5.heat Rate

OPG POWER GENERATION PVT LTD.
, DOC NO:
2X77, 1X80, 1X180 MW THERMAL POWER PLANT, GUMMIDIPOONDI OPGPG/0/O&E/SOP/01/005
DOC TITLE HEAT RATE AND ITS DEVIATION REV NO: 1 REV. DT. 12/11/13
HEAT RATE & ITS DEVIATION
There are several different definitions of heat rate that are used. Each definition is
valid and useful when properly applied. In General, Heat rate is a ratio of Heat Input to the Power
Output.
Heat rate monitoring is focused on identifying heat rate problems and then identifying
and implementing corrective actions to eliminate the efficiency loss. In this approach, heat rate
deviations from expected or design levels are identified and quantified. Then using fault trees or
other resources the cause(s) are identified. This method is useful, but the fact is, the heat
rate should not be allowed to deteriorate to the point that unexpected or unknown deviations
exist.
The personnel operating or maintaining the equipment should be aware of equipment
deterioration and corrective action should be taken prior to the point that it significantly
impacts the heat rate. By following good O&M practices and proactive action, heat rate
deteriorations can be avoided (or at least accounted for) before they are reflected in the overall
performance statistics.
This pro-active approach is accomplished by identifying key “primary process
indicators” , monitoring them and taking corrective actions immediately as indicated. If this
is done, the improvement in higher-level performance parameters (heat rate, availability, etc.)
will follow.
A secondary purpose for monitoring primary process indicators is to assist in
instrument validation/instrument calibration. By closely monitoring critical instruments, drifts
or irregularities can be quickly identified and the instrument calibrated or replaced.

OPG POWER GENERATION PVT LTD., DOC NO:
Responsibilities:
Role Responsible
Data Collection – from DCS O&E Engineer
Calculations & Analysis O&E Engineer

Verification / Approve O&E Head
Deviation Report:
If any performance deviation is noted during analysis means, the following channel is
followed for conveying the report to management
O & E Head
President - Operations
JMD
ASSUMPTIONS
The following assumptions have been made for the analysis of station Heat Rate:
1. Design Station Heat Rate has been evaluated based on design data of turbine heat rate and
boiler efficiency
2. The data related to various parameters of station heat rate such as generation, fuel
consumption, calorific values of fuels, etc. has been found.
3. Weighted average of Coal Gross Calorific Value (GCV) which is AR basis and Oil GCV has
been computed monthly/yearly for calculating heat rate.
EVALUATION METHOD
There are two methods for heat rate evaluation of Thermal Power Stations, i.e., Indirect
Method and Direct Method.
Indirect Method
Indirect method of Heat Rate Measurement is an instantaneous method which is used for
short duration and not possible throughout the year. It is a very complex method and basically a
loss based method of measurement of Heat Rate. This method is generally adopted during the
Energy Audit Studies.
Direct Method
Direct Method of Heat Rate Assessment is suitable for long duration in which averaging
gives almost actual Heat Rate because Coal consumption measurement is fairly accurate if taken
over a month/Year. Therefore, this method is employed at almost all stations as per the standard
practice.
The Heat rate can be calculated on two basis
 Coal Consumption basis

 Plant Parameter basis
HEAT RATE CALCUALTION
Data Required
a) Coal Bunkered in MT
b) Oil Consumed in kL
c) Coal Weighted Avg. GCV in kCal/kg
d) Oil GCV in kCal/kg
e) Total Power Generated in kWh
f) Feed water Flow in TPH
g) Spray water Flow in TPH
h) Make up water Flow in TPH
i) Main Steam Temp in ° C
j) Main Stream Press in bar (gauge pressure)
k) Enthalpy of Main Steam in kcal / kg
l) Enthalpy of Feed Water in kcal / kg
m) Heat rate is expressed in kCal / kWh
COAL BASIS:
(Coal Bunkered x 1000) x Coal GCV )

Unit Heat Rate =
Power Generated in kWh
(Oil Consumed x Oil GCV x 1000 x .89)

Actual Unit Heat Rate = Unit Heat Rate +
Power Generated in kWh
PLANT PARAMETER BASIS:
(FW Flow + SW Flow − MW Flow) ∗ (MS Enthalpy − FW enthalpy)

Turbine Heat Rate =
Power Generated in MWh
Turbine Heat Rate

Unit Heat Rate =
Calcualted Boiler Efficiency
Sample Calculation:
a) Coal Bunkered = 33637 MT

b) Oil Consumed = 37.18 kL
c) Coal Weighted Avg. GCV = 4443 kCal/kg
d) Oil GCV = 10400 kCal/kg
e) Total Power Generated = 47 630 000 kWh
f) Running Hours = 594.30 h
g) Feed water Flow (FW) = 312 TPH
h) Spray water Flow (SW) = 17.43 TPH
i) Make up water Flow (MW) = 5.008 TPH (3606 m3)
j) Main Steam Temp = 539 ° C
k) Main Stream Press = 91.33 bar
l) Enthalpy of Main Steam = 832.20 kcal / kg
m) Enthalpy of Feed Water = 258.67 kcal / kg
n) Calculated Boiler Efficiency = 82.28 %
COAL BASIS
(33637 𝑥 1000) 𝑥 4443 )
Unit Heat Rate =
47630000
Unit Heat Rate = 3138 kCal /kWh
(37.18 𝑥 10400 𝑥 100 𝑥 .89)

Actual Unit Heat Rate = 3138 +
47630000
Actual Unit Hear Rate = 3147 kCal/kwh
PLANT PARAMETER BASIS
(312 + 17.43 − 5.0086) 𝑥 (832.3 − 258.6)

Turbine Heat Rate =
80.14
Turbine Heat Rate = 2321 kCal / kg
Unit Heat Rate = 2821 kCal / kg
METHODOLOGY OF HEAT RATE DEVIATION CALCULATION
Heat rate deviations are calculated on the basis of parameter having direct impact on
Heat Rate. For arriving at best possible deviation value duration of data collection and
frequency of data collection plays vital role. Input data for all the parameter is available in Daily
DCS log and the final average value to be used for calculations.
The parameters used for Accountable Heat Rate Deviations are as follows,
 Load
 MS Pressure
 MS Temperature
 Condenser Back Pressure
 FW Temperature at HPH2 Outlet
 Make Up Water %
 Dry Flue Gas Loss
 Impact of Coal on Dry Gas Loss
 Wet Flue Gas Loss
 Combustibles in Fly Ash

 Combustibles on Bottom Ash
 Startup Oil Consumption
The deviations are calculated on the basis of Actual value compared with the Design value and
the Deviations are derived from the HR deviation curve.
1. LOAD
MS HR DEV
Average load based on gross energy meter reading is to Pressure(g) kCal/kWh
90 0
be taken for calculation. This average value of Load is to be
89 0
compared with Full load capacity of unit. The difference of Load 88 2.236
87 4.472
will be taken for Heat rate deviation calculation. The heat rate 86 6.708
deviation is to be derived from Load Vs HR deviation curve. Till 85 8.944
84 11.18
such time the customized correction curve is not available the 83 13.416
correction curves provided by manufacturer may be used. 82 15.204
81 17.44
80 19.676
Sample Calculation:
Design Full Load = 80 MW
Expected Load = 80 MW
Actual Load = 80.14 MW
Variance = -0.145 MW
Turbine HR Deviation = 0 (From Curve)

Tested Boiler Eff = 82.28 %
HR Deviation = 0 kcal/kWh
2. MAIN STEAM PRESSURE MS HR DEV

Pressure(g) kCal/kWh
90 0
MS Pressure before ESV – Day average of 24 hr is to be taken 89 0
every day and the monthly average is used for calculation. This 88 2.236
87 4.472
average value of actual pressure will be compared with expected 86 6.708
85 8.944
pressure (Expected pressure = Design pressure) required. The
84 11.18
difference of Pressure will be taken for Heat rate deviation 83 13.416
82 15.204
calculation based on customized correction curves developed by 81 17.44
station. 80 19.676
Sample Calculation:
Design Pressure = 89 kg/cm2 (abs)
Expected Pressure = 89 kg/cm2 (abs)
Actual Pressure = 92.18 kg/cm2 (abs)
Variance = -3.175 kg/cm2 (abs)
Turbine HR Deviation = 0 (from curve)

HR Deviation = 0
3. MAIN STEAM TEMPERATURE

Main steam temperature before ESV - Day average of 24
MS TEMP HR DEV
hrs is to be taken every day and the monthly average is used for
(deg C) kCal/kWh
calculation. This average value of temperature is to be 545 -8.494
544 -7.6
compared with expected temperature. (Expected temperature = 543 -6.706
Design Temperature). The difference will be taken for Heat rate 542 -5.812
541 -4.918
deviation calculation based on customized 540 -4.024
correction curves developed by station. 539 -3.13
538 -2.236
Sample calculation: 537 -1.788
536 -0.8944
Design M.S Temperature = 535 ◦C
535 0
Expected M.S Temperature = 535 ◦C 534 1.788
533 3.13
Actual M.S Temperature = 539.36 ◦C 532 4.472
Variance = -4.36 ◦C 531 5.8136
530 7.602
Turbine HR Deviation = -3.58 kCal/kwh
Tested Boiler Efficiency = 82.28 %

HR Deviation = -4.35 kcal/kWh
4. VACUUM PRESSURE
Condenser backpressure based on average of 24 hrs is to be
taken every day and the monthly average is used for calculation. This Vacuum
HR DEV
kg/cm2 (g)
average value of Condenser backpressure is to be compared with -0.87 -16.0992
expected condenser backpressure The difference of Average value -0.86 -13.8632
-0.85 -11.18
of Day and Expected value of condenser backpressure is to be -0.84 -8.0496
taken for Heat rate deviation calculation based on customized -0.83 -3.354
-0.82 0
correction curves developed by station.
-0.81 5.59
Sample calculation: -0.80 13.416
Design Vacuum Pressure = -0.82 kg/cm2 -0.79 19.677
-0.78 23.031
Expected Vacuum Pressure = -0.82 kg/cm2 -0.77 29.068
Actual Vacuum Pressure = -0.87 kg/cm2
Turbine HR Deviation = -16.099 kCal/kWh
HR Deviation = -19.567 kcal/kWh
5). FW TEMPERATURE AT ECONOMISER INLET:

Feed water temperature at top HPH outlet based on 24 hrs HR Dev
FW Temp.
average is to be taken every day and the monthly average is used for (kcal/Kwh)
252 -3.2422
calculation. This average value of Feed water temperature is to be 251 -3.2422
250 -3.2422
compared with the expected value of Feed water temperature
249 -2.5714
(Expected FW Temperature = Feed Water Temperature corrected 248 -1.9006
247 -1.2298
for load, derived from curve between Feed Water Temperature vs 246 -0.559
load). The difference of Average value of month 245 0
244 1.118
and Expected value of Feed water temperature is to be taken for 243 2.012
Heat rate deviation calculation based on customized correction 242 2.906
241 3.913
curves developed by station. 240 5.03
Sample Calculation:
Design FW Temperature = 244.9 C
Expected FW Temperature = 244.9 C
Actual FW Temperature = 249.45 C
Variance = -4.55 C
Turbine Heat Rate Dev = -3.24 kCal/kWh
Heat Rate Deviation = -3.94 kCal/kWh
6. DM MAKEUP WATER
Total DM Make up to the boiler in a unit is to be taken for calculation of % DM
makeup. For comparing Heat rate loss due to DM make up, it can be divided into 50:50 ratio
as 50 % steam side leakage and 50 % water leakage of total % of DM makeup.
Heat Value of make-up, H (Dev) = 0.5 x (H1- H2) + 0.5 x (H3- H2)
HR (Dev) = [Q x H (Dev) x 1000] / (GG)
Where
DM Makeup = Q M3
MS enthalpy = H1 kcal/kg
Makeup water enthalpy = H2 kcal/kg
Feed water enthalpy = H3 kcal/kg
Gross generation = GG kWh
Heat Rate Deviation = HR (Dev) kcal/kWh
Sample Calculation:
Design DM Make Up = 1%
Expected DM Make Up = 1%
DM Make Up-Q = 3606 m3
MS enthalpy H1 = 832.20 kcal/kg
Makeup water enthalpy H2 = 35.03 kcal/kg
Feed water enthalpy H3 = 258.67 kcal/kg
Gross Generation GG = 47.63 x 1000000 kWh
H (Dev) = 0.5 x (832.2 – 35.03) + 0.5 x (258.67 -35.03)
= 510.41 kcal/kg
HR Deviation = (3606 x 1000 x 510.41) / 47.63 x 1000000

HR Deviation = 38.643 kcal/kWh
For 1% DM Make Up
Heat Rate Deviation = 19.7625 kcal/kWh
So, Actual HR deviation is calculated by subtracting the HR dev value for 1 %
Actual HR Deviation = 18.889 kCal/kWh (=38.643-19.7625)
7. DRY FLUE GAS

The Dry flue Gas loss which is one of the loss of Boiler is to be compared with design Dry
Flue gas loss provided by the boiler manufacturer.
Sample Calculation:
Design Dry Gas Loss = 5.29 %
Expected Dry Gas Loss = 5.29 %
Actual Dry Gas Loss = 6.62 %
Variance = -1.33 %
Unit Heat Rate = 2821 kCal/kWh

Turbine Heat Rate = 2321 kCal/kWh
Heat Rate Deviation = Unit HR - (Turbine HR / (Tested Boiler Eff – Variance))
= 2821 – (2321 / (0.8228 – (-0.0133))
Heat Rate Deviation = 44.70 kCal / kWh
7a). IMPACT OF COAL ON DRY GAS LOSS

Dry Gas Loss to be corrected for Ambient air And Design Coal from the correction factors.
Correction factors to be calculated for the bunkered Coal and Ambient Temperature from the
correction curves.
Sample Calculation
Actual Dry flue Gas Loss = 6.60 %
Hydrogen in Coal = 3.53 %
Correction Factor (a) = 1.00
Moisture in Coal = 30.34 %
Correction Factor (b) = 0.97

GCV of the Coal = 4443 kCal/kg
Correction Factor (c) = 1.014
Ash in Coal = 6.97 %
Correction Factor (d) = 1.022
Ambient Temperature = 31º C
Correction Factor (f) = 0.9975
Overall correction Factor = axbxcxdxexf = 0.9975
Dry Gas Losses Corrected = Actual Dry Flue Gas Loss x Overall Correction Factor
Dry Gas Losses Corrected = 6.61 %
Impact of Coal on Dry Gas Loss (Variance) = 6.6 – 6.61 = -0.016 %
Heat Rate Deviation = (Turbine HR / (Tested Boiler Eff – Variance)) - Unit HR

= (2321 / (0.8228-(-0.00016)) - 2821
Heat Rate Deviation = 0.56 kCal / kg

Correction Factors for H2, Moisture, GCV, Ash and Ambient Temperature
8. WET FLUE GAS LOSS

Calculation of Wet flue gas loss for calculating HR deviations shall be based on
following parameters
 AH Exit Temperature - Daily 24 hrs Average Value and Monthly Average
 Air Inlet Temperature to AH- Daily 24 hrs Average Value and Monthly Average
 Proximate analysis of coal
Sample Calculation:
Design Wet Flue Gas loss = 10.4 %
Expected Wet flue gas Loss = 10.4 %

Actual Wet Flue gas Loss = 8.44 %
Variance = 1.96 %
Heat Rate Deviation = Unit HR - (Turbine HR/ (Tested Boiler Eff – Variance))
= (2321 / (0.8228 – 0.0196)) - 2821
Heat Rate Deviation = -68.82 kCal/kWh
9. COMBUSTIBLES IN FLY ASH

Change in Boiler Efficiency with Unburnt = 0.8 x (UBE-UBA) x ASH x 80.77/GCV
UBE - Expected level of unburned carbon in Ash
UBA - Measured value of unburned carbon (%)
ASH - Ash content of coal from proximate analysis (%)
GCV - Gross Calorific value of the as-fired fuel (kcal/kg)
Sample Calculation
Ash % in coal = 6.97 %
GCV = 4616 Kcal/kg
Expected Unburnt = 0.7 %
Actual Unburnt = 1.26 %
Variance = -0.56 %
Monthly Tested Boiler h = 82.28 %
Change in Boiler Efficiency with change in fly ash Unburnt CBE = 0.05 %
Heat Rate Deviation = (Turbine HR/ (Tested Boiler Eff – CBE)) - Unit HR
= (2321 / (0.8228 – 0.0005)) – 2821
Heat Rate Deviation = 1.87 kCal/kWh
10. COMBUSTIBLES IN BOTTOM ASH

Change in Boiler Efficiency with Unburnt (CBE) = 0.2*(UBE-UBA)*ASH*80.77/GCV
UBE - Expected level of unburned carbon in Ash

UBA - Measured value of unburned carbon (%)
ASH - Ash content of coal from proximate analysis (%)
GCV - Gross Calorific value of the as-fired fuel (kcal/kg)
Sample Calculation
Ash % = 6.97 %
GCV = 4616 Kcal/kg
Expected Unburnt = 0.3 %
Actual Unburnt = 0.33 %
Variance = -0.03%
Monthly Tested Boiler h = 82.28 %
Change in Boiler Efficiency with change in fly ash Unburnt =
= (0.2 x (0.3-0.33))x0.0697x80.77/4616
= -0.0007 %
Heat Rate Deviation = (Turbine HR / (Tested Boiler Eff – CBE)/100))-Unit HR
= (2321 / (0.8228 – 0.000007)) - 2821
Heat Rate Deviation = 0.03 kCal/kWh
11. STARTUP - OIL CONSUMPTION

Total oil consumption during startups (Light up to synchronization) and other
requirements is to be considered for loading in to heat rate deviation.
Sample calculation
Total Oil Consumption = 37.18 KL
Total Generation = 47.630 MU
Density = 0.89 kg/L
HR Deviation = (Oil cons x Density x GCV) / Generation
= (37180 x 0.89 x 10400) / (47.63 x 106)
HR Deviation = 7.23 kCal / kWh
OPG POWER GENERATION PVT LTD.,
DOC NO:OPGPG/1 OPN/SOP/003/005
2X77, 1X80, 1X180 MW THERMAL POWER PLANT, GUMMIDIPOONDI
DOC TITLE SOP – HEAT RATE & HEAT RATE DEVIATION REV NO 04
HR
Parameter values
Deviation
No Parameters Unit Loss % Loss RS
Design Expected Actual Variance kcal/kWh
1 Load MW 80 80 80.14 -0.145 0 0 0

Accountable HR Deviation
2 Main steam Pressure before ESV kg/cm2 89 89 92.18 -3.1755 0.000 0.000 0
3 Main steam Temp. before ESV °C 535 535 539.36 -4.36 -4.35 -0.138 -418236
4 Condenser back pressure kg/cm2 -0.82 -0.82 -0.87 0.05 -19.567 -0.622 -1882377
5 FW Temperature at HPH Outlet °C 244.9 244.9 249.45 -4.55 -3.94 -0.125 -379090
7 Makeup Water % MCR 1 1 1.565 -0.565 18.880 0.600 1816343
8 Dry Flue gas loss (DFG) % 5.29 5.29 6.615 -1.325 44.70 1.421 4300031
9 Impact of Coal on Dry Gas Loss % 6.615 6.61 6.60 0.016 0.56 0.018 53746
10 Wet Flue gas loss % 10.4 10.4 8.440 1.960 -68.82 -2.188 -6621166
11 Combustibles in Fly Ash % 0.7 0.7 1.26 -0.56 1.87 0.060 180341
12 Combustibles in Bottom Ash % -0.3 0.3 0.33 -0.03 0.03 0.001 2414
13 Startup-Oil Consumption kL 37.18 7.23 0.230 695095
Total Accountable HR Deviation kCal/kWh -23.42 -0.745 -2252900
14 Unidentified HR Deviation 445 14.163 42853665
15 Total HR Deviation 422.029 13.419 40600766

5.heat Rate

Uploaded by

Copyright:

Available Formats

You might also like

5.heat Rate

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

5.heat Rate

Uploaded by

Copyright:

Available Formats

OPG POWER GENERATION PVT LTD.

HEAT RATE & ITS DEVIATION

The personnel operating or maintaining the equipment should be aware of equipment

This pro-active approach is accomplished by identifying key “primary process

A secondary purpose for monitoring primary process indicators is to assist in

instrument validation/instrument calibration. By closely monitoring critical instruments, drifts

or irregularities can be quickly identified and the instrument calibrated or replaced.

Calculations & Analysis O&E Engineer

The Heat rate can be calculated on two basis

 Coal Consumption basis

HEAT RATE CALCUALTION

(Coal Bunkered x 1000) x Coal GCV )

(Oil Consumed x Oil GCV x 1000 x .89)

PLANT PARAMETER BASIS:

(FW Flow + SW Flow − MW Flow) ∗ (MS Enthalpy − FW enthalpy)

Turbine Heat Rate

a) Coal Bunkered = 33637 MT

Unit Heat Rate = 3138 kCal /kWh

(37.18 𝑥 10400 𝑥 100 𝑥 .89)

Actual Unit Hear Rate = 3147 kCal/kwh

PLANT PARAMETER BASIS

(312 + 17.43 − 5.0086) 𝑥 (832.3 − 258.6)

Turbine Heat Rate = 2321 kCal / kg

Unit Heat Rate = 2821 kCal / kg

METHODOLOGY OF HEAT RATE DEVIATION CALCULATION

 Combustibles in Fly Ash

Design Full Load = 80 MW

Turbine HR Deviation = 0 (From Curve)

2. MAIN STEAM PRESSURE MS HR DEV

Turbine HR Deviation = 0 (from curve)

3. MAIN STEAM TEMPERATURE

Tested Boiler Efficiency = 82.28 %

5). FW TEMPERATURE AT ECONOMISER INLET:

HR Deviation = (3606 x 1000 x 510.41) / 47.63 x 1000000

7. DRY FLUE GAS

Unit Heat Rate = 2821 kCal/kWh

7a). IMPACT OF COAL ON DRY GAS LOSS

Correction Factor (b) = 0.97

Heat Rate Deviation = (Turbine HR / (Tested Boiler Eff – Variance)) - Unit HR

Heat Rate Deviation = 0.56 kCal / kg

8. WET FLUE GAS LOSS

Expected Wet flue gas Loss = 10.4 %

9. COMBUSTIBLES IN FLY ASH

Heat Rate Deviation = 1.87 kCal/kWh

10. COMBUSTIBLES IN BOTTOM ASH

UBE - Expected level of unburned carbon in Ash

11. STARTUP - OIL CONSUMPTION

1 Load MW 80 80 80.14 -0.145 0 0 0

You might also like