Steam Path Audits

Presented by
Paul Roediger
Encotech, Inc.

encotec h,
h Inc.
1
 Overview

What is a Steam Path Audit?

Audit Results
Chronology of a Steam Path Audit
Damage
Measurement Techniques
2
 What is a Steam Path Audit?
A detailed inspection of the stationary and
rotating steam path components
An accounting of performance losses on a
stage-by-stage basis
A presentation of losses in power and heat rate

3
 Benefits of a SPA
Provides detailed inspection of steam path
Repair/replacement decisions, early in outage
Aid decisions for future repair
Provides excellent record/history of equipment
condition for future reference

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 The Outage Time-Line
TURBINE OUTAGE

Shutdown Startup
Disassembly Reassembly

Opening Steam Upgrade and Closing Steam

Pre-Outage Test Post-Outage
Path Audit Maintenance Path Audit Test

5
 Results
Quantification of losses measured in pre-outage
test
Quality check on maintenance performed during
the outage
Performance improvement resulting from
individual maintenance actions
Expected return-to-service performance
6
 Pow er Loss (kW)

1000
1200
1400
1600
1800

200
400
600
800

0
Interstage
Packings

End Packings

Tip Spill Strips

Miscellaneous
Leakages

Flow Path Damage

Surface
Roughness

Cover Deposits

Trailing Edge
Thickness
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Opening Audit Power Loss
 Po w e r L o s s (k W)

-200
200
600
1000
1400
1800
2200
2600
3000
Inters tage
Pac kings

End Pac kings

Tip Spill Strips

Mis c ellaneous
Leakages

Flow Path Damage

Surf ac e
Roughnes s

Cov er Depos its

Trailing Edge
Thic knes s
Closing Power Loss

Rec ov ery
8
 Results by Category
Encotech STPE - Fossil 5.2....05/11/2000..................Turbine Audit Summary

County Unit 1 Turbine Totals

Open audit 05/08/2000
Change In Heat Rate
Power Loss Heat Rate Loss
Audit Section (KW) (BTU/KWH) (%)
--------------------------- ---------- --------- ---------
Interstage Packings 152.9 118.20 1.10
End Packings 282.4 220.37 2.05
Tip Spill Strips 329.3 257.87 2.40
Miscellaneous Leakages 8.7 6.62 0.06
Flow Path Damage Results 109.5 20.42 0.19
Surface Roughness 122.7 94.70 0.88
Cover Deposits 0.0 0.00 0.00
Trailing Edge Thickness 0.0 0.00 0.00
Hand Calculations 0.0 0.00 0.00
--------------------------- ---------- --------- ---------
Totals 1005 759.8 7.07
See Casing Totals For Flow Change Impact

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 Results by Stage
Interstage Packing Root Spill Strip
<---Clearance----> <--Clearance---> Change In
Location Design Measured Design Measured Power Loss Heat Rate
Descr. (IN.) (IN.) (IN.) (IN.) (KW) (BTU/KWH)
-------- ------ -------- ------ -------- ----------- ---------
Stage 2 0.010 0.075 0.000 0.000 56.7 43.52
Stage 3 0.010 0.024 0.000 0.000 14.9 11.42
Stage 4 0.010 0.019 0.000 0.000 16.6 12.71
Stage 5 0.010 0.014 0.000 0.000 8.8 6.76
Stage 6 0.010 0.021 0.000 0.000 17.4 13.29
Stage 7 0.010 0.010 0.000 0.000 3.4 2.57
Stage 8 0.010 0.014 0.000 0.000 8.4 6.43

Total Power Loss (KW)........................ 153

Total Change In Heat Rate (BTU/KWH).......... 118.2
Total Heat Rate Loss (%)..................... 1.1

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Chronology
of a
Steam
Path Audit
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 Model
Create model using the Thermal Kit

Design heat balance (VWO)

Turbine cross section
Clearance and steam seal diagram
First stage shell pressure curve

12
 Day 1
Plan around grit blasting schedule
Inspect horizontal joint
Measure packing clearances
Measure top half tooth heights
Inspect shell sealing surfaces

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 Day 2

Measure solid particle erosion damage

Measure deposit thickness
Measure stationary blading surface roughness
Inspect for mechanical damage

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 Day 3

Measure bottom half tooth heights

Measure trailing edge thickness
Measure turbine geometry

15
 Day 4
Input data
Print Steam Path Audit reports
Present preliminary results

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SPA - Flow Path Damage

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Solid Particle Erosion

18
Solid Particle Erosion Pattern

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Inlet to the Diaphragm

20
Mechanical Damage

21
Cover Deposits

22
Blade Deposits

23
Foreign Object Damage

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SPA - Flow Path Damage

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Surface Roughness

encotec h,
h Inc.
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Surface Roughness

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Horizontal Joint

encotec h,
h Inc.
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Tip Spill Strip

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Tip Spill Strip Measurements

C B A Gap

CLEARANCE

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Clearance Calculation Method
GAP

Tooth Height (t)

Clearance (C)

STATIONARY
ELEMENT

ROTATING
Tooth FEATURE

31
Rubbed Teeth

32
Interstage Packing Burr

33
Burr Removal Tool

34
 Martins Formula

HILO Packing Coefficient K

F 1
(N
25K
AP
/ln1P P
)2)vP
1v
80

SPRING
70

PACKINGRING

2 1
60

ROTOR CLEARANCE
Coefficient K

50

40
=c
30

20
0 10 20 30 40 50 60 70

Radial Clearance (mils) 35

 Root & Tip ToothTypes
ROTATING STATIONARY
BLADE BLADE

SINGLE - AXIAL SINGLE - RADIAL DOUBLE STRAIGHT

TWO SINGLE DOUBLE & SINGLE STEP

36
 Interstage Tooth types

HILO SLANT - SLANT SLANT - SMOOTH

STRAIGHT - SMOOTH ALTERNATE HONEYCOMB

37
 Casing Spring
Diameter Diameter
tops - off tops - on

ROTOR

FLOW AREA
TOOTH
INCORRECT CLEARANCE
DUE TO CASING SPRING

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Elliptical Flow Area

Diameter
Diameter
tops - on
tops - off
Horizontal

Diameter
tops - on
ROTOR vertical

ELLIPTICAL
FLOW AREA TOOTH
INCORRECT CLEARANCE
DUE TO CASING SPRING

39
 Balance Hole Measurements

LARGE BALANCE HOLES SMALL BALANCE HOLES

RADIAL
POSITION AXIAL AXIAL AXIAL
LENGTH MINOR AXIS LENGTH RADIAL LENGTH RADIAL
POSITION POSITION

RADIAL
AXIAL MAJOR AXIS
POSITION
LENGTH

DIAMETER

TYPE 1 TYPE 2 TYPE 3 TYPE 4

WHEEL BLADE ROOT BLADE ROOT BLADE ROOT
0 BENDS 1 BEND 2 BENDS

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 Blade Geometry
BLADE
CARRIER

BLADE HEIGHT

TRAILING
EDGE
AXIAL
WIDTH

PITCH LINE

LEADING
EDGE

PITCH

DIAMETER

SEALING
ROTOR DIAMETE
R

ROOT DIAMETER
OF STATIONARY BLADE
41
Root Diameter Measurement
BLADE
CARRIER

STG
16 TIP SPILL
STRIPS STG
15

TRAILING
EDGE
STAGE 15
AXIAL WIDTH

PITCH LINE

LEADING
EDGE

STAGE 16
BLADE HEIGHT

ROOT DIAMETER ROOT DIAMETER

OF STAGE 15 OF STAGE 15
ROTATING BLADING STATIONARY BLADING
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 Impulse Blading

DIAPHRAGM
TIP TENON
SPILL STRIPS
TIP
LEAKAGE

COVER OR
SHROUD
STEAM FLOW
ROTATING STATIONARY
SHELL BLADE BLADE
PRESSURE
BOWL
ROOT LEAKAGE PRESSURE

ROOT
SPILL STRIPS
DOVETAIL

BALANCE HOLE
FLOW
BALANCE HOLE

PACKING
WHEEL

INTERSTAGE PACKING LEAKAGE

SHAFT
43
Stationary Blading Root Dia

DIAPHRAGM
TIP
SPILL STRIPS

STEAM FLOW

ROOT RADIAL
SPILL STRIP
ROOT AXIAL
SPILL STRIP

BALANCE HOLE

WHEEL

INTERSTAGE PACKING
STATIONARY
BLADE ROOT
DIAMETER
44
Rotating Blade Axial Width
AXIAL WIDTH

AXIAL WIDTH
ADJUSTMENT AXIAL WIDTH
ADJUSTMENT

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Cover Deposits

COVER DEPOSIT
DEPTH (INCHES)

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 Deposit & Throat Opening
PRESSURE (CONCAVE) SURFACE

SUCTION (CONVEX) SURFACE

FLOW

LEADING EDGE

RESTRICTED OPENING

TRAILING EDGE

DEPOSIT DEPTH

47
Foreign Object Damage

TRAILING EDGE DAMAGE

THAT INCREASES FLOW AREA

FOREIGN OBJECT WEDGED

IN THE STEAM PATH
DECREASES FLOW AREA

48
Erosion Measurements

TRAILING EDGE
DEPTH

TRIANGULAR SHAPED
SOLID PARTICLE EROSION

TRAILING EDGE
HEIGHT
TAPERED 50%

49
 Surface Roughness Measurement
CONVEX SIDE
LEADING LEADING SECTION
SECTION % OF SURFACE
CENTER WITH EMERY GRIT SIZE
SECTION
3 CENTER SECTION
2 3 % OF SURFACE
WITH EMERY GRIT SIZE

TRAILING 2
1 SECTION

TRAILING SECTION
% OF SURFACE
1 WITH EMERY GRIT SIZE

COMPARATOR

EMERY GRIT SIZE

9.8 7.1 4.9 2.3 1.3 0.7 0.5

3
LEADING SECTION 2
CENTER SECTION
1
TRAILING SECTION

CONCAVE SIDE

50
 Snout Rings
Steam
Leakage
Paths

(24) Outer
(23) Shell
8 Rings (22)
(21)
4 Inner (20)
4 Outer (19)
(18)
(17)
(16)
Typical
(15)
IP Inlet or
HP Exhaust (14)
(13)

(12)
4 Rings (11)
2 Inner (10)
Inner
2 Outer (9)
Shell
Locking Screw

(8)

First Stage Shell (7)

4 Rings (6) Retaining Ring

(5) Locking Ring
2 Inner
(4) Outer Seal & Fit
2 Outer
(3)
(2) Outer Seal
(1) Inner Seal
Steam
Flow

Nozzle
Box
51
First Stage
Bowl
Questions?
1-888-Encotech
www.encotech.com
Phone (518) 374-0924
53
54
 Computer Model
Create turbine model at Encotechs office
using the Thermal Kit
Design heat balance (VWO)
Turbine cross section
Clearance and steam seal system diagram
First stage shell pressure curve
55
 Coordinate Activities
Coordinate activities with owner
Review safety procedures
Sign contract
Plan around grit blasting schedule

56
 Coordinate Activities
Coordinate with outage crew
Place upper half of casing w/ horizontal joint up or
lay on ground w/ trailing edges up
Leave all packing (interstage & shaft end) in place
until measured. This speeds SPA process
significantly
All stages must be inspected prior to grit blasting

57
 Sequence of Events (Casing Lifted)
Inspect casing horizontal joint for leakage paths
Measure blade geometry
Measure packing teeth, interstage, tip, root, and
& shaft end
Create a photographic record of the steam path

58
 Before Lifting Rotor
Chart rotor for actual radial clearances
Interstage packings
Shaft end packings
Root spill strip clearances
Tip spill strip clearances

59
 After Lifting Rotor
Measure lower half tooth heights
Interstage packing and shaft end packing
Root and tip spill strips

Inspect lower half diaphragms

Surface roughness
Solid particle erosion
Mechanical damage
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 Rotor
Inspect rotating blades
Surface finish
Solid particle erosion
Mechanical damage
Cover deposits

61
 Geometric Data
Geometric data for the steam path must be
obtained to properly model turbine
Blade heights and widths
Blade root diameters
Balance holes

62
 Photographic Record
Photographs of the steam path document
condition
All packing teeth
Trailing edges of stationary and rotating blading
Specific damage associated with the steam path

63
 Completion
Enter audit data into STPE computer model

Review results

Present preliminary report to owner at site

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 STPE
Steam Turbine
Performance Evaluation

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