Steam turbines & Electric motors

“How can we rev you up?”

A Group F’s Production

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

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 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 Steam Turbine

& Many More!!!
Source: http://fsvpix.homestead.com/FSVtodaypix.html 4
 Drives sub-types
Electric Motors
• Constant Speed:
– A/C Squirrel-Cage Induction,
Synchronous A/C, etc.
• Variable Speed
– Two-Winding, Single-
Winding Consequent-Pole,
etc.
Source: http://www.gi4xsf.freeserve.co.uk/imgen/imgen.htm

Steam Turbines A Squirrel Cage Induction

– Condensing, Non- Motor. Squirrels not
condensing, Automatic
Extraction turbine, etc.
included. No, it doesn't run
on squirrels either. 5
Physical Principles

Electrical Motors

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 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
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 Ways the Speed of Electric
Motors are Varied
• Wound-Rotor Induction
Motor
– Efficiency is sacrificed for
controllability

Source: http://www.anaconsystems.com/text/pr11402eagle.html
• Gearbox control
– Gear shift to change rotation
speed.
– Discrete Operating Curve
(Step-curves).
– Cheaper Source: http://www.bostongear.com/

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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

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 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.

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

– Ideal for High Speeds

• 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.
2. Elastromeric
– Soft rotation – High inertial loads
– Allows for misalignment
– Low Temperature Applications.

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 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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 Troubleshooting:
Causes of Equipment Overload
• Electrical
– 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 538ºC (1000
ºF)
– 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 Source: http://www.airmotors.com/template.cfm?page=1

speed.
Power 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) “So, how much would the
• Superheat (ºF) 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
• Steam Turbines:
• Cost of Steam
• Blade degradation
• Coupling alignment
• Bearing wear
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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 39
 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. Perry’s Chemical’s 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 F1/3
Boiler
F1 F1/3 P2

P1

F1/3

F1=F11+F12+F13
  
F1=v1(P v2(P v3(P Multivalve Machines

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 Throttling Machine

From Boiler P2
P1 F1

1/2
F1=v(P/)

Throttling Machine

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 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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