CHAPTER 7 THERMAL (STEAM) TURBINE POWER PLANT

Er. Khem Gyanwali Lecturer

1. INTRODUCTION OF STEAM POWER PLANT

A steam turbine is a mechanical device that converts thermal energy in pressurized steam into useful mechanical work. The steam turbine has a higher thermodynamic efficiency and a lower power-to-weight ratio. The steam turbine is ideal for the very large power configurations used in power stations.
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1. INTRODUCTION OF STEAM POWER PLANT

The steam turbine derives much of its better thermodynamic efficiency because of the use of multiple stages in the expansion of the steam. This results in a closer approach to the ideal reversible process. Steam turbines are made in a variety of sizes ranging from small 0.75 kW units used as mechanical drives for pumps, compressors and other shaft driven equipment, to 1,500,000kW turbines used to generate electricity. 3 Steam turbines are widely used for marine applications for vessel propulsion systems.

1. INTRODUCTION OF STEAM POWER PLANT

1. INTRODUCTION OF STEAM POWER PLANT

Power plants generate electrical power by using fuels like coal, oil or natural gas. A simple power plant consists of a boiler, turbine, condenser and a pump. Fuel, burned in the boiler and super heater, heats the water to generate steam.

1. INTRODUCTION OF STEAM POWER PLANT

The steam energy is converted mechanical work by expansion through the turbine. The expansion takes place through a series of fixed blades (nozzles) and moving blades each row of fixed blades and moving blades is called a stage. The moving blades rotate on the central turbine rotor and the fixed blades are concentrically arranged within the circular turbine casing which is substantially designed to withstand the steam pressure. On large output turbines the duty too large for one turbine and a number of turbine casing/rotor units are combined to achieve the duty. These are generally arranged on a common centre line (tandem mounted) but parallel systems can be used called cross compound systems.

1. INTRODUCTION.

The steam is then heated to a superheated state in the super heater. This steam is used to rotate the turbine which powers the generator. Electrical energy is generated when the generator windings rotate in a strong magnetic field. After the steam leaves the turbine it is cooled to its liquid state in the condenser. The liquid is pressurized by the pump prior to going back to the boiler
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1. INTRODUCTION.
A simple power plant is described by a Rankine Cycle.

2. RANKINE CYCLE
Saturated or superheated steam enters the turbine at state 1, where it expands isentropically to the exit pressure at state 2. The steam is then condensed at constant pressure and temperature to a saturated liquid, state 3. The heat removed from the steam in the condenser is typically transferred to the cooling water. The saturated liquid then flows through the pump which increases the pressure to the boiler pressure (state 4), where the water is first heated to the saturation temperature, boiled and typically superheated to state 1. Then the whole cycle is repeated. 9

2. RANKINE CYCLE
The Rankine cycle is a steam cycle for a steam plant operating under the best theoretical conditions for most efficient operation. This is an ideal imaginary cycle against which all other real steam working cycles can be compared. There will no losses of energy by radiation, leakage of steam, or frictional losses in the mechanical components. The condenser cooling will condense the steam to water with only sensible heat (saturated water). The feed pump will add no energy to the water. The chimney gases would be at the same pressure as the atmosphere.
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2. RANKINE CYCLE
Within the turbine the work done would be equal to the energy entering the turbine as steam (h1) minus the energy leaving the turbine as steam after perfect expansion (h2) this being isentropic (reversible adiabatic) i.e. (h1- h2).

The energy supplied by the steam by heat transfer from the combustion and flue gases in the furnace to the water and steam in the boiler will be the difference in the enthalpy of the steam leaving the boiler and the water entering the 11 boiler = (h1 - h3).

2. RANKINE CYCLE
The ratio output work / Input by heat transfer is the thermal efficiency of the Rankine cycle and is expressed as:
RankineThermal Ef f iciency (h1 h2 ) (h1 h3 )

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2. RANKINE CYCLE
Although the theoretical best efficiency for any cycle is the Carnot Cycle the Rankine cycle provides a more practical ideal cycle for the comparison of steam power cycles ( and similar cycles ).

The efficiencies of working steam plant are determined by use of the Rankine cycle by use of the relative efficiency or efficiency ratio as below:
Re lative efficiency Thermal efficiency of actual plant Thermal efficiency of Rankine cycle
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2. RANKINE CYCLE
The various energy streams flowing in a simple steam turbine system:

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3. STEADY FLOW.

Boiler The energy streams entering and leaving the boiler unit are as follows: F + A + hd = h1 + G + hlb Hence, F + A = G + h1 - hd + hlb Turbine The energy streams entering and leaving the turbine unit are as follows: h1 = T + h2 + hlt hence 0 = T - h1 + h2 + hlt

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3. STEADY FLOW.
Condenser Unit The energy streams entering and leaving the boiler unit are as follows: Wi + h2 = Wo + hw + hlc Hence, Wi = Wo + hw - h2 + hlc Feed Water System The energy streams entering and leaving the Feed Water System are as follows: hw + de + df = hd + hlf hence de + df = - hw + hd + hl

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3. STEADY FLOW ENERGY EQUATIONS

The four equations on the right can be arranged to give the energy equation for the whole turbine system enclosed by the outer boundary:

F A Wi de d f G T Wo hl
Therefore,

F [T (de d f )] [G A] [Wo Wi ] hl

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3. STEADY FLOW ENERGY EQUATIONS

That is ..per unit mass the of working agent (water) the energy of the fuel (F) is equal to the sum of: - the mechanical energy available from the turbine less that used to drive the pumps (T - (d e+ d f) - the energy leaving the exhaust [G - A] using the air temperature as the datum. - the energy gained by the water circulating through the condenser [W o - W i] - the energy gained by the atmosphere surrounding the plant hl

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3. STEADY FLOW ENERGY EQUATIONS

The overall thermal efficiency of a steam turbine plant can be represented by the ratio of the net mechanical energy available to the energy within the fuel supplied, as indicated in the expressions below...

Net output shaft work Energy rejected 1 o Calorific value of fuel Energy sup plied T (de d f ) F [(G A) (Wo Wi ) hl ] F
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Fig. T-s diagram of a typical Rankine cycle operating between pressures of 0.06bar and 50bar

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RANKINE CYCLE WITH SUPERHEAT

In a real power plant cycle (the name 'Rankine' cycle used only for the ideal cycle), the compression by the pump and the expansion in the turbine are not isentropic. In other words, these processes are non-reversible and entropy is increased during the two processes. This somewhat increases the power required by the pump and decreases the power generated by the turbine. In particular the efficiency of the steam turbine will be limited by water droplet formation. As the water condenses, water droplets hit the turbine blades at high speed causing pitting and erosion, gradually decreasing the life of turbine blades and efficiency of the turbine. The easiest way to overcome this problem is by superheating the steam. On the Ts diagram below, state 3 is above a two phase region of steam and water so after expansion the steam will be very wet. By superheating, state 3 will move to the right of the diagram and 21 hence produce a drier steam after expansion.

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Fig. Rankine cycle with superheat

RANKINE CYCLE WITH REHEAT

The aim in reheating the cycle is to get rid of the moisture that the steam has at the final stages of the expansion process, basically lack of material that are resistant to such high temperatures. In this variation, two turbines work in series. The first accepts vapor from the boiler at high pressure. After the vapor has passed through the first turbine, it re-enters the boiler and is reheated before passing through a second, lower pressure turbine. The reheat temperatures are extremely close the inlet temperatures, if not equal, whereas the optimum reheat pressure needed is only one fourth of the original boiler pressure. Among other advantages, this prevents the vapor from condensing during its expansion which can seriously damage the turbine blades, and improves the efficiency of the cycle, as more of the heat flow into the cycle occurs at higher temperature. 23

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Fig. Rankine cycle with reheat

REGENERATIVE RANKINE CYCLE

The regenerative Rankine cycle is so named because after emerging from the condenser (possibly as a subcooled liquid) the working fluid is heated by steam tapped from the hot portion of the cycle. On the diagram shown, the fluid at 2 is mixed with the fluid at 4 (both at the same pressure) to end up with the saturated liquid at 7. This is called "direct contact heating". The Regenerative Rankine cycle (with minor variants) is commonly used in real power stations. Another variation is where bleed steam from between turbine stages is sent to feedwater heaters to preheat the water on its way from the condenser to the boiler. These heaters do not mix the input steam and condensate, function as an ordinary tubular heat exchanger, and are named "closed feedwater heaters". The regenerative features here effectively raise the nominal cycle heat input temperature, by reducing the addition of heat from the boiler/fuel source at the relatively low feedwater temperatures that would exist without regenerative feedwater heating. This improves the efficiency of the cycle, as more of the heat flow into the cycle occurs at higher temperature. This process ensures cycle economy. 25

STEAM TURBINE
A steam turbine is a device that extracts thermal energy from pressurized steam and uses it to do mechanical work on a rotating output shaft. Its modern manifestation was invented by Sir Charles Parsons in 1884 Because the turbine generates rotary motion, it is particularly suited to be used to drive an electrical generator about 90% of all electricity generation in the United States (1996) is by use of steam turbines. The steam turbine is a form of heat engine that derives much of its improvement in thermodynamic efficiency through the use of multiple stages in the expansion of the steam, which results in a closer approach to the ideal reversible process.

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CLASSIFICATION OF STEAM TURBINES

Steam supply and exhaust conditions Condensing Non-condensing Reheat Extraction Induction.

Casing or shaft arrangements Single casing Tandem compound Cross compound turbines.
Action of steam Impulse turbine Reaction turbine

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STEAM SUPPLY AND EXHAUST CONDITIONS

These types include condensing, non-condensing, reheat, extraction and induction. Condensing turbines are most commonly found in electrical power plants. These turbines exhaust steam in a partially condensed state, typically of a quality near 90%, at a pressure well below atmospheric to a condenser. 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. These are commonly found at refineries, district heating units, pulp and paper plants, and desalination facilities where large amounts of low pressure process steam are available.

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STEAM SUPPLY AND EXHAUST CONDITIONS

Reheat turbines are also used almost exclusively in electrical power plants. 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. Extracting type turbines are common in all applications. 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 heaters to improve overall cycle efficiency. Extraction flows may be controlled with a valve, or left uncontrolled. Induction turbines introduce low pressure steam at an 30 intermediate stage to produce additional power.

CASING OR SHAFT ARRANGEMENTS

These arrangements include single casing, tandem compound and cross compound turbines. Single casing units are the most basic style where a single casing and shaft are coupled to a generator. Tandem compound are used where two or more casings are directly coupled together to drive a single generator. A cross compound turbine arrangement features two or more shafts not in line driving two or more generators that often operate at different speeds. A cross compound turbine is typically used for many large applications.
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IMPULSE TURBINES
An impulse turbine has fixed nozzles that orient the steam flow into high speed jets. These jets contain significant kinetic energy, which is converted into shaft rotation by the bucket-like shaped rotor blades, as the steam jet changes direction. A pressure drop occurs across only the stationary blades, with a net increase in steam velocity across the stage. As the steam flows through the nozzle its pressure falls from inlet pressure to the exit pressure (atmospheric pressure, or more usually, the condenser vacuum). Due to this high ratio of expansion of steam, the steam leaves the nozzle with a very high velocity. The steam leaving the moving blades has a large portion of the maximum velocity of the steam when leaving the nozzle. The loss of energy due to this higher exit velocity is commonly called the carry over velocity or leaving loss.

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REACTION TURBINES
In the reaction turbine, the rotor blades themselves are arranged to form convergent nozzles. This type of turbine makes use of the reaction force produced as the steam accelerates through the nozzles formed by the rotor. Steam is directed onto the rotor by the fixed vanes of the stator. It leaves the stator as a jet that fills the entire circumference of the rotor. The steam then changes direction and increases its speed relative to the speed of the blades. A pressure drop occurs across both the stator and the rotor, with steam accelerating through the stator and decelerating through the rotor, with no net change in steam velocity across the stage but with a decrease in both pressure and temperature, reflecting the work performed in the driving of the rotor.

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COMPOUNDING OF STEAM TURBINES

Compounding of steam turbines is the method in which energy from the steam is extracted in a number of stages rather than a single stage in a turbine. A compounded steam turbine has multiple stages i.e. it has more than one set of nozzles and rotors, in series, keyed to the shaft or fixed to the casing, so that either the steam pressure or the jet velocity is absorbed by the turbine in number of stages.

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STEAM TURBINE GOVERNING

Steam turbine governing is the procedure of controlling the flow rate of steam into a steam turbine so as to maintain its speed of rotation as constant. The variation in load during the operation of a steam turbine can have a significant impact on its performance. In a practical situation the load frequently varies from the designed or economic load and thus there always exists a considerable deviation from the desired performance of the turbine. The primary objective in the steam turbine operation is to maintain a constant speed of rotation irrespective of the varying load. This can be achieved by means of governing in a steam turbine.
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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.

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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.

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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 figure.

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LUBRICATION IN STEAM TURBINE

Turbine oils are subjected to a wide range of conditions extreme heat, entrained air, moisture, contamination by dirt and debris, inadvertent mixing with different oil, etc. - that degrade the integrity of the hydrocarbon base stock and deplete the additive chemistries, causing irreversible molecular changes. There are two primary degradation mechanisms in turbine applications - oxidation and thermal degradation.

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ADVANTAGES AND DISADVANTAGES OF THERMAL POWER PLANT

A generating station which converts heat energy of coal combustion in to electrical energy is known as Thermal power plant or Steam power plant. Some of its advantages and disadvantages are given below. Advantages The fuel used is quite cheap. Less initial cost as compared to other generating plants. It can be installed at any place irrespective of the existence of coal. The coal can be transported to the site of the plant by rail or road. It require less space as compared to Hydro power plants. Cost of generation is less than that of diesel power plants.

Disadvantages It pollutes the atmosphere due to production of large amount of smoke and fumes. It is costlier in running cost as compared to Hydro electric plants.

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