Steam turbine

Prepared by: Mohammad Shoeb Siddiqui
Senior Shift Supervisor
Saba Power Company
Cell # +92 321 4598293

What is Steam Turbine?
 A Steam Turbine is a device that extracts Thermal
Energy from pressurized Steam and uses it to
do Mechanical Energy on a rotating output shaft.
 Steam Turbine is device where Kinetic Energy
(Heat) converted into Mechanical Energy (in shape
of rotation).
 Turbine is an Engine that converts Energy of Fluid
into Mechanical energy & The steam turbine is
steam driven rotary engine.
This Presentation is base on basic of Steam Turbine
& 134 MW Toshiba Steam Turbine.
Prepared by
Mohammad Shoeb Siddiqui

Rating & Design Data
 Turbine Type: SCSF-36, single cylinder, single flow
Reheat condensing turbine.
 Rated output: 134 MW
 Speed: 3000 RPM
 Direction of Revolution: Counter-clock-wise
(seeing from turbine front End)
 Steam Condition:
 Main Steam Press. (before MSV): 16548 kpa (g)
 Main Steam Temp. (before MSV): 538oC
 Reheat steam Temp. (before CRV): 538oC
 Exhaust pressure: 6.77 kpa (g)
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Rating & Design Data
 Number of Extraction: 6
 Number of Stage: 21
HP Turbine: 9 stages
IP Turbine: 7 stages
LP Turbine: 5 stages
 Number of Wheel: 21
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In order to better understand turbine operation, Four Basic
Classifications are discussed. Type of Steam Flow &
Division of Steam Flow, describes the flow of steam in
relation to the axis of the rotor. indicates whether the
steam flows in just one direction or if it flows in more than
one direction. Way of Energy Conversion & Type of
Blading, Reaction, Impulse and Impulse & Reaction
Combine. identifies the blading as either impulse blading
or reaction blading. Type of Compounding & Cylinder
arrangement refers to the use of blading which causes a
series of pressure drops, a series of velocity drops, or a
combination of the two. (number of cylinders; whether
single, tandem or cross-compound in design) Exhausting
Condition & Number of Stages is determined by whether
the turbine exhausts into its own condenser or whether it
exhausts into another piping system.
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1. Type of Steam Flow
Turbines may be classified
according to the direction of
steam flow in relation to the
turbine wheel or drum
- Axial.
- Radial.
- Mixed
- Tangential Or Helical.
- Reentry
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Radial Flow:
A turbine may also be
constructed so that the
steam flow is in a radial
direction, either toward or
away from the axis. In
figure illustrates an
impulse, radial
flow, auxiliary turbine such
as may be used as a pump
drive.
The radial turbine is not nor
mally
the preferred choice for
electricity generation and is
usually only employed for
small output applications Prepared by

Axial Flow:
The great majority of
turbines, especially those
of high power, are axial
flow. In such turbines the
steam flows in a direction
or directions parallel to the
axis of the wheel or rotor.
The axial flow type of turbi
ne is the most preferred for
electricity generation as
several cylinders can be
easily coupled together to
achieve a turbine with a
greater output.
.
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Reverse Flow
In some modern turbine designs the
steam flows through part of the high
pressure (HP) cylinder and then is
reversed to flow in the opposite
direction through the remainder of the
HP cylinder. The benefits of this
arrangement are:
 outer casing joint flanges and bolts
experience much lower steam
conditions than with the one direction
design
 reduction or elimination of axial
(parallel to shaft) thrust created within
the cylinder
 lower steam pressure that the outer
casing shaft glands have to
accommodate
A simplified diagram of a reverse flow high
pressure cylinder is shown in Figure Prepared by

2. Way of Energy Conversion & Types of Blading
- Impulse turbines
- Reaction turbines
- Impulse & Reaction Combine
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By Types of Blading:
The heat energy contained within the steam that
passes through a turbine must be converted
into mechanical energy. How this is achieved
depends on the shape of the turbine blades. The
two basic blade designs are:
1. Impulse
2. Reaction
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Impulse:
Impulse blades work on the principle
of high pressure steam striking or
hitting against the moving blades.
The principle of a simple impulse
turbine is shown in Figure.
Impulse blades are usually
symmetrical and have an entrance
and exit angle of approximately 200.
They are generally installed in the
higher pressure sections of the
turbine where the specific volume of
steam is low and requires much
smaller flow areas than that at lower
pressures. The impulse blades are
short and have a constant cross
section.
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Reaction:
The principle of a pure reaction turbine
is that all the energy contained within the
steam is converted to mechanical
energy by reaction of the jet of steam as
it expands through the blades of the rotor.
A simple reaction turbine is shown in
Figure. The rotor is forced to rotate as the
expanding steam exhausts the rotor arm
nozzles.
In a reaction turbine the steam expands
when passing across the fixed blades
and incurs a pressure drop and an
increase in velocity. When passing
across the moving blades the steam
incurs both a pressure drop and a
decrease in velocity
A section of reaction type blading is
shown in Figure
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Impulse stage
Whole pressure drop in
nozzle (whole enthalpy
drop is changed into
kinetic energy in the
nozzle)
Reaction stage
Pressure drop both in
stationary blades and in
rotary blades (enthalpy
drop changed into
kinetic energy both in
stationary blades and in
the moving blades in
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An impulse stage consists of
stationary blades forming
nozzles through which the
steam expands, increasing
velocity as a result of
decreasing pressure. The
steam then strikes the rotating
blades and performs work on
them, which in turn decreases
the velocity (kinetic energy) of
the steam. The stream then
passes through another set of
stationary blades which turn it
back to the original direction
and increases the velocity
again though nozzle action.
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In Reaction Turbine both the
moving blades and the non-
moving blades designed to act
like nozzles. As steam passes
through the non-moving
blades, no work is extracted.
Pressure will decrease and
velocity will increase as steam
passes through these non-
moving blades. In the moving
blades work is extracted. Even
though the moving blades are
designed to act like
nozzles, velocity and pressure
will decrease due to work
being extracted from the
steam.
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This utilizes the principle of
impulse and reaction. It is
shown diagrammatically :
There are a number of rows of
moving blades attached to the
rotor and an equal number of
fixed blades attached to the
casing. The fixed blades are set
in a reversed manner compared
to the moving blades, and act as
nozzles. Due to the row of fixed
blades at the entrance, instead of
nozzles, steam is admitted for
the whole circumference and
hence there is an all-round or
complete admission. Prepared by

Compounding of Impulse Turbine
 This is done to reduce the rotational speed of the
impulse turbine to practical limits. (A rotor speed
of 30,000 rpm is possible, which is pretty high for
practical uses.)
 Compounding is achieved by using more than one
set of nozzles, blades, rotors, in a series, keyed to
a common shaft; so that either the steam pressure
or the jet velocity is absorbed by the turbine in
stages.
 Three main types of compounded impulse turbines
are:
 a) Pressure compounded,
 b) velocity compounded and
 c) pressure and velocity compounded impulse turbines.
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With pressure compounding the total
steam pressure to exhaust pressure is
broken into several pressure drops
through a series of sets of nozzles and
blades. Each set of one row of nozzles
and one row of moving blades is referred
to as a stage
This involves splitting up of the whole
pressure drop from the steam chest
pressure to the condenser pressure into
a series of smaller pressure drops across
several stages of impulse turbine.
The nozzles are fitted into a diaphragm
locked in the casing. This diaphragm
separates one wheel chamber from
another. All rotors are mounted on the
same shaft and the blades are attached
on the rotor.
Pressure staging is also known as
RATEAU staging.
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When the velocity energy produced
by one set of fixed nozzles is unable
to be efficiently converted into
rotational motion by one set of
moving blades then it is common to
install a series of blades as shown in
Figure. This arrangement is known
as velocity compounding.
Velocity drop is arranged in many
small drops through many moving
rows of blades instead of a single
row of moving blades.
It consists of a nozzle or a set of
nozzles and rows of moving blades
attached to the rotor or the wheel and
rows of fixed blades attached to the
casing.
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This is a combination of
pressure-velocity compounding.
Most modern turbines have a
combination of pressure and
velocity compounding. This type
of arrangement provides a
smaller, shorter and cheaper
turbine; but has a slight
efficiency trade off.
Turbines using this
arrangement are often referred
to as CURTIS turbines after the
inventor. Individual pressure
stages (each with two or more
velocity stages) are sometimes
called CURTIS stages.
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This setup of a nozzle
followed by a set of moving
blades, non-moving
blades, and moving blades
makes up a single Curtis
stage. After steam exits the
nozzle there are no further
pressure drops.
However, across both sets
of moving blades there is a
velocity drop. This causes
the Curtis stage to be
classified as velocity
compounded blading.
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Turbines can be arranged either single cylinder or multi-stage in design.
The multi-stage can be either velocity, pressure or velocity-pressure
compounded (discussed as earlier.
Single cylinder construction or Single Flow Turbine
Single cylinder turbines have only one cylinder casing(although may be is
multiple sections). Steam enters at the high pressure section of the turbine
and passes through the turbine to the low pressure end of the turbine then
exhausts to the condenser. Figure shows a single cylinder turbine with a
high, intermediate and low pressure section contained within the one
cylinder casing.
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Tandem construction or Compound Flow Turbine
Dictated by practical design and manufacturers considerations modern
turbines are manufactured in multiple sections also called cylinders.
Greater output and efficiency can be achieved by coupling a number of
individual cylinders together in what is referred to as tandem (on one
axis).
Tandem compound
Large electric power generating turbines commonly have a high
pressure casing, which receives superheated steam directly from the
boiler or steam generator. The high pressure turbine may then exhaust
to an intermediate pressure turbine, or may pass back to a reheat
section in the boiler before passing to a reheat intermediate pressure
turbine. The reheat turbine may then exhaust to one or more low
pressure casings, which are usually two exhaust flow turbines, with the
low pressure steam entering the middle of the turbine and flowing in
opposite directions toward two exhaust end before passing into the
condenser. When the turbine casings are arranged on a single shaft, the
turbine is said to be tandem compounded.
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Tandem construction or Compound Flow Turbine
A tandem two cylinder turbine with a single flow high pressure (HP) cylinder and a
double flow low pressure (LP)cylinder is shown in Figure.
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Tandem Three Cylinder Turbine
It has a double flow LP cylinder with an IP cylinder arranged so that the
steam flow through it is in the opposite direction to the HP cylinder. This
design also greatly reduces the axial thrust on the rotor.
Tandem three cylinder turbine is shown in Figure as under:
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Tandem Four Cylinder Turbine
Large modern turbines are required to deliver high output and are
generally constructed of four cylinders with the exhaust steam from the
HP cylinder passing through are heater before entering the IP cylinder.
Tandem Four cylinder turbine is shown in Figure as under:
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Tandem Cross-Compounding Turbine
In cross compound turbines, the high-
pressure, exhaust passes over to
intermediate or low pressure casings which
are mounted on separate shafts. The two
shafts may drive separate loads, or may be
geared together to a single load.
In some larger overseas installations that
operate at 60 hertz (frequency) the use of
cross-compounding is some times employed.
Cross-compounding is where the HP and IP
cylinders are mounted on one shaft driving
one alternator while the LP cylinders are
mounted on a separate shaft driving another
alternator. This is done so as the LP cylinder
with its large diameter blading can be
operated at a greatly reduced speed thus
reducing the centrifugal force.
Tandem cross-compounding turbine is
shown in Figure:
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Tandem four cylinder turbine with reverse flow
The final turbine arrangement that is becoming increasingly popular is
the “Tandem four cylinder turbine with reverse flow HP cylinder, double
flow IP and twin double flow LP cylinders”. This arrangement is shown
in Figure:
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04. Number of Stages
- Single stage
- Multi-stage
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In an impulse turbine,
the stage is a set of
moving blades behind
the nozzle. In a
reaction turbine, each
row of blades is called
a "stage." A single
Curtis stage may
consist of two or more
rows of moving blades.

5. Exhaust Conditions
- Condensing
- Extraction
- Back-pressure
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By steam supply and exhaust conditions:
 Condensing
 Extraction, (Automatic or controlled )
 Non-condensing (back pressure),
 Mixed pressure (where there are two or more
steam sources at different pressures),
 Reheat (where steam is extracted at an
intermediate stage, reheated in the boiler, and re-
admitted at a lower turbine stage).
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Condensing
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The condensing turbine processes
result in maximum power and electrical
generation efficiency from the steam
supply and boiler fuel. The power output
of condensing turbines is sensitive to
ambient conditions.
The cooling water condenses the steam
turbine exhaust steam in the condenser
creating the condenser vacuum. As a
small amount of air leaks into the
system when it is below atmospheric
pressure, a relatively small compressor
(Vacuum pump) or Air Ejector System
removes non-condensable gases from
the condenser.

Extraction
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In an extraction turbine, steam is withdrawn from
one or more stages, at one or more
pressures, for heating, plant process, or feed
water heater needs. They are often called
"bleeder turbines.“
The steam extraction pressure may or may not
be automatically regulated. Regulated extraction
permits more steam to flow through the turbine to
generate additional electricity during periods of
low thermal demand by the CHP system. In utility
type steam turbines, there may be several
extraction points, each at a different pressure
corresponding to a different temperature. The
facility’s specific needs for steam and power over
time determine the extent to which steam in an
extraction turbine is extracted for use in the
process.

Back-pressure
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Figure shows the non-
condensing turbine (also
referred to as a back-
pressure turbine) exhausts its
entire flow of steam to the
industrial process or facility
steam mains at conditions
close to the process heat
requirements.

4. Rotational
Speed
- Regular
- Low-speed
- High-speed
5. Inlet steam
pressure
- High pressure
(p>6,5MPa)
- Intermediate
pressure(2,5MP
a <p<6,5MPa)
- Low-pressure
(p<2,5MPa)
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8. Application
- Power station
- Industrial
- Transport
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In actual practice, not all of the energy in the
steam is converted to useful work. Losses
common to all turbines are described
below:
Loss of working substance. Loss of steam
along the shaft through the shaft glands where
the shaft penetrates the casing.
Work loss. Loss due to mechanical friction
between moving parts.
Throttling loss. Wherever there is a reduction
in steam pressure without a corresponding
production of work, such as in a throttle valve.
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Leaving loss. The kinetic energy of the steam leaving
the last stage blading. This leaving loss can be
minimized by lightly loading the last stage blading by
increasing the annular exhaust area of the turbine. This
is often optimized through economic studies.
Windage loss. This is caused by fluid friction as the
turbine wheel and blades rotate through the
surrounding steam.
Friction loss as the steam passes through nozzles and
blading.
Diaphragm packing loss as the steam passes from one
stage to another through the diaphragm packing.
Tip leakage loss in reaction turbines as steam passes
over the tips of the blades without doing any useful
work.
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Rankine cycle with superheat
Process 1-2: The working fluid is
pumped from low to high pressure.
Process 2-3: The high pressure liquid
enters a boiler where it is heated at
constant pressure by an external heat
source to become a dry saturated vapor.
Process 3-3': The vapour is superheated.
Process 3-4 and 3'-4': The dry saturated
vapor expands through a turbine,
generating power. This decreases the
temperature and pressure of the vapor,
and some condensation may occur.
Process 4-1: The wet vapor then enters a
condenser where it is condensed at a
constant pressure to become a saturated
liquid.
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 Foundation
 Rotor or Shaft
 Cylinder or Casing
 Blades
 Diaphragm
 Steam Chest
 Coupling
 Bearings
 Labyrinth Seal
 Front Pedestal
 TSI
 D-EHC (Governor)
 MSV (Main Steam Stop Valve)
 CV(Control Valve)
 IV (Intercept Valve)
 CRV (Combined Reheat Valve)
 Turbine Turning Gear
 Turbine Bypass & Drains
 Atmospheric Relief
Diaphragm (Rupture Disk)
 Lube Oil System
 EHC Oil System
 Gland Steam System
 Condenser
 Steam Jet Ejector
 Vacuum Breaker
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 Frame (Base): Supports the stator, rotor and
governor pedestal.
 Shell: Consists cylinder, casing, nozzles, steam
chest & bearing.
 Rotor: Consists of low, intermediate, and high
pressure stage blades, and possible stub shaft (s)
for governor pedestal components, thrust
bearing, journal bearings, turning gear & main
lube oil system.
 Governor Pedestal: Consists of the EHC oil
system, turbine speed governor, and protective
devices
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An multistage steam turbines are
manufactured with solid forged
rotor construction. Rotors are
precisely machined from solid alloy
steel forgings. An integrally forged
rotor provides increased reliability
particularly for high speed
applications.
The complete rotor assembly is
dynamically balanced at operating
speed and over speed tested in a
vacuum bunker to ensure safety in
operation. High speed balancing
can also reduce residual stresses
and the effects of blade seating.
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The casings of turbine cylinders are
of simple construction to minimize any
distortion due to temperature changes.
They are constructed in two halves (top and
bottom) along a horizontal joint so that the
cylinder is easily opened for inspection and
maintenance. With the top cylinder casing
removed the rotor can also be easily
withdrawn with out interfering with the
alignment of the bearings.

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Most turbines constructed today either have a
double or partial double casing on the high pressure
(HP) and intermediate pressure (IP) cylinders. This
arrangement subjects the outer casing joint
flanges, bolts and outer casing glands to lower
steam condition. This also makes it possible for
reverse flow within the cylinder and greatly reduces
fabrication thickness as pressure within the cylinder
is distributed across two casings instead of one. This
reduced wall thickness also enables the cylinder to
respond more rapidly to changes in steam
temperature due to the reduced thermal mass.

The high-pressure end of the turbine is
supported by the steam end bearing housing
which is flexibly mounted to allow for axial
expansion caused by temperature changes.
The exhaust casing is centerline supported on
pedestals that maintain perfect unit alignment
while permitting lateral expansion. Covers on
both the steam end and exhaust end bearing
housings and seal housings may be lifted
independently of the main casing to provide
ready access to such items as the bearings,
control components and seals.
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HP Turbine Casing
IP Turbine Casing
LP Turbine Casing
Atmosphere Relief Diaphragm
HP Turbine Casing
CV
CV
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One method of joining the top
and bottom halves of the
cylinder casing is by using
flanges with machined holes.
Bolts or studs are insertion into
these machined holes to hold
the top and bottom halves
together.
To prevent leakage from the
joint between the top flange and
the bottom flange the joint faces
are accurately machined. A
typical bolted flange joint is
shown in Figure.
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Another method of joining
the top and bottom cylinder
flanges is by clamps bolted
radially around the outer of
the cylinder. The outer faces
of the flanges are made
wedge-shaped so that the
tighter the clamps are pulled
the greater the pressure on
the joint faces. This method
of joining top and bottom
casings is shown in Figure.
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Blade design is extremely important in attaining
high turbine reliability and efficiency. A large
selection of efficient blade profiles have been
developed and proven by extensive field service
allowing for optimal blade selection for all
conditions of service. Blades are milled from
stainless steel within strict specifications for proper
strength, damping and corrosion resistant
properties.
Disk profiles are designed to minimize centrifugal
stresses, thermal gradient and blade loading at the
disk rims.
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09HP Turbine Blades
07 IP Turbine Blades
05 LP Turbine Blades
Rotary Blades

Partitions between pressure stages in a
turbine's casing are called diaphragms. They
hold the vane-shaped nozzles and seals
between the stages. Usually labyrinth-type
seals are used. One-half of the diaphragm is
fitted into the top of the casing, the other half
into the bottom.
Nozzle rings and diaphragms are specifically
designed and fabricated to handle the
pressure, temperature and volume of the
steam, the size of the turbine and the required
pressure drop across the stage. The nozzles
used in the first stage nozzle ring are cut from
stainless steel. Steam passages are then
precision milled into these nozzle blocks
before they are welded together to form the
nozzle ring.
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The nozzles in the intermediate
pressure stages are formed from
profiled stainless steel nozzle sections
and inner and outer bands. These are
then welded to a circular center section
and to an outer ring then precision
machined.
The low-pressure diaphragms in
condensing turbines are made by
casting the stainless nozzle sections
directly into high-strength cast iron. This
design includes a moisture catching
provision around the circumference
which collects released moisture and
removes it from the steam passage.
Additional features such as windage
shields and inter-stage drains are used
as required by stage conditions to
minimize erosion. All diaphragms are
horizontally split for easy removal and
alignment adjustment. Mohammad Shoeb Siddiqui
Steam Turbine Components And Relative Equipments

Various root fixing shapes have been
developed for turbine blading to suit
both construction requirements and
conditions under which turbines
operate. The most popular types of
blade root fixing available are:
 Grooves
 Straddle
 Rivet

Groove construction
The groove type of root fixing fits into a
machined grove around the
circumference of the rotor wheel or
disc. Some examples of typical groove
type blade root designs are shown in
Figure A while a rotor disc with a
machined groove arrangement is
shown in Figure B.
Blade roots are installed through the
closing blade window and then slid
around the circumference of the disc
into their desired position. The last
blade root is installed in the closing
blade opening and secured in position
by dowel(s).

Straddle construction
Straddle construction is where the
blade root fits over the machining on
the outer periphery of the rotor wheel
or disc. An example of straddle fir-tree
blade root construction is shown in
Figure A. while the disc peripheral
machining is shown in Figure B.
Once again with this type of
construction the blade roots are
installed through the closing blade
window slid around the circumference
of the disc into position, then the last
blade inserted is doweled in the closing
blade window location.

Rivet construction
Rivet construction is where the blade root
either inserts into a groove or straddles the
disc and all blades are doweled into position.
Peripheral blade fixing
On larger blading where the blade length is
relatively long a system of lacing wire or
shroud rings are installed to give the blading
additional support and reduce
vibration. The lacing wire is installed a small
distance from the outer ends of the blades
while the shoud rings are fitted to tangs on
the outer edges of the blades and secured by
peening the tangs. A section of blading
showing the installation of the lacing wire is
shown in Figure A while a section of blading
showing shroud ring installation is shown in
Figure B.

Steam chest: The steam
chest, located on the
forward, upper half of the
HP turbine casing, houses
the throttle valve assembly.
This is the area of the
turbine where main steam
first enters the main engine.
The throttle valve assembly
regulates the amount of
steam entering the turbine.
After passing through the
throttle valve, steam enters
the nozzle block.
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With multi-cylinder turbines it is necessary to have
some method of connecting individual cylinder rotors.
It is also a requirement to connect the turbine to the
alternator rotor. To achieve these connections we
use a device known as a coupling. These couplings
must be capable of transmitting heavy loads and in
some turbines are required to accommodate for axial
expansion and contraction.
The types of couplings generally employed in power
plants are:
 Flexible coupling
 Solid shaft coupling
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Flexible couplings
Where axial shaft movement is required a flexible
coupling is employed and these are either:
1. Sliding claw (or tooth)
2. Flexible connection (between the two flanges)
With both of the above flexible couplings it is
necessary to have a separate thrust bearing for
each shaft to maintain the same relative position
between rotor and cylinder casing.
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Sliding claw (or tooth)
Sliding claw couplings consists of an inner
gears or tooth coupling half. The inner
half is shrunk onto its respective shaft
and secured by keys or driven pins.
The outer coupling half; machined in
the reverse shape is installed onto the
other shaft.
The gear or teeth coupling is positioned
inside the outer coupling half where it
is able to slide back and forth to allow
for expansion or contraction.
A diagram of a sliding claw coupling
prior to the inner claw section being
inserted into the outer half is shown in
Figure A, while a gear tooth coupling is
shown in Figure B.
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Flexible connection coupling
Flexible connections such as the bibby
coupling are constructed in two
halves. Each half is shrunk onto their
respective shaft and secured with keys
or driven pins. The halves are
machined with groves parallel or
nearly parallel to that of the alignment
of the shaft. Flexible spring steel grids
are inserted into these machined
groves and held in place with an outer
cover. This type of coupling is effective
in allowing axial expansion and
contraction along with the ability to
tolerate minor misalignment. A bibby
coupling is shown in Figure.
The flexible couplings just mentioned
are by no means the only flexible
couplings available but they are the
preferred choice for high load
applications.
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Solid shaft coupling
When shaft movement is not
required it is usual to install a
solid type coupling. Two flanges
are installed onto their
respective shafts and then the
two flanges are bolted together
to form a solid joint as shown in
Figure A.
Often teeth are machined on the
outer rim of these couplings and
used as a point for barring the
turbine shaft. (more about
barring the turbine later). Figure
B shows a solid shaft coupling
with a barring gear fitted Prepared by

Turbine Bearings
 Journal Bearing:
The turbine rotors are
supported by two journal
bearings. Both the No.1
and No.2 bearings are
of a double-tilting pad
type. The bearing metal
is divided into six pads
which are self-aligned. A
center adjustment of
these bearings can
easily be made with
shimmed pads.
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Turbine Bearings
Journal Bearing Design Data:
Bearing # Location Type
Nominal dia in
inches
Nominal
effective width
in inches
1 HP DTP 15” 8”
2 LP DTP 18” 12”
Note; D.T.P stands for Double Tilting Pad
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Turbine Bearings
DOUBLE TILTING PAD TYPE
JOURNAL BEARING
Double tilting pad bearing provides
maximum stability and freedom
from shaft vibration. The tilting-pad
design consists generally of six
steel pads (shoes) with Babbitt
linings on the bearing surface. The
pads are installed on the inner of
bearing ring, and can move radial
and axial direction. Therefore, the
pads Move smoothly, and maintain
the correct alignment at all
conditions. Hook fits in the inner of
bearing ring retain the pads, and the
pads are prevented from rotating by
means of loose-fitting lock pins. Prepared by

Turbine Bearings
TAPERED-LAND
THRUST BEARING
The thrust bearing is
located on the main
shaft of the turbine.
Independently mounted
inside the standard, the
thrust bearing absorbs
the axial thrust of the
turbine and generator
rotors, which are
connected by a solid
coupling.
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Turbine Bearings
TAPERED-LAND THRUST
BEARING
This tapered-land thrust
bearing consists of two
stationary thrust plates and
two rotating Thrust collars
on the turbine shaft which
will provide the front and
back faces to the bearing.
These plates are supported
in a casing so that they
may be positioned against
the rotating faces of the
collars. The thrust collar
faces are machined and
lapped, producing
smooth, parallel surfaces. Prepared by

Thrust
Bearing
Thrust Bearing
# 1 General
Bearing
General Bearing
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A labyrinth seal is a type
of mechanical seal that
provides a tortuous path to
help prevent leakage. An
example of such a seal is
sometimes found within
an axle's bearing to help
prevent the leakage of the oil
lubricating the bearing.
A labyrinth seal may be
composed of
many grooves that press
tightly inside another axle, or
inside a hole, so that the fluid
has to pass through a long
and difficult path to escape. Prepared by

Labyrinth seals are utilized as
end gland seals and also inter-
stage seals. Stationary labyrinth
seals are standard for all
multistage turbines and grooves
are machined on the rotating part
to improve the sealing effect. The
leakage steam from the outer
glands is generally condensed by
the gland condenser. Some
leakage steam from the
intermediate section of the steam
end gland seals can be
withdrawn and utilized by re-
injecting it into the low-pressure
stage or low- pressure steam
line. Prepared by

Turbine front standard
supports the No.1
bearing, thrust bearing and
the front end of the turbine
casing. Front standard is
shaped like a box. Upper
half of the standard can be
disassembled at horizontal
flange. A manhole located
front of upper half is used
oil strainer maintenance.
This box is not only the
bearing standard but control
box which contains some
important equipment. Prepared by
FRONT STANDARD & TSI

There are some instruments
and button on the outside of
the front pedestal cover.
These are used for turbine
operation and supervision.
Some protective devices
and speed detectors are
installed inside the
standard. Inside space of
the standard is connected to
oil tank and is kept slightly
vacuum so that the oil drain
or mist inside can not leak
out. Prepared by

Lubricating oil is
supplied from oil
pipe which is
located left side of
front standard and
flow out to oil tank
through 1ST journal
and thrust bearings.
Oil strainer is
located up stream of
bearing.
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Toothed-wheel for speed sensors
The turbine rotating speed is
sensed by the magnetic pickups
faced to the toothed-wheel (96
teeth) installed on the control rotor.
The pulse signal is produced when
each tooth passes the pickups. The
frequency signals from two (2)
pickups are converted into digital
value proportional to the turbine
speed through F/D (Frequency to
Digital) converters.
Other three (3) sensors are located
around toothed-wheel. These
sensors are used for trip detector.
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The electromagnetic pickup use for
speed detector is fixed facing the
tooth face of the speed detecting
gear connected directly to the rotor
end of the turbine. (Inside of front
standard) The turbine speed can be
detected as the sine wave frequency
signal in proportion to the turbine
speed. This frequency signal is
converted to an digital signal by
means of the F/D converter to
become a feedback signal to the
speed control circuit.
Over speed detector also make
frequency signal in proportion to the
turbine speed. They face to tooth-
wheel on control rotor. Pickup is
used eddy current type. Clearance
between sensor face and tooth face
is different from electromagnetic
pickup type.
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Turbine Supervisory Instrumentation (TSI) or Turbine
Supervision Equipment (TSE) is a generic term used in
the power generation industry. TSI refers to
instrumentation systems that specifically perform
measurements of critical control parameters on large
steam turbine generator trains.
The size of the machines can range between 50–1200
MW and their age can often be in excess of 30 years.
TSI systems are normally a mandatory requirement.
The same technology is employed on other turbine
types and in other industries, such as the hydrocarbon-
processing sector.
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Although the turbine is not readily accessible during operation, the turbine
supervisory instrumentation is sufficient to detect any potential malfunction.
The turbine supervisory instrumentation includes monitoring of the following:
(1) Vibration and eccentricity
(2) Thrust bearing wear
(3) Exhaust hood temperature and spray pressure
(4) Oil system pressures, levels, and temperatures
(5) Bearing metal and oil drain temperatures
(6) Shell temperature
(7) Valve positions
(8) Shell and rotor differential expansion
(9) Shaft speed, electrical load, and control valve inlet pressure indication
(10) Hydrogen temperature, pressure, and purity
(11) Stator coolant temperature and conductivity
(12) Stator-winding temperature
(13) Collector air temperatures
(14) Turbine gland sealing pressure
(15) Gland steam condenser vacuum
(16) Steam chest pressure
(17) Seal oil pressure
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The use of, and experience with, TSI
assists in reducing operating costs of the
generation units by:
• Reducing Turbine Roll Time:
During the run-up and coast-down of
large turbines, there are extensive soak
periods to ensure stationary and rotating
parts thermally expand equally. These
periods are usually of a conservative
length, but times can be further reduced
with continuous and accurate
measurement of key expansion clearances
(and related parameters) available with
TSI systems.
• Time Between Overhauls:
By using precise TSI measurement
information, in an outage, the exact
amount of work can be scheduled with
reduced risk of unknown problems
occurring after the overhaul is completed.
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Diagnostic and Troubleshooting
The trending of TSI data provides
the user with the machine’s basic
operating characteristics. Early
detection of changes in trended data
and comparison to normal
conditions allows decisions to be
made more quickly and
inexpensively. More advanced
analysis methods of this same
raw data can diagnose problems like
mass unbalance, misalignment,
loose or broken parts, shaft cracks,
seal rubs, and bearing instabilities
caused by improper lubrication or
bearing design. Early identification
of these problems allows for
corrections to be made at a time that
is convenient to both the work force
and system load.
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Automatic Shutdown
Sometimes unanticipated problems arise quickly, however, TSI
has the capability to limit damage to the machine and protect
against total destruction or catastrophic failure. Confining
damage flagged by vibration can make the difference between a
two week outage and three to six months of down time.
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TSI system measurements can be broken down into four major
categories:
Motion Measurements
Eddy current (proximity) probes, case mounted velocity
(seismic) transducers, shaft riders, and/or accelerometers can be used
to monitor vibrations. Monitoring points may include vibration on
main turbine generator and exciter, may also be used to measure rotor
eccentricity.

Position Measurements
Eddy current probes, LVDTs and
linear/rotary potentiometers can be used
to monitor thrust bearing wear, rotor
position, casing (shell)
expansion, differential expansion and
control valve position.
Speed Measurements
Active or passive electromagnetic or eddy
current probes can be used to monitor
main turbine speed and
acceleration, over-speed detection, zero
speed detection.
Process Measurements
Thermocouples or RTDs can be used to
monitor bearing white metal
temperature, shell differential
temperature, and lube oil temperature.
Piezoelectric or strain gauge pressure
transducers can be used to measure oil
and hydraulic pressures. Prepared by

Thermocouples for water Induction
When water flows into the turbine due to an
unexpected accident, there occurs a difference in
temperature between the upper half and the lower
half of the casing. As a result, (humped effect)
phenomenon is generated on the casing, giving
great damages to HP and IP casings, rotor
blade, and thrust bearing. To detect any flow of
water, therefore, thermocouples are provided at
several positions of the upper and lower parts of
the casing respectively to watch the difference in
temperature between the upper and lower parts of
the casing.
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At the time of cold starting of the turbine, there
occurs a difference in temperature between the
internal and external surfaces of casing with
subsequent generation of thermal stress, which
shortens the lives of turbine parts, To control the
lives of turbine parts, a thermocouple is
provided at each part of the casing for the
purpose of carrying out life control for the parts.
For the information on the fitting positions, see
the thermocouples mounting drawings.
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Principles Of Governing
During operation of a Turbine-Generator Unit
the Load carried by the Generator may vary
over time. In order to respond to changing
System Load demands the amount of steam
directed to the Turbine must be varied in
proportion to each demand.
The function of a governor is to provide rapid
automatic response to load variations.
STEAM TURBINE SPEED CONTROL

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The Speeder Gear of a Turbine
Governor
In order to maintain the system
frequency constant and at the
same time allow load variation to
occur, it is necessary to be able to
compensate for the loss of speed
experienced with increasing load
and the speed increase which
accompanies load rejection. To
achieve this a device is fitted in
conjunction with the governor
which effectively changes the
speed-load characteristic of the
turbine in such a way that speed
effectively becomes independent
of load. The device is known as
the speeder gear.

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Relays
In all but the smallest turbine, it is necessary to use some
means of amplifying the power of the governor in order to
maintain a small sensing and control device and yet still
have the motive force to position large sized throttle valves.
The devices used as amplifiers are known as relays. The
most common type of relay uses an oil system employing
valve and a power piston. There are two types of these
relays in use:
• Double acting
• Single acting

System Features
Application:
D-EHC system can be applied to control, protection and monitoring of steam
turbines for various type of power plants including conventional fossil-fired
power plants, combined cycle plants, co-generation plants, and atomic power
plants.
Powerful and reliable controllers:
High-speed control with state-of-the-art microprocessor based control system
Distributed and hierarchical architecture consists of;
System controller, Master controller, Programmable logic device,
Valve interface
Normal Operation:
During Normal Operation, the main stop valves, intermediate stop valves
and intercept valves are wide open. Operation of the T-G is under the control
of the Electro-Hydraulic Control (EHC) System. The EHC System is
comprised of three basic subsystems: the speed control unit, the load control
unit, and the flow control unit. The normal function of the EHC System is to
generate the position signals for the four main stop valves, four main control
valves, and intermediate stop valves and intercept valves. Prepared by

Improved monitoring and
operation ability:
Windows-2000¨ based HMI
(Human Machine Interface) and
IES (Integrated Engineering
System)
Standard interface (RS232C
Modbus, TCP/IP Ethernet, opc,
etc.) with external systems
Fully automatic turbine
startup sequences
turbine is automatically started
based on start up sequence
determined by inlet
steam/turbine metal
temperature miss-match, which
enables optimum operation and
longer equipment life.
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D-EHC System (Steam Turbine Startup)
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Auto Start Sequence Manual Start

 Turbine speed and Load Control
 Automatic Turbine Start-up control
 Line Speed Matching Control
 Full Arc admission (FA)/Partial Arc admission (PA) Transfer, if applicable
 Initial Pressure Regulator (IPR)
 Power Load Unbalance (PLU)
 Turbine Trip Function
 Turbine Trip Initiation (Primary overspeed, backup overspeed, EHC failure)
 Test Function (Valve Test, Overspeed Trip Test, Back up Overspeed Trip
Test)
 Control and monitoring function of turbine generator auxiliaries
 Extraction Steam Pressure Regulation (if applicable)
 Thermal Stress Calculation
 TSI (Turbine Supervisory Instruments) monitoring
 Back up operation and monitoring at monitor panel of EHC cabinet
 Interface with Distributed Control System (DCS) Prepared by

The main stop valve is located
in the main steam piping
between the boiler and the
outlet piping to turbine control
valve chest in turbine casing.
The main stop valve has one
inlet and two identical outlet
pipe connections. Outlet pipes
are welded directory.
The primary function of the
main stop valves is to quickly
shut off the steam flow to the
turbine under emergency
conditions such as failure of the
control valves to close on loss
of load.
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The control valves are
arranged into an upper
and lower valve group
with each group mounted
on common chest which is
an integral part of the
upper and lower turbine
outer shells.
Each control valve admits
steam from the valve
chest of its group to an
individual nozzle box, after
that controlled steam flow
into a particular section of
the turbine first stage
nozzles.
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During starting and loading operation without
turbine bypass system the intercept valves are
operated fully opened for full arc admission
starting. They remain fully open during transfer
of steam flow control to the control valves, as
well as all other periods of normal operation. The
other side, when turbine bypass system is
available for the starting up and loading. The
intercept valves are used to control the steam
flow to the intermediate turbine in conjunction
with the control valves. After the turbine bypass
operation is finished the intercept valves will be
fully opened by EHC control system.
The primary function of the intercept valve is
pre-emergency protection: however, they also
trip closed upon actuation of the emergency trip
system. The secondary one is to control the steam
flow during the starting and loading with
turbine bypass system. The reheat stop valve is
provided to quickly shut off the steam flow
storage in the reheater line to the turbine under
emergency condition.
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Two combined reheat
valves are provided, one
in each hot reheat line.
Supplying reheat steam to
the turbine. As the name
implies. The combined
valve is actually two valve.
The intercept valve and
the reheat stop
valve, incorporated in one
valve casing. Although
they utilize a common
valve casing, these valves
provide entirely different
functions. Prepared by

The motor driven turning gear
is mounted on the turbine
bearing cap, adjacent to the
turbine-generator coupling so
as to mesh with a bull gear
(spacer disk gear type). Which
is bolted between the turbine-
generator coupling faces.
The primary function of the
turning gear is to rotate the
turbine-generator shaft slowly
and continuously during
shutdown periods when rotor
temperature changes occur.
Turning Gear
Driven Motor
Turning Gear
Driven Chain
Turning Gear
Turning Gear Oil Supply
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When the turbine is shutdown, cooling of its inner
elements is continues for many hours. If the rotor
is allowed to remain stationary during this cooling
period, distortion begins almost immediately. This
distortion is caused by the flow of hot vapors to
the upper part of the turbine casing, resulting in
the upper half of the turbine being at a higher
temperature than the lower half. The parts do not
return to their normal position until the turbine has
cooled to the point where both the upper and
lower halves are at approximately the same
temperature.

Water induction can happen at any time;
however the most common situations are
during transients such as start up, shut
down and load changes. In figure
illustrates the percentage of times various
events contribute to water induction for a
conventional steam cycle. It is interesting
that only 18 percent of water induction
incidents occur when the unit is at load.
Turbine drains are necessary to avoid
slugging nozzles and blades inside the
turbine with condensate on start-up; this
can break these components from impact.
The blades were designed to handle
steam, not water.
Turbine casing drains remove the
condensate from the turbine casing during
warm-up, securing, maneuvering and other
low flow conditions. Prepared by

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Turbine Water Induction Protection (TWIP)
Turbine Water Induction Protection, often
abbreviated as TWIP, is the broad category of
equipment that is installed to prevent water
damage to steam turbines. Any connection to
the turbine is a potential source of water either
by induction from external equipment or by
accumulation of condensed steam. Steam
turbine damage by water induction is a costly
economic, safety and reliability concern. The
American Society of Mechanical Engineers
(ASME) formed a committee to address this
issue, and the first standard was issued in
1972. ASME publication ASME TDP-1-1998 is
titled “Recommended Practices for the
prevention of Water Damage to Steam Turbines
used for Electric Power Generation”. This
practice covers the
design, operation, inspection, testing, and
maintenance of these systems. TWIP
equipment is installed in the following power

In Figure shows a typical drain pot with redundant
level elements. This configuration is typically used in
"high risk" areas. One change in this standard that
is shown is the level sensing device, which is
labeled as a level element (LE). Drains should be
installed at each low point in the motive steam
piping. Drain Pots are recommended at the
following locations to enhance condensate
collection:
Cold reheat line at first low point downstream of the
steam turbine exhaust. (This application requires
redundant level elements.)
Motive steam lines that operate (admit steam to the
steam turbine continuously) with less than 100 F
(56 C) superheat unless a continuous drain has
been provided. (This application requires redundant
level elements.)
Motive steam lines with attemperators - e.g.
attemperator in HP steam line. The drain pot should
be between the attemperator and the steam turbine.
(This application requires redundant level Prepared by

Prepared by
Turbine Water Induction Protection (TWIP)
1. Main steam system, piping and drains 6. Turbine drain systems
2. Reheat steam systems, piping and
drains
7. Turbine steam seal system, piping and
drains
3. Reheat attemperating system 8. Main steam attemperator sprays
4. Turbine extraction systems, piping and
drains
9. Start-up systems
5. Feedwater heaters, piping and drains 10. Condenser steam and water dumps.
TWIP equipment is installed in the following power plant systems:
Avoid discharging high-energy bypass steam into the area between the condenser
hotwell and the tube bundle
Locate the curtain spray and bypass sprayer a safe distance from the condenser
tube bundles to allow a sufficient reduction in kinetic energy, so that high-energy
steam does not reach areas above and below the tube bundles and cause a
recirculation backflow with entrained water toward the turbine.
Determine an incidence angle of high-energy steam jets that will avoid reflected
velocity vectors toward the turbine exhaust.

Water induction damage
Water induction can damage steam turbines in several ways. The
damage can be caused by the impact of large slugs of water or by
the quenching effect of cold water on hot metal. The severity of
water damage can vary from minor seal rubs all the way to
catastrophic damage to the turbine. Generally, water damage
falls into the following categories:
Thrust bearing failure
Damaged blades
Thermal cracking
Rub damage
Permanent warping distortion
Secondary effects
Secondary effects include items such as seal packing ring
damage, pipe hangar and support damage, damage to
instrumentation and controls, etc. Prepared by

Sources of water induction
Water can be inducted into a steam turbine from several
sources. The following are some of the most common
sources of water:
Motive steam systems
Steam attemperation systems
Turbine extraction/admission systems
Feedwater heaters
Turbine drain system
Turbine steam seal system
Start-up systems
Condenser steam and water dumps (steam bypass)
Steam generator sources
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Turbine bypass systems should be
provided with the same level of protection
as motive steam piping. These should
include drains and drain pots (if applicable)
with power-operated drain valves.
Attemperators in bypass systems that
discharge to the cold reheat system (or any
other line connected back to the steam
turbine) should be designed to the same
requirements on motive steam system
attemperators. Non-return valves should be
provided in the cold reheat system to
prevent the reverse flow of bypass steam
into the steam turbine. Designers should
carefully consider the location, design and
orientation of large steam dumps (such as
turbine bypasses) into the condenser.
Prepared by
Turbine Bypass system

The atmospheric relief diaphragm is a safety feature
which protects the exhaust hood and condenser
against excessive steam pressure in case the
condenser water for any reason is lost.
The device consists of hard rolled silver bearing
copper sheet of sufficient area to pass full throttle
steam flow at a safe protective pressure. In normal
operation of the turbine with proper vacuum
conditions, the diaphragm is dished inward against
the supporting grid by atmospheric pressure should
the vacuum conditions fail for any reason and the
internal exhaust hood pressure raise to approximately
5 psig, it would force the diaphragm outward against
the cutting knife. The diaphragm would be cut free as
a disk relieving the exhaust pressure to atmosphere.
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Function
The function of lubrication is to interpose a film of
lubricant such as grease or oil between the moving
surfaces in a bearing.
Lubrication reduces friction, minimizes
wear, provides cooling and excludes water and
contaminants from bearing components. The
protection of rotating heavy machinery depends
greatly on the effective operation and supervision of
lubricating oil systems and bearings.
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Establishment of Oil Film
Oil lubricated bearings rely on the physical separation
of the two bearing surfaces by a thin film or wedge of
oil. In order to establish and maintain this oil film the
following conditions must be established.
1) There must be relative motion between the two beari
ng surfaces to build up sufficient pressure within the oil
to prevent the film breaking down.
2) There must be an uninterrupted supply
of oil available to the bearing.
3) The bearing surfaces must not be parallel and need
a narrow angle between them. This is to enable the oil
to be shaped into a thin wedge tapering off in the
direction of the motion

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Oil Film Dynamics
1). With the shaft at rest the journal lies in the
bottom of the bearing. The weight of the shaft
tends to squeeze the oil out of the bearing so
that metal to metal contact occurs.
2). As the shaft commences to rotate the first
action of the journal is to climb up the bearing
wall until it begins to slip and some metal to
metal contact occurs.
3) As the shaft continues to increase in speed
the oil is dragged around by virtue of viscosity
until it forms a thin oil wedge. it's

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Oil Film Dynamics
4) With the shaft now at
final or rated speed the
increased pumping action
on the oil increases the
journal internal oil
pressure. This displaces
the journal from the
central position in the
bearing enabling an ideal
oil wedge to be created.

Prepared by
Components of a Turbine Lubricating
Oil System
• Main Oil Tank
• Oil Purification Systems
• Oil Pumps
• Oil Coolers
• Strainers / Filters
• Instrumentation
• Jacking Oil Pumps
• Hydraulic Accumulator

Prepared by
The purpose of the
gland steam system
is to reduce steam
leakage to a
minimum and to
prevent air ingress.
Or
Function of the gland
sealing system falls
into two categories:
• Seal the turbine
glands under all
operating conditions
• Extract leak-off steam
from the turbine
glands.

Prepared by
Steam leakage leads to the requirement for
increased make up; this increases the load on
the feed and boiler water treatment chemicals
and to a deterioration of the working
environment surrounding the power plant.
Air ingress leads to a loss of vacuum and hence
reduction in plant efficiency, and causes
problems of thermal stressing around the gland
as well as increases oxygen content of the
exhaust steam.

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Gland Steam Condenser
The gland steam condenser is cooled by the
condensate extracted from the main condenser and so
acting as a feed heater. The gland steam often shares
its condenser with the air ejector reducing the cost of
having two units.
A fan is fitted to induce a flow through the system
without incurring a negative pressure in the final
pocket as this would allow the ingress of air. This is
ensured by the fitting on valves to the exhaust line
from the glands so enabling the back pressure to be
set.

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A surface condenser is a
commonly used term for a water-
cooled shell and tube heat
exchanger installed on the
exhaust steam from a steam
turbine in thermal power
stations. These condensers are heat
exchangers which convert steam
from its gaseous to its liquid state at
a pressure below atmospheric
pressure. Where cooling water is in
short supply, an air-cooled
condenser is often used. An air-
cooled condenser is however
significantly more expensive and
cannot achieve as low a steam
turbine exhaust pressure as a water-
cooled surface condenser.

Prepared by
For water-cooled surface
condensers, the shell's internal
vacuum is most commonly
supplied by and maintained by an
external steam jet ejector system.
Such an ejector system uses
steam as the motive fluid to
remove any non-condensable
gases that may be present in the
surface condenser. The Venturi
effect, which is a particular case
of Bernoulli's principle, applies to
the operation of steam jet ejectors.
Motor driven mechanical vacuum
pumps, such as the liquid ring
type, are also popular for this
service.

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The purpose of a Vacuum Breaker Valve is to quickly
allow air into the vacuum space of the condenser and
low pressure turbine exhaust hood. The vacuum
breaker valve is usually located on the steam turbine
or the condenser shell/transition.
A vacuum breaker valve is typically operable by a
controller responsive to losses of load on the steam
turbine.
Once opened, the vacuum breaker valve will allow air
into the steam space to quickly reduce the existing
vacuum and hence reduce the acceleration of the
steam turbine upon loss of load by the generator.

(1) Emergency trip pushbutton in control room
(2) Boiler Trip, Turbine trip
(3) Low condenser vacuum
(4) Low lube oil pressure
(5) LP turbine exhaust hood high temperature
(6) Thrust bearing wear
(7) Emergency trip at front standard
(8) Low hydraulic fluid pressure
(9) Loss of EHC
(10) Excessive turbine shaft vibration
(11) Loss of two speed signals - either Normal Speed Control or
Emergency Over speed Trip
(12) Over Speed Trip 1
(13) Over Speed Trip 2
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Prepared by
Saba Power Plant
Pakistan
shoeb.siddiqui@sabapower.com
shoeb_siddiqui@hotmail.com
shoeb_siddiquipk@yahoo.com

Steam turbine

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