Professional Documents
Culture Documents
Brajbhushan MISHRA
Steam Turbine Engineering & KWU Business Development
15/05/2008
POWER SERVICE
STEAM TURBINES
GENERATOR TURBINE
INTRODUCTION:
The Steam Turbine is governed by
following laws:
• The law of Conservation of Mass
• The law of Conservation of Energy
• The law of Conservation of Momentum
• Euler’s Turbine Equation
Steam Inlet
Steam Expansion
Steam flows in only one direction parallel to the axis of the turbine.
Steam Inlet
Steam Expansion
Steam flows parallel to the axis of the turbine and in two opposite directions. Axial
forces developed due to steam flow are counter balanced.
Steam Inlet
Steam
Expansion
Steam
Expansion
Vertically down
condensing type
To condenser
Axial condensing
To condenser type
• With the condensing turbine, the steam exhausts to the condenser and the latent
heat of the steam is transferred to the cooling water. The condensed steam is
returned to the boiler as feed-water.
Steam Turbines Introduction - 31/07/2008 - P 20
© ALSTOM 2007. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change
without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction,
use or disclosure to third parties, without express written authority, is strictly prohibited.
STEAM TURBINES - Back Pressure turbine
• Back-pressure turbines are often used in industrial plants, the turbine acts as a reducing
station between boiler and process steam header. The process steam pressure is kept
constant and the generator output depends on the demand for process steam.
Steam Turbines Introduction - 31/07/2008 - P 21
© ALSTOM 2007. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change
without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction,
use or disclosure to third parties, without express written authority, is strictly prohibited.
STEAM TURBINES - Reheat turbine
• In the Reheat cycle, steam at a given initial temperature is partially expanded through the turbine
(process C-D) doing some some work, and then is fed back to the boiler, where it is reheated to about
original temperature (process D-E). The heated steam is then fed through the remainder of the turbine
before being condensed (process E-F).
• In a reheat cycle, cycle heat input is increased and hence increase in thermal efficiency. But this
increases capital overlay in terms of re-heater pipe-work to, from and within boiler.
• In the Regenerative cycle, steam from different stages of turbine are bled and used for
heating the feed water. There will be a small loss of work available from the bled steam not
expanding in the turbine; however, this loss is out-weighed by the gain in cycle efficiency.
• In a Single Stage turbine, steam is expanded in only one stage. Generally these
turbines are of Impulse type with exhaust pressure higher than the atmospheric
pressure.
• In this type of turbines, steam is allowed to pass through a series of fixed and moving
blades. Total heat drop in the turbine is the sum of heat drop in each stage. They can
be of Back pressure type or Condensing type.
• In a Single cylinder turbine, entire action of steam takes place in only one cylinder.
They can be either Single Stage or Multistage turbines.
• In this type of turbines, steam is allowed to pass through two or more cylinders.
These turbines are of higher capacity and most of the time Re-heat type.
Velocity Compounding:
This is achieved by alternate rows of fixed blades and moving blades.
• The high velocity steam leaving the nozzle passes on to the first stage
moving blade suffers a partial velocity drop.
• Direction of this steam is then corrected by the next rows of fixed blades
and then the same is entered in next row of moving blade where again
the velocity reduces partially.
• Hence, only part of the velocity of the steam is used up in each row of
moving blades.
Pressure Compounding:
This is achieved by an alternate rows of nozzles and moving blades.
• The steam enters the first row of nozzles where it suffers a partial drop of
pr. and in lieu of that its velocity gets increased.
• The high velocity steam passes on to the first row of moving blades
where its velocity is reduced partially.
• Similarly again a pressure drop occurs in second stage nozzle and with increased
velocity steam enters in second stage moving blades where again the velocity is
reduced .
• Thus pressure drop (partial) takes place in successive stages, the increase in
velocities are not so high resulting in slow speed rise of turbine.
T
Evaporation phase –
E absorbs latent heat
M
P
Liquid phase. Sp heat ≈ 1 kcal/kg
Enthalpy
♦ The specific heat of water and steam & latent heat changes with
pressure. See next graph.
♦ Evaporation takes place in furnace, boiler bank (where present),
evaporation of water in spray type attemperator and at times even
in economiser , if economiser is steaming.
♦ Superheat or reheat is heating in vapour phase in Superheater &
reheater.
♦ Heating in liquid phase takes place in economiser (where installed).
Evaporation phase
T
E
M Vapour
Pr = Hi
P (Superheat)
phase.
Pr = Med
Pr = Low
Liquid phase.
Enthalpy
However, with increase in initial steam pr. at constant temp. & constant
condenser pr., wetness of steam in the last stages of turbine increases, thereby
internal efficiency of these stages decreases. Usually 1% moisture increase in
steam in a particular stage results in 0.9% to 1.2% decrease in turbine internal
efficiency and also the erosion becomes so severe that life of the turbine is
endangered.
In light of above considerations, lower initial steam pr. are used for smaller
turbines (simple design, quicker start up) and higher steam pr. for larger
turbine (higher efficiency).
Above 5400 C temp., austenitic steels could be used, which have higher co-
efficient of thermal expansion & lower thermal conductivity but due to poor
machineability and weldability as compared to ferrite steel, austenitic steel is
not preferred.
Hence, the steam after partial expansion is usually re-heated to initial steam
temp. at pr. 0.15 to 0.30 times initial pr. Absolute increase in thermal cycle
and thermal plant efficiency by re-heating is approx. 1.5% to 2%.
• Usually feed water is heated to 0.55 to 0.75 times saturation temp. in series
of heaters. As a consequence of steam extraction for feed water heating,
increased steam flow through turbine is required to generate the same power.
• This makes regenerative feed water heating even more attractive to the
following reasons:
Turbine Losses:
Losses in turbine can be divided in two groups:
Internal:
Frictional loss, loss due to leakage (heat loss), Leaving/ residual losses.
External:
Bearing friction losses, Auxiliaries drive power losses, radiation losses.
) Rotor
) Casing
) Moving blades
) Guide Blades / Nozzles/ Diaphragms
) Blading Materials
) Steam Sealing Arrangement
) Bearings & Bearing Pedestals
) Control and Stop Valves
) Auxiliary systems like Lube oil System, C & I, Gland Seal system,
Governing System etc.
Front Rear
Over-speed Trip Journal Journal
assembly
) Built-up rotor
) Forged disc rotor
) Combined rotor
) Drum type rotor
) Welded rotor
Built-up Rotor
Rotors are built up with shrunk on discs. Such rotors are simpler in manufacture,
but can operate only at moderate temperatures of steam. At high temperatures of
steam, stress relaxation can result in loosening of disc fastening on the rotor.
Example for such rotor: 200 MW LP Turbine Rotor of LMZ design
In Forged disc rotors, the discs and shaft are machined from a single forging, and
therefore , loosening of discs on the rotor in turbine operation is improbable. The
diameter of the forged rotors is limited, since it is is difficult to make large size
forging of sufficiently high quality. Machining of forged rotors is more intricate and
time consuming.
Example of such rotor: 200 MW HP turbine rotor of LMZ design.
Combined type of rotors are employed in steam turbines where the temperature of
steam can vary within wide range in a single cylinder.
Example of such rotor: 200 MW IP turbine rotor of LMZ design.
Drum type rotors are used in HP and IP cylinders of reaction type steam turbines. In
most of the cases, the rotor is a single forgings. However, in some cases, they are
made by welding together a number of small sizes forging. In this type of rotors,
blades are mounted on the rotor directly.
Example of such rotor: 140 MW HP & IP turbine rotors of CEM design.
• Couplings are essentially devices for transmitting torque but they may
also have to allow relative angular misalignment, transmit axial thrust
and ensure axial location or allow relative axial movement.
COUPLINGS
• Convert Kinetic Energy and or Heat Energy of steam into Mechanical Work.
• Considered as the “Heart” of the turbine.
• In an Impulse turbine, no heat drop occurs in moving blades. However, heat drop
do occur in the case of Reaction turbine whose extent depends on Degree of
reaction.
• Size of the moving blades increases from HP turbine to LP turbine to
accommodate expanding steam. The length of the last stage blade in LP turbine is
a limiting factor for size of the LP turbine and hence the output.
AIRFOIL SECTION
PRESSURE SIDE
SUCTION SIDE
PROFILE LENGTH
PITCH
ROOT
TANG SHOULDER
NECK
Steam Turbines Introduction - 31/07/2008 - P 70
© ALSTOM 2007. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change
without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction,
use or disclosure to third parties, without express written authority, is strictly prohibited.
STEAM TURBINES - Moving Blades
Moving Blade Nomenclature
Based on Working Principle Based on type of Profile Based on type of Root Based on type of Shroud Based on on direction of rotation
Impulse Blade Constant Profile "T" Root Separately Shrouded Right Hand
Free Standing
Stradle Root
Serrated Root
Serrated Root
Steam Turbines Introduction - 31/07/2008 - P 75
© ALSTOM 2007. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change
without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction,
use or disclosure to third parties, without express written authority, is strictly prohibited.
STEAM TURBINES - Moving Blades Roots
Classification based on type of Root
Fork Root
Blade with separate Shroud Blade with integral Shroud Free standing Blade
Blading Materials
• Shrouds
• Rivet pins
• Setting Springs
• Locking Piece
• Spacers
• Lacing Wires/ Damping wires
Setting Springs
• Used for providing necessary tightness during
blading.
Setting Spring
• They are placed below the blades.
Spacers
• Used for maintaining proper gap (pitch)
Spacer between two adjacent blades.
• Generally they are buried in the blade grooves.
• They can be manufactured with material
different than that for blades.
The nozzles, of the convergent divergent type, produce very high steam kinetic
energy, some of which is absorbed in the first row of moving blades, the remainder
being deflected back by the fixed guide blades and used in the second row.
Curtis Stage :
• It is the first stage of blades used in an Impulse or Impulse-reaction turbines.
• It is an impulse stage with Velocity compounding.
• Turbines employing Nozzle Governing arrangement, have Curtis Stage as their
Regulating stage.
• Curtis stage permits the utilisation of a large heat drop in the nozzles and
consequently helps in obtaining lower temperature and pressures in the
following stages.
• The use of Curtis stage in an Impulse-Reaction turbine reduces the number of
reaction stages and hence construction of turbine becomes simple and cheap.
• Curtis stage can have either Single row or Double rows of blades. Turbines with
high initial pressures are built with double row Curtis stage.
In this design the penultimate turbine stage is divided: the steam flow through
the outer annular part of the stage is led directly to the condenser, while the
inner part flows through the final stage on its way to the condenser.
Baumann Stage :
• Baumann stage is incorporated for increasing the power output of the turbine.
• Almost 1/3rd of the entire steam flow is directed through the upper portion of
Baumann stage and exhausted directly into the condenser; bypassing the last
stage.
• The increase in power of a turbine is by a factor of 1.5
• At the same time, it reduces the efficiency of the turbine for the same exit
velocity loss.
• The two parts of the moving blade in the Baumann stage have different duties,
hence there is a discontinuity in the blade profile.
• Blades in a Baumann stage are complex in nature and thus they are difficult to
design and manufacture.
• These blade do not have good vibration characteristics.
LP Inner casing
DOWEL
DOWEL ST UD M 100 X 4-T X 930 DOWEL ST UD M 76 X 4-T X 870
ST UDS
Un-shrouded Guide
blade
A typical Diaphragm
Steam Sealing
• For minimizing the steam leakage and for maintaining the peak efficiency Sealing
systems are used.
• Generally Labyrinth seals are used where the shaft passes through the casing end
glands and diaphragms.
• Water sealing system and Carbon ring packing are also used for steam sealing in
some designs.
• Sealing materials are of relatively softer material and assembled concentric with
the turbine shaft.
• Sealing system generally comprises of gland box, leak off manifold, Gland
condenser, air ejector and condensate tank.
Steam Chest
Balancing:
Rotors are dynamically balanced to a very high degree of precision.
Anchoring:
LP Casing ( heaviest part- min. movement/ expansion) is usually anchored
to foundation. This anchoring can be done at front or rear pedestals or at
the mid point of LP Casing. Rotors are anchored at thrust bearing w.r.to
casing.
Catenary of Rotors:
Due to weight of rotor sag takes place which is compensated by bearing
alignment (coupling flanges made parallel) in the sag shape of rotors also.
210 MW LP ROTOR
LIFTING BUSH ASSEMBLY (ONLY A PART SHOWN)
The major players in Steam Turbine Manufacturing and their installed set
rating in India are given below:
The lead centers for various design turbines installed in India are as follows:
* Berlin/ Mannheim, Germany:
Berlin, Mannheim, Ansaldo (BBC License).
* Rugby, United Kingdom:
AEI, EE, GEC, GEC Alsthom, AKZ, Toshiba, Parsons, Stork.
* Belford/ Velizy, France:
Alsthom, CEM, Rateau, SACM, Soget, TWOAX
* Elblag, Poland:
Zamech, LMZ, TMZ, Ch TGZ
* Service :
- Overhauls / Inspections: Major/ Minor/ Supervisory, OEM / Third
party
* Repair :
- At site or At works - normal (regular)/ critical
* CA or RLA:
- At site or At works - normal/ regular or critical
* Spares Supply:
- Fast moving and noble parts, OEM / Third party, original drg. /
reverse engg.