ESL-IE-85-05-19 ,"

PREDICTING STEAM TURBINE PERFORMANCE

James T. Harriz, EIT

Waterland, Viar & Associates, Inc.

Wilmington, Delaware

ABSTRACT ANALYSIS

Tracking the performance of extraction, back­ Five separate sources of information may be
pressure and condensing steam turbines is a crucial avai lab le to the engineer to begin turbine
part of minimising energy and maintenance costs for performance analysis.
large process industries. A thorough understanding
of key equipment performance characteristics 1. Equipment data sheets
promotes economical in-house power generation. 2. Wi11ans line or extraction curves
Proper Scheduling of of maintenance reduces 3. Exhaust or extraction steam Enthalpy curves
downtime. Rankine Efficiency as a function of 4. Exhaust or extraction Used Energy curves
steam flow can be accurately predicted from several 5. Actual performance test data
sources of available data. Sample analysis of
predicted performance data (Willans Line, flow Of these five sources, the first four come from the
versus extraction enthalpy, flow versus exhaust turbine manufacturer. While all of these are not
temperature and flow versus used energy) and test provided with all equipment, some (and sometimes
data are presented. Techniques for deriving several) usually are. Scrounge around the archives
efficiency curves from each source are described. a bit and see what turns up.
These techniques can be applied directly to any
steam turbine reliability study effort. 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
INTRODUCTION data. The following examples demonstrate the
conversion of raw data into useful information.
As the cost of energy resources continues to rise,
so does the incentive to produce mechanical and 1. EQUIPMENT DATA SHEET -- For equipment rated 200
electrical power while meeting process steam load BHP or less, the only manufacturer's data often
requirements. Cogeneration originally arose from a available is a Data Sheet. (Figure 1)
need for re liab le power, before the pub lic ut i li 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
pub 1ic 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 main tenance can be
scheduled on a convenient or as-necessary basis,
and the results of maintenance can be verified. Figure 1.

There are several approaches to predicting and
verifying the performance of steam turb ines, 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.
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.

106

Proceedings from the Seventh National Industrial Energy Technology Conference, Houston, TX, May 12-15, 1985
 ESL-IE-85-05-19

In addition to construction details, the Data Sheet This efficiency value represents expected ~s-new
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.
720°FTT, 35 psig)
0 Speed. (3560 RPM) 2. WILLANS LINE OR EXTRACTION CURVES Larger
0 Brake-Horsepower. (121 BHP) turb ines are often des igned to run part ly 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 e~ample,
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
variab Ie load machines. Another variab lei load
From this data, design efficiency can be calculated arrangement is the common-shaft coupl ing ! of a
as follows: b lower to a motor and turb ine driver, wh ich ,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 ~ariety
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

en tropy and exhaus t pressure

.!: !6JS~G;7;"'LO~F:.- .1_c?,tG .· - ·1 1" i'
(1125.90 Btu/lb). .: ;7400 HFj 10000; RPM I I :
c. The difference (f).h ~ 235.86)
represents

cou ld be
the

removed
theoretical
maximum energy (Btu's) that

from a

,00000
I
IE)(PECTr,;,O PEJ~FO :t"'At'J#-~E

i ".
~~,I?~ INtlNITE i°"-'Z.L,: r-0NT'~
I
!
j"

r
'
j ''! !
pound of steam under these .J<'oooo. .' ! . - 'I'
operating conditions. 'i .
d. Convert this ideal heat rate .. i
1· I

(Btu/lb) to ideal steam r···.. ' . i · ; · . i.' ! ", t-, : .:

rat~: I· _.. 12.000.a~~~_~_.j --_..~- .. r··-··-·
i .. L I I . . --I·

; ~:: . i·-::... I
1­
I'~ .: _.:~'~:(~.~-:." I'. _ .
.i

- _,F; ~t S~E~~, RriTE - ilDUhOS PER HP-Hl(

"'SiE" )~£S5U~t is 14.7 PSIA

ltf':~-~c
I w .' .:1:.:-,"' .. i . ' .: i
i.
: ,tSS.;~E OS: G £,:Xl. 0

!E"'~[RA"uQE -r 720. (I
S',' .>:L" &T J! .[:Ll61. 75
f}+(·r~ :'.. cj :
!.
I
S\"C>" 3~U;LB~ 1. 594
~ ~~-~-Q_~ ~::_~~.:?::-; ~- ._:.-=-~ . _._._. ----j- -; -_. --~ . .:....­ -. ...,_c !
--T'­
.'. . 0. ,.: fOOO : 2000 'lOO<.> 4Q(X) 5000 ,;<:ioo 8000
:.j. I "HOR5E..P,::)vvER;·· I
:
FIGURE 4.

~s ~S:G
:o~
SS~
EFF
EFF
5C':' EFF
25J EFF
:0.79
lb. bJJ
2:. 58
30.83
- a. As in la, b, c, and d above, calculate the: ideal
steam rate. The results are shown in Figure 5.
b. From the Willans line, calculate steam raFe for
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 gen~rator
~TE~ ASR Hc;ual IJ.~ 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 effic~ency.
Figure 6 summarizes this calculation, alon~ with
other useful information. '
CONDE~ATE TRA"ISFER ?lJMP 3l.3 81.31 :280.1+4 34.47

Figure 3.

107

Proceedings from the Seventh National Industrial Energy Technology Conference, Houston, TX, May 12-15, 1985
 k,

ESL-IE-85-05-19
,,. '

W1PRESSOR DRIVE TURBINE ~REDICTED PERFORMANCE CURVE

COMPRESSOR DRIVE TURBINE
80 TI----=~~=~=~==.t'-"'---~I
TURBINE STEAl RATE - PWID5 ~R H~1Il
~IENT PRESSURE IS 14.7 PSIA
~l -------.... ~ I
J.----- !
HUT PRESSURE PSI6 li15.0
60
/f"--- I
¥ i
IUT TEJl~ilATURE -f 720.0
INLET E.'f"HIlLPY BTll/LBI3liO.9O
40
I
i,~LfT EM ROPY IlTU/LBR 1.591
-------------------- I !

EXtA!ST PRESS 20

.1~,....--,--,-"~ ~J
:~ EFF 15.4S _
liSl' EFf 23. n
1:0 PSIS SOl' EFF 30.91 ,I

35l' EFf 44.15 o 20 40 60 80 100 120 140 160 180

THROTTLE FLOW - 1000's LBS/Hr
Figure 5.
Figure 7.

W1PRESSOR DRIVE TURBINE

ilrldicted Efficil!llCy tro. Manuficiurer's IHLUlNS LINE
:" -,"cOMPRE SiOR"uRiVt TURBiNE
~.:.. _.... :bI5~ 72. 0 .;=.-'110"-:6 ..... _ ~._.
'7400 HP: <cCOO RPM'

13liO.9O BTU/L811 THROTTLE ENTIIlPV :--- .zooc·qo _:.-~;.._..:...~--:---_..

... j
_.t---
;
---~ "
....
.._.- .- -. I
..
15.4SO L~/HP HR TlEORETICll. SIDlIl RATE
J ! . _....... . ', ' ; .

.:..... lbOOOO
. . _·_.L._'..
·". i. _. ! _
_ • • • . . . . __:_. _ _.1._"_._
1....:"._'

DELTA H WTl.ET RSR RAN<INE

····1 !--; \!
FLOW

.t.~·,~=:. ~-.·~ . •.r-~· •.-i.··-Z~_:-~~.~~~-\j.- .:J

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 1 \:
~_40000__~ _._.~:J_._.__'_~~:.. . _~._~_~ __:.: ~._~\
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 I I - i ...
,1
1£0.00 7liSO.O 121.li8 1239.22 20.92 73.87
Figure 6. . .. "'.' -----.:_._~_._'--.:._. ----... _-------_:_. __ .'.. ­
.. 0 ... : '00 ... ;.- .. 2.00.. 300 . 400. .. 500 ...
This can also be represented in graphical form, '.M .. .. -.; --:-' ...:. __ =)('HAU5T:_-rEMP==~ATURE._or.

to predict performance at any flow rate : :

(Figure 7). Figure 8.

Efficiency is now defined as a function of flow a. Determine inlet enthalpy from known thrott Ie
without restriction to a particular set of steam temperature and pressure data found on the curve
conditions. This curve is as valid for actual diagram, Figure 8.
header conditions as it is for those specified by b. Calculate actual lih and steam rate for a range
the manufacturer, within reasonable limits. of section flows; ideal s·teamrate is the same as
in 2a above; 15.45 lb/HP-HR.
3. EXHAUST OR EXTRACTION ENTHALPY /TEMPERATURE e. Calculate Rankine Efficiency as a function of
CURVES -- In addition to, or in lieu of, Willans flow (Figure 9).
lines, the manufacturer sometimes provides curves
describing exhaust steam enthalpy or temperature as
a function of section flow (Figure 8). This is Since a Willans Line was also provided for this
particularly common for extraction machines. This machine (Figure 4), the results of this calculation
data is valid only against a specified inlet can be superimposed on the manufacturer's
condition, but can be readily converted to the predictions for comparison, as shown on Figure 10.
familiar efficiency versus flow format for more
general evaluation.

108

Proceedings from the Seventh National Industrial Energy Technology Conference, Houston, TX, May 12-15, 1985
 ESL-IE-85-05-19

COMPRESSOR DRIvE TURBINE t---~

Oredlctea Efficiency from Manufacturers EXHAUST TEMP vs FLCIj curve ----~+---,
.------------ I
.
INLET C()/DITICJ/S:
PRESSURE (PSIS) 615.00 615.00 615.00 615.00
.~~.-~ ......D~ l
TEllPERIlTURE - (Deg Fl 720.00 720.00 720.00 720.00
I
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 61S#-720 0 FTT-liO#G
!'L(ft; - U0E3 LB/HR) 160.000 120.000 100.000 80.000 7400 HP 6000 ~PM

----------
EXIAJST IEXTRlCTI~l ~DITI()E:
PRESS IJlSlGl 110.00 110.00 110.00 110.00
TE~P (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 Figure 11.
I
However, you rarely need to disturb the tJrbine to
tET HP m2.3 5702.2 4541.5 3383.3 test it. What you do need is some reli~le test
RANKINE EFFICIEtf:Y 75.06 73.43 70.18 £.5.35
press~re
"
Figure 9. equipment. Recently calibrated and
temperature gauges are the best source of data. If
PREDICTED PERFORMANCE CURVE
your equipment has thermowells, use them. If not, I
COMPRESSOR DRIVE TURBINE then a long thermocouple can be inserte~ between
pipe and insulation in the throttle andJ exhaust

I
lines to get fairly accurate reading.. (The
temperatures wi 11 be a bit low, but about' the same
amount both up and downstream.) pressure! readings
I should be taken as close to the equiPment as
possible, to avoid penalizing the turbinerfor pipe
I hydraulics induced pressure losses. I
Also required is some indication of steam flow
through the turbine, corresponding to the measured
I
steam conditions.
meter will provide
A recently calibrated steam
the best data. Flow-by­
I
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
20 40 60 8'0 i 100 i 1'20 i 140 i 160 I lla humoring you). Then convert the test I data to
THROTTLE FLOW - 1000's LB/HR efficiency, for comparison to the as-new :predic ted
I
efficiency. i
D EXHAUST TEMP DATA + WILLANS LINE DATA
Figure 10. a. From inlet temperature and pressure, Ide termine
inlet enthalpy, as in La. above, for leach test
4. EXHAUST OR EXTRACTION USED ENERGY CURVES -- Data condition observed.
of this variety is usually provided for b. Simila~ly determine actual exhaust enthJl
I
py •
intermediate or tail sections of single- and c. Calculate actual Ah at known flow ratesj
multiple-extraction turbines. This is just another d. From inlet temperature and pressure, 4nd outlet
way of representing an extraction enthalpy curve, pressure, calculate ideal ah and ideal steam
except that an inlet condition (exhaust enthalpy rate as in l.b, c, and d above. I
from the upstream section) must first be determined e. Calculate actual steam rate, if throttle flow is
using another method: one of the three previous known. :
techniques wi 11 provide that value. From there, f. Calculate and plot turbine efficiency versus
the process is identical to the previous example. flow against manufacturer's predictions~
Figure 11 represents the data from Column 3 of I
Figure 6, and produces the same efficiency Figures 12 and 13 suuunarise field test data,
versus flow curve, Figure 7. calculation of actual performance parameters, and
comparison of results to manufacturer's; predicted
S. PERFORMANCE TEST DATA Once all the efficiencies. This machine appears [ to have
manufacturer's data has been reviewed and analyzed, suffered minor performance loss, but I may not
it is time to leave the office and go out into the warrent immediate repair. Continued lnonitoring
harsh environment of real equipment. Turbines over time will warn of further performa~ce decay,
never look like the sales brochures show; they get or comfirm continuing satisfactory perform~nce.
covered with insulation (and grime), and are hooked
up to some piece of critical equipment that nobody
wants you to (test) mess with.

109

Proceedings from the Seventh National Industrial Energy Technology Conference, Houston, TX, May 12-15, 1985
 ESL-IE-85-05-19

:J~PRESSOR "URBil>£ ~R:VE ., RE.D iC TED PER ,,-'-j RMAt'~CE C. UR'·.... r­

COMPRESSOR DRIVE TURBINE
=::.. D TEST DA,Q AAALYSIS 80~! - - _...-.--.- -------. -- -----.... -.....-----.. -----
---....--------..------.......

, _ -olr_ ._. ---:r----r

;',-F CC~DIT:ONS:
_.--.... -_.­
I
_ ....._w •• - ·

P<tSSlIRE .. (PSIG)
630.00 630.(>(1 630.00 630.0(1
TE~PERPTURE - lDeg F)
689.00 689.00
1341.78
689.00
1341.78
689.00
1341.78
'" 60-j
I
/' /
~THALPY - lBTU/,-BIIl
1341.78 I

"
-!
E~TROP,( lBT~/La. Rl
1.572 1.572 1. 572 l.S72 Test Data
=l.Qw il0E3 ~B/~R'
73.0(0) 105.000 119.000 140.000 ~ 40)
~ j
c.>
H
,

~ 1

;:X~ST (EXT;J~TI[}j) CONDlTIONS: ~ !

~
PRESS iPSIS) 81.00 81.00 81.00 81.00 20·1
~
TE~) Del ;, 410.00 383.00 378.00 372.00 Z i
H -l
1233.49 1219.15 1216.45 1213.18
ACT:.A. ENTHR.PY
:DEAL £NTtA.~y 1159.59 1159.59 1159.59 1159.59 §o :
-t---,---r--r--,---,-_·.--r~r-...,---r---r----r·-~--r--r---i
I
23.50 20.75 20.31 19.79
o 20 40 60 80 100 120 140 160 180
ACTUAL STEAM RATE ILB/'iJlt<9)
!DEGl STEAM IlCrE iLB/"iIi<RI :J. 97 13.97 13.97 13.97 THROTTLE FLOW - 1000's LB/HR

5059. (, 58bO.4 7074.1 Figure 13.

'It! ,,0 3106./
RP.,..CNE EFFl[~ E~CY ~ 59.4. 67.3! &8.79 70.58
The methods described are straight forward, and
Figure 12. readily adaptible to computer-assisted calculation
and data base record keeping to simplify trend
SUMMARY analyses; most of the figures presented here were
generated by computational programs.
The procedure for tracking steam turbine
performance is qui te straigh t forwarded. First, Testing at regular intervals will provide a
estimate turbine efficiency, independent of steam chronological record of turbine performance, and
condit ions, from any of several sources of changes can be tracked to indicate when water
manufacturer's data. Then, test the equipment in washing or repair is required. Time ly main tenance
operation and convert raw data into terms of can improve production rates by avoiding
efficiency. Plot both results on a common axis and unscheduled down time, and head off more costly
identify performance trends. If the equipment repairs.
seems to be doing poorly, check to see if there is
something simple to correct, like partly open hand The long range benefits are less trouble from
valves, speed control by throttling, or operating better maintained equipment for less money,
speed far off spec. If these do not seem to be supporting improved production. Sounds pretty
contributing to the problem, then closer exam­ good, doesn't it? Start searching those archives!
ination may be justified.

110

Proceedings from the Seventh National Industrial Energy Technology Conference, Houston, TX, May 12-15, 1985