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The assessment of a Coal-Fired Power Plant (CFPP) performance is an intricate process that involves the determination of Heat Rate (HR) deviations of current operational parameters from baseline or target values. This study focuses on HR deviations of a CFPP based on the Applicable Coal Price (ACP), and the influence of the ACP price on daily losses or gains are thoroughly analyzed for key performance parameters for three fixed ACP of RM12, 18, and 24 per GJ. This paper mainly investigates key parameters and related equipment that significantly affect the HR of the CFPP and ranks the parameters affecting HR from most significant to least significant. The baseline or target values are obtained from the plant commissioning manuals and the Performance Guarantee Test (PGT). Actual real-life operational data from a 700MWn CFPP is utilized to improve the accuracy and confidence levels of the results obtained. It was found that at the nominal operating baseload, the most significant negative HR deviation is for the Rotary Air Heater (RAH) gas exit temperature with a negative HR deviation of -137.9 kJ/kWh leading to an annual loss of RM17.6 million at ACP of RM24/GJ while the superheater and reheater spray flows are contributing least to the HR deviation. This analysis highlighting the impact of key parameters affecting the performance enables plant operations and maintenance teams to focus on such parameters to mitigate losses.

Evaluating Coal-Fired Power Plant (CFPP) performance is a complex process involving the determination of the turbine cycle Heat Rate (TCHR). This study focuses on determining the TCHR by developing a mathematical model. The model, which incorporates economic analysis of the plant, is developed using energy and mass balance relationships of the turbine cycle, validated using plant commissioning data from a 700MWn CFPP located in Perak, Malaysia. Actual plant data from a 700MWn CFPP is utilized to improve the accuracy and increase the confidence of the results of this study. It was found that at the nominal operating load of 729MWg, there is a Heat Rate (HR) deviation of -1,135 kJ/kWh, leading to daily losses of RM240,447 or USD 60,112. Furthermore, it is possible to utilize the developed model at lower loads as the plant is now being used to operate on “cyclic” loads. The daily losses at a lower load of 431MWg are RM125,767 or USD31,442. Thus, the model is able to compare the plant HR at various loads against commissioning data, and economic analysis is able to be carried out effectively. Valuable information for plant operations and performance engineers could be obtained using this model to determine plant HR.