"Of the making of books there is no end." This seems especially true of steam-turbine books, but the book which really appeals to the operating engineer, the man who may have a turbine unloaded, set up, put in operation, and the builders' representative out of reach before the man who is to operate it fully realizes that he has a new type of prime mover on his hands, with which he has little or no acquaintance, has not been written. There has been much published, both descriptive and theoretical, about the turbine, but so far as the writer knows, there is nothing in print that tells the man on the job about the details of the turbine in plain language, and how to handle these details when they need handling. The operating engineer does not care why the moving buckets are made of a certain curvature, but he does care about the distance between the moving bucket and the stationary one, and he wants to know how to measure that distance, how to alter the clearance, if necessary, to prevent rubbing. He doesn't care anything about the area of the step-bearing, but he does want to know the way to get at the bearing to take it down and put it up again, etc.The lack of literature along this line is the writer's apology for what follows. The Curtis 1500-kilowatt steam turbine will be taken first and treated "from the ground up."

On entering a turbine plant on the ground floor, the attention is at once attracted by a multiplicity of pumps, accumulators and piping. These are called "auxiliaries" and will be passed for the present to be taken up later, for though of standard types their use is comparatively new in power-plant practice, and the engineer will find that more interruptions of service will come from the auxiliaries than from the turbine itself.

Builders' Foundation Plans Incomplete

It is impractical for the manufacturers to make complete foundation drawings, as they are not familiar with the lay-out of pipes and the relative position of other apparatus in the station. All that the manufacturers' drawing is intended to do is to show the customer where it will be necessary for him to locate his foundation bolts and opening for access to the step-bearing.

Fig. 1 shows the builders' foundation drawing, with the addition of several horizontal and radial tubes introduced to give passage for the various pipes which must go to the middle of the foundation. Entering through the sides of the masonry they do not block the passage, which must be as free as possible when any work is to be done on the step-bearing, or lower guide-bearing. Entering the passage in the foundation, a large screw is seen passing up through a circular block of cast iron with a 3/4-inch pipe passing through it. This is the step-supporting screw. It supports the lower half of the step-bearing, which in turn supports the entire revolving part of the machine. It is used to hold the wheels at a proper hight in the casing, and adjust the clearance between the moving and stationary buckets. The large block which with its threaded bronze bushing forms the nut for the screw is called the cover-plate, and is held to the base of the machine by eight 1-1/2-inch cap-screws. On the upper side are two dowel-pins which enter the lower step and keep it from turning. (See Figs. 2 and 3.)

The step-blocks are very common-looking chunks of cast iron, as will be seen by reference to Fig. 4. The block with straight sides (the lower one in the illustration) has the two dowel holes to match the pins spoken of, with a hole through the center threaded for 3/4-inch pipe. The step-lubricant is forced up through this hole and out between the raised edges in a film, floating the rotating parts of the machine on a frictionless disk of oil or water. The upper step-block has two dowel-pins, also a key which fits into a slot across the bottom end of the shaft.

The upper side of the top block is counterbored to fit the end of the shaft. The counterbore centers the block. The dowel-pins steer the key into the key-way across the end of the shaft, and the key compels the block to turn with the shaft. There is also a threaded hole in the under side of the top block. This is for the introduction of a screw which is used to pull the top block off the end of the shaft. If taken off at all it must be pulled, for the dowel-pins, key and counterbore are close fits. Two long bolts with threads the whole length are used if it becomes necessary to take down the step or other parts of the bottom of the machine. Two of the bolts holding the cover-plate in place are removed, these long bolts put in their places and the nuts screwed up against the plate to hold it while the remaining bolts are removed.

How to Lower Step-Bearings to Examine Them

Now, suppose it is intended to take down the step-bearings for examination. The first thing to do is to provide some way of holding the shaft up in its place while we take its regular support from under it. In some machines, inside the base, there is what is called a "jacking ring." It is simply a loose collar on the shaft, which covers the holes into which four plugs are screwed. These are taken out and in their places are put four hexagonal-headed screws provided for the purpose, which are screwed up. This brings the ring against a shoulder on the shaft and then the cover-plate and step may be taken down.

While all the machines have the same general appearance, there are some differences in detail which may be interesting. One difference is due to the sub-base which is used with the oil-lubricated step-bearings. This style of machine has the jacking ring spoken of, while others have neither sub-base nor jacking ring, and when necessary to take down the step a different arrangement is used.

A piece of iron that looks like a big horseshoe (Fig. 5) is used to hold the shaft up. The flange that covers the entrance to the exhaust base is taken off and a man goes in with the horseshoe-shaped shim and an electric light. Other men take a long-handled wrench and turn up the step-screw until the man inside the base can push the horseshoe shim between the shoulder on the shaft and the guide-bearing casing. The men on the wrench then back off and the horseshoe shim supports the weight of the machine. When the shim is in place, or the jacking ring set up, whichever the case may be, the cover-plate bolts may be taken out, the nuts on the long screws holding the cover in place.

The 3/4-inch pipe which passes up through the step-screw is taken down and, by means of the nuts on the long screws, the cover-plate is lowered about 2 inches. Then through the hole in the step-screw a 3/4-inch rod with threads on both ends is passed and screwed into the top step; then the cover-plate is blocked so it cannot rise and, with a nut on the lower end of the 3/4-inch rod, the top step is pulled down as far as it will come. The cover-plate is let down by means of the two nuts, and the top step-block follows. When it is lowered to a convenient hight it can be examined, and the lower end of the shaft and guide-bearing will be exposed to view.

The lower guide-bearing (Fig. 6) is simply a sleeve flanged at one end, babbitted on the inside, and slightly tapered on the outside where it fits into the base. The flange is held securely in the base by eight 3/4-inch cap-screws. Between the cap-screw holes are eight holes tapped to 3/4-inch, and when it is desired to take the bearing down the cap-screws are taken out of the base and screwed into the threaded holes and used as jacks to force the guide-bearing downward. Some provision should be made to prevent the bearing from coming down "on the run," for being a taper fit it has only to be moved about one-half inch to be free. Two bolts, about 8 inches long, screwed into the holes that the cap-screws are taken from, answer nicely, as a drop that distance will not do any harm, and the bearing can be lowered by hand, although it weighs about 200 pounds.

The lower end of the shaft is covered by a removable bushing which is easily inspected after the guide-bearing has been taken down. If it is necessary to take off this bushing it is easily done by screwing four 5/8-inch bolts, each about 2 feet long, into the tapped holes in the lower end of the bushing, and then pulling it off with a jack. (See Fig. 7.)

Each pipe that enters the passage in the foundation should be connected by two unions, one as close to the machine as possible and the other close to the foundation. This allows the taking down of all piping in the passage completely and quickly without disturbing either threads or lengths.

Studying the Blueprints

Fig. 8 shows an elevation and part-sectional view of a 1500-kilowatt Curtis steam turbine. If one should go into the exhaust base of one of these turbines, all that could be seen would be the under side of the lower or fourth-stage wheel, with a few threaded holes for the balancing plugs which are sometimes used. The internal arrangement is clearly indicated by the illustration, Fig. 8. It will be noticed that each of the four wheels has an upper and a lower row of buckets and that there is a set of stationary buckets for each wheel between the two rows of moving buckets. These stationary buckets are called intermediates, and are counterparts of the moving buckets. Their sole office is to redirect the steam which has passed through the upper buckets into the lower ones at the proper angle.

The wheels are kept the proper distance apart by the length of hub, and all are held together by the large nut on the shaft above the upper wheel. Each wheel is in a separate chamber formed by the diaphragms which rest on ledges on the inside of the wheel-case, their weight and steam pressure on the upper side holding them firmly in place and making a steam-tight joint where they rest. At the center, where the hubs pass through them, there is provided a self-centering packing ring (Fig. 9), which is free to move sidewise, but is prevented from turning, by suitable lugs. This packing is a close running fit on the hubs of the wheel and is provided with grooves (plainly shown in Fig. 9) which break up and diminish the leakage of steam around each hub from one stage to the next lower. Each diaphragm, with the exception of the top one, carries the expanding nozzles for the wheel immediately below.

The expanding nozzles and moving buckets constantly increase in size and number from the top toward the bottom. This is because the steam volume increases progressively from the admission to the exhaust and the entire expansion is carried out in the separate sets of nozzles, very much as if it were one continuous nozzle; but with this difference, not all of the energy is taken out of the steam in any one set of nozzles. The idea is to keep the velocity of the steam in each stage as nearly constant as possible. The nozzles in the diaphragms and the intermediates do not, except in the lowest stage, take up the entire circumference, but are proportioned to the progressive expansion of steam as it descends toward the condenser.

Clearance

While the machine is running it is imperative that there be no rubbing contact between the revolving and stationary parts, and this is provided for by the clearance between the rows of moving buckets and the intermediates. Into each stage of the machine a 2-inch pipe hole is drilled and tapped. Sometimes this opening is made directly opposite a row of moving buckets as in Fig. 10, and sometimes it is made opposite the intermediate. When opposite a row of buckets, it will allow one to see the amount of clearance between the buckets and the intermediates, and between the buckets and the nozzles. When drilled opposite the intermediates, the clearance is shown top and bottom between the buckets and intermediates. (See Fig. 11.) This clearance is not the same in all stages, but is greatest in the fourth stage and least in the first. The clearances in each stage are nearly as follows: First stage, 0.060 to 0.080; second stage, 0.080 to 0.100; third stage, 0.080 to 0.100; fourth stage, 0.080 to 0.200. These clearances are measured by what are called clearance gages, which are simply taper slips of steel about 1/2-inch wide accurately ground and graduated, like a jeweler's ring gage, by marks about 1/2-inch apart; the difference in thickness of the gage is one-thousandth of an inch from one mark to the next.

To determine whether the clearance is right, one of the 2-inch plugs is taken out and some marking material, such as red lead or anything that would be used on a surface plate or bearing to mark the high spots is rubbed on the taper gage, and it is pushed into the gap between the buckets and intermediates as far as it will go, and then pulled out, the marking on the gage showing just how far in it went, and the nearest mark giving in thousandths of an inch the clearance. This is noted, the marking spread again, and the gage tried on the other side, the difference on the gage showing whether the wheel is high or low. Whichever may be the case the hight is corrected by the step-bearing screw. The wheels should be placed as nearly in the middle of the clearance space as possible. By some operators the clearance is adjusted while running, in the following manner: With the machine running at full speed the step-bearing screw is turned until the wheels are felt or heard to rub lightly. The screw is marked and then turned in the opposite direction until the wheel rubs again. Another mark is made on the screw and it is then turned back midway between the two marks. Either method is safe if practiced by a skilful engineer. In measuring the clearance by the first method, the gage should be used with care, as it is possible by using too much pressure to swing the buckets and get readings which could be misleading. To an inexperienced man the taper gages would seem preferable. In the hands of a man who knows what he is doing and how to do it, a tapered pine stick will give as satisfactory results as the most elaborate set of hardened and ground clearance gages.

Referring back to Fig. 11, at A is shown one of the peep-holes opposite the intermediate in the third stage wheel for the inspection of clearance. The taper clearance gage is inserted through this hole both above and below the intermediate, and the distance which it enters registers the clearance on that side. This sketch also shows plainly how the shrouding on the buckets and the intermediates extends beyond the sharp edges of the buckets, protecting them from damage in case of slight rubbing. In a very few cases wheels have been known to warp to such an extent from causes that were not discovered until too late, that adjustment would not stop the rubbing. In such cases the shrouding has been turned or faced off by a cutting-off tool used through the peep-hole.

Carbon Packing Used

Where the shaft passes through the upper head of the wheel-case some provision must be made to prevent steam from the first stage escaping. This is provided for by carbon packing (Fig. 12), which consists of blocks of carbon in sets in a packing case bolted to the top head of the wheel-case. There are three sets of these blocks, and each set is made of two rings of three segments each. One ring of segments breaks joints with its mate in the case, and each set is separated from the others by a flange in the case in which it is held. In some cases the packing is kept from turning by means of a link, one end of which is fastened to the case and the other to the packing holder. Sometimes light springs are used to hold the packing against the shaft and in some the pressure of steam in the case does this. There is a pipe, also shown in Fig. 12, leading from the main line to the packing case, the pressure in the pipe being reduced. The space between the two upper sets of rings is drained to the third stage by means of a three-way cock, which keeps the balance between the atmosphere and packing-case pressure. The carbon rings are fitted to the shaft with a slight clearance to start with, and very soon get a smooth finish, which is not only practically steam-tight but frictionless.

The carbon ring shown in Fig. 12 is the older design. The segments are held against the flat bearing surface of the case by spiral springs set in brass ferrules. The circle is held together by a bronze strap screwed and drawn together at the ends by springs. Still other springs press the straps against the surface upon which the carbon bears, cutting off leaks through joints and across horizontal surfaces of the carbon. The whole ring is prevented from turning by a connecting-rod which engages a pin in the hole, like those provided for the springs.

The Safety-stop

There are several designs of safety-stop or speed-limit devices used with these turbines, the simplest being of the ring type shown in Fig. 13. This consists of a flat ring placed around the shaft between the turbine and generator. The ring-type emergencies are now all adjusted so that they normally run concentric with the shaft, but weighted so that the center of gravity is slightly displaced from the center. The centrifugal strain due to this is balanced by helical springs. But when the speed increases the centrifugal force moves the ring into an eccentric position, when it strikes a trigger and releases a weight which, falling, closes the throttle and shuts off the steam supply. The basic principle upon which all these stops are designed is the same—the centrifugal force of a weight balanced by a spring at normal speed. Figs. 14, 15, and 16 show three other types.

The Mechanical Valve-Gear

Fig. 17 shows plainly the operation of the mechanical valve-gear. The valves are located in the steam chests, which are bolted to the top of the casing directly over the first sets of expansion nozzles. The chests, two in number, are on opposite sides of the machine. The valve-stems extend upward through ordinary stuffing-boxes, and are attached to the notched cross-heads by means of a threaded end which is prevented from screwing in or out by a compression nut on the lower end of the cross-head. Each cross-head is actuated by a pair of reciprocating pawls, or dogs (shown more plainly in the enlarged view, Fig. 18), one of which opens the valve and the other closes it. The several pairs of pawls are hung on a common shaft which receives a rocking motion from a crank driven from a worm and worm-wheel by the turbine shaft. The cross-heads have notches milled in the side in which the pawls engage to open or close the valve, this engagement being determined by what are called shield-plates, A (Fig. 18), which are controlled by the governor. These plates are set, one a little ahead of the other, to obtain successive opening or closing of the valves. When more steam is required the shield plate allows the proper pawl to fall into its notch in the cross-head and lift the valve from its seat. If less steam is wanted the shield-plate rises and allows the lower pawl to close the valve on the down stroke.

The valves, as can easily be seen, are very simple affairs, the steam pressure in the steam chest holding the valve either open or shut until it is moved by the pawl on the rock-shaft. The amount of travel on the rock-shaft is fixed by the design, but the proportionate travel above and below the horizontal is controlled by the length of the connecting-rods from the crank to the rock-shaft. There are besides the mechanical valve-gear the electric and hydraulic, but these will be left for a future article.

The Governor

The speed of the machine is controlled by the automatic opening and closing of the admission valves under the control of a governor (Fig. 19), of the spring-weighted type attached directly to the top end of the turbine shaft. The action of the governor depends on the balance of force exerted by the spring, and the centrifugal effort of the rectangular-shaped weights at the lower end; the moving weights acting through the knife-edge suspension tend to pull down the lever against the resistance of the heavy helical spring. The governor is provided with an auxiliary spring on the outside of the governor dome for varying the speed while synchronizing. The tension of the auxiliary spring is regulated by a small motor wired to the switchboard. This spring should be used only to correct slight changes in speed. Any marked change should be corrected by the use of the large hexagonal nut in the upper plate of the governor frame. This nut is screwed down to increase the speed, and upward to decrease it.

The Stage Valves

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.