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T2 T1
H H
H H
1% IPT Efficiency
1% LPT Efficiency
0.16%
0.5 %
0.16%
0.5 %
FOLLOW TEST CODES ASME PTC - 6 For Steam Turbines ASME PTC - 4.1 or BS- 845: 1987 for Boilers
860
Heat Rate
X 100
kW
kCal/hr
Turbine Losses
Internal Losses
a) Nozzle Friction
b) Blade Friction c) Disc Friction d) Diaphragm Gland & Blade Tip Losses e) Partial Admission Loss
f) Wetness
g) Exhaust
Turbine Losses
External Losses
a) Shaft Gland Leakage
b) Journal & Thrust Bearing c) Governor & Oil Pump
Nozzle blocks
Turbine blade erosion Functioning of the valves Operational status of HP heaters Performance of reheaters
10 MM HG IMPROVEMENT IN CONDENSER VACUUM LEADS TO 20 Kcal/kwh (1%) IMPROVEMENT IN HEAT RATE FOR A 210 MW UNIT
Background
Hot Water Condenser Air Cooling Tower Air
Cooled Water
Make-up Water
Performance of Condensers
Vacuum Efficiency: Ps- saturation pressure of steam in kg/cm2 corresponding to the steam temperature entering the condenser. Pt total pressure of air and steam in the condenser= (pa+ps) Pb- atmospheric pressure or barometric pressure. Ideal vacuum possible without air ingress=(Pb-Ps) Actual vacuum existing in the condenser due to air ingress = Pb-Pt= Pb-(Pa+Ps) Vacuum efficiency = actual vacuum/Ideal vacuum
Heat load considered for design Design inlet cooling water temperature/ Design TTD Cleanliness factor/ Cooling water temperature raise Condenser back pressure Cooling water flow/ Cooling water side pressure drop No of cooling water pass/ Total heat transfer area No. of tubes - Condensing zone - Air cooling zone Tube dimensions: - Tube OD x thickness - Length of tube
Effect of Varying the back pressure 1. CW Pumping Power 2. Leaving Loss 3. Reduced Condensate Temperature 4. Wetness of Steam.
Graphical Determination of Losses Contributing the departure of Back Pressure From Optimum 1. CW inlet temp different from design. 2. CW quantity flowing through condenser incorrect. 3. Fouled tube plates. 4. Dirty tubes. 5. Air ingress into system under vacuum.
Unit Deg C
Deg C Deg C Deg C
Optimum 16.5
25.0 8.5 30.5
Actual 18.2
28.2 10 35.0
Deg C
5.5
6.8
Loss due to CW inlet temp: Plot a line vertically from the actual CW inlet temp of 18.2 Deg C to the intersection with the optimum CW Rise of 8.5 Deg c. Them plot horizontally to the intersection with the optimum TTD line, and then vertically downward to cut the saturated steam temperature line. The corresponding back pressure is 47.2 m bar. Hence , the loss due to the high CW inlet temperature is the difference in back pressure between 47.7 mbar and optimum value of 43.65 ie. 4.05 mbar.
Loss due to CW flow: Plot a line vertically from the actual CW inlet temp of 18.2 Deg C to the intersection with the actual CW Rise of 10 Deg C. Them plot horizontally to the intersection with the optimum TTD line, and then vertically downward to cut the saturated steam temperature line of 33.7 Deg C. The corresponding back pressure is 52.0 m bar. Hence , the loss due to the CW incorrect CW flow is given by 52.047.7=4.30 mbar.
Loss due to air/dirty tubes: The effect of air and dirty tubes on heat transfer is to increase the TTD above optimum. They both give the same effect. The thermal resistivity of a layer of 0.254 mm thick is approx the same as that offered by slab of copper 3.35 meters thick. Plot from the actual CW inlet temp to the actual CW rise and hence across to the actual TTD line of 7 Deg C. Plotting vertically downward the saturated steam temp is 35.1 Deg C. the back pressure is 56.22 mbar. So the deviation due to air/dirty tubes is given by 56.22-52.0 mbar=4.22 mbar
The effect of air ingress into the condenser is to increase the value of air suction depression from optimum. In the case being considered the optimum value, obtained from acceptance tests is 4.5 Deg C but it is actually 8 Deg C, so there must be air present. Action should be taken to locate and stop the ingress. Incidentally when condenser tube is cleaned it is only dirty tube component which is cleaned.
Remedy
Performance of Condensers
T
Cp
oC
kcal/kg oC
2. Calculated condenser vacuum = Atmospheric pressure Condenser backpressure 3. Deviation in condenser vacuum = Expected condenser vacuum - Measured
Performance of Condensers
5. Condenser Effectiveness = Rise in cooling water temperature Saturation temperature - Cooling water inlet temperature 6. Condenser heat duty in kcal/h = Heat added by main steam + heat added by reheater + heat added by SH attemperation + heat added by RH attemperation + heat added by BFP - 860 x (Pgen + Pgen losses + heat loss due to radiation) 7. Condenser tube velocity (m/s) = Cooling water flow rate (m3/h) x 106 3600 x tube area (mm2) x ( no. of tubes per pass - no. of tubes plugged per pass )
COOLING TOWERS
inlet
inlet outlet
0C
TR = t outlet t fw inlet
economizer
Based on the above, if the HP heaters performance is poor, then additional load on economizer can be estimated by using the data sheet