ENERGY AUDIT
METHODOLOGY FOR
FOR TURBINE CYCLE
Presented By
M.V.Pande
Dy.Director
NPTI, Nagpur
COAL TO ELECTRICITY PROCESS
STEAM CYCLE FOR 210 MW UNIT
EFFECT OF STEAM PARAMETERS
P1 P2 P1
P3 P1 P2
T2
T1 T3
T2 T1
H
T1
H H
S S
S
Effect of Increasing Effect of Increasing Effect of Increasing
Pressure on Available Steam Temperature Steam Pressure &
Energy On Available Energy Temperature Both on
Available Energy
EFFECT OF STEAM PARAMETERS
H
H
S S
Effect of Changing Reheat Pressure Effect of Changing Reheat Temp.
THERMAL PROCESS LOSSES
Impact of Turbine Cylinder Efficiency on
HR/Output
Description Effect on Effect on
TG HR KW
1% HPT Efficiency 0.16% 0.3%
1% IPT Efficiency 0.16% 0.16%
1% LPT Efficiency 0.5 % 0.5 %
FOLLOW TEST CODES
• ASME PTC - 6 For Steam Turbines
• ASME PTC - 4.1 or BS- 845: 1987 for Boilers
210 MW KWU STEAM TURBINE STEAM & WATER CYCLE
TURBINE CYCLE LOSSES
STEPS INVOLVED IN CONDUCTING THE
TURBINE ENERGY AUDIT
Data collection
Observations and Analysis
Exploration for energy conservation
measures
Report preparation
DATA COLLECTION
Design Specification of turbine and associated equipment:
Type of the turbine, make and model
Number of cylinders
No of stages (for HP, IP and LP)
No of main and reheat valves
Construction details of HP, IP LP
Turbine extraction systems
Control systems
Type of governing
Type of sealing
Year of installation
Major modifications carried out during the recent past
DATA COLLECTION
Turbine Cycle Heat Rate Kcal/kwh
DATA COLLECTION
INSTRUMENTS REQUIRED
Temperature Indicator & Probe
Pressure gauges
Flow measuring instrument (steam and
water)
Ultrasonic leak detector
MEASUREMENTS & OBSERVATIONS TO BE MADE
Feed water at Inlet & Outlet of Heaters
Main steam parameters
Pressure
HP turbine extraction
Temperature
Hot reheat steam, Cold reheat Steam
Flow
IP extraction
IP Exhaust
Condenser back pressure
Cooling water flow and temperatures
Generator output
Barometric pressure
Reheater spray (flow)
Superheater spray (flow)
Feed water (flow)
MEASUREMENTS & OBSERVATIONS TO BE MADE
Past performance trends on turbine loading,
operation, PLF
Major constraint in achieving the high PLF, load or
efficiency
Major renovation and modifications carried out in the
recent past
Operational failures leading to inefficient operation
Tripping
Performance of associated equipment (condenser,
boiler, etc)
Plant side initiatives to improve the performance and
efficiency of the Turbine
TURBINE HR EVALUATION AND EFFICIENCY
Turbine heat rate is defined as the heat input (Kcal) required
to generate one unit of Electrical output (KWh). The trials are
to establish heat rate (Kcal/kWh) and turbine efficiency under,
as run conditions have to be carried out
The efficiency method given in this procedure is the
enthalpy drop efficiency method. This method determines the
ratio of actual enthalpy drop across turbine section to the
isentropic enthalpy drop
This method provides a good measure for monitoring
purposes. Each section of the turbine must be considered as
a separated turbine
Each section should be tested and results are trended
separately. While conducting the tests, it has to be ensured
that, it is conducted over normal operating load range
TURBINE HR EVALUATION AND EFFICIENCY
Q1 x (H1 – h2) + Q2 X (H3 – H2)
Turbine Heat Rate =
Gross Generator Output
860 kW
Turbine Cycle Efficiency = X 100
Heat Rate kCal/hr
TURBINE HR EVALUATION AND EFFICIENCY
Actual
Process
1-2-3-4-5
Comparison of Actual Expansion Actual Expansion in HP, IP & LP
with Isentropic Expansion in Turbine Cylinder
TURBINE HR EVALUATION AND EFFICIENCY
Variation of Heat Rate with Load Heat Rate Characteristics with
Condenser Exhaust Pressure
TURBINE EFFICIENCY EVALUATION DATA
Kcal/kg/oK
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
EFFECT ON HEAT RATE FOR PARAMETER
DEVIATION (500 MW UNIT)
DEVIATION IN PARAMETER EFFECT ON HEAT
RATE (KCAL/KWH)
1. HPT inlet press. by 5.0 ata 6.25
2. HPT inlet temperature by 10.0 deg C 6.0
3. IPT inlet temperature by 10.0 deg C 5.6
4. Condenser pressure by 10.0 mm of Hg 9.0
5. Re spray water quantity by 1.0% 4.0
6. HPT Cylinder efficiency by 1.0% 3.5
7. IPT Cylinder efficiency by 1.0% 4.0
EFFECT OF DEVIATION IN PLANT
PARAMETERS (210 MW UNIT)
Cause Effect
1% increase in plant efficiency - 3% reduction of coal consumption
- 3% reduction of CO2
200C reduction in M.S. temp. -1% loss of turbine cycle efficiency
25Kg/cm2 reduction in M.S. Pr. -1% loss of turbine cycle efficiency
10C CW inlet temperature rise 5 kCal/Kwh heat rate increase
10 mm deterioration in 20 kCal/Kwh heat rate increase
condenser vacuum
1 HP Heater out of service 50 kCal/Kwh heat rate increase
1 LP Heater out of service 25 kCal/Kwh heat rate increase
- 5% excess air - 1% O2 Increase in flue gas
- Every 20% excess air - 1% loss of boiler efficiency
200C increase in exit gas temp. - 1% loss of boiler efficiency
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
