Power Plant Chemistry

1. 8/2/2018

3. 8/2/2018
JUSCHEM SOLUTIONS PRIVATE LIMITED
Just-chemicals.com is an experienced chemistry focused company connecting all power
plant chemistry and water treatment related activities such as Power Plant Chemistry
Audit, water management, Training, Troubleshooting, commissioning help and freelancing
Consultancy for both IPP's and CPPs
About the founder:
The Founder, S Banerjee is a seasoned power plant Chemistry and water treatment
professional with in-hand experience of about 23 yrs after passing M.Sc. Applied Chemistry
from Government Engineering College, in 1995.He has worked with India’s Pioneer Water
Treatment Company and with Giant Private Power Generators in India viz. Tata Power,
Adani Power, Jindal Power, LPGCL as HOD Power Station Chemistry and Environment. He
has both experiences of sub critical and super critical power plants, commissioning-O&M
and troubleshooting. He was also associated with a Jindal Institute of Power Technology as
a faculty on Power Plant Chemistry. He has presented few papers on power plant chemistry
and water management in national seminars and magazines and also written an academic
text book on power plant chemistry for regular post graduate degree curriculum of Jindal
Institute of power technology.

4. Power Plant Economics
8/2/2018
The main purpose of design and operation of the plant is to bring the cost of energy
produced to minimum
 Fixed Cost viz. Capital investment, Interest on loans, ROE, Overhead charges cannot be
altered at late operational stage thus:
 The only area which increases the profitability is Variable Cost - Operating Cost which
includes reliability and sustenance i.e. lesser shutdowns and lower maintenance.
 Typically Cost of Fuel, manpower, maintenance & repairs, inventory and super vision
costs are in Variable cost. Each of these are being dealt separately by commercial
Function.
 There are 2 major raw materials that is Fuel and water and both play a very important
role in sustaining efficiency of a power station
 First: Coal contributes to 70-85% of the operating cost depending on size of power
plant and the Energy (Calorific Value) input and Output is considered as most
important. For measuring the input proper sampling and analysis of fuel is important.
 Second: water chemistry as any upset may cost heavily on equipment and generation
either by corrosion in boilers or condensers or deposit on heat transfer surfaces
effecting boiler efficiency and / or vacuum. We all know how important is condenser
vacuum in the complete cycle efficiency.

5. Our Capabilities cum offering
8/2/2018
With extensive experience in the thermal and co-generation industries, We have conducted
numerous extensive site cycle chemistry reviews, audits and benchmarking studies at plants
in India and Indonesia.
 For more information, please contact the team at Thermal Chemistry.
Audit for Power Plant Chemistry and Thermodynamic Efficiency:
 Coal sampling and analysis, recommending best practices and helping to create GCV
Balance. Correct sampling and analysis is one of the significant key in power plant
efficiency
 Water Management and Water Balance including their treatment practices and
recommend optimization
 Processes related to steam-water cycle chemistry and its systems, reporting, frequency
and data control
 Efficiency and effectiveness measures of Cooling water treatment, DM Plant and Boiler
water treatment
The technical process used by Thermal Chemistry is proven, robust and detailed. It clearly
identifies key areas of cycle chemistry risk for any plant. Practical, proven and detailed
recommendations are then made to lower the plants ongoing risk for future deposition and
corrosion related failures.

6. Our Capabilities cum offering - Continued
8/2/2018
Consultancy: Develop, review & upgrade the Standard Operating Practices related to
Water Treatment, Chemical lab and thermodynamics:
 Efficiency and Effectiveness monitoring using lead and lag indicators for all power
plant Chemistry related processes
 Identify the opportunities for improvement of efficiencies / root cause analysis /
troubleshooting in power plant chemistry including water treatment and water
related segments in boilers and Turbines. Recommend Necessary modifications /
reengineering on the existing chemical systems.
 Support and guide on regular monitoring of the water chemistry management
practices at site. Provide guidance to improve the cycle chemistry across all
generating stations. Water Management consultancy.
 Can Train people on power plant chemistry & Thermodynamics.
 Create Processes related to power plant chemistry and heat transfer
management.

7. Our Capabilities cum offering - Continued
8/2/2018
TECHNICAL TRAINING
 We are technical training experts within
the thermal co-generation industries in
India and Indonesia.
 As part of their specialist industrial,
power chemistry and water treatment
consulting services, Thermal Chemistry
provide the development and delivery
of customized chemistry training
programs for all aspects of Power Plant
chemistry and thermodynamics.
 This training is highly interactive and
customized to the clients needs and will
increase the knowledge, skills and
abilities of all attendees.
 To make a training enquiry, contact one
of the team at Thermal Chemistry.
You may choose from the topics
mentioned below, where you have the
highest concern: 
• Combustion Calculation of Coal Based plant
• Coal Sampling, sample preparation and analysis
• Water: Pre-treatment, filtration, disinfection, dosing
of chemicals
• Water External Treatment: De-Mineralization Plant,
RO Plant, UF plant, their trouble shooting
• Best Practices Water Chemistry of stream-water
cycle
• Circulating water Chemistry,
• Heat transfer and monitoring in cooling water
system including Variables affecting tower
performance and heat exchanger performance,
• Boiler Tube Failures mechanism inspection &
Corrective Actions
• RO Operation and Cleaning, best practices
• Applicability of Six Sigma in power station
• Water management and water balance
• Flow Accelerated Corrosion in Thermal Power Plant
• Condensate polishing unit
• Primary/Stator water chemistry
• Advances in Power Plant Chemistry
• Internet of Things (IoT) in power Stations

8. 8/2/2018
TROUBLESHOOTING AND INVESTIGATIONS
We offers specialist, independent chemistry and chemical engineering consultancy services
to the thermal power and co-generation industries.
Our Company offers our expertise for troubleshooting and investigations of cycle chemistry
issues for:
• Conventional subcritical and supercritical boilers
• Heat recovery steam generators
• Industrial boilers
• Steam turbines
• Water treatment plants
• Cooling water systems
With extensive experience in industrial, cycle chemistry and water treatment, the experts at
Thermal Chemistry conduct investigations at facilities in India.
Our Capabilities cum offering - Continued

9. Audit criteria – what should be and what is
Audit finding – what is compared with what should be
Training on aspects, How, What, why, When, Where, Who/Whom on area of concern
Defining process, SWOT and Planning improvement projects
Estimate likely impact of Improvements
Audit – Efficiency, effectiveness of process of thermodynamics and power plant Chemistry
as boiler efficiency, condenser efficiency, Cooling tower efficiency, coal sampling-analysis
and boiler water chemistry contributes significantly to power plant economics
What we do to improve at Sree Rayalseema Hi-Strength Hypo Ltd. CPP’s
Determine the causes and effects of the finding – recommend in audit report

10. 8/2/2018
Power plants are intended to operate at their best efficiency. Once a plant goes into operation, however, real life takes over and
sometimes design outcomes are not often realized. Improving plant performance is C K Birla Group’s objective, and there are some
very important indications that can be utilized to help steer the plant on a course to achieve best design conditions.
Designed for Success
The heat balance is the foundation of the power block design and contains a wealth of information useful for day-to-day operation
and maintenance.
1. The Heat Kit and Heat Balance
The heat kit contains information about the STG cycle’s performance. Shown on the cycle heat balance are the thermodynamic state
points, flows, pressures, temperatures, and enthalpies. The largest output is the heat rejected in the condenser and cooling system.
2. Flue Gas Exit Temperatures
The amount of energy lost up the stack is a function of the amount of flue gas (FG) and its temperature. If the FG mass flow is
measured by a continuous emissions monitoring system, heat loss up the stack can be calculated in KCal/hr using the FG temperature
and specific heat capacity.
3. Feed water Flow Ratio
Feed water flow ratio (kg/hr/kW) is another useful comparison. The feed water flow is the centerpiece of the Rankine turbine cycle.
In the traditional turbine cycle heat rate calculation, feed water flow and its variations are the predominant factor.
4. Circulating Water System
The purpose of the circulating water system is to remove the rejected heat from the condenser. If the flow rate through the
condenser is reduced because of fouling on the tube sheet or in the system or reduced pump output, the tube velocity will decrease
as will the basic heat transfer coefficient, all adding up to increased backpressure.
5. Putting Losses in Perspective
About 15% of fuel losses occur in the stack with about a third due to dry gas loss, about a third due to moisture, and about a third
due to miscellaneous losses.
• The stack loss reduction would be 0.5%.
• The blade path loss reduction would be 1%.
• The circulating water loss reduction would be 5%.
• For most power plants, the circulating water system, including the condenser, pumps, and tower, holds the greatest potential
for performance improvements.
6. Accurate Sampling and analysis of Fuels whose data are taken for efficiency calculation
7. Minimizing downtime due to corrosion or scale formation
The Seven key performance parameters presented here are our improvement target for this programme.

11. Measure Manage
Improve
Define the
Process
Establish
the metrics
Design
Measure and check
the performance
Stabilise:
Eliminate Variation
Execute
improvement
Action Plans
Analyse &
Plan
Improvement
Set
Improvement
Goals
We follow the Process Management Model in
our Audits-improvement projects (JURAN’S
TRILOGY)
Feedback to Design Process
Feedbacktoholdgain

12. Method Adopted by Juschem Solutions
2 August 2018Birlasoft Proprietary and Confidential12
Data
What is
being
supplied
Key Process
Steps
What is the
output of --
--(name
search is
on)---?
Target
machine /
process /
system
What is being Measured?
Efficiency (In-Process) Effectiveness (Output)
Measure Target
RUL
Predictabili
ty &
Prescriptio
n
Measure Target
Performanc
e
improveme
nt
• Design
• Commiss-
ioning
• Real-time
from
Plant
Operation
• Lag
Indicators
of
efficiency
and
effectiven
ess
• Quality
parameter
s
• Process
parameter
• Breakdow
n Info.
• Eqpt. Info
• Overhaul
info
• Research
• Basic
Analytics
• Develop
algorithm
s
• Develop
control
signals
• BI
Analytics
• Adv.
Analytics
• Trials
• Lead
indicators
• Optimizes
efficiency
and
effectiven
ess
• Extends
assest life
• Identifiabl
e process
Assurance
• Help in
troublesh
ooting.
Eqpt. In
good
working
state
Req. cost or
process
optimization
on man,
material or
machine
• Plant
operation
% reduction
of critical
equipment
downtime
5% min. 85% %
adherence
to Quality &
Quantity of
output
(meeting
demand)
98% 1-5%
minimum on
Efficiency
and large on
effectivenes
s
Quantifiable
in
improveme
nt trends of
lead and lag
indicators
2. Identify the Output of the
Process that will meet
Customer requirement
4. Who will provide those
Inputs?
6. Identify the Measures that
will reflect if Customer Needs
are being met
11. Asset life predictability
and prescription writing
1. Identify the Purpose
3. What and how inputs are
required to start the activities
of ----(name search is on)---?
7. Set Target for the identified
Measure
8. Impact on performance.
Measurable?
9. Identify the Measures that
will reflect ----(name search is
on)--- is efficient
5. What are the key steps in -
---(name search is on)---?
10. Set Target for the
Efficiency Measures

13. Process Improvement Goals
 Understanding existing processes
 Introduce process changes to improve quality, reduce costs, or saves time and efforts
 Industry is demanding increased attention to sustainability-low maintenance in general
 Most process improvement work focuses on defect reduction and prevention
 There are other process attributes that deserve our attention
Performance Audit
 Differs from regularity audit
 Different approach, more ad hoc, less rigid, different skills, But same insofar an
independent, objective assessment
 Audit of 3 Es: Economy, Efficiency & Effectiveness
 Aim to lead to improvements
 Two dominant approaches
 Performance oriented
 Problem oriented

14. The 3 Es
 For same level of quality
 Economy
 Is about keeping the cost low
 Minimising the cost of O&M used or required
 Efficiency
 Relationship between inputs-outputs such as coal, water, chemicals etc.
 Can I produce more from given resources, can I use less for a level of outputs?
 Spending well – Value for money spent
 Effectiveness
 Relationship between intended and achieved results of spending
 What is your internal customer feeling?
 Spending wisely
Assessment always relative to audit criteria (standards against which actual performance measured).
Important choice in audit design: Standards used to determine whether system meets or exceeds
expectations. Audit scope and design interprets economy, efficiency and effectiveness concretely.
Criteria should be relevant, reasonable, attainable eg. Historical; Similar programmes or other
locations; Legislation; Accepted standard; Professional opinion. Ideally measurement before and after
+ control group

15. Process Improvement Stages
 Process analysis
 modeling and quantitative analysis of existing processes
 Improvement identification
 quality, cost, and scheduling bottlenecks located
 Process change introduction
 modify process to remove bottlenecks
 Process change training
 train staff involved in process revision proposals
 Change tuning
 process improvements are revised and allowed to evolve

16. Process Improvement Activities
Process
model
Process change
plan
Training
plan
Feedback on
improvements
Revised process
model
Analyse
process
Identify
improvements
Tune
process changes
Introduce
process change
Train
engineers

17. Process Improvement Attributes
 Understandability - degree to which a process is well defined and understood
 Visibility - process activities have results that are externally recognizable
 Supportability - process activities supported by CASE tools
 Acceptability - defined processes are used and accepted by engineers
 Reliability - process is defined so that errors are avoided or trapped before product errors
result
 Robustness - process can continue despite unexpected problems
 Maintainability - process can evolve to reflect changing organizational requirements or
identified process improvements
 Rapidity - the time required to complete a system from specification to delivery

18. Process Analysis and Modeling
 Process analysis
 study of existing processes to understand relationships among process components
 allows comparisons with other processes
 Process modeling
 documentation of process in which the tasks, roles, and entities used are recorded
 best to represent models graphically
 several different perspectives may be used (e.g. activities, deliverables, etc.)
 model should be examined for weaknesses, this involves discussion with stakeholders
Process Exceptions
 Process models can’t represent how to handle exceptions
 key people are lost prior to a critical review
 failure of e-mail server for several days
 organizational reorganization
 request to respond to change requests
 General procedure is to suspend the process model and follow plans augmented with
the managers own initiatives

19. Process Model Example
Test
module
Signed-off test
record
Module test
data
Module
specification
Module compiles
without syntax
errors
All defined tests
run on module
Test
engineer
Pre-condition
Input
Process
Rôle
Post-condition
Outputs
Responsible
for

20. Process Measurement
 Wherever possible quantitative process data should be collected
 Organizations without process standards may have to be define processes before
measurements can be made (since they won’t know what to measure)
 Process measurements should be used to assess process improvements
 Organization objectives drive process improvement, not measurements
Process Measurement Classes
 Time taken to complete process activities
 e.g. calendar time to complete a milestone
 Resources required to complete processes or activities
 e.g. person months
 Number of event occurrences
 e.g. number of defects found

21. Capability Assessment Process
Select projects
for assessment
Distribute
questionnaires
Analyse
responses
Clarify
responses
Identify issues
for discussion
Interview
project managers
Interview
engineers
Interview
managers
Brief managers
and engineers
Present
assessment
Write report

22. Process Tool Support
Informal
process
Managed
process
Methodical
process
Improving
process
Specialized
tools
Analysisand
design
workbenches
Project
management
tools
Configuration
management
tools
Generic
tools

23. Fishbone Diagram

24. Performance Auditor’s domain
Input Output chain
Commitment Input Action/production Output Outcome
Purpose defined Resources
assigned
Activity undertaken Goods and
services
provided
Objectives
met
Performance dimension
Economy
•Physical and
financial
•Amount
•Timing
•Quantity
•Quality
Efficiency
Productivity
Unit cost
Operating ratios
Output
effectiveness
Level
Quantity
Timeliness
Quality
Price Cost
Customer
satisfaction
Outcome
effectiveness
Mission and
goal
achievement
Financial
viability
Cost benefit
Cost
effectiveness
Programme dimension
Auditor should
be careful not
to stray into
political
terrain
But, audit
findings can
include
reflections on
policies
Cross-cutting performance aspects
Compliance with laws and regulations; validity, reliability and availability of
information; maintaining underlying values; continuous improvement
Source: Waring C and
Morgan S, 2007. Public
Sector Performance
Auditing in Shah, A (ed):
Performance
Accountability and
Combating Corruption,
WBI, Washington DC

25. Heat exchanger Real Time Performance monitoring with
predictive Maintenance & Remaining Life Assessments
Heat Exchangers:
The heat exchangers are
integral part of any utility in
Power, Oil & Gas and
Manufacturing.
Our Solution falls under Asset
performance monitoring, where
we are acquiring the sensor
data, churning it with the design
data, further churning with
commissioning data also
considering the fluid / media
physical and chemistry
parameters and coming out with
the performance analytics with
predictive indication for
maintenance and Remaining life
Business Challenges:
Experiencing Heat loss, lower
plant availability and increased
operating expenses, Low
vacuum, High heat-rate and fuel
cost in power plant, High
Cleaning frequency and
associated cost mostly due to
fouling, Reduced life of
metallurgy due to cleaning &
Increase on CO2 emission.
Outcome: Improvement in
operational efficiency by 1-14%
Identification of preventive
Maintenance activities to
achieve lesser stoppages and
breakdowns
Innovative Idea for Mfg, O&G and Power & Water WORLD EXCLUSIVES
THE
JUSCHEM Idea

26. Award Winning Idea
Real-time RO Plant Performance
Monitoring and Predictive Maintenance
WOW NEWS
Now the water utilities do not
have to worry about
understanding what’s going on
with their RO systems.
Currently the RO plants are
having lag indication i.e.
indication of failure after it
happened.
Juschem Solutions brought
lead indicators (before things go
wrong) and overall plant
performance indicators for the
water utilities within a town or
industry.
The Challenges of lower
membrane life, higher specific
power consumption, lower
permeate volume and bad
permeate quality will be a
history.
Our Innovative Solution will
make the challenges a history,
while acquiring the sensor data,
churning it with the design data,
with commissioning data also
water chemistry parameters
coming out with Lead
performance & predictive
indication for maintenance and
Remaining life Assessment
Benefits for water utilities
Improvement in operation efficiency by min. 10% to Max. 35%
depending on plant age & configuration. Reduction in operational
cost by min. 7% to Max. 25% depending on plant age,
automation & configuration. Savings in terms of CAPEX,
maintenance cost, energy cost, chemicals costs, improve
inventory management of membranes and spares and helping
proactive action recommendation. Customer satisfaction due to
improved operations and fewer shutdowns i.e. Meeting Customer
Demands. Predictability with membranes + Enhanced Operating
Strategies --> 33-50% membrane replacement cost saving.
Date today 03/06/18
RO Plants are used worldwide for:
• Sea Water Desalination – converting sea water into potable
kind of water for downstream Industrial Processes or as
Drinking water
• Waste Water Recycling – Purifying and recycling water

27. Description Business Challenge Solution Approach
Heat exchangers have a significant
role in a power plant’s heat losses
and have greater influence on
power plant economy.
In most process plants, poor
performance of heat exchangers
will lead to loss of production.
Birlasoft has come up with a
solution that measures and
indicates the effective
performance monitoring of heat
exchangers and provide lead
indication against loss of
performance and fouling.
• Experiencing Heat loss,
lower plant availability and
increased operating
expenses
• Low vacuum, High heat-
rate and fuel cost in power
plant
• High Cleaning frequency
and associated cost mostly
due to fouling
• Reduced life of metallurgy
due to cleaning
• Increase on CO2 emission
1. Begin with operational data collection and
validation at regular intervals, consider historical
data and design specifications
2. Perform analytical study with inputs provided,
identify lead indicators, quality parameters,
process parameter and Breakdown Info
3. Develop algorithms which will have grater
impact on operation
4. Identify process deviations, factors effecting
performance and efficiency
5. Run advanced Analytics to optimize efficiency,
effectiveness and develop scenarios which helps
in extending asset life
Benefits (Tangible / Non-Tangible)
1. Improvement in operational efficiency by 5-10% and helps in
increased heat rate
2. Identification of preventive Maintenance related activities to
achieve lesser stoppages and breakdowns
3. Achieve reduction in Power consumption and attain higher
output per unit consumption
4. Enhance plant level availability and efficiency through
Improvement in Vacuum, Heat Rate, Fuel consumption and CO2
reduction
Condenser health monitoring and prediction

28. Problem statement Client requirements Solution Solution -Event Flow
A reliable integrated solution is
required in Mining Industry to
know:
• The exact path taken by the
truck with high accuracy to
know and control movement
of trucks within the pre
defined premises
• Methods to cross check and
prove the data is correct
• Integrate it with existing
solution/ERP.
• The solution must be user
friendly and industrial grade.
• Automation towards
efficient Material
Management
• Quick Installation
• No Consumable to
be used
• Ability to shut down
the vehicle when it
enter no entry zone.
• Able to detect if the
driver tries to move
the tracking
equipment from one
vehicle to another
vehicle
• No wire cutting to
the electrical wiring
of the vehicle.
• The complete mine,
plant and route can be
divided into small geo
fences , each geo fence
representing a specific
process.
• A set of geo fences can
be clubbed together to
create a route.
• When a vehicle enters
or exits the mine we
can map the vehicle
with a route as per
allow slip and monitor
the vehicle follows the
route .
• The entire Plant, Mine and
Path will be marked as
different geo fences.
• The entry of the truck into the
plant/mine will mark the start
of the trip.
• In case the truck tries to enter
a zone for which it is not
authorized, a buzzer will inform
the driver
• In case a trucks If the driver
does not adhere , the
immobilizer in the truck will
switch off the engine which
can be started again only by
the security staff from the
website.
Tracking, Tracing and Theft Evading – Cement & Mining Industry

29. What Are Essential Assets?
Essential
Assets
Boilers
Turbines
Condensers
Cooling Towers
Fans
Pumps
 Any asset whose outage can cause significant process disturbance, slowdown or shut
down
 Failure of such asset may be considered as low probability but high impact failure
 Failure may also be associated with high cost and adverse impact on environment and
health
Asset Performance
Management

30. Centralised Asset Performance Monitoring
Central
Server
Turbines Gear BoxesCondensers ID/FD Fans Pumps BoilersCooling Towers
Wireless/ LAN
Gateway
WebCloudClient PC

31. Data Integration, Decision Making Using Meaningful
Information/KPIs
Decision Making
Diagnostic
Data
Process
Data
Trend
Data
Process Data
Trend
Data/Historian
Diagnostic Data

32. Typical Energy Losses in a
Power Plant

33. Typical Energy Losses in a Boiler

34. Typical Energy Losses in Steam Cycle

35. “You cannot Manage what you
cannot Measure”
(Accurately)
 Heat rate of the plant
 Heat rate of the steam turbine cycle & Boiler Efficiency (direct and Indirect,
minimize unaccounted loss)
 Auxiliary Power Consumption
 Net heat rate of the power plant
 Air pre-heater efficiency
 Economizer efficiency