ETJOURNAL Autumn 2010

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Enhancing Thermal Efficiency Z

(f)
(f)

of Steam Turbine In Coal Fired

Thermal Power Plant
Sanjeev Sharma' R. J. Lalwanj2

Abstract
This paper describes some options for conservation
of energy in the turbine section of a 210MW unit of a
coal fired thermal power plant. It shows the need and
importance of energy conservation. In this paper, data
is collected from the power plant and analyzed for
determining different performance parameters of the
turbine section.
A continuing concern of operators of steam turbines is
increasing operating costs. These costs reflect not
only the rising cost of fuel and material but also the
decreased efficiency of the aging turbine fleet. Over
time, damage to turbine components and increased
steam leakage are the major factors resulting in lost
efficiency Steam leakage alone can account for as
much as 80 percent of the efficiency losses in
turbines. Since the cost of fuel and materials is largely
beyond the control of steam turbine operators, the
primary mechanism for realizing savings is in the
improvement of turbine efficiency
Keywords Coal Fired Thermal Power Plant, Steam
Turbine,Energy Conservation, ThermalEfficiency
'Asst. Prof
(Mechanical Engineering Department.)
Skyline Institute of Engineering
& Technology, Greater Noida
India
'Dean & HOD
(Mechanical Engineering Department.)
Skyline Institute of Engineering
& Technology, Greater Noida
India
Introduction
Due to increasing operating costs, the owners
and operators of steam electric generation
plants work under considerable pressure to
maximize the reliability, efficiency and capacity
of their plants. In this regard, the single most
critical component of the steam electric
generation plant is the steam turbine. Most
steam turbines operate below optimum
efficiency levels by as much as several
percentage points due to many factors including
damage, deposits, misalignment, unusual flow
phenomena and steam leakage. Additionally,
reliability is frequently compromised by these
factors. Sub-optimum unit performance is
becoming increasingly more costly as prices for
fuel and materials rise and production
competition becomes tougher. Detailed
evaluation of the turbine's operating state, and
practical selection of performance
improvements are critical to optimum operation
of the electric generation plant. Application and
implementation of state-of- the- art after-market
replacement components, along with improved
operating procedures and techniques, can lead
to significant improvements in reliable
performance and sustained optimum efficiency
and capacity.
Partly due to rising operating costs, as well as an
increasingly competitive energy marketplace,
steam turbine thermal performance has become
an extremely important aspect of the power
industry's fleet maintenance programs.
Although returning the turbine to its maximum ••..•..•
-r----1
 Autumn 2010

achievable efficiency is one primary goal of the Expert repair of components to return them
maintenance overhaul, the industry's trend to their optimum efficiency and reliability
towards an increased Mean - Time - Between- states
Overhaul (MTBO) demands new methods for
sustaining high efficiency levels over longer Regular application of available components-
periods of operation. With recent de.velopment of reliability and efficiency upgrades
cutting-edge technologies, sustained high Quantifiable verification of the results of
efficiency has become a practical goal of turbine maintenance activities
Operations and Maintenance teams [6].
Throughout the following pages, the author will
A thorough understanding of actual turbines
identify specific areas of the turbine steam path
efficiency level is important and the author
that are critical to thermal performance and
emphasizes that the nucleus of a turbine
reliability, and will describe enhancements
maintenance program should be centered
around the following inspection and repair/ which can significantly improve both reliability
improvement activities: and efficiency.

• Accurate and regular programs of Methodology

performance testing
The methodology presented in this study is for
Regular analysis of test data for identification determining turbine heat rate. It includes the
oftrends and "events"
relations for determining the turbine heat rate
• Appraisal of steam path conditions and and for determining the estimated savings in
quantification of damage mechanisms energy and its equivalent monetary worth.

r R
S
H
W

rn 11 12

LPT
HPT IPT

7
6

1.Determination of turbine heat rate

The following relations are shown to determine turbine
heat rate. Heat flow from turbine stop valve, Q, =
ETJOURNAL Autumn 2010
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DATA OBTAINED, OCT.30, 2008 from Ropar Power Plant, Punjab.

Table 1 Designed and tested values of steam turbine section

SI. Parameters Unit Design Test

No.

1 Load MW 210 208

2 1 stage steam pressure

SI kg/cm 96.5 87

3 Main steam temp before ESV 530 535

4 Main steam enthalpy (h,) Kcal/kg 816.8 800.9

5 Main steam flow (m,) T/hr 652.132 670

6 FW temp before ECO (T2) °C 244.65 247

7 FW inlet enthalpy before ECO (h,) Kcal/kg 253.32 255.7

8 Extraction steam pr-hph-7 (P7) kq/crn" 42.32 41.0

9 Extraction steam temp-hph-7 (T7) °C 386 416

10 Extraction steam enthalpy-hph-7 (h.) Kcal/kg 760 778.32

11 FW inlet temp to-hph-7 (Tg) C 222.6 223

12 FW inlet enthalpy to hph-7 (hg) Kcal/kg 229.32 228.32

13 FW temp outlet from hph-7 (T,o) °C 243.62 246

14 FW outlet enthalpy from-hph-7 (hlO) Kcal/kg 256.25 249.65

15 Drip temp-hph-7 (T.) °C 232.7 248

16 Drip enthalpy-hph-7 (he) Kcal/kg 243.61 261.8

17 FW flow (m,) T/hr 645.234 83

18 Extraction steam pr-hph-6 (p.) kq/crn" 28.05 25.6

19 Extraction steam temp-hph-6 (T.) °C 315.6 348

20 Extraction steam enthalpy-hph-6 (h.) Kcal/kg 729.57 748.07

21 FW inlet temp to hph-6 (T3) °C 190.12 184.23

22 FW inlet enthalpy to hph-6 (h3) Kcal/kg 190.23 187.23

23 FW outlet temp from-hph-6 (T4) °C 222 223

24 FW outlet enthalpy from-hph-6 (h4) KcaJ/kg 228.2 227.42

25 Drip temp -hph-6 (Ts) °C 204 228

26 Drip enthalpy-hph-6 (hs) Kcai/kg 205.5 235.08

27 IPT inlet steam pr(P'2) kq/cm" 28.31 24

28 IPT inlet temp (T'2) °C 530 535

29 IPT steam inlet enthalpy (h'2) Kcal/kg 844.67 848.34

2
30 HPT exhaust steam pr (P,,) kg/cm 28.07 25

31 HPT exhaust steam temp (T" ) °C 320 332

32 HPT exhaust steam enthalpy (h,,) Kcal/kg 729.29 737.73

33 RH spray water flow (m'3) T/hr 0 26

34 RH spray water enthalpy (h,,) Kcal/kg 253.13 255.58

 Autumn 2010

2. Energy and monetary savings estimation

h6, m6 The improvement in turbine performance
parameters and the savings are as shown
below:

Turbine heat rate (design) = 8639.48 kJ/k Whr

h4
FWH6 h3m3
Turbine heat rate (actual) = 8970.99 kJ/k Whr
% difference in heat rate of turbine = 3.69

HP cylinder efficiency = 80 %

h5 % Change in HPT cylinder efficiency = 8.1 %

Fig. 1 heat balance diagram of feed water heater 6

= 0.146%

Reduction in heat rate = 12.90 kJ/kWhr

Saving in energy = 21.766 X 109kJ/year

Assuming, the plant
availability factor = 94.09 %
Saving in coal
h10
FWH7 h9m12 consumption = 12.25 X 105 kg /
year
Assuming, coal CV =4250 kcal/kg
h8 Monetary saving = Rs/year 3.062 x 106
Assuming, coal cost = 2500 Rs /tonnes
Fig. 2 heat balance diagram of feed water heater 7
3. Suggestions for energy conservation
Fig 2 shows the heat balance diagram of feed water heater 7.
This analysis is done in order to calculate the mass flow rate The following is the description for finding
of steam coming from extraction 7. the potential of energy conservation in turbine
section of 210 MW unit of a coal fired thermal
Bled steam flow, rn, = power plant:

Replacement of HP and LP turbine modules

Bled steam flow, rn, = along with internals

Existing 210 MW steam turbine (LMW design) is

Reheat stream flow, m3 = m,-(m6+m7)
fitted with impulse blading. In this design, steam
Heat flow from (h '2 - h)11 pressure drop takes place only in guide blades
m3
reheater to turbine, Q2 = --3.6 provided in the diaphragms. While passing
through moving blades, there is negligible
Heat flow from
m'3 (h'2 - h,) pressure drop. The purpose of the proposed
reheater to spray water, Q3 =
3.6 modernization of HP and LP turbines (LMW

Total heat flow to turbine, Q = Q, +Q2+Q3 design) is to provide a cost effective modification
ETJOURNAL Autumn 2010
OFENGINEERING
&TECHNOLOGY

and upgradation package, to maximize the as secondary flow loss to include all the
improvement in HP and LP turbine performance. losses that otherwise are not accounted for
The upgradation of HP and LP turbine is possible [4].
by incorporating the use of improved blade profile
(iii) Tip leakage loss arises from the leakage flow
which results into reduction in the aerodynamic
over the tips of rotors and the hub clearance
flow losses ego profile loss, secondary flow loss and
between blade rows and the cavity flow. For
tip leakage loss. After renovation and
upstream stages, the secondary flow loss
modernization of HP and LP turbine by
and tip leakage loss also become important,
implementation of the proposal, their life is
and for admission stages in small-scale
expected to be about 25-30 years. Design cylinder
machines even more significant than the
efficiency shall be as under:
profile loss [5].
HP LP

Old 80% 78% RESULT

New 86.5% The results of the present study are shown in

80%
Table 2. In this table, reduction in heat rate,
The following are the benefits of improved blade
saving in energy, saving in coal consumption
profile:
and its equivalent monetary savings are shown.
A) The improved design and cylinder efficiency Table 2 Changes in percentage heat rate of turbine
shall help in reducing heat rate. and savings with use of improved blade profile

B) The existing turbine requires large

replacements as per RLA studies and should 1. % change in heat rate 0.146%
have run for more than 1, 50,000 hrs.
2. Reduction in heat rate 12.90kJ/kWhr
C) Life extension
3. Saving in energy 21.766 X 109
Every type of energy optimization is about
kJ/year
reducing the total cost of a generation, i.e.
reducing the losses in relation to the cost, 4. Saving in coal 12.25X 105
either by increasing the thermal efficiency of consumption kg/year

the process or the efficiency of its components. 5. Monetary saving Rs/ year
For example, a gain in the isentropic turbine 3.062 X 106
efficiency is of high interest in the field of steam
turbine research. Various losses related to
CONCLUSION
blade profiles are:
It can be analyzed that there are significant
(I) Profile loss is usually referred to as the loss
changes in percentage heat rate of turbine and
generated in the blade boundary layers,
savings from upgradation of HP turbine by use of
including the loss arising at the trailing edge
improved blade profile. By upgradation of the
[1].
HPT the estimated saving of energy is
(ii) End-wall loss arises from the annulus approximately 21.766 X 109 kJ/year and its
boundary layers, and is sometimes referred to equivalent monetary worth is nearly Rs. 30 lakhs. ''''"1I"T"""c::-::l

00
 Autumn 2010

REFERENCES: Durban, Singapore, Sydney, Toronto, Wellington,

1. Melvin H. Chiogioji, Industrial Energy Conservation, 1984; 495-535.

Marcel Dekker, Inc. New York. Basel (1979); 19-31. 5. Hunt G. F., Modem Power Station Practice, Volume

2. http://www. iea. org/textbase/papers/2003/ C, British Electricity International London,

Coalfired fossilfuels.pdf Pergamon Press, Oxford, New York, Seoul, Tokyo,

1991; 2-13.
3. http://w\vw.energy.qld.gov.au/i mag es/
energy_balance.gif 6. Arthur P. Fraas, M. Necati Ozisik, Heat Exchanger
Design, John Wily & Sons, Inc. N York, London,
4. Gill C ENG A. B., MI Mech. E, Power Plant
Sydney, 1965; 241-255.
Performance, 1st ed., Butterworth. Lund Boston

000