Steam turbines & Electric motors

How can we rev you up?

A Group Fs Production

http://www.revak.com/powergenpics.htm
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Presentation Outline
1. 2. 3. 4. 5. 6. 7. Typical Applications Types of Drives Physical Principles Troubleshooting Safety Operability Capital & Operating Costs
Were going to make Motors and Turbines jump through hoops for you!

So where do drives live in Chemical Engineering Land?

They live next to
Pumps Compressors Fans Conveyor belts Crushers Mills

And many more places

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Types of Drives

Electric Motor & Many More!!!

Steam Turbine
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Source: http://fsvpix.homestead.com/FSVtodaypix.html

Drives sub-types
Electric Motors
Constant Speed:
A/C Squirrel-Cage Induction, Synchronous A/C, etc.

Variable Speed
Two-Winding, SingleWinding ConsequentPole, etc.

Source: http://www.gi4xsf.freeserve.co.uk/imgen/imgen.htm

Steam Turbines
Condensing, Noncondensing, Automatic Extraction turbine, etc.

A Squirrel Cage Induction Motor. Squirrels not included. No, it doesn't run on squirrels either. 5

Physical Principles
Electrical Motors

Physical Principles: Electric Motors:

The rotor is wound with wire
Current flows through the wire to create an electromagnet Motor rotation is achieved through magnetic forces.

Source: http://www.howstuffworks.com/motor3.htm

Ways the Speed of Electric Motors are Varied

Wound-Rotor Induction Motor
Efficiency is sacrificed for controllability

Gearbox control
Gear shift to change rotation speed. Discrete Operating Curve (Step-curves). Cheaper

Source: http://www.anaconsystems.com/text/pr11402eagle.html

Source: http://www.bostongear.com/

How the Wound-Rotor Induction Motor Works

Rotor is an electromagnetic (wound with wires) Windings are connected to a slip ring which is connected to brushes Brushes are connected to a resistance which may be varied
Reduces current through the rotor Reduces magnetic strength of the rotor Reduces the speed of the rotor
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How Gearboxes Vary the Speed of Rotating Equipment

The shaft coupling connects to the gear box The gear box varies the speed of rotation with gears of varying diameters Smaller gears = larger rotation speed Larger gears = smaller rotation speed

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Physical Principles
Steam Turbines

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Physical Principles: Steam Turbines:

High Pressure Steam expands through a governor valve and a nozzle. Experiences an increase in velocity and momentum Pushes the impeller to drive the turbine.
http://home.pacifier.com/~rboggs/HP.GIF 12

Methods Varying of Steam Turbine Speed

Throttling valve Multi-valve machines
Basic With overload With stage valve
Salisbury, K.J., Steam Turbines and Their Cycles. Krieger Pub. Co., c 1950. 13

How Throttling Machines Work

Flow controlled by varying valve position Increased steam flow rate results in greater impeller speed Efficiency greatly reduced at low steam rate
Display 14

How Multivalves Machines Work

Flow split into smaller diameter pipes and controlled by on/off valves Valves operated in sequence by a camshaft When one valve closes flow is reduced
Resistance across each valve remains constant

Total pressure drop from feed steam into the turbine remains constant More efficient at low flow rates than throttling
Display 15

Physical Principles
Connecting the drives

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Coupling From Useless Spinning to Useful Shaft Work

Many coupling types Focus on Grid Couplings: Horizontal Split Cover
Small Footprint Easily Installed

Vertical Split Cover

Ideal for High Speeds

Source: http://www.lovejoy-inc.com/catalog/gd.pdf

Full Spacer Design

Extremely useful for pump applications.
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Coupling Selection Procedure:

Step 1:Determine:
Mover type(Motor/Turbine Type). Duty requirements. Equipment Characteristics (Shaft sizes) Misalignment Possible? Likelihood of excessive vibrations. Ambient conditions
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Coupling Selection Procedure:

Step 2: Determine Coupling Material Types: 1. Metallic
Stiff rotation Light inertial loads Non-tolerant to misalignment. High Temperature Applications. Soft rotation High inertial loads Allows for misalignment Low Temperature Applications.
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2. Elastromeric

Packing Preventing fluid leakage

Packing = Sealant on shaft bases to prevent leakage of process fluid and reduce misalignment, example: O-ring Sealant material:
Must be relatively inert to reaction with environment and process fluid. Low temperature applications: polymeric, rubbery material
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Troubleshooting

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Troubleshooting Workshop
The efficiency of a turbine in the boiler house has decreased, and Dave has observed vibrations. He shuts down the unit for maintenance and observes water pooled in the bottom of the turbine. What may have happened?
How can the problem be prevented?
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Common Problems with Steam Turbines

Vibration Cycling of the governor Sticky valves Temperature bow Erosion Excessive rotation speed Electrostatic discharge Steam condensation
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Common Problems with Electric Motors

Vibrations Mechanical & Electrical Overload Short-circuits Excessive rotation speed Locked Rotor Under-Voltage Sparking
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Trouble-shooting Causes: Vibrations

Possible Causes: Turbine misalignment Unbalanced turbine Rubbing parts Lubrication problems Steam condensation Settling of the foundation Cracked or worn parts
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Troubleshooting: Causes of Excessive Rotation Speed

Mechanical Overload Steam flows which are too high Loose gears or loose bearings Decoupling Aged gears (worn gears)

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 Electrical

Troubleshooting: Causes of Equipment Overload

Current surge Short circuit Rotor sticking Etc.

Mechanical
Excessive steam flow Pressure increase in the steam Etc.
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Troubleshooting: Sparking
Charge accumulation Poor contacting between the stator and the rotor Short circuit Etc.

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Safety

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Safety: Electric Motors

Different area classifications require different motor enclosures
Open, drip-proof Weather-protected, types I and II Totally enclosed motor Packing & casing around the coupling

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Safety: Steam Turbines

Slug of water may damage the turbine
Moisture separator prevents water from entering the turbine

Rotor imbalance Need to prevent high inlet pressure Temperature bow

Bends the shaft
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Cost and Operating Range

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Operability - Steam Turbines

Operating Window
Typically Operate below 538C (1000 F) Keep above dew point of process fluid.

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Operability Electric Motors

Trade-off between Torque and Speed.
Typical motors have an optimal point of max. power between max torque and speed.
Source: http://www.airmotors.com/template.cfm?page=1

Power a Torque*RPM

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Capital Cost
Principal Correlating Factor:
Drive Power (bhp).

Auxiliary Factors:
Electrical motors:
Rotation Speed (RPM), Enclosure Type/Design

Steam Turbines:
Pressure (psig) Superheat (F)

So, how much would the squirrel cage induction motor cost, if we wanted squirrels?
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Operating Cost:
Factors Affecting the Operating Cost: Electric Motors:
Price of Electricity Age of the Motor (efficiency) Coupling alignment Bearing wear Cost of Steam Blade degradation Coupling alignment Bearing wear

Steam Turbines:

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When to choose what?

Requirement: small torque and low flows.
Electric motors easily fitted into process.

Requirement: large torque and high flows

Steam turbines prove to be more efficient.

Excessive amounts of high pressure steam in process Steam Turbines to minimize cost. If sufficient budget and steam build both and alternate to minimize cost.
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Considerations in Drive Selection

Steam Turbine Pressure and Temperature of steam available Desired pressure and temperature exiting the turbine Steam cost, and turbine efficiency Flexibility in turbine speed Level of control required

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Considerations in Drive Selection

Electric Motor Cost of electricity Required Power Efficiency and applications (pump, fan, etc.) Time in service Required flexibility of speed Variable Speed is 4 times more expensive than single speed (at 3000 hp) Maintenance
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References

Perry, H. Perrys Chemicals Handbook, 7th Edition, McGraw-Hill, New York, NY. c1984. Salisbury, K. J., Steam turbines and their cycles, Krieger Pub. Co., 1974, c1950. http://www.lovejoy-inc.com/catalog/m.pdf http://www.vem-uk.com/1024/frameload.htm?frame2=/1024/products.html http://www.bostongear.com/ Microchip WebSite, http://www.microchip.com/1010/index.htm http://www.microchip.com/1010/suppdoc/design/mtrcntrl/menufaq/mtrtypes/ Premium-Efficiency Motors Initiative website, http://www.cee1.org/ind/motrs/motrs-main.php3 Energy Advisor website, http://www.ladwp.com/energyadvisor/PA_35fig.html Drive system Inc.website, http://www.drivesys.com/asdis.html

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Multivalve Machine
From Boiler F1 P1 F1/3 F1=F11+F12+F13
1/2

F1/3
F1/3 P2

F1=v1(DP/r) + v2(DP/r) + v3(DP/r)

1/2

1/2
Multivalve Machines 42

Throttling Machine

From Boiler P1 F1

P2

F1=v(DP/r)

1/2

Throttling Machine 43

Troubleshooting Explanation
Steam condensing within the turbine.
A temperature drop in the steam
Poor insulation Reduction in boiler efficiency Etc.

An excessive pressure drop across the nozzle

A blockage in the nozzle Decrease in inlet steam pressure Etc.

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Troubleshooting Solution
Monitor the steam pressure and temperature from the boiler
Increase boiler load if either is too low

Check and fix the insulation where applicable Monitor the pressure drop into the turbine
Clean nozzles and other parts if necessary
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