STEAM TURBINE THERMAL PERFORMANCE TESTING

(Alternative Test)

2008. 04. 10
증기터빈설계1팀
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

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 Steam Turbine Testing

‰ Location and Type of Test Instrumentation

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Steam Turbine Testing

‰ Variation in Measured Test Data

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

1100
Deviation from Reference
Temperature (F)

1000
Instability
from steady-
Difference

900
state

800

700
Two-hour Performance
600 Test
500

400

300 0 1 2 3 4 5 6 7
3
Time (hours)
 Steam Turbine Testing

‰ Permissible Deviation of Variables

Permissible Deviation
Variable Permissible Fluctuation
from Design Condition

O O
Temp +/- 30 F from design temp +/- 7 F from average value
Main Steam
Press +/- 3.0 % of the absolute press +/- 0.25% of the absolute press

O O
RTH Steam Temp +/- 30 F +/- 7 F

Exhaust Pressure +/- 0.05 psi +/- 0.02 psi

Power Factor Not Specified +/- 1.0%

Voltage +/- 5.0%

Speed +/- 10.0%

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 Steam Turbine Testing

‰ Effect of Measurement Error

Error HP Efficiency % IP Efficiency %

Throttle Pressure 1% -0.76%

Throttle Temperature 1ºF +0.27%
Cold Reheat Pressure 1% +0.69%
Cold Reheat Temperature 1ºF -0.33%
Hot Reheat Pressure 1% - -0.60%
Hot Reheat Temperature 1ºF - +0.21%
IPCrossover Pressure 1% - +0.59%
IP Crossover Temperature 1ºF - -0.26%

FOSSIL UNIT NUCLEAR UNIT

1% h HP = 0.16% HR & 0.30% KW 1% h HP = 0.26% ~ 0.41% HR & KW
1% h IP = 0.12% HR & 0.12% KW 1% h LP = 0.59% ~ 0.74% HR & KW
1% h LP = 0.50% HR & 0.50% KW
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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

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 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 *Δ P / ρ )
Where g : Gravitational constant
ΔP: Differential pressure
ρ : 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 *Δ P / ρ )
And mass flow rate(m) is calculated by multiplying Q by the density of the fluid at the operating
pressure and temperature:

M = ρ Q = ρ A Cq * sqrt ( 2g * Δ P / ρ )
Where Cq : Flow coefficient determined by calibration

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Steam Turbine Testing

„ ASME PTC 6.0 Flow Section

Q = 1890.07 * d2 * Fa * Cq * ΔP/ v * [ 1 / 1-β4 ]
Where d : Nozzle Diameter (inches)
D : Pipe Diameter (inches)
β :d/D
v : Specific Volume
ΔP: Differential Pressure
Fa : Thermal Expansion Factor
Cq : Flow coefficient from calibration data

Cq = Cx - 0.185 * Rd-0.2 * (1 - 361239 / Rd) 0.8

Where Cx : Coefficient determined by calibration

Rd : Reynolds Number

Rd = ρ * V * d / μ = 48 * Q / ( π * d * μ)

Where ρ : density
V : Velocity (ft/sec)
μ : Dynamic viscocity
Q : Flow (lb/hr)
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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 * ΔP / v * [ 1 / 1-β4 ] with predetermined Cq
(4) Determine Rd = 48 * Q / ( π * d * μ) with predetermined Q
(5) Iterate until Assumed Rd = Determined Rd

Cq = 1.0054 - 0.185 * Rd-0.2 * (1 - 361239 / Rd) 0.8

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Steam Turbine Testing

„ Sample Calculation for Final Feedwater Flow

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Steam Turbine Testing
„ Secondary Flow Elements

ORIFICE V-CONE

PITOT TUBE Forward-Reverse Tube 11

Steam Turbine Testing

„ Sample Calculation for Secondary Flow

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Steam Turbine Testing

‰ Test Cycle Heat Rate and KW Load

# Counts
KW Load = * K * WHMCF * CTRCF * PTR CF * CTR * PTR
Test Time(hrs)

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

Q throttle * (H throttle-H FFW) + Q HRT * ( H HRT – H CRH)
=
KW Load
Where

K : Watt-hour meter constant, 0.003125 Q throttle: Turbine throttle steam flow, lbm/hr
WHMCF : Watt-hour meter correction factor Q HRT : Turbine hot reheat steam flow, lbm/hr
CTRCF : Current tranformer ratio correction factor H throtle : Turbine throttle steam enthalpy , Btu/lbm
PTRCF : Potential tranformer ratio correction factor H HRT : Turbien hot reheat steam enthalpy, Btu/lbm
CTR : Current tranformer ratio H CRH : Turbien cold reheat steam enthalpy, Btu/lbm
PTR : Potential tranformer ratio H FFW : Final feedwater enthalpy, Btu/lbm

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Steam Turbine Testing
„ Sample Calculation of Test kW Load (1) -Measurement

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Steam Turbine Testing
„ Sample Calculation of Test kW Load (2) - Adjustment

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Steam Turbine Testing
„ Sample Calculation of Test Heat Rate (1) - Unaccounted for Flow

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Steam Turbine Testing
„ Sample Calculation of Test Heat Rate (2) - Throttle Flow and Heat Rate

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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

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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
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 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

표준원전: -315kW @518,859kW

⎛ %Corr ⎞
kW = 1+ ⎜⎜ ⎜
⎝ 100 ⎠

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 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

표준원전: -0.7kCal @2,312kCal/kWh

⎛
%Corr ⎞
HR = 1+ ⎜⎜ ⎜
⎝ 100 ⎠

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 Steam Turbine Testing
„ Top Heater Extraction Pressure Drop Correction
Sample Calculation
Measured ΔP (from TBN to HRT) = 10.13 psi
Design ΔP (from TBN to HRT) = 13.80 psi

Measured Pressure @ TBN = 478.80 psia

Expected Pressure @ HTR with Design ΔP = Pressure @ TBN - ΔP_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 ΔP = 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

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 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

⎛ %Corr (DCt − DCd) ⎞⎟

HR = 1 + ⎜⎜ ×
⎝ 100 10 deg F ⎟⎠
⎛ %Corr (DCt − DCd) ⎞
kW = 1 − ⎜⎜ × ⎟⎟
⎝ 100 10 deg F ⎠

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 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

⎛ %Corr (%TFt − %TFd) ⎞⎟

HR = 1 + ⎜⎜ × ⎟
⎝ 100 1% ⎠
⎛ %Corr (%TFt − %TFd) ⎞
kW = 1 + ⎜⎜ × ⎟⎟
⎝ 100 1% ⎠
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 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

⎛ %Corr (H_rise t − H_rised) ⎞⎟

HR = 1+ ⎜⎜ × ⎟
⎝ 100 1 Btu/lb ⎠
⎛ %Corr (H_riset − H_rised) ⎞
kW = 1+ ⎜⎜ × ⎟
⎟
⎝ 100 1 Btu/lb ⎠

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 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 (SCTt − SCTd) ⎞⎟

HR = 1+ ⎜⎜ × ⎟
⎝ 100 5 deg F ⎠
⎛ %Corr (SCTt − SCTd) ⎞⎟
kW = 1− ⎜⎜ × ⎟
⎝ 100 5 deg F ⎠

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 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 (%MUt − %MUd) ⎞⎟

HR = 1+ ⎜⎜ × ⎟
⎝ 100 1% ⎠
⎛ %Corr (%MUt − %MUd) ⎞⎟
kW = 1+ ⎜⎜ × ⎟
⎝ 100 1% ⎠
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Steam Turbine Testing

Sample Calculation for Group1 Correction with Correction Curves

Test Cycle Desing Cycle HR Factor kW Factor

TTD – Top Feedwater Heater 3.64 deg F 5.00 deg F 0.9997 1.0003
ELPD - Top Feedwater Heater 2.12% (10.13 psi) 3.0% (13.0 psi) 0.9998 1.0002
DC – Top Feedwater Heater 12.26 deg F 10.00 deg F 1.0000 1.0000
Feedwater Pump Turbine Extraction 158391 lbm/h 152482 lbm/h 1.0003 0.9997
Feedwater Pump Enthalpy Rise 2.69 Btu/lm 3.36 Btu/lm 1.0005 0.9995
Condensate Sub-cooling -0.24 deg F 0.00 deg F 1.0000 1.0000
Condenser Make-up Flow 0% 0.2 % 0.9995 1.0005
Combined Factor 0.9999 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

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 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;
Where
Qc : Corrected Throttle Flow
Pd x υ t Qt : Test Throttle Flow
Qc = Q t x Pd : Design Turbine Initial Steam Pressure
Pt x υ d Ud : Design Turbine Initial Steam Specific Volume
Pt : Test Turbine Initial Steam Pressure
For nuclear unit, use Steam Quality Ut : Test Turbine Initial Steam Specific Volume
instead of Steam Specific Volume...
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 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 ⎞
kW = 1+ ⎜⎜ ⎟
⎟
⎝ 100 ⎠

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 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 ⎞
HR = 1+ ⎜⎜ ⎟
⎟
⎝ 100 ⎠

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 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 ⎞
kW = 1+ ⎜⎜ ⎟
⎟
⎝ 100 ⎠
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 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 ⎞
HR = 1+ ⎜⎜ ⎟
⎟
⎝ 100 ⎠
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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 ⎞
kW = 1+ ⎜⎜ ⎟
⎟
⎝ 100 ⎠
⎛ %Corr ⎞
HR = 1− ⎜⎜ ⎟
⎟
⎝ 100 ⎠ 34
Steam Turbine Testing

Sample Calculation for Group2 Correction with Correction Curves

Test Cycle Design Cycle HR Factor kW Factor

Initial Pressure, psia 1076.8 psia 1035 psia 0.9970 1.0030
Initial Moisture, % 0.21% 0.45% 0.9994 1.0006
Exhaust Pressure, mm Hg 33.1 mm Hg 38.0 mm Hg 0.9988 1.0012
Combined Factor 0.9952 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

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Steam Turbine Testing

‰ Correction for Control Valves Throttling and MW Thermal Output

„ Correction for Control Valves Throttling

Wn ΔP mo - ΔP vwo
% HR Correction = x x 100 x K
W mo Pt

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)

(ΔP mo - ΔP 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
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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

ΔP vwo @ Design
= P initial @ Design x 0.99 - P CV#4 @ Design
= 1035 x 0.99 - 1014.97 = 9.68 psia
∴ ΔP vwo = P initial @ Measured x (ΔP vwo @ Design / P initial @ Design ) = 1076.82 x (9.68 / 1035) = 10.07 psia

3) ΔP 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 ⎛ %Corr ⎞

kW = 1 + ⎜⎜ ⎟⎟
⎝ 100 ⎠
kW = 1 + % Correction = 1 - ( 0.386 / 100) = 1.0039
⎛ %Corr ⎞
HR = 1 - % Correction = 1 + ( 0.386 / 100 ) = 0.9961 HR = 1 − ⎜⎜ ⎟⎟
⎝ 100 37 ⎠
Steam Turbine Testing

„ Correction for MW Thermal Output

Where
MW Thermal Output Q SG Outlet : Steam Generator Outlet Flow (lbm/hr)
= Net heat to the cycle x 3,412.14 H SG Outlet : Steam Generator Outlet Enthalpy (Btu/lbm)
H SG Inlet : Steam Generator Inlet Enthalpy (Btu/lbm)
= Q SG Outlet x ( H SG Outlet - H SG inlet ) / 3,412.14 3412. 14 : 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

⎛ %Corr ⎞
kW = 1 + % Correction = 1 + ( 0.136 / 100) = 1.0014 kW = 1+ ⎜⎜ ⎟
⎟
⎝ 100 ⎠

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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

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 Steam Turbine Testing

„ Test Result Calculation

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 Steam Turbine Testing

„ Contract Cycle Heat Rate

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END OF DOCUMENT

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