BEE - CODE DEVELOPMENT PROJECT

DRAFT CODE
ON
COGENERATION

Prepared by

Devki Energy Consultancy Pvt. Ltd.,

Vadodara
 OBJECTIVE
• The basic objective of this BEE Code is to
establish procedures, guidelines and rules for
conducting the performance tests on different
types of cogeneration Systems at site operating
conditions.

• The performance of cogeneration system is

widely understood in terms of Efficiency and Heat
Rate. The objective of this code is to determine
the Efficiency and Heat Rate for the cogeneration
System operating at specific operating conditions
prevailing at that site.
 Following Codes and Standards are widely used as
reference while preparing the code, as these are widely used
for conducting performance testing at manufacturers’ test
facilities and at operating site.

Steam Turbines

• DIN 1943 Thermal acceptance tests for steam turbines

• BN EN 60953 Rules for steam turbine’s thermal
acceptance tests
• ASME PTC 6 Steam turbine performance test code
• IEC 953 Rules for steam turbine’s thermal acceptance
tests
Gas Turbines

DIN 4341 Acceptance rules for gas turbines

BS 3135 Specification for gas turbine acceptance test
ASME PTC 22 Gas turbine power plants – Power test code
ISO 2314 Gas turbines - Acceptance tests
ISO 2314 Acceptance tests for combined cycle power plants,
Amendment 1

Reciprocating Engines

IS:10000 Part IV – 1980: Method of tests for Internal combustion

engines Declaration of power, efficiency, fuel consumption and
lubricating oil consumption
IS:10000 Part VIII – 1980: Method of tests for Internal
combustion engines Performance tests
Steam Boilers

ASME PTC 4.1 Steam generating units performance

test code
ASME PTC 4.4 Gas turbine heat recovery steam
generators performance test code
DIN 1942 Acceptance Test for Steam Generators

The performance of fired steam generating plant can be

determined in accordance with the method provided in
the respective BEE Code for Boilers and the performance
parameters so derived can be used to determine overall
performance of the cogeneration plant.
 GUIDING PRINCIPLES

Estimation of performance
The performance of Cogeneration System is widely
understood in terms of Efficiency and Heat Rate. Heat
rate is the heat input required per unit of power
generated (kJ/kWh), for specific fuel being fired and
specific site conditions.
 Performance testing of Cogeneration system defined in this code include
the following.

• Measurement and estimation of Power Generation from the cogeneration

plant at the site operating parameters of ambient air temperature, pressure
and relative humidity, site altitude, fuel being fired and its characteristics.

• Measurement and estimation of Steam Generation from the cogeneration

plant from waste heat recovery in gas turbine based plants and
reciprocating engine based plants.

• Estimation of Cogeneration Heat Rate or Heat Input per unit and

Cogeneration Efficiency at the site operating parameters of ambient air
temperature, pressure and relative humidity, site altitude, fuel being fired
and its characteristics.

• Measurement and estimation of Auxiliary Power Consumption at the site

operating parameters.
 Pre-Test Requirements

1. Once the test-protocol has been defined and agreed upon, a

final test procedure conforming to this code including
required test-data sheets is prepared. At this stage, it may be
necessary to give special instructions to the plant operating
personnel such as off-line washing of the gas turbine prior to
undertaking the test.

2. A plan for instrumentation required for the test of system and

system heat cycle can be drawn out prior to test. This plan
should take into account the instruments installed as part of
cogeneration system and to be installed for the purpose of
test.
 Adequate provision for physical location, installation and number of test
instruments needed to achieve test results with good repeatability should
be made. Some of the items to be considered are:
• Location and installation of a calibrated primary flow metering section.
• Provision for the accurate measurement of output.
• Location and installation of test connections for primary pressure and
temperature measurements.
• Provision for measurement of secondary leak-off and bypass flows,
which may affect the primary flow measurement or have a significant
effect in calculation of the test performance.
• Selection of test instruments capable of the repeatability required for
consistent test results.
• Location of test instruments in groups to facilitate calibration and use,
and minimize the number of observations required.
 Performance parameters in cogeneration plant
Estimation of following parameters need to be carried
out in performance testing in cogeneration plant.

Equipment Performance Associated parameter

parameter

Gas turbine · Electric Compressor Inlet

generator Power Output Temperature
system · Heat Rate Ambient Pressure
Exhaust Gas Compressor Inlet Relative
Temperature Humidity
DeNOx Steam Flow
Conditions
(pressure, temperature, flow
rate)
Steam Electrical Power Steam Turbine Throttle
turbine Output Flow Conditions
generator (temperature, pressure,
Heat Rate
system flow rate)
DeNOx Steam Flow
Conditions
(temperature, pressure,
flow rate)
Process Steam Flow
Conditions
(temperature, pressure,
flow rate)
Reciprocating Electric Power Output Engine Inlet
engine Heat Rate Temperature
generator Ambient Pressure
Exhaust Gas
system
Temperature Engine Inlet
Relative Humidity

Waste heat HP Steam Flow Rate Gas temperature

recovery Overall Effectiveness in HRSG inlet
boiler of System Exhaust Gas
Combined Flow
Economizer Feed ·Supplementary
water flow Firing Conditions
Exhaust Gas
Composition at
HRSG inlet
 INSTRUMENTS AND METHODS OF
MEASUREMENTS
Test instrument accuracy
Instrument Accuracy

Inlet air RTD, Thermocouples 0 – 1000C, ± 0.35%

(chrome alumel)
Exhaust air/flue gas RTD 0 – 1000C, ± 0.35%
Speed indication ± 1 rev/min, digital counter
Fuel weighing measurement ±1%
Fuel flow meter measurement ± 1 % (gas and liquid fuels)
Water flow meter measurement ±1%
Pressure instruments ±1%
Temperature instruments ±1%
Power measurement ±1%
Current transformer accuracy class 0.5
Voltage transformer accuracy class 0.5
 Measurement of feed water, condensate,
steam and cooling water flow

1. Feed water flow and Condensate flow – It is

recommended to use measured feed water flow as the
basis for the accurate determination of the primary
flow to the turbine.

The primary element for water flow measurement can

be an orifice/venture/ vortex flow meter designed
meeting the specification of fluid and system and
installed in a specially designed flow metering pipe
section.
2. Steam flow – It is recommended to use orifice/vortex based flow
measurement system similar to the one to be used for feed water
flow measurement with some exceptions and additions considering
the requirement of measuring the flow similar to gaseous flow.

2. The use of a flow measuring device in the low temperature portion of

the water cycle may also be considered to determine primary steam
flow to the turbine. For measuring flow of very high pressure steam,
steam flow nozzles may be used.

3. Cooling water flow –In the absence of in-line flow meters, use the
portable ultrasonic flow measurement instrument can be considered.
The V-notch or weir type of metering station can also be considered.
Wherever, specific accuracy is required, the method mentioned in
4.5.1 may be used.
 Measurement of fuel quantity
• Gaseous fuels
Besides the fuel supplying agency’s metering system, normally, a microprocessor
based online gas fuel flow and quantity measurement system is generally available,
integrated with the control and instrumentation system of individual gas turbine unit or
reciprocating engine unit, with continuous display of instantaneous gas flow and flow
totalisers. Calculation of gas volume at standard conditions from measured gas volume
using following relation.

Where,
Vs = total gaseous fuel volume in standard m3
Vm = measured or calculated volume(Pm  P
at test w) x 288
conditions, m3
Pm = measured  Vm
Vs gas x mm Hg
pressure,
Pw = water vapour pressure 101 .325
mm Hg, (zerox for
(Tdry  273) x
mgas) Z
Tm = measured gas temperature, 0C
Z = compressibility factor for gas
• Liquid fuels

For liquid fuel flow and consumption, either of following

suggested metering system can be used.

• To measure liquid fuel flow in pipelines, it is

recommended to use digital readout on a control panel of
equipment being fired with liquid fuel.

• If the system mentioned above is not installed, and if the

liquid fuel is clear such as Kerosene, Light diesel oil or High
speed diesel, the portable ultrasonic flow measurement unit
may be used.
 PERFORMANCE CALCULATION
PROCEDURE

Heat input to steam and water

Turbine cycle heat rate 
power output
Total heat input to boiler  boiler losses

power output
Total heat input to boiler  boiler losses
Boiler Efficiency  x 100 %
Total heat input to boiler

Total heat input to boiler x boiler efficiency

Turbine cycle heat rate 
power output
 Wf : Fuel flow
P : Pressure
t : Temperature
Qsteam: Estimated flow
WE1 : 1st extraction
Wsteam: Exhaust steam flow of throttle steam
WE2 : 2nd extraction
Wwtr : Cooling water flow
A : Analysis required
kW : Kilowatts
pf : Power factor
 Steam Turbine Calculation Procedure
Step 1:Calculate the actual heat extraction at each stage in
turbine.

Steam enthalpy at steam turbine inlet : h1, kJ/kg

Steam enthalpy at 1st extraction: h2, kJ/kg
Steam enthalpy at 2nd extraction : h3, kJ/kg
Steam enthalpy at condenser (turbine exhaust) : h4, kJ/kg

Heat extraction from inlet to 1st extraction, h5 : h1 – h2

Heat extraction from 1st – 2nd extraction, h6 : h2 – h3
Heat extraction from 2nd extraction – exhaust, h7 : h 3 – h4
Step 2: From Mollier, H - Φ diagram, the theoretical heat extraction for the
conditions mentioned in Step 1 is to be derived.

Theoretical enthalpy after 1st extraction : H1, kJ/kg

Theoretical enthalpy after 2nd extraction : H2, kJ/kg
Theoretical enthalpy at condenser conditions : H3, kJ/kg

Theoretical heat extraction from turbine inlet : h 1 - H1

to 1st extraction, h8
Theoretical heat extraction from 1st – 2nd : H1 – H 2
stage extraction, h9
Theoretical heat extraction from 2nd extraction : H2 – H 3
- condensation, h10
Step 3: Determine the steam turbine efficiency.

h5
Efficiency of 1st stage 
h8

h
Efficiency of 2nd stage  6
h9

Efficiency of conden. stage h7

h10
Determine the station heat rate.

m (h1  h11 )
Heat rate  kJ/kWh
P

Where, m : Mass flow rate of steam in kg/h

h1 : Enthalpy of inlet steam in kJ/kg
h11: Enthalpy of feed water in kJ/kg
P : Average power generated kW
 Gas turbine based cogeneration plant
Heat input to gas turbine, kJ [fuel input]
Gas turbine heat rate 
power output
Total output of WHRB, kJ [steam]
WHRB Efficiency 
Total heat input to WHRB

860 x 4.19 x 100

Overall gas turbine cycle heat rate  kJ/kWh
Overall plant efficiency

Thermal efficiency 
(Power output x 860 x 4.19)  (Steam generated x enthalpy)
x 100 %
Heat input (fuel) x LHV of fuel
 Calculation procedure

Fuel flow calculations

Specific fuel consumption calculations

Calculate the fuel consumption of the plant per

unit time using following formulae.
 Fuel flow calculations

Vng  Vs / Tt for gaseous fuels

Wl  Ww / Tt for liquid fuels

Where,
Vng = fuel consumption per hour, for gaseous fuels,
Sm3 or Nm3 /hr
Wl = fuel consumption per hour, for liquid fuels, kg/hr,

Tt = time duration of test, hours

Vs = total gaseous fuel volume in Sm3 or Nm3
Ww = total liquid fuel consumption, kg
 Calculate the specific fuel consumption of the
plant using following equation.
Vng Wl
Ws  for gaseous fuels Ws  for liquid fuels
P P

Where,
WS = specific fuel consumption, for gaseous fuels Sm3 or
Nm3
for liquid fuels kg/kWh
P = net electrical power output, kW
 Heat consumption rate calculations
Calculate the heat consumption rate of the plant using
following equation.

qr  Vng x Q lo for gaseous fuels

qr  Wl x Q lo for liquid fuels

Where,
qr = rate of heat consumption, kJ/hr

Qlo = lower heating value of fuel, for

gaseous fuels kJ/Nm3 or Sm3 for liquid fuels, kJ/kg,
 Heat rate calculations
Calculate the heat rate of the plant using
following equation.
qr
qs 
P

Where,
qs = heat rate, kJ/kWh

qr = rate of heat consumption, kJ/hr

P = net electrical power output, kW

 heat rate of the plant may also be calculated using
following equation.

3412.7
qs  for net electrical power, kW
ηgt

Where,
qs = heat rate, kJ/kWh

hgt = thermal efficiency based on net

electrical power output
 The heat rate of the plant using following equation.
Vng x Q lo
qs  for gaseous fuels
P

Wl x Q lo
qs  for liquid fuels
P
Where,
qs = heat rate, kJ/kWh
Qlo = lower heating value of fuel, for gaseous fuels
kJ/Sm3 or Nm3 for liquid fuels kJ/kg,
Vng = fuel consumption per hour, for gaseous fuels, Sm3
or Nm3/hr
Wl = fuel consumption per hour, for liquid fuels, kg/hr,
P = net electrical power output kW
 Thermal efficiency calculations for gas turbine

3412.7 x P x 100
ηgt 
qr
Where,
hgt = thermal efficiency based on net
electrical power output, percent
P = net electrical power output kW
qr = rate of heat consumption, kJ/hr
 Steam flow from WHRB calculations
Calculate the steam flow available from WHRB when
operating in unfired mode using following equation.

Weg x Cp x (t e  t pp )
Ws 
(h12  h11 )

Where,
Ws = steam rate, kg/sec
Weg = exhaust gas flow rate, kg/sec
Cp = average value of specific heat of exhaust gas,
kJ/kg0C
te = exhaust gas temperature, 0C
tpp = pinch point temperature, 0C (manufacturer’s data)
h11 = feed water enthalpy at drum inlet, kJ/kg
h12 = steam enthalpy at boiler outlet, kJ/kg
 Thermal efficiency calculations for WHRB
Ws x h12  h11 x 100
η whrb 
Weg x Cp x (t e  t pp )
Where,
hwhrb = thermal efficiency based on net steam
output, percent
Ws = steam rate, kg/sec
h12 = steam enthalpy at boiler outlet, kJ/kg
Weg = exhaust gas flow rate, kg/sec
Cp = average value of specific heat of exhaust gas,
kJ/kg0C
te = exhaust gas temperature, 0C
0
Overall plant efficiency calculations
[(P x 860 x 4.19)  (Ws x h12  h11 x 3600)]
ηplant  x 100
Vng or Wl x Q lo

Where,
hplant = overall plant efficiency based on net power &
steam output, percent
P = net electrical power output from gas turbine, kW
Ws = steam rate from WHRB, kg/sec
h12 = steam enthalpy at boiler outlet, kJ/kg
Qlo = lower heating value of fuel, for gaseous fuels
kJ/Sm3 or Nm3 for liquid fuels , kJ/kg,
Vng = fuel consumption per hour, for gaseous fuels,
Sm3 or Nm3/hr
Wl = fuel consumption per hour, for liquid fuels, kg/hr
Overall plant heat rate calculations
860 x 4.19 x 100
qscogen 
ηplant
Where,
qscogen= overall plant heat rate based on net power &
steam output, kJ/kWh
plant = overall plant efficiency based on net power &
steam output, percent
 Reciprocating engine based cogeneration
plant

Heat supplied to the reciprocating engine cycle is defined

as ratio of the heat supplied to the engine through fuel
input to power output from the generator driven by the
engine. The quantity of heat is arrived at from the
measurement of the total heat supplied to the engine and
of waste heat recovery boiler (WHRB) efficiency by the
input - output method.
 Heat supplied to the gas turbine cycle is defined as ratio of the
heat supplied to the gas turbine through fuel input to kW output
from the generator driven by the turbine. The quantity of heat is
arrived at from the measurement of the total heat supplied to the
gas turbine and of waste heat recovery boiler (WHRB) efficiency
by the input - output method.
Reciprocating engine Heat input to reciprocating engine

cycle heat rate power output
Total output of WHRB, [Steam]
WHRB efficiency 
Total heat input to WHRB

860 4.19 x 100

Overall engine cycle heat rate 
Overall plant efficiency

(Power output x 860 4.19)  (Steam generated x enthalpy)

Thermal efficiency  x 100 %
Heat input (fuel) x LHV of fuel
 Calculation procedure

Fuel flow calculations

Gaseous fuels – Method as provided in section 4.6
can be followed for determining the flow of gaseous
fuel.

Liquid fuels – For measurement of liquid fuel flow and

quantity, the procedure at section 4.6 can be
employed.
 Specific fuel consumption calculations
Calculate the fuel consumption of the plant per unit time using
following formulae.

Wng = Vs/ Tt, for gaseous fuels Wl = Ww/ Tt, for liquid fuels,
Where,
Vng = fuel consumption per hour, for gaseous fuels, Nm 3,
Sm3/hr
Wl = fuel consumption per hour, for liquid fuels, kg/hr,
Tt = time duration of test, hours
Vs = total gaseous fuel volume in standard m 3
Ww = total liquid fuel consumption, kg
 Calculate the specific fuel consumption of the plant
using following equation.

Vng Wl
Ws  for gaseous fuels Ws  for liquid fuels
P P
Where,
WS = specific fuel consumption, for gaseous
fuels Nm3 or Sm3/kWh for liquid fuels kg/kWh
P = net electrical power output, kW
Heat consumption rate calculations

qr  Vng x Q lo for gaseous fuels

qr  Wl x Q lo for liquid fuels

Where,
qr = rate of heat consumption, kJ/hr

Qlo = lower heating value of fuel, for

gaseous fuels kJ/Nm3 or Sm3 for liquid fuels ,kJ/kg,
Heat rate calculations

q
q  r
Where,
qs s= heat rate, kJ/kWh
qr
P
P
= rate of heat consumption, kJ/hr
= net electrical power output kW

Where,
qs = heat rate, kJ/kWh
hre = thermal efficiency based on net electrical power output

3412.7
qs  for net electrical power in kW
ηre
 heat rate of the plant -using following equation.

Vng x Q l0
qs  for gaseous fuel
P
Wl x Q l0
qs  for liquid fuel
P
Where,
qs = heat rate, kJ/kWh

Ql0 = lower heating value of fuel, for gaseous fuels kJ/Sm 3 or

Nm3 for liquid fuels kJ/kg,
Vng = fuel consumption per hour, for gaseous fuels, Sm3 or
Nm3/hr
Wl = fuel consumption per hour, for liquid fuels, kg/hr,

P = net electrical power output kW

Thermal efficiency calculations for reciprocating engine

3412.7 x P x 100
ηre 
qr
Where,
hre = thermal efficiency based on net electrical power
output, percent
P = net electrical power output kW
qr = rate of heat consumption, kJ/hr
Steam flow from WHRB calculations

Weg x Cp x (t e  t pp )
Ws 
Where, (h11 - h10 )
Ws = steam rate, kg/sec
Weg = exhaust gas flow rate, kg/sec
Cp = average value of specific heat of exhaust gas, kJ/kg0C
te = exhaust gas temperature, 0C
tpp = pinch point temperature, 0C (manufacturer’s data)
h10 = feed water enthalpy at drum inlet, kJ/kg
h11 = steam enthalpy at boiler outlet, kJ/kg
Thermal efficiency calculations for WHRB

Ws x h11  h10  x 100

η whrb 
Where, Weg x Cp x (t e - t pp )
hwhrb = thermal efficiency based on net steam output, %
Ws = steam rate, kg/sec
h11 = steam enthalpy at boiler outlet, kJ/kg
Weg = exhaust gas flow rate, kg/sec
Cp = average value of specific heat of exhaust gas, kJ/kg 0C
te = exhaust gas temperature, 0C
tpp = pinch point temperature, 0C (manufacturer’s data)
 Overall plant efficiency calculations

[(P x 860 x 4.19)  (Ws x h11  h10  x 3600)] x 100


ηplant Where,
h
plant
Wng
= overall plant efficiency or on
based Wlnetx power
Q lo & steam output, %
P = net electrical power output from gas turbine, kW
Ws = steam rate from WHRB, kg/sec
h11 = steam enthalpy at boiler outlet, kJ/kg
Qlo = lower heating value of fuel, for gaseous fuels – kJ/Sm3 or Nm3
for liquid fuels - kJ/kg,
Wng = fuel consumption per hour, for gaseous fuels, Sm3 or Nm3/hr
Wl = fuel consumption per hour, for liquid fuels, kg/hr,
Overall plant heat rate calculations

860 x 4.19 x100

qscogen 
ηplant
Where,
qscogen = overall plant heat rate based on net power &
steam output, kJ/kWh
hplant = overall plant efficiency based on net power &
steam output, %