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Power Limitation and High Exhaust Temperature of S

Wednesday, February 15, 2017   By: Osman Ali [2101] 0 Stars
We are operating a large Ammonia Urea Complex in Pakistan. Following are details of Steam Turbine driving Boiler Feed Water pump at our plant.

Type - Single stage impulse with one nozzle ring, one ring of reversing blades and two rows of moving blades
Normal power: 1742KW

Power requirement of the pump to produce required flow at desired pressure is 1742KW.
API 610 states, “steam turbine drivers shall be sized to deliver continuously 110 percent of the maximum power required for the purchaser’s specified conditions while operating at corresponding speed with specified steam conditions”. Thus it is clear that our turbine is undersized for the application.

Whenever we start the turbine, the pump gives the rated flow at the desired pressure however, after operation of couple of months, the turbine performance starts deteriorating with increase in exhaust temperature and drop in the RPM. Be noted that the turbine inlet steam conditions and exhaust pressure remain same.

Interestingly, when we shutdown the machine and without any maintenance work when it is restarted after 10~12 hrs of cooling, the turbine again starts exhibiting its normal power. Be noted that in past, turbine was overhauled many times, however its exhibits the same behavior.

I request the forum to comment on following

1- Clearly there is no power margin available in the turbine to operate the boiler feed water pump why the turbine exhibits normal power every time in the start up and after couple of months its performance deteriorates?
2- We strongly suspect that this inconsistency in turbine performance is due to overloading. Please comment.

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Saturday, February 18, 2017   By: Jim Watts [764] 5 Stars
This is typically what happens when water soluble solids from the boiler are carried over to the turbine.
The blades foul and lose efficience causing power drop and high exhaust temperature.
After shutting down and cooling the start up steam condenses on the blades and causes a blade wash during starting.
The turbine then works properly again until the fouling returns and the cycle is repeated.

Check your drum water levels and boiler water TDS and phosphate levels

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Saturday, February 18, 2017   By: Jim Watts [764] 5 Stars
PS Your boiler Feed pump only requires the 10 percent above maximum power for temporary overload and your existing turbine should be able to do this.

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