TURBINE

TUSHAR KUMAR JOSHI

TURBINE MAINTENANCE DEPARTMENT
DATE- 11.02.2021
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Training Objectives:

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1. Classification of Turbines,
2. Metallurgical considerations,
3. Working principles,
4. Description of main components i. e. Turbine casing, rotor, blades, steam
admission valves, Turning Gear, Couplings.
Steam turbine

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is

a rotating machine which converts heat energy of steam

to mechanical energy
 KAWAI TURBINE SPECIFICATION

• Make: Shanghai Turbine Co. Ltd

• Model: N660-24.2/566/566
• Supercritical pressure, Single shaft
• Tandem compounded three cylinders
• Reheat condensing turbine
• Main Stop valve Inlet pressure: 24.2 MPa (a)
• Rated power : 660 MW.
• HP & IP inlet temperature:566°C
• Double back pressure of condenser :10.13kpa
 Steam Turbine working Principle

Steam is allowed to expand through an orifice (nozzle) then enthalpy i.e. heat
energy, is converted into kinetic energy. This kinetic energy of steam is
changed to mechanical energy through the impact (impulse) or reaction of

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steam against the blades.

Blades are designed in such a way that steam is made to glide upon and not
impacted or bombarded on the blade. As steam moves over the blades, direction
is continuously changing and centrifugal pressure is exerted on the blade. The
total motive force acting on the blades is the resultant of all the
centrifugal forces plus the change of momentum. This causes the rotational
motion of blades.
 Steam Turbine working Principle

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https://www.youtube.com/watch?v=SPg7hOxFItI
 Classification based
on steam admission

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Impulse Reaction
 Principles of impulse turbine

Theoretically impulse is force acting for very small duration of time

In turbines there are two set of blades fixed and moving blades.

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In impulse turbine fixed nozzles
are used for expanding steam.
They convert steam pressure
into kinetic energy. This high
velocity steam acts on moving
blades
 Principles of Reaction turbine

 In reaction turbines the blades are designed in such a way that when the
steam passes over them reactionary force act on rotor of turbine

 In reaction turbine when steam moves over fixed blades it gets expand and

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the heat energy gets converted into kinetic energy

 This velocity steam acts on moving

blades. This results in change in
momentum and reaction effect.

 When the steam is moving over

moving blades some of it’s heat energy
also gets converted into kinetic energy
due to typical shape of fixed and moving
blades (Aerofoil)
Pressure velocity diagram of impulse and reaction turbines
16
SINGLE FLOW TURBINES
SHORTER SHAFT
LONGER BLADES
SUITABLE FOR LOW VOLUMETRIC
STEAM FLOW

DOUBLE FLOW TURBINES

 LONGER SHAFT
 SHORTER BLADES
 BALANCED THRUST
 TURBINE SPECIFICATION

• Make: Shanghai Turbine Co. Ltd

• Model: N660-24.2/566/566
• Supercritical pressure, Single shaft
• Tandem compounded three cylinders
• Reheat condensing turbine
• Main Stop valve Inlet pressure: 24.2 MPa (a)
• Rated power : 660 MW.
• HP & IP inlet temperature:566°C
• Double back pressure of condenser :10.13kpa
Steam Admission Parameters at Turbine Inlet
HPT IPT LPT
Pressure (MPa) 24.2 3.961 1.12
Exhaust Pr (MPa) 4.4 1.12 .01013
I/L Temp (Deg C) 566 566
378
O/L Temp(deg C) 315.3 378

Steam Flow (Tph) 1959 1649

1148

No of Stop valves 2 2
No of Control valves 4 4
No of stages 11+1 8
2x7 + 2x7
Components of Steam Turbine
 HIP& LPT#A & LPT#B turbine.
 Casing and stationary diaphragm
 Rotor
 Bearings.
 Bearing pedestal / pedestal plate
 Shaft sealing .
 Stop & control valves.
 Turbine control system.
 Turbine monitoring system.
 Turbine oil system.
• Three cylinders – HIP, LPT#A & LPT#B
• Double casing.
• Forged rotor.
• Four exhaust pipe( 2HP & 2 IP).
• Rigidly coupled shaft train.
HIP TURBINE
 HIP TURBINE
• Inner casing is keyed on outer casing.
• HIP cylinders are supported by 4 “cylinder claws” of
outer casing lower half in its front & rear bearing
pedestal .
• Outer casing upper half is bolted to its lower half.
• Front pedestal is free to slide over its pedestal plate
limited by guided key on foundation which allows its
motion in axial direction, but not horizontally.
• combined rotor is double-flow & is counter current.
• The rotor is supported on 2 radial bearings.
• The length of span is 6140 mm.
• The weight of the rotor with blades is about 34 ton.
• The HP blading comprises one control stage moving blades
and 11 pressure stages.
• The IP blading comprises 8 stages with.
• A series of grooves are arranged on the external of the rotor,
which are used to fix the diaphragms seal rings. The radial seal
rings are also arranged on
the shroud of the rotating blades. Grooves for seal rings are also
arranged on both side of the rotor.
• The HIP combined rotor is an alloy steel solid forging
without center hole.
• Threaded holes are arranged in the rotor, which are used
to fix the balancing nuts.
Nozzle block
HIP INNR OUTR
Inner casing

outer casing
 Pressure stages (HP Turbine)
Impulse stage (HP Turbine)

Dynamic Balancing holes

IP turbine steam inlet

HP turbine steam inlet

 IP rear bearing pedestal

Thrust bearing pedestal

 LPT# A & LPT#B
• LPT#A outer casing middle point is “Anchor
point” on both side of casing.
• Inner casing is supported by outer casing.
• Both turbine outer casing is connected via “I
type spacer beam”.
• Its exhaust steam path is connected with
condenser A & B with metallic bellow joints.
• Threaded holes are arranged in the rotor, which are
used to fix the balancing nuts.
LP TURBINE
Dynamic Balancing holes
Inner casing anchor point for LPT
#A & LPT #B
Anchor point
 Lube oil system
• Comprises of one AC & DC pump each.
• Two jacking of lifting oil pumps.
• One HP seal oil pump (Part of seal oil system)
• One turbine shaft driven Main Oil Pump.
• Two oil coolers
• Two oil filters
• Two vapour exhauster fans.
• One Main Oil Tank (M.O.T), capacity 48.8 m3.
 Bearings

• Journal bearing
– Four pad supported on keys.
• Bearing 1& 2 are Journal bearing is of the self-aligning
type consisting of four babbitt-lined steel bearing
shoes bored to a tolerance diameter. The support pad,
which is on the back of each Shoe.

• Bearing3 to 6 are tilting pad bearing, it is of the self-

aligning type and supported by five keys. It consists of
a steel bearing shell and four babbitt lined steel shoes.
 Turbine Bearings

The bearings used are

 Journal bearings - Tin based Babbitt (white metal )

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 Thrust bearings – Mitchell type tilting pad bearing
provided to absorb the axial thrust generated in HP turbine
Journal bearings

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Journal bearings

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Journal bearings

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Thrust bearings

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 TG BEARINGS
#1 #2 #3 #4 #5 #6 #7 #8 #9

IPT
IPT A B
B
HPT
HPT LPT
LPT LPT
LPT GEN
GEN EXT
EXT

T.B
Anchor point of Rotor

MOP
Anchor point of
casing

Designed life of is turbine 30 years.

THRUST BEARING COLLAR

Shaft collar
Thrust bearing pedestal
Thrust Pad
 Turbine Blades
Impulse Blades
Impulse type of moving blades are manufactured from a solid bar.

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Reaction Type Of Blades
In reaction type of blades high pressure drop occurs across both fixed
and moving blades . So, very effective seal between fixed and moving
blades is necessary. Which prevent steam leakage.
Blades
 These are most important (and, costly too) components of the turbine as these
are responsible for the main function of the turbine, i.e. converting heat energy
to mechanical energy.

• A blade has three main parts:

 AEROFOIL - It is the working part of the blade
 ROOT - It is the portion of the blade which is fixed with the rotor or casing.
 SHROUD - It can be riveted to the main blade or can be integrally machined with
the blade
(Note: Blades may be without shroud also).
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ROOT FIXING
Root fixing
 Turbine Glands

Types of glands

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Carbon ring glands Labyrinth glands

Labyrinth glands can withstand high pressure and temperature and easy
in maintenance are widely used in power plants
 Axial expansion of rotor

 For rotors the fixed point is thrust bearing which is bearing no.2
 HP turbine tries to expand towards bearing no.1 from this point

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where as LP and IP turbine rotor try to expand towards bearing no.5
 Axial expansion of Casing

The HP cylinder casing is anchored at bearing no.2 it expands

towards bearing no.1

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Differential expansion = Rotor expansion – casing expansion
 TURBINE CONTROL VALVES
3.96MPa / 566°c

HRH
24.2MPa/566ºC
1.12MPa / 378°c
RSV
MS LINE
MSV CV CV

CV CV
TO BLR RH

CRH
IPT #1 #2
HPT LPT LPT GEN

CRH

RCV
CV
CV RCV
CV

MSV CV CV
RSV
RSV
MS LINE

HRH
CONTROL VALVES
 Turbine Supervisory Instrumentation

It includes following supervising probes

1. Differential expansion HP.
2. Differential expansion LP.
3. Overall expansion.
4. Axial displacement or shift.
5. Shaft vibrations.
6. Bearing metal temperatures.
 Differential expansion

• Whenever a metal is subjected to certain

temperature it tends to expand or contract so
is the case with turbine rotor & casing.
• Moving & rotating blades have certain gap
within the which when overcome may cause
rotor to casing rubbing, hence important to
monitor during running condition as steam
contains heat energy which causes them to
expand.
Rotational speed measurement

Differential exp. HP
LPDE
 Axial displacement or shift
• Due to thrust forces caused because of
pressure difference around the blades rotor
tends to move in the direction of thrust force
• It may also cause due to sudden load throw
off, deposition on blades or damaged blades
Axial shift
Axial shift measurement point
 Vibrations
• Rotor is supported on bearings & when in
dynamic motion causes certain vibration,
caused because of unbalanced, misallingment,
foundation sinking, friction of bearing
pedestal base plate, foreign material, large
bearing clearences, babbit metal rub,
dynamic.
 Bearing metal temperatures
• Bearing babbit metal can withstand a given
maximum temperature, to avoid any damage
to it it is important to monitor.
 TURBINE EXTRACTIONS

Heaters Steam Flow Steam Pr Steam Temp Extraction

T/h MPa ºC Stages
HPH-1 114.5 6.28 360.8 9th stage of
HPT

HPH-2 166.7 4.40 315.3 CRH line

(HPT Exhaust)

HPH-3 68.9 2.07 466.1 5th stage of

IPT

Dearator 96.25 1.12 378 IPT Exhaust

HP IP TURBINE EXTRACTION
HP IP TURBINE EXTRACTION
 TURBINE EXTRACTIONS

Heaters Steam Flow Steam Pr Steam Temp Extraction

T/h MPa ºC Stage
LPH-5 109.7 0.46 270 2nd stage of
LPT A

LPH-6 53.1 0.12 136.3 4thstage of

LPT B
LPH-7A/7B 48.8 0.05 83.33 5th stage of
LPT A/B

LPH-8A/8B 27.9 0.02 62.8 6th stage of

LPT A/B
LP TURBINE EXTRACTION
LPT TURBINE EXTRACTION
 Service conditions
• Highly stressed at elevated
temperature.
• Thermal and mechanical cyclic
loading
• Impingement
• Corrosion and Erosion
Material property requirement
• High creep resistance
• Higher thermal conductivity
• Fatigue
• Hardness
• Chemical stability
• Rigidity
• High yield strength
• High strength to weight ratio
• Machine-ability
Materials
 High and intermediate pressure rotors are usually made from chromium-molybdenum-
vanadium steel a ferritic material which is suitable for wheel case steam temperatures
up-to 540°C.

 Austenitic materials are not favoured because of the cost of their manufacture and their
high coefficient of expansion.

 Low pressure rotors are made of 3 per cent chromium-molybdenum steel or 2 1/4 per
cent nickel chromium- molybdenum steel. The first of these is not used in modern
designs because of the tendency towards scuffing in the bearings during the early life of
the rotor.

 Low pressure discs are made of 3 per cent chromium-molybdenum-vanadium steel, or

more recently of 3 1/2 per cent nickel-chromium-molybdenum-vanadium steel.
TURNING GEAR
TURNING GEAR
COUPLING
Coupling Spacer