STEAM TURBINE THERMAL PERFORMANCE TESTING

(Alternative Test)

2008. 04. 10
1

Steam Turbine Testing

STEAM TURBINE PERFORMANCE TEST (ALTERNATIVE)

Raw Data Evaluation

Location and Type of Test Instrumentation

Variation in Measured Test Data
Permissible Variation of Variables
Effect of Measurement Error

Test Cycle Calculation

Contract Cycle Calculation
Verification of Performance Test Results

Steam Turbine Testing

Location and Type of Test Instrumentation

Steam Turbine Testing

Variation in Measured Test Data

Steady-state :
- Average Value Over Short Intervals Does Not Change
Stable :
- Value Does Not Fluctuate Over Time
Difference From Reference :
- Difference Between Average Value During Test and Value in Reference Case

1000
900
800
700

Deviation from Reference

Instability

Difference
from steadystate

Temperature (F)

1100

Two-hour Performance
Test

600
500
400
300

Time (hours)

Steam Turbine Testing

Permissible Deviation of Variables

Variable

Temp

Permissible Deviation
from Design Condition
+/- 30

F from design temp

Permissible Fluctuation

+/- 7

F from average value

Main Steam
Press
RTH Steam

Temp

Exhaust Pressure
Power Factor

+/- 3.0 % of the absolute press

+/- 30

+/- 0.25% of the absolute press

+/- 7

+/- 0.05 psi

+/- 0.02 psi

Not Specified

+/- 1.0%

Voltage

+/- 5.0%

Speed

+/- 10.0%
4

Steam Turbine Testing

Effect of Measurement Error

Error

HP Efficiency %

IP Efficiency %

Throttle Pressure

1%

-0.76%

Throttle Temperature

1F

+0.27%

Cold Reheat Pressure

1%

+0.69%

Cold Reheat Temperature

1F

-0.33%

Hot Reheat Pressure

1%

-0.60%

Hot Reheat Temperature

1F

+0.21%

IPCrossover Pressure

1%

+0.59%

IP Crossover Temperature

1F

-0.26%

FOSSIL UNIT
1% h HP = 0.16% HR & 0.30% KW
1% h IP = 0.12% HR & 0.12% KW
1% h LP = 0.50% HR & 0.50% KW

NUCLEAR UNIT
1% h HP = 0.26% ~ 0.41% HR & KW
1% h LP = 0.59% ~ 0.74% HR & KW
5

Steam Turbine Testing

STEAM TURBINE PERFORMANCE CALCULATION

Raw Data Evaluation
Test Cycle Calculation
Primary Flow & Secondary Flow
Test Cycle Heat Rate & kW Load

Contract Cycle Calculation

Verification of Performance Test Results

Steam Turbine Testing

Primary Flow & Secondary Flows Calculation

Calculation of Flow Rate from Differential Pressure
The average velocity(V) of the flow in the pipe can be calculated by the following formula:

V = sqrt ( 2g * P / )
Where

g : Gravitational constant
P: Differential pressure
: Density of fluid

However velocity is rarely calculated in practice, but volumetric and mass flow rate are.
Volumetric flow rate(Q) is calculated by multiplying the average velocity by the cross-sectional
area(A) of the pipe:

Q = A * sqrt( 2g * P / )
And mass flow rate(m) is calculated by multiplying Q by the density of the fluid at the operating
pressure and temperature:

M = Q = A Cq * sqrt ( 2g * P / )
Where

Cq : Flow coefficient determined by calibration

7

Steam Turbine Testing

ASME PTC 6.0 Flow Section

Q = 1890.07 * d2 * Fa * Cq * P/ v * [ 1 / 1-4 ]
Where

d : Nozzle Diameter (inches)

D : Pipe Diameter (inches)
:d/D
v : Specific Volume
P: Differential Pressure
Fa : Thermal Expansion Factor
Cq : Flow coefficient from calibration data

Cq = Cx - 0.185 * Rd-0.2 * (1 - 361239 / Rd)

Where

0.8

Cx : Coefficient determined by calibration

Rd : Reynolds Number

Rd = * V * d / = 48 * Q / ( * d * )
Where

: density
: Velocity (ft/sec)
: Dynamic viscocity
: Flow (lb/hr)
8

Steam Turbine Testing

Primary Flow Calculation Method

(1) Assume Reynolds Number
(2) Determine Cq = Cx - 0.185 * Rd-0.2 * (1 - 361239 / Rd)

0.8

with assumed Rd

(3) Determine Q = 1890.07 * d2 * Fa * Cq * P / v * [ 1 / 1-4 ] with predetermined Cq

(4) Determine Rd = 48 * Q / ( * d * ) with predetermined Q
(5) Iterate until Assumed Rd = Determined Rd
Cq = 1.0054 - 0.185 * Rd-0.2 * (1 - 361239 / Rd)

0.8

Steam Turbine Testing

Sample Calculation for Final Feedwater Flow

10

Steam Turbine Testing

Secondary Flow Elements

ORIFICE

PITOT TUBE

V-CONE

Forward-Reverse Tube

11

Steam Turbine Testing

Sample Calculation for Secondary Flow

12

Steam Turbine Testing

Test Cycle Heat Rate and KW Load

KW Load =

# Counts
Test Time(hrs)

* K * WHMCF * CTRCF * PTR CF * CTR * PTR

Heat Rate = ( Heat Supplied Heat Returned ) / KW Load

=

Q throttle * (H throttle-H FFW) + Q HRT * ( H HRT H CRH)

KW Load

Where
K
WHMCF
CTRCF
PTRCF
CTR
PTR

:
:
:
:
:
:

Watt-hour meter constant, 0.003125

Watt-hour meter correction factor
Current tranformer ratio correction factor
Potential tranformer ratio correction factor
Current tranformer ratio
Potential tranformer ratio

Q throttle:
Q HRT :
H throtle :
H HRT :
H CRH :
H FFW :

Turbine throttle steam flow, lbm/hr

Turbine hot reheat steam flow, lbm/hr
Turbine throttle steam enthalpy , Btu/lbm
Turbien hot reheat steam enthalpy, Btu/lbm
Turbien cold reheat steam enthalpy, Btu/lbm
Final feedwater enthalpy, Btu/lbm
13

Steam Turbine Testing

Sample Calculation of Test kW Load (1) -Measurement

14

Steam Turbine Testing

Sample Calculation of Test kW Load (2) - Adjustment

15

Steam Turbine Testing

Sample Calculation of Test Heat Rate (1) - Unaccounted for Flow

16

Steam Turbine Testing

Sample Calculation of Test Heat Rate (2) - Throttle Flow and Heat Rate

17

Steam Turbine Testing

STEAM TURBINE PERFORMANCE CALCULATION

Raw Data Evaluation
Test Cycle Calculation
Contract Cycle Calculation
- Group 1 Correction for ASME PTC 6.0 Alternative Test
- Group 2 Correction
- Correction for Control Valves Throttling and MW Thermal Output

Verification of Performance Test Results

18

Steam Turbine Testing

Group 1 Correction for ASME PTC 6 Alternative Test

Group 1 Correction Curves for The Alternative Procedure
Final Feed Water Temperature Correction
- Top Heater Terminal Temperature Difference
- Top Heater Drain Cooler Approach Temperature Difference
- Top Heater Extraction Line Pressure Drop
Correction for Auxiliary Extraction Steam Flow
- Extraction Steam to Station Heating
- Extraction Steam to Air Pre-heater (Fossil Only)
- etc.
Corrections for Main Steam De-superheating Flow (Fossil Only)
Corrections for Reheat Steam De-superheating Flow (Fossil Only)
Auxiliary Turbine Extraction Correction
Condensate Sub-cooling Correction
Condenser Make-up Correction
19

Steam Turbine Testing

Top Heater Terminal Temperature Difference Correction Curve for Load

Sample Calculation
Measured TTD : 3.64
Design TTD : 5.00
From this curve
kW % Correction @ 3.64 = 0.032%
kW = 1 + %Correction / 100
= 1 + 0.032 / 100 = 1.0003
: -315kW @518,859kW

%Corr

100

kW = 1+

20

Steam Turbine Testing

Top Heater Terminal Temperature Difference Correction Curve for Heat Rate

Sample Calculation
Measured TTD : 3.64
Design TTD : 5.00
From this curve
HR % Correction @ 3.64 = -0.032%
kW = 1 + %Correction / 100
= 1 - 0.032 / 100 = 0.9997
: -0.7kCal @2,312kCal/kWh

%Corr

HR = 1+
100

21

Steam Turbine Testing

Top Heater Extraction Pressure Drop Correction

Sample Calculation
Measured P (from TBN to HRT) = 10.13 psi
Design P (from TBN to HRT) = 13.80 psi
Measured Pressure @ TBN = 478.80 psia
Expected Pressure @ HTR with Design P = Pressure @ TBN - P_Design = 478.8 - 13.8 = 465.0 psia
Saturation Temperature @ 465.0 psia = 459.59
Measured Pressure @ HTR = 468.67 psia
Saturation Temperature @ 468.67 psia = 460.39
Change of TTD caused by test P = 460.39 - 459.59 = 0.8
From Top Heater Terminal Temperature Difference Correction Curves
kW % correction @ 4.2 = 0.019%
HR % correction @ 4.2 = - 0.019%
kW = 1 + %Correction / 100 = 1 + 0.019 / 100 = 1.0002
HR = 1 + %Correction / 100 = 1 - 0.019 / 100 = 0.9998

22

Steam Turbine Testing

Top Heater Drain Cooler Approach Temperature Correction Curve

Sample Calculation
Measured DC : 12.26
Design DC : 10.00
@ Test TFR of this curve
kW % Correction = 0.018%
HR % Correction = 0.022%
kW = 1-[ (0.018/100) x (12.26-10) / 10 ]
= 1.0000
HR = 1+[ (0.022/100) x (12.26-10) /10 ]
= 1.0000
(DCt DCd)
10 deg F
100
%Corr (DCt DCd)

kW = 1
100
10
deg
F

%Corr

HR = 1 +

23

Steam Turbine Testing

Feedwater Pump Turbine Extraction Correction Curve

Sample Calculation
Measured % Throttle Flow : 1.29 %
Design % Throttle Flow : 1.26 %
@ Test TFR of this curve
kW % Correction = -1.015%
HR % Correction = 1.019%
kW = 1 + [ (-1.019 / 100) x (1.29-1.26) ]
= 0.9997
HR = 1 + [ (1.015 / 100) x (1.29-1.26) ]
= 1.0003
(%TFt %TFd)

1%
100

%Corr (%TFt %TFd)

kW = 1 +
100
1%

%Corr

HR = 1 +

24

Steam Turbine Testing

Feedwater Pump Enthalpy Rise Correction Curve

Sample Calculation
Measured Enthalpy Rise : 2.69 Btu/lb
Design Enthalpy Rise : 3.36 Btu/lb
@ Test TFR of this curve
kW % Correction = 0.079%
HR % Correction = - 0.078%
kW = 1 + [ (0.079 / 100) x (2.69 - 3.36) ]
= 0.9995
HR = 1 + [ (-0.078 / 100) x (2.69 - 3.36) ]
= 1.0005
(H_rise t H_rised)

1 Btu/lb
100

%Corr (H_riset H_rised)

kW = 1+

1 Btu/lb
100

%Corr

HR = 1+

25

Steam Turbine Testing

Condenser Sub-cooling Correction Curve

Sample Calculation
Measured Sub-Cooled Temp : 0.24
Design Sub-Cooled Temp : 0
@ Test TFR of this curve
kW & HR % Correction = 0.027%
kW = 1 - [ (0.027 / 100) x (0.24 - 0.00) / 5 ]
= 1.0000
HR = 1 + [ (0.027 / 100) x (0.24 - 0.00) / 5 ]
= 1.0000

%Corr

HR = 1+

100

%Corr

kW = 1

100

(SCTt SCTd)

5 deg F

(SCTt SCTd)

5 deg F

26

Steam Turbine Testing

Condenser Make-up Correction Curve

Sample Calculation
Measured % Make-up : 0.00 %
Design % Make-up : 0.20 %
@ Test TFR of this curve
kW % Correction = - 0.255%
HR % Correction = 0.259%
kW = 1 + [ (-0.255 / 100) x (0.0-0.2) ]
= 1.0005
HR = 1 + [ (0.259 / 100) x (0.0-0.2) ]
= 0.9995
%Corr

HR = 1+

100

%Corr

kW = 1+

100

(%MUt %MUd)

1%

(%MUt %MUd)

1%

27

Steam Turbine Testing

Sample Calculation for Group1 Correction with Correction Curves

TTD Top Feedwater Heater
ELPD - Top Feedwater Heater
DC Top Feedwater Heater
Feedwater Pump Turbine Extraction
Feedwater Pump Enthalpy Rise
Condensate Sub-cooling
Condenser Make-up Flow
Combined Factor

Test Cycle

Desing Cycle

HR Factor

kW Factor

3.64 deg F
2.12% (10.13 psi)
12.26 deg F
158391 lbm/h
2.69 Btu/lm
-0.24 deg F
0%

5.00 deg F
3.0% (13.0 psi)
10.00 deg F
152482 lbm/h
3.36 Btu/lm
0.00 deg F
0.2 %

0.9997
0.9998
1.0000
1.0003
1.0005
1.0000
0.9995
0.9999

1.0003
1.0002
1.0000
0.9997
0.9995
1.0000
1.0005
1.0001

TEST HEAT RATE = 2,308.87 kcal/ kWh

TEST kW LOAD = 1,053,485 kW

Heat Rate after Group 1 Correction = Test Heat Rate / Combined HR Factor
= 2308.87 / 0.9999 = 2308.23 kcal / kWh
KW Load after Group 1 Correction = Test kW Load / Combined KW Factor
= 1,053,485 / 1.0001 = 1,053,385 KW
28

Steam Turbine Testing

Group 2 Correction

Turbine Initial Steam Pressure Correction

Turbine Initial Steam Temperature Correction
Turbine Hot Reheat Steam Temperature Correction (Fossil Only)
Turbine Initial Steam Moisture (Nuclear only)
Pressure Drop of Steam through the reheater systems (Fossil Only)
Turbine Exhauster Pressure

Use of Group 2 Correction Curves requires correction of the test throttle flow to design
conditions, as follows;

Qc = Q t x

Pd x t
Pt x d

For nuclear unit, use Steam Quality

instead of Steam Specific Volume...

Where
Qc : Corrected Throttle Flow
Qt : Test Throttle Flow
Pd : Design Turbine Initial Steam Pressure
Ud : Design Turbine Initial Steam Specific Volume
Pt : Test Turbine Initial Steam Pressure
Ut : Test Turbine Initial Steam Specific Volume
29

Steam Turbine Testing

Initial Pressure Correction Curve for Load

Sample Calculation
Measured Pressure : 1076.82 psia
Design Pressure : 1025 psia
%Change in pressure
= (1076.82-1035) / 1035 = 4.04%
From of this curve @ 4.04%
kW % Correction = 0.30%
kW = 1 + % Correction
= 1 + ( 0.30 / 100) = 1.0030

%Corr

100

kW = 1+

30

Steam Turbine Testing

Initial Pressure Correction Curve for Heat rate

Sample Calculation
Measured Pressure : 1076.82 psia
Design Pressure : 1035 psia
%Change in pressure
= (1076.82-1035) / 1035 = 4.04%
From of this curve @ 4.04%
HR % Correction = - 0.30%
HR = 1 + % Correction
= 1 + ( - 0.30 / 100) = 0.9970

%Corr

100

HR = 1+

31

Steam Turbine Testing

Initial Moisture Correction Curve for Load

Sample Calculation
@ Steam Generator Outlet
Pressure : 1109.98 psia
Moisture : 0.003%
Enthalpy : 1188.64 Btu/lb from steam table
@ Turbine inlet
Pressure : 1076.82 psia
Moisture : 0. 21% from steam table
Enthalpy : 1188.64 Btu/lb = H @ SG outlet
Design Moisture : 0.45%
From of this curve @ 0.21%
kW % Correction = 0.06%
kW = 1 + % Correction
= 1 + ( 0.06 / 100 ) = 1.0006
%Corr

100

kW = 1+

32

Steam Turbine Testing

Initial Moisture Correction Curve for Heat Rate

Sample Calculation
@ Steam Generator Outlet
Pressure : 1109.98 psia
Moisture : 0.003%
Enthalpy : 1188.64 Btu/lb from steam table
@ Turbine inlet
Pressure : 1076.82 psia
Moisture : 0. 21% from steam table
Enthalpy : 1188.64 Btu/lb = H @ SG outlet
Design Moisture : 0.45%
From of this curve @ 0.21%
HR % Correction = - 0.06%
HR = 1 + % Correction
= 1 + ( - 0.06 / 100 ) = 0.9994
%Corr

100

HR = 1+

33

Steam Turbine Testing

Exhaust Pressure Correction

Sample Calculation
Measured Exhaust Pressure : 32.1 psia
Design Exhaust Pressure : 38.0 psia
From of this curve @ 33.1 psia
kW & HR % Correction = 0.12%
kW = 1 + % Correction
= 1 + ( 0.12 / 100) = 1.0012
HR = 1 - % Correction
= 1 - ( 0.12 / 100 ) = 0.9988

%Corr

100

%Corr

= 1

100

kW = 1+
HR

34

Steam Turbine Testing

Sample Calculation for Group2 Correction with Correction Curves

Initial Pressure, psia
Initial Moisture, %
Exhaust Pressure, mm Hg
Combined Factor

Test Cycle

Design Cycle

1076.8 psia
0.21%
33.1 mm Hg

1035 psia
0.45%
38.0 mm Hg

HR Factor

kW Factor

0.9970
0.9994
0.9988
0.9952

1.0030
1.0006
1.0012
1.0048

HEAT RATE after Group1 Correction = 2,308.23 kcal / kWh

kW LOAD after Group1 Correction = 1,053,385 kW

Contract Cycle Heat Rate

= Heat Rate after Group1 Correction / Combined HR Factor

= 2,308.23 / 0.9952 = 2,311.27 kcal / kWh

Contract Cycle KW Load

= kW Load after Group1 Correction / Combined kW Factor

= 1,053,385 / 1.0048 = 1,050,996 kW
35

Steam Turbine Testing

Correction for Control Valves Throttling and MW Thermal Output

Correction for Control Valves Throttling
% HR Correction =

Wn
W mo

P mo - P vwo
Pt

x 100 x K

where subscript mo indicates highest load test, and

Wn / W mo = the ratio of flow through the final valve(s) to total flow during the highest load test
(decimal fraction of total flow being subject to extra throttling)
(P mo - P vwo) / P t = the ratio of (1) the difference between pressure drop across the final valve(s)
during the highest load test and the pressure drop across the same valve(s) at
VWO conditions to (2) throttle pressure (extra pressure drop due to final valves
not being wide open)
P t = absolute throttle pressure
K = 0.15 for turbines with nuclear steam supply operating predominantly in the moisture region
= 0.10 for turbines operating predominantly in the superheated region
36

Steam Turbine Testing

Sample Calculation
Measured Initial Steam Pressure
: 1076.82 psia
Measured Steam Chest Pressure
: 1073.73 psia
Measured CV#4 Discharge Pressure : 906.79 psia
Measured CV#4 Position : 28.97%
1) By interpolation between 23.43% and 30.08%
in the %Lift column of this table
Total Flow (W mo) = 12,185,173 lbm/hr
CV#4 Flow (W m ) = 2,152,956 lbm/hr
W m / W mo = 0.1767
2) Assuming 1% pressure drop at Main Stop Valves
P vwo @ Design
= P initial @ Design x 0.99 - P CV#4 @ Design
= 1035 x 0.99 - 1014.97 = 9.68 psia
P vwo = P initial @ Measured x (P vwo @ Design / P initial @ Design ) = 1076.82 x (9.68 / 1035) = 10.07 psia
3) P mo = P steam

chest

@ Measured - P CV#4 Discharge @ Measured = 1073.73 - 906.79 = 166.94 psia

% kW & HR Correction = 0.1767 x [ (166.94-10.07) / 1076.82 ] x 100 x 1.5 = 0.386

kW = 1 + % Correction = 1 - ( 0.386 / 100) = 1.0039
HR = 1 - % Correction = 1 + ( 0.386 / 100 ) = 0.9961

%Corr

100

kW = 1 +

%Corr

100 37

HR = 1

Steam Turbine Testing

Correction for MW Thermal Output
MW Thermal Output
= Net heat to the cycle x 3,412.14
= Q SG Outlet x ( H SG Outlet - H SG inlet ) / 3,412.14

Where
Q SG Outlet
H SG Outlet
H SG Inlet
3412. 14

:
:
:
:

Steam Generator Outlet Flow (lbm/hr)

Steam Generator Outlet Enthalpy (Btu/lbm)
Steam Generator Inlet Enthalpy (Btu/lbm)
Conversion factor from BTU to kW

Sample Calculation
1) Measured final feedwater flow : 12,879,666 lbm/hr
Measured unaccounted for flow :
20,222 lbm/hr
Q SG Outlet = 12,879,666 - 20,222 = 12, 859,444 lbm/hr
2) Calculate H SG Outlet and H SG Inlet using Steam Table
H SG Outlet = STMPTH (1,204.10 psia, 456.6 ) = 438.03 Btu/lb
H SG Intlet = STMPMH (1,109.98 psia, 0.003%) = 1,188.64 Btu/lb
3) MW Thermal Output = 12,859,444 x ( 1188.64 - 438.03) / 3,412.14 = 2828.84 MW
From Design MW Thermal Output of 2825 MW

% kW Correction = (2828.84 / 2825) - 1 = 0.136

kW = 1 + % Correction = 1 + ( 0.136 / 100) = 1.0014

%Corr

100

kW = 1+

38

Steam Turbine Testing

STEAM TURBINE PERFORMANCE CALCULATION

Raw Data Evaluation
Test Cycle Calculation
Contract Cycle Calculation
Verification of Performance Test Results
Test Result Calculation
Contract Cycle Heat Rate

39

Steam Turbine Testing

Test Result Calculation

40

Steam Turbine Testing

Contract Cycle Heat Rate

41

END OF DOCUMENT

42