Limbaja Energy

Power Plant Audit

Power Plant Audit

Overview

Performance testing of Captive, Cogen, Waste Heat Recovery, and Gas Power Plants in accordance with respective ASME PTC Codes.

Type of Plant

Captive Power Plant
Cogeneration Power Plant
Waste Heat Recovery power plant
Gas Power Plant

Scope of Work for Power Plant Audit

Performance testing of the following system of power plant in accordance with respective PTC Code
Steam Generator Boiler Efficiency evaluation by indirect Method by (ASME PTC 4)
Effectiveness of air pre-heater and air ingress identification (ASME PTC 4.3)
Turbine (ASME PTC 6 -2004)
HP-LP Feed Water Heater (ASME PTC 12.1)
Condenser (ASME PC 12.2)
Cooling Tower (ASME PTC 23)

Methodology

Measurement of Collecting Data
Analysis Data
Presenting Data
Recommendations

Steam Generator Boiler Efficiency Evaluation by indirect method by (ASME PTC 4 -2008)

Objective: Determine major loss Covered Are:

Objective: Determine major loss Covered Are:

Effectiveness of Air Pre heater & Ingress identification (PTC 4.3)

Effectiveness of Air Pre heater & Ingress identification (PTC 4.3)

Turbine (ASME PTC 6 -2004)

Turbine (ASME PTC 6 -2004)

HP – LP Feed Water heater (ASME PTC 12.1)

  • Performance Study of HP-LP Heaters

Condenser (ASME PTC 12.2)

  • Condenser performance with reference to Cooling Water flow and temperature of circulating water
  • Study of Deviation/Deterioration in the performance of condenser
  • Deviation in performance due to circulation water flow
  • Deviating due to scale formation
  • Cooling water pressure loss across condenser
  • Required Parameter Condensate Flow to deaerator
  • Condenser back pressure, CW inlet and outlet temperature, CW Flow will be measured using portable flow meter.

Cooling Tower (PTC 23)

  • Assessment of cooling tower capacity and efficiency/effectiveness
  • Assessment of condenser heat load
  • DBT, WBT air velocity and humidity CW Temperature shall be measured

Coal Analysis

  • Ultimate and Proximate Analysis of Coal
  • GCV Test of APH Ash, ESP Ash Economizer Ash and Bed Bottom Ash

Overview

  • Energy Conservation Measure : Use LP Heater Steam Line for Heating the Boiler Feed Water and Increase the Turbine Power.

Case Study

SNParameterUnitValue
1Power Generation Per day Without LP Heater RunningMWD347.86
2Power Generation Per day With LP Heater RunningMWD351.05
3Power Saving Per dayMWD3.20
4Annual Operation HoursDay300.00
5Annual Power SavingMW959.11
6Electricity Unit CostRs/kWh4.35
7Annual Saving in Monetary TermsRs/-41,72,422
8InvestmentRs/-5,00,000
9Simple Payback PeriodMonth1.44

Overview

  • Comparison of LP Heater Steam Line Off Condition and On Condition.

Case Study

SNParameterUnitLP Heater Steam Line Not Working ConditionLP Heater Steam line Working Condition
1Extraction 1st stage flow Turbine InletTPD13971397
2Extraction 1st stage flow Turbine OutletTPD44.880
3Extraction 2nd stage flow Turbine Outlet057.6
4Condensing Stage flowTPD1352.121339.4
5Extraction 1st stage Enthalpy inletkcal/kg805.4805.4
6Extraction 1st stage Enthalpy outletkcal/kg717.010717.01
7Extraction 2nd stage Enthalpy inletkcal/kg0717.01
8Extraction 2nd stage Enthalpy outletkcal/kg0.000633.13
9Extraction Condensing stage Enthalpy inletkcal/kg717.01633.13
10Extraction Condensing stage Enthalpy outletkcal/kg570.000570
11Extraction 1st stage Power GenerationMWD143.50
12Extraction 2nd Stage Power GenerationMWD0.0279.84
13Extraction Condensing Stage Power GenerationMWD231.1398.32
14Total Power GenerationMWD374.72378.16
15Turbine Generator Efficiency%9696
16Gear Box Efficiency%9797
17Calculated Power Output Power GenerationMWD347.86351.05
18More Power GenerationMWD3.20

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