AS RUN ENERGY EFFICIENCY ASSESSMENT OF HEAT RECOVERY STEAM GENERATORS &TURBINES

• TO ASSESS THE AS RUN PERFORMANCE OF HEAT RECOVERY STEAM GENERATORS

TOWARDS MAINT.PLG. AND UPKEEP

OBJECTIVE:

• G.T. AND S.T . OUTPUT MW

• Flue Gas TEMP AT HPSH INLET& OUTLET

• Flue Gas TEMP AT HP ECONOMISER INLET& OUTLET

• Flue Gas TEMP AT LPSH INLET& OUTLET

• Flue Gas TEMP AT LP ECONOMISER INLET& OUTLET

• Flue Gas TEMP AT LP EVAPORATOR INLET & OUTLET

• Flue Gas TEMP AT COND.PREHEATER INLET& OUTLET

• FEED WATER FLOW AND TEMP.

• PRESSURE & SUPER HEAT AT LP SUPER HEATER

AS RUN MEASUREMENTS INVOLVED:

HEAT RECOVERY STEAM GENERATORS(Illustrative as run values)

1. G.T.OUTPUT MW 89.622. S.T.OUTPUT MW 104.713. H.P.STEAM FLOW TPH 161.004. L.P. STEAM FLOW TPH 37.625. H.P. STEAM PRESSURE BAR 64.756. L.P. STEAM PRESSURE BAR 5.117. H.P.SUPER HEATER TEMP.oC 517.008. H.P.SUPER HEATER STEAM 827.00

ENTHALPY kCal/kg9. H.P. SATURATED STEAM 663.70

ENTHALPY kCal/kg10. Flue Gas TEMP. HP SUPER HTR. 527.00

INLET oC11. Flue Gas TEMP TO HPSH OUT 435/45112. HEAT PICK-UP IN HPSH 26.291

(MkCal/hr) Item 3*103(Item 8 - Item 9)

S.No. ITEM REFERENCE VALUE

HRSG PERFORMANCE FEATURES(Illustrative as run values)

13. Flue Gas TEMP. AT HP EVAP. 435/451INLET oC

14. Flue Gas TEMP. AT HP EVAP. 290/291OUTLET oC

15. ECONOMISER-2 OUT WATER 280.90ENTHALPY

16. HEAT PICK-UP IN H.P. 61.63EVAPORATOR(MkCal/hr) Item 3*103(Item 9 - Item 15)

17. Flue Gas TEMP @ HP ECON.-2 290/291 INLET oC

18. FG TEMP @ HP ECON.-2 225.00 OUTLET oC

19. WATER TEMP & ENTHALPY 106.90 @ HP ECON.1 INLET

20. HEAT PICK-UP IN H.P. 28.01ECONOMISERS-1 &2(MkCal/hr) Item 3*103(Item 15 - Item 19)

S.No. ITEM REFERENCE VALUE

HRSG PERFORMANCE FEATURES((Illustrative as run values))

21. FG TEMP. AT LP SUPER HTR. 225.00INLET O C

22. FG TEMP. AT LP SUPER HTR. 224.00OUTLET o C

23. LP SUPER HTR. TEMP.O C 197.20

24. ENTHALPY OF LP SUPER 680.00HEATER STEAM (kCal/kg)

25. ENTHALPY OF LP SATURATED 650.50HEATER STEAM (kCal/kg)

26. HEAT PICKUP IN LP SUPER 0.889HEATER ( MkCal/hr)item-4 * 103 (Item-24-Item-25)

S.No. ITEM REFERENCE VALUE

HRSG PERFORMANCE FEATURES(Illustrative as run values)

27. Fl.Gas TEMP. AT LP EVAP. 224.00

INLET oC

28. Fl.Gas TEMP. AT LP EVAP. 169.00OUTLET oC

29. F.WATER ENTHALPY AT 160.70EVAP. INLET kCal/kg

30. H. PICK-UP IN L.P. 18.727EVAP (Mkcal/hr) Item 4*103(Item 25 - Item 29)

S.No. ITEM REFERENCE VALUE

HRSG PERFORMANCE FEATURES(Illustrative as run values)

31. FG TEMP. AT LP/HP1 169/169ECONOMISER INLET oC

32. FG TEMP. AT LP/HP1 120/133ECONOMISER OUTLET oC

33. FG TEMP. AT LP ECONOMISER 104.60INLET oC

34. HEAT PICK-UP IN L.P. 0.889ECONOMISER-1(Mill.kcal/hr) (Item 4*103(Item 29 - Item 33)

S.No. ITEM REFERENCE VALUE

HRSG PERFORMANCE FEATURES(Illustrative as run values)

35. FG TEMP. AT CONDENSATE 120/133PRE HEATER INLET oC

36. FG TEMP. AT CONDENSATE 105.00PRE HEATER OUTLET oC

37. FLOW THROUGH CONDENSATE 190.62PRE HEATER TPH (Item3-Item4)

38. FW TEMP. AT CONDENSATE 47.00PRE HEATER INLET OC

39. FW TEMP. AT CONDENSATE 94.10PRE HEATER OUTLET OC

40. HEAT PICKUP IN 9.355 CONDENSATE PREHEATER (MkCal/hour)

41. TOTAL HEAT PICKUP BY 47.00HRSG BY WATER & STEAM CIRCUIT (MkCal/hr)

S.No. ITEM REFERENCE VALUE

BREAK UP OF HEAT PICKUP IN VARIOUSHEAT TRANSFER SURFACES

1. PERCENTAGE BREAKUP OF HEAT PICKUP IN VARIOUS HEAT TRANSFER SURFACES:

A. HP SUPER HEATER 17.89B. HP EVAP. 41.95C. HP ECON. 1&2 19.06D. LP SUPER HEATER 8.55E. LP EVAP. 12.74F. LP ECON. 1.42G. CONDENSATE PREHEATER 6.36

2. AMBIENT AIR TEMP. OC 29.00 3. THERMAL EFFY. OF HRSG 84.43 (Item10 - Item36/

(Item10 - Item43)*100Comparing the above as run values with design data Would serve as an audit and diagnostics tool for Improvements.

S.No. ITEM REFERENCE VALUE

COMB.CYCLE STEAM TURBINES

• TO ASSESS THE AS RUN PERFORMANCE AND EFFICIENCY OF STEAM TURBINE SYSTEMS

• HRSG HP SUPER HEATED STEAM FLOW TO TURBINE IN MT/HR

• HRSG LP SUPER HEATED STEAM FLOW TO TURBINE IN MT/HR

• HP STEAM PRESSURE IN BAR

• LP STEAM PRESSURE IN BAR

• HP SUPER HEATED STEAM TEMPERATURE IN OC

• LP SUPERHEATED STEAM TEMPERATURE IN OC

• CONDENSER VACUUM (MILLI BAR)

• STEAM TURBINE GENERATOR ACTIVE POWERIN MW

• DRYNESS FRACTION OF TURBINE EXHAUST : ESTIMATED AS WARRANTED

OBJECTIVE

AS RUN MEASUREMENTS INVOLVED:

STEAM TURBINE PERFORMANCE ASSESSMENT ILLUSTRATIVE

CALCULATION 1) Trial Duration : (As run Sample Reference)

2) HP Steam Flow : 350.26 TPH

3) HP Steam Pressure & Temperature

: 65.44 bar, 518 oC

4) HP Steam Enthalpy kJ/KG

: 3459.50

5) LP Steam Flow in TPH : 79.58 TPH

6) LP Steam Pressure & Temperature

: 4.35 bar, 194.2 oC

7) LP Steam Enthalpy kJ/KG

: 2842.40

8) Condenser Vacuum m bar

: 93.50

9) Condenser Saturated Temperature & Enthalpy

: 44.5 oC and 186

10) Exhaust Steam Enthalpy for 0.82 Dryness Fraction in kJ/KG

: 2144.20

11) Condensate Enthalpy kJ/KG

: 186.0

12) Heat Input to Steam Turbine 1000 * kJ/Hr.

: [(Total HP Steam Flow in TPH) * (HP Steam Enthalpy – LP Exhaust Enthalpy) + (Total LP Steam Enthalpy - LP Exhaust Enthalpy)]

: [(Item 2)(Item 4 - Item 10) + (Item 5) (Item 7 - Item 10)]

: (350.26)(3459.5 - 2144.2) + (79.58)(2842.40 - 2144.2)

: 460696.97 + 55562.76

: 516259.73 13) Theoretical Heat Input

to Turbine in MW :

3600 * 1000KJ/HR in Turbine toInput Heat

: Item 12/3600

: 143.40

14) Actual Generator Output (MW)

: 112.43

15) Turbine + Generator Efficiency

: Generator Output/Turbine Input

: Item 14 / Item 13

: 78.40%

1 6 ) T u r b i n e H e a t I n p u t w i t hR e f e r e n c e t oc o n d e n s a t e E n t h a l p y( 1 0 0 0 * k J / H r )

: [ ( T o t a l H P S t e a m F l o w i n T P H )* ( H e a t S t e a m E n t h a l p y -C o n d e n s a t e E n t h a l p y ) + ( t o t a lL P S t e a m F l o w i n T P H ) * ( L PS t e a m E n t h a l p y - C o n d e n s a t eE n t h a l p y ) ]

: [ ( I t e m 2 ) ( I t e m 4 - I t e m 1 1 ) +( I t e m 5 ) ( I t e m 7 - I t e m 1 1 ) ]

: [ ( 3 5 0 . 2 6 ) ( 3 4 5 9 . 5 - 1 8 6 ) +( 7 9 . 5 8 ) ( 2 8 4 2 . 4 - 1 8 6 ) ]

: 1 1 4 6 5 7 6 . 1 0 + 2 1 1 3 9 6 . 3 0

: 1 3 5 7 9 7 2 . 4 0

1 7 ) F e e d W a t e r a n d S t e a mT u r b i n e S y s t e m H e a tR a t e i n K c a l / k W h

: ( T u r b i n e H e a t I n p u t w . r . t .c o n d e n s a t e E n t h a l p y i nK c a l ) / ( T G O u t p u t i n k W h )

: ( I t e m 1 6 ) / 4 . 1 8 * 1 / ( I t e m 1 4 )

: 2 8 8 9 . 5 6 K c a l / k W h

1 8 ) T G O u t p u t a s % o f 1 0 0 %B a s e L o a d R a t i n g

:115.69

100 * (112.43)115.69

100 * 14) (Item

: 9 7 . 1 8 %