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MECHANICAL SCIENCE
CHAPTER 10
STEAM TURBINES
SHROUD
NOZZLE
BLADES (OR
BUCKETS)
RO
TA
TI
WHEEL
STATIONARY
DIAPHRAGM
STUDENT TEXT
REV 2
2003 General Physics Corporation, Elkridge, Maryland
TM
All rights reserved. No part of this book may be reproduced in any form or by
any means, without permission in writing from General Physics Corporation.
TABLE OF CONTENTS
FIGURES AND TABLES .......................................................................................................... iii
OBJECTIVES .............................................................................................................................. v
INTRODUCTION ....................................................................................................................... 1
STEAM TURBINES ................................................................................................................... 1
Impulse Turbines ...................................................................................................................... 2
Reaction Turbines..................................................................................................................... 3
TURBINE STAGING AND COMPOUNDING ......................................................................... 5
Impulse Turbine Stage.............................................................................................................. 5
Reaction Turbine Stage ............................................................................................................ 6
Compounding ........................................................................................................................... 8
Velocity-Compounded Impulse Turbine .................................................................................. 9
Pressure-Compounded Impulse Turbine .................................................................................. 9
Pressure-Velocity-Compounded Impulse Turbine ................................................................... 9
Pressure-Compounded Reaction Turbine ............................................................................... 11
Impulse and Reaction Combination Turbine.......................................................................... 11
TURBINE GENERAL EQUATION ......................................................................................... 12
STEAM FLOW ......................................................................................................................... 14
Axial Flow .............................................................................................................................. 14
Helical Flow ........................................................................................................................... 14
Radial Flow ............................................................................................................................ 14
Steam Flow Path ..................................................................................................................... 14
BEARINGS AND GLANDS .................................................................................................... 15
Bearings .................................................................................................................................. 15
Radial Bearings ...................................................................................................................... 15
Thrust Bearings ...................................................................................................................... 16
TURBINE SUPPORT SYSTEMS ............................................................................................ 17
Lube Oil System ..................................................................................................................... 18
Hydraulic Control System ...................................................................................................... 19
Shaft-Packing Glands ............................................................................................................. 19
Steam Seal and Water Seal Systems ...................................................................................... 20
Exhaust Hood Cooling System............................................................................................... 21
Turning Gear .......................................................................................................................... 22
Bearing Lift Pumps ................................................................................................................ 22
Shaft Grounding Brushes ....................................................................................................... 23
TABLE OF CONTENTS
Failure Mechanisms ............................................................................................................... 23
SUMMARY ............................................................................................................................... 24
PRACTICE EXERCISES .......................................................................................................... 26
GLOSSARY .............................................................................................................................. 27
PRACTICE EXERCISE ANSWERS ........................................................................................ 28
ii
iii
iv
OBJECTIVES
Upon completion of this chapter, the student will be able to perform the following
objectives at a minimum proficiency level of 80%, unless otherwise stated, on an oral
or written exam.
1.
DESCRIBE the process for converting heat energy to rotational energy in turbines.
2.
3.
4.
5.
6.
7.
8.
9.
vi
STEAM TURBINES
INTRODUCTION
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PRESSURE
ENTRANCE
HIGH THERMAL ENERGY
HIGH PRESSURE
LOW VELOCITY
STEAM INLET
EXIT
LOW THERMAL ENERGY
LOW PRESSURE
HIGH VELOCITY
STEAM EXHAUST
VELOCITY
IMPULSE TURBINES
CONVERGENT NOZZLE
ROTOR
NOZZLE
BLADES (OR
BUCKETS)
NOZZLE
RO
TA
TI
O
N
WHEEL
STEAM
CHEST
STATIONARY
DIAPHRAGM
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REPRESENTS MOVING
IMPULSE BLADES
PRESSURE
TURBINE
SHAFT
REACTION TURBINES
EXIT
LOW VELOCITY
STEAM EXHAUST
ENTRANCE
HIGH VELOCITY
STEAM INLET
VELOCITY
STEAM CHEST
REPRESENTS NON-MOVING
IMPULSE BLADES
PRESSURE
ENTRANCE
STEAM INLET
EXIT
STEAM EXHAUST
VELOCITY
NOTE: PRESSURE AND VELOCITY OF STEAM
DO NOT CHANGE ACROSS FIXED
IMPULSE BLADE. IT IS USED ONLY
FOR DIRECTIONAL FLOW CONTROL.
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REPRESENTS NON-MOVING
REACTION BLADES
PRESSURE
ENTRANCE
HIGH PRESSURE
LOW VELOCITY
STEAM INLET
EXIT
LOW PRESSURE
HIGH VELOCITY
STEAM EXHAUST
DIRECTION OF SPIN
REPRESENTS MOVING
REACTION BLADES
VELOCITY
PRESSURE
TURBINE
SHAFT
ENTRANCE
HIGH PRESSURE
HIGH VELOCITY
STEAM INLET
EXIT
LOW PRESSURE
LOW VELOCITY
STEAM EXHAUST
VELOCITY
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FIXED
BLADE
+
PRESSURE
MOVING
BLADE
VELOCITY
MOVING
BLADE
PRESSURE
VELOCITY
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NOZZLE
MOVING
BLADE
MOVING
BLADE
FIXED
BLADE
PRESSURE
MOVING
BLADE
VELOCITY
PRESSURE
ONE STAGE
NOZZLE & MOVING
BLADE
ONE STAGE
FIXED & MOVING
BLADE
VELOCITY
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MOVING
BLADE
NOZZLE
MOVING
BLADE
FIXED
BLADE
MOVING
BLADE
PRESSURE
PRESSURE
VELOCITY
ONE STAGE
NOZZLE & MOVING BLADE
ONE STAGE
FIXED & MOVING BLADE
VELOCITY
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COMPOUNDING
To efficiently utilize the energy of steam, a
turbine must normally have an arrangement of
nozzles and blading that will cause more than
one pressure drop or more than one velocity drop
as the steam passes through the turbine. This
process is called compounding. A turbine that
has more than one pressure drop is classified as
pressure-compounded. A turbine that has more
than one velocity drop is classified as velocitycompounded. A combination of pressure drops
and velocity drops is called pressure-velocity
compounding.
-OR
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VELOCITY-COMPOUNDED
IMPULSE TURBINE
PRESSURE-COMPOUNDED
IMPULSE TURBINE
MOVING
BLADE
NOZZLE
MOVING
BLADE
PRESSURE
NOZZLE
MOVING
BLADE
FIXED
BLADE
1ST STAGE
NOZZLE & MOVING
BLADE
MOVING
BLADE
2ND STAGE
NOZZLE & MOVING
BLADE
VELOCITY
PRESSURE
1ST STAGE
NOZZLE & MOVING
BLADE
2ND STAGE
FIXED & MOVING
BLADE
VELOCITY
CURTIS STAGE
NOZZLE, MOVING BLADE,
FIXED BLADE, AND MOVING BLADE
NOZZLE MOVING
BLADE
FIXED
BLADE
MOVING
BLADE
RATEAU STAGE
NOZZLE & MOVING
BLADE
NOZZLE MOVING
BLADE
PRESSURE
VELOCITY
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PRESSURE-COMPOUNDED
REACTION TURBINE
All reaction turbines are pressure-compounded.
They are arranged so the pressure drop across the
turbine from inlet to exhaust is divided into
many steps by means of alternate rows of fixed
and moving blades (see Figure 10-23).
NOZZLE
MOVING
BLADE
FIXED
BLADE
MOVING
BLADE
PRESSURE
1ST STAGE
2ND STAGE
NOZZLE & MOVING BLADE FIXED & MOVING BLADE
CURTIS STAGE
NOZZLE, MOVING BLADE,
FIXED BLADE, AND MOVING BLADE
NOZZLE MOVING FIXED MOVING
BLADE
BLADE BLADE
VELOCITY
2ND STAGE
REACTION FIXED
& MOVING BLADE
FIXED
MOVING
BLADE
BLADE
PRESSURE
VELOCITY
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TURBINE GENERAL
EQUATION
In determining the General Energy Equation for
a turbine, the potential energy terms can be
neglected. This is possible because of the small
difference in elevation between the entrance and
exhaust of the turbine. The kinetic energy may
also be neglected, as the change in velocity from
the inlet to the outlet is minor in comparison to
the other terms. There is heat loss to the
surroundings, but because most turbines are
heavily insulated it is very small in comparison
to the work output. Making these simplifications
to the General Energy Equation we obtain:
h1
h2
h2
2'
s
SPECIFIC ENTROPY (Btu/lbm R)
(a)
h-s DIAGRAM
CRITICAL POINT
SATURATION
VAPOR
P1
LINE
TEMPERATURE ( F)
Equation 10-1
& ) = (m
& )(h in h out )
w t (m
P2
CRITICAL POINT
w t = h in h out
To obtain the total rate of work, multiply both
sides by the mass flow rate but leave the
enthalpy terms as specific by not multiplying
through yet.
SATURATION
VAPOR
LINE
T1
P2
WET STEAM
T2 & T2
& =m
& (h in h out )
W
t
s
Equation 10-2
(b)
T-s DIAGRAM
t =
&
& ( h in h out ,real )
m
W
real
=
&
& (h in h out ,ideal )
m
W
ideal
t =
(h in h out ,real )
(h in h out ,ideal )
Equation 10-3
2003 GENERAL PHYSICS CORPORATION
REV 2
www.gpworldwide.com
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&
&
W
t , real = t ( m )(h in h out ,ideal )
Equation 10-4
The analysis of turbine performance is very
complex. Pressure drops across the turbine
throttle, mechanical windage losses, and other
energy losses all have an effect on turbine
performance. The simplifications that are used
here are useful in the analysis of simple power
cycles.
&
&
W
t ,ideal = m (h in h out ,ideal )
Btu
6 lb m
&
W
(1,200 780)
t , ideal = 1 10
hr
lb m
8 Btu
&
W
t , ideal = 4.2 10
hr
&
W
t , ideal
Btu
1 Hp
= 4.2 108
hr
5
&
W
t ,ideal = 1.65 10 Hp
&
&
W
t , real = t Wt ,ideal
5
&
W
t , real = (.90)(1.65 10 Hp)
5
&
W
t , real = 1.49 10 Hp
Example 10-1
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RADIAL FLOW
STEAM FLOW
There are three different ways in which steam
can flow through a turbine:
Axial flow,
Radial flow.
AXIAL FLOW
Most turbines are of the axial flow type, which
means the flow of steam is in the direction that is
almost parallel to the axis of the turbine shaft
(see Figure 10-26).
Steam
Inlet
Steam
Exhaust
HELICAL FLOW
Steam
Inlet
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Steam
Exhaust
Steam
Exhaust
its temperature;
its cleanliness;
load; and
speed.
RADIAL BEARINGS
Most turbines, including all main turbines, have
a radial bearing at each end of the rotor. These
bearings are generally known as journal
bearings, and may be either sleeve type or tiltingpad type. Each type may be either cylindricalseated or spherical-seated.
Except for
momentary metal-to-metal contact when the
turbine starts, a thin film of oil constantly
separates the two metallic surfaces of the journal
and bearing. Refer to Figure 10-28.
Shaft at Rest
Rotation Starts
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THRUST BEARINGS
In addition to the radial bearings that serve to
support and hold the rotor in correct radial
position relative to the casing, a turbine has an
axial, or thrust bearing, that limits the fore-andaft travel of the rotor, thereby maintaining the
necessary clearance between moving and
stationary parts within the turbine.
In some auxiliary turbines, thrust bearings of the
ball or roller type are used. In others, the radial
bearing is designed with a small thrust bearing
surface, along with the radial bearing surface;
this type of bearing is actually a combination
radial and thrust bearing.
OIL
BABBIT
THRUST
COLLAR
OIL
WEDGE
COLLAR
ROTATION
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TURBINE SUPPORT
SYSTEMS
The turbine, like most large pieces of equipment,
often requires support from a number of
subsystems or support systems for operation.
Turbine support systems for a large turbine
typically include:
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Turning gear
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SHAFT-PACKING GLANDS
A trip system.
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20 of 28
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TURNING GEAR
The turning gear turns the turbine rotor slowly,
about 3-7 rpm, during shutdown, prior to starting
the turbine, or when the turbine is hot. Turning
the rotor slowly ensures that it is heated or
cooled evenly. If the rotor is allowed to come to
a rest when hot, temporary bowing and excessive
vibration can result. Distortion of the turbine
casing also results because the hotter steam rises
to the top of the casing.
The turning gear consists of an electric motor
driving a speed reducing gear train. The gear
train drives a large clash pinion or pinion gear
as it is often called, that can swing toward or
away from the turbine rotor. A bull gear is
usually mounted on the outside diameter of the
coupling between the turbine and generator.
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FAILURE MECHANISMS
The primary failure mechanism for the main
turbine is water impingement on the main blades.
Excessive moisture will erode the blades causing
an imbalance leading to a vibration problem.
Protective setpoints are established to ensure that
excessive moisture called carryover does not
occur in the main turbine during normal
operation.
Another failure would be a failure of the lube oil
system. The turbine is such a large mass rotating
at 1,800 rpm; a loss of lube oil could be
catastrophic. By the time the turbine and
generator came to rest, significant and costly
damage could occur. To reduce the probability
of a lube oil failure, a DC powered emergency
bearing oil pump is installed to provide oil to the
bearings on a low pressure condition of the lube
oil system.
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Turbine Staging
SUMMARY
Components that Comprise a Turbine
Large commercial turbines used in power plants
are generally divided into smaller components.
One high pressure turbine mounted on the same
shaft with two or three low pressure turbines is a
common configuration. The electrical generator is
mounted at the end of the shaft. The electrical
generator converts the rotational energy of the
turbine to electrical energy.
Nozzles
Nozzles direct the steam flow in a turbine. The
nozzles decrease the steam pressure and increase
the velocity of the steam.
Turbine Efficiency
Turbine efficiency (t) is the ratio of work done
by a real turbine to the work done by an ideal
turbine in accomplishing the same gas
expansion.
t =
(h in h out , real )
(h in h out ,ideal )
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Steam
Inlet
Axial flow,
Radial flow.
Steam
Exhaust
Steam
Exhaust
Steam
Exhaust
systems
associated
with
Turning gear
In the double-flow turbine steam from the highpressure turbine enters at the center of the lowpressure turbine and flows outward in both
directions through two identical sets of turbine
staging.
turbines
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PRACTICE EXERCISES
1. Where in a turbine does the conversion from
heat energy to kinetic energy occur?
c. Tandem
b. Intermediate throttle.
d. Turbine stage
c. Turbine nozzles.
d. Turbine throttle valve.
2. Impulse turbines function on what basic
premise?
b. Helical flow
d. Radial flow
c. Tandem flow
7. The classification for a turbine that has more
than one velocity drop is __________.
a. Axial flow turbine
b. Tandem turbine
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GLOSSARY
Axial flow turbine
Flow of steam is in the direction that is almost parallel to the axis of the
turbine shaft.
Curtis stage
Double-flow unit
Steam from the high-pressure turbine enters at the center of the lowpressure turbine and flows outward in both directions through two identical
sets of turbine staging.
Flow of steam is at an angle to the rotor. The flow is directed into buckets
fixed onto the turbine wheel and then back out of the buckets into stationary
reversing chambers to be directed back into the buckets.
Pressurecompounded turbine
Classification for a turbine that has more than one pressure drop.
Pressure-velocity
compounded turbine
The flow of steam is directed either toward or away from the rotor. This type
turbine may be used for driving some small auxiliary equipment.
Rateau stage
A simple impulse stage having one set of nozzles and one row of moving
blades.
Single-flow unit
Steam turbine
Tandem
Components (i.e., high and low pressure turbine units, steam turbine and main
generator) mounted on the same shaft.
Turbine stage
A nozzle followed by one or more sets of moving blades in the same section
of a turbine (i.e., high pressure, low pressure).
Velocitycompounded turbine
Classification for a turbine that has more than one velocity drop.
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