International Journal of Engineering Trends and Technology (IJETT) - Volume4Issue5- May 2013

Increasing Co-Generation Efficiency Its Improvements,Operation & Maintenance

Ramananth.N.V#1 , Vijay.P*2 Mechanical department, K.L. University Vaddeswaram, green fields, Guntur(dt), 522502, Andhra Pradesh, India Mechanical department, K.L.University Vaddeswaram, green fields, Guntur(dt), 522502, India
Abstract--- This document gives the information and knowledge of importance of Co-generation system in the industries. The cogeneration or CHP system simultaneously produces both heat energy & electricity. In this paper the prime movers are also explained its operation and maintenance. Cogeneration was practiced in some of the earliest installations of electrical generation. Before central stations distributed power, industries generating their own power used exhaust steam for process heating. Large office and apartment buildings, hotels and stores commonly generated their own power and used waste steam for building heat. Types of prime movers that which are used in cogeneration (Back pressure steam turbine, extraction condensing steam turbine) its operation & maintenance. Improvements in increasing overall efficiency of steam turbine. Keywords---- Co-generation, prime movers, CHP, efficiency, baggasse, conveying energy, impulse, reaction, back pressure, condensate, high & low pressure steam, condenser, vacuum ejector, auxiliaries

Steam has been a popular mode of conveying energy since the industrial revolution. Steam is used for generating power and also used in process industries such as sugar, paper, fertilizer, refineries, petrochemicals, chemical, food, synthetic fiber & textile. The following characteristics of steam make it so popular and useful to the industry:Highest specific heat & latent heat, Highest heat transfer coefficient, Easy to control & distribute, Cheap & inert. In our country there is so much short fall of electricity day by day demand of electricity is tremendous and generation is less. Electricity is heart of industries and economy. Number of studies carried out in India by various government organizations has indicated the tremendous potential for generating surplus power from sugar factories through cogeneration system. BENEFITS OF CO-GENERATION/CHP Increased efficiency of energy conversion and use Lower emissions, especially CO2 Ability to use waste materials Large cost savings Opportunity to decentralize the electricity generation. Promoting liberalization in energy markets II. STEAM TURBINE Steam turbines are the most commonly prime mover for co generative applications. The principle of steam turbine involves conversion of thermal energy of high pressure steam to kinetic energy through nozzles and then to mechanical power through rotating blades. In the steam turbine, the incoming high pressure steam is expanded to a low pressure level. The passage of steam through blades may take place in such a manner that the pressure at the outlet side of

I.

INTRODUCTION

Cogeneration is well known concept in sugar industry, the sugar factories are already has been generating electricity from their capacitive use, while using the steam for their process upon the process steam consumption & prime movers. Steam consumption can be reduced up to by using efficient turbine with low steam consumption by using high pressure boilers & turbines the process steam consumption can be reduced by using double effect evaporation method at evaporator station. The high efficiency co-generation design not only uses the available baggasse efficiently but also yields substantial quantities of power for exporting to the grid, over and above their enhances energy needs. Reduced captive steam and power consumptions enhance baggasse availability for extra power generation and for extending their period of operation beyond the crushing season.

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International Journal of Engineering Trends and Technology (IJETT) - Volume4Issue5- May 2013
moving blade is equal to that at the inlet side. Such a turbine is termed as Impulse turbine. On the other hand, if the pressure of the steam at the outlet from the moving blade is less than that at the inlet side of the blade such a turbine is called Reaction turbine. A. Steam turbine co-generation system Most common types of steam turbine Co generation system are: 1. Back pressure steam turbine 2. Extraction condensing steam turbine B. Back pressure steam turbine The backpressure steam turbine has exhaust steam pressure above atmospheric pressure and this steam is not considered in the steam condenser but is used for process heating in the sugar production. The specific steam rate of these steam turbines is comparatively lower than the condensing turbine When the steam with high pressure strikes the turbine blades or runners, rotates and makes generator to rotate at higher speed to produce electricity. The controlled extraction is used for the process which means this is used to drive the machinery in the sugar production. An Ejector system is used to create vacuum in the condenser. The outlet steam is condensed or cooled in the condenser through the condensing process

C. Extraction condensing steam turbine: When one or two exhaust steam outlets generally at different higher pressure than atmospheric pressure and provided to the condensing steam turbine then it is called single or double extraction type condensing steam turbine. The single or double extraction system for feed water heating improves the efficiency of the energy cycle as the steam going to the condenser is less and the heat loss is reduced in the condenser. In condensate cum double extraction steam turbine the condenser is used to cool the steam temperature and allow it to recycle. The steam from the inlet at high pressure and temperature which can be reduced by passing over these stages.

The CONDENSING refers to the condensing system that is attached to the unit which acts to condense (turn back to water or condensate) the exhaust steam. In the act of condensing, the original volume of the exhaust steam decreases by several orders of magnitude and since the process takes place in a closed vessel, a steady state vacuum is created and maintained which keeps the process cycle going. The condenser drum has inside number of tubes in which the cool water from the cooling water tank flows through the tubes and the hot steam is surrounded to the tubes. In this process the cool water from the cooling water tank that flows in the tubes condenses the hot steam that which is extracted in the turbine is condensed and is sent to the boiler for recycling.

D. Operating procedure: Oil system establishment Centrifuge in operation Oil sample analysis Oil Vapor extraction fan on

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International Journal of Engineering Trends and Technology (IJETT) - Volume4Issue5- May 2013
Auxiliary oil pump on Seal oil system in operation Gate gearing valve opened Jacking oil pump in operation Turbine on turning gear Barring gear in operation Establish the lube oil system Ensure pressure in all bearing oil supply line & flow is site glasses Ensure pressure in seal oil supply line & flow in site glasses Ensure differential pressure regulator is functioning DC seal & DC lube oil pumps are on auto start mode Turbine protection checking Low vacuum trip Axial shift high trip Over speed test Main oil level tank low trip Lube oil pressure low trip Main steam pressure low Generator protection Vacuum system establishment Checking condenser on spring support Circulating water system charged Warm up line to land steam controller in charge Vacuum pump start Drain valves operation checking When vacuum achieved main MS HRH strainer drains open Drain before CRH-NRV open HP by-pass drain open Drain before interceptor valve open Drain before LP by-pass valve open HP casing drain open Drain before extraction NRVs HP/LP by pass in operation Warming up operation on Steam dumping operation on Steam purity checking The purity of steam is checked by passing pure feed water into the boiler. Before the passing of feed water into the boiler the water is de-mineralized in DM plant and adding required minerals for maintaining purity. Turbine ready for rolling The maintenance is practiced in the following way: a) Routine maintenance or preventive maintenance It is a daily maintenance of the power plant equipments and systems to avoid breakdown. The routine checks that are checked and recorded are: Checking of oil levels Checking of water levels Checking & recording of vibrations

b) Annual maintenance Annual maintenance is planned for short periods of time like 15-20 days which includes boiler cleaning, small repairs on pressure parts, rotating equipments, mills etc. On turbine side bearing inspection, small rectifications on auxiliaries, condenser tube cleaning, hot well and de aerator cleaning, generator inspections, hydraulic tests of various coolers etc. Capital maintenance Major overhaul works has been done in this stage turbines are opened, major parts like rotor blades, casing blades cleaning & ultrasonic tests, de penetrate tests are carried out over the bearings, rotor & blades. Major repairs are carried out proper setting of turbine clearances, alignments of rotors. All rotating equipments are overhauled any defective parts are replaced and re alignment of rotor is carried out.

c)

III.

IMPROVING STEAM TURBINE EFFICIENCY

Steam is a major energy consumer. Optimizing process operating conditions can considerably improve turbine water rate, which in turn will significantly reduce energy requirement. Various operating parameters affect condensing and backpressure turbine steam consumption and efficiency. The industrial sector is the largest energy consumer, accounting for about 30 % of total energy used. Fuel and energy prices are continuously rising. With the present trend of energy prices and scarcity of hydrocarbon resources lowering energy requirement is a top priority. Energy conservation benefits depend on the adopting minor or major modifications and using the latest technology.

E. Maintenance :

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International Journal of Engineering Trends and Technology (IJETT) - Volume4Issue5- May 2013
In the large process industries, steam turbines are the main energy consumers. Savings achieved here will be significant, with a better return on investment than for most other equipment. Turbines designed for particular operating conditions like: a) Steam inlet pressure b) Steam inlet temperature & c) Turbine exhaust pressure/ exhaust vacuum which affects the performance of turbines. Variations in these parameters affects in the steam consumption in the turbines and the turbine efficiency.

In condensing turbines it is observed that the exhaust vacuum of these turbines is much less than the vacuum at the condenser. Mainly, it is due to the higher pressure drop in the exhaust pipeline from turbine exhaust to the condenser. In order to improve the vacuum at turbine exhaust so as to reduce steam consumption in the turbine, exhaust pipeline of these turbines can be replaced with higher size.

1.

Effect of steam inlet pressure: All the turbines are designed for a specified steam inlet pressure which affects the turbine performance. For obtaining design efficiency, steam inlet pressure shall be maintained at a design level in the turbine. Lower the steam inlet pressure will hampers the turbine efficiency and steam consumption in the turbine will increase. At higher steam inlet pressure energy available to run the turbine will be high, which in turn will reduce the steam consumption in the turbine. Effect of steam inlet temperature: Enthalpy of steam is a function of temperature and pressure. At lower temperature, enthalpy will be low, work done by the turbine will be low, turbine efficiency will be low hence steam consumption for the required output will be higher. At higher steam inlet temperature, heat extraction by the turbine will be higher and hence for the required output, steam consumption will reduce. Effect of exhaust pressure/vacuum: Higher exhaust pressure/ lower vacuum, increases the steam consumption in the turbine, keeping all other operating parameters constant. Exhaust pressure lower than the specified will reduce the steam consumption and improves the Turbine efficiency. Similarly exhaust vacuum lower than the specified will lower the turbine efficiency and reduces the steam consumption Higher size of exhaust pipe:

2.

Factors affect the exhaust vacuum in the condensing turbine: Vacuum ejector system Vacuum ejector system creates and maintains the vacuum in the surface condenser by removing the air/ inert ingress. Removal of air/ inert ingress is important, as accumulation of this hampers the performance of surface condenser, which reduces the surface condenser vacuum. Motive steam condition shall be maintained as specified. Inter-after condenser shall be cleaned in the available opportunity, as they get choked due to foreign material coming with cooling water. Flange joints shall be tightened properly to avoid any ingress of air. Exhaust side of the turbine shall be properly steam sealed to avoid any ingress of air. 6. Increasing Efficiency Overall efficiency of steam turbine power plant strongly depends on turbines performance. Thus any improvement slightly can increase the power availability, decreases the component or equipment costs. The steam turbine efficiency ultimately depends on its condition, relative to its design. The evaluation of steam turbine design & operating conditions can help increase in plants efficiency in the following three areas: a) Combustion to improve fuel utilization and minimize environmental impact. b) Heat transfer & aerodynamics to improve turbine blade life and performance. Steam Turbine Power Generation

5.

3.

4.

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International Journal of Engineering Trends and Technology (IJETT) - Volume4Issue5- May 2013
Materials to permit longer life and higher operating temperatures. Improvement in turbine performance has resulted not only from developments in modern blading, but also in the redesign of turbine sidewall contours in high-pressure first stages, and in the reduction of humid steam conditions in low-pressure turbine sections that cause erosion. Such improvements have increased turbine efficiency up to 10 %. The turbine nozzles should be designed aerodynamically because as the steam strikes the blades from the nozzles forcely and there will not be any obstacles in the path of steam. By aerodynamic design the steam flows in the path very smoothly and strikes the blades without any admission losses. The turbine rotor material should withstand high temperature and pressure so that it can bear with out causing any disturbances in the rotation of the rotor. A hot steam blower is places across the low pressure stages of the turbine to add more heat in the last stages of the turbine for better efficiency. Lack of steam tightness of the h.p stop valve on the supply to the turbine can lead to condensation during shutdowns & consequent corrosion of the report. To avoid this drawback it is advisable to install two h.p stop valves, placed one in front of the other with a drain open to atmosphere between the two, to evacuate condensate due to possible leakage of the upstream valve. The wetness of steam 13% is the extreme limit, beyond that the droplets of water cause serious erosion of the blades in the last stage of the turbine. The silica % is much less than the 0.02 PPM in the steam that which can increase the efficiency. c) I would also like to thank P.Vijay (Asst. Professor, K.L.University) for giving me the guidance, encouragement and for the valuable information and suggestions.

REFERENCES http://en.wikipedia.org/wiki/Steam_turbine http://en.wikipedia.org/wiki/Compounding_of_stea m_turbines http://www.turbinesinfo.com/steam-turbineefficiency/

IV.

CONCLUSION

For the better performance of the steam turbine the operating procedure and the maintenance can be employed effectively and for improving the efficiency of the steam turbine the improvements listed can be employed to attain better efficiency based on the turbine design parameters and capacity.

ACKNOWLEDGEMENTS I would like to take this opportunity to express my heartfelt thanks to our college K.L.University for giving me a chance to come up with this paper and for the successful completion of this paper.

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