STEAM TURBINE

CONTENT
I. Introdution
II. Working principle
III. Construction
IV. Operation
 What is the Turbine?

TURBINE is a power machine to drive working machine such as

compressor, pump, electrical generator.

 Steam Turbine
 Gas Turbine
 Water Turbine
Steam Turbine
Gas Turbine
Water Turbine
 Steam turbines are made in a variety of sizes ranging from
small <0.75 kW (<1 hp) units (rare) used as mechanical drives
for pumps, compressors and other shaft driven equipment, to
1 500 000 kW (1.5 GW; 2 000 000 hp) turbines used to
generate electricity.
 Selection of steam turbine type depend on the overall process
requirement and configuration as well as project/ operation
cost reason.
Parts and equipment
 Steam turbine can be classified as the
following:
• By steam supply and exhaust conditions:
 Back pressure Turbine or none condensing turbine.
 Condensing Turbine.
 Extraction Steam Turbine.
 Induction Steam Turbine
 Reheat Steam Turbine
• By Blades and Stages design:
 Impulse Turbine
 Reaction Turbine.
Non-Condensing Steam Turbine:
Non-condensing or back pressure turbines are most widely used
for process steam applications. The exhaust pressure is controlled
by a regulating valve to suit the needs of the process steam
pressure.
Condensing Steam Turbine

Condensing turbines are most commonly found in electrical

power plants. These turbines exhaust steam from a boiler in a
partially condensed state, typically of a quality near 90%, at a
pressure well below atmospheric to a condenser.
Extraction Steam Turbine:
In an extracting type turbine, steam is released from various
stages of the turbine, and used for industrial process needs or sent
to boiler feed water heater to improve overall cycle efficiency.
Extraction flows may be controlled with a valve, or left
uncontrolled..
Induction Steam Turbine

Induction turbines introduce low pressure steam at an

intermediate stage to produce additional power.
Reheat Steam Turbine

In a reheat turbine, steam flow exits from a high pressure section

of the turbine and is returned to the boiler where additional
superheat is added. The steam then goes back into an
intermediate pressure section of the turbine and continues its
expansion. Using reheat in a cycle increases the work output
from the turbine and also the expansion reaches conclusion
before the steam condenses, there by minimizing the erosion of
Impulse & Reaction Turbines
Impulse Turbines
 Impulse Steam Turbine

 On Impulse Turbine a thermal expansion take place only in the

nozzles and static energy is converted to the kinetic energy
 There is no pressure different at inlet and outlet of blades on
the rotor, because the thermal expansion only in the nozzles. It
means no thrust force acting on the rotor disc.
 Reaction Steam Turbine

Reaction stage

Thermal expansion occurs both in the nozzles and blades. The impulse force
comes from the kinetic energy which is converted in the nozzles, and
reaction force created in the blades comes due to decreasing steam pressure.
These two forces produce the rotation torque of the blades on the rotor. On
this type, differential pressure between the inlet and outlet of blades
generates thrust force to turbine shaft. Therefore, to reduce the thrust force
acting on the shaft, shaft diameter is equal to the diameter of the blade root,
and blades are mounted on shaft directly.
Impulse and Reaction Turbine
Actually, Steam turbine using in the refineries are combined impulse and
reaction to get more advantages and less disadvantages
Nozzle
Thrust & Radial bearings
Journal Bearing
Self Equalizing tilting pad
Sealing Problem
Labyrinth effectiveness
Sealing of Steam Turbine
Monitoring system
 Function of Trip Throttle Valve (TTV)

 Adjustment of steam flow to turbine during

start-up.
 Close valve quickly as the pressure of
control oil lose due to interlock trip of
turbine or push the button trip.
 Partial stroke test of TTV.
Trip Valve and Control Valve
Trip Valve
Trip Throttle Valve
Trip Throttle Valve
Throttle valve operation
 Condensing system(Cond)

• Air in condenser is sucked by steam ejector and send to inter cooler

together with ejector driving steam. In inter cooler steam is cool
down by condensed water and convert to water and returns to
condeser through siphon tube.

• Air in inter cooler is suck again by steam ejector and send to after
cooler and only water in after cooler return to condenser through
steam trap and air goes to outside.
 OPERATION
Start-up Procedure
Assume that:
- Steam stream meets all the conditions about pressure and
temperatue before to be taken to turbine.
- All the systems including: electrical, control, pneumatic system,
closed cooling water system, condensate system, feed water
system, boiler) in normal operation condition. No more failure on
the devices
The steps for starting turbine as following:
1. Placing the turbine lubrication oil system in service:
- Start one duty pump and place the remain in spare
- Test change over
- Check parameter: pressure,temperature, condition of cooler,
filter..
2. Running turning gear system:
- Turning gear is done before start up and after shutdown turbine.
- The turning gear times depend on the outage duration of turbine
(start up) or metal temperature (shutdown), may be from severe
hours to one day in case of start up.
Less than one day: 2 hours
Up to7 days: 6 hours
Up to 30 days: 12 hours
Over 30 days: 24 hours
Normally, a motor is used for turning gear. The turning speed varies
from above ten rpm to hundred rpm.
3. Placing the turbine governing system (or EHC)
in service:
- Start the hydraulic pump, check header pressure
- Check condition of valve and pipe is not abnormal
- Trip test (by push Emergency stop button)
- Setting initial loading (for generator driven) or no-load
speed (compressor or pump driven) and loading limiter
(gradient)
4. Pre-runup checks of turbine valves
- In order to detect valve malfunction before steam admitted to the
turbine
- If having any problem in valve operation , it must be repaired
before turbine start up
- The valves are tested including stop valves and control valves
- During the valve checks, the turbine isolating valves close to
prevent steam flow through the turbine. Once valve completely
checked, these valve open to allow steam flow to the emergency
stop valve.
5. Place the condensate cooling water (ccw) system
in service:
-Start ccw pump, check the parameters
-Place the condensate cleaning system in service
-Place vacumn the primary system (for water box) in service
(if installed)
-Monitoring parameters..
6. Place the gland sealing steam system in service:
- To sealing turbine before pulling condensate vacumn
- Before start up, gland sealing steam is extracted from the
live steam system ( or auxiliary steam systeam) and
decreased both pressure and temperature (pressure: sligher
than atmospheric about 30-40 mbar, temperature: different
from metal temperature about 50oC)
- Check the gland steam condenser in normal condition
7. Pulling condenser vacumn:
Doing before start up:
-To reduce the tendency of the LP turbine exhause to overheat
-To prevent excessive flow – induced vibration of moving
blades in the turbine last stage
Activities:
-Start the vacumn pumps or ejectors.
-Monitoring the condensate pressure below 150 mbara
8. Placing the LP turbine exhaust cooling system in
service:
- Supply the cooling spray water to protect the LP turbine last
stages, condensate tubes from overheating when turbine
exhaust temperature is high.
- The control valve will open and closing base on exhaust
temperature.
9. Turbine warm-up
-To reduce thermal stress caused by temperature different
between live steam and turbine metal
-Normally, a control valve is used to extract steam from live
steam and taken to the turbine. The temperature rising of
turbine metal is limited and depend on the initial turbine metal
temperature, may from 30-100oC/hour.
-After temperature different between live steam and turbine
metal below 50oC, can finish warm-up step.
10. Start - up turbine:
Base on initial turbine metal temperature, can classify 3 start up
modes:
- Cold start: Turbine metal temperature < 150o C
- Warm start: Turbine metal temperature :150o C - 410o C
- Hot start: Turbine metal temperature > 410o C
Before start up, operators must carefully check performance of all the
system concerned are normal and ready, example: vacumn pressure,
lube oil pressure and temperature, position of drain valve….
-Setting the speed target, run up rate, initial loading, holding speed,
warm up time.. base on mismatch diagram. Carefully check in case of
auto-setting.
-Press start button to run up turbine.
-The control valve will slowly open and steam flow to the turbine for
rotary
-Turning gear disengaged and turbine run up base on start up curve.
Start up curve
Start up on DCS
Monitoring in operation:
- Critical speed
- Shaft eccentricity
- Thermal stress
- Shaft vibration
- Differential Expansion
- Temperature: lube oil temperature, bearing metal temperature
- Turbine exhaust hood: Vacumn, temperature,
- Steam qualities: Silica, conductivity, pH