Professional Documents
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Table of Contents
2
Dr. Hesham El-Batsh, Steam Turbines
Table of Contents-cont.
Chapter 3: Steam Turbine Accessories 80
3.1 Turbine Bearing 81
3.1.1 Journal Bearing.. 82
3.1.2 Thrust Bearing 85
3.2 Lubrication System 87
3.3 Couplings 89
3.3.1 Flexible Coupling 89
3.3.2 Solid Coupling 91
3.4 Shaft Gland Seal 93
3.5 Gland Exhaust System 101
om
3.6 Turning Gear
.c
Chapter 4: Steam Turbine Valves and Controls 107
4.1 Turbine Governing System fo 108
4.2 Steam Chest Arrangements and Construction 109
in
4.3 Turbine Controls 112
4.3.1 Turbine Control Valves 112
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in
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Chapter 1:
Thermodynamic
om
Principles
.c
fo
in
rs
ile
bo
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s:
tp
ht
5
Dr. Hesham El-Batsh, Steam Turbines
om
A system is a specified region, not necessarily of constant volume or
fixed boundaries, where transfer and conversions of energy and mass are
.c
taking place. An open system is one where energy and mass cross the
fo
boundaries of the system. A steady-state open system, also called the
in
steady-state, steady-flow (SSSF) system, is a system where mass and
rs
energy flows across its boundaries do not vary with time, and the mass
within the system remains constant.
ile
bo
Where
tp
6
Dr. Hesham El-Batsh, Steam Turbines
Figure 1.1: Schematic of a steady system with one inlet and one outlet
7
Dr. Hesham El-Batsh, Steam Turbines
Departures from the ideal situation described above are due to fluid
friction in the system, particularly the turbine, and heat transfer across
finite temperature differences in the feedwater heaters. These degrade
-
Dr. Hesham El-Batsh, Steam Turbines
Under part load conditions the steam entering the turbine is partially
throttled to reduce its flow. This has an effect on the expansion of the
steam in the turbine and ultimately on the power output per unit mass of
steam and hence the overall cycle efficiency.
9
Dr. Hesham El-Batsh, Steam Turbines
If the work input by the pump is , the heat input by the boiler
and the work output of the turbine then the efficiency of the cycle
is given by:
10
Dr. Hesham El-Batsh, Steam Turbines
The initial points are the same but additional heat is added to the
saturated steam to make it superheated. This process from Point 4 to
Point 6 is isobaric. Point 6 is further to the right of the T-s Diagram
than Point 4 was previously. Subsequent isentropic expansion in the
turbine from Point 6 to Point 7 results in less moisture in the steam at
the turbine exhaust. The efficiency of this cycle is again given by:
At high steam pressures the limiting steam temperature may still result in
steam conditions too far towards the left of the T-s Diagram. This
results in the turbine exhaust steam wetness still being too great. This
can be overcome by reheating the steam after part expansion in the
turbine. The resulting Superheated-Reheated Cycle is shown in Figure
1.3.
11
Dr. Hesham El-Batsh, Steam Turbines
Although this cycle is usually used at high pressures the basic conditions
in the figure are similar to those given previously for clarity and the
process up to Point 6 is as before. Steam expands partially in a high-
pressure (HP) turbine from Point 6 to Point 8. It is then returned to the
steam-generating unit for reheating to Point 9. It expands fully to Point
10 in a low-pressure (LP) turbine. Point 10 is further to the left of the T-
s Diagram than Point 7 previously thus demonstrating the reduction in
exhaust steam wetness.
a n
^HPturbbe d ^tpturbine is the work done in the high-pressure turbine and
a n
low-pressure turbine respectively and q h e t d q heat is the heat added
super a re
12
Dr. Hesham El-Batsh, Steam Turbines
The overall efficiency of the cycle is further improved since the average
temperature of heat addition to the cycle has been increased again. The
main purpose however is to reduce the wetness of the exhaust steam. A
third important advantage of reheating is the increased work done per
unit mass of steam. This partially compensates for the increased
complexity of the plant, as less fluid has to be circulated for a given
output.
being HBCDG. If, instead of heating the water in the boiler from G to
H, steam is extracted from the turbine, as it does work, to heat the water
to saturation, some improvement in efficiency can be obtained.
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Dr. Hesham El-Batsh, Steam Turbines
14
Dr. Hesham El-Batsh, Steam Turbines
15
Dr. Hesham El-Batsh, Steam Turbines
Figure 1.6 shows a similar cycle with again one feedwater heater. This
heater however is a surface or closed heater in which the hot steam
flows over the outside of tubes carrying the cold water. In condensing
the steam gives up its heat to the water. The fraction of extraction steam
required is again m. A heat balance in which the heat lost by the steam is
equal to the heat gained by the feedwater is:
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Dr. Hesham El-Batsh, Steam Turbines
In the ideal case the feedwater enters the heater at the same temperature
as the condensate leaving while the feedwater leaves the heater at the
same temperature as the steam entering. In reality there is a finite
terminal temperature difference at both the inlet and oudet of each
heater. Actual heaters usually have internal drain (condensate) coolers
18
Dr. Hesham El-Batsh, Steam Turbines
Feedwater Inlet
Drain Outlet
19
Dr. Hesham El-Batsh, Steam Turbines
As in the previous analysis, the flow rates of the heating steam r and of
the extraction steam n can be obtained from a heat balance on the
reheater and feedwater heater respectively. The separated water flow rate
s is simply the water fraction of the steam at the turbine exhaust. Note
that the extraction steam carries with it a certain water fraction but this
is not separated. If the steam quality at the high-pressure turbine exhaust
is x then the moisture fraction m is equal to (1 - x). The drain flows
from the separator will then be given by:
20
Dr. Hesham El-Batsh, Steam Turbines
as illustrated in Figure 1.8. In both cases a real plant would have more
heaters to increase cycle efficiency. The efficiency can be determined by
first calculating the flows to each heater as in the examples for
conventional fossil fuel fired plants.
21
Dr. Hesham El-Batsh, Steam Turbines
the bell shaped saturation line in the T-s Diagram becomes almost two
lines at right angles to one another with the right side line almost
horizontal. For steam turbines only part of the diagram is of interest.
This part is shown within the dotted lines of the figure and is commonly
known as the Mollier Diagram or Mollier Chart.
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Dr. Hesham El-Batsh, Steam Turbines
Modern steam turbines of similar size and type have very consistent
internal efficiencies usually above 80%. If the turbine steam inlet
conditions and turbine internal efficiency are known then the turbine
exhaust conditions can be determined using the above equation for
efficiency.
25
Dr. Hesham El-Batsh, Steam Turbines
26
Dr. Hesham EI-Batsh, Steam Turbines
Reference to the example in Figure 1.15 shows that, for fossil fired
boiler applications, the high-pressure cylinder is single flow and the
intermediate-pressure cylinder double flow while the two low-pressure
cylinders have a total of four flows to accommodate the increasing
steam specific volume. Water-cooled reactors however are limited by the
pressure of the reactor coolant and cannot produce steam at
temperatures higher than that of the reactor coolant. The lower-pressure
27
Dr. Hesham El-Batsh, Steam Turbines
28
Dr. Hesham El-Batsh, Steam Turbines
Where M is the mass flow rate of the steam. In order to reduce power
the obvious procedure is to reduce or throtde the steam flow by means
of a governing valve until the desired power output is obtained.
Throttling increases the pressure drop across the valve and hence
decreases the pressure immediately downstream of the valve. During
this process no heat or work transfer takes place and the enthalpy
remains constant. This constant enthalpy process is a horizontal line on
the h-s or Mollier Diagram as shown in Figure 1.16. Steam entering the
turbine is therefore at the same enthalpy but at a reduced pressure. This
shifts the turbine expansion line to the right. The pressure of the steam
leaving the turbine remains the same but the enthalpy is increased and
the moisture reduced. Overall the mass flow m is reduced significandy
and the enthalpy drop Ah reduced slighdy. Both give a reduction in
turbine power P.
29
Dr. Hesham El-Batsh, Steam Turbines
Figure 1.17: Relationship between steam pressure and steam flow and
turbine load
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Dr. Hesham El-Batsh, Steam Turbines
31
Dr. Hesham El-Batsh, Steam Turbines
Chapter (2):
Steam Turbine
Components
32
Dr. Hesham El-Batsh, Steam Turbines
Figure 2.1 illustrates a turbine with impulse blading. It has one velocity-
compounded stage (the velocity is absorbed in stages) and four pressure-
compounded stages. The velocity is reduced in two steps through the
first two rows of moving blades. In the moving blades, velocity
decreases while the pressure remains constant.
Figure 2.2 illustrates a reaction turbine. The reaction stages are preceded
by an initial velocity-compounded impulse stage where a large pressure
drop occurs. This results in a shorter and less expensive turbine.
33
Dr. Hesham El-Batsh, Steam Turbines
35
Dr. Hesham El-Batsh, Steam Turbines
In the radial flow turbines shown in figure 2.3, the steam is admitted to
the canter of the machine expanding outwards through two contra-
rotating rotor to the exhaust at the periphery.
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Dr. Hesham El-Batsh, Steam Turbines
Groups of stages within the turbine cylinder may be arranged for flow in
opposing axial directions. This arrangement is called double flow turbine
and is shown in figure 2.5b. The steam is admitted at the centre of the
cylinder and is divided to flow in opposite axial directions towards the
ends of the rotor. This arrangement is used to avoid the excessively long
blades which would be incurred by single flow arrangements. The
second benefit is that the double flow cylinder effectively reduces to
zero the axial thrust caused by the steam forces on the moving blades.
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Dr. Hesham El-Batsh, Steam Turbines
Thrust reduction is the main target for the reversed flow cylinder (figure
2.5c). Steam flows in one direction through one group of stages and
then internally or externally reversed to flow through a second group of
stages in the opposite axial direction.
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Dr. Hesham El-Batsh, Steam Turbines
The two types of steam turbines are condensing and back-pressure (non-
condensing). Figure 2.7 illustrates these types and some of their sub-
classifications. Back-pressure turbines exhaust the steam at the pressure
required by the process. Automatic extraction turbines allow part of the
steam to be withdrawn at an intermediate stage (or stages) while the
remainder of the steam is exhausted to a condenser. These turbines
require special governors and valves to maintain constant pressure of the
extraction steam while the turbine load and extraction demand are
varying. Uncontrolled extraction turbines are used to supply steam to
feedwater heaters, since the pressure at the extraction points varies with
the turbine load.
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Dr. Hesham El-Batsh, Steam Turbines
41
Dr. Hesham El-Batsh, Steam Turbines
In die normal case, steam turbines are directly coupled to the electrical
generator and there is no gearbox being used. The speed of rotation in
then given by:
The only two grid frequencies in use worldwide are 50 Hz and 60 Hz,
and the generators are usually designed with two poles or four poles.
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Dr. Hesham El-Batsh, Steam Turbines
43
Dr. Hesham El-Batsh, Steam Turbines
Most modern turbines, with steam pressures over 100 bar and ratings
greater than 100 MW have the HP casing of double-shell design. This
has been adopted because of the difficulty of designing a single casing to
withstand the thermal and pressure stresses and be capable of flexible
operation. With a double-shell casing, the space between the shells is
lifted with steam at exhaust conditions, allowing each casing to be
44
Dr. Hesham El-Batsh, Steam Turbines
45
Dr. Hesham El-Batsh, Steam Turbines
46
Dr. Hesham El-Batsh, Steam Turbines
Another casing design is shown in Figure 2.13. This also overcomes the
need for a very heavy flange in the high-pressure cylinder. Instead of
being split horizontally the entire outer casing of the high-pressure
turbine is shaped like a barrel. During assembly the inner casing is slid in
from the end and a large screwed plug fitted at the end. The inner casing
is split vertically and bolted together with long bolts through the casing
walls rather than through projecting flanges. Thermal advantages are the
same as with conventional double casings. Construction of these barrel
cylinders is simple but once in service the entire cylinder must be
removed to withdraw the inner casing before access to the rotor can be
obtained
48
Dr. Hesham El-Batsh, Steam Turbines
49
Dr. Hesham El-Batsh, Steam Turbines
50
Dr. Hesham El-Batsh, Steam Turbines
51
Dr. Hesham El-Batsh, Steam Turbines
Both of these have double casings with the exhaust steam circulating in
the annular space between the casings as in the case of the high-pressure
turbine. In addition these turbines have provision for the extraction of
some partly expanded steam for feedwater heating. The channels for this
steam are evident as annular spaces surrounding the inner casing. Steam
passes into these channels via grooves in the inner casing and passes out
via pipes above or below the turbine. In these turbines, both inner and
outer casings are split horizontally and fitted with flanges and bolts. In
double flow turbines axial thrust arising from the steam flow is balanced.
In low-pressure turbines temperatures and pressures are relatively low
and the casing is not as robust as in the high-pressure cylinders.
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Dr. Hesham El-Batsh, Steam Turbines
Both of these have double casings with the exhaust steam circulating in
the annular space between the casings as in the case of the high-pressure
turbine. In addition these turbines have provision for the extraction of
some pardy expanded steam for feedwater heating. The channels for this
steam are evident as annular spaces surrounding the inner casing. Steam
passes into these channels via grooves in the inner casing and passes out
via pipes above or below the turbine. In these turbines, both inner and
outer casings are split horizontally and fitted with flanges and bolts. In
double flow turbines axial thrust arising from the steam flow is balanced.
In low-pressure turbines temperatures and pressures are relatively low
and the casing is not as robust as in the high-pressure cylinders.
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Dr. Hesham El-Batsh, Steam Turbines
53
Dr. Hesham El-Bats h, Steam Turbines
Figure 2.18 shows a solid rotor with integral wheels machined from a
single forging. This is a development of the early solid rotors but the
excess material between the wheels has been removed to reduce the
mass and thickness of material. The shaft remains sufficientiy rigid but
the total mass is less and, more importandy, the material thickness is
substantially less. During heating, steam is able to penetrate between the
wheels and to heat them from both sides and to heat the central portion
more quickly. This minimises thermal stress while steam temperatures
are rising or falling due to changing load. Such a rotor must be machined
from a large piece of material and the machining costs are high but there
are no joints or welds to cause trouble.
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Dr. Hesham El-Batsh, Steam Turbines
55
Dr. Hesham El-Batsh, Steam Turbines
The generator rotor is the longest of the rotors making up the entire
turbine generator. A typical generator showing the rotor is illustrated in
Figure 2.22. The rotor carries the field coils, which excite the stator coils
to produce electric power. Since the field coils carry heavy currents they
must be sufficientiy robust and well cooled. The individual current
carrying bars must be well insulated and securely mounted to withstand
the centrifugal forces.
rotors. The stator is also cooled by hydrogen and often by water passing
through the wmdings as well. Electric power is produced at high voltage
and insulation must be designed accordingly.
Turbine blades are either fixed or moving and shaped so that energy
transfer is by the impulse or reaction principle. The design of the blades
is governed by the steam conditions in the turbine, the desired steam
velocities and directions and the steam forces on the blades. In addition
consideration must be given to geometrical limitations and dynamic
forces arising from the high-speed rotation of the turbine. The moving
blades in particular are subject to very high centrifugal forces and are
sensitive to vibration induced by turbine rotation and steam flow.
Turbine blades, and hence turbines having these types of blades, are
classified as impulse or reaction. When moving blades are driven entirely
by the impact of an external jet impinging upon them, they are known as
impulse blades. When the fluid in the moving blades accelerates and
leaves the blades at a higher velocity than when it entered them, it
57
Dr. Hesham El-Batsh, Steam Turbines
imparts a jet reaction to the blades making these reaction blades. With
reaction blades there is however always some impulse effect as the fluid
enters the moving blades so such blades have only a degree of reaction
which is commonly 50 percent.
In impulse turbines, the steam issues from a nozzle at high speed and
impinges upon a series of blades which are driven and so produce work.
The kinetic energy of the fluid stream is transferred to the rotating wheel
by momentum transfer within the blades. In the reaction turbine, steam
issuing from the nozzles at high velocity creates a reaction in the
opposite direction. This reaction drives the wheel and the energy of the
fluid is transferred to the rotating wheel. When the principles are
translated to large machines the mass flows become very large relative to
the machine itself and the impulse and reaction effects are very strong.
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Dr. Hesham El-Batsh, Steam Turbines
Within the moving blades the steam is turned to affect the transfer of
energy and leaves at a low velocity relative to the next row of fixed
blades.
Figure 2.23 shows four stages of fixed and moving blades of an impulse
turbine and, at the bottom, the pressure and velocity profiles over these
four stages. Since the energy in the steam is represented by the pressure
and velocity, the conversion and transfer of energy in the blading can be
visualised. Initially the pressure is high representing a high energy level.
In passing through the first row of fixed blades some potential energy is
converted into kinetic energy as indicated by the slight drop in pressure
and increase in velocity. In passing through the mating row of moving
blades the kinetic energy is transferred to the rotating wheel of the
turbine as indicated by the drop in velocity. There is no change in
pressure in the moving blades. It is evident that, at the exit from this
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Dr. Hesham El-Batsh, Steam Turbines
first stage, the steam has given up part of its initial energy and
transferred this to the rotating parts of the turbine. A similar process is
repeated in the remaining three stages. Additional stages may be added
to extract any remaining energy of the steam.
In the reaction turbine however the stage pressure drop is spread across
both the fixed and moving blades. The fixed blades act as nozzles and
accelerate the steam to a moderate velocity due to the partial pressure
drop. This steam then impinges upon the moving blades and imparts
some energy to them. Within the moving blades the steam is turned and
accelerated by the remainder of the pressure drop. The reaction effect
caused by this accelerating steam imparts more energy to the moving
blades. The steam leaves the stage at a low velocity relative to the next
row of fixed blades.
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Dr. Hesham El-Batsh, Steam Turbines
The main difference between the impulse turbine and the reaction
turbine is that, in the former, there is a pressure drop across the fixed
blades only, whereas in the latter, there is a pressure drop across both
the fixed and the moving blades. For similar boundary conditions this
7
results in a lower velocity of the steam leaving the fixed blades in the
case of the reaction turbine. This velocity leaving the fixed blades is
relative to the fixed components and is therefore described as the
absolute velocity. The velocity associated with the moving blades is
known as the relative velocity (relative to the moving blades).
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Dr. Hesham El-Batsh, Steam Turbines
In an impulse turbine the blades are symmetrical about the plane of the
turbine wheel carrying the blades whereas in a reaction turbine they are
not. Figure 25 and Figure 26 clarify the concept of flow areas and blade
symmetry. The difference between the two is easily seen when viewing
the blades from the end. In the latter figure the reduction in flow area
and consequent increase in velocity is clearly evident. On an actual
turbine rotor however the blades invariably have circumferential
shrouding over the tips and the blade profile cannot be seen. In such
cases the shape of the blade on the oudet side has to be compared with
the shape on the inlet side.
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Dr. Hesham El-Batsh, Steam Turbines
moving blades see the steam approaching them from behind at angle (p
and velocity V . This is the relative velocity relative to the moving
R1
blades. The angle at which the steam enters the moving blades is
therefore tp and the blade must be designed accordingly. Within the
moving blades the steam is turned and, according to the design of the
blade, leaves at an angle y to the plane of the wheel and with velocity
V r , . This is the relative velocity as seen by the moving blades. The
moving blades however are travelling at velocity V . Combining the
B
relative motion of the blades V and the relative velocity of the steam
B
63
Dr. Hesham El-Batsh, Steam Turbines
Since the full pressure drop occurs in the fixed blades, the velocity of the
steam leaving these blades V . The steam enters the moving blades at
B
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Dr. Hesham El-Batsh, Steam Turbines
Figure 2.29 shows the velocity diagrams for two stages of reaction
blading. This figure should be compared with Figure 2.24 which shows
the steam pressure and steam velocity profiles through similar blading.
As before, the velocity profile is that for absolute velocity. In reaction
blading the pressure drop is divided between the fixed and moving
blades of each stage. The velocity of the steam leaving the fixed blades
VS1 is therefore not as high as in impulse blading and is approximately
equal to that of the blade velocity VB. The steam enters the moving
blades at a fairly low relative velocity VR1 but, due to the changing flow
area within the blading, is accelerated to a higher relative velocity VR2.
As before, the steam enters the moving blades at angle cpl and leaves at
angle yl but yl is much less than cpl. The relative velocity VR2 is such as
to be roughly equal in magnitude to the blade velocity VB. The absolute
steam velocity VS2 at the exit is low and the steam is again discharged in
an approximately axial direction. The process is repeated in the next
stage with the steam approaching the fixed blades at low velocity. As
before, absolute velocities VS3 and VS4 and relative velocities VR3 and
VR4 are obtained.
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Dr. Hesham El-Batsh, Steam Turbines
Comparing Figure 2.28 and Figure 2.29 indicates that impulse blading
requires initial absolute steam velocities approximately double that of
reaction blading for equivalent blade velocities. Since kinetic energy is
proportional to the square of the velocity, it is evident that the steam
entering the impulse blading has about four times the energy of the
steam entering the reaction blading. Also the work done in a turbine is
proportional to the enthalpy drop across the turbine which in turn is
proportional to the square of the velocity. This indicates that in the
impulse turbine a greater energy change occurs per stage than in a
reaction turbine. This implies more work done per stage but further
analysis is required.
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Dr. Hesham El-Batsh, Steam Turbines
In reaction blading the enthalpy drop in the steam takes place across
both the fixed and moving blades. Thus some energy in the steam is
imparted to the blades by the impulse action of the steam leaving the
fixed blades, while the remaining energy is imparted to the blades by the
reaction of the steam leaving the moving blades. If the enthalpy drop is
divided equally between the fixed and moving blades, then half the
energy imparted to the moving blades is derived from the reaction of the
steam. Such blades are really only 50 percent reaction but are commonly
called reaction blades. In general all blades, which derive some energy
from the reaction of the accelerating steam within them, are known as
reaction blades.
68
Dr. Hesham EI-Batsh, Steam Turbines
At 0 percent reaction the velocity diagrams will be the same as those for
impulse blading. Practical design constraints place an upper limit on the
degree of reaction. Since the steam must be accelerated to some degree
to enter the moving blades, there is always some enthalpy drop
associated with the redirection of the steam flow leaving the fixed
blades. Therefore 100 percent reaction is not found in practice.
69
Dr. Hesham El-Batsh, Steam Turbines
It has already been seen that, as the steam expands through the turbine,
its specific volume increases enormously, particularly in the last few
stages of the turbine. This requires a large increase in flow area and
hence in blade length from the inlet to the exhaust of the low pressure
cylinders. The long moving blades near and particularly those at the
exhaust have a length which approaches the radius of the shaft on which
they are mounted. The longest blades thus have a tangential velocity
which almost doubles from the root to the tip of the blades. The value
of the blade velocity VB therefore varies along the length of the blade
and the velocity diagrams will change accordingly.
Figure 2.33 shows this variation for such a case. The three velocity
diagrams are those for the root, centre and tip of the blade. For each
location it is assumed that the steam absolute velocity VSI leaving the
fixed blades is the same and that the steam axial velocity through this
part of the turbine VA1 is the same. This makes the nozzle exit angle 6
the same for all three locations. The blade velocity VB is different for
each case and hence the relative velocity of the steam approaching the
blade and its direction are also different. This results in different values
for angle cp. At the exit of the moving blades it is assumed that the steam
axial velocity VA2 is the same at each location. To minimise the residual
kinetic energy in the steam, it is assumed that the steam absolute velocity
VS2 is a minimum thus making angle 8 equal to 90° in each case. The
blade velocity VB is different and hence the relative velocity VR2 will
also be different resulting in different values for angle y. In order to
70
Dr. Hesham El-Batsh, Steam Turbines
achieve smooth flow through the moving blades, the profile of each
blade must vary continuously over its length. This gives rise to the so
called twisted blades commonly employed in large turbines.
The blades are attached to the turbine rotors in various ways and in such
a pattern as to minimise unbalanced forces. Even with close
manufacturing tolerances there is a slight mass variation between blades.
Figure 2.34 shows a large steam turbine under construction. This turbine
has a nominal rating of 1000 MW. In the figure the lower half of a
diaphragm containing two rows of fixed blades for one low-pressure
cylinder is seen being lowered into position. Also shown are the moving
blades attached to the rotor of another low-pressure cylinder. In the
background is one complete rotor for a low-pressure turbine. It is
evident from this photograph that the fixed blades are securely fixed at
both ends in a robust diaphragm. The moving blades however are
attached only to the rotor discs and may or may not have tip shrouding
or lacing wires to increase rigidity. Both tip shrouding and lacing wires
are used in this machine and can be seen in the picture.
The design philosophy for fixed and moving blades is naturally different.
All large turbines have pressure compounded impulse blading or
reaction blading so there is a pressure drop across the fixed blading. The
blades must withstand this pressure drop and, if the design provides for
a large diaphragm, as is usually the case in low-pressure turbines, the
blades must also support the pressure difference across the diaphragm.
The blades may therefore be quite wide (as measured in the axial
direction) especially towards the outer diameter. Moving blades on the
other hand are subject to high centrifugal forces and have a slender
shape decreasing in width towards the outer diameter.
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Dr. Hesham El-Batsh, Steam Turbines
The securing of blades to the rotor is a critical design aspect for steam
turbines and different manufacturers have adopted various methods to
ensure security of the blades at high speed. The two principle methods
are grooves or pins with the former covering a wide range of designs.
The most commonly used methods will be described briefly.
Figure 2.35 shows a simple stepped blade root. Blades are inserted into a
circumferential groove in the turbine disc and slid into position. An
72
Dr. Hesham El-Batsh, Steam Turbines
73
Dr. Hesham El-Batsh, Steam Turbines
74
Dr. Hesham Ei-Batsh, Steam Turbines
The method of using pins to secure blades is shown in Figure 2.40 for
small turbines. Larger turbines with heavier blades have multiple stepped
roots with pins to distribute the stress more uniformly. The pins are
interference fits in the holes. Blades fitted by this method are relatively
75
Dr. Hesham El-Batsh. Steam Turbines
easy to install but the pins may deform slighdy in service making
removal more difficult.
76
Dr. Hesham El-Batsh, Steam Turbines
77
Dr. Hesham EI-Batsh, Steam Turbines
When steam expands below the saturation line, some condensation takes
place and the steam becomes wet. The very fine mist of droplets which
forms passes over the blading and some is deposited on the blades to
create a film of water. This film is swept off the blades and entrained by
the steam. The size of these entrained drops is governed by surface
tension effects rather than by condensation phenomena. They are
therefore somewhat larger than the original condensation droplets and
when travelling at high velocity can cause damage to any material on
which they impinge. Being larger and heavier they are also separated
from the main steam flow more easily during changes in direction. When
these larger drops are swept off the fixed blades their velocity tends to
be lower than that of the steam and the moving blades tend to run into
them at high speed. The impact of the drops on the blades (more
accurately the blades on the drops) causes material erosion from the
blades. Minute amounts of material are removed leaving a rough surface.
If severe, this material removal can change the blade profile and weaken
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Dr. Hesham El-Batsh, Steam Turbines
the blade. After impact on the moving blades the water film tends to be
thrown off towards the periphery by centrifugal action. Turbine blades
must be designed to withstand moisture erosion in the affected areas.
This is done using inserts of hard erosion resistant material such as
tungsten or by specialised heat treatment to harden the blades in selected
areas..,.
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Dr. Hesham El-Batsh, Steam Turbines
Chapter 3:
Steam Turbine
Accessories
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Dr. Hesham El-Batsh, Steam Turbines
Large steam turbines are made up of several rotating sections with each
section being coupled rigidly with the adjacent one. Normally each rotor
is mounted on a pair of journal bearings, one at each end, with the
couplings between the bearings of adjacent rotors. The bearings are
mounted on foundations to secure the rotating elements in the proper
vertical and transverse position. The bearings are supplied with
lubricating oil and the shaft rides on a hydrodynamic oil film without
metal to metal contact. When starting from rest with the oil film having
been squeezed out, there is metal to metal contact. To avoid rubbing
and scoring of the bearings, high pressure jacking oil is supplied to a
point under the shaft so as to lift the shaft off the bearings before
commencing rotation.
To secure the shaft in the proper axial position, a single thrust bearing is
provided usually close to the high-pressure turbine but always in a
location that will minimise the movement of the shaft in other parts of
the turbine due to thermal expansion. The shaft will naturally expand
outwards from the thrust bearing. The turbine casings are also fixed to
the foundations in a way that will permit free thermal expansion. These
fixing points must be positioned so as to minimise differential
movement between the casing and rotor and must maintain proper
radial alignment of the rotating parts within the fixed parts. Typical
locations of fixing points for a large turbine are shown in Figure 3.1.
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An oil-lift system (jacking oil) is needed for most large turbines to lift the
turbine and reduce the possibility of damage during start-up and
shutdown. The jacking oil system is also needed to reduce the starting
load on the turning gear. A positive-displacement pump delivers high-
pressure oil to openings in the bottom of the bearings. The high-
pressure oil lifts the shaft and floats it on an oil film until the shaft speed
is high enough to create a hydrodynamic film between the shaft and the
bearing. A phenomenon known as oil whip or oil whirl occurs in
relatively lightly loaded, high speed journal bearings. The center of the
journal (portion of the shaft inside the bearing) assumes an eccentric
position in the bearing. This position is determined by load, speed, and
oil viscosity. Since the stable position is near the center of the bearing,
the journal center starts to move in a circular path about the stable
position. The vibrations created by this motion have a frequency of less
than one-half the shaft speed.
Figure 2.1 shows a typical example for a modern steam turbine bearing.
The bearing assembly is split in halves on the horizontal centerline and
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The main oil pump is invariably driven directly from the main turbine
shaft. With older and smaller turbines it was common practice to employ
a mechanical drive directly to a pump in the oil tank. With larger
turbines however the oil tank is usually located away from hot turbine
components, such as steam pipes, to minimise the fire risk and in such a
location where any fire can be readily contained. Alternative driving
systems are therefore required. One system retains the main oil pump in
the oil tank but has an independent and un-interruptible electrical
connection between a small generator on the turbine shaft and the
motor of the pump. As the turbine runs up to speed more power is
provided to run the pump and at some intermediate turbine speed the
main oil pump output reaches the required amount.
which in turn drives the main oil pump in the oil tank. As with a solid
electrical connection, the pump operation follows that of the main
turbine.
A refinement of this method, commonly employed on large steam
turbines, is to mount the main oil pump direcdy on the turbine shaft and
to take part of the delivered oil to run a small turbine which drives a
booster oil pump in the oil tank. This booster pump provides the
necessary head to maintain the proper suction pressure at the main oil
pump.
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3.3 Couplings
The need for coupling arises from the limited length of shaft which is
possible to forge in one piece and from the frequent need to use
different materials for the various conditions of temperature and stress.
The multi-cylinder construction of large turbine-generators necessitates
the use of a coupled shaft system.
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. They may be
satisfied as flexible, semi-flexible or rigid. On smaller turbine-generators
(i.e., up to 120 MW) semi-flexible and flexible couplings were commonly
used, but for large turbine-generators it is now common practice to use
rigid couplings.
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The long shaft that is formed naturally bends under its own weight to
form a natural catenary. Because of this, the use of rigid couplings
means that the shaft alignment must be set to ensure that the coupling
bending moment forces are minimized.
Rigid couplings are either integral with shaft forging or are shrunk on to
the shaft. It is now common practice for the turbine rotors to have half
couplings. Shrunk-on couplings have been used on turbines and still are
used on the generator. They allow the couplings to be taken off for the
removal of turbine rotor discs or the generator rotor endwinding
retaining rings.
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Various types of glands have been devised but large steam turbines all
make use of the labyrinth type of seal. The distinct advantage of this
type of seal is the lack of direct mechanical contact. Under normal
circumstances this eliminates mechanical friction and wear and the build
up of heat.
In such a seal the steam is forced to find its way through an intricate
arrangement of paths between the fixed and rotating parts. Each time
the steam is made to change direction it loses energy thus increasing its
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Figure 3.10 shows some examples of labyrinth seals. A l l have a small gap
through which the steam can pass before entering a pocket where lower
flow and turbulence prevails. Early turbines tended to have both axial
and radial flows through the glands to promote changes in direction. As
turbines became larger, greater degrees of differential expansion between
the fixed and moving parts had to be accommodated and seals were
designed to rninimise the risk of interference due to axial movement of
the shaft. A high degree of machining accuracy and precise shaft
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The slender profile near the tips of the individual rings is a characteristic
of labyrinth seals. A further development is the mounting of the rings
on spring loaded segments so that, in the event of transverse movement
of the shaft, contact would move the whole segment against the pressure
of the springs. If such movement was of a short term temporary nature
only, the segment springs could absorb the movement with minimum
wear to die seal rings themselves. Seals of this type are shown in Figure
3.11. Shaft seals subject to the full steam pressure are normally made up
of a series of segments each with multiple rings whereas diaphragm seals
need only a few rings to control steam leakage.
A typical diaphragm seal is shown in Figure 3.12 and a typical shaft seal
in Figure 3.13. Both have provision for small amounts of shaft lateral
movement by the spring-mounted segments carrying the rings. They can
however accommodate only a limited degree of axial movement since
the rings are made to fit a stepped shaft, which slighdy increases the
resistance to steam flow.
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Pressure in the turbine drops from inlet to exhaust with the exhaust
being under sub-atmospheric conditions. Under these conditions, air will
leak into the turbine through the shaft seals creating difficulty in
maintaining the proper vacuum conditions. Air leaks can have an
adverse effect on the performance of the turbine and that there are
limits governing the effectiveness of air extraction systems.
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WATER C?
FROM tX}
RRW I A N K S
LIVE
STEAM SUPPT.Y
AIR 1 0
ATMOSPHERE
fans. The steam is condensed and the condensate passes to the main
condenser. A typical gland steam condenser is shown in Figure 3.18.
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disengages automatically when the torque reverses, that is, when the
speed of the output shaft exceeds that of the input shaft (Figure 3.20)
COVER
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Chapter 4:
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The steam leaving the superheater goes through the emergency stop
valves (ESVs) and associated governing valves (GVs) before entering the
high-pressure (HP) turbine. 1 The ESVs and GVs are housed in steam
chests. These steam chests are manufactured from closed-die alloy-steel
forgings welded together, or from alloy-steel castings. They also have
simple shapes. This is done to reduce the thermal stresses and hence the
possibility of thermal fatigue. Similar steam chests house the reheat
emergency stop valves (RESVs) and interceptor valves (TVs). These
steam chests are located between the reheater and the intermediate-
pressure (IP) turbines. They are manufactured from alloy-steel castings.
They are thinner but larger than the HP steam chests due to lower steam
pressures. The steam chests are normally mounted alongside the turbine.
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The four steam mains, together with four ESVs and four GVs, are
normally arranged two on each side of the turbine. Figure. 5.1 illustrates
a typical steam chest arrangement of a 660-MW unit. There is a steam
chest on each side of the machine. It has an ESV on each end and the
two GVs are connected to the common chamber between the ESVs.
The seats of the valves are of the removable-plate type. These seats are
normally screwed in place. The mating faces of the valves and their seats
are made of Stellite. This is done to resist wear caused by steam erosion.
The wear will occur mainly when the valve is cracked open. A jet is
propelled at high velocity due to the large pressure differential across the
narrow port opening. The Stellite facing also provides protection against
impact damage, which occurs during normal valve closure. It also occurs
during frequent high-speed test closures. This damage is alleviated
normally using cushioning devices in the relay system or slow-motion
testing. Specially treated alloy-steel sleeves in the valve covers support
and guide the valve spindles.
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The two purposes of the ESVs (also known as stop valves) are:
1. To interrupt the steam flow promptly during an emergency trip
2. To cut off the steam supply when the unit is shut down
The valves are tested on-power regularly (at least once a month) to
ensure they will close during an emergency. The load is reduced during
this testing. The valves are tested in sequence, one at a time, during the
on-load testing. The ESV is normally a single-seated unbalanced plug-
type valve. It has an internal small pilot valve that opens first. The pilot
valve can be opened against main steam pressure. It is also used during
run-up because the steam flow is from 1 to 2 percent of the full load
steam flow. It also reduces the force required to actuate the valve. When
the machine reaches operating speed, the GVs, which have been open,
close in. At this stage, it is possible to open the ESVs because the
upstream and downstream pressure of the valve has been equalized.
Figure 4.3 illustrates a typical ESV. Flap valves are used as reheat
emergency stop valves (RESVs) for some 500 and 660 MW units. The
steam in these valves has moderate pressure and large specific volume.
Governor Valves
The governor valves control the steam flow entering the mrbine. Since
the generator converts mechanical energy to electrical energy, the
governor valves control the generator load when the machine is
synchronized to the grid. Modern power plants use the governor valves
to throtde the steam flow during mrbine run-up to speed. However,
earlier machines use pilot valves in the ESV in conjunction with the
governor valves during run-up (the steam flow during run-up is less than
2 percent of the steam flow required during full-load operation). Figure
4.4 illustrates a typical governor valve.
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Steam Strainers
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1. Supervisory instrumentation
" 2. Efficiency instrumentation
3. Auxiliary system instrumentation
4. Condition-monitoring instrumentation
5. Instrumentation associated with protection and control equipment
6. Instrumentation to provide post incident records
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The preceding list includes dangers that only affect the turbine. Other
hazards specific to the boilers, generator, transformers, and high-voltage
connections can also initiate a mrbine-generator trip.
The consequences of over-speed are very serious for the plant and
personnel. Therefore, the protective systems have been designed to
prevent over-speed. The turbine governing system protects the unit
from over-speed. However, if it malfunctions, a separate over-speed
tripping system will become activated. When the generator is connected
to the grid, the mrbine cannot over-speed (the generator is coupled
magnetically with the grid). The possibility of over-speed occurs during
run-up and when the unit is disconnected suddenly from the load
(during a load rejection). The unit is normally disconnected from the
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When the steam flow drops below the one required to overcome friction
losses [bearings and windage (rubbing of air or hydrogen against the
generator rotor)], the generator starts to act as a motor. It starts to pull
current from the grid to continue running at the operating speed. The
circuit breaker now opens on reverse power. This sequence of activities
prevents the chance of over-speed. This type of a trip is known as
category B trip. I f the steam valves fail to close and the generator gets
disconnected from the grid, the unit will suffer disastrous consequences.
However, if the generator remains connected to the grid when the steam
valves fail to close, the mrbine will not over-speed. The unit can be shut
down safely by closing the boiler stop valves. All tripping conditions that
follow this sequence of events are known as category B trips. They
include the following:
• Governor failure
• Lubricating oil failure
• Over-speed
• Water ingress
• Manual emergency stop
Other trips, such as turbine high-exhaust pressure trips and some
electrical trips, require immediate disconnection of the generator from
the grid. These trips are known as category A trips. If the turbine
exhaust pressure is high, the last stage of the blades in the low-pressure
(LP) mrbine will become overheated and damaged. The turbine
unloading gear (included in the governing system) reduces the mrbine
load to avoid tripping. Some units use LP exhaust temperature sprays.
They are activated when high temperature is detected. They are also
used when the mrbine load drops below a predetermined value. The
possibility of heating the mrbine blading at low load is high. This is due
to the low flow that is unable to remove the heat generated. The LP
mrbine also has bursting diaphragms fitted in the casing. They operate at
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A trip closes the mrbine steam valves and opens the generator circuit
breaker. As explained earlier, the trips are divided into categories A and
B. Redundancy is built into the tripping system. The failure of one
element in the system does not prevent tripping. The system includes
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The interfaces with the electrical tripping system and the relays of the
emergency stop valves (ESVs) and governing valves (GVs) are also
shown. The redundancy of the electrical tripping system is not shown.
The unit has two sets of emergency trip valves and trip plungers. Each
set is associated with a set of over-speed trip bolts mounted in the
mrbine shaft. High-pressure fluid is supplied to the emergency trip
valves. If either valve is caused to trip (i.e., move to the left), the
protection fluid will be connected to drain via pipe A or pipe B. This
results in the closure of all mrbine steam valves.
The over-speed trip is initiated when the governing system fails to limit
the speed rise of the mrbine shaft. It is the final line of defense to
prevent a catastrophic failure of the mrbine. Turbine over-speed can
occur following a load rejection (when the unit becomes disconnected
from the grid). It can also occur when the unit is operating in the
islanding (unsynchronized) mode. If the governing system fails, higher
steam flow can enter the mrbine, leading to over-speed. If the over-
speed becomes excessive (approaching 100 percent), the centrifugal
forces acting on the rotating parts become extremely high. The blades
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will start to rupture and penetrate through the casing. The manufacturer
normally performs an over-speed test at 120 percent of the speed. This
speed is significandy lower than the design limit at which blade rupture
could occur (180 to 200 percent over-speed). The over-speed trip is
normally set in the range from 110 to 112.5 percent speed.
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