Explain the principles of operation of steam turbine plant.

Table of Content:
1. Definition
2. Components of Steam Turbine Plant
3. Parts of Steam Turbine
4. Gas Turbine Working & Operation Principle
5. Thermal Efficiency
6. Types of Steam Turbines
7. Modifications

Introduction:
Steam turbine plants are the backbone of the global power generation
industry, responsible for a significant portion of our electricity. Understanding
their operation is crucial for engineers, researchers, and anyone interested in
efficient energy production. This report will explore the fundamental
principles behind steam turbine plants, delving into the components,
processes, and thermodynamic cycles that govern their operation. We will
explore how these components work together to convert thermal energy
from burning fuel into usable mechanical energy that ultimately drives
electricity generation.
1) Definition:
A steam turbine is a machine that harnesses the thermal energy of pressurized steam to
generate mechanical work on a rotating output shaft. The steam is produced by heating
water using a heat source such as coal, gas, solar, or nuclear energy. As the steam flows past
the spinning blades of the turbine, it cools and expands, converting its potential energy into
kinetic energy in the blades. This makes steam turbines ideal for driving electrical generators,
as they generate rotary motion that can be converted into electrical energy through a
magnetic field. Steam turbines do not consume fuel directly, but rather rely on high-pressure
steam from boilers or heat recovery steam generators (HRSGs).

2) Components of Steam Turbine Plant:

1. Boiler: The boiler is responsible for generating high-pressure and high-temperature steam
by heating water using a fuel source, such as coal, natural gas, or oil. It consists of a
combustion chamber where fuel is burned, heating tubes or surfaces where heat transfer
occurs, and a steam drum or separator to separate steam from water.

2. Steam Turbine: The steam turbine is the heart of the power plant, where the energy of
the steam is converted into mechanical energy.

3. Generator: The generator is a key component that converts mechanical energy from the
turbine into electrical energy. It consists of a rotor, which is connected to the turbine shaft
and rotates, and a stator, which contains a set of stationary windings. As the rotor rotates, it
induces an electric current in the stator windings through electromagnetic induction,
generating electricity.

4. Condenser: The condenser is responsible for condensing the low-pressure steam coming
out of the turbine back into water. It facilitates the transfer of heat from the steam to a
cooling medium, such as water or air. The condensation process increases the efficiency of
the power plant by creating a pressure difference across the turbine and allows for the reuse
of the condensed water in the boiler.

5. Feedwater System: The feedwater system supplies water to the boiler, making up for the
water lost during steam generation and condensation. It typically consists of pumps that
pressurize and deliver the water to the boiler, a deaerator to remove dissolved gases from
the feedwater, and various control valves and instruments to regulate the flow and pressure
of the feedwater.

6. Cooling System: The cooling system is responsible for dissipating the waste heat
generated in the condenser. It can be a cooling tower system, where hot water from the
condenser is cooled through evaporation and contact with ambient air, or it can use other
cooling mediums such as rivers, lakes, or the sea.
3) Parts of Steam Turbine:
1. Rotor: The rotor is the central component of the steam turbine and is typically mounted
on a shaft. It consists of a series of rotating blades or buckets that are attached to the shaft.
The steam's high-pressure and high-temperature energy is transferred to the rotor, causing
it to rotate.

2. Stator: The stator is a stationary component surrounding the rotor. It consists of a series
of stationary blades or vanes that guide the flow of steam and direct it onto the rotor blades.

3. Casing: The casing is the outer shell or housing of the steam turbine.

4. Nozzles: Nozzles are fixed components located at the entrance of the steam turbine. They
are designed to control the flow and direction of steam into the turbine blades. The nozzles
accelerate the steam to high velocities, converting its thermal energy into kinetic energy.

5. Diaphragms: Diaphragms are stationary components located between different stages of

the steam turbine. They separate the steam flow into distinct pressure stages and direct the
steam onto the rotor blades of each stage. Diaphragms help maintain the pressure
difference across the turbine stages and ensure efficient energy extraction.

6. Bearings: Bearings support the rotor and allow it to rotate smoothly. They provide radial
and axial support, reducing friction and wear. Bearings play a critical role in maintaining the
alignment and stability of the rotor shaft.

7. Seals: Seals are used to minimize steam leakage between different sections of the turbine.
They prevent steam from bypassing the turbine stages, ensuring that the steam flows
through the rotor blades, maximizing energy extraction.

8. Couplings and Shafts: Couplings and shafts connect the rotor of the steam turbine to the
driven equipment, such as generators or pumps.
4) Gas Turbine Working & Operation Principle
a) Principle: The Rankine cycle is a fundamental principle in the operation of steam
turbines. The Rankine cycle is an idealised thermodynamic cycle of a heat engine that
transforms heat into mechanical work during a phase transition. Here the frictional
losses are neglected. By expanding through the turbine, steam energy is transferred to
mechanical work. The expansion occurs through a sequence of fixed blades (nozzles) and
moving blades. It is worth noting that,

1. The nozzle or blade passage is where the enthalpy of the steam is initially changed into
the kinetic energy of the steam.
2. The high-velocity steam that is created by the nozzle runs through the curved vane or
blade, causing it to change momentum as a result.
3. The steam turbine generates electricity by changing the momentum of a jet of steam as
it passes through a vane or blade.

b) Working:
1. Steam Generation: The process begins in the boiler, where water is heated using a fuel
source such as coal, natural gas, or oil. This generates high-pressure and high-temperature
steam.

2. Steam Entry: The high-pressure steam is directed into the steam turbine. It enters the
turbine at the inlet section, typically through a series of nozzles. The nozzles convert the
pressure energy of the steam into kinetic energy, increasing its velocity.

3. Steam Expansion: As the high-velocity steam passes through the turbine blades, it
undergoes a controlled expansion. The steam's high pressure causes the blades to rotate as
it flows over them. This rotation converts the kinetic energy of the steam into mechanical
energy.

4. Power Generation: The rotating turbine shaft is connected to a generator. As the turbine
rotates, it drives the rotor of the generator, which contains a set of stationary windings. The
relative motion between the rotating and stationary parts induces an electric current in the
windings, generating electricity.

5. Steam Exhaust: After passing through the turbine, the low-pressure and low-temperature
steam exits the turbine and is typically sent to a condenser. In some cases, it may be used for
other processes before being condensed.
c) Cycle:
Process 1-2: Constant Pressure Heat Addition: The high-pressure water (state is directed to a
boiler where it is heated at a constant pressure until the saturation temperature is reached.
The water is converted into high-pressure steam (Saturated steam), which is feed into the
turbine.
Qs=h2 - h1

Process 2-3: Isentropic Expansion: High pressure and high temperature superheated, dry
saturated or wet steam generated in the boiler at p1 and T1 is supplied to the steam turbine.
This steam expands isentropically into steam turbine up to the condenser pressure. Steam
turbine develops mechanical work, WT due to expansion of steam. Turbine work,
WT= h2 - h3
Process 3-4: Constant Pressure Heat Rejection: The low-pressure and low-temperature
steam (state 3) exiting the turbine is directed to a condenser. In the condenser, the steam is
condensed (at constant pressure) back into water using a cooling medium, such as water or
air. This process involves constant pressure heat rejection, where the excess heat from the
steam is transferred to the cooling medium.

QR=h3 - h4

Process 4-1: Isentropic compression (Pumping Process): The condensed water (state 4) is
then pumped by a feedwater pump to increase its pressure and prepare it for the boiler.
Pump work,
WP= h1 - h4
5) Thermal Efficiency
 Heat supplied by boiler, QS = (h2 - h1)
 Work developed by turbine WT = (h2 - h3)
 Heat rejected by condenser, QR = (h3 - h4)
 Work supplied to feed pump Wp = (h1 - h4)

 Net work developed, Wnet = Wt - Wp

Wnet = (h2 - h3) - (h1 - h4)

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6) Types of Steam Turbines
1. Based on the action of steam:
1.1. Impulse Turbine
1.2. Reaction Turbine
2. Based on the steam flow direction:
2.1. Axial flow turbine
2.2. Radial flow turbine
3. Based on the number of stages:
3.1. Single stage
3.2. Multi-stage
4. Based on the pressure of steam at the inlet:
4.1. Low pressure
4.2. Medium pressure
4.3. High pressure
4.4. Supercritical pressure
5. Based on governing method:
5.1. Throttle governing turbine
5.2. Nozzle governing turbine
5.3. Bypass governing turbine
6. Based on industrial usage:
6.1. Stationary turbine with constant speed
6.2. Stationary turbine with variable speed
6.3. Non-stationary turbines
7) Modifications in Steam Power Plants:
1. Increasing Pump Pressure (Raising Boiler Feedwater Pressure):
 Concept: The feedwater pump pressurizes water before it enters the boiler. Increasing
the pump pressure raises the pressure of the water entering the boiler.

 Benefits:
a) Higher Boiler Efficiency: Higher pressure water in the boiler allows for operation at
higher steam temperatures. This can lead to increased efficiency due to a larger
temperature difference between the heat source and the working fluid (steam) in the
Rankine cycle.

b) Reduced Moisture Content in Turbine: Higher boiler pressure results in drier steam
exiting the boiler. This minimizes the risk of water droplet formation in the turbine stages,
which can erode turbine blades.

c) Enhanced Power Output: Higher boiler pressures enabled by the increased pump
pressure can lead to higher power output from the steam turbine. This is because the
higher pressure steam has more energy available for conversion into mechanical work.

2. Lowering Condenser Pressure:

 Concept: The condenser condenses the exhaust steam from the turbine, creating a
pressure difference that drives the turbine. Lowering the pressure in the condenser
increases the pressure difference available for work extraction.

 By reducing the condenser pressure, the temperature difference between the steam
entering the condenser and the cooling water can be increased. This increased
temperature difference improves the efficiency of heat transfer from the steam to the
cooling water, resulting in better overall plant efficiency.

 Benefits:
a. Increased Turbine Work Output: A larger pressure differential between the steam
entering and exiting the turbine allows for more work extraction, leading to potentially
higher plant efficiency.
b. Reduced Steam Consumption: Lower condenser pressure results in a lower saturation
temperature for the exhaust steam. This means that less extraction steam is required for
heating purposes within the plant, resulting in reduced steam consumption.

3. Steam Bleeding (Extraction):

 Concept: Bleeding is a modification that involves extracting steam at intermediate stages
of the steam turbine, before it reaches the final stage. The extracted steam can be
utilized for various purposes within the plant, such as preheating feedwater, heating
processes, or driving auxiliary equipment.

Benefits:
a) Feedwater Heating (Regeneration): The extracted steam can be used to pre-heat the
feedwater entering the boiler in a closed or open feedwater heater. This reduces the
heat input required from the boiler, improving plant efficiency.

b) Deaeration: A small amount of steam can be used for deaerating the feedwater to
remove dissolved gases that can cause corrosion in the boiler.

Conclusion
Steam turbine plants operate on a well-established principle - converting thermal energy
from burning fuel into mechanical energy that drives a generator to produce electricity. The
key components of a steam turbine plant, including the boiler, turbine, condenser, and
feedwater pump, work in a continuous cycle to achieve this goal. By understanding the
principles behind each stage, from heat generation in the boiler to steam expansion in the
turbine, we gain valuable insight into the efficient operation and optimization of these vital
power generation facilities.