This document discusses heat rate audits in thermal power plants. It aims to identify causes of efficiency losses that increase heat rate. Some key points:
- Heat rate is the amount of heat input (fuel) required per unit of power generated and impacts generation costs. Lower heat rates reduce costs.
- Losses occur in the boiler, turbine, condenser/feedwater systems, circulating water system, and from electrical/steam auxiliaries.
- Common causes of higher heat rates include incomplete combustion, turbine erosion, condenser tube fouling, and electrical auxiliary inefficiencies.
- Tracking plant parameters and conducting monthly performance tests can identify losses and guide improvement efforts to lower heat rates.
2. The New Scenario
In the new competitive scenario, power
stations must face:
• To Reduce the generating costs.
• To Maintain high availability, efficiency
and operational flexibility.
• To Meet strict environmental
conditions.
• To Manage and extend the equipment
life, including systems modernization.
3. The Generation Cost
The variable overall cost =(The Plant
Availability Factor ,Station Heat Rate ,
Specific Fuel Oil Consumption , Auxiliary
Energy Consumption ).
The Variable Cost, decides the
competitiveness of the electric units in a
generating pool.
4. The Generation Cost Reduction
The kWh fuel cost = 70 % approx
the variable overall cost .
The Fuel cost components: The
station Heat Rate (kcal/kWh).
To reduce the variable cost through
the heat rate improvement.
5. Heat rate
Heat rate is the heat input (fuel)
required per unit of power generated
(kcal/kWh), for specific fuel being
fired and specific site conditions.
Station heat rate =
Turbine cycle heat rate
=-------------------------- x100
Boiler efficiency %
6. Objective
• To point out the causes
and location of efficiency losses.
• Improve station
heat rate.
7. LOSSES IN THERMAL POWER PLANT
1.Boiler losses
2.Turbine losses
3.Condensate/feed water system losses.
4.Circulating water system losses.
5.Steam conditions
6.Electrical auxiliary losses
7.Steam auxiliary losses
8.Fuel handing
9.Heat losses
10.Cycle isolation
11. Impact of parameter deviation on HEAT RATE
12.D M water Makeup
8. 1.Boiler losses
Symptoms
Boiler efficiency
Exit gas temp high
Excess air
Causes
1.1.Moisture losses
1.2.Dry gas losses
1.3.Incomplete
combustion
1.4.Radiation losses
14. 2.3. Flow area bypass
H P Turbine inlet bushing leakage
Main steam valve leakage
H P gland seal leakage
IP steam /intercept valve leakage
I P Turbine inlet bushing leakage
15. 2.4. Flow area increase
Spill strip or packing leakage.
Rubbing
Thermal stress
Erosion of turbine stages.
Solid particle erosion of nozzle block.
Condenser leaks
Poor water chemistry
Blade mechanism damage.
16. Leaking steam not
contribution to power
generation (in RED)
2.5.Cross section of turbine –showing
efficiency loss due to leakage
17. 3.Condensate / F W system
losses
Symptoms
Low feed water temp
Causes
HP/LP heaters out of service
CEP/BFP efficiency
Shaft rub
Impeller wear
Flow resistance path increase
LP/HP heaters (high TTD/DCA)
Excessive tube plugged
FW heater out/bypass
FW heater level low/high
18. 4.Circulating water losses
Symptoms
High back pressure
Causes
Number of CW pump in operation
Air binding of condenser tubes
Excessive air in leakage
Inadequate air removal capacity
Fouled condenser tubes
Microfouling
Plugged condenser tubes
Air binding water box
Low circulating water flow
Increased CW system resistance
Decreased CW pump performance
Excessive condenser tube plugged
19. 5.Steam condition
Firing conditions
High super heater spray flow
High re heater spray flow
Inadequate heat transfer surface
20. 6.Electrical auxiliary losses
Symptoms
Station load
Causes
Precipitator (ESP) performance
Ash deposit
Excessive rapping
High ash in coal
Fan (ID,FD,PA )
Change in fan efficiency
AHP chocking
Pump (BFP,CEP,CW )
Change in pump efficiency
LP/HP Feedwater heater tube plugged
Coal Mill performance
Classifier setting incorrect
Coal quality
21. 7.Seam Auxiliary Losses
Excessive soot blowing
Decreased in BFP Turbine efficiency
Low inlet steam temperature
Excessive steam flow through vacuum
pump/ejector
Steam trap/vent leaking
Excessive usage of steam coil
22. 8.Fuel Handling
Spillage from the belt/transport
Measurement inaccuracies
Coal pile erosion
Wind erosion
Water erosion
Coal pile fire
23. 9. Heat Losses
Insulation on duct, pipe , turbine etc .
No insulation
Insulation damages
Poor insulation
Cladding missing /loose
Steam leakage.
Leakage to blow down tank.
Leakage through vents, drains.
24. 10.Cycle isolation
Leakage from recirculation valves of BFP/CEP.
Leakage through bypass valves.
Leakage to condenser through high energy
drains.
Leakage to condenser through emergency
control valves of feed water heaters.
Check high energy drains after every startup.
Provide Thermocouple in High energy Drains,
To detect passing of drain valve.
25. 11.Impact of parameter deviation on HEAT
RATE (210 MW ,KWU Turbine )-operator
controllable parameters.
SN PARTICULAR UNIT DESIGN
PARAMETERS
INCREASE in HEAT
RATE DUE TO
DEVIATION from
design parameters
(IN KCAL/KWH)
MULTIPLICATION
FACTOR
1 PARTIAL LOADING MW 210 24.7 PER 20 MW 1.235
2 MS PRESS KG/CM2 150 25.5 PER 20
KG/CM2
1.275
3 MS TEMP AT HPT INLET DEG C 535 7.5 PER 10 DEG C 0.75
4 HRH TEMP AT IPT INLET DEG 535 6.6 PER PER 10
DEG C
0.66
5 CONDENSER VACUUM mmHg 660 23.4 PER 10 mm
Hg
2.34
6 FEED WATER TEMP DEG C 241 16 PER 20 DEG C 0.8
7 RH ATTEMP FLOW T/HR 0 6.4 PER 10 T/HR 0.64
8 OXYGEN % IN FLUE GASES % 3 8 PER 1% 8
•�From above it is clear that, to achieve minimum heat rate,
keep the operating parameters as close to the design parameters.
27. 12.DM Water makeup
Boiler tube leaks
Excess deaerator venting to atmosphere
Excess continuous blowdown
Excess steam lost through condenser
venting
Valve packing leaks
Pump seal leaks
Steam leaks to atmosphere
28. Normative station heat rate
• Existing Coal based Stations
– 210 MW – 2500 Cal/kWh
– 500 MW – 2425 Cal/kWh
– In respect of 500 MW and above units where the boiler
feed pumps are electrically operated, the station heat
rate shall be 40 Cal/kWh lower than the station heat rate
indicated above.
• New Coal based Stations
– 1.065 x Design heat rate.
– Prescribed maximum permissible design heat rate to
discourage procurement of inefficient machines
29. Heat Rate Monitoring
Daily Heat Rate Calculation by deviation
method & Identification Of Heat Rate Losses
Monthly Performance Test (as per ASME
PTC/BS/DIN PG test Method )
Boiler Efficiency
Air -Preheater performance
Economizer Performance
Turbine Heat Rate
HP-LP-IP Cylinder Efficiency
Heaters & condenser
Turbine cycle rate rate
31. Maximum Turbine Cycle Heat Rate
Note – Prescribed maximum permissible heat
rate to discourage procurement of inefficient machines
32. Example of 210 MW
Operating efficiency of unit is 37.5 %.
Unit heat rate is 2305 Kcal/kwhr
To produce 860 Kcal ( heat equivalent to
one kwhr) ,2305 kcal heat has to supplied
to boiler.
Losses in the boiler- 266 kcal
Losses in turbine generator- 1179 kcal
Total losses-(266 +1179)= 1445 kcal
Total heat input to boiler= (1445 + 860)kcal
LOSSES
Produces
One kwhr
35. Major Reasons for Higher Gross
Heat Rate in India
1. Low combustion efficiency lead to high carbon loss.
2. High force outages due to failure of boiler tubes.
3. Poor performance of milling system.
4. Lack of Maintenance planning and spare planning
5. Low turbine cylinder efficiency
6. High dry gas losses due to high unwanted excess air
7. Poor sealing and heat transfer in air pre-heaters
8. Low condenser vacuum.
9. High air ingress in the boiler and high heat loss due to poor
insulation
10. Poor Performance of ESP lead to failure of ID fan and low
availability.
11. High cooling water inlet temperature due to poor
performance of Cooling Tower.
12. Non availability of quantity and quality coal.
13. High auxiliary power consumption .
14. Obsolete C&I system .
15. Poor quality critical valves lead to passing and poor control
36. Conclusion
Only Improvements in the station
Heat Rate, Specific Fuel Oil
Consumption and Auxiliary Energy
Consumption can make
generating units competitive.
37. Less Emissions
As the heat rate decreases (heat rate
improves), the amount of fuel for the
same generation also goes down. Of
course with less fuel burned, emissions
(green house gases) are lowered.