Protecting Steam Turbines During Shutdown
Protecting Steam Turbines During Shutdown
Protecting Steam Turbines During Shutdown
A recent EPRI report describes the incipient damage that can be incurred by steam
turbines during improper power plant shutdown and reviews techniques for protecting the
turbines using dehumidified air.
The report is entitled Shutdown Protection of Steam Turbines Using Dehumidified Air
(1014195). Qualified funders may view or download a copy of the report by clicking on
the link below.
How to Apply the Results
Improper protection of steam turbines and subsequent corrosion damage are estimated to
cost the U.S electric industry in excess of $1 billion annually. This report describes
methods for the use of dehumidified air to protect steam turbines during shutdown. These
methods are applicable to all steam turbines, regardless of the fuel source. In particular,
combined-cycle heat-recovery steam generator (HRSG) and cycling/peaking fossil units
stand to realize the greatest benefit as a result of the repeated startup and shutdown
periods and highly transitional steam quality conditions.
Background
EPRI research has determined that proper protection of the steam turbine during
shutdown periods is essential to the prevention of damage by stress corrosion cracking
and corrosion fatigue.
Elimination of moisture following shutdown presents a major challenge to the power
plant engineer and operator. The steam environment naturally exceeds the 60% humidity
level at ambient conditions, which is frequently identified as required for proper turbine
protection. The object is to condition the turbine environment beginning at the initiation
of shutdown and control the moisture levels below 40%. Use of nitrogen to eliminate
oxygen presence in a turbine is deemed, by most utilities, too hazardous to personnel
safety to be a viable alternative.
EPRI Guidelines
For this report, EPRI developed a preliminary roadmap to understanding the damage
mechanisms and development of an overall dry or dehumidified air layup methodology.
The interface of the operating conditions, residual heat, and operator requirements were
considered in the development of appropriate methods for achieving dehumidification.
The EPRI project team noted that pitting of turbine components is initiated through the
synergistic action of oxygen and contaminants, such as chlorides, in the moist
environment occurring in the turbine during shutdown. Reduction and elimination of
moisture on surfaces of the turbine components prevent the formation of concentrated
electrolytic films containing oxygen, which are precursors to disruption of the passive
films and pit formation.
Use of dehumidified air, a method advocated by many turbine manufacturers, appears to
be the preferred approach for protection in fossil plant applications. Dehumidified air
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rapidly evaporates any residual water left after draining. However, such protection is
generally not provided at fossil plants, and better information is needed on how to best
assess plant needs so as to implement and apply it.
The report provides information on implementing dehumidified air systems, including
industry experience with the systems, equipment requirements, design inputs needed for
selecting a system, and plant conditions that need to be considered in system design.
The report also outlines an assessment methodology and methods for developing a design
for implementation of dehumidified air equipment for layup of a unit. Two case studies
are provided to serve as examples of dry air layup implementation.
For more information contact Jim Mathews, 704-595-2044, jmathews@epri.com.
View or download Shutdown Protection of Steam Turbines Using Dehumidified Air
(1014195).