STUDY OF STEAM TURBINE

SUBMITTED TO: MR. ABDUL WAHEED

(HEAD OF MECHANICAL DEPARTMENT)
SUBMITTED BY: HAMMAD NAEEM
(B.Sc. MECHANICAL INTERNEE)














Fatima Sugar Mills Limited
Fazal Garh, Sanawan, Kot Adu, Distt. Muzaffargarh


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Acknowledgement

I take this opportunity to express a deep sense of gratitude to
Mr. Mohammad Aslam Shift I ncharge, Mr. Babar Riaz,
Shift Engineer and Mr. Yasir Shahid Graduate Trainee
Engineer, Fatima Sugar Mills LTD, for cordial support,
valuable information and guidance, which helped me in
completing this task through various stages.


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(BACK PRESSURE TYPE)




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Fatima Sugar Mills Limited
Mills House Turbine Specification
KKK steam turbine (AK Tiengesellschafft Kuhnle Kopp &
Kaussch D-6710 Frankenthal)

Number of Steam Turbines in Mills House = 5
Model type = CF5G5
Pressure type = Back pressure
Output power = 650KW
Speed
Minimum speed 750 RPM
Maximum speed 1500 RPM
Inlet Steam Pressure
Minimum steam pressure 19.2 Kg/cm
2
Normal steam pressure 21.5 Kg/cm
2
Maximum steam pressure 23.8 Kg/cm
2
Outlet Steam Pressure
Minimum steam pressure 1.2 Kg/cm
2

Normal steam pressure 1.45 Kg/cm
2

Maximum steam pressure 1.7 Kg/cm
2
Trip speed = 1725 RPM
Inlet Steam Temperature = 340
Outlet steam temperature = 170
Speed reduction system
1000 RPM to 140 RPM then 140 RPM to 6 RPM


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Important Terms
Q: What is Impulse Turbine?
A: It involved striking of the blades by a stream or a jet
of high pressure steam, which caused the blades of the
turbine to rotate. The direction of the jet was
perpendicular to the axis of the blade.

Q: What is Reaction Turbine?
A: A power-generation prime mover utilizing the
steady-flow principle of fluid acceleration, where
nozzles are mounted on the moving element.
Q: What is Steam or Water Hammering?
A: Steam hammering is the sound that is heard as a
pinging, rattling, or banging in a steam system under
conditions of Start-up, shutdown, changing loads or
even in few cases, steady state full load operation.
Q: What Is Water Or Steam Hammering?
A: Steam hammering is the sound that is heard as a
pinging, rattling, or banging in a steam system under
conditions of Start-up, shutdown, changing loads or
even in few cases, steady state full load operation.


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Causes of steam hammering
Steam hammering is the phenomenon which occurs in
steam charging in the pipeline while there is a presence
of condensate in the line. This is because of sudden
drop in pressure of steam as it comes in contact of
condensate.
This can also occur due to poor heating of steam
network before the steam enters into the system. Piping
network remains cool and as soon as the hot steam
enters, condensation takes place and water gets
accumulated in the lines forming a Slug. As the steam
flow increases, steam carries the water with it and lot of
momentum is created and it hammers the line loops
with tremendous forces creating a lot of stress. Steam
hammers can blow flange joints and can damage piping
supports and even piping itself.
Poor condensate drainage in pipeline leads to this steam
hammering. Where air filled traps are used, these
eventually become depleted of their trapped air over a
long period of time through absorption into the water.
This can be cured by shutting off the supply, opening
taps at the highest and lowest locations to drain the
system and then closing the taps and re-opening the
supply.
Effects of steam hammering
The effect of steam hammering can result in following:
Cracking of steam traps and pressure gauges


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Break pipe welds and even rupture piping systems
Bend internal system mechanism
Causes valve failure
Cause heat exchanger equipment tube failures
Failure of pipe supports.
Prevention of steam hammering
Steam hammering condition exists in a steam system
where condensate coexists with generated steam or
flash steam. Typical examples include heat exchangers,
tracer lines, steam mains, condensate return lines and
sometimes, pump discharge lines.
A common example of steam hammer occurs during
start-up or energizing of a steam system. If the steam
line is energized too quickly without proper warm up
time and condensate created during the start-up is not
properly removed; steam hammer will be the result.
There are few design or system changes that can be
implemented to prevent or eliminate steam hammering:
Ensure correct steam and condensate design.
Have documented SOPs (standard operation
procedures) for steam system start-ups and shut
downs.
Proper training for plant personnel.
Have installation standards for steam components.
Correct condensate connections of branch lines to
the main condensate header and entry only from
the top of the header.


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Use steam traps that are properly sized and
appropriate for application.
Use warm up vales as steam line isolation valves
larger than 2 inch. Do not crack open large steam
isolation valves.
Check or repair the pipe insulation. It saves energy
and reduces accumulation of condensate in the
piping system





TUDY
















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Introduction

A steam turbine is a mechanical device that converts thermal energy in
pressurized steam into useful mechanical work. A steam turbine is a heat engine
in which the energy of the steam is transformed into kinetic energy by
expanding the steam through NOZZLE. This resultant kinetic energy is
converted into force by impinging on rings of MOVING BLADES (which
deflect the jets of steam) mounted on a rotating element called a ROTOR. A
steam turbine may be utilized in process industries, Power plants and for
transport.
The steam turbine obtains its power from the change of momentum of a jet of
steam flowing over curved vanes. The steam jet, in moving over the curved
surface of the blade, exerts a pressure on the blade owing to its centrifugal
force. This centrifugal pressure is exerted normal to the blade surface and acts
along the whole length of the blade. The resultant of this centrifugal pressure,
plus the effect of change of velocity, is the motive force on the blade.

Working Principle

The steam energy is converted mechanical work by expansion through the
turbine. The expansion takes place through a series of fixed blades (nozzles)
and moving blades each row of fixed blades and moving blades is called a
stage. The moving blades rotate on the central turbine rotor and the fixed blades
are concentrically arranged within the circular turbine casing which is designed
to withstand the steam pressure.


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Back pressure steam turbine cycle

Theory of Steam Turbines

Steam turbines extract heat from steam and transform it into rotational energy
by expanding the steam from high to low pressure, resulting in mechanical
work. Small and intermediate-sized steam turbines are used for a wide range of
applications, including power generation, drivers for mechanical services. When
coupled with gears they can be used to drive fans, reciprocating compressors
and other classes of low-speed machinery. The largest turbine applications are
generator drives in utility and other central power stations.
The turbines discussed in this manual are the low-pressure (LP) turbine. There
are several components which are turbine casing houses and supports the
turbine rotor, and bearings. The casing is cast in two halves and bolted together
with a metal to metal fit. This metal to metal fit is initially sealed using a sealing
compound vice a gasket. In the event of a steam leak around the edge of the
casing, a groove is machined around the peripheral of the turbine casing. This
groove is known as the gunning groove. The gunning groove provides the
ability to inject a sealing compound for emergency sealing of the turbine casing.


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The turbine rotor is the rotating part of the engine and is constructed of
chromium molybdenum (chromoly) steel. The rotor wheels, which are
mounted to the rotor shaft, carry the moving blades. The non-moving blades are
attached to the turbine casing. The moving blades are attached to the turbine
rotor. Non-moving blades are attached directly to the turbine casing. Short
strips of metal, shrouding, are attached to the outer edges of the blading. This
shrouding is used to assist in maintaining rigidity of the blades. In addition,
there is minimal clearance between the shrouding and the turbine casing
preventing steam from leaking around the outer edges of the turbine blading.
In the gland seal system, these seals prevent any steam from leaving the
turbine casing and also prevent any air from entering the turbine casing and
subsequently the main condenser.
Boiler feed water at is injected into the boiler.
Water is heated evaporated in the boiler. The resulting superheated steam
at to increase its enthalpy and reduce moisture.
Steam is expanded in the turbine to a lower pressure. A small portion of
the steam thermal energy is used to drive a generator.
The steam turbine is cogeneration system when an application involves the
sequential use of a single source of energy for both power generation and
useful thermal energy output.
A topping cycle uses a back-pressure or extraction turbine as a pressure-
reducing valve. As high pressure steam is expanded to a lower pressure, the
turbine generates shaft power.





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Steam Turbine Classification and
Types

Steam turbines are classified according to their fundamental operating
Principles, some of which are:
Number of stages: single or multi stage
Number of valves: single or multi valve
Steam supply: saturated or superheated; single or multi pressure
Turbine stage design class: impulse or reaction
Steam exhaust conditions: condensing, non-condensing
Types of driven apparatus: mechanical drive or generator drive

More focus will now be on the single-stage, non-condensing steam turbine as
it was the preferred choice in this application.
In a single-stage turbine, steam is accelerated through a nozzle and guided
into the rotating blades on the turbine wheel to produce power. A single
pressure drop occurs between the nozzle inlet and the exit for the last row of
blades. Single-stage turbines are usually limited to sizes of a few thousand hp
(kW) or less. The single-stage design is simplicity, dependability and first low
cost. Steam turbines can be generally classified as either condensing or Non-
condensing (back-pressure). A condensing turbine operates with an exhaust
pressure less than atmospheric or vacuum pressure. Because of the very low
exhaust pressure, the pressure drop through the turbine is greater and hence
more energy can be extracted from the steam flow. This design adds increased
capital and operating cost.
Non-condensing (back-pressure) turbines operate with an exhaust pressure
equal to or in excess of atmosphere. Exhaust steam is used for heating,
process or other purposes. Because all of the unused steam in the power


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generation process is passed on to the process application and, therefore, not
wasted, mechanical efficiency is not a major concern.
Turbine Stage Design Class

On the basis of operation, steam turbines can be classified as: Impulse turbine
and reaction turbine.
Impulse Turbine

The impulse turbine was one of the basic steam turbines. It involved striking of
the blades by a stream or a jet of high pressure steam, which caused the blades
of the turbine to rotate. The direction of the jet was perpendicular to the axis of
the blade. It was realized that the impulse turbine was not very efficient and
required high pressures, which is also quite difficult to maintain. The impulse
turbine has nozzles that are fixed to convert the steam to high pressure steam
before letting it strike the blades.
KKK 650 KW of steam turbine contain 27 nozzles in which 8 nozzles are used
for overload purpose.

Impulse Turbine


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Reaction Turbine

A reaction turbine also rotates its blades due to the impending pressurized
steam, but the steam does not strike the blades perpendicular, as in an impulse
turbine. The steam is directed to flow along the blades, thus causing the blades
to rotate because of the reaction force more than the impulse force.


Reaction Turbine
Components of Steam Turbine
Blades
For starters, a simple turbine works just like a windmill. The blades are
designed in such a way as to produce maximum rotational energy by directing
the flow of the steam along its surface. So the primary component that goes into
a steam turbine is its blades. The blades are made at specific angles in order to
incorporate the net flow of steam over it in its favor. The steam turbine contain
180 blades of length 25mm each and are moving type.


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Nozzles
In KKK steam turbine 27 nozzles are used in which 19 nozzles are worked as
standard loading and 8 nozzles are used as overloading.



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Shafts
The shaft is a power transmitting device and is used to transmit the rotational
movement of the blades connected to it at one end via the rotor to the coupling,
speed reducer or gear at the other end.

Turbine casings, bearing housings
The steam turbine is surrounded by housing or an outer casing which contains
the turbine and protects the device components from external influence and
damage. It may also support the bearings on which the shafts rest to provide
rigidity to the shaft. Usually split at the center horizontally, the casing parts are
often bolted together for easy opening, checking and steam turbine
maintenance, and are extremely sturdy and strong.



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Turbine casings are designed for disassembly, usually about the horizontal
plane, the casing halves are secured in service by the bolted flange, as in Fig.
below. Casing internals, including diaphragms, are split at the same plane, and
remain attached to their upper or lower casing halves when the turbine is
opened. The casing is usually steel, using all cast steel components, or, where
appropriate, a mixture of castings and plate, welded together. Some auxiliary
turbines have cast iron casings. Bearing housings are also split for disassembly




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Bearings
There are two types of bearings used in steam turbine shaft following are.
1. Thrust Bearing
2. General Bearing (Sliding Contact Bearing)
Thrust Bearing
A thrust bearing is used to guide or support the shaft which is subjected to a
load along the axis of the shaft. Such type of bearings are mainly used in
turbines and propeller shafts.

Sliding Contact Bearing
In sliding contact bearings, the sliding takes place along the surfaces of
contact between the moving element and the fixed element. The sliding contact
bearings are also known as plain bearings.




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Governor

The governor is a device used to regulate and control or govern the output of the
steam turbine. This is done by means of control valves which control the steam
flow into the turbine in the first place.




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Oil System
A steam turbine has many of moving parts and all these parts not only have to
move in high velocities, but also need to be protected from wear and tear over
the years. This is done by effective lubrication by the oil system, which governs
the pressure, flow and temperature of the turbine oil, the bearing oil and
lubrication of other moving parts. Generally following oil pumps are used in
KKK steam turbine.
Auxiliary pump turbine
Auxiliary pump gear box
Mechanical pump
Turbo pump
Auxiliary pump
The auxiliary oil pump has two functions
1. It operates during startup and shutdown when the turbine shaft is
not rotating fast enough for the main oil pump to deliver the
required pressure and flow.
2. It acts as a standby lube oil pump in the event of a main oil
pump failure


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Mechanical Pump
Mechanical oil Pump The main oil pump is the one that delivers all the oil
requirements for the turbine generator at high pressure during normal operation.
It is direct-driven from the turbine shaft and may be located at either the turbine
or generator end of the shaft




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Turbo pump
This pump is used as stand by when auxiliary and mechanical pumps are
malfunctioned. This pump is driven by steam and it contain rotating blades
which is coupled with the pump.

Pipes
The pipe is an all-important steam turbine component that brings the steam from
the boiler to the turbine. This has to be done without loss in pressure, and at the
same time, must be able to withstand all these pressures safely. The pipes
should be easy to clean.
Start and Stop Valve
This valve is hydraulically operated. The purpose of start and stop valve is to
start the flow of steam when required and In case of emergency this valve is
used of stop the flow of steam to turbine. Here reset knob use to reset the
turbine after emergency.


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Throttle valve

The throttle valve performs the functions of controlling the quantity of steam
admitted to the turbine by throttling and acting as a quick-closing emergency
valve (on some governors). It should always be closed by means of the manual
trip device. The throttle valve should receive careful attention and all moving
parts should be kept well lubricated.




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Steam Strainer

A steam strainer should be installed in the main steam line to the turbine to
prevent foreign particles from being carried into the turbine with the steam. It is
therefore an important accessory. Steam strainers are normally installed ahead
of and close to the throttle valve.

Overload Valve

The purpose of overload valve is that when the load on the turbine is increase
and turbine needs more steam to maintain the speed therefore this valve is
engage to maintain the speed and load. This valve engage the overload steam
nozzles.



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Expansion Bellows

A bellow is made up of a series of one or more convolutions, with the shape of
the convolution designed to withstand the internal pressures of the pipe, but
flexible enough to accept the axial, lateral, and/or angular deflections. In
simpler words, bellows are created in such a way that they can handle the
pressure on the inside of the pipe. they should also be flexible enough to move
either way. In most cases, expansion bellows are used to absorb movement and
vibration in the process of transfer of high temperature commodities like steam,
exhaust gases etc. However, expansion bellows are alsoused for other
alternative purposes like noise absorption, anti-vibration, and building
settlement. Expansion Bellows are auxiliary to any heavy duty, or high pressure
processes

Tachometer
Tachometer is an instrument used to measure the speed of the turbine in


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revolution per min RPM.
Pressure and Temperature Gauges

Pressure and temperature gauges installed on steam turbine can be used to
pending troubles. Thermometers on the oil inlet and discharge lines from a
bearing will indicate a rise in temperature caused by a bearing that is dirty or
out of adjustment, by an insufficient flow of oil. The normal temperature of a
steam turbine bearing usually should not exceed 150 degrees. Fahrenheit.

Reverse Gearing Clutch
When the mills rolls stop rotating due to increase in load on the steam turbine.
Fibers of cane stuck into the mills which cause of stopping the steam turbine.
To restart the steam turbine this element is used. This clutch contain a reversing
motor which rotates the mills in reverse direction, after fibers of cane free from
the mill, then steam turbine is start.



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Control panel
Control panel contain all the operation features of the steam turbine including
speed controlling, lubrication, rest, temperature, governor speed controlling,
reverse direction of reverse gearing clutch etc.


Lubricating oil cooler
This is used to cool the lubricating oil. This contains water pipes inside and
heated oil is passed between the cooled water pipes which cool the oil.




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Operation and Maintenance of Steam
Turbine
When warming up a steam turbine for use, the main steam stop valves (after the
boiler) have a bypass line to allow superheated steam to slowly bypass the valve
and proceed to heat up the lines in the system along with the steam turbine.
Also, a turning gear is engaged when there is no steam to the turbine to slowly
rotate the turbine to ensure even heating to prevent uneven expansion. After
first rotating the turbine by the turning gear, allowing time for the rotor to
assume a straight plane (no bowing), then the turning gear is disengaged and
steam is admitted to the turbine, first to the astern blades then to the ahead
blades slowly rotating the turbine at 10 to 15 RPM to slowly warm the turbine.
Problems with turbines are now rare and maintenance requirements are
relatively small. Any imbalance of the rotor can lead to vibration, which in
extreme cases can lead to a blade letting go and punching straight through the
casing. It is, however, essential that the turbine be turned with dry steam - that
is, superheated steam with a minimal liquid water content. If water gets into the
steam and is blasted onto the blades (moisture carryover), rapid impingement
and erosion of the blades can occur leading to imbalance and catastrophic
failure. Also, water entering the blades will result in the destruction of the thrust
bearing for the turbine shaft. To prevent this, along with controls and baffles in
the boilers to ensure high quality steam, condensate drains are installed in the
steam piping leading to the turbine.



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Over Speed Trip System
In order to prevent the turbine unit accelerating to a dangerous speed an
OVERSPEED TRIP GEAR IS FITTED. Over speed can be caused when the
turbine load is suddenly lost. This should normally be controlled by the speed
governor.

Process over Speed Trip System

In addition to a speed control system, steam turbines is fitted with a shutdown
system to prevent damage to the machine. In the event the speed governor fails
to control the speed, the over speed trip actuates to shut down the machine.
When shaft speed exceeds a 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 the
Mechanical system that is completely separate from the speed governing
systems. A trip pin or plunger is mounted in the turbine shaft with its center of
gravity slightly off center. In the event the speed regulating governor fails to


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control the speed, the unbalanced plunger overcomes a spring force at a preset
trip speed. As it moves outward, it strikes the trip-lever, causing release of a
spring dump valve that releases the trip circuit oil pressure.
Losses Common to All Turbines Are
Described Below
1. Loss of working substance. Loss of steam along the shaft through the shaft
glands where the shaft penetrates the casing.
2. Work loss. Loss due to mechanical friction between moving parts.
3. Throttling loss.
4. Windage loss. This is caused by fluid friction as the turbine wheel and
blades rotate through the surrounding steam.
5. Friction loss as the steam passes through nozzles and blading.














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Steam Turbine Troubleshooting
Vibrations
S.no Condition Identifiable by Probable cause Remedy
1 Unbalance
1. Uniform vibration
throughout the
turbine, decreasing
slightly under load.

1. Sprung shaft
2. Incorrectly located
balance weights.
3. Displacements of
balance weights.
4.corroded or eroded
blades or buckets
5.Sediment in blades or
buckets
6. Rotor unequally heated.
7. Broken blades or
buckets.

1. Replace shaft.
2. Relocate weights &
balance rotor.
3. Balance rotor.
4. Replace worn blades or
buckets.
5. Replace broken blades or
buckets.
6. Clean blades or buckets.
7. Consult manufacturer.
2
Poor
alignment
with driven
equipment.
2. Variable vibration
least noticeable at no
load; becoming worse
under load.
1. Eccentric flexibility
coupling
2. Driver & driven
equipment not aligned
properly at installation.
3. Piping strain on driver
or driven equipment.
4. Foundation selected
unequally.

1. Replace flexible coupling.
2. Realign driver with driven
equipments as per
manufacturer instructions.
3. Provide support for piping
to relieve strain.
4. Solidify foundation;
regrout if necessary.
3
Poor or
inadequate
foundation.
3. Vibration of
surrounding structure;
constant vibration of
turbine under all load
conditions.
1. Improper grouting.
2. Bed-plate not securely
foundation.
1. Regrout bed-plate.
2. Tighten foundation bolts.


4 Loose parts
4. localized vibrations
with noise at start-up &
shut-down.
1. Excessive bearing
clearance.
2. Ball joint of bearing is
loose.
3. Loose coupling or
coupling bolts.

1. Machine off joints between
bearing halves; replace
bearing if necessary.
2. Add shims as required to
tighten bearing; replace worn
parts as required.
3. Tighten setscrews securing
coupling to shaft; tighten
coupling bolts.

5
Internal
rubbing
5. localized vibrations
with varying with
turbine speed.
1. Rotating buckets
coming in contact with
stationary buckets.
2. Inadequate casing
clearance.
3. Thrust bearing is worn.
1. Check clearance; adjust as
required.
2. Check for chemical
deposits; adjust bearings.
3. Replace thrust bearing.

6
Steam
troubles
6. Unusual noise at the
intake; failure of
strainer.
1. Water coming in with
steam.
2.Sediment in steam
1. Re-evaluate piping; install a
separator ahead of the throttle
valve.
2. Test steam for sediment,
acid, or salt. Take corrective
action.



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General
S.no Condition Identifiable by Probable cause Remedy
1
Loss of
efficiency
1. Decreased power output with
increased steam consumption.
1. Failure of interstage
packing, gland seals, or
sealing strips.
2.Failure of nozzles &
buckets
3.Accumulation of
chemical deposits on
buckets or nozzles
1. Replace packing,
gland seals or
sealing strips as
required.
2. Repair or replace
nozzles or buckets.
3. Clean turbine
internally; change
feed water treatment
method.
2
Over speed
operation
2.Rapid increase in turbine
R.P.M.
1. Loss of load
2. Faulty governor or
governor linkage.
1. Shut down
turbine; check over
speed trip control.
2. Check governor
& governor linkage
for malfunction;
repair as required.
3 Bearing failure
3. Noisy operation; overheating
of operation.
1. Lack of lubrication.
2.poor grade of oil
3. Dirt & other
extraneous material in
bearing.
1. Check oil supply;
increase flow of oil
to bearings; replace
bearing if worn.
2. Drain oil &
replace with good
grade of oil as
recommended by the
turbine
manufacturer.


Site References
www.enggcyclopedia.com
http://en.wikipedia.org/wiki/Mechanical_engineering
www.slideshare.com
www.scribd.com
Book References
Thermodynamics for Engineers by R.S Khurrmi
Theory of Machines by R.S.Khurmi
Shigley's Mechanical Engineering Design 9th Edition