A project report

on

CASE STUDY OF IMPROVING TURBINE EFFICIENCY

IN 20 MW POWER PLANT
Submitted in partial fulfillment of the
Requirements for the award of the degree of
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
By
M.ADITYA KUMAR
(08023A3008)
Under the esteemed guidance of
Sri V.KALYANA MANOHAR, M.Tech,
Asst. Professor
Department of Mechanical Engineering

DEPARTMENT OF MECHANICAL ENGINEERING

SCHOOL OF CONTINUING AND DISTANCE EDUCATION
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY
KAKINADA - 533 003
2012-2013
 DEPARTMENT OF MECHANICAL ENGINEERING
SCHOOL OF CONTINUING AND DISTANCE EDUCATION
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY
KAKINADA - 533 003

CERTIFICATE
This is to certify that the project report entitled “CASE STUDY OF IMPROVING
TURBINE EFFICIENCY OF 20 MW STEAM TURBINE” is the bonafide work Mr.
M.ADITYA KUMAR, Roll No (08023A3008) submitted in partial fulfillment for the award of
BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING during the
academic year 20112-2013.
The results embodied in this project report have not been submitted to any other
University or Institution for the award of any degree diploma.

Internal Guide: External Guide:

Sri KALYAN MANOHAR, Sri R.V.V.S POLESWARA RAO,

M.Tech. Asst.Engineer
Asst. Professor, Nava Bharat Ventures Limited
Dept. of Mechanical Engineering Sugar Division-2,
JNTU, Kakinada. Dharamavaram.

CHAIRMAN
PROJECT REVIEW COMMITTEE
JNTU COLLEGE OF ENGINEERING,
KAKINADA-533 00
 ACKNOWLEDGEMENT

I wish to express my sincere gratitude to my internal guide Sri. V.KALYANA

MANOHAR, Asst.Professor, Department of Mechanical Engineering, JNTU, Kakinada, for
giving me an opportunity to work under his guidance, his constant technical support and
encouragement helped me in successful completion of the project work.
I acknowledge my thanks to Dr.V.V.SUBBA RAO, Professor and Head of the
Mechanical Engineering Department, JNTU, Kakinada, for his encouragement and providing me
with sufficient facilities for successful completion of the project work.
I record my thanks and appreciation to my external guide, Mr. R.V.V.S
POLESWARA RAO Asst.Engineer, Nava Bharat Ventures Limited, Sugar Division-2,
Dharamavaram, for giving his valuable guidance and the providing all facilities to carry out the
dissertation work.
 ABSTRACT

Electricity plays a vital role in our daily life. The power demand is not constant but varies
with time because of increase in population and development of nation. Our country mainly
depends on thermal power plant for electrical supply. In thermal power plants turbine is
considered to be HEART of the plant.
This project involves the construction features, start up, shut down, trouble shooting and
maintenance of the 20 mw turbine. During overhauling period, a crack was identified on the
upper casing of gear box at HSS bearing housing and removed by grinding with depth of 15 mm
and welded by the LH 115 and LH 117 electrodes to fill the crack. The scaling on the blades is
removed by alumina-sand blasting process. Turbine efficiency is calculated by heat rate method
and heat loss method and obtained overall plant efficiency. Results are validated with plant
efficiency before maintenance. A method was suggested to increase turbine efficiency by
optimize the extraction flows of steam turbine and validated these results with earlier.

.
 CONTENTS
Page No
1. A BRIEF VIEW ON STEAM TURBINE
1.1 Definition of steam turbine
1.2 Development of steam turbine
1.3 Working principle
1.4 Classification of turbine
1.4 Governing of steam turbine
2. ABOUT 20MW TURBINE
2.1 Details of 20MW steam turbine
2.2 Components of Steam Turbine
3. START UP AND SHUTDOWN OF TURBINE
3.1 Startup of turbine
3.2 Shut down procedures
3.3Types of speeds in start up
3.3 Types of running modes
4. PROTECTION OF STEAM TURBINE
4.1Turbine protections
4.2 List of turbine protections
5. TROUBLE SHOOTING
6. OVER HAULING
6.1 Over hauling
6.2 Problems identified in over haul period.
7. TURBINE CALCULATIONS
7.1 Turbine efficiency
7.2 Efficiency of 20MW steam turbine at 19.5MW load.
7.3 Optimize the extraction flows to increase the efficiency.
8. CONCLUSION
9. BIBLIOGRAPHY
 NOTATIONS

 MSSV - Main steam stop valve

 SNM - SHIN NIPPON MACHINERY
 DCS - Distributed control system
 DP - Differential pressure
 COP - Control oil pump
 AOP - Auxiliary oil pump
 MOP - Main oil pump
 APC - Auto power control
 QCNRV - Quick close non return valve
 ESV - Emergency stop valve
 HP - High pressure
 LP - Low pressure
 ISOCH - Isochronous
 MW - Mega watt
 µ - Microns
 CHAPTER -1

A BRIEF VIEW ON STEAM TURBINE

1.1 DEFINITION STEAM TURBINE:
Steam turbine is prime-mover which converts heat energy of steam to mechanical
energy. When steam is allowed to expand through an orifice then heat energy (enthalpy), is
converted into kinetic energy. This kinetic energy of steam is changed to mechanical energy
through the impact (impulse) or reaction of steam against the blades. The force of steam is
used to spin the turbine blades which spin the generator, producing electricity.
1.2 DEVELOPMENT OF STEAM TURBINES:
Historically first steam turbine was produced by Hero a Greek philosopher, in 120 B.C.
It was pure reaction turbine. In1629, an Italian named Branc actually anticipated the boiler
steam turbines combination that is a major source of power today.
First practical steam turbine was introduced by Charles Parson in1884 which was also
of the reaction type. Just after 5 years, in 1889, Gustav De-Laval produced the first practical
impulse turbine.
Most units used 14 kg/ cm2and 276 degree centigrade steam and capacity ranged from
5,000 to 30,000 KW. By 1930 steam conditions rise to 48 kg/ cm2and 398 degree centigrade and
by 1940 steam condition of 81 kg/ cm2 and 509 degree centigrade was achieved.
Reheat cycle was adopted widely and capacity increased gradually. While turbines of 900
MW are in use in USSR, in India the largest capacity is 500 MW with steam condition of 179 kg/
cm2and 540deg.C.
1.3WORKING PRINCIPLE:
When steam is allowed to expand through a narrow orifice, it assumes kinetic energy at
the expense of its enthalpy. This K.E of steam is changed to mechanical energy through the
impact (impulse) or reaction of steam against the blades.
It should be realized that the blade of the turbine obtains no motive force from the static
pressure of the steam (or) from any impact of the steam jet. The blades are designed in such a
way, that steam will glide on and off the blade without any tendency to strike it.
As the steam moves over the blades, its direction is continuously changing and centrifugal
pressure exerted as the result is normal to the blade is thus the resultant of all the centrifugal
forces plus the change of momentum. This causes the rotational motion of the blades. The total
power plant was operated by the rankine cycle.
1.3.1 RANKINE CYCLE:
There are four processes in the Rankine cycle. These states are identified by numbers (in
brown) in the above T-S diagram.

 Process 1-2: The working fluid is pumped from low to high pressure by the isentropic
compression process. As the fluid is a liquid at this stage the pump requires little input
energy.
 Process 2-3: The high pressure liquid enters a boiler where it is heated at constant pressure
by an external heat source to become a dry saturated vapor.
 Process 3-4: The dry saturated vapor expands through a turbine by isentropic expansion,
generating power. This decreases the temperature and pressure of the vapor, and some
condensation may occur.
 Process 4-1: The wet vapor then enters a condenser where it is condensed at a constant
temperature to become a saturated liquid.

Fig. 1 T-S diagram of a typical Rankine cycle

VARIBLES IN RANKINE CYCLE
Q Heat flow rate to or from the system (energy per unit time)

M Mass flow rate (mass per unit time)

ηThermal Thermodynamic efficiency of the process (net power output per heat input,

dimensionless)

η Thermal Isentropic efficiency of the compression (feed pump) and expansion (turbine)

processes, dimensionless
h1,h2,h3,h4. The "specific enthalpies" at indicated points on the T-S diagram.
h4s. The final "specific enthalpy" of the fluid if the turbine was isentropic
p1,p2. The pressures before and after the compression process

Generally, the efficiency of a simple Rankine cycle can be defined as:

`
W Turbine
η Thermal = --------------
Q in
1.4 CLASSIFICATION OF STEAM TURBINES:
1. According to the principle action of steam:
a) Impulse turbine
b) Reaction turbine
2. According to the no. of cylinders:
a) Single- Cylinder turbines
b) Double-Cylinder turbines
c) Three-Cylinder turbines
d) Four-Cylinder turbines
3. According to the method of governing:
a) Turbine with throttle governing
b) Turbine with nozzle governing
c) Turbine with bypass governing
4. According to the direction of steam flow:
a) Axial turbine
b) Radial turbine
5. According to the heat balance arrangement:
a) Condensing turbine with regeneration
b) Condensing turbine with extractions
c) Back pressure turbines
d) Topping turbines
6. According to the steam conditions at inlet to turbines:
a) Low pressure turbines
b) Medium pressure turbines
c) High pressure turbines
d) Turbines of very high pressures
e) Turbines with super critical pressure
7. According to steam arrangement:
a) Tandem compounded turbines
b) Cross compounded turbines
1.4 GOVERNING OF STEAM TURBINE:
Governing of steam turbine is the procedure of monitoring and controlling the flow rate
of steam into the turbine with the objective of maintaining its speed of rotation as constant. The
flow rate of steam is monitored and controlled by interposing valves between the boiler and the
turbine. Depending upon the particular method adopted for control of steam flow rate different
types of governing methods are being practiced. The principal methods used for governing are
described below:

1.4.1 Throttle governing:

In throttle governing the pressure of steam is reduced at the turbine entry thereby
decreasing the availability of energy. In this method steam is allowed to pass through a restricted
passage thereby reducing its pressure across the governing valve. The flow rate is controlled
using a partially opened steam stop valve. The reduction in pressure leads to a throttling process
in which the enthalpy of steam remains constant.

Fig. 2 Schematic of throttle governor

Throttle governing – small turbines:

Low initial cost and simple mechanism makes throttle governing the most apt method for
small steam turbines. The valve is actuated by using a centrifugal governor which consists of
flying balls attached to the arm of the sleeve. A geared mechanism connects the turbine shaft to
the rotating shaft on which the sleeve reciprocates axially.
 With a reduction in the load the turbine shaft speed increases and brings about the
movement of the flying balls away from the sleeve axis. This result in an axial movement of the
sleeve followed by the activation of a lever, which in turn actuates the main stop valve to a
partially opened position to control the flow rate.
Throttle governing – large turbines:

In larger steam turbines an oil operated servo mechanism is used in order to enhance the
lever sensitivity. The use of a relay system magnifies the small deflections of the lever connected
to the governor sleeve. The differential lever is connected at both the ends to the governor sleeve
and the throttle valve spindle respectively. The pilot valves spindle is also connected to the same
lever at some intermediate position. Both the pilot valves cover one port each in the oil chamber.
The outlets of the oil chamber are connected to an oil drain tank through pipes. The decrease in
load during operation of the turbine will bring about increase in the shaft speed thereby lifting
the governor sleeve. Deflection occurs in the lever and due to this the pilot valve spindle raises
up opening the upper port for oil entry and lower port for oil exit. Pressurized oil from the oil
tank enters the cylinder and pushes the relay piston downwards. As the relay piston moves the
throttle valve spindle attached to it also descends and partially closes the valve. Thus the steam
flow rates can be controlled. When the load on the turbine increases the deflections in the lever
are such that the lower port is opened for oil entry and upper port for oil exit. The relay piston
moves upwards and the throttle valve spindle ascend upwards opening the valve.

1.4.2 Nozzle governing:

In nozzle governing the flow rate of steam is regulated by opening and shutting of sets of
nozzles rather than regulating its pressure. In this method groups of two, three or more nozzles
form a set and each set is controlled by a separate valve. The actuation of individual valve closes
the corresponding set of nozzle thereby controlling the flow rate. In actual turbine, nozzle
governing is applied only to the first stage whereas the subsequent stages remain
unaffected. Since no regulation to the pressure is applied, the advantage of this method lies in the
exploitation of full boiler pressure and temperature. Figure shows the mechanism of nozzle
governing applied to steam turbines. As shown in the figure the three sets of nozzles are
controlled by means of three separate valves.
 Fig. 3 Schematic of nozzle governor

1.4.3 By pass governing:

Occasionally the turbine is overloaded for short durations. During such operation, bypass
valves are opened and fresh steam is introduced into the later stages of the turbine. This
generates more energy to satisfy the increased load. The schematic of bypass governing is as
shown in fig.4

Fig. 4 Schematic of bypass governor

 CHAPTER -2

20MW STEAM TURBINE

2.1 ABOUT 20MW TURBINE:

Fig. 5 Assembly drawing of 20MW steam turbine

Manufacturer:
SHIN NIPPON MACHINERY CO.LTD
Model no:
C8-R14-ER
C--- Condensing
8---Rotor diameter
R---Ratue stage
14---No stages (14 no’s)
E---Extraction type
R---With reduction gear coupled
Type of steam turbine:
Horizontal, Impulse, multi-stage, multi- valve, axial flow, condensing turbine with
1 uncontrolled+1 controlled extractions
Operating conditions:
Output (rated) ---20000kw
Speed (turbine/generator) --- 6194/1500rpm
Inlet steam pressure/temperature---85 kg/ cm2 A/510oc
Outlet steam pressure/temperature---0.1 kg/ cm2 A/45oc
Max. Inlet steam flow---100000 kg/hr
Max. 1st extraction pressure/flow---8.6kg/ cm2 A/16550 kg/hr
Max. 2nd extraction pressure/flow---3kg/ cm2 A/75790 kg/hr
Max. Exhaust pressure/flow ---0.1kg/ cm2 A/62920 kg/hr
Direction of rotation (view from the turbine front):
Turbine ---clock wise
Generator---counter clock wise
Speed governor:
Type---electro hydraulic governor
Model--- 505E
Make ---Wood ward
Adjustable speed --- 95-105% of rated speed
Range--- 109% of rated speed
Type of governor valves:
Type---throttle valve (quantity governing)
Description--- bar lift and multi-valve type
Over speed governor:
Mechanical eccentric trip--- value 115% on rated speed (7123 rpm)
Electrical Trip (signal from governor) --- value 114% on rated speed (7061 rpm)
Bearings:
Journal bearings (2 no’s)
Type---multi segmental tilting pad type
Material---carbon steel lined with Babbitt material
B) Thrust bearing (1 no’s)
Type---multi segmental tilting pad type (double side)
Material---carbon steel lined with Babbitt material.
Reduction gear box:
Type---horizontal, single reduction, double helical gear type.
Speed ratio---4.129:1
Lube oil system:
Kind of lube oil---Turbine oil ISO VG 46
Type of lubrication---forced
Min.oil flow required
Lube oil---651 lpm at 1.5 kg/cm2
Control oil---100 lpm at 14.0 kg/cm2
Trip oil---10 lpm at 4.0 kg/cm2
Material of steam turbine:
Casing:
HP---cast alloy steel (1.25cr-0.5Mo)
LP---carbon steel
Rotor--- Cr-Mo-V forged steel
Blades---Mo-13%Cr stainless steel
Nozzles--- Mo-13%Cr stainless steel
Diaphragm
HP---forged alloy steel
LP---carbon steel
Labyrinth packing---Ni-Pb bronze, carbon steel, stain less steel
Reduction gear box
Casing---cast iron
Pinion---forged alloy steel
Gear--- forged alloy steel
Base plate---carbon steel
Filters
Lube oil---40 microns (vertical, duplex type) made of stainless steel
Control oil---10 microns (vertical, duplex type) made of stainless steel
2.2 COMPONENTS OF STEAM TURBINE:
The main components in the steam turbine are mentioned below:
2.2.1Pedestal, Base Plate and Fixed Points:
The Turbines rest on the pedestals. The front pedestal houses the governor. The center
pedestal houses the combined journal and thrust bearing and the other pedestals contain one
journal bearing each. All pedestals are of fabricated construction. The front pedestal and the
center pedestal slide over their respective base plates, which are fixed to the foundation. While
the LP front and rear pedestals themselves are fixed to the foundation. On the rotating system the
fixed point is provided by the thrust bearing. The LP pedestals also carry the shaft seal housing
which is joined to the LP outer casing with compensators. Hence these gland clearances remain
unaffected by any deformation of LP cylinder during operation.

Fig. 6 Turbine base plate with front bearing pedestal

\
2.2.2 Casings:
Turbine casings are essentially pressure vessels, their weight being supported at each
end. These are therefore, designed to withstand hoop stresses in transverse plane and to be very
stiff in longitudinal direction to maintain accurate clearance between stationary and rotating
components. Usually casings are of two designs,
1. Single shell casing.
2. Multi (double) shell casings.
Single Shell casing:
Single shell casings take pressure drop from steam pressure to atmospheric pressure in
single shell, and hence required thick wall and heavy flanges at parting planes. This causes very
large incremental thermal stresses during transients, resulting in slower start-ups and shutdowns.
This problem to certain extent is solved for flange and stud heating.

Fig. 7 Turbine upper casing (single shell type)

Multi shell casing:
In multi shell casings, there is intermediate pressure (approximately 25% pressure of
main stream) between the shells and hence pressure drop is shared by two shells resulting in
thinner walls and lighter flanges at parting planes. This type of casing has lower incremental
thermal stresses during transients resulting in quicker start-ups and shut down. It is now
commonly used for HP and IP turbine.
2.2.3 Balding:
The turbines balding are designed for maximum efficiency and reliability. Blades are
single most costly element of turbine. Blades fitted in the stationary part are called guide blades
or nozzles and those fitted in the rotor are called moving or working blades. The following are
three main types of blades:
1. Cylindrical or constant profile blade.
2. Tapered cylindrical profile blade.
3. Twisted and varying profile blade.
The HP blades are machined from rectangular bars stock with integral shroud and T-root.
The root and shroud have rhomboid shape in order to have an additional clamping force at root
and a movement at shroud for increase rigidity of blade assembly. The blades are locked radially
into grooves of casing/rotor with the help of fitting pieces called caulking brass. The guide
blades in the medium and low temperature regions are made from solid drawn material and have
a hook type root. In this case shrouding is separating under riveted in position. The root is brazed
on to the blade. These blades are locked axially in the casing groove, with the help of precision
cast clamping pieces to achieve tight fitting.
These LP blades are suitably along their height to suit the different peripheral velocities from the
root to tip. The profiles are also made tapered to obtain most favorable stress distribution in the
profile. The trailing edge of these blades is very thin to avoid formation of streams of water.
The axial distance between the last stages is kept large facilitate breaking of any water
droplets which may still remain. The leading edges of the last stages are flame hardened to give
protection against erosion. Suitably sized longitudinal suction slits are provided in the last stage
guide blades to remove the water to the condenser accumulated on the profile boundaries due to
wetness of steam.
Fig. 8 HP Blades (shrouded blades) Fig. 9 LP Blades (lashing wired blades)

2.2.4Bearings:
The bearings are made in two halves and are all tilting type. The Rotor is supported by
two bearings. Bearing Babbitt temperatures are measured by the thermo couples directly under
the white metal. The temperature of the thrust pads is measured by the thermo couples in two
opposite pads on both turbine side and generator side. Lube oil is admitted in the oil spaces that
are milled into the bearing shells at the horizontal joint and are open to the shaft journal.
There are two types of bearings mostly used in turbine are
1. Journal bearings
2. Thrust bearings

Fig. 10 Journal bearing (segmental type) Fig. 11thrust bearing (tilting type)
 Fig. 12 Arrangement of journal and thrust bearing of turbine

2.2.5 Rotor:
If the turbine is impulse type the rotor is disc type i.e. blades are carried in the discs,
which may be integral forged with shaft or shrunk on the shaft. Each rotor is subjected to 20%
over speed test and is balanced at 6194rpm. The rotors carry the moving blades. The shaft seals
are axial. All the rotors are dynamically balanced to every fine degree of precision; this ensures
that there are minimum vibrations and dynamic loading of bearings. Labyrinths with the sealing
strips caulked into the shafts. Sealing in turbine casings is provided to check steam leakage from
HP side and air leakage into LP side.

Fig.13 20MW Turbine rotor

2.2.6 Glands:
In the HP the seals consist of a series of sealing strips caulked alternatively in the shaft and into
stationary rings. In the case of LP glands sealing strips are fitted in the stationary rings only.
Each sealing ring consists of 6 or 8 segments and is carried in grooves in the casing to allow
radial movement. Each segment is held in position against a shoulder by two coil springs. Both
fixed and moving blades are fitted with a continuous shroud in which steps have been machined
to produce a labyrinth. The sealing strips are caulked into the casing and shaft opposite to the
blade and are of stainless steel which can be easily replaced.
Turbine shaft glands are sealed with auxiliary steam supplied by an Electro hydraulically
controlled seal steam pressure control valve. A pressure of 0.01kg/cm2 is maintained in the seals.
Above a load of 80 the turbine becomes self-sealing. The leak off steam from HP glands is used
for sealing LP glands. The steam pressure in the header is then maintained constant by means of
a leak off control valve which is also controlled by the same Electro hydraulic controller,
controlling seal steam pressure control valve. The last stage leak off of all shaft seals is sent to
the gland steam condenser for regenerative condensate heating.

Fig. 14 Arrangement of glands to the turbine rotor

2.2.7 Coupling:
Since the shaft (rotor) is made in small parts due to forging limitations and other
technological and economic reasons, the couplings are required between any two rotors. The
coupling permits angular misalignment, transmit axial thrust and ensures axial location. The
couplings are either rigid or semi flexible.
The types of couplings used in 20MW turbine are
1. Diaphragm coupling for High Speed Side.
2. Full geared coupling for Low Speed Side.

Fig. 15 Fixed Coupling (Full geared)

Fig. 16 Flexible coupling (diaphragm type)

2.2.8 Emergency stop valve and governor valves:
Turbine is equipped with emergency stop valves to cut off steam supply and with control
valves regulate steam supply, Emergency Stop Valves (ESV) is provided in the main steam line.
Emergency stop valves are actuated by servo motor controlled by the protection system. ESV
remains either fully open or fully close. Control valves are actuated by the governing system
through servo motors to regulate steam supply as required by the load. Valves are either single
seat type or double seat type. Single seat type valves are preferred though these required higher
force for opening or closing.

Fig. 17 Emergency stop valve (ESV) Fig. 18 Governor Valve (HP & LP)
 CHAPTER – 3
START UP AND SHUTDOWN OF TURBINE
3.1 STARTUP OF THE TURBINE:
The turbine has to be stated according to the startup procedure to avoid the rubbing and
damage of the rotor and casing.
3.1.1 Types of Turbine startup:
There are three types of startup of turbine according to the time after shutdown of the turbine.
1) Cold startup (Over 8 hours after the shutdown)
2) Warm startup (Over 2-8 hours after the shutdown)
3) Hot startup (within 2 hours after the shutdown)

3.1.2 Check list before starting the turbine:

 Check the fixing bolts are loosened and the clearance ring clearance is recommended to
0.03-0.05mm.
 Check all valve positions of the steam and oil system of the turbine.
 Check the oil level in the main oil tank.
 Check the electrical system to the auxiliaries, control panel and governor panel.
 Check the cooling water and auxiliary cooling water system.
 Check the instrument air is at recommended pressure.
 Check the all oil filters DP are at recommended condition.
 Check the signaling and protection system of the turbine.

3.1.3 Turbine startup procedure:

 Take the lube oil system in to service (AOP) and put the turbine in to the rotation using
barring gear or turning gear usually at 60rpm. Make sure the EOP is in standby mode.
The function of turning gear is to rotate the shaft system at sufficient speed before start
up and after shut down to avoid irregular heating up or cooling shaft. The time period of
the turning gear is showed below:
 Cold startup 8 hours before synchronization.
 Warm startup 3 hours before synchronization.
 Hot startup 1 hour before synchronization.
 Take the cooling water system in to service before the vacuum pulling in the condenser.
 Charge the gland sealing system at the sealing pressure 0.1-0.2 kg/cm2.
 Start the vacuum pulling using huger ejector. When the vacuum in the condenser reached
to the 0.6-0.7 kg/cm2, the turbine is ready to the start.
 Reset the faults of the turbine at the panel and DCS, and open all the steam side valves
like ESV, chest drain and warm-up vent valves.
 Take the control oil in to service to operate the ESV, HP and LP governor valves.
 Open the MSSV and by pushing the TURBINE RESET button the governor panel opens
the ESV and QCNRV.
 Close the valves after removal of condensate at ESV, chest drain and warm-up vent
valve.
 By pushing the TURBINE START button the steam is admitted in to the turbine through
the HP governor valves and the governor maintains the speed of the turbine at 800 rpm.
At this speed the rotor and the casing was uniformly heated in this idling period. The
idling period of the turbine is showed below:
 Cold startup 10-20 minutes.
 Warm startup 5-10 minutes.
 Hot startup 1-5 minutes.
 Check all the vibrations and temperatures of the bearings during the idling period.
 By pushing the TURBINE RATED button the governor speeds up the turbine to the rated
speed 6194 rpm.
 At the 95% of rated speed the MOP will takes the lube oil system.
 Start the generator excitation and put the governor in to ISOCH mode for proceed to
synchronization.
 Synchronization is done in the synchronization panel and the initial load is above the
home load (approximate 2MW).
 Keep the Load for 5 minutes for generator warm-up.
 The load was raised through APC by enable the APC push button. And load raising on
the generator was shown below:
 Cold startup 60 minutes.
 Warm startup 40 minutes.
 Hot startup 20 minutes.
 Check all the vibrations and temperatures of the bearings, and expansions of the turbine.
3.2 SHUTDOWN PROCEDURES:
3.2.1 Normal Shutdown procedure:
 Reduce the load as per the load reducing curve.
 Cutoff the extractions as mentioned below:
 1st extraction --- 12MW.
 2nd extraction --- 4MW.
 Open the generator breaker.
 Push the “TURBINE STOP” push button to close the HP governor valve and ESV.
 After coast down of the turbine, open the vacuum break valve and put the turbine on
turning gear for 10 hours to uniform cooling of the rotor and casing.

3.2.2 Emergency Shutdown procedure:

 Open the generator breaker.

 Push the “EMERGENCY TRIP” to close ESV and HP governor valves.
 If necessary open the vacuum break valve to reduce the coast down period.

3.3 TYPES OF SPEEDS IN STARTUP:

While starting the turbine the turbine will operated at different speeds for uniform heating
and to avoid the damage.
3.3.1Turning speed:
The speed of the turbine which was rotated at minimum speed (60 rpm) to uniform heating or
cooling before or after starting the turbine. This speed was known as “turning speed”.
3.3.2 Idling speed:
The turbine was rotated at slow speed by the stem for uniform heating of the rotor and casing,
this speed was known as “idling speed” or “soaking speed”. The idling speed is 13-15% of the
rated speed.
The idling speed of the 20MW turbine is
For cold startup----10-20minutes
For warm startup--5-10minutes
For hot startup-----1-5minutes
3.3.3 Rated speed:
The speed of the turbine, which was designed by the manufacturer at running condition, was
known as “rated speed”.
The rated speed for the 20MW turbine is 6194 rpm.
3.3.4 Critical speed:
The speed of the turbine which numerically coincides with the natural frequency of the vibration
of the shaft (rotor) is known as “critical speed”. The speed interval of the critical speed was
known as “critical band”.
The critical band if the 20MW turbine is 2150-2650 rpm.
3.3.5 Coast down period:
The time required for the turbine from rated speed to turning speed was known as cost down
period.
3.4 TYPES OF RUNNING MODES:
The turbine was controlled to maintain the load by the running modes. There are two types of
running modes,
1. Isochronous mode ( speed mode)
2. Droop mode ( load mode)

3.4.1 Isochronous mode:

In the isochronous mode the governor system will control plant frequency or the speed of
the turbine as rated with irrespective of load. The isochronous mode was active when the unit is
independent with grid.
3.4.2 Droop mode:
When the unit was synchronized with grid the turbine speed was maintained by the grid
frequency. In this mode the governor system will control the generator load by govern the speed
drooped with the speed with irrespective of the actual speed. The droop mode was active when
the unit is parallel with grid.

Set rpm - actual rpm

The % of droop is = -----------------------------X 100
Actual rpm
 CHAPTER - 4

PROTECTIONS OF STEAM TURBINE

4.1 TURBINE PROTECTIONS:
4.1.1 Introduction:
Protection system shuts off steam supply to turbine by closing stop valves (independent of
control valves) and control valves in the following possible hazards.
1. over speeding
2. motoring
3. lube oil failure
4. thrust bearing failure
5. vacuum failure
6. boiler priming
7. excessive vibrations
8. excessive temperature differential
9. excessive eccentricity
It is not necessary to trip the turbine in all above mentioned eventualities. Manufacturers select a
group of these for tripping depending on their designs. In case of ‘lube oil failure’ and ‘thrust
bearing failure’, vacuum is also usually broken in order to bring turbine at standstill in minimum
time so that no damage occurs to turbine. Protection system consists of transducers for above
mentioned eventualities, their unstable pilots and associated hydraulic amplifiers which act on
stop and control valves. Turbine protection systems perform to cover the following functions:
a. Protection of turbine from inadmissible operating conditions.
b.In case of plant failure protections against subsequent damages.
c. It restricts occurring failure to minimum.
The tripping of the turbine was done by three types:
1. Hand trip.
2. Electrical trip.
3. Mechanical trip (over speed).
Hand trip:
The tripping of the turbine was done by operating the tripping valve at the turbine. This was
operated by draining the trip oil to close the ESV.
Electrical trip:
The Electrical trip was operated by the solenoid valve by draining the trip oil to close the ESV.
All the heavy faults are usually trips the turbine by operating the solenoid valve.
Mechanical trip (over speed):
The mechanical trip was operated by reaction force on the tripping device for the draining the
trip oil to close the ESV. The most mechanical tripping devices are used for over speed tripping
of the turbine, which was operated by centrifugal force.
4.1.2 Over-Speed Trip:
The two over speed trips are provided to protect the turbine against over speeding in the
event of load rejection coincident with failure of the speed governor. They can also be locally
tested by hand during turbine operation at rated speed with the aid of the over speed trip test
device.
The over speeds are:
1. Electrical over speed--------7061rpm (114% of rated speed)
2. Mechanical over speed-----7123rpm (115% of rated speed)
 4.2 LIST OF TURBINE PROTECTIONS:
LIGHT FAULT------ ALARM
HEAVY FAULTS----- TRIP
S.no NAME UNITS LIGHT FAULTS HEAVY FAULTS
LOW HIGH LO\LO HI\HI
1 Inlet steam Pressure kg/cm2 69 90 60 95
o
2 Inlet steam Temperature c 475 525 465 528
3 2nd extraction Pressure kg/cm2 n\a 3.2 n\a 4
4 Exhaust steam pressure kg/cm2 -0.5 n\a n\a 0.5
Turbine thrust bearing o
5 c n\a 110 n\a 120
Temp.(in-active)
Turbine thrust bearing o
c n\a 110 n\a 120
6 Temp.(active)
o
7 Turbine front brg.temp. c n\a 110 n\a 120
o
8 Turbine rear bearing temp. c n\a 110 n\a 120
Reduction gear pinion front o
9 c n\a 110 n\a 120
bearing temp.
Reduction gear pinion rear o
10 c n\a 110 n\a 120
bearing temp.
Reduction gear wheel front o
11 c n\a 110 n\a 120
bearing temp.
Reduction gear wheel rear o
12 c n\a 110 n\a 120
bearing temp.
o
13 Lube oil temperature c n\a 55 n\a n\a
Generator front bearing drain o
14 c n\a 85 n\a n\a
oil temp.
Generator rear bearing drain o
15 c n\a 85 n\a n\a
oil temp.
16 Turbine axial displacement mm -0.5 0.5 -0.7 0.7
17 Rotor differential expansion mm -2.2 2.2 -2.5 2.5
Turbine front shaft
18
vibrations µ n\a 40 n\a 80
19 Turbine rear shaft vibrations µ n\a 40 n\a 80
Reduction gear pinion front
20 µ n\a 86 n\a 126
shaft vibrations
Reduction gear pinion rear
21 µ n\a 86 n\a 126
shaft vibrations
Reduction gear wheel front
22 µ n\a 120 n\a 180
shaft vibrations
Reduction gear wheel rear
23 µ n\a 120 n\a 180
shaft vibrations
Generator front shaft
24 µ n\a 135 n\a 180
vibrations
Generator rear shaft
25 µ n\a 135 n\a 180
vibrations
Turbine over speed
26
(mechanical) rpm n\a n\a n\a 7123
Turbine over speed
27
(electrical) rpm n\a n\a n\a 7061
28 Hot well level mmwc n\a n\a n\a 800
2
29 Lube oil header pressure kg/cm n\a n\a 0.75 n\a
30 Lube oil pressure kg/cm2 1.1 n\a n\a n\a
31 Control oil pressure kg/cm2 12 n\a 10 n\a
32 Trip oil pressure kg/cm2 3.6 n\a n\a n\a
MOP\AOP discharge
33
pressure kg/cm2 4.2 n\a n\a n\a
40 Lube oil filter DP kg/cm2 n\a 0.8 n\a n\a
2
41 Control oil filter DP kg/cm n\a 0.8 n\a n\a
 CHAPTER – 5

TROUBLESHOOTING
5. IDENTIFICATION OF TROUBLES AND THEIR REMEDIES:

SL.NO TROUBLES CAUSES REMEDIES

1) High a) Bending of rotor due to a) Operate the rotor at
vibration supply the sealing steam slow speed for a long
without rotation of time up to the bend
turbine. recovered by it.
b) In sufficient warm-up b) Operate the turbine at
period. low speed for initial
warm-up.
c) Remained drain the c) Purge the drains.
turbine.
d) Foreign d) Check the ESV
Material in the steam. strainer.
e) Damage or rubbing of the e) Replace the bearing
journal bearing. by new one.
f) Less clearance between f) Adjust the clearance.
the rotor and the journal
bearing.
g) Unbalance of rotor. g) Rebalance the rotor.
h) Damaged run out. h) Repair the rotor
surface.
i) Wrong alignment. i) Recheck and adjust
the alignment.
j) Rubbing of labyrinth fin j) Inspect the rotor and
with rotor. if any rubbing
observed replace the
labyrinth.
2) Excessive axial a) Thrust pads worn-out. a) Inspect and replace
displacement them. Ensure sufficient
lubrication.
b) Less flow of oil, indicated b) Check the orifice size
by high drain oil and any blockage at the
temperature. oil inlet.
3) Excessive bearing a) Lake of lube oil quantity. a) Check the lube oil
temperatures. b) High temperature of lube pressure.
oil. b) Check the
temperature of the oil
and control it.
c) Less clearance between c) Adjust the clearance.
the rotor and the bearing.
d) Wrong alignment. d) Check and adjust the
alignment.
4) Abnormal sound. a) Steam leak. a) Check and arrest the
steam leak.
b) Foreign material in the b) Check the ESV
turbine. strainer.
c) Damage or rubbing of the c) Replace the journal
journal bearing. bearing pads by new.
d) Water hammer. d) Drain the steam line,
stop the turbine if
necessary.
e) High vibrations. e) Check the counter
measure of the
vibrations.
5) Maul function of the a) Stick the mechanism of a) Check the oil cup and
governor valve and the governor valve. inspect the linkage of
actuator. the governor valve.
b) Unstable movement of b) Readjust the
output shaft of governor dynamics of speed
valve. governor.
c) Foreign material from c) Check the inner parts
ESV. of the governor
valves.
d) High frequency of d) Relief the air by air
vibration of the actuator vent at the filters.
due to the air in the
control oil. e) Check for leak
e) Automatically speeding through the HP
of turbine after opening governor valve seat.
of the ESV due to the
leak of steam.

6) Can’t operate the a) Scale deposition on the a) Remove the scale.

ESV. shaft of the ESV.
b) Stick the mechanism of b) Inspect and Overhaul
the governor valve. the ESV.
c) Low pressure of the c) Check the control oil
control oil. pressure control
valve.
 Check the DP of the
filter.
 Check the orifice
plate at relay of ESV.
7) Water in lube oil. a) Increase the gland steam a) Check the glands for
quantity. leak, if observed
replace it.
b) Check and adjust the
b) High gland steam gland steam pressure
pressure. controller.
c) Check the GSC.

c) Lake of performance of
GSC. d) Operate the purifier.
d) No operation of the
purifier.
8) Low lube oil a) High DP in filters. a) Change over the oil
pressure. b) Oil leakage. filters or elements.
b) Check the oil points
of lube oil, control oil
and trip oil.

9) Un stable inlet a) Stick the governor a) Check the grease cup,

pressure. valves. if needed add the
grease.
 Over haul and
inspect the governor
valve linkage.
b) Check the pressure
b) Error in pressure transmitter.
transmitter.
10) Low generation a) Scale deposit on the a) Remove the scale and
output. nozzle and the blades if analyze it.
the turbine. b) Check the vacuum
b) Low vacuum. system.
c) High frequency in the c) Wait until the grid
grid frequency will low.
 CHAPTER – 6
OVER HAULING OF TURBINE
6.1 OVER HAULING:
Over haul refers to the check up and inspection procedure of the turbine on the stopping
the unit. So as to ensure the available unit and increase its performance unit during operating
hours Decisions regarding over hauls are taken keeping in view, the seasons, the grid conditions,
availability of hydro power and also sometimes political conditions in the state.
They may be times when the turbine unit operates at high resistance or transient conditions
because of startups, shut downs, accidental trips or forced outages. This is period when the
turbine operates rather un-smooth and experience more years.
The overhaul was classified according to the running hours of the turbine, in to three types:
1. Minor overhaul.
2. Medium overhaul.
3. Major overhaul.
6.1.1 Minor overhaul:
This should be carried out as required, simultaneously with shut downs of other plant
components or during stand still. This is done without opening the casing and generally done to
avoid the reduction in the un- availability of turbine due to forced out ages by inspection and
servicing are preventive maintenance. Scheduled intervals for minor over hauls are of the order
of 25000 equivalent operating hours.
6.1.2Medium overhaul:
The medium over haul is a planned shutdown, which involves the inspection. Servicing
and repair of the turbine and may need the opening of casings. Conclusions drawn from long
term observation and operating experience decide the criteria for a medium over haul.
6.1.3Major overhaul:
During a major over haul all the turbine casings need to be opened through checkup of
all the parts and accessories is generally done after 50000 operating hours. This process may take
more than a month.
 6.2 THE PROBLEMS IDENTIFIED IN THE OVER HAUL PERIOD,
DATED 01-08-2012.
6.2.1 Cracks:
The cracks are occurred on the upper casing of gear box at HSS bearing housing due to
high thermal stresses as shown in the fig.19
This crack was removed by grinding with depth of 15 mm and welded by the LH 115 and LH
117 electrodes to fill the crack. As shown in the fig.20

Fig.19 Crack before welding

Fig. 20after welding

6.2.2 SCALING:
Scaling on the blades is occurred due to the impurities present in the steam and corrosion of
blades. The scaling on the blades is removed by alumina-sand blast cleaning. Alumina-sand blast
consist of Aluminum-oxide 40% and sand powder 60%. This composition forcedly jet on to the
blade. By using this process we can remove the scaling on the blades. Fig. 21 scaling on the
blades (LP stage)

Fig. 21 scaling on the blades (LP stage)

 CHAPTER – 7

TURBINE CALCULATIONS
7.1 TURBINE EFFICIENCY:
Efficiency of any plant or equipment is the ratio of output to its input expressed as
percentage; Output and input are expressed in same physical Units, The output is the electrical
energy sent out to the grid and input is the heat energy of the fuels fired in boiler. This is
normally termed as overall Station efficiency.
Thus Over all station efficiency= (Output of station/Input of station) X 100

Energy sent out (KW)

Station efficiency = ----------------------------------------------------X 100
Fuel burnt (kg) X GCV fuel (Kcal / Kg)

Efficiency by taking Heat Rate:

Heat rate is the heat input to turbine needed to produce 1Kwh of electricity. Heat rate is more
usual way of defining and expressing overall Turbo- alternator efficiency.

Heat added to steam in boiler (Kcal)

Heat Rate = ------------------------------------------------------
Electrical energy sent out (kwhr)

Thus Unit of heat rate is Kcal/Kwhr

7.2 Efficiency of 20MW steam turbine at 19.5MW load:

7.2.1Turbine efficiency by heat rate method:

Data for calculations:
Mass of steam flow (M steam) = 75 TPH
Enthalpy of super-heated steam (H steam) = 809 kcal/kg (from steam tables)
Enthalpy of feed water (h water) = 165 kcal/kg (from steam tables)

Heat added = M steam (H steam – h water)

= 75 X 1000 X (809-165)
Heat added = 48300000 kcal

48300000
So Heat rate = ----------------
19500
= 2476.92 Kcal/Kwhr
So,
Output
Turbo- alternator efficiency = ---------------
Input
(We know that, 1kWh = 860 kcal)
860
So efficiency = --------------- x 100
Heat rate
Heat rate = 2476.92 kcal/kwh
860
So efficiency = -------------- X 100
2476.92
Efficiency of turbine (η turbine) = 34.72 %
Over all station efficiency:
Energy sent out = 19,500 KWH
Fuel burnt= 16.0 MT/hr.
Calorific value of fuel = 4200 Kcal/Kg
(1KW = 860 Kcal = 3600 KJ)
Energy sent out (KW)
Over all station efficiency = --------------------------------------------------- X 100
Fuel burnt (kg) X GCV fuel (Kcal / Kg)

19500 X 860
= ----------------------------- X 100
16 x 1000 x 4500

Over all station efficiency (η overall) = 23.29 %

7.2.2 Turbine efficiency by heat loss method: (after overhaul)

Fig. 21 Line diagram of 20MW steam turbine

In this turbine, the steam is removed from the turbine at two points B and B1.It is then
fed into two open feed water heater and to dearator. The steam (at pressure 85 bars) enters the
turbine at point A. Let a small amount of Steam after partial expansion (at pressure 7.8 bars) is
drained from the turbine at point B and enter the feed water heater. Similarly, let another small
amount of steam after further expansion (at pressure 2.1 bars) is drained from the turbine at point
B1 and enter the dearator. The Remaining steam (at pressure 0.09 bars) is further expanded in
turbine, and leaves it at point C.
The steam is then condensed in the condenser. The condensate from the condenser is
pumped into the feed water heater, where it mixes up with the steam extracted from the turbine.
Let,
h1 = Enthalpy of steam entering the turbine at A ----- (809 Kcal / Kg)
h2 = Enthalpy of steam bled at B ------ (658 Kcal / Kg)
h3 = Enthalpy of steam bled at B1 ------ (644 Kcal / Kg)
h4 = Enthalpy of steam leaving the turbine at C ----- (615 Kcal / Kg)
hf2 = Enthalpy of feed water leaving the feed water heater ------ (164 Kcal / Kg)
hf3 = Enthalpy of feed water leaving the dearator ----- (150 Kcal / Kg)
hf4 = Enthalpy of feed water leaving the condenser ----- (45.71 Kcal / Kg)
m = Amount of main steam -------- 75000 kg/hr.
m1 = Amount of steam bleed at B (1st extraction) ------- 7200 kg/hr.
m2 = Amount of steam bleed at BꞋ (2st extraction) ------ 112000 kg/hr.

So the work done by the turbine:

From A-B is
W1 = m X (h1-h2)
= 75000 X (809-658)
= 11325000kcal/kg
From B-B' is
W2 = (m-m1) X (h2-h3)
= (75000-7200) X (658-644)
= 949200kcal/kg
From B'-C is
W3 = (m-m1-m2) X (h3-h4)
= (75000-7200-11200) X (644-615)
= 1641400kcal/kg
Total work done (W) = W1+W2+W3
= 11325000+949200+1641400
= 13915600kcal/kg
Total heat supplied (Q) = m X (h1-hf2)
= 75000 X (809-164)
= 48375000kcal/kg
 Heat utilized
So the efficiency of the turbine = ----------------------------
Heat supplied

13915600
= ---------------------X 100
48375000

Turbine Efficiency(η turbine) = 28.766%

Overall efficiency of the plant:

The overall efficiency (η overall) = η boiler X η turbine X η generator

Taking
The boiler efficiency is 85.00% from indirect method (ASME PTC 4.0)
The generator efficiency is 98.00%
The overall efficiency is = 0.85 X 0.28766 X 0.98 X 100
= 23.96 %

The overall efficiency(η overall)= 23.96 %

7.2.3Turbine efficiency by heat loss method: (before overhaul)

Fig. 22 Line diagram of 20MW steam turbine

In this turbine, the steam is removed from the turbine at two points B and B1.It is then
fed into two open feed water heater and to dearator. The steam (at pressure 85 bars) enters the
turbine at point A. Let a small amount of Steam after partial expansion (at pressure 7.8 bars) is
drained from the turbine at point B and enter the feed water heater. Similarly, let another small
amount of steam after further expansion (at pressure 2.1 bars) is drained from the turbine at point
B1 and enter the dearator. The Remaining steam (at pressure 0.09 bars) is further expanded in
turbine, and leaves it at point C.
The steam is then condensed in the condenser. The condensate from the condenser is
pumped into the feed water heater, where it mixes up with the steam extracted from the turbine.
Let,
h1 = Enthalpy of steam entering the turbine at A ----- (809 Kcal / Kg)
h2 = Enthalpy of steam bled at B ------ (658 Kcal / Kg)
h3 = Enthalpy of steam bled at B1 ------ (644 Kcal / Kg)
h4 = Enthalpy of steam leaving the turbine at C ----- (615 Kcal / Kg)
hf2 = Enthalpy of feed water leaving the feed water heater ------ (164 Kcal / Kg)
hf3 = Enthalpy of feed water leaving the dearator ----- (150 Kcal / Kg)
hf4 = Enthalpy of feed water leaving the condenser ----- (45.71 Kcal / Kg)
m = Amount of main steam -------- 76100 kg/hr.
m1 = Amount of steam bleed at B (1st extraction) ------- 7800 kg/hr.
m2 = Amount of steam bleed at BꞋ (2st extraction) ------ 12000 kg/hr.

So the work done by the turbine:

From A-B is
W1 = m (h1-h2)
= 76100 X (809-658)
= 11491100kcal/kg
From B-B' is
W2 = (m-m1) X (h2-h3)
= (76100-7800) X (658-644)
= 956200kcal/kg
From B'-C is
W3 = (m-m1-m2) X (h3-h4)
= (76100-7800-12000) X (644-615)
= 1635600kcal/kg

Total work done (W) = W1+W2+W3

= 11491100+956200+1635600
= 14082900kcal/kg

Total heat supplied (Q) = m X (h1-hf2)

= 76100 X (809-164)
= 49084500kcal/kg
 Heat utilized
So the efficiency of the turbine = ----------------------------
Heat supplied

= 14082900
---------------------X 100
49084500

Turbine Efficiency (η turbine)= 28.69 %

Overall efficiency of the plant:

The overall efficiency (η overall) = η boiler X η turbine X η generator

Taking
The boiler efficiency is 85.00% from indirect method (ASME PTC 4.0)
The generator efficiency is 98.00% the overall efficiency is
The overall efficiency is = 0.85 X 0.28766 X 0.98
= 23.96 %

The overall efficiency(η overall)= 23.96 %

7.3 Optimize the extraction flows to increase the efficiency:
When the extraction steam was reduced the turbine efficiency will increases due to decrease in
heat loss by the bleed. Finding the minimum extraction steam required for gain the feed water
temperature to 1650c, we can calculate the minimum steam flows as following.

Fig. 23 Line diagram of 20MW steam turbine

In this turbine, the steam is removed from the turbine at two points B and B1.It is then fed into
two open feed water heater and to de-aerator the steam (at pressure 85 bars) enters the turbine at
point A. Let a small amount of steam (say m kg) after partial expansion (at pressure 7.8 bars) be
drained from the turbine at point B and enter the feed water heater. Similarly, let another small
amount of steam (say m2 kg) after further expansion (at pressure 2.1 bars) be drained from the
turbine at point B1 and enter the de-aerator. The remaining steam equal to (1-m1-m2) kg (at
pressure 0.09 bars) is further expanded in turbine, and leaves it at point C.
The steam is then condensed in the condenser. The condensate from the condenser is
pumped into the feed water heater, where it mixes up with the steam extracted from the turbine.
Now consider 1 kg of steam entering into the turbine at A.
Note: neglecting the heat losses in line and efficiency losses of heater.
Let,
h1 = Enthalpy of steam entering the turbine at A ----- (809 Kcal / Kg)
h2 = Enthalpy of steam bled at B ------ (658 Kcal / Kg)
h3 = Enthalpy of steam bled at B1 ------ (644 Kcal / Kg)
h4 = Enthalpy of steam leaving the turbine at C ----- (615 Kcal / Kg)
hf2 = Enthalpy of feed water leaving the feed water heater ------ (164 Kcal / Kg)
hf3 = Enthalpy of feed water leaving the dearator ----- (150 Kcal / Kg)
hf4 = Enthalpy of feed water leaving the condenser ----- (45.71 Kcal / Kg)
m1 = minimum Amount of steam bled at B per kg of steam supplied, and
m2 = minimum Amount of steam bled at B1 per kg of steam supplied.

As the that heat lost by bled steam at B = Heat gained by feed water
m1 (h2-hf2) = (1-m1) (hf2-hf3)
m1h2-m1hf2 = hf2-hf3-m1hf2+m1hf3
m1 = (hf2-hf3) / (h2-hf3)
164-150
m1 = ----------------
658-150

m1 = 0.028kg/hr.
So the m1 is 0.0295kg/hr.
Similarly, heat lost by bled steam at B1 =Heat gained by feed water
m2 (h3-hf3) = (1-m1-m2) (hf3-hf4)
m2h3-m2hf3 = hf3-hf4-m1hf3+m1hf4-m2hf3+m2hf4
m2 = ((1-m1) (hf3-hf4) / (h3-hf4)
(1-0.028) X (150-45.71)
m2 = --------------------------------
(644-45.71)

m2 = 0.169kg/hr.
So the m2 is 0.169kg/hr.
We know that Amount of steam (m) of turbine is 75000 kg/hr.
So the m1 &m2 for 75000 kg/hr. steam flow is
m1 = 75000 X 0.028
= 2100 kg/hr.
m2 = 75000 X 0.169
= 12675 kg/hr.

So the work done:

From A-B is
W1 = m X (h1-h2)
=75000 X (809-658)
= 11325000kcal/kg
From B-B' is
W2 = (m-m1) X (h2-h3)
= (75000-2100) X (658-644)
= 1020600kcal/kg
From B'-C is
W3 = (m-m1-m2) X (h3-h4)
= (75000-2100-12675) X (644-615)
= 1746525kcal/kg
Total work done (W) = W1+W2+W3
= 11325000+1020600+1746525
=14092125kcal/kg
Total heat supplied (Q) = m X (h1-hf2)
= 75000 X (809-164)
= 48375000kcal/kg
 Heat utilized
So the efficiency of the turbine = ----------------------------
Heat supplied

14092125
= ------------------- X 100
48375000
= 29.131 %

Turbine Efficiency(η turbine) = 29.131%

Overall efficiency of the plant:

The overall efficiency (η overall) = η boiler X η turbine X η generator

Taking
The boiler efficiency is 85.00% from indirect method (ASME PTC 4.0).
The generator efficiency is 98.00%
The overall efficiency is = 0.85 X 0.29131 X 0.98

The overall efficiency(η overall) = 24.27 %

CONCLUSION
 CONCLUSION

In this project, the study constructional features and maintenance of steam turbine for
increasing the performance and safe running of turbine. We also studied the starting, shutdown,
overhauling, protections, troubles and their remedies.
Those are:
1. Crack was identified on the upper casing of gear box at HSS bearing housing, and removed
by grinding with depth of 15 mm and welded by the LH 115 and LH 117 electrodes to fill
the crack.
2. The scaling on the blades is removed by alumina-sand blast cleaning during overhauling
period.
3. Also thermal calculations are carried out on the turbine to know the efficiency of the turbine
by different methods and finding the actual efficiency of the turbine and overall efficiency
of the plant, before and after overhaul conditions.
4. And found that the efficiency of the turbine was increased by 0.08%, so that the overall
plant efficiency is increases 0.07%.
5. And made calculations to increase the plant overall efficiency by optimizing the extraction
steam flows.
6. And found that the efficiency of the turbine was increased by 0.361%, so that the overall
plant efficiency is increases 0.31%. But the actual efficiency of the turbine is nearly equal to
designed efficiency for satisfied extraction flows.
 BIBLIOGRAPHY

1. Steam Turbine Operation & Maintenance

- SNM manual (20MW), Nava Bharat Ventures ltd
2. Steam Turbines
- Hubert E. Collins
3. Thesis on Steam Turbines by Heinz P. Bloch, Murari Singh

4. www.power-eng.com/topics/boiler-and-steam-turbine.htm

5. en.wikipedia.org/wiki/Steam turbine

6. www.energy-tech.com › Columns