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Chapter-1 Steam Turbine Theory
Chapter-1 Steam Turbine Theory
The steam turbine offers many advantages over other prime movers, both thermodynamically and
mechanically. From a thermodynamic point of view, the main advantage of the steam turbine over, say, a
reciprocating steam engine, is that in the turbine the steam can be expanded down to a lower back-
pressure, thereby making available a greater heat drop. In addition, the internal efficiency of the turbine is
high, so it is able to convert a high proportion of this relatively large heat drop into mechanical work.
From a mechanical point of view, the turbine is ideal, because the propelling force is applied
directly to the rotating elements of the machine and has not, as in the reciprocating engine, to be
transmitted through a system of connecting links, which are necessary to transform a reciprocating motion
into a rotary motion. Hence, since the steam turbine possesses rotary motion only, if the manufacture is
good and the machine is correctly designed, it ought to be free from out-of-balance forces.
If the load on a turbine is kept constant, the torque developed at the coupling remains constant. A
generator at a steady load offers a constant resisting torque. Therefore, a turbine is suitable for driving a
generator, particularly as they are both high-speed machines.
A further advantage of the turbine is that the exhaust steam is not contaminated with oil vapour
and can be condensed and fed back to the boilers without passing through filters. It also means that there
is considerable saving in lubricating oil when compared with a reciprocating steam engine of equal power.
Yet the steam turbine is not without disadvantages. It is non-reversible. Unlike the IC engine, it is
not a complete power plant, but must be associated with a steam generator. Steam rates are high unless
in condensing operation. The thermal (steam) power plant therefore was a duel phase cycle, i.e. vapour
and liquid. It is a closed cycle to enable the working fluid (water) to be used again and again. The cycle
used is "Rankine Cycle" modified to include superheating of steam, regenerative feed water heating and
reheating of steam.
In 1629, Giovanni Bianca (Italy) made drawings of simple impulse turbine, later developed by the
French Engineers, De Lavel and Rateau and others.
However, Parsons was the first to realize that successful turbine must rotate at very high speeds,
even in those early days. It was understood that a jet of steam could rotate a wheel with blades on its
circumference or that it could develop power when escaping tangentially from an orifice or nozzle in a
wheel by its own reaction. Either way, the problem confronting Parsons, was that of constructing a
practical turbine, using very high jet velocities of the order of 750 m/s of even L.P. steam exhausting to
atmosphere; or double that velocity of H.P. Steam exhausts via jets into a partial vacuum.
The utilization of these high velocities calls for the moving blades to travel at half these velocities,
i.e. velocities of the order of 375 m/s to 750 m/s. High linear speeds mean high rotational speeds and the
consequent centrifugal force of a severe nature. Blade speeds were reduced by sub-dividing the whole
expansion of steam into a number of stages so that moderate velocities have to be dealt with and this
forms the basis of the modern steam turbine as well. On this reaction principle, Parsons first commercial
turbine (1800 rpm) only generated 10 KW power in the year 1884.
Other inventors, i.e. C.G. Curtis (U.S.A.) and Prof. A. Rateau (France) preferred to use the
expansion of steam at each stage, by virtue of its velocity only, in fixed nozzles. Machines of this type,
where the steam drives the moving blading of each stage by virtue of its velocity only, are called impulse
turbines. Impulse turbines of fairly large size have been developed over the years, but it is recognized
that the reaction principle of Parsons Scores over the impulse, in having a higher efficiency.
Consequently, very large sets, which are nominally termed impulse, embody a certain amount of reaction.
Side-by-side with the introduction of the high-speed turbines, Parsons went on to invent the drum type of
generator stator (a.c.), to match the turbine.
Further contributions to the field of turbine power by Parsons were the steam jet air ejector and
regenerative feed heating, which was however first proposed by James Wier.
Shortly after the turn of the 19 th Century, steam turbines began to replace reciprocating steam
engines in power plants. Rapid development ensued and by 1909 units of 12 MW capacity were installed
in Chicago. The turbine performance and efficiency exceeded those of the reciprocating engine and
allowed the use of superheated steam on large scale. This led to the use of cast steel rather than cast
iron in turbines. Capacity rose steadily. A 208 MW unit was installed in New York in 1929. The rise was
helped in 1937 by the use of hydrogen-cooled generator. By the late 1950s capacities reached 450 MW.
In the post-world war-II era, capacities rose beyond 500 MW.
b) Curved Blades
The blades are attached to the turbine rotor. The rapidly moving particles of steam issuing from the
nozzle enter the blades. As the blades are curved (Fig. 1.3), the direction of motion of these particles of
Finally when the steam comes out of the blades, the pressure and temperature of the steam are
reduced, i.e. the drop of the enthalpy at the exhaust of the turbine due to expansion of steam. The
processes of expansion and direction changing may occur once (single stage) as in the simple impulse
turbine, or a number of times (multi-stage) as in pressure compounded impulse or impulse-reaction
turbine.
In this turbine, the steam is expanded once only, the steam enters the nozzles at the steam chest
pressure and issues from the nozzles at condenser pressure. The heat drop is comparatively large and
as the increase in Kinetic energy is equal to the heat drop, the nozzle exit velocity of the steam is high.
For maximum blade efficiency, the blade velocity should be slightly less than one half the steam velocity,
so in this type of turbine the blade velocity is very high. As the rotor diameter is kept fairly small, the
rotational speed is also very high, being of the order of 30,000 rpm. With speeds of this order it is often
necessary to reduce the speed of the driven machine by gear-box, thus increasing the cost and
The leaving loss in the last stage as compared to simple impulse turbine is proportionately less,
still it is appreciable.
In a pressure-compounded impulse turbine the nozzles are usually fitted into partitions, called
"diaphragms", which separate one wheel chamber from the next. The wheels are mounted individually
on the shaft and carry the blades on their periphery. As expansion of the steam takes place wholly in the
nozzles, the space between any two diaphragms is filled with steam at a constant pressure, but the
pressure on either side of any diaphragm are different. The greatest difference occurs in the first few
stages. Hence, steam will tend to leak through the space between the bore of the diaphragm and the
surface of the shaft. Fitting of labyrinth glands usually minimizes such leakage. A.C.E. Rateau first
designed this type of turbine.
As in other type of impulse turbines, the steam is expanded wholly in the nozzles and the wheels
rotate in steam at constant pressure. The total pressure drop from steam chest to condenser being split-
Since in the reaction type machine a pressure drop also occurs across the moving blades it is
necessary to provide effective sealing at the blade tips. This must be done to prevent leakage of steam
past the shrouding of the wheel and consequent loss in efficiency particularly at the high-pressure end of
the machine. These turbines may be designed for radial flow or axial flow. However, radial flow
machines are absolute now a days and all modern turbine employ axial flow designs.
The axial-flow impulse-reaction turbine consists of a number of rows of moving blades attached to
the rotor and an equal number of rows of fixed blades attached to the casing as shown in Fig. 1.9.
The fixed blades compare to the nozzles used in the impulse turbine. Steam is admitted
over the whole circumference and in passing through the first row of fixed blades undergoes a small drop
in pressure and its velocity is increased. It then enters the first row of moving blades and as in the
impulse turbine, suffers a change in direction and hence momentum giving an impulse on the blades.
During the steam passage through the moving blades it undergoes a further small drop in pressure
resulting in increase in velocity, which gives rise to a reaction in the direction opposite to that of the added
velocity. It is in this way that the impulse-reaction turbine differs from the pure impulse turbine. Thus the
gross propelling force in the impulse-reaction turbine, or the "reaction" turbine, is the vector sum of the
impulse and the reaction effects.
Fig. 1.9 shows how the blade heights increase as the specific volume of the steam increases with
reduction in pressure. It also shows how the pressure falls gradually as the steam passes through the
groups of blades. There is a pressure drop across each row of blades both fixed and moving. This is of
considerable practical importance, especially at the high-pressure end of the turbine where the pressure
drops are greatest, because this difference of pressure tends to force some steam through the clearance
spaces between the moving blades and the casing, similarly between the fixed blades and rotor. These
clearances have to be carefully controlled by using axial and/or radial seals at the blade tips; otherwise
The steam velocities in this type of turbine are moderate, the velocity for maximum blade
efficiency being roughly equal to the blade velocity. The leaving loss is normally about the same as for
the multi-stage impulse turbine.
The impulse-reaction turbine was developed by Sir Charles A. Parsons and is widely used in
power stations.
The work done by the moving blade is reduced due to three most predominant losses, i.e. profile
loss, secondary loss and tip leakage loss, which are shown in Fig. 1.12.
The extent of the leakage depends on whether the turbine is of an impulse or reaction type.
Reaction turbines suffer a pressure drop across the moving blades, so encouraging flow through the
clearances. Consequently, it is more important for a reaction turbine to have good tip sealing than it is for
an impulse turbine. The sealing of impulse and reaction turbine stages is shown in Fig. 1.14.
Erosion occurs because the water droplets travel far slower than steam, consequently their
velocity relative to the blades is significantly different in direction as well as speed. The result is the
impact of condensation droplets on the blades, in particular at the tip where the blade rotational velocity is
highest.
In the past, the leading edge of the blade has been protected either by an edge-hardening
process or by the brazing on of stellite strips, which is a very hard material. Now a day, with better
understanding of the mechanism of droplet erosion, has produced means of alleviating much of the
problem. Higher last-stage heat drops are employed along with higher mass flow loading. The result is a
higher pressure at the inlet to the moving blades leading to the reduction in the size of droplets.
Fig. 1.17 shows a section of the condition line displaying one stage only. (H 1 - H2) represents the
isentropic heat drop and (H1 - H3) the actual heat drop. Cylinder efficiency then is obtained for HP, IP and
LP turbines by considering the heat drop across all the stages of the cylinder.
It can be seen that though the pressure drop across the valves is at constant enthalpy, the
change in entropy affects the moving blade exit isentropic enthalpy so that :
H1 - H 2 H1 - H 2
(internal) = x 100% and (external) = x 100%
H1 - H 3 H1 - H 4
For HP and IP turbines, the kinetic energy effects at inlet and exhaust are small and usually ignored.
The kinetic energy at inlet to the LP turbine is also negligible but at the exhaust it is not so. As a result LP
efficiencies are calculated by considering either:
The total exhaust conditions - which includes the steam kinetic energy and is measurable with a
correctly aligned pitot.
The exhaust conditions - which represents conditions when the kinetic energy has been reduced to
zero and is measurable with pressure gauge.
Both exhaust conditions are displayed in Fig. 1.19 from which the following LP efficiencies can be
obtained. In LP turbine steam leaves the final stage with appreciable kinetic energy at the total pressure
and enthalpy shown in Fig. 1.19.
If the steam could be slowed down isentropically to zero kinetic energy, it would be at static
pressure and enthalpy. In practice the steam does slow down after leaving the last blade, but through the
conversion of its kinetic energy to flow friction losses. This is constant enthalpy process since the steam
cannot do work on blades that it has already left. Consequently steam comes to rest at the point "X" on
Fig. 1.18.
The heat loss between the total conditions at blade exit (H 2) and the static pressure line (H4) is
known as the leaving loss.
Where, Ve is the velocity of steam leaving the last row of blades. For a 500 MW turbine, the
velocity Ve is typically 170 m/s. Generally the leaving loss is responsible for 2% reduction in LP Cylinder
efficiency.
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