Sample diagnostic — illustrative

Stage 1 Performance Diagnostic.
Sample Report.

A representative output for one coal-fired unit, derived entirely from that unit's own DCS historian over a comparable load window. Numbers are illustrative.

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Unit
500 MW subcritical
Window
14 days
Resolution
1–5 s
Method
Deterministic P10
Headline findings
Recoverable Value
₹21
lakh / day
Fuel-Intensity Gap
10.9
kg / MWh
Heat-Rate Gap
47
kcal / kWh (3.3%)
Excess Fuel
2.59
t / h
Method

Signals canonicalised from the plant historian: gross MW, coal flow, GCV, excess O₂, main-steam pressure and temperature, reheat parameters, feedwater flow and temperature.

Operating points binned into load bands. Within each band, the P10 of fuel intensity defines the unit's best-observed performance. Current operation is compared against this envelope, row by row.

Excess fuel and recoverable value follow directly from the deviation, the measured GCV, and the unit's current fuel cost. No external benchmarks.

Findings by load band
Load bandHoursFI currentFI bestGapExcess fuel
350–400 MW62612.4603.19.3 kg/MWh1.97 t/h
400–450 MW118598.7586.811.9 kg/MWh2.71 t/h
450–500 MW156586.2574.911.3 kg/MWh2.84 t/h

FI = fuel intensity (kg/MWh). Values illustrative.

Deliverables
  • Row-traceable workbook (signals → bands → P10 → gap → ₹/day)
  • Per-band envelope plots and drift indicators
  • Daily and periodic fuel deviation summary
  • Engineering review pack for plant performance team