8/4/23, 3:26 PM Power plant and calculations: 100 + formulae for power plant calculations

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Power plant and calculations

Power plant and calculation site basically includes the detailed study of power plant operation and maintenance, its related all
calculations and thumb rules. It also involves detailed troubleshooting guides for operation and maintenance of power plant
system/equipments like Boiler, fans, compressors, belt conveyors, ash handling system, ESP, steam turbine, cooling tower, heat
exchangers, steam ejectors, condensers WTP. etc. Heat rate, efficiency

100 + formulae for power plant calculations Search This Blog

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A-Boiler
Home
1-Boiler efficiency direct method

Boiler effciency = (Mass of steam flow X Steam enthalpy-Feed water flow at economizer inlet X
Enthalpy-Attemperator water flow X Enthalpy) / (GCV of fuel X Fuel consumption)

2-Boiler efficiency by indirect method

Boiler efficiency = 100-Various losses

3-Theoretical air requirement for combustion

Theoretical air Thair = ((11.6 X C% + (34.8 X (H2-O2/8)) + (4.35 X %S))/100

Where C = % of carbon in fuel

H2 = % of Hydrogen present in fuel

S = % of sulphur present in fuel

4-Excess air requirement for combustion

%EA = O2% / (21-O2%)

Where O2 = % of oxygen present in flue gas

5-Mass of actual air supplied

AAS = (1 + EA / 100) X Theoretical air

6-Mass of flue gas

Mfg = Mass of Air + 1

6-Mass of dry flue gas

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8/4/23, 3:26 PM Power plant and calculations: 100 + formulae for power plant calculations
Mfg = Mass of Co2 in flue gas + Mass of Nitrogen in fuel + Mass of Nitrogen in combustion air + Followers
Mass of oxygen in flue gas + Mass of So2 in flue gas
CLOSE ADS Followers (1) CLOSE ADS
Mfg =(Carbon % in fuel X Molecular weight of CO2 / Mol.weight of Carbon) + N2 in fuel + (Mass
of actual air supplied X % of N2 in air i.e 77/100) + ((Mass of actual air – Mass of theoretical air) X
23/100) + S2 in fuel X Mol.weight of SO2 / Mol.weight of sulphur)
Follow
7-% of heat loss in dry flue gas

Heat loss = Mfg X Cp X (Tf-Ta) X 100 / GCV of fuel

About Me

Where,
Powerplant and calculations
Mfg = Mass of flue gas View my complete profile

Cp = Specific heat of flue gas in kacl/kg

Tf = Temperature of flue gas

Ta = Ambient air temperature December 2022 (2)

9-% of heat loss due to moisture in fuel

Heat loss = M X (584 + Cp X (Tf-Ta))  X 100 /  GCV of fuel Labels

Boiler
Where,
Efficiency & performance
M = Moisture in fuel
Electrical & Instrumentation
Cp = Specific heat of flue gas in kcal/kg
energy conservation & thumb rules in power
plant
10-% of heat loss due to moisture in air
ESP
Heat loss = AAS X humidity X Cp X (Tf-Ta) X 100/ (GCV of fuel)
fuel handling
Where,
power plant maintenance
AAS = Actual air supplied for combustion pumps/compressors/fans

Cp = Specific heat of flue gas in kcal/kg safety and energy

Tf = Temperature of flue gas steam turbine

Water treatment plant

Ta = Ambient air temperature

11-% of Boiler water blow down

Blow down % = (Feed water TDS X % of makeup water) X 100 / (Maximum permissible TDS in
Boiler water –Feed water TDS)

12-Steam velocity in line

Velocity of steam in pipe line,V = Steam flow in m3/sec / Area of pipe line (A)

Steam flow in m3/sec = (Steam flow in kg/hr / Density of steam X 3600)

2
Area of pipe, A = Pi X D  / 4

Where D is pipe internal diameter

13-Condensate flash steam calculation

Flash steam % = (H1-H2) X 100 / Hfg)

Where, H1 = Sensible heat at high pressure condensate in kcal/kg

H2 = Sensible heat of steam at low pressure in kcal/kg

Hfg = Latent heat of flash steam

14-Calculation of amount of heat required to raise the water temperature

Heat required in kcal=Mw X Cp X (T2-T1)

Where, Mw = Mass of water

Cp = Specific heat of water in kcal/kg (1 kcal/kg)

T1 = Initial temperature of water in deg C

T2 = Final temperature of water in deg C

15-Calculation of heat required to raise air temperature

Heat required in kcal=Mair X Cp X (T2-T1)

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Where, Mw = Mass of water

Cp = Specific heat of flue gas in kcal/kg (0.24 kcal/kg)

CLOSE ADS CLOSE ADS
T1 = Initial temperature of air in deg C

T2 = Final temperature of air in deg C

16-Surface heat loss calculation
S = (10 + (Ts-Ta) / 20) X (Ts-Ta) X A
S = Surface heat loss in kcal/hr m2
Ts= Hot surface temperature in deg C
Ta = Ambient air temperature in deg C
17-Dryness fraction of steam
X = Mass of dry steam / (Mass of dry steam + Mass of water suspension in mixture)
18-Heat content in wet steam
h = hf + xhfg
h= Heat content in saturated steam
x = Dryness factor of steam
Hfg =Enthalpy of evaporation
19-Heat content in dry saturated steam
h = hf + hfg
h= Heat content in saturated steam
Hfg =Enthalpy of evaporation
20-Heat content in superheated  steam
h = hf + hfg + Cps (Tsup - Ts)
h= Heat content in super heated steam
hfg =Enthalpy of evaporation
Cps = Specific heat of super heated steam
Tsup= Superheated steam temperature in deg C
Ts = Saturated temperature of steam in deg C
21-Calculation of Equivalent evaporation
Me = Ms X (h-hf) / hfg
Ms = Mass of steam
h = Steam enthalpy
hf= Feed water enthalpy
22-Factor of evaporation
Fe = (h-hf) / 539
23-Ash (Total) generation calculation
Ash generation in TPH = Fuel consumption per hour X % of ash in fuel / 100
24-Fly ash generation calculation
Fly ash generation in TPH = Fuel consumption per hour X % of ash in fuel X 80% / 100
25-Bottom  ash generation calculation
Bottom ash generation in TPH = Fuel consumption per hour X % of ash in fuel X 20% / 100
26-Calculation of ash generation in ESP
Ash generation in ESP in TPH = Fuel consumption per hour X % of ash in fuel X 80% X 80% / 100
27-Boiler safety valve blow down calculation
Blow down % = (Set pressure - Re seat pressure) X 100 / Set pressure
28-Calculation of attemperator water flow
Attemperator water flow  in TPH= Steam flow in TPH X (h1-h2) / (h2-h3)
h1 = Enthalpy of steam before desuper heating in kcal/kg
29-Economiser efficiency calculation
ηEco. = (Economiser outlet feed water temperature-Economizer inlet feed water temperature
)  X 100 / (Economizer inlet flue gas temperature - Economizer inlet feed water temperature)
30-APH efficiency calculation
APH air side efficiency
ηAPHa = (Air outlet temp-Air inlet temp)) X 100 / (Flue gas inlet temperature -Air inlet
temperature)

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APH gas side efficiency
ηAPHg = (Flue gas inlet temp.-Flue gas outlet temp) X 100 / (Flue gas inlet temperature -Air
inlet temperature )
CLOSE ADS CLOSE ADS
31-Calculation of steam cost
Steam cost per ton = Steam enthalpy  in kcal/kg X Fuel price per ton/ (Boiler efficiency % X GCV
of fuel used in kcal/kg)
32-Travelling grate Boiler heating surface calculation
Boiler heating surface (Appx) = Boiler capacity in kg/hr / 18
33-AFBC Boiler heating surface calculation
Boiler heating surface (Appx) = Boiler capacity in kg/hr / 22
34-Travelling grate slop fired Boiler heating surface calculation
Boiler heating surface (Appx) = Boiler capacity in kg/hr / 12
35-AFBC  slop fired Boiler (Low pressure up to 10 kg/cm2 WP) heating surface calculation
Boiler heating surface (Appx) = Boiler capacity in kg/hr / 8.2
36-Calculation of draught produced in Chimney

Hw = 353 X H (1/Ta – 1/Tg (Ma+ 1)/Ma)

H = Chimney height in meters

Ta = Atmospheric temperature in K

Tg = Flue gas temperature in K

Ma = Mass of air & Mass of flue gas = Ma+1

Also given as;

 P = 176.5 X H / Ta

Hw = Chimney height in meters

Ta = Absolute atmospheric temperature in Kelvin

Hw = Draught in mmwc

37-Calculation of mass of flue gas flowing through chimney

Mg (kg/sec)= Density of gas (kg/m3) X Area of Chimney (m2) X Velocity of flue gas in Chimney
(m/sec)

B-Turbine and Auxiliaries

1-Turbine heat rate calculation
a-Heat rate of Thermal power plant Turbine in kcal/kw =
Steam flow X (Steam enthalpy in kcal/kg-Feed water enthalpy in kcal/kg) / Power generation
b-Heat rate of Co-gen plant Turbine in kcal/kg =
Inlet steam flow X Enthalpy-(Sum of extraction steam flow X Their enthalpy + Exhaust steam X
Enthalpy) / Power generation
i.e THR = ((Steam Flow x Steam Enthalpy)-(1St EXT Flow x Its Enthalpy + 2nd Ext flow x its
Enthalpy + 3rd Ext flow x Its Enthalpy+ Exhaust Steam flow x its Enthalpy)) /Power Generation
Or
THR=((Steam Flow x Steam Enthalpy +Makeup Water flow x Its Enthalpy+ RC Flow x RC
Enthalpy)-(Process-1 steam flow x its Enthalpy + Process-2 steam flow x Its Enthalpy+ FW Flow
x FW Enthalpy)) /Power Generation
2-Turbine efficiency calculation
Efficiency = 860 X 100 /  Turbine heat rate
3-Steam condenser efficiency calculation

Condenser efficiency =Difference in cooling water inlet & outlet temperatures X 100/(Vacuum
temperature-condenser Inlet temperature of cooling water)

Condenser efficiency = (T2 - T1) X 100/(T3 - T1)

T2: Condenser outlet cooling water temperature,

T1: Condenser inlet cooling water temperature,

T3: Temperature corresponding to the vacuum or absolute pressure in the condenser.

4-Vacuum efficiency calculation

Vacuum efficiency = (Actual vacuum in condenser X 100)/Max. Obtainable vacuum.

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I.e

Vacuum efficiency in % =Actual vacuum X 100 / (Atmospheric pressure or barometric pressure-

CLOSE ADS CLOSE ADS
Absolute pressure)

5-Cooling tower range

Range = Cooling tower outlet water temperature-Cooling tower inlet water temperature
6-Cooling tower approach
Approach = Cooling tower outlet cold water temperature - Wet bulb temperature
7-Cooling efficiency calculation
Efficiency = Range X 100 / (Range + Approach)
8-Heat rejected or heat load of cooling towers
Heat load =Mass of circulating water X Specific heat of water Cp X Range
9-Cooling tower evaporation loss calculation
Evaporation loss in m3/hr = 0.00085 X 1.8 X Water circulation rate  m3/hr X Range 
Evaporation loss in % = Evaporation loss X 100 / Water circulation rate  m3/hr
10-Cooling tower blow down loss calculation
Blow down loss in % = Evaporation loss X 100 / (COC-1)
Where COC: Cycles of concentration
Its generally calculated as;
COC = Conductivity in circulation water / Conductivity in makeup water
OR
COC = Chloride in circulation water / Chloride in makeup water
11-Calculation of mass of cooling water required to condenser steam in surface condensers
Mw = (Ms X (hfg X dryness fraction(x) + Cpw (T3 - Tc)))/(Cpw X (T2 - T1))
Mw = Mass of cooling water required in TPH
Ms = Mass of exhaust steam to condenser in TPH
Hfg = Enthalpy of evaporation at exhaust pressure in kcal/kg
Cpw = Specific heat of cooling water in kcal/kg
T3= Temperature at exhaust pressure in deg C
Tc= Temperature of condensate in deg C
T1=Cooling water temperature entering condenser in deg C
T2 = Cooling water temperature leaving condenser in deg C
12-Steam turbine wheel chamber pressure calculation (Appx)
Turbine wheel chamber pressure (kg/cm2 ) = (Turbine inlet pressure (kg/cm2 ) X Turbine
operating load (MW) X 0.6) / Turbine rated capacity (MW).
13-Calculation of power generation in steam Turbine
Power generation in MW= Turbine inlet steam flow  in TPH X (Inlet steam enthalpy in kcal/kg-
Exhaust steam enthalpy in kcal/kg) / 860
14-Power generation calculation in multi stage Turbines
Power generation in MW= Steam flow from 1st stage X (Inlet steam enthalpy in kcal/kg- 1st
stage extraction steam enthalpy in kcal/kg) + Steam flow from 2nd   stage X (Inlet steam
enthalpy in kcal/kg- 2nd  stage extraction steam enthalpy in kcal/kg) + Exhaust steam flow to
condenser X (Inlet steam enthalpy in kcal/kg- Exhaust  steam enthalpy in kcal/kg) / 860
15-Calculation of work done per kg of steam in Turbine
Work done/kg of steam = Inlet steam enthalpy in kcal/kg-Exhaust steam enthalpy in kcal/kg
16-Calculation of steam required per per KWH
Steam required per KWH = 860 / (Work done per kg of steam)
Or
Steam required per KWH =860/(Inlet steam enthalpy in kcal/kg-Exhaust steam enthalpy in
kcal/kg)
17-Thermal power plant efficiency calculation
Efficiency = 860 X Power generation / Heat input
Efficiency = 860 X PG X 100 / (Fuel consumption X Fuel GCV)
18-Co gen-plant efficiency calculation
Efficiency = 860 X Power generation X 100 / (Fuel consumption X GCV + Make up water X Make
up water enthalpy + Return condensate water X Enthalpy-Process steam flow X Enthalpy)
19-HP heater steam consumption calculation
Steam flow in TPH = FW flow in TPH X (HP heater outlet FW temperature-HP heater inlet FW
temperature) /(Steam enthalpy in kcal/kg-HP heater outlet condensate water enthalpy in
kcal/kg)
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Where, FW =  Feed water
20-Deaerator steam consumption
MassADS
CLOSE of steam in TPH = (Deaeraor outlet Feed water flow in TPH X Enthalpy –CEP flow X CLOSE ADS
Enthalpy-Makeup water X Enthalpy) / (Enthalpy of steam-Enthalpy of deaerator outlet water)
Note: Enthalpy in kcal/kg
Feed water, CEP water & Make up water flow in TPH

C-Pumps fans and air compressors

1-Centrifugal pumps hydraulic power consumption
Hydraulic power in Kwh = Flow (M3/sec) X Total head (m) X Fluid density (kg/m3) X g (m/s2) /
1000
2-Pump shaft power calculation
Pumps shaft power Ps = Hydraulic power / Pump efficiency
3-Pump electrical power calculation
Electrical power = Pump shaft power / Motor efficiency
4-Pump affinity laws
2
a-Q1/Q2 = N1/N
Q1 & Q2 are pump flow at different RPM
N1 & N2 are pump speed
2 2
b-H1 / H2 = (N1)  / (N2)
Where H1 & H2 are pump head at different RPM
N1 & N2 are pump speed
3 3
c-P1 / P2 = (N1)  / (N2)
P1 & P2 are pump flow at different RPM
N1 & N2 are pump speed
5-Relation between head,flow ,power and impeller diameter
Q = D (Flow is directly proportional to impeller diameter)
H = D2 (Head is directly proportional to square root of impeller diameter)
P =D3 (Power is directly proportional to impeller diameter)
6-Relation between NPSHR, flow and speed
NPSHR = N2 (NPSHR is directly proportional to square root of speed)
That is as the flow and speed increase, pump need more NPSH
7-Fans volumetric flow calculation
Flow (m3/sec) = Velocity of fluid (m/sec) X Area of duct (m2)
8-Fans Mechanical efficiency calculation
Mechanical efficiency % = Flow (m3/sec) X Total pressure (mmwc) X 100 / (102 X power input
to fan shift in KW)
9-Fans Technical efficiency calculation
Static efficiency % = Flow (m3/sec) X Static pressure (mmwc) X 100 / (102 X power input to fan
shift in KW)
11-Fans affinity laws
a-Q1/Q2 = N1/N2
Q1 & Q2 are fans flow in m3/sec at different RPM
N1 & N2 are fans speed
2 2
b-SP1 / SP2 = (N1)  / (N2)
Where SP1 & SP2 are static pressure in mmwc of fan at different RPM
N1 & N2 are pump speed
3 3
c-P1 / P2 = (N1)  / (N2)
P1 & P2 are flow flow at different RPM
N1 & N2 are pump speed
11-Isothermal power of reciprocating compressors
P = P1 X Q X loge r/36.7

Where, P = Isothermal power

Q = Free air delivered by compressor in m3/hr
R = P2/P1

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P1 & P2 are absolute inlet & deliver pressure respectively
10-Isothermal efficiency of reciprocating compressors
Isothermal
CLOSE ADS efficiency = Isothermal power X 100 / Actual measured input power CLOSE ADS

11-Isothermal efficiency of reciprocating compressors

Isothermal efficiency = Free air delivered (m3/min) X 1007 / Compressor displacement
(m3/min)
12-Compressor displacement = 3.142 X D2 X L X S X n X N
Where, D = Cylinder bore in meter
L = Cylinder stroke in meter
S = Compressor speed in rpm
n= 1 for single acting & 2 for double acting cylinders
N=No.of cylinders
13-Compressed air leakage calculation
% of leakage = T X 100 /  (T+t)
Or air leakage in m3/min = T X Compressor capacity (m3/min) / (T+t)
T = Loading time in minutes, t = Unloading time in minutes
14-Calculation of intermediate pressure of reciprocating air compressors
P2 =SQRT ( P1 X P3)
Where P1,P2 & P3 are suction pressure, intermediate pressure and discharge absolute pressure
respectively

D-Fuel handling
1-Minimum length of belt conveyor take up
Total belt length X 1.5%
2-Conveyor belt speed calculation
Belt speed (m/sec) = 3.142 X D X N / 60
Where, D= Head pulley diameter in meter
N = Head pulley speed in RPM
Head pulley speed = Moto RPM / Gear box reduction ratio
3-Conveyor start up tension calculation
T (N/mm)= P X 3.2 / (V X W)
Where,P = Power consumption of conveyor
V = Belt speed in m/sec
W = Belt width in mm
4-Tensile strength of belt
Initial tension of the belt X 5.4 / Belt splicing efficiency

E-Mechanical Maintenance
1-V pulley speed calculation
N1/N2 = D2/D1
N1 & N2 are speed in RPM of drive and non drive end pulleys
D1 & D2 are diameter (inch or mm) of drive and non drive end pulleys
2-Gear box output speed calculation
Gear box out put shaft speed = Motor RPM / Reduction ratio
3-Speed of pulley calculation
Pulley speed (m/sec) = 3.142 X D X N / 60
Where, D = Diameter of pulley in meter
N = Pulley rotary speed in RPM
4-V belt length calculation
 L =∏ (R1+R2) + 2C + (R2+R1)2/C
Where, R1 & R2 are radius of DE & NDE pulleys
5-C is centre distance between two pulleys
6-Torque developed on a shaft
T = P X 60 / (2 X ∏ X N)
Where, P = Power consumption, N is speed of the shaft
7-Calculation of hub diameter of a shaft
Hub diameter = 2 X Shaft diameter

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8-Bearing lubrication quantity calculation
Bearing lubrication quantity in grams = Bearing OD (D) X Width (B) X 0.05
9-SafeADS
CLOSE working load of steel wire rope of size D (inches) CLOSE ADS

2
SWL = 8D
10-Safe working load of Chain block having Load link diameter D in mm
2
 Safe working load of chain block = 80 X 0.4 X D
Where 80 is the grade of chain block steel material
D is the link diameter in mm
12-Safe working load of Nylon lifting rope of  diameter D in mm
2
Safe working load of chain block = D
13-Calculation of weight of steel plate
Weight in kg = Plate length (m) X width (M) X Thickness (m) X density of steel (kg/m3)
14-Calculation of weight of round steel plate
2
Weight in kg = (∏D /4) X plate thickness in meter
D is diameter of plate in meter
15-Calculation of weight of hollow cylinder
2 2
Weight in kg = (∏R 2X h- ∏R 1X h) X steel density in kg/m3

Where, R1 & R2 are outer radius & inner radius of tank in meter
H is height of tank in meter

F-Electrical and Instrumentation

1-Single phase power consumption calculation
P = VI Cos θ
Where,Cos θ P is power consumption in Watts, V&I are Voltage in volts and current in Amps
receptively
Cos θ is power factor
2-Three  phase power consumption calculation
P = √3VI Cos θ
3-Apparent power = V X I (Voltage X Current)
4-Real power = √3VI Cos θ
5-Reactive power of 3-phase power =√3VI Sin θ
Reactive power of single-phase power =VI Sin θ
 
 
6-Resistance of a conductor
R = ƍ X L/A
R = Resistance in Ohm-meter or Ohm-cm
L & A are Length and area of conductor measured in meter & m2
7-Voltage, current and resistance relation
Voltage = Current X Resistance, i.e. V = IR

8-Resistance of a conductor at temperature t °C is given by

Rt = R0 (1 + α t) Where α is temperature coefficient at t °C.

8-Electrical Power calculation

   Power= Work done watt-sec./Time in second

   P = VI X t/t i.e. VI Watts

2
   P = I R… Watts

9-Power factor calculation

Power factor (cosՓ) = Active power (KW) / Apparent power (KVA)

10-Synchronous speed calculation

Synchronous speed/RPM = (120 X frequency)/No. of poles.

11-Absolute Pressure = Gauge Pressure + Atmospheric Pressure

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12-Relation between flow and differential pressure (DP). Flow (Q) = √(DP
Q1/Q2 = (√∆P1/∆P2)
CLOSE ADS CLOSE ADS
13-Compensated flow calculation
Compensated flow=  Raw value from flow meter X  Sqrt ((Absolute Design
temperature/Absolute Operating temperature) X (Absolute operating pressure/Absolute design
pressure))

For more read>>> Power plant and calculations

Practical Approach to Power Plant

Operation and Maintenance

Labels: Efficiency & performance

Location: India

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