Improving Steam Turbine Plants Performance Through Advanced Testing and Simulation

The prolonged operation of thermal power plants inevitably leads to component aging and a gradual decline in performance. This deterioration increases the gross heat rate and reduces electrical output, resulting in higher fuel consumption and lower electricity production. Consequently, these issues can cause significant financial losses and threaten the plant’s competitiveness. This paper presents a comprehensive methodology for improving the performance of existing plants. The methodology consists of two crucial elements: steam turbine testing and numerical simulation of the process. The tests should be comprehensive to ensure accurate measurements and reliable conclusions. The developed method for process simulation enables the calculation of overall performance, like specific heat rate and thermal efficiency, as well as the performance of individual components under various operational conditions. Comparing numerical results with experimental data can effectively identify operational problems. Based on these findings, targeted overhauls and other corrective measures can substantially improve the plant’s thermal efficiency and financial performance. The system was demonstrated through a case study of a 120 MW coal-fired steam turbine. The test revealed that it consumes more than 10% additional heat compared to its original design specifications. The analysis identified operational issues and recommended improvement measures, focusing exclusively on the steam turbine set while excluding the boiler.