2005 ASME Power Conference Performance Considerations in Replacement of Low Pressure Turbine Rotors...
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Transcript of 2005 ASME Power Conference Performance Considerations in Replacement of Low Pressure Turbine Rotors...
Objectives • Examine Design, Performance
& Test Considerations • Use of Performance Tool in
Evaluating Performance Gains • Recommendations for
Ensuring Objectives of LP Turbine Rotor Replacement Programs are Met
Background • Majority of U.S. Turbines
Originally GE or Westinghouse • 104 Turbines - 56 GE, 44
Westinghouse, 3 Siemens and 1 BBC
• LSB - 38” or 43” for GE, 40” or 44” for Westinghouse/Siemens, 52” for BBC
Table 1
1 Westinghouse TC4F-44" LSB 888,315 6,416,567 495.2 12,958 103%2 Westinghouse TC4F-44" LSB 888,315 6,416,567 495.2 12,958 103%1 Westinghouse TC6F-44" LSB 1,085,391 7,565,329 742.8 10,185 81%2 Westinghouse TC6F-44" LSB 1,085,391 7,565,329 742.8 10,185 81%1 General Electric TC4F-43" LSB 849,206 5,583,138 495.2 11,275 89%2 General Electric TC4F-43" LSB 849,206 5,583,138 495.2 11,275 89%1 Westinghouse TC6F-44" LSB 1,085,391 7,565,329 742.8 10,185 81%2 Westinghouse TC6F-44" LSB 1,085,391 7,565,329 742.8 10,185 81%1 General Electric TC6F-38" LSB 883,053 5,997,306 634.2 9,456 75%2 Westinghouse TC6F-40" LSB 877,967 5,869,854 634.2 9,256 73%1 General Electric TC6F-43" LSB 1,205,091 7,903,237 742.8 10,640 84%2 General Electric TC6F-43" LSB 1,205,091 7,903,237 742.8 10,640 84%1 Siemens TC4F-44" LSB 1,160,706 7,960,473 495.2 16,075 ------2 Siemens TC4F-44" LSB 1,160,706 7,960,473 495.2 16,075 ------
8 Westinghouse TC4F-44" LSB 800,838 5,608,615 495.2 11,326 90%1 General Electric TC6F-43" LSB 1,089,095 7,686,079 742.8 10,347 82%2 Brown Boveri TC6F-52" LSB 1,178,674 8,348,511 1055.0 7,913 ------
Plant
5
6
7
9
1
2
3
4
Total LPT Exhaust
Annulus Area, sq.ft.
LPT Exhaust End Loading,
lb/hr/sq.ft
Total LPT Exhaust Steam
Flow, lb/hrRating, KwType
Unit No.
Original Main Turbine Data
%End LoadingManufacturer
Background (contd.) • Usual Arrangement one HP
and Two or Three LP in Tandem
• LP Accounts for Bulk of Total Output with About 10% From Last Stage
Background (contd.) • Performance of LP Turbine
–Initial & Final Conditions –Slope & Shape of Expansion Line
–Moisture Removal Zones Effectiveness
–Exhaust Losses
Background (contd.) • Exhaust Losses
–Leaving Loss –Hood Loss
• Charged to Last Stage • End Loading (Flow/Annulus
Area) Critical Consideration in Operating Range/Losses
Background (contd.) • End Loading About 13,000
Lb/Hr/Sq.Ft. • Best Performance Close to
Choke Point (Max. Flow) • Higher End Loading
–Higher Losses –Narrower Useful Operating Range
Background (contd.) • LP Rotors Classification:
–Fully Integral (U.S., European) –Shrunk-on Disk (U.S., European)
–Welded Fabrication (BBC) • Since 1980’s, Solid
Monoblock Popular
Background (contd.) • Advantages Cited:
–Elimination of SCC –Reduced
Inspection/Maintenance –Improved Efficiencies –Integrally Shrouded Blades –Free-Standing, Longer LSB –End Loadings up to 18,000
Lb/Hr/Sq.Ft.
Fig. 3 – Original LP Rotors Thermal Kit Heat Balance
NSSS THERMAL POWER = 3423.01 MWTGENERATOR OUTPUT = 1162.43 MW
0 W1197.52 H
155,056 W 14,258,423 W162.87 P 370 W 765.00 P
1264.18 H 1197.52 H 1197.52 H0.40%M
10,440,812 W 11,054 W1264.18 H 1197.52 H
2.00 IN.HGA EFF. = 77.00 %995.70 H 14,865,549 W
PB = 722.93 805.00 P P1STG = 575.12 1197.52 H H1STG = 1180.64 0.25%M DELP = 5.50%
16,745 W PB = 165.23 2,846 W 2,846 W1166.74 H 1106.95 H 1106.95 H
337 W 337 W7,262 W 1032.13 H 1056.78 H 1087.89 H 155,056 W 1106.95 H 1106.95 H
1166.74 H 1048.63 H 1070.50 H 1097.60 H 1155.88 H 1155.88 H168.61 P 1156.98 H 1156.98 H
3.06 P 6.45 P 13.60 P 36.38 P 81.88 P 484.84 F 180.96 P 392.79 P 392.79 P 180.96 P7,890,612 W 16,745 W 1264.18 H
ELEP = 977.95 H 596,072 W 753.98 P 596,072 W TEP = 999.09 H TD = 25.00 F
2STG. RHTR. 743.43 P 0 W 596,072 W142,124 W 171.17 P 509.84 F 1197.52 H 499.69 h
110.20 h 415.96 F Blowdown60,629 W 16,745 W 1224.92 H 413,020 W 390.82 P 0 W
CWT = 61.45 F 1048.63 H 98,442 W 1166.74 H TD = 25.00 F 411.83 h HWT = 75.24 F 1.50 IN.HGA 0 W 176.24 h 0 W 1STG. RHTR. 385.35 P 413,020 W
TR = 13.79 F 347,867 W 1166.74 H 173.78 P 440.96 F 0 W 420.10 h GPM = 1,110,000 0 W Makeup 131,251 W 1097.60 H 520,142 W 1196.20 H 499.69 h
CF = 85.00 % 91.72 F 141.21 h 1149.90 H 179.15 P 1,009,092 W672,739 W 586,489 W 1106.95 H 0 W 467.12 h1070.50 H 1207.74 H MSEFF = 100.00 % 10.48 %M 21,418 W 1,156,867 W
250.00 P 1,240,033 W 824,482 W 422.18 h 1156.98 H 373.72 P59.74 h 6.32 P 13.41 P 33.81 P 77.78 P 176.20 P 171.44 P TD = 5.00 F
8,306 W TD = 5.00 F TD = 5.00 F TD = 5.00 F TD = 5.00 F 344.33 h TD = 5.00 F10,613,657 W 250.00 P 1099.02 P 14,865,549 W
10,613,657 W 91.83 F 167.31 F 202.40 F 252.25 F 305.10 F 364.11 F 365.51 F 366.99 F 433.00 F59.74 h 60.51 h 172.31 F 135.86 h 207.40 F 171.04 h 257.25 F 221.33 h 310.10 F 275.30 h 369.11 F 336.78 h 338.26 h 341.06 h 438.00 F 411.83 h
DC = 10.0 F DC = 10.0 F DC = 10.0 F DC = 10.0 F DC = 10.0 F178.20 h 25,590 W 369.11 F
2,365,236 W 2,356,930 W 1,552,941 W 1,106,631 W 586,489 W 341.96 h101.83 F 177.31 F 212.40 F 262.25 F 2,187,376 W69.84 h 145.32 h 180.61 h 231.14 h 376.99 F
350.61 h4,251,892 W 4,251,892 W
341.96 h 250.00 P341.96 h
X
TV CV TV
S
GC
FPT
TVRSV
A
CONDENSER
TANK
T
STM.HTG.
FP
LP TURBINE
REGULATOR
CP
HTR.21 HTR.22 HTR.23 HTR.24
N T
HTR.25
MOIST.SEP.
HP TURBINE
M
N
HTR.26
M
N
W W
S
M H
H
X
X A
STEAMGENERATOR
DP
Original LP Rotors • From Fig. 3:
–LSB 44” –Annulus Area 127.4 Sq.Ft. –Total Exhaust Flow 7,890,612 Lb/Hr –Exhaust Flow Per End =
7,890,612÷6 = 1,315,102 Lb/Hr –Maximum Design Exhaust Flow =
1,560,000 Lb/Hr (Fig. 2) –End Loading = 1,315,012/1,560,000
= 84%
Original LP Rotors (contd.) • From Fig. 3:
–Annulus Velocity = 1123 Fps –Exhaust Loss = 21.1 Btu/lb –HP Shaft Output = 359,763 Kw –LP Shaft Output = 821,047 Kw
= 70% of Total • Design Heat Balance Fig. 4
–Uses Thermal Kit/Design Data –Developed Using Performance
Tool
Fig. 4 – Original LP Rotors Design Heat Balance
0 W 0 W745.11 P 1197.52 H
1197.52 H14,236,296 W
144,230 W 370 W 765.00 P161.91 P 1197.52 H 1197.52 H
1264.13 H 0.40%M10,465,299 W 11,063 W
1264.13 H 1197.52 H
2.00 IN.HGA EFF. = 77.00 %995.94 H 14,842,360 W
PB = 722.48 805.00 P P1STG = 574.24 1197.52 H H1STG = 1180.54 0.25%M DELP = 5.56%
16,744 W PB = 165.62 2,841 W 2,841 W1166.82 H 1107.04 H 1107.04 H
144,230 W 337 W 337 W7,262 W 1032.17 H 1056.84 H 1087.62 H 1264.13 H 1107.04 H 1107.04 H
1166.82 H 1048.67 H 1070.56 H 1097.38 H 1156.03 H 1156.03 H169.00 P 1157.13 H 1157.13 H
3.07 P 6.47 P 13.57 P 36.43 P 82.09 P 484.84 F 181.39 P 393.76 P 393.76 P 181.39 P7,914,791 W 16,744 W 1264.13 H
ELEP = 977.83 H TEP = 999.10 H 142,559 W 595,002 W 753.98 P 595,002 W
110.33 h TD = 25.00 F60,815 W 743.42 P 0 W 595,002 W
1048.67 H 171.57 P 509.84 F 1197.52 H 499.69 h8,306 W 8,306 W 16,744 W 416.20 F 0 W
CWT = 61.40 F 178.20 h 1163.34 H 98,971 W 1166.82 H 1225.00 H 414,216 W 391.79 P 342.67 h HWT = 75.21 F 1.50 IN.HGA W 176.13 h 533,424 W W TD = 25.00 F
TR = 13.80 F 377,694 W 1149.85 H 1166.82 H 386.30 P 414,216 W GPM = 1,110,000 0 W 130,943 W 1097.38 H 174.19 P 441.20 F 420.37 h
CF = 85.00 % 91.72 F 141.35 h 585,183 W 1196.23 H 179.57 P 1,009,218 W630,400 W 1207.77 H 1107.04 H 467.14 h 0 W
253,781 W 1070.56 H MSEFF = 100.00 % 10.47%M 841,754 W 21,348 W 1,101,743 W 510.68 h484.70 P 1,240,981 W 1107.04 H 0 W 422.45 h 1157.13 H
61.54 h 176.61 P 499.69 h344.53 h 0 W
158,888 W 177,808 W 195,061 W 280,585 W 342.67 h374,363 W
6.34 P 13.38 P 33.86 P 77.98 P 171.84 P 374.64 PTD = 8.21 F TD = 5.31 F TD = 4.16 F TD = 4.39 F TD = 3.39 F 7,942 W TD = 6.27 F
1196.17 H3,542,439 W 3,542,439 W 3,542,439 W 3,542,439 W 3,542,439 W 3,542,439 W 3,542,439 W 4,947,453 W 4,947,453 W
92.24 F 172.44 F 164.23 F 207.30 F 201.98 F 201.84 F 257.33 F 253.18 F 310.28 F 305.89 F 365.90 F 384.70 P 1007.20 P 368.65 F 438.24 F 431.97 F61.54 h DC = 8.64 F 133.23 h DC = 12.46 F 171.01 h 171.01 h DC = 9.11 F 222.60 h DC = 9.2 F 276.38 h 338.87 h 10,627,317 W 367.03 F 368.65 F 342.67 h DC = 8.31 F 410.60 h
365.90 F 340.06 h 342.67 h785,539 W 531,758 W 176.69 F 372,869 W 210.95 F 195,061 W 262.33 F 0 W 288,527 W 369.29 F 338.87 h 0 W
100.88 F 68.87 h 144.68 h 179.11 h 231.13 h 342.16 h0 W 0 W 0 W 0 W 413,660 W 710,770 W 376.96 F 14,842,360 W
253,781 W 158,888 W 177,808 W 195,061 W 280,585 W 350.33 h 374,363 W 336,406 W 431.97 F6.34 P 13.38 P 10,627,317 W 33.86 P 77.98 P 171.84 P 0 W 374.64 P 410.60 h
TD = 8.21 F TD = 5.31 F 201.84 F TD = 4.16 F TD = 4.39 F TD = 3.39 F 7,942 W 1,405,014 W 384.70 P TD = 6.27 F171.01 h 1196.17 H 369.29 F 369.86 F
3,542,439 W 3,542,439 W 3,542,439 W 3,542,439 W 3,542,439 W 3,542,439 W 3,542,439 W 342.16 h 343.06 h 4,947,453 W 4,947,453 W92.24 F 172.44 F 164.23 F 207.30 F 201.98 F 201.84 F 257.33 F 253.18 F 310.28 F 305.89 F 365.90 F 384.70 P 1007.20 P 368.65 F 438.24 F 431.97 F61.54 h DC = 8.64 F 133.23 h DC = 12.46 F 171.01 h 171.01 h DC = 9.11 F 222.60 h DC = 9.2 F 276.38 h 338.87 h 367.03 F 368.65 F 342.67 h DC = 8.31 F 410.60 h
340.06 h 342.67 h785,539 W 531,758 W 176.69 F 372,869 W 210.95 F 195,061 W 262.33 F 0 W 288,527 W 369.29 F 0 W
100.88 F 68.87 h 144.68 h 179.11 h 231.13 h 342.16 h 710,770 W 376.96 F0 W 253,781 W 0 W 0 W 0 W 413,660 W 350.33 h 336,406 W
158,888 W 177,808 W 195,061 W 280,585 W 1,405,014 W 0 W 374,363 W6.34 P 13.38 P 33.86 P 77.98 P 171.84 P 369.29 F 374.64 P
TD = 8.21 F TD = 5.31 F TD = 4.16 F TD = 4.39 F TD = 3.39 F 7,942 W 342.16 h TD = 6.27 F1196.17 H 384.70 P
3,542,439 W 3,542,439 W 3,542,439 W 3,542,439 W 3,542,439 W 3,542,439 W 3,542,439 W 369.86 F 4,947,453 W 4,947,453 W92.24 F 172.44 F 164.23 F 207.30 F 201.98 F 201.84 F 257.33 F 253.18 F 257.33 F 305.89 F 365.90 F 343.06 h 368.65 F 438.24 F 431.97 F61.54 h DC = 8.64 F 133.23 h DC = 12.46 F 171.01 h 171.01 h DC = 9.11 F 222.60 h DC = 9.15 F 276.38 h 338.87 h 342.67 h DC = 8.31 F 410.60 h
0 W785,539 W 531,758 W 176.69 F 372,869 W 210.95 F 195,061 W 262.33 F 0 W 288,527 W 369.29 F 342.16 h
100.88 F 68.87 h 144.68 h 179.11 h 231.13 h 413,660 W 710,770 W 376.96 F0 W 0 W 0 W 0 W 350.33 h
1,405,014 W 384.70 P 0 W369.29 F 369.86 F342.16 h 343.06 h
S
HDP
TO COND.
TO COND.
TO COND.TO COND.
TO COND.TO COND.
TO COND.
TANK2B
TANK2C
TANK2A
SG BLOWDOWN
BYPASS BYPASSBYPASS
Y
TV CV TV
S
FPT
TVRSV
CONDENSER
T
FP
LP TURBINE
REGULATOR
CP
HTR.21A HTR.22A HTR.23A HTR.24A
MOIST.SEP.
HP TURBINE
HTR.26A
M
N
W
M H
H
X
X A
STEAMGENERATOR
W
A N T
HTR.21B HTR.22B HTR.23B HTR.24B
GSC
HTR.21C HTR.22C HTR.23C HTR.24C
COND. DEMIN.
HTR.25A
HTR.25B
HTR.25C
FP
HTR.26B
HTR.26C
Y
FROM FP
TO MSCDT
SG BLOWDOWN
1STG.RHTR.
2STG.RHTR.
LP EXHAUST
HDP
N
M
TO COND.
TO COND.
TO COND. TO COND.
TO COND.
TO COND.
TO COND.
TO COND.
TO COND.
TO COND.
TO COND.
FPT EXHAUST
HDP
Fig. 5 – Replacement LP Rotors Thermal Kit Heat Balance
0 W1197.53 H
154,030 W 14,064,720 W159.96 P 409 W 765.00 P
1264.36 H 1197.53 H 1197.53 H0.40%M
10,409,998 W 11,307 W1264.36 H 1197.53 H
2.00 IN.HGA EFF. = 77.00 %996.65 H 14,726,960 W
PB = 718.83 805.00 P P1STG = 548.55 1197.53 H H1STG = 1179.10 0.25%M DELP = 6.03%
17,006 W PB = 163.62 2,849 W 2,849 W1166.93 H 1106.21 H 1106.21 H
337 W 337 W7,536 W 1024.01 H 1049.91 H 1083.28 H 154,030 W 1106.21 H 1106.21 H
1166.93 H 1041.60 H 1064.62 H 1093.72 H 1152.37 H 1152.37 H166.96 P 1153.53 H 1153.53 H
2.72 P 5.91 P 13.22 P 35.55 P 79.39 P 484.84 F 179.20 P 367.24 P 367.24 P 179.20 P7,865,072 W 17,005 W 1264.36 H
ELEP = 977.51 H 650,933 W 753.98 P 650,933 W TEP = 995.21 H TD = 25.00 F
2STG. RHTR. 743.43 P 0 W 650,933 W151,655 W 169.50 P 509.84 F 1197.53 H 499.69 h
105.64 h 409.49 F Blowdown60,508 W 17,006 W 1221.36 H 361,028 W 365.41 P 0 W
CWT = 61.72 F 1041.60 H 105,758 W 1166.93 H TD = 25.00 F 404.44 h HWT = 75.41 F 1.50 IN.HGA 0 W 174.83 h 0 W 1STG. RHTR. 360.29 P 361,028 W
TR = 13.69 F 373,420 W 1166.93 H 172.09 P 434.49 F 0 W 412.89 h GPM = 1,110,000 0 W Makeup 140,135 W 1093.72 H 514,486 W 1196.05 H 499.69 h
CF = 85.00 % 91.72 F 137.40 h 1144.59 H 177.41 P 1,011,961 W626,473 W 581,960 W 1106.21 H 0 W 468.73 h1064.62 H 1203.50 H MSEFF = 100.00 % 10.54 %M 21,996 W 1,021,994 W
250.00 P 1,244,302 W 844,592 W 414.93 h 1153.53 H 348.23 P61.14 h 5.79 P 13.12 P 32.84 P 75.49 P 174.48 P 170.19 P TD = 5.00 F
8,619 W TD = 5.00 F TD = 5.00 F TD = 5.00 F TD = 5.00 F 343.48 h TD = 5.00 F10,582,115 W 250.00 P 1096.00 P 14,726,960 W
10,582,117 W 93.26 F 163.54 F 201.32 F 250.56 F 303.05 F 363.51 F 364.90 F 366.38 F 426.25 F61.14 h 61.94 h 168.54 F 132.08 h 206.32 F 169.95 h 255.56 F 219.62 h 308.05 F 273.19 h 368.51 F 336.16 h 337.61 h 340.41 h 431.25 F 404.44 h
DC = 10.0 F DC = 10.0 F DC = 10.0 F DC = 10.0 F DC = 10.0 F178.20 h 23,798 W 368.51 F
2,350,851 W 2,342,232 W 1,575,624 W 1,096,445 W 581,960 W 341.33 h103.26 F 173.54 F 211.32 F 260.56 F 2,055,950 W71.27 h 141.53 h 179.52 h 229.41 h 376.38 F
349.93 h4,144,845 W 4,144,845 W
341.33 h 250.00 P341.33 h
X
TV CV TV
S
GC
FPT
TVRSV
A
CONDENSER
TANK
T
STM.HTG.
FP
LP TURBINE
REGULATOR
CP
HTR.21 HTR.22 HTR.23 HTR.24
N T
HTR.25
MOIST.SEP.
HP TURBINE
M
N
HTR.26
M
N
W W
S
M H
H
X
X A
STEAMGENERATOR
DP
Replacement LP Rotors • From Fig. 5:
–LSB 47” –Annulus Area 139.18 Sq.Ft/End –Annulus Velocity = 1024 Fps –Exhaust Loss = 17.7 Btu/lb –HP Shaft Output = 361,668 Kw –LP Shaft Output = 838,937 Kw –Increase in LP Shaft Output = 18
Mw
Fig. 6 – Replacement LP Rotors Design Heat Balance
0 W 0 W745.11 P 1197.53 H
1197.53 H14,055,918 W
143,160 W 409 W 765.00 P160.28 P 1197.53 H 1197.53 H
1264.32 H 0.40%M10,432,599 W 11,311 W
1264.32 H 1197.53 H
2.00 IN.HGA EFF. = 77.00 %996.53 H 14,716,904 W
PB = 718.63 805.00 P P1STG = 548.23 1197.53 H H1STG = 1179.10 0.25%M DELP = 6.06%
17,006 W PB = 163.95 2,847 W 2,847 W1166.95 H 1106.20 H 1106.20 H
143,160 W 337 W 337 W7,536 W 1023.99 H 1049.91 H 1083.05 H 1264.32 H 1106.20 H 1106.20 H
1166.95 H 1041.59 H 1064.62 H 1093.52 H 1152.52 H 1152.52 H167.30 P 1153.68 H 1153.68 H
2.73 P 5.92 P 13.19 P 35.58 P 79.58 P 484.84 F 179.56 P 368.21 P 368.21 P 179.56 P7,877,284 W 17,004 W 1264.32 H
ELEP = 977.41 H TEP = 995.17 H 151,954 W 649,675 W 753.98 P 649,675 W
105.70 h TD = 25.00 F60,603 W 743.42 P 0 W 649,675 W
1041.59 H 169.84 P 509.84 F 1197.53 H 499.69 h8,619 W 8,619 W 17,006 W 409.74 F 0 W
CWT = 61.76 F 28.06 h 1163.65 H 106,190 W 1166.95 H 1221.46 H 362,395 W 366.37 P 341.96 h HWT = 75.43 F 1.50 IN.HGA 0 W 174.72 h 530,599 W 0 W TD = 25.00 F
TR = 13.68 F 399,648 W 1144.56 H 1166.95 H 361.24 P 362,395 W GPM = 1,110,000 0 W 139,867 W 1093.52 H 172.43 P 434.74 F 413.17 h
CF = 85.00 % 91.72 F 137.46 h 580,659 W 1196.08 H 177.76 P 1,012,070 W595,265 W 1203.57 H 1106.20 H 468.71 h 0 W
245,044 W 1064.62 H MSEFF = 100.00 % 10.54%M 864,371 W 21,937 W 978,099 W 510.68 h484.70 P 1,246,580 W 1106.20 H 0 W 415.21 h 1153.68 H
61.54 h 174.83 P 499.69 h343.65 h 0 W
168,613 W 176,866 W 193,553 W 288,124 W 341.96 h333,345 W
5.80 P 13.09 P 32.87 P 75.66 P 170.53 P 349.15 PTD = 7.95 F TD = 5.62 F TD = 4.14 F TD = 4.36 F TD = 3.44 F 6,184 W TD = 5.66 F
1196.06 H3,531,283 W 3,531,283 W 3,531,283 W 3,531,283 W 3,531,283 W 3,531,283 W 3,531,283 W 4,905,635 W 4,905,635 W
92.24 F 168.60 F 160.65 F 206.21 F 200.59 F 200.45 F 255.61 F 251.47 F 308.21 F 303.85 F 365.23 F 384.70 P 1007.20 P 367.97 F 431.50 F 425.84 F61.54 h DC = 8.22 F 129.66 h DC = 13.38 F 169.61 h 169.61 h DC = 8.98 F 220.87 h DC = 9.0 F 274.28 h 338.17 h 10,593,848 W 366.36 F 367.97 F 341.96 h DC = 6.86 F 403.90 h
365.23 F 339.35 h 341.96 h784,076 W 539,032 W 174.03 F 370,419 W 209.43 F 193,553 W 260.48 F 0 W 294,308 W 368.68 F 338.17 h 0 W
100.46 F 68.46 h 142.01 h 177.57 h 229.24 h 341.50 h0 W 0 W 0 W 0 W 415,527 W 670,702 W 374.83 F 14,716,904 W
245,044 W 168,613 W 176,866 W 193,553 W 288,124 W 348.05 h 333,345 W 337,357 W 425.84 F5.80 P 13.09 P 10,593,848 W 32.87 P 75.66 P 170.53 P 0 W 349.15 P 403.90 h
TD = 7.95 F TD = 5.62 F 200.45 F TD = 4.14 F TD = 4.36 F TD = 3.44 F 6,184 W 1,374,352 W 384.70 P TD = 5.66 F169.61 h 1196.06 H 368.68 F 369.24 F
3,531,283 W 3,531,283 W 3,531,283 W 3,531,283 W 3,531,283 W 3,531,283 W 3,531,283 W 341.50 h 342.41 h 4,905,635 W 4,905,635 W92.24 F 168.60 F 160.65 F 206.21 F 200.59 F 200.45 F 255.61 F 251.47 F 308.21 F 303.85 F 365.23 F 384.70 P 1007.20 P 367.97 F 431.50 F 425.84 F61.54 h DC = 8.22 F 129.66 h DC = 13.38 F 169.61 h 169.61 h DC = 8.98 F 220.87 h DC = 9.0 F 274.28 h 338.17 h 366.36 F 367.97 F 341.96 h DC = 6.86 F 403.90 h
339.35 h 341.96 h784,076 W 539,032 W 174.03 F 370,419 W 209.43 F 193,553 W 260.48 F 0 W 294,308 W 368.68 F 0 W
100.46 F 68.46 h 142.01 h 177.57 h 229.24 h 341.50 h 670,702 W 374.83 F0 W 245,044 W 0 W 0 W 0 W 415,527 W 348.05 h 337,357 W
168,613 W 176,866 W 193,553 W 288,124 W 1,374,352 W 0 W 333,345 W5.80 P 13.09 P 32.87 P 75.66 P 170.53 P 368.68 F 349.15 P
TD = 7.95 F TD = 5.62 F TD = 4.14 F TD = 4.36 F TD = 3.44 F 6,184 W 341.50 h TD = 5.66 F1196.06 H 384.70 P
3,531,283 W 3,531,283 W 3,531,283 W 3,531,283 W 3,531,283 W 3,531,283 W 3,531,283 W 369.24 F 4,905,635 W 4,905,635 W92.24 F 168.60 F 160.65 F 206.21 F 200.59 F 200.45 F 255.61 F 251.47 F 255.61 F 303.85 F 365.23 F 342.41 h 367.97 F 431.50 F 425.84 F61.54 h DC = 8.22 F 129.66 h DC = 13.38 F 169.61 h 169.61 h DC = 8.98 F 220.87 h DC = 9.00 F 274.28 h 338.17 h 341.96 h DC = 6.86 F 403.90 h
0 W784,076 W 539,032 W 174.03 F 370,419 W 209.43 F 193,553 W 260.48 F 0 W 294,308 W 368.68 F 341.50 h
100.46 F 68.46 h 142.01 h 177.57 h 229.24 h 415,527 W 670,702 W 374.83 F0 W 0 W 0 W 0 W 348.05 h
1,374,352 W 384.70 P 0 W368.68 F 369.24 F341.50 h 342.41 h
S
HDP
TO COND.
TO COND.
TO COND.TO COND.
TO COND.TO COND.
TO COND.
TANK2B
TANK2C
TANK2A
SG BLOWDOWN
BYPASS BYPASSBYPASS
Y
TV CV TV
S
FPT
TVRSV
CONDENSER
T
FP
LP TURBINE
REGULATOR
CP
HTR.21A HTR.22A HTR.23A HTR.24A
MOIST.SEP.
HP TURBINE
HTR.26A
M
N
W
M H
H
X
X A
STEAMGENERATOR
W
A N T
HTR.21B HTR.22B HTR.23B HTR.24B
GSC
HTR.21C HTR.22C HTR.23C HTR.24C
COND. DEMIN.
HTR.25A
HTR.25B
HTR.25C
FP
HTR.26B
HTR.26C
Y
FROM FP
TO MSCDT
SG BLOWDOWN
1STG.RHTR.
2STG.RHTR.
LP EXHAUST
HDP
N
M
TO COND.
TO COND.
TO COND. TO COND.
TO COND.
TO COND.
TO COND.
TO COND.
TO COND.
TO COND.
TO COND.
FPT EXHAUST
HDP
Table 3 Comparison of LP 10,465,299 10,432,599
165.62 163.951264.13 1264.32585,183 580,659
82.09 79.581207.77 1203.57
0.4956661 0.48538341856.36 60.76
5.899E+08 6.338E+089,880,115 9,851,940
533,424 530,59936.43 35.58
1149.85 1144.569,346,692 9,321,342
0.4437778 0.44707383257.916602 59.00663225.722E+08 5.813E+08
377,694 399,64813.57 13.19
1087.62 1083.0598,971 106,190176.13 174.72
1097.38 1093.520.3724004 0.370675533
62.23 61.515.816E+08 5.734E+088,870,026 8,815,503
LP Turbine
LP Bowl Flow, lb/hrLP Bowl Pressure, psiaLP Bowl Enthalpy, btu/lbExt. 3 Flow, lb/hrExt. 3 Pressure, psiaExt. 3 Enthalpy, btu/lbExt. 3 Press/LP Bowl Press.Work Done Per lb of SteamWork Done, btu/hrFFS3, lb/hrExt. 4 Flow, lb/hrExt. 4 Pressure, psiaExt. 4 Enthalpy, btu/lbFFS4, lb/hrExt. 4 Press/Ext. 3 Press.Work Done Per lb of SteamWork Done, btu/hrExt. 5 Steam Flow, lb/hrExt. 5 Pressure, psiaExt. 5 Enthalpy BMSR, btu/lbExt. 5 Moisture Removed, lb/hrExt. 5 Moisture Enthalpy, btu/lbExt. 5 Enthalpy AMSR, btu/lbExt. 5 Press/Ext. 4 Press.Work Done Per lb of SteamWork Done, btu/hrFFS5, lb/hr
Original Replacement LP Rotor
Table 3 Comparison of LP (contd.)
630,400 595,2656.47 5.92
1056.84 1049.91130,943 139,867141.35 137.46
1070.56 1064.620.4770318 0.449108965
40.54 43.613.596E+08 3.844E+088,108,683 8,080,371
60,815 60,6033.07 2.73
1032.17 1023.99142,559 151,954110.33 105.70
1048.67 1041.590.4744251 0.460255436
38.38 40.633.112E+08 3.283E+087,905,309 7,867,8140.736725 0.736725
977.83 977.41999.10 995.17
0.2399465 0.27026205349.57 46.42
3.918E+08 3.653E+082.806E+09 2.867E+09
822,475 840,0920.0044483 0.004493594
78.67% 78.95%72.83% 74.06%
LP Turbine
Ext. 6 Steam Flow, lb/hrExt. 6 Pressure, psiaExt. 6 Enthalpy BMSR, btu/lbExt. 6 Moisture Removed, lb/hrExt. 6 Moisture Enthalpy, btu/lbExt. 6 Enthalpy AMSR, btu/lbExt. 6 Press/Ext. 5 Press.Work Done Per lb of Steam
MRZ Moisture Removed, lb/hrMRZ Moisture Enthalpy, btu/lbMRZ Enthalpy AMSR, btu/lb
Work Done, btu/hrFFS6, lb/hrMRZ Blowdown Steam Flow, lb/hrMRZ Pressure, psia
LPT Efficiency (ELEP), %LPT Efficiency (TEP), %
Original
Work Done Per lb of SteamWork Done, btu/hrTotal Work Done in LP Turbine, btu/hTotal Work Done in LP Turbine, Kw
LP Exh. Pressure, psiaLPT ELEP, btu/lbLPT TEP, btu/lb
Replacement LP Rotor
LP Exhaust/LP Bowl Pressure
LP Exh. Press/Ext. 6 Press.
MRZ Press/Ext. 6 Press.Work Done Per lb of SteamWork Done, btu/hrFFSMRZ, lb/hr
MRZ Enthalpy BMSR, btu/lb
Fig. 7 – Exhaust Loss Curves
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
45.0
50.0
55.0
60.0
0 100 200 300 400 500 600 700 800 900 1000
Exhaust Volumetric Flow, million cft/hr
Dry
Exha
ust L
oss,
btu
/lbOriginal Replacement LP Rotor
Fig. 8 – LP Expansion Lines
950
1000
1100
1200
1.5
1.5
1.6
1.6
1.7
1.7
1.8
1.8 1.9 2.0
600 500 400 300 250 200 150 120 100 80 60 50 40 30 20 16 12 10 8.0 6.0 5.0 4.0
5.00"
5.00"
4.00"
4.00"
3.50"
3.50"
3.00"
3.00"
2.50"
2.50"
2.00"
2.00"
1.50"
1.50"
1.00"
1.00"
0.75
0.75"0.50"
520
500
480
460
440
420
400
380
360
340
320
300
280
260 240
220
200
180
160
12
34
56
78
910
1112
1314
1516
1718
9
Replacement LP Rotor Expansion Line
Original LP Rotor Expansion Line
Comparison of Results • HP Shaft Output About 2 Mw
Higher • Exhaust Losses About 3.5
Btu/Lb Lower • LP Shaft Output About 17.6
Mw Higher • Internal Moisture Removal
Zones Effectiveness Assumed Unchanged
Recommended Approach - Design
• From Thermal Kit Develop Licensed Power HB
• Revise to Include Design, Startup, Test, Plant Data
• Address Cycle Isolation • Obtain/Develop New Thermal
Kit Data for Replacement LP • Develop New
Baseline/Correction Factors
Recommended Approach - Test
• Conduct Test Close to Licensed Thermal Power
• Steady-State Conditions • Correct for Deviations in
Thermal Power, Throttle Pressure, LP Exhaust Pressure, Generator PF, etc.
• Isolate and/or Account for Leakages