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Replace Steam Turbines with High-Efficiency Electric Systems

Replace Steam Turbines with High-Efficiency Electric Systems

Replace Steam Turbines with High-Efficiency Electric Systems

Sumário

How to Replace Steam Turbines with High-Efficiency Electric Systems

Energy efficiency is revolutionizing the industry, particularly in the oil and gas sector. As companies strive to cut costs and meet sustainability goals, replacing steam turbines (replace steam turbine) with high-speed electric systems has gained traction. 

In this article, we explore why this transition is happening, how it’s planned, and the benefits it offers compared to traditional steam and gas turbines.
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Why Replace Steam Turbines?

Steam and gas turbines have been the backbone of industrial plants for decades, powering compressors, pumps, and blowers in refineries, petrochemical facilities, and fertilizer plants. However, they face growing challenges:

 

  • CO2 Emissions: A gas turbine emits about 0.5 kg of CO2 per kWh. For an 8 MW compressor running 8,000 hours annually, that’s 32,000 tons of CO2 per year. Even steam turbines, reliant on boilers, generate indirect emissions.
 
  • Limited Efficiency: Aeroderivative gas turbines reach up to 40% efficiency, while heavy-duty models hover around 27%. Condensing steam turbines range from 50% to 80% but lose energy to waste heat.
 
  • Intensive Maintenance: Turbines require annual inspections and major overhauls every 6-9 years, accumulating up to 140 days of downtime over their lifespan.
 
  • Operational Constraints: Turbines have a limited speed range (50-100% of nominal power), slow response times, and long startup periods (up to 15 minutes).
 

Replacing steam turbines (replace steam turbine) with electric systems addresses these issues, delivering superior efficiency, reliability, and sustainability.

Replace Steam Turbines with High-Efficiency Electric Systems
Replace Steam Turbines with High-Efficiency Electric Systems

Benefits of High-Speed Electric Systems (Replace Steam Turbines )

Electric systems, comprising transformers, frequency converters, and high-speed motors, offer significant advantages:

 

  • Energy Efficiency: Achieve up to 95% efficiency, surpassing the 35% of gas turbines and 50-80% of steam turbines.
 
  • Speed Control: Operate from 25% to 120% of nominal power, dynamically adjusting to process needs, such as gas fields with varying suction pressure.
 
  • Reduced Maintenance: Simple annual inspections and overhauls every 4-5 years eliminate major repairs for up to 25 years.
 
  • Fast Startup: Electric motors start in under 4 minutes, compared to the lengthy warmup cycles of turbines.
 
  • Zero Local Emissions: Paired with renewable energy, they eliminate carbon impact, unlike turbines reliant on direct or indirect combustion.
 
  • Compact Design: High-speed motors eliminate gearboxes, reducing mechanical losses and footprint.

How to Plan Steam Turbine Replacement

Replacing steam turbines (replace steam turbine) in existing plants is more complex than in greenfield projects but entirely feasible with proper planning. 

 

The process includes:

 

  1. Feasibility Study: A 1-3 year analysis to map power, speed, available space, and electrical grid conditions.
  2. Implementation Scenarios:
    • Install a new compressor designed for the electric motor, leveraging the existing foundation.
    • Refurbish the current compressor with an adapter plate.
    • Keep the compressor intact, requiring reverse engineering for compatibility.
  3. Foundation Adaptation: Steam turbines have specific weight distributions, while electric motors may need structural reinforcements. High-speed motors, with compact designs, minimize these changes.
  4. Electrical Integration: Install high-voltage infrastructure and conduct grid studies to assess harmonics and protection capacity.
  5. Rapid Commissioning: Electric systems are designed for plug-and-play installation, ready in as little as one day.

Watch the Video on the Subject Steam Turbine Replacement

Case Studies and Real Results – Replace Steam Turbine

A standout example is Braskem’s Vesta Project, completed in 2022 at its Q3 unit in São Paulo (Brazil). 

 

With a $120 million investment, the company replaced steam turbines with high-performance electric motors, supported by a new power generation unit fueled by residual process gas. 

 

The outcome? An 11.4% reduction in water consumption and over 6% in the unit’s CO2 emissions.

 

Data from the OGCI report further highlights that replacing condensing steam turbines with electric motors is the most viable decarbonization option, with an abatement cost of about $100 per ton of CO2 equivalent.

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Replace Steam Turbines - VSD Motor

Comparison: Steam Turbine vs. Electric Motor

CriterionSteam TurbineHigh-Speed Electric Motor
Efficiency50-80%>95%
Speed Range50-100%0-120%
Response Time>15 minutes<1 minute
EmissionsCO2 and other gasesZero (local)
Noise>100 dB<85 dB
MaintenanceIntensive (annual, every 5-9 years)Light (annual, every 5-6 years)
FootprintLarge, complex pipingCompact, simple installation

Challenges and Considerations

While replacing steam turbines (replace steam turbine) is promising, challenges remain:

 

  • Existing Infrastructure: Foundations and compressors may require significant adaptations.
 
  • Legacy System Integration: Electric motors must interface with older controls, demanding technical expertise.
 
  • Initial Investment: High CAPEX is offset by lower OPEX in energy, maintenance, and emissions over time.
 
  • Steam Balance: In steam-dependent processes, alternatives must be considered to maintain equilibrium.

Why It’s Worth It

Replacing steam turbines with electric systems isn’t just a technical upgrade—it’s a paradigm shift. Like swapping candles for electric lights, this transition modernizes operations, aligns plants with climate goals, and optimizes long-term costs. 

 

With 99.9% reliability, zero local emissions, and unmatched efficiency, high-speed electric motors are the future of industry.

"A steam turbine is a mechanical device that extracts thermal energy from pressurized steam and converts it into mechanical work."

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Maximize Your Team’s Expertise with TURBIVAP Training

Empower your team with TURBIVAP’s specialized training programs tailored for steam turbine operation and maintenance. 

 

Whether you’re looking for foundational knowledge or advanced techniques, TURBIVAP offers:

 

  • Digital Courses: Learn at your pace with recorded modules.
  • Live Remote Training: Interactive sessions with experts from anywhere.
  • In-Company Training: Hands-on experience at your facilities.

See the topics in the tab below. Total course load 25h.

 

*Includes the Essential Module

ESSENTIAL – Module 1

 

Start Here
Features and Tools
Course Presentation
Introduction
Application
Rankine Cycle – Transforming Heat into Work
Thermal Cycle Equipment
Types of Steam Turbines
Condensing Turbine
Backpressure Turbine
Types of Extraction
Speed ​​Diagram
Principles of Action and Reaction
Stage / Action Turbine (Impulse)
Stage / Reaction Turbine
Curtis Type Stage
Rateau Type Stage


ESSENTIAL – Module 2


Single and Multistage Turbines
Direction of Rotation
LOA-LA / HP-LP / AP-BP Concept
Components
Components – Steam Chamber
Components – Emergency Valve
Components – Partializing Valve
Components – Casings
Components – Injector / Expander
Components – Rotor
Components – Vanes
Components – Belt
Components – Fixed Vanes (Reverser)
Components – Diaphragm
Components – Diaphragm Holder
Components – Vane Holder
Components – Radial Bearing
Components – Axial Bearing
Components – Bearing Housing
Components – Vapor Sealing System
Components – Vapor Sealing – Carbon Ring
Components – Vapor Sealing – Labyrinth Ring
Components – Vapor Sealing – Sealing Blades
Components – Oil Sealing
Components – Mechanical Speed ​​Regulator
Components – Electronic Speed ​​Regulator
Components – Actuator
Components – Coupling
Components – Reducer
Components – Slow Rotation
Components – Lubrication System
What is TRIP?
Condensation System
Condensation System – Devices
Certificate
Final Considerations and Certificate

 


ADVANCED – Module 1 – Introduction and Fundamentals

 


Start Here
Course Presentation
Introduction
Historical Context
Application
Waste To Energy – Energy Recovery Plant “URE”
Module 1 Handout

 

 

ADVANCED – Module 2 – Basic Thermodynamics for Steam Turbines

 


Thermodynamic Characteristics
Steam Thermal Plant Cycles
Rankine Cycle – Transforming Heat into Work
Thermal Cycle Analysis – Condensation Turbine (Efficiency Comparison)
Thermal Cycle Equipment
Practical Rankine Cycle
TS Diagram
Mollier Diagram
Rankine Cycle Variations
Reheat Cycle
Regenerative Cycle
Combined Cycle
Reuse of Thermal Energy
What is Steam?
Quiz 1
Module 2 Handout


ADVANCED – Module 3 -Classification of Steam Turbines

 


Classification of Steam Turbines
Types of Steam Turbines
Condensing Turbine
Backpressure Turbine
Pressure Reduction Turbine
Types of Extraction
Operating Principle
Speed ​​Diagram
Principles of Action and Reaction
What is a Stage?
Action (Impulse) Stage / Turbine
Reaction Stage / Turbine
Curtis Type Stage
Rateau Type Stage
Quiz 2
Single and Multistage Turbines
Radial and Axial Turbines
Direction of Rotation
LOA-LA / HP-LP / AP-BP Concept
Applicable Standards
Internal Losses
Turbine Efficiency
Saturation Curve
Quiz 3
Module 3 Handbook

 

 

ADVANCED – Module 4 – Components Part 1


Components
Components – Steam Chamber
Components – “Quick Closing” Emergency Valve
Components – “Quick Closing” Emergency Valve Part 2
Components – Partializing Valve
Components – Casings
Torquing Turbine Casings – Hydraulic Tensioner
Sealant for Junction Plane (Housings) and Flanges
Components – Hood Spray System
Components – Injector / Expander
Components – Rotor
Rotor Components – Balance Piston
Rotor Components – Control Wheel (Wheel Chamber)
Rotor Components – Rigid and Flexible
Rotor Components – Runout
Rotor Components – Magnetization
Quiz 4

 


ADVANCED – Module 5 – Components Part 2
Automatically released after 7 days from the date of purchase.

 


Rotor Components – Alignment
Rotor Components – Mechanical Alignment
Rotor Components – Piano String Alignment
Rotor Components – Laser Alignment
Rotor Components – Catenary Curve
Rotor Components – Critical Speed
Rotor Components – Vibration
Rotor Components – Balancing
Quiz 5
Balancing – High Speed ​​Balance
Components – Vanes
Components: Vanes: 3D Printing
Components – Belt
Components – Fixed Vanes (Reverser)
Components – Diaphragm
Components – Diaphragm Holder
Components – Vane Holder
Module 5 Handbook

 

 

ADVANCED – Module 6  – Components Part 3

Automatically released after 7 days from the date of purchase.

 


Components – Radial Bearing
Bearing Components – Operating Principle
Radial Bearing Components – Cylindrical
Radial Bearing Components – Pressure Dam
Radial Bearing Components – Multilobular
Radial Bearing Components – Tilting Pad
Radial Bearing Components – Oil Lift
Bearing – General Concepts
Bearing Components – Materials
Bearing Components – Temperature Monitoring
Components – Tilting Pad Bearing – Temperature Monitoring
Radial Bearing Components – Alignment
Radial Bearing Components – Clearance
Radial Bearing Components – Clearance Complement
Components – Radial Bearing – Clearance Check
Axial Expansion
Components – Axial Bearing
Quiz 6


ADVANCED – Module 7 – Components Part 4
Automatically released after 7 days from the date of your purchase


Components – Bearing Housing
Components – Vapor Sealing System
Components – Vapor Sealing – Carbon Ring
Components – Vapor Sealing – Ring Maze
Components – Vapor Sealing – Sealing Blades
Components – Oil Sealing
Turbine Speed ​​Control – Overview
Components – Mechanical Speed ​​Governor
Mechanical-Hydraulic Speed ​​Governor – Deep Dive
Components – Electronic Speed ​​Governor
Components – Actuator
Components – Coupling
Quiz 7
Components – Reducer
Components – Slow Rotation
Components – Thermal / Acoustic Insulation
Components – Base and Foundation

 

ADVANCED – Module 8 – Systems: Condensation, Control, Safety and Others
Automatically released after 7 days from the date of purchase.

 


Condensation System – Overview
Condensation System – Devices
What is TRIP?
Types of TRIP – Turbine Disarming
TRIP Disarming Standards and Criteria
Synchronization

 

 

ADVANCED – Module 9 – Lubrication System
Automatically released after 7 days from the date of purchase.


Lubrication System – Overview
Lubrication System – Consumers
Lubrication System – Hydraulic Unit
Oil Catcher Ring Applied in Single-Stage Turbines
Oil Contamination Level – NAS Indicator
Limit Concentration of Water in Oil
Flushing in Lubrication System


ADVANCED – Module 10 – Operation, Inspection and Maintenance
Automatically released after 7 days from the date of purchase.


Turbine Start-up and Stop Curves
Turbine Start-up Procedures
Main Materials
NDT – Non-Destructive Testing
Routine Operation and Maintenance
Failure Analysis and Solutions
Performance Analysis and Diagnosis
Assembly Clearances
Questionnaire 8
Certificate
Instructions for issuing your Certificate
Final Considerations and Certificate

 

Module – Learning About Varnish

 

Handout 4

Concept, formation, detection, correction and prevention of varnish formation
Introduction to varnish
Types of Turbine Oils
What is varnish?
Varnish Formation
Why the increasing trend in varnish formation? Varnish Presence Limits and Correction
Patent Metal Adhesion Module

Inspection Guide and Technical Standards
Introduction
Patent Metal Application Methods
Patent Metal Application Standards
Details ISO 4386 Part 2 Destructive Testing
Design for ISO 4386 Part 2 Laboratory Testing
Manufacturing Test Specimens for ISO 4386 Part 2 Laboratory Testing
Execution of Destructive Tensile and Compression Testing

 


Failure Analysis Modules

 

Steam Turbine Blade – Shear
Failure Analysis of Unexpected Steam Turbine Trips
Remote Diagnostic Analysis – Excessive Vibration Problem Solution
Rotor and Stator Blade Erosion Analysis
Vane Failure – Change in Opening of Partializing Valves
PED Bearing Resonance LOA
Introduction to SCC Failure Analysis in Steam Turbines
Failure Analysis Vibration Peaks Steam Turbines (Turbopumps)

 


505 Controller Module

 

Hardware Overview and Front Panel
Installation, Power and Startup Basics
Changing Modes and Languages
Installation, Power and Startup Basics
Navigation Screens
Wiring Connections for Analog and Speed ​​Signals
Wiring Connections for Communication Links
Wiring Connections for Discrete Signals
Ethernet IP Address Settings

 

 

SST 800 Module

 

SST 800 Condensing and Backpressure Steam Turbine Details and Systems
Lubrication System – Hydraulic Unit
Lubrication System – Consumers
Control System
Condensing System
Steam System – Condensing Turbine
Steam System – Backpressure Turbine

 

 

SST 400 Module

 

SST 400 Condensing Steam Turbine Details and Systems
Lubrication System – Hydraulic Unit
Lubrication System – Consumers
Control System
Condensation System

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Conclusion

The push for operational efficiency and reduced emissions is driving the replacement of steam turbines (replace steam turbine) with electric systems. 

 

With meticulous planning—from feasibility studies to commissioning—industrial plants can achieve significant gains in sustainability, reliability, and cost savings. 

 

Whether in refineries, petrochemical plants, or power stations, this is a modernization opportunity that can’t be overlooked.

 

Want to learn more about replacing steam turbines in your facility? Drop a comment or reach out for specialized consulting!

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Note: The opinions and information contained in this publication do not necessarily reflect the opinion of TURBIVAP.

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