Steam Turbine Cycle and Performance

PEMP
RMD 2501
Steam
S e Turbine
u b e Cyc
Cycles
es
&
Cycle Performance
Session delivered by:
Prof. Q.H. Nagpurwala
04 © M.S.Ramaiah School of Advanced Studies 1

PEMP
Session Objectives
j RMD 2501
This
hi session
i isi intended
i d d to discuss
di the
h following:
f ll i
• Basic construction and classification of steam turbines
• Steam turbine cycles
• Pressure and velocity compounding
• S b iti l and
Subcritical d supercritical
iti l steam
t turbines
t bi
• Steam turbine cycle
y performance
p
• Combined cycle power plants

PEMP
Steam RMD 2501
Steam is a vapour used as a working substance in the operation of steam turbine.
Is steam a perfect gas?

Steam possess properties like those of gases, namely pressure, volume,
temperature, internal energy, enthalpy and entropy. But the pressure volume and
temperature of steam as a vapour are not connected by any simple relationship
such as is expressed by the characteristic equation for a perfect gas.
gas
Sensible heat – The heat absorbed by water in attaining its boiling point
Latent heat – The heat absorbed to convert boiling water into steam
Wet steam – Steam containing some quantity of moisture content.
content
Dry steam – Steam that has no moisture content.
Superheated steam – Dry steam when heated at constant pressure attains
superheat. Superheated steam behaves like perfect gas.
The properties of steam are dependent on its pressure.
PEMP
Steam Properties
p RMD 2501
Enthalpy (H) kJ/kg Internal energy (u) kJ/kg

Entropy (s) kJ/kg-K Specific volume (v) m3/kg
Density () kg/m3 Isobaric heat capacity (cp)
04 kJ/kg-K 4
© M.S.Ramaiah School of Advanced Studies
PEMP
Steam Turbine RMD 2501
 A steam turbine is a mechanical device that extracts thermal energy

from p
pressurized steam,, and converts it into rotary
y motion. Its modern
manifestation was invented by Sir Charles Parsons in 1884.
 The main components
p of a steam turbine are:
 Feed water pump
 Boiler
 Turbine stages, comprising nozzle/stator and rotor blade rows
 Condenser
 Steam from the boiler is expanded in the nozzle blade passages to
produce high velocity jets, which impinge on the rotor blades
mounted on a disc and shaft. The rate of change of momentum of
steam flow across the rotor blades produces the required torque for the
shaft to rotate
rotate.
 The conversion of energy across the blade rows takes place by
impulse reaction or impulse reaction principle
impulse, principle.
PEMP
Application of Steam Turbines RMD 2501
 Power generation
 Petrochemical refineries
 Pharmaceuticals
 Food processing
 Petroleum / gas processing
 P
Paper mills
ill
 Sugar industry
 Waste-to-energy

PEMP
Gas Turbine Power Plant

RMD 2501
Comb
ustor
stor Hot gas
Compressor
Exhaust gas
17-$Boiler_control

PEMP
Steam Turbine Power Plant

RMD 2501
17-$Boiler_control

PEMP

RMD 2501
Power Generation
Effi i
Efficiency = energy outt / energy in
i
17-$Boiler_control

PEMP
Rankine Cycle
y RMD 2501
Saturated Rankine cycle Superheated Rankine cycle

PEMP
Reheat Cycle
y
RMD 2501
T
3
Note that T5 < T3. Many wouthi
systems reheat to the qinhi qinlo 5
same tempp (T
( 3 = T5)
4
2 woutlo
Reheat is usually not
offered for turbines less
than 50 MW win 1 qout 6
s
PEMP
Schematic of Rankine Reheat Cycle

y RMD 2501
qinlo Low
5 Pressure
4 TURBINE
BOILER
w outhi
w outlo
3
High
Pressure 6
2 CONDENSER
TURBINE
qinhi qout
1
win PUMP

PEMP
Schematic of Rankine Cycle without Reheat

RMD 2501

PEMP
Steam Turbine Classification RMD 2501
Steam turbines can be classified in several different ways:

1
1. By details
d il off stage design
d i
• Impulse or reaction
2. By steam supply and exhaust conditions
• Condensing or non-condensing
• Automatic or controlled extraction
• Mixedi d pressure
• Reheat
3. By casing or shaft arrangement
• Single casing, tandem compound or cross compound
4. By number of exhaust stages in parallel
• Two flow,
fl four
f flow
fl or sixi flow
fl
5. By direction of steam flow
• Axial flow, radial flow or tangential flow
6. Single or multi-stage
7. By steam condition
• Superheated
h d or saturated
d
PEMP
Steam Turbine Classification RMD 2501
Non-Condensing
Non Condensing Turbine Extraction Turbine
The entire flow of steam is exhausted It has opening(s) in its casing for
to the industrial process or facility extraction of a portion of steam at
steam remains at conditions close to some intermediate pressure for use
the process heat requirements in a process or in a CHP facility, or
for feed water heating. The rest of
the steam is condensed
PEMP
Turbine Designation RMD 2501
H - Single Flow HP Turbine

K - HP/IP Opposite flow
E - HP/LP Opposite flow
N - Double flow LP Turbine
M - Double flow IP Turbine

PEMP
Steam Turbine Blade Rows RMD 2501
149 MW steam Single

g cylinder
y type
yp
turbine rotor turbine casing
Siemens SST-900 steam

turbine at Finspong plant
in Sweden
PEMP
Types
yp of Steam Turbine RMD 2501
Impulse Turbine Reaction Turbine
Complete expansion of steam takes Expansion of steam takes place partly

place in stationary nozzle blades and in nozzle / stator and partly in rotor.
rotor
the kinetic energy is converted into However, conversion of kinetic energy
mechanical work in rotor blades to mechanical work takes place only in
rotor blades
PEMP
Types of Steam Turbine RMD 2501
Parsons Reaction Turbine De Laval Impulse Turbine.

PEMP
Flow through
g Multistage
g Steam Turbine RMD 2501

PEMP
Compounding of Steam Turbines RMD 2501
 Compounding is done to reduce the rotational speed of the impulse turbine

to practical limits.
 Compounding is achieved by using more than one set of nozzle and rotor
blade rows, in series, so that either the steam pressure or the velocity (after
expansion)
i ) isi absorbed
b b d by b the
th turbine
t bi in i stages.
t
Three main types of compounded impulse turbines are:
a. Pressure compounded
b. Velocity compounded
c. Pressure andd velocity
l i compounded
d d impulse
i l turbines
bi
Pressure Compounding
Involves splitting of the whole pressure drop into a series
off smaller
ll pressure dropsd across severall stages
t off
impulse turbine. The nozzles are fitted into a diaphragm
locked in the casingg that separates
p one wheel chamber
from another. All rotors are mounted on the same shaft.
PEMP
RMD 2501
Compounding of Steam Turbines
Velocity Compounding
E ti pressure drop
Entire d is
i achieved
hi d across the
th first
fi t nozzle.
l
The high velocity is then reduced stage by stage across
the followingg rotor blade rows. There is no expansion
p
across the stator rows.
Pressure-Velocity Compounding
Pressure-velocity compounding is combination of
pressure and velocity compounding. It gives the
advantage of producing a shortened rotor compared to
pure velocity compounding.
compounding In this design steam
velocity at exit to the nozzles is kept reasonable and thus
the blade speed is reduced.

PEMP
Comparison of Impulse and Reaction Turbines

RMD 2501
Impulse Turbines Reaction Turbines

• 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 blades passages allowing pressure drop 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
velocity cannot be achieved in the low to the blade tips
pressure stages)

PEMP
Coupling of Turbine Modules

RMD 2501
In power stations, different types of turbines -- high pressure, medium

(intermediate) pressure and low pressure -- are used in series. This
coupling
li leads
l d tot an excellent
ll t efficiency
ffi i (over
( 40%),
40%) which
hi h is
i even
better than the efficiency of large diesel engines.

PEMP
Steam Turbine Cycle

y ((Subcritical)) RMD 2501
Rankine cycle with superheat Rankine cycle with reheat

PEMP
Steam Turbine Cycle

y ((Supercritical)
p )
RMD 2501
There are inherent advantages of supercritical steam cycle:

High pressures and temperatures enhance thermal efficiency;
avoid use of steam dryers and steam separators; and reduce
CO2 emissions.
PEMP
RMD 2501
Development of Conventional Coal Fired

Steam Power Plants

PEMP
Potential Efficiency Improvements RMD 2501
(Based on a 700MW bituminous coal fired plant

plant, with a
40mbar condenser pressure)
PEMP
Supercritical Steam Turbine Plant RMD 2501

PEMP
Rankine Cycle Efficiency RMD 2501
Work done by the turbine, W1 = m (h1- h2)

Work input to pump, W2 = m (h4- h3)
Net work output
p of the cycle
y = W1 - W2
Heat input in the cycle (boiler)
Q1 = m(h1-hh4)
Heat rejected in the condenser
Q2 = m(h2-h
h3)
Thermal efficiency
y of Rankine cycle
y
 
W1  W 2

h1  h 2   h 4  h3 
Q1 h1  h 4
 1
h 2  h3 
h1  h 4
PEMP
Energy
gy Flow in Steam Turbine System
y
RMD 2501
Flue Gas

PEMP
Steadyy Flow Energy

gy Equations
q RMD 2501
Boiler
F + A + h d = h 1 + G + hl b , hence
h F + A = G + h 1 - h d + hl b
Turbine
h 1 = T + h 2 + hl t , hence 0 = T - h 1 + h 2 + hl t
Condenser Unit
W i + h 2 = W o + h w + hl c , hence W i = W o + h w - h 2 + hl c
F dW
Feed Water S
System
h w + d e + d f = h d + hl f , hence d e + d f = - h w + h d + hl
The four equations on the right can be arranged to give the energy equation
f th
for the whole
h l turbine
t bi systemt enclosed
l d byb the
th outer
t boundary
b d
PEMP
Steadyy Flow Energy

gy Equations
q RMD 2501
Energy of fuel (F) per unit mass of working agent (water) is equal to the sum of the
mechanical energy available from the turbine less that used to drive the pumps
(T - (d e+ d f)
 the
th energy lleaving
i the
th exhaust
h t [G - A] using
i the
th air
i temperature
t t as the
th datum.
d t
 the energy gained by the water circulating through the condenser [W o - W i]
 the energy gained by the atmosphere surrounding the plant Σ hl
The overall thermal efficiency of a steam turbine plant can be represented by the
ratio
ti off the
th nett mechanical
h i l energy available
il bl to
t the
th energy within
ithi the
th fuel
f l supplied
li d :

PEMP
Steam Turbine Cycle

y on T-h Diagram
g
RMD 2501
The efficiency of the Rankine cycle

AB'CDEA iis
The efficiency of the

real cycle is

PEMP
Steam Turbine Installation

RMD 2501

PEMP

RMD 2501
2x130MW Power Station (JSW Energy)

Located at Jindal Vijaynagar Steel Plant complex Toranagallu, Bellary
PEMP
Combined Cycle
y Power Plant RMD 2501
Heat recovery steam generator
Gas turbine plant Steam turbine plant
9
Life steam
Electrical Air Fuel
energy
Electrical
energy
gy
6 5 1 2 3 10
7 11
4
Exhaust gas
8
9
Cooling tower
Gas turbine plant: Steam turbine plant: Condensate 12
1 Air intake 7 Steam turbine

2 Compressor 8 Condenser
C li
Cooling
3 Gas turbine 9 Feeding pump
air
4 Heat recovery 10 Generator
steam generator 11 Transformer
5 Generator 12 Circulating pump
6 Transformer
T f
Fresh water

PEMP
Single
g Shaft Combined Cycle
y Plant RMD 2501

PEMP
Multi Shaft Combined Cycle

y Plant RMD 2501

PEMP
Combined Cycle
y Power Plant RMD 2501
A 580 MW capacity combined cycle power plant at Ontario, Canada,

comprising two natural-gas fired turbines, one steam turbine and two
vertical heat recovery steam generators.
generators

PEMP
Typical
yp Steam Turbine Materials RMD 2501
Part name Material Code/Composition

Casing IS:2063
Inner casing GS 22Mo4 Shaft
Shaft 30CrMoV121
Blade high pressure X22CrMoV121
Blade Low pressure X20Cr3
Casing joint bolt 21CrMoV57
Crossover pipe ASTM 533 Gr.70
Valve spindle X22CrMoV121
Valve bodyy GS17crmov511
Valve seat 21CrMo57
Source BHEL Hyderabad

PEMP
Session Summaryy RMD 2501
In this session the following aspects of steam turbines have been

discussed:
 Constructional features of steam turbines

 Basic Rankine cycle and effect of reheat
 Velocity and pressure compounding of turbine stages
 Supercritical steam turbines
 Steam turbine performance parameters
 Combined cycle power plants

PEMP
RMD 2501
Th k you
Thank

Steam Turbine Cycle and Performance

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04 © M.S.Ramaiah School of Advanced Studies 1

04 © M.S.Ramaiah School of Advanced Studies 2

Steam RMD 2501

Steam is a vapour used as a working substance in the operation of steam turbine.

Is steam a perfect gas?

Enthalpy (H) kJ/kg Internal energy (u) kJ/kg

Steam Turbine RMD 2501

 A steam turbine is a mechanical device that extracts thermal energy

Application of Steam Turbines RMD 2501

04 © M.S.Ramaiah School of Advanced Studies 6

Gas Turbine Power Plant

04 © M.S.Ramaiah School of Advanced Studies 7

Steam Turbine Power Plant

04 © M.S.Ramaiah School of Advanced Studies 8

Steam Turbine Power Plant

04 © M.S.Ramaiah School of Advanced Studies 9

Saturated Rankine cycle Superheated Rankine cycle

04 © M.S.Ramaiah School of Advanced Studies 10

Schematic of Rankine Reheat Cycle

04 © M.S.Ramaiah School of Advanced Studies 12

Schematic of Rankine Cycle without Reheat

04 © M.S.Ramaiah School of Advanced Studies 13

Steam Turbine Classification RMD 2501

Steam turbines can be classified in several different ways:

Steam Turbine Classification RMD 2501

Turbine Designation RMD 2501

H - Single Flow HP Turbine

04 © M.S.Ramaiah School of Advanced Studies 16

Steam Turbine Blade Rows RMD 2501

149 MW steam Single

Siemens SST-900 steam

Impulse Turbine Reaction Turbine

Complete expansion of steam takes Expansion of steam takes place partly

Types of Steam Turbine RMD 2501

Parsons Reaction Turbine De Laval Impulse Turbine.

04 © M.S.Ramaiah School of Advanced Studies 19

04 © M.S.Ramaiah School of Advanced Studies 20

Compounding of Steam Turbines RMD 2501

 Compounding is done to reduce the rotational speed of the impulse turbine

04 © M.S.Ramaiah School of Advanced Studies 22

Comparison of Impulse and Reaction Turbines

Impulse Turbines Reaction Turbines

04 © M.S.Ramaiah School of Advanced Studies 23

Coupling of Turbine Modules

In power stations, different types of turbines -- high pressure, medium

04 © M.S.Ramaiah School of Advanced Studies 24

Steam Turbine Cycle

Rankine cycle with superheat Rankine cycle with reheat

Steam Turbine Cycle

There are inherent advantages of supercritical steam cycle:

Development of Conventional Coal Fired

04 © M.S.Ramaiah School of Advanced Studies 27

Potential Efficiency Improvements RMD 2501

(Based on a 700MW bituminous coal fired plant

Supercritical Steam Turbine Plant RMD 2501

04 © M.S.Ramaiah School of Advanced Studies 29

Rankine Cycle Efficiency RMD 2501

Work done by the turbine, W1 = m (h1- h2)

04 © M.S.Ramaiah School of Advanced Studies 31

Steadyy Flow Energy

Steadyy Flow Energy

04 © M.S.Ramaiah School of Advanced Studies 33