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    You cannot Manage what you

    cannot Measure

    (Accurately)

    - Jack Welch, CEO, General Electric

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    PATTERN OF ENERGY CONSUMPTION

    IN

    THERMAL POWER STATION

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    TYPICAL PLANT LOSSES

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    TYPICAL BOILER LOSSES

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    TYPICAL CYCLE LOSSES

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    1.0 USEFULNESS OF ENERGY AUDIT IN

    THERMAL POWER STATION

    Contd

    Identifies Wastage areas of Fuel, Power and

    Water & Air Utilization.

    Reduction in cost of generation by

    implementing findings of EA.

    Increases power generation by efficient

    utilization of steam in turbine cycle and

    reduction in Aux Power Consumption. Maintenance planning and availability

    improvement.

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    1.0 USEFULNESS OF ENERGY AUDIT IN

    THERMAL POWER STATION

    Provides guidance in Loading Sequences of

    the Units.

    Identification and Rectification of errors in on-

    line Instruments. Leads to reduction in Green House Gases.

    Utilizes specialized services of experienced

    Engineers.

    Training of O&M staff for Efficient Control of

    Unit Operation.

    Contd

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    Improves competitiveness by reducing unit

    generation.

    Creates bench mark for all equipments andsystems.

    Fulfills bureau of energy efficiency mandatory

    requirement of Energy Audit.

    1.0 USEFULNESS OF ENERGY AUDIT IN

    THERMAL POWER STATION

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    A. Plant on-line instruments with few audit instruments Accuracyaround 3.0%.

    B. Accurate calibrated instruments as per ASME-PTC-6 for steam

    turbine& ASME-PTC-4-1 for Boilers.

    Accuracy around 0.5 %

    ERROR OF PROCEDURE OF ENERGY AUDIT OTHER THAN

    ASME-PTC-6 for steam turbines and ASMEPTC-4.1 for boiler

    Error in Boiler Energy Auditaround 2.0%

    Error in steam turbine Energy Auditaround 3.0%

    Total error because of Instrumentation & Procedure 6.0%

    EFFECT OF INSTRUMENTATION ON ENERGY

    AUDITS

    Contd.

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    IMPORTANCE OF ACCURACY IN ENERGY

    AUDITS

    1.0% Deviation in findings means 25000 tons of coal

    loss/annum for 200 MW Unit or approx Rs. 5 crores /

    year (4000Kcal coal GCV & Rs.2000/ton coal cost)

    Difference in cost of Energy Audit between B & A is 12

    to 14 lacs as against 6 to 8 lacs.

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    SHORT FALL LOSS IN

    CRORES PER

    ANNUM

    TURBINE CYCLE HEAT RATE 1.0 % 5.0

    TG OUTPUT 1.0% 5.0

    BOILER EFFICIENCY 1.0% 1.75

    AUX. POWER CONSUMPTION 5.0 % 2.5NOTE:

    TG CYCLE HEAT RATE IS TAKEN AS 2000 KCAL / KWh

    COAL CV IS TAKEN AS 4000 KCAL / Kg

    PRICE OF COAL TAKEN AS Rs. 2000 / TON

    LOSS INCREASES WITH MACHINE SIZE

    ECONOMIC ASPECTS OF INEFFICIENT MACHINES

    (200 MW)

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    Description Effect on Effect onTG HR KW

    1% HPT Efficiency 0.16% 0.3%

    1% IPT Efficiency 0.16% 0.16%

    1% LPT Efficiency 0.5 % 0.5 %

    Output Sharing by Turbine Cylinders are around

    HPT 28%IPT 23%LPT 49%

    Impact of Turbine Efficiency onHR Output

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    HP/IP Turbine EfficiencyIns trument Inaccu racy / lack of correct ions

    HPTEfficiency

    Main Steam HPT Exhaust

    Pressure

    Kg/cm2Temp

    Deg C

    Pressure

    Kg/cm2Temp

    Deg C

    1 1 1 1

    0.6 % 0.6 % 2.0 % 0.7 %

    IPTEfficiency

    IPT Inlet IPT Exhaust

    PressureKg/cm2

    TempDeg C

    PressureKg/cm2

    TempDeg C

    1 1 1 1

    1.2 % 0.3 % 6.0 % 0.4 %

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    Effect o f Condenser Vacuum on Heat

    Rate

    10 MM HGIMPROVEMENT IN

    CONDENSER VACUUM

    LEADS TO 20 Kcal/kwh(1%)

    IMPROVEMENT IN HEAT RATE FOR A

    210 MW UNIT

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    EFFECT ON HEAT RATE FOR PARAMETER DEVIATION

    (500MW UNIT)

    DEVIATION IN

    PARAMETER

    EFFECT ON HEAT

    RATE(KCAL/KWH)

    1. HPT inlet press. by 5.0 ata 6.25

    2. HPT inlet temperature by 10.0deg

    C

    6.0

    3. IPT inlet temperature by 10.0deg C 5.6

    4. Condenser pressure by 10.0 mm of

    Hg

    9.0

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    Instrument calibration interval

    Calibration intervals should be based on the Specifications given by

    OEM / trended calibration observations.

    An example of Accuracy degradation as a function of time is:

    06 mth 12 mth 18 mth 24 mth

    Accuracy 0.2 0.2 0.2 0.2

    (% of span)

    Repeatability) 0.05 0.05 0.05 0.05

    (of calibrated span)

    Drift (@06months) 0.1 0.2 0.3 0.4

    Overall Ins trument 0.30 0.40 0.50 0.60

    accuracy

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    CONFORMITY FOR ENERGY AUDITSFOLLOW TEST CODES

    ASME PTC - 6 For Steam Turbines

    ASME PTC - 4.1 for Boilers

    CAL IBRATION LAB

    Govt. Accredited i.e. NABL Labs

    TEST SCHEME

    To be Furnished And Approved Sample enclosed

    BOILER EFFICIENCY

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    BOILER EFFICIENCY

    HEAT LOSS METHOD

    BOILER EFFICIENCY = 100 - % AGE LOSSES

    1. Heat Loss in Dry flue gas

    a. Hg = 0.24 wg (TgTa) as percentage of heat input

    G.C.V

    a. Hg = K (TgTa) /1.8 K=0.32 for fuel oil

    % CO2in flue gas K=0.35 for Bituminous coal

    2. Heat loss due to evaporation of moisture & H2in fuel

    Hm = Wm+9H (100 Tf) + 540 4.6 (Tg-100) %of heat input

    G.C.V3. Heat loss due to moisture in air

    Ha = 0.26 Wma(TgTa) % of heat input

    G.C.V4. Heat loss due to Incomplete combustion to Co

    Hco = 2414 C x CO x 1 as % of heat input

    CO+CO2 G.C.V

    5. Heat loss due to unburnt carbon C

    Hc = Wcx 7831 as % of heat inputG.C.V

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    6. Heat loss due to Blow Down

    Hbd = Wb(hbwhw) as % of heat input

    G.C.V

    7. Heat loss due to Radiation

    HR = Difficult to evaluate & thus take design values only

    In above

    Wg =Wt of dry flue gas

    W..G = [44.01 *CO2 + 32*O2 28.02 * N2 + 28.01*CO]*[Cb + 12.01 * S/32.07]12.01 * (CO2 + CO)

    Tg = Tempt. Of flue gas at exit of Boiler

    Ta = Tempt. Of air at inlet (ambient)

    Tf = Tempt. Of fuel inlet

    hbw-hw = Heat in blow down

    Wm = Weight of moistureWma = Wt of waterin Kg/Kg of air X Wt of air in Kg supplied / Kg of fuel

    Wc = Weight of unburnt C

    Wb = Wt of water blow down

    All wts are / kg of fuel

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    Economizer

    FG

    APH

    Sampling

    Locations

    FG

    APH

    Expansion

    Bellow

    HVS

    Annexure I

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    Annexure - I

    BOILER EFFICIENCY AND APH TEST SCHEME &

    INSTRUMENTATION DIAGRAM

    1. Grid measurement for gas compositionand gas temp. at air pre

    heater inlet / outlet.

    W/6 W/3T1

    W/3T2

    W/6T3

    N11 N21 N31 D/6

    N12 N22 N32D/3

    N13 N23 N33D/3

    D/6

    DEPTH

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    D = Duct Depth (Internal)

    W = Duct Width (Internal)

    Tx = Traverse (x) (Pockets)

    x =1 to 5 (Width wise)

    Nxy= Nodexy

    (Sketch for one half of flue gas duct cross - section)

    Grid measurement for gas sampling and temperature measurement at 3 to 5 locations on

    APH inlet & at 3 to 5 locations on APH outlet ducting as close to APH as possible shall be

    taken provided test pockets are available for inserting sampling probes. Flue gas sampling

    and temperature measuring probe shall be inserted at each location and traversed to collect

    data at these points in each location. This shall eliminate effect of gas stratification.

    Air temperature at inlet and outlet of APH shall be measured at two points each in casespare pockets are available.

    Ambient temperature, barometric pressure & RH is measured near F.D. fans.

    Note1 : WBPDCL to provide the test pockets in each of the Air and Gas path for

    inserting test instrument.

    Note2 : Test instruments shall be used for the above.

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    b) Turbine cycle heat rate.This varies with the system changes in cycle i.e.

    1. Location of Aux. Stm. Tapping.

    2. Whether Reheater spray is reqd. or not.

    3. Whether spray for superheater attemperation is tapped off from BFP discharge or

    after top heater.

    i. Cycle with Aux. Steam from MS or No Aux. Stm.;

    No. RH Spray, ;

    H. Rate = M1(H1hF) + M2(H3H2)

    Pg

    ii. Same as (a) but Aux. Steam from CRH

    H. Rate = [M1(H1hF) + M2(H3H2) MAS(H3Hc)]

    Pg

    iii. Same as (a) but with Reheat Spray.

    H. Rate = M1(H1hF) + M2(H3H2) + MRHS(H3hRHS)

    Pg

    iv. Same as (a) but Spray for Superheater from BFP discharge

    H. Rate = M1(H1hF) + M2(H3H2) + MSHS(hFhSHS)

    Pg

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    ENERGY AUDIT SCHEME FOR 210 LMW STEAM TURBINE

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    ENERGY AUDIT SCHEME FOR 210 LMW STEAM TURBINE

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    PERFORMANCE TEST PROCEDURE FOR PUMPS

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    PERFORMANCE TEST PROCEDURE FOR PUMPS

    Measured flow Q M3 / HR

    Suction pressure Ps kg / m2

    Discharge Pressure PDkg / cm2

    Test speed Nrpm

    Liquid temp. T C

    Specific weight of liquid W kg / M3

    Based ion characteristic curve of the pump the expected flow Q2M3/ Hr shall be worked

    out at H1MLC of total dynamic head (TDH)

    CONCLUSION

    For Normal Pump performance Q1M3/ Hr should be more than or equal to Q

    2M3/ Hr

    Q1> Q2

    Total dynamic head at test speed N

    H = (PDPS) X 10 / W MLC

    Total dynamic head at design speed N1H1 = HX (N1 / N)2MLC

    Fluid flow at design speed N1Q1 = QX (N1/ N) M

    3/ Hr

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    FREQUENCY OF READINGS FOR ACCURATE DATA COLLECTION

    TURBINE CYCLE AUDIT

    Pressure - 5 Minutes

    Temperature - 5 Minutes

    Flow - 1 Minute

    Power - 1 Minute

    Levels - 10 Minutes

    BOILER UNIT AUDIT

    Temperature - 15 to 30 Minutes

    Flue Gas Composition - to one hour

    DURATION OF AUDIT TEST

    Turbine Cycle - 2 Hrs

    Boiler Unit - 4 Hrs

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    TEST INSTRUMENTS ACCURACY, CODE & CALIBRATION

    LAB

    Accuracy of Energy Audi t Instruments

    Pressure Measuring Instruments 0.1 % Acc.

    Temperatures 1/2 DIN Tolerance

    Or ASME CLASS A

    Aux. Power Measuring Instruments 0.2 % Acc.

    Generator Power Measurement 0.1 % Acc.

    Flue Gas Analysis 0.5 % Acc.

    Data Logger 0.03 % Acc.

    Ultrasonic Flow Meter 0.5 % Acc.

    Note: - Price and Quality / Grade of Energy Audit Depends largely on

    Instrument Accuracies

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    3.0 METHODOLOGY TO BE ADOPTED FOR ENERGY

    AUDIT

    3.1 INTERACTION WITH PLANT ENGINEERS AND OBTAIN DATAON

    Various equipment problems.

    Present performance level i.e. unit heat rate, fuel

    consumption, DM Water and raw water consumption etc. Plant design data for the main and auxiliary equipments.

    Boiler TG Cycle layout, condensate, feed and steam pipe line

    schematics.

    Performance / Guarantee test reports of the tests carried out

    on equipments.

    Plant electrical power distribution system and transformer

    etc

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    Auxiliary power distribution system and transformer

    etc.

    Evaluation procedure for day to day monitoring i.e.plant M.I.S. systems

    Loading / requirement during test.

    3.2 Follow enclosed Test scheme for boiler and turbinetesting.

    3.3 Develop Energy Audit procedure covering followingfor each equipment

    Object of energy audit

    Scheme and list of measurements

    Range, make & class of accuracy of instruments.

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    Frequency of instrument readings.

    Duration of instrument readings.

    Required man power.

    Interconnected plant data required.

    Finalize procedure with customer / consultants

    3.4 CHECK UP THE AVAILABILITY OF INSTRUMENT

    MOUNTING POINTS AND ORGANIZE FOR MISSING

    POINTS. (CUSTOMER TO ARRANGE OR SPARE

    ALTERNATE POINTS)

    3.5 ARRANGE CALIBRATED INSTRUMENTS.

    3.6 PLAN SCHEDULE OF ACTIVITIES FOR ENERGY

    AUDIT.

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    3.7 Customer to Arrange shutdown if required for

    providing non available / missing points and

    attending defects noticed during walk down

    survey.

    3.8 Conduct test as per above plan.

    3.9 Prepare preliminary energy audit report.

    3.10 Evaluate Final Results.

    3.11 Conduct mass and energy balance in Turbine

    cycle components and boiler.

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    3.12 Make comparison with design Acceptancetest data and establish shortfall areas.

    3.13 Furnish recommendations in the form of

    cost benefit analysis.

    3.14 Give presentation on findings with backup

    data

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    SCOPE FOR CONSULTANT Frame SPECS for Energy Audits

    Approve Energy Audit Schematics

    Approve Procedure Covering Evaluation Procedure, Type

    and Class of Accuracy of Instruments & their Calibrations

    Installation of Instruments and Ensure Compatibility of Data

    Thermodynamically

    Supervise Conductance of Energy Audit

    Review & Acceptance of Audit Report

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    SCOPE OF WORK FOR ENERGY AUDIT OF THERMALPOWER PLANT UNITS

    Energy Audit should cover evaluation of the present performance

    level of all major equipments, identify the controllable losses and

    suggest remedial measures for improvements with cost benefit

    analysis and pay back period. The detailed scope of work covering

    the following is given as under.

    Boilers

    Turbine including regenerative cycle and condenser

    Electrical system

    Fans and Pumps in the above areas Insulation

    Balance of Plant including Station auxiliaries power

    consumption, Coal Handling plant, ash handling system, DM

    Plant, Station Compressed air system, CW system and Air

    conditioning.

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    Preliminary Energy Audit, Preliminary Checking / Hot

    walk down

    Energy Auditing agency to check the complete unit steam, condensate

    and feed water system along with the functioning of Heat cycle

    equipment like Boiler, Condenser Regenerative system Turbine

    Cylinders etc. during HOT WALK DOWN. Problem if any, shall be

    brought to the notice of the authority for rectification and arranging

    provisions for mounting audit instruments during Audit Preparatory

    Activities, prior to start of the detailed EA.

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    A Energy Audit Of Boilers

    Performance of Boiler and APH be established by measuring exit flue

    gas temperature and its analysis at around nine to fifteen points in flue

    gas duct cross section before and after APH to eliminate effect of gas

    stratification as per international practice (Refer enclosed boiler test

    scheme AnnexureI). This is because boiler efficiency differs by

    around 2.0% by this method than if the measurements are taken at

    single point. Scope will include the following

    DETAILED ENERGY AUDIT

    Conduct boiler efficiency measurements as per above test

    scheme by indirect method i.e heat loss method, evaluate Boiler

    efficiency and identify potential areas for improvements such as.

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    a. Heat loss due to heat in dry flue gas.

    b. Heat loss due to moisture in as fired fuel.

    c. Heat loss due to moisture from burning of hydrogen in fuel

    d. Heat loss due to moisture in air.

    e. Heat loss due to surface radiation and convection.

    f. Heat loss due to formation of carbon monoxide.

    g. Heat loss due to combustibles in bottom and fly ash

    Check up air ingress in boiler from LTSH area downwards

    upto I.D fans.

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    Determine Air preheater performance to establish.

    a. Gas Side EfficiencyAs ratio of gas temperature drop corrected

    for no air leakage to temperature heads.

    b. Air leakage as percentage of air passing from airside to gas side.

    c. X-RatioI,e heat capacity of air passing through the air heater to the

    heat capacity of gas passing through the air heater.

    d. Air side and gas side pressure loss across the air heater.

    Input power measurement of ID FANS / FD fans, PA fans, Fan

    Loading & combined efficiency of fan and motor and their specific

    power consumption Energy Audit test has to be carried out for four hours by recording

    parameters at every 15 minutes and average of data to be utilized

    for evaluation.

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    B Energy Audit of steam turbine cycle and it auxiliaries

    For Energy Audit of steam turbine cycle, all the parameters as per

    the enclosed scheme in AnnexureIIare to be measured

    simultaneously by hooking up these calibrated instruments to

    a data logger.The recording has to be at least for a minimum

    period of two hours with each measurement being recorded at an

    interval of one minute. Average of the data so collected to be

    utilized for evaluation of the following and suggestions for

    deficient areas for improvements to be made.

    1. Turbine cycle heat rate.

    2. HP and IP cylinders efficiency

    3. Turbine pressure survey

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    4. TTD & DCA of HP / LP heaters performance

    5. Condenser performance i.e

    Condenser back pressure after duly considering the effect of

    present C.W inlet temp. C.W flow, heat load on condenser

    and air ingress to condenser vis--vis design conditions

    C.W side pressure drop in condenser

    6. Cycle losses

    7. Performance of turbine glands

    8. Ejector performance

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    For accurate heat rate determination, Turbine inlet flow and reheat

    flow need to be evaluated as per international practice by

    measuring condensate flow through measurement of p of plant

    condensate flow orifice after checking its condition and using

    evaluated drip and extraction to deaerator flows through heat and

    mass balance across heaters and deaerator as per scheme. Fall in

    deaerator level and HPTV and IPV leak off flow are also considered.

    Alternately by mass balance across deaerator if flow orifices are

    installed in drip and extraction lines to deaerator. Deaerator outlet

    feed flow shall then be taken as the main steam flow after

    considering for RH spray tap off from Boiler feed line.

    C El t i l t

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    C. Electrical system

    1 Transformers Assessment of the health &

    Transformer load loss of GT, UAT,

    Station Service transformers etc. Identification of possible Energy

    conservation options in this area.

    2 Motors Assessment of Loading condition of

    HT and LT motors of Boiler area,

    Turbine area and Balance of Plantarea.

    Assessment of operating parameters

    like load variation, Power factor, of HT

    and LT motors consuming power

    more than 50 KW.

    Identification of possible Energy

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    Capacitors Assessment of health of capacitors.

    Plant Lighting system Lighting load survey and Assessment of

    installed load efficacy (I.L.E) and I.L.E

    ratio at various areas of plant.

    Assessment of present lighting controls

    Identification of Energy Conservation

    Opportunities.

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    D Fans and Pumps Performance

    Performance of fans consumingpower more than 50 KW such

    as ID, FD, PA fans etc. Input power measurement

    Fan loading and combined efficiency of fan and motor

    Specific energy consumption

    Pump performance for BFPs, CEPs, Aux C.W.P & C.W.Pand

    pumps consuming power more than 50 KW etc.

    Check Performance of the pumps by comparing the corrected

    measured flow at operating speed to design speed with that

    of the expected flow derived from the characteristic curves

    against the corrected total dynamic head at design speed.

    Determine Pump efficiency as the ratio of power input to thepump shaft to hydraulic power.

    Specific power consumption

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    E Insulation Audit:

    A. Walk through survey of Boiler, Turbine and associated steam

    piping to identify the damaged and Hot spot area.

    B. Surface temperature measurement at the damaged and Hot

    spot area by infrared temperature indicator.

    C. Estimation of heat loss in the hot spots and damaged

    insulation area.

    F Balance Of Plant

    (i) Compressed air system: Free Air Delivery i.e. Capacity evaluation of the Plant and

    Instrument air compressors.

    Checking volumetric efficiency of compressors.

    Assessment of compressed air leakage quantity.

    Assessment of Energy performance of the air compressors/specific power consumption.

    Study of the compressed air network and suggest suitable

    energy saving options.

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    (ii) Air conditioning system:

    Performance evaluation of AC Plant w.r.t net cooling /

    refrigeration capacity along with heat load of Air handling unit

    and energy requirements at the operating conditions vis--visdesign condition to be determined.

    (iii) Ash Plant

    Performance of ash Slurry pumps through power measurement

    and flow measurement.

    Ash water ratio assessment and recommendations foroptimization in water and power consumption.

    (iv) Cooling Tower Performance

    It shall include establishment of

    Liquid/Gas ratio

    Fan efficiency as the ratio of shaft power developed and thework done by the fan

    Cooling Tower Effectiveness, approach and range.

    Cooling capacity.

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    V Coal Handling Plant

    Input Power measurement of all the key equipment of the CHP area

    like: Paddle feeders, Conveyors, Stacker & Re-claimer, WagonTipplers, Crushers,

    Establishment of specific energy performance indicators.

    Accuracy and calibration of the instruments

    The proposed instruments should have following level of accuracy.

    i. Thermocouples and PRTsASME special class A i.e DINtolerance

    ii. Pressure and differential pressure - 0.1%

    transmitters better than

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    iii. Power Meter for generator & - 0.1%

    Unit Aux Power measurement

    iv Data Logger - 0.03%

    v Power transducers / Load Analyser - 0.5%

    vi Flue gas analyser - 0.5%

    vii Ultrasonic flow meters - 0.5%

    viii Anemometer - 1.0%

    xi Infrared Thermometer - 1.0%

    x Lux meter - 1.0%

    xi RH meter - 1.0%

    These should be duly calibrated from NABL accredited lab.

    The above accuracies for S.No. I to V are as per ASME specified for

    Performance Evaluation of Thermal Power Plants.

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    OUR EXPERIENCE OF ENERGY AUDITS OF

    THERMAL POWER PLANTS

    Two 2 x 210 MW units of M/s WBPDCL Kolaghat

    Thermal Power Plant.

    15 units of Saudi Electric company of Saudi Arabiahaving unit sizes varying from 60 MW to 660 MW.

    Two 2 x 18 MW units of M/s Shree Cements Captive

    Power Plant.

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    1) Operation of machine at very low turbine I/L parameters.

    2) Operation of turbine at lower loads.

    3) HP and IP turbine cylinder efficiencies are very low.

    4) Main steam and HRH inlet temperature to turbine very

    low.

    5) RH pressure drop high

    6) High quantity of SH Spray and its tapings before HPH-5

    resulting of loss in heat because of changed cycle.

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    POWER PLANT

    Contd.

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    7) HP heater no. 5 out of service.

    8) Turbine cycle not operating as per design scheme i.e.

    Ejector and Deaerator pegging steam from PRDS

    header as against normal source from deaerator &

    extraction steam respectively.

    9) Passing of turbine cycle drain valves.

    10) Make up quantity to cycle is very high which indicates

    excessive system steam (heat) loss.

    11) TTD & DCA of heaters high

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    POWER PLANT

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    12) Condenser air ingress and dirty tubes.

    13) Under loading of motors

    14) Excessive air leakage in compressed air system

    15) Faulty insulation

    16) Drain valves passing

    17) Air ingress to Boiler furnace18) FAD of compressors low

    METHODS / OBSERVATION FOR SAVINGS ENERGY IN

    POWER PLANT

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    ThanksEnergo Engineering Projects Ltd.A-57/4, Okhla Industrial Area, Phase II

    Phone: +91 - 11 - 26385323/ 28/ 29/ 38Fax: +91 11 26385333

    E-mail: [email protected]

    [email protected]

    Web: www.energoindia.com