ENERGY AUDIT

METHODOLOGY FOR
FOR TURBINE CYCLE
Presented By
S.V.Malpe
Dy.Director
NPTI, Nagpur
 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

TURBINE CYCLE LOSSES
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
 Pressure

.
.
.
T

V
S
Impulse Stage

1st Reaction

HP Exhaust

IP Inlet

Basic Turbine Pressure Survey Diagram LP Inlet

 Pressure

.
.
.
T

V
S
Impulse Stage

1st Reaction

HP Exhaust

IP Inlet

Effect of Range Turbine Pressure Survey Diagram LP Inlet

TURBINE HR EVALUATION AND EFFICIENCY

Variation of Heat Rate with Load Heat Rate Characteristics with

Condenser Exhaust Pressure
 Turbine Losses

Internal Losses
a) Nozzle Friction

b) Blade Friction

c) Disc Friction

d) Diaphragm Gland & Blade Tip Losses

e) Partial Admission Loss

f) Wetness
g) Exhaust
 Turbine Losses

External Losses
a) Shaft Gland Leakage

b) Journal & Thrust Bearing

c) Governor & Oil Pump

 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
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
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
 Background
Hot
Water
Cooling
Condenser Tower
Air Air

Cooled Make-up
Water Water
Performance of Condensers

Vacuum Efficiency:
Ps- saturation pressure of steam in kg/cm2
corresponding to the
steam temperature entering the condenser.
Pt – total pressure of air and steam in the
condenser= (pa+ps)
Pb- atmospheric pressure or barometric
pressure.

Ideal vacuum possible without air

ingress=(Pb-Ps)
Actual vacuum existing in the condenser due
to air ingress
= Pb-Pt= Pb-(Pa+Ps)

Vacuum efficiency = actual vacuum/Ideal

vacuum
The main parameter to be monitored is Condenser Back
Pressure

High condenser back pressure Causes :-

1)High Inlet Cooling water Temperature - uncotrollable
2) Low Cooling Water Flow
3)Partially Filled Water Box
4) Excessive Heat Load - uncontrollable
5) Fouled Tubes
6) Excessive Air In Leakage
7)Vacuum Equipment Problem
8) Tube Bundle Design Problem
CRITICAL PARAMETERS TO BE
MEASURED
Heat Rejection Rate
Cooling Water Outlet Temperature
Cooling Water Flow Rate
Fouling Factor can be measured or
calculated
 Data Collection- Condenser Specifications

Heat load considered for design

Design inlet cooling water temperature/ Design
TTD
Cleanliness factor/ Cooling water temperature
raise
Condenser back pressure
Cooling water flow/ Cooling water side pressure
drop
No of cooling water pass/ Total heat transfer area
No. of tubes - Condensing zone - Air cooling zone
Tube dimensions: - Tube OD x thickness - Length
of tube
Effect of Back pressure on
heat rate
Effect of Varying the back pressure
1. CW Pumping Power
2. Leaving Loss
3. Reduced Condensate Temperature
4. Wetness of Steam.
 Graphical Determination of Losses
Contributing the departure of Back Pressure
From Optimum

1. CW inlet temp different from design.

2. CW quantity flowing through condenser
incorrect.
3. Fouled tube plates.
4. Dirty tubes.
5. Air ingress into system under vacuum.
Condition Unit Optimum Actual
CW inlet temperature Deg C 16.5 18.2
CW Outlet Temperature Deg C 25.0 28.2
CW Temp rise (2-1) Deg C 8.5 10
Saturated Steam Deg C 30.5 35.0
Temperature corresponding
to back pressure
Terminal Temperature Diff Deg C 5.5 6.8
(4-2)
Air suction temperature Deg C 26.5 27.0
Air suction depression (4-6) Deg C 4.5 8.0
Back pressure mbar 43.65 56.22
Loss due to CW inlet temp:
Plot a line vertically from the actual CW inlet
temp of 18.2 Deg C to the intersection with the
optimum CW Rise of 8.5 Deg c. Them plot
horizontally to the intersection with the
optimum TTD line, and then vertically
downward to cut the saturated steam
temperature line. The corresponding back
pressure is 47.2 m bar. Hence , the loss due to
the high CW inlet temperature is the difference
in back pressure between 47.7 mbar and
optimum value of 43.65 ie. 4.05 mbar.
 Loss due to CW flow:
Plot a line vertically from the actual CW
inlet temp of 18.2 Deg C to the
intersection with the actual CW Rise of
10 Deg C. Them plot horizontally to the
intersection with the optimum TTD line,
and then vertically downward to cut the
saturated steam temperature line of 33.7
Deg C. The corresponding back pressure
is 52.0 m bar. Hence , the loss due to the
CW incorrect CW flow is given by 52.0-
47.7=4.30 mbar.
Loss due to air/dirty tubes:
The effect of air and dirty tubes on heat
transfer is to increase the TTD above optimum.
They both give the same effect. The thermal
resistivity of a layer of 0.254 mm thick is
approx the same as that offered by slab of
copper 3.35 meters thick. Plot from the actual
CW inlet temp to the actual CW rise and hence
across to the actual TTD line of 7 Deg C.
Plotting vertically downward the saturated
steam temp is 35.1 Deg C. the back pressure
is 56.22 mbar. So the deviation due to air/dirty
tubes is given by 56.22-52.0 mbar=4.22 mbar
The effect of air ingress into the
condenser is to increase the value of air
suction depression from optimum. In the
case being considered the optimum
value, obtained from acceptance tests is
4.5 Deg C but it is actually 8 Deg C, so
there must be air present. Action should
be taken to locate and stop the ingress.
Incidentally when condenser tube is
cleaned it is only dirty tube component
which is cleaned.
 Condenser Fault Symptoms
Readings T1 T2 T3 T4
Condenser exhaust tem Deg C 31.7 30.0 31.0 27.8
CW outlet temperature Deg C 21.1 23.3 20.0 21.1
Temp Diff Deg C 10.6 6.7 6.1 6.7
CW inlet temp Deg C 13.0 13.0 13.0 13.0
CW Temp rise Deg C 8.1 10.3 7.0 8.1
Condensate Temp Deg C 31.7 30.0 28.8 27.8
Exh temp – Cond temp 0.0 0.0 2.2 0.0
 Condenser Fault Symptoms
T1 T2 T3 T4
Symptom High High CW Temp (Ext Temp- Norm
s TTD rise Cond al
Temp)- High
Causes Dirty Insufficient CW Air ingress
Tube flow or high heat or faulty
surface loading operation of
air ejection
system
Remedy Clean Remove tube Check and
tubes, blockage, attend
increase Increase CW condenser
chlorinati pump discharge for air
on flow, Check ingress.
 Performance of Condensers
• The following needs to be computed:
1. Condenser heat load = Q x T x Cp
Parameter Details Unit
Q Water flow rate Kg/h
T Average CW temperature rise oC
Cp Specific heat kcal/kg oC

2. Calculated condenser vacuum =

Atmospheric pressure – Condenser back-
pressure
3. Deviation in condenser vacuum =
Expected condenser vacuum - Measured
 Performance of Condensers
5. Condenser Effectiveness =
Rise in cooling water temperature
Saturation temperature - Cooling water inlet temperature
6. Condenser heat duty in kcal/h =
Heat added by main steam + heat added by reheater + heat
added by SH attemperation + heat added by RH
attemperation + heat added by BFP - 860 x (Pgen + Pgen
losses + heat loss due to radiation)
7. Condenser tube velocity (m/s) =
Cooling water flow rate (m3/h) x 106
3600 x tube area (mm2) x ( no. of tubes per pass - no. of tubes
plugged per pass )
COOLING TOWERS
 Cooling Tower Performance
Cooling Tower Effectiveness :
Cooling Tower Effectiveness (in percentage)
is the ratio of rasnge, to the ideal range, i.e.
difference between cooling water inlet
temperature and ambient wet bulb
temperature, or in other words it is =
Range/(Range + Approach)
Cooling capacity :
Cooling capacity is the heat rejected in kCal/hr given in
product of mass flow rate of water, specific heat and
temperature difference.
 Cooling Tower Performance

Evaporation loss:
Evaporation loss is the water quantuty evaporated for
cooling duty and , theoretically for every 10,00,000kCal
heat rejected, evaporation quantity works out to 1.8
cubic meters. An emperical relation is often used :
Evaporation Loss (cu.m/hr)=0.00085 X 1.8 x circulation
rate (cu.m/hr)X (T1-T2)
Cycles of Concentration (COC):
Cycles of concentration is the ratio of dissolved solids in
circulating water to the dissolved solids in make-up
water.
 Cooling Tower Performance

Blow down :
Blow down losses depends upon cycles of concentration and the
evaporation loss and is given by the relation:
Blow down = Evaporation loss/(COC-1)

Liquid/ Gas (L/G) Ratio, of the cooling tower is the ratio between
the watewr and the air mass flow rates. Against design
values, seasonal variations require adjustment and tunning
of water and air flow rates to get the best cooling tower
effectiveness through measures like water box loading
changes, blade angle adjustments.
Heat removed from the water must be equal to heat absorbed
by the air.
 Performance of Cooling
Towers
 While conducting the cooling tower, visual observations need to
be made with respect to:
• Adequate water level in the trough
• Cross flow air from other cooling towers (which are under
• maintenance)
• Nozzle condition and operation
• Fill condition
• Change of blade angles during change of seasons
 The CT airflow shall be measured using an anemometer and
compared with calculated airflow derived from fan characteristic
curves of CT fans with actual power measurements.
 Calculate range, approach, L/G (Liquid to gas) ratio and
effectiveness for design and operating conditions for each tower
 Performance of Cooling
Towers
• Power consumption of CT fans
Exploration of Energy Conservation
Possibilities:
Condenser
• Possibility of Improvement in condenser
vacuum
• Turbine heat rate Reduction possibilities
• Improving the effectiveness of condenser
and TTD
FEED WATER HEATERS PERFORMANCE

inlet

inlet

outlet

0C
 FEED WATER HEATERS PERFORMANCE
After the collecting the above data, evaluate the following
 Terminal temperature difference – TTD
 Heater drain cooler approach temperature difference – DCA
 Feed water temperature rise across heater – TR

TTD = t sat – t fw outlet

FEED WATER HEATERS PERFORMANCE
DCA = t drains – t fw inlet

TR = t outlet – t fw inlet
 HEATER PERFORMANCE DEVIATION
Check following if TTD, DCA, TR are deviating from the
design and actual rise in feed water temperature is low:
High terminal temperature difference, TTD
 Excessive venting (worn vents, altered set point, vent
malfunctioning)
 Excessive make up
 High water level (tube leaks, improper setting)
 Header partition leaks
 Non condensable gases on shell side
 Excessive tube bundle pressure drop (excessive number of
tubes plugged, tubes folded internally)
 HEATER PERFORMANCE DEVIATION
High drain cooler approach temperature, DCA
 Drain cooler inlet not submerged
 Low drain water level (improper setting, excessive FW
heater drain bypass – bypass valve left open - bypass valve
malfunctioning / leaking)
 Excessive tube bundle pressure drop (excessive number
of tubes plugged / tubes folded internally)
 Feed water heater bypassed
 FW heater bypass valve leaking

Note: Similar approach shall be followed for LP Heaters

 ADDITIONAL LOAD ON ECONOMIZER

economizer

Based on the above, if the HP heaters performance is poor,

then additional load on economizer can be estimated by using
the data sheet