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ECO-06 MAZUT SONIC FLOW METERS The audit team learned through intervIews with station personnel that one area whIch has hampered the stations progress m energy Improvements IS the mabilIty to accurately measure the decrease m fuel consumption due to any changes in operation or equipment motivated by efficiency improvement ThIS is because the eXIsting fuel flow mstruments in place at the statIon are maccurate or don't work. If only modest gams m effiCIency could be realIzed due to the mcentIve proVIded by the abIlIty to more accurately evaluate such Improvements, such flow momtonng equipment could pay for Itself m a very short penod. Lme sizes and design informatIOn were obtained for speCIfying somc flow meters for two supply and two return mazut lines serving the boilers. ECO-07 ON-LINE NATURAL GAS CALORIMETER The most important concern and pnonty at Burshtyn was the urgent need for analytical instruments for momtonng fuel qUalIty (coal, mazut, gas). The data mdIcates that the plants are paying large sums of money for fuel energy content (heatmg value) whIch they do not receIve. Instruments for measuring the fuel heat value m Kcal/Kg and other parameters would prOVIde the documentation necessary for making claIms agaInst suppliers. They urgently need an on-Ime gas calorimeter to verify the heat content supplIed by Gasprom. Their laboratory calorimeter is not commercial (certified), the tests are not contmuous so they cannot make a claim for credIts. We were given test results for monthly averages for 1994, as well as gas consumption. The plant claims losses of about 1.905 X 10 10 Kcal (7.559 X 10 10 BTU's) which results in $159,000 loss per year. Although thIS loss of expenSIve gas fuel heatmg value has nothmg dIrectly to do WIth "combustIOn" efficiency, this IS also a pnority m reducing the large sums of hard currency they must pay for fuel gas. ECO-08 COAL FLOW METER The audIt team learned through mterviews WIth plant personnel that one area WhICh has hampered the plant progress in energy improvements IS the mabilIty to accurately measure the decrease In fuel consumption due to any changes m operatIOn or eqUIpment motivated by efficiency Improvements. This is because the plant does not have instruments to measure the fuel flow for eIther mazut and coal to each boiler. Natural gas flow meters already exist per each bOIler and work well. If only modest gaIns m effiCIency could be realized due to the mcenhve prOVIded by the abIlIty to more accurately evaluate such Improvements, such flow momtonng eqUIpment could pay to Itself m a short period of hme. Instruments to measure raw coal consumption to 200 MW Umt #4 on belt conveyors, located between raw coal bunkers and mills (coal feeder) are recommended. For detailed calculations see Appendix A-I. 5906-01l02A1BURSHTYN/5117/95 15
5.2 Medium and Lon& Term Opportunities COMBUSTION IMPROVEMENT PROGRAM ThIS is a longer range energy conservatIon program requmng larger mvestments ofcapItal WhIch will accomplIsh larger fuel savmgs, improvements in efficIency and relIabIlity and lIfe extensIon of the bOIlers. It is beyond the scope of this audIt to provIde detaIls other than enumerate measures which could reduce mazut and gas co-firing by as much as 10-30% and possIbly achieve some reductIon of NO x , reduce S02 and <strong>part</strong>Iculate: • Improve burner desIgn and combustIon aIr flow configuration and temperature profiles. • Improve pulverized coal flow to minimize pulsatIon and excess oxygen vanatIons. • Repair boIler aIr leaks. • Develop new procedures for startup and shutdown cyclmg based on results of metallurgical testIng for creep and fatIgue lIfe. • Continue rehabilitation upgradmg of precIpItators (electrofilters). • Consider lIme or lImestone injection technology for reduction of S02, consIstent with fuel quality improvement program. • Upgrade mstrumentation for load control, fuel control, combustIon air and boiler pressure control. • Repair and/or replace (asbestos) msulatIOn on boilers. There are other studies which have been done or are being done, and It IS recommended that the results and recommendations be coordmated to prevent overlap or confllctmg tasks MEASURES FOR IMPROVEMENT OF RELIABILITY Additional equipment items WhICh were requested by the chIef engmeer and hIS specIalists WhICh are urgently needed for maintaimng reliability of the boilers and power plant are lIsted below: 1. DESCRIPTION Infrared Temperature "Heat spy" used for locating sources of heat loss. Also useful for locatmg "hot spots" WhICh could lead to equipment faIlure, such as bearings, motor and generator wmdmgs, SWItchgear contacts, Iso-phase bus bar boltmg, etc. 5906-01l02A/BURSHfYN/5/17/95 16 $4,000 COST
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Page 22 and 23: DESCRIPTION COST 2. SIlica Analyzer
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• • • • • BURSHTYN COAL Q
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• • • • Polsky Coal Pure Pr
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l,rJ., I BURSTHYN 1994 Jan Feb Mar
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5906-01I02A1APPENDIX/41l8/95 APPEND
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5906-01/fJ2A/APPENDIXJ41l8/95 APPEN
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5906-01I02A/APPENDIX/411 8/95 APPEN
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• • • BOIlPOCHHK flO YKYtDIIE
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• • 5906-01 f02B/8f31197l8ursht
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• • • • ) ) mass flow meter
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) Audit Equipment RECOMMENDATIONS B
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• • t J • • • • ,-",I B
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') CHECKLIST IMPROVING COMBUSTION E
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EXECUTIVE SUMMARY INTRODUCTION GENE
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9) Four (4) 02 analyzers rated for
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INTRODUCTION ENERGO SYSTEM: LOCATIO
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PC boilers. They are also intereste
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1.1 IntroductIon TRIP REPORT USAID/
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• • • technology and requeste
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TRIP REPORT Delivery Order No 6 - E
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cooling water flow to condensers. N
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• • • Information system for
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• • • Instromet natural gas c
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• • 1 PTVM-100, Station 2 - adj
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availability of a pnnter, Its possi
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The Infrared thermometer was used u
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State Committee of the Autonomous C
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• • However, there are no recor
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Month Consumption ODESSA CHP PLANT
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Month Consumption ODESSA CHP PLANT
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BURsHTYN NATURAL GAS 1996 P 1997 P
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• • • • • • • Simfero
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