Turbine Performance EEC

STEAM TURBINE
PERFORMANCE
MONITIRING &
ANALYSIS
EEC WORKSHOP
25.09.2013-27.09.2013
WHAT STEAM TURBINE DOES
Steam Turbine gets Heat Energy in

the form of Superheated Steam from
Steam Generator
and converts it into mechanical
energy
to drive the Generator to generate
Electrical Energy
l
CONVERSION OF HEAT TO ELECTRICITY
1 KJ/S = 1 KW
3600 KJ/H = 1 KW
3600 KJ = 1 KWH
Heat Rate = 3600 KJ/KWH if 100%
Heat Energy could be converted into
Electricity
= 3600/4.1868 = 859.85 Kcal/KWH
l
Turbine Heat Rate as per

CERC
Pressure ata
150
170
170
247
247
SH/RH T degC
535/535
537/537
537/565
565/565
565/593
BFP Type
MDBFP
TDBFP
TDBFP
TDBFP
TDBFP
Heat Rate
Kcal/Kwh
1955
1950
1935
1900
1850
Efficiency = 859.85/1955 = 0.4398 = 43.98%

= 859.85/1850 = 0.4647 = 46.47%
We need to concentrate on Condenser where
this enormous energy is wasted to recover
whatever is possible
l
Condenser Vacuum versus MSL

Altitude
Barometric
Pressure
Barometric
Pressure
Condenser
Vacuum
metres
KPa
mmHg
Kg/cm2 g
Kpa g
mmHg g
101.32
760
-0.930
-91.2
-684
50
100.73
755.6
-0.924
-90.6
-679.6
100
100.13
751
-0.918
-90.0
-675.1
150
99.54
746.6
-0.912
-89.4
-670.6
200
98.95
742.2
-0.906
-88.8
-666.2
250
98.36
737.8
-0.9
-88.2
-661.8
300
97.77
733.4
-0.894
-87.6
-657.4
350
97.19
729
-0.888
-87.1
-653
400
96.61
724.7
-0.882
-86.5
-648.7
450
96.03
720.3
-0.876
-85.9
-644.3
500
95.45
716
-0.87
-85.3
-640
550
94.88
711.7
-0.864
-84.7
-635.7
Example of JSW Energy

Altitude metres
Condenser
Vacuum KPa
Vijaynagar
520
-85
Barmer
180
-89
Ratnagiri
50
-91
Lesson: Always convert gauge pressure to

absolute to analyse.
l
Effect of CW Inlet Temp

CW Temp
Kpa abs
Kpa g at
Ratnagiri
Kpa g at
Vijaynagar
33
10.2
-91.12
-85
32
9.69
-91.63
-85.51
31
9.21
-92.11
-85.99
30
8.74
-92.58
-86.46
27
7.46
-93.86
-87.74
34
10.73
-90.59
-84.47
35
11.29
-90.03
-83.91
36
11.87
-89.45
-83.33
37
12.47
-88.85
-82.73
38
13.11
-88.21
-82.09
Imprtance of CW Chlorination
If you are not getting Condenser
Vacuum check that residual Chlorine
is maintained.
If Condenser Vacuum deteriorates
after a few months after tube
cleaning it means Chlorination is not
being maintained
Measurement of Vacuum
If you compare Vacuum of two units and find a
difference of 1 Kpa i.e.
Unit 1 -90 Kpa
Unit 2 -89 Kpa
Before concluding check Condensate
Temperature in Hot well
Kpa g
Kpa abs
Sat Temp
Hotwell
Temp
-90
9.32
44.44
46
-89
10.32
46.43 is more
45 than Vacuum
Accuracy
of Hotwell
Temp
because Vacuum Transmitter is not calibrated
Calibration of Vacuum Transmitter
The C&I should have facility to

calibrate the Vacuum Transmitter
creating actual vacuum upto -96 Kpa
Monitoring of Condenser Fouling
Convert Vacuum gauge pressure to absolute

Determine Saturation Temperature for the
absolute pressure (Tsat)
Compare Tsat with Hotwell Temperature and
decide what to do
CW Outlet Temperature (To)
TTD of Condenser = Tsat-To
Compare TTD with the one noted after
Condenser Cleaning
Talk of poor Condenser Vacuum
This will generally start after Winter

season is over and you approach
summer and mansoon and people
will forget in Winter.
Because Wet Bulb Temperature is
maximum in mansoon.
10/09/13
Fuzeilentext
12
Effect on Heat Rate
10/09/13
Vacuum Kpa
Heat Rate
Kcal/Kwh
10.2
1950
Design
7.0
1911
2% Better
13.4
1999
2.5% Worse
15.0
2023
3.75% Worse
Fuzeilentext
13
Loss due to Make up

Heat Rate at 3% Make as per HBD
MS Flow = M1 MS Enthalpy = H1
FW Flow = Mf FW Enthalpy = Hf
RH Flow = M2 HRH Enthalpy = H3
CRH Enthalpy = H2
Generator Output = P
Heat Rate at 0% Make up = 1950
10/09/13
Supplier
Formula
Heat Rate
BHEL
(M1*(H1-Hf)+M2*(H3-H2))/P
1958
Chinese
(M1*H1-Mf*Hf+M2*(H3-H2))/P
1943
Actual
(Mf*(H1-Hf)+M2*(H3-H2))/P
1984
Fuzeilentext
14
Loss due to valve passing

This is a silent loss because it does not appear in
parameters.
Monitoring is done by temperature measurement on
downstreame (flash tank) side which is supposed to be
cold.
Passing through Main Steam, HP Bypass drain valves
may cause huge losses.
Loss due to Main Steam Pressure

Keeping Rated Main Steam Pressure results into
throttling loss.
Modern trend recommends Sliding Pressure Operation.
Pure Sliding Pressure Operation will result into
fluctuations in Load with Main Steam Pressure.
To reduce fluctuations a pressure buffer over Sliding
Pressure is used.
Loss due to partial

Loading
Load
Heat Rate
Kcal/Kwh
Loss Kcal/Kwh
100%
1950
80%
1990
40
60%
2064
114
40%
2201
251
VWO 106%
1943
-7
10/09/13
Fuzeilentext
17
Loss due to Low Reheat Temperature

Sometimes it is not possible to Maintain Hot Reheat Temperature
and there is loss:
Reheat Temperature
Loss Kcal/Kwh
Rated 538 degC
525
23
Summarize Losses
Design
1950
No Loss
CW Inlet 38
degC
1999
49
Make up 1%
2011
12
Loading
Factor 80%
2051
40
Low Reheat
Temperature
say 528 degC
2069
18
Total Loss
119

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STEAM TURBINE

WHAT STEAM TURBINE DOES

Steam Turbine gets Heat Energy in

CONVERSION OF HEAT TO ELECTRICITY

Turbine Heat Rate as per

Efficiency = 859.85/1955 = 0.4398 = 43.98%

Condenser Vacuum versus MSL

Example of JSW Energy

Lesson: Always convert gauge pressure to

Effect of CW Inlet Temp

Calibration of Vacuum Transmitter

The C&I should have facility to

Monitoring of Condenser Fouling

Convert Vacuum gauge pressure to absolute

Talk of poor Condenser Vacuum

This will generally start after Winter

Effect on Heat Rate

Loss due to Make up

Loss due to valve passing

Loss due to Main Steam Pressure

Loss due to partial

Loss due to Low Reheat Temperature

Rated 538 degC

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