STEAM TURBINES AND APPLICATIONS

Steam Turbines Versatile Rotating Equipment

One of the most versatile and oldest prime mover technologies in application for about 100 years
Steam utilised earlier to drive Reciprocating Steam Engines used as prime movers Steam Turbines replaced Reciprocating Steam Engines due to inherent technical and economical advantages

Feasibility of Steam Turbines for enhancement of Resource Utilisation Effectiveness in Industries Industries, wherein large quantity of steam generated at high pressure and temperature and utilised for various process applications at 2-3 lower different pressures and temperatures by directly reducing these parameters through Pressure reducing and de-superheating stations (PRDS) or De-superheating station, i.e. pharmaceutical units with chilling plants, etc. Industries having Heat:Power ratio greater than 3:1 depending on consumption pattern of electrical energy and steam, i.e. paper manufacturing units.

Industries wherein the waste heat energy generated during chemical process available in good quantum to generate high grade steam through waste heat recovery boiler utilising the waste heat, i.e. furnaces, sulphuric acid plants, incinerators, etc.

Efficiency of Typical Steam Distribution System

BOILER EFFICIENCY 85% BOILER FUEL INPUT 100% BOILER LOSSES 15% HP STEAM 100% HP STEAM 35% PRDS PRDS LOSSES 50% LP STEAM TO PROCESS 35% BOILER LOSSES 15% FOR STEAM GENERATION LOSSES 17.5% FOR 35% HP STEAM DRAWL FOR PROCESS THRO PRDS OVERALL THERMAL EFFICIENCY OF STEAM SYSTEM 67.5%

HP STEAM DIRECTLY UTILISED 65%

Efficiency of Typical Steam Distribution System with Steam Turbine

BOILER EFFICIENCY 85% BOILER FUEL INPUT 100% BOILER LOSSES 15% HP STEAM 35% TO BACK PRESSURE STEAM TURBINE TURBINE LOSSES 20% LP STEAM TO PROCESS 35% BOILER LOSSES 15% FOR STEAM GENERATION LOSSES 7.5% FOR 35% HP STEAM DRAWL FOR PROCESS THRO BACK-PRESSURE TURBINE OVERALL THERMAL EFFICIENCY OF STEAM SYSTEM 77.5% HP STEAM 100% HP STEAM DIRECTLY UTILISED 65%

ELECTRIC POWER

Typical Waste Heat Recovery from Process and Use for Steam Turbine

HIGH TEMP GASES FROM PROCESS

WASTE HEAT RECOVERY BOILER

HP STEAM TO CONDENSING STEAM TURBINE ELECTRIC POWER

PROCESS RAW MATERIAL INPUT

CHEMCIAL PROCESS/ REACTION

LP STEAM TO CONDENSER

Types of Steam Turbines

Back-pressure steam turbines

Extraction-cum-back-pressure steam turbines Single Extraction-cum-back-pressure steam turbines Double Extraction-cum-back-pressure steam turbines
Extraction-cum-condensing back-pressure steam turbines Single Extraction-cum-condensing steam turbines Double Extraction-cum-condensing steam turbines Straight condensing steam turbines

Steam Turbine Technology

ab - feed water supplied to boiler at medium to high pressure some heat added bc feed water heated in boiler to boiling temp corresponding to pressure, then converted into steam, superheated steam heat added cd - isentropic expansion of pressurized steam in steam turbine to lower pressure heat utilised in turbine for work like power generation da steam finally exhausted either to condenser at vacuum conditions in condensing steam turbines heat rejected from exhaust steam in condenser steam supplied at intermediate temperature/pressure to steam distribution system to deliver to industrial or commercial application in extraction/back pressure turbines - heat utilised in process

T1 T

T2

S Temperature Entropy Diagram Simple Rankine Cycle

Back-pressure Steam Turbine Cycle

Entire quantity of steam injected into steam turbine exhausted at parameters as required by process Enthalpy difference between inlet and outlet steam utilised for power generation through a generator coupled with the turbine No wastage of energy contained by steam as no direct condensation of high pressure, high temperature steam Due to optimum utilisation of energy, highest system efficiency achieved among all types of Cogeneration systems

Back-pressure Steam Turbines Merits and Demerits

Merits of back-pressure steam turbine system Simple configuration with few components Avoidance of the costs of expensive low pressure stages of the turbine Low capital investment for steam turbine No need of cooling water for steam condensing, and less cooling water requirement only for lube-oil cooling system Very high system thermal efficiency because of no heat rejection through a condenser Demerits of back-pressure steam turbine system Size of turbine larger for the same power output because of its operation under comparatively lower enthalpy difference of steam Dependence of steam mass flow rate through turbine on the thermal load, consequently power generated by steam put into turbine controlled by thermal load resulting into little or no flexibility in directly matching electrical output to electrical load Need of grid connection for purchasing electricity to meet short-fall in electricity generation as mentioned above

Extraction-cum-Condensing Steam Turbine Cycle

Part of total high pressure steam injected into steam turbine drawn out by extraction at parameters as required by process One or two extractions with condensing or one or two extractions with back pressure feature possible if steam required at two different levels Efficiency lower than back pressure turbine in extraction-cumcondensing mode due to condensation of part steam Efficiency marginally lower than back pressure turbine in extraction-cum-back pressure mode due to steam taken out from turbine at higher pressure and temperature levels

Extraction-cum-Condensing Steam Turbines Merits and Demerits

Merits of extraction-cum condensing steam turbine system Possible to meet variable electric power and heat load by regulating the extraction steam from the turbine No need of maintaining grid connection for purchasing electricity, or minimum gird support to meet unforeseen eventuality in the CPP Demerits of extraction-cum-condensing steam turbine system Configuration not as simple as that of back-pressure steam turbine Lower system thermal efficiency due to heat rejection in part steam condensing Higher capital investment for steam turbine due to condensing stage More requirement of cooling water for circulating in the steam condenser Dependence of steam mass flow rate through turbine on the thermal load, consequently power generated by steam put into turbine controlled by thermal load resulting into little or no flexibility in directly matching electrical output to electrical load

Feasibility of Steam Turbine and Performance Indices

For industry with steam supply from stand alone boiler for utilisation at different operating parameters Determination of existing steam generation & distribution system

Thermal efficiency

Total heat input to boiler (Boiler losses Steam system losses) % Total heat input to boiler

Heat losses in = Steam flow, kg/hr x (Enthalpy, kJ/kg Enthalpy, kJ/kg PRDS, kJ/hr at inlet at outlet) Losses in utilisation = Steam flow, kg/hr x Heat content in steam at end of process, kJ/kg Total heat input to boiler, kJ/hr = Fuel flow rate, kg/hr x Gross calorific value, kJ/kg Boiler losses to be determined as already discussed separately

Heat Rate of for steam generation

Total heat input to boiler, kJ/hr Steam genetared, kg/hr

kJ/kg of steam

Feasibility of Steam Turbine and Performance Indices

For industry with steam supply from stand alone boiler for utilisation at different operating parameters Determination of power generation potential from Steam Turbine
Power generation Steam flow kg/hrx (Enthalpy at inlet - Enthalpy at outlet), kJ/kg kW 4.19

Overall Cogen Efficiency after introducing Steam Turbine

Overall cogen efficiency

Electric power generated, kJ/hr Net heat of steam utilised % Total heat input to boiler

Convert electric energy from kWh to kJ/hr by applying conversion factor 1kWh = 3600 kJ

Overall Cogen Heat Rate after introducing Steam Turbine

Cogen Heat Rate

Total heat to boiler, kJ/hr - Fuel would required for steam gen. kJ/kWh Electrical power output, kWh

Fuel would required Fuel deemed to be required for process steam for steam gen. assuming the same boiler efficiency

Feasibility of Steam Turbine and Performance Indices

Determination of Steam Turbine Efficiency

Turbine Efficiency
ASR

Actual steam rate, kJ/kWh Theoretica l steam rate, kJ/kWh

Steam input, kg x (Enthalpy at inet, kJ/kg Enthalpy at outlet, kJ/kg) kJ/kWh Power generated, kWh

Actual Steam Rate [ASR]

: Quantity of heat energy required to generate one kWh of electric energy Theoretical Steam Rate : Theoretical quantity of heat [TSR] energy required to generate one kWh of electric energy [Enthalpy to be taken from Mollier Charts for calculating TSR]

Electrical Efficiency

Power generated, kWh x 4.19 [Convert to heat] Steam input, kg/hr x Enthaly drop in turbine, kJ/kg

Steam Turbine Performance

Efficiency of steam turbine Steam pressure drop through the turbine

means -

greater steam pressure drop across turbine result into more power output reduction in steam turbine exhaust steam pressure result into more power generation than an increase in pressure of steam at turbine inlet specific steam consumption depend on the absolute pressure ratio of the turbine

Feasibility of Steam Turbine and Performance Indices

For industry with potential of steam generation from Process Waste Heat Determination of steam generation potential from WHRB
Steam flow from WHRB Ws

Weg x Cp x (te t pp ) (h12 h11 )

Ws Weg Cp te tpp h11 h12

= = = = = = =

steam rate, kg/sec exhaust gas flow rate, kg/sec ave. value of specific heat of exhaust gas, kJ/kg0C exhaust gas temperature, 0C pinch point temperature, 0C (manufacturers data) feed water enthalpy at boiler drum inlet, kJ/kg steam enthalpy at boiler drum outlet, kJ/kg

Comparison of Steam Turbine Performance

Type of Steam Turbine Power:Heat Ratio Typical Electrical Efficiency Typical Overall Thermal Efficiency Remarks

Condensing Steam Turbine

Not applicable

Maximum

15 40%

Backpressure Steam Turbine ExtractioncumCondensing Steam Turbine ExtractioncumBack-pressure Steam Turbine 1:3 to 1:10 1:3 to 1:8 1:3 to 1:8 7 20% 70 85% 10 25% 50 75% 10 20% 60 80%

Best for only power generation applications, suitable for combined cycle plants with GT Not suitable for CHP application Power output sensitive to ambient conditions Best option for industrial cogen applications Reduction in thermal energy demand reduce power output Better option for industrial cogen applications Excellent operating flexibility with regulated extraction Best option for industrial cogen applications Moderate operating flexibility Reduction in thermal energy demand reduce power output

Optimising Steam Turbine Performance at Operating Stage

Best operational mode Power or heat operated - Depending on total power load of industry, number of steam turbines to be arranged on one line so that one or more steam turbines available for service according to demand of power Running of turbine close to its optimal operating range possible with such philosophy of operation Steam conditions Input steam conditions to be fixed between 30 - 70 bar and live steam temperature to be fixed between 400 500 0C to obtain desired steam turbine performance in case of 1 to 10 MW decentralised cogeneration power plants of low and medium output Steam quality Maintaining of steam quality injected into a steam turbine as per specified parameters extremely vital for performance of steam turbine Quality of DM water and boiler feed water sent to boiler determining factor for quality of steam generated by boiler and sent to steam turbine On-line monitoring of steam conductivity a must as a part of instrumentation to get the data for any impurity going to steam turbine Analysis of steam and water samples separately at least once in eight hours to ascertain the quality

Optimising Steam Turbine Performance at Operating Stage with Control and Monitoring
Control for Steam Turbines Throttle valve to be installed in front of the steam turbine to control pressure of steam flowing from steam line to individual turbine as well as output from each one Nozzle group control may be provided in individual turbine to permit individual nozzles before first blade wheel (control wheel) to switch in or off to control mass flow rate of other stages as well as to regulate output

Monitoring for Steam Turbines Continuous of on-line monitoring of following parameters extremely vital to avoid fall in steam turbine performance Conductivity of steam to ensure silica content in steam, turbine output adversely affected by silica deposits on blades Axial differential expansion, eccentricity, vibrations, etc. providing suitable microprocessor based instrumentation. Pressure and temperature of lube-oil circulation in bearings along with continuous cleaning of lube-oil through centrifuge

Optimising Steam Turbine Performance with Preventive Maintenance

Yearly Preventive Maintenance Program Inspection of steam turbines and steam pipelines to be carried out at least once a year for observing irregularities Checking of turbine bearings during yearly maintenance Cleaning of steam pipeline from boiler up to turbine inlet along with boiler Checking various control valve settings and calibrating as recommended Calibration of various local gauges, electronic and microprocessor instruments, on-line monitoring systems for accuracy Testing of turbine protections by simulating possible fault conditions after maintenance

Five Yearly Preventive Maintenance Program Thorough inspection by dismantling casing, lifting nozzles, rotors, bearings, etc. and complete overhauling to be resorted to every 5 years calling Service Personnel from the turbine manufacturers

Why Steam Turbine?

Higher electrical efficiencies in power generation applications Wide array of designs and complexity to match the desired application and/or performance specifications Lower costs capital and maintenance costs Better reliability and availability, life extremely long with proper operation and maintenance Low maintenance costs, major overhaul after longer service Capacities available for power generation from 50 kW to several hundred MW Suitability for combined heat and power applications Better suitability as prime movers for pumps, compressors Suitability for wide range of Power:Heat ratio Separation of functions enabling Steam Turbine system to operate with enormous variety of fuels to be fired in the Boiler for high pressure steam generation Fossil Fuels Natural gas, Coal, Lignite, Fuel oil, LSHS, Residual fuel oil Bio-waste Fuels Bagasse (waste from crushed sugar cane) Rice husk (waste from rice mills), Bio-gas, Municipal waste, Wood waste

Versatile Technology for Cogeneration Applications

Electrical energy generated normally as byproduct of heat (steam) generation in Steam Turbine based cogeneration system Energy transfer from the Boiler to Steam Turbine through high pressure steam utilised first to rotate Steam Turbine and Generator, and then supplied to process Steam at lower pressure extracted from steam turbines used directly or converted to other forms of thermal energy in process and CHP applications Designed to match steam parameters as required by process along with optimum electrical efficiency while providing desired thermal energy output, even feasible to supply steam at different levels Tailor made designs available to suit specific cogeneration applications

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