Steam Turbine

Introduction

A steam turbine is a mechanical device that

extracts thermal energy from pressurized
steam, and converts it into useful mechanical
work. Steam turbine uses expanding steam to
drive a rotating wheel with a power shaft. The
driving fluid is always steam. This makes design
of steam turbine considerably accurate,
because the properties of steam are known at
all applicable pressures and temperatures.
 Cont’d

Steam turbine can be run at different speed to suit the

system load. This means energy saving in some
applications which is not possible with motor driven
machine running at constant speed.

The plants where steam is generated as an integral part

of process, the supply of steam is considered very
reliable and is not subject to power failure,
interruption or transmission problems. Steam
turbines are chosen to drive the most critical items
of the plant. Process steam balances are to be
considered to make a process more energy efficient
 Uses

Turbine generates rotary motion and it is particularly

suited for drive applications that include centrifugal
pumps, compressors, ship propellers, and, most
important, electric generators.

About 86% of the world's electricity is generated using

steam turbines.
 Design Standards
Process industries use steam turbines designed as per
API standards

API standard 611: General purpose steam turbines for

refinery services
Steam pressure < 600 psig, 750oF,
speed < 6000 rpm, used in non-critical service

API standard 612: Special purpose steam turbines for

refinery services
Horizontal turbines, relatively large, used in critical
services
Typical simple mechanical-drive steam turbine
The essential parts for all steam turbines regardless of rating or
complexity are as follows:

(1) Casing, or shell, usually divided at the horizontal center line, with
the halves bolted together for ease of assembly and disassembly; it
contains the stationary blade system;
(2) Rotor carrying the moving buckets (blades or vanes) either on
wheels or drums, with bearing journals on the ends of the rotor;
(3) Set of bearings attached to the casing to support the shaft;
(4) Governor and valve system for regulating the speed and power of
the turbine by controlling the steam flow, and an oil system for
lubrication of the bearings and, on all but the smallest machines, for
operating the control valves by a relay system connected with the
governor;
(5) Coupling to connect with the driven machine; and
(6) Pipe connections to the steam supply at the inlet and to an exhaust
system at the outlet of the casing or shell.
Cutaway of small, single-stage steam turbine.
A rotor of a modern steam turbine, used in a power plant.
 Types of Turbines
Steam turbines are made in a variety of sizes ranging
from rare 1 hp (0.75 kW) units used as mechanical
drives for pumps, compressors and other shaft
driven equipment, to 2,000,000 hp (1,500,000 kW)
turbines used to generate electricity.

Steam turbines are classified

(1) by mechanical arrangement, as single-casing, cross-
compound (more than one shaft side by side), or
tandem-compound (more than one casing with a
single shaft);
(2) by steam flow direction (axial for most, but radial
for a few);
(3) by steam cycle, whether condensing, non-condensing,
automatic extraction, reheat, and
(4) by number of exhaust flows of a condensing unit, as
single, double, triple flow, and so on.
 Cont’d
Two basic types of turbines are:
1) Impulse turbine and
2) Reaction turbine

Turbine is a machine for generating

rotary mechanical power from
the energy in a stream of fluid.
The energy, originally in the form
of head or pressure energy, is
converted to velocity energy by
passing through a system of
stationary and moving blades in
the turbine. Changes in the
magnitude and direction of the
fluid velocity are made to cause
tangential forces on the rotating
blades, producing mechanical
power via the turning rotor. Turbine principles. (a) Impulse.
Turbines affect the conversion (b) Reaction.
of fluid to mechanical energy
through the principles of impulse,
reaction, or a mixture of the two.
 Impulse turbine
A turbine in which fluid is deflected without a pressure
drop in the blade passages.
A turbine is a power-producing machine fitted with
shaft-mounted wheels.
Turbine blades, attached to the wheels' periphery, are
driven by the through-flow of steam. The rotary
motion of the wheel is maintained by forces imparted
to the blades by the impingement against them of
high-speed steam.
Before the steam reaches the moving turbine blades, it
is accelerated in stationary passages called fixed
nozzles.
The nozzles are shaped to convert mechanical or
thermal energy of the fluid into kinetic energy; that
is, the nozzles increase the fluid's velocity while
decreasing its pressure and temperature.
Upon leaving the nozzles the high-speed fluid strikes
the moving blades, and a force is imparted to the
blades as the fluid is deflected by them.
 Cont’d
A pressure drop occurs in the nozzle. The pressure is
the same when the steam enters the blade as it
leaves the blade.

The steam leaving the moving blades still retains a large

portion of the velocity it had after leaving the nozzle.
The loss of energy due to this higher exit velocity is
commonly called the "carry over velocity" or "leaving
loss." In impulse turbines, steam expansion only
happens at nozzles.
 Reaction Turbine

If the fluid's deflection in the blade passage is

accompanied by a pressure drop and a relative
velocity rise, the turbine is called a reaction turbine.

In reaction turbines, nozzles are mounted on the moving

element. The rotor is turned by the reaction of the
issuing fluid jet.
 Basic difference betn Impulse & Reaction Turbines

All turbines contain nozzles; the

distinction between the impulse and
reaction principles rests in the fact
that impulse turbines use only
stationary nozzles, while reaction
turbines must incorporate moving
nozzles.
 Types based on stages and steam path arrangements

Based on Stages
Single stage and multi-stage steam turbines

Based on steam path arrangement

1) Non-condensing or Backpressure turbines
2) Condensing turbines
3) Extraction turbines
4) Induction turbine
5) Reheat turbines
 Cont’d

Non-condensing/Backpressure turbine

Noncondensing or backpressure turbines are most

widely used for the processes where process steam
demands are greater than the steam required for
process drivers and when various steam levels are
required by the process. The exhaust pressure is
controlled by a regulating valve to suit the needs of
the process steam pressure. These are commonly
found at refineries, pulp and paper plants, and
desalination facilities.
 Cont’d
Condensing turbines

It is selected when steam demand for process drivers is

greater than low-pressure process steam
requirements. It is also selected when no high
pressure steam is available.
Condensing turbines are most commonly found in
electrical power plants, and marine propulsion plants.
These turbines exhaust steam in a partially
condensed state at a pressure well below
atmospheric. Condensing turbines are used for all coal
fired generating stations, all oil and gas fired steam
electric plants, all nuclear power plants.
The moisture in the last turbine stages requires more
expensive materials; otherwise erosion of the blades
becomes a major problem.
 Cont’d
Extraction turbines
This is selected when there is a demand for
intermediate pressure steam and when there is a
variation in the amount of steam required. In an
extracting turbine, some of the steam is taken from a
point of the turbine having the desired temperature
and pressure, and used for industrial process needs
or sent to boiler feed water heaters.

A one-way valve is almost always located on the

extraction piping. In the event of an emergency
turbine shutdown, pressure from the extraction line
could supply enough energy to overspeed the turbine
if there is a loss of load on the machine. The check
valve prevents this from occurring.
 Cont’d (Extraction turbine)
Two Types
Controlled type: is selected when
there are large intermediate
pressure process steam
requirements with fluctuations in
demand
Uncontrolled type: is selected when
small intermediate pressure
process steam requirements with
little change in demand.
Extraction turbines are common in
many applications, particularly in
certain manufacturing sectors such
as papermaking which require
steam at a certain pressure and
temperature.
 Cont’d

Induction turbine

It is selected when excess steam at an intermediate

pressure is available.

Induction turbines introduce intermediate pressure

steam at an intermediate stage to produce additional
power
 Cont’d

Reheat turbine

In a reheat turbine, steam flow exits from a high

pressure section of the turbine and is returned to
the boiler where it is further superheated. The steam
then goes back into an intermediate pressure section
of the turbine and continues its expansion. Virtually
all reheat turbines are also classed as condensing
turbines.

Reheat turbines are also used almost exclusively in

electrical power plants.
Installation of different turbines
Cont’d
 Turbine Classification based on Casing or shaft
arrangement

3 arrangements
1. Single casing
2. Tandem compound and
3. Cross compounded turbines
1. Single casing is the most basic
arrangement where a single
casing and shaft are coupled to a
load.
2. Tandem compounding is used
where two or more casings are
directly coupled together to drive a
single load on one shaft.
3. A cross compounded turbine
arrangement features two or more
shafts driving two or more loads
that may operate at different
speeds.
 Advantages of non-condensing turbine

Advantages
Back-pressure turbines are most frequently selected
Lower capital cost
Most suitable for high speed operation
Simple construction
More reliable
Disadvantages
Blade excitation may be a chance
 Advantages & disadvantages of condensing turbine
Advantages
Different turbine loads demand less change in live steam supply
Easier to control
Less steam requirements, since enthalpy drop is high
Disadvantages
High capital cost due to its large size
Additional cost for condenser, ejector, extraction pump and other
auxiliaries
Lower overall reliability in operation
Due to its large structure, it requires larger blades
High operating cost (2/3 of the enthalpy is used to heat up the
cooling water in condenser)
Expensive polishing of boiler feed water is required (chlorides,
salts, silicates deposition may lead to premature blade failure)
Erosion of blade due to presence of water droplet in condensing
steam
 Advantages of Extraction and Induction turbines

Process steam can be supplied at two or more pressure

levels without extra boiler
Process steam requirements can be controlled at a
suitable pressure and volume required by the process
Easier steam balance by using these turbines
Flexibility of operation under changing plant load

Rule of thumb: Select an extraction turbine when 15-

20% of the driver power requirements can be
supplied by the extracted steam
 Disadvantages of extraction & induction turbines

Turbine blade excitation from steam flow through

intermediate nozzle may cause premature blade
failure
Excess extraction may cause starving in parts of
turbine causing overheating
Extra valves are required to control intermediate
pressure
Extra nozzles require longer turbine shaft may cause
vibration problems at critical speed
These turbines are 5% less efficient than back-
pressure turbine
 Major considerations for selecting a turbine

1. Horsepower and speed of the driven machines

2. Steam P & T available or to be selected
3. Steam required by process and its T & P
4. Steam cost, stage, turbine efficiency and source of steam
5. Should feed water be heated by extracted steam?
6. Should a condensing turbine with extraction for process be
chosen?
7. Control feature: Control system, pressure control, RPM
control, Process control, tolerance of speed and pressure
variation
8. Safety considerations: Overspeed trip, low oil trip,
vibration monitor, Temperature monitor, rotor & casing
expansion etc
9. Price: Single stage-cheap, Multistage- wide range
considering efficiency
Function of different parts of turbine
 Cont’d
Nozzles and Blades

Steam enthalpy is converted into rotational energy as it

passes through a turbine stage.

A turbine stage consists of a stationary blade (or

nozzle) and a rotating blade (or bucket).

Stationary blades convert the potential energy of the

steam (temperature and pressure) into kinetic energy
(velocity) and direct the flow onto the rotating
blades.

The rotating blades convert the kinetic energy into

impulse and reaction forces caused by pressure drop,
which results in the rotation of the turbine shaft or
rotor
 Cont’d

Erosion of blades

Erosion due to moisture: The presence of water

droplets in the last stages of a turbine causes erosion
to the blades. This has led to the imposition of an
allowable limit of about 12% wetness in the exhaust
steam

Solid particle erosion: The entrainment of erosive

materials from the boiler in the steam causes wear to
the turbine blades.
 Cont’d
Bearings and Lubrication
Two types of bearings are used to support and locate
the rotors of steam turbines:

Journal bearings are used to support the weight of the

turbine rotors. A journal bearing consists of two half-
cylinders that enclose the shaft and are internally
lined with (Babbitt) a metal alloy usually consisting of
tin, copper and antimony

Thrust bearings axially locate the turbine rotors.

High-pressure oil is injected into the bearings to
provide lubrication. The oil is carefully filtered to
remove solid particles. Specially designed centrifuges
remove any water from the oil.
 Cont’d

Turning gear

Large steam turbines are equipped with "turning gear"

to slowly rotate the turbines after they have been
shut down and while they are cooling. This evens out
the temperature distribution around the turbines
 Cont’d
Vibration

The balancing of the large rotating steam turbines is a

critical component in ensuring the reliable operation of the
plant. Most large steam turbines have sensors installed to
measure the movement of the shafts in their bearings.
This condition monitoring can identify many potential
problems and allows the repair of the turbine to be
planned before the problems become serious.

Cogeneration cycles

In cogeneration cycles, steam is typically generated at a

higher temperature and pressure than required for a
particular industrial process. The steam is expanded
through a turbine to produce electricity and the resulting
extractions at the discharge are at the temperature and
pressure required by the process.
 Typical control configuration

Turbine is used to operate a mechanical load at constant speed

Mollier Diagram (Turbine Efficiency)
 Types of Impulse Turbine Staging
Impulse turbines have two types of staging:
1. Two row or Curtis Stage (Velocity compounded
stage)
Curtis stage consists of
a row of stationary nozzles, followed by
a rotating row of buckets,
a stationary row of reversing buckets, and finally
a second rotating row of buckets

2. Single row or Rateau stage (Pressure compounded

stage)
Rateau stage consists of
A stationary row of nozzles followed by
A single rotating row of buckets
 Cont’d

• Using Curtis staging makes turbine shorter lengthwise

• Rateau stage offers higher efficiency

• Single stage turbine : Generally uses a single Curtis

Stage
• Multistage turbines: Generally composed of Rateau
staging
• (NOTE: Where energy difference betn inlet-outlet
stream is very high: One or two Curtis stages are
used at inlet end, after that a reasonable number of
Rateau stages are incorporated)
Pressure-Velocity Diagram (Impulse & Reaction Turbine)
P-V Diagram for
Impulse Turbine with three Rateau stages (pressure staging)
Steam flow through impulse staging
Reaction Turbine (P-V Diagram)
Safety Systems of Turbines
 Cont’d
Master safety element: Steam supply valve
(Block Valve or Throttling Valve is used)

Safety interlocks consist of

1. Oil failure
2. Bearing Temperature
3. Over speed and
4. Vibration

Oil Failure
It is generally monitored by pressure switch in pressure
lubrication system or by a level switch in non-pressure
system
Any anomaly between the set value and process value will
cause the turbine shutoff valve to close
 Cont’d
Overspeed
Measured by
Centrifugal switches
Electronic tachometer
Strain detecting device
Causes: Sudden loss of load causes the turbine and its
driven load to overspeed

Bearing Temperature
Indicates proper lubrication & Deterioration in bearing
Sudden temperature rise in bearing indicates ‘Incipient
Failure’
 Cont’d

Vibration
Stationary vibration monitoring system: It consists of
Accelerometers/proximity sensors set radially and
axially.
 Speed Governor
Speed Control by GOVERNOR
(Mechanical, hydraulic and electric)

All type Governors include some means of operating a

pilot valve, which controls the turbine inlet valve in
response to Shaft Speed.
Flyball Governor (Mechanical)
Basic Droop Governor (Me-Hydraulic)
NEMA Classification of Steam Turbine Governor
Cont’d
 Cont’d

Normal applies to the conditions at which the equipment

will usually operate, such as power, speed, and steam
conditions. This is the point at which the highest
efficiency is desired

Rated applies to the greatest turbine power specified

and the corresponding speed.

The maximum operating speed and power at which

turbine is designed
 Steam Turbine Specification

Indicate clearly both inlet & outlet steam conditions

Range of steam P & T expected must be given with an

indication of which steam conditions should be used
for design
 TECHNICAL SPECIFICATION OF 210 MW STEAM TURBINE
SL.NO DESCRIPTION PARAMETER

1 RATED CAPACITY 210 MW

2 PRESSURE AT STOP VALVE 150 KG/CM2
3 TEMPERATURE AT STOP VALVE 535 C
4 MAX. STEAM FLOW AT S.V 641 TONNES /HR
5 REHEAT/NON REHEAT REHEAT
6 TYPE OF GOVERNING THROTLLE CONTROL
7 TURBINE SPEED 3000 RPM
8 EXHAUST PRESSURE 76 MM HG.ABS
H.P-1,DOUBLE FLOW IP-
9 NUMBER OF CYLINDERS 1,DOUBLE FLOW LP-1
HP-25, IP-20 +20,LP-
10 NUMBER OF STAGES 8+8
11 HEIGHT OF LAST STAGE BLADE 676 MM
12 LAST STEAGE MEAN DIA 2132 MM
-DOUBLE SHELL HP
13 SPECIAL FEATURE WITH BARREL TYPE
OUTER SHELL - DOUBLE
SHELL DOUBLE FLOW IP
- HYDRAULIC BARRING
- ELECTRO-HYDRAULIC
GOVERNING
14 WEIGHT OF TURBINE 425 TONNES
15 LENGTH OF TURBINE 14.1 METERS
16 TYPE OF TURBINE REACTION
17 COLLABORATOR SIEMENS, GERMANY