International Journal of Innovative Technology and Exploring Engineering (IJITEE)

ISSN: 2278-3075, Volume-8 Issue-11, September 2019

PG test of 250 TPH, 9.8 Mpa Circulating Fluidized

Bed Combustion Coal Fired Boiler and 4 X 61.5
MW Condensing Steam Turbine.
Manish .R. Moroliya, K.D. Ganvir, N.D. Pachkawade

Abstract: The objective of this paper is study the various

methods and procedures involved in performance guarantee of II. PG TEST OF 250TPH CFBC BOILER
250 TPH, 9.8 Mpa CFBC (Circulating fluidized bed combustion
coal fired Boiler and 4 X 61.5 MW, 238 TPH, 8.83 MPA, 537 °C The Boiler when working with its associated equipment is
condensing turbine. Contractor has to demonstrate the guaranteed to give the following performance:
guaranteed performance in accordance with relevant section of
the Contract Document. The tests will be carried out as per
ASME PTC 4.1 - 1991 code for 04 hours duration. The various
values, parameters, conditions mentioned herein are in line with
the contract specifications. In case of any clarification, the
Purchase order shall be referred. This paper describes the
procedure of performance test to be conducted for testing of 61.5
MW Steam turbine generator. Performance test will be conducted
to establish the following agreed performance requirements. 1)
Heat Rate 2) Auxiliary Power consumption

Keywords: performance guarantee test, circulating fluidized

bed combustion, heat rate, auxiliary power consumption, power
factor.

I. INTRODUCTION
The objective of this paper is study the various methods
and procedures involved in performance guarantee of 250 Also the above figures are guaranteed based on operating
TPH, 9.8 Mpa CFBC (Circulating fluidized bed combustion the Boiler as per the fuel quality and feed water quality
coal fired Boiler and 4 X 61.5 MW, 238 TPH, 8.83 MPA, mentioned below and following operating conditions.
537 °C condensing turbine. Contractor has to demonstrate
the guaranteed performance in accordance with relevant
section of the Contract Document. The tests will be carried
out as per ASME PTC 4.1 - 1991 code for 04 hours
duration. The various values, parameters, conditions
mentioned herein are in line with the contract specifications.
In case of any clarification, the Purchase order shall be
referred. This paper describes the procedure of performance
test to be conducted for testing of 61.5 MW Steam turbine
generator. Performance test will be conducted to establish
the following agreed performance requirements. 1) Heat
Rate 2) Auxiliary Power consumption.

Revised Manuscript Received on September 06, 2019

Manish .R. Moroliya, Assistant Professor, Department of Mechanical
Engineering, Priyadarshini Bhagwati College of Engineering, Nagpur, Feed water temperature at economizer inlet = 235 °C
India. Email:manishmoroliya@gmail.com Ambient Temperature = 30 °C
K.D. Ganvir, Assistant Professor, Department of Mechanical
Engineering, Priyadarshini Bhagwati College of Engineering, Nagpur, Relative Humidity = 60 %
India. Email:manishmoroliya@gmail.com
N.D. Pachkawade, Assistant Professor, Department of Mechanical
Engineering, Priyadarshini Bhagwati College of Engineering, Nagpur,
India. Email:manishmoroliya@gmail.com

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DOI:10.35940/ijitee.K2405.0981119 3765 & Sciences Publication
 A. Required Feed water quality at battery E. Methods of Operation during Test
a. During the efficiency test no Blow down will bedone.
b. No Soot blower shall be operated. However, Soot
blowing as many times as required by the lead engineer
will be done prior to starting the test for cleaning of
heat transfersurfaces.
c. CBD shall be kept closed and Safety Valve is not
allowed to beblown.
d. No steam and water should be allowed to pass without
their respectivemeasurements.
e. Plant should be run for 8 hrs at rated conditions to attain
temperature equilibrium before the test isstarted.
f. During whole of this period the unit shall be fired with
guaranteefuel.
g. The load should be steady and withoutfluctuations.
h. Readings of power consumed by individual drives
should be noteddown.
F. Method of EfficiencyCalculation
a. Test code: ASME PTC 4.1 –1991
b. Efficiency calculation method: Indirect heat loss
method as per ASME PTC 4.1 –1991
c. Correction for variations: for Fuel analysis, calorific
value, ambient temperature, oversize bed material &
any other relevant correction if applicable by way of
correction curves will be applied on the calculated
efficiency. Relevant correction for Auxiliary power
consumption will be applied on recorded
powerconsumption.
B. Inputs Required from customer during the tests
1. Fuel (Performance fuel as specified above for 24 hrs
operation, considering stabilization period and PG III. PG TEST OF 4X61.5 MW CONDENSING
Testperiod) STEAM TURBINE
2. Feed Water, as per temperature and quality A. Heat Rate
mentionedabove. Heat rate test is conducted to establish performance of
3. All related plants like Coal feeding, Ash handling, STG for 61.5 MW. Heat rate shall be 2218.16 Kcal/Kw-hr
steam utilization (Process / Turbine etc.), DM Plant, as per the Heat Balance Diagram No. (RL0308196301)
Condensate & other related plants are working stable which is 100% TMCR with 3% make up. The cycle heat
without anyfluctuations. rate depends on individual performance of equipment as
4. Following materials needs to be arranged by customer mentioned below.
before starting thetest. a. Turbine
b. Generator at output of 61.5MW.
C. Method of Fuel Sampling c. Condenser
a. Sample of fuel to be taken from Fuel feeders and to be
d. Cooling water system with inlet temperature
collected in a container, oncean hour.
e. Deaerator.
b. The final sample collected will be mixed thoroughly
f. HPHeater
and be distributed in three parts. These three parts will
g. LPHeater
be put in 3 tins/packets and sealed by both theparties.
h. Power factor of0.8.
c. First packet will be taken by DFPS for analysing at a
recognized laboratory in India for analysis purpose. Conditions to be achieved for Heat rate test:
d. Second sample will be taken by AINL for theiruse.
e. Third sample will be kept in safe custody by M/S 1. Steam parameters shall be maintained at 100%
AINL for future reference ifrequired. rated conditions. In the event parameters are
D. Ash Samples different from rated, suitable corrections shall be
Samples of bottom ash, fly ash and Economizer ash shall applied in the analysis for Inlet steam pressure,
be collected to determine the loss due to combustible matter Inlet steam temperature & Exhaust pressure.
in the ash at intervals of 1 hr. Samples are also to be kept in 2. Machine shall be loaded to 100%TMCR at rated
sealed tins. Bed ash to be collected at discharge of ash power factor. In the event power factor is
cooler and economizer & fly ash to be collected from different from design value correction shall be
respective hoppers at intervals of 1 hr. The final samples applied on output for analysis.
collected will be mixed thoroughly and be distributed in
three parts for each type as mentioned at above.

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DOI:10.35940/ijitee.K2405.0981119 3766 & Sciences Publication
 International Journal of Innovative Technology and Exploring Engineering (IJITEE)
ISSN: 2278-3075, Volume-8 Issue-11, September 2019

Duration of test:
ExhaustPressure P2 Kg/cm2
Test reading shall be taken for a minimum of two Feed water Temperature at the
hours of stable operation. TG shall be running at T1 °C
outlet ofHPHeater-1
stable rated condition for at least one hour prior to
starting of test. Frequency of collection of test data FeedwaterEnthalpy E KJ/Kg Feed
shall be as given in instrument list.
waterFlow Q Kg/Hr
However, the following guidelines shall be followed for data
acquisition. GeneratorOutput P KW
a) Primary flow (Feed water flow to Boiler, Main steam
PowerFactor PF2%
flow to Turbine):2 minutes.
b) Electrical Output: 2 minutes.
c) Secondary flow : 5 minutes. c) Correction Factors from the Turbine Manufacturers
d) Pressure and temperatureIntegrated flows, Integrated curves
power measurement, storage level changes:30minutes.
Heat Rate Output
B. Calculation of Heat Rate for Design Condition
Description correction correction
Heat rate @ 61.5 MW output=((Steam inlet flow to
values value
turbine) X (Enthalpy of inlet Steam to Turbine - Enthalpy
of Feed water inlet to Economizer)-(Make up water flow) Inlet Steam Pressure λ1 β1
x (Enthalpy of Feed water inlet to Economizer – Enthalpy
of Make up water ))/(Power at Generator Terminals) Inlet Steam Temperature λ2 β2
Heat rate = ((Q1 x (H1 – H2) -(Q2 x (H2 – H3))/P)
kcal/Kw-hr Exhaust Pressure λ3 β3
Where as
Product of Correction X Y
Q1 = Steam Inlet Flow (Kg/hr). Factors
Q2 = Make up water Flow(Kg/hr)
H1 = Enthalpy at Steam Turbine Inlet (Kj/Kg).
d) Test for Auxiliary Power consumption
H2 = Enthalpy of Feed waterinlet to Economizer (Kj/Kg).
H3 = Enthalpy of Make-up water (Kj/Kg) This test will be conducted to check the power consumed
P = Recorded Power output(Kw) by the auxiliary power equipment at 100%MCR condition
C. Procedure for calculating Heat Rate and for STG Auxiliaries which is 174.0 KW and cooling water
correction factor
temperature of 32 °C & power factor of 0.8.
Equipment, which are guaranteed for aux. Power
Hear Rate @ 61.5 MW output=2218.16 Kcal/Kwhr consumption are;

a) Guarantee ConditionParameters
InletSteamPressure Pd = 90.04Kg/cm2 Sr.No. EQUIPMENT

InletSteamTemperature Td = 537 °C 1 CONDENSATE EXTRACTION PUMP

InletSteamEnthalpy Ed = 3480KJ/Kg 2 DRAIN TRANSFER PUMP

ExhaustPressure P1 = 0.0917Kg/cm2 3 LUBE OIL TANK VAPOUR EXTRACTOR

FAN
PowerFactor PF1 = 80%
Power consumed at each feeder shall be measured in TG
HeatRate Hd = 9287KJ/Kwh MCC for above equipment.
Duration of test shall be two hours. Frequency of readings
shall be every fifteen minutes. Average power
b) Performance test parameter consumption will be taken for performance.
InletSteamPressure Pt Kg/cm2

SteamTemperature Tt °C

InletSteamEnthalpy Et KJ/Kg

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D. Minimum measurements required for Heat 4TH EXTRACTION
19
Rate PRESSURE AT NOZZLE PT-109 Kg/cm²
(DTC SUPPLY)
Sr. Parameter to be Tag No. Unit
No. measured 4TH EXTRACTION
20
PRESSURE AT LP PT-0709 Kg/cm²
ELECTRICAL POWER AT HEATER-3 INLET
1
GENERATOR TERMINALS * MW
5TH EXTRACTION
21
TEMPERATURE AT LP TE-0709 °C
2 TURBINE SPEED - HEATER-2 INLET
RPM
5TH EXTRACTION
22
PRESSURE AT NOZZLE PT-110 Kg/cm²
3 POWER FACTOR - - (DTC SUPPLY)
5TH EXTRACTION
23
PRESSURE AT LP PT-0710 Kg/cm²
4 MAIN STEAM FLOW
FT-0701 TPH HEATER-2 INLET
6TH EXTRACTION
24
5 INLET STEAM PRESSURE TEMPERATURE LP TE-0710 °C
PT-0701 Kg/cm² HEATER-1 INLET
6TH EXTRACTION
25
6 INLET STEAM PRESSURE AT NOZZLE PT-111 Kg/cm²
TEMPERATURE TE-0701 °C (DTC SUPPLY)

STEAM PRESSURE AFTER 6TH EXTRACTION

7 26
GOVERNING STAGE PT - 101 Kg/cm² PRESSURE AT LP PT-0711 Kg/cm²
HEATER-1 INLET
STEAM TEMPERATURE
8 27 EXHAUST TEMPERATURE
AFTER GOVERNING STAGE TE - 105 °C TE-0711 °C

1ST EXTRACTION
9 28 EXHAUST PRESSURE
TEMPERATURE AT HP TE-0705 °C PT-0712 Kg/cm²
HEATER-1 INLET
1ST EXTRACTION COOLING WATER INLET
10 29 TE-
PRESSURE AT NOZZLE TEMP. AT CCONDENSER
PT - 106 Kg/cm² 0804/080 °C
(DTC SUPPLY) 6
1ST EXTRACTION COOLING WATER
11 30 TE-
PRESSURE AT HP PT-0706 Kg/cm² OUTLET TEMP. AT
HEATER-1 INLET 0805/080 °C
CCONDENSER
7
2ND EXTRACTION
12
TEMPERATURE AT HP TE-0706 °C 31 CONDENSATE FLOW TO LP FT-
HEATER-2 INLET HEATER-1 0801/080 TPH
1A
2ND EXTRACTION
13
PRESSURE AT NOZZLE PT-107 Kg/cm² CONDENSATE INLET
(DTC SUPPLY) 32
TEMPERATURE TO LP TE - 1201 °C
2ND EXTRACTION HEATER-1
14
PRESSURE AT HP PT-0707 Kg/cm² CONDENSATE INLET
HEATER-2 INLET 33
PRESSURE TO LP PT-1201 Kg/cm²
3RD EXTRACTION HEATER-1
15
TEMPERATURE AT TE-0707 °C CONDENSATE INLET
DEAERATOR INLET 34
TEMPERATURE TO LP
HEATER-2 FROM LP TE - 1202 °C
3RD EXTRACTION
16 HEATER-1
PRESSURE AT NOZZLE PT-108 Kg/cm²
(DTC SUPPLY) CONDENSATE INLET
35
PRESSURE TO LP
17 3RD EXTRACTION PT-1202 Kg/cm²
HEATER-2 FROM LP
PRESSURE AT DEAERATOR PT-0708 Kg/cm² HEATER-1
INLET
4TH EXTRACTION CONDENSATE INLET
36
18 TEMPERATURE TO LP
TEMPERATURE AT LP TE-0708 °C TE - 1203 °C
HEATER-3 FROM LP
HEATER-3 INLET
HEATER-2

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DOI:10.35940/ijitee.K2405.0981119 3768 & Sciences Publication
 International Journal of Innovative Technology and Exploring Engineering (IJITEE)
ISSN: 2278-3075, Volume-8 Issue-11, September 2019

CONDENSATE INLET
37
PRESSURE TO LP
HEATER-3 FROM LP PT-1203 Kg/cm²
HEATER-2
CONDENSATE OUTLET
38
TEMPERATURE FROM LP TE - 1204 °C
HEATER-3
CONDENSATE
39
OUTLET PRESSURE PT - 1204 Kg/cm²
FROM LP HEATER-3
40 DTP DISCHARGE
PRESSURE PT - 1205 Kg/cm²

41 DEAERATOR STORAGE
TANK TEMP TE - 0302 °C

42 DEAERATOR STORAGE
TANK PRESSURE PT - 0302 Kg/cm²

FEED WATER 2. Correction curve for Inlet Steam Pressure v/s

43
TEMPERATURE AT BFP TE - 0303 °C HeatRate.
SUCTION HEADER
FEED WATER
44
TEMPERATURE AT BFP TE - 0304 °C
DISCHARGE HEADER
FEED WATER PRESSURE
45
AT BFP DISCHARGE PT - 0303 Kg/cm²
HEADER
FEED WATER INLET
46
TEMPERATURE TO HP TE - 1101 °C
HEATER-2
FEED WATER INLET
47
PRESSURE TO HP HEATER - PT - 1101 Kg/cm²
2
FEED WATER INLET
48
TEMPERATURE TO HP
HEATER-1 FROM HP TE - 1102 °C
HEATER-2

49 FEED WATER INLET

PRESSURE TO HP HEATER - PT - 1102 Kg/cm²
1 FROM HP HEATER-2 3. Correction curve for Inlet Steam Temperature
v/sOutput.
50 FEED WATER OUTLET
TEMPERATURE FROM HP TE - 1103 °C
HEATER-1
FEED WATER OUTLET
51
PRESSURE FROM HP PT - 1103 Kg/cm²
HEATER - 1
FEED WATER FLOW
52
FROM HP HEATER- 1 TO FT-
BOILER ECONOMISER TPH
0001/0001A
INLET

IV. OPERATING CURVES

1. Correction curve for Inlet Steam Pressure

v/sOutput.

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4. Correction curve for Inlet Steam Temperature v/s V. CONCLUSION
Heat Rate.
The performance guarantee test was successful completed
and the various parameters and readings were found of 250
TPH CFBC boiler and 4X61.5MW condensing Turbine and
based on the readings found, various operating curves are
prepared which gives the pictorial representation of the
various parameters. The correction curve for Inlet Pressure
and output represents that as the throttle pressure increases
the output also increases. The correction curve for Inlet
Pressure and Heat rate represents that as the throttle pressure
increases the Heat rate decreases. The correction curve for
Inlet Temperature and Output represents that as the throttle
temperature increases the output increases. The correction
curve for Inlet Temperature and Heat rate represents that as
the throttle temperature increases the Heat rate decreases.
The correction curve for Exhaust pressure and output
represents that as the Exhaust pressure increases the output
also increases up to 4 KPa, after that it decreases
continuously. The correction curve for Exhaust pressure and
5. Correction curve for Exhaust Pressure v/sOutput. Heat rate represents that as the Exhaust pressure increases
the Heat rate decreases up to 4 KPa, after that it increases
continuously.

REFRENCES

1. Dong Fang Power systems private limited Performance Test manual.

2. Abhijeet MADC Nagpur energy private limited Lab Manual.
3. Boiler Operation by Chattopadhyay.
4. Manish R. Moroliya, Bhojraj N. Kale and Ashish Mathew
Pullenkunnel, “Energy conservation of Boiler feed pump by
Differential pressure Autoscoop control Method (Audit and Result
analysis)” International Journal of Current Engineering and
Technology, Vol-05, No. 3, June-2015
5. Subodh Panda, Bikash Swain,Sandeep Mishra, Blow Down Losses
Control In Thermal Network Power Plants International Using
NeuralJournal of Advancements In Research & Technology, Volume
2, Issue5, May-2013
6. Ramesh kumar ,,. M.C.navindgi , G Srinivas,Performance Guarantee
Test Assessment of CFBC Boiler,IJISET - International Journal of
Innovative Science, Engineering & Technology, Vol. 3 Issue 7, July
2016
7. R.Pachaiyappan 1 , Dr.S.Gopalakannan 2 , J.Niresh 3 , Siddharth
Shrivastava 4,Performance Evaluation of A Steam Turbine Test RIG
6. Correction curve for Exhaust Pressure v/s and Oil Fired Boiler, International Journal for Research in Applied
Science & Engineering Technology (IJRASET)Volume 3 Issue XI,
HeatRate. November 2015
8. A review on energy conservation in building applications with
thermal storage by latent heat using phase change materials." Energy
conversion andmanagement 45.2 (2004): 263-275.
9. Gadgil, Madhav, Prema Iyer, and F. Berkes. "On the diversification of
common-property resource use by Indian society."Common property
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(1989): 240-255.
10. Kearton, William Johnston. Steam turbine theory and practice: a
textbook for engineering students. I. Pitman, 1948.Szwedowicz, J., et
al. "On forced vibration of shrouded turbine blades." ASME Turbo
Expo 2003, collocated with the 2003

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 International Journal of Innovative Technology and Exploring Engineering (IJITEE)
ISSN: 2278-3075, Volume-8 Issue-11, September 2019

AUTHORS PROFILE 3rdAuthor

1st Author

Mr. Manish R. Moroliya is presently working as a

Nikhil D.Pachkawade,
Assistant Professor in the Department of
Mechanical Engineering in Priyadarshini Bhagwati Assistant professor,
College of Engineering under Rashtrasant Tukdoji Priyadarshini Bhagwati College of Engineering
Nagpur,
Maharaj Nagpur University. He has more than 10
years of Teaching and Industrial experience. His Teaching Experience 6.5years
teaching and research areas include Fluid
B.E (Mechanical engineering)
Mechanics, Thermal Engineering, Heat Transfer
and Energy Management and systems. He also M.Tech (Mechanical Engineering Design)
worked as a Project Engineer in various Thermal Power Projects and
Teaching Experience 7years
specialized in Erection and Commissioning of Large Capacity Boilers and
Auxiliaries.
Number of Publications:
International Journal :2
He received his Diploma in Mechanical Engineering, B.E in Mechanical
Engineering and M.Tech in Heat Power Engineering and pursuing PhD. He International Conference:2
National Conference:1
has published one reference book on Fluid Mechanics.

He has 3 Copyrights under Copyright Office, Government of India, New- Projects guided to UG:
1)Design & Fabrication of material handling system using E-vehicle.
Delhi and has published more than 20 Research Papers in National and
International Journal and Conferences. He awarded certificate of
Meritorious contribution towards successful and ahead schedule of Achievements:
1)Won 1st prize in Power point presentation conducted by RAHE, GHRCE
commissioning of Prestigious “4X61.5 MW Mihan Power Project.”
in Nagpur national level paper presentation
He is a life member of Indian Society of Technical Education (I.S.T.E), 2)won first prize in state level competition conducted by ABVP in Latur.
3)Won second prize in national symposium conducted by SRKNEC
International Association of Engineers (IAENG) and Individual member of
Solar Energy Society of India (SESI). Nagpur.

Skills: Auto-cad, Creo, Catia V5,CNC machines

nd
2 Author Membership:IAENG
Contact detail:9326733739
Kanchan.D.Ganvir
Assistant professor, Priyadarshini Bhagwati
College of Engineering Nagpur
B.E (Mechanical Engineering)
M.Tech (CAD/CAM)

Teaching Experience- 9years

Number of Publications: 12
International Journal:8
International Conference: 4
National Conference :4

Projects guided to U.G:

1.Design and fabrication of biomass pellet burner
2.Development and enhancement of 4-stroke I-C engine to use acetylene as
an alternative fuel.
3.Design and fabrication of river trash cleaning mechanism

Achievements:
1)BEST PAPER AWARD IN international conference on science,
Engineering &Technology ICSET- 2019, HELD AT TASHKENT,
UZBEKISTAN
2)Won 1st prize in national level paper presentation
3)won first prize in project competition on national level

Skills: Auto cad, pro-e, CNC machines

Membership:IAENG, ISTE,AMM,

Contact detail: 9021941439

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