Modern Computer Applications in Science and Education

Numerical Methods applied for Power Plant Calculations

IOANA OPRIŞ, SORINA COSTINAŞ, VICTOR CENUŞĂ

Department of Energy Use and Generation

University POLITEHNICA of Bucharest
Splaiul Independenţei 313, 060042 Bucureşti
ROMANIA
ilopris@gmail.com, sorina_costinas@yahoo.com, cenusa_victor@yahoo.com

Abstract: - The pre-dimensioning of a thermal power plant implies a lot of calculation for which the use of
numerical methods are a helpful instrument. The paper presents an application of a numerical method for the
determination of the steam flow rates necessary for heating the feed-water that enters into the steam generator.
Usually, these values are obtained by writing the equations of heat balance for each heater and by calculating the
rates one by one. The use of numerical methods for determining the unknown parameters consists in solving a
system of linear equations by using a numeric algorithm.The elements of the matrix that describes the system can
be easily determined by following specific rules, which resulted from writing the balance equations for the whole
system. The method proposed in the paper can be used in applications for optimization of the operation of a
power plant, maintenance issues or education purposes.

Key-Words: - regenerative circuit, specific flow rate, power plant, numerical method

1. Introduction with a minimum effort [4, 5, 6]. New mathematical

In a power plant, the regeneration process consists methods can now be used easily for solving design
of preheating the make-up water that enters into the problems, as a result of the increase of computational
steam generator by using steam extracted from the power at lower costs [7].
turbine [1]. The extraction of steam before its During the design of a power plant, the steam flow
complete expansion in the turbine to heat the water rates extracted from the turbine must be determined.
that enters into the steam generator (the dashed line This is usually made by making the heat balance (heat
in fig. 1) is made with the goal of improving the in = heat out) and the mass balance (flow rate in =
efficiency of the Rankine thermodynamic cycle [1, 2, flow rate out) for the regenerative circuit. The steam
3]. flow rates result from the balance equations, written
for each heat exchanger apart.
The paper proposes the use of numerical methods
Steam generator Steam turbine to solve the problem holistically, by writing a linear
system of equations for the whole circuit. The
dimension of the system is given by the number of
heaters contained in the regenerative circuit. The
Condenser unknown values are the specific steam flow rates
Preheating circuit
extracted from the turbine.
Such an approach may lower the mistakes
Figure 1. The main water/steam flows in a power plant occurred while writing the balance equations for each
heat exchanger and improve the teaching process by
linking courses on power plants with courses on
The extraction of steam from the turbine is made numerical methods.
at several pressures, so as to assure most benefits As an example, the regenerative circuit for a
from the feed-water preheating. 200MW fossil-fuel power plant is calculated with the
Several approaches can be used to obtain a higher two methods: the classical sequential approach and
energy efficiency of the regenerative circuit of a the one based on numerical methods.
power plant, so as to achieve a desired temperature of
the feed-water at the entrance in the steam generator

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2. The feed-water heating circuit for a To steam generator

200 MW fossil-fuel power plant

The feed-water regenerative system contains three SDS6, [a6]
categories of heaters (figure 2):
- low-pressure heaters (between the condenser WDS6, [1]
and the deaerator): LPH 1, LPH2, LPH3;
HPH 7
- thermal deaerator (between the low-pressure
heaters and the feed-water pump): TD; S7, [a7]
- high-pressure heaters (between the feed-
water pump and the steam generator): C7
HPH 5, HPH 6, HPH 7. [a7] W7, [1]
The low-pressure heaters (LPH) and the high- HPH 6
pressure heaters (HPH) are surface (closed) heaters. S6, [a6]
In surface heaters, the feed-water and the extraction
steam are separated one from the other by the tube
walls, a direct contact being not allowed. The feed- C6
[a7+ W6, [1]
water heats itself by flowing inside tubes, while the
a6] HPH 5
extraction steam condenses on the outer side of the
tubes [2]. S5, [a5]
To take advantage of superheated steam
(exhausted by the high-pressure section of the turbine W5 C5, [a7+a6+a5]
and reheated in the steam generator), a separate [1]
desuperheater (DS 6) is used for HPH 6. The steam
Feed- S4, [a4]
extracted from the turbine crosses DS 6 and
water
condensates in HPH 6. pump
The deaerator (TD) is a contact (open) heater. The TD
feed-water and the extraction steam (having the same W4,
Wpump
pressure) are mixed directly, thus preheating the [1-a4-a5-a6-a7]
[1]
feed-water. Besides preheating the water, the role of
the deaerator consists in removing of oxygen from it, LPH 3
with the scope of avoiding corrosion [8]. The
dissolved gases are drawn out from the feed-water as S3, [a3]
a result of the decrease of their solubility along with C3
the decrease of the partial pressure above the solution [a3] W3
(Henry’s law) and the temperature rise close to the [1-a4-a5-a6-a7]
saturation temperature (the relation between gas
solubility and temperature) [9]. LPH 2
In figure 2, the regenerative scheme is passed by S2, [a2]
the following fluids:
- the feed-water (W), make-up water that C2
comes from the condenser, is heated in the [a2+a3] W2
regenerative circuit and sent to the steam [1-a2-a3-a4-
generator; a5-a6-a7]
- the steam (S), that is extracted from the LPH 1
turbine for each heater separately;
- the condensate (C), resulted from the S1, [a1]
condensation of steam in the heat
exchangers. C1
The condensate resulted from the high-pressure [a1]
W1
heaters (HPH 5, HPH 6, HPH 7) flows in cascade [1-a2-a3-a4-
from the last heater (HPH 7) to the first one (HPH 5) To condenser a5-a6-a7]
and then into the deaerator (TD), from where it is
introduced into the main feed-water circuit. From condenser

Figure 2. The feed-water preheating circuit

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The condensate resulted from the last low- ℎ𝑠7 ∙ [𝑎7] + ℎ𝑤7 ∙ [1] = ℎ𝑐7 ∙ [𝑎7] + ℎ𝑤𝐷𝑆6 ∙ [1]
pressure heater (LPH 3) enters into the former heater, (1)
LPH2. Both condensates are then pumped into the
main feed-water circuit, between LPH 3 and LPH 2. where:
The condensate from the LPH 1 is exhausted to the ℎ𝑠7 , ℎ𝑐7 , ℎ𝑤7, ℎ𝑤𝐷𝑆6 – specific enthalpy of steam,
condenser. condense, water in and water out for HPH 7, in kJ/kg;
[a7] – specific steam flow rate at HPH 7;
[1] – specific feed-water flow rate to the steam
generator.
3. Thermal balances for determination
of the steam specific flow rates
In writing the heat balance equations for each heat High pressure heater HPH 6: fig. 4 and eq. (2)
exchanger, the following assumptions [10] and
notations are made (see figure 2): To
The steam rate is calculated as a specific value, From HPH7
relative to the steam produced by the steam generator HPH 7
(entered into the turbine). Also, it is considered that
the steam generator produces 1 kg of steam from 1 kg
C7 W7:
of feed-water entered. [a7] [1]; ℎ𝑤7
To determine the steam rate extractions from the ℎ𝑐7 HPH 6
turbine, the heat balance equations are written for
each heat exchanger, starting from the last heater S6:
(before the steam generator) to the first one (after the [a6]; ℎ𝑠6
condenser).
To understand and follow easily the notations in C6 W7:
figure 2, the names of the important points were [a6+a7] [1]; ℎ𝑤6
given so as to suggest the passing fluid (W - water, ℎ𝑐6
S - steam, C - condensate) and the position of the From
heater in the circuit (1 … 7). To HPH 5
HPH 5
Each heat exchanger receives a fraction of the
steam from the turbine. The number following the Figure 4. Heat balance for HPH 6
letter “a” designates the number of the heater in the
regenerative circuit.
According to these rules, the heat balances ℎ𝑠6 ∙ [𝑎6] + ℎ𝑤6 ∙ [1] + ℎ𝑐7 ∙ [𝑎7]
equations, written from the last heat exchanger to the = ℎ𝑐6 ∙ [𝑎6 + 𝑎7] + ℎ𝑤7 ∙ [1] (2)
first one are [1], [10-11]:
where:
High pressure heater HPH 7: fig. 3 and eq. (1) ℎ𝑠6 , ℎ𝑐6 , ℎ𝑤6 – specific enthalpy of steam, condense,
entering water for HPH 6, in kJ/kg;
To DS6 and steam generator [a6] – specific steam flow rate at HPH 6.

WDS6:
[1]; ℎ𝑤𝐷𝑆6 High pressure heater HPH 5: fig. 5 and eq. (3)
HPH 7
ℎ𝑠5 ∙ [𝑎5] + ℎ𝑤5 ∙ [1] + ℎ𝑐6 ∙ [𝑎6 + 𝑎7]
S7: = ℎ𝑐5 ∙ [𝑎5 + 𝑎6 + 𝑎7] + ℎ𝑤6 ∙ [1] (3)
[a7]; ℎ𝑠7
where:
C7 W7: ℎ𝑠5 , ℎ𝑐5 , ℎ𝑤5 – specific enthalpy of steam, condense,
[a7]; [1]; ℎ𝑤7 entering water for HPH 6, in kJ/kg;
ℎ𝑐7
[a5] – specific steam flow rate at HPH 5.
From
To HPH 6
HPH 6

Figure 3. Heat balance for HPH 7

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 Modern Computer Applications in Science and Education

To Low pressure heater LPH 3: fig. 7 and eq. (5)

From HPH 6
HPH 6 To DT

C6 W6: W4:
[a6+ [1]; ℎ𝑤6 [1-a4-a5-a6-a7]
a7] HPH 5 ℎ𝑤4
ℎ𝑐6 LPH 3
S5:
[a5]; ℎ𝑠5 S3:
[a3]; ℎ𝑠3
C5 W5:
[a5+a6 C3
[1]; ℎ𝑤5 W3:
+a7] [a3]; [1-a4-a5-a6-a7]; ℎ𝑤3
ℎ𝑐5 From ℎ𝑐3
To DT From
DT LPH 2
To
Figure 5. Heat balance for HPH 5 LPH 2
Figure 7. Heat balance for LPH 3

Deaerator DT: fig. 6 and eq. (4)

ℎ𝑠3 ∙ [𝑎3] + ℎ𝑤3 ∙ [1 − 𝑎4 − 𝑎5 − 𝑎6 − 𝑎7]
From = ℎ𝑐3 ∙ [𝑎3] + ℎ𝑤4 ∙ [1 − 𝑎4 − 𝑎5 − 𝑎6 − 𝑎7] (5)
HPH 5
where:
C5 ℎ𝑠3 , ℎ𝑐3 , ℎ𝑤3 – specific enthalpy of steam, condense,
[a5+a6+a7]
entering water for LPH 3, in kJ/kg;
ℎ𝑐5
[a3] – specific steam flow rate at LPH 3;
To S4:
feedwater [a4]; ℎ𝑠4
pump Low pressure heater LPH 2: fig. 8 and eq. (6)

Wpump
The balance is made for the dashed line contour,
[1] TD in the hypothesis that the condensate that exits
ℎ𝑤𝑝𝑢𝑚𝑝 LPH 2 enters into the feed-water stream with the
W4 output enthalpy of the water (ℎ𝑐2 = ℎ𝑤3 ).
[1-a4-a5-a6-a7] To
ℎ𝑤4 From LPH3
LPH 3
From C2
W3:
LPH 3 [a2+a3]
[1-a4-a5-a6-a7]; ℎ𝑤3
C3 ℎ𝑐2 = ℎ𝑤3
Figure 6. Heat balance for TD [a3]
ℎ𝑐3 LPH 2
ℎ𝑠4 ∙ [𝑎4] + ℎ𝑤4 ∙ [1 − 𝑎4 − 𝑎5 − 𝑎6 − 𝑎7] +
+ℎ𝑐5 ∙ [𝑎5 + 𝑎6 + 𝑎7] = ℎ𝑤𝑝𝑢𝑚𝑝 ∙ [1] (4) S2:
[a2]; ℎ𝑠2
where:
ℎ𝑠4 , ℎ𝑤4 , ℎ𝑤𝑝𝑢𝑚𝑝 – specific enthalpy of steam, W2:
entering and leaving water for DT, in kJ/kg; [1-a2-a3-a4-a5-a6-a7];
[a4] – specific steam flow rate at DT. ℎ𝑤2
From
Note that for the deaerator, the condensate flow LPH 1
and the feed-water flow are one and the same thing
(as they mix themselves in the heat exchanger). Figure 8. Heat balance for LPH 2

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ℎ𝑠2 [𝑎2] + ℎ𝑐3 [𝑎3] + ℎ𝑠1 [𝑎1] + ℎ𝑤1 [1 − 𝑎2 − 𝑎3 − 𝑎4 − 𝑎5 − 𝑎6 − 𝑎7] =

+ℎ𝑤2 [1 − 𝑎2 − 𝑎3 − 𝑎4 − 𝑎5 − 𝑎6 − 𝑎7]
= ℎ𝑤3 [1 − 𝑎4 − 𝑎5 − 𝑎6 − 𝑎7] (6) = ℎ𝑐1 [𝑎1] + ℎ𝑤2 [1 − 𝑎2 − 𝑎3 − 𝑎4 − 𝑎5 − 𝑎6 − 𝑎7]
(7)
where: where:
ℎ𝑠2 , ℎ𝑐2 , ℎ𝑤2 – specific enthalpy of steam, condense, ℎ𝑠1 , ℎ𝑐1 , ℎ𝑤1 – specific enthalpy of steam, condense,
entering water for LPH 2, in kJ/kg; entering water for LPH 1, in kJ/kg;
[a2] – specific steam flow rate at LPH 2. [a1] – specific extraction steam flow rate at LPH 1.

Low pressure heater LPH 1: fig. 9 and eq. (7) 4. Numerical methods for the
determination of the specific steam
flow rates
To LPH 2 The determination of the specific steam flow rates
extracted from the turbine is based on the heat
W2: balance equations given in chapter 3, but written as a
[1-a2-a3-a4-a5-a6-a7] system of equations. For the regenerative circuit
ℎ𝑤2 considered in fig. 2, it results a linear system of seven
LPH 1 equations with seven unknown values (a1,…, a7).
S1:
After rearranging the terms in a matrix form, a
[a1]; ℎ𝑠1 matrix of 7 rows and 8 columns is obtained (table 1).
The result is a lower triangular matrix that
C1 contains the coefficients of the specific flow rates.
W1: The matrix is extended with a column vector that
[a1]; [1-a2-a3-a4-a5-a6-a7]; ℎ𝑤1
ℎ𝑐1 contains the coefficients that correspond to the unit
From specific flow rate (the independent terms).
condenser The rules for completing the matrix can be
observed in table 1:
To - The rows correspond to the heaters, beginning
condenser from the last one (row 1 = heater 7) towards
the first one (row 7 = heater 1);
Figure 9. Heat balance for LPH 1

Table 1. Preheating circuit matrix

[a7] [a6] [a5] [a4] [a3] [a2] [a1] [1]

HPH7 hs7 – hc7 0 0 0 0 0 0 hwDS6 – hw7

HPH6 hc7 – hc6 hs6 – hc6 0 0 0 0 0 hw7 – hw6

HPH5 hc6 – hc5 hc6 – hc5 hs5 – hc5 0 0 0 0 hw6 – hw5

TD hc5 – hw4 hc5 – hw4 hc5 – hw4 hs4 – hw4 0 0 0 hwpump – hw4

LPH3 hw4 – hw3 hw4 – hw3 hw4 – hw3 hw4 – hw3 hs3 – hc3 0 0 hw4 – hw3

LPH2 hw3 – hw2 hw3 – hw2 hw3 – hw2 hw3 – hw2 hc3 – hw2 hs2 – hc2 0 hw3 – hw2

LPH1 hw2 – hw1 hw2 – hw1 hw2 – hw1 hw2 – hw1 hw2 – hw1 hw2 – hw1 hs1 – hc1 hw2 – hw1

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- The columns correspond to the specific steam 5. Example of application

flow rates from the turbine to the heaters, To verify the model, the data for the pre-
beginning from the last rate (column 1 = [a7]) dimensioning of a 200 MW coal-fueled power plant
towards the first one (column 7 = [a1]); was considered, according to the preheating scheme
- The main diagonal contains for each of fig. 2.
corresponding heater, the result of the The known enthalpies that are necessary for the
following subtraction: specific enthalpy of calculation of the specific steam flow rates are given
steam that enters into the heater minus in table 2.
specific enthalpy of the condensate that exits
the heater; Table 2. Input data for the 200 MW power plant model
- The elements of the lower diagonal contain Heater’s Steam Condense Water
for each corresponding heater (according to position in out in
the row), the result of the subtraction between in the
ͦ the specific enthalpy of the condensate that scheme hsi hci hwi
enters and exits the heater, for HLP and TD, i [kJ/kg] [kJ/kg] [kJ/kg]
ͦ the specific enthalpy of the condensate that
HPH7 7 3127.27 909.29 892.29
enters and water that exits the heater, for the
specific rate of condense that enters into LHP, HPH6 6 2950.00 833.80 818.73
ͦ the specific enthalpy of the water that exits
HPH5 5 3282.60 758.60 745.18
and enters, for all other elements of LHP;
*
- The elements of the upper diagonal are zero; TD 4 3143.20 583.70
- The elements of the last column are the result LPH3 3 2962.76 466.60 446.30
between the feed-water specific enthalpy at
the exit and the entrance in the heater. LPH2 2 2785.81 446.30 308.90
These rules of completing the matrix, LPH1 1 2611.17 191.08 171.50
presented in a synthetized form in fig.10, avoid *
hwDS6 = 1039.4 hwpump = 721.1
the need of writing the heat balance equations for
kJ/kg kJ/kg
each component, simplifying considerably the
solving of the problem.
The data in table 2 resulted from the calculus of
the power plant according to the following main
[a7] [a6] … [a1] [1] assumptions [10, 13]:
HPH 7 - The turbine operates with inlet steam at 140
… bar (540 ºC), condenser back pressure of 0.06
TD 0 bar (39 ºC), reheats the steam exhausted by
the high-pressure section in the steam
LPH 3 generator, and uses seven regenerative heat
… exchangers. The turbine data parameters
LPH 1 (inlet, extracting stages, exit) are known;
- The steam for the last heater (HPH 7) is taken
LPH1
For HPH and TD: (hwater_out –
hwater_in)
from the exit of the high-pressure section of
(hcondense_in – hcondense_out) the turbine. HPH 6 is supplied through DS 6
(hsteam_in – with reheated steam from the entrance in the
hcondense_out) medium & low-pressure section of the
turbine. From this section of the turbine are
For LPH: supplied also the following heaters, with
- if [a] is condense from another heater: steam extracted at various stages;
(hcondense_in – hwater_in) - For the regenerative system, it is considered
- else: that the increase of feed-water enthalpy is
(hwater_out – hwater_in) divided equally through the heaters. Each
HPH increases the enthalpy with 73.55 kJ/kg,
Figure 10. Rules for completing the solving matrix except the last that has a double value. Each
HPH and the TD have an increase of enthalpy
of 137.4 kJ/kg;

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Table 3. Solving matrix for the 200 MW power plant

2217.67 0 0 0 0 0 0 147.11
75.8 2116.2 0 0 0 0 0 73.555
75.2 75.2 2524 0 0 0 0 73.555
174.9 174.9 174.9 2559.5 0 0 0 137.4
137.4 137.4 137.4 137.4 2496.16 0 0 137.4
137.4 137.4 137.4 137.4 137.4 2476.91 0 137.4
137.4 137.4 137.4 137.4 137.4 137.4 2420.09 137.4

- The rise of enthalpy through the feed-water 6. Conclusion

pump is known (24.08 kJ/kg); The paper presents two methods that are used for
- The condense from LPH 2 enters into the determining the specific steam flow rates extracted
feed-water stream with the output enthalpy of from a turbine for preheating the feed-water. Both
the water; methods are based on the heat balance equations
- The deaerator operates at the pressure of 8 bar written for each heat exchanger of the feed-water
- At the entrance in the first heater, a corrected regenerative circuit.
temperature is used for the heat exchangers The difference between the methods consists in
located between the condenser and LPH 1, the solving methodology:
corresponding to a specific enthalpy of - The classical approach is the one in which the
2611.17 kJ/kg; unknown specific steam flow rates are
- The feed-water that enters into the steam calculated one by one, by solving each
generator at 240 ºC (170 bar). equation starting with the last heat exchanger
The values from table 2 represent input values for towards the first one (chapter 3);
completing the elements of the solving matrix, - The approach based on numerical methods
according to the rules given in chapter 4, fig. 10. The (chapter 4) uses a holistic approach, in which
matrix that resulted is included in table 3. the specific flow rates are determined by
Once the elements of the matrix are completed, a solving a system of linear equations. The
numerical method can be used to determine the number of equations is given by the number
unknown specific steam flow rates: the Gauss or of heat exchangers.
Gauss-Jordan method [12]. Then, the flow rates may The tests gave identical results for both methods,
be calculated by multiplying each specific flow rate which show that they are similar.
by the flow rate that enters into the turbine. The second method - based on numerical methods
The system was solved in MATLAB® [14], using - has the advantage of solving the problem by
the Gauss-Jordan method [15]. The description of the completing a matrix according to some rules, without
algorithm of the method is out of the paper’s subject. the need to write balance equations. This simplifies
The execution of the program showed the the problem solving and reduces the risks of
following results: mistakes.
When teaching, the classical method is good for
- For HPH 7: [a7] = 0.0663 demonstrating the physics of the regenerative circuit
- For HPH 6: [a6] = 0.0324 of a power plant. Besides this, the numerical methods
- For HPH 5: [a5] = 0.0262 are good for developing the necessary background of
- For TD: [a4] = 0.0451 using mathematics and programming skills in
- For LPH 3: [a3] = 0.0457 engineering. At present, as a result of the new
- For LPH 2: [a2] = 0.0435 computational power, the use of mathematical
- For LPH 1: [a1] = 0.0421 methods and modelling is a must in solving design
problems.
The results are identical results with the ones Moreover, the method can be easily included in a
obtained by writing the heat balance equations, smart management tool of a power plant, for
according to the methodology described in chapter 3. maintenance issues [16] or for the optimization of
Thus, the correctness of the numerical methods operation.
approach is demonstrated.

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POWERTECH'09

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