CCPP 2 Thermal Audit Report PDF

THERMAL ENERGY AUDIT REPORT
of
DHUVARAN COMBINED CYCLE POWER STATION
112 MW, UNIT NO.-2
GUJARAT STATE ELECTRICITY CORPORATION
LTD.
PART-2
(Thermal Audit)
By
Energy Management Section

Materials Technology Division
Electrical Research and Development Association

ERDA Road, Makarpura Industrial Estate
Vadodara-390 010
Dec - 2009
Recipient of Petroleum Conservation Research Association (PCRA) Best

Improvement in Performance Award/Best Energy Auditor Award for the years
1998-1999, 1999-2000 & 2000-2001.
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
ACKNOWLEDGEMENT
The Energy Management Section of Electrical Research and Development
Association (ERDA) place its sincere gratitude to M/s Dhuvaran Combined
Cycle Power Station, GSECL for having entrusted the Energy Audit study to
us.
Our sincere thanks are due to Mr. Prakash, S.E.(SME), Shri
K.Devkinandan, E.E (Effi) ,Shri A. Saxena, Dy. Ex. Engineer (Effi), and
other staff members for proper coordination, timely help during the energy
audit study and providing accurate data required for preparing energy audit
report.
We are thankful to other staff members of the company whose contribution

directly or indirectly helped us during the Energy Audit Study at Dhuvaran
Combined Cycle Power Station.
CONTENTS
1.0
2.0
3.0
4.0
5.0
6.0
7.0
Page No.
Introduction: Performance evaluation of Gas Turbine: 2.1

Heat and Mass balance of Gas turbine-: 2.1.1
Heat and Mass Balance equation and terminology used -2.1.2
Gas Turbine Design Constants used to solve balance equation:
2.1.3
Fluid properties input to Heat balance: - 2.1.4
Measurement values for Gas Turbine: -2.1.5
Calculated output from Gas Turbine Heat Balance: 2.2
Calculation of Compressor efficiency: 2.3
Calculation of Expander efficiency: 2.4
Calculation of Open Cycle Heat Rate: 2.5
Calculation of Closed Cycle Heat Rate2.6
Calculation of Open Cycle corrected Heat Rate: 2.7
Calculation of Degradation in Gas Turbine
:2.8
Results and discussion: Performance evaluation of HRSG (Heat Recovery Steam Generator):3.1
Measurement and Data Collection: 3.1.1
Measured HRSG Parameters: 3.1.2
Properties value used in calculation: 3.1.3
Flue gas analysis and flue gas properties: 3.2
Calculation of HRSG efficiency: 3.3
Calculation of Effectiveness: 3.4
HRSG pressure elements performance and heat & mass balance: 3.5
HRSG temperature profile for heat balance: 3.6
Results and Discussion: Steam Turbine: 4.1
Performance evaluation of Steam Turbine: 4.1.1
Steam Turbine Cycle Heat Rate: 4.1.2
Calculation of Turbine Cylinder efficiency: 4.1.3
Result and Discussion: C.W. Systems
:5.1
Measurement & Calculation: 5.2
Formula used to calculate deviations: 5.3
Results and Discussion: 5.4
Saving Potential: Steam trap & Condensate recovery
Insulation survey
01
03
03
04
05
06
07
08
09
09
10
10
10
12
12
14
15
15
16
17
18
18
19
32
34
35
36
36
38
38
39
39
42
43
44
45
47
SUMMARY OF OUTCOME
Sl.
No.
Energy Conservation
Measures
Anticipated
Savings/Yr
(Rs. Lakh)
Approximate
Investment
(Rs. Lakh)
Payback
Period
(Months)
Condenser
vacuum
improvement by plugging air
ingress
22.56
12.0
7.0
Thermal Energy Saving Potential per Year
= Rs. 22.56 Lakh
Approximate Investment Required
= Rs. 12.0 Lakh
Payback Period
= 7 months
1.0
Introduction:Dhuvaran power plant has Gas based Combined Cycle Power Plant (CCPP) comprising
of two units namely CCPP-1 and CCPP-2. Each unit comprises of one Gas Turbine
Generator & one Steam Turbine Generator. Exhaust gas of Gas Turbine is used to
produce steam through HRSG (Heat Recovery Steam Generator) to run the Steam
Turbine. Energy audit study has been carried out by ERDA as per scope of work which
comprises - Open cycle & Combined cycle heat rate.
Heat Recovery Steam Generator performance.
Gas turbine & Steam turbine performance.
Performance study of steam traps.
Insulation and refractory study.
HP and LP cylinder efficiency.
Condenser performance.
Vacuum system
Heat Balance & Mass Balance.
Technical specification of the CCPP-2 is given below.
Particulars
UoM
CCPP-2
Model
Frame 6FA
Fuel
Natural Gas
Fuel supply
M/s GSPL
Design
GE, USA
EPC contract
M/s BHEL
Installed capacity of GTG
MW
72.51
Installed capacity of STG
MW
39.94
Installed capacity of (GT+STG)
MW
112.45
Commissioning Date of GT
Date
17/03/06
Commissioning Date of STG
Date
13/08/07
Commercial operation Date
Date
01/11/07
Aux. consumption in open cycle
MW
1.54
Aux. consumption in Combined cycle
MW
4.135
kCal/kWh
2584
kCal/kWh
1666
kCal/kWh
2640
kCal/kWh
1729.6
Design Net Efficiency (open cycle)
33.28
Design Net Efficiency (combined cycle)
51.62
Design Gross Efficiency (open cycle)
32.57
Design Gross Efficiency (combined

cycle)
49.72
Design Heat Input (combined cycle)
kCal/hr
187.3 x 106
Design Heat rate (open cycle) based on

fuel NCV
Design Heat rate (combined cycle)
based on NCV
Design Heat rate (open cycle) based on
fuel GCV
Design Heat rate (combined cycle)
based on GCV
During the energy audit different parameters like temperature, pressure, velocity head,
static head of air, fuel & flue gas has been measured to evaluate the performance of Gas
Turbine, HRSG & Steam Turbine. Technical specification of the GT is given below:
Gas Turbine model series and Make
: MS6001FA+FA: GE, USA
Category of Design
: CATEGORY B
2.0
Model No
: PG6111 FA
Rated output
: 72.51 MW
Rated speed
: 5231 rpm
No. of stages
:3
No. of Combustion Chambers
:6
No. of Burners
:6
Compressor ratio
: 15.6
NOX Control
: Water injection
Design Condition
:32.6 Deg C Ambient @ 64% RH
Performance evaluation of Gas Turbine

2.1
Heat and Mass balance for Gas turbine:
Fuel
COMB
Water
Comb
Discharge
Air
Exhaust
Fire
COMP
NOZ
EXP
Cool
Bleed
(2.1.1)
Heat and Mass Balance equation and terminology used:-
mair = Mass flow rate of air (kg/sec)

mdis = Mass of discharge air from compressor (kg/hr)
mcool = Rate of mass flow of cooling air to nozzle (kg/hr)
mbleed = Rate of mass flow of bleed air to expander cooling (kg/hr)
mfuel = Rate of fuel firing (kg/sec)
mcomb = Rate of mass flow of combustion air to nozzle (kg/sec)
mfire = Rate of mass flow of combustion air from nozzle to expander (kg/sec)
mexh = Rate of mass of exhaust combustion product gas (kg/sec)
mwater = Rate of flow of mass of water (kg/sec)
CP = Respective specific heat of all input/ output
TAir = Air inlet temperature (0C)
TDis = Discharge air temperature (0C)
Tcomb = Combustion gas temperature (0C)
TFire = Combustion gas temperature before entering first stage nozzle (0C)
TBleed = Bleed air temperature (0C)
TCool = Cool air temperature (0C)
Tfuel = Fuel entering temperature (0C)
Twater = Spray water inlet temperature (0C)
Texh = Exhaust gas temperature (0C)
POWcomp = Power compressor (kW)
POWExp = Power Expander (kW)
Compressor balance
mair = mdis +mbleed +mcool
mair.Cp,air Tair+ POWcomp = (mdis Cp,dis Tdis)+( mbleed Cp,bleed Tbleed)+(mcool Cp,cool Tcool)
Combustor balance
mcomb = mdis +mfuel +mwater
mcomb.Cp,comb Tcomb
= (mdis Cp,dis Tdis)+ mfuel comb( LHV + Cp,fuel Tfuel)+(mwater Cp,water Twater)
Nozzle Balance
mfire = mcomb +mcool
mfire.Cp,fire Tfire = (mcomb Cp,comb Tcomb)+( mcool Cp,cool Tcool Tcool)
Expander Balance
mexh = mfire +mbleed
(mexh.Cp,exh Texh) + POWEXP = (mfire Cp,fire Tfire)+ mbleed Cp,bleed (Tbleed Tcool)
Shaft Energy balance
shaftPOWEXP = POWshaft + POWcomp
POWNET = GEN POWshaft POWAUX
(2.1.2)
Gas Turbine Design Constants used to solve balance equation:S.No
Design Constants
Notation
Values
Fraction of inlet air used to cool

first stage nozzle
Fraction of inlet air used to cool
first stage nozzle
cool
0.11
bleed
0.11
Temperature factor of cooling air
cool
0.99
Temperature factor of bleed air
bleed
0.95
1
2
Temperature loss of bleed air going

to cool nozzle
Temperature loss of bleed air going
to cool expander
5
6
Tcool
110C
Tbleed
140C
Shaft efficiency
shaft
99.5
Generator efficiency
Gen
0.99
Combustor efficiency
Comb
0.99
10
Combustor pressure loss fraction
0.03
(2.1.3)
Fluid properties input to Heat balance:S.No

1
2
3
4
5
6
7
8
Properties
Specific heat of air at inlet
temperature
Specific heat of discharge air at
corresponding temperature
Specific heat of cooling air at
Specific heat of bleed air at
Specific heat of combustion gas
air at corr. temperature
Specific heat of comb. air to 1st
stage rotor at corr. temp
Specific heat of exhaust air at
Specific heat of discharge air at
Notation
Values (kJ/kg.0C)
Cp,air
1.005
Cp,dis
1.041
Cp,cool
1.041
Cp,bleed
1.063
Cp,comb
1.196
Cp,fire
1.184
Cp,exh
1.108
Cp,fuel
2.17
LHV
49145.6
Lower Heating value at STP
10
Air ratio of Specific Heat
1.4
11
Gas ratio of specific heat
1.34
(2.1.4)
Measurement values for Gas Turbine:S.No

1
2
3
Parameters
Air inlet temperature
Pressure of inlet air (After
subtracting inlet and filter
pressure loss)
Compressor discharge
temperature
Compressor discharge pressure
Average exhaust gas temperature
Unit
o
Values
23
Bar (abs))
0.99
395
Bar (abs)
14.36
629
Exhaust gas pressure
Bar (abs)
1.01
Gas turbine net power
kW
67700
Auxiliary power cons.(Open

cycle)
kW
1540
Fuel firing rate
Kg/sec
4.06
10
Fuel temperature
11
IGV Position
12
Turbine status
13
Speed
rpm
5160
14
Frequency
Hz
49.3
15
Barometric pressure
Bar
1.00
20
85.06
Base load
(2.1.5)
Calculated output from Gas Turbine Heat Balance:_

S.No
Design Constants
Unit
Values
Kg/sec
203.4
Rate of Inlet air flow
Cooling air temperature to nozzle
391.05
Compressor bleed temperature
375.25
Power consumed by compressor
kW
119488.8
Combustor exit gas temperature
Combustor exit gas pressure
1324.85
Bar(abs)
13.91
Rate of Compressor exit gas flow
Kg/sec
160.70
Rate of Combustor exit gas flow
Kg/sec
164.76
Rate of first stage inlet gas flow
Kg/sec
187.12
10
Rate of first stage nozzle cooling air

flow
Kg/sec
22.37
11
Rate of expander cooling air flow
Kg/sec
20.34
12
Firing temperature (first stage rotor inlet

temperature)
13
Turbine inlet temperature
14
First stage nozzle area
15
1226
1121.73
Inch2
183.58
Expander power production
kW
189446.6
16
Shaft power to generator
kW
69608
17
Exhaust gas flow rate
Kg/sec
207.46
Above results are calculated from the mass and energy balance equations of four control
volumes (Compressor, Combustor, Nozzle and Expander). Heat balance calculation also
considers the following losses which could not be considered in the overall turbine heat
balance. These are
The shaft efficiency.
Cooling air losses temperature to the environment.
Bleed air losses temperature to the environment.
Design mass flow of GT is around 206 kg/s with allowable combustion temperature of
2420 0F (1325 0C) which is almost equal to calculated values. This shows that GT
performance is near optimum point with the assumption of above mentioned design data
in absence of real design data for Dhuvaran CCPP.
Exact GT performance comments require detailed design data.
(2.2) Calculation of Compressor efficiency:

compressor = Tinlet ((Pdis / Pinlet)(( air 1)/ air) -1)/ (TDis - TInlet)
compressor = 296 ((14.35 / 1.0t)(( 1.4 1)/ 1.4) - 1)/ (395 - 23)
compressor = 90.7%
(2. 3) Calculation of Expander efficiency:
expander = (Tfire Texh)/ Tfire (1 - (Pexh / Pcomb)(( gas 1)/ gas))
expander = (1226 629)/ 1499 (1 - (1.01/13.91 )(( 1.34 1)/ 1.34))
expander = 81.95%
(Neglecting the effect of cool & bleed air, i.e. assuming no cool
and bleed air is extracted)
10
(2.4) Calculation of Open Cycle Heat Rate:
Heat Rate = (mass flow rate of fuel LHV)/ Net Power output
Heat Rate
(kCal)
(kWh)
4.06 X 49145.6 X 3600

67700 X 4.18
Heat Rate = 2538.33 kCal/kWh
(Based on fuel NCV)
(2.5) Calculation of Closed Cycle Heat Rate:
Heat Rate = (mass flow rate of fuel LHV)/ Net Power output (GT + STG)
Heat Rate
4.06 X 49145.6 X 3600

(67700 + 34100)X 4.18
Heat Rate
1688.06 kCal/kWh
(kCal)
(kWh)
(Based on fuel NCV)
(2.6) Calculation of Open Cycle corrected Heat Rate:

Correction is required to compare the operating results with guarantee test. Following
correction factors have been used:
Correction for Heat rate and Power (Open cycle):
S.No.
Affecting Parameters
Design
Operating
Heat Rate
Power
value
value
correction
correction
Inlet temperature
N.A
23
---
1.0
Inlet humidity
N.A
82.5
----
1.0
11
Ambient temperature and

humidity
32.6 & 64% 30.1 & 27.2
1.024
0.9174
Ambient pressure
1.013
1.009
----
1.003
Water injection
3.638
0.00
1.021
1.062
Shaft speed
5231
5134
0.9784
1.0105
Generator power factor
0.98
0.98
---
1.0
Inlet pressure loss
6.2
6.23
0.999
1.0057
Exhaust pressure loss
N.A
140
1.0
1.0
10
Fuel temperature
N.A
20
---
1.0
11
Fuel composition
----
--
----
1.0
100
13562.7
0.979
1.041
N.A
N.A
----
1.0
85
85
1.0
1.0
1.000
1.033
12
Correction for firing

hours
13
Inlet bleed heat
14
IGV position
15
Net correction
12
Corrected Heat Rate = Actual heat rate X Correction factor
Heat Rate
2538.33 X 1.000
(kCal)
(kWh)
Corrected Heat Rate = 2538.33 kCal/kWh
(Based on fuel NCV)
Corrected power output = 67.7 (MW) X 1.033

Corrected power output = 69.93 MW
(2.7) Calculation of Degradation in Gas Turbine Power:
POWCorrected = 69.93 MW
POWRated = 72.51 MW
POWERDegradation = POWRated - POWCorrected
POWERDeg = 72.51 69.93
POWERDeg = 2.58 MW
(2.8) Results and discussion:
Actual open cycle heat rate is less than the design value of 2584 kCal/kWh and it is
2538 kCal/kWh. Present performance of GT is improved from guaranteed value due to
favorable operating ambient condition. (i.e. 30.1 oC & 27.2% RH).
Closed cycle actual heat rate based on fuel NCV is found 1688.06 kCal/kWh against the
design value of 1666.0 kCal/kWh. This is slightly higher than the guaranteed value due to
performance degradation of steam cycle and HRSG. (Root cause shall be investigated in
the section HRSG performance).
Power degradation due to aging effect of GT parts and ambient change is calculated as
2.58 MW.
13
Compressor efficiency is calculated as 90.7% which is very good, but expander efficiency
comes on lower side and is approximately 82% (generally 87 88%) with a assumption
of no cooling/bleed air is supplied to cool expander which is not true in this case because
expander is normally operated with 21% of total compressor air extracted at different
stages to cool expander and nozzle. No method is available to calculate the efficiency
unless cooling air to expander has to terminate during the period of expander efficiency
measurement.
Operating power output from GT is deviated from guaranteed value due to following
reasons:
1. Ambient condition is changed from guarantee condition.
2. Expander performance may be degraded. It should be checked in OEM schedule
inspection.
3. Expander nozzle area may be changed due to aging and wear & tear. It should be
inspected in next scheduled Combustion Gas Path Inspection (HGPI).
4. Water injection is not in operation where as it is in service at the time of guarantee
test. As per GE guideline (Manufacturer) water injection is allowed only for NOX
control not for power augmentation. Due to this constraint, water injection in
Dhuvaran CCPP # 2 not was in operation.
5. Compressor water washing has been not done since long time. It is recommended
to carry out compressor water washing as per OEM recommendation.
6. Online daily compressor water washing is useful practice to improve the GT
performance but this system is not available for Dhuvaran site Gas turbine Power
Plant. In place of this, Offline water washing is available and has been carried out
at every two to three months. At the time of measurement it is due and
recommended to carry out.
It is expected an increase of significant amount of power output by applying OEM

maintenance practices.
14
3.0
Performance evaluation of HRSG (Heat Recovery Steam Generator)

Heat recovery steam generators serve the function of boiler for gas turbine based power
plants. The purpose of the HRSG is to transform the exhaust energy from a gas turbine
into useable steam energy that may be sent to a steam turbine to generate electricity or
sent to a process where the steam energy may be utilized as heat input. An HRSG
consists of convective heat exchangers where hot exhaust gas heats steam or water within
tubes. Three type of heat exchangers are typically used in HRSGs economizer,
evaporators and super heaters. Schematic diagram of CCPP # 2 HRSG is as follows:
HP
Drum
H
P
F.G. Path
S
H
1
H
P
S
H
2
IP
Drum
H
P
.
E
V
A
P
LP
Drum
H
P
E
C
O
5
I
P
.
S
H
H
P
E
C
O
#
4
I
P
L
P
E
V
A
P
S
H
H
P
E
C
O
#
3
I
P
H
P
L
P
H
P
E
C
O
E
C
O
#
2
E
V
A
P
E
C
O
C
P
H
#
1
15
Dhuvaran HRSG # 2 consists of HP SH, HP evaporator, four HP economizers, IP SH, IP

evaporator, IP economizer, LP evaporator, Condensate pre-heater and their arrangement
in HRSG is shown in the diagram.
(3.1) Measurement And Data Collection:
Measurement of parameters in each elemental parts of HRSG is not possible due to
unavailability of tapping at intermediate positions of HRSG sections. In that case
calculated value from Heat and mass balance has been used. Measured values are shown
in the table below:
(3.1.1) Measured HRSG Parameters:

S.No
Measured Parameters
Design
Operating
Value
Value
616.7
629
Kg/hr
718900
746856
N.A
100.5
Kg/cm2a
107
103.1
542
535.8
Kg/hr
118200
107960
Unit
0
Gas inlet temperature to HRSG
Gas inlet flow (calculated)
Final Gas Exit temperature
HP steam pressure at HRSG
HP steam temperature at HRSG
HP steam flow at HRSG
HP feed water pressure at HRSG
Kg/cm2a
112
111.2
IP steam pressure at HRSG
Kg/cm2a
30
27.32
IP steam temperature at HRSG
260
272.5
10
IP steam flow at HRSG
Kg/hr
8300
8260
11
IP feed water pressure at HRSG
Kg/cm2a
32
28.1
12
LP steam pressure at HRSG
Kg/cm2a
6.0
6.01
16
13
LP steam temperature at HRSG
14
LP steam flow at HRSG
15
200
216.5
Kg/hr
6600
8705
HP Drum pressure
Kg/cm2a
N.A
107
16
IP Drum pressure
Kg/cm2a
N.A
28
17
LP Drum pressure
Kg/cm2a
N.A
6.4
18
Condensate net flow to CPH
Kg/hr
183340
125860
19
CPH feed water inlet temperature
60
47.2
20
CPH feed water outlet temperature
100
97.5
21
Feed water temperature to ECO
105
113
22
HRSG inlet pressure
mmWC
N.A
-4.2
23
HRSG outlet pressure
mmWC
N.A
-2.06
(3.1.2)
Properties value used in calculation:
S.No
Properties value
Notation
Value
Specific heat of flue gas at inlet temp.
CP,gas in
1.10
Sp. heat of flue gas at outlet temp.
CP,gas out
1.07
Enthalpy of HP steam at final SH
HHP,STM
3464.06
Enthalpy of IP steam at final SH
HIP,STM
2932.41
Enthalpy of LP steam at final SH
HLP,STM
2885.9
Enthalpy of feed water
HFW
474.05
Enthalpy of condensate in to CPH
HCPH, IN
200.96
Enthalpy of out to CPH
HCPH, OUT
408.52
17
(3.1.3)
S. No.
Flue gas analysis and flue gas properties:
Properties
Unit
Design
Value
Value by
volume
fraction
Value by
mass
fraction
Oxygen percentage
Fraction
0.1129
0.14
0.159
Carbon dioxide
Fraction
0.0421
0.039
0.060
Fraction
0.0084
0.000027
0.0000268
Carbon mono-oxide &

Argon
Water vapor
Fraction
0.1321
0.105
0.067
Nitrogen
Fraction
0.7051
0.716
0.712
F.G outlet temperature
99
99
mmWC
52
52
28.15
28.15
1.085
1.085
F.G. discharge
pressure
Molecular weight of
flue gas
Avg Sp. heat across
HRSG
kJ/kg 0C
18
(3.2) Calculation of HRSG efficiency:

Basic difference between efficiency and effectiveness is that efficiency calculation
includes the actual heat transfer to steam/water while effectiveness uses the heat loss
from gas side as the actual heat transfer. Higher efficiency of HRSG indicates good heat
transfer.
HRSG Efficiency = Energy absorbed by steam

Total Gas side energy input
= MHP X (HHP,STM HFW) + MIP (HIP,STM HFW) + MLP (HLP,STM HFW) + MCPH(HO-HIN)
MGas X Cp,avg X (TGas,in TReference)
= 107960 (3464.06 474.05) + 8260 (2932.41 474.05) + 8705 (2885.9 474.05)+ 170000(408.4 200.96)
746856 X 1.085 X (629 0)
Efficiency = 78.35%
(3.3) Calculation of Effectiveness:

Following formula has been used to calculate HRSG effectiveness:-
Effectiveness =( TGas, in TGas,out)/ (TGas,in TGas, min)

Here minimum possible gas outlet temperature is controlled by LP Evaporator pinch (it
can be easily seen in HRSG gas temperature profile for heat and mass balance). CCPP # 2
HRSG of Dhuvaran is designed for Low Pressure Evaporator pinch which is been
concluded in heat and mass calculation in next section.
Approx. HRSG minimum Gas Temperature for evaporator pinch:
19
Tgas,min
= Tgas,out Tpinch,evap FR [Tgas/Twater]eco X Tsubcool - FR [Tgas/Twater]CPH
= 104.4 19.5- (1.15[29.28/47.0] X 0.6) - (1.15[46.8/50]
= 104.4 19.5 0.42 1.07
Tgas,min = 83.410C
Effectiveness
= (629 104.4) X 100

(629 83.41)
Effectiveness = 96%
(3.4) HRSG pressure elements performance and heat & mass balance:
The overall efficiency or effectiveness may not be good an indicator of HRSG
performance because high pressure steam is much more valuable than low pressure
steam, but the efficiency and effectiveness calculations do not recognize this difference in
value. For this reason section by section heat and mass balance have been done to find
out performance of each part of HRSG.
A super heater is a heat exchanger in an HRSG that raises the temperature of
saturated steam coming from an evaporator up to a higher temperature using the heat
from the exhaust of gas turbine. This superheated steam then flows out of the HRSG to
feed the steam turbine. In CCPP # 2 there are two super heaters 1 & 2 and one DSH
between them to control the outlet steam temperature by water spray. Heat and mass
balance across heating element has been done to calculate unknown quantity (gas outlet
temperature across heater). Effectiveness and heat duty calculation is as follows:
20
Stm pr = 106.9 kg/cm2a

Temp = 314.5 0C
Stm pr = 103 kg/cm2a
Temp = 535 0C
Gas =
746856
kg/hr
T = 629 0C
TGAS =
520.4
0
C
TGAS =
602.5 0C
SH-2
HP
DRUM
SH-1
Flow = 2.0 tph
Temp = 110 0C
HP
Evap
DSH
Temp = 470 0C

Temp = 489 0C
F.W = 300 0C
F.W = 113 0C
HP ECO-1
ECO-2
ECO-3
ECO-4
ECO-5
HP Super heater 2 effectiveness from heat & mass balance:

Steam inlet temperature = 470 0C
Steam outlet temperature = 535 0C
Steam outlet pressure = 103 kg/cm2a
Steam inlet enthalpy = 3254.79 kJ/kg
Steam 0utlet enthalpy = 3464.06 kJ/kg
Steam flow rate (HP) = 107960 kg/hr
21
SH -2 Heat duty = Mass flow of steam X Enthalpy change

QSH-2 = Heat duty = 22592789.2 kJ/hr
Flue gas inlet temperature = 629 0C
Flue gas flow rate to HRSG = 746856 kg/hr
Flue gas outlet temperature = TGas,in __ [QSH-2_____]
[CP, Gas X MGAS]
Flue gas outlet temperature from SH-2 = 602.5 0C
Gas side Effectiveness = (629 602.5) / (629 470)
Effectiveness = 16.7 % (gas side)
HP Super heater 1 Effectiveness from heat and mass balance:

Steam inlet temperature = 314.5 0C
(at HP drum pressure saturation temperature)
Steam outlet temperature = 489 0C
(before DSH)
Steam outlet pressure = 106.8 kg/cm2a

Steam inlet enthalpy = 2715.66 kJ/kg
Steam 0utlet enthalpy = 3340.49 kJ/kg
Steam flow rate (HP) = 105960 kg/hr (after subtracting SH spray of 2000 kg/hr)
SH -1 Heat duty = Mass flow of steam X Enthalpy change
QSH-1 = Heat duty = 66206986.7 kJ/hr
Flue gas inlet temperature = 602.5 0C
(From above SH-2 calculation)

Flue gas outlet temperature = TGas,in __ [QSH-1_____]
[CP, Gas X MGAS]
Average value of specific heat of gas = 1.08 kJ/kg 0C
Flue gas outlet temperature from SH-1 = 520.41 0C
Gas side Effectiveness = (602.5 520.41) / (602.5 314.5)
Effectiveness = 28.5 % (Gas side)
22
HP Evaporator Heat & Mass balance :

Latent heat of Steam at sat. Temp. & Pressure = 1287.51 kJ/kg
HP BFP flow = 108300 kg/hr
Steam drum pressure = 106.9 kg/cm2a
Steam sat temp = 314.5 0C kJ/kg
Feed water temperature from last ECO # 5 to EVAP = 300 0C
Enthalpy of feed water in to EVAP = 1344.05 kJ/kg
Enthalpy of feed water at saturation temperature = 1427.85 kJ/kg
Enthalpy of subcool = 83.8 kJ/kg
EVAP Heat duty = (Mass flow of water X (latent heat + Total enthalpy of subcool)
QEVAP= Heat duty = 148512873 kJ/hr
(From above SH-1 calculation)

Flue gas outlet temperature = TGas,in __ [QEVAP_____]
[CP, Gas X MGAS]
Flue gas outlet temperature from EVAP = 336.3 0C
HP ECO 5 Heat & Mass balance :

Feed water temperature outlet from ECO # 5 to EVAP = 300 0C
Feed water inlet temperature to ECO 5 = 280 0C
Enthalpy of feed water to ECO -5 = 1236.08 kJ/kg
Enthalpy change in feed water in ECO -5 = 107.97 kJ/kg
23
Economizer Heat duty = (Mass flow of water X Change in enthalpy)

QECO-5 = Heat duty = 11693151 kJ/hr
(From above EVAP calculation)

Flue gas outlet temperature = TGas,in __ [QECO-5_____]
[HChange X MGAS]
Flue gas outlet temperature from EVAP = 321.730C
Gas side Effectiveness = (336.3 321.73) / (336.3 280)
HP section combined effectiveness:

HP section effectiveness can be determined by following equations:
Minimum possible gas outlet temperature in HP section considering HP evaporator pinch
is given by Tgas,min = Tgas,out Tpinch,evap FR [Tgas/Twater]eco X Tsubcool
Tgas,min = 321.73 21.8 1.15 (14.6/20.0) X 14.5
Tgas,min = 287.75 0C
Finally,
HP section Effectiveness
= (629 321.73) X 100

(629 287.75)
HP section Effectiveness = 90.0%
24
IP Heat & Mass balance:

Intermediate pressure parts are shown in the following diagram with terminal measured
and calculated parameters. Detailed calculation is as follows:
IPSTM Flow = 8260 KG/HR

IP STM PR =27.3
IPSTM TEMP=272.5
Drum PR =27.8
TEMP=230.1 0C
IP Drum
F.W PR =28.0
TEMP=0C
T=299.960C
Gas flow=746856
KG/HR
T = 321.730C
IP EVAP
IP SH
IP SAT. STM TEMP =230.1 0C

IP STM FLOW = 8260 KG/HR
T=274
.75
0
C
IP ECO
F.W. Flow =10000 kg/hr

F.W. Temp =113 0C
F.W..Pr = 27.96kg/cm2
IP Super Heater Heat & Mass balance :

IP Steam flow rate flow = 8260 kg/hr
IP Steam temperature from SH = 272.5 0C
IP Steam pressure = 27.3 kg/cm 2a
Enthalpy of IP SH steam = 2930.45 kJ/kg
Gas
flow=746
856
KG/HR
T = 231.8
0
C
25
Enthalpy of inlet IP steam to SH= 2803.04 kJ/kg (at saturation T & P)

Enthalpy change in IP steam = 127.41 kJ/kg
IP SH Heat duty = (Mass flow of Steam X Change in enthalpy)
QIP-SH = Heat duty = 1052406.6 kJ/hr
(From above ECO-5 calculation)

Flue gas outlet temperature = TGas,in __ [QIP-SH_____]
[HChange X MGAS]
Flue gas outlet temperature from IP SH =320.4 0C

Feed water temperature from outlet temp. = 280 0C
(From above IP-SH calculation)

[HChange X MGAS]
Effectiveness = (320.4 299.96) / (320.4 250)
26
IP Evaporator Heat & Mass balance :

Latent heat of Steam at sat. temp & pressure = 1819.28 kJ/kg
IP BFP flow = 10000 kg/hr
Steam sat temp = 228.64 0C kJ/kg
Feed water temperature from IP ECO to IP EVAP = 190 0C
Enthalpy of feed water in to EVAP = 807.66 kJ/kg
Enthalpy of feed water at saturation temperature = 983.64 kJ/kg
EVAP Heat duty = (Mass flow of water X (latent heat + Total enthalpy of subcool)
QIP,EVAP= Heat duty = 19952600 kJ/hr

Flue gas outlet temperature = TGas,in __ [QIP,EVAP_____]
[CP, Gas X MGAS]
Gas side Effectiveness = (299.96.45 274.75) / (299.96 228.64)
27
LP Heat & Mass Balance:

Low pressure heat & mass balance schematic is as follow. Performance calculation one
by one is given below in detais:
Drum PR =6.4 kg/cm2

TEMP=161.4
LPSTM Flow = 8705 KG/HR

LP STM PR =6.01
LPSTM TEMP=216.4
LP Drum
F.W. Flow =10300 kg/hr

F.W. Temp =113 0C
F.W..Pr = 27.96kg/cm2
T=203.50C
Gas flow=746856
KG/HR
T = 269.30C
LP EVAP
LP SH
T=172.2
0
C
LP SAT. STM TEMP =161.4 0C

LP STM FLOW = 8705 KG/HR
LP Super Heater Heat & Mass balance:

IP Steam flow rate flow = 8705 kg/hr
IP Steam temperature from SH = 216.4 0C
IP Steam pressure = 6.01 kg/cm 2a
Enthalpy of LP SH steam = 2885.68 kJ/kg
Enthalpy of inlet IP steam to SH= 2759.49 kJ/kg (at saturation T & P)
Enthalpy change in IP steam = 126.2 kJ/kg
LP SH Heat duty = (Mass flow of Steam X Change in enthalpy)
28
QLP-SH = Heat duty = 1098484 kJ/hr

(From above IP-EVAP calculation)

Flue gas outlet temperature = TGas,in __ [QIP-SH_____]
[HChange X MGAS]
Flue gas outlet temperature from IP SH =273.3 0C

(From above IP-SH calculation)

[HChange X MGAS]
29
IP ECO Heat & Mass balance :

Feed water inlet temperature to IP ECO = 113 0C
Enthalpy change in feed water in IP ECO = 333.6 kJ/kg
QIP-ECO = Heat duty = 3335500 kJ/hr
(From above HP-ECO-3 calculation)

Flue gas outlet temperature = TGas,in __ [QIP-ECO_____]
[HChange X MGAS]
Flue gas outlet temperature from IP-ECO = 236.7 0C

(From above IP-ECO calculation)

[HChange X MGAS]
30

Gas side Effectiveness = (236.7 211.3) / (236.7 - 160)
LP Evaporator Heat & Mass balance :

Latent heat of Steam at sat. temp & pressure = 2080.25 kJ/kg
Steam sat temp = 160.63 0C
Feed water temperature from to LP EVAP = 113 0C
Enthalpy of feed water to EVAP = 474.05 kJ/kg
Enthalpy of feed water at saturation temperature = 680 kJ/kg
LP EVAP Heat duty = (Mass flow of water X (latent heat + Total enthalpy of subcool)
QLP, EVAP= Heat duty = 23547860 kJ/hr

Flue gas outlet temperature = TGas,in __ [QLP,EVAP_____]
[CP, Gas X MGAS]
31

(From above LP-EVAP calculation)

[HChange X MGAS]
CPH Heat & Mass balance :

CPH flow = 170000 kg/hr
Feed water temperature from outlet temp. = 97.0 0C
Feed water inlet temperature to CPH = 47.0 0C
Enthalpy change in feed water in CPH = 205.5 kJ/kg
QCPH = Heat duty = 34935000 kJ/hr
(From above HP-ECO-1 calculation)

Flue gas outlet temperature = TGas,in __ [QCPH_____]
[HChange X MGAS]
32

Gas side Effectiveness = (150.8 104) / (150.8 47)
(3.5) HRSG temperature profile for heat balance:

HRSG temperature profile has been made to know the minimum possible gas outlet
temperature. Generally, if the HRSG is not limited by evaporator pinch, the minimum gas
outlet temperature is simply the water inlet temperature. This situation is called
economizer pinch. CCPP # 2 HRSG is designed for evaporator pinch and gas outlet
temperature is limited by low pressure evaporator thats why to know the pinch
temperature difference and pinch point location temperature profile has been made. It is
easily seen from the temperature profile. Following data used to make HRSG temperature
profile which comes from heat and mass balance.
Data for HRSG gas temperature profile:

Gas inlet
Gas outlet
Fluid inlet
Fluid outlet
Heat duty
temp.
temp
temp
temp.
(kJ/hr)
HP-SH-2
629
602.5
470
535
22592789
HP-SH-1
602.5
520.4
314.5
489
66206986
HP-EVAP
520.4
336.3
300
314.5
148512873
HP-ECO-5
336.3
321.7
280
300
11693151
IP-SH
321.7
320.4
228.6
272.5
1052406
HP-ECO-4
320.4
299.9
250
280
16327308
IP-EVAP
299.9
274.7
190
228.6
19952600
LP-SH
274.7
273.3
160.6
216.4
1098484
HP-ECO-3
273.3
241.1
200
250
25227402
10
IP-ECO
241.1
236.7
113
190
3335500
S.No
HRSG Components
33
11
HP-ECO-2
236.7
211.3
160
200
19139859
12
LP-EVAP
211.3
180.0
113
160.6
23547860
13
HP-ECO-1
180.0
150.8
113
160
21833280
14
CPH
150.8
104
47
97
34935000
15
Total
16
HRSG
17
18
415455498
629
104
Radiation &
Unaccounted
Radiation & Unaccounted loss in % of total HRSG Heat Input
425427849
9972351
2.34
Temperature Profile Diagram for HRSG Heat Balance

700
Gas temperature
profile
SH-2
600
SH-1
HP-EVAP
SH-2
Temperature (C)
500
HP-ECO-5
SH-1
SH-2
IP-SH
ECO-4
400
IP-EVAP
HP-EVAP
HP-EVAP
SH-1
300
HP-ECO-5
HP-ECO-5
ECO-4
ECO-4
IP-SH
IP-SH
200
LP-SH
ECO-3
ECO-3
IP-EVAP IP-EVAP
LP-SH
LP-SH
IP-ECO
ECO-3
IP-ECO
ECO-2
IP-ECO
LP-EVAP
ECO-2
LP-EVAP
ECO-1
ECO-2
LP-EVAP
ECO-1
100
CPH
ECO-1
CPH
CPH
0
0
50000000
100000000
150000000
200000000
250000000
300000000
350000000
400000000
Heat Transfer (kJ/Hr)
450000000
34
(3.6) Results and Discussion:
Following conclusion has been drawn from above HRSG heat balance calculation:
HRSG is operated with the efficiency of 78.35 % and effectiveness of 96%.
Design HRSG efficiency is generally around 83.0% with the effectiveness in of 91%.
Effectiveness of HP section is 90.0% where as design value is in the range of 90
95%. Effectiveness of HRSG is deteriorated in some extent. Also low HP steam

generation as compare to design than IP & LP steam also supports this conclusion.
This concludes that HP section of HRSG is suffering from internal/external
deposition and major portion of heat is transfer occurred in IP & LP section. It is

recommended to go for acid claiming in HP section. Adequate surface heating area in
HRSG HP section for generating design HP steam flow is also suspected.
HP steam generation is less than design where as LP steam generation is more than
design. This means that heat transfer in HP section is less than design value where as in
LP section it is more. Due to low heat transfer in HP section, flue gas enters in IP & LP
section at higher temperature than design.
Dhuvaran CCPP # 2 HRSG design for evaporator pinch as we have seen from
temperature profile diagram that it comes at LP evaporator. So minimum temperature

difference between gas and steam/water that can be achieved from good heat transfer is
20.00C (i.e 180.8 -160.4) which is at LP evaporator section.
HP steam pressure at super heater outlet is lower than the design value of 106
kg/cm2a. This result in greater gas to steam heat transfer and increases the steam
production. Thus, HRSG can produce more steam at lower pressures, but the steam is less
valuable for electricity production because of the lower pressure level.
Due above reason it is suggested to operate HRSG at higher pressure and
temperature close to design value.
35
Radiation loss from HRSG surface after heat & mass balance is found 2.3% which
is close to design value of 2.0 to 3.0%.
Total gas flow rate to HRSG is 746856 kg/hr which is slightly higher than the
design value of 718900 kg/hr, higher gas flow increases the steam production but
operating parameters of HP steam generation is less than the design value. This gives the
indication of deposition on HP evaporator heating surface, though effectiveness of HP
evaporator is good is 83.5%. (It should be nearly 90%).
4.0
Steam Turbine:
Combined Cycle Power Plant # 2 has one condensing type steam turbine. Technical
specifications of the turbine are given below:
Turbine:
Make
: BHEL
Type
: HNK 71/3.2-4
M/c No.
: T-0609
Rated output
: 40.3 MW
Speed
: 3000
Inlet HP steam pressure
: 103 atm
Inlet HP steam temperature
: 539.6C
Exhaust pressure
: 0.098 atm
36
4.1
Performance evaluation of Steam Turbine:
(4.1.1)
Steam Turbine Cycle Heat Rate:
Turbine cycle heat rate is calculated separately to know the efficiency of turbine cycle in
combined cycle power plant #2 of Dhuvaran. Measured value has been shown in the table
below:
Measured value:
S.No
Measured Parameters
Unit
Design
Operating
Value
Value
Steam generator net output
MW
40.3
34.1
Steam turbine speed
rpm
3000
2959.8
Gas inlet temperature to HRSG
616.7
629
Gas inlet flow (calculated)
TPH
718.9
746.856
Final Gas Exit temperature
97
100.5
HP steam pressure at HRSG
Kg/cm2a
107
103.1
HP steam temperature at HRSG
542
535.8
HP steam flow at HRSG
TPH
118.2
107.96
HP feed water pressure at HRSG
Kg/cm2a
112
111.2
10
IP steam pressure at HRSG
Kg/cm2a
30
27.32
11
IP steam temperature at HRSG
260
272.5
12
IP steam flow at HRSG
TPH
8.3
8.26
13
IP feed water pressure at HRSG
Kg/cm2a
32
28.1
14
LP steam pressure at HRSG
Kg/cm2a
6.0
6.01
15
LP steam temperature at HRSG
200
216.5
37
16
LP steam flow at HRSG
TPH
6.6
8.705
17
Condensate flow to CPH
TPH
183.34
192.0
18
CPH feed water inlet temperature
60
53
19
CPH feed water outlet temperature
100
97.5
20
Feed water temperature to ECO
105
113
C
C
C
Fluid Properties:
S. No
Properties
Unit
Design
Operating
Enthalpy with the HP steam
kCal/kg
830.15
826.9
Enthalpy with the IP steam
kCal/kg
689.58
700.39
Enthalpy with the LP steam
kCal/kg
680.78
689.19
Condensate water Enthalpy
kCal/kg
60
53
Feed water enthalpy
kCal/kg
105
113.2
Avg. Sp. Heat of gas
kCal/kg
1.08
1.08
Steam Turbine Cycle Heat Rate Calculation:
Design H.R.=
MHP X (HHP,STM HFW) + MIP (HIP,STM HFW) + MLP (HLP,STM HFW) + MCPH(HO-HIN)
POWgen
118.2 (830.15 105) + 8.3 (689.58 105) + 6.6 (680.78 105) + 183.34(100-60)
40.3
Design Heat Rate = 2523.5 kCal/kWh
Design turbine cycle efficiency = 34%
Operating H.R.=
MHP X (HHP,STM HFW) + MIP (HIP,STM HFW) + MLP (HLP,STM HFW) + MCPH(HO-HIN)
38
POWgen
107.96 (826.9 113.3) + 8.26 (700.39 113.3) + 8.705 (689.19 113.3) + 192.0(97.5-53)
34.1
Design Heat Rate = 2799.02 kCal/kWh
Design turbine cycle efficiency = 30.0%
(4.1.2)
Calculation of Turbine Cylinder efficiency:
Dhuvaran CCPP # 2 consists of one HP cylinder, IP cylinder, and LP cylinder. Exhaust of

cylinder is fed to upstream cylinder and finally to condenser. Measured values are
tabulated in the table below:
Measured value:
S.No
Measured parameters
Unit
1
2
3
4
5
6
7
8
HP steam cylinder inlet pressure

HP steam cylinder inlet temperature
HP steam cylinder exhaust pressure
HP steam cylinder exhaust temperature
IP steam cylinder inlet pressure
IP steam cylinder inlet temperature
IP steam cylinder exhaust pressure
IP steam cylinder exhaust temperature
kg/cm2a
0
C
kg/cm2a
0
C
kg/cm2a
0
C
kg/cm2a
0
C
Operating
Value
99.0
535
N.A
N.A
27.2
267
N.A
N.A
Calculation of turbine cylinder efficiency:

Turbine cylinder efficiency can not be measured due to unavailability of correct tapping
positions and other practical difficulties.
(4.1.3)
Result and Discussion:
Following observation has been made from above calculation:
39
Operating turbine cycle efficiency is lower than the design value.

Reason behind is turbine entering steam pressure and temperature is less than the
design value hence thermodynamically possible work output from turbine has been
reduced.
Condenser back pressure is slightly greater than design. (See condenser section)
Steam turbine cylinder efficiency may be deteriorated. (Steam turbine efficiency
calculation is not possible due to unavailability of measured data)
5.0
C.W. Systems
The generating Unit-2 CCPP consists of single shell condenser units with single passes.
The design specification of condenser of the generating station is given below. On the
basis of site measurement and data collection performance of the condenser unit was
evaluated and given below: Measured data are tabulated in the table.
5.1
Measurement & Calculation:

Losses contributing to deviation of backpressure from optimum (Design)
The usual reasons for deviation of condenser parameters from design are:
(1) Cooling water inlet temperature is different from design value
(2) Cooling water quantity flowing through condenser is different from design
(3) Fouled and dirty tubes
(4) Air ingress into the system under vacuum
The contribution of above factors to a given deviation of backpressure from optimum is
determined analytically and presented below:
40
Measurement Table:
Sl.No.
Measured parameters
Unit
Design
value
Measured value
MW
40.3
34.1
Generation
CW inlet temperature
36
26.8
CW Outlet temperature
42
32.3
CW Inlet pressure
kg/cm2a
2.2
2.2
CW Inlet pressure
kg/cm2a
1.1
1.6
CW Temperature rise
5.5
Mean temperature
39
29.55
Barometric pressure at site
mmHg
757
757
Condenser vacuum
mmHg
682.5
677
10
Condenser back pressure
mmHg
74.500
80.000
11
kg/cm2a
0.1012
0.1087
12
mbar
99.32
106.65
13
Sat. Temp at back pressure
45.68
47.05
14
Hot well temperature
48
49
15
CW Flow rate to
condenser
TPH
12500
12350
16
Air ingress
m3/hr
30
17
Heat transfer surface
m2
N.A.
Calculated Parameters
1
Terminal temp. Difference
3.68
14.7
Initial temp.difference
9.68
20.2
LMTD
6.20
17.30
41
Air ingress
kg/hr
Heat load on condenser
kCal/Hr X 1000
Overall Heat Transfer

Coeffi
kCal/m2.C.m2
Effectiveness
20
74549.2
67516.7
N.A.
61.98
27.22
Deviation calculation of condenser parameters from Design

S.No
Parameters
Unit
Values
Deviation Due to change in CW inlet temperature

1
Change in inlet cooling water temperature
-9.2
New outlet temperature (other parameters

suppose to be constant)
32.8
New average temperature
29.8
New temperature rise
6.63
36.88
5
6
New LMTD (Effect of changes in heat

transfer coefficient due to lower CW inlet
temperature)
Calculated New saturation temperature (by
formula)
Corresponding back pressure
mbar
62.4
Deviation
mbar
-36.92
Deviation Due to change in CW flow

1
CW temp rise due to change in flow
6.072
New CW outlet temperature
42.07
New average temperature
39.036
6.241
45.76
4
5
New LMTD (Effect of changes in heat

transfer coefficient due to change in CW
inlet flow)
formula)
42
mbar
99.7
Deviation
mbar
0.374
Fraction
0.846
5.076
5.249
44.190
Deviation due to load

1
Change in heat rejection to condenser from

design
CW temp rise due to Heat rejection
3
4
New LMTD (Due to variation in heat

transferred)
formula)
mbar
91.9
Deviation
mbar
-7.425
mbar
-43.975
mbar
55.34
mmHg
41.51
34.75
mbar
106.65
mbar
51.30
mmHg
38.47
Final condition
1
2
3
4
5
6
7
Net deviation in back pressure due to

change in all parameters from design
Back pressure that can be achieved Ideally
without any air ingress or fouled tubes
Back pressure that can be achieved Ideally
without any air ingress or fouled tubes
Sat. Temp at estimated (probably achieved)
back pressure
Measured back pressure
Back pressure lost due to fouled tubes and
air ingress
Back pressure lost due to fouled tubes and
air ingress
N.A.: Not Available

(5.2) Formula used to calculate deviations:LMTD = Logarithmic mean temperature difference.
T1= ts-t1= temperature difference at the CW inlet condition
43
T2 = ts-t2= temperature difference at the CW outlet condition

ts.= saturation temperature at given back pressure.
t1= Design CW inlet temperature.
t2= Design CW outlet temperature
T1= Operating CW inlet temperature
T2= Operating CW outlet temperature
t4 = Design CW temperature rise
T4 = Operating CW temperature rise
T4= t1-T1 = New rise
Q1= Design CW flow
Q2 = Operating CW flow
L1 = Design load.
L2 = Operating load
(1). Deviation in back pressure due to change in inlet temperature:
From the following formula, new saturation temperature has been calculated hence back
pressure in condenser.
(1).New LMTD ={(Design LMTD)(Design Avg. Temp. /New Avg. Temp.) 0.25}
(2).New LMTD = [(T1-T2)/ln ((Ts-T1)/(Ts-T2))]
(2). Deviation due to C.W. flow
(1).New CW Temp. Rise (T4) = (Q1/Q2) t4)
(2).New LMTD = (Design LMTD (Q1/Q2)0.5
(3) New LMTD = [(T4)/ln ((T3-t1)/(T3-t2))]
From the above formula, new saturation temperature has been calculated hence condenser
back pressure.
44
(3). Deviation due to heat rejected to the condenser

(1).New CW Temp. Rise (T4) = (L2/L1) t4
(2) New LMTD = Design LMTD (L2/L1)
(3) New LMTD = [(T4)/ln ((T3-t1)/(T3-t2))]
(5.3) Results and Discussion:
9 Back pressure deviated due to lower CW inlet temperature is -36.92 mbar from
design value. This means condenser is getting a benefit of vacuum of 36.92 mbar.
9 Back pressure deviated due to lower CW flow is 0.374 mbar from design value.
This means condenser is getting a debit of vacuum of 0.374 mbar.
9 Back pressure deviated due to lower load is -7.425 mbar from design. This means
condenser is getting benefit of vacuum of 7.425 mbar.
9 Back pressure that could be achieved ideally as per design without any fouling and
air ingress with present operating condition is 55.34 mbar
9 Operating back pressure of CCPP # 2 is 106.65 mbar this means vacuum lost due
to fouled tubes and air ingress is 51.3 mbar.
9 Effectiveness of the condenser is calculated 27.2.0 % where as design value is
62.0%. Higher TTD also support the statement of air ingress and dirty tubes.
9 Air ingress has been measured by Rota meter and is 20.0 kg/hr which is close to
design value. Air ingress generally in the range of 10 20 kg/hr for similar
capacity condenser.
Though condenser is operated at a point of optimum design vacuum but it is offset by
tubes fouling to get a benefit of lower CW inlet temperature. If condenser has heat
transfer coefficient near the design value, less CW flow to condenser could give the
same vacuum. After taking corrective measures 20% less CW flow can give the same
amount of vacuum. So, at least 10% of total power of CW pump can be saved by
reducing the flow by throttling.
45
So, the condenser is suffering from tubes fouling/dirt and need to be corrected in
scheduled plant shutdown.
(5.4) Saving Potential

Operating back pressure in the condenser
= 106 mbar
Design back pressure at operating condition
= 114.66 mbar
Power consumed by CW pump
= 986 kW
Power saved @ of 10%
= 98.6 kW
Unit saved per year
= 780912 kWh
Considering 330 days operation per year )

Amount saved per year @ Rs 2.89/unit
= Rs 22.56 Lakh
(Net investment for tubes acid cleaning (approx.)

= 12 Lakh
Payback period
= within 7.0 months
Fig: 1 - Condenser Performance

120
Increase/Decrease in
slope indicate less/more
CW flow
Increase/Decrease in slope
indicates heavy fouling/no
fouling
Saturation Temp.
100
40
20
47
42
34.75
32.3
32.3
CW supply
41.516
45.68
36
26.8
26.8
80.000
74.500
Back pressure
in mmHG (abs)
CW outlet Temp.
CW inlet temp.
80
60
Increase /decrease in
slope indicates more/no
air leakage
Condenser Fouling
Air Leakage
0
Design Condition
Operating Condition
Estimated condition
45
(6.0) Steam Trap & Condensate recovery:

Following points have been observed during the survey of condensate collection
system:
1. Condensate from HP, IP, LP and other steam line is collected in the Flash
Tank 1 via drain pipe where flash steam is generated at 1 atmosphere pressure.
Flash steam and condensate is then discarded into drainage as a waste through
over flow pipe of Flash Tank.
Incoming condensate temperature = 240 0C
Drain temperature = 1010C
2. Some quantity of condensate from different steam line is collected in
condenser level balance line from where it is drained through overflow line to
drainage system as a waste.
Condensate Temp. = 49 0
3. All HRSG header drain and Steam drain collected in FT Flash tank -2 and this
condensate has been discarded to drainage system at 850c as a waste also all
HRSG drain and CPH drain are mixed with impure boiler blow down in IBT
tank and send to treatment plant ETP plant at a temperature of 1000C.
4. All HP drain, LP Drain, SH drain (steam side drain ) is mixed with impure
ECO, LP, HP ,blow down water and sent to IBD from where it sent to ETP.
Recommendation:
Collect pure and impure condensate in separate tank by closing the valve of
line where it mixes. Valve passing of condensate should be checked and
arrested.
Stop the overflowing of condensate from flash tank and prevent draining of
condensate to drainage line.
46
Check technical feasibility to sent back all collected pure condensate to DA

by installing pump trap (which utilize high pressure steam as motive force)
after discussing with BHEL officials.
(7.0)
Insulation survey
(7.1) Introduction:-
Insulation survey has conducted in CCPP #2 at Dhuvaran for estimation of radiation

heat loss in HRSG, steam line for calculation of heat loss through heating surface.
For this temperature of heating surface has been recorded with the help of calibrated
Thermal Image Camera.
Surface temperature along with insulation condition is summarized in the

table along with total heat loss & heat loss saving potentials calculation. Reference
thermal image (at sample basis) has been also captured to indicate the correct
location of un-insulated area. At the time of measurement Dhuvaran CCPP # 2 GT
was at a steady load of 67.7 MW and HRSG at 34.1 MW. Site condition was
closely monitored during the measurement and are given below
1 - Ambient temperature
30 0C
2.- Relative humidity
30.1 %
3 .-Wind velocity (Avg)
0.5 to 0.8 m/s
Dhuvaran site is located on the bank of ARAB Sea and condition is windy, hot and
humid in summer. For this reason natural convection as well as forced convection
loss is also included in the radiation loss calculation. For natural convection average
47
wind velocity of 0.5 m/s is taken for calculation purpose. Total radiation heat loss
from radiating surface is calculated by taking the average surface temperature of
that region and average ambient temperature throughout the day (30 0C).Overall
CCPP insulation was found excellent and well placed with cladding except some
insinuated places mentioned in the audit report. Details of total heat loss with heat
saving potential calculation are given in calculation part in the table. Reference
Thermal Image is also attached with the report for identifying correct location of
hot spot and bare surface. Soft copy of Thermal images (jpeg format) is sent along
with hard copy of report.
(7.2) Key Findings: HRSG insulation is found excellent and need not any immediate attention.
Near HP super heater location, hot spot on the HRSG surface has been
observed.
Steam line insulation is good and need not to any immediate attention.
In De-aerator, steam and feed water line insulation have been observed
damage in some places but surface temperature is not high.
Steam turbine insulation is found excellent.
(7.3) Heat loss calculation with saving potential:

Figure to identify correct location of heat loss as reference made in calculation table:
48
6m
9m
9m
5m
11 m
K
M
43 mtr
Calculation table part wise part:

Radiation measurement of HRSG (CCPP # II)
HRSG - II
Location (PART-A)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
55
1912
Good
TH-01
LHS Wall
None
55
1912
Good
49
HRSG - II
Location (PART-B)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
50
23
3294
Good
TH-02
LHS Wall
None
48
23
2912
Good
HRSG - II
Location (PART-C)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m2)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
Near expansion
joints
65
2231
586
Weak
TH-3
LHS Wall
Near expansion
joints
65
2231
586
Weak
TH-18/19
HRSG - II
Location (PART-D)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
42
40.75
3225
Good
TH-4/5/6
92
0.25
142
84
Weak
TH-3
50
41
5873
Good
At maintenance window
LHS Wall
None
50
HRSG - II
Location (PART-E)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
45
13
1331
Good
TH-7
LHS Wall
None
55
12.5
2330
Good
TH-20
110
0.5
393
272
Weak
TH-20
Hot spot near 24 way junction

box.
HRSG - II
Location (PART-F)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
45
60
6145
Good
TH-9
LHS Wall
None
55
58
10810
Good
TH-21/22
120
3677
2683
Weak
TH-21,22,24
Hot spot in part F1 at five

location
HRSG - II
Location (PART-G)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
45
33
3380
Good
TH-10
LHS Wall
None
58
33
7039
635
Good
51
HRSG - II
Location (PART-H)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m2)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
42
33
2612
Good
TH-12
LHS Wall
None
60
33
7645
1114
Good
HRSG - II
Location (PART-I)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
45
10
1024
Good
TH-11
LHS Wall
None
55
10
1864
Good
HRSG - II
Location (PART-J)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
40
28
1798
Good
TH-13/14
LHS Wall
None
58
28
5972
539
Good
52
HRSG - II
Location (PART-K)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m2)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
40
28
1798
Good
TH-16
LHS Wall
None
58
28
5972
539
Good
HRSG - II
Location (PART-L)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
40
10
642
Good
TH-15
LHS Wall
None
55
10
1864
Good
HRSG - II
Location (PART-M)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
43
57
4947
Good
TH-17
LHS Wall
None
45
57
5837
Good
53
HRSG - II
Top/Bottom portion
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
Top portion
None
55
300
55914
Good
26,27,28,29
Bottom
portion
None
55
280
52186
Good
DEAERATOR
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
DEAERATOR
None
65
25
6973
1831
Good
41
Storage tank
None
35
88
2579
Good
55
2.5
466
cladding
open
31,34,35,38,36
Photograph
Insulation open at different

positions in steam line near by
DA
Steam Headers (HP,IP,LP)

Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
HP Steam
pipe
None
60
120
27798
60
Good
IP steam
None
60
130
30115
60
Good
LP Steam
None
55
140
26093
55
Good
54
Total heat loss from HRSG
= 2, 18,932 kCal/hr
Total heat loss from Steam path system (HP, IP, LP)
= 84,006 kCal/hr
Total system heat loss
= 3, 02,938 kCal/hr
Total heat input to HRSG from GT exhaust
= 5.09 108 kCal/hr
% of heat loss from total heat input
= 0.06 %
Total Heat saving potential realized in total system
= 8,868 kCal/hr
(This heat saving potential has negligible amount as compare to total heat input)
(7.4)
Recommendation:
Hot spot have been observed in HRSG HP Super-heater area so it is recommended

to check the refractory healthiness and replace damaged and wearing out refractory.
Actual investment can not be judged without knowing how many refractory bricks
have been damaged or worn out.

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THERMAL ENERGY AUDIT REPORT

Energy Management Section

Electrical Research and Development Association

Recipient of Petroleum Conservation Research Association (PCRA) Best

We are thankful to other staff members of the company whose contribution

Introduction: Performance evaluation of Gas Turbine: 2.1

Thermal Energy Saving Potential per Year

= Rs. 22.56 Lakh

Approximate Investment Required

= Rs. 12.0 Lakh

Installed capacity of GTG

Installed capacity of STG

Installed capacity of (GT+STG)

Commissioning Date of STG

Commercial operation Date

Aux. consumption in open cycle

Aux. consumption in Combined cycle

Design Net Efficiency (open cycle)

Design Net Efficiency (combined cycle)

Design Gross Efficiency (open cycle)

Design Gross Efficiency (combined

Design Heat Input (combined cycle)

Design Heat rate (open cycle) based on

: MS6001FA+FA: GE, USA

No. of Combustion Chambers

:32.6 Deg C Ambient @ 64% RH

Performance evaluation of Gas Turbine

Heat and Mass balance for Gas turbine:

Heat and Mass Balance equation and terminology used:-

mair = Mass flow rate of air (kg/sec)

Gas Turbine Design Constants used to solve balance equation:S.No

Fraction of inlet air used to cool

Temperature factor of cooling air

Temperature factor of bleed air

Temperature loss of bleed air going

Combustor pressure loss fraction

Fluid properties input to Heat balance:S.No

Lower Heating value at STP

Air ratio of Specific Heat

Gas ratio of specific heat

Measurement values for Gas Turbine:S.No

Compressor discharge pressure

Average exhaust gas temperature

Exhaust gas pressure

Gas turbine net power

Auxiliary power cons.(Open

Fuel firing rate

Calculated output from Gas Turbine Heat Balance:_

Rate of Inlet air flow

Cooling air temperature to nozzle

Compressor bleed temperature

Power consumed by compressor

Combustor exit gas temperature

Combustor exit gas pressure

Rate of Compressor exit gas flow

Rate of Combustor exit gas flow

Rate of first stage inlet gas flow

Rate of first stage nozzle cooling air

Rate of expander cooling air flow

Firing temperature (first stage rotor inlet

Turbine inlet temperature

First stage nozzle area

Expander power production