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Chapter-6
Steam Turbine
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Out Line
Introduction
Work in a turbine
Classification of steam turbine
Description of common types of turbine
- Impulse turbine
- Reaction turbine
compounding in steam turbine
steam supply and exhaust conditions
casing or shaft arrangement
Principle of operation and design
Turbine efficiency
Basic Blades Force and Strength Analysis
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History
Invention attributed to Sir Charles Parsons in
1884.
First compound (multi stage) turbine
developed in 1887.
A majority of the worlds power today is
produced by steam turbines from a variety of
fuels including:
Coal
Nuclear
Oil
Concentrated Solar
Geothermal
Some major manufacturers include:
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Siemens 1/16/19
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Introduction
A steam turbine is a device that extracts thermal energy from
pressurized steam and uses it to do mechanical work on a rotating output shaft. Its
modern manifestation was invented by Sir Charles Parsons in 1884.
Steam Turbine may also be define as a device which converts heat energy of the
steam to the mechanical energy which finally converted into electrical energy.
Because the turbine generates rotary motion, it is particularly suited to be used to
drive an electrical generator – about 90% of all electricity generation in the United
States, is by use of steam turbines.
The steam turbine is a form of heat engine that derives much of its improvement
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Why are steam turbine blades higher at the exit ?
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The modern steam turbine was invented in 1884 by Sir Charles
major world power stations, and the size of generators had increased
from his first 7.5 kW set up to units of 500MW capacity.
Steam turbines are made in a variety of sizes ranging from small
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Classification of Steam Turbine
Classification of steam turbines may be done as following:
(b) Reaction turbine : There is change in both pressure and velocity as the steam flows through the moving blades.
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The other ways to classify turbines are
given below:
Central-station turbines: These turbines are used to
drive electrical generators at synchronous speed
(usually 3000 rev/min) and have capacities ranging
from 16 to 1500 MW.
Condensing or non-condensing turbines: Steam
turbines are classified as condensing or non-
condensing depending upon whether the back
pressure is below or above atmospheric pressure.
Reheat turbines: The reheat turbine returns the
steam, after partial expansion, to the boiler for
superheating and then expands it to back pressure.
Superposed or topping turbines: These are high
pressure non-condensing turbines installed in existing
low pressure steam plants. They exhaust into the
existing low pressure turbines, thus, increasing plant
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capacity and overall thermal efficiency.
Description of common types of Turbines.
The common types of steam turbine are
1. Impulse Turbine.
2. Reaction Turbine.
The main difference between these two turbines lies in the way of
expanding the steam while it moves through them.
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Impulse and Reaction Turbine.
1. Impulse turbine: steam is expanded in
stationary turbine nozzles, where it attains
a high velocity. This high velocity jet then
flows over moving blades without further
expansion, that is, its pressure remains
constant.
2. Reaction turbine: steam is expanded in
both fixed blade (nozzle) and moving
blades. The relative amount of expansion
varies with a particular design.
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In the impulse turbine, the steam expands in the nozzles and it's
pressure does not alter as it moves over the blades. In the reaction
turbine the steam expanded continuously as it passes over the blades
and thus there is gradually fall in the pressure during expansion below
the atmospheric pressure.
Pressure-velocity diagram for a turbine nozzle
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Simple impulse Turbine.
It the impulse turbine, the steam expanded within the nozzle and there
is no any change in the steam pressure as it passes over the blades
Impulse turbine principle
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An impulse turbine has fixed nozzles that orient the steam flow into high speed
jets. These jets contain significant kinetic energy, which is converted into shaft
rotation by the bucket-like shaped rotor blades, as the steam jet changes
direction.
A pressure drop occurs across only the stationary blades, with a net increase in
steam velocity across the stage. As the steam flows through the nozzle its
pressure falls from inlet pressure to the exit pressure (atmospheric pressure, or
more usually, the condenser vacuum). Due to this high ratio of expansion of
steam, the steam leaves the nozzle with a very high velocity.
The steam leaving the moving blades has a large portion of the maximum
velocity of the steam when leaving the nozzle. The loss of energy due to this
higher exit velocity is commonly called the carry over velocity or leaving loss.
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Pressure-velocity diagram for a moving impulse blade
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Reaction Turbine
In this type of turbine, there is a gradual pressure drop and takes place
continuously over the fixed and moving blades. The rotation of the shaft
and drum, which carrying the blades is the result of both impulse and
reactive force in the steam. The reaction turbine consist of a row of
stationary blades and the following row of moving blades.
The fixed blades act as a nozzle which are attached inside the cylinder
and the moving blades are fixed with the rotor as shown in figure
When the steam expands over the blades there is gradual increase in
volume and decrease in pressure. But the velocity decrease in the moving
blades and increases in fixed blades with change of direction.
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Because of the pressure drops in each stage, the number of stages
therefore the diameter of the turbine must increase after each group of
blade rings.
Reaction turbine principle
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In the reaction turbine, the rotor blades themselves are arranged to form
convergent nozzles. This type of turbine makes use of the reaction force
produced as the steam accelerates through the nozzles formed by the rotor.
Steam is directed onto the rotor by the fixed vanes of the stator. It leaves
the stator as a jet that fills the entire circumference of the rotor. The steam
then changes direction and increases its speed relative to the speed of the
blades.
A pressure drop occurs across both the stator and the rotor, with steam
accelerating through the stator and decelerating through the rotor, with no
net change in steam velocity across the stage but with a decrease in both
pressure and temperature, reflecting the work performed in the driving of
the rotor.
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Pressure-velocity diagram for a moving reaction blade
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6.1. Impulse Turbine
The impulse turbine is characterized by the
fact that it has fixed nozzles and that the
pressure-drop of the steam takes place
in the nozzles.
The steam enters the turbine with high
velocity. With the whole of the pressure drop
having taken place in the nozzles, the
pressure in the turbine remains constant. In
the turbine, the velocity of steam is reduced
as some of the kinetic energy in the steam is
used up in producing work in the turbine
shaft.
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Lf the whole pressure drop from boiler to
Compounding of Steam Turbine
The steam produced in the boiler has
sufficiently high enthalpy when superheated. In
all turbines the blade velocity is directly
proportional to the velocity of the steam
passing over the blade. Now, if the entire
energy of the steam is extracted in one
stage, i.e. if the steam is expanded from
the boiler pressure to the condenser
pressure in a single stage, then its
velocity will be very high. Hence the velocity
of the rotor (to which the blades are keyed) can
reach to about 30,000 rpm, which is pretty high
for practical uses because of very high
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vibration. Moreover at such high speeds 1/16/19
the
centrifugal forces are immense, which can
Compounding in Steam Turbine
The compounding is the way of reducing the wheel or rotor speed of the turbine to
optimum value. It may be defined as the process of arranging the expansion of steam or
the utilization of kinetic energy or both in several rings.
There are several methods of reducing the speed of rotor to lower value. All these
methods utilize a multiple system of rotors in series keyed on a common shaft, and the
seam pressure or jet velocity is absorbed in stages as the steam flower over the blades.
1.Velocity Compounding
2.Pressure Compounding
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Velocity Compounding
There are number of moving blades separated by rings of fixed blades
as shown in the figure. All the moving blades are keyed on a common
shaft. When the steam passed through the nozzles where it is expanded
to condenser pressure. It's Velocity becomes very high. This high
velocity steam then passes through a series of moving and fixed blades
When the steam passes over the moving blades it's velocity decreases.
The function of the fixed blades is to re-direct the steam flow without
altering it's velocity to the following next row moving blades where a
work is done on them and steam leaves the turbine with allow velocity
as shown in diagram.
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Velocity Compounding of Impulse Turbine
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Pressure Compounding
These are the rings of moving blades which are keyed on a same shaft in series,
The kinetic energy of the steam thus obtained is absorbed by moving blades.
The steam is then expanded partially in second set of nozzles where it's pressure
again falls and the velocity increase the kinetic energy so obtained is absorbed
by second ring of moving blades.
This process repeats again and again and at last, steam leaves the turbine at low
velocity and pressure. During entire process, the pressure decrease continuously
but the velocity fluctuate as shown in diagram.
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Pressure Compounding of Impulse Turbine
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Pressure Velocity compounding
This method of compounding is the combination of two previously
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Pressure-Velocity Compounded Impulse Turbine
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Pressure-velocity Compounded Impulse Turbine
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Reaction Turbine
The reaction turbine essentially consists of
a row of blades mounted on a drum. The
drum blades are separated by rows of fixed
blades mounted in the casing, Fig. below.
No nozzles are mounted in a reaction
turbine.
The fixed blades act both as nozzles in
which the velocity of steam is increased
and also as a means by which the steam is
correctly directed onto the moving blades.
Steam enters a reaction turbine on the
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whole blade annulus -a condition which is
Reaction Turbine
The steam also expands in the moving blades
of a reaction turbine with consequent pressure
drop and velocity decrease in these moving
blades.
This gives are extra reaction to the moving
blades over that which would be obtained if the
blades were impulse, other things being equal.
This extra reaction gives the turbine its name
the reaction turbine. The steam velocity in a
reaction turbine is not very high and hence, the
speed of the turbine is relatively low.
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Velocity Diagram for Impulse
Turbine Blade
In an impulse turbine, steam jet impinges on one end of
the blade after leaving the nozzle. The jet then glides-
over the inside surface of the blade and finally leaves at
the other edge.
The following symbols are used to designate the velocity
conditions for steam flowing through the turbine blade
passages,
nozzle;
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Principle of Operation and Design
An ideal steam turbine is considered to be an isentropic process, or constant
entropy process, in which the entropy of the steam entering the turbine is
equal to the entropy of the steam leaving the turbine
No steam turbine is truly isentropic, however, with typical isentropic
are more commonly referred to. One set of stationary blades is connected to
the casing and one set of rotating blades is connected to the shaft.
The sets intermesh with certain minimum clearances, with the size and
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Operation and Maintenance
When warming up a steam turbine for use, the main steam stop valves
(after the boiler) have a bypass line to allow superheated steam to slowly
bypass the valve and proceed to heat up the lines in the system along
with the steam turbine. Also, a turning gear is engaged when there is no
steam to the turbine to slowly rotate the turbine to ensure even heating to
prevent uneven expansion.
After first rotating the turbine by the turning gear, allowing time for the
rotor to assume a straight plane (no bowing), then the turning gear is
disengaged and steam is admitted to the turbine, first to the astern blades
then to the ahead blades slowly rotating the turbine at 10–15 rpm (0.17–
0.25 Hz) to slowly warm the turbine.
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Any imbalance of the rotor can lead to vibration, which in
extreme cases can lead to a blade breaking away from the rotor at
high velocity and being ejected directly through the casing. To
minimize risk it is essential that the turbine be very well balanced
and turned with dry steam - that is, superheated steam with a
minimal liquid water content
If water gets into the steam and is blasted onto the blades
(moisture carry over), rapid impingement and erosion of the
blades can occur leading to imbalance and catastrophic failure.
Also, water entering the blades will result in the destruction of the
thrust bearing for the turbine shaft.
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To prevent this, along with controls and baffles in the boilers to ensure
high quality steam, condensate drains are installed in the steam piping
leading to the turbine. Modern designs are sufficiently refined that
problems with turbines are rare and maintenance requirements are
relatively small.
The steam turbine operates on basic principles of thermodynamics using
the part of the Rankine cycle. Superheated vapor (or dry saturated vapor,
depending on application) enters the turbine, after it having exited the
boiler, at high temperature and high pressure. The high heat/pressure
steam is converted into kinetic energy using a nozzle. Once the steam
has exited the nozzle it is moving at high velocity and is sent to the
blades of the turbine.
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A force is created on the blades due to the pressure of the vapor on
actual and the ideal turbines, but at turbine exit the energy content
('specific enthalpy') for the actual turbine is greater than that for
the ideal turbine because of irreversibility in the actual turbine.
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Turbine Efficiency
To maximize turbine efficiency the steam is expanded,
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STEAM NOZZLES
The pressure and volume are related by the simple expression,
PV = constant, for a perfect gas.
Steam deviates from the laws of perfect gases. The P-V
relationship is given by:
PVn = constant
where:
where h1 and h2 are the enthalpies at the inlet and outlet of the
nozzle, respectively.
As the outlet pressure decreases, the velocity increases.
Eventually, a point is reached called the critical pressure ratio,
where the velocity is equal to the velocity of sound in steam.
Any further reduction in pressure will not produce any further
increases in the velocity.
The temperature, pressure, and density are called critical
temperature, critical pressure, and critical density, respectively.
The ratio between nozzle inlet temperature and critical
temperature is given by:
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where Tc is the critical temperature at which section M = 1.
Assuming isentropic flow in the nozzle, the critical pressure
ratio is:
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Figure:- Nozzle expansion process for a vapor.
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Mollier chart for a multi-stage turbine.
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Since the isobars diverge, R.F. > 1.
The reheat factor may be used to relate the stage
efficiency and the turbine efficiency.
Turbine isentropic efficiency is given by:
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STAGE DESIGN
A turbine stage is defined as a set of stationary blades (or
nozzles) followed by a set of moving blades (or buckets or
rotor).
Together, the two sets of blades allow the steam to perform
work on the turbine rotor.
This work is then transmitted to the driven load by the shaft on
which the rotor assembly is carried.
Two turbine stage designs in use are: the impulse stage and
reaction stage.
In impulse stage: - the total pressure drop occurs across the
stationary blades (or nozzles). This pressure drop increases the
velocity of the steam.
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However, in the reaction stage, the total pressure drop is
divided equally across the stationary blades and the moving
blades.
The pressure drop again results in a corresponding increase in
the velocity of the steam flow.
the shape of the stationary blades or nozzles in both stage
designs is very similar
However, a big difference exists in the shapes of the moving
blades.
In an impulse stage, the shape of the moving blades or
buckets is like a cup.
The shape of the moving blades in a reaction stage is more
like that of an airfoil.
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THE IMPULSE STEAM TURBINE
Consider the steam supplied to a single-wheel impulse turbine
expands completely in the nozzles and leaves with absolute
velocity C1 at an angle 1, and by subtracting the blade velocity
vector U, the relative velocity vector at entry to the rotor V1 can
be determined.
The relative velocity V1 makes an angle of β1 with respect to U.
The increase in value of 1 decreases the value of the useful
component, C1 cos1 and increases the value of the axial or flow
component Ca sin1.
The two points of particular interest are the inlet and exit of the
blades.
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Figure: - Velocity triangles for turbine stage.
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Vectorially subtracting the blade speed results in absolute
velocity C2. The steam leaves tangentially at an angle β2 with
relative velocity V2. Since the two velocity triangles have the
same common side U
Since Cw2 is in the negative r direction, the work done per unit
mass flow is given by:
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The overall efficiency is determined as
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where h0 is the enthalpy at the entry to the nozzle and h 1 is the
enthalpy at the nozzle exit, neglecting the velocity at the inlet
to the nozzle.
The energy supplied to the blades is the kinetic energy of the
jet, C21/2 and the blading efficiency
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And the rate of work performed per unit mass = 2(C1 cosa1 -
U)U Therefore:
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or
Substituting this value into the power output per unit mass
flow rate at the maximum blade efficiency:
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AXIAL FLOW STEAM TURBINES
Sir Charles Parsons invented the reaction steam turbine.
The reaction turbine stage consists of a fixed row of blades
and an equal number of moving blades fixed on a wheel.
In this turbine pressure drop or expansion takes place both in
the fixed blades (or nozzles) as well as in the moving blades.
Because the pressure drop from inlet to exhaust is divided into
many steps through use of alternate rows of fixed and moving
blades, reaction turbines that have more than one stage.
In a reaction turbine, a reactive force is produced on the
moving blades when the steam increases in velocity and when
the steam changes direction.
Reaction turbines are normally used as low-pressure turbines.
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DEGREE OF REACTION
The degree of reaction or reaction ratio (Λ) is a parameter that
describes the relation between the energy transfer due to static
pressure change and the energy transfer due to dynamic
pressure change.
The degree of reaction is defined as the ratio of the static
pressure drop in the rotor to the static pressure drop in the
stage.
It is also defined as the ratio of the static enthalpy drop in the
rotor to the static enthalpy drop in the stage.
If h0, h1, and h2 are the enthalpies at the inlet due to the fixed
blades, at the entry to the moving blades and at the exit from
the moving blades, respectively, then:
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The static enthalpy at the inlet to the fixed blades in terms of
stagnation enthalpy and velocity at the inlet to the fixed blades
is given by
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BLADE HEIGHT IN AXIAL FLOW MACHINES
The continuity equation, = AC, may be used to find the
blade height h.
The annular area of flow = πDh. Thus, the mass flow rate
through an axial flow compressor or turbine is:
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Exercise 1
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Exercise 2
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Exercise 3
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THE END
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