Thermal Power Plant

Performance Monitoring

Dr. T K Ray
AGM – PMI
NTPC Limited
E-mail: rayt3@asme.org

September 3, 2014
 Presentation outline

• Performance parameters - significance, impact, PTC

• Performance monitoring program – continuous/periodic

• Efficiency monitoring methods – Daily, Weekly and monthly

• Review process, Gap analysis, Improvement measures –

suggestions and action plan

• Test frequency, pre & post OH performance comparison

• Possible structure and responsibilities of EEMG

2
 Performance parameters

 Availability (%)

 Heat rate (kcal/kWh)

 Sp. oil cons. (ml/kWh)

 APC (%)

3
 Impact of HR deviation
– an example in a 3000 MW station

 2160 MU, Coal 1.620X106 ton, ₹ 2268X106

(₹1400/ton, HR 2400 kcal/kWh,   35.83% )
HR 2420 kcal/kWh (  35.54%)
Coal 1.633X106 ton, ₹ 2287X106
 0.3
 ₹ 18.9X106 (increase in monthly coal expenses)
 Unit HR (for a given period) =(Fuel consumption X

Weighted average CV)/(Net Energy output)

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 Typical plant efficiency losses

Net Plant Heat Rate = 860/0.362 =2375 kcal/kWh

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 Energy flows
180 MW
505 MWe

2864 MW
Boiler Turbine G

TG Losses
9 MW

1684 MW

1360 MW 667 MW

1 MW

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 Heat rate of the Unit

 Unit HR (test) =(Test GTCHR)/(Test Boiler Efficiency)

 Unit HR (Cor.) =(Cor. GTCHR)/(Cor. Boiler Efficiency)

 GTCHR is corrected to design CW inlet temp.

- ASME PTC 6 - 2004: Steam Turbines, PTC 6A

 Boiler Efficiency is corrected to

- design ambient condition, coal quality

- ASME PTC 4 (Boiler), PTC 4.2 (Pulverizers), PTC 4.3 (Air Heaters)

7
7
 ASME PTC PM: Guidelines for Power Plants
ASME PTC 4: Fired Steam Generators

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 Boiler Efficiency
The % of heat input to the boiler absorbed by the working fluid

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 Boiler Efficiency determination

(i) Input /output method

  (m he e  m i hi )
*100
Hf B

(ii) Heat Loss method

L
  100  *100
Hf B

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 Inputs for boiler efficiency assessment

AH inlet and exit FG O2 / CO2 /CO

AH inlet and exit FG temp
Primary / Secondary air temp at AH inlet
Dry/Wet bulb temperatures
Ambient pressure, bar (abs)
Proximate Analysis & GCV of Coal
Combustibles in Bottom Ash and Fly ash

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1
12
 Typical Boiler Efficiency
Boiler Losses Typical values (%)
Dry Gas Loss 4.56
Un-burnt C Loss 1.50
Hydrogen Loss 3.29
Moisture in Fuel Loss 2.53
Moisture in Air Loss 0.12
CO Loss 0.04
Radiation/Unaccounted Loss 0.89
Total Heat Loss 12.93

Heat credit 0.44

Boiler Efficiency =100-12.93+0.44=87.51

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14
 Turbine cycle 6

W T
Wnet HP turbine IP turbine LP turbine G

TC 
 Ei
3
2

4
i
7

5
21 7a
BOILER 30
21b 19
20
22 21a C
23 12 18
8 29
11 10
15 D 28
1 9
L3 L2 L1 8a
H6 H5 13
14
26 27

W CEP
CEP
25 BFP
BFPT
24 16

Wnet  WT  WCEP 17 21c

 i  1 (h2  h1 )  m 16 (h2  h16 )  m 4 (h5  h4 )  m 17 (h5  h17 )

 m
E
i

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 Turbine cycle heat rate
 GTCHR=(heat input rate to TC)/(Work output rate)

- Following ASME PTC 6A and PTC 6

 Deviation from design

 Loss on account of each relevant operation parameter

- Using curves specified in design

 Diff. of sum of losses from total dev. is unac. loss attributed to

- passing of HE drain valves

- measurement error / limitation (LPC, BFPT)

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 Parameters that influence TC HR
SH spray
RH spray
MS pres
MS temp
HRH temp
RH pres drop
Load
Condenser back pressure
FW inlet temp
TTD HPH 6
TTD other heaters
CW inlet temp
Make up water

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∆HRTC due to variation in condenser back pres

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 ∆HRTC due to RH pres loss

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 ∆HRTC due to HRH and MS temp variation

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 ∆HRTC due to different terminal conditions

STN 1 2 3 4 5

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 Definition of Performance Monitoring (PM)
An overall long-term effort to measure, sustain, and improve
-The plant thermal efficiency, capacity, generation cost
-and maintenance planning.
 A decision to implement a PM program based on
-Local needs, Organization, Economics
 Resources required
-Personnel knowledgeable of the process
-The instrumentation, Representativeness
-The data collection medium
-and the required analysis and interpretation techniques.

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Objectives of Performance Monitoring

1. Providing operator f. b. on controllable losses

2. Tracking controllable losses over long time periods

3. Establishing unit heat rate

•for fuel accounting and regulatory records or

•for performance comparisons

4. Determining cycle component contribution to total unit performance

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Objectives of Performance Monitoring

5. Diagnosing component condition

•for establishing OH schedule and scope

•to improve ordering of parts requiring long lead times

6. Individual cycle component optimization

7. Determining input/output characteristics for Economic/

incremental loading

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 On-line PM Programs

•A decision which significantly characterizes a program

- Whether periodically, continuously, or combination

•The benefits of continuous or “on-line" monitoring:

- Ability to accumulate HR over time for official record

- Knowledge of when changes occur & under what circumstances

- for early recognition of impact on operation and maintenance

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 On-line PM Programs

- Ability to anticipate potentially serious impacts from initial indications

- Ability to know cost of power as it is generated

- Opportunity to dispatch the unit based on current cost

- Ability to track controllable losses over time

- Opportunity for continuous optimization

- less labor required for automated systems than for batch systems

once implemented

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 Periodic / Diagnostic Tests
 Diagnostic tests are required for the following

 Root cause analysis of different problems

 Identifying reasons for inefficiency

 To verify the feedback from online instruments

 Acceptance Test / PG Test is not cost justified, but there’s a need

 to obtain representative & accurate performance data

 and trend the same

• Accurate determination by mounting field instruments

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 Factors Critical to Successful PM Program
 Complex levels of performance monitoring may require

increased quantities of instrumentation

 Requires a significant knowledge of operation of the specific

local cycle components and commercials.

 May often be more effective when plant staff’s goals and

bonuses are tied to the use and results of the system

 Successful programs involve operations, maintenance, and

management

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Functions included in PM Program
- Instrumentation Calibration
- DAAS, Engineering Units Conversion
- Data Storage, Data Averaging, Data Sufficiency Checks
- Performance Calculations, Steam and Water Properties
- Validity Checking, Regression Analysis
- Curve Plotting, Graphics Generation
- Statistical Analysis, Uncertainty Analysis
- Data Retrieval, Data Set Manipulation & What If Analysis
- Report Generation

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 Heat rate deviation monitoring
methodology (Daily, Monthly and Weekly)

 On daily basis, based on 24 hrs. daily average value.

 Correction for load and other boundary conditions

 Monthly & Weekly HR dev. based on selected parameters

will be the weighted average of daily HR dev.

 Monthly/Weekly HR = (Sum of product of daily HR & daily

gen.) / (Total gen. of the month/Weekly)

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 Daily HR deviation report

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 Daily HR deviation report

 Value in Expected Column is based on Actual Load condition

 Actual parameters used are 24 hours average value taken from DAS
 Coal Analysis Used is based on the latest Proximate Analysis
 For arriving at Unit HR dev., Design Boiler Efficiency & GTCHR is taken
as reference .
 Combustibles in FA & BA to be taken based on last analysis report.

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 Impact of performance parameter
Deviation on Heat Rate (A Typical List)

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 Impact of performance parameter
Deviation on Heat Rate (A Typical List)

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 Periodic Review Meeting at Station
- Daily Review

 HR deviations are to be discussed in daily plant planning meeting

 Corrective actions to be planned for controllable parameters for
which shut down is not required.
 The actions to be recorded in the daily planning meeting minutes
and action taken be reported & reviewed in the next day meeting.
 Daily HR deviation report shall put in the intranet. This data shall
be utilized by for review project management
 However, weekly and monthly HR deviations reports are to be sent
to region and corporate for their review.

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 Periodic Review Meeting at Station
- Monthly Efficiency Meeting
 The purpose of monthly meeting is to
−review the progress towards achieving the station’s targets
−discuss results of tests carried out during the months.
−Review corrective action plans for the long term and short-term.
 The meeting is chaired by head of the station and attended by operation,
maintenance, planning, TS staff and other concerned area executives.
 Minutes of the meeting is sent to Regional Office for further
interaction/follow up with CC.
 POG activities are also to be discussed in this meeting.
 The report developed on the basis of monthly test as per the guideline
/requirement
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 Heat rate Gaps & Recovery Plan (Punch List)

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 MONTHLY - Efficiency Gap Analysis

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 MONTHLY - Efficiency Gap Analysis

1. Boiler efficiency considering expected un burnt loss (%), to be

arrived based on best achieved figure
2. Dry Flue gas Loss after applying necessary changes based on
expected un burnt loss.
3. Tested Boiler efficiency Corrected to Design Coal and Design A/H
air inlet temperature
4. Test GTCHR Corrected for design CW inlet temperature
5. Expected Unit Heat rate = Design GTCHR*100/Expected Boiler
Efficiency.
6. Corrected Test Unit Heat rate = Corrected Test GTCHR*100 /
Corrected Test Boiler Efficiency.
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 MONTHLY - Efficiency Gap Analysis

Test Dry Flue Gas Loss is Corrected to design coal & design air
temperature at AH inlet (%)

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 MONTHLY - Efficiency Gap Analysis

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 MONTHLY - Efficiency Gap Analysis

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 MONTHLY - Efficiency Gap Analysis

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 MONTHLY - Efficiency Gap Analysis

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 MONTHLY - Efficiency Gap Analysis

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 MONTHLY - Efficiency Gap Analysis

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 MONTHLY - Efficiency Gap Analysis

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 MONTHLY - Efficiency Gap Analysis

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 MONTHLY - Efficiency Gap Analysis

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 MONTHLY - Efficiency Gap Analysis

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 Test frequency

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 Pre & post OH performance comparison

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 Pre & post OH boiler efficiency

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 Pre & post OH boiler efficiency

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 Pre & post OH AH performance

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 Pre & post OH AH performance

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 Pre & post OH GTCHR

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 Pre & post condenser performance

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 Pre & post OH HPH performance

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 Pre & post HP/IP turbine performance

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 EEMG Structure at Station

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 EEMG Responsibilities – PMG at Station
• Parameter monitoring, trending and analysis
• On-line & Off-line performance test of Systems & Equipment
• Daily / Monthly HR deviation reports and follow up of corrective actions
• Pre overhaul system survey (Valve passing, Duct leakage, air ingress etc.)
• Coordination for POGs
• Effect of modifications / mode of operation
• Use of Math modelling for diagnosis and analysis
• Critical instrument performance, defect list and replacement
• Calibration of On-line / Off-line performance test instruments
• Implementation of efficiency related work.
• Involvement in efficiency related proposals
• APC Monitoring and measures/action plan for reduction
• Monitoring of unit stat up activities & related preparations.
• Monitoring and reduction of specific oil and make up consumption
• Other issues related to Plant performance.
• Pre / Post Overhaul performance test
• Work related to HR improvement w.r.t targets.

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 EEMG Responsibilities – during OH

• Implementation of Punch list action plan.

• Implementation of performance test recommendation.
• Trip committee recommendations, OS / CenPEEP / Knowledge team
recommendations.
• Regular O/H jobs related to restoration of equipment performance
• Boiler Cleaning/Water washing
• Inspection of HP heaters for parting plane leakages
• High Energy drain valves replacement

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 EEMG Responsibilities – during OH
• Cooling Tower inspection / repair
• Penthouse cleaning and inspection
• Boiler Air tightness test before & after repair
• Flue gas Duct inspection & getting it repaired
• Seal Trough Area
• Condenser Tubes inspection for cleanliness after tube cleaning.
• The amount and type of debris removed and type of scaling and its
chemical testing co-ordination.
• Condenser Flood test during OH for leakages in the
• condenser and associated piping by filling the condenser up to neck.
• Major Condenser air ingress points

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• OLTC defects
 EEMG Responsibilities – during OH
• SADC / Air Registers checking after repair.
• APH inspection: APHs are to be inspected during Unit
• Overhaul and the condition of baskets, sector plate and seals
• Condition of Mill discharge orifices: to be checked / replaced.
• Condition of Heat transfer surfaces in Boiler.
• Boiler heat transfer surfaces are to be inspected
• Pattern and type of slagging /fouling in different zones
• Other important O/H events:
• BFP/CEPs/CW O/H, Fan O/H type of damage found, repair, etc
• Major air ingress points on Boiler side, Major Steam/Water leakages
• LRSB related work.
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 MIS Responsibilities

• ORT, RMCM, ROPR, MCM coordination

• Coordination with Corporate Centre, OS, Region, CEA, REB etc.

• Trip analysis

• Oil , Coal Accounting & Survey

• MIS Reports related to plant performance

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 Thanks

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