Efficiency monitoring

BY:
M A H E S H K U M A R
M A D H U R S A H R A W A T
A N I L B I S H T
 Overview

 HPHs Performance monitoring

 D/A pressure control at low load
 Analysis of condensor peformance(Stage-I)
 Use of PADO
 Proactive actions
 HPH performance

 C&I pursued to display HPH performance parameters in all units.

 HPHs performance parameters displayed at HPH screen in all units for
ready availability of parameters along with their design data.
 LPHs temperature rise(TR) displayed in stage-II units.

Heaters Performance
Impact on Heat Rate
Parameters
Terminal
(Saturation temp of steam extraction
Temperature pressure (Abs)-Feed water Outlet Temp)
Improvement in GTCHR by 1kCal/ 1 Degree
Difference (TTD)

Drain Cooler
(Heater Drip outlet temp- FW inlet temp) Improvement in GTCHR by 0.25kCal/1 Degree
Approach (DCA)

Temperature (Feed water outlet temp- Feed water inlet

---
Rise (TR) temp)
HPH 5A-6A parameters
HPH 5B-6B parameters
LPH-3 Parameters
LPH-2 Parameters
LPH-1 Parameters
 Variation of TTD/DCA with HPH Level

We are trying to find out knee point of every HPHs to

achieve best performance by adjusting level using hit and
trial method.
 Design/Actual Parameters

 Stage-I HPHs Performance at full load

HPH-5/6 Design Unit-1 Unit-2 Unit-3 Unit-4

Parameters
Load 210 209.8 196.8 208.4 209.3

TTD 0/0 -1.5/-6.2 -1.5/-1.6 0.0/0.14 -1.8/-0.2

DCA 6/6 5.5/21.0 9.0/8.0 7.3/14.0 11.24/11.9

TR 36/47 33/42.9 28.3/42.6 33.5/42.3 35.5/43.0

Level --- -5/15mm 10/40mm -3/19mm -7/-1mm
 Design/Actual Parameters

 Stage-II HPHs Performance at full load

Design
HPH-5/6 Unit-5 Unit-6
Parameters

Load(MW) 490 488 482

HPH-5A/6A HPH-5B/6B HPH-5A/6A HPH-5B/6B

TTD -0.4/-0.4 1.0/2.9 4.9/0.7 -1.5/-2.1 -7.1/-3.7

DCA 4.7/4.7 6.7/3.4 7.2/5.4 3.7/3.7 6.1/5.5

TR 37.8/50.1 39.3/46.7 35.3/52.8 36.7/51.1 38.9/50.0

Level --- -430/-401 -462/-440 -462/-428 -460/-453

 HPH performance issues

 It is observed that for the same performance parameters, HPHs level

need to maintain differently for different heaters (?), for both in stage-I
& II.
 Design data available is for full load and most of time units runs on
partial load, So need felt to optimize level set point.
 It is being tried to obtain optimum level for best performance
at partial load by varying level up to permissible limit.
 Our idea is to have variable set point at different
load/Extraction pressure for optimum utilization of HPHs.
 This is long process and time consuming, effort are being
made in this regard.
 For obtaining optimum level, EPRI document is being
referred to.
 It is analyzed that stage-1 HPH TR is less by 2-3 than design
even at full load. Unit5’s HPH-6A/5B TTD/TR is also poor.
 Deaerator pressure control

 At low load, D/A pressure get reduced as deaerator

pressure control scheme is not in service.
 It is tried to keep D/A pressure control scheme in service
in unit5.
 This will increase average FW temp that in turn will
reduce losses due to feed water temp before economizer,
which is presently in the range of 3-7kCal.
 For maintaining D/A pressure at low load, Aux
Steam v/v ASV-8 commissioned.
 For taking ASV-8 in service, flushing may needed,
this will be deliberated further and action will be
taken accordingly.
D/A pressure control by ASV-8 at low load.
 Analysis of condenser performance of Stage-1 Units dated 01.06.2018
PARAMETERS UNIT DESIGN Unit1 Unit2 Unit3 Unit4
Pass-A PASS-B PASS-A PASS-B PASS-A PASS-B PASS-A PASS-B
LOAD MW 210 202 197 203 203
CW INLET TEMPERATURE DEG C 33 30 32.54 32.1 31.89 33.51 32.27 32.09 32.27
CW OUTLET TEMPERATURE DEG C 42 45 45.28 45.8 46.15 46.39 44.94 43.53 43.23
CW TEMPERATURE RISE DEG C 9 15 12.74 13.8 14.26 12.88 12.67 11.44 10.96
CONDENSER BACK PR Kg/Cm2-A 0.1042 0.131 0.152 0.127 0.129
mmHg -A 76.62 99.23 115.52 96.52 98.04
CONDENSATE TEMP AT CEP SUCTION DEG C 47 51.79 49.91 50.01 46.78
SATURATION TEMP CORROSPONDING TO CONDENSER BACK PRESSURE DEG C 46.22 51.38 54.56 50.94 51.16
CW FLOW T/HR 32000
CW DP ACROSS CONDENSER KG/CM2 NA 0.651 0.647 0.683 0.651 0.647 0.43 0.44
LPT EXHAUST TEMPERATURE DEG C 51.4 45.94 47.3 47.3
RESULT :
TTD DEG C 4.22 6.38 6.10 8.73 8.41 4.55 6.00 7.63 7.93
EXPECTED COND. BACK PR DUE TO CW INLET PRESSURE MM HG 65.36 75.00 73.08 72.31 78.46 73.85 73.08 73.85
CONDENSER BACK PR DUE TO CW FLOW MM HG 89.09 90.45 93.18 94.55 95.45 89.09 82.92 81.67
VARIATION OF COND BACK PR DUE TO CW INLET TEMP MM HG -11.26 -1.62 -3.54 -4.31 1.84 -2.77 -3.54 -2.77
VARIATION OF COND BACK PR DUE TO CW FLOW/HEAT LOADING MM HG 23.73 15.45 20.10 22.24 16.99 15.24 9.84 7.82
VARIATION OF COND BACK PR DUE TO AIR/DIRTY TUBE MM HG 10.13 8.77 22.34 20.97 1.07 7.43 15.12 16.37
TOTAL VARIATION OF CODENSER BACK PRESSURE MM HG 22.61 22.61 38.90 38.90 19.90 19.90 21.42 21.42

Observations: Unit2 Condenser tubes is more chocked/dirty than other units of stage-1
Unit2 condenser performance is poor in respect of all parameters.
Unit4 condenser TTD is also on higher side.
 Use of PADO

 Soot blowing (WW & LRSB) is being done as per

PADO recommendation.
 It is tried to keep mill loading as per PADO
recommendation.
 Optimized set points like Oxygen, Burner tilt and
Average Mill height are also being tried to maintain
as per PADO recommendation.
 Proactive actions

 Mill outlet temp set point is being modulated as per

specific coal, to improve X-ratio of APH, thereby
improving boiler efficiency.
 Burner tilt is being kept in auto.
 PA header pressure is being maintained 74o and
760mmwcl in stage-I & stage-II respectively.
Thanks a lot