Objective:

The purpose of this procedure is to provide guidelines and detail information related to implementation
of a Steam Turbine performance Test at TEL site. The Steam Turbine performance monitoring regime is
implemented to achieve following objectives:

Scope:

Boiler performance test will be conducted on half yearly basis in order to:

a) Efficient Steam Turbine operation and high plant availability

b) Evaluation of Steam Turbine performance for baseline, trending and statistical analysis
c) Steam Turbine performance optimization
d) Steam Turbine performance related proactively troubleshooting
e) Timely Steam Turbine maintenance planning

Reference Standards:

Performance Testing Code for Steam Turbine ASME-PTC6

Responsibility:

Process Engineer: Initiate the test and conduct it successfully. Generate recommendation and follow up
with them.

E&I Manager: Ensure the availability of Test instruments and Calibration of installed instruments.

Mechanical Manager: Ensure the availability of mechanical machines and mechanical integrity of the
system

Test Procedure:

The parties to any test under this Code shall reach definite agreement on the specific objective of the
test and method of operation. This agreement shall reflect the intent of any applicable contract or
specification. Any specified or contract operating conditions or specified performance pertinent to the
objective of the test shall be ascertained. Unless the alternative test procedures are specified, full-scale
test procedures shall be used. Omissions or ambiguities about any of the conditions must be eliminated
or their values or intent agreed upon before the test is started. The cycle arrangement, operating
conditions, and testing procedures shall be established during the agreement on test methods.

Test Boundary:
 1. Isolation points:

The accuracy of the test results depends on the isolation of the system. Extraneous flows should be
isolated, if possible, to eliminate errors. Extraneous flows for equipment that is included in the contract
cycle should be isolated only with mutual agreement by the parties. If there is any doubt about the
ability to isolate extraneous flows during the test, preparations shall be made prior to the test to
measure the flows. Following interconnection to be isolated from Turbine cycle before the
commencement of test.

1. Large-volume storage tanks not directly in the cycle.

2. Evaporators and allied equipment, such as evaporator condenser and preheaters.
3. Bypass systems and auxiliary steam lines for starting.
4. Bypass lines for primary flow measuring devices.
5. Turbine sprays.
6. Drain lines on stop, intercept, and control valves.
7. Drain lines on main steam, cold reheat, hot reheat, and extraction steam piping.
8. Interconnecting lines to other units.
9. Demineralizing equipment. Isolation of demineralizing equipment does not necessarily
mean removing the equipment from the cycle (It does, however, mean that all ties with
other units must be isolated and such components as recirculating lines that affect the
primary flow measurement must be isolated or the flows measured).
10. Chemical feed equipment using condensate.
11. Steam generator fill lines.
12. Steam generator vents.
13. Steam-operated soot blowers.
14. Condensate and feed water flow bypassing heaters.
15. Heater drain bypasses.
16. Heater shell drains.
17. Heater water-box vents.
18. Hogging jets.
19. Condenser water-box priming vents.
20. Steam or water lines for station heating.
21. Steam or water lines installed for water washing

2. Data Acquisition:

An important part of Performance Test includes the method of data acquisition. Data acquisition can be
both manual of automatic via Distributed Control System (DCS), online or periodic. At TEL, data will be
acquired online via DCS, in case of any limitation in online data collection, data shall be collected on
Performance Test input data sheet.

3. Test Instrumentation:

All performance tests require instrumentation of appropriate accuracy and repeatability to provide test
measurements necessary to determine Total plant and equipment efficiencies.
Performance is not measured directly, parameters like pressure, temperature, flow, differential
pressure, current and voltage are measured and the required results are computed using these
parameters. Performance. This is why Calibration regime of instruments required for Performance
testing shall be defined and implemented.

3.1 Accuracy Class

Min. Accuracy Class

Instrument
Required
Potential transformers (metering type) 0.3% accuracy class
Current transformers (metering type) 0.3% accuracy class
Portable indicating D-C ammeters 0.25% accuracy class
D-C voltmeters 0.25% accuracy class

excitation and auxiliary power services (switchboard type) 0.25% accuracy class

0.05% (or better)

differential pressure transducers
accuracy class
Calibrated pressure transducers for all critical pressure
0.10% accuracy class
measurements
Absolute pressure transducers 0.10% accuracy class
for pressures below 35 Psia (240 kPa), use calibrated
0.10% accuracy class
manometers
for pressures above 35 Psia (240 kPa), use calibrated
0.10% accuracy class
deadweight gages having a piston ratio of 10:1 or less
pressure transducers where a high degree of accuracy is
0.25% accuracy class
not required (laboratory Bourdon gages)

3.2 Calibration:

All measuring instruments shall be accurate and reliable and calibrated as required in ASME PTC-6.
Frequency of instruments calibration shall be defined according to the type and usage of instruments.
Consideration shall be given to the environment in which the calibration takes place. Even under
laboratory conditions, the quantity being measured and instruments obtaining the measured value can
be influenced by vibration, magnetic fields, ambient temperature, changes in local acceleration due to
gravity, fluctuation, instability of the voltage source, and other variables.

The calibration report should include the identification of the calibration equipment and instruments, a
description of the calibration process, a statement of uncertainty of the measuring standard, and a
tabulation of the recorded calibration data. The report should be signed by a responsible representative
of the calibration laboratory.

Where appropriate, calibration shall be performed with test instruments installed in place for the test,
and all calibrations shall be available prior to the test. In-place calibration of station instrumentation is
necessary when secondary flow measurements are made by a permanently installed flow element for
which calibration is required or where station instruments and a computer are used for test data
acquisition.

4. Stabilization criteria

Preparatory to any test run, the turbine and all associated equipment shall be operated for a sufficient
time to attain steady-state condition. Appropriate means shall be employed for securing constant load.
This may be accomplished by blocking the means of Load limiter application.

5. Operating Conditions:

Every effort shall be made to run the tests under specified operating conditions, or as close to specified
operating conditions as possible in order to avoid the application of corrections to test results, or
minimize the magnitude of the corrections. In addition, variations in any condition that may influence
the results of the test shall be made as nearly constant as practicable before the test begins and so
maintained throughout the test. Steam generator and turbine controls shall be fine-tuned prior to the
test to minimize deviation of variables.

6. Deviations

Deviations of variables in excess of the limits prescribed in below table, may occur during a test run. If
such deviations are observed during the test run, the cause shall be eliminated and the test continued, if
possible, until all variables are within the specified limits for the planned duration of the test run. If the
cause of the deviations cannot be eliminated during the test run, or if deviations are discovered during
computation of results from a completed test run, that run shall be rejected in whole, or in part, and
repeated as necessary after the cause of the deviations has been eliminated, except in the case of initial
steam pressure and initial and reheat steam temperature. If the initial steam pressure, initial steam
temperature, or reheat steam temperature exceed the maximum permissible deviation indicated in
below table, the correction factors for these variables must be calculated for the specific cycle being
considered and used in place of the standard steam conditions corrections normally provided with the
turbine. Any rejected portions of the test run shall not be used in computing the overall averages.

7. Test Qualification Criteria:

As per ASME PTC 6, a test shall be termed as qualified

Permissible Deviation of Variables

Permissible Deviation for the
Average of the Test Conditions Permissible Fluctuations During Any
Variable
from Design or Rated Conditions Test Run [Note (2)]
[Note (1)]
±0.25% of the absolute pressure or
Initial steam pressure ±30% of the absolute pressure 5.0psi (34.5 kPa), whichever is
larger
±15°F (8K) when superheat is
±4°F (2K) when superheat is 27°–
Initial and reheat steam 27°–50°F (15–30K); ±30°F (16K)
50°F (15–30K); ±7°F (4K) when
temperature when superheat is in excess of
superheat is in excess of 50°F (30K)
50°F (30K)
Initial steam quality ±0.5 percentage points of quality ±0.1 percentage points of quality
 for turbines with wet throttle
for turbines with wet throttle steam
stem
Primary flow Not specified Refer to para. 4-10.1
±5.0% × (primary flow)/(secondary Same as (d) × (primary
Secondary flows
flow) flow)/(secondary flow)
Pressure drop through fossil
±50.0%  
unit reheater
Extraction pressures ±5.0%  
Extraction flows [Note (3)] ±5.0%  
Temperature of feed water
±10°F (6K)  
leaving final heater
±0.05 psi (0.34 kPa) or ±2.5% of ±0.02 psi (0.14 kPa) or ±1.0% of th
Exhaust pressure [Note (4)] the absolute pressure, whichever absolute pressure, whichever is
is larger larger
Load Refer to para. 3-13.5 ±0.25%
Voltage ±5.0%  
Power factor Not specified ±1.0%
Speed ±5.0% ±0.25%
Aggregate isentropic
enthalpy drop of anyone of
±10.0%  
the sections of an automatic
extraction turbine

8. Test Data acquisition method

A test shall be consisted of at least more than one Run, where Run is a complete set of reading, it is
recommend to take three set of reading in order to improve the quality of data. Efficiency Calculations
shall be done on the average data of all the runs. The data taken during the test shall be reviewed and
rejected in parts or in whole if not in compliance with the constancy of test and under the permissible
range of parameters.

9. Efficiency Calculation:

Step by step calculation of test results from the reduced data including detail calculation for Feed water
flow, Main steam flow, Extraction steam flows, thermal efficiencies of HP, IP and LP turbines, Turbine
cycle efficiency and cycle heat rate or any or any specific disposition set as the objective of test shall be
done.

Further, a detail discussion shall be set forth for onward discussion of test results and generate
recommendation.

Calculations shall be performed using ASME Steam Tables.

Correction of Test Results:

Correction factors shall be applied on the test results in order to account for the parameters other than
the design values. The typical correction factors curves shall be given by the OEM. Typically, depending
upon the conditions, following correction factors are applied to the test results:
1. Final feed water temperature
2. Main steam temperature
3. Main steam pressure
4. Turbine Exhaust pressure
5. Turbine Speed
Appendix 1:

ASME PTC-6 Data Input Sheet

Ambient Site Conditions

Engineering Data Set Data Set Data Set
Parameter
Unit 1 2 3
Date        
Time        
Reference Dry Bulb Temperature        
Reference Wet Bulb Temperature        
Reference Pressure        
Relative Humidity        
Boiler Steam Data
Main Steam Temperature        
Main Steam Pressure        
Cold Reheat Steam Temperature        
Cold Reheat Steam Pressure        
Hot Reheat Steam Temperature        
Hot Reheat Steam Pressure        
Cross Over Temperature        
Soot blowing Steam supply from CRH        
Cross Over Pressure        
Boiler Spray Water Data
SH Spray Temperature        
SH Spray Pressure        
SH Spray Flow        
Reheater Spray Temp        
Reheater Spray Pressure        
Reheater Spray Flow        
Extraction Steam Data
Extraction Steam to LP-1 Pressure        
Extraction Steam to LP-2 Temperature        
Extraction Steam to LP-2 Pressure        
Extraction Steam to LP-3 Temperature        
Extraction Steam to LP-3 Pressure        
Extraction Steam to LP-4 Temperature at Heater        
Extraction Steam to LP-4 Pressure at Heater        
Extraction Steam to D/A Temperature        
Extraction Steam to D/A Pressure        
Extraction Steam to BFP-T Pressure        
Extraction Steam to BFP-T Flow        
Return from BFP-T Temperature        
Extraction Steam to HP-6 Temperature        
Extraction Steam to HP-6 Pressure        
Extraction Steam to HP-7 Temperature        
Extraction Steam to HP-7 Pressure        
Extraction Steam to HP-8 Temperature        
Extraction Steam to HP-8 Pressure        
Condensate / Feedwater Temperature
Condenser Hot well Temperatue        
Condenser Hot well Pressure        
Condenser Hot well Level (Start)        
Condenser Hot well Level (End)        
Condenser Makeup Flow        
Condensate Flow        
Condensate to HP-8 Inlet Temperature        
Condensate to HP-8 Inlet Presssure        
Condensate to HP-7 Inlet Temperature        
Condensate to HP-7 Inlet Pressure        
Condensate to HP-6 Inlet Temperature        
Condensate to HP-6 Inlet Pressure        
Condensate to LP-3 Inlet Temperature        
Condensate to LP-3 Inlet Pressure        
Condensate to LP-2 Inlet Temperature        
Condensate to LP-2 Inlet Pressure        
Condensate to LP-2 Outlet Temperature        
Condensate to LP-1 Inlet Temperature        
Condensate to LP-1 Inlet Pressure        
Leakage flow from CEPs        
Condensate to GS Cooler Inlet Temperature        
Condensate to GS Cooler Inlet Pressure        
Condensate Recirculation Flow        
Condensate to D/A Inlet Temperature        
Condensate to D/A Inlet Pressure        
Condensate to D/A Inlet Flow        
Condensate to LP-4 Inlet Temperature        
Condensate to LP-4 Inlet Pressure        
Condensate to Ash Cooler Inlet Flow        
Condensate to Ash Cooler Inlet Temperature        
Condensate to Ash Cooler Inlet Pressure        
Condensate to Ash Cooler Outlet Temperature        
Return Condensate Drip Data
Drip Off (LP-1 to Condenser) Temperature        
Drip Off (LP-2 to LP-1) Temperature        
Drip Off (LP-2 to LP-1) Pressure        
Drip Off (LP-3 to LP-2) Temperature        
Drip Off (LP-3 to LP-2) Pressure        
Drip Off (LP-4 to LP-3) Temperature        
Drip Off (LP-4 to LP-3) Pressure        
Drip Off (HP-7 to HP-6) Temperature        
Drip Off (HP-6 to D/A) Temperature        
Drip Off (HP-8 to HP-7) Temperature        
Leak Offs Data
Leak off (Gland-1 LP to GS Header) Temperature        
Leak off (Gland-1 LP to GS Header) Pressure        
Leak off (Gland-1 LP to GS Header) Flow        
Leak Off (Gland -1) Temperature        
Leak Off (Gland -1) Pressure        
Leak off (Gland-1 Sub atmospheric) flow        
Leak off (Gland-2 to GS Header) Temperature        
Leak off (Gland-2 to GS Header) Pressure        
N2 Gland Leakage Flow        
Leak off (Gland-4 LP to GS Header) Temperature        
Leak off (Gland-4 LP to GS Header) Pressure        
Leak off (Gland-4 LP to GS Header) Flow        
Leak off (Gland-3 to GS Header) Temperature        
Leak off (Gland-3 to GS Header) Pressure        
Leak Off (MSVs) Temperature        
Leak Off (MSVs) Pressure        
Leak Off (MSVs) Flow        
Leak off (Gland-1 HP to D/A) Temperature        
Leak off (Gland-1 HP to D/A) Pressure        
Leak off (Gland-1 HP to D/A) Flow        
Leak Off (to Hot RH) Temperature        
Leak Off (to Hot RH) Pressure        
Leak Off (to Hot RH) Flow        
Leak off (Gland-4 Sub Atmospheric) flow        
BFP Sealing / Gland Sealing Data
Sealing Water Flow to BFPs        
Sealing Water to BFPs Temperature        
Sealing Water to BFPs Pressure        
Sealing Water Return from BFPs        
Leakage from BFPs        
GS Supply from CRH Steam        
GS Supply from Aux Steam        
GS Supply to LP and BFP-T Temperature        
GS Supply to LP and BFP-T Pressure        
GS Supply to LP and BFP-T Flow        
GS Cooler De-superheating Spray Temperature        
GS Cooler De-superheating Spray Pressure        
GS Cooler De-superheating Spray Flow        
Steam Seal to (LP Glands) Flow        
GS Return to Gland Steam Cooler Temperature        
GS Return to Gland Steam Cooler Pressure        
GS Return to Gland Steam Cooler Flow        
GS Steam Excess flow to LP Heater Temperature        
GS Steam Excess flow to LP Heater Pressure        
GS Steam Excess flow to LP Heater Flow        
Auxiliary Steam Data
Auxiliary Steam Flow from CRH        
Auxiliary Steam to D/A Temperature        
Auxiliary Steam to D/A Pressure        
Auxiliary Steam to D/A Flow        
Turbine/Generator Data
D/A Level (Start)        
D/A Level (End)        
Area of D/A        
FW Flow from D/A to FWPs Temperature        
FW to Eco Inlet Temperature        
FW to Eco Inlet Pressure        
Turbine/Generator Data
Generator Gross Output        
Excitation Voltage        
Excitation Current        
Auxiliary Power        
Power Factor        
Voltage        
H2 Pressure        
Generator Losses at 60 hg pressure        
Annulus Area