Turbine Section

The Turbine Section provides a wide range of tests and measurements of heating or cooling systems and the assessment of technical state of the tested equipment.

Key activities:

  • Thermal testing of power units fired with hard coal and lignite, among others (performance tests, tests before and after modernization, tests before and after repair)
  • Thermal testing of turbines, pumps, compressors, coolers and other power equipment (performance / operating / diagnostic tests)
  • Thermal testing of gas-steam units and natural gas or furnace oil-fired equipment
  • Special measurements using tracer methods (among others, ball migration in the systems for continuous cleaning of the condenser, flow measurements in the closed and open ducts, including waste water flows in the ducts and treatment plants)
  • Determination of start-up losses of the power units
  • Acceptance tests before commissioning the plants
  • Testing of dynamic state of power rotor equipment

Contact


Turbine Section
Manager: Tomasz Słupik
tel. +48 32 237 63 30
fax +48 32 237 63 01
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Thermal testing of power units

The tests include complex balance and efficiency measurements of power units, including their auxiliaries and installations as well as preparatory and analytical operations.

We offer:

  • performance tests
  • post-assembly / start-up tests
  • operating tests
  • tests related to repair and modernization of the turbine sets.

Depending on the purpose of the test, we determine the specific testing scope and operating conditions of equipment during measurements. The tests aim to:

  • check if the manufacturers’ guarantees for the power unit and individual primary and auxiliary equipment are met
  • assess power units, turbine sets and boilers with regard to the performed tasks (modernization, repair) and their technical state using the obtained values of technical-economic indicators and efficiency.

The testing procedures employ testing methodology based on the agreed standards. The power unit test includes measurements of the turbine set, the boiler and auxiliary power consumption. Besides, we perform separate tests of turbine sets.

The testing of the turbine set covers the determination of:

  • parameters and indicators of operation of the turbine set, the regeneration system and the condenser
  • maximum capacity and power of the turbine set
  • characteristics of total / specific steam and heat consumption
  • efficiency characteristics of turbine sets, turbines and their particular parts
  • the distribution of steam pressure in the turbine and water temperature in the regeneration system.

On the basis of the measurements of the turbine set and the simultaneous test of the boiler and the measurement of auxiliary power consumption, the following characteristics of the power unit are determined, among others:

  • boiler efficiency and energy losses in the boiler
  • total and specific consumption of chemical energy of fuel by the power unit, gross and net
  • relative increment in the consumption of chemical energy of fuel by the power unit, net
  • efficiency of electric energy production by the power unit, gross and net
  • auxiliary power consumption.

Thermal testing of gas equipment

The tests include complex balance and efficiency measurements of gas equipment, including their auxiliaries and installations as well as preparatory and analytical operations.

We offer:

  • performance tests
  • post-assembly / start-up tests
  • operating tests
  • tests related to repair and modernization.

Depending on the purpose of the test, we determine the specific testing scope and operating conditions of equipment during measurements.

The tests usually aim to:

  • check if the manufacturers’ guarantees for the power unit and individual primary and auxiliary equipment are met
  • assess the efficiency of power units, turbine sets and boilers with regard to the performed tasks (modernization, repair) and their technical state using the obtained values of technical-economic indicators and efficiency.

The testing procedures employ research methodology based on the standards agreed upon with the Client.

Complex tests of gas equipment include, among others:

  • determination of the technical parameters of gas turbine sets (nominal power, generating capacity, fuel consumption and efficiency for characteristic operating points, temperature and exhaust gas quantity)
  • determination of the technical parameters of gas-steam units (nominal thermal and electric power, auxiliary power consumption, heat consumption indicators and efficiency for characteristic operating points)
  • noise level measurements
  • measurements of vibrations of gas and steam turbine sets and feed water pumps of high and low pressure
  • gas emission measurements (NOx, CO).

Thermal testing of cooling cycles and auxiliary systems

The tests include complex balance and efficiency measurements of cooling cycles and auxiliary systems as well as preparatory and analytical operations. We offer:

  • performance tests
  • operating tests, including audit-like tests
  • ztests related to repair and modernization.

Depending on the purpose of the test, we determine the specific testing scope and operating conditions of equipment during measurements.

The tests usually aim to:

  • check if the manufacturers’ guarantees are met
  • assess the cooling effect of (fan) cooling towers, efficiency and effectiveness of operation of the turbine auxiliary systems with regard to the performed tasks (modernization, repair).

The testing procedures employ research methodology based on the agreed standards.

Thermal-hydraulic tests of cooling cycles determine, among others:

  • water temperature at the cooler inlet in spray apparatus or overflow outlets of the water distribution channels
  • water temperature at the cooler outlet by grid method in water discharge channels of the bowl
  • temperature and moisture of atmospheric air
  • wind velocity
  • hydraulic load of the cooler by isotope method or using calibrated elbow reducers to measure streams of water delivered by the pump system
  • capacity of cooling water pumps
  • overpressure at the pump suction and forcing
  • rotations and electric power consumption by engines of the cooling water pumps
  • overpressure in water distribution channels.

Flow rate testing by isotope method

Depending on the purpose of the test, we determine the specific testing scope and operating conditions of equipment during measurements.

The tests usually aim to measure:

  • flow rate of water delivered by pump systems from the cooler / water tank / river to condensers of the turbine sets
  • water flow rate at different conditions when it is impossible to use traditional measurement methods, e.g.: by means of measuring reducers or impact tubes.

Water flow measurements by isotope method consist in a continuous dosage of the isotope tracer solution into the pipelines and simultaneous sampling of water with the dissolved tracer in the place where it undergoes complete mixing.

Acceptance tests for PSE OPERATOR SA

We perform acceptance tests required before commissioning of power units for PSE OPERATOR SA in public and industrial power industry. The tests are usually based on the indications of operational apparatus installed at the plants under examination.

Energy efficiency audit

An energy audit is good engineering practice which results in the enhanced investment, modernization and repair operations and constitutes the basis for activities to improve technical and economic indicators of operation of a specific company.
A significant improvement in the efficiency of energy production, transmission and utilization requires knowledge and awareness of the potential of pro-efficiency measures. An energy audit is a diagnostic tool for its identification.
The audit may cover not only the main technological or production process but also auxiliary processes or particular equipment the technological line is composed of. The plan of activities to decrease energy consumption of technological processes may be determined thanks to the complex energy audit, which encompasses all the activities related to energy flow at a specific company.
A full scope audit provides a comprehensive view on equipment, installation or technological line which specifies the present technical state of equipment / installation/ technological line (on the basis of their characteristic indicators that determine operation efficiency).
Thus it is possible to identify the reasons for a potential worsening of the above mentioned indicators, point out the ways of improving the efficiency of operation of equipment / installation / technological line and determine the expected costs of the proposed undertaking.

The audit consists of a number of operations which aim to:

  • identify the sources generating the losses of energy, egzergy and medium in the cycle
  • specify the actual reference level as regards the present technical solutions
  • propose measures to minimize the identified losses
  • make the simplified analysis to determine a simple payback period of the proposed pro-efficiency measures.

The scope of the audit encompasses:

  • inventory of equipment / processes
  • development of the audit program including, among others, a general schedule of operations related to on site measurements and its approval by the client
  • on site measurements – tests specified in the audit program and supplementary measurements resulting from the performed work
  • development of the test and analysis results in the form of a report
  • implementation and monitoring of solutions that fulfill the profitability criteria of technological processes.

The estimated time of an audit depends on a number of factors (e.g. the size of a company) and, in general, may range from a couple of days to a couple of weeks. In case of a company which consists of a lot of sections or departments, the time undergoes multiplication. What is essential during the performance of tasks related to the energy audit is the cooperation between the client’s competent personnel and the audit team.

Because of its complex nature, the determination of the actual level of losses at the specific site usually requires the use of advanced measuring apparatus and methods. The competence of the audit company in this respect is of vital importance because an energy audit should be a low-investment operation to support the process of improving energy efficiency and, as a consequence, the technical and economic indicators of operation of the company.

Therefore, the measures included in the scope of the energy audit require great experience, advanced apparatus and measuring methods. Energopomiar fulfills all these criteria. We have advanced measuring equipment, the proven methodology and the experienced team which has rendered services for professional and public power industry, distribution networks and industry.

TKE – implementation of complex systems for balancing and operation supervision

  • System for balancing and operation supervision using the TKE®method of technical and economic control of operation of conventional power plants and CHP plants
  • System for balancing and operation supervision of steam-gas systems
  • System for technical and economic control of operation and assessment of repair efficiency
  • System for the simulation of technical and economic indicators – including the influence of changes in the selected parameters on the indicators and variable costs
  • System for planning the operation of power plants and CHP plants – simulation and test modules
  • System for the control of the auxiliaries
  • Balancing system for industrial plants
The system provides information on the size, location and reasons for the occurrence of energy losses, which is helpful for loss reduction and optimization of operation of power units by:
  • systematic control and assessment of the technical state of power equipment
  • correct operation
  • planning of operation according to the present and expected situation
  • proper management of production, correct operation, proper decisions regarding optimum repair policy and rationalization measures.

      The system ultimately allows the optimization of operation of power units, assistance in production management and planning of operation.
      The systems are a tool that enables the formation of an integrated modern system for management of electricity and heat generation processes.
      It is possible to extend or update the scope of the system because of the modernization of equipment and computer systems while maintaining the comparability of calculation results. The systems are dedicated to particular plants and hence take account of their specific conditions and the existing IT platform.
      The way of collecting data for calculations corresponds to the existing or designed logging system and control and measuring apparatus. The system makes calculations for particular equipment, groups of equipment and for the whole plant.

      The development of the system consists of, among others:
    • preparation of data collection and verification algorithms as well as calculation algorithms
    • system software using Internet technologies, database development
    • author’s supervision and assistance during the system implementation.
    • The service is provided by the Turbine Section and the Energy Economy Analysis Section.