2012

Bharat Heavy Electricals Limited

Ramachandrapuram,Hyderabad502032,Andhra Pradesh,INDIA

INDUSTRIAL TRAINING REPORT

The report is focused on the study of the steam turbines and various methods to increase their efficiency.

Presented By G.Sai Jayanth Reddy Mechanical Engineering MIT, manipal

Acknowledgment
I have taken efforts in this project. However, it would not have been possible without the kind support and help of many individuals and organizations. I would like to extend my sincere thanks to all of them. I am highly indebted to Bharat Heavy Electricals Ltd. for their guidance and constant supervision as well as for providing necessary information regarding the project & also for their support in completing the project. I would like to express my gratitude towards my parents for their kind co-operation and encouragement which helped me in completion of this project. I would like to express my special gratitude and thanks to industry persons specially Mr. M.Rajeshwara Rao for giving me such attention and time. My thanks and appreciations also go to my colleagues in developing the project and people who have willingly helped me out with their abilities.

Objective
The primary objective of the internship was to gain experience working in an industry environment during the course of the summer leave in June 2012, apart from studying about the steam turbines. The challenges faced within a work environment are unique and dealing with them through a planned, organized approach is essential. Moreover, to avoid any interruptions in the functioning of an industry, prior planning and risk evaluation is necessary at every stage. The advantages of working as an intern with the T and C department were The student got to learn about Steam Turbines and how to maximize their efficiency; There were many other avenues to learn about industry applications of engineering education; The student got to develop secondary and tertiary skills required to effectively work in an Industry environment; And finally, it was an extremely productive way to utilize one month of summer holidays.

Company Profile
Established more than 40 years ago, BHEL is the largest engineering and manufacturing enterprise of India in the energy & infrastructure related sectors. BHEL is amongst world's rarest few who have the capability to manufacture entire range of power plant equipment. Since its inception, BHEL is maintaining a consistent track record of growth, performance and profitability. The company has grown in stature over the years with continued inflow of orders, manufacturing prowess, continued thrust on technology leading to a strong presence in domestic and international markets as a major supplier of power plant equipment besides establishing substantial inroads in select segment of products in Industrial sector and Railways. The company has realized the capability to deliver 15,000 MW p.a. power equipment capacities and the further expansion program is underway to reach 20,000MW p.a by 2012. BHEL caters to core sectors of the Indian Economy viz., Power Generation and Transmission, Industry, Transportation, Renewable Energy, Defense, etc. The wide network of BHEL's 15 manufacturing divisions, 2 repair units, 4 power sector regions, 8 service centers, 15 regional offices, 2 subsidiaries and a large number of Project Sites spread all over India and abroad enables the company to provide most

suitable products, systems and services- efficiently and at competitive prices. The company has entered into a number of strategic joint ventures in supercritical coal fired power plants to leverage equipment sales besides living up to the commitment for green energy initiatives. BHEL, where Quality Systems as per ISO-9000 have taken deep roots, has now made significant achievements in Business Excellence by securing recognition certificates from CII for four out of five units that participated in the CII-EXIM Business Excellence Award scheme in 201011. Continuing its tradition of bagging prestigious national/international awards, the company has been honored with several awards which included "EEPC Star Performer Award" in the Product Group of Project Exports for 20th consecutive year; SCOPE Award for Excellence and Outstanding Contribution to the Public Sector Management; "Dainik Bhaskar India Pride Award:2010" in Heavy Industries Category; "ICWAI National Awards for Excellence in Cost Management" for 2009 among public and private sector companies for the fifth successive year; "India Power Award for Equipment Manufacturing and for electrifying Lakshadweep Islands with Solar Power" from Council of Power Utilities; Six Prime Minister's Shram Awards including one "Shram Bhushan" and three "Vishwakarma Rashtriya Puraskars"; "IEI Industry Excellence Award 2010" for Overall Business Excellence and Industry Practices from the Institution of Engineers (India); "NDTV Profit Business Leadership Award 2010".

STEAM TURBINES
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. Steam turbines are made in a variety of sizes ranging from small <0.75 kW (1< hp) units (rare) used as mechanical drives for pumps, compressors and other shaft driven equipment, to 1,500,000 kW (2,000,000 hp) turbines used to generate electricity. There are several classifications for modern steam turbines. Based on the design of power plant, turbines are divided into three types namely Captive, Utility and Combined cycle variants. Captive power plants are those power plants which operate independent of wheeling to grid. They are mostly meant by in-house power generation for industry and not selling the power to grid of electricity boards. Utility power plants are those power plants which generate and transmit power for public. In a combined cycle power plant (CCPP), or combined cycle gas turbine (CCGT) plant, a gas turbine generator generates electricity, and the heat of its exhaust is used to make steam, which in turn drives a steam turbine to generate additional electricity. This last step enhances the efficiency of electricity generation, and combined-cycle plants can achieve efficiencies of 60%.

Turbines are divided into controlled and uncontrolled extraction turbines on the basis of extraction type. Based on the type of flow, they are divided into two types, single axial flow in which the steam flows in

only one direction parallel to the axis of the turbine rotor. Steam enters the forward end of the turbine and exhausts through the after end of the turbine. On a dual flow turbine the steam enters in the center of the turbine rotor and flows both forward and aft simultaneously. Based on the steam supply and exhaust they are divided into condensing, non-condensing, reheat, extraction and induction. Based on the type of blading they are divided into impulse, reaction, impulse reaction turbines.

Uncontrolled Extraction

Controlled Extraction

Apart from these turbines are further classified depending on the type of casing /shaft arrangement, number of exhaust stages, steam supply, condenser arrangement and type of governors.

Combined cycle power plant

Combined cycle power plant is a combination of both Brayton cycle and Rankin cycle .In this type of power plants the exhaust of the gas turbine is connected to HRSG (heat recovery steam generator). This is further connected to a steam turbine .Thus power is generated in a combined cycle power plant. In another type of combined cycle power plant the flue gases from various processes are fed into a WHRB (waste heat recovery boiler).This is further connected to a steam turbine. This way we can use the waste gases and exhaust gases to generate power.
Combined Cycle Design

In sugar factories and paper industries we need to supply steam at different pressures .This can be done by the use of throttle valves and different cylinders. But to reduce the amount of losses PRDS (pressure reducing desuperheating) technique is used. By correct usage of PRDS and throttling valves steam can be sent to respective places.

IMPULSE AND REACTION TURBINES

There are two principal turbine types: reaction and impulse. In a reaction turbine, the steam expands in both the stationary and moving blades. The moving blades are designed to utilize the steam jet energy of the stationary blades and to act as nozzles themselves. Because they are moving nozzles, a reaction forceproduced by the pressure drop across themsupplements the steam jet force of the stationary blades.These combined forces cause rotation.

To operate efficiently the reaction turbine must be designed to minimize leakage around the moving blades. This is done by making most internal clearances relatively small. The reaction turbine also usually requires a balance piston (similar to those used in large centrifugal compressors) because of the large thrust loads generated. Because of these considerations, the reaction turbine is seldom used for mechanical drive in the United States, despite its occasionally higher initial efficiency. Reaction turbines are, nevertheless, in widespread use in Europe and the rest of the world. The impulse turbine has little or no pressure drop across its moving blades. Steam energy is transferred to the rotor entirely by the steam jets striking the moving blades.

CARNOT CYLCE
The Carnot cycle is a theoretical thermodynamic cycle proposed by Nicolas Lonard Sadi Carnot in 1824 and expanded by Benoit Paul mile Clapeyron in the 1830s and 40s. It can be shown that it is the most efficient cycle for converting a given amount of thermal energy into work, or conversely, creating a temperature difference (e.g. refrigeration) by doing a given amount of work. When a system is taken through a series of different states and finally returned to its initial state, a thermodynamic cycle is said to have occurred. In the process of going through this cycle, the system may perform work on its surroundings, thereby acting as a heat engine. A system undergoing a Carnot cycle is called a Carnot heat engine, although such a 'perfect' engine is only a theoretical limit and cannot be built in practice.

The efficiency

is defined to be:

We take Carnot cycle as the reference to various thermodynamic cycles. So to increase the efficiency of those cycles we must increase the efficiency of the Carnot cycle. Here to increase the efficiency we can decrease the temperature of the sink but thats nature dependent so, its highly difficult to decrease its temp. Also this method has its own disadvantages. One more method to increase the efficiency of the cycle is to increase the temperature of the source. But scientists are still working on this method.

RANKINE CYCLE
The Rankine cycle is a cycle that converts heat into work. The heat is supplied externally to a closed loop, which usually uses water. This cycle generates about 90% of all electric power used throughout the world, including virtually all solar thermal, biomass, coal and nuclear power plants. It is named after William John Macquorn Rankine, a Scottish polymath and Glasgow University professor. The Rankine cycle is the fundamental thermodynamic underpinning of the steam engine.

Generally in this cycle heat is lost in condenser. This is a major loss. To overcome this loss a hole is made to the turbine at required position and the heat is sent to a heater which is further connected to boiler.To increase the efficiency there are three methods. They are: 1) By increasing/decreasing the inlet parameters depending on the requirement. 2) Using a reheat cycle. 3) Using a regenerative cycle. There is a small storage under this condenser to which the water formed due to the latent heat is sent. By this the whole mass in the system is balanced.

Thrust Balancing
Thrust balancing is the balancing of the forces experienced by the steam turbines rotor during operation, both axially and radially. This thrust experienced can cause deformation or damage to the steam turbine over time, resulting in loss of efficiency and eventually inoperability of the turbine. The forces experienced by the turbine are further divided into negative and positive forces axially. Positive forces are those that are experienced by the turbine axially towards the outlet of the steam turbine, these are primarily caused by: 1. Force exerted due to the passage of steam through the turbine, this steam exerts a force on the turbine components towards the outlet direction. 2. Force experienced on the tapering of the rotor present between the groups of blading, this too acts to deform the turbine but is not as highly damaging. 3. The force acting on the rotor tapering directly below the blading, the forces acting on the blading also get transmitted to the tapering partially The negative force present in the turbine is generated by glands to counteract the positive forces it experiences, this balancing is called Thrust Balancing. The primary among these forces is that generated by the Balance Piston Gland present in the tapering area between the impulse and reaction blading

The Balance Piston Gland has to do with counteracting thrust. When high pressure steam enters the first stage turbine wheel there will be a thrust toward the low pressure end. This occurs in each successive stage. The balance piston disc is arranged on the turbine wheel so that some high pressure steam is introduced on the low pressure side to push the other way. This takes load off of the thrust bearing. Methods present here to improve efficiency are to reduce the diameter of the negative force acting area and take the leakage of steam to the intermediate areas between blading according to pressure allocations. Impulse blading is maintained at higher diameters to maintain the b/c ratio at a favourable number.

Steam leakage

Balance Piston Gland

TURBINE SEALING
Gland seal systems
are very important to main and auxiliary turbines. Turbine shafts must exit their casings in order to couple up or connect with the unit that the turbines drive (reduction gears, pumps, etc.) The main and auxiliary gland seal systems enable the turbine to be sealed where the shaft exits the casing; in effect keeping "air out and steam in." The purpose of gland seal system is to prevent the leakage of air from the atmosphere into turbine casings and prevent the escape of steam from turbine casings into the atmosphere.

Sealing Arrangements for Casing

Operation Overview
1. The pressure differential between the atmosphere and inside the main engine turbine casing will vary depending on ship's speed. Similarly, the differential between the atmosphere and inside the ship's service turbine generator (SSTG) turbine casing will vary depending on electrical load.

2.

Labyrinths-

Sets of labyrinth packing are employed along the

turbine rotor where the rotor exits the turbine casing to maintain this pressure differential.

a. The labyrinths create many little chambers causing pressure drops along the shaft. The number of labyrinth sets depends greatly on the steam pressure possible in that area. Labyrinth packing alone will neither stop the flow of steam from the turbine nor prevent air flow into the turbine. 3. Gland Sealing Steam a. The gland sealing system provides low pressure steam to the turbine gland in the final sets of labyrinth packing. This assists the labyrinth packing in sealing the turbine to prevent the entrance of air into the

turbine, which would reduce or destroy the vacuum in the associated condenser. Excess pressure (excess gland seal) is removed by the gland seal unloader. 4. Gland Exhaust a. Since there are times when steam escapes from the seals, a gland exhaust system is provided. The gland exhaust system consists of low pressure piping connected to the gland area between the last two outer sets of labyrinths which receives and prevents steam from escaping to the atmosphere. This system collects the steam and directs it to a condenser for further use in the steam plant. C. Main Engine Gland Seal System Components. 1. The gland seal regulator a. Senses system pressure on the outlet side of the regulator. The gland seal regulator valve reduces 150 psig auxiliary dry or wet steams depending on the ship type steams to gland seal system pressure of .5 to 2 psig. The valve begins to open at 2 psig and is fully open at .5 psig. The bypass valve allows the operator to maintain system pressure in the event the regulator valve is inoperable. 2. The Gland seal unloader valve

a. This valve senses the pressure of the gland seal supply piping. The unloader piping is wider in diameter than the regulator piping. The gland seal unloader "dumps" the excess gland seal piping pressure to the LP turbine exhaust trunk. The unloader begins to open at 2 psig,

and is fully open at 3 psig. It has a handwheel to permit manual operation of the unloader to control gland seal system pressure during a loss of control air causality.

Piping system
a. The regulator supplies the gland seal header. This header has branch lines to each turbine gland area and a branch line to the unloader. The ahead throttle valve assembly and the astern throttle valve also have a connection to receive gland sealing steam. The reason is the same on the unloader- to prevent the possible introduction of air into the system. Any air entering the turbines or piping systems affect the vacuum in the main condenser. b. On some ships, spectacle flanges are installed in the supply lines to the HP turbine glands to allow the gland seal and gland exhaust system to be isolated when singling up with the LP turbine operating. c. Inputs to the gland seal system include the gland seal regulator, astern throttle leak-off, ahead throttle lifting rod leak-off, HP turbine forward and after gland leak-off, and main steam emergency throttle leak-off (on ships with singling up capabilities). 4. Main engine gland exhaust system a. Steam leaking from the gland seal section of the shaft packing is drawn off by the gland exhaust system. Gland exhaust is drawn into the gland exhaust condenser section of the Main Engine Air Ejector. b. The gland exhaust steam is then condensed and returned to the fresh water drain collecting tank. The air and non-condensable gases are drawn off by the gland exhaust fan.

5. Gland Seal steam system operation a. The gland seal regulator supplies .5 to 2 psig steam to the glands in varying degrees as bells change on the main engine. When answering a low bell or all stop, the gland leak off is minimal, causing the regulator to supply the total gland sealing steam. As engine speed increases, the casing is pressurized and the increased gland leak off, along with the regulator, supplies the entire gland sealing steam required by the system. (1) As ship's speed increases, the main engine becomes self sealing. The gland seal regulator is fully shut and the unloader is functioning to maintain the system pressure between 2 3 psig, dumping the excess gland seal steam to the LP turbine exhaust trunk. (2) As ship's speed slows, the gland seal system operates in reverse sequence.

A brush seal D. SSTG Gland Seal System Components 1. These components are almost identical to the main engine gland sealing components. The major difference between the main and SSTG system is the size. a. The Gland seal regulator (1) Senses pressure on the drain pot (or manifold). The drain pot or manifold is similar to a header and acts as "collection area" for the system steam. This area allows for the sensing lines to accurately measure the system pressure. The valve functions by reducing 150 psig auxiliary steam to the system pressure of .5 2 psig.

Carbon ring seal 2. The Gland seal unloading valve a. Senses the pressure on the drain pot. The operating range is 2 3 psig, unloading excess gland seal pressure to the lower section of the turbine exhaust casing. 3. The piping system (see Figure 7) a. Consists of piping to the forward and after glands from the drain pot or manifold. The inputs to the system are gland seal regulator, and the forward turbine bearing. At a 60% load on the generator, leakage from the forward end of the turbine (high pressure end) supplies the system, the regulator is closed and the unloader bleeds excess to the turbine exhaust trunk.
E.

Gland Exhaust System

1. Steam leaking from the gland seal area of the shaft packing, steam

leak off from the steam chest lift rods, and steam leak off from the trip throttle valve is drawn into the gland exhaust system and into the air ejector condenser. 2. The steam is condensed in the SSTG air ejector condenser. Air and non condensable gases are discharged to the atmosphere via the gland exhaust fan which maintains a slight vacuum on the auxiliary air ejector condenser.
F.

Causes of System Failure

1. Since most gland seal regulators are air operated reducing valves, improper pressure settings on the air pilots for the regulating and unloading valves can cause system pressure to be too high or low, or both valves may be open at the same time. Ruptured diaphragms may occur in these air pilot controllers and air operated valves. Oil and water in the air lines to the pilots or air operated valves can cause erratic operation and deterioration of the rubber diaphragms. Upon loss of air pressure, both valves fail open and the unloader valve must be operated with the manual handwheel to control gland seal pressure. 2. Painted valve stems or improper packing installation can cause binding of the stem, restricting valve operation. 3. Improperly calibrated gages can cause the system to be improperly operated. 4. In the event of a jammed gland seal regulator, the operator should take control of gland seal pressure by using the regulator bypass valve.
G.

Safety Precautions

1. Do not admit steam to the glands of an idle turbine, as varying degrees of corrosion, erosion, or a bowed rotor may result. 2. Ensure the gland seal system is in operation on the main engine before aligning the main engine air ejectors. This helps prevent dirt and

debris from being drawn into the turbine glands. 3. Adjustment of components shall be conducted by qualified and knowledgeable personnel. When performing adjustments, careful coordination of involved personnel will minimize confusion of gage indication.

Mechanical governor controls for an extraction turbine.

Losses in steam turbines

Admission losses
In practice the flow of steam through nozzle is not isentropic, but accompanied with losses which decrease the kinetic energy of steam coming out of the nozzle. The decrease in kinetic energy is due to the following reasons

Viscous forces between steam particles Heat loss from steam before entering the nozzle Deflection of flow in the nozzle Boundary layer development in the nozzle Turbulence in the nozzle The friction in the nozzle which reduces available enthalpy drop and hence actual velocity leaving the nozzle is less than that obtained with isentropic expansion

Leakage losses
Steam leaves the boiler and reaches the condenser after passing through the main valve, regulating valves, nozzles, clearance spaces between nozzles and moving blades, diaphragm and rotating shaft etc. Further there is large pressure difference between inside of steam turbine and the ambient and also from one location to another location across these devices. Therefore steam leakage takes place through

Main valve and regulating valve Seals and glands Spaces between nozzles and moving blades Spaces between diaphragm and shaft of turbine Space between moving blade rings and turbine casing Leakage of steam through these is a direct loss of energy.

Friction losses
Frictional resistance is offered during flow of steam through nozzles on moving and stationary blades. In most of the turbines the blade wheels rotate in a space full of steam. The viscous friction at the wheel surface causes admission losses as steam passes from nozzle to wheel. The effect of partial admission creates eddies in the blade channels. The surface of curved moving blades and stationary blades offers resistance, which increases with increase in roughness of blade surface and relative velocity between steam and rotating blade. The energy loss also takes place when the steam jets turns along the curvature of the blade surface. The turning losses depend on the angle of turning.

Exhaust loss
The energy content of steam is not fully utilized in the turbine. Despite of being at very low pressure the exhaust coming out of the turbine and entering the condenser carries some of kinetic energy and useful enthalpy, which is direct energy loss.

Radiation and convection losses

The steam turbine operates at a relatively high temperature; therefore some of the heat energy of steam is radiated and convected from the body of the turbine to its surrounding. These direct losses and are minimized by proper insulation's.

Losses due to moisture

The steam passing through the last stage of turbine has high velocity and large moisture content. The liquid particles have lesser velocity than that of vapor particles and hence the liquid particles obstruct the flow of vapor particles in the last stage of turbine and therefore, a part of kinetic energy of steam is lost. If the dryness fraction of steam falls below 0.88, the erosion and corrosion of blades can also take place.

Carry over losses

When steam passes from one stage to another through the diaphragm, some energy losses takes place, which are referred to as carry over losses and therefore, the kinetic energy of steam available at succeeding stage of moving blades for utilization is less than that of the exit at preceding stage. This is due to formation of eddies in annular space between the nozzle and moving blades.

Correction of parameters of steam turbine

Using calculations we may reiterate given formulae while rounding certain parameters to obtain greater degrees of accuracy as is shown in the examples below:
Here the values of velocities of the ESV and GV are to be calculated and hence we first find out the corresponding change in enthalpy, then mass flow rate and then we find velocities by correcting the diameters of the valves. Taking P= 25MW, ESV vel= 60m/s and GV vel= 180 m/s and is 0.8 s at 80 Bar, 480 C is 6.6586 kJ/kgK (const) h at same is 3348.4 kJ/kg specific vol is 0.04034 m3/kg then x(quality)= s sf / sfg x for 0.1 bar= 6.6586-0.6493/7.5009 =0.801 h for 0.1 bar= hf + xhfg =191.83+(0.801)2392.8 =2108.463 kJ/kg H= h1-h2 =1239.937kJ/kg Now P=m. H. Or 25000= m X 1239.937 X 0.8 Or m= 25.2 kg/s Now for ESV vinital=60m/s And mX sp vol= A X v Or A= mX sp vol / v Or sp vol / v Or d = 146.87 mm Rounding to nearest multiple of 25 we get 150mm Putting back to get v V= m X sp vol/A Or v= 57.53 m/s Then for GV v= 180m/s And mX sp vol= A X v Or A= mX sp vol / v Or sp vol / v
80 Bar 480 C

0.1 Bar

Or d = 84.8 mm Rounding to nearest multiple of 10 we get 80 mm Putting back to get v V= m X sp vol/A Or v= 202.24 m/s

In this case there are intermediate stages where some steam is 0 extracted and resupplied and hence the enthalpy changes for these must be taken individually to give the total mass flow rate which the steam consumption, the specific steam consumption and the heat rate. P= 25MW, is 0.8. s at 100 Bar, 500 C is 6.5966 kJ/kgK (const) h at same is 3373.7 kJ/kg
H

100 Bar 500 C 60 Bar 1

then x(quality)= s sf / sfg x1 = 6.5966-3.0627/2.8625 =1.2482 h1 = hf + xhfg =1213.35+(1.2482)1571 =3174.27 kJ/kg H01= h0-h1 =199.43 kJ/kg X2 = 6.5966-1.7766/5.1193 = 0.9415 h1 = hf + xhfg =604.74+(0.9415)2133.8 =2613.7127kJ/kg H12= h1-h2 =560.56 kJ/kg X3 = 6.5966-0.6493/7.5009 = 0.7929 H3 = hf + xhfg =191.83+(0.7929)2392.8 =2089.08kJ/kg H23= h2-h3 =524.633 kJ/kg Therefore P= (m X H01 + (m+1) X H12 +m X H23) Or 25000/0.8 +560.56 = m X 1284.623
3 2

4 Bar

0.1 Bar

Or m = 24.7626 kg/s (or the steam consumption rate) Specific steam consumption rate is= m/P= 0.9905 kg/ kWs Heat Rate is= Htotal X m /P = (3573.7-191.83) X 24.7626/ 25000= 3.152 kJ/ kW

As in the previous calculation if a series of ranges of temperature and pressure are taken for the same power generation and efficiency then the following results are obtained:
For 25 MW, 0.8
drop to 0.1 bar 80 bar/480 C 100 bar/ 500 C 120 bar/ 520 C

Steam Consumption Rate (kg/s) Specific Steam Consumption Rate (kg/kWs) Heat Rate (kJ/kW)

25.66

24.7626

23.9865

1.02668

0.9905

0.95946

3.24

3.152

3.0798

As we can see that as the Temperature-Pressure limit increase the overall efficiency of the system decreases. This is due to the heat rate and overall steam consumption rate decreasing.

Conclusion
Hence we have seen how the workings, processes and parameters of a steam turbine can be thermodynamically enhanced to give higher turbine efficiency. Also we have seen the various types of turbines and their multiple applications. With this our study on the Improvement of Thermodynamic Cycles of Turbines is complete. It must be noted that efficiency of a steam turbine is very important in our current day and age with the overall energy crisis and demand ever growing. Hence every effort must be made to increase the overall efficiency of power generation

_____________________________

Signature of Project Guide

References

General information en.wikipedia.org/wiki/steam_turbine Bharat Heavy Electricals Limited

http://web.bhelhyd.co.in/

Steam Turbines-design application and re-rating by Heinz P.Bloch/Murari P.Singh