Thermal Engineering O.S
Thermal Engineering O.S
ON
Technical Education
(MSBTE)
Govt.Of.Maharashtra
(BY(2022-2023)
CERTIFICATE
This is to certify that the project work entitled
Is
Submitted by
Sheikh arkan javed [2114660082]
Yenare Mahesh [2114660081]
Bichkule omkar [2114660080]
Date:
Place:Mhasne Phata,Parner
Abstract:-
In power generation mostly steam turbine is used because of its greater thermal
efficiency and higher power-to-weight ratio. Because the turbine generates rotary motion, it is
particularly suited to be used to drive an electrical generator – about 80% of all electricity
generation in the world is by use of steam turbines.
Rotor is the heart of the steam turbine and it affects the efficiency of the steam
turbine. In this project we have mainly discussed about the working process of a steam
turbine. The thermal efficiency of a steam turbine is much higher than that of a steam engine.
INTRODUCTION
A steam turbine is a mechanical device that converts thermal energy in pressurized
steam into useful mechanical work. The steam turbine derives much of its better
thermodynamic efficiency because of the use of multiple stages in the expansion of the
steam. This results in a 32closer approach to the ideal reversible process. Steam turbines are
made in a variety of sizes ranging from small 0.75 kW units used as mechanical drives for
pumps, compressors and other shaft driven equipment, to 150 MW turbines used to generate
electricity. Steam turbines are widely used for marine applications for vessel propulsion
systems. In recent times gas turbines, as developed for aerospace applications, are being used
more and more in the field of power generation once dominated by steam turbines.
PRINCIPLE
Steam turbines may be classified into different categories depending on their construction,
the process by which heat drop is achieved, the initial and final conditions of steam used and
their industrial usage as follows:
The necessity to keep down the production costs lead to standardization of the types
of steam turbines, such as back pressure, condensing, extraction back pressure and
extraction condensing, injection condensing
Condensing turbines
Back pressure turbines
Multiple extraction turbines
Injection condensing turbines for combined cycle plant
Reheat condensing turbines for utility type
Most of the industrial steam turbines are high speed turbines for the power
output range of 1-30MW with speed reduction by turbo gears which in turn means
smaller sizes and higher efficiency for the turbine for the output of 30MW and above
the turbine speed is 3000rpm.
b) Diffuser:
It is a mechanical device that is designed to control the characteristics of steam at
the entrance to a thermodynamic open system. Diffusers are used to slow the steam's
velocity and to enhance its mixing into the surrounding steam. In contrast, a nozzle is
often intended to increase the discharge velocity and to direct the flow in one
particular direction.
Flow through nozzles and diffusers may or may not be assumed to be adiabatic.
Frictional effects may sometimes be important, but usually they are neglected.
However, the external work transfer is always assumed to be zero. It is also assumed
that changes in thermal energy are significantly greater than changes in potential
energy and therefore the latter can usually be neglected for the purpose of analysis.
c) Blades Or Buckets: The blades or buckets form the rotor flow passage and serves
to change the direction and hence the momentum of the steam received in the
stationary nozzles.
d) Guide Or Guide blades: Often a turbine is arranged with a series of rotor flow
passages. Intervening between the blades comprising the rotor passages are rows of
stationary guide blades. The purpose of this guide is to reverse the direction of steam
leaving the preceding moving blade row so that general direction of steam leaving the
preceding moving blade rows is similar. If guide blades were not provided, opposing
force would be exerted on the rotor which would largely negate each other.
e) Casing Shell Or Cylinder: The turbine enclosure is generally called the casing
although the other two names are in common use. The nozzle and guide are fixedon
casing, which in addition to confining the steam serves as support for the bearings.
Sometimes the word cylinder is restricted as a cylindrical form attached to inside of
the casing to which the guides are fixed.
f) Shaft, Rotor, Spindle: These terms are applied to the rotating assembly which
carries the blades.
g) Disc Or Wheel: The moving blades are attached to the disc which in turn is keyed
to the shaft.
h) Diaphragm: The diaphragm which is fixed to the cylinder or casing contains the
nozzle and serves to confine the steam flow to nozzle passage.
i) Packing: Packing in the form of carbon rings minimizes the leaking in the annular
space between the diaphragm and shaft.
k) Exhaust Hood: The exhaust hood is the portion of the casing which collects and
delivers the exhaust steam to exhaust pipe or condenser.
l) Steam Chest: The steam chest is the supply chamber from which steam is
admitted to the nozzles
n) Throttle Or Stop Valves: The throttle and stop valves are located in the steam
supply line to the turbine. The stop valve is hydraulically operated quick opening and
shutting valves designed to be either fully opened or shut. On small turbines the stop
valves may be manually operated but in any case is intended for emergency use or
when fully shut down. The throttle valve is used in smaller turbines in addition to stop
valve as a means of regulating steam flow during the starting or stopping the
operation.
The steam turbine is fed with steam under temperature t1, pressure p1, and enthalpy
h1. Expanding within the turbine, steam produces work Wt and goes into the
condenser under conditions p2 and h2. Hence its rejects heat Qr to cooling water and
the resulted condensate with enthalpy h3<<h2, but with the same t3=t2 and pressure
p3=p2 comes to the pump. At the expense of the pump work Wp , the feed water
pressure and enthalpy rise to values p4 and h4 with which feed water enters the steam
generators where it is heated and evaporated due to the heat added Qa .
Ideal Rankine cycle with superheated steam as a working fluid consists of the
following processes: 1-2 Adiabatic reversible expansion in the turbine
Thermal efficiency of ideal Rankine cycle for superheated –steam turbine power
plant can be defined as:
Here nth is the gross thermal efficiency that is without regard to the
expense of energy with in the cycle. If pump working is neglected, then the
efficiency,
N = (h1 -h2 ) / (h1 -h4 )
STEAM REHEAT
In the cycle with steam reheat instead of through adiabatic steam
expansion from initial steam pressure p1 to end pressure p2, steam expands within
the HP turbine part to the intermediate pressure (point5) and then is heated
isothermally to steam reheat temperature (point 6) and then expands within IP-LP
part to same end pressure p2 as shown below. In this case, for ideal cycle the
thermal efficiency is approximately given by:
(h1 - h5 )+ (h6 - h2 )
nth = (h1 - h4)+ (h6 - h5)
2 Series Turbines:
These series of turbines are of standard type and have been designed
for the best efficiency for range parameters. Based upon the inlet conditions like
pressure temperature, material selection is varied. Designs being the standard
further based on then steam flow quantities size of the turbine is selected .in these
series of turbines the fixed blade grooves are machined directly in the outer casing
and guide blades are inserted. Different sizes of -2 types of turbines are:
G250-2 EK/K 600-2
G300-2 EK/K 800-2
G400-2 EK/K 1000-2
G500-2 EK/K 1100-2
G800-2 EK/K 1400-2
EK/K 1800-2
“G” stands for back pressure turbine
“K” stands for condensing turbines
“E” stands for controlled extraction The number besides the letter indicates the
area of the exhaust of the turbines
3 Series Turbine:
Based on customer’s requirements and steps involved in design, the turbine is
divided into different sections: inlet section, transition, exhaust or condensing
section .these sections can be combined with each other. The figure shows the
various sections of these series and possible combinations of withy one size of
admission section. the admission sections are supplied in two versions, one for
normal initial steam conditions up to 100 bar / 510 deg C and for high steam
initial steam conditions up to 140 bar /540deg C .the size of the section is
geometrically graded in the ratio to 1.25 to form different sizes of section .The
parts associated with front section as front bearing pedestal, control valves, safety
devices like emergency stop valves are fixed for a particular size. Also the same is
done for the exhaust sections. With this arrangement for a particular front and rear
section selected the connecting parts to the sections are common from case to
case. now the length of the middle are transition section can varied based upon the
number of blade stages required and the number of extractions required . with this
concepts, besides optimizing the flow path, the use of standard and proven
components like casings , guide blade carriers , bearing pedestals, nozzles, servo-
motors, stop and governing valves fro a particular model are ensured .unlike the -2
series the blade grooves in these turbines are made in the guide blade carriers
which is supported in outer casing .
Robust drum type rotors with integral shrouds, labyrinth glands for sealing of
rotor ends and inter stage blading, ensure greater reliability and efficiency. These
turbines usually employ a gear box between turbine and generator to achieve
optimum efficiencies.
4 Series Turbines:
These types of series are called as centre admission steam turbines with
counter flow for the mid range of power, between 30MW to 150 MW. Using these
concepts results in the compact single casing solution in many cases up to 100
MW. The flow path is initially towards the front and in inner casing after being
admitted in the centre.
The steam reverses the direction on the reaching the end of inner casing to flow
around inner casing and expands towards the rear end of the turbine. This process
of reverse flow of steam helps in control the axial thrust to a large extent. The rear
portion of the turbine is constructed based upon the building block principle as
explained in -3 series, front being a standard fro particular range of inlet
parameters. These turbines are directly coupled to the generator. The valve blocks
in these turbines are separate and hence faster startups of the turbine .these
turbines are best suited for combined cycle plant application.
TURBINE BLADES
Blades are the heart of a turbine, as they are the principal elements that convert
the energy of working fluid into kinetic energy. The efficiency and reliability of a
turbine depend on the proper design of the blades. It is therefore necessary for all
engineers involved in the turbines engineering to have an overview of the
importance and the basic design aspects of the steam turbine blades, Blade design
is a multi-disciplinary task. It involves the thermodynamic, aerodynamic,
mechanical and material science disciplines. A total development of a new blade
is therefore possible only when experts of all these fields come together as a team.
The number of turbine stages can have a great effect on how the turbine blades are
designed for each stage. The number of stages depends upon the load we have and
the quantity of power we required. Too many stages may also develop bending
moment and high torque which in turn the reason of failure of the entire unit of the
plant.
X20 and x22 are the material specification which contains the alloying elements in
given percentage. Proper selection of blade material plays a n important role in
blade design. The factors that influence the selection of blade materials are: -
1) Method of manufacture
2) Ease of machining
3) The ability to produce blade sections free from flaws.
4) Ductility both allow of rolling of shapes.
5) The capacity for being welded.
6) Ease of forging easily.
7) Condition of operations.
8) Suitable tensile strength at high temperature.
9) Resistance to creep.
10) Cost
Mechanical Properties:
All the Among the different materials typically used for blading are 403
stainless steel, 422 stainless steel, A-286, and Haynes Stellite Alloy Number 31
and titanium alloy. The 403 stainless steel is essentially the industry’s standard
blade material and, on impulse steam turbines, it is probably found on over 90
percent of all the stages. It is used because of its high yield strength, endurance
limit, ductility, toughness, erosion and corrosion resistance, and damping. It is
used within a Brinell hardness range of 207 to 248 to maximize its damping and
corrosion resistance. The 422 stainless steel material is applied only on high
temperature stages (between 700 and 900°F or 371 and 482°C), where its higher
yield, endurance, creep and rupture strengths are needed. The A-286 material is a
nickel-based super alloy that is generally used in hot gas expanders with stage
temperatures between 900 and 1150°F (482 and 621°C). The Haynes Stellite
Alloy Number 31 is a cobalt-based super alloy and is used on jet expanders when
precision cast blades are needed. The Haynes Stellite Number 31 is used at stage
temperatures between 900 and 1200°F (482 and 649°C). Another blade material is
titanium. Its high strength, low density, and good erosion resistance make it a
good candidate for high speed or long-last stage blading. Blades are made of alloy
steel which mainly contains carbon, chromium, nickel, molybdenum X20 and x20
are the material specification which contains the alloying elements in given
percentage.
Types Of Blades:
Blades are classified on the basis of following application
1) Pressure at stages
HP BLADES (high pressure blades)
IP BLADES (intermediate pressure blades)
LP BLADES (low pressure blades)
Original forging
Precision forging blades
b) Root: The root which fixes into the turbine rotor which gives the
proper anchor to the blade and transmitting the kinetic energy of blade to
the rotor.
The steam turbines are utilized in several industries viz.. Paper, fertilizers,
chemical petro chemicals, sugars, refinery, metallurgical etc foe power
generation and mechanical drives already described. The following
illustration explains the selection - application criteria of industrial
turbines
REFERENCE
[1]. A handbook on the steam engine, with especial reference to small and
medium-sized engines, for the use of engine makers, mechanical
draughtsman, engineering students, and users of steam power (1902)
[2]. http://archive.org/details/handbookonsteame00haeduoft
[3]. Thermal engineering by R.K. RAJPUT
ACKNOWLEDGME
NT
An endeavour over long period can be successful only with advice
and guidance of many well-wishers.
My sincere thanks to the management and Prof.Anarse.B.V.,
Principal, of Shree Samarth Polytechnic, Mhasne Phata,Ahmednagar
for providing me the opportunity to conduct my project work.
I am highly indebted to Mr.R.K. Kadus Head Of Department
Mechanical For his assistance and constant source of encouragement.
I wish to express my profound and deep sence of Mrs.Yewale.A.N.
project coordinator for sparing her valuable time to extent helps in
every step of my project work.
I would also like to thanks the staff of Science Department for their
generous guidance.
Last but not the least we would Like to thank for our friends and for
their help in every way for the success of this report
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Micro-Project Evaluation Sheet
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