A presentation for PGDC students at NPTI by Anil Palamwar

1. ANIL PALAMWAR
RETIRED
CHIEF ENGINEER, KHAPERKHEDA TPS.
DIRECTOR (OPERATION) MAHAVITARAN
• NEED FOR ENERGY AUDIT.
• AUDIT PROCEEDURES
• ENERGY AUDIT –
• MACRO LEVEL
• AND
• MICRO LEVEL.
1

2. Energy Audit ?????
• We know Financial Audit.
• Audit of Public Enterprises.
• Balancing of Income & Expenses.
• Whether rules are followed ?
• E.A. is slightly different.
• Energy Audit deals with -
• Losses – Efficiency – Conservation
• Promotes :- Economy, competitiveness &
Environment.
2

3. ENERGY CONSERVATION
ENERGY IS THE CAPACITY TO DO WORK.
ENERGY IS AVAILABLE FROM
WIND-WATER-SUN -FOSSIL FUEL
MOSTLY WE WORK WITH ELECTRICAL OR THERMAL
ENERGY.
Why Conserve?
1. - RESOURCES ARE LIMITED.
2.-COST REDUCTION TO REMAIN VIABLE IN
COMPETITION.
3.- Environment - Global warming - GHGs
3

4. EFFICIENCY OF RANKINE CYCLE IS LIMITED TO 35-40 %.
C.C.G.T. PLANTS GO UP TO 52-55 %.Efficiency. [Combined Cycle Gas
Turbines]
SO IF HEAT IS USED DIRECTLY,
[WITHOUT CONVERTING TO ELECTRICITY],
CYCLE EFFICIENCY WILL INCREASE.
CO-GENERATION ADOPTS THIS PRINCIPLE.
Industrial units must explore the possibility of use of waste heat.
Where ever a furnace is used,
lot of waste heat is available for use in some way or other.
IN SIMPLE WORDS –
WHEN 100 M.T. OF FUEL IS USED, ONLY 40 MT IS USED TO
PRODUCE ELECTRICITY,
HEAT VALUE OF REMAINING 60 M.T. GOES UNUSED TO THE
ATMOSPHERE.
4

5. ALSO- CONSIDER THE SYSTEM LOSSES-
Transmission
Three Transformers-220/33; 33/11 ; 11/0.415 KV---
Efficiency=0.99 x0.99 x 0.99 =0.97 or 97%
Transmission Efficiency= 94 %,
Distribution Efficiency=85%
Motor Efficiency=80 %
Pump Efficiency = 80%
Total system Efficiency=
0.97x0.94x0.85x0.80x0.80=0.4960 or 49.60%
5

6. It means that for every unit consumed, two units are
generated and sent from a power station.
Conservation is therefore necessary. Waste must be
avoided .
Cost is the most powerful motivating factor for
conservation.
Maharashtra State needs approximately 300 MU of
electricity per day. (Average)
Only about 150 MU are really utilized.
Efficiency is of utmost importance.
Every process needs thorough check to identify losses.
6

7. Transformers- Losses within limits-e.g. MSEDCL
Motors-Pumps-Fans- e.g. Feed Pump and P.A. Fans at KPKD
TPS.
Procurement-Installation-O&M -
All these affect performance-and losses.
Ducting and its aerodynamics- Eddy formation
Selection of correct pipe dia and cleanliness of pipes.
Air conditioning- use of vapour cycles
where waste heat is used.
Properly set thermostats.
Maximum use of daylight and Natural ventilation.
7

8. ENERGY AUDIT
FRIENDS & ENEMIES
8
NEGATIVE FORCES
GOAL -TO REDUCE ENERGY CONSUMPTION
POSITIVE FORCES
HIGH PRICEOF ENERGY
EFFICIENTTECHNOLOGY
TAX ON ENERGY
TOP MANAGEMENTSUPPORT
ENERGY INTENSIVE INDUSTRY
NO CORPORATE ENERGY POLICY
NO AWARENESS IN THE COMPANY
INSUFFICIENTSKILLS & KNOWLEDGE
COMPETING CORPORATE POLICIES
INSUFFICIENT FUNDS

9. FOUR PILLARS OF ENERGY
MANAGEMENT
9
TECHNICAL ABILITY
MONITORING
SYSTEM
STRATEGY
PLAN
TOP MANAGEMENT
SUPPORT
ENERGY MANAGEMENT

10. MATERIAL BALANCE
10
SOLID WASTE FOR
STORAGE &
DISPOSAL
WATER / AIR
PROCESS
OPERATIONS
REUSABLE WASTE
GASEOUS EMISSION
PRODUCT
BYE PRODUCT
WASTE WATER
LIQUID WASTE FOR
STORAGE &
RAW MATERIALS
CHEMICALS

11. ENERGY BALANCE
11
ENERGY IN HOT RESIDUE
ENERGY IN CONDENSATE
COMPRESSED AIR
ENERGY IN COOLING
WATERENERGY IN RAW MATERIAL
ENERGY IN VAPOUR
ELECTRICITY
STEAM RADIATION LOSS
PROCESS
OPERATIONSCOOLING WATER ENERGY IN HOT PRODUCTS

12. 12

13. 13

14. 14

15. NON Renewable Energy Sources
15

16. Renewable Energy Sources
16

17. 17
It took more than 3 million years to convert to Fossil
Fuels.

18. INTRODUCTIONINTRODUCTION
Conventional source of energy such as coal,
oil and gas are scarce and exhaustible.
Energy prices will rise in the long run to
reflect their relative scarcity and high cost
of exploration and extraction.
Hence, all attempts must be made
expeditiously to ensure the optimal use of
the available resources to manage the
viability and availability of energy.
18

19. INTRODUCTION (contd.)INTRODUCTION (contd.)
 Government of India enacted the Energy
Conservation Act – 2001.
 For efficient use of energy and its conservation to
mitigate the gap between demand and supply and to
promote economic competitiveness.
 The Act provides for
 Institutionalizing and strengthening delivery
mechanisms for energy efficiency services in the
country and
 Provides the much-needed coordination between the
various organizations and stakeholders,
 Within the Government and in the private sector.
19

20. Enacted in October 2001Enacted in October 2001
Become effective from 1st March 2002Become effective from 1st March 2002
Bureau of Energy Efficiency (BEE) operationalizedBureau of Energy Efficiency (BEE) operationalized
from 1from 1stst
March 2002.March 2002.
MISSION OF BEEMISSION OF BEE
Develop policy and strategies with aDevelop policy and strategies with a
thrust on self regulation and marketthrust on self regulation and market
principles, within the overall framework of theprinciples, within the overall framework of the
EC Act with the primary objective of reducingEC Act with the primary objective of reducing
energy intensity of the Indian economy.energy intensity of the Indian economy. 20

21. 1. DESIGNATED CONSUMERS1. DESIGNATED CONSUMERS
( Energy Intensive Industries and other Establishments)( Energy Intensive Industries and other Establishments)
A programme to initially focus on energy policyA programme to initially focus on energy policy
issues of energy efficiency improvement,issues of energy efficiency improvement,
 in organized sectors such asin organized sectors such as
 energy intensive industries and.energy intensive industries and.
 commercial sector,commercial sector,
 through establishment of energy managementthrough establishment of energy management
system,system,
 capacity building of energy professionals,capacity building of energy professionals,
implementation of energy audits,implementation of energy audits,
establishments of specific energy consumption normsestablishments of specific energy consumption norms
 support to consumers on providing information onsupport to consumers on providing information on
authentic energy dataauthentic energy data
21

22. Designated Industries Schedule - Responsibilities
 Schedule to EC Act provides list of 15 energySchedule to EC Act provides list of 15 energy
intensive industries and other establishments to beintensive industries and other establishments to be
notified as designated consumers (DC).notified as designated consumers (DC).
 Designated Consumers to -Designated Consumers to -
Appoint or designate energy managersAppoint or designate energy managers
Get energy audits conducted by accreditedGet energy audits conducted by accredited
energy auditorsenergy auditors
Implement techno-economic viableImplement techno-economic viable
recommendationsrecommendations
Comply with norms of specific energyComply with norms of specific energy
consumption fixedconsumption fixed
Submit report on steps takenSubmit report on steps taken
22

23. 1)
Designated Consumers
Thermal Power Stations- 30,000 Million tonne of oil
equivalent (MTOE) per year and above
2) Fertilizer- 30,000 MTOE per year and above
3) Cement- 30,000 MTOE per year and above
4) Iron & Steel- 30,000 MTOE per year and above
5) Chlor-Alkali- 12,000MTOE per year and above
6) Alluminium- 7,500 MTOE per year and above
7)
Railways- One traction substation in each Zonal Railway ,
Production units and Workshops of Indian Railways having
total annual energy consumption of 30,000 MTOE or more
under Ministry of Railways
8) Textile-3,000 MTOE per year and above
9) Pulp & Paper-30,000 MTOE per year and above
23

24. WHY ENERGY EFFICIENCY IS IMPORTANT ?WHY ENERGY EFFICIENCY IS IMPORTANT ?
• We do something to enjoy, save money &
resources and finally because it is the LAW.
• So Energy Audit – Because,
• Depleting fossil fuel-Resources are scarce
• Optimum plant utilization-Competitiveness.
• Global warming-Carbon Credit
• Designated consumer-E.A. is Mandatory.
• Generate more energy with same quantity of
fuel 24

25. PERIOD STEAM
PRESSURE&
TEMPERATURE
UNIT SIZE
(MW)
TURBINE
Heat Rate
(Kcal/kWh)
Unit Heat Rate
(Kcal/kWh)/
Efficiency
1951-60 60 kg/cm2
, 482o
C 30 – 57.5 2470
1961-75 70 kg/cm2
, 496o
C to
90 ata 538o
C
60 – 100 2370
1961-75 130 ata 535/535o
C 110 – 120 2170 – 2060 2552-2423
1977-82 130 ata 535/535o
C 210
(Russian)
2060 2423/
35.4%
1983+ 150 ata 535/535o
C 210
(Siemens)
2024 2335
36.8%
1984+ 170 ata 535/535o
C 500 1950 (TDBFP) 2294
37.4%
1990+ 150 ata 535/535o
C
170 ata 538/538 o
C
210/ 250
250/ 500
1950
(MDBFP)
1950 (TDBFP)
2294
2294
THIS CHART SHOWS THE GRADUAL IMPROVEMENT
IN HEAT RATE
TO ACHIEVE ECONOMY
25

26. EFFICIENCY IMPROVEMENT
CAN GIVE YOU
For an average increase of 1 % in the Efficiency would
result in:-
 Coal savings of approx. 11 million tons per annum
worth Rs.13,000 Million
 CO2 reduction about 13.5 million tons per annum
 Lower generation cost per kWh- as more efficient the
unit works, the more economical it is
 1% increase in efficiency for 210 Mw unit with heat
rate 2335 kcal/kwh means heat rate improvement to
2275 kcal/kwh
26

27. MAJOR CAUSE OF INEFFICENCY IN POWER PLANTMAJOR CAUSE OF INEFFICENCY IN POWER PLANT
• High Flue gas exit Temp
• Excessive amount of excess air(O2)(Increases dry flue gas
loss)
• Poor Mill/Burners performance causing high unburnt
carbon in fly and bottom ash.
• Poor insulation.
• Poor house Keeping.
• Poor instrumentation and automation
27

28. MAJOR CAUSE OF INEFFICENCY INMAJOR CAUSE OF INEFFICENCY IN
POWER PLANTPOWER PLANT (Cont…)
• Not running the units on design parameter
• Heaters not in service or poor performance
of regenerative system
• Poor condenser vacuum
• Excessive DM water consumption- passing
and leakages
• Use of Reheat spray to control Reheat
Temperature
• Poor Cylinder Efficiency of turbine
28

29. CONTROLLABLE PLANT
PARAMETERS
• M.S. & R.H. Steam Temperatures
• M.S. Steam Pressure
• Condenser Vacuum
• Final Feed Water Temperature
• DP Across Feed Regulation Station
• Auxiliary Power Consumption
• Make Up Water Consumption
29

30. HOW TO ACHIEVE ENERGYHOW TO ACHIEVE ENERGY
EFFICIENCY ?EFFICIENCY ?
• Adopt state of the art technologies
• Adopt cutting edge technologies
• Review & Re-engineering of the existing
systems
• Bench Marking
• Energy Auditing
30

31. CAN WE IMPROVECAN WE IMPROVE
EFFICIENCY?EFFICIENCY?
 Yes, provided we shed the myths and
believe in applying result oriented
efforts
 Workout to identify & quantify the cost
of hidden losses
 Bring in requisite operational
behavioral change
31

32. SOME OF THE MYTHS
 High PLF & availability translates into
Optimum Efficiency
 Heat rate is the responsibility of Efficiency
Management Group at Stations
 Equipment maintenance to be taken-up based
on periodic overhaul schedule
 Boiler performance degradations has no
relation to Turbine Cycle performance
32

33. Some of the Myths contd…
• Design heat rate is the best achievable heat rate
• Efficiency tests are the same as performance guarantee
test
• Heat rate improvement requires large investment.
• Results follow immediately after testing is completed
• Heat rate is the responsibility of Energy & Efficiency
Management Group (EEMG) at Stations
• Station instruments are accurate for monitoring heat
rate parameters
33

34. Some of the Myths contd…
“Design” is not the best achievable performance
• Predicted performance based on Turbine Heat Balance
Diagrams and Boiler Efficiency at different loads
• ‘Design’ is based on specific ambient conditions that vary
throughout the year
• Actual initial performance could be different from design or
changes might have been made to plant
• Current performance to be compared to an achievable
‘expected’ value to establish efficiency gaps
34

35. SYNERGIZE OPERATION
OF UNIT
Need to clearly understand the relation between
performance & fuel, operation and design
parameters
Operational behavior and performance
Impacts of operating efficiency of Boiler, Turbine
and their auxiliaries on Net Unit Heat Rate
Maximum Achievable Load, Maintenance &
Availability
35

36. SOME CRITICAL FACTORS AFFECTING
BOILER PERFORMANCE
• Fuel:- Heating Value, Moisture Contents, Ash
Composition, Ash Contents,& Volatile Matter.
• Operational Parameter:- Level of Excess Air, &
operating Condition of Burner Tilt Mechanism.
• Design:- Heating input per plan area, Height of Boiler,
Platens & pendants heat transfer Surfaces, Burner & wind
Box design.
36

37. BEHAVIOURAL IMPACTS
• Low heat value results in over firing of fuel causing more heat
availability for super heater and re-heater thus more attempration
spray requirement. Hence increase in THR, overloading of ash
handling system, fans and increased soot blowing
• Moisture content increase causes increase in heat transfer to S.H, and
R.H. Hence again increase in attempration spray and THR (Turbine
Heat Rate)
• Ash composition and contents increases damage to pressure parts
surfaces because of melting behavior of low fusion ash temperature of
blended coal in particular
• In consistency in fired fuel characteristics results in variation in excess
air requirement thereby increasing stack loss and hence boiler
efficiency reduction, overloading of ID Fan and ultimately unit load
limitation
• High heat value causes excessive radiant heat transfer to water walls
thereby leaving lesser heat for super heater and re-heater
• .
37

38. Normally excess air ranges from 15% to 30% of
stoichiometric air.
• High O2 % and presence of CO at ID Fan outlet are indicator
of air in leakages and improper combustion in furnace
• Poorly effective damper control also is the cause of higher
SEC of fans both primary and secondary
• The quality and purity of feed water and make up water is also
required to be maintained in a meticulous way by limiting
blow down losses to nearly 1% and by checking the passing
and leakages of valves. However, maximum 3% of flow can
be taken as make up for these causes including soot blowing
requirements
• Soot blowing is dependent on ash contents and is unit specific.
Intelligently devised soot blowing can result in saving the fuel
BEHAVIOURAL IMPACTS
38

39. • Cascading effects on efficiency, loading and
availability because of following systems and
equipments performance also needed to be looked
into. The systems are:-
Fuel receiving, preparation and handling systems.
Pulverizing system
Air Heater
Fans
Electrostatic Precipitator
Fly ash handling system
Bottom ash handling system
Waste disposal system
BEHAVIOURAL IMPACTS
39

40. PERFORMANCE IMPACTS ON STEAM
CYCLE , UNIT HEAT RATE & OUTPUT
• Various design & operating parameters of a
unit are responsible for its cycle
performance, heat rate,& out put
40

41. CRITICAL FACTORS AFFECTING
CYCLE PERFORMANCE
1. Re-heater & its system pressure drop
2. Extraction line pressure drop
3. Make up
4. Turbine exhaust pressure
5. Air preheat
6. Condensate sub-cooling
7. S/H & R/H spray flows
8. Wet Bulb Temp
9. Top Heaters out of service
10. H.P. heater drain pump
11. Type of BFP drives & method of flow control 41

42. RH & ITS SYSTEM PRESSURE DROP….
• Every one 1% decrease in drop can improve
THR and output by 0.1% & 0.3%
respectively
• Normally designed for pressure drop
equivalent to 10% of HP exhaust pressure
• Causes are
Feed Heater abnormalities
R/H safety valve passing
42

43. EXTRACTION LINE PRESSURE
DROP…
• Permissible pressure drop between stage
pressure & Shell pressure is maximum 6%
• For every 2% increase in this pressure drop,
THR would be poorer by 0.09%
43

44. CYCLE MAKE-UP….
• Acceptable value of make up water is 3% to
offset cycle water losses
• For every 1% increase in make up 0.4%
increase in THR & 0.2% reduction on
output is there
44

45. EXHAUST PRESSURE…
• Increase & decrease in exhaust pressure do
affect the THR.
• Though no valid thumb rule has been devised
so far, however last stage blade design &
exhaust area of turbine do affect the impact of
changing exhaust pressure.
45

46. AIR PRE-HEAT….
• Air preheating of combustion air before entry to
regenerative air heater is done with either steam coil
air pre - heater or hot water pre heating coil to
maintain Average Cold End Temperature (ACET) to
escape dew point temperature complications
• Condensate retrieval is necessary to avoid
deterioration to THR depending upon unit load and
combustion pre heating duty
46

47. CONDENSATE SUB-COOLING…
• For 30% total flow and 2.5 deg C sub-
cooling ,an increase of 0.001% in THR can
be there for every subsequent 10% increase
in flow
47

48. R.H & S.H. SPRAY FLOW…
• Spray water whether drawn from BFP or
after the final heater, it is always less the
generative and less productive as well
• Every 1% spray flow, correction need to be
done in THR & load computed from the
curves supplied with the machine
48

49. TOP HEATER OUT OF SERVICE….
• Extraction steam flow meant for top heater
passes through the turbine thereby increasing
the output.
• But at the same time final feed water temp is
lowered resulting in poor Total Heat Return.
• More fuel must be used in the boiler to add the
sensible heat (Not imparted by the feed heater)
• The % loss increases from lowest stage (.5 to .6 )
to highest stage (1.2 to 1.5%)
• Roughly each Deg C in TTD will result in a loss
of 0.25% efficiency.
49

50. PERFORMANCE MONITORING
• Analyze the poor efficiency areas from previous record
• Go down to specific system and then to component
• Carry out performance/diagnostic study as suggested in
the Auditing Manual & operating manual
• Devise a unit specific efficiency control sheet for few
terminal conditions (Actual vs Design)
• Monitor once per shift to know the operating efficiency
and check any deterioration
50

51. Coal Handling Plant
• Coal Crushers-
• If significant quantity of coal >20 mm size is
observed on down side of crusher then it may led to
substantial decrease in mill performance.
• Identification of combination of various least power
consuming equipment and recommending merit
order operation.
• Use of natural daylight through conveyor galleries
and use of fire resistant translucent sheet.
51

52. Soft Starters- V.F.D.
• Explore Installation of power saver device in
major LT motors. (Conveyor belt etc.):
• Major HT /LT motors i.e. conveyors, crushers
etc. are often partially loaded & also there are
frequent starts /stops.
• Explore the possibility of providing power
saver devices (soft starters) in major motors.
52

53. Power Factor of Motors.
• Power factor correction possibility:
• Induction motors may have vey low power factor,
leading to lower overall efficiency.
• Capacitors connected in parallel with the motor are
used to improve the power factor.
• The PF correction reduces KVA demand,
• reduced I2
R losses in cable upstream of capacitor,
• reduced voltage drop in cables (leading to improved
voltage regulation),
• and an increase in the overall efficiency of the plant
electrical system.
53

54. Chemicals for Dust Suppression
• Explore the possibility of using chemicals for
reduced water spray:
• Mixing of chemical compounds in water provides
much better atomization of water spray, by
reduction in surface tension of water.
• Thus for the given application of dust
suppression, less quantity of water is sprayed
which also results into less wastage of latent heat
in the steam generator.
54

55. Use of Bull Dozers ?
• Maximum Mechanical Handling:
• Minimum Bulldozing: Receipt, unloading, stacking
and reclaiming and the selection of machinery should
be such that all the handling operations are
accomplished without the use of semi mechanized
means like bulldozers which are more energy
intensive equipment.
• When coal is stocked in yard for more than
incubation period (duration between coal mined and
getting self ignited), special precautions like
compacting, water spraying must be taken.
55

56. Bunkering Frequency
• Reduced Number of Fillings:
• Live storage capacity of raw coal bunkers and the
filling pattern of bunkers is so planned that,
• 24 hours coal requirement of the generating units
is met by not more than two fillings per day.
• This will eliminate frequent starting and stopping
of the CHP system.
56

57. Boiler Scheme
57

58. Energy audit of Boiler
• Coal quality - composition and calorific value
• Coal milling aspects
• Combustion and excess air
• Re-heaters
• Heat recovery units – Economisers, air preheaters, etc,
• Insulation aspects
• Boiler blow down aspects- Water Chemistry
• Soot blowing aspects- Effectiveness
• Operation and maintenance features which affect the energy
efficiency
• Condition & status of boiler and their internals
• Feed water system aspects
• Air and flue gas system aspects 58

59. STEPS IN ENERGY AUDIT
• Data collection
• Observations and Analysis
• Exploration for energy conservation measures
• Report preparation
– DATA COLLECTION
• The first step in energy audit of boiler is to collect the
design / PG test parameters pertaining to boiler,
economiser, air preheaters, coal and coal milling, soot
blowing and other key associated equipment.
59

60. Particulars Unit
Details at Normal
cont. rating, NCR
Make BHEL
Type Water tube single
drum
Capacity tph 627.32
Main Steam pressure kg/ cm2 155
Main Steam temperature 0C 540
Boiler efficiency % 87.16
Super heater outlet flow tph 627.32
Reheater outlet flow tph 565.6
Coal Calorific value –GCV kcal/ kg 4350
Coal consumption tph 106.2
Total combustion air tph 822
LTSH outlet temperature 0C 420
Reheater outlet temperature 0C 540
Water- economizer inlet
temperature
0C 241
Water- economizer outlet
temperature
0C 280
Oxygen content at Economizer
outlet
% 4.23
60

61. Unit Design NCR Actual
Make
Type
Year of Installation
Main Steam Pressure kg/ cm2
Main Steam Temperature oC
Main Steam Flow tph
Steam pressure at LTSH out let kg/ cm2
Steam temperature at reheater inlet oC
Steam temperature at reheater outlet oC
Steam pressure at reheater inlet kg/ cm2
Steam pressure at reheater outlet kg/ cm2
Steam temperature at LTSH out oC
Saturated steam temperature in drum oC
Super heater platen outlet temperature oC
Pressure drop in reheater Kg/ cm2
Super heater spray tph
Reheater Spray tph
Design ambient temperature oC
Coal consumption tph
DESIGN DATA
61

62. ECONOMISER DATA
Unit Design Actual
Feed water pressure at the inlet kg/ cm2
Feed water pressure at the outlet kg/ cm2
Feed water flow Tph
Feed water temperature at the inlet oC
Feed water temperature at the out let oC
Oxygen content in flue gas before
economizer %
Excess air % in flue gas before
economizer %
Exhaust gas inlet temperature oC
Exhaust gas outlet temperature oC
Exhaust gas quantity Tph
62

63. AIR PRE HEATER DATA
Unit Design Actual
Air quantity at APH outlet (primary) Tph
Tempering air Tph
Air heater outlet (secondary) Tph
Total combustion air Tph
Air temperature at fan outlet oC
Air outlet temperature of APH – primary oC
Air outlet temperature of APH– secondary oC
Oxygen content in flue gas before APH %
Oxygen content in flue gas after APH %
Excess air % in flue gas before
APH %
Flue gas inlet temperature oC
Flue gas outlet temperature oC
Flue gas quantity Tph
Others
63

64. EXHAUST GAS TEMPERATURE PROFILE
Unit Design Actual
Temperatures at different location oC
Super heater platen outlet oC
RH front inlet oC
RH rear inlet oC
SH final inlet oC
LTSH inlet oC
Economizer inlet oC
APH inlet oC
APH outlet oC
ID Fan inlet oC
ID fan outlet oC
64

65. BOILER HEAT BALANCE
Unit Design
Ambient temperature oC
Excess air %
Dry flue gas loss %
Hydrogen loss %
Moisture in fuel loss %
Moisture in air loss %
Unburnt combustible loss %
Radiation loss %
Un accounted loss %
Gross boiler efficiency on HHV %
Guaranteed efficiency %
65

66. Feed water & Boiler water limits
Unit Feed water Remarks
pH at 25oC
Oxygen – maximum ppm
Total iron- maximum ppm
Total silica – maximum ppm
Conductivity at 25oC Microsiemens
Hydrazine residual ppm
Total solids – maximum ppb
Chlorides ppm
Copper – maximum ppm
Permanganite consumption ppm
66

67. MILLS AND BURNERS PERFORMANCE
Unit
Requirement
at MCR
Actual Remarks
No of coal burners No
PA flow tph
No of mills in operation No
Mill loading %
Air temperature at mill inlet
after tempering
oC
Air – fuel mixture temperature
after leaving mills
oC
Total coal fired tph
Air Coal ratio
67

68. Mill specifications:
• Type of mill :
• Make :
• Capacity : __________tph at coal
________grind
• Fineness : ___________% through
________mesh
• Motor rating :____________kW
• Motor voltage :________ V
• No of mills :__________
• Running /Standby :_________/________
68

69. COAL DATA
• Design coal parameter
• Moisture :_____%
• Ash :_____%
• Volatile matter :_____%
• Fixed carbon :______%
• HGI :_____%
69

70. SOOT BLOWERS
Type number
Soot blowers for furnace
Soot blowers for super heaters
Soot blowers for reheaters
Soot blowers for air preheaters
Medium of blow
Steam pressure before reduction
Steam pressure after reduction
Steam consumption
70

71. Instruments For Energy Audit
• The following instruments are required for conducting the
boiler energy audit.
• Power Analyser: Used for measuring electrical parameters
such as kW, kVA, pf, V, A and Hz
• Temperature Indicator & Probe
• Stroboscope: To measure the speed of the driven equipment
and motor
• Sling hygrometer or digital hygrometer
• Anemometer
• Available On line instruments at the site ( Calibrated )
• Digital Manometer of suitable range and appropriate probes
for measurement of pressure head and velocity head.
•
71

72. • Additional pressure gauges with appropriate
range of measurement and calibrated before
audit.
• Flue gas analysers / Orsat apparatus
• Infrared pyrometers
• Pressure gauges
• Steam trap tester / Ultra sonic leak detectors
• Instrument to measure coal velocity in coal
feed pipe
72

73. MEASUREMENTS & OBSERVATIONS
• Average GCV of coal during audit period
• Coal analysis – ultimate and proximate
• Coal consumption details
• Performance parameters of coal mills
• Steam parameters of main steam, reheat, super
heater, LTSH (flow, pressure and temperature)
• Air – flow, temperature, pressures
73

74. MEASUREMENTS & OBSERVATIONS
• Flue gas – Flow, temperature and pressure
• Flue gas analysis
• Ambient temperature
• Boiler loading
• Motor electrical parameters (kW, kVA, Pf, A, V, Hz,
THD)
• Surface temperatures of insulation and boiler surfaces
• Un-burnt coal (in fly ash and bottom ash)
74

75. 75

76. 76

77. 77

78. 78

79. 79

80. 80

81. 81

82. 82

83. 83

84. 84

85. 85

86. 86

87. 87

88. 88

89. 89

90. 90

91. 91

92. 92

93. 93

94. 94

95. 95

96. 96

97. 97