Energy Audit & Efficiency

Improvement of Operating Power

Plants

28 July 2015

Dr. Y. P. Abbi
Senior Advisor/Energo Engineering Projects Limited,
Ex- Executive Director/BHEL, Senior Fellow/TERI, President/Energo
 Energy Efficiency Improvement of Thermal
Power Plants
• It is responsibility of Operation & Maintenance
Engineers/Managers of the plant
• It involves systematic data collection & analysis
(weekly/fortnigtly); and not once a year by an External
Energy Auditor
• Understand the science/technology for each equipment
sub-system of the plant; and keep yourself abreast with
their latest technology development
• Planned improvements in stages; don’t wait for R&M
• Retire old plants with Heat Rate deviation more than
20 %
Energy Efficiency Improvement – A Necessity

• Power demand (as on date) is low (PLF); thus

need for efficiency improvement for financial
sustainability
• Energy efficiency improvement leads to fuel
cost saving and thus plant profitability
• It leads to CO2 emission reduction (a national
& international commitment)
Change Mindset for Energy Efficiency Improvement
• Don’t make excuse that coal quality has become bad
• We have to work with the available fuel, and achieve
the best possible results
• Blame no more the design defects; it is we who have
to overcome/remove these
• Don’t be defensive while analyzing results, or
receiving suggestions from external Energy Auditors
• Make PG Test results as the baseline; and make all
efforts to achieve & maintain these
• Important that all key instruments used in the plant
are calibrated regularly and at least conform to
prescribe accuracy
Required Accuracy of Instruments
Instrument Accuracy (+/- %)
Thermocouples Temp. Range: 0 to 277 0C – 1.1 0C;
277 to 1260 0C – 3/8 %
Pressure Transducers 0.1
Power Meter 0.1
Data Logger 0.03
Power Transducer 0.5
Flue Gas Analyzer 0.5
Ultrasonic Flow Meter 0.5
Anemometer 1.0
Infrared Thermometer 1.0
Lux Meter 1.0
RH Meter 1.0
Calibrated Test Flow Assembly 0.25
LET US CONSIDER THE PATTERN OF
ENERGY CONSUMPTION & LOSSES
IN A
THERMAL POWER STATION
Typical Energy Losses in a
Power Plant
Typical Energy Losses in a Boiler
Typical Energy Losses in Steam Cycle
“You cannot Manage what you
cannot Measure”

(Accurately)

- Jack Welch, CEO, General

Electric
 What needs to be measured for
Efficiency Improvement of a
Power Plant ?
• Heat rate of the plant
• Heat rate of the steam turbine cycle & Boiler
Efficiency
• Auxiliary Power Consumption
• Net heat rate of the power plant
(Monitored by CEA & BEE under PAT scheme)
 Heat Rate of Steam cycle and the
Power Plant
Heat Rate of steam cycle, HRsc = {(Enthalpy of SH steam)
+(Heat added during RH) – (Sensible heat in feed water)} /
(kW electricity generated), kCal/kWh

Efficiency of steam cycle, ƞsc = 860 /HRsc

Gross Heat Rate of the Power Plant, HRpp = HRsc / ƞBOILER ,

kCal / kWh
Gross Calorific value of Fuel = GCV kCal /kg of fuel
Specific fuel consumption = HRpp / GCV, kg/kWh
Net Heat rate of the Power Plant = HRpp / (1 – APC in fraction)
Perform Achieve & Trade (PAT) scheme
under Energy Conservation Act 2001
• Applicable for all Designated Consumers (DCs)
• Thermal Power Plants are also DCs
• Every DC is given a target for reduction in
energy consumption by end of three years
• For power plants, the target will be in terms of
reduction of Net Heat Rate of the Plant
• Power plants who don’t achieve the target will
have to buy Energy Certificates from those
who have achieved more than their targets
Benefits from Heat Rate Improvement
Take the case of a typical 210 MW power plant and assume that
it has the following operating variables:
Heat rate = 2450 kCal/kWh
Plant load factor = 85 %
Coal GCV = 3997 kCal/kg (C = 41.7 %)
Coal cost = INR 2000 /t
CO2 emission per t of coal burnt = (41.07/100) x (44/12) =
1.5059 t
The coal consumed and its cost, and CO2 emissions per year are
as follows:
Specific coal consumption = 2450/3997 =0.613 t/MWh
Electricity produced = 210 x 0.85 x 365 x 24
= 1,563,660 MWh Contd.1
Contd. 1
Coal consumed = 1,563,660 x 0.613
= 958,524 t
Coal cost = INR 958,524 x 2,000
= INR 1,917,048,000
CO2 emissions = 958,524 x 1.5059
= 1,443,441 t
If the energy audit and modifications in O&M practices yields
an improvement of heat rate by just 50 kCal/kWh, the fuel and
fuel cost saved per year would be as follows:
Heat rate (improved to) = 2400 kCal/kWh
Specific coal consumption = 2400/3997
= 0.60045 t/MWh
Contd. 2
Contd. 2
Coal consumed for generating
1,563,660 MWh of electricity = 1,563,660 x 0.60045
= 938,900 tonne
Coal cost = 938,900 x 2000
= 1,877,800,000 INR
CO2 emissions = 938,900 x1.5059
= 1,413,890 t

Thus, coal cost saved in one year = INR (1,917,048,000 –

1,877,800,000)
= INR 39,248,000
CO2 emissions saved in one year = 1,443,441 - 1,413,890
= 29,551 t
 Objectives of an Energy Audit or
Performance Monitoring
• To improve Heat Rate and reduce Auxiliary
Power Consumption of the power plant
• To identify energy efficiency improvement
measures
• To develop medium-term and long-term
energy conservation measures, & work out
techno-economics
 Evaluation of efficiency of Boilers
• Standards – ASME PTC 4 or BS 2885 or IS 8753
• Applicable for boilers fired with oil, gas, solid
fuels
• Two Methods used – a) Direct Method, & b)
Indirect Method
• Applicable for different firing systems –Stoker,
pf, FBC
• Applicable for subcritical and supercritical
boilers
 Direct Method
Boiler efficiency = (Heat output/Heat input) ×
100
= {Steam flow rate × (steam enthalpy – feed
water enthalpy) × 100}/
(Fuel firing rate × gross calorific value)

*Fuel as fired basis only

 Calculation of Boiler Efficiency
(ASME PTC 4)
• Heat losses in the boiler (%)
Dry flue gas losses (sensible heat + un-burnt CO)
Loss due to hydrogen and moisture in the flue gases
Loss due to moisture in air
Un-burnt carbon losses (fly ash and bottom ash)
Loss due to sensible heat in fly ash and bottom ash
Radiation & convection losses from boiler surface
Total losses = Sum of all above
• Boiler Efficiency
ŋBOILER = 100 – Total losses
 Data required for boiler efficiency
calculations
• Ultimate analysis of fuel (C, H, O, N, S, H2O, ash)
• GCV of fuel, kCal/kg
• O2 in flue gas (% by vol.)
• CO in flue gas (% by vol.)
• Tg, Flue gas temperature, oC
• Ambient air temp., humidity in air
• Combustibles (un-burnt) in fly ash & bottom ash
Measurement of temp., press., flow should be done
at multiple points in the duct
 Recommended excess air levels
Fuel/Type of boiler Excess air (%)
• Coal
PC • 15-20
FBC • 20-25
Stoker • 25-35
• Fuel oil • 03-15
• Bagasse • 25-35
• Wood • 20-25
• Blast furnace gas • 15-30
 Cold air leakage in an air heater
Flue gas from Flue gas to ID fan
economizer

Air heater

Hot air for combustion Air from FD fans

 Cold air leakage in Air Heaters
As per ASME PTC 4.1
wAL, % leakage =
{(% O2 in gas leaving the heater - % O2 in gas
entering the heater)/ (21 - % O2 in gas leaving
the heater)}x 90
 Corrected flue gas temperature
leaving the air heater for no leakage
tGONL = {% leakage x CpA x (tGO – tAI)/ (100 x CpG)}
+ tGO

where
CpA = Mean specific heat between temperature
tAI and tGO
CpG = Mean specific heat between temperature
tGO and tGONL
Case study of Energy Audit of a
500 MW Boiler
 Case study: Boiler efficiency evaluation for a
500 MW unit (Steam parameters- 1700 t/h, 179
ata,540oC/540oC)
• Coal properties
Design Actual
C (Wt %) 37.92 44.73
H 02.33 01.99
S 00.29 00.37
N 00.84 00.62
O 06.23 01.83
H2O 12.00 14.10
Ash 40.39 36.22
GCV (kCal/kg) 3500 3622
 Measured data for energy audit
• Boiler
O2 in flue gas (%) 4.01
Excess air (%) 23.06
CO (ppm) 9.3
Flue gas temp. (OC) 167.57
Ambient temp. (OC) 23.9
Wet bulb temp. (OC) 18.1
• Air heater
O2 (%) in flue gas after eco. 4.01
O2 (%) in flue gas after air heater 7.50
 Calculation of boiler efficiency
Parameter (%) Design Calculated
Dry flue gas loss 5.08 8.89
Heat loss due to CO 0.00 0.00
Heat loss due to moisture in air 0.12 0.12
Heat loss due to moisture and
Hydrogen in fuel 5.95 5.78
Heat loss due to unburnt in bottom ash 0.90 0.07
Heat loss due to unburnt in fly ash 0.00 0.02
Sensible heat in bottom ash 0.38 0.26
Sensible heat in fly ash 0.18 0.33
Surface & unaccounted loss 0.67 0.10
Total heat losses 12.57 15.65
Boiler efficiency 87.43 84.35
 Analysis of boiler efficiency test
results
• Flue gas losses are higher than design
• Excess air level is 23.6 % (recommended value
is 20 %)
• Flue gas temperature (OC)
Measured 167.57
Corrected after applying
leakage correction 190.0
Design value 146.0
 Expected improvement in boiler
efficiency
From To
Flue gas temp. (OC) 190 146
Excess air (%) 23.6 20.0
Boiler efficiency (%) 84.35 87.18*

* This would be very close to the design value of

87.43%.
 Coal and monetary savings potential
through efficiency improvement
Current coal consumption (t/y) 2,632,181
Saving potential through
efficiency improvement (t/y) 74,490
Coal cost (INR/t) 2,000
Monetary savings (INR/y) 148,980,000
Energy Audit of Steam Turbines
 Energy audit of steam turbines
(Data required)
• Steam flow, temperature and pressure conditions at the entry to the HP
turbine
• Cold reheat steam temperature and pressure
• Temperature and pressure of hot reheat steam at the inlet of IP turbine
• Temperature and pressure of IP exhaust steam
• LPT exhaust pressure
• Extraction temperature and pressure of steam of all the extractions (6 in
case of 500 MW and 5 in case of 210 MW)
• Super heater and reheater spray conditions (quantity, pressure and
temperature)
• Feed water condition at the economiser inlet (quantity, pressure and
temperature)
• Make up water quantity
• Coal consumption and power generation
 Analysis of steam turbine data
• TG heat rate (HR)
= (Heat input to turbine)/Power generated

• Heat input to turbine = {Heat in main steam + Heat picked up in reheat +

Heat in make-up water + Heat picked up in super heater (SH) spray + Heat
in reheater (RH) spray – Heat in feed water}

• Heat picked up in reheat = {HRH flow x (Enthalpy of HRH Steam –

Enthalpy of CRH steam)}

• Heat picked up in SH spray = {SH spray quantity x (Enthalpy of SH spray –

Enthalpy of feed water at economiser inlet)}

• HRH flow = CRH flow = {MS flow – Extraction-6 quantity – Gland steam
leakages}
 Assumed as 1.5% of the MS flow to turbine

• Extraction-6 quantity = { FW flow through HPH-6 (enthalpy in – enthalpy

out)} / (enthalpy of steam in – enthalpy of steam out)
 Analysis of steam turbine data
(Contd.)
• TG efficiency = 860/TGHR
• Plant heat rate = (TGHR/Boiler efficiency)x100
• Steam rate (SR) in kgs/kWh is steam input to the
turbine (kgs) to actual power output from the turbine
(kWh)
• Specific coal consumption (SCC) in kgs/kWh is overall
plant heat rate (kCal/kWh) to the GCV of coal (kCal/kg)
on as-fired basis.
• Cylinder efficiency (HP/IP)= (actual enthalpy drop /
isentropic enthalpy drop)x 100
=(steam inlet enthalpy – steam outlet enthalpy)/(steam
inlet enthalpy – Isentropic enthalpy)x 100
Audited performance parameters of a
500 MW steam turbine
Parameters Flow (t/h) Pressure Temperature Enthalpy Isentropic
(bar) (OC) (kCal/kg) enthalpy
(kCal/kg)
Main steam 1575.97 169.17 535.08 809.11 -

CRH-HPT 1450.00 46.47 343.49 731.05 721.71

exhaust

HRH-IPT 1450.00 42.47 530.09 838.87 -

inlet

IPT exhaust - 6.727 268.39 715.03 707.72

LPT exhaust - 0.096 - 531.02 -

Audited performance parameters of a
500 MW steam turbine (contd.)
Parameters Flow (t/h) Pressure Temperature Enthalpy Isentropic
(bar) (OC) (kCal/kg) enthalpy
(kCal/kg)
FW at eco 1580.90 210.02 249.54 259.05 -
inlet

SH spray 35.17 195.31 314.50 337.81 -

RH spray 2.49 115.56 183.94 187.65 -

Make-up 9.74 - 25.00 25.04 -

water

- - - - - -
Audited performance parameters of a
500 MW steam turbine (contd.)

• Coal consumption 286.66 t/h*

• Power generation 504.95 MW

* Unit control board value

 Analysis of performance of steam
turbine
Parameter Design@0% Design @3% PG test value Audited
makeup water makeup water Performance

TGHR, 1988.10 2023.6 1994.38 2030.74

kCal/kWh

TG efficiency, 43.26 42.50 43.12 42.35

%

Boiler 87.43 87.43 88.90 84.35

efficiency, %

Plant HR, 2273.93 2314.54 2243.48 2407.51

kCal/kWh
 Analysis of performance of steam
turbine (Contd.)
Parameter Design@0% Design @3% PG test value Audited
makeup water makeup water Performance

Overall plant 37.82 37.16 38.33 35.72

efficiency, %

Steam rate, - - - 3.12

kg/kWh

GCV of coal, 3500 3500 - 3622

kCal/kg

Specific coal 0.650 0.661 - 0.665

consumption,
kg/kWh
Specific coal - - - 0.568
consumption,
kg/kWh-UCB
value
 Cylinder efficiency of three turbines
Parameter PG Test Audit
HPT efficiency (%) 87.24 89.32
IPT efficiency (%) 91.36 94.42
LPT efficiency (%) 56.33 52.29
Overall efficiency (%) 43.12 42.36
 Inference & Recommendations
• SH spray is 2.39%, which is higher than
prescribed limit
• Turbine heat rate of 2030.74 (at 0.63%
makeup water)is higher than the design value
of 1988.10
• Coal consumption as calculated is higher than
UCB value. Thus, Gravimetric Feeder needs
re-calibration
 Inference & Recommendations
(Contd. 1)
• HPT & IPT efficiencies are better than the PG test
level. This leads to lesser enthalpy drop in LP cylinder,
and thus LP cylinder efficiency is lower.
• SH spray causes less feed water flow through the
water walls (once-thru boiler) and thus affects its
performance.
• RH spray causes less bleed steam flow to the FW
heaters and thus loss of efficiency.
• RH spray also lowers the cycle efficiency as the steam
formed by spray water in reheater bypasses the HP
cylinder, and thus affects the efficiency.
 Inference & Recommendations
(Contd. 2)
• Overall performance of turbine can be improved
by reducing the SH and RH sprays by suitably
tilting downwards the burners.
• Maintain recommended condensate levels in FW
heaters. With this no heat transfer areas are
immersed in the drain condensate.
• Overall plant efficiency is a function of
efficiencies of both boiler and steam turbine. In
this case, the improving boiler efficiency can
make a major contribution.
Plant Auxiliaries
Performance Data
of
JSW Energy Plants
(compiled by Centre for Science and
Enviroment)
JSW Energy Ltd., Ratnagiri
• 4 x 300 MW; Sub-critical; Imported coal –based; sea
water cooling; Supplied by Shanghai Electric Co.;
Commissioned in 2010 (units # 1,2) & 2011 (units # 3,4)
• Sp. Coal consumption = 0.49 kg/kWh
• Sp. CO2 emission = 1.03 t CO2/MWh
• Plant availability (2011-12) = 89 %
• PLF = 71.8 %
• APC = 8.53 %
• GHR = 2418 kCal/kWh
(12.4 % higher than design)
• NHR =2673 kCal/kWh
• Not included in PAT scheme
JSW Energy Ltd., Thoranagullu
• SBU I: 2 x 130 MW with Corax Gas & Imported Coal
(BHEL) + SBU II: 2 x 300 MW with Imported Coal
(Shanghai Electric)= 860 MW
• During 2010-11, 11-12, 12-13
Availability = 91 %
PLF = 96 %
GHR = 2261 kCal/kWh
GHR (design) = 2162 kCal/kWh
APC = 7.46 %
CO2 emission = 0.93 t CO2/MWh
Continued
• Avg. Steam Cycle HR = 1978 kCal/kWh
Design Steam Cycle HR = 1930 kCal/kWh
• Boiler efficiency = 88.3 %
Design boiler efficiency = 89.3 %
• CWP efficiency
SBU I 68% (Low)
SBU II 87.67 %
• PAT Targets (NHR)
SBU I: 2515 to 2503 kCal/kWh
SBU II: 2422 to 2420 kCal/kWh
Rajasthan West Power Plant, Barmer
• 2 x 120 MW, High Sulphur Lignite fired, CFBC
boilers
• PAT Targets (NHR)
3723 to 3559 kCal/kWh
 Thank you
ypa4@yahoo.co.in
abbi.yashpal@energoindia.com

Books Authored

Y P Abbi & Shashank Jain

“Handbook on Energy Audit and Environment Management”,
published by TERI Press, 2006

Y P Abbi
“Energy Audit of Thermal Power, Combined Cycle, and cogeneration
Plants”, published by TERI Press, 2012

http://bookstore.teriin.org