Turbine, Their Types, Construction,

Gland seal Steam system, Governing

of the turbine ,Turbine Protections

BY
NAVEEN MALHOTRA
 INTRODUCTION

The steam turbine is a prime mover in

which the potential energy of steam is
transformed into kinetic energy , and latter
in its turn is transformed to mechanical
energy of rotation of the turbine shaft.
Utilised in most diverse fields of industry,
for power generation and for transport
 Classification of Turbines

 Based on action of steam

 Impulse
 Reaction
 Combination of impulse and reaction
 Based on number of pressure stages
 Single stage
 Multi stage Impulse and Reaction turbines
 Based on Direction of steam flow
 Axial turbines
 Radial turbines
 Based on no of cylinders
 Single
 Double
 Three cylinder
 Four cylinder
 More Classification

 Based on method of governing

 Throttle governing
 Nozzle governing
 According to steam conditions at inlet
 Low pressure (1.2-2 atm)
 Medium pressure ( up to 40 atm )
 High pressure (above 40 atm )
 Very high pressure ( 170 atm and above and temp of 550 C and above )
 Super critical (above 225 atm )
 Based on usage in industry
 Stationary ( variable and constant speed )
 Non stationary
 Advantages of Steam Turbines over Steam
Engines

• Thermal efficiency higher for steam turbine

• Power generation at uniform rate
• Higher speeds and higher outputs
• No internal lubrication and minimised balancing
problem
• No loss due to initial condensation of steam
• Utilise high vacuum very advantageously
 Common Types of Turbines

• Simple impulse turbine

Steam Expands only in nozzle & there is no pressure drop in the moving
blades e.g. De Laval Turbine
 Reaction Turbine

 Steam Expands continuously over fixed as well as moving blades &

there is gradual fall in pressure during Expansion. No of stages
required is more in case of reaction turbines
 Difference Between Impulse & Reaction Turbines

S.No Particulars Impulse Turbine Reaction Turbine

1 Pressure Drop Only in nozzles & not Both in fixed as well as
in moving blades moving blades
2 Area of Blade Constant Varying
channels
3 Blades Profile type Aerofoil Type
4 Steam admission Not All Around All Around
5 Nozzles /Fixed Diaphragm Contains Fixed Blades attached to
Blades Nozzles the casing
6 Power Small Power capacity Much Power can be
developed
7 Space Less Space for more Requires more space
power
 Difference Between Impulse & Reaction Turbines

S.No Particulars Impulse Reaction

Turbine Turbine
8 Efficiency Low High
9 Suitability Small Power For medium & high
requirements power
requirements
10 Blade Easy Difficult
Manufacture
 About 210 MW KWU Turbine

 The turbine is a tandem compound machine which separates the HP,IP

and LP Sections. HP Section is single flow while IP & LP Sections are
double flow.
 The turbine rotor and generator rotor are connected by rigid couplings.
 The HP turbine is throttle controlled, the steam is entered ahead of
blades via combination of two stop & control valves.
 The turbine comprises of modules H 30-25 for HP turbine, M30-20 for
IP turbine, and N 30- 2x8 for LP Turbine.
 The turbine is condensing type with single reheat. It is basically
engineered on reaction principle.
 The lines leading from the two HP exhaust branches to the reheater are
provided with swing check non-return valves (CRH NRVS), which
prevent hot steam from the reheater flowing back into the HP turbine
when turbine is tripped.
 Technical Specifications of HP Turbine

S. No Description Parameter
1 Rated Capacity 210 MW
2 Main Steam Pressure at ESV 147 kgf/cm2
3 Main steam Temperature at ESV 535 °C
4 Steam Flow at ESV 641 T/Hr
5 Reheat/Non-Reheat Reheat
6 Type of Governing Throttle Governing
7 Turbine Speed 3000 RPM
8 Exhaust Pressure 76 mm of Hg abs
9 No of Cylinders HP-1 single Flow,IP-1,Double
Flow, LP-1 Double Flow
 Technical Specifications of HP Turbine

S. No Description Parameter
10 No of Stages HP-25 ,IP 20+ 20, LP 8+8
11 Height of last stage Blade 676 mm
12 Last Stage Mean Diameter 2132 mm
13 Weight of Turbine 425 Tones
14 Length of Turbine 14.1 M
15 Type of Turbine Reaction
16 Manufacturer/Design BHEL/Siemens
Sectional View of 210 MW KWU Turbine
 About 210 MW KWU Turbine

 The steam coming from the reheater is admitted to the IP turbine via
two reheat stop and control valves. The exhaust of IP turbine is
connected to LP turbine via two cross-around pipes laid at floor level.
 Six bled steam tapings are taken as follows:
 - HPT exhaust (25th stage) to HP heater 6
 - IPT, 36th stage to HP heater 5
 - IPT exhaust, 45th stage to Deaerator (extraction 4)
 - LPT, 48th stage to LP heater 3
 - LPT, 50th stage to LP heater 2
 - LPT, 52nd stage to LP heater 1
 HP Turbine

 The outer casing of the HP turbine is of barrel type construction without any
massive horizontal flange. This unique construction permits rapid start-up
from any thermal state and high rates of load changes of the turboset
 The steam and metal temperature matching requirements are also less
stringent as there is no asymmetry of mass distribution in transverse and
longitudinal planes.
 Although HP inner casing is with a horizontal split joint, yet it acts like a thin
thermal membrane. As the inner casing is not subjected to large pressure drops
across the wall, the horizontal flange joint and bolts are made of thin sections
thus permitting large transverse temperature changes. Inner casing is
kinematic ally supported within the outer barrel.
 The barrel type casing permits flexibility of operation in the form of short start-
up times and a high rate of change of load even at high initial steam conditions.
 IP Turbine

 The IP turbine is double flow and double casing type split horizontally. Double
flow design permits the axial thrust (produced due to reaction stages) balanced
by itself and does not impose any loading on thrust bearing.
 IP inner casing is kinematic ally supported within outer casing. IP inner and
outer casings are suspended from top halves so as to totally eliminate the effect
of TG centre line with the heating of flanges. Although the casings are of
horizontal split design yet these do not impose any constraints in start-up
period and rapid load changes.
 The reheated steam is admitted to the inner casing through the top and bottom
centre of the casing. The arrangement of an inner casing confines the high
steam inlet conditions to the admission branch of the casing, while the joint of
the outer casing is only subjected to the lower pressure and lower temperature
at the exhaust of the inner casing.
 LP Turbine

 LP turbine is also double flow type with exhaust area optimally

selected for the expected vacuum conditions. The casing of LP
turbine is connected with IP cylinder by two cross-around pipes,
one on either side of the machine and level with the floor.
 The casing of the double flow LP cylinder is of three-shell design.
The shells are axially split and of rigid welded (fabricated)
construction. The inner shell taking the first rows of guide blades
is attached kinematic ally in the middle shell. Independent of the
outer shell, the middle shell is supported at four points on
longitudinal beams. Two rings carrying the last guide blade rows
are also attached to the middle shell.
 LP Turbine

 Special design measures have been adopted to remove the

moisture from last stages by reducing the thickness of water film
on guide blades. The axial clearances between guide blades. The
axial clearances between guide and moving blades have been so
chosen so as to reduce the droplet sizes and erosion of leading
edge.
 Low-pressure extraction has been optimized not only from
thermodynamic considerations but to effectively drain out
moisture also. Free standing blades (without lacing wire) have
been envisaged. The blades are designed to operate in the speed
range corresponding to 47.5 to 51.5 Hz grid frequency.
 Turbine Blading

 In steam turbine, the blades transform the thermal energy into

mechanical energy. It is obvious that blading has got direct
impact on the efficiency and reliability of turbine.
 Appropriate blade profile, with high aero-thermodynamic
efficiency having sufficient mechanical strength to withstand the
steam forces, are determined after excessive research.
 Utmost care is taken while designing to avoid resonance and to
ensure that the natural frequencies of unshrouded free standing
rotor blades are compatible with the rotational frequency of the
machine. A final accurate check is made when the blades have
been fitted into the rotor. The opportunity is also taken to
carefully check the root fastening of the blades.
 HP & IP Turbine Blades

 These blades have a 50% reaction component and both fixed and
moving blades have the same profile. Each rotor blade is milled from a
single piece of material complete with inverted T-root and integral
shroud.
 After they have been fitted in the rotor groove, they are caulked into
position with brass wire. The blade roots are made of appropriate size
to give the required blade spacing, and hence the designed width of
blade passage, and hence the necessity of spacer-pieces.
 Fixed blades are of the same type as the moving blades with an inverted
T-root and integral shroud. In medium and low temperature regions,
the fixed blades are made of solid drawn material with brazed on or
loose spacer pieces and have a hook-type root. In this case the
shrouding is separate and riveted in place.
 LP Turbine Blading

 The fixed and rotor blades of the first few stages of the LP turbine are
similar to the IP turbine blades. However, the last three stages of the LP
turbine have twisted blades
 The fixed blades of the last two stages are hollow. They are fabricated
from sheet steel and slots are provided in the blade surface through
which any water passing over the surface of the blades may be drawn
away to the condenser.
 The trailing edge of the blades is very thin in order to avoid any patches
and the formation of streams of water. The axial distance between the
final stages is kept at optimum value to facilitate the break-up of any
water droplets, which may still remain. This will reduce the relative
velocity between the droplets and the leading edges of the moving
blades.
 LP Turbine Blading

The leading edges of the final stage rotor blades

are flame hardened to give protection against
erosion.
The leading edges of the final stage rotor blades
are flame hardened to give protection against
erosion.
 Valves

 The HP turbine is fitted with two combined emergency stop and

control valves. A stop and control valve fitted in a common body
with their spindles arranged at right angles to each other and in
the same plane.
 The stop valves are spring operated single-seat valves and
similarly control valves also of single-seat design having diffusers
to reduce pressure losses. The two valves operate with two
separate servomotors independent of each other.
 The IP turbine has also two combined reheat stop (IV) and
control valves. The reheat stop valves are spring-loaded single-
seat valves. The control valves, also spring loaded and single seat
design, have diffusers
 Valves

 The control valves operate in parallel and are fully open in

the upper load range. In the lower load range, they control
the steam flow to the IP turbine and ensure stable
operation even when the turboset is supplying only the
station load.
 Throttle governing method is adopted to regulate the
turbine load. Both the emergency stop and reheat stop and
their control valves are supported kinematic ally on the
foundation ceiling below the machine floor before the
turboset. Individual oil hydraulic servomotors actuate all
valves.
 Rotors, Couplings & Bearings

 The rotating elements consisting of three monobloc rotors of HP, IP &

LP turbines are coupled together rigidly by means of integrally forged
flanges (coupling halves), thus in effect forming a single shaft system.
 The critical speeds of the HP and IP rotors are designed to be above the
normal rated speeds. Each rotor is subjected to 20% overspeed test.
 The HP rotor is supported by two bearings, a double-wedge journal
bearing at the front end of the turbine and a combined journal and
thrust bearing directly adjacent to the coupling with the IP rotor.
 The IP and LP rotors have a journal bearing each at the end of the
shaft.
 Rotors, Couplings & Bearings

 The combined journal and thrust bearing incorporates a self-adjusting double-

wedge journal bearing and a thrust bearing which takes up residual thrust from
both directions. The other journal bearings are self-adjusting elliptical bearings.
The bearing temperatures are measured by thermocouples in the lower shell
directly under the white metal lining. The temperature of the thrust bearing is
measured in two thrust pads on each side
 The front and rear bearing pedestals of the HP turbine are placed on base plates.
The pedestals of the LP turbine are fixed in position, whereas the front pedestal
and the pedestal between the HP and IP turbine are able to move in axial
direction to permit free longitudinal expansion of HP and IP turbine casings.
 The brackets at the sides of the HP and IP cylinders are supported by the
pedestals at the level of the machine axis. In the axial direction the HP and IP
casings are firmly connected with the pedestals by means of casing guides,
without restricting radial expansion. Since the casing guides do not yield in
response to axial displacement, the HP and IP casings as well as the associated
bearing pedestals move forward from the front LP bearing pedestal on thermal
expansion.
 Shaft Glands

 The rotor shafts of HP, IP and LP turbines are sealed at both the ends
by employing labyrinth-type gland seals. In case of HP and IP turbines,
there consists of a series of sealing strips alternatively caulked into the
shaft and into stationary rings.
 In case of LP turbine, gland sealing strips are fitted in the stationary
rings only. The pressure of the steam leaking through the gland is
reduced by converting the pressure energy into velocity energy, which
is then dissipated as eddies as the steam passes through large number
of strips.
 Turbine Shaft Gland Sealing Arrangement

 The number of sealing strip rings used depends on the pressure drop required.
Each ring consist of six or eight segments and is carried in grooves in the casing
or inner casing to allow radial movement.
 Each segment is held in position against a shoulder by two helical springs. In
the event of the shaft coming into contact with the strips in the segments, the
affected segments will move away radially.
 A possible slight contact between the shaft and the thin strips will generate
only a small amount of heat that cannot lead to a deformation. All the shaft
glands, sealing the steam in the cylinder against atmosphere are axial flow
labyrinths.
Turbine Gland Seal System
 Turning Gear

 The turbine is equipped with hydraulic turning gear capable to rotate

the shaft system at high speed during start-up and shutdown periods in
order to minimize thermal distortion of the turbine casings and shaft.
 Due to fanning action of the blades, the steam inside the casing brings
about heat transfer conducive to temperature equalization between the
upper and lower parts of the casings.
 The turbine gear assembly is located in the front bearing pedestal of LP
cylinder and consists of two rows of moving blades mounted on
coupling flange IP turbine rotor, an inlet nozzle box with stationary
nozzles and guide blades.
 The turbine-generator shaft system is rotated by the double row wheel
which is driven by pressure oil supplied by the auxiliary oil pump. After
passing through the blading, the oil drains to the bearing pedestals and
combines with the bearing lube oil returning to the main oil tank.
 Turning Gear

 In addition, shaft system is equipped with facility for manual barring in

the event of failure of hydraulic turning gear.
 Hydraulic turning gear is envisaged to ensure uniform and rapid
heating and cooling of the casings and rotors during start-up and trip
out respectively. The turning gear is located on IP coupling flange,
between IP and LP turbine coupling. As there is no mechanical contact
between the hydraulic turning gear and shaft, the likelihood of a break-
down is far less than mechanical types employing disengaging gears,
interlocks and checking devices.
Turbine Oil Supply System
 Turbine Stress Evaluator

 The turbine stress evaluator continuously scans the critical

sections of E.S.V., HP control valves, HPT casing, HPT
shaft and IPT shaft by measuring temperature difference
between surfaces in contact with steam and 50% depth of
metal wall.
 TSE provide instantaneous information regarding safe
limits of load fluctuations based on the fatigue life of the
material and state of thermal stresses at that particular
instant. This ensures a stress consistent start-up operation.
 Turbine Monitoring System

 In addition to the measuring instruments and instruments indicating

pressures, temperatures, valve positions and speed, the monitoring
system also includes instruments mounted on turbine to indicate the
following values.
 - Absolute expansion, measured at the front and rear bearing pedestals
of the HP turbine.
 - Differential expansion between the turbine rotor and casing,
measured at :
 Front bearing for HPT
 Bearing No. 3 for IPT
 Bearing No. 4 for LPT
 Axial shift measured at bearing No. 2 (combine thrust and journal
bearing)
 Bearing pedestal vibrations measured at all turbine bearings
 Turbine Monitoring System

 Relative shaft vibrations (bearing pedestal shaft) measured at all

turbine bearings
 - Absolute shaft vibrations, obtained from bearing pedestal
vibration and relative shaft vibration by calculation
 - Bearing babbit metal temperatures by RTDs
 - Turbine speed by hall probe located in front pedestal on MOP
shaft
 - Top bottom turbine casing temperatures at 50% and 90% depth
by thermocouples.
 Oil Supply System

 Turbine oil supply system provides oil for –

 Lubrication and cooling of bearings
 Control oil for turbine governing and protection system and
hydraulic actuators
 Control oil for LP bypass governor
 Hydraulic turning gear
 The main oil pump located in the front pedestal and directly
driven by HP turbine shaft draws oil from the main oil tank via
injector, during normal operation of turbine. However, during
start-up and shutdown, Auxiliary Oil Pump (AOP) driven by AC
motor maintains the oil supply.
 OIL Supply System

 Before starting the turning gear, a jacking oil pump forces high
pressure (120 kg/cm2) oil under the shaft journals to lift the
shaft. This is in order to prevent boundary layer lubrication and
metal-to-metal contact.
 The lubricating and cooling oil is passed through water-cooled oil
coolers before being supplied to the bearings.
 Two AOPs, one EOP (DC motor) and two JOPs are mounted on
the main oil tank.
 Turbine Anchoring & Expansion

 In designing the supports for the turbine on the foundation,

attention is given to the expansion and contraction of the
machine during thermal cycling (warming up and cooling).
Excessive stresses would be caused in the components if the
thermal expansion or contraction were restricted any way.
 The method of attachment of the machine component and their
coupling together, are also decisive factors in determining the
magnitude of the relative axial expansion (differential expansion)
between the rotor and turbine casing. The differential expansion
aspect is most important factor, which is taken into account
while designing the internal clearances of the machine.
 Turbine Anchoring & Expansion

 . The fixed points of the turbine are as follows:

 i) The bearing pedestal between the IP and LP turbines. From
this point the IP and HP casings expand towards the front
bearing pedestal of the HP turbine.
 ii) The rear bearing housing of the LP turbine (LP/Generator
bearing pedestal)
 iii) The middle portion of each longitudinal girder of LP turbine.
From these points the longitudinal girders expand in both the
directions (Turbine side and Generator side).
 iv) The thrust bearing in rear bearing casing of HP turbine.
 Expansion of Turbine Casing

 The front bearing pedestals of the HP & IP turbines can slide on

their base plates in an axial direction. Any lateral movement
perpendicular to the machine axis is prevented by fitted keys.
The HP & IP casings are supported by lugs on bearing pedestals.
 The guides provided for supporting ensures that the turbine
casings maintain their central position while at the same time
allowing axial movement. Thus the origin of the cumulative
expansion of the HP & IP casings is at front bearing pedestal of
the LP turbine (pedestal between IP & LP turbine).
 The IP expands towards HP turbine by which the middle pedestal
(between HP & IP turbine) also moves in the same direction.
Hence the absolute expansion of IP turbine is registered at
middle pedestal.
 Expansion of Turbine Casing

 The HP turbine casing, which is supported on middle pedestal and front

pedestal expands towards front pedestals, which also moves on base plate.
Hence the cumulative expansion of HP and IP turbine is recorded at front
pedestal.
 The outer casing of the LP turbine is located axially by fitted keys at the middle
of their longitudinal beam members. Free lateral expansion is allowed. The
centre guides for these longitudinal beams are recessed in the foundation.
There is no restriction on axial movement of the casings.
 At the front and rear supports of the longitudinal beam members the casing is
free to expand horizontally in any direction. Hence, when there is a
temperature rise, the outer casing of the LP turbine expands from its fixed
point towards IP turbine and generator.
 Differences in expansion between the outer casing and the fixed bearing
pedestals to which the housings for the shaft glands are attached, are taken by
shaft seal compensators (expansion bellows).
 Rotor Expansion

 The thrust bearing is incorporated in the rear bearing housing of

the HP turbine (middle pedestal). Since this bearing housing is
free to slide on the base plate, the shafting system moves with it.
 Both the rotor and casing of HP turbine expand towards front
bearing housing with respect to rear bearing housing of HP
turbine (middle pedestal). On the other hand, the rotor and
casing of IP turbine expand towards the generator in a similar
manner.
 The LP turbine rotor is displaced towards the generator by the
expansion of the shafting system from the thrust bearing. The
magnitude of this displacement due to expansion, however, is
reduced by the amount by which the thrust bearing is moved in
the opposite direction by the casing expansion of the IP turbine.
 Differential Expansion

 Differential expansion between the rotors and casing results from the
difference between the rotor expansion originating from thrust bearing and the
casing expansion originating from the rear bearing housing of IP turbine
(Bearing No.3 housing).
 This means that the maximum differential expansion of the HP and IP turbines
occur at the end furthest from the thrust bearing.
 Differential expansion between the rotor and casing of the LP turbine results
from the difference between the expansion of the shafting system originating
from the thrust bearing and the casing expansion originating from the fixed
point of the LP turbine casing on the longitudinal girder.
 Axial Shift

The axial shift is the measure of axial displacement

of the shaft within the thrust bearing.
Axial shift is set at zero when thrust is at the center
of the axial clearance at the thrust pads.
Axial shift towards generator is positive and towards
generator is negative.
Alarm and tripping is provided when the axial shift
reading exceeds the set value.
Internals of 210 MW KWU Turbine
Thx a lot for your tolerance