The writeup details the Heat Balance of BHEL 210 MW Turbine Cycle. The Input and Output steam condition of Turbines, Extractions, Deaerator, LP Heaters, Condensers etc have been computed as per the specifications of the turbine manufacturer

1. MANOHAR TATWAWADI total output power solutions Page 1
210 MW BHEL Turbine Cycle Heat Balance
Calculation of Heat Rate of 210 MW BHEL Turbine Cycle with Regenerative Feed Water Heating
consisting of seven feed water heaters shown in the schematic flow diagram attached.
From station to station the C.W. Temp for the condenser cooling changes and therefore the vacuum
conditions and the exhaust temperature also changes accordingly. A specimen calculation shown has
been done for the values at 652000 kgs of steam per hour flow at 130 kg/cm2
absolute pressure and
5550
C superheat Temperature. Similar such calculations can be done at different loads for calculation of
heat rate of the turbine regenerative feed water heating cycle at those particular loads.
While calculating the Turbine Heat Rate following assumptions have been made in the original drawings,
giving the values of Enthalpy and other Properties.
1. Under cooling in the drain coolers of Heater No 6 and heater No 7 has been taken as 100
C. The
effect of drain cooler of Heater No 5 has been ignored.
2. Wherever a dash has been given in place of reading, the equipment is inoperative in that range.
3. The values of temperatures mentioned are approximate. Whenever the steam is wet (especially
at the LP Exhaust), instead of giving the temperature, dryness fraction has been mentioned in
the temperature column.
4. When press in Heater No 5 approaches 10.5 Kg/cm2
absolute, drain from Heater No 6 is diverted
to Deaerator bypassing Heater No 6 and drain of Heater No 5 is diverted to Heater No 4.
5. The Specific Heat Rate does not include the consumption of steam in the main Ejector.
Similar such calculations for the turbine heat rate can also be carried out for over load working of TA set
at 215.78 MW and at 211.05 MW Loads, at 670 T/hr steam flow and with 3% makeup water added to
the Hotwell of Condenser and at different cooling water temperatures ranging from 300
C to 360
C at
Condenser inlet. A separate calculation can also be done to calculate the turbine heat rate when HP
Heaters are out of service at 206.135 MW Load.
These figures should however, be not taken as guaranteed performance figures and will vary from
station to station depending upon the actual working conditions, age of stations etc.
1) INTRODUCTION
Before calculating the Turbine Heat Rate we shall first consider the stage by stage efficiency of the
Turbine Cycle.
A Complete Turbine Cycle single line schematic diagram is as per attached drawing, wherein the
parameters for Steam, Condensate and Feed water are marked for full load. Similar such chart can be
worked out by inserting the values for the parameters calculated from BHEL Drawing No C-210-
130/TDC-210-60.2. The Turbine Cycle Diagram indicates the direction of flow of various fluids involved.

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2) STAGE BY STAGE EFFICIENCY
2.1 Ejector:-
Ejector is supplied with steam from Deaerator (d4) at 4.5Kg/cm2
having 1550
C Temp and the condensate
from hotwell passes through the same, which is pumped by the condensate extraction pump to the
further feed water regenerative heating cycle. The ejector drain is recovered back to the flash chamber
on the condenser. Calculations have been made assuming the efficiency of 99.8% for the Ejector from
which the Enthalpy / Temperature for the drain from the Ejector to the Flash Chamber is derived.
2.2 Gland Steam Condenser GC1:-
The Gland Steam Condenser GC1, which is next to the Ejector in the regenerative feed water heating
cycle, sucks steam and air mixture from outermost HP, IP and LP Turbine glands. The necessary required
vacuum of about 100 mm is established in the Gland Steam Condenser by an Ejector, which is provided
with steam (d2) from the Deaerator. The condensate (gd1) is recovered back to the flash chamber on
the condenser. From the calculations it is seen that the efficiency of the Gland Steam Condenser No 1 is
99.7%.

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2.3 LP Heater No 1:-
The Feed water Heater 1 (LP Heater No 1) is fed with Extraction Steam (e1) from the Extraction No 1 on
LP Turbine and the heater drain (hd1) is fed to the flash chamber on condenser. The condensate after
GC1 flows through Heater No 1. From the calculations shown in the sketch the efficiency comes to
99.80%.
2.4 Gland Steam Condenser No 2:-
Gland Steam Condenser No 2 is fed with Leakage steam from HP and IP Turbine Glands and the drain
from GC2 is recovered back to flash tank on the condenser. As per the calculations shown in the sketch,
the efficiency comes to 80%, because not all the condensate at full load passes through GC2. However,
actually a part of the condensate is bypassed over GC2. The efficiency of GC2 drops accordingly. That is
to say that if 80% of the condensate is passing through GC2, the efficiency drops to 80%.

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2.5 LP Heater No 2:-
The steam from IP Turbine Extraction No 2 (e2) is fed to the feed water heater LP Heater No. 2. The
drain (hd2) is pumped back with the help of Drip Pump into the main condensate flow path before the
condensate entry to Heater no 3 as shown. This also increases the temperature of condensate from
100.860
C to 1o1.520
C at the entry in Heater No 3. From the calculations as above the efficiency of LP
Heater No 2 comes to 99.8%.
2.6 LP Heater No 3:-
Heater No 3 is provided with steam from IP Turbine Extraction No 3 (e3) and the drain from heater no 4
(hd4) is also fed back to heater No 3. It may also be noted that the amount of condensate passing
through heater No 3 increases in quantity by the amount of drain from heater No 2 (hd2). Heater no 3
drain is fed back to LP Heater No 2. The calculated efficiency of LP Heater No 3 comes to 99.8%.

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2.7 LP Heater no 4:-
LP Heater No 4 is fed with Extraction steam from IP Turbine (e4). Leakage steam from HP and IP Glands
(g3) is also fed to the LP Heater No 4. Drain from LP Heater No 4 is fed back to LP Heater No 3. HP Heater
No 5 drain (hd5) is cascaded to LP Heater No 4 below 150 MW load. For loads more than 150 MW HP
Heater No 5 drain normally goes to Deaerator. In the calculations at full load, HP Heater No 5 drain (hd5)
is not considered as fed to Heater No 4. The calculated Efficiency comes to 99.7%.
2.8 Deaerator:-
Dearator is supplied with heating steam from Extraction tapped from either Extraction no 5 or
Extraction No 6 (ed). Extraction No 5 is taken from IP Turbine and Extraction No 6 is taken from HP
Turbine at HP Exhaust. For loads below 150 MW, deaerator heating steam supply (ed) is derived from
Extraction No 6, which is changed over to Extraction No 5 at loads above 150 MW. Auxiliary steam
supply to the main Ejector, Gland steam ejector and sealing steam of Turbine Glands is changed over
from auxiliary PRDS to Deaerator.

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The Deaerator pegging steam supply is initially given from auxiliary PRDS, which is changed over from
auxiliary source to Extraction No 6 at about 90 to 100 MW Load.
The gland leakage from ESV and IV is fed to the deaerator. Heater No 5 and Heater No 6 Drains (hd5 or
hd6) are also fed to the deaerator. Actually HP Heaters are taken in service after 60 to 70 MW Load is
taken on the turbine. Heater No 5 Drain (hd5) goes to Heater No 4 for loads less than 150 MW. For
Turbine loads higher than 170 MW, Heater No 6 Drain (hd6) goes to Heater No 5. And heater no 5 drain
(hd5) is diverted to Deaerator instead of Heater No 4. From the heat balance calculations, the deaerator
efficiency comes to 96.8%.
2.9 Boiler Feed Pump:-
It may be noted that the total quantity of feed water supplied from feed water tank to boiler feed water
pump is equal to main steam flow to the HP Turbine.
In this connection, it may be noted that heat added by Boiler Feed water pump due to Mechanical
churning of water has been also taken into consideration, which is equal to 4179320 Kcal.
2.10 HP Heater No 5:-
HP Heaters are taken into service in block after a load of 60 to 70 MW is taken on the turbogenerator.
HP Heater No 5 is supplied with steam from Extraction No 5 (e5) taken from IP Turbine. Heater No 5
Drain (hd5) goes to Heater No 4 below 150 MW, which is changed over to Deaerator at loads more than

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170 MW. Heater No 6 Drain (hd6) is cascaded to Heater no 5. From the heat balance calculations the
efficiency of HP Heater No 5 comes to 93.7%.
2.11 HP Heater No 6:-
Heater No 6 is supplied with steam from Extraction No 6 (e6) from HPT Exhaust. It is cold reheat steam.
The spindle leakage steam from HPT (g5) is also fed to Heater No 6. Heater No 7 Drain (hd7) is cascaded
to Heater no 6 and Heater no 6 drain (hd6) is cascaded to Heater No 5. From the calculations the
efficiency is 99.7%.
2.12 HP Heater No 7:-
Heater No 7 is provided with Extraction steam from HP Turbine (e7). The drain (hd7) is cascaded to
Heater No 6. Feed water at the outlet of the heater is finally fed to back to the boiler through the feed
water regulating valve. From the calculations the efficiency comes out to be 99.5%.

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2.13 Condenser:-
210 MW Turbine has two condensers connected in parallel. The total quantity of the condensed steam
exhausted from the LP Turbine is mixed with drains from Ejector consisting of condensate of steam from
Deaerator(d4) and GC1 condensate of steam from HPT and IPT.
The steam from LPT at a Pressure of 0.0889Kg/cm2 and quantity 460008 kg/hr is condensed by cooling
water quantity 270000 m3 which equals to 27000000 kg/hr and hence the circulating water required for
cooling 1 kg of steam is 27000000/460008 = 58.6 kg.
From the heat balance equation of condenser:-
The total heat loss to cooling water = Steam from LPT Exhaust * Enthalpy of water at Hotwell
= 2 X 230004 * (589.18 – 43.16) = 251173568 Kcal/hr.
If the condenser efficiency is assumed to be 80% then the gain in temp of cooling water
= (251173568/0.8)/27000000 = 110
C
From the calculations shown it will be seen that if 270000 m3
/h water flow is maintained for the
circulating water through the condenser having 80% efficiency the terminal temperature difference for
the circulating water will be of the order of 110
C.

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3) TURBINE CYCLE HEAT RATE
The turbine cycle heat rate is calculated as per the formula:-
Total Heat Supplied to the Turbine in kcal QM*(MSE - FWE) + QR*(RHE - CRHE)
Heat Rate =
Total Generation in KWH W
QM= Main Steam Flow = 652000 Kg/hr
MSE= Main Steam Enthalpy = 819.94 Kcal/kg
FWE= Feed Water Enthalpy at HP7 Outlet = 253.94 kcal/kg
QR = Reheat Steam Flow = 566369 kg/hr
RHE = Enthalpy of Reheat Steam = 845.83 Kcal/kg
CRHE= Enthalpy of Cold Reheat Steam = 732.99 Kcal/kg
W = Total Power Developed at Generator output in KWH = 211902 KWH
652000 * (819.94 - 253.94) + 566369 * (845.83 – 732.99)
HR at 210 MW =
211902
652000 * 566 + 566369 * 112.84 432941078
= = = 2043.11 Kcal/KWH
211902 211902
Calculated Heat Rates at different loads are :-
a) 2043.11 Kcal/KWH at 210 MW
b) 2068 Kcal/KWH at 176 MW,
c) 2070 Kcal/KWH at 150 MW and
d) 2156 Kcal/KWH at 100 MW
4) EXTRACTIONS
4.1 Total Heat given to Turbine Cylinders
High Pressure Turbine
Flow Enthalpy Heat in Kcal
Input Steam 652000 819.94 534600880
Output Steam 566369 732.99 415142813
Heat Given to HP Turbine 119458067
Intermediate Pressure Turbine
Flow Enthalpy Heat in Kcal
Input Steam 566369 845.83 479051891
Output Steam 470857 678.41 319434097
Heat Given to IP Turbine 159617794

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Low Pressure Turbine
Flow Enthalpy Heat in Kcal
Input Steam 470857 678.41 319434097
Output Steam 460008 589.18 271027514
Heat Given to LP Turbine 48406583
Total input to the Turbine Cylinders = Heat given to HP + IP + LP Cylinders
= 119458067 + 159617794 + 48406583 = 327482444 Kcal for generating 211902 kWH of Power.
A small quantity of Leakage steam from ESV & IV spindle leaks to Deaerator and gland steam condenser,
which is also utilized for feed water regenerative heating. The condensate derived thereby is also added
in the system. The heat content of this auxiliary steam is neglected.
4.2 The total quantity of steam extracted for regeneration
Symbol Work Pressure Temp. Flow Enthalpy Total Heat
e1 Extraction 1 LP Heater 1 0.8895 45 11989 622.05 7,457,757
e2 Extraction 2 LP Heater 2 1.369 183 25369 678.41 17,210,583
e3 Extraction 3 LP Heater 3 2.974 264 21033 715.68 15,052,897
e4 Extraction 4 LP Heater 4 6.911 364 23838 762.69 18,181,004
ed Steam to Deaerator Deaerator 12.96 449 5984 802.92 4,804,673
e5 Extraction 5 HP Heater 5 12.96 444 16640 802.92 13,360,589
e6 Extraction 6 HP Heater 6 28.07 327 40391 732.99 29,606,199
e7 Extraction 7 HP Heater 7 42.18 381 31844 755.97 24,073,109
Total Extraction Flow / Enthalpy 177088 TPH 129,746,812
Total Steam Extracted*100 177088 * 100
Percentage of quantity of steam extracted = = = 27.16%
Total Steam supplied 652000
Total Heat to Extractions *100 129746812*100
Percentage of Heat Tapped = = = 39.61%
Total Heat input to the cylinders 327482444
Out of the above heat given to the extractions, total heat regained by feed water regenerative heating
cycle:-
 Upto LP Heater No 2 480106 * (100.86-43.16) = 27702116 Kcal
 After LP Heater No 3 555281 * (156.52 – 100.86) = 30906940 Kcal
 After Deaerator 555281 * (166.71 – 156.52) = 5658313 Kcal
 In Feed water Pump 652000 * (173.12 – 166.71) = 4179320 Kcal
 After HP Heater 7 652000 * (253.94 – 173.12) = 52694640 Kcal
Total heat regained by Feed Water = 121141330 Kcal

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Heat Loss in Feed Water Regenerative Heating Cycle = Total heat to extractions – Heat regained
= 129746812 – 121141330 = 8605482 Kcal
4.3 Total Heat Lost to cooling water
= (Enthalpy of steam at exhaust – Enthalpy of condensate in Hotwell)* Quantity of Exhaust steam
= (589.18 – 43.16) * 460008 = 251173568 Kcal
4.4 Turbine gross heat rate
Turbine Heat Input - (Heat Extracted from all Ext.)+(Heat Lost in Regen. Heating)+ ( Heat Lost to CW)
Power Generated
327482444 – 129746812 + 8605482 + 251173568
211902
= 2159 Kcal/kwh
4.5 Specific Steam Consumption
At normal specified steam pressure and temperature of Main Steam and Reheat Steam Specific Steam
Consumption of this turbine is as below:-
Load in kw 211902 202000 176669 151400 101200
Specific Steam Consumption 3.004 2.966 3.006 3.045 3.077
(in Kg/kwh)
******************

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210 MW Parameters at different regimes at CW Temp 300
C
S.N
PARAMETERS PRESSURE IN KG/SQCM ABS TEMPERATURE / DRYNESS
Regime IN KW 211902 202200 176669 151400 101200 211902 202200 176669 151400
10120
0
A MAIN STEAM
1 MAIN STEAM 130 130 130 130 130 535 535 535 535 535
2 COLD REHEAT (CRH) 28.07 26.4 22.52 18.96 12.22 327 322 311 301 286
3 HOT REHEAT (HRH) 24.19 23.2 20.17 17.22 11.46 535 535 535 535 535
3.1 STEAM AFTER IPT 1.369 1.299 1.134 0.971 0.6725 183 184 184 185 190
3.2 STEAM BEFORE LPT 1.343 1.274 1.118 0.9519 0.6594 183 183 183 183 183
4
LPT EXHAUST TO
COND 0.0889 0.086 0.0798 0.0739 0.0637 0.9529 0.9549 0.9001 0.9663
B EXTRACTION STEAM
e7 TO HEATER NO 7 42.18 39.77 34.38 29.06 19.68 381 375 364 354 349
e6 TO HEATER NO 6 28.07 26.7 22.58 18.96 12.22 327 322 311 301 286
e5 TO HEATER NO 5 12.96 12.27 10.65 9.068 6.2 444 444 444 444 446
ed TO DEAERATOR 12.96 12.27 10.65 9.068 12.22 444 444 444 444 286
e4 TO HEATER NO 4 6.911 6.545 5.694 4.858 3.334 364 364 364 365 365
e3 TO HEATER NO 3 2.974 2.808 2.453 2.097 1.44 264 265 265 265 271
e2 TO HEATER NO 2 1.369 1.299 1.134 0.971 0.6729 183 184 184 185 190
e1 TO HEATER NO 1 0.2895 0.2754 0.241 0.2073 0.1449 0.992 0.9935 0.9965 61 68
C SERVICE STEAM
d1 TO GLAND SEALING 1.03 143
d2 TO EJECTOR OF GC1 4.5 155
d3 LEAKAGE INTO LPT 0.0889 0.086 0.0798 0.0739 0.0637 139
d4 TP MAIN EJECTOR 4.5 155
D LEAK OFF STEAM
g1 TO GLAND COOLER 1 0.97 286
g2 TO GLAND COOLER 2 0.361 0.343 0.308 0.265 0.197 346 337 329 318 296
g3 TO HEATER 4 6.911 6.545 5.694 4.853 3.334 403 400 393 386 383
g4
FROM SPINDLES TO
DEAERATOR 7.5 479
g5 TO HEATER 5 28.07 26.4 22.98 18.96 12.22 464 457 448 438 433

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210 MW Parameters at different regimes at CW Temp 300
C
Tag
No
PARAMETERS ENTHALPY KCAL/KG QUANTITY IN KG/HR
Regime IN KW 211902 202200 176669 151400 101200 211902 202200 176669 151400 101200
A MAIN STEAM
1 MAIN STEAM 819.94 819.94 819.94 819.94 819.94 652000 616000 531000 449000 304000
2 COLD REHEAT (CRH) 732.99 730.57 727.11 723.41 720.69 566369 534409 484930 395441 259703
3 HOT REHEAT (HRH) 845.83 846.22 846.86 847.54 848.82 566369 534409 484930 395441 259703
3.1 STEAM AFTER IPT 678.41 678.84 679.34 680 682.82 470857 447226 390074 333899 230723
3.2 STEAM BEFORE LPT 678.41 678.84 679.34 680 682.82 470857 447226 390074 333899 230723
4
EXHAUST STEAM TO
COND 589.18 590.08 592.41 595.31 606.03 230024 218790 191648 134954 115604
B EXTRACTION STEAM
e7 TO HEATER NO 7 755.97 753.53 750.42 746.79 746.64 31844 29654 24925 20263 13294
e6 TO HEATER NO 6 732.99 730.57 727.11 723.41 720.65 40391 37134 29752 23261 4638
e5 TO HEATER NO 5 802.92 803.23 803.88 804.52 808.2 16440 13129 6605 545
ed TO DEAERATOR 802.92 803.23 803.88 804.52 720.69 5984 7937 11610 14306 18728
e4 TO HEATER NO 4 762.69 763.02 763.73 764.56 767.84 23838 22311 18460 14945 3108
e3 TO HEATER NO 3 715.68 716.07 716.63 717.2 720.32 21033 19547 16312 13584 8488
e2 TO HEATER NO 2 678.41 678.84 679.36 680 682.32 25369 13756 19679 16276 10038
e1 TO HEATER NO 1 622.05 622.43 623.07 623.78 626.45 11989 10787 7919 5132 634
C SERVICE STEAM
d1 TO GLAND SEALING 659.83 2930
d2 TO EJECTOR OF GC1 659.8 400
d3 LEAKAGE INTO LPT 659.83 570
d4 TP MAIN EJECTOR 659.83 1500
D LEAK OFF STEAM
g1 TO GLAND COOLER 1 728.2 728.22 728.29 728.36 728.48 1260
g2 TO GLAND COOLER 2 756.8 752.66 748.77 743.1 732.92 4949 4733 4225 3735 2863
g3 TO HEATER 4 782.31 780.58 777.65 774.47 773.97 4935 4663 4020 3399 2301
g4
FROM SPINDLES TO
DEAERATOR 820.28 820.29 820.32 820.35 820.39 2300
g5 TO HEATER 5 806.5 803.66 799.78 795.63 795.4 4381 4140 3568 3017 2043

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210 MW Parameters at different regimes at CW Temp 300
C
Tag
No
PARAMETERS ENTHALPY KCAL/KG QUANTITY IN KG/HR
Regime IN KW 211902 202200 176669 151400 101200 211902 202200 176669 151400 101200
E CONDENSATE
5.0 HOTWELL 43.16 42.53 41.11 39.66 36.92 460008 437577 383296 329907 231289
5.W CEP SUCTION 43.16 42.53 41.11 39.66 36.92 480106 456529 398599 341934 237891
5.D BEFORE EJECTOR 43.16 42.53 41.11 39.66 36.92 480106 456529 398599 341934 237891
5.A AFTER EJECTOR 45.07 44.54 43.41 43.35 40.79 480106 456529 398599 341934 237891
5.1 AFTER GC1 47.18 46.76 45.96 45.32 44.86 480106 456529 398599 341934 237891
5.2 AFTER HEATER 1 61.05 59.92 57.08 53.77 46.35 480106 456529 398599 341934 237891
5.3 AFTER GC2 68.1 66.99 64.29 61.17 54.47 480106 456529 398599 341934 237891
5.4 AFTER HEATER 2 100.86 99.31 95.9 91.07 81.32 480106 456529 398599 341934 237891
5.5 BEFORE HEATER 3 101.52 99.97 96.12 91.69 81.87 555281 526534 463675 390683 376826
5.6 AFTER HEATER 3 125.27 123.83 118.85 113.82 102.33 555281 526534 463675 390683 376826
5.7 AFTER HEATER 4 156.52 154.33 148.83 143.18 129.23 555281 526534 463675 390683 376826
F FEED WATER
6.0 BFP SUCTION 166.71 652000 616000 531000 449000 304000
7.0 AFTER FEED PUMP 173.12 652000 616000 531000 449000 304000
7.1 AFTER HP HEATER 5 189.61 187.14 180.76 173.75 173.12 652000 616000 531000 449000 304000
7.2 AFTER HP HEATER 6 228.8 225.28 216.632 207.35 185.82 652000 616000 531000 449000 304000
9.0 AFTER HP HEATER 7 253.94 250.11 241.1 231.11 209.73 652000 616000 531000 449000 304000
G DRAINS
gd1 FROM GC1 100 1660
hd1 FROM HEATER NO 1 65.93 64.8 61.86 58.6 54.14 11989 10787 7919 5132 634
gd2 FROM GC2 72.94 71.78 69.26 65.97 59.38 4949 4733 4225 3735 2868
hd2 FROM HEATER NO 2 105.78 104.24 100.34 96.01 86.23 75175 70275 65076 48749 29935
hd3 FROM HEATER NO 3 130.26 128.32 123.83 118.77 107.25 49806 46519 45397 32473 19897
hd4 FROM HEATER NO 4 161.73 159.51 153.97 148.72 134.2 28773 26974 29085 18639 11409
hd5 FROM HEATER NO 5 189.51 186.91 180.38 173.22 93265 84059 6605 545
hd6 FROM HEATER NO 6 198.05 195.43 188.86 181.64 180.99 76616 70930 53245 46541 19976
hd7 FROM HEATER NO 7 238.65 234.98 225.92 216.29 194.08 31344 29654 24925 20263 13294

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H PRESSURE IN HEATERS
HEATERS DATA AT
LOADS 211902 202200 176669 151400 101200 TTD
HP7 HEATER NO 7 38.8 36.59 31.63 26.74 18.1 2.5
HP6 HEATER NO 6 26.67 25.09 21.44 18.01 11.6 4.5
HP5 HEATER NO 5 11.92 11.29 9.8 8.343 2
LP4 HEATER NO 4 6.358 6.021 5.238 4.469 3.067 5
LP3 HEATER NO 3 2.736 2.584 2.267 1.929 1.325 5
LP2 HEATER NO 2 1.26 1.195 1.043 0.8933 0.467 5
LP1 HEATER NO 1 0.2664 0.2534 0.2217 0.1907 0.1333 5
I HEAT RATE IN KCAL/KWH
Regime IN KW 211902 202200 176669 151400 101200
HEAT RATE
Kcal/KWH 2040 2039 2051 2066 2154
*********************

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