TURBO MACHINES ( IP-605)

MODULE - 1
Basics of turbo machines, Principles of impulse and reaction machines. Steam turbines: Impulse staging,
Velocity and Pressure Compounding, Utilization factor, Analysis for optimum U.F Curtis stage, and Rateau
stage, includes qualitative analysis, Effect of Blade and Nozzle losses on Vane Efficiency, Stage efficiency,
Analysis for Optimum Efficiency, Mass Flow and Blade Height.

FLUID MACHINERY:
 A fluid machinery (turbo-machinery) is a mechanical device that converts the energy stored by a fluid
into mechanical energy or vice versa
 The energy stored by a working fluid may be in the form of potential, kinetic, and intermolecular energy
 The mechanical energy is usually transmitted by a rotating shaft.
 Hydraulic Machines: Machines use mainly water, for most of the practical applications

TURBO- MACHINERY:
Turbo-machinery is defined as a device that transfers fluid energy between a rotor (a moving wheel with
blades) and a fluid. It involves rotating parts called as rotors. The rotor can be an impeller for pumps and a
turbine for power generation. Turbomachinery is part of fluid machinery focussing on mechanical machines.

There are generally two types of turbomachinery:

1) Turbines: Turbines extract energy from a fluid flow and convert it into mechanical energy. This
mechanical energy can be used to generate electricity or propel vehicles. In a turbine, the fluid enters
the machine at high pressure and velocity, striking the blades of the rotor. The blades are designed in a
way that the fluid's kinetic energy is transferred to the rotor, causing it to rotate. The rotation of the
rotor is then utilized to perform useful work.
2) Compressors/Pumps: Compressors and pumps perform the opposite function of turbines. They transfer
mechanical energy to the fluid, increasing its pressure and velocity. Compressors are used to compress
gases, while pumps are used to increase the pressure of liquids. In these devices, the rotor blades
accelerate the fluid, increasing its energy level and pressure as it passes through the machine.

The working principle of turbomachinery is based on the interaction between the rotating blades (rotor) and
the fluid.The working principle of turbomachinery relies on several key concepts:

a) Blade Design: The design of the rotor blades is crucial for efficient energy transfer. Blades are designed
to efficiently extract or impart energy to the fluid while minimizing losses due to friction and turbulence.

b) Fluid Dynamics: Understanding the behavior of the fluid flow is essential for optimizing turbomachinery
performance. Factors such as flow rate, pressure, temperature, and density influence the efficiency and
effectiveness of the machine.

c) Rotor Speed: The speed of the rotor plays a significant role in determining the performance of the
turbomachinery. Higher rotor speeds generally result in increased energy transfer but may also lead to
higher stresses on the components.

d) Control Mechanisms: Turbomachinery often incorporates control mechanisms to regulate the flow rate,
pressure, and other parameters to meet specific operational requirements.
The principle components of a turbo machine are:
1. Rotating element (vane, impeller or blades)– operating in a stream of fluid.
2. Stationary elements – which usually guide the fluid in proper direction for efficient energy conversion
process.
3. Shaft – This either gives input power or takes output power from fluid under dynamic conditions and runs
at required speed.
4. Housing – to keep various rotating, stationery and other passages safely under dynamic conditions of the
flowing fluid.

Classification of turbo machines

1. Based on Direction of Energy Conversion
a) Power Producing Device: The device in which the energy stored in a fluid is converted in the form of
mechanical energy of a rotating member is called as a turbine. The energy stored in the fluid may
in kinetic, potential, or inter molecular energy.
b) Power Absorbing Device: The machines which transfer mechanical energy from moving parts to a
fluid by increasing its pressure or velocity are known as power absorbing fluid machine such as fans,
compressors, pumps, or blowers

2. Based on fluid flowing in turbo machine

a) Water b) Air c) Steam d) Hot gases e) Liquids like petrol etc.

3. Based on direction of flow through the impeller or vanes or blades, with reference to the axis of shaft
rotation
a) Axial flow – The fluid path is mostly or entirely parallel to the rotation axis. The radial component
of the fluid velocity is negligible. Kaplan turbines and some water pumps are examples of axial
turbos. Eg. Axial pump, compressor or turbine
b) Radial flow – The fluid path is mostly or entirely in a plane perpendicular to the rotation axis. The
change of radius between the entry and the exit is finite.Centrifugal pump or compressor.
c) Mixed flow – Both axial and radial flow are present and neither is negligible.Mixed flow pump,
Francis turbine
d) Tangential flow – Pelton water turbine

4. Based on condition of fluid in turbo machine

a) Impulse type (constant pressure) E.g. Pelton water turbine
b) Reaction type (variable pressure) E.g. Francis reaction turbines
5. Based on position of rotating shaft
a) Horizontal shaft – Steam turbines
b) Vertical shaft – Kaplan water turbines
c) Inclined shaft – Modern bulb micro

IMPULSE TURBINE:
An impulse turbine is a type of steam turbine that uses
the impact force of high-velocity steam jets to generate
mechanical energy. It operates on the principle of
Newton’s third law of motion, which states that every
action has an equal and opposite reaction. One of the
advantages of impulse turbines is their simplicity in
design and operation, making them suitable for use in
smaller power generation systems. They also have high
efficiency, as they can convert up to 70% of thermal
energy into mechanical energy.
Eg. Pelton wheel turbine.
Working Principle of Impulse Turbine
The working principle of an impulse turbine is based on the conversion of the kinetic energy of a high-
velocity jet of steam into Mechanical Energy.

1) Fluid Flow: The working fluid, often water or steam, enters the turbine with high pressure and velocity.
This fluid flow is typically controlled by a nozzle, which directs the fluid onto the rotor blades.
2) Nozzle: The fluid passes through a series of nozzles arranged around the perimeter of the turbine casing.
These nozzles convert the pressure energy of the fluid into kinetic energy by accelerating the fluid to a
high velocity.
3) Rotor Blades: The high-velocity fluid jets from the nozzles are directed onto the rotor blades. These
blades are arranged in such a way that they are struck by the fluid jets at a specific angle. The blades are
designed to efficiently capture the kinetic energy of the fluid.
4) Impulse Action: As the high-velocity fluid strikes the blades, it imparts an impulse force to the blades.
This impulse force causes the rotor to rotate. The rotation of the rotor converts the kinetic energy of
the fluid into mechanical energy.
5) Pressure Drop: After striking the rotor blades, the fluid loses its velocity and kinetic energy. The
pressure of the fluid drops as it passes through the turbine, but its velocity remains relatively low
6) Exit: The fluid exits the turbine at a lower pressure and velocity compared to its entry into the turbine. It
may then be directed to other parts of the system for further processing or discharged back into the
environment.

REACTION TURBINE:
Reaction turbines are a specific type of turbine that generates
rotational force by responding to the pressure or mass of a gas
or fluid. The operation of these turbines is based on Newton's
third law of motion, where action and reaction are equal and
opposite. Reaction turbines are commonly used in various
applications to harness energy from fluid flow and are designed
to efficiently convert hydraulic energy into mechanical work.
Types of Reaction Turbine

 Radial flow turbines.

 Axial flow turbines.
 Mixed flow turbines.
Working of Reaction Turbine
1) The reaction turbine operates with low head and high-velocity water entering the spiral casing, flowing
through guide vanes, and striking the runner blades.
2) Guide vanes ensure proper angle alignment for maximum power output, maintaining pressure energy
consistently throughout the spiral casing due to its decreasing cross-sectional area.
3) The adjustability of guide vanes and runner blades enables flow rate control, optimising efficiency
across a wide range of water potential and load demands.
4) After striking the runner blades, the water exits at low pressure, and to recover pressure, it passes
through a draft tube with a uniformly increasing cross-section area until reaching the tail race. However,
the high-pressure difference may lead to cavitation and corrosion issues.

Difference between Impulse Turbine and Reaction Turbine

Basis of Impulse Turbine Reaction Turbine
Difference

The type of turbine in which only kinetic The type of water turbine in which both kinetic
energy of water (impulse force) is used to energy as well as pressure energy of water is
Definition
rotate the turbine is known as impulse used turn the turbine is called the reaction
turbine. turbine.

In an impulse turbine, the water flows In reaction turbine, the water is guided by the
Water flow through a nozzle and strikes to the blades guide blades (fixed blades) to flow over the
of the turbine. turbine.

Force on In impulse turbine, an impulsive force In reaction turbine, a reaction force on the
blades rotates the turbine. blades is rotation the turbine.

Change in In impulse turbine, all the pressure of water In reaction turbine, there is no change in the
pressure of is converted into kinetic energy before pressure of water before striking the turbine
water striking the turbine blades. blades.

The impulse turbines are most suitable for The reaction turbines are suitable for relatively
Water head
large water heads. low water heads.

Water flow The impulse turbines are suitable for Reaction turbines are suitable in cases where
rate comparatively low water flow rates. water flow rates are higher.

The blades of an impulse turbine are of The blades of a reaction turbine are
Blades profile
symmetrical profile. asymmetrical, having aerofoil profile.

For the same power output, the size of The reaction turbine have relatively large size
Turbine size
impulse turbine is smaller. for the same power output.

Popular examples of impulse turbine are: Popular examples of reaction turbines are:
Examples Pelton wheel turbine, Turgo turbine and Francis turbine and Kaplan turbine.
cross-flow turbine.

First and Second Laws of Thermodynamics Applied to Turbomachines:

In the field of turbomachinery, the application of the first and second laws of thermodynamics is of utmost
importance. These laws provide a fundamental understanding of energy transfer, conversion, and efficiency
in turbo machines.
Consider single inlet and single output steady state turbomachine, across the sections of which the velocities,
pressures, temperatures and other relevant properties are uniform.

The application of the first and second laws of thermodynamics in turbines allows engineers to analyze the
energy transfer and conversion processes.
By applying the first law, engineers can determine the work input and output of the turbine, as well as any
losses or gains in the system.

The second law of thermodynamics helps engineers understand the irreversibility and efficiency of the
expansion process. By minimizing the increase in entropy during expansion, the efficiency of the turbine can
be improved.
Aspect Pressure Compounding Turbine Velocity Compounding Turbine
Principle Pressure compounding turbines utilize Velocity compounding turbines utilize
multiple stages where each stage operates at multiple stages where each stage operates at
a different pressure level. a different velocity level.
Pressure Drop Pressure drops gradually across each stage. Pressure drop may not be as gradual as in
pressure compounding turbines.
Blade Design Blades are designed to extract energy Blades are designed to extract energy
primarily from the pressure drop. primarily from the velocity of the fluid.
Efficiency Generally exhibits higher efficiency. Efficiency may vary depending on design and
operating conditions.
Applications Commonly used in steam turbines and some Commonly used in low-pressure steam
types of gas turbines. turbines, wind turbines, and some types of
water turbines.
Complexity Typically more complex due to multiple Typically simpler compared to pressure
pressure stages. compounding turbines.
Size May be larger due to the need for multiple Can be relatively compact due to fewer
stages. stages.
Cost May be higher due to complexity and Generally lower due to simplicity, but can
additional components. vary depending on design and materials.

Pressure Pressure variation between stages is Pressure variation between stages may not
Variation significant. be as significant compared to pressure
compounding turbines.
Velocity Velocity variation between stages may not be Velocity variation between stages is
Variation significant. significant as it's the primary mode of energy
transfer.

Effect of Blade and Nozzle losses on Vane Efficiency

Blade and nozzle losses have a significant impact on vane efficiency in turbines and compressors. Let's
discuss their effects:
 Blade Losses: Blade losses occur due to several factors such as friction between the fluid and the blade
surfaces, secondary flow effects, and profile losses. These losses result in a decrease in the effective
work output from the blades. Some effects include:
a) Friction Losses: Friction between the fluid and blade surfaces leads to energy dissipation in the
form of heat. This reduces the kinetic energy of the fluid and consequently reduces the overall
efficiency of the turbine or compressor.
b) Secondary Flow Losses:These secondary flows lead to additional losses by disrupting the smooth
flow of the fluid through the turbine or compressor.
c) Profile Losses: Profile losses occur due to deviations from the ideal blade shape. These
deviations can lead to flow separation, increased turbulence, and increased pressure losses.
 Nozzle Losses: Nozzle losses primarily occur in turbines during the expansion process. These losses are
associated with the conversion of pressure energy into kinetic energy in the nozzle. Factors contributing
to nozzle losses include:
a) Shock Losses: In supersonic flow conditions, shock waves can form within the nozzle, leading to
additional energy losses.
b) Irreversibility: The expansion process in the nozzle is irreversible, meaning that some of the
available energy is inevitably lost as the fluid accelerates. This irreversible energy loss reduces
the overall efficiency of the turbine.