Академический Документы
Профессиональный Документы
Культура Документы
of
DHUVARAN COMBINED CYCLE POWER STATION
112 MW, UNIT NO.-2
GUJARAT STATE ELECTRICITY CORPORATION
LTD.
PART-2
(Thermal Audit)
By
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
ACKNOWLEDGEMENT
The Energy Management Section of Electrical Research and Development
Association (ERDA) place its sincere gratitude to M/s Dhuvaran Combined
Cycle Power Station, GSECL for having entrusted the Energy Audit study to
us.
Our sincere thanks are due to Mr. Prakash, S.E.(SME), Shri
K.Devkinandan, E.E (Effi) ,Shri A. Saxena, Dy. Ex. Engineer (Effi), and
other staff members for proper coordination, timely help during the energy
audit study and providing accurate data required for preparing energy audit
report.
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
CONTENTS
1.0
2.0
3.0
4.0
5.0
6.0
7.0
Page No.
01
03
03
04
05
06
07
08
09
09
10
10
10
12
12
14
15
15
16
17
18
18
19
32
34
35
36
36
38
38
39
39
42
43
44
45
47
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
SUMMARY OF OUTCOME
Sl.
No.
Energy Conservation
Measures
Anticipated
Savings/Yr
(Rs. Lakh)
Approximate
Investment
(Rs. Lakh)
Payback
Period
(Months)
Condenser
vacuum
improvement by plugging air
ingress
22.56
12.0
7.0
Payback Period
= 7 months
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
1.0
Introduction:Dhuvaran power plant has Gas based Combined Cycle Power Plant (CCPP) comprising
of two units namely CCPP-1 and CCPP-2. Each unit comprises of one Gas Turbine
Generator & one Steam Turbine Generator. Exhaust gas of Gas Turbine is used to
produce steam through HRSG (Heat Recovery Steam Generator) to run the Steam
Turbine. Energy audit study has been carried out by ERDA as per scope of work which
comprises - Open cycle & Combined cycle heat rate.
Heat Recovery Steam Generator performance.
Gas turbine & Steam turbine performance.
Performance study of steam traps.
Insulation and refractory study.
HP and LP cylinder efficiency.
Condenser performance.
Vacuum system
Heat Balance & Mass Balance.
Technical specification of the CCPP-2 is given below.
Particulars
UoM
CCPP-2
Model
Frame 6FA
Fuel
Natural Gas
Fuel supply
M/s GSPL
Design
GE, USA
EPC contract
M/s BHEL
MW
72.51
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
MW
39.94
MW
112.45
Commissioning Date of GT
Date
17/03/06
Date
13/08/07
Date
01/11/07
MW
1.54
MW
4.135
kCal/kWh
2584
kCal/kWh
1666
kCal/kWh
2640
kCal/kWh
1729.6
33.28
51.62
32.57
49.72
kCal/hr
187.3 x 106
During the energy audit different parameters like temperature, pressure, velocity head,
static head of air, fuel & flue gas has been measured to evaluate the performance of Gas
Turbine, HRSG & Steam Turbine. Technical specification of the GT is given below:
Gas Turbine model series and Make
Category of Design
: CATEGORY B
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
2.0
Model No
: PG6111 FA
Rated output
: 72.51 MW
Rated speed
: 5231 rpm
No. of stages
:3
:6
No. of Burners
:6
Compressor ratio
: 15.6
NOX Control
: Water injection
Design Condition
Fuel
COMB
Water
Comb
Discharge
Air
Exhaust
Fire
COMP
NOZ
EXP
Cool
Bleed
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
(2.1.1)
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
Compressor balance
mair = mdis +mbleed +mcool
mair.Cp,air Tair+ POWcomp = (mdis Cp,dis Tdis)+( mbleed Cp,bleed Tbleed)+(mcool Cp,cool Tcool)
Combustor balance
mcomb = mdis +mfuel +mwater
mcomb.Cp,comb Tcomb
= (mdis Cp,dis Tdis)+ mfuel comb( LHV + Cp,fuel Tfuel)+(mwater Cp,water Twater)
Nozzle Balance
mfire = mcomb +mcool
mfire.Cp,fire Tfire = (mcomb Cp,comb Tcomb)+( mcool Cp,cool Tcool Tcool)
Expander Balance
mexh = mfire +mbleed
(mexh.Cp,exh Texh) + POWEXP = (mfire Cp,fire Tfire)+ mbleed Cp,bleed (Tbleed Tcool)
Shaft Energy balance
shaftPOWEXP = POWshaft + POWcomp
POWNET = GEN POWshaft POWAUX
(2.1.2)
Design Constants
Notation
Values
cool
0.11
bleed
0.11
cool
0.99
bleed
0.95
1
2
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
5
6
Tcool
110C
Tbleed
140C
Shaft efficiency
shaft
99.5
Generator efficiency
Gen
0.99
Combustor efficiency
Comb
0.99
10
0.03
(2.1.3)
Properties
Specific heat of air at inlet
temperature
Specific heat of discharge air at
corresponding temperature
Specific heat of cooling air at
corresponding temperature
Specific heat of bleed air at
corresponding temperature
Specific heat of combustion gas
air at corr. temperature
Specific heat of comb. air to 1st
stage rotor at corr. temp
Specific heat of exhaust air at
corresponding temperature
Specific heat of discharge air at
corresponding temperature
Notation
Values (kJ/kg.0C)
Cp,air
1.005
Cp,dis
1.041
Cp,cool
1.041
Cp,bleed
1.063
Cp,comb
1.196
Cp,fire
1.184
Cp,exh
1.108
Cp,fuel
2.17
LHV
49145.6
10
1.4
11
1.34
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
(2.1.4)
Parameters
Air inlet temperature
Pressure of inlet air (After
subtracting inlet and filter
pressure loss)
Compressor discharge
temperature
Unit
o
Values
23
Bar (abs))
0.99
395
Bar (abs)
14.36
629
Bar (abs)
1.01
kW
67700
kW
1540
Kg/sec
4.06
10
Fuel temperature
11
IGV Position
12
Turbine status
13
Speed
rpm
5160
14
Frequency
Hz
49.3
15
Barometric pressure
Bar
1.00
20
85.06
Base load
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
(2.1.5)
Design Constants
Unit
Values
Kg/sec
203.4
391.05
375.25
kW
119488.8
1324.85
Bar(abs)
13.91
Kg/sec
160.70
Kg/sec
164.76
Kg/sec
187.12
10
Kg/sec
22.37
11
Kg/sec
20.34
12
13
14
15
1226
1121.73
Inch2
183.58
kW
189446.6
16
kW
69608
17
Kg/sec
207.46
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
Above results are calculated from the mass and energy balance equations of four control
volumes (Compressor, Combustor, Nozzle and Expander). Heat balance calculation also
considers the following losses which could not be considered in the overall turbine heat
balance. These are
The shaft efficiency.
Cooling air losses temperature to the environment.
Bleed air losses temperature to the environment.
Design mass flow of GT is around 206 kg/s with allowable combustion temperature of
2420 0F (1325 0C) which is almost equal to calculated values. This shows that GT
performance is near optimum point with the assumption of above mentioned design data
in absence of real design data for Dhuvaran CCPP.
Exact GT performance comments require detailed design data.
(Neglecting the effect of cool & bleed air, i.e. assuming no cool
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
10
Heat Rate = (mass flow rate of fuel LHV)/ Net Power output
Heat Rate
(kCal)
(kWh)
Heat Rate = (mass flow rate of fuel LHV)/ Net Power output (GT + STG)
Heat Rate
Heat Rate
1688.06 kCal/kWh
(kCal)
(kWh)
(Based on fuel NCV)
Affecting Parameters
Design
Operating
Heat Rate
Power
value
value
correction
correction
Inlet temperature
N.A
23
---
1.0
Inlet humidity
N.A
82.5
----
1.0
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
11
1.024
0.9174
Ambient pressure
1.013
1.009
----
1.003
Water injection
3.638
0.00
1.021
1.062
Shaft speed
5231
5134
0.9784
1.0105
0.98
0.98
---
1.0
6.2
6.23
0.999
1.0057
N.A
140
1.0
1.0
10
Fuel temperature
N.A
20
---
1.0
11
Fuel composition
----
--
----
1.0
100
13562.7
0.979
1.041
N.A
N.A
----
1.0
85
85
1.0
1.0
1.000
1.033
12
13
14
IGV position
15
Net correction
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
12
Heat Rate
2538.33 X 1.000
(kCal)
(kWh)
POWCorrected = 69.93 MW
POWRated = 72.51 MW
POWERDegradation = POWRated - POWCorrected
POWERDeg = 72.51 69.93
POWERDeg = 2.58 MW
(2.8) Results and discussion:
Actual open cycle heat rate is less than the design value of 2584 kCal/kWh and it is
2538 kCal/kWh. Present performance of GT is improved from guaranteed value due to
favorable operating ambient condition. (i.e. 30.1 oC & 27.2% RH).
Closed cycle actual heat rate based on fuel NCV is found 1688.06 kCal/kWh against the
design value of 1666.0 kCal/kWh. This is slightly higher than the guaranteed value due to
performance degradation of steam cycle and HRSG. (Root cause shall be investigated in
the section HRSG performance).
Power degradation due to aging effect of GT parts and ambient change is calculated as
2.58 MW.
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
13
Compressor efficiency is calculated as 90.7% which is very good, but expander efficiency
comes on lower side and is approximately 82% (generally 87 88%) with a assumption
of no cooling/bleed air is supplied to cool expander which is not true in this case because
expander is normally operated with 21% of total compressor air extracted at different
stages to cool expander and nozzle. No method is available to calculate the efficiency
unless cooling air to expander has to terminate during the period of expander efficiency
measurement.
Operating power output from GT is deviated from guaranteed value due to following
reasons:
1. Ambient condition is changed from guarantee condition.
2. Expander performance may be degraded. It should be checked in OEM schedule
inspection.
3. Expander nozzle area may be changed due to aging and wear & tear. It should be
inspected in next scheduled Combustion Gas Path Inspection (HGPI).
4. Water injection is not in operation where as it is in service at the time of guarantee
test. As per GE guideline (Manufacturer) water injection is allowed only for NOX
control not for power augmentation. Due to this constraint, water injection in
Dhuvaran CCPP # 2 not was in operation.
5. Compressor water washing has been not done since long time. It is recommended
to carry out compressor water washing as per OEM recommendation.
6. Online daily compressor water washing is useful practice to improve the GT
performance but this system is not available for Dhuvaran site Gas turbine Power
Plant. In place of this, Offline water washing is available and has been carried out
at every two to three months. At the time of measurement it is due and
recommended to carry out.
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
14
3.0
HP
Drum
H
P
F.G. Path
S
H
1
H
P
S
H
2
IP
Drum
H
P
.
E
V
A
P
LP
Drum
H
P
E
C
O
5
I
P
.
S
H
H
P
E
C
O
#
4
I
P
L
P
E
V
A
P
S
H
H
P
E
C
O
#
3
I
P
H
P
L
P
H
P
E
C
O
E
C
O
#
2
E
V
A
P
E
C
O
C
P
H
#
1
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
15
Measured Parameters
Design
Operating
Value
Value
616.7
629
Kg/hr
718900
746856
N.A
100.5
Kg/cm2a
107
103.1
542
535.8
Kg/hr
118200
107960
Unit
0
Kg/cm2a
112
111.2
Kg/cm2a
30
27.32
260
272.5
10
Kg/hr
8300
8260
11
Kg/cm2a
32
28.1
12
Kg/cm2a
6.0
6.01
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
16
13
14
15
200
216.5
Kg/hr
6600
8705
HP Drum pressure
Kg/cm2a
N.A
107
16
IP Drum pressure
Kg/cm2a
N.A
28
17
LP Drum pressure
Kg/cm2a
N.A
6.4
18
Kg/hr
183340
125860
19
60
47.2
20
100
97.5
21
105
113
22
mmWC
N.A
-4.2
23
mmWC
N.A
-2.06
(3.1.2)
S.No
Properties value
Notation
Value
CP,gas in
1.10
CP,gas out
1.07
HHP,STM
3464.06
HIP,STM
2932.41
HLP,STM
2885.9
HFW
474.05
HCPH, IN
200.96
HCPH, OUT
408.52
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
17
(3.1.3)
S. No.
Properties
Unit
Design
Value
Value by
volume
fraction
Value by
mass
fraction
Oxygen percentage
Fraction
0.1129
0.14
0.159
Carbon dioxide
Fraction
0.0421
0.039
0.060
Fraction
0.0084
0.000027
0.0000268
Water vapor
Fraction
0.1321
0.105
0.067
Nitrogen
Fraction
0.7051
0.716
0.712
99
99
mmWC
52
52
28.15
28.15
1.085
1.085
F.G. discharge
pressure
Molecular weight of
flue gas
Avg Sp. heat across
HRSG
kJ/kg 0C
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
18
Efficiency = 78.35%
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
19
Tgas,min
= Tgas,out Tpinch,evap FR [Tgas/Twater]eco X Tsubcool - FR [Tgas/Twater]CPH
= 104.4 19.5- (1.15[29.28/47.0] X 0.6) - (1.15[46.8/50]
= 104.4 19.5 0.42 1.07
Tgas,min = 83.410C
Effectiveness
Effectiveness = 96%
(3.4) HRSG pressure elements performance and heat & mass balance:
The overall efficiency or effectiveness may not be good an indicator of HRSG
performance because high pressure steam is much more valuable than low pressure
steam, but the efficiency and effectiveness calculations do not recognize this difference in
value. For this reason section by section heat and mass balance have been done to find
out performance of each part of HRSG.
A super heater is a heat exchanger in an HRSG that raises the temperature of
saturated steam coming from an evaporator up to a higher temperature using the heat
from the exhaust of gas turbine. This superheated steam then flows out of the HRSG to
feed the steam turbine. In CCPP # 2 there are two super heaters 1 & 2 and one DSH
between them to control the outlet steam temperature by water spray. Heat and mass
balance across heating element has been done to calculate unknown quantity (gas outlet
temperature across heater). Effectiveness and heat duty calculation is as follows:
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
20
TGAS =
520.4
0
C
TGAS =
602.5 0C
SH-2
HP
DRUM
SH-1
Flow = 2.0 tph
Temp = 110 0C
HP
Evap
DSH
Stm pr = 104 kg/cm2a
Temp = 470 0C
F.W = 300 0C
F.W = 113 0C
HP ECO-1
ECO-2
ECO-3
ECO-4
ECO-5
21
(before DSH)
22
23
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
24
Drum PR =27.8
TEMP=230.1 0C
IP Drum
F.W PR =28.0
TEMP=0C
T=299.960C
Gas flow=746856
KG/HR
T = 321.730C
IP EVAP
IP SH
T=274
.75
0
C
IP ECO
Gas
flow=746
856
KG/HR
T = 231.8
0
C
25
26
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
27
LP EVAP
LP SH
T=172.2
0
C
28
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
29
30
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
31
32
Gas outlet
Fluid inlet
Fluid outlet
Heat duty
temp.
temp
temp
temp.
(kJ/hr)
HP-SH-2
629
602.5
470
535
22592789
HP-SH-1
602.5
520.4
314.5
489
66206986
HP-EVAP
520.4
336.3
300
314.5
148512873
HP-ECO-5
336.3
321.7
280
300
11693151
IP-SH
321.7
320.4
228.6
272.5
1052406
HP-ECO-4
320.4
299.9
250
280
16327308
IP-EVAP
299.9
274.7
190
228.6
19952600
LP-SH
274.7
273.3
160.6
216.4
1098484
HP-ECO-3
273.3
241.1
200
250
25227402
10
IP-ECO
241.1
236.7
113
190
3335500
S.No
HRSG Components
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
33
11
HP-ECO-2
236.7
211.3
160
200
19139859
12
LP-EVAP
211.3
180.0
113
160.6
23547860
13
HP-ECO-1
180.0
150.8
113
160
21833280
14
CPH
150.8
104
47
97
34935000
15
Total
16
HRSG
17
18
415455498
629
104
Radiation &
Unaccounted
Radiation & Unaccounted loss in % of total HRSG Heat Input
425427849
9972351
2.34
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
Gas temperature
profile
SH-2
600
SH-1
HP-EVAP
SH-2
Temperature (C)
500
HP-ECO-5
SH-1
SH-2
IP-SH
ECO-4
400
IP-EVAP
HP-EVAP
HP-EVAP
SH-1
300
HP-ECO-5
HP-ECO-5
ECO-4
ECO-4
IP-SH
IP-SH
200
LP-SH
ECO-3
ECO-3
IP-EVAP IP-EVAP
LP-SH
LP-SH
IP-ECO
ECO-3
IP-ECO
ECO-2
IP-ECO
LP-EVAP
ECO-2
LP-EVAP
ECO-1
ECO-2
LP-EVAP
ECO-1
100
CPH
ECO-1
CPH
CPH
0
0
50000000
100000000
150000000
200000000
250000000
300000000
350000000
400000000
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
450000000
34
Following conclusion has been drawn from above HRSG heat balance calculation:
Design HRSG efficiency is generally around 83.0% with the effectiveness in of 91%.
HP steam generation is less than design where as LP steam generation is more than
design. This means that heat transfer in HP section is less than design value where as in
LP section it is more. Due to low heat transfer in HP section, flue gas enters in IP & LP
section at higher temperature than design.
Dhuvaran CCPP # 2 HRSG design for evaporator pinch as we have seen from
HP steam pressure at super heater outlet is lower than the design value of 106
kg/cm2a. This result in greater gas to steam heat transfer and increases the steam
production. Thus, HRSG can produce more steam at lower pressures, but the steam is less
valuable for electricity production because of the lower pressure level.
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
35
Radiation loss from HRSG surface after heat & mass balance is found 2.3% which
Total gas flow rate to HRSG is 746856 kg/hr which is slightly higher than the
design value of 718900 kg/hr, higher gas flow increases the steam production but
operating parameters of HP steam generation is less than the design value. This gives the
indication of deposition on HP evaporator heating surface, though effectiveness of HP
evaporator is good is 83.5%. (It should be nearly 90%).
4.0
Steam Turbine:
Combined Cycle Power Plant # 2 has one condensing type steam turbine. Technical
specifications of the turbine are given below:
Turbine:
Make
: BHEL
Type
: HNK 71/3.2-4
M/c No.
: T-0609
Rated output
: 40.3 MW
Speed
: 3000
: 103 atm
: 539.6C
Exhaust pressure
: 0.098 atm
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
36
4.1
(4.1.1)
Turbine cycle heat rate is calculated separately to know the efficiency of turbine cycle in
combined cycle power plant #2 of Dhuvaran. Measured value has been shown in the table
below:
Measured value:
S.No
Measured Parameters
Unit
Design
Operating
Value
Value
MW
40.3
34.1
rpm
3000
2959.8
616.7
629
TPH
718.9
746.856
97
100.5
Kg/cm2a
107
103.1
542
535.8
TPH
118.2
107.96
Kg/cm2a
112
111.2
10
Kg/cm2a
30
27.32
11
260
272.5
12
TPH
8.3
8.26
13
Kg/cm2a
32
28.1
14
Kg/cm2a
6.0
6.01
15
200
216.5
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
37
16
TPH
6.6
8.705
17
TPH
183.34
192.0
18
60
53
19
100
97.5
20
105
113
C
C
C
Fluid Properties:
S. No
Properties
Unit
Design
Operating
kCal/kg
830.15
826.9
kCal/kg
689.58
700.39
kCal/kg
680.78
689.19
kCal/kg
60
53
kCal/kg
105
113.2
kCal/kg
1.08
1.08
Design H.R.=
MHP X (HHP,STM HFW) + MIP (HIP,STM HFW) + MLP (HLP,STM HFW) + MCPH(HO-HIN)
POWgen
118.2 (830.15 105) + 8.3 (689.58 105) + 6.6 (680.78 105) + 183.34(100-60)
40.3
Design Heat Rate = 2523.5 kCal/kWh
Design turbine cycle efficiency = 34%
Operating H.R.=
MHP X (HHP,STM HFW) + MIP (HIP,STM HFW) + MLP (HLP,STM HFW) + MCPH(HO-HIN)
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
38
POWgen
107.96 (826.9 113.3) + 8.26 (700.39 113.3) + 8.705 (689.19 113.3) + 192.0(97.5-53)
34.1
Design Heat Rate = 2799.02 kCal/kWh
Design turbine cycle efficiency = 30.0%
(4.1.2)
Measured parameters
Unit
1
2
3
4
5
6
7
8
kg/cm2a
0
C
kg/cm2a
0
C
kg/cm2a
0
C
kg/cm2a
0
C
Operating
Value
99.0
535
N.A
N.A
27.2
267
N.A
N.A
(4.1.3)
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
39
5.0
C.W. Systems
The generating Unit-2 CCPP consists of single shell condenser units with single passes.
The design specification of condenser of the generating station is given below. On the
basis of site measurement and data collection performance of the condenser unit was
evaluated and given below: Measured data are tabulated in the table.
5.1
The usual reasons for deviation of condenser parameters from design are:
(1) Cooling water inlet temperature is different from design value
(2) Cooling water quantity flowing through condenser is different from design
(3) Fouled and dirty tubes
(4) Air ingress into the system under vacuum
The contribution of above factors to a given deviation of backpressure from optimum is
determined analytically and presented below:
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
40
Measurement Table:
Sl.No.
Measured parameters
Unit
Design
value
Measured value
MW
40.3
34.1
Generation
CW inlet temperature
36
26.8
CW Outlet temperature
42
32.3
CW Inlet pressure
kg/cm2a
2.2
2.2
CW Inlet pressure
kg/cm2a
1.1
1.6
CW Temperature rise
5.5
Mean temperature
39
29.55
mmHg
757
757
Condenser vacuum
mmHg
682.5
677
10
mmHg
74.500
80.000
11
kg/cm2a
0.1012
0.1087
12
mbar
99.32
106.65
13
45.68
47.05
14
48
49
15
CW Flow rate to
condenser
TPH
12500
12350
16
Air ingress
m3/hr
30
17
m2
N.A.
Calculated Parameters
1
3.68
14.7
Initial temp.difference
9.68
20.2
LMTD
6.20
17.30
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
41
Air ingress
kg/hr
kCal/Hr X 1000
kCal/m2.C.m2
Effectiveness
20
74549.2
67516.7
N.A.
61.98
27.22
Parameters
Unit
Values
-9.2
32.8
29.8
6.63
36.88
5
6
mbar
62.4
Deviation
mbar
-36.92
6.072
42.07
39.036
6.241
45.76
4
5
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
42
mbar
99.7
Deviation
mbar
0.374
Fraction
0.846
5.076
5.249
44.190
3
4
mbar
91.9
Deviation
mbar
-7.425
mbar
-43.975
mbar
55.34
mmHg
41.51
34.75
mbar
106.65
mbar
51.30
mmHg
38.47
Final condition
1
2
3
4
5
6
7
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
43
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
44
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
45
So, the condenser is suffering from tubes fouling/dirt and need to be corrected in
scheduled plant shutdown.
= 106 mbar
= 114.66 mbar
= 986 kW
= 98.6 kW
= 780912 kWh
= Rs 22.56 Lakh
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
Increase/Decrease in slope
indicates heavy fouling/no
fouling
Saturation Temp.
100
40
20
47
42
34.75
32.3
32.3
CW supply
41.516
45.68
36
26.8
26.8
80.000
74.500
Back pressure
in mmHG (abs)
CW outlet Temp.
CW inlet temp.
80
60
Increase /decrease in
slope indicates more/no
air leakage
Condenser Fouling
Air Leakage
0
Design Condition
Operating Condition
Estimated condition
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
45
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
46
(7.0)
Insulation survey
(7.1) Introduction:-
1 - Ambient temperature
30 0C
30.1 %
Dhuvaran site is located on the bank of ARAB Sea and condition is windy, hot and
humid in summer. For this reason natural convection as well as forced convection
loss is also included in the radiation loss calculation. For natural convection average
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
47
wind velocity of 0.5 m/s is taken for calculation purpose. Total radiation heat loss
from radiating surface is calculated by taking the average surface temperature of
that region and average ambient temperature throughout the day (30 0C).Overall
CCPP insulation was found excellent and well placed with cladding except some
insinuated places mentioned in the audit report. Details of total heat loss with heat
saving potential calculation are given in calculation part in the table. Reference
Thermal Image is also attached with the report for identifying correct location of
hot spot and bare surface. Soft copy of Thermal images (jpeg format) is sent along
with hard copy of report.
(7.2) Key Findings: HRSG insulation is found excellent and need not any immediate attention.
Near HP super heater location, hot spot on the HRSG surface has been
observed.
Steam line insulation is good and need not to any immediate attention.
In De-aerator, steam and feed water line insulation have been observed
damage in some places but surface temperature is not high.
Steam turbine insulation is found excellent.
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
48
6m
9m
9m
5m
11 m
K
M
43 mtr
Location (PART-A)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
55
1912
Good
TH-01
LHS Wall
None
55
1912
Good
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
49
HRSG - II
Location (PART-B)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
50
23
3294
Good
TH-02
LHS Wall
None
48
23
2912
Good
HRSG - II
Location (PART-C)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m2)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
Near expansion
joints
65
2231
586
Weak
TH-3
LHS Wall
Near expansion
joints
65
2231
586
Weak
TH-18/19
HRSG - II
Location (PART-D)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
42
40.75
3225
Good
TH-4/5/6
92
0.25
142
84
Weak
TH-3
50
41
5873
Good
At maintenance window
LHS Wall
None
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
50
HRSG - II
Location (PART-E)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
45
13
1331
Good
TH-7
LHS Wall
None
55
12.5
2330
Good
TH-20
110
0.5
393
272
Weak
TH-20
HRSG - II
Location (PART-F)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
45
60
6145
Good
TH-9
LHS Wall
None
55
58
10810
Good
TH-21/22
120
3677
2683
Weak
TH-21,22,24
HRSG - II
Location (PART-G)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
45
33
3380
Good
TH-10
LHS Wall
None
58
33
7039
635
Good
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
51
HRSG - II
Location (PART-H)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m2)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
42
33
2612
Good
TH-12
LHS Wall
None
60
33
7645
1114
Good
HRSG - II
Location (PART-I)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
45
10
1024
Good
TH-11
LHS Wall
None
55
10
1864
Good
HRSG - II
Location (PART-J)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
40
28
1798
Good
TH-13/14
LHS Wall
None
58
28
5972
539
Good
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
52
HRSG - II
Location (PART-K)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m2)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
40
28
1798
Good
TH-16
LHS Wall
None
58
28
5972
539
Good
HRSG - II
Location (PART-L)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
40
10
642
Good
TH-15
LHS Wall
None
55
10
1864
Good
HRSG - II
Location (PART-M)
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
RHS Wall
None
43
57
4947
Good
TH-17
LHS Wall
None
45
57
5837
Good
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
53
HRSG - II
Top/Bottom portion
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
Top portion
None
55
300
55914
Good
26,27,28,29
Bottom
portion
None
55
280
52186
Good
DEAERATOR
Normal
Temp. zone
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
Photograph
DEAERATOR
None
65
25
6973
1831
Good
41
Storage tank
None
35
88
2579
Good
55
2.5
466
cladding
open
31,34,35,38,36
Photograph
Above normal
temp. zone
Avg
Temp.
C
Surface
area
(m)
Total
heat loss
(kCal/hr)
Saving
Potential
(kcal/hr)
Insulation
condition
HP Steam
pipe
None
60
120
27798
60
Good
IP steam
None
60
130
30115
60
Good
LP Steam
None
55
140
26093
55
Good
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat
54
= 2, 18,932 kCal/hr
Total heat loss from Steam path system (HP, IP, LP)
= 84,006 kCal/hr
= 3, 02,938 kCal/hr
= 0.06 %
= 8,868 kCal/hr
(This heat saving potential has negligible amount as compare to total heat input)
(7.4)
Recommendation:
Thermal Energy Audit Report of CCPP # 2, Dhuvaran Combined Cycle Power Plant, GSECL, Gujarat