STEAM TURBINES FOR POWER GENERATION

CONTENTS
Chapter
Chapter 1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
Chapter 2
2.1
2.2
2.3
2.4
2.5
2.6
Chapter 3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
Chapter 4
4.1
4.2
4.3
Chapter 5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
Chapter 6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9

Title
Steam Turbine Theory
Introduction
Evolution of Steam Turbine
Energy Conversion in Steam Turbine
Impulse & Reaction Principle
Blade Efficiency & Internal Losses in Turbine
Stage Efficiency
Cylinder Efficiency
Steam Cycle Theory
Modern Steam Cycle
Rankine Cycle Development
Modified Rankine Cycle
Turbine Efficiency
Turbine Heat Rate
Effect of Steam Conditions
General Design & Constructional Features of Turbine
Machine Size
Direction of Steam Flow
Cylinder Arrangement
Turbine Foundation
Turbine Construction
Rotor Testing & Balancing
Turbine Lagging (Insulation)
Turbine Materials
Overview of KWU Steam Turbine
General Description
Turbine Systems Overview
Turbine Anchoring & Expansion
KWU Steam Turbine Technical Data
Turbine Specification
Constructional Data
Speed Data
Steam Parameters
Limiting Values of Turbovisory Parameters
Materials for Turbine Components
Turbine Governing Specifications
Emergency Main Stop Valves, Strainers & Control Valves
Interceptor Valves, Strainers and Control Valves
Main Condenser
Limits of Casing Temperatures
Performance Parameters
HP Turbine Construction
Design Features
Cylinder Supports & Guides
Internal Construction
Front Bearing Pedestal
Rear Bearing Pedestal
Combined Journal & Thrust Bearing
Journal Bearing
Assembly of HP Turbine
HPT Components Photographs

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Chapter

Chapter

Chapter

Chapter

Chapter

Chapter
Chapter

7
7.1
7.2
7.3
7.4
7.5
8
8.1
8.2
8.3
8.4
8.5
9
9.1
9.2
9.3
9.4
9.5
9.6
10
10.1
10.2
10.3
10.4
11
11.1
11.2
11.3
11.4
11.5
11.6
11.7
11.8
11.9
12
12.1
12.2
13
13.1
13.2
13.3
13.4
13.5
13.6
13.7
13.8
13.9
13.10

IP Turbine Construction
Design Features
Cylinder Supports & Guides
Construction
Assembly of IP Turbine
IP Turbine Photographs
LP Turbine Construction
Design Features
Construction
LP Turbine Assembly
Expansion Joints at the Shaft Seals
LP Turbine Components Photographs
Turbine Steam System
Steam Circuit
Steam Admission & Exhaust System
Heating & Drainage System of Turbine
Gland Steam System
Regenerative Feed Heating System
HP-LP Bypass System
Turbine Oil System
Function
Oil Specification
Oil System
Oil Pumps & their Functions
Governing & Protection System
Features of KWU Turbine Governing
Description of Governing System
Trip Oil Circuit
Secondary Oil Circuit
Description of Control Loops
Starting & Load Limiting Device
Load Rejection Relay
Trimming Device
Functioning of Protection System
Turbine Supervisory Instrumentation
Vibration, Expansion & Axial Shift Measurement
Turbine Stress Evaluator
Turbine Operation
General Operation Philosophy
Turbine Start-up Requirements
System Checks & Operation
Turbine Warming-up Criteria
Turbine Rolling Procedure
Turbine Loading
Changing over of Governing System on Load
Turbine Unloading & Shutdown
Turbine Operational Emergencies
Automatic Turbine Tester

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STEAM TURBINES FOR POWER GENERATION

LIST OF ILLUSTRATIONS
Fig. No.
Fig. 1.1
Fig. 1.2
Fig. 1.3
Fig. 1.4
Fig. 1.5
Fig. 1.6
Fig. 1.7
Fig. 1.8
Fig. 1.9
Fig. 1.10
Fig. 1.11
Fig. 1.12
Fig. 1.13
Fig. 1.14
Fig. 1.15
Fig. 1.16
Fig. 1.17
Fig. 1.18
Fig. 1.19
Fig. 2.1
Fig. 2.2
Fig. 2.3
Fig. 2.4
Fig. 2.5
Fig. 2.6
Fig. 2.7
Fig. 2.8
Fig. 2.9
Fig. 2.10
Fig. 2.11
Fig. 2.12
Fig. 2.13
Fig. 2.14
Fig. 2.15
Fig. 2.16
Fig. 2.17
Fig. 2.18
Fig. 2.19
Fig. 2.20
Fig. 2.21
Fig. 2.22
Fig. 2.23
Fig. 2.24
Fig. 2.25
Fig. 3.1
Fig. 3.2
Fig. 3.3
Fig. 3.4
Fig. 3.5
Fig. 3.6
Fig. 3.7

Caption
Hero's Reaction Turbine
Basic Elements of Turbine
Action of Steam on Curved Blades
Arrangement of Simple Impulse Turbine
Simple Impulse Turbine Rotor
Pressure Compounded Impulse Turbine

Velocity Compounded Impulse Turbine

Velocity & Pressure Compounded Impulse Turbine
Axial Flow Reaction Turbine
Double Casing Impulse Reaction Turbine
Ideal Efficiency Curves for Impulse & Reaction Stages
Steam Flow & Losses in a Turbine Stage
Secondary Flows in Blades
Interstage Sealing of Impulse & Reaction Stage
LP Turbine Blades Stiffened by Lacing Wire
Turbine Condition Line
Stage Condition Line
HP, IP Cylinder Efficiencies
LP Cylinder Efficiency
Simplified Power Plant Cycle
Basic Rankine Cycle Power Plant
Basic Rankine Cycle T-S Diagram
Superheated Cycle Pant
Superheated Cycle T-S Diagram
Reheat Cycle Pant
Reheat Cycle T-S Diagram
Rankine Cycle with Regenerative Feed Heating
Regenerative Feed Heating T-S Diagram
Modified Rankine Cycle
Comparison of Actual Expansion with Isentropic Expansion in Turbine
Actual Expansion in HP, IP & LP Turbine
Turbine Cycle for Derivation of Heat Rate
Willan's Line for a Typical Unit
Variation of Heat Rate with Load
Effect of Increasing Pressure on Available Energy
Effect of Increasing Steam Temperature on Available Energy
Effect of Increasing Steam Pressure & Temperature both on a Available
Energy.
Effect of Changing Reheat Pressure
Effect of Variation of Reheat Temperature
Loss of Available Energy due to Control Valves Throttling
Effect of Condenser Saturation Temperature on Cycle Work Done
Effect of Exhaust Pressure on Turbine Expansion
Heat Rate Characteristics with Condenser Exhaust Pressure
Decrease in Power Output with Condenser Exhaust Pressure
G.E. Make 67.5 MW Turbo-generator
Single & Double Flow Turbines
Reversed Flow Turbine
Single Cylinder Modular Type Turbine
Multi cylinder Turbine Arrangements
210 MW KWU Steam Turbine Arrangement
Tandem & Cross Compounded Arrangements

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Fig. 3.8
Fig. 3.9
Fig. 3.10
Fig. 3.11
Fig. 3.12
Fig. 3.13
Fig. 3.14
Fig. 3.15
Fig. 3.16
Fig. 3.17
Fig. 3.18
Fig. 3.19
Fig. 3.20
Fig. 3.21
Fig. 3.22
Fig. 3.23
Fig. 3.24
Fig. 3.25
Fig. 3.26
Fig. 3.27
Fig. 3.28
Fig. 3.29
Fig. 3.30
Fig. 3.31
Fig. 3.32
Fig. 3.33
Fig. 3.34
Fig. 3.35
Fig. 3.36
Fig. 3.37
Fig. 3.38
Fig. 3.39
Fig. 3.40
Fig. 3.41
Fig. 3.42
Fig. 3.43
Fig. 3.44
Fig. 4.1
Fig. 4.2
Fig. 4.3
Fig. 4.4
Fig. 4.5
Fig. 4.6
Fig. 4.7
Fig. 4.8
Fig. 4.9
Fig. 4.10
Fig. 6.1
Fig. 6.2
Fig. 6.3
Fig. 6.4
Fig. 6.5
Fig. 6.6
Fig. 6.7
Fig. 6.8
Fig. 6.9

Isometric view of Typical Tandem Compounded Machine

Spring Foundation
Main Components of Turbine
Distortion of Turbine Casing due to Thermal Stresses
Double & Single Shell Design
Carrier Ring Design
Inner & Outer Shells Type Design
Old Barrel Type Design
Modern Barrel Type Turbine with Integral Exhaust Section
Solid Forged Rotor
Integral Disc Type Forged Rotor for HP Turbine
Hollow Drum Type Rotor
Solid Drum Type Rotor
Built-up Rotor
Welded Rotor
Impulse type Blades with Inverted T-root
Blades with Hook Type Root
Riveted Shrouding of Impulse Stages
Built-up Diaphragm
Diaphragm with Cast-in Nozzle Plate
Reaction Type Blades
Unshrouded Reaction Type Thin Tipped Blades
Blades with Serrated Roots
Twisted Blades for LP Last Stages
LPT Rotor with Twisted Blades
Various Types of Blade Root Fixings
Turbine Shaft Glands
Dummy Piston Arrangement for Thrust Balancing
Journal Bearing with White Metal Lining
Combined Journal & Thrust Bearing
Front & Rear Pedestals of HP Turbine
Flexible Couplings
Semi-flexible Coupling
Rigid Coupling
Stress-Strain Characteristics
Creep-Strain Characteristics
Stress-Number of Cycles Curve
Sectional Arrangement of Turbine
Turbine Outline Drawing
Steam Admission Circuit
HP & IP Turbine Blade Roots
LP Turbine Last Stage Blades
Blade Tip Sealing Arrangement
Shaft Gland Sealing Arrangement
Fixed Points of Turbine
Expansion of Turbine Casings
Expansion of Turbine Rotors
Sectional View of HP Turbine
HP Turbine Supporting on Pedestals
Details of HP Cylinder Supports & Guides
Steam Admission Connections
Threaded Sleeve Type Steam Line Joint
Support and Centering of Guide Blade Carrier
Axial Holding and Centering of Guide Blade Carrier
I-ring Seal at Exhaust Side
Front Drum Stages

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Fig. 6.10
Fig. 6.11
Fig. 6.12
Fig. 6.13
Fig. 6.14
Fig. 6.15
Fig. 6.16
Fig. 6.17
Fig. 6.18
Fig. 6.19
Fig. 6.20
Fig. 6.21
Fig. 6.22
Fig. 6.23
Fig. 6.24
Fig. 6.25
Fig. 6.26
Fig. 6.27
Fig. 6.28
Fig. 6.29
Fig. 6.30
Fig. 6.31
Fig. 6.32
Fig. 6.33
Fig. 6.34
Fig. 6.35
Fig. 6.36
Fig. 6.37
Fig. 6.38
Fig. 6.39
Fig. 6.40
Fig. 6.41
Fig. 6.42
Fig. 7.1
Fig. 7.2
Fig. 7.3
Fig. 7.4
Fig. 7.5
Fig. 7.6
Fig. 7.7
Fig. 7.8
Fig. 7.9
Fig. 7.10
Fig. 7.11
Fig. 7.12
Fig. 7.13
Fig. 7.14
Fig. 7.15
Fig. 7.16
Fig. 7.17
Fig. 7.18
Fig. 7.19
Fig. 7.20

Rear Drum Stages

Bottom Inner Casing Complete with Fixed Blading
HPT Rotor Inserted in Inner Casing Half
HPT Admission side Shaft Seal
HPT Exhaust side Shaft Seal
Installation of Sealing Rings
Front Bearing Pedestal
Cross-Section of Journal Bearing
Cross-Section of Main Oil Pump
Longitudinal Section of Rear Bearing Pedestal
Cross-Section through Combined Journal & Thrust Bearing
Combined Journal & Thrust Bearing
Journal Bearing
Centering of Inner Casing
Installation of Inner Casing in Barrel Casing
Rotor Centering in Half Casing
Radial & Axial Clearances Measurement
Gland Seal Clearances Checking in Bottom Inner Casing
Inner Casing Box-up
Preparation of Inner Assembly for Insertion in Barrel Casing
Insertion of Inner Casing Assembly into Barrel Casing
Closing of Inlet Side Barrel Casing
Installation of Outer Sealing Segments
HPT Barrel Casing in Vertical Position
Barrel Casing Admission Side View
HPT Top-Bottom Inner Casing Assembled view
Guide Blade Carrier View from Exhaust End
U-ring for Admission Side Sealing
HP Turbine Rotor Views
Front Pedestal & MOP Views
MOP Installation
HPT Front & Rear Bearing
Combined HP Stop & Control Valve
Cut-away Section of IP Turbine
Supporting Arrangement of IP Turbine
Details of Supports & Guides
Longitudinal Section of IP Turbine
Steam Admission Arrangement
Inner Casing & Outer Casing Joint and attachment
Centering of Inner Casing in Vertical Plane
Front Drum Stages
Rear Drum Stages
Front & Rear Shaft Seal
Section at Sealing Rings
Rear Bearing Pedestal
Arrangement of Hydraulic Turning Gear
Turning Gear Cross-sectional View
Manual Turning Gear
Placement of Bottom-half Inner Casing in Bottom-half outer Casing
Centering of Inner Casing with Dummy Shaft
Placement of Top-half Inner Casing & Inserting the Centering Pins
Fitting of Shaft Seal Cover
Axial Alignment of IP Turbine Shaft

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Fig. 7.21
Fig. 7.22

Radial Clearance Checking

Measurement of Clearances between Inner & Outer Casing

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167

Fig. 7.23
Fig. 7.24
Fig. 7.25
Fig. 7.26
Fig. 7.27
Fig. 7.28
Fig. 7.29
Fig. 7.30
Fig. 7.31
Fig. 7.32
Fig. 7.33
Fig. 7.34
Fig. 7.35
Fig. 7.36
Fig. 8.1
Fig. 8.2
Fig. 8.3
Fig. 8.4
Fig. 8.5
Fig. 8.6
Fig. 8.7(a)
Fig. 8.7(b)
Fig. 8.8
Fig. 8.9
Fig. 8.10
Fig. 8.11
Fig. 8.12
Fig. 8.13
Fig. 8.14
Fig. 8.15
Fig. 8.16
Fig. 8.17
Fig. 8.18
Fig. 8.19
Fig. 8.20
Fig. 8.21
Fig. 8.22
Fig. 8.23
Fig. 8.24
Fig. 8.25
Fig. 8.26
Fig. 8.27
Fig. 8.28
Fig. 8.29
Fig. 8.30
Fig. 8.31
Fig. 8.32
Fig. 8.33
Fig. 8.34
Fig. 8.35(a)
Fig. 8.35(b)
Fig. 8.36
Fig. 8.37

Installing the Temperature Measurement Lines in the Inner Casing

Final Assembly of Inner Casing
Bolts Tightening & Completion of Final Assembly
IP Turbine Ready for Dispatch
IP Inner Bottom-half Casing
Inner Top-half Casing
Gland Housing
Views of Outer Top-half Casing
Outer Bottom-half Casing Installed in Position
Views of IPT Rotor
IPT Rotor Placed in Outer Casing
Turning Gear Stages
Interceptor Valve Seal
LP & HP Control Valve Plugs
Triple Shell, Double Flow LP Turbine
Longitudinal Section of LP Turbine
Inner Casing Arrangement
Axial Fix Point of Outer Casing
LP Turbine Outer Casing Guide
LP Turbine Inner Casing Guide
Inner Casing Fixed Point
Inner Casing Non-fixed Point
Arrangement of Inner Shell in Outer Shell
Top View of Joint Face
Inner Casing Fixed Support
Inner Shell Non-fixed Support
Centering of Inner Shell
Atmospheric Relief Diaphragm
Assembled Diaphragm
LP Turbine Blading for Initial Five Stages
LP Turbine Blading for Last Three Stages
LPT Front & Rear Seals
Sealing Rings
Rear Bearing Pedestal
Journal Bearing Arrangement
Anchor Point of LP Turbine
Turbine Shaft Treated with Protective Agent
Final Blades Removed for Transportation
Checking the Centering Fit Before Installation
Screwing in the Guide Bolts
Measuring Radial Blade Clearances Using Feeler Gauges
Checking Axial Clearances Using Feeler Gauges
Attaching Lead Wires for Clearance Checking
Setting Down the Top-half Inner Shell of the Inner Casing
Inner Shell in Assembled Condition
Heating the Casing Joint Bolts
Fixing Lead Wires for Tip Clearances Check
Setting down the Top-half Outer Shell
Outer Shell of Inner Casing Mounted
LPT Rotor with Expansion Joint
Expansion Joint as Installed
LP Turbine Outermost Top Casing
LP Turbine Top-half Inner Outer Shell

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Fig. 8.38
Fig. 8.39

Views of Top Innermost Shell

Bottom Inner Shells Mounted in Position

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200

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Fig. 8.40
Fig. 8.41
Fig. 9.1
Fig. 9.2
Fig. 9.3
Fig. 9.4
Fig. 9.5
Fig. 9.6
Fig. 9.7
Fig. 10.1
Fig. 10.2
Fig. 10.3
Fig. 10.4
Fig. 10.5
Fig. 10.6
Fig. 11.1
Fig. 11.2
Fig. 11.3
Fig. 11.4
Fig. 11.5
Fig. 11.6
Fig. 11.7
Fig. 12.1
Fig. 12.2
Fig. 12.3
Fig. 12.4
Fig. 12.5 (a)
Fig. 12.5 (b)
Fig. 12.6
Fig. 12.7
Fig. 12.8
Fig. 12.9
Fig. 12.10
Fig. 12.11
Fig. 12.12
Fig. 13.1
Fig. 13.2
Fig. 13.3
Fig. 13.4
Fig. 13.5
Fig. 13.6
Fig. 13.7
Fig. 13.8
Fig. 13.9

Longitudinal Beam End Fixed Support

LPT Rotor Views
Steam Admission Circuit for KWU Steam Turbine
Steam Strainer
Combined Main Stop & Control Valve
Combined Reheat Stop & Control Valve
Gland Sealing System for 210 MW KWU Turbine
Regenerative Feed Heating System for 210 MW KWU Turbine
HP-LP Bypass System for 210 MW KWU Turbine
Lube oil Circuit for 210 MW KWU Turbine
Main Oil Tank Connections
Duplex Filter with Changeover Valve
Jacking Oil System
Main Oil Pump
Oil Cooler Arrangement
Structure of Turbine Control System
Action of Protection & Governing System on Turbine Stop & Control
Valves
Generation of Trip Oil
Generation of Secondary Oil
Governing & Protection Oil System for KWU Steam Turbine
Electro-hydraulic Controller for KWU Steam Turbine
Turbine Protection System
Seismic Type Vibration Pick-up
Impedance Characteristic of Inductive Coil with Air Gap
Inductive Type Axial Shaft Position & Differential Expansion Pick-up
Bridge Circuit
Casing & Rotor Expansions
Location of Differential Expansion Sensors for HP, IP & LP Turbines
Expansion and Shaft Position Pick-ups
Turbine Stress Evaluator Scheme
Turbine Stress Evaluator Display
Wall Temperature (WT) Sensor
Computation of TSE Temperature Margins
Effect of TSE Influence on Speeding Rate
Effect of TSE Influence on Loading Rate
Minimum & Maximum Allowable Main Steam Temperatures for Opening
of Main Stop Valves
Maximum Allowable Main Steam Pressure for Opening of Main Stop
Valves
Minimum Degree of Superheat in Main Steam Before Opening Main
Control Valves
Recommended Minimum Main Steam Temperature before Opening Main
Control Valves
Recommended Minimum Reheat Temperature for Opening IP Control
Valves
Criterion for Bringing Turbine Speed to Rated Speed
Criterion for Loading the Turbine
Coal Start-up Curves for 210 MW KWU Steam Turbine
Turbine Controls

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