Heat Rate Calculations

PLANT PERFORMANCE CALCULATIONS
KHAPERKHEDA TPS, MSPGCL

UNIT NO. 4
DATE : 12/3/2008
TIME : 10:00
(A) BOILER EFFICIENCY
INPUT DATA
Sr.No. Particulars Variables Readings Unit
1 Load EPG 165.00 MW

2 Main steam flow at boiler outlet TSF 476.61 T/Hr
3 Flue gas temp.at air heater outlet (L) TGOL 126.20 o
C
4 Flue gas temp.at air heater outlet (R) TGOR 143.77 o
C
5 Flue gas temp.at air heater inlet (L) TGIL 313.66 o
C
6 Flue gas temp.at air heater inlet (R) TGIR 323.67 o
C
7 Dry bulb temp.at inlet of FD fans DBT 26.50 o
C
8 wet bulb temp.at inlet of FD fans WBT 21.00 o
C
9 Barometric pressure BARPR 720.00 mm of Hg
10 Carbon di-oxide percent in FG at AH outlet (L) O2IL 14.00 %
11 Carbon di-oxide percent in FG at AH outlet (R) O2IR 13.80 %
12 Oxygen percent in FG at air heater outlet (L) O2OL 4.20 %
13 Oxygen percent in FG at air heater outlet (R) O2OR 4.20 %
14 Unburnt percent in bottom ash UBA 1.67 %
15 Unburnt percent in fly ash UFA 0.64 %
16 Moisture content in coal on as fired basis MF 19.03 %
17 Carbon Monoxide at Stack (A) COA 22.80 ppm
18 Carbon Monoxide at Stack (B) COB 23.60 ppm
Proximate analysis of coal ( Air dried basis )
17 Moisture content in coal MD 5.76 %

18 Ash content in coal AD 40.82 %
19 Fixed carbon in coal CD 30.04 %
20 Volatile matter in coal VD 23.38 %
21 Calorific value of coal CVCD 3864 Kcal/kg
CALCULATIONS
Proximate analysis of coal ( As fired basis )
1 Moisture content in coal MF 19.03 %

2 Ash content in coal AF 35.07 %
3 Fixed carbon in coal CF 25.81 %
4 Volatile matter in coal VF 20.09 %
5 Calorific value of coal CVCF 3320 Kcal/kg
Ultimate analysis of coal ( As fired basis )

3 Total carbon in coal TCF 33.06 %
4 Hydrogen content in coal ( Taken from actual ) H2F 2.80 %
5 Nitrogen content in coal N2F 1.56 %
6 Sulphur content in coal SF 0.40 %
1
7 Oxygen content in coal O2F 8.07 %
2
BOILER LOSSES
(1) LOSS DUE TO UNBURNT CARBON :- L-1 0.63 %
Unburnt carbon in fly ash UF 0.0020 Kg/kg

Unburnt carbon in bottom ash UB 0.0006 Kg/kg
Total unburnt carbon U 0.0026 Kg/kg
(2) LOSS DUE TO MOISTURE IN FUEL :- L-2 3.62 %
Average temp. of flue gas at air heater outlet TGO 134.99 oC

Sensible heat of water vapour SHWV 2642.47 Kj/kg
(3) LOSS DUE TO HYDROGEN IN FUEL :- L-3 4.79 %
(4) LOSS DUE TO MOISTURE IN AIR :- L-4 0.12 %
Min. air reqd. for complete combustion of fuel WA 4.42 Kg/kg

Avg. percentage of oxygen in FG at AH outlet O2O 4.20 %
Excess air EA 25.00 %
Total combustion air TA 5.53 Kg/kg
Relative humidity of air RHA 62.02 %
Specific humidity of air SHA 0.014 Kg/kg
Total moisture contained in air TMA 0.079 Kg/kg
(5) LOSS DUE TO DRY GAS :- L-5 4.72 %
Avg. percentage of CO2 at AH outlet CO2O 13.90 %

Weight of dry gas WDG 0.20 Kg/kg
Sensible heat of dry gas SHDG 655.82 KJ/kg
(6) LOSS DUE TO RADIATION :- L-6 0.26 %
Boiler load LB 69.01 %
(7) UNACCCOUNTED LOSSES :- L-7 1.50 %
TOTAL LOSSES TL 15.63 %
BOILER EFFICIENCY EB 84.37 %
EXPECTED BOILER EFFICIENCY EEB 86.96 %
DEVIATION IN BOILER EFFICIENCY EBD 2.59 %
Designed steam flow at actual load 493.82 T/Hr

Designed boiler load 71.51 %
Unit heat rate UHR 2392.31 Kcal/kwh
EXCESS HEAT CONSUMED DUE TO BOILER LOSSES

DETAILS DESIGN ACTUAL EXCESS
OF LOSS LOSS HEAT
LOSSES % % Kcal/kwh
Unburnt loss 2.00 0.63 15.17

Loss due to moisture & hydrogen in fuel 5.23 8.41 76.04
Loss due to moisture in air 0.21 0.12 -2.27
Dry gas loss 3.85 4.72 20.82
Radiation loss 0.25 0.26 6.15
3
Unaccounted losses 1.50 1.50 0.00
Total losses 13.04 15.63 62.03
CORRECTED BOILER EFFICIENCY
Designed ambient temp. DBTD 38.00 o

C
Avg. temp. of flue gas at AH inlet TFGAHI 320.00 o
C
Corrected temp. of flue gas TGAHOC 138.00 o
C
DESIGNED
1 Moisture content in coal DMF 10.0 %

2 Ash content in coal DAF 42.0 %
3 Total carbon in coal DTCF 35.8 %
4 Hydrogen content in coal DH2F 2.8 %
5 Nitrogen content in coal DN2F 0.8 %
6 Sulphur content in coal DSF 0.4 %
7 Oxygen content in coal DO2F 8.2 %
8 Calorific value of coal DCVCF 3500.0 Kcal/kg
BOILER LOSSES (CORRECTED)

Min. air reqd. for complete combustion WA 4.73 Kg/kg


(6) LOSS DUE TO RADIATION L-6 0.26 %
(7) UNACCCOUNTED LOSSES L-7 1.50 %
(8) MANUFACTURERS MARGIN L-8 1.50 %
TOTAL LOSSES TLC 14.86 %
CORRECTED EFFICIENCY OF BOILER EBC 85.14 %

4
(B) T/G HEAT RATE
INPUT DATA
1 M. S. pr. At HPT inlet before ESV 126.29 Kg/cm2

2 M. S. temp. At HPT inlet before ESV 536.07 o
C
3 Total steam flow at boiler outlet 476.61 T/hr
4 M. S. flow to PRDS 0.00 T/hr
5 Feed water temp. at HPH-5 outlet 196.91 o
C
C
7 Feed water flow at HPH-6 outlet 449.78 T/hr
8 M. S. pr. At HPT outlet before NRV 31.86 Kg/cm2
9 M. S. temp. At HPT outlet before NRV 352.33 o
C
10 M. S. pr. At IPT inlet before IV 29.48 Kg/cm2
11 M. S. temp. At IPT inlet before IV 538.75 o
C
12 Reheat spray flow ( left + right ) 6.42 T/hr
13 Steam extraction pr. To HPH-6 30.80 Kg/cm2
14 Steam extraction temp. To HPH-6 347.21 o
C
15 Drip temp. of HPH-6 206.36 o
C
16 Steam extraction pr. To dearator (EX-4) 4.87 Kg/cm2
17 Steam extraction temp. To dearator (EX-4) 314.37 o
C
18 Condenser vacuum (-) 0.93 Kg/cm2
19 Aux. Power consumption ( UAT + STN ) 16.00 MW
20 HPH out of service ( No. 5 / 6 / BOTH / NONE ) NONE
21 EX-12 of HPH-6 ( OPEN / CLOSE ) OPEN
22 AS-306 of dearator heating ( OPEN / CLOSE ) CLOSE
Enthalpy by empirical formulae
1 M.S. Enthalpy at HPT inlet 820.91 Kcal/kg

2 M.S. Enthalpy at HPT outlet 743.19 Kcal/kg
3 M.S. Enthalpy at IPT inlet 846.42 Kcal/kg
4 FW Enthalpy at HPH-6 outlet 241.64 Kcal/kg
6 Drip Enthalpy of HPH-6 210.63 Kcal/kg
7 Steam extraction Enthalpy to dearator (Extrn-4) 738.05 Kcal/kg
8 Steam extraction Enthalpy to HPH-6 (Extrn-6) 721.51 Kcal/kg
9 At HPH-6 outlet at expected FW temp. (oC) = 236.96 244.87 Kcal/kg
10 Isentropic Enthalpy of steam at HPT outlet 723.99 Kcal/kg
11 Isentropic Enthalpy of steam at IPT outlet 725.59 Kcal/kg
CALCULATIONS
Barometric pressure 0.98 Kg/cm2
Condenser back pressure 0.05 Kg/cm2
M. S. pr. at HPT inlet (ab) 127.27 Kg/cm2
CRH pressure (ab) 32.84 Kg/cm2
HRH pressure (ab) 30.46 Kg/cm2
Extrn-4 pressure (ab) 5.85 Kg/cm2
HEAT IN STEAM AT HPT INLET 391.25 MKcal/hr
M. S. flow at HPT inlet 476.61 T/Hr
5
HEAT IN STEAM AT HPT OUTLET 324.11 MKcal/hr
HPT gland leakage flow 4.28 T/Hr

Heat gained by feed water in HPH-6 18.50 MKcal/hr
Steam extraction flow to HPH-6 36.22 T/Hr
M. S. Flow at HPT exhaust 436.11 T/Hr
HEAT IN STEAM AT IPT INLET 374.57 MKcal/hr
Flow of steam through CR-306 if open 0.00 T/Hr

M.S. flow at IPT inlet 442.53 T/Hr
HEAT IN FEED WATER AT HPH-6 OUTLET 108.69 MKcal/hr
NET HEAT USED IN T/G SYSTEM 333.02 MKcal/hr
% CHANGE IN HR DUE TO DEV. OF HPT EFFY. 0.00 %

SR. NO. MAIN RESULTS UNIT ACTUAL EXPCTD.
1 GROSS T/G HEAT RATE Kcal/kwh 2018.32 1939.30
2 GROSS T/G EFFICIENCY % 42.61 44.35
3 GROSS UNIT HEAT RATE Kcal/kwh 2392.31 2234.22
4 GROSS UNIT EFFICIENCY % 35.95 38.49

% CHANGE IN HR DUE TO DEV. OF IPT EFFY. -0.71 %
% CHANGE IN HR -0.72 %
% CHANGE IN ACTUAL HR 4.07 %
EXCESS HEAT CONSUMED IN T/G SYSTEM
OF VALUE VALUE HEAT
PARAMETERS Kcal/kwh
Main steam pressure at HPT inlet (Kg/cm2) 150.00 127.27 25.46
Main steam temperature at HPT inlet (oC) 540.00 536.07 2.86
Main steam temperature at IPT inlet (oC) 540.00 538.75 0.66
Percentage M.S. pr. Drop in reheater (%) 10.00 7.25 -3.37
Condenser back pressure (Kg/cm2) 0.091 0.05 -59.03
FW temperature at HPH-6 outlet (oC) 236.96 233.99 8.80

Flue gas temp. at air heater outlet 129.43 134.99 6.65
Others ( By difference ) 114.03
DEVIATION DUE TO CYLINDER EFFY. -13.868 Kcal/kwh

HEAT RATE DEVIATION
I) TURBINE 79.02 Kcal/kwh
II) BOILER 79.07 Kcal/kwh
III) UNIT 158.09 Kcal/kwh
CORRECTED T/G HEAT RATE 2051.74 Kcal/kwh
TURBINE EFFICIENCY (%) Expected Actual Deviation

I) HPT 85.00 80.19 4.81
II) IPT 90.40 89.69 0.71
COAL MILLS A B C D E F
FLOW T/HR N IN S 28 29 30 28 29
COAL FEEDERS => ALL GRAVIMETRIC MODE
6
7
RESULTS OF PERFORMANCE TEST
UNIT NO. 4
DATE : 12/3/2008
SR. NO. PARTICULARS UNIT DESIGNED ACTUAL
1 LOAD MW 210 165.00
2 HP HEATERS OUT NOS. NONE NONE
3 HP TURBINE EFFICIENCY % 85.00 80.19
4 IP TURBINE EFFICIENCY % 90.40 89.69
7 CORRECTED T/G HEAT RATE Kcal/kwh 1939.30 2051.74
8 BOILER EFFICIENCY % 86.80 84.37
9 CORRECTED EFFICIENCY OF BOILER % 86.80 85.14
12 HEAT RATE DEVIATION FROM STD.
I) TURBINE Kcal/kwh 0 79.02

II) BOILER Kcal/kwh 0 79.07
III) UNIT Kcal/kwh 0 158.09
13 DETAILS OF HEAT RATE DEVIATION
A) M. S. PRESSURE AT HPT INLET Kcal/kwh 0 25.46

B) M. S. TEMPERATURE AT HPT INLET Kcal/kwh 0 2.86
C) HRH TEMPERATURE Kcal/kwh 0 0.66
D) CONDENSER VACUUM Kcal/kwh 0 -59.03
E) % REHEATER PRESSURE DROP Kcal/kwh 0 -3.37
F) FLUE GAS TEMP. AT AIR HEATER EXIT Kcal/kwh 0 6.65
G) UNACCOUNTED(R/H SPRAY LOSS ETC.) Kcal/kwh 0 46.28
H) FINAL FEED WATER TEMPERATURE Kcal/kwh 0 8.80
I) UNBURNT COAL Kcal/kwh 0 15.17
J) MOISTURE IN FUEL & AIR Kcal/kwh 0 73.77
` K) DRY FLUE GAS Kcal/kwh 0 20.82
L) RADIATION Kcal/kwh 0 6.15
M) CYLINDER EFFY.(HPT & IPT) Kcal/kwh 0 13.87
8

UNIT NO. 4
DATE : 11/6/2008
TIME : 10:00
INPUT DATA

C
C
C
C
C
C

CALCULATIONS


9
BOILER LOSSES




(7) LOSS DUE TO SENSIBLE HEAT IN BOTTOM ASH :- 0.53 %
(8) LOSS DUE TO SENSIBLE HEAT IN FLY ASH :- 0.22 %


OF LOSS LOSS HEAT
LOSSES % % Kcal/kwh
Unburnt loss 2.00 0.63 15.30

Dry gas loss 3.00 4.72 41.53
10
Loss due to sensible heat in bottom & fly ash 0.85 0.75 -2.41
Total losses 13.04 16.38 80.69

C
C
C
Designed Bottom Ash temp. 1050.00 o
C
Designed Fly Ash temp. 140.00 o
C
DESIGNED




(7) LOSS DUE TO SENSIBLE HEAT IN BOTTOM ASH :- L-7 0.61
(8) LOSS DUE TO SENSIBLE HEAT IN FLY ASH :- L-8 0.24
11
12
(B) T/G HEAT RATE
INPUT DATA

C
C
C
C
C
C
C
C

CALCULATIONS
13




OF VALUE VALUE HEAT
PARAMETERS Kcal/kwh


HEAT RATE DEVIATION

I) HPT 85.00 80.19 4.81
II) IPT 90.40 89.69 0.71
FLOW T/HR N IN S 28 29 30 28 29
14
UNIT NO. 4
DATE : 11/6/2008
1 LOAD MW 210 165.00


K) DRY FLUE GAS Kcal/kwh 0 41.53
N) SENSIBLE HEAT IN BOTTOM & FLY ASH Kcal/kwh 0 -2.41
15

UNIT NO. 4
DATE : 12/3/2008
TIME : 10:00
INPUT DATA

C
C
C
C
C
C
17 Carbon Monoxide at Stack (A) COA 22.80 ppm
18 Carbon Monoxide at Stack (B) COB 23.60 ppm

CALCULATIONS


16
BOILER LOSSES




(7) LOSS DUE TO SENSIBLE HEAT IN BOTTOM ASH :- L-7 0.53 %
(8) LOSS DUE TO SENSIBLE HEAT IN FLY ASH :- L-8 0.22 %
(9) LOSS DUE TO CARBON MONOXIDE :- L-9 0.009 %
CO at Stack CO 0.002 %
Carbon Burnt per Kg of Fuel CB 0.33 Kg/kg
CV of Carbon Monoxide CVCO 23627.64 KJ/kg


OF LOSS LOSS HEAT
LOSSES % % Kcal/kwh
Unburnt loss 2.00 0.63 15.31

Dry gas loss 2.99 4.72 41.77
17
Loss due to sensible heat in bottom & fly ash 0.85 0.75 -2.41
Loss due to carbon monoxide 0.01 0.01 -0.02
Total losses 13.04 16.39 80.92

C
C
C
Designed Bottom Ash temp. 1050.00 o
C
Designed Fly Ash temp. 140.00 o
C
DESIGNED




(7) LOSS DUE TO SENSIBLE HEAT IN BOTTOM ASH :- L-7 0.61
(8) LOSS DUE TO SENSIBLE HEAT IN FLY ASH :- L-8 0.24
(9) LOSS DUE TO CARBON MONOXIDE :- L-9 0.010 %
CO at Stack CO 0.002 %
Carbon Burnt per Kg of Fuel CB 0.35 Kg/kg
CV of Carbon Monoxide CVCO 23627.64 KJ/kg
18
19
(B) T/G HEAT RATE
INPUT DATA

C
C
C
C
C
C
C
C

CALCULATIONS
20




OF VALUE VALUE HEAT
PARAMETERS Kcal/kwh


HEAT RATE DEVIATION

I) HPT 85.00 80.19 4.81
II) IPT 90.40 89.69 0.71
FLOW T/HR N IN S 28 29 30 28 29
21
UNIT NO. 4
DATE : 12/3/2008
1 LOAD MW 210 165.00


K) DRY FLUE GAS Kcal/kwh 0 41.77
N) SENSIBLE HEAT IN BOTTOM & FLY ASH Kcal/kwh 0 -2.41
O) CARBON MONOXIDE Kcal/kwh 0 -0.02
22

Heat Rate Calculations

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Heat Rate Calculations

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PLANT PERFORMANCE CALCULATIONS

KHAPERKHEDA TPS, MSPGCL

(A) BOILER EFFICIENCY

Sr.No. Particulars Variables Readings Unit

1 Load EPG 165.00 MW

Proximate analysis of coal ( Air dried basis )

17 Moisture content in coal MD 5.76 %

Proximate analysis of coal ( As fired basis )

1 Moisture content in coal MF 19.03 %

Ultimate analysis of coal ( As fired basis )

1 Moisture content in coal MF 19.03 %

(1) LOSS DUE TO UNBURNT CARBON :- L-1 0.63 %

Unburnt carbon in fly ash UF 0.0020 Kg/kg

(2) LOSS DUE TO MOISTURE IN FUEL :- L-2 3.62 %

Average temp. of flue gas at air heater outlet TGO 134.99 oC

(3) LOSS DUE TO HYDROGEN IN FUEL :- L-3 4.79 %

(4) LOSS DUE TO MOISTURE IN AIR :- L-4 0.12 %

Min. air reqd. for complete combustion of fuel WA 4.42 Kg/kg

(5) LOSS DUE TO DRY GAS :- L-5 4.72 %

Avg. percentage of CO2 at AH outlet CO2O 13.90 %

(6) LOSS DUE TO RADIATION :- L-6 0.26 %

Boiler load LB 69.01 %

(7) UNACCCOUNTED LOSSES :- L-7 1.50 %

TOTAL LOSSES TL 15.63 %

BOILER EFFICIENCY EB 84.37 %

EXPECTED BOILER EFFICIENCY EEB 86.96 %

DEVIATION IN BOILER EFFICIENCY EBD 2.59 %

Designed steam flow at actual load 493.82 T/Hr

EXCESS HEAT CONSUMED DUE TO BOILER LOSSES

Unburnt loss 2.00 0.63 15.17

CORRECTED BOILER EFFICIENCY

Designed ambient temp. DBTD 38.00 o

1 Moisture content in coal DMF 10.0 %

BOILER LOSSES (CORRECTED)

(1) LOSS DUE TO UNBURNT CARBON :- L-1 0.79 %

Unburnt carbon in fly ash UF 0.0015 Kg/kg

(2) LOSS DUE TO MOISTURE IN FUEL :- L-2 1.77 %

Sensible heat of water vapour SHWV 2599.84 Kj/kg

(3) LOSS DUE TO HYDROGEN IN FUEL :- L-3 4.47 %

(4) LOSS DUE TO MOISTURE IN AIR :- L-4 0.11 %

Min. air reqd. for complete combustion WA 4.73 Kg/kg

(5) LOSS DUE TO DRY GAS :- L-5 4.46 %

Avg. percentage of CO2 at AH outlet CO2O 13.90 %

(6) LOSS DUE TO RADIATION L-6 0.26 %

Boiler load LB 69.01 %

(7) UNACCCOUNTED LOSSES L-7 1.50 %

(8) MANUFACTURERS MARGIN L-8 1.50 %

TOTAL LOSSES TLC 14.86 %

CORRECTED EFFICIENCY OF BOILER EBC 85.14 %

1 M. S. pr. At HPT inlet before ESV 126.29 Kg/cm2

Enthalpy by empirical formulae

1 M.S. Enthalpy at HPT inlet 820.91 Kcal/kg

HEAT IN STEAM AT HPT INLET 391.25 MKcal/hr

M. S. flow at HPT inlet 476.61 T/Hr

HPT gland leakage flow 4.28 T/Hr

HEAT IN STEAM AT IPT INLET 374.57 MKcal/hr

Flow of steam through CR-306 if open 0.00 T/Hr

HEAT IN FEED WATER AT HPH-6 OUTLET 108.69 MKcal/hr

NET HEAT USED IN T/G SYSTEM 333.02 MKcal/hr

% CHANGE IN HR DUE TO DEV. OF HPT EFFY. 0.00 %

2 GROSS T/G EFFICIENCY % 42.61 44.35

3 GROSS UNIT HEAT RATE Kcal/kwh 2392.31 2234.22

4 GROSS UNIT EFFICIENCY % 35.95 38.49