Understanding a steam turbine

TURBINE

A turbine is a fluid machine which operates to convert fluid power to shaft power.

A turbine can be used either to generate power or to drive other equipments such as a compressor, pump etc.
Classification of turbine

FLUID TYPE OF TURBINE

WATER HYDRAULIC
TURBINE
STEAM STEAM TURBINE
FREON VAPOUR TURBINE
GAS/AIR GAS TURBINE
WIND WIND MILLS
Shaft power to fluid power

Fluid Type of machine

Water or other Pumps

liquids
Air & other gases Fans & Blowers

Air & other gases Blowers &

with higher pr. Compressors
Steam turbine

As the name suggests working fluid is steam.

At the inlet of the turbine condition of steam is superheated.
Thermodynamic cycle : Rankine cycle
Maximum moisture content allowed at the end of expansion is 15%.
Rankine cycle
Type of steam turbines
Impulse turbine: Nozzles are stationary & there is no pressure drop across the moving blades.
There is only one set of nozzles & complete expansion from steam chest pressure to exhaust pressure takes place
there only.
Due to very large ratio of expansion , steam leaves the nozzle at a very high velocity of about 1000m/sec.
Impulse turbine contd.

Even though rotor diameter are kept fairly small , rotational speed of the magnitude of 30000 rpm may be
obtained. For example : De-laval turbine.
This would call for very large reduction gear if turbine is to be used for power generation.
Leaving losses are also high in this case.
 Pressure compounded Impulse turbine

This arrangement amounts to splitting up of the whole pressure drop into a series smaller pressure drops across
the successive impulse stages.
The exhaust steam of first stage enters the nozzles of the succeeding impulse stage.
Each set of nozzle combined with one disc of moving blade is called a stage .
Thus rotational speed is lowered. Rateau turbine.
Velocity compounded impulse turbine.

This consists of a set of nozzles , rows of moving blades & rows of fixed blades to the casing.
The entire expansion takes place in the nozzle & the high velocity steam parts with only a portion of K.E in the
first set of moving blades & then passes to guide vanes where only change in direction takes place.
This jet then passes through another set of moving blades where further drop in K.E occurs. Kurtis turbine.
Reaction turbines

Impulse-reaction turbine : Both moving & fixed blades are nozzles. No. of moving blades fixed to shaft is equal to
no. of fixed blades to the casing.
The driving force is vector sum of impulse & reaction forces.
Steam velocity in this type is comparatively low , the maximum being about equal to blade velocity..
Steam jet does the maximum work when bucket speed is half the steam speed.
Reaction turbine contd.

Since there is a pressure drop across fixed as well as moving blades , there is a steam flow around the tip of all
fixed & moving blade. Consequently each blade has a sealing arrangement . Leakage is greatest at the initial
stages as the specific volume of steam is low.
This problem is overcome by installing an impulse stage at the inlet of the turbine.
Steam turbine components

Rotor assembly : Solid shaft of forged steel. API standards 611 & 612.
Casings : Metal to Metal horizontal split design & joint sealing. Each section of the casing is hydrostatically tested
to rigorous API standard 612 requirements.
Blades : Roots & shape are selected based on each turbine’s operating conditions. Blades are machined from
solid stainless steel bar stock in confirmation with API 612 specification.
Component Contd.

Thrust Bearing : A thrust bearing is required to firmly fix the rotor at its axial position & to withstand the coupling
thrust by load transmission. Mostly they are of double acting tilting pad design with thrust collar.
Journal Bearing : It is utilized to support the shaft.These bearings are bronze- backed & babbitt- lined for long life.
Split at horizontal center line for easy access & replacement without removing the rotor. Pressurized oil
supply is used to provide sufficient lubrication & proper cooling.
 Component Contd.

Labyrinth packing : The packing is segmented & assembled concentric to the turbine shaft & held in place by multiple
coil springs. The segmented packing design allows for movement under upset conditions maintaining the integrity
of steam path.
Governor : Self-contained governing system hydraulically powered for high output.
Governor contd.

The task of a governor is to measure the speed & compare it with set speed value & when the speed variation
occurs it gives an output signal which brings the variation back to zero or within the proportional band.
Even with a full load throw-off the governor must arrest the speed before reaching over-speed & bring it back to
rated speed.
Governor contd.

It consists of
A pressure reducer which acts as a set value input
A real set value comparator i.e the rotor which is driven by turbine rotor. This rotor controls governor output
pressure by two fly-weights supported in the radial holes.
Governor output pressure is inversely proportional to square of the speed.
 Turning gear

Basically rotor is to be turned after every shut-down, before every start-up & during the time of pre-heating the turbine.
This prevents any differential temp. in the rotor & the shaft remains straight.
The necessary power for turning the rotor is produced as pressure by a separate pump unit & transmitted to a hydraulic
motor.
 Turning gear contd.

Additionally , by the ventilation effect when turning , a uniform temp. in the casing is obtained preventing the distortion
of the casing.
If during cool-down period turning device fails , the rotor must be turned through 90 deg. every 10 minutes. Before re-
start turbine must be completely cooled down.
Over speed trip bolt
It is arranged radially in the turbine rotor in such a way that its C.G lies outside the rotor center.
It is installed in the NDE of the rotor.
In normal operating condition, at maximum rated speed trip bolt is held in position below the guide bush by the
larger spring force acting against the centrifugal force caused by eccentricity. On reaching trip speed the bolt
strikes against the catch lever of the emergency trip relay.
 Over speed bolt contd.

A shoulder in the shaft hole locates the bolt assembly with respect to the center of rotation.
The bolt assembly is held in place against the shoulder by set screws and by the unbalance loading of the bolt itself.
A shoulder in the sleeve of the bolt assembly limits the stroke of bolt.
 Component Contd.

Safety trip system

Emergency shut-down valve.
Control valves
Ejector
Condenser
Safety valve.
Condenser

Basically a heat exchanger used to extract heat from the exhaust steam.
It is of two types:
Jet condenser : steam & water is mixed. Heat is transferred by conduction. Temperature of outgoing stream is
same.
Surface condenser : No direct contact of the two streams. Condensate & cooling water streams are separately
withdrawn. Cooling water passes through tubes. Can be used as make-up water.
 Condenser contd.

Excessive cooling water flow may cause under-cooling of condensate.

Lower than optimum flow would increase back pressure.
If cooling water temp. rise remains unaffected even by abnormal opening of the valve, condenser tube plates are fouled
with debris.
 Parameters monitored

Steam temp. & pressure : Maximum temp. limit is

566 degC. Above this creep strength of ferritic steel
decreases sharply.
Condenser Level : High level would damage turbine &
low level detrimental for pump operation.
Speed : Under frequency harmful to the blades of the
turbine. Various stages of turbine have buckets of
different shapes, lengths & natural frequencies.
 Parameters monitored

Vacuum : Increases efficiency of the turbine. Poor vacuum could be because of

Extremely low motive steam pressure
Insufficient sealing
Leaky gland packing
Excess water level in the condenser.
Insufficient cooling water inlet temp.
 Parameters monitored

Exhaust temperature : Over temp. can damage turbine LP parts particularly during start-up when steam flow is less &
turbine tends to over-heat.
Wheel chamber pressure : Indicates salting up of turbine. If higher than recommended then
inhibits loading of turbine.
 Parameters Monitored

Oil temperature : If high then can affect bearing health adversely & if low then can lead to sluggish operation of
hydraulic actuators.
Oil tank level .
Lube oil pressure fed to the bearings.
Control oil pressure.
 Parameters Monitored

Axial displacement .
Bearing Temperature.
Bearing vibration.
Drain header temperature.
Sealing steam temperature.
Extraction pressure.
 Start-up of a steam turbine.

Warming-up of the entire loop as per the program.

Drain header system in line.
Condensate system line-up.
Lube oil & control oil system checks.
Monitoring of speed during critical speed phase.
Start-up contd.

The most important aspect of start-up is even heating of different parts of the turbine.
Design temp. of LP section is comparatively lower.
Clearance between rotor & stator is only a few mm.
Speed set point is programmed & speed is increased by governor motor & accordingly steam input to the
turbine
Vibration

Unbalance causes radial vibration at the rotational frequency. Unbalance means C.G of shaft not coinciding with
C.G of rotation.
Misalignment & defective coupling can cause axial vibration.
Shaft bow & shaft rub can cause high vibration at running speed.
Uneven deposition at the blade passage can also lead to vibration.
Efficiency of a turbine.

Stage Efficiency :
( Actual heat drop/isentropic heat drop)*100
This indicates the effectiveness of a particular stage.
Thermal Efficiency :
(power output/heat input)
power output must be converted to heat equivalent.
Another method to evaluate the performance of a
turbine is by calculating specific steam consumption.
 Steam purity

Turbine deposits can accumulate in a very short period of time when steam quality is poor.
Steam flows from inlet to outlet in a fraction of second. Consequently , deposition is shifted down-stream from the
saturation point by the high steam velocities.
 Steam purity contd.

Important parameters are PH , Silica (mainly in the form of silicates), Conductivity , Ammonia & chlorides.
Higher silica content more than 20 ppb should not be permitted as silica has a tendency to get deposited in the LP
section of the turbine & thereby reducing the efficiency.
 Steam purity contd.

Erosion at the HP end is caused by solid particles ( usually iron oxide ) present in the steam.
Erosion in the IP & LP blades is caused by wet steam. Operation below design inlet steam temp. or at low load can cause
condensation in these stages leading to erosion problems.
Steam purity contd.

The major corrodents are sodium chloride, hydroxide, sulfate & sulfides.
Iron forms intact oxide layers. The oxide layers formed by copper & its alloys are porous & leaky allowing water,
oxygen & copper ions to move to & from the metal surface.
Pitting is commonly associated with chlorides deposits & occurs on rotor , discs & buckets. It occurs in moist
oxygen laden atmosphere when turbine is out of service.
 Steam purity contd.

Ammonia is harmful for copper-based alloys used in the condenser.

Source of ammonia in steam could be either hydrazine injection in the de-aerator or morpholine injection in the pre-
boiler section.
Limit is 1ppm for cu-alloys & 1.5 ppm for others.
 Washing of turbine

Water soluble deposits can be washed off with condensate or wet steam.
Water insoluble deposits are removed mechanically by opening the turbine.
Procedure for washing :
Fill the turbine with condensate at 100degC.
Put the turbine on Turning gear.
 Washing contd.

The difference between condensate & casing temp. must not exceed 40degC.
The temp. difference between upper & lower casing to be maintained at less than 30 degC.
Condensate must not enter live steam line.
Collect sample at regular intervals to assess the effectiveness of washing.
 Washing contd.

With wet steam Turbine is to be operated at 20% of

the nominal speed. Wet steam is generally produced
by injection of condensate.
Upstream valve is throttled to the extent that
emergency stop valve & control valve are opened
fully.
Washing steam wetness : 0.90-0.95%
All casing drains should be open.
 Washing contd.

When washing isolate gland sealing steam.

Washing steam temp. not to be changed by more than 1 degC/min.
When the conductivity Approximates that of washing steam entering , washing can be stopped.
Water insoluble deposits are removed by blasting , using fly-ash.
 Servicing measures & checks

Steam quality daily

Oil quality Weekly test
Oil change Every 4-5 years normally
Filter (fouling, gasket, As required. ( Approx.
movement of switch monthly)
lever)
Oil cooler for fouling Annually
Oil pumps (gland Tighten or re-pack as
packing) when required.
Oil mist Extraction unit Change filters every 3
months.
 Servicing measures & checks

Nozzle erosion by steam weekly

Oil tank Tap off water , de-sludge
every three months.
Condensate pump :
Vibration level daily
Bearing temp.(not more daily
than 100 degC)
Motor power daily
consumption
Seal water supply Daily.
 Overhauling checks

Check the condition of rotor blades, guide blades, shrouding, rivet heads for damage, rubbing marks, salt deposits,
erosion, corrosion, cracks etc.
Steam strainer of ESV : condition of perforation.
Rotor Turning Gear : State of gear & moving parts.
 Overhauling checks contd.

Speed governor: Free movement of fly-

weights,deposits,condition of diaphragms & springs
as well as needle valve.
Excitation equipments :contacts
Gear-box: Cracks in casing. After opening the casing
correct installation of bearing & gear teeth . Check
tooth contact with transparent tape. Check the teeth
for cracks by dye-check.
 Overhauling checks contd.

Coupling : Condition of teeth, o-ring seals, sealing

surfaces & axial flexibility.
Bearings ( turbine ) : Condition of babbitt metal &
upper surface. Axial thrust bearing clearance, thrust
pads ( Individual scratches are to be removed by fine
polishing). Check the tilting edges for damage
The oil supply channels must be cleanly recessed
inside the bearing to assure free oil flow.
 Overhauling checks contd.

When assembling the tilting pads ensure that

screwed dowels used to fix the five tilting pads do not
sit tight in the pads themselves. The tilting pads must
be movable. Insertion of pads must be in the same
sequence as when dismantling.
Condenser : Inspection of tube surface , tube sheet &
tie-rod . Cleaning of tubes also to be done during
major over hauling irrespective of cleanliness
condition.
 Possible dangerous conditions

Loss of cooling water

Extremely varying live steam conditions
Bursting of steam lines
Failure of any part in the oil loop leading to oil
leakage/splash.
Extremely rough running and/or abnormal noise
development.
Fire.