STEAM TURBINE CYCLE

Table of Contents
Turbine Cycle, Heat Balance concept, Thermal Efficiency & PG Test .........................................................................2
Objective: ..................................................................................................................................................................2
Thermal Cycle: .............................................................................................................................................................. 2
Cycle efficiency & Heat Rate: .......................................................................................................................................6
Key parameters affecting the Thermal cycle efficiency: ............................................................................................... 7
A typical 250 MW HBD is shown below: .....................................................................................................................8
Performance Guarantee Test: ........................................................................................................................................9
Significance of PG Test .................................................................................................................................................9
Non fulfillment of PG Test clauses results in: ...............................................................................................................9
The Guaranteed parameters to be proved during the tests are: ......................................................................................9
The Demonstration (functional) tests to be carried out include: ....................................................................................9
Basis of conducting PG Test: ...................................................................................................................................... 10
PG Test codes: ............................................................................................................................................................. 10

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Turbine Cycle, Heat Balance concept, Thermal Efficiency & PG Test
Objective:
Clean and cost-effective power generation is of paramount importance to cope with the Challenges
imposed by an increasing energy demand throughout the world. Investment cost and fuel costs are
the main contributors to the cost of electricity.
This chapter section covers the thermodynamic basics for design of any fossil fuel fired power plant.
The various aspects of cycle design which contributes in enhancement of thermal efficiency are also
elaborated here.
The chapter also discusses the international practices followed for evaluation and assessment of
thermal power plant performance.

Thermal Cycle:

A Carnot cycle is the most efficient cycle for converting a given amount of thermal energy into
work. Efficiency obtained by the Carnot cycle is the theoritical upper limit of performance.

In this cycle, efficiency is a function of only two parameters viz. higher temperature and lower
temperature and is represented as follows:

Thermal efficiency, η = 1- (Temp. at which is heat is rejected/Temp. at which heat is added)

It is our immediate endeavour to conceive a power plant which is operating nearer to Carnot
cycle performance level. All efforts to do this in a practicable power plant so far have failed
because the processes involved are impossible to achieve within finite space and economic costs

Modern day Power plants are based on the basic vapour cycle- The Rankine cycle

In a simple Rankine cycle, the water is pumped to the boiler by the feed pump (process A-B).
The water is then heated to produce dry saturated steam (process B-C). The dry saturated steam
is expanded isentropically through the turbine (process C-D). Finally the wet steam gives up its
heat in the condenser and returns to water state.

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Simple Rankine cycle

Practical cycle using superheat: In the superheat cycle, the dry saturated steam leaving the boiler
drum is further heated before entering the turbine. Here there is improvement in cycle efficiency.
Another advantage is that the exhaust wetness in the last turbine stages can be maintained within
the physical limits.

Thermal efficiency, η = W/Q1= (W1-W2)/Q1

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Reheat cycle: The desire for further improvement in cycle conditions and consequently cycle
efficiency led to the addition of steam reheat during turbine expansion.

In the reheat cycle, steam at a given initial temperature is partially expanded through the turbine
doing work and then is taken back to the boiler, where it is again heated to its original
temperature and then returned to the IP Turbine for further expansion.
Reheating increases the average temperature at which heat is added. Hence efficiency of hte
cycle increases. Also the dryness fraction of the steam leaving the turbine increases and therefore
reduces the chances of erosion & corrosion of the last stage blades.
The most important disadvantage is the complication and the high cost of pipings and fittings.

Regenerative Feed heating: A small fraction of steam which is expanding through the Turbine is
bled off from different stages of the turbine & utilized for the heating of feed water, this is called
regenerative feed heating. Some torque is sacrificed in the process but the saving of energy
increases the overall efficiency. Further, the extractions from the last stages of the turbine act as
the moisture extractor & hence reduces blade damage due to water droplet impact. Reduced flow
at turbine exhaust demands lesser exhaust area, resulting in smaller blades in the last stages,
which is limiting factor in turbine design. The decrease in steam flow at turbine exhaust also
reduces flow of working fluid in condenser, CEP’s and LP Heaters, thereby reducing their sizes
and saving in capital investment.

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Although power plant efficiency increases with increase in the number of heaters but it is not
economical to use large number of heaters. On the basis of the techno-economic study, the
optimum number of heaters in 250 or 500 MW plant generally has been worked out to be 6 to 7
which increases the overall efficiency by ~ 5 to 6%.

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Cycle efficiency & Heat Rate:

The overall cylinder efficiency may be noted as:

Heat Rate: The heat rate is determined by measurement of various plant operating parameters.
These include Flow rate, enthalpy & electric power.

The heat rate is defined as:

Heat Rate: Heat input from Boiler (kCal/h) / Electrical output from generator (kW)

Requirements of Efficiency improvements in TG Cycle:

• To meet the Challenges in the Competitive Environment.

• Environmental concerns by reducing GHG emissions.
• Saving in consumption of natural resources i.e. Coal, oil
• improve profit margin and lead to better availability

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Key parameters affecting the Thermal cycle efficiency:

(i) Initial/ Reheat Steam Temperature

(ii) Initial Steam Pressure
(iii)Reduction of Condenser Pressure
(iv) Reheating
(v) Regenerative feed heating

(i) Initial/reheat Steam Temperature :

The temperature at which heat is supplied to the turbine can be increased without increasing
the boiler pressure by superheating the steam to high temperatures.

The result is that work output and heat input increase by superheating the steam to higher
temperature. Overall increase in the thermal efficiency is obtained. Also, moisture content of
the steam at turbine exhaust decreases.
Limitation: Metallurgical considerations.

(ii) Initial steam pressure:

Increasing the initial steam pressure, automatically raises the temperature at which heat is
added to the cycle. This results in overall increase in the thermal efficiency. However, the
moisture content of the steam at turbine exhaust increases. With increase in pressure,
thickness of castings/flanges etc. increase.
Limitation: Metallurgical considerations.

(iii)Reduction in Condenser pressure:

Lowering the condenser pressure implies lowering mean temperature at which is rejected to
sink, thereby increasing the thermal efficiency. Lower condenser pressure also means larger
volumetric flow of steam at turbine exhaust resulting in larger LP turbine and bigger
condenser. Also, the increase in exhaust wetness tends to increase the erosion of the last
stage blades. Condenser pressure is dependent on the cooling water temperature. The lower
the cooling water temperature, the deeper the obtainable condenser pressure.

(iv) & (v) have already been deliberated above

HBD: The “heat balance diagram” is a schematic flow diagram for a thermal power cycle, in
which thermodynamic properties (pressure, temperature and enthalpy) and mass flow are
indicated, for all major flow streams in the power cycle.

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In addition to determining flow and thermodynamic properties for all flows in the cycle, the
calculation also presents the overall predicted performance (efficiency/Heat rate and output) of
the generating unit at different operating conditions.

A heat balance diagram is the reference document for the sizing of all the equipment in the
power generating cycle.

A typical 250 MW HBD is shown below:

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Performance Guarantee Test:

• It is a test carried out on a fully operational TG set to ascertain its efficiency levels as
well as health of auxiliaries. The tests are carried out to prove the guaranteed parameters
in line with the contract specifications.

Significance of PG Test
• Prime Customer Requirement
• Fulfils The Contractual commitment
• Huge Financial Repercussion To Corporation
• Reputation Of The Company At The Stake
• Design Validation Of Steam Turbine
• Feed Back For Further Improvements In The New Tender
• Identification Of Grey Areas
• Closure Of Site Office
• Strengthening Of Customer’s Confidence
• Maximum Capability Under varied Operating Modes
• Validation Of Plant Instrumentation

Non fulfillment of PG Test clauses results in:

• Liquidated Damages
• Poor Reflection Of Company’s Image & Reputation
• Affects Chances Of Winning Orders
• Delay In Contract Closing
• Difficulty In Closing Site Office
• BHEL Forced To Attend Routine Problems Till Contract Closing.

The Guaranteed parameters to be proved during the tests are:

(A) Heat rate at 100%, 80% & other loads

(B) Rated Power Output (Generally at worst Vacuum)
(C) Condenser Back pressure
(D) Auxiliary Power Consumption
(E) CW Pumping Power

The Demonstration (functional) tests to be carried out include:

(A) Continuous output corresponding to VWO condition

(B) TG Output corresponding to HP Heater out condition
(C) Half Condenser operation

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Basis of conducting PG Test:
• Agreed procedure
• PG Test Code (ASME-PTC 6 etc.)
• Instrumentation Scheme
• Heat Balance Diagram

PG Test codes:

• For conventional Steam Turbine plants ASME-PTC-6

• For combined cycle ASME-46
• For gas turbine ASME-PTC-22
• For HRSG ASME-PTC-4.4

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