Saudi Aramco Steam Turbine Training Course
Saudi Aramco Steam Turbine Training Course
Saudi Aramco Steam Turbine Training Course
STEAM TURBINES
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramco’s employees.
Any material contained in this document which is not already in the public
domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.
Steam Turbines
Section Page
INTRODUCTION............................................................................................................. 3
COMMON TYPES OF STEAM TURBINES IN USE AT SAUDI ARAMCO ..................... 4
Principle of Operation ................................................................................................ 4
Curtis Stage.......................................................................................................... 5
Other Types of Stages.......................................................................................... 6
Turbine Classification................................................................................................. 7
Classifications of Mechanical Drive Turbines ....................................................... 7
Turbine and Cycle Efficiency...................................................................................... 8
Types of Steam Turbines......................................................................................... 10
Backpressure or Non-Condensing Turbines....................................................... 10
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Condensing Steam Turbines .............................................................................. 14
Extraction Turbines............................................................................................. 16
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MECHANICAL COMPONENTS AND THEIR FUNCTIONS .......................................... 18
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Trip and Throttle Valve............................................................................................. 18
Governor Valve ........................................................................................................ 18
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Steam Chest ............................................................................................................ 19
Hand Valve .............................................................................................................. 19
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Nozzles .................................................................................................................... 19
Blades...................................................................................................................... 19
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CALCULATIONS........................................................................................................... 20
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Outlet Temperature.................................................................................................. 20
Example Calculation - Efficiency of an Operating Turbine ....................................... 25
Turbines With Saturated Exhaust Steam............................................................ 29
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Steam Turbines
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LIST OF FIGURES
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Figure 1. Steam Turbine - Principle of Operation ------------------------------------------------ 4
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Figure 2. Nozzles and Blades------------------------------------------------------------------------- 5
Figure 2a. Steam Turbine Blade Types------------------------------------------------------------- 6
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Figure 3. Turbine Isentropic Efficiency-------------------------------------------------------------- 8
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Steam Turbines
INTRODUCTION
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Steam Turbines
Principle of Operation
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The high-velocity jets from the nozzles strike the blades and
cause them to move. In the moving blades, velocity energy is
converted to mechanical work, or power.
Steam Turbines
Steam Turbines
Other Types of
Stages
In a multistage turbine, each stage after the first one has one
row of nozzles (stationary) and one row of blades (rotating).
These stages may be the "Rateau" type, also known as impulse
type, or the "reaction" type. Refer to Figure 2A for the definition
of impulse and reaction blading.
Steam Turbines
Turbine Classification
Classifications of
Mechanical Drive
Turbines
Mechanical drive turbines may be General Purpose or Special
Purpose.
Steam Turbines
Actual Work
Turbine Isentropic Efficiency =
Ideal (Isentropic) Work
Steam Turbines
Steam Turbines
Backpressure or
Non-Condensing
Turbines
Backpressure or non-condensing turbines are used when there
is a need for shaft work and a requirement for steam for
process heating (Figure 5). High-pressure steam is fed to the
turbine. The turbine produces work. The steam leaving the
turbine is at medium to low pressure, between 225 and 15 psig.
This remaining steam is then distributed to those parts of the
plant that need the steam energy to produce heat or as inlet
steam to steam turbines having a lower inlet steam pressure
design.
Steam Turbines
Steam Turbines
Steam Turbines
Steam Turbines
Condensing
Steam Turbines
Condensing turbines are employed where there is no suitable
use for the exhaust steam (Figure 6). Exhaust steam is
condensed by means of cooling water or air-cooled fin
condensers. The condensate is recovered and pumped back to
the steam generating system.
Steam Turbines
Steam Turbines
Extraction
Turbines
Frequently there is a use for part of the steam from a turbine
but not all of it. In this case, an extraction/condensing turbine
can be used (Figure 7).
Steam Turbines
Steam Turbines
The trip and throttle valve is a manual (start up) valve and a
safety device that shuts off the supply of steam in case of a
malfunction or an Emergency Shutdown Signal (ESD). The
usual malfunctions are:
• High vibration
The inlet steam takes a minimum pressure drop when the trip
valve is open. The trip valve is sometimes combined with the
governor valve.
Governor Valve
The governor valve is the main control for the rate of steam flow
into the turbine. It acts with the governor to maintain the speed
of the turbine. The governor valve may be a single valve, or for
more complex machines, it may be multiple valves. It may be
operated mechanically or hydraulically.
Steam Turbines
Steam Chest
Steam Turbine
Supply Exhaust
Trip and Governor Steam Nozzles
Throttle Valve Chest and
Valve Blades
Hand Nozzles
Valve and
Blades
(Single Valve
Turbines Only)
Hand Valve
Nozzles
Blades
Steam Turbines
CALCULATIONS
Given:
Steam Turbines
Calculate:
− temperature
− % moisture
Solution:
Use the Mollier chart for steam (Elliot Bulletin H-37B, inside
back cover); see Figure 9 for a graphic illustration of this
problem.
Steam Turbines
Steam Turbines
∆his = h1 - h2
= 1350 − 923
= 427 Btu/lb
Btu
2545
hp − hr
Therefore,
2545
Theoretical Steam Rate, TSR =
Isentropic ∆h
Btu
2545
hp − hr
TSR =
Btu
427
lb
lb
= 5.96
hp − hr
TSR
ASR =
Turbine Efficiency
5.96 lb hp − hr
=
0.75
= 7.95 lb/hp/hr
Steam Turbines
lb
= 1000 hp × 7.95
hp − hr
lb
= 7950
hr
= 320 Btu/lb
Actual h2 = h1 − Actual ∆h
= 1350 − 320
= 1030 Btu/lb
Read Outlet
Moisture Content = 8.4%
Read Outlet
Temperature = 130ºF
Steam Turbines
This type of problem is also solved using the Mollier Chart. The
method is illustrated by the following sample problem:
Calculate:
Procedure:
Steam Turbines
∆his = h1 − h2 is
= 1335 − 1127
= 208 Btu/lb
Calculate ∆hact:
∆hact = h1 − h2 act
= 1335 − 1196
= 139 Btu/lb
∆hact
Efficiency =
∆his
139
=
208
= 0.67
Steam Turbines
Steam Turbines
2545
Water Rate =
∆hact
Btu
2545
hp hr
=
Btu
139
lb
= 18.3 lb/hp−hr
28,000 lb hr
=
18.3 lb hp hr
= 1530 hp
Steam Turbines
Turbines With
Saturated Exhaust
Steam
Note that the five-step method above cannot be used if the
exhaust gas is saturated, because it is not possible to measure
the moisture content of the exhaust steam.
2545
TSR =
∆his
TSR
Efficiency =
ASR
Efficiencies of
Steam Turbines
for Use in
Calculations
Use efficiency curves provided by manufacturers, if they are
available. If they are not available, estimates can be made from
references. For multistage turbines, GPSA Figures 15-12, 15-
13, and 15-17 give the basic efficiency of turbines operating at
full power.
For factors to estimate the efficiency at less than full power, use
GPSA Figure 15-11. For single-stage non-condensing turbines,
efficiencies can be obtained from Work Aid 4.
Steam Turbines
Use of Hand
Valves to
Maximize
Efficiency
Turbines should always be operated at maximum efficiency to
reduce the amount of steam required. If a turbine is operating
at full power, the efficiency is determined only by the turbine
design. At reduced power, there are other ways to improve the
efficiency.
On large turbines, the multiple valves that block off some of the
nozzles are all controlled by the governor mechanism. They
open and close automatically at the proper time. On smaller
turbines, only a single main valve is controlled by the governor.
The others are hand valves. The hand valve must be operated
manually in order to achieve maximum efficiency. It must be
either fully open or fully closed; it is not designed to be a throttle
valve. Note: If hand valves are supplied on steam turbines in
auto start or critical applications (lube/seal oil pumps), all hand
valves should be open to ensure that maximum power will be
available if required.
Steam Turbines
With steam rate tables, you cannot calculate the outlet steam
temperature or steam quality. Also, it is not possible to
calculate the efficiency of an operating turbine from plant data.
Mollier charts must be used for these two calculations.
Performance Curves
Figure 11 is a typical performance curve for a condensing
turbine. The curves for backpressure turbines are similar in
format.
Steam Conditions:
Steam Turbines
Steam Conditions:
Steam Turbines
• Low efficiency
• Erosion of blades
• Vibration
Steam Turbines
Steam Conditions:
P1: psia
T1: ºF
P2: psia
bhp required hp
3. ∆his = h1 - h2
= ( )−( )
2545 2545 lb
= = =
∆his ( ) hp − hr
ASR =
TSR
=
( )= lb
Turbine Eff . ( ) hp − hr
Steam Turbines
= ( )×( )
= ( )×( )
= Btu/lb
Actual h2 = h1 − Actual ∆h
= ( )−( )
= Btu/lb
T2 = ºF
% Moisture =
Steam Turbines
P1: psia
T1: ºF
P2: psia
T2: ºF
h2 isentropic = Btu/lb
4. ∆h is = h1 − h2 is
= ( )−( )
= Btu/lb
5. ∆h act = h1 − h2 act
= ( )−( )
= Btu/lb
∆h act
6. Turbine Efficiency =
∆h is
=
( )=
( )
Steam Turbines
2545
7. Water Rate =
∆h act
2545
= = lb/hp-hr
( )
=
( ) lb / hr = hp
( ) lb / hp − hr
Steam Turbines
P1: psia
T1: ºF
P2: psia
bhp: hp
h2 isentropic = Btu/lb
Btu
=
lb
4. TSR =
2545 2545 lb
= =
∆his ( ) hp − hr
=
( ) lb hr =
lb
( ) hp hp − hr
6. Turbine Efficiency =
TSR
=
( )=
ASR ( )
Steam Turbines
h2Actual = h1 − ∆h actual
Read % Moisture %
T2 ºF
Steam Turbines
Correction Factors
Steam Turbines
Steam Turbines
Common Operating Problems
Vibration • Deposits
• Erosion
• Broken blades
• Damaged bearings
• Misalignment of piping
Steam Turbines
GLOSSARY
Steam Turbines
Rateau Stage A steam turbine stage with one row of nozzles and
one row of blades. A relatively small pressure drop
is taken in the rotating blade of a Rateau stage.
Theoretical Steam Rate The flow rate of steam in pounds per hour required
(TSR) to produce 1 horsepower in an ideal turbine. TSR is
determined by steam inlet temperature and
pressure and outlet pressure.
Water Rate The actual steam rate required per unit of power.
(Pounds per horsepower-hour.)
Steam Turbines
REFERENCES
Supplementary Text
Vendor's Bulletins
Industry Standards