Steam turbine


A steam turbine or steam turbine engine is a machine or heat engine that extracts thermal energy from pressurized steam and uses it to do mechanical work utilising a rotating output shaft. Its modern manifestation was invented by Sir Charles Parsons in 1884. It revolutionized marine propulsion and navigation to a significant extent. Fabrication of a modern steam turbine involves advanced metalwork to form high-grade steel alloys into precision parts using technologies that first became available in the 20th century; continued advances in durability and [|efficiency] of steam turbines remains central to the energy economics of the 21st century. The largest steam turbine ever built is the 1,770 MW Arabelle steam turbine built by Arabelle Solutions, two units of which will be installed at Hinkley Point C Nuclear Power Station, England.
The steam turbine is a form of heat engine that derives much of its improvement in thermodynamic efficiency from the use of multiple stages in the expansion of the steam, which results in a closer approach to the ideal reversible expansion process. Because the turbine generates rotary motion, it can be coupled to a generator to harness its motion into electricity. Such turbogenerators are the core of thermal power stations which can be fueled by fossil fuels, nuclear fuels, geothermal, or solar energy. About 42% of all electricity generation in the United States in 2022 was by the use of steam turbines. Technical challenges include rotor imbalance, vibration, bearing wear, and uneven expansion.

History

The first device that may be classified as a [|reaction] steam turbine was little more than a toy, the classic Aeolipile, described in the 1st century by Hero of Alexandria in Roman Egypt. In 1551, Taqi al-Din in Ottoman Egypt described a steam turbine with the practical application of rotating a spit. Steam turbines were also described by the Italian Giovanni Branca and John Wilkins in England. The devices described by Taqi al-Din and Wilkins are today known as steam jacks. In 1672, an impulse turbine-driven small toy car was designed by Ferdinand Verbiest. A more modern version of this car was produced some time in the late 18th century by an unknown German mechanic. In 1775, at Soho James Watt designed a reaction turbine that was put to work there. In 1807, Polikarp Zalesov designed and constructed an [|impulse turbine], using it for the fire pump operation. In 1827, the Frenchmen Real and Pichon patented and constructed a compound impulse turbine.
The modern steam turbine was invented in 1884 by Charles Parsons, whose first model was connected to a dynamo that generated of electricity. The invention of Parsons' steam turbine made cheap and plentiful electricity possible and revolutionized marine transport and naval warfare. Parsons' design was a reaction type. His patent was licensed and the turbine scaled up shortly after by an American, George Westinghouse. The Parsons turbine also turned out to be easy to scale up. Parsons had the satisfaction of seeing his invention adopted for all major world power stations, and the size of generators had increased from his first set up to units of capacity. Within Parsons' lifetime, the generating capacity of a unit was scaled up by about 10,000 times, and the total output from turbo-generators constructed by his firm C. A. Parsons and Company and by their licensees, for land purposes alone, had exceeded thirty million horse-power.
Other variations of turbines have been developed that work effectively with steam. The de Laval turbine accelerated the steam to full speed before running it against a turbine blade. De Laval's impulse turbine is simpler and less expensive and does not need to be pressure-proof. It can operate with any pressure of steam, but is considerably less efficient. Auguste Rateau developed a pressure compounded impulse turbine using the de Laval principle as early as 1896, obtained a US patent in 1903, and applied the turbine to a French torpedo boat in 1904. He taught at the École des mines de Saint-Étienne for a decade until 1897, and later founded a successful company that was incorporated into the Alstom firm after his death. One of the founders of the modern theory of steam and gas turbines was Aurel Stodola, a Slovak physicist and engineer and professor at the Swiss Polytechnical Institute in Zurich. His work Die Dampfturbinen und ihre Aussichten als Wärmekraftmaschinen was published in Berlin in 1903. A further book Dampf und Gas-Turbinen was published in 1922.
The [|Brown-Curtis turbine], an impulse type, which had been originally developed and patented by the U.S. company International Curtis Marine Turbine Company, was developed in the 1900s in conjunction with John Brown & Company. It was used in John Brown-engined merchant ships and warships, including liners and Royal Navy warships.

Manufacturing

The present-day manufacturing industry for steam turbines consists of the following companies:
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 turbines used to generate electricity. There are several classifications for modern steam turbines.

Blade and stage design

Turbine blades are of two basic types, blades and nozzles. Blades move entirely due to the impact of steam on them and their profiles do not converge. This results in a steam velocity drop and essentially no pressure drop as steam moves through the blades. A turbine composed of blades alternating with fixed nozzles is called an impulse turbine,, Rateau turbine, or Brown-Curtis turbine. Nozzles appear similar to blades, but their profiles converge near the exit. This results in a steam pressure drop and velocity increase as steam moves through the nozzles. Nozzles move due to both the impact of steam on them and the reaction due to the high-velocity steam at the exit. A turbine composed of moving nozzles alternating with fixed nozzles is called a reaction turbine or Parsons turbine.
Except for low-power applications, turbine blades are arranged in multiple stages in series, called compounding, which greatly improves efficiency at low speeds. A reaction stage is a row of fixed nozzles followed by a row of moving nozzles. Multiple reaction stages divide the pressure drop between the steam inlet and exhaust into numerous small drops, resulting in a pressure-compounded turbine. Impulse stages may be either pressure-compounded, velocity-compounded, or pressure-velocity compounded. A pressure-compounded impulse stage is a row of fixed nozzles followed by a row of moving blades, with multiple stages for compounding. This is also known as a Rateau turbine, after its inventor. A velocity-compounded impulse stage is a row of fixed nozzles followed by two or more rows of moving blades alternating with rows of fixed blades. This divides the velocity drop across the stage into several smaller drops. A series of velocity-compounded impulse stages is called a pressure-velocity compounded turbine.
By 1905, when steam turbines were coming into use on fast ships and in land-based power applications, it had been determined that it was desirable to use one or more Curtis wheels at the beginning of a multi-stage turbine, followed by reaction stages. This was more efficient with high-pressure steam due to reduced leakage between the turbine rotor and the casing. This is illustrated in the drawing of the German 1905 AEG marine steam turbine. The steam from the boilers enters from the right at high pressure through a throttle, controlled manually by an operator. It passes through five Curtis wheels and numerous reaction stages before exiting at low pressure, almost certainly to a condenser. The condenser provides a vacuum that maximizes the energy extracted from the steam, and condenses the steam into feedwater to be returned to the boilers. On the left are several additional reaction stages that rotate the turbine in reverse for astern operation, with steam admitted by a separate throttle. Since ships are rarely operated in reverse, efficiency is not a priority in astern turbines, so only a few stages are used to save cost.

Blade design challenges

A major challenge facing turbine design was reducing the creep experienced by the blades. Because of the high temperatures and high stresses of operation, steam turbine materials become damaged through these mechanisms. As temperatures are increased in an effort to improve turbine efficiency, creep becomes significant. To limit creep, thermal coatings and superalloys with solid-solution strengthening and grain boundary strengthening are used in blade designs.
Protective coatings are used to reduce the thermal damage and to limit oxidation. These coatings are often stabilized zirconium dioxide-based ceramics. Using a thermal protective coating limits the temperature exposure of the nickel superalloy. This reduces the creep mechanisms experienced in the blade. Oxidation coatings limit efficiency losses caused by a buildup on the outside of the blades, which is especially important in the high-temperature environment.
The nickel-based blades are alloyed with aluminum and titanium to improve strength and creep resistance. The microstructure of these alloys is composed of different regions of composition. A uniform dispersion of the gamma-prime phase – a combination of nickel, aluminum, and titanium – promotes the strength and creep resistance of the blade due to the microstructure.
Refractory elements such as rhenium and ruthenium can be added to the alloy to improve creep strength. The addition of these elements reduces the diffusion of the gamma prime phase, thus preserving the fatigue resistance, strength, and creep resistance.