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The design and operating parameters have a number of impacts on the
performance of regenerative cycle system. These are as follows:-
These factors influence the steam cycle's mass and energy balance,
thereby causing performance impacts. Though these need to be maintained
carefully and are hard in optimizing the cycle performance, yet can be achieved
for bringing in improvement in cycle efficiency through adoption of best practices
in operation & maintenance. If the changes in these parameters are observed,
the relevant poorly performing component/equipment must be corrected on
priority as these have cascading effect on each other’s performance, as well as
cycle performance besides the economics of its operation & cost of power thus
generated.
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3. Impact of cycle make up: – A typical value between 0% & 3% are
normally acceptable for a cycle make up to offset cycle water losses
which may be on account of various retrievable leakages, boiler blow
down, soot blowing and passing of valves & leakages. The additional
make up flow result in higher feed water thermal duties which causes
additional extraction flows and higher pump duty requirement. For 1%
make up, approx 0.4% increase in THR and reduction of 0.2% on output
can be observed for boiler blow down for saturated conditions at boiler
drum pressure.
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7. Impact of RH & Superheater Spray flow: - To control the MS temp &
RH temp, desuperheaters are provided which draw spray water either
from discharge & inter stage or BFP respectively or from after the final
feed water heater. These spray water adversely affect the THR when
drawn from the BFP discharge. M S Spray evaporates in the boiler &
becomes the part of the MS flow. Since this additional flow was less
regenerative the THR is affected. Likewise R/H spray is also not only
less regenerative but this additional flow by passes the HPT also. For
every 1% of each de-superheating flow the correction for THR & load for
varying % of VWO flow, has to be carried out as per curves supplied in
the thermal kit by the turbine manufacturer.
9. Impact of top heater out of service:- In the event of top heaters being
taken out of service due to leakages or otherwise, the extraction steam
flow meant for these heaters passes through turbine thereby increasing
the output of turbine. At the same time the heat input to turbine is
increased and final feed water temperature is lowered and THR
becomes poor for the given throttle flow. This also causes larger steam
flow in the last stage of LP turbine as well as through IPT. Thus, the
turbine also needed to be checked up with manufacture to know it’s
compatibility to cope up with this condition before permitting to take out
top heaters from service in the regenerative heat cycle.
10. Impact of HPH drain pump:- Normally at full /more than 50% load, the
difference of pressure between HPH- 6&7 is sufficient enough to push
the condensate to deaerator. Typically at around 50% load, pressure is
not enough to drive this condensate (drip) to deaerator. Thus either HP
heater drain pump is deployed for the purpose, or it is dumped in
condensate hot well/ flashes it to next lower pressure heater. This way
THR can be improved by 2.52 kCal/kWh for 50% load condition.
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11. Impact of type of BFP drive & flow controls :- Normally, any of the
following four alternate BFP drive & control concepts are installed for the
boiler feed water pumping to boiler drum.
(a)Constant speed, motor driven BFP with throttle valve control;
(b)Motor driven BFP with variable speed coupling control
(c) Variable speed motor driven BFP
(d)Turbine driven BFP
Both the bhp (Brake Horse Power) & net electric power consumption for the
pump at ‘a’ above is highest & lowest for the pump at ‘d’ for 100% to 50%
throttle flow. Likewise the net THR & net turbine output too reduces for the pump
configuration ‘a’ to ‘d’. Thus for the best turbine cycle heat rate and turbine
output, the turbine drive BFP arrangement is the best as it improves the net THR
& net turbine output by about 0.56% & 0.58% respectively for 100% throttle flow.
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Note:- The values stated herein are indicative only.
Ref.: 1. "Power Plant engineering" by Black & Veatch
2. " Power Plant Performance" by AB Gill