Steam Turbine MRO Market Trends

Growth Drivers

• Steam turbine for rotating equipment drives MRO costs and energy savings: Steam turbines are prime movers for driving air compressors, forced or induced-draft fans, boiler feedwater pumps, blowers, and other rotating equipment. A 300-hp steam turbine, as per DOE estimates, has a43% isentropic efficiency of 43% and a steam rate of 26 lb/hp-hr as a result of the introduction of 600-pounds-per-square-inch-gauge (psig)/750°F steam for a 40-psig/486°F exhaust. Given the natural gas price of USD 8.00/MMBtu and an 80% boiler efficiency, the steam turbine operation cost is USD 8.00/hr. A 300-hp motor with a full-load efficiency of 95% would require energy of 235.6 kWh/hr and a steam turbine drive can save costs when electricity price exceeds 3.4 cents/kWh.
  
  A facility's energy costs and feedwater pump annual operational hours have a significant impact on the overall annual energy savings. The table below shows the annual energy savings for different electrical rates and pump maintenance, repair, and operation schedules. Steam turbine maintenance costs should be compared to electric motor maintenance costs in addition to operational cost savings.

Annual Energy Savings when Using a Steam Turbine Feedwater Pump Drive*, (Costs in USD)

*Savings are based upon operation of a 300-hp steam turbine drive with a steam rate of 26 lb/hp-hr. A natural gas cost of $8.00/MMBtu is assumed.

Source: U.S. DOE

• Technological developments for potential efficiency gains:  Multiple design, technological integration, and operation and maintenance (O&M) factors influence the efficacy of stationary combustion turbine electric generating units (EGU) including steam turbines.

Comparison Of Various Turbine Technological Upgrades

Source: EPA

Maintenance and repair of heat recovery steam generator (HRSG) components affects turbine performance. Contaminants such as ammonium bisulfate can accumulate in the HRSG and lead to pressure losses. According to the 2023 EPA report, GE removed 14 tons of debris, reducing the turbine back pressure by 8 inches in the water column and annual fuel savings netted the at USD 500,000. Similarly, condensers require regular maintenance and repair to ensure optimized performance. Turbine overhauls of USD 2 to USD 12 million for 200-MW steam turbines can render heat rate improvements of up to 300 Btu/kWh. Furthermore, correct O&M practices have the potential to limit heat rates by 30-70 Btu/kWh, which is about 0.7% of the steam cycle. Feed pump repair and retrofits enhance steam cycle heat rates by 0.25-0.5% for costs of USD 250,000 to USD 350,000.

Challenges

• Increasing use of solar energy for the generation of power: The high investment in solar energy owing to the increasing adoption of natural energy sources is estimated to hamper the steam turbine MRO market growth and pose a threat of substitution. The rising installations of solar power plants in many residential and commercial buildings are hindering market growth in the coming years.
• Skilled labor shortages: The MRO sector is experiencing a dearth of qualified technicians and engineers proficient in-stream turbine maintenance. This shortage can lead to increased labor costs and potential delays in maintenance schedules, affecting overall operational efficiency.