1

Introduction to Turbine

2
 Introduction to Turbine
What is Turbine?
i. “The turbine is a prime mover in which gradual change
of momentum of fluid is utilized to produce rotation of
the mobile member” (Jude).

ii. “The turbine is a machine in which a rotary motion is

obtained by the gradual change of momentum of fluid”
(Neilson).

iii. “The turbine is a prime mover in which a rotary motion

is obtained by centrifugal force brought into action by
changing the direction of a jet of a fluid escaping from
a nozzle at high velocity.”
 Introduction to Turbine
 The steam turbine is universally used as a prime mover in all
steam power plants.

 Steam turbine is a power unit which produces power from a

continuous supply of steam.

 Its power generation capacity ranges from 1000 MW to 1500 MW.

 The steam being delivered to the turbine at high pressure

and exhausted to condenser at low pressure.

 The way in which the overall pressure drop in the turbine occurs
is a characteristic of the particular design, which increase the
kinetic energy of the steam. 4
 Basically, the operation of steam turbines entirely depends on the
dynamic action of the steam.

 Which is expanded through the nozzle or fixed blades (NGV).

 Large type turbines are used for driving electric generators and
ship propellers.

 Small type turbines are used for driving pumps, fans and
compressors.

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sectional view:

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Component of Impulse Steam Turbine
Main components are
1. Casing
2. Rotor
3. Blades
4. Stop and control valve
5. Oil befell, steam befell
6. Governor
7. Bearing(general and thrust bearing)
8. Gear box(epicyclic gear box)
9. Oil pumps

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 Construction of steam turbines

1 – steam pipeline 9 – rotor disc 21 – bearing pedestal

2 – inlet control valve 10 – rotor 22 – safety governor
3 – nozzle chamber 11 – journal bearing 23 – main oil pump
4 – nozzle-box 13 – thrust bearing 24 – centrifugal governor
5 – outlet 14 – generator rotor 25 – turning gear
6 – stator 15 – coupling 29 – control stage impulse blading
7 – blade carrier 16 – labyrinth packing
8 – casing 19 – steam bleeding (extraction)
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Construction of steam turbines

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Classification Steam Turbine
The turbines are generally classified according to:

Stages

Direction of flow of steam (Axial/Radial)

Terminal pressure

Steam pressure

Source of steam.

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Steam turbine
Steam Turbine System:
• Widely used in CHP(combined heat and power)
applications.
• Oldest prime mover technology
• Capacities: 50 kW to hundreds of MWs
• Thermodynamic cycle is the “Rankin cycle” that uses a
boiler
• Most common types
• Back pressure steam turbine
• Extraction condensing steam turbine

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Rankin cycle
1-2 Isentropic compression in a pump
2-3 Constant pressure heat addition in a boiler
3-4 Isentropic expansion in a turbine
4-1 Constant pressure heat rejection in a condenser

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Steam Turbine
Back Pressure Steam Turbine
• Steam exits the turbine at a higher pressure that the
atmospheric

HP Steam
Advantages:
-Simple configuration
-Low capital cost
Boiler Turbine -Low need of cooling water
-High total efficiency
Fuel

Disadvantages:
Condensate LP
Process Steam
-Larger steam turbine

Figure: Back pressure steam turbine

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Steam Turbine
Extraction Condensing Steam Turbine
HP Steam

• Steam obtained by
extraction from an Boiler Turbine

intermediate stage Fuel

• Remaining steam is Condensate

LP Steam

Process
exhausted
• Relatively high
capital cost, lower Condenser

total efficiency

Figure: Extraction condensing steam turbine

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Classification Steam Turbine
i. Impulse Turbine (De-Laval Turbine)

ii. Reaction Turbine (pure)

iii.Impulse-Reaction Turbine

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Impulse Turbine Principle
ROTOR

NOZZLE

STEAM
CHEST

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Impulse Turbine

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18
19
 Impulse Turbine
In these turbines first enthalpy of steam at higher pressure is converted into
 kinetic energy by passing through the nozzle.

High velocity steam from nozzle impinges on the blades fixed on the periphery
of the rotor.

Blades change the direction of flow without changing its pressure.

Resulting rotative force (due to change in the momentum) causes the rotation
of the rotor or turbine shaft.

Linear momentum of steam change to the wheel tangentially gives the

tangential force.

That cause the wheel to rotate.

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Reaction Turbine Principle
ROTOR

STEAM CHEST
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Reaction Turbine (Pure)

Pure reaction turbines are old type.

They are not in use at Present time

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Impulse-Reaction Turbine

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24
25
Impulse-Reaction Turbine
In impulse-Reaction turbine pressure drop takes place in fixed blades

This drop in pressure gives the reaction to the moving blades.

Fixed blades are also known as guided blade.

Fixed blade row works as stator and fixed in the casing

Moving blade row works as rotor and fixed on shaft

When steam enters in whole blade annulus known as Full dimension.

Pressure decrease and velocity increase in fixed blade

Pressure drop and velocity drop in moving blades.

50% enthalpy drop in moving blade is called 50% degree of reaction. 26

Flow over Impulse Turbine Blade
Fixed Blade
The jet of steam at high velocity (C) impinges
on left hand side of fixed blade.

Steam jet change its direction as it passes over Inlet

+ ve
the blade and leave the blade in reverse
direction with negative velocity (-C).

According to Newton’s 2nd law:

- ve Exit
F rate of change of momentum

F=m(change in velocity)

F=mC
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C=velocity at exit-velocity at inlet

C= (-C)-(C)

C=-2C

F= -2mC

This is opposite force on the jet.

-ve sign shows that the force acts from right to left in opposite direction to the
Flow, which satisfied the Newton’s statement:

“Every action has an equal and opposite reaction”

The reaction force provides the driving force/ impulse force on the blade in
direction of motion. Therefore,

F= 2mC
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Moving Blade
Fluid enters or leave the wheel passages in tangential direction with
Absolute velocity. (Cai, Cae)

If Cb>Cai

There is no effect on the motion of blade.

If Cai >Cb
Then steam impinges on blade with relative velocity,

Cr = (Cai- Cb)

If there is no reduction in relative velocity due to friction.

Steam leaves the blade with the relative velocity,- (Cai- Cb).
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We know that according second law of Newton

F= m (change in relative velocity)

F = m xCr

Cr= - (Cai- Cb) - (Cai- Cb)

Cr= -2(Cai- Cb)

F = -2m(Cai- Cb) Opposite force on the jet

F = 2m(Cai- Cb)

Impulse force on the blade in the direction of motion.

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Angle of Nozzle/Jet

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As we know that the turbine wheel consists of series of blades fixed on its
circumference

These blades receive steam from series of nozzles at certain angle (i )

This angle permits the steam to enter or leave the blade at absolute
velocity (Cai) and (Cae) respectively.

The selection of (i ) angle is one of compromise type,

Since the increase in (i ) reduces the value of velocity and increases the
axial flow Components.

The flow components must be sufficient to allow the steam to flow across
the wheel and its value influences the size of the wheel space.

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Shape &Angle of Turbine Blade

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Shape of Turbine Blade

Aerofoil type turbine blade 34

 Comparison between Impulse and
Reaction turbine
Impulse Turbine Impulse-Reaction Turbine
i. Steam completely expands in i. Steam expands partially in the
the nozzles and its pressure fixed blades and partially in
remain constant, while moving blades.
passing through the blades.

ii. The relative velocity of steam ii. The relative velocity of steam
remain constant while passing increases as it expands in
over the moving blade. moving blades.

iii. The shape of blade is profile/ iii. The shape of blades is of

symmetrical. aerofoil type/non symmetric.

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 Comparison between Impulse and
Reaction turbine
Impulse Turbine Impulse-Reaction Turbine
iv. The blade passage of constant iv. The blade passage of variable
x-section area, as there is no x-section area to allow
expansion expansion

v. The number of stages required v. The number of stages required

are less for the same power are large for the same power
generation. generation.

vi. The blade speed and steam vi. The blade speed and steam
speed are high due to large speed are low due to small and
pressure drop in nozzles. gradual pressure drop.

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 Comparison between Impulse and
Reaction turbine
Impulse Turbine
vii. There is more friction losses as
compare to leakage losses.
viii. Less space is required per unit
power.
ix. They are suitable for small
power requirement.
x. Steam impinges on the blades
with kinetic energy (k.E).
xi. Steam may or may not be
admitted over the whole
circumference.
Impulse-Reaction Turbine
vii. Leakage losses are more as
compared to friction losses.
viii. More space is required for per
unit power.
ix. They are suitable for medium
and high power requirement.
x. Steam glides over moving
blades with the pressure and
K.E.
xi. Steam must be admitted over
over the whole circumference
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Velocity Diagram For Impulse
Turbine Blade

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Velocity Diagram For Impulse Turbine Blade

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Velocity Diagram For Impulse Turbine Blade

Cb=Blade Velocity
Cr= Relative Velocity
Ca= Absolute Velocity
Cf = Flow Velocity/Cause to produce axial thrust on blade
Cw = Whirl Velocity/cause to rotate the blade
α = Nozzle angle/angle of steam entering and leaving the blade.
β = Angle of blade/relative Velocity.
i ,e =inlet and exit of blade
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Velocity Diagram For Impulse Turbine Blade

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 Work done by Impulse Turbine Blade
(Velocity Diagram)

D O A E
e i e i
Cae
Cfe Cri Cfi
Cre Cai

C
F
Cw B

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Work done by Impulse Turbine Blade
W.D = Force x Displacement

Absolute velocity (Ca) has two components:

Axial (Cf) velocity

Tangential (Cw) velocity

We know that (Cw) component cause to rotate the blade, By Newton’s 2nd Law

F = m x change in velocity

F m
  ( C we )  (C wi )

F  m
 (C we  C wi )
-ve sign shows that force acts in opposite direction
F  m
 Cw to the rotation
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According to Newton’s 3rd law

F m
 Cw
This +ve sign reaction force provide the driving force / thrust on the
Wheel to rotate.

Units
kg m kg  m
F   2
N
sec sec sec

FN W .D  N 
m

J
sec sec
Now, work done by blade

W .D  m
 C w Cb W .D
 Power  Watt
sec
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The tangential force acting on the jet is given by

F=mxchange in velocity in tangential direction

Tangential velocity of steam relative to the blade at inlet and exit are given by

CW  DE  AD  AE
AE  Cri. cos  i
AD  Cre. cos  e
F m CW
Change in tangential velocity = velocity at exit – velocity at inlet

 Cre. cos  e  Cri. cos  i

 (Cre. cos  e  Cri. cos  i )

 (Cre. cos  e  Cri. cos  i )

F  m Tangential force on the wheel
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Reaction force on the wheel provide the driving thrust on the wheel

 (Cre. cos  e  Cri. cos  i )

F m

If the blade is symmetrical and no friction loss and blade velocity coefficient (K)

Cre.
K  1
Cri
 Cre  Cri
e  i

By considering the friction loss

Cre  KCri
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C w  2Cri. cos  i  ()

Cri. cos  i  Cai. cos i  C b  ()

Substitute the value of Cri in equation (*)

C w  2(Cai. cos i  Cb )
Now, W.D by symmetrical blades without friction

 (Cai. cos i  Cb ).Cb

W .D  2m

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Axial force / Axial Thrust

C f  CF  EB  DC

C f  C fi  C fe

Axial( F )  m
Cf

If , C fe C fi

The end thrust is along the turbine shaft in the direction of velocity flow

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If , C fe  C fi
The end thrust is in opposite direction to the velocity flow

Usually

C fe C fi
Diagram Efficiency

d= Rate of doing work per kg of steam / Energy supplied per kg of steam
 Cb C w
m
d 
Cai 2

m
2

2C b C w
d 
Cai 2 49
Diagram Efficiency for symmetrical blade without loss

2m (Cai. cos i  C b ).C b

d   Cw  2(Cai. cos i  Cb )
Cai 2
m
2
4(Cai. cos i  C b ).C b
d 
Cai 2

Cb Cb
d  4 (cos i  ) (  
Cb
)
Cai Cai Cai

Cb
d  4 (cos i   )
Cai
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Blade Speed (Cb)
Cb  .r

2N
Cb  r
60

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Problem(11.1-Eastop)
The velocity of steam leaving the nozzle of an impulse turbine is 900 m/sec and the
Nozzle angle is 20o. The blade velocity is 300 m/sec and blade velocity coefficient is 0.7.
Calculate for a mass flow of 1 kg/sec and symmetrical blading.

(a) Blade inlet angle

(b) The driving force on the wheel
(c) The axial thrust
(d) The diagram power
(e) The diagram efficiency

The information given is indicated on figure and required quantities can be calculated
By construction of velocity diagram and by calculations.

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Velocity Diagram

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(a) The blade inlet angle (i)

The blade inlet angle can be measured directly from fig or analytically

Take  OAB and apply the cosine rule

Cri 2  Cai 2  C b  2C b .Cai. cos i

2

Cri 2  (900) 2  (300) 2  2  300  900  cos 20

Cri  626.5m / sec

Now apply the sine rule in triangle OAB

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 Cai Cri

SinOAB Sin  i

CaiSin  i
Sin  i 
Cri

SinOAB  Sin  i

900 Sin 20
Sin  i   0.491
626.5
 i  29o
 i   e  29o
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 (b) Driving force on the wheel

Cre
K
Cri

Cre  K  Cri

Cre  0.7  626.5

Cre  438.5m / sec

AD  Cri. cos  i  626.5  Cos 29

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AD  545.8m / sec

AE  Cre. cos  e  438.5  Cos 29

AE  381.9m / sec

Cw  DE  AD  AE

Cw  381.9  545.8

Cw  927.6m / sec

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 Driving force on the wheel

F m
 Cw

F  1  927.6

F  927.6 N / kg / sec

(C) Axial Thrust

C f  C fi  C fe
C fi  C ri Sin  i  626.5  Sin 29
C fi  307.6 m / s
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C fe  C re Sin  e  438.5  Sin 29
C fe  215.3m / s
C f  C fi  C fe
C f  307.6  215.3
C f  92.3m / s

Axial Thrust = F m
Cf

F  1  92.3

F  92.3 N / kg / sec
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(d) Diagram power(P) per kg / sec

Pm
 Cb  C w
P  1  300  927.7
P  278300Watt
P  278.3kW

(e) Diagram Efficiency

2C b C w 2  300  927.7
d    100
C ai 2 900  2

 d  68.7%

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Problem (24.1-Khurmi)
The velocity of steam at inlet of a simple impulse turbine is 1000 m/sec and the angle is 20o.
The mean blade speed is 400 m/sec and the blades are symmetrical. The mass flow rate of
Steam is 0.75 kg/sec. The friction effects on the blade are negligible .
Estimate : (a) Blade angle
(b) The tangential force
(c) The axial thrust
(d) Diagram power
(e) The diagram efficiency

DATA
Cai  1000m / sec
Cb  400m / sec
  0.75
m
 i  20 o
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(a)From velocity diagram, due to symmetrical blading

 i   e  33o
(b)Tangential force on the wheel

F  m Cw

F  0.75  1120

F  840 N
(c) Axial thrust

F  m C f We know that blade is symmetrical and without friction

Therefore, Cfe = Cfi
F 0
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(d) Diagram power

P  m CwCb

P  0.75 1120  400

P  336 KW
2CwCb
(e) Diagram Efficiency
d 
Cai 2
2  1120  400
d 
(1000) 2

 d  89.6%
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Problem (example:105-Joel)
The nozzles of a simple impulse turbine are inclined at an angle of 20o to the direction of the
flow path of the moving blades and the steam leaves the nozzles at 375 m/sec. The blade speed
is 165 m/sec.
Find the suitable inlet and outlet angles for the blades in order that there shall be no
Axial thrust on the blades allowing for the velocity of the steam is passing over the blades being
reduced by 15%.
Determine also power developed for a steam flow of one kg/sec at the blade and K.E
of the steam finally leaving the wheel.

DATA
 i  20 o REQUIRED
(i )  i
Cai  375m / s (ii )  e
(iii ) Power
Cb  165m / sec (iv ) K .E
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From velocity diagram

Blade inlet angle  EBC  34 O

Blade outlet angle  ABD  41O
Whirl velocity= Cw  320m / sec
Power developed for one kg of the steam flow
Power  m
 CwCb

P  1  320  165

P  52800Watt

P  52.8kW
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Kinetic energy (K.E) of steam finally leaving the wheel.
Cae 2
K .E  m

2

(132.5) 2
K .E .  1 
2

K .E  8778 J / kg / sec

K .E  8.778 KJ / kg / sec

K .E  8.778kW / kg
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Velocity Diagram for Two Rows
of Impulse Turbine Blade

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Velocity Diagram for Two Rows of Impulse Turbine Blade

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Velocity Diagram for Two Rows of Impulse Turbine Blade

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Problem:
Two-rows of a velocity-compounded impulse turbine have a mean blade
speed of 150 m/s and nozzle velocity of 675 m/s. The nozzle angle is 20o.
The exist angles of first row of moving blades, fixed blades and second row
of moving blades are 25,25 and 30o respectively. There is a 10% loss of
velocity due to friction in all blades. The steam flow rate is 4.5 kg/s. Draw
the velocity diagram to a suitable scale and determine:
i. The power output of the turbine
ii. The diagram efficiency
Data
Cb = 150 m/s
Cai1 = 675 m/s
αi1 = 20o
βe1= 25o
αi2 = 25o
βe2 = 30o
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 From velocity diagram:
Cw1  915m / s
Cw2  280m / s
 (a) Power of the turbine
P  m Cb (Cw1  Cw2 )
P  4.5 150(915  280)

P  806.625kw

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 (b) Diagram Efficiency
2Cb (Cw1  Cw 2 )
d 
Cai2 1
2 150(915  280)
d 
6752

 d  78.8%

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Problem
The first stage of a turbine is a two-row velocity-compounded impulse turbine.
The steam velocity at inlet is 600 m/s, the mean blade velocity is 120 m/s, and
the blade velocity coefficient for all blades is 0.9. The nozzle angle is 16o and
the exit angles for the first row of moving blades, the fixed blades and the
second row of moving blades are 18,21 and 35o respectively.
Calculate:
i. The blade inlet angles for each row
ii. The driving force for each row of moving blades and the axial thrust on the
wheel, for a mass flow rate of 1 kg/sec,
iii. The diagram power per kilogram per second steam flow, and the diagram
efficiency for the wheel.
iv. The maximum possible diagram efficiency for the given steam inlet velocity
and nozzle angle.

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Data
Cb = 120 m/s
Cai1 = 600 m/s
αi1 = 16o
βe1= 18o
αi2 = 21o
βe2 = 35o

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 Solution
 The velocity Diagrams are drawn to scale and the relative velocities at exit
are calculated by

Cre1  k1Cri1
Cre1  0.9  486
Cre1  437.4m / s

Cre2  k1Cri 2
Cre2  0.9  187.5
Cre2  169m / s

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 The absolute velocity at inlet to the second row of moving blades, Cai2 is to
the velocity of the steam leaving the fixed row of blades,
 i.e.
Cai 2  k1Cae1
Cai 2  0.9  327
Cai 2  297m / sec
 (i) The blade inlet angles are measured from the velocity diagram as:

Inlet blade angle, first row of moving blades,  i1  20o

Inlet blade angle, fixed blades,  e1  24.5o

Inlet blade angle, second row of moving blades,  i 2  34.5o

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 (ii) Driving force on the wheel, F m
 Cw
 Then,
 First row of moving blades, F m
 Cw1
F  1 874  874 N
 Second row of moving blades, F m
 Cw 2
F  1 292.5  292.5
 Total Driving force on the wheel, F m
 (Cw1  Cw2 )
F  1(874  292.5)

F  1166.5 N

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 (iii) Power developed,
P  F  Cb
1166.5 120
P
103
P  140kw / kg / sec
 Energy supplied to the wheel,

1 600 2
2

mCai1
  180kJ / sec
2 2 10 3

 Diagram Efficiency,

140
d   0.779
180
 d  80%
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 (vi) Maximum Diagram Efficiency,

 d max .  Cos 2 i
 d max .  Cos 216 o
 d max .  0.923
 d max .  92.3%

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80
 Compounding of Impulse Turbine
It is a process of reducing rotor speed to practical limit by adopting a multi
system of rotors in a series.

All rotors are keyed on common shaft and steam pressure and velocity is
absorbed in each stage of the system.

In recent year, high pressure(100 to 140 bar) and temperature steam is used in
power plants to increase their thermal efficiency.

If entire pressure drop (boiler to condenser) is carried out in only one stage,
then velocity of steam entering into the turbine will be extremely high.

It will make the turbine rotor to run at a very high speed (30000 rpm).

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From practical point of view, such high speed of the turbine rotor have some
disadvantages

Structure failure due to centrifugal stresses.

10 to 15% loss of K.E.

Friction losses due to high speed.

Reducing of unit efficiency

In order to reduce the rotor speed, various methods are employed

i. Gearing system between turbine and generator/system.

ii. Compounding Method

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METHODS OF COMPOUNDING

1. Velocity Compounding

2. Pressure Compounding

3. Pressure-Velocity Compounding

83
1. Velocity Compounding: (Curtis Turbine)

84
1. Velocity Compounding: (Curtis Turbine)

85
1. Velocity Compounding: (Curtis Turbine)
 In this method of compounding total expansion of steam take place in
nozzle/series of nozzles.

 When the steam passed through the nozzles where it is expanded to condenser
pressure. It's velocity becomes very high.

 High velocity (k.E.) is converted in mechanical energy in different moving

blades.

 There are number of moving blades separated by rings of fixed blades and
keyed on a common shaft as shown in the figure.

 This high velocity steam then passes through a series of moving and fixed
blades.
86
1. Velocity Compounding: (Curtis Turbine)
 When the steam passes over the moving blades it's velocity decreases.

 The function of the fixed blades is to re-direct/ correct direction 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 a low
velocity as shown in diagram.

 Maximum fall of velocity occurs in moving blade ring while pressure

remain constant in all the rings.

87
ADVATAGES
i. Relatively few numbers of stages required, hence the initial cost is low.
ii. It requires less space.
iii. The system is reliable and easy to start.
iv. The turbine and turbine casing are subjected to comparatively low pressure
v. Therefore, do not required strong body components.

DISADVANTAGES
i. Friction losses are more due to high speed
ii. Efficiency of turbine is low due to the ratio of blade velocity to steam velocity.
iii. It is not optimum for all wheels, because power developed in later rows only
the fraction of 1st row,
iv. whereas all stages required the same space, material or cost of material.

88
2. Pressure Compounding: (Rateau and Zoelly Turbine)

89
2. Pressure Compounding: (Rateau and Zoelly Turbine)

90
2. Pressure Compounding: (Rateau and Zoelly Turbine)

 Total pressure drop divided in portions.

 Instead of one set of nozzles, there are several sets of nozzles are used.

 They are separated from each other by rotor wheels, which are keyed on a
shaft in series.

 The kinetic energy of the steam thus obtained is absorbed by moving blades.

 Pressure drop takes place in different rings of the nozzles until whole
pressure has been absorbed.

 Pressure remain constant in moving blades.

 Velocity is dropped in moving blades.

91
Reaction turbine pressure compounding

92
3. Pressure-Velocity Compounding: (Moore &Curtis Turbine)

93
3. Pressure-Velocity Compounding: (Moore &Curtis Turbine)

94
3. Pressure-Velocity Compounding: (Moore &Curtis Turbine)
 This method of compounding is the combination of two previously discussed
methods.

 The total drop in steam pressure is divided into stages and the velocity
obtained in each stage is also compounded.

 The rings of nozzles are fixed at the beginning of each stage and pressure
remains constant during each stage as shown in figure.

 The turbine employing this method of compounding may be said to combine

many of the advantages of both pressure and velocity staging by allowing a
bigger pressure drop in each stage, less number stages are necessary and hence
a shorter turbine will be obtained for a given pressure drop.
 Volume will be increase due to large pr. drop in the nozzles.
 Turbine disc size increases with increase in volume.
95
Internal Losses in the Steam Turbine
All the losses which reduce the out put of the turbine is known as internal losses.
These are:

1. Residual velocity loss

2. Loss due to friction and turbulence of steam

3. Leakage loss

4. Loss due to mechanical friction

5. Radiation loss

6. Loss due to moisture

96
1. Residual Velocity loss
This loss takes place in terms of absolute velocity at exit of single-stage turbine,
which may be about 10 to 12%.

This loss can be reduced by using the multistage turbine.

2. Loss due to Friction and Turbulence of Steam

Friction loss may be 10% and occurred in:

Nozzles

Turbine blades

Rotating discs

This loss is taken into account by introducing the nozzle efficiency factor.
97
Effects:
This loss effect on the

velocity diagram

relative velocity

whirl velocity

power out put.

The extra energy is required to over come the friction, which results the reheat of steam

Reheat effect will improve the quality of steam at exit.

98
3. Leakage loss

 The leakage of steam occurs at different points in the turbine this may be
between

 Shaft and bearings

 Shaft and stationary casing in case of reaction turbine

 Leakage at blade tips in case of reaction turbine

 Total loss/ leakage is about 1-2%

99
4. Loss due to Mechanical friction

 This loss may be occurred in moving parts of the turbine

 Loss due to friction between shaft and bearings

 Some losses also occurred in regulating valves.

 These losses can be reduced by proper and efficient lubrication.

100
5. Radiation loss

 Heat loss from turbine to atmosphere because of poor insulation.

 This loss can be reduced by proper insulation system.

6. Loss due to moisture

 When steam pass through different stages it may condense and contain water
particles, which are dragged along the steam and reduce the K.E.

101
 Overall Efficiency, Stage efficiency ,
Reheat factor and Condition Curve
During the expansion of steam through the turbine, there are friction losses between
Steam and nozzle surface and turbine blade passages.

Further losses take places due to leakage of steam, which results useful enthalpy drop.

According to steady flow energy equation b/w inlet and outlet for assumed isentropic
conditions

C12 C22
h1   Q  h2  W
2 2
Q  0, C  0
h1  h2  W Isentropic

h1  h2,  W Actual
102
For single-stage turbine overall efficiency as,

o= Useful enthalpy drop / Isentropic enthalpy drop

h1  h2, hu o
o   Figure
h1  h2 hI o
hu o
o  For single stage
hI o

103
 Multi-Stage Efficiency
Suppose,
The expansion of steam through the four successive stages of turbine repres:
By h-S chart (Moillier Diagram).

If the effect of blade friction is neglected in all stages, then expansion shown by
Line A1-D

But in actual practice friction losses are observed in each stage of the turbine
From h-S chart heat drop in each stage shown by:

(i) Isentropic heat drop in each stages Figure

hI  A1 B1  A2 B2  A3 B3  A4 B4
hI  hI 1  hI 2  hI 3  hI 4

104
(ii) Actual heat drop in each stages
hu  A1C1  A2 C 2  A3 C3  A4 C4
hu  hu1  hu 2  hu 3  hu 4
 hI  hu
We know that, Stage Efficiency

s= Useful enthalpy drop in each stage/Isentropic enthalpy in the stage

hu
s 
hI

105
Overall efficiency of multi-stage turbine= o
 o   s  R.F
 hI
o  s 
hI o

Since, R.F   hI  hI o

Therefore, reheat factor always greater than one/unity, (i-e: R.F=1.04, 1.05)

R.F= It is a ratio of cumulative heat drop to isentropic heat drop

 AB
R.F 
A1 D

106
Internal / Isentropic Efficiency / turbine efficiency

i = Total useful heat drop / Total isentropic heat drop

A1C1  A2 C 2  A3 C 3  A4 C 4
i 
A1 D
(hA1  hC1 )  (hA2  hC 2 )  (hA3  hC 3 )  (hA4  hC 4 )
i 
hA1  hD
hA1  hC 4
i 
hA1  hD

107
Efficiency Ratio

E.R = Total useful heat drop / Total isentropic heat drop

E.R = Total work produced at the driving shaft / Total isentropic heat drop
Rankine Efficiency
R = Isentropic heat drop / Heat supplied
hA1  hD
R 
hA1 h f D

Where, hfD Enthalpy of water at point D.

108
Problem
In a thermal plant, the steam is supplied at a pr. Of 30 bar and temperature of 300oC
to a high pressure side of steam turbine where it is expanded to 5 bar. The steam is
then removed and reheated to 300 oC at constant pressure. It expanded to the low pr.
side of the turbine to 0.5 bar. Find the efficiency of cycle with and without reheating.
Data:

p1  30bar
Fig.
p 2  5bar
p 3  0.5bar
T1  300 o C
T2  300 o C

109
 C
A

B
D

E
111
The reheating of steam is represented on Moillier Chart, we find that,

h A  2990 kJ / kg
hB  2625kJ / kg
hC  3075kJ / kg
hD  2595kJ / kg
hE  2280 kJ / kg
From steam table corresponding to a pr. Of 0.5 bar, we find that sensible heat of
Water at “D”
h fD  h fE  340.49kJ / kg
We know that efficiency of the cycle with reheat

hA  hB   hC  hD 
1 
h A  hC  hB   h fD 
112
1 
2990  2665   3075  2595 
2990  3075  2665   340.8 
845
1   100
3099.4

 1  27.3%
Efficiency of cycle without reheating

hA  hE 2990  2280
2   100
hA  h fD 2990  340.6

 2  26.8%
113
Problem
The steam is supplied to a three stage turbine at 30 bar and 350oC. The steam leaves
the 1st stage at 7 bar, 2nd stage at 1bar, finally at 0.1bar. If each stage has an efficiency
of 0.7. Determine:
1. Rankine Efficiency
2. Final condition of steam
3. Reheat factor
4. Overall thermal efficiency
Fig.
5. Overall efficiency Turbine
6. Stage efficiency of turbine
7. Isentropic efficiency

Data:
p1  30bar , p 2  7 bar
p3  1bar , p4  0.1bar
T1  350 o C
  0.7
114
 30 Bar 7 Bar 1 Bar

0.1 Bar

A1

A2
C1
B1 A3
C2
B2

C3 A4
B3

D
Now, let us draw on Moillier diagram three stages for the expansion of steam.

1. Enthalpy of steam at point “A1” at pressure of 30 bar and 350oC from Moillier
Chart.
hA1  3120kJ / kg
2. Enthalpy at point “B1”

hB1  2790kJ / kg

3. Now, cut off the A1C1 equal to   h A1  hB 1 

0.7  3120  2790 
 231kJ / kg

116
4.Now, Enthalpy of steam at point “C1”
C1  hC 1  h A1  231
hC 1  3120  231
hC 1  2889 kJ / kg
5.Now, at “A2” draw vertical line “A2 B2” meet at pre. 1 bar
Enthalpy at point B2

hB 2  2535kJ / kg
Now, cut off at “A2 C2” equal to
A2 C 2   h A2  hB 2 
A2 C 2  0.7 2889  2535 
A2 C 2  248 kJ / kg
117
Therefore, enthalpy at point “C2” equal to
C 2  hC 2  h A2  248   2889  248 
hC 2  2641kJ / kg

6.Now, from “A3” draw vertical line upto “B3” meet at pre. 0.1 bar
Enthalpy at point B3

hB 2  2300kJ / kg
Now, cut off at “A3 C3” equal to
A3 C 3   h A3  hB 3 
A3 C 3  0.7 2641  2300 
A3 C 3  239 kJ / kg

118
Therefore, enthalpy at point “C3” equal to
C 3  hC 3  h A3  239   2641  239
h A4  hC 3  2402kJ / kg
Now, tabulate the enthalpies of steam from Moillier Chart

h A1  3120 kJ / kg
h A 2  hC 1  2889 kJ / kg
h A3  hC 2  2641kJ / kg
h A4  hC 3  2402 kJ / kg
hB 1  2790 kJ / kg
hB 2  2535 kJ / kg
hB 3  2300 kJ / kg
hD  2140 kJ / kg
119
From steam table, corresponding to a pressure of 0.1 bar, we find that the enthalpy
of water.
h fD  191.83kJ / kg
1. Rankine Efficiency

We know that:
R = Isentropic heat drop / Heat supplied
hA1  hD
R 
hA1 h f D
3120  2140
R   100
3120  191.8

 R  33.5%
120
2. Final condition of steam

From Moillier Diagram, the final condition of steam/dryness fraction at A4 at pr. 0.1bar

Dryness fraction =X =0.93

3. Reheat Factor (R.F)

hI hI A1 B1  A2 B2  A3 B3
R.F   
hI O A1 D A1 D

R.F 
hA1  hB1   hA2  hB 2   hA3  hB 3 
hA1  hD

R.F 
3120  2790  2889  2535  2641  2300
3120  2140
R.F  1.046
121
4. Overall Thermal Efficiency
hA1  hC 3
O 
hA1  h f D
3120  2402
O   100
3120  191.8

 O  24.5%

5. Overall efficiency of multi-stage turbine

 o   s  R.F
 hI
o  s 
hI o
122
6. Stage efficiency of turbine
hu (hA1  hC1 )  (hA2  hC 2 )  (hA3  hC 3 )
S  
hI (hA1  hB1 )  (hA2  hB2 )  (hA3  hB3 )
(3120  2889)  (2889  2641)  (2641  2402) 718
S  
(3120  2790)  (2889  2535)  (2641  2300) 1025
718
S   100
1025
 S  70%

 o   s  R.F
 o  0.7  1.046
 o  73.2%
123
7. Isentropic Efficiency

A1C1  A2 C 2  A3 C 3  A4 C 4
i 
A1 D
(hA1  hC1 )  (hA2  hC 2 )  (hA3  hC 3 )
i 
hA1  hD
hA1  hC 3 718
i    100
hA1  hD 980

 i  73.2%

124
Problems in steam turbine:
 Stress corrosion cracking

 Corrosion fatigue

 Pitting

 Oil lubrication

 imbalance of the rotor can lead to vibration

 misalignment

 Thermal fatigue

125
 Probable Failure Modes
• Bearing failures from: • Blade failures:
• Loss of lubrication • Foreign object damage
• Lubrication contamination • Erosion
• Excessive load • Fatigue

• Valve failures: • Steam seal failures:

• Solid particle damage • Wear
• Erosion • Erosion
• Fatigue • Corrosion

• Overspeed protection • Insulation failure

• Governor/Regulation failure • Coupling failures
• Hydraulic system failure • Alignment Changes

126
BLADE FAILURES:
 Unknown 26%

 Stress-Corrosion Cracking 22%

 High-Cycle Fatigue 20%

 Corrosion-Fatigue Cracking 7%

 Temperature Creep Rupture 6%

 Low-Cycle Fatigue 5%

 Corrosion 4%

 Other causes 10%

127
Corrosion:
 Resultant damage:
 Extensive pitting of airfoils, shrouds, covers, blade root
surfaces.
 Causes of failure:
 Corrosive elements in the steam Chemically attack the turbine.

128
Creep:
 Resultant damage:
 Airfoils, shrouds, covers permanently deformed.
 Causes of failure:
 Deformed parts subjected to steam temperatures in excess of
design limits.

129
Fatigue:
 Resultant damage:
 Cracks in airfoils, shrouds, covers, blade roots.
 Causes of failure:
 Loosing of parts (cover, tie wire, etc.)
 Fatigue life exceeded the design limit

130
Stress Corrosion Cracking:
 Resultant damage:
 Cracks in highly stressed areas of the blading.
 Causes of failure:
 caused by the combined presence of corrosive elements and
high stresses in highly loaded locations.

131
132