Instructions

This model is meant to calculate the OEE (Overall Equipment Efficiency) of a Boiler primarily based on the Direct Method of Calculation

Working of the Model

2. Other details need to filled in the worksheet "Output_OEE_Boiler" where the effectiveness of the Boiler is calculated and the GAP with respect to the Rated Boiler Efficiency is also calculated.3. The worksheet "Steam_Table_Lookup" is a look up Table to locate the enthaply values for Feedwater and Steam as per the Temperature and Pressure measured respectively.

1. The Boiler Running-in Data needs to be filled in the Worksheet "Input_Machine_Running_In_Data" after the user has selected the frequecny of calculation of the OEE for the Boiler. The Data has to be filled Datewise. The Dates are used only for the purpose of referncing and do not hold implications in the efficiency calcultaions.

This model is meant to calculate the OEE (Overall Equipment Efficiency) of a Boiler primarily based on the Direct Method of Calculation

2. Other details need to filled in the worksheet "Output_OEE_Boiler" where the effectiveness of the Boiler is calculated and the GAP with respect to the Rated Boiler Efficiency is also calculated.3. The worksheet "Steam_Table_Lookup" is a look up Table to locate the enthaply values for Feedwater and Steam as per the Temperature and Pressure measured respectively.

1. The Boiler Running-in Data needs to be filled in the Worksheet "Input_Machine_Running_In_Data" after the user has selected the frequecny of calculation of the OEE for the Boiler. The Data has to be filled Datewise. The Dates are used

Boiler Running-In Data

Fortnightly

Uptime Downtime

Date Hours Minutes Date Hours Minutes

8-Apr-23 22 30 8-Apr-23 2 30

7-Apr-23 7-Apr-23

6-Apr-23 6-Apr-23

5-Apr-23 5-Apr-23

4-Apr-23 4-Apr-23

3-Apr-23 3-Apr-23

2-Apr-23 2-Apr-23

1-Apr-23 1-Apr-23

31-Mar-23 31-Mar-23

30-Mar-23 30-Mar-23

29-Mar-23 29-Mar-23

28-Mar-23 28-Mar-23

27-Mar-23 27-Mar-23

26-Mar-23 26-Mar-23

25-Mar-23 25-Mar-23

Frequency at whichOEE is to be analysed

Instructions: If the Frequency is daily, then the values for Uptime & donwntime will be picked from cells A6 to F6. If the Frequency is Weekly then the values will be picked up from cell Range A6 to F12, similarly if the Frequency is Fortnightly then the values will be picked up from cell Range A6 to F20 and finally if the Frequency is Monthly then the values will be picked up from cell Range A6 to F36

Cumulative Numbers

Hours Minutes

Total Uptime 22 30

Total Downtime 2 30

Instructions: If the Frequency is daily, then the values for Uptime & donwntime will be picked from cells A6 to F6. If the Frequency is Weekly then the values will be picked up from cell Range A6 to F12, similarly if the Frequency is Fortnightly then the values will be picked up from cell Range A6 to F20 and finally if the Frequency is Monthly then the values will be picked up from cell Range A6 to F36

Input Machine Oil Consumption Data

Fortnightly 1

Tank 1 Tank 2

Date Reading In Cms Date

8-Apr-23 0 10 1 1 8-Apr-237-Apr-23 0 0 0 7-Apr-236-Apr-23 0 0 0 6-Apr-235-Apr-23 0 0 0 5-Apr-234-Apr-23 0 0 4-Apr-233-Apr-23 0 0 3-Apr-232-Apr-23 0 0 2-Apr-231-Apr-23 0 0 1-Apr-23

31-Mar-23 0 0 31-Mar-2330-Mar-23 0 0 30-Mar-2329-Mar-23 0 0 29-Mar-2328-Mar-23 0 0 28-Mar-2327-Mar-23 0 0 27-Mar-2326-Mar-23 0 0 26-Mar-2325-Mar-23 0 0 25-Mar-2324-Mar-23 0 0 24-Mar-23

0 00 00 00 00 00 00 00 00 00 00 00 00 00 00 0

Frequency at whichOEE is to be analysed

Total Consumption for the Frequency Selected in Cms

Refill done in Ltrs

Refill done in Cms

Consumption in Cms

Input Machine Oil Consumption Data

10

Tank 2

Reading In Cms Refill done in Ltrs Refill done in Cms

0 0 10 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 0

Total Consumption for the Frequency Selected in Ltrs

Cumulative Consumption of the

Tanks in CmsConsumption in Cms

Feedwater Temperature Data

Frequency Selected for the OEE Evaluation Fortnightly

Average Feedwater Temperature

Date Hourly Temperature Record in Degree CelsiusTime 0:00 1:00 2:00 3:00 4:00 5:00 6:00 7:00

8-Apr-23 100 100

7-Apr-23

6-Apr-235-Apr-234-Apr-233-Apr-232-Apr-231-Apr-23

31-Mar-2330-Mar-2329-Mar-2328-Mar-2327-Mar-2326-Mar-2325-Mar-23

Feedwater Temperature in Degree Celsius

Average Feedwater Temperature

100.00 Degree Celsius

Hourly Temperature Record in Degree Celsius8:00 9:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00

Hourly Temperature Record in Degree Celsius17:00 18:00 19:00 20:00 21:00 22:00 23:00

100

000000000000000000000000000000

Average Temperature for the Day in Celsius

Output Steam Pressure Data

Frequency Selected for the OEE Evaluation Fortnightly

Average Output Steam Pressure

Date Hourly Pressure Record in BarsTime 0:00 1:00 2:00 3:00 4:00 5:00 6:00 7:00

8-Apr-23 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5

7-Apr-23

6-Apr-235-Apr-234-Apr-233-Apr-232-Apr-231-Apr-23

31-Mar-2330-Mar-2329-Mar-2328-Mar-2327-Mar-2326-Mar-2325-Mar-23

Pressure of the generated Steam in Bars

Average Output Steam Pressure

8.50 Bar

Hourly Pressure Record in Bars8:00 9:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00

8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5

Hourly Pressure Record in Bars17:00 18:00 19:00 20:00 21:00 22:00 23:00

8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5

000000000000000000000000000000

Average Pressure for the Day in Bars

OEE Calculations

Input Data

Average Temperature of Feedwater in Degree Celcius 100 Degree Celsius

9 Bar

Total amount of Fuel Consumed 9.00 Kg

Please enter the Gross Calorific Value of the Fuel Used by the Boiler in Kcal/KG 3200.0000 Kcal/Kg

25.00 Tonnes

Quantity of Steam Generated in Tonnes Per Hour (TPH) 0.0694444444444445 TPH

Quantity of Fuel Consumed for Steam Generation in Tonnes Per Hour (TPH) 0.025 TPH

Output Parameters

Availability of the Boiler 90.00%Performance of the Boiler 48.67%Quality of the Output (An Assumption) 100.00%

OEE (Overall Effectiveness of the Boiler) 43.81%

Average pressure of steam in Bar of Kg/cm3

Please enter the Quantity of steam (in tonnes ) generated during the period in which the OEE is to be calculated

Input Data

Output Parameters

Steam Look Up Table

Look Up Values for Feedwater Look Up Values for Steam

Enthalpy in KJ/kg

0.01 0.01 0.0024 0.04 25544 16.79 3.9976 0.06 25675 21 5.0000 0.08 25776 25.21 6.0024 0.1 25858 33.61 8.0024 0.2 261010 42.01 10.0024 0.3 262511 46.19 10.9976 0.4 263712 50.4 12.0000 0.5 264613 54.59 12.9976 0.6 265314 58.8 14.0000 0.7 266015 62.99 14.9976 0.8 266616 67.17 15.9929 0.9 267117 71.36 16.9905 1 267518 75.57 17.9929 1.5 269419 79.76 18.9905 2 270720 83.94 19.9857 3 272521 88.13 20.9833 4 273922 92.32 21.9810 5 274923 96.5 22.9762 6 275724 100.7 23.9762 7 276425 104.9 24.9762 8 276926 109 25.9524 9 277427 113.2 26.9524 10 277828 117.4 27.9524 20 280029 121.6 28.9524 30 280430 125.8 29.9524 40 280131 130 30.9524 50 279432 134.1 31.9286 60 278433 138.3 32.9286 70 277234 142.5 33.9286 80 275835 146.7 34.9286 90 274236 150.8 35.9048 100 272538 159.2 37.9048 110 270640 167.5 39.8810 120 268545 188.4 44.8571 130 266250 209.3 49.8333 140 263855 230.2 54.8095 150 261160 251.1 59.7857 160 258165 272 64.7619 170 254770 293 69.7619 180 251075 313.9 74.7381 190 246580 334.9 79.7381 200 241185 355.9 84.7381 220.9 209990 376.9 89.738195 398 94.7619100 419 99.7619110 461.3 109.8333120 503.7 119.9286130 546.3 130.0714140 589.1 140.2619

Temperature in Degree Celcius

Enthalpy in KCal/kg

Pressure in Bar or Kg/cm3

Enthalpy in KJ/kg

150 632.2 150.5238160 675.5 160.8333170 719.2 171.2381180 763.2 181.7143190 807.6 192.2857200 852.4 202.9524210 897.8 213.7619220 943.6 224.6667230 990.1 235.7381240 1037.3 246.9762250 1085.3 258.4048260 1134.4 270.0952270 1184.5 282.0238280 1236 294.2857290 1289 306.9048300 1344 320.0000320 1461.5 347.9762340 1594.1 379.5476360 1760.5 419.1667

374.14 2099.3 499.8333

Look Up Values for Steam

608.0952611.1905613.5714615.4762621.4286625.0000 100 Degree Celsius627.8571 9 Bar630.0000631.6667 Enthalpy of Feedwater in Kcal/Kg 99.7619 Kcal/Kg633.3333 Enthalpy of Steam in Kcal/Kg 660.4761905 Kcal/Kg634.7619635.9524636.9048641.4286644.5238648.8095652.1429654.5238656.4286658.0952659.2857660.4762661.4286666.6667667.6190666.9048665.2381662.8571660.0000656.6667652.8571648.8095644.2857639.2857633.8095628.0952621.6667614.5238606.4286597.6190586.9048574.0476499.7619

Enthalpy in KCal/kg

Temperature of Feedwater in 0cPressure of steam in Bar or Kg/cm3

MATHEMATICAL CALIBERATION CHART OF TANK ( Furnace Oil)Dia = 1950 mm Length=5500mm. Capacity =16426 Ltrs.

Look Up Values for Fuel Quantity DIP versus QTYDIP cm. QTY. Ltrs Ltrs/mm. QTY. Ltrs

0 0 1.02 01 10 1.87 102 29 2.41 293 53 2.85 534 81 3.22 815 114 3.55 1146 149 3.85 1497 188 4.12 1888 229 4.38 2299 273 4.62 27310 319 4.84 31911 367 5.05 36712 418 5.25 41813 470 5.44 47014 525 5.63 52515 581 5.80 58116 639 5.97 63917 699 6.13 69918 760 6.29 76019 823 6.43 82320 887 6.58 88721 953 6.72 95322 1020 6.85 102023 1089 6.98 108924 1159 7.11 115925 1230 7.23 123026 1302 7.35 130227 1375 7.47 137528 1450 7.58 145029 1526 7.69 152630 1603 7.79 160331 1681 7.89 168132 1760 7.99 176033 1840 8.09 184034 1920 8.19 192035 2002 8.28 200236 2085 8.37 208537 2169 8.45 216938 2253 8.54 225339 2339 8.62 233940 2425 8.70 242541 2512 8.78 251242 2600 8.86 260043 2688 8.93 268844 2778 9.00 277845 2868 9.07 286846 2958 9.14 295847 3050 9.21 305048 3142 9.27 314249 3234 9.34 3234

Look Up Values for Fuel Quantity DIP versus QTY

50 3328 9.40 332851 3422 9.46 342252 3516 9.51 351653 3611 9.57 361154 3707 9.63 370755 3803 9.60 380356 3900 9.73 390057 3998 9.70 399858 4090 9.83 409059 4194 9.88 419460 4292 9.92 429261 4392 9.97 439262 4491 10.01 449163 4591 10.05 459164 4692 10.09 469265 4793 10.13 479366 4894 10.17 489467 4996 10.20 499668 5098 10.24 509869 5200 10.27 520070 5303 10.31 530371 5406 10.34 540672 5509 10.37 550973 5613 10.39 561374 5717 10.42 571775 5821 10.45 582176 5926 10.47 592677 6030 10.50 603078 6135 10.52 613579 6241 10.54 624180 6346 10.56 634681 6452 10.58 645282 6557 10.60 655783 6663 10.61 666384 6770 10.63 677085 6876 10.64 687686 6982 10.66 698287 7089 10.67 708988 7196 10.68 719689 7302 10.69 730290 7409 10.70 740991 7516 10.70 751692 7623 10.71 762393 7730 10.72 773094 7838 10.72 783895 7945 10.72 794596 8052 10.72 805297 8159 10.72 815998 8266 10.72 826699 8374 10.72 8374100 8481 10.72 8481101 8588 10.72 8588102 8695 10.71 8695103 8802 10.70 8802104 8909 10.70 8909105 9016 10.69 9016106 9123 10.68 9123

107 9230 10.67 9230108 9337 10.66 9337109 9443 10.64 9443110 9550 10.63 9550111 9656 10.61 9656112 9762 10.60 9762113 9868 10.58 9868114 9974 10.56 9974115 10080 10.54 10080116 10185 10.52 10185117 10290 10.50 10290118 10395 10.47 10395119 10500 10.46 10500120 10604 10.42 10604121 10709 10.39 10709122 10813 10.37 10813123 10916 10.34 10916124 11020 10.31 11020125 11123 10.27 11123126 11225 10.24 11225127 11328 10.20 11328128 11430 10.17 11430129 11531 10.13 11531130 11633 10.09 11633131 11734 10.05 11734132 11834 10.01 11834133 11934 9.99 11934134 12034 9.92 12034135 12133 9.88 12133136 12232 9.83 12232137 12330 9.78 12330138 12428 9.73 12428139 12325 9.68 12325140 12622 9.63 12622141 12718 9.57 12718142 12814 9.51 12814143 12909 9.46 12909144 13004 9.40 13004145 13098 9.34 13098146 13191 9.27 13191147 13284 9.21 13284148 13376 9.14 13376149 13467 9.07 13467150 13558 9.00 13558151 13648 8.93 13648152 13737 8.86 13737153 13826 8.78 13826154 13914 8.70 13914155 14001 8.62 14001156 14087 8.54 14087157 14172 8.45 14172158 14257 8.37 14257159 14341 8.28 14341160 14423 8.19 14423161 14505 8.09 14505162 14586 7.99 14586163 14666 7.89 14666

164 14745 7.79 14745165 14823 7.69 14823166 14900 7.58 14900167 14975 7.47 14975168 15050 7.35 15050169 15124 7.23 15124170 15196 7.11 15196171 15267 6.98 15267172 15337 6.85 15337173 15405 6.72 15405174 15473 6.58 15473175 15538 6.43 15538176 15603 6.29 15603177 15666 6.13 15666178 15727 5.97 15727179 15787 5.80 15787180 15845 5.63 15845181 15901 5.44 15901182 15955 5.25 15955183 16008 5.05 16008184 16058 4.84 16058185 16107 4.62 16107186 16153 4.38 16153187 16197 4.12 16197188 16238 3.85 16238189 16277 3.55 16277190 16312 3.22 16312191 16344 2.85 16344192 16373 2.41 16373193 16397 1.87 16397194 16415 1.02 16415195 16426 0.00 16426

MATHEMATICAL CALIBERATION CHART OF TANK ( Furnace Oil)

Look Up Values for Fuel Quantity DIP versus QTYDIP cm. Ltrs/mm.

0 1.021 1.872 2.413 2.854 3.225 3.556 3.857 4.128 4.389 4.62

10 4.8411 5.0512 5.2513 5.4414 5.6315 5.8016 5.9717 6.1318 6.2919 6.4320 6.5821 6.7222 6.8523 6.9824 7.1125 7.2326 7.3527 7.4728 7.5829 7.6930 7.7931 7.8932 7.9933 8.0934 8.1935 8.2836 8.3737 8.4538 8.5439 8.6240 8.7041 8.7842 8.8643 8.9344 9.0045 9.0746 9.1447 9.2148 9.2749 9.34

50 9.4051 9.4652 9.5153 9.5754 9.6355 9.6056 9.7357 9.7058 9.8359 9.8860 9.9261 9.9762 10.0163 10.0564 10.0965 10.1366 10.1767 10.2068 10.2469 10.2770 10.3171 10.3472 10.3773 10.3974 10.4275 10.4576 10.4777 10.5078 10.5279 10.5480 10.5681 10.5882 10.6083 10.6184 10.6385 10.6486 10.6687 10.6788 10.6889 10.6990 10.7091 10.7092 10.7193 10.7294 10.7295 10.7296 10.7297 10.7298 10.7299 10.72100 10.72101 10.72102 10.71103 10.70104 10.70105 10.69106 10.68

107 10.67108 10.66109 10.64110 10.63111 10.61112 10.60113 10.58114 10.56115 10.54116 10.52117 10.50118 10.47119 10.46120 10.42121 10.39122 10.37123 10.34124 10.31125 10.27126 10.24127 10.20128 10.17129 10.13130 10.09131 10.05132 10.01133 9.99134 9.92135 9.88136 9.83137 9.78138 9.73139 9.68140 9.63141 9.57142 9.51143 9.46144 9.40145 9.34146 9.27147 9.21148 9.14149 9.07150 9.00151 8.93152 8.86153 8.78154 8.70155 8.62156 8.54157 8.45158 8.37159 8.28160 8.19161 8.09162 7.99163 7.89

164 7.79165 7.69166 7.58167 7.47168 7.35169 7.23170 7.11171 6.98172 6.85173 6.72174 6.58175 6.43176 6.29177 6.13178 5.97179 5.80180 5.63181 5.44182 5.25183 5.05184 4.84185 4.62186 4.38187 4.12188 3.85189 3.55190 3.22191 2.85192 2.41193 1.87194 1.02195 0.00