•Assessment of true performance

•Establishing Performance Bench Mark of the Unit

•Computation of performance deterioration due to

Ageing

•Deterioration apportioning analysis

•Cost effectiveness of suggested modification

•Performance Optimized Operation of the set

Focus on
1. Reliability of available data
2. Consistency of operating parameters
3. Weeding out incorrect/ doubtful data
4. Stable and predictable TG Cycle
5. Accounting of leakages & passing
6. Adjustment in the performance for variation in
terminal parameters & cycle configuration
Cylinder Internal Efficiency
First Stage Pressure Vs Flow characteristic
System Leakage
Heatrate
Auxiliary Power Consumption
Original HBDs are valid for brand new condition
Cycle data in HBD’s are predicted based on design, though actual
data may be different in some cases.
Unit Specific conditions to be incorporated
Actual Cycle conditions may differ from the design condition, like
•Main steam Pressure/ Temperature
•Reheat steam Temperature
•Reheat Circuit Pressure Drop
•Reheat/ Superheater spray
•Cooling water inlet temperature/Condenser Vacuum
•Regenerative Feedheater(s) out of service
How to workout predicted performance?
•Tests to be preferably performed at full load or VWO
condition.
•Data can be obtained from plant instrumentation, with
suitable corrections.
•Performance data obtained from tests, to be corrected for
actual cycle conditions.
•Data to be compared with corrected HBD/ Last available
test report.
•Allowance to be made for performance deterioration due to
ageing
•Realistic assessment of unit performance can be done.
 Calculation of performance deterioration due to ageing as per
International standards
AGEING OF STEAM TURBINES

1.6

1.4

1.2
PERCENTAGEPOINTS

0.8

0.6

0.4

0.2

0
0 5 10 15 20 25
-0.2
M ONTHS

DIN ASME BS
Above Curves are prepared by
ASME/DIN/BS based on feedback of
large no of sample machines.
Depends upon
• Grid healthiness
• Operating Condition
• Unit Size
• Water/Fuel chemistry
Similar exercise needs to be carried out
by Indian Utilities
Actual feedback on ageing with the
influence of
• Rapid Grid Fluctuations
• Fluctuations in the terminal Parameters
• Condenser Tube fouling
• Higher leakages/ Passing
 Compilation of performance data of
similar machines will form back-bone to
Bench Marking
This data can be used to calculate actual
Ageing of machine
Leading to true assessment of
performance.
*********************************************
 PRESENT POWER SECTOR SCENARIO

MAJOR IMPETUS ON

• EFFICIENCY

• RELIABILITY

• AVAILABILITY

• POLLUTION NORMS

• COST
RESULTING IN ENHANCED EMPHASIS ON

REDUCTION IN GENERATION COST

BY HAVING
LOWER EQUIPMENT COST
HIGH EFFICIENCY OF TG CYCLE
FUEL COST
REDUCED O & M COSTS
REDUCED FORCED OUTAGES
 RESULTING IN ENHANCED EMPHASIS ON

=> INCREASED AVAILABILITY

SHORTER GESTATION PERIOD

REDUCED DOWNTIME
UNIT CAPABILITY TO OPERATE AS BASE
LOAD MACHINE FOR MAXIMUM TIME
REDUCED PLANNED SHUTDOWN TIME
ENHANCED SPAN BETWEEN TWO
OVERHAUL
RESULTING IN ENHANCED EMPHASIS ON

RELIABILITY (CAPABILITY TO FULFILL)

GRID REQUIREMENTS
GRID FLUCTUATIONS
SUDDEN LOAD THROW OFF
HOUSE LOAD OPERATION
COLD,WARM & HOT START
RESULTING IN ENHANCED EMPHASIS ON

=>MINIMIZING ENVIRONMENTAL HAZARDS

BETTER HEATRATE LEADS TO
Reduced Green House Effects
Lower Coal requirement
Lower emissions of NOx, SO2, CO
Reduction in quantity of ash disposal
Less Air Pollution during coal transportation
Reduction in Heat release to CW
*****************************************************
IMPROVEMENT IN TG PERFORMANCE

POSSIBLE THROUGH
• INCREASE IN TURBINE CYLINDER
INTERNAL EFFICIENCY
• ENHANCING TERMINAL PARAMETERS
• OPTIMISATION OF REGENERATIVE
FEEDHEATING CYCLE
• IMPROVED O & M PRACTICES
O & M ISSUES INFLUENCING PERFORMANCE

1. Variation in terminal parameters from

the design cycle
2. Deviation/ Malfunctioning of equipment
3. Passing of valves & system Leakages
4. Load fluctuations
5. Frequency variation
6. Higher Auxiliary Power Consumption
 O & M ISSUES –
Variation in terminal parameters

Major factor affecting the performance-

Main Steam Pressure

Main Steam Temperature
Hot Reheat Temperature
Cooling Water Inlet Temperature
Condenser Back Pressure
Final Feed Water Temperature
Reheater spray
O & M ISSUES –
Variation in terminal parameters

TG Set performance will be optimum

while operating the set at rated
design condition. Any variation in the
terminal parameters mentioned
earlier may not result in better than
optimum performance
O & M ISSUES-
Deviation from the design TG Cycle

Condition of
Source of extraction for Deaerator/BFPT
Alternate drain lines of HP/LP Heaters
Passing of HP Bypass valves
HP Heater FW Bypass valves
Superheater /Reheater spray
Vent lines of Deaerator/ HP/LP heaters
Recirculation lines of CEP/BFP
Air ingress in condenser
 O & M ISSUES –
Malfunctioning of equipments

Major factors affecting the performance

1. Steam Turbine
Worn-out Glands of HP/IP & LP Front
& Rear shaft sealing
Worn-out inter-stage sealing
Higher balance piston leakage
Variation in seal steam header set pressure
 O & M ISSUES –
Malfunctioning of equipments

Major factors affecting the performance

1. Steam Turbine
Steam leakage through parting plane,
bellows, hoses
Leakage through MAL Valves
Poor cylinder internal efficiency
Variation in First stage pressure
characteristic
 O & M ISSUES –
Malfunctioning of equipments
Major factors affecting the performance
2. Regenerative Feed Heating Cycle
Level variation in heaters
Improper cascading of drains
HP/LP Bypass in operation
Higher system leakage & Makeup
Superheater & Reheater spray
Poor efficiency of CEP/ BFP/ BFPT
 O & M ISSUES –
Malfunctioning of equipments
Major factors affecting the performance
2. Regenerative Feed Heating Cycle
• Higher air ingress leads to poorer vacuum
• Cleanliness of condenser
• HP/LP Heaters out of service
• Poor TTD/DCA of heaters
• Higher intake of steam for BFP drive Turbine
O & M ISSUES-
System Leakage

Higher system leakage implies enhanced

DM water requirement.
It is generally 0.4 - 1.0 % of the MS Flow.
As per international norms within 0.1 %.
Leakage deteriorates the Unit performance.
More in the High pressure region of BFP/HP
Heaters & Boiler having high heat content.
 O & M ISSUES-
Passing through valves

Internal leakage
Affects the performance more
Difficult to identify & quantify
Being internal – gets low attention
Damages the valve seat & other components
Faster growth of damage if not arrested.
 RECOMMENDED DIAGNOSTICS

A. Turbine Cylinder Internal Efficiency

• Most vital check
• Any abnormality in the Steam Turbine will
effect efficiency.
• Can be done through plant instrumentation
• Should be carried out at regular interval
• Ensure correctness of the data
 RECOMMENDED DIAGNOSTICS

A. Turbine Cylinder Internal Efficiency

H1 =f(P1,T1)
S1= f(P1,T1)

H2adia =f(P2,S1) H2 =f(P2,T2)

Efficiency (%) = (H1-H2) * 100/(H1-H2adia)

 Cylinder Efficiency –
Various Possibilities

A. Gradual Deterioration
Normal Ageing Process
Wear & Tear of Sealing Fins
Deterioration in steam flowpath
Deposition in the steam flow path
Erosion in the valve seat
Erosion in the last stages
 Cylinder Efficiency –
Various Possibilities
B. Abrupt deterioration in Efficiency
Probable causes may be
Blade failure
Sealing fins
Interstage sealing
Internal mixing of steam at different temp.
Foreign material in the steam path
Water Ingress in the turbine
RECOMMENDED DIAGNOSTICS

A. First Stage Pressure Characteristic

• Most vital check
• Any abnormality in the Steam Turbine will
effect Characteristic.

Procedure
•Main Steam Flow is derived by theoretical curve
•Validate the characteristic by actual measured one
Undertake measurement at regular intervals
•Compare the characteristic with earlier data
 RECOMMENDED DIAGNOSTICS

B. First Stage Pressure -Flow Characteristic

Procedure(contd)
• Analyse if variation is gradual or Abrupt
• If variation is gradual, whether synchronous
with change in cylinder efficiency
• Gradual variation can be permissible.
• If variation is abrupt, it is a serious issue
• Analyse the possible reasons
*********************************************************
 ACHIEVING OPTIMUM PERFORMANCE
DURING OPERATION

Throttle Control reaction turbine has best

performance at higher load.

It will always be advantageous to operate the set at

higher load/ full load.

During part load operation, running the set at pure

sliding pressure operation mode will result in best
performance .
ACHIEVING OPTIMUM PERFORMANCE
DURING OPERATION

But it will not have any margin for spinning

reserve.

Quick load increase under such condition not

possible

To overcome this shortcoming in case load

fluctuations are expected, at part load, operate
the set with modified sliding pressure with
around 10% throttling.
CONCLUDING REMARKS

1. Operate the set near to the rated parameters

2. TG Cycle close to design
3. For Throttle Control Machine run as base load
4. Minimum system leakage
5. Reduced steam/ water passing
6. Minimum SH/RH Spray
7. Regular monitoring of Cylinder Internal Efficiency
8. Regular monitoring of First Stage Pressure
STEAM TURBINE ENGINEERING BHEL, HARDWAR