TOPICS BEING COVERED

1. BRIEF INTRODUCTION OF BASIC PRINCIPLES OF

STEAM TURBINE
1.1 IMPULSE TURBINE
1.2 REACTION TURBINE

2.

MODE OF STEAM ADMISSION

2.1 NOZZLE CONTROL MACHINE

2.2 THROTTLE CONTROL MACHINE
2.3 SLIDING PRESSURE OPERATION MODE
2.4 MODIFIED SLIDING PRESSURE OPERATION MODE

3. ARRANGEMENT OF STEAM/WATER CYCLE

3.1
3.2

210 MW
250 MW

BASIC PRINCIPLES OF STEAM TURBINE

CONVERSION OF HEAT ENERGY INTO KINETIC
ENERGY
DEPENDS UPON THE DYNAMIC ACTION OF THE
STEAM
DROP IN PRESSURE OF STEAM THROUGH SOME
PASSAGE RESULTING TO
INCREASE IN VELOCITY
CHANGE IN DIRECTION OF MOTION GIVES
RISE TO A CHANGE OF MOMENTUM OR FORCE
THIS IS DRIVING FORCE OF THE PRIMEMOVER

IMPULSE TURBINE
Maximum steam velocity( Impulse) is created at the
inlet of moving blade
Which means high Kinetic Energy
This energy is utilised for rotation of moving blade
Steam Velocity can be maximised by having
maximum pressure drop in the Nozzles.
Hence in 100% Impulse steam Turbine, whole
pressure drop will be in stationary blades or nozzles
To sustain high velocity impulse stage should be very
robust in construction.

REACTION TURBINE
Reaction is created due to action of change of
direction of steam through bucket.
This thrust or reaction causes the driving
force
This requires whole pressure drop in moving
blade
100% Impulse or Reaction stage is purely a
theoretical assumption not practically feasible

PRACTICAL SCENARIO
FOLLOWING COMBINATIONS FEASIBLE
1. NOZZLE CONTROL MACHINE WITH
FIRST IMPULSE STAGE AS CURTIS
WHEEL, REGULATING STAGE &
SUBSEQUENT STAGES WITH VARYING
DEGREE OF REACTION
2. THROTTLE CONTROL MACHINE WITH
ALL STAGES HAVING VARYING DEGEE
OF REACTION AROUND 50%

MODE OF STEAM ADMISSION

NOZZLE CONTROL MACHINE

THROTTLE CONTROL MACHINE

SLIDING PRESSURE OPERATION MODE

MODIFIED SLIDING PRESSURE OPERATION MODE

NOZZLE CONTROL MACHINE

SALIENT FEATURES ARE
IMPULSE TURBINE WITH DIAPHRAGMS, LINEAR
NOZZLE SEGMENTS IN THE PERIPHERY
PRESSURE DROP IN THE NOZZLES
SEQUENTIAL VALVE OPENING
PARTIAL ARC ADMISSION
LOWER THROTTLING LOSS AT PART LOADS
PERFORMANCE NOT VERY POOR AT PART LOAD
TURBINES IDEAL FOR PEAK LOAD OPERATION

THROTTLE CONTROL MACHINE

FEATURES IN COMPARISON ARE
IMPULSE TURBINE WITH DIAPHRAGMS,
LINEAR

REACTION TURBINE
NO NOZZLE SEGMENTS

NOZZLE SEGMENTS IN THE PERIPHERY

NO PRESSURE DROP

PRESSURE DROP IN THE NOZZLES

SIMULTANEOUS VALVE
OPENING

SEQUENTIAL VALVE OPENING

PARTIAL ARC ADMISSION

FULL ARC ADMISSION

HIGHER THROTTLING LOSS AT
PART LOADS

LOWER THROTTLING LOSS AT PART LOADS

PERFORMANCE NOT VERY POOR AT PART

PERFORMANCE POOR AT PART
LOAD
LOAD
TURBINES IDEAL FOR PEAK LOAD
OPERATION

TURBINES IDEAL FOR BASE

LOAD OPERATION

STEAM TURBINE CHARACTERISTIC CURVE

ThrottleControlled
Machine

NOZZLE
CONTROL
MACHINE

N
o
z
z
l
e

C
o
n
t
r
o
l

SLIDING PRESSURE OPERATION MODE

IN THROTTLE CONTROL MACHINE
ADMISSION VALVES FULLY OPEN AT
ALL LOADS
BOILER PRESSURE TO BE MATCHED
WITH FIRST STAGE
HENCE STEAM PRESSURE SLIDES
WITH RESPECT TO LOAD
MINIMUM THROTTLING LOSS

SLIDING PRESSURE OPERATION

PROBLEMS

NO SPINNING RESERVE
CANNOT MEET THE GRID DEMAND
OF SUDDEN LOAD INCREASE
COMPLEX BOILER CONTROL
NO LOAD CONTROL ON TURBINE
GOVERNING
TURBINE CONTROL INEFFECTIVE

MODIFIED SLIDING PRESSURE

OPERATION MODE
SOME THROTTLING RESERVE ( 10 TO
20% ) MAINTAINED
ADMISSION VALVES NOT FULLY OPEN
BUT SLIGHTLY CLOSED
MAIN CONTROL STILL WITH BOILER
CONSTANT THROTTLING LOSS AT ALL
THE LOADS
PERFORMANCE SLIGHTLY POOR

210 MW LWZ DESIGN

200/210 MW KWU DESIGN
250 MW KWU DESIGN
500 MW KWU DESIGN

CROSS SECTIONAL ARRANGEMENT

HP TURBINE

SINGLE FLOW
IPT

LP TURBINE

CROSS SECTIONAL ARRANGEMENT OF

NEW DESIGN OF 210 MW

IMPROVEMENT IN TG PERFORMANCE
POSSIBLE THROUGH

INCREASE IN TURBINE CYLINDER

INTERNAL EFFICIENCY
ENHANCING TERMINAL PARAMETERS
OPTIMISATION OF REGENERATIVE
FEEDHEATING CYCLE
IMPROVED O & M PRACTICES

IMPROVEMENT IN STEAM
TURBINE PERFORMANCE
POSSIBLE BY

1. IMPROVED BLADE PROFILE

2. OPTIMISED FLOWPATH
3. IMPROVEMENT IN SHAFT SEALING SYSTEM
4. REDUCTION IN PRESSURE DROPS
5. REDUCED FRICTION LOSSES
6. OPTIMISATION OF INLET & EXHAUST
SECTION
7. OPTIMISED EXHAUST LOSS

WHY TO OPT FOR NEW DESIGN ?

MORE EFFICIENT

STEAM TURBINE
SIGNIFICANT REDUCTION IN POLLUTION
ENVIRONMENT FRIENDLY
ADVANTAGE OF BETTER HEATRATE FOR
THE ENTIRE LIFE
TECHNO-ECONOMICAL
COST EFFECTIVE & QUICKLY RECOVERABLE
COMPACT DESIGN
EASE IN ERECTION & OVERHAULING
REDUCTION IN OVERHAULING DOWN TIME

MAJOR DEVELOPMENTS IN
210 MW SETS
VARIANT A
-- T2 PROFILE BLADING

-- SMALLER INLET VALVES

-- A1 EXTRACTION BEFORE LAST STAGE
-- WELL PROVEN & RELIABLE
EARLIER SETS ARE OF THIS DESIGN

MAJOR DEVELOPMENTS IN
210 MW SETS
VARIANT B
-- T4 PROFILE BLADING
-- BIGGER SIZED INLET VALVES
-- LP HEATER 1 EXTRACTION TAPPED
BEFORE PENULTIMATE STAGE OF LPT
-- WELL PROVEN & RELIABLE
UNCHAHAR TPS, RAICHUR-7, KOTA-6 & PARICHHA PROJECTS

MAJOR DEVELOPMENTS IN
210 MW SETS
VARIANT C
-----

BIGGER STEAM TURBINE MODULES

SINGLE FLOW IP TURBINE
T4 PROFILE BLADING
LP HEATER 1 EXTRACTION STEAM TAPPED
BEFORE PENULTIMATE STAGE OF LPT
-- WELL PROVEN & RELIABLE
-- BETTER HEAT RATE
UNDER EXCELLENT OPERATION IN KHAPERKHEDA UNITS 3 & 4
OFFERED IN RAYALASEEMA-II & AMARKANTAK-5

MAJOR DEVELOPMENTS IN
250 MW SETS
VARIANT A NOZZLE CONTROLLED SET
HP TURBINE WITH REGULATING STAGE
PARTIAL ARC ADMISSION
SINGLE FLOW IP TURBINE
DOUBLE FLOW LP TURBINE
NOZZLE CUM THROTTLE GOVERNING
UNDER OPERATION IN DAHANU UNIT 1 & 2
EXCELLENT PERFORMANCE PROVED
OFFERED FOR SANTALDIH-5

MAJOR DEVELOPMENTS IN
250 MW SETS
VARIANT B THROTTLE CONTROL SET
SINGLE FLOW HP & IP TURBINE

DOUBLE FLOW LP TURBINE

UNDER OPERATION IN KOTHAGUDEM
SURATGARH & PANIPAT TPS
EXCELLENT PERFORMANCE DEMONSTRATED
OFFERED IN BATHINDA, MEJIA, CHANDRAPURA, RAIGARH

MAJOR DEVELOPMENTS IN
250 MW SETS
VARIANT C -- ADVANCED REACTION DESIGN

HP TURBINE & IP TURBINE WITH

LATEST STATE OF ART BLADING
LP TURBINE WITH ADVANCED BLADING
SIGNIFICANT HEATRATE IMPROVEMENT
MORE ENVIRONMENT FRIENDLY
OFFERED IN KORBA EAST

MAJOR DEVELOPMENTS IN
250 MW SETS
VARIANT D -- REACTION DESIGN
HP & IP TURBINE WITH T4 BLADING
LP TURBINE WITH ADVANCED BLADING
IMPROVED HEATRATE
COST EFFECTIVE VARIANT
OFFERED IN NEW PARLI, PARAS & BHILAI

MAJOR DEVELOPMENTS IN
500 MW SETS
VARIANT-A :FIRST DESIGN (4 VALVES)
SMALLER HP & IP MODULES
OLD SHAFT SEALING ARRANGEMENT
T4 BLADING IN HP/IP/LP TURBINE
SMALLER VALVES
LARGE MARGINS
OPERATING AT SINGRAULI, KORBA,
RAMAGUNDAM, CHANDRAPUR & FARAKKA

MAJOR DEVELOPMENTS IN
500 MW SETS
VARIANT-B NEW DESIGN (2 VALVES)
LARGER HP & IP MODULES
MODIFIED SHAFT SEALING ARRANGEMENT
T4 BLADING IN HP/IP/LP TURBINE
LP TURBINE SAME AS VARIANT-A
LARGER VALVES WITH REDUCED PRESSURE DROP
OPTIMISED MARGINS
OPERATING AT CHANDRAPUR-7 & VINDHYACHAL-II

MAJOR IMPROVEMENTS IN
500 MW SETS
VARIANT-C ADVANCED LP DESIGN

HP & IP TURBINE AS IN VARIANT-B

ADVANCED BLADING IN LP TURBINE
PERFORMANCE PROVEN
OPERATING AT SIMHADRI, TALCHER-II ,
RAMAGUNDAM-7, RIHAND-II
OFFERED IN, VINDHYACHAL-III, BIRSINGHPUR-5

MAJOR IMPROVEMENTS IN
500 MW SETS
VARIANT-D ADVANCED DESIGN

ADVANCED BLADING IN LP TURBINE

LATEST STATE OF ART BLADING
IN HP & IP TURBINE
OFFERED IN KAHALGAON-II, SIPAT-II & BELLARY
ALSO OFFERED IN MANGALORE (507.5 MW)

COMBINED CYLINDER CONCEPT

COMPACT LAYOUT

SUPPORTED ON THREE BEARINGS

LOWER MECHANICAL LOSSES
FIXED PEDESTAL ARRANGEMENT
MINIMIZES CASING DEFORMATIONS
BETTER HEATRATE
CAN BE OFFERED UPTO 400 MW
BEING OFFERED IN NEW 300/350 MW PROJECTS

CROSS SECTIONAL ARRANGEMENT

COMPACT HP-IP TURBINE

EFFICIENCY IMPROVEMENTS BY
ADVANCED STEAM CONDITION
SUPERCRITICAL PARAMETERS
==>INLET STEAM PARAMETERS MORE THAN
CRITICAL STATE
STEAM PRESSURE

> 221.2 BAR

STEAM TEMPERATURE > 374.15 Deg C

ULTRA SUPERCRITICAL PRESSURE( 300 BAR)
INCREASE OF MAIN & REHEAT TEMPERATURE
SIGNIFICANT IMPROVEMENT IN HEATRATE

800 MW SUPERCRITICAL SETS

PARAMETERS:
MAIN STEAM: 246 ata/ 565 Deg C, RH: 593 Deg C
CYCLE: 8 HEATERS WITH EXT. FROM HP TURBINE
CONSTRUCTION:
-- ADVANCED PROFILE BLADING
-- 1 HPT/ 1 IPT/ 2 LPT
-- LP HEATERS 1 & 2 INSIDE CONDENSER
-- TURBINE & CYCLE DESIGN BEING FIRMED UP

ADVANCED DESIGN BLADES

BLADE TYPE

APPLICATION

3DS BLADE

INITIAL STAGES OF HP & IP TURBINE

TX- PROFILE BLADES

TWISTED BLADES WITH

INTEGRAL SHROUD (F-BLADES)

TAPER & FORWARD LEANING

GUIDE BLADE (BANANA BLADES)
ADVANCED TAPERED & TWISTED

FREE STANDING BLADES

MIDDLE STAGES OF HP & IP TURBINE

INITIAL STAGES OF LP TURBINES
LAST STAGES OF HP & IP TURBINES

MIDDLE 1 OR 2 STAGES OF LP TURBINES

ONLY LAST STAGE OF LP TURBINES

LAST TWO STAGES OF MOVING BLADES
OF LP TURBINES

ACHIEVING OPTIMUM PERFORMANCE

DURING OPERATION
TG CYCLE CLOSER TO THE DESIGN
RATED TERMINAL PARAMETERS
CONTINUOUS EFFORT TO REDUCE SYSTEM
LEAKAGE
ATTENDING VALVE LEAKAGE & PASSING
MINIMIZATION OF FLUCTUATIONS
MINIMIZATION OF SUPERHEATER/
REHEATER SPRAY
PERIODICAL RECORDING & MONITORING OF
TURBINE EFFICIENCY

RETROFITTING & UPGRADATION

OF OLDER SETS
COST EFFECTIVE
MODIFICATIONS IN TURBINE INTERNALS
ONLY
OUTERCASING, PIPINGS, VALVES, PEDESTAL
FIXING ARRANGEMENT , STEAM PARAMETERS
& FOUNDATION DETAILS UNALTERED
INCREASE IN POWER OUTPUT WITH MINIMUM
CHANGES
SHORTEST POSSIBLE OUTAGE TIME
INCREMENTAL MODIFICATIONS FEASIBLE

RETROFITTING & UPGRADATION

OF OLDER SETS
PRE-REQUISITE

IDENTIFY THE HEALTH OF THE UNIT

PRESENT LEVEL OF PERFORMANCE
REFERENCE PERFORMANCE AUDIT
RESIDUAL LIFE ASSESSMENT STUDY OF
CRITICAL COMPONENTS
ANALYSIS OF HISTORY & OPERATING DETAILS

RETROFITTING & UPGRADATION

OF OLDER SETS
MAJOR MODIFICATIONS IN
GUIDE & MOVING BLADE
(LATEST STATE OF ART PROFILES)
STEAM FLOWPATH
ROTORS & INNER CASINGS OF TURBINE
SHAFT SEALINGS
ADVANTAGE IN HEATRATE/OUTPUT CAN BE
WORKED OUT ON CASE TO CASE BASIS

CONCLUSION
ADVANTAGEOUS TO OPT FOR MORE
EFFICIENT TURBINE
BENEFICIAL & TECHNO-ECONOMIC IN THE
LONG RUN
ECO-FRIENDLY, PROVIDING CLEAN AIR
MORE RELIABLE

BHEL HARIDWAR IS POISED TO SUPPLY

CUSTOMIZED & EFFICIENT STEAM
TURBINES / SPARES WITH SHORTEST
DELIVERY SCHEDULE &
TIMELY
TECHNICAL SUPPORT.