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FIG. 1.8 COMPOUDING FOR PRESSURE FIG.1.9 REACTION TURBINE PRESSURE AND
AND VELOCITY VELOCITY CURVES
The fixed blades compare to the nozzle used in the impulse turbine. Steam is
admitted over the whole circumference, and in passing through the first row of fixed
blades, undergoes a small drop in pressure and its velocity is increased. It then
enters the first row of moving blades and, as in the impulse turtiine, suffers a
change in direction and hence momentum giving an impulse on the blades. During
the steam passage through the moving blades, k undergoes a further small drop in
pressure resulting in an increase in velocity which gives riseto areaction inthe
direction opposite tothat of the added velocity. It is in thisthat the impulsereaction
turbine differs from the pure impulse turbine. Thus the gross propelling force in the
impulse-reaction turbine, (or the 'reaction' turbine as it is commonly called), is the
vector sum of the impulse and the reaction forces.
(Fig. 1.9) also shows how the blade heights increase as the specific volume of
the steam increases with reduction in pressure. Note, how the pressure falls
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(Fig. 1. 1 3). The unit uses steam at a pressure of 1 00 bar absolute, temp. 540'c
(813'K) and rejects it to the condenser at 30 m bar (saturation temp. 24.1 "c).
At point'A'the condensate is at boiling temperature corresponding to the back
(condenser) pressure. Its pressure is raised to 1 00 BAR in Feed Pump
corresponding to point'B'. Heat (sensible) is added to this water to raise its
temperature. At the point C it reaches its saturation temp. at a pressure of 1 00 bar.
Evaporation begins at the point C. Heat (latent-because no rise in temperature
between C and D, as evident from the diagram), addition continues. At D all the
water evaporates and super-heating commences. This is shown by the curve DE.
FIG. 1.13 SENSIBLE LATENT AND SUPERHEAT, 100 BAR, 540OC CYCLE ON T-S DIAGRAM
The mode of action of the turbine can best be studied by following the path of
fluid through a single stage at the mean radius of the annulus, as in (Fig. 1.15)
(a). The fluid enters the nozzles with velocity C0 at pressure Po and is expanded
to pressure P0 . It leaves the nozzles with a velocity C1, in a direction making an
PAGE15
The guide blade carrier is kinematrically supported and located and this is
guaranted by 4 projections on e,@ s the inlet side and 2 projections on the exhaust
side of the guide blade carrier, which match with corresponding e ofslotsand
havesliding contacts. Thesliding contacts make it possibleforthe blade carrierto be
exactly guided igh into the vertical and horizontal planes. A ring with a buttress
thread holds the guide blade carrier in the barrel-ant type casing. As the
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Casing Expansion
PAGE 29
A better way of controlling over speed, which becomes even more important as
the size of the machine and steam conditions rise, is to mount single governing chests
Like some H.P. steam chest the I.P steam chests may also have a combined stop and
control valve.
A reheat strainer is fitted immediately before the steam chest to protect the valve & IP
bladign from damage by debris. A typical strainer is shown in (Fig. 3.13).
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3.5 STEAM VALVES
A turbine is equipped with one or more emergency stop valves, in order to cut off
the steam supply dun'rn pe~of shut down and to provide prompt interruption of the
a) Shows a “ double--beat" valve having two seatings, the object being to balance the
forces due to steam pressure. It is suitable for most pressures, but not for high
temperatures as differential expansion between the valve and cage would cause
one or other sealing to owrapm.
b) Shows another double-beat valve of the hollow type in which the steam from one
sealing is led through the centre of the valve. The thinner walls promote even
heating and lesser differential expansion.
c) Shows a modern sphedcal valve used for control linghigh temperature steam.
Beinga' sing @beatvalve with one seating, the pressure forces are not balanced and
a large operating force is required.
d) Shows a similar valve fitted with an internal pilot valve which, by opening first,
equalises the pressures and provides initial fine control.
e) Shows a cylindrical valve in which steam pressure is prevented from acting on the
back of the valve by fine annular clearance.
b) The integral rotor in which the wheels and shaft are formed from one solid
forging. (Fig. 3.21).
The built up rotor is made up of a number of separately forged discs or
wheels and the hubs of these wheels are shrunk and keyed on to the central shaft.
The outer rims of the wheels have suitable grooves machined to allow for fixing
the blades. The shaft is sometimes stepped so that the wheel hubs can be threaded
3.7.2 Balancing
When assembled complete with blades the rotor is balanced both statistically and
dynamically.
In the case of built-up rotors, each bladed disc is balanced individually
before assembly. The aim of balancing is to reduce vibration to a tolerable level,
usually accepted to be about 35μm at the bearing pedestal of a 3000 rev / min.
machine.
A stationary shaft supported between bearings has a natural frequency of
vibration depending upon its diameter and the distance between the bearings. If its
speed of rotation corresponds to its natural vibration frequency, the residual out –
of-balance forces can build up to a dangerous extent. This speed is known as the
3.7.3 Materials
High and intermediate pressure rotors are usually made from chromium-moly
bdenum-vanadium steel ferritic materiao which is suitableforwheeicase steam
temperatures up to 540'C. Austenitic materials are no favoured because of the cost
of their manufacture and their high coefficient of expansion.
Low pressure rotors are made of 3 per cent chromium-molybdenum steel or
2 114 per cent nickd chromium-molybdenum steel. The first of these is not used
in modern designs because of the tendenq towards scuffing in the bearings during
the early life of the rotor.
Low pressure discs are made of 3 per cent chromium-molybdenum-
vanadium steel, or more recentn 0 3 112 per cent nickel-chromium-molybdenum-
vanadium steel.
3.8 BLADES
These are most important (and co" too) components of the turbine as these are
respcinsible for the ma:i@ function of the turbine, i.ib. conveting heat energy to
mechanical energy.
A blade has three main parts:
- AEROFOIL - It is the working part of the blade
- ROOT - It is the portion of the blade which is fixed with the
rotor or casing.
- SHROUD - It can be rivetted to the main blade or can be integrally
machined with the blade
(Note: Blades maybe without shroud also).
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3.8.3 Impulse Type Fixed Blading (Fig. 3.26).
The fixed blading in an ampluse turbine takes the form of nozzles mounted in
diaphragms. The diaphragm is made in two halves, one half being fixed to the
upper half of the cylinder casings by means of keys so that when expansion
occurs fouling of the shaft seals is avoided. Special carrier rinfs are generally used
to support the diaphragms in H.P. cylinders.
Because of the steam pressure difference on each side of the diaphragm,
seals are provided at the bore where the shaft passes through the diaphragm, to
prevent steam leakage along the shaft.
PAGE 48
maintenance purposes, to rotate the turbine shaft manually. An auxiliary source of
power from U.P.S. (Uninterrupted Power Supply) or Diesel Generating set is also
provided in some cases for reliability of T /G operation.
Fig.3.35 shows the functional arrangement of a turning gear.
In BHEL 1 21 0 MW LMW turbine, the T./ G is mounted on LP rotor rear
coupling. It consists of a worm,,
3.12 COUPLING
3.12.1 Introduction
The need for couplings arises from the limiting length of shaft which it tis possible
to forge in one piece and from the frequent need to use different materials for the
various rotors, in view of the various conditions of temperature and stress.
PAGE 53
The side clearances between the impeller and seal chamber must be fairly
small, and so the use of this seal is restricted to positions on a turbine where the
axial differential expansions are within the effective limits of impeller and seal
chamber clearance. When this type of seal is used on a high pressure turbine, the
seal cannot absorb the full differential pressure so air-sealed labyrinth glands are
used to breakthe pressure down to a figure which the water seal can handle.
Since a water seal absorbs and generates heat, the water contained in the
annular chamber of the water - sealed gland is continuously evaporated; the water
losses are made up from a header tank.
4.1.2 Labyrinth glands
In modern turbines the labyrinth gland are used because it can withstand high
pressures and temperatures and yet requires little maintenance.
The labyrinth gland provides a series of very fine annualar clearances, in
the gap between the cylin@, wall and the shaft. The steam isthrottled through this
gap and its pressure reduced step by step. In expandii@,, through each clearance,
the steam develops kinetic energy at the expense of its pressure energy; idealism
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CONDENSATE SYSTEM
A typical condensate system consists of the following:
i) Condenser (including hot-well)
ii) Condensate pumps
iii) Air Extraction System
iv) Gland coolers and L.P. heaters
v) Deaerator
5.1 CONDENSER
The functions of condenser are:
i) To provide lowest economic heat rejection temperature for the steam. Thus
saving on steam required per unit of electricity.
ii) To convert exhaust steam to water for reuse thus saving on feed water
requirement.
iii) Deaeration of make-up water introduced in the condenser.
iv) To form a convenient point for introducing make up water.
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Constructional feature
Each condenser has been sub-divided into upper and lower parts. Front water box,
shell and rear water box constitute the lowerpart. Two end tube plates and six
support plates are located inside the lower body of the condenser.
Front water boxes have been divided into two parts to make the condenser
two pass design. End covers of water boxes are kept detachable for facilitating
repairs and replacement of tubes. Manholes have been provided for routine
maintenance and visual inspection along with venting and draining arrangement
for individual water boxes. Condensertubes are secured to the end tube plates by
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PAGE 65
FIG. 5.14 (A) SACRIFICIAL ANODE TYPE OF FIG. 5.14 (B) IMPRESSED CIRCUIT SYSTEM OF
PUMP :
MOTOR
b) Liquid Ring Type Air Pump (Nash Vacuum Pump) (Fig. 5.19).
PAGE 75
PAGE 82
electric motor driven feed Pump of 50% capacity is also provided for start up and
stand by). Number of steam turbines driven feed pumps per unit also vary. Some of
500 MW Units provide only one steam turbine driven feed pump of 1 00% capacity
and some provide two steam turbine driven feed pumps of 50% capacity each). It
normally takes steam from either CRH or lst Extraction and the exhaust normally
goes to one of the low pressure heaters.
One of the major gains in using steam turbine as the primemover for BFPs is
an increase in overall efficiency. The power consumed by feed pump is transfered to
feed water. But when the power consumed is electricity, ft has been generated at
around 33% efficiency only. So loss of power at feed pump drive is (in terms of %
of boiler heat input).
Pump Power (1 - n.)
So if the power consumption of feed pump of a 500 MW Unit is 14 MW, then the
pump motor will consume 141 500 of the alternator output at an efficiency of 0.33
so, pump loss (% of boiler heat input)
= 14 - (100-0.33) / 500
= 1.88%
Now in case of turbine driven feed pump, the loss will be 14 / 500 (1 00 - n b) =
0.42% of boiler heat input. In addition, the steam turbine driven feed pump has
the foliowing other advantages:
1) Compared with the system using electrically driven pumps there is again in
therrnal and overall efficiency since thermally, the extraction of steam from the
feed pump turbine requires an increased steam flow through the early stages of
the turbine. This allows the use of longer blades resulting in higher stage
efficiency.
2) As the bled steam is normally taken from the cold reheat line the steam flow
through the reheater is reduced. This permits reduction of cost of reheater
steam pipe works because of the reduction of size. The main turbine
construction is simplified as there is no bled steam tapping points for HP
heaters.
3) Thermodynamically, it is advantageous to use the low temperature steam bled
from the feed pump steam turbine for feed heating in HP heaters as it helps
avoiding degradation of high super-heat steam tapped from H.P. and ].P.
turbine.
lf steam is bled from a turbine and is made to give up its latent and any supe.-heat it
may possess, to a heater, this system is called regenerative, because the fluid (steam)
gives up heat, which would be otherwise wasted, to the fluid whilst in another state
(water) to raise its temperature. The highest A heorectical temperature to which the
feed water may be raised in the heater is the saturation temperature of the bled steam.
There is an optimum point at which the steam is bled from the turbine once a feed
temperature is selected, a tappling point near the stop valve produces no gain in
efficiency as practically live steam is used for heating. An intermediate point, if
carefully chosen, gives maximum feed temperature rise with minimum loss of
mechanical power at the turbine. The steam, having given up a proportion of lits work
to the turbine, then gives up all its latent heat which would otherwise be lost to the
condenser C.W.The heat gained in this way outweighs the loss of mechanical power and
a gain in efficiency follows. Other advantages of this cycle are that less C.W. is
required with a decrease in pumping power, a smaller condenser can be used and the
turbine exhaust annulus is smaller.
The thermal gain resulting from feed water heating can be illustrated by
considering an example with approximate figures as follows (Single Feed
Heater).
The difference between these values is 4.23% which can result in a considerable
yearly saving in fuel consumption.
7.2 Types of feed water heaters
A feed water is simply a heat exchanger which is arranged so that the water leaving
a condenser is pre-heated before it is fed to a boiler. The feed heater is supplied by
steam which has already performed some useful work. This steam, which is taken
from suitable stages along a turbine, transfers its latent heat to the boiler feed water
and accordingly increases the water temperature.
It is now universal practice to use feed heaters to heat the feed water from the
temperature at which it leaves a condenser to a temperature approaching the
saturation temperature of the boiler steam pressure.
When a feed heater is in operation, it requires no regulation because the bled
steam consumption responds automatically to the temperature and quantity of feed
water passing through the heater.
Low pressure feed heaters are positioned after an extraction pump, while high
pressure feed heaters are positioned after a boiler feed pump and, therefore, have to
be constructed to withstand the full discharge pressure of a boiler feed pump.
Two types of feed heaters are used; the surface type, in which the feed water is
passed through tubes, with the bled steam surrounding them; and the direct contact
type, in which the steam and water mix together.
PAGE 86
7.2.1 The surface – Feed Heater
PAGE 93
type heater combined with feed storage tank of adequate capacity. The heating
steam is normally supplied from turbine extractions but during starting and low
load operation the steam is supplied from auxiliary source.
The deaerator comprises of two chambers:
i) Deaerating column
PAGE 96
TURBINE OIL SYSTEM
8.1 PURPOSE OF OIL SYSTEM
The turbine oil system fulfils four fuctions. It:
a) Provides a supply of oil to the journal bearings to give an oil wedge at the shaft
rotates.
b) Maintains the temperature of the turbine bearings constant at the required level.
The oil does this by removing the heat which is produced by the shaft
conduction, the surface friction and the turbulence set up in the oil.
c) Provides a medium for hydraulically operating the governor gear and controlling
the steam admission valves.
PAGE 98
During initial starting a A.C. driven starting oil pump meets the requirement of
both the bearing oil and governing oil.
Two standby oil pumps are incorporated in the system to supply bearing oil in
emergency. One of these is A.C. driven and the other is D.C. driven.
PAGE 104
9.4 INTERLOCKS
1 . The HP-bypass system are influenced by the following interlocks:
a) Generator circuit - breaker
α= ΔT/1
Where 1 is the machine inertia. As a machine s~ rises, the speed governor acting
through the control system will throttle the steam valves unite the turbine torque is
equal to the new power demand. (Fig. 1 0.1 (b) shows the response of turbine to a
sudden change in load and the resultant change in s~.
The percentage charbge in rated s~ corresponding to 100% change in load is
termed the "speed regulation" or the mdroopm of the turbine. It is nomially
around 4%. The regulations of the turbines operating in parallel Influence the load
sharing amongst them.
2) Protection Devices
a) Emergency trip valve
b) Over speed governor
c) Acceleration governor
d) Overspeed Limiting gear
e) Pre-emergency governor Low vacuum run back / unloading unit
g) Initial pressure regulator/ low initial pressure unloading unit (Gear).
10.6 BRIEF DESCRIPTION OF GOVERNING & PROTECTION SYSTEM &
THE DEVICES
The stop valves & control valves in the steam lines to the turbine are actuated by
hydraulic servomotors. The servomotors consist of a cylinder and a spring loaded
piston which is held in open position by admission of high pressure oil, against the
spring force, which ensures positive closing on the oil being drained out. The high
pressure oil supplied by the oil pump to the governing system is fed to the
servomotors through their pilot valves. The position of the pilot valve determines
the opening or closing of the servomotor. The high pressure oil which actuates the
servomotor is usually termed as "Power Oil" or "Sensing Oil".
PAGE 111
PAGE 112
10.9 PROTECTION DEVICES
10.9.1 Emergency Trip Valve
The function of the valve has already been explained. (Fig. 10.4) shows a typical
trip valve in "Reset" position with provision for manual and oil injection tripping
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PAGE 116
10.9.8 Initial Pressure Regulator (IPR)
The device is similar to low vacuum unloading gear. If the throttle pressure
should fali to more than 10% below normal, the device comes into operation and
starts closing the CVs until a balance is reached. It is provided with a stop to
avoid motoring and also equipped with a cutout device to block the regulator
PAGE 125
FIG.11.6
PAGE 137
FIRE RESISTANT FLUID
12.1 INTRODUCTION
Mineral lubricating oils used in hydraulic systems situated adjacent to equipments
maintained at high temperatures have always constituted a considerable fire risk.
(B)
* BHEL is considering to lower it to 2910 r.p.m. (48.5 Hz)
16. Permissible below 2 Hrs. 2 Hrs. BHEL is considering to
47.5 Hz and 51.5 allow 5 minutes continuous
Hz in life time (Total) operation between 48 Hz
and 48.5 Hz not exceeding
3 hrs. in total life.
2 2 2
24. HP cylinder exhaust 45 Kg / cm 39.2 Kg / cm 27 Kg / cm
pressure
(abs) (abs) (abs)
o o o
25. HP cylinder exhaust temp. 342.5 c 343 c 327 c
2 2 2
26. IP cylinder stop valve 40.5 Kg / cm 34 Kg / cm 35 Kg / cm
intel pressure. (abs) (abs) (abs)
o o o
27. IP cylinder stop valve 537 c 535 c 535 c
intel temp.
28. Bleed Steam point 1 Nos. -CRH
(stages of turbine) 2 Nos. - IPT
1 Nos. Cross around 25,36,45,48, 9,12,15,18,21,23,25
pipe between IPT 50,52
& LPT, 2 Nos. LPT
29. Extraction valves 500 MW (KWU) 200 MW (KWU) 200 MW (LMW)
a. Extraction 1- No Valve 1 swing No Valve 1 swing No Valve 1 NRV
b. Extraction 2- check valve with check valve with (lift check type) with Aux.
Aux. Actuator Aux. Actuator actuator
c. Extraction 3- 1 swing check valve 1 swing check 1 NRV (lift check type)
with Aux.actuator valve with Aux. with Aux. Actuator
Actuator
d. Extraction 4,1- 2 swing check valves Extraction-4 1 NRV (lift check type)
with 1 swing check with Aux. Actuator
Aux. Actuator valve with Aux.
Actuator
4,2
e. Extraction 5- 1 swing check valve 1 swing check 1 NRV (lift check type)
with valve with Aux. with Aux. Actuator
Aux.actuator Actuator
f. Extraction 6- No valve No valve 2 NRVs (lift check type)
with Aux. Actuator
g. Extraction 7- 1 NRV (lift check type)
with Aux. Actuator