JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY

HYDERABAD

STEAM TURBINES OPERATION, PERFORMANCE AND ITS TROUBLE SHOOTING

Submitted to Jawaharlal Nehru Technological University, Hyderabad in partial fulfillment Of Bachelor Of Technology in Mechanical Engineering.

Submitted By N. SHRAVAN KUMAR (09D41A0374) B. VIKRAM SENA YADAV (09D41A0375) I. RAJASEKHAR (09D41A03B1)

Under the Guidance of

Mr. M SRINIVAS RAO

HOD

DEPARTMENT OF MECHANICAL ENGINEERING

SRI INDU COLLEGE OF ENGINEERING AND TECHNOLOGY, IBRAHIMPATNAM, RR DIST

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
Certified that the project work entitled STEAM TURBINES OPERATION, PERFORMANCE AND ITS TROUBLE SHOOTING which is a bonafide work carried out by Mr. N SHRAVAN KUMAR, Mr. B VIKRAM SENA YADAV, Mr. I RAJA SEKHAR, bearing register Nos. 09D41A0374, 09D41A0375 09D41A03B1, in partial fulfillment for the award of the degree of Bachelor of Technology in MECHANICAL ENGINEERING of Jawaharlal Nehru Technological University, Hyderabad during the year 2012-2013. It is certified that all corrections/suggestions indicated for internal assessment have been incorporated in the report. The project report has been approved as it satisfies the academic requirements in respect of project work prescribed for the said degree.

Guide

Head of the Department

Principal

Examiner 1

Examiner 2

ANDHRA PRADESH POWER CORPORATION LIMITED

GENERATION

Dr. NARLA TATA RAO THRMAL POWER STATION

CERTIFICATE
This is to certify that the project work entitled STEAM TURBINES OPERATION, PERFORMANCE AND ITS TROUBLE SHOOTING is the bonafied project work carried out by these students of SRI INDU COLLEGE OF ENGINEERING submitted in AND partial TECHNOLOGY, IBRAHIMPATNAM

fulfillment of the requirements for the award of the degree of Bachelor of Technology in Mechanical Engineering during the year 2012-2013. This is a record of the student own work carried out by them under our supervision and my guidance from 20.02.2013 to 19.03.2013. During the above period they attended plant regularly. List of students:
N. SHRAVAN KUMAR (09D41A0374) B. VIKRAM SENA YADAV (09D41A0375) I. RAJASEKHAR (09D41A03B1)

ASST. DIVISIONAL ENGINEER TURBINE MAINTENANCE STAGE-II/ Dr.NTTPS. IBRAHIMPATNAM.

DECLARATION
We the members of the project Steam Turbine Operation, Performance and its Trouble Shooting , hereby declare that the matter embodied in this project is the genuine work done by us and not been submitted either to this university or to any other university/institute for the fulfillment of the requirement of any course of study.

N. SHRAVAN KUMAR (09D41A0374) B. VIKRAM SENA YADAV (09D41A0375) I. RAJASEKHAR (09D41A03B1)

ACKNOWLEDGEMENT
Fruitful thoughts from the delightful hearts to thank all the ingenious pillars behind us. We would like to express our sincere thanks to external project guide Mr.M.RAGHUNATH, A.D.E/T.M/STAGE-II, Dr. NTTPS, for his magnificent guidance which enlighten us the thing achievable from inconceivable. We would like to acknowledge the perfectionist, R V RAO, Director of SRI INDU COLLEGE OF ENGINEERING AND TECHNOLOGY, HYDERABAD . We are indebted to our beloved Principal , Mr. P MALLESHAM, for his kind consent in doing the course, project and incitement towards us. We found immense pleasure in expressing our gratitude to M. SRINIVAS RAO, HEAD OF THE DEPARTMENT, department of mechanical engineering, for his timely help through out the project schedule and the course of study. We would like to express our sincere thanks to project guide Mr.M.RAGHUNATH, for sparing his valuable time in coordinating the project and taking active interest at each step. We feel extremely proud to thank all the staff members for their stunning support during the course of our dissertation work. Finally we thank one and all who directly and indirectly helped us to complete our project successfully.

ABSTRACT

To meet the variation of fluctuating demands of different consumers from time to time, the power plants has to optimize their efficiency of its components like boiler, turbine etc. The study of turbine operation and performance plays a vital role for different working conditions of power plant. The project deals with the operation and evaluating the performance of steam turbines and find out some of the troubles and suggesting suitable remedies in steam turbines and highlighting the modifications for optimum performance taking Dr. Narla Tatarao Thermal Power Station station (Dr.NTTPS) as our work place. An ideal steam turbine is considered to be an isentropic process in which entropy of the steam entering is equal to entropy of steam leaving. Because of its greater thermal efficiency and higher-power to weight ratio, steam turbines are almost replaced reciprocating steam engine. The main focus of this project is on the calculation of turbine efficiency and comparing it with design efficiency by taking into consideration of steam pressure values for HP and IP turbines at outlets and inlets. We also concentrate on operating conditions and some of the trouble shooting factors that affects the steam turbine.

CONTENTS

Chapter No. 1

Description INTRODUCTION TO THERMAL POWER PLANTS

Page No.

1.1 GEOGRAPHYCAL LOCATION & DETAILS 1 OF INSTALATION 1.2 SPECIAL DESIGN FEATURES OF Dr.NTTPS 1.3 ENERGY CYCLE 1.4 GENERATION FLAME 1.5 GENERATION OF STEAM 1.6 GENERATION OF POWER 1.7 POWER PLANT CYCLE 2 PLANT LAYOUT 2.1 PLANT LAYOUT OF Dr.NTTPS 2.2 SPECIFICATIONS OF TURBINE 3 BASIC CYCLES IN POWER PLANTS 3.1 RANKINE CYCLE 3.2 REGENERATIVE CYCLE 3.3 REHEAT CYCLE 4 BOILER FEED PUMPS 4.1 INTRODUCTION 4.2 PRINCIPLE OF CENTRIFUGAL PUMPS 4.3 HIGH PRESSURE FEED PUMP 4.4 ROTOR 4.5 INSIDE STATOR 14 18 20 6 13 2 2 3 4 4 5

4.6 MECHANICAL SEAL 4.7 BALANCING DEVICE 4.8 CAVITATION 4.9 SUCTION HEAD 4.10 WORKING PRINCIPLE OF BOILER FEED PUMP 4.11 TYPICAL SPECIFICATIONS OF BFP 4.12 RECIRCULATION SYSTEM 4.13 BOOSTER PUMP 4.14 TYPICAL SPECIFICATIONS OF BOOSTER PUMP 4.15 BFP DRIVE 4.16 HYDRAULIC COUPLING 4.17 LUBRICATING SYSTEM 4.18 OPERATIONAL CHECKS

11

CONCLUSION BIBILOGRAPHY

83 84

LIST OF FIGURES

S. No.

Description

Page No.

2.1 2.2 2.3 3.1 3.2 3.3 3.4 3.5

PLANT LAYOUT OF Dr.NTTPS DEAERATOR CROSS-SECTIONAL VIEW OF TURBINE RANKINE CUCLE RANKINE CYCLE ON P-V CHART RANKINE CYCLE ON T-S AND H-S CHARTS 11 12 14 16 17 19 21

REGENERATIVE CYCLE AND ITS T-S CHART REHEATING CYCLE ON T-S AND H-S CHART S

LIST OF TABLES

Chapter 1

Introduction to Thermal Power Plant

1.1

GEOGRAPHICAL

LOCATION

AND

DETAILS

OF

INSTALLATION:
Dr. Narla Tatarao Thermal Power Station is located on the left side bank of the river KRISHNA within a distance of 2KM and is located in between Ibrahimpatnam and Kondapalli villages and 16KM of the north side of Vijayawada. The site lies at an elevation of about 26.5 mtrs above the mean sea level. Dr. Narla Tatarao Thermal Power Station complex consists of four stages. First three stages consists of two units each, which are of 210 MW and Fourth stage consists of one unit of 500 MW. The total capacity of the station is 1760MW. Units 1 to 7 are commissioned as detailed below. Stage no 1 2 3 4 Unit 1 2 3 4 5 6 7 Capacity 210MW 210MW 210MW 210MW 210MW 210MW 500 MW Date of

commissioning 01/11/1979 10/10/1980 05/10/1989 23/08/1990 31/03/1994 24/02/1995 06/04/2009

Table 1.1: UNIT CAPACITIES Dr. Narla Tatarao Thermal Power Station is unique in its layout and famous for easy operation and maintenance. The large reservoir created by Prakasam barrage provides an efficient direct circulation of cooling water system and meets other requirements for the plant. Originally the Dr. Narla Tatarao Thermal Power Station is linked to Singareni Collieries Company Limited (S.C.C.L) for supply of coal. The average distance of S.C.C.L Coalfields by train is about 250KM.

Dr.NTTPS, stage 2&3 are linked to Talcher coalfields in Orissa to meet the increased demand. The average distances of Talcher coalfield by train 950KM.

1.2 SPECIAL DESIGN FEATURES OF Dr.NTTPS:

STAGE-1: The coal bunkers and mills are located in between boiler house and electrostatic precipitators unlike usual arrangement elsewhere in the country of placing the bunkers and mills between the turbine house and boiler. Thus the turbine house is completely isolated from mills so as to ensure dust free atmosphere in the turbine house and also to ensure easy accessibility of the mills for the maintenance. Multiple flue chimneys are also a new feature at this power station. STAGE-2&3: The second and third stages consist of boilers, turbines and generators. These are completely of new design. Tower type boilers of single pass design are manufactured by M/s B.H.E.L. Ltd; under collaboration with M/s stein industries. KWU turbines and generators of West Germany design are installed in the 2 &3 stages.

1.3 ENERGY CYCLE:

In this process of power generation which involves various transformations of energy is discussed in brief. Chemical energy in the form of coal is converted in to heat energy by burning it in the boiler furnace, which release high temperature gas. These gases exchanges heat to water which converts it into steam and this steam is further super heated and passed through the steam turbine. The turbine shaft rotates; the

mechanical energy thus produced is converted into electrical energy by means of a generator. In this way electrical energy is produced from the chemical energy of coal.

1.4 GENERATION OF FLAME:

The coal from the mines is brought to the plant through the conveyor belt and is sent to Ball mills. Here the coal is pulverized to fine powder with the coal powder now called pulverized fuel is filtered by using very fine filters up to size of around 70 microns. Primary air is blown into the mills with the help of primary air fans. This will preheat the pulverized fuel in the mills and bring to the furnace here the pulverized fuel (PF) is injected in to the boiler from the burners arranged at the four corners at six elevations of the boiler. This type of firing is called tangential firing and this will create a swirling effect and give increased turbulence for the complete combustion of the PF. In between coal guns there are oil and secondary air guns alternatively. Many coal fired power stations use oil for light up purpose and for low load operations. The preheated secondary air supplied by forced draft fans is utilized for the proper combustion of fuel.

1.5 GENERATION OF STEAM:

To avoid corrosion in the pipes dematerialized water is used in the whole process. This water is taken in the water drum at the top of the boiler and is circulated continuously through the water walls of the boiler as a result the water in the pipes is heated by radiation process and becomes the steam being less dense flows up and assumes upper position. The drum equipped with mechanical turbo separators to alienate saturated steam from water. The saturated steam thus produced is again superheated in the super heater of the boiler. This will eliminate the moisture contents present in the saturated steam thus obtained is called main steam and which has a temperature of 5400C and a pressure of 150 Kg/sq cm.

1.6 GENERATION OF POWER:

The main steam from super heater pipes of the boiler is passed through high pressure turbine (HPT). This steam moves through number of sets of fixed and moving blades of the HPT and rotates the shaft. As a result the main steam loses its temperature to 3400 C and pressure to 35 Kg/sq cm. as the steam at the end of the HPT is colder than the main steam. It is called Cold Re Heat (CRH) steam and this doesnt posses enough energy to drive intermediate pressure turbine (IPT). Hence this CRH is reheated to 5400C while maintaining the same pressure. Now the obtained steam, called Hot Re Heat (HRH) steam is sent to IPT. The steam that comes out of IPT has a temperature of 330 0C and a pressure of 7 Kg/sq cm. This steam is directly sent through the low pressure turbine (LPT) and finally to condenser for recirculation.

The shaft passes through all the three turbines and is also connected to generator and exciter by means of rigid couplings. Because of the rotation of shaft,

the flux developed by exciter in the rotor is cut by the armature conductors fixed in the casing of generator. Then the generated power is taped and is synchronized to the grid.

1.7 POWER PLANT CYCLE:

A working fluid goes through a respective cyclic change and this cyclic change involving heat and work is known as thermodynamic cycle. Thus a thermodynamic cycle is a series of operations, involving a heat receiver, a machine or utilizes between the source and the receiver and a working substance. In steam power station, heat is released by burning fuel; this heat is taken up by water which works as the working fuel. Water is converted into steam as it receives heat in a boiler. The steam then expands in a turbine producing mechanical work which is then converted into electrical energy through a generator. The exhaust steam from the turbine is then condensed in a condenser and condensate thereafter pumped to the boiler where it again receives heat and the cycle is repeated.

Chapter 2

Plant Layout Dr.NTTPS

of

2.1 PLANT LAYOUT OF Dr.NTTPS

FIG 2.1: PLANT LAYOUT OF Dr.NTTPS

BOILER: Water is evaporated into steam inside the boiler necessary heat is obtained by burning coal in boiler furnace to save time and economize fuel consumption feed water is preheated in economizer. Flue gases from the boiler provide heat to feed water. They are also used to preheat air before they flow to chimney. A modern boiler produces steam at the rate of 300 to 400 tons per hour at 130 to 140 bar absolute pressure and 5400C by burning the coal at the rate of 200 tons per hour. STEAM TURBINE: This is a prime mover and the main power unit of the plant. Steam from super heater is admitted into the turbine through nozzle. It expands over the blades of turbine rotor pressure falls and thus heat in steam drops. This drop in enthalpy (heat energy) is converted in to mechanical energy. As a results turbine shaft rotates at high rotational speeds and this shaft connected to generator. CONDENSER: Condenser is placed at the exhaust end of turbine so that the exhaust steam from turbine is discharged into it. Condenser condenses the steam making use of certain cooling medium such as water. Condensed steam is called condensate this is recirculated to boiler as feed water. BOILER FEED PUMP: The main aim of feed pump is to send condensate from hot well to boiler and also increase the pressure of the condensate.

FURNACE: A boiler furnace is that space under or adjacent to a boiler in which fuel is burned and from which the combustion products pass into the boiler properly. It provides a chamber in which the combustion reaction can be isolated and confined so that the reaction remains a controlled force. DRUM: The drum is a pressure vessel. The boiler drum forms a part of the circulation system of the boiler. The drum serves two functions: a. It separates steam from the mixture of water and steam. b. The drum houses all equipment used for purification of steam after being separated from water. This purification equipment is commonly referred to as the drum internals. The boiler drum is made of carbon steel plates. SUPER HEATER: Super heaters are usually classified according to the shape of the tube banks and position of the header, also according to whether they receive heat by radiation or convection, although in some instance it may be a combined of both methods. The super heaters increase the heat energy in the steam supplied to steam turbines and to ensure that the dry steam supplied until it reaches the last stage of LPT. REHEATER: Increased capacity of generators necessitates increased capacity units. The steam entering high pressure turbine does some work due to steam expanding through various stages. The steam exhaust in high pressure turbine is again admitted in the reheater circuit to reheat the steam at constant pressure to raise its temperature to almost equal to super heated steam. The heat energy in the steam is increased in

the reheater and this reheated steam is admitted into IPT and steam is expanded doing some additional work before exhausting into condenser from LPT. RAW COAL MILLS: The most efficient way of utilizing coal for steam generation is to burn it is in pulverized form. In pulverized fuel firing method the coal pulverized to a fineness of 70% to 80% by hot primary air through pipes directly to burners. The motives behind the development of pulverized fuel firing systems are: a. Efficient utilization of cheaper and low grade coals. b. Flexibility in firing with ability to meet fluctuating loads. c. The ability to use higher combustion air temperature there by increasing the overall efficiency of the steam operator. AIR HEATERS: Air heater is a heat transfer surface in which air temperature is raised by transferring heat from other media such as flue gas. Since air heater can be successfully employed for reclaim heat from flue gas at low temperature levels than is possible with economizer. The heat rejected to chimney can be reduced to higher extent thus increasing the efficiency of the boiler. For every 20 0C drop in flue gas temp, the boiler efficiency increased by about 1%. FANS: The purpose of the fan is to move air/gas continuously against moderate pressure. Fans are used in boiler for different applications such as supplying air for combustion, removal of combustion products, and air for cooling of equipment working in hot zone set. Fans are designed according to the fans they do in the boiler, e.g. Induced draft fan, forced draft fan, primary air fan etc.

Primary Air fan [PA fan]: The primary air has two functions, drying the coal and transportation into the furnace. Boiler provided with two nos of primary air fans. Each PA fan is provided with blade pitch control for controlling the loading on fans. Outlet damper for isolation to facilitate start up or maintenance of fan. Forced Draft fan: [FD fan] The function of FD fan is to supply excess air required for complete combustion. Boiler is provided with two no. of forced draft fans. Each FD fan is provided with blade pitch control for controlling the loading on fans. Outlet damper for isolation to facilitate start up/maintenance of fan.

Induced Draft fan [ID fan]:

The function of induced draft fan is to suck the gases out of furnaces and throw them into stack. Boiler is provided with two no. of induced draft fans. Each ID fan is provided with regulating damper control and scoop control for controlling the load on fans, inlet/outlet gates for isolation to facilitate start up/maintenance of fan. Flue gas inter connection with damper is provided before ESP in order to maintain balanced flow through both the APH second pass when only one ID fan is running. DEAERATOR: The function of the deaerator is to remove dissolved non condensate gases and to heat boiler feed water. It consists of a pressure vessel in which water and steam are mixed in a controlled manner. When this occurs, water temperature rises

FIG 2.2: DEAERATOR and all non condensable dissolved gases are liberated and removed the efficient water may be considered corrosion free from an oxygen or carbon dioxide stand point. Free air or other non condensable gases should be rented prior permitting the fluid to enter the deaerator. A deaerator protects the feed pumps, piping, boiler and any other piece of equipment that is in the boiler feed and return cycle from the effects of corrosive gases, i.e. oxygen and carbon dioxide to a level where they are no longer a corrosive factor. CONDENSATE EXTRACTION PUMPS: The function of these pumps is to pump the condensate to the deaerator through ejectors, gland steam cooler, drain cooler and LP heaters. In a 210MW unit 3pumps are installed, having a pumping capacity of 50% each. Two pumps are for normal operation and one is stand by. Since the suction is at a negative pressure, the special arrangements have been made for providing sealing to glands.

EJECTORS: Ejectors are used to extract non condensing gases from condenser and heat exchangers of turbine. The pressure and discharge of non condensing gases depend upon the conditions of working of condensers and ejectors. ECONOMISER: An economizer is device in which the waste heat of the flue gases is utilized for heating the feed water. GENERATOR: Generator is used to convert the mechanical energy into electrical energy.

FIG 2.3: CROSS-SECTIONAL VIEW OF TURBINE

2.2TURBINE SPECIFICATIONS:

Type Speed Steam pressure Steam temperature Exhaust pressure HP stages IP stages LP stages Extraction points

: Tandem compounded reheat type : 3000RPM : 150kg/cm 2 : 540C : 0.91 bar : 25 : 2*20 : 2*8 :6

Chapter 3

Basic Cycles Power Plants

in

3.1 Rankine Cycle: The Rankine cycle is a steam cycle for a steam plant operating under the best theoretical conditions for most efficient operation. This is an ideal imaginary cycle against which all other real steam working cycles can be compared. The theoretic cycle can be considered with reference to the figure below. There will no losses of energy by radiation, leakage of steam, or frictional losses in the mechanical components. The condenser cooling will condense the steam to water with only sensible heat (saturated water). The feed pump will add no energy to the water. The chimney gases would be at the same pressure as the atmosphere.

FIG 3.1: RANKINE CYCLE

Within the turbine the work done would be equal to the energy entering the turbine as steam (h1) minus the energy leaving the turbine as steam after perfect expansion (h2) this being isentropic (reversible adiabatic) i.e. (h1- h2). The energy supplied by the steam by heat transfer from the combustion and flue gases in the furnace to the water and steam in the boiler will be the difference in the enthalpy of the steam leaving the boiler and the water entering the boiler = (h1 - h3). Basic Rankine Cycle The ratio output work / Input by heat transfer is the thermal efficiency of the Rankine cycle and is expressed as

Although the theoretical best efficiency for any cycle is the Carnot Cycle the Rankine cycle provides a more practical ideal cycle for the comparison of steam power cycles (and similar cycles). The efficiencies of working steam plant are determined by use of the Rankine cycle by use of the relative efficiency or efficiency ratio as below:

A steam turbine is a prime mover that derives its energy of rotation due to conversion of the heat energy of steam into kinetic energy as it expands through a series of nozzles mounted on the casing or the fixed blades.

Water is converted to steam by application of heat in the boiler, which makes the steam at specified pressure and temperature. To convert the steams energy into work, it must go through a thermodynamic cycle that combines expansion compression, heat input, and heat rejection. The most efficient thermodynamic cycle for an ideal fluid is Carnot cycle. It consists of an isothermal heat input, isentropic expansion, isothermal heat rejection, and an isentropic compression. Regardless of the combination, the efficiency of the cycle, assuming constant mass flow is based on the difference in the enthalpy and between the beginning and end of the cycle.

FIG 3.2: RANKINE CYCLE ON P-V CHART 1 to 2: Isentropic expansion 2 to 3: Isothermal heat rejection 3 to 4: Isentropic compression 4 to 1: Isothermal heat supply

Steam can be used as the working fluid in the Carnot Cycle. But its properties adversely impact its usefulness. In this case the steam expansion process takes place

completely in the moisture region. This requires compression of a vapour/moisture mixture to return to the cycles starting point. Moisture is an expansion process imposes large mechanical efficiency losses. Also, vapour compression is inefficient and consumes relatively large amounts of power. To avoid a two-phase vapour compression process, turbines are based on the Rankine cycle. It is similar to the Carnot Cycle, except that the initial pressure of the steam is raised and the condensation process that accompanies heat rejection continues until the liquid saturation point is reached. At the end of the cycle, then, condensate is simply pumped back to the boiler to begin the cycle. The role of the steam turbine is to expand the steam from high pressure and temperature to lower pressure and temperature. Rankine cycle is a heat engine with vapor power cycle. The common working fluid is water. The cycle consists of four processes

FIG 3.3:

RANKINE CYCLE ON T-S AND H-S CHARTS 1 to (Steam 2 to (Condenser) 3 compression 2: 3: to Isentropic turbine) Isobaric heat 4: (Pump) expansion rejection Isentropic

4 (Boiler)

to

1:

Isobaric

heat

supply

Several things can be done to steam to improve the Rankine Cycle efficiency. Raise initial steam condition and reduce the amount of moisture near the end of expansion stage. The first is accomplished by superheating the steam before it does any work. The second involves re- heating steam to near initial-conditions after it is partially expanded by directing it back to the heat source, then completing the expansion. In converting the thermal energy of steam into mechanical energy turbines takes advantage of these facts- as it expands or drops in pressure, through a small nozzle or opening, it accelerates and forms a high-speed jet. Directing this momentum in a rotating blade provides mechanical energy.

3.2 REGENERATIVE CYCLE: In the Rankine cycle it is observed that the condensate which is fairly at low temperature has an irreversible mixing with hot boiler water and this result in decreases of cycle efficiency. Methods are therefore, adopted to heat feed water from the hot well of condenser irreversibly by interchange of heat within the system and thus improving the cycle efficiency. This heating method is called regenerative feed heat and cycle is called regenerative cycle. The principle f steam generation can be practically utilized by extracting steam from the turbine at several locations and supplying it to the regenerative heaters. The resulting cycle known as regenerative or bleeding cycle. The heating arrangement comprises of: (1) For medium capacity turbines not more than 3 heaters ;(2) For high pressure high capacity turbinesnot more than 5 to 7 heaters ;and (3) For turbines of super critical parameters 8 to 9 heaters. The most advantageous

condensate heating temperature is selected depending on the turbine throttle conditions and this determines the number of heaters to be used. The final condensate heating temperature is kept 50 to 60degreeC below the boiler saturated steam temperature so as to prevent evaporation of water in the feed mains following a drop in the boiler drum pressure. The conditions of steam bled for each heater are so selected that the temperature of saturated steam will be 4 to 40 degree C higher than the final condensate temperature.

FIG 3.4: REGENERATIVE CYCLE AND ITS T-S CHART

Shown in a diagrammatic layout of a condensing steam power plant in which a surface condenser is used to condense all the steam that is not extracted for feed water heating. The turbine is double extracting and the boiler is equipped with a super heater. The cycle diagram (T-s) would appear as shown in figure. This arrangement constitutes a regenerative cycle.

3.3 REHEAT CYCLE: For attaching greater thermal efficiencies when the initial pressure of steam was raised beyond 42 bars it was found that resulting condition of steam after, expansion was increasingly wetter and exceeded in the safe limit of 2 percent condensation. It therefore, became necessary to reheat the steam after part of expansion was over so that the resulting condition after complete expansion fell within the region of permissible wetness. The reheating or re superheating of steam is now universally used when high pressure and temperature steam conditions such as 100 to 250bar and 500 degree C to 600 degree C are employed for throttle. For plants of still higher pressure and temperature, a double reheating may be used. In actual practice reheat improves the cycle efficiency by about 5% for an 85/bar cycle. A second reheat will give a much less gain while the initial cost involved would be so high as to prohibit use of two stage reheat except in case of very high initial throttle conditions. The cost of reheat equipped consisting of boiler ,piping and controls may be 5%to 10% more than that of the conventional boilers and this additional expenditure s justified only of gain in thermal efficiency is

sufficient to promise a return of this investment. Usually a plant with a base load capacity of 50000kW and initial steam pressure of 42bar would economically justify the extra cost of reheating. The improvement in thermal efficiency due to reheat is greatly dependent upon the reheat pressure with respect to the original pressure of steam. Schematic diagrams of a theoretical single-stage reheat cycle. The corresponding representation of ideal reheating process on T-s and h-s chart is shown in figure. FIG 3.5: REHEATING CYCLE ON T-S AND H-S CHART

5-1 shows the formation of steam in the boiler. The steam as at state point 1 (i.e., pressure P1 and temperature T1) enter as the turbine and expands isentropically to a certain pressure P2 and temperature T2. From this state point 2 the whole of steam is drawn out of the turbine and is reheated in a reheater to a temperature T3. (Although there is an optimum pressure at which the steam should be removed for

reheating, if the highest return is to be obtained, yet, for simplicity, the whole steam is removed from the high pressure exhaust, where the pressure is about one-fifth of boiler pressure, and after undergoing a 10% pressure drop, in circulating through the heater, it is then readmitted to the turbine where it is expanded to condenser pressure isentropically.

BOILER FEED PUMP

1. INTRODUCTION: Boiler Feed pump (BFP) is a multistage pump provided for pumping feed water to economizer Generally three pumps each of 50% of total capacity are provided. For rated capacity two pumps will be working in parallel and the third will be in service. The high pressure BFP is a very expensive machine, which can comply with the stated requirements. The safety in operation and efficiency of the feed pump does not only depend on the correct design and careful manufacturing in the works, but also reliable operation and maintenance, so the operation and maintenance staff should be well acquainted with the instructions and procedures laid down by supplier. 1. PRINCIPLE OF CENTRIFUGAL PUMP: A Centrifugal pump is defined as a machine, which increases the pressure energy of a fluid with the help of centrifugal action. Whirling motion is imparted to the fluid by means of blades mounted on the disc known as impeller. It consists mainly of one or more impellers equipped with vanes, mounted on a rotating shaft and enclosed by a casing. Fluid enters into the impeller axially near the shaft and has energy both kinetic and potential, imparted to it by the vanes. As the fluid leaves the impeller at a relatively high velocity, it is collected in a volute or series of diffusing passages which transforms the kinetic energy into pressure. This is of course, accompanied by a decrease in the velocity. After the conversion is accomplished, the fluid is discharged from the machine. 1. HIGH PRESSURE FEED PUMP: The high pressure feed pump KHI of barrel type satisfy in all respects the latest developments achieved for the design and operation of the feed pumps. It consists of the pump barrel into which is mounted the inside stator together with the rotor. The hydraulic part is closed by the HP cover along with the balancing device.

The LP covers along with the stuffing box casings close the suction side of the barrel and the space in the HP cover behind the balancing device. The bracket of the radial bearing of the suction side and the bracket of the radial thrust bearing of the discharge side are fixed to the LP covers. The entire pump is mounted on a foundation frame. The Hydraulic coupling and two claw couplings with coupling guards are also provided. The water-cooling and oil lubricating connections are provided with their accessories. All the instruments necessary for observing a perfect run of the feed pump are mounted on the pump and on the piping. Feed pumps consist of the following major parts. 1. 2. 3. 4. I. ROTOR: The rotor of the BFP consists of the shaft, impellers, distance bushes, throttle bush, balancing disc, supporting rings, stuffing box bushes, nuts for holding the stuffing box bushes, the disc of the axial thrust bearing, with the lock nut, nuts for screwing the claw coupling, shaft keys and lubricating rings. For obtaining the shrink fitting of the impellers on to the shaft, the impellers are first heated and then assembled on to the shaft. The balancing disc (which is keyed to the shaft) takes up the axial thrust of the rotor, which is limited to the extent of dilation gap that exists between the throttle bush and the supporting ring. The dilation gap should be within the limit of 0.2 to 0.3mm. The Maximum run out of the assembled rotor, at the sealing impeller diameters, the throttle bush and stuffing box bushings is up to 0.06mm. The impeller (statically balanced) and the rotor as a whole is dynamically balanced with in the permissible inbalance according to the standard of the works. Prior to the dynamic balancing of the rotor, the deflection of the rotor due to its selfweight is also measured. The deflection of the rotor due to self weight moves in the limits of 0.01 to 0.12mm.
I.

Rotor Inside Stator Mechanical seal Balancing device

INSIDE STATOR:

The inside stator consists stage bodies and diffuses (consists diffusing vanes and guide vanes), which are assembled together. Diffuses are centrally mounted in the stage bodies. They are secured against motion by locating pins. Stage bodies are fitted with wearing rings at the place where it is likely to come into contact with the wearing rings of impeller and the wearing rings are secured to the stage bodies with the help of screws. The entire inside stator is connected together by four connecting bolts. Another four connecting bolts are screwed on to the suction side of the barrel and they connect the inside stator to the barrel. The nuts at the ends of these bolts are tightened in order to pre-stress the bolts to suit the working pressure and they are screwed with the help of locking washers. The centering of the inside stator is carried out by aligning the inlet stage to the suction side of the barrel and by aligning the HP cover to the end diffuses while

the pump is in operation the inside stator will get heated earlier than the pump barrel together with the HP cover. This means that the expansion of the inside stator owing to the temperature will be more than the expansion of the barrel and of the HP cover. A dilation gap of 6mm is therefore maintained between the end diffuses and the HP cover. I. MECHANICAL SEAL: The advantages are: a) b) C) d) The Mechanical seal eliminates the losses of feed water in stuffing box. Working ability of the feed pump increases. With the mechanical seal, cooling of stuffing box space should be perfect. Cooling is carried out by the circulation of water by means of a pumping ring through a cooler. e) Cooling of the stuffing box space is different from the seal cooler. f) Even after stopping of the pump stuffing box space temperature below 80C. g) Pump need not be removed from base frame, to'replace mechanical seals.

IV. BALANCING DEVICE: Balancing system of the pump takes up the entire axinl thrust of the rotor, by means of the balancing disc. Balancing device is an important aspect of the pump as far as the design and material selection is concerned. Balancing device consists of balancing disc, secured to the shafts !Deal ing ring fitted to the HP cover by means of the tightening flange and bolts with nuts, which are locked by washers. Axial sealing gap is formed between the bearing ring and the balancing disc. Contact surfaces of bearing ring and balancing disc are mutually lapped against each other. Full pressure developed by the last impeller is not carried on to the balancing device but throttled by means of the taper bush mounted on the shaft before the balancing disc. The feed water passes through the taper bush, through the axial sealing gap. The axial sealing gap is approximately 0.1mm. 3.1 CAVITATION: If the pressure at any point inside a pump drops below the vapour pressure corresponding to the temperature of the liquid, the liquid will vapourise and form cavities of vapour. The vapour bubbles are carried along with the stream until a region of higher pressure is reached, where they collapse or implode with a tremendous shock on the adjacent walls. This phenomenon is called cavitation. 3.2 SUCTION HEAD OR NPSH (Net Positive Suction Head): Since cavitation occurs when the absolute pressure on the liquid reaches its vapour pressure, it is obvious that the phenomena is closely related to the pump suction head, The suction head has the equivalent total head at the center line. 3.3 WORKING PRINCIPLE OF BOILER FEED PUMP: The water with the given operating temperature should flow to the pump under a certain minimum pressure (NPSH); water passes through the suction branch into the intake spiral and from here is directed to the

first impeller. After leaving through the impeller it passes through the distributing passages of the diffuser where it get certain pressure rise and flows over to guide vanes to the inlet of the next impeller. This process repeats from one stage to the other till it passes through the last impeller and the end diffusers. Thus the feed water arriving into the discharge space develops the necessary operating pressure. A small part of feed water i.e. about 10% is taken off from the space behind the last impeller for the operation of the automatic balancing device to balance the hydraulic axial thrust of the pump rotor. 3.4 TYPICAL SPECIFICATIONS OF BOILER FEED PUMP (200 KHI TYPE): 1) 2) 3) 4) 5)
6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17)

No. of stages Suction pressure Quantity of water for 100 Tons/hr. Discharge capacity/ head Quantity of water for warming up Feed water temperature Consumption of cooling water Speed Lubrication Stuffing box Net weight of pump Axial Thrust of Designed Speed. MOTOR Output Rated Voltage Current Speed Frequency, Power factor

6 12.3 atm 430'T/hr./1830 MWC 8 Tons/hr. 164.2 C. 280 PM. 4320 'rpm. Forced Mech. seal 5850 Kg. 34 Tonnes. 4000 KW 6.6 KV 421 Amps 1483 rpm 50 c/s, 0.914

3.5 RECIRCULATION SYSTEM: To maintain a reasonable efficiency in the pump, running clearances between stationary and rotating part must be fairly narrow. Liquid flow through these clearances acts as a lubricant to prevent seizure. The power input to the pump is partly converted into hydraulic energy due to the increase in pressure of the liquid. The remaining energy is wasted in the form of friction, eddies and mechanical losses. This power loss causes slight increase in the liquid temperature while the liquid passes from suction to discharge. This temperature rise to maximum at zero discharge and the water soon flashes into steam. Flashing breaks down the thin film of lubricating water between the parts and this usually causes seizure. The trouble occurs so quickly that stationary parts cannot expand as rapidly as the rotating parts, because they will be heated more slowly, being of greater mass and also exposed to atmosphere. Greater expansion of rotating parts will reduce the normal running clearance and aggravate the conditions. It is therefore, imperative that sufficient water must be kept moving through the pump to prevent its temperature from reaching the

flash point in the pump when the regulator closes the main discharge line due to low load or less water requirements in the drum or when the pump is just started. To ensure this an automatic leak off system is provided between the pump discharge and the deaerator to establish a minimum flow through the pump. A solenoid operated diaphragm valve or a motorised valve is installed in the leak off line which opens when the pump runs at a lower capacity. The recirculation valve opens when the flow at pump suction is below 100T/hr. and closes when it increases to 220 T/hr. The flow through recirculation line is 125 T/hr.

WARMING UP: Centrifugal pumps handling hot water should always be maintained nearly at operating temperature when idle, if suddenly hot water is admitted into the pump, the relative expansion of the casing barrel and of the inner elements goes through two separate phases. The inner elements expand faster than the barrel resulting in distortion of the pump. To avoid this, a small quantity of the medium is always passed through the steam pump for warm up. Various methods are used for this purpose. In some, the flow is from the suction, through the pump and out through the balancing chamber to the flash tank. In others, a by pass across the main discharge non-return valve is provided with a pressure reducing orifice, The flow is from the discharge and through the pump and back to the deaerator.

Chapter 11

Conclusion

CONCLUSION
Since the power output of the power plant is to be maintained at a constant frequency with very less tolerance, steam turbine plays very important role in achieving the above task. Out of various turbines that are used in power plants, reaction turbine is proved to be the most efficient one because with the development of steam power plants, large flow rates of steam have to be operated which may not be possible by conventional turbines. The performance of steam turbine can be further improved by reducing the prior mentioned losses. The efficiencies of the turbines are calculated and are found to be nearer to the design values thus concluding that the recorded values are correct. By our experimental study the efficiency of H.P. Turbine is found to be 74.35% and the design efficiency value is 87.973% and in the same way the efficiency of I.P. Turbine is found to be 89.6% which is nearer to the design value of 90.78%. The over all plant efficiency is found to be 40.7% which is nearer to the design value of 42.97%. This can be improved further by taking some factors into consideration and recovering the waste heat that is lost to a maximum extent. In this project we also studied the Constructional features, Operation of steam turbines and also some common Trouble Shootings in power plants. We have also executed the efficiency of H.P. Cylinder at different values of pressures and temperatures by using C program and finally we conclude that the actual efficiency of the turbine is nearly equal to designed efficiency.

Bibilography

1. A Course in Power Plant Engineering: -S.C.Arora, S.Domkundwar Dhanapat Rai & Co.2001

2. Thermal Engineering: -R.S.Khurmi, S.Chand Publisher

3. Thermal Engineering: -R.K.Rajput, Laxmi Publishers, 2000

4. Power plant Engineering: -G.Nagpal

5. Steam Turbine Operation & Maintenance -B.H.E.L.Hardwar

6. Modern Power Station Practice 3rd Edition, Volume C -British Electricity International, London

7. Blade Plane LPT -Drawing No: 9-10304-01000C, Dr.NTTPS Drawing Manual

8. www.Matweb.com