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
Scope of Work for Power Plant Audit
Methodology
Steam Generator Boiler Efficiency Evaluation by indirect method by (ASME PTC 4 -2008)
Objective: Determine major loss Covered Are:

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

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
| SN | Parameter | Unit | Value |
|---|---|---|---|
| 1 | Power Generation Per day Without LP Heater Running | MWD | 347.86 |
| 2 | Power Generation Per day With LP Heater Running | MWD | 351.05 |
| 3 | Power Saving Per day | MWD | 3.20 |
| 4 | Annual Operation Hours | Day | 300.00 |
| 5 | Annual Power Saving | MW | 959.11 |
| 6 | Electricity Unit Cost | Rs/kWh | 4.35 |
| 7 | Annual Saving in Monetary Terms | Rs/- | 41,72,422 |
| 8 | Investment | Rs/- | 5,00,000 |
| 9 | Simple Payback Period | Month | 1.44 |
Overview
- Comparison of LP Heater Steam Line Off Condition and On Condition.
Case Study
| SN | Parameter | Unit | LP Heater Steam Line Not Working Condition | LP Heater Steam line Working Condition |
|---|---|---|---|---|
| 1 | Extraction 1st stage flow Turbine Inlet | TPD | 1397 | 1397 |
| 2 | Extraction 1st stage flow Turbine Outlet | TPD | 44.88 | 0 |
| 3 | Extraction 2nd stage flow Turbine Outlet | 0 | 57.6 | |
| 4 | Condensing Stage flow | TPD | 1352.12 | 1339.4 |
| 5 | Extraction 1st stage Enthalpy inlet | kcal/kg | 805.4 | 805.4 |
| 6 | Extraction 1st stage Enthalpy outlet | kcal/kg | 717.010 | 717.01 |
| 7 | Extraction 2nd stage Enthalpy inlet | kcal/kg | 0 | 717.01 |
| 8 | Extraction 2nd stage Enthalpy outlet | kcal/kg | 0.000 | 633.13 |
| 9 | Extraction Condensing stage Enthalpy inlet | kcal/kg | 717.01 | 633.13 |
| 10 | Extraction Condensing stage Enthalpy outlet | kcal/kg | 570.000 | 570 |
| 11 | Extraction 1st stage Power Generation | MWD | 143.5 | 0 |
| 12 | Extraction 2nd Stage Power Generation | MWD | 0.0 | 279.84 |
| 13 | Extraction Condensing Stage Power Generation | MWD | 231.13 | 98.32 |
| 14 | Total Power Generation | MWD | 374.72 | 378.16 |
| 15 | Turbine Generator Efficiency | % | 96 | 96 |
| 16 | Gear Box Efficiency | % | 97 | 97 |
| 17 | Calculated Power Output Power Generation | MWD | 347.86 | 351.05 |
| 18 | More Power Generation | MWD | 3.20 |
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