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.
Blading
Erosion by solid
particles(also erosion by
water droplets on latter LP
blades)
Blading
Bearings
Scoring damage to
whitemetal
Rotors
Rubbing, temporary
unbalance, cracking,
misalignment
Valve
spindles
Leakage due to wear,
Shaft and
distortion, breakage
interstage
glands (seals)
Casing joints
LP manhole
gaskets
Internal steam
piping and
fittings
Steam valve
strainers
Valve
spindles
Blading
Generator
rotor, stator
Insulation faults
Condenser
Feedwater
heaters
Valves - HP,
Leakage
IP bypass, etc
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.
Generator Output MW
355.8
12155
1.02285
12255
1.02053
529.5
0.99832
526.7
0.99773
525.8
1.0101
539.5
0.99873
6.76
0.99814
6.03
0.99633
9.34
1.01225
12.44
1.03615
0.923
1.00012
0.945
1.00064
6.5
0.99889
24.6
0.99584
234.9
1.0005
230.5
0.98957
349.7
1.04741
372.7
1.03521
362
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
pressure
Extraction temperatures to According to design, a higher than expected steam inlet temperature
feedheaters in superheated may indicate relative internal bypassing leakage in the turbine upstream
sections
of the extraction point..
Extraction temperatures to
feedheaters in saturated
steam sections
Estimated N2 packing
leakage (on turbines with
combined HP-IP casings)
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.
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.
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:
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