ENERGY & EFFICIENCY MANAGEMENT GROUP

Ramagundam

EFFICIENCY AT FINGERTIPS
Sr Deviation descriptions Effect on Approx Monetary
No Heat Rate loss per day (Rs) for

200MW 500MW
1 1 Degree rise in CW inlet temp deteriorates 5.2 Kcal/Kwhr 23400 55000
condenser vacuum by 4 mmHg
2 1 mmHg deterioration of condenser vacuum 1.8 Kcal/Kwhr 8100 20000
3 3 TPH increase in RH Spray 1 kcal/kwhr 4500 11000
4 25 TPH of SH Spray 1 kcal/kwhr 4500 11000
5 1 Degree deviation in MS Temperature 0.7 Kcal/Kwhr 3150 7700
6 1 Degree deviation in HRH Temperature 0.5 Kcal/Kwhr 2250 5500
7 1 Degree deterioration in FW Temp at Eco inlet 1 kcal/kwhr 4500 11000

8 1 TPH of Condenser make up water 1.2 Kcal/kwhr 5400 13000

9 1 Degree rise in Flue Gas exit Temp (FGET) at 1 kcal/kwhr 4500 11000
APH common outlet
10 20 Degree rise in Flue Gas exit Temp at APH 20 Kcal/Kwhr 90000 220000
common outlet deteriorates Boiler efficiency by
1%
11 1% HPT/IPT Efficiency deviation from design 4 kcal/kwhr 18000 44000
12 1% LPT Efficiency deviation from design 8-9 Kcal/Kwhr 40500 90000

13 10 Tons of TDBFP ACV passing 1 kcal/kwhr 4500 11000

14 1 set of HP Heater out 25 kcal/kwhr 112500 275000

Must Know:
 Heat Rate is energy required to generate one unit of electricity
(Kcal/kwhr)
 Gross Heat rate is Turbine Heat rate per unit of Boiler efficiency
 Net Heat rate Gross Heat rate/(1-APC). PAT target is monitored in
terms of NHR
 1 Kcal/Kwhr Heat rate deterioration in 500 MW emits additional 4 Tons
CO2 in a day
 CRH temperature after attemperation must be more than 10 degree
Superheat. Two phase flow of steam may damage the boiler tubes
 Air ingress in Boiler through Peep holes/manholes/SB glands leads to
increase in FGET and thus reduction in Boiler efficiency
 For proper combustion, Wind Box DP should be maintained around
design
 5 Degree increase in all running Mill outlet Temp may reduce FGET by
around 1 deg C and thus improved Heat rate
 Increased TTD (Saturation temp corresponding to condenser vacuum –
CW outlet temp) indicates tube deposits and thus vacuum deterioration
 Air suction depression more than 5 degree (Hotwell Temp – Air suction
Temp to vacuum Pump) is the indication of air ingress in Condenser
 Increased DO in condenser may be due to air ingress through various
water lines (CEPs/Flash Tank drains/level Standpipes/drains etc)
connected to Condenser
 Sudden decrease in FW outlet Temp at HPH outlet may be indication of
parting plane leakage. This will also increase the TTD of HPH
 Increased Drain Cooler Approach (DCA = Drain out Temp – Feed water
inlet temp) indicates low Heater Level. Very low heater level may have
impact on tube failure and have less heat transfer in drain cooling Zone
of heater
 In case of unidentified condenser air ingress and vacuum loss more than
3 mmHg it is advisable to keep both Vacuum pump in service
 Increased air pre heater seal leakages may result into increased draft
Power

By-

M K JHA
AGM (EEMG)