Challenges © Rising fuel costs which in most of power generating companies are passed through to customer ,caught the attention to regulating agencies. 5 Regulating agencies are now paying more attention to efficiency of power plants.Heat Rate Definitions 5 Heat rate is defined in units of kJ/kWh and is simply the amount of heat input into a system divided by the amount of power generated by a system. | Less heat rate (less fuel) means more efficient system.BENEFIT -identification of losses Efficiency increase Green house gases emission decrease Particulate emission reduction Availability improvement Reduction in O&M cost Less capacity addition Increase profitability yee eg a etSteam Turbine losses Symptoms BPAEIEE section efficiency less than design. Causes (any one or more than one) Change in internal conditions of turbine 1.Mechanical damages 2.Flow area decreases 3,Flow area bypass 4.Flow area increases Change in inlet conditions oa nDooooo01.MECHANICAL DAMAGES 0 Symptoms | Sudden change in section efficiency. & Sudden change in section pressure ratio. © Cause 5 Metallurgical defects. © Maintenance practice.Mechanical damages2.FLOW AREA DECREASE Symptoms Increase in pressure ratio Decrease in section efficiency Increase in up stream pressure cause Mechanical blockage Sudden increase in pressure ratio Sudden decrease in section efficiency Sudden increase in up stream pressure Blade deposits Gradual increase Gradual decrease Gradual increase pressure ratio section efficiency upstream pressure noappeenpeeagMechanical blockageBLADE DEPOSITDEPOSIT IN SINGLE STAGE CASING TURBINESOLUBILITY TRENDS THROUGH TURBINEMollier diagram with (LP Turbine) region of chemical and corrosion effect3.FLOW AREA BYPASS Symptoms Decrease in section efficiency Decrease in pressure ratio Decrease in upstream pressure Cause Hp turbine bushing leakage Main steam stop valve leakage HP gland seal leakage IP stop/intercept valve leakage IP turbine bushing leakage ea) ce a en eg cl4.Flow area increase a o a o a a a a a Symptoms Decrease in pressure ratio Decrease in section efficiency Decrease in upstream pressure Cause Spill strip or packing leakage Erosion of turbine stages Solid particle erosion of nozzle block Blade mechanical damageMollier diagram with (LP Turbine) region of chemical and corrosion effectSpill strip or packing leakage Symptoms Increased down stream extraction temperatures Sudden decrease in stage efficiency Cause Thermal stress Rubbing Vibration Operating procedures a} co | hee! eae) | a) ly4.Flow area increase o o a o o o o: Oo o Symptoms Decrease in pressure ratio Decrease in section efficiency Decrease in upstream pressure Cause Spill strip or packing leakage Erosion of turbine stages Solid particle erosion of nozzle block Blade mechanical damageErosion of turbine stages Symptoms Gradual decrease in pressure ratio Gradual decrease in section efficiency Gradual decrease in upstream pressure Rae ie ReBlade mechanical damages Symptoms Sudden decrease in pressure ratio Sudden decrease in section efficiency Sudden decrease in upstream pressure. a a a a3.FLOW AREA BYPASS o a 0 o a a a a a a Symptoms Decrease in section efficiency Decrease in pressure ratio Decrease in upstream pressure Cause Hp turbine bushing leakage Main steam stop valve leakage HP gland seal leakage IP stop/intercept valve leakage IP turbine bushing leakageCross section of turbine -showing efficiency loss due to leakage _SOLID PARTICLE EROSIONTURBINE EFFICIENCY AND SURFACE FINISH OF BLADE SURFACE L.P. SECTION LP. SECTION = H.P. SECTION EN 041 081 1.60 318 635 127 254 eee kK cre 16 32 il 125 250 500 1000 micros ‘SURFACE FINISH 690 400° 240 LOSS IN STAGE EFFICIENCY, % eo enon eewn so T EMERY GRADEImpact of parameter deviation from design Parameters on HEAT RATE (210 MW ,KWU Turbine )-operator controllable parameters.. —— SN PARTICULAR UNIT _ DESIGN INCREASE in MULTIPLICATIO PARAMETERS MEAT RATE DUE N FACTOR parameter (IN "eat /KwH ) 1 PARTIAL LOADING mw 210 24.7 PER 20 MW 1.235 zi Ms PRESS keyem2 150 25.5 PER 20 1.278 KG/em2 3 MSTEMPATHPT INET DEG 535 7.5 PER 10 DEG 07s c 4 HRHTEMP ATIPTINLET DEG 535 6.6 PER PER 0.66 10 DEGC 5 CONDENSER VACUUM vm 660 23.4 PER 10 mm 234 Ho 6 FEED WATER TEMP DEG C 2a 16 PER 20 DEG 08 = 7 RH ATTEMP FLOW WHR ° 6.4 PER 10 7/HR 0.64LOSSES IN A THERMAL POWER PLANT (CEA)HP CYLINDER EFFICIENCY KWU TURBINE 210 MW SIN” DESCRIPTION 1 POWER OUTPUT INLET PRESS TO HP CYLINDER INLET TEMP TO HP CYLINDER ‘OUTLET PRESS FROM HP CYLINDER ‘OUTLET TEMP FROM HP ‘CYLINDER ENTHALPY OF INLET STEAM ISENTROPIC ENTHALPY AFTER EXPANSION ACTUAL ENTHALPY AFTER EXPANSION CYLINDER EFFICIENCY oOmANnN au KRW” UNIT Mw kgjcm2 DEGC KG/CM TEMP. KCAL/KG KCAL/KG KCAL/KG % DESIGN 210 150 535 3348 814.73 719.95 730.88 88.4 210 139.7 537.8 819.25 728.77 746.15