Turbine Cycle Performance

Assessment

17th January 2014

Turbine Cycle
Performance Assessment

Slide No.1

Topics Covered

Concept of PG/PE Test

Objective of PG Testing
Need for test at part loads
Stages of PG Testing
Performance assessment
Pinpointing areas of concern
Related Issues

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Turbine Cycle
Performance Assessment

Slide No.2

Concept of Performance Guarantee (PG) /

Performance Evaluation(PE) Test

It is a test carried out on a fully operational

TG set to ascertain its efficiency levels as
well as health of auxiliaries.

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Turbine Cycle
Performance Assessment

Slide No.3

Objective of Performance Guarantee (PG)

Testing

It is to carry out acceptance tests in line

with contract specifications to prove the
guaranteed parameters

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Performance Assessment

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What is Guaranteed in the TG Cycle?

With LD
Heatrate at 100% & other loads (Depending upon Contract Specification)
Rated Power Output (Generally at worst Vacuum)
Condenser Performance
Auxiliary Power Consumption
CW Pumping Power

Demonstration (Functional) Tests

Capability of Unit Operation at
VWO condition
HP Heaters out of service
Half condenser in service

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Performance Assessment

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Guaranteed Parameters under

Liquidated Damages Category 1
Turbine Cycle Heat Rate in Kcal/Kwh under rated steam
conditions at 77 mm Hg (abs) design condenser pressure
with 0% make up at 500MW Unit Load. 1932 Kcal/Kwh for
Jhajjar (3*500 MW).
Turbine Cycle Heat Rate in Kcal/Kwh under rated steam
conditions at 77 mm Hg (abs) design condenser pressure
with 0% make up at 400MW Unit Load. 1975 Kcal/Kwh for
Jhajjar (3*500 MW).
Condenser Pressure in mm Hg (abs) measured at 300mm
above the top row of condenser tubes under VWO
condition, 3% make up, design CW temperature & CW flow.
77 mm Hg(abs)
Continuous TG output of 500 MW under rated steam
conditions at 89 mm Hg (abs) worst condenser pressure
with 3% make up. 500 MW
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Performance Assessment

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Guaranteed Parameters under

Liquidated Damages Category 1
CW pumping power in KW for design CW flow and the
pressure drop on CW side being measured between
BHEL terminal points corresponding to guaranteed
pressure drop between these terminal points. ( Power
consumption shall be computed based on overall
effeiciency of 83% of CW pump and drive set).- 995 KW
per 500 MW unit.

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Guaranteed Parameters under

Liquidated Damages Category 1
The total auxiliary power consumption for all the
Turbine Generator auxiliaries and turbine cycle
equipments and other common auxiliaries
required for continuous unit operation at TMCR
(500MW) load under rated steam conditions and
at condenser pressure of 89 mm HG (abs) with
3% make up per 500MW unit. 3550 KW.
400 MW 2300 KW.

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Turbine Cycle
Performance Assessment

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Requirement of multiple tests

Tests are normally performed to satisfy
guarantees &/or to derive performance of the
machine at various conditions.
To derive performance of machine, tests at
atleast two loads preferred
Normally two to three test at one load (Say
100%) for two hours duration
Test Results to match each other within 0.25%

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Performance Assessment

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Need for Part Load Tests

Heatrate

Most of the machines are reaction

type with throttle control valve
arrangement.
It has linear straight line
characteristics
By knowing the heatrate at two
loads straight line can be drawn
Running the unit at reduced load for
PG Test is not advisible due to

Load

Generation loss & revenue

Same level of Aux Power Consumption
Hence PG Test at part loads can be avoided

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Turbine Cycle
Performance Assessment

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Economic viability of conducting PG Test

PG Testing as per ASME-PTC-6 is very

costly & time consuming activities.
As per present global scenario it is
sparingly used.
It is carried out for design validation by
the supplier.

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Performance Assessment

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Basis of PG Testing

Agreed procedure
PG Test Code (ASME-PTC 6 etc.)
Instrumentation Scheme
Heat Balance Diagram
All Guarantees are valid for brand new
condition

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Performance Assessment

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Assessment of true performance

Focus on
1. Reliability of available data
2. Consistency of operating parameters
3. Weeding out incorrect/ doubtful data
4. Stable and predictable TG Cycle
5. Accounting of leakages & Passing
6. Adjustment in the performance for variation in
terminal parameters & cycle configuration to
enable comparison with design data
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Performance Assessment

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SIGNIFICANCE
Prime Customer Requirement
Fulfils The Contractual commitment
Financial Ramification
Reputation Of The Product
Design Validation Of Steam Turbine
Feed Back For Further Improvements In New Tenders
Identification Of Grey Areas
Closure Of Site Office
Strengthening Of Customers Confidence
Maximum Capability Under varied Operating Modes
Validation Of Plant Instrumentation

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Performance Assessment

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Performance Indices of TG Cycle

Cylinder Internal Efficiency
First Stage Pressure Vs Flow characteristic
System Leakage
Heatrate
Power output
Auxiliary Power Consumption

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Performance Assessment

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Performance Benchmarking
Best achievable performance of Unit
Unit Specific
Original HBDs are valid for brand new original condition
Actual Cycle conditions may differ from design condition
Terminal steam parameters
Reheat Circuit Pressure Drop
Extraction Line Pressure Drop
Cooling water inlet temperature/Condenser Vacuum
Regenerative Feed heater out of service

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Performance Assessment

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Performance Assessment

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Stages of PG Testing
Pre PG Test Stage
Activities involved are
Checking of Unit Healthiness
Shutdown for PG Test Preparation
Attending the Valves Leaking /Passing
To install Flow Nozzle
Making the unit ready for Test

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Performance Assessment

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Stages of PG Testing
Preliminary Activities involved before
commencement of PG Test are
Mock Test to ascertain the availability &
correctness of required Instrumentation.
Rectification if any required
Preliminary PG Test preferably at full load
Calculation & Analysis of Heatrate & output
based on preliminary PG Test
Discussion with customer/consultant for
proceeding further for Final PG Test
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Performance Assessment

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Stages of PG Testing
Pre Final PG Test activities
Ensure Closing of Valve as per Valve Isolation List at least 1/2
hour prior to start of test.
Terminal Parameters nearer to rated as indicated in the
corresponding HBDs
Steady load condition at least three hours prior to test
Steady Terminal Parameters. Fluctuations within specified limits
TG Regenerative Feedheating Cycle corresponding to HBDs &
Steady.
Alternate drain lines to HP/LP Heaters should be closed
Steam from & to Common Auxiliary header should be closed
Makeup supply to Deaerator feedstorage Tank & Condenser
hotwell closed

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Stages of PG Testing
Final PG Test activities
Ensure the steadiness & consistency of Load & all
parameters for next two to three hours
Ensure Data Capturing of all instrumentation in
Datalogger at regular interval.
Ensure completeness of all readings.
Data capturing of all tank levels & other supplementary
control room reading.
Measurement/Estimate of all external leakage in the
TG/SG Cycle during the test
Repeat the Test at the same load in the same setting
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Performance Assessment

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Major Issues

Malfunctioning of Various equipments in the TG Cycle

Major Deviations in the Cycle
VWO condition
RH/SH Spray
Performance Deterioration due to Ageing
System Leakage
Instrument Inaccuracy & Measurement uncertainty
Global perspective
Economic viability of conducting PG Test

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Turbine Cycle
Performance Assessment

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Malfunctioning of equipments
Major factors affecting the performance
1. Steam Turbine
Worn-out Glands of HP/IP & LP Front
Rear shaft sealing

&

Worn-out inter-stage sealing

Higher balance piston leakage
Variation in seal steam header set pressure

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Performance Assessment

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Malfunctioning of equipments
Major factors affecting the performance
1. Steam Turbine
Steam leakage through parting plane,
bellows, hoses
Leakage through MAL Valves
Poor cylinder internal efficiency
Variation in First stage pressure
characteristic
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Turbine Cycle
Performance Assessment

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Malfunctioning of equipments
Major factors affecting the performance
2. Regenerative Feed Heating Cycle
Level variation in heaters
Improper cascading of drains
HP/LP Bypass in operation/passing
Higher system leakage & Makeup
Superheater & Reheater spray
Poor efficiency of CEP/ BFP/ BFPT
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Turbine Cycle
Performance Assessment

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Malfunctioning of equipments
Major factors affecting the performance
2. Regenerative Feed Heating Cycle

Higher air ingress leads to poorer vacuum

Cleanliness of condenser

HP/LP Heaters out of service

Poor TTD/DCA of heaters

Higher intake of steam for BFP drive Turbine

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Turbine Cycle
Performance Assessment

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Variation in terminal parameters

TG Set performance will be optimum while
operating the set at rated design condition.
Any variation in the terminal parameters
mentioned earlier may not result in better
than optimum performance

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Turbine Cycle
Performance Assessment

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Deviation from the design TG Cycle

Source of extraction for Deaerator/BFPT
Alternate drain lines of HP/LP Heaters
Passing of HP Bypass valves
HP Heater FW Bypass valves
Superheater attemperation spray
Reheater attemperation spray
Vent lines of Deaerator
Recirculation lines of CEP/BFP
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Performance Assessment

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Deviation from the design TG Cycle

Vent lines of HP heaters
Vent lines of LP Heaters
Air ingress in condenser
System Leakage
Higher Pressure Drop across condenser
Deviation in terminal parameters
Fluctuation in the Load
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Turbine Cycle
Performance Assessment

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VWO Philosophy
VWO margin is kept by the designer over and above Name plate
rating so as to
Ensure guaranteed power output of the set.
Machine should generate name plate rating throughout the
entire life of the set.
It is designers margin to accommodate manufacturing / Erection
/ Commissioning & Ageing tolerance
VWO margin of 5% is based on Siemens design practice
It comprises of 2.5% ageing tolerance plus 2.5% manufacturing
tolerance.
All manufacturing drawings have +/- tolerance on the
dimensions.
It can be reduced but can not be made Zero.
Ageing of the machine is a physical unavoidable phenomenon.
Interval between two overhaul is decided based on limiting the
ageing to 2.5% maximum.
After Overhaul part of the performance deterioration is restored.
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Slide No.31
Performance Assessment

VWO Philosophy
There is no time restriction to run the unit at VWO
continuously.
But
VWO Output & Steam Flow can not be guaranteed.
None of the international standard recommend it
As per Customer Specification
Power Output is guaranteed at 100% Maximum Continuous
Rating (MCR), 3% Makeup & worst Vacuum
Intent of this requirement is to ensure Name Plate Rating
even with worst Back Pressure & makeup.

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Performance Assessment

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RH/SH Spray
Use of SH /RH Spray is made to control
SH/RH outlet temperature.
Normally it is sourced from BFP discharge
Thermodynamically it is loss to the cycle.
Not only does it deteriorate the Unit
Heatrate but also affects the TG Cycle
performance.
Therefore it is best avoided.

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Turbine Cycle
Performance Assessment

Slide No.33

Effect Of Reheater Spray on HP Exhaust Temperature

RH Spray increases HP Exhaust Pressure which in turn increases Exh
Temp.

1% RH Spray increases the HP Exhaust Temp by 1.0 Deg C

How?
RH Spray is the quantity of Feedwater not doing any work in HP Turbine but
joining in IP & LP Turbine.
This results change in the internal power distribution between HPT & IP/LPT.

Less power from HP Turbine & more from IP/LP Turbine.

Increased Steam Flow in IP Turbine will result to higher stage pressure in
IPT.
From the backend steam flow/pressure relationship IP Inlet Pressure
increases.
This results to High HP Exhaust Pressure.
In the Expansion line of Mollier Diagram, High HP Exhaust pressure means
high HP Exhaust Temp.

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Turbine Cycle
Performance Assessment

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Performance Deterioration due to ageing

All Guarantees pertain to Machine in brand new
condition.
Ageing is a Physical Phenomena
All mechanical components will have mechanical
wear & tear.
Therefore, PG Test must be carried out within 3
months of initial synchronisation.
If it is delayed then HP,IP & LP Turbine Cylinders
should be opened & inspected for clean flowpath.
Ageing is Higher in case of more fluctuations &
Depends upon water chemistry
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Turbine Cycle
Performance Assessment

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Performance Deterioration due to ageing

Reasons of Deterioration due to ageing
Salt deposition on blades
Deterioration of surface finish of blades
Increase in the clearances in the blading flowpath.
Deposits on heat transfer areas.
Increase in Valve seat losses
Presence of large excursion in throttle & reheat temperature.
Evidence of boiler tube exfoliation
Unusual shaft vibration
Existence of any water induction incidents in turbine
Excessive boiler water silica content, Wornout sealing
strips/rings in the turbine shaft sealing, pump shaft sealing etc.
Rapid & more occurrences of Valve leakages
Frequent tube failure in heat exchangers.
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Performance Assessment

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Ageing Trends

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Performance Assessment

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Performance Deterioration due to ageing

These curves are based on average actual performance of the
units operating in that country
Operating conditions of the power stations in those countries is
quite different compared to our country due to
More grid fluctuation in frequency & load pattern
More variation in parameters.
Wide variation in cooling water temperature
Adverse water chemistry
Variation in Calorific values of Coal
Ageing process starts once steam enters in the Steam Turbine.
It is much more faster when the machine is in standstill condition
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Turbine Cycle
Performance Assessment

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System Leakages-1
Higher cycle leakage implies enhanced DM
water requirement.
System losses is generally found to be around
0.8 to 1.5 % of the main stream flow while as per
international practice it should be within 0.1 %.
Conduction of PG Test just after
synchronization may resolve this problem to
some extent .
Delay in testing may also result more repair
/replacement of valves passing /leaking.
Generally Unit healthiness is carried out jointly
to identify leaking/passing valves.
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Turbine Cycle
Performance Assessment

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System Leakages
These valves are also attended in the shutdown
arranged by the customer.
By the time PG Test starts many new leakages
develops resulting to enhanced system leakages.
It may not be practical for the customer to provide
another Shutdown and incur generation loss.
It has also observed that System leakage quantity is
independent of Load as it is directly proportional to
fluid pressure.
Customer may take shutdown at their convenience
clubbing other activities.

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Turbine Cycle
Performance Assessment

Slide No.40

Assessing Performance of TG Cycle

Keeping regular ( say monthly) records of:
Cylinder Internal Efficiency
First Stage Pressure Vs Flow characteristic
Heaters performance
Condenser performance
System Leakage
Auxiliary Power Consumption
SH/RH spray pattern
Change in pattern gives clue to area of concern
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Turbine Cycle
Performance Assessment

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THANK YOU
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Turbine Cycle
Performance Assessment

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