ENERGY AUDIT METHODOLOGY FOR FOR TURBINE CYCLE

Presented By

S.V.Malpe Dy.Director NPTI, Nagpur

EFFECT OF STEAM PARAMETERS

P1 P2 P3 T1 P1 P1 T3 P2 T2 H T1

T2 T1
H H

Effect of Increasing Pressure on Available Energy

Effect of Increasing Steam Temperature On Available Energy

Effect of Increasing Steam Pressure & Temperature Both on Available Energy

EFFECT OF STEAM PARAMETERS

H H

Effect of Changing Reheat Pressure

Effect of Changing Reheat Temp.

THERMAL PROCESS LOSSES

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

TURBINE CYCLE LOSSES

TURBINE HR EVALUATION AND EFFICIENCY

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

Turbine Cycle Efficiency =

860

Heat Rate

X 100

kW

kCal/hr

TURBINE HR EVALUATION AND EFFICIENCY

Actual Process 1-2-3-4-5

Comparison of Actual Expansion with Isentropic Expansion in Turbine

Actual Expansion in HP, IP & LP Cylinder

Pressure T . S . V . Impulse Stage 1st Reaction HP Exhaust IP Inlet LP Inlet

Basic Turbine Pressure Survey Diagram

Pressure T . S . V . Impulse Stage 1st Reaction HP Exhaust IP Inlet LP Inlet

Effect of Range Turbine Pressure Survey Diagram

TURBINE HR EVALUATION AND EFFICIENCY

Variation of Heat Rate with Load

Heat Rate Characteristics with Condenser Exhaust Pressure

Turbine Losses
Internal Losses
a) Nozzle Friction
b) Blade Friction c) Disc Friction d) Diaphragm Gland & Blade Tip Losses e) Partial Admission Loss

f) Wetness
g) Exhaust

Turbine Losses
External Losses
a) Shaft Gland Leakage
b) Journal & Thrust Bearing c) Governor & Oil Pump

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

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

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

Background
Hot Water Condenser Air Cooling Tower Air

Cooled Water

Make-up Water

Performance of Condensers
Vacuum Efficiency: Ps- saturation pressure of steam in kg/cm2 corresponding to the steam temperature entering the condenser. Pt total pressure of air and steam in the condenser= (pa+ps) Pb- atmospheric pressure or barometric pressure. Ideal vacuum possible without air ingress=(Pb-Ps) Actual vacuum existing in the condenser due to air ingress = Pb-Pt= Pb-(Pa+Ps) Vacuum efficiency = actual vacuum/Ideal vacuum

The main parameter to be monitored is Condenser Back Pressure

High condenser back pressure Causes :1)High Inlet Cooling water Temperature - uncotrollable
2) Low Cooling Water Flow 3)Partially Filled Water Box

4) Excessive Heat Load - uncontrollable

5) Fouled Tubes 6) Excessive Air In Leakage 7)Vacuum Equipment Problem 8) Tube Bundle Design Problem

CRITICAL PARAMETERS TO BE MEASURED

Heat Rejection Rate

Cooling Water Outlet Temperature

Cooling Water Flow Rate Fouling Factor can be measured or calculated

Data Collection- Condenser Specifications

Heat load considered for design Design inlet cooling water temperature/ Design TTD Cleanliness factor/ Cooling water temperature raise Condenser back pressure Cooling water flow/ Cooling water side pressure drop No of cooling water pass/ Total heat transfer area No. of tubes - Condensing zone - Air cooling zone Tube dimensions: - Tube OD x thickness - Length of tube

Effect of Back pressure on heat rate

Effect of Varying the back pressure 1. CW Pumping Power 2. Leaving Loss 3. Reduced Condensate Temperature 4. Wetness of Steam.

Graphical Determination of Losses Contributing the departure of Back Pressure From Optimum 1. CW inlet temp different from design. 2. CW quantity flowing through condenser incorrect. 3. Fouled tube plates. 4. Dirty tubes. 5. Air ingress into system under vacuum.

Condition CW inlet temperature

CW Outlet Temperature CW Temp rise (2-1) Saturated Steam Temperature corresponding to back pressure Terminal Temperature Diff (4-2)

Unit Deg C
Deg C Deg C Deg C

Optimum 16.5
25.0 8.5 30.5

Actual 18.2
28.2 10 35.0

Deg C

5.5

6.8

Air suction temperature Air suction depression (4-6) Back pressure

Deg C Deg C mbar

26.5 4.5 43.65

27.0 8.0 56.22

Loss due to CW inlet temp: Plot a line vertically from the actual CW inlet temp of 18.2 Deg C to the intersection with the optimum CW Rise of 8.5 Deg c. Them plot horizontally to the intersection with the optimum TTD line, and then vertically downward to cut the saturated steam temperature line. The corresponding back pressure is 47.2 m bar. Hence , the loss due to the high CW inlet temperature is the difference in back pressure between 47.7 mbar and optimum value of 43.65 ie. 4.05 mbar.

Loss due to CW flow: Plot a line vertically from the actual CW inlet temp of 18.2 Deg C to the intersection with the actual CW Rise of 10 Deg C. Them plot horizontally to the intersection with the optimum TTD line, and then vertically downward to cut the saturated steam temperature line of 33.7 Deg C. The corresponding back pressure is 52.0 m bar. Hence , the loss due to the CW incorrect CW flow is given by 52.047.7=4.30 mbar.

Loss due to air/dirty tubes: The effect of air and dirty tubes on heat transfer is to increase the TTD above optimum. They both give the same effect. The thermal resistivity of a layer of 0.254 mm thick is approx the same as that offered by slab of copper 3.35 meters thick. Plot from the actual CW inlet temp to the actual CW rise and hence across to the actual TTD line of 7 Deg C. Plotting vertically downward the saturated steam temp is 35.1 Deg C. the back pressure is 56.22 mbar. So the deviation due to air/dirty tubes is given by 56.22-52.0 mbar=4.22 mbar

The effect of air ingress into the condenser is to increase the value of air suction depression from optimum. In the case being considered the optimum value, obtained from acceptance tests is 4.5 Deg C but it is actually 8 Deg C, so there must be air present. Action should be taken to locate and stop the ingress. Incidentally when condenser tube is cleaned it is only dirty tube component which is cleaned.

Condenser Fault Symptoms

Readings Condenser exhaust tem Deg C CW outlet temperature Deg C Temp Diff Deg C CW inlet temp Deg C CW Temp rise Deg C Condensate Temp Deg C Exh temp Cond temp T1 31.7 21.1 10.6 13.0 8.1 31.7 0.0 T2 30.0 23.3 6.7 13.0 10.3 30.0 0.0 T3 31.0 20.0 6.1 13.0 7.0 28.8 2.2 T4 27.8 21.1 6.7 13.0 8.1 27.8 0.0

Condenser Fault Symptoms

Symptom s Causes T1 High TTD Dirty Tube surface T3 T4 (Ext Temp- Norm Cond al Temp)- High Insufficient CW Air ingress flow or high heat or faulty loading operation of air ejection system Remove tube blockage, Increase CW pump discharge flow, Check Check and attend condenser for air ingress. T2 High CW Temp rise

Remedy

Clean tubes, increase chlorinati on

 The following needs to be computed:

Performance of Condensers

1. Condenser heat load = Q x T x Cp

Parameter Q Details Water flow rate Unit Kg/h

T
Cp

Average CW temperature rise

Specific heat

oC
kcal/kg oC

2. Calculated condenser vacuum = Atmospheric pressure Condenser backpressure 3. Deviation in condenser vacuum = Expected condenser vacuum - Measured

Performance of Condensers
5. Condenser Effectiveness = Rise in cooling water temperature Saturation temperature - Cooling water inlet temperature 6. Condenser heat duty in kcal/h = Heat added by main steam + heat added by reheater + heat added by SH attemperation + heat added by RH attemperation + heat added by BFP - 860 x (Pgen + Pgen losses + heat loss due to radiation) 7. Condenser tube velocity (m/s) = Cooling water flow rate (m3/h) x 106 3600 x tube area (mm2) x ( no. of tubes per pass - no. of tubes plugged per pass )

COOLING TOWERS

Cooling Tower Performance

Cooling Tower Effectiveness : Cooling Tower Effectiveness (in percentage) is the ratio of rasnge, to the ideal range, i.e. difference between cooling water inlet temperature and ambient wet bulb temperature, or in other words it is = Range/(Range + Approach) Cooling capacity : Cooling capacity is the heat rejected in kCal/hr given in product of mass flow rate of water, specific heat and temperature difference.

Cooling Tower Performance

Evaporation loss: Evaporation loss is the water quantuty evaporated for cooling duty and , theoretically for every 10,00,000kCal heat rejected, evaporation quantity works out to 1.8 cubic meters. An emperical relation is often used : Evaporation Loss (cu.m/hr)=0.00085 X 1.8 x circulation rate (cu.m/hr)X (T1-T2) Cycles of Concentration (COC): Cycles of concentration is the ratio of dissolved solids in circulating water to the dissolved solids in make-up water.

Cooling Tower Performance

Blow down : Blow down losses depends upon cycles of concentration and the evaporation loss and is given by the relation: Blow down = Evaporation loss/(COC-1) Liquid/ Gas (L/G) Ratio, of the cooling tower is the ratio between the watewr and the air mass flow rates. Against design values, seasonal variations require adjustment and tunning of water and air flow rates to get the best cooling tower effectiveness through measures like water box loading changes, blade angle adjustments. Heat removed from the water must be equal to heat absorbed by the air.

Performance of Cooling Towers

While conducting the cooling tower, visual observations need to be made with respect to: Adequate water level in the trough Cross flow air from other cooling towers (which are under maintenance) Nozzle condition and operation Fill condition Change of blade angles during change of seasons The CT airflow shall be measured using an anemometer and compared with calculated airflow derived from fan characteristic curves of CT fans with actual power measurements. Calculate range, approach, L/G (Liquid to gas) ratio and effectiveness for design and operating conditions for each tower

Performance of Cooling Towers

Power consumption of CT fans

Exploration of Energy Conservation Possibilities: Condenser Possibility of Improvement in condenser vacuum Turbine heat rate Reduction possibilities Improving the effectiveness of condenser and TTD

FEED WATER HEATERS PERFORMANCE

inlet
inlet outlet

0C

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