ANIL PALAMWARRETIRED

CHIEF ENGINEER, KHAPERKHEDA TPS.DIRECTOR (OPERATION) MAHAVITARAN

• NEED FOR ENERGY AUDIT.

• AUDIT PROCEEDURES

• ENERGY AUDIT –

• MACRO LEVEL

• AND

• MICRO LEVEL.

1

Energy Audit ????? • We know Financial Audit.

• Audit of Public Enterprises.

• Balancing of Income & Expenses.

• Whether rules are followed ?

• E.A. is slightly different.

• Energy Audit deals with -

• Losses – Efficiency – Conservation

• Promotes :- Economy, competitiveness & Environment.

2

ENERGY CONSERVATION  ENERGY IS THE CAPACITY TO DO WORK.

 ENERGY IS AVAILABLE FROM WIND-WATER-SUN -FOSSIL FUEL

 MOSTLY WE WORK WITH ELECTRICAL OR THERMAL

ENERGY. Why Conserve?

1. - RESOURCES ARE LIMITED.

 2.-COST REDUCTION TO REMAIN VIABLE IN COMPETITION.

3.- Environment - Global warming - GHGs

3

EFFICIENCY OF RANKINE CYCLE IS LIMITED TO 35-40 %. 

C.C.G.T. PLANTS GO UP TO 52-55 %.Efficiency. [Combined Cycle Gas Turbines]

 SO IF HEAT IS USED DIRECTLY,

[WITHOUT CONVERTING TO ELECTRICITY], 

CYCLE EFFICIENCY WILL INCREASE. 

CO-GENERATION ADOPTS THIS PRINCIPLE. 

Industrial units must explore the possibility of use of waste heat.Where ever a furnace is used,

lot of waste heat is available for use in some way or other. IN SIMPLE WORDS –

WHEN 100 M.T. OF FUEL IS USED, ONLY 40 MT IS USED TO PRODUCE ELECTRICITY,

HEAT VALUE OF REMAINING 60 M.T. GOES UNUSED TO THE ATMOSPHERE.

4

ALSO- CONSIDER THE SYSTEM LOSSES-Transmission

Three Transformers-220/33; 33/11 ; 11/0.415 KV---

Efficiency=0.99 x0.99 x 0.99 =0.97 or 97%Transmission Efficiency= 94 %,

Distribution Efficiency=85%

Motor Efficiency=80 %

Pump Efficiency = 80%

Total system Efficiency=

0.97x0.94x0.85x0.80x0.80=0.4960 or 49.60%5

It means that for every unit consumed, two units are generated and sent from a power station.

 Conservation is therefore necessary. Waste must be

avoided . 

Cost is the most powerful motivating factor for conservation.

 Maharashtra State needs approximately 300 MU of

electricity per day. (Average) 

Only about 150 MU are really utilized. 

Efficiency is of utmost importance. 

Every process needs thorough check to identify losses. 6

Transformers- Losses within limits-e.g. MSEDCL  Motors-Pumps-Fans- e.g. Feed Pump and P.A. Fans at KPKD

TPS. Procurement-Installation-O&M -

All these affect performance-and losses. 

Ducting and its aerodynamics- Eddy formation  

Selection of correct pipe dia and cleanliness of pipes. 

Air conditioning- use of vapour cycles where waste heat is used.

 Properly set thermostats.

 Maximum use of daylight and Natural ventilation.

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ENERGY AUDIT FRIENDS & ENEMIES

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NEGATIVE FORCES

GOAL -TO REDUCE ENERGY CONSUMPTIONPOSITIVE FORCES

HIGH PRICE OF ENERGY

EFFICIENT TECHNOLOGY

TAX ON ENERGY

TOP MANAGEMENT SUPPORT

ENERGY INTENSIVE INDUSTRY

NO CORPORATE ENERGY POLICY

NO AWARENESS IN THE COMPANY

INSUFFICIENT SKILLS & KNOWLEDGE

COMPETING CORPORATE POLICIES

INSUFFICIENT FUNDS

FOUR PILLARS OF ENERGY MANAGEMENT

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TECHNICAL ABILITYMONITORING

SYSTEM

STRATEGY PLAN

TOP MANAGEMENT SUPPORT

ENERGY MANAGEMENT

MATERIAL BALANCE

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SOLID WASTE FOR STORAGE & DISPOSAL

WATER / AIR PROCESS

OPERATIONS

REUSABLE WASTE

GASEOUS EMISSION

PRODUCT

BYE PRODUCT

WASTE WATER

LIQUID WASTE FOR STORAGE &

RAW MATERIALS

CHEMICALS

ENERGY BALANCE

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ENERGY IN HOT RESIDUE

ENERGY IN CONDENSATE

COMPRESSED AIRENERGY IN COOLING

WATERENERGY IN RAW MATERIAL

ENERGY IN VAPOURELECTRICITY

STEAM RADIATION LOSSPROCESS

OPERATIONSCOOLING WATER ENERGY IN HOT PRODUCTS

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NON Renewable Energy Sources

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Renewable Energy Sources

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It took more than 3 million years to convert to Fossil Fuels.

INTRODUCTION INTRODUCTION

Conventional source of energy such as coal, oil and gas are scarce and exhaustible.

Energy prices will rise in the long run to reflect their relative scarcity and high cost of exploration and extraction.

Hence, all attempts must be made expeditiously to ensure the optimal use of the available resources to manage the viability and availability of energy.

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INTRODUCTION (contd.)INTRODUCTION (contd.) Government of India enacted the Energy

Conservation Act – 2001. For efficient use of energy and its conservation to

mitigate the gap between demand and supply and to promote economic competitiveness.

The Act provides for Institutionalizing and strengthening delivery

mechanisms for energy efficiency services in the country and

Provides the much-needed coordination between the various organizations and stakeholders,

Within the Government and in the private sector.

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Enacted in October 2001Enacted in October 2001

Become effective from 1st March 2002Become effective from 1st March 2002

Bureau of Energy Efficiency (BEE) operationalized Bureau of Energy Efficiency (BEE) operationalized from 1from 1stst March 2002. March 2002.

MISSION OF BEEMISSION OF BEEDevelop policy and strategies with a Develop policy and strategies with a

thrust on self regulation and market thrust on self regulation and market principles, within the overall framework of the principles, within the overall framework of the EC Act with the primary objective of reducing EC Act with the primary objective of reducing energy intensity of the Indian economy.energy intensity of the Indian economy. 20

1. DESIGNATED CONSUMERS1. DESIGNATED CONSUMERS( Energy Intensive Industries and other Establishments)( Energy Intensive Industries and other Establishments)

A programme to initially focus on energy policy A programme to initially focus on energy policy issues of energy efficiency improvement,issues of energy efficiency improvement,

in organized sectors such asin organized sectors such as energy intensive industries and.energy intensive industries and. commercial sector,commercial sector, through establishment of energy management through establishment of energy management

system,system, capacity building of energy professionals, capacity building of energy professionals,

implementation of energy audits, implementation of energy audits, establishments of specific energy consumption norms establishments of specific energy consumption norms support to consumers on providing information on support to consumers on providing information on

authentic energy data authentic energy data 21

Designated Industries Schedule - Responsibilities

Schedule to EC Act provides list of 15 energy Schedule to EC Act provides list of 15 energy intensive industries and other establishments to be intensive industries and other establishments to be notified as designated consumers (DC).notified as designated consumers (DC).

Designated Consumers to -Designated Consumers to -Appoint or designate energy managersAppoint or designate energy managersGet energy audits conducted by accredited Get energy audits conducted by accredited energy auditorsenergy auditorsImplement techno-economic viable Implement techno-economic viable recommendationsrecommendationsComply with norms of specific energy Comply with norms of specific energy consumption fixed consumption fixed Submit report on steps takenSubmit report on steps taken

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1)Designated Consumers

Thermal Power Stations- 30,000 Million tonne of oil equivalent (MTOE) per year and above

2) Fertilizer- 30,000 MTOE per year and above

3) Cement- 30,000 MTOE per year and above

4) Iron & Steel- 30,000 MTOE per year and above

5) Chlor-Alkali- 12,000MTOE per year and above

6) Alluminium- 7,500 MTOE per year and above

7)

Railways- One traction substation in each Zonal Railway , Production units and Workshops of Indian Railways having total annual energy consumption of 30,000 MTOE or more

under Ministry of Railways

8) Textile-3,000 MTOE per year and above

9) Pulp & Paper-30,000 MTOE per year and above23

WHY ENERGY EFFICIENCY IS IMPORTANT ?WHY ENERGY EFFICIENCY IS IMPORTANT ?

• We do something to enjoy, save money & resources and finally because it is the LAW.

• So Energy Audit – Because,

• Depleting fossil fuel-Resources are scarce

• Optimum plant utilization-Competitiveness.

• Global warming-Carbon Credit

• Designated consumer-E.A. is Mandatory.

• Generate more energy with same quantity of fuel

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PERIOD STEAM PRESSURE&

TEMPERATURE

UNIT SIZE(MW)

TURBINEHeat Rate(Kcal/kWh)

Unit Heat Rate(Kcal/kWh)/Efficiency

1951-60 60 kg/cm2, 482oC 30 – 57.5 2470

1961-75 70 kg/cm2, 496oC to 90 ata 538oC

60 – 100 2370

1961-75 130 ata 535/535oC 110 – 120 2170 – 2060 2552-2423

1977-82 130 ata 535/535oC 210 (Russian)

2060 2423/35.4%

1983+ 150 ata 535/535oC 210 (Siemens)

2024 233536.8%

1984+ 170 ata 535/535oC 500 1950 (TDBFP)

229437.4%

1990+ 150 ata 535/535oC 170 ata 538/538 oC

210/ 250250/ 500

1950 (MDBFP)

1950 (TDBFP)

22942294

THIS CHART SHOWS THE GRADUAL IMPROVEMENT IN HEAT RATE

TO ACHIEVE ECONOMY 25

EFFICIENCY IMPROVEMENT CAN GIVE YOU

For an average increase of 1 % in the Efficiency would result in:-

Coal savings of approx. 11 million tons per annum worth Rs.13,000 Million

CO2 reduction about 13.5 million tons per annum Lower generation cost per kWh- as more efficient the

unit works, the more economical it is 1% increase in efficiency for 210 Mw unit with heat

rate 2335 kcal/kwh means heat rate improvement to 2275 kcal/kwh

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MAJOR CAUSE OF INEFFICENCY IN POWER PLANTMAJOR CAUSE OF INEFFICENCY IN POWER PLANT

• High Flue gas exit Temp

• Excessive amount of excess air(O2)(Increases dry flue gas loss)

• Poor Mill/Burners performance causing high unburnt carbon in fly and bottom ash.

• Poor insulation.

• Poor house Keeping.

• Poor instrumentation and automation

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MAJOR CAUSE OF INEFFICENCY IN MAJOR CAUSE OF INEFFICENCY IN POWER PLANTPOWER PLANT (Cont…)

• Not running the units on design parameter• Heaters not in service or poor performance

of regenerative system• Poor condenser vacuum• Excessive DM water consumption- passing

and leakages• Use of Reheat spray to control Reheat

Temperature• Poor Cylinder Efficiency of turbine

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CONTROLLABLE PLANT PARAMETERS

• M.S. & R.H. Steam Temperatures

• M.S. Steam Pressure

• Condenser Vacuum

• Final Feed Water Temperature

• DP Across Feed Regulation Station

• Auxiliary Power Consumption

• Make Up Water Consumption

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HOW TO ACHIEVE ENERGY HOW TO ACHIEVE ENERGY EFFICIENCY ?EFFICIENCY ?

• Adopt state of the art technologies

• Adopt cutting edge technologies

• Review & Re-engineering of the existing systems

• Bench Marking

• Energy Auditing

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CAN WE IMPROVE CAN WE IMPROVE EFFICIENCY?EFFICIENCY?

Yes, provided we shed the myths and believe in applying result oriented efforts

Workout to identify & quantify the cost of hidden losses

Bring in requisite operational behavioral change

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SOME OF THE MYTHS High PLF & availability translates into

Optimum Efficiency

Heat rate is the responsibility of Efficiency Management Group at Stations

Equipment maintenance to be taken-up based on periodic overhaul schedule

Boiler performance degradations has no relation to Turbine Cycle performance

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Some of the Myths contd…• Design heat rate is the best achievable heat rate• Efficiency tests are the same as performance guarantee

test• Heat rate improvement requires large investment.• Results follow immediately after testing is completed

• Heat rate is the responsibility of Energy & Efficiency Management Group (EEMG) at Stations

• Station instruments are accurate for monitoring heat rate parameters

33

Some of the Myths contd… “Design” is not the best achievable performance

• Predicted performance based on Turbine Heat Balance Diagrams and Boiler Efficiency at different loads

• ‘Design’ is based on specific ambient conditions that vary throughout the year

• Actual initial performance could be different from design or changes might have been made to plant

• Current performance to be compared to an achievable ‘expected’ value to establish efficiency gaps

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SYNERGIZE OPERATIONOF UNIT

Need to clearly understand the relation between performance & fuel, operation and design parameters

Operational behavior and performanceImpacts of operating efficiency of Boiler, Turbine

and their auxiliaries on Net Unit Heat RateMaximum Achievable Load, Maintenance &Availability

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SOME CRITICAL FACTORS AFFECTING BOILER PERFORMANCE

• Fuel:- Heating Value, Moisture Contents, Ash Composition, Ash Contents,& Volatile Matter.

• Operational Parameter:- Level of Excess Air, & operating Condition of Burner Tilt Mechanism.

• Design:- Heating input per plan area, Height of Boiler, Platens & pendants heat transfer Surfaces, Burner & wind Box design.

36

BEHAVIOURAL IMPACTS• Low heat value results in over firing of fuel causing more heat

availability for super heater and re-heater thus more attempration spray requirement. Hence increase in THR, overloading of ash handling system, fans and increased soot blowing

• Moisture content increase causes increase in heat transfer to S.H, and R.H. Hence again increase in attempration spray and THR (Turbine Heat Rate)

• Ash composition and contents increases damage to pressure parts surfaces because of melting behavior of low fusion ash temperature of blended coal in particular

• In consistency in fired fuel characteristics results in variation in excess air requirement thereby increasing stack loss and hence boiler efficiency reduction, overloading of ID Fan and ultimately unit load limitation

• High heat value causes excessive radiant heat transfer to water walls thereby leaving lesser heat for super heater and re-heater

• .37

Normally excess air ranges from 15% to 30% of stoichiometric air.

• High O2 % and presence of CO at ID Fan outlet are indicator of air in leakages and improper combustion in furnace

• Poorly effective damper control also is the cause of higher SEC of fans both primary and secondary

• The quality and purity of feed water and make up water is also

required to be maintained in a meticulous way by limiting blow down losses to nearly 1% and by checking the passing and leakages of valves. However, maximum 3% of flow can be taken as make up for these causes including soot blowing requirements

• Soot blowing is dependent on ash contents and is unit specific. Intelligently devised soot blowing can result in saving the fuel

BEHAVIOURAL IMPACTS

38

• Cascading effects on efficiency, loading and availability because of following systems and equipments performance also needed to be looked into. The systems are:-Fuel receiving, preparation and handling systems.Pulverizing systemAir HeaterFansElectrostatic PrecipitatorFly ash handling systemBottom ash handling systemWaste disposal system

BEHAVIOURAL IMPACTS

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PERFORMANCE IMPACTS ON STEAM CYCLE , UNIT HEAT RATE & OUTPUT

• Various design & operating parameters of a unit are responsible for its cycle performance, heat rate,& out put

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CRITICAL FACTORS AFFECTING CYCLE PERFORMANCE

1. Re-heater & its system pressure drop2. Extraction line pressure drop3. Make up4. Turbine exhaust pressure5. Air preheat6. Condensate sub-cooling7. S/H & R/H spray flows8. Wet Bulb Temp9. Top Heaters out of service10. H.P. heater drain pump11. Type of BFP drives & method of flow control

41

RH & ITS SYSTEM PRESSURE DROP….

• Every one 1% decrease in drop can improve THR and output by 0.1% & 0.3% respectively

• Normally designed for pressure drop equivalent to 10% of HP exhaust pressure

• Causes are Feed Heater abnormalities R/H safety valve passing

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EXTRACTION LINE PRESSURE DROP…

• Permissible pressure drop between stage pressure & Shell pressure is maximum 6%

• For every 2% increase in this pressure drop, THR would be poorer by 0.09%

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CYCLE MAKE-UP….

• Acceptable value of make up water is 3% to offset cycle water losses

• For every 1% increase in make up 0.4% increase in THR & 0.2% reduction on output is there

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EXHAUST PRESSURE…• Increase & decrease in exhaust pressure do

affect the THR.

• Though no valid thumb rule has been devised so far, however last stage blade design & exhaust area of turbine do affect the impact of changing exhaust pressure.

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AIR PRE-HEAT….• Air preheating of combustion air before entry to

regenerative air heater is done with either steam coil air pre - heater or hot water pre heating coil to maintain Average Cold End Temperature (ACET) to escape dew point temperature complications

• Condensate retrieval is necessary to avoid deterioration to THR depending upon unit load and combustion pre heating duty

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CONDENSATE SUB-COOLING…

• For 30% total flow and 2.5 deg C sub-cooling ,an increase of 0.001% in THR can be there for every subsequent 10% increase in flow

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R.H & S.H. SPRAY FLOW…

• Spray water whether drawn from BFP or after the final heater, it is always less the generative and less productive as well

• Every 1% spray flow, correction need to be done in THR & load computed from the curves supplied with the machine

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TOP HEATER OUT OF SERVICE….• Extraction steam flow meant for top heater

passes through the turbine thereby increasing the output.

• But at the same time final feed water temp is lowered resulting in poor Total Heat Return.

• More fuel must be used in the boiler to add the sensible heat (Not imparted by the feed heater)

• The % loss increases from lowest stage (.5 to .6 ) to highest stage (1.2 to 1.5%)

• Roughly each Deg C in TTD will result in a loss of 0.25% efficiency.

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PERFORMANCE MONITORING• Analyze the poor efficiency areas from previous record

• Go down to specific system and then to component

• Carry out performance/diagnostic study as suggested in the Auditing Manual & operating manual

• Devise a unit specific efficiency control sheet for few terminal conditions (Actual vs Design)

• Monitor once per shift to know the operating efficiency and check any deterioration

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Coal Handling Plant

• Coal Crushers-• If significant quantity of coal >20 mm size is

observed on down side of crusher then it may led to substantial decrease in mill performance.

• Identification of combination of various least power consuming equipment and recommending merit order operation.

• Use of natural daylight through conveyor galleries and use of fire resistant translucent sheet.

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Soft Starters- V.F.D.

• Explore Installation of power saver device in major LT motors. (Conveyor belt etc.):

• Major HT /LT motors i.e. conveyors, crushers etc. are often partially loaded & also there are frequent starts /stops.

• Explore the possibility of providing power saver devices (soft starters) in major motors.

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Power Factor of Motors.

• Power factor correction possibility:• Induction motors may have vey low power factor,

leading to lower overall efficiency. • Capacitors connected in parallel with the motor are

used to improve the power factor.• The PF correction reduces KVA demand, • reduced I2R losses in cable upstream of capacitor,• reduced voltage drop in cables (leading to improved

voltage regulation),• and an increase in the overall efficiency of the plant

electrical system. 53

Chemicals for Dust Suppression• Explore the possibility of using chemicals for

reduced water spray:

• Mixing of chemical compounds in water provides much better atomization of water spray, by reduction in surface tension of water.

• Thus for the given application of dust suppression, less quantity of water is sprayed which also results into less wastage of latent heat in the steam generator.

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Use of Bull Dozers ?

• Maximum Mechanical Handling: • Minimum Bulldozing: Receipt, unloading, stacking

and reclaiming and the selection of machinery should be such that all the handling operations are accomplished without the use of semi mechanized means like bulldozers which are more energy intensive equipment.

• When coal is stocked in yard for more than incubation period (duration between coal mined and getting self ignited), special precautions like compacting, water spraying must be taken.

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Bunkering Frequency• Reduced Number of Fillings:

• Live storage capacity of raw coal bunkers and the filling pattern of bunkers is so planned that,

• 24 hours coal requirement of the generating units is met by not more than two fillings per day.

• This will eliminate frequent starting and stopping of the CHP system.

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Boiler Scheme

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Energy audit of Boiler• Coal quality - composition and calorific value

• Coal milling aspects

• Combustion and excess air

• Re-heaters

• Heat recovery units – Economisers, air preheaters, etc,

• Insulation aspects

• Boiler blow down aspects- Water Chemistry

• Soot blowing aspects- Effectiveness

• Operation and maintenance features which affect the energy efficiency

• Condition & status of boiler and their internals

• Feed water system aspects

• Air and flue gas system aspects 58

STEPS IN ENERGY AUDIT

• Data collection• Observations and Analysis• Exploration for energy conservation measures • Report preparation

– DATA COLLECTION• The first step in energy audit of boiler is to collect the

design / PG test parameters pertaining to boiler, economiser, air preheaters, coal and coal milling, soot blowing and other key associated equipment.

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Particulars Unit Details at Normal

cont. rating, NCR

Make BHEL

Type Water tube single

drum

Capacity tph 627.32

Main Steam pressure kg/ cm2 155

Main Steam temperature 0C 540

Boiler efficiency % 87.16

Super heater outlet flow tph 627.32

Reheater outlet flow tph 565.6

Coal Calorific value –GCV kcal/ kg 4350

Coal consumption tph 106.2

Total combustion air tph 822

LTSH outlet temperature 0C 420

Reheater outlet temperature 0C 540

Water- economizer inlet

temperature

0C 241

Water- economizer outlet

temperature

0C 280

Oxygen content at Economizer

outlet

% 4.23

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Unit Design NCR Actual

Make

Type

Year of Installation

Main Steam Pressure kg/ cm2

Main Steam Temperature oC

Main Steam Flow tph

Steam pressure at LTSH outlet kg/ cm2

Steam temperature at reheater inlet oC

Steam temperature at reheater outlet oC

Steam pressure at reheater inlet kg/ cm2

Steam pressure at reheater outlet kg/ cm2

Steam temperature at LTSH out oC

Saturated steam temperature in drum oC

Super heater platen outlet temperature oC

Pressure drop in reheater Kg/ cm2

Super heater spray tph

Reheater Spray tph

Design ambient temperature oC

Coal consumption tph

DESIGN DATA

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ECONOMISER DATA Unit Design Actual

Feed water pressure at the inlet kg/ cm2

Feed water pressure at the outlet kg/ cm2

Feed water flow Tph

Feed water temperature at the inlet oC

Feed water temperature at the out let oC

Oxygen content in flue gas before

economizer %

Excess air % in flue gas before

economizer %

Exhaust gas inlet temperature oC

Exhaust gas outlet temperature oC

Exhaust gas quantity Tph

62

AIR PRE HEATER DATA Unit Design Actual

Air quantity at APH outlet (primary) Tph

Tempering air Tph

Air heater outlet (secondary) Tph

Total combustion air Tph

Air temperature at fan outlet oC

Air outlet temperature of APH – primary oC

Air outlet temperature of APH– secondary oC

Oxygen content in flue gas before APH %

Oxygen content in flue gas after APH %

Excess air % in flue gas before

APH %

Flue gas inlet temperature oC

Flue gas outlet temperature oC

Flue gas quantity Tph

Others

63

EXHAUST GAS TEMPERATURE PROFILE

Unit Design Actual

Temperatures at different location oC

Super heater platen outlet oC

RH front inlet oC

RH rear inlet oC

SH final inlet oC

LTSH inlet oC

Economizer inlet oC

APH inlet oC

APH outlet oC

ID Fan inlet oC

ID fan outlet oC

64

BOILER HEAT BALANCE

Unit Design

Ambient temperature oC

Excess air %

Dry flue gas loss %

Hydrogen loss %

Moisture in fuel loss %

Moisture in air loss %

Unburnt combustible loss %

Radiation loss %

Un accounted loss %

Gross boiler efficiency on HHV %

Guaranteed efficiency %

65

Feed water & Boiler water limits

Unit Feed water Remarks

pH at 25oC

Oxygen – maximum ppm

Total iron- maximum ppm

Total silica – maximum ppm

Conductivity at 25oC Microsiemens

Hydrazine residual ppm

Total solids – maximum ppb

Chlorides ppm

Copper – maximum ppm

Permanganite consumption ppm

66

MILLS AND BURNERS PERFORMANCE

Unit Requirement

at MCR Actual Remarks

No of coal burners No

PA flow tph

No of mills in operation No

Mill loading %

Air temperature at mill inlet

after tempering

oC

Air – fuel mixture temperature

after leaving mills

oC

Total coal fired tph

Air Coal ratio

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Mill specifications:

• Type of mill : • Make : • Capacity : __________tph at coal

________grind • Fineness : ___________% through

________mesh• Motor rating :____________kW • Motor voltage :________ V• No of mills :__________• Running /Standby :_________/________

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COAL DATA

• Design coal parameter• Moisture :_____%• Ash :_____%• Volatile matter :_____%• Fixed carbon :______%• HGI :_____%

69

SOOT BLOWERS

Type number

Soot blowers for furnace

Soot blowers for super heaters

Soot blowers for reheaters

Soot blowers for air preheaters

Medium of blow

Steam pressure before reduction

Steam pressure after reduction

Steam consumption

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Instruments For Energy Audit• The following instruments are required for conducting the

boiler energy audit.

• Power Analyser: Used for measuring electrical parameters such as kW, kVA, pf, V, A and Hz

• Temperature Indicator & Probe

• Stroboscope: To measure the speed of the driven equipment and motor

• Sling hygrometer or digital hygrometer

• Anemometer

• Available On line instruments at the site ( Calibrated )

• Digital Manometer of suitable range and appropriate probes for measurement of pressure head and velocity head.

• 71

• Additional pressure gauges with appropriate range of measurement and calibrated before audit.

• Flue gas analysers / Orsat apparatus

• Infrared pyrometers

• Pressure gauges

• Steam trap tester / Ultra sonic leak detectors

• Instrument to measure coal velocity in coal feed pipe

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MEASUREMENTS & OBSERVATIONS

• Average GCV of coal during audit period

• Coal analysis – ultimate and proximate

• Coal consumption details

• Performance parameters of coal mills

• Steam parameters of main steam, reheat, super heater, LTSH (flow, pressure and temperature)

• Air – flow, temperature, pressures

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MEASUREMENTS & OBSERVATIONS

• Flue gas – Flow, temperature and pressure• Flue gas analysis• Ambient temperature• Boiler loading • Motor electrical parameters (kW, kVA, Pf, A, V, Hz,

THD) • Surface temperatures of insulation and boiler surfaces• Un-burnt coal (in fly ash and bottom ash)

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