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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. Key Words: condition monitoring; optimisation; plant performance; predictive maintenance; steam turbines; testing; N2 packing
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.
Wearout problem
Blading
Usually occurs gradually, worst at inlet Erosion by solid blading. Less usual on sets with drum particles(also erosion boilers and/or sub-critical inlet steam by water droplets on conditions, or with bypass systems. latter LP blades) Performance analysis detects. Parts breaking off Scoring damage to whitemetal Rubbing, temporary unbalance, cracking, misalignment Usually sudden. Vibration analysis and Performance analysis detects. Performance analysis, vibration analysis, wear particles in oil (but representative sampling at each bearing is rare). Vibration analysis, and off-line, some NDT (not detailed in this paper)
Blading
Bearings
Leakage due to wear, Likely to occur gradually, but can be distortion, breakage sudden. Performance analysis detects.
Effect of seal wear is relatively greater for HP blading. For impulse machines, the relative lost output for each 25m increase above design clearance of about 600m is:
HP: blade tips, 5kW; interstage seals, 6kW per stage; end glands 15 to 25kW. IP: blade tips, 2.5kW; interstage 2kW per stage; end glands 5kW LP: blade tips and interstage, 1.5kW per stage; end glands 2kW.
For reaction blading, the effect will be greater. Likely to occur gradually, mostly in areas around 260C. Some on-load blade washing occurs with forced steam cooling. Performance analysis detects. Blade surface roughness has biggest Steam valve effect at higher steam pressures. One Deposits (more strainers case gave 17% drop in output from prevalent with base loaded sets as cyclic deposits varying between 250 to 2300 Valve loading tends to have m in thickness. spindles a blade washing effect). Permissible roughness for LP blading Blading can be 100 coarser than for HP blading. One test with surface finish equivalent to 500 grit emery paper caused 5% to 7% less efficiency in HP blading, about 2% in LP. Generator rotor, stator Condenser Feedwater heaters Insulation faults Air inleakageTube fouling Electrical plant testing (several techniques (not detailed in this paper) Performance analysis (not detailed in this paper)
Air inleakage, tube Performance analysis (not detailed in fouling by scale or oil this paper) Performance analysis. Acoustic leakage detection (not detailed in this paper) is also possible.
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.
Steam Temperature - Main C Steam Temperature Reheat C Reheater Pressure Drop % Condenser Pressure - kPa Generator Power Factor
529.5
0.99832
526.7
0.99773
525.8
1.0101
539.5
0.99873
Steam Temp. Cont. Spray 6.5 Main kg/s Steam Temp. Control Spray 0 - Reheater kg/s Final Feedwater Temperature C Combined correction factor Corrected VWO Output MW 372.7 234.9
0.99889
24.6
0.99584
1.0005
230.5
0.98957
1.04741 362
1.03521
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 Steam strainer pressure drop Section enthalpy drop efficiency (superheated steam sections) Comments Best measured with a differential pressure transducer rather than an upstream and a downstream pair. An increase indicates blockage, probably from metal particles from boiler tube welding repairs. Calculated using steam tables computer program. A drop indicates blade fouling, or erosion damage.
Stage pressures can be corrected to standard inlet pressure, but any error in measuring it is applied to Section pressure ratios all the stage pressures. Ratios use only the outlet and inlet pressures of each section. Changes show up erosion or deposition. Corrected First Stage pressure Extraction temperatures to feedheaters in superheated sections Extraction temperatures to feedheaters in saturated steam sections Drain line At VWO, proportional to steam flow through the turbine, indicates first stage condition. Increase points to upstream erosion, or downstream blockage, and vice versa. According to design, a higher than expected steam inlet temperature may indicate relative internal bypassing leakage in the turbine upstream of the extraction point.. Increases above saturation temperature indicate leakage of steam from a stage upstream of the extraction point. Where available, these may indicate relative leakage,
according to design. A similar approach can be used for points before and after pipe junctions of two streams of different temperatures. Pipe surface temperatures are sufficient for repeatable assessment.
Estimated N2 packing leakage (on turbines Test by varying relative inlet steam temperatures and with combined HP-IP observing effect on IP enthalpy drop efficiency. casings) Table 2: Some parameters of condition of individual turbine sections
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.
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.
where: h3 = enthalpy of steam into Intermediate Pressure blading h1 = enthalpy of steam leaking into IP blading through the N2 gland h2 = enthalpy of hot reheat steam entering the IP turbine.
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).
Coade, R W and Nowak, S (1993) Remaining life study of a 350MW HP/IP turbine Conference on pressure vessels and pipework, Sydney Cotton, K C (1993) Evaluating and improving steam turbine performance Cotton Fact Inc ISBN 0 963 995502 Groves, K (1996) Turbine steam path monitoring using plant DPA system unpublished degree major project Monash University Haynes, C J; Medina, C A; Fitzgerald, M A (1995) The measurement of HP-IP leakage flow: the largest source of uncertainty in code tests of low pressure turbines PWR-Vol 28 IEEE-ASME Joint Power Generation Conference Kuehn, S E (!993) Steam turbine technology keeps pace with demands Power Engineering Leyzerovich, L (1997) Large Power Steam Turbines: Design and Operation Vol 2 PennWell ISBN 0 87814 716 0 McCloskey, T H; Pollard, M A and Schimmels, J N (1995) Development and implementation of a turbine-generator outage interval extension strategy PWRVol 28 ASME/IEEE International Joint Power Generation Conference Sanders, W P (1989) Efficiency Audit of the turbine steam path, classifying damage and estimating unit losses ASME/IEEE International Joint Power Generation Conference Tezel, F H et al (1989) Maintenance scheduling for steam turbine generators ASME/IEEE International Joint Power Generation Conference Vetter, H & Schwiemler, G (1989) First turbine inspection after a 15-year operating period VGB KRAFTWERKSTECHNIK.
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