BASICS

&
CONSTRUCTION
OF
STEAM TURBINES
Prepared by, MIHIR RAMKRISHNA

Checked by, KB FOJDAR

Proprietary & Confidential

Slide 1 / 9

Approved by,

GC

Introductions!
Participant Introductions
Name
Position
Location (city)
How long with Reliance
Expectations

Instructors Introduction

Proprietary & Confidential

Slide 2 / 9

GC

Course Logistics
PowerPoint Presentation
Follow along with the trainer
Student Guide
Student Notes
Support information

Logistics

Proprietary & Confidential

Slide 3 / 9

Breaks, Lunch
Toilet, Water
Mobile phones
GC

Learning Objectives On successful completion of this course the participants would be able to:

Describe the hierarchical structure of control system

Define the Distributed control system
Identify various components at structured levels in a
control system
Perform a visual check and study of various structured
level components
Describe the advantages of structured control systems
Describe the comparison of the two major DCSs in GC
Identify: Different make/model of DCS at GC

Proprietary & Confidential

Slide 4 / 9

GC

Course Content
Day One/ Module 1
Topic 1
Topic 2
Topic 3
Day Two/ Module 2
Topic 1
Topic 2
Topic 3
Day Three/ Module 3
Topic 1
Topic 2
Topic 3
Proprietary & Confidential

Slide 5 / 9

GC

Any Questions?
Are we supposed to know .. to start this course?
Yes, but ..
Are we getting hands-on exercises?
Yes/ No
Will there be a test at the end?
No! There will be test at regular intervals and also
at the end
Please ask any question that comes to your mind

Raise your hand!

Ask on a break.
The only dumb question is
the one that is not asked!
Proprietary & Confidential

Slide 6 / 9

GC

Module #

Arial 32, Normal with shadow

Arial 48, Bold with shadow

Module Title

Proprietary & Confidential

Slide 7 / 9

GC

Topic Title

Proprietary & Confidential

Slide 8 / 9

Arial 40, Bold with shadow

GC

Slide Title
1.

Arial 32, Bold with Shadow

Main Points
a.

1.

a.

Sub points
i.

Arial 24, Bold

Arial 20
i.

Sub-sub points

Arial 16

Line spacing :

1.0 1.1

Para spacing:

1.2 1.5

Font color : (Title & text) Blue

Slide Background : Plain white

Proprietary & Confidential

Slide 9 / 9

GC

Module #

BASICS
&
CONSTRUCTION OF
STEAM TURBINES

Proprietary & Confidential

Slide 7 / 9

GC

STEAM TURBINE

Proprietary & Confidential

Slide 8 / 9

GC

STEAM TURBINE
A STEAM TURBINE IS A PRIME MOVER THAT
DERIVES ITS ENERGY OF ROTATION DUE TO
CONVERSION OF THE HEAT ENERGY OF
STEAM INTO KINETIC ENERGY AS IT EXPANDS
THROUGH A SERIES OF NOZZLES MOUNTED
ON THE CASING OR PRODUCED BY THE FIXED
BLADES.

IMPORTANT ASPECTS FOR STEAM

TURBINE FUNCTIONING
1.

STEAM AT HIGH TEMPERATURE AND PRESSURE

CONTAINS THE POTENTIAL ENERGY.

2.

POTENTIAL ENERGY OF THE STEAM IS

CONVERTED INTO A MECHANICAL WORK
THROUGH EXPANSION IN A NOZZLE AND IMPACT
AND/OR REACTION WITH A BLADE.

3.

MECHANICAL WORK OF MANY SETS OF BLADES

ATTACHED TO A SHAFT PRODUCES ROTATIONAL
POWER.

THE USE OF STEAM TURBINES FOR :

1. POWER GENERATION IN POWER PLANTS
2. DRIVES FOR CRITICAL CENTRIFUGAL/AXIAL
COMPRESSORS IN REFINERIES,
FERTILIZERS & PETROCHEMICAL PLANTS
3. DRIVE UNITS FOR PUMPS AND FANS

ADVANTAGES COMMONLY ATTRIBUTED

TO STEAM TURBINES ARE:
1. Ability to utilize high pressure and high temperature steam.
2.
3.
4.
5.
6.
7.
8.
9.

Flexibility to use multiple inlet and exhaust pressure

High efficiency.
Inherent variable speed operation
High rotational speed.
Operation independent of electric power supply
High capacity/weight ratio.
Smooth, nearly vibration-free operation.
No internal lubrication.

CARNOT CYCLE
1 TO 2: ISENTROPIC EXPANSION
2 TO 3: ISOTHERMAL HEAT REJECTION
3 TO 4: ISENTROPIC COMPRESSION
4 TO 1: ISOTHERMAL HEAT SUPPLY

1 to 2: isentropic expansion (steam turbine)

2 to 3: isobaric heat rejection (condenser)
3 to 4: isentropic compression (pump)
4 to 1: isobaric heat supply (boiler)

RANKINE CYCLE

1 to 2: Isentropic expansion (Steam turbine)

2 to 3: Isobaric heat rejection (Condenser)
3 to 4: Isentropic compression (Pump)
4 to 1: Isobaric heat supply (Boiler)

REHEAT RANKINE CYCLE

WHEN STEAM LEAVES THE TURBINE, IT IS TYPICALLY
WET. THE PRESENCE OF WATER CAUSES EROSION OF
THE TURBINE BLADES. TO PREVENT THIS, STEAM IS
EXTRACTED FROM HIGH PRESSURE TURBINE (STATE 4),
AND THEN IT IS REHEATED IN THE BOILER (STATE 5)
AND SENT BACK TO THE LOW PRESSURE TURBINE.

ADVANTAGES OF REHEATING
1.
2.
3.
4.
5.

Erosion and corrosion is avoided

Increased output
Increased thermal efficiency
Increased final dryness fraction
Increased nozzle and blade efficiency

DISADVANTAGES OF REHEATING
1. No appreciable increase in thermal efficiency
2. More maintenance

REGENERATIVE FEED HEATING CYCLE

Regeneration helps improve the Rankine cycle efficiency by
preheating the feedwater into the boiler. Regeneration can be
achieved by open feedwater heaters or closed feedwater
heaters. In open feedwater heaters, a fraction of the steam
exiting a high pressure turbine is mixed with the feedwater at
the same pressure. In closed system, the steam bled from the
turbine is not directly mixed with the feedwater, and
therefore, the two streams can be at different pressures.

ADVANTAGES OF REGENERATIVE FEED HEATING

1. Irreversibility in feed water heating is minimised
2. Increased Av Temp of heat addition, thus increase in thermal
efficiency
3. Reduced temp ranges and thermal stresses in Boiler
4. Less amount of steam passes through low pressure stages, so
blade height is reduced resulting in low cost of LP turbine
5. Reduced condenser capacity
6. Reduced heat rate

DISADVANTAGES OF REGENRATIVE FEED HEATING

1. Increased complications in plant
2. Costlier heaters and piping
3. Require larger boiler capacity for given power

REHEAT REGENERATIVE FEED HEATING

CYCLE

TURBINE OPERATION
WATER IS CONVERTED TO STEAM BY APPLICATION OF
HEAT IN THE BOILER, WHICH MAKES THE STEAM AT
SPECIFIED PRESSURE AND TEMPERATURE.
TO CONVERT THE STEAMS ENERGY INTO WORK, IT
MUST GO THROUGH A THERMODYNAMIC CYCLE THAT
COMBINES EXPANSION COMPRESSION, HEAT INPUT,
AND HEAT REJECTION.
THE MOST EFFICIENT THERMODYNAMIC CYCLE FOR AN
IDEAL FLUID IS CARNOT CYCLE. IT CONSISTS OF AN
ISOTHERMAL HEAT INPUT, ISENTROPIC EXPANSION,
ISOTHERMAL HEAT REJECTION, AND AN ISENTROPIC
COMPRESSION.

TURBINE CLASSIFICATION
1. ON THE BASIS OF PRINCIPLE OF OPERATION:
a. Impulse
b. Reaction
c. Impulse and reaction combined

2. ON THE BASIS OF NUMBER OF STAGES:

a. Single stage
b. Multi-stage

One or more revolving vanes separated by

stationary reversing vanes.

3. ON THE BASIS OF DIRECTION OF INLET STEAM FLOW :

a.axial
b.radial
c.tangential
d.reentry

4. ON THE BASIS OF INLET STEAM PRESSURE:

a.high Pressure
b.medium pressure
c. low pressure

5. ON THE BASIS OF SOURCE OF HEAT REJECTION:

a.extraction
b.regenerative
c.condensing
d.non-condensing

6. ON THE BASIS OF MEANS OF STEAM SUPPLY

a.single pressure
b.Dual pressure
c.Reheat turbine

7. ON THE BASIS OF NO OF ARRANGEMENT OF

CYLINDERS OR GENERAL FLOW OF STEAM
a.single flow
b.double flow
c.reverse flow

8. ON THE BASIS OF NO OF SHAFTS:

a.tandem compound
b.cross compound

IMPULSE
STAGE:
Impulse nozzles
organize the steam
so it flows in wellformed high-speed
jets. Moving
blades, also called
buckets, absorb
the jets kinetic
energy and
convert it to shaft
rotation.

TYPICAL IMPULSE STAGE

SIMPLE IMPULSE TURBINE

1. Works on the principle of Impulse
2. Also called de Laval turbine
3. Expansion takes place only in nozzles
4. Steam velocity at nozzle is approx 1100m/s.
5. Very high blade speeds and rotational speeds
6. High carryover or leaving velocity losses

COMPOUNDING OF IMPULSE TURBINE

Employing more than one set of nozzles, set of blades,
rotor in series so that either the steam pressure or the
jet velocity or both are absorbed by the turbine stages.
This process is called COMPOUNDING of steam
turbine.
Thus it is method for
1. Reducing rotational speeds of Impulse Turbine
2. Reducing leaving or carryover losses
3. Improving performance

METHODS OF COMPOUNDING
1. PRESSURE COMPOUNDING
2. VELOCITY COMPOUNDING
3. PRESSURE VELOCITY COMPOUNDING

PRESSURE COMPOUNDING
It is done for pressure of steam
only
Splitting up the whole press.
Drop into series of stages
Pressure between the two
consecutive diaphragms is
constant
Press on either sides of
diaphragm is different, so
leakages are prominent
Rotational speeds can be
reduced by increasing no. of
stages
Invented by prof. L Rateau
hence called Rateau Turbine

VELOCITY COMPOUNDING

It is done for velocity of steam

only
Consist of a nozzle or a set o
nozzles and alternating
stages of moving blades &
guide blades
Whole pressure drop takes
place only in nozzles
Velocity drop takes place in
moving blades only
Problem of leakage across
stages is eliminated
Slight velocity drop in guide
blade due to friction
Leaving losses are only 2% o
initial K.E.
Also called Curtis Turbine

PRESSURE - VELOCITY COMPOUNDING

It is the combination of both
pressure and velocity
compounding
Each wheel or rotor is velocity
compounded
Press drop takes place in
nozzles only placed prior to
each rotor thus pressure
compounded.
This arrangement was more
popular then pressure
compounded turbine due to
simplicity in construction
Rarely used now a days due
to poor efficiency

Reaction Type:
steam enters the
fixed
blade
passages
and
leaves as steam jet
that fills the entire
rotor
periphery.
Steam
flows
between
moving
blades that in-turn,
form
moving
nozzles. There it
drops in pressure,
and its speed rises
relative to that of
blades.

REACTION PRINCIPLE

IMPULSE REACTION TURBINE

1. Utilizes the principle of impulse

and reaction both
2. A No. of sets of moving blades
attached to rotor
3. An equal No. of fixed blades are
attached to casing
4. Fixed blades corresponds to
nozzles
5. Steam is admitted all around or
complete admission
6. Small pr. drop in moving blades
increases KE, this KE gives rise t
reaction.
7. Total force on blade is vector sum
of impulse force and reaction
force.
8. Moderate steam velocity approx
blade velocity
9. Mostly used in power plants
10. Ex. Parsions turbine

DIFFERENCE BETWEEN IMPULSE AND

REACTION TURBINE
Pr drops only in nozzles

Pr drops in fixed as well as moving

blades

Profile type blades

Aerofoil type blades A

Not all round admission of steam

All round or complete admission of

steam

Diaphragms contains the nozzles

Fixed blades similar to moving

blades are attached to the casing

Not much power can be developed Much power can be developed

Occupies less space for same
power

Occupies more space for same

power

Low efficiency

Higher efficiency

Suitable for small power

For Medium to higher power

Less costly blades

Costly blades

Higher leaving losses

Reduced leaving losses

BACK-PRESSURE TYPE:
The turbine normally operates against a constant backpressure. The turbine exhaust steam is supplied to the
process and the electric output is dependent on the
demand for the process steam.

BACK PRESSURE TURBINES WITH

UNCONTROLLED EXTRACTION:
This type with uncontrolled extractions is particularly
suitable when two steam systems operating at different
pressures are to be supplied and the extraction flow is less
than the exhaust flow.

CONDENSING TURBINE:
Straight-condensing turbines are advantageous, especially
when large quantities of a reliable power source are
required or an inexpensive fuel, such as process byproduct gas, is readily available.

EXTRACTION -CONDENSING TURBINE:

Extraction-condensing turbines generate both process
steam and stable electric power. Process steam, at one or
more fixed pressures, can be automatically extracted as
needed.

AUXILIARY STEAM TURBINE

LARGE TURBINE INTERNALS

GOVERNOR ACTUATOR & CONTROL VALVE

EMERGENCY STOP VALVE:

The ESV is the main shut of
provision between the steam inlet
and the turbine. The ESV can cut off
the steam supply in a minimum time

OVERSPEED TRIP:
The OST is a mechanical device,
which shuts down the turbine in the
vent of over speed. It initiates trip if
speed exceeds an admissible limit
more than 10%.

TURBINE JOURNAL BEARING:

The function of the journal bearings is
1. To support the turbine rotor centrally in the outer
casing and its guide blade carriers.
2. To carry a load perpendicular to the axis of rotation
made up of the weight of the rotor, constant or
fluctuating steam forces and kinetic forces caused by
the unstable running or any residual unbalance.

TURBINE THRUST BEARING:

The function of the Thrust bearing is:
1. To keep the rotor in exact position in
the casing
2.To absorb any axial thrust on the
rotor

GOVERNOR
To control turbine load automatically speed governor
takes care to measure shaft speed and adjust governor
valve openings to pass the required steam flow, in turns,
maintain speed within the governors regulating range.
Turbine speed will remain constant as long as shaft load,
governing valve openings are unchanged and steam
conditions remain steady. But when shaft load decreases
with constant governing valve opening, the turbine speed
increases because it is getting too much steam. To bring
shaft speed to normal, governing valve must throttle
steam flow to match the new load.

TYPES OF GOVERNOR:
CONSTRUCTION WISE:
a. mechanical governor:

simple flyweight arrangement

b. mechanical + hydraulic governor
using the principle of flyweight & hydraulic amplification

c. electronic governor
microprocessor based controls

FUNCTION WISE:
a. constant speed governor
b. variable speed governor

METHODS OF GOVERNING
1. THROTTLE GOVERNING
2. NOZZLE CONTROL GOVERNING
3. BY-PASS GOVERNING
4. COMBINATION OF 1&2 OR 1&3

THROTTLE GOVERNING
With throttle governing a single large control valve controls
the load from 0% to 100%. For large turbines two control
valves operating in parallel replace a large single valve. When
steam is throttled, the superheat increases and the turbine
exhaust steam is drier, reducing the turbine blade erosion,
but with the drier steam entering the condenser, the
condenser losses increase.

THROTTLE GOVERNING

NOZZLE CONTROL GOVERNING

WITH NOZZLE
GOVERNING A SERIES
OF NOZZLE VALVES
OPEN IN SEQUENCE AS
THE LOAD INCREASES.
THIS TYPE OF
GOVERNING IS MOST
EFFICIENT AND IS USED
FOR IMPULSE
TURBINES.

BY-PASS GOVERNING
THIS SYSTEM IS USED ON IMPULSE AS
WELL AS REACTION TURBINES, AN EXTRA
SET OF CONTROL VALVES ADMIT STEAM
TO THE SPACE BEHIND THE CURTIS
WHEEL OR FOR A REACTION TURBINE TO
AN ANNULAR SPACE BEHIND THE FIRST 8
- 12 STAGES. BY-PASSING PART OF THE
TURBINE INCREASES THE TURBINE
CAPACITY (OVERLOADS THE TURBINE)
BUT AT A REDUCED EFFICIENCY. THE BYPASS VALVES ARE SMALLER THAN THE
REGULAR GOVERNOR VALVES

BY-PASS GOVERNING

COMPONENTS OF STEAM TURBINE

1. CONDENSOR
2. ROTOR
3. BLADES/NOZZLES
4. BEARINGS
5. GLAND
6. CONDENSER
7. GLAND STEAM CONDENSER
8. AIR EJECTOR

CASING
Casings or cylinders are of the horizontal split type. This is not ideal, as
the heavy flanges of the joints are slow to follow the temperature changes
of the cylinder walls. However, for assembling and inspection purposes
there is no other solution.
The casings are heavy in order to withstand the high pressures and
temperatures. It is general practice to let the thickness of walls and
flanges decrease from inlet- to exhaust-end.
Large casings for low-pressure turbines are of welded plate construction,
while smaller L. P. casings are of cast iron, which may be used for
temperatures up to 230C. Casings for intermediate pressures are
generally of cast carbon steel able to withstand up to 425C. The high
temperature high-pressure casings for temperatures exceeding 550C are
of cast alloy steel such as 3 Cr iMo (3% Chromium + 1% Molybdenum.)

The reason for using different casing materials is that materials at the given
maximum temperatures and under constant pressure continue to deform with
very slowly increasing strain of the material; this phenomenon is called "Creep".
The casing joints are made steam tight, without the use of gaskets, by matching
the flange faces very exactly and very smoothly. The boltholes in the flanges
are drilled for smoothly fitting bolts, but dowel pins are often added to secure
exact alignment of the flange joint. The assembled casing is then machined off
inside on a boring-mill, where grooves are made for the diaphragms (for
impulse turbines) or for the stationary blades (reaction turbines). Borings are
also made for shaft seals and in many cases for the bearings also.
For high-pressures the flanges of the casings must be very heavy and will
heat up much slower than the casing walls. Flange heating, by steam through
machined channels between the flanges or holes drilled axially through the
upper and lower flanges, is often applied.Double casings are used for very
high steam pressures. The high pressure is applied to the inner casing, which
is open at the exhaust end, letting the turbine exhaust to the outer casings the
pressure is divided between the casings, and most important, the temperature
is also divided of the flange and is forced to flow round the bolt by means of
baffle and thermal stresses on casings and flanges are greatly reduced.
Radiation losses are also decreased. The inner casing may be assembled
with shrink rings giving an ideal casing without flanges.

ROTOR
The design of a turbine rotor depends on the operating principle of the turbine.
The impulse turbine with pressure drop across the stationary blades must have
seals between stationary blades and the rotor. The smaller the sealing area, the
smaller the leakage; therefore the stationary blades are mounted in diaphragms
with labyrinth seals around the shaft. This construction requires a disc rotor.
The reaction turbine has pressure drops across the moving as well as across
the stationary blades and the use of a disc rotor would create a large axial
thrust across each disc. The application of a drum rotor eliminates the axial
thrust caused by the discs, but not the axial thrust caused by the differential
pressure across the moving blades.

Disc Rotors
All larger disc rotors are now machined out of a solid forging of nickel steel; this
should give the strongest rotor and a fully balanced rotor. It is rather expensive,
as the weight of the final rotor is approximately 50% of the initial forging. (Fig.
20) Older or smaller disc rotors have shaft and discs made in separate pieces
with the discs shrunk on the shaft.

The bore of the discs is made 0.1% smaller in diameter than the shaft. The
discs are then heated until they easily are slid along the shaft and located in
the correct position on the shaft and shaft key. A small clearance between the
discs prevents thermal stress in the shaft.
The first reaction turbines had solid forged drum rotors. They were strong,
generally well balanced as they were machined over the total surface. With the
increasing size of turbines the solid rotors got too heavy and the hollow drum
rotor was introduced. This rotor is made of two or more pieces. For good
balance the drum must be machined both outside and inside and the drum
must be open at one end. The second part of the rotor is the drum end cover
with shaft. The end cover is made with a shrink fit and welded ( Fig 21).

Hollow Drum Rotor

A fairly light and rigid drum rotor may be manufactured from discs welded
together to form a drum as shown in Fig. 24 Before welding, the rotor is heated
by induction heating, then the welding is performed with automatic welding
machines for the "Argon-arc" process, where the arc burns in an argon
atmosphere.Most rotors are now made of nickel alloy-steels with elastic limits of
around 300 x 10 Pascal Rotors for high outputs and high temperatures are
generally made of chromium-nickel-molybdenum steels with elastic limits of
600 - 700) x 106 Pascal.

BLADES/NOZZLES
TURBINE BLADES
The efficiency of the turbine depends more than anything else on the design of
the turbine blades. The impulse blades must be designed to convert the kinetic
energy of the steam into mechanical energy. The same goes for the reaction
blades, which furthermore must convert heat energy to kinetic energy. The later
years' increase in blade efficiency is due to increased aerodynamic shape
calculated by computers and the milling of blades on automatic milling
machines.
It is not always possible to give the blades the theoretically best profile, as
several other considerations must be taken. The blade must be made strong
enough to withstand high temperatures and stresses from heavy, often
pulsating steam loads. There is also the stress due to centrifugal force ( for
large L.P blades the centrifugal force on a single blade may exceed 200 tonnes
) Vibrations and resonant vibrations in particular must be taken into account
and finally there is erosion and corrosion.
The material that comes closest to the ideal for all mentioned considerations is
a chromium-nickel steel, for instance 17 Cr'13 Ni - steel.

Stationary Blades and Nozzles

The first set of nozzles for an impulse turbine is the control set and is divided
into three to six sections with each section having a steam control valve. For
smaller turbines all sections may be located in the upper half of the casing,
while the sections for larger turbines cover the entire circumference. All stages
following the control stage have the nozzles located in diaphragms ( Fig. 37 )
The diaphragms are in halves and fitted into grooves in the casing. Locking
pieces in the upper part of the casing prevent the diaphragm from turning. All
modern diaphragms are of an all-welded construction.
The stationary blades in reaction turbines are fitted into grooves in the casing
halves; keys as shown (Fig. 3S and Fig. 39) lock the blades in place. In some
cases, the blades have keys or serration on one side of the root and a caulking
strip on the other side of the root is used to tighten the blades solidly in the
grooves. The blades are often supplied with a shroud band with radial and/or
axial sealing strips to minimize leakage losses.
The stationary blades for a Curtis wheel are attached to the casings, as are the
stationary blades for reaction turbines.

BEARINGS
JOURNAL BEARINGS
The bearings for small turbines are often self-aligning spherical ball or rollerbearings or they may be ring lubricated sleeve bearings with bronze or babbitt
lining.

THRUST BEARINGS
The main purposes of the thrust bearing are:
To keep the rotor in an exact position in the casing.
To absorb any axial thrust on the rotor.
From the thrust bearing the shaft must be free to expand in either direction,
thus a shaft can have only one thrust bearing. The thrust bearing should be
located at the steam inlet, where the blade clearances are most critical. When
shafts of a tandem compound turbine are joined together with solid couplings,
only one thrust bearing can be applied. If flexible couplings take up the axial
expansion, each shaft must have a thrust bearing.

The axial thrust is very small for impulse turbines as the pressure is equal acros
the rotor discs ensured by equalizing holes in the discs. A simple thrust bearing
such as a ball bearing for small turbines and radial babbitt facing on journal
bearings for larger turbines is very common.

The pressure drop across the moving blades of reaction turbines creates a heav
axial thrust in the direction of steam flow through the turbine and a thrust bearin
suitable for heavy axial loading is needed. The tilting pad Kingsbury or Michel
thrust bearings operating on the same principle as the tilting pad journal bearing
are generally applied. The axial thrust in impulse turbines does not require tilting
pad thrust bearings, but due to their excellent performance, they are the most
common thrust bearing for large impulse turbines. The axial thrust in reaction
turbines can be nearly eliminated by the use of balance or dummy pistons. With
the correct size of a dummy piston exposed to two different bleed point pressure
the thrust is nearly equalized, There is a small leakage across the labyrinth seal
the dummy piston as steam leaks from the high to the lower bleed point.

The axial position of the rotor is very important and an axial position indicator is
often applied to the thrust bearing. It may be a large dial micrometer with alarm
setting for an axial movement of 0.4 millimeter and shutdown at 0.8 millimeter, A
oil pressure gage connected to an oil leak-off device may also be used as an ax
position indicator.

The oil is supplied at say 500 kPa, flows through an orifice and leaks off
through a nozzle The pressure between orifice and nozzle depends on the
distance between the nozzle and shaft thrust collar; the larger the distance the
lower the pressure. The pressure gage can be calibrated in millimeter
clearance and may have alarm and shutdown settings.

SEALS
Blade Seals
The efficiency of reaction turbines depends to a large extent on the blade seals;
radial as well as axial seals are often part of the shroud with the seal
clearances kept as small as possible. As protection for the axial seals some
manufacturers apply an adjustable thrust bearing. The whole thrust block is
cylindrical and fits like a piston in the cylinder with the whole thrust block able to
be axially adjusted as shown in Fig. 28. During startup the thrust block is
pushed against a stop in the direction of exhaust for maximum seal clearances.
When the turbine is heated up and has been on load for a short time the thrust
block is pulled forward against a forward stop for minimum seal clearance and
maximum blade efficiency.

Shaft Seals
Shaft seals must be provided in order to prevent or at least reduce steam
leakage where the shafts extend through the casings. Also when low pressure
turbines are under vacuum the seals must prevent air from leaking into the
casing.

Ordinary soft packing may be used for shaft sealing in small turbines. Carbon
rings are also very common for small turbines. The carbon ring is made up of
three segments butting together tightly under the pressure of a garter spring.
The ring has a few hundreds of a millimeter clearance around the shaft and is
prevented from turning by a locking pin.
The ring has a slight side clearance in the housing allowing it to move freely
in radial directions. Carbon rings are self-lubricating but have a tendency to
corrode the shaft when the turbine is shut down. The presence of moisture
accelerates the corrosion. The carbon rings are from 10 to 25 millimeters
wide and may cause heating when they ride on the shaft. They are, for that
reason, limited to shafts less than 150 millimeters in diameter. For larger
diameter shafts where the surface speed is high, labyrinth seals are applied.
The labyrinth seal consists of a number of rings 1 - 2 millimeters thick fixed
to the shaft, tapered at the outer periphery to nearly knife-sharp with a
clearance to the casing of a few hundreds of a millimeter. The rings are of
brass or stainless steel; the sharp edge gives better sealing and rubs off
easily without excessive heating in case of a slightly eccentric shaft. Some
labyrinth seals are very simple, others are complicated.

CARBON RING SEAL

High pressure turbines operating at 12 090 to 15 000 kPa cause a sealing
problem, as a straight labyrinth seal for that pressure would be extremely long
or have lots of steam leaking through. The problem is solved by a series of
steam pockets between sets of labyrinth seals. The high pressure steam leaks
through 100 - 200 millimeters of labyrinth seal into the first pocket, which is
connected to the H. P exhaust, thus any steam leaking through the seal is used
in the I P. Turbine. After the first pocket the steam leaks through the second
seal 75 -150 millimetres long and into the second pocket connected to an H.P.
feedwater heater. Then steam leaks through the third labyrinth seal to the third
pocket connected to the I P. exhaust. The steam then leaks through the fourth
seal into the fourth pocket, which is connected to the L. P shaft seals supplying
them with sealing steam. On the steam line between pocket number 4 and the
L. P. seals are two connections with pressure control valves. One is a spill-over
valve to the condenser, which will open to the condenser if the gland st~am
exceeds the set point of a few centimetres of water above atmospheric
pressure. The other connection has a control valve to supply gland steam when
the pressure decreases to near atmospheric pressure. This valve operates
during start-ups and low loads.

Neither the carbon nor the labyrinth shaft seals prevent all leakage. If a positive
or leak-proof seal is needed, a water seal may be installed. The water seal
consists of an impeller on the turbine shaft which rotates in a waterfilled casing
and water thrown out from the impeller forms a leak-proof water barrier. Water
seals are mainly applied to L. P glands to guard against air leakage, but they
may also be applied as the final seal for H.P. and I. P. glands.
The water seal cannot operate properly at low speed and gland steam must be
applied for sealing during start-up until the turbine speed is approximately 2000
rev/mm. Water seals are supplied with clean cool condensate from the
extraction pump. It may be supplied directly or via a head tank with automatic
level-control
The diaphragms of impulse turbines have labyrinth seals at the shaft. These
seals are made of brass of stainless steel and are in six segments, each
segment is springloaded and kept against a stop allowing a very small
clearance between seal and shaft. In case of a bent shaft, the shaft may push
the segment back against the spring pressure, preventing serious damage to
shaft or seal

CONDENSERS

GLAND STEAM CONDENSER

AIR EJECTORS

OVER SPEED TRIP

The high rotational speed of steam turbines creates large
centrifugal forces, as these forces increase with the square
of the speed. Therefore an absolute reliable overspeed
protection must be provided.
The overspeed trip in Fig. 44 is mechanical-hydraulic and
shows clearly the operating principle of all overspeed trips
for turbines with hydraulic governor systems. The
springloaded tripping bolt located in the turbine shaft has
the centre of gravity slightly off the centre of the shaft in
direction of the bolt head The nut at the end of the bolt
provides a stop for the bolt in tripped position and for the
tripping speed adjustment. During normal operation the
main spring holds the relay rod against the tripping lever;
piston A has closed the oil drain and H.P. oil passes between
pistons A and B to the stop valve.

When turbine speed increases to the trip setting, usually 110% of

operating speed, the centrifugal force overcomes the bolt spring, the bolt
moves to the tripping position, strikes the tripping lever, unlatching the
relay rod and the main spring moves the relay to the tripped position in
which piston A opens the stop valve oil-port to drain, while piston B
closes off the H.P. oil inlet port.
For all hydraulic systems the overspeed trip closes off for H.P. oil and
opens the stop valve oil cylinder to drain allowing the valve to close
under spring force.

JACKING OIL SYSTEM

Large turbines with heavy rotors are generally equipped
with a jacking oil pump, supplying the lower part of the
bearings with oil at approximately 10 000 kPa, thereby lifting
the shaft and supplying lubricating oil.
The jacking oil is applied before start-up of the turning gears
and for slow rev/mm the oil is left on, but for high rev/mm
(50 - 60 rev/mm) it is generally shut down as soon as the
turning gear is up to speed.

TURNING/BARRING GEAR
When a turbine is left cold and at standstill, the weight of the
rotor will tend to bend the rotor slightly. If left at standstill
while the turbine is still hot, the lower half of the rotor will
cool off faster than the upper half and the rotor will bend
upwards "hog". In both cases, the turbine would be difficult
if not impossible to start up. To overcome the problem the
manufacturer supplies the larger turbines with a turning or
barring gear consisting of an electric motor which through
several sets of reducing gears turns the turbine shaft at low
speed.

The first turning gears turned the shaft at approximately 20

rev/mm, later increased to 40 and up to 60 rev/mm as
proper lubrication is difficult to obtain at low speed; the
same goes for the hydrogen seals of generators. Some
turning gears, electric or hydraulic, turn the shaft 1 800 at
set times over a period of 24 hours.Before a cold turbine is
started up it should be on the barring gear for
approximately three hours. When a turbine is shut down, it
should be barring for the next 24 hours.

SUPPORT SYSTEMS
1.
2.
3.
4.
5.
6.

Lube oil system

Control oil system
Trip oil system
Jacking oil system
Turning Gear
Governing system

TURBINE MONITORING:
The principal criteria of monitoring, which can indicate
a dangerous condition during normal operation are as
follows:
1.
2.
3.
4.
5.

Oil and Bearing Temperatures

Bearing housing and Shaft vibrations
Shaft axial displacement
Steam Parameters like
Oil Quality

STEAM PARAMETERS MONITORING

1.TEMPERATURE
The satisfactory functioning and life of the various components of the turbine
are to a large extent dependant on the absolute main steam temperatures and
temperatures fluctuations. Consequences of exceeding the permitted
tolerances are:
a. a shortening of the life the affected components.
b. a build up scale in guiding and sealing devices.
c. permanent distortion of housing and casings.
d. temporary or permanent changes in radial
clearances.

2. INLET STEAM PRESSURE MONITORING:

The objective of Inlet Steam Pressure monitoring:

a.
b.
c.
d.

Maintain the inlet steam pressure within the permitted tolerance.

Keep the initial steam pressure as constant as possible during
steady state operation.
Match the initial steam pressure to the requirement of power output.
Maintain the pressure and changes during start-up as
far as possible in accordance with the actual casing temperatures.

C. WHEEL CHAMBER PRESSURE

MONITORING:
Wheel Chamber pressure monitoring is a good indication
of rotor condition. As these pressure is direct function of
steam mass flow. If the measurement indicates higher
values at constant mass flow then it is an indication of
deterioration of turbine operation. All operating conditions
need to be checked.

OPERATION GUIDELINES:
To ensure the trouble free operation, the turbine must be:
1.
2.
3.
4.
5.
6.

operate as per specified operating parameters

maintain Proper lubrication
protective devices in line& functioning
operate as per SOP
regularly inspect/maintain as per Vendor guidelines
turbine steam quality to be ensured for the build up
of deposits in turbine due to impurities
in the steam can cause both thermodynamic
and mechanical problem which can
lead to blade failure.

GOVERNING SYSTEM

TURBINE DATA SHEET

LUBE OIL SYSTEM

STEAM TURBINE ROTOR

TURBINE CASING LOWER HALF

IMPULSE BLADE

REACTION BLADE

BLADES OF STEAM
TURBINES

JOURNAL BEARING

ROTOR POSITION IN BEARING

SHAFT PACKING GLANDS

Shaft packing glands prevent the leaking of
steam outa of or air into the turbine casing where
the turbine rotor shaft extends through the
turbine casing. Labyrinth and carbon rings are
two types of packing. They are used either
separately or in combination. Labyrinth packing
consists of rows of metallic strips or fins. The strips
fasten to the gland liner so there is a small space
between the strips and the shaft. As the steam
from the turbine casing leaks through the small
space between the packing strips and the shaft,
steam pressure gradually reduces.

Labyrinth packing
gland

VARIOUS TYPES OF GLAND ARRANGEMENTS

VARIOUS TYPES OF GLAND

ARRANGEMENTS

WHEEL AND DIAPHRAGM

ARRANGEMENT IN
IMPULSE TURBINE

WHEEL AND DIAPHRAGM

ARRANGEMENT IN
REACTION TURBINE

IMPULSE WHEEL AND DIAPHRAGM CONSTRUCTION

THANK YOU