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					                                                                                                                                           ASIA-PACIFIC PARTNERSHIP ~ Peer Review Activities ~                                                     THE FEDERATION OF ELECTRIC POWER COMPANIES OF JAPAN
                                                                                                                                                                                                                                                   TOKYO ELECTRIC POWER COMPANY
                                                                                                                                                                                                                                                   AMERICAN ELECTRIC POWER
                                                                                                                                                                                                                                                   INTERNATIONAL POWER HAZELWOOD, AUSTRALIA
Boiler                                                                                                                                                                                                                                             NTPC Ltd., INDIA
                                                                                                                                                                                                                                                   CII GODREJ GBC, INDIA
                                                                                                                                                                                                                                                                                                       Column 8 on the
                                                                                     COAL FIRED POWER PLANT EFFICIENCY IMPROVEMENT CHECKLIST (3rd Draft)                                                                                                                                               "Review Sheet"

                                                                                                                                                                      Physical Causes                                                              Procedure Improvements to prevent
        Equipment        Description of the physical situation            Effect on the efficiency                Indication by operating figures                                                                 Countermeasures                                                                        Person          Company     Country
                                                                                                                                                                    ( ):Related incident No.                                                                the recurrence
B-1   Boiler Casing   Air breathing into the furnace (from        Boiler efficiency reduction . Boiler auto-   Main steam temperature decline. Reheat Opening due to the corrosion. Manhole            Repair of corrosion and opening             Combustion air damper activation test         P     Taniguchi    Tokyo          Japan
                      manholes, ducts, expansion joints, etc.)    control malfunction and manual               steam temperature decline. Increasing packing deterioration.                                                                        Combustion tuning                                                Electric
                                                                  intervention. Loss of combustion balance     flue gas O2. Increasing flue gas CO.                                                                                                Analyzing the repetitive defects              P
                                                                  Generation of unburnt fuel.                  Increasing SH spray flow                                                                                                            Operating information is to be recorded       D
                                                                                                                                                                                                                                                   and analyzed.                                 D
                                                                                                                                                                                                                                                   Maintenance information integration and
                                                                                                                                                                                                                                                   reevaluation                                  C/A

B-2   Boiler Casing   Air breathing from the clinker hopper       Boiler efficiency reduction . Boiler auto- Main steam temperature decline. Reheat Opening due to the corrosion. Waterseal            Repair of corrosion and thickness           same as above                                       Taniguchi    Tokyo          Japan
                                                                  control malfunction and manual             steam temperature decline. Increasing defect. Deformation of moving parts,                reduction. Repair of the water seal.                                                                         Electric
                                                                  intervention. Loss of combustion balance SH spray flow                            degradation.                                       Boiler hopper seal modification if
                                                                  Generation of unburnt fuel.                                                                                                          necessary. Repair of the moving parts
                                                                                                                                                                                                       and treatments.
B-3   Boiler Casing   Corrosion/erosion on the gas ducts / EP     Boiler efficiency reduction. IDF overload.   Flue gas O2 abnormal. Flue gas             Air breathing from the flue gas duct. (one Repair of the damaged area.                   Reviewing the operating condition             C     Taniguchi    Tokyo          Japan
                      hoppers and breathing the air.              (leakage into gas ducts before air heater    temperature low after the air heater.      possibility) Flue gas temperature high for                                               including flue gas temperature.                                  Electric
                                                                  impacts efficiency and fan power,            Electric precipitator hopper temperature   preventing corrosion.) Flue gas velocity                                                 Rectifying the operating condition.           A
                                                                  leakage into gas ducts/precipitator after    abnormal. IDF motor current increase.      increase.
                                                                  air heater impacts fan power).



B-4   Boiler Casing   Corrosion/erosion on the gas duct           Leakage into gas ducts before air heater Flue gas O2 abnormal. Flue gas                 Inleakage due to the corrosion /erosion/     Repair of the damaged expansion joints. Replace with optimised design.                    C/A   Tony         IPRH           Australia
                      expansion joints                            impacts efficiency and fan power,         temperature low, IDF motor current            fatigue.                                                                                                                                     Innocenzi
                                                                  leakage into gas ducts/precipitator after increase / capacity limit.
                                                                  air heater impacts fan power.


B-5   Boiler Tubes    Furnace water wall tube degradation,        Boiler efficiency reduction .                SH metal temperature increase. SH          Boiler feedwater quality decline. Heat       Scale formation measurement. Chemical Conducting the scale monitoring (NDT,               D     Taniguchi    Tokyo          Japan
                      internal scale production.                  Boiler feedwarter pump performance           spray water flow increase. Economizer      transfer rate decline. Accelerated scale     cleaning based on the measurement.      sampling).                                                           Electric
                                                                  decline.                                     inlet feedwater pressure increase.         formation due to the increasing metal        Introduction of CWT (OT) if affordable. Analyzing the velocity of scale progress.         C     Naganuma     Kyushu
                                                                                                               Waterwall metal temperature increase.      temperature.                                                                                                                                              Electric
                                                                                                               Recirculation gas flow decline. RH spray                                                                                            Chemical cleaning based on the                A
                                                                                                               water flow increase.                                                                                                                analysis.
                                                                                                                                                                                                                                                   Continuous monitoring.                        A
B-6   Boiler Tubes    SUS CrMo scale magnetite production         Boiler efficiency reduction.                 SH/RH metal temperature high.              Boiler feedwater quality decline.            Non destructive measurement (RT, etc.) Operation parameters monitoring.                   D     Taniguchi    Tokyo          Japan
                      inside the SH or RH tubes.                                                                                                          Operation with the high temperature          Scale reduction based on the                 Inspection, analysis and prediction of the   C                  Electric
                                                                                                                                                          above the prescribed limitation. Pressure    measurement. Operation following the         frequency of scale magnetite removal.
                                                                                                                                                          loss increase due to the scale formation.    prescribed limitation. Introduction of shot- Revision the monitoring method based on      A
                                                                                                                                                                                                       blast tubes if affordable.                   the feedback.


B-7   Boiler Exit Gas Exit gas temperature setting higher than  Boiler efficiency reduction.                   Measure SO3 Dewpoint at typical coals      Exit gas temperature higher than             Reduce exit gas temperature air heater      Measure SO3 Dewpoint when a new coal          C/A   Keck         AEP            USA
      Temperature     necessary to maintain adequate exit gas                                                  being consumed                             necessary                                    manufacture guidelines at given SO3         source has occurred and develop a
                      temperature above SO3 dewpoint to prevent                                                                                                                                        concentration of coal                       database of coal versus SO3
                      ductwork corrosion                                                                                                                                                                                                           concentration
B-8   Boiler Excess   O2 Measurement inaccuracy or unbalance      Boiler efficiency reduction                  Unbalance of O2 Profile Control O2         Calibration drift. Unbalanced burner air     Calibrate O2 probes. Adjust burner       Calibrate O2 probes on a regular interval.       C     Keck         AEP            USA
      Air                                                                                                      Measurement different than test O2.        flow resulting in high or low O2             shrouds or dampers to balance burner air Test O2 profile with test instrumentation
                                                                                                               High CO and flyash LOI                                                                  flow                                     and compare to control room
                                                                                                                                                                                                                                                measurement

B-9   Boiler Excess   Not operating at the optimal value.         Lower boiler efficiency than achievable.     O2 reading. Use CO measurement to          Manufacturer's set point may not be          Test program to determine optimal O2        N/A                                                 Tony         IPRH           Australia
      Air                                                                                                      trim O2 level.                             optimal.                                     level.                                                                                          Innocenzi
B-10 Sootblowers      Slagging on the furnace water wall tubes    Boiler efficiency reduction.                 SH metal temperature increase. SH          Increased fuel input for maintaining the   Fine tuning of the sootblowing frequency.     Monitoring the metal temperature and the      D     Taniguchi    Tokyo          Japan
                      and the ceiling tubes.                                                                   spray water flow increase. Waterwall       rated operation. Increased heat input into Introduction of water cannon if affordable.   sootblowing frequency.                                           Electric
                                                                                                               metal temperature decline.                 the furnace. Heat transfer rate decline.                                                 Continuous monitoring of the coal quality     C
                                                                                                                                                          Inappropriate sootblowing frequency.                                                     and analyzing it.
                                                                                                                                                                                                                                                   Reflection to the actual operation.           A
B-11 Sootblowers      Fouling on the pendant and horizontal       Boiler efficiency reduction.                 SH steam temperature decline.              heat transfer rate decline due to fouling.   Fine tuning of the sootblowing frequency. Monitoring the metal temperature and the        D     Taniguchi    Tokyo          Japan
                      convection tubes.                                                                                                                   Inappropriate sootblowing frequency.                                                   sootblowing frequency.                                             Electric
                                                                                                                                                                                                                                                 Continuous monitoring of the coal quality       C
                                                                                                                                                                                                                                                 and analyzing it.
                                                                                                                                                                                                                                                 Sootblowing frequency adjustment.               A

B-12 Sootblowers      Boiler tube failure by sootblower erosion   Boiler efficiency reduction.                 Make-up water quantity increase            Inappropriate sootblowing frequency.         Fine tuning of the sootblowing frequency. Sootblowing frequency adjustment.               A     Kobayashi    Chubu          Japan
                                                                                                               Main steam flow increase                                                                                                          Continuous monitoring of Make-up water          D                  Electric
                                                                                                                                                                                                                                                 quantity




                                                                                                                                                                  ( 1/14 )
                                                                                                                        ASIA-PACIFIC PARTNERSHIP ~ Peer Review Activities ~                                                   THE FEDERATION OF ELECTRIC POWER COMPANIES OF JAPAN
                                                                                                                                                                                                                              TOKYO ELECTRIC POWER COMPANY
                                                                                                                                                                                                                              AMERICAN ELECTRIC POWER
                                                                                                                                                                                                                              INTERNATIONAL POWER HAZELWOOD, AUSTRALIA
Boiler                                                                                                                                                                                                                        NTPC Ltd., INDIA
                                                                                                                                                                                                                              CII GODREJ GBC, INDIA
                                                                                                                                                                                                                                                                              Column 8 on the
                                                                              COAL FIRED POWER PLANT EFFICIENCY IMPROVEMENT CHECKLIST (3rd Draft)                                                                                                                             "Review Sheet"

                                                                                                                                                  Physical Causes                                                             Procedure Improvements to prevent
       Equipment     Description of the physical situation          Effect on the efficiency      Indication by operating figures                                                         Countermeasures                                                                       Person          Company   Country
                                                                                                                                                ( ):Related incident No.                                                               the recurrence
B-13 Boiler        Fire ball center dislocation              High RH spray flow,               RH spray flow increase,                The center of the fire ball displaced,   Repair of the burner nozzle,                   Monitoring the condition of combustion,   D/C   Peer Review FEPC Japan Japan
     Combustion                                              Uneven flue gas temperature,      Sootblower frequently used,            Primary or secondary air shortage,       Adjustment of dampers and tilting,             Checking the condition of burners and           at NTPC
     (Tangential                                             Frequent use of sootblowers,      Uneven boiler metal temperatures,      Burner nozzle damaged by fire,           Wind box air flow measurement,                 dampers during shutdown,                  D/C   Dadri, INDIA
     firing)                                                 Boiler efficiency reduction       Uneven Furnace Exit Gas Temperatures   Burner damper opening fixed,             Monitoring the wind box diff pressure,         Correcting the fireball center at any
                                                                                                                                      Uneven fuel flow through burners         Correcting the fireball center,                available opportunities                   A
                                                                                                                                                                               Adjustment of the fireball center by orifice
                                                                                                                                                                               plates when applicable




                                                                                                                                              ( 2/14 )
                                                                                                                                                     ASIA-PACIFIC PARTNERSHIP ~ Peer Review Activities ~                                              THE FEDERATION OF ELECTRIC POWER COMPANIES OF JAPAN
                                                                                                                                                                                                                                                      TOKYO ELECTRIC POWER COMPANY
                                                                                                                                                                                                                                                      AMERICAN ELECTRIC POWER
                                                                                                                                                                                                                                                      INTERNATIONAL POWER HAZELWOOD, AUSTRALIA
Combustion Air & Flue Gas System                                                                                                                                                                                                                      NTPC Ltd., INDIA
                                                                                                                                                                                                                                                      CII GODREJ GBC, INDIA
                                                                                                                                                                                                                                                                                                          Column 8 on the
                                                                                        COAL FIRED POWER PLANT EFFICIENCY IMPROVEMENT CHECKLIST (3rd Draft)                                                                                                                                               "Review Sheet"

                                                                                                                                                                           Physical Causes                                                            Procedure Improvements to prevent
         Equipment        Description of the physical situation              Effect on the efficiency                  Indication by operating figures                                                                Countermeasures                                                                       Person          Company     Country
                                                                                                                                                                         ( ):Related incident No.                                                              the recurrence
AG-1 Air Heater         Rotary air heating element deterioration.    Rotary air heater efficiency reduction.       AH inlet/outlet air temperature abnormal. AH heating element thickness reduction        AH heating element inspection/             Capture of the performance decline.           D    Taniguchi     Tokyo          Japan
     Baskets                                                         Boiler efficiency reduction.                  AH inlet/outlet gas temperature           and removal. Increased AH heating             assessment. Repair/replacement             Capture the condition of the equipment        D                  Electric
                                                                                                                   abnormal. AH differential pressure        element fouling.                              program based on the inspection results.   on the inspection results.
                                                                                                                   increase.                                                                               Introduction of enamel element if          Reflection to the repair/replacement          A
                                                                                                                                                                                                           affordable.                                program.


AG-2 Air Heater         Rotary air heating element fouling           Rotary air heater efficiency reduction.        AH gas outlet temperature high. AH         AH heating element fouling caused by        AH sootblower inspection/assessment.       Inspect air heater lance tubes during         C    Keck          AEP            Japan
     Baskets                                                         Boiler efficiency reduction.                  differential pressure increase.             sootblower failure                          Holes in lance tube or end missing         outage


AG-3 Air Heater         Rotary air heater elements becoming lose in Rotary air heater efficiency reduction.         AH gas outlet temperature high. AH         AH heating element loosening caused by Optimising sootblowing frequency,               Inspection of air heater baskets to           C    Tony          IPRH           Australia
     Baskets            basket and blocking air heater or falling out Boiler efficiency reduction.                 differential pressure increase.             excessive sootblowing, sootblower      replace nozzle, increase element                optimise sootblowing, inspection of                Innocenzi
                                                                                                                                                               nozzle failure or corrosion            temperature, corrosion resistant                sootblower nozzles, measure air inlet and
                                                                                                                                                                                                      elements, element replacement program           gas exit temperatures


AG-4 Air heater heat    Exit gas temperature high                    Boiler efficiency reduction.                  AH gas outlet temperature high              Insufficient air heater heat exchange area Change the type of element profile or       N/A                                                Tony          IPRH           Australia
     exchange area                                                                                                                                                                                        increase the heat transfer area if spare                                                       Innocenzi
                                                                                                                                                                                                          space is available
AG-5 Air Heater    Air damper stick ./ loss of seal.                 Boiler efficiency reduction. Loss of          Flue gas O2 abnormal. Nox content           Damper link system defects. Damper          Air damper maintenance Periodical          Collating the information from operator to   D/C/A Taniguchi     Tokyo          Japan
     Bypass Damper                                                   combustion balance. Generation of             increase. CO discharge. Particle            deformation, seal degradation.              function tests. Modification of the link   incorporate them into the future program.                        Electric
                                                                     unburnt fuel.                                 discharge increase.                                                                     system.                                    Monitoring the operating parameters.          D
AG-6 Air Heater Exit    Exit gas temperature inaccuracy              Rotary air heater efficiency reduction.        AH gas outlet temperature higher than      Insufficient exit gas thermocouples to      Install grid of thermocouples to       Compare exit gas temperature with test            C    Keck          AEP            Japan
     Gas                                                             Boiler efficiency reduction.                  actual when compared to test readings.      measure average temperature                 accurately measure downstream exit gas measurements
     Temperature                                                                                                                                                                                           temperature
     Probes
AG-7 Air heater Inlet   Flue gas damper stick / loss of seal.        Boiler efficiency reduction. Loss of          Main steam temperature fluctuation.         Damper link system degradation due to       Gas damper maintenance. Periodical         Collating the information from operator to   D/C/A Taniguchi     Tokyo          Japan
     and Outlet                                                      combustion balance.                           Economizer outlet gas temperature           high temperature. Damper deformation,       function tests. Modification of the link   incorporate them into the future program.                        Electric
     Dampers                                                                                                       abnormal. Spray water flow fluctuation.     seal degradation.                           system.                                    Monitoring the operating parameters.
                                                                                                                   Nox content increase.
AG-8 Air Heater Seals Air leakage from rotary air heater.            Rotary air heater efficiency reduction.       AH inlet /outlet air temperature abnormal. AH sealing system defects.                   Repair and treatment of AH sealing         Capture of the performance decline.          D/C/A Taniguchi     Tokyo          Japan
                                                                     Boiler efficiency reduction. (hot end seals   AH inlet/outlet gas temperature                                                         system.                                    Reflection to the repair program.                                Electric
                                                                     leakage impact efficiency and fan power,      abnormal. Inlet/outlet O2 density
                                                                     cold end and hot end impact fan power)        abnormal. Ash leakage from AH.



AG-9 Air preheating     Steam valve leakage to air preheating steam Rotary air heater efficiency reduction.     AH gas outlet temperature higher than          Valve leakage on steam preheating coil      Repair leaking valve                       Compare inlet and outlet air temperature      C    Keck          AEP            USA
     steam coils        coils                                       Boiler efficiency reduction. Turbine cycle setpoint                                        supply                                                                                 on the air preheating coils when coils are
                                                                    efficiency reduction                                                                                                                                                              not required


AG-10 FD Fans           FDF / IDF variable vane malfunctions.        Unbalanced air flow. Fan driving loss.        Air / fuel ration fluctuation .             Control system abnormal (valve stem         Control system maintenance. Control oil Planning and conducting the routine             C/A   Taniguchi     Tokyo          Japan
                                                                                                                                                               stick, link system deterioration, control   quality monitoring.                     maintenance.                                                        Electric
                                                                                                                                                               oil deterioration.)
AG-11 FD Fans           FDF silencer deterioration.                  FDF overload.                                 Differential pressure on FDF increase.      Corrosion of deformation of the silencer.   Repair of FDF silencer.                    Reflection of the inspection results.         C    Taniguchi     Tokyo          Japan
                                                                                                                                                                                                                                                      Listing the issues to be followed as          A                  Electric
                                                                                                                                                                                                                                                      planned.




                                                                                                                                                                       ( 3/14 )
                                                                                                                                ASIA-PACIFIC PARTNERSHIP ~ Peer Review Activities ~                                                THE FEDERATION OF ELECTRIC POWER COMPANIES OF JAPAN
                                                                                                                                                                                                                                   TOKYO ELECTRIC POWER COMPANY
                                                                                                                                                                                                                                   AMERICAN ELECTRIC POWER
                                                                                                                                                                                                                                   INTERNATIONAL POWER HAZELWOOD, AUSTRALIA
Main Firing & Fuel Delivery System                                                                                                                                                                                                 NTPC Ltd., INDIA
                                                                                                                                                                                                                                   CII GODREJ GBC, INDIA
                                                                                                                                                                                                                                                                                  Column 8 on the
                                                                                 COAL FIRED POWER PLANT EFFICIENCY IMPROVEMENT CHECKLIST (3rd Draft)                                                                                                                              "Review Sheet"

                                                                                                                                                      Physical Causes                                                              Procedure Improvements to prevent
        Equipment     Description of the physical situation           Effect on the efficiency           Indication by operating figures                                                         Countermeasures                                                                    Person          Company     Country
                                                                                                                                                    ( ):Related incident No.                                                                the recurrence
MF-1 Pulverizer     Pulverized fuel leakage                   Loss of fuel                           Fuel coal leakage                     Thickness reduction due to erosion and     Repair of corrosion and thickness            Organizing the historical records of       C   Taniguchi    Tokyo          Japan
                                                                                                                                           corrosion. Flange degradation. Feeder      reduction. Repair of the flange. Repair of   troubles.                                                   Electric,
                                                                                                                                           conveyor defects.                          the feeder conveyor.                         Analysing the inspection results.          C   Kobayashi    Chubu
                                                                                                                                           Seal air defects                           Adjustment of the pulverizer seal            Reflecting the identified risks into the   A                Electric
                                                                                                                                                                                      dampers                                      future program.

MF-2 Pulverizer     Low Pulverizer Fineness                   Boiler efficiency reduction. High Flyash Coal Fineness Readings              Improper combustion High PA fan flow       Extend classifier blades, Check air flow During rebuild maintain tolerance on           D   Keck         AEP            USA
                                                              LOI                                                                          Pulverizer calibration error. Large or     curves (High flow reduces fineness),      pulverizer throat gap. Perform routine mill
                                                                                                                                           small pulverizer throat opening            Adjust spring tension, Calibrate Feeders, inspections and calibration
                                                                                                                                                                                      check for wear

MF-3 Pulverizer     Low pulverizer outlet temperature         Boiler efficiency reduction.           Increased exit gas temperature Low    Low pulveriser temperature increases air   Add synthetic oil to the pulveriser roll  Adjust pulveriser outlet temperature          C   Keck         AEP            USA
                                                                                                     pulveriser outlet temperature         heater air bypass                          wheel bearings and gearbox which allows based on fuel conditions
                                                                                                                                           Injection water valve seat leakage         higher pulveriser operating temperature   Monitor coal on the coal feeder belt.         D   Kobayashi    Chubu          Japan
                                                                                                                                           Hot/cold air damper defects                with coal conditions will be the limiting                                                                Electric
                                                                                                                                                                                      factor
                                                                                                                                                                                      Repair the injection water valve seat.
                                                                                                                                                                                      Adjust the Hot/cold air dampers.




                                                                                                                                                  ( 4/14 )
                                                                                                                                          ASIA-PACIFIC PARTNERSHIP ~ Peer Review Activities ~                                                  THE FEDERATION OF ELECTRIC POWER COMPANIES OF JAPAN
                                                                                                                                                                                                                                               TOKYO ELECTRIC POWER COMPANY
                                                                                                                                                                                                                                               AMERICAN ELECTRIC POWER
                                                                                                                                                                                                                                               INTERNATIONAL POWER HAZELWOOD, AUSTRALIA
Turbine                                                                                                                                                                                                                                        NTPC Ltd., INDIA
                                                                                                                                                                                                                                               CII GODREJ GBC, INDIA
                                                                                                                                                                                                                                                                                                   Column 8 on the
                                                                                       COAL FIRED POWER PLANT EFFICIENCY IMPROVEMENT CHECKLIST (3rd Draft)                                                                                                                                         "Review Sheet"

                                                                                                                                                                   Physical Causes                                                             Procedure Improvements to prevent
        Equipment        Description of the physical situation              Effect on the efficiency             Indication by operating figures                                                              Countermeasures                                                                        Person          Company     Country
                                                                                                                                                                 ( ):Related incident No.                                                               the recurrence
T-1   Feedwater        Water / steam leakage from condensate /      Turbine efficiency reduction.            Make-up water increase. In house power Steam leakage. Drain increase.                 Repair of the water leakage from the        Monitoring the performance.                  D      Taniguchi    Tokyo          Japan
      Conditions       feedwater system.                                                                     consumption rate increase.                                                            condensate system pumps. Repair of          Improving the routine procedure.            C/A                  Electric
                                                                                                                                                                                                   the steam leakage from the feedwater
                                                                                                                                                                                                   system pumps.

T-2   Turbine          Turbine faulty assembling (lack of the gap   Turbine efficiency reduction.            Changes in the steam inlet temperature    Improper assembling, maintenance.           Proper control of the gap.                  Improving the gap control procedure.        C/A     Taniguchi    Tokyo          Japan
                       control)                                                                              and the exhaust pressure.                 Improper adjustment.                                                                                                                                     Electric


T-3   Turbine          SCC on the turbine cross over pipe bellows. Turbine efficiency reduction.             MW reduction due to steam leakage.        SCC defect due to the water quality.        Repair of the bellows with changing their                                                D      Taniguchi    Tokyo          Japan
                                                                                                             Condenser vacuum decline. Casing          Abnormal rubbing when the cross over        design. Water quality improvement.                                                                           Electric
                                                                                                             external temperature increase.            pipe bellow slides.

T-4   Turbine          Damage on the turbine blades / nozzles /     Turbine internal efficiency loss.        Turbine bearing vibration.                Overload operation. Operation beyond        Repair the bearing. Repair of the crack / Sharing and analyzing the trouble             D/C     Taniguchi    Tokyo          Japan
      Bearings         shafts / bearings. (Improper operation,                                                                                         the prescribed limitation. Thermal or       replacement of the blades/nozzles.        information.                                                       Electric
                       water induction, etc.                                                                                                           mechanical shock during operation.                                                    Prevention measures of recurrence,             A
                                                                                                                                                       Water injection into the turbine cylinder                                             proper training.
                                                                                                                                                       from: *steam extraction system. *Main
                                                                                                                                                       steam line. *RH spray. *Gland steam
                                                                                                                                                       system. *Blow-down system. *Drain
                                                                                                                                                       line, etc.

T-5   Turbine Blades   Scale accumulation on the surface of         Turbine internal efficiency loss.        Turbine exhaust pressure / temperature    Erosion caused by drain, etc. Scale         Repair or replacement of the blades /   Collecting and collating the related OEM         D      Taniguchi    Tokyo          Japan
                       turbine blades, erosion, and the nozzle                                               abnormal.                                 capture (5) and adhesion. Creep             nozzles (modern blades and nozzles give information.                                                         Electric
                       deformation.                                                                                                                    deformation on the nozzles.                 efficiency improvements).               Analyzing the operation data.                     C
                                                                                                                                                                                                                                           Collating and analyzing the maintenance         D/C/A
                                                                                                                                                                                                                                           results.

T-6   Turbine Oil      Turbine lubrication oil leakage, oil         Turbine mechanical loss. Turbine stop.   Changes in the return oil temperature.    Oil deterioration. Foreign material         Repair of the oil leakage, monitoring oil   Improving the oil flushing procedure.       C/A     Taniguchi    Tokyo          Japan
                       deterioration, foreign material.                                                      Differential pressure on the oil pump     inclusion.                                  quality, oil flushing. Oil replacement. Oil Improving the routine maintenance           C/A                  Electric
                                                                                                             strainer increase.                                                                    purifier improvement.                       procedure.


T-7   Turbine Seal     Turbine gland leakage.                       Turbine external leakage loss.           Condenser vacuum decline. Expansion       Improper operation during the switching of Repair of the turbine gland packing.         Operation condition and procedure           D/C     Taniguchi    Tokyo          Japan
      Packing                                                                                                deviation.                                gland steam system causing an                                                           management.                                                      Electric
                                                                                                                                                       excessive thermal shock. Packing                                                        Collating the inspection results            D/C
                                                                                                                                                       defects.                                                                                chronologically.

T-8   Turbine Strainer Main steam strainer checking.                Pipes pressure loss.                     Differential pressure with the strainer   Scale capture (5)                           Boiler scale removal.                       Improving the boiler scale management.      C/A     Taniguchi    Tokyo          Japan
                                                                                                             increase.                                                                                                                                                                                          Electric

T-9   Turbine valves   Major turbine valves erosion, seat leak      Turbine valves pressure loss.            Change in the pressure loss. Change in Valve seat erosion. Drain increase.            Repair of the valve seat. Boiler scale Monitoring the performance.                       D      Taniguchi    Tokyo          Japan
                                                                                                             the valve opening. Sound of leakage.   Steam leakage. Scale capture (5)               removal. Install new low pressure drop Improving the boiler scale management.           C/A                  Electric
                                                                                                             Pipe temperature high. Valve opening                                                  control valves.
                                                                                                             hysteresis curve change.


T-10 Turbine Blades    Fouling by silica scale                      Turbine internal efficiency loss.        Turbine exhaust pressure / temperature    Silica scale fouling                        Remove the scale from blades and            Keeping the concentration of silica in       D      Naganuma     Kyushu         Japan
                                                                                                             abnormal.                                                                             nozzles.                                    feedwater and/or drum water low.                                 Electric

T-11 Turbine steam     Steam leakage increase due to the erosion Turbine internal efficiency reduction       Main steam flow increase,                 Wear of fin/packing over years              Periodical overhaul of the steam turbine    Plant operation data collection and trend   D/C/A Maruta         Kyushu         Japan
     sealing fin       at the rotor radial fin                                                               Turbine CV opening increase                                                           Measurement and adjustment of gaps to       monitoring,                                                      Electric
                       Steam leakage increase due to the wear of                                                                                                                                   meet their set values                       Periodical turbine overhaul and gaps
                       diaphragm packing and rotor shaft packing                                                                                                                                   Replacement will be conducted if such       adjustment,
                                                                                                                                                                                                   abnormal wears are found that the set       Maintenance program development
                                                                                                                                                                                                   values cannot be achieved.                  utilizing the accumulated data on
                                                                                                                                                                                                                                               measurement and operation monitoring


T-12 Turbine rotor     Scale adhesion and accumulation on the       Turbine internal efficiency reduction    Main steam flow increase,                 Scale adhesion and accumulation over        Periodical turbine overhaul,                Plant operation data collection and trend   D/C/A Maruta         Kyushu         Japan
     blades and        steam paths                                                                           Turbine CV opening increase               years                                       Repair and treatment of areas that are      monitoring,                                                      Electric
     diaphragm                                                                                                                                                                                     overhauled,                                 Periodical turbine overhaul and gaps
                                                                                                                                                                                                   Removal of scale                            adjustment,
                                                                                                                                                                                                                                               Maintenance program development
                                                                                                                                                                                                                                               utilizing the accumulated data on
                                                                                                                                                                                                                                               measurement and operation monitoring




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                                                                                                                                ASIA-PACIFIC PARTNERSHIP ~ Peer Review Activities ~                                                  THE FEDERATION OF ELECTRIC POWER COMPANIES OF JAPAN
                                                                                                                                                                                                                                     TOKYO ELECTRIC POWER COMPANY
                                                                                                                                                                                                                                     AMERICAN ELECTRIC POWER
                                                                                                                                                                                                                                     INTERNATIONAL POWER HAZELWOOD, AUSTRALIA
Condensate System                                                                                                                                                                                                                    NTPC Ltd., INDIA
                                                                                                                                                                                                                                     CII GODREJ GBC, INDIA
                                                                                                                                                                                                                                                                                         Column 8 on the
                                                                                    COAL FIRED POWER PLANT EFFICIENCY IMPROVEMENT CHECKLIST (3rd Draft)                                                                                                                                  "Review Sheet"

                                                                                                                                                          Physical Causes                                                             Procedure Improvements to prevent
        Equipment        Description of the physical situation           Effect on the efficiency      Indication by operating figures                                                                Countermeasures                                                                      Person          Company     Country
                                                                                                                                                        ( ):Related incident No.                                                               the recurrence
CON- Circulating       Condenser vacuum decline.                 Turbine efficiency reduction.      Condenser vacuum decline. Low            Circulating water pump impellor wear          Rebuild Pumps as needed based from        Perform water circulating water flow test     D     Keck         AEP            USA
 1   Water Pumps                                                                                    Waterbox Differential                    Water leakage from pump bearings              inspections                               and or routine circulating water pump
                                                                                                                                                                                                                                     inspection
CON- Condenser         Condenser vacuum decline.                 Turbine efficiency reduction.      High condenser air in leakage            Air leakage from expansion joints             Expansion joint repair or replacement.    Improving the inspection program.             C/A   Taniguchi    Tokyo          Japan
 2                                                                                                                                           (internal leak), rupture diagram on turbine   Check for condenser leaks by flooding     Performance monitoring and improving its       D                 Electric
                                                                                                                                             hood, leaks in condenser inlet piping or      the condenser. Check leaks using          procedure.
                                                                                                                                             leaks from LP heaters                         helium detector                           Monitor condenser air leakage                 D
CON- Condenser         Condenser Startup Drain Valve Leakage     Turbine efficiency reduction.      Condenser vacuum decline. High           Drain leakage from failed or leaking          Check and repair valves. Close hand       Check startup drain valves after every        D     Keck         AEP            USA
 3                                                                                                  hotwell temperature                      drains to the condenser                       valves for isolation                      startup and routinely check valves prior to
                                                                                                                                                                                                                                     an outage to prioritize repairs

CON- Condenser      Velocity Basket Deterioration                Turbine efficiency reduction.      Abnormal condenser vacuum reading.       Condenser velocity basket deterioration       Check control instrumentation to test     Routinely inspect condenser steam side        D     Keck         AEP            USA
 4   Backpressure                                                                                                                            due to steam erosion                          equipment connections                     internals
     Measurement
CON- Condenser      Condenser backwash valve leakage             Turbine efficiency reduction.      Condenser vacuum decline. Outlet         Backwash valve seal leakage or operator Adjust limits on operator or rebuild            Routinely Inspect backwash valve and          C/A   Keck         AEP            USA
 5   Backwash Valve                                                                                 circulating water temperature abnormal   failure                                 backwash valve seal                             operator

CON- Condenser inlet Condenser valves not fully operating        Turbine efficiency reduction.      Condenser vacuum decline. Outlet         Condenser valve operator failure              Adjust limits on operator                 Routinely Inspect inlet and outlet valves     D     Keck         AEP            USA
 6   and outlet valves                                                                              circulating water temperature abnormal
                                                                                                    Water box differential abnormal
CON- Condenser         Condenser cooling tube leakage.           Turbine stop.                      Condensate water cation conductivity     (Cooling Tower)                           Plugging the leaking tubes or replacing       Improving the condensate water quality        C/A   Taniguchi    Tokyo          Japan
 7   Tubes                                                                                          increase.                                - Cooling water leakage due to the        them.                                         control. Improving the cooling water                             Electric
                                                                                                                                             physical wear or the corrosion caused by                                                quality control.
                                                                                                                                             chemical additives to prevent bacteria
                                                                                                                                             from propagating
                                                                                                                                             (Sea water cooling)                                                                                                                         Naganuma     Kyushu
                                                                                                                                             - Cooling water leakage due to the                                                                                                                       Electric
                                                                                                                                             physical wear or the corrosion caused by
                                                                                                                                             the defects of the protective film on the
                                                                                                                                             inner surface of tubes


CON- Condenser         Condenser tube sheet pluggage             Turbine efficiency reduction.      Condenser vacuum decline. High           Debris from river or cooling tower            Pick condenser or clean condenser using Maintain travelling screens and screen          D     Keck         AEP            USA
 8   Tubes                                                                                          Waterbox Differential                                                                  scrappers or high pressure water        spray nozzles

CON- Condenser         Condenser tube sheet fouling              Turbine efficiency reduction.      Condenser vacuum decline.                Buildup of scale from river or cooling        Clean condenser using scrappers or high Maintain chemical treatment on                  C     Keck         AEP            USA
 9   Tubes                                                                                                                                   tower                                         pressure water                          circulating water. Setup cleaning cycle
                                                                                                                                                                                                                                   for cleaning condenser based on water
                                                                                                                                                                                                                                   quality

CON- Condenser         Condenser vacuum decline.                 Turbine efficiency reduction.      Condenser vacuum decline. Low            Vacuum pumps not performing well              Clean cooling water strainers Rebuild or Routinely inspect vacuum pumps and             D     Keck         AEP            USA
 10 Vacuum Pump                                                                                     Waterbox Differential High cooling water Changes in the cooling water flow /           replace vacuum pumps or check orifices system
                                                                                                    temp                                     temperature.                                  on steam jets Repair of the cooling
                                                                                                                                                                                           water pump.

CON- Condenser         Low condenser waterbox water level        Turbine efficiency reduction.      Condenser vacuum decline. Low            Vacuum Priming Pots not operating or          Repair vacuum priming pots or repair      Check vacuum on priming pots and              C     Keck         AEP            USA
 11 Waterbox                                                                                        Waterbox Differential                    pump not performing well                      vacuum pump                               condenser waterbox level

CON- Cooling Tower     Cooling tower fill pluggage               Turbine efficiency reduction.      Condenser vacuum decline. Inlet          Mud and silt buildup in cooling tower fill    Add chemical dispersant to remove mud Routinely inspect cooling tower and hose          D     Keck         AEP            USA
 12                                                                                                 circulating water temperature high                                                     from fill or replace fill material    out mud. Perform cooling tower testing
                                                                                                    Summer Load Reduction
CON- Cooling Tower     Loss of cooling tower fill.               Turbine efficiency reduction.      Condenser vacuum decline. Inlet          Cooling tower fill failure.                   Repair replace cooling tower fill         Routinely inspect cooling tower.              D     Tony         IPRH           Australia
 13                                                                                                 circulating water temperature high.                                                                                              Perform cooling tower testing.                      Innocenzi
                                                                                                    Summer Load Reduction.
CON- Cooling Tower     Cooling tower Flow Distribution           Turbine efficiency reduction.      Condenser vacuum decline. Inlet          Water flow uneven on tower                    Adjust water flow valves Unplug debris    Routinely inspect cooling tower and           D     Keck         AEP            USA
 14                                                                                                 circulating water temperature high                                                     on top of tower                           perform cooling tower testing
                                                                                                    Summer Load Reduction

CON- Turbine Gland     Turbine gland seal damage                 Turbine efficiency reduction.      Condenser vacuum decline. High           Air leakage to condenser from turbine         Increase steam seal pressure until seals Monitor vibration during startup and follow    D     Keck         AEP            USA
 15 Seals                                                                                           condenser air in leakage                 gland seals                                   can be repaired Inspect gland seal piping operation guidelines
                                                                                                                                                                                           in condenser for holes




                                                                                                                                                      ( 6/14 )
                                                                                                                                      ASIA-PACIFIC PARTNERSHIP ~ Peer Review Activities ~                                                  THE FEDERATION OF ELECTRIC POWER COMPANIES OF JAPAN
                                                                                                                                                                                                                                           TOKYO ELECTRIC POWER COMPANY
                                                                                                                                                                                                                                           AMERICAN ELECTRIC POWER
                                                                                                                                                                                                                                           INTERNATIONAL POWER HAZELWOOD, AUSTRALIA
Feedwater System                                                                                                                                                                                                                           NTPC Ltd., INDIA
                                                                                                                                                                                                                                           CII GODREJ GBC, INDIA
                                                                                                                                                                                                                                                                                               Column 8 on the
                                                                                       COAL FIRED POWER PLANT EFFICIENCY IMPROVEMENT CHECKLIST (3rd Draft)                                                                                                                                     "Review Sheet"

                                                                                                                                                                Physical Causes                                                            Procedure Improvements to prevent
        Equipment        Description of the physical situation               Effect on the efficiency         Indication by operating figures                                                              Countermeasures                                                                       Person          Company     Country
                                                                                                                                                              ( ):Related incident No.                                                              the recurrence
FW-1 Feedwater      Feedwater bypassing the heater                   Turbine Cycle efficiency reduction    Low Feedwater outlet temperature.        Heater bypass valve leaking or actuator     Repair bypass valve and adjust actuator    Periodically check valves using ultrasonic    D    Keck          AEP            USA
     Heaters Bypass                                                                                                                                 failure                                     limits                                     flow measurement
     Valve
FW-2 Feedwater      Improper heater level                            Turbine Cycle efficiency reduction    Flashing in drain cooler                 Low Heater Level                            Adjust level setpoint. Check drain valve Add to Operator Operational Guidelines         D/C/A Keck          AEP            USA
     Heaters                                                                                               TTD Increase                                                                         for proper operation
     Controls                                                                                              DCA No change or decrease

FW-3 Feedwater         Improper heater level                         Turbine Cycle efficiency reduction    Shell Pressure may increase.             High Heater Level                           Adjust level setpoint. Check drain valve Add to Operator Operational Guidelines         D/C/A Keck          AEP            USA
     Heaters                                                                                               TTD Increase                                                                         for proper operation
     Controls                                                                                              DCA No change or decrease

FW-4 Feedwater         Failed heater partition plate                 Turbine Cycle efficiency reduction    Low Feedwater outlet temperature.        Partition Plate Leaking                     Repair partition plate                     Add to Operator Operational Guidelines       D/C/A Keck          AEP            USA
     Heaters                                                                                               TTD Increase
     Partition Plate                                                                                       DCA No change

FW-5 Feedwater         Feedwater heater heat exchange rate           Turbine Cycle efficiency reduction    Feedwater temperature decline. Change Tube thickness reduction, rate of the          Plugging the leaking tubes or replacing    Review the current maintenance program.       C    Taniguchi     Tokyo          Japan
     Heaters Tubes     reduction.                                                                          in the feedwater inlet / outlet temperature plugged tubes. Tube fouling. Feedwater   them. Cleaning the tubes. Fine tuning                                                    A                  Electric
                                                                                                           (TD, DC)                                    short path, baffle plate deformation.    of the turbine system including the        Revision of the program if there are
                                                                                                                                                       Drain control failure.                   feedwater heater drain control.            anything unsuitable.


FW-6 Feedwater         Failed heater tubes                           Turbine Cycle efficiency reduction    Increased Drain Flow                     Heater Tube Leak                            Plug tube leak                             Perform eddy current testing for              D    Keck          AEP            USA
     Heaters Tubes                                                                                         TTD No Change                                                                                                                   preventative measures
                                                                                                           DCA Decrease
FW-7 Feedwater         Failed heater tubes                           Turbine Cycle efficiency reduction    Low Feedwater outlet temperature.        Large percentage of tubes plugged           Perform eddy current testing to measure Recommend retubing heater at 20%                 D    Keck          AEP            USA
     Heaters Tubes                                                                                         TTD Increase                                                                         the remaining life of the tubes         plugged tubes
                                                                                                           DCA Increase
FW-8 Feedwater         Scale buildup on heater tubes                 Turbine Cycle efficiency reduction    Low Feedwater outlet temperature.        Feedwater tube fouling                      Clean tube with scrappers                  Check water quality for proper                D    Keck          AEP            USA
     Heaters Tubes                                                                                         TTD Increase                                                                                                                    specifications
                                                                                                           DCA No change
FW-9 Feedwater         Failure of venting valves or operator error   Turbine Cycle efficiency reduction    Low Feedwater outlet temperature.        Inadequate venting                          Check venting valves                       Add to Operator Operational Guidelines       D/C/A Keck          AEP            USA
     Heaters Vents                                                                                         TTD Increase
                                                                                                           DCA No change or decrease
FW- Feedwater          Failure of HPHs.                              Turbine Cycle efficiency reduction.   Heaters out of service.                  Failure of feedwater heaters.               Repair / renew and re-install feed water   Improve feed water heater design.            D/C/A Tony          IPRH           Australia
 10 Heaters not                                                                                                                                                                                 heaters.                                                                                      Innocenzi
    serviceable
FW- High Pressure      Increase of high pressure feedwater heater    Boiler feedwater pump performance     Increase of high pressure feedwater      Magnetite scale growth on the inner         Introduction of oxygenated treatment (or   Conducting the scale monitoring (NDT,         D    Naganuma,     Kyushu         Japan
 11 Feedwater          differential pressure                         reduction                             heater differential pressure             surface of the heater tubes                 Combined water treatment)                  sampling).                                         Oka           Electric,
    Heater                                                                                                                                                                                                                                 Analyzing the velocity of scale progress.                        EPDC

                                                                                                                                                                                                                                           Chemical cleaning based on the
                                                                                                                                                                                                                                           analysis.
                                                                                                                                                                                                                                           Continuous monitoring.




                                                                                                                                                            ( 7/14 )
                                                                                                                                    ASIA-PACIFIC PARTNERSHIP ~ Peer Review Activities ~                                                 THE FEDERATION OF ELECTRIC POWER COMPANIES OF JAPAN
                                                                                                                                                                                                                                        TOKYO ELECTRIC POWER COMPANY
                                                                                                                                                                                                                                        AMERICAN ELECTRIC POWER
                                                                                                                                                                                                                                        INTERNATIONAL POWER HAZELWOOD, AUSTRALIA
Valve and Steam Trap                                                                                                                                                                                                                    NTPC Ltd., INDIA
                                                                                                                                                                                                                                        CII GODREJ GBC, INDIA
                                                                                                                                                                                                                                                                                           Column 8 on the
                                                                                         COAL FIRED POWER PLANT EFFICIENCY IMPROVEMENT CHECKLIST (3rd Draft)                                                                                                                               "Review Sheet"

                                                                                                                                                              Physical Causes                                                           Procedure Improvements to prevent
        Equipment         Description of the physical situation                Effect on the efficiency      Indication by operating figures                                                         Countermeasures                                                                         Person          Company     Country
                                                                                                                                                            ( ):Related incident No.                                                             the recurrence
V-1   Attemperator      Valve Seat leaks or valve actuator limits out Boiler efficiency reduction.        Low Reheat Steam Temps.                  Valve Erosion                          Planned valve overhaul                        Add to Operations Checklist                 D/C/A Keck          AEP            USA
      Valves            of adjustment                                                                     Attemperation flow when valve is closed.
                                                                                                          Pipe temperature high

V-2   Steam Traps       Excessive Trap Leakage and Failure            Turbine efficiency reduction        High trap downstream temps. Trap not    Dirt in trap. Steam erosion of trap     Trap Replacement or cleaning                  Add to Operations Checklist                 D/C/A Keck          AEP            USA
                                                                                                          operating


V-3   Turbine & Boiler Valve seat leaks (starting-system valves,      Boiler efficiency reduction.        Pipe temperature high. Sound of         Starting system valve erosion.          Planned valve overhaul.                       Revision of the monitoring method based     D/C/A Taniguchi     Tokyo          Japan
      Drain Valves     drain valves, shutoff valves.)                                                     leakage.                                                                                                                      on the feedback.                                                Electric
                                                                                                                                                                                                                                        Perform thermal imaging or ultrasonic
                                                                                                                                                                                                                                        testing prior to outage and develop
                                                                                                                                                                                                                                        priority repair list
V-4   Turbine MSV       Valve seat leaks,                             Turbine efficiency reduction        Main steam flow increase,               Scratch on the valve seats by foreign   Detect abnormal valves and overhaul.          Plant operation data collection and trend   D/C/A Maruta        Kyushu         Japan
      Drain Valves      Internal fluid leakage within/ out of the                                         Turbine CV opening increase             objects when they open and close        AE (Acoustic Emission) method is              monitoring,                                                     Electric
                        system                                                                                                                                                            effective for the seat leakage detection of   Periodically check of the valves' seat
                                                                                                                                                                                          valves.                                       leakages by the AE method.
                                                                                                                                                                                                                                        Maintenance program development
                                                                                                                                                                                                                                        utilizing the accumulated data on
                                                                                                                                                                                                                                        measurement and operation monitoring


V-5   Boiler Feed       Valve seat leaks,                             Turbine efficiency reduction        BFP driving steam increase,             Scratch on the valve seats by foreign   Detect abnormal valves and overhaul.          Plant operation data collection and trend   D/C/A Maruta        Kyushu         Japan
      Pump Drain        Internal fluid leakage within/ out of the                                         Boiler feed water decrease              objects when they open and close        AE (Acoustic Emission) method is              monitoring,                                                     Electric
      Valves            system                                                                                                                                                            effective for the seat leakage detection of   Periodically check of the valves' seat
                                                                                                                                                                                          valves.                                       leakages by the AE method.
                                                                                                                                                                                                                                        Maintenance program development
                                                                                                                                                                                                                                        utilizing the accumulated data on
                                                                                                                                                                                                                                        measurement and operation monitoring


V-6   HP Heater Drain Valve seat leaks,                               Turbine efficiency reduction        HP Heater bled steam increase           Scratch on the valve seats by foreign   Detect abnormal valves and overhaul.          Plant operation data collection and trend   D/C/A Maruta        Kyushu         Japan
      Valves          Internal fluid leakage within/ out of the                                                                                   objects when they open and close        AE (Acoustic Emission) method is              monitoring,                                                     Electric
                      system                                                                                                                                                              effective for the seat leakage detection of   Periodically check of the valves' seat
                                                                                                                                                                                          valves.                                       leakages by the AE method.
                                                                                                                                                                                                                                        Maintenance program development
                                                                                                                                                                                                                                        utilizing the accumulated data on
                                                                                                                                                                                                                                        measurement and operation monitoring




                                                                                                                                                          ( 8/14 )
                                                                                                                          ASIA-PACIFIC PARTNERSHIP ~ Peer Review Activities ~                                               THE FEDERATION OF ELECTRIC POWER COMPANIES OF JAPAN
                                                                                                                                                                                                                            TOKYO ELECTRIC POWER COMPANY
                                                                                                                                                                                                                            AMERICAN ELECTRIC POWER
                                                                                                                                                                                                                            INTERNATIONAL POWER HAZELWOOD, AUSTRALIA
Environmental System                                                                                                                                                                                                        NTPC Ltd., INDIA
                                                                                                                                                                                                                            CII GODREJ GBC, INDIA
                                                                                                                                                                                                                                                                             Column 8 on the
                                                                             COAL FIRED POWER PLANT EFFICIENCY IMPROVEMENT CHECKLIST (3rd Draft)                                                                                                                             "Review Sheet"

                                                                                                                                                    Physical Causes                                                         Procedure Improvements to prevent
      Equipment     Description of the physical situation          Effect on the efficiency      Indication by operating figures                                                              Countermeasures                                                                  Person          Company     Country
                                                                                                                                                  ( ):Related incident No.                                                           the recurrence
EV-1 SCR          SCR catalyst clogging                     NOx emission increase             NOx removal efficiency reduction,         SCR catalyst clogging caused by the        Monitor the NOx removal efficiency.       Periodically check the ammonia leakage.   D     Sakata       Chugoku        Japan
                                                                                              Ammonia leakage increase                  accumulation of (1) ammonia sulfate        Catalyst cleaning.                        Develop a predictive maintenance.                            Electric
                                                                                                                                        <(NH4)2SO4> where gas temperature is       Check if gas temperature sits between its program.                                  C/A
                                                                                                                                        below 250 deg.C and (2) dust in the flue   upper and lower limits.
                                                                                                                                        gas.


EV-2 SCR          SCR catalyst gas passing                  NOx emission increase             NOx removal efficiency reduction,         Catalyst packing came loose.               Monitor the NOx removal efficiency.      Periodically check the condition of the    D     Taniguchi    Tokyo          Japan
                                                                                              Ammonia leakage increase                                                             Repair the catalyst packing.             catalyst packing.                                             Electric



EV-3 SCR          SCR catalyst sintering                    NOx emission increase             NOx removal efficiency reduction,         Catalyst degradation                       Monitor the ammonia leakage.             Periodically check the ammonia leakage.    D     Sakata       Chugoku        Japan
                                                                                              Ammonia leakage increase                                                             Monitor the NOx removal efficiency.      Develop a predictive maintenance.                             Electric
                                                                                                                                                                                   Chemical cleaning.                       program.                                   C/A
                                                                                                                                                                                   Predict the life of catalyst.
                                                                                                                                                                                   Plan the replacement of the catalyst.

EV-4 EP           Ash increase at the collector             Dust emission increase            Abnormal electric load,                   Change in the gas temperature or the       Cleaning of the collector,               Periodical review of hammering,            C     Sakata       Chugoku        Japan
                                                                                              EP power consumption increase,            electric resistance of dust,               Adjustment of the hammering schedule     Periodical cleaning                        D                  Electric
                                                                                              EP outlet dust content increase           Inappropriate hammering,
                                                                                                                                        Collector fouling


EV-5 FGD          SCR absorber degradation                  SOx emission increase             Absorber recirculation pump variable vane Impeller/ casing erosion,                  Repair/ replacement,                     Planned inspection of the pump             P     Sakata       Chugoku        Japan
                                                                                              opening increase,                         Spray nozzle clogging                      Internal cleaning                        condition,                                                    Electric
                                                                                              Increased number of the operating         Scale accumulation                                                                  Develop a predictive maintenance.          C/A
                                                                                              recirculation pumps,                                                                                                          program.
                                                                                              Absorber pH decline,
                                                                                              Recirculation pump discharge pressure




                                                                                                                                                ( 9/14 )
                                                                                                            ASIA-PACIFIC PARTNERSHIP ~ Peer Review Activities ~                THE FEDERATION OF ELECTRIC POWER COMPANIES OF JAPAN
                                                                                                                                                                               TOKYO ELECTRIC POWER COMPANY
                                                                                                                                                                               AMERICAN ELECTRIC POWER
                                                                                                                                                                               INTERNATIONAL POWER HAZELWOOD, AUSTRALIA
Coal Quality                                                                                                                                                                   NTPC Ltd., INDIA
                                                                                                                                                                               CII GODREJ GBC, INDIA
                                                                                                                                                                                                                     Column 8 on the
                                                                    COAL FIRED POWER PLANT EFFICIENCY IMPROVEMENT CHECKLIST (3rd Draft)                                                                              "Review Sheet"

                                                                                                                               Physical Causes                                 Procedure Improvements to prevent
       Equipment   Description of the physical situation   Effect on the efficiency   Indication by operating figures                                        Countermeasures                                           Person          Company   Country
                                                                                                                             ( ):Related incident No.                                   the recurrence
CQ-1




CQ-2




CQ-3




CQ-4




CQ-5




                                                                                                                           ( 10/14 )
                                                                                                                                             ASIA-PACIFIC PARTNERSHIP ~ Peer Review Activities ~                                                    THE FEDERATION OF ELECTRIC POWER COMPANIES OF JAPAN
                                                                                                                                                                                                                                                    TOKYO ELECTRIC POWER COMPANY
                                                                                                                                                                                                                                                    AMERICAN ELECTRIC POWER
                                                                                                                                                                                                                                                    INTERNATIONAL POWER HAZELWOOD, AUSTRALIA
Auxiliary Power                                                                                                                                                                                                                                     NTPC Ltd., INDIA
                                                                                                                                                                                                                                                    CII GODREJ GBC, INDIA
                                                                                                                                                                                                                                                                                                        Column 8 on the
                                                                                          COAL FIRED POWER PLANT EFFICIENCY IMPROVEMENT CHECKLIST (3rd Draft)                                                                                                                                           "Review Sheet"

                                                                                                                                                                        Physical Causes                                                             Procedure Improvements to prevent
         Equipment         Description of the physical situation                Effect on the efficiency            Indication by operating figures                                                               Countermeasures                                                                         Person          Company     Country
                                                                                                                                                                      ( ):Related incident No.                                                               the recurrence
AX-1 Air compressors Air Line Leaks                                     Auxiliary Power                          Low compressed air pressure. High          Control and plant air line leaks          Repair air line leaks, aspirating air ports   Routinely inspect the air lines, aspirating   D     Keck          AEP           USA
                                                                                                                 compressor loading                                                                   and valves                                    air ports and valves.
AX-2 Ash Handling        High pump vacuum pressure                      Auxiliary Power Reduction                Operating with too many vacuum pumps Increased pump wear                             Add automatic controls or change              Revise Operating Procedure                    C/A   Keck          AEP           USA
     water pumps                                                                                                 or when not required                                                                 operating guideline
AX-3 Circulating water Subcooling of the condensate                     Turbine Cycle Efficiency and Auxiliary   Operating below 40F 4.5 C River            Turbine design exhaust hood limitations   Remove one circulating water pump out         Revise Operating Procedure                    C/A   Keck          AEP           USA
     pumps                                                              Power Reduction                          Temperature causes subcooling of the                                                 of service when inlet temp. are below
                                                                                                                 condensate                                                                           40F 4.5 C
AX-4 FD & ID Fans        Constant speed motors                          Auxiliary Power Reduction                Operating with control dampers under       Fan design oversized                      Install VSD drives or gearbox                 N/A                                           C     Keck          AEP           USA
                                                                                                                 80% loading
AX-5 FD fan turning      Holes in turning vanes and/or insufficient     Auxiliary Power                          FD fan capacity limitations and higher     Deteriorated FD fan turning vanes and/or Replace turning vanes and/or install flow Inspect FD fan turning vanes and/or                D     Keck          AEP           USA
     vanes               flow correction devices                                                                 auxiliary power                            insufficient flow correction devices     correction devices                        inspect areas where the could be
                                                                                                                                                                                                                                               insufficient flow devices

AX-6 Flue gas ducting Holes in turning vanes and/or insufficient        Auxiliary Power                          ID fan capacity limitations and higher     Deteriorated flue gas duct and            Replace turning vanes and/or install flow Inspect flue gas ductwork and precipitator        D     Tony          IPRH          Australia
     and precipitator flow correction devices                                                                    auxiliary power                            precipitator turning vanes and/or         correction devices                        turning vanes and/or inspect areas where                Innocenzi
     turning vanes                                                                                                                                          insufficient flow correction devices                                                the could be insufficient flow devices


AX-7 ID Fan Bypass       Damper failure to close                        Auxiliary Power                          High Furnace Pressure     High ID fan      Damper operation limits not properly      Adjust damper drive                           Routinely inspect the ID fan bypass           D     Keck          AEP           USA
     Dampers                                                                                                     amps                                       adjusted                                                                                damper
AX-8 Precipitator        Oversized Precipitator                         Auxiliary Power Reduction                Fields not required to maintain opacity    Excess power in the precipitator fields   Upgrade controls to allow power               N/A                                           C     Keck          AEP           USA
     Controls                                                                                                                                               resulting in no reduction in opacity      reduction to the fields while achieving
                                                                                                                                                                                                      lowest possible opacity
AX-9 Pulverizer PA       Excess Pulverizer Primary Air Fan flow         Auxiliary Power Reduction & Boiler       Few or no pyrites      Low pulverizer Increased pulverizer and burner line wear. Calibrate pulverizer air flow to maintain    Check calibration of pulverizers on a              C     Keck          AEP           USA
     Fans                                                               Efficiency                               fineness High PA fan amps             Low pulverizer fineness. High Flyash LOI require fuel to air ratio in the pulverizer as routine basis and calibrate pulverizers
                                                                                                                                                                                                  recommended by Manufactor                    after a rebuild.


AX-10 Fouling of boiler Increased system pressure/resistance due        Auxiliary Power                          Increase in fan power requirements        Inappropriate/ineffective sootblowing      Fine tuning of the sootblowing frequency Monitoring the ID fan pressure/amps.               C     Tony          IPRH          Australia
      heat transfer     to fouling of boiler tubing                                                              resulting in possible generation loss due frequency or performance.                  and monitoring sootblower performance. Sootblowing frequency adjustment.                          Innocenzi
      surfaces                                                                                                   to IDF limits.
AX-11 Boiler feed water passing of automatic recirculation line         auxiliary power consumption reduction    increase in ampearage.                     wearout of valve parts and leads to       replace the ordinary automatic                have a periodic check on passing of           D     Karthikeyan   CII-Godrej    India
      pump                                                                                                                                                  passing                                   recirculation valves with multi stage         recirculation by measuring the                                    GBC
                                                                                                                                                                                                      pressure reduction drag valves                recirculation line temperature or ultra
                                                                                                                                                                                                                                                    sound detection method
AX-12 Boiler feed water pressure drop across the three element          auxiliary power consumption reduction    Incease in BFP power consumption           set with higher pressure drop say 10 kg/ Gradually reduce the set pressure and          Educate the operators                         D     Karthikeyan   CII-Godrej    India
      pump              control valve, which is a set point for scoop                                                                                       cm2 for operational flexibility.         reduce the BFP power consumption.                                                                                GBC
                        control                                                                                                                                                                      Target pressure 4-5 kg/cm2


AX-13 Condensate      Constant speed motors                             auxiliary power consumption reduction    operating with control valve opening of    Excess capacity / head available in the   reduce the number of stages of the pump N/A                                                 C     Karthikeyan   CII-Godrej    India
      extraction pump                                                                                            less than 60%                              pump                                      to match with the requirement or install                                                                        GBC
                                                                                                                                                                                                      variable frequency drive


AX-14 auxiliary cooling control valves throttled at user end,           auxiliary power consumption reduction    Excess water flow at the user end          Excess capacity / head available in the   install next lower size impeller / install    N/A                                           C     Karthikeyan   CII-Godrej    India
      water pumps       Constant speed motor                                                                     indicating very low temperature difference pump                                      correct size (capacity & head) pump                                                                             GBC
                                                                                                                 across the users. Valve throttled at the
                                                                                                                 discharge / at the user end leading to
                                                                                                                 pressure loss and hence energy loss


AX-15 ID fan - IGV and Both IGV & scoop utilised for controlling the auxiliary power consumption reduction       IGV control results in lower operating     Oversizing of the fan and inefficient     Complete control with scoop. Keep the     N/A                                               C     Karthikeyan   CII-Godrej    India
      scoop control    draught.                                                                                  efficiency and increased auxiliary power   control mechanism                         IGV fully open. (applicable when the load                                                                       GBC
                                                                                                                 consumption.                                                                         is stable)


AX-16 Seal air fans      Damper throttled at the user ends and          auxiliary power consumption reduction    Damper throttling leads to pressure loss   Required pressure about 150 - 200     install variable speed drive with feed back       Periodically check the seal clearance in      C     Karthikeyan   CII-Godrej    India
                         operating pressure much higher than                                                     and hence energy loss                      mmWC more than the user end operating control. Feed back control can be                 the Mill sealing. Increase in clearance                           GBC
                         requireement                                                                                                                       pressure.                             differential pressure of user end operating       results in increased air consumption and
                                                                                                                                                                                                  pressure and seal air fan pressure.               hence increase in seal air fan power
                                                                                                                                                                                                  Maintain a differential pressure of 200           consumption
                                                                                                                                                                                                  mmWC




                                                                                                                                                                   ( 11/14 )
                                                                                                                                     ASIA-PACIFIC PARTNERSHIP ~ Peer Review Activities ~                                             THE FEDERATION OF ELECTRIC POWER COMPANIES OF JAPAN
                                                                                                                                                                                                                                     TOKYO ELECTRIC POWER COMPANY
                                                                                                                                                                                                                                     AMERICAN ELECTRIC POWER
                                                                                                                                                                                                                                     INTERNATIONAL POWER HAZELWOOD, AUSTRALIA
Auxiliary Power                                                                                                                                                                                                                      NTPC Ltd., INDIA
                                                                                                                                                                                                                                     CII GODREJ GBC, INDIA

                                                                                  COAL FIRED POWER PLANT EFFICIENCY IMPROVEMENT CHECKLIST (3rd Draft)
                                                                                                                                                             Physical Causes                                                          Procedure Improvements to prevent
        Equipment       Description of the physical situation           Effect on the efficiency            Indication by operating figures                                                          Countermeasures                                                                 Person       Company       Country
                                                                                                                                                           ( ):Related incident No.                                                            the recurrence
AX-17 ID fan          leakages in ducts and bellows             auxiliary power consumption reduction   Gradual increase in speed of the fan /   leakage in duct joints, erossion of      arrest external air ingress into duct.      Periodically measure the oxygen at     C     Karthikeyan   CII-Godrej   India
                                                                                                        increase in vane opening                 metallic bellows in the joints.          Install thermofabric on joints and metallic various locations upto ID fan inlet.                       GBC
                                                                                                                                                                                          bellows to minimise leakages                Increase in Oxygen level is a clear
                                                                                                                                                                                                                                      indication of external air ingress


AX-18 FGD Booster     Mist eliminator clogging                  Auxiliary power                         Mist eliminator differential pressure    Scaling on the mist eliminator           Clean the mist eliminator                  Periodical inspection                   D     Sakata        Chugoku      Japan
      Fan                                                                                               increase                                 pH reduction to promote the growth of    pH adjustment                              Operation value monitoring                                  Electric
                                                                                                                                                 scale                                    Check liquid to gas ratio


AX-19 SCR             SCR catalyst clogging                     Auxiliary power of ID Fan               SCR differential pressure increase       Clogging of SCR catalyst caused by dust Clean the SCR catalyst                    Periodical inspection                     D     Sakata        Chugoku      Japan
                                                                                                                                                 sticking or ammonia sulfate             Monitoring of the NOx removal efficiency, Operation value monitoring                                    Electric
                                                                                                                                                                                         molecule ratio, ammonia leakage



AX-20 FDF, IDF, and   Economizer outlet O2 high                 FDF, IDF, and PAF power consumption     Economizer outlet O2,                    Excessive air flow,                      Adjustment of the O2 set point with        Periodical operation monitoring and     C/A   Peer Review FEPC Japan Japan
      PAF power                                                 high                                    FDF, IDF, and PAF power,                 Uneven fuel flows among burners,         monitoring flue gas CO, mill outlet        review                                        at Kota TPS,
                                                                                                        Auxiliary power,                         Uneven gas flow                          temperature, boiler metal temperatures,                                                  INDIA
                                                                                                        Abnormal spray flows                                                              and spray flows,
                                                                                                                                                                                          Adjustment of the fuel flows




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                                                                                                                          ASIA-PACIFIC PARTNERSHIP ~ Peer Review Activities ~                                         THE FEDERATION OF ELECTRIC POWER COMPANIES OF JAPAN
                                                                                                                                                                                                                      TOKYO ELECTRIC POWER COMPANY
                                                                                                                                                                                                                      AMERICAN ELECTRIC POWER
                                                                                                                                                                                                                      INTERNATIONAL POWER HAZELWOOD, AUSTRALIA
Heat Rate Measurement                                                                                                                                                                                                 NTPC Ltd., INDIA
                                                                                                                                                                                                                      CII GODREJ GBC, INDIA
                                                                                                                                                                                                                                                                        Column 8 on the
                                                                             COAL FIRED POWER PLANT EFFICIENCY IMPROVEMENT CHECKLIST (3rd Draft)                                                                                                                        "Review Sheet"

                                                                                                                                                     Physical Causes                                                  Procedure Improvements to prevent
       Equipment      Description of the physical situation         Effect on the efficiency      Indication by operating figures                                                            Countermeasures                                                              Person          Company    Country
                                                                                                                                                   ( ):Related incident No.                                                    the recurrence
HR-1 Coal Scale     Calibration error                         Heat Rate Measurement            Large coal scale comparison deviation.   Calibration error due to weather change.   Clean and calibrate scale          Set up guideline for routine scale          C     Keck         AEP            USA
                                                                                                                                        Material under or on the weight frame.                                        calibration
                                                                                               High or low heat rate unknown penalty    Belt replacement


HR-2 Coal Scale     Calibration error                         Heat Rate Measurement            Large coal scale comparison deviation.   Scale drift. Replacement of belt. New Perform material weigh test             Set up guideline for conducting coal pile   C/A   Keck         AEP            USA
                                                                                                                                        scale installation                                                            inventory to determine if material weight
                                                                                               High or low heat rate unknown penalty                                                                                  testing is needed


HR-3 Coal Sampler   Bias Error                                Heat Rate Measurement            High or low heat rate unknown penalty    High or low coal sampler collection        Perform coal sampler bias test     Set up guideline for periodically coal      C/A   Keck         AEP            USA
                                                                                                                                        weights Moisture errors                                                       sampler bias testing

HR-4 Generator      Integrator Error                          Heat Rate Measurement            High or low heat rate unknown penalty    Integrator calibration drift               Calibrate integrator measurement   Set up guideline to routinely compare       C/A   Keck         AEP            USA
     Integrator                                                                                                                                                                                                       integrator readings to actual generation
     Measurement                                                                                                                                                                                                      measurement and calibration check of
                                                                                                                                                                                                                      integrator readings




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                                                                                                                                           ASIA-PACIFIC PARTNERSHIP ~ Peer Review Activities ~                                             THE FEDERATION OF ELECTRIC POWER COMPANIES OF JAPAN
                                                                                                                                                                                                                                           TOKYO ELECTRIC POWER COMPANY
                                                                                                                                                                                                                                           AMERICAN ELECTRIC POWER
                                                                                                                                                                                                                                           INTERNATIONAL POWER HAZELWOOD, AUSTRALIA
Enhancement                                                                                                                                                                                                                                NTPC Ltd., INDIA
                                                                                                                                                                                                                                           CII GODREJ GBC, INDIA

                                                                                         COAL FIRED POWER PLANT EFFICIENCY IMPROVEMENT CHECKLIST (3rd Draft)
                                                                                                                                                      Physical Causes                                                                      Procedure Improvements to prevent
         Equipment      Description of the physical situation              Effect on the efficiency               Indication by operating figures                                                 Countermeasures                                                                      Person       Company       Country
                                                                                                                                                     ( ):Related incident No.                                                                       the recurrence
Eh-1 Modern Design                                               The efficiency increase is dependent on the                                                                    Installation of new turbine cylinders with modern 3 D                                          N/A   Tony          IPRH         Australia
     Turbine Blading                                             design and amount of deterioration of the                                                                      design, high efficiency blading                                                                      Innocenzi
                                                                 existing turbine and can be up to 6%.                                                                          Enhancement is more economical where the existing
                                                                                                                                                                                turbine has come to the end of its life


Eh-2 Variable Speed                                              Provides saving in auxiliary power                                                                             Installation of variable speed drives on equipment which                                       N/A   Tony          IPRH         Australia
     Drives                                                      consumption which is dependent on the                                                                          is not operating at the speed which gives the best                                                   Innocenzi
                                                                 operating position in relation to the optimum                                                                  efficiency
                                                                 operating speed.                                                                                               Less saving in auxiliary power consumption when
                                                                                                                                                                                power station is operating as bas load.

Eh-3 On-line                                                     Cleaner condensers providing improvement                                                                       Inclusion of On-line Condenser Cleaning Systems                                                N/A   Tony          IPRH         Australia
     Condenser                                                   in turbine heat rate depending on condenser                                                                    Chemical treatment may be more economical                                                            Innocenzi
     Cleaning                                                    fouling. Increases in efficiency of up to 0.8%                                                                 depending on environmental impacts
     Systems                                                     are possible.


Eh-4 Co-Firing                                                   Natural gas co-firing can offer efficiency                                                                     Firing Natural gas in combination with coal                                                    N/A   Tony          IPRH         Australia
     Natural gas                                                 improvements and lower greenhouse gas                                                                          The higher fuel cost reduces the economic benefits.                                                  Innocenzi
                                                                 emissions by partially displacing a less                                                                       Using the natural gas in a CCGT would be more
                                                                 efficient fuel with natural gas. Increases in                                                                  economic.
                                                                 efficiency up to 5% are possible depending
                                                                 on the initial efficiency of the plant.


Eh-5 Coal Drying                                                 The more effective coal drying process                                                                         Drying high moisture coal using a process which                                                N/A   Tony          IPRH         Australia
                                                                 reduces the loss duct to the coal moisture                                                                     recovers the heat in the water vapour produced from the                                              Innocenzi
                                                                 in the flue gas up to 14% saving with high                                                                     drying process
                                                                 moisture coals.                                                                                                The higher the coal moisture the higher the potential
                                                                                                                                                                                savings. Reduced sent out energy.

Eh-6 Condensate/                                                 There is a increase in efficiency due to the                                                                   Using the exhaust gas from a gas turbine to heat feed                                          N/A   Tony          IPRH         Australia
     Feedwater                                                   use of the exhaust gas, but a reduction in                                                                     water.                                                                                               Innocenzi
     Heating using                                               the steam cycle efficiency due to the                                                                          More economic if the existing feedwater heater(s) are
     Exhaust Gas                                                 reduction in the use of bled steam for feed                                                                    not serviceable. Using the natural gas in a CCGT would
     from a GT                                                   heating. Increases in efficiency of up to 14%                                                                  be more economic.
                                                                 is possible depending on the initial
                                                                 efficiency of the plant.


Eh-7 Condensate/                                                 There is an efficiency improvement if the                                                                      Using the temperature of the flue gas after the air                                            N/A   Tony          IPRH         Australia
     Feedwater                                                   existing feedwater heater(s) are not                                                                           heater to heat the ondensate/Feedwater                                                               Innocenzi
     Heating using                                               serviceable and air heater flue gas exit                                                                       More economic if the existing feedwater heater(s) are
     Flue gas                                                    temperature is well above the acid dew                                                                         not serviceable.
                                                                 point. Increases in efficiency up to 5% is
                                                                 possible depending on the initial efficiency
                                                                 of the plant.

Eh-8 Solar Heating of                                            Increases in efficiency up to 1% is possible.                                                                  Using energy from the sun to heat the condensate                                               N/A   Tony          IPRH         Australia
     Feedwater/                                                                                                                                                                 More economic if the existing condensate/feedwater                                                   Innocenzi
     Condensate                                                                                                                                                                 heater(s) are not serviceable.




Eh-9 Condenser CW                                                Increases in efficiency dependent on                                                                           Increase flow through condenser using aux. cooling                                             N/A   Tony          IPRH         Australia
     boost                                                       additional aux. cw flow available.                                                                             water system thereby improving vacuum                                                                Innocenzi
                                                                                                                                                                                Economic if the Unit suffers from poor vacuums
                                                                                                                                                                                (especially over summer) and as a result the benefits
                                                                                                                                                                                achieved outweigh the cost of conversion costs.


Eh-10 Utilise cold     Main steam utilised for auxiliary steam   Increase in Heat rate                            Increased steam consumption                                   Utilse the cold reheat steam for auxiliary steam           N/A                                 N/A   Karthikeyan   CII-Godrej   India
      reheat steam for requirement such as emergency turbine                                                                                                                    consumption. Keep the provision for extraction of                                                                  GBC
      meeting          seal requirement, fuel oil heating etc                                                                                                                   mainsteam as standby
      auxiliary steam
      requirement




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