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The steam turbine is the most important utility which generates power for plant operations. Steam turbine conversion heat energy of process steam to power in a very economical manner.
Installing the steam turbine is most important. And steam piping plays a major role in the performance of steam turbines.

Steam piping should be reviewed, analyzed, designed, and properly installed to ensure there will be no excessive forces transmitted to the turbine flanges. Steam piping may exert forces from four sources:

Pipe dead weight

Thermal expansion

Thrust

Spring rate is caused by different types of expansion joints

The thermal expansion also causes movement of the turbine’s flanged connections, which must be considered during the piping design.

The steam piping must be designed to allow for expansion and contraction of the steam piping. The steam lines must have the correct number of appropriately sized hanger supports. Guides should ensure there are no forces or moments on the tur­bine that exceed the values provided by the turbine manufacturer. If the piping is unable to flex while accom­modating the expansion and contrac­tion, then consider the installation of an expansion device such as a pipe loop or expansion joint.
Inlet and outlet lines of the turbine should be carefully designed.
Steam piping must be designed to provide full-line steam pressure at the turbine inlet at full-load capacity. The supply line size needs to be calcu­lated not only for the load but also to include the pressure drops due to the length of pipe and system components, including valves and fittings. Any pres­sure loss in the supply line will affect turbine performance.

The discharge piping exhaust pressure will dictate the required discharge line size. As with the inlet piping, all pressure drops must be taken into consideration. Excessive pressure must be eliminated so turbine performance is not affected.

Typically the inlet and outlet steam piping size will be equal to or greater than the actual turbine connections provided by the manufacturer.

Steam traps are to be provided in all steam lines to avoid condensate accumulation.
Ensure that all the steam piping is supported properly to carry all the load and it should not produce any undesirable support reactions.

The steam turbine is the most valuable essential equipment in sugar, distillery, food industry, Edible oils, Paper Industry, Dairy plants, Cement plants, and many more industries. It generates power at the lowest cost as compared to grid power. Hence while installing steam turbines proper care needs to be taken for successful power generation. There are 5 secrets of successful steam turbine installation.

1. Avoid the dust environment of the turbine room. The steam turbine room in the powerhouse building will be provided with air washer units. The turbine room should have exhaust fans for maintaining a clean environment of turbine room.
2. Proper Piping stress analysis. Ensure the correct weight of the valve, flange, and any inline items, and mark the weight in the stress sketch. Branch piping. Check insulation density carefully. Wherever spring supports are used, define spring rate and cold load.
3. Layout considerations for turbine piping. Enough flexibility in steam turbine piping has to be provided to make up for thermal. Stresses as these lines are subjected to high temperatures by providing long-run pipes, loops, and bends. Line routing should be fabricated by bending or welding processes instead of flange connections to avoid leakage in steam lines. All main area piping has to be done by a vendor or inspected by OEM as per requirement. Steam traps are to be provided in all steam lines to avoid condensate accumulation. Expansion bellows can be used in large diameter and short span, rigid piping systems.
4. Maintain steam quality and water quality as per OEM.
   The most challenging systems to design are low-pressure steam systems, as the lower pressure steam can contain more moisture. With the help of proper separation or scrubbing devices in the steam, the drum can improve the steam quality. Maintain steam inlet pressure and temperature as per design of OEM.
5. Higher steam turbine competent operator and provide training from OEM only.
6. Follow statutory standards and norms in your turbine area as per recommended by OEM.
   Turtle Turbines have a number of successful steam turbines installation within India and abroad. Turtle Turbines always do commissioning at the site and run the turbine successfully as committed by Turtle Turbines. For more information please visit www.turtleturbines.com.

Turtle Turbines is one of the most reputed Steam Turbine Manufacturers In India.

Steam turbines are used for many applications for Power generation in power plants, combining power and heat application, cogeneration, etc. It’s power generating equipment. Steam turbines are the most valuable essential equipment in sugar, distillery, food industry, Edible oils, Paper Industry, Dairy plants, Cement plants, and many more industries. It generates power at the lowest cost as compared to grid power.
While installing steam turbines proper care needs to be taken for successful power generation. There are 5 mistakes in the installation of steam turbines that are ignored sometimes.

1. Turbine room layout not planned properly – As per OEM, the turbine room layout should be planned properly. For ex. Fuel (coal) and ash circuit, air and flue gas circuit, feed water, and steam flow circuit, and cooling water circuit should be as per OEM plan layout.
2. Steam turbine generating set orientation is not done as per planned layout.
3. Drain pipes and cables are not routed through trenches.
   Underground drain pipes and cables are protected from ice storms, lightning, and high winds. Hence drain pipes and cables should be routed through trenches.
4. Steam piping layout not done properly – Turbine piping stress analysis is one of the most critical analyses that need to be done as per OEM.
5. The turbine room does not have sufficient air and natural light. The turbine room environment should be clean and clear for successful turbine operations.
   Turtle Turbines supplies steam turbines from the range of 100kW to 3000kW. For more information please visit www.turtleturbines.com.

Turtle Turbines is one of the most reputed Steam Turbine Manufacturers In India.

The steam turbine is Equipment used to produce electrical power using steam.
To have a good performance of the turbine it needs to be operated properly. Below are the secrets of successful steam turbine operation

1. Steam quality:
   Steam turbine operation and performance require the correct steam pressure at the tur­bine inlet and high steam quality (steam without condensate entrapment) to ensure high turbine reliability. Low-quality steam reduces the steam turbine efficiency and causes erosion of steam turbine components (blades, governor valves, blading, and nozzles).
2. Lubrication system:
   Lubrication of the rotating parts is very important to reduce the friction and wear and tear of the components. A proper lubrication system needs to be provided for the steam turbine which includes MOP, AOP, and EOP. Ensure the required oil level in the lube oil tank. The lubricating oil should be kept at the appropriate operating temperature as possible this is to be achieved by providing an oil cooling system.

3 Bearing maintenance: Bearings of the steam turbine shaft should be checked regularly. Desired pressure needs to be maintained in the lubrication system to circulate the oil through bearings and other passages.

4 cleanliness of the steam turbine room:
The steam Turbine room must be clean properly all the instrumentation needs to check for their proper functioning. Instruments are to be calibrated at regular intervals. Instrument air should be free of dirt and oil.

5 general maintenance of the turbine.
Steam turbine regular maintenance procedures to be followed on a timely basis to ensure the hazel-free operation of steam turbines

Turtle Turbines is one of the most reputed Steam Turbine Manufacturers In India.

The term Energy conservation itself defines the energy which can be conserved by reducing wastage and losses, improving efficiency through technological upgrades, and improving operations and maintenance.

FACT I: Many industrial facilities produce steam at a pressure higher than that demanded by process requirements. Steam passes through pressure-reducing valves at various locations in the steam distribution system to reduce its pressure. A Back-Pressure Steam Turbine can perform the same pressure-reducing function as a PRV while converting steam energy into electrical energy, which leads down to Energy Conservation. A pressure difference must exist between the steam supply and the exhaust for any Steam Turbine to operate.

FACT II: Considering waste heat from Industries, which can recover heat from a hot gas or water stream and produces steam that can be used in industrial and manufacturing processes or can be also used to drive a Steam Turbine to improve efficiency, reduces operating cost and lowering carbon footprints. This leads us to Energy Conservation. Waste Heat is basically the byproduct from Chemical Industries, Gas Turbines, etc., where this waste heat can be converted into steam, which can be used further in Steam Turbine Generators to produce Electrical Power. Ultimately this fact will increase the value of Energy Conservation.

Turtle Turbines is one of the most reputed Steam Turbine Manufacturers In India.

To make the turbine installation successful it is very important to follow the simple things. The installation success starts at the very beginning with proper application engineering. Several things like steam parameters, selection of turbine type, gearbox, alternator, control system, power evacuation, etc. are important during application engineering.

During the installation of the Turbine readiness of the site contributes to the successful installation. The steam piping’s stress analysis should be done properly and piping should be supported properly according to the stress analysis report. The steam blowing should be done until the desired target plate reading is observed. The steam consumption in the process and a total electrical load of the plant should also be matched with the Turbine design parameter or alternative provisions should be done to overcome the problem.

Any process industry that generates steam for their process heating has an opportunity to generate electrical power using a Steam Turbine Generator. So the application of steam turbine will be in below three categories,
A. Energy Conservation
B. Co-Generation
C. Cative Power

An Energy conservation application is that where the plant is having small or medium pressure mostly saturated boiler and steam is being used at lower pressure in the process. There exists a possibility of power generation using a Micro Steam Turbine.

For Co-generation applications like in Distilleries, Sugar, Paper mills, etc. the selection of Boilers from medium pressure to high pressure with Superheated steam is done to meet the fully or partial total electrical load of the plant. Mainly Back Pressure, Extraction Back Pressure, or Extraction Condensing type of Steam Turbines are used for Co-generation.

For a captive power application, the steam turbines are designed with only the purpose of power generation due to lack of local grid power availability or utilize the waste heat generated from the process or many such reasons. For such applications fully condensing steam turbines are used.

We at Turtle Turbines understand the requirement of the customer to deliver the best suitable product for their Energy conservation/Co-generation/Captive Power need.

Turtle Turbines is one of the most reputed Steam Turbine Manufacturers In India.

Continuous steam supply is required for effective distillation and to maintain the operating cost.

In distilleries, steam is employed in a number of processes to produce hot water and regulate the temperature of the water during distillation. Steam is needed to clean and sterilize the equipment.
Not only the volume of steam is important depending on the production batch but the quality of steam is also essential to the distillation process. high-quality steam is needed for effective product distillation.

Steam distillation is carried out by passing low-pressure dry steam through the plant material whereby the steam volatile compounds are volatilized, condensed, and collected in receivers.
High pressure, superheated steam is produced by the boiler. In PRV/PRDS, this steam is lowered to the necessary pressure. Additionally, the steam temperature is controlled using a de-superheater. The co-generation solution provided by turtle turbines substitutes the PRS by installing back pressure or extraction steam turbine which provides uninterrupted steam flow at desired quality and also generated power.

The power generated by such steam turbines in the distillery directly reduces the demand for power from the grid. The cost of generating power in Distillery through co-generation is reduced to 40 to 50 %. At the same time, grid power costs almost twice to thrice the cost of co-generated power.
Every single production process needs energy, so generating electricity on-site using turtle turbine back pressure solutions lowers the production’s upfront costs. Cutting down the monthly electricity bills and delivering the desired quality of steam with an uninterrupted flow is the best solution for every distillation plant

Knowing the true cost of power is very important to improving the company’s bottom and operation efficiency.
The power we use has both economic and social impacts and to understand the true cost of power we need to dig deep into both of them.

Cost of power generation:
There are many ways to generate power, mainly hydropower, nuclear power, solar wind, and thermal power plants. Out of these main categories, thermal power plants are the most popular and have the highest market share among the others. Most thermal power plants work on the Rankine cycle. The fuel such as coal and natural gas is burned into the boiler. The boiler generates high pressure and superheated steam. Steam is further passed through a steam turbine to generate the power. Owing to the intrinsic limited efficiency of the Rankine Cycle, only about 30% of Energy generated by burning the fuel is converted into Electrical Power.
per kW of power generated majorly depends on
Fixed costs (FC), mainly interest, depreciation, insurance, and taxes, depending on the capital invested, i.e. on the construction costs of the plant including the cost of the land.
Operation and maintenance (O & M) cost cover salaries and wages, overhauling of equipment, repairs including spare parts, water, lubricating oil, chemicals, and miscellaneous expenses.
Fuel costs, depend on the amount of electricity generated. Cost also varies with the quantity of fuel, source of fuel, and availability of fuel. Apart from capital expenditure on the infrastructure and capital equipment the consumption of fuel accounts for more than 50% of the power plant operating cost.

Cost of distribution:
Usually, Power is generated at a centralized location and transmitted via Grid to the industry. Power distribution requires a huge network of wire/cable of several hundred kilometers along with many distribution stations. developing this infrastructure is very capital intensive. Up to 20% of this power (ie. 6% of the Energy in Coal) is lost as Transmission and Distribution losses, thus only about 24% of Energy reaches the consumption point. The remaining 76% is dumped as Heat into the atmosphere adding to Global Warming.

As an industrialist, we can reduce the cost of power by generating our own power at the site ( near to the point of consumption) which almost eliminates the capital infrastructure cost of the power distribution network and also minimizes the distribution losses. In case of Cogeneration, both Heat and Power are generated from a single primary source of Fuel. The exhaust heat from the Cogeneration Power Plant can be utilized in the process of heating the industry and the Power is consumed locally. The system efficiency of the Cogeneration Power Plant thus reaches as high as 84%, compared to just 24% of Centralised Power Plant.

Generating power at the site through waste heat or instead of the PRS system is the best option to reduce the cost of power and increase the process efficiency.
On-site power generation reduces the waste heat dumped into the atmosphere. Which in turn reduces the global warming effect by almost 70% as compared to the conventional centralized power generation.

Blog ~
Role of Steam Turbine in Energy Conservation

The global energy landscape will change more in the next 10 years than in the previous hundred. As the world’s energy sector moves away from fossil fuels toward renewable energy sources, industrial companies are challenged with addressing this transition in transformative ways.
Digitization will be key to making power-generating assets more efficient, the electric grid more secure and resilient, the aviation industry more sustainable, and helping manufacturers reduce waste.

Energy conservation means the efforts made to reduce the consumption of energy by using less energy. This can be achieved either by using energy more efficiently or by reducing the amount of service used. Energy can be conserved by reducing wastage and losses, improving efficiency through technological upgrades, and improving operation and maintenance. Steam Turbine is one of the best options to conserve energy in industries where steam is used in the processes industries like a distillery, sugar, paper, Dairy plants, oils and refineries, Textiles, Edible oil, and many more industries.

A steam turbine is an equipment that extracts thermal energy from pressurized steam and uses it to do mechanical work on a rotating output shaft and generates power. Steam turbines play a very important role in energy conservation. With the help of a steam turbine, waste energy can be harnessed. Due to steam turbines, the overall efficiency of the process increases. It will help to reduce the production cost. Because of energy conservation, there will be less waste of energy. Hence with the help of a steam turbine maximum amount of energy can be conserved.
Turtle Turbines manufactures exceptionally reliable steam turbine Generators with highest efficiency in their class at lowest ownership cost. The products can generate power at 25% of the grid power cost.
Turtle Turbines supplies steam turbines from the range of 100kW to 3000kW within India and abroad. For more information please visit www.turtleturbines.com