual heat rate and comparing the actual heat rate
to some “baseline” and trending the deviation, we can determine if
the performance of the unit is improving or deteriorating. One
advantage of this method is that the cost of the overall
performance deterioration can be calculated
3-6
3.3 PARAMETERS TO BE TRACKED
3-7
be lost for every 6 mm Hg increase in condenser pressure. Usually
a heat rate deviation is calculated due to the difference between
the expected and actual condenser pressure. It is also possible to
divide this deviation into two parts. The first heat rate deviation is
due to the cooling water flow rate being different from design, and
the second heat rate deviation due to fouling and air ingress of
tubes.
• Deviation due to CCW flow
• Deviation due to fouling and air ingress.
There are three ways of calculating deviations due to the feed water
performance. First, a deviation can be calculated due to the final
feed water temperature being lower than expected. Second, a
deviation can be calculated from the amount of time a heater or a
string of heaters are bypassed. Third, both methods can be
combined, where the final feed water temperature deviation is used
when all heaters are in service and the deviation for heaters being
bypassed is used (and the final feed water temperature is ignored)
when one or more heaters is bypassed. The reason the final feed
water temperature cannot be used alone is two fold. First, the heat
rate deviation for the top heater being bypassed is different from
the deviation that would be calculated based on the resulting final
feed water temperature. Second, if a lower pressure heater is
bypassed, the final feed water temperature may not change, but
there is a heat rate deviation due to the higher extraction flow to
higher-pressure heaters.
3.3.1.3 Makeup
Makeup is the quantity of water that is lost from the cycle during
operation. It is not simply the water supplied to a unit, as water is
also supplied for boiler hydrostatic tests, chemical cleanings, etc.
Water supplied for these purposes should be excluded. The heat
rate deviation for makeup is an approximation, as the location in
the cycle of each loss is not known, therefore the exact heat rate
deviation is not known. Losses from main steam are the most
expensive, because so much energy has been added to it. Losses
from LP heaters are relatively inexpensive.Typically, an assumption
is made that the loss is from the boiler drum, half at saturated
liquid condition and half at saturated vapour.
3-8
3.3.1.4 Turbine Efficiency
• SCAPH
• TDBFP
• Steam Jet Air Ejectors (SJAE)
• Steam supplied to/received from other units
3-9
• Misc. auxiliary steam headers
Periodically, ash samples can be collected from the bottom ash and
the carbon content of the ash determined. The unburned carbon
represents chemical energy that was supplied to the boiler, but
was not converted to thermal energy, extracted, rather it was lost.
To convert this to a heat rate deviation some assumption about
how much ash goes to fly ash and how much ash goes to bottom
ash must be made. Typically, for pulverized coal fired unit it is
assumed that 80 % of the ash in the coal goes to fly ash and 20 %
of the ash goes to bottom ash.
The exit gas temperature is one of the two parts of dry gas loss, the
energy that is lost out the stack. The temperature of the flue gas
leaving the air preheater is measured. The temperature at this
3-10
location is stratified; therefore it is important to measure the
temperature at enough locations forming a grid to get a
representative temperature. Quantity of gas and its temperature
at APH outlet is used in calculating this loss.
The other part of dry gas loss is the quantity of gas that leaves the
boiler. Normally, rather than directly measuring the amount of gas
flow, it is calculated from the O2 concentration of the gas and the
coal analysis. Due to air in-leakage in the convection pass, the
percentage of oxygen in the flue gas varies from point to point in
the duct. There are two methods used to determine the
representative O2 in the duct. First, multiple probes can be used.
(An advantage of this method is that if one probe fails, there are
other probes in the duct supplying the operator with information to
run the unit.) The second method is to periodically traverse the
duct sampling the flue gas at multiple locations, at different loads
or mill combinations. For each test, determine the average O2 in
the duct, and locate the station probe at a location that represents
the duct average under the different load or mill combinations.
3-11
issues, and then their “expected” value would be some value less
than the “design” value.) For a unit operating under “Variable
Pressure”, the “expected” value will vary as a function of the steam
flow to the turbine.
As with the Main steam pressure, this is measured just before the
turbine stop valves. If there are multiple lines between the super
heater outlet and the turbine, the temperature should be
measured in each, as there can be differences pipe to pipe.
3-12
deviation due to fuel burned prior to synchronization, the quantity
of fuel burned before the unit is synchronized is measured. If this
deviation and the deviation for “Station Service (Prorated) - Idle”
are subtracted from the actual heat rate, the result is the
“operating” heat rate.
The heat rate deviation due to auxiliary power usage is divided into
three areas: unit auxiliary power, station service-operation, and
station service-idle.
3-13
Other types of, errors include calculation procedure errors, i.e. the
calculated heat rate deviation of a 2% point change in HP turbine
efficiency could be different from the true heat rate deviation.
3-14
4. BASELINE FOR COMPARISION WITH THE
ACTUAL PERFORMANCE
To calculate a heat rate deviation for a parameter, its actual
value must be compared to some standard. There are several
options that may be used. They are
4.1 Design
4-1
Frequently, acceptance tests are run with the makeup
isolated, no soot blowing, no sluicing, etc.
• 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.
4-2
4.5 Current “Expected”
Note-
1. Where PG test is conducted in one unit the same
value can be taken for other similar units.
4-3
5. METHODOLOGY OF HEAT RATE DEVIATION
CALCULATION
5.2.1 Load
Note- Customized correction curves are to be developed with the help of math
modeling software.
5-1
DAILY HEAT RATE DEVIATION REPORT
STATION:
UNIT NO: DATE:
S. Parameter Unit Parameter Values Heat Rate Deviation
N Design Expe- Actual Varia- Daily Cumml.
cted nce Kcal/kWh Kcal/kWh
1 Load MW
Accountable HR Deviation
2 Main steam Press before ESV kg/cm2
3 Main steam Temp before ESV °C
4 Hot Reheat Temp before IV °C
5 Superheat Attemperation * t/hr
6 Reheat Attemperation * t/hr
7 Condenser Back Pressure * mm Hg
8 CW inlet temperature °C
9 Makeup Water % MCR
10 FW temperature at HPH O/L * °C
11 Dry Flue Gas loss (DFG)* %
Effect of Coal quality on DFG %
1) Oxygen at Eco Outlet %
2) APH Exit temperature °C
(Corrected)
3) APH Leakage %
12 Wet Flue Gas loss* %
1) Moisture in coal %
13 Combustibles in Fly ash %
14 Combustibles in Bottom ash %
15 Startup-Oil Consumption KL
16 HP Turbine Efficiency %
17 IP Turbine Efficiency %
18 Total (A) (Total Kcal/
Accountable HR Deviation) kWh
19 Unaccountable HR Dev ( B ) Kcal/
(Based on monthly Test) kWh
20 TOTAL HR Deviation (A+B) Kcal/
kWh
21 PG Test HEAT RATE at full Kcal/
load (C) kWh
22 DERIVED UNIT HEATRATE Kcal/
(A+B+C)= D kWh
23 REPORTED HEAT RATE = E Kcal/
(On The Basis Of Coal) kWh
24 DIFF OF (E-D) Kcal/
kWh
Note: -1. * - Value in Expected Column is based on Actual Load condition
2. Actual parameters used are 24 hours average value taken from DAS
3. Coal Analysis Used is based on the latest Proximate Analysis
4. For arriving at Unit Heat rate Deviation, Monthly tested Boiler Efficiency & GTCHR is taken
as reference.
Format-5.1
5-2
MONTHLY EFFICIENCY REPORT
PARAMETERS IMPACT ON HEAT RATE DEVIATION
STATION:
UNIT NO: MONTH : DATE:
Sr. Parameter Unit Average Kcal/ Remark
No Value kWh
Reasons For Deviations Action Plan
1 Load MW
Accountable HR Deviation
2 Main steam Press before ESV kg/cm2
8 CW inlet temperature °C
5-3
Sr. Parameter Unit Average Kcal/ Remark
No Value kWh
Reason with date Action Plan
12 Wet Flue Gas loss %
15 Startup-Oil Consumption KL
16 HP Turbine Efficiency %
17 IP Turbine Efficiency %
Format-5.2
5-4
5.2.2 Main Steam Pressure
Note- Customized correction curves are to be developed with the help of math
modeling software.
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 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 developed by station. Till such time the
customized correction curve is not available the correction curve
provided by manufacturer may be used.
Note- Customized correction curves are to be developed with the help of math
modeling software.
5-5
0
Variance (Exp. - Act. M.S Temp.) = -7.52 C
HR Deviation =(2000/(86.8/100))*(1-0.998)
= 4.6 kcal/kWh
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 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 developed by station.
Till such time the customized correction curve is not available the
correction curves provided by manufacturer may be used.
Note- Customized correction curves are to be developed with the help of math
modeling software.
HR Deviation = (2000/(86.8/100))*(1-0.998)
= 4.6 kcal/kWh
5-6
taken for Heat rate deviation calculation based on customized correction
curves developed by station.
Till such time the customized correction curve is not available the
correction curves provided by manufacturer may be used. Corrections for
S/H spray is to be applied in case tapping of S/H Spray is taken form the
location before HPH heater.
Note- Customized correction curves are to be developed with the help of math
modeling software.
HR Deviation = (2000/(86.8/100))*(1-0.999)
= 2.34 kcal/kWh
Note- Customized correction curves are to be developed with the help of math
modeling software.
5-7
Actual R/H Attemperation = 18 t/hr
Variance (Exp. – Act. R/H Attemp) = -12 t/hr
= -2% of Main Steam Flow
Turbine HR Correction Factor = 0.9968 From Curve
Monthly Tested Turbine HR = 2000 Kcal/kWh
Monthly Tested Boiler η = 86.8 %
HR Deviation =(2000/(86.8/100))*(1-0.9968)
= 7.37 kcal/kWh
Note- Customized correction curves are to be developed with the help of math
modeling software.
HR Deviation =(2000/(86.8/100))*(1-0.995)
= 11.52kcal/kWh
5-8
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. Till such times the customized
curve are available the correction curves provided by manufacturer may
be used.
Till such time the customized correction curve is not available the
correction curves provided by manufacturer may be used.
Note- Customized correction curves are to be developed with the help of math
modeling software.
HR Deviation =(2000/(86.8/100))*(1-0.99)
= -23 kcal/kWh
5.2.9 DM Makeup Water
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
5-9
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. DM Makeup) = -100 tones
H (Dev) = 0.5*(850-40)+0.5*(250-40)
HR Deviation = (100*510*1000)/4.032/1000000
= 12.65 kcal/kWh
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 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
developed by station.
Till such time the customized correction curve is not available the
correction curves provided by manufacturer may be used.
Note- Customized correction curves are to be developed with the help of math
modeling software.
5-10
HR Deviation = (2000/(86.8/100))*(0.996-.995)
= 2.30kcal/kWh
5-11
5.2.11.3 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.
5.2.11.4 Proximate analysis of coal
Last tested proximate analysis shall be used.
5.2.11.5 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.
5.2.11.6 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.
- TOTAL MOISTURE = M %
- ASH = A %
- VOLATILE MATTER = VM %
- FIXED CARBON = FC %
-------------------
TOTAL - 100 %
5-12
Ndf(T) = Nitrogen On Dry Ash Free Basis
= [ 2.1 - ( 0.012 * VmDf(T)]
Where
Rsa - Ratio SA flow to Total Air flow = Fsa/Fta
Rpa - Ratio PA flow to Total Air flow = Fpa/Fta
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 basis
5-13
CO2 % at AH Outlet
Where
Pfa/Pba - % of ash in fly ash and bottom ash respectively
Cfa/Cba - % Unburnt in fly ash and bottom ash respectively
Where
Ca = % Carbon in fuel
S = % Sulfur in fuel
U = Carbon in ash / kg of fuel
CO2 = % Carbon dioxide at AH outlet
Where
Cp = Specific heat of gas kg/kg/C
Tgo = Avg. Flue Gas Temp at AH Out
Sample calculation
Moisture = 12.2 %
Ash = 40 %
Volatile Matter = 22.9 %
5-14
Fixed Carbon = 24.9 %
Gross Calorific Value = 3320 %
Leakage = 10 %
AH Inlet Oin (Wet) = 2.7 %
Moisture in Flue Gas = 10 %
5. Carbon in ash
5-15
6. Weight of dry gas (Wd) = (Ca+S/2.67-100*U)/
(12*CO2out)
= 0.2314 kg/kg of coal
Dry Gas Losses Corrected for Ambient air And Design Coal
= 4.71 %
HR Deviation = (2000/(86.8-0.33)/100)-
(2000/(86.8/100))
= 8.8 kcal/kWh
5.2.13 Wet Flue Gas Loss
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.
5-16
=2602 KJ/kg
HR Deviation = (2000/(86.8-1.82/100) –
(2000/(86.8/100))
= 49.3 kcal/kWh
Sample Calculation
Ash % = 40 %
GCV = 3320 Kcal/kg
Expected Unburnt in Fly Ash = .5 %
Actual Unburnt in Fly Ash = 0.4 %
Variance (Expected - Actual Unburnt in Fly Ash) = -0.1 %
5-17
Monthly Tested Turbine HR = 2000 kcal/kWh
Monthly Tested Boiler η = 86.8 %
Change in Boiler Efficiency with change in Flyash Unburnt = -0.062 %
HR Deviation = (2000/((86.8-0.062)/100))-(2000/(86.8/100))
= - 1.65 kcal/kWh
Sample Calculation
Expected Unburnt in Bottom Ash = 2%
Actual Unburnt in Bottom Ash = 2.5 %
Variance (Expected – Actual Unburnt in Bottom ash)
= 0.50 %
HR Deviation = (2000/((86.8-0.077)/100))-(2000/(86.8/100))
= 2.07 kcal/kWh
5-18
Day Generation = 4.0 Mus
HR Deviation = 10*10/4
= 25 kcl/kWh
HR Deviation = 0.2/100*(2000/(86.8/100))
= 4.6 kcal/kWh
5-19
Monthly Tested Turbine HR = 2000 Kcal/kWh
Monthly Tested Boiler η = 86.8 %
HR Deviation = 0.2/100*(2000/(86.8/100))
= 4.6 kcal/kWh
Monthly Heat rate = (Sum of product of daily Heat rate & daily
Generation) / (Total generation of the month)
5-20
6. PERIODIC TESTING WITH ON LINE
INSTRUMENT
6.1 Introduction
6-1
6.2 Types of Tests
6.2.1.1 Purpose
6.2.1.2 Frequency
Time based, typically 6 monthly, but the other triggers can take
precedence:
6.2.2.1 Purpose
6.2.2.2 Frequency
Time based, typically every month, but other triggers can take
precedence:
• High condenser back pressure
• Pre and post tube cleaning
• High water box dP
6-2
• Excessive CW temperature rise
6.2.3.1 Purpose
6.2.3.2 Frequency
Time based, typically every month, but the other triggers can take
precedence:
• High TTD
• High DCA
• High drain temperature
• Low FW temperature
• Excessive tube bundle pressure drop
6.2.4.1 Purpose
6.2.4.2 Frequency
Time based, typically every 12 months, but the other triggers can
take precedence:
6-3
• Before and after pump or hydraulic coupling overhauls
• High Balancing Drum Leak Off (BDLO) pressure.
• Abnormal difference in the motor current on two pumps at
the same flow.
• Abnormal difference in the flow of two pumps at the same
motor current.
• Change in the flow/motor current ratio
• High power usage recorded during a Unit Auxiliary Power
Consumption Test
6.2.5.1 Purpose
6.2.5.2 Frequency
Time based, typically every 6 months, but the other triggers can
take precedence:
6.2.6.1 Purpose
6.2.6.2 Frequency
Time based, typically every month, but the other triggers can take
precedence:
• Before and after turbine overhauls
• Increase or decrease in steam flow at constant turbine
control valve position
• Abnormal first stage pressure
• High extraction temperatures
• High Condenser heat load
• Increase in ‘unaccountable” heat rate deviation
6-4
6.2.7 Primary Air Flow Calibration
6.2.7.1 Purpose
6.2.7.2 Frequency
6.2.8.1 Purpose
6.2.8.2 Frequency
6-5
• Large O2 spread at AH inlet to maintain equal steam
temperatures.
• High content of combustibles in fly ash
• Poor flame appearance
6.2.9.1 Purpose
This test is useful for calculating Air ingress in the various section
of the boiler
Detect pressure drop at the various section of FG duct
Detect reason for gas loading ESP
Detect Leakages in APH
6.2.9.2 Frequency
Time based, typically after every year before and after the unit
overhaul, but the other triggers can take precedence:
6.2.10.1 Purpose
6.2.10.2 Frequency
Time base once in a month, but the other triggers can take
precedence
• Prior to unit outages to determine whether corrective action
is required to maintain optimum air heater performance
6-6
• AH tests are done following outages to assess improvement
in air heater performance on account of work done on the air
heater.
6.2.11.1 Purpose
6.2.11.2 Frequency
Time base once in a month, but the other triggers can take
precedence
6.2.12.1 Purpose
6.2.12.2 Frequency
Time base twice in a year and one of them in the period between
July to September, but the other triggers can take precedence
• High condenser pressure
• Increase in CW temperature
6-7
6.3 TESTING FREQUENCY
6-8
7. INSTRUMENTATION
In order to operate power plants efficiently, the operators must
have reliable and accurate information on the unit. Small errors in
sensors can result in large “unaccountable” heat rate deviations.
For example, if the unit is “expected” to operate at 538°C steam
temperature at the turbine stop valves, but the instrumentation is
indicating 3°C higher than the actual temperature, the unit will
operate with the steam temperature 3°C low, resulting in a heat
rate deviation of around 2.5 kcal/kWh. Same is applicable to the
reliability of the test results if accuracy of the instrument that is
used to collect the raw data is not up to the mark. In fact the
standard codes emphasize this to the point that pre and post test
calibrations are required for many instruments. Another
important part of an instrument calibration program is the quality
of the calibration facility and the personnel who work there. This
must also be considered in the calibration procedure.
7.2 Temperature
Temperature Measurement
Thermocouples are more used because of their low cost and high
reliability. RTDs, while much more accurate, have not been used
widely (until recently) due to their higher cost and poorer
reliability.
7-1
In recent years, the reliability of RTDs has improved greatly and,
while still not as durable as a thermocouple, the higher accuracy
has made the higher cost acceptable.
7.2.1 Thermocouples
7.2.2 RTDs
7.3 Flow
“L” type pitots are used for measuring clean airflows in small
ducts or pipes (such as is done in a pulverizer clean air tests, etc.).
7-2
For measuring air or gas flows in large ducts (or in small ducts
with large concentrations of particulates) “S” type pitots should are
used.
For performance testing, the gases that are measured in flue gas
are carbon dioxide (CO2), oxygen (O2), and carbon monoxide (CO).
Accurate, reliable, and fast gas analyzers are necessary to analyze
for these gases. For many years, the use of an Orsat was the
standard, and Orsats are still used today for checking single point
measurements. However, when running a test, an Orsat is not
sufficient to perform the number of analyses necessary in a
reasonable amount of time. Various types of portable electronic
7-3
analyzers are available. Chemical cell analyzers are frequently
used, but they must be used with caution, as the cell must be
replaced periodically as it exhausts. More accurate analyzers,
which use a paramagnetic sensor for O2 and infrared sensors for
CO2 and CO, are better choices. (Portability aspect may be
reviewed.)
Gas analyzers for CO, O2 and CO2 etc. should be checked with
standard gases of different concentration every year.
However, the gas analyzers need to be checked for calibration
before the start of the test for correcting the drifts if any.
7-4
7.6 Additional Equipment
7-5
8.
8-1
9. HEATRATE ACTION PLAN
9.1 Preparation of action Plan
The second step is to rank all known areas where heat rate
deviations exist from the largest to the smallest, and calculate the
cost of each.
The fourth step, taken after the root cause is determined, is to list
what options are possible, calculate the cost and benefits of each,
and determine the best course of action. For example if the
efficiency of a turbine section is down, there are several options
available, each option will cost a different amount, and each option
will have different benefits.
9-1
In addition to the description of the activity, a measurable process
indicator should be listed with its current value, the anticipated
change or target value, and the method of verification. For
example, for the activity “Replace Air Heater Seals, and Set to
Design Clearances,” the process indicator might be “Air Heater
Leakage.” The current value might be 20% and the target (post
replacement) value might be 12%, and this would be verified by a
post outage test.
Once the plan is developed for each unit, roll-ups can be made to
determine target heat rates for groups of units. For example if a
plant is composed of both 200 and 500MW units, in addition to the
target heat rate for each unit, a target heat rate for the 200 MW
9-2
units and a target heat rate for the 500 MW units can be
calculated by weight averaging the individual heat rates by the
projected net generation for each unit. A target heat rate can be
calculated in a similar fashion for the entire plant.
Each station is to fix heat rate for the financial years. This target
document should include action plan for likely improvement in
heat rate at the start of the year.
9-3
10. REPORTING SYSTEM AND FORMATS
10.1 Information Flow
Like any other programme, key ingredient to the success of any efficiency
improvement activity is continuous and free information flow within the
utility structure. Communication must occur from Top down as well as
from the bottom up in the organization. Corporate objective must be
translated into specific goal, which plant personnel can understand and
provide clear guidance for achieving these performance improvement
goals.
EEMG has a responsibility to ensure the information flows from the plant
to region and to corporate management. Performance related data should
be consolidated and reported regularly to higher management in a format
which can be readily interpreted. The following mechanism of
communication can be effective in enhancing information flow.
10-1
Regional-HQ as per the requirement or as well as to produce to the MIS
reports for the management.
Regional PPB will review the monthly Heat rate Deviation Reports, Result
of tests carried out at the stations and the action plan of stations of the
region. After review, region will put up the exception report to regional
ED and Concerned group at corporate center. Regional ORT coordinator
will discuss the action plan during ORT.
Corporate CenPEEP will review the exception reports of all the regions
and after review a report will be put up to the management for their
consideration.
10-2
MONTHLY EFFICIENCY REPORT FORMAT NO-10.1
STATION : MONTH : DATE Of Report
S.N Test PG / Design UNIT • Unit--1 Unit-2 Unit-3 Unit-4 Unit-5 Unit-6 Unit-7
1 Boiler Efficiency Test Test Date
Boiler η %
Un burnt C η Loss %
10-3
MONTHLY EFFICIENCY REPORT
ACTION PLAN FOR HEAT RATE DEVIATION DUE TO EQUIPMENT & SYSTEM
STATION: MONTH:
DATE:
Boiler
Efficiency START END
Test
Turbine
Heat rate
Test
Condense
r
Performa
nce test
APH
Performa
nce Test
Turbine
Efficiency
Test
CT
Performa
nce Test
Format no-10.2
10-4
Regional Exception Reports
REGION:
REPORT OF MONTH:
DATED:
Format no –10.3
10-5
11. EEMG STRUCTURE AND RESPONSIBILITY
The activities related to performance improvement & monitoring shall be
looked after by “Centre of Excellence for Efficiency” (CEE) group
within Corporate CenPEEP. The structure & responsibilities of
performance related activities at Station, Region and Corporate Centre
shall be as given below.
Station Head
PPB CEETEM
11-1
11.1.1 EEMG Responsibilities – PPB at Station
11-2
• Trip analysis
• Oil , Coal Accounting & Survey
• MIS Reports
Structure at Region
ED (Region)
Head of OS
Regional
CenPEEP
Station Performance
Monitoring Management
and Support Systems
Group Group Regional CenPEEP
(SMSG) (PMSG) PPB Activites
MIS
related
to EEMG
11-3
11.2.1 Responsibilities – PPB at Region
Following are the activities proposed to be carried out for all the Stations
in the region:
11-4
Structure at Corporate
D(O)
Regional
OS
Knowledge
Operation CenPEEP team for
Services
EEMG
Technical
Support & CenPEEP Centre of
MIS related Activities Excellence for
to EEMG Efficiency (CEE)
11-5
• Training to executives
• Follow up and interaction with POGs
• Issues to be taken up with Engg. (Like test instruments, test ports
etc.)
• New techniques and systems
• Plant performance audit
11-6
12. TOOLS
12.1 Introduction
This section discusses the “tools” that should be readily available with
PPB group, who are responsible for monitoring the thermal performance
of a unit. Many of the necessary tools have already been discussed in
detail in other sections of this manual, such as detailed test procedures
for major equipment, generic heat rate logic trees, calculation procedures
for determining the impacts of various parameters on unit performance,
etc. This section discusses additional tools that should be at the
disposal of the “performance engineer.” Some of this information is
contained in “Technical Diaries or Plant Detail Books” that are developed
for a particular project, but for detailed analysis of thermal performance,
additional data must be available.
Another curve (or family of curves) that is given is the generator loss
curves. These curves represent the amount of energy loss in the
generator. The turbine produces a certain torque on the shaft, and the
generator converts 98-99% of that energy to electrical energy. The other
1-2% is “generator losses”, which includes both mechanical and electrical
losses. The amount of loss is given in different formats
Sometimes the fixed losses are included in the curve, and sometimes it is
tabulated.
12-1
Since the losses also vary with the hydrogen pressure, sometimes a
family of curves is given for various hydrogen pressures, sometimes an
additional curve is given with a correction factor as a function of the
hydrogen pressure.
When the steam passes through the last row of rotating blades in the LP
turbine, it has a very high velocity (kinetic energy). As it turns down and
slows, this kinetic energy is converted to an increase in enthalpy. The
enthalpy of the steam leaving the last row of blades is called the
Expansion Line End Point (ELEP). The enthalpy of the steam that is
condensed in the condenser is the Used Energy End Point (UEEP). The
difference between these two is the exhaust loss. (It also includes losses
due to friction, and for very low velocities a rotational loss.)
These curves are usually plotted one of two ways. First, as a single curve
as a function of the velocity of the steam (the velocity must be calculated
using the mass flow, and the specific volume of the steam and the
annular area). The second type of plot is of a family of curves versus
exhaust flow, with each curve for a different condenser pressure.
To determine the flow from turbine gland leakages and from valve stem
leakages. For each gland or valve stem leakage, a “packing constant” is
usually given, again where the leakage flow is calculated by multiplying
the constant by the square root of the pressure divided by the specific
volume Q = C * √(p/v). Occasionally, instead of specifying packing
constants, these flows will be given as a curve as a function of the
pressure ahead of the leakage.
12-2
below, along with the information from the thermal kit, should be
collected into a single notebook.
Usually, several heat balance diagrams are provided for a range of steam
flows and condenser pressures. Occasionally, some additional heat
balance diagrams are also provided to some special conditions, such as
the HP heater out of service, or over pressure. Additionally, if a
thermodynamic model is built for the plant, additional diagrams will be
generated. All these should be kept together.
The performance engineer should have a full set of flow or P&ID drawings
showing all steam, water, air and flue gas streams. These drawings
should include pipe sizes, locations of station instruments and test
points.
In order to evaluate the performance of large pumps and fans, the curves
of head, power and efficiency versus flow should be provided, along with
supplemental data such as the speed(s) for which the curve(s) were
drawn, the temperature, pressure and density for the fluid, impeller size,
etc. It is preferable to have curves based on tests, but that is not always
possible, especially for large pumps. The pumps and fans for which
curves should be available include:
Pumps Fans
Boiler Feed water Forced Draft
Boiler Feedwater Booster Primary Air
Condensate Extraction Induced Draft
CW pump
12-3
Some boiler feedwater pumps have a balancing drum leakoff that
includes an orifice for measuring the leakoff flow. If the pumps have this
design, there should be a curve provided showing the relationship
between the differential pressure and the flow rate.
This information should be collected and tabulated in one location for all
flow elements such as:
12-4
• Effective surface area(s)
• Design conditions (temperature, pressure and flow rates) of each
stream in and out
• Design Performance (TTDs, DCA, temperature rises, LMTDs, etc.)
• Pressure drop on the water side ands in each zone on the shell side
Most local pressure gauges and pressure transmitters do not read the
true pressure of the steam/water. Instead, they read slightly higher, due
to the water that fills the impulse tubing between the pipe and the
instrument. For normal operation, the difference usually is not
significant, but for high accuracy measurements, it can be. In order to
be able to correct for these “water legs,” a table should be maintained
that lists either:
12-5
12.2.14 Control System Logic Diagrams/Controller Set Points
The previous information has all been “design” data. While it is useful, it
does not represent the actual initial condition and operating
characteristics of the unit. That is why it is imperative that the
performance guarantee tests should do much more than just settle
contractual issues. It is the best opportunity to collect high quality data
on the unit, to which future operating data and performance will be
compared.
Also, any time a test is run on the unit, a test report with not only a
summary of the results and recommendations, but also containing all
data, should be issued and kept. In addition, a computer database can
be made for storing and trending the results of “routine” performance
tests, such as turbine efficiency, condenser performance, auxiliary power
usage, air heater leakage, pulverizer fineness, etc.
A valuable resource for future years is to record data from every station
instrument, at various loads, immediately after the unit achieves steady
operation. This includes all points on the DAS (if applicable), as well as
local gauges.
One use of such data is when there are any very slow, gradual changes
in the performance of the unit, that may not be noticed. However, when
current data is compared to the data when the unit was new, any
gradual changes in performance will become apparent.
With the advent of low cost computers and storage media, it is cost
effective to collect and retain large amounts of operating data. A detailed
12-6
data storage strategy should be developed. For example some critical
DAS data might be kept complete (every value from every scan) for 6
months, then reduced to hourly average/maximum/minimum, and these
three hourly values retained for 2 years, then only daily averages
retained after that. Other data might be reduced to daily averages each
day, and those might be retained for a few months only.
Each time the boiler is inspected (wall thickness readings taken, tube
samples cut out, etc.) the reports on what was found, recommendations,
etc., should be published and made available to the performance
engineer.
The performance engineer should have access to the as-found and as-left
seal clearances of the air heater, for comparison to the results of leakage
tests.
With the large number of valves that can contribute to cycle isolation
problems, having a database of which valves have caused problems in
the past is useful to help determine where to look first, or which valves
should be monitored continuously (because they frequently leak) and
which may only require periodic monitoring. Also, if the database
12-7
includes the type of valve, then there may be some correlation between
the valve type (or manufacturer) and frequency of leaks.
12-8
13. (Appendix-E) HEAT RATE LOGIC TREE
HEAT RATE
LOSSES
PERFORMANCE FACTOR
A B C D
CONDENSER HP/IP/LP
FEEDWATER TEMPERATURE
BOILER EFFICIENCY BACKPRESSURE EFFICIENCIES
DIFFERENCE
EXIT GAS TEMPERATURE CIRCULATING WATER INLET STEAM FLOW
AIR HEATER TEMPERATURE TEMPERATURE GENERATOR
DIFFERENCE OUTPUT'
EXCESS AIR W/ P/v
E F I G H
STATION LOAD BOILER FEEDPUMP EFFICIENCY SYSTEM WALKDOWN SYSTEM WALKDOWN SYSTEM WALKDOWN
VACUUM PUMP FLOW FUEL INVENTORY CHECKS PYROMETER HIGH PIPE WALL
TEMPERATURES
DOWNSTREAM OF ISOLATION
VALVES
STEAM TRAP CHECKS
13-1
BOILER LOSSES A
BOILER EFFICIENCY
EXIT GAS TEMPERATURE
AIR HEATER TEMPERATURE DIFFERENCE
EXCESS AIR
EXCESSIVE SOOT CHANGE IN BURNER TIPS INCORRECT INCORRECT GAS FOULED HEAT
AMBIENT CHANGE IN COAL BYPASS DAMPER TRANSFER
BLOWING PLUGGED FUEL-TO-AIR
CONDITIONS QUALITY SETTING SURFACES
RATIO
DECREASED EXIT GAS TEMP CHANGE IN RELATIVE COAL COMPOSITION BYPASS DAMPER POSITION
INCREASED MAIN STEAM TEMP HUMIDITY ANALYSIS
INCREASED SUPERHEATER SPRAY
FLOW
INCREASED CONDENSATE MAKE-UP
INCREASED MAKEUP FLOW DECREASED MILL OUTLET INCREASED H 2 CHANGE IN COAL DECREASE IN PRIMARY AIR SIEVE TEST DECREASED O 2 1
TEMPERATURE INCREASE IN INTERNAL CARBON CONTENT FLOW INCREASED WIND BOX
DECREASED STACK
INCREASED MILL MOISTURE PRESSURE
TEMPERATURE
CURRENT DRAW INCREASED STACK GAS INCREASED STACK GAS
PRECIPITATOR EFFICIENCY
INCREASED PRIMARY AIR TEMPERATURE TEMPERATURE
PRECIPITATOR CURRENT
TEMPERATURE INCREASED FURNACE
DRAW
DECREASED STACK GAS PRESSURE DROP
STACK OPACITY
TEMPERATURE EXCESS 0 2 (NORMAL)
BOILER WATER
WALLS SUPERHEATER AIR PREHEATER REHEATER ECONOMIZER
INCREASED MAIN STEAM DECREASED MAIN STEAM LOW EXIT AIR DECREASED ECONOMIZER
TEMPERATURE TEMPERATURE DECREASED HOT REHEAT OUTLET TEMPERATURE
TEMPERATURE
INCREASED SUPERHEATER DECREASED SUPERHEATER TEMPERATURE INCREASED MAIN STEAM
NORMAL INLET AIR AND
SPRAY FLOW SPRAY FLOW DECREASED REHEAT SPRAY FLOW TEMPERATURE
GAS TEMPERATURES
INCREASE IN AIR HEATER INCREASED SUPERHEATER
DELTA-P (PLUGGAGE) SPRAY FLOW
DECREASE IN AIR HEATER
DELTA-P (EROSION)
13-2
DRY GAS LOSSES 2A
IMPROPER INCORRECT
BOILER CASING AIR BURNER DAMPER AIR PREHEATER
IN-LEAKAGE LEAKAGE FUEL-TO-AIR RATIO
SETTINGS
13-3
TURBINE CYCLE
B
LOSSES
INCREASE IN TTD
INCREASE IN DCA
DECREASED FEEDWATER
TEMPERATURE RISE
CHANGE IN FEEDWATER
INCREASED TUBE
DECREASED FEEDWATER HEATER LEVEL
INCREASED TUBE BUNDLE BUNDLE PRESSURE DROP
OUTLET TEMPERATURE DECREASED FEEDWATER
PRESSURE DROP DECREASED EXTRACTION
DECREASED EXTRACTION OUTLET TEMPERATURE
DECREASED EXTRACTION PRESSURE DROP
PRESSURE DROP CYCLING OF EMERGENCY DRAIN
PRESSURE DROP GRADUAL CHANGE IN
VALVES
STEP CHANGE IN FEEDWATER FEEDWATER OUTLET
OUTLET TEMPERATURE TEMPERATURE
INCREASED DRAIN
INCREASED EXTRACTION DECREASED FEEDWATER OUTLET DECREASED DECREASED FEEDWATER
COOLER OUTLET
PRESSURE DROP TEMPERATURE ECONOMIZER INLET OUTLET TEMPERATURE
TEMPERATURE
DECREASED FEEDWATER HIGH FEEDWATER HEATER LEVEL TEMPERATURE DECREASED TUBE
LOW FEEDWATER
OUTLET TEMPERATURE DECREASED DRAIN COOLER OUTLET BUNDLE PRESSURE
HEATER LEVEL
TEMPERATURE DROP
INCREASED DRAIN COOLER OUTLET
PRESSURE
13-4
COOLING WATER
C
CYCLE LOSSES
CONDENSER BACKPRESSURE
CIRCULATING WATER INLET TEMPERATURE
INCREASED HEAT
CHANGE IN AMBIENT LOW CIRCULATING
AIR IN-LEAKAGE TUBE CLEANLINESS LOAD ON
CONDITIONS WATER FLOW
CONDENSER
DEGRADATION OF CHANGE IN AMBIENT UNEQUAL FLOW IMPROPER FILL INADEQUATE FAN INADEQUATE DECREASED FAN
INADEQUATE CELLS RECIRCULATION
FILL MATERIAL CONDITIONS DISTRIBUTION MATERIAL CAPACITY CHEMICAL CONTROL EFFICIENCY
FIGURE E-5. HEAT RATE LOGIC TREE - COOLING WATER CYCLE LOSSES
13-5
TURBINE LOSSES D
DECREASE IN LP POWER DECREASE IN REHEAT DECREASE IN HP EFFICIENCY DECREASE IN REHEAT REHEATER PRESSURE DROP
OUTPUT TURBINE EFFICIENCY DECREASE IN REHEAT FLOW PRESSURE DROP CHANGE IN REHEAT
DECREASE IN IP-2 DECREASE IN REHEAT DECREASE IN REHEAT TURBINE EFFICIENCY
SECTION EFFICIENCY IP PRESSURE DROP TURBINE EFFICIENCY INCREASED EXIT GAS TEMP.
DECREASE IN REHEAT FLOW
OPERATING
THERMAL STRESS RUBBING VIBRATION EXFOLIATION CYCLING
PRACTICES 3
13-6
LOSS DUE TO
E
ELECTRICAL
AUXILIARIES
CONTINUOUS
PRECIPITATOR RUNNING OF
PUMP EFFICIENCY MILL PERFORMANCE
PERFORMANCE NONCONTINUOUS
LOADS
PUMP DISCHARGE FLOW VIBRATION MONITORING HIGH VOLTAGE MILL FINENESS COAL MOISTURE
PUMP CURRENT DRAW COAL GRINDABILITY
BLADE PITCH INCREASED FLOW CHANGE IN AMBIENT OUTLET DAMPER EXCESSIVE AIR
EXCESSIVE DRIFT EXCESSIVE AIR SHAFT RUB
INCORRECT PATH RESISTANCE AIR CONDITIONS SETTINGS LEAKAGE
IN-LEAKAGE
INCORRECT
MAKEUP INCREASED WET BULB TEMPERATURE VIBRATION MONITORING
RELATIVE HUMIDITY O2MEASUREMENTS DAMPER POSITION
INLET DAMPER
SHAFT RUB SETTINGS SHAFT RUB BLADE EROSION SHAFT RUB
INCORRECT
CHANGE IN FLOW
EXCESSIVE AIR PATH RESISTANCE
HEATER LEAKAGE
FURNACE PRESSURE DROP
AIRHEATER PRESSURE DROP
O2 MEASUREMENTS PRECIPITATOR PRESSURE DROP
13-7
LOSSES DUE TO
STEAM AUXILIARIES F
BFP EXTRACTION
INCREASE IN
RECIRCULATION LINE EXCESSIVE SHAFT LOW INLET STEAM INCREASE IN REHEAT HIGH EXHAUST BACK DAMAGED TURBINE LINE CHECK VALVES
SUPERHEATER
OPEN LEAKAGE TEMPERATURE SPRAY FLOW PRESSURE BLADES OR NOZZLES STUCK OR PARTIALLY
SPRAY FLOW
OPEN
HEAT LOSSES
G
FIGURE E-8. HEAT RATE LOGIC TREE - STEAM AUXILIARY, FUEL HANDLING, AND HEAT LOSSES
13-8
CYCLE ISOLATION H
RECOVERABLE NON-RECOVERABLE
LOSSES LOSSES
3 INCREASED MAKE-UP
LEAKAGE THROUGH
LEAKAGE FROM DEAERATOR LEAKAGE THROUGH
HEATER TO HEATER LEAKS TO THE CONSTANT FEEDWATER HEATER BOILER FEED PUMP LEAKAGE THROUGH
LEAKS TO THE
THROUGH BYPASS CONDENSER PRESSURE STEAM BYPASS LINES SEAL INJECTION BYPASS LINES
DEARATOR
LINE SUPPLY LINE
INCREASED BFP OUTLET
TEMPERATURE
A1 B1
LEAKAGE THROUGH
BFP 1 GLAND STEAM LEAKAGE THROUGH
LEAKAGE THROUGH LEAKAGE THROUGH
LEAKAGE TO THE #1 LEAKS TO THE #2 I.P. DESUPERHEATER SPILLOVER CONTROL
BFP A MINIMUM BFP B MINIMUM FEEDWATER HEATER FEEDWATER HEATER
I.P. MANIFOLD MANIFOLD CONTROL VALVE VALVE BYPASS
FLOW FLOW #3 BYPASS LINES #5 LINES
BYPASS
C1 D1
LEAKAGE THROUGH
LEAKAGE TO THE LEAKAGE TO THE LEAKAGE THROUGH LEAKAGE THROUGH
GLAND STEAM HP
LOW PRESSURE TURBINE DRAIN FEEDWATER HEATER SPILLOVER CONTROL
SUPPLY CONTROL
MANIFOLD MANIFOLD #6 BYPASS LINES VALVE BYPASS
VALVE BYPASS
E1 F1
13-9
NON-RECOVERABLE
3 LOSSES
LEAKAGE THTROUGH
LEAKAGE THROUGH LEAKAGE THROUGH LEAKAGE THROUGH LEAKAGE THROUGH LEAKAGE THROUGH LEAKAGE THROUGH
VALVE PACKING LEAKAGE THROUGH GLAND STEAM
CONDENSER VACUUM 2" DRAIN LINE FROM 2" DRAIN LINE FROM 2" DRAIN LINE FROM HOT REHEAT SAFETY COLD REHEAT
LEAKS CONDENSER DRAINS HEADER SAFETY
BREAKER #1 HEATER HEATERS 5 & 6 HEATERS 2 & 3 VALVE SAFETY VALVES
VALVES
LEAKAGEH THROUGH LEAKAGEH THROUGH LEAKAGE THROUGH LEAKAGE THROUGH LEAKAGE THROUGH
LEAKAGE THROUGH LEAKAGE THROUGH
FEEDWATER HEATER FEEDWATER HEATER FEEDWATER HEATER FEEDWATER HEATER FEEDWATER HEATER LEAKAGE TO BOILER LEAKAGE THROUGH
BFP A SEAL DRAIN BFP B SEAL DRAIN
#1 VENTS AND #2 VENTS AND #3 VENTS AND #5 VENTS AND #6 VENTS AND BLOWDOWN TANK STEAM TRAP DRAINS
LINE DRAIN LINE DRAIN
DRAINS DRAINS DRAINS DRAINS DRAINS
H1 H1 H1 H1 H1 G1 H1 H1 H1
LEAKAGE THROUGH
LEAKAGE THROUGH
EMERGENCY DRAIN LEAKAGE THROUGH
CONDENSATE,
LINE DRAINS AND COLD REHEAT DRAIN
DRAINS
VENTS
13-10
LEAKS DIRECTLY TO
THE CONDENSER A1
LEAKAGE OR LEAKAGE OR
EXCESSIVE FLOW EXCESSIVE FLOW LEAKAGE THROUGH
CYCLING OF HEATER CYCLING OF HEATER
THROUGH HEATER #2 THROUGH HEATER #3 BFP A GLAND STEAM
#5 EMERGENCY #6 EMERGENCY
VENT ORIFICE VENT ORIFICE SUPPLY DRAIN TRAP
DRAIN DRAIN
13-11
LEAKAGE
TO LOW PRESSURE
E1
MANIFOLD
LEAKAGE THROUGH
FEEDWATER HEATER H1
VENTS AND DRAIN
13-12
LEAKAGE
TO BOILER
BLOWDOWN TANK G1
13-13
LEAKAGE TO
LP. #1
MANIFOLD C1
LEAKAGE THROUGH LEAKAGE THROUGH LEAKAGE THROUGH LEAKAGE THROUGH LEAKAGE THROUGH
BFP 6A H.P. STEAM BFP 6B H.P. STEAM BFP 6A LP STEAM BFP 6B LP STEAM COLD REHEAT DRAIN
SUPPLY DRAIN SUPPLY DRAIN SUPPLY DRAIN SUPPLY DRAIN
STEAM TRAP LEAK IN STEAM TRAP LEAK IN EXCESSIVE FLOW EXCESSIVE FLOW LEAKAGE THROUGH
DEAERATOR DEAERATOR THROUGH H.P. SEAL THROUGH L.P. SEAL BFP 6A
EXTRACTION LINE ISOLATION LINE STEAM SUPPLY STEAM SUPPLY L.P. STEAM TRAP
DRAIN DRAIN ORIFICE ORIFICE BYPASS VALVE
LEAKAGE THROUGH
LEAKAGE THROUGH STEAM TRAP LEAK IN DEAERATOR EXTR. STEAM TRAP LEAK IN LEAKAGE THROUGH LEAKAGE THROUGH LEAKAGE THROUGH LEAKAGE THROUGH
LINE #6 EXTRACTION LINE STEAM TRAP LEAK DEAERATOR #5 EXTRACTION LINE #6 EXTRACTION LINE COLD REHEAT DRAIN
BFP 6B #5 EXTRACTION LINE
STEAM TRAP ISOLATION VALVE IN COLD REHEAT ISO VALVE STEAM STEAM TRAP STEAM TRAP LINE STEAM TRAP
LP, STEAM TRAP ISOLATION VALVE
BYPASS VALVE DRAIN BYPASS VALVE TRAP BYPASS VALVE BYPASS VALVE BYPASS VALVE BYPASS VALVE
BYPASS VALVE DRAIN
LEAKAGE TO
LP. #2 D1
MANIFOLD
13-14
15