DOCUMENT TITLE: DOCUMENT NUMBER:

METHOD FOR COMPUTATION OF HEAT RATE PE-DC-339-100-N122 REV 00

PROJECT TITLE: 1X600 MW KWPCL RAIGARH PROJECT, CHATTISGARH PAGE 2 OF 11
1.0 HEAT AND MASS BALANCE ACROSS HP HEATERS:

Steam extractions to HP heaters is to be evaluated from thermal balance of the heaters. Feed water Mffw going to the economizer
comprises of the feed water quantities Ma and Mb coming from HP heater trains A and B respectively.
The heat and mass balance equations at this point are:

Ma+Mb = Mffw (A)

Ma.H5a + Mb.H5b = Mffw.H11 (B)

From these two equations, the value of Ma and Mb can be evaluated in terms of Mffw.

1.1 HEAT BALANCE ACROSS HPH-6A:

Ma.(H5a-H4a) = Za.(H10a-H6a) (C)

1.2 HEAT BALANCE ACROSS HPH-6B:

Mb.(H5b-H4b) = Zb.(H10b-H6b) (D)

1.3 HEAT BALANCE ACROSS HPH-5A:

Ma.(H4a-H3a) = Za.(H6a-H7a)+Ya.(H9a-H7a) (E)

1.4 HEAT BALANCE ACROSS HPH-5B:

Mb.(H4b-H3b) = Zb.(H6b-H7b)+Yb.(H9b-H7b) (F)

Putting the values of Ma and Mb in terms of Mffw, we can calculate the values of Za, Zb, Ya and Yb in terms of Mffw.






DOCUMENT TITLE: DOCUMENT NUMBER:
METHOD FOR COMPUTATION OF HEAT RATE PE-DC-339-100-N122 REV 00
PROJECT TITLE: 1X600 MW KWPCL RAIGARH PROJECT, CHATTISGARH PAGE 3 OF 11
2.0 HEAT AND MASS BALANCE ACROSS THE DEAERATOR:

M2.H2 = (Ya+Za).H7a+(Yb+Zb).H7b+X.H1+M1.H8 (G)

M2 = M1+X+Ya+Yb+Za+Zb Mdea (H)

From the equations (G) and (H), the value of M2 can be calculated in terms of Mffw.

3.0 FINAL FEED WATER FLOW:

Mffw = M2 -Mrhs (I)

In the above equation, Mrhs is measured and M2 is calculated in terms of Mffw.
Hence, the value of Mffw can be calculated.

NOTE:
1. When there is an increase in the level of Deaerator, -ve sign shall be used for Mdea.
2. When there is a decrease in the level of Deaerator, +ve sign shall be used for Mdea.
3. When there is an increase in the level of Boiler Drum, -ve sign shall be used for Mdrum.
4. When there is a decrease in the level of Boiler Drum, +ve sign shall be used for Mdrum.


4.0 SUM OF STORAGES [Msto] INCREASES OR DECREASES FOR THE FOLLOWING TANKS:

a) Hotwell Storage
b) Drum Storage
c) Condensate Make up storage
d) Deaerator Storage






DOCUMENT TITLE: DOCUMENT NUMBER:
METHOD FOR COMPUTATION OF HEAT RATE PE-DC-339-100-N122 REV 00
PROJECT TITLE: 1X600 MW KWPCL RAIGARH PROJECT, CHATTISGARH PAGE 4 OF 11
NOTE:

For the above storages if there is a net increase in the level, +ve sign is to be taken for Msto and if there is a net decrease in level, -ve
sign is to be used for Msto to arrive at the Total Cycle Losses to be reflected in the main steam flow [Mms].

Mms = Mffw Msto (J)

Reheat Steam Flow, Mrh = Mms-Za-Zb-Md+Mrhs (K)

5.0 SYMBOLS:

M1 = Mass flow measured from flow measuring device FP01 [Condensate flow to deaerator] (Kg/hr)

Md = Gland leakages A, B and C from HP turbine to be computed (Kg/hr)

Msto = Total increase/decrease of storage in system [from level gauges] during test (Kg/hr)

Mdea = Change in deaerator storage during the test (Kg/hr)

Mdrum = Change in drum level during test (Kg/hr)

X = Extraction steam flow to deaerator [Calculated from thermal balance] (Kg/hr)

Ya = Extraction flow to HPH-5A [Calculated from thermal balance] (Kg/hr)

Yb = Extraction flow to HPH-5B [Calculated from thermal balance] (Kg/hr)

Za = Extraction flow to HPH-6A [Calculated from thermal balance] (Kg/hr)

Zb = Extraction flow to HPH-6B [Calculated from thermal balance] (Kg/hr)

H1 = Enthalpy of steam entering deaerator based on measurements PA21 & TW58, TW59 (Kcal/kg)



DOCUMENT TITLE: DOCUMENT NUMBER:
METHOD FOR COMPUTATION OF HEAT RATE PE-DC-339-100-N122 REV 00
PROJECT TITLE: 1X600 MW KWPCL RAIGARH PROJECT, CHATTISGARH PAGE 5 OF 11
H2 = Enthalpy of feed water at deaerator outlet based on measurements (PA22, TP75 & TP76) and (PA23, TP77 & TP78) (Kcal/kg)

H3a = Enthalpy of feed water at HPH-5A inlet based on measurements PD21, TW35 & TW36 (Kcal/kg)

H3b = Enthalpy of feed water at HPH-5B inlet based on measurements PD22, TW37 & TW38 (Kcal/kg)

H4a = Enthalpy of feed water at HPH-5A outlet based on measurements PD23, TW43, TW44, TW39 & TW40 (Kcal/kg)

H4b = Enthalpy of feed water at HPH-5B outlet based on measurements PD24, TW45, TW46, TW41 & TW42 (Kcal/kg)

H5a = Enthalpy of feed water at HPH-6A outlet based on measurements PD25, TW47 & TW48 (Kcal/kg)

H5b = Enthalpy of feed water at HPH-6B outlet based on measurements PD26, TW49 & TW50 (Kcal/kg)

H6a = Enthalpy of HPH-6A drain based on measurements PD29, TW66 & TW67 (Kcal/kg)

H6b = Enthalpy of HPH-6B drain based on measurements PD30, TW68 & TW69 (Kcal/kg)

H7a = Enthalpy of HPH-5A drain based on measurements PD31, TW70 & TW71 (Kcal/kg)

H7b = Enthalpy of HPH-5B drain based on measurements PD32, TW72 & TW73 (Kcal/kg)

H8 = Enthalpy of condensate entering deaerator based on measurements PA20, TP22 & TP23 (Kcal/kg)

H9a = Enthalpy of extraction steam entering HPH-5A based on measurements PD17, TW31 & TW32 (Kcal/kg)

H9b = Enthalpy of extraction steam entering HPH-5B based on measurements PD18, TW33 & TW34 (Kcal/kg)

H10a = Enthalpy of extraction steam entering HPH-6A based on measurements PD09, TW15 & TW16 (Kcal/kg)

H10b = Enthalpy of extraction steam entering HPH6BA based on measurements PD10, TW17 & TW18 (Kcal/kg)




DOCUMENT TITLE: DOCUMENT NUMBER:
METHOD FOR COMPUTATION OF HEAT RATE PE-DC-339-100-N122 REV 00
PROJECT TITLE: 1X600 MW KWPCL RAIGARH PROJECT, CHATTISGARH PAGE 6 OF 11
6.0 HEAT RATE:

Mms[Hms-Hffw] + Mrh[Hrho-Hrhi] + Mrhs[Hrhi-Hrhs]
HR = Pnet (L)


HR = Heat Rate (Kcal/KW.Hr)

Mms = Main steam flow at HPT inlet [As calculated] (Kg/Hr)

Mrh = Reheat steam flow at IPT inlet [As calculated] (Kg/Hr)

Mrhs = Reheater attemperation flow measured from Plant Flow measuring device FP06 & FP07 (Kg/Hr)

Hms = Enthalpy of steam before ESV based on measurements PD01 to PD02 & TW03 to TW06 (Kcal/Kg)

Hffw = Enthalpy of final feed water after HP heaters based on measurements PD25, PD26 & TW51, TW52 (Kcal/Kg)

Hrho = Enthalpy of Hot Reheat steam before IV based on measurements PD11 to PD12 & TW21 to TW24 (Kcal/Kg)

Hrhi = Enthalpy of Cold Reheat steam based on measurements PD04 & TW07 to TW08 (Kcal/Kg)

Hrhs = Enthalpy of Reheater attemperation based on measurements PD27, TW64 & TW65 (Kcal/Kg)

Pnet = Pgen-Paux (kW)

Pnet = 600MW for 100% MCR

Pgen = Power measured at Generator Terminals (kW)

Paux = Power required for Integral Auxiliaries (kW)

NOTE:


DOCUMENT TITLE: DOCUMENT NUMBER:
METHOD FOR COMPUTATION OF HEAT RATE PE-DC-339-100-N122 REV 00
PROJECT TITLE: 1X600 MW KWPCL RAIGARH PROJECT, CHATTISGARH PAGE 7 OF 11

1. POWER REQUIRED FOR INTEGRAL AUXILIARIES-

For all the auxiliaries included in the Heat Rate calculations, the design values shall be considered in arriving at the total Auxiliary
Power [Paux] to be deducted from the power measured at the generator terminals [Pgen] in the Heat Rate formula.

DEATIL FOR INTEGRAL AUXILIARIES:

1. Oil Vapor Exhauster 0.75 kW
2. CF Pump & CF Vapour Exhauster 110.00 kW
3. Circulating Pump for CF purification system 0.75 kW
4. Generator Auxiliary power requirements 35.00 kW
5. GSC Exhauster 3.00 kW

TOTAL 149.50 kW ( 150 kW)

7.0 COMPUTATION OF TOTAL GLAND LEAKAGES:

Steam leakage through the glands A, B and C is calculated using the formula given below:

[P1
2
P2
2
]
G = K
[P1.V1]


G = Steam Leakage through the Glands (T/Hr)

P1 = Pressure before the Glands (Ata)

P2 = Pressure after the Glands (Ata)

V1 = Specific volume at inlet conditions to the Glands (m
3
/kg)



DOCUMENT TITLE: DOCUMENT NUMBER:
METHOD FOR COMPUTATION OF HEAT RATE PE-DC-339-100-N122 REV 00
PROJECT TITLE: 1X600 MW KWPCL RAIGARH PROJECT, CHATTISGARH PAGE 8 OF 11
Data for design case is given below [Refer HBD No. PE-DC-339-100-N151, REV 00]

PARAMETER HPT INLET END HPT OUTLET END

G 2.648 3.487
P1 45.00 45.00
P2 7.13 7.13
V1 *0.07565 **0.057896

* Based on 45 Ata and 810.7 Kcal/kg.
** Based on 45 Ata and 337.0C.

For design case P1, P2 and V1 and G are known and hence K can be evaluated.

K values calculated for the design case are as given below:

A) For Gland Leakage from HPT inlet end K = 0.10996
B) For Gland Leakage from HPT outlet end K = 0.12668

For test case, by putting this value of K and the test values of P1, P2 and V1 the computation of G can be done.





For the test case, the values of P1, P2 and V1 are determined as given below:

FOR HPT INLET END:
P1 is based on measurements PD04
P2 is based on measurements PA05 to PA06
V1 is based on measurements PD04 and Ta
Ta is calculated on the basis of PD04 and Enthalpy correspondinmg to PD01, PD02 and TW03 to TW06.



DOCUMENT TITLE: DOCUMENT NUMBER:
METHOD FOR COMPUTATION OF HEAT RATE PE-DC-339-100-N122 REV 00
PROJECT TITLE: 1X600 MW KWPCL RAIGARH PROJECT, CHATTISGARH PAGE 9 OF 11
FOR HPT OUTLET END:
P1 is based on measurements PD04
P2 is based on measurements PA05 and PA06
V1 is based on measurements PD04 and TW11, TW12

8.0 NOTE:

1.0 The Heat Rate is guaranteed with 0% makeup and hence no makeup will be supplied to the condenser during the PG test. Under
these conditions the storage in the deaerator feed storage tank and Hotwell are utilized towards the leakages losses and the measured
Heat Rate shall be corrected using the correction curves viz. change in Heat Rate vs. change in storage of feed water storage tank
and change in Heat Rate vs change in Hotwell Level.

2. 0 In case the temperature measured at the HP turbine exhaust [measurements TW07 to TW08] is less than the temperature of
extraction steam at HP Heater No. 6 inlet or the Temp. at downstream of mixing of HP Bypass [measurements TW15 to TW18 or
TW09 & TW10] then leakage through the HP bypass valve is suspected. The leakage shall be estimated as given below: -


[ Mms - Md ] [ H10 - Hrhi ]
Mhpb =
[ Hms - Hrhi ]


Where, Mhpb = Quantity of steam leakage through the HP bypass valve

Value of H10 will be based on measurement TW09, TW10 & PD05
The quantity of steam entering the HP turbine [Mmsl] shall be corrected for the leakage through the HP bypass as given below and shall
be used in the equation (L) instead of Mms.

Mmsl = Mms - Mhpb






DOCUMENT TITLE: DOCUMENT NUMBER:
METHOD FOR COMPUTATION OF HEAT RATE PE-DC-339-100-N122 REV 00
PROJECT TITLE: 1X600 MW KWPCL RAIGARH PROJECT, CHATTISGARH PAGE 10 OF 11
9.0 GUARANTEE CONDITION:

1. Guaranteed Heat Rate at:

A) 100% LOAD = 1944.0 Kcal/KWHr


(Refer HBD Nos. PE-DC-339-100-N151 REV00, Titled 600MW, 0%MU, 76 mm Hg ATA BACK PR.)
2. The total tolerance on Heat Rate due to instrument uncertainty shall be 1.0%.

3. The PG test shall be conducted with valves wide-open position by suitably adjusting the main steam pressure.

4. If the test is carried out later than three (3) months, after the date of commissioning, due to any reason whatsoever, the specific heat
consumption shall be increased by 0.1% for each month or part of a month by which the period between the initial commissioning and
the acceptance test exceeds 3 months.

5. The pressure drop between MS strainer and ESV & between ESV and HPT in the MS line and between HRH strainer and IV &
between IV & IPT in HRH line have not been considered in the heat balance calculations since same is to be accounted in the
respective system piping pressure drops. The actual pressure drops shall be estimated during the PG test based on layout envisaged
and the calculated steam flows and necessary corrections applied on the measured pressures.

10.0 LIST OF CORRECTION CURVES:
HEAT RATE CORRECTION CURVES:
1. Main Steam Pressure
2. Main Steam Temperature
3. Reheat Steam Temperature
4. Back Pressure
5. Change in Feed Water Storage in Deaerator FW storage tank
6. Change in Hot Well Level
7. Power Factor
8. Frequency
9. Generator Hydrogen Pressure


DOCUMENT TITLE: DOCUMENT NUMBER:
METHOD FOR COMPUTATION OF HEAT RATE PE-DC-339-100-N122 REV 00
PROJECT TITLE: 1X600 MW KWPCL RAIGARH PROJECT, CHATTISGARH PAGE 11 OF 11
10. Generator Voltage
11. SH Spray
12. RH Spray
13. RH circuit pr. drop
14. Change in Feedwater economiser inlet Pressure
OUTPUT CORRECTION CURVES:
1. Main Steam Pressure
2. Main Steam Temperature
3. Reheat Steam Temperature
4. Back Pressure
5. Change in Feed Water Storage in Deaerator FW storage tank
6. Power Factor
7. Frequency
8. Generator Hydrogen Pressure
9. Generator Voltage
10. Auxiliary Steam Consumption
11. Make Up to Hot Well
12. SH Spray
13. RH Spray
14. RH circuit pr. drop
15. Change in Feedwater economiser inlet Pressure