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A presentation for PGDC students at NPTI by Anil Palamwar
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ANIL PALAMWARRETIRED
CHIEF ENGINEER, KHAPERKHEDA TPS.DIRECTOR (OPERATION) MAHAVITARAN
• NEED FOR ENERGY AUDIT.
• AUDIT PROCEEDURES
• ENERGY AUDIT –
• MACRO LEVEL
• AND
• MICRO LEVEL.
1
Energy Audit ????? • We know Financial Audit.
• Audit of Public Enterprises.
• Balancing of Income & Expenses.
• Whether rules are followed ?
• E.A. is slightly different.
• Energy Audit deals with -
• Losses – Efficiency – Conservation
• Promotes :- Economy, competitiveness & Environment.
2
ENERGY CONSERVATION ENERGY IS THE CAPACITY TO DO WORK.
ENERGY IS AVAILABLE FROM WIND-WATER-SUN -FOSSIL FUEL
MOSTLY WE WORK WITH ELECTRICAL OR THERMAL
ENERGY. Why Conserve?
1. - RESOURCES ARE LIMITED.
2.-COST REDUCTION TO REMAIN VIABLE IN COMPETITION.
3.- Environment - Global warming - GHGs
3
EFFICIENCY OF RANKINE CYCLE IS LIMITED TO 35-40 %.
C.C.G.T. PLANTS GO UP TO 52-55 %.Efficiency. [Combined Cycle Gas Turbines]
SO IF HEAT IS USED DIRECTLY,
[WITHOUT CONVERTING TO ELECTRICITY],
CYCLE EFFICIENCY WILL INCREASE.
CO-GENERATION ADOPTS THIS PRINCIPLE.
Industrial units must explore the possibility of use of waste heat.Where ever a furnace is used,
lot of waste heat is available for use in some way or other. IN SIMPLE WORDS –
WHEN 100 M.T. OF FUEL IS USED, ONLY 40 MT IS USED TO PRODUCE ELECTRICITY,
HEAT VALUE OF REMAINING 60 M.T. GOES UNUSED TO THE ATMOSPHERE.
4
ALSO- CONSIDER THE SYSTEM LOSSES-Transmission
Three Transformers-220/33; 33/11 ; 11/0.415 KV---
Efficiency=0.99 x0.99 x 0.99 =0.97 or 97%Transmission Efficiency= 94 %,
Distribution Efficiency=85%
Motor Efficiency=80 %
Pump Efficiency = 80%
Total system Efficiency=
0.97x0.94x0.85x0.80x0.80=0.4960 or 49.60%5
It means that for every unit consumed, two units are generated and sent from a power station.
Conservation is therefore necessary. Waste must be
avoided .
Cost is the most powerful motivating factor for conservation.
Maharashtra State needs approximately 300 MU of
electricity per day. (Average)
Only about 150 MU are really utilized.
Efficiency is of utmost importance.
Every process needs thorough check to identify losses. 6
Transformers- Losses within limits-e.g. MSEDCL Motors-Pumps-Fans- e.g. Feed Pump and P.A. Fans at KPKD
TPS. Procurement-Installation-O&M -
All these affect performance-and losses.
Ducting and its aerodynamics- Eddy formation
Selection of correct pipe dia and cleanliness of pipes.
Air conditioning- use of vapour cycles where waste heat is used.
Properly set thermostats.
Maximum use of daylight and Natural ventilation.
7
ENERGY AUDIT FRIENDS & ENEMIES
8
NEGATIVE FORCES
GOAL -TO REDUCE ENERGY CONSUMPTIONPOSITIVE FORCES
HIGH PRICE OF ENERGY
EFFICIENT TECHNOLOGY
TAX ON ENERGY
TOP MANAGEMENT SUPPORT
ENERGY INTENSIVE INDUSTRY
NO CORPORATE ENERGY POLICY
NO AWARENESS IN THE COMPANY
INSUFFICIENT SKILLS & KNOWLEDGE
COMPETING CORPORATE POLICIES
INSUFFICIENT FUNDS
FOUR PILLARS OF ENERGY MANAGEMENT
9
TECHNICAL ABILITYMONITORING
SYSTEM
STRATEGY PLAN
TOP MANAGEMENT SUPPORT
ENERGY MANAGEMENT
MATERIAL BALANCE
10
SOLID WASTE FOR STORAGE & DISPOSAL
WATER / AIR PROCESS
OPERATIONS
REUSABLE WASTE
GASEOUS EMISSION
PRODUCT
BYE PRODUCT
WASTE WATER
LIQUID WASTE FOR STORAGE &
RAW MATERIALS
CHEMICALS
ENERGY BALANCE
11
ENERGY IN HOT RESIDUE
ENERGY IN CONDENSATE
COMPRESSED AIRENERGY IN COOLING
WATERENERGY IN RAW MATERIAL
ENERGY IN VAPOURELECTRICITY
STEAM RADIATION LOSSPROCESS
OPERATIONSCOOLING WATER ENERGY IN HOT PRODUCTS
12
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NON Renewable Energy Sources
15
Renewable Energy Sources
16
17
It took more than 3 million years to convert to Fossil Fuels.
INTRODUCTION INTRODUCTION
Conventional source of energy such as coal, oil and gas are scarce and exhaustible.
Energy prices will rise in the long run to reflect their relative scarcity and high cost of exploration and extraction.
Hence, all attempts must be made expeditiously to ensure the optimal use of the available resources to manage the viability and availability of energy.
18
INTRODUCTION (contd.)INTRODUCTION (contd.) Government of India enacted the Energy
Conservation Act – 2001. For efficient use of energy and its conservation to
mitigate the gap between demand and supply and to promote economic competitiveness.
The Act provides for Institutionalizing and strengthening delivery
mechanisms for energy efficiency services in the country and
Provides the much-needed coordination between the various organizations and stakeholders,
Within the Government and in the private sector.
19
Enacted in October 2001Enacted in October 2001
Become effective from 1st March 2002Become effective from 1st March 2002
Bureau of Energy Efficiency (BEE) operationalized Bureau of Energy Efficiency (BEE) operationalized from 1from 1stst March 2002. March 2002.
MISSION OF BEEMISSION OF BEEDevelop policy and strategies with a Develop policy and strategies with a
thrust on self regulation and market thrust on self regulation and market principles, within the overall framework of the principles, within the overall framework of the EC Act with the primary objective of reducing EC Act with the primary objective of reducing energy intensity of the Indian economy.energy intensity of the Indian economy. 20
1. DESIGNATED CONSUMERS1. DESIGNATED CONSUMERS( Energy Intensive Industries and other Establishments)( Energy Intensive Industries and other Establishments)
A programme to initially focus on energy policy A programme to initially focus on energy policy issues of energy efficiency improvement,issues of energy efficiency improvement,
in organized sectors such asin organized sectors such as energy intensive industries and.energy intensive industries and. commercial sector,commercial sector, through establishment of energy management through establishment of energy management
system,system, capacity building of energy professionals, capacity building of energy professionals,
implementation of energy audits, implementation of energy audits, establishments of specific energy consumption norms establishments of specific energy consumption norms support to consumers on providing information on support to consumers on providing information on
authentic energy data authentic energy data 21
Designated Industries Schedule - Responsibilities
Schedule to EC Act provides list of 15 energy Schedule to EC Act provides list of 15 energy intensive industries and other establishments to be intensive industries and other establishments to be notified as designated consumers (DC).notified as designated consumers (DC).
Designated Consumers to -Designated Consumers to -Appoint or designate energy managersAppoint or designate energy managersGet energy audits conducted by accredited Get energy audits conducted by accredited energy auditorsenergy auditorsImplement techno-economic viable Implement techno-economic viable recommendationsrecommendationsComply with norms of specific energy Comply with norms of specific energy consumption fixed consumption fixed Submit report on steps takenSubmit report on steps taken
22
1)Designated Consumers
Thermal Power Stations- 30,000 Million tonne of oil equivalent (MTOE) per year and above
2) Fertilizer- 30,000 MTOE per year and above
3) Cement- 30,000 MTOE per year and above
4) Iron & Steel- 30,000 MTOE per year and above
5) Chlor-Alkali- 12,000MTOE per year and above
6) Alluminium- 7,500 MTOE per year and above
7)
Railways- One traction substation in each Zonal Railway , Production units and Workshops of Indian Railways having total annual energy consumption of 30,000 MTOE or more
under Ministry of Railways
8) Textile-3,000 MTOE per year and above
9) Pulp & Paper-30,000 MTOE per year and above23
WHY ENERGY EFFICIENCY IS IMPORTANT ?WHY ENERGY EFFICIENCY IS IMPORTANT ?
• We do something to enjoy, save money & resources and finally because it is the LAW.
• So Energy Audit – Because,
• Depleting fossil fuel-Resources are scarce
• Optimum plant utilization-Competitiveness.
• Global warming-Carbon Credit
• Designated consumer-E.A. is Mandatory.
• Generate more energy with same quantity of fuel
24
PERIOD STEAM PRESSURE&
TEMPERATURE
UNIT SIZE(MW)
TURBINEHeat Rate(Kcal/kWh)
Unit Heat Rate(Kcal/kWh)/Efficiency
1951-60 60 kg/cm2, 482oC 30 – 57.5 2470
1961-75 70 kg/cm2, 496oC to 90 ata 538oC
60 – 100 2370
1961-75 130 ata 535/535oC 110 – 120 2170 – 2060 2552-2423
1977-82 130 ata 535/535oC 210 (Russian)
2060 2423/35.4%
1983+ 150 ata 535/535oC 210 (Siemens)
2024 233536.8%
1984+ 170 ata 535/535oC 500 1950 (TDBFP)
229437.4%
1990+ 150 ata 535/535oC 170 ata 538/538 oC
210/ 250250/ 500
1950 (MDBFP)
1950 (TDBFP)
22942294
THIS CHART SHOWS THE GRADUAL IMPROVEMENT IN HEAT RATE
TO ACHIEVE ECONOMY 25
EFFICIENCY IMPROVEMENT CAN GIVE YOU
For an average increase of 1 % in the Efficiency would result in:-
Coal savings of approx. 11 million tons per annum worth Rs.13,000 Million
CO2 reduction about 13.5 million tons per annum Lower generation cost per kWh- as more efficient the
unit works, the more economical it is 1% increase in efficiency for 210 Mw unit with heat
rate 2335 kcal/kwh means heat rate improvement to 2275 kcal/kwh
26
MAJOR CAUSE OF INEFFICENCY IN POWER PLANTMAJOR CAUSE OF INEFFICENCY IN POWER PLANT
• High Flue gas exit Temp
• Excessive amount of excess air(O2)(Increases dry flue gas loss)
• Poor Mill/Burners performance causing high unburnt carbon in fly and bottom ash.
• Poor insulation.
• Poor house Keeping.
• Poor instrumentation and automation
27
MAJOR CAUSE OF INEFFICENCY IN MAJOR CAUSE OF INEFFICENCY IN POWER PLANTPOWER PLANT (Cont…)
• Not running the units on design parameter• Heaters not in service or poor performance
of regenerative system• Poor condenser vacuum• Excessive DM water consumption- passing
and leakages• Use of Reheat spray to control Reheat
Temperature• Poor Cylinder Efficiency of turbine
28
CONTROLLABLE PLANT PARAMETERS
• M.S. & R.H. Steam Temperatures
• M.S. Steam Pressure
• Condenser Vacuum
• Final Feed Water Temperature
• DP Across Feed Regulation Station
• Auxiliary Power Consumption
• Make Up Water Consumption
29
HOW TO ACHIEVE ENERGY HOW TO ACHIEVE ENERGY EFFICIENCY ?EFFICIENCY ?
• Adopt state of the art technologies
• Adopt cutting edge technologies
• Review & Re-engineering of the existing systems
• Bench Marking
• Energy Auditing
30
CAN WE IMPROVE CAN WE IMPROVE EFFICIENCY?EFFICIENCY?
Yes, provided we shed the myths and believe in applying result oriented efforts
Workout to identify & quantify the cost of hidden losses
Bring in requisite operational behavioral change
31
SOME OF THE MYTHS High PLF & availability translates into
Optimum Efficiency
Heat rate is the responsibility of Efficiency Management Group at Stations
Equipment maintenance to be taken-up based on periodic overhaul schedule
Boiler performance degradations has no relation to Turbine Cycle performance
32
Some of the Myths contd…• Design heat rate is the best achievable heat rate• Efficiency tests are the same as performance guarantee
test• Heat rate improvement requires large investment.• Results follow immediately after testing is completed
• Heat rate is the responsibility of Energy & Efficiency Management Group (EEMG) at Stations
• Station instruments are accurate for monitoring heat rate parameters
33
Some of the Myths contd… “Design” is not the best achievable performance
• Predicted performance based on Turbine Heat Balance Diagrams and Boiler Efficiency at different loads
• ‘Design’ is based on specific ambient conditions that vary throughout the year
• Actual initial performance could be different from design or changes might have been made to plant
• Current performance to be compared to an achievable ‘expected’ value to establish efficiency gaps
34
SYNERGIZE OPERATIONOF UNIT
Need to clearly understand the relation between performance & fuel, operation and design parameters
Operational behavior and performanceImpacts of operating efficiency of Boiler, Turbine
and their auxiliaries on Net Unit Heat RateMaximum Achievable Load, Maintenance &Availability
35
SOME CRITICAL FACTORS AFFECTING BOILER PERFORMANCE
• Fuel:- Heating Value, Moisture Contents, Ash Composition, Ash Contents,& Volatile Matter.
• Operational Parameter:- Level of Excess Air, & operating Condition of Burner Tilt Mechanism.
• Design:- Heating input per plan area, Height of Boiler, Platens & pendants heat transfer Surfaces, Burner & wind Box design.
36
BEHAVIOURAL IMPACTS• Low heat value results in over firing of fuel causing more heat
availability for super heater and re-heater thus more attempration spray requirement. Hence increase in THR, overloading of ash handling system, fans and increased soot blowing
• Moisture content increase causes increase in heat transfer to S.H, and R.H. Hence again increase in attempration spray and THR (Turbine Heat Rate)
• Ash composition and contents increases damage to pressure parts surfaces because of melting behavior of low fusion ash temperature of blended coal in particular
• In consistency in fired fuel characteristics results in variation in excess air requirement thereby increasing stack loss and hence boiler efficiency reduction, overloading of ID Fan and ultimately unit load limitation
• High heat value causes excessive radiant heat transfer to water walls thereby leaving lesser heat for super heater and re-heater
• .37
Normally excess air ranges from 15% to 30% of stoichiometric air.
• High O2 % and presence of CO at ID Fan outlet are indicator of air in leakages and improper combustion in furnace
• Poorly effective damper control also is the cause of higher SEC of fans both primary and secondary
• The quality and purity of feed water and make up water is also
required to be maintained in a meticulous way by limiting blow down losses to nearly 1% and by checking the passing and leakages of valves. However, maximum 3% of flow can be taken as make up for these causes including soot blowing requirements
• Soot blowing is dependent on ash contents and is unit specific. Intelligently devised soot blowing can result in saving the fuel
BEHAVIOURAL IMPACTS
38
• Cascading effects on efficiency, loading and availability because of following systems and equipments performance also needed to be looked into. The systems are:-Fuel receiving, preparation and handling systems.Pulverizing systemAir HeaterFansElectrostatic PrecipitatorFly ash handling systemBottom ash handling systemWaste disposal system
BEHAVIOURAL IMPACTS
39
PERFORMANCE IMPACTS ON STEAM CYCLE , UNIT HEAT RATE & OUTPUT
• Various design & operating parameters of a unit are responsible for its cycle performance, heat rate,& out put
40
CRITICAL FACTORS AFFECTING CYCLE PERFORMANCE
1. Re-heater & its system pressure drop2. Extraction line pressure drop3. Make up4. Turbine exhaust pressure5. Air preheat6. Condensate sub-cooling7. S/H & R/H spray flows8. Wet Bulb Temp9. Top Heaters out of service10. H.P. heater drain pump11. Type of BFP drives & method of flow control
41
RH & ITS SYSTEM PRESSURE DROP….
• Every one 1% decrease in drop can improve THR and output by 0.1% & 0.3% respectively
• Normally designed for pressure drop equivalent to 10% of HP exhaust pressure
• Causes are Feed Heater abnormalities R/H safety valve passing
42
EXTRACTION LINE PRESSURE DROP…
• Permissible pressure drop between stage pressure & Shell pressure is maximum 6%
• For every 2% increase in this pressure drop, THR would be poorer by 0.09%
43
CYCLE MAKE-UP….
• Acceptable value of make up water is 3% to offset cycle water losses
• For every 1% increase in make up 0.4% increase in THR & 0.2% reduction on output is there
44
EXHAUST PRESSURE…• Increase & decrease in exhaust pressure do
affect the THR.
• Though no valid thumb rule has been devised so far, however last stage blade design & exhaust area of turbine do affect the impact of changing exhaust pressure.
45
AIR PRE-HEAT….• Air preheating of combustion air before entry to
regenerative air heater is done with either steam coil air pre - heater or hot water pre heating coil to maintain Average Cold End Temperature (ACET) to escape dew point temperature complications
• Condensate retrieval is necessary to avoid deterioration to THR depending upon unit load and combustion pre heating duty
46
CONDENSATE SUB-COOLING…
• For 30% total flow and 2.5 deg C sub-cooling ,an increase of 0.001% in THR can be there for every subsequent 10% increase in flow
47
R.H & S.H. SPRAY FLOW…
• Spray water whether drawn from BFP or after the final heater, it is always less the generative and less productive as well
• Every 1% spray flow, correction need to be done in THR & load computed from the curves supplied with the machine
48
TOP HEATER OUT OF SERVICE….• Extraction steam flow meant for top heater
passes through the turbine thereby increasing the output.
• But at the same time final feed water temp is lowered resulting in poor Total Heat Return.
• More fuel must be used in the boiler to add the sensible heat (Not imparted by the feed heater)
• The % loss increases from lowest stage (.5 to .6 ) to highest stage (1.2 to 1.5%)
• Roughly each Deg C in TTD will result in a loss of 0.25% efficiency.
49
PERFORMANCE MONITORING• Analyze the poor efficiency areas from previous record
• Go down to specific system and then to component
• Carry out performance/diagnostic study as suggested in the Auditing Manual & operating manual
• Devise a unit specific efficiency control sheet for few terminal conditions (Actual vs Design)
• Monitor once per shift to know the operating efficiency and check any deterioration
50
Coal Handling Plant
• Coal Crushers-• If significant quantity of coal >20 mm size is
observed on down side of crusher then it may led to substantial decrease in mill performance.
• Identification of combination of various least power consuming equipment and recommending merit order operation.
• Use of natural daylight through conveyor galleries and use of fire resistant translucent sheet.
51
Soft Starters- V.F.D.
• Explore Installation of power saver device in major LT motors. (Conveyor belt etc.):
• Major HT /LT motors i.e. conveyors, crushers etc. are often partially loaded & also there are frequent starts /stops.
• Explore the possibility of providing power saver devices (soft starters) in major motors.
52
Power Factor of Motors.
• Power factor correction possibility:• Induction motors may have vey low power factor,
leading to lower overall efficiency. • Capacitors connected in parallel with the motor are
used to improve the power factor.• The PF correction reduces KVA demand, • reduced I2R losses in cable upstream of capacitor,• reduced voltage drop in cables (leading to improved
voltage regulation),• and an increase in the overall efficiency of the plant
electrical system. 53
Chemicals for Dust Suppression• Explore the possibility of using chemicals for
reduced water spray:
• Mixing of chemical compounds in water provides much better atomization of water spray, by reduction in surface tension of water.
• Thus for the given application of dust suppression, less quantity of water is sprayed which also results into less wastage of latent heat in the steam generator.
54
Use of Bull Dozers ?
• Maximum Mechanical Handling: • Minimum Bulldozing: Receipt, unloading, stacking
and reclaiming and the selection of machinery should be such that all the handling operations are accomplished without the use of semi mechanized means like bulldozers which are more energy intensive equipment.
• When coal is stocked in yard for more than incubation period (duration between coal mined and getting self ignited), special precautions like compacting, water spraying must be taken.
55
Bunkering Frequency• Reduced Number of Fillings:
• Live storage capacity of raw coal bunkers and the filling pattern of bunkers is so planned that,
• 24 hours coal requirement of the generating units is met by not more than two fillings per day.
• This will eliminate frequent starting and stopping of the CHP system.
56
Boiler Scheme
57
Energy audit of Boiler• Coal quality - composition and calorific value
• Coal milling aspects
• Combustion and excess air
• Re-heaters
• Heat recovery units – Economisers, air preheaters, etc,
• Insulation aspects
• Boiler blow down aspects- Water Chemistry
• Soot blowing aspects- Effectiveness
• Operation and maintenance features which affect the energy efficiency
• Condition & status of boiler and their internals
• Feed water system aspects
• Air and flue gas system aspects 58
STEPS IN ENERGY AUDIT
• Data collection• Observations and Analysis• Exploration for energy conservation measures • Report preparation
– DATA COLLECTION• The first step in energy audit of boiler is to collect the
design / PG test parameters pertaining to boiler, economiser, air preheaters, coal and coal milling, soot blowing and other key associated equipment.
59
Particulars Unit Details at Normal
cont. rating, NCR
Make BHEL
Type Water tube single
drum
Capacity tph 627.32
Main Steam pressure kg/ cm2 155
Main Steam temperature 0C 540
Boiler efficiency % 87.16
Super heater outlet flow tph 627.32
Reheater outlet flow tph 565.6
Coal Calorific value –GCV kcal/ kg 4350
Coal consumption tph 106.2
Total combustion air tph 822
LTSH outlet temperature 0C 420
Reheater outlet temperature 0C 540
Water- economizer inlet
temperature
0C 241
Water- economizer outlet
temperature
0C 280
Oxygen content at Economizer
outlet
% 4.23
60
Unit Design NCR Actual
Make
Type
Year of Installation
Main Steam Pressure kg/ cm2
Main Steam Temperature oC
Main Steam Flow tph
Steam pressure at LTSH outlet kg/ cm2
Steam temperature at reheater inlet oC
Steam temperature at reheater outlet oC
Steam pressure at reheater inlet kg/ cm2
Steam pressure at reheater outlet kg/ cm2
Steam temperature at LTSH out oC
Saturated steam temperature in drum oC
Super heater platen outlet temperature oC
Pressure drop in reheater Kg/ cm2
Super heater spray tph
Reheater Spray tph
Design ambient temperature oC
Coal consumption tph
DESIGN DATA
61
ECONOMISER DATA Unit Design Actual
Feed water pressure at the inlet kg/ cm2
Feed water pressure at the outlet kg/ cm2
Feed water flow Tph
Feed water temperature at the inlet oC
Feed water temperature at the out let oC
Oxygen content in flue gas before
economizer %
Excess air % in flue gas before
economizer %
Exhaust gas inlet temperature oC
Exhaust gas outlet temperature oC
Exhaust gas quantity Tph
62
AIR PRE HEATER DATA Unit Design Actual
Air quantity at APH outlet (primary) Tph
Tempering air Tph
Air heater outlet (secondary) Tph
Total combustion air Tph
Air temperature at fan outlet oC
Air outlet temperature of APH – primary oC
Air outlet temperature of APH– secondary oC
Oxygen content in flue gas before APH %
Oxygen content in flue gas after APH %
Excess air % in flue gas before
APH %
Flue gas inlet temperature oC
Flue gas outlet temperature oC
Flue gas quantity Tph
Others
63
EXHAUST GAS TEMPERATURE PROFILE
Unit Design Actual
Temperatures at different location oC
Super heater platen outlet oC
RH front inlet oC
RH rear inlet oC
SH final inlet oC
LTSH inlet oC
Economizer inlet oC
APH inlet oC
APH outlet oC
ID Fan inlet oC
ID fan outlet oC
64
BOILER HEAT BALANCE
Unit Design
Ambient temperature oC
Excess air %
Dry flue gas loss %
Hydrogen loss %
Moisture in fuel loss %
Moisture in air loss %
Unburnt combustible loss %
Radiation loss %
Un accounted loss %
Gross boiler efficiency on HHV %
Guaranteed efficiency %
65
Feed water & Boiler water limits
Unit Feed water Remarks
pH at 25oC
Oxygen – maximum ppm
Total iron- maximum ppm
Total silica – maximum ppm
Conductivity at 25oC Microsiemens
Hydrazine residual ppm
Total solids – maximum ppb
Chlorides ppm
Copper – maximum ppm
Permanganite consumption ppm
66
MILLS AND BURNERS PERFORMANCE
Unit Requirement
at MCR Actual Remarks
No of coal burners No
PA flow tph
No of mills in operation No
Mill loading %
Air temperature at mill inlet
after tempering
oC
Air – fuel mixture temperature
after leaving mills
oC
Total coal fired tph
Air Coal ratio
67
Mill specifications:
• Type of mill : • Make : • Capacity : __________tph at coal
________grind • Fineness : ___________% through
________mesh• Motor rating :____________kW • Motor voltage :________ V• No of mills :__________• Running /Standby :_________/________
68
COAL DATA
• Design coal parameter• Moisture :_____%• Ash :_____%• Volatile matter :_____%• Fixed carbon :______%• HGI :_____%
69
SOOT BLOWERS
Type number
Soot blowers for furnace
Soot blowers for super heaters
Soot blowers for reheaters
Soot blowers for air preheaters
Medium of blow
Steam pressure before reduction
Steam pressure after reduction
Steam consumption
70
Instruments For Energy Audit• The following instruments are required for conducting the
boiler energy audit.
• Power Analyser: Used for measuring electrical parameters such as kW, kVA, pf, V, A and Hz
• Temperature Indicator & Probe
• Stroboscope: To measure the speed of the driven equipment and motor
• Sling hygrometer or digital hygrometer
• Anemometer
• Available On line instruments at the site ( Calibrated )
• Digital Manometer of suitable range and appropriate probes for measurement of pressure head and velocity head.
• 71
• Additional pressure gauges with appropriate range of measurement and calibrated before audit.
• Flue gas analysers / Orsat apparatus
• Infrared pyrometers
• Pressure gauges
• Steam trap tester / Ultra sonic leak detectors
• Instrument to measure coal velocity in coal feed pipe
72
MEASUREMENTS & OBSERVATIONS
• Average GCV of coal during audit period
• Coal analysis – ultimate and proximate
• Coal consumption details
• Performance parameters of coal mills
• Steam parameters of main steam, reheat, super heater, LTSH (flow, pressure and temperature)
• Air – flow, temperature, pressures
73
MEASUREMENTS & OBSERVATIONS
• Flue gas – Flow, temperature and pressure• Flue gas analysis• Ambient temperature• Boiler loading • Motor electrical parameters (kW, kVA, Pf, A, V, Hz,
THD) • Surface temperatures of insulation and boiler surfaces• Un-burnt coal (in fly ash and bottom ash)
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