001 conservation-Energy Audit -Methods
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Anil Palamwar discusses the need for energy audits at both the macro and micro levels. He outlines some of the key reasons for conserving energy, including limited resources, cost reduction, and environmental impacts. Palamwar also discusses the importance of efficiency, providing examples of system losses throughout generation, transmission, and distribution. He emphasizes the importance of identifying and reducing losses to improve efficiency.
![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](https://image.slidesharecdn.com/001conservation-130724053135-phpapp01/85/001-conservation-Energy-Audit-Methods-4-320.jpg)
001 conservation-Energy Audit -Methods
- 1. ANIL PALAMWAR RETIRED CHIEF ENGINEER, KHAPERKHEDA TPS. DIRECTOR (OPERATION) MAHAVITARAN • NEED FOR ENERGY AUDIT. • AUDIT PROCEEDURES • ENERGY AUDIT – • MACRO LEVEL • AND • MICRO LEVEL. 1
- 2. 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
- 3. 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
- 4. 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
- 5. 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
- 6. 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
- 7. 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
- 8. ENERGY AUDIT FRIENDS & ENEMIES 8 NEGATIVE FORCES GOAL -TO REDUCE ENERGY CONSUMPTION POSITIVE FORCES HIGH PRICEOF ENERGY EFFICIENTTECHNOLOGY TAX ON ENERGY TOP MANAGEMENTSUPPORT ENERGY INTENSIVE INDUSTRY NO CORPORATE ENERGY POLICY NO AWARENESS IN THE COMPANY INSUFFICIENTSKILLS & KNOWLEDGE COMPETING CORPORATE POLICIES INSUFFICIENT FUNDS
- 9. FOUR PILLARS OF ENERGY MANAGEMENT 9 TECHNICAL ABILITY MONITORING SYSTEM STRATEGY PLAN TOP MANAGEMENT SUPPORT ENERGY MANAGEMENT
- 10. 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
- 11. ENERGY BALANCE 11 ENERGY IN HOT RESIDUE ENERGY IN CONDENSATE COMPRESSED AIR ENERGY IN COOLING WATERENERGY IN RAW MATERIAL ENERGY IN VAPOUR ELECTRICITY STEAM RADIATION LOSS PROCESS OPERATIONSCOOLING WATER ENERGY IN HOT PRODUCTS
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- 15. NON Renewable Energy Sources 15
- 17. 17 It took more than 3 million years to convert to Fossil Fuels.
- 18. INTRODUCTIONINTRODUCTION 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
- 19. 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
- 20. Enacted in October 2001Enacted in October 2001 Become effective from 1st March 2002Become effective from 1st March 2002 Bureau of Energy Efficiency (BEE) operationalizedBureau of Energy Efficiency (BEE) operationalized from 1from 1stst March 2002.March 2002. MISSION OF BEEMISSION OF BEE Develop policy and strategies with aDevelop policy and strategies with a thrust on self regulation and marketthrust on self regulation and market principles, within the overall framework of theprinciples, within the overall framework of the EC Act with the primary objective of reducingEC Act with the primary objective of reducing energy intensity of the Indian economy.energy intensity of the Indian economy. 20
- 21. 1. DESIGNATED CONSUMERS1. DESIGNATED CONSUMERS ( Energy Intensive Industries and other Establishments)( Energy Intensive Industries and other Establishments) A programme to initially focus on energy policyA 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 managementthrough 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 normsestablishments of specific energy consumption norms support to consumers on providing information onsupport to consumers on providing information on authentic energy dataauthentic energy data 21
- 22. Designated Industries Schedule - Responsibilities Schedule to EC Act provides list of 15 energySchedule to EC Act provides list of 15 energy intensive industries and other establishments to beintensive 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 managers Get energy audits conducted by accreditedGet energy audits conducted by accredited energy auditorsenergy auditors Implement techno-economic viableImplement techno-economic viable recommendationsrecommendations Comply with norms of specific energyComply with norms of specific energy consumption fixedconsumption fixed Submit report on steps takenSubmit report on steps taken 22
- 23. 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 above 23
- 24. 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
- 25. PERIOD STEAM PRESSURE& TEMPERATURE UNIT SIZE (MW) TURBINE Heat Rate (Kcal/kWh) Unit Heat Rate (Kcal/kWh)/ Efficiency 1951-60 60 kg/cm2 , 482o C 30 – 57.5 2470 1961-75 70 kg/cm2 , 496o C to 90 ata 538o C 60 – 100 2370 1961-75 130 ata 535/535o C 110 – 120 2170 – 2060 2552-2423 1977-82 130 ata 535/535o C 210 (Russian) 2060 2423/ 35.4% 1983+ 150 ata 535/535o C 210 (Siemens) 2024 2335 36.8% 1984+ 170 ata 535/535o C 500 1950 (TDBFP) 2294 37.4% 1990+ 150 ata 535/535o C 170 ata 538/538 o C 210/ 250 250/ 500 1950 (MDBFP) 1950 (TDBFP) 2294 2294 THIS CHART SHOWS THE GRADUAL IMPROVEMENT IN HEAT RATE TO ACHIEVE ECONOMY 25
- 26. 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
- 27. 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
- 28. MAJOR CAUSE OF INEFFICENCY INMAJOR 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
- 29. 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
- 30. HOW TO ACHIEVE ENERGYHOW 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
- 31. CAN WE IMPROVECAN 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
- 32. 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
- 33. 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
- 34. 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
- 35. SYNERGIZE OPERATION OF UNIT Need to clearly understand the relation between performance & fuel, operation and design parameters Operational behavior and performance Impacts of operating efficiency of Boiler, Turbine and their auxiliaries on Net Unit Heat Rate Maximum Achievable Load, Maintenance & Availability 35
- 36. 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
- 37. 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
- 38. 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
- 39. • 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 system Air Heater Fans Electrostatic Precipitator Fly ash handling system Bottom ash handling system Waste disposal system BEHAVIOURAL IMPACTS 39
- 40. 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
- 41. CRITICAL FACTORS AFFECTING CYCLE PERFORMANCE 1. Re-heater & its system pressure drop 2. Extraction line pressure drop 3. Make up 4. Turbine exhaust pressure 5. Air preheat 6. Condensate sub-cooling 7. S/H & R/H spray flows 8. Wet Bulb Temp 9. Top Heaters out of service 10. H.P. heater drain pump 11. Type of BFP drives & method of flow control 41
- 42. 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
- 43. 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
- 44. 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
- 45. 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
- 46. 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
- 47. 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
- 48. 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
- 49. 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
- 50. 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
- 51. 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
- 52. 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
- 53. 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 I2 R 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
- 54. 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
- 55. 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
- 56. 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
- 57. Boiler Scheme 57
- 58. 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
- 59. 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
- 60. 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
- 61. 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 out let 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
- 62. 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
- 63. 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
- 64. 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
- 65. 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
- 66. 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
- 67. 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
- 68. 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
- 69. COAL DATA • Design coal parameter • Moisture :_____% • Ash :_____% • Volatile matter :_____% • Fixed carbon :______% • HGI :_____% 69
- 70. 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
- 71. 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
- 72. • 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
- 73. 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
- 74. 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) 74
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