8/13/2014 Steam Turbines Basic Information --- Power Generation in Pakistan

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STEAM TURBINES BASIC INFORMATION

Various types of turbines are used for Power
generation.
A particular type of turbine is used in each area
depending upon available options. For example, if
strong winds are available at some location, Wind
Turbine can be the best solution for Electricity
Generation at that area.


Diesel, Natural Gas and Furnace Oil are mostly used
to drive Combustion turbines for Electricity generation
at larger ratings, provided that these sources are
available easily and at right price.
Many Combustion Turbine IPPs are functioning in
Pakistan.

However, these fuel sources are not only expensive,
but also a major source of pollution. Efforts are made
through out the World to reduce dependence on
Petroleum products.

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The major source of Electricity Generation in Pakistan
are Dams. Water Turbines are rotated through water
flow to produce electricity, providing free and vast
energy.
This natural gift is not abundant anymore due to lack of
water flow, Rain timings, Political issues, absence of
funds and skill for machinery refurbishing, etc.
Hence the load-shedding.




Steam Turbines Introduction


Power generated by steam turbines have lit the first
light bulbs for over one and a half century. In fact, the
first power plant (run by Thomas Edison using his
dynamos and located at Pearl Street in New York City)
was a CHP plant that generated power using a steam
turbine. The excess steam was used to heat homes.

Because a steam turbine runs off of steam produced
by a boiler, it can support many different types of fuels.

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Natural gas, coal, nuclear, wood, biomass, municipal
solid waste and more can all be used to run a steam
turbine. As a result, facilities that have an excess of
waste products such as oil or wood tend to implement
steam turbines. As the figure below indicates, current
steam turbine CHP systems run off of a variety of fuels.

Another attractive feature of steam turbines is that they
can be modified to fit any CHP system. Therefore, the
steam turbine can be fitted to match a facilities
pressure and temperature requirements.
Furthermore, steam turbines can be retrofitted into an
existing steam system. Furthermore, water and steam
are very well understood. Using the steam tables, we
can know exactly the properties of our working fluids at
certain temperatures and pressures. Therefore, steam
is very predictable.

Brief Technological Description

Steam turbines are slightly different than other CHP
prime movers in that they require a separate boiler or
HRSG (Heat Recovery Steam Generator) to create its
working fluid (steam). Sometimes, plants will already
have a boiler producing steam for a process or to
satisfy a heating/cooling load and rather than using a
pressure reducing valve to isenthalpically reduce
the pressure of the steam, they will run the steam
through a back pressure steam turbine and generate
electricity. In CHP applications, a boiler or HRSG will
generate steam which will be put through a steam
turbine. The steam turbine will produce electricity and
the remaining exhaust steam can be used for hot
water or heating/cooling. The diagram below
summarizes a boiler/steam turbine cycle.

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The basic process behind steam power generation is
the Rankine Cycle. Water is heated until it is a
saturated liquid. From there, it is compressed into
steam. The steam is transferred to a turbine where the
pressure of the steam is reduced (usually to sub
atmospheric pressures) by expansion over the turbine
blades. This process produces electricity. The low
pressure steam is condensed back to a liquid. The
water, now referred to as return water, is mixed with
new water, referred to as feedwater, and pumped
back to the boiler. The figure below shows a common
diagram used to describe the Rankine Cycle.

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Types of Steam Turbines:


There are basically two types of steam turbines:
- Condensing,
- Non-condensing,
Condensing steam turbines are very economic and
fuel efficient. These turbines are mostly used for large
amount of power generation. Small industires where
electricity unit rate is a basic issue, can also apply
condensing steam turbine system.
Non-condensing steam turbines are also referred to
as back pressure steam turbines. Here, steam is
expanded over a turbine and the exhaust steam is
used for to meet a facilities steam needs. The steam
is expanded until it reaches a pressure that the facility
can use. The figure below shows the process of a
back pressure steam turbine.

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The other type of steam turbine used in CHP
applications is called an extraction turbine. In these
turbines, steam in extracted from the turbine at some
intermediate pressure. This steam can be used to
meet the facilities steam need. The remaining steam
is expanded further and condensed. Extraction
turbines can also act as admission turbines. In
admission turbines, additional steam is added to the
turbine at some intermediate point. The figure below
schematically shows the process of an extraction
steam turbine.
Waste heat from a steam turbine (either collected
through the exhaust or from extraction), can be used for
space heating or cooling, for process, or it can be used
to create chilled or hot water. Steam turbines can also
be part of a combined cycle process. In these
processes, waste steam from an electricity producing
process (i.e. waste steam produced by a gas turbine)
is run through a steam turbine to produce more
electricity. While this is very energy efficient, it is not
considering CHP because no heating or cooling loads
are satisfied in any part.

Impulse & Reaction:

Most modern steam turbines are a combination of the
reaction and impulse design. Typically, higher
pressure sections are impulse type and lower
pressure stages are reaction type.


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An impulse turbine has fixed nozzles that orient the
steam flow into high speed jets. These jets contain
significant kinetic energy, which the rotor blades,
shaped like buckets, convert into shaft rotation as the
steam jet changes direction. A pressure drop occurs
across only the stationary blades, with a net increase
in steam velocity across the stage.
As the steam flows through the nozzle its pressure
falls from steam chest pressure to condenser
pressure (or atmosphere pressure). Due to this
relatively higher ratio of expansion of steam in the
nozzle the steam leaves the nozzle with a very high
velocity. The steam leaving the moving blades is a
large portion of the maximum velocity of the steam
when leaving the nozzle. The loss of energy due to this
higher exit velocity is commonly called the "carry over
velocity" or "leaving loss".



In the reaction turbine, the rotor blades themselves are
arranged to form convergent nozzles.
This type of turbine makes use of the reaction force
produced as the steam accelerates through the
nozzles formed by the rotor.
Steam is directed onto the rotor by the fixed vanes of
the stator. It leaves the stator as a jet that fills the entire
circumference of the rotor. The steam then changes
direction and increases its speed relative to the speed
of the blades.
A pressure drop occurs across both the stator and the
rotor, with steam accelerating through the stator and
decelerating through the rotor, with no net change in

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steam velocity across the stage but with a decrease in
both pressure and temperature.
Net result reflecting the work performed in the driving of
the rotor.
Casing or Shaft Arrangements


These arrangements include single casing, tandem
compound and cross compound turbines.
- Single casing units are the most basic style where a
single casing and shaft are coupled to a generator.
- Tandem compound are used where two or more
casings are directly coupled together to drive a single
generator.
- Cross compound turbine arrangement features two
or more shafts not in line driving two or more
generators that often operate at different speeds. A
cross compound turbine is typically used for many
large applications.


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Warming & Starting

When warming up a steam turbine for use, the main
steam stop valves (after the boiler) have a bypass line
to allow superheated steam to slowly bypass the valve
and proceed to heat up the lines in the system along
with the steam turbine.
Also a turning gear is engaged when there is no steam
to the turbine to slowly rotate the turbine to ensure even
heating to prevent uneven expansion.
After first rotating the turbine by the turning gear,
allowing time for the rotor to assume a straight plane
(no bowing), then the turning gear is disengaged and
steam is admitted to the turbine, first to the astern
blades then to the ahead blades slowly rotating the
turbine at 10 to 15 RPM to slowly warm the turbine.


Maintenance
Problems with turbines are now rare and maintenance
requirements are relatively small. Any imbalance of the
rotor can lead to vibration, which in extreme cases can
lead to a blade letting go and punching straight
through the casing. It is, however, essential that the
turbine be turned with dry steam.
If water gets into the steam and is blasted onto the
blades (moisture carryover) rapid impingement and
erosion of the blades can occur, possibly leading to
imbalance and catastrophic failure. Also, water
entering the blades will likely result in the destruction
of the thrust bearing for the turbine shaft. To prevent
this, along with controls and baffles in the boilers to
ensure high quality steam, condensate drains are
installed in the steam piping leading to the turbine


Speed regulation
The control of a turbine with a governor is essential, as
turbines need to be run up slowly, to prevent damage
while some applications (such as the generation of
alternating current electricity) require precise speed
control.
Uncontrolled acceleration of the turbine rotor can lead
to an over-speed trip, which causes the nozzle valves
that control the flow of steam to the turbine to close.

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Efficiencies
Efficiencies of steam systems are hard to calculate.
40-50% is a number that is usually attached to steam
turbine efficiencies. However, this number could be
misleading because it does not take into account
boiler efficiencies.
Boilers are generally 80-85% efficient. If such a boiler
is included in the steam system, then the efficiency of
the steam system drops to 32-42.5%.
However, if the boilers are already in place and a
steam turbine is added later, then generally the boiler
efficiency need not be considered.
Another point to consider is if a back pressure steam
turbine is replacing a pressure reducing valve or
steam blow off practice, then any energy you can get is
energy efficient.
The reasoning behind this is that the plant was
previously loosing energy either by isenthalpic
expansion or by simply blowing excess steam away.
Now, the plant is using the energy and therefore, when
compared to before, the plant is much more energy
efficient.


Emissions
Steam turbines do not emit anything themselves.
However, the steam generator emits pollutants.
Therefore, the emissions from a steam turbine system
are highly variable and depend on the type of fuel being
used to create the steam and the method by which
steam is created.
Boilers will emit NOx, SOx, PM, CO, and CO2.

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There are a variety of emissions control technologies
for steam systems. Some of these include:
-Flu-gas recirculation,
-low excess air firing,
-combustion control,
-using low nitrogen fuel oil,
-inserting water/steam to lower NOx,
-selective non-catalytic reduction,
-selective catalytic reduction and others.



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