RECIPROCATING STEAM ENGINES

Components of steam engines

•STEAM GENERATOR /BOILER

• MOTOR UNIT

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ENGINE CYCLE

• TAKES ONE ROTATION /TWO PISTON STROKES TO

COMPLEATE

• CYCLE CONSISTS OF 4 EVENTS

– ADMISSION
– EXPANSION
– EXHAUST
– COMPRESSION

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• IMPORTANCE OF COMPRESSION PHASE

– THE EXH PORTS CLOSES BEFORE PISTON REACHES THE

END OF THE STROKE
– THE TRAPPED STEAM GIVES A CUSHION EFFECT TO THE
PISTON,TO REDUCE THE VELOCITY OF PISTON
– OBVIATES THE PRESSURE AND TEMPERATURE SHOCK

LEAD
– ADMISSION OF STEAM BEFORE THE END OF EXH. STROKE
– THIS STEAM GIVES THE ABV EFFECTS

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COMPOUND ENGINES:
EXPANSION OF STEAM TAKES PLACE IN H.P.
AND L.P. CYLINDERS

Two-cylinder compounds can be arranged as:

• Cross compounds - The cylinders are side by
side.
• Tandem compounds - The cylinders are end
to end, driving a common connecting rod
• Angle compounds - The cylinders are
arranged in a vee (usually at a 90° angle) and
drive a common crank.
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 MULTIPLE EXPANSION ENGINES
• SPLITS THE EXPANSION TO MORE STAGES
• Uses a series of double acting cylinders

• Triple expansion engines

• Quadruple expansion engines

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 STEAM TURBINES

• The steam turbine is a device for obtaining

mechanical work from the energy stored in
steam
• The high-pressure steam from the boiler is
expanded in nozzles to create a high-velocity
jet of steam (heat energy to kinetic energy.)
• This jet is directed on to the blades

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 The steam does not 'blow the wheel around'.
The shaping of the blades causes a change in
direction and hence
velocity of the steam jet.
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TYPES OF TURBINE
IMPULSE TURBINE :
• The impulse arrangement is made up
of a ring of nozzles followed by a ring
of blades
• The high-pressure, high-energy steam
is expanded in the nozzle to a lower-
pressure, high-velocity jet of steam.
• This jet of steam is directed into the
impulse blades and leaves in different
direction
• The changing direction and therefore
velocity produces an impulsive force
which rotates the blade

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REACTION TURBINES

• The reaction arrangement is made up of a

ring of fixed blades attached to the casing,
and a row of similar blades mounted on the
rotor, i.e. moving blades.
• The blades are mounted and shaped to
produce a narrowing passage which, like a
nozzle, increases the steam velocity.
• This increase in velocity over the blade
produces a reaction force which has
components in the direction of blade
rotation.
• There is also change in direction of the
velocity, leading to the development of
impulsive forces in the blades.

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 Compounding

• Compounding is the splitting up, into two or more stages,

of the steam pressure or velocity change through a turbine

- Pressure compounding
- velocity compounding
- Pressure velocity compounding
- Cross compounding

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 Pressure compounding
• Pressure compounding of an impulse turbine is the use of a number of
stages of nozzle and blade to reduce progressively the steam pressure
• Each stage contains a row of nozzles and a row of blades
i.e.; it is built of a number of simple impulse turbines
• To prevent steam leakage between the pressure zones ,shaft seals of
diaphragm packing is provided

ADVANTAGES:-
-results in lower or more acceptable steam flow speeds
-with smaller velocity, slower speed of rotation is possible and
centrifugal effects are minimized
-efficiency is increased

DISADVANTAGES:-
-increased first cost
-increased length of the turbine

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 PRESSURE COMPOUNDING

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 VELOCITY COMPOUNDING
• Turbine consists of row of nozzles, through which a large pressure drop
takes place
• It is followed by alternate rows of moving and fixed blades
• Fixed guide blades are connected to the turbine casing
• Moving blades are attached to a wheel (curtis wheel)

ADVANTAGES:-
- Reduction in turbine length
- Reduction in cost since less material is required
- Large pressure in the nozzle which reduces the gland length and
reduces the pressure stresses
DISADVANTAGES:-
- Lower efficiency
- increased steam consumption

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 VELOCITY COMPOUNDING

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• The two arrangements may be combined to give what is
called
'pressure-velocity compounding'.

• REACTION TURBINES
• The reaction turbine as a result of its blade arrangement
changes the steam velocity in both fixed and moving blades
with consequent gradual steam pressure reduction. Its basic
arrangement therefore provides compounding

• The term 'cross-compound' is used to describe a steam

turbine unit made up of a high pressure and a low pressure
turbine

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 CROSS COMPOUNDING

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 Plant layout

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 Closed feed system
• This feed system allows the continuous recycling of water and steam
• Steam turbine will exhaust in to the condenser which will be at high
vacuum
• Extraction pump takes the water from there and circulates through the air
ejector
• Air in the condenser is removed by this air ejectors(steam operated
ejectors )
• Condensate then passed to the gland steam condenser ,where it gets get
heated
• Both the air ejector and gland steam condenser improves the plant
efficiency by recovering the heat and increase the feed water temp.
• condensate passes to the de-aerator where it is heated by the feed
heating steam( direct contact type)
• Due to the heating the dissolved gases are released from the feed water
• The feed water then passes through the high pressure feed heater then to
the boiler
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 Open feed system

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 Open feed system
• In this system ,the exhaust steam from various services are condensed in
the same condenser
• From the condenser water goes to the hot well
• It will receive drains from the other systems (e.g. f.o. heating system,oil
tank heating system etc)
• Observation tank permits the inspection of drains
• Feed filter and hot well tank is arranged with internal baffles to aid the oil
separation
• Feed heaters may be of direct contact type
• Apart from heating the feed water ,they function as a de-aerators

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 Warming - through

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 Warming - through
• Open all the turbine casing drains
• Open the steam line drain valve
• Ensure all the steam control valves at the maneuvering station and
around the turbine are closed
• Start the l.o. pump and see that the oil is flowing freely to each bearing
and gear sprayers
• Obtain the clearance to turn the shaft
• Engage the t/g and rotate the turbine
• Start the sea water pump for the condenser
• Allow slow quantity of steam to pass through the turbine and heat it
• Turbine should be turned continuously until uniform temp is reached (75)
• Raise the vacuum in main condenser ,open gland steam disengage t/g
• Introduce short blast of seam to turbine to spin the propeller through one
revolution, repeat this every 5 min for next 30 min.

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 materials
• Desired properties:-
– Creep resistance
– Strength at high temperatures
– Erosion resistance
– Corrosion resistance
– Abrasion Resistant

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 Alloying materials and properties imparted

• Nickel : increases strength and erosion resistance

• Chromium : increases resistance to corrosion and erosion
• Molybdenum : increases strength at high temperatures
• Vanadium : increases strength and fatigue resistance

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 Parts and Materials
• Rotors
– The turbine rotor acts as the shaft to transmit the mechanical power
produced to the propeller shaft through gearing
– It may be a single piece or built up from a shaft and separate wheels
– Journal bearings are fitted at both ends of the rotor
– One end of the shaft got thrust collar
– The blades are fitted into grooves of various designs cut into the
wheels.
– material use is forged chrome-molybdenum steel or
0.5% molybdenum steel

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 blades
• High speed rotation develops high
centrifugal force on the blading
• Variation of vel. creates vibration
• Expansion and contraction will occur
during turbine operation

• Materials used
 0.125% C,12% Cr,1% Ni Stainless steel
 0.24% C ,12% Cr stainless steel
 0.25% C ,12% Cr 36% Ni steel

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 Fixing the blades to the rotor

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• Fitting the blades involves placing the blade root into the wheel through a
gate or entrance slot and sliding it into position
• All the blades are inserted and the gate closed with closing blade which is
pinned in to place
• Shrouding is then fitted over tenons on the upper edge of the blades.
• lacing wires may be passed through and brazed to all the blades.

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• Nozzles
-Nozzles serve to convert the high pressure and high energy of the
steam into a high-velocity jet of steam with a reduced pressure and
energy
- the nozzles are arranged in different groups having control valves,
so we can control the speed as how many control v/v’ s are open
- material used Stainless iron or 67% Ni,28%Cu Monel metal
• Gland
-Steam is prevented from leaking out of the
rotor high-pressure end and air is prevented
from entering the low-pressure end by the use
of glands.
-Mechanical glands are usually of the labyrinth
type

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• Casing
– The turbine casing completely surrounds
the rotor and provides the inlet and
exhaust passages for the steam
– L.P casing is made of Cast steel
– H.P casing is made of 3% molybdenum
cast steel or
0.5% molybdenum,0.3% Va cast steel

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 LUBRICATING OIL SYSTEM
• Lubricating oil serves two functions in a steam turbine:
– 1. It provides an oil film to reduce friction between moving parts.
– 2. It removes heat generated in the bearings or conducted along
the shaft.

• The properties required are :-

– Anti corrosion
– Anti rust
– Anti foaming
– Stability against hydrolysis
– Demulsibility
– De aeration
– Stability at high temperatures
– Filterability with or with out water

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 • A common lubrication system is used to supply oil to the turbine,
gearbox and thrust bearings and the gear sprayers.

• Turbine rotating at very high speed requires time to stop, so if the

main l.o. pumps fails an emergency supply arrangement would be
necessary

• There are 2 systems

– Gravity system
– Pressure system

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 Gravity system

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• The oil is drawn from the sump via suction filter and magnetic filter and
pumped to the coolers
• Leaving the cooler, oil passes thru one more filter
• Then it is distributed to the gearbox, the turbine bearings and the gearbox
sprayers.
• Some of the oil also passes through an orifice plate and into the gravity
tank from which it continuously overflows (this can be observed through
the sight glass).
• In the event of a power failure the gearbox sprayers are supplied from
the engine driven pump.
• In the event of total pump failure oil can pass unrestricted thru the non
return valve to distribution points

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 Pressure system

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 Pressure system

• Oil is drawn from the sump by main and shaft driven pumps
• In the event of main pump failure (eg blackout), the shaft driven pump
will continue to deliver
• At low revolutions the oil pressure from the pump reduces, the supply of
oil I continued from the small gravity tank
• The total run out time is about 25 to 30 min,which is sufficient to start the
st-by pump or stop the machinery

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 Care And Testing Of Lubricating Oil
• Leakage of water from gland steam and water pipe glands must be
prevented
• Maintain correct oil temperature to avoid cracking of lube oil
• Maintain correct oil pressure(low pressure leads to starving of oil leading
to overheating)
• Temp differences across coolers to be checked and maintained
• Check bearing temp regularly
• Ensure ventilation system is in good order
• Operate oil purification system continuously
• Check the condition of filters regularly
• Samples of the oil to be taken and tested for the properties
• Tests done onboard:-
– Water and salt content
– Viscosity
– Total and strong acid numbers
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 Gearing
• Steam turbines operate at speeds up to 6000rev/min.
• This speed has to be reduced to 750rpm for power generation or to abt 80-
100rpm for propulsion
• The speed reduction is obtained with a system of gearing
• Helical gears were used for this
• Epicyclic gears are preferred b’cos of their compactness and light weight
construction

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 Epicyclic gearing
• This is a system of gears where one or more wheels travel around the
outside or inside of another wheel whose axis is fixed
• The different arrangements are known as planetary gear, solar gear and
star gear
• The wheel on the principal axis is called the sun wheel.
• The wheel whose centre revolves around the principal axis is the planet
wheel.
• An internal-teeth gear which meshes with the planet wheel is called the
annulus
• The different arrangements of fixed arms and sizing of the sun and planet
wheels provide a variety of different reduction ratios.

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 Planetary gear

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 Solar gear

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 Star gear

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 Steam turbine gearing may be double or triple reduction and will be
a combination from input to output of star and planetary modes in
conjunction with helical gearing

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 Helical gears
• Helical means that the teeth form part of a helix on the periphery of the
pinion or gear wheel.
• This means that at any time several teeth are in contact and thus the
spread and transfer of load is much smoother
• Double helical refers to the use of two wheels or pinions on each shaft
with the teeth cut in opposite directions.
• This is because a single set of meshing helical teeth would produce a
sideways force, moving the gears out of alignment
• The double set in effect balances out this sideways force.
• Single or double reduction systems may be used

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Double helical Single helical

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 Single reduction
• In single reduction, the turbine drives a pinion with a small number of
teeth and this pinion drives the main wheel which is directly coupled to the
propeller shaft

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 Double reduction system
• In double reduction the turbine drives a primary pinion which drives a
primary wheel
• The primary wheel drives, on the same shaft, a secondary pinion which
drives the main wheel
• The main wheel is directly coupled to the propeller shaft

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 gearing

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 Glands and gland sealing.
• Steam is prevented from leaking out of the rotor high-pressure end and
air is prevented from entering the low-pressure end by the use of glands
• A combination of mechanical glands and a gland sealing system is usual.
• Mechanical glands are usually of the labyrinth type.
• A number of pockets are provided in the gland sealing system
• Working of sealing system
– When the turbine is running at full speed steam will leak into the first
pocket and a positive pressure will be maintained there
– Any steam which further leaks along the shaft to the second pocket
will be extracted by an air pump or air ejector to the gland steam
condenser.
– Any air which leaks in from the machinery space will also pass to the
gland steam condenser
– At very low speeds or when starting up, steam is provided from a low-
pressure supply to the inner pocket.

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 Gland steam sealing system

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 Turbine drain system

• During warming through operations or when manoeuvring, steam will

condense and collect in various places within the turbine and its pipelines
• A system of drains must be provided to clear this water away
• Otherwise this water will be carried over into the blades and damage it
• Localised cooling or distortion due to uneven heating could also be
caused.
• Modern plants have automatic valve which opens when warming through
or manoeuvring and close when running at normal speed

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 Turbine protection

• A turbine protection system is provided with all installations to prevent

damage resulting from an internal turbine fault or the malfunction of
some associated equipment.
• Arrangements are made in the system to shut the turbine down using an
emergency stop and solenoid valve
• Operation of this device cuts off the hydraulic oil supply to the
manoeuvring valve and thus shuts off steam to the turbine
• main fault conditions are :
– 1. Low lubricating oil pressure.
– 2. Over speed.
– 3. Low condenser vacuum.
– 4. Emergency stop.
– 5. High condensate level in condenser.
– 6. High or low boiler water level

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 CONDENSERS

The primary functions of a condensing plant are:

o Extraction of air, non- condensible gases and vapours in the steam
o To create max vacuum by condensation so maximum steam work in the
turbine
o To fully condense the steam with no under cooling of the condensate
(i.e. reduction of condensate temperature below the steam temperature)

Work done by steam:-

the lower the exhaust pressure, for a given admission pressure , the work
done will be more
Steam at 0.1 bar occupies appx. 14000 times the vol it occupies as water so
that condensation in a closed space creates partial vacuum which can be
much increased by extracting the air and non condensable gases which hv
leaked into the system.

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Factors considered in selection of parameters
1. Velocity of cooling water in the tubes:
Mainly governed by the possibility of impingement
The velocities used give streamlined flow (erosion attack is reduced but
gives poor heat transfer)
Using titanium tubes the vel can be increased to turbulent flow with out
impengement attack
2. Number of passes of cooling water
3. Cooling water temperature
4. Condenser tube materials
5. Tube dimensions and distribution
6. Cleanliness of tubes
7. The quantity of air in the condenser and the capacity and efficiency of the
air ejectors

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• The condenser is a heat exchanger which removes the latent heat from
exhaust steam so that it condenses and can be pumped back into the
boiler. This condensing should be achieved with the minimum of under-
cooling, i.e. reduction of condensate temperature below the steam
temperature. A condenser is also arranged so that gases and vapours
from the condensing steam are removed.
An auxiliary condenser is shown in Figure The circular cross-
section shell is provided with end covers which are arranged for a two-
pass flow of sea water. Sacrificial corrosion plates are provided in the
water boxes. The steam enters centrally at the top and divides into two
paths passing through ports in the casing below the steam inlet hood. Sea
water passing through the banks of tubes provides the cooling surface for
condensing the steam. The central diaphragm plate supports the tubes
and a number of stay rods in turn support the diaphragm
plate. The condensate is collected in a sump tank below the tube banks.
An air suction is provided on the condenser shell for the withdrawal of
gases and vapours released by the condensing steam.

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• Main condensers associated with steam turbine propulsion
machinery are of the regenerative type. In this arrangement some of the
steam bypasses the tubes and enters the condensate sump as steam. The
condensate is thus reheated to the same temperature as the steam,
which increases the efficiency of the condenser. One design of
regenerative condenser is shown in Figure . A central passage enables
some of the steam to pass to the sump, where it condenses and heats the
condensate. A baffle plate is arranged to direct the gases and vapours
towards the air ejector. The many tubes are fitted between the tube
plates at each end and tube support plates are arranged between. The
tubes are circulated in two passes by sea water.

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 LEAK DETECTION
• Fluorescein leak detection:
– The condenser shell is drained and water containing the dye is slowly pumped
in. this water will pass thru’ any perforation in a tube wall and emerge from
the interior of the tube at the tube end. Ultra violet light illuminating the
outer end of the condenser will cause the water to fluoresce and so allow easy
detection of the faulty tube.
• Ultra sonic method :
– A ultra sonic generator is placed inside the condenser ‘floods’ it with ultra
sound. By using a head set and a probe ,the leaking tube can be spotted out.
where a pin hole exists ,sound ‘leaks’ through and where the tube is thinned it
vibrates like diaphragm transmitting the sound thru’ the tube wall
• Using steam :
– With a slight steam pressure in the condenser ,leakage of steam thur’ a pin
hole in the tube generates ultra sound which can be picked up a probe and a
head set
• vacuum method:
– Plastic sheets placed over the tube plate will be drawn in to a leaking tube
with the condenser under vacuum
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 TURBINE CONTROL

• There are two basic ways of controlling the steam the turbine

– Throttle control

• This utilises a single valve to control the flow of steam through

the complete power range. This means that if a ship operates at low
power for significant periods of time the steam entering the turbine has
been heavily
throttled and this adds to the losses involved in running at a point well
removed from full power for which the turbine will have been designed.

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Nozzle control

• In this case the inlet nozzles to the HP turbine are divided into
groups with each group supplied from its own individual control valve. In
this case the valves are closed sequentially as power is reduced so that
throttling only takes place on the steam being supplied to one group of
nozzles so minimising the losses. The most efficient way of operating at
reduced power is at a so called 'nozzle point' where one or more of the
nozzle valves are completely closed to give the desired reduction in
power, but those remaining in service are all fully open

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