Power Plant Performance Rev

Thermal Power Plant
Efficiency & Performance

Enhancement
Fundamentals
Evaluation Methods
Corrective Actions
Need For E & P Enhancement
Bath Tub curve

Failure Rate
No of Years
Present Performance Conditions
Boiler Eff Unit Heat Rate Remarks

Unit # 1 89.39% 2637 Both HPH not in service
Unit # 2 87.80% 2656
Unit # 3 88.48% 2497
Unit # 4 87.60% 2590
APH LMTD
Unit # 1 87.70
Unit # 2 79.50
Unit # 3 97.35
Unit # 4 98.86
Equipment
§ Boiler
§ Air Heater
§ Mills
Equipment
§ Boiler
§ Air Heater
§ Mills
AREAS CONTRIBUTING TO VARIOUS LOSSES IN A BOILER
‡ COMBUSTION IN BOILER
‡ AIR HEATER PERFORMANCE
‡ MILL PLANT PERFORMANCE
‡ FANS
‡ WATER LOSSES
FACTORS AFFECTING PERFORMANCE OF

COMBUSTION
¤ SURFACE CONTACT AREA OF FUEL WITH AIR

¤ AIR-FUEL RATIO
¤ RETENTION TIME
¤ COMBUSTION CHAMBER TEMPERATURE
¤ TURBULANCE IN COMBUSTION CHAMBER
¤ REMOVAL OF PRODUCTS OF COMBUSTION
LOSSES IN BOILER
• CONTROLLABLE
# COMBUSTIBLE IN ASH LOSS
# DRY GAS LOSS
# CO IN FLUE GAS
# MILL REJECTS LOSS
• UN CONTROLLABLE
# MOISTURE IN FUEL
# HYDROGEN IN FUEL
# AIR MOISTURE
# SENSIBLE HEAT IN ASH
# RADIATION AND UNACCOUNTED
COMBUSTION
• TIME
– SUFFICIENT RETENTION TIME MUST BE ALLOWED FOR THE

FUEL TO STAY INSIDE THE FURNACE TO COMPLETE
COMBUSTION
– TIME REQUIRED/AVAILABLE DEPENDS

• FUEL TYPE,QUALITY,SIZE
• FURNACE SIZE
• VELOCITY
– DRAUGHT
COMBUSTION
• TEMPERATURE
– EFFECTS THERMAL DIFFUSION OF REACTING MOLECULES

DUE TO INCREASED VELOCITY OF MOLECULES WITH
INCREASE IN TEMPERATURE
– INFLUENCE THE RATE OF REACTION
• FACTORS AFFECTING TEMPERATURE
– HEAT ABSORBED BY FURNACE

– HEAT ABSORBED BY REACTANTS TO BRING THEM TO
IGNITION TEMPERATURE
– HEAT ABSORBED BY NITROGEN IN AIR
COMBUSTION
• TURBULANCE
– MECHANICAL AGITATION OF REACTANTS TO BRING

THEM INTO PHYSICAL CONTACT
– REQUIREMENT IS MORE AT FINAL STAGE OF
COMBUSTION
– LESSER THE TURBULANCE MORE CARBON LOSS
– DEPENDS
• WIND BOX TO FURNACE DIFF.PR.IN CORNER FIRED

BOILERS
• TERTIARY AIR IN WALL FIRED BOILERS
COMBUSTIBLE IN ASH
CARBON LOSS
• HEAT LOSS DUE TO UNBURNT CARBON LEAVING THE BOILER ALONG

WITH EITHER BOTTOM ASH OR FLY ASH
FACTORS AFFECTING
1 AIR DISTRIBUTION
– DISTRIBUTION
– EXCESS AIR
2 PARTICLE SIZE
– MILL FINENESS -200 mesh
– MILL FINENESS + 75%
3 COAL QUALITY
– VOLATILE MATTER
4 COMBUSTION
– TIME
– TEMPERATURE
– TURBULANCE
AIR DISTRIBUTION
• EXCESS AIR
– AIR SUPPLIED IN ADDITION TO STOCHIOMETRIC AIR FOR

COMPLETE COMBUSTION OF FUEL
• OPTIMUM EXCESS AIR DEPENDS ON
– FUEL QUALITY
– FIRING SYSTEM DESIGN
• EXCESS AIR LESS THAN OPTIMUM RESULTS
– INCREASED CARBON IN ASH

PARTICLE SIZE
† COARSER THE FUEL PARTICLE MORE THE CARBON LOSS
† MAINTAIN OPTIMUM FUEL SIZE BY PERIODICALLY MONITORING

P.F.SIZE
† OPTIMUM FINENESS FOR H.V.SUB BITUMINOUS COAL
† 100% THROUGH 50 MESH

VOLATILE MATTER
« LOWER THAN DESIGNED VALUE NEEDS MORE

TIME FOR COMPLETE COMBUSTION WHICH
FURNACE CAN NOT PROVIDE
« LEADS TO INCREASED COMBUSTIBLES IN ASH
« REMEDY
« BLENDING OF COAL
DRY FLUE GAS LOSS
• HEAT CARRIED AWAY BY THE DRY CONSTITUENTS OF FLUE GAS
THROUGH THE CHIMNEY
DRY FLUE GAS LOSS
HEAT CARRIED AWAY

BY DRY FLUE GAS SHD = WD*CP*(TG - TA) Kcal/Kgf
WHERE
WD WEIGHT OF DRY FLUE GAS Kgm/Kgf

CP SPECIFIC HEAT OF DRY FLUE GAS Kcal/Kgm0C
TG GAS TEMPERATURE AT AIR HEATER OUTLET 0C
TA AMBIENT TEMPERATURE 0C
DRY FLUEGAS LOSS = (SHD/C.V.)*100 %
WHERE
SHD - HEAT CARRIED AWAY BY DRY FLUE GAS Kcal/Kgf

C.V. - CALORIFIC VALUE OF FUEL Kcal/Kgf
O2 MEASUREMENT
• DRY BASIS
– MEASURED THROUGH ORSAT APPARATUS
• WET BASIS
– WET MEASURED THROUGH ONLINE
ANALYSERS LIKE ZIRCONIA PROBE
• DIFFERENCE BETWEEN WET AND DRY

O2% IN FLUE GAS
COAL FIRED BOILERS - 0.2%
FACTORS AFFECTING DRY FLUEGAS LOSS
• COAL QUALITY
– MOISTURE
– CARBON
– CALORIFIC VALUE
• AIR INLET TEMPERTATURE
– AMBIENT TEMPERTURE
• FLUE GAS QUANTITY
– EXCESS AIR
– AH LEAKAGE
Equipment
§ Boiler
§ Air Pre Heater
§ Mills
AIR HEATER PERFORMANCE
• GAS OUTLET • GAS OUTLET

TEMPERATURE TEMPERATURE HIGHER
LOWER THAN THAN OPTIMUM
OPTIMUM
– MORE DRY GAS LOSS
– LEADS TO COLD END
CORROSION – RISE OF 22 deg C ABOVE
OPTIMUM REDUCE BOILER
• LOSS OF HEAT EFFICIENCY BY 1%
TRANSFER
ELEMENTS
– 20 C RISE ABOVE OPTIMUM
• The optimum temp is
146 C RESULTS LOSS OF 600Kcal
(approx.) HEAT IN 1 TONNE
OF F.G.
FACTORS AFFECTING A.H. GAS OUTLET TEMPERATURE
• FLUE GAS O/L TEMPERATURE LOWER THAN OPTIMUM

– LIGHTING AND FIRING COLD BOILER
• USE SCAPH
– AIR LEAKAGE
• SEALS CONDITON
• DIFF. PR. BETWEEN AIR AND F.G
• FLUE GAS O/L TEMPERATURE HIGHER THAN OPTIMUM

– QTY. OF AIR PASSING THROUGH A.H.
• TEMPERING AIR ( cold air to mill)
– TEMP.OF GAS ENTERING A.H
• DEPOSITS ON BOILER HEAT TRANSFER AREAS
• DELAYED/SY.COMBUSTION
• FEED WATER TEMP
– FOULED / CORRODED ELEMENTS
– DEFECTIVE BAFFLES
– QTY.OF GAS PASSING THROUGH A.H.
AIR HEATER PERFORMANCE TESTS
• PERFORMANCE ITEMS DETERMINED
– GAS SIDE EFFICIENCY

– AIR LEAKAGE
– X-RATIO
ARRANGEMENT OF AIR PRE HEATER
AIR HEATER CALCULATIONS
GAS SIDE EFFICIENCY
 F.G I/L to APH – F.G. O/L to APH with no leakage

G = 100
F.G I/L to APH – Air I/L to APH
Air Heater Gas Efficiency
• Current Plant Performance
GAS EFFICIENCY(wrt PA Temp.) GAS EFFICIENCY(wrt SA Temp.)

Unit
RIGHT LEFT RIGHT LEFT
Unit #1 59.85% 59.55% 57.90% 57.64%
Unit #2 61.25% 60.33% 59.20% 58.11%
Unit #3 64.05% 63.56% 62.08% 61.63%
Unit #4 63.82% 62.43% 61.72% 60.44%
EFFECTS OF TRAMP AIR TO BOILER
• DOES NOT CONTRIBUTE TO COMBUSTION
• OFTEN IT IS COLD
• INCREASE GAS VELOCITY THROUGH E.S.P
• INCREASES DRY FLUE GAS LOSS
SOURCES OF AIR INGRESS

• ASH HOPPER SEALS
• ASH HOPPER DOOR LEFT OPEN
• DEFECTIVE EXPANSION JOINTS
• DUCT OPENINGS (MANHOLES) UNCOVERED
• BOILER ROOF DEFECTIVE
• COLD AIR DAMPERS PASSING
Determining (X RATIO)
HEAT CAPACITY OF AIR PASSING THROUGH A.H.

X RATIO = --------------------------------------------------------------------------
HEAT CAPACITY OF GAS PASSING THROUGH A.H.
F.G I/L to APH –

WA9 *CpA
F.G. O/L to APH with no leakage
X RATIO = ------------- = 100
WG14 *CpG Air O/L to APH – Air I/L to APH
CpA / CpG = 0.95

X Ratio
• Present Plant Performance
GAS EFFICIENCY(wrt PA Temp.) GAS EFFICIENCY(wrt SA Temp.)

Unit
RIGHT LEFT RIGHT LEFT
Unit #1 85.35% 81.46% 70.92% 69.10%
Unit #2 84.34% 82.64% 68.53% 65.81%
Unit #3 91.95% 86.98% 70.14% 73.08%
Unit #4 84.77% 82.93% 72.12% 70.26%
Equipment
§ Boiler
§ Air Pre Heater
§ Mills
MILL PERFORMANCE FACTORS
• P.F. FINENESS
– CARBON LOSS
– MILL POWER CONSUMPTION
• COAL-AIR RATIO
• MILL REJECTS
EFFECTS OF P.F.FINENESS
• TOO COARSE
– WEAR IN COAL PIPE
– SLOWER IGNITION
– POOR FIREBALL MIXING
– UNSTABLE FLAME FRONT AT LOW LOADS
– HIGH CARBON LOSS
• TOO FINE
– INCREASED WEAR OF PULVERISER
– DECREASED PULVERISER OUTPUT( INCREASE IN MILL
RECIRCULATION)
– INCREASED POWER CONSUMPTION
• 1% CHANGE IN FINENESS EQUALS APPROXIMATELY 1.5% IN
CAPACITY
COAL PROCEDURE FOR CHECKING FINENESS
• PERIODICAL COLLECTION OF
COAL SAMPLE FROM ALL PIPE
LINES OF A MILL IN TWO
PLANES USING STANDARD
PROBE
• BEFORE COLLECTING SAMPLE

ENSURE
– MILL IS RUNNING AT MORE THAN
75% LOAD
– MILL IS RUNNING AT A STEADY
LOAD FOR 30 MINUTES
– NO LOAD CHANGE TAKES
PLACE DURING SAMPLE
COLLECTION
£ MIX ALL THE SAMPLES COLLECTED FROM A MILL
HOMOGENEOUSLY
£ TAKE REQUIRED MASS OF SAMPLE BY CONING AND

QUARTERING
£ CONDUCT SIEVE ANALYSIS ON THE SAMPLE
£ OPTIMUM FINENESS
£ 100% THROUGH 50 MESH
EFFECTS OF COAL AIR RATIO
• HIGH AIR FLOW

¿ AFFECTS COAL CLASSIFICATION
¿ REDUCES DISCHARGE OF PYRITES
¿ INCREASES COAL PIPE EROSION
¿ AFFECTS IGNITION POINT
¿ MORE P.A. FAN POWER CONSUMPTION
• LOW AIR FLOW

¿ INCREASES COAL PIPE SPILLAGE
¿ CAUSES DRIFTING IN COAL PIPE AND ULTIMATE
COAL PIPE CHOKING
CLEAN AIR FLOW TEST
• DETERMINES
– WHETHER THERE IS ENOUGH AIR TO TRANSPORT
THE COAL
– AIR FLOW DISTRIBUTION IN COAL PIPES
– COAL PIPE OBSTRUCTION
• METHOD
P IS MEASURED BY PITOT TUBE IN

COAL PIPE AT 0.935R, 0.791R, 0.612R, AND
0.354R WHERE 'R' IS THE RADIUS OF PIPE
IN INCHES
CLEAN AIR FLOW TEST
PV 0.5
AIR VELOCITY = 18.275 [ ----------------------------- ] Ft/s
1.326 Pb +0.0735 PS
{ ------------------}
460+T
WHERE
PV - PITOT TUBE DIFF.PR.IN INCHES OF WC.

Pb - BAROMETRIC PRESSURE IN INCHES OF Hg.
PS - STATIC PRESSURE IN INCHES OF WC.
T - TEMPERATURE IN 0F
PV 0.5
AIR VELOCITY = 5.5702 [ ---------------------------------------- ] M/s
18.7113 Pb / 25.4 + PS /345.34
( -------------------------- )
273.3 + T
WHERE
PV - PITOT TUBE DIFF.PR.IN mm. OF WC.

Pb - BAROMETRIC PRESSURE IN mm OF Hg.
PS - STATIC PRESSURE IN mm OF WC.
T - TEMPERATURE IN 0C
CLEAN AIR FLOW TEST
AIR FLOW = 0.32725*D2*V* lbs/min
D - DIA. OF PIPE IN INCHES

V - AIR VELOCITY ft/s
 -AIR DENSITY
DESIRED RESULTS
MEASURED AIR FLOW BETWEEN 135% AND 160% OF

STANDARD AIR FLOW
MEASURED AIR VELOCITIES ARE WITHIN 5% OF

AVERAGE VELOCITIES
CAUSES OF MILL REJECTS
• LOW AIR VELOCITY

λ LOW AIR FLOW
λ AIR BYPASSING
• HIGH RE CIRCULATION RATIO

λ WEAR OF GRINDING ELEMENTS
λ IMPROPER SETTING OF GRINDING ELEMENTS
λ OPERATING MILL WITH HIGHER FINENESS
λ HIGH MOISTURE COAL/LOW MILL OUTLET
TEMPERATURE
Factors affecting Fan Performance
• Higher ambient temperatures result in less stack draft.
• ID fan capacity limitation may result in load reduction or

inability to maintain desired excess air levels.
• Low excess air due to fan capacity limitation can result

in
– Increased slagging and fouling
– High Flyash Loss On Ignition
– Superheater and Reheater tube overheating
– High boiler exit gas temperature
Causes for Poor Performance
Conditions causing Poor Performance of Boiler
• Non-Optimum Reheat or Superheat steam temperatures.
• Higher than design economizer exit gas temperature or

furnace exit gas temperature caused by poor combustion.
• Higher than design Re heater or Super heater De-

Superheating spray flows.
• Fly ash Unburned Carbon or Loss on Ignition greater than

5% for Bituminous Coals
• High Bottom Ash Loss on Ignition.

• Non-Optimum utilization or distribution of primary air, secondary air
• Increased auxiliary power consumption by coal pulverizers and fans
• Reductions in capacity factors due to excessive furnace or convection pass

slagging or fouling.
• Excessive boiler setting air in-leakage.
• Excessive air heater leakage.
• Increased cycle losses with increased sootblowing due to non-optimum

combustion.
• Reductions in capacity factors due to pulverizer or fan

capacity limitations.
• Reductions in capacity factors due to Superheater or

Reheater tube overheating and/or coal-ash corrosion.
Requirements for achieving
Optimum operating Conditions
Requirements For Achieving Optimum Conditions
• Furnace exit must be oxidizing, preferably 3% excess O2.
• Minimal air in-leakage between the furnace exit and economizer

exit.
• Pulverizer fineness of >75% passing 200 Mesh and <0.3%

remaining on 50 Mesh.
• Secondary (combustion) air balanced to within ±5% between

burners
• Optimum windbox to furnace differential, typically 100 mm w.c. at

full load.
• Optimum Pulverizer Primary Air to Fuel Ratio. In most cases, air to

Requirements For Achieving Optimum Conditions
• Fuel balanced between each pulverizers fuel lines to within ±10%
deviation from the mean.
• Pulverized coal line dirty airflow balanced between each pulverizers

fuel lines within ±5%.
• Pulverized coal line clean air velocities balanced to ±2% of the

mean.
• Burner mechanical tolerances with burner buckets stroked and

synchronized to within ±2° (tangentially fired).
• Primary airflow metered and controlled to ±3% accuracy.

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Thermal Power Plant

Efficiency & Performance

Bath Tub curve

Boiler Eff Unit Heat Rate Remarks

FACTORS AFFECTING PERFORMANCE OF

¤ SURFACE CONTACT AREA OF FUEL WITH AIR

– SUFFICIENT RETENTION TIME MUST BE ALLOWED FOR THE

– TIME REQUIRED/AVAILABLE DEPENDS

– EFFECTS THERMAL DIFFUSION OF REACTING MOLECULES

• FACTORS AFFECTING TEMPERATURE

– HEAT ABSORBED BY FURNACE

– MECHANICAL AGITATION OF REACTANTS TO BRING

• WIND BOX TO FURNACE DIFF.PR.IN CORNER FIRED

• HEAT LOSS DUE TO UNBURNT CARBON LEAVING THE BOILER ALONG

– AIR SUPPLIED IN ADDITION TO STOCHIOMETRIC AIR FOR

• OPTIMUM EXCESS AIR DEPENDS ON

• EXCESS AIR LESS THAN OPTIMUM RESULTS

– INCREASED CARBON IN ASH

† COARSER THE FUEL PARTICLE MORE THE CARBON LOSS

† MAINTAIN OPTIMUM FUEL SIZE BY PERIODICALLY MONITORING

† OPTIMUM FINENESS FOR H.V.SUB BITUMINOUS COAL

† 100% THROUGH 50 MESH

« LOWER THAN DESIGNED VALUE NEEDS MORE

« LEADS TO INCREASED COMBUSTIBLES IN ASH

HEAT CARRIED AWAY

WD WEIGHT OF DRY FLUE GAS Kgm/Kgf

DRY FLUEGAS LOSS = (SHD/C.V.)*100 %

SHD - HEAT CARRIED AWAY BY DRY FLUE GAS Kcal/Kgf

• DIFFERENCE BETWEEN WET AND DRY

• GAS OUTLET • GAS OUTLET

• FLUE GAS O/L TEMPERATURE LOWER THAN OPTIMUM

• FLUE GAS O/L TEMPERATURE HIGHER THAN OPTIMUM

• PERFORMANCE ITEMS DETERMINED

– GAS SIDE EFFICIENCY

GAS SIDE EFFICIENCY

 F.G I/L to APH – F.G. O/L to APH with no leakage

• Current Plant Performance

GAS EFFICIENCY(wrt PA Temp.) GAS EFFICIENCY(wrt SA Temp.)

SOURCES OF AIR INGRESS

HEAT CAPACITY OF AIR PASSING THROUGH A.H.

F.G I/L to APH –

CpA / CpG = 0.95

GAS EFFICIENCY(wrt PA Temp.) GAS EFFICIENCY(wrt SA Temp.)

• BEFORE COLLECTING SAMPLE

£ TAKE REQUIRED MASS OF SAMPLE BY CONING AND

£ CONDUCT SIEVE ANALYSIS ON THE SAMPLE

• HIGH AIR FLOW

• LOW AIR FLOW

P IS MEASURED BY PITOT TUBE IN

PV - PITOT TUBE DIFF.PR.IN INCHES OF WC.

PV - PITOT TUBE DIFF.PR.IN mm. OF WC.

AIR FLOW = 0.32725*D2*V* lbs/min

D - DIA. OF PIPE IN INCHES

MEASURED AIR FLOW BETWEEN 135% AND 160% OF

MEASURED AIR VELOCITIES ARE WITHIN 5% OF

• LOW AIR VELOCITY

• HIGH RE CIRCULATION RATIO

• Higher ambient temperatures result in less stack draft.

• ID fan capacity limitation may result in load reduction or

AIR FLOW = 0.32725D2V* lbs/min