SP.

ENTHALPY, H

SP. ENTROPY,S
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Need of efficiency & performance monitoring : High cost of installation of new power plant Rs. 3.5 to 4 Crore /MW installation +Rs. 1.5 to 2 Crore /MW for T&D Increased plant performance leads to increased plant availability and vice versa Maximising generation with minimum generation cost For increasing station performance main areas : Planned Maintenance Loss Thermal Efficiency Factors Plant Load factor Forced outages Plant Availability Factor Optimising terminal conditions of the unit

MS parameters Rejection 2 Parameters

Areas of concentration for increasing Efficiency :

Heat rate of Turbine Boiler Efficiency DM water Make-up Specific Oil Consumption Excess air Condenser Back Pressure

Basic Concepts of Efficiency :

Overall Station Efficiency = Output Input

Energy Sent Out (KW) = Fuel Burnt (Kg) * Calorific Value of Fuel Rankine Cycle
Boiler Efficiency ((Steam Supplied in Kgs * Total heat in superheated steam) Total heat of feed water))

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TEMPERATURE, T

=
Fuel Burnt (Kg) * Calorific Value of Fuel (Kcal/Kg)

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ENTROPY,S
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B =

Ms*h3-Mf*h1 * 100 Mc * C.V.

Heat Balance Diagram Showing Losses : 100 BOILER LOSSES 10 - 13 %

PERCENTAGE

HEAT INPUT

CONDENSER LOSSES 45 - 49 % GENERATOR LOSS 2-4% USEFUL HEAT OUTPUT 34 - 39 %

Weight of Air required for Combustion : (i) Carbon C + O2 = CO2 12 + 32 = 44 1 + 8/3 = 11/3 O2 = 8/3 C --------- (a) Oxygen required = 8/3 times wt. Of Carbon

(ii)

Hydrogen

2H2 + O2 = 2H2O
4 + 32 = 36 1 + 8 = 9 O2 = 8H -----------(b)

Oxygen required = 8 times the wt. Of Hydrogen

Weight of Air required for Combustion : contd... (iii) Sulphur (iv) S + O2 = SO2 32 + 32 = 64 1+ 1=2 O2 = 1 S --------- (c) Oxygen required = Same as wt. of Sulphur Combining formula (a), (b) & (c) Oxygen required / gm of fuel = 8/3 C + 8H + S ------- (d) (v) Assuming all the Oxygen in the fuel will combine with Hydrogen in the fuel the actual amount of Hydrogen requiring air is (H - O/8) Oxygen in gm/gm of fuel = 8/3C + 8(H - O/8) + S Air in gm / gm of fuel = 4.31[ 8/3C + 8(H-O/8) + S ]
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(vi)

Excess Air requirement : Optimum Excess air = 20 % of Stoichiometric (perfect) air for combustion

PERCENTAGE HEAT LOSS

40

30

20

MINIMUM LOSS
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EXCESS AIR FOR MINIMUM LOSS

0 0 20 40 60 80 100

PERCENTAGE EXCESS AIR

Boiler Efficiency : Direct method ( Enthalpy of Steam - Enthalpy of Feed water) * Steam flow Fuel Burnt (Kg) * Calorific Value of Fuel

Boiler Efficiency =

Indirect or losses method Boiler Efficiency = Boiler Losses Dry Flue Gas Loss Wet Flue Gas Loss Due to moisture in fuel Due to Hydrogen in fuel Unburnt Carbon Loss Rejection Loss in Ash Radiation Loss Unaccounted Loss
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100 % - Total Loss in Percentage

Boiler Efficiency :
L1 = DRY FLUE GAS LOSS = {100 * Qa * Cpg * (Tg Ta)} (Wg * GCV)

Qa = TOTAL AIR FLOW IN Kg/Hr Tg = FLUE GAS TEMP. AT ESP OUTLET Tr = REFERENCE AMBIENT TEMP. IN Wg = COAL FLOW RATE IN Kg/Hr Cpg = SPECIFIC HEAT OF FLUE GAS = 0.246 Kcal GCV = GROSS CALORIFIC VALUE OF FED COAL IN Kcal /Kg

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Boiler Efficiency :
L2 = LOSS DUE TO MOISTURE IN FUEL = {100* M* Wg* ( hg - ha)} Wg * GCV

hg = SP. ENTHALPY OF VAPOUR AT AIRHEATER OUTLET IN Kcal/Kg(FOR AIR

ha = SP. ENTHALPY OF WATER AT AIRHEATER INLET IN Kcal/Kg (FOR AIR) M = MOISTURE CONTENT IN FED COAL IN % OF WEIGHT

L3

= LOSS DUE TO HYDROGEN IN FUEL = {9 * 100* H* Wg* ( hg - ha)} Wg * GCV

H = HYDROGEN CONTENT IN FED COAL IN % OF WEIGHT

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Boiler Efficiency :
L4 = LOSS DUE TO UNBURNT IN ASH = {100* Wg * U * A * K Wg * GCV

U = WEIGHTED AVERAGE OF UNBURNT CONTENT IN % A = ASH CONTENT IN FED COAL IN % K = C. V. OF CARBON BURNT TO CO2 IN Kcal/Kg = 8139 L5 = DUE TO HEAT REJECTED IN ASH = [ 100* Cpg * A * {0.1*(Tba Ta) + 0.9*(Tg-Ta)}] GCV

Tba = BOTTOM ASHING TEMP. IN L6 L7

= RADIATION LOSS = 0.8 (ASSUMED) = UNACCOUNTD LOSS = 0.647 ( DESIGN FIGURE )

= 100 [ L1 +L2 +L3 +L4 +L5 +L6 +L7]

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Other parameters affecting Boiler Efficiency :

CONTROL OF BLOW DOWN AND MAKE UP
AUXILIARY POWER CONSUMPTION OPTIMIZATION OF OIL CONSUMPTION AIR HEATER PERFORMANCE AND TRAMP AIR TO BOILER
MINIMUM LOSS

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PERCENTAGE HEAT LOSS

HEAT LOSS DUE TO UNBURNT HEAT LOSS DUE TO FLUE GAS HEAT LOSS DUE TO UNBURNT GAS

30

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TOTAL HEAT LOSS

10

0 0 20 40 60 80 100 13

PERCENTAGE EXCESS AIR

HEAT RATE :
TURBINE HEAT RATE = Qs * (Hs - Hf) Eg
Qs = STEAM FLOW AT TURBINE INLET IN KG/HR Hs = TOTAL HEAT OF STEAM AT TURBINE INLET IN KCAL/KG Hf = TOTAL HEAT OF FEED WATER AT ECONOMISER INLET IN KCAL/KG Eg = NET LOAD GENERATED IN KW

TURBINE EFFICIENCY =

860 * 100 HEAT RATE

PLANT HEAT RATE =

860 *100 TURBINE EFF. *BOILER EFF.

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CONDENSER PERFORMANCE :
20 p4 16

EFFICIENCY = (H1-H2) / H1
= (T1-T2) / T1

DELTA T = CW O/L - CW I/L

Pressure, bar abs.

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p1 8

TERMINAL TEMP. DIFF. (TTD) = EXH. HOOD - CW O/L CONDENSER VACUUM = BAROMETRIC PR. - BACK PR.

4 p2 p3 0 0 1 2 3

Volume, m3/kg 15

CONDENSER PERFORMANCE :
LIMITATIONS IN REDUCING BACK PRESSURE :
INCREASED CW PUMPING POWER

HIGH LEAVING LOSS LEAVING LOSS SQR (VELOCITY) SQR (SP. VOL) 1 / SQR (BACK PRESSURE)

REDUCED CONDENSATE TEMP.

WETNESS OF STEAM EVERY 1 % INCREASE IN WETNESS = 1 % DECREASE IN EFFICIENCY OF ASSOCIATED STAGE

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PUMP PERFORMANCE & MONITORING Terms used in pumping system :

A : Potential head/geometric head/ static head = head due to height + head due to pressure = H
+ P/D*g where , H= height of water column P = pressure on the surface of water in the tank D = water density at a particular temp. g = acceleration due to gravity

B : Kinetic head / dynamic head = V2/2*g

where , V= velocity of liquid in the pipe line This head is proportional to flow rate(Q).
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C : Frictional head = 4* f*L*V2 / 2*g*D

where , f= pipe surface roughness L= length of pipe V= flow velocity D= inner dia. of pipe g= gravitational constant

D : Gross total head = potential head + kinetic

head + losses

E : Net positive suction head (NPSH)

NPSH) available = (P - Pv)* 2.31/ sp. Gravity -losses +/- Z Where , P= absolute pressure at liquid surface Pv = vapour pressure of liquid at pumping temp. Losses = kinetic head + frictional head + entrance loss Z= static elevation from liquid level in suction 18 tank to the centre line of the first stage impeller of the pump

NPSH) available

NPSH
NPSH)required

Cavitation starts

FLOW RATE Q As a general rule the NPSH ) available should be 30% higher than the required NPSH at the operating point.
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NOTE : If NPSH) available approaches to zero than there will be severe cavitation in the pump.

IMPROVEMENT IN NPSH AVAILABLE OF BFP

1:Raise the deaerator height for more static head. 2: Incorporate slow speed booster pump to have lower NPSH) required. 3: Keep dp across the suction filter less than 0.5 kg/cm2.

IMPROVEMENT IN NPSH AVAILABLE OF CEP

1: Use larger size suction piping with larger radius bend instead of elbows. 2: Use long radius suction bell mouths in case of vertical pumps.
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