TP038

Performance Acceptance Test For A Condensing Turbine

Mechanical Drive Superheated Inlet

J. Lamberson
R. Moll
Dresser-Rand, Wellsville, N.Y., USA

The test procedure that follows is intended to convey Dresser-Rand's position to customers in regard to field
performance acceptance testing. The instrumentation required for the Dresser-Rand test is less costly and
fewer component readings are required as compared to a PTC-6 high accuracy performance acceptance test.
This in no way diminishes the importance or the necessity of the PTC-6 documents, for all steam turbine testing
compiled by United States manufacturers will reference these procedures to some degree.

INTRODUCTION
The following document is a simplified ASME performance test procedure which Dresser-Rand believes is
satisfactory for the majority of condensing turbines. The instrumentation required for this test is much less
costly, and fewer component readings are needed to obtain good results as compared to a full ASME PTC-6
test. In this simplified test, only the quantities necessary to establish the actual power output will be measured.
Reducing the amount of measurement devices does not eliminate the requirement for proper device installation.
Drawing CB-182930-U indicates placement and maximum allowable uncertainty of all necessary
instrumentation which should be calibrated before and after the test. (This procedure generally follows the
guidelines of PTC-6.)

TIMING AND DURATION OF TEST

The test should be conducted as soon as possible after initial operation under load, but no longer than 90 days.
If this timing is impossible to achieve, the test may be run immediately after the first complete inspection. At this
time, the manufacturer and the customer must both agree that the turbine is in "like new" condition for a proper
acceptance test.

The test should be conducted for a two hour period. If inconsistencies appear during this duration, the source of
these variations should be located, the problem rectified, and the test should be restarted.

PERMISSIBLE DEVIATION OF VARIABLES*

Variable Deviation

1 Initial Steam Pressure 5.0% of absolute pressure

2 Initial Steam Temperature 30F
3 Primary Flow 8.0% of guarantee
4 Exhaust Pressure 10.0% of the absolute pressure
5 Speed 5%

An effort should be made to operate the turbine at specified contract conditions with constant load. To achieve
minimum load deviation, running the test at the valves wide open position is desirable.
*Turbine mechanical limits should not be exceeded.

PRIMARY FLOW MEASUREMENT

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Figure 1

Note 1 Figure taken from PTC-6-1976.

Note 2 Beta ratio (d/D) must have range of .25 to .5.
Note 3 A diffuser on the downstream side of the nozzle will greatly decrease the pressure loss.
Note 4 Flow nozzle should be calibrated prior to installation and visually inspected before and after the test.
Note 5 Flow straightener shall have a minimum of 30 tubes.

Figure 1 shows the required arrangement for measuring steam or water flow. It is recommended that boiler
feedwater flow be utilized rather than steam since better accuracy is achievable when the medium is a liquid. A
first stage pressure versus primary steam flow curve is a good tool to use for double checking the inlet flow
meter reading. This curve will be supplied by Dresser-Rand and is normally accurate to within 2.0% when the
machine is in new condition. The end gland leakage flow values will also be supplied by Dresser-Rand.

Primary flow measurements are to be taken at no greater interval than one minute during the test.

MEASUREMENT OF PRESSURES
A calibrated test Bourdon gauge may be used for pressures above 35 psia; for pressures below 35 psia, a
calibrated absolute pressure transducer should be utilized.

The initial steam pressure indicator should be in the steam line as close as possible to the trip and throttle valve
on the upstream side. All pressure readings should be taken upstream of any flow disturber (thermowells,
elbows, etc.) and in a straight section of pipe. The steam strainer should be known to be clean by placing a
gauge downstream of the T[T valve and reading differential pressure.

Exhaust pressure should be taken as close to the turbine exhaust flange as possible. (This reading may require
more than one transducer due to exhaust size.)

Test measurements are to be taken at a maximum interval of five minutes.

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MEASUREMENT OF TEMPERATURE
Temperature should be obtained by using a continuous lead thermocouple in conjunction with a precision
potentiometer or other calibrated readout device. The initial steam temperature indicator should be in the steam
line as close as possible to the T[T valve on the upstream side. The accuracy of this temperature is very critical;
therefore, two thermocouples should be used. Each thermocouple should have its own thermometer well and
located 90 degrees apart from one another.

The temperature element (thermocouple and well) should be immersed in the fluid a minimum of three inches
but not less than one-quarter of the pipe diameter. If the pipe is less than four inches, the element must be
arranged in such a way to allow for the minimum immersion distance.

Test measurements should be taken at a maximum interval of five minutes.

MEASUREMENT OF POWER OUTPUT AND SPEED

The power output can be determined from a torque meter placed between the turbine and the driven machine.
The meter specification should be compiled and purchased coincidently with the turbine purchase. This permits
the correct device selection for a particular operating situation. Due to the high uncertainty and poor
repeatability of the majority of torque meters, a heat balance across the driven machine may be necessary as
another means of establishing output power.

The turbine speed should be monitored by utilizing a magnetic pickup and gear in conjunction with a readout
device.

Test measurements should be taken at a maximum interval of one minute.

PERFORMANCE RESULTS
To establish the turbine performance, the test power output will be compared to an analytically predicted power
based on test conditions and utilizing the same calculation method employed in the contract performance
prediction.

Correction curves for off-design conditions (pressure, temperature, etc.) will be supplied by Dresser-Rand.

Refer questions to:

Contact D-R

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