WORKSHOP ON STEAM TURBINE O&M

HOLISTIC APPROACH

De LAVAL PARSON CURTIS RATEAU

TURBINE FLEET IN NTPC

Steam Turbines of Following OEM,s are running in NTPC LMZ ( Russia) KWU, Siemens ( Germany) ABB- Alstom (Germany) GEC- Alstom ( U.K) SKODA, (Chezkoslovakia) MHI ( Japan) GE (USA) ANSALDO ( Italy)

TURBINES IN NTPC THERMAL

STATION SSTPS KSPTS VSTPS RhSTPS TSTPS FSTSP NCPS Dadri FgUTPS KhTPS BTPS TTPS TnTPS Simhadri RSTPS 500MW &ABOVE MAKE NO. KWU/BHEL 02 KWU/BHEL 03 KWU/BHEL 04 a. GEC(UK) 02 b. KWU(BHEL) 02 a. ABB 02 b. KWU(BHEL) 04 KWU(BHEL) 02 210/200MW MAKE NO. LMZ/BHEL 05 KWU/BHEL 03 LMZ(RUSSIA) 06 MAKE <200MW NO.

KWU(BHEL) KWU(BHEL) -doLMZ(RUSSIA) LMZ(BHEL)

03 04 05 04 02

LMZ(BHEL) a. SKODA b. GE SKODA

03 02 04 04

X100 X110 X60 X110

KWU(BHEL) -doTOTAL

02 04 27

ANSALDO TOTAL

03 35

TOTAL

13

GAS STATION Ratin g 130.19 137.76 88.71 111.19 106 144.3 115.2 Make GT No. Ratin g 154.51 156.07 153.20 109.30 116.1 224.49 129.18 Make Siemens(BHEL) Siemens(BHEL) ABB MHI GEC-alstom ABB BHEL ST No. 2 1 1 2 2 1 1 10

Dadri GPS Siemens 4 FdGPS Siemens(BHEL,Hw) 2 AnGPP ABB 3 AuGPP MHI 4 KWGPP GEC-Alstom 4 JGPP ABB 3 KYGPP GE(BHEL,Hyd) 2 Total 22 All Capacities are on natural gas Except kayamkulam UNDER ERECTON/COMMISSIONING PROJECT MAKE Sipat a. Power Machine b. KWU (BHEL) Kahalgaon KWU (BHEL) Farakka KWU(BHEL) Simhadri KWU(BHEL) Dadri KWU(BHEL) Korba KWU(BHEL)

RATING 660 500 500 500 500 490 500

NO 3 2 3 1 2 2 1

WORKING OF STEAMTURBINE
A steam turbine works on the principle of conversion of High pressure & temperature steam into high Kinetic energy , thereby giving torque to a moving rotor. For above energy conversion there is requirement of converging /ConvergingDiverging Sections Such above requirement is built up in the space between two consecutive blades of fixed and moving blades rows.

Two equations are very important for defining energy and flow status at any point in the Circuit
Continuity equation Area X Velocity = Constant Bernoulli's Theorem P + Z + V = Constant

TYPE OF TURBINE
IMPULSE TURBINE = In a stage of Impulse turbine the pressure/Enthalpy drop takes place only in Fixed blades and not in the moving blades REACTION TURBINE = In a stage of Reaction Turbine the Pressure/enthalpy drop takes place in both the fixed and moving blades.

 DEGREE OF REACTION= ( Heat drop in Moving stage) ( Heat drop in moving blade + Heat drop in fixed blade)
In impulse stage ,degree of reaction is O Single stage impulse turbine is called as De-laval Turbine. Series of impulse stages is called as Rateau Turbine Double Stage Velocity Compounded impulse turbine is called as Curtis Stages 50% Reaction turbine is called as Parson Turbine Practically the degree of reaction of a stage can be 0 - 60% over the different stages of a turbine

Velocity Compounded Turbines Here the High temperature, Pressure Steam is expanded in a single row of fixed blades into very high velocity which is then fed to 2 or 3 rows of moving blades with one each guide/turning row placed in between the two moving stages. Pressure compounding Turbines Here the pressure is dropped in stages and employs low velocity of Steam in each stage. Each stage consists of Fixed blade( nozzles) and moving blades .

 All the Steam turbines in Power Sector are PRESSURE COMPOUNDED .

110 MW Skoda make steam Turbine at Tanda ,Kanti and Talcher ,have two stage Velocity compounding impulse rows are there at the inlet of HP Turbine. The LMZ Turbines of 210 MW has one pure impulse in the first stage which is also the controlling stage.

 LMZ Turbines are more impulse in nature KWU Turbines are more reactive in nature Sparing Rateau and Curtis stages, all other stages of turbine is a mixture of Impulse and Reaction with varying degree of reaction. Pressure/Enthalpy drop is more in Impulse stage than in reaction. Comparatively Reaction Blade is more efficient than the Impulse blade. Impulse turbine requires fewer no. of stages than reaction turbine for same condition of steam and power requirement.

Thermal Efficiency of Steam Cycle

Super Heated steam is generated by supplying Heat to water.( Through HP Heaters, Economizers, water walls & than Super heaters) Capacity to do work depends on steam conditions, i.e. Main Steam Pressure and its temperature that is terminal conditions Unfortunately in steam cycle, all the heat added is not converted in to work.( Rejection in condenser) To get work done by steam, heat needs to be rejected so that steam is converted back to water to start the cycle again.

Thermal Efficiency
To obtain high efficiency from cycle, it should reject as little heat as possible and add as much heat as possible. Ratio of Heat added to Heat rejected is the crux of cycle efficiency. When heat is added to water to raise its temperature, it is called sensible heatWhat is latent heat? Does latent heat requirement varies with cycle conditions.

 To obtain high efficiency from cycle, it should reject as little heat as possible and add as much heat as possible. Cycle efficiency is the theoretical ideal efficiency for a given set of terminal conditions, i.e. initial steam pressure, temperature, reheat pressure and temperature , vacuum and final feed water temperature.

Temperature Entropy diagrams

Turbine Efficiency
Steam turbine is a device which converts heat made available into mechanical work & than in to electricity via alternator. A modern turbo alternator can convert 80 to 85% of available energy into electricity. Overall turbo alternator efficiency is the heat equivalent of electricity generated as a percentage of the heat added to the working fluid. It is product of the cycle efficiency,

Turbine Efficiency
Heat rate of turbine is used industry wide to express the heat input required at Turbine inlet to produce one kilowatt hour of electricity. (500 MW machine has better HR Dividing the heat equivalent of one kwh(3,412 Btu) by heat rate in Btu/kWh gives overall turbo alternator efficiency. Improvement in HR are obtained by reducing cycle losses as well as by using turbo alternators with higher

 Role of Steam Generator is to generate steam which is used to convert heat energy into kinetic energy. Boilers generally operate at Gross efficiency of 87.5%. Level of boiler efficiency is marginally dependant on unit size Once through or Supercritical brand Gross boiler efficiency level depend more on coal quality and less on type of cycle. Improvement in boiler efficiency with better coal comes at a cost & we know fuel cost can be passed on to consumer with consent of regulator. Why not use better coal, an optimum performance can be sustained with less

Power plant cycle efficiency

Power plant cycle efficiency

Boiler Efficiency varies with output & boiler efficiency at MCR rating would be around 0.3 less as compared to at nominal load Gross boiler efficiency at any point of operation can be improved by consuming more electricity through Mills & fans. When we are using low cost inferior coalswe consume more auxiliry power consumption to improve operating efficiency. Usage of an additional pulverizer to handle poor coal results in increased power consumption , however, corresponding improvement in Gross boiler efficiency may not be achieved.

Power plant cycle efficiency

Impact of coal quality on expected Boiler Efficiency is rather difficult to predict. Modeling tools are generally not available with a station to understand the role of change in operating regime on expected performance. Based on actual Performance, we can revise our targets and instead of comparing performance with design values , we can compare with expected values. Combustion efficiency is quite a different term as compared to thermal efficiency ?