Pulkit Ppt Steam Turbine3 (2)

IMPROVING EFFICIENCY & RELIABILITY

of

STEAM TURBINEPROJECT REPORT

BY:NAME: PULKIT KHANDURI

SUBMITTED TO:DGM (TMD NTPC BADARPUR) S K GARG

ROLL NO:12109059FINAL YEAR (MECHANICAL ENGINEERING)

NIT JALANDHAR

IN THE PRESENT POWER SECTOR SCENARIO

FOCUS IS ON

• ENHANCING EFFICIENCY• RELIABILITY• STRICTER POLLUTION NORMS• COST REDUCTION

RESULT IN IMPROVEMENT IN EFFICIENCY OF TURBINE

1. REDUCTION IN GENERATION COST HIGH EFFICIENCY OF THE CYCLE

LOWER EQUIPMENT COST SHORTER GESTATION PERIOD

REDUCED MAINTENANCE TIME2. INCREASED RELIABILITY

3. MINIMIZING ENVIRONMENTAL HAZARDS

IMPROVEMENT IN STEAM TURBINE IMPROVEMENT IN STEAM TURBINE PERFORMANCEPERFORMANCE

POSSIBLE BY1. IMPROVED BLADE PROFILE• REDUCTION IN THE AERODYNAMIC

FLOW LOSSES e.g.PROFILE LOSSSECONDARY FLOW LOSSTIP LEAKAGE LOSS

•MORE UNIFORM FLOW DISTRIBUTIONCONTD……..

IMPROVEMENT IN STEAM TURBINE PERFORMANCEIMPROVEMENT IN STEAM TURBINE PERFORMANCE

POSSIBLE BY ….contd...

2. OPTIMISED FLOWPATH

3. IMPROVEMENT IN SHAFT SEALING SYSTEM

4. REDUCTION IN PRESSURE DROPS

5. REDUCED FRICTION LOSSES

6. OPTIMISATION OF INLET & EXHAUST SECTION

7. OPTIMISED EXHAUST LOSS

METHODS EMPLOYED TO IMPROVE STEAM TURBINE EFFICIENCY

1. DEVLOPEMENT OF BETTER BLADE PROFILE FOR STEAM TURBINE.

2.2. RETROFITTING & UPGRADATION OF RETROFITTING & UPGRADATION OF OLDER SETS INOLDER SETS IN

(A)(A) HP TURBINEHP TURBINE(B)(B) LP TURBINELP TURBINE3. TECHNICAL PROPOSALS FOR IMPROVEMENT 3. TECHNICAL PROPOSALS FOR IMPROVEMENT

IN DESIGNIN DESIGN

1. IMPROVEMENT IN OF PROFILES FOR 1. IMPROVEMENT IN OF PROFILES FOR

CYLINDRICAL TURBINE BLADESCYLINDRICAL TURBINE BLADES

T4 PROFILE HAS 1% LOWER PROFILE LOSSES COMPARED TO T2 PROFILE.

NEWLY DEVELOPED TX HAS 0.2% LOWER PROFILE LOSSES COMPARED TO T4 PROFILE.

2 . CONSIDERATIONS IN RETROFITTING & UPGRADATION 2 . CONSIDERATIONS IN RETROFITTING & UPGRADATION OF OLDER SETSOF OLDER SETS

• COST EFFECTIVENESS• MODIFICATIONS IN TURBINE INTERNALS ONLY• INCREASE IN POWER OUTPUT WITH MINIMUM CHANGES• OUTER CASING, PIPINGS, VALVES, PEDESTAL FIXING ARRANGEMENT , STEAM PARAMETERS & FOUNDATION DETAILS REMAIN UNALTERED• SHORTEST POSSIBLE OUTAGE TIME

RETROFITTING & UPGRADATION OF OLDER SETSRETROFITTING & UPGRADATION OF OLDER SETS

PRE-REQUISITE

•IDENTIFY THE UNIT

•PRESENT LEVEL OF PERFORMANCE

•RESIDUAL LIFE ASSESSMENT STUDY OF CRITICAL COMPONENTS

•ANALYSIS OF HISTORY & OPERATING DETAILS

RETROFITTING & UPGRADATION OF OLDER SETSRETROFITTING & UPGRADATION OF OLDER SETS

• MAJOR MODIFICATIONS INMAJOR MODIFICATIONS IN GUIDE & MOVING BLADE GUIDE & MOVING BLADE

(LATEST STATE OF ART PROFILE)(LATEST STATE OF ART PROFILE) STEAM FLOWPATHSTEAM FLOWPATH ROTORS & INNER CASINGS OF ROTORS & INNER CASINGS OF

TURBINETURBINE SHAFT SEALINGSSHAFT SEALINGS [ADVANTAGE IN HEATRATE / [ADVANTAGE IN HEATRATE /

OUTPUT CAN BE WORKED OUT OUTPUT CAN BE WORKED OUT ON CASE TO CASE BASISON CASE TO CASE BASIS]]

3 DS BLADE

(HPT/IPT)

TWISTED PROFILE

BLADE (HP/IPT)

BANANA TYPE

BLADE (LPT)

210 MW STEAM TURBINE

(IMPULSE DESIGN SET-LMW) HP TURBINE

2(A) RETROFITTING OF HP TURBINE

EXISTING 210 MW HP TURBINE EXISTING 210 MW HP TURBINE WITH IMPULSE BLADINGWITH IMPULSE BLADING

PROPOSED NEW DESIGN WITH PROPOSED NEW DESIGN WITH LATEST STATE OF ART BLADINGLATEST STATE OF ART BLADING

210 MW STEAM TURBINE (IMPULSE DESIGN SET) HP TURBINE

HP TURBINE

EXISTINGEXISTING IMPULSE BLADING ( PRESSURE DROP ONLY IN

STATIONARY BLADES) EFFICIENCY : 83.6 % (FOR NEW MACHINE) EFFICIENCY FOR EXISTING

CONDITION : ~ 80%

NEWNEW• REACTION BLADING

( PRESSURE DROP IN STATIONARY AS WELL AS MOVING BLADES

EFFICIENCY : 86.5 %

ACTIVITIES INVOLVED

REMOVAL OF EXISTING HP ROTOR, LINERS AND DIAPHRAGMS

INSTALLATION OF NEW LINERS FITTED WITH STATIONARY BLADES AND NEW HP ROTOR

FITTING DIMENSIONS ARE TO BE MEASURED DURING PREVIOUS OVERHAUL AND LINERS ARE MACHINED ACCORDINGLY.

REMOVED HP ROTOR AND DIAPHRAGMS CAN BE USED AS SPARE FOR OTHER SETS

A. Reference data for ORIGINAL brand new turbineReference Heat Balance Diagram TCD - 210 - 33 - 2, Regime No. 1

Rated parameters

Main steam Flow 662 T/h

Main Steam Pressure 130 ata

Main Steam Temperature 535 Deg C

Hot reheat Temperature 535 Deg C

Condenser Vacuum 0.1042 ata

TG Heatrate 2062 kCal/kWh


Rated parameters







B. Expected present performance level (210 MW Original rating)

Considering deterioration due to ageingdeterioration due to ageing as per ASME-PTC-6Report 1985•Expected Power output

with 662 T/h main steam flow

and rated parameters 202.4 MW

•Expected TG Heatrate with 662 T/h main steam flow

and rated parameters 2164 kCal/kWh







EXPECTED PERFORMANCE IMPROVEMENT IN THE EXISTING EXPECTED PERFORMANCE IMPROVEMENT IN THE EXISTING IMPULSE DESIGN SET DUE TO HP TURBINE REFURBISHMENTIMPULSE DESIGN SET DUE TO HP TURBINE REFURBISHMENT

• INCREASE IN POWER OUTPUT : 8.6 MW

• IMPROVEMENT IN HEATRATE : 4% (FROM EXISTING PERFORMANCE LEVEL OF

THE SET WITH RATED STEAM PARAMETERS & THROTTLE STEAM FLOW)

BRAND NEW SET

EXPECTED PRESENT

DETERIORATED CONDITION

UPGRADED HPT

OUTPUT (MW)

210 202.4 (3.6% DECREASE)

211 (4.2% INCREASE)

HEAT RATE (KCAL/ KWh)

2062 2164 (4.9% INCREASE)

2077 (4.02% IMPROVEMENT)

EXPECTED PERFORMANCE IMPROVEMENT IN THE EXPECTED PERFORMANCE IMPROVEMENT IN THE EXISTING IMPULSE DESIGN SET DUE TO HP TURBINE EXISTING IMPULSE DESIGN SET DUE TO HP TURBINE

REFURBISHMENTREFURBISHMENT

EXISTING AFTER RETROFIT

WORK INVOLVED IN RETROFIT OF LP WORK INVOLVED IN RETROFIT OF LP TURBINETURBINE

WORK TO BE DONE AT SITE:

•CUTTING OF DEFLECTORS / RIBS & BLANKING THE SPACE IN LP CASING TO FACILITATE REMOVAL OF BAUMEN STAGE.•MODIFICATION OF STRUCTURE AT THE EXHAUST END OF LPC TO FACILITATE INSTALLATION OF DIFFUSOR.•MODIFICATION OF STRUCTURE AT THE STEAM INLET END OF LPC TO FACILITATE INSTALLATION OF 1ST STAGE OF GUIDE BLADES.

.


Rated parameters








Rated parameters







BRAND NEW ST

EXPECTED PRESENT DETERIORATED CONDITION

UPGRADED HPT

UPGRADED LPT

UPGRADED HPT & LPT

OUTPUT (MW)

210 202.4 211 212.5 214HEAT RATE (KCAL / KWH)

2062 2164 2077 2066 2047

ADDITIOAL GEN (MU)

NA NA 55.04 64.64 74.24

COMPARISONCOMPARISON

• INCREASE IN POWER OUTPUT : 10.1 MW• IMPROVEMENT IN HEATRATE : 102 KCAL / KWH (FROM EXISTING PERFORMANCE LEVEL OF THE SET

WITH RATED STEAM PARAMETERS & THROTTLE STEAM FLOW)

3.TECHNICAL PROPOSAL

FOR R & D OF 210 MW STEAM TURBINES (KW/U

DESIGN)

EXISTING DESIGN:

HP Turbine:•HP ROTOR : WITH MOVING BLADES OF T2 PROFILE

•INNER CASING: WITH STATIONARY BLADES OF T2 PROFILE

•INLET INSERTS: WITH 580X9 MM BUTTRESS THREADS

•EXHAUST ELBOWS: WITH SERRATED GASKET.

CROSS SECTIONAL VIEW OF 210 MW STEAM TURBINE

210 MW STEAM TURBINE (REACTION DESIGN SET-KWU)

HP TURBINE

RETROFITTING 210 MW REACTION TURBINE WITH IMPROVED BLADING

IMPROVEMENTS IN PROPOSED IN DESIGN:

HP MODULE:

1 INNER CASING & HP ROTOR WITH OPTIMISED HIGHLY EFFICIENT T4 PROFILE BLADING.

ADVANTAGE:INCREASED EFFICIENCY

2 MODIFIED HPT INLET INSERTS WITH BUTTRESS THREADS OF SIZE 580X20 MM IN HP OUTER CASING & BREECH NUTS.ADVANTAGE:EASE IN ASSEMBLY & DISMANTLING

3 MODIFIED HP EXHAUST ELBOWS WHICH HAVE U-RING IN PLACE OF SERRATED GASKET.ADVANTAGE:ENHANCED RELIABILITY

HP EXHAUST ELBOWS

Exhaust ElbowHP OUTER CASING

HP EXHAUST ELBOWS

HP EXHAUST ELBOWS

U-RING

SCOPE OF SUPPLY

FOR HP TURBINE:

•COMPLETELY ASSEMBLED HP MODULE WITH T4 PROFILE BLADING ALONGWITH MODIFIED HP INLET ASSEMBLY & HP EXHAUST ELBOWS.

210 MW STEAM TURBINE (REACTION DESIGN SET-KWU)

IP TURBINE

RETROFITTING 210 MW REACTION TURBINE WITH IMPROVED T4 PROFILE BLADING

ADVANTAGE:IMPROVED PERFORMANCE.

SCOPE OF SUPPLY (CONTD.)

FOR IP TURBINE:• IP INNER CASING & IP ROTOR•WITH T4 PROFILE BLADING.•A SET OF HPR-IPR & IPR-LPR COUPLING BOLTS.•NECESSARY KEYS ETC.

WORK REQUIRED TO BE DONE AT SITE:

[NOT INCLUDED IN THE SCOPE OF THIS TECHNICAL OFFER]• PERFORMANCE TESTING PRIOR & AFTER R & M.•OVERHAULING.•RLA STUDY.•COMPONENTS IDENTIFIED DURING OVERHAULING/ RLA STUDY WHICH NEED REPLACEMENT

WORK REQUIRED TO BE DONE AT SITE: (FOR HP Turbine)

•REMOVAL OF OLD HP MODULE FROM ITS POSITION AFTER

DISMANTLING OF HP INLET INSERTS AND HP EXHAUST ELBOWS.

•OLD HP INLET ASSEMBLY (INLET INSERTS WITH BREECH NUTS) & HP EXHAUST ELBOWS ARE TO BE CUT FROM MS PIPES & CRH PIPES RESPECTIVELY.• HP EXHAUST ELBOWS ARE TO BE WELDED WITH CRH STEAM PIPES.

•ASSEMBLY OF HP INLET INSERTS & HP EXHAUST ELBOWS TO BE COMPLETED

•INSTALLATION OF NEW IMPROVISED HPT MODULE IN POSITION,

CENTERING & ALIGNMENT.

•WELDING OF HP INLET ASSEMBLY OF NEW MODULE WITH MAIN

STEAM PIPES

WORK REQUIRED TO BE DONE AT SITE:FOR IP Turbine

•REMOVAL OF OLD IP ROTOR & IP INNER CASING.

•INSTALLATION OF NEW IP INNER CASING & IP ROTOR WITH T4 PROFILE BLADING, ITS CENTERING & ALIGNMENT.•COMPLETION OF BOX UP OF IP Turbine.

CONDITION AFTER R & M OF HPT & IPT (UNDER RATED CONDITION):

RATED PARAMETERS:At 100% MCR condition

•MAIN STEAM FLOW : 641.3 T/HR•MS/ HRH STEAM TEMP:535/535 DEG C•MAIN STEAM PR: 150 ATA•BACK PR: 0.121 ATA

EXPECTED PRESENT PERFORMANCE:

CONSIDERING DETERIORATION DUE TO AGING AS PER ASME-PTC-6 REPORT 1985 FOR AVERAGE LIFE OF 20 YEARS, FOLLOWING WILL BE EXPECTED PERFORMANCE AT 641.3 T/HR MAIN STEAM FLOW AND RATED PARAMETERS OUTPUT: 202.3 MW HEAT RATE: 2067 KCAL/KWH

COMPARISON OF PERFORMANCE:

PAY BACK PERIOD1) REDUCTION IN OF PERIOD: 25 DAYSRESULTING TO ADDITIONAL POWER GENERATION FOR 25 DAYSYIELDING TO

GUAREENTED MINIMUM ADDITIONAL REVENUE:= 209MW x 1000 x 25DAYS x 24HRS x 0.80PLF x 2.00RS

=RS 20.06 CRORES

2)ADDITIONAL ANNUAL REVENUE GENERATION DUE TO INCREASE IN OUTPUT & IMPROVED HEAT RATE:

= 6.7 MW x 1000 x 8000 HRS x 0.80 PLF x RS 2.00 = RS 8.576 CRORES PER YEAR

HENCE, PAY BACK PERIOD < 3 YEARS

THANK YOU

Pulkit Ppt Steam Turbine3 (2)

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