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Condition Monitoring of Steam Turbines by Performance Analysis
Condition Monitoring of Steam Turbines by Performance Analysis
Abstract Steam turbines today are required to run for well beyond their intended lifetimes. Opening
up machines for inspection is expensive, and owners need to consider all relevant information in
making the decision. Problems in steam turbines which reduce machine efficiency and output, such
as deposits on blades and erosion of internal clearances, can be detected and monitored using
condition monitoring by performance analysis. The paper outlines with some examples some
condition monitoring techniques which have contributed to running some large machines for up to 17
years without opening high pressure sections.
In machines with an HP-IP opposed-flow casing, increased N2 packing internal steam leakage can
occur from the high pressure turbine section into the intermediate pressure section has a large effect
on output and efficiency. The application of a simple test method for estimating this leakage explained
observed poor performance on two sets.
INTRODUCTION
Steam turbine generators are reliable machines, and often operate continuously for many months.
Such operation at steady outputs can lead to deposition from the steam on the fixed and moving
blades. Deposits cause output and efficiency to drop, by reducing the efficiency of energy transfer and
eventually restricting steam flow. This occurs less on sets which vary in load, as they undergo a
regular bladewashing effect.
Where a machine is taken from service, coastdown and running up through shaft bending critical
speeds can allow momentary rubbing at the internal seals. The resulting enlarged flow area can
reduce the internal efficiency, such that less energy is extracted from the steam. This also results from
internal leakage within a casing which allows steam to bypass blading stages. These effects are
particularly evident on the turbine design with both High Pressure and Intermediate Pressure sections
in the one casing, with flow in opposite directions.
Retractable packings have been developed by manufacturers and after-market suppliers. These avoid
shaft rubbing as they do not close into their normal clearances until the machine is near operating
speed, having passed through the bending critical speed or speeds.
Vibration analysis can detect the occurrence of such shaft rubbing and other conditions of the rotor
line, but cannot detect the extent of internal wear or deposition. It is well suited for other quite different
failure modes, such as when blades or parts of them come off and cause consequential damage. As
with the application of all condition monitoring, the rule is to choose techniques to match the likely
failure/wearout modes. As steam turbines are critical machines, all the main techniques have their
place.
Performance analysis can be applied to most machines, rotating and stationary. It is the one condition
monitoring technique which allows the optimum time for restorative maintenance to be calculated,
where the deterioration results in increased fuel consumption, or in reduced output, or both. (Beebe
1998)
For some plant items, it is possible to use the normal plant instruments and data processing system to
determine condition parameters. (Beebe 1998a). In the case of steam turbines, a more refined
method using test quality instruments is needed to give warning well in advance of changes evident
from permanent instrumentation systems. (Groves 1996).
This paper describes some performance tests used for monitoring turbine condition and their
application.
An outage for such work on one casing may take several weeks, and cost millions of dollars. In
making this decision, plant owners need all the relevant information. Condition monitoring by
performance testing has been used to extend time between opening of casings to up to 17 years,
making its cost/benefits very favourable. (Beebe 1995, Vetter et al 1989). The overhaul decision
should not be made unless there is a compelling technical or economic reason for opening a casing.
A current EPRI project is aimed at extending the accepted interval between overhauls (McCloskey et
al 1995).
It should be accepted that an outage after such a long time in service will probably take longer than if
scheduled more frequently, as distortion is likely to have occurred, and parts such as casing studs will
probably need replacement (Coade 1993). Once a casing is opened and clearance measurements
made, it is possible to estimate the performance improvements achievable by refurbishment and so
justify the expenditure (Kuehn 1993; Sanders 1989). However, it is clearly preferable to try and
determine the internal condition by testing, and use this information to help make the decision as to
the extent of overhaul.
In Table 1, the main wearout problems with steam turbines are summarised, together with an outline
of how how condition monitoring can detect them.
The inlet area for steam flow is set to datum by opening the steam control (ie governor) valves fully. This
should be verified by direct measurement at the valve power servos, rather than relying on control room
indicators. Fully open is the only truly repeatable setting.
The temperatures of main inlet and hot reheat steam are set as close to datum as can be achieved. This
is usually the same as the rated values.
The inlet pressure is set to the datum value. As most turbines have capacity beyond their nameplate
rating, the standard inlet steam pressure may need to be below the rated value if undesirably high
outputs would result.
Condenser pressure is largely a function of seasonal conditions and weather, and is usually taken at the
best attainable on the day.
Extractions to feedwater heaters should be all fully open. If feedwater heater unreliability means that
some heaters are out of service for long periods, that condition may have to be used as datum, unless a
method of allowing for this effect on turbine output can be derived.
Test readings during as test run of an hour or so are carefully made using calibrated test instruments,
with two separate measurements of each point. Readings of test transducers can be made manually,
but it is now usual to use a data logger coupled with a computer. With the exception of some minor
flows read from plant instruments and used only in correction factors, test measurements of flow are
not made. This simplifies the test considerably and minimises the cost considerably compared with
the full heat rate test used for the initial acceptance tests for guarantee checks.
The generator MW output over about an hour of steady operation is read using test instruments, and
corrected for any variations from the datum terminal conditions. For example, if the condenser
pressure on the test is higher than the datum, then the turbine output will be less that which would be
expected at datum condenser pressure. Corrections are usually provided by the manufacturer for use
in the initial acceptance tests but can be obtained using cycle modelling programs or from special
tests. With the instrument calibration information available, the calculations are usually performed
immediately following the tests.
Significant changes are often small, and it is unlikely that they can be detected by the permanent
instrumentation and data processing systems fitted for operation and monitoring (Groves, 1996). This
may be possible with highly stable transducers of recent design, or with adequate calibration
arrangements.
From experience, the reduction observed is significant. Further tests would be performed to ascertain
parameters of condition of individual machine components which can be separately opened. Data for
these is often gathered concurrently with the VWO tests.
SECTION PARAMETERS
Measurement of temperatures and pressures at available points along the turbine enable condition of
individual sections to be assessed. If the VWO Output has reduced, then the section or sections
causing the reduction can be localised. Table 2 gives some of the parameters used and their
application. The following sections give examples of some of these in use.
Parameter Comments
Best measured with a differential pressure transducer rather than an
Steam strainer pressure
upstream and a downstream pair. An increase indicates blockage,
drop
probably from metal particles from boiler tube welding repairs.
Section enthalpy drop
Calculated using steam tables computer program. A drop indicates blade
efficiency (superheated
fouling, or erosion damage.
steam sections)
Stage pressures can be corrected to standard inlet pressure, but any
error in measuring it is applied to all the stage pressures. Ratios use only
Section pressure ratios
the outlet and inlet pressures of each section. Changes show up erosion
or deposition.
At VWO, proportional to steam flow through the turbine, indicates first
Corrected First Stage
stage condition. Increase points to upstream erosion, or downstream
pressure
blockage, and vice versa.
Extraction temperatures to According to design, a higher than expected steam inlet temperature may
feedheaters in superheated indicate relative internal bypassing leakage in the turbine upstream of the
sections extraction point..
Extraction temperatures to
Increases above saturation temperature indicate leakage of steam from a
feedheaters in saturated
stage upstream of the extraction point.
steam sections
Where available, these may indicate relative leakage, according to
Drain line temperatures from
design. A similar approach can be used for points before and after pipe
casings, or from shaft seal
junctions of two streams of different temperatures. Pipe surface
(gland) sections
temperatures are sufficient for repeatable assessment.
Estimated N2 packing
Test by varying relative inlet steam temperatures and observing effect on
leakage (on turbines with
IP enthalpy drop efficiency.
combined HP-IP casings)
This can only be determined for the superheated steam sections. For assessment across a turbine
section within a casing, stage conditions are usually available in steam extraction lines to feedwater
heaters. Naturally, these cannot be used for temperature measurement if the associated feedwater
heater is out of service.
In the two test series given earlier, the corresponding enthalpy drop efficiencies were:
Test A Test B
High Pressure casing (from Main Stop Valve inlet) 85.5% 83.8%
Intermediate Pressure casing (from Reheat Stop Valve inlet) 88.2% 88.3%
Figure 1: Section of Mollier Chart showing expansion line. P1, T1 etc are steam pressure and
temperature measured at points of extraction flows in superheated sections
A relative deterioration in the HP casing is evident. Further study would be made of any other
parameters available in this area.
As this leakage steam is at a higher temperature then the extraction steam, relative leakage is shown
by the temperature difference between the mixture and the normal extraction temperature. On one of
six machines of this design, even when new this difference was as high as 60°C. The extraction
steam temperature can be estimated closely enough from the steam expansion line plotted on a
Mollier Chart. To remove the effect of any blading deterioration of stages upstream, a permanent
thermocouple was arranged to fit through the High Pressure outer casing to measure the true stage
temperature.
It was deduced from careful study of construction details from available drawings that the second
bellows had failed. This conclusion was confirmed by the manufacturer.
During starting up of a 200MW turbine, great difficulty was experienced with extremely high in-leakage
into its condenser. Despite all the air removal pumps running, condenser pressure was still well above
the normal. During loading, the problem disappeared - above 40% load.
By examining the stage pressure vs load curves, it was noticed that the pressure to LP feedheater 2
was below atmospheric until above 40% load, when it becomes positive. The air leak was therefore
somewhere in the turbine system connected to that point. Meticulous study of piping drawings and
inspection of the machine revealed a sprung joint in a flange joint in the leakoff piping from a shaft end
gland. This piping led to the LP2 feedheater.
Such investigations are not necessarily easy - few drawings may be available, the piping and
connections may be under lagging, access is required to areas of the machine which are probably
dark, noisy, certainly hot, and special staging may need to be built.
As this gland is near the centre of the rotor span, rotor deflection during starting up and coastdown
operation can cause rubbing, and thereby increase the clearances. Leakage has a dramatic effect on
turbine efficiency, as the leakage flow effectively circulates in a non-reheat cycle of lower efficiency.
Typically, leakage of 1% of initial steam supplied to the turbine results in an output reduction of 0.3%
and efficiency reduction of about 0.16%.
Leakage flow enters after the steam temperature into the IP casing is measured, and because the
leakage steam is at a lower temperature than hot reheat steam, the IP outlet steam will be at a lower
temperature and hence enthalpy. The result is to give an incorrect high value of IP enthalpy drop
efficiency. Therefore, in routine testing of such turbines, if an increase in IP enthalpy drop efficiency is
found, then increased N2 gland leakage should be suspected.
The leakage steam flow cannot be measured, but there are two ways of estimating it to sufficient
accuracy for routine condition monitoring: Cotton (1993) and Booth (1984) and later EPRI
publications. The first method requires the running of IP enthalpy drop efficiency tests before and after
opening the packing blowdown valve, where fitted. A modification which gives better accuracy is to
install a bypass line around the packing blowdown valve, with a flowmeter.
The alternative method requires no plant modifications. Tests are run where some differences
between main steam and reheat steam temperatures are arranged. This is readily done at Valves
Wide Open by holding the hot reheat steam temperature constant while reducing the main steam inlet
temperature. Three steps are suggested. At each test, the IP efficiency is calculated, and plotted
against two assumed leakage flows. The intercept enables a reasonable estimate of the leakage flow.
A critical assessment of the accuracy is given in Haynes, et al (1995).
For the first test, at rated conditions, the enthalpy of the leakage steam is estimated at first stage
pressure from a plot of the expansion line. The steam flow through the IP blading is assumed constant
throughout the test series (as it is the sum of hot reheat flow and N2 leakage under all conditions).
The enthalpy of the steam entering these blades can be calculated by heat balance for both the initial
conditions and for an assumed 10% leakage flow:
The IP efficiency is plotted at datum and 10% leakage conditions. When these points are joined, the
intersection of the lines gives a reasonable estimate of the actual leakage flow (Figure 2).
Figure 2: schematic plot of results for N2 gland leakage: x is estimated flow
Some years later, routine tests were arranged to include the second approach described above. The
estimated N2 gland leakage flow was found to be 4 to 5 times the design value which had been used
in calculating the results of the original thermal efficiency tests. This was consistent with the reduced
thermal efficiency and reheater problems. Inspection at the first overhaul confirmed that the N2 gland
clearances were larger than design, as predicted by the tests, and had apparently been so since new.
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centrifugal pumps MFPT Society 52nd Annual Meeting
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Annual Meeting
Booth, J A & Kautzmann, D E (1984) Estimating the leakage from HP to IP turbine sections EPRI
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project Monash University
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largest source of uncertainty in code tests of low pressure turbines PWR-Vol 28 IEEE-ASME Joint
Power Generation Conference
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87814 716 0
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unit losses ASME/IEEE International Joint Power Generation Conference
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