Steam Turbines
Steam Turbines
A steam turbine is a key unit in a steam power plant from which we get power. A steam turbine
is a turbo-machine and a prime mover in which potential energy of steam is transformed into
kinetic energy and this kinetic energy is then transformed into mechanical energy of rotation of
shaft of turbine. In reciprocating steam engines, the pressure energy of steam is utilised and
dynamic action of Steam is negligible. In steam engines, steam acts on piston as a load or
weight and so, the action of steam is - static. Steam engines may be operated without any
expansion or drop of pressure in the cylinder. The expansive property of steam is not utilised to
fullest extent even in the best types of multi expansion steam engines.
Steam turbines can't be operated as that of steam engines. The turbine depends wholly upon the
dynamic action of steam. The turbine utilises the kinetic or velocity energy of steam instead of
pressure energy only. The expansive property of steam is almost utilised in the turbine either in
admission nozzles or in the turbine blading.
The steam is caused to fall in pressure in a nozzle during admission to the turbine, due to this
fall in pressure; certain amount of heat energy is converted into kinetic energy. A steam turbine
consists of a number of curved blades fixed uniformly on the rim of a wheel which is fastened
to a shaft and we obtain power from this shaft.
The high velocity steam from nozzles impinges on the blades of turbine, suffers a change in the
direction of motion and thus gives rise to change in momentum and so a force. This constitutes
the driving force of the turbine. The blades obtain no motive force from the static pressure of
steam or from any impact of steam jet because blades are designed and curved in such a way
that steam enters the blades without any shock and will glide ON and OFF the blades.
According to Newton's second law of motion, the force is proportional to rate of change of
momentum (Mass x velocity). If the rate of change of momentum is caused by allowing a
high velocity steam jet to pass over a curved blade, then, steam will impart a force to the
blade. If the blade is free, then it will move (rotate) in the direction of force.
PRINCIPLE OF OPERATION
1. A nozzle in which heat energy of high pressure steam is converted into kinetic energy so that
steam issues from the nozzle with very high velocity.
2. Blades which change the direction of steam issuing from the nozzle so that a force acts on
blades due to change of momentum and rotates them.
So, the basic principle of operation a steam turbine is generation of high velocity steam jet by
expansion of high pressure steam in a nozzle and motive power in the turbine is obtained by
change in momentum of the high velocity steam jet by allowing it to impinge on curved blades.
Steam turbines are steady flow machines, have large exhaust outlets (for discharging used
steam) and the speed of flow is very high. So, they can handle large volume of steam and
produce higher power and the processes are assumed to be adiabatic. Steam turbines are capable
of expanding steam to the lowest exhaust pressure obtainable in the condenser. The turbine is a
constant high speed machine and really must be operated condensing in order to take full
advantage of greater range of steam expansion.
Steam turbines are mainly used for electric power generation and for large marine propulsion.
These are also used for direct drives of fans, compressors, pumps etc. When properly designed
and constructed, a steam turbine is the most durable prime-mover.
TYPES OF STEAM TURBINES
Steam turbines may be classified in many ways. Considering the action of steam which is most
important factor, steam turbines are mainly classified as :
1. Impulse turbines.
If the flow of steam through the nozzles and moving blades of a turbine takes place in such a
way that steam is expanded and entire pressure drop takes place in nozzles only and pressure at
the outside of blades is equal to inside of blades, then such a turbine is known as - impulse
turbine.
In these turbines, the pressure drop takes place in nozzles only and not in moving blades. This is
obtained by making the blade passage of constant cross sectional area.
In impulse reaction turbines, the pressure drop takes place in nozzles as well as moving blades.
The drop of pressure of steam while flowing through the moving blades results in the
generation of kinetic energy within the moving blades giving rise to reaction and adds to the
driving force which is then transmitted through the rotor to the turbine shaft. This turbine works
on the principles of both impulse and reaction. This is achieved by making the blade passage of
varying cross sectional area.
IMPULSE TURBINE
The turbines in which complete process of expansion of steam takes place in stationary nozzles
and the kinetic energy is converted into mechanical work on the turbine blades are known as -
Impulse turbines.
In impulse turbines, the entire pressure drop takes place in nozzles only. The pressure drops
from steam chest pressure to condenser or exhaust pressure. The pressure in the blade passages
remains approximately constant and is equal to condenser pressure.
An impulse turbine for its operation, depends wholly on the impulsive force of high velocity
steam jets, which are obtained by expansion of steam in nozzles. The action of steam jet
impinging on the blades is said to be impulse and the rotation of rotor is due to impulsive forces
of steam jets.
Generally, converging - diverging nozzles are used. Due to relatively large expansion ratio,
steam leaves the nozzles at a very high velocity (Even supersonic). The steam at high velocity
impinges over blades, both pressure and enthalpy remain constant, work transfer takes place,
velocity reduces gradually and steam comes out with appreciable velocity. The nozzle angle is
inclined at a fixed angle to tangent of rotor wheel.
Mostly, impulse turbines are axial flow turbines and they have zero degree of reaction
(discussed later). The entire pressure drop takes place in nozzles resulting in enthalpy drop. The
energy transfer is derived from a change of absolute velocity.
Impulse turbines are generally employed where relatively small amounts of power are required
and where rotor diameter
is fairly small.
RUNNER AND BUCKET OF DE-LAVEL TURBINE
The essential parts of an impulse turbine are - nozzles, blades and casing.
In nozzles, the expansive property of steam is utilised to produce jets of steam with very high
velocity. The nozzle guides the steam to flow in the designed direction. It also regulates the
flow of steam. It is kept very close to turbine blades to minimise wind age losses.
The runner or rotor consists of a circular disc mounted on a shaft. On the periphery of the
runner, a number of buckets or curved blades are fixed uniformly.
The surface of the blades is made very smooth to minimise losses due to friction. Mostly, the
blades are bolted to the disc. Sometimes, the blades and disc are cast as a single unit. The
function of blades is to change the direction of steam jet and hence momentum of the jet and so
to produce a force which will rotate the blades.
The casing is air tight metallic case which houses the rotor and blades. It controls the flow of
steam from blades to condenser and to safeguard the runner against any accident.
A De-lavel turbine consists of a single impulse wheel on which steam jets impinge from several
nozzles arranged around the circumference. The blades are made symmetrical with angles of
about 30° at inlet and exit. It has spherical bearings. It uses helical gears to reduce high
rotational speed to a practical value.
The steam jet after leaving the nozzle, impinges on one end the blade, glides over the inside
surface of the blade and finally leaves from the other edge.
Let Vb = Linear velocity of moving blade.
V1 = Absolute velocity of steam at inlet to moving blade i.e., exit velocity of nozzle.
Vw1 = Tangential component of entering steam. Vw1 Also known as velocity of whirl at entrance.
Vr1 = Relative velocity of steam with respect to tip of blade at inlet. It is the vectorial difference
between Vb and V1
Vf1=Velocity of flow = Axial velocity at entrance to moving blades. It is the vertical component
of V1
α1= Angle of nozzle = Angle which the entering steam makes with the moving blade at entrance
- with the tangent of the wheel at entrance.
β1 = Angle which the relative velocity makes with the tangent of the wheel - direction of motion
of blade. It is also known as blade angle at inlet.
The above notations stand for inlet triangle.
V2, Vw2, Vf2, Vr2, α2, β2 are the corresponding values at the exit of the moving blades.
They stand for outlet triangle.
The steam jet with absolute velocity V1 impinges on the blade at an angle of α 1 to the tangent of
the blade. The absolute velocity V2 can be considered as having two components. The tangential
component called whirl component Vw1 = V1cosα1 is parallel to direction of rotation of blades
and axial or flow component Vf1 = V1 sin α1 is perpendicular to the direction of rotation of
blades.
The tangential component of the steam jet does work on the blade because it is in the same
direction as the motion of the blade. The axial component doesn't work on the blades because it
is perpendicular to the direction of motion of blade. It is responsible for the flow of steam
through the turbine. Change of velocity in this component causes an axial thrust on the rotor. As
the blade moves with a tangential velocity in peripheral direction, the entering steam jet will
have relative velocity to the blades. If there is no friction loss at the blade, relative velocity at
inlet is equal to relative velocity at outlet i.e.,
Vr1= Vr2.
As the steam glides over the blades without shock, the surface of the blade at inlet must be
parallel to relative velocity Vr1. So, the moving blade at inlet must be inclined to the tangent of
the blade at an angle β1. In other words, to avoid shock at
entrance, vector Vr1 must be tangential to the blade tip at entry i.e, β 1 must be equal to angle of
blade at entrance. The blade is designed on this principle. From the above analysis, following
points are to be noted.
1. No expansion of steam takes place in the moving blades. The blades only deflect steam.
This causes change in momentum and consequently force.
2. If the steam has to enter and leave the blades without shock, angle β1, should be angle of
blade at inlet and angle β2 should be angle of blade at outlet. This is an essential condition.
3. Since there is no pressure drop in the moving blades, the pressure on the two sides of the
blades is equal.
4. α1 is the outlet angle of nozzle. If steam has to enter the next nozzle ring without shock, its
inlet angle must be equal to α2.
5. In a simple impulse turbine, the loss at exit is the whirl component at outlet - V2 cos α2. For
minimum loss, this quantity should be minimum, i.e., α2 should be equal to 90°. In that case the
turbine discharges axially and it is called axial turbine.
1. Force on Rotor:
According to Newton's second law of motion,
Tangential force on rotor = mass x tangential acceleration
m = Mass rate of steam flow - kgs/sec.
Actually, Vw2 is negative as the steam is discharged in opposite direction to blade
motion. So, Vw1 ,and Vw2 are added together. Generally,
3. Nozzle efficiency
3. Nozzle Efficiency:
It is defined as the ratio of energy supplied to blades per kg of steam to total energy supplied
per stage per kg of steam.Energy supplied to blades per kg of steam = ½*m*V12 Total energy
supplied per stage per kg of steam = (h1-h2)
Stage efficiency = blade efficiency x nozzle efficiency.
Energy converted to heat by blade friction= Loss of kinetic energy during flow over the blades
The ratio of Vr2 to Vr1 is called blade velocity coefficient or coefficient of velocity friction factor
K. The effect of blade friction is to reduce relative velocity at outlet and consequently V w2 This
in turn will cause reduction in work done and blade efficiency. Depending upon the shape of the
blades, value of K varies from 0.75 to 0.85
The blading efficiency will be maximum when V 1 is minimum. From combined velocity
diagram, we can observe that, value of V1, will be minimum when α2=90°. So, for maximum
efficiency, the steam should leave the turbine blades at right angles to their motion. Also, for
This is a very important factor in the design of turbines and efficiency of a turbine depends
largely on the value of ρ
2. Velocity compounding.
1. Pressure Compounding:
In this, the whole expansion of steam is carried out in a number of steps by employing a number
of simple impulse turbines in series on same shaft as shown in fig.
We can arrange a number of
simple impulse turbines in
series on same shaft
allowing exhaust steam from
one turbine to enter the
nozzles of next turbine.
Then, each of the simple
impulse turbine is termed as -
stage of the turbine, each
stage containing a set of
nozzles and blades.
This is equivalent to splitting
the whole pressure drop into a series of smaller pressure drops and so it is called - pressure
compounding. The total pressure drop of steam doesn't take place in the first set of nozzles but
divided equally among all nozzle sets and the pressure remains constant while flowing over the
moving blades. The nozzles are usually fitted into partitions termed as diaphragms which
separate one wheel chamber from the next.
The steam from boiler pressure is passed through the first set of nozzles (A number of nozzles
are arranged around the circumference of the wheel. All nozzles for one wheel constitute one
set of nozzles); where only a small pressure drop occurs with an increase in velocity of steam.
While flowing over the first set of moving blades, pressure remains constant but velocity
decreases. This constitutes one stage. A stage consists of a set of fixed nozzles and a set of
moving blades. A stage itself is a simple impulse turbine.
The steam from first set of moving blades enters the second stage - into second set of nozzles
where its pressure is further reduced. Consequently, the velocity increase again. Now, the steam
enters the second set of moving blades in which pressure remains constant but velocity
decreases.
This process is repeated in the remaining stages also until condenser pressure is reached.
As pressure drop per stage is reduced, the velocity of steam is reduced which in turn reduces the
blade or rotor velocity. The speed of the turbine can be reduced further by increasing number of
stages. The leaving velocity of the last stage of the turbine is much less compared to simple
impulse or De-lavel turbine.
This is the most efficient type of impulse turbine because the ratio of blade velocity, to steam
velocity remains constant. But to obtain very low speed, number of stages required are more
and it becomes more expensive. Now-a-days, pressure compounded impulse turbines are not
being used. Rateau and Zoelly turbines belong to this group.
2. Velocity Compounding:
In this, the entire pressure drop takes place in one set of nozzles thereafter, the pressure remains
constant while the steam flows over the blades. Due to the entire pressure drop, the velocity of
steam becomes high, and this velocity is absorbed in steps while steam flows over different sets
of moving blades.
Here, the turbine consists of a set of nozzles and a wheel fitted with two or more rows of
moving blades. There are fixed or guide blades arranged between moving blades and set in
reverse manner.
The expansion of steam takes place in the set of nozzles from boiler pressure to condenser
pressure. The resulting high
velocity of steam is utilized by as
many sets of rotor blades as
necessary.
A portion of initial high velocity
of steam is absorbed by the first
set of moving blades. The steam
from first set of moving blades
comes out with a fairly high
velocity. It then enters the fixed or
stationary or guide blades which
change the direction of steam and direct the steam into second set of moving blades; without
affecting the velocity appreciably. There is slight drop in velocity in guide blades due to
friction. While passing through the second set of moving blades, steam suffers a change of
momentum and gives up another portion of its velocity -kinetic energy to the rotor.
The process is repeated and the steam finally enters the condenser from the last set of moving
blades.
The entire pressure drop takes place in the nozzles only and no pressure drop occurs in fixed
(guide) blades or moving blades. This method of velocity compounding is known as - Curtis
principle and Curtis turbine is an example of velocity compounded impulse turbine.
Calculations:
Wt = work done in first moving blade set + work done in second moving blade set.
Blading or diagram efficiency for a two stage turbine:
Maximum efficiency implies minimum rejection of energy which is obtained when discharge is
axial i.e., α1 = 90°.
For any given blade speed, a two row wheel (two sets of moving blades) can utilize four times
the enthalpy drop of a simple impulse turbine
The casing is an air tight metallic case in which steam from boiler under high pressure is
distributed around the fixed blades which are positioned at the entrance. The casing is so
designed that steam enters the fixed blades with uniform velocity.
The guide mechanism consists of fixed or guide blades. They allow the steam to enter the rotor
without shock and they allow required quantity of steam to enter the turbine. The guide blades
may be opened or closed by a regulating shaft which allows steam to flow according to the
need.
The runner consists of moving blades. These blades are designed properly to allow steam to
enter and leave the blades without shock. The steam after passing through the rotor flows to
condenser through a draft tube. It minimises losses due to eddies.
In impulse turbines, steam pressure on both sides of moving blades is same and axial thrust is
negligible. But, in a reaction turbine, this thrust is considerable due to fall of pressure within the
blades and difference between blade sizes in various steps. (To accommodate increased volume,
height of blades in increased progressively). Thrust bearings are used to balance this thrust.
In a reaction turbine, the pressure is reduced in both fixed and moving blades. The velocity
increases in fixed blades and reduces while passing through moving blades.
In reaction turbines, both fixed and moving blades act as nozzles as pressure drop takes place in
both
HEIGHT OF BLADES FOR A REACTION TURBINE:
In designing blades, the height of blade plays an important role. In a reaction turbine, the steam
enters the moving blades over the whole circumference. So, the area through which steam flows
is always full of steam
DEGREE OF REACTION
The energy transfer is by change of dynamic pressure and by change of dynamic pressure in
rotor passage. The ratio of energy transfer by means of change of static pressure in the rotor to
total energy static pressure in the rotor to total energy transfer in the rotor is called the degree of
reaction.
In case of turbines, a stage consists of a set of nozzles (or fixed blades) and rotor having moving
blades. The fig shows the H-S diagram for isentropic flow of steam through stationary (fixed)
and moving blade
The degree of reaction is defined as the ratio of enthalpy drop in moving blades to total
enthalpy drop in a stage.
3. Blade passage is of constant cross sectional area as there is no expansion. Due to expansion,
the blade passage is of variable cross sectional area. 4 Blade shape is profile type and easy to
manufacture. Blade shape is aerofoil type and difficult to manufacture.
6. Admission of steam is partial over the circumference Admission of steam is full over the
whole circumference.
7. Because of large pressure drop, number of stages is less. Because of small pressure drop, for
same pressure drop, larger numbers of stages are required. Reaction turbines are multi stage
turbines only.
8. Because of large pressure drop, velocity of steam and velocity of blade are higher. Because
of small pressure drop, the velocity of steam and velocity of blade are lower.
9. The diagram efficiency decreases rapidly with change in designed blade speed ratio. Greater
working range is possible.
10. Suitable for small power requirements. Suitable for medium and higher power requirements
11. Occupies less space per unit power. Occupies more space per unit power. 12 Degree of
reaction is zero Degree of reaction is greater than zero
The choice of stages in a steam turbine depends upon relative importance of capital cost and
turbine efficiency. Higher turbine efficiency results in lower steam consumption and smaller
size of boiler and condenser which in turn reduces the capital cost of total steam power plant.