Nikunj Sir Final

TURBINE HEAT
RATE
BY- NIKUNJ SHAH

BTG BOP OPERATION
HEAT
The heat is defined as the energy transferred, without transfer of
mass, across the boundary of a system because of a temperature
difference between the system and the surroundings .
WHAT IS HEAT RATE
Heat rate is the amount of fuel energy that must be supplied to
produce one unit of electrical energy.
Heat rate is a measure of how efficiently it converts the

chemical energy contained in fuel into electrical energy.
Since coal chemical energy is measured in kilocalories (kCal) and
electrical energy is measured in unit i.e. kolowatt-hours (kwh), the
unit of heat rate are kilocalories par kilowatt-hours (kcal/kwh).
Empirically, 1% improvement in efficiency is equal to 3%

improvement in heat rate
First Law of Thermodynamics
•“The heat and mechanical work are mutually convertible.”
•“The energy can neither be created nor destroyed though it
can be transformed from one from to another.”
Second Law of Thermodynamics
•Kelvin – Plank statement. ;-“It is impossible to construct an engine working on

a cyclic process, whose sole purpose is to convert heat energy from a single
thermal reservoir into an equivalent amount of work.”
•Clausius Statement. ;-“It is impossible for a self acting machine, working in a

cyclic process, to transfer neat from a body at a lower temperature to a body at a
higher temperature without the aid of an external agency.”
Third Law of Thermodynamics
“The third law of thermodynamics states that the entropy
of a perfect crystal at a temperature of zero Kelvin
(absolute zero) is equal to zero.”
HEAT RATE - CONCEPT
• Common term used for indicating Power Station

efficiency
• Heat rate Heat input in Kcal

• = ------------------------------
• Power output in Kwh
Defination : Heat required in Kcal to generate one Kwh

of Power
HEAT RATE
UHR=Unit Heat Rate=GTCHR/( BOILE EFFY/100)
= 2000/0.85 = 2353 kcal/kWh.
Gross Unit thermal Efficiency = 860/2353*100=36.55%
NHR (Net Heat rate)= UHR /(1-apc%/100)= UHR/0.93

(Assumed APC %= 7 %)
= 2353/0.93= 2530 kcal/kWh
This means 7% APC is equivalent to( 2530-2353) kcal/kwhr
Hence 0.1%APC is 2.5 kcal/kwhr
Net Unit Thermal Efficiency= 860/2530 * 100 = 33.99 %

1 ton of coal saved is approx 1.25ton of Co2 avoided
IMPROVEMENT IN HR BY 1Kcal/KWh
Capacity-660MW
PLF -90%
GCV-3500kcal/kg
Coal price-Rs 2500/Ton
Impact of Imp in HR by 1kcal per annum in Lacs of Rupees=HR
Imp*(Capacity*1000*24*365*0.9)*coal price per kg/(GCV)/100000
=1*500*1000*24*365*0.9*2.5/3500/100000
=28.15 Lacs Rs
(Coal saved per annum is 1126 T that is around
3.1 T/day of coal saved means approx 3.9 T/day Co2 emission avoided )
Hence Improvement in 0.1 APC is 70.4 lacs Rs
MONETARY IMPACT OF HR & APC
IMPROVEMENT
• HR Impact of 1kcal/kWh ~17 Cr/Annum
• APC imp by 0.1% ~39 Cr/Annum
• Assuming coal price of ~Rs2500/ton
• Capacity of 35000MW
• PLF -78%
• GCV-3500kcal/kg
Typical value of Impact of improvement of 1 kcal per Annum

Pit Head stations Non Pit Head stations
For 200MW unit
8-10 Lacs 15-18 Lacs
For 500 MW unit
20-22 Lacs ~35-40 Lacs
For 660 MW
28-30 lacs 45-50 lacs
GROSS TURBINE CYCLE HEAT RATE
Fms( H1 - Hf ) +Frhs( H3 - H2 ) + Fss ( Hf - Hs ) + Frs ( H3 - Hr )
= ----------------------- ------------------------------------------------x1000 Kcal/Kwh
PG
Where,
Fms = Main steam flow (T/Hr) Hs = Enthalpy of S/H spray water
Frhs= Hot reheat steam flow Hr = Enthalpy of R/H spray water
Fss= Superheater spray flow Pg = Power generated
Frs= Reheater spray flow
H1 = Enthalpy of Main steam
Hf= Enthalpy of feed water
H3 = Enthalpy of Hot reheat steam
H2= Enthalpy of Cold reheat steam
Fms( H1 - Hf ) +Frhs( H3 - H2 ) + Fss ( Hf - Hs ) + Frs ( H3 - Hr )
= ----------------------- ---------------------------------------------------------------x1000 Kcal/Kwh
Pg
1992(813.97-323.92)+1646.32(871.7-728.11)+20(323.92-378.82)+9.8(871.7-187.63)
= ----------------------------------------------------------------------------------------------------------------- x1000
660*1000
= 1845 Kcal/Kwh
DATA FLOW(tph) PR kg/cm2 TEMP °C ENTHALPY kcal/kg
Fms = Main steam flow (T/Hr) 1992 238 566 813.97

Frhs= Hot reheat steam flow 1646.32 52.13 593 871.7
Fss= Superheater spray flow 20 269 345 378.82
Frs= Reheater spray flow 9.8 107 184 187.63
H1 = Enthalpy of Main steam 813.97
Hf= Enthalpy of feed water 1983 271 305 323.92
H3 = Enthalpy of Hot reheat steam 871.7
H2= Enthalpy of Cold reheat steam 1645 55 346 728.11

Hs = Enthalpy of S/H spray water 20 269 345 378.82
Hr = Enthalpy of R/H spray water 187.63
Pg = Power generated MW - 660
Heat Added to cycle :
Heat Added MS
= Flow MS * (hMS - hFW), kcal/hr
Heat Added CRH

= Flow CRH* (hHRH - hCRH),kcal/hr
Heat added by SH Attemp

= Flow SH Attemp* (hMS-hSHFFT) Kcal/hr
Heat added by RH Attemp

= Flow RH Attemp * (hHRH-hRHATT) Kcal/hr
IMPACT OF TURBINE 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 %
Output Sharing by Turbine Cylinders
500MW 660MW
HPT 27% 26%
IPT 34% 38%
LPT 39% 33%
TG CYCLE LOSS – RELATED
PARAMETERS
• Load
• HPH loss
• R/H attemperation
• S/H attemperation( if s/h spray is taken before hp heater)
• Condenser loss
• Cooling tower loss(expected cw inlet temperature> design cw inlet temp)
• Cylinder efficiency
• MS and HRH temperature
• TDBFP efficiency
• Make up
• HPH out of service
• TDBFP ext steam line up( CRH or IP Exhaust)
TURBINE LOSSES
1.External Losses
2. Internal Losses
TURBINE EXTERNAL LOSSES
1. Shaft gland leakage Losses

2. Journal & thrust bearing losses
3. Governor & oil pump losses
TURBINE INTERNAL LOSSES
• Inter stage gland leakage loss
• Wetness loss
• Leaving Loss
• Exhaust loss
• Pressure drop losses
• Control valves
• Pipes
Power Loss (kW)
10000
2000
4000
6000
8000
0
Interstage Packings
585.1
Tip Spill Strips

3473.0
End Packings
601.3
Miscellaneous Leakages
Flow Path Damage

94.0
Flow Change Impact
Surface Roughness
4486.7
SUMMARY OF LOSSES
Cover Deposits
47.7
Hand calculations
Trailing Edge Thickness
Total
9287.8
FACTORS AFFECTING TURBINE CYCLE HEAT RATE
• Unit Load
• Main steam temperature
• Main steam pressure
• Hot and cold reheat temperature and pr
• Condenser back pressure
• Final feed water temperature
• Make up
FACTORS AFFECTING TURBINE CYCLE HEAT RATE
• Reheater pressure drop

• Superheater spray flow
• Reheater spray flow
• HP cylinder efficiency
• IP cylinder efficiency
• Tdbfp/HPH line up
• Generator hydrogen pressure
• Grid frequency
HIGH ENERGY DRAINS
Passing of High Energy drain valve affects in 3 ways
1.Loss of High Energy steam
2.Deterioration in Condenser Vacuum

3.Damage to the valve
TG# LOAD DATE-
UNIT-
SL. NO. VALVE
BEFORE BODY AFTER
1 MS DRAIN MOV RHS

2 MS DRAIN MOV LHS

3
M.S(LHS) to TFT
4
M.S(LHS) to AFT
5
M.S(RHS) to TFT
6
M.S(RHS) to AFT
7
HRH DRAIN MOV RHS
8
HRH DRAIN MOV LHS
9
HRH(LHS) to TFT
10
HRH(LHS) to AFT
11
HRH(RHS) to TFT
12
HRH(RHS) to AFT
13
CRH(LHS) to TFT
14
CRH(LHS) to AFT
15
CRH(RHS) to TFT
16
CRH(RHS) to AFT
17
CRH PORT DRAIN TO TFT
18
CRH PORT DRAIN TO AFT
19
HRH WARMUP DARIN MIV(LHS)
20
HRH WARMUP DARIN MIV(RHS)
UNACCOUNTABLE LOSSES
High Energy drain Passing

Instrument Error / Uncertainty
System Water Loss –D/A drop test
L.P. Turbine Performance
L.P. Heaters
Insulation loss- higher temp loss between B O
and TG inlet more than design of around 3 deg C
METHODOLOGY TO REDUCE UNACCOUNTABLE
High energy drains passing
• Listing of all the drains/steam traps

• Temperature mapping of drains
• Action plan for repair replacement of valves
• Installation of thermocouples on valve down stream
• Progressive replacement of High energy drain valves
• Attending valves during opportunity shut down.
• Checking of valve of valve passing before O/H
• Joint checking by Operation & TMD after unit startup
METHODOLOGY TO REDUCE UNACCOUNTABLE
üInstrument Error
• Use of accurate & calibrated Instrument
üSystem Water Loss
• D/A drop test to be conducted periodically.

TURBINE HEAT CONSUMPTION TEST
• When heat consumption at different load are plotted on a graph,

it is supposed to lie on a straight line called ‘Willans Line’.
• At lower load the heat rate increases because the prominence

of fixed heat component on total heat consumption.
• The slope of the curve is known as incremental heat rate.

Sensitive Analysis of Turbine Efficiency on
Heat Rate
1 % change in HP or IP Turbine Efficiency in a 660

MW unit leads to change in HR by about
4.5 kcal/kWh and having cost implication of about Rs
57 lakhs per year (rail fed station)
Parameters required For efficiency calculation
1 Gross Load 13 FW Press HPH Inlet

2 MS Pressure before ESV 14 FW Temp HPH Inlet
3 MS Temp before ESV 15 FW Press HPH Outlet
4 HPT Exhaust Pressure 16 FW Temp HPH Outlet
5 HPT Exhaust Temp. 17 Main Steam Flow (Q1)

6 HRH Steam Press. before IV 18 Feed Water Flow (Qf)
7 HRH Steam Temp. before IV 19 CRH Flow (Q2)
8 FW press after top heater 20 S/H Spray Flow (Qs)
9 FW Temp at Eco inlet 21 R/H Spray Flow (Qr)
10 HPH Ext. Steam Temp 22 S/H Spray Temp.
11 HPH Shell Pressure 23 R/H Spray Temp.
12 HPH Drip Temp 24 Leak Off Flow

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TURBINE HEAT

BY- NIKUNJ SHAH

Heat rate is a measure of how efficiently it converts the

Empirically, 1% improvement in efficiency is equal to 3%

•Kelvin – Plank statement. ;-“It is impossible to construct an engine working on

•Clausius Statement. ;-“It is impossible for a self acting machine, working in a

• Common term used for indicating Power Station

• Heat rate Heat input in Kcal

Defination : Heat required in Kcal to generate one Kwh

Gross Unit thermal Efficiency = 860/2353*100=36.55%

NHR (Net Heat rate)= UHR /(1-apc%/100)= UHR/0.93

Net Unit Thermal Efficiency= 860/2530 * 100 = 33.99 %

Fms = Main steam flow (T/Hr) 1992 238 566 813.97

H2= Enthalpy of Cold reheat steam 1645 55 346 728.11

Heat Added CRH

Heat added by SH Attemp

Heat added by RH Attemp

1% IPT Efficiency 0.16% 0.16%

1% LPT Efficiency 0.5 % 0.5 %

Output Sharing by Turbine Cylinders

TURBINE EXTERNAL LOSSES

1. Shaft gland leakage Losses

Tip Spill Strips

Flow Path Damage

Flow Change Impact

Trailing Edge Thickness

• Reheater pressure drop

Passing of High Energy drain valve affects in 3 ways

1.Loss of High Energy steam

2.Deterioration in Condenser Vacuum

High Energy drain Passing

• Listing of all the drains/steam traps

• Use of accurate & calibrated Instrument

üSystem Water Loss

• D/A drop test to be conducted periodically.

• When heat consumption at different load are plotted on a graph,

• At lower load the heat rate increases because the prominence

• The slope of the curve is known as incremental heat rate.

1 % change in HP or IP Turbine Efficiency in a 660

1 Gross Load 13 FW Press HPH Inlet

5 HPT Exhaust Temp. 17 Main Steam Flow (Q1)

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