ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

SUB: ELEMENTS OF MECHANICAL ENGINEERING
II SEMESTER ACADEMIC YEAR 2012-13 Sub Code

: 10EME24

Staff: SRINIVAS Y V

UNIT-2 TURBINES
PRIME MOVER: Prime mover is a self moving device which converts the natural source of energy into mechanical energy to drive other machines. TURBINE: A turbine is a power producing machine, it is a rotary engine made with a series of blades attached to a rotating shaft. They are used to drive electric generators ( to produce electricity) and pumps to (to supply fluid). STEAM TURBINES A steam turbine is a mechanical device (prime mover) that extracts thermal energy from pressurized steam, and converts it into rotary motion. The heat energy of the steam is first converted into kinetic energy which in turn transformed into mechanical energy. Components of a Steam Turbine 1) Nozzle: It is a device designed to control the direction or characteristics of a fluid flow (especially to increase velocity) as it exits (or enters) an enclosed chamber or pipe via an orifice. A nozzle is often a pipe or tube of varying cross sectional area and it can be used to direct or modify the flow of a fluid (liquid or gas). Nozzles are frequently used to control the rate of flow, speed, direction, mass, shape, and/or the pressure of the stream that emerges from them.

Fig2.1: Nozzle The high pressure and low velocity steam generated in boiler enters the nozzle and it passes between the entry and the throat, it expands to a low pressure. The drop in pressure reduces the enthalpy. The steam performs work upon itself by accelerating itself to a high velocity. Hence steam comes out of nozzle with low pressure with high velocity. 2) Blades: These are made in the form of curved plates and are fixed on the circumference of a revolving wheel called rotor. The rotor is then connected to the shaft. The steam coming out of the nozzle at high velocity impinges on these blades. The impingement of steam on the
SRINIVAS Y V. Asst. Prof. Dept. of AUTO. Engg. Ac.IT Page 1

ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

SUB: ELEMENTS OF MECHANICAL ENGINEERING
II SEMESTER ACADEMIC YEAR 2012-13 Sub Code

: 10EME24

Staff: SRINIVAS Y V

blades rotates the rotor which in turn rotates shaft connected to it. Therefore the Kinetic energy is converted into mechanical energy. 3) Casing: It is the outside cover of the steam turbine. Rotors are placed inside the casing.

Classification of steam turbines: Based on the type of action of steam on to the blades. 1) Impulse turbine 2) Reaction turbine. 1) IMPULSE TURBINE (De Laval turbine) It works on the principle of impulse where the kinetic energy of the jet of steam is used to exert a force on a set of moving blades. Ex: De Laval turbine. The impulse turbine consists basically of a rotor mounted on a shaft that is free to rotate in a set of bearings. The outer rim of the rotor carries a set of curved blades, and the whole assembly is enclosed in an airtight case. An impulse turbine has fixed nozzles that orient the steam flow into high speed jets as shown in fig2.2. These jets contain significant kinetic energy, which impinges on to blades as shown in fig2.3; the blades are shaped like buckets, these blades are fixed on to the outer surface of the rotor, which convert into shaft rotation as the steam jet changes direction.

Fig2.2: Arrangement of nozzles

Fig2.3: flow of jet on blade

The term impulse means that the force that turns the turbine comes from the impact of the steam on the blades. Steam nozzles are located at the turbine inlet. As the steam flows through the nozzle its pressure falls from high (inlet) pressure to the low (exit) pressure. Due to
SRINIVAS Y V. Asst. Prof. Dept. of AUTO. Engg. Ac.IT Page 2

ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

SUB: ELEMENTS OF MECHANICAL ENGINEERING
II SEMESTER ACADEMIC YEAR 2012-13 Sub Code

: 10EME24

Staff: SRINIVAS Y V

this higher ratio of expansion of steam in the nozzle the steam leaves the nozzle with a very high velocity. This steam is directed toward the turbine blades and turns the rotor. The velocity of the steam is reduced in passing over the blades. Some of its kinetic energy has been transferred to the blades to turn the rotor.

The expansion of steam takes place in the nozzles over the blades. The pressure drop is represented by AB. As there is no change in the pressure of steam passing over the lade, the flow is represented by horizontal line BC since the velocity of the steam in the nozzle increases due to expansion of the steam, the increase in velocity of steam is represented by PQ. The blades absorb the K.E. of steam as it flows over them and the velocity decreases represented by QR. Impulse turbines may be used to drive force draft blowers, pumps, and main propulsion turbines as shown in fig2.4.

fig2.4: pressure velocity changes in impulse turbine

2) REACTION TURBINE (Parsons Turbine) Reaction Principle: It works on the principle of Newtons third law of motion, which states: For every action there must be an equal and opposite reaction. In the reaction turbine, the rotor blades themselves are arranged to form convergent nozzles.
SRINIVAS Y V. Asst. Prof. Dept. of AUTO. Engg. Ac.IT Page 3

ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

SUB: ELEMENTS OF MECHANICAL ENGINEERING
II SEMESTER ACADEMIC YEAR 2012-13 Sub Code

: 10EME24

Staff: SRINIVAS Y V

This type of turbine makes use of the reaction force produced as the steam accelerates through the nozzles formed by the rotor. It consists of several alternate rows of fixed and moving blades. The fixed blades are attached to a stationary casing while the moving blades are mounted on the periphery of rotor. Steam is directed onto the rotor by the fixed vanes of the stator. 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. The high pressure steam passing in the 1st row of fixed blades undergoes a small drop in pressure causing increase in velocity of steam. Next it enters 1st row of moving blades in which further drop in pressure takes place and the K.E is converted to rotational energy decreasing the velocity of the steam. This continues till pressure of steam is almost reduced as shown in fig2.5.

Fig 2.5: pressure velocity changes in reaction turbine

Comparison between Impulse Turbine and Reaction Turbine: Impulse Turbine Reaction Turbine
1) Expansion of steam takes place in the nozzle before it enters the casing. 2) Blades are symmetrical 1) Expansion takes place continuously over the fixed and moving blades 2) Blades are asymmetrical in shape (Aerofoil) Page 4

SRINIVAS Y V. Asst. Prof. Dept. of AUTO. Engg. Ac.IT

ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

SUB: ELEMENTS OF MECHANICAL ENGINEERING
II SEMESTER ACADEMIC YEAR 2012-13 Sub Code

: 10EME24

Staff: SRINIVAS Y V

3) The pressure on both the ends of moving blade is same 4) Occupies less space per unit power developed 5) Suitable for small capacity plants 6) Requires compounding due to high speeds 7) Size of overall unit is small.

3) Pressure on both the ends of moving blade is different 4) Occupies more space 5) Suitable for medium and large power plant 6) Doesnt require compounding due to relative slow speed 7) Size of overall unit is large for same output.

Fig 2.6: comparision

COMPOUNDING OF STEAM TURBINE (METHODS OF REDUCING SPEED): Utilization of high pressure energy of the steam by expanding it in successive stages is called compounding. It is the method of reducing speed of the impulse turbine due to practical imitations of its use. To reduce high speeds, one or more set of blades are used so as to allow the steam to expand in different stages.

PURPOSE OF COMPOUNDING: If the whole pressure energy of the steam is converted into K.E. in one stretch, the turbine rotates at very high speed (around 30000rpm). Such speed leads to many technical problems such as: 1) Difficulty in coupling 2) Overheating of bearings
SRINIVAS Y V. Asst. Prof. Dept. of AUTO. Engg. Ac.IT Page 5

ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

SUB: ELEMENTS OF MECHANICAL ENGINEERING
II SEMESTER ACADEMIC YEAR 2012-13 Sub Code

: 10EME24

Staff: SRINIVAS Y V

3) Vibrations 4) To increase the efficiency by effective utilizing the energy So to prevent these problems compounding is necessary. TYPES OF COMPOUNDING: 1) Velocity compounding 2) Pressure compounding 3) Pressure velocity compounding. 1) VELOCITY COMPOUNDING: In this fixed and moving blades are arranged alternatively. The expansion of steam takes place in one set of nozzles, velocity increases; this velocity is passes through several set of blades at constant pressure. Fixed blades are fixed to the casing and moving blades on the rotor, the fixed blades change the direction of steam at constant pressure. The velocity of steam decreases gradually as it passes through moving blades. The K.E. is converted into mechanical energy and later to electrical energy as shown in fig 2.7.

Fig 2.7: pressure velocity changes in velocity compounding.

2) PRESSURE COMPOUNDING When the expansion of steam takes place in more than one set of nozzles, and each set of nozzles is followed by a set of moving blades this turbine is called pressure compounded turbine. It is a combination of several impulse turbines. The steam at boiler pressure enters the 1st set of nozzle and expands partially. The K.E. of steam is absorbed by 1st row of moving blades. Then the steam expand partially in 2nd set of fixed nozzle where the pressure falls and
SRINIVAS Y V. Asst. Prof. Dept. of AUTO. Engg. Ac.IT Page 6

ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

SUB: ELEMENTS OF MECHANICAL ENGINEERING
II SEMESTER ACADEMIC YEAR 2012-13 Sub Code

: 10EME24

Staff: SRINIVAS Y V

velocity increases, the K.E. is absorbed by 2nd row of moving blades. The same follows in 3rd stage and finally steam leaves the turbine at low velocity and pressure as shown in fig 2.8.

Fig 2.8: pressure velocity changes in pressure compounding.

3) PRESSURE-VELOCITY COMPOUNDING The turbines which work on the combination of pressure and velocity are called pressure velocity compounded turbines. A set of fixed nozzles are followed by a set of moving blades, a set of fixed blades and again moving blades. This combination is called Curtis stage. In this type of compounding the 1st pressure drop occurs in the 1st set of nozzle, the resulting gain in K.E. is absorbed in the two rows of moving blades before 2nd pressure drop occurs in the 2nd set of nozzle. The K.E. gained due to 2nd pressure drop in second set of nozzle is absorbed successively in the two rows of moving blades as shown in fig 2.9.

SRINIVAS Y V. Asst. Prof. Dept. of AUTO. Engg. Ac.IT

Page 7

ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

SUB: ELEMENTS OF MECHANICAL ENGINEERING
II SEMESTER ACADEMIC YEAR 2012-13 Sub Code

: 10EME24

Staff: SRINIVAS Y V

Fig 2.9: pressure velocity changes in pressure velocity compounding.

Advantages of Steam Turbines over other prime movers: 1) Thermal efficiency of steam turbine is higher, because of higher power output & speeds. 2) Large amount of heat energy of steam is converted into mechanical work. 3) Ideal prime movers because propelling force is directly applied to rotating element, for driving machines with uniform torque and speed. 4) It is ideally suited in thermal power plants. 5) Usually used for high speed machines. 6) Power generation in a steam turbine will be at uniform rate. 7) Less vibration and noise, no wear and tear of parts. 8) Steam turbines can work at higher temperatures and very high steam pressure. 9) Initial and maintenance costs are low.

GAS TURBINES:
A gas turbine, also called a combustion turbine, is a type of internal combustion engine. It has an upstream rotating compressor coupled to a downstream turbine, and a combustion chamber in between. Energy is added to the gas stream in the combustor, where fuel is mixed with air and ignited. In the high pressure environment of the combustor, combustion of the fuel increases the temperature. The products of the combustion are forced into the turbine section. There, the high velocity and volume of the gas flow is directed through a nozzle over the turbine's blades, spinning the turbine which powers the compressor and, for some turbines, drives their mechanical output. The compressor and turbine are mounted on the same shaft. Therefore part of power developed by turbine runs the air compressor while remaining power is utilized for doing external work. The energy given up to the turbine comes from the reduction in the temperature and pressure of the exhaust gas. Classification of gas turbine: Depending upon the flow of working fluid during the cycle of operation, gas turbines are classified as 1) Open Cycle Gas Turbine. 2) Closed Cycle gas turbine.

SRINIVAS Y V. Asst. Prof. Dept. of AUTO. Engg. Ac.IT

Page 8

ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

SUB: ELEMENTS OF MECHANICAL ENGINEERING
II SEMESTER ACADEMIC YEAR 2012-13 Sub Code

: 10EME24

Staff: SRINIVAS Y V

Open Cycle Gas turbine:

Fig 2.10: Open Cycle Gas Turbine

Principle of Operation: It consists of a compressor, combustion chamber and gas turbine. Both the compressor and turbine are mounted on the same shaft. The atmospheric air is drawn into the compressor and compressed to high pressures. The high pressure and relative high temperature air flows to the combustion chamber where heat is added to the air by the combustion of the fuel in the combustion chamber. The high pressure, high temperature gases are then passed to the turbine, where it expands to lower pressure driving the turbine shaft producing the mechanical energy of rotation and the gas is exhausted to the atmosphere. The working fluid is replaced in every cycle as shown in fig 2.10. Closed Cycle Gas turbine

SRINIVAS Y V. Asst. Prof. Dept. of AUTO. Engg. Ac.IT

Page 9

ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

SUB: ELEMENTS OF MECHANICAL ENGINEERING
II SEMESTER ACADEMIC YEAR 2012-13 Sub Code

: 10EME24

Staff: SRINIVAS Y V

Fig 2.11: Closed Cycle Gas Turbine

Principle of Operation: it consists of a compressor, a heater, a cooler, and a gas turbine. Both the compressor and turbine are mounted on the same shaft. The compressed gas coming out of compressor is heated by external source in the heater which increases temperature of the gas. The high pressure and temperature gas is passed to the gas turbine where it expands to low pressure driving the turbine shaft producing mechanical energy of rotation. The gas exhausted from the turbine enters the cooler where it is cooled from external cooling source. The cooled exhaust gas at low temperature & pressure enters the compressor where it is compressed to high pressure and temperature and the same cycle repeats as shown in fig 2.11. Difference between Closed Cycle gas turbine and Open Cycle gas turbine: Closed Cycle gas turbine 1) Working fluid is continuously circulated in every cycle 2) The gases after the work are cooled and feedback to the compressor for next cycle. 3) Only heat and work transfer take between system and the surroundings 4) Any fluid with better thermodynamic properties can be used 5) Since the exhaust gases have to be circulated again, large amount of cooling water is required to cool the exhaust gas. 6) Installation and maintenance costs are high. 7) Weight of turbine per kW developed is more. 8) High thermal efficiency. Open Cycle gas turbine 1) Fresh working fluid enters every cycle 2) The gases after the work are exhausted to the atmosphere. 3) There is mass transfer along with work and heat transfer. 4) Only atmospheric air is used as working fluid. 5) There is no necessity to cool the exhaust gases however they are left to the atmosphere. 6) Low maintenance and installation cost. 7) Weight of turbine per kW developed is less 8) Low thermal efficiency.

WATER TURBINES
A water turbine is a hydraulic prime mover which converts the potential and kinetic energy of water into mechanical energy in the form of rotation of the shaft. Classification of water turbines:
SRINIVAS Y V. Asst. Prof. Dept. of AUTO. Engg. Ac.IT Page 10

ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

SUB: ELEMENTS OF MECHANICAL ENGINEERING
II SEMESTER ACADEMIC YEAR 2012-13 Sub Code

: 10EME24

Staff: SRINIVAS Y V

a) Based on the action of flow of water: 1) Impulse turbine (Pelton Wheel, Bankine turbine) 2) Reaction turbine (Francis turbine and Kaplan turbine) b) Based on head available at the inlet: 1) Low head turbine (Kaplan Turbine) 2) Medium head turbine (Francis Turbine) 3) High head turbine (Pelton wheel) c) Based on direction of flow of water: 1) Tangential flow turbine (Pelton wheel) 2) Radial flow turbine (Francis Turbine) 3) Axial flow turbine (Kaplan Turbine) 4) Mixed flow turbine (Modern Francis turbine) PELTON WHEEL TURBINE: It is a tangential flow impulse turbine used for high heads and small quantity of water flow. It consists of 1) Nozzle with a spear head: It is a penstock attached to the penstock. The flow of water is controlled by a spearhead. The spearhead is operated by6 a hand wheel which provides a smooth flow of water with negligible energy losses. 2) Runner and Buckets: The runner is circular wheels with a series of evenly spaced buckets fixed around its periphery.They are shaped like a bowl or a double hemispherical cup. The advantage of having double cup shaped buckets is that, the jet of water gets split and leaves symmetrically on both sides of the bucket. This helps to eliminate the end thrust or axial thrust on the bearing and shaft. The runner is coupled to the rotating shaft. 3) Turbine Casing: It prevents the splashing of the water and it also helps to discharge the water into the tail race.

SRINIVAS Y V. Asst. Prof. Dept. of AUTO. Engg. Ac.IT

Page 11

ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

SUB: ELEMENTS OF MECHANICAL ENGINEERING
II SEMESTER ACADEMIC YEAR 2012-13 Sub Code

: 10EME24

Staff: SRINIVAS Y V

Fig 2.12: Pelton wheel Turbine

The Pelton wheel is an impulse turbine which is among the most efficient types of water turbines. Water from the reservoir having potential energy flows through the penstock and enters the nozzle. The potential energy of water is completely converted into kinetic energy in the nozzle. The high velocity jet of water from the nozzle impinges on the curved blades fixed around the runner. The impulse force due to high velocity jet of water sets the runner into rotary motion. The shaft coupled to the runner also rotates thereby doing useful work. The potential energy of water is converted to mechanical energy and later the water discharges to tail race.

FRANCIS TURBINE
It is a Radial flow reaction turbine used for medium head and requires large quantity of water. It consists of: 1) Runner: it is a circular wheel on which a series of blades are fixed. The runner in turn is coupled to the rotating shaft. 2) Guide wheel: a guide wheel is stationary wheel around the runner of the turbine. A number of stationary or guide blades are fixed around the circumference of the guide wheel. Guide blades allow the water to strike at a certain angle onto the moving blades. Blades are designed in such a way that water while flowing through the blades will subject to the nozzle effect. 3) Spiral casing: It is a closed passage whose cross sectional area decreases along the flow direction. The spiral casing is tapered to distribute water uniformly around the entire perimeter of the runner. 4) Draft tube: It is a pipe of gradually increasing area and is used for discharging water from the exit of the turbine to tail race. Working: Water from the reservoir flows through the penstock and enters the spiral casing. A part of the potential energy of water is converted into kinetic energy in the spiral casing. Water flows through the guide blades, gets deflected and then flows radially inwards to the periphery of the runner. The water then moves over the moving blades in the radial direction and is finally discharged too the tail race axially from the center of the runner via draft tube. During its flow over runner blades, the blades passages act as nozzles and the remaining part of the potential energy is converted to kinetic energy. Since the water leaves the blades at high velocity, there is a reaction force on the runner. This force sets the runner into rotary motion. The shaft connected to the runner also rotates thereby doing useful work. Francis turbines located in India are: Shivanasamudram, Bhakra, & Gandhinagar.
SRINIVAS Y V. Asst. Prof. Dept. of AUTO. Engg. Ac.IT Page 12

ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

SUB: ELEMENTS OF MECHANICAL ENGINEERING
II SEMESTER ACADEMIC YEAR 2012-13 Sub Code

: 10EME24

Staff: SRINIVAS Y V

Fig 2.13: francis Turbine

KAPLAN TURBINE
It is an axial flow reaction turbine and is used where large quantity of water is available at low heads. It consists of a hub or boss fixed to vertical shaft. The runner blades are attached to the hub which can be adjusted & can be turned depending on the load. The runner of Kaplan turbine resembles the propeller of a ship so which is also called as Propeller Turbine. In operation water from the reservoir flows through the penstock and enters spiral casing. A part of P.E. of water is converted into K.E. in the casing. The water then moves through the guide blades and from the guide blades, the water turns 90O and flows axially through the runner blades. During the flow the blade passages acts as nozzle & the remaining part of P.E. is converted into K.E. When the water leaves the blade at high velocity, a reaction force is set up & this force rotates the runner. The P.E. of water is converted to mechanical work. The draft tube is a tube or pipe of gradually increasing area & is used for discharging water from the exit of turbine to tail race at lower pressure. Availability in India: Tungabhadra, Kolhapur, Kota.

SRINIVAS Y V. Asst. Prof. Dept. of AUTO. Engg. Ac.IT

Page 13

ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

SUB: ELEMENTS OF MECHANICAL ENGINEERING
II SEMESTER ACADEMIC YEAR 2012-13 Sub Code

: 10EME24

Staff: SRINIVAS Y V

Fig 2.12: Kaplan Turbine

SRINIVAS Y V. Asst. Prof. Dept. of AUTO. Engg. Ac.IT

Page 14