Identification of Performance Gaps

&
Heat Rate Recovery Plan

Subodh Kumar
CenPEEP
Presentation Coverage

• Introduction

• Performance Gaps Analysis

• Heat Rate Improvement Program

• Accurate Gap Assessment
• O&M Interventions – Punch List
• Implementation

• Conclusion
 Plant Performance Indices: Heat Rate
• The HR of a conventional Coal fired power plant
is a measure of how efficiently it converts the
chemical energy contained in the fuel into
electrical energy.

• If a power plant converted 100% of the chemical

energy in the fuel into electricity, the plant would
have a heat rate of 860 kcal/kWh.

• A modern conventional power plant might have

at best a design full load heat rate of 2200
kcal/kWh, which is about 39% efficient.
 Definitions

Unit Heat Rate = Electricity generated / Heat Input

Heat Input = Coal consumption X GCV of coal

Limitations: Measurement of coal consumption and

GCV

Alternate Method:

Unit Heat Rate = GTCHR / Boiler Efficiency

GCTCHR = Gross Turbine Cycle Heat Rate
Actual Heat Rate differs from design!

• Operating air/cooling water inlet

temperature different from design Corrections to design
• Coal quality differs from design

• Degradation in equipment
performance with time Focus Area
• Operation at OFF-design
parameters

Actual Heat Rate varies from 80-300 kcal/kWh from design HR

 DEFINITION
• Design Unit Heat Rate : It is the heat rate the designer
anticipates will occur at the design condenser pressure and
load, make up
• Reference Unit Heat Rate :Heat rate the unit based on the
initial design configuration. Derived from the turbo generator
& Boiler PG test results.
• Test Unit Heat Rate
• Corrected Unit Heat Rate: Test unit heat rate corrected for
variation in coal, design air inlet temp and design CW inlet
temp
 Why HR Deviation
• To assess the current performance level of unit vis-à-
vis design / reference
• To determine if the performance of the unit is improving
or deteriorating.
• Segregate the impact of operational parameters and
equipment degradations
• To identify the major loss areas
• Magnitude (heat rate deviation) of each problem area
can be determined.
• In a unit, the problem areas can be ranked, and most
costly can be addressed first.
• Cost benefit analysis of the action can be calculated.
 Performance Analysis: Methododlogy
KPI
HPT / IPT Eff.
FWH TTDs
Condenser

Objective
GTCHR
•Identification of
degradation,
•Root causes analysis
Operating •Remedial Action plan
Parameter

Unaccountable
Losses
Heat Rate Losses: 50 – 200 Kcal/kWhr
 Plant Performance Indices

• Unit heat rate

• Gross turbine cycle heat rate
• Boiler efficiency
• HP/IP Turbine efficiency
• HP heaters TTD / DCA
• Condenser (TTD, DP, Temp rise)
• AH leakages, efficiency
• RH sprays
• MS temp / HRH temp
• Main steam flow
 HR Improvement Program

Evaluation & Accurate Gap

Dissemination Assessment

Retrofits
Capability
Building Gap analysis

PIPs
Action Plans

Resource
Implementation
Mobilization

Focus on degradations in Individual Equipment

Efficiency Management System
A. Accurate Gap Assessment - system for Identification &
correct assessment of major HR gaps and RCA
B. Improvement Action Plans - Development and
implementation of unit specific HR improvement plans
C. Performance Improvement Projects - Focused initiatives
for solving specific problems
D. Retrofits & Technology Upgrades -
E. Capability Building - Diagnostic and analytical capability of
O&M engineers
 Step I - Identification & Assessment of major
heat rate gap areas

• Monitoring of critical operating parameters

• Performance tests for accurate assessment and
validation of Heat Rate gaps
• IT enablement of data monitoring, analysis & MIS
• Expert systems for performance analysis
 Major Heat Rate Losses

Major Heat Rate Losses

20% 16%
Dry Flue Gas
Condenser & CTs
Turbine (HP/IP)
7%
RH Spray
7% 31% Others
Unaccountables
19%

Identification of the performance gaps - first step in improvement

Methodology For HR Gap Assessment

• Daily HR Deviation

• Periodic Performance Testing of equipment

degradation assessment
 Parameters To Be Tracked
• Turbine Cycle
– Condenser Back Pressure
– Final FW Temp & HP Heaters Bypassed
– Makeup
– Turbine Efficiency
• Auxiliary Steam Usage
• Boiler Cycle
– Combustibles in Bottom Ash & Fly Ash
– APH Flue Gas Exit Gas Temperature
– Oxygen at the Boiler Outlet/Air Heater Inlet
– Fuel Characteristics
– MS temp & Press Before ESV
– Hot Reheat Steam Temperature Before IV
– Reheat Attemperation
– Superheat Attemperation
– Start-up Fuel
 Periodic Performance Testing
Periodic Performance Tests :
Carried Out With on line and / or off line Calibrated
Instruments to

• Compare the current performance with expected

performance
• Assess performance degradation
• Account for heat rate losses
• Determine the most efficient operating regime for
equipment and system
• Evaluate the effectiveness of maintenance work
 Typical Performance Tests Schedule
S.N TEST ON LINE TEST OFF LINE TEST
FREQUENCY FREQUENCY
1 HP/IP Turbine Efficiency Once in a Year & Pre &
Post COH
2 Condenser Test Monthly Once in a Year
3 HP Heater Test Monthly Once in a Year
4 BFP Performance Test Once in Year
MDBFP & TDBFP
5 Turbine Press. Survey Once in a Year , And Pre &
Post COH
6 Turbine Cycle Heat Monthly Once in a Year
rate Test
7 Dirty Air Flow Test --- Pre & Post O/H
8 APH Performance Test Quarterly
9 FG Path Oxygen --- Six Monthly &
Mapping Pre & Post O/H
10 Boiler Efficiency Test Monthly Pre & Post O/H
11 Cooling tower Test Once in a Year for NDCT / IDCT Preferably in
the period July-Sept
 Accountable Unit Heat Rate Deviation
1. Main steam Press before ESV
2. Main steam Temp before ESV
3. Hot Reheat Temp before IV
4. Superheat Attemperation
5. Reheat Attemperation
6. Condenser Back Pressure
7. FW temperature at HPH O/L
8. HP Turbine Efficiency
9. IP Turbine Efficiency
10. Dry Flue Gas loss
11. Wet Flue Gas loss
12. Unburnt loss
• Total Accountable HR Deviation (HRDAccountable)
• Expected Unit Heat rate (UHRExp)
• Test Heat rate corrected(UHRAct)
• Unaccountable HR Dev (HRDUnAcc)
=(UHRAct -UHRExp)- ΣHRDAccountable
 Step II - Development and implementation of Heat
Rate Recovery Action Plans

• Gap analysis & development of action plans

• Implementation during overhauls
• Parametric Optimisation
• Periodic MIS reports on implementation of action plans
• Evaluation of recovery achieved through maintenance

Gap Analysis
 Diagnosis – High AH Exit FG temp
Start

No
Is AH FG O/L temp Diagnosis is for high AH O/L
higher than design Stop
FG temp

Yes

No
Is AH FG I/L temp Problem suspected in AH;
higher than design proceed for AH diagnosis
Imbalance btwn air and
Yes
gas flows; check for
•boiler open doors
Yes •Failed expansion joints
High FG temp at AH inlet is
Is AH X ratio •Boiler air ingress
An indication of boiler lower than design
heat transfer problem •Penthouse leakages
No
Yes
Is AH pressure drop Indication of
high air heater plugging;
Air heater soot blowing
B AH basket cleaning
No

Indication of AH heat transfer

Problem due to
metal loss / seals / gaps
 B Diagnosis – High AH Exit FG temp

Heat transfer problem

No
Is RH spray suspected in convection pass Stop
Higher than design Check DPs of economisers, LTSH etc
Operate soot blowers

Yes

High gas temp entering

Convection pass suspected

Furnace heat transfer problem

Is final feed water No Suspected
temp lower Blow water wall tubes
than design Lower burner tilts
Check excess O2
Bias coal flow to lower mills
Yes

Lower feed water temp is

leading to overfiring
Condition;
Refer low FW temp
diagnostics
 HR Improvement Action: Operational Intervention

• Unit operation at rated parameters

• Optimized soot blowing
• Minimal tempering air in mills
• Operation at rated / optimized PA header pressure and WB
pressure
• Ensure desired coal fineness at mill outlet / boiler inlet
• Checking and corrective action for air ingress in boiler (peep
holes, bottom ash hoppers) and condenser
• Optimization of excess air, SADC and wind box DP
HR Improvement Action: Operational Intervention

• Smooth cold and hot start up of unit - Turbine rolling as per

ATRS
• Use of on line condenser tube cleaning system /
condenser backwashing
• Minimization of high energy drain valves passing and valve
leakages
• Maintain good water chemistry – it prevents deposits
formation in the boiler and turbine flow path and thus help
sustain improved HR
• Maintain good CW water condition through chlorine dosing
(if required) and adequate measures for removal of floating
debris / foreign material
 HR Improvement Action: Key Activities
• Tube cleaning
• Tubes replacement
Condenser • Repair of air ingress points
• Acid cleaning
• Installation / restoration of OLTC
• Repair / repl’t of HED Valves

• CW ducts inspection / cleaning / painting

• CW Chemical dosing system
CW System
• Repair / repl’t of CW pumps
• Repair / repl’t of fills / nozzles, CT fans
• CT Area to be obstruction free

Focus: Advanced Planning for execution during overhaul

 HR Improvement Action: Key Activities
• Repair / repl’t of gland / inter-stage / tip seals
Turbine • Steam path audit
• Alumina blasting of blades / diaphragms
• Repl’t / refurb’t of blades / modules / diaphragms

• Repair of casing, penthouse and ducts

• Repair / repl’t of expansion joints
Boiler • Extensive cleaning of boiler and AH baskets
• Repl’t of AH Baskets, seals & sector plates
• Repl’t of mill internals, coal burners & orifices
• Boiler acid cleaning and tube replacement
Punch List • Insulation repair work

Focus: Availability of required material before overhaul

HR Improvement Action: Improvement Projects
• Gaps persisting after O&M intervention;
• Improvement sustainability issue
• Design deficiency
• High gap areas

Typical Steps
• Definition of the problem with all supporting data
• Involve domain experts - an OEM / Consultant
• Collect more data if required by domain experts for analysis
• Modeling of the equipment using design data / other sources
• Recommendations for action and their implementation
• Assessment of action in terms of its desired impact
• Final report and recommendations
 Reasons for Unaccountable
First is actual losses that are not able to be measured, such as

• Low pressure turbine efficiency

• Cycle isolation
• Boiler radiation losses
• Low pressure feed water heater performance etc.

The second types of problems are errors/measurement accuracy.

• Coal heating value measurements

• Proximate to Ultimate analysis conversion for coal
• Instrument errors for measuring parameters such as
– Main steam temperature , Condenser pressure
– Economizer outlet O2 ,Feed Flow, Steam Flow, etc
• Sampling errors attached with
– Coal sampling
– Unburnt Carbon sampling, etc
 Steps to reduce Unaccounted Losses
High Energy Drains
– Listing of all high energy drains with specific valve Nos.
– Routine checking of drain temperatures
– Provision for on-line temperature measurement
– Prioritizing the valves and replacing the valves with better
quality
– HPH Vent line loss evaluation.
– Checking of vent line orifice condition and replacement as per
need.
System Modifications: Effect of Site specific System modifications
carried out if any on HR to be analyzed
Test Conditions
– Test to be carried out as per EEMG guidelines.
– D/A level drop to be monitored during the test
– Equivalent DM make-up to be calculated and HR loss to be
accounted for.
Gland Steam Cooler
– Steam flow Assessment for Sealing Steam flow to Gland Steam
Cooler by heat balance of Gland Steam Cooler
 Steps to reduce Unaccounted Losses
Instrument Accuracy
• Parameter uncertainty :
– Uncertainty level of parameters used for Boiler & Turbine HR
calculation to be accessed
• Improving accuracy of Instruments
– Replacing the instruments with better accuracy
• Redundant / Duplicate measurement
– Provide duplicate measurement points for pressure & temperature
measurements.
– PG test points to be revived for use in testing.
• FW flow validation
– FW flow element condition assessment to be done during the
shutdown for the units which has run for longer period.
• Accuracy of Generator Energy Meter, CT & PT
– Meters, CT, PT may be upgraded to 0.2 class accuracy
• Representative sampling
– Grid sampling to be used for of O2 measurement
– Unburnt sampling through HVS
– Multiple Coal sampling to be done from each feeder during tests
 In Conclusion
• Potential for efficiency improvement even in best run
utility
• Correct performance assessment and root cause
analysis: essential pre-requisites
• Improvements in on line measurements and
equipment’s performance tests
• Action plan development:

Operational optimization and

Maintenance and overhauls
• Maximum improvements possible through overhauls
• Availability of materials & contracts during overhauls
• Sustainability through structured ‘Efficiency
Management System’ Low hanging fruits with limited
investment
Thank You