TP002

APPLYING STEAM TURBINES FOR PUMP DRIVES

John Elmore Randy Palmer Dresser-Rand, Wellsville, N.Y., USA

Steam turbines are well-suited for pump drive service for a number of reasons. First is their ability to operate across a wide speed range. This enables them to do two things: operate at the pump's most efficient speed and match the system head curve at varying pump flows, thus reducing throttling losses. This can make the turbine a good choice for marginal NPSH applications as it can avoid drastic speed reductions. When operating at low speed, turbines reduce radial reaction in centrifugal pumps operating at low flows. Turbines also work well as pump drives because they can be used safely in an explosive atmosphere, do not fail when overloaded, have high starting torque (useful for positive displacement pumps), and are rugged and reliable. This discussion mainly addresses single-stage turbines 3,500 hp and smaller, but most comments apply to larger single- and multi-stage turbines as well. Below is a review of steam cycle and turbine performance terms. You should be familiar with these before trying to make performance comparisons and analyze selection data.
Wheel Pitch Diameter Hp/Rpm 300/3600 300/1800 300/1200 50/3600 50/1800 50/1200 14 inches Steam Rate-lbs/hp-hr 39.8 High Exh. Velocity High Exh. Velocity 43.1 77.3 111.2 20 inches Steam Rate-lbs/hp-hr 31.4 53.4 77.6 35.3 59.4 87.1 28 inches Steam Rate-lbs/hp-hr 26.7 41.2 57.9 36.5 42.8 69.6

Inlet: 600 psig @750F; exhaust: 40 psig. Please keep in mind that the table reflects actual steam rates based on turbine efficiency only. Turbine
performance is only a component of the customer's steam cycle performance (for the entire plant steam loop). Table 1. Performance comparisons: wheel pitch diameter vs. speed (single-stage).

STEAM CYCLES Non-Condensing Cycle The non-condensing cycle (back pressure operation) involves taking medium-to-high-pressure steam into the turbine and exhausting it to a process header where the pressure is higher than atmospheric Cycle efficiency is high because the turbine and process absorb most of the heat before the condensate returns to the boiler. Turbine arrangement is usually straight non-condensing (no turbine extraction), and it is the most commonly used cycle for pump drive service. For pump ratings of 3,500 hp or less, steam turbines are usually single-stage. Condensing Cycle This cycle takes the turbine's exhaust steam to a condenser at below atmospheric pressure. Because the condenser's cooling water absorbs most of the heat, cycle efficiency is low. Condensing cycles are sometimes used when taking lowpressure process exhaust steam (as low as 5 psig) to the turbine inlet through a multi-stage turbine, or when waste fuel is burned in the boiler. Condensing cycles are not often used for pump drive service. The cycle is not very efficient, and the cost of a multi-stage turbine, condenser, condenser pump and cooling water can be prohibitive. Condenser cooling water availability is also a concern for many processes. STEAM RATES Theoretical Steam Rate (TSR) This is the quantity of steam per unit of power required by an ideal Rankine cycle heat engine, which assumes a no-loss (isentropic) expansion between turbine inlet and exhaus. TSR is expressed as pounds of steam per horsepower hour (or kg/kw-hr) and is universally recognized and used as a benchmark for measuring steam turbine performance. You can look up TSRs in the latest ASME Steam Tables (the easiest method) or derive them from a Mollier chart for steam (which requires time and good eyesight). Actual Steam Rate The actual steam rate reflects turbine efficiency and is expressed in the same units as the TSR. Manufacturers determine its value using pump and steam conditions. The product of actual steam rate and pump horsepower is the steam flow required to develop a given pump power.

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FACTORS AFFECTING TURBINE PERFORMANCE Steam Conditions

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Greater pressure drop across the turbine makes more heat energy (BTUs) available. Less than 50 Btu/lb enthalpy drop through the turbine is not generally workable due to low turbine efficiency resulting in high steam flows. (This is a rule of thumb figure, not an exact one.) Imposing a wide range of steam conditions usually causes the turbine manufacturer to provide excess inlet nozzle area than required for normal operating point.

Handvalves
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These are used to reduce throttling across the governor valve when the system is operated for long periods at above or below normal pump power. Part-load performance can be improved by closing handvalve(s) to decrease nozzle area. Maximum load/overload capability performance is improved by opening handvalve(s) to increase nozzle area. Handvalves are set either full open or full closed. (They are not used for throttling.)

Power and Speed

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Generally, higher powers and speeds result in greater turbine efficiencies. Speeds slower than 1,800 rpm usually require attention to whether there is sufficient steam flow availability, the high exhaust temperature and the type of lubrication.

Wheel Pitch Diameter

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Larger pitch diameters perform well at higher power ratings and lower operating speeds than smaller wheels. Small pitch diameters are best at low power ratings (under 100 hp) and high exhaust pressures. They also produce less exhaust loss.

Inlet and Exhaust Nozzle Size

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Keeping steam velocities below limits specified by NEMA Standards can minimize friction losses. NEMA Standard SM-23 velocity limits are 175 ft/sec at turbine inlet and 250 ft/sec non-condensing exhaust (450 condensing).

TURBINE BASIC SELECTION DATA REQUIRED

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Minimum requirements: r inlet steam pressure and temperature r exhaust steam pressure r pump power (rated max.-min.) r pump speed (rated max.-min.) and maximum allowable over-speed for trip r speed control (manual or type of process signal) r site conditions: indoor/outdoor and ambient conditions r cooling water data (pressure, temp and cleanliness) Any off-normal steam or pump operating conditions: r affects turbine steam path areas and ability to make power r low power conditions create high exhaust temperature (affects lubrication method) Type of pump and service: r centrifugal or positive displacement r normal or quick start r continuous or standby duty r site electrical rating (if electrical accessories are involved) Specifications: r customer required scope and turbine shop tests r API-611/612-3rd or 4th editions (API data sheets required) r steam cost evaluation r sound level requirements

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Reprinted from Pumps and Systems Magazine. Refer questions to: Contact D-R

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