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RMD510
Steam RMD510
Power generation
Petrochemical refineries
Pharmaceuticals
F d processing
Food i
Petroleum / gas processing
Paper mills
Sugar industry
Waste-to-energy
gy
T
3
Note that T5 < T3. Many wouthi
systems reheat to the qinhi qinlo 5
same temp (T3 = T5)
4
2 woutlo
Reheat is usually not
offered for turbines less
than 50 MW win 1 qout 6
s
17 M.S.Ramaiah School of Advanced Studies, Bengaluru 8
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qinlo Low
5 Pressure
4 TURBINE
BOILER
w outhi
w outlo
3
High
Pressure 6
2 CONDENSER
TURBINE
qinhi qout
1
win PUMP
Compounding
C di is i done
d to
t reduce
d the
th rotational
t ti l speedd off the
th impulse
i l turbine
t bi
to practical limits.
Compounding is achieved by using more than one set of nozzle and rotor
bl d rows, in
blade i series,
i so that
th t either
ith the
th steam
t pressure or the
th velocity
l it (after
( ft
expansion) is absorbed by the turbine in stages.
Three main types of compounded impulse turbines are:
a. Pressure compounded
b. Velocity compounded
c Pressure and velocity compounded impulse turbines
c.
Pressure Compounding
Involves splitting of the whole pressure drop into a series
of smaller pressure drops across several stages of
impulse turbine. The nozzles are fitted into a diaphragm
locked in the casing that separates one wheel chamber
from another. All rotors are mounted on the same shaft.
17 M.S.Ramaiah School of Advanced Studies, Bengaluru 16
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RMD510
Compounding of Steam Turbines
Velocity Compounding
Entire pressure drop is achieved across the first nozzle.
The high velocity is then reduced stage by stage across
the following rotor blade rows. There is no expansion
across the stator rows.
Pressure-Velocity
i Compounding
C i
Pressure-velocity compounding is combination of
pressure and velocity compounding. It gives the
advantage of producing a shortened rotor compared to
pure velocity compounding. In this design steam
velocity at exit to the nozzles is kept reasonable and thus
the blade speed is red
reduced.
ced
I
Impulse
l Turbines
T bi R ti Turbines
Reaction T bi
An impulse turbine has fixed nozzles Reaction turbine makes use of the
that expand steam flow to produce reaction force produced as the steam
high velocity jets accelerates through the rotor blade
Rotor blade profile is symmetrical as passages
no pressure drop takes place across Rotor blades have convergent
these
h bl
blades
d passages allowing
ll i pressure dropd to
The design is suitable for efficiently occur partly through them
absorbing high velocity and high Efficient at the low pressure stages
pressure Fine blade tip clearances are
Steam pressure is constant across the necessary due to the pressure leakages
blades and therefore fine tip Lower efficiencies in high pressure
clearances are not necessary stages due to the leakage losses
Efficiency is not maintained in the around the blade tips
low pressure stages (high steam Fine tip clearances can cause damage
y cannot be achieved in the low
velocity to the blade tips
p
pressure stages)
Lacing
L i Wire
Wi Loss:
L D tto fl
Due flow blockage
bl k created
t d by
b the
th presence off lacing
l i
wires in long blade of LP stages.
Wetness Loss: Due to moisture entrained in the low ppressure steam at the
exit of LP turbine. The loss manifests in: firstly, a reduction in turbine
efficiency due to energy absorption by the water droplets, and secondly,
erosion of rotor blade leadingg edges
g in last stages.
g
Annulus Loss: Due to significant amount of diffusion between adjacent
stages or where wall cavities occur between the fixed and moving blades.
The extent of loss is greatly reduced at high annulus area ratios if the
expansion of steam is controlled by a flared casing wall.
Leaving Loss: Due to kinetic energy of steam leaving the last stage of LP
turbine. In practice, the steam slows down a bit after leaving the last blade,
due to frictional losses.
Partial Admission Loss: Due to partial filling of steam,
steam the flow between
the blades is considerably accelerated causing a loss in power.
17 M.S.Ramaiah School of Advanced Studies, Bengaluru 20
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Nomenclature RMD510
Suffix
1 Inlet
2 Outlet
17 M.S.Ramaiah School of Advanced Studies, Bengaluru 21
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Vw1
U
Inlet
W1
V1 Va1
Vw2 U
V2
Va2
W2
Exit
Vw2 Vw1
W1
Va2 V2 V1 Va1
W2
Vw
If the
th blade
bl d is
i symmetrical,
t i l then
th 1 = 2 and
d neglecting
l ti frictional
f i ti l effects,
ff t W1 = W2.
In actual case, the relative velocity is reduced by friction and expressed by a blade
velocity coefficient k. Thus k = W2 /W1
k Thus,
The Euler work done by the steam is given by;
Wt = U(Vw1+Vw2) (1)
Since
i Vw2 is
i ini negative
i direction,
di i the h workk done
d per unit
i mass flow
fl is i given
i by,
b
If Va1 = Va2, then,
Wt = U Va (tan1+ tan2) or Wt = U Va (tan1+ tan2) (2)
Equation (2) is often referred to as the diagram work per unit mass flow and hence
the diagram efficiency is defined as:
d =
Diagram work done per unit mass flow
Work available per unit mass flow
4U U U/V1 is called the
It can be shown that d cos 1
V1 V1 blade speed
p ratio.
and max. d 4 cos 1
2
The static enthalpy at the inlet to the fixed blade in terms of stagnation enthalpy
and velocity at the inlet to the fixed blades is given by
V02 similarlyy V22
h0 h00 h2 h02
2C p 2C p
Substituting
h1 h2
V 2
V 2
h00 0 h02 2
2C p 2C p
17 M.S.Ramaiah School of Advanced Studies, Bengaluru 26
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But for a normal stage, V0 = V2 and since h00 = h01 in the nozzle, then;
h1 h2
(17)
h01 h02
h h V Vw22
2
We know that (h01 h02) = 1 2
w1
0
2
Substituting for (h1- h2) in equation (17),
(17)
V V
2 2
V 2
Vw21
w2
w2 w1
2h01 h02 2U Vw1 Vw2 (18)
Assuming the axial velocity is constant through out the stage, then
V
Vw21
2
w2
2U U Vw1 Vw2 U
Vw2 Vw1 Vw2 Vw1
2U Vw1 Vw2 (19)
Va tan 2 tan 1
2U (20)
From the velocity
y triangles
g it is seen that
Vw1 U Vw1 Vw 2 Vw 2 U
P1 P2 P3 P4
i.e.,
P2 P3 P4 P5
Let o is the overall efficiency of expansion and is defined as the ratio of actual
work done per kg of steam to the isentropic work done per kg of steam between
1 and 5.
Wa h1 h5
i.e. 0 or 0
Ws h1 h5'
The actual work done per kg of steam Wa = o Ws ((22))
Isentropic or ideal values in each stages are Ws1, Ws2, Ws3, Ws4.
Therefore the total value of the actual work done in these stages is,
Wa = (1-2)+(2-3)+(3-4)+(4-5)
Also stage efficiency for each stage is given by
F stage
For t 1
Wa1 h1 h2 Wa1
i.e., s1 orWa1 s1Ws1
Ws1 h1 h2 Ws1
'
Wa Wa s1Ws1 s 2 Ws 2 s 3 Ws 3 s 4 Ws 4
For same stage efficiency in each stage s1 s 2 s 3 s 4
Wa s Ws1 Ws 2 Ws 3 Ws 4 s Ws (23)
h
T
s p
17 M.S.Ramaiah School of Advanced Studies, Bengaluru 35
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This shows that the constant pressure lines must diverge towards the right.
Therefore Ws
.
1
Ws
F expansion
For i process. ItI is
i obvious
b i that
h theh enthalpy
h l increases
i when
h we move
towards right along the constant pressure line. Hence the summation of Ws1
Ws1 etc., is more than the total isentropic enthalpy drop Ws
Th ratio
The ti off summation
ti off isentropic
i t i enthalpyth l drop
d f individual
for i di id l stage
t t the
to th total
t t l
isentropic enthalpy drop as a whole is called Reheat factor. Thus
RF
Ws1 Ws 2 Ws 3 Ws 4 (1 2' ) (2 a ' ) (3 b ' ) (4 c ' )
Ws Ws (1 5)
RF (25)
Ws
Therefore the overall efficiency of the expansion process,
process
0 stage RF (26)
Since RF (Ws / Ws ) 1
th overall
the ll efficiency
ffi i off the t bi 0 is
th turbine i greater
t than
th stage
t ffi i i s
efficiencies
i.e.,0 s for turbines (27)
17 M.S.Ramaiah School of Advanced Studies, Bengaluru 36
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Advantages of Reheating
1. There is an increase in the overall output
p of turbine.
2. Erosion and corrosion problems in steam turbines are reduced.
3. There is an improvement in overall thermal efficiency of the turbine.
4. Condition of steam in last stage is improved.
Demerits
1. Capital cost required for reheating
2. Increase in thermal efficiency is not appreciable compared to expenditure
incurred in reheating for smaller capacity turbines.
Development
p of Conventional Coal Fired
Steam Power Plants
Comb
ustor Hot gas
Compressor
Exhaust gas
17-$Boiler_control
17-$Boiler_control
P
Power G
Generation
i
Efficiency = energy out / energy in
17-$Boiler_control
17 M.S.Ramaiah School of Advanced Studies, Bengaluru 45
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T bi Design
Turbine D i
Aerodynamic Parameters
Incidence angle
Stator rotor interaction
Degree of reaction
Whirl distribution
Geometric Parameters
Blade profile
Blade solidity
Blade aspect
p ratio
Blade stacking
17 M.S.Ramaiah School of Advanced Studies, Bengaluru 46
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Tip
p clearance and passage
p g vortices
Stator Rotor
Loss coefficient across the last stage stator and rotor of a large steam turbine
(Power = 1000 MW ; Speed = 3000 rpm ; length of rotor blade = 1.085 m)
[Ref: M. Stastny, et al, Czech Technical University, Praha]
The blade sections should be designed for low loss incidence, both under
design and off-design conditions. This requires extensive cascade testing
of blade sections to arrive at acceptable low loss profiles.
Separation Bubble
Squealer tip
Blade-wake interaction
3 D Blading RMD510
Conventional and 3D
bl d and
blades d comparison
i
of thermal efficiencies
Source: J. Franke, R. Kral, and E. Wittchow (1999): Steam generators for the next generation of
power plants aspects of design and operating performance. VGB Power Tech 12/9. 17-$Boiler_control
17 M.S.Ramaiah School of Advanced Studies, Bengaluru 61
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Working principle
Classification of steam turbines
Types of compounding
Workk ddone andd efficiency
ffi i off steam turbine
bi stages
Broad design concepts
Supercritical steam turbines
Future trends in steam turbine design