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You cannot Manage what you
cannot Measure
(Accurately)
- Jack Welch, CEO, General Electric
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PATTERN OF ENERGY CONSUMPTION
IN
THERMAL POWER STATION
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TYPICAL PLANT LOSSES
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TYPICAL BOILER LOSSES
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TYPICAL CYCLE LOSSES
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1.0 USEFULNESS OF ENERGY AUDIT IN
THERMAL POWER STATION
Contd
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.
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1.0 USEFULNESS OF ENERGY AUDIT IN
THERMAL POWER STATION
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
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Improves competitiveness by reducing unit
generation.
Creates bench mark for all equipments andsystems.
Fulfills bureau of energy efficiency mandatory
requirement of Energy Audit.
1.0 USEFULNESS OF ENERGY AUDIT IN
THERMAL POWER STATION
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A. Plant on-line instruments with few audit instruments Accuracyaround 3.0%.
B. Accurate 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 ASMEPTC-4.1 for boiler
Error in Boiler Energy Auditaround 2.0%
Error in steam turbine Energy Auditaround 3.0%
Total error because of Instrumentation & Procedure 6.0%
EFFECT OF INSTRUMENTATION ON ENERGY
AUDITS
Contd.
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IMPORTANCE OF ACCURACY IN ENERGY
AUDITS
1.0% Deviation in findings means 25000 tons of coal
loss/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.
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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 % 2.5NOTE:
TG CYCLE HEAT RATE IS TAKEN AS 2000 KCAL / KWh
COAL CV IS TAKEN AS 4000 KCAL / Kg
PRICE OF COAL TAKEN AS Rs. 2000 / TON
LOSS INCREASES WITH MACHINE SIZE
ECONOMIC ASPECTS OF INEFFICIENT MACHINES
(200 MW)
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Description Effect on Effect onTG 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%
Impact of Turbine Efficiency onHR Output
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HP/IP Turbine EfficiencyIns trument Inaccu racy / lack of correct ions
HPTEfficiency
Main Steam HPT Exhaust
Pressure
Kg/cm2Temp
Deg C
Pressure
Kg/cm2Temp
Deg C
1 1 1 1
0.6 % 0.6 % 2.0 % 0.7 %
IPTEfficiency
IPT Inlet IPT Exhaust
PressureKg/cm2
TempDeg C
PressureKg/cm2
TempDeg C
1 1 1 1
1.2 % 0.3 % 6.0 % 0.4 %
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Effect o f Condenser Vacuum on Heat
Rate
10 MM HGIMPROVEMENT IN
CONDENSER VACUUM
LEADS TO 20 Kcal/kwh(1%)
IMPROVEMENT IN HEAT RATE FOR A
210 MW UNIT
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EFFECT ON HEAT RATE FOR PARAMETER DEVIATION
(500MW UNIT)
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
Hg
9.0
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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 Ins trument 0.30 0.40 0.50 0.60
accuracy
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CONFORMITY FOR ENERGY AUDITSFOLLOW TEST CODES
ASME PTC - 6 For Steam Turbines
ASME PTC - 4.1 for Boilers
CAL IBRATION LAB
Govt. Accredited i.e. NABL Labs
TEST SCHEME
To be Furnished And Approved Sample enclosed
BOILER EFFICIENCY
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BOILER EFFICIENCY
HEAT LOSS METHOD
BOILER EFFICIENCY = 100 - % AGE LOSSES
1. Heat Loss in Dry flue gas
a. Hg = 0.24 wg (TgTa) as percentage of heat input
G.C.V
a. Hg = K (TgTa) /1.8 K=0.32 for fuel oil
% CO2in flue gas K=0.35 for Bituminous coal
2. Heat loss due to evaporation of moisture & H2in fuel
Hm = Wm+9H (100 Tf) + 540 4.6 (Tg-100) %of heat input
G.C.V3. Heat loss due to moisture in air
Ha = 0.26 Wma(TgTa) % of heat input
G.C.V4. 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 = Wcx 7831 as % of heat inputG.C.V
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6. Heat loss due to Blow Down
Hbd = Wb(hbwhw) 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 moistureWma = 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
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Economizer
FG
APH
Sampling
Locations
FG
APH
Expansion
Bellow
HVS
Annexure I
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Annexure - I
BOILER EFFICIENCY AND APH TEST SCHEME &
INSTRUMENTATION DIAGRAM
1. Grid measurement for gas compositionand gas temp. at air pre
heater inlet / outlet.
W/6 W/3T1
W/3T2
W/6T3
N11 N21 N31 D/6
N12 N22 N32D/3
N13 N23 N33D/3
D/6
DEPTH
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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 casespare pockets are available.
Ambient temperature, barometric pressure & RH is measured near F.D. fans.
Note1 : WBPDCL to provide the test pockets in each of the Air and Gas path for
inserting test instrument.
Note2 : Test instruments shall be used for the above.
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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(H1hF) + M2(H3H2)
Pg
ii. Same as (a) but Aux. Steam from CRH
H. Rate = [M1(H1hF) + M2(H3H2) MAS(H3Hc)]
Pg
iii. Same as (a) but with Reheat Spray.
H. Rate = M1(H1hF) + M2(H3H2) + MRHS(H3hRHS)
Pg
iv. Same as (a) but Spray for Superheater from BFP discharge
H. Rate = M1(H1hF) + M2(H3H2) + MSHS(hFhSHS)
Pg
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ENERGY AUDIT SCHEME FOR 210 LMW STEAM TURBINE
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ENERGY AUDIT SCHEME FOR 210 LMW STEAM TURBINE
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PERFORMANCE TEST PROCEDURE FOR PUMPS
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PERFORMANCE TEST PROCEDURE FOR PUMPS
Measured flow Q M3 / HR
Suction pressure Ps kg / m2
Discharge Pressure PDkg / cm2
Test speed Nrpm
Liquid temp. T C
Specific weight of liquid W kg / M3
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 Q
2M3/ Hr
Q1> Q2
Total dynamic head at test speed N
H = (PDPS) X 10 / W MLC
Total dynamic head at design speed N1H1 = HX (N1 / N)2MLC
Fluid flow at design speed N1Q1 = QX (N1/ N) M
3/ Hr
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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
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TEST INSTRUMENTS ACCURACY, CODE & CALIBRATION
LAB
Accuracy of Energy Audi t 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
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3.0 METHODOLOGY TO BE ADOPTED FOR ENERGY
AUDIT
3.1 INTERACTION WITH PLANT ENGINEERS AND OBTAIN DATAON
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
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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 turbinetesting.
3.3 Develop Energy Audit procedure covering followingfor each equipment
Object of energy audit
Scheme and list of measurements
Range, make & class of accuracy of instruments.
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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.
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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.
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3.12 Make comparison with design Acceptancetest 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
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SCOPE FOR CONSULTANT Frame SPECS for Energy Audits
Approve Energy Audit Schematics
Approve Procedure Covering Evaluation Procedure, Type
and Class of Accuracy of Instruments & their Calibrations
Installation of Instruments and Ensure Compatibility of Data
Thermodynamically
Supervise Conductance of Energy Audit
Review & Acceptance of Audit Report
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SCOPE OF WORK FOR ENERGY AUDIT OF THERMALPOWER 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.
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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.
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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 AnnexureI). 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
DETAILED ENERGY AUDIT
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.
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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.
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Determine Air preheater performance to establish.
a. Gas Side EfficiencyAs 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-RatioI,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.
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B Energy Audit of steam turbine cycle and it auxiliaries
For Energy Audit of steam turbine cycle, all the parameters as per
the enclosed scheme in AnnexureIIare 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
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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
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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 El t i l t
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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 Plantarea.
Assessment of operating parameters
like load variation, Power factor, of HT
and LT motors consuming power
more than 50 KW.
Identification of possible Energy
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Capacitors Assessment of health of capacitors.
Plant Lighting system Lighting load survey and Assessment 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.
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D Fans and Pumps Performance
Performance of fans consumingpower 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 thepump shaft to hydraulic power.
Specific power consumption
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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.
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(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--visdesign condition to be determined.
(iii) Ash Plant
Performance of ash Slurry pumps through power measurement
and flow measurement.
Ash water ratio assessment and recommendations foroptimization 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 thework done by the fan
Cooling Tower Effectiveness, approach and range.
Cooling capacity.
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V Coal Handling Plant
Input Power measurement of all the key equipment of the CHP area
like: Paddle feeders, Conveyors, Stacker & Re-claimer, WagonTipplers, Crushers,
Establishment of specific energy performance indicators.
Accuracy and calibration of the instruments
The proposed instruments should have following level of accuracy.
i. Thermocouples and PRTsASME special class A i.e DINtolerance
ii. Pressure and differential pressure - 0.1%
transmitters better than
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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 analyser - 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.
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OUR EXPERIENCE OF ENERGY AUDITS OF
THERMAL POWER PLANTS
Two 2 x 210 MW units of M/s WBPDCL Kolaghat
Thermal Power Plant.
15 units of Saudi Electric company of Saudi Arabiahaving unit sizes varying from 60 MW to 660 MW.
Two 2 x 18 MW units of M/s Shree Cements Captive
Power Plant.
METHODS / OBSERVATION FOR SAVINGS ENERGY IN
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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.
METHODS / OBSERVATION FOR SAVINGS ENERGY IN
POWER PLANT
Contd.
METHODS / OBSERVATION FOR SAVINGS ENERGY IN
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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
METHODS / OBSERVATION FOR SAVINGS ENERGY IN
POWER PLANT
Contd.
METHODS / OBSERVATION FOR SAVINGS ENERGY IN
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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 furnace18) FAD of compressors low
METHODS / OBSERVATION FOR SAVINGS ENERGY IN
POWER PLANT
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ThanksEnergo Engineering Projects Ltd.A-57/4, Okhla Industrial Area, Phase II
Phone: +91 - 11 - 26385323/ 28/ 29/ 38Fax: +91 11 26385333
E-mail: [email protected]
Web: www.energoindia.com