ENERGY CONSERVATION IN STEAM TURBINE CYCLE

Presented By M.V.Pande Dy.Director NPTI, Nagpur

Costing of Thermal Power Generation

Major cost is fuel cost in thermal power generation

The fuel consumption can be reasonably brought down by conservation techniques

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210 MW KWU Steam Turbine Steam & Water Cycle

Steam Cycle For 210 Mw Unit

Principles Of Cycle Efficiency Improvement

Superheated or dry steam should not enter into condenser Wetness of steam at turbine exhaust should not exceed 12% Maximum possible temperatures at SH & RH outlet are used,however, restricted due to metallurgical constraints 560 0C

Principles Of Cycle Efficiency Improvement

The mean temperature of heat addition in boiler should be as high as possible so as to approach Carnot cycle process The temperature of heat rejection should be lowest possible to reduce heat rejection to condenser The throttling across turbine Stop & Control Valves Should be minimum
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500 MW Turbine Generator Unit

210 MW Utility Steam Turbine

LP Turbine IP Turbine HP Turbine Bearing Gen. End

Foundation

Condenser
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Barrel Casing Inner Casing

Balance Piston

Gland

Moving Blades

Steam Inlet

Barrel Type HP Turbine

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Steam Exhaust

Reaction Type KWU HP Turbine Rotor

Impulse-Reaction Type HPT Rotor

10 KWU LP Turbine Rotor

Thermal Process Losses

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Turbine Cycle Losses

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Controllable Plant Parameters

M.S. & R.H. Steam Temperatures M.S. Steam Pressure Condenser Vacuum Final Feed Water Temperature DP Across Feed Regulation Station Auxiliary Power Consumption Make Up Water Consumption
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Impact of Turbine Cylinder Efficiency on HR/Output

Description 1% HPT Efficiency Effect on TG HR 0.16% Effect on KW 0.3%

1% IPT Efficiency
1% LPT Efficiency

0.16%
0.5 %

0.16%
0.5 %

FOLLOW TEST CODES ASME PTC - 6 For Steam Turbines

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Effect Of Steam Parameters

H H

Effect of Changing Reheat Pressure

Effect of Changing Reheat Temp.

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Turbine Heat Rate & Efficiency Evaluation

Actual Process 1-2-3-4-5

Comparison of Actual Expansion with Isentropic Expansion in Turbine

Actual Expansion in HP, IP & LP 16 Cylinder

Turbine Heat Rate & Efficiency Evaluation

Turbine Heat Rate = Q1 x (H1 h2) + Q2 X (H3 H2) Gross Generator Output kCal/ kWh

Turbine Cycle Efficiency =

860

Heat Rate

X 100

Actual Heat Drop Cylinder Efficiency = ------------------------------ x 100 Isentropic Heat Drop

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Turbine Heat Rate Variation

Variation of Heat Rate with Load

Heat Rate Characteristics with 18 Condenser Exhaust Pressure

Turbine Efficiency Evaluation Data

Kcal/kg/oK

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Turbine Performance Monitoring

Indicators of Reduced Performance - Increase of turbine inlet Steam pressure - High exhaust steam temperature - Gland steam supply header leak-off valve opening increased - Increase of condenser back pressure - Higher MS flow at rated load - Increasing trend of bearing oil temperatures at outlet - Axial shift on higher side
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Steam Turbine Heat Consumption Test

These tests are conducted for acceptance

purpose or for routine assessment of turbine performance The objective of test is to determine required heat input to the turbine for an output on the machine The heat rate is calculated from the data & compared with optimum The tests are conducted at 40%,60%,80% & 100% load
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Heat Consumption vs Load

7% for throttle governed machines

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Cylinder Efficiency Factors

Cylinder Efficiency depends on Internal Losses occurring in the steam flow path inside the turbine + External Losses of steam through Glands & Mechanical Power Transmission Losses
Cylinder efficiency varies from 85 90%
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Internal Losses of Turbine

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Wetness Loss
This loss is incurred by moisture entrained in the low pressure steam towards exhaust stages of turbine This reduces the efficiency due to absorption of energy by water droplets The result is the erosion of leading edges of blades particularly at the tip Erosion cause the inlet blade angle to change & prevents tangential entry of steam
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IPT & LPT Blade Erosion Due To Moisture

IPT Last Stage Moving Blades

LPT Last Stage Moving Blades

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LPT Exhaust Losses

Residual Velocity or Leaving Loss - This loss is due to exhaust velocity of steam Leaving Loss=Ve2/2 J/Kg - This loss is reduced by increasing the last stage blade heights Exhaust Hood Loss - This loss is due to the turning of steam through 900 to enter the condenser. Loss is reduced by providing Diffusers at the exhaust 27

Diffuser

KWU Turbine LPT Inner Top-Half Casing

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Effect of Reheater Spray

Reduction of cycle efficiency due to fresh steam bypassing the HP turbine Reduction of power output from HP turbine due to reduction of steam flow through HP turbine Higher Silica deposition in IP & LP turbine
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Effects of Silica Deposition on Turbine

Silica deposition causes the passage areas between blades to progressively reduce Increases the first stage pressure of turbine progressively The Cylinder efficiency is reduced

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Remedies To Reduce Silica Deposition

Do not raise the boiler pressure until Silica level is normal Give Blow down as required Minimum use of superheater & reheater spray Steam washing of turbine by wet steam at low speeds

Silica in Steam with Boiler Pressure

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Feed Heaters Survey

Feed heaters survey evaluate the performance of heaters & predicts the deterioration causes Following parameters are noted down - Steam pressure at heater - Steam temperature at heater - Feed water inlet & outlet temperature - Heater drain temperature Evaluate the steam flow to each heater by heat balance Compare the flow values with optimum Calculate T.T.D. for each heater The results indicate following problems - The elevated TTDs on the heater train suggests water side contamination (oil) - The high steam flow to particular heater may be due to lower feed water inlet temperature, suggesting the problem in previous heater32

Turbine Pressure Survey

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Optimum Condenser Back Pressure

It is a misconception that minimum back pressure should be maintained at all loads The lower back pressure is justified only if the efficiency gain due to this is greater than power consumption of CW pumps & cooling tower fans With the reduction in condenser back pr. the isentropic heat drop across the last stage increases & so additional work is done in the turbine
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Optimum Condenser Back Pressure

Effect of lower exhaust pr. Volumetric flow rate increases ( high specific volume of steam),giving rise to more Leaving Losses Wetness Loss increases CW pumping power increases

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Optimum Condenser Back Pressure

Hence to overcome above problems optimum vacuum as shown in graph is maintained

Optimum Back Pressure at Full Load

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External Losses of Turbine

Shaft & Gland leakage loss -Steam leakage through labyrinth sealing at the turbine shaft end,which is about 3% of total steam flow. Loss increases in square proportion with increase in labyrinth clearances Journal & Thrust Bearing losses Governor & oil pump loss
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KWU HP Turbine Rotor

Admission Side Sealing

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Sliding Pressure Operation at Part Loads

In sliding pressure operation,the control valves are kept wide open & the pressure before the stop valves is varied through boiler to achieve required part load This reduces throttling losses across control valves The initial temperature is maintained at reduced pressure unlike throttling process The net effect is to improve cycle efficiency as compared to constant pressure operation
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Heat Saving By Sliding Pressure Operation

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Effect On Heat Rate For Parameter Deviation (500 MW Unit)

DEVIATION IN PARAMETER
1. HPT inlet press. by 5.0 ata 2. HPT inlet temperature by 10.0 deg C
3. IPT inlet temperature by 10.0 deg C 4. Condenser pressure by 10.0 mm of Hg 5. Re spray water quantity by 1.0% 6. HPT Cylinder efficiency by 1.0% 7. IPT Cylinder efficiency by 1.0%

EFFECT ON HEAT RATE (KCAL/KWH)

6.25 6.0
5.6 9.0 4.0 3.5 4.0
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