Turbo Generador PDF

Macek Power &
Turbomachinery Engineering
Mastering the Science of Energy
Texas Registered Engineering Firm F-9789

P.O. Box 2480
Friendswood, TX 77549 USA
info@macekpower.com
www.macekpower.com
Tel 1: (+1) 281-993-3737 Tel 2: (+1) 281-724-8788 Fax: (+1) 281-648-2294
ENGINEERING EVALUATION
Document:
Machine:
Model:
Serial Number:
Job:
Customer:
Date:
Subject:
Engineer:
EE-2010-0007-R00
Ellioitt/Ideal Electric Steam Turbine Generator
Various
Various
2010-0027
Sonino
2010.10.01
Steam Turbine Generator Skid Inspection
Michael Macek, P.E.
BACKGROUND
On September 17, 2010, Macek Power inspected a skid mounted steam turbine generator (STG)
package on behalf of its client, Sonino. The unit was originally constructed and installed in the
late 1980s as part of a combined-cycle generation facility at the Kellogg Company plant in Battle
Creek, Michigan. The equipment, therefore, is approximately 20 years in age. As constructed,
the skid consists of the major equipment listed below. More detail will be given about each
major equipment piece later in the evaluation. The supply scope as presented by the seller can be
seen in the appendix at the end of this evaluation.
Major Equipment
Skid Base:
Steam turbine:
Gear:
Generator:
Lube Oil System:
Fabricated steel construction

Elliot, multi-stage model NV-7
Lufkin, single reduction double helical, model N2100C
Ideal Electric, type SAB synchronous
Independent, forced via AC/DC centrifugal pumps
The inspecting engineer from Macek Power was Michael Macek. Witnessing the inspection on
behalf of Sonino was Project Manager, Ing. Astolfo Pincay. A summary of the persons involved
with the inspection and their home office locations is given by Table 1.
The equipment is currently housed by the Wabash warehouse in Saginaw, Michigan, USA as
shown in Figure 1. Sonino has expressed an interest in acquiring the equipment for the Miguel
Macek Power Document EE-2010-0007-R00

Page 2 of 20
Angel sugar mill that it is currently constructing in Ecuador. The purposes of the inspection,
therefore, were the following.
Visual inspection of equipment condition

Technical assessment of the equipment package
Assessment of equipment value
Name
Affiliation
Home Office
Function
Astolfo Pincay
Sonino
Guayaquil, Ecuador
Purchaser
Michael Macek
Macek Power
Friendswood, TX, USA
Purchaser representative
Rick Caitung
Wabash
Wheeling, IL, USA
Seller/Equipment owner
Venkatesha Naik
Belyea
Easton, PA, USA
Seller/Equipment owner
Rafael Sanchez
Prodek
Miami, FL, USA
Equipment broker
Table 1. Persons present during inspection
Figure 1. Elliott/Ideal Electric steam turbine generator skid
P.O Box 2480, Friendswood, TX, 77549 USA Tel: (+1) 281-724-8788
Apartado Postal 1076-3000, Herdia, Costa Rica Tel: (+506) 2262-1952

Page 3 of 20
ANALYSIS
Part 1: Equipment Condition
Equipment Base
The equipment base is a skid fabricated in typical fashion from various welded beam sections
(see Figure 1). For installation, the skid assembly may be grouted in place to a concrete
foundation by means of J-bolts. The skid was observed well constructed and in good condition.
Steam Turbine
According to documentation, the steam turbine was manufactured in the late 1980s by Elliott.
Original design specifications obtained from the equipment manual follow.
Manufacturer:
Model:
Type:
Design Inlet Condition:
Design Extraction Pressure:
Design Exhaust Pressure:
Speed:
Capacity:
Elliott
NV-7
Multi-stage, single automatic extraction
265 psig, 580 F
160 psig
40 psig
4005 RPM
4300 kWe (zero extraction)
Upon arrival, the turbine was observed ready for inspection with the upper case half, rotor,
bearings, and seals removed (see Figures 2, 3, and 4). The steam path was observed to consist of
a total of seven (7) stages: Two (2) high-pressure (HP) section stages, and 5 low-pressure (LP)
section stages. The original design made use of extraction steam taken from the turbine casing
between the HP and LP sections, presumably for process at the original installation site. The
major stationary turbine components listed in Table 2 were visually inspected. Observations
made are also listed in the table. In general, these components were found in good visual
condition. Exposed surfaces were either painted or coated with preservative as appropriate.
Regardless of the observed visual condition, cleaning, non-destructive testing (NDT), and
clearance checks should be made prior to returning the hardware to service.
A partial view of the turbine rotor is presented by Figure 5. It was observed that the rotor had
been refurbished and was being carefully stored in a crate. Exposed surfaces at risk to corrosion
were coated with preservative and wrapped. Steam path surfaces had been coated as part of the
refurbishment work. General rotor visual condition is described more specifically by Table 3.
As with most rotors that have been out of service for a significant length of time, proper
inspection prior to return to service is strongly recommended. Such inspection would include
NDT, runout and balance checks, and diameter and axial location measurement.
In addition to the main steam turbine stationary and rotating components, a variety of ancillary
steam turbine hardware was briefly visually inspected. The inspection of this equipment was

Page 4 of 20
brief due to time constraints and the less critical nature of the pieces. Some of this equipment
included expansion joints, safety relief valves, coupling guards, various piping, and various
valves (see Appendix for more detail). Overall, the visual condition of this hardware appeared
good. Little or no work would be expected necessary to return the ancillary hardware to service.
Component
General
Condition
Remarks
Casing Lower
Good
No observed split-line surface cuts or leakage evidence
Casing Upper
Good
No observed split-line surface cuts or leakage evidence

Evidence of corrosion caused by pooled condensate at interior of
HP inlet flange (not an issue of concern)
Inlet trip & throttle valve
Unknown
Requires disassembly, inspection, and testing
HP governing valve linkage

and actuator
Good
Pneumatic actuator requires testing
HP governing control valves
Unknown
Access for close visual inspection not possible
HP nozzle
Good
None
HP Diaphragms
Good
None
LP governing valve linkage

and actuator
Good
Hardware not required for proposed application
LP governing control valves
Good
Hardware not required for proposed application
LP nozzle
Good
None
LP Diaphragms
Good
None
Shaft end oil seals
Good
Check clearances
Steam seals
Good
Complete set of new seals included with offer (check clearances)
Rdial bearing thrust end
Good
Check clearance
Thrust bearing - active
Good
None
Thrust bearing - inactive
Good
None
Radial bearing coupling

end
Good
Check clearance
Split-line threaded fasteners
Good
A few fasteners with damaged threads
Table 2. Turbine stationary component inspection

Page 5 of 20
Component
General Condition
Remarks
Radial bearing journals
Good
None
Thrust collar
Good
None
Shaft end seal journals
Good
None
Interstage seal journals
Fair/Good
Light erosion stages 5-7
HP blades
Good
Protective coating applied during refurbishment
LP blades
Fair/Good
Light erosion
Protective coating applied during refurbishment
Table 3. Rotor inspection
Figure 2. Turbine casing lower-half

Page 6 of 20
Figure 3. Turbine casing upper- half
Figure 4. Turbine casing lower-half steam path

Page 7 of 20
Figure 5. Rotor (partial view)
Speed Reducing Gear Set

The speed reducing gearbox is pictured in Figure 6. This unit was manufactured by Lufkin and
consists of a single reduction, double helical gear set. The bearings and gear teeth are force
lubricated by the system described later in this evaluation. Design specifications are shown
below.
Manufacturer:
Model:
Input Speed:
Output Speed:
Ratio:
Service Rating:
Service Factor:
Required Oil Flow:
Lufkin
N2100C
4005 RPM
1800 RPM
2.225:1
6122 kW
1.35
44 GPM
Both high and low speed couplings are Kop-Flex brand gear tooth type, grease lubricated
flexible couplings. Overall, the gearbox seemed in good condition. The gear teeth are illustrated
by Figure 7. The teeth were observed in visually good condition. It is recommended that the
gearbox be disassembled, cleaned, and inspected prior to return to service. Inspection should
include shaft balance checks, bearing condition and clearance checks, gear tooth contact checks,
and lubrication system checks.

Page 8 of 20
Figure 6. Speed reducing gearbox
Figure 7. Speed reducing gears

Page 9 of 20
Generator
The generator can be seen in Figure 8. It is an Ideal Electric brand, water to air cooled, brushless
AC unit with design specifications shown below.
Manufacturer:
Type:
Rating:
Power Factor:
Speed:
Voltage:
Frequency:
Ideal Electric
SAB
7339 kVA/5871 kW
0.8
1800 RPM
13,800 VAC
60 Hz, 3-Phase
At the time of inspection, the generator was observed with internal heaters on to protect the
unit from humidity while out of service. It is not known how long the heaters had been in
operation or if the heaters have been used consistently since the unit was removed from service.
To gain a better understanding of generator condition, a subcontractor, Hamilton Electric
(Saginaw, Michigan) was employed to conduct stator winding insulation resistance tests.
Insulation resistance tests were completed between each phase to ground and between each
phase to the other two phases. Phase to ground tests were done with 5000 VDC and phase to
phase tests were done with 2500 VDC. Each test had duration of 10 minutes so that a
polarization index value could be calculated. Specific results are shown below in Table 4.
The minimum acceptable insulation resistance for this generator is approximately 15 M. Table
4 demonstrates that all insulation resistance readings were consistently much higher than this
value. Polarization index values greater than 4.0 are considered excellent. Table 4 shows that all
six (6) polarization index values calculated from the stator tests were greater than 4.0. Although
more in depth inspection and testing should be done, these basic test results indicate a high
probability that the generator is in good working condition.
Test
Resistance (15 sec)
Resistance (1 min.)
Resistance (10 min.)
Polarization Index
A to Gnd (5000 VDC)
3.60
11.6
439
37.8
B to Gnd (5000 VDC)
4.35
15.8
570
36.1
C to Gnd (5000 VDC)
4.70 G
18.7
614
32.8
A to B (2500 VDC)
192 G
479
2.52
5.3
A to C (2500 VDC)
151 G
431
1.77
4.1
141 G
366 G
1.80 T
Table 4. Generator stator insulation resistance and polarization index test results
B to C (2500 VDC)
4.9

Page 10 of 20
Figure 8. Ideal Electric AC generator
Lubricating and Control Oil System

The lubricating and control oil system was constructed integral to the skid. This is shown by
Figure 9. The system consists of the following major components.
Oil supply tank and exhauster blower

Primary AC pump, filter and cooler
Auxiliary AC pump, filter and cooler
Backup DC pump and filter
Nitrogen accumulator tank for emergency rundown
Piping, tubing, and valves
Various instrumentation and switches
The system is complete and appeared to be in good condition, but no statement can be made
about internal cleanliness or fitness for service. The system must be thoroughly cleaned prior to
return to service. Furthermore, it is strongly recommended that system testing, including alarm
and trip switch functionality, be tested prior to return to service.

Page 11 of 20
Figure 9. Lubricating and control oil system
Steam leak-off system

The steam leak-off system consists of a skid mounted water cooled shell and tube heat
exchanger, motor driven condensate pump, and air ejector. The system is complete, and
appeared in visually good condition. No statement, however, can be made about its internal
condition or readiness for service. A partial view of the system showing the heat exchanger and
condensate pump is given by Figure 10. The steam leak-off system is relatively simple in its
design and constructed from fairly inexpensive components. Shop disassembly, inspection,
cleaning and testing is an option prior to return to service. An end user (buyer) that is technically
competent, however, may be able to inspect the unit and make any necessary repairs, thereby
reducing costs.

Page 12 of 20
Figure 10. Steam leak-off system
Electrical Switchgear and Control Panels

The equipment package does not include electrical switchgear. Electrical disconnecting
hardware such as fuses and circuit breakers will have to be obtained to make the steam turbine
generator package complete. One or more transformers may also be required depending upon
the electrical energy distribution system employed at the installation site. The acquisition cost of
switchgear and transformer can vary greatly depending upon need and system complexity.
Based on experience only, switchgear may cost $10,000 - $50,000 USD and a refurbished
transformer may cost $50,000 - $100,000 USD on the surplus market.
Although switchgear is not part of the STG package, a number of control panels and the
generator main terminal box are included. These are shown in Figures 11 through 13. The
instrumentation and alarm panel shown in Figure 11 was observed typically designed and
constructed, and in good cosmetic condition. No statement can be made about its functional
condition or service readiness. It is recommended that the alarm panel be left as-is should the
unit be purchased. Tests and any necessary repairs could be handled by a sufficiently qualified
and experienced technician and/or electrical engineer at the installation site (Ecuador).

Page 13 of 20
The turbine and generator control panels are shown in Figure 12. An adequate generator
protection relay system is missing from the panels and should be incorporated into the design
prior to generator operation. The estimated cost for a solid state, microprocessor based relay
system is $10,000 USD. No other comments can be made about the condition or service
readiness of the control panels. This hardware should be tested prior to attempting to return the
generator to service.
Figure 13 depicts the generator main terminal box. No comment can be made by Macek Power
regarding the condition or completeness of this hardware. A qualified electrical engineer should
be consulted.
Figure 11. Instrumentation and alarm panel

Page 14 of 20
Figure 12. Control panels


Page 15 of 20
Figure 13. Generator main terminal box


Page 16 of 20
Documentation
Included with the equipment package are five (5) notebooks containing original OEM
documentation specific to the unit. The set is pictured below in Figure 14. The documentation
appeared complete and was found in relatively good condition. The availability of such
complete documentation would be of significant benefit to the equipment buyer and/or installer.
A brief description of each notebook follows.
Volume 1:
Volume 2:
Volume 3:
Volume 4:
Turbine
Accessories
Speed reducing gear and generator
Instrumentation
As shown in Figure 14, there was also one notebook without a volume designation. This volume
contained mostly drawings along with some information found in Volumes 1-4.
Figure 14. Included documentation

Page 17 of 20
Part 2: Unit Performance
As stated previously, the STG was originally designed to operate with automatic extraction. As
such, the steam path currently consists of two (2) stages in the HP section and five (5) stages in
the LP section. The proposed operating conditions, however, do not specify a need for extraction
steam. Original and proposed operating conditions are summarized in Table 5.
Design Parameter
Original Design
Proposed Application
Inlet Pressure [psig]
265
284
Inlet Temperature [F]
580
545
Extraction Pressure [psig]
160
Not Required
Exhaust Pressure [psig]
40
20
Shaft Speed [RPM]
4005
4005
Steam Flow [lbm/h]
137,500
106,000
4000
4300
Output [kWe]
Table 5. Operating conditions comparison
Note that the steam flow and output shown in Table 5 for the original design correspond to zero
extraction (maximum flow to exhaust). With extraction, the turbogenerator was originally
capable of producing 5300 kWe. For the proposed application, the output given by the table
corresponds to the requirement specified by Sonino, and the steam flow is a calculated estimate
of that required to produce the desired power.
As Table 5 indicates, there are a number of significant differences between the original and
proposed operating conditions. Besides the obvious extraction requirement difference, there are
differences between the inlet and exhaust conditions. These differences affect the way the steam
path should be designed.
The original throttle flow capacity was 250,000 lbm/h. With an increase in steam density of
11.9% corresponding to the proposed conditions, it can be shown that the new throttle flow
capacity would be 280,000 lbm/h if the HP nozzle is left unmodified. This equates to
approximately 2.6 times the steam flow requirement for the proposed conditions. Similarly,
because the turbine was originally designed to provide a large extraction flow, the 2nd stage
diaphragm, if dimensionally inspected, would be found to contain substantially more flow area
than required for the proposed application. This means that both the 1st and 2nd stage flow areas
must be reduced by the appropriately calculated amounts to achieve desired performance.
The LP section of the turbine was originally designed to flow approximately 1.3 times as much
steam to exhaust (at 40 psig) as would be needed for the proposed conditions. This would
suggest that the stationary flow areas of stages 3-7 should also be reduced by various amounts.
Complicating the issue, however, is the decrease in the proposed exhaust pressure compared to
original. Exact statements cannot be made, therefore, about the modifications that would be

Page 18 of 20
required for the LP section of the turbine to operate as needed. This can only be determined with
measurement of the steam path followed by thermodynamic performance simulation.
Although it is not possible to specify exact modification details at this time, it can be concluded
based on experience, that the turbine is suitable for re-application to the proposed operating
conditions through the completion of the necessary engineering calculations.
Part 3: Economic Considerations
Of course, cost factors largely into making the decision to purchase the equipment. The
following cost estimates are provided to help with the decision making process.
New Equipment
The estimated cost of a comparable equipment package purchased new from one of the major
providers is $1,600,000 US (not installed and without swtichgear) with a delivery of
approximately one year. These values may be used as a reference for determining a reasonable
purchase price for the package currently under consideration.
Refurbished Equipment
As a rule of thumb, the cost of surplus equipment in good condition may generally be taken as
40-75% of the value of new equipment. Given that little concrete information is available about
the operating and maintenance history of this unit, and given the age of the unit (approximately
30 years), Macek Power believes that it is appropriate to use the lower end of the surplus
equipment cost range as the reference. Using 40% of new equipment cost as the total cost to
acquire the equipment, inspect and test as appropriate, and make ready for service, the reference
value becomes $640,000 US. By subtracting estimated costs that would be anticipated following
equipment purchase, an approximate purchase price can be determined. See Table 6 for details.
Item Number
Item Description
Estimated Cost [$US]
Steam turbine cleaning, inspection, reassembly, clearance checks
Steam path re-engineering and modification
30,000
Gearbox disassembly, cleaning, inspection, reassembly, clearance checks
25,000
Generator cleaning, inspection, testing
40,000
Generator protection relay hardware
10,000
Miscellaneous electrical panel testing and repair
18,000
Repairs resulting from inspections
70,000
Total
140,000
333,000
Table 6. Anticipated equipment inspection and readiness costs
The difference between 640,000 and the total (333,000) given in Table 6 is 307,000. It is
recommended, therefore, that a reasonable equipment purchase price should fall within the range

Page 19 of 20
of $300,000 - $350,000 US. Other costs associated with the project, but not included in the
comparison between new and refurbished equipment costs are shipping, import taxes, and
installation. For budgetary purposes, $40,000 may be used as the shipping cost for the STG skid
and auxiliary parts (to Ecuador). No comment can be made about destination charges or
installation labor costs in Ecuador.
CONCLUSIONS
1. The visually inspected steam turbine generator package appears to be in good mechanical
condition. This statement, however, does not guarantee upon completion of appropriate
service readiness inspections, that repair will not be necessary. Minor repair and part
replacement should be expected to prepare the equipment for a return to service.
2. Based on stator insulation resistance test results, it seems probable that the generator is in
good electrical condition.
3. From a thermodynamic design perspective, the steam turbine is a good candidate for
reapplication to the proposed operating conditions provided that the steam path is reengineered and modified by qualified service providers.
4. A fair purchase price for the equipment has been estimated as $300,000 - $350,000 US.
RECOMMENDATIONS
Completion of the following is recommended prior to placing the equipment back into service.
1. Steam turbine disassembly, cleaning, NDT, clearance checks, rotor dimensional and
balance checks
2. Gearbox disassembly, cleaning, shaft balance checks, bearing condition and clearance
checks, gear tooth contact checks, lubrication system checks.
3. Generator disassembly for complete inspection and testing
4. Lubrication and control oil system cleaning and testing
5. Generator relay protection system acquisition and installation

Page 20 of 20
APPENDIX
Supply scope as presented by seller(s).
ELLIOTT STEAM TURBINE GENERATOR PACKING LIST
CUSTOMER:
CUSTOMER JOB:
SEAL NUMBER:
TOTAL NUMBER OF PCS:
TOTAL WEIGHT:
ITEM
QNTY
DESCRIPTION
APPROXIMATE
APPROX. TOTAL
NO.
SIZE L X W X H
WEIGHT IN LBS
(EACH)
1
2
3
4
5
6
7
1
1
1
1
1
1
1
8
9
10
11
12
13
14
15
16
17
2
1 box
1
1
1
1
1 box
1
4
1 lot
18
19
4
1 lot
Turbine generator skid

Turbine Rotor
Generator
Turbine upper casing
Stop valve
Turbine alarm panel
Generator and turbine
control panel
Expansion joint
Turbine insulation blankets
Heat exchanger
Generator terminal box
Lube oil pipe
Lube oil pipe
Turbine old seals
Extraction steam actuator
Miscellaneous skids
40 feet container
1 expansion joint
3 lube oil pump motor mcc
2 buckets bolts and nuts
1 lot miscellaneous pipes
1 coupling
1 bearing
2 coupling guards
1 butterfly valve 24
1 pallet small pipes
2 safety valves
2 Flexible connector pipes
10 small valves
2 extraction valves
1 check valve
Vol-1 to vol-4 manuals

Set of drawings
296 L x8 6 x 9
124 x 4 x 53
12 x 77 x 78
8 x 8 x 68
6 x 4 x 4
4 x 4 x 7
5 x 4 x 7
44,000
3,600
38,000
19,000
2,500
800
1000
10 6 x 43 x 2 2
106 x 43 x 2 2
11 x 32 x 42
4 x 4 x 5
108 x 15 x15
128 x 24 x 15
33 x33 x22
4 x 4 x 3
3 x 3 x 2
2000
1000
1500
500
200
200
255
150
300
20
Steam turbine serial number: B704000E

Generator seril number: 338718

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Macek Power &

Texas Registered Engineering Firm F-9789

Tel 1: (+1) 281-993-3737 Tel 2: (+1) 281-724-8788 Fax: (+1) 281-648-2294

Fabricated steel construction

Macek Power Document EE-2010-0007-R00

Visual inspection of equipment condition

Friendswood, TX, USA

Wheeling, IL, USA

Easton, PA, USA

Miami, FL, USA

Table 1. Persons present during inspection

Figure 1. Elliott/Ideal Electric steam turbine generator skid

Macek Power Document EE-2010-0007-R00

Macek Power Document EE-2010-0007-R00

No observed split-line surface cuts or leakage evidence

No observed split-line surface cuts or leakage evidence

Inlet trip & throttle valve

Requires disassembly, inspection, and testing

HP governing valve linkage

Pneumatic actuator requires testing

HP governing control valves

Access for close visual inspection not possible

LP governing valve linkage

Hardware not required for proposed application

LP governing control valves

Hardware not required for proposed application

Shaft end oil seals

Complete set of new seals included with offer (check clearances)

Rdial bearing thrust end

Thrust bearing - active

Thrust bearing - inactive

Radial bearing coupling

Split-line threaded fasteners

A few fasteners with damaged threads

Table 2. Turbine stationary component inspection

Macek Power Document EE-2010-0007-R00

Radial bearing journals

Shaft end seal journals

Interstage seal journals

Light erosion stages 5-7

Protective coating applied during refurbishment

Figure 2. Turbine casing lower-half

Macek Power Document EE-2010-0007-R00

Figure 3. Turbine casing upper- half

Figure 4. Turbine casing lower-half steam path

Macek Power Document EE-2010-0007-R00

Figure 5. Rotor (partial view)

Speed Reducing Gear Set

Macek Power Document EE-2010-0007-R00

Figure 6. Speed reducing gearbox

Figure 7. Speed reducing gears

Macek Power Document EE-2010-0007-R00

Resistance (15 sec)

Resistance (10 min.)

A to Gnd (5000 VDC)

B to Gnd (5000 VDC)

C to Gnd (5000 VDC)

Macek Power Document EE-2010-0007-R00

Figure 8. Ideal Electric AC generator

Lubricating and Control Oil System

Oil supply tank and exhauster blower

Macek Power Document EE-2010-0007-R00