WORK SHOP ON STEAM TURBINES & AUXILIARIES –

DESIGN, PERFORMANCE AND MAINTENANCE ASPECTS

TDBFP DESIGN ASPECTS AND

PERFORMANCE ISSUES

R. Kiran
Dy. Manager
BHEL-Hyderabad
 Contents
 Review of thermodynamics
 Basic principle of steam turbine
 Classification of steam turbine
 Thermodynamic calculation
 Steam turbine selection and design codes
 Axial thrust calculation
 Turbine gland sealing
 BFP Drive turbine -Thermodynamic design
 Operating conditions of BFP
 Operating conditions of BFPDT
 Design inputs required for BFPDT
 Typical data of BFPDTs
 Possible improvements of BFPDT
 Performance issues

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Review of Thermodynamics (Contd.)

Thermodynamic Cycles - CARNOT CYCLE

 The basic cycle to all power cycles is Carnot cycle.

It provides a bench mark with which a
comparison can be made of a power cycle to
determine how non-ideal the individual power
cycle is.

 Carnot cycle is a reversible cycle.

 Carnot efficiency is to be considered as an upper

limit when building real cycles.

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Review of Thermodynamics (Contd.)

Thermodynamic Cycles - CARNOT CYCLE

 Efficiency of Carnot Cycle = 1 - T2 X 100

T1
 Solely a function of Upper and Lower Temperature.
 Upper Temperature limited by strength of available
materials.
 Lower Temperatures are limited by ambient conditions.
 Carnot Cycle cannot be used in Practical device as
Isothermal and Isentropic processes are not
practicable processes.

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Review of Thermodynamics (Contd.)

Thermodynamic Cycles - Ideal Rankine Cycle

RANKINE CYCLE

D'

C D

TEMPERATURE, T
PROCESS A-B: ISENTROPIC/ADIABATIC COMPRESSION PROCESS WORK DONE
B
FEED WATER TO BOILER IS PRESSURIED TO BOILER
A E E'
PROCESS B-C: CONSTANT PRESSURE PROCESS
FEED WATER HEATED UPTO SATURATION TEMP T1 CALLED HEAT REJECTED

SENSIBLE HEATING POINT C IS INTERMEDIATE POINT OF

STEAM GENERATION ENTROPY, S

PROCESS C-D: CONSTANT PRESSURE & TEMPERATURE PROCESS

FEED WATER IS VAPOURISED CALLED LANTENT HEAT OF
VAPOURISATION POINT D IS STEAM IS DRY & SATURATED.

PROCESS D-E: ISENTROPIC/ADIABATIC EXPANSION PROCESS

EXPANSION OF STEAM TO VACCUM

PROCESS E-A: CONSTANT PRESSURE & TEMPERATURE PROCESS

REJECTION OF HEAT TO CONDENSOR TO CONDENSE THE STEAM.
AT POINT D, STEAM IS DRY & SATURATED.

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Review of Thermodynamics (Contd.)

Thermodynamic Cycles - Rankine Cycle

Rankine Cycle:- How to increase the Efficiency ?
 Lowering Condenser pressure to the extent possible.
(Lowering Condenser pressure has side effects like increased air
leakage into condenser, increased wetness of steam etc.)
 Superheating Steam to Higher temperatures. The average
temperature at which heat is added to the steam can be increased
without increasing boiler pressure by superheating steam to higher
temperature.
(The temperature to which steam can be superheated is limited by
metallurgical considerations.)
 Increase the boiler pressure. This also results in increase in
average temperature at which heat addition takes place.
(The undesirable effect of increased wetness can be overcome by
going in for reheat cycle)

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Review of Thermodynamics (Contd.)

Thermodynamic Cycles - Reheat Cycle

 Reheating helps in :
- Reducing moisture level in LP region
- Higher thermal efficiency
 Review of Thermodynamics (Contd.)

Thermodynamic Cycles - Regenerative Reheat Cycle

 Largest single loss of Energy in a Power Plant occurs at condenser.
 In Regenerative cycle the cycle efficiency is improved by reducing
this rejected heat.
 Gain depends on number of stages of feed heating and the final
feed water temperature.
 The cost of heaters, pipes, valves and accessories put a limit to the
number of feed heaters.
 However an optimum final feed water temperature should be
selected to see that reduction in efficiency of boiler does not
offset the increase in Turbine efficiency.
 Review of Thermodynamics (Contd.)
Major equipments in thermal
•Turbine
power•Generator
plants produce
produce electricity
power •GENERATOR

•Boiler boils the water to •TURBINE

generate steam at high
Temperature
•B
O •Condenses
I the steam to
L water
E
R •DEAERATOR •CONDENSER

•BFP •Increases the

•HP •Increases the pressure of
pressure of •LP •CE PUMPwater
HEATERS HEATERS
water
•Heat the water •Heat the water
 Review of Thermodynamics (Contd.)
Combined Cycle Power Plants

FUEL+AIR
AIR

CC

COMPRESSOR TURBINE STACK

GAS TURBINE
STEAM TURBINE
HRSG

TURBINE

COMBINED CYCLE PLANT CONDENSER

PUMP
 Basic principle of Steam Turbine

 Steam Turbine Converts the Heat Energy into Mechanical Energy.

 Drop in Pressure of Steam through some passage, resulting :

 Increase in Velocity
 Change in direction of motion, which gives rise to a change in
Momentum or Force.

 This is the Driving Force of the Prime mover.

 Basic principle of Steam Turbine

Impulse Vs Reaction

A A SECTION A-A
Impulse (SIMPLIFIED DIAGRAM)

A B SECTION A-B
Reaction ( SIMPLIFIED DIAGRAM )
 Basic principle of Steam Turbine

Impulse Vs Reaction

S. No Impulse Reaction
1 Expansion only in stationary Expansion in both stationary
blades and rotating blades
2 Steam velocity slightly Steam velocity continuously
decreases in rotating blades increasing in rotating blades
3 Profiles are symmetrical Profiles use aerofoil cross-
section and are asymmetrical
4 Rotating blades are in action Rotating blades are in action
when they are in front of at all the time
stationary blades
5 Pressure remain same before Differential pressure exists
and after rotating blade before and after rotating
blade
 Basic principle of Steam Turbine

Impulse Vs Reaction

S. No Impulse Reaction
6 No. of stages are less No. of stages are more
7 Steam velocity and blade Steam velocity and blade
speed are more speed are less
8 Influence of blade speed Influence of blade speed
ratio on efficiency is more ratio on efficiency is less at
maximum value of efficiency
 Basic principle of Steam Turbine

Type of governing
Throttled controlled

Nozzle controlled
Basic principle of Steam Turbine

Nozzle controlled Vs Throttle controlled governing

 Basic principle of Steam Turbine

Cross section of steam turbine showing control

valves and nozzle box

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Basic principle of Steam Turbine

Type of governing
Nozzle controlled Throttled controlled

Nozzle controlled + Bypass Throttle controlled + Bypass

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Basic principle of Steam Turbine

Advantages of Overload Bypass Valve

 To meet requirement of VWO

 To take of inlet parameter variation
 To obtain optimum performance at 100% MCR
as well as at part loads

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Basic principle of Steam Turbine
Throttle control valve with Bypass valve

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Classification of Steam Turbines
1. Based on Blading Design
a) Impulse turbine
b) Reaction turbine
c) Combination of Impulse & Reaction turbine
2.Based on General arrangement
a) Single flow
b) Double flow
c) Compound, Two / Three Cylinder
d) Divided flow (Eg. Two or more LP turbines)
3. Based on direction of steam flow relative to plane of
rotation
a) Axial flow
b) Radial flow
c) Tangential flow

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Classification of Steam Turbines (Contd.)
3. Based on steam and exhaust condition
a) High pressure condensing
b) Back pressure
c) Extraction / Injection condensing / Back pressure
4. Based on Application
a) Utility turbines
b) Industrial turbines
c) Nuclear turbines
d) Marine turbines

4. a) Utility Turbines
- Regenerative feed heating
- Regenerative feed heating with Reheat
- Combined cycle plants

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Classification of Steam Turbines (Contd.)
4b. Industrial Turbines
Captive Power plant
- Straight Condensing with / without bleeds
- Straight Condensing with Injection
Co-generation Power Plant (Power + Steam to process)
- Straight Back Pressure
- Extraction Condensing
- Extraction Back Pressure
- Double Extraction Back Pressure/ Condensing
- Extraction / Injection
Drive Turbines
- Compressor drive
- Blowers drive
- Boiler feed pump drive etc.

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Classification of Steam Turbines (Contd.)

Type of processes extractions

Uncontrolled extraction

Wander Extraction Controlled Extraction

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Classification of Steam Turbines (Contd.)

Typical Back Pressure Turbine cross section

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Classification of Steam Turbines (Contd.)

Typical NK Turbine cross section

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Classification of Steam Turbines (Contd.)
Typical ENK Turbine cross section

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Classification of Steam Turbines (Contd.)
Typical -4 Turbine cross section

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Classification of Steam Turbines (Contd.)

Typical KN Turbine cross section

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Classification of Steam Turbines (Contd.)

Large Utility Turbine- Generator Set

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Classification of Steam Turbines (Contd.)

Single Cylinder Reheat 150 MW Turbine cross section

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Classification of Steam Turbines (Contd.)

Single Cylinder Reheat 150 MW Turbine cross section

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 INDUSTRIAL TURBINE - PARAMETER RANGE
INLET PRESSURE : 4 ata to 140 ata

INLET TEMPERATURE : ~140°C TO 540°C

EXTRACTION PRESSURE : ~1.5 ata to 64 ata

EXHAUST PRESSURE : CONDENSING TO 45 ata

SPEEDS : 3000 rpm to 15000 rpm

POWER : ~ 3MW TO 157.5MW

DRIVEN MACHINES : GENERATOR

COMPRESSOR
AXIAL TURBO BLOWER
BOILER FEED PUMP
23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Industrial Steam Turbine - Building Block System

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 INDUSTRIAL TURBINES - BUILDING BLOCK SYSTEM
Front Section in two varients
 for normal steam inlet conditions upto 100 bar / 510°C
 for higher inlet steam conditions upto 140 bar / 540°C
Rear Section (Exhaust) in 3 Versions
 for normal back pressure upto 20 bar
 for higher back pressure upto 45 bar
 for condensing Turbines

Centre Section
 Blading system can be extended by extension section
 Matching of front section with larger flow Rear sections
by means of transition section

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Total Steam Turbines from Hyderabad
Type of Machine No. of Machines Type of Machine No. of Machines
Upto 30MW 754 Condensing 863
Above 30MW 256 Back pressure 147
Total 1010 Total 1010

Type of Machine No. of Machines Type of Machine No. of Machines

Controlled extn. 203 Utility 384
Without controlled 807 Industrial 626
extn.
Total 1010
Total 1010
Applications No of Steam Turbines
Generator 582
BFP Drives 249
Compressor Drives 179
Total 1010
23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance•36
and Maintenance aspects
 STEPS INVOLVED IN DESIGN OF STEAM TURBINE
• Perform thermodynamic and axial thrust calculation to decide
diameters and axial length of blading
• Perform rotor-dynamic calculations and suggest any change of length
or diameter to repeat above step
• Select suitable turbine extensions and carriers to meet above blading
geometry.
• Select suitable material to meet steam parameters
• Select suitable governing system and protection system
• Prepare ordering / manufacturing documents incorporating above
selections
• Prepare operating and maintenance procedure for the turbine

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Thermodynamics Calculations – Turbine Selection

Selection of Steam Turbine depends on:

 Inlet Parameters

 Exhaust Parameters

 Power Requirements

 Type of Extraction

 High speed / Direct Drive

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Thermodynamics Calculations – Turbine Selection

Inlet Parameters:
 Size of Inlet section depends on inlet parameters.

 The velocities in stop and control valves have to be limited to

ensure that pressure drop is within limits.
(Generally the inlet pressure drop shall be limited to 5%).

 Selecting 2 stop valves ( i.e 2 inlets ) if required, thus

reducing the size of inlet section thereby reducing the cost.

 H or N inlet section based on inlet pressure and

temperature.

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Thermodynamics Calculations – Turbine Selection

Exhaust parameters:
 Condensing or Back pressure turbine

 Select suitable exhaust pressure based on cooling water

inlet temperature and maximum CW temperature rise
permitted. Sometimes the exhaust pressure is specified
by customer.

 Select suitable LP blading (for condensing turbine) for

exhaust flow and exhaust pressure selected above by
pitching at optimal exhaust velocity.

 For back pressure turbines, the exhaust section is

decided based on exhaust velocity through exhaust
flange.

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Thermodynamics Calculations – Turbine Selection

Power Requirements:
 Selection based on flow or power criterion

 Optimal selection is done to ensure that best

performance (Specific steam consumption/Heat rate),
least cost, best delivery are achieved.

 The selection is done to ensure that the turbine is

capable of delivering the maximum power specified by
customer under all valves wide open condition.

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Thermodynamics Calculations – Turbine Selection

Type of Extraction:

 Controlled / Uncontrolled

 For controlled extraction turbines, data required are:

- Extraction flows (Normal, min and max)
- Normal / Maximum flow through control valves.
- ZER (Zero Extraction Rating)

 For uncontrolled extraction turbines – turn down required.

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Thermodynamics Calculations – Turbine Selection

High Speed/Direct drive:

 Manufacturing cycle time is less for high speed turbines.

 High speed models are offered upto 60 MW only.

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Thermodynamics Calculations – Design Codes

International standards
 IEC 45
 API 612
 ISO 10437

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Thermodynamics Calculations
Axial thrust calculation
Reasons for thrust How to balance the thrust?
 Steam thrust  Change BP gland diameter

 Rotor steps / taper  Shift BP gland connection

Constraints in thrust balancing

 Max. Dia. Is restricted due to A-Wheel taper pins
 More leakages due to large diameters
 More losses due to shifting of BP gland connection
23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Thermodynamics Calculations
Turbine gland sealing system
TO
GLAND STEAM
CONDENSER
(0.98 ata)

TURBINE

CONDENSER

1.04 to 1.10 ata

TO BFP

FROM SEAL STEAM

AUX. STEAM VALVE
HEADER

LEAK OFF VALVE TO

CONDENSER

TURBINE GLAND STEAM SYSTEM

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Thermodynamics Calculations
Turbine gland sealing system TO GSC

TURBINE

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 BFP Drive Turbine

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Thermodynamics Calculations

Operating Conditions of Boiler Feed Pump

 Design case: VWO, 3% MU

 Run-out case: One Pump, 65% unit load

 Best Efficiency case : TGMCR, 3% MU

 Emergency case : 105% BMCR flow & SV set Pressure

 No. of BFPs in service in each operating case

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Thermodynamics Calculations

Operating Conditions of BFP Drive Turbine

 Design case: Best efficiency case

 VWO case: One Pump, 65% unit load

 Steam source change over case

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Thermodynamics Calculations

Input to BFP Drive Turbine

 BFP and BP power consumption

 BFP and BP speed

 Steam Parameters at inlet and exhaust of BFPDT

 Direction of rotation

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 500 MW BFPDT – Cross-section

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 660 MW BFPDT Cross-section

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Informative Steam consumption Curve of BFPDT

Inlet steam consumption

Turbine output

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 TYPICAL DATA FOR 500 MW BFP DRIVE TURBINE

Turbine Model : K 1401-2

Inlet Steam Parameters (Design) : 6.33 Ata / 290.6 deg C

Inlet Flow (Design) : 35.0 T/Hr

Aux. Steam Parameters : 20.0 Ata / 350 deg C

CRH Steam Parameters (Pump Run-out) : 11.3 Ata / 320 deg C

Exhaust Steam Press. (Design) : 0.1064 Ata

Exhaust Steam Flow (Design) : 35.0 T/Hr

Power (Design) : 5821 KW

Power (Emergency Cond.) : 7030 KW

Speed (Design) : 5295 rpm

Trip Speed : 6300 rpm

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 TYPICAL DATA FOR 600 MW BFP DRIVE TURBINE

Turbine Model : K 1401-2

Inlet Steam Parameters (Design) : 6.67 Ata / 326.2 deg C

Inlet Flow (Design) : 44.0 T/Hr

Aux. Steam Parameters : 16.0 Ata / 320 deg C

CRH Steam Parameters (Pump Run-out) : 11.3 Ata / 329 deg C

Exhaust Steam Press. (Design) : 0.105 Ata

Exhaust Steam Flow (Design) : 44.0 T/Hr

Power (Design) : 7243 KW

Power (Emergency Cond.) : 9106 KW

Speed (Design) : 5520 rpm

Trip Speed : 6072 rpm

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 TYPICAL DATA FOR 660 MW BFP DRIVE TURBINE

Turbine Model : NK 63/71-3

Inlet Steam Parameters (Design) : 11.79 Ata / 382.1 deg C

Inlet Flow (Design) : 65.5.0 T/Hr

Aux. Steam Parameters : 16.0 Ata / 310.0 deg C

CRH Steam Parameters (Pump Run-out) : 15.5 Ata / 396.6 deg C

Exhaust Steam Press. (Design) : 0.118 Ata

Exhaust Steam Flow (Design) : 65.5 T/Hr

Power (Design) : 13085 KW

Power (Emergency Cond.) : 13575 KW

Speed (Design) : 5695 rpm

Trip Speed : 6265 rpm

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 TYPICAL DATA FOR 800 MW BFP DRIVE TURBINE

Turbine Model : NK 63/71-3

Inlet Steam Parameters (Design) : 11.94 Ata / 364.2 deg C

Inlet Flow (Design) : 61.7 T/Hr

Aux. Steam Parameters : 20.0Ata / 320.0 deg C

CRH Steam Parameters (Pump Run-out) : 15.5Ata / 397.3 deg C

Exhaust Steam Press. (Design) : 0.0875 Ata

Exhaust Steam Flow (Design) : 61.7 T/Hr

Power (Design) : 12241 KW

Power (Emergency Cond.) : 15396 KW

Speed (Design) : 4735 rpm

Trip Speed : 5434 rpm

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Existing Unit Size and Efficiency
Unit Size (MW) MS Pressure MS / RH Temp Gross Design
(Kg/cm2) (Deg C) Efficiency (%)
30 - 50 60 482 ~31

60 - 100 90 535 32 - 33

100 / 120 130 535 / 535 35 - 36

210 150 537 / 537 37.8

250 (Advanced) 150 537 / 537 38.4

500 170 537 / 537 38.6

Source : CEA

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Thermodynamics Calculations

Possible design improvements in BFPDT

 State of art blading

 Latest type of seals

 Expected improvement based on above is 0.5%

 Techno-economically not advisable

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 BFPDT - Performance Issues

Parameters to monitor for BFPDT

 Ist stage pressure

 BP Leak-off Parameters
 Steam quality

Maintenance of BFPDT

 Periodic wet steam washing

 Periodic overhauling

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects
 Thank you!

23/10/2013 Work shop on Steam turbine & Auxiliaries- Design, Performance and Maintenance aspects