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HEMATICAL MODEL FOR ESTIMATION
OF STEAM LEAKAGE FOR HIGH
ENERGY DRAIN VALVES ALONG WITH
STANDARDIZED CHECK POINTS FOR
BETTER UTILIZATION OF RESOURCES IN
THERMAL POWER PLANTS
SAMPAD GHOSH, SUJAY SAHU
BUDGE BUDGE GENERATING STATION
Abstract
Internal leakages of high pressure and temperature steam valves are a potential contributor to poor heat rate
in power plants. Monitoring the valve bonnet temperature with an infra-red thermography camera is the most
popular technique to identify valve internal leakage across power plants. However, high bonnet temperature
may not be conclusive always for decision making for valve renewal. Bonnet temperature can rise due to
leakage from gland, bonnet joint, associated pipelines or due to valve internal leakage. This paper standardize
the techniques and further uses a mathematical model for quantification of the leakages as proposed by
Sherikar[1] and experimentally validated by Sulaiman [2]. The underlying principle is to calculate the heat loss
along an un-insulated length of pipe just downstream of the valve and obtain the mass flow rate of the same. The
results of the correlation serve as a tool for detecting valves with only internal leakages and the financial loss
associated to that, thus helps in scheduling and prioritizing of renewal of the valves in case of too many passing
valves with limited inventory. Our proposed MS Excel based model “5 Point Checking & 5 Point Measurement”
will standardize the entire process & save us from unnecessary valve renewal by leading us to the root cause
of the problem.
Index Terms: Bonnet, correlation, financial loss, gland leak, high pressure and temperature, infra-red thermog-
raphy camera, internal leak, mass flow rate, prioritizing of renewal of valves.
ABBREVIATIONS BFP-Boiler Feed Pump
IRT-Infrared thermography
BBGS-Budge Budge Generating Station FY-Financial Year
CESC-Calcutta Electric Supply Corporation SFEE- Steady Flow Energy Equation
HED-High Energy Drain
53
OF STEAM LEAKAGE FOR HIGH
ENERGY DRAIN VALVES ALONG WITH
STANDARDIZED CHECK POINTS FOR
BETTER UTILIZATION OF RESOURCES IN
THERMAL POWER PLANTS
SAMPAD GHOSH, SUJAY SAHU
BUDGE BUDGE GENERATING STATION
Abstract
Internal leakages of high pressure and temperature steam valves are a potential contributor to poor heat rate
in power plants. Monitoring the valve bonnet temperature with an infra-red thermography camera is the most
popular technique to identify valve internal leakage across power plants. However, high bonnet temperature
may not be conclusive always for decision making for valve renewal. Bonnet temperature can rise due to
leakage from gland, bonnet joint, associated pipelines or due to valve internal leakage. This paper standardize
the techniques and further uses a mathematical model for quantification of the leakages as proposed by
Sherikar[1] and experimentally validated by Sulaiman [2]. The underlying principle is to calculate the heat loss
along an un-insulated length of pipe just downstream of the valve and obtain the mass flow rate of the same. The
results of the correlation serve as a tool for detecting valves with only internal leakages and the financial loss
associated to that, thus helps in scheduling and prioritizing of renewal of the valves in case of too many passing
valves with limited inventory. Our proposed MS Excel based model “5 Point Checking & 5 Point Measurement”
will standardize the entire process & save us from unnecessary valve renewal by leading us to the root cause
of the problem.
Index Terms: Bonnet, correlation, financial loss, gland leak, high pressure and temperature, infra-red thermog-
raphy camera, internal leak, mass flow rate, prioritizing of renewal of valves.
ABBREVIATIONS BFP-Boiler Feed Pump
IRT-Infrared thermography
BBGS-Budge Budge Generating Station FY-Financial Year
CESC-Calcutta Electric Supply Corporation SFEE- Steady Flow Energy Equation
HED-High Energy Drain
53
