International Scientific Journals
of Scientific Technical Union of Mechanical Engineering "Industry 4.0"

This paper shows analysis of each regenerative heater’s influence on global steam power plant operating parameters. Analysis is performed for nine steam power plant versions (configurations) – from the Base power plant without regenerative heating system up to the Final plant which consists of eight regenerative heaters (one mixing and seven non-mixing regenerative heaters). According to the defined fluid operating parameters throughout the plant, it is obtained that each new regenerative heater added to the plant continuously reduces the mechanical power produced by the turbine, for 4.33 MW on average. Simultaneously, each added regenerative heater increases feedwater temperature at the steam generator inlet, which results in power plant cumulative fuel consumption continuous decrease (for 0.414 kg/s on average) to obtain the same steam outlet parameters. Considering plant overall efficiency, it must be highlighted that each regenerative heater added to the plant continuously increases plant overall efficiency from the Base plant until the Final plant, for 0.43% on average.

This paper presents exergy analysis results of a complex three cylinder steam turbine with nominal power 210 MW. The analysis is performed for each cylinder, cylinder part and whole turbine as well as for each segment of each turbine cylinder. In the observed turbine, Low Pressure Cylinder (LPC) has the highest exergy destruction (8668.15 kW) and the lowest exergy efficiency (87.19%), while Intermediate Pressure Cylinder (IPC) has the highest exergy efficiency (92.15%) of all cylinders. Exergy efficiency is the highest for each segment at each cylinder entrance and continuously decreases for all segments during steam expansion through each cylinder. In each cylinder, a segment which is the lowest influenced by the ambient temperature change is inlet segment – as steam expands through each cylinder, further segments became more and more influenced by the ambient temperature change. Steam re-heating process has a very beneficial influence on the exergy efficiency of the first two IPC segments (Seg. 3 and Seg. 4) which have the highest exergy efficiency in comparison to all other segments.

In this paper, an uncertainty analysis is performed related to the marine MAN B&W 6S70ME-C diesel engine. Uncertainty analysis is based on six different engine operating parameters (Maximum pressure, Compression pressure, Mean indicated pressure, Exhaust Gas Outlet Temperature, Cooling Fresh Water Outlet Temperature, and Piston Cooling Oil Outlet Temperature) measured in each engine cylinder. Various engine loads are observed. Exhaust Gas Outlet Temperature uncertainties are the highest in comparison to uncertainties of all other considered operating parameters. The highest Exhaust Gas Outlet Temperature uncertainty is detected at engine load of 90% and is equal to ±2.421%, while considering all observed engine loads, Exhaust Gas Outlet Temperature uncertainty is equal to ±4.296%. Overall uncertainty of the analysis performed in this paper (which considers all observed operating parameters at all engine loads) is equal to ±4.837%, which also falls within the range of the recommended uncertainty limit (±5%).

In this paper are presented results of the isentropic analysis related to the cylinders, segments and whole three cylinder steam turbine from the conventional power plant. In the analyzed steam turbine Low Pressure Cylinder (LPC) is the dominant mechanical power producer of all cylinders – it produces 130.16 MW of mechanical power in the real expansion process and it can produce 142.80 MW of mechanical power if the expansion conditions are ideal. The satisfactory isentropic performance of the whole High Pressure Cylinder (HPC) is a combination of two segment’s isentropic performance – one of these segments show extremely good isentropic performance (Seg2), but another segment (Seg1) shows very poor isentropic performance. Both Intermediate Pressure Cylinder (IPC) segments (Seg3 and Seg4) show similar isentropic performance, what result with the balanced IPC operation. LPC has an isentropic efficiency of 91.15%, what is the highest isentropic efficiency of all cylinders from the observed steam turbine. Whole observed steam turbine has an isentropic efficiency of 88.42% what is better isentropic performance in comparison to similar steam turbines from conventional power plants.

In this paper are presented isentropic analysis results of a steam turbine, their cylinders and cylinder parts which nominal power is equal to 250 MW. The analyzed steam turbine is a complex three-cylinder turbine which operates in a CCPP (Combined Cycle Power Plant). Considering all cylinders, the dominant mechanical power producer in the observed turbine is LPC (Low Pressure Cylinder) which produces 111.80 MW of mechanical power in real (polytropic) steam expansion process (almost half of the real mechanical power produced in the whole turbine). Developed mechanical power in turbine cylinders and isentropic losses are directly proportional – higher produced mechanical power will result in higher isentropic losses and vice versa. Whole analyzed steam turbine, their cylinders and cylinder parts how very good isentropic performance and high isentropic efficiencies of around 90%. The isentropic performance of the whole analyzed steam turbine, their cylinders and cylinder parts is in the range of the steam turbines (and their cylinders) from supercritical and ultrasupercritical power plants which are proven to be the best steam turbines from isentropic point of view.

This paper presents energy and exergy analysis results of whole gas turbine set and all its components. From the energy viewpoint, combustion chamber has the lowest energy loss (21.31 MW) and the highest energy efficiency (97.20%) of all gas turbine set components. Exergy analysis shows totally opposite trend in comparison to the energy analysis. From the exergy viewpoint, turbocompressor and turbine have low exergy destruction (both around 12 MW) and very high exergy efficiencies (92.43% for turbocompressor and 96.12% for turbine) at the base ambient state. Simultaneously, at the base ambient state combustion chamber has an exergy destruction of 159 MW and low exergy efficiency of 73.29% only. The combustion chamber is the most sensitive to the ambient temperature change of all components from the gas turbine set – the ambient temperature change of 10 °C will result with combustion chamber exergy efficiency change of approximately 0.67%. Whole gas turbine set (plant) has an energy efficiency of 34.40% and exergy efficiency of 33.08%.

In this paper are presented isentropic analysis results of a steam turbine, their cylinders and cylinder parts which nominal power is equal to 250 MW. The analyzed steam turbine is a complex three-cylinder turbine which operates in a CCPP (Combined Cycle Power Plant). Considering all cylinders, the dominant mechanical power producer in the observed turbine is LPC (Low Pressure Cylinder) which produces 111.80 MW of mechanical power in real (polytropic) steam expansion process (almost half of the real mechanical power produced in the whole turbine). Developed mechanical power in turbine cylinders and isentropic losses are directly proportional – higher produced mechanical power will result in higher isentropic losses and vice versa. Whole analyzed steam turbine, their cylinders and cylinder parts show very good isentropic performance and high isentropic efficiencies of around 90%. The isentropic performance of the whole analyzed steam turbine, their cylinders and cylinder parts is in the range of the steam turbines (and their cylinders) from supercritical and ultrasupercritical power plants which are proven to be the best steam turbines from isentropic point of view.

In this paper are presented isentropic analysis results of a steam turbine and each of its cylinders which operate in Municipal Solid Waste (MSW) power plant. Low Pressure Cylinder (LPC) which produces the highest real mechanical power has the lowest isentropic loss of all cylinders equal to 4344.75 kW, while High Pressure Cylinder (HPC) which produces the lowest real mechanical power has the highest isentropic loss of all cylinders equal to 5204.54 kW. Isentropic losses and isentropic efficiencies are reverse proportional, because the cylinder with the lowest isentropic loss (LPC) has the highest isentropic efficiency equal to 88.92%, while the cylinder with the highest isentropic loss (HPC) has the lowest isentropic efficiency equal to 84.58%. Surprisingly, isentropic efficiency of the Intermediate Pressure Cylinder (IPC) is equal to 86.80% only, which is higher in comparison to HPC but notably lower than LPC. The observed turbine strongly differs from other comparable steam turbines from the literature where IPC has notably higher isentropic efficiencies than both HPC and LPC. Whole observed steam turbine produces real mechanical power equal to 97513 kW, while its isentropic efficiency is equal to 86.87%.

Exergy analysis of three cylinder steam turbine segments is performed in this research. The highest mechanical power of 47389.66 kW is developed in the first segment (Seg. I, which actually represents the entire HPC – High Pressure Cylinder). Intermediate Pressure Cylinder (IPC) is the dominant mechanical power producer of all cylinders and it develops 48.95% of cumulative mechanical power produced in the whole turbine. The outlet Low Pressure Cylinder (LPC) segments (Seg. VII and IX) have the highest exergy destructions and the lowest exergy efficiency (equal to 61.27%) of all turbine segments. The best exergy performance shows IPC segments – Seg. V has the lowest exergy destruction (equal to 363.84 kW), while Seg. II has the highest exergy efficiency (equal to 94.04%) of all turbine segments. Outlet LPC segments (Seg. VII and IX) are the most sensitive to the ambient temperature change – their exergy efficiency decreases for 3.19% when the ambient temperature increases from 5 °C to 45 °C.

In the presented paper are performed energy and exergy analyses as well as a comparison of two similar steam turbines from conventional power plants. The first turbine is from an older, while the second turbine is from newer steam power plant. The dominant mechanical power producer in an older steam turbine is LPC (which produces mechanical power of almost 66 MW), while in a newer steam turbine the dominant mechanical power producer is IPC which produces power equal to 102.4 MW. Whole older steam turbine has higher energy and exergy loss in comparison to the whole newer steam turbine. Whole turbine from the newer power plant has much higher energy and exergy efficiencies in comparison to whole turbine from an older power plant. In an older steam turbine, LPC did not show the expected performance because its exergy efficiency is very low (equal to 75.49%), what is much lower than in any other cylinder from both observed turbines. The ambient temperature change sensitivity of the two observed steam turbines and their cylinders is reverse proportional to efficiencies (both energy and exergy). Steam turbine from an older power plant is much more sensitive to the ambient temperature change.

This paper presents results of the Main Feedwater Pump (MFP) isentropic and exergy analyses at three power plant loads. Observed MFP is a constituent component of condensate/feedwater sub-system from conventional steam power plant. In real exploitation conditions, MFP uses mechanical power higher than 3000 kW, considering all observed power plant loads. Main isentropic and exergy parameters of the MFP at various plant loads show the same general trends (increase in power plant load simultaneously increases MFP losses and efficiencies and vice versa, from both isentropic and exergy viewpoints). Analyzed MFP has high isentropic and exergy efficiencies, considering all plant loads and ambient temperatures (at any plant load MFP isentropic efficiency is higher than 85%, while the lowest MFP exergy efficiency is equal to 89.24% at the lowest observed plant load and the highest observed ambient temperature). The change in isentropic and exergy efficiency of the MFP is small if all observed plant loads and ambient temperatures are taken into consideration.

This paper presents isentropic analysis results of the whole steam turbine (as well as turbine cylinders) from nuclear power plant. In the analyzed steam turbine, LPC (Low Pressure Cylinder) is the dominant mechanical power producer – mechanical power produced in the LPC is more than two times higher in comparison to mechanical power produced in the HPC (High Pressure Cylinder). Whole analyzed steam turbine produces real mechanical power equal to 1372.47 MW, while the highest possible mechanical power which can be produced in the whole turbine when all the losses are neglected (ideal mechanical power) equals 1686.96 MW. LPC has a notably higher isentropic efficiency than HPC, regardless of higher isentropic loss (isentropic efficiencies of the LPC and HPC are 84.41% and 74.84%, respectively). HPC has notably higher specific steam consumption and specific heat consumption in comparison to LPC. Whole turbine has an isentropic efficiency equal to 81.36%, isentropic loss equal to 314.48 MW, specific steam consumption of 9.15 kg/kWh and specific heat consumption of 3799.06 kJ/kWh, what is in the range of similar comparable steam turbines from nuclear power plants.