General Purpose

Steam Turbines

Agenda
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Introduction

Steam Turbine classification

Steam Turbine Parts & Equipment

Governor Mechanism

Elliot Turbine

Practical Demonstration

Introduction
A prime mover in which heat energy is transformed
into mechanical energy.
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Working Principal
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out of nozzle at high speed. The jet of steam strikes the
bucket and it moves, thus converting thermal energy to
mechanical energy.
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Bernoullis principle is applied;

Pressure head + velocity head + datum = 0
(Total energy remains conservative)

Types of Steam Turbines

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Impulse Turbine

Reaction Turbine

Condensing Turbine

Non-Condensing Turbine

Extraction Turbine

Induction Turbine

Impulse Turbine
High velocity steam directed towards the buckets is an
impelling force which causes the rotor to turn. Such a turbine
is called an impulse turbine.
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In between stages pressure remains constant while the

velocity of steam drops.
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Nozzles are fitted in casing periphery which direct the steam

velocity to the rotor blades.
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Exhaust pressure is considerably higher in impulse turbines.

Relationship between pressure & velocity in impulse turbines.

Reaction Turbine
A turbine having a large portion of expansion occurring in
the buckets of the wheel.
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Buckets or guide blades are used to increase steam velocity

since they are shaped like nozzles.
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Pressure drop occurs in every row of blades either it is

stationary or rotary.
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In between stages velocity remains constant whereas

pressure drops.
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Steam exhaust pressure is considerably low in reaction

turbine.
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Guide blades are as many as rotary blades and are fitted in

casing after every row of rotary blades.
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Relationship between pressure & velocity in reaction

turbines.
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Condensing Turbine
Condenser is installed after the turbine which further lowers
the pressure of low pressure steam.
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Uses all the pressure of exhaust steam & condensate is

routed to boiler.
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Examples : TK-2502, TK-2503

Non-Condensing Turbine
It does not utilize all of the available thermal energy present
in the steam.
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Extraction Turbine
It does not utilize all of the available thermal energy present
in the steam.
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Induction Turbine
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Steam is fed into the turbine at an intermediate stage.

Classification of Impulse
Turbine
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Pressure Compounded impulse turbine

Velocity Compounded impulse turbine

Pressure Velocity Compounded impulse turbine

1) Pressure Compounded
Impulse Turbine
Expansion of steam is arranged to take place in a number of
simple impulse machines in series on the same shaft.
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Exhaust of one impulse machine enters the nozzles of next.

Whole pressure drop is divided into a number of smaller drops

and turbine is said to be pressure compounded.

No change in pressure through blades.

Nozzles are fitted in diaphragm which serve as division

between stages so that the space surrounding the moving
blades and between diaphragms is filled with steam of uniform
pressure.
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2) Velocity Compounded Impulse

Turbine

This machine consists of one set of nozzles, however, the

steam velocity is transformed into kinetic energy in 2 or more
rows of moving blades.
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Fixed or guide blades are attached to the casing between

the rows of moving blades.
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The guide blades need not extend around whole of the

circumference but only over an arc.
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Relationship b/w pressure & velocity

3) Pressure Velocity Compounded

Impulse Turbine
Pressure compounded turbine suffers from the disadvantage of
steam leakage past the diaphragm because of the large pressure
drop across them, while velocity compounded machine expands
the steam in one set of nozzles and consequently may have
excessive steam speeds. In order to overcome these problem, a
combination of these two is available.
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This turbine consists of two or more simple velocity

compounded turbines in series on the same shaft. The total
pressure is then divided between the number of sets of nozzles
fitted , and the turbine becomes pressure compounded as well as
velocity compounded.
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Relationship between pressure & velocity.

Turbine Parts & Eqpt.

1) Rotor Assembly
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Rotor assembly consists of wheels, buckets and a shaft.

Buckets are usually made separately and then mounted on the

shaft.
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On some rotors, a hot wheel is placed on the shaft and allowed

to cool. The wheel shrinks & fits on the shaft. On others, shaft and
wheel are forged as one unit.
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Build-up rotor is first made in 2 parts and then shrunk together

as one unit.
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Elliot AYR turbines are typically of build-up design where discs

are keyed and shrunk on the rotor shaft.
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Rotor assy is dynamically balanced to provide smooth operation.

2) Bearings

Straight Disc
Assy

Profile Disc
Assy

a) Journal Bearings
Self-aligning ball or roller bearings or ring lubricated sleeve
bearings with bronze and babbitt lining.
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Small turbines often use ball bearings either single or double

row, deep-groove type where end thrust is min. and double
row, angular thrust type for heavier loading.
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b) Thrust Bearings
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Main purpose is;

1) to keep rotor in an exact position in the casing.

2) to absorb any axial thrust on the rotor.
Since axial thrust is small for impulse turbines as the
pressure is equal across the rotor discs ensured by equalizing
holes, deep groove ball bearings are used. For large impulse
turbines, radial babbitt facing on journal bearings is used.

The pressure drop across the moving blades of reaction

turbines creates a heavy axial thrust in the direction of steam
flow through the turbine.
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The tilting pad Kingsbury thrust bearing is used in such

turbines.
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3) Nozzle Ring & Reversing Blade assembly

The nozzle ring is bolted to the inside of the steam end turbine
casing.
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The nozzles, located in the nozzle ring, direct the steam against
the blades on the first rotor disk.
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The reversing blade assembly is bolted to the nozzle ring.

The reversing blades reverse the steam flow as it exits the first
disk and directs the steam into the blades on the 2nd disk.
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The reversing bucket assembly is positioned by spacers and

require no further adjustment.
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1st rotor disk must be checked whenever the
rotor assy, nozzle ring or reversing blade assy
is removed or replaced. Clearance :
0.050~0.072
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4) Shaft sealing system

A pressure difference exists at many points in an average steam
turbine. Leakage of these points must be reduced since they
increase the steam consumption.
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Four methods of sealing rotating parts can be used:

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Labyrinths and Diaphragms

Packing Box

Carbon Rings

a) Labyrinths & Diaphragms

Labyrinth seal is made of soft material like brass and reduces
the space between diaphragm & shaft. Diaphragm separates the
two stages and is mounted to the casing.

Labyrinth consists of metal rings or ridges that fit close to the

shaft.
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As steam enters the seal, it forms eddies (whirlpools) in each

compartment.
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Steam pressure decreases as it passes through the

compartment. Consequently, a small amount of steam passes
between the shaft and the seal.
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b) Packing Box
Pressure at exhaust of a non-condensing turbine is greater than
the air pressure around it. Steam tends to leak from the area
where shaft extends the casing.
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Packing boxes reduce or minimize steam leakage.

Packing boxes are packed with rings of soft material.

Packing boxes are also fitted with labyrinth seals as shown

below. (Non-condensing turbine)
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The ridged of packing rings form small compartments which

resist steam flow.
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Towards the outer end of packing box, two or more leak-offs are
provided to remove steam which can be used again in a lower
pressure system or disposed of in a drain or ejector.
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These seals and leak-offs allow very little steam to leave the
casing.
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In case of condensing turbine, the exhaust steam pressure is less

than outside air pressure
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Leakage along the shaft at exhaust end allows air to enter

turbine which consequently, increase exhaust pressure.
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To avoid this, steam is injected between two sections of labyrinth

as shown.
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Air attempts to enter the exhaust through the packing box, but
flow of sealing steam prevents it.
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The portion of sealing steam flowing towards casing passes into

the exhaust and is condensed by the condenser.
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c) Carbon Rings

This packing is made of carbon rings.

Carbon rings resist steam flow from the casing. Steam leaked
through the rings may led to a lower - pressure system or a drain
by leak-off connection.
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Each carbon ring assembly consists of 3 carbon segments and

an anti-rotation stop, which are held together by a retainer spring.

Axial positioning of the carbon rings is maintained by spacer

rings which fit into the machined grooves in packing cases.
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Carbon ring packing may also be steam sealed.

Carbon ring has great anti-friction properties than the labyrinth

packing, so that the carbon ring can fit close to the shaft than the
labyrinth.
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Combination of Carbon rings and Labyrinth

High pressure end of a multi-stage turbine may use this

combination.
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The labyrinth controls the leakage from casing to the first leakoff connected to low-pressure system.
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The leakage from labyrinth to atmosphere is controlled by the

carbon rings.
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At exhaust end, packing alone is often adequate to seal this end.

4) Over-Speed Trip Mechanism

This mechanism is provided to safeguard the turbine against
overspeeding which may cause damage to the machine.
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The overspeed trip pin assembly is contained in the trip body

mounted on the turbine rotor shaft.
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When turbine speed increases above rated operating speed,

centrifugal force exerted on trip pin increases.
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When centrifugal force overcomes the force of trip pin spring,

the weighted end of pin protrudes from the trip body.
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The pin strikes the plunger assembly, forcing it against the

adjustable screw in the bottom of hand trip lever.
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The lever pivoted on a shoulder stud causes the top of lever to

move away from the resetting lever.
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This movement disengages the latch from the resetting lever

knife edge and allows the closing spring to pull the trip valve
closed.
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This stops the steam flow through the turbine.

Governors
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This device controls the speed or required rpm of the turbine.

Four different types are illustrated as under.

a)

Mechanical Governor

b)

Hydraulic Governor

c)

Oil Relay Governor

d)

Electronic Governor

a) Mechanical Governor

Fly balls are the main part of this governor.

They rotate with the shaft of the steam turbine and close or
open the main steam valve of turbine by centrifugal force.

b) Hydraulic Governor

In this mechanism, steam inlet valve is controlled by oil pressure.

An oil pump is attached with turbine shaft . The oil pressure varies with
turbine shaft rpm. As the shaft runs faster, excess oil pressure closes steam
valve and vice versa.

c) Oil Relay Governor

It covers the features of hydraulic & fly ball governor.

Oil pressure operates a piston and the spring tension keeps the piston in place
until a change in oil pressure acts on the piston.

Fly balls position the pilot valve that controls the oil flowing through the oil inlet
and the outlet of oil relay,

d) Electronic Governor

In some governors, oil relay is not operated by a set of fly balls. An electric
generator is attached to turbine shaft to adjust oil relay.
Changes in the speed of shaft change the output of electric current.
This change in electric current adjusts the pilot valve of the relay.

Steam Turbine Troubleshooting Guide

Troubleshooting guide is attached with presentation.

Practical Session on Elliot Turbine