The JapanSociety

The Japan Society of Mechanical Engineers

ofMechanicalEngineers

Proceedingsof the
lntemationalOonference on Power Engineering-03
(ICOPE-03) Nevember 9-13, 2003, Kobe, Japan
C202
A STEAM TURBINE MATHEMATICAL MODEL
FOR ON-LINE OPTIMIZATION OF LOAD DISTRIBUTION
KrzysztofBadyda
ofHeat Engineering,Warsaw University
lnstitLvte of[[bchnolegy,
25 Nowowiejska St.,OO-665 Wdrsaw, Poland

ABSTRACT The general structure and purposes of thedisnibutedcontrol systems (DCS)are reminded in
connection withthecapal)ilityto use them foron-1ine optimization of the load distribution in large,multi-unit
power stations. The basicassumptions, equations and structure of a model ofbackpressure extraction turbineare
presented.The tasks,real{zed using this model in collaboration withtheDCS's measuring and archive systems,

are defined. The principlesof using and correcting theinputdatafortheconsidered tasksare described.
Model calculation results and recorded measuring dataare cornpared. The inputdataqualityand influence of the
DCS recerd mode on theal)ilities to use the model appropriately are discussed,

Keywords: MathematicaiModelling;SteamTurbine;
On-lineOptimization

1.INTRODUCTION Within a typical corrfiguration of such systems,

presented on Fig. 1, signals from multiple distributed
The developmentof modern methods of co11ecting measuring systems (connectecl withvarious facilities,
being
contrel and measuring data brought new capahilities of parts of the controlled installation)
are transmittedto a
computer applying inpower plants. At the presenttime,al1 comrnon, maln plantnetwork path(system highway).
[[hose
thepower units under construction are being equipped with signals become thenavai1ahle fortheprocessautomatic,
digita1 distributedcontrol systems (DCS). In the older operation, engineeg archive and other computer stands
power stations, the traditional,analog control systems and (stations),
realizing special tasks and collaborating with the
automatics havebeenrecently reconstructed to digita1ones. main path,

":T:.l
--1... ..um.1 Systerp.hisw{!kl.
:..'. wwnv.

/ / ".t
/
t",
..
.. ,I/ww.ma1/fim""itwI
f,.:
umrm-/
/,./f
lili
fits l I
i･"
' Controllers
g
li :
fi,
tttt
tt

t'
t,

xeIVmpltwT- ..7s

".･ 'x t-
,\I-;i'l･l,
..V. Tt ..t/.
'ww"
'''um'v"um ･ --''r','-" cl
- 1
:lm

es--l
l' "'
D
l es--ifi'
i' 'l･lri'
-Swr
･: 'ww''

llLl
..
Engineering
stattons "
operator
i'statlons
l
L
Archive
stations

Fig.1.Basicequipment and inforrnation

transferina disuibuted
control system (DCS)

Ibgether providing mode of implementationofvarious application software productsEl].

infbrrnationwith
transfer andconvenient
storage, DCS enable For instance, the availabllity of the system mernory

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resources enal)les on-1ine complex analysis of the main controlled extraction. Ihe mass flowrates of theinlet and

power facilities (boilers.

turbine generetors), outlet steam are measured atthepoirrts, marked on the flow
[[1iebasic assumptions and dependencesof a diagram, presentedon Fig. 2. the measurements are
rnathematical rnodel of backpressure extraction stearn perfbrmed sqparately in thetwo parallel pipelines.At the
turbine,used to determine the machine perfbrrnance,are uncontrolled extractions, thepressureand mass fiowrate
presentedinthe pape:lnon-line collaboration witha DCS, are measured. As for the considered purposes,this
the calculation results were used foroptimization of the rneasuring system is net uniform: it is insuMcient in
load distribution in a largecombined heatand powerplant relation to pressure and temperature data no (e,g.
with characteristic,complex technological output stnJcture. infbrrnationabout the steain parametersbetweentheturbine
stage grvups isprovidod);and on the other hand, it provides
fu11inforrnation about all the inletand outlet steam flows,
2. MODELASSUMPTIONS AND STRUCTURE except the glandIeaks.The main nominal parurnetersof one
ofthe modeled turbinegenerators are set inTlable1.
Ihe considered turbine hastwo uncontrolled and one

q L

Rll;;
lpJoutL
GoL,TLt,
PaL

G,, '

ex xHP

mo

NL,
t5/'-"'

i.
iGoutmPontR
GoRy R,RG.2 -
aR,
q.--
Fig.2.Ibrbine
flowdiagrurri - inputdataofthe
and measured quantities mathematical model

1 '
offu.gggft
gS･(2E--.--n =.F-

gkyE =39yfi
.'.',Egsi
o
8Efu :-
3
s
4 El E2
By-passog.ergks
Ntsgigsg.h gEg!.E8
skieg8im =agat&gk

eutse
tttt
xE

Fig,3.Scheme ofthe turbine mathematical model, corresponding to the flow diagram on Fig.2

The model was used forrealization of two part and . simulation: calculation of the turbine pertiormance,
consecluenttasks: including
the generated
electric capacity IV}t
.te and

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stage group irrternal

eMciencies, basing on the .kJ=
measuring data k-1
rv; (4)
. datareconciliation: correction of themeasured steam

mass flows,conveptng the calculated capacity Mekota '

to themeasured generatedelectric capacity IVLi.,.and

clesing the rnass baianoe.
E= i'(fi".") for n>n. (5a)
Tlie model and corrected data were next used for
or
eptimization of the loaddistribution,
theresults frornwhich
are beyond thispaper as a task.
E#1 for XSZer; (5b)
and
2

Table1,Exemplarymain nominal pararneters Eo= i-(nio--xz.c:o) for no>n.o (6aj

of modelled turbine generator
or
Psrameter SymbolUnitValue Eb=1 for rre S rr.o; (6b)
Nominalrotationalspeed nrpm3000
NominalgeneratodcapacityNclkW55000 z=k'; (7)
Liyesteampressure Pa
poMPa13
Livesteamtemperature TeoC535
. internal
eMciency equation, basedon approximationg
dependenton the operation conditions and design
LivesteammassflowrateGokglsIOO solution [4],
[5],
[6]:
Extraction1pressure MlMPa4.0
Extraction2pressure imMPa2,95 i-!L.ffa,x),
ne
(8)
Controlledextr.pressure PEMPa1.75
where:
Outletpressure PoutMPae.75
a=f(X,z); (9)
Module structure of theturbinemathernatical model was
irrtroduced,[fhefo11owingseparately modeled e!ernerrts
X=l--1x1'--1ne (10)
(modules)of theflow path were digtinguished:
. three turbine stage groups in the high-pressure (HP)
part;
. one stagegrvupinthemediurn-pressure (MP)part; in general
two basicappreaches to determining turbine
. govemingstagesoftheHPandMPparts; stage group characteristics under offLdesign operuting
. control-valvesystemsoftheHPandMPparts. conditions by calculations can be distinguished: the
The model diagrarn withdetermined connections between approach based on expanded mathematicai models of the
these elements and balance nodes, at which stream splits detaileddata al)out
the group, and the
grvup, requiring
ispresentedon Fig.3.
takeplace, approach basedon approximation models, using simpler
The turbinemathematical model was based on the mass dependencies ofintegral type [5].
and energy balanceequations, withthe rnass and energy The second of these approaches, inwhich a general1ack
accumulation neglected inallthe modules model): ("static" of properdataand infbrmation occurs, isconsidered inthis
paper. Eq. (8) is used for internaleenciency calculadon.
nZG,
Procedures shown in [4].[5]for detetmination of
=o;
(1) coefficient a inEq.(9) are used foral1stage greups of the
±
i 1nZG,
turbine,

h, +{fLN-o, (2)
i=1 3. A??LICifi]ION ANP RESUI;TS EROM
MEASUREMENTSANDCALCULMIONS
and characteristics ofthe above mentioned elements,
For instance, themodel of turbine stage group(in the The presented steam turbineinatherriatical modet was
considered case, impulse type)isdescribed by [1],
[2]: applied foron-line simulation of theturbine's perfbrmance
. mass flow rate equation (output quantity:
pressure), under theconditions of unit connection with a boiler and
basedon thesimilarity principlesand detemined[3] headerconnection frem the technolegical output side [1],
forconstant in tirne,rated rotational spoeci: [7],Ihe stearn mass fiowrates, pressures and temperatures,
and generated capacity (seeFig, 2) were used as input

JIIiSiil}
Theirfulllist
quantities. isas fo11ows: GoL+GoR;GEt;Gm;
i "

{lf."o (3)
=
' GEL;GER;GeutL; GeutR;lb;po;pa"t; IVLi,with7h,po and p.ut
averaged ffom thecorresponding values, measured at the
where: lefiand rightstearn pipelines. [theoutput quantities weTe:

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pressuresbetweentheparticularstage groups; extraction The considered model was used as a component ofa
and outlet steam temperatures,and generated capacity rnachine-hall mathernatical model. [[1ie1atterisa partof
Ne]caic, calculation proeedure, collaborating with an optimization
ln the industrial measuring systems of power program. 1[hemodels of therest of thestearri turbineswere
installations,
considerable in on-line measurements
errors created inanalogous way.
may occur, The main the lackof current
reasens are Comparisons between measurement and calculation
equilibrium condition of the insta11ation, caused by results are presentedon Fig.4, 5 and 6, These results were
operation parameter changes, and incorrectness of the registered during special session, but during normal
measuring paths.Unlike under laboratory conditions, the operation. On Fig.4, thelower(thicker) lineillustratesthe
moment of realization, and often the measurement changes in the generator load during measuring. These
conditions, cannot be selected itmay be dificultto
(e,g. changes are expressed by relating the measured elecnic
findstraight pipelinesection long enough for accurate capacity IV}i.,.to therated generatorcapacity IV}io, The
measurement), mode of collaboration with the measuring and aTchive
Most easily considerable inconsistency is observed in systems conditioned thereading (and writing) time step to 3
measurements of mass flowrates, Before the realization of rninutes, The registration of the steam mass fiow rates
the presented task, analysis of consistency of registered started witha 3O-minute delayto thegeneratedcapacity and
measurements of inlet,
extraction and outlet steam mass caused lack of data for the beginning periodon Fig.5 and
fiow rates was made fortheconsidered turbinegenerator, Fig.6.
Takingthe glandsirrto account, itappeared [1]that the Four circumstances cansed thedifferences between the
(variable in time) difference
may reach even 24% of the measurement and simulation results, appearing in the
live-steam
mass flowrate. considered entertainment: firstlx themodel is inaccurate;
Additional results were obtained by realizing the secondly; the measurement (sigr1al transrnission) paths
task - Eq. (l1),
reconciliation The steam mass flowrates happenedto fail;thirdly, the measurements themselves
Gbeerr,
GEt 6Ez GE
cern and Geutcerr
mm were determined
corr have certain range of accuracy, which causes lack of
by correcting the corresponding measured values balanceeven in cases of relatively loRgsteady operation;
counter-proportionally to theirlevel ofreliability, expressed and finally,
such steady conditions hardly obtainable
are
using therelation SD,i(]i.The reconciliation was to provide duringnotrnal operatiog and al1the data were processed
mass and energy balance, and calculated generatedcapacity on-Iine.
equal to themeasured one, using the condition: As itisvisible on Fig, 4, in the case of the generated
capacity thedivergence didnot exceed 1O% (the exception

(9i
il'2'2!L)
2.min in one of the pointsis incidenta1). A correction of the
]Ii.;i . (m live-steam mass flowrate of similar range appeared
sufficient (seeFig. 5 and 6a). The difilerences
to be
were
sigriificantly largerin the cases of the extraction- and
SDi are in Eq. (11)permissiblevalues of the standard outlet-steam mass fiowrates (Fig.6b and 6c).
deviationofmeasuTed steam mass fiow rates G,.

1.2

1.0

Rg
,.,
,li

O,6

o.4
O 20 40 60 80 100 120 140 160
t[s.60]

Fig,4.Relativechanges ofthe tmfbinegenerator generatedcapacity duringmeasuing precess,

Comparison with simulation results obtained from themathematical model

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-T ------
1,OrG-i.';t'F' r"-'u
i" : / T i
/t i
l.･
te' S"
-
p lg M'
Gbeorr
J.
ts 'turl
-s.
,-----" ! /.-"//gx'i

O,8t 1
1 1, /''L-;'
11/ i l
O.6
i L..".t 'V"t 'i i-r'nv
""rrr-4 -' rF'

G e"t },- '1,i

//

sg eorr 1/ A1
1t trie
//t

,,i 'F.
..--･ tv- at..v..

`l 1/
' l t-""'+nt'
i Geutmeas s/l,1 ･s---"-;,i , '"
Y--'x

it 1 -1,u-ua).
o,4 -H"LL 'tG -il"'7'
/ t,
-

/'1
thOrrFo cl-
1,/

/ u'/;. -.-
1
/
.t---.-
GEmeasi
--
I ttt/r"
////e-/
/ t-
I
O,2ti--- --t..tttttttttttrr..T-. .-.L. ...-.-.mL- ----e
I 1/

ZL120
il
i,

l-･i･ i
l/1
t
i

L-r)/
123, 126, l32
' i
o.o-,ljs,eg,rr,ef,tkoe,?W
t -/tt
ittttmTt7.-r-ttitttt..tt.rTr
o 20 40 60 got[s.60] 1OO 140 160

Changesofinlet, conirolled extraction and outlet steatrirnass fiowrate - cornparison between

Fig,5.
measurenierrt results and corrected used inthemodel. Goo- rated livesteam flow me
data,

p
loO r-"""'-'m '"r' The
very large correction in thecase of outlet steam
4l50r
a)
ge-"ex-8ec,.gv it"' i rnass fiow rate needs additional explanation. In order to
----------
/

1
ewoid irnl)alance,thismeasuring datawere rejected as input
-
l dataforthesimulation task,and theoutlet stearn flow rate
-----g resulted directly from the other fiow data. For the
",
o- -.-.,e-'th v:
It reconciliation purposes, the outlet steam mass flow rate was
-50 :
-t assumed to be leastreliable,as theoperating conditions of

'
/'-'-T---'TT-TT-T=
-t-tJtt-tttttt

the corresponding measuring devices were farffom the

1-100 rated or required.
+.
The time,needed forrealization of thecalculation tasks
O 40 80 120 160 within the subsequent time steps, depended mainly on the
t[s 60]
±
"'L'r--u'm""""j quality of the measurement ln the cases of

F----------g
reading.
100- especially badreading data, the calculadon results could not
geL." i be obtained fdstenough to start the next scheduled reading,
50R-"8 Then the old calculation results were lefiin the system and
theprogramproceededto calculadons forthenext timestep.
L "
Obajk x2.tt'tr'-' e;･-tt..t...7
datacorrection was
'"`'f
In thecases of failed rcading
lrnpossible.
of thegeneratedcapacity, the
The above-mentioned cases
-5og ---tt"-u.u.....r"J
ll t /

11TT-
are markeci and commented on Fig.4 and 5.1[hecases of

-100 +rv'r''･"r'r'J--T--'T
o 40 80t[s
-T7120 ; 160
lackof correction are marked also on Fig.6.

60] 4.SUMMARY
100geg
A comparison ofcalculation results from a stearri turbine
5oxEoee, mahematical model for load optimization in large
indusuial combined heat and power station, used
forsimulation withinitial
data,continuously and direetly
collected ffom the digita1distributed
control system (DCS),
.50gg

-1OO Fig.6.Relativedivergence betweenthemeasured

0 and corrected mass fiow rates of the:allivesteam;
60]
t{s
b)steam ffomthecontrolled extraction;
c) outlet steam

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is presented. Problems occurring with sach using of NOMENCLi\TURE

measuring data,resulting ffom suclt implementation,are
pointed, E - pressurecoeMcient [-];
The basic problem with any model, in which current G - mass flow rate [kgts];
measuring dataare beingused as inpatdata, isto interpret N- generatedcapac{ty (kW];
thatdataappropriately, i.e. to eliminate the improper values,
beatfiuxckw];
to balancethe mass and energy fiows etc. The presentation
{ek-
-
T temperature [eC];
of theprincip!es ef using and correc ting the inputquantities
was made in [1]. but is beyond thispaper as a task. F];
X-pressure factor
- [-];
Nevenheless, thepresentedresults illustrate very well the a coefficient

irnportanee of theinputdataquality. f- non-linear function;

The above problems do not dispualify theattempts to h - specific [kJlkg];
enthalpy

use measuring dataforon-line simuladon. The optimization J- normal [MJlkg];

enthalpy

program,realized witli using the above model, diseovered k - isentropic

index[-];
considerable capabilities of overall plantperfonnance p - pressure [MPa];
improvement in the forrn of increasingthe generated t- time[s];
v - specific volurne
eleetric capacity with unchanged technologicaloutput, [m31kg];
live-steamparameters and overall demand, z - number of turbinestages ina groirp[-];
Anotherapproach, alternative to the presented medel n - internal eenciency [-];
formulation,could be based on characteristics, n- pressureratio[-].
approximating the dependence between the internal
capacity and mass flow rate forthe particular, properly Subscripts:
differentiated partsof theturbine.This could sigriificantly
simplify themathematical description.
The initial
attempts O - indexes rated or live-steam parameter;
tointroducesuch model forrnulation
forthe considered task 1 - indexesfirst uncontro11ed extraction;

gave promising results and firrther

investigation in that 2 - indexessecond uncontrolled extraction;
direction
isheld. E - indexescentrelled extraction;
caic - indexescalculated value;
corr - indexes corrected value;
REFERENCES cr - indexes criticalpararneter;
el - indexes electrical capacity;
L Badyda K., Problems of MathernaticalModelling of meas - measurement resuk;

(2001),
PQwer Installations, Publishing
House of the out - indexes outlet steam parameter;
Warsaw Universityof fechnologylVVhrsawL a- indexes inletstream;
2. Uzunow; N., Influenceof the Steam TUrbine's Flow to- indexes
outlet strearn,
Path Diseretizationon the Results from Transient
Process Simulation,Ph, D. thesis,(2001), Warsaw
Universityof TfechnotogMWhrsaw/
3. Miller,A., Lewandawski, J.,Stearri
Thrbine Operation
Under OfFdesigri Conditions, (1992), Publishing
House of the Waisaw University of Tbchnology,
Warsaw,Abed,
4. K., A., Miller,A., Lewandowski, J,,
PeifbrrnanceCharacteristics of ImpulseType Turbine
Stage Groups,Archive ofMechanical Engineering,Vbl.
XLII(1995) Nr.3-4,pp.211-231.
5. Abed, K., A., Mille; A,, Lewandowski,J,, A
Contributionto the FIUgel's- Stodola'sLaw forFlow
Capacity of Turbine Stages GTvup, VDI Berichte,Vbl.
Il85 (1995), pp, 391405.
6. Milleg A,, Lewandowski, J.,Abed K, A,, Trzcifiska
Z.,
Generalized Perfbrmance Characteristics of ltrbine
Stage Groups, An Attempt to Supplement The FMgel's
- Stodola's Law, Archives of Machine Constmction,
Nbl.XVVII Nt 1,(2000), pp, 33-52,
7. Badyda, K., Uzunew;N.,SteamThrbine Matheinatical
Model forOptimisation of Load Disuibutionin a
Header Combined Heat and Power Station,
Scientific
Wbrks of theDepartrnent
of AppliedMechanics
of the
SilesianUniversity
of [EechnologM I8,(2002),
Xiol. pp,
15-2e.

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