Part 2

Fig. 20 represents one of the several designs of stage valve, sometimes called the overload valve, the office of which is to prevent too high pressure in the first stage in case of a sudden overload, and to transfer a part of the steam to a special set of expanding nozzles over the second-stage wheel. This valve is balanced by a spring of adjustable tension, and is, or can be, set to open and close within a very small predetermined range of first-stage pressure. The valve is _intended_ to open and close instantly, and to supply or cut off steam from the second stage, without affecting the speed regulation or economy of operation. If any leaking occurs past the valve it is taken care of by a drip-pipe to the third stage.

The steam which passes through the automatic stage valves and is admitted to the extra set of nozzles above the second-stage wheel acts upon this wheel just the same as the steam which passes through the regular second-stage nozzles; i.e., all the steam which goes through the machine tends to hasten its speed, or, more accurately, does work and _maintains_ the speed of the machine.

II. SETTING THE VALVES OF THE CURTIS TURBINE[2]

[2] Contributed to _Power_ by F. L. Johnson.

Under some conditions of service the stage valve in the Curtis turbine will not do what it is designed to do. It is usually attached to the machine in such manner that it will operate with, or a little behind, in the matter of time, the sixth valve. The machine is intended to carry full load with only the first bank of five valves in operation, with proper steam pressure and vacuum. If the steam pressure is under 150 pounds, or the vacuum is less than 28 inches, the sixth valve may operate at or near full load, and also open the stage valve and allow steam to pass to the second-stage nozzles at a much higher rate of speed than the steam which has already done some work in the first-stage wheel. The tendency is to accelerate unduly the speed of the machine. This is corrected by the governor, but the correction is usually carried too far and the machine slows down. With the stage valve in operation, at a critical point the regulation is uncertain and irregular, and its use has to be abandoned. The excess first-stage pressure will then be taken care of by the relief valve, which is an ordinary spring safety valve (not pop) which allows the steam to blow into the atmosphere.

The mechanical valve-gear does not often get out of order, but sometimes the unexpected happens. The shop man may not have properly set up the nuts on the valve-stems; or may have fitted the distance bushings between the shield plates too closely; the superheat of the steam may distort the steam chest slightly and produce friction that will interfere with the regulation. If any of the valve-stems should become loose in the cross-heads they may screw themselves either in or out. If screwed out too far, the valve-stem becomes too long and the pawl in descending will, after the valve is seated, continue downward until it has broken something. If screwed in, the cross-head will be too low for the upper pawl to engage and the valve will not be opened. This second condition is not dangerous, but should be corrected. The valve-stems should be made the right length, and all check-nuts set up firmly. If for any purpose it becomes necessary to "set the valves" on a 1500-kilowatt mechanical gear, the operator should proceed in the following manner.

Setting the Valves of a 1500-Kilowatt Curtis Turbine

We will consider what is known as the "mechanical" valve-gear, with two sets of valves, one set of five valves being located on each side of the machine.

In setting the valves we should first "throw out" all pawls to avoid breakage in case the rods are not already of proper length, holding the pawls out by slipping the ends of the pawl springs over the points of the pawls, as seen in Fig. 21. Then turn the machine slowly by hand until the pawls on one set of valves are at their highest point of travel, then with the valves wide open adjust the drive-rods, i.e., the rods extending from the crank to the rock-shaft, so that there is 1/32 of an inch clearance (shown dotted in Fig. 17, Chap. I) at the point of opening of the pawls when they are "in." (See Fig. 22.) Then set up the check-nuts on the drive-rod. Turn the machine slowly, until the pawls are at their lowest point of travel. Then, with the valves closed, adjust each _valve-stem_ to give 1/32 of an inch clearance at the point of closing of the pawls when they are "in," securely locking the check-nut as each valve is set. Repeat this operation on the other side of the machine and we are ready to adjust the governor-rods. (Valves cannot be set on both sides of the machine at the same time, as the pawls will not be in the same relative position, due to the angularity of the drive-rods.)

Next, with the turbine running, and the synchronizing spring in mid-position, adjust the governor-rods so that the turbine will run at the normal speed of 900 revolutions per minute when working on the fifth valve, and carrying full load. The governor-rods for the other side of the turbine (controlling valves Nos. 6 to 10) should be so adjusted that the speed change between the fifth and sixth valves will not be more than three or four revolutions per minute.

The valves of these turbines are all set during the shop test and the rods trammed with an 8-inch tram. Governors are adjusted for a speed range of 2 per cent. between no load and full load (1500 kilowatt), or 4 per cent. between the mean speeds of the first and tenth valves (no load to full overload capacity).

The rods which connect the governor with the valve-gear have ordinary brass ends or heads and are adjusted by right-and-left threads and secured by lock-nuts. They are free fits on the pins which pass through the heads, and no friction is likely to occur which will interfere with the regulation, but too close work on the shield-plate bushings, or a slight warping of the steam chest, will often produce friction which will seriously impair the regulation. If it is noticed that the shield-plate shaft has any tendency to oscillate in unison with the rock-shaft which carries the pawls, it is a sure indication that the shield-plates are not as free as they should be, and should be attended to. The governor-rod should be disconnected, the pawls thrown out and the pawl strings hooked over the ends.

The plates should then be rocked up and down by hand and the friction at different points noted. The horizontal rod at the back of the valve-gear may be loosened and the amount of end play of each individual shield-plate noticed and compared with the bushings on the horizontal rod at the back which binds the shield-plates together. If the plates separately are found to be perfectly free they may be each one pushed hard over to the right or left and wedged; then each bushing tried in the space between the tail-pieces of the plates. It will probably be found that the bushings are not of the right length, due to the alteration of the form of the steam chest by heat. It will generally be found also that the bushings are too short, and that the length can be corrected by very thin washers of sheet metal. It has been found in some instances that the thin bands coming with sectional pipe covering were of the right thickness.

After the length of the bushings is corrected the shield-plates may be assembled, made fast and tested by rocking them up and down, searching for signs of sticking. If none occurs, the work has been correctly done, and there will be no trouble from poor regulation due to friction of the shield-plates.

The Baffler

The water which goes to the step-bearing passes through a baffler, the latest type of which is shown by Fig. 23. It is a device for restricting the flow of water or oil to the step- and guide-bearing. The amount of water necessary to float the machine and lubricate the guide-bearing having been determined by calculation and experiment, the plug is set at that point which will give the desired flow. The plug is a square-threaded worm, the length of which and the distance which it enters the barrel of the baffler determining the amount of flow. The greater the number of turns which the water must pass through in the worm the less will flow against the step-pressure.

The engineers who have settled upon the flow and the pressure decided that a flow of from 4-1/2 to 5-1/2 gallons per minute and a step-pressure of from 425 to 450 pounds is correct. These factors are so dependent upon each other and upon the conditions of the step-bearing itself that they are sometimes difficult to realize in every-day work; nor is it necessary. If the machine turns freely with a lower pressure than that prescribed by the engineers, there is no reason for raising this pressure; and there is only one way of doing it without reducing the area of the step-bearing, and that is by obstructing the flow of water in the step-bearing itself.

A very common method used is that of grinding. The machine is run at about one-third speed and the step-water shut off for 15 or 20 seconds. This causes grooves and ridges on the faces of the step-bearing blocks, due to their grinding on each other, which obstruct the flow of water between the faces and thus raises the pressure. It seems a brutal way of getting a scientific result, if the result desired can be called scientific. The grooving and cutting of the step-blocks will not do any harm, and in fact they will aid in keeping the revolving parts of the machine turning about its mechanical center.

The operating engineer will be very slow to see the utility of the baffler, and when he learns, as he will sometime, that the turbine will operate equally well with a plug out as with it in the baffler, he will be inclined to remove the baffler. It is true that with one machine operating on its own pump it is possible to run without the baffler, and it is also possible that in some particular case two machines having identical step-bearing pressures might be so operated. The baffler, however, serves a very important function, as described more fully as follows: It tends to steady the flow from the pump, to maintain a constant oil film as the pressure varies with the load, and when several machines are operating on the same step-bearing system it is the only means which fixes the flow to the different machines and prevents one machine from robbing the others. Therefore, even if an engineer felt inclined to remove the baffler he would be most liable to regret taking such a step.

If the water supply should fail from any cause and the step-bearing blocks rub together, no great amount of damage will result. The machine will stop if operated long under these conditions, for if steam pressure is maintained the machine will continue in operation until the buckets come into contact, and if the step-blocks are not welded together the machine may be started as soon as the water is obtained. If vibration occurs it will probably be due to the rough treatment of the step-blocks, and may be cured by homeopathic repeat-doses of grinding, say about 15 seconds each. If the step-blocks are welded a new pair should be substituted and the damaged ones refaced.

Some few experimental steps of spherical form, called "saucer" steps, have been installed with success (see Fig. 24). They seem to aid the lower guide-bearing in keeping the machine rotating about the mechanical center and reduce the wear on the guide-bearing. In some instances, too, cast-iron bushings have been substituted for bronze, with marked success. There seems to be much less wear between cast-iron and babbitt metal than between bronze and babbitt metal. The matter is really worth a thorough investigation.

III. ALLIS-CHALMERS COMPANY STEAM TURBINE

In Fig. 25 may be seen the interior construction of the steam turbine built by Allis-Chalmers Co., of Milwaukee, Wis., which is, in general, the same as the well-known Parsons type. This is a plan view showing the rotor resting in position in the lower half of its casing.

Fig. 26 is a longitudinal cross-section cut of rotor and both lower and upper casing. Referring to Fig. 26 the steam comes in from the steam-pipe at C and passes through the main throttle or regulating valve D, which is a balanced valve operated by the governor. Steam enters the cylinder through the passage E.

Turning in the direction of the bearing A, it passes through alternate stationary and revolving rows of blades, finally emerging at F and going out by way of G to the condenser or to atmosphere. H, J, and K represent three stages of blading. L, M, and Z are the balance pistons which counterbalance the thrust on the stages H, J, and K. O and Q are equalizing pipes, and for the low-pressure balance piston similar provision is made by means of passages (not shown) through the body of the spindle.

R indicates a small adjustable collar placed inside the housing of the main bearing B to hold the spindle in a position where there will be such a clearance between the rings of the balance pistons and those of the cylinder as to reduce the leakage of steam to a minimum and at the same time prevent actual contact under varying temperature.

At S and T are glands which provide a water seal against the inleakage of air and the outleakage of steam. U represents the flexible coupling to the generator. V is the overload or by-pass valve used for admitting steam to intermediate stage of the turbine. W is the supplementary cylinder to contain the low-pressure balance piston. X and Y are reference letters used in text of this chapter to refer to equalizing of steam pressure on the low-pressure stage of the turbine. The first point to study in this construction is the arrangement of "dummies" L, M, and Z. These dummy rings serve as baffles to prevent steam leakage past the pistons, and their contact at high velocity means not only their own destruction, but also damage to or the wrecking of surrounding parts. A simple but effective method of eliminating this difficulty is found in the arrangement illustrated in this figure. The two smaller balance pistons, L and M, are allowed to remain on the high-pressure end; but the largest piston, Z, is placed upon the low-pressure end of the rotor immediately behind the last ring of blades, and working inside of the supplementary cylinder W. Being backed up by the body of the spindle, there is ample stiffness to prevent warping. This balance piston, which may also be plainly seen in Fig. 25, receives its steam pressure from the same point as the piston M, but the steam pressure, equalized with that on the third stage of the blading, X, is through holes in the webs of the blade-carrying rings. Entrance to these holes is through the small annular opening in the rotor, visible in Fig. 25 between the second and third barrels. As, in consequence of varying temperatures, there is an appreciable difference in the endwise expansion of the spindle and cylinder, the baffling rings in the low-pressure balance piston are so made as to allow for this difference. The high-pressure end of the spindle being held by the collar bearing, the difference in expansion manifests itself at the low-pressure end. The labyrinth packing of the high-pressure and intermediate pistons has a small axial and large radial clearance, whereas the labyrinth packing of the piston Z has, vice versa, a small radial and large axial clearance. Elimination of causes of trouble with the low-pressure balance piston not only makes it possible to reduce the diameter of the cylinder, and prevent distortion, but enables the entire spindle to be run with sufficiently small clearance to obviate any excessive leakage of steam.

Detail of Blade Construction

In this construction the blades are cut from drawn stock, so that at its root it is of angular dovetail shape, while at its tip there is a projection. To hold the roots of the blades firmly, a foundation ring is provided, as shown at A in Fig. 27. This foundation ring is first formed to a circle of the proper diameter, and then slots are cut in it. These slots are accurately spaced and inclined to give the right pitch and angle to the blades (Fig. 28), and are of dovetail shape to receive the roots of the blades. The tips of the blades are substantially bound together and protected by means of a channel-shaped shroud ring, illustrated in Fig. 31 and at B in Fig. 27. Fig. 31 shows the cylinder blading separate, and Fig. 27 shows both with the shrouding. In these, holes are punched to receive the projections on the tips of the blades, which are rivetted over pneumatically.

The foundation rings themselves are of dovetail shape in cross-section, and, after receiving the roots of the blades, are inserted in dovetailed grooves in the cylinder and rotor, where they are firmly held in place by keypieces, as may be seen at C in Fig. 27. Each keypiece, when driven in place, is upset into an undercut groove, indicated by D in Fig. 27, thereby positively locking the whole structure together. Each separate blade is firmly secured by the dovetail shape of the root, which is held between the corresponding dovetailed slot in the foundation ring and the undercut side of the groove.

Fig. 29, from a photograph of blading fitted in a turbine, illustrates the construction, besides showing the uniform spacing and angles of the blades.

The obviously thin flanges of the shroud rings are purposely made in that way, so that, in case of accidental contact between revolving and stationary parts, they will wear away enough to prevent the blades from being ripped out. This protection, however, is such that to rip them out a whole half ring of blades must be sheared off at the roots. The strength of the blading, therefore, depends not upon the strength of an individual blade, but upon the combined shearing strength of an entire ring of blades.

The blading is made up and inserted in half rings, and Fig. 30 shows two rings of different sizes ready to be put in place. Fig. 31 shows a number of rows of blading inserted in the cylinder of an Allis-Chalmers steam turbine, and Fig. 32 gives view of blading in the same turbine after nearly three years' running.

The Governor

Next in importance to the difference in blading and balance piston construction, is the governing mechanism used with these machines. This follows the well-known Hartung type, which has been brought into prominence, heretofore largely in connection with hydraulic turbines; and the governor, driven directly from the turbine shaft by means of cut gears working in an oil bath, is required to operate the small, balanced oil relay-valve only, while the two steam valves, main and by-pass (or overload), are controlled by an oil pressure of about 20 pounds per square inch, acting upon a piston of suitable size. In view of the fact that a turbine by-pass valve opens only when the unit is required to develop overload, or the vacuum fails, a good feature of this governing mechanism is that the valve referred to can be kept constantly in motion, thereby preventing sticking in an emergency, even though it be actually called into action only at long intervals. Another feature of importance is that the oil supply to the bearings, as well as that to the governor, can be interconnected so that the governor will automatically shut off the steam if the oil supply fails and endangers the bearings. This mechanism is also so proportioned that, while responding quickly to variations in load, its sensitiveness is kept within such bounds as to secure the best results in the parallel operation of alternators. The governor can be adjusted for speed while the turbine is in operation, thereby facilitating the synchronizing of alternators and dividing the load as may be desired.

In order to provide for any possible accidental derangement of the main governing mechanism, an entirely separate safety or over-speed governor is furnished. This governor is driven directly by the turbine shaft without the intervention of gearing, and is so arranged and adjusted that, if the turbine should reach a predetermined speed above that for which the main governor is set, the safety governor will come into action and trip a valve which entirely shuts off the steam supply, bringing the turbine to a stop.

Lubrication

Lubrication of the four bearings, which are of the self-adjusting, ball and socket pattern, is effected by supplying an abundance of oil to the middle of each bearing and allowing it to flow out at the ends. The oil is passed through a tubular cooler, having water circulation, and pumped back to the bearings. Fig. 33 shows the entire arrangement graphically and much more clearly than can be explained in words. The oil is circulated by a pump directly operated from the turbine, except where the power-house is provided with a central oiling system. Particular stress is laid by the builders upon the fact that it is not necessary to supply the bearings with oil under pressure, but only at a head sufficient to enable it to run to and through the bearings; this head never exceeding a few feet. With each turbine is installed a separate direct-acting steam pump for circulating oil for starting up. This will be referred to again under the head of operating.

Generator

The turbo-generator, which constitutes the electrical end of this unit, is totally enclosed to provide for noiseless operation, and forced ventilation is secured by means of a small fan carried by the shaft on each end of the rotor. The air is taken in at the ends of the generator, passes through the fans and is discharged over the end connections of the armature coils into the bottom of the machine, whence it passes through the ventilating ducts of the core to an opening at the top. The field core is, according to size, built up either of steel disks, each in one piece, or of steel forgings, so as to give high magnetic permeability and great strength. The coils are placed in radial slots, thereby avoiding side pressure on the slot insulation and the complex stresses resulting from centrifugal force, which, in these rotors, acts normal to the flat surface of the strip windings.

Operation

As practically no adjustments are necessary when these units are in operation, the greater part of the attention required by them is involved in starting up and shutting down, which may be described in detail as follows:

_To Start Up_