20101102 Boiler OEE Calculation Ver1.00

Instructions This model is meant to calculate the OEE (Overall Equipment Efficiency) of a Boiler primarily based on the Direct Me Working of the Model 1. The Boiler Running-in Data needs to be filled in the Worksheet "Input_Machine_Running_In_Data" "Input_Machine_Running_In_Data" after the user h for the purpose of referncing and do not hold implications in the efficiency calcultaions. 2. Other details need to filled in the worksheet "Output_OEE_Boiler" where the effectiveness of the Boiler is calculate 3. The worksheet "Steam_Table_Lookup" is a look up Table to locate the enthaply values for Feedwater and Steam

thod of Calculation

as selected the frequecny of calculation of the OEE for the Boiler. The Data has to be filled Datewise. The Dates ar  d and the GAP with respect to the Rated Boiler Efficiency is also calculated. s per the Temperature and Pressure measured respectively.

used only

Boiler Running-In Data

Frequency at which OEE is to be analysed

Instructions: If the Frequency is daily, then the values for  be picked up from cell Range A6 to F12, similarly if the Fre Frequency is Monthly then the values will be picked up fro

Fortnightly

Uptime Date

Downtime

Hours 7-Nov-10

Minutes 22

Date 30

Hours 7-Nov-10

6-Nov-10

6-Nov-10

5-Nov-10

6-Nov-10

4-Nov-10

5-Nov-10

3-Nov-10

4-Nov-10

2-Nov-10

3-Nov-10

1-Nov-10

2-Nov-10

31-Oct-10

1-Nov-10

30-Oct-10

31-Oct-10

29-Oct-10

30-Oct-10

28-Oct-10

29-Oct-10

27-Oct-10

28-Oct-10

26-Oct-10

27-Oct-10

25-Oct-10

26-Oct-10

24-Oct-10

25-Oct-10

Minutes 2

30

ptime & donwntime will be picked from cells A6 to F6. If the Frequency is Weekly then the values will quency is Fortnightly then the values will be picked up from cell Range A6 to F20 and finally if the m cell Range A6 to F36

Cumulative Numbers Hours Total Uptime Total Downtime

Minutes 22

30

2

30

Input Machine Oil Consumption Data

Frequency at which OEE is to be analysed

Total Consumption for the Frequency Selected in Cms

Fortnightly

1

Tank 1

Date

Refill done in Ltrs

Reading In Cms 7-Nov-10 6-Nov-10 5-Nov-10 4-Nov-10 3-Nov-10 2-Nov-10 1-Nov-10 31-Oct-10 30-Oct-10 29-Oct-10 28-Oct-10 27-Oct-10 26-Oct-10 25-Oct-10 24-Oct-10 23-Oct-10

0 0 0 0

Refill done in Cms 10

Consumption in Cms 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Date 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

7-Nov-10 6-Nov-10 6-Nov-10 5-Nov-10 4-Nov-10 3-Nov-10 2-Nov-10 1-Nov-10 31-Oct-10 30-Oct-10 29-Oct-10 28-Oct-10 27-Oct-10 26-Oct-10 25-Oct-10 24-Oct-10

Total Consumption for the Frequency Selected in Ltrs

10

Tank 2

Reading In Cms Refill done in Ltrs

Cumulative Consumption of the Tanks in Cms

Consumption in Cms

Refill done in Cms 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Feedwater Temperature Data

Average F Frequency Selected for the OEE Evaluation

Fortnightly

Feedwater Temperature in Degree Celsius Date Time 7-Nov-10 6-Nov-10 5-Nov-10 4-Nov-10 3-Nov-10 2-Nov-10 1-Nov-10 31-Oct-10 30-Oct-10 29-Oct-10 28-Oct-10 27-Oct-10 26-Oct-10 25-Oct-10 24-Oct-10

0:00 100

22:59 100

21:59

3:00

19:59

5:00

6:00

16:59

edwater Temperature Err:512

8:00

9:00

Hourly Temperature Record in Degree Celsius 13:59 11:00 12:00 10:59

14:00

15:00

7:59

17:00

18:00

4:59

20:00

21:00

1:59

23:00

Average Temperature in Celsius Err:512 Err:512 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

or the Day

Output Steam Pressure Data

Average O Frequency Selected for the OEE Evaluation

Fortnightly

Pressure of the generated Steam in Bars Date Time 7-Nov-10 6-Nov-10 5-Nov-10 4-Nov-10 3-Nov-10 2-Nov-10 1-Nov-10 31-Oct-10 30-Oct-10 29-Oct-10 28-Oct-10 27-Oct-10 26-Oct-10 25-Oct-10 24-Oct-10

0:00 8.5

22:59 8.5

21:59

3:00 8.5

8.5

19:59 8.5

5:00

6:00 8.5

16:59 8.5

8.5

utput Steam Pressure Err:512

8:00

9:00 8.5

8.5

Hourly Pressure Record in Bars 13:59 11:00 12:00 8.5 8.5 8.5

10:59 8.5

14:00 8.5

15:00 8.5

7:59 8.5

17:00

18:00 8.5

4:59 8.5

8.5

20:00 8.5

21:00 8.5

1:59 8.5

23:00 8.5

Average Pressure for  Bars Err:512 Err:512 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

the Day in

OEE Calculations Input Data Average Temperature of Feedwater in Degree Celcius

Err:512

3

Average pressure of steam in Bar of Kg/cm

Err:512

Total amount of Fuel Consumed

Err:501

Please enter the Gross Calorific Value of the Fuel Used by the Boiler in Kcal/KG Please enter the Quantity of steam (in tonnes ) generated during the period in which the OEE is to be calculated

3200.0000 Kcal/Kg 25.00 Tonnes

Quantity of Steam Generated in Tonnes Per Hour (TPH) Quantity of Fuel Consumed for Steam Generation in Tonnes Per Hour (TPH)

Err:501

Output Parameters Availability of the Boiler Performance of the Boiler Quality of the Output (An Assumption)

OEE (Overall Effectiveness of the Boiler)

90.00% Err:512 100.00%

Err:512

Steam Look Up Table Look Up Values for Feedwater Temperature in Degree Celcius 0.01 4 5 6 8 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 38 40 45 50 55 60 65 70 75 80 85 90 95 100 110 120 130 140 150 160

Enthalpy in KJ/kg 0.01 16.79 21 25.21 33.61 42.01 46.19 50.4 54.59 58.8 62.99 67.17 71.36 75.57 79.76 83.94 88.13 92.32 96.5 100.7 104.9 109 113.2 117.4 121.6 125.8 130 134.1 138.3 142.5 146.7 150.8 159.2 167.5 188.4 209.3 230.2 251.1 272 293 313.9 334.9 355.9 376.9 398 419 461.3 503.7 546.3 589.1 632.2 675.5

Look Up Values for Steam Enthalpy in KCal/kg 0.0024 3.9976 5.0000 6.0024 8.0024 10.0024 10.9976 12.0000 12.9976 14.0000 14.9976 15.9929 16.9905 17.9929 18.9905 19.9857 20.9833 21.9810 22.9762 23.9762 24.9762 25.9524 26.9524 27.9524 28.9524 29.9524 30.9524 31.9286 32.9286 33.9286 34.9286 35.9048 37.9048 39.8810 44.8571 49.8333 54.8095 59.7857 64.7619 69.7619 74.7381 79.7381 84.7381 89.7381 94.7619 99.7619 109.8333 119.9286 130.0714 140.2619 150.5238 160.8333

Pressure in Bar or  Kg/cm3 0.04 0.06 0.08 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.5 2 3 4 5 6 7 8 9 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 220.9

Enthalpy in KJ/kg 2554 2567 2577 2585 2610 2625 2637 2646 2653 2660 2666 2671 2675 2694 2707 2725 2739 2749 2757 2764 2769 2774 2778 2800 2804 2801 2794 2784 2772 2758 2742 2725 2706 2685 2662 2638 2611 2581 2547 2510 2465 2411 2099

170 180 190 200 210 220 230 240 250 260 270 280 290 300 320 340 360 374.14

719.2 763.2 807.6 852.4 897.8 943.6 990.1 1037.3 1085.3 1134.4 1184.5 1236 1289 1344 1461.5 1594.1 1760.5 2099.3

171.2381 181.7143 192.2857 202.9524 213.7619 224.6667 235.7381 246.9762 258.4048 270.0952 282.0238 294.2857 306.9048 320.0000 347.9762 379.5476 419.1667 499.8333

Enthalpy in KCal/kg 608.0952 611.1905 613.5714 615.4762 621.4286 625.0000 627.8571 630.0000 631.6667 633.3333 634.7619 635.9524 636.9048 641.4286 644.5238 648.8095 652.1429 654.5238 656.4286 658.0952 659.2857 660.4762 661.4286 666.6667 667.6190 666.9048 665.2381 662.8571 660.0000 656.6667 652.8571 648.8095 644.2857 639.2857 633.8095 628.0952 621.6667 614.5238 606.4286 597.6190 586.9048 574.0476 499.7619

Temperature of Feedwater in 0c Pressure of steam in Bar or Kg/cm3 Enthalpy of Feedwater in Kcal/Kg Enthalpy of Steam in Kcal/Kg

Err:512 Err:512 Err:512 Err:512

MATHEMATICAL CALI Dia = 1950 mm

Length=5500mm.

Look Up Values for Fuel Quantity DIP versus QTY DIP cm. QTY. Ltrs Ltrs/mm. 0 0 1.02 1 10 1.87 2 29 2.41 3 53 2.85 4 81 3.22 5 114 3.55 6 149 3.85 7 188 4.12 8 229 4.38 9 273 4.62 10 319 4.84 11 367 5.05 12 418 5.25 13 470 5.44 14 525 5.63 15 581 5.80 16 639 5.97 17 699 6.13 18 760 6.29 19 823 6.43 20 887 6.58 21 953 6.72 22 1020 6.85 23 1089 6.98 24 1159 7.11 25 1230 7.23 26 1302 7.35 27 1375 7.47 28 1450 7.58 29 1526 7.69 30 1603 7.79 31 1681 7.89 32 1760 7.99 33 1840 8.09 34 1920 8.19 35 2002 8.28 36 2085 8.37 37 2169 8.45 38 2253 8.54 39 2339 8.62 40 2425 8.70 41 2512 8.78 42 2600 8.86 43 2688 8.93 44 2778 9.00 45 2868 9.07 46 2958 9.14 47 3050 9.21 48 3142 9.27 49 3234 9.34 50 3328 9.40

51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108

3422 3516 3611 3707 3803 3900 3998 4090 4194 4292 4392 4491 4591 4692 4793 4894 4996 5098 5200 5303 5406 5509 5613 5717 5821 5926 6030 6135 6241 6346 6452 6557 6663 6770 6876 6982 7089 7196 7302 7409 7516 7623 7730 7838 7945 8052 8159 8266 8374 8481 8588 8695 8802 8909 9016 9123 9230 9337

9.46 9.51 9.57 9.63 9.60 9.73 9.70 9.83 9.88 9.92 9.97 10.01 10.05 10.09 10.13 10.17 10.20 10.24 10.27 10.31 10.34 10.37 10.39 10.42 10.45 10.47 10.50 10.52 10.54 10.56 10.58 10.60 10.61 10.63 10.64 10.66 10.67 10.68 10.69 10.70 10.70 10.71 10.72 10.72 10.72 10.72 10.72 10.72 10.72 10.72 10.72 10.71 10.70 10.70 10.69 10.68 10.67 10.66

109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166

9443 9550 9656 9762 9868 9974 10080 10185 10290 10395 10500 10604 10709 10813 10916 11020 11123 11225 11328 11430 11531 11633 11734 11834 11934 12034 12133 12232 12330 12428 12325 12622 12718 12814 12909 13004 13098 13191 13284 13376 13467 13558 13648 13737 13826 13914 14001 14087 14172 14257 14341 14423 14505 14586 14666 14745 14823 14900

10.64 10.63 10.61 10.60 10.58 10.56 10.54 10.52 10.50 10.47 10.46 10.42 10.39 10.37 10.34 10.31 10.27 10.24 10.20 10.17 10.13 10.09 10.05 10.01 9.99 9.92 9.88 9.83 9.78 9.73 9.68 9.63 9.57 9.51 9.46 9.40 9.34 9.27 9.21 9.14 9.07 9.00 8.93 8.86 8.78 8.70 8.62 8.54 8.45 8.37 8.28 8.19 8.09 7.99 7.89 7.79 7.69 7.58

167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195

14975 15050 15124 15196 15267 15337 15405 15473 15538 15603 15666 15727 15787 15845 15901 15955 16008 16058 16107 16153 16197 16238 16277 16312 16344 16373 16397 16415 16426

7.47 7.35 7.23 7.11 6.98 6.85 6.72 6.58 6.43 6.29 6.13 5.97 5.80 5.63 5.44 5.25 5.05 4.84 4.62 4.38 4.12 3.85 3.55 3.22 2.85 2.41 1.87 1.02 0.00

BERATION CHART OF TANK ( Furnace Oil) Capacity =16426 Ltrs.

Look Up Values for Fuel Quantity DIP versus QTY QTY. Ltrs DIP cm. Ltrs/mm. 0 0 1.02 10 1 1.87 29 2 2.41 53 3 2.85 81 4 3.22 114 5 3.55 149 6 3.85 188 7 4.12 229 8 4.38 273 9 4.62 319 10 4.84 367 11 5.05 418 12 5.25 470 13 5.44 525 14 5.63 581 15 5.80 639 16 5.97 699 17 6.13 760 18 6.29 823 19 6.43 887 20 6.58 953 21 6.72 1020 22 6.85 1089 23 6.98 1159 24 7.11 1230 25 7.23 1302 26 7.35 1375 27 7.47 1450 28 7.58 1526 29 7.69 1603 30 7.79 1681 31 7.89 1760 32 7.99 1840 33 8.09 1920 34 8.19 2002 35 8.28 2085 36 8.37 2169 37 8.45 2253 38 8.54 2339 39 8.62 2425 40 8.70 2512 41 8.78 2600 42 8.86 2688 43 8.93 2778 44 9.00 2868 45 9.07 2958 46 9.14 3050 47 9.21 3142 48 9.27 3234 49 9.34 3328 50 9.40

3422 3516 3611 3707 3803 3900 3998 4090 4194 4292 4392 4491 4591 4692 4793 4894 4996 5098 5200 5303 5406 5509 5613 5717 5821 5926 6030 6135 6241 6346 6452 6557 6663 6770 6876 6982 7089 7196 7302 7409 7516 7623 7730 7838 7945 8052 8159 8266 8374 8481 8588 8695 8802 8909 9016 9123 9230 9337

51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108

9.46 9.51 9.57 9.63 9.60 9.73 9.70 9.83 9.88 9.92 9.97 10.01 10.05 10.09 10.13 10.17 10.20 10.24 10.27 10.31 10.34 10.37 10.39 10.42 10.45 10.47 10.50 10.52 10.54 10.56 10.58 10.60 10.61 10.63 10.64 10.66 10.67 10.68 10.69 10.70 10.70 10.71 10.72 10.72 10.72 10.72 10.72 10.72 10.72 10.72 10.72 10.71 10.70 10.70 10.69 10.68 10.67 10.66

9443 9550 9656 9762 9868 9974 10080 10185 10290 10395 10500 10604 10709 10813 10916 11020 11123 11225 11328 11430 11531 11633 11734 11834 11934 12034 12133 12232 12330 12428 12325 12622 12718 12814 12909 13004 13098 13191 13284 13376 13467 13558 13648 13737 13826 13914 14001 14087 14172 14257 14341 14423 14505 14586 14666 14745 14823 14900

109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166

10.64 10.63 10.61 10.60 10.58 10.56 10.54 10.52 10.50 10.47 10.46 10.42 10.39 10.37 10.34 10.31 10.27 10.24 10.20 10.17 10.13 10.09 10.05 10.01 9.99 9.92 9.88 9.83 9.78 9.73 9.68 9.63 9.57 9.51 9.46 9.40 9.34 9.27 9.21 9.14 9.07 9.00 8.93 8.86 8.78 8.70 8.62 8.54 8.45 8.37 8.28 8.19 8.09 7.99 7.89 7.79 7.69 7.58

14975 15050 15124 15196 15267 15337 15405 15473 15538 15603 15666 15727 15787 15845 15901 15955 16008 16058 16107 16153 16197 16238 16277 16312 16344 16373 16397 16415 16426

167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195

7.47 7.35 7.23 7.11 6.98 6.85 6.72 6.58 6.43 6.29 6.13 5.97 5.80 5.63 5.44 5.25 5.05 4.84 4.62 4.38 4.12 3.85 3.55 3.22 2.85 2.41 1.87 1.02 0.00