DVC – Operation Services

Heat Rate Improvement

- identifying the losses
 Structure

• Typical Thermal Plant efficiency • Turbine cycle losses

opportunities
• Cooling water cycle losses
• Impact of controllable losses on
Plant efficiency • Turbine losses

• Heat rate impact on fuel cost • Electrical Auxiliaries losses

• Impact of deviation of key • Steam Auxiliaries, Fuel and Heat

parameters on Heat Rate losses

• Heat rate logic tree • Cycle isolation losses

• Boiler losses • Mitigating the heat rate & efficiency

losses
Impact of Key parameter deviation on Heat
rate
 Heat Rate logic tree

Heat Rate
Losses

Turbine Cycle Cooling Water Turbine

Boiler Losses
Losses Cycle losses Losses
• Boiler Efficiency • Feed water Temperature • Condenser Backpressure • HP/IP/LP Efficiencies
difference
• Exit Gas Temperature • C W inlet Temperature • Steam Flow

• Air Pre-heater Temperature • Generator Output

Difference
• W/√p/v
• Excess Air

Electrical Steam Auxiliary Fuel Handling Cycle

Heat Losses
Auxiliary Losses Losses Losses Isolation

• Station Load • Boiler Feed pump • System Walk down • System Walk Down • System Walk Down
Efficiency
• Fuel Inventory • Pyrometer • High Pipe wall
• Vacuum Pump Flow Checks temperature downstream
of Isolation Valves

• Steam Trap Checks

 Boiler Losses
Boiler Losses

Moisture Dry Gas Incomplete Carbon Radiation Stack Gas

Losses Losses Combustion Losses Heat Losses Losses

Excessive Soot Change in Incorrect gas Fouled Heat

Blowing Coal Quality Change in Coal
Bypass damper transfer
Quality
setting Surfaces
Change in Ambient Burner Tips
Conditions plugged Increased Mill
Tail ends
Incorrect Fuel Classifier Vanes
to Air Ratio Improperly adjusted
Tube Leaks Change in Mill
Fineness

Increase in Coal Improper Burner Loss of Roller

Tension
Surface Moisture Damper Settings

Excessive Ring or Roller

Change in Coal Fouling
Wear
Quality

Classifier Vane
Wear

Boiler Water Air

Super-heater Re-heater Economizer
Walls Pre-heater
 Dry Gas Losses

Dry Gas Losses

Boiler Casing Improper Burner Air Pre-Heater Incorrect Fuel to

Air-in Leakages Damper Settings Leakage Air Ratio

• Decreased Furnace exit • Decreased wind box • Decreased Stack • High O2 at Boiler exit
Temperature pressure gas temperature
• High excess Air
• High O2 at the Boiler exit • Increased Boiler exit • Increased O2 at measurement
gas temperature Air Heater exit
• Normal excess Air
Measurement • Decreased CO2
at Air Heater exit
• Increased Boiler exit
temperature • Normal O2 at the
Boiler exit
• Increased Superheat
Spray Flow
 Turbine Cycle Losses
Turbine Cycle
Losses

Non condensable Tubes fouled

Tube leaks Tubes Plugged
gases in shell side internally

• Decreased Feed water • Change in FW heater LVL • Increased Tube Bundle Press Drop • Increased Tube bundle Pr
drop
O/L temperature
• Decreased FW O/L Temp • Decreased extraction pressure drop
• Decreased Ext Pr drop
• Decreased extraction
pressure drop • Cycling of Emergency • Cycling of Emergency drain valves
drain valves • Gradual change in FW
O/L Temperature

Feed water
Excessive venting Feed Water Feed water Heater FW Heater Baffle of
Heater Low
or steam leaks heater High Level out of service Bypass Valve leak
Level
• Increased extraction • Increased drain cooler • Decreased FW O/L • Decreased Economizer • Decreased FW O/L
temperature
pressure drop O/L temperature temperature inlet temperature
• Decreased Tube Bundle
• Decreased FW O/L • Low Feed water Heater • High Feed water Heater
Press Drop
temperature level level

• Decreased drain cooler

O/L temperature

• Increased drain cooler

O/L pressure
 Cooling Water Cycle losses
Cooling Water
Cycle losses

Change in Ambient Low Circulating Increased heat

Air in-leakage Tube Cleanliness
conditions Water Flow load on Condenser
• Change in CW I/L • Change in CW I/L • Increased Condenser • CW O/L temperature • Decrease in Turbine
water temperature water temperature TTD • CW pump Discharge Pr
efficiency
• Wet bulb • Wet bulb • Tube Bundle Pr Drop • Tube bundle Pr drop • Cycle isolation
temperature temperature • CW pump current
problems

Cooling Tower Losses

{ Wet bulb temperature, cooling tower range, cooling tower approach }

Degradation of Change in Ambient Improper Fill

Inadequate Cells Recirculation
Fill Material conditions Material
• Wind Direction • Wet Bulb temperature
• Fan current drawal
• Lapse rate

Inadequate Fan Unequal Flow Inadequate Decreased Fan

Capacity Distribution Chemical control efficiency
• Water Analysis

Spray valves Spray valves Structural damage to

Fill material Plugged
blocked improperly adjusted upper basin
 Turbine Losses
Turbine Losses

Inadequate Leakage past Excess

Mechanical Excess Fouled heat
Damage
heat transfer closed re-heater Flow area
surface governor valve spray gas transfer
decrease
bypass surfaces
• Low MS temp • Pr in Steam I/L • Low RH Temp • Decrease in ratio of • Decreased
• Low RH Temp pipe > First stage • RH Spray flow stage downstream MS Temp
• High exit gas temp • RH spray control to upstream Pr • Decreased
Turbine • Low FW temp at Pressure v/v position • Gradual decrease in HRH Temp
losses economizer O/L stage efficiency • Increased Flow area
• Gradual decrease in exit gas temp bypass
Turbine High SH Flow area W/√P/V
losses Spray Flow Increase
IP-2 end packing
• Decrease in
Sudden change in stage η
Spill strip or Solid Particle erosion LP Power Output
packing leakage of Nozzle Block IP-1 end packing

Erosion of Turbine Blade Mechanical • Decrease in RH turbine η

Improper Spray Leaking Spray • Decrease in IP2 sec η
Control isolation Valve stage Blades damage
• Low MS Temperature • Spray valve position • Sudden decrease in stage η
• Sudden decrease in stage η Dummy seal HP-IP2
• Sudden decrease in W/√P/V • Decrease in HP η
• No change in √P/V
• Increased downstream • Decrease in RH Flow
extraction temperatures Cycling • Decrease in RH Pr drop

Operating Dummy seal HP-IP1

Vibration • Decrease in RH Pr drop
Practices Exfoliation
• Decrease in RH turbine η
Thermal Leaking Reheat Bypass v/v
Rubbing
Stress Condenser Leakage Poor water Chemistry • RH Pr drop
• Condenser Hot well level • Water quality • Decrease in RH turbine η
• Water quality • Increased exit gas temp
 Electrical Auxiliaries losses
Loss due to Electrical
Auxiliaries

Continuous running
Precipitator Change in Fan
Pump Efficiency Mill Performance of non continuous
Performance efficiency
loads
Emitter ash Excessive Classifier Low
Shaft rub
deposits rapping setting primary air
• High Voltage incorrect flow
Impeller
Change in • Mill fineness • Mill temperature
wear • Mill tailings
• Pump discharge flow coal quality
• Pump current draw • High Ash Mill skid Coal quality
Change in • Coal Moisture
Flow path Change in FD Change in ID • Coal grindability
resistance Fan Efficiency Fan Efficiency
• Pressure drop
Increased Change in Excessive O/L damper Change in PA Fan
Change in cooling
Flow path Ambient air Air In setting Efficiency
tower fan efficiency conditions Leakage incorrect
resistance
• wet bulb temp
• increased ∆ p • O2 Measurement • Damper position
• Relative Humidify
Incorrect Change in flow Excessive Air in
Shaft rub Shaft Rub
Excessive Blade pitch I/L damper Shaft rub path resistance -leakage
drift incorrect settings • Furnace Pr drop
• Vibration Monitoring • Vibration Monitoring • Vibration Monitoring
• Make up • Damper • APH Pr drop
position Excessive air • ESP Pr drop Blade
Shaft rub
heater leakage erosion
• Vibration Monitoring • O2 Measurement
 Steam Aux, Fuel & heat losses
Steam Auxiliaries
losses
Excessive steam
Excessive Soot
flow through
Blowing
vacuum pumps
• Increased Makeup • Vacuum pump flow
• Decreased exit gas temp
Decrease in BFPT η
• Increased HP steam
supply flow

Excessive Low I/L Increase in High Damaged Increase in Extraction

Recirculation
shaft steam SH spray exhaust blades of RH spray NRV
v/v passing
leakage temp flow Back Pr Nozzle flow passing
• Low RH temp • High Condenser Pr • Decreased turbine η
• Decrease in BFP I/L Pr
• Increase in extraction
Fuel handling line ∆ p
losses

Spillage from Coal Coal pile Coal pile Measurement

Belts sampling erosion fire inaccuracies

Wind Water
erosion erosion

Heat Losses

Heat loss Damaged Damaged Improper Improper Damaged Heat loss

through cycle Insulation of insulation of insulation insulation of turbine from D/A,
isolation Cond return lines steam lines of Boiler Air/flue ducts insulation FW heaters
 Cycle Isolation
Cycle isolation

Recoverable Non recoverable

Losses losses
• Increased Make up

Leaks Leaks to Leaks from Leakage from Leakage

Leaks to BFP Seal
from Htr the D/A FW Htr through
the D/A injection
to Htr Condenser supply line Bypass lines Bypass lines
• Increased O/L temp
Leakage
Leakage from Exh
Erosion of Leakage Leakage to through Boiler
Leakage of hood spray
htr vent directly to turbine drain start up
heater vent control bypass
orifice condenser manifold bypass v/v
Leakage through
all the FW heater Leakage through Leakage from
BFP A Min BFP B Min Leakage Leakage bypass lines BFP GS desup spillover control
Flow to IP #1 to IP #1 control v/v bypass v/v bypass
Flow
Manifold Manifold
Leakage from
Leakage from GS
Leakage to Leaks to HW make up
HP supply control
LP HP control v/v
v/v bypass
Manifold Manifold bypass

Leakage from Leakage from

condensate recirc condensate
control v/v bypass controlv/v bypass

Leakage through Leakage from

steam pr control v/v GS condensate
bypass bypass
 Cycle Isolation(contd..)
Non recoverable
losses

Leakage Leakage Leakage Lkg through Leakage Leakage

Valve Lkg through
through from drn through drain line through through
packing GS Hdr
vacuum line from condense from HRH safety CRH safety
leaks safety v/v’s
breaker heater r drains heaters v/v v/v

Lkg Lkg thr. Lkg thr. Lkg thr. SH

Leakage thr. Lkg thr. Lkg thr. SH Lkg thr. Soot
through FW Htr MS spray control
HW lvl MS drain spray Hdr blower Stm
HW MU Atm drain 1st stage Hdr
control drain RHS drain supply S/V
drain Vents LHS drain

Lkg from Lkg through Excessive Lkg through

Lkg through Lkg through Lkg thr Lkg through
Drum D/A flow Soot blower
Economizer D/A water D/A safety MS Safety
safety emergency through supply hdr
vent gauge drain v/v v/v
v/v’s drain D/A vents safety v/v

Lkg Leakage Leakage Leakage

Leakage through Leakage
through Lkg through through through BFP through
emergency drain through CRH
FW heater Boiler BD tank Steam trap seal line condensate
line drains & vents drain
& Drain drains drains drains
 Cycle Isolation (contd..)

Leaks directly to
condenser

Excessive flow Leakage of

Leakage through Leakage through
through LP Heaters
the condensate BFP -A GS supply
Heaters vent emergency
recirculation line drain trap
orifice drains

Leakage Leakage
Leakage
through BFP through BFP
through BFP
leak-off drain emergency
drain float v/v
trap dump

Leaks to HP
manifold

Leak through
Lkg through Lkg through
impulse
steam I/L steam I/L
chamber drain
pipe drain pipe drain
line
LHS RHS
 Cycle Isolation (contd..)

Leakage to LP
Manifold

Excessive flow through Excessive flow through Leaking steam trap in Leak through Extraction
HP Gland seal steam LP Gland seal steam extraction #2 line #2 line isolation valve
drain orifice drain orifice isolation valve drain steam trap bypass valve

Leaking steam trap Leaking steam trap in Leaking steam trap Leaking steam trap in
in extraction #1 line extraction #2 line in Extraction#3 Extraction#3 line
drain drain line drain isolation valve drain

Leakage through Leakage through Leakage through Leaking in Extraction#3

Extraction line#1 steam Extraction line#2 steam Extraction line#3steam line iso valve steam trap
trap bypass valve trap bypass valve trap bypass valve bypass valve

Leakage to Turbine
Drain Manifold

Leakage through HRH Leakage through HRH I/L Leakage through outer Leakage through outer
I/L line drain LHS line drain RHS cylinder Non orifice drain cylinder orifice drain

Leakage through FW
heater drains & Vents

Leakage
Leakage Leakage Leakage Leakage Leakage
through
through through start through through level through shell
channel relief
shell drain up shell vent channel vent control drain relief valve
valve
 Cycle Isolation (contd..)

Leakage to Boiler
BD Tank

Leakage through Leakage through Leakage through Leakage through Leakage Leakage through
division wall I/L division wall I/L Steam drain water SH O/L Header through RHS primary convection
header drain LHS header drain RHS gauge drain drain wall HRH drain SH header drain

Leakage through Leakage through Leakage through Leakage through Excessive

RHS Lower LHS Lower Economizer I/L Right lower Rear steam drum
partition drain partition drain Header drain W/W header drain blow down

Leakage through Leakage through Leakage through Leakage through

right lower front right lower front right lower side left lower side
W/W header drain W/W header drain wall drain wall drain
 Cycle Isolation (contd..)

Leakage to LP#1
Manifold

Leakage through Leakage through Leakage through Leakage through

Leakage through
BFP #A HP steam BFP #A HP steam BFP #A LP steam BFP #A LP steam
CRH drain
supply drain supply drain supply drain supply drain

Steam trap leak Steam trap leak Excessive flow Excessive flow Leakage through
in D/A extraction in D/A isolation through HP seal through LP seal steam BFP # A LP steam
line drain line drain steam supply orifice supply orifice trap bypass valve

Leakage through Steam trap leak in Leakage through D/A Steam trap leak in
BFP#A LP steam Extraction #5 line Extraction line steam Extraction # 6 line
trap bypass valve isolation valve drain trap bypass valve isolation valve drain

Steam trap leak Leakage through Leakage through D/A Leakage through
in CRH bypass extraction#6 line steam isolation valve steam CRH drain line steam
valve trap bypass valve trap bypass valve trap bypass valve

Leakage to LP#2
manifold

Leakage Leakage through Leakage through

Leakage HRH O/L hdr
through HRH through HRH CRH I/L header
main drain line RHS drain drain
Leakage LHS drain Leakage Leakage through
through through HRH CRH I/L header
Boiler drains RHS drain LHS drain
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