Submitted:

Dated: 19th Jan 2010

For approval of CPPl& 2 Heat rate calculation methodology

The plant heat rate calculation methodology for CPP 1 and CPP2 is as shown below for the purpose of production incentive calculations:

MS flow * MS Enthalpy - FW flow * FW Enthalpy

Turbine heat rate

Power generated in kwhr

Turbine Heat rate

Plant Heat rate

Estimated Boiler(s) Efficiency

Calculation methodology has been exemplified in the attachment

The document is placed for your perusal and kind approval.

sr.ct::P-l

~d cUe/Ii)· U

VIce Pres! ent ~ .

Approved

~

Attachmen s:

1. Turbine heat rate calculations of CPP-l &2

2. Assessing Boiler efficiency based on design and actual conditions of CPP- 1&2

3. Curve showing most probable boiler efficiency with respect to Exit gas temperature after considering all variables.

CPP-1 HEAT RATE CALCULATION

INPUT PARAMETERS

SI.NQ. Del;cription

1 Average Load for the day

2 Average TufbiHe Steam inlet biomp. for the day

3 Avernoe Turbine Steam inlel Pro for the dav

4 Average Steam flow ror the day

5 A""rage Feed water flow for Ih" day

6 Average Feed water PL at lOco. Intet fur the day

7 Averaae Feed waterternc, at Eco .. Inlel for the dav

8 Average SF gas Flow fu rille day

9 Avemge Corex gas Flow for the day

10 SF gas CV

11 Corex cas CV

l' 2 Boiler air Ik>w

13 Average Flue gas Exit temp. for Dledsy

14 Average AirinlellE!mo. for the dsy

15 corex cas H2 %

16 8Fgas H2%

17 De nsit}' of Bf gas

18 Density of Corex gas

19 ""thaiPI' steam at Turtllne inlet

20 Enthalpy of Feed water alEconomizer Inlet

CAlCULATION OF TURBINE HEAT RAliE

Tumlne Heat rate

T urb ine Heal rate

CALCULATION ()f BOilER EffiCIENCY

Filleges Flow

Total Flue 9a.s Flow Mass Flow of Fuel M.a~ .. Flow nf ,Fuel

Flue gas flow per Kg of Fuel

Flue gas flow per Kg of Fllel

r:"lnrifir. v,,11l1> of r .... mhin<><f F"pl

Calorific value of Comblned Fuel

Value Unit
104 MW
5.211 DegC
87.4 Bar
406 TPH
409 TPH
103 Sar
243 DeaC
60 kiNm31Hr
118 K:Nm3/Hr
790 KcallKSt
1850 KcaliKa
289 TPH
140- De{l C
~2 D<i!QC
1_59 %bVWt
0.22 %byWl
1.36 K.gINm'
1.28 KgINm'
3447.65 KJ/,Ko
1052.59 I(JIKg .f. "'~.~~ '"'/. f-i~~

(Efltlla;lpy of Steam - Enthalpy of Feed water at Eco inlet) X 'Fsa~ '¥<lIe, flow

Loar! (MW) X 4.186

(3447.85·1052.59) X409 (IQ4X 4.1861

'" 2250.32

KcaUKWHr

(Mass flow of COrel( gas .. Mass flow of BF gas ... Tolal air flow) 11f1X 1 :;>R .. llf'lX 1 ?fi .. ?RQ

521;6 TPH

60 X 1.36" 118 X 1.:28

TPIJI

Total FlUe gas Row -----.--. Kg/Kg oftusl

Tnt.:=-I m:J~~ flnw nf fll'lc~1

521.6

Kg/Kg: of FUIII

(Corex flow X Corex CV .. BF Gas fiow X SF gas CV)

Mass Flow of Fuel

118 X 1850" 60 X 780

232 .. 64

KeallKQ of fuel

Dry Flue gas loss

Dry Flue gas loss

H2 % In combin.ed Fuel

Enthalpy of vapor all Psi & at exit Flue gas temp. (Hv) Enthalpy of saturated liquid at inlet air temp. (Hw)

Loss due to Hydrogen in Fuel

Loss due to Hvdrogen in Fuel

Summary of losses in Boiler

Loss due to Dry Flue gas Loss due to Hvdrocen in Fuel Loss due to molsture in ruel Loss due to moisture in air Loss due to radiation

Total losses In boUer

Boiler Efficiency

Plant heat rate

Plant heat rate

Corex Flow

Corel! Flow

+

Flue gas flow per Kg of Fuel X Sp. Heat (Flue gas temp. - Inlet air tempo) x 100

r.<>lnrifi,., II"''' 'I>nf r.nmr.;nl>rI 1""",,1 )( 4 1 AA

2.2423 X 0.999 X (140 - 32 ) X 100 )

11::1Q !'i::l )( 4 1RA

::: 5_072

0/0

(Cor-ex flow X Density X Corex H2% + SF flow X Density X SF H20/0)

(Corex flow X Density + SF flow X Density)

(118 X 1.28 X 1.59 + 60 X 1.36 X 0.22)

(118 X 1.28 + 60 Xl.36)

2764.17 '" 133.952

KJ/Kg KJ/Kg

8_936 X H2% in fuel X (Hv -Hwl

Calorific value of Combined Fuel X 4.186

8.936 X 1.109 X (2764 .. 17-133 .. 952)

1139.S3X 4.186

5.464

%

5.072 %
5.464 0/0
0.187 %
0.168 %
n ;>4on Ot,
::: 11_131 %
'" 88.87 % Turbine heat rate

= .-.-----------"--"-"- Kcat/KWHr Boller Efficiency

2250 .. 3155

n.flRR7

= 2532.18 Kcai/KWHr

Plant heat rate x Load - SF gas flow X SF gas CV

Corex uas CV

2532.18 X (104 - 60) X780

= 117_05

BOILER EFFICIENCY AT EXIT TEMPERATURE

LL LL W

0::

UJ ...J

6

III

1.10

120

130

140 150 EXIT FLUE GAS TEMP

160

170

180

Assesment of DFG and WFG losses at load 104MW, 150 Exit gas temp, and THR 2250
.,SI no BFG Co rex DFG WFG Boiler Em Plant HR PlantHR
1 140 83 6.28 4.54 88.59 25.4 2540
,
2 120 93 6.08 4.78 88.54 25 .. 4 2541
3 100 101 5.89 5.03 88.48 25.4 2543
4 80 110 5.71 5.27 88.42 25.4 2545
5 60 118 5.54 5.50 88.36 25.5 2546
6 40 126 5.37 5.70 88.29 25.5 2548
7 20 135 5.19 6.00 88.23 25.5 2550
8 0 144 5.00 6.20 88.17 25.5 2552 160~--------------------------------------------------------------------------~

1

2

3

4

5

6

7

8

-.-SFG __ corex

--DFG ~WFG -'-Soiler effi _plant HR

Survey of Heat Rate at various loads

--
Enthalpy or Enthalpy of Feed Heat Rate 10 r Heat Rate '" r
SI.Nc Date Time Load veccum MSP, Pr In KPA MS Flow Not MS now MS Temp FWFlow FWTemp Ste,ll.m Water Gross Steam Net Steam Flow
Flow
1 10-Jan-tO 06:00 to 1'4:00 104 0,08 67,80 6780 400.0 398.0 528.40 408,0 243,50 I 3459,38 1,054,77 2209.39 2198.34
I
2 21·Dec-09 22:00 to 06:00 73 0,07 75.47 7547 261.6 279.6 520,20 284,0 228,94 3452,85 977.08 2281.51 2265.30
3 17·Nov-09 15:00 to 20:00 60 0,07 79.85 7985 238.0 236,0 516,,19 239,4 218,23 3436.34 937,23 2370.06 2350.14
I
4 5,Jan-l0 15:00 to 19:00 48 0.05 13.91 7391 180.0 I 1780 J 522,50 178,3 20526 3460.07 878.35 2413.37 23B6.56 2450.00
I
2400.00 + ____ I
.---1--- --
i
2350.00 -> I
.> 1
2300.00
»>: 1.........--
,
2250.00
l~ ~
220000 t
2150,00 .

2100.00 ,
1 2. 3 4 · .
11o~ / I/s. ~fCp , cf1o-tJ "
Chart Title
88.7
88.6
88.5
88.4
88.3
88.2
88.1 v= 88.66e·o.OOO7x
R2::: 0.9989
88.,0
87.9
140 120 100 80 60 40 20 0 Sino BFG BoUer Effi corrected to 140 corrected to 145 corrected to 150 corrected to 155 corrected to 160
1 140 88.59 89.09 88.84 88.59 88.34 88.09
2 120 88.54 89.04 88.79 88.54 88.29 88,04
3 100 88048 88.98 88.73 88.48 88 . .23 87.98
4 80 88.42 88.92 88.67 88.42 88.17 87.92
5 60 88.36 88.86 88.61 88.36 88.11 87.86
6 40 88.29 88.79 88.54 88.29 88.04 87.79
7 20 88.23 88.73 88.48 88.23 87.98 87.73
8 0 88.17 88.67 88.42 , 88,17 87.92 87.67 INPUT PARAMETER~

51.No. 1

2

3

4

8

9 10 11 12 13 14 15 16 17 18 19 20

Description

Average Load for the day

Average Turbine Stearn inlet temp. for the day Average Turbine Steam inlet Pr, for the day Average Steam flow for the day

Average BF 9.as Flow for the day

Average Corex gas Flow for the day

BF gas GV

Corex gas CV

Boiler air flow

Average Flue gas Exit temp. for me day Average Air inlet temp. for the day Corex gas H2 %

BF gas H2 %

Density of SF gas

Density of Corex gas

Enthalpy steam at Turbine inlet

Enthalpy of Fleed waterat Economizer inlei

CALCULATION OF TURBINE HEAT RArE

Turbine Heat rate

Turbine Heat rate

!:P.P-2 HEAT RATE CALCULATION

Value Unit
105.2 MW
501.1 Deg C
83.3 Bar
391.5 TPH
184 KNm3/Hr
0 KNm3/Hr
816 Kcal/Kg
1850 Kcal/Kg
204.6 TPH
138 Deg C
32 DegC
1.59 % byWt
0.22 %byWt
1.36 Kg/Nm3
1.28 Kg/Nm3
3397.60 KJ/Kg
736.64 KJ/Kg ~y..l~vI'~rNJ . L.A~~

j.M r

..,c..

(Enthalpy of Steam 9 Enthalpy of Feed water at Eco inlet) X MaiR·StClaA'l flew

= -~ .. ------- - ----- - - - - .. - -- ~.!!!! --- --- -----._ ------" ----_ _,-_- ----------_.

Load (MW) X 4. 186

(3397.595222866899 73fL642824914675) X391.5

= ...- ~ - - .. ---- --------- -;-- ...

(105.2X4.186 )

_, 2365.67 Kc:aif I{WHr

CALCULATION OF BOILER"9 EFFICIENCY

Flue gas· Flow

= (Mass flow of Corex gas + Mass flow of SF ~~as + Total air flow) - 0 X 1.28 + 184 X 1.36 + 204.6

= 454.8 TPH

= 184 X 1.36 + OX 1.28

= 250.2 TPH

TotalHae gas Flow Mass Flow of Fu~!1 Mass Flow of FLlel

Flue gae flow per Kg of Fuel

Total Flue gas Flow

- ~~~~-----~-~---------.-. Kg/~I of fuel Total mass flow of fuel.

454.8

= __ - _-_ ...

250.2

Flue ganflow per Kg of I::'uel

= 1.8176 Kg/Kg of Fuel

(Carex flow X corex CV + BF Gas flow X SF gas CV)

Calorific value of Combined Fuel

= .. ............ _ ... _,_ ......... _ ............ RrJ' ... _ ...... ...... __ ·' ........ • ............ _ ........ ......, .... __ _...

Mass Flclw of FUE'I

OX 1850 + 184 X 816

= ........ _-----_ ..... _ ......... _-_ ...... _._ ...... _--

250.24

Calorific value O'f Combined Fuel

= 600

KcallKg of fuel

+

F'lue gas flow per Kg of Fuel X Sp. Heat (Flue gas temp. -Inlet air temp.) x 100

Dry Flue gas lose

= -- --- -- -- - -- -- ~ --- -- _ - _ _:- _---_ _ _ --------_.

Calori·fic value of Combined Fuel X 4.186

1.8176 X 0.999 X (138 - 32) X 100)

600 X 4.'186

Dry Flu.) gas loss

= 7.663 %

(Corex flow X Density X Corex H2.% + SF flow X Density X ar H2%)

H2 % in combined Fuel

= _----_ _ _-_ __ - _ __ __ .. - _-_ _ __ .. _ _ _ __ -_ .. _ __ _ _--- _ - -

(Carex flow X Density + SF flow X [)ensity)

· '

H2 % in combined Fuel

Enthalpy of vapor at 1 Psi & at exit Flue gas temp. (Hv) Enthalpy of saturated liquid cit inlet air temp. (Hw)

Loss due: to Hydrog.3n in FUEII

Loss due to Hydrogen in Fuel

Summary of losse!; in Boil~r

Loss due to Dry Flu3 gas Loss due to Hydrog'3n in Fuel Loss due to moisture in fuel Loss due to moisture in air Loss due to radiation

Total losses in boiler

Boiler Efff'icil~n.:;y

CALCULATION Of HRB-1 t08 EFF'ICIENC'~

IDesign Dry Flue gaB loss@200degC Other Loss as per Design

IDesign temp

HRB Dry flue gas Loss

(0 X 1.28 X 1.e9 + 184 X 1.36 X 0.22)

(0 X 1.28 + 18'~ X1.36)

= 0.22 %

= 2760.33 KJ/I(g

= 133.952 KJ/Kg

8.936 X H2% ill fuel X ( Hv - Hw)

= - -- -- ,.~- ------------~,--- -------- -_ ...

Calorific value of Combined Fuel X 4.186

8.936 X 0.22 X (2760.33-133.952 )

= _ __ ._._ 'w _ , _ _ __ ...

600X 4.186

= 2.056

%

= 7.663 %
- 2.056 %
= 0.900 %
= 0.129 %
= 0 .. 270 %
= 11.018 %
= as.ss % - 11.2 %
= 5.9 %
= 200 Deg.e - (Flue gas exit temp-Ambo Temp) X 11.2 /(.oesign FlUE gas ten p. - Amb temp.

HRB effiency

- (100~HRB Dry flue gas Ics8-5.9)
HRB#1 HRB#2 Hr.B#3 HRB#t HRB#~ HRB#( HRB#~ HRB#( Boiler~f
= 29.3 23.3 23.1 31.2 37.1 33.3 34.6 38.1 162.0
= 246 265 254 229 267 247 267 270 138.0
= 14.3 15 .. 6 14.8 13.1 15.7 14.4 15.7 15.9 4.2
= 79.8 78.5 73.3 81.0 78.4 79.7 78.4 78.2 89.0 Av MS Flow in TPH

Flue gas Exit Temp in De~ C Dry Flue gas loss in %

HRB Efficiency in %

Weighted Avg ef'ficie·lcy : l alii. uller

82.'9"1' %

Turbine heat rate

.Plant heat .rate

Boiler Efficiency

2365.67

0.8297

Plant heat rate

= 2851

Kcal/KWHr