Turbine and auxiliaries

performance calculaTion
of
 Turbine cycle heat rate
 Turbine efficiency
 Condenser performance
 HP Heater performance
 Cooling Tower performance
J N DUBEY
Ex Additional General Manager – NTPC
Mobile No 9650994697 0
TURBINE CYCLE HEAT RATE
Concept & Calculation Methodology

1
 Turbine Cycle Heat Rate calculation

Turbine Cycle Heat rate depends upon, how much heat is

utilized in Turbine Cycle for generation of one unit (kWh)
Total heat input to the turbine cycle (kCal)
GTCHR = --------------------------------------------------------------- kCal/kWh
Gross electrical output (kWh)

Heat in steam of Boiler output - Heat in steam of Turbine Input

Heat Added in the Boiler:

 Heat Added to Feed Water--------------- Main steam

 Heat added to SH spray water --------- Main steam
 Heat Added to Cold Re Heat ------------ Hot reheat steam
 Heat added to RH spray water ------== Hot reheat steam

2
 Turbine Cycle Heat Rate calculation

Heat Added to cycle :

Heat Added to MS = FW Flow * (HMS - hFW), kcal/hr
Heat added to SH spray = SH spray Flow * (HMS- hSHspray), kcal/hr
Heat Added to CRH = CRH Flow * (HHRH - HCRH), kcal/hr
Heat added to RH spray = RH spray Flow * (HHRH- hRHspray), kcal/hr

Turbine Cycle Heat Rate (kcal/kWh)

Qf (H1 - h1) + Qs (H1-hs)+Q2 (H3 - H2 )+ Qr (H3-hr)

=--------------------------------------------------------
Gross Generation
Where:
Q1 = Total steam flow Q2 = CRH Flow
Qs = SH spray flow Qr = RH spray flow
H1 = Enthalpy of MS H2 = Enthalpy at HPT Exh
H3 = Enthalpy of HRH h1 = Enthalpy of FW HP Heater outlet
hs = Enthalpy of SH spray hr = Enthalpy of RH spray 3
 Turbine Cycle Heat Rate calculation

Calculation of Main Steam Flow

Total MS steam flow (Q1) = Feed Flow (Qf)+ S/H Spray Flow (Qs)

Calculation of Reheat Steam Flow

CRH Flow (Q2) =
Main Steam Flow (Q1) – HPH Extraction Flow (Qe)- - Leak Off
steam flow
Total HRH Flow = CRH Flow (Q2) + RH spray flow

Leak off steam flow derived from design leak off flow as per
Heat balance diagram

4
 Calculation of Extraction Flow

Extraction Flow (Qe) X Hext = Qf (Hout – Hin) + Drip flow X Hdrip

Drip flow= Extraction Flow (Qe)
Extraction Flow (Qe) X Hext = Qf (Hout – Hin) + Extraction Flow (Qe) X Hdrip
Extraction Flow (Qe) X Hext - Extraction Flow (Qe) X Hdrip = Qf (Hout – Hin)
Extraction Flow (Qe) X (Hext – Hdrip) = Qf (Hout – Hin)
Qf (Hout – Hin)
Extraction Flow (Qe) = -----------------------
(Hext – Hdrip)
Qe = Extraction Flow Qf = Feed Flow
Hout = F W Enthalpy at HPH Out. Hin = F W Enthalpy at HPH in
Hext = Enthalpy of Extraction Steam Hdrip = Enthalpy of Drip
5
HEAT BALANCE DAIGRAM

6
 Turbine Cycle Heat Rate calculation

Turbine Cycle Heat Rate - Parameters to be Measured

1 Gross Load 13 FW Press HPH Inlet
2 MS Pressure before ESV 14 FW Temp HPH Inlet
3 MS Temp before ESV 15 FW Press HPH Outlet
4 HPT Exhaust Pressure 16 FW Temp HPH Outlet
5 HPT Exhaust Temp. 17 Main Steam Flow (Q1)*
6 HRH Steam Press. before IV 18 Feed Water Flow (Qf)
7 HRH Steam Temp. before IV 19 CRH Flow (Q2)*
8 FW press after top heater 20 S/H Spray Flow (Qs)
9 FW Temp at Eco inlet 21 R/H Spray Flow (Qr)
10 HPH Ext. Steam Temp 22 S/H Spray Temp.
11 HPH Ext Steam Pressure 23 R/H Spray Temp.
12 HPH Drip Temp 24 Leak Off Flow**
7
 Test Conditions

Data of Turbine & Auxiliaries to be collected in following

operating conditions:
 Unit Operating at Full Load
 Main Steam and Reheat Steam Temperatures at rated value
 All Feed water Heaters in Service, Normal Drain cascading
 Soot Blowing completed one hour before testing starts
 De-ashing to be completed one hour before testing starts
 No Auxiliary Steam supply to Other Units
 No DM make up
 No CBD Operation during test
 Stability of parameters achieved before starting the test

8
 INPUT DATA FOR HEAT RATE COMPUTATION
S No Description Unit Test value
1 Measured power MW 250.015
2 Total MS flow calculated HR for calculation TPH 765.00
3 Total Feed water flow including spray TPH 765.00
4 Total SH spray flow TPH 20.00
5 Total RH spray flow TPH 0.00
6 Average Main steam Pressure Kg/cm2 144.85
7 Average Main steam Temperature ℃ 525.00
8 Average HPT exhaust Pressure Kg/cm2 38.00
9 Average HPT exhaust temperature ℃ 346.00
10 Average Hot Reheated steam Pressure Kg/cm2 35.50
11 Average Hot Reheated steam Temperature ℃ 544.00
12 SH water spray pressure Kg/cm2 190.00
13 SH spray water temperature ℃ 246.00
14 RH spray water pressure Kg/cm2 190.00
15 RH spray water temperature ℃ 246.00
16 HPH- 6 Extraction steam Pressure ( HE ) Kg/cm2 37.74
17 HPH- 6 Extraction steam Temperature HE ℃ 343.70
18 HPH- 6 inlet feed water Temperature ℃ 200.20
19 HPH- 6 outlet feed water Temperature ℃ 245.50
20 HPH- 6 inlet feed water Pressure Kg/cm2 190.00
21 HPH- 6 outlet water Pressure Kg/cm2 189.50
22 HPH- 6 drain Temperature ℃ 210.00
23 Condenser back pressure Kg/cm2 ( ab) 0.12
24 HPT seal steam leakage TPH 5.22
25 Atmospheric Pressure Kg/cm2 ( ab) 1.00 9
 Turbine Cycle Heat Rate calculation

Correction for Pressure Measurement

 Necessary water leg correction to be applied
 Pressure measurements available in DCS are gauge values
 To be corrected to absolute value by adding ambient pressure

10.0 m
MS Line

10.0 m 8.5 m
Pressure Transmitter
(144.85 Kg/cm2 gauge)

1.5 m 1.5 m
0m

 Measured pressure = 144.85 Kg/cm2 gauge

 Ambient pressure =1.0 Kg/cm2
 Height difference of pipe and instrument = 10-1.5 =8.5 M= 0.85 Kg/cm2
 Water leg correction = - 0.85 Kg/cm2
 Corrected pressure (abs) = Measured pressure (G) + ambient pressure + Water leg correction
 144.85+1.0 - 0.85= 145 Kg/cm2 (abs) 10
 Turbine Cycle Heat Rate calculation

Water leg measurement

S No Descriptio Unit Kg/cm2
1 Avg Main steam Pressure Kg/cm2 - 0.85
2 HPT exhaust Pressure Kg/cm2 - 0.5
3 Hot Reheated steam Pressure- Kg/cm2 - 0.2
4 HPH- 6 Extraction steam Pressure ( HE ) Kg/cm2 - 0.1
5 HPH- 5 Extraction steam Pressure ( HE ) Kg/cm2 - 0.1
6 HPH- 5 inlet feed water Pressure Kg/cm2 - 0.15
7 HPH- 5 outlet water Pressure Kg/cm2 - 0.15
8 HPH- 6 outlet water Pressure Kg/cm2 - 0.15

11
 ENTHALPY CALCULATION
S No Description Unit Test value
1 Main Steam Press before ESV Kg/cm2 ( ab) 145.00
2 Main Steam temp before ESV Deg C 525.00
3 Main Steam enthalpy Kcal / Kg 809.92
4 HPT exhaust pressure Kg/cm2 ( ab) 38.50
5 HPT exhaust temperature Deg C 346.00
6 HPT exhaust steam enthalpy Kcal / Kg 737.71
7 HRH steam pressure before IV Kg/cm2 ( ab) 36.30
8 HRH steam temp before IV Deg C 544.00
9 HRH steam enthalpy Kcal / Kg 848.07
10 SH spray water pressure Kg/cm2 ( ab) 190.85
11 SH spray water temp Deg C 246.00
12 SH spray water enthalpy Kcal/Kg 255.02
13 RH spray water pressure Kg/cm2 ( ab) 190.85
14 RH spray water temp Deg C 246.00
15 RH spray water enthalpy Kcal/Kg 255.02
16 FW pressure at HPH-6 inlet Kg/cm2 ( ab) 190.85
17 FW temp at HPH-6 inlet Deg C 200.20
18 Enthalp of FW at HPH-6 inlet Kcal/Kg 205.57
19 FW pressure at HPH-6 outlet Kg/cm2 ( ab) 190.35
20 FW temp at HPH-6 outlet Deg C 245.50
21 Enthalp of FW at HPH-6 outlet Kcal/Kg 254.46
22 Extraction steam to HPH- 6 pressure Kg/cm2 ( ab) 38.64
23 Extraction steam to HPH-6 temp Deg C 343.70
24 Enthalpy of extraction steam to HPH- 6 Kcal/Kg 736.27
25 HPH- 6 drip pressure Kg/cm2 ( ab) 38.64
26 HPH-6 drip temperature Deg C 210.00
27 Enthalpy of drip HPH-6 Kcal/Kg 214.57
12
 CRH STEAM FLOW CALCULATION
S No Description Unit Test value
1 HPH 6 feed water flow TPH 765.0
2 Enthalpy of HPH-6 Extraction Steam Kcal/Kg 736.3
3 Enthalpy of HPH 6 FW inlet Kcal/Kg 205.6
4 Enthalpy of HPH 6 FW outlet Kcal/Kg 254.5
5 Enthalpy of HPH 6 drip Kcal/Kg 214.6
6 HPH 6 Drip Flow TPH 71.705
7 M S flow with SH Spray TPH 765.0
8 HPT seal steam leakage TPH 5.22
9 CRH flow TPH 688.09
10 RH spray TPH 0.00
11 HRH flow with RH spray = (CRH + RH spray ) TPH 688.08
CRH Flow CALCULATION =
Main steam Flow (Q1) – Extraction Flow (Qe) of HPH 6 - Leak Off steam flow
Leak off steam flow derived from design leak off flow as per load

(Feed Flow X (Enthalpy of HPH 6 FW outlet – Enthalpy of HPH 6 FW inlet )

Extraction Flow (Qe) = ------------------------------------------------------------------------------------------------
(Enthalpy of HPH-6 Extraction Steam – Enthalpy of HPH 6 drip )

765000 x ( 254.5- 205.6) 37408500

Extraction Flow (Qe)=------------------------------- = ----------------- =71705 Kg/hr= 71.705 T/hr
(736.3- 214.6) 521.7

HRH Flow CALCULATION = 765.0- 71.705- 5.22 = 688.08 T/hr

13
 Calculation of Turbine Cycle Heat Rate
S No Description Unit Test S No Description Unit Test
1 Measured power MW 250.015 8 Main Steam enthalpy Kcal / Kg 809.92
2 Main Steam Flow excluding SH spray T/hr 745.000 9 Feed water enthalpy Kcal/Kg 254.46
3 SH spray water flow T/hr 20.000 10 HRH steam enthalpy Kcal / Kg 848.07
4 Main Steam Flow including SH spray T/hr 765.000 11 CRH steam enthalpy Kcal / Kg 737.71
5 HRH flow excluding RH spray T/hr 687.997 12 SH spray enthalpy Kcal / Kg 255.02
6 RH spray water flow T/hr 0.000 13 RH spray enthalpy Kcal / Kg 255.02
7 HRH flow with RH spray T/hr 687.997

1: Heat Added for MS = Flow FW * (HMS - hFW ), kcal/hr = 745000 X (809.92- 254.46 ) = 413817700 kcal/hr
2: Heat Added for HRH = Flow HRH * (HHRH - HCRH), kcal/hr = 687.997X(848.07-737.71) = 75927349 kcal/hr
3: Heat added to SH spray = Flow SH spray* (HMS-hSHAT)kcal/hr =20.0X(809.92-255.02) = 11098000 kcal/hr
4: Heat added to RH Attemp = Flow RH Attemp * (HHRH-hRHATT), kcal/hr
As RH spray flow is 0.0 T/H hence Heat added to RH Attemp = 0

Turbine Cycle Heat Rate (kcal/kWh)=

( Heat Added for MS+ Heat Added for HRH + Heat added to SH spray + Heat added to RH spray) kcal/hr
=----------------------------------------------------------------------------------------------------------------------------------------------
Generation ( KWh)

(413817700 + 75927349 + 11098000 + 0 ) kcal/hr 500843049 kcal/hr

=---------------------------------------------------------------------- = ------------------------ = 2003.25 Kcal/kwh
250015 ( KWh) 250015 ( KWh)

14
Rated MS pressure = 150.0 Kg/cm2
Test MS pressure = 145.0 Kg/cm2
Correction factor = 0.997
15
Rated MS Temperature = 537 Deg C
Test MS Temperature = 525 Deg C
Correction factor = 0.997
16
Rated HRH Temperature = 537 Deg C
Test HRH Temperature = 544 Deg C
Correction factor = 1.002
17
Rated condenser back pressure = 0.1047
Test condenser back pressure = 0.12
Correction factor = 0.9925
18
Rated RH spray (% of MS flow) = 0.0 %
Test RH spray (% of MS flow) = 0.0 %
Correction factor = 1.0
19
RH circuit pressure drop VS Heat Rate correction curve

Rated RH Circuit pressure drop (% of HPT exhaust pressure) = 10.0 %

Test RH Circuit pressure drop (% of HPT exhaust pressure) = 5.0 %
Correction factor = 1.004

20
 PARAMETER CORRECTION
correction
S No Parameter Unit Design Test
factor
a MS Tpressure Kg/cm2 ( ab) 150 145.0 0.9970
b MS temperature Deg C 537 525.0 0.9970
c HRH temperature Deg C 537 544.0 1.0020
d RH Spray % of MS flow t/hr 0 0.00 1.0000
e Condenser back pressure Kg/cm2 ( ab) 0.1047 0.12 0.9925
f RH pressure drop Kg/cm2 10.0 5.0 1.0040
Total correction = a x b x c x d x e x f 0.99248
Corrected Turbine cycle heat rate = Test Turbine cycle heat rate X correction factor
Test Turbine cycle heat rate = 2003.25 Kcal / kwh
Correction factor = 0.99248
Corrected Turbine cycle heat rate = 2003.25 X 0.99248 =1988.2 Kcal / kwh
Design Turbine cycle heat rate = 1945.20 Kcal / kwh
Deviation in Turbine cycle heat rate = 1988.2-1945.20 = 43.0 Kcal / kwh
21
 TURBINE CYCLE HEAT RATE CALCULATION REPORT
S No Description Unit Test value
1 Measured power MW 250.015
2 Main Steam Flow including SH spray T/hr 765.000
3 Main Steam Flow excluding SH spray T/hr 745.000
4 HRH flow with RH spray T/hr 688.1
5 HRH flow excluding RH spray T/hr 688.1
6 SH spray water flow T/hr 20.00
7 RH spray water flow T/hr 0.00
8 Main Steam Press Kg/cm2 ( ab) 145.0
9 Main Steam temp Deg C 525.0
10 Main Steam enthalpy Kcal / Kg 809.9
11 HPT exhaust pressure Kg/cm2 ( ab) 38.50
12 HPT exhaust temperature Deg C 346.0
13 HPT exhaust steam enthalpy Kcal / Kg 737.7
14 HRH steam pressure Kg/cm2 ( ab) 36.3
15 HRH steam temp Deg C 544.0
16 HRH steam enthalpy Kcal / Kg 848.1
17 Feed water pressure Kg/cm2 ( ab) 190.4
18 F W temp Deg C 245.500
19 Feed water enthalpy Kcal/Kg 254.46
20 SH spray water pressure Kg/cm2 ( ab) 190.9
21 SH spray water temp Deg C 246.0
22 SH spray water enthalpy Kcal / Kg 255.0
23 RH spray water pressure Kg/cm2 ( ab) 190.9
24 RH spray water temp Deg C 246.0
25 RH spray water enthalpy Kcal / Kg 255.0
26 Turbine cycle heat rate Kcal / kwh 2003.25
15 Corrected Turbine cycle heat rate to CW temp Kcal / kwh 1988.2
16 Design Heat Rate Kcal / kwh 1945.2
17 Deviation Kcal / kwh 43.0 22
Turbine Cycle Heat Rate Gap analysis

23
 Turbine Cycle Heat Rate Gap analysis
Design GTCHR- 1945.20 Kcal/kwh
Test HR- 2003.25 Kcal/kwh
Total Deviation- 58.05 Kcal/kwh
Accountable HR Deviation & Unaccountable HR Deviation
S No Parameter Unit Design Test GAP HR
1 MS pressure Kg/cm2 ( ab) 150 145.00 5.00 6.01
2 MS temperature Deg C 537 525.00 12.00 6.01
3 HRH temperature Deg C 537 544.00 -7.00 -4.01
4 RH Spray % of MS flow t/hr 0 0.00 0.00 0.00
5 Condenser back pressure Kg/cm2 ( ab) 0.1047 .12 15.0
6 RH pressure drop Kg/cm2 10.0 5.0 4.98 -8.01
Heat rate deviation due to parameter (Kcal / kwh) 15.02
7 HP Turbine Cylinder Efficiency (VWO) % 89.20 88.15 1.05 4.20
8 IP Turbine Cylinder Efficiency % 91.25 89.08 2.17 8.68
Deviation due to Turbine efficiency 12.88
Total Accountable HR Deviation 27.90
Unaccountable HR Deviation (Total Deviation-Accountable Deviation )
= (58.05- 27.90) Kcal/kwh 30.15
24
Turbine Cycle Heat Rate Gap analysis

Un-accountable HR Deviations:

LPT efficiency
N2 Packing Leakage
Instrument Uncertainty
High Energy drain valves passing
Insulation loss
LP Heater performance

25
 Correction Curve for MS pressure
Heat Rate deviation calculation
Description Unit Data
Design MS pressure Kg/cm2 150
Expected MS pressure Kg/cm2 150
Actual MS pressure Kg/cm2 145
Pressure Variation
(Expected pressure-Actual Kg/cm2 5
pressure)
Turbine HR correction
0.9970
factor
Measured Turbine CHR Kcal/kwh 2003.25
Boiler Efficiency % 86.8

To obtain corrected value, multiply measured value by correction factor

Corrected GTCHR = Measured Turbine Heat Rate X CF = 2003.25 x 0.997=1997.24
Deviation in GTCHR =(2003.25- 1997.24) = 6.01 Kcal/kwh

Deviation in GTCHR 6.01 Kcal/kwh due to 5 Kg/cm2 pressure deviation ( 1.2 Kcal/kwh / Kg/cm2
deviation)
Deviation in unit heat rate =1.2/0.868 = 1.4 Kcal/kwh
26
 Correction Curve for MS Temperature
Heat Rate deviation calculation
Description Unit Data
Design MS temperature Deg C 537
Expected MS temperature Deg C 537
Actual MS temperature Deg C 525
Temperature Variation
(Expected temperature Deg C 12
-Actual temperature)
Turbine HR correction factor 0.9970
Measured Turbine CHR Kcal/kwh 2003.25
Boiler Efficiency % 86.8

To obtain corrected value, multiply measured value by correction factor

Corrected GTCHR = Measured Turbine Heat Rate X CF = 2003.29 x 0.997=1997.24
Deviation in GTCHR =(2003.25 - 1997.24) = 6.01 Kcal/kwh

Deviation in GTCHR 6.01 Kcal/kwh due to 12 Deg C temperature deviation ( 0.52 Kcal/kwh / Deg C
deviation)
Deviation in unit heat rate =0.5/0.868 = 0.58 Kcal/kwh
27
 Correction Curve for RH Temperature
Heat Rate deviation calculation
Description Unit Data
Design RH temperature Deg C 537
Expected RH temperature Deg C 537
Actual RH temperature Deg C 544
Temperature Variation
(Expected temperature Deg C 7
-Actual temperature)
Turbine HR correction factor 1.002
Measured Turbine CHR Kcal/kwh 2003.25
Boiler Efficiency % 86.8

To obtain corrected value, multiply measured value by correction factor

Corrected GTCHR = Measured Turbine Heat Rate X CF = 2003.25 x 1.002 = 2007.26
Deviation in GTCHR =(2003.25 - 2007.26) = - 4.01 Kcal/kwh
Deviation in GTCHR 4.01 Kcal/kwh due to 7 Deg C temperature deviation ( 0.57 Kcal/kwh / Deg C
deviation)
Deviation in unit heat rate =0.57/0.868 = 0.66 Kcal/kwh

28
 Correction Curve for condenser back pressure
Heat Rate deviation calculation
Description Unit Data
Design back pressure Kg/cm2 0.1047
Actual MS pressure Kg/cm2 0.1200
Pressure Variation
(Expected pressure-Actual Kg/cm2 -0.0153
pressure)
Turbine HR correction
0.9925
factor
Measured Turbine CHR Kcal/kwh 2003.25
Boiler Efficiency % 86.8

To obtain corrected value, multiply measured value by correction factor

Corrected GTCHR = Measured Turbine Heat Rate X CF = 2003.25 x 0.9925 = 1988.23
Deviation in GTCHR =(2003.25 - 1988.23 ) = 15.02 Kcal/kwh

Deviation in GTCHR 15.0 Kcal/kwh due to 0.0153 Kg/cm2 ( 11.25 mmHg C ) pressure deviation ( 1.33
Kcal/kwh / mm Hg C deviation)
Deviation in unit heat rate =1.33/0.868 = 1.53 Kcal/kwh by deviation 1 mmHgC
29
HP-IP TURBINE EFFICIENCY
Concept & Calculation Methodology

30
 Impact of Turbine Efficiency on Heat Rate

Description Effect on TG HR

1% HPT Efficiency 0.2% (approx 4 kcal)

1% IPT Efficiency 0.2% (approx 4 kcal)

1% LPT Efficiency 0.5% (approx 10 kcal)

31
 Turbine Enthalpy Drop Efficiency Test

• The most cost effective , accurate Turbine Test is enthalpy drop efficiency test
• The enthalpy drop efficiency test measures how much of the available energy in
the steam supplied to turbine is actually used to produce power
Used Energy
Turbine Efficiency = ------------------------- X 100
Available Energy

(HA – HC )
Turbine Efficiency = -------------------- x 100
( HA – HB )
Where
HA = Enthalpy at Cylinder Inlet conditions
HC = Enthalpy at Cylinder Outlet conditions
HB = Isentropic Enthalpy
The test to be done at VWO condition
To minimize throttling loss

• Entropy of the steam at appoint ‘C’ (exhaust ) is greater than that at point A (inlet)
• This is because there are some losses that occur in the turbine which causes some of the energy in
the steam entering the turbine to be unavailable to produce power
• If there were no increase in entropy , there would be no losses turbine would be 100 % efficient but
practically not possible. 32
PARAMETER FOR TURBINE EFFICIENCY CALCULATION

Description Unit
Unit Load MW
HPT inlet steam pressure (left) Kg / cm2
HPT inlet steam pressure (right) Kg / cm2
HPT inlet steam temperature (left) Deg C
HPT inlet steam temperature (right) Deg C
HPT exhaust steam pressure (left) Kg / cm2
HPT exhaust steam pressure (right) Kg / cm2
HPT exhaust steam temperature (left) Deg C
HPT exhaust steam temperature (right) Deg C
Water leg measurement (M)
IPT inlet steam pressure (left) Kg / cm2
IPT inlet steam pressure (right) Kg / cm2
IPT inlet steam temperature (left) Deg C
IPT inlet steam temperature (right) Deg C
IPT exhaust steam pressure (left) Kg / cm2
IPT exhaust steam pressure (right) Kg / cm2
IPT exhaust steam temperature (left) Deg C
IPT exhaust steam temperature (right) Deg C
Atmospheric pressure Kg / cm2
HP Turbine Control valve position %
HP Turbine Control valve position % 33
HP & IP efficiency measurement locations

34
 Turbine Enthalpy Drop Efficiency Test
Operating Conditions :
 Unit should be in VWO Condition with stable load
 Main Steam and Reheat Steam Temperatures at nearer to
design
 All Feed water Heaters in service along with normal drain
cascading.
 No Auxiliary Steam supply to Other Units.
 No Soot Blowing during test.
 No DM water makeup during test

For reliable measurement of pressure & temperature data

should be collected every minute for one hour duration at
stable load condition and rated steam parameters

35
 HP/IP Turbine Efficiency

Impact of Measurement error on Turbine efficiency

Main Steam HPT Exhaust
Pressure Temp Pressure Temp
Impact on Kg/cm2 Deg C Kg/cm2 Deg C
HPT
Efficiency 1 1 1 1
0.6 % 0.6 % 2.0 % 0.7 %

IPT Inlet IPT Exhaust

Pressure Temp Pressure Temp
Impact on Kg/cm2 Deg C Kg/cm2 Deg C
IPT
Efficiency 1 1 1 1
1.2 % 0.3 % 6.0 % 0.4 %
36
 PARAMETER FOR TURBINE EFFICIENCY CALCULATION
Description Unit Test
Unit Load MW 251.41
HPT inlet steam pressure (left) Kg / cm2 134.97
HPT inlet steam pressure (right) Kg / cm2 134.83
HPT inlet steam temperature (left) Deg C 536.20
HPT inlet steam temperature (right) Deg C 538.10
HPT exhaust steam pressure (left) Kg / cm2 36.58
HPT exhaust steam pressure (right) Kg / cm2 35.65
HPT exhaust steam temperature (left) Deg C 344.85
HPT exhaust steam temperature (right) Deg C 345.64

IPT inlet steam pressure (left) Kg / cm2 34.00

IPT inlet steam pressure (right) Kg / cm2 34.00
IPT inlet steam temperature (left) Deg C 538.14
IPT inlet steam temperature (right) Deg C 536.33
IPT exhaust steam pressure (left) Kg / cm2 5.61
IPT exhaust steam pressure (right) Kg / cm2 5.66
IPT exhaust steam temperature (left) Deg C 309.15
IPT exhaust steam temperature (right) Deg C 309.71
Atmospheric pressure Kg / cm2 1.0
HP Turbine Control valve position % 100
HP Turbine Control valve position % 100 37
 Water leg measurement ( with proper sign)

Description Kg/cm2
HPT inlet steam pressure (left) -0.85
HPT inlet steam pressure (right) -0.85
HPT exhaust steam pressure (left) -0.5
HPT exhaust steam pressure (right) -0.5
IPT inlet steam pressure (left) -0.2
IPT inlet steam pressure (right) -0.2
IPT exhaust steam pressure (left) -0.1
IPT exhaust steam pressure (right) -0.1

38
 HPT Turbine Efficiency calculation

Description Unit Design Test

Average HPT inlet steam pressure Kg/cm2 (ab) 150.16 135.05
Average HPT inlet steam temperature Deg C 537.00 537.2
Enthalpy of HPT inlet steam Kcal/Kg 816.40 820.40
Average HPT exhaust steam pressure Kg/cm2 (ab) 41.95 36.61
Average HPT exhaust steam temperature ℃ 347.40 346.3
Enthalpy of HPT exhaust steam Kcal/Kg 736.60 738.94
Entropy at HPT inlet Steam 6.491 6.556
Enthalpy (Isentropic expn) Kcal/Kg 726.90 727.99
HPT Efficiency % 89.2 88.15
Deviation % -1.05

( Enthalpy of HPT inlet steam - Enthalpy of HPT exhaust steam )

HPT EFFICIENCY =----------------------------------------------------------------------------------------------X 100
( Enthalpy of HPT inlet steam - Enthalpy Isentropic expansion )

(820.40 - 738.94 ) 81.5

HPT EFFICIENCY =------------------------- X100 = ------- X 100 = 88.15 %
(820.40 - 727.99 ) 92.4
Deviation from design = Test HPT Efficiency – Design HPT Efficiency =
=88.15 – 89.20 = -1.05 %
39
 IPT Turbine Efficiency calculation
Description Unit Design Test
Average IPT inlet steam pressure Kg/cm2 (ab) 37.76 34.80
Average IPT inlet steam temperature Deg C 537.00 537.2
Enthalpy of IPT inlet steam Kcal/Kg 843.90 844.75
Average IPT exhaust steam pressure Kg/cm2 (ab) 7.09 6.53
Average IPT exhaust steam temperature ℃ 303.70 309.4
Enthalpy of IPT exhaust steam Kcal/Kg 732.60 735.81
Entropy at IPT nlet Steam 7.24 7.278
Enthalpy (Isentropic expn) Kcal/Kg 721.93 722.46
IPT Efficiency % 91.25 89.08
Deviation % -2.17

( Enthalpy of IPT inlet steam - Enthalpy of IPT exhaust steam )

IPT EFFICIENCY =----------------------------------------------------------------------------------------------X 100
( Enthalpy of IPT inlet steam - Enthalpy Isentropic expansion )

(844.75 - 735.81) 109

IPT EFFICIENCY =------------------------- X100 = ------- X 100 = 89.08 %
(844.75 - 722.46 ) 122

Deviation from design = Test IPT Efficiency – Design IPT Efficiency =

=89.08- 91.25 = - 2.17 % 40
 HP/IP Turbine Efficiency

Problems in Performance Assessment

 High variation in Efficiency if trend is plotted.
 HP/IP Efficiency worked out to be low after O/H
 HP/IP Efficiency improves after O/H even though
Cylinder was not opened.
 Efficiency of HP/IP improves better than design

41
 HP/IP Turbine Efficiency

Computation Error Reasons

Followings are the reasons for error in computation of
efficiency:
 Instrument not calibrated
 Water leg , atmospheric pressure correction not done
 Test is not done at VWO
 Test setups are not same for all tests.
 Steady conditions of Unit is not achieved.
 Measurement points are not accurate

42
 Case Study
Summary of Test Data – VPO vs CPO
(210 MW KWU unit)

Sr. Parameter CPO VPO (VWO)

No 213 MW 215 MW
1 Avg MS temp at ESV (C) 530.6 534.4
2 Avg MS press. at ESV (bar a) 148.03 134.66
3 Avg HPT Exh. temp (C) 344.3 352.6
4 Avg HPT Exh. press. (bar a) 36.38 36.58
5 HP Turbine efficiency (%) 77.08 82.08 (+5)
6 HPT valve position 50 / 60 100 / 100
CV 1/ CV2 (%)

43
 Case Study
Summary of Test Data – VPO vs CPO
(210 MW KWU unit)

Sr. Parameter CPO VPO (VWO)

No 192 MW 191 MW
1 Avg MS temp at ESV (C) 533.9 536.7
2 Avg MS press. at ESV (bar a) 150.96 118.36
3 Avg HPT Exh. temp (C) 344.5 358.2

4 Avg HPT Exh. press. (bar a) 32.83 32.6

5 HP Turbine efficiency (%) 70.87 81.96 (+11)
6 HPT valve position 40/45 100/100
CV 1/ CV2 (%)

44
 Case Study
Summary of Test Data – VPO vs CPO
(210 MW KWU unit)

Sr. Parameter CPO VPO (VWO)

No 175 MW 173 MW
1 Avg MS temp at ESV (C) 533.4 536.3
2 Avg MS press. at ESV (bar a) 146.23 108.30
3 Avg HPT Exh. temp (C) 342.8 357.9

4 Avg HPT Exh. press. (bar a) 30.12 29.5

5 HP Turbine efficiency (%) 69 81.82 (+13)
6 HPT valve position 35/44 100/100
CV 1/ CV2 (%)

45
 Summary of Test Data – VPO vs CPO
(210 MW KWU unit)

HP Turbine Efficiency vs Load

Turbine Cycle heat Rate Tests
83
HP Turbine Efficie ncy (%)

81
79 HP Turbine Efficiency at CPO (%)
HP Turbine Efficiency at VPO (%)
77
75
73
71
69
67
65
170 180 190 200 210 220
Gross Generator Output (MW)

46
Reasons of low Turbine efficiency from design value

Causes of Turbine efficiency deviation (any one or more)

 Erosion of nozzle blocks

 Erosion of turbine blades
 Damaged turbine blades
 Excess shaft packing leaks
 Excess spill strips and diaphragm packing leaks
 Malfunctioning control valves
 Plugged nozzle blocks
 Deposits on nozzles and/or blades
 Improper stroke stop, intercept and control valves

47
Reasons of low Turbine efficiency from design value

Possible Corrections

• Repair or replace nozzle block

• Repair or replace turbine blades
• Clean turbine blades
• Replace shaft packings
• Replace turbine spill strips and diaphragm packings
• Ensure proper setup of stop valve intercept and
control valves
48
CONDENSER PERFORMANCE
Concept & Calculation Methodology

49
 CONDENSER PERFORMANCE

Condenser performance indicators

1: Deviation in condenser back pressure

2: TTD = Terminal Temperature Difference
= Tsat- CW outlet Temp
where
Tsat = Saturation Temp corresponding to back pressure
3: Under cooling = Tsat- Condensate temp in Hot well
4: Air Depression = Tsat – T air steam mixure
5: Dissolved O2 in condensate in hot well
6 : Differential pressure of C W in/outlet

50
FACTOR AFFECTING CONDENSER BACK RESSURE

1 ) C W inlet temperature.
2 ) C W Flow. Variable parameters
3 ) Condenser Heat Load.
4 ) Air ingress.
5 ) Fouling in steam side tube.
6 ) Fouling / Scale in water side tube.
7 ) Micro Biological growth.
8) Steam flow distribution through tube bundle.
9) Water flow distribution through tube bundle
10) Poor vacuum pump/ ejector performance
51
Effect of CW temperature on condenser back pressure

• Higher CW temperature entering the condenser

increases condenser back pressure which will
increase the heat rate of the unit
• High CW inlet temperature may be due to
• Poor cooling tower performance
• Ambient condition
• Higher CW flow to condenser decreases
condenser back pressure which will decrease the
heat rate of the unit
Reason of low CW flow:
• Choking and scaling of water box and
condenser tubes .
• Poor performance of CW pump
• High condenser heat load increases condenser
backpressure . Reason of high condenser heat load
• High turbine cycle heat rate
• High energy drain passing
• LP/HP heater emergency drains are routed back to
the condenser
• Passing of Heaters alternate drains
52
 CONDENSER PERFORMANCE
Calculation of Deviation in condenser back pressure

 The Heat Transfer in any Heat Exchanger is

 Calculation of proportional to LMTD (Log Mean Temp.
deviation of Difference) & Surface Area
condenser back  The test LMTD corresponds to measured
back pressure, C.W. velocity, actual surface
pressure due to area and C.W. inlet temperature is
variation of different calculated
parameters like:  LMTD is corrected for designed C.W. inlet
 CW inlet temperature temperature, velocity and heat rejected to
 CW flow condenser.
 Condenser heat load  The corrected condenser back pressure is
 Air & dirty tube computed from corrected test LMTD.
 The corrected back pressure is compared
with the design back pressure for the purpose
Routine condenser of final evaluation
performance monitoring Performance guarantee test of condenser 53
 Evaluation of condenser performance
DESIGN DATA
Description Unit Notation Unit No
Unit Load MW Ld 210
Condenser Back Pressure mm Hg c (ab) BPd 76
C W inlet temperature Deg C CWind 32.0
C W outlet temperature Deg C Cwoutd 42.80
Temperature rise Deg C Trd 10.80
Condensate temperature Deg C Hwtd 46.09
Sat Temp Corresponding back pr Deg C Sattd 46.09
Optimum TTD Deg C TTDd 3.29
CW flow m3/hr CWfd 22500
Cond CW DP Kg/cm2 CWdpd 0.45
TEST DATA
Description Unit Notation Unit No
Unit Load MW La 213.13
Condenser Back Pressure mmHgc (ab) Bpa 45.00
C W inlet temperature (pass-1) Deg C Cwinla 17.60
C W inlet temperature (pass- 2) Deg C Cwinra 17.80
C W outlet temperature (pass-1) Deg C Cwoutla 32.30
C W outlet temperature (pass-2) Deg C Cwoutra 31.70
Condensate temp in Hot well Deg C Hwta 34.70
Air steam mix temp Deg C Airta 30.00 54
 Evaluation of condenser performance

1: Average CW inlet Temperature

C W inlet temperature (pass-1) Deg C Cwinla 17.6
C W inlet temperature (pass- 2) Deg C Cwinra 17.8
C W inlet temperature ( Avg)
=(Cwinla+Cwinra)/2 Deg C Cwina 17.70
2: Average CW outlet Temperature
C W outlet temperature (pass-1) Deg C Cwoutla 32.30
C W outlet temperature (pass-2) Deg C Cwoutra 31.70
C W outlet temperature (Avg) =
(Cwoutl+Cwoutr)/2 Deg C Cwouta 32.00
3: Temperature rise
C W outlet temperature (Avg) =
(Cwoutl+Cwoutr)/2 Deg C Cwouta 32.00
C W inlet temperature ( Avg)
=(Cwinla+Cwinra)/2 Deg C Cwina 17.70
Temperature rise Deg C Tra 14.30
55
 Evaluation of condenser performance

4: Expected temperature rise at test load

= Design Temp rise X actual load /Design load
= 10.8 X 213.13/210 = 10.96 Deg C
Temperature rise due to increase in load = 10.96-10.80 = o.16 Deg C

5: Temperature rise corrected for load = 14.30-0.16 = 14.14 Deg C

6: Terminal temperature difference ( TTDa)

Condenser back pressure = 45 mm Hgc (ab)
Sat Temperature Corresponding condenser back pressure ( Tsat)= 36.18 Deg C
CW outlet temperature = 32.00 Deg C
TTD= Tsat- CW outlet temp = 36.18-32 = 4.18 Deg C

7: Subcooling = Tsat- Condensate temp in Hot well

Tsat = 36.18 Deg C
Condensate temp in Hot well =36.00 Deg C
= 36.18- 36.00= 0.18
56
 Evaluation of condenser performance

8: Air Depression = Tsat – T air steam mixture

Tsat = 36.18 Deg C
T air steam mixture =30.00 Deg C
= 36.18- 30.00= 6.18
9 Back pressure variation due to CW inlet temp
Expected Sat. Temp due to change in CW inlet Temp=
Expected Tsat = CW inlet temp (a) + CW temp rise (d) + TTD (d)
= 17.7 + 10.8+ 3.29 = 31.79 Deg C
Expected back pressure = Pressure corresponding to
Expected saturation temp = Pcwi= 35.23 mmHgc
(From steam table)
Variation due to CW inlet temp = Pcwi- Pd
=35.23-76 = - 40.77 mmHgc ( Gain)
a) Variation due to CW inlet temp - 40.77 mmHgc ( Gain)
57
 Evaluation of condenser performance

10 Back pressure variation due to change in load

Expected Sat. Temp due to change in unit load=
Expected Tsat = CW inlet temp (d) + Exp CW temp rise (d) + TTD (d)
= 17.7 + 10.96 + 3.29 = 31.95 Deg C
Expected back pressure corresponding to Expected saturation temp =
35.56 mm Hgc
b) Back pr variation due to unit load =35.56-35.23= 0. 0.33 mm
Hgc

11 Back pressure variation due to change in flow

Effect of CW inlet temp , CW flow and load
Expected Sat. Temp due to change in CW inlet Temp , flow and load
Expected Tsat = CW inlet temp (a) + CW temp rise (a) + TTD (d)
= 17.70+ 14.30+3.29 = 35.29 Deg C
Pressure corresponding to Expected saturation temp = 42.85 mm Hgc
(A) 58
 Evaluation of condenser performance

Effect of CW inlet temp and load

Expected Sat. Temp due to change in CW inlet Temp and load
Expected Tsat = CW inlet temp (a) + CW temp rise exp at load +
TTD (d) = 17.70+ 10.96+3.29 = 31.95 Deg C
Pressure corresponding to Expected saturation temp = 35.56 mm
Hgc ( B)

c) Back pressure variation due to change in flow = A-B = 42.85-

35.56 = 7.29 mm Hgc ( B)

Back pr variation due to air ingress and dirty tube =

= Actual condenser back pressure (a) –- Condenser back pressure
due to change in CW inlet Temp , flow and load (A)
= 45- 42.85 = 2.15 mmHg C
d) Back pr variation due to air and dirty tube = 2.15 mmHg C
59
 Evaluation of condenser performance

Condenser performance analysis

Description Unit Design Test
Unit Load MW 210 213.13
Condenser Back Pressure mm Hg c (ab) 76 45
C W inlet temperature Deg C 32.0 17.70
Temperature rise Deg C 10.80 14.30

Back pressure variation

Design Condenser back pressure 76 mm HgC
Actual Condenser back pressure 45 mm HgC
Gap = (-31.0) mm HgC
Back pr variation due to cw inlet temp mmHgc -40.77
Back pr variation due to unit load mmHgc 0.33
Back pr variation due to cw flow mmHgc 7.29
Back pr variation due to air and dirty
mmHgc 2.15
tube ( Bad performance of condenser) 60
 Evaluation of condenser performance
DESIGN DATA
Description Unit Notation Unit No
Unit Load MW Ld 210
Condenser Back Pressure mm Hg c (ab) BPd 76
C W inlet temperature Deg C CWind 32.0
C W outlet temperature Deg C Cwoutd 42.80
Temperature rise Deg C Trd 10.80
Condensate temperature Deg C Hwtd 46.09
Sat Temp Corresponding back pr Deg C Sattd 46.09
Optimum TTD Deg C TTDd 3.29
CW flow m3/hr CWfd 22500
Cond CW DP Kg/cm2 CWdpd 0.45
TEST DATA
Description Unit Notation Unit No
Unit Load MW La 213.13
Condenser Back Pressure mmHgc (ab) Bpa 45.00
C W inlet temperature (pass-1) Deg C Cwinla 17.60
C W inlet temperature (pass- 2) Deg C Cwinra 17.80
C W outlet temperature (pass-1) Deg C Cwoutla 32.30
C W outlet temperature (pass-2) Deg C Cwoutra 31.70
Condensate temp in Hot well Deg C Hwta 34.70
Air steam mix temp Deg C Airta 30.00
61
 Evaluation of condenser performance
Description Unit Data

Expected Sat. Temp due to change in CW inlet Temp= Expected Tsat =

Deg C C 31.79
CW inlet temp (a) + CW temp rise (d) + TTD (d)

Expected Back pressure due to change in CW inlet temp mmHgc D 35.23

Expected Sat. Temp due to change in CW inlet Temp and load Expected
Deg C G 31.95
Tsat = CW inlet temp (a) + CW temp rise exp at load + TTD (d)

Expected Back pressure due to change in CW inlet temp and load mmHgc H 35.56
Expected Sat. Temp due to change in CW temp, flow and load
Deg C I 35.29
Expected Tsat = CW inlet temp (a) + CW temp rise (a) + TTD (d)
Expected Sat. back pr due to change in CW temp, flow and load mmHgc J 42.85

RESULT
Back pr variation due to cw inlet temp mmHgc D-BDd -40.77
Back pr variation due to unit load mmHgc H-D 0.33
Back pr variation due to cw flow mmHgc M=J-H 7.29
Back pr variation due to air and dirty tube ( Bad
mmHgc N=Bpa-J 2.15
performance of condenser)
Air Depression Deg C Satta-Airta 6.18
Sub cooling Deg C Satta-Hwta 0.18
62
CONDENSER PERFORMANCE CALCULATION
(Condenser back pressure correction method)

63
 CONDENSER PERFORMANCE CALCULATION
(Condenser back pressure correction method)

Variation of Condenser Back pressure varies on variation of

 CW inlet temperature,
 CW flow
 Condenser Heat Load
 Heat transfer rate ( performance of condenser)
 Measured Back pressure is corrected for CW inlet temperature,CW flow
Condenser Heat Load
 The corrected back pressure is compared with the design back pressure
for the purpose of final evaluation.
 The Heat Transfer in any Heat Exchanger is proportional to 1.LMTD (Log
Mean Temp. Difference) & 2.Surface Area
 The actual ( test ) log mean temperature difference is calculated.
 The test LMTD corresponds to measured back pressure, C.W. velocity,
actual surface area and C.W. inlet temperature. Hence, it shall be
corrected for designed C.W. inlet temperature, velocity and heat rejected.
 The corrected condenser back pressure will be computed from
corrected test LMTD
64
 CONDENSER PERFORMANCE CALCULATION
(Condenser back pressure correction method)

Computation of circulating water quantity / velocity will be done based on

circulating water temperature measurements, heat load on condenser and
actual total tube sectional area per pass.

Heat rejected to condenser

CW flow rate =---------------------------------------------------------------------------------- m3/hr
Mean C W temp rise X Specific Heat of water X Density of water

C W flow rate
C W velocity =-------------------------------- m/sec.
C W flow area X 3600

 Heat rejected to condenser will be calculated based on the uncorrected and actual
heat rate of the Turbine Generator package at the time of test.
 Heat rejected to condenser will be the difference of Heat supplied to the Turbine
less the Turbine output (Generator output corrected for mechanical / electrical
losses and turbine losses).

65
 DESIGN DATA

S No Symbol Description Unit Design

1 Hlg Condenser Heat load kcal/hr 546160000
2 Qg Coolig water flow m3/hr 54000.00
3 tw1d Coolig water inlet temp Deg C 33.00
4 Psg Back pressure mmHgC 77.00
5 L Effective tube length mm 13300.00
6 N Number of tubes no 24398.00
7 do x t Tube out side dia mm 31.75
8 t Tube thickness mm 0.7112
9 di Tube in side dia mm 30.33
Dissolved oxygen in hotwell
10 - condensate cc/l 0.015
11 d Water density kg/m3 1000.00
12 Cp Water sp heat kcal/kg 1.00
13 v Design CW velocity m/sec 1.71
14 Dtwd Design C W temp rise Deg C 10.05
66
DATA FOR COMPUTATION OF CONDENSER PERFORMANCE

S No Description Unit Data

1 Unit Load MW 531.536
2 Condenser Back Pressure mmHgc 78.33
3 Condenser Back Pressure mmHgc 78.33
4 C W inlet temperature (Pass-I) •C 31.42
5 C W inlet temperature (Pass-II) •C 31.54
6 C W outlet temperature (Pass-I) •C 43.58
7 C W outlet temperature (Pass-II) •C 43.56
8 Average C W inlet temperature •C 31.479
9 Average C W outlet temperature •C 43.57
10 Temp Rise •C 12.087

67
 CALCULATION OF CONDENSER HEAT LOAD

S No Symbol Description Unit Data

1 tw1m Mean cw in temp Deg C 31.479
2 tw2m Mean cw out temp Deg C 43.566
3 Dtw Mean temp rise Deg C 12.09
4 d Water density kg/m3 1000
5 Cp Water sp heat kcal/kg 1
6 HR Raw heat rate kcal/kwh 1960.680
7 Pg TG out put (Generation) kw 531536.0
8 Ge Gen efficiency 0.9870
9 ml Mechanical loss kw 1444.0000
10 Ha Cycle heat addition kcal/hr 1042172004
11 To Turbine out put kcal/hr 464297246
12 Hr Condenser heat load kcal/hr 577874758

Heat added in the cycle = heat rate x Generation =1960.680 X 531536 = 1042172004 kcal/hr
Generation 531536
Turbine Output = -------------------------+ Mechanical loss =-----------+ 1444.0= 539980.98 KW
Generator efficiency 0.9870

Turbine Output =539980.98 x 859.84= 464297246

Condenser heat load = Cycle heat addition- Turbine out put =
= 1042172004- 464297246 = 577874758 kcal/hr 68
 CALCULATION OF CONDENSER CW FLOW AND VELOCITY
S No Symbol Description Unit Data
1 tw1m Mean cw in temp Deg C 31.479
2 tw2m Mean cw out temp Deg C 43.566
3 Dtw Mean temp rise Deg C 12.09
4 d Water density kg/m3 1000
5 Cp Water sp heat kcal/kg 1
12 Hr Condenser load kcal/hr 577874758.0
13 Qw CW flow rate m3/hr 47797.7
14 n Tube number 24398
9 di Tube in side dia mm 30.33
15 Aw CW flow area m2 8.81
16 V CW velocity m/sec 1.507
Condenser load
CW flow rate =-------------------------------------------------------------------------------------------- m3/hr
Mean C W temp rise X Specific Heat of water X Density of water

577874758 577874758
CW flow rate= ------------------------------------ = ------------------- = 47797.7 m3/hr
12.09 X 1 X 1000 12090
C W flow area = 3.14 X Tube in side dia X Tube in side dia X Tube number =
4 x2
= 3.14 X0.3033 X0.3033 X24398 = 8.81 m2
8
C W flow rate 47797.7
C W velocity =-------------------------------- m/sec.=--------------------= 1.507 m/sec
C W flow area X 3600 8.8079 X 3600
69
 Test LMTD Calculation

Symbol Description Unit Data

tw1m Mean inlet Temp deg C 31.479
tw2m Mean outlet Temp deg C 43.566
Dtw Mean Temp Rise deg C 12.087
Pa Condenser Back Pressure mmHgc 78.33
ts Saturation Temp (Test) deg C 46.7
dt Test LMTD (Test) deg C 7.622

tw
LMTD=------------------------------------ DegC
ln[(ts–tw1m)/(ts–tw2m)]
12.087
LMTD= ---------------------------------------------------- = 7.622 DegC
ln[(46.7–31.479)/(46.7 43.566]

70
TEMPERATURE CORRECTION CURVE

Rated CW inlet temperature = 33 Deg C

Test CW inlet temperature = 31.479 Deg C
Correction factor = 0.993
71
CW VELOCITY CORRECTION CURVE

Rated CW velocity = 1.71 m/sec

Test CW velocity = 1.507 m/sec
Correction factor = 0.941
72
HEAT LOAD CORRECTION CURVE

Rated heat condenser load = 546160000 Kcal/hr

Test heat condenser load = 577874758 Kcal/hr
Correction factor = 0.945

73
 CORRECTION OF LMTD AND BACK PRESSURE
Description Unit Data
Test LMTD deg C 7.622
Design Cooling water inlet temp Deg C 33.00
Mean Temp Rise deg C 12.09
Design C W temp rise Deg C 10.05
CW inlet Corr. Factor 0.993
CW velocity (Flow) inlet Corr. Factor 0.941
Heat Load Corr. Factor 0.945
Corrected LMTD dt x ft x fv x fh deg C 6.73
Exponential 4.451
Corresponding Saturation Temperature deg C 45.96
Corrected Back Press mmHgC 75.52
Design condenser back pressure mmHgC 77.00
Deviation mmHgC -1.48
Corrected LMTD = Test LMTD XCF temp XC Fcwv X CF load
Corrected LMTD = 7.622 X 0.993 X 0.941X 0.945 = 6.73 deg C
Exponential = exp(Design C W temp rise / Corrected LMTD)
Exponential = exp(10.05 / 6.73)= 4.451
Corresponding Saturation Temperature= tw1d+X*twd/(X-1)
=Design CW inlet+ Design C W temp rise X Expo/ (Expo-1)=
= 33.00 +10.05X 4.451/ (4.451 -1)=45.96 Deg C
Corrected Back Press= 75.52 mm HgC 74
 Condenser performance report
Description Unit Data
Design condenser back pressure mmHgc 77.00
Test condenser back mmHgc 78.33
Design CW inlet temp Deg C 33.00
Design CW outlet temp Deg C 43.05
Design CW Temp rise Deg C 10.05
Test CW inlet temp Deg C 31.48
Test CW outlet temp Deg C 43.57
Test CW Temp rise Deg C 12.09
Design Saturation temp Deg C 46.34
Test Saturation temp Deg C 46.68
Design Terminal Temp Diff. Deg C 3.29
Test Terminal Temp Diff. Deg C 3.11
Condensate temp Deg C 47.02
Air+Steam mix temp Deg C 42.47
Corrected condenser back pressure mmHgc 75.52
Deviation from design condenser back pressure mmHgc -1.48
Under cooling Deg C -0.34
Air+Steam mix temp Depression Deg C 4.21

Terminal temperature difference ( TTDa)

TTD= Tsat- CW outlet temp = 46.68-43.57 = 3.11 Deg C
Under cooling = Tsat- Condensate temp = 46.68- 47.02= -0.34
Air Depression = Tsat – T air steam mixture = 46.68- 42.47 = 4.21
75
 HP Heater Performance
Concept & Calculation Methodology

76
 HP HEATER PERFORMANCE TESTING & OPTIMISATION

Performance of H.P. Heaters can be analysed by

monitoring / trending:

 the terminal temperature difference (TTD)

 the drain Cooler approach temperature (DCA)

 the pressure drop on the feed water side

 the temperature rise across the heater

 the extraction flow to heater

77
 Terminal Temperature Difference (TTD) &
Drain Cooler Approach (DCA)

• Terminal Temperature Difference (TTD) i.e. the

difference between the Saturation temp. of steam
corresponding to shell pressure(ts) and feed water
outlet temp. (to) :
TTD = ts – to

• Drain Cooler Approach (DCA) i.e. the difference

between heater drain outlet temp.(tdo) and the
feed water inlet temp (ti) :
DCA = tdo – ti
78
 HPH Extraction Flow

Qf (Hout – Hin)
 Extraction Flow (Qe) =
(Hext – Hdrip)

Where: Qf = Feed Flow

Hout = Feed Water Enthalpy at HPH Out.
Hin = Feed Water Enthalpy at HPH in
Qe = Extraction Flow
Hext = Enthalpy of Extraction Steam
Hdrip = Enthalpy of Drip

79
 HP HEATER PERFORMANCE TESTING & OPTIMISATION

The impact of deterioration of Heater Performance on

Unit Heat Rate :

 1 deg.C rise in TTD amounts to loss in TCHR of 0.85 kcal/kWh

(top heater).

 1 deg.C rise in DCA amounts to loss in TCHR of 0.25 kcal/kWh

 Turbine Cycle Steam Flow altered depending on source of

Extraction Steam to Heater, altering work done.

 Feed water temperature at Economiser inlet affected.

80
 DATA FOR HP HEATER PERFORMANCE
S No Description Unit
1 Measured power MW
2 Total Feed water flow including SH and RH spray TPH
3 HPH- 6 Extraction steam Pressure ( HE ) Kg/cm2
4 HPH- 6 Extraction steam Temperature HE
5 HPH- 6 inlet feed water Temperature
6 HPH- 6 outlet feed water Temperature
7 HPH- 6 inlet feed water Pressure Kg/cm2
8 HPH- 6 outlet water Pressure Kg/cm2
9 HPH- 6 drain Temperature
10 HPH- 5 Extraction steam Pressure ( HE ) Kg/cm2
11 HPH- 5 Extraction steam Temperature HE
12 HPH- 5 inlet feed water Temperature
13 HPH- 5 outlet feed water Temperature
14 HPH- 5 inlet feed water Pressure Kg/cm2
15 HPH- 5 outlet water Pressure Kg/cm2
16 HPH- 5 drain Temperature
17 Atmospheric Pressure Kg/cm2 ( ab)
81
HP HEATER PERFORMANCE TESTING & OPTIMISATION

82
 DATA FOR HP HEATER PERFORMANCE
S No Description Unit Test value
1 Measured power MW 250.02
Total Feed water flow including SH and RH
765.00
2 spray TPH
3 HPH- 6 Extraction steam Pressure ( HE ) Kg/cm2 37.74
4 HPH- 6 Extraction steam Temperature HE 343.70
5 HPH- 6 inlet feed water Temperature 200.20
6 HPH- 6 outlet feed water Temperature 245.50
7 HPH- 6 inlet feed water Pressure Kg/cm2 190.00
8 HPH- 6 outlet water Pressure Kg/cm2 189.50
9 HPH- 6 drain Temperature 210.00
10 HPH- 5 Extraction steam Pressure ( HE ) Kg/cm2 15.60
11 HPH- 5 Extraction steam Temperature HE 424.00
12 HPH- 5 inlet feed water Temperature 161.00
13 HPH- 5 outlet feed water Temperature 200.20
14 HPH- 5 inlet feed water Pressure Kg/cm2 191.00
15 HPH- 5 outlet water Pressure Kg/cm2 190.00
16 HPH- 5 drain Temperature 166.50
Kg/cm2 (
1.00
17 Atmospheric Pressure ab)
83
 ENTHALPY CALCULATION
S No Description Unit Test value
1 FW pressure at HPH-6 inlet Kg/cm2 ( ab) 191.15
2 FW temp at HPH-6 inlet Deg C 200.20
3 Enthalp of FW at HPH-6 inlet Kcal/Kg 205.57
4 FW pressure at HPH-6 outlet Kg/cm2 ( ab) 190.65
5 FW temp at HPH-6 outlet Deg C 245.50
6 Enthalpy of FW at HPH-6 outlet Kcal/Kg 254.46
7 Extraction steam to HPH- 6 pressure Kg/cm2 ( ab) 38.74
8 Extraction steam to HPH-6 temp Deg C 343.70
9 Enthalpy of extraction steam to HPH- 6 Kcal/Kg 736.21
10 HPH- 6 drip pressure Kg/cm2 ( ab) 38.74
11 HPH-6 drip temperature Deg C 210.00
12 Enthalpy of drip HPH-6 Kcal/Kg 214.57
13 FW pressure at HPH-5 inlet Kg/cm2 ( ab) 192.15
14 FW temp at HPH-5 inlet Deg C 161.00
15 Enthalp of FW at HPH- 5 inlet Kcal/Kg 164.98
16 FW pressure at HPH-5 outlet Kg/cm2 ( ab) 191.15
17 FW temp at HPH-5 outlet Deg C 200.20
18 Enthalp of FW at HPH-5 outlet Kcal/Kg 205.57
19 Extraction steam to HPH- 5 pressure Kg/cm2 ( ab) 16.70
20 Extraction steam to HPH-5 temp Deg C 424.00
21 Enthalpy of extraction steam to HPH-5 Kcal/Kg 789.69
22 HPH- 5 drip pressure Kg/cm2 ( ab) 16.70
23 HPH- 5 drip temperature Deg C 166.50
24 Enthalpy of drip HPH- 5 Kcal/Kg 168.24 84
 CALCULATION OF HPH-6 PERFORMANCE CALCULATION
S No Description Unit Test value
1 HPH- 6 inlet feed water Temperature ℃ 200.20
2 HPH- 6 outlet feed water Temperature ℃ 245.50
3 HPH- 6 drain Temperature ℃ 210.00
4 Extraction steam to HPH- 6 pressure Kg/cm2 ( ab) 38.74
5 HPH-6 Saturation temperature of extraction steam Deg C 247.3
6 HPH 6 feed water flow TPH 765.00
7 Enthalpy of HPH-6 Extraction Steam Kcal/Kg 736.21
8 Enthalpy of HPH 6 FW inlet Kcal/Kg 205.57
9 Enthalpy of HPH 6 FW outlet Kcal/Kg 254.46
10 Enthalpy of HPH 6 drip Kcal/Kg 214.57
CALCULATION:
1: Terminal Temp Difference TTD = ( ts – to ) = (247.3- 245.50) = 1.8 Deg C
2: Drain Cooler Approach DCA = ( tdo – t ) = (210.00- 200.20) = 9.8 Deg C
3: Temperature rise = (tdo – ti ) = (245.50- 200.20 ) = 45.30 Deg C

Extraction Flow (Qe) X (Hext – Hdrip) = Qf (Hout – Hin)

Qf (Hout – Hin) 765000X(254.46–205.57) 37400850

4: Extraction Flow-HPH 6 = -------------------- =------------------------------ =----------- = 71.70 T/hr
(Hext – Hdrip) (736.21– 214.57) 521.6

85
 CALCULATION OF HPH-5 PERFORMANCE CALCULATION
S No Description Unit Test value
1 HPH- 5 inlet feed water Temperature ℃ 161.00
2 HPH- 5 outlet feed water Temperature ℃ 200.20
3 HPH- 5 drip temperature Deg C 166.50
4 Extraction steam to HPH- 5 pressure Kg/cm2 ( ab) 16.70
5 HPH-5 Saturation temperature of extraction steam Deg C 202.5
6 HPH 5 feed water flow TPH 765.000
7 Enthalpy of HPH-5 Extraction Steam Kcal/Kg 789.69
8 Enthalpy of HPH 5 FW inlet Kcal/Kg 164.98
9 Enthalpy of HPH 5 FW outlet Kcal/Kg 205.57
10 Enthalpy of HPH 5 drip Kcal/Kg 168.24
11 Enthalpy of HPH 6 drip Kcal/Kg 214.57
12 HPH 6 Drip Flow TPH 71.69
CALCULATION:
1: Terminal Temp Difference TTD = ( ts – to ) = (202.5- 200.20) = 2.3 Deg C
2: Drain Cooler Approach DCA = ( tdo – t ) = (210.00- 200.20) = 5.5 Deg C
3: Temperature rise = (tdo – ti ) = (200.20 - 161.00 ) =39.2 Deg C

Extraction Flow HPH-5 X(H5 ext – H5 drip)+Drip HPH6 flow (H6drip-H5drip)= FW flow (Hfwout –Hfwin)

( FW flow (Hfwout – Hfwin)- Drip HPH6 flow (H6drip-H5drip))

Extraction Flow HPH-5=---------------------------------------------------------------------------------------
(H5 ext – H5 drip)

(765000 X(205.57- 164.98)-71.69X(214.57-168.24)) 31048028.60

Extraction Flow HPH-5=-------------------------------------------------------------------=-----------------= 43 t/hr
(789.69– 168.24) 721.45
86
 HPH-5 HPH-6
Description Design Test Design Test
Feed water inlet temperature 161.3 161.00 200.1 200.20
Feed water outlet temperature 200.1 200.20 246.00 245.50
Temperature rise 38.80 39.20 45.90 45.30
Terminal Temperature difference -0.2 2.3 -0.2 1.8
Drain cooler approach 5.00 5.5 4.8 9.80
Drip Flow 43.1 43.0 69.2 71.7

87
cooling Tower performance
Concept & Calculation Methodology

88
Salient Terms Used in Cooling Tower

Performance indices
1. Range ( 8 Deg C to 11 Deg C)
2. Approach (4 Deg C to 5 Deg C )
3. Effectiveness ( 67 % to 69 %)
4. Cooling capacity (90 % to 95%)
5. Evaporation loss (1.6 % to 1.8 %)
6. Cycles of concentration (5-6)
7. Blow down losses
8. Liquid / Gas ratio

89
 Salient Terms Used in Cooling Tower

 Range is the temperature

difference between the hot water
entering the cooling tower and
the cold water leaving.
 Approach is the difference
between the temperature of the
water leaving the tower and the
wet bulb temperature of the
entering air.
 Effectiveness is the ratio of
range, to the ideal range, i.e.,
difference between cooling water
inlet temperature and ambient
wet bulb temperature

90
 Salient Terms Used in Cooling Tower

TOWER CAPABILITY
• Cooling Tower Capability (also sometimes referred to as efficiency) is
the ratio of the water flow that can be cooled through a given range at
a given wet bulb temperature and design fan power to the predicted
flow that could be cooled through the same range at the same
conditions.
Tower Capability in Percentage = Test CW Flow
Predicted CW flow

Tower Capability in Percentage = Adjusted Test Flow Rate

Predicted Water Flow Rate
Adjusted Test Flow Rate
= Measured flow x Design KW of fans 0.333
{Test KW of Fans}
Predicted Water Flow Rate
Calculated from Manufacturer graphs and actual test condition 91
 Salient Terms Used in Cooling Tower
Evaporation loss
Evaporation loss is the water quantity evaporated for cooling duty

Circulation Rate (m3/hr) * Temp. Difference in oC

Evaporation Loss (m3/hr) = ----------------------------------------------
675
Cycles of concentration (C.O.C)
Cycles of concentration (C.O.C) is the ratio of dissolved solids in circulating
water to the dissolved solids in make up water.

Blow down
Evaporation losses
Blow down = -------------------------
(COC-1)
Make up water requirement = Evaporation loss + blow down loss + drift loss

92
 Salient Terms Used in Cooling Tower

Liquid/Gas (L/G) ratio

Liquid/Gas (L/G) ratio, of a cooling tower is the ratio
between the water and the air mass flow rates.
L/G ratio = Water flow in Kg/sec / Air flow in Kg/sec
Against design values, seasonal variations require
adjustment and tuning of water and air flow rates to get the
best cooling tower effectiveness through measures like
water box loading changes, blade angle adjustments
• Low L/G ratio indicates that cooling tower is under
utilized. ( high air flow)
• High L/G ratio indicates availability of less air flow for
actual cooling water flow

93
 Salient Terms Used in Cooling Tower

Fan air flow actual ( N m3/h/cell) =

Rated fan flow in Nm3,h x (fan input KW actual)1/3

= ----------------------------------------------------------
(fan input rated)1/3

Air mass flow /cell =Air flow x Density

94
Cooling tower performance test procedure

Parameters to be Measured
 Wet bulb temperature of air
 Dry bulb temperature of air
 Cooling tower inlet water temperature
 Cooling tower outlet water temperature
 Water flow rate
 Ambient air velocity
 Exhaust air temperature ( For IDCT)
 Electrical readings of fan motors ( For IDCT)
 Air flow rate ( For IDCT)
95
 Cooling tower performance Test procedure

Test Parameter Unit Design Test

Unit load MW 250.0 252.0
Average Hot Water Temperature Deg C 41.0 39.10
Average Cold Water Temp Deg C 32.0 29.10
Average Air WBT Deg C 27.0 24.0
Average Air DBT Deg C 37.4 26.7
Average Ambient Air RH % 45.0 80.0
Average Wind Velocity m/sec 3.0 1.72
Total CW Flow m3/hr 37500 36000
Total CW Flow % of design flow % 100.0 96.0
96
 cooling Tower performance calculaTion
Range = Hot water temperature ( CT inlet) - Cold water temperature ( CT outlet)
Hot water temperature( CT inlet)= 39.1 Deg C
Cold water temperature ( CT outlet) = 29.10 Deg C
Cooling tower Range = 39.1 - 29.10 = 10.0 Deg C
APPROACH
Approach = Cold water temperature ( CT outlet) - Wet bulb temperature
Cold water temperature ( CT outlet) = 29.10 Deg C Wet bulb temperature = 24.00 Deg C
Approach = 29.10 – 24.00 = 5.1 Deg C
EFFECTIVENESS
Range X100 10.0 X 100 1000
CT Effectiveness = ------------------------- =---------------------- = --------- =66.23 %
(Range + Approach) ( 10.0+5.1 ) 15.1

TOWER THERMAL CAPABILITY

Measured Test Flow Rate 36000

Tower Thermal Capability =------------------------------------ X100 =--------- = 85.71 %
Predicted Water Flow Rate 42000
97
Test Data
Air WBT Deg C 24.0
CW Cooling Range Deg C 10.0
Ambient Air RH % 80.0
Wind Velocity m/sec 1.7

Expected Cold Water Temperature at 80% Flow Deg C 28.30

Expected Cold Water Temperature at 100% Flow Deg C 28.80
Expected Cold Water Temperature at 120 % Flow Deg C 29.40
Expectecd Cold Water Temp Deg C 28.70
Correction due to Wind Velovity (from curve ) Deg C 0.00
98
 Cooling tower performance Test procedure

Total CW Flow m3/hr 36000

Total CW Flow % of design flow % 96.0
Average Cold Water Temperature Deg C 29.10
Expected Cold Water Temp Deg C 28.70
Predicted flow as per curve % of design
% 112.0
flow
Predicted flow as per curve m3/hr 42000.0 99
 Cooling tower performance Test Report

Dev from
Description Design Expected Actual Expected
Cold Water Temperature 32.0 28.7 29.1 0.40
Cooling Range of Cooling
Tower 9.00 10.40 10.00 -0.40
Approach of Cooling Tower 5.00 4.70 5.10 0.40
Cooling Tower Effectiveness 64.29 68.87 66.23 -2.65
Cooling Tower Capability 100.00 100.00 85.71 -14.29

100
Thank you

101