Assoc. Prof. Eng. Liviu-Constantin Stan PhD.

STEAM GENERATORS, STEAM AND

GAS TURBINES I, II
Laboratory

The technical-constructive analysis of the aquatic and ignitubulare

naval boilers

The technical-constructive analysis of a heating boiler

1. Technical features
- Operating pressure p=5(bar)
- Heating surface s=134,2 m2
- Actual water volume v=1,71 m2
2. Purpose
The boiler is used for acquiring operating water /fresh water (treated chemically)
of the mixture water-steam at p=5 (bar) necessary in household and has as heating
carrier exit-gases from the main engine of the vessel.
3. Building/ Structure
Constructively the heating boiler is made of the following parts:
- The body of the heating boiler ( made of welded sheet-metal)
- Boiler fittings (set on the body of the boiler)
- Heating elements (made of tubes in the following shapes: straightened and
fixed on tube sheets welded also on the body of the boiler and on the double
finned coil;
- The stripping has the role of eliminating heating loss in the atmosphere and is
made of asbestos cement plates thick of 4 mm or from the mineral wool.
The boiler from the vessel is made of:
- Inlet governor
- Water and steam collector (3) si (4)
- Spiral tubes which contain heating elements
- Body of the boiler

On the boiler the following fittings are set:

Double safety valve
Outlet valve water-steam
Two vent valves
A drain valve
A cock for the manometers

4. Functioning
The water-tube boiler of La Mont type functions at the same time with the
auxiliary boilers. The feed pump absorbs the water from the inferior feed drum of
boiler with fuel and discharge it through the boilers serpentines and after that in
the superior feed drum with fuel which has the role of a separator.
Through the forced circulation of water through the serpentines, the water
evaporates partially and reaches the separator like a mixture of water-steam. Here
the water is separating from the steam, the water is revalorized while circulation,
through the waste-heat serpentines is coming again in the fuel boiler and
participates once again in the circulation.
The control of the boilers flow is made with the help of an automatization system,
which operates over the control wheel considering the steams pressure. The boiler
is fitted with the plates necessary for a long time functioning: safety valve, cocks
for manometer, manometer, vent valve, drain valves, water-steam drain valve.
5. Way of operating:
At the boilers functioning the following operations must be respected:
- The vent valve of boiler is opened
- The water-supply valve from the circulation pump is opened
- The circulation pump is initiated
- The steam-water outlet valve is opened
For cutting-off the boiler while the engine functions the following things must
be respected:
- The feed valve is stopped
- After some time necessary for the water to be evaporated the main steam valve
is closed
3

- The safety valve is opened and this valve is maintained open by this producing
a rapid decrease of pressure in the boiler.

The technical-constructive analysis of heat exchangers associated

with thermic circuits component of boilers installation (heaters,
preheaters, super heaters, condensers)

Boiler
1. Technical information:
- Work pressure: p=5 [bar]
- heating surface: s = 134,12 [m2]
- Total volume of water: v= 1,71 [m3]
2. Destination
The purpose of the boiler is the obtaining from fresh water of the water mixture: water-steam
(p=5 bar) required in household and it has as heating agent the gases recovered from the main
engine of the vessel.
3. Structure
Constructively, the boiler is composed from next parts:
- Boiler hull (it's made from welded sheet)
- Plates (mounted on boiler's hull)
- heating elements (made of pipes with forms: straight and fixed in tube sheets welded from the
boiler's hull, serpentines, finned tubes)
- Isolation (eliminates the heating loss in atmosphere and it's made from asbestos cement board
of 4mm thickness or mineral wool/wadding)
The boiler from M/N "NEPTUN" is composed of:
- inlet governor
- steam and water collector (3) and (4)
- spiral tubes that contains heating elements
- boiler's hull.
On boiler are mounted the next plates:
- double safety valve (5)
- one discharge water-steam valve (6)
- two vent valves (7) and (8)
5

- a drain valve (9)

- one valve for pressure-gauge (10)
4. Operating
The water-tube boiler of La Mont type functions at the same time with the auxiliary
boilers. The feed pump absorbs the water from the inferior feed drum of boiler, with fuel and
discharge it through the boilers serpentines and after that in the superior feed drum with fuel
which has the role of a separator.
Through the forced circulation of water through the serpentines, the water evaporates
partially and reaches the separator like a mixture of water-steam. Here the water is separating
from the steam, the water is revalorized while circulation, through the waste-heat serpentines is
coming again in the fuel boiler and participates once again in the circulation.
The control of the boilers flow is made with the help of an automatization system, which
operates over the control wheel considering the steams pressure. The boiler is fitted with the
plates necessary for a long time functioning: safety valve, cocks for manometer, manometer, vent
valve, drain valves, water-steam drain valve.
6. Way of operating:
At the boilers functioning the following operations must be respected:
- The vent valve of boiler is opened
- The water-supply valve from the circulation pump is opened
- The circulation pump is initiated
- The steam-water outlet valve is opened
For cutting-off the boiler while the engine functions the following things must be respected:
- The feed valve is stopped
- After some time necessary for the water to be evaporated the main stream valve is closed
- The safety valve is opened and this valve is maintained open by this producing a rapid
decrease of pressure in the boiler.
Water-steam-gas circuit scheme:

1.
2.
3.
4.
5.
6.
7.
8.
9.

Boilers hull
Vaporizer
Butterfly
Inlet gases
Funnel uptake.
Steam dome
Circulation pumps
Feed pumps
Cascade tank/hot well

Auxiliary boiler
-

Is of forced-circulation type (water-tube boiler) and the steam has the same features as the
boiler.
As energetic source it uses exhaust gases from the main engine.
The control is realized through the variation of the gases quantity which passes through the
auxiliary boiler.
Water-steam circulation layout

1. Auxiliary boilers hull.

2. Moist steam section.
3. Moist water section.
4. Circulation pumps.
5. Blow-off pipes.
6. Main distribution steam valve.
7. Service valve.
8. Pressure steam reductor.
9. 10. Surface/bottom blow-off valve
11. Feed water pumps.
Isolation of boiler
1. The circulation pump is stopped (1 or 2)
2. The circulation pump cooling is closed (small valves under the pump)
3. The feed tap of boiler is closed.
4. The Main stream valve of auxiliary boiler is opened.
5. The feed taps of auxiliary boiler are being opened.
6. It bypasses to auxiliary boiler command of feed pumps.
7. The auxiliary boiler starts.
8

Operating Auxiliary Boiler (AB) + Exhaust Gas Boiler (EGB)

1. Open the feed tap of AB
2. Start circulation pump with AB cooling opened
3. Open a single feed tap of EGB
4. Open main steam valve of EGB
5. Pass the command on (EGB+CA)
6. Start EGB
7. Check the pressure increase in AB and stop the EGB for a while.
Functioning of AB
1. Open feed tap.
2. Start circulation pump with cooling opened.
3. Bypass the feed pumps command on AB functioning.
4. Isolate EGB by closing the feed water taps and main service steam valve.
5. Adjust the pressure of steam by adjusting the position of damper from ECR

10

Burning study
Combustion control outbreaks in naval boilers

Automatic burner fuel of a donkey boiler from the Neptune ship

Component parts. (Fig. 1)

It is a two-burner type nozzles UD 252 E

1. body burner
2. the common donkey boiler and burner
3. fuel pump
4. manometer
5. filter
6. electric motor
7. electrical heater fuel
8. electromagnetic valve
11

9. nozzle
10. staring electrode
11. ignition transformer
12. ledge connections
13. photocell
14. cavity administration
15. shut-off valve.
Burner body consists of a boiler front, mounted in donkey boiler and the body
itself. The outside has a attachment flange with 4 holes. In donkey boiler side is
provided with a blend disk, which can control the combustion process according to
the conditions of donkey boiler.
Air supply system
Fan of the burner the body is mounted on the motor shaft, fitted to a part of the
body wall. The same shaft with the fan is coupled fuel pump (gear). Between the
pump and burner head is the air inlet and control valve. One of the flaps can be set
manually (the nozzle 1), the other being powered by an electromagnet (for tip 2).
While electric engine rotor is spinning, the fan absorbs air and then sends it
through the exhaust pipe and tube combustion chamber (furnace boiler). Air
entered is twisted by the swirl disk to be done a uniform mix and correct
positioning of the flame.
Fuel System
This type of burner is used both for diesel and heavy fuel.

12

Includes (Fig. 2):

1. flexible pipes
2. fuel filter
3. Gear Pump
4. pressure gauge
5. electromagnetic valve
6. nozzles
7. Fuel pipes
8. Fuel heater.
The fuel passes through flexible pipes by filter that clears it solid, smooth and then
enter into the pump. The fuel pump forces the fuel passing through the heater to
electro valve. The pump is provided with a excessive pressure valve that opens
when the pressure increased, the fuel reaches the nozzle head.
Nozzle spray angle is 60 degrees.
The electrical system
Composed of:
1. engine burner
2. Photoelectric sensing device of the flame
3. ignition transformer
4. ignition electrodes
13

5. electro valve
6. electromagnetic valve in air intake
7. safety switch
8. maximum temperature control thermostat heater
Photocell is made of selenium. This serves to interrupt the fuel supply if that is not
luminous arc between two electrodes. The photo element is very sensitive to
shocks and therefore must be tested regularly. Ignition transformer is used to
generate a luminous arc between the electrodes, leading to fuel ignition.
10 000 V output voltage.
Electrons do not have to find on the fuel spray nozzle channel. Air tends to
advance under the influence of spray force.
The block system
This makes it impossible to start the burner to the following conditions:
- Decreased burner flame during operation or where an luminous arc occurs during
the operation cycle. This system only works automatically.
- Low temperature of fuel below the permitted level. This system can be operated
manually and automatically. Fuel temperature is 70-150 degrees.
- Excessive increase in pressure in the bucket and the water level too low on
donkey boiler.

Stop with the automatic control system

With this system, the burner is turned on and off on accordance with a
program required. Starting and stopping the burner depends on donkey boiler
pressure. Depending donkey boiler pressure can be connected one or both
injectors. After 3 seconds of booting, become operational the fan and fuel pump.
Donkey boiler ventilation takes place for 63 seconds that can be extended up to
180 seconds, but not less than 60 seconds. With three seconds before the first
injection electromagnetic valve opens, it is connected the power transformer of a
luminous arc. The transformer works 25 seconds. After ventilation time passed, the
first electromagnetic valve injector opens and fuel is sprayed, while the circulation
electromagnetic valve is closed.
14

The burner off, it takes place ventilation of combustion chamber (furnace). So

starting and stopping the burner is done automatically. Starting and stopping is
manual only when it damages the control system.
Maintenance
The burner should be checked at least once a year. Chamber where the burner is
mounted must be very clean. The burner should not aspire polluted air dust and
dirt.
Dirt from the fan rotor and the air pipes often influences venting.
Antifriction metal engine bearings must be lubricated bearings on points at equal
time intervals (1 to 2 months) with the few drops of fuel without acids and resins.
Operation component parts of the burner should be checked and replace
worn parts. Such checks are on the following cases:
- Turning on the burner after a long rest;
- Periods of continuous use daily burner
- At the end of burner operation for the stop a long time;
When put on operation the burner should check operation of component
parts. You can make these measurements for a nozzle and two nozzles of the
burner:
- CO2 and O2 content in flue gas;
- The content of soot;
- Flue gas temperature at the outlet;
- Pressure in the combustion chamber.
Fuel consumption should be taken from the chart depending on nozzle
pressure capacity. The turbine wheel position has essential influence on the results
of combustion.
Before fighting burner when donkey boiler is stopped or repair, in the last 5
minutes of burner operation must operate on lighter fuel, to avoid solidification of
heavy fuel burner pipes.

15

Functional phases of naval boilers installation

Starts Stops Surveillance

1. Preparation for the operating of steam generators

This operation is executed before lifting pressure whether the steam generators are
after a short operation.
a) Steam generators are after a repair. In this case runs two types of repairs:
interior and exterior.
Internal control: check:
- Cleaning of deposits on internal surfaces;
- check the correct fitting of internal accessories;
- checking for the presence of foreign objects.
External control:
- Check condition of masonry combustion chamber;
- Check fixing the base plate of the steam generator;
- Check opening the chimney cowls;
- Check opening the air cock;
- Fill with water steam generator.
Observation - water supply steam generator must have the same qualities that
water used in operation.
- the temperature of steam boiler feed water should not exceed 50-60 oC.
b) The steam generator is after a short stationary. In this case run than external
control.
2. Raising the pressure steam generator
Duration or heating time and to obtain nominal pressure is done according to
the following features:
- Construction type of the steam generator;
- The expansion possibilities of the steam generator;
- Water volume;
16

- Feed water temperature;

- Water circulation in the steam generator.
Pressure rise time is from 15 minutes to 4 hours.
On the ship there are three specific cases to rise the pressure feature:
a) When the ship does not have any energy.
This case is found to the old ships which have steam powered turbine.
Pressure is 2-5 bar. Then the auxiliary machinery steams powered are put in
motion. In this case the increase pressure process is achieved through two
phases:
I - ignition flame to obtain 2-5 bar pressure when their mechanisms are
coupled;
II - putting in motion mechanisms to achieve the operating pressure.
b) When we have power.
This process consists of two phases:
I - use electrically operated mechanisms until 2-5 bar pressure;
II - from putting in motion of mechanisms powered by steam until obtain
nominal pressure.
c) When we have steam.
Steam-powered vessels have and auxiliary steam generator.
3. Maintenance of steam generator in operation.
1) Water supply steam generator.
- Maintaining the water level in steam generator level bottles;
- Purge bottles level at regular intervals;
- In case of breakage level bottle, the maximum change time is 20 minutes;
- When the water level in the bottles level disappeared stops the steam
generator.
2) Maintaining the pressure value (constant) in the steam generator.
- Management of the combustion process in combustion chamber
- adjusting the quantity of fuel into the combustion chamber;
- adjusting the amount of air into the combustion chamber.
3) Maintaining fuel temperature between 80-90.
4) Maintaining the operating mode of all mechanisms and auxiliary devices.
5) Supervision of MCD (measuring and control devices).
17

4. Oprirea generatorului de abur.

1) Oprirea focarului;
2) Ventilarea in continuare a focarului;
3) Inchiderea valvulei principale de abur;
4) Continuarea alimentarii cu apa a generatorului de abur;
5) Generatorul de abur se lasa sa se raceasca lent;
6) Remedierea tuturor defectiunilor aparute in timpul marsului;
7) Indepartarea tuturor materialelor inflamabile;
8) Executarea plinurilor.
5. Measures of work protection on steam generators.
- Eliminate all leaks;
- Checking the insulation of steam generator and piping;
- Remove all flammable materials in the compartment;
- Prohibition of working with open flame;
- Check safety valves;
- Lighting and extinguishing fire correctly;
- Maintaining into a good condition the measure and control instrumentation.

18

Auxiliary boiler

1. Technical features:
Operating pressure p=5 (bar)
Working change surface S=61,6 m2
operating pressure collector tc=650 C
steam ratio s=2500 kg/h

2. Purpose:
It produces moist steam with p=5 bars necessary for:
- Reheating the heavy oil;
- Producing hot water;
- Blanket the fire.
3. Construction/ Structure
The structure is of straight and tube type, made of two drums set vertically one after the other,
connected through the tubes of the boiling tanks (19) and (20). The endings of the boiling tanks
tubes are welded on the tube sheets (17) and (21) which are actually boiler ends/bottoms for the
superior (22) and inferior(8) drums. Inside the inferior drum there is a burner in shape of shank
(14), united in the lower part through a connection ring (11) with the cylindrical part of the drum
(8). The furnaces arch/the burners arch (15) welded over the shank burner it continues to the
superior part with the flame tube (16), the other side being welded to the chasing part of the
inferior plate (17), making the connection between the burner and the space gases between the
two drums. Through the exterior this space is closed by the dead-front belt (18), which could be
set in order to clean the tubes. The flue-gas collector (6) has at the inferior part a soot cleaning
tap (7) and at the superior parts a flange (4) for coupling at the exhaust piping tube.
The burners cone is connected to the cylindrical part of the inferior drum (8) through the
injecting nozzle (tunnel) (9) ended with the flange (10) for coupling the burner with the boiler. In
the inferior drum there are two elliptic scuttles and three circular inspection windows (13). The
scuttles and the inspection windows are closed with taps at the inferior part, and the inferior
drum ends with the welded flange (12) of which the boilers anchorage to the socle is made.
The boilers clothing is made of a asbestos card board on which is set mineral wad bound with
binding wires which assures for the exterior a high temperature of about 60 C.
For water supply the boiler has two delivery ends (39) set on the inferior drum form which water
gets to the distributer (3) situated in the superior drum from where it is discharged into the boiler.
The low-water alarm (30) realizes the water supply automatically, keeping the water into the
boiler at the working/proper level and it is connected to the working and steam space of the
19

boiler through two valves. The foam and the impurities collected in the foam collector (2) are
discharged through the extraction surface valves (35). The inferior relief of the boiler is made on
the inferior drum and put over the water collector for tests (34) with a cock for taking tests (43).
On the buckled bottom of the boiler are set:
- Double safety valves
- Main steam valve
- Auxiliary steam valve
- Pressure switch valve
- Air discharge cock.
- Pressure switch valve (42)
- Vent valve (37)
To engage the boiler, on Lamont: type, on the bottom drum are mounted two valves (29).
The water-steam mixture from boiler enters in auxiliary boiler with liquid fuel through the
angle cock (24).
4. Functioning
The fuel oil supply of burner its done with some systems whose components are included in
the ships fuel oil system, its realized through the delivery head. Thereby the boiler its
filled with water until the level when feed pump is automatically decoupled. The boilers
supply its controlled by one low-water alarm which, depending of the water level, start or
stops the feed pumps. This commands to start of pump when the level is low or commands
to stop the pump when level is high. The cocks and valves are functioning by spinning the
maneuvering wheel, and the double safety valve is working under steam pressure. Thus,
when overpressure 5 bars the pneumatic valve is ascending from pneumatic seal, permitting
pressure reduce in evaporation surface. The gauge glass is mounted on boiler through a
sleeve which connect the inside of boiler in the evaporation surface.
5. Maintenance
To check :
- General working condition of boiler
- Water presence in boiler
- Water level inside the supply tank
- Fuel level inside the fuel tank
If the boiler was opened for repairing or cleaning it will be made the inspection of furnace
and outside of boiler and also inspection of fire tubes, and, if necessary drying the furnace
brickwork.
After all above mentioned operations will start the boiler, by firing the burner respecting the
working instructions.
Increasing of pressure until working pressure in 3 phases :
Faze 1 : Boilers water boils in 1-2 hours
Faze 2 : Increasing the steam pressure up to 3 bars in 30-60 minutes;

20

Faze 3 : Checking the steam pressure from 3 bars to normal working pressure in 10-15
minutes. At 4 bars pressure open the double safety valve.
6. Water-steam circuit.
This circuit contains the following :
a) Main steam valve
b) Steam connection to consumption
c) Pressure reducer
d) Steam consumers
e) Return valve with condense from consumers
f) Return valve condense.
g) Sea water outlet
h) Sea water inlet
i) Observation tank
j) Discharging sewage
k) Main feed pump
l) Fresh water tank
m) Bottom blow-off valve
n) Boiler feed pumps
o) Boiler feed tap.

21

The technical-constructive analysis of naval steam turbines

1. Generalities
Steam turbine is the thermal machine in which the potential energy of the steam
produced in boiler is transformed, firstly, in kinetic energy for the energy to be
transformed in rotation effective work, transmitted through the axial line to the
propeller of the vessel or directly through an engine or an auxiliary mechanism.

2. Operating principle

Figure 1
A unit turbine is made of a wheel with it vanes of one row of nozzles. The
ensemble made of a rotor and a casing nozzle is called pressure scale. The steam
enters through the inlet manifold (7), through the nozzles (4), getting in then
through the space between the blades (2), and the grooving rotors producing the
22

turbine rotation, after that the steam is evacuated through the discharge chest (8).
Depending on the way the steam expands in the rotors blades, there are two types
of turbines:
- Action turbine E p Ek
- Reaction turbine E p Ek Em

Figure 2
The steam enters with a p0, it expands and the potential energy transforms
completely in kinetic energy, at a p pressure, with which enters between the spaces
of the blades. In nozzle the speed of the steam increases from c0 to c1. In case of
reaction turbine the steam expands not only in the nozzles but also in the mobile
blades. The potential energy of the steam which enters transforms partially in the
turbines blades and totally on the mobile blades of the rotor, where again the
kinetic energy transforms in mechanic energy in the turbine shaft.
The steam enters with p0 pressure; it expands until p, when it enters into the
mobile blades, where it continues to expand until p2.
The steam speed is exactly the same as the action turbine.
23

3. Constructive elements
Fixed components:
a. The foundation is a steel or cast iron member, depending on the crib on
which all the turbine ensemble stands.
b. The purpose of the turbine framework is to close the space through which
the steam is flowing, providing a sufficient flow space between the rotor and
the stator. It has cylindrical shape. In the casing there are four places for the
setting of the axial and block bearings of the diaphragm with nozzles, of the
labyrinth glands.
c. The shapes of the diaphragms are of cast iron waste, fixed in the turbines
framework and made of two pieces. At the periphery the turbines nozzles
are set.
d. The turbines nozzles special shape pieces set at the diaphragms periphery
with an inside way with an irregularly section. In the nozzle the expansion of
the steam happens. The shape of the nozzles is of three types:
- Non-expanding nozzle
- Divergent nozzle
- Non-expanding-divergent nozzle
At reaction turbines the nozzles are made of fixed fans of the same profile as the
mobile ones.
The diaphragms with the nozzles constitute together with the filling pieces the
turbines stator.
Mobile components:
a. The shaft on it the reels and wheels are fixed with the mobile blades. Its
purpose is to take the turning moment produced by the steams force, which
operates over the mobile blades, transmitting itself to the axial line or to the
auxiliary mechanism with which it is coupled.
b. The wheels fixed on the shaft. At their extremities the mobile blades are
set.
c. The reels used in reaction and combination turbines.
24

d. The blades/dash boards the main mobile pieces of the rotor.

There are action blades (symmetrical blade) or reaction blades (asymmetrical
blade).
Components:
- The blades body (underside) active part.
- The blades fixing flack in diaphragm or reel.
4. The turbines bearings
There are three types of bearings:
- Angular the shaft is supported by it. Usually are of sliding. In the bearing
inside a cylindrical piece is fixed made of two halves, and called auxiliary.
- Axial the axial force is taken into the turbine, due to the differences of
pressure existent between the turbines stages.
- Angular axial at high pressure only one bearing is used, reducing the
overall size of the turbine.
5. The turbines glands
The shaft and the framework are in relative movement from one another, and in the
different parts of the turbine the steams pressures are different.
The up-steam end - psteam patm
Vapour outlet psteam patm
For the run-off steam not to be permitted a gland shaft over framework is
necessary. Special gland systems are used:
a. With labyrinths, with the help of a labyrinth chamber which because of the
sections variations; the steam is throttle ding producing a pressure decrease.
b. With graphite rings, 4-8 flat section rings cut in more pieces.

25

Determining features of adjusting a steam turbine

1. Generalities
The control static characteristic of a turbine shows the dependence between the
turbines speed and the power of shaft generator, n=f (Pel).
In case of a steam turbine that functions separately, at a certain charge/load, under
the control device, there is a certain position of the intake valve of the steam,
which is a certain speed.
At a constant position of the synchronizer, if the power of the turbine varies from
unloaded running to maximum load, the speed varies suitably from the unloaded
running n1 to the maximum load n2.

Fig. 1. Static control characteristic of turbine for a fixed position of the

synchronizer

The difference between maximum load n1 and minimum load n2 expressed in

percentage from medium load nmed is called irregular power of the controller,
between 3 and 5% from the rated speed, thus:
100(n2 n1 ) / nmed

when:
nmed (n1 n2 ) / 2

26

[%]

The ab curve represents n variation, considering Pd, when the load increases from
unloaded running to nominal one.
By determining the variation of the number of the turbines rotations, at the loads
decrease from nominal to unloaded running the a1b1 curve is obtained.
The difference between ab and a1b1 depends on (functional and wear) movements
in the levers hinges of control mechanism, on inertia governor, on frictions. The
ratio between delta n and nmed in percentages is called insensibility rate of control:
n / nmed

[%]

in which: n is the difference between the ordinates of the curves ab and a1b1. For
the a normal functioning of the turbine 0,5% .
Depending on the way it is this irregularity a high rate of the turbine, the static
characteristic of the turbine would be also more inclined.
At a turbine variation of n corresponds a power variation with P which is even
higher as the curve control characteristic is more flat. For this reason the
characteristic control curves with slant easy inclined parts are undesirable.
Table 1:
Parameters name

Symbol

Unit of measure

Torque
Measurements duration
Developed electric energy
Electric power
Dysfunction ratio
Insensibility ratio

W
Pd

Rot/min
s
J
kW
%
%

27

Number of tries

Exploitation of naval steam and gas turbines

General principles to consider in the utilization of a turbine:

1. Starting
Before taking about the proper turbine, a whole turbine set and condenser visit
must be made, in order to check if it is in the appropriate state of functioning.
The following are being checked:
- Axial and radial clearance of the turbines rotor, of the reducting gear and the
axial and angular thrust bearing;
- The state and functioning of the speed reduction unit, of the quick locking
valve and of the maximum speed governor;
- The quantity and the quality of the available oil, the existence of the oil
container consumption;
- The supply with oil of all attended parts;
- The possibility of controlling the control cocks.
After checking, it passes to the heating of turbine. At large turbines, the heating
is not made through the main pipe, but through a minor pipe.
While heating, the turbines are moving to and from and are rotating with the
help of the rotation unit.
The heating of the last stages of the turbine is made after setting free the
rotation unit, through the step-by-step opening of the master valves of input
and output, in order that the rotor to make a couple of rotations, the speed will
be of about 10% from the maximum speed. The trimming is starting
immediately after the steam is dismissed into the waterproofing, for avoiding
the irregular heating of the axial.
Equally, the steam must be let out into the waterproofing for preventing the
entering of air into the turbine, after the depression formed through the
condensation of the steam.

28

While heating, all the drain and insulation cocks are getting open over the
turbines and over the pipes for avoiding condensation.
The rotation of the turbine while the heating process will be started only after
the axial clearance of the warm turbine has been controlled.
While heating, the steam which worked into the auxiliary mechanisms of the
vessel must be orientated through the auxiliary condenser or in his absence, in
the atmosphere.
After finishing the turbines heating, keeping further the drain cocks open, the
slow opening of the reverse valve the turbines are once again swinging to the
astern going.
The drain cocks are kept open, while the steam is dumpy.
The moment a vibration is felt, the speed is reduced until the disappearance of
it, after that the speed is increased step-by-step, if after these three attempts, the
vibrations keep being present, the turbine is stopped and the cause is analyzed.

2. Functioning
The following are being followed up:
- The maintenance of the necessary speed;
- The maintenance of the normal pressure and temperature of the oil circuit, the
oil temperature mustnt get over 65C;
- The supervision of the packing at the steams outlet from each body/part;
- The indication of the manometer of the final packing of the turbine must not
pass 1 atm;
- The supervision of the indicator mechanisms/apparatus.
- The supervision of the axial and thrust/radial bearing;
- The supervision of the normal functioning of the speed governor.
Occasionally, it is controlled if the water did not enter into the oil, as well as the
quality of the steam which comes from the boiler.
At the appearance of some strange noises, clattering, vibrations, or disturbances in
the oil system/circuit, urgent proceedings will be taken for discarding the cause and
stop the turbine.
29

3. Stopping/Locking the turbine

It is made through step-by-step maneuvering through the maneuvering valve. For
avoiding the running away, if the turbine has a supplementary steam extraction or
steam is introduced through supplementary stages, these must be isolated before
the main maneuvering valve is opened. After closing up this, the drain cocks are
being opened immediately. After 20 or 30 minutes from the opening, the stockers
are being announced to reduce the fire from the boilers. If after the stopping the
vessel stands still for a while, the turbine must be dried.
4. The turbines maintenance
Each turbine which is not functioning must be rotated daily. At longer intervals, of
about maximum one week, the condenser unit must be putted in action and the
turbines are dried. While standing still, the turbine must be occasionally controlled,
in such way the axial and radial clearances of the rotor are checked.
The main cases in which the use of the turbine is not allowed are:
-

The breakdown of one of the automatic functioning controller;

The missing of the exact data about the rotors clearance;
Abnormal vibrations and noises;
The clogging of maneuvering valves and blades with rock;
The breakdown of the rotor, the line of shafting or one of the oil pump;
The leakiness of the turbine;
The absence of repair pieces.

30

Cases of failure and incidents during the operation of naval steam

machines and naval gas turbine installations

The most common incidents are classified according to severity:

I. Incidents that do not allow the continued operation of the steam generator.
a) Loss of water bottles level.
Symptoms: - absence of water in level bottles;
- Redness heating surfaces;
- Odor (rubber);
- Deformation and explosion of pipes or parts of the steam generator.
Causes: - ignoring of watch keeping staff;
- level bottle is obstructed;
- Steam generator tubes is broken and lost water;
- Fuel pump not realize the pressure needed.
Measurements: - stops the steam generator.
- Execute a detailed control of heating surfaces;
- Cools the steam generator;
- Fill with water of steam generator;
- Lighting fires and monitoring the behavior of steam generator.
b) Breaking the steam generator tubes
Symptoms: - intense steam basket;
- Specific noise;
- Powerful steam jet tube .
Causes: - local overheating of the tubes;
- Lack of water in the tube;
- Thick crust on the walls of tube;
- Disturbance of circulation;
- Pipes corrosion.
Measurements: - stops the steam generator;
- Cools the steam generator;
31

- Empties the steam generator of water and relax;

- Detect broken pipes and their fouling.
c) Cracks occurrence in steam generator.
Symptoms: - steam in pipe - extinguishing the combustion chamber
Causes: - not uniform heating;
- blast cooling of steam generator;
- Cold air into the combustion chamber.
Measurements: - stops the steam generator;
- Cools the steam generator;
- Empties the steam generator of water;
- Welding crack.
II. Incidents that can cause dangerous damage.
a) Increasing the pressure above the nominal value.
Symptoms: - can see on the gauges.
Causes: - ignoring of staff watch keeping.
- Damage to the gauge.
Measurements: - reducing the quantity of fuel;
- The generator is fed with water;
- To check each gauge with the standard gauge.
b) Ebullitions (every water pipe in the upper collector). This phenomenon is
manifested by excessive water level oscillation in bottles level between upper and
lower minimum value.
Symptoms: - large variations of water in level bottles;
- Occurrence of hydraulic hammers.
Causes: - water contains oily impurities or mechanical;
- Increasing water hardness;
- Sudden opening of the main valve.
Measurements: - execution extraction of surface and bottom.
- Reduction of machines speed and opening the purges.
c) Breaking level bottles.
Causes: - the level bottles were heated uniformly in during of pressure growth;
- the level bottles were installed wrong.
Measurements: - isolating the level bottles;
32

- Replacement of level bottles within 20 minutes;

- Close observation of the level bottles remained in function.
III. Incidents that allow still operation of the steam generator, but under close
supervision.
a) Incomplete combustion. This is revealed by the color of the chimney exhaust
and chemical analyzes.
Causes: - fuel temperature is lowered below 80 C:
- Fuel contains more water;
- Pulverizer damaged;
- Lack of air into the combustion chamber;
- Introduction of large quantities in the combustion chamber.
Measurements: - maintaining the temperature between 80-90o C;
- Change the fuel tank;
- Replacement of damaged pulverizer;
- The continued operation of the fan;
- adjusting the quantity of fuel into the combustion chamber.
b) Excessive overheating of external metal walls.
Causes: - fuel is projected by pulverizer on the vertical walls of the steam
generator;
- isolation is damaged.
Measurements: - replacement pulverizer;
- Stopping the steam generator when the isolation is damaged on a large
area.

33

Construction of a naval auxiliary boiler

1. Generalities
The piston-type steam engine is a thermal machine in which the potential
energy of steam turns into mechanical work inside a piston cylinder. The steam
acts on both sides of the cylinder. The piston moves inside the cylinder and
forward mechanical work through the crank and connecting-rod assembly to
propeller shaft or to shaft of the auxiliary mechanism.
Marine steam engine are classified by:
- Main machine: are designed to propulsion of the ship;
- Auxiliary machinery: for the operation of auxiliary mechanisms.
Marine steam engines are different types, but the main elements are the
same, as the operating principle. Steam distribution in the machine cylinder is
made by a regulator valve, which is a disk fixed on which there is a scupper lip that
is fixed the rod of regulator valve.
Once the crankshaft is rotating the eccentric, slipping inside the scupper lip,
allowing vertical movement. Radius of this arc is the distance between the
transversal reaction center and eccentric center and is called eccentric radius.

2. Fixed parts of the steam engine

The bed plate is designed to maintain the machines manufacturing and has
two cross bars. On these are placed the inlets to fix the main bearing which support
the crankshaft. The bed plate is fixed to the ship bone by screws.
The arm is designed to maintain the cylinder block, to delineate the area of
movement of the cross bearings, connecting rods and crankshaft. The arm can be
made of heavy iron bars provided with ribs that are attached to crosshead guide.
34

The cylinder is the most important fixed part of the machine. The cylinders are
mold separately for each pressure scale or a whole block. The cylinder is generally
iron, but at high pressure they are steel. Internal surface is finely processed. In the
exterior is covered with asbestos and sheet steel. At the top, the cylinder is fitted
with a molded lid separated by the cylinder, and the lower end is provided a place
to seal the piston rod.
Distribution box is the space on which there are steam distribution cylinders with
slide valves. It is rectangular or cylindrical shape and provided with removable
covers.

3. Moving parts of machines alternative

The piston is made of cast iron or rolled steel, has disc shape to high
pressure cylinders and tapered to the low pressure.
In the order to seal the work spaces the pistons are iron rings called
segments.
Sealing can be done with a flat segment or an elastic iron ring that can be
eccentric or concentric, has the contact surface with the cylinder right or a
lubricating pit for a good seal.
Ends of segments can be straight, oblique or covered. The rod is catch by the
piston. Piston rod is a large piece of steel cylindrical, both ends being provided
with fine thread worked for a better grip on sealing ways and the other end is fixed
with a nut at the cross head.
The cross head is an intermediate part between the piston and machine shaft.
The slide is the part on witch slides the cross head. It is attached on the trunk
machine and the head of sled is a prism piece of steel fixed on skates that slides on
a vertical direction and is covered with a layer of metal bearing. The slide is
provided with cooling channel through which cooling water.
The crankshaft is built of rolled steel and heat treated. It can have one or
more arms.
35

STEAM GENERATION PLANT

1. General
There is oil fired (OF) water-tube boiler for port and cargo pumping duties, and an exhaust
gas boiler (EGB) for steam supply at sea. Feedwater for the OF boiler is supplied via the
economizer section of the EGB at all times.
Water from the OF boiler water drum is circulated through the EGB Evaporator section
before being returned to the OF boiler steam drum. Saturated steam is passed through the
superheater section of the EGB ti supply the turbo-alternator at sea.
There are two fuel pumps (main and auxiliary) drawing from the feed tank which can be
topped up by the Make-up feed pump from the Distilled Water tank. The auxiliary feedwater
36

pump is used only for high steam production as it has a capacity of 500% of the main feed water
pump. Condensate returns directly to the feed tank but other returns are via an Observation tank
to prevent the oil contamination. The screen will display to indicate oil contamination of the
condensate returns.
The water level in the steam drum is controlled by PID level controller, driving the two water
control valves in parallel from a common I/P converter.
Both feed water pumps trip at high-high steam drum water level to protect steam consumers
from water strike caused by water in the outlet steam.
The heat transfer in the exhaust boiler is controlled by exhaust dampers witch by-pass some
of the exhaust from the main engine. The exhaust damper position is automatically set by a PID
controller thus controlling the steam pressure.
The condensate from heating and miscellaneous service application returns to a condensate
filter/inspection tank and then flow back to the feed water tank. The condensate from the
condenser is pumped directly to the feed water tank.
The feed water tank and the filter / inspection tank are modeled with heat loss to the
surroundings. They will therefore gradually cool if the inlet flows are stopped.
The temperature of the condensate entering the inspection tank is assumed to have a constant
value (80o C).
The system is designed to operate in two distinctive modes:
a) Cargo pumping (in port use):
The oil fired boiler operates at a steam pressure of 16 or 7 bar. Steam is supplied to the four
cargo pump turbine, with a total output capacity of 40 tones /hour.
b) Turbo generator operation (at sea use)
When the ME is running, the water heat in the exhaust gas is used to generate steam, between 7
and 9 bar. The minimum pressure of 7 bar can be maintained by automatic operation of the oil
fired boiler if required, whilst the exhaust damper control will limit the maximum pressure to 12
bar.

37

ME Lubrification Oil System

1. Generalities
The lubrification oil from the main engine sump is collected in a sump tank below the
engine.
The LO pumps are protected by a pressure relief valve which opens when the pressure rises
over a preset valve. These valves are not modeled in detail and are not available from the various
lists.
The service tank oil can also be circulated by the LO purifier.
New oil is supplied by a make-up pump with flow directly to the sump tank.

38

The lubrification oil is cooled in two LT fresh water cooled LO coolers and is then passed
through an automatic backlash filter or a standby convention filter before it enters the main
engine. The LO temperature is controlled by a PI controller, which regulates a by-pass valve for
the LO coolers.
The LO filters must be checked regularly to avoid pressure / flow reduction.
The sump tank oil level will gradually decrease due to oil consumption and possible drain /
sludge discharge from the purifier.
The level is unstable in poor weather and if the level is low, there may be false alarms / shut
downs.
If the purifier is operated with broken water seal, oil is continuously discharged to the
sludge tank and there is a risk of emptying the LO sump tank completely. The oil pressure after
the pumps will be reduced towards zero as the LO sump tank runs dry.
The oil temperature in the sump tank is affected by the return oil flow / temperature from the
main engine, the oil flow / temperature from the purifier and the heat loss to the surroundings. If
all inlet flows stop, the temperature will gradually approach ambient air temperature. Low oil
temperature gives reduced flow at main engine.
2. Cylinder lubrification
A simple cylinder model is included. The day tank is refilled by pump from the storage tank.
There will be a steady consumption of cylinder oil, dependent on main engine speed.
The cylinder LO tank must be refilled periodically. At low cylinder LO tank level there will
be ME slow down / shut down.
3. Cam lubrication
The lubrication iol from the main engine cam shaft is collected in a cam shaft LO tank.
The LO pressure is controlled after the two cam LO pumps by a pressure control valve with
return flow to the cam LO tank.
Cam LO tank make-up is taken from the LO inlet main engine line. Discharge of the tank is
directly to the spill oil tank.
The cam lubrication oil is cooled by a LT fresh water cooled LO cooler and is then passing a
double filter before it enters the main engine. The LO temperature is controlled by a P controller,
which regulates a by-pass valve for the cam LO cooler. The LO filters must be cleaned regularly
to avoid pressure / flow reduction.
4. Operation procedures
Start up for main engine
- Ensure main engine sump has sufficient oil.
- Set temperature controller to AUTO and 45o C.
39

Ensure suction and delivery valves on both main lube oil pumps are open.
Ensure one cooler has inlet and outlet valves open.
Ensure inlet and outlet valves to back flush filter are open.
Ensure main bearing supply valve is open.
Start one of the main lube pumps in manual wait until the lube oil pressure has risen
to about 3 bar then, in pump / compressor Aotuchief page, set pump control to auto.
If should only be necessary for one pump to be running with the other in standby.
Ensure oil is flowing to piston cooling and main bearings at correct temp.

Start up of cam shaft system

- Set temperature control to 50o C.
- Ensure Cam lube oil tank level is more than 0,3 m.
- Set cam lube oil pressure at 4 bar.
- Check one filter in use and suction and delivery valves on both pumps open.
- One pump started manually then switched to AUTO when pressure reaches about 3,7 bar.
Start up for cylinder LO system
- Ensure day tank level is more than 0,3 m.
- Check all relevant valves are open.
- The flow will vary with engine speed.
System shut down
When engine has stopped at Finished with Engines wait for approx 30 minutes to ensure
engine has cooled down and stop all lube oil pumps. Sump temperature in port is normally
maintained by continually running the lube oil purifier.

40

ME Turbocharger System

1. Generalities
The main engine is supercharged by two constant pressure turbo-chargers. The turbo-charged
air is cooled in fresh water-cooled air cooler before entering the main engine.
The air cooler must be kept clean to enable it to provide a sufficient amount of cool air to the
engine. Hot air will lead to high exhaust temperatures, greater heat losses and increased specific
fuel oil consumption.
After the air leaves the air coolers, it enters the demister units that are fitted to reduce the
water content of the air. Water is drained off the demister units via the water trap, where the level
and flow of the drained water can be noted from the screen display.
Dirty turbo-charger air filters throttle the scavenging airflow and will result in reduced
engine performance.
The exhaust gas from the main engine cylinders enters the common exhaust gas receiver.
From this receiver the exhaust gas can either flow direct into the waste heat exhaust gas boiler or
via the Selective Catalytic Reduction (SRC) Receiver before entering the Exhaust Gas Boiler.
41

The exhaust boiler must be kept clean. High back pressure reduces scavenging air flow and
engine efficiency, especially at high power.
The turbo-charger model is composed of two separate units, a centrifugal air compressor and
a single stage gas turbine.
Major variables influencing the compressor torque:
- discharge pressure (air receiver)
- suction pressure (air filter differential pressure)
- air inlet temperature (density)
- compressor speed
Major turbine torque variable:
- exhaust receiver pressure
- exhaust receiver temperature
- back pressure (exhaust boiler differential pressure)
- turbine speed
The turbo-charger speed is computed on the basis torque balance differencial equation shared
by the turbine and the compressor model units.
In the event of a scavenge fire a CO2 release is provided.
2. Operation procedure
- Line up the system by opening the fresh water cooling throttle valves to air coolers 1 and
2.
- Ensure the scavenge air receiver drain ins closed
- Check that the SCR Reactor is isolated at engine start-up
- Check that the Aux. Blowers 1 and 2 are in AUTO and running. These are operated from
MD20 or MD102. Preset values for start / stop of aux. blower is respectively 0,2 bar and
0,4 bar.
3. In the event of a scavenge fire
Indicators of scavenge fire:
- High scavenge air temperature
- One or more cylinder exhaust temp. high
- Engine running rough
- Turbochargers surging
Slow down and stop when safe to do so.
While waiting to stop:
- Shut off fuel to affected cylinder
- Increase cylinder oil slightly
Stop aux. blowers.
Release CO2.

42

ME Fuel Oil High Pressure System

1. General
The screen indicates the Variable Injection Timing (VIT) system for the engine. VIT will
advance the fuel timing to raise the combustion pressure at engine loads below 100%, and hence
improve the fuel efficiency. The start and finish of the fuel advancement can be adjusted over the
range of the engine, by means of the starting and ending point.
To adjust the timing of fuel pumps, three options are available:
1) The individual adjustment at the upper control lever.
2) The collective adjustment input.
3) The variable adjustment due to fuel rack position.
43

The actual VIT advancement applied to each fuel pump is displayed beside the upper fuel pump
control lever, and is the summation of the above three option.
Hence each individual fuel pump can be adjusted to provide the optimum fuel timing with
regards to fuel type and quality, and engine load. Excess fuel timing advancement should be
avoided as the will:
a) Increase the maximum combustion pressure, and hence cylinder and bearing loading
b) Affect the ability of the engine to start effectively.
Following adjustments to the VIT system the operator should monitor the combustion pressure
over the complete engine load range, especially from 50 100 % load using the Cylinder
Indication screen MD 120.

44

Cylinder Indication Press / Angle

General
The cylinder indicator is used as a teaching aid and investigative system to enable regular
monitoring of the engine cylinders to be undertaken. Faults within the combustion system can be
located, and cleared using the malfunction editor function.
There are four different displays that can be selected to indicate the cylinder pressure
conditions, namely pressure / angle (also called a draw card or out of phase diagram), pressure /
volume (also called a power card, or in-phase diagram), the weak.
The pressure / angle diagram would be used for:
- Display the compression pressure curve, for comparisons with the other cylinders, to
indicate cylinder sealing efficiency.
- Display the approximate timing of the fuel ignition.
- Display the fuel pressure trace (using the alternate pressure measurements of 0 3000
bar).
To enable the cylinder indicator to measure the combustion pressure, the following
actions are required:
1. Select one of the field button in the INDICATE column.
45

2. Type in your identifying comments in the INDICATE field to aid fault identification.
3. Select the same field button in the SELECT CURVE column. Either the blue, magenta,
or brown curve can be selected.
4. Select the cylinder 1 to 5 that you wish to be measured.
To measure and compare the same cylinder after a period of operation, or when a
malfunction it is present. Using cylinder 2 as an example:
1. Carry out the tasks 1 to 3 above using the blue curve column and I2.
2. Select cylinder 2 to measure.
3. Select another field button in the Indicate column.
4. Type in your identifying comments in the Indicate field.
5. Select I3 in Select Curve of the magenta column.
6. Select cylinder 2 to measure the combustion parameters of cylinder 2 again.
The following parameters are displayed in the numeric data display, at the instant when
the cylinder indicator is taken, once a cylinder is selected together with tha two indicate (I)
buttons:
Speed This is the engine speed (N).
Index This is a measure of the fuel index.
MIP This is the Mean Indicated Pressure (MIP) measured in bar. This pressure
is the equivalent pressure that acts on the piston throughout its vertical
power stroke.
IKW This is the Indicated Power of the cylinder.
TIGN This is the timing of the ignition. The time between the TINJO and TIGN
indicates the ignition delay present for that cycle. Increasing ignition
delays will cause increased PMAX and large delta pressure.
PMAX This is the maximum pressure present during the working cycle. This will
be affected by the quantity and timing of the fuel admission.
TMAX This is the position of the maximum temperature during the working
cycle.
PCOMPR This is the pressure due to compression alone after the compression stroke.
PINJO This is the fuel pressure when the fuel injector opens. It provides useful
information that the fuel injector is correctly adjusted.
PINJM This is the maximum fuel pressure generated by the fuel pump. This
indicates the internal sealing properties of the pump, and whether internal
wear is present.
TINJO This is the timing of the fuel injection. The fuel pump timing will change
when the VIT operation is selected on MD28, but it should be similar for
all fuel pumps.

46

LINJ -

This is the length of the fuel injection period, and is dependent on the
setting of the fuel control lever.

47