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THERMAL POWER PLANT

PERFORMANCE

210 MW BHEL TURBINE CYCLE


HEAT BALANCE

7/16/19 Manohar Tatwawadi 1


ASSUMPTIONS
Under Cooling in the drain coolers of Heater No6 and Heater
No 7 is 100C. The effect of drain cooler of Heater No 5 has
been ignored.
When Pressure in Heater No 5 approaches 10.5 kg/cm2
absolute, drain from Heater No 6 is diverted to Deairator
bypassing Heater No 5 and drain of Heater No 5 is diverted
to Heater No 4.

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Ejector
F- Flow in
Kg/Hr
Steam from Deaerator
P- 4.5, T - 155
F - 1500, E-659.83
Condensate
Condensate *T - 45.07 T - 43.16
from CEP
to G.C.1 F - 480106 F - 480106
Discharge

*Assuming the Effy. to be 99.8% T - 47.27 Drain to Flash


Ejector Outlet Temp T Calculated F - 1500 Chamber
Output Heat taken by condensate 480106(45.07-43.16)*100
Input heat given by steam = 1500 (659.83-T) T = 45.070C
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GLAND STEAM CONDENSER GC1
Steam Air
Steam from Deaerator Mixture from
P- 4.5, T - 155
glands
F - 400, E-659.83 P- 0.97, T - 280
Ejector
F - 1260, E-728.20

Condensate T - 47.18 GLAND STEAM T - 45.07 Condensate


to LPH 1 F - 480106 from Ejector
F - 480106 COOLER (GC1)

T - 100 Drain to Cond


F - 1660 Flash Tank
Gland Steam 480106(47.18-45.07)*100
Condenser Effy. = = 99.7%
1260(728.20-100)+400(659.83-100)
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LOW PRESSURE HEATER NO 1
Steam from
P- 0.89, T - 85
F- Flow in Kg/Hr Extraction e1
F - 11989, E-622.05
from LPT

LPH 1
Condensate T - 61.05 T - 47.18 Condensate
to GC 2 F - 480106 F - 480106 from GC 1

T - 65.93 Drain to flash


F - 11989 chamber in Cond.
(hd1)
480106(61.05-47.18)*100
Effy of LPH No 1 = = 99.8%
11989(622.05-65.93)

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GLAND STEAM CONDENSER NO 2

P- 0.50, T - 325 Steam from HP


F - 4949, E-756.90 & IP Glands g2
F- Flow in Kg/Hr

Condensate T - 68.10 80% T - 61.5 Condensate


to LPH 2 F - 480106 F - 480106 from LPH 1
GC 2

20% T - 72.94 Drain to flash


F - 4249 chamber on Cond.
Flow through GC2 (gd2)
Effy of Gland 0.8*480106(68.10-61.05)*100
Steam = = 80% (20% of
4949(756.80-72.94)
Condenser GC 2 condensate is
7/16/19 Manohar Tatwawadi bypassed) 6
LOW PRESSURE HEATER NO 2
F- Flow in Kg/Hr
Drain from T - 130.26
P- 1.369, T - 183 Steam from IPT
LPH3 (hd3) F - 49806
F - 25369, E-678.41 out e2

T-100.86, F-480106

LPH 2
Condensate T - 101.52 T - 68.10 Condensate
to LPH 3 F - 555281 F - 480106 from GC 2

T - 105.78 Drain to
Drip Pump F - 75175 Condensate line
(hd2)

480106(100.86-68.10)*100
Effy of LPH 2 = 25369(678.41-105.78)+49806(130.26-105.78) = 99.8%

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LOW PRESSURE HEATER NO 3

Drain from T - 161.73


P- 2.974, T - 264 Steam from IPT
LPH4 (hd4) F - 28773
F - 21033, E-715.68 Extr (e3)

LPH 3 Condensate
Condensate T - 125.27 T - 101.52
from LPH2 &
to LPH 4 F - 555281 F - 555281
Drip Pump

T - 130.26
Drain to LPH 2
F - 49806 (hd3)
F- Flow in Kg/Hr
555281(125.27-101.52)*100
Effy of LPH 3 = 21033(715.68-130.26)+28773(161.73-130.26) = 99.8%

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LOW PRESSURE HEATER NO 4
P-6.9, T - 161.73
Leak off F - 4935, E-782.31
steam HP P- 6.911, T - 364 Steam from IPT
& IP (g3) F - 23838, E-762.69 Extr (e4)

LPH 4
Condensate T - 156.52 T - 125.27 Condensate
to Deairator F - 555281 F - 555281 from LPH3

T - 161.73
Drain to LPH 3
F - 28773 (hd4)
F- Flow in Kg/Hr
555281(156.52-125.27)*100
Effy of LPH 4 = 23838(762.69-161.73)+4395(782.31-161.73) = 99.7%

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DEAERATOR - FEED TANK
Gland leakage P-7.5, T - 479 P-1.03, T - 141 Steam supply to
F - 2930, E-659.83 glands (d1)
from ESV/IV F - 2300, E-820.28
Steam supply to
Drain from HPH T - 181.51 P-4.5, T - 155
Ejectors (main
5/6 (hd5 or hd6) F - 93256 F - 1900, E-659.83
& GC1) d2+d4
Deaerator
E - 802.51 T - 156.52 Condensate
pegging steam
F - 5984 F - 555281 from LPH4
From PRDS or
Extr.6(ed)

T - 166.71

Feed water T - 173.12 F - 652000

to HPH5 F - 652000

(555281(166.71-156.52)+4830(820.28-659.83))*100
Deaerator Effy =2300(820.28-166.71)+93256(181.51-166.71)+5984(802.92-166.71)= 96.8%

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Deaerator
Supply
1. Below 150 MW Deaerator heating steam heating steam from
extraction tapped from HPT at HPT exhaust.(Extraction 6)
2. Above 150 MW from Extraction No 5 from IPT.
3. Above 150 MW Aux Steam Supply to Main Ejector, Gland
Steam Ejector and sealing steam of Turbine Glands is changed
over from Aux PRDS to Deaerator.
4 Gland leakage Steam from ESV & IV, Drains of Heater No 5
and 6 are also fed to the deaerator.
5. Pegging steam supply is initially from PRRDS and changed
over to Extraction 6 at about 100 MW Load.
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Boiler Feed Pump
The total quantity of feed water supplied from feed water tank
to boiler feed water pump is equal to the main steam flow to
the HP Turbine
Heat Added by Boiler feed pump due to mechanical churning
of water is also taken into consideration and equals to:-

T=173.12 T=166.71
Flow= 652000

= 652000(173.12-166.71) = 4179320 Kcal.

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HIGH PRESSURE HEATER NO 5
T - 198
F - 76616, E-198
Drain from P- 12.96, T - 444 Steam from IPT
HPH6 (hd6) F - 16640, E-802.92 Extr (e5)

HPH 5
Feed Water T - 189.69 T - 173.12 Feed water
to HPH 6 F - 652000 F - 652000 from BFP
Discharge

T - 181.51
Drain to Deaeator (hd5)
F - 93256

652000(189.69-173.12)*100
Effy of HPH 5 = 16640(802.92-181.51)+76616(198.05-181.51) = 93.7%

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HIGH PRESSURE HEATER NO 6
T - 238
F - 31844, E-238.65
Drain from P- 28.07, T - 327 Steam from
HPH7 (hd7) F - 40391, E-732.99 HPT Exh. (e6)

HPH 6
Feed Water T – 228.80 T – 189.69 Feed water
to HPH 7 F - 652000 F - 652000 from HPH 5

Spindle P- 28.07, T - 464 T - 198.01


Leakage from Drain to HPH 5 (hd6)
F - 4381, E-8.6.50 F - 76616
HPT (g5)

652000(228.80-189.69)*100
Effy of HPH 6 =
40391(732.99-198.05)+31844(238.65-198.05)+9381(806.50-198.05)
= 99.7%

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HIGH PRESSURE HEATER NO 7

P- 42.18, T - 381 Ext. Steam


F - 31844, E-755.97 from HPT (e7)

Feed Water to
Economiser T – 253.94 HPH 7
T – 228.80 Feed water
F - 652000 F - 652000 from HPH 6

T – 238.65
Drain to HPH 6 (hd7)
F - 31844

652000(253.94-228.80)*100
Effy of HPH 7 = 31844(755.97-238.65)
= 99.5%

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Condenser
Steam from LPT P-0.0889, F-2*230004, E- 589.18
Drains to cond
Flash Tank. Cooling
gd1-1160 Water out
gd2-4949 to Cooling
Towers
hd1-110989
ejd - 480106
Cooling
Water from
T – 30 CW Pumps
Make up F – 270000 m3
F-20098
CEP Disc.
Steam to circ.water Ratio= 1.70 P- 22, T – 43 To
CEP
F–180106, E-43.1
T. T. D.. =110C Effy = 80%
7/16/19 Manohar Tatwawadi Ejector
16
Turbine Cycle Heat Rate
Total Heat Supplied to Turbine in Kcal
Heat Rate =
Total Generation in Kwh
Q1(I1-IWE) + QR(I3-I4)
Q1= Live steam flow 652000kg/hr W
I1 – Enthalpy of Live Steam 819.94 Kcal/Kg
IWE – Enthalpy of Feed water at HP7 outlet 253.94 Kcal/kg
QR – Reheat Steam Flow 566369 Kg/hr
I3 – Enthalpy of Reheat Steam 845.83 Kcal/kg
I4 – Enthalpy of Cold Reheat Steam 732.99 Kcal/kg
W – Total power Developed at gen out in Kwh 211902kwh.
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Heat Rate Calculations

652000(819.94-253.94)+566369(845.83-732.99)
Heat Rate =
211902

Heat Rate = 2043.11 Kcal/Kwh At 210 MW

Percentage of Extraction Steam = 27.16%


Percentage of Heat Tapped (Not used in Turbine) = 39.61%
Specific Steam Consumption at 210 MW = 3004 kg / kw

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NATIONAL SCENE
PERFORMANCE IMPORTANT TO
REGULATORY AGENCIES, CUSTOMER,
STAKE HOLDERS.
70% GENERATION IS THERMAL
COAL WITH VERY HIGH ASH & FROM
OPEN CAST MINES.
ENVIRONMENTAL STANDARDS ARE MORE
STRINGENT.
DEMAND OF RELIABLE & LOW COST
ENERGY.
DEMAND & SUPPLY GAP IS INCREASING.

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OBJECTIVES
RESTORE LOSS CAPACITY.
RECOVER DETERIORATED EFFY.
INCREASE AVAILABILITY.
INCREASE CAPACITY UTILIZATION
CAPACITY AUGUMENTATION
ENSURE SAFETY.
MEETING ENVIRONMENTAL NORMS
ENERGY CONSERVATION
OPERATOR TRAINING
O& M PROCEDURE UPDATE.

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THERMAL PLANT EFFYCIENCY
HEAT RATE :TOTAL HEAT ADDED/TOTAL KILLOWATS
PRODUCED.
IF 100% CHEMICAL ENERGY IN FUEL IS CONVERTED
INTO ELECTRICAL THE HEAT RATE WILL BE 860
KCAL/KWH.
PRACTICALY HR 2200 EQUIVALENT TO 39 % EFF.
ABOUT 30% INDIAN TPS ARE HAVING EFFY < 30%.
EFFY IS AFFECTED BY– TEMP.,PRESSURE,BOILER
EFFY,VACCUM,ECO. INLET TEMP, AUX STEAM
USAGE,STEAM/WATER LEAKS,AUX POWER USAGE.

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EFFECT OF COAL QUALITY I
COAL QUALITY IMPORTANT DESIGN
CONSIDERATION.
VELOCITY TO BE RESTRICTED TO 10/15 M/SEC DUE
TO ASH EROSIVE PROPERTIES(SIO2.FE2O3)
HARD COAL REQUIRE MORE MILL MOTOR POWER.
HIGH ASH WILL RESULT HIGH MASS GAS
FLOW,MORE POWER FOR ID ,ESP.
WET COAL OVERTAX MILLS DUE TO INSUFFICIENT
PRIMARY AIR.
INCREASE IN AIR DUE TO POOR MIXING CAPABILITY
& INSUFFICIENT FINENESS INREASE FD POWER.

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EFFECT OF COAL QUALITY II
SLAGGING & FOULING INCREASES SOOT
BLOWING FREQ. (HEAT LOSS)
ASH CORROSON/EROSON—IN HIGH AND LOW
TEMP AREAS DUE TO REACTION BETWEEN
SODIUM /POTASSIUM SALTS AND SO3 IN ASH.
EROSION DUE TO ASH IN SECOND PASS.
VERY HIGH OPERATION & MAINTANANCE COST.
DUE TO OPEN CAST MINED COAL –WET COAL
PROBLEMS, HEAVY OIL CONS. & GEN LOSS.

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STEPS TO IMPROVE PERFORMANCE
CORPORATE LEVEL:

1. COAL LINKAGE CO-ORDINATION

2. TIMELY OUTAGES OF UNITS

3. R& M CO-ORDINATION

4. APPLICATION OF LATEST TECHNOLOGIES.

5. FINANCE FOR IMPROVEMENT

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STEPS TO IMPROVE PERFORMANCE
LOCAL LEVEL:
1. DEDICATED GROUP UNDER DIRECT
CONTROL OF UNIT INCHARGE
2. REGULAR REVIEW OF PARAMETERS &
DATA LOGGING.
3. DECIDE ACHIEVABLE PERFORMANCE.
4. DRAW ACTION PLAN
5. APPRAISAL AT VARIOUS LEVELS

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STEPS TO IMPROVE PERFORMANCE
BOILER EFFY IMPROVEMENT
1. EXCESS O2 OPTIMISATION.
2. MILL PERFORMANCE IMPROVEMENT
3. AIR HEATER PERFORMANCE IMPROVEMENT
4. AIR/FUEL RATIO OPTIMISATION
5. UNIFORM GAS DISTRIBUTION PATTERN IN
THE BACK PASS PATH.
6. BURNER/AIR REGISTERS ADJUSTMENTS.

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STEPS TO IMPROVE PERFORMANCE
TURBINE EFFY IMPROVEMENT
1.HP/IP/LP TURBINE
EFFY(EROSION,DEPOSITS,SEAL LEAKS).
2. FEED PUMP
PERFORMANCE(CLEARANCES)
3. CONDENSER
PERFORMANCE(FOULING)
4.HP/LP HEATER PERFORMANCE( BAFFEL
PLATES),LEVELS
5.AUX STEAM LEAKAGES.
6. PASSING OF VALVES.

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EFFY LOSS OF HP/IP
TURBINES(MECHANICAL)
DEFICIENCY EFFYCIENCY LOSS
HP IP
SOLID PARTICLE
EROSIN 2% ½%
BLADE DEPOSIT 5% 3%
MECH DAMAGE 2% 1%
WORN SEALS 4% 1%
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SAVINGS DUE TO HEAT
RATE IMPROVEMENTS I
LOCATION PIT HEAD RAIL FED
UNIT SIZE 210 500 210 500
1% HR 55 131 147 350
1% O2 AH IN 16 39 43 103
1MM HG VAC 4.5 10.6 12 28.
10C AH EXIT T 2.6 6.3 7.06 16.8
10C STEAM T 1.41 3.36 3.76 8.97
10C HRH T 1.3 3.1 3.47 8.26
1 T/H RH SPR. .54 1.29 1.44 3.44
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SAVINGS II
ASSUMPTION FOR SAVING
CALCULATIONS.
PLF 70 %.
FUEL HHV 3500 KCAL/KG.
FUEL COST RS 600/TON FOR PIT HEAD
STN & RS 1600 FOR RAIL BOUND STN.
SAVINGS ARE IN RS lakhs/YEAR
BASIS FOR HEAT RATE 2500 KCAL/KWH
HEAT RATE IMPROVEMENT OF 0.5% TO 3
% HAVE BEEN SHOWN POSSIBLE.
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SAVING III (CONDENSER
TUBE CLEANING)
IMPROVEMENT IN VACC. 14 MM HG.
IMP. IN HEAT RATE 31 KCAL/KWH
FUEL SAVINGS 9400 TONS/YEAR
CO2 REDUCTION 11,750 TONS/YR
MONEY SAVED RS 15 MILLION/YR
EXPENDITUREIN CONDENSER CLEANING
RS 0.5 MIILLION/YEAR
NET SAVING RS 14.5
MILLION/YEAR.
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CENPEEP EXPERIMENTS
CENTER FOR POWER EFFICIENCY &
ENVIRONMENT PROTECTIONS.A-8-
A,SECTOR –24,NOIDA201301. PHONE 91-
118-4410316.
JOINT VENTURE OF NTPC & UNITED
STATE AGENCY FOR INTERNATIONAL
DEVELOPMENT.
FOCUS: TO INCREASE ENERGY EFFY. OF
EXISTING PLANTS.
AREAS:
MILLS,BOILERS,AIRHEATER,CONDENSER.
7/16/19 Manohar Tatwawadi 32
CENPEEP RECOMMENDED
TESTS I
ISOKINETIC COAL SAMPLING:DIRTY
PITOT TUBE FOR CLEAN AIR/AIR FUEL
FLOW MEASUREMENT.EACH PIPE
STATUS.FINENESS,A/F RATIO.IMPROVE
MILL PERFORMANCE
HIGH VELOCITY TRAVERSE TEST: TO
DECIDE OPTIMUM
COMBUSTION,FURNACE TEMP
MAPPING,O2 STATUS.
FLUE GAS ANALYSER: CO,O2 STATUS
FLY ASH SAMPLING
7/16/19
FOR CARBON
Manohar Tatwawadi 33
CONTENTS.
CENPEEP TESTS II
TUBE CLEANING FOR
CODENSERS:CONCO TUBE CLEANING.
SPRING LOADED METAL SCRAPPERS
,PROPELLED AT 3 TO 6 M/SEC SPEED BY
15 TO 25 KG/CM2-PRESSURE WATER
GUN.TUBE LIFE
INCREASES,CLEANLINEES ASSURED. 400
TUBES/HR CAN BE CLEANED.
PREFERABLE TO HIGH PRESSURE
JETTING(LONG OUTAGE) & CHEMICAL
CLEANING(RISK FACTOR,TUBE LIFE
AFFECTED)
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CENPEEP TESTS III
CASE STUDY OF 210 MW.
(COMPUTATIONAL SOFTWARE)
1. CONDENSER CLEANLINESS LOW .
HEAT RATE LOSS 79 KCAL/KWH.
HP/IP TURINE DETERIORATION , HEAT
RATE LOSS 80 KCAL/KWH.
HP HEATERS TERMINAL TEMP DIFF. HIGH.
LOSS 41.8. KCAL/KWH
BFP NOT OPERATING AS PER CURVE.
( FLOW,AUX POWER)
HP DRAIN VALVES
7/16/19 PASSING
Manohar Tatwawadi 35
CENPEEP TESTS IV
MULTIPLE TECHNOLOGY BASED GEN X
MER PREDICTIVE DIAGNOSTICS
PROGRAMM.
ULTRASONIC INSPECTION OF PARTIAL
DISCHARGE
INFRARED THERMOGRAPHY.
DISOLVE GAS ANALYSIS IN OIL
SOUND LEVEL
VIBRATION SPECTRUM ANALYSIS.

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TURBINE CYCLE
PERFORMANCE
EFFECT OF OPERATING UNIT AT
REDUCED PARAMETERS
1.PRESUURE <30 PSIG THAN DESIGN
REDUCES EFFY BY 1/10 TH OF 1 %.
2.TEMP <50 0F THAN DESIGN REDUCES
EFFY BY ½%.
3.REHEAT TEMP. <30 0F THAN DESIGN
EFFY DOWN BY ½%.
4. 10 TO 15 MMHG OF VACCUM
IMPROVEMENT RESULTS IN IMPROVING
HEAT RATE BY 20
7/16/19 TOTatwawadi
Manohar 25 KCAL/KWH. 37
SEVEN STEPS TO IMPROVE
PERFORMANCE
1.ESTABLISH DEPT OF ENERGY
MANAGEMENT.
2.DAILY REVIEW OF KEY PERFORMANCE
PARAMETERS.
3.COMPARE WITH THE BEST FIGURES
ACHIEVED TILL DATES OF SAME UNIT OR
OTHER UNIT.
4. ANALYSE REASONS FOR LOWER THAN
“PREVIOUS BEST”
5.COMPUTE BEST ACHIEVABLE RESULTS
FOR EACH UNIT.Manohar Tatwawadi
7/16/19 38
SEVEN STEPS (CONTD)

6. COMPARE YOUR STN PERFORMANCE


WITH BEST ACHIEVED FIGURES OF
OTHER INDIAN STN.
7. PREPARE ACTION PLAN FOR
CORRECTIVE ACTIONS( SHORT
TERM,MEDIUM TERM,LONG
TERM).CLOSELY MONITOR . ENSURE
HIGHER LEVEL SUPPORT.
( MANY LEADING ORGANISATIONS ARE
BENEFITED BY APPLYING THESE
STRATEGIES).
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9 STEPS FOR BOILER
PERFORMANCE
OPTIMISATION
1. TREND MILL PERFORMANCE
PARAMETRS & CORRECT
DEGRADATIONS.
2. CONDUCT REGULAR DIRTY PITOT
TUBE TESTS TO ENSURE BALANCED
DISTRIBUTION OF PF & PA BETWEEN
BURNERS.
3.CHECK FINENESS IN ALL FUEL PIPES.
4.CALIBRATE HOT PA FLOWS TO
INDIVIDUAL MILLS.
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9 STEPS (CONTD)
5. ASSESS AIR INGRESS THROUGH NOSE
ARCH,PENTHOUSE,CONVECTION PASS
USING HVT ( TEMP MEASUREMENT &
EXTRACT GAS SAMPLE)PROBE.
6. CONFIRM THROUGH GRID
MEASUREMENTS OF O2 AT AH INLET
.THESE VALUES ARE INDICATING DUCT
CONDITIONS.
7. ENSURE UNIFORM SECONDARY AIR
FLOW TO BURNERS BY CHECKING
DAMPER POSITIONS
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9 STEPS ( CONTD)
8 CONDUCT REGULAR AIR HEATER
PERFORMANCE TESTS TO ASSESS
DEGRADATIONS FOR RECTIFICATION
DURING NEXT SHUT DOWN
9. CONDUCT “ PERFORMANCE
OPTIMISATION TESTS” TO EVOLVE A
SAFE , RELIABLE & EFFICIENT
OPERATING REGIME OF UNIT.
(HVT PROBES ARE WATER COOLED &
STAND TO 1300 OC. INNER MOST PIPE
HOUSES K TYPE THERMCOUPLE. OTHER
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TWO PIPES FOR WATER INLET/OUTLET)
DYNAMIC CLASSIFIERS
IMPROVED PARTICLE SIZE
CONTROL(FINER,MORE EVENLY
GROUNDED COAL).
20% INCREASE IN MILL CAPACITY.
IMPROVED FUEL &AIR DISTRIBUTION TO
BURNERS.
INCREASED COMBUSTION EFFY.
IMPROVED RESPONSE TO BOILER LOAD
DEMANDS.
INCREASED MILL & UNIT TURN DOWN.
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COMENTS
HEAT RATE IMPROVEMENTS DIRECTLY
RELATES TO IMPROVED MANAGEMENT
PRATICES.
IMPROVEMENT PROGRAMMES
MEANS:AWARENESS,IDENTIFICATION,PRI
ORITIZATION,IMPLEMENTATION.
PERFORMANCE IMPROVEMENT OF
EXISTING PLANT IS PROVEN,COST
EFFECTIVE,GIVING ENVIRONMENTAL
BENEFITS.
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