Industrial Resources, Inc.

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Power Plant Fundamentals

Training Program

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 INDUSTRIAL RESOURCES, INC.

Power Plant Fundamentals

Training Program

Module 10 Turbines

© 2009 - Industrial Resources, Inc.

 MODULE OBJECTIVES
Demonstrate Basic Knowledge of the Steam
Cycle and Turbine Operation
Knowledge of Turbine Construction and
Principles of Operation
Knowledge of Turbine Valves and Support
Systems
Knowledge of Turbine Control,
Instrumentation and Protection Systems
Knowledge of Turbine Operation
3
Steam Cycle and Turbine Operation

Review the purpose of the Steam Turbine

Look at general arrangement of Steam
Turbines
Look inside a Steam Turbine to see what
is happening to the Steam passing
through it

4
5
6
Turbine Principles of Operation
Accessories
There are many accessories necessary for
commercial operation of a steam turbine
– Governing systems
– Bearing lubrication system
– Piping systems for steam supply and exhaust
– Steam condensing system are a few of the
auxiliary systems required

7
Simple Impulse & Reaction
Turbines

8
Power Plant – Energy Converter
Fuel (Chemical Air
Energy) (Oxygen)

Boiler
Steam (Thermal Energy)

Turbine
Torque (Mechanical Energy)

Generator

9
Function of the Steam Turbine

10
Turbine Sections

11
12
13
 Some Turbine Basics
Energy Conversion in a Turbine-Generator

Steam Turbine Shaft Generator Electricity

Heat Mechanical Electrical

Energy Energy Energy
(Torque)

14
Turbine
Blades

Impulse
Blades

15
Turbine
Blades

Reaction
Blades

16
 Comparing Types of Blades

High Low
Pressure Pressure

17
18
19
Steam
Turbine
Stage

20
Shell and Stationary Blades

21
Disk Type Rotor

22
Drum Type Rotor

23
Basic Turbine Cutaway

Stages

First
Stage

24
 Question 1

What is the purpose of the Steam

Turbine?
– Convert mechanical energy into thermal
energy
– Convert thermal energy into mechanical
energy
– Convert electrical energy into mechanical
energy
– Act as a heat sink for the Boiler

25
 Question 1 Answer

If you said convert thermal energy into

mechanical energy, you were right. We
want to change the heat in steam into
torque on the shaft connected to the
Generator.

26
 Question 2

In a Steam Turbine, a set of Fixed

Blades followed by a set of Rotating
Blades is called a _____________.
– turbine
– rotor
– stage
– steam chest

27
 Question 2 Answer

If you said stage, you were right.

28
 Turbine Construction

Have a basic idea of how a simple turbine

works
But want to look at a more complicated,
and common, turbine
Steam passes through stages, dropping in
pressure and expanding
Steam gives up thermal energy
Will look at one made up of several simple
turbines.

29
 Multistage Turbines
Multistage turbines use both impulse and
reaction blading to provide the most
efficient means of energy conversion
Turbine classifications
– Pressure velocity compounded
– Impulse reaction
– Straight reaction staging, are terms describing
ways in which manufacturers incorporate the
principles of blade design.
30
Single Flow Turbine

31
Double Flow Turbine

32
 Compound Turbine
All turbines may also be classified as
either single casing or compound
As the name implies, a single casing type
has only a single steam path from throttle
to exhaust
The term compound signifies a
construction in which the steam leaves the
high pressure casing before expansion is
complete and then goes through one or
more low pressure casings
33
 Tandem Compound Turbine

LP Turbine
IP Turbine LP Turbine
HP Turbine B
A

34
Cross-Compound Turbine

35
Extraction Turbine

36
Extraction Steam System

37
Extraction Non-return Valve

38
 Reheat Turbine
Reheat turbines have been provided to
meet the demand for greater economy in
the operation of a modern power plant
In the reheat turbine
– High pressure steam is expanded through the
highest pressure section
– Then withdrawn and returned to the reheat
section of the boiler to increase its energy
level before expansion through the lower
pressure sections of the turbine
39
 Steam Flows – HP Turbine
P T P T
Main
Steam Drains Flash Tank
SV-1 SV-2 SV-3
Sample

Condenser

Warm-Up Line
CV Chest

T P
To Reheater

To Steam Air
Heaters

HP Turbine

T P
To Reheater

To Soot
Blowers
40
 Steam Flows – IP Turbine
Crossover to LP Turbines

T
South Hot
Reheat Line

Main Stop Leakoff CRV-1

From Ventilator Valve

IP Turbine

T
North Hot
Reheat Line
CRV-2

41
Basic Turbine Flows

42
Turbine Casing

43
Turbine Casing

44
Sliding Pedestal

45
Turbine Pedestal

46
 Main Turbine
Front HP IP LP
Standard Turbine Turbine Crossover Turbines

47
 Bearings Packing
1 2 3 4 5 6 7 8
HP IP LP LP
N Turbine N N Turbine N N Turbine A N N Turbine B N
1 2 3 4 5 6 7 8

Shaft 1 2 3 4
Thrust IP Turbine
HP Turbine
Packing
N1 N2 N3 N4
Bearing

5 6 7 8
LP LP
Turbine A Turbine B
N5 N6 N7 N8

48
 Question 3

In a large Steam Turbine, Cold Reheat

Steam leaves the _______ Turbine
section, goes to the Reheater in the
Boiler, and then returns as Hot Reheat
Steam to the ______ Turbine section.
– IP, HP
– HP, IP
– IP, LP
– LP, HP

49
 Question 3 Answer

If you said HP, IP, you were right.

50
 Question 4

In a large Steam Turbine, Crossover

Steam is the steam that leaves the
_____ Turbine section and goes to the
_____ Turbine section.
– IP, HP
– HP, IP
– IP, LP
– LP, HP

51
 Question 4 Answer

If you said IP, LP, you were right.

52
 Turbine Valves

Main Control Valves

Main Stop Valves
Combined Reheat Stop Valves (CRVs)
Turbine Drains
Valve Drains
Blowdown Valve
Ventilator Valve

53
 Control Valve Poppet Valve
Stems

Poppet
Valves

First Stage
Diaphragm Steam
Inlet

54
Full & Partial Arc Admission

55
Control Valves

56
Control Valves

57
Main Stop
Valve
Valve Body

Above Seat Drain

Stem Leak-Off

Below Seat Drain

Hydraulic Operator

58
Main Stop Valve Bypass

59
Combined
RH Stop &
Intercept
Steam In
Valves
Intercept
Disc

Reheat Steam
Stop Out
Disc

60
CRVs Operating
Linkage
Valve
Stem
Valve
Body

61
 Turbine Drain Valves

Main Steam Leads – manual

Turbine Bypass Valves – pneumatic
Stop Valves Before Seat – MOVs
Stop Valves After Seat – MOVs
Cold Reheat – manual
CRVs Before Seat – manual
CRVs After Seat – manual
Extraction Lines - manual

62
Turbine Drain Valves

63
Operating Turbine Drains

64
 SV-2 SV-1
SV-2 After Before SV-1 After Before
Seat Drain Seat Drain Seat Drain Seat Drain

Stop
Valve
Drains

65
 Blowdown Valve
Releases Steam from N2 Packing on Turbine
Goes to Condenser

Ventilator Valve
Releases Steam from Extraction Line on HP Turbine
Protects last few stages from windage on load rejection
Goes to Condenser

66
Blowdown Valve

67
Ventilator Valve

68
 Question 5

Which Turbine Valve acts as a stop valve

for Hot Reheat Steam going to the IP
Turbine?
– Main Stop Valve
– Main Control Valve
– Combined Reheat Valve (CRV)
– Main Poppet Valve

69
 Question 5 Answer

If you said Combined Reheat Valve (CRV),

you were right.

70
 Question 6

Which Turbine Valve controls the exact

flowrate of Main Steam to the HP
Turbine?
– Main Stop
– Main Control Valve
– Combined Reheat Valve (CRV)
– Above Seat Drain Valve

71
 Question 6 Answer

If you said Main Control Valve, you were

right.

72
 Turbine Support Systems

Turning Gear
Turbine Lube Oil System
– Turbine Oil Reservoir
– Turbine Oil Pumps
– Turbine Oil Conditioner
Turbine Steam Seal System

73
 Turbine Lube Oil System
Clean lubricating oil at the proper
pressure, temperature and flow must be
provided at all times that the turbine-
generator shafts are rotating
Lubricating oil provides a necessary
cooling affect on the bearings, even when
the rotors are at rest
Because of the critical nature of a
continuous supply, back up AC and DC
pumps are provided for off-line or
emergency situations
74
Turbine Lube Oil System (cont.)
The normal source for lube oil is the shaft
driven oil pump
A few units use a small turbine driven
pump as a backup
Cleanliness is very important in the lube oil
system
Contaminant's can affect lubricating
properties and foreign material can plug
lines or score bearing surfaces.

75
 Turbine Lube Oil (cont.)
Oil temperature is very important for
operation.
– Too low a temperature at speed will cause
vibration problems (oil whip)
– Too high a temperature will decrease the
viscosity and increase wear of bearing
surfaces
The lube oil also acts to cool the bearing

76
 Main Oil Pumps
P

Bearing Oil
Header
Main Oil
Pump Motor Suction Emergency Oil Turning Gear
Lube Oil
Pump Pump Oil Pump

P
Coolers

LO
Cond.

L
P

Booster
Pump (Pri.) LO Filter
Pump

Oil Reservoir

77
78
 Motor Suction Pump
P

Bearing Oil
Header
Main Oil
Pump Motor Suction Emergency Oil Turning Gear
Lube Oil
Pump Pump Oil Pump

P
Coolers

LO
Cond.

L
P

Booster
Pump (Pri.) LO Filter
Pump

Oil Reservoir

79
 Emergency Bearing and Turning
Gear Oil Pumps
P

Bearing Oil
Header
Main Oil
Pump Motor Suction Emergency Oil Turning Gear
Lube Oil
Pump Pump Oil Pump

P
Coolers

LO
Cond.

L
P

Booster
Pump (Pri.) LO Filter
Pump

Oil Reservoir

80
81
 Turbine Oil Coolers
P

Bearing Oil
Header
Main Oil
Pump Motor Suction Emergency Oil Turning Gear
Lube Oil
Pump Pump Oil Pump

P
Coolers

LO
Cond.

L
P

Booster
Pump (Pri.) LO Filter
Pump

Oil Reservoir

82
83
 Turbine Oil Conditioner
P

Bearing Oil
Header
Main Oil
Pump Motor Suction Emergency Oil Turning Gear
Lube Oil
Pump Pump Oil Pump

P
Coolers

LO
Cond.

L
P

Booster
Pump (Pri.) LO Filter
Pump

Oil Reservoir

84
85
Lube Oil Vapor Extractor

86
GE Turbine Lube Oil System

87
Westinghouse Lube Oil System

88
 Bearings
Oil In

Shaft

Rotation

Bearing

Oil Out
89
90
Journal and Thrust Bearings

91
Steam Seal

92
Steam Seal System

93
94
95
Labyrinth Steam Seal

96
97
98
99
Turbine Water Seal

100
Water Seal

101
102
 Turbine Packing
N1 N2 N3 N4 N5 N6 N7 N8
MSV Below
Seat Drains

Blowdown
CV Valve Stem Valve
Leak-off

Ventilator
Hot Valve
Reheat

To/From BFPT
Gland Steam F
Steam Seal
Drains

MOV
System
M

Diverting Valve
To Heater
M

MOV7021 SSUV

To Condenser A
SSFV SSAFV
M
M

Main Aux.
Steam Steam
MOV MOV

103
 Turbine Packing
N1 N2 N3 N4 N5 N6 N7 N8
MSV Below
Seat Drains

Blowdown
CV Valve Stem Valve
Leak-off

Ventilator
Hot Valve
Reheat

Steam to
To/From BFPT
Gland Steam
Drains
F
Packing
MOV
M

Diverting Valve

To Heater
M

MOV7021 SSUV

To Condenser A
SSFV SSAFV
M
M

Main Aux.
Steam Steam 104
MOV MOV
 Turbine Packing
N1 N2 N3 N4 N5 N6 N7 N8
MSV Below
Seat Drains

Blowdown
CV Valve Stem Valve
Leak-off

Hot
Reheat
Ventilator
Valve Unloading and
Diverting
To/From BFPT
Gland Steam
Drains
F
Valves
MOV7
M

308

Diverting Valve

To Heater 3B
M

MOV7021 SSUV

To Condenser A
SSFV SSAFV
M
M

Main Aux.
Steam Steam 105
MOV7020 MOV7025
 Packing Exhaust

Gland
From Steam
BFPTs Condenser

Turbine N1 N2 N3 N4 N5 N6 N7 N8
Packing

Seal Seal Seal Seal Seal Seal Seal Seal

Steam Steam Steam Steam Steam Steam Steam Steam

Steam Air
Heater
Extraction Line

106
 High Pressure Packing
Steam Seal
Lands

Steam Air
Steam Steam Steam
Packing Packing Packing

Sealing
Sealing Steam
In During Steam
Start Up & Exhaust
Low Load,
Out at Load
107
Low Pressure Packing
Slant Cut
Seal Grooves

Air

Sealing Sealing
Steam Steam
In Exhaust
108
109
Turning Gear

110
111
112
Turning Gear Controls

113
 Question 7
What component seals steam inside the HP
Turbine casing?
– Thrust bearing
– Journal bearings
– Packing glands
– Turning gear

114
 Question 7 Answer

If you said packing glands, you were right.

They seal air out of the LP turbine.

115
 Question 8

Why is the Turbine shaft rotated at slow

speed while it cools down?
– Prevent sagging of the shaft of the Turbine
– Prevent it from cooling down too rapidly
– Keep adequate flow of oil
– To reduce the steam flow to the turbine

116
 Question 8 Answer

If you said prevent sagging of the shaft,

you were right.

117
Turbine Control & Instrumentation

Extraction Control
Speed Control
Instrumentation (Supervisory)
Electro-Hydraulic Control (EHC)
Turbine Protective System
Turbine Trips

118
Turbine Control Valve

119
Hydraulic Actuator

120
Pilot Valve and Actuator

121
Mechanical Governor

122
Mechanical Governor

123
Hydraulic Governor

124
Electro-Hydraulic Control

125
Electronic Governor

126
Speed Changer Assembly

127
Speed Changer Switch

128
 Extracting Steam
Front Standard - Control
Extraction
Control
Devices

129
 Turbine Protective System
Turbines, even though massive, can be
damaged rather easily. Several operating
parameters must be maintained to prevent
damage
When a turbine rotor is allowed to run at
overspeed conditions, there may be
enough speed to cause complete
destruction of the turbine

130
 Turbine Protective System
1st Line of Protection 2nd Line of Protection
– Main Speed Governor – Emergency Governor
(GE, West.) (Mechanical)
– Pre-Emergency Governor (GE,West.,ABB)
(GE) – Backup Emergency
– Auxiliary Governor Governor (Electrical)
(Westinghouse) (GE, WEST, ABB)
– Cut Out Pre-Emergency
Governor
(GE)
– HP Speed Governor
– RH Speed Governor
(ABB)

131
Emergency
Governor
Centrifugal
Force

132
Emergency
Trip Device
133
134
 Generator Motoring
Turbines drive generators which deliver power
to the system under normal operating
conditions
If the steam input to the turbine is less than the
power required to maintain the turbine at rated
speed while the generator is synchronized to
the system, the power required to maintain the
generator and turbine at synchronous speed
will come from the system

135
 Generator Motoring (cont.)
Turbines have limits to their ability to
operate under motoring conditions
The last stages of the low pressure rotors
have very long blades which can be
overheated by reduced steam flow or
degraded back pressure
The increased density of the blade
environment will result in the overheating
of the blades and exhaust hood

136
Main Turbine Trips

137
Turbine Supervisory
Instrumentation
Local
EHC Panel
Front Standard
Control Room Bench Boards
Control Room Vertical Boards
DCS

138
EHC Panel

139
 Load

Mechanical Trip Vacuum Trip

Trip Emerg. Trip Reset

System

Circuit Breaker

Loading Rate Limit

Load Set

Load Selector

140
 Control Room Instruments &
Controls
Throttle Throttle
Pressure Pressure Throttle
Before Seat Before Seat Pressure First Stage
(Narrow Range) (Wide Range) After Seat Pressure

141
142
143
Turbine Supervisory Instruments
(cont.)
Because the rotating parts of a turbine are
in close proximity to the stationary parts, it
is necessary to measure the expansion of
each and compare these measurements
to ensure that the parts do not touch.
The three measurements of importance
are shell expansion, rotor expansion, and
differential expansion.

144
Diff and Rotor Expansion Detectors

145
Relationship Between Rotor and
Shell Expansion

146
147
Eccentricity Measurement

148
Hot Turbine Rotor Bow

149
This section is about Turbine Vibration

150
Shaft Rider

151
Proximity Probe

152
153
154
 Thrust Bearings

Abrasion

155
Thrust Bearings

156
Thrust Bearings

157
Thrust Bearing Wear Detector

158
Normal Thrust Bearing

159
Failed Thrust Bearing

160
GE Thrust Bearing Wear Detector

8 psi
decreasing

161
 Westinghouse Thrust Bearing
Wear Detector
30 psi alarm
80 psi trip

162
Turbine Control - EHC

Hydraulic Power Unit

EHC Cabinets
EHC Operating Panel
Valve Operators
Emergency Trip System

163
 EHC Power Unit
Primary Pump Fluid Cooler Filter Pump

EHC Fluid Tank Instrumentation

164
 Servo Valve Current

Starting Rate

Speed Set - RPM Trip

Valve Position
Stop Valves Control Valves Comb. Reheat Valves
Auxiliary Valves

Chest Pressure
Test Valves Test Valves Test Valves

Master Trip
Pre-Warming Mech. Trip Test Load Limit Initial Pressure Limit
Solenoid Test

Alarms Trip Anticipator Load Limit Set

Warming Rate
Limiting
Pressure

165
 Load

Mechanical Trip Vacuum Trip

Trip Emerg. Trip Reset

System

Circuit Breaker

Loading Rate Limit

Load Set

Load Selector

166
 Load

Mechanical Trip Vacuum Trip

Trip Emerg. Trip Reset

System

Circuit Breaker

Loading Rate Limit

Load Set

Load Selector

167
 Causes of Turbine Trip
Thrust Bearing Wear
Low Hydraulic Pressure
Loss of Stator Cooling to Generator
Low Main Oil Pump Discharge Pressure
Loss of both BFPs
Loss of EHC pressure
Manual Trip
Loss of all speed signals
High Exhaust Hood temperature
Low vacuum in Condenser
Loss of Hydraulic Trip pressure
168
 Master Trip Solenoid

Closes:
– Main Stop Valves
– Main Control Valves
– Combined Reheat Valves
– Extraction line trip Valves
Opens:
– Packing Blowdown Valve
– Ventilator Valve

169
 Question 9
One purpose of extracting steam from a
Steam Turbine, other than removing
moisture, is to save _________.
– water
– heat
– pressure
– temperature

170
 Question 9 Answer

If you said heat, you were right.

171
 Question 10
Which of the following will likely be the first
indication of mechanical problems or
damage in a Steam Turbine?
– High exhaust hood temperature
– High vibration
– Speed slightly low
– Reheat Steam temperature high

172
 Question 10 Answer

If you said high vibration, you were right.

173
Turbine Operation

Startup
Normal Operation
Shutdown

174
Starting and Loading Instructions (SALI)

175
 Turbine Startup
Verify all necessary systems are operating

 Electrical Power System,

 Instrument Air System,
 Turbine Lube Oil System,
 Turbine Steam Seal System,
 Closed Cooling Water System,
 Hydrogen Seal Oil System,
 Generator Stator Cooling System,
 Circulating Water System,
 Auxiliary Boilers and CRASS,
 Condensate System,
 Feedwater System.

176
Verify that the following conditions exist:
 At least one Circulating Water Pump is
operating with the other Pump in hot
standby,
 Closed Cooling Water Header pressure is
at least 75 psig,
 Condenser Hotwell level is at least 12
inches but less than 36 inches,

177
 Condensate Pump discharge temperature
is less than 125 degrees Fahrenheit and
discharge pressure is greater than 75 psig,
 Deaerator level is at least 5 feet but less
than 9 feet, with pressure greater than 75
psig.
 Condenser vacuum has been established
of at least 25 inches of Hg,
 Generators are full of hydrogen,
 Turbine Gear Oil Pump is in operation,
 Motor Suction Oil Pump is running,
178
 Main Turbine is on Turning Gear for the
required amount of time,
 EHC System is operating properly,
 the Turbine Lube Oil Pump trip and the
EHC Fluid Pump has been tested,
 Main Turbine is tripped,
 Exhaust Hood Spray is ready for
operation,
 Steam seals are established on the
Turbine,

179
 Vacuum has been drawn in the
Condensers,
 The Boiler Trip is reset,
 The Turbine Master Trip is reset,
 The EHC First Hit and the Generator-Main
Transformer Trip Relays are reset,
 All Turbine valves are in the proper position
for starting the Turbine.
 Position all Turbine drain valves for Turbine
start to make sure that no moisture in the
Turbine or Steam lines could damage the
Turbine blades.
180
 Shaft Pre-Warming
Servo Valve Current

Starting Rate

Speed Set - RPM Trip

Valve Position
Stop Valves Control Valves Comb. Reheat
Auxiliary Valves Valves

Chest Pressure
Test Valves Test Valves Test Valves

Master Trip
Pre-Warming Mech. Trip Test Load Limit Initial Pressure
Solenoid Test
Limit

Alarms Trip Anticipator Load Limit Set

Warming
Rate
Limiting
Pressure

181
Preparing to Roll

182
 Servo Valve Current

Starting Rate

Speed Set - RPM Trip

Valve Position
Stop Valves Control Valves Comb. Reheat
Auxiliary Valves Valves

Chest Pressure
Roll Up the Turbine
Test Valves Test Valves Test Valves

Master Trip
Pre-Warming Mech. Trip Test Load Limit Initial Pressure
Solenoid Test
Limit

Alarms Trip Anticipator Load Limit Set

Warming
Rate
Limiting
Pressure

183
Synchronize and Load
Load

Mechanical Trip Vacuum Trip

Trip Emerg. Trip System Reset

Circuit Breaker

Loading Rate Limit

Load Set

Load Selector

184
Normal Operation

185
 Turbine Shutdown
Load

Mechanical Trip Vacuum Trip

Trip Emerg. Trip System Reset

Circuit Breaker

Loading Rate Limit

Load Set

Load Selector

186
 Question 11
The main purpose of Turbine Starting and
Loading instructions is to reduce Turbine
stress and maintain the Turbine
___________.
– design
– warranty
– speed
– vibration

187
 Question 11 Answer

If you said warranty, you were right.

188
 Question 12
As a Steam Turbine is being started up, the
most important instrumentation to check as
speed increases is the _______________.
– pressure
– temperature
– vibration
– thrust

189
 Question 12 Answer

If you said vibration, you were right.

190
This concludes this training
presentation.
If you have further questions
about Power Plant
Fundamentals, consult with
your supervisor or training
manager.

191