management of thermal pppp

8/14/2019 Management of Thermal PPPP

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Learning Agenda Identification and analysis of input parameters as;

Uncontrollable

Semi-controllable

Controllable Managerial aspect of thermal power plant performance

parameters Estimation of energy efficiency parameters i.e. boiler

efficiency, THR, UHR and SHR

Determination of inevitable effect on performanceparameters under design specified operating parameters

Preparation of guidance message to the input materialmanagers and operation managers


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NeedPerformance of Indian Thermal Power Units hasbeen very poor due to;

Wide variation in input (fuel, air and water)parameters than that of the design

Inadequate appreciation and understanding ofsuitably modifying/changing the operatingparameters to accommodate the uncontrollableinput parameters

Lack of managerial will to prioritize performanceparameters in sequence of human safety,equipments life, energy/exergy efficiency andavailability.


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Need

The needexisted; To analyze the variation in input parameters and their

adverse effect on thermal power plant performance

parameters and to modify operating parameters of variouspower plant process equipments to minimize the adverseeffect on performance parameters

To promote performance management system to keepvigil over cause and effect relationship of all processes at

micro level for the achievement of most optimized valuesof performance control parameters even when inputparameters are significantly different from the designprescribed values


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Objective and Issues Involved

Objective of the study is based on basic issues of

national growth, advancement of status of the

citizens, internal / external security, safety of men

/ material and environmental protection, which

depends upon electricity at large

Quality power to all at competitive price


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ObjectiveTo manage most optimized values of thermal

power plant operating parameters in accordance

with variation in uncontrollable input parameters,

which control; Electricity availability parameters

Energy efficiency parameters

Equipments life parameters Human safety (pollution) parameters


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Issues Involved

Large population and population growth

High National economic growth rate

Growing electricity demand and gap

between the demand and supply

Increasing coal and electricity tariff

Life deterioration of the power plant

process equipments Safety of the power personnel

Environmental protection


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Efforts Rely Upon

Fundamental research, renovation, modernization,retrofitting etc of the process equipments

True representative sample analysis Accuracy of the measurements Process superiority of the equipments Proper site selection, plant layout, engineering,

procurement, construction, commissioning andtesting Awareness of design specified standards of

operation and maintenance practices


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GapsOptimization centered integrated approach of managing

operating parameters to accommodate wide variation of

uncontrollable input parameters to minimize adverse effect on

Overall Efficiency,

Equipments Life and

Environmental Pollution

has not been adopted, which is essential for maintaining thedesired standards of performance parameters.


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Utility of Latest Advancement

Fundamental research, renovation and

modernization of the coal based thermal power

plant process equipments is required to be utilized

in integrated approach of improvement in overall

performance of the plant


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Compressed Air Flow Model


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Thermal Power Plant Flow Synthesis

Combustion Air Flow Model


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DM Make Up Water Flow Model

FEED LINE AFTER F.C.S.TO FILL ECONOMIZER

WATER WALL DRAIN HEADER TO FILL EVAPORATORAND DRUM

Figure 3.6 - De-Mineralized Make Up Water Flow Model


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Feed Water Flow Model


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Steam Expansion Model


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Electricity Generating Model


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Dynamic Modeling of TPPPP

1. Primary Air Flow System2. Secondary Air Flow System

3. Coal flow System

4. Coal and Primary Air Flow System

5. Fuel Air Supply System (Coal Burners, SADC and Furnace)6. Drum Model (Coal Combustion and steam generation)

7. Flue Gas Exhaust Temperature (FGET) Regulating System

8. Condenser Flow system

9. Feed water heating system

10. Expansion of Steam through Turbine

11. Electricity Generation System

12. Integrate Grand Model of TPPPP


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Dynamic Modeling of Thermal Power Plant Process Parameters

Primary Air Flow Model


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Secondary Air Flow Parameters


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Coal Flow Model


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Coal and Primary Air Flow Systems


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Drum Level Control


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Flue Gas Exhaust Temperature Model


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Electricity Generation Systems


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Performance Parameters

Availability Parameters

Efficiency Parameters

Equipments Life Parameters

Human Safety Parameters


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Availability Parameters

Availability Factor

Plant Load Factor


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Efficiency Parameters

Boiler Efficiency

Turbine Heat Rate

Unit Heat Rate

Station Heat Rate


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Equipments Life Parameters

Pre Combustion Parameter

Combustion Parameters

Post Combustion Parameters

Steam quality parameters Condenser Parameters

Turbo Supervisory Parameters

Generator Parameters

Tube Erosion ParametersParticle Trajectories

Particle-Tube Impact Frequency

Impact Velocity and Impingement Angle


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Human Safety Parameters

Air pollution parameters

NOx, SOx and SPM Water pollution

Noise pollution


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Estimation of Energy Efficiency Parameters

Boiler Efficiency (Direct and Indirect method)

Turbo Alternator Heat Rate

Turbo Alternator Efficiency

Unit Heat Rate

Station Heat Rate


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Energy Efficiency of the Boiler

(Qc*CV+Hcredit)

Qms*(Hms-hfw)+Qrh*(Hhrh-Hcrh)

Boiler Efficiency by Direct Method

b =


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Energy efficiency of the Boiler

Boiler Efficiency by Indirect Method

i.e. by the assessment of losses

b = 100 Total % Losses


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Boiler Efficiency by Assessment of Losses

DFL =W * Cpg * (T t)W = (C/100+S/267-CinAsh)*100/12(CO2+CO) KgMol/Kg Coal

WFGL=[1.88*(T-25)+2442+4.2*(25t)]*(Mc+9H)/100 KJ/Kg coal

CinAshL=C in A * 33,820 KJ/kg Coal

UGL=23,717*(C/100+S/267-inAsh)*CO/12(CO2+CO)KJ/kgCoal

MainAirL= Ma * Hu * Cp * (T-t) KJ/Kg Coasl

SHinAshL= FlyAsh*Cpfa*(Tt)+BottomAsh*Cpba*(Tf-t) KJ/KgCShinRejectL= Qmr*Cpr*(Tc+a-t)

R&UA/CL (B in KJ/Kg Coal) Log10 B = 0.8167 - 0.4238 log10 C


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Energy Efficiency of the Turbine

Turbo Alternator Heat Rate

THR = (Qms*(Hms-hfw)+Qrh*(Hhrh-Hcrh))/MWExpressed in KJ/KWHrn or in KCal/KWHr

THR = 3600/ ta in KJ/KWHr

THR = 860/ ta in KCal/KWHr


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Energy Efficiency of the Turbine

UNIT HEAT RATE

UHR = (THR in KJ/KWHr)/b

UHR = QC*CVC/MW in KJ/KWHr


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Energy efficiency of the Turbine

STATION HEAT RATE

SHR = Qct*CV/MWt

SHR = 100*Qct*CV/(MWt*(100-%APC))

SHR = UHR*100/(100-%APC)


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Condenser Vacuum Management

Effects of cooling water inlet temperature

The primary one is to alter the steam saturation

temperature by the same amount as the change.

The secondary effect is caused by the fact that the heattransfer of the cooling water film in contact with condenser

tubes change with temperature of the water.

The primary and secondary changes are in opposite

direction. The magnitude of the secondary effect isapproximately equal to the fourth root of the mean cooling

water temperature.


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Cooling Water FlowThe primary effect of a change of cooling water flow is to

alter its temperature rise. The secondary effect, which

operates in the same direction as the primary, results

from the change of heat transfer rate, due to the

changed thickness of the cooling water boundary film. It

is approximately proportional to the square root of the

flow


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Change in Heat Transfer

Level in Condenser Hot Well

Steam Flow Internal/External Tube Deposits


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Effect of Load on Condenser Vacuum)

42.543

43.544

44.5

4545.5

4646.5

47

47.548

43568

44439

45328

46234

47159

48102

43568

42696

41842

41005

40185

39382

Qs (Steam Flow)

T

s(SaturationTem

Series2


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Steam Ejectors / Vacuum Pumps

Mal operation of vacuum pump and steam ejectorsreduce vacuum. Starting ejector creates vacuum up to

540 mmHgCl, 10 to 30 minutes after, the main ejectorshould be cut into service followed by immediatewithdrawal of starting ejector. Parallel operation ofboth the ejector shall not only develop the lesservacuum but also damage the main ejector. Vacuumpump has auto change over from starting to main andnormally run satisfactory


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Performance ParametersDe superheating = T-Ts

Sub cooling = Ts-td

LMTD = (t2-t1)/ln((Ts-t1)/(Ts-t2))Temperature rise = t2-t1

TTD =Ts-t2 is high because of;Higher gaseous impurities

Air ingressExternal tube deposits

Internal tube deposits


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Feed Water Temperature Management

Feed water heating system is consisted of two main

ejectors, two gland coolers, four low pressure

heaters, one direct contact deaerator and three high

pressure heaters Feed water temperature at the outlet of the last high

pressure heater is a very important efficiency control

parameter, which should be optimally half of the

main steam temperature


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Feed water heaters problems and solutions Gaseous impurities in the steam can be managed by better

management of boiler and pre-boiler system Vapour line of each heater plays vital role in maintaining the

design prescribed value of saturation temperature and alsokeep terminal temperature difference in acceptable operatingrange.

External tube deposits can gradually increase terminaltemperature difference which needs better de mineralizedwater quality management

Internal tube deposits can be effectively minimized by on-linecondensate polishing/treatment to maintain terminaltemperature difference and condensate/feed waterdifferential pressure across the heater


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Deaerator is the only direct contact heat exchanger andremaining ten heaters of regenerative feed heating systemare indirect contact type, major portion of which function likea condenser and hence required to be managed in similarmanner discussed for condenser.

Both end portions of the each heater perform separatefunctions, one at the high temperature end works as desuper heater and the other at low temperature end works like

a sub cooler. De super heating and sub cooling in theheaters are exergetically undesirable and hence attemptsshould be made to minimize the both


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Excess Air Management

Oxygen in flue gas represents the excess air over

and above the theoretical air, which is

proportionate to coal combustibles but Excess Air

requirement increases with increasing coalimpurities


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Management of Oxygen in Flue Gas

Theoretical Air

=4.31*[8*C/3 + 8*(H-O/8) +S] Kg/Kg Coal --- (1)

Excess Air

=[(TheoreticalCO2%/ActualCO2%)-1]*100%-(2)

Excess Air=(O2%*100)/(21-O2%)-----------------------------

(3)


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Shortcomings of the Existing Practice- Unlike theoretical air, no coal parameter is

incorporated and hence it does not give any

guidance message to operator for suitable changein excess air supply on the basis of coal quality

parameters.

- Accurately estimated O2% in flue gas for aparticular coal may not be valid for a coal

different in rank, petrology and composition.


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Shortcomings of the Existing Practice- Excess air calculated by using both the above

referred equations, is the information of excess air

that had been supplied rather than would besupplied for a particular coal.

- Information of O2 % at the outlet of boiler does not

provide reliable guidance message to forceddraught fan operator to supply accurate quantity of

air due to time lag and slow combustion response.


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Existing method of maintaining a fixed or an

arbitrary percentage of oxygen % in flue gas leads

to either

Over supplyor

Under supply

of excess air particularly in case of wide variation in

coal quality than that of the design.


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Alternative Method of Excess Air Estimation Excess Air

=K1*FC-K2*VM+K3*M+K4*A**2+K5--------(4)

Excess Air

=K1*C-K2*(5H+3*O/8+S+N)+K3*M+K4*A**2+K5--(5)

Excess Air

=k1*I-k2*V-k3*E+k4*M+k5*A**2+k6---------(6)


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Assumptions for Applying New Method Impact of Hard Grove Index (HGI), Moisture and Ash

on pulverizer capacity and fineness is taken caresuitably as per the pulverizer condition curves.

Pulverizer discharge valve orifices are healthyenough to ensure equal flow to all the four burners atthe same elevation.

Burner tips and tilting mechanism is not out of

synchronism All the fuel air dampers and auxiliary dampers are

healthy enough to follow the operating signals asspecified


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Assumptions for Applying New Method No leakage of air anywhere in the air and flue gas

path.

Proper functioning of the furnace safeguardsupervisory system (FSSS) ID, FD & PA Fans are healthy enough to maintain

Furnace vacuum, Furnace differential pressure, Windbox pressure, Hot P.A. header pressure

ID, FD & PA Fans have sufficient extra capacity(above MCR)


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Test of Equations Have been carried out for large numbers of the

coal samples, a good numbers of which werecollected from different thermal power stations for

the purpose of calculating the excess air. The coalparameters of actual samples vary randomly andhence leading to the same kind of variation incalculated excess air.

Large numbers of coal samples were simulatedby gradually varying the coal parameters so thatthe results can be presented into an user friendlysimple graphics.


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Estimated excess air is converted into to equivalent amount ofO2 % in flue gas, because there is no practice of maintainingexcess air as operating parameters. Graphs are plotted forguidance of forced draught fan operator to maintain required

oxygen percentage in flue gas on the basis of variation in coalparameters.

Coal samples from leading Indian thermal power stations areplaced in ascending order of calorific value along with other

proximate/ultimate parameters and estimated excess air (O2% in flue gas) graphically represented for estimating theexcess air (O2 % in flue gas) by the forced draught fanoperator. A large numbers of simulated coal samples arealso considered in similar manner


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Fig. 4 - Effect of Coal Parameter (Proximate Analysis) on Excess Air (O2% in Flue gas)

0

0.1

0.2

0.3

0.4

0.5

0.6

1 4 7 10 13 16 19 22 25 28 31

Ash Kg/Kg coal

Moisture Kg/Kg coal

Oxygen % in FG / 5 (E.7)

CV in KJ/Kg coal / 40000

Volatile Matter Kg/Kg coal

Fixed Carbon Kg/Kg coal


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Fig. 3 - Effect of Coal Parameter (Ultimate

Analysis) on Excess Air (O2% in Flue gas)

0

0.1

0.2

0.3

0.4

0.5

0.6

1 4 7 10 13 16 19 22 25 28 31

Carbon Kg/Kg of coal

Hydrogen Kg/Kg coal

Oxygen Kg/Kg coal

Nitrogen Kg/Kg coal

Sulfur Kg/Kg coal

Ash Kg/Kg coal

Moisture Kg/Kg coal




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Fig. 5 - Effect of Coal Parameter (Proximate Analysis) on Excess Air (O2% in Flue

gas)

0

0.1

0.2

0.3

0.4

0.5

0.6

1 4 7 10 13 16 19 22 25 28

Ash Kg/Kg coal

Moisture Kg/Kg coal


CV in K.J./Kg coal / 40000




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Fig, 8 - Effect of Coal Parameter (Ultimate


0

0.1

0.2

0.3

0.4

0.5

0.6

1 4 7 10 13 16 19 22 25 28 31


Hydrogen Kg/Kg coal

Oxygen Kg/Kg coal

Nitrogen Kg/Kg coal

Sulfur Kg/Kg coal

Ash Kg/Kg coal

Moisture Kg/Kg coal



Operational Feasibility Analysis of the Proposals


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Fig. 9 - Effect of Coal Parameter (Proximate Analysis) on Excess Air (O2% in Flue gas)

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1 4 7 10 13 16 19 22 25 28 31

Ash Kg/Kg coal

Moisture Kg/Kg coal







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p y y p



Analysis ) on Excess Air (O2% in Flue gas)

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31

Carbon Kg/Kg of coalHydrogen Kg/Kg coal

Oxygen Kg/Kg coal

Nitrogen Kg/Kg coal

Sulfur Kg/Kg coal

Ash Kg/Kg coal

Moisture Kg/Kg coal

Oxygen %in FG / 5 (E.8)

CV in KJ /Kg coal / 40000


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p y y p




0

0.2

0.4

0.6

0.8

1

1.2

1.4

1 4 7 10 13 16 19 22 25 28 31


Hydrogen Kg/Kg coal

Oxygen Kg/Kg coal

Nitrogen Kg/Kg coal

Sulfur Kg/Kg coal

Ash Kg/Kg coal

Moisture Kg/Kg coal





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Fig. 13 - Effect of Coal Parameter (Proximate Analysis) on Excess Air(O2% in Flue gas)

0

0.2

0.4

0.6

0.8

1

1.2

1 4 7 10 13 16 19 22 25 28 31

ash kg/kg Coal

Most kg/kg Coal

Oxygn % in FG/5 (E.7)

CVcoal KJ/Kg/ 40000

VM kg/kg Coal

FC kg/kg Coal




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g yg

Effect of Ultimate Parameter on Excess Air (O2% in Flue gas)

0

0.2

0.4

0.6

0.8

1

1.2

1 4 7 10 13 16 19 22 25 28 31

Crbn kg/kg Coal

Hdgn kg/kg Coal

Oxgn kg/kg Coal

Ntgn kg/kg Coal

Slfr kg/kg Coal

ash kg/kg Coal

Most kg/kg Coal

Oxygn % in FG/5 (E.8)

CVcoal KJ/Kg/ 40000



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Variation in CV due to combustibles lead to the proportionate changes in

theoretical air but excess air requirement changes indifferently dependingupon quantities of impurities (oxygen, nitrogen, sulfur, moisture and ash)in coal and their combustion behavior .

Proposed excess air is leading to a value of oxygen in flue gas near to theconventional value (i.e. 4%) in many cases, which are operating at or near

to the design coal parameters. Excess air (O2 % in flue gas) requirement is increasing tremendously for

poor coals with higher ash content. Excess air (O2 % in flue gas) is too low for superior coals specifically with

high volatile matter and low ash content.



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Limitations of New Method of Excess Air Estimation Proposal of increasing excess air leads complete combustion of poor coal but may

increase dry flue gas loss than the reduction in combustible loss. In such cases,minimum total of combustible loss and dry flue gas loss shall decide the optimizedquantity of excess air rather than formula under reference.

Even this may leads to total flue gas volume, which may be higher enough to

cross limits of critical velocity and exponentially increases the flue gas erosion. Inthis situation load has to be reduced in place of reducing the optimized air. Loadreduction cannot be more than 65% for very poor coal and supplementary fuel oilor gas has to be used to minimize loss of boiler life and efficiency.


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Management of Flue Gas Exhaust Temperature

Flue gas exhaust temperature rise from 18 deg C to 20 degC causes 1% loss of boiler efficiency for higher ash coal to

the moderate ash coal respectively


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0

5

10

15

20

80

90

100

110

120

130

140

150

160

170

180

190

Flue Gas Temperature in deg. C

Lossesin

Dry Gas

Loss %

Wet Flue

Gas Loss %

Moisture In

Combustion

Loss %

Boiler

Losses %



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78

80

82

8486

88

90

80 90 100

110

120

130

140

150

160

170

180

190

Flu Gas Temperature in deg. C

Blr.

Effic

ien


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Flue Gas Exhaust Temperature Management

Boiler Input System

Combustion air flow system

Coal & fuel oil flow system

Flue gas flow system

Water/steam flow system


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Combustion Air Flow System

Accurate assessment and correct distribution of

combustion air solve many of the steam generators

problems


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Coal Flow System

Unit coal flow system Bunkers

Feeders

Coal burners Pulverizes

Primary air fans,

Hot and cold primary air ducts

Air pre heaters


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Coal Flow System

Coal input parameter Fixed Carbon

Volatile Matter

Ash

Moisture

Hard groove index

Coal flow


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Coal Flow System

Operating parameters Hot primary air flow Hot primary air pressure Hot primary air temperature Pulverized coal fineness

Temperature of the coal air mixture Coal flow Raw coal feeder speed Mill differential pressure Coal/air mixture pressure drop from mill outlet to burner


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Coal Flow System

Coal supply limits Fan power limit Pulverized coal fall out limit Pulverized coal pipe erosion limit Mill outlet temperature limit

Mill power limit Maximum coal flow limit Grinding, drying & pulverized coal fineness stability limit Air/coal ratio explosion limit



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Coal Flow System

Notable Features of the Coal Flow System Design specified quantity of the hot primary air is decided to be

adequate to dry maximum possible moisture in the coal. Relatively

lesser percentage of actual moisture in coal than that of the design

is accommodated by mixing cold primary air also known to be

tempering air Mill constraints drawn on airflow versus coal flow graph left very

small space for mill operation, known as mill operating window


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Flue Gas Flow System

System Equipments SADC & Burners

Mills, Boiler Fans and APH

Flame Scanners and Soot Blowers

Evaporator, SH, RH and Economizer

Boiler Drum


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System Parameters Parameters of input Fuel and Air Wind box to furnace differential pressure Mill to furnace differential pressure Furnace vacuum Burner tilt (n-2) coal elevations out of n Differential pressure and temperature of the flue gas across WW,

PSH, RH, FSH, LTSH Eco, APH & ESP Fire Ball Position




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y

Control of Soot Deposits Frequent soot blowing with designed steam pressure and temperature

can keep the tubes clean to improve the heat transfer. Long retractable soot blowers do not function satisfactorily and causing

lot of soot deposition on platen super heater, re-heater, final superheater, low temperature super heater and economizer.

Air pre heater soot blowing also should be managed well because itschoking results in reduced heat transfer and higher flue gas exhaust

temperature. Air pre heater seals are also very important and must bemaintained.



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Control of Acid DepositionFlue gas exhaust temperature can be optimally reducedto avoid occurrence of flue gas dew point temperature.Reduction of flue gas exhaust temper shall be lower for

lower flue gas dew point temperature and high ambienttemperature. High ash content of the coal neutralizes theacidic effect due to its alkalinity and lead to a lower fluegas dew point temperature.



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SPM Control in Flue GasElectro static precipitator reduces the suspended

particulate matter up to the extent of 150 mg/NM3,

higher fly ash erode the induced draught fan impeller

very severely and makes it quite difficult to maintain thedifferential pressure across the various heat exchangers

of the steam generators.



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Water / Steam Flow System

Heat released in coal combustion is utilized in converting pressurized water intosuperheated steam. Heat is absorbed as

Sensible heat of water in economizer, Latent heat of steam in water walls and Sensible heat of steam in SH/RH.

Design specified parameters of flue gas and water / steam across various heat

exchangers lead to a constant ratio of heat absorption in them. Variation inairflow, coal flow and flue gas flow parameters vary the water / steam flowparameters which lead to change in heat absorption ratio


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Heat Balance Equation for the Boiler

Heat given by flue gas = heat taken by water/steam

Qc*CVc - Losses = Qms (Hms-hw) + Qrh (Hhrh Hcrm)

Qfg*Cpfg*(Tf -Teco) = Qms*(Hmshw) + Qrh (Hhrh Hcrh)


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Detailed Heat Balance

Qfg*Cpfg*[ (Tf-Tpsh) + (Tpsh-Trh) + (Trh-Tfsh)

+ (Tfsh-Tltsh) + (Tltsh-Teco) + (Teco-Taph) ]

= Qw*S*(tfwotfwi) + Qw*S*(Ts tfwo) + Qms*L

+ Qms*Cps*(TmsTs) + Qcrh* Cps* (ThrhTcrh)

I1+I2+I3+I4+ I5+I6 = F1+F2+F3+F4


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Management of Equipments Life Parameters

Erosion


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High velocity fluid streams with suspended solid impurities erode heat exchanger inthermal plants ranging from condenser to boiler. On average, the erosion wear is

proportional to the impact velocity of the particles to the power 2.5. In general theextent of surface erosion by impingement of abrasive particles depends upon thefollowing factors.

System operation conditions (such as particle impinging velocity, impact angle,particle number density at impact, properties of the carrier fluid).

Nature of target tube material (such as material properties, tube orientation and

curvature, and surface condition) The properties of impinging particles (such as particle type and grade, mechanical

properties, size and sphericity)



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Erosion

Erosion Control Parameters

Free stream velocity of the fluid (Uo)

Impact velocity (W1)

Frequency of impaction ()

Impingement angle (1)



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Erosion

Boiler Erosion ControlIndian boilers have already suffered an irreparable loss of

life and capacity utilization. Large deviation in coal

parameters from the design specified values, leads to

significant variation in impacting particles properties (grade,size and shape), which erodes external tube surface and

cause the failure much before the expiry of design life time.



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Erosion

Flue Gas Volume

Vfg=Vair+Vm*(H/4+CO/24+M/18+N/28+O/32)*Qc



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Erosion

0

2

4

6

8

10

12

14

16

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31

C% IN C/10

H %

O %

N %

S %

%hike Total vol

HHV KCal/kg/4000



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Erosion

0

0.1

0.2

0.3

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31

Hydrogn Kg/Kg coal

Oxygen Kg/Kg coal

Nitrogn Kg/Kg coal

Sulfur Kg/Kg coal

%total volum Chang/45

Carbon Kg/Kg coal/5



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g q p

Erosion

0

0.1

0.2

0.3

0.4

0.5

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29

Hydrogn Kg/Kg coal

Oxygen Kg/Kg coal

Nitrogn Kg/Kg coal

Sulfur Kg/Kg coal


Carbon Kg/Kg coal/5



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g q p

Erosion

0

0.1

0.2

0.3

0.4

0.5

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31

Hydrogn Kg/Kg coal

Oxygen Kg/Kg coal

Nitrogn Kg/Kg coal

Sulfur Kg/Kg coal

%total volum

Chang/10



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g q p

Erosion

0

0.1

0.2

0.3

0.4

0.5

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31

Hydrogn Kg/Kg coal

Oxygen Kg/Kg coal

Nitrogn Kg/Kg coal

Sulfur Kg/Kg coal


Carbon Kg/Kg coal/5



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g q p

Erosion

0

0.1

0.2

0.3

0.4

0.5

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31

Hydrogn Kg/Kg coal

Oxygen Kg/Kg coal

Nitrogn Kg/Kg coal

Sulfur Kg/Kg coal

%total volum

Chang/30Carbon K /K coal/5



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Erosion

0

0.1

0.2

0.3

0.4

0.5

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31

Hydrogn Kg/Kg coal

Oxygen Kg/Kg coal

Nitrogn Kg/Kg coal

Sulfur Kg/Kg coal

%total volumChang/20Carbon Kg/Kg coal/5



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ErosionFree Stream Velocity Control Air flow

Coal flow

Coal fineness

Burner tilt Mill outlet temperature

Secondary air temperature

Combustion temperature



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Erosion

Free Stream Velocity Control Cont. Secondary air damper position Heat absorption Air pressure at outlet of forced draught fan Flue gas pressure drop across the platen super heater, re-heater, final

super heater, low temp super heater, economizer Flue gas temperature drop across platen super heater, re-heater, final

super heater, low temp super heater, economizer


Flue Gas Erosion Abatement Techniques


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Some of the tube erosion parameters such as shape, size grade,

frequency & velocity of the impacting particle, free stream velocity ofthe carrier fluid and surface condition of the tube itself depend upon

various boiler operating and input parameters which can be

improved by;

- Use of beneficiated coal reduces the frequency of impacting

particles. In case of poor coal quality, coal blending and oilsupport also reduce the boiler tube erosion.




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- Flue gas volume is proportional to the volume of the combustion air.

Accurate excess air management is quite essential to keep free stream

velocity well within the erosion limits

- Frequent use of soot blowing keeps the tube surface clean which do not

allow the cross section area to reduce to a value at which free stream

velocity can cross the erosion limits.

- Baffle plates can be used in high speed zone of boiler to keep the flue gas

velocity within the specified ranges.




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- Furnace Vacuum and differential pressures across the wind box,platen super heater, re heater, final super heater and economizeralso influence the impacting particle velocity. Well maintained boilerfans are essential to keep various deferential pressures within thespecified ranges.

- Particle size can be controlled by maintaining pulverizers healthy.Reduced pulverizer capacity operation is essential in case of lowerhard groove index, high ash content, high moisture content of thecoal, and larger particle size or poor fineness at its outlet.

M t f H S f t P t


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Management of Human Safety Parameters

Global warming

Acid rain

Desertification

Ozone layer depletion

Management of Human Safety Parameters


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Air pollution

SOx

NOx

Suspended particulate matter


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Conclusions

Some of the improvement potential parameters have been analyzed and

examined for implementation to reduce the avoidable loss component of

various processes and equipments

Many other parameters, which also influence the thermal power plant

performance, are not included either because of the satisfactory

practices in the power plants or because of the academic limitations of

the work


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Conclusions

Main contribution of the work is related to the assessment of

performance loss of various processes and process equipments due to

variation in input parameters and its distinction, partly as inevitable and

partly as avoidable, which help the power plant performance manager to

focus their full attention to reduce the latter of the two.Some of the contributions are briefly concluded in next slides;

Conclusions

Ambient Air Parameters


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Temperature Humidity

Purity

Influence Air conditioning systems

Air cooled devices

Air handling devices

Conclusions



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Performance loss for A/C systems

Change in air conditioning load on account of ambient airtemperature/ relative humidity up to the acceptable optimumvalues for the men and material inside control volume is

inevitable. Difference between inevitably optimized valuesand pre- decided standard values is avoidable.

Conclusions



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Performance loss of air cooled devices

Huge amount of heat is rejected to the ambient air from cooling water,air cooled electrical/electronic equipments and electromechanicallosses. Temperature, Humidity and Purity influence the functionalperformance of various air cooled devices either because of alteration insensible heat addition to the air or because of reduction in latent heat

addition to the air on account of different values of ambient airtemperature and humidity respectively.

Conclusions




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Difference between the dry bulb temperature and wet bulb temperature,is proportional to the evaporation of the cooling water through wetcooling tower, which in turn proportionately reduces the temperature ofthe cooling water and finally it leads to better condenser vacuum, failingwhich the difference between hot cooling water temperature and ambientair temperature must be high enough to absorb the total heat of coolingwater as the sensible heat of air flowing through the cooling tower and

failing both, loss of vacuum becomes inevitable.


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Conclusions


Few other effects of high ambient air temperature


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Few other effects of high ambient air temperature

High air temperature helps in reducing down the flue gas exhausttemperature by increasing average air pre heater metal temperaturesand delaying the sulfuric acid formation.

High air temperature also helps in maintaining relatively higher values ofhot primary air and secondary air, which leads to better pulverization andcombustion.

Combustion air play vital role at the fire side of the boiler input and

output, positive aspects of the changes increase the prescribedstandards of the performance and reduce the avoidable component ofinefficiency and vice-versa.

Conclusions

Raw Water Parameters


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Deterioration in raw water quality increase the cost of chemical treatment

for drinking, bearing cooling and main working media (de-mineralizedwater).

No such treatment is done for the condenser cooling water and

deteriorates the condenser life by tube erosion and corrosion, which

adversely influence electricity availability and thermal efficiency.

Conclusions



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Loss of Condenser Vacuum

Condenser vacuum is a semi controllable parameter which is limited by

cooling water inlet temperature. Such loss in condenser vacuum is

inevitable and hence its impact has been quantitatively determined so

that managerial efforts of vacuum improvement can be concentrated on

avoidable loss which is equal to actual loss minus the estimated

inevitable


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Conclusions

De Mineralized Water Parameters


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Initial FillingIt is observed that the de mineralized make up water separately filled incondenser hot well, deaerator and boiler drum by using make up waterpump, emergency lift pumps and boiler fill pumps respectively. This bypasses starting facilities of supplying auxiliary steam to last low pressureheater, hydrazine dozing after deaerator. This do not save starting timeand energy as it is claimed but likely to reduce boiler and turbine life dueto improper quality of the boiler feed water.

Conclusions

DM W t /St P t


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DM Water/Steam Parameters

Causes of abnormal water level in the condenser Failure of the auto control valve High steam flow Malfunctioning of the condensate pump Tube failure

Consequences Sub cooling of the condensate increase heat loading High level reduce the heat transfer area for condensation, which results in poor

condenser vacuum low level may lead to the damage of the pump and heaters. Raw water damages the entire DM water and steam circuit in a catastrophic manner

Conclusions

DM W t /St P t


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Condensate SystemExtraction steam flow/pressure/temperature and condensate/feed water

flow/temperature are the uncontrollable parameters and in turn these

make the feed water outlet temperature as the uncontrollable parameter.

A very little control on auxiliary steam flow to the last low pressure

heater for initial heating before the deaerator is rarely utilized, whichleads to loss of life and efficiency

Conclusions

DM W t /St P t


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Proper DeaerationDeaerator is meant for physical deaeration of the feed water and raising

its temperature and pressure to the suction requirement of boiler feed

pump.Hydrazine is injected after the deaerator to reduce the oxygen less than

the minimum displayable value of the instrument provided for.


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Conclusions



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Feed Water Flow to the BoilerControlling device of the boiler feed pumps quickly ensure the sufficient

differential pressure across the feed control station from where actual flow to

the boiler is regulated to maintain the design prescribed water level in the

boiler drum.

Normal drum level represents the thermodynamic stability of the boiler,which is controlled by rate of steam generation and steam flowing out of the

boiler. Steam generation depends upon firing rate and feed water supply.

Conclusions



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Sensible heat addition in economizer

Feed water temperature at the inlet of the economizer must

be more than the flue gas dew point temperature.

And at the outlet of economizer must be sufficiently lowerthan the corresponding flue gas temperature

Conclusions



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EvaporationSteam generation rate in the water walls (evaporator) is controlled byheat absorption at external surface of the tubes and fire ball position.Evaporation abnormalities reflects on drum level, un-stability of whichindicates poor boiler health.

Provision of restricting orifices at the evaporator tubes inlet to ensureequal flow through the tubes help in reducing localized starvation andsubsequent overheating.

Conclusions



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Steam Super Heating and Re Heating

Steam temperature at the outlet of the super heater and re heater should

be maintained without injecting any attemperation by properly controllingthe other parameters, such as burner tilt and selecting the lower

elevation for fuel firing

Conclusions



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Expansion of steam in turbineExpansion of steam through steam turbine must be

monitored in terms of design specified reductions in

temperatures and pressures

Variation in turbo supervisory parameters must beanalyzed for the improvement of running parameters

beginning with steam temperature, pressure and purity.

Conclusions



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Steam Flow Control Flow of steam to the turbine is controlled by turbine governing system in

line with turbo supervisory parameters, generator parameters,condenser vacuum, grid frequency and boiler parameters inclusive ofsteam temperature and pressure.

Normal governing equipments, test equipments, pre emergencyequipments and emergency equipments must be maintained well andkept on auto functioning until there is a dire need to bypass any one ofthem

Conclusions

Coal Flow System Parameters


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Mill Capacity ModulationAsh

Moisture

Hard Groove Index

Fixed carbon

Fineness

Conclusions



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Hot primary air flow regulation

Moisture content in the coal

Hot primary air temperature Cold primary air temperature

Conclusions



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Combustion air flow regulation

Stoichiometric air flow

Excess air flow estmation

Conclusions



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Secondary air flow regulation

= Stoichiometric air + Excess air Primary air


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Conclusions



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Secondary air damper control system play vital role in successfulcombustion, some of which modulate in proportion to the fuel quantityand known as fuel air dampers where as the others are meant formaintaining prescribed differential pressure in between the secondaryair wind box and furnace. Place and direction of secondary air supplyis as valuable as the estimation of correct quantity.

Conclusions



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Role of supplementary fuel firing equipments, monitoring

devices, soot blowers etc play equally important role

combustion management as that of secondary air

dampers, burners, burner tilting mechanism etc.

Conclusions



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Heat transfer from flue gas to the water/steam is influenced by input,output and differential temperatures of both the hot and cold fluid.

External and internal tube deposits or any input/ output variation

destabilize the proportionate heat transfer and cause abnormalities

leading to the loss of boiler life and efficiency.

Air pre heater is the last heat exchanger in the coal combustion flowpath, which extract heat from the minimum temperature and send it back

to the boiler through combustion air


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Recommendations

Recommendations



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Recommendations for air conditioning systems

- 18 deg C, 50-60% RH in winter

- 28 deg C, 50-60% RH in summer

In place of alignment point of 25 deg C, 50% RH or lower value

Woolen cloths in the winter as usual and internal air circulation in thesummer to reduce APC.

Recommendations



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Recommendations for air cooled devicesAmount of air supply has to be increased to increase the totalevaporation up to the most optimized limits and rest of theperformance loss has to be treated as inevitable. Recirculation

flow will also help in avoiding the avoidable component of loss.

Recommendations



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Recommendations for Wet Cooling Towers

It is recommended to install air flow variation system with

cooling tower fan to partially curtail the loss of condenser

vacuum in the situations of high heat and humidity so that the

avoidable component of loss of efficiency due to poorcondenser vacuum can be set aside.

Recommendations



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Recommendations for air handling devices

Low flow high discharge pressure compressors should be

provided with pre cooler and inter cooler to minimize the

avoidable loss where as for high flow, low dischargepressure the loss should accepted as inevitable

Recommendations



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In case of high ambient air temperature, we should

maintain lower flue gas exhaust temperature due to low

FGDPT, which lead to better boiler efficiency.

Recommendations



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Recommendations for Condenser VacuumAfter exhausting all the efforts of cooling water inlet temperatureoptimization, associated inevitable component of the loss of condenservacuum has to be determined. So determined inevitable component isdeducted from the actual loss to determine the avoidable, which is

minimized by increasing cooling water flow, keeping tubes clean,minimizing the air ingress, improving the steam quality and effectivelyutilizing the vacuum creating devices

A paper to this effect was presented in a global conference in 2004 at JMI

Recommendations


High TTD causes and remedial measures;


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High TTD causes and remedial measures; Higher gaseous impurities in the steam can be managed by better

management of boiler and pre-boiler system Air ingress can be avoided by frequent leak detection test and effective

steam sealing of low pressure turbine. External tube deposits can gradually increase terminal temperature

difference which needs better de mineralized water quality management. Internal tube deposits causing higher terminal temperature difference with

higher cooling water pressure across the condenser can be effectivelyminimized by on-line condenser tube cleaning.

Recommendations



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Recommendations for reducing the avoidable component of

condenser vacuumSE creates vacuum up to 540 mmHgCl. It is better to sufficiently wait till the

capacity of starting ejector is exhausted and stable vacuum is maintained.

10 to 15 minutes after the establishment of stable vacuum by starting

ejector, ME should be cut into service followed by withdrawal of SE. Parallel

operation of both the ejector shall not only develop the lesser vacuum butalso damage the main ejector tips.

Recommendations

De Mineralized Water Parameters


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Recommendations for initial fillingIt is recommended that after filling condenser hot well to required level,condensate extraction pump should be started to divert the extra DMwater to the deaerator until it is half filled.

After the establishment of deaerator parameters, boiler feed pump shouldbe started and then feed water should be taken to economizer till water

level in the drum is adequate.Boiler fill pumps and emergency lift pumps must not be used for normalstart up because they provided to fill boiler for the purposes other than thestart up.

Recommendations



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a e /S ea a a e e s

Recommendations for Feed Heaters Steam and drip control of the heaters should be improved. It is also recommended to have control valves on

extraction lines to have better control on feed water outlet

temperature. Vapour line of every heater should be kept clean to

improve the heat transfer.

Recommendations



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Recommendations for Proper Deaeration

Quantity of the hydrazine injected to the feed water, after the deaerator to reducethe oxygen less than the minimum displayable value of the instrument should beoptimized to reduce non condensable gases in the condenser.

Attempt should be made to maximize the physical deaeration by properlymaintaining the deaerator parameters and repairing the internals to minimize thechemical deaeration to further reduce the formation of non condensable gas in

condenser.Auxiliary steam supply to last low pressure heater is beneficial and helps inmaintaining the deaereator parameters quickly, which improves physicaldeaeration.

Recommendations



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High Pressure HeatersAdequate drip level in the heaters and its proper diversionsave heat at high potential, which leads to the lessdestruction of exergy. Practicing exergy analysis for heatexchangers in general, help in improving the performance

and applicable to the regenerative feed heating equipmentstoo.

Recommendations



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Recommendations for low feed water temperature at the

outlet of economizer

Low temperature feed water should be heated introducing an

additional heater in between the last high pressure heater and

economizer to ensure heat transfer in the boiler under design

prescribed differential temperatures and proportions of heat flux.

Recommendations



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Recommendations for the evaporatorBoiler blow downs should be optimally utilized.

CBD & IBD should utilized only on the basis of chemical analysis of

feed water samples from evaporator and use of EBD should be

avoided by better co-ordination of fuel firing to the boiler and steam

supply to the turbine.

Phosphate dozing should be optimized.

Recommendations



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Steam Super Heating and Re Heating

Pressure dominated steam must not be allowed for

expansion in steam turbine.

Recommendations



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Expansion of steam in turbineOn line determination of energy and exergy parameters help

operation managers to estimate avoidable component of

performance loss and in turn to initiate the action to curtail the

same.

Axial shift, differential expansion, eccentricity and vibration are alsoutilized for the improvement of running parameters beginning with

steam temperature, pressure and purity.

Recommendations



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Recommendations for Auxiliary SteamSignificant amount of steam is taken from the main steam line for

auxiliary purposes.Temperature and Pressure are reduced from 540deg C and 137 Kg/sqcm to 200 deg C and 15 Kg/sqcm by mixing

water, which results in large loss of exergy.

It will be better to take steam of lower exergetic potential from thedifferent source such as lower temperature header of the super heater,

extraction from the turbine, pressure vessel etc.

Recommendations


After exhausting all the efforts of using design specified


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After exhausting all the efforts of using design specified

coal, following efforts should be made to minimize theadverse effect of relatively inferior coal quality than that

of the design; Pit head coal washing should be done.

Fuel blending is recommended

Coal mill capacity should be reduced in accordance with mill

operating condition curves

Recommendations


Total air flow should be modified in accordance with equation 7 and 8

of the chapter VII and total flow through the boiler should be restricted


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of the chapter VII and total flow through the boiler should be restricted

sufficiently lower than that of the critical velocity in any part of the

steam generators. Lot of attention is required to improve the operation

and maintenance of secondary distribution system particularly for the

Indian boilers. A reliable operator friendly secondary air damper control

system should be introduced. Paper was presented in 2005 at DCE in

international seminar and 2004 JMI)

Recommendations


Capacity of the individual mill should be further reduced either


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because of inadequate pulverized coal fineness or because of

high current of the mill driving motor. It is also recommended to supply supplementary fuel oil or gas

to maintain loading conditions nearest possible to the maximum

continuous rating, particularly for the units, which are not stable

at partial loads.

Recommendations



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Long retractable soot blowers of many thermal units, do not

function satisfactorily and cause lot of soot deposition on PSH,RH, FSH, LTSH & Economizer. APH soot blowing also should

be managed well because its choking results in reduced heat

transfer and higher flue gas exhaust temperature. Air pre heater

seals are also very important and must be maintained.

Recommendations



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FGDPT in case of high ash and low sulfur coals is relatively lower,which must be incorporated in the design for a lower flue gas exhausttemperature. Operational efforts also should be made to optimallyreduce the flue gas exhaust temperature to improve boiler efficiencyas there is no possibility of occurrence of acid deposition. Highambient temperature increases the average air pre heater metaltemperature and permit for further lowered down the flue gas exhaust

temperature. (Paper was presented at national seminar in Coakata in 2006)

Recommendations



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Drum level operator should be provided with additional

instrument showing coal flow and steam flow so that he can

maintain better heat and mass balance with matching

responses.


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Recommendations

Coal Flow Systems Parameters

Soot blowing also keeps the tube surface clean which do not allow thecross section area to reduce to a value at which free stream velocity


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cross section area to reduce to a value at which free stream velocitycan cross the erosion limits. An improper management of soot blowingitself causes the erosion of the tubes.

Baffle plates can be used in high speed zone of boiler to keep the fluegas velocity within the specified ranges.

Particle size can be controlled by maintaining pulverizers healthy.Reduced pulverizer capacity operation is essential in case of high ash &moisture content of coal, lower hard groove index and higher particle

size (fineness) at its outlet.

Recommendations


Furnace Vacuum and differential pressures across the wind box,platen super heater re heater final super heater and economizer also


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platen super heater, re heater, final super heater and economizer alsoinfluence the impacting particle velocity. Well maintained boiler fansare essential to keep various deferential pressures within the specifiedranges.

Sufficient clearance must be incorporated at the design stage itself onthe basis of erosion severity.

Tubes of higher erosion resistance should be used. Boiler should not be allowed to run at higher loads with very poor coal Air ingress through men holes, peep holes, inspection doors and

cracks should be minimized.

Recommendations

Coal Flow Systems Parameters

SOx reduction has become essential for high sulfur coal based stationsby making use of fuel desulphurization unit and putting the flue gas


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by making use of fuel desulphurization unit and putting the flue gasdesulphurization units at the discharge of the electro static precipitator.To prevent ozone layer depletion, leakage of green house gases has tobe stopped. CO2 is produced in abundance and increases quantity ofthe green house gases, which can be minimized either by forestation orby putting the decarburization plant before the chimney.

- Using low NOx Burners- Space for flue gas de-sulfurization units

- Noise control

Recommendations

General Recommendations


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Apart from the flow process improvement, following

recommendations improve the over all performance of plant

- Grid frequency

- Coal and ash transport

- Plume effect

- Vents and safety valve

Recommendations

Scope of the Work

Thermal power plant operation and efficiency managers can make useof the results and recommendation in accordance with chapter IV to VII


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of the results and recommendation, in accordance with chapter IV to VII.

This also evolves useful suggestions to the equipment designers,engineering, procurement and construction managers, commissioningorganizers, maintenance personnel and thermal power plantenvironmentalists. This work is also quite useful for those students ofApplied Thermodynamics, Heat Transfer and Fluid Mechanics, whom soever wish to be the Power Engineer and decides to develop expertise

in the field of operation and efficiency.

Recommendations

Future Linkages

Any thermal power plant can incorporate the mathematical model with

their data acquisition system to give online guidance message to their


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their data acquisition system to give online guidance message to their

operator. This work also gives many specific areas (coal parameters,cooling water flow and its inlet temperature to the condenser, flue gas

exhaust temperature, O2 % in flue gas, equipments life, environmental

protection etc), which attract the power plant researchers to know more

and more about less and less. Dynamic models evolves lot of scope to

researchers.

Introduction

Future Linkages Integrated dynamic model of the thermal power plant processes of this work, can

b f th d d f b tt l i d i ti f i l l d


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be further advanced for better analysis and examination of micro level cause and

effect relationship for the optimization of the performance control, which inviteresearch in future, linking the present work.

Informal validation of this work conducted on some unit of the utility sector was

not permitted to be published due the classified stringent constrained with the

power plant personnel, under the help and guidance of whom this studied was

conducted and concluded. Project on formal validation of the proposals for any

specific coal based thermal unit shall be a future linkage leading to the

commercial benefit of reference unit.

Conclusions and Recommendations

Desired effect from the thermal power plant is electricity ofstandardized quantity and quality at the minimum


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standardized quantity and quality at the minimum

consumption of input fuel oil and coal as the primary cause.To facilitate the first effect as heat from the primary cause offuel supply, combustion supporting air and initial ignitionenergy has to be supplied to the furnace as an integral part ofthe primary cause. Liberated heat is the effect of combustion

system, which cause steam generation.

Conclusions and Recommendations- Cont.Similarly all intermediate effect become the cause for the next process

and hence regulation of every process and monitoring its cause and effect

in measurable parameters help in improving the performance of

i d R bl id li h b id d


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associated process. Reasonable guide lines have been provided to

optimize the performance of most of the thermal power plant processesalong with system wise integration of the same. Integrated mathematical

model is capable of providing energy and exergy parameters to

incorporate the same in dynamically managing the performance

influencing parameters in accordance with causal relationships

established in the dynamic model.


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Thank you

*

management of thermal pppp

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