STEAM TURBINES

Process Design / Safety Aspects

BY
Muhammad Bux Soomro
INTRODUCTION

•CONVERTS THERMAL ENERGY OF STEAM TO ROTATIONAL MECHANICAL ENERGY.

ADVANTAGES

 High efficiency (up to 80%)

 High rotational speed. (up to 10000 rpm)
 High capacity / weight ratio.
 Smooth, nearly vibration-free operation.
 No internal lubrication.
 Oil free exhaust steam
 Can be built in small and very large units (5-32000)hp
DISADVANTAGES

 For slow speed application reduction gears are required.

 The efficiency of small simple steam turbines is poor.

TYPES OF STEAM TURBINES

 Impulse turbine / Reaction turbines.

 Condensing turbines / Back pressure turbines
 Extraction turbines / Topping turbines.
 THERMODYNAMICS

 Two non ideal processes (Turbine and BFW pump)

 Adiabatic efficiency
= [(H1-H2)/ (H1 - H2s)]X100
 Condensing steam turbines efficiency (70-82%)
 Non condensing steam turbines efficiency (30-40%)
TERMINOLOGY

ACUTAL STEAM RATE (ASR)

 Actual steam required by the turbine per hour per horse power.
(6-7) lb/hr per Hp for condensing steam turbines.
(35-40) lb/hr per Hp for non condensing steam turbines.
THEORITICALSTEAM RATE
 Theoretical steam required by the turbine per hour per horse power. It depends upon inlet pressure, exhaust pressure and
hp of turbine.

CRITICAL SPEED
 The RPM of turbine at which the phenomena of resonance occur. At this speed
the vibration of turbines increase. This speed is specific to the equipment.

TURBINE GOVERNORING
 The process of controlling the speed of the turbine is called turbine governing. In nozzle governing series of nozzle
valve open in sequence as load increases. In throttle governing a single large control valve controls the load.
INSTRUMENTATION

CONTROL LOOPS
 RPM control (Local / Remote).
 Lube oil pressure control (Control valve / auxiliary lube oil pump).
 Lube oil temperature control (Manual / Alarms)
 Tripping of turbine (Solenoid valve / TNT valve).
 Lube oil flow control. (RO’s)

SECURITIES

 Over speed trip ( F proportional to V2).

 Low lube oil pressure (Alarm / Tripping).
 High / low lube oil temperature (Alarm / Tripping).
 Lube oil pressure relief (PRV’s).
 Steam pressure relief ( Sentinel valve / PRV).
PROCESS DESIGN

API611-3rd addition covers process / mechanical and instrument design of steam turbines.
HORSE POWER
 10% of rated Hp can be increased by operating hand wheels,TK-2503/A
 25% Hp can be increased by modify steam inlet path.

INLET STEAM CONDITION

 Site steam balance. High pressure turbines have high capital cost and efficiency.
OUTLET STEAM CONDITONS
 Site steam balance and load on condensers.
 Back pressure turbines are used for medium hp requirement (Up 500 Hp)
 Condensing steam turbines are used for high hp requirement.
RPM OF TURBINE
 High speed turbines are more efficient than low steam turbines.
 Gearbox can be used to reduce the speed according to requirement but it adds capital cost.
PSV SIZING
 Set pressure and relief requirement depends upon the turbine hardware.
UTILITIES
 Cooling water / Fire water.
 Power supply for auxiliary lube oil pump.
 Control supply for turbine control.
STEAM PIPING FOR TURBINES
3 "-H S U -1 0 5 -F 3 2 4 "-H S U -1 0 3 -F 3 2

5 8 5 p s ig s te a m

3 /4 " 3 /4 "

PR O C ES S
P I P I
TI 3 /4 " TI 3 /4 "

3"-HSU -104-F32
L5 : B e lo w s e a t d r a in ( S te a m c h e s t)

ELLIOT F-32

ELLIOT F-32
3 /4 " 3 /4 "
M 5 M 5
L4 : T r ip v a lv e s te a m le a k o ff
1 /2 " 1 /2 "
M 5 : A b o v e s e a t d r a in L4 L4

M : T u r b in e c a s in g d r a in . 1 /2 " 1 /2 "
L5 L5

L5 : G o v e r n o r v a lv e s te a m le a k o ff C O N T R O L 3 /4 " K T- C O N T R O L 3 /4 "
R O O M M 4 2504A R O O M M 4

L3 : L e a k o ff fro m s h a ft p a c k in g c a s e s

L 3 -1 : L e a k o ff fro m s h a ft p a c k in g c a s e s
L 3 -1 L3 ID F A N 1 /2 " 1 /2 "
1 /2 " 3 /4 " 1 /2 "
L 3 -1
L3 ID F A N
3 /4 "

B-30 ELLIOT
B-30ELLIOT
8 " -B 3 0 M 8 " -B 3 0 M

6" / 4"

6" / 4"
P S V -9 0 6 P S V -9 0 5
S P -6 0 # S P -6 0 #

4"-LS-104-B30
PI PI
T I T I

4 0 p s ig s te a m h e a d e r
4 "-L S -1 0 5 -B 3 0 6 "-L S -1 0 1 -B 3 0
N o t e : A ll s te a m d r a in s s h o u ld b e r o u te d to fu n n e ls o f d r a in h e a d e r

T N T V a lv e L o c a l d r a in N ew

G ear box G ovenor E x is tin g

P R IM A R Y R E F O R M E R ID F A N S S T E A M
T U R B IN E U P R A T E (S T E A M S Y S T E M )
ID fa n S p e c b re a k
P R E P A R E D B Y M A C H E C K E D B Y JW
COOLING WATER PIPING

4 "-A 2 C O O L IN G W A T E R R E T U R N H E A D E R

3 /4 " -A 2 3 /4 " A -2

PR O C ESS 2 "-A 2
2 "-A 2

3/4"A2

3/4"A2

3/4"A2

3/4"A2
3 /4 "
2"-A2

2"-A2
1"-A 2

1"-A 2
3 /4 "
3 /4 " 3 /4 " 3 /4 "
3 /4 "
T I 2" 1" 2" 1"
TI
TI TI

E -2 5 6 1 E -2 5 6 2 E -2 5 5 9 E -2 5 6 0
M K -2 5 0 4 B
2"-A2

3 /4 " 3 /4 "
1"-A2

2"-A 2

1"-A2
3 /4 " 3 /4 "

3/4"A2

3/4"A2
3/4"A2

3/4"A2
3/4"A 2

K T -2 5 0 4 A
3/4"A2

K T -2 5 0 4 A
PI PI
2"-A2

2"-A2
3 /4 " 3 /4 "

4 "-A 2
4 "-A 2

C O O L IN G W A T E R S U P P L Y H E A D E R

F IR E W A T E R S Y S T E M
N O T E: A L L D R A IN S W IL L B E R O U T E D T O C O O L IN G W A T E R B A S IN V IA D R A IN H E A D E R .
4 "-L F 3 "-L F
FIRE HIDRANT NO 46

FU R N A C E T O P G ear box N ew
M o to r

4 "-L F

E -2 5 0 1 A /B S O U T H ID fa n E xchanger E x is tin g
4 "-L F

C O O L IN G W A T E R / F IR E W A T E R S U P P L Y
F -2 5 0 1 W E S T
T O N E W ID F A N S S T E A M T U R B IN E S
P R E P A R E D B Y M A C H E C K E D B Y JW
SAFETY ISSUES

 PHA should be done for this sort of modification.

 Fire fighting equipment should be evaluated for the fire on lube oil reservoir.
 Relief requirement should be carefully evaluated.
 High pressure steam tie-ins should be removed.

LESSONS LEARNT
 Horse power of the machine should be decided after careful evaluation of future
modifications
 Instrumentation (PI’s / TI’s) should be installed for proper troubleshooting.
 Lube oil coolers should be over designed (up to 50%) due to over cooling water quality.
 Back washing arrangement for lube oil coolers should be provided.
QUESTIONS