Paper No.

626

Turbine and Boiler Modeling Application (Turbo PC) for Optimization of

Powerplant Heat Rate
Rahmat Dian Amir, Zulham
PT. PLN (Persero) Pembangkitan Sumatera Utara, Medan, Indonesia
Rahmatdian.amir@gmail.com, joule059@gmail.com

ABSTRACT

Turbo PC is application to improve company performance, which aims to calculate the efficiency of turbine
and boiler quickly, accurately, and user friendly. This application has been applied to Tarahan and Labuhan Angin
Steam Power Plant. By using this Turbo PC Turbo PC, the process of calculating the efficiency of boiler-turbine
becomes more practical (ONE CLICK), accurate, and fast when compared to the manual through steam & water
properties tables that takes up to 10 hours. The use of Turbo PC Turbo PC can improve the performance of the
company through the perspective of efficiency improvement. Before using the Turbo PC Turbo PC KPI plant
efficiency improvement, especially maturity model based normalization is still at level 2, which is "obtained the
calculation of sub-optimized model”. The accuracy of these calculations is often questionable. This means that the
correctness of the calculation is still doubtful because it still uses conventional ways that are not practical that allows
a lot of errors (human error). By implementing Turbo PC Turbo PC, maturity model based normalization has increased
to level 4, "Optimization model based on normalization". The efficiency team is able to make minor changes to the
model when necessary. " In terms of financial, indirectly this Turbo PC can identify in detail the loss of energy in
Turbine and Boiler, so that action opportunities can be done to provide saving cost to the company.

KEYWORD : TURBOPC, HEATRATE, MODELLING

1 INTRODUCTION
Turbo PC is used for performance of monthly performance test in order to support KPI asset management
program of plant efficiency improvement. With Turbo PC, the calculation of efficiency can be done quickly and
accurately, by inputting the data parameters of boiler and turbine operations, such as mass flow rate, pressure,
temperature, and so on.
The purpose of making this Turbo PC is to create a calculator boiler and turbine efficiency devices that are
fast, accurate, and user friendly and prepared for the performance test performance of PLTU. The benefits obtained
are to facilitate the operation of the plant efficiency engine and the generator unit operator in calculating and analyzing
the efficiency of boiler and turbine power plant, by inputting the parameters of actual operation.
This Turbo PC is custom designed specifically to calculate the efficiency of boiler and turbine power plant,
can be used on other PC & CFB boilers, with a few modifications.
The manufacture of Turbo PC covers the following stages: data and formula collection, Formulation: Mass
system of power & energy PLTU, Steam table calculation, Perfomance Test Boiler and Turbine. Application to the
programming language, Design, and Testing.

2. Basics of Turbo PC
2.1 Thermal Power Plant Cycle
The power plant work cycle is a closed cycle can be described with a T - s (temperature - entropy) diagram.
This cycle is the application of simple rankine cycles, which can generally be described in the following figure.

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Figure 1. power plant work cycle

Process :
1 – 2 : isentropic compression
2 – 3 : boiling & vapourizing
3 – 4 : isentropic expansion
4 – 1 : condensation

Figure 2. T-s Rankine Cycle Diagram

In general the efficiency of simple Rankine thermal cycles can be defined as follows:
ௐ̇ ೟ೠೝ್೔೙ ି ௐ̇ ೛ೠ೘ ೛
ηthermal = (1)
ொ̇ ೔೙

ܳ̇ ௜௡ = ݉̇ (ℎଶ − ℎଷ) ܹ̇ ௣௨௠ ௣ = ݉̇ (ℎଶ − ℎଵ) (2)

̇ ௢௨௧ = ݉̇ (ℎସ − ℎଵ)
ܳ ܹ̇ ௧௨௥௕௜௡ = ݉̇ (ℎଷ − ℎସ) (3)

With : - W = power, kJ/s

- Q = Heat, kJ/s
- ݉̇ = mass flow, kg/s
- h = enthalpy = f (P,T), kJ/kg

2.2 Turbine Efficiency

Turbine efficiency is the maximum work that a turbine can provide to absorb the kinetic energy of
superheated steam, reduced by mechanical and thermodynamic losses. In reference books, articles, and journals,

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turbine efficiency is calculated by comparison between actual turbine power with isentropic turbine power (constant
entropy). So that the efficiency of turbine can be said as isentropic efficiency (isentropic efficiency).

Figure 3. Actual Expansion Process and Isentropic Expansion of Steam Turbine

Assuming that the heat transfer between the turbine and the environment is negligible, the turbine turbine
power becomes:
ௐ̇
ቀ௠̇೟ቁ = ℎଵ − ℎଶ,௦ (4)
௦

So that the turbine isentropic efficiency can be defined as follows.

ௐ̇ ೟ ௛భି ௛మ
ߟ௧ = = (5)
(ௐ̇ ೟)ೞ ௛భି ௛మ,ೞ

௉̇ ೒೐೙೐ೝೌ೟೚ೝ
ߟ௧ீ = (6)
ௐ̇ ೟,ೞ

2.3 Boiler Efficiency

Understanding of boiler efficiency is how much boiler ability to change the value of coal energy into heat
energy. There are two approaches to calculating boiler efficiency:
a. Direct Method
This method is an old model approach (started rarely used since the 1950s). This approach obtains an efficiency
value by measuring the amount of heat present in the vapor, and comparing it with the amount of heat supplied
by the coal material.

Figure 4. Heat Balance Scheme In Boilers Without Loss

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௛௘௔௧௢௨௧௣௨௧
ߟ௕ = ‫ ݔ‬100% (7)
௛௘௔௧௜௡௣௨௧
௦௧௘௔௠ ௙௟௢௪ ௥௔௧௘ ௫ (௦௧௘௔௠ ௘௡௧௛௔௟௣௬ି௙௘௘ௗ௪ ௔௧௘௥ ௘௡௧௛௔௟௣௬)
ߟ௕ = (8)
௙௨௘௟௙௜௥௜௡௚ ௥௔௧௘ ௫ ௚௥௢௦௦௖௔௟௢௥௜௙௜௖ ௩௔௟௨௘
ொ ௫ (ு ି௛)
ߟ௕ = ‫ ݔ‬100% (9)
௤ ௫ ீ஼௏

Q = steam mass rate, kg/s

q = rate of fuel mass consumed, kg/s
H = steam enthalpy, kCal/kg
h = feed water enthalpy, kCal/kg
GCV = fuel gross calorific value, kCal/kg

The advantages of this method:

- The calculation is easier. From the vapor aspect, by looking at the indicators of steam parameters (flow, pressure,
temperature), then seen in the steam table, can be obtained nialai steam heat. While from the fuel aspect, just
looking at the net calorific value data per fuel mass (LHV) and multiplying by the amount of fuel mass, will bias
get the potential value of fuel calor.
- Does not require a complicated measuring instrument, simply utilize the meter installed in the boiler.
The disadvantages of this method:
- The value of error is large, where the accuracy of measuring instruments (instrumentation) greatly affect the
measurement results.
- Not knowing the source of the losses component (loss) of the boiler, so it can not take steps to reduce the losses
of the boiler.

b. Indirect Method
In this method, the boiler efficiency value is calculated by measuring the amount of heat potential of the fuel
(LHV) and reducing it with the losses contained in the boiler. Various types of heat losses that may appear in the
boiler can be seen in the following figure.

Figure 5. Heat Balance Scheme In Boiler with Loss

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There are 8 losses based on the calculation of the indirect method:

1. Dry Flue Gas Losses (loss due to dry exhaust gas)
This loss occurs because the exhaust gas temperature is still high enough after passing the Air Heater (the initial
air heater) compared with the ambient air (ambient temperature). This high temperature carries a high enough
temperature, but can not be used for boilers anymore.
2. Hydrogen in Fuel Losses
This loss occurs because of the moisture heating that is formed from the hydrogen reaction contained in the fuel
with air.
3. Moisture in Fuel Losses
This loss occurs due to the presence of steam in the exhaust gases, which arise from the warming of water content
contained in the fuel.
4. Moisture in Air Losses
This loss occurs due to the presence of steam in the exhaust gases, which arise from the warming of water content
contained in the air.
5. CO Losses
6. Surface radiation & convection Losses
7. Fly Ash Losses
This loss occurs because there is still carbon in the burning ash wasted with the flue gas.
8. Bottom Ash Losses
This loss occurs because there is still carbon in the burning ash wasted in the solid drain material channel of the
boiler.
ηb = 100% - (L1 + L2 + L3 + L4 + L5 + L6 + L7 + L8) (10)

The advantages of this method are:

- The accuracy of this approach is quite good, the accuracy of the measuring instrument is small enough to affect
the value of efficiency.
- This approach not only measures efficiency but also measures large boiler losses.
The disadvantages of this method are:
- Complex analysis is needed, in terms of analysis of the amount of air entering, and exhaust gases from the boiler.

2.4 Formulasi Enthalpy

The amount of power generated or absorbed by an energy conversion machine such as a turbine or a pump
depends on how much energy (enthalpy) is contained in the fluid through which it is in the initial and final phase of
the process. The amount of enthalpy contained in a moving fluid can be calculated through the pressure and
temperature parameters that occur. This means that enthalphy is a function of pressure and temperature, f (p, T).
The elaboration of the formula enthalpy properties of water and steam to be copied on VB will use the
International Formulation 1997 International Association Properties Water and Steam (IAPWS) referral. The
definition of fluid boundary conditions at certain pressures and temperatures based on IAPWS IF-97 can be explained
in the p-T diagram of Figure 6. The p-T diagram is illustrated with the following pressure and temperature constraints.
273.15 K ≤ T ≤ 1073.15 K p ≤ 100 MPa
1073.15 K < T ≤ 2273.15 p ≤ 50 MPa
This restriction is taken, since pressure and temperature are most likely to be in that range.

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Figure 6. P-T Diagram Identification of Boundary Condition

Figure 6 above comes from a three-dimensional p, v, T diagram projected bi-dimensionally into p, T and
p-v diagrams, as in the following figure.

Figure 7. Projection p-v-T Diagram Become a p-T Diagram and a p-v Diagram
Enthalpy in regions 1, 2, and 5 (high temperature) were developed using the fundamental equation of Gibbs
free energy g (p, T). In region 3 is calculated using the fundamental equation of free energy Helmholtz (Helmholtz
free energy). While region 4 is saturation line (saturation line).
Region 1
The boundary condition of region 1 based on Figure 6 is defined as follows.
273.15 K ≤ T ≤ 623.15 K ps ( T ) ≤ p ≤ 100 MPa
The formula of enthalpy calculation :
(11)

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(12)

Region 2
The boundary condition of region 2 based on Figure 6 is defined as follows.
273.15 K ≤ T ≤ 623.15 K 0 < p ≤ ps ( T )
623.15 K < T ≤ 863.15 K 0< p ≤ p(T)
863.15 K < T ≤ 1073.15 K 0 < p ≤ 100 MPa
The formula of enthalpy calculation :

(13)

(14)

Region 3
The boundary condition of region 3 based on Figure 6 is defined as follows.
623.15 K ≤ T ≤ T ( p ) p ( T ) ≤ p ≤ 100 MPa
The formula of enthalpy calculation :

(15)

(16)

Region 4
The boundary condition of region 4 based on Figure 6 is defined as follows.
611.213 Pa ≤ p ≤ 22.064 MPa
273.15 K ≤ T ≤ 647.096 K
The formula of enthalpy calculation :

(17)

(18)

With, T = Tsat

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Region 5
The boundary condition of region 5 based on Figure 6 is defined as follows.
1073.15 K ≤ T ≤ 2273.15 K 0 ≤ p ≤ 50 MPa
The formula of enthalpy calculation :

(19)

(20)

The enthalpy formulas in various regions and their boundary conditions are then programmed according to
the logic of the programming language (if-then). When the worksheet in Microsoft Visual Basic is done, just by
entering the pressure and tempertaur data, Turbo PC will automatically calculate the enthalpy generated and provide
information on whether the fluid is in the subcooled, compressed liquid, saturated (liquid, vapour) or superheated.
Then through the efficiency formula that has been programmed, Turbo PC automatically will calculate the value of
turbine efficiency that occurs by entering the mass flow rate data.

4 Turbine and Boiler Modeling Application (Turbo PC)

Below is a Turbo PC layout view of Steam Table counters, turbine efficiency, boiler efficiency, database and
completed reporting designed.

4.1 Steam Table

With a data input temperature (T) and pressure (P) and press the calculate button, the obtained data from
T and P.

1. Input data T

2. Input data P

3. Calculate click

4. Obtained Data

Figure 8. Water and Steam Properties Display Turbo PC

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4.2 Turbine Performance Test Calculation

By inputting Temp (T), Pressure (P) data and other data on white box, one click will get the result of gross
turbine performance test.

1. Input data in white box 2. Click “calculate” 3. Obtain individual Turbine test results

Figure 9. Screen Display of Gross Turbine Efficiency Calculation

Performance test results can be stored into the data base, can print any time a report, or trending graph
3.4 Energy Performnce Assesment Boiler
By inputting data and data in the white box, then with one click obtained the results of the performance test
boiler.

2. Input data in white box 3. Click “calculate” 3. Obtain individual Turbine test results

Figure 10. Screen Display of Boiler Efficiency Calculation

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Performance test boiler results can be stored into the data base, can print any time a report, or trending graph
4.5 Other Turbo PC Facilities
Turbo PC Turbo PC is also equipped with a calculation of the efficiency of Boiler Turbine in direct methode and
converter (Caloric, Concentration, Energy, Pressure and others

4.6 Benefits
1. Non-financial benefits
Nonfinancial benefits that can facilitate the work of plant efficiency engine and generator unit operator in
calculating and analyzing the efficiency of boilers and turbines PLTU Tarahan, by inputting the actual operating
parameters as desired
2. Financial Benefits.
Financially indirect Turbo PC is able to identify in detail the loss of energy in Turbine and Boiler quickly, so can
be done opportunities for improvement actions that provide saving cost to the company. Besides, when purchased
the same Turbo PC in the Turbo PC market, will require a large cost as well.

5. Conclusion
1. By using Turbo PC Turbo PC, the process of calculating the efficiency of boiler-turbine PLTU Tarahan project
to be more simple and faster when compared with the manual through the table properties steam & water, and
when compared with the Turbo PC commercial on the market that only calculate the physical properties of fluids
such as enthalpy, inner energy, specific volume, and so on.
2. Indirectly, this Turbo PC can also be used to calculate the efficiency of turbine-boiler PLTU Pulverized and other
CFB plants, with only a few modifications to programming.

REFERENCE
[1] ALSTOM Power Inc, Design and Operational Manual Steam Generator and Auxilaries, 2008
[2] Babcock & Wilcox, Steam its Generation and Use. 1992. USA
[3] Charles E Baukal, The John Zink Combution Hand Book, Tulsa-Oklahoma
[4] Fox, R.T., McDonald, A.T., Introduction to Fluid Mechanics John Wiley & Sons,Inc , 1994
[5] Gilchrist J. D. Fuels, Furnaces and Refractories, 1977
[6] Perry.”Chemical Water handbook”. 1999. Mc. Graw Hill Company
[7] P. Basu, Combustion and Gasification in Fluidized Bed. Boca Raton: Taylor and Francis, 2005
[8] PT. PLN (Persero) Sektor Pembangkitan Tarahan, BUKU OPERASIONAL & MAINTENANCE PLTU
CFB TARAHAN , 2008
[9] PT. PLN (Persero) Proyek Induk Pembangkit Dan Jaringan Sumatera Selatan, Jambi, Lampung, Bengkulu,
Bangka Belitung, Sumatera Barat, Riau, STEADY-STATE CFB PERFORMANCE TEST PROCEDURE ,
2007
[10] School of Engineering and Materials Science, The International Association for the Properties of Water and
Steam, Lucerne, Switzerland, August 2007
[11] Williams, F. A., Combustion Science and Engineering Series, Combustion Theory
The Fundamental Theory of Chemically Reacting Flow Systems, 1985

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