U#6 Pre and Post Overhauling Test Report

From 11 Aug to 9 Oct 2016

Parameters Unit Design Pre O/H

Unit Parameter
1 Load MW 490
2 Coal Flow TPH 402
3 GTCHR Kcal/kWh 1944.4 2076
4 Boiler Efficiency % 87.32 85.88
5 Unit Heat Rate Kcal/kWh 2227 2418
6 FG temp Boiler exit deg C 125 153.9
7 Draft Power Consp MW -- 9.495
Condenser
1 Expected Cond Vacuum mmHg 77 87.67
2 Test Cond Vacuum mmHg 77 100.35
Air Pre-Heaters Leakges
1 PAPH 6A % 12 18.8
2 PAPH 6B % 12 24.7
3 SAPH 6A % 8 14.2
4 SAPH 6B % 8 16.4

Draft Power Consumption

EQUIPMENT Unit Pre O/H
1 ID Fan - A MW 2.818
2 ID Fan - B MW 2.922
TOTAL MW 5.740
1 FD Fan - A MW 0.455
2 FD Fan - B MW 0.509
TOTAL MW 0.964
1 PA Fan - A MW 1.538
2 PA Fan - B MW 1.253
TOTAL MW 2.791
GRAND TOTAL MW 9.495

Corrected Boiler Efficiency

Parameter Unit Design Pre O/H
Mills 7 No ABCDEGK
PA Header Pr mmWC 829
1 Dry Gas Loss % 4.21 6.23
2 Loss due to Unburnt Carbon % 1.0 0.34
3 Loss due to moisture in fuel % 2.85 2.86
4 Loss due to Hydrogen in Fuel % 4.01 4.04
5 Boiler Efficiency % 87.32 85.88

Corrected Turbine HeatRate

Parameter Unit Design Pre O/H
1 MAIN STEAM TEMP BEF HPT Deg C 537.0 502.7
2 MAIN STEAM TEMP BEF IPT Deg C 537.0 516.7
3 FW TEMP AT ECO IL Deg C 253.4 253.9
4 CONDENSER I/L TEMP Deg C 32.2 34.8
5 CONDENSER BACK PR mmHg 87.33 100.35
6 HPT EFFICIENCY % 93.15 84.75
7 IPT EFFICIENCY % 94.32 91.90
8 GTCHR, Corrected Kcal/Kwh 1944.4 2076.4
improvement in HeatRate 38.25 Intangible cost saving
Kcal Imp, 90% PLF 1.5078E+011
Avg GCV 3200 1. Reliability of equipment in
Coal savings, ton 47119 2. Reduction in running mai
Coal Cost 2800 3. Reduction in ESP emissi
Cost Savings, Rs Cr 13.19 4. System improvement wo

Power Saving, KW 1600

Yearly Saving, KWh 90% AVF 12614400
Selling Price, Rs 2.9
Saving, Rs Cr 3.66

Net Saving 16.85

Cost of OH 9
Payback, month 6.41

Generation lost, MU 483.57

Marginal Contribution, paisa 10
loss, Rs Cr 4.52

DC loss 5.90
loss, Rs Cr 33

Net Loss 46.52

month 33.13
Intangible cost saving in overhauling

1. Reliability of equipment increased.

2. Reduction in running maintenance cost.
3. Reduction in ESP emission due to reduced FG temperature.
4. System improvement works results in increased system reliability.