3.

ENERGY PERFORMANCE ASSESSMENT OF COGENERATION SYSTEMS WITH STEAM AND GAS TURBINES
3.1 Introduction
Cogeneration systems can be broadly classified as those using steam turbines, Gas turbines and DG sets. Steam turbine cogeneration systems involve different types of configurations with respect to mode of power generation such as extraction, back pressure or a combination of backpressure, extraction and condensing. Gas turbines with heat recovery steam generators is another mode of cogeneration. Depending on power and steam load variations in the plant the entire system is dynamic. A performance assessment would yield valuable insights into cogeneration system performance and need for further optimization.

3.2 Purpose of the Performance Test

The purpose of the cogeneration plant performance test is to determine the power output and plant heat rate. In certain cases, the efficiency of individual components like steam turbine is addressed specifically where performance deterioration is suspected. In general, the plant performance will be compared with the base line values arrived at for the plant operating condition rather than the design values. The other purpose of the performance test is to show the maintenance accomplishment after a major overhaul. In some cases the purpose of evaluation could even be for a total plant revamp.

3.3 Performance Terms and Definitions

Overall Plant Performance 1. Overall plant heat rate, kCal/kWh

Mass flow rate of steam x ( Enthalpy of steam, kCal / kg Enthalpy of feed water , kCal / kg ) Power output , kW
2. Overall plant fuel rate kg/kWh = Fuel consumption* in kg/hr Power output,kW

*Total fuel consumption for turbine and steam

Bureau of Energy Efficiency

46

3. Energy Performance Assessment of Cogeneration Systems

Steam Turbine Performance

Turbine cylinder efficiency, % = Actual enthalpy drop across the turbine, kCal / kg x 100 Isentropic (theoritical ) enthalpy drop across the turbine, kCal / kg

Gas Turbine Performance

Air compressor efficiency, % = Theoritical temperature rise across the compressor , oC x 100 Actual temperature rise, oC

Overall Gas turbine efficiency (Compressor + Gas turbine), % = Power output , kW x 860 x 100 Fuel input for Gas Turbine, kg / hr x GCV of fuel , kCal / kg

Heat Recovery Steam Generator (HRSG) Performance

Heat Recovery Steam Generator efficiency, %

Steam generated , kg / hr x (hs , kCal / kg hw , kCal / kg ) [ Mass flow of flue gas, kg / hr x C p x (tin tout )] + [auxiliary fuel consumption, kg / hr x GCV of fuel , kCal / kg ] where, hs hw tin tout = Enthalpy of steam = Enthalpy of feed water = inlet temperature of flue gas = outlet temperature of flue gas

3.4 Reference standards

Modern power station practices by British electricity International (Pergamon Press) ASME PTC 22 Gas turbine performance test.

Bureau of Energy Efficiency

47

3. Energy Performance Assessment of Cogeneration Systems

3.5 Field Testing Procedure

The test procedure for each cogeneration plant will be developed individually taking into consideration the plant configuration, instrumentation and plant operating conditions. A method is outlined in the following section for the measurement of heat rate and efficiency of a co-generation plant. This part provides performance-testing procedure for a coal fired steam based co-generation plant, which is common in Indian industries.
3.5.1 Test Duration The test duration is site specific and in a continuous process industry, 8-hour test data should give reasonably reliable data. In case of an industry with fluctuating electrical/steam load profile a set 24-hour data sampling for a representative period. 3.5.2 Measurements and Data Collection The suggested instrumentation (online/ field instruments) for the performance measurement is as under:

Steam flow measurement Fuel flow measurements Air flow / Flue gas flow Flue gas Analysis Unburnt Analysis Temperature Cooling water flow Pressure Power Condensate

Orifice flow meters Volumetric measurements / Mass flow meters Venturi / Orifice flow meter / Ion gun / Pitot tubes Zirconium Probe Oxygen analyser Gravimetric Analysis Thermocouple Orifice flow meter / weir /channel flow/ non-contact flow meters : Bourdon Pressure Gauges : Trivector meter / Energy meter : Orifice flow meter

: : : : : : :

It is essential to ensure that the data is collected during steady state plant running conditions. Among others the following are essential details to be collected for cogeneration plant performance evaluation.
I. Thermal Energy : Flow Pressure a a a a a a a a a a a a a Temperature a a a a a a -

1 2 3 4 5 6 7 8

Steam inlet to turbine Fuel input to Boiler /Gas turbine Combustion air Extraction steam to process Back Pressure Steam to Process Condensing steam Condensate from turbine Turbine bypass steam

Bureau of Energy Efficiency

48

3. Energy Performance Assessment of Cogeneration Systems

9 Flue gas to HRSG 10 Exit flue gas 11 Cooling water to condenser II. Electrical Energy: 1. 2. 3. 4. 5.

a a

a a+ composition a

Total power generation for the trial period from individual turbines. Hourly average power generation Quantity of power import from utility ( Grid )* Quantity of power generation from DG sets.* Auxiliaries power consumption

* Necessary only when overall cogeneration plant adequacy and system optimization / upgradation are the objectives of the study.
3.5.3 Calculations for Steam Turbine Cogeneration System

The process flow diagram for cogeneration plant is shown in figure 3.1. The following calculation procedures have been provided in this section. Turbine cylinder efficiency. Overall plant heat rate

h1

h11
Boiler Extraction cum condensing Turbine

h11
Boiler

Power output kW

h2 1st Extraction
2st

H1
h3 H2 h4 Extraction

H3

Condenser
Figure 3.1 Process Flow Diagram for Cogeneration Plant

Step 1 :

Calculate the actual heat extraction in turbine at each stage,

Bureau of Energy Efficiency

49

3. Energy Performance Assessment of Cogeneration Systems

Steam Enthalpy at turbine inlet Steam Enthalpy at 1st extraction Steam Enthalpy at 2nd extraction Steam Enthalpy at Condenser

: : : :

h1 kCal / kg h2 kCal / kg h3 kCal / kg h4* kCal / kg

* Due to wetness of steam in the condensing stage, the enthalpy of steam cannot be considered as equivalent to saturated steam. Typical dryness value is 0.88 0.92. This dryness value can be used as first approximation to estimate heat drop in the last stage. However it is suggested to calculate the last stage efficiency from the overall turbine efficiency and other stage efficiencies. Heat extraction from inlet : h1 h2 kCal / kg to stage 1 extraction (h5) Heat extraction from 1st 2nd extraction (h6) : h2-h3 kCal / kg

Heat extraction from 2nd : h3-h4 kCal / kg Extraction condenser (h7) Step 2: From Mollier diagram (H- Diagram) estimate the theoretical heat extraction for the conditions mentioned in Step 1. Towards this: a) Plot the turbine inlet condition point in the Mollier chart corresponding to steam pressure and temperature. b) Since expansion in turbine is an adiabatic process, the entropy is constant. Hence draw a vertical line from inlet point (parallel to y-axis) upto the condensing conditions. Read the enthalpy at points where the extraction and condensing pressure lines meet the vertical line drawn. Compute the theoretical heat drop for different stages of expansion. : H1 : H2 : H3 : h1 H1

c)

d)

Theoretical Enthalpy after 1st extraction Theoretical Enthalpy after 2nd extraction Theoretical Enthalpy at condenser conditions Theoretical heat extraction from inlet to stage 1 extraction, h8 Theoretical heat extraction from 1st 2nd extraction, h9 Theoretical heat extraction from 2nd extraction condensation, h10

: H1-H2 : H2-H3

Bureau of Energy Efficiency

50

3. Energy Performance Assessment of Cogeneration Systems

Step 3 : Compute turbine cylinder efficiency

h Heat extraction actual h1 h2 Efficiency of 1st stage 5 = h Heat extraction theoritical = h H 1 1 8 h Heat extraction actual h2 h3 Efficiency of 2 nd stage 6 = h Heat extraction theoritical = H H 1 2 9

Efficiency of condensing stage

Step 4 : Calculate plant heat rate*

: h7 h10

Heat rate, kCal/kWh =

M x (h1 h11 ) P

M Mass flow rate of steam in kg/hr h1 - Enthalpy of inlet steam in kCal/kg h11 - Enthalpy of feed water in kCal/kg P - Average Power generated in kW *Alternatively the following guiding parameter can be utilised Plant heat consumption = fuel consumed for power generation, kg/hr Power generated, kW

3.6 Example
3.6.1 Small Cogeneration Plant

A distillery plant having an average production of 40 kilolitres of ethanol is having a cogeneration system with a backpressure turbine. The plant steam and electrical demand are 5.1 Tons/hr and 100 kW. The process flow diagram is shown in figure 3.2.Gross calorific value of Indian coal is 4000kCal/kg

Bureau of Energy Efficiency

51

3. Energy Performance Assessment of Cogeneration Systems

Coal 1550 kg/hr

Boiler

Steam to turbine Q 5100 kg/hr P 15 kg/cm 2 g T 250 o C

Back Pressure Turbine

Power output 100kW

Process Steam Q 5100 kg/hr P 2 kg/cm 2 g T 130 o C

Figure 3.2 Process Flow Diagram for Small Cogeneration Plant

Calculations : Step 1 :

Total heat of steam at turbine inlet conditions at 15kg / cm2 and 250oC, h1 =698kCal/kg

Step 2 :

Total heat of steam at turbine outlet conditions at 2 kg/cm2 and 130oC, h2 = 648 kCal/kg
Step 3 :

Heat energy input to turbine per kg of inlet steam (h1- h2)

Step 4 :

= (698-648) = 50 kCal/kg

Total steam flow rate, Q1 Power generation Equivalent thermal energy

Step 5 :

= 5100 kg/hr = 100 kW = 100 x 860 = 86,000 kCal /hr

Energy input to the turbine

Step 6 :

= 5100 x 50 = 2,55,000 kCal/hr.

Bureau of Energy Efficiency

52

3. Energy Performance Assessment of Cogeneration Systems

Power generation efficiency of the turbo alternator =

Energy output x 100 Energy input

=
Step 7 : Efficiency of the turbo alternator Efficiency of Alternator Efficiency of gear transmission

86,000 ------------- x 100 = 34% 2,55,000

= 34% = 92 % = 98 %

EfficiencyofTurbine =

Power generation efficiency of turbo alternator Efficiency of gear transmission * Efficiency of Alternator = 0.34 = 0.38 0.98 * 0.92

Step 8 :

Quantity of steam bypassing the turbine

Step 9 :

= Nil

Coal consumption of the boiler

Step 10:

= 1550 kg/hr.

Overall plant heat rate, kCal/kWh

= Mass flow rate of steam x ((Enthalpy of steam, kCal/kg Enthalpy of feed water,kCal/kg)

Power output, kW

= 5100 x (698 30) 100

= 34068 kCal/kWh*
*Note: The plant heat rate is in the order of 34000 kCal/kWh because of the use of backpressure turbine. This value will be around 3000 kcal/kWh while operating on fully condensing mode. However with backpressure turbine, the energy in the steam is not wasted, as it is utilised in the process.

Overall plant fuel rate including boiler

= 1550/100 = 15.5 kg coal / kW

Bureau of Energy Efficiency

53

3. Energy Performance Assessment of Cogeneration Systems

Analysis of Results:

The efficiency of the turbine generator set is as per manufacturer design specification. There is no steam bypass indicating that the power generation potential of process steam is fully utilized. At present the power generation from the process steam completely meets the process electrical demand or in other words, the system is balanced. Remarks: Similar steps can be followed for the evaluation of performance of gas turbine based cogeneration system.

Bureau of Energy Efficiency

54

3. Energy Performance Assessment of Cogeneration Systems

QUESTIONS

1. What is meant by plant heat rate? What is its significance? 2. What is meant by turbine cylinder efficiency? How is it different from turbogenerator efficiency? 3. What parameters should be monitored for evaluating the efficiency of the turbine? 4. What is the need for performance assessment of a cogeneration plant? 5. The parameters for back pressure steam turbine cogeneration plant is given below Inlet Steam: P =16 kg/cm , T = 310 C , Q = 9000kg/hr 2 o Outlet Steam: P = 5.0 kg/cm , T = 235 C , Q = 9000kg/hr Find out the turbine cylinder efficiency? 6. Explain why heat rate for back pressure turbine is greater than condensing turbine. 7. Explain the methodology of evaluating performance of a gas turbine with a heat recovery steam generator.
REFERENCES
2 o

1. NPC report on Assessing cogeneration potential in Indian Industries 2. Energy Cogeneration Handbook, George Polimeros, Industrial Press Inc.

Bureau of Energy Efficiency

55