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STEAM TURBINE (API-611)

1. What is meaning of kg/kw-hr & it will be highest @ which steam condition?


Turbine Steam rate is expressed in kg/kw-hr or in lb/hp-hr.
Turbine steam rate is the quantity of inlet steam required by turbine per unit of power output, measured
at the output shaft of turbine.

Steam rate is higher at minimum inlet condition & maximum exhaust conditions & based on these
conditions, maximum nozzle area needed can be determined

2. What is the purpose of hand valve? Can it use for auto start & if not, then what needs to be done for
selecting steam turbine?

In many cases, driven equipment will have range of operating conditions specified & steam turbine needs
to be capable at all of them. In addition, the operating steam conditions for turbine can vary. These factors
can sometimes result in a turbine that is capable of much greater power than normal conditions dictate
and lead to relatively inefficient operation at normal conditions. Hand valves on the turbine can help to
address these alternate operating points. Hand valves are used to allow variations in operating conditions
to be met without significantly affecting a design steam rate.

A hand valve(s) is the valve which isolate steam flow to group of nozzles to permit efficient operation at
reduced power or with dual steam conditions. Hand valves
3. What is difference between NEMA A & D governor & where they applied
NEMA Class A used when Oil relay (hydraulic) governor is required. If purchase needs an Electronic
governor, then NEMA Class D will be installing on the turbine. It is an optional requirement.)

For General purpose steam turbine (API 611), NEMA A or D governor can be used, whereas for Special
purpose steam turbine (API612) NEMA D governors are only used

The governor shall conform to NEMA SM 23 and shall have the same or better characteristics as those
shown in below table.

4. How PEAK 150 governor used for constant speed pump application? Also refer 7.4.2.2
The Peak® 150 digital control is designed to control a steam turbine driving a mechanical load. It provides
tight control of speed (NEMA D) and includes an input for a 4–20 mA remote speed control signal, which
can be used for a process-generated input to control the speed setting. Other features include dual speed
control dynamics and overspeed trip test capabilities

5. What are the parameters checked under MRT?


- Temperature (bearing metal & bearing oil)
- Turbine speed
a. From minimum allowable speed to maximum continuous speed (with 10% increment)
b. At 110% of maximum continuous speed (for 15 min)
c. Non trending trip values within ± 2 % of the nominal trip setting are attained.
d. Speed reduced to the maximum continuous speed and the turbine shall be run for 1
hour continuously
- Vibration readings shall be taken at maximum continuous speed, just below trip speed and at
minimum specified governor speed,

6. What is pros & cons of single stage & multistage API 611 turbine construction?
Single Stage Steam turbine:
The Single Stage Steam Turbine search the function in process industries and are designed to offer
customers with reliability and economic drives for fans, compressors, water, oil pump and generators.
The type of single stage turbine provides reliable machine which is used for smaller power capacities
of generally up to 2 MW.
Single-stage turbines shall be suitable for immediate start-up to full load. The purchaser shall allow
for warm-up and proper drainage of the inlet piping, turbine casing, steam chest, and packing glands

Features:

 Can be made available in different frame sizes as well as design horizontal (axial & radial split)
and vertical options as per requirement of clients.
 These design features include metallic/carbon seals, overhung & bearings wheel designs,
electronic/hydraulic/mechanical governors.
 These also feature direct driven/with integral gear boxes and mechanical/electronic safety trip
system with suitable lubrication system
 System designed for achieving higher efficiencies as well as operating conditions
 Axial split casing provides for easier inspection as well as servicing of rotor and wear parts

In a single stage steam turbine, the steam is run through a nozzle to give it maximum velocity, thus
the blades move at very high speeds, impractical for some applications, and only some of the energy
is used, about 85-90%.

Single stage turbine shall be suitable for immediate startup to full load. The purchaser shall allow for
warm-up and proper drainage of the inlet piping, turbine casing, steam chest, and packing glands

- Multistage Turbines
Multistage turbines are back pressure turbines that can be made available in form of single stage or
multi-stage options. These turbines find application for drive application/power generation
applications and are of straight-back pressure type. Finding application in areas where back pressure
steam is fully utilized, the power generation is incidental to process steam demands.

Features:

 Back pressure turbines can also be provided with bleed points/uncontrolled extractions
for meeting steam demands at intermediate pressures
 This provision is also applicable where bleed/medium pressure steam volume demand is
low as well as pressure variations can be tolerated
 Turbines are made available of bleed cum back pressure type
 With back pressure turbine with single controlled extraction point option possible, this
extraction steam finds use in meeting process steam demands at intermediate pressure,
especially in areas where volume demand is high as well as pressure variations cannot be
tolerated

- Multistage turbines are purchased where single stage turbines are not suitable or improved
efficiency is needed due to:
a. Larger exhausts are needed than those available on single stage units, usually on
applications with condensing exhaust pressure
b. The steam rates or consumption is of greater importance to the customer. A multistage
turbine is usually significantly more efficient than single stage turbing
c. The power requirement exceeds the capability of single stage turbine for blade loading
reasons
In multi-stage or compound turbines, the steam goes through a nozzle to increase its velocity, then
after going through a set of blades, it is run through another nozzle to bring the steam back up to the
correct velocity. After multiple stages there is no longer enough pressure left to up the velocity of the
steam. This method increases the efficiency of the turbine and also decreases wear on the components
caused by the high speed of a single stage.

7. When carbon ring packing is allowed as per API 611?


Carbon-ring packing shall be used only if the rubbing speed at the shaft sealing surface is less than 50 m/s
(160 ft/s). The number of carbon rings shall be determined by the service and venting requirements, with
2.4 bar (35 psi) being the maximum allowable average differential pressure per active sealing ring. Springs
for carbon packing shall be made of nickel-chromium-iron alloy (heat treated after cold coiling) or equal
material. Variations in operating steam temperature shall be considered when the required cold
clearances for packing rings are established.

8. When you apply API 611 & API 612 Steam turbines?
API 611 General Purpose
General-purpose turbines are horizontal or vertical turbines used to drive equipment that is usually
spared, is relatively small in size (power), or is in non-critical service

Steam turbines generally used where steam conditions will not exceed a pressure of 48 bar (700 psig) and
a temperature of 400 °C (750 °F) or where speed will not exceed 6,000 r/min.

API 611 General Purpose Turbines typically used for mechanical drives Process pumps, ID & FD fans, BFP
Spared equipment

API 612 Special Purpose


Special-purpose turbines are those horizontal turbines used to drive equipment that is usually not
spared, is relatively large in size (power), or is in critical service.

API 612 Special Purpose turbines typically used for critical drives Compressors, axial blowers, BFP
Critical applications

9. Up to what rating API 677 gearbox allowed as per API 611?


Separate parallel-shaft gear units conform to API 677 shall be used up to 1,500 kilowatts (2,000
horsepower) as per API 611

10. Explain which are leak points, which are to be connected to steam traps?
In steam turbine common points for steam leakage are through shaft seals (often carbon rings) and
bearing housing seals and getting into the oil.
Steam traps are mostly installed on turbine drain lines

11. What is limitation of using built-up rotor as per API 611? How you will evaluate?
The purchaser’s approval is required for built-up rotors if blade tip velocities at maximum continuous
speed exceed 250 m/s (825 ft/s) or if stage inlet steam temperatures exceed 400 °C (750 °F).
12. Draw Steam turbine performance curve with hand vale Open =0, Open=1.

13. What is arrangement required for auto start of Steam turbine?


When a turbine is used in a quick start / AUTO-START application, there are several principle areas of
concern including:
1] Condensate Ingestion (Slugging) & Water hammer (Flashing)
Since the velocity of a water particle passing through a turbine is low relative to the steam and rotating
blade velocity, the particles can cause extensive damage as they impinge on the turbine’s rotating
blading. Furthermore, the down-stream force generated by such particles impinging on the blading can
be high enough to damage the thrust bearing.
In addition, steam condensate that has not been properly drained from the casing prior to turbine startup
can flash when exposed to the incoming high temperature steam and create a water hammer that could
move the turbine wheel on the shaft.
Warming and trapping of the steam turbine allows for vaporization and/or removal of condensate in the
steam inlet line ahead of the turbine, and in the low points of the turbine casing.
The client’s steam piping must be carefully designed and trapped to prevent condensate accumulation
upstream of the automatic start/stop valve and the turbine’s inlet steam connection. The turbine’s steam
condensate drain connections must also be trapped to prevent condensate accumulation within the
turbine.
A small amount of inlet steam flow may be routed around the client’s auto start/stop valve and into the
turbine inlet connection to heat the turbine casing. The warming steam flow must be sufficiently
controlled so as to not cause any turbine shaft rotation. In lieu of using a small inlet steam flow to warm
the turbine, exhaust backpressure can be applied to the turbine exhaust casing for warming purposes.
For all quick start applications, the client’s turbine exhaust header piping must always be open and
unrestricted so the turbine casing cannot be over pressurized.
2] Lubrication
Without immediate and constant oil lubrication of the turbine bearings upon start up, the heat generated
by the shaft rotation in the bearings can cause bearing failure.
Oil ring lubricated bearings provide immediate lubrication as the shaft begins to turn, as long as the
proper oil level is maintained within the turbine bearing housings.
For turbines with “pure” oil mist lubrication, the mist supply system must be in operation prior to turbine
start up.
For turbines with motor operated circulating oil cooling systems, the system must be operating at the
time of turbine start up.
For turbines with pressure lubricated bearings, the lubrication system must be arranged such that the
lubricant fills the oil supply lines to the turbine bearing housings and is feeding the bearings when the
shaft begins to turn.
3] Acceleration Rate
When a single stage turbine is started under no load conditions, the acceleration rate of the low inertia
rotating element can be so high that the speed control system may not react quickly enough to throttle
the inlet steam flow and prevent over speeding and tripping the turbine. This is particularly true for
turbine generator sets.
To help minimize this issue, the steam inlet auto start/stop valve should be configured to allow
adjustment of the valve opening rate, and/or for applications with electronic speed controls the governor
ramp rate should be configured for a controlled turbine throttle valve opening rate, thus controlling the
turbine’s acceleration rate.
4] Thermal Shock
Steam tracing, inlet and/or exhaust warming, and the warming of electronic instruments and/or
lubricants all may be necessary to start the turbine and/or to minimize thermal shock issues in low
ambient temperature areas. In addition, when the turbine is in standby, steps must be taken to insure
cooling water and/or steam condensate does not freeze.

14. How over speed shutdown system works? Also refer 7.4.2.3.

The overall control scheme of a steam turbine consists of an operating speed governor, and a separate
shutdown system to prevent overspeed. Such a system for a mechanical (MHC) governor is shown in
Figure.
In the event the speed regulating governor fails to control the speed of the turbine, a fraction of a second
is all the reaction time available to sense an overspeed, start, and complete the correction process.
Overspeed shutdown systems generally begin to function at 110 percent of design speed and must
function to stop the steam flow in less than one second completely if no damage is to occur). Trip valves
separate from the governor valve(s) should shutoff the steam supply completely.
The standard shutdown system consists of three sections:
 A weight, in the main shaft or in a stub attached to it, with spring tension resisting outward
movement of the weight. When shaft speed exceeds a desired safe level of about 10 percent,
centrifugal action throws the weight outward about 1/s in against-
 A latching device, either hydraulic or mechanical, which releases and allows a spring to close-
 A special emergency stop valve(s)

Tripping device
 Whenever the turbine is being tripped, the governing oil pressure (trip oil line after tripping
device) is being drained by tripping device.
 Thus pressure in front of stop valve piston disc secondary oil pressure falls resulting in closure
of stop valve piston disk and control valves.
 In addition to speed control system, steam turbines are fitted with a shutdown system to
prevent damage to the machine
 In the event the speed governor fails to control the speed, the overspeed trip actuates the
shutdown of the machine
 When shaft speed exceeds desired safe level, generally 10% over speed, a latching device or oil
dump mechanism is actuated to close a special emergency stop valve.
 This system is totally independent of governor
Overspeed Governor
 Overspeed governor protects the turbine against speed higher than the safe value for turbine
operation
 Overspeed governor consist of an eccentric pin located inside the turbine shaft and held in
position with a spring
 At a preset speed (trip speed) centrifugal force of eccentric pin will move out of the shaft
 The outward movement of the pin actuates a lever of tripping device and thereby tripping the
turbine.
 A mechanical system that is completely separate from the speed governing system
 A trip pin or plunger is mounted in turbine shaft with its central of gravity slightly off center.
 In the event of speed regulating governor fails to control the speed, the unbalanced plunger
overcomes a spring force at a preset trip speed
 At it move outward, it strike to trip lever, causing release of spring dump valve that releases the
trip circuit oil pressure
 This unbalances a piston ring combination and cause the trip and throttle valve to slam shut by
the force of a spring and the steam pressure above the valve disk
15. List manufacturer’s supplying API 611 steam turbine, their models, range and nomenclature.
 Elliott
 Dresser-Rand / Siemens

16. What is position of trip valve, governor valve during normal start-up? What are the actions?

17. Client has specified ST for pump application.


- Vendor ‘A’ quotes with Pump + Gear Box + ST with pump running at @1500 rpm & ST @5000 rpm
- Vendor ‘B’ quotes with Pump + ST with train, both @ 1500 rpm

What are impacts on:

a) Layout
b) Capital Cost
c) Operating Cost
d) What shall we do when doing feed & during detailed engineering

18. Will you have 2 different curve, one for normal steam end & one for worst steam end?

19. What is meaning of “Normal” & “No load” exhaust temperature? What we need to do if downstream
piping is not rated for normal / no lad exhaust temp condition?

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