Documentos de Académico
Documentos de Profesional
Documentos de Cultura
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
(Accurately)
Air heater
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*
• HRH flow = CRH flow = {MS flow – Extraction-6 quantity – Gland steam
leakages}
Assumed as 1.5% of the MS flow to turbine
- - - - - -
Audited performance parameters of a
500 MW steam turbine (contd.)
Books Authored
Y P Abbi
“Energy Audit of Thermal Power, Combined Cycle, and cogeneration
Plants”, published by TERI Press, 2012
http://bookstore.teriin.org