HEAT AND MASS BALANCE

INDEX

S.N. TOPICS PAGE NOS

1 BASICS OF HEAT RATE 2-5

FACTORS AFFECTING THE TURBINE

2 HEAT RATE 6 - 12

3 BOILER LOSSES AND EFFICIENCY 13 - 20

210 MW LMW TURBINE CYCLE HEAT

4 21 – 37
& MASS BALANCE

BOILER EFFICIENCY
5 38 - 42
CALCULATIONS

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BASICS OF HEAT RATE

Generator output = 1 kWH = 860 kCal

Losses in the Generator = 20 kCal
Input to the Generator = 880 kCal
Turbine Exhaust and Regen Losses = 1185 kCal
Heat Input to the Turbine = 2065 kCal (Turbine Heat Rate)

Boiler Output = 2065 kCal

Boiler Losses = 331 kCal
Input Heat Energy to the Boiler = 2396 kCal (Unit Heat rate)

If the Heat Value of Coal is 4000 kCal/kg, = 2396 / 4000 = 0.599kg of coal
then Coal Rate i.e. coal required to generate
one unit of electricity (1 kWH)

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Plant Heat Rate

If the losses increase, the heat rate will also increase and the coal required will also
increase, thereby increasing the cost of generation.

HEAT RATE OF THERMAL POWER PLANT:

In thermal power plant, Chemical Energy of fuel is converted to electrical energy. The
conversion cycle is based on Thermodynamic Vapor Cycle, called Rankine Cycle.
Conversion takes place through various stages and different processes are involved for
the purpose. Due to the various limitations nature has imposed, such as Irreversibility in
the process, heat losses to atmosphere, Friction losses, Heat Transfer losses, to name a
few, efficiency of conversion is always less than 100%. In addition to these losses, some
heat energy is rejected because, steam temperature and pressure drop to such low values
(after doing work in Turbine), that further conversion to useful work is not possible. Due
to all these reasons, energy input is much more for one kWh electrical energy output
from the Generator. If the Chemical / Electrical conversion process should have been
100% efficient, 860 Kcal heat energy input should have given one kWh electrical energy
out put at Generator terminals. This ratio of Electrical Energy Output over a certain period
of time to Chemical Energy input to the Plant over the same period is called Heat rate.

In modern plants, designed for High temperature and pressure Steam admission to
Turbine, efficiency and heat rate can be around 36% and 2400 Kcal/ KWh respectively.
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The term “Heat rate” is defined in many ways as follows:

Net Unit Heat rate: It is the ratio of energy input to Boiler in terms of Heat energy of
fuel, for one kWh of electrical energy output at Bus Bars, i.e. after UAT. If the out put
and input is considered for a period of an hour, then it is Net Unit Heat rate for one
Hour. Similarly, it can be calculated over a period of a Day, a Week, a Month or a Year.

In this case, it is the sent out energy that is considered, hence, consumption of electrical
energy for driving the plant’s auxiliaries is also accounted for.

Gross Unit Heat rate: It is the ratio of energy input to Boiler in terms of Heat energy of
fuel, for one kWh of electrical energy output at Generator Terminals. In this case,
auxiliary consumption is NOT accounted for.

Net Turbine Cycle Heat rate: It is the ratio of heat energy contained in steam admitted
to Turbine for one kWh of electrical energy output at Generator Terminals. In this case,
auxiliary consumption and losses in Boiler are NOT accounted for.

Operating Heat rate: It is the heat rate calculated by considering the inputs and outputs
from the plant only when it is synchronized with the grid. In this case, the fuel input
required for steam conditioning, from light up to synchronization is not considered. Also
auxiliaries consumption during the period of plant shut down is not considered.

What information does “ Heat rate “ give?

The plant is designed to generate electricity at certain design heat rate. Deviations from
design values give a valuable information regarding the operational and maintenance
practices. Also, by comparison with the historical data, decisions can be taken while
making investments on the maintenance and renovation. Also, problem area can be
identified and analyzed for improvements. A deviation in Gross Turbine Cycle heat rate
tells us about energy conversion scenario in turbine, including condenser and
regenerative feed heating process. If Net average unit heat rate deviates from that of
design, it tells us how much extra amount of energy is put in and how much money is
“wasted”.

Now a days, tariff for supply of electricity to consumers is fixed by Maharashtra

Electricity Regulatory Commission. While fixing tariff, MERC has given the benchmark
heat rate values for all power plants in MAHAGENCO. If actual heat rate is more than
the benchmark heat rate, the additional expenditure incurred shall not be considered in
Generation cost for fixing tariff. Naturally MAHAGENCO will have to absorb the cost
of this expenditure. Another important aspect is of conservation of fast depleting natural
resources, such as coal and fuel oil. When power is generated at optimum heat rate,
minimum possible fuel is consumed. Less fuel consumption also leads to lesser extent of
pollutants added to the environment. Hence monitoring and controlling the heat rate to
the optimum level has many benefits.

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Calculations of heat rate:

Net Unit Heat rate, for given time period, is calculated by the formula,

(Coal Consumption × Its Calorific Value) +( Oil Consumption × Its Calorific Value)
------------------------------------------------------------------------------------------
Generation measured at Bus Bars

To measure coal consumption accurately is very difficult. Also the calorific value of coal
varies and its continuous, on line measurement is not possible.

Hence, in normal practice, unit heat rate is calculated by the simpler method:

Unit Heat rate = Turbine Cycle Heat rate / Boiler Effi. calculated by loss method.

Turbine Cycle Heat rate = (Total Heat added to Turbine in Kcal)/Generation in MU

Total Heat added to Turbine Cycle =

((Sp. Enthalpy of S.H. Steam at Boiler Outlet  Total Steam Flow Rate to H.P.T.) –
(Sp. Enthalpy of Feed Water at economizer inlet  Feed Water Flow rate at
economiser inlet))

+ (Sp. Enthalpy of R.H. Steam at Reheater outlet – Sp. Enthalpy of C.R.H. steam
at Reheater inlet)  Reheat Steam Flow

+ (Sp. Enthalpy of S.H. Steam at Boiler Outlet – Sp. Enthalpy of S.H. spray) 

S. H. Attemperator Flow

+ (Sp. Enthalpy of R.H. Steam at Reheater outlet – Sp. Enthalpy of Reheat

attemporator)  R. H. Attemperator Flow.

Values of temperature, pressure and flow rate are known from instrumentation and
specific enthalpy can be known from Steam tables. The value of generation is known
from the Energy Meters. If reading of energy meter connected to Generator terminals is
considered in this formula, the heat rate obtained is Gross Heat rate and if that from Bus
Bar energy meter is considered, then it is the net heat rate.

For method of calculation of Boiler efficiency by loss method pl. refer the chapter on the
topic.

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FACTORS AFFECTING THE TURBINE HEAT RATE:
1) Main Steam Temperature at H.P.T Inlet

2) Main Steam Pressure at H.P.T Inlet

3) Reheat Steam Temperature at I.P.T Inlet

4) Reheat Steam Pressure at I.P.T Inlet

5) Condenser Vacuum

6) Temperature of Feed Water at Economiser Inlet.

7) Boiler efficiency

8) S.H. and R.H. attemperation flow rate.

The effect of individual parameter is discussed below:

Rankine cycle efficiency, η rankine = 1 – (T2/ Tm1) (1)

Where; T2 is temperature of heat rejection, (2)

Tm1 is Mean temperature of steam admission = (h1 - h4s) / (s1 - s4s). (3)

h1 & s1 are specific enthalpy and entropy of steam at admission temperature and
pressure, h4s and s4s are the Sp. Enthalpy & entropy of feed water at Economiser inlet.

1) Temperature and Pressure of steam admission (M. S. as well as H.R.H): For η

Rankine to be high, Mean temperature of Steam admission (Tm1 in expression 1
above) should be as high as possible. Metallurgical constrains limit these values for
the given Turbine. However, by maintaining the steam parameters close to the
values specified by the Manufacturer, maximum possible Mean temperature of
Steam admission is achieved thus cycle is operated at design efficiency. Effect on
heat rate due to Deviation from design values for 210 MW LMW plant is as follows:

Parameter Expecte Actual Heat rate Excess Coal Excess coal

d Value Value deviation Consumption consumption
/KWh ( C.V. over the year,
Kcal/kwh 3500 Kcal/Kg) at 80% PLF

Main Steam 537° C 532° C 16.48 0.0048 8660 Tons

temp.

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 H.R. Steam 537° C 532° C 3.3342 0.0009 2190Tons
temp.

Main Steam 140 138 2.417 0.0.0006 1016 tons

Pressure Kg/cm² Kg/cm²

2) Condenser Vacuum plays a very important role in efficiency of the Rankine Cycle. If
vacuum is less than design value, i.e. if Condenser absolute pressure is more than
design value, corresponding saturation temperature is more, thus Heat is rejected at
Higher Temperature (T2 in expression 1 is less than design) and cycle efficiency
drops. This increases Heat rate. Also the of the L.P.T. backpressure increases, thus
reducing the conversion of Heat Energy to work in Turbine. This increases specific
steam rate thus increasing fuel consumption. In Condenser, only latent heat is
rejected, hence condensate temperature is always at saturation temperature. If
condenser pressure is less than design value, temperature of condensate shall also be
less. This causes low feed water temperature, thus increasing the heat rate. Following
table shows effect of deterioration of condenser vacuum on heat rate.

Parameter Expected Actual Excess Excess Coal Excess coal

Heat Consumption / consumption
rate Kcal KWh ( C.V. over the year,
/ KWh 3500 Kcal/Kg) at 80% PLF

Condenser 690 mm 670 mm 19 0.0054 7989 Tons

Vacuum Hg. Hg

3) Less Temperature of feed water at Economizer inlet causes efficiency of Rankine

Cycle to drop, as Mean temperature of steam admission decreases. Values of h4s and
s4s in expression 3 above are high, thus reducing Mean temperature.

Parameter Expected Actual Excess Excess Coal Excess coal

Heat Consumption / consumption
rateKcal KWh ( C.V. 3500 over the year,
/ kWh Kcal/Kg) at 80% PLF

Feed Water 253° C 248° C 22 0.0063 9261 Tons

Temp

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Reasons for Low Steam temperature and Pressure:

In the Power Plant, there can be many reasons for low temperature of Steam at Boiler
and Reheater outlet. Passing spray water control valves and motorized valves,
inadequately tuned temperature control system, fouled surfaces of the Super Heaters are
some of the reasons. These reasons become more dominant when the plant is operating
at loads below maximum rating. Throttling of steam flow due to partially shut valves is
the major reason for low pressure of steam at Turbine admission.

Reasons for poor vacuum in Condenser:

1) Air ingrace in condenser: Air ejection system of the condenser has the capacity
to remove non-condensable gases present in the steam in normal operation. As
the condenser is operated at less than atmospheric pressure, it is prone for air
leaking in to it. Sealing systems, such as Turbine Gland Sealing, Water sealing of
the evacuation system Valves, are provided to prevent the air ingrace. If Gland
sealing steam pressure and temperature and Valve Gland sealing water
pressure are not maintained properly, atmospheric air enters the condenser in
large quantity. Evacuation system can not remove the excess air and hence
condenser pressure increases. Condensers are also provided with many tapping
points for instrumentation. Many of these tapping points are used only for
carrying out acceptance tests. Once these tests are over, the temporary
instrumentation connected to condenser is removed. If any of such tapping
point remains open by oversight, air enters the condenser. There is also a chance
of cracks developed on the connection between L.P.T. casing and condenser.
Damaged gaskets on flanged joints, leaking vent valves provided on Pressure
gauges, cracked impulse lines, passing vacuum breaker valves, atmospheric
vent or drain valves on C.E.P. inlet piping, if are open, also cause air ingrace.
Evacuation equipment, such as Steam Ejectors, Electrical Vacuum Pumps are
provided with airflow measuring devices. Any increase in the flow rate
indicates air ingrace. Condenser air leaks can be identified by manual inspection
while the plant is on load. Helium Leak Detectors can also check air leaks. When
the unit is shut down, condenser leaks can be detected by filling Condenser with
D.M. Water up to certain high level. But this test needs lot of prior preparation.

2) High C.W. Temperature, Insufficient Flow rate or Fouled heat transfer

surface: Condensers are heat exchangers. Heat transfer takes place from steam
to cooling water from the tube surface. Cooling water takes away the Latent
Heat from condensing steam. The heat transfer equation is

Q= U * A * ΔTm (1)

Where Q is heat load on condenser, a function of mass rate of steam condensing

U is the coefficient of heat transfer,

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 A is the surface area of tubes

ΔTm is Log Mean Temperature Difference,

ΔTi - ΔTf
Where ΔTm = ---------------------- (2 )
Ln (ΔTi / ΔTf)

ΔTi = (saturation temperature of steam – C.W. inlet temperature) (3)

ΔTf = (saturation temperature of steam – C.W. outlet temperature) (4)

Also called Terminal Temperature Difference or TTD

Relationship between Water flow rate and heat load is given by

mw = Q / ( cp * (T2 – T1) ) (5)

(T2-T1) = (mw * cp) / Q (6)

Where mw is Mass flow rate of Water

cp is specific heat of water = 4.18 Kj / Kg / °C,

T2 is Temperature of Water at condenser outlet

T1 is Temperature of Water at condenser inlet,

In the installed system, Mass flow rate of water (depends on the C.C.W pumping
capacity) and Heat Load (Mass of steam from LPT exhaust) becomes constant. And as
per equation 3 above, heat removal capacity solely depends on (T2 - T1). Temperature of
Cooling Water, T2, at Condenser outlet can increase only up to the value decided by
design T.T.D. for the condenser,

Design value for T.T.D. in Condensers is generally 2.5° C, as designing condenser for
TTD below this is not viable. Hence, ultimately, the heat removal becomes directly
dependent on Cooling Water Inlet temperature (assuming other factors to be constant
for the given case). Increase in this temperature will cause reduction in mass of steam
getting condensed. In such cases, some steam remains in vapour form, causing
Condenser Pressure to increase. Similarly, even if Cooling Water temperature is within
design limits, but its mass flow rate reduces, same scenario can be expected.

If heat transfer coefficient deteriorates, it again lead to increased Condenser Pressure,

as all the steam do not condense because of insufficient cooling.
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Reasons for High C.W. temperature:

In Cooling Towers, evaporative cooling of Hot water takes place. Air, sucked by the
C.T. Fan, flows in cross flow direction to water flow, comes in contact with air, causing
evaporation of water. The heat energy required is taken from Water, thus cooling it. The
rate of evaporation is dependent on Relative Humidity of air and its dry bulb
temperature C.T. design is made considering yearly average value of R.H. found from
historical data.

If the R.H. and Dry bulb temperature of ambient air is high, evaporation is low and
hence Water temperature does not drop to the design values. This situation may arise
during some periods of the year and is not controllable. The controllable reasons are;

1. Non availability of some of the C.T. fans,

2. Unequal distribution of water to individual cell of the cooling tower,

3. Some of the water not coming in contact with air stream,

4. Reduced surface are of mass of water due to damaged or plugged nozzles,

5. Sensible heat gain by cold water when it flows from C.T. to C.W. Pump sump.

Reasons for Low C.W. Flow rate;

1) C.W. Flow rate required for maintaining Condenser Vacuum at rated generation
from the plant are calculated by designers. Accordingly C.W. Pump rating is calculated.
Velocity of cooling water through condenser tubes is the controlling factor. The pumps
selection is based on calculated values of Hydraulic Resistance of the C.W. Lines,
Condenser tubes, elevation to which hot water should reach etc. Hydraulic resistance
of the C.W. circuit increases due to following reasons:

i. Number of Plugged condenser tubes more than considered while designing the
system

ii. Reduction in Tube cross sectional area due to scaling in the tube or deposit of
mud, algae or organic growth within the tubes

iii. Throttling of Flow distribution valves at C.T. Cells

iv. Throttled isolating valves in the system

v. Deterioration of pump performance due to eroded or corroded impeller.

vi. Heavy and undetected leakage from the under ground piping.

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 Reasons for deterioration of Heat transfer coefficient:

Scaling and fouling, corrosion, and organic growth on condenser tubes reduces the
ability of heat transfer between Steam and cooling water. Ingrace of ambient of air in to
the condenser, which blankets the tube surface. Air has very low thermal conductivity
and it causes drop in Heat Transfer coefficient.

To minimize the problems of scaling, it is extremely necessary that cooling water

softness be maintained. Calcium and Magnesium salt precipitates stick to the metal
surface forming hard and difficult to remove scales. These salts have very poor thermal
conductivity. Commonly encountered scales are

i. Calcium Carbonate

ii. Calcium Sulphate

iii. Silicate Scales

iv. Calcium Orthophosphate

v. Magnesium salts

vi. Iron salts

Fouling is caused by deposition of suspended matter, insoluble in water. Foulants are

Mud and silt, Natural Organics, Microorganisms, Air borne Dust, Vegetation etc.

Preventive Measures:

The concentration of salts takes place because of evaporation of water in the cooling
towers. Even if softened water is used, concentration of these salts increases in closed
circulation system. One of the ways to reduce the concentration is taking fresh water in
to the cooling pond to make up for the evaporated water. But by this method, huge
quantity of make up water is required. Another way is to softening. But soft water has
greater tendency for corrosion. Maintaining pH of water between 6.0 to 8.0 by feeding
acid in the system. But there are many disadvantages such as control of pH, safety in
handling huge quantity of acid etc. On line circulation of sponge balls through
condenser tubes, and occasional acid cleaning of the condenser tubes are other ways to
prevent scaling.

Microbial Growth: Microorganisms enter cooling towers through air, make up water and
dust. The major problems are Algae, Fungi and Bacteria. Chlorine is usually adequate to
prevent the growth. But, it is effective only if pH is 8.3 or below. Free chlorine of 0.2 to
0.5 ppm is sufficient. Beyond 8.3 pH Chlorination does not satisfactory results.

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Temperature of feed water at Economizer inlet:

Feed water temperature is another factor, which decides the efficiency of Rankine Cycle,
as is evident from expression 1 above. Tm1 decreases if temperature of feed water at
Boiler outlet is low. High availability of feed water heating system and also its optimum
performance are important factors. Reasons for poor performance of feed heaters are:

1. Scaling of the tubes

2. Inadequate venting of Feed waters before cutting those in service

3. Passing and leaking heater bypass valves

4. Heater getting bypassed frequently due to High water level of because of inefficient
heater level control instrumentation

*********

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BOILER LOSSES AND EFFICIENCY:
Boilers are designed to operate at certain efficiency. Typical figures of the losses in the
Boiler (designed values) are:

Loss taking place % loss

Dry Flue Gas loss 4.64

HO and H2 in fuel 5.60

H2O in air 0.18

Unburnt Carbon 0.60

Radiation 0.19

Unaccounted 0.40

Manufacturers Margin 0.50

Total Losses 12.11

Efficiency 87.9

Controllable losses are 1) Dry Flue Gas loss and 2) Unburnt Carbon. Losses due to
Moisture in fuel and air are uncontrollable. Ambient air, when introduced in the boiler,
also carries with it water vapors. Hydrogen in Coal reacts with Oxygen in air and forms
moisture. Along with flue gas, water vapors also receive heat energy produced from
combustion of fuel. This energy is lost to atmosphere through Chimney.

Flue gas loss and Unburnt Carbon loss are the controllable losses. Effect of deviation of
some of the parameters on Heat rate :

Parameter Expected Actual Excess Excess Coal Excess coal

Heat rate Consumption / consumption
Kcal / KWh ( C.V. 3500 over the year, at
kWh Kcal/Kg) 80% PLF

Excess 3.5 % 4.0% 3.467 0.001 1600 Tons

Oxygen

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Unburnt 1.0% 1.5 % 3.782 0.0011 1700 Tons
Carbon

Flue Gas 135 145 18.67 0.00533 7853 Tons

Temp

Moisture 9% 11% 2.75 .00078 1156 Tons

in coal

Flue Gas Loss:

Combustion of fuel produces flue gas. Its major constituents are

1. Carbon Di Oxide produced by Carbon & Oxygen reaction,

2. Nitrogen from air,

3. Fly ash,

4. Oxygen,

5. Water Vapours.

Temperature of flue gas leaving air pre heaters is maintained at 135 to 140° C. Total Heat
content in the flue gas is =

(Volume of flue gas in m³/sec  Sp. Heat of the flue gas  Specific Weight  Flue gas
temperature)

 Specific Heat of the flues gas is 30.6 kJ / Kgmole /° C.

 Specific weight of the flue gas is 0.796 Kg/ m³.

When boiler is operated with Optimum air supply and temperature of flue gas at APH
outlet must is maintained within the design limits, flue gas loss is at its minimum.
Primary Air + Secondary air is the total Combustion air supplied to Boiler. Depending
on the Coal Analysis and required velocity of air + coal mixture through coal pipes,
manufacturers specify P.A. Flow through coal mill in relation to Coal Feeding.

Combustion Air requirement for the Boiler: Requirement of air for combustion of coal
varies as per the constituents of coal being fired. If it is less than required, incomplete
combustion takes place leading to high unburnt carbon loss. If it is more than required,
combustion can be complete but Flue gas quantity increase leading to higher flue gas
losses.

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 For Pulverized coal fired Boilers, 20% Excess air supplied under specific
conditions, ensure complete combustion. By maintaining 3.5 % Oxygen in flue gas (On
dry flue gas basis) at Economizer outlet ensures, that the Boiler if being fed with 20%
excess air. It needs to be emphasized that “Specific Conditions” must be met to ensure
minimum losses. These conditions are:

1. Fuel particle size must confirm to specified dimensions.

2. All the coal nozzles must admit equal mass of fuel in furnace and hence , primary air
velocity through pipes must be equal and as P.A. flow to mill should be
proportional to mill loading as specified by the manufacturer

3. Coal / Air mixture temperature at Pulveriser outlet must be 77° C.

4. Secondary air must enter combustion chamber from pre determined places only.

5. Secondary air must enter the furnace at predetermined velocity from all elevations.

6. Diffusers on the coal nozzles must be in proper condition to ensure that the jet of
air/coal mixture, emanating from nozzle, is well distributed.

7. Furnace must be air tight to eliminate possibility of entry of ambient air.

When all these conditions are satisfied, then only efficient combustion in the
furnace, supplied with 20 % excess air is ensured. Fuel admission and combustion
system has following equipment to ensure these conditions.

1. Oxygen Analyzers: In situ, Zirconia probe Oxygen Analyzers, installed on

Economiser outlet ducts, continuously monitor Oxygen in flue gas. Automatic air
flow control loop regulates F.D. Fan Inlet Guide Vanes in such a way that 3.5%
Oxygen in flue gas is maintained through out the operation of Boiler.

2. Fuel air dampers (named after the coal elevations i.e. A, B, C, D etc) on all the Four
Corners should be open only for the elevations that are in service. Position of these
dampers must be equal for all the corners. Regulation of these dampers is as per the
quantity of coal feeding measured as Coal Feeder speed. Dampers of the elevations
AA. FF, BC and DE should open equally for all Four Corners. These dampers are
regulated to maintain Furnace – Windbox D.P. to the value specified by the
manufacturer. Dampers AB, CD and EF are regulated as per Fuel Oil pressure for Oil
elevation in service. For the oil elevation not in service, dampers regulate as per the
Furnace – Windbox D.P.

3. Orifice plates in Coal Pipes: To ensure that all burners (nozzles) at all coal elevations
admit equal mass per sec in the furnace, two requirements should be fulfilled.
Primary air flow velocity in each of the pipe must be equal and fuel/ air ratio in all
pipes should be the same. Inserting the Orifice plates, thus equalizing the hydraulic
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 resistance of all the pipes equalizes pipe velocity. Cold air flow tests are conducted
on coal mills at regular intervals. Results from these tests give valuable information
of condition of Orifice plates and partially or fully choked up pipes. If coal mill is
operated with Primary air flow rate less than that specified, velocity of coal air
mixture drops below 20 mtr/sec, causing separation of coal particles from stream
and consequent settlement in pipes, resulting partial choke up. If the temperature of
coal / air mixture at coal mill outlet drops below 60° C, there is a possibility of
condensation of water vapor which also result in separation of coal particles and its
settlement.

4. Mill air flow control dampers: For ensuring the coal / air ratio equal, P.A. flow rate to
mill should be as per mill loading and hence regulated by feeder speed. Coal mill
manufactures give the P.A. Flow rate and mill loading characteristics.

5. Mill temperature control system: By ensuring coal air mixture at 77° C, adequate
dryness of coal is ensured, which is one of the important requirements for proper and
efficient combustion.

6. Furnace – Windbox DP Control system: Velocity at which secondary air enters the
furnace is determined by Furnace – Wind box differential pressure. For every boiler,
value of Furnace – Wind box differential pressure is specified for different loading
conditions. By sticking to the specified values, it is ensured that velocity of secondary
air is as per the combustion reaction requirement. For this purpose, opening of
Secondary Air dampers of the wind box is controlled by automatic control loop for
Furnace – Windbox DP. Set point for this loop is generated as per the boiler load as
indicated in the enclosed Fig.1.

7. Corner Firing: For achieving efficient and sustained combustion at desired rate,
Oxygen in Air must reach the Coal particles at that rate. Oxygen molecule reach
burning coal particles by a process called Diffusion. Ratio of Concentration of
Oxygen at particle surface to that in surrounding gas mixture decides rate of
diffusion. This rate is highest when Coal particle is surrounded by air which contains
21 % Oxygen. Furnace atmosphere is made of mixture of Coal, Air, Flue Gases and
Ash particles. To ensure that coal particles will always remain surrounded by air,
place of air admission, velocity at which air is admitted and turbulence in the furnace
are of prime importance. First two requirements are fulfilled as discussed above.
Tangential firing fulfills requirement of turbulence.

8. Air tight Furnace: Furnace pressure is always maintained at 4 – 5 mm W.C. below

atmosphere. If furnace is not air tight, ambient air will enter furnace. But, the velocity
of this air is very low. This air can not mix with the jets of Secondary air and Primary
air / Fuel mixture admitted at very high velocities and hence does not take part in
combustion. But, it travels with flue gas, and distorts the Oxygen reading, thus

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 replacing the Secondary air. It is therefore extremely important that tramp air entry
be prevented.

9. Pulverization of coal for design particle size: The above discussions deal with the
importance of Fuel firing equipment and air supply to boiler. Role of particle size is
as important as that of proper supply and distribution of air in the furnace. As
explained, care is taken that coal particles will always be surrounded by air in the
furnace. In furnace, very small size air “Packets” are interspersed in the
homogeneous mixture of gases. Total oxygen required for complete combustion of
the individual particle depends on mass of particle, which in turn depends on the
size to which particle is pulverized. Smaller is the size of particle, smaller the
quantity of Oxygen required for its complete combustion. Hence, by ensuring that
70% of Coal passes through 200 Mesh, it will always remain surrounded by air
“packet” which will contain enough Oxygen. But, it is also important that size
distribution of balance 30 % coal should be:

Passing through 100 mesh; 85% and above

Retained by 50 Mesh: Less than 0.5%
Resident time of particles in the furnace is generally 1 to 2 seconds. Bigger particles will
not burn completely due to lack of Oxygen, within this time and leave the furnace as
unburnt Carbon, thus increasing losses. Coarser particles also lead to increase in
slagging.

Optimization of Combustion Process: Supplying 20% excess air ensures that

combustion will be complete. However, there is always a possibility that in certain type
of Coal and combustion conditions, Excess Oxygen requirements can even go below
20%. It may also be possible that in some conditions, excess Oxygen requirements may
be more than 20%. In power plants, where coal from different mines is fired regularly,
such conditions may arise very frequently. To ensure that combustion remain efficient in
varying condition and Optimum air is supplied to Boiler in all conditions, Carbon Mono
Oxide monitoring in flue gas is done. If combustion is not complete, concentration of CO
in flue gases increases. Complete combustion is indicated by 100 ppm Co in flue gas at
Economizer outlet. If combustion is incomplete due to insufficient air, Co level shot up
immediately to very concentration values. Fig. 2 shows the variations in Co with ref to
Air supplied to Boiler.

Other Factors:

Following factors also cause deterioration of plant performance, thus increasing heat
rate. Many times, these factors are not measurable directly by plant’s instrumentation.
But, their effect can be known from regular tests.

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Low efficiency of H.P. Turbines, I.P. Turbine and L.P. Turbine: Turbine cylinder
isentropic efficiency is the measure of how efficiently turbine has converted input heat
energy in to mechanical work. Isentropic efficiency of Turbine Cylinder is given by:

Actual Enthalpy of steam at Inlet – Actual Enthalpy of steam at exhaust

Efficiency = ------------------------------------------------------------------------------
Actual Enthalpy of steam at Inlet – Ideal Enthalpy of steam at exhaust
Actual Enthalpy is known from steam parameters at Inlet and Exhaust. If steam
expands in turbine without change of Entropy, then it is called ideal expansion. By
finding out Temperature for Actual exhaust pressure and actual entropy of steam at
Turbine inlet, value of ideal enthalpy is known. Turbine manufacturers give the
expected Efficiencies. Any subsequent deviation from expected values indicate
deterioration of Turbine and can be corrected in the planned outages.

Air Heater leakage:

In Trisector Airheaters, air leakage, through seals, in to flue gas takes place. Due to
rotating rotor, the air side and flue gas side sectors are sealed by radial as well as axial
seal plates. Deterioration of sealing arrangement increases air leakage increasing I.D.
Fans loading. Leakage of ambient air in to flue gas through damaged ducts and through
E.S.P. Hoppers is another reason of increased loading fo the I.D. Fans. The extent of both
the leakages can be so high that I.D. Fan loading reaches its maximum, leading to either
restriction on Generation or in worst case, purposeful reduction of Secondary air. By
measuring Oxygen at Air Heater outlet and ESP outlet monitoring of extent of air
leakage is possible.

Make up water consumption:

Consumption of make up water is because of following reasons:

1. Soot blowing

2. Steam ejectors

3. Opening of C.B.D.

4. Passing of drain valves

5. Leakages of steam or feed water.

6. Steam used for Oil heating and steam tracing of oil lines.

7. Operation of auto drain traps to remove condensate from steam pipelines.

To certain extent, steam consumed for Soot Blowing, Oil heating and Ejectors and

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Water lost through C.B.D. can be calculated. If this data is monitored regularly, extent of
leakage from system can be guessed. Any leakage from system indicates heat lost and
lead to increased heat rate.

Spray Water Flow rate for Steam temperature Control.

There is no direct effect of attemperation flow in heat rate deviation. But increased
sprey flow rate indicates deterioration of Boiler Conditions.

Auxiliary Consumption:

Increased Auxiliary Consumption indicates more energy consumed by auxiliaries. It also

makes less energy available for distribution to consumers. Closely monitoring these
values helps in monitoring of health of the auxiliary. Regular energy audit gives
valuable information on repairs to be carried out and planned maintenance.

Conclusions: From above discussions, it can be concluded that, operation of the

Thermal Power Plant at optimum conditions reduces Gross Unit heat rate. The factors
that affect heat rate are:

1) Parameters of steam at HPT, IPT inlets,

2) Condenser Performance

3) Cooling Tower Performance,

4) Combustion of fuel in Boiler with Optimum air supply, thus reducing Dry
Flue Gas loss and Unburnt Carbon loss.

5) Auxiliary Consumption

6) Air heater leakage

7) Duct Leakage

8) Ingrace of tramp air in Boiler

9) Make up water consumption

10) Turbine Cylinder Efficiency

11) Feed Water temperature at Economizer Inlet.

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 Fig. 1, Variation in Furnace Windbox DP control ckt. set point with load

140 mm Wcl.

Furnace –
Windbox DP

40 mm Wcl.

40 % 70 %
Boiler Load

Fig.2, Change in CO in flue gas with combustion air supply

CO in flue gas
In ppm

Deficient air supply

100 ppm

Optimum Air Supply Air supply to Boiler

********

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210 MW LMW TURBINE CYCLE HEAT & MASS BALANCE
Heat & Mass Balance
Calculation of Heat Rate of 210 MW BHEL Turbine Cycle with Regenerative Feed Water
Heating consisting of seven feed water heaters shown in the schematic flow diagram
attached.

From station to station the C.W. Temp for the condenser cooling changes and therefore
the vacuum conditions and the exhaust temperature also changes accordingly. A
specimen calculation shown has been done for the values at 652000 kgs of steam per
hour flow at 130 kg/cm2 absolute pressure and 5550C superheat Temperature. Similar
such calculations can be done at different loads for calculation of heat rate of the turbine
regenerative feed water heating cycle at those particular loads.

While calculating the Turbine Heat Rate following assumptions have been made in the
original drawings, giving the values of Enthalpy and other Properties.

1. Under cooling in the drain coolers of Heater No 6 and heater No 7 has been taken
as 100C. The effect of drain cooler of Heater No 5 has been ignored.
2. Wherever a dash has been given in place of reading, the equipment is inoperative
in that range.
3. The values of temperatures mentioned are approximate. Whenever the steam is
wet (especially at the LP Exhaust), instead of giving the temperature, dryness
fraction has been mentioned in the temperature column.
4. When press in Heater No 5 approaches 10.5 Kg/cm 2 absolute, drain from Heater
No 6 is diverted to Deaerator bypassing Heater No 6 and drain of Heater No 5 is
diverted to Heater No 4.
5. The Specific Heat Rate does not include the consumption of steam in the main
Ejector.

Similar such calculations for the turbine heat rate can also be carried out for over load
working of TA set at 215.78 MW and at 211.05 MW Loads, at 670 T/hr steam flow and
with 3% makeup water added to the Hotwell of Condenser and at different cooling
water temperatures ranging from 300C to 360C at Condenser inlet. A separate calculation
can also be done to calculate the turbine heat rate when HP Heaters are out of service at
206.135 MW Load.

These figures should however, be not taken as guaranteed performance figures and will
vary from station to station depending upon the actual working conditions, age of
stations etc.

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1) INTRODUCTION

Before calculating the Turbine Heat Rate we shall first consider the stage by stage
efficiency of the Turbine Cycle.

A Complete Turbine Cycle single line schematic diagram is as per attached drawing,
wherein the parameters for Steam, Condensate and Feed water are marked for full load.
Similar such chart can be worked out by inserting the values for the parameters
calculated from BHEL Drawing No C-210-130/TDC-210-60.2. The Turbine Cycle
Diagram indicates the direction of flow of various fluids involved.

2) STAGE BY STAGE EFFICIENCY

2.1 Ejector:-

Steam from Deaerator

P- 4.5, T - 155
F - 1500, E-659.83

Condensate *T - 45.07 T - 43.16

to G.C.1 F - 480106 F - 480106

*Assuming the Effy. to be 99.8% T - 47.27 Dr

Ejector Outlet Temp T Calculated F - 1500 Ch
Output Heat taken by condensate 480106(45.07-43.16)*100
Input heat given by steam = 1500 (659.83-T)

Ejector is supplied with steam from Deaerator (d4) at 4.5Kg/cm 2 having 1550C Temp
and the condensate from hotwell passes through the same, which is pumped by the
condensate extraction pump to the further feed water regenerative heating cycle. The
ejector drain is recovered back to the flash chamber on the condenser. Calculations have
been made assuming the efficiency of 99.8% for the Ejector from which the Enthalpy /
Temperature for the drain from the Ejector to the Flash Chamber is derived.
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2.2 Gland Steam Condenser GC1:-

Steam from Deaerator

P- 4.5, T - 155
F - 400, E-659.83
Ejector

Condensate T - 47.18 T - 45.

GLAND STEAM
to LPH 1 F - 480106 F - 480
COOLER (GC1)

T - 100 Dr
F - 1660 Fl
Gland Steam 480106(47.18-45.07)*100
Condenser Effy. = =
1260(728.20-100)+400(659.83-100)
The Gland Steam Condenser GC1, which is next to the Ejector in the regenerative feed
water heating cycle, sucks steam and air mixture from outermost HP, IP and LP Turbine
glands. The necessary required vacuum of about 100 mm is established in the Gland
Steam Condenser by an Ejector, which is provided with steam (d2) from the Deaerator.

The condensate (gd1) is recovered back to the flash chamber on the condenser. From the
calculations it is seen that the efficiency of the Gland Steam Condenser No 1 is 99.7%.

2.3 LP Heater No 1:-

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 P- 0.89, T - 85
F - 11989, E-622.05

Condensate T - 61.05
LPH 1 T - 47.18
to GC 2 F - 480106 F - 480106

T - 65.93 Drain
F - 11989 cham
(hd1)
480106(61.05-47.18)*100
Effy of LPH No 1 = = 99.8%
11989(622.05-65.93)
The Feed water Heater 1 (LP Heater No 1) is fed with Extraction Steam (e1) from the
Extraction No 1 on LP Turbine and the heater drain (hd1) is fed to the flash chamber on
condenser. The condensate after GC1 flows through Heater No 1. From the calculations
shown in the sketch the efficiency comes to 99.80%.

2.4 Gland Steam Condenser No 2:-

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 P- 0.50, T - 325
F - 4949, E-756.90

Condensate T - 68.10 80% T - 61.5

to LPH 2 F - 480106 F - 4801
GC 2

20% T - 72.94 Drai

F - 4949 cham
Flow through GC2 (gd2
Effy of Gland 0.8*480106(68.10-61.05)*100
Steam = = 80%
Condenser GC 2 4949(756.80-72.94)
conde
bypas
Gland Steam Condenser No 2 is fed with Leakage steam from HP and IP Turbine Glands
and the drain from GC2 is recovered back to flash tank on the condenser. As per the
calculations shown in the sketch, the efficiency comes to 80%, because not all the
condensate at full load passes through GC2. However, actually a part of the condensate
is bypassed over GC2. The efficiency of GC2 drops accordingly. That is to say that if 80%
of the condensate is passing through GC2, the efficiency drops to 80%.

2.5 LP Heater No 2:-

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 Drain from T-
P- 1.369, T - 183
LPH3 (hd3) F - 49806
F - 25369, E-678.4
T-100.86, F-480106

Condensate T - 101.52
LPH 2 T - 68
to LPH 3 F - 555281 F - 48

T - 105.78 Drain to
Drip Pump F - 75175 Condensa
(hd2)

480106(100.86-68.10)*100
Effy of LPH 2 = 25369(678.41-105.78)+49806(130.26-105.7
The steam from IP Turbine Extraction No 2 (e2) is fed to the feed water heater LP Heater
No. 2. The drain (hd2) is pumped back with the help of Drip Pump into the main
condensate flow path before the condensate entry to Heater no 3 as shown. This also
increases the temperature of condensate from 100.860C to 1o1.520C at the entry in Heater
No 3. From the calculations as above the efficiency of LP Heater No 2 comes to 99.8%.

2.6 LP Heater No 3:-

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 Drain from T-
P- 2.974, T - 264
LPH4 (hd4) F - 28773
F - 21033, E-715.6

Condensate T - 125.27
LPH 3 T - 10
to LPH 4 F - 555281 F - 55

T - 130.26
Drain to
F - 49806 (hd3)

555281(125.27-101.52)*100
Effy of LPH 3 = 21033(715.68-130.26)+28773(161.73-130.2
Heater No 3 is provided with steam from IP Turbine Extraction No 3 (e3) and the drain
from heater no 4 (hd4) is also fed back to heater No 3. It may also be noted that the
amount of condensate passing through heater No 3 increases in quantity by the amount
of drain from heater No 2 (hd2). Heater no 3 drain is fed back to LP Heater No 2. The
calculated efficiency of LP Heater No 3 comes to 99.8%.

2.7 LP Heater no 4:-

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 P-6.9, T - 161.73
Leak off F - 4935, E-
steam HP P- 6.911, T - 364
& IP (g3) F - 23838, E-762.6

Condensate T - 156.52
LPH 4 T - 12
to F - 555281 F - 55
Deairator

T - 161.73
Drain to
F - 28773 (hd4)

555281(156.52-125.27)*100
Effy of LPH 4 = 23838(762.69-161.73)+4935(782.31-161.73
LP Heater No 4 is fed with Extraction steam from IP Turbine (e4). Leakage steam from
HP and IP Glands (g3) is also fed to the LP Heater No 4. Drain from LP Heater No 4 is
fed back to LP Heater No 3. HP Heater No 5 drain (hd5) is cascaded to LP Heater No 4
below 150 MW load. For loads more than 150 MW HP Heater No 5 drain normally goes
to Deaerator. In the calculations at full load, HP Heater No 5 drain (hd5) is not
considered as fed to Heater No 4. The calculated Efficiency comes to 99.7%.

2.8 Deaerator:-

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 P-7.5, T - 479 P-1.03, T - 141
Gland leakage
F - 2300, E-820.28 F - 2930, E-659
from ESV/IV
Drain from HPH T - 181.51 P-4.5, T - 155
5/6 (hd5 or hd6) F - 93256 F - 1900, E-65

Deaerator E - 802.51 T - 156

pegging steam
F - 5984 F - 5552
From PRDS or
Extr.6(ed)

T - 166.71

Feed water T - 173.12 F - 652000

to HPH5 F - 652000

(555281(166.71-156.52)+4830(820.28-659.83))*
Deaerator Effy =2300(820.28-166.71)+93256(181.51-166.71)+5984(802
166.71)

Dearator is supplied with heating steam from Extraction tapped from either Extraction
no 5 or Extraction No 6 (ed). Extraction No 5 is taken from IP Turbine and Extraction No
6 is taken from HP Turbine at HP Exhaust. For loads below 150 MW, deaerator heating
steam supply (ed) is derived from Extraction No 6, which is changed over to Extraction
No 5 at loads above 150 MW. Auxiliary steam supply to the main Ejector, Gland steam
ejector and sealing steam of Turbine Glands is changed over from auxiliary PRDS to
Deaerator.

The Deaerator pegging steam supply is initially given from auxiliary PRDS, which is
changed over from auxiliary source to Extraction No 6 at about 90 to 100 MW Load.

The gland leakage from ESV and IV is fed to the deaerator. Heater No 5 and Heater No 6
Drains (hd5 or hd6) are also fed to the deaerator. Actually HP Heaters are taken in
service after 60 to 70 MW Load is taken on the turbine. Heater No 5 Drain (hd5) goes to

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Heater No 4 for loads less than 150 MW. For Turbine loads higher than 170 MW, Heater
No 6 Drain (hd6) goes to Heater No 5. And heater no 5 drain (hd5) is diverted to
Deaerator instead of Heater No 4. From the heat balance calculations, the deaerator
efficiency comes to 96.8%.

2.9 Boiler Feed Pump:-

It may be noted that the total quantity of feed water supplied from feed water tank to
boiler feed water pump is equal to main steam flow to the HP Turbine.

In this connection, it may be noted that heat added by Boiler Feed water pump due to
Mechanical churning of water has been also taken into consideration, which is equal to
4179320 Kcal.

T=166.71
Flow=

= 652000(173.12-166.71) = 4179320 Kcal.

2.10 HP Heater No 5:-

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 T - 198
F - 76616, E-
Drain from P- 12.96, T - 444
HPH6 (hd6) F - 16640, E-802.9

Feed Water T - 189.69

HPH 5 T - 17
to HPH 6 F - 652000 F - 65

T - 181.51
Drain to
F - 93256

652000(189.69-173.12)*100
Effy of HPH 5 = 16640(802.92-181.51)+76616(198.05-181.5
HP Heaters are taken into service in block after a load of 60 to 70 MW is taken on the
turbogenerator. HP Heater No 5 is supplied with steam from Extraction No 5 (e5) taken
from IP Turbine. Heater No 5 Drain (hd5) goes to Heater No 4 below 150 MW, which is
changed over to Deaerator at loads more than 170 MW. Heater No 6 Drain (hd6) is
cascaded to Heater no 5. From the heat balance calculations the efficiency of HP Heater
No 5 comes to 93.7%.

2.11 HP Heater No 6:-

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 T - 238
F - 31844, E-
Drain from P- 28.07, T - 327
HPH7 (hd7) F - 40391, E-732.9

Feed Water T – 228.80

HPH 6 T – 18
to HPH 7 F - 652000 F-

Spindle P- 28.07, T - 464 T - 198.01

Leakage from Drain to
HPT (g5) F - 4381, E-806.50 F - 76616

652000(228.80-189.69)*100
Effy of HPH 6 =
40391(732.99-198.05)+31844(238.65-198.05)+43
Heater No 6 is supplied with steam from Extraction No 6 (e6) from HPT Exhaust. It is
cold reheat steam. The spindle leakage steam from HPT (g5) is also fed to Heater No 6.
Heater No 7 Drain (hd7) is cascaded to Heater no 6 and Heater no 6 drain (hd6) is
cascaded to Heater No 5. From the calculations the efficiency is 99.7%.

2.12 HP Heater No 7:-

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 P- 42.18, T - 381
F - 31844, E-755.9

Feed Water to
Economiser T – 253.94 HPH 7 T – 22
F - 652000 F-

T – 238.65
Drain to
F - 31844

652000(253.94-228.80)*100
Effy of HPH 7 = 31844(755.97-238.65)

Heater No 7 is provided with Extraction steam from HP Turbine (e7). The drain (hd7) is
cascaded to Heater No 6. Feed water at the outlet of the heater is finally fed to back to
the boiler through the feed water regulating valve. From the calculations the efficiency
comes out to be 99.5%.

2.13 Condenser:-

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 Steam from LPT P-0.0889, F-2*230004, E
Drains to cond
Flash Tank. Cooli
gd1-1660 Water
to Co
gd2-4949
Towe
hd1-11989
ejd - 1500

Make up
20 T T–3

F–2
Steam to circ.water Ratio= 0.00178
P- 22, T – 43
0 CEP
T. T. D.. =11 C Effy = 80% F–480106, E

210 MW Turbine has two condensers connected in parallel. The total quantity of the
condensed steam exhausted from the LP Turbine is mixed with drains from Ejector
consisting of condensate of steam from Deaerator(d4) and GC1 condensate of steam
from HPT and IPT.

The steam from LPT at a Pressure of 0.0889Kg/cm2 and quantity 460008 kg/hr is
condensed by cooling water quantity 270000 m3 which equals to 27000000 kg/hr and
hence the circulating water required for cooling 1 kg of steam is 27000000/460008 = 58.6
kg.

From the heat balance equation of condenser:-

The total heat loss to cooling water = Steam from LPT Exhaust * Enthalpy of water at
Hotwell

= 2 X 230004 * (589.18 – 43.16) = 251173568 Kcal/hr.

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If the condenser efficiency is assumed to be 80% then the gain in temp of cooling water

= (251173568/0.8)/27000000 = 110C

From the calculations shown it will be seen that if 270000 m3/h water flow is maintained
for the circulating water through the condenser having 80% efficiency the terminal
temperature difference for the circulating water will be of the order of 11 0C.

3) TURBINE CYCLE HEAT RATE

The turbine cycle heat rate is calculated as per the formula:-

Total Heat Supplied to the Turbine in kcal QM*(MSE - FWE) + QR*(RHE - CRHE)
Heat Rate =
Total Generation in KWH W
QM = Main Steam Flow = 652000 Kg/hr

MSE= Main Steam Enthalpy = 819.94 Kcal/kg

FWE= Feed Water Enthalpy at HP7 Outlet = 253.94 kcal/kg

QR = Reheat Steam Flow = 566369 kg/hr

RHE = Enthalpy of Reheat Steam = 845.83 Kcal/kg

CRHE= Enthalpy of Cold Reheat Steam = 732.99 Kcal/kg

W = Total Power Developed at Generator output in KWH = 211902 KWH

652000 * (819.94 - 253.94) + 566369 * (845.83 – 732.99)

HR at 210 MW=
211902
652000 * 566 + 566369 * 112.84 432941078
= = = 2043.11 Kcal/KWH
211902 211902
Calculated Heat Rates at different loads are :-

a) 2043.11 Kcal/KWH at 210 MW

b) 2068 Kcal/KWH at 176 MW,
c) 2070 Kcal/KWH at 150 MW and
d) 2156 Kcal/KWH at 100 MW

4) EXTRACTIONS

4.1 Total Heat given to Turbine Cylinders

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High Pressure Turbine

Flow Enthalpy Heat in Kcal

Input Steam 652000 819.94 534600880

Output Steam 566369 732.99 415142813

Heat Given to HP Turbine 119458067

Intermediate Pressure Turbine

Flow Enthalpy Heat in Kcal

Input Steam 566369 845.83 479051891

Output Steam 470857 678.41 319434097

Heat Given to IP Turbine 159617794

Low Pressure Turbine

Flow Enthalpy Heat in Kcal

Input Steam 470857 678.41 319434097

Output Steam 460008 589.18 271027514

Heat Given to LP Turbine 48406583

Total input to the Turbine Cylinders = Heat given to HP + IP + LP Cylinders

= 119458067 + 159617794 + 48406583 = 327482444 Kcal for generating 211902 kWH of

Power.

A small quantity of Leakage steam from ESV & IV spindle leaks to Deaerator and gland
steam condenser, which is also utilized for feed water regenerative heating. The
condensate derived thereby is also added in the system. The heat content of this
auxiliary steam is neglected.

4.2 The total quantity of steam extracted for regeneration

Symbol Work Pressure Temp. Flow Enthalpy Total Heat

e1 Extraction 1 LP Heater 1 0.8895 45 11989 622.05 7,457,757

e2 Extraction 2 LP Heater 2 1.369 183 25369 678.41 17,210,583

e3 Extraction 3 LP Heater 3 2.974 264 21033 715.68 15,052,897

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 e4 Extraction 4 LP Heater 4 6.911 364 23838 762.69 18,181,004

Ed Deaerator Deaerator 12.96 449 5984 802.92 4,804,673

e5 Extraction 5 HP Heater 5 12.96 444 16640 802.92 13,360,589

e6 Extraction 6 HP Heater 6 28.07 327 40391 732.99 29,606,199

e7 Extraction 7 HP Heater 7 42.18 381 31844 755.97 24,073,109

Total Extraction Flow / Enthalpy 177088 TPH 129,746,812

Total Steam Extracted * 100 177088 * 100

Percentage of quantity = = 27.16%
of steam extracted Total Steam supplied 652000

Total Heat to Extractions *100 129746812*100

Percentage of Heat Tapped = = = 39.61%
Total Heat input to the cylinders 327482444

Out of the above heat given to the extractions, total heat regained by feed water
regenerative heating cycle:-

 Upto LP Heater No 2 480106 * (100.86-43.16) = 27702116 Kcal

 After LP Heater No 3 555281 * (156.52 – 100.86) = 30906940 Kcal
 After Deaerator 555281 * (166.71 – 156.52) = 5658313 Kcal
 In Feed water Pump 652000 * (173.12 – 166.71) = 4179320 Kcal
 After HP Heater 7 652000 * (253.94 – 173.12) = 52694640 Kcal

Total heat regained by Feed Water = 121141330 Kcal

Heat Loss in Feed Water Regenerative Heating Cycle

= Total heat to extractions – Heat regained

= 129746812 – 121141330 = 8605482 Kcal

4.3 Total Heat Lost to cooling water

= (Enthalpy of steam at exhaust – Enthalpy of condensate in Hotwell)* Quantity of

Exhaust steam

= (589.18 – 43.16) * 460008 = 251173568 Kcal

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4.4 Turbine gross heat rate

Turbine Heat Input - (Heat Extracted from all Ext.)+(Heat Lost in Regen. Heating)+ (
Heat Lost to CW)

Power Generated in kwh

327482444 – 129746812 + 8605482 + 251173568

211902

= 2159 Kcal/kwh

4.5 Specific Steam Consumption

At normal specified steam pressure and temperature of Main Steam and Reheat Steam
Specific Steam Consumption of this turbine is as below:-

Load in kw 211902 202000 176669 151400 101200

Specific Steam 3.004 2.966 3.006 3.045 3.077

Consumption (in Kg/kwh)

******************

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 210 MW Parameters at different regimes at CW Temp 300C
S. PARAMETERS PRESSURE IN KG/SQCM ABS TEMPERATURE / DRYNESS
N Regime IN KW 211902 202200 176669 151400 101200 211902 202200 176669 151400 101200

A MAIN STEAM

1 MAIN STEAM 130 130 130 130 130 535 535 535 535 535
COLD REHEAT
2 (CRH) 28.07 26.4 22.52 18.96 12.22 327 322 311 301 286
HOT REHEAT
3 (HRH) 24.19 23.2 20.17 17.22 11.46 535 535 535 535 535
STEAM AFTER
3.1 IPT 1.369 1.299 1.134 0.971 0.6725 183 184 184 185 190
STEAM BEFORE
3.2 LPT 1.343 1.274 1.118 0.9519 0.6594 183 183 183 183 183
LPT EXHAUST TO
4 COND 0.0889 0.086 0.0798 0.0739 0.0637 0.9529 0.9549 0.9001 0.9663
EXTRACTION
B STEAM

e7 TO HEATER NO 7 42.18 39.77 34.38 29.06 19.68 381 375 364 354 349

e6 TO HEATER NO 6 28.07 26.7 22.58 18.96 12.22 327 322 311 301 286

e5 TO HEATER NO 5 12.96 12.27 10.65 9.068 6.2 444 444 444 444 446

ed TO DEAERATOR 12.96 12.27 10.65 9.068 12.22 444 444 444 444 286

e4 TO HEATER NO 4 6.911 6.545 5.694 4.858 3.334 364 364 364 365 365

e3 TO HEATER NO 3 2.974 2.808 2.453 2.097 1.44 264 265 265 265 271

e2 TO HEATER NO 2 1.369 1.299 1.134 0.971 0.6729 183 184 184 185 190

e1 TO HEATER NO 1 0.2895 0.2754 0.241 0.2073 0.1449 0.992 0.9935 0.9965 61 68

C SERVICE STEAM
d1 Gland Sealing 1.03 143
d2 Ejector of GC1 4.5 155
d3 Leakage into LPT 0.0889 0.086 0.0798 0.0739 0.0637 139
d4 Main Ejector 4.5 155

total output power solutions Manohar Tatwawadi Page 39

D Leak off Steam

g1 Gland Cooler 1 0.97 286

g2 Gland Cooler 2 0.361 0.343 0.308 0.265 0.197 346 337 329 318 296

g3 TO HEATER 4 6.911 6.545 5.694 4.853 3.334 403 400 393 386 383
FROM SPINDLES
g4 TO DEAERATOR 7.5 479

g5 TO HEATER 5 28.07 26.4 22.98 18.96 12.22 464 457 448 438 433

total output power solutions Manohar Tatwawadi Page 40

 210 MW Parameters at different regimes at CW Temp 30 0C
Tag PARAMETERS ENTHALPY KCAL/KG QUANTITY IN KG/HR
No Regime IN KW 211902 202200 176669 151400 101200 211902 202200 176669 151400 101200

A MAIN STEAM

1 MAIN STEAM 819.94 819.94 819.94 819.94 819.94 652000 616000 531000 449000 304000
COLD REHEAT
2 (CRH) 732.99 730.57 727.11 723.41 720.69 566369 534409 484930 395441 259703
HOT REHEAT
3 (HRH) 845.83 846.22 846.86 847.54 848.82 566369 534409 484930 395441 259703
STEAM AFTER
3.1 IPT 678.41 678.84 679.34 680 682.82 470857 447226 390074 333899 230723
STEAM BEFORE
3.2 LPT 678.41 678.84 679.34 680 682.82 470857 447226 390074 333899 230723
EXHAUST STEAM
4 TO COND 589.18 590.08 592.41 595.31 606.03 230024 218790 191648 134954 115604
EXTRACTION
B STEAM

e7 TO HEATER NO 7 755.97 753.53 750.42 746.79 746.64 31844 29654 24925 20263 13294

e6 TO HEATER NO 6 732.99 730.57 727.11 723.41 720.65 40391 37134 29752 23261 4638

e5 TO HEATER NO 5 802.92 803.23 803.88 804.52 808.2 16440 13129 6605 545

ed TO DEAERATOR 802.92 803.23 803.88 804.52 720.69 5984 7937 11610 14306 18728

e4 TO HEATER NO 4 762.69 763.02 763.73 764.56 767.84 23838 22311 18460 14945 3108

e3 TO HEATER NO 3 715.68 716.07 716.63 717.2 720.32 21033 19547 16312 13584 8488

e2 TO HEATER NO 2 678.41 678.84 679.36 680 682.32 25369 13756 19679 16276 10038

e1 TO HEATER NO 1 622.05 622.43 623.07 623.78 626.45 11989 10787 7919 5132 634
C SERVICE STEAM
TO GLAND
d1 SEALING 659.83 2930
TO EJECTOR OF
d2 GC1 659.8 400
LEAKAGE INTO
d3 LPT 659.83 570
TP MAIN
d4 EJECTOR 659.83 1500
LEAK OFF
D STEAM
TO GLAND
g1 COOLER 1 728.2 728.22 728.29 728.36 728.48 1260
TO GLAND
g2 COOLER 2 756.8 752.66 748.77 743.1 732.92 4949 4733 4225 3735 2863

g3 TO HEATER 4 782.31 780.58 777.65 774.47 773.97 4935 4663 4020 3399 2301
FROM SPINDLES
g4 TO DEAERATOR 820.28 820.29 820.32 820.35 820.39 2300

g5 TO HEATER 5 806.5 803.66 799.78 795.63 795.4 4381 4140 3568 3017 2043
 210 MW Parameters at different regimes at CW Temp 30 0C
Tag PARAMETERS ENTHALPY KCAL/KG QUANTITY IN KG/HR
No Regime IN KW 211902 202200 176669 151400 101200 211902 202200 176669 151400 101200
E CONDENSATE
5.0 HOTWELL 43.16 42.53 41.11 39.66 36.92 460008 437577 383296 329907 231289

5.W CEP SUCTION 43.16 42.53 41.11 39.66 36.92 480106 456529 398599 341934 237891

5.D BEFORE EJECTOR 43.16 42.53 41.11 39.66 36.92 480106 456529 398599 341934 237891

5.A AFTER EJECTOR 45.07 44.54 43.41 43.35 40.79 480106 456529 398599 341934 237891
5.1 AFTER GC1 47.18 46.76 45.96 45.32 44.86 480106 456529 398599 341934 237891

5.2 AFTER HEATER 1 61.05 59.92 57.08 53.77 46.35 480106 456529 398599 341934 237891

5.3 AFTER GC2 68.1 66.99 64.29 61.17 54.47 480106 456529 398599 341934 237891
5.4 AFTER HEATER 2 100.86 99.31 95.9 91.07 81.32 480106 456529 398599 341934 237891
BEFORE HEATER
5.5 3 101.52 99.97 96.12 91.69 81.87 555281 526534 463675 390683 376826
5.6 AFTER HEATER 3 125.27 123.83 118.85 113.82 102.33 555281 526534 463675 390683 376826

5.7 AFTER HEATER 4 156.52 154.33 148.83 143.18 129.23 555281 526534 463675 390683 376826
F FEED WATER
6.0 BFP SUCTION 166.71 652000 616000 531000 449000 304000
AFTER FEED
7.0 PUMP 173.12 652000 616000 531000 449000 304000
AFTER HP
7.1 HEATER 5 189.61 187.14 180.76 173.75 173.12 652000 616000 531000 449000 304000
AFTER HP
7.2 HEATER 6 228.8 225.28 216.632 207.35 185.82 652000 616000 531000 449000 304000
AFTER HP
9.0 HEATER 7 253.94 250.11 241.1 231.11 209.73 652000 616000 531000 449000 304000
G DRAINS
gd1 FROM GC1 100 1660
FROM HEATER
hd1 NO 1 65.93 64.8 61.86 58.6 54.14 11989 10787 7919 5132 634

gd2 FROM GC2 72.94 71.78 69.26 65.97 59.38 4949 4733 4225 3735 2868
FROM HEATER
hd2 NO 2 105.78 104.24 100.34 96.01 86.23 75175 70275 65076 48749 29935
FROM HEATER
hd3 NO 3 130.26 128.32 123.83 118.77 107.25 49806 46519 45397 32473 19897
FROM HEATER
hd4 NO 4 161.73 159.51 153.97 148.72 134.2 28773 26974 29085 18639 11409
FROM HEATER
hd5 NO 5 189.51 186.91 180.38 173.22 93265 84059 6605 545
FROM HEATER
hd6 NO 6 198.05 195.43 188.86 181.64 180.99 76616 70930 53245 46541 19976
FROM HEATER
hd7 NO 7 238.65 234.98 225.92 216.29 194.08 31344 29654 24925 20263 13294

SYNERGEN HEAT RATE Page 42

H PRESSURE IN HEATERS

HEATERS DATA
AT LOADS 211902 202200 176669 151400 101200 TTD

HP7 HEATER NO 7 38.8 36.59 31.63 26.74 18.1 2.5

HP6 HEATER NO 6 26.67 25.09 21.44 18.01 11.6 4.5

HP5 HEATER NO 5 11.92 11.29 9.8 8.343 2

LP4 HEATER NO 4 6.358 6.021 5.238 4.469 3.067 5

LP3 HEATER NO 3 2.736 2.584 2.267 1.929 1.325 5

LP2 HEATER NO 2 1.26 1.195 1.043 0.8933 0.467 5

LP1 HEATER NO 1 0.2664 0.2534 0.2217 0.1907 0.1333 5

I HEAT RATE IN KCAL/KWH

Regime IN KW 211902 202200 176669 151400 101200

HEAT RATE
Kcal/KWH 2040 2039 2051 2066 2154

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SYNERGEN HEAT RATE Page 44
SYNERGEN HEAT RATE Page 45
Boiler Efficiency calculation by
“HEAT-LOSS METHOD”

Proximate Analysis of fuel / Coal

 Following parameters are to be obtained from the lab, on day-to-day basis, for
determining the ‘Proximate Analysis’ of coal. Those usually are on Air-dried
basis.
# Parameters (Air-dried basis) Unit
1 Fixed Carbon %
2 Inherent Moisture %
3 Volatile Matter %
4 Ash %
5 Gross Calorific Value kcal/kg
6 Total Moisture %

 A constant (K) is derived by the given formula: - K = (100 – TM) / (100 – M)

 By multiplying this constant K with the above parameters, Proximate Analysis
on ‘As-Received’ basis can be calculated & these parameters are used for the
calculation of Ultimate Analysis.
# Parameters (As-Received Basis) Unit Abbreviation

1 Fixed Carbon % FC As per Lab

2 Inherent Moisture % M As per Lab
3 Volatile Matter % VM As per Lab
4 Ash % A As per Lab
5 Gross Calorific Value kcal/kg Q As per Lab
6 Total Moisture % TM As per Lab

SYNERGEN HEAT RATE Page 46

 Ultimate Analysis
 Using those above parameters, the ‘Ultimate Analysis’ can be calculated as below: -
# Parameters Unit Abbre Formula
A Sulphur Content in Coal S % Fixed or
Obtained
from Lab
B Carbon Content in Coal C % Parr’s
= (1- 0.01*Z)*Cp + (0.05*A) – (0.5*S) method
where, Z = Mineral matter content of the fuel burnt % Parr’s
= (TM + 1.1*A +0.1*S) method
And Cp= Carbon content on “Mineral matter free % Parr’s
basis” = (0.0015782*Qp) – (0.2226*Vp) + 37.69 method
Where Qp = Calorific value in kCal/kg Parr’s
= (100*Q*4.186)/(100-Z) method
And Vp = Volatile matter content % Parr’s
= (100*(V - 0.1*A - 0.1*S))/(100 – Z) method
C H2 Content in Coal H2 % Parr’s
= (1- 0.01*Z )*Hp +(0.01*A) – (0.015 * S) method
where, Hp = Hydrogen content on “Mineral matter
free basis” = (0.0001707*Qp) + (0.0653*Vp) – 2.92
D N2 Content in Coal N2 % Gebhardt’s
= [2.1 -(0.012*VM)] formula
E And O2 Content in Coal O2 % By diff.
= 100 -( C + H + S + N + A +TM )

SYNERGEN HEAT RATE Page 47

 In addition to this, following parameters are required to be noted during the test.

# Parameters Unit Abbreviations Values

As per Control
1 Avg Flue Gas o/l Temp 0C T
Room
As per Control
2 Ambient Temp - Dry bulb 0C t
Room
As per Control
3 Ambient Temp - Wet bulb 0C
Room
As per Control
4 O2 at APH Inlet % O2
Room
As per Control
5 CO2 at APH inlet % CO2
Room
As per Control
6 N2 at APH inlet % N2
Room
7 Unburnts in Bottom ash % UBA As per Lab
8 Unburnts in Fly ash % UFA As per Lab
As per
9 CO at APH Out ppm CO
measurement

SYNERGEN HEAT RATE Page 48

BOILER LOSSES CALCULATION

Loss Due to Unburnt Carbon

= (33820*Unburnt Carbon in ash kg/kg)*100/(4.186*Q)
UC LOSS
Where, Unburnt Carbon in ash per kg of coal
= (0.00008*A%*% UFA) + (0.00002*A%*% UBA)

Loss due to Dry Flue Gas

= (100/(12*(CO2+CO)))*(( C/100 + S/267- carbon in ash))* DF LOSS
(30.6*(T - t))*100/(4.186*Q)

Loss due to Wet Flue Gas

= ((TM + 9*H )/100) * (1.88*(T -25) + 2442 + 4.2*(25 - t )) *
WF LOSS
100 /(4.186*Q)

Loss due to Moisture in Air

= (Ma*h*1.88*(T - t)*100)/(4.186*Q )

Where, Ma = Dry air for combustion in kg / kg fuel

= (3.034*% of N2 in flue gas/(% of CO2 + CO ))*
MA LOSS
(C/100 + S / 267 - C in ash)

Where h = Mass of moisture per kg of dry air

= From Psychometric chart

Loss due to CO = CO in ppm*10-6*Fuel Rate per Hour*28*5744/Q CO LOSS

Unmeasured Losses (Including Radiation, Blowdown) U LOSS

Total Losses = (UC + DF + WF + MA + CO + U) LOSS

Boiler Efficiency = 100 – Total Losses

SYNERGEN HEAT RATE Page 49

Reduction in fuel consumption and saving

1. Boiler Efficiency before tuning of boiler = Effy(Pre)

2. Boiler Efficiency after tuning of boiler = Effy(Post)

Effy(Post) – Effy(Pre)
3. Reduction in fuel consumption = 100*
Effy(Pre)

4. Saving in fuel per day = Fuel consumption per day * Reduction in fuel
consumption

5. Cost of fuel saved per day = Saving in fuel per day* Cost of fuel

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