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Improving Efficiency & Reliability of STEAM TURBINE Through R & M BY: AMITABH SRIVASTAVA SR.DGM, BHEL HARDWAR.

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Presentation on theme: "Improving Efficiency & Reliability of STEAM TURBINE Through R & M BY: AMITABH SRIVASTAVA SR.DGM, BHEL HARDWAR."— Presentation transcript:

1 Improving Efficiency & Reliability of STEAM TURBINE Through R & M BY: AMITABH SRIVASTAVA SR.DGM, BHEL HARDWAR

2 IN THE PRESENT POWER SECTOR SCENARIO FOCUS IS ON ENHANCING EFFICIENCY RELIABILITY STRICTER POLLUTION NORMS COST REDUCTION

3 RESULTING TO ENHANCED EMPHASIS ON => REDUCTION IN GENERATION COST  HIGH EFFICIENCY OF TG CYCLE  LOWER EQUIPMENT COST  SHORTER GESTATION PERIOD  REDUCED MAINTENANCE TIME => INCREASED RELIABILITY => MINIMIZING ENVIRONMENTAL HAZARDS

4 IMPROVEMENT IN STEAM TURBINE PERFORMANCE POSSIBLE BY 1. IMPROVED BLADE PROFILE REDUCTION IN THE AERODYNAMIC FLOW LOSSES e.g.  PROFILE LOSS  SECONDARY FLOW LOSS  TIP LEAKAGE LOSS MORE UNIFORM FLOW DISTRIBUTION CONTD……..

5 IMPROVEMENT IN STEAM TURBINE PERFORMANCE POSSIBLE BY ….contd 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

6 DEVELOPMENT OF PROFILES FOR CYLINDRICAL 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.

7 CONSIDERATIONS IN RETROFITTING & UPGRADATION OF 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

8 RETROFITTING & 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

9 RETROFITTING & UPGRADATION OF OLDER SETS MAJOR MODIFICATIONS IN MAJOR MODIFICATIONS IN  GUIDE & MOVING BLADE (LATEST STATE OF ART PROFILE) (LATEST STATE OF ART PROFILE)  STEAM FLOWPATH  ROTORS & INNER CASINGS OF TURBINE  SHAFT SEALINGS [ADVANTAGE IN HEATRATE / OUTPUT CAN BE WORKED OUT ON CASE TO CASE BASIS] [ADVANTAGE IN HEATRATE / OUTPUT CAN BE WORKED OUT ON CASE TO CASE BASIS] 3 DS BLADE (HPT/IPT) TWISTED PROFILE BLADE (HP/IPT) BANANA TYPE BLADE (LPT)

10 Retrofitting of HP Turbine with STATE OF ART REACTION BLADING

11 210 MW STEAM TURBINE (IMPULSE DESIGN SET-LMW) HP TURBINE

12 EXISTING 210 MW HP TURBINE WITH IMPULSE BLADING PROPOSED NEW DESIGN WITH LATEST STATE OF ART BLADING 210 MW STEAM TURBINE (IMPULSE DESIGN SET) HP TURBINE

13 PROPOSED NEW DESIGN WITH LATEST STATE OF ART BLADING

14 EXISTING  IMPULSE BLADING ( PRESSURE DROP ONLY IN STATIONARY BLADES)  EFFICIENCY : 83.6 % (FOR NEW MACHINE)  EFFICIENCY FOR EXISTING CONDITION : ~ 80%NEW REACTION BLADING ( PRESSURE DROP IN STATIONARY AS WELL AS MOVING BLADES i EFFICIENCY : 86.5 % HP TURBINE

15 ACTIVITIES INVOLVED a REMOVAL OF EXISTING HP ROTOR, LINERS AND DIAPHRAGMS a INSTALLATION OF NEW LINERS FITTED WITH STATIONARY BLADES AND NEW HP ROTOR a FITTING DIMENSIONS ARE TO BE MEASURED DURING PREVIOUS OVERHAUL AND LINERS ARE MACHINED ACCORDINGLY. Z REMOVED HP ROTOR AND DIAPHRAGMS CAN BE USED AS SPARE FOR OTHER SETS

16 a THE RETROFIT CAN BE DONE WITHIN NORMAL OVERHAUL PERIOD. a PAY BACK PERIOD IS LESS THAN 3 YEARS ACTIVITIES INVOLVED

17 A. Reference data for ORIGINAL brand new turbine Reference Heat Balance Diagram TCD , 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 ata TG Heatrate 2062 kCal/kWh A. Reference data for ORIGINAL brand new turbine Reference Heat Balance Diagram TCD , 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 ata TG Heatrate 2062 kCal/kWh

18 B. Expected present performance level (210 MW Original rating) deterioration due to ageing Considering deterioration due to ageing as per ASME-PTC-6Report 1985 Expected Power output with 662 T/h main steam flow and rated parameters MW Expected TG Heatrate with 662 T/h main steam flow and rated parameters 2164 kCal/kWh B. Expected present performance level (210 MW Original rating) deterioration due to ageing Considering deterioration due to ageing as per ASME-PTC-6Report 1985 Expected Power output with 662 T/h main steam flow and rated parameters MW Expected TG Heatrate with 662 T/h main steam flow and rated parameters 2164 kCal/kWh

19 EXPECTED PERFORMANCE IMPROVEMENT IN THE EXISTING IMPULSE 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)

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

21 COMPARISON GAIN WITH UPRATED HPT: ADDITIONAL GEN. OF MU = MW X1000 X HRS.X PLF = 8.6 X 1000 X 8000 X 0.80 = MU ADDITIONAL GEN. OF RS 2/= PER UNIT = X 2 = RS 11 CR

22 200/210 MW IMPULSE DESIGN SET (LMW)

23 EXISTING AFTER RETROFIT

24

25

26 WORK INVOLVED IN RETROFIT OF LP TURBINE 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. CONTD….

27 MODIFICATION OF STRUCTURE AT THE STEAM INLET END OF LPC TO FACILITATE INSTALLATION OF 1ST STAGE OF GUIDE BLADES. WORK INVOLVED IN RETROFIT OF LP TURBINE WORK TO BE DONE AT SITE:

28 A. Reference data for ORIGINAL brand new turbine Reference Heat Balance Diagram TCD , 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 ata TG Heatrate 2062 kCal/kWh A. Reference data for ORIGINAL brand new turbine Reference Heat Balance Diagram TCD , 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 ata TG Heatrate 2062 kCal/kWh

29 B. Expected present performance level (210 MW Original rating) deterioration due to ageing Considering deterioration due to ageing as per ASME-PTC-6Report 1985 Expected Power output with 662 T/h main steam flow and rated parameters MW Expected TG Heatrate with 662 T/h main steam flow and rated parameters 2164 kCal/kWh B. Expected present performance level (210 MW Original rating) deterioration due to ageing Considering deterioration due to ageing as per ASME-PTC-6Report 1985 Expected Power output with 662 T/h main steam flow and rated parameters MW Expected TG Heatrate with 662 T/h main steam flow and rated parameters 2164 kCal/kWh

30 EXPECTED PERFORMANCE IMPROVEMENT IN THE EXISTING SET DUE TO LP TURBINE REFURBISHMENT 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)

31 COMPARISON

32 COMPARISON GAIN WITH UPRATED LPT: ADDITIONAL GEN. OF MU = MW X1000 X HRS.X PLF = 10.1 X 1000 X 8000 X 0.80 = MU ADDITIONAL GEN. OF RS 2/= PER UNIT = X 2 = RS CR

33 COMPARISON

34 COMPARISON GAIN WITH UPRATED HPT & LPT: ADDITIONAL GEN. OF MU = MW X1000 X HRS.X PLF = 11.6 X 1000 X 8000 X 0.80 = MU ADDITIONAL GEN. OF RS 2/= PER UNIT = X 2 = RS CR

35 TECHNICAL PROPOSAL FOR R & M OF 210 MW STEAM TURBINES (KWU DESIGN) OF TUTICORIN TPS

36 CROSS SECTIONAL VIEW OF 210 MW STEAM TURBINE

37 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.

38 210 MW STEAM TURBINE (REACTION DESIGN SET-KWU) HP TURBINE RETROFITTING 210 MW REACTION TURBINE WITH IMPROVED BLADING

39 HP INLET INSERTS BREECH NUT HP OUTER CASING

40 HP INLET INSERTS HP INLET INSERTS (OLD DESIGN): HP OUTER CASING & BREECH NUTS THREAD SIZE : 580X9 MM HP INLET INSERTS (NEW DESIGN): HP OUTER CASING & BREECH NUTS THREAD SIZE : 580X20 MM

41 IMPROVEMENTS IN PROPOSED DESIGN: HP MODULE: INNER CASING & HP ROTOR WITH OPTIMISED HIGHLY EFFICIENT T4 PROFILE BLADING. ADVANTAGE: INCREASED EFFICIENCY

42 IMPROVEMENTS IN PROPOSED DESIGN: (CONTD.) HP MODULE (CONTD.): MODIFIED HPT INLET INSERTS WITH BUTTRESS THREADS OF SIZE 580X20 MM IN HP OUTER CASING & BREECH NUTS. ADVANTAGE: EASE IN ASSEMBLY & DISMANTLING.

43 IMPROVEMENTS IN PROPOSED DESIGN: (CONTD.) HP MODULE (CONTD.): MODIFIED HP EXHAUST ELBOWS WHICH HAVE U-RING IN PLACE OF SERRATED GASKET. ADVANTAGE: ENHANCED RELIABILITY.

44 HP EXHAUST ELBOWS Exhaust Elbow HP OUTER CASING

45 HP EXHAUST ELBOWS

46 U-RING

47 SCOPE OF SUPPLY FOR HP TURBINE: COMPLETELY ASSEMBLED HP MODULE WITH T4 PROFILE BLADING ALONGWITH MODIFIED HP INLET ASSEMBLY & HP EXHAUST ELBOWS.

48 210 MW STEAM TURBINE (REACTION DESIGN SET-KWU) IP TURBINE RETROFITTING 210 MW REACTION TURBINE WITH IMPROVED T4 PROFILE BLADING ADVANTAGE: IMPROVED PERFORMANCE.

49 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.

50 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

51 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.

52 WORK REQUIRED TO BE DONE AT SITE:(CONTD.) INSTALLATION OF NEW IMPROVISED HPT MODULE IN POSITION, CENTERING & ALIGNMENT. WELDING OF HP INLET ASSEMBLY OF NEW MODULE WITH MAIN STEAM PIPES.

53 WORK REQUIRED TO BE DONE AT SITE:(CONTD.) HP EXHAUST ELBOWS ARE TO BE WELDED WITH CRH STEAM PIPES. ASSEMBLY OF HP INLET INSERTS & HP EXHAUST ELBOWS TO BE COMPLETED.

54 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.

55 CONDITION AFTER R & M OF HPT & IPT (UNDER RATED CONDITION): RATED PARAMETERS: At 100% MCR condition MAIN STEAM FLOW : T/HR MS/ HRH STEAM TEMP:535/535 DEG C MAIN STEAM PR: 150 ATA BACK PR: ATA

56 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 T/HR MAIN STEAM FLOW AND RATED PARAMETERS OUTPUT: MW HEAT RATE: 2067 KCAL/KWH

57 COMPARISON OF PERFORMANCE:

58 PAY BACK PERIOD 1) REDUCTION IN OH PERIOD: 25 DAYS RESULTING TO ADDITIONAL POWER GENERATION FOR 25 DAYS YIELDING TO GUAREENTED MINIMUM ADDITIONAL REVENUE: = 209MW x 1000 x 25DAYS x 24HRS x 0.80PLF x 2.00RS =RS CRORES

59 PAY BACK PERIOD 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 CRORES PER YEAR HENCE, PAY BACK PERIOD < 3 YEARS

60

61 PRESENT EXPECTED CONDITION: OUT PUT = MW (641.3T/HR) THEREFORE, OUT PUT = 210 MW (665.7 T/HR) FOR THIS FLOW : IT IS OPERATING NEAR TO VWO CONDITION WHICH IS NOT DESIRABLE.

62 EXPECTED CONDITION AFTER R&M: OUT PUT = 209 MW (641.3T/HR) THEREFORE, OUT PUT = MW (665.7 T/HR) FOR THIS FLOW : IT WILL BE OPERATING NEAR VWO CONDITION WHICH IS NOT DESIRABLE.


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