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A PRESENTATION ON 660MW TURBOGENERATOR ,ITS AUXILIARIES

AND ASSOCIATED SYSTEMS


By
Ashvani Shukla
C&I
BGR energy

STEAM TURBINE K-660-247

GENERAL INFORMATION

TG DECK IS VIS SUPPORTED AND HAS 26 CONCRETE COLUMNS


(T1 T26).

TG HALL IS CONSTITUTED OF 3 MAINS ROWS OF COLUMNS


A,B ,C ROW AND TWO BAYS AB BAY AND BC BAY. THE WIDTH
OF AB BAY IS 36m AND BC BAY IS 12m

CONDENSER TUBE BANKS (CW PATH) HAS AN INCLINATION OF


40.

THERE ARE TWO MAIN EOT CRANES FOR TG HALL.EACH EOT


CRANE IS HAVING A CAPACITY OF 200t FOR MAIN HOIST AND
20t FOR AUXILIARY HOIST. 35.5m IS THE MAXIMUM VERTCAL
DISTANCE A HOIST CAN TRAVEL.TANDEM OPERATION OF TWO
EOT CRANES ARE ALLOWED.

RATED CONDITIONS
LOAD
:
660MW
BEFORE HP STOP VALVE
STEAM PRESSURE
:
247KSC
STEAM TEMPERATURE
:
5370C
STEAM FLOW
:
2023.75T/HR

AFTER HPC
STEAM PRESSURE
STEAM PRESSURE

BEFORE IP STOP VALVE


STEAM PRESSURE
STEAM TEMPERATURE

:
:

48KSC
298.710C

43.2KSC
:
5650C

STEAM FLOW TO REHEATER :


1681.12T/HR.
DESIGN CONDENSER PRESSURE :
0.105KSC (abs.)
COOLING WATER FLOW :
64000M3/HR
FINAL FEED WATER TEMP.
:
286.350C
FREQUENCY RANGE :
47.5 51.5 Hz

STEAM TURBINE

Generator rated speed

Generator manufacturer - Electrosila

No. of bleedings

Length of the turbine

No. of stages

HPT

17

IPT

11x2

LPT-1

5x2

LPT-2

5x2

Total

59

3000 rpm

8
36.362

STEAM TURBINE

Parameters
Pr. Before HPC SV
247.0 Ksc
Temp. before HPC SV
537.0 0C
Steam flow 2023.75
TPH
Pr. After HPC48.0
Ksc
Temp. after HPC 298.71 0C
Pr. Before IP SV 43.2
Ksc
Temp. before IP SV 565.0 0C
Steam flow to reheat
1681.12
TPH
Design Cond pr. 0.105 Ksc
CW flow 64000 TPH
Final FW Temp. 286.35 0C

STEAM TURBINE
Turbine

Governing system

Mode

of Governing

Type

E/H

Control

Nozzle

fluid Firequel-L make


Supresta-USA

Normal

Operating Pr. 50 Ksc

Capacity

600 lpm

Fluid

pump motor rating

Filter

material

Mesh

size 25

Ultipor

200 KW

STEAM TURBINE

Lube oil system

Lube oil Tn-22C Russia Mobil DTE Oil light Teresso 32


In accordance with ISO VG 32

Absolute viscosity

16.7

Kinematic viscosity

-32 Centistokes

Specific gravity

Flash point

Fire point 240 0C

Oil requirement per bearing

0.89

180 0C

N1

200 lpm

N2

200 lpm

N3

450 lpm

N4

280 lpm

N5

350 lpm

N6

350 lpm

N7

350 lpm

N8

350 lpm

N9

600 lpm

N10 600 lpm

Centipoise

STEAM TURBINE

Lube oil system

Total oil system capacity

52000

lit

Full volume of oil tank

58000

lit

Material of tank

Normal lube oil pressure

Oil temp at inlet of bearings

SS
1.2

Normal

55

Maximum

59

Piping

Ksc

SS

Seal steam system

Source of gland sealing system

During normal operation

During low load operation

End glands of HPC & IPC


End glands of HPC & IPC + AS

Quantity of seal steam required

3.54 TPH

Seal steam pressure at turbine glands

1.1-1.2

Seal steam temperature at turbine glands

160

Ksc
0

TURBINE SEAL STEAM

TWO

HEADERS OR COLLECTORS ARE


THERE i.e. HOT
COLLECTOR AND COLD COLLECTOR.
INITIAL SOURCE OF STEAM SUPPLY IS
APRDS (UNIT
HT,16KSC,310OC).
PRESSURE AND TEMPERATURE OF COLD
HEADER OR COLLERTOR ARE 1.1TO1.15 KSC
ABSOLUTE AND 140TO 180OC RESPECTIVELY.
PRESSURE AND TEMPERATURE OF HOT
HEADER OR COLLERTOR ARE 1.1TO1.15 KSC
ABSOLUTE AND RESPECTIVELY.

STEAM TURBINE

Turbine

Protection
Over speed trip
110-112 %
Low lube oi pressure
0.3 (g)Ksc
Low vacuum trip
0.3 (abs)Ksc
Thrust bearing excessive wear trip
+1.2/-2.0 mm
Pressure relief diaphragm setting
1.2 (abs) Ksc

STEAM TURBINE

Materials of construction
HP Outer casing
15Cr1Mo1V
HP blade/carrier casings15Cr1Mo1V
IP Outer casing
15Cr1Mo1V
LP inner casing
Steel 3
LP Outer casing
Steel 3
HP Shaft
25Cr1Mo1V
IP Shaft
25Cr1Mo1V
LP Shaft
26CrNi3Mo2V
Moving blades
HPT first stage blades
18Cr11MoNiVNb (1-5)
HPT other stages
15Cr11MoV (6-17)
IPT first stage
18Cr11MoNiVNb (1-3)
IPT other stages
15Cr11MoV (4-11)
LPT last stage
13Cr11Ni2W2MoV
LPT other stages
20Cr13 (1-2)
LPT other stages
15Cr11MoV (3-4)

STEAM TURBINE

HPT first stage

HPT other stages

IPT first stage

IPT other stages

LPT first stage

LPT Other stages

18Cr11MoNiVNb (1-5)
15Cr11MoV (6-17)
18Cr11MoNiVNb
15Cr11MoV
12Cr13 (1-4)
08 Cr13 (5)

Number of stages

Fixed blades

HPT

Impulse stages

Reaction stages

1
16

IPT

Impulse stages

Reaction stages

22
0

LPT

Impulse stages

Reaction stages

20
0

All rows of blades are integrally shrouded

STEAM TURBINE

No. of HP Stop valves 2

No. of HP Control valves 4

Type of control valve unit Block united

No. of IP Stop valves 2

No. of IP Control valves

Type of control valves Separate

No. of Journal bearings for turbine

No. of Journal bearings for Gen

No. of thrust cum journal bearing

Type of thrust bearing Tilting

Type of journal bearing

Material of bearing shell Alloy steel

Type of lining Babbit

LPT diaphrams 4

4
8

4
1

6-Fixed & 2-Tilting pad

STEAM TURBINE

Turbine model No
K-660-247
Generator model No
TBB-660-2T3
Strainers are installed in the steam chests of the stop valves
In HPT, having passed the control stage and 8 stages which
generate left jet of steam (from generator towards front
bearing) steam changes its direction 180 and flows between
internal and external cylinders to 8 stages of right jet (towards
generator)
In CRH lines, NRV has a bypass with electric valve and control
valve to enable counter flow mode of HPT with the aim of
warming up of cylinder and high pressure cross over pipes at
turbine start up and cold condition
HPT has nozzle steam distribution system
IPT has throttle steam distribution system
On each upper half (cover) of low pressure cylinder four
membrane type relief valves are installed which are activated
when the absolute pressure in exhaust nozzles rises up to 1.35
1.4 Ksc absolute

TG SEAL STEAM SYSTEM

HPT SEAL STEAM CONNECTION

TO BLED STEAM TO LPH # 4

1ST CHAMBER

2ND CHAMBER

HPT

TO 2nd CHAMBER EXHAUST

TO HOT SEAL STEAM HEADER

TO GSC

TO BLED STEAM TO D/A

IPT SEAL STEAM CONNECTION

IPT

TO COLD SEAL STEAM HEADER

TO GSC

LPT SEAL STEAM CONNECTION

LPT

FROM COLD SEAL STEAM HEADER

TO GSC

IN HIGH PRESSURE DRAINAGE EXPANSION TANK A VALVES IN DRAINAGE COLLECTORS FROM EXTRACTION
STEAM PIPES TO HPHs (10MAL20AA110, 10MAL20AA120, 10MAL20AA140) AND IN LOW PRESSURE
DRAINAGE EXPANSION TANK VALVES IN DRAINAGE COLLECTORS FROM EXTRACTION STEAM PIPES TO
LPHs(10MAL30AA110, 10MAL30AA120) CLOSE AUTOMATICALLY IF TURBINE LOAD INCREASES OVER 200MW
AND AT THE SAME TIME ALL VALVES ARE OPEN IN THE CORRESPONDING STEAM EXTRACTION FROM THE
TURBINE TO HPHs AND LPHs.

VALVES IN DRAINAGE PIPES OF HPBP AND LPBP (10MAL30AA107, 10MAL30AA108) CLOSE AUTOMATICALLY IF
TURBINE LOAD INCREASES OVER 30MW.

CONTROL FLUID SYSTEM

FIRE RESISTANT SYNTHETIC HYDRAULIC FLUID FYRQUEL L MANUFACTURED BY SUPRESTA IS USED AS


OPERATING FLUID.ITS SELF IGNITION TEMPERATURE IS ABOUT 740OC.

OPERATING PRESSURE IS APPROXIMATELY 50KSC.

OPERATING TEMPERATURE IS 45-55OC.

CONTROL OIL SUPPLY UNIT CNSISTS OF A RESERVOIR (10MAX10BB001)OF CAPACITY 7.0m3 ,2NOS.OIL
COOLERS(10MAX10AC001,10MAX10AC002),DE-AERATOR,MESH FILTER,FINE FILTER(10MAX18AT001),DUPLEX
FILTER(10MAX14AT001) AND 2 NOS. OF VERTICALLY MOUNTED CENTRIFUGAL
PUMPS(10MAX11AP001,10MAX12AP001) DRIVEN BY AC MOTOR (1W+1S).EACH PUMP IS HAVING A CAPACITY
OF 36m3/h AND DISCHARGE PRESSURE IS 50KSC.

CONTROL FLUID RESERVOIR IS SEPERATED BY TWO NUMBERS OF TANDEM MESHES OF CELL SIZE 0.25mm
INTO TWO SECTIONS ,DIRTY AND CLEAN. DE- AERATOR IS INSTALLED INSIDE THE RESERVOIR INFRONT OF
MESHES AND IT CONSISTS OF SLOPING PLATE ASSEMBLY.

CF FINE FILTER FOR REMOVING MECHANICAL IMPURITIES IS INSTALLED IN RESERVOIR. DURING NORMAL
OPERATION CF IS SUPPLIED TO THE FINE FILTER THROUGH AN ORIFICE OF DIAMETER 4mm FROM
UNSTABILIZED PRESSURE LINE VIA VALVE 10MAX18AA501 . AFTER THAT IT IS DISCHARGED IN THE DIRTY
CHAMBER OF THE RESERVOIR. WHEN TURBINE IS STOPPED CF IS SUPPLIED TO THE FINE FILTER WITH THE
HELP OF ANOTHER PUMP (CF TRANSFER PUMP,10MAX19AP001,CAPACITY 4m3/hr, AND DISCHARGE
PRESSURE 25KSC) VIA VALVES 10MAX19AA503 AND10MAX19AA504 FOR FILTERING PURPOSE KEEPING MAIN
PUMPS IN OFF CONDITION.

OIL PURIFICATION IS CONTINUOUS DUE TO FILTERING OF ITS PART VIA CONCURRENTLY MOUNTED WORKING
FILTER CARTRIDGES INSTALLED INSIDE THE FINE FILTER HOUSING.

FILTER CARTRIDGES DESIGN ALLOWS USAGE OF DIFFERENT FILTERING MATERIAL.

METAL SEMI-PINCEBECK MESH WITH FILTERING DEGREE OF 70 MICRONS TO FLUSH SYSTEM


AFTER INSTALLATION OR MAINTENANCE.

FILTER BELTING FABRIC WITH FILTERING DEGREE 30 40 MICRONS FOR PRIMARY REFINING
DURING TURBINE OPERATION.

FILTERING ELEMENTS MANUFACTURED BY PALL WITH FILTERING DEGREE 12 MICRONS FOR


CONTINUOUS OIL FILTERING DURING TURBINE OPERATION.

OCCURRENCE OF PRESSURE OF 0.1 TO 0.3KSC IN FILTER HOUSING WITHIN 1-3 HOURS SHOWS CORRECT
ASSEMBLY OF FILTER AND ITS PROPER OPERATION.

IT IS NECESSARY TO SWITCH OFF THE FINE FILTER AND REPLACE FILTERING ELEMENTS IF PRESSURE IN FILTER
HOUSING RISES UPTO 2KSC.WHICH SHOWS CONTAMINATION OF FILTER FABRIC.

INSIDE FILTER HOUSING THERE IS A RELIEF VALVE BYPASSING FLUID BESIDES FILTER CARTRIDGES WHEN
THEY ARE CONTAMINATED AND PRESSURE RISES UPTO 5KSC.

AN OIL LEVEL GAUGE WITH ALARM SYSTEM WHISKERS (10MAX10CL001,10MAX 10CL002) IS PROVIDED IN
THE CLEAN SIDE OF THE RESERVOIR.

NORMAL OPERATING LEVEL IS 700mm FROM THE UPPER COVER (30 GRADUATION OF L.G.) AND THE
AMOUNT OF CF IS 2.5m3

MAXIMUM ALLOWALABLE UPPER LIMIT (WITH CF PUMPS IN STOPPED CONDITION) IS 150mm FROM THE
UPPER COVER (85 GRADUATION OF L.G.) AND MINIMUM OPERATING LEVEL IS 800mm (20 GRADUATON OF
L.G.) FROM THE UPPER COVER.

CF PUMP STOPS AUTOMATICALLY INCASE OF RESERVOIR OIL LEVEL LOW-LOW.

FOR VISUAL OVSERVATION OF OIL LEVEL ,LEVELGLASSES HAVE BEEN PROVIDED IN THE BOTH SIDES (DIRTY
AS WELL AS CLEAN).

DIFFERENTIAL PRESSURE SWITCH (10MAX10CP001) HAS BEEN PROVIDED TO WARN ABOUT INCREASE IN
PRESSURE DIFFERENCE IN SIDE THE MESH FILTER. ALLOWABLE DIFFERENCE IN MESHES DOESNOT EXCEED
150mm.

THE STANDBY CF PUMP STARTS WHEN THE RUNNING ONE TRIPS OR SYSTEM PRESSURE DROPS TO 36KSC.

IT TAKES 2 MINS FOR THE SYSTEM TO GET PRESSURIZED.

IF SYSTEM PRESSURE DROPS TO 20KSC (10MAX14CP001) AND STOP VALVES START CLOSING ,THE
OPEARTING PUMP WILL STOP AND NO SIGNAL WILL BE GENERATED TO START THE STAND BY PUMP (SENSING
OIL LEAKAGE).

CF PUMP ALSO TRIPS ON FIRE PROTECTION.

DUPLEX FULL PASSAGE FILTER WITH FILTERING DEGREE 20-25MICRONS IS INSTALLED IN GENERAL
PRESSURE COLLECTOR OF CONTROL SYSTEM.IF PRESSURE DIFFERENCE (10MAX14CP301,10MAX15CP301)
ACROSS THE RUNNING FILTER REACHES 0.8KSC,THE STANDBY FILTER HAS TO BE TAKEN INTO SERVICE.

2 NOS.OF CF COOLERS (A&B) ARE INSTALLED IN THE CF SUPPLY LINE BEHIND THE DUPLEX FILTER. THESE
COOLERS ARE DOUBLE PASS (BY WATER) SURFACE HEAT EXCHANGERS WITH TUBULAR DESIGN ,WATER
STREAM FLOWS INSIDE THE TUBES AND CONSIST OF 148 TUBES OF SIZE 16X1500mm AND HEAT
EXCHANGE AREA 25m2.CF FLOWS FROM TO DOWNARD.

COOLERS ARE DESIGNED FOR A MAXIMUM COOLING WATER PRESSURE OF 10 0.5KSC AND CF PRESSURE
OF 68.7 0.5KSC.CF FLOW RATE TO EACH COOLER IS 50m3/hr AND PRESSURE DROP IS 0.2KSC. CW FLOW
RATE TO EACH COOLER IS 80m3/hr AND PRESSURE DROP IS 0.194KSC.

FOR HYDRODYNAMIC FLUSHING OF PIPELINES DURING MAINTENANCE,THERE IS A BYPASS VALVE


(10MAX14AA501)TO THE COOLERS WHICH SHOULD BE CLOSED AND SEALED DURING ROUTINE OPERATION.

IN THE INPUT AND OUTPUT TO THE COOLERS CF LINE IS PROVIDED WITH TRIPLE-PASS SWITCHING OVER
VALVES WHICH PREVENT FALSE ACTIVATION OF BOTH COOLERS.

CF TEMPERATURE IS MAINTAINED (48-52OC)BY COOLING WATER FLOW VARIATION WITH THE HELP OF A
FLOW CONTROL STATION CONSISTING OF A PNEUMATIC CONTROL VALVE (10PGM20AA001) AND A BYPASS
MOTORIZED CONTROL VALVE(10PGM20AA002).IN CASE TEMPERATURE RISES TO 55OC
(10MAX14CT001,10MAX14CT002),MOTORIZED BYPASS VALVE OPENS TO MAINTAIN THE CF TEMPERATURE.
THE MAXIMUM LIMIT OF CW TEMPERATURE AT COOLER INLET IS 37OC.IF CW TEMPERATURE IS BELOW 36OC
ONE COOLER CAN BE PUT OUT OF OPERATION.

CF SUPPLY TO CONTROL UNITS IS CARRIED OUT BY TWO PRESSURE COLLECTORS OF STABILIZED AND
UNSTABILIZED PRESSURE.

CF IS SUPPLIED TO UNSTABILIZED PRESSURE COLLECTOR THROUGH AN ORIFICE OF SIZE 22mm. STOP AND
CONTROL VALVE ACTUATORS ARE FED FROM THIS COLLECTOR.

INTO STABILIZED PRESSURE COLLECTOR WHICH FEEDS OIL TO ALL CONTROL DEVICES,CF IS SUPPLIED FROM
THE SECTION BETWEEN PUMPS AND THE ORIFICE.

DUE TO THE ARRANGEMENT MENTIONED ABOVE ,THE PRESSURE VARIATION IN UNSTABILIZED PRESSURE
COLLEECTOR CAUSED BY INCREASE IN CF CONSUMPTION WITH OPEN ACTUATORS AFFECTS IN A LESS
DEGREE PRESSURE VARIATION IN STABILIZED PRESSURE COLLECTOR.

SPRING-WEIGHT ACCUMULATOR (10MAX20BB001) IS CONNECTED TO UNSTABILIZED PRESSURE COLLECTOR


TO PREVENT DECREASE IN FORWARD PRESSURE IN CASE OF LOSS AC SUPPLY TO THE PUMPS FOR 5-7SECS
OR DURING PUMP CHANGE-OVER.

THE SETTING OF FLUID PRESSURE LEVEL (45KSC) TO BE ENSURED BY THE ACCUMULATOR IS DETERMINED
BY A WEIGHT WHICH IS CONCRETE FILLED IN THE SITE.

ONE NRV IS INSTALLED IN THE LINE CONNECTING THE ACCUMULATOR TO THE UNSTABILIZED PRESSURE
COLLECTOR. ACCUMULATOR IS FILLED WITH THE CF THROUGH AN ORIFICE OF SIZE 5mm INSTALLED IN THE
BYPASS LINE OF THE NRV.

TWO EXHAUST FANS (1W+1S) ,10MAX21AN001,10MAX21AN002 (CAPACITY OF 3200m3/hr AT A HEAD OF 520mm OF WATER COLUMN) ARE ALSO INSTALLED TO REMOVE CF VAPOUR FROM CF RESERVOIR AND
SYSTEM.

THE EXHAUSTER SWITCHES ON AUTOMATICALLY WHEN CF PUMP STARTS AND SWITCHES OFF AUTOMATICALLY
WITH 15mins TIME DELAY AFTER THE STOPPING OF CF PUMP AND CF SYSTEM PRESSURE DROPS BELOW
2.0KSC.

HYDRAULIC TEST OF PIPE LINES CARRIED OUT AT A PRESSURE OF 90KSC.HYDRAULIC TEST SHOULD BE
CARRIED OUT AFTER ASSEMBLING,OVERHAUL AND INSPECTION.

CONTROL FLUID SYSTEM

CONTROL FLUID SYSTEM

Isolation valves on pump suction & discharge side

Pump discharge pressure

Capacity

Stabilized pressure header supply oil to servo motors of SV & CV

Un stabilized pressure header with 22 mm orifice

Accumulator in unstabilized pressure header

CF tank capacity

Duplex filter

Control fluid transfer pump to empty the CF tank

CF Temperature control by control station in the ECW line

50 Ksc

41 TPH

6.9 m3

COMPONENT OF GOVERNING SYSTEM

1.

ELECTRO-HYDRAULIC CONVERTER SUMMER 8 NOS.

2.

SUMMER 8NOS.

3.

ELECTRO-MECHANICAL CONVERTER 8NOS.

4.

GOVERNING BLOCK

1.

CONTROLGEAR(AE001) 1NO.

2.

EMERGENCY GOVERNOR OR OVERSPEED GOVERNOR 1NO.

3.

TRIP SOLENOID (AA213,AA214)-2NOS.

4.

TEST ELECTROMAGNETS(AA211,AA212) 2NOS.

5.

ROTATIONAL SPEED DETECTOR -3 NOS.

6.

LIMITER OF PRESSURE (AA502) 1NO.

7.

SPEED TRANSDUCER 1NO.

8.

LEVER OF OVER SPEED GOVERNOR (AX201) 1NO.

9.

PILOT VALVE FOR SUPPLY (AX202) 1NO.

5.

ACCUMULATOR 1NO.

6.

OIL SUPPLY AND PURIFIER UNIT

7.

SERVOMOTOR OF HPSV 2NOS.

8.

SERVOMOTOR OF HPCV 4NOS.

9.

SERVOMOTOR OF IPSV 2NOS.

10.

SERVOMOTOR OF IPCV 4NOS.

11.

SERVOMOTOR OF CRH NRV 2NOS.

12.

LOCKING PILOT VALVE (AA001,AA002,AB001,AB002)- 4NOS.

13.

EX.STOP VALVE SERVOMOTOR OR ESV (10LBQ10AA101) 1NO.

DIFFERENT TYPES OF OIL


1.

HEAD PRESSURE LINE (STABILIZED,50KSC,10MAX15)

2.

HEAD PRESSURE LINE ( NON-STABILIZED,50KSC,10MAX15)

3.

LINE OF PROTECTION (50KSC,10MAX51)

4.

LINE TO COCK THE OVERSPEED GOVERNOR SLIDE VALVE (50KSC)

5.

CONTROL OIL LINE TO STOP VALVE SERVOMOTORS (50KSC,10MAX16)

6.

CONTROL LNE TO SUMMATORS (35KSC,10MAX17)

TURBINE PROTRCTIONS

1.

OUT OF TOLERANCE ROTOR OVERSPEED : ALARM AT 3300RPM AND TRIPPING AT 3360RPM

2.

OUT OF TOLERANCE AXIAL DISPLACEMENT OF ROTOR:

TOWARDS FRONT BEARING BY 0.6mm (-0.6mm) -ALARM.

TOWARDS FRONT BEARING BY 1.2mm (-1.2mm) - TRIPPING.

TOWARDS GENERATOR BY 1.4mm (+1.4mm)A- ALARM.

TOWARDS GENERATOR BY 2.0mm (+2.0mm) - TRIPPING.

3.

LUBRICATING OIL PRESSURE DROP: ALARM AT 0.70KSC AND TRIPPING AT 0.30KSC WITH 3SECS TIME
DELAY.

4.

PRESSURE RISE IN CONDENSER:ALARM AT 0.15KSC abs. AND TRIPPING AT 0.20KSC abs. PROTECTION
IS INTRODUCED AUTOMETICALLY AT UNIT START-UP AFTER PRESSURE DROP IN CONDENSER LOWER THAN
0.15KSC abs. OR AT TURBINE SPEED INCREASE OVER 1500RPM. PROTECTION IS IN OPERATION UNTIL
STOP VALVES ARE OPEN

5.

INCREASE OF BEARING VIBRATION: ALARM SOUNDS AT INCREASE OF VERTICAL OR TRANSVERSE OR


AXIAL COMPONENT OF VIBRATION ON ANY BEARING OF TG SET REACHES 4.5mm/s .TRIPPING OCCURS
WITH 2 SECS TIME DELAY AT INCREASE OF VERTICAL OR TRANSVERSE COMPONENT OF VIBRATION OVER
11.2mm/s ON ANY TWO BEARINGS OF TG SET.

6.

RISE IN STEAM TEMPERATURE AT HPT OUTLET:

7.

LIVE STEAM TEMPERATURE BEFORE TURBINE FALLS BELOW 470 OC:

8.

LIVE STEAM TEMPERATURE BEFORE TURBINE RISES ABOVE 565 OC:

9.

STEAM TEMPERATURE BEFORE IV FALLS BELOW 500 OC:

10.

STEAM TEMPERATURE BEFORE IV RISES ABOVE 593 OC:

11.

MOT LEVEL LOW-LOW:

12.

DRIP LEVEL HIGH-HIGH IN ANY HPH:

13.

ANY FAILURE IN TURBNE CONTROL SYSTEM ELECTRONICS:

14.

GENETERATOR PROTECTION:

15.

FIRE PROTECTION OPERATED:

16.

EPB PRESED.

TURBINE LUBE OILSYSTEM

LUBRICATION OIL SYSTEM IS DESIGNED TO SUPPLY OIL TO TURBINE AND GENERATOR BEARINGS IN ALL
TURBINE PLANT OPERATION MODES AND ALSO TO PROVIDE ROTOR JACKING OIL SYSTEM AND GENERATOR
SEAL OIL SYSTEM WITH OIL.

LUBRICATION OIL IS ISO VG 32 TYPE WITH FOLLOWING PROPERTIES:

ABSOLUTE VISCOCITY

16.7CENTIPOISE

KINEMATIC VISCOSITY

32CENTISTOKE

SPECIFIC GRAVITY

0.89

SPECIFIC HEAT

0.459Kcal/Kg Deg.C

FLASH POINT

180OC

FIRE POINT

DEGREE OF CLEANLINESS

PERMISSIBLE SUSPENDED PARTICLE SIZE

WATER CONTENT

<10PPM

240OC
:

16/13 ISO 4406


25 MICRON

LUBE OILTANK IS MADE OF STAINLESS STEEL AND HAVING A CAPACITY OF 58m3 . PROVISION IS MADE FOR
OIL TREATMENT INSIDE THE TANK BY PROVIDING TWO ROWS OF FLAT GRIDS WITH MESH DIMENSIONS
0.25mm LOCATED INSIDE THE TANK WHICH DIVIDES THE TANK INTO DIRTY AND CEAN COMPARTMENTS. THE
AIR SEPARATOR CONSISTING OF TILTED METAL PLATES SET IS INSTALLED TO SEPARATE THE AIR DISSOLVED IN
OIL.

THE OIL TANK HAS ATTACHMENTS FOR OIL DRAINING TO OIL TREATMENT PLANT FOR SLUDGE DRAIN AND TO
EMERGENCY TANK INCASE OF FIRE.

NORMAL OPERATING LEVEL IS 600mm FROM TANK TOP COVER.ALARM IS AT 500mm AND TURBINE TRIP IS
THERE AT 400mm.

4 NOS OF LUBE OIL PUMPS (SINGLE STAGE CENTRIFUGAL) ARE INSTALLED VERTICALLY ABOVE THE TANK .2
PUMPS (AUXILLIARY OIL PUMP) ARE ac MOTOR DRIVEN AND 2 PUMPS ARE dc (EMERGENCY OIL PUMP) MOTOR
DRIVEN.

ONE PUMP WITH ac MOTOR IS CONTINUOUS RUNNING AND OTHER IS KEPT STANDBY.

EACH ac PUMP IS HAVING A DISCHARGE CAPACITY OF 300m3/hr A DISCHARGE PRESSURE OF 4.3KSC.

EOP WLL START IN CASE OF LOSS OF AC.EACH EOP IS HAVING A DISCHARGE CAPACITY OF 250m3/hr AND A
DISCHARGE PRESSURE OF 2 KSC.FOR HIGHIER RELIABILITY EOP DELIVERS OIL DIRECTLY TO THE BEARING
BYPASSING COOLER AND THROTTLE VALVE.

TG LUBE OIL SUPPLY SYSTEM

TG LUBE OIL SYSTEM

TG LUBE OIL SYSTEM

Turbine oil is ISO VG 32

KV

20-23 CST at 500C

Acidity Number< 0.05 mg KOH/r

Viscosity index > 90

Bearings

HPT Front

N1

HPT Rear

N2

IPT Front (TB)

N3

IPT Rear

N4

LPT-1 Front

N5

LPT-1 Rear

N6

LPT-2 Front

N7

LPT-2 Rear

N8

Generator Front

N9

Generator Rear

Exciter Front

N11

Exciter Rear

N12

N10

TG LUBE OIL SYSTEM

DC Lube oil pump 1 No.


Equipment

Capacity (m3/hr)

Head (Ksc)

AC Lube oil pump

300

4.3

DC Lube oil pump

250

2.0

NRV & Isolation valve in each Lube oil pump


discharge line

Oil first goes to duplex filter instead of cooler

Coolers Bypass line with isolating valve

Hydraulic Pressure control valve maintains the


pressure at the center shaft level at 1.2 Ksc

PCV Bypass with throttling orifice which provides


lubrication even at fully closed control valve

TG LUBE OIL SYSTEM

Oil is first delivered to bearing brasses through emergency


tanks located on bearing cap

Emergency tanks capacity in m3

N1

0.43

N2

0.35

N3

0.75

N4

0.44

N5

0.44

N6

0.44

N7

0.44

N8

0.44

N9

0.5

N10

0.44

N11

0.1

N12

0.1

TG LUBE OIL SYSTEM

Lube oil temperature control by control station in the ECW


inlet line to Lube oil coolers

View glasses in the oil return line from each bearing

MOT Capacity

Duplex filters fineness

Provision is made for oil cleaning by delivering a portion of


oil from the oil pressure pipe to the oil tank through the fine
cleaning filter with fineness of 12-15 m

Fresh oil is filled through the above filter only

Oil recirculation pump to purify the oil

Electrical oil heater of 152 KW capacity is provided for the


preliminary oil warming in the lubrication oil tank before
turbine start up by running the oil recirculation pump

Oil draining to Emergency lube oil tank in case of emergency


with MOV

58 m3
25 m

TG LUBE OIL SYSTEM

Oil trap at the suction of the vapor extractor fans

Oil trap drain to lubrication oil tank

Jacking oil pumps suction also given from lube oil discharge header after
coolers & before control valve

TG JACKING OIL AND BARRING GEAR SYSTEM

Barring gear & Jacking oil system

Automatic barring gear engagement at the rotor stop


and barring gear disengaging at the start-up

High pressure oil supply for bearing inserts oil jacking

Barring speed 1.05 rpm

Motorized barring gear

Torque transfer from the barring gear motor to the


turbine shaft is carried out via three stage reducer and
free wheel clutch

Reduction gear first stage shaft end mounts special


handle for hand barring

Normal source for jacking oil pumps suction is from


lube oil pumps discharge header after coolers

JOP discharge pressure: 120 Ksc

Barring Gear & Jacking oil system

Dozing devices at each bearing of the Turbine & Generator


which contain strainer, NRV, orifice & isolation valve

Bearing jacking oil is supplied via separate lines for oil jacking of
inserts of bearing no: 4-9

Stand-by bearing insert oil jacking pump is not provided


as the system is designed to realize auxiliary functions
at turbine start-up. If this pump does not start when it is
required then also the turbine can be operated normally
without any bearing damage and disturbance of turbine
operation

Each bearing insert jacking oil line is equipped with


orifice only

Both pumps cut in/cut out is 1500/1500

Barring gear cut in/cut out is 1500/1500

Barring Gear & Jacking oil system

Bearing Insert Oil Jacking Pump is started automatically, if the rotor

neck displacement becomes more than 0.1 mm relative to the


insert of any of bearings No. 4,9 provided that the oil pressure to
rotor jacking is higher than 45 kg/cm2 or the turbine rotor
rotational speed is higher than 1500 rpm

Pump is stopped automatically, with time delay of 30 seconds, if the rotor


neck displacement is less than 0.1 mm relative to the insert of bearings No.
4-9

GENERATOR SEAL OIL SYSTEM

GENERATOR SEAL OIL SYSTEM

Seal oil pumps suction from MOT

No Hydrogen side seal oil pump

Pumps re-circulation line directly to MOT

Coolers bypass valve

Magnetic filters 2 No. (1W+1SB)

NRV in the seal oil line after filters

DPR

DPR bypass manual control valve

GENERATOR SEAL OIL SYSTEM

Damper tanks 2 No.: 1 for TE & 2 for EE, designed for oil supply
to front and back generator shaft seals with drop, specified by
the height of damper tank installation, and also to seal at shorttime interruption in oil supply, at the moment of automatic
transfer from working pump to standby and at generator
runback with generator shaft seal pumps switched of

View glasses in return oil lines

Float hydraulic seal functions as SOT

Hydraulic seal overflows in to return oil header

No SOST

Provision of trap upstream of fans

Fans suction is from return oil header

GENERATOR STATOR WATER COOLING SYSTEM

STATOR WATER COOLING SYSTEM

Water tank not on the generator

Ejector to make vacuum over the water tank to prevent air


ingress

Ejector cooling by auxiliary cooling water

Air venting of Generator through Gas trap connected from


winding inlet and outlet headers

Gas trap to determine hydrogen present which will be


extracted from trap cap to gas analyzer

Coolers bypass valve

Ion exchanger-1 contains anion & cat ion in H-OH form to


maintain conductivity

Ion exchanger-2 contains anion & cat ion in Na-OH form to


maintain Ph if it decreases below 8

Ion exchanger-1 first will be put in to service for reducing


dissolved oxygen below 5.0 s/cm and then it will be put out
of service. Then Ion exchanger-2 will be put in to service to
increase the Ph value. If conductivity increases above 12.5
s/cm, Ion exchanger-2 to be stopped

STATOR WATER COOLING SYSTEM

Control valves at the inlet of individual Ion exchanger


circuits
DM water flow through ion exchanger is 1.5 to 2.0 m
No NAOH dozing system
Ion exchangers separate bypass lines
Mechanical filter at the inlet of Ion exchanger circuit
Dissolved oxygen analyzer & Ph analyzer
Winding inlet valve for flow adjustment
Winding outlet valve for pressure adjustment
Normal make up from DM make up line & emergency make
up line from CST
Filter in the common make up line
Control station in the common make up line

GENERATOR GAS SUPPLY SYSTEM

GENERATOR GAS SUPPLY SYSTEM

Two Hydrogen manifolds to connect 16 cylinders each


Direct acting Pressure regulator installed on cylinder connecting line to
Manifold header to reduce the Hydrogen pressure from 175 Ksc to 10 Ksc
Total Pressure regulators
32
Safety valve on each manifold header which operates when the Hydrogen
pressure in the manifold exceeds 10.5 Ksc
MOV & NRV in each manifold header
Three CO2 manifolds to connect 17 cylinders each
Each manifold header contains MOV, NRV & Isolation valve
MOV with manual bypass valve at the inlet of CO 2 heater
CO2 heater is steam heated
Steam source is from auxiliary steam system
Steam parameters: 15 Ksc & 210 0C
MOV in the steam inlet line
Steam exhaust will go to FWSV Dish flash tank
Manifold header pressure is 175-20 Ksc
Control station with Pressure regulator provided D/S of heater to maintain a
pressure of 2.0-2.2 Ksc with manual bypass valve
SV installed D/S of pressure regulator operates if the pr > 5.0 Ksc
Capacity of one cylinder 50 lit

GENERATOR GAS SUPPLY SYSTEM

One Hydrogen manifold is in operation under normal


operating conditions

If the pr decreases below < 10 Ksc, an alarm will come and


operator connects the standby manifold and disconnects the
first manifold

Two CO2 manifolds are in operation under normal operating


conditions

If the pr decreases below < 20 Ksc, an alarm will come and


operator connects the standby manifold and disconnects the
first manifold

Provision is given for emergency removal of hydrogen from


generator itself by providing a line with one manual isolating
valve & 2 No. MOV

FLASH TANKS

DRAINS FROM THE TURBINE AND STEAM LINES


ARE REMOVED TO TWO HP DRAIN FLASH TANKS A (10MAL10BB001) AND B (10MAL20BB001) AND
ONE LP DRAIN FLASH TANK (10MAL30BB001)

BOTH THE HP FLASH TANKS ARE HAVING A


CAPACITY OF 2.6m3. LP DRAIN FLASH TANK IS
ALSO HAVING A CAPACITY OF 2.6m3.

CONDENSER

Design LMZ

Design CW Flow

Vacuum

64000 m3/hr

77 mm Hg (abs) at 33 0C

89 mm Hg (abs) at 36 0C

No. of passes 1

Total no. of tubes 22.225 (OD)x0.71 (t) 29920


22.225 (OD)x1.00 (t) - 2080

Tube material ASTM A-249 TP 304

Rated TTD 3.40C

DT of CW

100C

CONDENSATE EXTRACTION PUMP

Design flow rate

238.75 Kg/s

Discharge pressure

Shut of head

395

Pump speed

1480

rpm

Power input 972.3 KW

No. of stages

Type of first stage impeller double


entry

Depth 7.43

32.15 Ksc

DE-AERATOR

Design

Pressure 13 Ksc
No. of trays
896
Spray valves
132
Design temp for D/A 395 0C
Design temp for FST
250
0C

DRIP PUMP

Design flow rate

Discharge pressure

Shut of head

306.7 m

Pump speed

1486

Power input

310.1 KW

No. of stages

Type of first stage impeller

Depth

1090

324.509 TPH
43

mm

ata
rpm

centrifugal, single entry

MDBFP

Pump flow

769.950 TPH

Suction temp

186.2

BP Suction pr.

BFP Suction pr.

BFP Discharge pr. 335.78 ata

BFP Discharge temp. 187.9

BP Discharge pr. 22.01

ata

Shut of head

4830

BFP Speed

6275

rpm

BP Speed

Normal R/C flow 220 TPH

HC Rated O/P Speed 6505

Outer casing typebarrel

No. of stages

BFP warm up flow15 TPH

14.05
21.01

1490

ata

ata
C

rpm

rpm

TDBFP

Pump flow

1283.14 TPH

Suction temp

186.2

0C

BP Suction pr.

14.10

ata

BFP Suction pr.

28.24

ata

BFP Discharge pr. 335.83 ata

BFP Discharge temp.

BP Discharge pr.

29.06

ata

Shut of head

4580

BFP Speed

4678

rpm

BP Speed

Normal R/C flow

HC Rated O/P Speed

Outer casing type barrel

No. of stages

BFP warm up flow 20 TPH

2098

187.8

0C

rpm

365 TPH
6505

rpm

TDBFP GOVERNING SYSTEM

GOVERNING SYSTEM

PARTS OF GOVERNING SYSTEM


Hydraulic Accumulator (HA)
Remote switch (RS)
Lubrication system pressure relay (LSPR)
Trip Gear (TG)
Stop valve (SV)
Governor valve 1 (GV1)
Governor valve 2 (GV2)
Cut of pilot valve (COPV)
Electro mechanical converter (EMC)
Electro mechanical converter position transducer (ECPT)
Electronic control part (ECP)
Servo motor (S)
Governor valves position transducer (GVPT)

TDBFP TURBINE

Number of stages

Casing

Steam admission

Steam pressure at inlet

Steam temperature at inlet

469

Turbine operating speed

4678

rpm

Steam consumption

Steam pressure at exhaust 0.128 ata

Turning gear speed

Type of governing system

Over speed type trip

JOP

Lube oil tank capacity

Lube oil

Split
Dual
20.82 ata

61.4

TPH

15 rpm
Electro-Hydraulic
Centrifugal + electrical

Not required
10.97 m3

Same as main turbine

TDBFP CONDENSER

CW flow

3000

TPH

Vacuum in the condenser

Total no. of tubes

Tube OD and thickness

No. of water passes

Tube material

0.128

Ksc (abs)

3312
22.225x1.06
2
ASTM A-249 TP321

mm

TDBFP LUBE OIL SYSTEM

TDBFP EXTRACTION SYSTEM

TDBFP CONDENSATE SYSTEM

ACW SYSTEM

ACW SYSTEM

Suction header is from all the 4 CW inlet


lines to condensers
MOV at Suction header from CW line
MOV at SCS inlet
MOV at PHE inlet & outlet
Supply to
Ejector of Stator water cooling system
TDBFP vacuum pumps (4 No.)
Main turbine vacuum pumps (1 No. extra)
MOV at return header to CW line

TURBINE VACUUM SYSTEM

TURBINE HEATING FLANGES SYSTEM

AUXILIARY STEAM SYSTEM

CONDENSATE SUPPLY SYSTEM TO EXT NRVS

EXHAUST HOOD SPRAY

FEED WATER SYSTEM

TDBFP-A FEED WATER SYSTEM

MDBFP FEED WATER SYSTEM

LP DOZING & OXY TREATMENT SYSTEM

HP BYPASS SYSTEM

LP BYPASS SYSTEM