Performance of Non-Condensing Steam Turbine by Using Energy and Energy Analysis

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1 Performance of Non-Condening Steam Turbine by Uing Energy and Energy Analyi Mr. K.Lavanya, M.Tech Aitant Profeor, Department of Mechanical Engineering, Sanketika Vidya Parihad Engineering College, P.M.Palem, Viakhapatnam. ABSTRACT: In the exiting cenario mot of electricity produced throughout the world i from team power plant. Coal hare major chunk of fuel ued to produce power in thermal power plant in India. Coal reerve are limited and preent coal conumption rate i in increaing trend to full fill the power demand. Steam turbine i an excellent prime mover to convert heat energy of team to mechanical energy. Of all heat engine and prime mover the team turbine i nearet to the ideal and it i widely ued in power plant and in all indutrie where power i needed for proce. About 80% of electricity generation in the world i done by team turbine. The objective of thi work i to evaluate the performance of non-condening team turbine by uing the energy analyi and energy analyi baed on the firt law of thermodynamic and econd law of thermodynamic repectively. Energy analyi deal with quantity apect wherea energy analyi deal with quality apect in addition to quantity. In thi analyi, energy efficiency, energy detruction, energy efficiency and turbine heat rate are evaluated baed on the requirement of load demand. B.Harikrihna Raju B.E Department of Mechanical Engineering, Sanketika Vidya Parihad Engineering College, P.M.Palem, Viakhapatnam. plant. Coal hare major chunk of fuel ued to produce power in thermal power plant in India. Coal reerve are limited and preent coal conumption rate i in increaing trend to full fill the power demand[1]. Energy analyi conervation tudy i focued on energy efficiency. It i completely baed on firt law of thermodynamic which i normally ued to analyze the energy utilization, but it doen't ue the quality apect of energy. The energy of ytem i defined a the ratio of energy of output to the energy of input to the ytem. Exergy analyi deal with quality and quantity apect of energy. It i completely baed on econd law of thermodynamic. It i a property that enable u to determine the ueful work potential of given amount of energy at ome pecified tate. It can pecify where the proce can be improved and therefore, it will ignify what area hould be given conideration. Exergy provide u with a better undertanding of procee for qualifying energy. Therefore, it would be better to ue exergy to locate, qualify and quantify energy detruction. KEYWORDS: Steam Turbine, Energy, Efficiency, Exergy. INTRODUCTION A team turbine i a mechanical device that convert thermal energy in preurized team into ueful mechanical work. Steam power plant are utilized for power demand in India. Coal i the major ource of energy in thee power Fig 1: Sectional View of Steam Turbine Exergy can play an important role in trategic development of power plant and proviion of ue of intruction in exiting power plant[2,3]. Page 32

2 Non-condening Steam Turbine i a type of team turbine which ue the high preure team for rotation of blade and then the team leave the turbine at the atmopheric preure or lower preure. Thi type of turbine i alo known a back-preure team turbine. The preure outlet team depend on the load. The low preure team ue for proceing and no team i ued for conideration. thee turbine are motly ued in chemical indutry, paper mill and dealination plant etc. Thee turbine act a preure reducing tation and at the ame time provide reliable power for thee plant[4]. In thi team turbine, the team i expanded from inlet and continuouly flow through the outlet. In thi turbine there i no high preure extraction but there i only low preure extraction which i ued for indutrial proce. In thi proce, we don't ue condener o that the remaining team i releaed in atmopheric air. Steam turbine i uually analyzed by energy analyi which ue firt law analyi but better undertanding i attained when a more complete thermodynamic view i taken, which utilize the econd law of thermodynamic in conjunction with energy analyi, via exergy method [5]. Fig 2: Flow Diagram of team turbine Thi tudy i focued on energy and exergy analyi of 6.1 MW Non-Condening team turbine. Therefore the energy efficiency, exergy efficiency and turbine heat rate are evaluated baed on the requirement of load demand[6]. LITERATURE REVIEW A.H.Rana et al.[1] wa propoed on Energy and Exergy Analyi of Extraction cum Back Preure Steam Turbine. In thi analyi, energy efficiency, exergy efficiency, exergy detruction and turbine heat rate are evaluated at 70% and 85% maximum continuou rating (MCR) of team turbine. Analyi how that operating turbine at 85% MCR attract heat rate improvement by 17.01KJ/KWh, which reduce CO 2 emiion by 26.89kg/h, SO 2 emiion by 26.89kg/h and ah generation by kg/day. Turbine exergy efficiency i lower than it energy efficiency a utilization of heat i at lower temperature than inlet. When Turbine MCR i increaed from 70 to 85%, coal conumption i reduced by kg/h and ah handling plant load i reduced by kg/day. CO2 emiion i reduced by kg/h, while SO2 emiion i reduced by 0.62 kg/h. Thu, it i more advantageou to run turbine at higher MCR. Ivenunit rout et al.[2] wa propoed on thermal analyi of team turbine power plant. To improve the power output of the turbine, thermal efficiency and pecific team conumption in conventional team power plant. Three cycle i.e. Regenerative cycle, uper heater cycle and co-generation cycle are conidered to formulate the data and obtain better reult in team turbine power plant. The power output of the turbine wa highet in the co-generation in the team plant a compared to the Regenerative tem plant and uper heater team plant with increae in turbine inlet temperature. The thermal efficiency of uper heater team plant i highet a compared to the regeneration and co-generation team plant with increae in turbine inlet temperature. The pecific team conumption i leat in co-generation team plant a compared to the regenerative and uper heater team plant with the increae in turbine inlet temperature. Finally co-generation team power plant are more efficient a compared to the conventional team power plant. The turbine efficiency improve and the pecific team conumption i low. The low grade wate heat from the proce heater are ued for doing work and alo generate power and electricity. Page 33

3 Pratap more et al.[3] ha been calculated the thermal analyi of energy and exergy of back preure team turbine in ugar co-generation Plant.Energy efficiency, exergy efficiency, exergy detruction, turbine heat rate are evaluated at 70% and 80% MCR(Maximum continuou rating) of back preure team turbine in ugar co-generation plant. Thi analyi how that operating turbine at 85% MCR attract heat rate improvement by kj/kwh. Turbine exergy efficiency i lower than it energy efficiency a utilization of heat i at lower temperature than inlet. Turbine exergy lo i 12.32% and 12.56% at 70% and 85% MCR, there i an improvement oberved in turbine heat rate by 17.01kj/kwh. A.Sudheer Reddy et al.[4]wa explained about Analyi of Steam Turbine. In power generation motly team turbine i ued becaue of it greater thermal efficiency and higher Power-to-weight ratio. Becaue the turbine generate rotary motion, it i particularly uited to be ued to drive an electrical generator about 80% of all electricity generation in the world i by ue of team turbine. In thi project we have mainly dicued about the working proce of a team turbine. The thermal efficiency of a team turbine i much higher than that of a team engine. Thi paper ha attempted to cover ome of the iue related to Steam turbine which a deigner hould be aware of. It i hoped that thi note help a working Engineer have a better inight into the variou apect of the Steam turbine, o that the related iue can be tackled with better knowledge and confidence. Anjali T H et al.[5] ha theoretically experimented about analyi of efficiency at a thermal power plant. The objective of thi work i to ue the energy analyi and exergy analyi baed on the firt law of thermodynamic and econd law of thermodynamic repectively, to identify the location and magnitude of loe in order to maximize the performance of a 15 MW thermal power plant in a paper mill, to evaluate the boiler, turbine and condener efficiencie. The efficiency of component in the power plant i found out by uing energy and exergy calculation. The overall efficiency of thermal power plant very le (13%), then need an energy and exergy analyi in every component. finally the overall efficiency of a thermal power plant i increaed by uing energy and exergy analyi in every component. Dev Kumar Pate let al.[6] ha tudied about how to improve team turbine efficiency by ue of Reheat Rankine Cycle. Thi paper contain the effect of operating condition of turbine, back preure turbine inlet team temperature and advantage of improving inlet team temperature by reheat cycle on the efficiency of team turbine and total energy production of power plant. In thi paper it how impact of operating condition on team turbine. Saving preented are for typical operating condition. Huge benefit can be reaped by optimizing operating parameter, by minor modification and even by replacing old in-efficient turbine. P. RavindraKumar et al.[7]wa propoed on team turbine for power plant unit with uper critical team parameter, thee parameter are conidered by conidering the team turbine loe and pipe loe. The dependence of the efficiency of the unit on the ientropic efficiencie of individual turbine tage i.e. High Preure Turbine (HPT), Intermediate Preure Turbine (IPT), and Low Preure Turbine (LPT) tage in a layout i conidered. The computation how that the efficiency of the turbine plant hould be 49 %, that of the boiler hould be %, and that of the power unit hould be 46%. At the preent time the ue of the meaure mentioned allow the following efficiency of the Turbine: 0.92 for HPT, 0.94 for IPT, and 0.9 for LPT, which correpond to the world level. INDUSTRIAL INVESTIGATION WORKING PROCESS: From the cogeneration plant, the fuel (generally coal of 45TPH) i burnt in a furnace and hot gae are produced. Thee hot gae come in contact with water veel where the heat of thee hot gae tranfer to the water and conequently team i produced in the boiler. A the high preure team coming from the boiler to Page 34

4 the inlet of team turbine which pae through the throttle governing. In thi proce, 505 Woodward governor i ued to control any proce directly related to unit load and it i ued for plant power control and it control the turbine peed & the mechanical throttle governing. The throttle governing i ued for paing the team flow into the turbine. In thi method team i paed through a retricted paage thereby reducing it preure acro the governing valve. The flow rate i controlled uing a partially opened team control valve. There are three throttle governing of 30%, 70% &100%.Firt 30% throttle governing open when it reache to MW. Then 70% throttle governing open when it reache to MW. Then 100% throttle governing open when it reache to MW.When all the throttle valve get open the team will fall on the turbine wheel and the team get decreaed by 50%.The reduction in preure lead to a throttling proce in which the enthalpy of team remain contant. The remaining 50% team pae with high preure into the turbine. High Preure team i ued for rotation of impule turbine blade and the turbine rotate with the peed of 8226rpmand the team flow continuouly to the reaction turbine blade, the flow of team get decreaed contantly. Thu the remaining team backed up which i releaed in atmopheric air (or) end to indutrial proce.thi turbine gauge with preure witch cum tranmitter panel help for meauring the preure value by uing preure gauge and temperature value by digital indicator. When the turbine i in running condition, the preure and temperature value are noted down when it reache to teady tate (For Example: For full load the preure value i 64kg/cm 2 and temperature i 485 o c). In thi proce, the thrut bearing i ued to provide a poitive axial location for the turbine rotor which i relative to the cylinder and journal bearing are ued to retain the rotor ytem in it correct radial poition, relative to the cylinder and it i ued for turbine bearing and lubrication control. In thi proce, the lube oil i ued for lubrication and to reduce the heat loe which are generated by turbine. The lube oil filter i ued for oil purification. In thi proce, Auxiliary Oil Pump i ued for turbine rolling tart-up (for increaing full peed) and it i automatically cloed and Main Oil Preure take over it. The Main oil pump (MOP) i the one that deliver all the oil requirement for the turbinegenerator at high preure during normal operation. It pae the lubrication oil to the lube oil cooler and the lube oil filter then pae the oil to turbine front and thrut bearing and then to the rear bearing and to the gear box and to the alternator front and rear bearing. When the bearing doen t receive lubrication oil in time to run the turbine in that cae we ue the Emergency oil pump. Emergency oil pump (EOP) run on the battery for 20min.It ha a over head tank of 2000 litre. After running the turbine for certain amount of time, the lube oil which i ued in the turbine proce i collected back and end to oil cooler for oil temperature reduction. After cooling proce i done the lube oil i ued again for turbine proce. The Accumulator i ued to control the oil preure for maintaining contant preure and it ha nitrogen ga of 10kg. The turbine haft which i connected to the gear box in which the preure and kinetic energy i converted into mechanical energy then the gear box which i connected to the generator it convert the mechanical energy into electrical energy. Fig 3: Non-condening Steam Turbine DATA OF STEAM TURBINE Data i taken from different load of non-condening team turbine working at Hetero Infratructure Sez LTD., Nakkapally(mandal), viakhapatnam (ditrict),a.p. Page 35

5 TABLE 1: STEAM DATA AT INLET TABLE 2: STEAM DATA AT EXHAUST ASSUMPTIONS: Ambient temperature and preure are taken a 30 o c and 1.013bar There i no team lo acro team turbine. Gear box efficiency a per manufacturer i 98.40% Generator efficiency a per manufacture i 98.03% Exhaut team from the turbine i utilied for further proce in the indutry. STEAM TURBINE SPECIFICATIONS Manufacturer: Triveni Turbine Model Type: TST-1060-SB-037 MAIN STEAM FLOW: 45TPH Normal team preure: 64 kg/cm 2 Normal Steam Temperature: 495 o c Normal Exhaut Preure: 5.1 kg/cm 2 Normal Exhaut Temperature:270 o c Number of tage: (1+5)/ (Impule + Reaction) Governor Manufacturer: Woodward Governor Type: Electric & Hydraulic. ANALYSIS MODEL CALCULATIONS FOR LOAD OF 2.6MW: A) ENERGY ANALYSIS: 1) Energy input at entry: E i = m i h i E i = E i = KJ 2) Energy output of heat exhauted: E o = m ext h ext E o = E o = KJ 3) Work done i equal to the energy in team at entry to turbine minu team at exit: W. D = E i E o W. D = W. D = KW 4) Actual Power Develop by Turbine Shaft: Generator power P = η gearbox η generator 3500 P = P = KW 5) Energy Efficiency (1t Law of efficiency) of turbine: η I Actual Power Develop by Turbine Shaft = (E in E out ) η I = η I = or 65.06% 6) Heat rate of turbine: Net Heat Input H. R = Turbine Power H. R = (E in E out ) H. R = H. R = KJ KWh Page 36

6 ENERGY EFFICIENCY OF TURBINE (%) EXERGY EFFICIENCY OF TURBINE (%) HEAT RATE OF TURBINE(KJ/KWh) B) EXERGY ANALYSIS: 1) Exergyinput: ψ in = m h T o ψ in = ψ in = KJ 2) Exergy out: ψ out = m h exh T o ex h ψ out = ψ out = KJ 3) Exergy detruction in turbine: ψ de = ψ in ψ out ψ power ψ de = ψ de = KJ 4) Exergy Efficiency (2nd Law of efficiency) of turbine: ψ power η = ψ in ψ out η = η = or 55.28% GRAPHICAL REPRESENTATION LOAD 4.4 (MW) Fig 5: Graph between Load and Heat rate of Turbine LOAD (MW) Fig 6: Graph between Load and Exergy Efficiency of Turbine RESULTS AND DISCUSSIONS TABLE 3: FINAL DATA OF ENERGY ANALYSIS LOAD (MW) TABLE 4: FINAL DATA OF EXERGY ANALYSIS: Fig 4: Graph between Load and Energy Efficiency of Turbine Page 37

7 Experimental reult how that power load on the team turbine increae at different load Turbine energy and exergy efficiency increae at different load. The exergy efficiency i lower than the energy efficiency at different load. Thi mainly due to thermal product, which i higher than electrical power, i delivered at a lower temperature. There i an improvement oberved in the turbine that the turbine heat i rate i reduced and efficiency of the turbine increae. CONCLUSION Hence in the overall project we have worked on the performance of non-condening team turbine uing energy and exergy analyi. Therefore the energy efficiency, exergy efficiency and turbine heat rate are evaluated baed on the requirement of load demand. Turbine exergy efficiency i lower than the energy efficiency a utilization of heat i at lower temperature than inlet. Therefore thi turbine efficiency increae for different load. Thu the heat rate of turbine reduce to give better output to the turbine. Thi type of turbine give better efficiency than other turbine. It i more advantageou to run the turbine in different environmental condition. ACKNOWLEDGEMENT The upport for thi work provided by Shri S.Kullayi Reddy,General Manager,Hetero Lab Ltd of Hetero infratructure Sez Ltd, N.Narapuram, Nakkapalli Mandal, Viakhapatnam Ditrict, Andhra Pradeh (India) i gratefully acknowledged. Thi i to certify the teaching and Non-teaching of Department of Mechanical Engineering, Sanketika Vidya Parihad Engineering College, P.M.Palem, Viakhapatnam, Andhra Pradeh for their valuable upport and encourgement. REFERENCES [01] A. H. Rana, J. R. Mehta, Energy and Exergy analyi of extraction cum back preure team turbine, International Journal of Modern Engineering Reearch (IJMER), PP , (2013). [02] Ivan Sunit Rout, Abhihek Gaikwad, Vinod kumar verma, Mohammad Tariq, Thermal Analyi of Steam power plant, IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE), PP 28-36, (2013). [03] Pratap S More, Prof. Azim Aijaz, Thermal analyi of energy and exergy of back preure team turbine in ugar cogeneration plant, International Journal of Emerging Technology and Advanced Engineering (IJETAE), PP ,(2014). [04] A.Sudheer reddy, MD.Imran Ahmed, T.Sharath Kumar, A.Vamhi Krihna Reddy and V.V.Prathibha Bharathi, Analyi of Steam Turbine, International Referred Journal of Engineering and Science (IRJES),PP 32-48,(2014). [05] Anjali T H, Dr.G.Kalivarathan, Analyi of efficiency at a thermal power plant, International Reearch Journal of Engineering and Technology (IRJET), PP , (2015). [06] Dev Kumar Patel, Improve Steam Turbine Efficiency by ue of Reheat Rankine Cycle, International Journal of Engineering Science & Reearch Technology (IJESRT), PP ,(2015). [07] P.Ravindra Kumar, Huain haik, P.Aruna and J.Subba Reddy, Steam Turbine for Power Plant unit with Supercritical Steam Parameter, International Reearch Journal of Engineering and Technology (IRJET),PP ,(2015). [08] R k Rajput, Thermal engineering, 8th edition, laxmi publication (p) ltd. [09] PK Nag, Engineering Thermodynamic. Page 38

8 [10] R S Khurmi, J K Gupta, Thermal engineering, 15th edition. [11] R.Yadav, Steam Turbine and Ga Turbine and Power Plant Engineering. [12] Heinz P.Bloch, Murari P.Singh, Steam Turbine Deign, Application and Rerating. Page 39

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