,"

PREDICTING STEAM TURBINE PERFORMANCE

James T. Harriz, EIT
Waterland, Viar & Associates, Inc.
Wilmington, Delaware
ABSTRACT
Tracking the performance of extraction, back-
pressure and condensing steam turbines is a crucial
part of minimising energy and maintenance costs for
large process industries. A thorough understanding
of key equipment performance characteristics
promotes economical in-house power generation.
Proper Scheduling of of maintenance reduces
downtime. Rankine Efficiency as a function of
steam flow can be accurately predicted from several
sources of available data. Sample analysis of
predicted performance data (Willans Line, flow
versus extraction enthalpy, flow versus exhaust
temperature and flow versus used energy) and test
data are presented. Techniques for deriving
efficiency curves from each source are described.
These techniques can be applied directly to any
steam turbine reliability study effort.
INTRODUCTION
As the cost of energy resources continues to rise,
so does the incentive to produce mechanical and
electrical power while meeting process steam load
requirements. Cogeneration originally arose from a
need for reliable power, before the public utili ty
system could support large industrial loads. While
there is still a need for the generating capacity
of private industry, this need is being met with
increasingly expensive fuel. With the introduction
of PURPA regulations, additional incentive has been
placed on the private sector to produce and sell
electricity. Even without going into the electric
business, private industry will keep operating
costs down by producing prime shaft power with
efficient topping turbines to reduce purchases of
pub1ic power.
The key to economical power production (electrical
or mechanical) is to employ efficient turbines, and
maintain them at an acceptable performance
standard. Since equipment tends to degrade with
time, procedures must be established to monitor
performance. Over a period of time, the degree of
degradation can be observed and maintenance can be
scheduled on a convenient or as-necessary basis,
and the results of maintenance can be verified.
There are several approaches to predicting and
verifying the performance of steam turbines, just
as there are several different types of turbines.
However, all machines are governed by the same
first and second laws of thermodynamics, and can be
treated in fairly standard form.
ANALYSIS
Five separate sources of information may be
available to the engineer to begin turbine
performance analysis.
1. Equipment data sheets
2. Wi11ans line or extraction curves
3. Exhaust or extraction steam Enthalpy curves
4. Exhaust or extraction Used Energy curves
5. Actual performance test data
Of these five sources, the first four come from the
turbine manufacturer. While all of these are not
provided with all equipment, some (and sometimes
several) usually are. Scrounge around the archives
a bit and see what turns up.
The objective is to predict as-new expansion
efficiency for a machine under the conditions it is
actually subject to, for comparison to on-site test
data. The following examples demonstrate the
conversion of raw data into useful information.
1. EQUIPMENT DATA SHEET -- For equipment rated 200
BHP or less, the only manufacturer's data often
available is a Data Sheet. (Figure 1)
Figure 1.
This catagory of equipment is generally designed
for on/off operation to support pumping loads
(cooling water, condensate, and product transfer),
or draft fans and air blowers for boilers or
process.
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Proceedings from the Seventh National Industrial Energy Technology Conference, Houston, TX, May 12-15, 1985
In addition to construction details, the Data Sheet This efficiency value represents expected
includes the following design information: performance under design conditions. If any
machine ever sees design conditions, it is, rare,
0 Steam Conditions throttle pressure, temp- but within a moderate range of throttle and exhaust
erature, and exhaust pressure. (600 psig, pressures it will continue to function well.
720FTT, 35 psig)
0 Speed. (3560 RPM) 2. WILLANS LINE OR EXTRACTION CURVES Larger
0 Brake-Horsepower. (121 BHP) turbines are often designed to run partly loaded.
0 Steam (or Water) rate. (31.3 LB/HP-HR) Turbogenerators can be set up to control an
exhaust or extraction header pressure, for
In some circumstances, this information is given and vary electric generation (at constant speed) to
for several possible operating speeds. meet a steam demand. Compressor drives are jusualy
variabIe load machines. Another variablei load
From this data, design efficiency can be calculated arrangement is the common-shaft coupling ! of a
as follows: blower to a motor and turbine driver, which ,allows
load sharing between the two.
a. Ideal (100% efficiency) expansion for a turbine
would occur' at constant entropy (isentropic).
A Willans line defines net BHP or KW over a
Use steam tables, curves or a steam properties of throttle flow rates. Again, it is keyed to a
computer program to determine inlet steam
specific throttle temperature/pressure and e:xhaust
enthalpy and entropy from temperature and
pressure profile (Figure 4). From it, w,e can
pressure (1361.75 Btu/lb &1.594 Btu/lbOR).
predict efficiency and exhaust conditions over the
b. Find the enthalpy value
turbines range of operation. i
corresponding to inlet " i ;. ,T.' ;" 'I";.'. .- '". "J
entropy and exhaust pressure
.!: .1_c?,tG . - i' 1 1"
(1125.90 Btu/lb).
.: ;7400 HFj 10000; RPM I I :
c. The difference (f).h 235.86) ,00000 IE)(PECTr,;,O !
I I j"
represents the theoretical
i ". INtlNITE i"-'Z.L,: r
maximum energy (Btu's) that
could be removed from a
'''! !
j
pound of steam under these .J<'oooo.
.' ! . - 'I'
operating conditions. 'i .
i
d. Convert this ideal heat rate .. 1
", t-,
(Btu/lb) to ideal steam r..' .i;.i.' !
i
I _.. --_.. .. r-- ..
... --I
; . i-::... I
1-
.: . I'._
- _,F; RriTE - ilDUhOS PER HP-Hl(
"'SiE" is 14.7 PSIA

. i
I w .'.:1:.:-,"' .. i.' .:
: OS: G ,:Xl. 0
-r 720. (I :'..cj :
i
S',' .>:L" &TJ! .[:Ll61. 75
.._._._. ----j-
S\"C>" 1.594
.'..0. ,.:fOOO : 2000 'lOO<.> 4Q(X)
:.j. I I
"HOR5E..P,::)vvER;
:
FIGURE 4.
EFF :0.79 a. As in la, b, c, and d above, calculate the: ideal
EFF lb.bJJ - steam rate. The results are shown in Figure 5.
5C':' EFF 2:.58 b. From the Willans line, calculate steam raFe for
25J EFF 30.83 a range of flow/power pairs.
W Flow
or
Flow
Figure 2.
BHP (KW x Generator Eff)
e. The ratio of ideal to manufacturer's rated water
where generator efficiency can generaqy. be
rate yields rated efficiency (Figure 3).
concidered 93 to 97%. Space does not peJtmlt a
thorough discussion of variable
ASR Hc;ual tl>1 RATED
losses, and a fixed value will not be far off.
LB/HP-HR BTtJ/LB f<itJiLB EFF j
c. As in I.e. above, calculate Rankine
Figure 6 summarizes this calculation, with
other useful information. '
TRA"ISFER ?lJMP 3l.3 81.31 :280.1+4 34.47
Figure 3.
I I
!
--T'-
8000
-. ...,_c
,;<:ioo
I
i.
!.
I
-;-_. ..:....-
: .:
L
5000
107
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Proceedings from the Seventh National Industrial Energy Technology Conference, Houston, TX, May 12-15, 1985
--------------------
--- ---
k,
,
,.
'
W1PRESSOR DRIVE TURBINE PERFORMANCE CURVE
COMPRESSOR DRIVE TURBINE
80
TURBINE STEAl RATE - PWID5
PRESSURE IS 14.7 PSIA
HUT PRESSURE PSI6 li15.0
IUT -f 720.0
INLET E.'f"HIlLPY BTll/LBI3liO.9O
EMROPY IlTU/LBR 1.591
EXtA!ST PRESS
EFF 15.4S _
liSl' EFf 23.n
1:0 PSIS SOl' EFF 30.91
35l' EFf 44.15
Figure 5.
W1PRESSOR DRIVE TURBINE
ilrldicted Efficil!llCy tro.Manuficiurer's IHLUlNS LINE
13liO.9O BTU/L811 THROTTLE ENTIIlPV
15.4SO HR TlEORETICll. SIDlIl RATE
DELTA H WTl.ET RSR RAN<INE
FLOW PlIoER EHTJR.PY EFfICIEIICY
Ul.B/HRl HIP) (BTU/L8II) IBTU/L8II) (LB/HAlr) (l'l
45.00 1500.0 84.83 127li.07 30.00 51.SO
0.00 2250.0 95.44 1265.46 2li.li7 57.94
80.00 3355.0 101i.73 1254.17 23.85 4.79
100.00 4450.0 113.25 1247.liS 22.47 li8.75
120.00 55SO.0 117.71 1243.19 21.2 71.46
140.00 li6OO.0 119.98 1240.92 21.21 72.84
10.00 7liSO.O 121.li8 1239.22 20.92 73.87
Figure 6.
This can also be represented in graphical form,
to predict performance at any flow rate
(Figure 7).
Efficiency is now defined as a function of flow
without restriction to a particular set of steam
conditions. This curve is as valid for actual
header conditions as it is for those specified by
the manufacturer, within reasonable limits.
3. EXHAUST OR EXTRACTION ENTHALPY/TEMPERATURE
CURVES -- In addition to, or in lieu of, Willans
lines, the manufacturer sometimes provides curves
describing exhaust steam enthalpy or temperature as
a function of section flow (Figure 8). This is
particularly common for extraction machines. This
data is valid only against a specified inlet
condition, but can be readily converted to the
familiar efficiency versus flow format for more
general evaluation.
-------.... I
J.----- !
60
/f"--- I
i
I
40
I
!
20
,I
o 20 40 60 80 100 120 140 160 180
THROTTLE FLOW - 1000's LBS/Hr
Figure 7.
:" -,"cOMPRESiOR"uRiVt TURBiNE
_.... 72.0.;=.-'110"-:6..... _
'7400 HP: <cCOO RPM'
:--- .zoocqo .._.t--- ".. _.- .- -. ..
... j ; .... I .
J ! . _....... . ', ' ; .
. . . ". i. ! _ ....__ .... :_.1 :"._' _.1._"_._
:.....lbOOOO __.L._'.. _. _ _
1 !--; \!
. .. ... .- .:J
1 \:
__ .._ .. __:.:
II-i ...
,1
... "'.' ----... _-------_:_.__.'..-
.. 0 ... : '00... ;.- .. 2.00.. 300 . 400. .. 500...
'.M .. .. -.; --:-' ...:. __
: :
Figure 8.
a. Determine inlet enthalpy from known thrott Ie
temperature and pressure data found on the curve
diagram, Figure 8.
b. Calculate actual lih and steam rate for a range
of section flows; ideal steamrate is the same as
in 2a above; 15.45 lb/HP-HR.
e. Calculate Rankine Efficiency as a function of
flow (Figure 9).
Since a Willans Line was also provided for this
machine (Figure 4), the results of this calculation
can be superimposed on the manufacturer's
predictions for comparison, as shown on Figure 10.
108
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Proceedings from the Seventh National Industrial Energy Technology Conference, Houston, TX, May 12-15, 1985
----------
COMPRESSOR DRIvE TURBINE
Oredlctea Efficiency from Manufacturers EXHAUST TEMP vs FLCIj curve
INLET C()/DITICJ/S:
PRESSURE
(PSIS) 615.00 615.00 615.00 615.00
TEllPERIlTURE - (Deg Fl 720.00 720.00 720.00 720.00
ENT;R.PY - IBTU/Uill 1360.91 1360.91 1360.91 1360.91
ENTROPY - IBTU/UiI Rl 1.591 1.591 1.591 1.591
!'L(ft; - U0E3 LB/HR) 160.000 120.000 100.000 80.000
EXIAJST
PRESS IJlSlGl 110.00 110.00 110.00 110.00
(Deg Fl 425.00 430.00 440.00 455.00
ACTUAL ENTlRPY 1237.28 1239.97 1245.33 1253.27
lDEIll ENTHALPY 1196.21 1196.21 1196.21 1196.21
ACTUAL STEAM RIlTE ILB/HPHR) 20.59 21.04 22.02 23.65
lllEAi. STEAM RATE tLB/HPHR) 15.45 15.45 15.45 15.45
tET HP m2.3 5702.2 4541.5 3383.3
RANKINE EFFICIEtf:Y 75.06 73.43 70.18 .5.35
"
Figure 9.
PREDICTED PERFORMANCE CURVE
COMPRESSOR DRIVE TURBINE
I
I
I
I
I
I
40 60 8'0 100i 1'20i 140i 160 I lla i
20
THROTTLE FLOW - 1000's LB/HR
D EXHAUST TEMP DATA + WILLANS LINE DATA
Figure 10.
4. EXHAUST OR EXTRACTION USED ENERGY CURVES -- Data
of this variety is usually provided for
intermediate or tail sections of single- and
multiple-extraction turbines. This is just another
way of representing an extraction enthalpy curve,
except that an inlet condition (exhaust enthalpy
from the upstream section) must first be determined
using another method: one of the three previous
techniques wi 11 provide that value. From there,
the process is identical to the previous example.
Figure 11 represents the data from Column 3 of
Figure 6, and produces the same efficiency
versus flow curve, Figure 7.
S. PERFORMANCE TEST DATA Once all the
manufacturer's data has been reviewed and analyzed,
it is time to leave the office and go out into the
harsh environment of real equipment. Turbines
never look like the sales brochures show; they get
covered with insulation (and grime), and are hooked
up to some piece of critical equipment that nobody
wants you to (test) mess with.


.----------
-- I
.
...... l
I
61S#-720
0
FTT-liO#G
7400 HP 6000
Figure 11.
I
However, you rarely need to disturb the tJrbine to
test it. What you do need is some test
equipment. Recently calibrated and
temperature gauges are the best source of data. If
your equipment has thermowells, use them. IIf not,
then a long thermocouple can be between
pipe and insulation in the throttle andJ exhaust
lines to get fairly accurate reading.. (The
temperatures wi11 be a bit low, but about'the same
amount both up and downstream.) pressure!readings
should be taken as close to the equiPment as
possible, to avoid penalizing the turbinerfor pipe
hydraulics induced pressure losses. I
Also required is some indication of steam flow
through the turbine, corresponding to the measured
steam conditions. A recently calibrated steam
meter will provide the best data. Flow-by-
difference should be the last resort. To the
extent possible, take data for a variety of turbine
flow rates (until an operator gets rtired of
humoring you). Then convert the testI data to
efficiency, for comparison to the as-new :predicted
efficiency.
I
i
a. From inlet temperature and pressure, Idetermine
inlet enthalpy, as in La. above, for leach test
condition observed.
b. determine actual exhaust enthJl py
c. Calculate actual Ah at known flow ratesj
I
d. From inlet temperature and pressure, 4nd outlet
pressure, calculate ideal ah and ideal steam
rate as in l.b, c, and d above. I
e. Calculate actual steam rate, if throttle flow is
known. :
f. Calculate and plot turbine efficiency versus
flow against manufacturer's
I
Figures 12 and 13 suuunarise field test data,
calculation of actual performance parameters, and
comparison of results to manufacturer's; predicted
efficiencies. This machine appears [ to have
suffered minor performance loss, butI may not
warrent immediate repair. Continued lnonitoring
over time will warn of further decay,
or comfirm continuing satisfactory
109
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Proceedings from the Seventh National Industrial Energy Technology Conference, Houston, TX, May 12-15, 1985
"URBil>
=::...DTEST DA,Q AAALYSIS
;',-F
P<tSSlIRE .. (PSIG)
- lDeg F)
- lBTU/,-BIIl
Rl
=l.Qw il0E3
630.00
689.00
1341.78
1.572
73.0(0)
CONDlTIONS:
PRESS iPSIS) 81.00
Del ;, 410.00
ACT:.A. ENTHR.PY 1233.49
:DEAL 1159.59
ACTUAL STEAM RATE ILB/'iJlt<9) 23.50
!DEGl STEAM IlCrE iLB/"iIi<RI :J. 9
7
'It! ,,0 3106./
RP.,..CNE 59.4.
Figure 12.
SUMMARY
630.(>(1 630.00 630.0(1
689.00 689.00 689.00
1341.78 1341.78 1341.78
1.572 1.572 l.S72
105.000 119.000 140.000
81.00 81.00 81.00
383.00 378.00 372.00
1219.15 1216.45 1213.18
1159.59 1159.59 1159.59
20.75 20.31 19.79
13.97 13.97 13.97
5059.(, 58bO.4 7074.1
67.3! &8.79 70.58
The procedure for tracking steam turbine
performance is quite straight forwarded. First,
estimate turbine efficiency, independent of steam
conditions, from any of several sources of
manufacturer's data. Then, test the equipment in
operation and convert raw data into terms of
efficiency. Plot both results on a common axis and
identify performance trends. If the equipment
seems to be doing poorly, check to see if there is
something simple to correct, like partly open hand
valves, speed control by throttling, or operating
speed far off spec. If these do not seem to be
contributing to the problem, then closer exam-
ination may be justified.
., RE.D iCTED PER,,-'-j C.UR'.... r-
COMPRESSOR DRIVE TURBINE
--_...-.--.- -------. -- -----.... -.....-----... ----- ---....--------..------.......
,
-olr_ ._. ---:r----r
_.--.... -_.-
_
_ ....._w -
'" 60-j
I
/'/
I
I
-!
"
Test Data
40)
j
c.> ,
H
1

!

201

Z i
H

-l
: I
o
o 20 40 60 80 100 120 140 160 180
THROTTLE FLOW - 1000's LB/HR
Figure 13.
The methods described are straight forward, and
readily adaptible to computer-assisted calculation
and data base record keeping to simplify trend
analyses; most of the figures presented here were
generated by computational programs.
Testing at regular intervals will provide a
chronological record of turbine performance, and
changes can be tracked to indicate when water
washing or repair is required. Timely maintenance
can improve production rates by avoiding
unscheduled down time, and head off more costly
repairs.
The long range benefits are less trouble from
better maintained equipment for less money,
supporting improved production. Sounds pretty
good, doesn't it? Start searching those archives!
110
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Proceedings from the Seventh National Industrial Energy Technology Conference, Houston, TX, May 12-15, 1985