Steam Turbines

Design, Applications, and Rerating

Heinz P. Bloch Murari P. Singh

Second Edition

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Me Graw Hill Lisbon London

Contents

Preface xiii Acknowledgments

xvii

Chapter 1. Introduction
1.1 1.2 Why Mechanical Drive- Steam Turbines Are Applied Overview of Steam Turbine Fundamentals 1.2.1 Steam turbine staging can vary 1.2.2 Modern impulse design 1.2.3 Single-valve vs. multivalve construction 1.2.4 Steam balance considerations Overview of Steam Turbine Types and Controls 1.3.1 Straight noncondensing 1.3.2 Automatic extraction noncondensing 1.3.3. Automatic extraction condensing 1.3.4 Basic steam control considerations 1.3.5 Automatic extraction condensing controls 1.3.6 Geared and direct-drive types 1.3.7 Modular design concepts

1
1 2 5 5 5 9 9 14 15 15 18 21 21 23

1.3

Chapter 2. Turbine Casing and IViajor Stationary Components

2.1 2.2 2.3 Casing Design Steam Admission Sections Steam Turbine Diaphragms and Labyrinth Packing .

29
29 33 36

Chapter 3. Bearings for Mechanical Drive Turbines

3.1 Journal Bearings for Industrial Turbomachinery 3.1.1 Fixed-geometry journal bearing stability 3.1.2 Tilting-pad journal bearings 3.1.3 Advanced tilting-pad journal bearings 3.1.4 Lubrication-starved tilting-pad bearings 3.2 Key Design Parameters 3.3 Thrust-Bearings for Turbomachinery 3.4 Active Magnetic Bearings

51
51 52 56 61 65 68 69 75

vii

viii

Contents 81 81 82 83 84 89 90 91 92 94 95 95 99 100 105 109 ' 111 111 113 114 120 125 125 128 129 132 135 135 137 137 140 140 141 141 141 141 143 144 144 145 145 148 150 150 150

Chapter 4. Rotors for Impulse Turbines 4.1 Long-Term Operating Experience 4.2 Pitch Diameter and Speed 4.3 Steam Temperature 4.4 Built-Up Construction 4.5 Solid Construction 4.6 Shaft Ends 4.7 Turbine Rotor Balance Methods 4.7.1 At-speed rotor balancing 4.8 Balance Tolerance Chapter 5.. Rotors for Reaction Turbines 5.1 5.2 5.3 5.4 Solid Rotors Materials for Solid Rotors Welded Rotor Design Welded Rotor Materials

Chapter 6. Turbine Blade Design Overview 6.1 Blade Materials 6.2 Blade Root Attachments 6.3 Types of Airfoils and Blading Capabilities 6.4 Guide Blades for Reaction Turbines 6.5 Low-Pressure Final Stage Blading Chapter 7. Turbine Auxiliaries 7.1 7.2 7.3 7.4 7.5 7.6 Lube Systems Barring or Turning Gears Trip-Throttle or Main Stop Valves Overspeed Trip Devices Gland Seal Systems Lube Oil Purifiers

Chapter 8. Governors and Control Systems 8.1 8.2 General Governor System Terminology 8.2.1 Speed regulation 8.2.2 Speed variation 8.2.3 Dead band 8.2.4 Stability 8.2.5 Speed rise 8.3 NEMA Classifications 8.4 Valves 8.4.1 Single-valve turbines 8.4.2 Multivalve turbines 8.5 PG Governors 8.6 Electronic Governors 8.7 Governor Systems 8.7.1 General 8.7.2 Extraction control

Contents

ix

Chapter 9. Couplings and Coupling Considerations

9.1 9.2 9.3 9.4 9.5 9.6 9,7 Power Transmission Shaft Alignment Maintenance Influence on the Critical Speeds Differential Expansions Axial Thrusts Limits of Application

157
157 160 162 162 162 163 163

Chapter 10. Rotor Dynamics Technology

10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 10.11 10.12 10.13 10.14 10.15 10.16 10.17 Rotor Model Dynamic Stiffness Effects of Damping on Critical Speed Prediction Bearing-Related Developments Refinements Bearing Support Considerations Foundations Impedance Partial Arc Forces ' Design Procedure ,', Rotor Response Instability Mechanisms ~ Subsynchronous Vibration Service Examples Labyrinth and Cover Seal Forces Rotor Stability Criteria Experimental Verification

165
165 166 169 170 172 173 174 174 178 179 180 180 180 183 185 187 187

Chapter 11. Campbell, Goodman, and SAFE Diagrams for Steam Turbine Blades
11.1 Goodman Diagram 11.2 Goodman-Soderberg Diagram 11.3 Campbell Diagram 11.3.1 Exciting frequencies 11.4 SAFE DiagramEvaluation Tool for Packeted Bladed Disk Assembly 11.4.1 Definition of resonance . 11.4.2 Mode shape 11.4.3 Fluctuating forces 11.5 SAFE Diagram for Bladed Disk Assembly 11.6 Mode Shapes of a Packeted Bladed Disk 11.7 Interference Diagram Beyond NI2 Limit 11.8 Explaining Published Data by the Use of Dresser-Rand's SAFE Diagram 11.9 Summary Chapter 12. Reaction vs. Impulse Type Steam Turbines 12.1 12.2 Introduction Impulse and Reaction Turbines Compared

189
189 190 191 195 197 198 198 200 203 209 211 214 217 219 219 220

Contents 12.3 12.4 Efficiency Design 12.4.1 Rotor 12.4.2 Blading Erosion Axial Thrust Maintenance Design Features of Modern Reaction Turbines Deposit Formation and Turbine Water Washing 220 223 223 224 230 232 233 233 235 243 243 245 246 253 257 261 261 264 264 265 267 267 271 303

12.5 12.6 12.7 12.8 12.9

Chapter 13. Transmission Elements for High-Speed Turbomachinery 13.1 Spur Gear Units 13.2 Epi'cycfic Gears 13.3 Clutches 13.4 Hydroviscous Drives 13.5 Hydrodynamic Converters and Geared Variable-Speed Turbo Couplings 13.5.1 Function of the multistage variable-speed drive 13.5.2 Design and operating details 13.5.3 Working oil and lube oil circuits 13.5.4 Lubricating system 13.5.5 Lubricant oil containment on gear and variable-speed units Chapter 14. Shortcut Graphical Methods of Turbine Selection 14.1 Mollier Chart Instructions 14.2 Estimating Steam Rates 14.3 Quick Reference Information to Estimate Steam Rates of Multivalve, Multistage Steam Turbines Chapter 15. Elliott Shortcut Selection Method for Multivalve, Multistage Steam Turbines 15.1 Approximate Steam Rates 15.2 Stage Performance Determination 15.3 Extraction Turbine Performance Chapter 16. Rerates, Upgrades, and Modifications 16.1 Performance and Efficiency Upgrade 16.1.1 Brush seals and labyrinth seals 16.1.2 Wavy face dry seals 16.1.3 Buckets Reliability Upgrade 16.2.1 Electronic controls 16.2.2 Monitoring systems Life Extension Modification and Reapplication 16.4.1 Casing 16.4.2 Flange sizing 16.4.3 Nozzle ring capacity 16.4.4 Steam path analysis

309 309 313 320 329 331 332 336 348 352 352 356 356 358 359 360 362 362

16.2

16.3 16.4

Contents 16.4.5 Rotor blade loading 16.4.6 Thrust bearing loading 16.4.7 Governor valve capacity 16.4.8 Rotor 16.4.9 Shaft end reliability assessment 16.4.10 Speed range changes 16.4.11 Auxiliary equipment review 16.4.12 Oil mist lubrication for general-purpose steam turbines 16.4.13 Problem solving 16.5 Summary Appendix A. Glossary Appendix B. Units of Measurement Bibliography and List of Contributors Index 407

xi 363 363 364 364 364 366 366 367 376 376

377 385 399