Welcome to the session
on
Overview of PG Test
PERFORMANCE
PERFORMANCE
GUARANTEE
PERFORMANCE
GUARANTEE TESTING
Output Electrical Power
3 Work output
Turbine Generator
4 Cooling Water IN
Qin
Boiler
Condenser Qout
BFP
Cooling Water OUT
2 1
SIMPLIFIED STEAM CYCLE
RANKINE CYCLE
(K)
(Kcal/ K)
TURBINE HEAT RATE
Hin (Kcal) Hout (Kcal)
Wt (kWh)
•Heat rate of turbine=(Hin – Hout)/Wt
•Efficiency and Heat rate are related terms. Lower the Heat Rate
higher will be the efficiency
•Heat Rate of a thermal Power project is in the range of 2200 to 1950
kCal/kWh
Annual Saving due to Improvement in Heatrate (Indicative)
Calculation for improvement in Heatrate by 1 kCal/kWh
PLF % 90 %
Coal cost 2200 Rs/Ton
Calorific Value 4400 kcal/kg
No. of hours in a year 24 x 365 8760 hrs
FORMULA
Annual Coal Saving due to Improvement in Heatrate = UNIT RATING(kW) xDelta HR(kCal/kWh)
Annual Saving x [Link] hrs x PLF /Calorific Value (kCal/kg)
500 MW set
Heatrate improvement 1 kCal/kWh
Annual Coal Saving 895.9 Tons/ year
Annual saving 19.7 Rs lacs/ year
Techno-Economical advantage
a) Improvement in Heatrate at 100% Load 10 kCal/kWh
b) Bid Evaluation Factor on Heatrate ( indicative 126.79 Rs
value) lacs/unit
heatrate
c) Price Advantage during Bidding 1267.9 Rs lacs
d) Annual saving due to improvement in Heatrate 197 Rs Lacs
e) Annual saving in Coal consumption 8950 T/yr
PURPOSE OF TG-PG TEST
Technical scenario
• Proving the contractual guarantees agreed with the customer.
• To demonstrate the heat consumption under specific conditions.
• Evaluation of performance of the various plant equipments in
actual working conditions.
• Acts as a tool for further improvements in design characteristics
of the power plant equipments.
• Actual performance of the TG set is critically examined with
reference to guaranteed figures / design .
• Such analysis is vital for formulating future strategy for enhancing
business potential .
PURPOSE OF TG-PG TEST
Commercial scenario
• Fulfils The Contractual commitment
• Getting balance payment released from the
customer.
• Contract closing
• Closure of Site Office
BASIS OF PG TESTING
Agreed procedure
PG Test Code (ASME-PTC 6 etc.)
Instrumentation Scheme
Heat Balance Diagram
All Guarantees are valid for brand new condition
ASME PERFORMANCE TEST CODES
To provide uniform basis for Test Procedures
Established in 1880
First Test Code established in 1884
It Consists of
Section 1 – Objective and scope
Section 2 – Definition and description of terms
Section 3 – Guiding Principles
Section 4 –Instruments and Methods of Measurement
Section 5 – Computation of results
Section 6 – Report of Results
Main ASME codes used in Thermal Power Plants
PTC 4.1 – Steam Generating Units
PTC 4.2 – Coal Pulverizers
PTC 4.3 – Air Heaters
PTC 6 - Steam turbines
PTC 6 A – Appendix A to Test Code for Steam turbine
PTC 6 S Report – Guidance for evaluation of Measurement
uncertainty in Performance Tests of Steam Turbine
PTC 6 Report – Simplified procedures for routine of Steam
Turbine
PTC 12.1 – Closed Feed Water Heaters
PTC 12.2 – Code on Steam Condensing Apparatus
PTC 12.3 - Deaerators
A) Guarantees with Penalties
• Heat Rate
• Generator output
• Condenser Vacuum
• Aux Power
B) Demonstration Guarantees
• HP/LP Bypass Capability
• Noise level
• Load Through Off
• Unit Start-up
•Category I conditions fall under liquidated damages
•Turbine cycle Heat Rate under rated steam conditions at 76 mm Hg
(abs) design condenser pressure with zero makeup at 100%, 80%,
60%, 50% load
•Condenser pressure measured above the top row of condenser
tubes under VWO conditions, 3% makeup ,design CW temperature
and flow
•Continuous TG output under rated steam conditions at 89 mm Hg
(abs) worst condenser pressure with 3% makeup
•CW Pumping Power for design CW flow through the condenser
• Category III conditions also called functional Guarantees are to
be demonstrated only .There is no provision for any penalties
•TG set capability at VWO conditions with 3% makeup at 76mm
Hg(abs) condenser pressure
•TG set capability with one string of HP heater out of operation at
3% and 0% makeup
•TG set capability with all HP heater out of operation at 3% and
0% makeup
Category II guarantees do not fall in the scope of
TG PG Test.
Maximum Nox emission should not be more than
260 grams per giga joule of the heat input to the
boiler during the entire operating range of steam
generator for the range of coal specified.
ASSESSMENT OF PERFORMANCE
Focus on
1. Reliability of available data
2. Consistency of operating parameters
3. Weeding out incorrect/ doubtful data
4. Stable and predictable TG Cycle
5. Accounting of leakages & Passings
6. Adjustment in the performance for variation in terminal
parameters & cycle configuration to enable comparison
with design data
MAJOR PERFORMANCE INDICATORS OF
A TG CYCLE
Heat Rate
Power output
Auxiliary Power Consumption
Condenser Vacuum
TYPICAL GUARANTEES FOR 500 MW
Parameter Guaranteed
Value
Turbine Cycle Heat Rate in Kcal/Kwh under rated steam 1944.60
conditions At 77 mm Hg (abs) design condenser Pressure KCal/KWh
with zero make up at 500 MW Unit Load
Turbine Cycle Heat Rate in Kcal/Kwh under rated steam 1989.30
conditions At 77mm Hg (abs) design condenser Pressure KCal/KWh
with zero make up at 400 MW Unit Load
Turbine Cycle Heat Rate in Kcal/Kwh under rated steam 2065.20
conditions At 77 mm Hg (abs) design condenser Pressure Kcal/KWh
with zero make up at 300 MW Unit Load
Turbine Cycle Heat Rate in Kcal/Kwh under rated steam 2138.40
conditions At 77 mm Hg (abs) design condenser Pressure Kcal/KWh
with zero make up at 250 MW Unit Load
Condenser pressure in mm Hg (abs) 77 mm Hg (abs)
measured at 300 mm above the top row of
condenser tubes under VWO conditions, 3%
make up, Design CW temperature and CW
flow.
Continuous TG Output of Steam Turbine 500 MW
Generator in KW Under rated steam
conditions at 89 mm Hg (abs) worst
condenser pressure with 3% make up.
C.W. Pumping Power in KW for design CW 1847 KW per
flow through the Condenser. 500 MW unit
PENALTIES TOWARDS SHORTFALL IN PERFORMANCE
PARAMETERS
Variation factor Penalty (indicative values)
Increase in turbine cycle heat rate under USD 3.25 lakhs per kCal/kWh
rated steam conditions at 76 mm of Hg or part thereof increased in
with 0% makeup at 100% load at generator heat rate from guaranteed
terminals value
Efficiency shortfall in percentage of steam USD 8.27 lakhs for every
generator at 92.2% BMCR at rated 0.1% or part thereof shortfall in
conditions efficiency from guaranteed
values
Total Auxiliary power consumption of all USD 2600/kW increase per
auxiliaries at 500 MW at 76 mm of Hg kW or part from guaranteed
(back pressure) with 0% makeup at 100% value
load
Total Auxiliary power consumption of all USD 900/kW increase per kW
auxiliaries at 400 MW (80%) at 76 mm of or part from guaranteed value
Hg (back pressure) with 0% makeup.
PLANT CYCLE OPERATING
CONDITIONS
All efforts are made to bring the cycle parameters
closer to design.
Due to various constraints it is difficult to
maintain the design parameters.
Correction curves – As per the international codes
and agreement with customer.
MS PRESSURE VS HEAT RATE CORRECTION CURVE
1.00600
1.00400
HEAT RATE CORRECTION FACTO
1.00200
1.00000
0.99800
0.99600
0.99400
140 145 150 155 160
MS PRESSURE (ATA)
MS TEMPERATURE VS HEAT RATE CORRECTION CURVE
1.00600
HEAT RATE CORRECTION FACTO
1.00400
1.00200
1.00000
0.99800
0.99600
0.99400
510 520 530 540 550 560
M S TEMPERATURE (DEG C)
RH TEMPERATURE VS HEAT RATE CORRECTION CURVE
1.00600
HEAT RATE CORRECTION FACTO
1.00400
1.00200
1.00000
0.99800
0.99600
0.99400
510 520 530 540 550 560
RH TEMPERATURE (DEG C)
BACK PRESSURE VS HEAT RATE CORRECTION CURVE
1.02000
HEAT RATE CORRECTION FACTO
1.01000
1.00000
0.99000 100% LOAD
0.98000
0.97000
0.96000
0.0400 0.0600 0.0800 0.1000 0.1200 0.1400 0.1600
BACK PRESSURE (ATA)
MS PRESSURE VS OUTPUT CORRECTION CURVE
1.06000
1.04000
OUTPUT CORRECTION FACTO
1.02000
1.00000
0.98000
0.96000
0.94000
140 145 150 155 160
MS PRESSURE (ATA)
MS TEMPERATURE VS OUTPUT CORRECTION CURVE
1.00500
OUTPUT CORRECTION FACTO
1.00400
1.00300
1.00200
1.00100
1.00000
0.99900
0.99800
0.99700
0.99600
0.99500
510 520 530 540 550 560
MS TEMPERATURE (DEG C)
RH TEMPERATURE VS OUTPUT CORRECTION CURVE
1.02000
1.01500
OUTPUT CORRECTION FACTO
1.01000
1.00500
1.00000
0.99500
0.99000
0.98500
0.98000
505 515 525 535 545 555 565
RH TEMPERATURE (DEG C)
BACK PRESSURE VS OUTPUT CORRECTION CURVE
1.02500
1.02000
1.01500
OUTPUT CORRECTION
1.01000
1.00500
1.00000
0.99500
0.99000
0.98500
0.98000
0.0400 0.0600 0.0800 0.1000 0.1200 0.1400 0.1600
BACK PRESSURE (ATA)
SELECTION OF MEASURING INSTRUMENTS
PARAMETER TO BE RANGE MEASURING
MEASURED INSTRUMENT
Differential pressure 0-2.5 Kg/ cm2 Transmitters
Pressure 0-250 Kg/ cm2 Transmitters
Condenser Back 0-780 mm Hg Transmitters
pressure
Temperature 0-300 0C RTD
Temperature 300-600 0C K Type Thermocouple
Generator Power 0-1000 Watts Digital Power Meter
0-5 Amp
0-65 Volts
Mass Flow Standard Test Flow
PRESENT MARKET SCENARIO
Higher penalty rates
Guarantee at part load also (500 MW)
Heat Rate Competitively quoted
Squeezed or nil tolerances
Emphasis on reduction of time cycle of submission of Report
Enhanced customer awareness
Vetting of performance calculations by third party
STAGES OF PG TESTING
Preparatory Stage
Preparation of
Instrumentation List
Finalization of Flow Nozzle location
Method of Computation of Heatrate
Heat Balance Diagrams
Heatrate & Output correction Curves
De-aerator/ Hot-well sizing curve.
Valve Isolation List.
Preparation of PG Test Procedure incorporating above mentioned
documents and contract requirement
Submission of PG Test Procedure to the customer and getting
approval.
STAGES OF PG TESTING
Pre PG Test Stage
Activities involved are
Calibration of Instruments
Submission of Calibration Certificate to customer
Procurement of Flow Nozzle
Checking of Unit Healthiness
Shutdown for PG Test Preparation
Attending the Valves Leaking /Passing
Preparing the unit ready for Test
STAGES OF PG TESTING
Preparatory work
Installation of Flow Nozzle
Installation of Pressure Transmitters, Differential Pressure
Transmitters for Pressure/flow measurements
Installation of Thermocouples/ PRTs for temperature
measurements
Installation of Power meters for Power Measurements &
measurement of Auxiliary Power Consumption
Installation of Dataloggers
Tuning of instruments
STAGES OF PG TESTING
Preliminary Activities involved before commencement of PG
Test are
Finalisation of Junction List
Joint protocol for height correction in pressure measurements
Submission of Final Junction List, calibration certificates &
deviations from the agreed procedures to customer/consultant.
Mock Test to ascertain the availability & correctness of
required Instrumentation.
Rectification if any required
Preliminary PG Test preferably at full load
Calculation & Analysis of Heatrate & output based on
preliminary PG Test
Discussion with customer/consultant for proceeding further
for Final PG Test
STAGES OF PG TESTING
Pre Final PG Test activities
Ensure Closing of Valve as per Valve Isolation List at least
three hours prior to start of test.
Terminal Parameters nearer to rated as indicated in the
corresponding HBDs
Steady load condition at least three hours prior to test
Steady Terminal Parameters. Fluctuations within specified
limits
TG Regenerative Feed heating Cycle corresponding to
HBDs & Steady.
Alternate drain lines to HP/LP Heaters should be closed
Steam from & to Common Auxiliary header should be
closed
Makeup supply to De-aerator feed-storage Tank &
Condenser hot-well closed
STAGES OF PG TESTING
Final PG Test activities
Ensure the steadiness & consistency of Load & all
parameters for next two to three hours
Ensure Data Capturing of all instrumentation in
Datalogger at regular interval.
Ensure completeness of all readings.
Data capturing of all drum levels & other supplementary
control room reading.
Measurement/Estimate of all external leakage in the
TG/SG Cycle during the test
Repeat the Test at the same load in the same setting
SQUEEZED TOLERANCES
No tolerance due to measurement uncertainty. This has
to be absorbed in the quoted Heat Rate
Ageing tolerance is generally allowed by the customer
only the running period of the delay caused by the
customer .
It is always difficult to convince the customer about the
delay on account of customer .
Rate of deterioration due to ageing is also reduced
Customer generally do not allow any tolerance on the
quoted Heat Rate
QUOTED HEAT RATE
Due to stiff market condition,best Heat rate is normally quoted .
No margin to account for measurement uncertainty
,deterioration due to ageing, higher system leakage and
deterioration the guaranteed cycle
Once a level of Heat Rate is quoted ,in the subsequent tenders
,level of Heat Rate can not be deteriorated to account for no
tolerance etc.
CRITICAL ISSUES BEING FACED
1. Expected liquidated damages due to non fulfillment of
guarantees.(Problem is max in case of 500 MW projects)
2. More competitive Heat Rate Guarantees
3. No allowance in performance due to manufacturing
tolerance
4. No or insufficient ageing tolerance
[Link] for excess system leakage
6. Loading on Heat Rate due to deviation from guaranteed
cycle (like present NTPC projects)
7. Verification of PG Test calculation by Customer
,Consultant , third party agency
ACHIEVING OPTIMUM PERFORMANCE
DURING OPERATION
• TG CYCLE CLOSER TO THE DESIGN
• RATED TERMINAL PARAMETERS
• CONTINUOUS EFFORT TO REDUCE SYSTEM
• LEAKAGE
• ATTENDING VALVE LEAKAGE & PASSING
• MINIMIZATION OF FLUCTUATIONS
• MINIMIZATION OF SUPERHEATER/
• REHEATER SPRAY
WAY FOR IMPROVEMENT
Conduction of PG Test at earliest.
More emphasis on System Leakage Control.
More emphasis on bringing TG sep operation to
design
Quoting optimum level of Heat Rate
Obtaining PG - Test report of our competitor & closer
analysis.
Emphasis on elaborate micro-level detailed analysis of
Calculations to safe guard the interest of corporation .
