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    4 EA Turbine Cycle

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    emre gedikli
    The document describes the methodology for conducting an energy audit of a turbine cycle. It discusses collecting operational data on steam and water parameters, measuring turbine efficiency, identifying factors that cause heat rate deviations, and evaluating the performance of feedwater heaters. The goal is to explore opportunities for improving energy conservation and reducing heat rate.

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    © All Rights Reserved
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    4 EA Turbine Cycle

    Uploaded by

    emre gedikli
    48 views33 pages
    The document describes the methodology for conducting an energy audit of a turbine cycle. It discusses collecting operational data on steam and water parameters, measuring turbine efficiency, identifying factors that cause heat rate deviations, and evaluating the performance of feedwater heaters. The goal is to explore opportunities for improving energy conservation and reducing heat rate.

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    343611997-4-EA-Turbine-Cycle

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    The document describes the methodology for conducting an energy audit of a turbine cycle. It discusses collecting operational data on steam and water parameters, measuring turbine efficiency, identifying factors that cause heat rate deviations, and evaluating the performance of feedwater heaters. The goal is to explore opportunities for improving energy conservation and reducing heat rate.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    48 views33 pages

    4 EA Turbine Cycle

    Uploaded by

    emre gedikli
    The document describes the methodology for conducting an energy audit of a turbine cycle. It discusses collecting operational data on steam and water parameters, measuring turbine efficiency, identifying factors that cause heat rate deviations, and evaluating the performance of feedwater heaters. The goal is to explore opportunities for improving energy conservation and reducing heat rate.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 33

    ENERGY AUDIT

    METHODOLOGY FOR
    FOR TURBINE CYCLE
    Presented By
    M.V.Pande
    Dy.Director
    NPTI, Nagpur
    COAL TO ELECTRICITY PROCESS
    STEAM CYCLE FOR 210 MW UNIT
    EFFECT OF STEAM PARAMETERS
    P1 P1
    P2
    P3 P1 P2
    T2
    T1 T3
    T2
    H T1
    T1
    H H

    S S
    S

    Effect of Increasing Effect of Increasing Effect of Increasing


    Pressure on Available Steam Temperature Steam Pressure &
    Energy On Available Energy Temperature Both on
    Available Energy
    EFFECT OF STEAM PARAMETERS

    H
    H

    S S

    Effect of Changing Reheat Pressure Effect of Changing Reheat Temp.


    THERMAL PROCESS LOSSES
    Impact of Turbine Cylinder Efficiency on
    HR/Output

    Description Effect on Effect on


    TG HR KW

    1% HPT Efficiency 0.16% 0.3%

    1% IPT Efficiency 0.16% 0.16%

    1% LPT Efficiency 0.5 % 0.5 %

    FOLLOW TEST CODES

    • ASME PTC - 6 For Steam Turbines

    • ASME PTC - 4.1 or BS- 845: 1987 for Boilers


    210 MW KWU STEAM TURBINE STEAM & WATER CYCLE
    TURBINE CYCLE LOSSES
    STEPS INVOLVED IN CONDUCTING THE
    TURBINE ENERGY AUDIT

    Data collection
    Observations and Analysis
    Exploration for energy conservation
    measures
    Report preparation
    DATA COLLECTION
    Design Specification of turbine and associated equipment:

     Type of the turbine, make and model


     Number of cylinders
     No of stages (for HP, IP and LP)
     No of main and reheat valves
     Construction details of HP, IP LP
     Turbine extraction systems
     Control systems
     Type of governing
     Type of sealing
     Year of installation
     Major modifications carried out during the recent past
    DATA COLLECTION

    Turbine Cycle Heat Rate Kcal/kwh


    DATA COLLECTION
    INSTRUMENTS REQUIRED

     Temperature Indicator & Probe


     Pressure gauges
     Flow measuring instrument (steam and
    water)
     Ultrasonic leak detector
    MEASUREMENTS & OBSERVATIONS TO BE MADE
     Feed water at Inlet & Outlet of Heaters
    Main steam parameters
    Pressure
     HP turbine extraction
    Temperature
     Hot reheat steam, Cold reheat Steam
    Flow
     IP extraction
     IP Exhaust
     Condenser back pressure
     Cooling water flow and temperatures
     Generator output
     Barometric pressure
     Reheater spray (flow)
     Superheater spray (flow)
     Feed water (flow)
    MEASUREMENTS & OBSERVATIONS TO BE MADE
     Past performance trends on turbine loading,
    operation, PLF
     Major constraint in achieving the high PLF, load or
    efficiency
     Major renovation and modifications carried out in the
    recent past
     Operational failures leading to inefficient operation
     Tripping
     Performance of associated equipment (condenser,
    boiler, etc)
     Plant side initiatives to improve the performance and
    efficiency of the Turbine
    TURBINE HR EVALUATION AND EFFICIENCY
     Turbine heat rate is defined as the heat input (Kcal)
    required to generate one unit of Electrical output (KWh). The
    trials are to establish heat rate (Kcal/kWh) and turbine
    efficiency under, as run conditions have to be carried out
     The efficiency method given in this procedure is the
    enthalpy drop efficiency method. This method determines the
    ratio of actual enthalpy drop across turbine section to the
    isentropic enthalpy drop
     This method provides a good measure for monitoring
    purposes. Each section of the turbine must be considered as
    a separated turbine
     Each section should be tested and results are trended
    separately. While conducting the tests, it has to be ensured
    that, it is conducted over normal operating load range
    TURBINE HR EVALUATION AND EFFICIENCY

    Q1 x (H1 – h2) + Q2 X (H3 – H2)


    Turbine Heat Rate =
    Gross Generator Output

    860 kW
    Turbine Cycle Efficiency = X 100
    Heat Rate kCal/hr
    TURBINE HR EVALUATION AND EFFICIENCY

    Actual
    Process
    1-2-3-4-5

    Comparison of Actual Expansion Actual Expansion in HP, IP & LP


    with Isentropic Expansion in Turbine Cylinder
    TURBINE HR EVALUATION AND EFFICIENCY

    Variation of Heat Rate with Load Heat Rate Characteristics with


    Condenser Exhaust Pressure
    TURBINE EFFICIENCY EVALUATION DATA

    Kcal/kg/oK
    Effect of Condenser Vacuum on
    Heat Rate

    10 MM HG IMPROVEMENT IN
    CONDENSER VACUUM
    LEADS TO 20 Kcal/kwh (1%)
    IMPROVEMENT IN HEAT RATE FOR A
    210 MW UNIT
    EFFECT ON HEAT RATE FOR PARAMETER
    DEVIATION (500 MW UNIT)
    DEVIATION IN PARAMETER EFFECT ON HEAT
    RATE (KCAL/KWH)
    1. HPT inlet press. by 5.0 ata 6.25
    2. HPT inlet temperature by 10.0 deg C 6.0

    3. IPT inlet temperature by 10.0 deg C 5.6

    4. Condenser pressure by 10.0 mm of Hg 9.0


    5. Re spray water quantity by 1.0% 4.0
    6. HPT Cylinder efficiency by 1.0% 3.5
    7. IPT Cylinder efficiency by 1.0% 4.0
    IDENTIFYING FACTORS FOR HR DEVIATION
    After evaluating the turbine heat rate and efficiency,
    check for the deviation from the design and identify the
    factors contributing for the deviations. The major factors
    to be looked into are:
     Main steam and reheat steam inlet parameters
     Turbine exhaust steam parameters
     Reheater and super heater spray
     Passing of high energy draining
     Loading on the turbine
     Boiler loading and boiler performance
     Operations and maintenance constraints
    IDENTIFYING FACTORS FOR HR DEVIATION

     Condenser performance and cooling water parameters


     Silica deposition and its impact on the turbine efficiency
     Inter stage sealing, balance drum and gland sealing
     Sealing fins clearances
     Nozzle blocks
     Turbine blade erosion
     Functioning of the valves
     Operational status of HP heaters
     Performance of reheaters
    FEED WATER HEATERS PERFORMANCE

    inlet

    inlet

    outlet

    0C
    FEED WATER HEATERS PERFORMANCE
    While collecting the heater wise parameters, collect
    the following data:
     Unit load MW
     Main steam pressure, temperature & flow
     Feed water flow
     Super heater & Reheater attemperation flow
     Boiler feed pump discharge pressure
     HP Heater levels
     Condenser vacuum, Barometric pressure
    FEED WATER HEATERS PERFORMANCE
    After the collecting the above data, evaluate the following
     Terminal temperature difference – TTD
     Heater drain cooler approach temperature difference – DCA
     Feed water temperature rise across heater – TR

    TTD = t sat – t fw outlet


    FEED WATER HEATERS PERFORMANCE
    DCA = t drains – t fw inlet

    TR = t outlet – t fw inlet
    HEATER PERFORMANCE DEVIATION
    Check following if TTD, DCA, TR are deviating from the
    design and actual rise in feed water temperature is low:
    High terminal temperature difference, TTD
     Excessive venting (worn vents, altered set point, vent
    malfunctioning)
     Excessive make up
     High water level (tube leaks, improper setting)
     Header partition leaks
     Non condensable gases on shell side
     Excessive tube bundle pressure drop (excessive number of
    tubes plugged, tubes folded internally)
    HEATER PERFORMANCE DEVIATION
    High drain cooler approach temperature, DCA
     Drain cooler inlet not submerged
     Low drain water level (improper setting, excessive FW
    heater drain bypass – bypass valve left open - bypass valve
    malfunctioning / leaking)
     Excessive tube bundle pressure drop (excessive number of
    tubes plugged / tubes folded internally)
     Feed water heater bypassed
     FW heater bypass valve leaking

    Note: Similar approach shall be followed for LP Heaters


    ADDITIONAL LOAD ON ECONOMIZER

    economizer

    Based on the above, if the HP heaters performance is poor,


    then additional load on economizer can be estimated by using
    the data sheet

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