STEAM TURBINES Unit 1 PrinciplesPILOT 8—PUMP AND COMPRESSOR DRIVERS UNIT 2—STEAM TURBINES Unit 1 Principles... Single- and Multi-t Stationary Buckets Reaetion Turbine... Condensing and Non-t Condensing ‘Turbines. Extraction and Induction a Governors, .... Direct-Acting Flyball Governor Hydraulic Governor : Oil-Relay Governor... Overspeed ‘Trip... Review and Summary e ‘Turbines... . Unit 2 Parts and Equipment... The Rotor. .... ‘The Casing. . Diaphragms and Labyrinth Seals. Packing Boxes........ : Bearings. . Single- and Multi-Valve Governors, Oil Circulation: . Review and Summary Unit 3 Operation. Excessive Casing Pressure. Insulation. Condensation of Steam Effects of Uneven Heating and Cooling Shaft Bow, ... Packing Box Leakage. Vibration . . Critical Speed ‘ Bluding Deposits... . Lubrication . * Water in the Oil System a Overspeed Trip... Turbine Speed Adjustment Instrumentation, epee Visual Inspections Before Startup. . Review and Summary 23 + 28 23 2A 26 31 - 42 45 45 45 46 aT 48 50 51 at 56 57 58 . 59 61 62 62Steam turbines may differ from one another in size, appear ance, and construction, but all steam turbines are similar in operation and work on similar principles, Tn Unit 1 of this program, you will learn how impulse and yeaction turbines convert thermal encrgy to mechanical energy. You will learn how condensing and non-condensing turbines work, how turbine speed is controlled, and how the sainst failure of other In Unit 2 you learn the construction of the turbine: rotor and easing, diaphragms, seals, and packing boxes, including. labyrinth and carbon-ring packing, You will learn the con- struction of the bearings and bearing combinations used in turbines, of singles and multi-valve governors, anil of the vil circulation system. In Unit 8, you will learn turbine operation and operating problems; the effects of pressure, heat, and steam condensa- tion; of uneven heating and cooling; lenkage of steam, vibra- tion; lubrication and lubrication problems; speed adjustment, instrumentation, and visual inspections to be conducted before startup, Through this understanding of turbine principles, constrn tion, and control, you will be better able tn assure the efficiency and safety of turbine operations,HERE ARE SOME SAMPLE ITEMS TO GIVE YOU PRACTICE WITH "PROGRAMED LEARNING", First, we say something, like this: “A program may look very much like a test, or exam- nation, but it is not a test.” Next, we ask you for an interpretation, or we say more about what we have just said but leave something out for you to fill in, like this: “A program is not a Next, you fill in the blank, and then move down the mask at the right to see if your answer és correct If your answer is wrong, review until you can see why it is wrong, and then go on to the next item. If your answer is right, Ao on at once. Instead of a blank to fill in, we may give you @ choice of two answers. Circle or underline the right one. “No one grades you on the answers you give in studying 4 program. However, filling in all the answers is important for your own learning and remembering, “It (is/is not) important to fill in all the answers as you study @ program.” Here is one more example: "A program permits you to study at your own rate of speed. "Take time to read each item carefully, because skim- ming and guessing make for poor leurning, “In studying a program, it is (helpful/wasteful) to give each item close attention.” Notice that the left hand pages from here on are printed upside down, The program is designed so that you will xo through all the righthand pages firs and then turn the book upside down and yo through the other pages Now, yo on to Page 2 and beyin, iy Before beginning, cover this column with the mask. test helpfulNow pull the exhibits out of the center of the book. PRINCIPLES 1 10. n. Heat is the flow of thermal energy. Thermal can be changed to mechanical energy. A steam turbine changes thermal energy to energy. When water boils and turns to steam, the steam has more energy than the water had. Heating water in a closed container (inere: creases) the pressure of its vapor, Steam pressure in a boiler is increased by adding Pressure builds up in the container. mF ef 4 & NOZZLE ~—— cmaeeeey HEAT SOURCE Steam pressure in the container becomes (higher/ lower) than the pressure of the atmosphore. ‘The higher pressure forces steam ty expand through the, Steam is forced out of the nozzle at (high/low) speed or velocity, A jet of steam strikes the bucket, and the bucket moves. Mechanical energy is produced as the high-velocity strikes the bucket and causes it to move. When steam expands through the nozzle, its pressure (increases/decrenses) . As the pressure of the steam flowing through the noz- le is reduced, the velocity of tho steam increases ‘The nozzle changes steam pressure to stem High-velocity steam striking the — turns the rotor and produces mechanical work. energy mechanical increases heat. higher nozzle high steam deereases: velocity bucket2. 13, dd. 15. 16. 17. 18, 19. 20, ‘The drawing shows a simple turbine. HEAT SOURCE ‘The rotor consists of “blades” or buckets mounted on a —i 1@ nozzle directs the flow of —__ toward the buckets. Steam pressure is (higher/lower) at the rotor than in the boiler. Steam (can/cannot) Now if there is no pressure dif- ference. Increasing the pressure difference (ineroases/ decreases) the amount of flowing steam. As steam leaves the nozzle, its pressure and tempera ture (increase/decrease). Us velocity . Heat (thermal energy) produces steam pressure, and the steam pressure is converted to steam velocity by the nozale. After steam strikes the buckets, steam velocity Cinereases decreases) . ‘The rotor turns and produces mechanical work, ‘The Steam has (gained/lost) energy. More steam produces more work than less steam when both are at the same temperature and pressure. If more nozzles ave added, or if the nozzle is enlarged, (more/less) steam strikes the buckets. More nozzles or a larger nozzle produces more work, [8] shaft steam lower cannot inereases, decrease increases: decreases lost more mechanical21. To inerease the amount of steam flow: —_________ the pressure difference or. a the nozzle opening while keeping the pressure differ- ence constant, 22. The purpose of the nozzle is: steam at the buckets and to convert steam ______ to steam 28, The rotor in this turbine differs from the rotor in the previous drawing, EXHAUST STEAM BUCKETS: STEAM CHEST GOVERNOR CASING VALVE wee EASY, NOZZLE STEAM INLET FROM BOILER ‘The buckets are mounted on a —— rather than directly on the shaft. 24. The three ba: source of parts are still a rotor, a nozzle, and a 25. The nozzle or nozzles are located in the wall of the steam —t 26. The flow of steam into the steam chest is controlled by the governor —___. 27. By controlling the amount of steam flowing into the steam chest, the governor valve controls the output of energy. 28, The rotor is mounted inside a metal __. 29. For the steam to flow into the easing through the noz- vlc, the steam pressure in the casing must. be —_ than the steam pressure in the steam chest. 30. Without a pr and no difference, the steam cannot flow can be produced, (4] inerease; increase, or enlarge direct pressure, velocity wheel steam chest. valve mechanical casing lower, or less mechanical work, or energy31. The high-velocity steam directed toward the buckets is an impelling force (impulse) which causes the rotor to turn, Because the turbine uses the impulse of steam on the buckets to turn the rotor, the turbine is called an _ turbine. 32. Look at the drawing. CASING - 33, 34, 35. 36. 38, 89, 40. GOVERNOR SHAFT VALVE STEAM IN A B ‘There is a____on each shaft. Because there is less load on turbine A, turbine A needs (more/less) energy than turbine B to do its job. ‘The most convenient way to increase the power output of the turbine is to allow steam into the steam chest, When more energy is needed, the governor valve is to let more steam into the steam chest. If the load on the shaft increases (but the steam flow is not increased), the speed of the rotor (increases/ decreases). Opening the governor valve the rotor. _ the speed of ‘The speed of the rotor also increases as the __ on the shaft is decreased. If the rotor turns too fast, it may be damaged. Speed is controlled by the ______ valve. Shaft speed depends on: the amount of ____ on the shaft and the amount of _____ flowing into the steam chest, (5) STEAM OUT impulse load less more opened decreases increases Joad governor Joad steamSingle- and Multi-Stage Turbines 41. The area into which steam expands is a staye. Steam pressure ii ereased/decreased) in a stage. 42. When pressure is reduced in one stage only, a turbine is called single-stage, If steam pressure is vedueed in more the turbine is called multi-_ one stage 43, Look at the drawing. CST NSS EXHAUST ne STEAM HEAT SOURCE This turbine has (one/more than one) wheel, 4, sure is reduced in stage. 45. This is a_ -stage turbine, 46, Look at the drawing, Ist STAGE 2nd STAGE 3rd STAGE ar Rites NO EXHAUST STEAM HEAT SOURCE This turbine has __ wheels 47. Pressure is reduced in _______ stages. 48. ‘This is a__-stage turbine. 49. All of the stages are located in____ easing. 50. Steam leaves the turbine through the (6) decreased stage one one single three three multi ‘one exhaust51. Look at the drawing. CASING NOZZLE BUCKET > J EXHAUST ae STEAM ARR DIAPHRAGM HEAT SOURCE 4 STAGE LAST STAGE All the wheels are mounted on shaft one 52, Each stage is isolated by a whieh holds diaphragm the nozzles. 58. All the previous drawings have shown — one nozzle per stare. 54. Instead of one large nozzle, a row of smaller nozz! ean be used. WHEEL HIGHER be PRESSURE STATIONARY DIAPHRAGM STEAM JETS DIRECTED TOWARD BUCKETS ROW OF NOZZLES There is_____ row of nozzles per stage. one igh inlet pressure and lew its pressure reduced Turbines having large pressure drops between inlet and exhiust are usually (single-/multi-) stage tur multi- [7]56. Look at the drawing. (Rotor A/Rotor B) is single-stage, (Rotor“A/Rotor B) is multi-stage, (Rotor A/Rotor B) reduces pressure in steps. (Rotor A/Rotor B) is probably in the larger turbine, 57. Steam expanding from stage to stage inereases in volume. To provide for the larger volume in the later stages, the buckets are longer. Tn Rotor B, the buckets on the last wheel are than the buckets on the first wheel. Stationary Buckets 58. One kind of stare uses two rows of buckets instead of one. But is only ce there is only one pressure reduction, there stage. 59. The row of nozzles directs steam at the first row of buckets. voz2t oN A WS DIRECTION OF MOVING \ BUCKETS BUCKETS. As the steam leaves the buckets, it is moving in the (same direction as/opposite direction from) the mov- ing bucket: (8) A B longer one opposite direction from60, In order to move a second row of buckets in the same direction as the first, the must be redirected, steam 61. Look at the dra \ EN SS ss aN Between the two rows of buckets is a row moving of stationary buckets. 62, These stationary buckets =< the steam jets redirect into another row of moving buckets, 68. Since the stationary buckets do no change the pressure of the steam jets to any great extent, they (are/are not) are not like a row of nozzles. 64, The stationary buckets are mounted on the casing and do not —___. move 65. Look at the drawing. STATIONARY BUCKET’ Although the picture shows more than one wheel in a stage, most stages have just — __ wheel. one t9]Reaction Turbine 66. In an impulse turbine, all the steam expansion oecurs through a stationary nozzle. All turbines described so far are __ turbines. impulse 67. A reaction turbine has a large portion of the expansion oveurring in the buckets or blading of the wheel. A turbine having a large amount of expansion oceur- ving in the wheel blading is a (reaction/impulse) reaction turbine, 68, Look at the drawing. . vais. aR ELOCITY NOZZLE > roToR eocir WHEEL BOILER —»| ante BUCKET EAT SOI “HIGH"~ HEAT SOURCE PRESSURE STEAM ‘These reaction turbines have no stationary nozzles, All the drop occurs in the wheel or rotor. pressure 69. The turbine blading acts like moving ___. nozzles 70. In the impulse turbine, expansion of steam (pressure drop) occurs across the stationary nozzles. In the reaction turbine, some or all expansion occurs in the. __ mounted on the rotor, buckets, or nozzles 71. In the reaction turbine, the steam expands as it flows through the buckets. In the impulse turbine, steam (expands/does not ex- pand) to a great extent in the buckets. does not expand 72, Normally, reaction turbines, like impulse turbines, have stationary nozzles, but in the reaction turbine, (part/ none) of the expansion oveurs in the buckets. part 73. Reaction turbines, although sometimes more efficient than impulse turbines, require more stages than im- pulse turbines. ‘They are seldom used is pump or compressor driv Plants usually use (reaction/impulse) turbines, impulse (107Condensing and Non-Condensing Turbines 74, Steam expands from a higher pressure to a lower pressure, Therefore, steam exhausts from the turbine at a (ower higher) pressure than steam entering the lower turbine. 75, Steam flows from the boiler at a higher pressure and leaves the turbine through the at a lower pressure. 76. Low-pressure steam ean still be used ty run a turbine, Low m can expand into an area of still sure, lowe a 3 Look at the drawing, STEAM CHEST ] COOLING WATER —», CONDENSER’ A 8 ‘Turbine B has a _______ installed at the exhaust. condenser 78. A condenser removes heat and thus lowers pressure. ‘The condenser cools the steam leaving the turbine and changes it into water 79. (Turbine A/Turbine B) is a non-condensing turbine. Turbine A 80, ‘The exhaust pressure of turbine A is (higher/lower) higher than the exhaust pressure of turbine B. B81, When the steam is condensed, the water be re. turned to the boiler for reheating 82. The non-condensing turbine (utilizes/does not utilize) does not utilize all of the a lable thermal energy present in the steam, fy83, From the same amount of steam (at the same inlet pressure), the (condensing/non-condensing) turbine condensing produces more mechanical work, 84. Sinee large pressure drops are common in condensing turbines, the steam pressure is usually reduced in steps. Condensing turbines are usually _____-_-stage multi turbines, Extraction and Induction 85. Look at the drawing, Ist STAGE INTERMEDIATE FINAL EXHAUST. STEAM INDUCTION = ==> EXTRACTION Some steam may be removed from or added to a stage before it reaches the exhaust 86. Steam removed from a stage can be used for processes that need steam at pressures and temperatures: (above, below) the pressure and lemperature of the exhaust. above 87. Removing stes Steam from the turbine can be used extracted for other processes. an intermediate stage is extraction. 88. Steam may also be fed or “induced” into the turbine at an aKe. intermediate 89. Sometimes excess steam is available in the plant, at the pressure of a turbine’s intermediate stage, ‘This steam can be into the turbine at that fed, or induced atayse SOVERNORS 90. ‘The governor valve regulates the amount of steam allowed into the Lurbine wud the amount of — mechanical wark produced. D1, When a heavier load is placed on the turbine, (more/ less) power is needed than when the turbine is only more partially loaded. 92, The speed of the driven equipment must be controlled to perform ‘ating function, The ___________ valve is used to control turbine governor speed,98. The governor is a mechanism which opens and closes the governor valve. ‘The speed of the turbine is controlled by the 94. If the turbine starts to speed up or slow down, its speed must be brought back to normal, ‘The governor corrects for changes in 95. The drawing shows a flyhall governor, FLYBALL, SPRING AT REST HIGH SPEED The fiyballs arc held together by the force of a 96, As the governor turns, the spinning (centrifugal) foree moves the flyballs (farther apart/eloser together). 97. At (low/high) speed, the force of the spring keeps the Ayballs together. 98. At____speeils, the fyballs move farth V apart, 99. The ______the governor turns, the farther apart the Aybulls move. ct-Acting Flyball Governor 100. Look at Exhibit 1. When the turbine is not operating, the spring holds the flyballs close to the shaft. Refore the turbine is started, the governor valve is (vide open/elosed tight). 101, As the shaft starts to turn, the force of the prevents the flyballs from moving apart, 102, As the shaft approaches operating: speed, spring ten- sion is overeome by the force of spinning (centrifugal force), and the balls move (toward/away from) each other, 103, As the flyballs separate, the governor valve is (opened closed). When the turbine reaches operating speed, the governor valve allows (more/less) steam in than at startup, and the turbine stops accelerating. 104. When an increased load on the turbine slows the tur bine down, the flyballs are pulled in toward each other, The governor valve is________so that the turbine (speeds up/slows down). fis) governor speed spring farther apart low higher faster wide open spring away from closed less opened speeds up105, 106. 107. 108. 109. 110. in. 112, us. 14, 115, 116. I the load is suddenly removed, the turbine. up, If the inlet steam pressure is suddenly reduced, turbine speed (Increases/decreases). ‘The governor valve must Tf the exhaust pressure ris decreases). 8, the turbine speed (increases/ As the load is removed from a fully-loaded turbine, speed If a governor could compensate completely for this change in speed, the speed at zero load (would/would not) be the same as the speed at full load. With no difference between the speeds at full and no load, regulation would be zero. But if the governor design permits some increase in speed as the turbine load is decreased, the turbine regulation (is/is not) zero, A narrow governor tends to keep changes in speed as small ns possible, A governor with zero regulation is an extreme]; governor. Most narrow governors do not maintain zero regulation, but keep the drift in speed as low as 4%. A governor with 4% regulation is still a governor, To find the speed drift, multiply the rated speed by the percentage of regulation, ‘To find the speed at no load, (add/subtract) the speod arift to the rated speed, (4% of 3000 is 120.) Tf a turbine's vated speed at full load is 3000 RPM and its governor has 4% regulation, its speed at no load is___ RPM. A direct-acting flyball governor that is narrow keeps turbine speed changes (large/small). Friction in the governor mechanism tends to resist move- ment of the governor it ‘The governor must overcome the resistance of this ‘The governor must also overcome unbalanced forees steam pressure and steam flow in the valve, [14] speeds decreases open decreases increases would is not harrow narrow add 3120 small friction sovernor117. On turbines equipped with a narrow flyball governor, if there is a slight change in turbine speed, the gover- nor must first overcome friction and any unbalanced before it can move the governor valve. 118. The flyballs cannot control the speed within a small range, because the forces opposing the governor cause the valve to overtrayel, Correcting for load change, the governor moves the valve too 119. Overshooting constantly, the governor never precisely finds the operating speed, The turbine is continually speeding up or ——____ down a little. 120, This alternate speeding and slowing is “hunting”; that is, the governor hunts for the correet setting. A narrow flyball governor correcting small changes in turbine speed is more likely to» __than « broad governor, 121. A broad governor does not move the valve as far to cor rect a small change in speed as a narrow governor does. Only a (large/small) speed change causes the broad gov- ernor to move the valve from the opened to the closed position, 122. For u given speed change, the broad governor moves its valve i shorter distance than the narrow governor, and thus does not overshoot the correet valve setting, ‘The broad governor (tends/does not tend) to hunt. 123. A broad governor as broad as 10% ally has a range of operating speed As the load is decreased from full load to no load, turbine speed (increases/decreases) by 10° of full-load speed. 124, If 4 turbine’s rated speed at full load is 3500 RPM, with 10% regulation, its speed at no load is RPM. Hydraulic Governor 125. Look at Exhibit 2, which shows a hydraulic yovernor, To regulate turbine speed, the hydraulic governor uses an —- in plaee of flyballs, 126, An oil pump is connected directly ta the turbine [16] forces far slowing hunt large does not tend increases 8850 oil pump shaftEXHIBIT 1 SPEED CHANGER GOVERNOR SPRING o FLYBALL 0 | << GOVERNOR LINKAGE | STARTUP GOVERNOR SPRING FLYBALL GOVERNOR SPRING TOO FAST Pull this set of exhibits out of the book.EXHIBIT 2 _|} NEEDLE VALVE LEAK.OFF OIL PUMP SHAFT RETURN LINE TO RESERVOIR on PRESSURE 7 - NEEDLE a || VALVE r LEAK. t |} | oFF DIAPHRAGM lL PUMP SHAFT Olt RETURN LINE TO RESERVOIR Ol ice ~— | Mi NEEDLE DIAPHRAGM VALVE | LEAK.OFF O1L PUMP RETURN LINE TO RESERVOIR OIL PRESSURE t DIAPHRAGM,EXHIBIT 3 OUTLET TO RESERVOIR lL INLET = 4 OIL RELAY FLYBALL PILOT VALVE = lo "2 ~ PISTON‘TRIP TRIP PIN EXHIBIT 4 LEVER TRIP TRIGGER STEAM FROM BOILER STEAM TO STEAM CHEST TRIP VALVE on EXHIBIT 5 anne UNDER ~ PRESSURE —3 S PISTON T J+ CYLINDER RESTRICTION ORIFICE STEAM FROM DUMP VALVE BOILER STEAM TO. STEAM CHEST TRI VALVE: RETURN LINE TO RESERVOIR “ STEAM FROM iS BOILER steam 1o_ If STEAM CHEST TRIP VALVE RETURN LINE TO RESERVOIR127. 128. 129, 130, 131, 132, 183, 134, 185, 136, 137, 138, 139, When the turbine is not running, the ofl pump puts no pressure into the hydraulic piping, With no pressure on the governor valve, the valve remains (closed /open) As the shaft turns, oil is pumped into the piping to the valve. Most of the oil passes out of the leak-off and returns to the reservoir to provide a constant supply of to and from the oil pump, ‘The governor valve is connected to a flexible diaphragm. Changes in oil adjust the valve, When the turbine speeds up, more oil is pumped. ‘The oil pressure goes (up/down), The increased pressure acts on the diaphragm to (open, close) the valve, If more load is placed on the turbine, the turbine and the oil pump slow down. Oil pressure goes (up/down), and the valve —_ If oil pressure in the hydraulic s nor vulve moves to a Lully. ‘stem is lost, the gover- open position, ‘Thus if the hydraulic running, the turbine _ system fails while the turbine is ‘Temperature affects the viscosity (thiekness) of the oil. A change in oil temperature may affect the governor _—______ setting. Temperature must be carefully controlled, Too much hot thin oil passes through the oil leak-off so that sufficient oil pressure does not build up in the system and the tur- bine operates at (too high,too low) 2 speed, Cold thick oil pumps very well and not enough of it passes through the leak-off. Pressure in the hydraulic system becomes too great and tends to (open/close) the gover- nor valve. A change in temperature changes the governor valve set- ting and the turbine ___ setting. Hydraulic governors ure well suited to high-speed use. A high-speed turbine works best with a (hydraulic/ flyball) governor, Since temperature changes can affect the adjustment of the hydraulic governor, hydraulic governors are usually (narrow/broad) governors. (16) open oil pressure up close down, opens overspeeds valve too high close speed hydraulic broadOil-Relay Governor 140. wl. 142. 148. 144, 147. us, 19, 150. Look at Exhibit 3. ‘The oil-relay governor combines the features of the hydraulic and the ~__— governors. Oil pressure operates a. ‘The spring keeps the piston in place until a change in oil_______*_acts on the piston. Flyballs position the pilot valve that controls the oil Aowing through the oil inlet and the oil of the oil relay. At normal operating speed, both the oil inlet and outlet are partially open. Bul when the yovernor valve must open to compensate for un increased load, the flybulls reduce the outlet opening and increase the _ opening. . Ta close the governor valve, the flyballs reduce the opening and increase the opening. Unless the inlet is fully open or fully closed, oil eon- stantly cireulates through the relay system, regardless of the setting. Oil from the outlet connection is returned to an oil ——— to be pumped into the hydraulic system again. Tf oil pressure is suddenly lost (through failure of the oil pump, Tor example), the spring forces the piston to close the valve, With the oil-relay governor, loss of oil pressure does not cause the turbine to ——— as with the hydraulic governor, The oil-relay governor uses hydruulie force to move the valve so that it has (more/less) power than a fiyball governor by itself. It easily maintains narrow control by overcoming fric- tion and the unbalanced forces of steam. The oil-relay governor can be a narrow governor and (tends /does not tend) to hunt. OF the available governors, the (direct-acting flyball/ hydraulic/oil-relay) governor ig superior in maintain- 1 A narrow range of speed. Since the flyballs adjust the speed setting, a change in oil temperature (affects/does not affect) the turbine speed setting. L477 flyball piston pressure outlet inlet inlet, outlet reservoir overspeed more does not tend oil-velay does not affect151. In some turbines, the oil relay is not operated by a set of fyballs, An electric generator attached (o the turbine shaft adjusts the —__ 152. sing the speed of the generator changes its output of electric current, Changes in electric current adjust the pilot valve, which opens and closes the /° ___ and _ openings. Overspeed Trip 153. The sovernor regulates the turbine under normal con- ditions, but sometimes abnormal conditions occur. If all load is suddenly removed from a fully-loaded tur- bine, the turbine may — 154. Sometimes the governor reacts too slowly or fails to respond at all. Af the steam is — u hot shut off promptly, the turbine il it fies apart. 155. A Wip pin in the turbine shatt is used to shut off the flow in an emergency. 156, ‘Che drawing shows a trip pin in the shaft. WEIGHT At normal speeds the trip pin remains inside the 157. ‘The pin consists of an unbalanced weight held in the shaft by a . 158, If the turbine overspeeds, the pin is ejected from the _____ by centrifugal force (force of rotation). Lis] oil relay inlet, outlet overspeed overspeeds steam shaft spring shaft159. 160. 162. 163. 164. 166. 167. 168, 169. 170. 7. 172. Look at Exhibit 4. When the turbine overspeeds, the extended pin strikes the overspeed-trip ‘The trigger releases a latch holding the trip lever, which is then pulled down by a____, ‘The force of the spring the trip valve. ‘The trip valve closes and cuts off the stcam fiow to the steam The turbine Unlike governors (which are self-correcting), the overspeed-trip mechanism must be ___ afler the turbine stops, Look at Exhibit 5, Large trip valves use oil under pressure to open them and hold them open, ‘The spring-loaded valve is held open by the pressure of the ‘When the turbine overspeeds and the trip pin is ejected, the pin triggers a latch, as in Exhibit 4, ‘The latch opens the oil ____valve. ‘The force of the ______ ejects the oil from the cylinder, and the trip valve slams shut. As with the direct-acting trip, the mechanism must be after the turbine has slowed down Overspeed-trip pins are set to act at speeds 10 to 15%: over the maximum turbine speed. Af the turbine overspeeds 84% over the maximum, the pin (is/is not) ejected from the shaft. Other overspeed safety devices are used on turbines. On one type of small turbine, the rotor is equipped with a brake rim that is activated when the turbine ‘The brake acts like the brake of a ear. When the rotor overspecds, centrifugal force stretches or expands it until its rim rubs on the wall of the and slows down the rotor, If the brake-rim rotor does overspeed, some damage may occur to the wheel. ‘The rotor might have to be after over- speeding. [19] latch spring closes chest stops reset oil dump spring reset is not overspeeds casing removed, or repairedREVIEW AND SUMMARY 173. The purpose of the nozzle is to: 2) allow steam to flow from the steam f b) direct the steam jet at the ‘ buckets ©) convert steam —_ to velocity. pressure 174. Vor the turbine to operate, there must be a pre — hetween the steam chest and the difference 175. Name the parts indicated by the blanks. GOVERNOR LINKAGE STATIONARY BUCKET 176. The turbine illustr (single-/multi-) stayre single: turbine. 177. The houses the rotor, casing [20]178. 179, 180. 181, 182. 183. 184, 185. 186, Mechanical energy is transferred to the driven equip- ment by coupling the pump or compressor shaft to the ——— of the turbine. ‘The output of mechanical energy and the speed of the rotor are regulated by the ___, Steam can he induced or extracted from a turbine at an intermediate —_. In 2 condensing turbine the condenser is located al the The vil-relay governor combines the advant and _____ ______ governors. sof the A governor that cannot find the correct operating speed and is continually increasing and decreasing turbine speed is said to be —__., A (narvow/broad) flyball governor is more likely to hunt. The oil-relay governor is (more/less) likely to hunt than a mechanical flyball governor in a narrow range becuuse it has the power to overcome the unbalunced forces resisting the governor, In case the governor docs not correct overspeeding, Lhe ———_ is used as a safety device. shaft governor stage exhaust flyball, hydraulic hunting narrow: less overspeed tripUnit 2 Parts and EquipmentPARTS AND EQUIPMENT The Rotor 1 ‘The rotor consists of wheels, buckets, and a___. 2 The buckets are usually made separately and then mounted on the = 8. On some rotors, a hot wheel is placed on the shaft and allowed to cool. Cooling causes the wheel to shrink and fil tightly on the shaft. On other rotors, the shaft and wheel are forged as one 4, The (built-up/solid) rotor is first made in two parts, then shrunk together as one unit. 5. Because of its single-unit construction, the (built-up/ solid) rotor is the stronges 6, However, the rotor is less costly to make, The Casing 7. The turbine operates because there is a difference in essure Letween steam in the steam chest and steam in Steam pressure is (higher/lower) in the steam chest than in the casing, 8, Without this pressure difference, steam (would flow/ would not flow) through the nozzle. 9. Tf the exhaust becomes blocked, pressure builds up in the casing. As pressure builds up in the casing, the difference is lost. 10. Because the turbine is designed for greater pressure in the steam chest than in the casing, the (casing/ steam chest) is made stronger, 11. IF pressure in {he easing were allowed to go up as high as the inlet pressure, the easing would be, 12, For this reason turbines must never be started with the (inlet /exhaust) valve closed. 13, Some turbines have a safety valve installed on the ex- haust line to relieve excessive pressure, The valve prevents excessive pressure from the casing. Ces] shaft wheel unit, or piece built-up solid built-up hisher would not flow pressure steam chest damaged, or ruptured exhaust damaging14. On some turbines, a sentinel valve whistles if pressure ‘in the easing rises too high. This valve warns of high ____in the easing. 15. However, the __________valve does not adequately relieve the pressure, 16. Under correct startup and operating conditions, the sentinel yalve should never open to sound a warning. Tf the sentinel valve ever sturts to open, the operator must take immediate action to —_— the pressure. Diaphragms and Labyrinth Seals 17. In a multi-stage turbine there is a___ — in pressure between stages. 18. Look at the drawing. NOZZLES DIAPHRAGM. SOURCE OF LEAKS Whe part mounted to the casing. It separates two stages and holds the nozzles. m occurs where the phragm. 19. Leakage of ste: through the 20, Steam pas: buckets does Steam leaking along the shaft, bypassing the nozzles in the diaphragm, (does/does not ie) useful work in that stage, ing through the nozzles and striking the useful work, 21, Usable _—______is lost. 22, The diaphragm could be made to surround the shaft closely, but if the shaft rubs on the diaphragm und damages it, (part of the/the whole) diaphragm has to be replaced, [24] pressure sentinel reduce difference, or drop diaphragm shatt docs not do steam, or energy the whole23. Since the diaphragm is made of hard metal, the shaft is if the diaphragm rubs against it. damaged is 24. Look at the drawing. NOZZLES <+— DIAPHRAGM |~—— LABYRINTH SEAL A labyrinth seal is inserted in the space where the _ passes through the diaphragm. shatt 25, ‘The lahyrinth seal reduces the ___ hetween the space diaphragm and the shaft. 26, The seal ix made of soft metal (like, brass), so that if it rubs on the shaft it does not .____ the shat damage to any extent. 27, The seal heeomes damaged if the turning shaft rubs ayutinst it, ‘The sen} is removable from the diaphragm so that if it is damaged it can be without replacing replaced the whole diaphragm, 28, The labyrinth consists of metal rings or ridges that fit close to Lhe sha ‘The ridges (tonch ‘do not touch) the shaft. do not touch 29. A small space between the shaft and the lubyviuth allows ______to pass through. steam [25]30. As steum enters the seal, it forms eddies (whirlpools) in each compartment. |J<+—— DIAPHRAGM LABYRINTH SEAL ————>} EDDIES Steam pressure (inereases/decreases) as it passes through the compartments, a1, The de in pe eam ps seal pert 2 (lurge/small) amount of sti between the shaft and the seal. through the Mm Lo pass Packing Boxes 82. Look at the drawing of a non-condensing turbine. STEAM CHEST: STAGE LOWER PRESSURE STAGE ‘The pressure at the exhaust of 4 non-condensing tur. bine is (greater/less) than the air pressure around it. 88, Steam ten s to leak from the packing boxes where the tends through the casing. [26] decreases small greater shaft34. ‘The greater the amount of leakage from the packing box at the inlet side, the greater the loss of usable —— to the atmosphere. steam With leakage of steam from this packing: box, (more/ less) steam must flow through the steam chest nozzles. more 35, The bearings are close to the packing boxes. Condensate from escaping steam can get into the and damage them, bearings 36. non-condensing turbine i or heating requirements. ised again for proc A leaix at the exhaust end of the shaft loses steam which could be used for other purposes, 37. Packing boxes reduce or minimize stcam leakage where the shaft extends through the — casing 88. The packing boxes on some equipment are packed with rings of soft material. ‘This soft material prevents from leaking steam through the easing. 39. In turbines, the soft puckiay we out quickly and {is/is not) a good sealing: mater is not 40, This is a packing box fitted with a labyrinth seal. LEAK-OFF FOR LOW PRESSURE STEAM —+| LEAK-OFF TO DRAIN OR GLAND EJECTOR Like the interstage-diaphragm labyrinths, this seal minimi: leakage of steam along the _., shaft fe7]41, 42, 43. 44, 5. In the condensing turbine, the exhaust-steam The ridges of the packing rings form small compart ments which resist the Now of . ‘Toward the outer end of the packing box, tivo or more remove steam, to be used again ina lower pressure system or disposed of in a drain or ejector. Took at the drawing. HIGH-YELOCITY STEAM STEAM FROM ~| t LEAK-OFF CONNECTION EJECTOR High-velocity steam flowing through the draws steam leakage out of the leak-oit. These seals and leak-offs allow (a great deal of/very little) steam to leave the casing. sure is fess than the outside air pressure. STEAM CHEST PACKING BOX CONDENSER S&S 7 aa Leakage along the shaft at the exhaust end of the tur- bine allows (steam to escape/air to enter) the exhaust. [28] steam leak-offs, or dvi ejector very little air to enter ory46, Air does not condense, It must be removed by a vacuum pump or ejector, If air is allowed to enter the exhaust and is not removed by an ejector, the exhaust pressure (increases/ deereases). increases 47, The packing box at the high-pressure steam inlet. end ng the casing along the shaft, 48, ‘The packings box at the low-pressure end of the eo donsing turbine prevents from entering th casing. 49. Took at the drawing. SEALING STEAM——>| CASING aa | LABYRINTH ‘SEAL STEAM LEAKAGE AR TO TURBINE INFLOW EXHAUST LEAK-OFF TO DRAIN OR GLAND EJECTOR Tn this packing box, steam is (added/removed) be- added tween sections of the labyrinths. 50, ¢ slenm Injected into the packing box flows in two directions along the — shaft 51, Air attempts to enter the exhaust through the packing box, bul the flow of sealing: prevents it team ‘The portion of the sealing steam flowing toward the casing passes into the exhaust and is condensed by the condenser 58. Sinee this steam is erease exhaust pre ndensed, it (loes/does not) ine does not ure. £29]BA. 60. ‘This drawing shows another type of packing. STEAM SEAL CONNECTION <— SHAFT CARBON RINGS GARTER SPRINGS LEAK-OFF CONNECTION This packing is made up of —______ rings. h ving is held together by 1 — : Like labyrinth packing, the carbon rings are separated by compartments, from Steam thal leaks through the rings may be led to a lower-pressure system or a drain by a - comnectior Carbon-ring packing may alsa he steam-sealed to pre- vent the eutrance of — into the exhaust cnet of a condensing | ‘There is a small space belween the carbon rings and the shatt. ‘The carbon vings provide low friction so that if they do foweh the shaft only a small amount of to the shaft oceurs. The carbon ring has greater anti-friction properties than the labyrinth packing, so that the carbon-ring packing ean fit closer to Lhe shaft than the packing. . ‘The (earbon-ving/labyrinth) packing allows less steam loakasre However, labyrinth packing, because it is metal, can take much higher temperatures and pressures than carbon-ring packing. ‘The (ahyrinth/carbon-ring) packing is more likely to be used for high-pressure sealing. 30] carbon springs steam leak-off air wear labyrinth carbon-ving63. Some turbines use a combination of labyrinth seal and carbon-ring packing. LABYRINTH SEAL HIGH PRESSURE LEAK-OFF CARBON RING SEAL A LEAK TO DRAIN OR TO LOW-PRESSURE SYSTEM GLAND EJECTOR ‘The high-pressure end of » multistage turbine may use bolt a and = packing in the packing box, G4. ‘The labyrinth packing controls leakage fr to the first leak-off connected to a low-pressure The leakage from the labyrinth to the atmosphere is controlled by the ns 65, At the exhaust end, temperature and pressire are very much redueed. The packing alone is often ade- quate to seal this end. 66. Condensing turbines usually use labyrinths to seal the packing box at the exhaust end. 67. Carbon-ring packing cannot be used on a shaft having a high surface speed. A shaft with a high surface speed is sealed with a seal, Beorings 68. If the turbine is to operate properly, the shaft must rotate with minimum friction, Resistance to ____of the shaft must be as small as possible, 69. ‘The rotor must be kept in position while it turns, The shaft must not be free to directions. in other 131] labyrinth, carbon-ring carbon-ring carbon-ving steam labyrinth rotation move70. The three types of shaft movement are shown. omg a aes ROTATION AXIAL MOVEMENT. (Turning) (Theust) RADIAL MOVEMENT Besides rotating, the shaft can tend to move in _ two other ways, 71, As steam strikes the rotor, it forees the shaft to thrust (tend to move away from the nozzle). ‘This movement along the shaft is (axial/radial) axial movement, 72, Movement also results when the shaft tends to move off-center, ‘This is (axial/radial) movement. radial 73. Both radia! and axial ___ must be control- movement. led to keep the rotor in position, 74, Bearings support the shaft and allow it to rotate with minimum friction. Bearings also control radial and —______ movement axial of the shaft. 75. ‘The lubricant to the bearing provides a film between the rotating shaft and the stationary parts which sup- port and center the shaft. This Nuid film prevents the shaft and stati ports from — mary sup- ayainst each other. rubbing 76. ‘The thrust bearings limit movement of the shaft toward the ends of the turbine, The thrust bed movement. nes limit the amount of —— axial 77. The radial or journal bearing in whieh the shaft ves controls — movement. radial [82] Now turn the page, turn the book over, and78. Look at the drawing. RADIAL BALL BEARING THRUST BALL BEARING The shaft of this small turbine is supported by bearings (both thrust and racial) 79. The balls offer (erent /liltle) resistance ta shaft rot tion, but (xreat/little) resistance to axial and radi movement 80. The bearings are lubricated so that there is on the bearings, the shaft, or the support, 81. ‘This combination of bearings is used on many turbines whieh drive pumps, THRUST BALL BEARING f SLEEVE OIL RING — BEARING ‘This shaft is supported by a———_____ bearing. [a3 Vall litte ssreat sleeve82. The sleeve bearing mounted at the end of the shaft prevents (radial/axial) movement, radial 83. The sleeve bearing is lubricated by a film of a oil 84. The ball bearing can be used as a thrust bearing if the force is not too great. axial 85, Ball thrust bearings are used on (large/small) turbines. small he drawing shows lubrication of a sleeve an oil ring. ‘ings by SLEEVE BEARING RESERVOIR om OIL RING OIL RING ‘The oil ring picks up oil from the oi] _____. reservoir 87. Rotation of the s L turns the ring and ea leeve i bearing carry oi] up to the s 88. The drawing shows another thrust- and journal bearing combination, STATIONARY, THRUST. SURFACE EEVE BEARING Fu OIL _UNDER THRUST — PRESSURE RUNNER Oil is supplied under pressure to the a , bearings [34]89. ‘The sleeve bearing prevents (radial/axial) movement, radial "90. The thrust colle sleeve bei are fixed to the shaft next to the hey turn with the shaft. The thrust (radially a illars prevent the shaft from moving ly). axially 91. Oil ix supplied under pressure to the thrust surf: In some bearings the stationary thrust sin with thrust shoes that till when the is fitted tues shait THRUST SHOE SLEEVE BEARING STATIONARY THRUST RUNNER THRUST SURFACE 92. Oil wedyes form between the shoes and the thrust runner. ‘The thrust shoes keep the oil from being squeezed out of the bearing by the foree of —____ axial movement, 3. ‘The oil wedges allow the shaft to rotate freely, but de not allow it to move (axially radially) Single- and Multi-Valve Governors 94, Steam released into the steam chest by the governor valve is directod at the hy the nozzles, buckets When the load on the turbine is reduced trom full to partial load, Jess steam is needed to keep the turbine up to speed. ‘The governor valve — closes 96, Press in the steam chest Cinereases/dverens the governor valve closes. ss) as decreases [35]97. 99. 100. Wl. 102, 103, or optimum: elficieney, maximum pressure should be maintained in the steam chest. Any steam pressure less than the optimum is (more/ less) efficient. less When less thermal cnergy is used by the turbine and more thermal energy passes out with the —__ exhaust steam, efficiency is lowered. Closing some nozzles in the nozzle row creates a smaller area for the steam lo flow through. With a smaller nozzle area to flow through, the steam ——_ in the steam chest can be held clase to pressure optimum. AL partial load, closing some nozzles maintains more efficient. steam —_____in the steam chest. pressur Look at the drawing, TURBINE WHEEL HIGH PRESSURE STEAM SPACE NOZZLE HAND VALVE WEN With a single-valve governor at partial load, hand valves close off nozale openings to — _the maintain efficiency of the turbine. When the turbine is at full load, all or most of the are open, nozzles, or hand valves When the load is reduced, some nozzles should be closed by the hand valves: [36]110. Only one valve vemains partially open or closed as the turbine is throttled. ‘The rest of the valves are cither fully or — 111, More force is needed to operate a multi-valve than a single-valve system. Since the oil-re! than the di governor is an - ___ governor, Oil Circulation 112. In a pressure lubrication system, the oil is supplied to the bearing under 112. Tf the oi not Juln ure is lost, the bearing is (Inbricated/ ed) ne equipped with an oil-relay governor must 1 ample supply of clean oil available under img Iubrication and for the governor pressure for hi hydraulie system. ating: system kee ——— lowing to the governor 1 good supply of clean and bearings, typical oil-circulation system. OIL TO DRAIN DRIVE GEARS FILTER OIL TO BEARINGS MAIN OIL PUMP Oil is stored in a large il [38] open closed pressure not lubricated oil J+ OIL RELAY GOVERNOR J— OIL TO GOVERNOR HIGH PRESSURE y ACCUMULATOR OIL RESERVOIR OL COOLER110. Only one valve vemains partially open or closed as the turbine is throttled. ‘The rest of the valves are cither fully or — 111, More force is needed to operate a multi-valve than a single-valve system. Since the oil-re! than the di governor is an - ___ governor, Oil Circulation 112. In a pressure lubrication system, the oil is supplied to the bearing under 112. Tf the oi not Juln ure is lost, the bearing is (Inbricated/ ed) ne equipped with an oil-relay governor must 1 ample supply of clean oil available under img Iubrication and for the governor pressure for hi hydraulie system. ating: system kee ——— lowing to the governor 1 good supply of clean and bearings, typical oil-circulation system. OIL TO DRAIN DRIVE GEARS FILTER OIL TO BEARINGS MAIN OIL PUMP Oil is stored in a large il [38] open closed pressure not lubricated oil J+ OIL RELAY GOVERNOR J— OIL TO GOVERNOR HIGH PRESSURE y ACCUMULATOR OIL RESERVOIR OL COOLER116. 17. 118. 119, STEAM FROM, BOILER STEAM TO STEAM CHEST TRIP VALVE 126. 127. . Oil that becomes too . Severe dam . ‘Thus, a . Some turbines may be stopped by a hydra Oil is forced to flow from the reservoir to the bearings and governor by means of an oil As oil is pumped, it passes through an oil to be cleaned of any impurities. As the oil passes around the bearings, it removes heat that builds up in them, ‘The oil is pumped through a cooler on its way to the Oil that becomes too hot loses its ability to maintain an oil film in the bearing. Oil that is too hot (is/is not) a good Tubs nl. may also decompose. » However, oil that is too cold becomes too thick and may not_________ the hearings properly. Oil must be kept at a proper e to the turbine may result if the oil- circulation system fails to deliver oil to the bearings. ‘The bearings out. _ of oil must be maintained at all times while the turbine is in operation. trip when the lubricating oil pressure becomes too low. RETURN LINE TO RESERVOIR An automatic dump valve releases oil from a trip cylinder when oil pressure is too (low/high). If the dump valve opens, it causes the trip valve to (open/close) and stop the turbine. Unless dual or standby equipment has been provided, the turbine may have to be shut down a filter or cooler begins to clog or the oil pump shows wear. Standby equipment permits the flow of to be maintained if trouble occurs with the operating filter, cooler, or oil pump. [39] pump filter bearings is not hot lubricate temperature melt, or burn flow low close oil128. 129. 180. as. 132, 138, 134, Large turbines are equipped with (one/two) pump One is used during normal operations, and the other in _ —. When one pump fails, the second pump takes over automatically and maintains oil —___. irs which store voir, Some turbines have pressure accumu oil at high pressure near the oil ress When the circulation system switches frem the main to the standby pump, this reserve 0 keeps the oil circulating. If the oil-rolay system needs inerensed oil flow beenuse of a large load change on the turbine, this reserve — maintains oil flow, Sometimes a filter becomes clogsed or the cooling su face of a cooler becomes fouled with deposits. If a standby filter or is provided, the flow can be switched to the clean set withonl having to shut down the turbine. Sometimes a filter is equipped wilh « relief yalye x0 that if it does clog, the oi] ean bypass it, Unfiltered ofl, possibly containing dirt or foreign L, then flows to the bearings until the filter — or the flow is switehed (wa standby filter, Look at the drawing. OUTLET OIL PRESSURE BYPASS INLET OIL PRESSURE Tf the filter becomes clogued, pressure decreases on the (inlet/outlet) sid 140] twa emergencies flow pressure pressure, or capacity cooler replaced outlet135. 136. 137, 138, When the pressure differential becomes great enough, the should open to maintain oil flow, “High pressure differential” indicates a plugged filter. When u specified pressure difference is observed by the operator, the flow should be switched to the filter. Some units are equipped with alarms. When the lube-oil pressure begins to fall, an —___ warns the operator. ‘There may also be a (high/low) temperature alarm, bypass standby alarm highREVIEW AND SUMMARY 139, 140. 141, 142, Name the turbine parts. ie ell II {| bl ‘The above turbine is (single-/multi-) staged. It is equipped with a (single-/multi-) valve steam chest. The space between the shaft and the diaphragm is sealed by a The shaft is sealed into the casing hy — boxes at the inlet and exhaust ends of the shaft. [42] 1. shaft leeve bearing sing. - - diaphragm governor ae govern Sf = labyrinth seal, or weking box multi- single- labyrinth packing3, 144, 145, 146, 147. 148. 149, 150, Look at the drawing. This packing box is fitted with a — I. ‘The connections A and B are —— for steam leakage, Stenm sealing is used in the packing box at the Cinlet/exhaust) end of a (condensing non-condensing) turbine, ‘The bearings prevent two types of shaft movement: and___ movement. ‘The thrust bearing prevents movement. and the journal bearing prevents movement, A large multi-stage turbine probably uses a (single-/ multi-) valve governor. On a single-valve governor, sections of the - may be turned on and off by hand valves. Oil supplied to the bearings aud the governor must be kept at the proper and and must be kept free of ____. [43] labyrinth leak-ofts exhaust, condensing radial, axial axial radial multi- nozzles temperature, pressure dirtREVIEW AND SUMMARY 189. Name the turbine parts. 1. shaft 2. sleeve bearing ing 4. diaphragm gov alve © a governor x labyrinth seal, or ‘kings box: 8. exhaust 140. The above turbine is (single-/multi-) staged. multi- At is equipped with a (single-/multi-) valve steam chest. single- 141, The space between the shaft and the diaphragm is sealed by a—___. labyrinth 142. The shaft is sealed into the casing by packing boxes at the inlet and exhaust ends of the shaft. [42]Unit 3 OperationOPERATIONS Excessive Casing Pressure 1. For steam to flow through the turbine, there must be a pressure ———. between the inlet and the exhaust, During startup of the turbine, the exhaust valve must be opened before the inlet valve, or excessive pressure may rupture the = Tf the inlet valve were opened before the exhaust valve, — would build up in the casing, ‘Turbines are sometimes equipped with safety valves to relieve excessive pressure. Safety valves located in the exhanst piping operate (manually ‘automatically). Sometimes the safety valve does not reset properly after it has opened. ‘The valve continues to leak through the relief line, and usable steam is lost lo the 2 Some turbines have only a sentinel valve and not a y valve, A sentinel valve sounds a warning when the — in the casing is too high. The operator must _______ the pressure im- mediately 7. ‘The sentinel valve hy itself’ (protects /does not protect) the casing against overpressuring, 8. Stopping the flow of steam to the turbine reduces the pressure, The operator (opens’closes) the inlet valve immedi- ately to stop the flow of steam, 9, To start up, the (inlet/exhaust) valve is opened first. ‘Yo shut down, the ______ valve is closed first. 10, Large high-pressure turbines must operate at low, speeds until they are warm, The inlet valve on these turbines should be (wide/ partially) open. Insulation 11. Insulation prevents the loss of _____ from the unit. [45] difference casing pressure automatically steam pressure decrease does not protect closes exhaust inlet partially heat12. The turbine is insulated to prevent heat Joss and pro- tect the operator from burns. The operations. ———. should be kept intact during insulation . If insulation is removed during repairs or inspection, it must be ______ before startup. replaced Condensation of Steam 14, ‘The temperature of steam leaving the turbine is always lower than the temperature of steam entcring the turbine. ‘The higher the inlet steam temperature, the (more/ less) likely the exhaust steam is to be dry. more 15. Condensing turbines have low exhaust temperatures, Usually some of the steam condens: through the later stages. it passes ‘These turbines are designed so that a moderate amount of condensate does not cause erosion of the ———__. buckets 16. If the inlet steam temperature falls below the design temperature, too much steam condenses in the earlier stages, These stages are not designed for condeusute. This condensate may eause — over xt period erosion of time. 17, During shutdown, the turbine cools, and any residual steam left in the turbine or the lines a= 3 condenses 18. Water collects in low points in the inlet line, oily (picks up/does not piek up) the does not pick up er as it passes over it, 19. During startup, many turbines opernte at (low/histh) low speed, and the steam flowing to the turbine i low velocity. (46)20. When the turbine is brought up to speed, the steam velocity is great enough to pick up and earry — — water with the steam. 21, Aslug of water traveling through a nozzle could break ees off the wheel. bucket 22. Low points in the lines and in the turbine casing are equipped with drains, Low points should be ____ before startup. drained 23. Drain valves should be opened and steam blown through them al (high/low) velocity. high When the steam blows dry, (most/all) of the water all that ean cause damage his been removed. 24. Some drains are equipped with steam traps. A steam trap automatically draina the hot condensate, If the line from the steam trap remains cold, the trap (is/is not) working properly. is not Effects of Uneven Heating and Cooling 25. Steam enters the turbine at relatively high tempera- tures. At startup after a long shutdown, the turbine is (hot/ cool). cool he metal components of the turbine expand rapidly when heated. ‘The parts that contact the hot steam —_ rapidly, expand 27, During startup of a condensing turbine, the condenser is put into operation before steam is admitted to the turbine. The condenser keeps the exhaust temperature relatively (high/low). low 28, The exhaust end of a condensing turbine is designed to operate at (higher/lower) temperatures than the lower exhaust end of & non-condensing turbine. 29. If the exhaust temperature rises too high, the bolting on the easing flanges is stretched and may loosen when the temperature returns to normal. ‘The easing flange may __ steam at the exhaust Teak end. 30. During startup, the rotor comes up to operating tem- perature somewhat faster than the casing does. ‘The rotor expands (more/less) than the casing. more (47131. 23, ‘The interstage dixphragms Tf the casing does not expand, the diaphragms (change/ do not change) position, ure positioned in the casing. As the rotor expands, it lengthens, ‘The wheels ure so close to the diaphragms that they rub on the w+ if the rotor expands much faster than the casing. During startup of steam through th to lot the easing multi-stage turbine, the flow of urbine should be kept small so as nid the rotor expand together. The roter (rubs/docs nol rub) on the diaphragms, Shaft Bow 24. 35. 36. 37. 38. 39. As steam thening over * inlo the tubine, the rotor must be lowly. STEAM When the rotor is not turning, the hot steam contacts (the upper half/both halves) of the rotor. The upper half — _ more than the lower half. ‘The shaft —_ from uneven heating. When the steam supply is shut off, the turbine starts to + Metal components shrink or contract rapidly as they cool. During shutdown the rotor shaft cools and Uneven cooling is (more/less) of a problem in large turbines with long shafts than in small turbines. [48] do not change diaphragms does not rub the upper half expands bows, or bends cool contracts, or shrinks more40. ai. 42, 43, 44, 46. 48. 49. Look at the drawing. BOWED SHAFT CooL At shutdown the steam in the casing starts to __. ‘The cooler, heavier steam (rises to the top/falls to the bottom) of the easing. ‘The rotor then cools (faster/slower) at the bottom than at the top, The shaft then tends to The turbine slowly cools until the entire rotor is all one temperature. ‘The bow is greatest a short time after shutdown when a (large/small) temperature difference exists in the turbine. Beewuse the wheels fit tightly to the shaft, the bow may remain, even when cooling is complete, ‘The shaft may still be at startup, ‘The metal parts __ again at startup. 7. Operating the turbine at low speeds for a period during startup lets the bowed shaft straighten, Reeause this bow straihtens it is a (permanent/ temporary) bow. Starting at high speeds can turn a temporary bow into a __. bow. The slow turning with even expansion straightens the shaft during startup. ” the The turning “shake: out of the shaft. [49] ool falls to the bottom faster bow large bowed expand temporary permanent bow50. Centrifugal force pulling on the bowed shaft can increase the bow, Speeding up the turbine before the bow has straighten- ed causes the bow in a shaft to (inerease/decrease), increase 51. If the bow increases, the shaft rubs on a diaphragm. ‘The friction of the rubbing generates intense —____. heat 52. This intense heat may cause the shaft to take a —__—set, The turbine then has to be over- permanent hauled. 53. In order to prevent uneven heating or uneven cooling during shutdown, larger units are equipped with a turning gear which rotutes the rotor so that ull sides 0 ae evenly 64. When the entire rotor is rotated, all sides receive an equal amount of contact with the hotter Inyer of steam. The whole assembly _______ evenly. cools 55, Small single-stage turbines operating on moderate steam pressures have few problems with uneven heating, Many small turbines can be brought up to speed (gradually /immediately) . immediately 56. Larger multi-stage turbines should be run at 206% of operating speed for about 30 minutes before being brought up to speed. This slow run-in is to prevent expansion or shaft rub. uneven Packing Box Leakage 57. At startup, the clearance between the shaft and pack- ing is greater than normal and some leakage occurs. As the shaft warms up, it _______and the clearance expands is reduced. ’ 58. As the turbine and shaft warm up, leakage should (increase/decrease) . decrease 59. If the packing is badly worn, leakage (decreases/ does not decrease) as the turbine warms up. does not decrease [50]60. Sometimes the leak-off connections become plugged, or Lhe valve in the steam line serving the leak-off is closed. LEAK.OFF LEAK-OFF Steam would out of the casing to the air. leak 61, For the packing box to seal, the - lenk-of connections must be operating. 62. The packing at the exha is steam-scaled, end of a condensing turbine Steam is (put into/removed from) the packing box. put into 63. Tf there is Loo much sealing steam, the ejector cannot remove it all, and some steam pa out of the _ass leakage. easing, or packing box 64, If the sealing steam is turned on before the turbine is rolling, the steam heats up the rotor on one side more than on the other. ‘The shaft expands on that one side and may develop ‘ bow Vibration 65. Two vibrational effects occur: 1, The frequency (the number of vibrations or move- ments in a given period of time). 2. ‘The amplitude (the distance the shaft or bearing moves). equency is the —¢ of vibrations over a number period of time. 151766. 67. 68. 69. nm. One complete vibration is a eyele. Frequency is ex- pressed in eycles per minute, Vibrations of 300 eyeles per minute have a greater ——= than vibrations of 100 eycles per minute. - The specd of vibration (number of vibrations for a given period of lime) refers to (frequeney /amplitude). Frequency is not related directly to the amplitude of the vibration, Increasing the frequency (increases/does not necessari- ly inerease) the extent of shaft or hearing movement. Shafts A and B are vibrating at the same frequency. — = —= _— _——— —— A B Shaft A moves (more/less) than shaft B. Amplitude is measured in mils (1 mil equals 1/1000 of an inch) A shaft vibrating at 10 mils (1/100 of an inch) moves (more/less) than a shaft vibrating at 4 mils (1/250 of an inch). Amplitude is measured in three directions: one axial, and two radial. 2, HORIZONTAL RADIAL se 3. VERTICAL RADIAL In 1, the shaft is vibrating —___ In 2, the _________ vibration is being’ measured along the horizontal plane, Tn 8, the radial vibration is being measured along the plane, [52] frequency frequency does not necessarily in more more axially radial vertical2 In normal operation the amplitude of vibration is low. Increased amplitude of the vibration indicates an ab- normal condition which should be — . Amplitude may increase if the shaft is out of bala MORE WEIGHT A bowed shaft may have more —__ on one side than on the ather sid . As a bowed shaft tur heavier » This unba de of vibration, When weight is vibra unequally distributed, amplitude of is (wreat/small). . ‘The couplings connecting the turbine to a pump may be misaligned. ALIGNED. ANGULAR MISALIGNMENT PARALLEL MISALIGNMENT COMBINATION ‘The greater the misalignment the greater the of vil n, §. A wheel with a bucket broken off has an unequal dis- tribution of weight and causes excessive _. If the rotor is binding on something, vibration (ampli- tude) increases. Newly installed carbon-ring packing whieh is rubbing ‘on the shaft may cause some —____until it wears in, [53] corrected weight great amplitude vibration (amplitude) vibration78. ‘The bearings must restrict axial and radial movement. A ___ hearing does not restrict axial and radial worn movement enough. 79. As the bearing clearance increases through wear, vibra- tion of the shaft (increases/decreases) . increases 80. In order to reduce the vibration, the be replaced. — must bearing Critical Speed 81, Look at the drawing. Lf the free end of a thin atrip of spring steel is pulled back and released, it vibrates ut one frequency (speed), its natural ——____. frequency 82, This natural frequency depends purlly on the length of the strip. A longer strip vibrates at a frequency (the same as/ different from) the frequency of a shorter strip. different from 83, A stiff strip also vibrates ata frequency different: from a more flexible one, 84, Like the metal strip, a shaft has a tendency to vibrate at its own naturel frequency 85. A longer shaft has a lower natural frequency than a shorter shaft of the same stiffness, A longer, multi-stage turbine shaft has a (higher/ lower) nutural frequeney than a single-stage shaft. lower 86. Two shafts of the same length but different stiffness have different natural frequen The stiffer shaft has the (higher/lower) natural higher frequency. 87, As a shaft turns, it sets up vibrations at the same rate it turns, That is, a shaft rotating at 1000 RPM vibrates at a frequency of ______eyeles per minute. 1000 154)BB 91 92, 93, 4. 96. 98. 99. » To avoid damage to the beari A shaft rotating al 3600 RPM vibrates at a rate of —_—— cycles per minute. . The faster a shaft rotates, the faster it —_. When a shaft rotates at a speed equal to its natu frequency, it is at its critical speed. That i speed. the vibration caused by rotation is equal to the frequency of the shaft at its critical At most speeds, the vibration caused by rotation is (different from/the same as) the natural frequency At speeds other than the critical speed the amplitude of vibration is normally small. At the critical speed, amplitude becomes A turbine thal must pass through a eritical speed befure reaching the operating speed is known as a flexible- shaft turbine. A ilexible-shaft turbine has a crilical speed (helow/ above) its operating speed. A turbine which has a stiff shaft does not have to past through a critical speed. A stiff-shaft turbine (has/does not have) x critical apeed below the operating speed. . A high speed. multi-stage lurbine usually has an oper- ating speed above the evitiea! speed. A high speed, multi-stage turbine usually has a shart. Since shaft movement is restricted by bearings, exces- sive vibrution — __ the bearings over a period of time, 5 the turbine must not. for he permitted to run at the any length of time. Tf the shaft on a multi-stage turbine is bowed, its am- plitude of vibration is (greater/less) when passing through the eritieal specd, Vibration is detected by an instrument. Excessive vibration can also be detected by touching the 3500 vibrates natural different from large below does not have flexible damages critical speed greater turbine, or bearing housiBlading Deposits 100. 101, 102, 108, 104. 105. Tf steam entering a turbine contains solids carried over from the boiler, this material may collect on the buckets and form —— — If cnough deposit builds up on the bucket, the shape of the bucket changes. HIGHER PRESSURE DEPOSIT \E LOWER PRESSURE LOAD The path of steam through the buckets (remains the same/is reduced in size) when the deposit forms ‘The reducti build up on nin flow causes steam __..__to ne side of the wheel, — / ‘This change in steam flow acting on the bucket causes the rotor to push forward. ‘This pushing increases the load on the (radial/thrust) bearing. When deposits form on the buckets, they form evenly on all the buckets, ‘The weight of the deposits unevenly). is distributed (evenly/ Tf some of the deposits break off from the buckets, the distribution of weight becomes (even/uneven). Vibration of the rotor —_____ Lubrication 106, All components which support or connect moving parts must be lubricated. The bearings must be [56] Sp THRUST deposits is reduced in size pressure thrust evenly uneven increases lubricated107. 108. 109. 110. UL 112. 3, In the oil-ring sleeve bearing, a metal ring picks up oi] from a reservoir and carries it up into the bearing. The oil__________ must be filled to the correct level before startup. Oil is supplied under pressure to a pressure-lubricated sleeve bearing. ‘The oil-eirculating system supplying the oil must have sufficient. vi When the oil is too cold during startup, the oil may be too (thick/thin). Because cold, thick oi] does not circulate well, too little oil may reach the bearing. Cold oi] must be —______up before sta turbine. ing the Once the turbine has started up, heat from the steam and bearing friction tends to heat the oil. After startup, oil temperature (increases/decreases) . If the oil temperature rises too high, the oil may break down (decompose). ‘The oil (heater/cooler) must be in service while the turbine is running, Af the temperature rises too high, the oil thins out and does tot maintain the film necessary between shaft and bearing. Cooling the oil maintains proper of the Water in the Oil System 114. Water rusts bare steel surfaces. If water gets into the oil system, it —__ unpro- tected steel surfaces. 115. Water often combines with chemicals to make them corrosive. If water-laden oil absorbs these chemicals from the air, they combine with the and become corrosive. 116. Water mixed with oil forms a thick emulsion. An oil-water emulsion can an oil filter. Ls7] reservoir pressure thick heated, or warmed increases cooler thickness, or viscosity rusts water plug117. Water, oil, and air mixed together form a foam. If the oil then mi: water- witer mixture passes through a bearing wend es with air in the bearing housing, the oil ir mixture forms a ss y 118. ‘This foam may overflow from the bearing housing: to the outside of the turbine and soak into the insulation. If the oil absorbed in the insulation reaches a high enough temperature, it may 119. If sufficient water collects in the bottom of the gil rvoi instead of oil may be pumped to the bearings. resi 120. Since oil floats on water, water can be drained from the reservoir at the (top/bottom) of the reservoir, 121, Pressure drop across the oil filter should be watched, so that it does not become too —__ The governor spindle bearings must also be kept lubricated, Tf the flyball governor is not — , it could fail and permit the turbine to overspeed or shutdown. Overspeed Trip 123. The overspeed trip mechanism must be ready to oper- ate in ease the turbine —____. 124, Before startup, the hand trip lever should be pyshed to see whether the trip valve responds and properly. 125. The trip and alarm circuits should be checked periodi- cally to make certain that they are working. The most opportune times to make these ehecks are when the turbine is (idle/running). [58] foam ignite, or flash water Dottom high lubricated closes idle126. When the turbine is to be shut down, it is brought to a stop by hitting the hand trip lever. The steam is shut off by hitting the — __ _____ hand trip lever. 127. Larger Lurbines are equipped with hydraulic and_elec- trical trip mechanisms, For these hydraulic trips to work, the hydraulic ———. system must be operating. oil Turbine Speed Adjustment 128, Look at the drawing of the direct-acting flyball governor, SPEED CHANGER GOVERNOR SPRING FLYBALL STARTUP GOVERNOR LINKAGE Until the turbine reaches operating speed, the governor holds the flyballs together, spring 129. Connected to the governor linkage is another - spring: whose tension can be varied to change the speed set- point. 130. The centrifuga) force of the flyballs is balanced against the tension of these two —_____. springs 131, The tension of the speed-changer spring can be varied by turning the knob. Increasing the spring tension makes the flyballs turn (faster /slower) to move the governor valve, faster 182. Increasing the tension of the speed changer makes the valve close at higher speeds and —.the increases operating speed. [59]133, 136, 137. 188, ‘This is the hydraulic governor. NEEDLE VALVE LEAK-OFF OIL PUMP SHAFT RETURN LINE TO RESERVOIR OIL ~——— _]} | PRESSURE ee DIAPHRAGM As the turbine speed increases, (more/less) oil is more pumped into the governing system. |. As more oil is pumped, the pressure increases and the governor valve (opens/closes). closes Increasing the opening of the needle valve reduces resistance to the flow of oil from the governing system, Oil pressure __. decreases The govertior pump has to run faster to develop enough pressure to close the valve. Opening the needle valve (incrcases/decreases) the increases turbine speed setting. Reducing the opening of the needle valve en deers the turbine speed setting. The oil leak-off on the hydraulic governor allows a greater change in speed than the speed changer on the flyball governor, The (flyball/hydraulic) governor offers a greater range hydraulic of speeds. [60]In the oil relay, the speed setting is changed by adjust ing the pilot valve. INLET OIL OUTLET uy LOT VALV ADJUSTING PILOT VALVE se Adjusting the pilot valve changes the oil inlet and settings without ehansing the flyball setting. outlet Instrumentation 10. In the circulating-oil pressure must bem yatem, proper Lemperature and intained. GOVERNOR PRESSURE GAGE >) +—OIL RELAY GOVERNOR OIL TO DRAIN «OIL TO GOVERNOR -aHIGH PRESSURE OIL GAGE i? FILTER SHAFT —>| iat PUMP DISCHARGE + PRESSURE GAGE HIGH PRESSURE [ MULATOR OIL TO + AECOMUEATO BEARINGS () }<— RESERVOIR BEARING “ PRESSURE GAGE MAIN OIL PUMP OIL COOLER throughout the ofl system, mages141, 142. 143, 144. 145, ‘The gage at the main oil-pump discharge measures the oil-pump discharge pressure, ‘The oil then passes through a — Another gage is on the other side of the filter. If this gage records the is bey emulsion. significantly lower oil pressure, inning to plug with dirt or oil Gages also indicate governor oil pressure and bei oil pressure. ring Because of the force required to position the oil relay system, pressure to the bearings should be (more/less) than oil pressure in the governor oil system. Bearings are often equipped with to indicate bearing temperatures we turbines usually have (high/low) lube-oil pres- arms and atitomatic shutdown devices, sui Visual Inspections Before Startup Ui 47, 148. 149. 150, 151, Before starting a turbine, the operator should carefully look over the external parts of the turbine, Governor linkage should be adequately = to avotd friction or binding of the parts. ‘The linkage (should /should not) be loose fitting. Auxiliary piping and instruments should be in place and the instruments should be — Mange bolting should be in place and (loose/tight). No should be leaking from the oil system, Lubricant should not be ———_____ rem the shaft coupling. REVIEW AND SUMMARY 152. During turbine startup, the (inlet should be opened first. At shutdown, the _ xhaust) valve valve should be closed first. (A small single-stage/A larye multi-stage) turbine is more likely to develop a bowed shaft. [62] filter filter less thermometers: low should not operating, or functioni tight oil Jeaking exhaust inlet A large multi-stage159, 160. Speeding up the turbine too rapidly ut startup increases the — in an already —____ shaft, how, bowed (Prequeney/ Amplitude) of vibration is excessive in a Amplitude bowed shaft. b. At critical speed: 1. ‘The shaft is rotating at the speed of its —_ _ natural frequency. 2. ____ of vibration becomes excessive, Amplitude It a shaft is bowed, the turbine (can/cannot) be cannot, brought throwsh its critienl speed. A (stiff/tlexible) shaft turbine must pass Uhrough its flexible critical speed (o yet to its operating speed. A (stiff/flexible) shaft is usually found in small single- sti stage turbines: Steam traps remove condensate from the drains (automatically manually). automatically Look at the drawing. OUTLET OIL PRESSURE INLET OIL PRESSURE ‘The oil filter shown (is/is not) plusyed. is not 163]PILOT EIGHT — PUMP AND COMPRESSOR DRIVER UNIT FIVE COUPLINGS, GEAR TRAINS, AND V-BELT DRIVES SECTION 1: COUPLINGS An Introduction to Power Transmission . Couplings... cece cece eee v eee Transferring Force from One Machine to Another How Machines Are Connected to Each Other Rigid Couplings Review and Summary . How Shaft Alignment Is Maintaine How Machines Become Misaligned . Flexible Coupling End Float : Gear Couplings. Torque and Torque-Cushioning Couplings |. Review and Summary. Couplings with Removable Centers . Lubrication of Couplings . Review ancl Summary... SECTION 2: GEAR TRAINS Gear Trains .. Introduction. ‘ Force and Power - How Gears Affect Power Why Gears Are Used. How Gear Trains Are Us As Speed Changes : 40 Compound Gear Trains .....-- ce Lag Gear Trains for High-Torque Loads... see AB Gears for Parallel Shafis ...... ave Spur Gears io Helical Gears ....... Double-Helical Gears . Review and Summary Gears for Perpendicular Shaft Bevel Gears Worm Ges Lubrication Shock Loads. Review and Summary SECTION 3: V-BELT DRIVES V-Belt Drives Introduction, V-Belt Drives Can Be Used As Speed Changer Variable-Speed V-Belt Drives V-Bolt Slippage. How V-Belts Are Construct How Bolts Are Adjusted . Belt Replacement The V-Belt Drive in Operation | Review and Summary Comparison of Gear ant