Performance

management of Boiler,
Turbine , Cycle
Efficiency and other
performance
Parameters.
Goal: To generate electricity from heat input!!!

Carnot Power Cycle

Carnot Power Cycle
 Practical Problems Associated with A
Carnot Cycle

• Maximum temperature limitation for a cycle.

• Quality of steam at later stages of expansion
in a turbine or engine.
• Feasibility of Compression of wet steam.
 The Rankine Cycle: An
Alternate Ideal
Thermodynamic Model
Ideal Rankine Cycle
 How about a modified cycle - A Rankine
cycle
• To avoid transporting and
compressing two-phase fluid, try to
condense all fluid exiting from the
turbine into saturated liquid before
compressed it by a pump.
• when the saturated vapor enters
the turbine, its temperature and
pressure decrease and liquid
droplets will form by condensation.
• These droplets can produce
significant damages to the turbine
blades due to corrosion and impact.
• One possible solution: superheating
the vapor.
• It can also increase the thermal
efficiency of the cycle.
 Equivalent Carnot Model of Rankine Model

Tm,in

Tm,out

smin smax
 REMARKS ON STEAM RANKINE CYCLE

In fossil -power plants, an increase in thermodynamic

efficiency of 0.1% can be worth crores of rupees per year.

There is a continued quest for higher efficiencies in thermal

power plants, which has resulted in some innovative
modifications to the basic steam-power cycle .

Among these, there is the regenerative cycle, where the

temperature of
feedwater is raised from that on leaving the condenser to the
final feedwater temperature using steam extracted from various
stages of the turbines.

The determination of the optimal fraction of mass flow rate to

be extracted from each stage of the turbines is a complex
optimization problem.

In the regenerative cycle, a fraction of the steam that could

have been used to produce work in the turbine is used to heat the
feedwater instead. There is a gain of efficiency by one side, there
is loss by the other.
 Efficiency in Power
Generation
• Efficiency = Output/ Input
= (Input – losses)/ Input.
• Types of losses
• Exit heat loss
• Radiation loss
• Condenser loss
• Auxiliary power loss.
 Efficiency in Power
Generation
How to minimise the losses?
• Heat exchanger

• Insulation

• Vacuum

• Efficient auxiliaries and optimization.

 Energy Conservation
Why?

• Mother earth has limited resources.

• Energy production leads to

environmental degradation.
 Energy Conservation
How?

• Changing attitude and practices.

• Creating awareness.

• Optimisation.

• Using energy efficient devices.

 NEED
• Almost Rs. 4.00 Crore Per MW
• Cost Savings
• Resource Saving
• Life of Plant
 Concepts
• Cycle Efficiency is the efficiency of whole
cycle and can be improved by particular
set of steam condition employed
• Turbine Efficiency is the efficiency of turbo
alternator converting the available energy
in the cycle into electrical energy.
• Boiler Efficiency is effectiveness of
combustion and heat transfer
• Auxiliary Power efficiency depends on the
ratio of Electricity sent out to Electricity
Produced.
 Requirement of Boiler
• Should be able to produce at
required parameters over
• Compatible with feed water
conditions which changes with
turbine loads
• Capable of following changes in
demand for steam without excessive
pressure swing
• Reliable
 BOILER SYSTEM
• Feed Water System
Makeup Water System
Condensate System
• Steam System
• Fuel System
 Reheater
S
Drum C

Platen SHTR
R
DPNL E
E
SHTR n

Gooseneck LTSH
Chimney
Downcomer

waterwall
Fireball Economiser

ID fan

ESP
APH

Bottom Ash
210 MW Boiler: Water and Steam Circuit

LTSH
Final SH.
Platen SH.
330-375C
500-540C
375C-425C

Economizer
Water Wall
240-310C
310C
 FOCUS
• Assess Boiler Efficiency by Direct
and Indirect Method
• Calculate and Optimize Boiler
Blow Down
Identify and Implement energy
efficiency measures
 Direct Method
Where energy gain of the working fluid
(Water & Steam) is compared with the
energy content of the boiler fuel.

Heat Output
Boiler Efficiency= X 100
Heat Input
 Q x ( h g – hf )
Boiler Efficiency (ή )= X100
q x GCV
Q : Qty of Stm generated in Kg/Hr
q : Qty of Fuel Used in Kg/Hr
hg: Enthalpy of Saturated Stm in
KCal/Kg of Stm
hf: Enthalpy of Feed Water KCal/Kg
of Water
GCV: Gross calorific Value of Fuel in
Kcal/KG of Fuel
 Advantages of Direct
Method

• Evaluation is quick
• Requires Few parameters for
Computation
• Needs Few Instrument for
monitoring
 Disadvantages of Direct
Method
• No Clue to the operator

• Does not calculate various losses

accountable for low efficiency
 Indirect Method
• The efficiency is the difference
between the losses and the energy
input.
• Loss Method
• Boiler Efficiency (ή )= 100% - Losses
 Types of Losses
• Loss of Heat due to Dry Flue gases
• Loss of Heat due to Moisture in Fuel
and combustion air
• Loss of Heat due to Combustion of
Hydrogen
• Loss of Heat due to Radiation
• Loss of Heat due to Unburnt
 Data Required
• Ultimate Analysis of Fuel i.e. H2,
O2, S, C, Moisture & Ash Content
• %age of O2 or CO2 in Flue Gas
• Flue Gas Temperature
• Ambient Temperature
• Humidity of Air
• GCV of Fuel
• Percentage of Combustibles in ash
• GCV of ash
 Dry Flue gas Losses
• Excess Air
• Air Heater gas Outlet temperature
 Air Heater gas Outlet
temperature
• Lack of Soot Blowing
• Deposits on Boiler Heat Transfer
Surface
• High Excess Air (Causes less heat
generation in Furnace and more in SH)
• Higher Elevation burners in service at
low load
• Defective baffles and bypass dampers,
causing gas short circuiting
• Improper Combustion
• Poor Milling Plant Performance
• Air recirculation
 Wet Flue Gas Loss
• Moisture in Fuel
• Moisture in Combustion
• Moisture in Air
 Carbon in Ash Loss
• High Carbon in Ash
• Low Carbon in Ash
 High Carbon in Ash
• Coarse Grinding
• Mal adjustment of flame
• Unequal loading of different Mills
• Incorrect PA air temperature
 Low Carbon in Ash
• Exhauster speed too low
• Mill Adjustment
• Rich Fuel / Air Mixture
• Separator ( Classifier) speed too high
 Boiler Blow Down
• Lower Pretreatment Cost
• Less make up water consumption
• Reduce maintenance downtime
• Increased Boiler life
• Lower consumption of treatment
chemicals
BLOW DOWN CALCULATION

Feed Water TDS x % Make up water

Blow Down(%)=
Max. Permissible TDS in Boiler Water

TDS: Total Dissolved Solids

Blow Down Rate = Boiler Evaporation rate X Blow

Down(%)
 Energy Efficiency
Opportunity
• Stack Temperature
• Feed Water Preheating using
Economiser
• Combustion Air Preheat
• Incomplete Combustion
• Excess Air Control
• Radiation and Convection Heat
Losses
Energy Efficiency Opportunity

…….Contd.

• Reduction in Scaling and Soot Losses

• VFDs for Fans, Blowers and Pumps
• Proper Boiler Scheduling
• Milling plant performance
• ESP performance
 SIMPLE RANKINE CYCLE
• LOW INITIAL COST
HEAT GAIN IN
THE BOILER
• LOW CYCLE EFFICIENCY
• HIGH MOISTURE AT TURBINE OUTLET
• LIMITATION ON MAXIMUM PRESSURE
BFP
• LIMITATION ON CONDENSER PRESSURE

MODIFIED RANKINE CYCLE

• HIGHER CYCLE EFFICIENCY
• LOW MOISTURE AT TURBINE OUTLET
(LP TURBINE DESIGN EASIER)
• NO LIMITATION ON MAXIMUM PRESSURE
• NO LIMITATION ON CONDENSER PRESSURE
• HIGHER INITIAL COST
 FOR 200 MW UNITS
• INITIAL STEAM PR- 150 Kg/Sq. CM (abs.)
• INITIAL STEAM TEMPERATURE - 537 Deg C
• REHEAT STEAM TEMPERATURE - 537 Deg C

 FOR 500 MW UNITS (SUB CRITICAL UNITS)

• INITIAL STEAM PR- 170 Kg/Sq. CM (abs.)
• INITIAL STEAM TEMPERATURE - 537 Deg C
• REHEAT STEAM TEMPERATURE - 537 Deg C

 FOR 660 MW UNITS (SUPER CRITICAL UNITS)

• INITIAL STEAM PR- 246 Kg/Sq. CM (abs.)
• INITIAL STEAM TEMPERATURE - 537 Deg C
• REHEAT STEAM TEMPERATURE - 565 Deg C
• IMPULSE TURBINES

• REACTION TURBINES
 Turbine Efficiency
output Kwh
Efficiency = =
Input Input
1 Kwh = 3600 K J
output
Efficiency = x 100 %
Heat Input
 Turbine Efficiency
……
Contd.

Heat rate:
210MW LMW Turbine= 2040 K Cal/kWh
ή = 42.15%
500 MW = 7940 K Cal/kWh
ή = 45.3%
Degree of Reaction (R)
Enthalpy Drop in Moving Blade
R=
Enthalpy Drop in Stages
 Factors Affecting
Operation
 Effect of Load
 Throttle Governing
 Nozzle Governing
 Overload (By Pass) Governing
Terminal Conditions
 Effects of Vacuum
 Effects of MS and RH Temperature
 Effects of MS and RH Pressure
 Pressure Drop through Reheaters
Effect of Heater Efficiency
Gland Wear
Feed Pump Power
 Turbine Losses
 Internal
 Friction in Nozzle, Blades & Disc
 Diaphragm gland and blade tip
leakage
 Partial Admission
 Wetness
 Exhaust
 External
 Shaft Gland Leakage
 Journal and Thrust Bearing
 Governor and Oil Pump
 Condenser Performance
• Back Pressure
» CW Pumping Power
»Leaving Loss
»Reduced Condensed
Temperature/ Increased Blade
steam
»Wetness of Steam
Energy Saving Opportunities in
Steam System
• Monitoring Steam Traps
• Avoiding Steam Leakages
• Providing Dry Steam for Processes
• Utilising Steam at the lowest
Acceptable Pressure for the process
• Proper Utilisation of Directly Injected
Steam
 Energy Saving Opportunities in
Steam System ……. Contd

• Minimizing Heat Transfer Barriers

• Proper Air Venting
• Condensate Recovery
» Financial Reasons
» Effluent Restriction
» Maximizing Boiler output
» Boiler Feed Quality

• Insulation of Steam Pipelines and

Hot Process Equipments
• Flash Steam Recovery
 Control & Instrumentation
• Data Acquisition System

• Distributed Digital Control

Monitoring Information System
 Functions
• Data Acquisitions
• Data Monitoring and Status
Reporting
• Alarm Monitoring & Status Reporting
• SOE Recording
• Mimics and Guidance's
• Long Term data storage Retrieval
and Statistical Analysis
 Functions
…….. Contd.

• Better Human Machine Interface

• Online Performance Monitoring
• Report Generation
• Pre and Post Trip Analysis
 Factors for Unit
Performance
• Planned maintenance loss
• Thermal Efficiency factors
• Plant Load Factor
• Forced Outages
• Plant Availability Factor
• Availability and Efficiency has a
direct relationship
• Higher availability leads to higher
efficiency
• Efficient Unit leads to better
availability due to better combustion
control conditions, better fluid
dynamic condition and better heat
transfer condition
 Conclusion
• Performance • Efficiency
Improvement Improvement

• Effective Capacity • Lower Cost of

Utilisation Generation
• Investment Cost • Saving in
• Lower Cost of Resources
Generation • Increased Life of
Plant
 INDIAN POWER SECTOR
COAL : 69450
GAS : 13582
OIL : 1202
HYDRO: 34110
NUCLEAR: 3900
RENEWABLE 6191
TOTAL 128435
 COST IMPLICATION

•69450* 0.73= 50698.5 MW

•18751.5 MW
•Rs. 75006 Crore
 Classification
• Impulse • Simple Impulse
• Velocity Compounded
• Impulse – • Pressure Compounded
Reaction • Pressure- Velocity
Compounded
 NOZZLE
• All turbine have nozzles in which the
pressure of the steam is reduced and
the velocity increased.
• In Impulse Turbine the nozzles are
stationary which is stationary Blade.
• In Impulse-Reaction turbine both
the fixed and moving blades are
nozzles.