ENERGY AUDITS

IN
THERMAL POWER STATION

Material Prepared and Presented: by:

Mr. V.K.Gupta, EX. Sr. Maint. Engineer, NPTI
What is Energy Audit and what is its purpose

Energy audit is a technique used to establish pattern of

energy use; identify how and where loses are occurring;
and suggest appropriate economically viable engineering
solutions to reduce such losses, enhance energy efficiency
and optimal use of the resources in a system under review.

PURPOSE:
Instrumented and diagnostic energy audits (with aims
ranging from identifying ways of conserving energy to
evolution of a new blue print for the energy system) provide
insight into the modes of better utilization of fossil resources
and high-grade energy and exploration of renewable energy
options.
2
The general methodology of instrumented
& diagnostic energy audit consists of the
following :
Preliminary data analysis
Measurement at site
Data analysis
Recommendations based on economic viability-
short term, medium term & long-term measures
for improvements.
Report preparation, submission, discussion and
recommendation for improvements & finalization
of findings of the audit after discussion with the
client.
3
What is carried out during Energy Audit:
Energy Efficiency & Renewable Energy experts and individual
agencies like BIS, CPRI establish benchmarks of the unit heat
rates and station heat rates of coal fired units of various
thermal power stations through conducting performance tests
on various systems and equipments. Present performance
indices are computed and compared with the design based
values or other applicable standards and suggest ways and
means for immediate, medium and long term solutions for
improvements. .

The performance indices cover unit heat rates (UHR), station

heat rates (SHR), specific oil consumption (SOC) and auxiliary
power (AP) consumption etc.

.
4
Specific Secondary Fuel Oil Consumption (SFC):- it remains around 0.3ml/kwh
to 0.5 ml/kwh.

5
What are the objectives
of Energy Audit

6
Order of significance in a power plant operation and efficiency:-
1. Legal compliance
2. Life of the plant
3. Output of the plant
4. Efficiency
Legal Compliance:- Firstly legal and environmental compliance
is very important for continuing operation of the plant.
Life of the plant:- Secondly life of the plant and its equipment is
very important for it to live design expected life and thus
capable of producing power for its life time.
Output of the plant:- Thirdly output is very important for
sustaining operation and ensuring accomplishment of
purpose of plant.
Efficiency :- Efficiency comes in fourth position and it will
decide how well a power unit is performing in converting coal
energy to electrical energy.
7
HEAT RATE

8
 Heat Rate is simply a ratio between heat input and energy
output. There are four definitions.
1. Unit heat rate:- Heat input to boiler / gross electrical output
2. Net heat rate:- Heat input to the boiler / net electrical
generation
(Auxiliary consumption must be subtracted from gross
generation)
3. Actual unit heat rate- Total heat input to the boiler / actual
net generation of the period under consideration.
4. Design Unit heat rate:- Design heat rate is the heat rate
anticipated at the design parameters at specific load like
MCR (maximum continuous rating) , VWO (valve wide open
operation) etc. with design efficiencies of equipments.

9
A. HEAT RATE DEVIATION WITH PARAMETER DEVIATIONS

1 MAIN STEAM PRESSURE 14.54 kcal/kwh for1 Mpa

2 MAIN STEAM 0.38Kcal/kwh for 10C

TEMPERATURE
3 REHEAT STEAM 0.38Kcal/kwh for 10C
TEMPERATURE
4 Vacuum Standard 89.50 Kpa
89 kpa Loss 27.15 kcal/kwh
88kpa Loss 46.54 kcal/kwh
87kpa Loss 60.12kcal/kwh
86kpa Loss 75.63kcal/kwh
85kpa Loss 89.21 kcal/kwh
10
 93.85kpa Improvement of 34.91 kcal
5 SUPERHEAT SPRAY 0.28 kcal/kwh for 10 Tons
6 REHEATER SPRAY 0.18 kcal / kwh for 1 ton
7 MAKE UP 0.16 kcal/kwh for 1 TPH
8 CONDENSER SUB 0.89 kcal/kwh for 10C
COOLING
9 HPH HEATER TTD 1.8 Kcal/kwh for 10C
DEVIATION
10 HPH HEATER DCA 0.25 Kcal/kwh for 10C
DEVIATION
11 HP HEATER -1 OUT OF 23 kcal/kwh
SERVICE
12 HP HEATER -2 OUT OF 17 kcal/kwh
SERVICE
14 HP/IP TURBINE CYLINDER 4 kcal/%
EFFICIENCY
15 EXCESS AIR IN BOILER 7 kcal/kwh

16 COAL MOISTURE 2-3 kcal/kwh

17 BOILER EFFICIENCY 22 kcal/kwh

18 UNBURNT CARBON / % 10 15 kcal/kwh

B. COST OF HEAT RATE LOSS

Heat rate increase by 1 kcal/kwh

Total generation in a day at 90% PLF = 12960000 kwh
So total coal consumed per day at @ 4300 kcal/kg GCV = 3.o3 MT
So cost of this extra coal per day @ Rs 6000 / MT
Cost per month = 18033x30 = Rs 5.4 lac PM

12
Energy Audit a mandatory
and regulatory requirement
of every electricity
generating Unit

13
Energy Audit is a mandatory and regulatory
requirement imposed by CEA and Department of
energy GOI, that every TPS has to undergo once
every year first by their own people and later by an
outside licensed agency like BIS, CERI etc. These
agencies find out how best various energy resources
are utilized at the concerned TPS, what is the plant
heat rate, energy loses and wastages at different
portions of the plant, operating efficiencies of the
various equipments, auxiliary power consumption,
compile all their observations into report, compare
with the designed data or initially agreeable data,
suggest ways and means which are technically and
economically viable for improments.
14
 Accounting of Coal and heat utilization:
The principles of accounting of coal quantity and its
heating values at various points; and computation of
station heat rate is reviewed in depth. Procedures
and instrumentation measurements of the qualitative
and quantitative data are taken to answer to the
observations of auditing team.
Since coal is the single important item accountable
for unit heat rate, cost of generation and also saving
measures fossil fuel reserves, coal accountability
become very important. An account / break-up /
responsibility of the coal from the mine to the station
entrance, from the tipplers to the bunkers and from
the mills to the furnace is drawn and responsibility
fixed. 15
In the recent trend digital instruments are preferred
over analog measuring instruments which can be
connected to central server having provision for
storing and downloading data into a data base
server.

There are two types of parameters in a boiler:

Quantity parameters (like flow, current, etc.) which are
directly plant load dependent
Quality parameters (like temperature, voltage, pressure,
etc.) which are designed to be plant load
independent for the load range 60 % UMCR
through maximum load.

16
The study encompasses capture and dissemination of
tactics, operational knowledge, maintenance knowledge and
forced outage knowledge which is essential for progress and
performance. It assesses and validates the internal
knowledge sharing processes. It reviews the maintenance
philosophy, maintenance organization structure, tooling,
techniques, maintenance performance mapping,
maintenance delivery system, maintenance planning,
standardization of procedure, benchmarking of timing of
outages caused by BTL (boiler tube leaks), etc. Performance
orientation linked with knowledge based maintenance,
condition based guidelines, component reliability and risk
evaluation procedures are part of the study.

17
The benefits of 5 year rolling plans for pressure parts
replacements (like ECO coils, primary SH coils, WW tubes,
etc.), heat exchanger replacements (like lube oil coolers, feed
water heaters, vent condensers, etc.), thermal skin insulation
replacement, 20 %/year painting and upkeep plan have been
brought out.

The study points out that R & M must be a continuous activity

and the plans must not be equipment centric but must be
aligned with benefits of improvements in unit heat rate and/or
other unit performance parameters.

The stress on performance optimization, cleanliness and

leakage control being a round the clock activity with ISO
objective focus to achieve the required results is a part of the
study.
18
On the financial side, a critical re-look through audits for the
simplification and modification of administrative and
accounting processes to bring down the lead times for the
procurement cycle (which has an impact on inventory
carrying costs and overall business cycle) is studied.
Analysis of decision making processes is also a part of the
study.

19
Coming to HRD, the study revisits job functions, both
operation and maintenance, re-orientation towards
performance and accountability at all levels, job rotation
system, alternative ways of augmenting the shortage of
manpower, reward of invention talent, support of quality
circles, mid career educational intervention, reduction of
attrition rate, etc., are studied. A critical review of training
needs in the present day context such as operational
optimization, maintenance methodologies, regulatory
requirements, etc., is undertaken.

20
The performance tests give the Test TG heat rate (UHR)
(boiler, turbine & generator only) at 80 % load against the
Design heat rate (DHR). The Test station Overall Station heat
rate (considering besides the boiler and turbo generator
other factors such as DM water make up; rejects;
consumptions due to hot, warm and cold starts; heat in MS &
RH pipelines, seasonal deviations (if any) at 80 % load which
accounts for all the coal at the bunker. The life time
degradation rates are computed. The capacity adequacy is
also checked.

21
The tests include total electrical system audit including
transformer load management, power factor management
and load balancing. The performance evaluation of auxiliary
equipment like boiler feed pumps, condensate extraction
pumps, induced daft fans, forced draft fans, primary air
fans, mills, etc. Energy efficiency also covers the common
station auxiliaries like coal handling plant, ash handling
plant, DM plant, circulating water system, air compressors,
etc. Suggestions for improving the energy efficiency of
these equipments with techno-economic feasibility study are
also proposed.

22
Suggestions for measures to improve the KPI (key
performance indices) like station heat rate, auxiliary power
consumption and specific oil consumption with time bound
action plans are given. Objective oriented Monsoon
management plan is required to be in place for maintaining
the KPI within regulatory limits as the deviations in station
load, monthly SOC and monthly PLF are predominant
during monsoon seasons.

23
The study benchmarks the performance, identifies
undone works which were historically ignored but which
are of current importance and proposes changes leading
to reliability, transparency and cleanliness in an
environment of competitive cutting edge power
generation. In short the study encompasses the business
process re-engineering for enhancing station
performance to maintain market leadership. If the existing
plant processes and procedures are made more effective,
the improvement of performance will be a natural
consequence.

24
TYPICAL PLANT LOSSES
TYPICAL BOILER LOSSES
TYPICAL CYCLE LOSSES
1.0 USEFULNESS OF ENERGY AUDIT IN
THERMAL POWER STATION

Identifies Wastage areas of Fuel, Power and

Water & Air Utilization.
Reduction in cost of generation by
implementing findings of EA.
Increases power generation by efficient
utilization of steam in turbine cycle and
reduction in Aux Power Consumption.
Maintenance planning and availability
improvement.

Contd

 Provides guidance in Loading Sequences of
the Units.
Identification and Rectification of errors in on-
line Instruments.
Leads to reduction in Green House Gases.
Utilizes specialized services of experienced
Engineers.
Training of O&M staff for Efficient Control of
Unit Operation.

Contd

1.0 USEFULNESS OF ENERGY AUDIT IN
THERMAL POWER STATION

Improves competitiveness by reducing unit

generation.
Creates bench mark for all equipments and
systems.
Fulfills bureau of energy efficiency mandatory
requirement of Energy Audit.
 EFFECT OF INSTRUMENTATION ON ENERGY
AUDITS
a. Plant on-line instruments with few audit instruments Accuracy
around 3.0%.

b. Accurately calibrated instruments as per ASME-PTC-6 for steam

turbine & ASME-PTC-4-1 for Boilers. Accuracy around 0.5 %

ERROR OF PROCEDURE OF ENERGY AUDIT OTHER THAN

ASME-PTC-6 for steam turbines and ASME PTC-4.1 for boiler

Error in Boiler Energy Audit around 2.0%

Error in steam turbine Energy Audit around 3.0%

Total error because of Instrumentation & Procedure 6.0%

Contd.
 IMPORTANCE OF ACCURACY IN ENERGY
AUDITS

1.0% Deviation in findings means 25000 tons of coal

loss per annum for 200 MW Unit or approx Rs. 5 crores
/ year (4000Kcal coal GCV & Rs.2000/ton coal cost)

Difference in cost of Energy Audit between B & A is 12

to 14 lacs as against 6 to 8 lacs.
 ECONOMIC ASPECTS OF INEFFICIENT MACHINES
(200 MW)

SHORT FALL LOSS IN

CRORES PER
ANNUM

TURBINE CYCLE HEAT RATE 1.0 % 5.0

TG OUTPUT 1.0% 5.0

BOILER EFFICIENCY 1.0% 1.75
AUX. POWER CONSUMPTION 5.0 % 2.5

NOTE:

TG CYCLE HEAT RATE IS TAKEN AS 2000 KCAL / KWh

COAL GCV IS TAKEN AS 4000 KCAL / Kg
PRICE OF COAL TAKEN AS Rs. 2000 / TON
LOSS INCREASES WITH MACHINE SIZE
 Impact of Turbine Efficiency on
HR/Output

Description Effect on Effect on

TG HR KW

1% HPT Efficiency 0.16% 0.3%

1% IPT Efficiency 0.16% 0.16%

1% LPT Efficiency 0.5 % 0.5 %

Output Sharing by Turbine Cylinders are around

HPT 28%
IPT 23%
LPT 49%
 HP/IP Turbine Efficiency
Instrument Inaccuracy / lack of corrections

Main Steam HPT Exhaust

Pressure Temp Pressure Temp
Kg/cm2 Deg C Kg/cm2 Deg C

HPT 1 1 1 1
Efficiency
0.6 % 0.6 % 2.0 % 0.7 %

IPT Inlet IPT Exhaust

Pressure Temp Pressure Temp
Kg/cm2 Deg C Kg/cm2 Deg C
1 1 1 1
IPT
Efficiency 1.2 % 0.3 % 6.0 % 0.4 %
Effect of Condenser Vacuum on Heat
Rate

10 MM HG IMPROVEMENT IN
CONDENSER VACUUM
LEADS TO 20 Kcal/kwh (1%)
IMPROVEMENT IN HEAT RATE FOR A
210 MW UNIT
EFFECT ON HEAT RATE FOR PARAMETER DEVIATION
(500MW UNIT)

S.NO. DEVIATION IN PARAMETER EFFECT ON HEAT

RATE (KCAL/KWH)
1. HPT inlet press. by 5.0 ata 6.25
2. HPT inlet temperature by 10.0deg C 6.0
3. IPT inlet temperature by 10.0deg C 5.6
4. Condenser pressure by 10.0 mm of 9.0
Hg
5. Re spray water quantity by 1.0% 4.0
6. HPT Cylinder efficiency by 1.0% 3.5
7. IPT Cylinder efficiency by 1.0% 4.0
 Instrument calibration interval
Calibration intervals should be based on the Specifications given by
OEM / trended calibration observations.
An example of Accuracy degradation as a function of time is:
06 mth 12 mth 18 mth 24 mth
Accuracy 0.2 0.2 0.2 0.2
(% of span)
Repeatability) 0.05 0.05 0.05 0.05
(of calibrated span)
Drift (@06months) 0.1 0.2 0.3 0.4
Overall Instrument 0.30 0.40 0.50 0.60
accuracy
CONFORMITY FOR ENERGY AUDITS

FOLLOW TEST CODES

ASME PTC - 6 For Steam Turbines

ASME PTC - 4.1 for Boilers

CALIBRATION LAB
Govt. Accredited i.e. NABL Labs ( National Accreditation
Board for Testing and Calibration Laboratories

TEST SCHEME
To be Furnished And Approved Sample enclosed
 BOILER EFFICIENCY
HEAT LOSS METHOD
BOILER EFFICIENCY = 100 - % AGE LOSSES
1. Heat Loss in Dry flue gas
a. Hg = 0.24 wg (Tg Ta) as percentage of heat input
G.C.V
a. Hg = K (Tg Ta) /1.8 K=0.32 for fuel oil
% CO2 in flue gas K=0.35 for Bituminous coal
2. Heat loss due to evaporation of moisture & H2 in fuel
Hm = Wm+9H (100 Tf) + 540 4.6 (Tg -100) %of heat input
G.C.V
3. Heat loss due to moisture in air
Ha = 0.26 Wma (Tg Ta) % of heat input
G.C.V
4. Heat loss due to Incomplete combustion to Co
Hco = 2414 C x CO x 1 as % of heat input
CO+CO2 G.C.V
5. Heat loss due to unburnt carbon C
Hc = Wc x 7831 as % of heat input
G.C.V
6. Heat loss due to Blow Down
Hbd = Wb (hbw hw) as % of heat input
G.C.V
7. Heat loss due to Radiation

HR = Difficult to evaluate & thus take design values only

In above
Wg =Wt of dry flue gas
W..G = [44.01 *CO2 + 32*O2 28.02 * N2 + 28.01*CO]*[Cb + 12.01 * S/32.07]
12.01 * (CO2 + CO)
Tg = Tempt. Of flue gas at exit of Boiler
Ta = Tempt. Of air at inlet (ambient)
Tf = Tempt. Of fuel inlet
hbw-hw = Heat in blow down
Wm = Weight of moisture
Wma = Wt of waterin Kg/Kg of air X Wt of air in Kg supplied / Kg of fuel
Wc = Weight of unburnt C
Wb = Wt of water blow down

All wts are / kg of fuel

 FG
Expansion
Bellow

Economizer

HVS
APH

Sampling
Locations
APH

FG
 Annexure - I
BOILER EFFICIENCY AND APH TEST SCHEME &
INSTRUMENTATION DIAGRAM

1. Grid measurement for gas composition and gas temp. at air pre
heater inlet / outlet.
W/6 W/3 W/3 W/6
T1 T2 T3

D/6
N11 N21 N31

D/3 DEPTH
N12 N22 N32

D/3
N13 N23 N33

D/6
 D = Duct Depth (Internal)
W = Duct Width (Internal)
Tx = Traverse (x) (Pockets)
x =1 to 5 (Width wise)
Nxy = Nodexy

(Sketch for one half of flue gas duct cross - section)

Grid measurement for gas sampling and temperature measurement at 3 to 5 locations on
APH inlet & at 3 to 5 locations on APH outlet ducting as close to APH as possible shall be
taken provided test pockets are available for inserting sampling probes. Flue gas sampling
and temperature measuring probe shall be inserted at each location and traversed to collect
data at these points in each location. This shall eliminate effect of gas stratification.
Air temperature at inlet and outlet of APH shall be measured at two points each in case
spare pockets are available.
Ambient temperature, barometric pressure & RH is measured near F.D. fans.
Note : Test instruments shall be used for the above.
b) Turbine cycle heat rate.
This varies with the system changes in cycle i.e.
1. Location of Aux. Stm. Tapping.
2. Whether Reheater spray is reqd. or not.
3. Whether spray for superheater attemperation is tapped off from BFP discharge or
after top heater.
i. Cycle with Aux. Steam from MS or No Aux. Stm.;
No. RH Spray, ;
H. Rate = M1 (H1 hF) + M2 (H3 H2 )
Pg
ii. Same as (a) but Aux. Steam from CRH
H. Rate = [M1 (H1 hF) + M2 (H3 H2) MAS (H3 Hc )]
Pg
iii. Same as (a) but with Reheat Spray.
H. Rate = M1 (H1 hF) + M2 (H3 H2) + MRHS (H3 hRHS )
Pg
iv. Same as (a) but Spray for Superheater from BFP discharge
H. Rate = M1 (H1 hF) + M2 (H3 H2) + MSHS (hF hSHS )
Pg
ENERGY AUDIT SCHEME FOR 210 LMW STEAM TURBINE
 PERFORMANCE TEST PROCEDURE FOR PUMPS

Measured flow Q M3 / HR
Suction pressure Ps kg / m2
Discharge Pressure PD kg / cm2

Test speed Nrpm

Liquid temp. TC
Specific weight of liquid W kg / M3
Total dynamic head at test speed N
H = (PD PS) X 10 / W MLC

Total dynamic head at design speed N1

H1 = HX (N1 / N)2 MLC

Fluid flow at design speed N1

Q1 = QX (N1 / N) M3 / Hr
Based ion characteristic curve of the pump the expected flow Q2M3 / Hr shall be worked
out at H1MLC of total dynamic head (TDH)

CONCLUSION

For Normal Pump performance Q1M3 / Hr should be more than or equal to Q2 M3 / Hr

Q1 > Q2
FREQUENCY OF READINGS FOR ACCURATE DATA COLLECTION

TURBINE CYCLE AUDIT

Pressure - 5 Minutes
Temperature - 5 Minutes
Flow - 1 Minute
Power - 1 Minute
Levels - 10 Minutes

BOILER UNIT AUDIT

Temperature - 15 to 30 Minutes
Flue Gas Composition - to one hour

DURATION OF AUDIT TEST

Turbine Cycle - 2 Hrs

Boiler Unit - 4 Hrs
TEST INSTRUMENTS ACCURACY, CODE & CALIBRATION
LAB

Accuracy of Energy Audit Instruments

Pressure Measuring Instruments 0.1 % Acc.

Temperatures 1/2 DIN Tolerance
Or ASME CLASS A
Aux. Power Measuring Instruments 0.2 % Acc.
Generator Power Measurement 0.1 % Acc.
Flue Gas Analysis 0.5 % Acc.
Data Logger 0.03 % Acc.
Ultrasonic Flow Meter 0.5 % Acc.

Note: - Price and Quality / Grade of Energy Audit Depends largely on

Instrument Accuracies
3.0 METHODOLOGY TO BE ADOPTED FOR ENERGY
AUDIT

3.1 INTERACT WITH PLANT ENGINEERS AND OBTAIN

INFORMATION / DATA ON
Various equipment problems.
Present performance level i.e. unit heat rate, fuel consumption,
DM Water and raw water consumption etc.
Plant design data for the main and auxiliary equipments.
Boiler TG Cycle layout, condensate, feed and steam pipe line
schematics.
Performance / Guarantee test reports of the tests carried out on
equipments.
Plant electrical power distribution system and transformer etc
 Auxiliary power distribution system and transformer etc.
Evaluation procedure for day to day monitoring i.e. plant M.I.S.
systems
Loading / requirement during test.

3.2 Follow enclosed Test scheme for boiler and turbine testing.
3.3 Develop Energy Audit procedure covering following for
each equipment
Object of energy audit
Scheme and list of measurements
Range, make & class of accuracy of instruments.
 Frequency of instrument readings.

Duration of instrument readings.

Required man power.

Interconnected plant data required.

Finalize procedure with customer / consultants

3.4 CHECK UP THE AVAILABILITY OF INSTRUMENT

MOUNTING POINTS AND ORGANIZE FOR MISSING
POINTS. (CUSTOMER TO ARRANGE OR SPARE
ALTERNATE POINTS)

3.5 ARRANGE CALIBRATED INSTRUMENTS.

3.6 PLAN SCHEDULE OF ACTIVITIES FOR ENERGY

AUDIT.
3.7 Customer to Arrange shutdown if required for
providing non available / missing points and
attending defects noticed during walk down
survey.

3.8 Conduct test as per above plan.

3.9 Prepare preliminary energy audit report.

3.10 Evaluate Final Results.

3.11 Conduct mass and energy balance in Turbine

cycle components and boiler.
3.12 Make comparison with design Acceptance
test data and establish shortfall areas.

3.13 Furnish recommendations in the form of

cost benefit analysis.

3.14 Give presentation on findings with backup

data
SCOPE OF WORK FOR ENERGY AUDIT OF
THERMAL POWER PLANT UNITS
Energy Audit should cover evaluation of the present performance
level of all major equipments, identify the controllable losses and
suggest remedial measures for improvements with cost benefit
analysis and pay back period. The detailed scope of work covering
the following is given as under.
Boilers
Turbine including regenerative cycle and condenser
Electrical system
Fans and Pumps in the above areas
Insulation
Balance of Plant including Station auxiliaries power
consumption, Coal Handling plant, ash handling system, DM
Plant, Station Compressed air system, CW system and Air
conditioning.
Preliminary Energy Audit, Preliminary Checking / Hot
walk down
Energy Auditing agency to check the complete unit steam, condensate
and feed water system along with the functioning of Heat cycle
equipment like Boiler, Condenser Regenerative system Turbine
Cylinders etc. during HOT WALK DOWN. Problem if any, shall be
brought to the notice of the authority for rectification and arranging
provisions for mounting audit instruments during Audit Preparatory
Activities, prior to start of the detailed EA.
 DETAILED ENERGY AUDIT

A Energy Audit Of Boilers

Performance of Boiler and APH be established by measuring exit
flue gas temperature and its analysis at around nine to fifteen
points in flue gas duct cross section before and after APH to
eliminate effect of gas stratification as per international practice
(Refer enclosed boiler test scheme Annexure I). This is because
boiler efficiency differs by around 2.0% by this method than if the
measurements are taken at single point. Scope will include the
following
Conduct boiler efficiency measurements as per above test
scheme by indirect method i.e heat loss method, evaluate
Boiler efficiency and identify potential areas for
improvements such as:
a. Heat loss due to heat in dry flue gas.
b. Heat loss due to moisture in as fired fuel.
c. Heat loss due to moisture from burning of hydrogen in fuel
d. Heat loss due to moisture in air.
e. Heat loss due to surface radiation and convection.
f. Heat loss due to formation of carbon monoxide.
g. Heat loss due to combustibles in bottom and fly ash

Check up air ingress in boiler from LTSH area downwards

upto I.D fans.
 Determine Air preheater performance to establish.

a. Gas Side Efficiency As ratio of gas temperature drop corrected

for no air leakage to temperature heads.
b. Air leakage as percentage of air passing from airside to gas side.
c. X-Ratio I,e heat capacity of air passing through the air heater to the
heat capacity of gas passing through the air heater.
d. Air side and gas side pressure loss across the air heater.

Input power measurement of ID FANS / FD fans, PA fans, Fan

Loading & combined efficiency of fan and motor and their
specific power consumption
Energy Audit test has to be carried out for four hours by
recording parameters at every 15 minutes and average of
data to be utilized for evaluation.
 ENERGY AUDIT OF STEAM TURBINE CYCLE AND IT S
AUXILIARIES
For Energy Audit of steam turbine cycle, all the parameters as
per the enclosed scheme in Annexure II are to be measured
simultaneously by hooking up these calibrated instruments to a
data logger. The recording has to be at least for a minimum
period of two hours with each measurement being recorded at
an interval of one minute. Average of the data so collected to be
utilized for evaluation of the following and suggestions for
deficient areas for improvements to be made.
1. Turbine cycle heat rate.
2. HP and IP cylinders efficiency
3. Turbine pressure survey
4. TTD & DCA of HP / LP heaters performance
5. Condenser performance i.e
Condenser back pressure after duly considering the
effect of present C.W inlet temp. C.W flow, heat load on
condenser and air ingress to condenser vis--vis
design conditions
C.W side pressure drop in condenser
6. Cycle losses
7. Performance of turbine glands
8. Ejector performance
For accurate heat rate determination, Turbine inlet flow and
reheat flow need to be evaluated as per international practice
by measuring condensate flow through measurement of p
of plant condensate flow orifice after checking its condition
and using evaluated drip and extraction to deaerator flows
through heat and mass balance across heaters and deaerator
as per scheme. Fall in deaerator level and HPTV and IPV leak
off flow are also considered. Alternately by mass balance
across deaerator if flow orifices are installed in drip and
extraction lines to deaerator. Deaerator outlet feed flow shall
then be taken as the main steam flow after considering for
RH spray tap off from Boiler feed line.
C. Electrical system
1 Transformers Assessment of the health & Transformer
load loss of GT, UAT, Station Service
transformers etc.
Identification of possible Energy
conservation options in this area.
2 Motors Assessment of Loading condition of HT and
LT motors of Boiler area, Turbine area and
Balance of Plant area.
Assessment of operating parameters like
load variation, Power factor, of HT and LT
motors consuming power more than 50 KW.
Identification of possible Energy
conservation options in this area (with
latest techniques).
3.Capacitors Assessment of health of capacitors.

4.Plant Lighting Lighting load survey and Assessment

system of installed load efficacy (I.L.E) and
I.L.E ratio at various areas of plant.
Assessment of present lighting
controls
Identification of Energy Conservation
Opportunities
D Fans and Pumps Performance
Performance of fans consuming power more than 50 KW such
as ID, FD, PA fans etc.
Input power measurement
Fan loading and combined efficiency of fan and motor
Specific energy consumption
Pump performance for BFPs, CEPs, Aux C.W.P & C.W.Pand
pumps consuming power more than 50 KW etc.
Check Performance of the pumps by comparing the corrected
measured flow at operating speed to design speed with that of the
expected flow derived from the characteristic curves against the
corrected total dynamic head at design speed.
Determine Pump efficiency as the ratio of power input to the pump
shaft to hydraulic power.
Specific power consumption
E Insulation Audit:
A. Walk through survey of Boiler, Turbine and associated steam
piping to identify the damaged and Hot spot area.
B. Surface temperature measurement at the damaged and Hot
spot area by infrared temperature indicator.
C. Estimation of heat loss in the hot spots and damaged
insulation area.

F Balance Of Plant
(i) Compressed air system:
Free Air Delivery i.e. Capacity evaluation of the Plant and
Instrument air compressors.
Checking volumetric efficiency of compressors.
Assessment of compressed air leakage quantity.
Assessment of Energy performance of the air compressors/
specific power consumption.
Study of the compressed air network and suggest suitable
energy saving options.
(ii) Air conditioning system:
Performance evaluation of AC Plant w.r.t net cooling /
refrigeration capacity along with heat load of Air handling unit
and energy requirements at the operating conditions vis--vis
design condition to be determined.
(iii) Ash Plant
Performance of ash Slurry pumps through power measurement
and flow measurement.
Ash water ratio assessment and recommendations for
optimization in water and power consumption.
(iv) Cooling Tower Performance
It shall include establishment of
Liquid/Gas ratio
Fan efficiency as the ratio of shaft power developed and the
work done by the fan
Cooling Tower Effectiveness, approach and range.
Cooling capacity.
V Coal Handling Plant
Input Power measurement of all the key equipment of the CHP
area like: Paddle feeders, Conveyors, Stacker & Re-claimer,
Wagon Tipplers, Crushers,
Establishment of specific energy performance indicators.

VI Accuracy and calibration of the instruments

The proposed instruments should have following level of
accuracy.
i. Thermocouples and PRTs ASME special class A i.e DIN
tolerance
ii. Pressure and differential pressure - 0.1%
transmitters better than
iii. Power Meter for generator & - 0.1%
Unit Aux Power measurement
iv Data Logger - 0.03%
v Power transducers / Load Analyser - 0.5%
vi Flue gas analyzer - 0.5%
vii Ultrasonic flow meters - 0.5%
viii Anemometer - 1.0%
xi Infrared Thermometer - 1.0%
x Lux meter - 1.0%
xi RH meter - 1.0%
These should be duly calibrated from NABL accredited lab.
The above accuracies for S.No. I to V are as per ASME specified for
Performance Evaluation of Thermal Power Plants.
 PREVENTION / OBSERVATION FOR SAVINGS
ENERGY IN POWER PLANT

1) Operation of machine at very low turbine I/L

parameters.

2) Operation of turbine at lower loads.

3) HP and IP turbine cylinder efficiencies are very low.

4) Main steam and HRH inlet temperature to turbine very

low.

5) RH pressure drop high

6) High quantity of SH Spray and its tapings before HPH-5

resulting of loss in heat because of changed cycle.
Contd.
 PREVENTION / OBSERVATION FOR SAVINGS
ENERGY IN POWER PLANT

7) HP heater no. 5 out of service.

8) Turbine cycle not operating as per design scheme

i.e. Ejector and Deaerator pegging steam from PRDS
header as against normal source from deaerator &
extraction steam respectively.
9) Passing of turbine cycle drain valves.
10) Make up quantity to cycle is very high which
indicates excessive system steam (heat) loss.
11) TTD & DCA of heaters high
Contd.
 PREVETION / OBSERVATION FOR SAVINGS ENERGY
IN POWER PLANT

12) Condenser air ingress and dirty tubes.

13) Under loading of motors
14) Excessive air leakage in compressed air system
15) Faulty insulation
16) Drain valves passing
17) Air ingress to Boiler furnace
18) FAD of compressors low
Thanks