8.

1 HP TURBINE & IP TURBINE EFFICIENCY TEST

8.1.1 Introduction

This procedure provides a systematic method for conducting routine

efficiency tests on steam turbine sections operating in the superheated
steam region. The test results produce a statistic, which is an
expression of the steam turbine section enthalpy drop efficiency.

8.1.2 Objective

The objective of the efficiency test is to provide information to allow

accounting for the contribution of steam turbine performance
deficiencies on unit heat rate and capacity and to provide a check of
accuracy of critical station instruments.

8.1.3 Test Procedure

The test method outlined in this procedure is the enthalpy drop efficiency
method. The procedure is performed to provide information for
diagnosing the steam turbine condition and to identify abnormal changes
in performance of steam turbines.

This method determines the ratio of actual enthalpy drop across

turbine section to the isentropic enthalpy drop. This efficiency
method provides a good measure for monitoring purposes, provided
certain qualifications are met in obtaining results.

Each section of the turbine must be considered a separate turbine. For

example, a double flow high-pressure section consists of two turbines,
the governor end section and the generator end section. Each section
must be tested and the results of each trended separately. As well, it is
necessary to operate the turbine with the same control valve setting from
test to test for the test results to be comparable .In view of this it is
proposed to do Turbine cylinder efficiency test at Valve wide Open
(VWO) condition to avoid variation in CV position from one test to
another; it is also necessary that the feed water heaters served by the
turbine be in service and operated normally, otherwise stage pressure
changes will be affected and mask any actual steam path problems.

To ensure accuracy, each independent variable must be controlled, such

that all subsequent tests may be related to all previous tests.

8.1-2
8.1.3.1 Station Instrumentation Required

Measurement Temperature Location Pressure Location

Main Steam Yes At ESV Inlet Yes At ESV
(L&R ) Inlet
HPT Exhaust Yes Near the Yes Near the
(L&R) Turbine Turbine
Exhaust Exhaust
Hot Reheat Steam Yes At IV Inlet Yes At IV Inlet
(L&R )
IPT Exhaust Yes IPT Exhaust Yes IPT
(L&R) Exhaust

8.1.3.2 Operating Conditions for Each Test Run

i. Unit Load Control on manual mode and Steady

ii. Unit should be in VWO Condition
iii. Main Steam and Reheat Steam Temperatures at Current
Expected Value
iv. All Feed water Heaters in Service, Normal Drain cascading.
v. No Auxiliary Steam supply to Other Units.
vi. No Soot Blowing.
vii. Other aspects as given in sample Check Sheet enclosed (format-
8.1.2)
viii. The Test Engineer is responsible for ensuring that the unit has
reached steady state before beginning a test data collection

Note: It may not be possible to achieve VWO with rated steam conditions
on certain units. In this case, reducing the main steam pressure, and
thereby increasing the steam specific volume, may allow VWO operation.

As an alternative, if VWO cannot be achieved with rated steam pressure, a

lower valve point may be substituted for VWO on sequential valve
controlled turbines. The travel of the control valve stem may be used on
full throttling turbines

8.1.3.3 Stability Condition

Stability of parameters is to be ensured before starting the test. This is

needed for effective test data. However based on local conditions the best

8.1-3
possible stable parameter may be achieved.

8.1.3.4 Data Collection

i. Form a data group in the DAS for Data collection during the test
(format 8.1.2).
ii. Each test must be conducted for about 30 min for the purposes of
data collection.
iii. The frequency of data collection in DAS should be 1 min or minimum
possible to achieve, depending upon the data collection rate of DAS.

8.1.3.5 Turbine Efficiency-Calculation

Actual Enthalpy drop

Turbine Efficiency (%) = ----------------------------------- X 100
Isentropic Enthalpy drop

hin - hout
= ----------------------- X 100
hin – hisen
Where

hin = Enthalpy of Steam at Cylinder Inlet conditions

hout = Enthalpy Steam at Cylinder Outlet conditions
hisen = Isentropic Enthalpy

8.1.3.6 Sample Computation

HP Turbine Efficiency

Unit Load MW 210

2
Main Steam Pressure Before ESV kg/cm (abs) 150
0
Main Steam Temperature before ESV C 537.00
2
HP Turbine Exhaust Pressure kg/cm (abs) 41.0
0
HP Turbine Exhaust Temperature C 349

8.1-4
HP Turbine Inlet Enthalpy (hin) kcal/kg 813.49
HP Turbine Exhaust Enthalpy (hout) kcal/kg 736.21
HP Turbine Exhaust Isentropic Enthalpy kca/kg 723.22
(hisen)

(hin - hout)
HP Turbine Efficiency = ---------------- X 100
(hin - hisen)

813.49 – 736.21
= ---------------------- X 100 = 85.58 %
813.49 – 723.22

IP Turbine Efficiency

Hot reheat pressure at IV inlet kg/cm2 (abs) 36.52

0
Hot Reheat temperature at IV inlet C 537.00
IP Turbine Exhaust Pressure kg/cm2 (abs) 7.135
0
IP Turbine Exhaust Temperature C 310

IP Turbine Inlet Enthalpy (hin) kcal/kg 841.24

IP Turbine Exhaust Enthalpy (hout) kcal/kg 733.51
IP Turbine Exhaust Enthalpy isentropic kcal/kg 722.06
(hisen)

(hin - hout)
IP Turbine Efficiency = ---------------- X 100
(hin - hisen)

841.24 - 733.51
= ---------------------- X 100 = 90.39 %
841.24– 722.06

Sample test Report format is given in format 8.1.3

8.1.4 References

ASME Performance Test Code 6A Appendix to code for steam Turbine

8.1-5
 Typical HP / IP Turbine Efficiency Test Pre – Test
Check Sheet

Station : ________________ Unit No:_______ Date: ____/____/____

Checks Made By:____________________

Description Status Initials

Control Valve Position “A” & “B” %
Auxiliary Steam Feed Isolated
Both NRVs to No ----- HP FWH: Open
Both NRVs to No ----- HP FWH: Open
Both NRVs to No ----- HP FWH: Open
Both NRVs to Deaerator: Open
Both NRVs to No ----- LPH Open
Gland Steam Pressure Controller: Auto and set to ----
kg/cm2
HP Bypass Valves “A” & “B” Closed
LP Bypass Valves “A” & “B” Closed
Main Steam Line Drains (total) Closed
Hot Reheat Drains (----No. total) Closed
Cold Reheat Drains (---- No. total) Closed
HP Steam Chest Warming (---- No. total) Closed
HPH Drain Cooling Zone Steam Vent Closed
HPH Drip to Condenser Closed
HPH --- Extr. Drain to condenser (----No. Closed
total)
HPH --- Extr. Drain to condenser (---- No. Closed
total)
DA High Load Extr. Drain to Condenser (---- Closed
No. total)
DA Low Load Extr. Drain to Condenser (----- Closed
No. total)
LPH --- Extr. Drain to Condenser (----No. Closed
total)
Trap Bypasses Closed

Notes / Special Conditions:

Format-8.1.1

8.1-6
 HP / TP Turbine Efficiency Test

Typical DAS Points for HP / IP Turbine Efficiency Testing

Sl. Description Unit Readings

No.
1. Unit Load MW
2. Control Valve “A” %Open
3. Control Valve “B” %Open
0
4. MS Temp Before ESV (Left) C
0
5. MS Temp Before ESV (Right) C
2
6. MS Pressure Before ESV (Left) kg/cm (abs)
7. MS Pressure Before ESV (Right) kg/cm2(abs)
0
8. HP Turbine Exhaust Temp (Left) C
0
9. HP Turbine Exhaust Temp (Right) C
10. HP Turbine Exhaust Press (Left) kg/cm2(abs)
11. HP Turbine Exhaust Press (Right) kg/cm2(abs)
0
12. HRH Temp Before IV (Left) C
0
13. HRH Temp Before IV (Right) C
14. HRH Pressure Before IV (Left) kg/cm2(abs)
15. HRH Pressure Before IV (Right) kg/cm2(abs)
0
16. IP Turbine Exhaust Temp (Left) C
0
17. IP Turbine Exhaust Temp (Right) C
2
18. IP Turbine Exhaust Press (Left) kg/cm (abs)
19. IP Turbine Exhaust Press (Right) kg/cm2(abs)

Format-8.1.2

8.1-7
 Turbine Efficiency Test Report

Station: Date :

Parameters Unit-1 Unit-2 Unit-3 Unit-4

Load MW
HP Turbine
Main Steam Pressure Before ESV kg/cm2 (abs)
0
Main Steam Temperature before ESV C
HP Turbine Exhaust Pressure kg/cm2 (abs)
0
HP Turbine Exhaust Temperature C
HP TURBINE EFFICIENCY (%)
PG TEST HP TURBINE EFFICIENCY (%)
HR Deviation Due To HPT EFFICIENCY kcal/kWh
IP Turbine
Hot reheat pressure at IV inlet kg/cm2 (abs)
0
Hot Reheat temperature at IV inlet C
2
IP Turbine Exhaust Pressure kg/cm (abs)
0
IP Turbine Exhaust Temperature C
IP TURBINE EFFICIENCY (%)
PG TEST IP TURBINE EFFICIENCY (%)
HR deviation Due to IPT EFFICIENCY kcal/kWh

Format 8.8.3

8.1-8
8.1-9