CONTENTS

SL.No TOPICS PAGE NO.

1. ABOUT BHEL 1-5

2. THERMAL POWER PLANT 6-9

3. RANKINE CYCLE 10-11

4. PARAMETERS OF PV, PH DIAGRAMS 12-13

5. STEAM TURBINES 14-28

6. MANUFACTURING PROCESS 29-34

7. CONCLUSION 35
 BHEL

ANOVERVI
EW:

I
n1956I
ndi
atookamaj
orst
ept
owar
dst
heest
abl
i
shmentofi
tsheav
yindust
ry
whenBhar
atHeav
yEl
ect
ri
cal
sLt
d.,
(BHEL)set
upatBhopal
.Itr
api
dlyandt
hree
mor
efact
ori
eswenti
ntopr
oduct
ioni
n1965.Themai
nai
m ofest
abl
i
shi
ng
BHEL wast
o meett
he gr
owi
ng powerr
equi
rementoft
he count
ry.BHEL
appear
edont
hepowermapofI
ndi
ain1969whent
hef
ir
stuni
tsuppl
i
edbyi
t
wascommi
ssi
onedatt
heBasi
nBr
idgeTher
malPowerSt
ati
oni
nTami
l
nadu.
Wi
thi
nadecad,BHELhadcommi
ssi
onedt
he100t
huni
tatSant
aldi
h,West
Bengal
.BHELhast
akenI
ndi
afr
om aneart
otaldependenceoni
mpor
tst
o
compl
etesel
fr
eli
ancei
nthi
svi
talar
eaofpowerpl
antequi
pment
.BHELhas
suppl
i
ed97% oft
hepowergener
ati
ngequi
pmentt
hatwascommi
ssi
onedi
n
I
ndi
adur
ing 1979-
80.BHELhasal
readysuppl
i
ed gener
ati
ng equi
pmentt
o
v
ari
ousut
il
it
iespr
oduceannual
l
y;equi
pmentcapabl
eofgener
ati
ng6000MW.
BHELt
echnol
ogi
calexcel
l
enceandt
urnkeycapabi
l
iti
eshav
ewoni
twor
ldwi
de
r
ecogni
ti
on.Ov
er40count
ri
esi
nthewor
ldov
erhav
epl
acedor
der
swi
thBHEL
cov
eri
ngequi
pmentt
ocompl
etepowerst
ati
onsonat
urnkeybasi
s.I
n1978-
79

1
expor
treached Rs.
122 cr
oce,t
he hi
ghestf
orany y
ear
.BHEL has i
ts
headquar
ter
s atNew Del
hi.I
ts oper
ati
ons ar
e spr
ead ov
ermanuf
act
uri
ng
pl
ant
sandnumberofengi
neer
ingandser
vicedi
vi
si
onsl
ocat
edacr
osst
he
count
ry.Theser
vicedi
vi
sionsi
ncl
udeanet
wor
kofr
egi
onalbr
anchof
fi
ces
t
hroughout
Indi
a.

VARI
OUSFACTORI
ESOFBHELANDTHEI
RMAI
NPRODUCTS
FACTORI
ES:

BHOPAL :
Heav
yEl
ect
ri
cal
Equi
pment
plant

BANGLORE :
Cont
rol
Equi
pmentDi
vi
si
on,
Elect
ro-
Por
cel
ainDi
vi
si
on

HARDWA :
Heav
yEl
ect
ri
cal
Equi
pmentPl
ant
,Cent
ral
Foundr
yFor
ge

GOI
NDWAL :
Indust
ri
alVal
vesPl
ant
JAGDI
SHPUR :
HighTensi
onCer
ami
cInsul
ati
onPl
ant
JHANSI :
Transf
ormer
Plant

HYDERABAD :
Heav
yPowerEqui
pment
Plant

TI
RUCHI
RAPALLI :
HighPr
essur
eBoi
l
erPl
ant

RANI
PET :
Boi
l
erAuxi
l
iar
iesPr
oject

BHEL-
HYDERABAD:
(RAMACHANDRAPURAM )UNI
T

Asa memberoft
hepr
est
igi
ous'
BHEL f
ami
l
y',BHEL-
Hyder
abad has
ear
ned a r
eput
ati
on as one ofi
ts mosti
mpor
tantmanuf
act
uri
ng uni
ts,

2
cont
ri
but
ingi
tsl
i
on'
sshar
einBHELCor
por
ati
on'
sov
eral
lbusi
nessoper
ati
ons.
The Hy
der
abad uni
twas setup i
n 1963 and st
art
ed i
ts oper
ati
ons wi
th
manuf
act
ure ofTur
bo-
gener
atorset
s and auxi
l
iar
ies f
or60 and 110 MW
t
her
malut
il
it
yset
s.Ov
ert
hey
ear
sithasi
ncr
easedi
tscapaci
tyr
angeand
di
ver
sif
iedi
tsoper
ati
onst
omanyot
herar
eas.Today
,awi
der
angeofpr
oduct
s
ar
emanuf
act
uredi
nthi
suni
t,cat
eri
ngt
otheneedsofv
ari
etyofi
ndust
ri
esl
i
ke
Fer
ti
li
zer
s&Chemi
cal
s,Pet
rochemi
cal
s&Ref
iner
ies,Paper
,sugar
,st
eel,et
c.
BHELuni
thascol
l
abor
ati
onswi
thwor
ldr
enownedMNCsl
i
keM/
SGener
al
El
ect
ri
c,USA,M/
S Si
emens,Ger
many
,M/
S Nuov
o Pi
gnone,et
c.BHEL-
Hy
der
abad,a Manuf
act
uri
ng Uni
tlocat
ed nearHy
der
abad ci
ty.The maj
or
pr
oduct
s oft
he Hy
der
abad uni
tand t
he shops wher
ethe pr
oduct
s ar
e
manuf
act
ured and assembl
ed ar
e gi
ven bel
ow.The t
echnol
ogyofBHEL-
Hy
der
abad,
fort
he
pr
oduct
s/sy
stemsi
son parwi
tht
he l
atest/besti
nthe wor
ld.BHEL-
Hy
der
abadhascol
l
abor
ati
onswi
thl
eadi
ngcompani
esi
nthewor
ldl
i
keM/
s
Gener
alEl
ect
ri
c-USA,
M/sSi
emens,
Ger
many
,M/
sNuov
oPi
gnone-
It
alyet
c
SHOP PRODUCT/ PROCESSAREAS
1 Steam Tur
bines,
GasTurbi
nes&
Centr
if
ugalCompressor
s
2 TurboGenerator
sandExci
ter
set
c

3 SwitchGear s
4 FerrousFoundr y
5 Non- FerrousFoundr
y
6 HeatExchanger s
7 ToolRoom
8 HeatTr eat
ment
9 PatternShop
10 SparesManuf act
uri
ng
11 OilFieldEquipment’s(
Oil
Rigs)
51 CoalPul veri
zers
70 Cent ri
fugalPumps

3
TURBI
NES,
COMPRESSORSANDGASTURBI
NES201SHOP

I
tist
hebiggestshopfloorwi
thpl
int
har eaof35,
500sq-
m.Thev
ari
ous
pr
oduct
smanuf actur
edinthi
sshopfloorare
St
eam t
urbi
nes:
a)I
ndust
ri
alset5MW andabov
eupt
o60MW

b)
Uti
l
ity
set
s 60MW andabov
eupt
o
120MW
Gast
urbi
nes:a)Fr
ame-
1 (
5MW)

b)Fr
ame-
3 (
10MW)

c)Fr
ame-
5B (25MW)

d)Fr
ame-
6B (37MW)

e)Fr
ame-
9E (
123MW)

f)Fr
ame-6FA (70MW)
e)Frame-
9FA (
240MW)

Cent
ri
fugal
Compr
essor
s:a)Hor
izont
alspl
i
t
ty
peb)Verti
calspl
i
t
ty
pe
201SHOP:

Bay
-1:
superheav
ymachi
neshop

Bay
-2:
heav
ymachi
neshop

Bay
-3:
Bladeshop

Bay
-4:
M&S/Rot
orshop

Bay
-5:
Wel
ding/GTwheel
shop

Bay
-6:
Medi
um machi
neshop

Bay
-7:
GTmachi
neshop

4
 CLASSI
FICATI
ONOFPRODUCTS

Accor
dingtoi
ndust
ri
estowhicht
heyar
emeantt
o,cl
assi
fi
cat
ionoft
he
pr
oductscanbedoneasf
oll
ows:
Powergener
ati
onandt
ransmi
ssi
on:

1)Steam turbine-generatorset
s&auxili
ari
es,2)Boil
erandboi l
erauxil
iari
es,
3)once-t
hroughboi lers,4)nuclearpowergenerati
onequi pment,5)hydro
turbi
negener atorsetsandauxil
i
ar i
es,6)Mini/Mi
croHy droGenerator
Sets,7)Gas
TurbineGener atorSets,8)Wast eHeat Recover
yBoil
ers,9)heatExchangers,10)
Condensers,11)Bowl MillsandTubeMi l
ls,12)
Valves,13)Pumps
PowerDi
str
ibut
ion:

1)
Sy nchronousCondenser
s,2)
Switchgear,3)cont
rol
gear,
4)Di
str
ibut
ed
Di
gital
ControlforPower
Stati
ons, 5) Duct
s, 6)
Recti
fi
er
System &Servi
ces:

TurnkeyUtil
i
tyPowerSt
ati
ons/EPCContract
s,2)
CaptivePowerPl
ant
s,
Cogenerat
ionSyst
ems,4)CombinedCy
clePowerPlant
s

I
ndust
ri
es:

Steam Tur
bineGener
atorSet
s,2)Tur
bineGener
atorSet
s,3)
Diesel
Engi
ne
BasedGenerat
ors
Equi
pment
s:

DDCf orProcessIndustri
es,2)Thyrist
erEquipment,3)Power
Devices,
4)EnergyMet er
s,5)
Transformers, 6) Swit
chgear
,
7)I
nsulat
or,8)Capaci
tors,9)
Wi ndElect
ricGenerator
s,10)Sol
arPower
edWater
Pumps, 11)SolarWaterHeatingSystems, 12)Photo 13)
Volt
aicSyst
ems, .
Equipments

LawsofTher
mody
nami
cs:
Zer
oth

Law:

5
 Temper
atur
emeasur
ement

t
her
mal
equi
l
ibr
ium

Fi
rstLaw:
∑Wcycle=J( ∑Qcycl
e)foracycl
icpr
ocess
Equi
valenceofheatandwork
Pri
nci
pleofconservat
ionofener
gy

SecondLaw:
Givesconditi
onofheatandworkt
ransf
er
Wor kishi
ghgr adeener
gyandheatisl
owgr adeener
gy.
Allheatcannotbeconvert
edt
owork.
Secondlawcanbei mpl
ementedbyheatengi
ne.

Thi
rdLaw:

syst
em cannotbereducedt
oabsol
utezer
o(-
2730Cbyaf
ini
te
numberofoperat
ions)
THERMALPOWERPLANTRESOURCE:

I
ndi
ahasl
argedeposi
tofcoal
(about170bi
l
li
ont
ones)
,5t
hlar
gesti
nwor
ld.

I
ndi
ancoal
sar
ecl
assi
fi
edasA-
Ggr
adecoal
s.
Power
gener
ati
onf
romcoal
canbeest
imat
edby
meansof
it
scal
ori
fi
cva
l
uekCal
/kgor
kJ/
kg.
Thecal
ori
fi
cval
uesofmaj
ort
ypesofcoal
sar
egi
venbel
ow.

Sel
ect
ionofsi
tef
ort
her
mal
powerpl
ant
:

1)Tr
anspor
tat
ionnet
wor
k:

Easyandenoughaccesst
otranspor
tati
onnetwor
kisr
equi
redi
nbot
h
powerpl
antconst
ructi
onandoperat
ionper
iods.
Gaspi
penet
wor
k:

Vi
cini
tyt
othegaspi
pesr
educest
her
equi
redexpenses.

Powert
ransmi
ssi
onnet
wor
k:

6
Tot r
ansfert
hegener at
edel ect
ri
cit
ytotheconsumers,t
heplantshoul
dbe
connectedtoelect
ri
caltransmissi
onsyst
em.Theref
orethenearnesstothe
el
ectri
cnetwor
kcanpl ayaroll
.
Geol
ogyandsoi
lty
pe:

Thepowerpl
antshoul
dbebuil
tinanareawi
thsoilandr
ockl
ayer
sthatcoul
d
st
andthewei
ghtandvibr
ati
onsofthepower
plant
.
Ear
thquakeandgeol
ogi
cal
faul
ts:

Evenweakandsmal leart
hquakescandamagemanypar
tsofapowerpl
ant
i
ntensiv
ely
.Therefor
et hesiteshoul
dbeawayenoughfrom t
hefaul
tsand
pr
ev i
ouseart
hquakeareas.
Topogr
aphy:

Itis proved thathigh elevat

ion has a negati
ve eff
ecton producti
on
eff
ici
encyofgast urbi
nes.Inaddit
ion,changi
ngofasl opingar
eaint
oaf lat
sit
efort heconstr
ucti
onoft hepowerpl antneedsextr
abudget.Theref
ore,
theparametersofelevat
ionandslopeshouldbeconsidered.
Ri
ver
sandf
loodway
s:

Obvi
ousl
y,t
hepowerplantshoul
dhaveareasonabl
edi
stancef
rom
per
manentandseasonalr
iver
sandfl
oodways.
Wat
err
esour
ces:

Fortheconst ructi
onandoper atingofpowerpl antdif
ferentvol
umesof
waterarerequired.Thiscoul
dbesuppliedfr
om ei
therr
iversorundergr
ound
waterresources.Therefor
ehavingenoughwatersuppl
iesindefi
nedv i
ci
nit
y
canbeaf actorintheselecti
onofthesi
te.
Env
ironment
alr
esour
ces:

Operat
ion ofa powerpl anthas importantimpacts on envi
ronment
.
Theref
ore,prior
it
ywi llbegiventothelocati
onsthatar
ef arenoughfr
om
nati
onalparks,wil
dli
fe,pr
otectedar
eas,
etc.
Popul
ati
oncent
ers:

Fort
hesamer
easonsasabov
e,t
hesi
teshoul
dhav
eanenough

7
di
stancef
rom popul
ati
oncent
ers.
Needf
orpower
:

I
ngener
al,
thesi
teshoul
dbeneart
hear
east
hatt
her
eismor
eneedf
or
gener
ati
oncapaci
ty,
todecr
easet
heamountofpowerl
ossand
t
ransmi
ssi
onexpenses.
13
Cl
i
mat
e:

Parameterssuchast
emper
atur
e,humi
dit
y,wi
nddi
recti
onandspeedaff
ectt
he
pr
oducti
vit
yofapowerpl
antandal
waysshoul
dbetakenint
oaccount
.
Landcover:

Somel andcovertypessuchasf orest

s,orchard,agri
cul
tur
all and,pastur
eare
sensit
ivetothepollut
ionscausedbyapowerpl ant
.Theef fectoft hepower
plantonsuchlandcovertypessur
roundingitshouldbecountedf or.
Ar
easi
ze:

Befor
eanyotherconsi
derati
on,themini
mum areasi
zer
equi
redf
ort
he
const
ruct
ionofpowerplantshouldbedefi
ned.
Di
stancef
romai
rpor
ts:

Usuall
y,apowerpl
anthashightowersandchi
mney
sandlar
gev ol
umeofgas.
Consequent
lyf
orsecur
it
yreasons,t
heyshoul
dbeawayf
rom ai
rport
s.

Ar
cheol
ogi
cal
andhi
stor
ical
sit
es:

Usuall
y hi
stor
icalbuil
ding …aref
ragi
l
e and atsame ti
me ver
yval
uable.
Theref
orethevibr
ati
oncausedbypowerpl
antcandamaget
hem,
andadefi
ned
di
stanceshoul
dbeconsidered.
Schemat
icofaTher
mal
PowerPl
ant
:

8
Schemat
icofaTher
mal
PowerPl
ant
-2

Maj
orComponent
sofaTher
mal
PowerPl
ant
:

Coal
handl
i
ngpl
ant
Pul
ver
izi
ngpl
ant

Dr
aftordr
aught
fan

Boi
l
er

Ashhandl
i
ngpl
ant

Tur
bineandgener
ator

Condenser

Cool
i
ngt
owerandponds

Feedwat
erheat
er

Economi
zer

Superheat
erandr
eheat
er

9
 Ai
rpr
eheat
er

Al
ter
nat
orwi
thexci
ter

Pr
otect
ionandcont
rol
equi
pment

I
nst
rument
ati
on

Ranki
necy
cle:

TheRanki necy clei sat her mody nami ccy clewhi chconv er t
sheati ntowor k.
Theheati ssuppl iedext er nall
yt oacl osedl oop,whi chusual l
yusesWat eras
thewor kingf l
ui d. t
hiscy clegener atesabout80% ofal lelectri
cpowerused
throughoutt hewor ld,i ncl udi
ngv i
rtuallyallsolart hermal, biomass,coaland
nuclearpowerpl ants.i ti snamedaf terWi ll
i
am Johnmacquor nRanki ne, a
Scottishpol ymat hphy sicall ayoutoft hef ourmai ndev icesusedi nt heRanki ne
cycle.Theef fici
encyofRanki necy clei susual lylimit
edbyt hewor kingf l
uid.
Withoutt hepressur egoi ngsupercr i
ticalthet emper aturer angethecy clecan
operat e ov eri s quite smal l,turbine ent ry are ar ound 30° c.this giv es a
theoreticalCar notef fi
ci encyofar ound63%compar edwi t
hanact ualefficiency
of42% f ora moder n coal- fi
red powerst ation.t hi
sl ow turbine ent ry
temper at ureiswhyt heRanki necy clei sof t
enusedasabot t
omi ngcy clein
combi nedcy cl
egast urbi nepowerst at i
ons.Thewor ki
ngf luidinRanki necy cle
foll
owsacl osedl oopandI 'dre- usedconst antl
y. thewat erv aporandent rained
dropletsof t
enseenbi llowi ngf rom powerst ati
onsi sgener atedbyt hecool ing’s
andsy stemsandr epresent sandt hewast eheatt hatcoul dnotbeconv ertedt o
useful wor k.
Pr
ocessoft
heRanki
necy
cle:

1)Pr
ocess 1-
2:t he worki
ng fl
uidis
pumpedfrom lowt ohighpressur
e,as
thefl
uidisal iquidatthisstagethe
pumpsrequir
esLi tt
lei
nputener
gy.
2)Process2-
3:t
hehighpr
essureli
quid
entersaBoilerwherei
tisheatedat
constantpr
essurebyanext
ernalheat

10
 source t o become a dr y
saturat
edvapor.
3)Process 3-4:The dry satur
ated v aporexpands t
hrough a tur
bine,
generati
ngpower .Thi
sdecr easest het emper
atur
eandpr essur
eoft he
vapor,andsomecondensationmay occur.
4)Pr
ocess4-1:t
hewetvaporthenent
ersaCondenserwher
eiti
s
condensedatconst
antP&Ttobecomeasaturat
edli
qui
d.
Thepressur
eandtemperat
ureoft
hecondenseri
sfi
xedbyt
he
temperat
ureoft
hecool
ingcoil
sasthef
lui
disunder
goi
ngaphase-
change.
Super heat erandReheat er:
Superheat edst eam isthatst eam whi ch
containsmor eheatthant hesat uratedsteam
atthesamepr essur
e.Theaddi t
ionalheat
providemor eener gytot het urbi
nehence
powerout puti smore..
Super heat edst eam causesl esserer osi
on
ofthet urbinebl adesandcanbet r
ansmi t
ted
forlongerdi stancewi thlit
tleheat loss
Thef unctionoft hesuperheat eristoremove
thelastt r
ashofmoi stur
ef rom t he
saturatedst eam. .
Asuper heat ermaybeconv entiont y
pe,
radiantt ypeor combi nation.
Reheat er:
I
naddi t
iontosuperheat
ermodernboil
erhasreheateralso.Thefunct
ion
ofther eheateri
stosuperheatt
hepart
lyexpandedsteam from t
he
turbine,thi
sensuret
hatThesteam r
emaindrythroughthelastst
ageof
theturbine.
Ar
eheat
ermaybeconv
ent
iont
ype,
radi
antt
ypeorcombi
nat
ion.

FeedWat
erHeat
ers:

FeedWat
erheat
ingi
mpr
oveov
eral
l
eff
ici
ency
.

11
 Thedissolv
edoxy genwhi chwouldot herwisecauseboi lercorrosi
on
arer
emov edint hefeedWat er
heater.
Thermalstressesduet ocoldwaterenteringt heboil
erdr um areavoi
ded.
Quanti
tyofst eam pr oducedbytheboi l
erisincreased.
Someot herimpur i
tiescarri
edbyst eam andcondensat e, duet o
corr
osioni
nboi lerandcondenser ,
ar eprecipit
atedoutsidet heboil
er.
Regenerati
on:

T-
sDi
agr
am ofLower
ingt
heCondenserPr
essur
e

Inasimpl eRanki necy cle,heati saddedt othecy cledur i

ngprocess2- 2'-
3( see
the T-s diagram on t he l eft)
.Dur ing t hi
sf i
r stst age (process 2- 2'),the
temperatureoft hewat erisl ow.Thatr educest heav eragetemper aturedur i
ng
heataddi t
ion( process2-2' -3)
.Tor emedyt hisshor tcoming,i ncreasi ngt he
temperatureoft hef eedwat er(wat erleav ingthepumpandent eringt heboi ler)
canbeconsi der ed.Thisi saccompl ishedbyext r acti
ngst ream from t het urbine
to heatthef eed wat er.Thi spr ocessi scal led r egenerati
on and t heheat
exchangerwher eheati st ransfer r
edf r
om st eam t of eedwat eri scal l
eda
regener
ator,oraf eedwat erheat er.Ther eareact uall
yt womai nt y
pesoff eed
waterheaters.Ifthest eam mi xeswi tht hecompr essedwat erfrom t hepump, it
i
sanopenf eedwat erheat er.Ifthest eam doesnotmi xwi t
ht hecompr essed
waterfr
om t hepump, itisacl osedf eedwat erheat er.
Par
amet
ers:
P-v

di
agr
am:

Sat
urat
ioncur
veonP-
Vdi
agr
am

The ov eral
l shape of t he P-V
diagr
am i s si
milar t
o t he T-V
diagr
am exceptt hatthe const
ant
temperature l
i
nes are
droopi
ngdownwar d.
From theabov eP-Vdi
agram as
pressuredecreasesatconst
ant
temper at
ure,
thespecif
ic

12
 vol
umeofliquidincr
eases
margi
nall
ybut t
he
speci
fi
cvol umei fv
aporincr
easesconsi
der
abl
y.

I
sot
her
mal
li
nesar
eHor
izont
all
i
nei
nvapor
done

I
sot
her
mal
li
nesar
erect
angul
arhy
per
bol
ainsuper
heat
edr
egi
on.

Thesuperheat
edv
aporpr
oper
ti
esar
ever
ysi
mil
art
oideal
gaspr
oper
ti
es.
P-Hdi
agram:

Thepr essur eent hal pydi agr am f orst eam

i
s an excel lent t ool t o gai n an
under standi ngoft hest eam t abl es.The
pressur e- enthalpydi agr am descr ibest he
l
iqui d,v aporandmi xr egionofwat er.As
shown i nt he f ollowi ng f igure,t he P- H
diagr am consi stsofPr essur e(PSI A)on
they -axi sandEnt halpy( Bt u/lbm)ont hex- axis.Itisi mpor tantt onot et hat
pressur ei sshownonal ogar i
thmi cscal ewhi leenthalpyisshowni nanor mal
scal e.Int hemi ddleoft hedi agr am i st hev apordome.Thi sdomesepar atest he
sub- cool edl iquid( akawat er)ont hel ef tsi de,super -
heatedv apor( akast eam)
ont her i
ghtsi deandt hel iquid- vapormi xr egion(akami xedr egionorwet
region)i nt he mi ddle.The P- H di agram i s al so helpfuli ni l
l
ust rat
ing t he
relationshi pbet weent heent halpyoft hesat ur atedli
quid,sat uratedv aporand
theent hal pyofv apor ization.Asshownont hef ol
l
owingf igure,ont heleftt he
ent halpyofsat uratedl iquidi sf oundandasent hal
pyisaddedt ot hesatur ated
l
iqui d,mov i
ngf rom l eftt or ightatconst antpr essure,t
heent halpyofsat ur ated
gas( st eam)i sf oundatt hesat uratedv aporl i
ne.Thedi fferencebet weent he
twoent hal piesi sthel at entheat( enthal py )ofv apori
zati
on.

STEAM TURBI
NE:

GENERALDESCRI PTION:
Theturbineiscondensing,tandem compound,threecyl
inder,hor
izontaldisc
anddiaphragm t
ypewithnozzlegoverningandr
egenerat
ivefeedwat erheat
ing.
Thedoubl efl
ow L.P.turbi
nei ncor
poratesamul t
iexhaustineachf l
ow.t he

13
compl eteassembl yi smount edonapedest alsandsol epl at es,whi char e
desi gnedt oensur et hatt hecomponent sar ef reet oexpandwhi lstcor r ect
alignmenti smai ntainedunderal lconditions.Li v
est eam f rom t heboi lerent ers
i
nt woemer gencyst opv al ves( ESV)ofhi ghpr essuret urbi nes.Fr om ESVst eam
flowst ot hef ourcont rolv alv es( CV)mount edont hecasi ngofhi ghpr essur e
tur bine( HPT)att hemi ddlebear ingside.Cont rolvalvei nt ur nfeedt hest eam t o
nozzl eboxesl ocat edi nsidet heHPT.
19Thehi ghpr essur et ur binecompr isesof12st ages,t hef i
rstst agebei ng
gov er ningst age.Thest eam f lowi nHPTbei ngi nr ev ersedi rect i
on,t hebl ades
i
nHPTar e
desi gnedf orant i
clockwi ser otat i
on, whenv i
ewedi nt hedi rect ionofst eam f low.
aaf terpassi ngt hr oughH. P.t ur binest eam f lowst oboi lerf orr eheat i
ngand
reheat edst eam comest ot hei ntermedi at epr essuret urbine( IPT)t hr ought wo
Int ercept orv al ves( IV)andf lowcont rolv alves( CV)mount edont heI PTi tsel f
.
thei nt ermedi atepr essur et urbi nehas11 st ages.H. P.and I .P.r ot orsar e
connect edbyr i
gidcoupl ingandhav eacommonbear ing.af terflowi ngt hr ough
IPT,st eam ent erst hemi ddl epar tofl ow pr essur et urbine, (LPT)t hrought wo
cr ossov erpi pes.I nLPt ur bine, st eam flowsi nopposi tepat hhav i
ngf ourst age
i
neachpar t.Af terl eavingt heL. P.turbine, theexhaustst eam condensesi nt he
sur facecondenser swel deddi rectlyt ot heexhaustpar toft heL. P.t urbi ne.
Rot orofi nter medi ateand l ow pr essuret urbinear econnect ed bya semi
flexi blecoupl ing.

Thedi r
ectionoftherotationoft herotorsi sclockwi sewhenv iewedf r
om t he
frontbear i
ngendt owardst hegener ator.Thet hreerot orsar esuppor tedonf iv
e
bear i
ngs.Thecommonbear ingofH. P.andI .P.rotorsi sacombi nedj ournal
andr adialthr
ustbearing.Theanchorpoi ntoft het urbinei sl ocatedatt he
mi ddlefoundationfr
ameoft hefrontexhaustpar toflowpr essurecy li
nder .The
turbineexpandst owardst hef rontbear i
ng bynear ly30 mm and t owar ds
gener atorby3mm i nst eadyst ateoperationatf ulll
oadwi thr at
edpar amet ers.
Tur bi
nei sequippedwitht urninggearwhi chr otatesther otoroft het urbineata
speedofnear ly3.4r.p.m .f orprovi
dinguni form heat ingdur i
ngst artingand
uniform cool i
ngdur i
ngshutdown.I nor dert o heatt hef eedwat eri nthe
regener ati
vecycleofthet urbine,condensat efrom thehotwel lofcondenseri s
pumpedbyt hecondensat epumps, andsuppl i
edt othet hroughej ectors, gl
and

14
steam coolers,L.P.heatersandgl andcooler.From ,thef eedwat erissuppl i
ed
toboilerbyboi lerf eedpumpst hr
oughH. P.heat er
s.Steam f rom t hev arious
pointsofthet urbinei sut
il
izedtoheatt hecondensat e.St eam enteringfrom a
smallopeni ng at tains a very hi
gh v el
ocit
y.( The velocity at
tained dur i
ng
expansiondependsont heinit
ialandfinalcontentofthest eam.Thedi ff
er ence
i
ni ni
tialandf i
nalheatcont entrepresenttheheatener gyt obeconv ertedt o
ki
neticenergy .
Partsofsteam t urbine:

1)Tur
bineCasi
ngs:

Thecasi ngshapeandconst ruct i

ondet ail
sdependonwhet heriti saHi gh
Pressure( HP)orLowPr essure( LP)casi ngs.Forlowandmoder ateinletsteam
pressureupt o120bar ,asi ngleshel lcasingisused.Wi t
har isei ni nl
et
pressuret hecasingt hicknessast obei ncreasi
ng.Handl i
ngsuchheav ycasing
i
sv erydi ff
icul
talso t het urbineast o slowlybr oughtupt ot heoper at i
on
temper ature.Otherwiseunduei nternalst ressordistorti
onstot hethickcasi ng
mayar i
se.Toov ert hisforhighpr essur eandt emper at
ureappl i
cationdoubl e
casingi sused.I nthedoubl ecasi ngi nnercasingisf orHighpr essureandt he
outercasi ngisforhol dthel owpr essur e.Mostoft heturbinehav ecasingswi th
horizontalspl i
tt y
pe.Due t o hor izontalspl i
titeasy f orassembl i
ng and
dismant l
ingf ormaint enanceoft urbine.Al so,maintai
npr operaxialandr adial
clearancebet weent her otorandst ationarypar t
s.
Usual
ly,t
het urbinecasingsareheavyinor
dert
owi thst
andthehighpressures
andtemper atures.Itisgeneralpract
icet
hethicknessofwall
sandf langes
decr
easef r
om t heinlettoexhaustendduetot
hedecr easei
nsteam pressure
fr
om inl
ettoexhaust .
2)Tur
bineRot
ors:

Thesteam turbinerotorsmustbedesi gnedwiththemostcar easi ti

smost l
y
thehighl
yst ressedcomponenti nt het urbi
ne.Thedesi gnofat ur
biner ot
or
dependsont heoper ati
ngprincipleoft het ur
bine.t
hei mpulset ur
bine,inwhich
thepressur
edr opsacr ossthest ationaryblades.Thest at i
onarybladesar e
mountedint hediaphragm andt hemov i
ngbladesfixedorf orgedont herotor
.
Steam l
eakagei sinbet weent hest ationarybladesandt her otor
.Thel eakage
ratei
scontroll
edbyl abyri
nthseal s.Thisconst r
ucti
onr equi
resadi scr
otor.

15
Ther eact i
ont urbi
nehaspr essuredropsacrossthemov i
ngaswel lasacross
thest ationaryblades.Thedi scrot
orwouldcr eat
eal argeaxialthrustacross
eachdi sc.Hencedi scrotorsarenotusedi nt hereact ionturbi
ne.Fort hi
s
application,adr um rotorisusedt oeli
minatetheaxi althrustcausedbyt he
discs,butnott heax ialt
hrustcausedbyt hediff
erentialpressureacr ossthe
mov ing bl ades.Duet othis,theconfi
gurati
on ofr eaction t
urbinei smor e
compl icated.

DiscTypeRot
ors:Thisty
peofr otori
slargel
yusedinsteam turbines.Thedisc
ty
per otor
sar
emadebyf or
gingprocess.Normall
ytheforgedr otorweightis
around50%higherthanthefinalmachinedrot
ors.Ref
erabov efigurefordisc
ty
perotor.
Drum Ty peRot ors:Initi
all
y,ther eacti
ont urbinesr otorsaremadebysol i
d
forgeddr um-typerotor.Ther otor
sar eheavyandr i
gidconst r
ucti
on.Duet othis,
theinerti
aoft herotori sveryhighwhencompar ewi t
ht hedisc-
typerotorofthe
samecapaci ty.Toov ercomet hi
snowaday st hehol low drum-t
y perotorsare
usedi nsteadofsol i
dr igi
dr otor
s.Usual l
y,thist y
peofr otorismadeoft wo
piecesconst ruct
ion.Insomespeci alcases,ther otorismadeupofmul ti
-pi
ece
construction.thedrumsar emachi nedbothout si
deandi nsi
det ogetper f
ect
rotorbalance.
TurbineBl ades:theef f
iciencyoft het ur
binedependsonmor ethanany thi
ng
el
seont hedesi gnoft het urbineblades.Thei mpulsebl
adesmustbe
designedt oconv erttheki neticenergyoft hesteam i
ntomechanicalenergy.
Thesamegoesf orther eactionblades, whichfurt
hermor
emustconv er
t
pressureener gytoki neticener gy.Stati
onaryBlades(Di
aphr
agms)and
Nozzles: nozzlesareusedt ogui dethest eam tohitt
hemovingbladesandt o

16
convertthepr essureener gyintot hekineticenergy.Inthecaseofsmal l
i
mpul seturbine, t
henozzl esar elocatedi nthelowerhal fofthecasi
ng.Butin
thecaseoft hel argerturbine,thenozzl esarelocatedont heupperhal
fofthe
casi
ng.St ati
onar yBlades( Diaphragms) :
Allstagesfoll
owi ngthecontrolst
age
havethenozzl esl ocatedindi aphragms.Thedi aphragmsar ei
nhalvesand
fi
tt
edi nt
ogr oov esinthecasi ng.Ant i
-rotati
ngpinorl ockingpiecesinthe
upperpar tofthecasi ngpr eventthedi aphragm torotate.
BladeFast ening:St eam Tur bineBasicPar t
saf t
erturbinebladesar emachined
throught hemi ll
ingpr ocess.Thent hebladesar einsertedint herotorgroove.
Dependupont heappl i
cat i
ont hebladerootsect i
onv ari
es
Twi st
ed Bl ades:t hist ype ofbl adesi sused i nt he lastst age ofa large
mul ti
stagest eam turbine.Thesear et helargestbladeint ur
bineandcont ri
bute
around10% oft het urbinet otaloutput.Duet olargeri nsize,thesetypesof
bladesar esubject edt ohi ghcent ri
fugalandbendi ngf orces.Toov ercome
thesef orcestwistedconst ruct i
onisused.
Turbi
neBear
ings:Oneofthest
eam t
urbi
nebasicpar
tisbeari
ng.Theyar
etwo
ty
pesofbear
ingsusedbasedonthet
ypeofloadactonthem 1)
Radial
Beari
ng,
2)Thr
ust
Bear
ing
RadialBeari
ngs:Forsmal lturbi
nesmost lyequipped wi
thant
i-
fr
ict
iont ype
beari
ngs.Widelyusedanti-
fr
ict
ionbearingsaretheself
-al
i
gni
ngsphericalbal
l
orroll
erbear
ingwit
hfloodedtypelubr
icati
onisused.
Thr
ustBear
ings:
Themai
ntwopur
posesoft
het
hrustbear
ingar
e:1)
To

keept
her
otori
nanexactposi
ti
oni
nthecasi
ng.
2)
Toabsor
baxi
alt
hrustont
her
otorduet
ost
eam f
low.

Shrouds: Shroudsareusedt oreinf

or cethet urbi
nebladesfreeendstoreduce
vibr
at ionandleakage.Thisisdonebyr everti
ngaf l
atendov ert
hebladesrefer
fi
gur e.Insomecasesespeci all
yatt heear lyst
ages,theshroudmaybei ntegral
witht heblade.Whent hebladesarev erylongasi nthecaseoft hel
aststageof
LPt urbine.Therotorbladesarefur
therr einfor
cedbyusi nglaci
ngwires
(caulkingwire)whichcircumferent
iallyconnect sal
lthebladesatadesir
ed
radiusandshr oudingiselimi
nated.

17
TurbineBar ringdevice:Whenat urbinei sl ef
tcoldandatst andsti
ll
,thewei ght
ofther otorwi llt
endt obendt herot orsl i
ghtly.I
fleftatthest andsti
llwhil
et he
tur
bi nei sstillhot,t
hel owerhalfoft her otorwi l
lcoolofffasterthant heupper
halfandt her otorwillbendupwar ds“ hog”.Inbothcases, thet ur
binewoul dbe
dif
ficulti f noti mpossi bl
et o st artup.To ov ercome t he pr oblem t he
manuf acturersuppl ies the l
argert urbines withat urni
ng orbar r
ing gear
consi sti
ngofanel ectri
cmot orwhi cht hroughsev eralset
sofr educinggear s
tur
nst het urbineshaftatlowspeed.
TurbineSeal s:Sealsar eusedt or educet heleakageofst eam bet weenthe
rot
aryandst ati
onarypar t
soft hesteam tur bi
ne.Dependupont helocati
onof
seal,thesealsarecl assif
iedast wotypes,theyar e,shaftSeal ,
bladeSeal
ShaftSeal s:Shaf tseal sareusedt oprev entt hest eam leakagewher ethe
shaftsextendt hrought hecasing.Inthecaseofasmal l
tur
bine( asperAPI611)
carbonr i
ngsar eusedasshaf tsealupt ot hesur facespeedoft heshaftis
50m/ s.Thecar bonr i
ngi smadeupoft hreesegment sbutt
ingt ogetherti
ghtl
y
undert hepressur eofagar t
erspring.Thecar bonr ingsaref reefloati
nginthe
housingandanant i
-rotati
ngpi nisusedtopr eventt herot
ationofcar bonr i
ng
seal.
BladeSeals:Bladeseal
sareusedtopreventthesteam l
eakagebetweenthe
diaphragm andtheshaft
.Theeff
ici
encyofthetur
binedependslar
gelyonthe
bladeseals.Labyri
nthseal
sareusedasbl adesealsinthesmallandlarge
turbi
nes.Inthecaseoflargest
eam tur
binespri
ngloadedlabyr
int
hsealsare
used.
TurbineCouplings:Thepurposeofcoupli
ngsistot r
ansmitpowerfrom the
pri
memov ert
othedrivenpi
eceofmachiner
y.Fl
exi
bletypecoupl
ingsareused
i
nturbines.Thecoupli
nghubsaretaperbor
eandkeywayt ofitt
hetaperedend
oftheshaft.
Gov ernor
:Thegov ernorisoneofthest eam turbinebasicparts.I
tsmai n
functionistocont
roltheoper
ati
onofasteam turbine.General
l
y,t
hegov er
nor
i
scl assi
fi
ed astwo t y
pe1)speed gov
er nor2)Pr essur
esensing orload
gover nor
Speed Sensi
ng Gov
ernor
:speed gov
ernor
s ar
e used i
n powergenerat
ion
appl
icat
iontomaint
ainaconst
antspeedwithr
especttotheloadchangein

18
gov
ernor
. Droop is one of t
he i
mpor
tant char
act
eri
sti
cs of t
his
gov
ernor
sel
ecti
on.
Pressur
esensiti
vegov er
nor:
Theseareappl
i
edtobackpr
essur
eandextr
acti
on
tur
binesinconnecti
onwi tht
hespeedsensi
ti
vegover
nor
.Theyar
ethr
eet y
pes
ofgovernorusedinsteamtur
bine
Mechani
cal
Gov
ernor

Hy
dro-
mechani
cal
Gov
ernor

El
ect
roni
cGov
ernor

Lubricat
ion Syst
em:Oi lfl
ood l ubri
cati
on is used forsmal lturbi
nes and
pressuri
zedlubri
cati
onisusedf orlargert
urbi
nes.Thepr essuri
zedlubri
cati
on
system consist
sofl ubeoiltank,oilpump,fil
ter,cool
er,pressur
er egul
ati
ng
valve,et
c.,Thepressuri
zedlubricat
ionsystem ofturbineshallbeasperAPI
614.

TYPESOFSTEAM TURBI
NES:

CONDENSI
NGTURBI
NES

CONDENSI
NG-
BLEEDERTURBI
NES

BACK-
PRESSURETURBI
NES

TOPPI
NGTURBI
NES

MI
XEDPRESSURETURBI
NES

CROSSCOMPOUNDTURBI
NES

TANDEM COMPOUNDTURBI
NES

EXTRACTI
ONTURBI
NES

CONDENSI
NGTURBI
NES:

Withthecondensi
ngturbi
ne,thesteam exhaust
st ot
hecondenserandthe
l
atent
heatofthesteam istransf
err
edtot hecooli
ngwat
er.Thecondensed
st
eam isr
etur
nedtotheboil
erasfeedwat
er.

19
 CONDFENSI
NG-
BLEEDERTURBI
NE:

Thecondensi
ng-
bleedert
urbi
nereducesthecondenserl
ossesassteam i
sbl
ed
offatsever
alpoi
ntsoft hetur
bine.Thebleed-
steam i
susedf orfeedwat
er
heat
ing,
upto20%oft hetot
alst
eam flowmaybebl edof
f.
BACK-PRESSURETURBI NES:
Back-pr
essuretur
binesareoftenusedi nindustri
alplant
s,t
heturbi
neactsasa
reduci
ngstati
onbetweenboi l
erandprocessst eam header.Theprocesssteam
pressur
eiskeptconstantandt hegeneratoroutputdependsonthedemandf or
processsteam.Theback-pressureturbinemayal sohavebleedpointsandi s
thencall
edaback-pressur
e-bl
eederturbine.
Noncondensi
ngst
eam cy
cle(
backpr
essur
etur
bine)

EXTRACTI
ONTURBI
NES:

Extracti
onst eam t urbi
nes:Thi sser vesand
controlssteam net wor ksi nt hecust omer ’
s
plant using def i
ned st eam Par amet ers.
Dependi ng on themodeofoper ati
on,t he
quant i
ty ofst eam and t he pressur e,an
extracti
on controlst age,adj ustabl e stat
or
bladesort heov erfl
ow t hrott
lear eusedt o
controlextr
action.Theext r
actionv al
v esare
l
ocat edinthetopoft hecasi ng.Extraction
nozzlescanbef i
ttedunder neathort ot heside.Theminimum cool
antquant
it
y
forthelowbl adeisguar anteedev enatt hemaxi mum ext
ract
ionquant
it
y.

CONDENSI NG, CONTROLLEDEXTRACTI ONTURBI NES:

Acontroll
edt urbi
nethatbleedsof
f(condenses)partofthemainstr
eam fl
ow
atone(singleextr
act
ion)ortwo(doubl
eextracti
on)point
s.Usedwhenprocess
steam i
sr equi
redatpressuresbel
owtheinletpressur
eandabovetheexhaust

20
pr
essur
e.
Non-condensi ngorbackpr essuret urbinesar emostwi delyusedf orpr ocess
steam appl i
cation.Theexhaustpr essur eiscont rolledbyar egulat
ingv alv eto
suittheneedsoft heprocessst eam pr essure.Thesear ecommonl yfoundat
refi
neries,districtheat ing unit
s,pul p and paperpl ants,and desal inat i
on
facil
i
tieswher el argeamount sofl ow pressurepr ocesssteam ar eav ailable.
Condensi ngt urbi nesaremostcommonl yf oundi nelectr
icalpowerpl ants.
Theset ur
binesexhaustst eam inapar ti
all
ycondensedst ate,ty
picall
yofa
quali
tynear90%, atapressurewel lbelowat mospher i
ctoacondenser .Reheat
turbi
nesar ealsousedal mostexclusivelyinelectricalpowerpl ant
s.Inar eheat
turbi
ne,st eam f low exit
sf rom ahi ghpr essuresect i
onoft het urbi
neandi s
retur
nedt otheboi l
erwher eadditionalsuper heati sadded.Thest eam t hen
goesbacki ntoani nt
ermediatepressur esect i
onoft heturbineandcont inues
i
tsexpansi on.
Extracti
ngt urbinesarecommoni nal lappl
icat
ions.Inanext r
acti
ngt urbi
ne,
steam isr el
easedf rom var
iousst agesoft heturbi
ne,andusedf orindustri
al
processneedsorsentt oboi lerfeedwat erheaterstoimproveov er
allcycle
effi
ciency.Extracti
onflowsmaybecont r
oll
edwithav al
ve,orlef
tuncontroll
ed.
Inducti
ont urbinesintr
oducel ow pressuresteam atanintermediat
est aget o
produceaddi ti
onalpower.
Applicati
onsofSt eam Turbines

Steam t
urbi
nesareapar
tofvariousindust
ri
es,f
rom medi
um t
olar
gescal
e,
andincl
udedozensofi
nsti
tut
ionalappli
cat
ions.
Chemi calIndust
ry:Providi
ng heat and elect
ri
cit
yt o dr
ive dif
fer
ent
processesinthechemicalandphar maceut
icali
ndustr
ies,st
eam turbi
nes
ar
ei ntegr
atedint
heprocessofproduci
ngpower.
WastePl
ant
s:St
eam tur
bineshel
pgener
atet
hepowerneededt
ohar
ness
ener
gyfr
omwastes.
Oil&Gas:Usedasapumpdr i
veoracompressor
,st
eam t
urbi
nessuppor
t
dozensofoperat
ionsi
ntheoi
landgasi
ndustr
y.
4)
SugarMil
ls:Of
fer
inghi
ghlev
elsofeff
ici
encyandsustainabl
eoperat
ions,
st
eam tur
binesareused t
o producegreen car
bon-
dioxideener
gyf rom

21
 bagasse,
someoft hemostpopul
arappli
cat
ionsofa st
eam t
urbi
nei
n
di
ffer
entindust
ri
esi
ncl
udet
hef
oll
owing:
1.Combi
nedHeatandPower
:

Steam turbinesare an essent

ialcomponentofmostCHP sy stems.They
supportcombi nedheatandpowersy st
emst hatareusedtopoweri ndustr
ial
processes,undercondi
ti
onswher ewastefuelsareavail
abl
ef ortheboi l
erto
safel
yutil
ize.Whenusedf orCHPs,t
hesteam emit
tedbythesteam t ur
binecan
beuseddirectl
y.
Steam turbi
nepoweredCHPsar etypicall
yfoundinpapermill
s,wheret herei
s
anabundanceofwast efuel
srangi
ngf rom bl
ackli
quortohogf uel
,eachequall
y
successfull
yinpoweri
ngtheboil
er.Theycanal sobefoundinchemi calplant
s
thatmakeex cessi
veuseofsteam t
urbines;f
oll
owedbytheiruseofmet als.
2.Dr
ivi
ngMechani
cal
Equi
pment
:

Steam t ur
bines areaf armor e effi
ciental t
ernat
ivet
o el
ect
ri
calpower.
Especial
lywheni tcomestodri
v i
ngdifferentequipmentl
i
keai
rcompressor
s,
boil
erfeedwat erpumps,
ref
ri
geratorchi
llers,
etc.
3.Distr
ictHeati
ng&Cooli
ngSystems:

Diff
erentinsti
tuti
onsthroughoutdif
fer
entci
ti
esr el
yondistr
ictcool
ingand
heati
ngsy stems.Thesesy st
emsusuall
yhaveast eam t
urbi
neplacedbet
ween
the boil
erand t he di
str
ibuti
on sy
stem orplaced as a r
epl
acementf ora
pressurereducti
onstat
ion.
I
ti stobenotedthat
,moreoft
en,boiler
sarecapabl eofproducingmoderate-
pressur
esteam whil
ethedist
ri
butionrequir
eslow pressuresteam.Bri
dging
thi
sgapbet weenthetwo,asteam turbinegeneratesenergyusingthehigh
pressur
est
eam andemitsl
owpr essur
esteam int
ot hedi
str
ibut
ionsyst
em.
4.Combi
nedCy
clePower
Plant
s:

Steam turbi
nesall
owpowerpl antstogenerat
epowerusingagast urbi
neand
uti
lizegasandheatpr oducedintheprocesstogenerat
esteam that,i
nt urn,
producesadditi
onalpower.Combinedcyclepowerpl
antssupport
edbyst eam
turbines ar
e capable ofproducing oraccompli
shi
ng elect
ric generat i
on
effi
cienci
es ext
ending bey
ond the 50-
percentmarkand are used inlar ge

22
i
ndust
ri
alappl
i
cat
ions.
Mostoft heelect
ri
cit
ythroughoutt
heUni t
edStatesisproducedwitht
hehel
pof
steam turbi
neengines.Offeri
nghighereffi
ci
encies,l
ow costs,andaposi
tiv
e
i
mpactont heenv ir
onment ,st
eam turbi
neshav ebecomeai nt
egr
alpar
tof
sever
alAmer i
canindust
ri
es.
SELECTI
ONOFMATERI
ALFORMANUFACTURI
NGOF

STEAMTURBI
NE:

REQUI
REMENT:

Abi
l
ityt
owi
thst
andcent
ri
fugal
for
cespr
opor
ti
onal
tot
her
otat
ional
speed.

Abil
it
ytowit
hstandt
ransi
entt
her
mal
str
essesatst
art
-up/
shut
-downor
onl
oadchanges.
Goodf at
igue/not
chtoughnesst
owi
thst
andl
ocal
str
essconcent
rat
ions
at
bladeattachmentareas.
Abil
i
tyofmedium pr
essurer
otort
owithst
andcr
eepl
oadi
ngduet
o
hi
ghtemper
aturecausedbydoubl
ere-
heats.
CHARACTERISATI
ONOFMATERI ALS:

Thefoll
owingmicrost
ructur
alparameter
saretobesyst
emati
cal
l
ydet
ermined
foral
ltherel
evantmat
erial
sinthevir
gincondi
ti
onandfol
lowi
ngl
ongt
erm
creepstr
essi
ng:-
Har
dness.

Pr
imar
yphasedescr
ipt
ion(Mar
tensi
te,
fer
ri
te)
.

Locat
ion(
int
ergr
anul
ar,
cel
l
boundar
ies)
.

Chemi
cal
composi
ti
on.

I
nter
mol
ecul
arspaci
ng.

Cel
lsi
ze&shape.

Di
slocat
iondensi
ty.

23
 TESTI
NGOFMATERI
ALS:

Testr
equi
redt
obecar
ri
edoutt
odet
ermi
net
hel
ongt
erm pr
oper
ti
es:

Met
all
ogr
aphi
ctest
s.

Tensi
l
eandi
mpactener
gyt
est
s.

Longt
erm embr
it
tl
ement
test
s.

Lowcy
clef
ati
guet
est
s.

Ot
heri
mpor
tantpr
oper
ti
est
obedet
ermi
nedsuchas:

Det
ermi
nat
ionofcr
eepst
rai
nbehav
ior
.

Longt
erml
owcy
clef
ati
guebehav
ior
.

Mul
tiaxi
alcr
eepbehav
ior
.

Cr
eepandcr
eepf
ati
guecr
ackbehav
ior
.

SEQUENCEOFOPERATI
ONSI
NBLADI
NGPLANMACHI
NING

Mat
eri
alat
test
ati
onof
for
ging
Cent
eri
ngonbot
hendsi
ncl
udedangl
e90deg/60deg
Loadi
ngi
nbet
weencent
re’
sonl
athe
Ref
erencecutf
orst
eady
Shi
ftt
hest
udyt
oref
erencecut
area
Cor
rectt
hecent
re’
sandgi
vet
ail
stocksuppor
t
Roughmachi
ningofBl
adi
ngpl
anDi
asandl
engt
hswi
thsur
faceal
l
owanceof
1mm
St
rai
ghtgr
oov
esr
oughi
ng(
SGR)
Fi
nishmachi
ningofBl
plan
l
10l
engt
hsmachi
ning
Gr
oov
ewi
dthsmachi
ning

24
D10Di
asr
oughi
ng
D10Di
asf
ini
shi
ng
Machi
ningsuspensi
ongr
oov
elef
tandr
ight
Packi
nggr
oov
es
Ext
ernal
chamf
ersl
eftandr
ight
Machi
ningofseal
i
ngf
ingr
oov
es
Roughi
ngandf
ini
shi
ngofl
Panda-
wheel
Bal
anci
nggr
oov
esonDRP
Fr
ontandr
eargl
andr
oughi
ngandf
ini
shi
ng
Mar
king12par
tsandi
ndi
cat
ions

GOVERNI
NGSYSTEMS:

Thecont rolofat urbi newi t

hagov ernorisessent ial
,asturbi
nesneedt ober un
upsl owlyt opr eventdamage.Someappl ications,suchast hegener ati
onof
elect
rici
ty,r equir
e pr eci
se speed cont rol
.Uncont roll
ed accel
eration oft he
turbi
nerot orcanl eadt oanoverspeedt r
ip,whi chcausesthenozzl ev al
vesthat
controlthef low ofst eam t othet urbi
net ocl ose.Ifthisfai
ls,t
het urbinemay
conti
nue accel eratingunt i
litbr eaks apart,of t
en spectacular
.Tur bines are
expensivet omake, requiri
ngpr eci
sionmanuf actureandhighqual i
tymat er
ial
s.
The mostcommon and si mpl
estrequirementofgoverni
ng system ofan
i
ndustrialt
urbineisthecont r
oloverspeed.Thecommonr equir
ementsof
i
ndustrialt
urbinegoverningsyst
em whi chareencount
eredini ndust
ri
esat
presentwit
hv ary
ingdegreeofaut
omationare:
Speed/l
oadcont
rol
forTur
bogener
ator
s.

Speedcont
rol
forTur
bocompr
essor
s.

ExhaustSt
eam (
back)pr
essur
econt
rol
.

Doubl
eext
ract
ionSt
eam pr
essur
econt
rol
.

Ext
ract
ionandexhaustSt
eam pr
essur
econt
rol
.

25
 I
nject
ionSt
eam pr
essur
econt
rol
.

Tur
binepr
otect
ions.

Thef unct
ionofthegov er
ningsyst
em ismai nt
ainingtheconst
antspeedof
tur
bineat3000RPM i r
respect
iveofthel
oad.Fort hispur
posewecontrolt
he
quantit
yofthest
eam enter
ingint
othetur
bine.
SOMEBASI
CUSEFULTERMS:

Int
hissect
ionf
ewbasicter
msareint
roducedwhi
char
emost
commonlyusedint
urbi
negover
ningsyst
em.
GOVERNI
NGSYSTEM:

Asy st
em whosepur
posei
stogov
ernorcont
rol
apr
imemov
eri
scal
l
ed
governi
ngsyst
em.
SPEEDGOVERNOR:

Thegover
norwhichcont
rol
sthespeedoft
hepri
memov eri
scalledasspeed
gover
nor.
I
tincl
udesthoseel
ementswhi
charedir
ect
lyr
esponsi
vetospeed.

SPEEDCHANGER:

Thespeedchangeri
sadevi
ceforchangi
ngt
heset
ti
ngoft
hegover
ning
syst
em wit
hint
hespeci
fi
edspeedrangewhi
l
ethet
urbi
nei
sinoper
ation.
SPEEDRANGE:

Speedrangei sspeci
fi
edrangeofoperati
ngspeedsbel
ow andaboverated
speedforwhichthegover
norisadj
ust
ablewhenthet
urbi
nei
soperat
ingunder
thecontr
olofspeedgover
nor.
SPEEDVARI
ATI
ON:

Speedvar
iat
ionexpressedasper
cent
ageofr
atedspeedisthetot
almagni
tude
ofthespeedchangeort hefl
uct
uati
onsf
rom thespeedsett
ingunderst
eady
st
ateoperat
ingcondit
ion.
DEADBAND:

I
tist
het
otal
magni
tudeoft
hei
nputsi
gnal
forwhi
cht
her
eisnomeasur
abl
e

26
changei
nout
put
.
DEADTI
ME:

Iti
sthet
imethatel
apsesbetweenthest
artofani
nputchangeandt
he
star
toft
heresul
ti
ngoutputchange.
RESPONSETI
ME:

Thet
imer equi
redforagov
er nororgover
ningsyst
em t
omakeachange
fr
om i
nit
ialval
uetoaspeci
fied(lar
ge)percent
ageoft
hefi
nal
steadyv
alue.
STABI
LITY:

Theabil
it
yofagover
nororcontr
olsyst
em tomakecorrect
ionsintheshort
est
possi
bleti
mesothatsust
ainedosci
l
lat
ionsofspeedi
snotpr oducedbythe
gover
ningsyst
em.
GAI
N:

I
tist
her
ati
ooft
hechangei
nout
putsi
gnal
tochangei
ninputsi
gnal
.

RESETTI
ME:

Theti
mer equi
redbyadev i
cetoproduceoutputsi
gnalequalt
o63.3%ofi
ts
fi
nal
valueforastepchangeininputsi
gnalt
ot hecont
roldev
ice.

STEAM TURBI
NEGOVERNI
NG:

NOZZLEGOVERNI
NG:

Withnozzlegov erningaser i
esofnozzl eval
v esopeni nsequenceast hel oad
i
ncreases.thistypeofgov er
ningismostef fi
ci entandisusedf ortheimpul se
tur
binesthrott
legov erni
ng.Wi tht
hr ott
legov
er ningasinglelar
gecont rolv al
ve
control
sthel oad f rom 0% t o 100%.Forl arget urbi
nest wo controlv anes
operati
nginpar all
elr eplaceal ar
gesi ngl
eval ue.Whent hesteam i sthrottl
ed
thesuperheatincr easesandt het urbi
neexhaustst eam isdrierreducingt he
tur
binebladeer osi on,butwi tht hedr i
ersteam ent eri
ngt hecondensert he
condenserl osses i ncreases.Thr ottl
i
ng ofst eam through a v al
vei s an
i
senthalpi
c( constantent hal
py)pr ocessandnoheati sl ost
.Thesocal l
ed

27
t
hrot
tl
ingl
ossesoccuri
nthecondenser
.

BYPASSGOVERNI
NGOROVERLOADGOVERNI
NG:

Thissystem isusedoni mpulseaswellasr eact iont urbi

nes.Anext r
asetof
contr
olv alvesadmi tsteam tot hespacebehi ndt heCur ti
swheelorf orthe
react
iont urbi
net oanannul arspacebehi ndt hef ir
st8- 12stages.Bypassing
partofthet ur
bineincreasestheturbi
necapaci tybutatr educedeffi
ciency.The
bypassv alv
esar esmal l
erthantheregul
arGov er norvalvesastoomuchby pass
steam mayst arvetheby passedstagesr otat
ingi nst eam atv er
yhighdensi t
y
andthebl adesmay overheat.
TURBI
NEGOVERNORS:

Thet wogener altypesofgovernorsusedarethespeedsensiti

vegovernorand
thepr essur
esensi ti
vegovernor.Speedsensit
ivegovernor
sar eappl
iedtoall
kindsof
turbine.Pr essure sensit
ive governor
s ar
e appli
ed to back pressure and
extract i
onturbinesinconnect
ionwi tht
hespeedsensi
tiv
egov er
nor.
SPEEDGOVERNI
NG:

Thef requencyof50Hzisusedasthesetpoi
ntofbalancebetweensupplyand
thedemandofanel ect
ri
cnetwork.Anyover
supplyofenergywilli
ncr
easethe
frequencyandanundersupplywil
ldecr
easethefrequency
.Thesupplyusedat
anyt i
mei sequalt
othedemandandt okeept
hefrequencyatexactl
y50Hz.

OVERSPEEDTRI
P:

Thehighrotati
onalspeedoft
urbinescreateslar
gecentr
if
ugalf
orcesasthese
for
cesincreaseswi t
hthesquareoft hespeed.Ther
efor
eanabsoluter
eli
able
overspeedprotect
ionmustbeprovided.
Theov erspeedtri
pismechani cal-
hydraulicandshowscl ear
lytheoper ati
ng
pri
ncipl
eofalloverspeedt r
ipsforturbineswithhy dr
aulicgovernorsystems.
Thespr i
ngloadedtri
ppingboltlocat
edi nt hetur
bineshaf thast hecentreof
gravi
tysli
ght
lyofft
hecent r
eoft heshafti ndi
rect
ionoft hebolthead.Thenut
attheendoftheboltprovi
desast opfort hebolti
nthet r
ippedposi t
ionandfor

28
tri
ppi
ngspeedadj ust
ment .Duri
ngnormaloperat
ionthemainspri
nghol
dst
he
rel
ayr odagai
nstthetri
ppingleverpi
stonAhasclosedtheoi
ldrai
nandHPoil
passesbetweenthepistonsAandBt ot hest
opvalv
e.
Steam t
urbi
negoverning:

29
 Manuf
act
uri
ngpr
ocess:

Manuf act uri

ngpr ocessi st hatpar tofpr oductionpr ocesswhi chi sdi rectl
y
concer nedwi t
ht hechangeoff or m ordi r
ect i
onsoft hepar t
sbeingpr oduced.I t
doesn' ti ncludet het ransportationhandl i
ngorst oragepar t
s,ast heyar enot
directlyconcer nedwi ththechangesi ntofor m ordi mensi onsofpar tpr oduced.
Manuf act uri
ngi sthebackboneofanyi ndust r
iali
zednat ion.Manuf acturi
ngand
techni calst af fini ndustrymustknow t hev ari
ousmanuf act
ur i
ng pr ocess.
Mat erials ar e bei ng pr ocessed,t ools and equi pmentf orManuf act uri
ng
differentcomponent sorpr oduct swi th optimalpr ocesspl an using pr oper
precaut i
ons,andspeci fi
edsaf etyr ulet oav oi dacci dent .Besi
desabov e,all
kindsoft hef utureengi neermustknow t hebasi cr equi r
ementsofwor kshop
activiti
esi nt ermsofman,machi ne.,mat eri
al,met hods, moneyandot her
i
nf rastruct urefacil
iti
esneededt oposi t
ionedpr oper l
yf oropt i
mal shopl ay outor
plantl ayoutandot hersuppor tservi
cesef f
ect i
v el
yadj usted.
Cl
assi
fi
cat
ionofmanuf
act
uri
ngpr
ocess:

Forproducingofpr oductsmat er
ial
sar eneeded. i
tist hereforeimportantt o
knowt hechar act
er i
sti
csoft heavailableengi neeri
ngmat eri
als.Rawmat er
ials
usedManuf actur
ingofpr oducts,tools,machi ne,andequi pment '
sinfactori
es
orindustr
iesar ef orprovidingcommer cialcasti
ng,call
edi ngots.Suchingot s
arethepr ocessedi nr oi
li
ngMi l
lstoobt ainmar ketform ofmat eri
alsupplyi n
form ofbelt
s, sl
absandr ods.Allthesepr ocessusedi nmanuf actur
ingconcer n
forchangingt heingot sintousabl epr oductsmaybecl assifiedintosi
xMaj or
groupsas
Pr
imar
yshapi
ngpr
ocesses

Secondar
ymachi
ningpr
ocesses

Met
alf
ormi
ngpr
ocesses

Joi
ningpr
ocesses

Sur
facef
ini
shi
ngpr
ocesses

Pr
ocessesef
fect
ingchangei
npr
oper
ti
es

30
 Pr
imar
yshapi
ngpr
ocesses:

Cast
ing
Powder
met
all
urgy
Gascut
ti
ng
Bendi
ng
For
ging
Secondar
yormachi
ningpr
ocesses:

1)Tur
ning. 11)Br
oaching
2)Thr
eading. 12Hobbling
)
3)Knur
li
ng. 13Grindi
ng
)
4)Mi
l
li
ng. 14)Gearcutt
ing
5)Dr
il
li
ng. 15)Thr
ead
cut
ti
ng
Bor
ing.
Pl
anni
ng
Shapi
ng
Sl
ott
ing
Sawi
ng
Unconventi
onalmachini
ng pr ocesses namel
y machini
ng wit
h numeri
cal
Contr
ol(NC)machinestool
sorcomput ernumeri
calContr
ol(CNC)machi
ne
tool
usingECM,LBM,AJM,USM setups.
Cl
assi
fi
cat
ionofbl
ock3:

Bay
-1i
sfur
therdi
vi
dedi
ntot
hreepar
ts:

1.HMS:

I
nthisshopheavymachi
neworki
sdonewi t
hthehel
pofdiff
erentNC
@CNCmachi nessuchascent
erl
athes,
ver
ti
calandhor
izont
albori
ngand
mil
l
ingmachines,

31
Asi
a’sl
argestv
ert
icalbori
ngmachinehereandCNChor
izont
albor
ing
mil
l
ingmachinesfrom SkodaofCzechosl
ovaki
a.
2.Assembl
ySect
ion(
ofhy
drot
urbi
ne’
s):

st
Inthissecti
onassembl yofhydr
ot ur
binesaredone.Bl adesofturbi
neare1
assembl eont herotorandaft
eritthi
sr otori
st r
ansport
edt obal
ancingtunnel
wheret hebalancingisdone.Aft
erbalancingther ot
or,rot
orandcasingsboth
i
nternalandext er
nalaretr
anspor
tedtot hecustomer.
Total
Assemblyoft urbi
neisdoneinthecompanywhi chpurchasedi
tbyBHEL

3.OSBT(
OverSpeedBal
anci
ngTunnel
):

Int hi
ssect i
onrotorsofal lt y
peoft urbi
nesl i
keLP( l
ow pr essure),
HP(hi
gh
pressure)andIP(
Intermediatepressure)rot
orsofSt eam tur
bine,rotorsofGas
andHy dr
oturbi
near ebalanced. I
nal argetunnel
,Vacuum of2t orriscreat
ed
withthehelpofpumpsandaf t
ert hatrot
orisp[lacedonpedest alandr ott
ed
withthespeedof2500-4500r pm Afteri
tinacomput ercontr
ol r
oom t heaxi
sof
rotati
onofr ot
orisseenwi t
hhel pofcomput erandt henbalancet her ot
orby
i
nser t
ingthesmallbalanci
ngwei ghtinthegroovescutonrotor.

BAY-
2ISDI
VIDEDI
NTO2PARTS:

1.HMS:
I
ncaseshopsev eral componentsofsteam tur
binelikeLP,HP,IPRotor,
i
nternal&exter
nalcasingar emanufact
uredwi t
hthehel pofdiff
erent
operati
onscarr
iedoutt hroughdif
fer
entNC&CNCMachi neli
kegrindi
ng
,dri
l
ling,ver
ti
cal&hori
zont almil
l
ingandbor i
ngmachi ne,cent
erlathe,
planer,
koppmi l
li
ngmachine.

2.
ASSEMBLYSECTI
ON:
st
Inthesectionassembl yofst eam turbi
neupt o1000MW I sassembl ed.1
mov i
ngbladesar ei nsertedinthegroov escutonci rcumferenceofrot or,t
hen
rot
orisbalancedi nbal anci
ngtunnelinbay -
1.Afteri
sdonei nwhi chguideblade
areassembledi nsidet heint
ernalcasing&t henr ot
orisfi
ttedinsidethecasing
.Aft
eritt
hisinternal casingwit
hr ot
orisinsertedint
ot heexter
nal

32
 Bay
-3I
sdi
vi
dei
ntot
hreepar
ts:

1.Bear
ingsect
ion:
I
nt hissecti
ongeneralbear
ingsaremanufactur
edwhi char
eusedin
turbinestoover
comet hevi
brati
onsandroll
ingfr
ict
ionsbyprov
idi
ngthe
properlubri
cati
on.

2.Tur
ningsecti
on:
I
nthissectionsmal llat
hemachines,mil
li
ngandbori
ngmachi
nes,gri
ndi
ng
machi
nesanddr i
l
li
ngmachi nesareinst
all
ed.I
nthi
ssect
ionsmallj
obsare
manuf
acturedli
kerings,st
ubset
c.

3.Gov erni
ngsecti
on:
Int his secti
on governor
s are manufactur
ed .This governors are used i
n
turbinesf orcontr
oll
i
ngt hespeedforrot
orwithinthecer t
ainli
mits.Fir
stallt
he
component soft hegov ernoraremadebydi ff
erentoper at
ionst henthisall
partsar et r
eatedinheattreatmentshopforprovidi
ngt hehardness.Thent hi
s
allcomponent sareassembl edintothecasing.Theyar emor ethan1000of
gov ernors.

Bay
-4I
sdi
vi
dei
ntot
hreepar
ts:

1.TBM (t
urbinebl
ademanufactur
ing):
Inthisshopsol i
dbladesofbot hsteam andgast ur
binesar
emanuf act
ured
.severalCNCandNCmachi nesar einstall
edher
esuchascopy i
ngmachi ne,
gri
ndingmachi ne,mi
ll
ingmachine,T-rootmachinecenter
.Hori
zont
altool
ing
centerver
ti
calandhori
zont
alboringmachi neet
c.

2.Turningsecti
on:
Sameast heturningsect
ioni
nbay-3,
theyar
esev
eralsmallmachi
nes
l
ikelathesmachi nes,mil
l
ing,
bor
ing,gri
ndi
ngmachineset
c.

3.Heattr
eat
mentshop:
I
nthisshoptheyar
eseveralt
est
sperf
ormedforcheckingthehardnessof
di
ffer
entcomponents.
Testsper
for
medareSerel
it
ing,Nit
ri
ding,DPTest.

33
 Bladeshop:
Bladeshopi sanimportantshopofbl ock3Bl adesofal lt
hestageoftur bi
ne
are made int hi
s shop only.Theyhav ev ar
iet
yofcent erlathe and CNC
machi nestoperf
ormthecompl eteoper at
ionofblades.Thedesi
gnsofbl ades
aresentt oshopandt her especti
vejobi sdistr
ibut
edt otheoperator
s.The
operatorsper
formthei
rjobinaf i
xedinterv
alofti
me.

Ty
pesofBl
ades:

Thebasi call
ydesignofBl adesiscl assi
fi
edaccordingtothestageoft urbi
ne.
ThesizeLPt ur
binebladeisgenerall
ygr eatert
hanthatofHPt ur
bineBlades.At
thefirstT1,T2,T3andT4ki ndsofbl adeswereused,t hesewer esecond
generati
onbl ades.Thenitwasr eplacedbyTX,BDSof( forHPt urbi
nes)andF
shapedbl adesmostmoder nBladesar eFandZshapedbl ades.
Oper
ati
onsper
for
medonBl
ades:

Someoft
hei
mpor
tantoper
ati
onsper
for
medonbl
ademanuf
act
uri
ngar
e

Mi
l
li
ng

Bl
ankcut
ti
ng

Gr
indi
ngofbot
hthesur
faces

Cut
ti
ng

Root
mil
l
ing

Machi
ningofBl
ades:

Machi
ningofbl
adeswi
tht
hehel
pofl
atheandCNCmachi
nes.someoft
he
machi
nesare
Cent
erLat
heMachi
ne

Ver
ti
cal
bor
ingMachi
ne

Ver
ti
cal
mil
l
ingMachi
ne

CNCl
atheMachi
ne

34
CONCLUSI
ON:

ConclusionSteam t
urbi
nesactassteam engi nesthatconvertheatenergy
i
nt omechanicalenergy
.Steam t
urbi
nesext r
actthermalenergyfr
om steam
thati
sexposedt oextr
emelyhighpressures.Duet oit
srotarymot i
on,the
steam turbi
nesareusedtodri
vemot or
sf ortheelect
ri
ci
tygenerati
on.

35
36
37