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7. LP Turbine
Wheels and Bearings
Diaphragms
Packing
Head
LP Casing
LP Inner Casing
Nomenclature
Toshiba
LP Turbine Structure
LP Steam Turbine
The efficiency of modern HP and IP steam turbines can be predicted very accurately because it is mainly a
function of the flow losses in the blade (steam path).
The flow losses have been established in systematic experiments in the fluid mechanics laboratories for all
geometric dimensions and flow conditions.
The economic optimization (availability, efficiency, and capital cost) of the LP turbine design is not always so
successful.
Wet steam and three-dimensional flow patterns make complete and accurate measurements difficult.
The high costs of systematic tests with LP turbines have until now also prevented the accumulation of data
which would permit an accurate efficiency analysis of the LP turbine alternatives.
In addition, the LP efficiency has hardly been indentified theoretically, so that an empirical evaluation based
on a few measuring points was all that was possible.
Currently, this kind of problem has being solved with an aid of CFD techniques.
However, the problem related to the wet steam is still vague because phase change can not be solved with
CFD techniques.
In conclusion, in order to optimize the LP turbine, we have to rely on the experience of engineers who are
familiar with the complexity of the problem and can bridge the gaps with reasonable assumptions.
LP Steam Turbine
Casing
LP터빈은 입구부터 배기까지 온도차가 매우 크기 때문에 케이싱을
2중 구조로 제작하여 각각의 케이싱에서 발생하는 온도차를 적게하
여 케이싱의 열변형 방지.
Casing
Casing
A push rod concept permits parallel axial thermal expansion of LP rotor and inner casing.
This reduces clearances between rotor and casing and improves the efficiency.
SST5-6000 Steam
Turbine (Siemens)
LP Exhaust Hood
Siemens
LP Exhaust Hood
Configuration GE
GE
Radial
plates
Steam guide
LP Exhaust Hood
1) Axial Flow Exhaust
The flow distribution is uniform on LSB exit plane along the circumferential direction.
It has a higher exhaust loss than axial flow LP exhaust hood because of the change of flow direction from
axial to radial, and then downward finally.
LP Exhaust Hood
3 Major Functions
Pressure loss of 1 in.Hg in a LP exhaust hood can result in a 1% increase in plant overall
heat rate.
This arrangement is used to minimize the rotor span, and thus minimize rotor bending
from the gravitational force and to optimize critical speeds of the rotor
It supports the weight of the inner casing and diaphragms and must provides
precise positioning of the inner casing, diaphragms, bearing and packing.
LP Exhaust Hood
Function
⑥ X-over pressure
⑦ Moisture
⑧ Mechanical
1.0
(a) Started from LSB hub (b) Started from LSB pitch (c) Started from LSB tip
Condenser Flange
(a) Newly Designed LP Exhaust Hood (a) Conventional 500 MW Steam Turbine
Coanda Effect
0.50
E D C B A
0.00
V2
-0.50 0.5
0.75 A B CD E
-1.00
-1.50
[ Normalized
-1.50 Velocity
-1.00 -0.50Magnitude
0.00 on0.50
the LSB Exit Plane
1.00 1.50 ]
V1
1) Discuss the flow behavior on the LSB exit plane in terms of power output.
2) LP turbine vibration can be improved?
Some Issues
Some Issues
Some Issues
GEA18786 (June/2011)
207D-17
Steam Turbine
109D-14
Steam Turbine
LP Rotor Shaft
블레이드가 장착되어 있는 로터축은 LP터빈 전체 가
격의 약 40% 차지.
Shrunk-on rotor
Monoblock rotor
Welded rotor
Steam Turbine 7. LP Turbine 30 / 53
HIoPE
LP Rotor Shaft
열박음 로터축(shrunk-on rotor)
• 초대형 잉곳을 확보하기 어려울 때 사용.
• 지름이 작은 로터축을 제작한 후에 휠 디스크를 제작하여 열박음 통하여 일체화.
• 제작이 쉬운 반면에 기동정지 시에 불안정한 진동이 발생하기 쉬우며, 휠 디스크에 응력부식균열이 발생
하는 단점 보유.
• 최근에는 거의 채택하지 않고 있음.
일체형 로터축(monoblock rotor)
• 최근 제강기술이 발달하여 가공중량 200톤 정도의 일체형 로터축 제작
• 열박음 로터축에 비해 강도가 한층 높으며, 응력부식균열이 나타나지 않기 때문에 신뢰성이 높음.
• 열박음 로터축에 비해 제작에 많은 시간이 소요.
• 국내 화력발전 LP터빈 로터축은 모두 일체형이며, 원자력발전은 영광 5.6호기와 울진 5.6호기부터 모두
일체형으로 설계.
용접 로터축(welded rotor)
• 원자력발전과 같은 대형 LP터빈에 사용. 현재는 용접기술과 열처리기술이 발달하여 몇 개의 로터를 용접
으로 연결하여 하나의 로터축으로 제작한 용접 로터축 많이 사용.
• 가격이 상대적으로 저렴한 작은 잉곳 여러 개를 이용하기 때문에 전체적으로 가격 저렴.
• 제작단계에서 재료결함 검사가 용이하기 때문에 신뢰성 우수. 일반적으로 로터축 내부 빈 공간은 부식 방
지를 위해 진공 유지.
• 두 가지 이상의 서로 다른 재료를 용접하여 사용할 수 있기 때문에 로터축 온도분포에 따른 최적의 로터축
제작. 초임계압 발전에서 나타나는 고온부식을 줄이기 위해 전통적으로 사용하던 CrMoV에 9Cr과 12Cr강
을 용접하여 사용.
3) LSB가 길어질수록 배기손실이 감소하여 증기터빈 성능이 향상된다. 그러나 동일한 출력을 가지는 증기터빈
의 경우 LSB가 길어질수록 제작비가 증가한다.
5) LSB가 길어지면 큰 회전속도가 나타나는 LSB 팁 부위에서 초음속유동이 발생한다. 따라서 길이가 긴 LSB
팁 부위 날개형상은 초음속유동에 적합한 수축-확산노즐 형태를 가진다.
6) LSB는 습증기 영역에서 운전되며, 큰 회전속도를 가지는 팁 부위에서는 물방울과 큰 속도로 충돌하기 때문
에 습분침식이 발생한다. 따라서 대부분의 LSB는 화염 경화나 방식막 부착 등을 통해서 습분침식에 대비하
고 있다.
7) LSB에는 큰 인장응력이 발생한다. 최근에는 인장응력을 이겨내기 위해서 티타늄합금을 이용하여 LSB를 제
작하고 있다. 티타늄합금은 습분침식과 부식 저항성이 우수하기 때문에 LSB 재료로 많이 사용되고 있다. 그
러나 티타늄합금은 가공성이 불량하기 때문에 LSB 가격이 비싸진다.
Sout = dp2(h/dp)
where, dp = pitch diameter of LSB, h = active
length of blade)
45 LSB results in a 28% increase in annulus area over that of the 40 LSB.
Longer LSB provides reduced leaving velocity, which results in low exhaust losses and improved heat rate.
Increasing the turbine exhaust annular area gives increased capacity and turbine efficiency, but it increases
turbine size and capital and construction costs.
Increasing the LSB length is restricted by centrifugal stresses in blades, and the number of LP flows and LP
cylinders cannot be too great because of the total turbine length.
A way to reduce the centrifugal loads and make the longer LSB is to use titanium materials, which is lighter
and stronger than steel.
Longer blades are more expensive than shorter ones because they have a better resistance to water droplet
erosion.
The longer the blades, the harder vibration control of blades because of lower natural frequency.
A cylinder with too long a rotor has to be designed with increased radial clearances in its steam path
because of weight bowing of the rotor and danger of its increased vibration.
32-LSB/3600rpm (Siemens)
Blade Overlap
Blade Overlap
It was found that, with reduced volumetric flow in the last stage
blade, the steam moves towards tip section, Thus, when the
overall volumetric flow is decreased, the flow distribution over
the blade length changes, resulting in a much larger reduction
of flow in the hub section and little change at the tip section
Typically, discharge velocity at the tip of LSB does not drop [ Free standing LSB (Siemens) ]
below a Mach number of 1.3, which justifies the application of
the convergent-divergent profile under typically changing
operating conditions of power plants
Both tangential and axial lean are applied to the L-0 nozzle.
Compound tangential lean is utilized to impart an inward radial force on the flow – forcing more flow into the
hub region and increasing the pressure.
Combined with the flow path contouring the L-0 nozzle lean reduces the radial pressure gradient at the
nozzle exit, raises the root reaction.
Axial lean is used to control the nozzle to bucket spacing while minimizing the potential for erosion.
An increased nozzle to bucket distance near the tip reduces the possibility of nozzle induced stimulus, which
results in a more robust mechanical design.
Advanced LSB nozzle not only reduces losses within its boundaries, but also optimizes the flow conditions
for the following moving blades.
The advanced forward curved and twisted blade provides an optimal flow distribution with increased flow at
the hub avoiding flow separation, and reduced flow at the moving blade tip for minimizing boundary losses.
The best performing center section of moving blade receives an increased mass flow.
The follow stationary blade is ideally suited to form a thick profile at the outer diameter and to provide suction
slots for moisture removal.
Nozzle
During the low load and high exhaust
pressure, random vibration or stall C1,design
flutter occurs in last stage blades of W1,design
LP turbine.
W1,off C1,off
In such condition the steam inlet flow W1,design
angle is larger than normal resulting U
W1,off
in negative angle of attack.
Stall
As a result of large negative angle at U = Wheel speed
the inlet to the blade, steam flow C1 = Absolute velocity
separation causes the blades to W1 = Relative velocity
vibrate in stall flutter.
Bucket
In the power generation industry, there is a drive to increasingly large exhaust areas of low-pressure steam
turbines, leading to longer blades.
Under this condition, design of turbine blades is more likely to react to the effects of dynamic loading due to
unsteady aerodynamics.
The last stage blades, that contribute approximately 10% of the overall output of a modern power plant are
surrounded by hostile aerodynamic environment due to the transonic and droplet laden flow.
The longest blades of the last row in a LP turbine are always tapered and twisted to accommodate the
demands of mechanical integrity and aerodynamic performance.
The tip section of freestanding blades in the last row is more flexible, thus it is difficult to control tip vibration
and its susceptibility to flutter.
Continuously coupled blade row has greater stiffness that helps to resist vibration and bending forces.
① Harmonic excitation
• By design practice all the long blades are tuned so as to avoid due to harmonic excitation
• This is primarily due to temporal unsteadiness of the flow over the stationary blades.
• Sudden changes in the flow path and steam extraction have been observed to initiate flutter in the
blade
③ Self excitation
• Stall flutter, usually occurred during low load operation and high exhaust pressure, belongs to this.
The kinetic energy of the steam leaving the LSB exit plane is
assumed to be almost completely lost.
Hence for a given volume flow, this lost kinetic energy will
depend only upon exhaust area.
7
It becomes a matter of economic optimization to select the
optimum exhaust area and therefore the active length of the 8 2
LSB. This process is known as cold-end optimization.
But, within the given limits, the investigation will provide the [ Fluid Flow in LP Turbines ]
economic optimum.
h
1 Output m
h
h
ho p2
p2
2
m2
EL
p2
18
The kinetic energy of the steam 16 6F32"
leaving the LSB exit plane
increases as the condenser 14
pressure decreases.
Power Gain, MW
12
4F38"
10
However, at a certain condenser Choking
8
pressure, the choking condition is 4F32"
reached at the last stage. 6
4
4F30"
Any further decrease of the 2
condenser pressure increases
exhaust losses, h remaining 0
unchanged.
0.5 1.0 1.5 1.76 2.0 in.Hga
0 2 12 16 19 C
h increases as the condenser pressure decreases, but the temperature of the condensate at the inlet to the
lowest LP feedwater heater falls.
In this case, the extracted steam flow rate increases, and the steam flow through LSB will decreases at the
same time.
The selected condenser pressure will determine a set of parameters including turbine output, cost of
components and operating costs.
For given climatic conditions, the condenser pressure can be lowered only by taking measures which
increase the cost of the plant and the cooling system, for example by increasing cooling water flow and
condenser heat transfer surface.
Similarly, the added thermal resistance of dry or wet cooling tower will generally require increased condenser
size and result in a higher optimum condenser pressure.
Modified sliding pressure operation uses control valve reserve so the valves are slightly closed at 90% to
95% and some boiler stored energy can respond more quickly to rapid load change near full load.
If the grid frequency requires high power demand and the unit is in modified sliding pressure
operation(hybrid operation), the turbine control valve is opened to raise the load (except if the valves are fully
opened already).
Simultaneously the main condensate control valve is throttled to a calculated position allowing a reduced
condensate mass flow passing through the LP feedwater heaters.
Considering a certain time respond, the extraction steam mass flow of the LP feedwater heater and the
deaerator / feedwater tank are reduced.
The surplus steam remains in the turbine and generates additional power.
The resulting load increase depends on the amount of pre-set throttling of main control valve of the turbine,
the throttling of the main condensate control valve and the actual unit load.
By means of additional fast acting valves in the regarding extraction steam lines the response time behavior
can be optimized.
This condensate throttling serves as compensator for the transient time behavior of the boiler.
The accumulated condensate is stored in the condenser hotwell or a separate condensate collecting tank.
Parallel to the above mentioned measures the firing rate of the boiler is increased to meet the load
requirements.
During this time the condensate flow reduction is gradually released and has reached steady state condition
again.
Refilling of the feedwater storage tank is initiated by releasing the condensate control valve to control the
level of the hotwell or condensate collecting tank.
The maximum allowable condensate mass flow is monitored and the refill flow is limited to a maximum value.
Due to the increased condensate flow through the LP feedwater heaters and into the deaerator, the steam
extraction from the affected turbine extractions is increased.
However, the maximum allowable superheater outlet flow is limited to 100% BMCR(Boiler Maximum
Continuous Rating)
50
Fixed Pressure Mode
25
• At a certain part load, the control valves can to be
throttled to improve the primary response capacity
0
0 20 40 60 80 100
Steam Turbine Load, %
질의 및 응답
작성자: 이 병 은 (공학박사)
작성일: 2015.02.11 (Ver.5)
연락처: ebyeong@daum.net
Mobile: 010-3122-2262
저서: 실무 발전설비 열역학/증기터빈 열유체기술