INTRODUCTION

Types and Working Principles- Steam Turbines

1.0 Introduction
Steam turbine is a rotating machine which converts heat energy of Steam to mechanical
energy.
In India, steam turbines of diferent capacities, varying from 15 MW to 500 MW, are
employed in the feld of thermal power generation. The design, material, auxiliary systems
etc. vary widely from each other depending on the capacity and manufacturer of the sets.
Therefore the discussions in the chapters will follow the general patterns applicable to almost
all types of turbines.
1.1 Development of Steam Turbine
Historically, frst steam turbine was produced by Hero, a Greek Philosopher, in 120 B.C. (Fig
1.1). In 1629, an Italian named Branc actually anticipated the boiler-steam turbine
combination that is a major source of power today First practical steam turbine was
introduced by Charles Parsons in 1884 which was also of the reaction type. Just after fve
years, in 1889, Gustav De Laval produced the frst practical impulse turbine.
Fig. 1.1 Heros Turbine Fig.1.2 Brancas Turbine
Active development of steam turbine made it the principal prime mover of generating stations
by 1920. Most units used 14 kg/cm
2
and 276
o
Celsius, steam and capacity ranged from 5,000
to 30,000 KW. By 1930 steam conditions improved to 48 kg/cm
2
and 398
o
c and 1940 steam
condition of 81 kg/cm
2
and 509
0
Celsius was achieved.
After second world war (1945), reheat cycle was adopted widely and capacity increased
gradually. While turbine of 900 MW is in use in USSR, in India the largest capacity is 500
MW with steam condition of 179 kg/cm
2
and 540
0
Celsius.
1.2 Working Principles
When steam is allowed to expand through a narrow orifce, it assumes kinetic energy at the
expense of its enthalpy (Heat energy). This kinetic energy of steam is changed to
mechanical (rotational) energy through the impact (impulse) or reaction of steam against the
blades.
It should be realised that the blade of the turbine obtains no motive force from the static
pressure of the steam or from any impact of the steam jet. The blades are designed in such
a way, that steam will glide on and of the blade without any tendency or strike it. As the
steam moves over the blades, its direction is continuously changing and centrifugal pressure
exerted as the result is normal to the blade surface at all points. The total motive force acting
on the blade is thus the resultant of all the centrifugal force plus the change of momentum.
This cause the rotational motion of the blade
1.3 Turbine Types
Basically there are two broad classifcations of steam turbines :
i) Impulse : In impulse turbine , the steam is expanded, i.e. pressure is reduced in fxed
nozzles. The high velocity steam issuing from the nozzles does work on the moving blades
which causes the shaft to rotate, The essential feature of an impulse turbine is that all the
pressure drops occur in the nozzles only, and there is no pressure drop over the moving
blades.
(ii) Impulse-reaction : In this type, pressure is reduced in both fxed and moving blades.
Both fxed and moving blades act like nozzles and are of same shape. Work is done by the
impulse afect due to the reversal of direction of the high velocity steam plus a reaction efect
due to the expansion of steam through the moving blades. This turbine is commonly called a
reaction turbine.
Fig. 1.5 Steam fow through a reaction turbine
1.4 Compounding
Several problems crop up if the energy of steam is converted in one step, i.e. in a single row
of nozzle-blade combination. With all heat drop taking place in one row of nozzles (or single
row of nozzles and blades in case of reaction turbine) the steam velocity becomes very high
and even supersonic (velocity of steam is proportional to square root of heat drop in nozzle;
V = 44.8 K(H
1
- H
2
) m/sec,. where K = constant, H
1
Enthalpy at nozzle inlet; H
2
Enthalpy at
nozzle outlet. The rotational speed of the turbine also becomes very high and impracticable.
So, in order to convert the energy of steam within practical speed range, it is necessary to
convert it in several steams and thus reducing the velocity of steam and rotor speed to
practical levels. This is termed compounding.
Following are the various types of compounding.
1.4.1Velocity Compounded Impulse Turbine
Like simple impulse turbine this has also only one set of nozzle and entire steam pressure
drop takes place there. The kinetic energy of high velocity steam issuing from nozzles is
utilized in a number of moving row of blades with fxed blades in between them (instead of a
single row of moving blades in simple impulse turbine). The role of the fxed guide blades is
just to change the direction of steam jet and guide it to next row of moving blades. This type
of turbine is also called Curtis turbine.
1.4.2.Pressure Compounded Impulse Turbine
This is basically a number of simple impulse turbines in series on the same shaft - the
exhaust of one steam turbine entering the nozzle of the next turbine. The total pressure drop
of the steam does not take place in the frst nozzle ring, but is divided equally between all of
them. Steam is passed through the frst nozzle ring in which it is only partially expanded. It
then passes over the frst moving blades where most of its velocity is absorbed. From this
ring it exhausts into the next nozzle ring and is again partially expanded. The velocity
obtained from the second nozzle ring is absorbed by the next wheel moving blades. This
process is repeated in the remaining rings until the whole of the pressure has been
absorbed. This type of turbine is also called Rateau turbine after its inventor.
1.4.3Pressure-Velocity Compounded Impulse Turbine
Pressure-Velocity Compounding is a combination of both the previous methods and has the
advantage of allowing a bigger pressure drop in each stage and so less stages are
necessary. Hence, for a given pressure drop the turbine will be shorter. But the diameter of
the turbine is increased at each stage to allow for the drop the turbine will be shorter. But the
diameter of the turbine is increased at each stage to allow for the increasing volume of
steam. This type was once very popular. But it is rarely, used a efciency is quite low.
1.4.4Multistage Reaction Turbine
A multistage reaction turbine consisting of a number of rows of moving blades attached to
the rotor and an equal number of rows of fxed blades attached to the casing. Each stage
utilise a portion of energy of steam. Theoretically this may be called pressure compounded
turbine as the pressure of steam drops gradually over the succeeding stages.
The fxed blades compare to the nozzle used in the impulse turbine. Steam is admitted over
the whole circumference, and in passing through the frst row of fxed blades, undergoes a
small drop in pressure and its velocity is increased. It then enters the frst row of moving
blades and, as in the impulse turbine, sufers a change in direction and hence momentum
giving an impulse on the blades. During the steam passage through the moving blades, it
undergoes a further small drop in pressure resulting in an increase in velocity which gives
rise to a reaction in the direction opposite to that of the added velocity. It is in this that the
impulse-reaction turbine difers from the pure impulse turbine. Thus the gross propelling
force in the impulse-reaction turbine, (or the reaction turbine as it is commonly called), is
the vector sum of the impulse and the reaction forces.
The blade heights increase as the specifc volume of the steam increases with reduction in
pressure, Note, how the pressure falls gradually as the steam passes through the groups of
blades. There is a pressure drop across each row of blades both fxed and moving. This is of
considerable practical importance, especially at the high pressure end of the turbine where
the pressure drops are greatest. Because this diference of pressure tends to force some
steam through the clearance spaces between the moving blades and the casing and
between the fxed blades and the rotor. These clearances have to be carefully controlled by
using axial and / or radial seals at the blade tips, otherwise the leakage would be so large
that the turbine would be inefcient. The pressure drop across the moving blades gives rise
to a large axial thrust on the rotor, towards the low pressure end of the turbine, and special
balance pistons/thrust bearings have to be ftted to counteract it. The dummy (balance)
piston diameter is so calculated that the steam pressure acting upon it in the opposite
direction to the steam fow, balance out the force on the rotor blades in the direction of steam
fow./ Preferably the dimensions are so arranged to keep a small thrust towards the inlet end
of the turbine. To maintain this condition at all loads in some designs, a balance pipe is
usually connected from the casing, on the outer side of the balance piston, to some tap of
point down the cylinder. This pipe maintains the steam pressure on the out board side of the
dummy piston to correspond with pressure at the state down the turbine cylinder to which the
balance pipe is connected. Under steady load conditions the steam leakage through the
dummy piston labyrinth pickings fows, from out board side of dummy piston, through the
balance pipe and does work in the lower stages of turbine.
The steam velocities in this type of turbine are moderate. The velocity of steam for maximum
blade efciency being roughly equal to the blade velocity. The leaving loss is normally about
the same as for the multistage impulse turbine.
The impulse-reaction turbine was developed by the late Sir. Charles A. Parson and widely
used in power stations. It is sometimes called Parsons turbine.
1.5 Impulse Vs Reaction-present Trend
The hard and fast distinction between the impulse reaction is becoming progressively less
important. The trend is to have some percentage of reaction for an impulse turbine or to
have some percentage of impulse for a reaction turbine.
It can be mathematically proved that efciency of reaction stage is greater than efciency of
impulse stage./ A pressure diference exists across the reaction type moving blades,
therefore, the changes of leakage of steam from around the blade is more in a reaction
stage. The advantage of efciency is of set by the interstage leakage of steam which fows
without doing useful work. Hence a reaction stage should be located in the low pressure
region of turbine.
There is a general rule to use a greater percentage of impulse on the HP end and greater
percentage of reaction on the LP end. The percentage of reaction progressively increases as
we go towards LP end. In actual turbines it is common for the best feature of various type to
be incorporated in one machine. For example, a turbine may have a velocity compounded
(curtis) frst stage followed by pressure compounded impulse (Rateau) stages and, at the low
pressure end of the machine, reaction blading.
1.6 Classifcation of Steam Turbines
Steam turbines may be classifed into diferent categories depending on their construction,
the progress by which heat drop is achieved, the initial and fnal conditions of steam used
and their industrial usage etc. They are classifed according to the :-
1.6.1 Direction of steam Flow
a) Axial turbines : in which the steam fows in a direction parallel to the axis of the turbine.
b) Radial turbines : in which the steam fows in a direction perpendicular to the axis of the
turbine.
1.6.2 Number of Cylinders
a) Single - Cylinder turbines.
b) Double - Cylinder turbines
c) Three - Cylinder turbines &
d) Four - Cylinder turbines etc.
1.6.3According to the Method of Governing
a) Turbines with throttle governing in which fresh steam enters through one or more
(depending on the power developed) simultaneously operated throttle valves.
b) Turbines with nozzle governing in which fresh steam enters through two or more
consecutively opening regulators.
c) Turbine with by-pass governing in which steam besides being fed to the frst stage is
also directly led to one, two or even three intermediate stages of the turbine.
1.6.4According to the Principle of Action of Steam
a) Impulse Turbine
b) Reaction Turbine
1.6.5According to the Head Balance Arrangements
a) Condensing turbines with regeneration; in these turbines steam at a pressure less than
atmospheric is directed to a condenser; besides, steam is also extracted from intermediate
stages for feed water heating, the number of such extractions usually varies from 2-3 to as
much as 8-9. Small capacity turbines of earlier designs often do not have regenerative feed
heating.
b) Condensing turbines with one or two intermediate stage extractions at specifc
pressures for industrial and heating purposes.
c) Back pressure turbines : the exhaust steam from these turbines is utilised for industrial
or heating purposes.
d) Topping turbines : these turbines are also of the back pressure type with the diference
that the exhaust steam from these turbines is further utilised in medium and low-pressure
condensing turbines. These turbines, in general, operate at high initial conditions of steam
pressure and temperature, and are mostly used during extension of power station capacities,
with a view to obtain better efciencies.
By extension of power stations capacities here is meant additional installation of high
pressure boiler (critical and super critical pressures) and topping turbines as additional units,
delivering steam to the already existing medium-pressure turbines from the exhaust of
topping turbines.
e) Back-pressure turbines with steam extraction from intermediate stages at specifc
pressures; turbines of this type are meant for supplying the consumer with steam of various
pressure and temperature conditions.
f) Low-pressure (exhaust-pressure) turbines in which the exhaust steam from
reciprocating steam engines, power hammers, presses etc. is utilised for power generation
purposes.
g) Mixed pressure turbines with two or three pressure stages, with supply of exhaust
steam to its intermediate stages.
1.6.6According to the Steam Conditions at Inlet to Turbines
a) Low-pressure turbines, using steam at pressure of 1.2 to 2 ata.
b) Medium-pressure turbines, using steam at pressure of up to 40 ata.
c) High-pressure turbines, utilising steam at pressures above 40 ata. and below 170 ata.
d) Turbines of very high pressures, utilising steam at pressures of 170 ata and higher and
temperatures of 550
o
Celsius and higher.
e) Turbines of supercritical pressures, using steam at pressures of 225 ata and above.
1.6.7According to Shaft Arrangements
i) Tandem compounded turbines - Here all the cylinders are arranged so as to drive a single shaft.
ii) Cross compounded turbines - Here various cylinders are arranged to drive two or more
shafts with separate generators with every shaft.
1.6.8Automatic / Non Automatic Extraction Turbines
Automatic-extraction unit bleeds of part of main steam fow at one, two or three points,
Valved partitions between selected turbine stages control extracted steam pressure at the
desired level.
Non automatic-extraction turbines bleed steam at as many as nine diferent stages. Pressure
of extracted steam at each state varies with the turbine shaft load; extracted steam is used
for feed heating.
1.7 Basic Principles
The Thermal Power Plants with steam turbine uses Rankine cycle. Rankine cycle is a vapour
power cycle having two basic characteristics :
i) the working fuid is a condensable vapour which is in liquid phase during part of the
cycle and
ii) the cycle consists of a succession of steady fow processes, with each process carried
out in a separate component specially designed for the purpose. Each constitute an open
system, and all the components are connected in series so that as the fuid circulates
through the power plant each fuid element passes through a cycle of mechanical and
thermodynamic stages.
1.7.1Temperature Entropy Diagram
The temperature-entropy (T-S) diagram is probably the most useful diagram of all illustrating
certain fundamental points about Rankine steam cycles. Ideal condition for a unit on a T-S
diagram are indicated in (Fig. 1.13) The unit uses steam at a pressure of 100 bar absolute,
temp. 540
o
Celsius (or 813
o
K) and rejects it to the condenser at 30 m bar (saturation temp.
24.1
o
Celsius)
At point A the condensate is at boiling temperature corresponding to the back (condenser)
pressure. Its pressure is raised to 100 bar in Feed Pump corresponding to point B, Heat
(sensible) is added to this water to raise its temperature. At the point C it reaches its
saturation temp. at a pressure of 100 bar. Evaporation begins at the point C. Heat (latent-
because no rise in temperature between C and D, as evident from the diagram), addition
continues. At D all the water evaporates and super-heating commences. This is shown by
the curve DE.
Steam then expands isentropically i.e. enters the turbine and rotates it, as shown by the line
EFG. At point F there is not superheat left in the steam and so from F to G there is
increasing wetness. At G steam is at a pressure of 30 m bar and is passed out of the turbine
to the condenser and condensation of steam takes place as represented by the line GA. At
point A the steam has all been condensed and condensate is at boiling temperature ready to
begin another cycle.
To summaries the above :
AB pressure Rise in BFP.
BC heating of feed water (i.e. sensible heat addition)
CD evaporation of water in boiler (i.e. latent heat addition)
DE superheating of steam (i.e. superheat addition)
EFG expansion of steam in turbine, point E denotes demarcation between superheated and
wet steam/GA condensation of steam in the condenser.
An important basic fact to remember is that heat is product of absolute temperature and
change of entropy. In other words heat is represented by the area under the diagram
Sensible Latent and superheat, 100 bar, 540
0
C Cycle on T-S Diagram
1.7.2Velocity Diagrams
Let us consider an axial-fow turbine consisting of one or more stages, each stage
comprising one annulus of fxed nozzles and one annulus of moving blades. Usually the total
pressure drop across the stage is divided between the nozzle and blades. The division is
usually expressed, not in terms of pressure drops, but in terms of the corresponding enthalpy
drops. The criterion used in the degree of reaction A, defned as
Enthalpy drop in moving blades (H
1
-H
2
), A= Enthalpy drop in stage (H
0
-H
1
)
In Impulse Turbine, A < 0.5
In Reaction Turbine, A > 0.5
The mode of actin of the turbine can best be studied by following the path of fuid through a
single stage at the mean radius of the annuals. The fuid enters the nozzles with velocity C
0
at pressure P
0
and is expanded to pressure P
1
. It leaves the nozzles with a velocity C
1
, in a
direction making an angle L
1
with the tangential direction, i.e. the place of rotation. It must
satisfy the energy equation
1/2 x (C
1
2
- C
0
2
) = H
0
-H
1
The velocity of the fuid relative to the moving blades can be found by subtracting vectorially
the blade speed U. This is easily accomplished by drawing the inlet velocity triangle. To avoid
a multiplicity of indices, relative velocities are denoted by V, and the relative velocity at inlet
to the blades is therefore V
1
, V
1
makes an angle B
1
with the tangential direction, and if the
fuid is to fow smoothly into the blade passages without undue disturbance, the inlet angle
THERMODYNAMICS AND POWER PLANT CYCLES
Mollier Chart
Simplifed graphical representation of Steam table is Mollier chart. Which is easy to refer to.
For constant pressure heating, dq = dh where dq is the amount of heat supplied and dh is
change in enthalpy. With the help of H-S diagram heat supplied dq can be found out readily
as
dq = dh = Tds
or dh/ds = T, where ds is the change in entropy and dh/ds is the slope or inclination of the
constant pressure curve on H-S diagram and this will be equal to T which is absolute
temperature of the system. This H-S diagram is known as Mollier chart. In commercial
Mollier chart in addition to the constant pressure, constant temperature lines, constant
quality (dryness fraction) and throttling process (constant enthalpy) lines are also drawn.
Thermodynamics and Power Plant Cycles
Thermal power plant operation is based on the theory of thermodynamics which deals with
heat energy and its conversion to work and vice versa.
The frst law of thermodynamics is a statement of the principle of conservation of energy. It
states that heat and work are mutually convertible. The conditions under which such
conversion can take place are indicated in the second law which states that heat from a
source can be converted into work but some portion of this heat is rejected into the sink. The
second law can also be stated as heat cannot by itself fow from a body at lower temperature
to a body at a higher temperature without any work being done. A process is said to be
reversible when the following conditions are met :
i) When the direction of the process is reversed the system taking part in the process can
assume the states traversed in the direct process but in the reverse order.
ii) The external actions are the same for the direct and reverse process.
iii) The system undergoing change as well as the connected systems can be restored to
initial conditions.
Any process that fails to meet these requirements is an irreversible process. A reversible
process is an ideal process and seldom practicable. All real processes are irreversible, the
main reason being the process like conversion of work into heat through friction, transfer of
hat due to temperature diference, throttling and mixing of fuids, etc.
Throttling is a process of expansion of a fuid from a high pressure region to a region of lower
pressure. Throttling is an irreversible process as pressure drop is without doing external
work, the released energy being dissipated away as heat.
Application of Thermodynamic Principles
The thermodynamic laws provide a quantitative method of looking at the sequential process
by which the working substance in a given initial state goes through a series of changes in its
thermodynamic properties and fnally returns to the initial state; the working substance is
said to undergo a thermodynamic cycle.
Carnot Cycle
In 1824, Said Carnot, a French engineer, presented for the frst time the concepts of the
cycle and reversible processes. Later these concepts proved to be the foundation of the
second law of thermodynamics. The reversible cycle he proposed, often called the Carnot
cycle, is the most efcient cycle that can operate between two constant temperature
reservoirs. In fact, the Carnot cycle is still used as a comparison for other power-producing
cycles.
The Carnot cycle consists of the following processes as shown in Fig. 12.
1. The process 1-2 is reversible and isothermal. Heat is transferred from the high-
temperature reservoir.
2. The process 2-3 is reversible and adiabatic. The working substance expands and has
its temperature decreased to that of the low-temperature reservoir.
Fig. 12 Carnot Engine utilising a two phase saturated vapour as the working substance
4. The process 3-4 is reversible and isothermal. Heat is transferred to the low
temperature reservoir.
4. The process 4 - 1 is reversible and adiabatic. The working substance is compressed
and has its temperature increased back to that of the high-temperature reservoir.
To achieve the frst reversible and isothermal process, if the working substance is a pure
substance such as water, this isothermal process can be carried out in an evaporation
process. The second process occurs in the turbine. Because there is no heat transfer, the
process must be isentropic and has the same entropy at the turbine inlet and outlet. In this
process steam expands reversibly and produces the useful work. In the third process, heat is
transferred from the condensing steam to the low-temperature reservoir. When steam
condensation takes place at a temperature infnitesimally higher than that of the low-
temperature reservoir, the process is reversible and isothermal. The fourth process occurs in
the pump. Similar to the second process, the entropy of the working substance will be the
same at pump inlet and outlet. In this process the substance is compressed back to the initial
state at the beginning of the cycle.
The Carnot cycle is an ideal cycle that could not be attained in practice. To realize a heat
transfer process through an infnitesimal temperature diference, an infnite amount of time or
an infnite amount of heat transfer surface would be required. To have a frictionless
expansion or compression, the fuid would have to move at a velocity infnitesimally close to
zero. Also as shown in Fig. 12 both expansion and compression processes are in the wet
steam region. These will undoubtedly present a difcult problem in design as well as in
operation.
The Carnot cycle has no counterpart in practice. Since the processes are reversible, the
Carnot cycle ofers maximum thermal efciency attainable between two constant
temperature reservoirs. The cycle thermal efciency is generally defned as
Where T
h
is the temperature of the heat source (i.e. the high - temperature reservoir) and T
l
is the temperature of the heat sink (i.e. the low-temperature reservoir). Therefore Carnot
cycle efciency can be increased by either increasing the temperature T
h
or lowering the
temperature T
l
. Referring to Fig. 12 the heat transferred to the working substance is
represented by the area 1-2-a-b-1 and the heat from the working substance by the area 3-a-
b-4-4. From the frst law the diference of these two areas, namely 1-2-3-4-1, must represent
the work produced in the Carnot cycle. Using these areas, the Carnot cycle efciency is
area 1-2-3-4-1
efciency of cycle =
area 1-2-a-b-1
In analyzing the Carnot and other cycles it is helpful to think of these areas in relation to the
cycle efciency. Any relative change in these areas will afect the cycle efciency.
Rankine Cycle
When the Rankine cycle was devised, it was readily accepted as the standard for steam
power plants and it remains so today, Whereas the Carnot cycle is a cycle for all fuids, the
Rankine cycle is a vapour-and-liquid cycle.
The Rankine cycle used in power plants is much more complex than the original simple ideal
Rankine cycle. It is by far the most widely used cycle for electric-power generation today.
The Ideal Rankine Cycle
Because it is a vapour-liquid cycle, it is most convenient to draw it on both the P-V and T-S
diagrams with respect to the saturated-liquid and vapour lines of the working fuid, which is
water for thermal power plant application.
Fig. 13 below shows simple steam power plant operating on the Rankine cycle and the
Rankine cycle on a T-S Diagram.
Fig. 13 Simple Steam Power Plant Operating on the Rankine Cycle
Cycle 2-3-4-1-a-2 is a saturated Rankine cycle. The cycle being reversible has the following
processes :
2-3 : Adiabatic reversible expansion through turbine
3-4 : Constant temperature heat rejection in the condenser = T
2
(S
3
- S
4
)
4-1 : Adiabatic reversible compression by the pump of saturated liquid at the pressure
3 to sub-cooled liquid at the steam generator pressure 1.
1-2 : Constant pressure heat addition in the steam generator. The portion 1-a
represent the subcooled liquid 1 to saturated liquid at a. The section 1-a in
boiler is called an economiser. The portion a-2 represents heating saturated
liquid to saturated vapour.
The Carnot cycle is represented by the area 1-b-2-3-4-1.
In other words, the triangular area bounded by 1-a-b-1 is the loss of cycle work due to the
irreversibility in the liquid heating. The lower efciency of Rankine cycle is also evident in
terms of the average temperature at which the working substance receives heat. In the
Rankine cycle, the average temperature for the liquid heating process (1-a) is much lower
than the temperature during evaporation; thus the average temperature for heat addition is
lower than the maximum temperature.
There are several important parameters afecting the Rankine cycle efciency. These include
condenser pressure, steam conditions, use of reheating and regenerative process. First, let
us consider the efect of condenser pressure on the Rankine cycle.
A Rankine cycle with two diferent condenser pressures in the T-s diagram. The one with the
condenser pressure P3 has the cycle work represented by the area 1-2-3-4-1 while the one
with the lower pressure P
3
' has the work by the area 1'-2-3'-4'-1'. Evidently, the work
produced in the Rankine cycle can be increased by lowering the condenser pressure. Since
the heat transferred to the steam is almost the same for both cases, the net result is an
increase in cycle efciency. However, it does not mean the condenser pressure should be
reduced infnitely. Lowering the condenser pressure can cause an increase in the moisture
content in the turbine exhaust end. These in turn will afect adversely the turbine internal
efciency and the erosion of turbine blades. Also, a low condenser pressure will result in an
increase in condenser size and cooling water fow rate. In modern steam turbine design the
moisture content in steam is usually limited to 15% or less.
Next we consider the efect of steam conditions on the Rankine cycle. A Rankine cycle with
two diferent steam temperatures at the turbine inlet. One is saturated steam while another is
the superheated steam. The area bounded by 2-2' 3'-3 (shown by the crosshatching) is the
increase in the cycle work when the steam temperature is increased from T
2
to T
2
'.
Increasing the steam temperature also results in an increase of heat supplied to the boiler.
This increase is represented by the area 2-2' - bb-2. Since the ratio of increase in the cycle
work to increase in the heat supply is greater than the ratio for the balance of the cycle, the
net result is an increase in cycle efciency. This is also evident from the fact that the average
temperature at which heat is transferred to the steam is increased.
Increasing the steam temperature not only improves the cycle efciency, but also reduces
the moisture content at the turbine exhaust end. In steam turbine design the maximum steam
temp. is in the range of 1000 to 1100
0
F. The steam pressure in the turbine inlet is important.
To have a fair comparison, the maximum steam temperature and the condenser pressure are
held constant as shown in Fig. 15 (b). It is seen that as the steam pressure increases, the
net work tends to remain unchanged (i.e. the single-crosshatching area is approximately
equal to the double-crosshatching area). Since the heat rejected decreases by the area 3-b-
b-34. the net result is an increase in cycle efciency. Similarly increasing the steam
pressure increases the area on subcooled side of feed water (i.e. area 4-a-b-3) thereby
increasing the efciency. This conclusion is also evident by determining the average
temperature at which heat is supplied to the steam. While the thermodynamic analysis
indicates that the Rankine cycle efciency can be improved by increasing the steam
pressure, the selection of the steam pressure in power plant design must be tempered with
consideration of technical and economic factors.
The use of reheating process is very common in steam power plants. In the reheat cycle
steam expands partially in the turbine and then returns to the boiler for reheating. The reheat
is a constant pressure process and represented by the curve 3-4 in the T-s diagram.
After reheating steam continues its expansion in the turbine and eventually exhausts to the
condenser. Reheating process may not substantially improve the cycle efciency, but it does
reduce the moisture content in the steam leaving the turbine. This may then improve the
turbine internal efciency and thus improve the cycle performance. The double reheat cycle
is thermodynamically superior to the single reheat. But for various reasons the double reheat
is seldom used in practice.
Next, we consider the regenerative process in the Rankine cycle. To discuss this problem we
must remember the average temperature for heat addition in the Rankine cycle is usually
lower than the maximum temperature. It is mainly due to the liquid heating in the boiler. If this
liquid heating could be eliminated from the boiler, the average temperature for heat addition
would be greatly increased and would equal the maximum cycle temperature in the limiting
case. The water circulates around the turbine casing and fows in the direction opposite to
that of the steam fow in the turbine. Because of the temperature diference, heat is
transferred to the water from the steam. Consider that this is a reversible heat transfer
process, that is, at each point the temperature of the steam is only infnitesimally higher than
the temperature of the water. At the end of the heating process the water enters the boiler at
the saturation temperature TI. Since the decrease of entropy in the steam expansion line 2-3
is exactly equal to the increase of entropy in the water heating process 5-1 the ideal
regenerative Rankine cycle will have the same efciency as the Carnot cycle, 1-2-3'-4'-1.
FIG. 18 (A) & (B) An Ideal Rankine Cycle with one Contact Heater
Obviously this ideal regenerative Rankine cycle is not practical, It is almost impossible to
carry out the reversible heat transfer process just described. In addition, the moisture in the
steam turbine will be too great for a safe and efcient operation.
The practical regenerative cycle usually involves the use of feed water heaters. If feed water
heaters, water is heated by the steam that is extracted from the turbine. Fig. 18 presents a
Rankine cycle with one contact heater. Because of a reduction of water heating in the boiler,
the cycle efciency is expected to be improved.
Overall Efciency of Power Plant
The overall efciency of fossil fred power plant can be given by the relation.
Energy utilised Shaft power developed in KW x 3600
E
Y
= =
Energy applied Fuel burning rate in boiler (kg/hr) x
Calorifc value of fuel (Kcal/kg)
where,
Energy utilised = Shaft power developed in KW x 3600
Energy applied = Fuel burning rate in boiler (kg/hr) x Calorifc value of fuel (Kcal/kg).
STEAM CYCLE THEORY AND CYCLE CONSTRAINTS
2.0 STEAM CYCLE THEORY AND CYCLE CONSTRAINTS
2.1 Over the years, and particularly the last three decades the size and terminal conditions of
generating plants has continuously increase at a remarkable rate as shown in the table given
below :
TABLE - 1
Steam conditions Design Size of set
Press/Temp/Reheat Efciency in MW
in Bar/ Deg Celsius in %
41.4 / 462 27.5 30
62.1 / 482 30.5 60
104.4/566 34.7 100
104.4/538/538 Reheat 35.7 120
162/566/538 Reheat 37.3 200
158.6/566/566 Reheat 37.7 275
158.6/566/566 Reheat 38.4 550
158.6/566/566 Reheat 38.4 350
241.3/593/566 Supercritical 39.0 375
158.6/566/566 Reheat 39.25 500
The main incentive to keep striving for bigger and better plant is that one expects the thermal
efciency to improve with size and the capital cost per MW decreases with the increase of
size.
It can be seen that steam temperatures have increased at quite a slow rate. This is because
increasing steam temperature is intimately bound up with metallurgical advances and such
advances are painfully slow. On the other hand, by increasing the steam pressure,
introducing reheat and rapidly increasing output it has been possible to reduce the cost per
MW of installed plant considerably.
Increased output is normally associated with increasing pressure and temperature
conditions. This is because :-
i) The higher cost of high temperature components is partly efected by a reduction in the
number of components per MW.
ii) Losses become proportionately smaller in the larger machine.
iii) High density steam must be associated with large fows to give reasonably sized H.P.
blades.
2.2 Temperature Entropy Diagram
The temperature-entropy (T-S) diagram is probably the most useful diagram of all for
illustrating certain fundamental points about steam cycles. Ideal condition for an unit on a T-
S diagram are indicated in (Fig. 6-1. The unit uses steam at a pressure of 100 bar absolute,
temp. 566
0
C (839
0
K) and rejects it to the condenser at 30 mbar (at saturation temp. 24.1
0
C).
At point A the condensate is at boiling temperature corresponding to the back (condenser)
pressure. Heat (sensible) is added to this water to raise its temperature and pressure, At the
point B it reaches its saturation temp (38.961
0
C obtainable from steam table) at a pressure of
100 bar. Evaporation beings at the point. B. Heat (latent-because no rise in temperature
between B & C, as evident from the diagram) addition continues. At C all the water
evaporates and superheating commences. This is shown by the curve CD and at D and
superheated steam temperature is 566
0
Celsius.
Steam then expands is entropically i.e. enters the turbine and rotates it, as shown by the line
DEF. At point E there is no superheat left in the steam and so from E to F there is increasing
wetness. At F and steam is a pressure of 30m bar and is passed out of the turbine to the
condenser and condensation of steam takes place as represented by the line FA. At point A
the steam has all been condensed and condensate is at boiling temperature ready to begin
another cycle.
To summaries the above :
AB - heating of feed water
(i.e., sensible heat addition)
BC - evaporation of Water in boiler
(i.e. latent heat addition)
CD - superheating of steam
(i.e. superheat addition)
DF - expansion of steam in turbine, point E denotes and demarcation between
superheated and wet steam.
FA - condensation of steam in the condenser.
An important basic fact to remember is that heat is product of absolute temperature and
change of entropy. In other words the heat is represented by the area under the diagram :
Fig. 2.1
Sensible, Latent and superheat, 100 bar, 566 C cycle on T-Diagram
2.3 More information from T.S Diagram
2.4.1Sensible heat addition
In Fig. 2.1 the sensible heat added is represented by the area AB. At A the temperature is
24. IC and at B it is 311
0
C.
Now amount of sensible heat added can be found :
Sensible heat at A = 101 kj/kg
Sensible heat at B = 1408 kj/kg
(Both the values obtained from table)
So, sensible heat added
= B - A = 1408 - 101 = 1307 kj/kg
It should be noted that increasing pressure in the boiler to get more output in turbo-alternator
(i.e. more MW) means more sensible heat per kilogram Fig. 2.2 also presents it graphically.
As sensible heat is almost supplied in feed heaters and economisers number of feed heaters
of area of feed heating surface increases with more elevated steam condition. Table 1 shows
the increase of sensible heat with corresponding pressure.
Table 1. Sensible Heat at saturation temperature.
Absolute pressure Saturation Temperature Sensible
Heat
(bar) (
0
C) (kj/kg)
50.0 264.90 1154.5
100.0 311.00 1408.0
150.0 342.10 1611.0
200.0 365.70 1826.5
221.2 374.15 2107.4
Fig 2.2 Pressure Bars absolute
Sensible heat at Saturation Temperature at Various Pressures
2.4.2As stated before all most of all sensible heat is supplied in the feed heaters and economiser.
Water entering the boiler water wall tubes is almost at boiling temperature, last bit of sensible
heat is added to water at the lower part of water wall tubes and thereafter latent heat addition
starts taking place.
As there is no change of temperatures (line BC in Fig. 2.1 indicates so) the water/steam
mixture is about constant temperature from the bottom to the top of the tubes. The area nBCI
represents the latent heat added. Its amount can be calculated in the following way:
Latent heat required = (S
2
- S
1
), where
T = temp. of boiler water at B = 311
0
C = 584.15
0
K
S
2
= Entropy at C
= 5.6198 kj/kg
0
K (from T - S diagram. Also available from table)
S
1
= Entropy at B
= 4.3605 (from T - S diagram, Also available from table)
= so, Latent heat required
= 584.111 (5.6198 - 4.3605)
= 1319.7 kj/kg
0
K
It should be noted that unlike sensible heat the amount of latent of latent heat required to convert boiling water to
dry saturated steam reduces with increase of pressure. At the critical pressure of 221.2 bar absolute it is Zero.
So in supercritical pressure boilers water after attaining saturation temperature fashes instantaneously to
dry saturated steam and super heating commences.
Table II Latent heat at saturation temperature
Absolute pressure Saturation Temperature
(bar) (C) (kj / kg)
50.0 264.90 1639.7
100.0 311.00 1319.7
150.0 342.10 1004.0
200.0 365.70 591.9
221.2 374.15 0
2.4.3Superheat Addition
The curve CD in Fig. 2.1 shows the process of steam being superheated at a constant
pressure of 100 bar from the state of dry saturated steam of 311
0
C to the designed stop
valve temperature of 566
0
C. The area pICD represents the amount of superheat. The
amount of heat required is obtained by deducting the total heat at C from total heat at D and
is equal to 811.6 kj/kg.
Quantity of heat required to superheat steam to a given temperature varies with pressure as
given in Table III.
TABLE III - VARIATION OF SUPERHEAT FOR DIFFERENT PRESSURES
(fnal temperature 570
0
C).
Pressure BarSuperheat reqd.
Absolute kj/kg.
50 800.9
100 821.5
150 885.4
200 1034.2
2.4.4.Thermal Efciency of the cycle
Thermal Efciency of the cycle is defned as :
Thermal efciency = useful heat

Total heat
Useful heat means that part of total heat which is used in rotating the turbine, i.e., when the
steam expand adiabatically (adiabatic expansion means to heat is accepted or rejected
during the process; all work done by steam at the expense of its internal energy) in the
turbine represented by the line DEF in Fig. 2.4 Expansion of steam takes place upto a
pressure of 30m (24.1 deg C). The condensation takes place at a constant temperature, as
indicated by the line FA, until all latent heat is removed.
Heat removed from steam or useless heat is shown by the rectangle pmAF. Amount of this
rejected heat can be calculated as follows :
FIG . 2.4 ENTROPY, KJ/KG K
BASIC IDEAL CYCLE SHOWING USEFUL REJECTED
HEAT COMPONENTS
Heat Rejected = T x (S2 - S1) where,
T = Absolute temperature of FA = (24.1 + 274.15) = 297.25
0
K
Sz = Entropy at F
= 6.8043 kj/kgk
S1 = Entropy at A = 0.3544 kj/kgk
So, Rejected heat
= 297.25 x (6.8043 - 0.3544)
= 1917.2 kj/kg
Now, total heat = Sensible heat + latent heat + superheat
= 1307 + 1319.7 + 811.6
= 3438.3 kj/kg
Useful heat = Total heat - Rejected heat
So, Thermal Efciency =
Total heat - rejected heat

Total heat
= 1 - rejected heat

Total heat
=1- (1917.2 / 3438.2)
= 0.4423 or 44.23%
This is the highest possible efciency for a basic Rankine Cycle with steam at 100 bar
absolute, 566
0
C and back pressure is 30 m bar. Of course, in practice a turbine operating
under this cycle will be less efcient. It can also be noted that how superheating of steam
adds to efciency. If steam is not superheated the total amount of heat in this cycle will be
addition of sensible heat and latent heat only i.e.
1307 + 1319.7 = 2626.7 kj/kg
So, Thermal efciency rejected heat
= 1 -
total heat
= 1 - 1917.2
2626.7
= 0.2701 or 27.01 %
Hence, efciency of the basic Rankine Cycle can be improved by increasing the superheat.
But this scope becomes limited due to limitations of materials which can withstand very high
temperature and the cost associated with it.
2.4 Reheating :
As told before, one obvious way to increase the heat available compared to the heat rejected
to increase the superheated steam temperature. Unfortunately this is only possible to a very
small degree because of metallurgical limitations. Thus there is very little scope in this
direction. Therefore the alternative is to probably expand the steam in the turbine to some
suitable intermediate condition and then pass it back to the boiler to be reheated to some
high temperature. It is then piped back to the turbine to continue its expansion.
Let us consider that same 100 bar cycle, now with reheat. Fig. 2.5 shows the cycle. Steam
as usually starts expanding after being superheated. At the point G when the pressure had
dropped to 20 bar the steam is taken out of turbine and reheated to 566
0
C as shown by the
line GH. It is then fed to the L.P. turbine where it expands to the condenser pressure.
The efciency of the cycle is determined in a similar manner to the previous cases and works
out to be 46.09%
So, reheating had improved efciency from 44.23% to 46.09%. A further advantage of
reheating is that the wetness of the exhaust steam is reduced considerably.
2.5 Regenerative Feed Heating
Steam in a thermal cycle will normally reject heat in two ways. Firstly the heat rejected can
go to waste via the condenser cooling water and secondly, the steam can reject heat to the
feed water by means of feed heaters. In the second case, all the heat is kept within the cycle
and not lost. The more steam which can be prevented from going to the condenser, the more
heat will be saved from rejection to waste. Consequently, if the steam is allowed to expand to
a certain extent in the turbine and perform useful work before it is allowed to transfer its
remaining heat to the feed water, then the quantity of work is obtained without any condenser
loss and the cycle efciency is improved. In modern design of high capacity units the bled
steam has been used for turbine driven feed pump and its exhaust used for feed heating in
addition to the conventional extractions.
Let us again see the previous 100 bar cycle, this time with regenerative feed heating (Fig.
2.6). The steam expands is entropically in the turbine until the temperature is 250
0
C after
which the steam is bled to an infnite number of feed heaters. The result is that quantity of
heat represented by the area under the curve KL is transferred to the water side shown by
the area under the curve AM. Note that M and K are both at 250
0
C and curve KL is identical
to the curve AM. so, water now has a fnal feed temperature of 250
0
C. The heat represented
by the area LFpr has been given to feed water whereas before it would have been rejected in
the condenser. The heat represented by the area LKF has also been transferred to feed
water, where as formerly it would have done some useful work in the turbine. So there is
some loss of work too. Yes, but on the balance it is better to lose the power from the triangle
LKF to save the heat represented by large rectangle (LFpr) that would have been wasted.
Regenerative feed heating elevates the condensate temperature represented at A along the
boiling water line to M and the remaining sensible heat is supplied in the economiser and
boiler to point B.
Fig. 2.5 Entropy . KJ/kgk
Modifed Basic Cycle to Incorporate Reheat
Lest us fnd the efciency with reheat :
Total heat supplied = Sensible heat from M to B + latent heat + superheat
Among of latent heat and superheat in this cycle are same on the previous cycle with
superheat (Fig. 2.1) and equal to 1319.7 kj/kg and 811.6 kj/kg respectively.
Now, sensible heat = Total heat at B - total heat at M
= 322.2kj/kg (from steam table)
So, total heat supplied = 322.2 + 1319.7 + 811.6
= 2453 kj/kg.
Heat rejected Area under Alrm
= 1192.kj/kg (from steam table
So, efciency = 1 - rejected heat

total heat
= {1 - (1192.2 /2454.5)}
= 0.5140 or 51.4%
Fig. 2.6 Entropy KJ/kg
o
K
Modifed Basic cycle to incorporate feed heating
Hence you fnd how efciency of the Rankine cycle changes with reheating and feed heating.
Basic efciency (Fig. 2.4) = 44.23%
Reheat cycle efciency (Fig. 2.5) 46.09%
Feed heating cycle efciency (Fig. 2.6) = 51.4%
A combination of reheating and feed heating will give higher ideal cycle efciency.
2.5.1Choice of Feed Water Temperature
Typical improvements possible with a straight regenerative cycle, as the number or feed
heating stages is increased are shown in Figure 2.7 for various steam conditions at the
turbine stop valve. It is clearly seen that the efciency improved with each additional heater
but the incremental gain with each becomes progressively smaller. Front Fig. 2.7 the
following points can be noted.
(1) For given initial steam temperature the decrease in heat consumption kj/kWh) is
greater the higher the initial pressure.
(2) For a given initial steam pressure the decrease is slightly smaller with a higher initial
temperature.
(3) The optimum fnal feed temperature is raised as the initial steam pressure is increased.
4.0 CONDENSER & AIR HANDLING
4.1 CONDENSERS, PUMPS AND COOLING WATER PLANT
4.2 Hydraulic Test
There are mandatory requirements for hydraulic tests on the components of the condensing
plant, and these are summarized in Table shown.
TABLE
CONDENSING PLANT COMPONENT TESTS
Component Test pressure, in bar
Water boxes 4.1 (hydraulic)
Tubes 4.4 (Pneumatic)
Pumps, Pipework 1.5 times max. working
and valvesPressure pressure
Condenser structures, NDT, dye penetrant
welds testing
4.3 Protection and cleanliness of condensers
During plant manufacture, storage, transport to site and site erection, special precautions are
taken to ensure that all plant items remain clean and reasonably protected. To achieve this
condenser internal surfaces are usually grit-blasted at the works and a temporary protective
coating applied, i.e., a type of coating which does not require to be removed prior to the unit
entering service. Tube holes are protected by a lacquer which is removed immediately prior
to condenser tubing. External ferrous surfaces are either grit-blasted or wire-brushed and
decreased, and a suitable primer is applied to the cleaned surface.
In the post-erection period, until commissioning, deterioration of internal surfaces is
minimised by keeping the condenser surfaces dry. If the condenser is used and has to be
put into storage again before commissioning, steps are taken to ensure that all water is
removed from the condenser.
In order to operate a condenser at its optimum level, on-load cleaning methods are used
which ensure the high availability of condensing plant.
4.4.1Debris Filter
Coastal power station condensers are more vulnerable to the intake of debris such as
mussels, fsh, wood, plastic and fbrous materials, than inland power station condensers.
One solution to prevent the blockage of condenser tubes is the installation of a debris flter in
the CW inlet side of the condenser.
All particles in the cooling water larger than 10 mm are kept in the flter and rinsed away
through the debris discharge. Throttling of the flter inlet isolating valve cause a change in
fow direction near the screen, creating a rinsing efect. The discharge water quantity from
the flter ranges from 3 to 10% of the main CW fow, over a rinsing period of 5 to 10 minutes.
4.4.2Condenser tube cleaning system
Oversized rubber balls are continuously pressed through the condenser tubes by the water
fow. Screens located downstream of the condenser water boxes extract the ball from the
main CW discharge fow. They are then drawn of and pumped through a collector to be
subsequently discharged into the CW inlet to the condenser.
This system removes fouling and even hard deposits from the internal surface of the tubes,
which would otherwise lower the heat transfer characteristics of the tubes, which would
otherwise lower the heat transfer characteristics of the tubes, with a resulting loss in
condenser efciency.
4.4 Special considerations
In addition to the normal function of condensing the steam which is discharged from the LP
turbines, condensers on nuclear power stations are designed to provide a heat sink for the
removal of heat from the reactors. These condensers are ftted with steam and water
dumping facilities of the pressure breakdown type. The condenser structures are suitably
reinforced to take the reaction forces and erosion efects of high velocity fows from the
steam dump difusers. Condensing tube surfaces are protected by impingement plates and
de-superheating sprays. A more detailed account of the steam and water dumping
requirements on nuclear power stations is covered in chapters 1 and 2 of this volume.
4.5.Operational life limiting constraints
The main constraints which limit the operational life of a condenser are summarised under
the following headings :
- Condenser air leakage.
- Cooling water leakage.
- Condenser fouling and cleaning.
An awareness of these problems at the design state can signifcantly reduce lifetime running
costs and maintenance costs. Operational experience of the various techniques employed
for each of the three constraints listed are now discussed.
4.5.1Condenser air leakage
Techniques used for the location of leaks are outlined, and methods for measuring the rate of
air leakage in condensers are described.
The reasons why it is desirable to minimise air ingress are :
- To improve condenser heat transfer performance.
- To reduce the capital cost of the air extraction equipment required.
- To reduce air extraction plant running costs.
Tests have indicated that with well ventilated condenser tube nests, air ingress within the
capability of the air extraction plant installed (100-200 Kg/h for 500 MW units) does not
adversely afect the condenser heat transfer performance. The objectives for minimising air
ingress rate on new condensing plant are, therefore, aimed at reducing capital costs and
running costs.
Operational levels of air ingress, however, vary between diferent station designs. For
example, stations with underslung condensers and indirect feed heating plant have an
advantage over stations with pannier condensers and direct-contact feed heating plant.
4.5.2Locating air leaks
Air leakage can occur in any part of the condensing stem which operates near or below
atmospheric pressure, and is often caused by failure of joints, at fanges, and also by weld
and material failures. When the turbine is of-load, detection of air leakage is made in some
parts of the system by fooding with water,. Water seepage from sections normally under
vacuum indicate leakage areas.
When the turbine is on-load, however, diferent techniques must be employed. These include
a) Audible methods (if the leak is large enough and the background noise low);
b) Visible means, by observing the action of a lighted taper when in the proximity of air
fowing towards a leakage point; and the spraying of suspect areas of plant with a tracer gas
which is easily detected by careful monitoring of the air extraction equipment.
c) The last methods is the most common technique employed today.
Most leakage points are found at fanges and joints, and are usually small cracks or holes.
These can normally be sealed with any of a number of proprietary metallic resin or rubber-
based sealing compounds.
4.5.3Measurement of air leakage rate
Apart from the air extraction system, air leakage measuring equipment is generally not
installed as permanent instrumentation on British power stations. As in locating the air leaks,
there are several techniques available to measure the rate of air leakage.
Operational techniques are used to determine whether a reduction in condenser
performance is due to condenser fouling, or air ingress overloading the air extraction
equipment. The operations carried out, which only require measurement of condenser back
pressure, are:
- Isolation of the air extraction equipment from the condenser on-load, and monitoring
the subsequent rate of vacuum decay.
- Changing the number of vacuum pumps in service, and establishing the efect of this
on the vacuum.
Typical unacceptable vacuum decay rates are 4 mbar/min and above, as compared with
expected rates of approximately 1 mbar/min.
Where these techniques are not either favoured or practical, other diagnostic techniques are
often employed which require measurement of :
- Air temperature in the air extraction line from the condenser; increase in air quantity
handled reduces the mixture temperature because of low water vapour partial pressure.
- Undercooling of the condensate outlet from the condenser; high air partial pressures
give increased undercooling in some condensers.
- Diferential pressure between LP cylinder exhaust and air extraction plant; low
diferential pressures indicate that the air extraction plant is controlling the vacuum and not
the condenser heat transfer performance.
The fnal technique relies on temporary instrumentation to make direct measurements of air
leakage on a periodic basis, or when a condenser performance problem exists. The methods
employed include the use of Pitot tubes, anemometers, hot wire anemometers, rotameters
and orifce place assemblies.
Measurements are made both on the air suction pipe and at the air extraction plant
discharge. Care is needed at both locations. The assumption made when measuring in the
condenser air suction pipe is that the water vapour present is saturated. When measuring at
the air extraction plant., if more than one pump is operating, the fow between the pumps is
not always evenly distributed.
4.5.4 Cooling water leakage in condensers
The methods employed in British power stations for the detection of leakage of cooling water
into the condenser, and of the consequent pollution of the condensate are :
- Condensate conductivity.
- sodium contamination.
Location of condenser leakage is infuenced by the following factors :
- CW supply, i.e. fresh, Pond or sea water.
- Condenser design, i.e., underslung or pannier.
Experience has shown that the techniques used to locate the region of leakage in fresh
water condensers are not sufciently sensitive to locate leakage in seawater condensers.
This means that on-load location and elimination of leaks is considerably simplifed, often
without output loss. The method of locating condenser CW leakage with a unit on-load
has three separate stages:
- Location of the afected tube nest by condensate conductivity measurement (desirable
conductivity of condensate approximately 0.1 mu-Sec/cm).
- Location of the physical level of the leakage within the waterbox.
- Location of the leaking tube or joint.
The frst stage is carried out using conductivity probes with the unit on-load. The tube nest
causing the problem is identifed by an increase in condensate conductivity. This is simplifed
in transverse underslung condensers, where multi-sectioning means that local increases in
condensate conductivity will be signifcant at the location of the leak, and therefore easily
detectable.
Having identifed which condenser tube nest is at fault, the second stage is to determine the
level of the leakage in that nest. This can be found either by altering the cooling water level in
the waterbox and monitoring the condensate conductivity or by introducing a tracer gas into
the waterbox, dropping the cooling water level, and monitoring at the air extraction plant for
the appearance of the gas as the leak is uncovered.
It is interesting to note that these two methods are not suitable for all power stations, e.g. the
former method is satisfactory at sea-cooled stations, but, it is unsuitable for freshwater-
cooled stations where the latter method is adopted.
These procedures are adequate for narrowing the feld of search to within two or three rows
of tubes, but stage three provides techniques which will precisely locate the source of the
leak.
The techniques used include :
Fluorescein method; the steam side of the condenser is fooded with a fuorescein
solution.
Foam or flm methods; the condenser tube plates are covered with a foam or thin flm
material whilst a vacuum is maintained on the steam side.
Bubbler devices; air bubbling through a jar of water is used to detect a tube leak.
Tracer gas methods; a halogen gas detector is situated at the air extraction equipment
and the suspect tubes sprayed with gas.
Flame and smoke techniques; the fame from a taper (or smoke) is used to indicate
a fow of air into a leaking tube.
Ultrasonics; the noise generated by air passing through a leak is detected.
4.5.5.1 Fluorescein method
The steam side of the condenser is fooded to above the tube nest with a 10 mg/kg solution
of the sodium salt of fuorescein. A search is carried out in the waterbox using ultra-violet
light to detect traces of fuorescein. The tube which is leaking is therefore identifed. There
are, however, disadvantages of this method :
It is restricted to underslung condensers of-load.
The reverse action of water pressure on the tubes compared with normal operation is known
to close up the leak in some cases.
The water pressure is low at the top of the condenser and small leaks may escape detection.
Residual fuorescein can afect feedwater and boiler water analysis, and impair judgement as
to whether repair of the leak was successful.
This method requires an operator to carry it out.
4.5.5.2. Foam or flm methods
The principle of this method relies on the development of a vacuum in a leaking tube. If the
tube is then sealed at each end, the vacuum draws in a foam blanket or a flm of polythene
or paper, and thus identifes the location of the leak.
4.5.5.3 Bubbler devices
4.5.5.4 Tracer gas methods
Detectors for halogen organic gases are extensively used for both air and cooling water
leakage location; Generally leakage rates of around 1000 ml /hr can be detected with the
unit on-load, as long as a vacuum can be obtained. One operator can carry out of a search
using a transmitter/detector, although more normally two operators are employed.
4.5.5.5 Flame and smoke methods
These methods are fairly insensitive and involve the use of lighted tapers or smoke
tubes. Due to their insensitivity, these are generally used as primary methods of detection
when massive leaks are suspected.
4.5.5.6 Ultrasonic method
Again, this is a fairly insensitive method which is not generally used. It involves the use
of ultrasonic detectors to pick up turbulence efects of the air near a pinhole. Owing to the
noise from the steam fow, and to an extent tube vibration, only leaks close to the ends of the
tube can be detected.
4.6Condenser fouling and cleaning
The types of fouling encountered in condensers, and methods of on-load and of-load
cleaning of condensers are now described.
4.6.1Condenser fouling
Various forms of fouling have already been covered in detail in Section 4 of this
chapter, which looked at the erosion/corrosion of condenser tubes from impingement attack.
Basically there are three aspects of fouling which are beyond the scope of the CW
screening plant installed :
Blockage by debris.
Biological slimes.
Scaling.
Biological fouling refers to marine life which contribute to the
formation of the slimy deposits on the heat transfer surfaces of condensers. These include
bacteria, fungi and algae. The slimes formed by these microorganisms adhere to the metallic
surface, resist heat fow and form a layer to which other suspended matter can adhere to
reduce condenser performance further. Some forms of marine life, such as mussels and
barnacles, can cause problems by restricting fow and blocking tubes. Scale formation is
caused by the deposition or reaction of inorganic material on heat transfer surfaces. It
usually occurs at inland river-cooled stations, using cooling tower systems. The scales are
usually calcium carbonate or calcium phosphate, or mixtures of both, and arise from
variations in their solubility products with temperature and pH changes . The temperature
efect is due to the inverse solubility characteristics of calcium salts. The pH changes arise
by carbon dioxide stripping in the cooling towers.
4.6.2On-load condenser cleaning
Two principal methods of on-load fouling prevention are employed to avoid unnecessary
costly shutdown of condenser plant, in order that efcient through life costs are realised :
Chlorination of the cooling water.
Fine fltration, plus tube cleaning using rubber balls.
Intermittent chlorination of the cooling water entering the condenser is carried out on all
British power stations, and forms the accepted on-load fouling preventive technique. It is
efective in controlling the growth of mussels in seawater systems, and the formation of slime
in freshwater systems.
At coastal sites, marine fouling is signifcantly reduced by continuous chlorination of the
cooling water. The degree of chlorination required is inversely proportional to the CW fow
rate, a chlorine concentration of 0.5 mg/kg of CW being required at 1.5 m/s. Fine
fltration plus tube cleaning, however, is installed in some 10% of all locations, and is
becoming more widely used following experience on power stations with recirculating
systems.
4.6.3Of-load condenser cleaning
Although improvements in the on-load techniques continue to be made, of-load cleaning is
frequently required for various reasons.
Failure to cope (or breakdown) of the on-load equipment, may cause a fouling condition to
develop which becomes irrecoverable when the plant is recommissioned. Late flling of the
fne debris flters immediately upstream of condenser water boxes may allow marine fouling
to occur, necessitating tube plate picking to remove debris.
Except in a few exceptional circumstances, of-load condenser cleaning is done during
outages. The techniques used are now discussed.
4.7 BULLETING
This is the most extensively used method of cleaning the inside surface of condenser tubes,
and involves forcing bullets down the tubes to brush of surface deposits. Depending on the
form of deposit to be removed, the bullets vary from hollow and solid rubber balls, to Nylon
and steel bristle designs. Compressed air or water pressure, or a combination of both, forces
the bullets down the tubes from lightweight guns which are designed to develop a seal at the
tube plate without efort from the operator.
4.7.1 ACID CLEANING
This method is restricted to condensers sufering from scaling problems, e.g., Midland
stations which draw their makeup water from the River Bed. Calcium carbonate and
phosphate scales form the deposits and have been cleaned using a variety of acids,
including hydrochloric, citric, acetic, and EDTA (ethylene diamine tetra-acetate). It is
important when adopting this technique that the condenser steam space is subsequently
fooded with demineralised water to prevent acid entering the condensate when the unit is re-
commissioned.
4.7.2 GRIT CLEANING
An alternative to bulleting, this method is known as sinusoidal grit blasting; it involves
blasting graded silica-free mineral grit through the condenser tubes. A special grit blasting
nozzle incorporates a venturi which accelerates the grit and causes it to follow a sinusoidal
path through the tube, stripping of deposits which have accumulated. This method has a
90% efectiveness in cleaning tubes, and requires a charge of grit at approximately 1 m/s.
Water Washing
This method uses either high or low water pressure, depending on the application. To
remove surface deposits, a high pressure lance with forward and side-facing jets is passed
down each tube, blasting water at a pressure of 700 bar. This method has an advantage over
acid or grit cleaning method, since its action does not have a detrimental efect on the tube
surface. However, its operation is awkward within the confnes of the water boxes, and is
therefore generally not used.
Low pressure water washing is efectively used to remove loose sludge and sediment
deposits prior to leaving the condenser dry during overhaul. Often a combined
water/compressed air gun (similar to the type used in bulleting) is employed, having a
discharge pressure of 7 bar.
Thermal Methods
These have been used to control mussel growth in seawater station CW culverts, and to
clean condenser tubes by drying internal deposits prior to fushing with water.
The former application controls marine fouling by raising the temperature to 40
0
C for one
hour every six weeks. This restricts mussel growth to sizes which will not lodge in condenser
tubes. The heating is achieved either by introducing an auxiliary steam source in the CW
culvert, or by reversing the fow of CW through the condenser.
Drying the deposits in condenser tubes prior to fushing has also been successful: fan
heaters are used to blow warm air through the condenser waterbox access doors.
4.8.Plant testing
4.8.1Introduction
Condenser thermal performance tests are carried out for two reasons :
As acceptance tests to establish that a condenser meets its specifed performance,
and is capable of producing the desired condenser steam inlet pressure when operating
under specifed conditions.
As routine operational tests to monitor the condenser performance periodically, and to
verify that station thermal efciency is not being adversely afected by a deterioration in the
condensing plant heat transfer coefcient.
In both acceptance tests and routine tests, a high standard of instrumentation is required,
particularly in the measurement of the condenser steam inlet pressure, and the cooling water
temperatures. Routine tests generally use less instrumentation than acceptance tests, but
only when it is certain that this is not detrimental to accuracy.
4.8.1.1 Test codes and practices
Condensing plant is the only major item of power plant which is at present not covered by a
British Standard code for thermal performance testing.
Scope
This Code covers requirements for acceptance, routine and diagnostic testing of water-
cooled surface-type steam condensing plant, including multi-pressure designs. It specifes
procedures for testing condensers, and for calculating and reporting the results, so that the
condenser performance may be checked against contractual obligations In addition, the
performance of diferent condensers may be readily compared, and the operational
performance of condensing plant may be assessed.
General outline
The assessment as to whether a condenser meets its guaranteed performance is based on
comparison of the condenser inlet pressure measured on the acceptance test (corrected to
specifed conditions of CW)
4.8.2Determination of air extraction quantity
To ensure adequate removal capacity under operating conditions, the capacity of the air
extraction plant must be greater than the maximum amount of air and non-condensable
gases expected to be removed from the condensate.
The main parameters which determine the quantity of air to be extracted from the condenser
and, hence, the design of the condenser air cooling system and air removal equipment are:
The design air leakage into the condenser.
The degree of sub-cooling of the air/steam mixture leaving the air cooling section.
Table 4.6 indicates recommended values for typical fossil-fred power stations of varying
size.
Table 4.6
Design air leakage rates for typical fossil-fred stations
Turbine size, in MW 300 500 600
Design air leakage rating, kg/h 73 120 161
Design air suction temperature at outlet, in
o
Celsius 42
Limiting CW outlet temperature, in
o
Celsius 33
However, experience has shown that, on balance, the adoption of these ratings has been
economically justifed as a means of counteracting the following :
High air leakage, due to valve packing failures, joint leaks, etc.
Higher than design pressure loss through the condenser and air extraction pipework.
Excessive steam penetration through the air cooling system.
Adverse efects of part-load operation and low cooling water temperature conditions.
The limiting diference between the condensing temperature and the cooling water deserves
brief mention. This limit is aimed at ensuring reasonable CW outlet-end condensing zone
and air cooling section performance. Most large condensers in operation have temperature
diferences in excess of this Figure; latest thinking suggests that a temperature diference
closer to 5
0
C is desirable if pressure loss on the steamside and/or excessive steam carryover
to the air extraction equipment is not to become a critical factor in determining condenser
performance.
The mechanism of air extraction:- The mechanism by which non-condensable gases
are transported between the points of entry to the condenser shell and the discharge to
atmosphere can be subdivided into three stages :
Transfer of non condensable gases from the main condensing zone to the air cooling
section of the condenser.
Cooling of the non condensable gases and associated steam in the air cooling section.
Extraction and compression of the non condensable gases from condenser vacuum to
atmosphere.
In order to meet the objectives outlined earlier, it is important that all three stages in the
process are carried out efciently.
Details of how this is achieved are described, and the diferent equipment types are
reviewed.
4.8.2.2 The condenser air cooling section
In order for the air cooling section to perform efciently, its position within the condenser and
the method of venting must be optimised, and the transport of non condensable gases from
the condensing zone must be efective.
This ensures that the air cooling process is achieved with minimum pressure loss through
the condenser, and without creating stagnation regions within the main condensing zone or
introducing excessive steam penetration into the air cooling section.
Air cooling sections designed on the frst principle have the basic features of a redistribution
passage for the steam and incondensable gas mixture in the tube axial direction, together
with a bafing arrangement towards the cold end of the condenser to force the mixture
across the tube nest before fnal extraction.
In multi-point extraction condensers, the steam and incondensable gas mixture usually make
one transverse pass of the air cooling section tubes, and no facilities are provided for
reintroduction of the mixture into the air cooling section tube nest.
Condensers with single and multiple water passes, and with single and multiple vacuum
arrangements have adopted both types of air cooling section, and have generally operated
satisfactorily.
The single-point air extraction concept generally requires a higher pressure drop in the
condenser to ensure satisfactory fow through the air cooling section than the multi-point
arrangement, but it reduces the probability of excessive steam carryover to the air extraction
equipment.
With the introduction of air extraction equipment which incorporates a direct contact pre-
condenser, the carryover of steam is not such a critical factor in determining the air extraction
capacity.
Review of air extraction equipment
The main development of air extraction equipment for large condensers has evolved through
the use of air extraction pumps. Steam-jet air ejectors were in common use, but for the
higher pressure and temperature cycles adopted today, these have proved to be less
economic than air pumps, both in capital and running costs.
Many diferent air extraction equipment designs have been developed, all of which combine
the functions of vacuum maintaining and vacuum raising, either in full or in part, depending
upon the volume to be evacuated and the time specifed for synchronising the machine.
It is interesting to note that the last-row blades of turbine will overheat if they run at speed
and at low load in a poor vacuum.
4.8.4.1 Hydraulic air pumps
The hydraulic pump unit is a water-operated ejector, which uses a motor-driven single-stage
recirculating lift pump, and a covered water seal and air separation tank.
The water tank serves the dual function of acting as a heat sink for the air and vapour drawn
from the condenser and providing a suction supply for the lift pump to recirculate the sealing
water.
Make-up water is introduced to the tank at the bottom to replace any losses, and maintain
the tank at a steady temperature. The tank overfow is controlled by a weir, and is discharged
to waste.
The air suction line to the water-operated ejector incorporates an electrically-operated
isolation valve and disc-type non-return valve to prevent backfow of air and water to the
condenser in the event of pump failure. Some arrangements also include a barometric loop
in the air suction line as a further safeguard.
Separate electrical control systems are provided for the hydraulic air pumps and booster
pumps. The operation of the pumps and their ancillary equipment is semiautomatic and
sequence controlled to ensure that start-up and shutdown procedures are correctly
implemented. When common booster pumps are installed, the system is interlocked to
prevent the pumps being connected to a running turbine. Booster pumps are generally
arranged to shut down automatically when the condenser vacuum reaches a predetermined
level.
4.8.4.2 Liquid-ring type air pump
This is essentially a centrifugal displacement pump. A multi-blade impeller revolves within an
ofset casing which is partially full of water. The rotating impeller throws the liquid outwards,
resulting in a solid ring of liquid revolving in the casting at the same speed as the rotor, but
following the shape of the casing.
CONDENSATE & FEED WATER SYSTEM
4.0 Condensate System
A typical condensate system consists of the following :
i) Condenser (including hot-well)
ii) Condensate pumps
iii) Air Extraction System
iv) Gland coolers and L.P. heaters
v) Deaerator
4.1 Condenser
The functions of condenser are :
i) To provide lowest economic heat rejection temperature for the steam. Thus saving on
steam required per unit of electricity.
ii) To convert exhaust steam to water for reuse thus saving on feed water requirement.
iii) Deaeration of make-up water introduced in the condenser.
iv) To form a convenient point for introducing make up water.
Type of Condenser
Condenser is basically a heat exchanger and hence can be of two type :
i) Direct contact
ii) Surface contact
4.1.1Direct Contact Type (Jet Condenser)
In this type, condensation of steam takes place by directly mixing exhaust steam and cooling
water. Requirement of cooling water is much less here compared to surface type. But cooling
water quality should be equal to condensate quality
4.1.2Surface Condenser
This type is generally used for modern steam turbine installations. Condensation of exhaust
steam takes place on the outer surface of the tubes which are cooled by water fowing inside
them
The condenser essentially consists of a shell which encloses the steam space. Tubes
carrying cooling water pass through the steam space. The tubes are supplied cooling water
from inlet water box on one side and discharged, after taking away heat from the steam, to
the outlet water box on the other side.
Instead of one inlet and one outlet water boxes, there may be two or more pair of separate
inlet-outlet water boxes, each supplying cooling water to a separate bundle of tubes. This
enables cleaning and maintenance of part of the tubes while turbine can be kept running on
a reduced load.
4.2.3Description of Condenser for 210 MW (BHEL) Turbines
The condenser group consists of two condensers, each connected with exhaust part of low
pressure casing. These two condensers have been interconnected by a by-pass branch
pipe. The condenser has been designed to create vacuum at the exhaust of steam turbine
and to provide pure condensate for reusing as feed water for the boilers. The tube layout of
condenser has been arranged to ensure efcient heat transfer from steam to cooling water
passing through the tubes, and at the same time the resistance to fow of steam has been
reduced to the barest minimum.
Construction Feature
Each condenser has been sub-divided into upper and lower parts. Front water box, shell and
rear water box constitute the lower part. Two end tube plates and six support plates are
located inside the lower body of the condenser.
Front water boxes have been divided into two parts to make the condenser two pass design.
End covers of water boxes are kept detachable for facilitating repairs and replacement of
tubes. Man holes have been provided for routine maintenance and visual inspection along
with venting and draining arrangement for individual water boxes. Condenser tubes are
secured to the end tube plates by expanding and fanging of tube ends which provides very
good sealing arrangement against penetration of circulating water into the steam space. The
tubes have been so arranged that there is equal distribution of steam on the tube nest with
minimum resistance to steam fow. Non-condensable gases are continuously sucked with the
help of steam ejectors.
With a view to allow relative expansion between tubes and the body of the lower part, lens
type compensator has been provided in the body itself at the rear water box end. This
arrangement prevents deformation of the body and damage to connections between tubes
and end plates.
Upper part of condenser has been designed to allow smooth fow of steam over tube nest. It
consists of mild steal fat walls, strengthened from inside by gratings of longitudinal and
transverse rods and from outside by channels. These rigid bars help the condenser to retain
its shape against atmospheric pressure.
The weight of the condenser and its tubes is taken by the springs and through them by the
condenser foundation. The weight of circulating water and the condensate along with the
thrust of springs during expansion is transferred to turbine foundation.
Special care has been taken for removal of condensate formed as a result of condensation
of steam. Bafe plate have been provided to guide the steam fow on the tube nest and for
collecting the condensate tricking from upper rows of tubes and directing it towards the
intermediate support plates for fowing down in narrow layers, leaving the passage free from
steam fow.
A steam throw of device has been incorporated in each condenser for dumping the steam
into the condenser during start up and sudden load throw of from the set.
4.14Material for Condenser Tubes
Selection of tube material depends mainly on the quality of cooling water and the cost.
Copper bearing alloys are preferred as copper has very high heat transfer coefcient. But as
copper has very little mechanical strength; it has to be reinforced by alloying with other
metals. Copper alloys are basically of three categories : (i) Brasses, (ii) Cupronickel and (iii)
Bronzes.
Stainless steel tubes has also been used and has good corrosion resistance through heat
transfer coefcient is quite lower than the copper alloys. Because of high cost, stainless steel
is used only where water is highly corrosive. Some sea side power plants are also using
Titanium despite high cost, because of highly corrosive environment.
4.15Tube Packing
The method of attachment of the tubes to the tube plate is very important. The tubes being
brass will expand more than the steel shell when the condenser warms up under working
conditions and allowance must be made for this extra expansion when the tubes are
attached to the tube plate.
The method adopted is to allow the tube to slide through the tube plate as it expends. This
means that the holes must be bigger than the tube and, to prevent leakage, the gap between
tube and tube plate must be sealed. Linen or metallic packing are used for sealing purposes.
The packing are held in place by means of ferrules which slide over the tube and screw into
the tube plate. Lines tape treated with raw linseed oil has given very satisfactory service, but
metallic packing is often preferred. Metallic packing gives a frm metal contract from tube to
tube plate./ This, it is claimed, prevents corrosion of the tube ends by electrolytic action,
which is corrosion due to the passage of very small electric currents.
When using ferrules, it is important that sufcient space is left at the end to allow the tube to
expend fully. If ferrules are used at both ends of the tube it is better that fush ferrules be
used at the inlet end to cause least interference with water fow
4.16Expand Tubes
Alternatively, the inlet ends of the tubes may be bell mouthed and expanded. Occasionally
tubes are expanded at both ends and in this case expansion must be allowed for in other
ways, for example by a bellows arrangement built into one end of the condenser.
4.17Tube Nest Arrangement
In addition to designing the condenser to give a low back pressure while using as little
pumping power as possible, it is also necessary to ensure that the condensate is not
undercooled and that the pressure drop of the steam path through the condenser is as small
as possible.
In early condenser the tube bundles were tightly packed together. As a result, little steam
penetrated to the bottom of the condenser, and most of it condensed in the upper parts of
the condenser. Consequently, as the droplets of condensate fell through the condenser tube
nest and struck more tubes, they were cooled below the saturation temperature of the steam.
The frst step in improving the tube nest arrangement was to provide considerable space
around the tube bundles and to incorporate wide steam lanes to allow steam to circulate
freely. The steam can penetrate to the bottom of the condenser to assist the even heat
distribution to the lower passes of the condenser. This design allowed only part, of the
stream to condense in the lower parts of the condenser with the advantage that those
condensate droplets did not have for to travel; those droplets which fell from the upper parts
of the condenser also has to pass through the warn steam., so helping to reduce under
cooling.
A further improvement was the introduction of condensate defectors. These plates or trays
collect the condensate droplets and direct them away from the lower tubes so that they fall
directly into the hotwell again reducing undercooling.
In modern condensers particular care is gives to channelling part of the exhaust steam
directly to the space immediately above the hotwell; the object of this is to recover as much
as possible of its velocity - heat energy to achieve the maximum vapour pressure above the
condensate in the hotwell. Some of this vapour condenses directly on the surface of the
condensate in the hotwell. This belt of higher pressure and higher temperature steam has to
be crossed by the condensate droplets falling into the hotwell, and so their temperature is
increased.
By improving the steam distribution in the condenser the pressure drop across the
condenser has also been reduced. However, with the conventional exhaust arrangement with
underslung condensers, the necessity to pass the top half of the exhaust steam across the
horizontal joint imposes a limit on the degree of pressure recover that can be obtained
economically.
This difculty has been overcome by raising the condenser from below the low pressure
cylinder to the same level as the cylinder. Under conditions, the exhaust steam fows directly
into the condensing surfaces, with the result that the length and complexity of the steam path
is greatly reduced.
4.1.8Condenser leaks
Air leakage into the condenser is one of the main cause of poor vacuum
4.1.8.1 Location of air leaks
The traditional method of locating air leaks when the turbine is on load is to pass a lighted
taper round the joints which are suspected of having a leak. The fame of the taper is drawn
towards the place where the air is being drawn into the condenser.
Thisis a time-consuming technique as the taper has to be passed slowly over every area
where a leak is suspected, and the presence of droughts can make this a very frustrating
job. A quicker way of locating leaks is to spray the suspected area with freon or other
halogen gas. This is then drawn into the condenser and sucked into the air extraction
equipment. If a lighted blow lamp is placed with its fame above the air discharge port on the
air extraction equipment the normally blue fame with change to orange when the halogen is
emitted.
A more modern development of his method is the use of halogen gas detectors. These are
inserted into the air discharge line from the air extraction equipment and meter registers
when a halogen gas passed the detector. A suitable gas (such as freon) is sprayed round the
suspected area until the detector registers.
The disadvantages of these systems are :
a) The operation needs two men : one man spraying, and the other watching the blow
lamp or indicator.
b) Time must be allowed to elapse after each spray so that, if there is an indication, the
operator knows which area that has been sprayed contains the leak.
Of-load leak searches are carried out by flling the condensate system and steam space with
water to a level below the turbine blades. Care must be taken to ensure that the condenser
supports have frst been set in the correct position to cater for the extra load in the
condenser.
Fluorescence is added to the water, and if any leakage takes place the fuorescene can be
detected by the use of an ultraviolet lamp. Leakage is detected by this method, not only at
the condenser mountings, but also on the lower pressure feed heater train.
4.1.8.2 Circulating (Cooling) Water Leakage
There are two kings of CW leakage, internal and external, Internal leakage into the steam
and condensate space is the most important of these two.
4.1.8.3 Internal Leakage
of cooling water into the condensate can be caused by several faults, but the main ones are :
a) Tube to tube plate fxing leakage.
b) Internal corrosion and erosion of the tubes.
c) External erosion of the tubes.
d) Fatigue and stress cracking of the tubes.
The Efects of CW Leakage into the Condensate
Leakage of cooling water into the condenser steam side can have serious consequences.
The CW carries impurities with it, into the condensate system; the most detrimental are
those containing chlorides, such as sodium chloride (NaCl). These impurities are then
carried forward into the boiler.
The presence of chlorides in the boiler water constitutes a potential hazard, principally
because acid chlorides can be formed and boiler tube erosion can result. The higher the
boiler/pressure the greater is the danger. It is, therefore, very important that CW leakage
should be detected., the source of leakage located, and the leak rectifed.
The Initial Indication of a Tube Leak
Fortunately, the impure water has a property which can be utilized to detect it. The impure
water conducts electricity better than the pure condensate and is said to have a higher
conductivity. If the conductivity of the condensate is monitored a changes will be detected
when a leakage of CW occurs.
The practical advantage of condensate conductivity measurement is that it indicates
changes, not only in the actual value but also it increases above the normal running value.
To a plant operator, this often givens the frst indication of condenser leakage.
Where underslung condensers are ftted it is possible to fll the steam space with condensate
containing fuorescence and examine the tube plate with an ultra-violet lamp to fnd the
leaking tube. Where Pannier or integral condenser have been ftted this method cannot
be used if the steam space is flled with water the low pressure cylinder could be under water
The Double tube Plate
On modern turbine plate extensive use is being made of the double-tube plate in an attempt
to reduce the efect of leakage at tube fxing.
The interspace A can either be under vacuum (in which case leakage will be into space) or it
can be with condensate under pressure a leakage from the system. Alternatively, the
conductivity of the drainage from the interspace A can be monitored; an increase indicating a
leaking tube fxing.
4.1.4External leakage
External Leakage from condenser water boxes and joints is usually due to metal removal by
erosion or corrosion. Erosion is the physical removal of metal by excessively turbulent water
(particularly when it contains air bubbles), or by water carrying grit or other suspended
solids. This makes particularly susceptibly those places where water has to change direction
quickly, such as water boxes, or in areas of excessive turbulence due to the throttling action
of valves. Leakage path erosion between the impeller eye and casing of large C.W. pumps
may necessitate the use of wearing rings at this point. An external leakage sources may also
be a broken anode in a cathodic protection system.
Corrosion is the result of electrochemical actin, which can be reduced but cannot be entirely
eliminated. Cast iron condenser water boxes are particularly afected by sea water, which
dissolves the iron content of metal, leaving behind weak and porous graphite in original
shape. The application of protective coatings and cathodic protection adoption help to reduce
electrolytic corrosion. Painting gives some protection to condenser water-boxes, although
adequate surface preparation and coverage is difcult to achieve; severe localised corrosion
may occur where there is a defect in point flm. Natural or synthetic rubber coatings are more
successful and have a longer life, although initial cost is high. An unprotected water box,
however, provides some protection for copper alloy condenser tubes by limited cathodic
protection mechanism. Conversely, successful coating of water boxes accelerates corrosion,
elsewhere, particularly at tube ends. Thus, cooling should extend a short distance into tubes,
or plastic inserts may be placed in tube ends.
Cathodic protection is based on the principle of a corrosion cell if two dissimilar metals are
placed in electrolyte, corrosion of the more electro-negative one (anode) takes place in
preference to the other (cathode). In cooling water systems the iron components from the
anodes and the copper alloys (tubes) from the cathodes. If third electrode, more electro-
negative than the iron and the copper alloys, is added to the system and is electrically
connected to the other two electrodes, the new electrode corrodes in preference to the iron,
or the copper alloys. The system is known as the sacrifcial anode type of cathodic protection
4.2 Condensate Extraction Pumps
Condensate extraction pumps are normally multistage, vertical, centrifugal pumps. They are
generally required to operate on minimum net positive suction head (NPSH). The
condensate pumps operate on few inches of suction submergence. A vent line connects the
hotwell, from where the condensate pumps take suction with the condenser. This equalises
the vapour pressure of condenser and hotwell.
No. of stages in the pump is determined by the discharge pressure required for the
condensate cycle. In 60 MW unit, two condensate pumps, each having 100 % capacity, are
provided for pumping the condensate to deaerator. Condensate water is also used for :
i) Sealing of glands of valves operating under vacuum.
ii) Temperature control of L.P. bypass steam.
iii) Filling syphons of main ejectors and 15 meter syphon of drain expander.
iv) Actuating the forced closing non-return valves of turbine steam extraction lines.
v) Operating of group protection device for bypassing H.P. heaters.
vi) For cooling steam dumped through steam throw of devices.
Pump : TYPE 150CJAV/6, Centrifugal, VERTICAL
SPEED OF THE PUMP- 1480 RPM
Discharge - 276 M
3
/hr.
Discharge head 160 MWC
THRUST Bearing type: Roller bearing 29326
No. of stages - 6,
Motor
Power - 160 KW, Voltage - 6.6. Kv, RPM- 1500,
4.3 Air Extraction System
Air extraction system is needed to extract air and other non condensable gases from the
condenser for maintaining vacuum.
Amount of air to be extracted from condenser during start up is quite large and the extraction
should be done as rapidly as possible so as to allow the turbine to be started.
Under normal operating conditions quantity of air to be extracted is lower. It consists of air
leakage into the condenser via fanges and glands and also of very little non condensable
gases present in steam.
To guard against excessive water vapour extraction along with air, the space beneath the air
extraction bafes has been provided with its own cooling tubes in order to condense as
much water vapour as possible and thus preventing its removal from condenser.
4.4.1Air Ejectors
The operating medium of the air ejector can be either high pressure gas or liquid. In thermal
power stations steam of low parameter (Approx. 4.5 kg/cm
2
, 250
0
C) is used for the air
ejector. The operating principle is simple - steam is passed through a nozzle and the
pressure energy converted into velocity energy. High velocity fuid aspirates air and other
non condensable gases from the condenser and moves into difuser which re-converts the
velocity energy into pressure energy. The pressurised mixture of steam and air is exhausted,
either directly to atmosphere or through coolers to recover the steam in the form of
condensate.
Starting Ejector
Starting ejector is recommended to be used for accelerating the initial pulling of vacuum.
During this period starting ejector operates in parallel with main ejector. When the vacuum in
the condenser reaches 500-600 mm of Hg column, the starting ejector is switched of.
It may be noted that the steam along with the mixture of air and other gases is exhausted to
the atmosphere. Generally starting ejector is single stage and has high steam consumption.
Main Ejector
The main ejector with a standby unit is usually provided for normal operation. The main
ejector is a multi stage . type, the number of stages depends on the cooling water condition.
Steam at suitable pressure is pass through a converging - diverging nozzle and the pressure
energy of steam is converted into velocity energy. This high velocity steam jet entrains air
and incondensable gases and then enters a difuser steam/air mix is then cooled in the fst
stage shell by condensate. Steam is thus condensed, heat in the operating system is partly
recovered, and the steam / air mixture volume is reduced, allowing the second stage nozzle
and steam consumption to be reduced. The second stage cooler can be followed by a third
stage nozzle, and after cooler.
An air measuring device for measurement of air discharge from condenser may be ftted at
the air exit of the ejector. It measures dry air discharge while the condenser and ejectors are
in operation.
4.4.2Air Pumps
In the ejector system high quality steam from the boiler is used by reducing both pressure
and temperature. For example, for running the ejection the main steam from boiler having
140 kg/cm
2
and pressure 540
0
c temp. is reduced to 4.5 Kg /cm
2
and 250
0
c. Due to this
reason the steam operated air ejector, which in other circumstances is perfectly satisfactory,
is not ideal for use in the high pressure, high temperature units. hence, now-a- day air
pumps are being used in the condensers of the 500 MW units.
Air pumps allows greater fexibility as it is not dependent on the boiler for raising vacuum. Air
pumps operates on a separate water circuit and there is no risk of the concentration of
soluble incodensable gases in the condensate. Air pump can deal with either starting and
normal conditions and therefore a separate starting equipment is unnecessary.
Air pumps are basically of 3 types : rotary, liquidating and hydraulic.
a) Rotary Air Pumps
It has two impellers each consisting of a blanking plate mounted on the pump shaft. The
closely spaced blades are attached to the rim of the blanking plate. Sealing, water is fed
from an elevated tank into the compartments.
Trainee Manual on Operation of Turbine and auxiliaries
Trainee Manual on Operation of Turbine and auxiliaries
FEED WATER DEAERATION
Feedwater Deaeration
Feedwater chemistry requirements are stringent with regard to the permissible level of
dissolved oxygen. The main concern is that of minimising waterside corrosion of boiler tubes.
Waterside corrosion and freside corrosion lead to thinning tube walls and the subsequent
risk of rupture by the internal fuid pressure. Feed Water Deaeration fulfls important primary functions :
- It serves as a feedwater heater.
- Feedwater is de-aerated down to the necessary low gas content.
- It acts as a bufer to the fuctuations of condensate feedwater fow that occur in service.
- The rank height provides a hydrostatic heat to satisfy the suction pressure requirements of the boiler feed
pumps.
Feedwater from LP feedheaters is admitted to the twin towers on the tank. Steam, typically
bled wither from the main turbine or boiler feed pump turbine, or taken from the feed pump
turbine exhaust, is supplied for heating and de-aerating the ingoing feed-water. Feedwater,
de-aerated to a boiler quality standard of typically 5 Kg (of oxygen) per kg (of water), i.e., fve
parts per billion.
Design practice has been to install high level plant in an auxiliary plant annexe between the
boiler house and turbine hall, at a level set by boiler house steel-work. Provision of generous
margins over the steady state NPSH requirements of suction stage feed pumps has proved
possible.
Typically, tanks have had a total volume equal to about ten minutes feedwater fow rate, with
an eight minute store to provide a bufer for transients and time to unload the plant should
the condenser extraction pumps fail. The mass of water stores is about half a tonne per
megawatt of plant capacity (i.e., 215-225 M
3
volume of water, about 30 - 35 T for current 60
MW plant).
In summary, this type of combined plant, which is described in detail fulfls important primary
functions :
- It serves as a feedwater heater.
- Feedwater is de-aerated down to the necessary low gas content.
- It acts as a bufer to the fuctuations of condensate feedwater fow that occur in
service.
- The rank height provides a hydrostatic heat to satisfy the suction pressure
requirements of the boiler feed pumps.
PUMPS
Condensate Extraction Pump & Boiler Feed Water Pump
BOILER FEED PUMP
Boiler Feed Pump (BFP) is a multistage pump provided for pumping feed water to
economiser. Generally two pumps each of 100% of total capacity are provided. One pump
will be in operation while the other one serves as resrve capacity.
6.1 Description of Feed Pump (BHEL - 150 KHI series, for 60 MW Unit).
Boiler Feed Pump consists of the following major parts :
1) Pump Barrel
2) Rotor
3) Stator
4) Mechanical Seal
5) Balancing Device.
6.1.1Pump Barrel
The barrel is essentially a cylinder which houses both the stator and rotor. The suction side
of the barrel and the space in the high pressure cover behind the balancing device are
closed by the low pressure cover alongwith the stufng box casings. The brackets of the
radial bearing of the suction side and the bracket the radial and thrust bearings of the
discharge side are fxed to the low pressure covers. The entire pump mounted on a
foundation frame. As the pump handles hot water, sometimes, arrangements are made for
cooling foundation frame to prevent unequal expansion of the frame.
6.1.2Rotor
The rotor of boiler feed pump consists of the shaft, impellers, distance bushes, balancing
disc, supporting rings etc. The axial thrust of the rotor is taken up by the balancing disc.
which is keyed to the shaft in between the two parts supporting rings which are mounted in
the grooves in the shaft. The rotor is supported on two part bearing shells. The baring
brackets are connected to the low pressure cover.
6.1.3Stator
The stator consists of stage bodies. The difusers withe difusing wheels and guide wheels
are assembled to the stage bodies. The end difuser is connected to the outlet stage outside
the stage body. Stage bodies are ftted with wearing rings at the place where it is likely to
come into contact with the wearing rings of impellers, and the wearing rings are secured to
the stage bodies with the help of screws.
6.1.4Mechanical Seal
Sealing of the pump is achieved by a specially designed mechanical seal. It minimises the
loss of the feed water in the stufng box and the working ability of the pump increases. With
the use of the mechanical seal, the cooling is carried out by the circulation of water between
the stufng box space and the cooler. The feed water is circulating in the cooling circuit
through the cooler and back by means of a pumping ring. The coolers are so designed that
water temperature in the stufng box remains below 80
0
Celsius.
6.1.5Balancing Device
As in other multistage pumps, all the six impellers are arranged on the shaft with inlets in the
same direction. This causes a thrust of about 34 Tons in the direction of suction ends of the
pump while running. This axial thrust is taken up by the balancing device. About 10% of feed
water which is not calculated to the guaranteed delivery capacity is taken of
from the space behind the last impeller for operation of the automatic balancing device. The
balance disc is fxed to the shaft and rotates between a renewable seating and the balance
disc cover. The thrust generated by the impellers tends to force the disc agent its seating, but
the high pressure water, bled of the delivery stage of the pump, fows along an annual space
between the hub of the disc and the bush, which is an integral part of the balance disc
seating, to a pressure chamber.
The pressure in the chamber builds up until is exerts sufcient pressure on the balance disc
to overcome the end thrust of the impeller. Water then escapes between the face of the disc
and its seating. The balance disc thus runs on a flm of water and does not come into
metallic contact with the seating. Water leakage across this disc is called balance water and
is returned to the deaerator.
A thrust kingsberry bearing takes over the function of the balancing device when feed pump
is started. The kingsberry shell is forced against the direction of action of balancing disc on
the disc by means of springs located in the kingsberry bearing. By action of springs, an axial
gap of about 1.0 mm is formed between the contract surface of the bearing disc and
balancing disc. The total pull of springs is equal to 500 kg. With the starting of the pump the
axial thrust increases gradually and the thrust kingsberry bearing is in action until the time
when the magnitude of the axial thrust overcomes the pressure of the springs mounted in
mitchell bearings, the rotor will move to the suction side and balancing disc comes into
contact with bearing disc, reducing the axial gap and due to the increases pressure on the
balancing disc, the rotor move to the middle position creating the gap between the balancing
disc and the bearing ring.
Even under worst condition when the rotor moves to the suction side and the balancing disc
is likely to come into contact with the bearing ring before the necessary pressure being built
up on the balancing disc to overcome the axial thrust, a certain amount of water fows
through the axial gap between the balancing disc and the bearing ring and there is no
danger of balancing device getting seized.
It is evident that behind the balancing disc the pressure must not rise, otherwise the
hydraulic equilibrium will be broken and there fore equalising piping must have a sufcient
fow capacity.. For safe operating, the pressure in the equalising piping should be 0.5 to 2
atm, higher than the intake suction branch pressure. When the pressure in the balancing
space rises by 5 atm above suction pressure it is necessary to trip the pump in order to fnd
out the cause of defect and to rectify it.
6.2 Working of boiler feed pump
The water with the given operating temperature should fow to the pump under a certain
minimum pressure (NPSH), water passes through the suction branch into the intake spiral
and from here is directed to the frst impeller. After leaving through the impeller it passes
through the distributing passages of the difuser where it get certain pressure rise and fows
over to guide vanes to the inlet of the next impeller.
This process repeats from one stage to the other till it passes through the last impeller and
the end difusers. Thus feed water arriving into the discharge space develops the necessary
operating pressure, a small part of feed water i.e. about 10% is taken of from the space
behind the last impeller for the operation of the automatic balancing device to balance the
hydraulic axial thrust of the pump rotor.
Typical specifcations of Boiler feed pump (150 KHI Type)
PUMP
No. of Stages 9
Suction Pressure 3.5 ata
Quantity of water for minimum fow 60 Tons / hr.
Head1375 MWC
Discharge capacity 315 T/ Hr
Quantity of water for warming up 6 Tons / hr.
Feed water temperature 144.7
0
C
Consumption of Cooling water 280 LPM
Speed of BFP 2980 rpm
Lubrication Forced, 60 LPM
Stufng box Mech., Seal
Axial Thrust at Designed speed 15 Tonnes
Minimum NPSH 11.7 MWC
MOTOR
Output 2000 KW
Rated voltage 6.6 KV
Current 100 Amps.
Speed 2980 rpm
Frequency / Power factor 50 c/s / 0.914
6.3 Recirculation System
To maintain a reasonable efciency in the pump, running clearances between stationary and
rotating parts must be fairly narrow. Liquid fow through these clearances acts as a lubricant
to prevent seizure. The power input to the pump is partly converted into hydraulic energy due
to the increase in pressure of the liquid. The remaining energy is wasted in the form of
friction, eddies and mechanical losses. This power loss causes slight increase in the liquid
temperature while the liquid passes from suction to discharge. This temperature rise is
maximum at zero discharge and the water soon fashes into steam. Flashing breaks down
the thin flm of lubricating water between the parts and this usually causes seizure. The
trouble occurs so quickly that stationary parts cannot expand as rapidly as the rotating parts,
because they will be heated more slowly, being of greater mass and also exposed to
atmosphere. Greater expansion of rotating parts will reduce the normal running clearance
and aggravate the conditions.
It is, therefore, imperative that sufcient water must be kept moving through the pump to
prevent its temperature from reaching the fash point in the pump when the regulator closes
the main discharge line due to low load or less water requirements in the drum or when the
pump is just started. To ensure this an automatic leak of system is provided between the
pump discharge and the deaerator to establish a minimum fow through the pump. A
solenoid operated diaphragm valve or a motorised valve is installed in the leak of line which
opens when the pump runs at a lower capacity.
the recirculation valve opens when the fow at pump suction is below 70 T/hr & closes when
it increases to 90 T/hr. The fow through reciurculation line is 80 T/hr.
6.4 Warming Up
Centrifugal pumps handling hot water should always be maintained nearly at operating
temperature when idle, If suddenly hot water is admitted into the pump, the relative
expansion of the casing barrel and of the inner element goes through two separate phase.
The inner elements expands faster than the barrel resulting in distortion of the pump. To
avoid this, a small quantity of the medium is always passed through the steam pump for
warm up. Various methods are used for this purpose. In some, the fow is from the suction,
through the pump and out through the balancing chamber to the fash tank. In others, a by
pass across the main discharge non-return valve is provided with a pressure reducing orifce.
The fow is from the discharge and, through the pump and back to the deaerator. Larger the
pump the longer is the time and the larger is the quantity of hot water required for warming
up.
6.5 Variable speed hydraulic (Fluid) Coupling
Some boiler feed pumps including the KHI type are coupled with their driving motor through
a variable speed hydraulic coupling. The hydraulic coupling serves the purpose of controlling
the speed of feed pump for maintaining defnite delivery head and delivered quantity of the
feed water as per requirement of the boiler. This reduces the power consumption particularly
at part load operation.
6.5.1Basic Principle and Operation
A fuid coupling is basically a combination of pump and turbine connected in series.
To rotating impeller energy to the operating fuid. The resultant centrifugal force causes the
fuid to fow outwards whereby the velocity is increased by the impeller. The fow of the fuid
into the runner takes place at the outwards whereby the velocity is increased by the impeller.
The fow of the fuid into the runner takes place at the outer diameter, where the energy is
transmitted from the fuid. The fuid contained in the runner blade chambers then fows
inwards to the centre and back into the impeller blade chambers. This circuit is maintained
by the centrifugal force diference resulting from the speed diference between the impeller
and runner. This speed diference is called slip, which nominally is in the order 1.5 to 3.5%
In contrast to the constant-flled type turbo-coupling, the oil flling of the variable-speed turbo
coupling can be varied between fully flled and drained while in operation. In this way
stepless speed regulation of the drive machine over a large range is achieved when the
coupling operates against the load characteristics. This regulating range is 4:1. remaining
energy is wasted in the form of friction, eddies and mechanical losses. This power loss
causes slight increase in the liquid temperature while the liquid passes from suction to
discharge. This temperature rise is maximum at zero discharge and the water soon fashes
in to steam. Flashing breaks down the thin flm of lubricating water between the parts and
this usually causes seizure. The trouble occurs so quickly that stationary parts cannot
expand as rapidly as the rotating parts, because they will be heated more slowly, being of
greater mass and also exposed to atmosphere. Greater expansion of rotating parts will
reduce the normal running clearance and aggravate the conditions.
It is, therefor, imperative that sufcient water must be kept moving through the pump to
prevent its temperature from reaching the fash point in the pump when the regulator closes
the main discharge line due to low load or less water requirements in the drum or when the
pump is just started. To ensure this an automatic leak-of system is provided between the
pump discharge and the deaerator to establish a minimum fow through the pump. A
solenoid operated diaphragm valve or a motorised valve is installed in the leak of line which
opens when the pump runs at a lower capacity.
The recirculation valve of BFP opens when the fow at pump suction is below 80 T/hr &
closes when the FLOW increases more than 90 T/ hr.
6.4 Warming up
Centrifugal pumps handling hot water should always be maintained nearly at operating
temperature when idle, If suddenly hot water is admitted into the pump, the relative
expansion of the casing barrel and of the inner element goes through two separate phase.
The inner elements expands faster than the barrel resulting distortion of the pump. To avoid
this, a small quantity of the medium is always passed through the pump for warm up. Various
methods are used for this purpose. In some, the fow is from the suction, through the pump
and out through the balancing chamber to the fash tank. In others, a by pass across the
main discharge non-return valve is provided with a pressure reducing orifce. The fow is from
the discharge and , through the pump and back to the deaerator. Larger the pump the longer
is the time and the large is the quantity of hot water required for warming up.
6.5 Variable speed hydraulic (Fluid) coupling
Some boiler feed pumps including the KHI type are coupled with their driving motor through
a variable speed hydraulic coupling. The hydraulic coupling serves the purpose of controlling
the speed of feed pump for maintaing defnite deliver head and delivery quantity of the feed
water as per requirement of the boiler. This reduces the power consumption particularly at
part load operation.
6.5.1Basic Principle and Operation
A fuid coupling is basically a combination of pump and turbine connected in series
The rotating impeller energy to the operating fuid. The resultant centrifugal force causes the
fuid to fow outwards whereby the velocity is increased by the impeller. The fow of the fuid
into the runner takes place at the outer diameter, where the energy is transmitted from the
fuid. The fuid contained in the runner blade chambers then fows inwards to the centre and
back into the impeller blade chambers. This circuit is runner. This speed diference is called
slip, which normally is in the order 1.5 to 3.5%
Boiler Feed Pump
The steady increase in boiler operating pressures, even beyond the critical limit and the large
increase in unit capacity requires that the boiler feed pump should have commensurate
capability to pump the required quantity of feedwater against the needed head. The boiler
feed pump capacity is established by maximum boiler capacity plus a margin plus the
eventual reduction in efective capacity due to ageing. This margin may vary from 20% in
small plants to 5% in the large central stations. The total required capacity must be handled
either by a single pump or more than one pump operating in parallel. Central stations usually
have a single pump of 100% capacity or two of 50% capacity each. To ensure reliability in
service it is usual to have a standby pump of 100% capacity or three pumps in all, each of
50% capacity. The standby pumps are made to come into service automatically on failure of
the running pump.
Net Positive Suction Head
The net positive suction head, or NPSH represents the net suction head at the pump suction,
referred to the pump centre line over and above the vapour pressure of the feedwater. For a
feed pump taking suction from a deaerating heater, the NPSH is equal to the static
submergence between the water level in the storage space and the pump centre line less the
friction losses in the intervening. A margin of safety must be added to the theoretical NPSH
to protect the boiler feed pump against the transient conditions following a sudden reduction
in load for the main turbo generator. The required or minimum NPSH is usually specifed by
the pump manufacturer.
Cavitation and its Efects
The formation and subsequent collapse of vapour flled cavities in a liquid due to dynamic
action are due to cavitation. The cavities may be bubbles, vapour-flled pockets, or a
combination of both. the local pressure must be at or below the vapour pressure of the liquid
for cavitation to begin, and the cavities must encounter a region of pressure higher than the
vapour pressure in order to collapse.
The generation of vapour bubbles will tend to modify the velocity in the rotor passages of the
pump. Further raising of the pump will increase the area of disturbance, until fnally it has
extended completely across the rotor passages. The discharge depends only on conditions
in the suction system and at the rotor inlet.
When a fuid fows over a surface having convex curvature, the pressure near the surface is
lowered and the fow tends to separate from the surface. The separated region contains
turbulent eddying fuid at pressures higher than the vapour pressure. When the pressure is
low enough, the separated region may contain a vapour pocket which flls from the down
stream end, collapses and forms again, many times each second. This causes noise and
vibration.collapse for a sufciently long time. This is called cavitation erosion or
pitting.Centrifugal pumps begin to cavitate when the suction head is insufcient to maintain
pressure above the vapour pressure. The most sensitive areas usually are the low pressure
sides of the impeller vanes near the inlet edge and the front shroud where the curvature is
greatest. As the suction head is reduced, all existing areas of cavitation tend to increase and
additional areas may develop. Apart from the noise and vibration, cavitation damage may
render an impeller useless within a few weeks of continuous operation. Cavitation also tends
to lower the axial thrust of an impeller which could also impair the balancing and produce
vibration.
Pump Drive
Feed pumps for relatively smaller units are driven by constant speed squirrel-cage induction
motors. Feed pump power usually accounts for between one-third and one-half of the total
generating plant auxiliary load. The increase in the size of generating units has resulted in
corresponding increase in the power of the pump drive. In these large sizes conventional
induction motor drives are costly, take up appreciable plant space and impose heavy burden
on electrical supply equipment on pump start-up. For these reasons, large auxiliary drive
turbines and direct main turbine, shaft drives are being considered for higher unit sizes.
These eliminate electrical switching equipment, reduce auxiliary transformer size and also
increase the station efciency.
Variable speed pumping is another alternative. The variable speed is generally achieved by
hydraulic coupling where the two co-axial shafts no longer revolve at the same speed. The
reduction in pump speed in relation to the speed of the drive shaft is controlled by regulating
the amount of oil in the coupling. Torque is transmitted without change. Since power is the
product of torque and speed the pump power input is less than the drive power output. The
energy diference is wasted in heat and means must be found for dissipating the heat. The
energy lost in the coupling at low pump outputs will be much less than the energy that would
be wasted in a throttle valve if a constant speed direct-coupled pump is used.
Some Constructional Aspects
For a given speed, a limit is set on the diameter of the pump impellers by the tip speed of the
vanes. At high tip speeds erosion of the vanes becomes a problem although chrome steel
impellers, help to resist erosion. To achieve a given pressure rise across a pump, the
number of impellers (or stages) is increased since the diameter of the impeller is limited. To
direct the water from one impeller tip to the eye of the next impeller, a stationary difuser is
used. Velocity head imparted to the water by the impellers is converted to pressure head by
the difusers. Each impeller and its associated difuser is termed a stage. The increase in
pressure, or head per stage is proportional to the square of the impeller tip velocity.
A balance valve is used to oppose the axial thrust of the pumps and to preserve the
alignment of the rotor relative to the stationary difusers. The axial thrust is towards the pump
suction end since water fowing through the pump forces the rotor in the opposite direction to
the travel of the water.
Operation
A boiler feed pump will generally not operate at any capacity beyond design condition. In
other words, a boiler feed pump has a very defnite maximum capacity because it operates
on a system-head curve made up of the boiler drum pressure plus the friction losses in the
discharge.
At low values of efciency, typical for feed pumps at the low load portion of their
characteristic, the temperature rise in the feedwater across the pump can be steep. With
extended running at very low loads there is the danger of the pump overheating due to this
phenomenon. Protection of this pump is achieved as load is reduced by the automatic
operation of a leak-of valve initiated by a fow measuring device installed in the discharge
pump with a suitable back up. The leak-of valve closes automatically as the load on the
pump increases. The leak-of fow is discharged to the deaerator. Pressure in the leak-of
piping is broken down by a series of orifce plates.
Boiler Feed Pump - in a Captive Power Plant
Description
The feed pumps are multi-stage machines consisting of suction and delivery castings as well
as stage rings held together by draw bolts. Each stage of the pump consists of stage rings,
impeller and stator. The seal between individual stage rings is ensured by tight ftting of
lapped mating surfaces. The pump shaft is mounted in radial slide bearings and Mitchel type
reversible slide bearing. The bearings are pressure lubricated with oil where it passes
through the stufng box, the shaft is protected with replaceable bushes and sealed with
packing. The stufng box packing is cooled with water. Stufng boxes together with covers
are fxed to suction are delivery casings. Axial thrust of rotary unit is taken over by
counteracting balancing disc and axial slide bearing. The pump is provided with thermal
lagging and steel sheet metal.
Pump Data
a) Capacity = 297 m
3
/hr
b) Head = 1650 MWc
c) Rotary speed = 3724 RPM
d) Efciency = 76%
e) Input power = 1597 KW
f) Motor power
Rating = 2300 KW
g) Wt. of the = 3380 Kg
Pump
h) Wt. of the
base plate = 445 Kg
Axial Thrust Balance Arrangement
The pump is provided with balancing disc to counteract axial thrust or rotary unit. The disc is
fxed to the shaft. It is separated by a small clearance from the balancing disc head, which is
fxed to the casing. The leakage through this clearance fows into the balancing chamber and
from there to pump suction. The back of the balancing disc is subject to the balancing
chamber back pressure where as the disc face experiences range of pressures.
If the axial thrust of impellers should exceed the thrust acting on the disc during operation,
the disc is moved toward the disc head, lowering back pressure in the balancing chamber.
This lowering of pressure automatically increases the pressure diference acting on the disc
and moves it away from disc head, increasing the clearance. Now the pressure builds up in
the balancing chamber, and the disc is again moved toward the disc head until an equilibrium
is reached.
Light Load Protection
The pump is ftted with automatically controlled minimum fow valve to protect it against flling
with steam during low load operation. Minimum fow valve is electro-hydraulically operated by
pressure switch.
Use of Booster Pump
Modern boiler feed pumps operate at speeds considerably higher than 3600 rpm and NPSH
requirement of the pumps are as high as 46 to 76m. In most cases, it is not practical to install
the direct contact heaters from which the feed pumps take suction high enough to meet
NPSH requirements. In such case, a booster pump operating at lower speed such as 1750
rpm is used to provide a greater available NPSH to boiler feed pumps. Booster pumps are
generally of the single stage, double suction design.
Pump Lubrication System
The feed pump consists of two radial sleeve bearings and one thrust bearing. All the
bearings are force lubricated by the main oil pump or auxiliary oil pump. Before the start of
the pump main motor lubrication to the various bearings is supplied through the oil pump. A
flter is provided before each bearing to ensure fow of clean oil. The flters should be cleaned
from time to time. Two coolers are provided in the oil system. One for the working oil and the
other for lubricating oil. Before putting the lubrication system into operation all the oil lines
and bearings should be clean.
Condensate Pumps
Condensates pump takes its suction from the condenser hot well and discharge to the
deaerating heater. (In closed system it discharges into the suction of the boiler feed pump).
These pumps operate with a low pressure in their suction - 1 to 3 mm Hg abs. The available
NPSH is obtained by the submergence between the water level in the condenser hot well
and the centreline of the condensate pump frst stage impeller. Because of the low available
NPSH condensate pumps operate at relatively low speeds.
A liberal excess capacity margin is provided above the full load condensing fow to take care
of the heater drains that may be dumped into the condenser hot well when the heater drain
pumps become not available.
Multistage pumps are used for higher capacity pumps. The drive is constant speed induction
motor.
The most important factor in extraction pump design is the sealing against the ingress of
oxygen into the condensate system. The glands which are under vacuum when the pump is
in service need proper sealing arrangement so that the vacuum is maintained. The gland
connections to the stand by pump should be isolated from the pump in operation. This may
necessitate changing over of the sealing connections when bringing the stand by pump into
service.
Friction losses on the suction side of the pump are kept to an absolute minimum by having
the piping connection from the hotwell to the pump as direct as possible, of ample size and
with as few fttings as possible.
Cavitation in condensate pumps is not very serious concern because the energy level of the
fuid at the point where the vapour bubbles collapse is insufcient to create a shock wave of
a high enough intensity to cause physical damage on the pump parts.
Vertical canister type pumps are also used for condensate extraction service. The main
advantage of these pumps is that ample submergence can be provided without the necessity
of building a dry pit. The fst stage of the pump is located at the bottom of the pump. The
available NPSH is the distance between the water level in the hotwell and the centre line of
the fst stage impeller.
Vertical Turbine Pumps
Vertical Turbines fnd their application in various felds where centrifugal pumps cannot be
used either due to medium, limited suction capacity or due to medium capacity demands.
Vertical turbine pumps are either of radial fow centrifugal Francis type of mixed fow
category having specifc speeds of 130 to 600 metric units. Vertical tribune pump have three
distinct sections.
a) Bowl Assembly
b) Head Assembly
c) Column Assembly
a) Bowl Assembly : One set of impeller and stationary bowl is known as Bowl assembly. Bowl
assembly consists of several identical stages. The impeller may be centrifugal, Francis or
mixed fow type. The impeller can be close or semi open type.
b) Head Assembly : The head assembly consists of the
(1) Base from which the column, shaft assembly and bowl assembly are suspended,
(2) Discharge head elbow which directs water into delivery piping system and
(3) Driver motor.
c) Column Assembly : Column assembly connects the bowl assembly with head assembly
and forms a medium for letting the water up.
Submersible Pumps
These pumps are essentially single or multistage centrifugal turbine pumps designed to form
a compact unit in conjunction with a coupled wet type induction motor, both of which operate
totally submerged below the surface of water.
AIR EXTRACTION SYSTEM
Major specifcation of a typical 150 CJAV/ 6 Condensate Extraction Pump (for 60 MW)
5.1 Pump :
2 Nos. per unit, 2 X 100 %
Multistage, vertical centrifugal pump.
Low specifc sped, medium head
Medium Capacity
Discharge - 276 M
3
/Hr.
Manometric Head -160 MWC
Min NPSH - 2.7 METERS
RPM - 1480
No. of stages - 6
5.2 Motor
Power - 160 KW, Voltage - 6.6 KV, RPM-1500
5.3 Air Extraction System
Air extraction system is needed to extract air and other non condensable gases from the
condenser for maintaing vacuum.
Amount of air to be extraction from condenser during start up is quite large and the
extraction should be done as rapidly as possible so as to allow the turbine to be started.
Under normal operating conditions quantity of air to be extracted is lower. It consists of air
leakage into the condenser via fanges and glands and also of very little non condensable
gases present in steam.
To guard against excessive water vapour extraction alongwith air, the space beneath the air
extraction bafes has been provided with its own cooling tubes in order to condense as
much water vapour as possible and thus preventing its removal from condenser.
5.3.1Air Ejectors
The operating medium of the air ejector can be either high pressure gas or liquid. In thermal
power stations steam of low parameter (Approx. 4.5 kg/ cm
2
, 250
0
C) is used of the air ejector.
The operating principle is simple - steam is passed through a nozzle and the pressure
energy converted into velocity energy. High velocity fuid aspirates air and other non
condensable gases from the condenser and moves into difuser which re-converts the
velocity energy into pursuer energy. The pressurised mixture of steam and air is exhausted,
either directly to atmosphere or through coolers to recover the steam in the form of
condensate.
Starting Ejectors
Starting ejector is recommended to be used for accelerating the initial pulling of vacuum.
During this period starting ejector operates in parallel with main ejector. When the vacuum in
the condenser reaches 500-600 mm of Hg column, the starting ejector is taken out of
operation.
It may be noted that the steam alongwith the mixture of air and other gases is exhausted to
the atmosphere.. Generally starting ejector is single stage and has high steam consumption.
Main Ejector
The main ejector with a standby unit is usually provided for normal operation. The main
ejector is a multi stage type, the number of stage depends on the cooling water condition.
Steam at suitable pressure is passed through a converging-diverging nozzle and the
pressure energy of steam is converted into velocity energy. This high velocity steam jet
entrains air and incondensable gases and then enters a difuser steam/air mixture is then
cooled in the frst stage sheel by condensate. Steam is thus condensed, heat in the
operating system is partly recovered, and the steam / air mixture volume is reduced,
allowing the second stage nozzle and its after cooler (as done in BHEL 210 MW unit) drains
are usually returned to the condenser via suitable loop seals; cooler condensate as a cooling
medium is taken from the extraction pump discharge, with a recirculation arrangement to
avoid overheating of the eject at low loads.
An air measuring device from measurement of air discharge from condenser may be ftted at
the air exit of the ejector. It measures dry air discharge while the condenser and ejectors are
in operation.
CONTROL VALVES & TURBINE LUBRICATION OIL SYSTEM
Turbine Construction
A turbine, which is split horizontally and is of double shell construction. A double fow inner
casing (4.5) is supported in the outer casing (2,3). Steam enters the inner casing from top
and bottom through two inlet nozzles (7) fanged to the mid section of the outer casing. The
arrangement provides opposed double fow in the two blade sections and compensate axial
thrust. The centre fow prevents the steam inlet temperature from afecting the support
brackets and bearing sections. In the arrangement the steam inlet conditions are limited to
the inlet section of the inner casing, where as joint of the outer casing is only subjected to the
lower pressure and lower temperature prevailing at the outlet of the inner casing. The joint
fange is kept small and material accumulations reduced to a minimum in the fange area and
therefore difculties arising from deformation of a casing with fange joint due to non-uniform
temperature rises during start-up and shutdown can be avoided.
The inlet and extraction nozzles are provided with sealing rings to provide a tight seal as well
as arrangement permits the inner casing to move freely in all directions. The inlet nozzles (7)
and the extraction nozzles (6) are bolted to the outer casing (2,3).
Due to the diferent temperature of the inner casing relative to the outer casing, the inner
casing is attached to the outer casing in such a manner as to be free to expand axially from
a fxed point and radially in all directions, while maintaining the concentricity of the inner
casing relative to the shaft. The steam inlet connections and the extraction connections are
designed to avoid any restrictions due to thermal expansion, the inner casing is attached to
the outer casing in the horizontal and vertical plane.
The stationary and moving blades are provided with T-roots. The moving and stationary
blades are inserted into the shaft and inner casing respectively. Sealing strips are pressed
into the inner casing and the shaft to reduce leakage losses at the blade trips.
Shaft seals are provided to seal the interior of turbine casing against the atmosphere at both
ends of the turbine. The sealing between the rotating and stationary elements of the turbine
is achieved by means of seal strips which are pressed into the individual sealing rings. The
prevailing pressure is reduced by converting the pressure energy into velocity energy which
is then dissipated as turbulence as the steam passes the large number of strips.
1. Turbine rotor
2. Outer casing, upper part
3. Inner casing, lower part
4. Inner casing, upper part
5. Inner casing, lower part
6. Extraction Nozzle
7. Inlet Nozzle.
Fig. showing the turbine Cross Section - Double Shell Type
Steam Strainer
Steam strainers are installed in the main steam lines and in the hot reheat lines from the
boiler. They protect the admission elements of the HP and LP turbines from foreign object
which could be picked-up in the boiler or associated piping. The strainer is used for both
initial commissioning of the turbine and for regular operation. The strainer is generally made
of corrugated strip wound on a frame.
Steam Chest
Steam is admitted to a turbine from the superheater outlet via the high pressure steam main
to the steam chest. The steam chest normally houses the steam strainer, emergency stop
valves and governing valves in case of small capacity turbines. It consists of a steel casting
or sometimes in the case of very high steam conditions of a solid forging.
Main Stop and Control Valves
The main stop valve is provided as the main check valve between the steam circuit and
the turbine and can interrupt the supply of steam to the turbine extremely quickly. The
function of the control valve is to control the amount of steam admitted to the turbine in
accordance with the load requirements of the unit.
Main Stop Valve
Steam enters the valve casing (14) via the inlet connection above the main stop valve disc
(2). A pilot valve, integral with the valve stem (10) operates inside the main stop valve disc.
Packing rings (6) seal the valve stem where it passes through the valve body. The valve disc
has a back seating arrangement which is forced against the base bushing (3) and when the
valve is fully opened forms the seal at this point. This also provides additional sealing for the
passages of the steam. Steam and valve disc are prevented from rotating the valve body (4)
which is secured in the valve casing (14) by means of the threaded ring (8). The main stop
valve is opened hydraulically by servomotor (13) and closed by spring force (1).
Control Valve
The control valve disc is integral with the stem (17). The efort required to open the valve is
reduced by relief holes in the valve disc. Valve disc and steam (17) are guided by bushings
in the valve body (18), the steam being sealed by packing rings (21). Additional sealing is
provided by the back seating arrangement of the valve disc which lies against the base
bushing (20) when the valve is wide open.
As with the stop valve, the valve body (18) is secured in the valve casing 9145) by a thread
ring (23) and sealed by the shaped seal ring (22). The control valve is operated by the piston
of the actuator (29) which is opened hydraulically and closed by spring force (3).
HP Control Valve Servomotor
Each control valve is driven by separate unilateral acting servomotor. The servomotors are
opened by real oil pressure and shutdown with a help of springs. Control oil is supplied
under the controlling slide which with its edges controls the oil pressure under the
servomotors piston.
The restoring mechanism of the servomotors is of hydraulic type. The slide of the restoring
mechanism is driven from the servomotors pistons by the cam system. The position of
servomotor is univocally determined by control oil pressure.
Stop Valve Servomotors
The stop valve are driven by separate servomotors. The servomotor is opened by the oil
pressure and closed spring. The oil line controlling the servomotor is connected to the
central safety line through the hand operated trip device of the turbine.
Lubrication oil system
Essentially oil is required for lubrication of bearings. This requires only a small quantity of oil.
However, shaft conductivity, surface friction and turbulence set up in the oil produce a
considerable amount of heat and to keep the bearing temperature constant at the desired
level a large quantity of oil is circulated to remove this heat.
The pressure of oil supplied to the bearing is in the order of 0.5 to 2./0 kg/cm
2
(g). This
pressure is required to ensure that the pressure in upper part of the bearing does not fall
below atmospheric and cause discontinuity in the oil flm. ON the other hand if oil pressure is
too high, the oil will be sprayed out from the ends of the bearings at a high velocity and will
become atomised and my easily escape from bearing housing.
The temperature of oil must be kept within limits. If the oil temperature entering the bearing is
too low, inefcient bearing lubrication will occur due to high viscosity. If the oil temperature on
leaving the bearing is too high, this will lead to deterioration of the oil due to high rates of
oxidation Generally the oil temperature entering the bearing is in the range of 38
0
C - 45
0
C
and outlet temperature is maintained about 55
0
C to 60
0
C by adjusting the supply of oil to
each bearing. To allow adequate adjustment generous piping diameters are used and
removable orifce plate is often provided.
The turbine oil system fulflls the following functions
(a) Lubricating and cooling the bearings
(b) Driving the hydraulic turning gear (if provided instead of A.C. motor driven turning gear)
(c) jacking-up the shaft at low speed
(d) Oil supply to hydraulic governing system
Control oil for hydraulic governing system is required in the pressure range of 4-15 kg/cm
2
(g)
depending on the system design. In case oil for the control system is to be supplied from the
lubricating oil system, the total oil is pressurized to such high pressure and then lubricating
oil is drawn of through a reducing valve. This method is often adopted for its simplicity, and
also relays automatically close the stop valve if lubricating oil supply fails but there is some
additional pumping energy.
The operating and environmental conditions of steam turbine required use of specially
compounded lubricating oil to ensure the physical and chemical properties are retained over
long period of operation. Lubricating oil is a complex mixture of chemical compounds, mainly
hydrocarbons. When hydrocarbons are exposed to heat or impurities like air, water, dirt, etc.
the oil has a tendency to oxidise. The rate of oxidation is dependent upon the rate of
exposure. Oxidation usually leads to the formation of sludge, which gets deposited in various
parts of the lubrication system in the area of low temperature and points of low turbulence.
Water is the most common contaminant of oil and may enter the lubricating system from
leaking shaft glands or from the condensation of humid air in reservoirs, bearing pedestals
or drain lines.
The high surface speed of turbine bearings generates high temperature in the lubricating oil
flm due to high rate of shear. Thus an oil with a comparatively low viscosity is use for turbine
oils to keep the local temperature below a level where a high rate of oxidation would occur.
On the other hand oil with a very low viscosity would result in discontinuity in the flm at high
temperatures and pressures. The viscosity of oil is normally chosen as compromise between
these conficting requirements. A typical value is 150 Redwood seconds at 38
0
C.
Although mineral oils usually posses good resistance to oxidation, foaming and
emulsifcation and have good anti-rust properties, the extreme requirements for the modern
stem turbine lubricating oil are usually met by the addition of inhibitors to a high quality base
oil that is selected for its high degree of chemical stability coupled with a capacity to absorb
the additives.
Properties of Turbine Oil
The properties of oil used for turbine shall be as per the recommendation of the turbine
manufacturer. A typical properties of turbine oil in use is given below.
1) Kinematic Viscosity at 50
0
C : 28 Centi Stokes
2) Inorganic acidity : Nil
3) Organic acidity : max. 0.14 mg of KOH per gm of oil
4) Nautralisation No. : Max. 0.20 mg of KOH per gm of oil
(Total Acidity)
5) Specifc gravity at 50
0
C : 0.852
6) Flash point : Min 200
0
C
7) Pour point : (-) 6
0
Celsius (max)
8) Rust preventing Characteristics : Negative test passed
9) Deaeration capacity at 50
0
C: 6 minutes (max)
10) Ash (5 by weight) : Max. 0.01
11) Water content : Below the limit of quantitative detectability
12) Mechanical solid : Below the limit of quantitative detectability
13) Emulsion characteristics : 40.40.0 (20 minutes)
14) Foaming characteristics (max) :
a) at 24
0
C : Nil
b) at 93.5
0
C : Nil Volume in ml. of foam after
c) at 24
0
C after testing : Nil 10 minutes foam collapse
at 93.5
0
C
Schematic Arrangement of Turbine lubricating Oil System
Under normal operating conditions, the main oil pump (1) situated in Front bearing
pedestal and coupled directly to the turbine shaft draws oil from the main oil tank (2) and
supplies it to the pressure oil system.
The suction of the main oil pump is aided by two injectors. The injectors produce pressure at
the suction connection to the main oil pump. This guarantees that the main oil pump takes
over the supply of oil and cavitations that could occur due to greater suction heads are
avoided. The amount oil required for driving is extracted from the pressure oil circuit and
adjusts by means of throttles (31,32)
The oil for the hydraulic turning gear (6) is also extracted from the pressure oil system. Oil is
admitted to the nozzles by opening the shut-of valve (16).
The pressure oil is cooled in the oil coolers (30) and reduced to lubricating oil pressure in the
throttle (28). The throttle is adjusted on initial start-up.
The amount of oil required for each bearing is adjusted on start-up by means of the oil
throttles (13).
During turning gear operation and start-up and run-down operation, one of the two three-
phase A.C. full-load auxiliary oil pumps (24, 25) supplies the pressure oil system and takes
over the function of the main oil pump when it is not in operation because the turbine is
running too slowly.
The full-load submersible auxiliary oil pumps are situated on the main oil tank (2) and draw
in oil directly. Check valves behind the auxiliary oil pumps and in the suction line of the main
oil pump prevent oil from fowing back via pumps that are not in operation.
When main and full-load auxiliary oil pumps fail, the lubrication oil supply is maintained by a
D.C. driven emergency oil pump. This pump supplies oil directly to the lubricating oil line, by
passing the oil cooler and thus preventing damage to the bearing shells.
The full-load auxiliary oil pumps and the emergency oil pump are automatically started
control as soon as the pressure switch limit has been reached. The pressure switches are
set in sequence so that the pumps can be started in succession if necessary. The function of
the pressure switches arranged in the lube oil circuit is to operate the main trip valve when
the lube oil pressure drops below a set valve. The lubricating oil from the bearings is
returned to the main oil tank via a header. A loop in the return oil piping behind the seal oil
serve tank (15) prevents H
2
- gas reaching the main oil tank (2) when there is a disturbance in
the seal oil system. The main oil tank is designed to be air tight. The extractors (18) produce
a slight vacuum in the main oil tank and the bearing pedestals to draw of any oil vapour. Oil
for the combined journal and thrust bearing is passed through the duplex oil flter (17) which
can be switched over and cleaned during operation.
System Components
Main Oil Pump
The main oil pump is driven by the turbine shaft either directly or through gears. For many
years the normal type of pump used on turbines has been the gear pump. This requires no
priming and provides positive oil displacement but must be driven through reduction gears at
about 400 rpm. However, on large turbines the quantity of oil used makes it economical to
incorporate a centrifugal pump driven directly by the turbine shaft, thus overcoming the need
for large and expensive gear wheels. The efciently of centrifugal pump is comparable to
that of gear pump, but it is not self priming and requires an oil injector to overcome the
suction head both when starting and during running.
the main oil pump located in the front bearing pedestal supplies the entire turbine generator
oil requirement. If the turboset is out of operation or the main pump fails, the auxiliary oil
pumps also supply oil in the suction branches of main oil pump until the main oil pump
takes over. The oil pump capacity is fxed by the total amount of oil required by the bearings,
seal and governing system together with a liberal margin. The pump shaft (20) runs in a
journal bearing (3) and the combined journal and thrust bearing (11). Both bearings are
lubricated from the pressure chamber of the main oil pump via oil lines.
Auxiliary Oil Pump
The auxiliary oil pump is a vertical single-stage centrifugal pump with a radial impeller and
spiral casing. It is fxed to the cover of the oil tank motor that is bolted to cover plate (1). The
oil enters the suction connection from underneath and is supplied to the oil system via the
pressure pipe (18). The pump shaft has a sleeve bearing (12) in the pump casing and a
grooved ball bearing (7) in the bearing yoke.
The bearings are lubricated from the pressure chamber of the pump, the sleeve bearing via
a bore in the casing the grooved ball bearing via a lube oil line.
D.C. Emergency Oil Pump
The emergency oil pump is of the vertical, centrifugal, submerged type and serves for
lubrication and cooling of the bearings during emergency conditions. The unit is located on
top of the main oil tank and driven by a D.C. motor./ The complete pump - motor assembly is
attached to a mounting plate which is bolted to the top of the main oil tank.
Main Oil Tank
The main oil tank contains the oil required for lubricating, and control systems of the turbine.
It not only serves as a storage tank but also for deaerating the oil.
The capacity of the tank is such that the full quantity of oil is circulated not more than 8 times
per hour. This results in a retention time of approx. 7 to 8 minutes from entry into the tank to
suction by the pumps. This time allows sedimentation and detrainment of the oil.
Oil returning to the tank from the oil supply system frst fows through a submerged inlet (9)
into the riser section of the tank where the frst stage of deaeration takes place as the oil
rises to the top of the tank. Oil overfows from the riser section through the oil strainer (6) into
the adjacent section of the tank where it is then drawn of on the opposite side by the suction
pipe or the oil pumps.
Turbine Lube Oil Cooler
The efciency of an oil pump may be of the order of 55% and remaining 45% of the pump
input energy generates heat in oil. The oil also absorbs a large amount of heat from bearing
friction and shaft conduction. To remove this heat the oil is passed through coolers which
reduces the temperature to the required for bearings.
The cooling water enters and leaves through the lower water box which is divided by a
partition plate so as to force water through one half of the tube system to the upper water
box and from there through other half back to lower water box. Closed end tubes are
arranged in tube system in line with the partition plate to avoid oil by-passing. Inlet and outlet
branches of water box are provided with thermometers. When flling in oil, vent valve is
opened. For draining the shell, drain valveis provided.
Oil Vapour Exhauster
The function of the exhauster provided on main oil, tank is to produce a slight negative
pressure in the main oil tank and in the bearing casings and thus draw of oil vapour.
The casing is constructed as a spiral with aerodynamic features and is provided with
supports for the exhauster. The motor is bolted to the cover of the casing. The exhauster
wheel, cast in light metal, is situated on the free end of the shaft. The ball bearing serves as
a horizontal guide for the exhauster shaft.
Turbine Oil Purifcation System
During the lubrication cycle, the turbine oil comes in contact with water, air particles and
other foreign materials. These impurities cause a steady deterioration in the lubricating
properties of the oil. These impurities if not removed may damage the TG bearings and
hydraulic control system elements. To prevent such happenings, a on-line turbine oil
purifcation system is installed. The efcient conditioning of turbine oil, the purifcation system
must operate on continuous basis because purifer operating only part time permits
accumulation of undesirable contaminants. Generally continuous by-pass type turbine oil
purifcation system is used to ensure trouble free operation against turbine oil contamination.
A certain amount of turbine oil from main oil tank is led to the purifer so that desired quality
of turbine oil can be maintained in the main lube oil tank. The over fow sight ftting near the
turbine oil tank is adjusted to achieve required fow to the purifer unit and to maintain the
normal operating level in the oil tank.
The capacity of turbine oil purifcation equipment is generally selected to handle on hourly
fow rate equal to about 20 per cent of the total oil in the system which includes the turbine
lube oil reservoir capacity at normal operating level plus fow back when the unit is
shutdown.
Types of Oil Purifers
Basically there are two types of oil purifer viz. Static type and Cetrifuge type are most
frequently used since they can efectively remove water as well as solids.
Static Type Oil Purifer
Static type oil purifer will have three compartments viz. precipitation compartment, fltration
compartment and storage compartment. In the frst stage of operation, gross free water is
removed by setting in precipitation section and smaller droplets coalescing on the screens.
Precipitated water settles in a through on base from where water is removed. In the second
stage i.e. if fltration compartment oil fows thorough cloth covered flter elements from
outside to inside. There flter elements remove foreign matter down to 35 microns size and
also break-up the coarser water emulsions. Oil passes from the interior of these flter
elements through a manifold into the storage compartment of purifer in the third stage. From
here oil is pumped by purifer oil circulation pump through fne polishing flter, which removes
matter down to 5 microns and also coalesces any remaining free water. At this stage more
than 99.9% of the original free water will have been removed leaving clean and moisture free
oil to be discharged back to turbine main oil tank.
Static type oil purifer do not require an oil feed pump when purifer is located below the
turbine oil tank, and oil feed from the turbine oil tank is by gravity. However, in case purifer is
located at an elevation such that the gravity feed from turbine oil tank to the purifer is not
possible, purifer feed pump is provided along with one auxiliary oil tank between turbine oil
tank and purifer. This also gives an additional storage capacity to accommodate the excess
fow back of turbine oil.
Centrifuge Type Oil Purifer
Centrifugal type purifer have a high speed rotating bowl where oil to be purifed is fed down
through the center of the bowl. The bowl contains many conical shaped discs which divide
the oil into extremely thin layers. Centrifugal action separates oil, water and solids. Solids are
thrown
Directly to the bowl wall and may be removed by cleaning during purifer shutdown or during
operation, depending on the centrifuge design. The oil with its lighter density is displaced
inward. Water and conditioned oil are discharged through separate openings. Purifer unit is
provided with an indirect type electric heater to preheat the oil entering the centrifuge device
for purifcation. The heating of the oil fowing through the spiral tubes is done by water stored
in the shell which is in turn heated by electric immersion heaters. The heater unit is insulted
by glass wool and provided with thermostats for automatic cutting in the cutting out to
maintain the oil temperature.
The purifer is equipped with a dirty oil feed pump to feed the dirty oil into the centrifuge and
a clean oil discharge pump to deliver the clean oil to the lube oil tank. Both pumps are of
rotary gear type and generally driven by a common driver motor. At the discharge end of
each clean oil pump, a polishing flter is provided, which is capable of removing all the solid
particles upto a minimum size of two microns and the moisture or vapour cloud in the oil by
stripping action.
Control Oil System
A common lubrication and control oil system provides a simplifed system as a single pump
is used to supply the lubricating oil quantity required for the turbine bearings and for the
hydraulic relays. The single pump usually generates an oil pressure of 10-15 ata to suit the
relay gear and the lower pressure required for the bearing oil is used after pressure
reduction. The oil pressure in the relay system is usually limited to approximately 15 ata
when lubricating oil is used, in view of the fre risk, if a serious oil leak occurred. When higher
steam pressure cycles are adopted or when large steam valves are used this limitation on
operating pressure necessitates the use of large diameter relays which are difcult to
accommodate and maintain. The reduce the size of the relays, a higher relay pressure must
be adopted. The adoption of higher fuid pressure also has the advantage of improving the
steam valve response and thus reduces the transient speed rise on load rejection.
When higher relay pressures are used on large capacity turbines say 500 MW and above,
fre-resisting fuids will generally be adopted. Water-based fuids are available, such as a
water solution of ethylene glycol, but they usually lack many desirable properties as hydraulic
fuids. The most common fre resisting fuids in use today are based on phosphate esters
with various additives to improve their viscosity change with temperature and their hydraulic
stability. The fre resisting fuids are relatively sensitive to degradation in service, due to
contamination, by water lubricating oil and humid air, and by exposure to high temperatures.
Care is taken in the design of the hydraulic system to ensure a reasonable replacement life
for the fuid. Where a freresistant fuid is used, the governing hydraulic system is entirely
separate from the lubricating oil system.
The control fuid system essentially compresses oil tank (main lube oil tank in case of
common fuid for lube and control system or a separate control fuid in case of fre resistance
fuid for control system), the control fuid pumps, and motor connecting piping. The control
fuid system is generally split-up in high pressure (HP) control fuid system and low pressure
(LP) control fuid system.
The HP control fuid is supplied in all operating modes by one of the 100% HP oil pumps
installed in the main oil tank. At pump discharge the HP control fuid is branched of to
various points of use. The HP oil pumps are generally designed as multistage centrifugal
pumps to meet the system requirements for HP control fuid.
The LP control fuid for the turbine and bypass control system is supplied in normal operating
mode from the turbine driven main oil pump (in case of common oil for lube and control
system) and during start-up from one of the auxiliary LP oil pumps. The LP control fuid is
routed to the speed governor cabinet where it is used to supply the hydraulic control and
protective equipment. Hydraulic signal lines lead either directly or via the control fuid supply
units from the control cabinet to the actuators of the valves concerned.
Jacking Oil System
When the turbine is started up or shutdown, the jacking oil system is used to maintain the oil
flm between rotor and bearings. The necessary torque from the turning device or from the
manual turning device is reduced in this way. The bearings are relieved by high pressure oil
that is forced under the individual bearing, thus raising the rotor. In order to avoid damage to
the bearings, the jacking oil pump must be switched on below a certain speed.
The jacking oil pumps are generally jack-screw immersion pumps situated on the main oil
tank to supply the high pressure oil for the lifting device. Generally two 100% capacity
jacking oil pumps are provided. The oil ids drawn of directly by one of the two a.c. motor
driven 100% pumps. The pressure oil piping of the lifting oil pump that the jacking oil system
from damage due to improper switching on of the jacking oil pump when the check valve is
closed a spring-loaded safety valve is situated in the piping between the jacking oil pump
and the check valve. The necessary pressure in the system is kept constant by means of the
pressure limiting valve. The pursuer limiting valve can be relieved by the bypass valve. The
superfuous fow from the pump is conducted into the main oil tank.
The necessary jacking oil pressure are set for each bearing by the fne control valves in the
oil pipes. Check valves in the jacking oil pipes prevent oil from fowing out of the bearings
into the header during turbine operation when the jacking oil system is naturally switched of.
TURBINE GLAND SEALING SYSTEM
Introduction
Gland are provided in all turbines where the shaft leaves the casing. Labyrinth glands are
most widely used for the purpose of minimizing the steam leakage. Each gland comprises a
bush A which is in halves, bolted together. These bushes are located by machined surfaces
at each end of the cylinder and are provided with some form of labyrinth packing. In the type
of gland illustrated the Hp gland is furnished with three separate groups of packing, namely,
B situated between the frst-stage and the leak-of pocket H, C between H and the vapour
hood J, and D between J and the atmosphere. There are three group of packing in the LP
gland, namely, E between the stem pocket K and the exhaust space, F between K and the
vapour hood L, and G between L and the atmosphere. In general, group B contains the
largest number of packing rings, while group E contains the next largest. Group
C and F are made similar, also D and G; but the number of constrictions in C and F will
usually be greater than those in diagrammatically in Gig. 69, and in the operation of such
connections it may be said at once that the steam pressure in pocket K must be continuously
maintained at a valve slightly above atmospheric. There is a free connection between
pockets H and K, and under normal load conditions, most of the steam which leaks past
group B enters pocket K of the Lp gland. Some of this steam fows into the turbine through
group E and the rest fows outwards, so preventing leakage of air. If the steam pressure in
the pocket H is excessive, e.g. under full load or overload condition, then the valve M may be
opened just sufciently to maintain a slight fow of steam through the vapour pipes. At light
loads the steam pressure in the fst stage will fall to such an extent that there will be
insufcient steam available to seal the Lp gland. Under these conditions, live steam is
admitted to both glands through the valve No.
In some cases, the HP gland is provided with an additional pocket on the cylinder side This
is connected by an external pipe to a suitable stage of the turbine where the pressure is
normally well above atmospheric. Thus a part of the leaking stem is able to do work in the LP
stages of the turbine. It will be seen that there are now four separate groups of packing in the
HP gland. The steam connections are shown and do not call for much explanation. Live
steam is supplied continuously to the LP gland so that its performance is not afected by load
changes. The pressure in the pocket K is then controlled by opening the valves P or Q,
according as the turbine load is heavy or light.
In tandem turbines the HP glands are usually provided with two or even three tappings, the
steam being led either to latter stages or to feed-water heater, according to the conditions.
Live steam connections are also ftted for steam sealing at light loads. As superheated boiler
steam is used for the purpose, its temperature after wire drawing is very high indeed and it
any be advisable to desuperheat the steam before supplying it to the glands. The LP turbine
is supplied with steam-sealed glands or hydraulic seals.
Type of Labyrinth Packing
System Description
To eliminate the possibility of steam leakage to the atmosphere or air leakage to the
atmosphere or air leakage into the cylinder from both the ends of the turbine cylinders
through which the rotor shaft has come out, labyrinth glands generally of radial clearance
type are provided which ensure a trouble free, frictionless sealing. Each gland seal consists
of a number of sealing rings divided into segments; each segment is backed by two fat
springs. The sealing rings are housed in grooves machined in gland bodies which are in turn
housed in the turbine casings or bolted to the casing at the ends.
a) Steam to turbine glands is supplied from auxiliary steam header during start-up,
b) Low load and no-load operation of steam turbine.
c) Above approximately 40% turbine load, sealing steam from auxiliary header is not
required as turbine become self-sealing.
Gland sealing steam is supplied to the sealing chamber at a pressure of about 1.03 to 1.08
kg/cm
2
(abs) and temperature at 180
0
to 200
0
C from sealing steam header, where the steam
pressure is maintained constant. The air-steam mixture from the last sealing chamber is
sucked out with the help of two (one working and the other standby) gland steam exhaust
fans through the gland steam condenser to the atmosphere.
HP-LP Bypass System
and Factors Afecting Turbine Reliability
The permissible temperature diference (T
p
) is determined on the basis of expected load
cycle on turbine thermal fatigue, strength of material, and the geometry of the components.
Permissible temperature diference is derived from function generators, built into analogue
computing circuits.
The temperature margins are evaluated in an analogue computing circuit and displayed on
instrument as positive or negative temperature margins upto synchronisation and as load
margins after synchronisatin. The display meter also indicates the component which is
critical at any given moment
HP - LP Bypass System
A limiting factor for start up of large size steam turbine using steam parameters in line with
present day practice is the thermal stress due to temperature changes in thick walled
components. By the uncoordinated operating phases primarily during any mode of start
upon, to allow the boiler to build up matching steam temperatures independent the turbine.
The steam generated by boiler that the turbine is unable to accept during start-up is
conserved within the power cycle past the turbine and thus loss of steam into atmosphere is
cut down to the barest minimum level. Bypass systems enable short start-up times to be
achieved so that even large steam turbines can be operated for higher economy and
particular, restarted in a minimum time. Apart from this instead of tripping the whole unit
following total loss of export load, the set can be kept on spinning with house load and his
ensures the availability of machine for a much higher loading rate after the elimination of the
electrical system fault within reasonable period of time or establishment of an alternative
channel or power export.
The HP-LP bypass station in our country are generally about 60% of boiler capacity. The Hp
bypass system consists of parallel branches that divert steam from the main stem line,
ahead of the main steam valve to the cold reheat line. Similarly the LP bypass system also
consists of branches to carry steam from the hot reheat line to the steam throw of devices in
condenser.
HP Bypass System
The HP bypass valves can regulate the main steam pressure by controlling the amount of
steam bypassed from the main steam line to the cold reheat line. The temperature control
spray water valve serve to control the temperature of steam discharged by HP bypass
system, and spray water pressure control valve controls the spray water pressure,. The
following control loops are made use of for the automatic operation of the HP bypass
scheme to achieve the above functions.
a) Main steam pressure control loop which positions the HP bypass valve according to a
set point for MS pressure from a motorised set point station.
b) Independent steam discharge temperature control loop, one for each branch of the
HP bypass steam. These loops position the spray water temperature control valves. These
valves have a common set point.
c) Spray water pressure control valve according to a set point for the pressure of spray
water.
d) Interlock and Protections
The HP bypass valve will receive a closing signal if the:-
i) Bypass valve is less than 2% open and the bypass station is in manual mode.
ii) Down stream temperature exceeds adjustable present valve.
ii) Steam discharge temperature of any branch of the LP bypass is too high.
iv) Spray water pressure to steam dump device is low.
General Start-up and shutdown procedure
Start-up and shutdown procedure to be followed shall be as per the specifc instructions for
operation and supervision furnished by the turbine manufacturer. The above aspect can be
summarized in a general way as follows :
Factors Afecting Turbine Reliability and Availability
Turbine reliability and availability result from a combination of two major factors.
a) The inherent reliability of the machinery as designed and manufactured
b) The extent to which installation procedures, environmental conditions and operating
practices enhance or degrade the inherent reliability of the equipment
Major causes of tribune Forced Outages.
In case of turbine major causes of forced outage are steam deposits, water induction,
lubrication system problems, governing system problems, miscellaneous turbine valve
problems, miscellaneous turbine electronics problems, etc.
a) Steam Path Deposits
With respect to the problem of steam path deposits, the most common efects are :
i) Reduction in turbine efciency by as much as 10% in some cases
ii) Reduction in turbine fow capacity
iii) Sticking of valve steam and control parts
iv) Increase in thrust forces by as much as 200% in serve cases
v) Embrittlement and cracking of critical steam path parts
vi) Stress corrosion cracking of wheels and shafts
vii) Excessive over-speed.
Some common steam contaminants which have potentially harmful efects on the turbine are
sodium chlorides, sodium sulphides, sodium sulphate and silica. Although deposits which
plug fow passage area can be extremely troublesome, the long term efects of contaminants
which cause corrosion or cracking can be potentially more disruptive. In this case the
problem can sometimes be complicated by the fact that contaminant accumulations may bot
be readily apparent.
Fundamentally, control of the introduction of corrosive and deposit forming materials into the
turbine is not a design problem but basically this is an operating problem and the solution
lies in the area of better plant design, operating control and close monitoring of peripheral
water treatment equipment and procedures.
b) Water Induction in Steam Turbines
Modern large steam turbines are, designed for efcient, reliable operation. This requires high
pressures and temperature with resulting heavy metal sections in the early stage, moderate
clearances between rotating and stationary parts and long buckets in the last stages. The
accidental induction of water in any part of the turbine can cause the following damages:
(i) Thrust Bearing Failure
Water carry-over from boiler will increases the thrust load to the point where thrust
bearing may fail. The actual amount of thrust increase can be 10 times than normal. The
greater density of water as compared to steam, prevent its proper acceleration. The relate
velocity of water is therefore backward against the buckets instead of through them and a
large pressure drop across the bucket develops.
(ii) Thermal Cracking
Thermal cracking results from either extremely high thermal stresses or from either
extremely high thermal stresses or from repeated thermal stresses of lesser magnitude. In
some cases there may appear to be no noticeable permanent dame after water has been
admitted, but if repeated several times cracks may develop.
(iii) Rub Damage
Water introduced from the main steam and reheat lines can cause diferential
expansion problems between the rotating and stationary parts in the form of axial rub. Water
induction from extraction lines and cold reheat lines will cause contraction of the shell lower
half, that can lift diaphragm packing against the rotor causing radial rubs.
(iv) Permanent Warping or Distortion
Permanent warping or distortion of metal parts may result when subjected to severe
quenching.
(v) Secondary Efects
In addition there may be secondary efects such as axial rubbing after a thrust bearing
failure or damage to bearings, foundations and oil lines cause by turbine vibration due to
heavy rubbing or blade damage.
In order to avoid water induction, the following operation procedure shall be observed :
1) Operators shall be instructed to take care of all level alarms by taking prompt actin to
prevent water entering the turbine.
2) Periodically test alarms and valves.
3) Do not operate heater if some of the protective devices are known to be faulty.
c) Lubrication System Problems
The third major contributor to turbine forced outage downtime is the lubrication system
including bearings. While such things as dirty oil, sludge, water contamination etc. are
occasional contributors to problem, the two factors are failure of lube supply and bearing
damage or failure.
Turbine Preservation
If a turbine stand idle for a long period it is liable to corrosion attack which may cause
deterioration of the components. During long idle periods when the turbine has cooled to the
ambient temperatures, all components which come into contract with steam vapour, water or
damp air are liable to corrosion attack. Chemically corrosive gases and vapours are seldom
encountered in normal power stations to cause damage. However, if a turbine is installed in
or near a chemical plant it may be possible for such gases and vapours to increase the
amount of corrosion. Generally the water has been responsible for corrosion in turbine which
have been cooled down and idle for some time. The rusting loss increases sharply when the
relatively humidity is high. Therefore, to prevent corrosion attack in an idle turbine, the
relative humidity of the enclosed air shall be maintained below 50% as far as possible.
It is essential that no steam shall enter the turbine while it is idle. Any auxiliary steam lines
which will remain under steam pressure during a complete unit shutdown shall be isolated in
a manner which ensures that no steam can enter the turbine. The turbine itself and its
connecting pipe work must be well drained throughout the idle period. It is also preferable to
drain the condensate from the condenser. There are basically two methods of preventing
corrosion attack caused by condensation from the air inside the turbine.
a) The turbine components can be heated by means of a hot air blower to a temperature above
that of outside air. The high relative humidity air inside the turbine can be exchanged for dry
air. Regarding the preservation of turbine oil system, generally the turbine oil contains
corrosion inhibitors therefore it is not necessary to adopt any special measures to preserve
oil carrying components except to operate auxiliary oil pump for an hour at intervals of two to
three weeks.
STEAM WASHING OF TURBINE
During unit operation, deposits on the turbine blades occur to a greater or lesser degree
depending on the steam purity and the pressure and temperature of the operation steam.
These blade deposits will result in reduction in turbine efciency due to changes in the fow
profles and thicker boundary layers in the steam fow as a result of rough surfaces. In
extreme cases the fow area of turbine may get reduce with consequent reduction in the
maximum possible output. Salt deposited are water soluble and can be removed by purging
with saturated steam. Silicate deposits are either water soluble (e.g. alkali silicate) or occur
as hard water insoluble coating, depending on their composition. In case of hard silicate
deposits, the deposits can only be removed mechanically during overhauls.
The process of saturated steam washing is simpler as compared to opening the turbine.
Therefore, in case reduction in turbine efciency is observed, frst saturated steam washing
shall be performed. Steam washing is started when casing temperature drops below 100
Deg. C. During steam washing, the initial saturated steam temperature is kept as low as
possible. Steam washing with a constant steam condition is not very efective because after
a certain time, the turbine balding reaches the temperature of the washing steam and the
condensation that brings about the efect is lost. To make the steam washing more efective,
the steam temperature shall be increase in stage by increasing the pressure. As the
temperature is raised, the turbine speed will generally increase, however, care shall be taken
to avoid critical stem range. The steam entering the condenser shall be condensed during
the entire process and therefore one circulating water pump shall be in operation.
During steam washing process condenser can be either kept under
atmospheric pressure or at sub-atmospheric pressure with ejector in operation. The
condensate condensing in the condenser shall be discharged to the atmosphere. Sample for
fnding out the salt when the turbine generator unit would be started up and loaded after
steam washing. Any dissolved salt residues remaining on the blading will be blown out due
to the high velocity of the steam under load condition.
On-Line Turbine Blades Washing
The practice of washing steam turbines without disrupting operation, when there is suspicion
of a soluble-salt deposit on the blades, it popular in Europe. This is accomplished by
decreasing the load and reducing superheated steam temperature and boiler pressure
according to a carefully prepared programme. Efect is to modify substantially the ratio of dry
to wet turbine blades along the turbine path. In a relatively short time salt deposits are
dissolved from the blades which ordinarily operate in a dry condition, then temperature and
pressure returned gradually to their normal values.
The entire washing process can be followed by measuring rate of deposit removal, either by
means of a conductivity recorder or by sampling the efuent every fve or ten minutes.
Examination show also that a considerable amount of insoluble deposits is removed,
apparently because of the high-velocity blast of wet steam. After an initial period which
requires some additional staf, the process usually can be carried out over-night by the
normal operating staf. The operation can be performed when starting from either full load or
no load, although it seems preferable to start from a loaded condition.
TURBINE OPERATION
1.0 Introduction
Economical operation of a turbine plant is largely dependent on its operational safety. A
criterion for operational safety is the availability of the machine.
The availability is principally afected by the damages occurring with the parts of the turbine.
The monitoring of the operations serves the purpose of preventing such damages and
troubles or, at least, limiting them. Operating conditions that are likely to result in damage to
the machine either immediately or after a few recurrences, have to be remedied by an
appropriate change in the operating schedule as soon as the hazard becomes apparent.
Safety or protective devices are employed for monitoring those operational quantities which
in the case of a disturbance are changing at a quick rate. Appropriate counter measures will
be automatically released by these devices as soon as the monitored quantities are attaining
a critical limit.
The operating personnel should attempt to apply the measures described in the instructions,
in order to safeguard the turbine plant against the hazards of damage, of automatically or
manually released shutdown, or of outage.
In the fulfllment of their task, the personnel have the recordings of operational values at their
disposal. The actual readings of the instruments should be compared with the normal
reference values in order to obtain reliable information of the actual operating conditions of
the turbine. If the measures taken by the operating personnel for protecting the turbine from
a dangerous condition are failing, the specifed emergency measures have to be taken. This
must be done even in cases where the correctness of instrument reading or alarm release
value is in doubt.
It is necessary for the operating personnel to understand the turbine operation vis-a-vis
loading in general to appreciate the turbine control system.
Main steam fow and load can be controlled varying the active nozzle area of the frst stage
(nozzle control) or by varying the steam pressure at the inlet of the frst stage nozzle
(pressure control). The frst method is called partial arc admission or multivalve point
operation, and the second is called full arc admission or single valve point operation. In the
later instance, the steam fow is controlled either by throttling on the governor valves
(constant throttle pressure operation) or by varying the throttle pressure while holding the
governor valves in a fxed position.
With full arc admission, the frst stage, turbine cycle efciency is higher with sliding throttle
pressure operation than with constant throttle pressure operation because the valve throttling
is eliminated and the boiler feed pump power is reduced. Sliding throttle pressure can also
improve low load efciency of partial arc admission designs. In this instance valves are
successively closed as the load is initially reduced from the maximum value. When a specifc
valve point is reached, the valve position is held constant and further load reductions are
achieved by reducing the throttle steam pressure. This is sometimes called the hybrid mode
of operation. Published studies have shown that the optimum transfer point from constant to
sliding throttle pressure operation occurs when one-half the governor valves are wide open
and on-half are fully closed, about 70 percent load corresponding to 50 percent active are
admission on the frst stage.
Operation in the hybrid mode results in higher efciency for practically the entire load range,
except above 95 percent load, as compared to full arc admission, sliding pressure designs.
Moreover as compared to constant pressure, partial arc admission operation because of the
smaller change in the frst stage exit temperature. In addition, the load response approaches
that of constant pressure operation during sliding throttle pressure operation and is much
faster than that of sliding throttle pressure full arc admission operation.
2.0 Normal Operation
2.1 Guidelines for Turbine Operation
During operation the turbine operator has to take readings at the measuring points indicated
in the log book at least once every hour and in addition to this check all relevant remaining
indicating instruments between intervals. This mainly concerns :
- all steam, oil and water pressures
- all steam, oil and air temperatures.
- all steam and water fow rates
- the casing temperatures
- the indications of the vibration recorder
- the valve lifts
- the generator load
- the relative shaft displacement
- the thermal expansion of the casing
- the thrust bearing.
It is not sufcient, however, that the readings are entered in the log book, but it is the
operators duty to detect from the records in good time where and to what extent a variation
in the reading has occurred which result from conditions other than operational ones. In such
a case the operator has to take appropriate measures or immediately inform his superior if
he is unable to obtain a clear picture as to the conditions.
In such cases it should be generally heeded that if necessary the relevant measuring
instrument should frst be checked as to whether the reading is correct before further
measures are taken.
Any irregularities or precautionary measures taken during operation or observations made
should also be recorded by the operator on duty in an appropriate manner in the log book. In
addition to this the starting and slowing down periods, all work carried out on the turbine and
measures taken during standstill periods should as well be recorded in the log book.
2.2 Monitoring
In an efective monitoring much more is involved than just a data collection and recording.
Data, once acquired, is inert until it has been analysed and the analysis is of little value until
it has been interpreted. Interpretation generally involves either comparison with acceptable
values or the application of experienced judgement.
Some conditions which refect the physical well-being of the machinery are amenable to
quantitative on-line measurements with available tools or instruments. Other conditions must
be evaluated by some from of inspection which requires removing the equipment from
service with or without partial disassembly.
Useful data is furnished in the following Figures for operators guidance :
3.0 OPERATION UNDER ABNORMAL / EMERGENCY CONDITIONS
As a general guidelines for Turbine Operation, the operating personnel have to be always
alert and ever ready to meet any abnormal / emergency conditions. Various abnormalities
and exigencies usually faced during turbine start-up, shutdown and normal operation are
explained below with possible causes, plant response and operator action.
3.1 Boiler-Turbine Steam Temperature Mismatch
(Applicable for Hot or Warm Starts of Turbine)
Steam temperature at ESV must be atleast 50
0
C higher than the metal temperature of
turbine. Admission of steam at lesser temperatures cause sudden negative expansions of
turbine rotor, opening of HP or ESV fanges and cause thermal shock to turbine. Every such
start deprives the turbine of a portion of useful life.
Operator Action
- Consult starting curves for steam temperature matching.
- Do not roll turbine under mismatch, conditions.
- During hot rolling, efort should be made to load turbine quickly.
- During every rolling and loading of the set, continuously watch turbine diferential
expansions.
3.2 Water Hammer in Main Steam Line
Possible Causes
- Water carry over from boiler.
- Inadequate draining at the time of charging main steam line.
- Water entry from spray systems of pressure reducing and desuperheating stations.
Plant Response
- Water hammering can result in damage to steam lines and hanger supports,
connected valves or even steam turbine.
- Live steam temperature drops suddenly.
Operator Action
- Open all drains wide.
- If main steam temperature is below 450
0
C ensure that turbine has tripped.
- Trip boiler in case of water carry over.
- Close spray control valves on attemperator stations.
- Check heater levels.
3.3 Rapid Change of Steam Temperature at Turbine Inlet
Possible Cause
- Steam temperature at turbine inlet must increase (or decrease) slowly. Rapid increase,
coupled with rapid changes of load will lead to high positive (or negative) diferential
expansions in turbine cylinder, causing dangerous situations, seal rubs etc.
Plant Response
- High diferential expansions.
- Turbine HP, ESV fanges may open causing steam leakage.
- Thermal shock to turbine.
Operator Action
- Control steam temperatures in boiler by spray, excess air etc.
- If temperature rises or falls rapidly, to control efects on turbine, load may be increased
or decreased depending on conditions (combined boiler-turbine efect)
- At temperature above permissible (say 563
0
C). Turbine to be tripped, if situation
persists for more than 15 minutes.
3.4 Control Valves Malfunction
Possible Causes
- Problems in control valve linkages, closing of one or more control valves, hunting etc.
This may be mechanical problem or choking in servomotor ports, air locks in oil control
system etc. Malfunction of mechanical feedback mechanism of the control valve servomotr.
Plant Response
- Load hunting.
- Load cannot be increased.
- Speed fuctuations till synchronising. Secondary oil pressure fuctuation.
Operator Action
- Immediately bring to the notice of a competent Turbine Maintenance Engineer for
check up and advise.
- Trip unit, if no advice is readily forthcoming.
- Check up whether primary oil pressure is steady at the pressure corresponding to 3000
rpm. Secondary oil pressure variation may cause primary oil pressure disturbance. Attention
to be paid of the above type of occurrence.
3.5 First Stage Pressure High
Possible Causes
- Salting in the turbine blades.
- High loads when HP heaters are not in service or when LP heaters are not in service
- Operating with low steam temperature on high loads or with full open servomotor
control valves.
- Overloading of machine
- Change in the magnitude of the axial shift.
Plant Response
- Axial shift may increase.
- Thrust load on turbine increases with possible premature wear of thrust pads.
- Extraction pressure at selected points may increases.
Operator Action
- Reduce load immediately to restrict frst stage pressure.
- If salting in turbine is suspected, plan for a turbine steam was during next cold start-up.
- Bring in heaters.
- Check steam purity in boiler. Maintain steam purity. Trip unit when abnormal steam
quality condition exist.
- Boiler drum water level normal (high level frequently causes carry over).
- Maintain boiler steam parameters consistent with turbine load as per
recommendations.
3.6 Turbine Vibrations High
Possible Causes (Only transient reasons considered here)
- Steam inlet pressure and temperature sudden changes, (not as per recommendation
with respect to load etc.)
- Lub oil temperature and pressure too high or too low after the oil coolers, destroying oil
flm under the bearings.
- Gland steam temperature low.
- Temperature diference between top and bottom cylinders exceed permissible
valve(50
0
C) during start ups or during steam parameter and load changes.
- High turbine diferential expansions/over all expansion.
- High axial shift.
- Low vacuum/high exhaust hold temperature.
- Rotor eccentricity high.
- Sudden load changes.
Plant Response
- Turbine vibration increases.
Operator Action
- Ask turbine vibration instrument reading to be cross-checked by portable instrument
and also by feel.
- Listen to bearing sounds using an acoustic probe.
- check gland steam temperature and maintain at normal valve.
- Open gland steam dumping valve to condenser for drainage of possible condensate.
- Maintain steam parameters as per recommendations. Adjust turbine load to suit.
- Check lub oil pressure and temperature after oil coolers. Maintain as per
recommendations.
- During start-up, particularly during hot restarts open drains, select low parameters,
warm up cylinders thoroughly and follow starting procedures carefully to avoid top and
bottom to narrow down the diference. Barring gear must have been in operation atleast for a
few hours before a warm start. Trip the turbine if temperature diferential cannot be
controlled.
- High diferential expansions. Control boiler steam parameters rate of change of load
etc.
- High axial shift (Refer to next item no. 3.7)
- Vacuum/ exhausthood temperature high (Refer item no. 3.1.3 below).
- Do not roll turbine when eccentricity exceeds 7 micron when on barring gear. Trip
running turbine if eccentricity exceeds 2 micron.
3.7 Axial Shift High
Possible Causes
- Abrupt changes of load.
- Sudden drop of vacuum.
- sudden closure of HP heaters.
- Sudden closure of NRV in extension steam line.
- Lub oil failure to thrust bearing.
- Fast pick up of load.
- Turbine overload.
- Salting in turbine.
Plant Response
- Seal rubs can be expected at extreme values. Metallic sound from turbine when
interference exists.
- Possible increase in turbine vibrations.
Operator Action
- Improve condenser vacuum.
- Increase the boiler steam temperature or load turbine fast.
- During rolling, if possible, choose lower steam pressure.
Caution :
When turbine diferential expansion is at extreme negative when the machine has already
been rolled, tripping is not an ideal solution as it would worsen the situation. Boiler parameter
correction, rapid loading are better alternatives mismatch of steam parameters or already
when negative expansion is predominant. However, if turbine is tripped, break vacuum
immediately to reduce possible damages.
3.8 High Positive Turbine Diferential expansions
Possible Causes
- High steam temperature for rolling.
- Too fast rolling or too fast pick up of load.
- Inadequate soaking during rolling as well as during turbine loading.
- Gland stem temperature high.
Plant Response
- Same as in item no. 3.7
Operator Action
- Reduce vacuum.
- Reduce boiler steam temperature.
- Hold turbine load (soak)
- Check and control gland steam temperature.
- In case of high positive turbine expansion, tripping turbine will help in reduction, break
vacuum to reduce damage.
3.9 Turbine Eccentricity High
Possible Cause
Defection of turbine rotor either due to improper heating during start-up, improper drain of
steam lines contribution water entry to turbine, abrupt drop of main steam temperature due
to water carry-over from boiler, moisture in gland steam deformation of cylinders, disengaged
barring gear etc.
Plant Response
- Turbine vibration increases, unusual noise from turbine.
Operator Action
- Follow start-up procedure regarding steam parameters, draining of steam lines,
soaking times etc. strictly.
- Before rolling turbine, see that eccentricity does not exceed 7 micron and while running
not more than 20 micron.
- See that lub oil temperature is maintained between 40
0
C and 45
0
C.
- Check quality of lubricating oil, bearing temperatures of running turbines etc.
- Keep spray control valves of bypass system properly isolated on an idle turbine.
Note:Minor increased in eccentricity can be reduced by either prolonged barring gear operation
and if that is not possible, rotating shaft by 1800C at regular intervals, sometimes, if
possible, running at 500 rpm for 3 to 4 hours can reduce eccentricity.
3.10High Bearing Temperature
Possible Action
- High lub oil inlet temperature.
- Excessive vibration of bearing.
- Bearing failure, excessive clearance.
- contaminated lub oil (thick moisture, dirt etc.)
- Inadequate oil fow or low lub oil pressure.
Plant Response
- Bearing failure and turbine failure will result in case of operation for long periods at
high bearing temperature.
Operator Action
- check and maintain correct lub oil fow, pressure and temperature to bearing.
- Periodically analyses lub oil for moisture contamination etc.
- Check return oil for contamination and temperature.
- Verify babbitt temperature by other means (to rule out faulty instrument)
- Check axil shift, if thrust bearing temperatures are higher.
- Check bearing for vibrations.
- If bearing vibrations are high, and if bearing temperature continues to be higher than
75
0
C, reduce load to see if situation improves, otherwise trips unit.
3.11Turbine Over-Speed
Possible Causes
- Failure of stop valve and control valves to close in case of turbine trip.
- Emergency governor failure at the time of Overspeed.
- In case of turbine trip, the non-return valves of extractions not force closed, resulting in
steam admission through extraction lines.
- High grid frequency.
- Governing system failure
Plant Response
- If turbine overspeeds, turbine is likely to get destroyed causing serious damage, to
mean and machinery in the vicinity.
Operator Action
- Periodically check overspeed test mechanism as per recommended schedule (without
actually tripping, while turbine is working).
- Check atleast once in three months actually overspeed trip by simulation. This is a
must after every major overhaul of turbine.
3.12 High CW Temperature.
- This problem may be acute either during summer (high ambient) or when number of
CW pumps available is less. The major criterion is the diference of temperature of CW outlet
water from condenser over its inlet. This temperature should not exceed design data value.
- Possibility of air lock in cooling water lines at condenser outlet.
- Dirty condenser tubes will also cause this by reduced heat transfer.
Plant Response
- Fall of vacuum.
- Possible tube failures in condenser.
Operator Action
- Try to increase CW to condenser by starting additional pumps, or by fully opening
valves or working pumps.
- Deaerate by opening vent valve in CW outlet.
- Reducing load on unit if necessary to reduce CW outlet temperature.
- Start reserve ejector.
- During a shutdown, clean condenser tubes.
- Take hourly readings of CW inlet and outlet, pressure and temperatures in condenser.
- Restrict steam dump to condenser (HP bypass). Check temperature of dumped steam
to condenser (start-up conditions mainly.
3.13 Exhaust Hood Temperature High
Possible causes
- Fall of vacuum in condenser.
- CW pump failure.
- High steam parameters during cold start-up.
- Running at 3000 rpm without synchronising generator or at low load for long periods.
- Steam dumping valve(HP bypass) spray failure at low loads.
- High load from steam dump to condenser at low vacuum or steam dump at high
temperature.
Plant Response.
- Diferential expansion may go excessive (negative side).
- Prolonged high exhaust hood temperature may lead to vibration, unusual sounds from
turbine loosening of shrunk ft rotors.
- Blade erosion.
Operators Action
- Open exhaust hood spray valve MC-7.
- Increase CW fow if found low (criterion temperature diference between inlet and
outlet).
- Try to improve vacuum (vacuum and high exhaust hood temperature form a vicious
circle).
- HP drains connected to hotwell can be reduced.
- Reduce steam dumping to condenser.
- If possible, synchronise generator and raise load.
- Charge LP heaters as quickly as possible.
- Try to reduce boiler pressure and temperature during rolling so as to give a large mass
fow through the turbine.
- Check gland steam temperature and pressure. Regulate to recommended values.
- If all the above measures are not successful, trip the turbine, break vacuum, cool down
the exhaust hood restore diferential expansions to normal and then restart machine.
3.14 Turbine Trip
Possible Causes
For the causes of turbine trip refer item no. 3.14A to 3.14D as given below.
3.14A Exhaust Steam Pressure High
In the event of rise in exhaust steam pressure i.e. fall in condenser vacuum, the temperature
of the exhaust steam will increase and may possibly damage the last rows of balding and the
condenser tubes, since under the temperature infuence the tubes will expand excessively
and possibly buckle. To take care of this a protective device is used.
Three pressure switches are used in this protection PS5-1 set at 0.6 ata for high exhaust
steam pressure (low vacuum annunciation to alert operator. PS5.2 and PS5.4, both are set
at 0.8 ata and used with AND gate for tripping TG set on Class-B protection. The trip signal
from pressure switches goes to main trip solenoid valve (2222).
The setting of the vacuum trip is dictated by the ability of the last stage turbine balding to
withstand the high temperature conditions that arise when operating at a poor vacuum.
Operation of the vacuum trip should be checked during shutdown of the TG set. If the TG set
is shutdown frequently, the vacuum trip can be checked when vacuum is broken and no
special test will be necessarily.
3.14B Condenser Hotwell Level High
For condenser hotwell level regulation, certain controls are used which maintain the level
constant at desired value. I however, level rises upto air zone from where suction to air
extraction equipment is taken, extraction of air from condenser is afected due to blockage of
air zone with water. This causes fall in vacuum with efect on turbine as described above.
Two level switches LS 4.4 and LS 4.34 are used with AND gate for tripping TG set on
Class-B protection when condenser hotwell level is very high (2.2 meter below centre line).
The trip signal from level switch goes to main trip solenoid valve (2222)
3.14C Exhaust Hood Safety Diaphragm
The exhaust hood is ptotected from over-pressure by rupture diaphragm. In the event of
positive exhaust hood pressure, the diaphragm is forced against knife edge. If pressure
continues to increase, the diaphragm would eventually be ruptured by the knife edge and
pressure is relieved. It ruptures at 1.5 times of atmospheric pressure.
Since non-destructive testing of the diaphragm is not possible it should be inspected during
outage for overhaul to establish that the knife edges are sharp and are free from corrosion.
3.14D Turbine Axial Displacement
Turbine axial displacement (thrust bearing wear detectors) indicate the position of the rotor
relative to the standard cap at the thrust bearing. Also, the indicate which thrust plate is
loaded, by Comparison of successive readings over a period of time, the thrust bearings
wear can be determined. In addition, the detectors are used for alarm and tripping the TG set
in the event of excessive wear on thrust bearing.
Two turbine axial detectors are employed for the protection of TG set. One is mechanical and
another is electronic.
3.14.D-1 Mechanical
This acts directly on emergency trip gear. Two cams are provided on turbine shaft at
emergency trip gear. By an axial displacement of the turbine rotor either of the two cams lifts
the tripping lever so that emergency trip is brought into action to trip the TG set. This is set at
1.0 mm axial displacement.
3.14D-2 Electronic
The detailed description of this detector is given in Turbine Supervisory Instrumentation.
This is set at 0.5 mm axial displacement for annunciation to alert operator and at 0.8 mm for
tripping the TG set.
3.14D-3 Bearing Temperature High
Turbine and generator bearings are provided with thermocouples for monitoring bearing
temperatures These are set at 80
0
C for high temperature annunciation and at 110
0
C for very
high temperature TG set tripping.
Plant Response
- Turbine trip initiates boiler and generator trip.
Operator Action
- As a preventive step, follow instructions under appropriate item concerning the cause
of turbine trip so as to avoid such trips.
- Action after trip - as for unit trip.
4.0 DOs and DONTs
4.1 DOs and DONTs for Turbine Operation
Sl. Equipment DOs DONTs
1) Emergency Once in every month
Governor. overspeed to be
checked with the help
of emergency governor
testing device, for
free movement of pin
With the help of
accelerator 1117 speed
can be increased to
overspeed.
The period may be
once a year or may be
during long shutdown.
2. Steam leak- Observe the steam Dont operate the
machine
ages through leakage if any in the if steam leakages
are
steam joints. system during running. heavy, in critical
areas
Excessive steam leak- like balancing piping and
ages cause damage to gland steam, which may
turbine internals cause unbalancing steam
Apply Molykote paste fow across the blades.
to all moving parts Increase in thrust due to
provided for grease bearing and blades.
injection.
3) Control In stand still Dont open steam
inlet
valves condition check for valve during this
check
easy and smooth
valve operation by do not apply grease/oil
operating the starting to the valve spindles.
device.
Verify lift valve for If the valves are found
full open position of jammed in a particular
valve. position, dont operate
machine till it is
If turbine is in rectifed.
operation for long
time with unaltered
valve opening (un-
altered load). Check
for smooth movement
of valve spindles by
short actuations, the
speeder gear or by
varying the load on
driven machine.
4) Oil level Maintain the level in During running the
level
tankthe tank when the in the tank should neither
machine is stationary go below minimum and
and observe the level nor above maximum.
in running condition also.
5) Oil Check oil samples Dont operate the machine
quality once in a month with excessive
water
a month. content in the oil until
It is centrifuged for
Water accumulation in removal of water.
the tank to be removed
in stand still condition.
When pump is not in
operation, the water
collected from bottom
of tank.
6) Oil Diferential pressure Dont operate with
flter(DP) to be maintained clogged flters since
around 0.8 kg/cm
2
- high diferential pressure
1.5 kg/cm
2
. can result in damage of
flter elements and less fow
If DP exceeds, change of oil to the bearings.
over to stand by flter
and clean the main flter.
Rotate the plate Dont open the drain plug
flters in governing when pump is in operation.
oil line in operation
and cleaning of the
same in stand still
condition at the time
of shutdown.
7) Oil Observe oil tempe Dont operate cooler with
coolers rature diference reduced cooling
efect.
across cooler and
also CW temperature.
Change over to stand
by cooler if temperature
diferential reduces because
of cooler tubes clogging.
Clean the coolers
once in a year.
Isolate on cooling
water side when oil
pump is not in service.
8) Holding Do check the freeness Dont adjust the
down bolts. of washer on holding clearances while
the
down bolts which is machine is running.
approximately 0.1 mm.
Keep the washers and Dont continue running
holding down bolt, while washers are tight
dust free and clean. and vibrations are increasing.
Apply Moiykote powder.
9) Casing Check smooth expansion Dont change loads
if
expansions. during load changes, they cause jerky
movement
increases of load during of casing while expanding.
start up of the set. Clean the sliding path.
Left and right sides of
front bearing pedestal to
indicate equal expansion.
10) Steam jet air Maintain rated parameters Dont operate with
higher
ejectors. to obtain vacuum. Check parameters as they
may
the proper operation of cause damage to nozzles.
the heating condensate Dont operate without
drain traps to turbine condensate fow through
condenser. ejector.
11) Main oil Pumps. In standstill condition Dont operate the
machine
during long shutdown. in abnormal variation/
fuctuation in discharge
pressure by 1 kg/cm
2
at
the rated speed.
Check coupling between Do not operate fast while
gear box and turbine governing/ MOP taking over
shaft so as to avoid hunting.
Free rotation of the pump
and governor shaft.
Back lash between gears.
Ensure smooth and gradual
operation of governor/MOP
taking over.
12) Turbine Check centering and bearing
bedding at the time of major
shutdown after long operation.
13) Control desk. Do check the adjustment Dont meddle with
follow
values before frst rolling up piston springs.
of turbine and after
shutdown Dont do any adjustments
during running.
14) Servomotor. Before starting the machine Dont adjust any
values
check up the start of on servomotor when it is
opening and full lift of the in operation.
servomotor by operating
the starting device.
Also check up the free Dont run the set
rotation of pilot valve. continuously with servomotor/
governor valves spindles
Chattering or hunting too
much.
15) Gland steam Maintain gland steam dont increase the
gland
pressure at rated value. steam pressure above
Do maintain the gland normal. It may damage
steam pressure till the turbine gland fns.
(vacuum) falls to minus
0.2 atg while shut down.
Admit the gland steam
after allowing (vacuum) of
Minus 0.2 atg.
Proper control must be
ensured while crossing
critical speeds and sudden
variation of loads.
16) Protections. Always keep all protections Dont bypass any of
the
in the line and ensure their trips and interlocks as
working before startup. they are meant for
protecting the main
equipment.
Adjustment, if any, should
be done only in stand
still condition.
17) Vibrations. Do ensure that vibration Dont run the
machine on
indication is O.K. high vibrations continuously
till the fault is evaluated
and rectifed.
Do check the centering
and alignment if vibration
increase.
18) Bearing oil Maintain oil temperature Dont continue to
run the
after oil cooler between machine if bearing
40-40
0
C during operation. temperature exceeds 80
0
C
till the fault is rectifed.
Dont run the machine if
inlet oil temperature is
going below 35
0
C.
19) Turning gear Always put on turning Do not operate
turning
gear during machine gear without oil in the
coasting down and gear sum of barring gear.
ensure stoppage of
turning gear after turbine If turning could not be
is rolled. done with in 20 min. of
stopping dont try for
Ensure lube oil to bearing barring further allow the
and normal operation of rotor for natural cooling
jacking oil pump before upto ambient temperature.
putting turning gear into
service whatever provided. Do not restart running gear
till the above fault is
evaluated.
Continue turning gear
operation till the casing
expansion comes to
within one mm or casing
temperature. comes
below 100
0
C.
20) Temperature Monitor oil temperature
measuring at bearing inlet and outlet.
Compare indicated values
with that of First
Commissioning report.
If the diference between
inlet and outlet temperature
increases abruptly then :
i) analyses the reason
for the same and/ or
ii) Stop the machine and
check up the bearings.
21) Emergency Test the emergency Do not start the
machine
tripping trip gear for proper with defective
tripping
device. functioning. device.
i) at the time of
shurting down
ii) before restarting,
iii) at the time of
inspection by
a) opewrating the knob
or lever,
b) remote operation.
Ensure instantaneous
closing of control
valves and emergency
stop valve.
22) Auxiliary check up the oil
oil pumps pressures in the
governing and lube.
Oil circuits before
every start and during
inspection. These
values shall be
compared with those
in the First
Commissioning report.
23) Emergency Check freeness of the Do not keep the
tester in
stop valve. stop valve spindle test position after
the
with the help of check is over. Bring
the tester, once in back to Normal position.
every week during
continuous operation Do not start the set with
of the set. defective stop valve.
At standstill condition
during shutdown, check
the function with starting
device.
24) Start up Do follow the start Do not keep the
machine
Curves & up curves strictly running. in the
critical
Loading the set. during start-up loading speed zones.
and unloading of the
machine.
Do operate the machine Do not keep running the
slowly and steadily set on load when steam
observe critically the vital inlet parameters suddenly
parameters otherwise drop.
it may lead to vibration
problems.
25) Extraction Ensure that the Do not keep the
valves. extraction valves are extraction valves in
open
fully closed before condition after tripping.
start up of the machine. or on stoping of the machine.
Ensure the hand wheel Do not close the drain
for hydraulic actuator speeder hand wheel with
of extraction valve in too much force.
closed position by hand
operation. Do not open the extraction
valves until the turbine has
been loaded to such an
extent that steam fows from
the turbine into the system.
26) Warming up Warm up the inlet Do not admit up to
the
of turbine steam line upto ESV ESV suddenly and
do not
system. by operating the by heat up at higher
rate
pass valve across the than specifed. This may
main isclation valve. lead to warping/deformation
Do maintain the of the casing.
heating rate at 3 to
4
0
C per minute.
Do make sure that all Do not restart the
drains are kept open machine immediately after
during/warm-up including trip without ensuring
those of extraction that warm up vent valves
valve. before stop valves. open to ensure
normal steam
temperature for hot start..
Do open warm up vent
valves before stop
valve immediately
after trip and before
hot start-up.
27) Insulation Carry-out proper Do not operate the
of turbine insulation of the machine on load
without
valves and machine, extraction proper insulation.
pipings. valves and piping
before loading of
the machine.
Do ensure original
insulation after
completion of
maintenances jobs
if any.
28) Inlet steam Do maintain steam Do not start the
machine
temperature. temperature within till at least 50
0
C
superheat
specifed limits. is available for the
corresponding pressure.
Ensure immediate Do not continue to run
turbine trip when the set when sudden
boiler trip occurs temperature drop beyond
to avoid carry-over. 20
0
C is noticed. It is advisable
to reduce load immediately.
29) Exhaust hood Monitor exhaust hood Do not run the set if
temperature temperature specially temperature rises
to
during hot start-up more than 120
0
C.
and maintain below 100
0
C.
4.2.Important Dos during Turbine Running
1) Carry out freeness test of ESV with the help of ESV freeness tester 2309.
2) Check by draining oil from bottom of Main Oil Tank for checking water/sediment in the oil.
3) Check that Main Oil Tank vapour exhaust fans are in service.
4) Check that Main oil Tank vapour exhaust fans are in service.
5) Dust of the turbine.
6) Check the availability of H
2
& CO
2
bottles.
7) Check the quality (moisture, acidity, chemical impurities) in turbine MOT (Main Oil Tank)
once in a day.
8) Check the availability of AC & DC Lube OIL Pumps.
9) Take-out oil tank flters one by one for routine check-up and clean them by blowing dry
compressed air through them.
10) Operate the standby equipments in rotation and no equipment should be kept idle for more
than one week.
11) Test emergency (overspeed) governor by oil injection.
4.2.1Important Dos for Turbine Operation
1) Check by draining oil from bottom of Main Oil Tank for checking water/ sediment in the oil.
2) Keep a close watch on the leakages of oil from the bearings of the turbine which may result
in local fres.
3) Observe the level before and after the (Main Oil Tank) flters on Main Oil Tank carefully. If the
diference between the oil flters is more than 300mm, clean the flters.
4) Take care while removing the fne and coarse flters that the sediments collected on the flter
media does not fall back into the tank.
5) Take-out oil tank flters one by one for routine check up and clean by blowing dry
compressed air through them.
6) See that the standby (AC) and emergency (DC) lube oil pumps are made available at all
times.
7) The oil purifer is to be put into service periodically to ensure the oil quality.
8) Check that Main Oil Tank vapour exhaust fans are in service.
9) check that Main Oil Tank level is normal.
10) While putting the Turbine on barring gear particularly after major overhauls, the current take
by the barring gear motor is to be compared with its original value to ascertain whether any
rotor turbine is present or not.
11) While putting the turbine on barring gear particularly after major overhauls, the current taken
by the barring gear motor is to be compared with its original value to ascertain whether any
rotor rubbing is present or not.
12) Sudden deviations in turbine metal temperature (between top and bottom of casings,
between inner surface and outer surface of casings, in particular) are to be investigate
thoroughly.
13) While reducing the load on the unit, if the load does not drop below a certain limit, slightly
increase the load and report to UCB for the cause to be investigated.
14) See that all local instruments, turbine supervisory pick ups on turbine are not time damaged
or in non-working condition.
15) Log in all the following details and have a continuous watch on them.
a) Turbine generator load.
b) Temperature of bearings.
c) Oil temperatures.
d) Exhaust hood temperatures.
e) Gland steam supply pressures.
f) Turbine expansions (casing and diferential).
g) Turbine rotor displacement.
h) Bearing and shaft vibrations.
i) Turbine casing, rotor, valves temperatures.
j) Inlet steam parameters.
16) Operate the standby equipments in rotation and no equipment should be kept idle for more
than one week.
17) Follow all operational procedures strictly.
18) See that after maintenance of any equipments, the area is cleared for safer operation of the
equipment.
19) Have a continuous watch on the hydrogen purity.
20) Report any sudden deviation in the parameters from normal, and any abnormality noticed, to
the appropriate persons for corrective action.
21) Check the availability of AC & DC lube oil pumps.
22) Check the availability of H
2
& CO
2
bottles.
23) Dust of the turbine.
4.3 Important DONTs for Turbine Operation
1) Do not start the turbine with oil temperature at bearing inlet is less than 40
0
C.
2) Do not operate the machine if the water content in oil exceeds 0.2% of the volume of oil tank.
3) Never drain the oil containing hydrogen into the oil tank.
4) Do not force to rotate the rotor by hand if there is no oil supply to bearings.
5) do not try to rotate the rotor forcibly while the turning gear is not able to rotate it. The rotor
might have been jammed.
6) Do not supply the steam to turbine gland sealings if M/C is not on turning gear.
7) do not exceed the rated gland steam pressure so as to avoid the steam coming out of the
glands. It also results in moisture carry over to the lubricating oil.
8) Do not operate the condenser with fooded condensate condition (high level). This will cause
deterioration in condenser vacuum and may result in tripping of the unit.
9) Do not lead the steam into a cold line without properly draining the condensate and
sufciently warming up the line.
10) During M/C on turning gear, if rotor eccentricity exceeds 0.07 mm, do not roll the turbine.
11) Dont start the turbine if the control signalling and protection system are not in working order.
12) Never try to roll the unit when the unit has tripped on thrust wear protection without carrying
out proper investigation.
13) Do not linger in the speed range in which the critical speeds of the rotor system lie, during
starting and shutting down of the turbine.
14) Never run the machine when the temperature of oil at bearing outlet exceeds permissible
limit./ Immediately trip the set.
15) Do not allow the turbine to run in the steamless condition (generator motoring) for more than
4 minutes. Check up the vacuum conditions during this period. It can occur only when
protections have failed.
16) During shutdown do not open the atmospheric drains on steam admission pipes and
cylinders, till the metal temperature falls below 200
0
C.
17) Do not charge the HP heaters suddenly to avoid thermal shock.
18) Do not charge the steam side of any heater before charging its water side.
19) Do not operate the heaters with excessive condensate levels.
20) Do not overlook abnormality in any important reading.
21) Never assume things for granted. Report to the appropriate authority in case of difculty and
get it clarifed.
22) Do not stop the centrifugal pumps with their discharge valve open (during normal stopping).
23) Do not try to bypass operational procedures or cut short the operation procedures.
Turbine Governing System
1 Introduction
Power Station Turbines are constant speed machine. In our country these are supposed to
rotate always at a speed of 3000 RPM (within a small band of fuctuations on either side) to
enable the coupled generator to produce electricity at 50 Hz frequently. The main purpose
of governor is to maintain this desired speed of turbine during fuctuations of load on
the generator by varying steam input to the turbine
The governing system in addition to ensuring the falling load-speed characteristic of the
turbine (i.e. a characteristic of falling output power with raising shaft speed above nominal
value) also ensures the following functions :
i) The run up of the turbine from rest to rated speed and synchronising with the grid.
ii) Meeting the system load variations in a predetermined manner, when running in
parallel with other machines.
iii) Protecting the machine by reducing the load or shutting of completely in abnormal and
emergency situations.
The governing system also includes other devices to protect the turbine from abnormal
conditions that may arise during operation.
2. Methods of Governing
Basically there are three methods ofvarying the steam admission which are briefy explained.
2.1 Throttle Governing : Here the supply of steam to the turbine is controlled through single
batch of nozzles either by a single valve or two or more valves operating in parallel. On
speed increase due to reduction in load on the machine, the throttle valve is partially closed
and as a result steam fow to turbine is reduced and the power developed by the turbine is
regulated.
2.2 By-Pass Governing : i love you
In this system, in general, the steam is supplied through a primary valve and is adequate to
meet a major fraction of the maximum load which is called economic load. At loads less than
this, the regulation is done by throttling steam through this valve. When the load on the
turbine exceeds this economic load which can be developed by the unthrottle, full fow
through the primary valve, a secondary valve, is opened and throttled steam is supplied
downstream, by passing the frst stage and some high pressure stages. This steam joins the
partially spent steam admitted through the primary valve, developing additional blade torque
to meet the increase load.
2.3 Nozzle Control Governing:- Here the frst stages are divided into number of groups, from
three (3) in a simple system, to six (6) or more in more elaborate arrangement. The steam
supply to each group of nozzles is controlled by a valve and the number of valves opened is
varied according to the load on the turbine. In such cases, if say, seven (7) valves are
opened to meet any given load condition, then six of them remain full open and the actual
regulation will be done by modulating the seventh valve.
3. Speed Sensing Device
As mentioned, the job of governor is to vary the steam admission according to variation of
speed, it is imperative that some form of speed sensors (also called speed governors) are
required. Speed sensors sense the changes in magnitude of speed from the desired value
and generate corresponding correcting signals to control steam fow.
The system is in speed equilibrium till the turbine torque T
t
is equal to the generator torque
T
E
. If there is a sudden fall in load demand, the excess torque developed by turbine T will
accelerate the machine at a rate.
L - T/ I
where I is the machine inertia. As a machine speed rises, the speed governor acting through
the control system will throttle the steam valves until the turbine torque is equal to the new
power demand
the percentage change in rated speed corresponding to 100% change in load is termed the
speed regulation or the droop of the turbine. It is normally around 4%. The regulations of
the turbines operating in parallel infuence the load sharing amongst them
4. Types of Speed Sensors / Governors
4.1 Mechanical
The earliest known automatic turbine speed governor was a mechanical governor of
centrifugal fy ball type, the governor being driven by the turbine main shaft directly or
through gearing. The centrifugal force acting on two revolving weights, is opposed by the
elastic force of a spring, so that the weight take up diferent radius for each speed and
produce a proportional displacement of the sleeve linked to the fy balls through hinges
Fig. 4 Flyweight governor balances the force of spring and weights, moves speeder rod
4.2 Electrical
The electrical governor is a more recent innovation and made practicable by the
development of robust servomechanism and circuit components. An AC generator, driven by
the turbine shaft provides an electrical signal of a frequency proportional to the speed. A
frequency sensitive circuit produces voltage proportional to this frequency. This voltage, after
amplifcation, is fed to a torque motor which in turn produces a proportional displacement.
4.3 Hydraulic
In simple form, a hydraulic governor for a turbine consists of a centrifugal pump driven from
the turbine main shaft. The pressurised oil from it being fed into a cylinder containing a
spring loaded piston. The oil pressure is proportional to the square of the speed so the
position of the piston also becomes a function of the speed.
4.4 Hydro-Mechanical (Used in BHEL 6MW Turbine)
Here speed transducer is usually mechanical centrifugal type speed governor, controlling
through a combination of hydraulic relays & linkages. Oil for hydraulic system is supplied by
the main oil pump, which may supply oil to lubricating oil system also at a reduced pressure.
4.5 Electro Hydraulic (in parallel with hydraulic governing)
Due to large interconnected systems and growing automation of turbine generator sets,
governing system has to meet many additional requirements. The combined advantages of
electrical measuring and signal processing (fexibility, dynamic quality, and simple
representation of complicated functional relationships) and hydraulic control (continuous
control of large positioning forces) provide a very good combination.
The important characteristics of electro-hydraulic governing are (a) exact steady state
regulation with high sensitivity (b) safe load shedding by avoiding any speeding up along the
steady state regulation characteristic (c) possibility to adjust steady state regulation in fne
steps.
In electro hydraulic governing all transducers are electrical / electronic components. The
acquired signals (of control valve lift, speed, load & initial pressure etc.) are processed
electronically and processed signal is introduced at a suitable point in the hydraulic circuit
through a electro-dydraulic converter which is used as a connecting link between the
electronic modules and valve actuators. Hydraulic signal before application to control valves
servomotors is suitably amplifed.
Change over from electro-hydraulic governing to hydraulic governing is possible during
operation. When one system fails, other one comes into operation automatically.
The displacement of the piston in a hydraulic governor, of the torque motor in the electrical
governor, or of the sleeve of the fy ball governor, which is a function of the shaft speed, is
used to control the throttle valve of the turbine through hydraulic relay action of mechanical
linkages or a combination of both.
The arrangement of the various devices varies for diferent types and makes of the turbines
but their basic functions are similar.
5. Major Components of Governing System
1) Governing Devices
a) Speed governor with pilot valve
b) Speeder Gear or Load-Speed Changer
c) Load Limiting Gear and
2) Protection Devices
a) Emergency trip valve
b) Over speed governor
c) Acceleration governor
d) Overspeed Limiting gear
e) Pre-emergency governor
f) Low vacuum run back / unloading unit
g) Initial pressure regulator / low initial pressure unloading unit (Gear)
6. Brief Description of Governing & Protection System & the Devices
The stop valves & control valves in the steam lines to the turbine are actuated by hydraulic
servomotors. The servomotors consist of a cylinder and a spring loaded piston which is held
in open position by admission of high pressure oil, against the spring force, which ensures
positive closing on the oil being drained out. The high pressure oil supplied by the oil pump
to the governing system is fed to the servomotors through their pilot valves. The position of
the pilot valve determines the opening or closing of the servomotor. The high pressure oil
which actuates the servomotor is usually termed as Power Oil or Sensing Oil.
The pilot valves of the stop valve servomotors are positioned in OPEN position by yet
another branch of oil / Trip Oil either directly or through hydraulic relays. The Protection
Oil is the same high pressure oil but supplied through an Emergency Trip Valve. The
Emergency Trip Valve, in Reset position, admits oil through it, to be supplied to the various
pilot valves of servomotors, thereby enabling the opening of the stop and control valves. In
Trip position it suits of the oil supply and drains out the oil from the lines downstream of it,
there by ensuring the quick closure of the stop & control valves.
The protection oil being fed to the HP control valve servomotor pilot actuating device is
regulated through the Speed Governor Pilot Valve. The change in speed which causes a
corresponding change in the governor pilot valve, varies the oil pressure which in turn
regulates the position of the control valve through the servometer and its pilot valve. There
are variations in this arrangement. The other governing and protection devices like load
limiting Gear, Low Vacuum. Pay of unit, Initial Pressure Regulator are hooked up into this
control valve governing system through hydraulic relays and linkages.
7. Governing Devices
7.1 Speed Governor Pilot Valve
The pilot valve consists of a movable sleeve with ports for oil inlet, outlet and drain inside
which the double bobbin valve moves, actuated by the centrifugal fyball governor. The high
pressure oil or protection oil is admitted through the inlet ports of the cylinder and sleeve.
The pressure of the outlet oil to the control valve servomotor pilot valve actuated relay is
regulated by the relative displacement / position of the piston and sleeve. Any change in
shaft speed produces a corresponding change in the pilot valve position, thereby causing a
corresponding change in the control valve opening.
7.2 Speeder Gear
A speeder gear is essential in the governing system of turbine of electricity generating
stations, for synchronising the machine with the grid and to vary load when operating in
parallel. Speeder gear is needed to match the speed of the turbine to that of grid while
synchronising. After synchronising, the speed being determined by the grid frequency, the
speeder gear is used to raise or lower the load on the machine. It is explained earlier how
the relative position of the piston and ported sleeve of the governor pilot valve regulates the
control oil. While the piston is actuated by the governor, the sleeve is operated by the speed
gear. Hence at a particular position of the piston movement of the sleeve varies the oil
pressure. The speeder gear is either operated manually from local or by a small motor, from
remote.
7.3 Load Limiting Gear
This device is incorporated in the governing system to limit the maximum opening of the HP
Control Valves to the desired upper limit. This may be done mechanically by stopping
movement of linkages connected with relays in the control system or by limiting the sensitive
oil pressure in the hydraulic system thereby restricting the movement of speed relay by
shutting of or draining the oil. A small motor is provided usually for remote operation of the
gear.
Fig. 3 (a) Control Diagram Turbines
Fig. 3 (b) Control Diagram of a Typical Concentric Relay-Type System
8. Protection Devices
8.1 Emergency Trip Valve
The function of the valve has already been explained. Remote tripping by Emergency Push
Button also can be incorporated to trip the trip valve position through a solenoid.
8.2 Over-Speed Limiting Gear (OLG)
The purpose of the OLG is to limit the overspeed which would occur, should a sudden loss of
load take place. The control operates on each of the Emergency Stop Valves. On RH
turbines, it operates on both the HP and IP Emergency Stop valves. The gear comprises an
additional solenoid operated pilot valve which releases oil from the steam stop valve power
cylinder, when the solenoid is energised, valve closes rapidly under the action of the spiring.
There are two sets of contracts in series. One is operated by a Watt-metric relay and the
other by a relay under steam pressure in a selected range of the turbine. For example, the
contact operate by steam pressure may be set to remain close over the range 60% top 100%
load and that operate by the load at 0 to 30% load. If a load exceeding 60% is suddenly
reduced to less than 30%, the load operated contact will close at once but the pressure
operated contact will not open immediately because steam already in the turbine continues
to expand thus with both contact closed the solenoid is energised and the emergency stop
valves close. The solenoid will de-energie and open the valve when the Steam pressure
drops and the contact opens.
8.3 Acceleration Sensing Device
To cope with the rapid rise in speed that would occur in the event of a sudden loss of load,
an acceleration sensitive governor is ftted. This causes the rapid closure of HP throttle and
IP intercepter valves and when the acceleration of the turbine cases the speed would be
come down generally to such a value that the main governor will keep these valves closed.
If for any reason the speed should continue to rise the over speed governor will come into
action and trip the turbine causing closure of the HP and IP emergency stop valves.
A typical acceleration governor consists of two concentric tubes which normally rotate
together. The inner tube is driven through gearing by the turbine rotor. The outer tube carries
an inertia wheel and is driven by the inner tube through a torsional spring. There are ports in
each tube connected to the HP control oil and IP control oil circuit. Under normal conditions
these ports remain closed. During high acceleration periods, extra spring force is required to
accelerate the out tube and inertia wheel, resulting in the inner driving tube advancing its
position relative to the outer tube. This movement aligns the ports in the inner and outer tube
and draining the control oil with resultant rapid closure of the valve.
8.4 Pre Emergency Governor
The IP control valves / Intercepter valve independently or along with the HP control valves
are operated either by another centrifugal governor or the same main speed governor by an
acceleration sensing diferentiotor and pilot valve. The operation is similar to that of HP
control valve governing. The intercepter valves are normally full open at rated speed. In a
typical case, they would begin to close at a speed about 3% above normal and completely
close at about 5% above normal. The fnal speed rise due to time delay in relay operation
and the efect of steam in loop pipes, is about 7 to 8% above normal. The IP or Pre-
emergency governor is normally present and is not changed during normal operation.
Fig. 4 Emergency Trip Valve
On-Load Testing
To ensure that governing and emergency valve spindles remain free during long periods on
load, provision is made to close and open the valve whilst the machine is on load, to detect
any deterioration in valve action. Various methods of valve tripping are adopted depending
upon the design of the valve relays; where an electrical trip signal is used to close the steam
valves, this facility is used to close individual valves.
Determination of valve motion is detected by a regular comparison of valve closing times.
The valve stroking time is determined either by the use of an electrical timer actuated by
micro-switches positioned along the valve spindle, or by the use of a simple X-Y plotter that
produces a curve on a chart showing the actual valve motion, plotted against a constant time
base.
Steam Turbine Protection System
The function of turbine protection system is to protect the turbine under any dangerous
operating conditions. The more likely dangers to which a turbine is subjected during
operation may be summarized. :
a) Over-speeding
b) Motoring
c) Oil failure
d) Thrust bearing failure
e) Vacuum failure
f) Excessive vibration
g) Excessive temperature diferentials (Water induction)
h) Excessive eccentricity
There are automatic devices known as trip and unloading gear provided for immediate
shutdown of the turbo-generator under emergency conditions.
Protection Device
Main Trip Valve
The function of the main trip valve is to open the trip oil circuit in the event of abnormal
conditions, thereby closing the main and reheat stop and control valves and thus shutting of
the admission of steam to the turbine.
Solenoid Valve for Remote Operation of Main Trip Valve.
The solenoid valve is installed in the pressure oil pipe to the main trip valve and, when
operated, interrupts the oil fow. This causes the tripping oil circuit to be opened and the
turbine to be stopped. The solenoid valve is remote controlled electrically, e.g. from the
control room or from other protective device.
Tripping Devices
Overspeed Trip
If a turbine is allowed to overspeed, the stresses in the rotating components increase as the
centrifugal stresses are proportional to square of speed. The stresses in some components,
such as the larger wheel, blades and the generator end-bells are the frst to reach a stage
when local plastic yielding occurs and if the speed continues to rise, it eventually leads to
failure. It, therefore, generally follows that the speed of turbo-generators shall not be allowed
to exceed by 12.5% of the normal speed except for once when it is works proof tested after
manufacture, during which the rotors are usually run for a few minutes at 20% overspeed in
a test pit.
Although the governor should limit the speed to a level well below 110% safety device is
invariably ftted and usually duplicated, to close the emergency stop valves should the speed
rise above this value. It consists of a spring-loaded bolt or ring, incorporated into the shaft at
the governor end, having its centre of gravity a short distance from the axis of rotation. the
out of balance force is arranged to overcome the spring compression at 10% overspeed.
Emergency Hand Trip
This tripping device is usually in the form of a lever on the governor pedestal that operates
the trip valve of the overspeed trip gear, thus closing all valves by releasing the HP oil
pressure. It caters for emergencies not covered by the automatic trip gear.
Remote Trip Gear
To permit the machine to be tripped remotely from the control, room, the emergency hand
trip lever can be actuated by means of a solenoid or a torque motor. The actuators are
energised by the station battery when the control room switch is closed.
Oil Failure Trips
Loss of lubricating oil to the bearings would quickly lead to damage of the journal and thrust
bearings, with consequent damage to the shaft. It may be caused by :
a) Low oil level, due to leakage (e.g. through a corroded cooler tube). This is detected by
a foat-operated switch which may be used to sound an alarm or operate the remote trip
gear.
b) Low HP oil pressure (where a common pump is used to supply oil to both the
lubricating system and governing gear). Low pressure may be due to pump failure, leakage
or blockage. No special trip arrangement is required as the steam valves will close
automatically on loss of relay oil pressure.
c) Low LP oil pressure due to main oil pump failure or low running speed. This is detected
by a pressure switch, which automatically starts up the AC auxiliary oil pump. In the event of
a failure of unit and station AC supplies a relay starts the DC emergency pump which is fed
from the station battery.
Thrust Bearing Trip Device
Owing to variation of the thrust load, the thrust bearing is more susceptible to wear then the
journal bearings. To prevent damage to blades and glands should the wear become
excessive, a thrust trip device is ftted.
In the event of axial displacement of the shaft due to excessive wear of the thrust bearing
pads, the function of the thrust bearing trip device is to open the auxiliary trip oil circuit, thus
shutting down the unit to avoid damages.A typical construction of thrust bearing trip device.
The two rows of tripping cams (2) which are arranged on opposite side of turbine shaft (1)
have a specifc axial thrust bearing trip. If the axial displacement of the shaft exceeds the
permissible limit, the cam engages pawl (3) which releases piston (7) to depressurize the
auxiliary trip oil circuit and at the same time to actuate limit switch (10)
Low Vacuum Trip
Should the vacuum unloading gear fail to halt a falling vacuum, a vacuum trip device is
incorporated that either operates main trip valve or the pressure switch. The setting of the
vacuum trip is dictated by the ability of the last stage turbine balding to withstand the high
temperature condition that arise when operating at a poor vacuum. the purpose of the low
vacuum trip is to operate when a failure of vacuum occurs in the condenser, the tripping out
the main and reheat stop and control valves and shutting of the supply of steam to the
turbine within the shortest possible time. compression spring (3) set to a specifc tension,
pushes downwards against diaphragm (4), the top side of which is subjected to the vacuum.
If the vacuum is too weak to counteract the spring tension, the spring moves valve (6)
downwards. The pressure beneath valve (6) downwards. The pressure beneath valve (7) is
thereby depressurization of the auxiliary trip oil circuit actuates main trip valve, thereby
closing all turbine valves.
Vacuum Breaker for Reducing the running Down Time of the Turbine
With normal shutdown or tripping of the machine, the function of the vacuum breakers is to
cause an increase in condenser pressure by inducting atmospheric air into the condenser
together with bypass steam fowing into the condenser from the bypass station (if provided).
When the pressure in the condenser increases, the ventilation of the turbine balding is
increased which causes the turbo-set to slow down so that the running down time of the
turbo-set and the time needed for passing through critical speeds are shortened.
The partial vacuum breaker is used when the running down time is to be shortened with
normal shutdown and plant conditions are free of disturbance. Taking blade stress into
consideration the permissible operational condenser pressure of about 0.3 ata should not be
exceeded. For this reason the limiting value for the condenser pressure is set at about 0.2
ata.
Electrical Control of Partial Vacuum Breaker
The vacuum breaker valve is actuated to open once by a manual key. It closes automatically
when the pressure in the condenser rises. This control achieves a rapid passing through the
speed range up to turning operation. The pressure switch installed in the condenser for
registering the pressure increases is set at 0.18 ata so that the condenser pressure does not
exceed 0.2 ata after the valve has closed.
Electrical Control of Total Vacuum breaker
To break the vacuum without limitation due to condenser pressure, a further manual key is
provided. This key also opens the vacuum breaker valve. However, it cannot go into the
closing position until the close key provided for closing is used. This control enables a
complete equalisation of condenser and ambient pressure.
Automatic Control
The vacuum breaker is also actuated automatically by the turbine fre protection system to
shut the turbo-set down more quickly. It is switched back manually using the close key in this
case.
Low Vacuum Unloading Gear
Should the vacuum fall to a poor value, the temperature of the exhaust increases and may
possibly damage the last rows of balding and the condenser tubes, since under the
temperature infuence, the tubes will expand excessively and possibly buckle. To avoid this,
low vacuum unloading gear is used which, below a certain vacuum, progressively
decreases the steam fow as the exhaust pressure rises, thus tending to restore the vacuum.
The gear is designed so that it cannot reload the turbo-generator automatically when the
vacuum is restored, as this might result in load snatching, which would disturb the electrical
system. An added precaution against sudden loss of vacuum damaging the last rows of
balding consists of rupture discs which are ftted on the exhaust hoods of the low pressure
cylinders. In an emergency these are capable of passing the full load condenser steam fow
without the last row of balding being subject to a dangerous temperature.
Low Steam Pressure Unloading Gear
The correct functioning of the turbine control gear depends on the maintenance at the stop
valve of the steam condition. If the boiler failed to maintain the steam pressure, the turbine
would demand more steam, which would cause the pressure to fail still further. Further more,
if the fall in pressure were sudden (due to, say, loss of ignition), the sudden demand for more
steam might cause water to be carried into the turbine, causing serious damage. Protection
against this may be obtained by reducing the load on the turbine, should the inlet steam
pressure fall below about 90% of normal superheater outlet pressure.
Protection against Water Induction and Over-speeding
The steam turbine extraction lines to the feed water heaters are provided with power assisted
quick closing non-return or reverse current valves which shall close automatically when the
steam turbine is tripped, to prevent any back fow of fash steam from the heaters into the
steam turbine, which might cause overspeeding of the steam turbine. The non return valve
also closes on heater high level to prevent water induction into turbine. The reverse current
valves are designed for a minimum pressure drop. The reverse current valve are either
pneumatically operated or hydraulically operated.
In case of pneumatic valve, each valve is provided with air cylinder and spring devices to
assist in the opening and closing operation respectively. In case of hydraulically operated
valve, the hydraulic operated circuit is common to the governing oil system.
Exhaust Temperature Limiting Equipment
The steam turbine low pressure exhaust hood may be equipped with water sprays. The
sprays limit steam temperature at the exhaust under unusual conditions. For this purpose
thermostats are provided at or near the low pressure end of the steam turbine where the
most rapid increase in exhaust temperature can be expected. The steam turbine exhaust
hood spray water is generally taken from the discharge of the condensate pump. A motor
operated valve may be provided on the spray water line. The motor operated valve closes
remote manually, when the exhaust temperature comes down to within acceptable limits.
Lubrication Oil System
Essentially oil is required for lubrication of bearings. This requires only small quantity of oil.
However, shaft conductivity, surface friction and turbulence set up in the oil produce a
considerable amount of heat and to keep the bearing temperature constant at the desired
level a large quantity of oil is circulated to remove this heat.
The pressure of oil supplied to the bearing is in the order of 0.5 to 2.0 kg/cm
2
(g). This
pressure is required to ensure that the pressure in upper part of the bearing does not fall
below atmospheric and cause discontinuities in the oil flm. On the other hand if oil pressure
is too high, the oil will be sprayed out from the ends of the bearings at a high velocity and will
become atomised and may easily escape from bearing housing.
The temperature of oil must be kept within limits. If the oil temperature entering the bearing is
too low, inefcient bearing lubrication will occur due to high viscosity. If the oil temperature on
leaving the bearing is too high, this will lead to deterioration of the oil due to high rates of
oxidation Generally the oil temperature entering the bearing is in the range of 38
0
C-45
0
C and
outlet temperature is maintained about 55
0
C to 60
0
C by adjusting the supply of oil to each
bearing. To allow adequate adjustment generous piping diameters are used and removable
orifce plate is often provided.
The turbine oil system fulfls the following functions :
1. Lubricating and cooling the bearings.
2. Driving the hydraulic turning gear (if provided instead of AC motor driven turning gear).
3. Jacking-up the shaft at low speed.
4. Oil supply to hydraulic governing system.
Control oil for hydraulic governing system is required in the pressure range of 4-15 kg/cm
2
(g)
depending on the system design. In case oil for the control system is to be supplied from the
lubricating oil system, the total oil is pressurized to such high pressure and then lubricating
oil is drawn of through a reducing valve. This method is often adopted for its simplicity, and
also relays automatically close the stop valve if lubricating oil supply fails but there is some
additional pumping energy.
The operating and environmental conditions of steam turbine requires use of specially
compounded lubricating oil to ensure the physical and chemical properties are retained over
long period of operation. Lubricating oil is a complex mixture of chemical compounds, mainly
hydrocarbons. When hydrocarbons are exposed to heat or impurities like air, water, dirt, etc.
the oil has a tendency to oxidise. The rate of oxidisation is dependent upon the rate
exposure. Oxidation usually leads to the formation of sludge, which gets deposited in various
parts of the lubrication system in the area of low temperature and points of low turbulence.
Water is the most common contaminant of oil and may enter he lubricating system from
leaking shaft glands of from the condensation of humid air in reservoirs, bearing pedestals or
drain lines.
The high surface speed bearings generates high temperatures in the lubricating oil flm due
to high rate of shear. Thus an oil with a comparatively low viscosity is used for turbine oils to
keep the local temperatures below a level where a high rate of oxidation would occur. On the
other hand oil with a very low viscosity would results in discontinuities in the flm at high
temperatures and pressures. The viscosity of oil is normally chosen as compromise between
these conficting requirements. A typical value is 150 Redwood seconds at 38
0
C.
Although mineral oils usually possess good resistance to oxidation, foaming and
emulsifcation and have good anti-rust properties, the extreme requirements for the modern
steam turbine lubricating oil are usually met by the addition in inhibitors to a high quality base
oil that is selected for its high degree of chemical stability coupled
Properties of Turbine Oil
The properties of oil used for turbine shall be as per the recommendation of the turbine
manufacturer. A typical properties of turbine oil in use is given below :
1) Kinematic viscosity at 50
0
C : 28 Centi stokes
2) Inorganic acidity : Nil
3) Organic acidity : Max. 0.14 mg. of KOH per gm of oil
4) Neutralisation NO. (Total Acidity) : Max 0.2 mg of KOH per gm of oil
5) Specifc gravity at 50
0
C : 0.852
6) Flash point : Min. 200
0
C
7) Pour point : (-) 6
0
C (max)
8) Rust preventing characteristic : Negative test passed
9) Deaeration capacity at 50
0
C : 6 minutes (max)
10) Ash (% by weight) : Max. 0.01
11) Water content : Below the limit of quantitative Dectability
12) Mechanical solid : -do-
13) Emulsion characteristics (max) :
a) at 24
0
C : Nil
b) at 93.5
0
C : Nil Volume in ml. of foam after
c) at 34
0
C after testing at 93.5
0
C : Nil 10 minutes foam collapse
Schematic Arrangement of Turbine Lubricating Oil System
Under normal operating conditions, the main oil pump (1) situated in Front bearing pedestal
and coupled directly to the turbine shaft draws oil from the main oil tank (22) and supplies it
to the pressure oil system.
The suction of the main oil pump is aided by two injectors. The injectors produce pressure at
the suction connection to the main oil pump. This guarantees that the main oil pump takes
over the supply of oil and cavitations that could occur due to greater suction heads are
avoided. The amount of oil required for driving is extracted from the pressure oil circuit and
adjusted by means of throttles (31, 32). The oil for the hydraulic turning gear (6) is also
extracted from the pressure oil system. Oil is admitted to the nozzles by opening the shut-of
valve (16)
The pressure oil is cooled in the oil coolers (30) and reduced to lubricating oil pressure in the
throttle (28). The throttle is adjusted on initial start-up. The amount of oil required for each
bearing is adjusted on start-up means of the oil throttles (13)
During turning gear operation and start-up and run-down operation, one of the two three-
phase AC full- load auxiliary oil pumps (24, 25) supplies the pressure oil system and takes
over the function of the main oil pump when it is not in operation because the turbine is
running too slowly.
The full-load submersible auxiliary oil pumps are situated on the main oil tank (22) and draw
in oil directly. Check valves behind the auxiliary oil pumps and in the suction line of the main
oil pump prevent oil from fowing back via pumps that are not in operation.
When main and full-load auxiliary oil pumps fail, the lubrication oil supply is maintained by a
DC driven emergency oil pump (26). This pump supplies oil directly to the lubricating oil line,
bypassing the oil cooler and thus preventing damage to the bearing shells.
The full-load auxiliary oil pumps and the emergency oil pump are automatically started as
soon as the pressure switch limit has been reached. The pressure switches are set in
sequence so that the pumps can be started in succession, if necessary. The function of the
pressure switches arranged in the lube oil circuit is to operate the main trip valve when the
lube oil pressure drops below a set value. The lubricating oil from the bearings is returned to
the main oil tank via a header. A loop in the return oil piping behind the seal oil reserve tank
(15) prevent H
2
gas reaching the main oil tank (22) when there is a disturbance in the seal oil
system. The main oil tank is designed to be air tight. The extractors (18) produce a slight
vacuum in the main oil tank and the bearing pedestals to draw of any oil vapour. Oil for the
combined journal and thrust bearing is passed through the duplex oil flter (17) which can be
switched over and cleaned during operation.
SYSTEM COMPONENTS
Main Oil Pump
The main oil pump is driven by the turbine shaft either directly or through gears. For many
years the normal type of pump used on turbines has been the gear pump. This requires no
priming and provides positive oil displacement but must be driven through reduction gears at
about 400 RPM. However, on large turbines the quantity of oil used makes it economical to
incorporate a centrifugal pump driven directly by the turbine shaft, thus overcoming the need
for large and expensive gear wheels. The efciency of centrifugal pump is comparable to
that of gear pump, but it is not self priming and requires an oil injector to overcome the
suction head both when starting and during running.
The main oil pump located in the front bearing pedestal supplies the entire turbine generator
oil requirement. If the turboset is out of operation or the main pump fails, the auxiliary oil
pumps also supply oil in the suction branches of main oil pump until the main oil pump takes
over. The oil pump capacity is fxed by the total amount of oil required by the bearings, seal
and governing system together with a liberal margin..
Auxiliary Oil Pump
The auxiliary oil pump is a vertical single-stage centrifugal pump with a radial impeller and
spiral casing. It is fxed to the cover of the oil tank motor that is bolted to cover plate (1). The
oil enters the suction connection from underneath and is supplied to the oil system via the
pressure pipe (18). The pump shaft has a sleeve bearing (12) in the pump casing and a
grooved ball bearing (7) in the bearing yoke.
The bearings are lubricated from the pressure chamber of the pump; the sleeve bearing via
a bore in the casing the grooved ball bearing via a lube oil line.
D.C. Emergency Oil Pump
The emergency oil pump is of the vertical, centrifugal, submerged type and serves for
lubrication and cooling of the bearings during emergency conditions.. The unit is located on
top of the main oil tank and driven by a DC motor. The complete pump-motor assembly is
attached to a mounting plate which is bolted to the top of the main oil tank.
Main Oil Tank
The main oil tank contains the oil required for lubricating, and control systems of the turbine.
It not only serves as a storage tank but also for deaerating oil. The capacity of the tank is
such that the full quantity of oil is circulated not more than 8 times per hour. This results in a
retention time of approximately. 7 & 8 minutes from entry into the tank to suction by the
pumps. this time allows sedimentation and detrainment of the oil.
Oil returning to the tank from the oil supply system frst fows through a submerged inlet 99)
into the riser section of the tank where the frst stage of deaeration takes place as the oil
rises to the top of the tank. Oil overfows from the riser section through the oil strainer (6) into
the adjacent section of the tank where it is then drawn of on the opposite side by the suction
pipe or the oil pumps.
Turbine Lube Oil Cooler
The efciency of an oil pump may be of the order of 55% and remaining 45% of the pump
input energy generates heat in oil also absorbs a large amount of heat from bearing friction
and shaft conduction. To remove this heat the oil is passed through coolers which reduces
the temperature to that required for bearings.
Essentially, the oil cooler consists of a tube nest (6), inner and outer shells (7), (10), lower
water box and upper water box. The tube nest through which cooling water fows in
surrounded by the oil space formed by the outer shell (10). The oil to be cooled enters the
outer shell at inlet nozzle (1) 6 and fows into the inner shell (7). The shell supports the large
bafes (8) which are provided with an opening in the centre. Between every two large bafes
there is a small bafe plate (9) held and supported by short tubes (12) placed in steel rods
(11). The intermediate plates are smaller in diameter than the inner shell (7) and thus leave
an annular gap. This arrangement serves to achieve a cross fow pattern forcing the oil
fowing towards outlet to fow through the middle or large bafes and over the edge of the
smaller bafes and increases the heat transfer rate. The cooling water enters and leaves
through the lower water box which is divided by a partition plate so as to force water through
one half of the tube system to the upper water box (1) and from there through other half back
to lower water box.
Oil Vapour Exhauster
The function of the exhauster provided on main oil tank is to produce a slight negative
pressure in the main oil tank and in the bearing casings and thus draw of the oil vapour. The
casing is constructed as a spiral with aerodynamic features and is provided with supports for
the exhauster
Turbine Oil Purifcation System
During the lubrication cycle, the turbine oil comes in contact with water, air particles and
other foreign materials. These impurities cause a steady deterioration in the lubricating
properties of the oil. These impurities if not removed may damage the TG bearings and
hydraulic control system elements. To prevent such happenings, a online turbine oil
purifcation system is installed. The efcient conditioning of turbine oil, the purifcation system
must operate on continuous basis because purifer operating only part time permits
accumulation of undesirable contaminants. Generally continuous by-pass type turbine oil
purifcation system is used to ensure trouble free operation against turbine oil contamination.
A certain amount of turbine oil from main oil tank is led to the purifer so that desired quality
of turbine oil can be maintained in the main lube oil tank. The over fow sight ftting near the
turbine oil tank is adjusted to achieve required fow to the purifer unit and to maintain the
normal operating level in the oil tank.
The capacity of turbine oil purifcation equipment is generally selected to handle on hourly
fow rate equal to about 20% of the total oil in the system which includes the turbine lube oil
reservoir capacity at normal operating level plus fow back when the unit is shutdown.
Types of Oil Purifers.
Basically there are two types of oil purifer viz. Static type and Centrifuge type are most
frequently used since they can efectively remove water as well as solids.
Static Type Oil Purifer
Static type oil purifer will have three compartments viz. precipitation compartment, fltration
compartment and storage compartment. In the frst stage of operation, gross free water is
removed by setting in precipitation section and smaller droplets coalescing on the screens.
Precipitated water settles in a trough on the base from where water is removed. In the
second stage i.e. in fltration compartment oil fows through cloths covered flter elements
from outside to inside. Static type oil purifer do not require an oil feed pump when purifer is
located below the turbine oil tank, and oil feed from the turbine oil tank is by gravity.
However, in case purifer is located at an elevation such that the gravity feed from turbine oil
tank to the purifer is not possible, purifer feed pump is provided along with one auxiliary oil
tank between turbine oil tank and purifer. This also gives an additional storage capacity to
accommodate the excess fow back of turbine oil.
Centrifuge Type Oil Purifer
Centrifugal type purifer have a high speed rotating bowl contains many conical shaped discs
which divide the oil into extremely thin layers. Centrifugal action separates oil, water and
solids. Solids are thrown directly to the bowl wall and may be removed by cleaning during
purifer shutdown or during operation, depending on the centrifuge design. The oil with its
lighter density is displaced inward. Water and conditioned oil are discharged through
separate openings. Purifer units is provided with an indirect type electric heater to preheat
the oil entering the centrifuge device for purifcation. The heating of the oil fowing through
the spiral tubes is done by water stored in the shell which is in turn heated by electric
immersion heaters. The heater unit is insulated by glass wool and provided with thermostats
for automatic cutting in and cutting out to maintain the oil temperature.
Control Oil System
A common lubricating and control oil system provides a simplifed system as a single pumps
is used to supply the lubricating oil quantity required for the turbine bearings and for the
hydraulic relays. The single pump usually generates an oil pressure of 10-15 ata to suit the
relay gear and the lower pressure required for the bearing oil is used after pressure
reduction. The oil pressure in the relay system is usually limited to approximately 15 ata
when lubricating oil is used, in view of the fre risk, if a serious oil leak occurred. When higher
steam pressure cycles are adopted or when large steam valves are used this limitation on
operating pressure necessitates the use of large diameter relays which are difcult to
accommodate and maintain. To reduce the size of the relays, a higher relay pressure must
be adopted. The adoption of higher fuid pressure also has the advantage of improving the
steam valve response and thus reduces the transient speed rise on load rejection.
When higher relay pressures are used on large capacity turbines say 200/ 210 MW and
above, fre-resisting fuids (FRF) will generally be adopted. Water-based fuids are
available, such as a water solution of ethylene glycol, but they usually lack many desirable
properties as hydraulic fuids. The most common fre resisting fuids in use today are based
on phosphate esters with various additives to improve their viscosity change with
temperature and their hydraulic stability. The fre resisting fuids are relatively sensitive to
degradation in service, due to contamination, by water lubricating oil and humid air, and by
exposure to high temperatures. Care is taken in the design of the hydraulic system to ensure
a reasonable replacement life for the fuid. Where a fre-resisting fuid is used, the governing
hydraulic system is entirely separate from the lubricating oil system.
JACKING OIL SYSTEM
When the turbine is started up or shut down, the jacking oil system is used to maintain the oil
flm between rotor and bearings. The necessary torque from the turning device or from the
manual turning device is reduced in this way. The bearings are relieved by high pressure oil
that is forced under the individual bearing, thus raising the rotor. In order to avoid damage to
the bearings, the jacking oil pump must be switched on below a certain speed.
The jacking oil pumps are generally jack-screw immersion pump situated on the main oil
tank to supply the high pressure oil for the lifting device. The superfuous fow the pump is
conducted into the main oil tank.
The necessary jacking oil pressures are set for each bearing by the fne control valves in the
oil pipes. Check valves in the jacking oil pipes prevent oil from fowing out of the bearings
into the header during turbine operation when the jacking oil system is naturally switched of.
TURBINE GOVERNING SYSTEM OF CPP-II, ROURKELA STEEL PLANT
Introduction
High response governing system for the steam turbine is necessary to maintain the turbine
speed at the desired set points during start-up and normal operation. It also serve to prevent
overspeeding of turbine following sudden loss of load. In the event of generator breaker
opening following a full load loss, governing system prevents the overspeeding of the set to a
dangerous level and quickly stabilizes the set on house load or on no load. This enables
quick reloading in case of spurious loss of load.
The turbine is equipped with electrohydraulic governing system and hydraulic governing
system. The special feature of the governing system is that the electronic governor is
designed to act as primary governor and hydraulic speed governor as back up governor.
Upon failure of electronic governor, hydraulic speed governor takes over the control of the
turbine.
Also for opening of turbine extraction valves hydraulic control system has been provided
which will actuate the NRVs depending on load on the machine
DESCRIPTION AND FUNCTION OF HYDRAULIC GOVERNING
Speed Governor SR-IV Type
A hydraulic governor type SR-IV consisting of a starting device, transducer, reference value
spring and a device for comparing actual speed with reference value is employed to control
turbine speed and maintain it at a constant valve.
Mode of Operation
Refer i) Fig 6 Governor Oil Diagram
ii) Fig. 7 Diagram of Speed Governing with SR- IV Governor
The governor impeller (1111) converts the rotational speed of the turbine into directly
proportional oil pressure called primary oil pressure. It is driven by turbine main shaft and it
is supplied with a small quantity of oil from the main oil pump. Depending upon the speed of
the turbine, the governor impeller builds-up a pressure of 1.5 to 2.5 kg/cm
2
. This oil pressure
is called Primary Oil Pressure which acts on the governor bellow (transducer) (1112). The
governor bellow is connected to comparator lever (1110.1) through a tappet. The force
exerted on the bellow by primary oil pressure is transmitted to the lever through the tappet. A
compression spring (reference value spring) is mounted on the top of the lever which is pre-
compressed by speeder gear motor (1851) or a hand wheel (1113). The force which the
bellow exerts on the lever is counteracted by the reference value spring. Any deviation of
actual speed from a given reference value will therefore cause a defection of the lever.
Under steady state conditions the spring force will equal the bellow force.
The comparator lever at its free end is connected to the control sleeve (1830.2). The hollow
follow-up piston (amplifer) (1830) is ftted into the control sleeve,. The follow-up piston and
control sleeve are provided with ports : the degree of overlap of these ports is dependent on
primary oil pressure and speeder gear position. Depending on the degree of their overlap,
discharge of larger or lesser quantities of oil is controlled. Any variation in primary oil
pressure due to speed change or change of speeder gear position cause readjustment of
overlap of ports. The subsequent increase or decrease in the secondary oil pressure results
in a displacement of servo motor, caused by the change in the rate of draining of pressure oil
through the port at the overlap.
In order to enable the turbine to be stopped from the control room, a solenoid valve (2222) is
provided in the pressure oil circuit. For tripping the turbine, a control pulse is given to the
solenoid valve. The opening of the solenoid valve brings down the trip oil pressure and the
secondary oil pressure immediately to zero. This causes emergency stop valve and control
valves to close.
Emergency Stop Valve
The emergency stop valve (2001) is of quick closing type. The valve is actuated by means of
a hydraulic cylinder. The actuating mechanism consists of a spring loaded piston and a
piston disc which is connected to the valve cone through a spindle. For opening the stop
valve start-up oil is admitted to the space above spring loaded piston by operating the
starting device (1840). Due to start-up oil pressure the piston displaces towards the piston
disc and they form a tight seal against each other. Oil from the trip oil circuit is then admitted
to the space under the piston disc and the space above the piston is connected to oil drain.
The trip oil now forces both piston disc and the piston to the outlet position thereby opening
the stop valve. As long as the trip oil pressure is maintained the piston and the piston disc
cannot be separated by spring force The stop valve is closed only when the trip oil pressure
drops substantially. On loss of trip oil pressure the secondary oil pressure also drops to zero
(as secondary oil is tapped from trip oil circuit), thus causing the control valves to close. This
arrangement provides a two fold protection against steam entering the turbine.
Turbine Control Valve Servomotors
Secondary oil pressure is acting via a damping device (5600) as abrupt start input to servo
motor. The spindle of servomotors (1910 and 1911) consisting of pilot valve (1910.1) and
actuator (1910. 21) are connected to the turbine control valve (0801 and 0802) through a
lever system. The follow-up piston amplifes the small pressure change which is produced by
the governor impeller on a change in speed. It also reverse the direction of pressure in the
secondary oil circuit. An interruption of this secondary oil circuit leads to an immediate
closure of the control valves.
When, owing to a decrease in turbine speed, the balance at the comparator lever is
disturbed, secondary oil pressure will increase. The pilot valve piston of the servomotor goes
upward under the infuence of the increased secondary oil pressure until a new balance
between secondary oil pressure and the force of spring (1910.3) is established. Depending
on the value of secondary oil pressure, and thus on the position of the pilot valve piston,
pressure oil is admitted, although somewhat restricted by the efect of the throttle, to the
space (1910.2) above the actuator piston while the space underneath is connected to the oil
drain line. In this way, the actuator piston is pressed downward thereby opening the turbine
control valves. A feedback element (1919.4) on the actuator restores the pilot valve piston to
the ON-PORT position thus stabilising the position of the actuator piston, thus stopping
further opening of the control valves.
Speed Setting
The speed of the turbine can be adjusted within the limits of approximately 85% to 107%.
The adjustment can be efected either by hand locally or by an electric motor remotely.
Changing the force exerted by the reference-value spring (change in reference value) has
the efect of shifting the speed-load characteristic. This has the consequence that both the
speed and the output is altered when the turboset is operated as an isolated unit or the
output alone with interconnected operation.
Starting Device
The starting device opens the emergency stop valve by means of trip oil and simultaneously
limits the output of the amplifer i.e. secondary oil pressure so that it is impossible for the
turbine control valves to lift while opening of emergency stop valves is in progress. The
starting device is also used to start the turbine by opening control valves after emergency
stop valves are opened and conduct run up of the turbine until the hydraulic governor takes
over.
The starting device (item No. 1840 of governor oil diagram) is contained in the housing of the
hydraulic governor. Its main components are the starting control (hand wheel and motorised
actuator) push-rod, valve sleeve and valve.
The valve sleeve (6) is located vertically in the governor housing and fxed in position. The
valve (7) can move vertically in the sleeve and is bored to allow the push rod to pass
through. In the position shown in the diagram the valve is being forced by a compression
spring (8) against a stop (13) in the valve sleeve. The push-rod (4) is held in position by a
cover (5) and the valve sleeve. As its lower end it is connected to the comparator arm (9)
through a bearing (10 and compression spring (11).
Mode of Operation : Start-up
After frst releasing the locknut (2) rotate the starting control clockwise to more it downward.
This causes the push-rod (4) to move downwards against the resistance of the spring (3). A
collar on the push-rod also carries the valve (7) downwards against the force of the spring (8)
making the comparator arm (9) to move thus, causing the hydraulic governor into the close
control valves position.
In the position the trip oil at connection E, has access to the position of the emergency stop
valve and it forces the piston tightly against of the piston plate. This oil is called start-up oil.
If the starting control is now rotated anti-clockwise in an upward direction, the push-rod and
valve follow, forced upwards by the respective springs. According to the arrangement of the
control lands on the valve sleeve and valve, the trip oil is now allowed access to the piston
plate of the emergency stop valve. Further the starting control is moved upwards, the greater
the increase in pressure at the piston plate of the emergency stop valve.
The start-up oil pressure downstream of the piston of the emergency stop valve decreases at
the same time due to the reduction in the oil supply and the simultaneously opening of drains
at starting device. As soon as sufcient pressure diference has built up between the space
upstream of the piston plate and down stream of the piston, the emergency stop valve
opens. The opening time of the valve can be adjusted by means of a throttle screw (12) in
drain T so that positive opening of the emergency stop valve is assured under all
circumstances.
When the emergency stop valve is open, further upward movement of the push-rod and the
comparator arm connected to it moves the hydraulic governor to the open control valves
position. The secondary oil pressure then rises so that the control valves lift. Then the
starting device can be used to increase the speed of the turbine until the governor takes over
control. When this has happened, the starting control is screwed upwards as far as possible
and secured with the locknut.
Mode of Operation : Shutting Down
For Shutting down, the starting control is moved downwards together with the push-rod and
valve as already described for start-up. The push-rod operates through the comparator arm
to move the hydraulic governor into the close control valves position. The supply cross area
of the line to the piston place of the emergency stop valve is reduced at the same time so
that the emergency stop valve closes when the starting device valve moves further
downwards. If the main trip valve is also disengaged the push-rod and valve are restored to
their original position. This mode operation is not conventional. Normally, after achieving the
closed control valve position (i.e. minimum load condition) the emergency stop valve are
closed. By hand tripping the turbine, the trip oil ahead of emergency stop valve gets drained
i.e. valves are closed. Subsequently the push-rod of starting device control is brought to fully
downward condition.
Extraction Control System
Each of the extractions is equipped with following hydraulic fttings
(i) Automatic load limiter 2241
(ii) High level trip solenoid 2223
(iii) Drain speeder
(iv) Non-return extraction valve 2351 to 2355
Automatic Load Limiter (2241)
This is a spring loaded hydraulic valve which allows the trip oil to pass through it. Under no
load or turbine trip conditions this remains in closed condition due to spring force. When load
on machine is increase secondary oil pressure increases. This secondary oil pressure
overcomes the spring forced and opens the valve allowing trip oil to go towards next ftting
(i.e. high level trip solenoid valve). The spring force adjust with respect to the load on which a
particular heater will cut in. On reduction of load secondary oil pressure will drop and will cut
of the trip oil circuit.
High Level Trip Solenoid (2233)
Trip oil coming out from 2241 will pass through this solenoid valve only when respective
heater water level is not high. Whenever heater level goes high this solenoid will cut-of the
trip oil supply to next ftting (drain speeder).
Drain Speeder (5400)
The trip oil from the high level trip solenoid enter into drain speeder. It is a spring loaded
valve. When trip oil pressure acts against the spring force this valve opens and allows the trip
oil to fow to the actuating piston of NRV. As long as trip oil pressure is available this valve
remains open. When trip oil supply is cut-of due to actuation of 2241 or 2223 or trip of
machine this valve closes on spring force. On closing it drains the blocked trip oil between it
and NRV actuating piston.
This valve (drain speeder) has been provided with a hand wheel also which can be operated
manually to close the valve. With the closing by hand wheel extraction can be taken out even
if all other conditions are satisfed. During normal operation hand wheel is kept fully released.
Non-return Extraction valve (2351-55)
This is a spring loaded piston and cylinder mechanism which opens the non-return valve, to
allow steam to fow from turbine to heater, when trip oil pressure acts on other side of the
piston and overcomes the spring force. As long as trip oil pressure is available this NRV
remains open. Whenever turbine trips, or due to any other reason connected heater is taken
out, the trip oil supply is cut-of closing extraction NRV. The trip oil blocked between (5400)
and piston of (2351-55) is drained via drain speeder.
List of Equipment and Code Numbers
(With Governing Oil Diagram)
001 : Turbine
0801: Control valves
0802: Control valves
1110.1 : Comparator lever
1111: Hydro dynamic governor (governor impeller)
1112: SR IV governor transducer (governor bellow)
1113: Hand-wheel (reference valve spring adjustment)
1114: Speed gear
1117: Accelerator
1118: Accumulator
1120: Woodward governor
1800: electrohydraulic convertor
1830: amplifer (follow-up-piston)
1840: Starting device
1841: Starting device hand wheel
1851: Speed gear motor
1852: Motor for starting
1910: Servomotor
1911: Servomotor
2110: Overs-peed governor
2130: Pressure protection
2134: Vacuum protection
2135: Lube oil protection
2210: Tripping device (emergency trip gear)
2211: Axial motion protection (part of tripping device (Mechanical)
2221: Solenoid valve for load shedding relay
2222: Solenoid valve for remote tripping
2223: Solenoid valve
2224: Solenoid valve for load shedding relay
2241: Automatic load limiter for closing NRVs
2242: Auxiliary slide valve
2250: Hand trip valve
2301: Emergency stop valve
2309: Three-way valve (stop valve testing device)
2351 to
2355: Non-return extraction valve
2360 to
2365: Actuating mechanism for non-return extraction valve
2811: Overspeed governor tester
4520: Governor oil flter
4600: Oil accumulator
5400: Drain speeder
5600: Damping device
Lg : Impulse air
DAMPING DEVICE
Purpose
The damping device is installed in the secondary oil line in proximity of the control valve
actuator. Its purpose is to prevent the transmission of possible oscillations (Pressure
fuctuations) arising in the secondary oil circuit to the control piston of the actuator.
Design and Mode of Operation
A flter (2) which is inserted into the housing (1), carries, in addition to a number of axially
drilled holes, a system of slots milled perpendicularly to the holes. The lybyrinth formed by
these holes and slots induces a whirling motion in the oil fow by which the oscillations and
pressure fuctuations of the secondary oil circuit are dampened.
DESCRIPTION AND FUNCTION OF ELECTRO HYDRAULIC TURBINE CONTROL (EHTC)
Introduction
The function of the electrohydraulic turbine control (EHTC) system is to regulate the speed of
the turbine generator and to control its output when it has been synchronized with supply
system. Changes in speed (during start-up) and changes in load (when synchronised) are
only allowed by a turbine wall stress evaluator provided they do not exceed thermal stresses
which endanger the turbine.
By means of a limit pressure controller, the EHTC system prevents the steam pressure
upstream of the control valve falling excessively in order to assist the steam generator in
maintaining pressure.
When the EHTC system is controlling the turbine, hydraulic governor (SR-IV) tracks it
continuously in order to provide backup control. In case of failure of electrohydraulic control,
mechanical governor already in tracking position takes over control.
Structure of the Control System
Basically, the EHTC system comprises three separate controllers - the speed controller, limit
pressure controller and valve lift controller. The speed controller and limit pressure controller
work in tandem through minimum valve selection circuit and issue their output signals to the
subordinate valve lift controller as valve position set-points. The valve lift controller supplies
the signals to the electrohydraulic converter through a power amplifer. Changes in speed
setpoint are made according to temperature margins provided by a two channel turbine wall
stress evaluator.
Hardware Arrangements
The electronic components are mounted on printed circuit cards whose dimensions 100X160
mm are standardised in accordance with DIN41494. all the modular printed circuit cards are
plugged in subracks. The subracks are ftted in a cubicle, which is totally enclosed with
regard to the control room with single leaf door at the front. The cubicle is suitable for
installation against wall and cable entry is from below.
The individual controller parameters can be adjusted from the front face of the module. The
font face is also provided with light emitting diodes for indicating the status of the individuals
signals.
Power Supply Unit
For reliability, the electro hydraulic controller is provided with redundant power supplies. The
24V supply to the electronic circuit elements is taken from 415V, 3-phase alternating current
supply and 220V direct current supply.
Both power supplies are coupled on 24V side through coupling diodes so that loss of one
source results in a bumpless transfer to the other. Loss of one supply is alarmed.
SPEED CONTROL
Speed Acquisition and Overspeed Protection
The turbine speed is measured digitally through three independent channels. The speed
transducers (hall probes) whose working principle is based on Hall efect, produce sinusoidal
chain of pulses. The frequency of pulse train is proportional to the turbine speed. These
pulse trains are converted into a sequence of almost square voltage pulses in a pulse
convertor. These three channels are continuously monitored for regularity of pulses. In the
event of failure of any one channel, the defective channel is automatically disconnected and
an alarm is produced to that efect. Emergency trip occurs only when all the three channels
become defective.
Only one channel at a time is utilised for the actual speed signal for speed controller. Further,
in speed acquisition system, the frequency signal is converted into frequency proportional
DC voltage for analog display and emergency tripping when turbine speed is greater than
110%.
Speed Reference
Speed reference can be set manually by raise and lower push buttons provided on control
desk. It is possible that the speed reference can be adjusted upwards or downwards at
diferent adjustable rates in speed reference controller. Time dependent analog speed
reference signal can be measured by an indicator.
Maximum valve of speed reference is limited to less than trip speed to avoid overspeeding by
default. When over speed trip test is desired, the maximum speed reference limit can be
released by Overspeed reference release.
When an emergency trip is initiated, the speed reference is reduced to 0% immediately, so
that the control valves are closed fully, resulting in coasting down of the turbine. Hence, it is
possible, after the emergency stop valves have been opened, to bring the coasting down
turbine under control with the speed controller and re-synchronize it.
In case of generator circuit breaker trip for isolated operation of the unit, the reference
increases immediately to 100%. This ensures that the turbine does not overspeed and trip,
but remains ready for immediate re-synchronization.
Speed Controller
The speed controller exhibits a steady state proportional control to form the necessary droop
characteristics. The dynamic response is improved by the addition of proportional integral
and diferential elements. The speed controller realises the following function :
- Start-up of the turbine
- synchronization of generator
- Provide a minimum load operation.
- Operation of turbine generator set in complete power range during isolated operation.
- Possibility of valve position limitation.
Turbine wall stress Evaluator
The speed reference produced by speed reference controller is not fed directly to the speed
controller. Changes in speed reference are limited by the reference controller whose time
constant is related to the temperature margin as described in turbine wall stress evaluator.
Limit Pressure Controller
The task of the limit pressure controller (initial pressure controller) is to assist the steam
generator in maintaining a constant pressure. Thus, the limit pressure controller closes the
turbine control valves until there is no deviation between the setpoint and actual value of
initial pressure. Naturally, it causes a reduction in the electrical output.
Referred to the pressure setpoint, this means that it must be lower than the instantaneous
actual value, so that switch on can be bumpless. If the pressure controller is at the lower
limit, the no-load valve lift, switch-ON cannot take place. This prevents a step-change in
turbine load, which would always occur if switch-ON took place with the pressure below the
setpoint. In order, nevertheless, for the controller to be switch on under such circumstances,
the setpoint must be reduced below the instantaneous actual valve. After switching-ON, the
setpoint can be returned to its original value.
Switching-OFF
Once again, as with switching-ON, the pressure controller must be at the upper limit (speed
controller operative) is order to satisfy the switching criteria. It means that the setpoint of the
limit pressure controller must be lower than the actual value. If this condition is not fulflled,
the speed controller can be brought into operation by reducing the speed setpoint. This will
be indicated by the lamp Limit Pressure Controller-ON going out and the lamp Speed
Controller-ON lighting up. Thus, the limit pressure controller is again at the upper limit, and
so switching-OFF is possible. The lamp Pressure Controller-OFF will indicate the new
status.
Valve Lift Controller
The valve lift control loop comprises the position controller with PIDT-1 action, a power
amplifer, the electo-hydraulic converter, a diferential transformer for acquiring the position of
the servomotor and a matching module for valve position.
The valve lift controller acts on the electrohydraulic controller, (EHC) and controls the
secondary oil pressure by means of a hydraulic amplifer, which in turn positions the control
valves.
A position transducer measures the position of the power piston in the EHC and provides the
actual position value. The valve lift reference values is furnished by the speed controller.
The lift controller compensates for non-linearity in the adjusting mechanism of the control
valves, and for difering viscosity or oil pressure in the hydraulic system. The static and
dynamic characteristics of the turbine control system are thus improved.
Interface Between Hydraulic and Electrohydraulic System
SR-IV Governor
As described earlier, the turbine can also be controlled by the type SR-IV hydraulic governor.
It is possible to change over from the EHTC system to the hydraulic governor and vice versa
at any time. The following is a detailed description of the interface between the two types of
control.
Tracking Device with Step Controller
The tracking device keeps the hydraulic controller output constantly slightly above the
electrical controller. By means of selecting the minimum signal in the hydraulic oil circuit, the
electrical controller is always leading. The EHC is adjusted such that 0 volt on the input
represents 100% on the output.
In the event of failure of the electrical controller, the tracking device is switched of and the
hydraulic controller takes over. The hydraulic speed controller can be operated from the
control desk in such a case.
Changeover Logic
Changeover to the SR-IV governor can be efected either intentionally by hand or
automatically; the latter occurs when one of the following faults arises in the EHTC system :
- Valve position measuring malfunction
- Electrohydraulic converter control malfunction
- Actual value and setpoint of valve position not equal.
When any of these fault occur, a stored alarm Position Controller Fault is triggered which
can be reset in the EHTC system by operating a slide switch when none of the three are no
longer existing. When the alarm is given, the tracking of the hydraulic governor in the EHTC
system is stopped immediately and plunger coil of the EHTC system de-energised.
The EHTC plunger coil drifts towards greater valve lift (by mechanical pre-loading) and in this
way the SR-IV governor takes over automatically, with the valve lift being somewhat greater
due to the tracking diference of the SR-IV governor.
The position of the EHTC/SR-IV selector switch in the control room is irrelevant and so can
be left where it is. When the fault has been rectifed, the plunger coil is reorganized
automatically, provided the lift controller of the EHTC system issues full open. This can be
brought about by setting the speed setpoint to the upper limit and the EHTC/ SR- IV selector
switch to position EHTC. The EHTC system can be back into operation by reducing the
speed setpoint lamp SR-IV Goes ON goes out.
With an intentional Changeover from EHTC to SR-IV plunger coil remains energized; only
the tracking of the governor is interrupted. The plunger coil can also be de-energized
deliberately by hand when the hydraulic governor is controlling the turbine.
ELECTROHYDRAULIC CONVERTER (EHC)
The convertor is the connecting link between the electrical and hydraulic parts of the
governing system. Its function is to amplify the signals from the electric governor so that they
are capable of operating the control valves and all other control devices operated by
Secondary oil pressure. The arrangement of the convertor in the governing system is shown
in the governor oil diagram (item No. 1800). The electrohydraulic convertor acts as an
interface element between the control valve positioning drive and electronic circuity. It
provides the large positioning forces required with an acceptably high positioning speed.
The electrohydraulic convertor, It consists of a permanent magnet coil system (11), a control
slide (13), a pilot piston (14), a servo-piston (16) and a diferential transformer (12)
The control slide determines the position of the rotating pilot piston, those inlet and outlet
posts to the servo-piston (16) are covered or uncovered.
The servo-piston moves the follow-up piston (15 of a hydraulic amplifer in the secondary oil
circuit and causes variations of the secondary oil pressure. The turbine control valve position
is changed proportional to this pressure.
ANNUNCIATIONS - CAUSES AND
OPERATING CONTROLS
Signals to the control room Speed controller driving the turbine.
Speed controller ON.
Limit pressure controller ON Limit pressure controller reducing the control
valve lift because the steam generator cannot maintain pressure
Position limiting Position limiting has fxed setting of 120%
SR-IV governor ON This signal appears in the control room as an
alternative to the three above. The EHTC system is not driving the turbine any more.
Overspeed setpoint enabled. This signal accompanies operation of the
enable overspeed setpoint control.
Limit pressure controller ON. Indicate that the limit pressure controller is
ON.
Limit pressure controller OFF Indicates that the limit pressure controller is
OFF.
Emergency stop valve 1 open. Signal acquired by pressure the emergency
trip unit, switches ON.
Emergency stop valve 2 open. See above
Emergency stop valves ready. This signal is given when both emergency
stop valves are pressurised for opening i.e. there is oil pressure above the piston and below
the piston plate.
Annunciation in the EHTC system
a) Limit value shifted switch After operation of slide BE035, S12 this LED
(BE043, H12) indicates that the limit value for emergency
tripping has been shifted.
b) Plunger coil de-energized BE035, After operation of slide switch S13 this LED
(BE043, H15) indicates that the plunger coil on the
electrohydraulic convertor is de-energized.
When there is a malfunction in the EHTC system, the cubicle lamp lights up and a
foating contact is opened. In addition to this ground fault alarm, there are also selective fault
alarms in the control room. This individual fault alarms comprising the group fault alarm are
described in Section.
a) Speed acquisition (Control) fault Signal given when 1 or 2 channels of the
speed acquisition system are down
b) Speed acquisition (Protection) fault. As above
c) Position controller fault. Group alarm given when the valve position
control loop is defective. It initiates changeover to the SR-IV governor.
d) Power supply fault this group alarm is given when the +24 V
feeder is defective the fuse of the signalling supply PM has blown (AH043).
All external operating controls related to the EHTC system are placed in the control room.
The following is a list of them and a brief description of each :
a) Speed Increase. Operating this push button increases the
speed setpoint.
b) Speed decrease. Similar to (a) above
c) Lamp test This push button tests the service ability of all
lamps.
d) Overspeed setpoint enable This control is needed for testing the
overspeed trip system on overspeed.
e) EHTC/SR-IV Change-over this control permits the international
changeover from EHTC to SR-IV and vice versa
f) SR IV increase Setpoint adjuster for the SR-IV governor.
g) SR IV decrease Similar to (f)
h) Limit pressure This push button switches on controller ON,
the limit pressure controller.
i) Limit pressure controller OFF. Similar to (h)
j) Limit pressure setpoint increase enable pressure setpoint to be increased
k) Limit pressure setpoint decrease Similar to (k) decrease
l) Emergency stop valves open command to open the two emergency stop
valves.
m) Emergency stop valves close command to close the two emergency stop
valves.
Operating Controls on the EHTC Cubicle
a) BEO35 S11 This slide switch has the same function as
seen above (d)
b) BE035 S12 This slide switch shifts the limit value for
emergency trip testing.
c) BE035 S13 This slide switch isolates plunger coil control.
d) BE035 S14 Momentary operation of this slide switch
resets the stored alarm position controller fault provided there is no longer a fault alarm.
TURBINE GOVERNING SYSTEM OF DURGAPUR & BOKARO (CAPTIVE POWER PLANTS
1.0 Introduction
High response governing system for the steam turbine is necessary to maintain the turbine
speed at the desired set point during start-up normal operation. It also serves to prevent
undesired over-speeds following sudden loss of export load. In the event of generator
breaker opening, following a full load loss, governing system prevents the overspeeding of
the set to a dangerous level and quickly stabilises the set on house load or on- no-load. This
enables quick reloading in case of spurious loss of export load.
The governing system 9K66 turbine is of hydraulic type with mechanical centrifugal speed
governor. This system is provided to ensure :
a) Control of turbine speed/load.
b) Safeguarding of turbine against excessive speed increases.
c) Safeguarding of turbine against water-shock from the boiler.
d) Safeguarding of turbine against dropping vacuum.
e) Limiting turbine from excessive loading.
The mechanical centrifugal speed governor is the primary component of the governing
system which regulates the speed and load of the turbine. The efective range of governor
operation is between 600 and 3600 rpm. The turbine overspeed protection is provided by two
spring loaded plunger type safety governors. The safety governors are triggered at 111%
and 112% of the rated turbine speed by governors 1 and governors 2 respectively. The
turbine protection system protects the turbine against its failure by tripping it. In case of such
tripping ESVs and the HP governing valves will close cutting of the steam supply to the
turbine. The system is arranged in such a manner that the central protection line is divided
into two independent lines right and left reach with its own supply. Either line can be cut-of
from the central line by means of a testing slide valve. During testing, the turbine is protected
by the protection units coupled with the other protection line remains non-isolated.
2.0 DESCRIPTION AND FUNCTIONS
2.1 Mechanical Centrifugal Speed Governor
It is centrifugal type with two spinning weights and coil spring. It is mounted on the shaft
rotating in the ball bearings and driven by a gear transmission from the shaft of the turbine.
Nominal revolution of the speed governor causes increases in the centrifugal force of the
weights and spring tension. The speed governors cover plate is fxed on the fexible strip and
is displaced together with it with speed change. This displacement is a measure of revolution
and is approximately 13 mm corresponding to 3600 rpm. As preliminary coil spring tension is
small the speed governor begins to operate at about 600 rpm.
2.1.1Slide Block of the speed Governor
The speed governor slide valves block consists of three slide valves connected through a
lever which is turned about a constant place. The displacement of the top slide valve may be
carried out by Hand-wheel on which a scale is fxed to indicate the top slide valve position.
For remote operation, a motor is provided through a drive having sets of toothed wheel and
clutch for SLOW and FAST operation. The follow-up slide valve or middle slide valve follows
the motion of the face strap of the speed governor. The bottom slide valve controls the
governor valves travel by varying the pressure in the control oil line.
Block of the speed governor slide valves does the following duties :
a) Resetting of the hand operated turbine emergency trip gear.
b) Controlling of emergency stop valve and HP control valves Servomotors, thereby
starting of the turbine and bringing it to rated speed is accomplished.
c) Conversion of the speed governor face strap motion into variable oil pressure in the
control oil line (i.e. the impulse line controlling the HP control valves travel).
d) Changing the speed on idle run of the turbine as well as changing the load of turboset
connected to network.
e) Serving additional protection against speed increase.
At turbine standstill, the follow-up slide valve is in left extreme position. By turning the Hand-
wheel in the clockwise direction till zero of the scale, the top slide valve moves to the left
side opens the run-of ports controlling the stop valve servomotor, followed by the resetting of
the manual emergency trip gear. Bottom slide valve moves to right side by the connecting
lever with the pivot axis of the follow-up slide valve push rod as fulcrum, thereby opening the
run-of post, controlling the governor valves operation.
By turning the Hand-wheel in the anti-clockwise direction the top slide valve is shifted to the
right side, oil pressure is restored in the line controlling ESV servomotors and the resetting
line of the manual turbine emergency trip gear is drained. Simultaneously the bottom slide
valve is moved to the left side, thus closing the run-of port and enabling oil pressure to
restore in the control oil line.
If safety conditions of the turbine are correct the hand operated switch of the turbine remains
ftted-out. By further turning the Hand-wheel still to the anti-clockwise direction ESV
servomotors open. Further turning causes pressure increases in the control oil line, which
makes the control valve servomotors to open. The control oil line is supplied with relay oil
through the valve SE 16 used for change of static characteristic of governor. Opening of the
control valves servomotors causes starting of the turbine. Speed of the turbine is increased
to nominal speed with the help of the Hand-wheel, then the turbine is synchronised and
loaded.
The electric drive of the top slide valve has two speeds, switch-ON by electro magnetic
switches, Slow changeover time of the electric motor in the range of load 0 to 100% is equal
to about 60 seconds. The limit switches in the slide block are so set up that the frst one
switches-OFF the motor when the hand wheel is in the Outft position. The second one
switches-OFF the motor in the position corresponds with 107% of nominal speed of the
turbine. There are the position indicator and extreme positions signalling of the top slide in
the control room.
The additional protection of the turbine against speed increase operates as soon as speed
has raised by 14-15% above rated one. then the follow-up slide valve will move far enough,
to open drain from its rear changer and to cause oil pressure fall in the central safety line.
2.1.2Acceleration Limiter
To prevent excessive, dynamic overspeed of the turbine in case of load rejection, the
governing system is equipped with the inertia type acceleration limiter. It is driven from the
turbine shaft by the toothed gear. Nominal speed of the limiter is 200 rpm. In this the rotating
motion of the inner bush is transmitted to the concentric outer bush through a torsion spring.
When the turbine is in operation the whole arrangement is in rotary motion with constant
speed. In case of a fast increase in speed with time the holes in inner bush are displaced in
relation to the holes the outer bush by an angle 20
0
. This displacement causes the holes in
both the bushes to coincide, thereby draining of oil through the hole of the inner hole of the
inner bush as well as fall of oil pressure in the impulse line governing the HP control valves.
Thus the operation of the limiter causes immediate closing of the HP control valves. After
decay of distortion the control valves reopen automatically.
2.1.3HP Control Valves Servomotor
Each control valve is driven by separate unilateral acting servomotor. The servo-motors are
opened by relay oil pressure and shutdown with the help of springs. Control oil is supplied
under the controlling slide which with its edges control the oil pressure under the servo-
motors piston. The restoring mechanism of the servo-motor is of hydraulic type. The slide of
the restoring mechanism is driven from the servomotors piston by the cam system.
2.2 THE LIMITERS
2.2.1The Live Steam Pressure Limiter
The limiter protects the turbine against water entry from the boiler when there is sudden drop
of the live steam pressure. The limiter is a slide valve functions together with the electronic
live steam pressure regulator.
Live steam pressure drop causes, droop in pressure in the sensitive oil line of the pressure
limiter and that of the load limiter and thereby reduces the control oil pressure of the HP
steam control valves. The position of the live steam pressure limiter slide is transferred
remotely with a help of the potentiometer and extreme switches.
2.2.2The Vacuum Limiter
This limiter protects the turbine against operation with too high exhaust temperature. Rise in
condenser pressure causes drop in pressure in the sensitive oil line of the vacuum limiter,
thereby operates the pressure diference relay./ When the pursue diference relay operates
the motor of the load limiter is switched-ON in direction to Decrease of the turbine load.
Hence pressure in the control oil line of HP steam control valve decreases, causing control
valve to close. The pressure diference relay senses the diferential pressure of sensitive oil
line of load limiter and that of vacuums limiter.
Load of the turbine can be increased only after the condenser vacuum stabilises to the
required level. Load is raised with a help of electric motor or by hand turning the hand wheel
of the load limiter. Appropriate variation of the pressure controlling the HP control valves
servomotors with the pressure in the condenser
2.2.3Load Limiter
This limiter protects the turbine against excessive load. It is a controlling slide comprising the
oil pressure controlling the load limit and sensitive oil pressure of the load limiter. Pressure in
the controlling line of the limiter is set up the slide driven by the electric motor or Hand-wheel.
Extreme positions of the slide driven by the electric motor are signalled by extreme switches.
The pressure in the controlling oil line of the limiter is measured and calibrated in the
percentage of load.
2.2.4Control Oil Maximum Pressure Limiter of HP Control Valves.
This limiter limits the pressure of the control oil line, that operates the HP control valves from
increasing beyond the valve corresponding to the maximum load what is identical with
limitation of maximum speed after full load rejection. When manual raising of the speed
during idle running the limiter does not interfere. During idle running of the Turbine the speed
can be increased upto the speed of the safety governor actuation by Hand-wheel for testing.
The actuation of the limiter is signalled with the lamp switch-On by the extreme switch
operated by the bottom slide valve of the speed governor block. Simultaneously it switches-
OFF the driving motor of the speed governor block acting in the direction of increasing load
setting. During this time, setting is to be reduced immediately to put out the signal lamp from
the limiter.
2.2.5Pressure Regulator Slide
It is the control circuit of 1 out of 2 logic i.e., out of the two signals being received, the
control unit transmits the signal of lower values to the governing system. The pressure
regulating slide operates on the principal of equilibrium of forces i.e., the hydraulic oil
pressure acts on either side of the pressure slide. The lower pressure is transmitted to the
governor. The higher pressure results in draining of the oil from the drain oil lines and thus
ensuring an equilibrium.
3.0 Technical Data
Type : Hydraulic with Mechanical Speed
Governor
Operational range of speed governor : 600- 3600 RPM
Response speed of safety governor : 3345+15 RPM
Adjustable range of static characteristic
of speed governor : 3.5 - 4.5 - 6.0% of nominal speed,
Nn
Intensitivity of speed governor : -0.10% Nn
Regular speed change between idle run
and nominal load : 5 to 5% Nn
Maximum speed increase after load
Rejection : < 10% Nn
Relay oil pressure, PR : 20 atg
Safety oil pressure, PS : 1.5 atg
Safety governor trip setting : 1.5 atg
Safety governor no. 1 at : 111% Nn
Safety governor no. 2 at : 112% Nn
4.0 Starting and Operation
Setting-up the Hand-wheel of the slide valve block in OUTFIT position (i.e. extreme position
when rotated clockwise) result in outftting of the hand trip gear of the turbine and safety
governor slide valves. Before starting-up, load limiter is detached on electrical side. Then
turning the Hand-wheel in anti-clockwise direction, the control and stop valves servomotor
are opened. Now the turbine is started.
Load limiter is switched-ON when the condenser vacuum stabilises to be required level.
Then, speed is brought to the rated speed. At 80% of nominal speed the auxiliary oil pump
can be switched-OFF. The turbine can operate with inland or rigid power network.
Displacement of the cover plate of the speed governor under the infuence of speed is
transferred by the follow-up slide and levers on the lower slide of the speed governor block. It
results in change of control oil pressure of control valves. This control oil pressure Pct varies
with the speed of the turbine for diferent position of the controller hand wheel in the speed
governor block.
The speed is the controlled value when the unit is operating with its own inland network and
the load will be the controlled value when it is operating in parallel with the rigid network.
During normal operation the speed governor controls the HP control valves.
List of Equipment shown in Fig. 7
1) Speed Governor
2) Speed Governor Slide Valve Block
3) Lever of the Slide Valves
4) Speed Governor Slide Valves
5) Turbine Emergency Trip Gear
6) ESV Servomotor
7) HP control Valve Servomotor
8) Hand-wheel
9) Governor Static Characteristic Adjustment Cock, SE-16
10) Electromagnetic Solenoid Valves
11) Run-of Amplifer, SE74 S301
12) Run-of Amplifer, SE74, S302
13) Electromagnetic, Solenoid Valve SJ92 S311
14) Turbine lube Oil Pump
15) Emergency Lube Oil Pump
16) Auxiliary Lube Oil Pump
17) Relay Oil Pump-1
18) Relay Oil Pump-2
Legend for Fig 7
I - Safety Governor-1
II - Safety Governor-2
COPL- Control Oil Maximum Pressure Limiter
ALT - Acceleration Limiter
PLT - Live Steam Pressure Limiter
LLT - Load Limiter
VLT - Vacuum Limiter
DPR- Pressure Diference Relay
PR - Relay Oil Line Pressure
PS - Safety Oil Line Pressure
PL - Lube Oil Line Pressure
PC - Control Oil Line Pressure
PPL- Sensitive Oil Pressure of Pressure Limiter
PLL - Sensitive Oil Pressure of Load Limiter
PVL- Sensitive Oil Pressure of Vacuum Limiter
PC - Controlling Pressure of Load Limiter
Steam Turbine Protective Devices
1. Turbine Protective Devices
1.1 Possible Hazards
Abnormal operating conditions, including those where the turbine and its system are not
working as designed, will cause damage to the plant and possibly to personnel if allowed to
persist. The dangers likely to be encountered are :
- Over-speeding.
- Lubricating oil failure
- High turbine exhaust pressure(low condenser vacuum)
- Governor failure.
- Water ingress to blading.
- Thrust bearing failure.
- Excessive vibration
- Excessive temperature diferentials
- Excessive eccentricity.
If the plant is manned by responsible operating staf on a continuous basis, the last four
items can be monitored by supervisory equipment having preset alarm levels. This allows
the operator freedom to manoeuvre the operating conditions to reduce the dangerous
condition. If unable to do this, the operator must trip the plant manually.
The other dangers have more immediate efects on the plant and are generally detected by
special trip gear which releases the protection system hydraulic pressure, and thus closes all
the steam valves and disconnects the generator.
The above list only includes those dangers which are special to the turbine. Other hazards
specifc to the boiler, generator, trasformers, and high voltage connections may also initiate
a turbine-generator trip. The system described here can be tripped by signals from these
devices, which are described in the relevant volume.
Overspeed would shave serious consequences for both plant and personnel, therefore the
protective arrangements have been designed to eliminate any possibility of a dangerous
overspeed.
The turbine governing system provides the frst line of defence against overspeed and the
second line of defence is provided by separate overspeed trips. The turbine cannot
overspeed when the generator is connected and in synchronism with the electrical power
system network. The turbine is at risk during run-up and also when a disconnection occurs
on-load. Since disconnection can occur as a result of another trip function, e.g., loss of
lubricating oil, it is desirable to reduce the potential for overspeed by co-ordinating the
tripping of the circuit-breaker and the closure of the steam valves. An overspeed will only
occur if the steam passing through the turbine exceeds that required to match the load.
Thus, if possible, tripping of the turbine steam valves. When the steam fow has reduced
nearly to the no-load valve, the generator may be disconnected from the power system
network without risk of overspeed. This known as a Category B trips. These include governor
failure and lubricating oil failure as well as overspeed, water-ingress trips and the operators
emergency stop button.
Other tripping functions, such as turbine high exhaust-pressure trips and certain electrical
trips, require immediate generator disconnection. As these trips are unlikely to have a cause
common with any condition which is likely to lead to jamming of the turbine steam valves,
this can be done without any signifcant degradation to the overspeed integrity of the unit.
These are referred to as Category A trips.
The high exhaust-pressure trip is, like the overspeed trip, the last line of defence against an
abnormal operating condition. The danger is that if the exhaust pressure is excessive, the
last-stage LP turbine balding will become overheated and damaged. Since the prime cause
of poor exhaust-pressure is likely to be loss of CW fow, it is usual practice to provide high
exhaust pressure unloading gear as part of the governing system in an efort to reduce
turbine load and avoid tripping. LP exhaust temperature sprays are often provided as another
stage of protection, coming into operation when a high temperature is sensed or when the
turbine load falls below a predetermined value. Note that there is a greater potential for
heating the balding at very low loads as there is no steady fow through the turbine casing.
These are normally set to operate at slightly above atmospheric pressure.
Although a continuous supply of lubricating oil is practically ensured by separate AC and
standby DC pumps there is always the possibility of a fractured pipe. The turbine is then
tripped on low lubricating-oil pressure.
In the event of a complete failure of the turbine governing system, i.e., failure of more than
one channel or a failure which renders the governor operative, the governor is designed to
sent trip-initiating signals to the protection scheme.
Water ingress to the turbine can occur due to malfunction of boiler or feed controls,
especially during a change in load, In this case, wet steam or even slugs of water could be
introduced through the HP steam line. The degree of hazards and the type of protection
required depends on the boiler type and steam conditions at the inlet to the turbine. When a
drum boiler is used to supply superheated steam, turbine protection may not be necessary,
providing loss of boiler fring is adequately detected and alarmed so that the operator can
take the necessary corrective action, In the case of a once-though boiler supplying
superheated steam, it is necessary to trip the turbine on low steam temperature before
saturated steam conditions reach the turbine. The danger is that, if not tripped, serve
distortion could occur, causing seizure of the turbine steam valves or fracture of the turbine
balding. Once-Through boiler supplying dry saturated steam represent less of a hazard due
to chilling. However, the sudden ingress of set steam could result in serve thrust loadings on
the turbine and balding, so the plant must be designed to accept this or be protected against
It Water ingress may also occur from feedheateing plant via back-fow to the tapping points
on the main turbine. The arrangement to protect against this are discussed in Chapter 3 on
feedheateing Plant
1.2 Protectin Scheme
The trip-initiating devices as described in the previous paragraph will of two types :
- Devices where an electrical changeover contact operates.
- Devices capable of direct tripping of the hydraulic fuid system.
The result of a trip initiation will be to close the turbine steam valves and trip the generator
circuit-breaker, having regard to the division in Categories A and B. The tripping system
includes redundancy, so that the failure of any one element in the system does not prevent
tripping, and is also designed to avoid spurious tripping as far as possible. The interfaces
withe electrical tripping system and the stop and governor valve relays are also shown. The
diagram does not show the redundancy associated with the electrical tripping system, which
is described later in this section.
1.4 Overspeed Trip
The overspeed trip is the fnal protection against catastrophic failure of the turbine following a
load rejection, causing the unit to become disconnected from the power system. Additionally,
an overspeed may be caused by a governor failure on an unsynchronised turbine causing an
excessive steam demand. An excess approaching 100% would cause a rapid acceleration of
over 10% speed per second. In documented cases where this has occurred, the centrifugal
stress limits of the rotating parts have been exceeded and a major rupture has taken place
with components penetrating the casing. Speeds as high as 180% have been recorded.
The manufacturer normally carries out a works overspeed proof test at 120%, well below the
design limit at which failure could occur. The setpoint of the overspeed trip is such that this
speed would never be exceeded even at the maximum acceleration rate of the turbine.
Because of the delay time associated with the mechanisms, the fnite response time of the
valve relays and the stored energy in the form of steam and water within the turbine, it is
logical to split the 20% range of available overspeed equally between the governor and the
overspeed trip. The stop valves (operated by the overspeed trip) and the governing valves
will therefore are similar requirements for their maximum closure ates. The overspeed trip is
set in the range of 110-111% speed. This recognises normal governor action over a 1%
speed range.
Overspeed is detected by means of a pair of spring-paded trip bolts mounted in an extension
to the turbine shaft at the HP end of the machine. One trip bolt assembly is used for each trip
channel and each assembly as provided with independent on-load test facilities. The bolt has
its centre of gravity a short distance from the axis of rotation and, at low speeds, is held
retracted by a spring. At 10% overspeed, the out of balance force overcomes the spring
force, causing the bolt to extend beyond the shaft where it trips the static trip lever and
releases the latch to trip the turbine. Adjustment to the tripping speed is carried out when the
turbine is stationary and access to the adjusting plug is possible.
The overspeed trip can be tested without actually overspending or taking the set of-load.
This is done by selecting either the front or rear system for testing, thus automatically
isolating the associated emergency trip valve. An interlocked movement of the trip test lever
and trip test valve then injects a supply of lubricating oil under pressure into the rotating
turbine shaft, through porting which directs it to the over-speed bolt under test. This then fies
out and trips its emergency trip valve via the lever and trip plunger. Following release of the
test pressure, these items are reset and the second bolt selected for test.
1.5 Mechanically-Operated Trips
Included under this heading are any trips which may be implemented by means of a direct
mechanical or hydraulic action onto the latching trip lever.
The low lubricating-oil pressure trip is sometimes implemented in this manner. Lubricating oil
under pressure is supplied to a single-acting spring-loaded trip cylinder. The oil is supplied
via a deadweight accumulator common to front and rear channels. This smooths out
fuctuations in oil pressure and, in the event of a sudden loss of oil pressure, will maintain the
pressure to the trip cylinder for several seconds, thus allowing possible recovery by starting
of the emergency pumps.
Similarly, a direct high exhaust-pressure trip is often implemented using the same spring-
loaded trip cylinder For the front tripping system, there are two sets of detectors labelled 1
and 2. Lubricating oil is supplied to the detectors via an orifce plate. The downstream
pressure is controlled by a leak-of valve, actuated by bellows unit. The top half of the
bellows is evacuated and sealed at a reference pressure close to zero mbar absolute. The
lower half of the bellows is connected to the condenser. The leak-of valve is normally fully
seated, since the force supplied by spring A exceeds that exerted by the condenser
pressure.
As the condenser pressure rises, a point is reached where the spring force is counter-
balanced and a further pressure increases causes the leak-of valve to unseat. As lubricating
oil pressure is lost within the vacuum trip unit, plunger B is moved downwards by spring force
and the pressure in the short length of pipe C is lost. If detector 2 also trips, lubricating oil
supplying the front trip cylinder is connected to drain, thus releasing the trip latch. A similar
pair of exhaust pressure detectors operate into the trip cylinder of the year system. On-load
testing is enabled by a mechanical interlock on the trip test lever, so that when the front
protection system is isolated, its two associated exhaust pressure detectors can be tested in
turn by slowly raising the pressure by a needle valve admitting atmospheric air. This permits
resetting of the trip point if desired.
1.6 Operator Tripping Facilities
It is normal practice to provide some direct mechanical means of tripping the turbine from the
front pedestal. Originally, this was an essential safeguard for personnel when carrying out
overspeed tests - either on-load oil-injection tests of of-load tests actually overspeeding the
machine.
This form of trip is still retained, even where complete remote testing can be carried out, as it
provides an independent and very direct means of shutting down the turbine-generator,
should a plant attendant observe local conditions which are hazardous to men or the
machine. For the same reason an electrically-signalled push-button trip is provided near the
generator-end of the machine.
A remote emergency stop pushbutton is also provided in the control room, where the
operator has various instruments to guide him. Typically, the operator may decide to trip the
machine in the event of persistent high vibration. this pushbutton is also the normal means of
shutting down a turbine from a low load.
2. TURBINE INSTRUMENTATION
A large modern turbine-generator comprises a number of cylinder coupled together to form a
rotating shaft line, Chapter 1 has described this arrangement in detail. The nature and
complexity of this arrangement required information to be presented to the operator clearly
and concisely. Associated turbine systems, described in this chapter, need to be controlled
and any abnormal conditions drawn to the operators attention. Particular requirements for
instrumentatin are dealt with in the appropriate subsection.
These categories are :
- Supervisory instrumentation.
- Efciency instrumentation.
- auxiliary system instrumentation.
- condition monitoring instrumentation.
- Instrumentation associated with protection and control equipment.
- Instrumentation to provide post-incident records.
2.1 Classifcation of Instrumentation
2.1.1Supervisory instrumentation
these are instruments required on a continuous basis to determine the present conditions
and trends of the main rotating and stationary components, (a) to ensure safe operation
within the defned limits and (b), to give advance warning of deteriortin or change in the main
turbine-generator behavour, which may rquire either maintenance attention or a temporary
restriction in the operating role.
The parameters measured are :
- Rotor axial position : In conjuction with cylinder expansion measurements, this
enables the relative axial movement to be meaasured so that adequate clearance margins
are maintained under all conditions of operatin. Typically this mesurement is provided on
each cylinder of the machine.
- Cylinder expansion : In addition to its use in determining clearnace margins between
the rotor and cylinders, diferential measurment systems are provided to monitor the
expansion and movement of cylinders relative to each other and their support structures.
Measurements ar provided on each cylinder of the machine.
- Bearing pedestal vibration : These are measured at each bearing to continuouldy
monitor the dynamic behaviour of the machine
- Shaft eccentricity : The peak-to-peak radial excursion of the rotor relative to the non-
rotaing parts is mesured on ech rotor to nomitor qualittive changes in the behaviour of the
rotor which may indicate abnormal or unsafe conditions.
- Shaft speed : A single measurement of shaft speed is required, independent of the
turbine governor, for operator reference, particularly during turbine run-up.
- Steam valve positions : An analogue measurement of the position of each steam
valve is useful to the operator for general reference, to check the capability for carrying more
load or for assistance in fault fnding.
- Metal temperature measurement : These provide a knowledge of the thermal state of
the turbine during both transient and steady state operation. Measuring points are located in
the walls of the HP and interceptor steam valve chests, and in the HP and IP cylinders.
- Thrust Bearing wear : This measurement ensures that thrust pads wear is maintained
with safe design limits.
All of these parameters are displayed to the operator either on continuous, direct-reading
instruments or on a VDU formate associated with a computer-based data processing system.
If a VDU display is used, it is selectable for continuous access and scanned at intervals of
less than 10s to ensure that the operator is kept informed of the current valve. Certain
parameters, such as steam valve positions and speed, can change substantially in a fraction
of a second. It is essential that the operator has available a true value of the present reading,
therefore direct reading is always employed.
Because of their close association with the running machine, generally using transducers
mounted in a severe environment, a highly specialised and thoroughly proven equipment is
essential. The processing equipment is cubicle mounted and includes, where necessary,
alarm ouptuts so that the operators attention can rapidly be drawn to parameter excursions
requireing corrective action. When computer processing is involved, the whole scheme is
subejct to careful review to ensure that if the computer fails, the operator still has sufcient
information to continue running at a steady load or to permit safe shutdown.
All of the turbine supervisory paramters are used to provide post-incident records. Some are
also used in the control equipment of turbine run-up.
2.1.2Efciency Instrumentation
These are instruments required to determine or infer the operating efciency of the plant,
both for short term monitoring and the detection of long term trends.
The temperatures and prssures of steam and water are measured to confrm that the plant
compenents are operating efciently and in the intended manner. For example,
measurement of the steam and water conditions at the inlet and outlet of a feedwater heater
enables an operator confrm its satisfactory operation. Unsatisfactory operation is unlikely to
prejudice the continued running of the plant but does afect its efciently. The category of
instrumentation therefore draws attentation to maintenance activities which are efciency-
related.
Alarms are derived from some parameters in this category, for example, steam temperature
upstream of the Hp stop valves. These alarms are less critical than those derived from
supervisory instrumentaion and therefore the alarm processing may be carried out
exclusively in the data processing computer. Steam temperatures upstream of the turbine Hp
stop valves are used to provide data for the long time history.
Some of the parameters in the efciency instrumentation category are used for the heat rate
test instrumentation for local operation or fault fnding. Wherever their operation is essential
\to the main turbine-generator unit, facilities for remote alarms and indications in the control
room are necessary.
2.1.4Condition Monitoring Instrumentation
This defned list of instruments is used on a periodic basis to confrm the absence of long
term trends which might lead to unplanned outages and to defne activities for future
outages. To this extent, some of the instrumentation in this category is of a diagnostic nature.
The defne subcategories are :
- Heat rate test instrumentation.
- Machine level instrumentation.
- shaft vibration instrumentation.
The purpose and scope of each of these subcategories is described below.
- Heat rate test instrumentation
- Machine level instrumentation
- Shaft vibration instrumentation
The purpose and scope of each of these subcategories is described below.
Heat Rate Test Instrumentation
The manufacturer supplies pockets for insertion of thermocouples and pressure tapping
points up to and including the primary isolating valve. Where possible, steam and
condensate fows are measured by diferential pressure devices and so the provision made
on the plant as-built can again be confned to fxed orifces with suitable tapping points. The
main condensate fow measurement is one of the most critical Provision is generally made to
insert the calibrated orifce plants in sections of condensate pipework parallel to the main
path. When test are to be preformed, the main path is isolated and all the fow passes
through the orifce plates. provision is also made for the connection of a transmission-type
dynamometer to measure the power supplied by the boiler feed pump turbine (if ftted).
In some plants, a more limited range of parameters is measured on a permanent basis to
provide a routine on-line efciency monitoring schemes inevitably provide less-accurate
information than would be obtained from plant acceptance tests, using recently calibrated
transducers. The value of on-line monitoring is that it enables trends to be identifed and
appropriate maintenance work scheduled. Where alternative plant operating strategies are
possible, for example, selection of a standby fed pump instead of a faulty duty pump, then
the operator can take measures to improve the efciency of the plant on-line.
Machine Level Instrumentation
This comprises equipments for automatically measuring and recording changes in the
relative levels of the turbine-generator bearing pedestals. Primarily used for fault diagnosis,
this equipment is sometimes supplied built-in by the turbine manufacturer. An alternatively
approach is to provided facing and connection points on the pedestals so that portable
equipment can be sued to make the check during maintenance outages.
Shaft vibration instrumentation
The scope of the measuring points required for this is more complex than the provision made
for turbine supervisory purposes. At each bearings, two transducer measure vibration in the
same plane but displaced at 90
0
to each other. This facilitates the recording of shaft vibration
signatures on run-down and also orbit plots may be taken on-load so that a complete picture
of changes in shaft dynamics can be formulated by an expert or an expert computing
system. Such an analysis can lead to improvements in the prediction of maintenance
routines.
2.1.5Instrumentation associated with protection and control equipment
This comprises instrumentation used in conjuction with a control loop, either locally or for the
main plant control systems. The turbine governing system (described in section 1 of this
chapter) is an example of the latter, whilst any local control loops not covered by auxiliary
Systems for part of the former. These local controls are used to operate plant prior to a unit
start-up or following maintenance, where operator action from the control from is not
necessary. Also, some plant requires control which may not be immediately connected with
the minute-by-minute operation of the unit. Further local controls are sometimes needed to
permit a detailed fault analysis to be carried out following identifcation of a problem in the
central control room.
2.1.6Instrumentation to provide post-incident records
The detectors required to provide these records are derived from other categories of
instrumentation, mainly from the supervisory instrumentation. These records provide critical
plant data for designated periods before and after an incident to enable the cause to be
investigated. The recording is initiated by a unit or plant trip (for example, the trip of a feed
pump), or directly by the operator on demand. These records are produced by data
processing computers and, since continuous scanning of all the input parameters is
necessary, some compromises have to be made in the scanning speed. Thus, assuming a
minimum scanning internal of 3s and depending on their relative position in the scanning
cycle, a parameter might respond up to 3 s before or 3 s after the recording shows the trip to
have operated. In specifying the requirements of the date logging system, the turbine plant
designer consider these limitation to provide a compromise which is both cost efective and
valuable to operators.
3. TURBINE FOUNDATIONS
The turbine-generator foundations consists of the support structure, the sub-foundation and
the subsoil; they perform the following functions :
- Support the static load of the turbine-generator and associated pipe loads, and
transmit these forces to the subsoil.
- Restrain the plant from undue movement due to dynamic forces resulting from the load
torque, unbalance forces, electrical faults, etc., by transmitted and absorbing the associated
energy.
- Maintain the alignment of the plant under all operating conditions.
- Accommodate the thermal expansion of the structure and static parts of the plant
under all operating conditions.
- Raise the plant above the turbine house foor to provide access for electrical
connections and pipe work. Bottom connection of the main steam pipe-work is particularly
desirable to avoid dismantling pipe work during maintenance and to prevent the pipework
draining into the turbine. The height of the turbine above the basement foor level is partly
determined by the need to accommodate the condenser and condenser neck, when an
underslung condenser is used, and partly by consideration of condensate drainage
requirements. The bled-steam piping should drain away from the turbine and the drains from
LP heaters must be returned to the condenser. For this to be achieved with gravity drainage
requires a certain minimum height diference between turbine and condenser hotwell.
For main turbine-generator plant, these requirements have been satisfed by either
reinforced concrete or steel support structures, which are described in more details in later
sections.
It is also necessary to monitor the movement of the foundations throughout the life of the
station. Settlement of the whole foundation in service is not very serious, provided that it is
not large enough to afect electrical and steam connections, but diferential movement
between bearing supports must be avoided if the alignment of the plant is to be maintained
within reasonable limits. Multi-limb manometric level measuring systems are therefore
installed on the bearing supports to monitor relative level changes.
Salve units are ftted to each bearing supports, with a master reference unit at one point and
the whole system is flled with water. A uniform level is thus established by the water surface
and movement of the bearing support relative to the fxed water level can be detected by
suitable sensors ftted on each slave unit. Sensors using micrometer adjustment of an
electrical contact probe, and foats with LVDT position measurement have been used in the
past, but both systems have disadvantages. Present day systems use an ultrasonic sensor
ftted in the base of each salve unit which measures the position of the water surface by
sound refection technique. Accuracy of measurement is typically +0.05 mm, with a minimum
measurement range of +2.5 mm about nominal level.
Cooling water is circulated around jackets on each slave unit to eliminate errors due to
manometer water temperature variations. The balance box is then vented to atmosphere at a
single point.
STEAM TURBINE PROTECTION SYSTEM
The function of turbine protection system is to protect the turbine under any dangerous
operating conditions. The more likely dangers to which a turbine is subjected during
operation may be summarized :
a) Overspeeding
b) Motoring
c) Oil failure
d) Thrust bearing failure
e) Vacuum failure
f) Excessive vibration
g) Excessive temperature diferentials (water induction)
h) Excessive eccentricity
There are automatic devices known as trip and unloading gear provided for immediate
shutdown of the turbo-generator under emergency conditions.
PROTECTION DEVICES
Main Trip Valve
The function of the main trip valve is to open the trip oil circuit in the event of abnormal
conditions, thereby closing the main and reheat stop and control valves and thus shutting of
the admission of steam to the turbine.
Solenoid Valve for Remote Operation of Main Trip Valve
The solenoid valve is installed in the pressure oil pipe to the main trip valve and, when
operated, interrupts the oil fow. This causes the tripping oil circuit to be opened and the
turbine to be stopped. The solenoid valve is remote controlled electrically, e.g. from the
control room or from other protective device.
TRIPPING DEVICES
Overspeed Trip
If a turbine is allowed to overspeed, the stresses in the rotating components increase as the
centrifugal stresses are proportional to square of speed. The stress in some components,
such as the larger wheel, blades and the generator end-bells are the frst to reach a stage
when local plastic yielding occurs and if the speed continues to rise, it eventually leads to
failure. It, therefore, generally follows that the speed of turbo-generators shall not be allowed
to exceed by 12.5% of the normal speed except for once when it is works proof tested after
manufacture during which the rotors are usually fun for a few minutes at 20% overspeed in a
test pit.
Although the governor should limit the speed to a level well below 110% a safety device is
invariably ftted and usually duplicated, to close the emergency stop valve should the speed
rise above this Value . It consists of a spring-loaded bolt or ring, incorporated into the shaft at
the governor end, having its centre of gravity a short distance from the axis of rotation. The
out of balance force is arranged to overcome the spring compression at 10% overspeed
Emergency Hand Trip
This tripping device is usually in the form of a lever on the governor pedestal that operates
the trip valve of the overspeed trip gear, thus closing all valves by releasing the HP oil
pressure. It caters for emergencies not covered by the automatic trip gear.
Remote Trip Gear
To permit the machine to be tripped remotely from the control room, the emergency hand trip
lever can be actuated by means of a solenoid or a torque motor. The actuators are energised
by the station battery when the control room switch is closed.
Oil Failure Trips
Loss of lubricating oil to the bearings would quickly lead to damage of the journal and thrust
bearings, with consequent damage to the shaft. It may caused by :
a) Low oil level, due to leakage (e.g. through a corroded cooler tube). This is detected by
a foat-operated switch which may be used to sound an alarm or operate the remote trip
gear.
b) Low HP oil pressure (where a common pump is used to supply oil to both the
lubricating system and governing gear). Low pressure may be due to pump failure, leakage
or blockage. No special trip arrangement is required as the steam valves will close
automatically on loss of relay oil pressure.
c) Low l.p. oil pressure due to main oil pump failure or low running speed. This detected
by a pressure switch, which automatically starts up the A.C. auxiliary oil pump. In the event
of a failure of unit and station A.C. supplies a relay starts the D.C. emergency pump which is
fed from the station battery.
Thrust Bearing Trip Device
Owing to variation of the thrust load, the thrust bearing is more susceptible to wear than the
journal bearings. To prevent damage to blades and glands should the wear become
excessive, a thrust trip device is ftted.
In the event of axial displacement of the shaft due to excessive wear of the thrust bearings
pads, the function of the thrust bearings trip device is to open the auxiliary trip oil circuit, thus
shutting down the unit to avoid damages. . The two rows of tripping cams (2) which are
arranged on opposite side of turbine shaft (1) have a specifc axial clearance, equivalent to
the permissible shaft displacement, relative to pawl (3) of the thrust bearing trip. If the axial
displacement of the shaft exceeds the permissible limit, the cam engages pawl (3) which
releases piston 97) to depressurize the auxiliary trip oil circuit and at the same time to
actuate limite switch (10)
FIG : THRUST BEARING TRIP
Low Vacuum Trip
Should the vacuum unloading gear fail to halt a falling vacuum, a vacuum trip device is
incorporated that either operates main trip valve or the pressure switch. The setting of the
vacuum trip is dictated by the ability of the last stage turbine balding to withstand the high
temperature condition that arise when operating at a poor vacuum. The purpose of the low
vacuum trip is to operate when a failure of vacuum occurs in the condenser, thus tripping out
the main and reheat stop and control valves and shutting of the supply of steam to the
turbine within the shortest possible time. On the trip device, compression spring (3) set to a
specifc tension, pushes downwards against diaphragm (4), the top side of which is
subjected to the vacuum. If the vacuum is too weak to contract the spring tension, the spring
moves valve (6) downwards. The pressure beneath valve (7) is thereby depressurization of
the auxiliary trip oil circuit actuates main trip valve, thereby closing all turbine valves.
Vacuum Breaker for Reducing the Running Down Time of the Turbine
With normal shut down or tripping of the machine, the function of the vacuum breakers is to
cause an increase in condenser pressure by inducting atmospheric air into the condense
together with bypass steam fowing into the condenser from the bypass station (if provided).
When the pressure in the condenser increase, the ventilation of the turbine balding is
increased which causes the turboset to slow down so that the running down time of the
turboset and the time needed for passing through critical speeds are shortened.
The partial vacuum breaker is used when the running down time is to be shortened with
normal shut down and plant conditions are free of disturbance. Taking blade stress into
consideration the permissible operational condenser pressure of about 0.3 ata should not be
exceeded. For this reason the limiting valve for the condenser pressure is set at about 0.2
ata. In special cases requiring a rapid shutdown of the turboset, the total vacuum breaker is
employed.
Electrical Control of Partial Vacuum Breaker
The vacuum breaker valve is actuated to open once by a manual key. It closes automatically
when the pressure in the condenser rises. This control achieves a rapid passing through the
speed range up to turning operation. The pressure switch installed in the condenser for
registering the pressure increase is set at 0.18 ata so that the condenser pressure does not
exceed 0.2 ata after the valve has closed.
Electrical Control of Total Vacuum Breaker
To break the vacuum without limitation due to condenser pressure, a further manual key is
provided. This key also opens the vacuum breaker valve. However, it cannot go into the
closing position until the close key provided for closing is used. This control enables a
complete equalisation of condenser and ambient pressure.
Automatic Control
The vacuum breaker is also actuated automatically by the turbine fre protection system to
shut the turboset down more quickly. It is switched back manually using the close key in this
case.
Low Vacuum Unloading Gear
Should the vacuum fall to a poor value, the temperature of the exhaust increases and may
possibly damage the last rows of balding and the condenser tubes, since under the
temperature infuence, the tubes will expand excessively and possibly buckle. To avoid this,
low vacuum unloading gear is used which, below a certain vacuum, progressively decreases
the steam fow as the exhaust pressure rises, thus tending to restore the vacuum.
The gear is designed so that it cannot reload the turbo-generator automatically when the
vacuum is restored, as this might result in load snatching, which would disturb the electrical
system. An added precaution against sudden loss of vacuum damaging the last rows of
balding consists of rupture discs which are ftted on the exhaust hoods of the low pressure
cylinders. In an emergency these are capable of passing the full load condenser steam fow
without the last row of balding being subjected to a dangerous temperature.
Low Steam Pressure Unloading Gear
The correct functioning of the turbine control gear depends on the maintenance at the stop
valve of the design steam condition. If the boiler failed to maintain the steam pressure, the
turbine should demand more steam, which would cause the pressure to fall still further.
Further more, if the fall in pressure were sudden (due to, say loss of ignition), the sudden
demand for more steam might cause water to be carried into the turbine causing serious
damage. Protection against this may be obtained by reducing the load on the turbine, should
the inlet steam pressure fall below about 90% of normal superheater outlet pressure.
Protection Against Water Induction and Overspeeding
The steam turbine extraction lines to the feed water heaters are provided with power assisted
quick closing non-return or reverse current valve which shall close automatically when the
steam turbine is tripped, to prevent any back fow of fash steam from the heaters into the
steam turbine, which might cause overspeeding of the steam turbine. The non return valve
also closes on heater high level to prevent water induction into turbine. The reverse current
valves are designed for a minimum pressure drop. The reverse current valves are either
pneumatically operated or hydraulically operated.
In case of pneumatic valve, each valve is provided with air cylinder and spring device to
assist in the opening and closing operation respectively. In case of hydraulically operated
valve, the hydraulic operated circuit is common to the governing oil system.
Exhaust Temperature Limiting Equipment
the steam turbine low pressure exhaust hood may be equipped withe water sprays. The
sprays limite steam temperature at the exhaust under unusal conditions. For this purpose
thermostats are provided at or near the low pressure end of the steam turbine where the
most rapid increase in exhaust temperature can be expected. The steam turbine exhaust
hood spray water is generally taken from the discharge of the condensate pump. A motor
operate valve may be provided on the spray water line. The motor operated valve closes
remote manually, when the exhaust temperature.
TURBINE SUPERVISORY INTSTRUMENTATION SYSTEM
General
A complex rotating machine like steam turbine needs very close monitoring and supervision
of certain physical phenomena which it undergoes during various stages of operation like
start up, loading, load changes and shut down. The turbine supervisory stem is an aid which
enable to process the information for safe and proper operation of steam turbine with respect
to -
i) Axial shift of rotor
ii) Diferential expansion of rotors and cylinders
iii) Shaft eccentricity
iv) Overall thermal expansion
v) Bearing vibrations
i) Axial Shift of Rotor
The axial displacement of the rotor from its position is measured by means of a suitable
measuring device and the same is indicated and recorded continuously.
The thrust cooler, a part of the turbine rotor, exerts a pressure against the thrust shoes which
are located on both sides of the thrust cooler. A small axial displacement occurs when the
electrical load on the machine is changed or due to the wear of the thrust shoes. The
measurement of axial shaft makes use of an electromagnetic pick up. The pick up is of
contactless diferential transformer type.
To have a fool proof tripping of the unit in cases of abnormal axial shifts of rotor, a
hydromechanical protection is also incorporated for turbines. In this system, the lubricating
oil is supplied to a slide which moves along the rotor in case of its movement. As the rotor
movement occurs, the pressure of oil is reduced by draining of oil which is due to the
movement of slide. When the movement of the rotor is say 0.7 mm, the pressure drop in the
oil is communicated through a manostart which causes the turbine to trip.
Proper setting of extreme limits of axial shift are set with the rotor pressing the thrust shoe
towards the exhaust (Normal Position, takes as 0 mm)
ii) Diferential Expansions of Rotors and Cylinders
When steam is admitted into the turbine, thermal expansion afects both the rotor and the
casing. If the rotor expands at the same rate as the casing, there will be no problem. But
since the rotor is of a lighter mass than the casing,. It will heat up fast and therefore, expand
faster than the casing. Axial clearances between the stator and rotor are provided to allow
diferential expansion of the turbine. However, rubbing between the rotating parts and the
stationary parts will occur if allowable diferential limits are exceeded. So, the purpose of the
diferential expansion indicator/recorder is to indicate the relative motions of the stator and
rotor for monitoring by the operation personnel.
The measurement of diferential expansions of rotors and stators is carried out by making
use of electromagnetic pickups. There are two coils mounted with equal air gap on both
sides of the reference cooler when the rotor is pressed towards the generator. This position
of the rotor with the reference collar in the middle is the O position. The primary winding of
the pick up is fed with an A.C. voltage. When the unit is heated up and axial movement
occurs, the air gap on one side increase while on the other side it decreases. This causes an
unbalance in the circuitry and an electrical output signal proportional to the diferential
expansion is fed to the indicator/recorder for measurement.
iii) Shaft Eccentricity
When a unit is shut down, the turbine rotor will tend to bow because of uneven cooling
between the upper and the lower half of the turbine rotor. By rotating the rotor slowly on
turning gear, uniform cooling of the rotor results, allowing the rotor to run true. Eccentricity
monitoring system enables the operating personnel to keep a constant watch over the rotor
defation during steady as well as changed conditions of operation of turbine.
A reluctance type detector having active and passive detector coils is mounted inside the
bearing pedestal. The active and passive coils are magnetically isolated from each other.
Both the elements of the detectors are connected in an initially unbalanced bridge
conFiguration excited by a suitable power supply. The rotation of the shaft alters the air gap
between the detector face and shaft collar. The alteration of magnetic reluctance is a
function of the change in air gap. The change in air gap is dependent on shaft bow
(eccentricity).
iv) Overall Thermal Expansion of Casings
As a unit is taken from its cold condition to its hot and loaded state, the thermal change in
the casing will cause it to expand. As the turbine casing is anchored at the condenser and
(LPT middle), the casing will try to expand (towards the front pedestal) away from this
anchored end. The opposite end is designed to move freely along longitudinal lubricated key
ways. If for some reason the non-secured end of the unit is hampered from sliding smoothly
along the guide keys as the casing expands, damaging stress can develop causing serious
damage to the unit.
The measurement of overall thermal expansions of turbine is carried out at the middle and
front bearing pedestals. The detector are of indicating type and are located on the sole
plates of the bearing pedestals. The detection of casing expansion is made using a
potentiometer type transmitter. This transmitter consists of a spring loaded rod to which a
toothed rack is fastened. The rod is butted against the casing housing, so that the expanding
causing will move the rod. A gear on the detector potentiometer shaft is coupled to the rod
rack to cause the potentiometer to rotate proportionately to the casing expansion.
BHILAI STEEL PLANT, POWER & BLOWING STATION
Area of power plant: Turbo-Alternators
TURBINE DETAILS : There are 03 nos of machines, each of 12 MWs in
capacity.
Operation Instruction for T.G.# 0
Capacity : 12 MW Machine
Type : K-12-35-T
Turbine Type : Impulse - Reaction
No. of Stages : 17
Speed : 3000 RPM
1. Diferent Component & Their Function
A. Auto Stop Valve
It allows steam to the turbine steam chest and cuts of the steam instantaneously and save
the machine, whenever.
i) Oil pressure drops, in the H.P. oil system, down to 3 Kg/Cm
2
ii) Emergency governor trip.
iii) Hand tripping of the automatic closing device.
iv) Remote tripping by of a special remote switch.
v) Non permissible axial displacement of turbine rotor.
B. Remote Switch
The oil supply to support the Auto Stop Valve passes through it. There is pilot valve in the
remote switch which can be operated in either position. In one position it allows oil to Auto
Stop Valve and in the other position it cuts of the oil and opens the oil stock under Auto Stop
Valve to drain and the machine trips. This remote switch piston can be operated from a push
button switch on the panel. Also when the axial stress is more in the trust bearing, by an
electrical impulse received from the axial stress manometer this piston will operate and trips
the machine.
C. Emergency Governor
This is situated in the main shaft. Whenever the machine runs at particular overspeed the
bolt from the emergency governor will project out due to centrifugal force and hits the latch of
the automatic closing device which in turn trips the machine.
D. Automatic closing Device
It is similar to remote switch. The oil supply to the A.S.V. will be cut of by operating the slide
valve of the automatic closing device resulting in tripping of the machine. The slide valve of
this device can be tripped manually or by the emergency governor bolt whenever their is
overspeed.
E. Main Oil Pump
It supplies oil to regulation and lubrication system constantly when the machine is working. It
is situated on the main shaft of the machine.
F. Speeder Gear (Speed Governor)
This controls the speed of the machine to be strictly at 3000 RPM. By operating it either
manually or by remote motor from the control desk or control room the load on the machine
can be varied as desired. The speed of the machine can be varied from 2650 to 3100 RPM
during idle run.
G. Turbo Pump Governor
It gets impulse from the power oil system. If the pressure of the power oil system falls by any
reason the steam valve in it will be opened and steam will be supplied to the T.O.P.
H. Oil Cooler
This is to cool the oil mainly going to lubrication. The oil pressure inside the cooler is same
as that in the power oil system.
I. Oil Tank
The capacity of the oil tank is 1.5 M
3
. The T.O.P. & the main oil pump injector is located
inside the tank. Main oil pump suction lubrication oil flter, remote switch, bearing gear pump,
E.O.P. relay etc. are mounted on the oil tank top.
J. Main Oil Pump Injector
It takes little quantity of high pressure oil and supplies large quantity of low pressure oil
injected from the oil tank to the M.O.P. suction.
K. Turbo Oil Pump (TOP)
This is used to supply the regulation and lubrication systems during starting, stopping and in
emergency of main oil pump failure.
L. Main Oil Pump Filter
Normally one side of the flter will be working and the other side will be in reserve. The
procedure of change over is frst to rotate the handle slowly to the neutral position side and
released the air lock in the reserve flter. Then smoothly change over the flters observing the
oil pressure after M.O.P.
M. Electric Oil Pump Relay
Whenever lubrication oil pressure fails it will give impulse for the starting of E.O.P. (Normal
set pressure is 0.25 kg/cm
2
)
N. Electric Oil Pump (EOP)
This supplies lubrication oil to all the main bearings of the machine except the front bearing
of turbine. It may be noted that the oil supplied by E.O.P. does not pass through the oil
cooler.
PREPARATION FOR STARTING
1. The oil level indicator should be about 1M above the top edge of the graduated pipe before
T.O.P. is started.
2. Fill the condenser by chemical water about 2/3
rd
of gauge glass.
3. Check the condensate pump as following :
a) Open the Air valve, suction valve and Del valve and adjust cooling water to gland and
bearings.
b) Check the oil level in the Bearings.
c) Start one pump and see the Pressure about 4-5 kg/cm
2
is developing when
Recirculation valve is full open and check for any abnormal sound and vibration.
d) Start the other pump and see the Pressure and Performance.
e) Check the interlock of the Pumps.
4. Check that the Circulation water inlet valve oil cooler and air cooler valves are fully open and
main outlet valves are fully closed.
5. Check the signalling system by pressing the test, Acknowledge and reset Buttons.
6. Check whether the EOP is switched into operation (when the control desk is being switched
in, the EOP should automatically start and indication will come at the desk. Make sure that
the Pressure in the lubrication system is not below 0.25 kg/cm
2
and oil is fed to the bearings
(by checking the light glass) then stop the EOP by pressing the OFF push button.
7. Switch of the voltage to the control desk.
8. Check contact position on the electric contact Pressure. gauges on the control desk.
9. Start EOP and put the Barring device in operation by pressing the switch manual Cont
Rotation.
10. Prepare the Main steam line for heating up. For this proceed as following :-
a) Open all atmospheric drains before and after M.S.V. & ensure that M.S.V is closed.
b) First By-pass valve of steam collector heat up the line gradually, then by Gate Valve of
steam collector bring the pressure 35 kg/cm
2
and temp. about 350
o
C - 400
o
C.
c) Start heating the steam line from MSV to Auto Stop valve by check opening of the MSV
by-pass valve.
d) After 10-20 min. have elapsed make sure that the steam pipe line is warmed up and
drained, begin raising the steam pressure in the pipe line by gradually opening of the main
st. valve (about 25-35%) carefully so that no hydraulic impact should take place.
11. Check the operation of Turbo oil pump as follows :
a) Open the drain of steam line to turbo pump.
b) Heat up the steam pipe line and turbo pump at a low speed by slowly opening
the by-pass steam valve.
c) Check if the oil coolers are flled with oil by opening the air cocks on the oil cooler and
close them when the oil appears.
d) Adjust the oil pressure, supplied to the governing system and to the oil injector, ranges
within 6.5-7.5 kg/cm
2
by the inlet steam valve.
e) Close the by-pass valve and check that the TOP pressure governor is maintaining the
oil pressure.
12. Check the oil level in the tank after TOP is started. The level indicator pointer edge should
not be below mark 1/2".
13. Ensure that the oil temperature after oil cooler is within 30-40
o
C.
14. Check of the protection system and regulation system. (This check to be conducted before
MSV is put under heating.)
a) Check the auto stop valve by rotating its handwheel in close direction up to stop.
b) Check the automatic closing device.
c) Check the remote control switch of the stop valve by pressing push button on the
control desk marked switch in. This will cause the pilot valve of the remote control switch to
move and to stop the oil drainage from the quick closing device of the main stop valve thus
making it possible to open the stop valve.
d) Open the stop valve and check its closing by pressing the switch Of on the desk.
e) Again open the stop valve after cocking the stop valve, remote switch & automatic
closing device, then check its closing by pressing the knob of the automatic closing device.
15. Cut in EOP supply via the control desk. Stop TOP, check whether sound and light signals
operate (when the oil pressure in the lubrication system has fallen) and whether the EOP is
switched into operation, cancel the signal.
16. Start the technical ejector, then open the cooling water Over/Flow valve by 30%. Stop it after
about 200 mm of Hg. vacuum is created.
17. Vacuum Building Sequence :
Start the stating ejector in the following way. Open the steam valve and adjust the pressure
at 16 kg/cm
2
then open the Air valve. Check that the condenser vacuum is building (Mercury
column).
After obtaining about 100 mm hg vacuum, start second stage of main ejector, keep steam
pressure of 16 kg/cm
2
open the Air valve. Give gland sealing and when vacuum is about 500
mm of Hg. and vacuum is no more raising, start 1st stage of main ejector at a steam
pressure of 16 kg/cm
2
and open the secondary condensate valve of 1st stage. When the
vacuum reaches at about 550-600 mm of Hg. stop starting ejector. For this 1st close the
starting ejector air valve and then steam valve Gradually the vacuum will reach to 670-680
mm of Hg. Before this vacuum building check that all water valves in the main condensate
line remain full open except the LPH outlet valve and condensate pump should run with
recirculation valve full open.
18. Set the speeder gear into the position corresponding to a minimum speed of the turbine rotor
by rotating the speeder gear hand wheel on the governor gear anti-clockwise to the rest.
19. Cock the automatic closing device and remote control switch.
20. Cock the autostop valve by turning the handwheel for closing to the rest.
21. Check whether the regulating valves are opened.
STARTING THE TURBINE
1. After heating up the main steam pipe line upto the Auto stop valve, open the main steam
valve by about 50%
2. Stop the Barring gear from control desk by pressing switch STD OFF check physically that
barring gear is stopped and its spindle has come to its upper position.
3. Crack open the ASV until the turbine rotor starts moving. After this quickly close the valve
and slightly open it again to the extent required for maintaining the turbine rotor speed within
300 to 400 RPM.
4. Carefully examine the turbine and make sure that there are no abnormal noise and
vibrations. If abnormal noise is observed, immediately stop the turbine and do not start again
until the reasons of abnormal operation of the machine are revealed and eliminated.
5. Heat up the turbine at a low speed not exceeding 1000 RPM within 40 to 50 min. While
heating up regularly check the turbine and the temperature rise of bearings and oil in
lubrication system by the thermometer mounted at oil inlet and outlet of the bearings and by
the instruments mounted on the turbine control panel.
When the oil temp. at the oil cooler outlet reaches 40 to 40
o
Celsius start the cooling water
supply to the oil cooler by opening the gate valves frst on the water outlet line and then on
the water inlet lines to the oil cooler.
Inlet and outlet valve are used for adjustment of the water consumption to the oil coolers, at
this the water pressure in the oil cooler should not exceed the oil pressure at the oil cooler
outlet, being at the same time above the atm. pressure. The water supply should be adjusted
in such a way that the oil temp. after the oil cooler is 45
o
Celsius
6. When the turbine is heated up at a low speed bring gradually the turbine speed in 20-30
minutes time, to the speed of about 2850 RPM. i.e. the minimum speed of speed governor.
The critical speed of turbine rotor is 1580 RPM & that of turbine rotor-generator rotor system
are 2060 & 2080 RPM, and that speed range should be crossed as quick as possible. If the
vibration appears the speed should be lowered and the heating time should be increased.
When the rotor speed reaches 2850 RPM the oil c developed by the main oil pump should
rise up to 8.5 kg/cm
2
and the T.O.P. should be automatically stopped by its governor. At this
the lube oil pressure will drop down to 0.5 to 0.4 kg/cm
2
but not lower than this value.
In case of TOP not getting automatically stopped when the oil pressure reaches 9.0 kg/cm
2
in
the governing system, the pump can be stopped by hand by closing the by-pass valve. In
case of unexpected emergency shutting done of the turbine immediately open the steam to
the T.O.P.
Continue opening of the ASV and make sure that governor valves have closed and the
turbine maintains the speed at 2850 rpm. Open the ASV full.
Rise the turbine speed upto the nominal value with the aid of the speeder gear, turning the
handwheel on the governor gear manually, or through remote control from the control desk of
the turbine by turning universal switch to the left.
Make sure that the temp. of the bearings become stable and does not exceed 60
o
C. If it is
found that gov. oil Pressure is less then previous valve or dropping then the main oil flter
section to be chanted over and flter to be cleaned.
If during normal operation lubrication oil pressure is found less than 0.5 kg/cm
2
, the lub. oil
flter to be changed over to By-pass by turning then handle and then flter to be taken out
and cleaned. After putting back the flter, switch the flter into operation by turning the handle
to position FILTER.
7. Overspeed protection test of the turbine :
For checking the function of the centrifugal emergency governor proceed as follows :
a) Set the speeder gear into position of minimum speed.
b) By rotating the adjusting screw increase the tension of the spring of the cut of pilot
valves so as the increase the turbine speed upto 3080-3100 RPM.
c) By means of the speeder gear go on increasing the turbine speed until the emergency
governor trips, which must take place within the speed range from 3300 to 3360 RPM
d) Note the tripping speed, cock the automatic closing device & ASV. Set the adjusting
screw of the cut of pilot valve and the speeder gear into the initial position. Overspeed
testing of the two pins separately position. Overspeed testing of the two pins separately may
be done only after capital repair. For the above separate testing frst test the overspeed
tripping at 3300 RPM pin After the rotor has come to the 3300 RPM, stop lockpin and then
test the second pin for tripping at 3360 RPM. After testing unlock the 3300 RPM pin.
8. Loading of the Turbine
a) Give information to main control room that the machine is ready for synchronisation.
Take about 20 % of load (2-3 MW) through speeder gear initially.
b) Adjust the gland sealing, by closing the live seam valve and directing excess steam
to the 12th stage of turbine by opening to respective valve.
c) After getting clearance from W.C.T.P. send the main condensate to Deaerator.
9. Commissioning of L.P. Heater
a) Open the secondary condensate valve of L.P. heater and open the air cock for relief of
the air from the heater to condenser.
b) Check that the both inlet and outlet valve of main condensate line of L.P. Heater are
opened i.e. water fow through L.P. Heater is established.
c) By slowly opening the valve of the non-regulable bleeder of L.P. steam heat up the
steam pipe line to the L.P. heater. Open the steam valve of L.O. heater fully.
10. Commissioning of H.P. heater
a) Open the secondary condensate drain of H.P. heater and open the air cock for relief of
air from the heater shell into the Deaerator.
b) Open the valves of feeder water inlet and outlet of H.P. heater.
c) Check that the drain of st. line of H.P. heater is opened. Then by slowly opening the
valve of the H.P. heater st. line heat up the st. line. Full open the steam inlet valve of H.P.
heater
The H.P. heater can be turned into operation from control desk. For this, turn the
handle of universal switch to the right. This will result in simultaneous opening of motorised
feed water inlet and outlet valves and closing of feed water by-pass valve of H.P. heater.
For opening of motorised steam gate valve of H.P. heater steam line, turn the handle of
the Universal switch to the left.
A switching in of the electrically operated steam gate valve is possible only when the
H.P. heater water feed is switch in.
INSTRUCTION FOR REGULAR OPERATION
By the instruments on the control desk watch the oil pr. in lubrication system and temp. of the
bearings. The normal oil pr. in the lubrication system in 0.5 kg/cm
2
. The temp. of the bearings
must be within the range of 50
o
to 55
o
C at the oil temp of 40
o
Cto 45
o
C in the bearing inlets.
Continuously check the oil level.
Record in the log sheet all the abnormalities in operation i.e., leaking of oil, steaming through
piping joints and deviation of normal operating parameters.
Shutting Down of Turbine
Proceed as follows :
a) Isolate H.P. heater on steam side.
b) Isolate L.P. heater on steam side.
Take of the electrical load. Adjust condenser water level & gland steam supply then close
the A.S.V. by the hand switch after closing by hand wheel about 75 %.
During the turbine shutting down procedure make sure that the T.O.P. has started. This takes
place when the oil pr. in the turbine governing system is 7.5 kg/cm
2
. If the T.O.P. has not
started automatically, start it manually by the By-pass valve of T.O.P. governor.
Stop the steam feed to main ejector. Ejector air valve to condenser to be closed when
vacuum in condenser comes to zero. When vacuum is about 200-250 mm of Hg. stop gland
sealing.
After 30 minutes have passed after the main ejector steam feed is cut of, stop the
condensate pump.
When the rotor comes to low rotations, switch in the hydraulic type Barring device. For this
press push button under the plate continuous rotation. Close the water valves to the oil
cooler. Close the M.S.V. After 8 hours stop TOP. Close the gate valve on steam collectors.
Open all atmospheric drains of steam line. De-energise the control desk by turning the
universal switch on position OFF.
Some Aspects on Protection System
Protection on axial shift relay :
a) In the Axial Stress manometer there are two contact needles, one is placed at 10 kg/cm
2
and the other at 100 kg/cm
2
.
b) When the pressure indicator goes below 10 kg/cm
2
the turbine will trip automatically.
c) When the pressure indicator goes to 100 kg/cm
2
(or whatever is set at higher limit) a signal
of overload on the turbine is received.
d) In Governing System manometer there are two contact needles one placed at 12 kg/cm
2
.
e) When the indicator is below 9.0 kg/cm
2
. the Axial stress manometer is put of from the
protection system and will not function.
f) When the indicator of Governing System manometer is between 9 to 12 kg/cm
2
the Axial
stress manometer is put in service automatically as a protection device for axial shift and
indiction for overloading of the turbine.
g) When the T.O.P. is working and the machine is not running at full speed the pressure in
the governing system manometer is about 7 kg/cm
2
and hence the axial stress manometer is
cut of, thus it is possible to open the A.S.V. The pressure in the Governing system
manometer sill be between 9 to 12 kg/cm
2
only when the rotor speed is above 2850 rpm by
which time the Axial stress manometer is put in service for protection. If by this time the
pressure in the Axial stress manometer is not above 10 kg/cm
2
(which is minimum
allowable) this will correspond to an emergency and A.S.V. will trip resulting the stopping of
the turbine.
POWER AND BLOWING STATION, T.G. # 1 & 2
Starting Preparation
1. a) Carefully inspect the turbine, generator, exitor auxiliaries and entire installation.
b) Check the level of oil in the oil tank.
c) Check up the inlet & outlet valves turbo oil pump, electric oil pump and oil coolers are
open.
d) Take the readings on thermal expansion indicators.
e) Check up the electronic signalling system is working properly.
f) All the atmospheric drains of the steam lines are open fully.
2. Heating up main steam line up to Auto stop valve.
a) Open all the atm. drain in this section.
b) Open the by pass of main steam valve slightly and keep the steam pressure at 3.0
kg/cm
2
for 15 mts.
c) Slowly raise this pressure. Throttle the atmospheric drain open the expander drains
fully.
3. Commissioning the auxiliaries :
a) Check up that in the bearings of all the auxiliary pumps there is sufcient lubricant and
cooling water.
b) Start the E.O.P. put on its interlock. Engage the shaft turning device by rotating its
handwheel in clockwise direction and switch on its motor.
c) Check up and set the Auto stop valve of the turbo oil pump. Open the drain before auto
stop valve.
d) Open steam to T.O.P. slightly and warm up the turbine at slow speed. After heating up
raise the speed of the T.O.P. gradually so that the oil pressure supplied to the regulation
system is in between 5-6 kg/cm
2
close the steam drain.
e) Check up the condenser and its level glasses are in working order.
f) Fill up the condenser steam space with chemical water up to 23/3 of the gauge glass.
g) After informing the shift engineer and establishing fow in the cooling water system.
Open the condenser air water oil valve about 40% and see that oil vacuum is obtained 300-
350 MMWC. Operate technical ejector if necessary.
h) Charge CW flter of air cooler & oil cooler and release air.
i) Supply water to the glands of the condensate pumps. Open its air valve to condenser
& open the suction & del. valves.
j) Start one condensate pump and adjust the fow at 35-40 T/hr. by recirculation valve.
k) Open steam to starting ejector slowly and raise to 12 kg/cm
2
pressure & then open the
air valve from condenser steam space.
l) Open condensate to one of the ejector.
m) Open the steam slowly up to 16.0 kg/cm
2
.
n) Open the 1st stage secondary condensate to condenser and that of second stage to
atmosphere.
o) Check up that the ejector is building up full vacuum then open the air valve to
condenser.
p) Open condensate water to gland cooler, then supply steam to gland cooler steam
ejector up to 10.0 kg/cm
2
.
q) Open slightly live steam to the turbine labyrinth glands through steam cooler.
r) Open cooling water to the steam cooler.
s) See that the vacuum in the condenser steam space is slowly increasing.
t) Open all the drains going to condenser fully.
4. Checking up the regulation system.
a) Slowly reduce the steam supply to T.O.P. As the lubrication pressure falls to 0.2 kg/cm
2
the E.O.P. should start automatically. Immediately raise the speed of T.O.P. and stop E.O.P.
If the barring gear has stopped commission it again.
b) Close the main pilot valve and open slowly.
c) Commission the 8-13 and 1.2/2/5 servomotors and their block regulators. See that the
pilot valves are rotating freely.
d) Open speed governor and rotate in anti-clockwise direction, observe that all the
servomotors are opening, and all of the them close when speed governor is rotated in
clockwise direction, when 8-13 Block regulator is opened (rotating in anti-clockwise
direction), 8-13 servomotor closes, main servomotor will open and 1.2/2.5 servomotor
closes. When 1.2/2.5 block regulator opened (rotating in anti-clockwise) main servomotor
opens, 8/13 servomotor open 1.2/2.5 servomotor closes.
e) Shut down 8/13 and 1.2/2.5 servomotors and block regulators.
f) By operation the axial displacement relay artifcially the main pilot valve should
trip if the air pilot valve should trip if the axial displacement is above 1.0 mm.
5. Heating up the steam pipe line upto regulating valves.
a) Close the regulating valves fully by closing down slightly the main pilot valve.
b) Open the drains on this section to condenser.
c) Open the stop valve slightly so that the steam pressure after it is 3.0 kg/cm
2
.
d) After 10 mts. close the condenser drains, open the expander drains on this section and
slowly raise the pressure by opening stop valve. heat up this section of pipe lines upto a
temperature of 250
O
Celsius.
6. Heating up the Turbine
By this time the vacuum should have come up to 500 mm of Hg.
a) Close the main steam valve by pass fully.
b) Open the regulating valve fully (if necessary by opening 8/13 and 1.2/2/5 block
regulators.
c) Open the A.S.V. up to 25 marks.
d) Open reg. chest drain to condenser.
e) Stop the barring gear. Physically check that the it is disengaged and rotor is stopped.
f) Crack open the main steam by pass valve and give a kick to the rotor. Maintain the
speed between 400-500 RPM.
g) Observe the sound from the bearings, glands and from diferent parts of the machine.
h) See the temperature of the bearings. The heating up at this speed is to be continued
for 1/2 hr. Stop the starting ejector when the vacuum comes to 550 mm of hg. and steady.
i) Slowly raise the speed to 1000 RPM
j) By this time the vacuum in condenser should have reached maximum. Run the turbine
at 1000 rpm for 10 mts. Before further raising speed observe the machine thoroughly.
k) Slowly raise the speed to 1500 RPM
j) By this time the vacuum in condenser should have reached maximum. Run the turbine
at 1000 rpm for 10 mts. Before further raising speed observe the machine thoroughly.
k) Slowly raise the speed to 1500 RPM.
l) Latter raise the speed from 1500 to 2500 RPM quickly crossing over the critical speed
of the machine.
m) Raise the speed from 2500 RPM to 2850 RPM. See that the reg. valves are closing
automatically.
n) Open the main steam by-pass valve fully & see that the speed is not further raising.
o) Raise the speed to 3000 RPM by operating the speed governor.
p) Slowly stop the T.O.P. (in TG-2 slowly open the by-pass valve of A.C. pump del. line &
then switch of the pump). Check up the main oil pump is supplying the oil to the regulation &
lubrication systems.
q) Adjust the steam coming out from the gland packings open the A.S.V. full.
r) Adjust the condensate level.
s) Check up the vibration bearing temperatures.
Note : If more vibrations are observed any time while raising the speed of the machine, it is
necessary to reduce the speed to the extent that the vibrations disappear. The machine
should be run at that speed for some more time, check up once again and if everything is
normal raise the speed slowly. The speed should not be raise when there are obejctionable
vibrations persisting on the machine.
t) Adjust lubrication oil temperature after cooler by opening required quantity of cooling
water at 40
O
C.
u) Open cooling water to alternator & exciter air coolers.
v) If everything is normal give signal to the main control room that machine is ready for
synchronising.
w) Inform WCTP people to take analysis of the main condensate, if it is good send it to
deaerator.
x) Open the H.P. heater steam line drain & bleeder line drains slightly, to prevent water
knocking. Close all the drains on main steam line.
7.0 STOPPING THE TG-SET
a). Remove the regulable bleeder load from the set.
b). Isolate the high pressure heater from steam side.
c). Inform the main control room people and get the load reduced slowly and gradually to
0 M.W. and switch of the generator. While reducing the load, the level in the condenser, the
steam coming out of the gland packings, the temperature of the lubrication oil after oil
coolers are to be maintained. d). Start E.O.P.
e). Close the condensate going to deaerator fully and open the recirculation.
f). Trip the turbine and close the M.S.valve. Open the expander drain before M.S.valve.
g). The vacuum is to be maintained till the rotor comes to rest.
h). After the rotor is stopped engage the barring gear and switch on its motor.
i). Cut of the ejector steam. Break the vacuum through the ejector air valve when the
vacuum is 150-200 mm of Hg cut of gland steam. Shut down steam to gland cooler ejector.
j). If the exhaust temperature comes down, stop the condensate pump.
k). All the drains are to be opened to atmosphere fully.
l). The barring gear and electric oil pump are to continue working up to 8 hrs. and can be
stopped if the turbine metal temperature comes down.
BHILAI STEEL PLANT, POWER PLANT-2
Cycle for 30 MW Turbine
Turbine DATA
In BSP, PP-2 is having 3 Nos. of T-G sets. The capacity of each TG is as follows :
TG-1: 30 MW - Impulse type - 18 stages Condensing type
TG-2: 30 MW - Impulse type - 18 stages Condensing type
TG-3: 14 MW - Reaction Type - 8 stages, Back-pressure type Turbine.
30 MW Turbine Generator Set :
The cycle used is of regenerative type,. There are two low pressure and two high pressure
regenerative heaters. The steam for heaters is taken four diferent stages of turbine.
Technical Particulars of 30 MW Turbine
1. Type : Horizontal signal cylinder impulse turbine
2. MCR : 30 MW
3. Most Economical
Continuous Rating : 25 MW
4. Nozzle control Point : Four valves controlling nozzle group for 40%, 60%,
83.33%, 100% load (Approx.)
5. Steam Pressure : 59.25 Kg/cm
2
. turbine stop valve at MCR
6. Steam Temperature : 482
0
C
7. Speed at which
emergency governor
operates : 10% and 11% over speed of turbine = 3300 RPM & 3330
RPM
8. Size and number of
main steam inlet
connection : 2 Nos. 0152.4 mm Bore
9. 1st Critical Speed : 1800 rpm
10. Condenser Vacuum : 69.85 cm (at MCR)
11. Heat Rate :
Load Heat Rate
100% : 2506.33 Kcal/ KW Hr
83.33% : 2494.41 Kcal/ kw Hr
60% : 2526.08 Kcal/ kw Hr
40% : 2666.95 Kcal/ kw Hr
No of Impulse stage - 18
12. Condenser :
The condenser is of the high efciency annular central fow surface type, arranged for
the steam to fow and rotor through tubes, It is welded directly to the turbine exhaust fange.
Tubes are 25.4 mm OD and 1.219 mm the made of Brass, Hyd. test to be carried out at 5.25
kg/cm
2
.
No. of tubes : 4360
Total surface : 1910 M
2
,
Water quantity : 6920 M
2
,
Length between tube plates:25.4 mm
13. Main Oil Pump
(a) Type of Pump : Gear type driver by Turbine shaft through reduction gear.
(b) Capacity of Pump : 43.64 M
3
/Hr.
(c) Speed of Pump : 813 RPM
(d) Relay Oil Pr. : 5.62/6.33 Kg/cm
2
(e) Lab. Oil Pr. : 0.63 / 0.84 Kg/cm
2
14. AC. AOP :
(a) Type : PLURO - VANE
(b) Speed : 1475 rpm
(c) Capacity : 43.64 m
2
/hr
(d) Pr. at which pump
cut in : 0.07 Kg/cm
2
below the normal.
15. Total quantity of oil
in system : 9.09 (approx) m
3
/hr
16. Type of oil : Turbine oil-46
17. Main Oil Tank Capacity : 7.27 m
3
/hr
18. Max. temp. of oil
leaving bearing : 71.11
0
C
19. Governor :
(Speed Governor) : The governor is a low inertia centrifugal governor driven
by turbine shaft through reduction gear.
Speeder Gear : This is used to vary the speed at no load for
synchronising when connected to grid, change in speeder gear position results in speeder
gear position results in change of load on the turbine.
Oil Coolers : This for the shell type consists of a nest of tube within a
cylindrical shell, arranged for the oil to fow over and the cooling water through the tubes.
Tubes OD : 14.3 mm, 0.914 mm thick
Quantitty of oil cooling: 51.84 m
3
/hr
Qty of C.W. Required. : 128.1 m
3
/hr
Tube surface : 49.25 m
2
.
CEP (Condensate Extraction Pump)
(i) Type : Horizontal Split Casing, 2 stage
(ii) Capacity : 120 m
3
/hr
(iii) Efciency of pump : 68%
(iv) Head : 115.82 M
(v) Motor : 97.5 KW
HP Deaerator
The function of deaerator is to remove dissolved oxygen in the feed water.
(i) Type : Gravity feed direct contract tray type.
(ii) No. of trays : 05
(iii) Pr. : 5.5 Ata
(iv) Deaerating cap : 125 T/hr.
LP Deaerator : (Make up water Deaerator)
Pressure : 1.5 ata
Capacity : 125 T/hr.
Boiler Feed Pump : Specifcation an no of pumps installed
- Multistage Centrifugal Pumps
- 156 T/hr at 95 atm discharge pressure
- 2 Nos. for each boiler, 2 X 3 = 6 Nos. (total)
- For suction draw water from HP Deaerator
- Discharge to boiler through HP heaters.
Figure : 14 MW TG & Process Steam PP2. BSP TG# 3
14 MW BACK PRESSURE Turbine :
It operates on open cycle. The system after expansion through this is used as process steam
at diferent locations of Bhilai Steel Plant. There are two Steam lines one at 18 ata pressure
and other at 8 ata pressure
Turbine : Single fow, back pr. type
Normal Output : 13200 KW
Max. output : 14 MW
Normal Speed : 7000 RPM
Max. speed : 7200 RPM
Trip speed : 7920 RPM
Inlet pr. : 60 ata
Inlet Temp : 485 - 490
0
C
Pressure at outlet : Minimum Normal Maximum in ata
: 06 08 10 ata
08 ata fow at exhaust : 95 -110 T/Hr. at 260
0
C
18 ata fow at extraction : 100 -110 T/Hr.
18 ata pressure at extraction : 18.5 - 20.5 ata Temperature - 380
0
C
Direction of rotation viewed from turbine to M/s is counter clockwise.
Figure : Steam Pipe Lines of Power Plant-2, Bhilai Steel Plant
Figure : 14 MW TG and Process Steam
14MW T.G. SET (BSP)
Steam Rolling of the Turbine to the Rated Speed
1. Ensure full opening of MS stop valve VS 20.
2. Ensure Auto operation of SAT PRDU and full opening of exhaust line isolation valve either
VS 59 or VS 61.
3. Gradually open the emergency stop valve by rotating the handle of starting device in anti
clockwise direction.
4. After full opening of ESV gradually open the HP & LP control valves by further rotation of the
starting device, keeping a watch on the barring gear disengagement.
5. On barring gear auto disengagement switch of the barring gear motor.
6. Gradually rise the speed by keeping a close watch on the rotor vibration, steam parameters
and oil pressures.
7. Soak the turbine at 2000 RPM for observing the satisfactory running of the turbine.
8. If the running is found satisfactory in view of rotor vibration, axial, shift, bearing metal
temperature, casing metal temp. Steam parameters etc. steadily raise the speed to 4500
RPM
9. Soak the turbine at 4500 RPM to 5000 RPM and observe the rising trends in casing metal
temperature.
10. Alert the person monitoring the lub. oil temperature and diferential pressure across the flter.
11. Gradually raises the speed, the governor takes over the speed control at 6400 RPM. Further
raise in the speed to the rated value of 7200 RPM can be achieved by rotating the speeder
gear wheel in anti-clockwise direction.
12. Auxiliary oil pump may be stopped after ensuring the take over the main oil pump, which will
be indicated by negative pressure in Main oil pump suction line.
13. At raged speed observe the parameters indicating the satisfactory running of the turbine.
The following are the few indicators :
a) Motor vibration : 50 microns for turbine rotor and input shaft of gear box.
: 75 microns for output shaft of gear box and Generator
b) Axial shift : -0.1 mm
c) Lubricating heater pressure : 1.75 atg.
d) governing Oil pressure: 8 atg
e) Trip oil pressure : 6 atg.
f) Bearing metal temp : 85
o
C
g) First stage steam pressure : 12 atg
h) Steady rated parameter to and from the turbine:-
Main steam inlet : 60 atg 480
o
C
Exhaust steam outlet: 08 ata 390
o
C
14. If the running of turbine is found to be satisfactory and the steam consumption in 8 ATA
header is to the tune of 45 T/hr. clearance may be given to synchronise the set with the grid.
15. Out in 18 ata Extraction system after synchronising, when there is a 18 ata demand of about
50T/hr. by gradually opening oil trip NRV & control knob at desk.
DURGAPUR STEEL PLANT, OLD POWER PLANT
Area : Turbo-Alternators
Operational Instructions For Turbo Alternators
PREPARATION FOR STARTING.
The following auxiliaries should be in operation before starting the turbine
01. Circulating water system in condenser.
Ensure full load circulating water fows passing through the condenser with air and oil
coolers primed.
02. Having ensured the circulating water supply is available, partly open the inlet C.W. Valve to
condenser. When all air has been removed from the water box close the air release cock and
then open the inlet C.W. valve fully.
03. Open the C.W. outlet valve sufcient, as found by experience, to pass full C.W. quantity.
04. Condensate System :
Ensure extraction pump is in operation with condensate recirculating through the air ejectors.
Main steam line to be drained & heated up properly.
05. Oil System
Check the oil level of the oil reservoir. Open steam isolating valve (steam to auxiliary Oil
Pump isolator). The auxiliary Oil pump should then start automatically and speed of the
turbo pump will be under control of the pressure regulator. (In case of failure of the regulator,
or to boost oil pressure regulator by-pass may be opened.)
06. Ejector.
Start the ejector as per instruction given separately.
Starting the Turbine :
Main steam : 475 p.s.i.g.; 750
0
F.
Pass out steam pr : 75 p.s.i.g.
01. The machine should be started with the knurled tappet on top of the pass out control gear
screwed fully down (i.e. no pass out).
02. Before opening the main inlet steam isolator check that the emergency stop valves and
governor valves operate freely.
03. Set the relay oil trip lever to the running position and observe that all eight governor valve
open fully, then open both H.P. and L.P. emergency stop valve using the hand wheels.
04. Release the trip lever and check that all valve close freely; then wind the stop valve hand
wheels to their closed positions. Reset the trip to open all the governor valves.
05. Set the speeder gear to hand control and adjust to lowest speed position.
06. Slowly open the main inlet steam isolator to establish pressure upto the H.P. emergency
valve. Control drainage as necessary.
07. Steam seal the turbine glands. A small quantity of vapour will be visible at the atmosphere
vent pipe.
08. Steam seal the L.P. gland. Water seal the turbine exhaust gland. Fully open the water to
turbine exhaust gland valve..
09. Inspect all bearings for oil fow.
10. Raise vacuum. start the quick start exhauster and then the air ejector.
11. When condenser vacuum has reached a valve of about 20" of Hg. admit steam to the turbine
by slowly opening the H.P. emergency stop valve until the turbine spindle frst commences to
turn.
Raising Speed
01. Continue to admit steam but, as speed is increasing to 400 r.p.m. again cheek that the fow
of oil through each bearing is normal and that the machine is running smoothly with the
turbine eccentricity (Peak to peak) less than 0002" as shown on the dial indicator on the
thrust pedestal.
02. When satisfed with condition of the machine, slowly increase speed to 800- 900 RPM,
ensuring that the conditions in the instruction (01) above is maintained. The turbine should
be allowed to run at this speed (say about 40 minutes) until cylinders and motors have been
warmed to such a temperature (Judged by overall expansion) which, from experience, is
known to represent a satisfactory state from which to continue raising the speed.
03. Still maintaining the conditions of instructions (01) increases speed at a uniform rate of
approximately 200 RPM.
04. Observe that Oil pressures are maintained at their correct values and that the auxiliary oil
pump gradually stops under infuence of the regulator as the main oil pump delivery
increases.
05. Close emergency valve drain dust before the H.P. governor valves start to close.
06. When the machine approaches governing speed, check that the H.P. Governor valves
progressively close and take full control of the speed. Water seal the L.P. gland and cut of
steam to L.P. gland.
07. When satisfed that speed is under Governor Control, open the H.P. emergency stop valve
fully.
08. Increase speed to 3000 RPM by hand control on the speeder gear.
09. When the oil inlet temperature to the bearing reaches a value of 110
0
-120
0
F, establish a fow
of water through the oil coolers to maintain the temp within these limits.
10. Adjust the H.P. gland steam isolator to a minimum opening without afecting the vacuum. Do
not make any further adjustments to the steam quantity while the unit is running. This is to
ensure that in the event of a sudden loss of load the gland will remain sealed.
11. Set the speeder gear to motor control for synchronising purposes.
Taking Load
01. Prepare and synchronise the generator.
02. Rate of applying load is governed by the thermal conditions of the turbine and inlet steam
temperature. The efect of these may be gauged by reference to the axial expansion of the
turbine shown on the scale on the H.P. thrust pedestal. It is advisable that loading be
restricted to not more than 5% M.C.R. per minute.
03. Establish a fow of water through the generator air cooler as load is applied to maintain the
inlet air temperature at 30
0
C.
04. Open the main pass out steam isolator and control drainage as necessary, using the drains
from pass out emergency stop valve.
05. Apply load until the pressure before the L.P. Governor valves is approximately equal to the
pressure in the pass out main.
06. When pressure on both sides of pass out emergency stop valve is balanced, open this valve.
07. Open the reducing box and hydron bellows isolators on the pass out control unit; then screw
the adjustable tappet slowly to its limit in the upward direction.
08. Increase load by means of the speeder gear if required.
09. When the machine has carried a small load for approximately 5 minutes, close H.P. cylinder
drain valves and gland balance drain valve.
10. Close the trap by pass on pass out drain to condenser when fow has been established in
the pas out main for a similar period.
Shutting Down.
01. Close L.O. Emergency stop valve.
02. Slowly screw the tappet on the pass out control unit to its limit on the down ward direction.
Close the steam isolator to the reducing box and bellows (Load swing may occur during
operation 01 and 02)
03. Reduce the load by using speeder gear.
04. Open the recirculating valve as load is decreased to 30% of M.C.R.
05. When wall load has been removed, isolate the generator from the bus bars and remove all
excitation. Check that the governor maintains full control of the speed.
06. Ensure that the auxiliary oil pump is prepared for automatic starting (i.e. a supply of steam
available at the regulator).
07. Operate the Oil trip lever and note that the steam admission valves close. Return the H.P.
emergency stop valve handwheel to the closed position. Close the main inlet and pass out
steam isolators and open the turbine inlet steam and pass out steam drains.
08. Observe that the auxiliary oil pump automatically comes into operation as turbine speed
decreases.
09. Shut down the air ejector and close exhaust gland water isolator valve.
10. Close the circulating water supply to the Oil Coolers (to avoid unnecessary cooling of the oil)
and also to the air cooler.
11. Close inlet gland steam isolators when the condenser vacuum has fallen to zero and the
deaerator system is no larger required.
12. Take the condensate and C.W. supply system out of operations.
13. Keep the auxiliary oil pump is operation for at least 10 hours after shut down.
TURBINE PLANT MAINTENANCE
1. Introduction
2. Efect of High Merit Plant Outage
3. Efect of Water and Impurities in steam
3.1 Water
3.2 Impurities
4. Efect of Deposits
4.1 Turbine Balding
4.2 Vibration of Rotors
4.3 Steam Purity
5. Methods of Removal Blade Deposits
5.1 Soluble deposits
5.2 Insoluble Deposits
6. Condenser Defects
6.1 Air Leaks
6.2 Tube Fouling
6.3 Tube Plate Fouling
6.4 Circulating Water Leaks
6.5 Graphitization
7. Turbine Overhaul
7.1 Frequency of Overhaul
7.2 Regular Servicing
7.3 Availability
8. Planning
8.1 Turbine Overhaul Programmes
8.2 At National Level
8.3 At Regional Level
8.4 At the Generating Station
8.5 Advance Planning
9. Turbine Annual Maintenance
9.1 Inspection of Bearings
9.2 Oil Clearance
9.3 Thrust Baring Inspection
9.4 Shaft Alignment
9.5 Steam Control and Emergency Valves
10. Turbine Major Overhauls
10.1Inspection and Planning
10.2Casing Fastenings
10.3Running Clearances
10.4Rotor Removal
10.5Inspection of Other Equipment
10.6Radial Clearances
10.7Replacement of Rotors
11. Associated Plant
11.1Steam Receivers and Feed Heaters
11.2Feed Heaters
11.3Oil Coolers
11.4Steam Ejectors
11.5Oil System
11.6Removal of Generator Rotor
12. Turbine Defects
12.1Blade Defects
12.2Gland Wear
12.4Bearing Defects
12.5Oil Pump Defects
12.6Oil System Defects
12.7Governor System Defects
12.8Governor Hunting
13. Maintenance of Condensers
13.1Cleaning
13.2Condenser Testings
14. Turbine Vibration
14.1Critical Speed of Rotors
14.2Balancing of Rotors
14.3Defects Causing Shaft Vibration
14.4Conclusions
TURBINE PLANT MAINTENANCE
1. INTRODUCTION
Maintenance of power station plant and equipment is of the highest importance to ensure
that plant remains available for service when required and no interruption of supplies of
electricity to the consumers occurs.
year but so much has been done to improve matters that this has now been overcome. new
plant has been installed as rapidly as possible but this is very costly and has been and still is
restricted by the amount of capital expenditure allowed. It is, therefore, most essential that all
plant be kept in good order and fully available for service as required.
This Lesson discussion some of the many aspects involved in the maintenance of turbine
plant including the causes and efects which often lead to plant failure.
2. EFFECT OF HIGH MERIT PLANT OUTAGE
Generating stations have their load allocated by the system area grid control centre, normally
in accordance with their fuel cost and efciency. stations generating electricity cheaply are
more continuously loaded than those with high generating costs and lower efciency. The
latter tend to be used only during peak load periods. Thus, if high efciency and low fuel cost
plant is taken out of service for any reason, its share of the total system load has to be
carried by less efcient plant with a corresponding increase in generating costs.
In order to keep down the cost of generation, the availability of the more efcient and low fuel
cost plant must be kept as high as possible. This can only be achieved by a high standard of
operation and maintenance.
3. EFFECTS OF WATER AND IMPURITIES IN STEAM
3.1 Water
Tiny particles of water entrained in the steam have, over a period of time, much the same
efect on turbine blades as sand blasting and, s a result, some of the blades become worn,
or eroded on their inlet edges. Water in the step normally occurs only at the L.P. end of the
turbine and it is here that blade erosion takes place.
When water is laying stagnant as a small pool or flm inside a steam line or vessel, or drips
onto one particular spot, an area is set up which is relatively colder than the remainder of the
line or vessel which is at steam temperature. Thermal stresses are set up by the diferential
expansion of the resulting hot and cold areas and the presence of water lowers the
endurance of the metal. Tiny cracks will commence to form round the cold spot and if this
condition is allowed to continue, serious damage to the steam line or vessel can result.
This type of damage which is known as Corrosion Fatigue is likely to be even more serious
when the water contains dissolved gases or solids.
It is evident, therefore, that careful drainage of steam lines, vessels and turbines is most
important since both blade erosion and corrosion fatigue can cause lengthy outage of plant.
3.2 Impurities
Solid impurities, both soluble and insoluble in water, can be carried over with the steam in
some cases pass through the turbine stop valve and settle on the blades as a fne coating or
deposit. This condition is sometimes referred to as build up or blade fouling.
4. EFFECT OF DEPOSITS
4.1 Turbine Blading
Each stage of the turbine is designed with a defnite area through the nozzles and blades to
give the required drop in pressure and take the desired amount of work out of the steam.
Thus, if any appreciable build up occurs in the nozzle passages, the shape of the blades
consequently changes and the pressure at each stage will deviate from the design valve.
Therefore, the contribution of the afected stages to the total output of the turbine will be less
than originally intended and this, in turn, reduces the efciency of the turbine.
Surface fnish is also known to afect blade efciency and roughness of the small blades at
the HP end of the turbine caused by deposits, is particularly signifcant in this respect.
Partial blockage causes an increase in the axial thrust of the rotor in the direction of the
steam fow through the cylinder, resulting in a greater load than normal having to be carried
by the thrust bearing.
4.2 Vibration
All turbine rotors have what are known as critical speeds at which natural vibration occurs
and these are dependent upon such design features as length, weight and the manner in
which the weight is distributed along the rotor. Rotors are designed so that the critical speed
or speeds are always well clear of the normal running speed. At speeds of 3,000 rev/min the
centrifugal efect of increased in weight, such as could be caused by deposits on the blading
might be sufcient to alter the critical speed.
Blading deposits seldom distribute themselves evenly round the turbine blade rows and
therefore any cause a rotor to become out of balance and produce vibration.
4.3 Steam purity
Where a steam purity meter, which operates on the same principle as a dionic meter, is
ftted, indication will be given of impurities, in the steam from the boiler. steam purity
conditions in the large modern station are very rigidly controlled and deposit problems
greatly minimised.
The presence of deposits on balding may be defected by the following observations :
(i) Gradual departure from normal inter-stage pressures.
(ii) A slow decrease of turbine capacity over a period for a given steam input.
(iii) Vibration of the turbine rotor, gradually becoming worse.
5. METHODS OF REMOVING BLADE DEPOSITS
5.1 SOLUBLE DEPOSITS
The most common balding deposit is generally soluble in water and can be removed without
opening up the set by the simple method of running up the turbine to a low speed, using low
pressure saturated or wet steam. This procedure has to be carefully arranged and controlled
to avoid thermal shock in the various parts of the turbine. Measuring in the low pressure
steam does not have an erosive efect on the blades under these conditions.
The deposits are washed by the water in the wet steam and the resultant condensate is
passed to waste. By observing the dionic readings of this condensate a check can be kept
on the blade washing operations which can be consider complete when a suitably low and
constant reading has been obtained.
In stations where plant is regularly shut down at night and run up again in the morning the
turbines are usual relatively free from soluble deposits, the running up procedure in the
morning producing conditions not dissimilar to the blade washing operations outlined.
5.2 Insoluble Deposits
the type of balding deposit insoluble in water is almost entirely silica. This is normally carried
ever into the turbine from the boilers in vapour form. Fortunately the amount is usually small
and does not reach such high proportions as the soluble type of deposits. It should rarely
cause a shift in critical speed but can afect blade surfaces and so reduce the efciency of
the machine.
Silica deposits are not easy to remove but blasting with suitable abrasive substance is the
generally accepted method. This is carried out when the rotors are removed for maintenance
or repair.
6. CONDENSER DEFECTS
6.1 AIR LEAKS
Air leaks into the steam space of the condenser have a bad efect on plant efciency, as
described in Lesson 6. The large number of connections to the condenser makes the job of
locating such leaks both difcult and tedious but once the leak is found, the repair is often
only a matter of renewing small joints or gland packings and therefore very worthwhile.
6.2 TUBE FOULING
Any foreign matter which forms on the tubes also has a bad efect on the plant efciency. the
injection of chlorine into the circulating water system usually prevents the formation of slime
but very hard water and sewage efuent can, in some cases, produce a scale on the
circulating water side of the tubes.
6.3 TUBE PLATE FOULING
Leaves and other debris which fnd their way past the circulating water screens, lodge on the
condenser tube plates and restrict the fow of cooling water through the tubes. Broken laths
from cooling towers can also cause similar trouble.
At some coastal stations the growth of mussels and other marine life can become a problem
in the circulating water system. The most efective method of controlling these growths is by
chlorination of the circulating water.
6.4 CIRCULATING WATER LEAKS
Circulating water leaks into the condenser steam space contaminate the condensate and
give rise to serious trouble if allowed to continue particularly if the water is from the sea or
polluted estuaries.
Condenser tubes must be allowed to expand with temperature and are held in the tube
plates by ferrules and packings as described in Lesson 6. These packings can often be the
source of circulating water leaks. Tubes may become eroded after a period of time,
particularly near the CW inlet end.
Stay bolts may also be the source of circulating water leaks and these should be checked for
tightness at the tube plate.
Condenser tubes are often made of copper alloys and ammonia in the circulating water may
attack the copper and cause leaking tubes. Sewage works and industrial efuents
discharging into rivers and canals are, in many cases, sources of ammonia in circulating
water and the Station Chemist will be constantly testing for such contamination in the cooling
water.
6.5 GRAPHITIZATION
The cast iron water boxes of condensers can be subject to a form of attack known as
graphitization, which can reach serious proportions if left unchecked. The method of
protection against this form of attack was described in Lesson 6.
All these various condenser defects must be borne in mind when the condenser is opened
up for overhaul.
7. TURBINE OVERHAUL
7.1 FREQUENCY OF OVERHAUL
There are no set tules governing the frequency of turbine overhauls and opinions difer about
the length of time a machine should run before the cylinders are opened up for inspection.
This is mainly because such decisions are based on the hours run, the service record and
the history of the particular turbine. Many turbines have been known to run for several years
quite satisfactorily without any internal examination. Some engineers consider that a turbine
should have a major overhaul every four years with the Lp cylinders opened up for thorough
examination of the internal and a minor overhaul every two years.
The minor overhaul consists of a look at the bearing and a general inspection, together with
servicing of auxiliary equipment and, of course, takes much less time then the major
overhaul. this system has the advantage that spares, which often take considerable time to
manufacture, can be ordered well in advance of the major overhaul period.
7.2 REGULAR SERVICING
Whatever the time interval decided upon between regular overhauls, a certain amount of
servicing must be carried out at convenient opportunities. In the case of plant operating on
the unit system, turbine maintenance can be done during the period when the boiler is out of
service for statutory survey, which occurs every fourteen months for boilers with riveted
drums, or every twenty-six months for boilers of modern design.
7.3 AVAILABILITY
In order to satisfy the system winter demand all generating plant should be fully available
from early October onwards and the period from October to March is always one of some
anxiety. It has, therefore, been the rule that planned maintenance be confned to the period
April to September.
8. PLANNING
8.1 TURBINE OVERHAUL PROGRAMME
Turbine overhauls must be planned to ft in with those of the boilers and other plant to suit
both the local station arrangements, those of the Generating Region and the National grid
System as a whole.
In order to accomplish a task of such magnitude, much advanced planning and forethought
has to be undertaken both at the station, at Regional Headquarters and at National
Headquarters. A brief account of the methods used in this advanced planning will help
students to understand the more general aspects.
8.2 AT NATIONAL LEVEL
Some two to three years in advance of the overhaul periods (April to September inclusive
each year) estimates of the loading expected during the period are made; due allowance is
given for expected growth of the load, ability to transfer load between areas, repairs capacity
available in manufactures works and new plant to be commissioned before the period.
8.3 AT REGIONAL LEVEL
Having the guidance of the National estimates and with local knowledge of area loadings
and usual requirements, the region can indicate to each station how much plant may be out
of service for overhaul at any time during the April to September period.
8.4 AT THE GENERATING STATION
Knowing how much plant is to be overhauled, how much may be taken out of service at any
one time and the amount of work required on each unit, the station plans the overhaul
schedules for the coming years. As the programmes advance, these schedules are followed
by more detailed schedules. The detailed schedules will cover all the work necessary and
show estimates of time required for each job. They will include a list of the replacement parts
and stores required so far as can be judged at the time.
In practice, of course, there is much give and take between station, Regional and National
Headquarters to allow for special outages of plant for repairs or modifcations by
manufacturers, for special work and for major breakdowns which may occur. Programmes
should be available for all the planned maintenance which is to be done in the following two
years and in the case of large modern units, three years.
8.5 ADVANCE PLANNING
advance planning is essential if the work on any turbine plant is to go smoothly and the
maintenance staf will have decided the length of outage required for the inspection and
overhaul of the turbine.
Special spares required for overhauls should be ordered well in advance to ensure delivery
before the actual outage of plant and when the overhaul schedules are planned. The
maintenance staf assess their requirements and order accordingly. There is a
comprehensive national plant progressing scheme in use by the Central Electricity
Generating Board which endeavors to ensure deliveries of difcult items from manufacturers
to site as required.
Unforeseen requirements for spares and material, due to breakdown or defects found when
the plant is opened up for overhaul, are met by urgent progressing and special arrangements
for delivery from manufacturers; sometimes the help of other stations that may have the
items required in stock is enlisted.
Minor repairs should, if possible, always be attended to as they arise and should never be
allowed to accumulate.
9. TURBINE ANNUAL MAINTENANCE
Some of the maintenance work usually carried out annually, or whenever the opportunity
arises after a suitable period of running is described below.
9.1 INSPECTION OF BEARINGS
Bearing keeps should be lifted and the top half of the bearing shell removed. The wear on
the bearings can be measured by means of a bridge gauge placed over the shaft journal,
with the turbine cold, and a measurement mud with feelers In some cases a micrometer
gauge is used instead of feelers. This measurements is recorded and compared with
previous records.
To remove the bottom half of the being shell for inspection the shaft is supported on a type of
jack and the bottom half shell turned out.
Careful inspection is made of the white metal for cracks or hard sports but usually vary few
defects occur in modern turbine bearings.
9.2 OIL CLEARANCE
before boxing up the bearing the oil clearance is measured by means of leads. To do this,
pieces of lead wire are placed across the journal, the top half of the bearing shell and keep
replaced and tightened down with the securing bolts. After removing the keep and top half of
the bearing shell, the lead wire is found to be fattened. This thickness of the fattened leads
can be measured with micrometer to give the amount of oil clearance.
Oil clearances adopted by diferent manufacturers will be found to vary slightly, but a useful
rule to apply for clearance in any white metal bearing is a minimum of one thousandth of
an inch per inch of shaft diameter : thus a 12 inch diameter journal would have a minimum
clearance of 12 thousandths of an inch (0.012 inches). unit is thou/ inch.
9.3 THRUST BEARING INSPECTION
The thrust bearing should be opened up. The pads removed, inspected and measured with a
micrometer. Usually very little wear is found on pads of the normal Michell type thrust
bearings. The pads should be replaced in the positions from where they were removed and
not be mixed up.
9.4 SHAFT ALIGNMENT
The alignment of shafts should be checked, if possible, annually by means of clock gauge
indicators, readings being taken at four points 90 degrees apart from each other between
coupling faces and around the circumference of the couplings. Alignment is an important
factor, since incorrect alignment of shafts may not only afect the smooth running of the plant,
but can also cause excessive wear on such parts as fexible couplings and bearings.
Inclinations of the shaft journals can be taken by means of a spirit level. From such reading
movement or distoration of bed plates and foundations can be detected. The more up to date
equipment used for detecting foundation and turbine movement is the manometric levelling
gear which is permanently ftted to some modern units.
9.5 STEAM CONTROL AND EMERGENCY VALVES.
Steam control and emergency valves should be opened up periodically for examination.
Worn valves should be ground in and re-seated and, in bad cases, the faces renewed.
10. TURBINE MAJOR OVERHAULS
10.1INSPECTION AND PLANNING
Planning at station level before a major overhaul is of vital importance if the work is to be
completed in the time allowed for outage of the turbine. Prior arrangements must be made if
a manufacturers representative is required on side for inspection or other purposes. Lifting
tackle, special tools, bolts and spars parts required should be on site before the work is
commenced.
Lagging will have to be removed from cylinder casings and cleared away before lifting
covers.
10.2CASING FASTENINGS
It will be necessary to heat the H.P. casing bolts or clamps before removal as they are
prestrained.
L.P. cylinder casings are usually fastened with ordinary bolts or studs and can be removed in
the normal manner bolt heating being unnecessary.
It will be noticed that the ftted bolts, nuts and their respective positions on the cylinder are
marked with a number. It is important that the nuts and bolts be replaced in their correct
position on reassembly.
On some makes of turbines, usually of the reaction type, it is necessary to push the H.P.
rotor right back on the thrust adjustment to give maximum blade clearance before
commencing to lift the top half of the casing.
10.2 LOWERING L.P. CASING WITH GUIDE COLUMNS IN POSITION
After all bolts have been removed, four graduated columns are ftted to guide the cover while
it is being either raised or lowered to prevent it fouling rotor blades. Before lifting the top half
cylinder, coupling alignment readings should be taken in the manner described earlier and
recorded.
10.3RUNNING CLEARANCE
The lifting tackle can now be assembled and the cylinder lifted, great care being taken to lift
squarely. When the cylinder top has been removed the axial clearance on each wheel and
the preceding diaphragm or fxed row of blades should be measured on each side of the
turbine and be compared with earlier records. This will show whether the rotor position has
altered or whether an individual part has become distorted.
The top half cylinder will have to be turned over after removal to allow the top half
diaphragms or rows of fxed balding to be examined.
10.4ROTOR REMOVAL
The steam rotor can now be lifted, but frst, bearing and thrust block keeps must be removed.
Wire slings are placed around the shaft and attached to the lifting beam suspended on the
crane hook. Raise rotor slightly and ensure that it is level and not fouling the stationary
balding at any point, continue lifting carefully and evenly until clear of the cylinder bottom
half. The rotor can now be placed on trestles and a careful examination made for damaged
shrouding, lacing wires, fractured blades, corroded and eroded blades. The fxed balding can
be scrutinised carefully. It is sometimes necessary to remove diaphragms, where ftted, at
each overhaul to prevent seizure between diaphragm and cylinder casing.
10.5INSPECTION OF OTHER EQUIPMENT
Couplings should be cleaned, and driving faces examined for wear.
External and internal glands should be inspected. If carbon rings are used for external
glands, the condition of rings and shaft sleeves should be noted and any items renewed
where necessary.
Cylinder drainage holes should be checked to ensure they are clear; efcient drainage has
an important bearing on the life of balding.
After all repairs and inspections are completed and before replacing the rotor in the turbine
cylinder, a careful check must be carried out to ensure that all tools, rags, nuts and bolts, and
other materials have been removed. The cylinder casing can then be blown out with
compressed air to remove dust and small particles of dirt.
10.6RADIAL CLEARANCES
Lead wire is placed on all stationary glads at the bottom centre and at 45
0
to it on each side.
The rotor is then carefully lowered into position whereupon more leads are added at the top
centre of it and at 45
0
angle each side. The top half casing is then assembled and every
other joint bolt tightened up. The top half casing and rotor are removed and the indented
leads measured to ascertain the radial clearances existing in the fully assembled running
condition. Adjustments to the glands are then made where necessary and a fnal set of leads
taken to establish the accuracy of the work done. In some large modern machines with
double cylinder it has been found necessary to measures the movement of diaphragms with
the top halves bolted up by means of a boring bar in place of the rotor, measurement being
taken with clock gauges.
10.7REPLACEMENT OF ROTORS
The rotor can now be fnally lowered into the turbine bottom half cylinder casing. Bearing top
halves and keeps can be ftted and the cover lowered carefully, using the graduated columns
as guides. Bolts can be re-ftted, those on for the H.P. and I.P. cylinders being heated with
suitable equipment. All bolts must be tightened in the corrected sequence and tensioned
according to the manufacturers instructions.
It is essential that the H.P. and I.P. cylinders be lagged and that the lagging is thoroughly dry,
before any running of the turbine is undertaken otherwise distortion or damage may result.
11. ASSOCIATED PLANT
11.1Steam Receivers and Feed Heaters.
Steam Receivers and Feed heaters with Steam pressures above atmospheric pressure are
classed as pressure vessels and under the factory Acts, Inspection of steam receivers is
usually a straightforward job. After Isolation and draining and the necessary safety
precautions have been taken, the manhole doors are opened and inspection made.
11.2Feed Heaters
A hydraulic test is generally accepted in place of an internal examination. Heater relief valves
should be dismantled and inspected.
11.3Oil Coolers
Oil coolers should be cleaned during the outage of the turbine for overhaul. Covers are
removed, the insides of tubes brushed and the external surfaces of tubes de-greased by
either trichloroethylene vapour or by a detergent solution.
11.4Steam Ejectors
Ejector nozzles should be inspected and if there has been undue wear the nozzles should be
renewed.
11.5Oil System
If it is necessary to drain the turbine oil system it is usual to seek the assistance of the oil
suppliers.
11.6Removal of the Generator Rotor
The generator rotor is sometimes removed for repairs or cleaning and inspection during
overhaul. Although not a difcult operation care must be taken, as it is not possible to use a
direct lift with a crane and the manufacturers instructions should be followed closely. The
exciter and generator brush gear should frst be removed. The rotor suspended from the
crane by slings around the shaft and the rotor and bearing removed. A steel plate or cradle,
rolled to the internal circumference of the stator, is inserted under the rotor and the crane
supporting it moved away from the generator. It is then usually possible to sling the rotor
midway along, when it can be moved out of the stator tunnel by means of the crane, for
inspection.
12. Turbine Defects
Since the whole object of maintenance of any kind of plant is to fnd wear and defects which
would in time lead to failure and cause breakdown of the plant, a description of some of the
most common defects will be helpful.
12.1Blade Defects
Failure of blades shrouding or lacing wires from cracking or fracture is usually the result of
resonant vibration. Resonant vibration of blades is usually confned to a particulars row,
rough running of the set or any other external disturbing infuence having little or no
connection with its occurrence. If a machine has a history of defective balding, such balding
should be subjected to crack detection tests each time the cylinder covers are lifted. If roots
are found cracked, the blades must be renewed, in which case arrangements may have to
be made to send the rotor back to the manufacturers works. If the manufacturers is likely to
take a long time and the turbine is required for load, it is usually possible to remove the
afected stage of moving blades and run the turbine without it until new blades can be ftted,
so long as excessive stresses are not put in the next row. In the case of a stage in which one
or two blades are missing, it is sometimes possible to remove an equal number of blades
diametrically opposite to restore the rotor balance and run the turbine in this state until
permanent repairs can be made. New lengths of shrouding can usually be ftted on site and
broken lacing wires should also be repaired.
12.2Erosion and Corrosion
Blade corrosion and erosion, which have been deals with earlier, can cause severe pitting of
the surfaces and very ragged inlet edge, but blades in this condition may be safety run for
years with little or no loss of efciency. So long as the cross sectional area is not too far
reduced and sufcient strength is left at particular positions, such as at the lacing wire levels,
to allow for the further wear which will occur before the next major overhaul, there will be no
need to reblade. Erosion is usually confned to the last stage blades of the L.P. cylinders.
12.3Gland Wear
Labyrinth gland packing strips may be found damaged or worn from being in contact with the
shaft and this will cause an increase in steam consumption. Renewal of the labyrinth packing
strips is usually a fairly simple matter.
12.4Bearing Defects
Bearing may be found to have chattered in their spherically shaped seats but can generally
be tightened by adding extra shims or packing liners to the top half bearing pads. Scoring of
the white metal can be easily dealt with by touching up the surface with a scraper.
Deterioration in the bonding of the white metal, or cracking, needs careful checking and
assessment and may prove sufciently serious to warrant remetalling.
12.5Oil Pump Defects
Breakdown of the main oil pump from any cause such as a fractured pump shaft, or failure of
driving gears, will automatically operate the oil pressure regulator and start up the auxiliary
oil pump. Frequent testing of the regulator should ensure that bearing failures will not arise
from such a breakdown.
In some designs the main oil pump driving gear also drives the turbine governor and in the
event of a drive failure the set would be without governor control. So long as the generator is
connected to the electrical system, the speed will remain constant but should the circuit
breaker be opened the turbo-generator will overspeed and trip out on its overspeed
governors.
This illustrates the importance of making the right decision when faced with failure of control
mechanisms, for under certain circumstances, tripping electrically before steam is shut of
may seriously aggravate the situation.
12.6Oil System Defects
Dirty oil coolers will prevent proper cooling of the oil with the result that the bearings may
become overheated. The oil will tend to carbines, flling oil grooves and ultimately may cause
heavy bearing wear and failure.
Great care must be taken to clean all oil ways, pipes and tanks of newly erected sets before
the turbine is run. It is usual to circulate the entire oil system with fushing oil and, to ft
additional fne mesh screens on all flters. One or two bearings should be lifted after fushing
to see whether any rust or scale remains and, if so, this will have to be removed by hand.
12.7Governor System Defects
The most common defects are those in the governor system control valves and usually
consist of steam cuts in the valve faces or wear of the valve stems due to working in the
guides. In many cases such defects necessitate complete renewal.
12.8Governor Hunting
Any of the following defects may be responsible for hunting or erratic behavior of the
governor control system :-
(a) Slackness of governor weights or interconnecting links, because of wear in the
components.
(b) Excessive friction in governor mechanism or relays, which can only be overcome by an
abnormal change in speed before the steam control valves are actuated, with the result that
when movement does take place it is too great and produces overswing.
(c) Defects in the oil supply to the relay controlling the power oil for steam control valve
operation. If the oil relay gear is taken adrift great care should be taken to note the datum
measurements so that on re-assembly, the gear may be adjusted to the original setting.
13. Maintenance of Condensers
13.1 Cleaning
Most turbine operators are familiar with cleaning condenser tubes on the circulating water
side, but for those who are not the methods employed will described.
Where twin condensers are ftted each half may be cleaned in turn with the machine on load.
One of the more general methods of cleaning is to pass brushes or bullets through the tubes
by means of water or air pressure. During their passage through the tubes these bullets or
brushes remove any deposits from the inner surfaces of the tubes. With older and smaller
plant it is still the practice to clean tubes by using a brush attached to the end of a long rod
which is pushed through each tube by hand. Where condenser tubes are badly scaled with
deposits and bulleting is not successful, acid cleaning is often employed. Acid cleaning
consists of passing an acid solution, such as hydrochloric acid through the tubes by a pump.
An inhibitor is added to the acid to prevent attack on the tube metal. The job is often carried
out by a contractor who specialises in this work.
13.2Condenser Testing
The usual method of condenser testing is to fll the steam side with condensate and enter the
water boxes to take note of any tubes, ferrules or stay bolt fxings which are leaking.
Fluorescein dye can be added to the condensate to facilitate locating these leaks as
described in Lesson 6. Leaks at ferrules and stay bolts can usually be stopped by tightening,
whilst leaking tubes are plugged. Brass plugs are usually more satisfactory than wooden
plugs. Expanded tubes eliminate ferrule leakage and can cut down a common source of
condenser leakage.
Before flling a condenser for test, the jacking bolts must be screwed hard down or packing
inserted to take the extra weight of the condenser supporting springs and prevent a heavy
strain being imposed upon the connection between the condenser and the turbine exhaust.
With a new turbine, or on conclusion of a turbine overhaul it is good practice to carry out a
low pressure hydraulic test on the condenser and L.P. steam piping. In addition to proving the
condenser tight, this test shows up any air leaks.
14 Turbine Vibration
14.1Critical Speed of Rotors
All turbine and generator rotors have critical speeds, that is a speed or speeds at which they
will vibrate naturally if subjected to sufciently great excitation forces. Many rotors are
designed so that their lowest critical speed is well above any speed likely to be met in normal
operation but for various reasons (chiefy efciency, and in the case of generator rotors the
lack of any alternative) some have critical speeds below normal running speed. In these
cases, the rotor has to run through the critical speed between start up and synchronising
and, of course, when being shut down.
Well balanced rotors rarely exhibit noticeable signs of vibration when passing through a
critical. However, the efects of service conditions can cause deterioration in balance and
this may provide sufcient exciting force to create quite heavy vibration if the turbine speed
is held at the critical speed for the particular shaft involved. Normal practice therefore, is to
always quickly run through the bands containing the critical speeds of the various individual
critical speed are always clearly marked on the tachometer face as an indication to the
operator to move the turbine quickly through this speed range.
In modern sets, whilst individual rotors should behave ideally in respect of critical speeds this
ideal is not realised in practice because of the efect of temperature variations and
foundation settlement on running alignment. Balancing rotors is a highly skilled job to ensure
freedom from vibration.
14.2Balancing of Rotors
Turbo-generator rotors are checked and adjusted at works, after manufacture, in a balancing
machine where weights are added to give what may be called, for all practical purposes, a
balanced rotor. If the generator rotor is out of balance then correction can sometimes be
made on site by a skilled balancer without the use of special equipment but a great deal of
experience is necessary to balance rotors on site in this way.
14.3Defects Causing Shaft Vibration
A bent shaft can result from the following causes :-
(a) Movement of the foundations.
(b) Incorrect alignment of turbine shafts
(c) Casing distortion, or faulty steam pipe expansion arrangements.
(d) Failure to use barring gear correctly.
(e) Incorrect operation of gland steam.
If a turbine has not been put on barring gear after coming of load or the gland steam is
incorrectly applied and the turbine is then run up whilst still warm or hot there is a danger of
bending a rotor. A slow and careful run up to speed may straighten a shaft bent in this way
and vibration should gradually decrease, but damage may have been done to gland
packings due to contact with the shaft.
Vibration can also be caused by incorrect alignment of turbo-generator shafts. Such vibration
does not usually change with the machine speed but increases as the load is increased.
Misalignment may be caused by the settling of foundations or faulty expansion arrangements
of steam piping causing heavy force and bending moments on the casing even in a turbine
which has been operating for some time.
When vibration is experienced, couplings should be checked for attainment. Any restriction
to free expansion or contraction (perhaps due to some fault on the casing or bearing
pedestals) can be a contributory cause.
14.4Conclusions
Fortunately serious turbine vibrations are rare occurrences, and this is a tribute to turbine
designers, construction, maintenance and operation stafs, but the foregoing does give some
idea of the magnitude of the problems involved particularly on large modern turbines. By
careful operation and accurate and adequate maintenance, power station stafs can make an
important contribution to achieving a high standard of turbine availability.
TECHNICAL DETAILS OF SAIL TURBINES( BSL, DSP & RSP)
Turbine Details of RSP : ROURKELA STEEL PLANT, CAPTIVE POWER PLANT - II.
The steam Turbine - Generator was manufactured and supplied by M/s. Bharat Heavy
Electrical Ltd. The steam turbine is a single cylinder, condensing impulse reaction (with frst
stage impulse) type with 44 stages and fve non-controlled extractions.
A.0.Description and Functions
A.1 Design Features
The steam turbine-generator set has a maximum continuous rating of 66,000 KW operating
at the rated speed of 3000 RPM with throttle steam conditions of 88.2 kg/cm
2
, 535
0
C and the
exhaust pressure of 0.0843 kg/cm
2
. The steam turbine is a single cylinder impulse reaction
machine with a control stage and fve uncontrolled extraction to supply steam to two high
pressure feed water heater and two low pressure feed water heaters and a deaerating
heater. The turbine is equipped with an electrohydraulic and hydraulic governing system.
1.0 Technical Data of Turbine : ROURKELA STEEL PLANT, CAPTIVE POWER PLANT- II.
Type of steam turbine : HNK 71/2-8/32-4
(HN represents High Pressure Turbine
K represents Condensing Type 71 is the dimension of outer casing at steam inlet portion in
centimeters (inner radius of outer casing) 2-8 is dimension of rotor in terms of fow area in
square meters through the last stage.
32 is the length of rotor in casing in
excess w.r.t. basis turbine 320 mm.
4 is the fourth generation)
Machine nos. : T/-0249 & 0250
Normal output : 60 MW
Maximum output : 66 MW
Speed : 3000 RPM
Specifed initial steam pressure : 88.2 kg/cm
2
Abs
Permissible deviation at
no load operation : 92.6 kg/cm
2
abs
Permissible deviation
instantaneous for a total
duration of 12 hrs. per annum : 1114.7 kg/cm
2
abs
Pressure in HP wheel chamber
of turbine must not exceed : 77 kg/cm
2
abs
Specifed initial steam
temperature : 535
0
C
Permissible deviation for
longer periods : 543
0
C
Permissible deviation for
400 hrs. per annum : 549
0
C
Permissible deviation for
80 hrs. per anuum but no
longer than 15 min. at a time : 563
0
C
Cooling Water Temperature
- Normal : 33
0
C
- Maximum : 36
0
C
- Start-up time (Rolling time) : 35 Min.
- Time required for placing
on load : 100 Min.
- Time required for start-up
and placing on load : 135 Min.
- Critical speed range : 1500 to 2400 RPM
- No. of stages : 44
- No, of extraction : 5
(Extraction No. 5 after 15th stage
Extraction No. 4 after 26th stage
Extraction No. 3 after 33rd stage
Extraction No. 2 after 38th stage
Extraction No. 1 after 41st stage &
exhausthood at after 44
th
stage)
2.0 Technical Data of Turbine Auxl Lubrication System
2.1 Main Oil Pump
Make: M/s BHEL
Type: Centrifugal
Capacity : 190m
3
/hr
Normal discharge pressure : 8 kg/cm
2
(g)
2.2 Auxiliary Oil Pump (2 nos.)
Make: Halberg
Type: Centrifugal
Capacity : 53 m
3
/hr. at 8 bar
145 m
3
/hr at 6 bar
Normal discharge pressure : 7.0 kg/cm
2
(g)
Speed : 3000 rpm
Type of coupling : Flexible
Motor rating : 55 KW
2.3 Emergency Oil Pump (2nos.) AC/DC
Make: Kirloskar
Type: Centrifugal, horizontal
Capacity : 40 m
3
/hr
Normal discharge pressure : 1.8 bar
Motor rating for both AC & DC : 5.5 KW
2.4 Jacking OIL Pump
Make: Dension Hydraulics
type: Vane pump
Capacity : 50 LPM
Pressure : 150 bar
Speed : 1500 rpm
Motor rating : 22 KW
2.5 Oil Cooler
Type: Vertical shell and tube
Nos.: 2 X 100%
Cooling water requirement : 60 m
3
/hr.
Cooling water temperature : 36
0
C
Friction head water side : 0.2 kg/cm
2
Cooling surface approx.. : 70m
2
.
2.6 Oil Filter
Filter cartridge : 5 microns paper flter
2.7 Oil Tank
Capacity : 6.3 m
3
2.8 Turbine Oil Purifcation System
Purifers : 2 nos.
Capacity : 1600 ltr./hr. each
3.0 TECHNICAL DATA OF EJECTORS
3.1 Hogging Ejector
Working steam pressure : 11 kg/cm
2
Working steam temperature : 240
0
C
Steam consumption : 1000 kg/hr.
Capacity : 440 kg/hr. of dry air
Suction pressure : 250 mm Hg
Materials of Construction
Mixing chamber : carbon steel IS 2062
Difuser : Carbon steel/CSN 11416.1
Nozzle : 350 kg
Assembly weight
3.2 Main Ejector
Number of ejector units : 2
Number of stages : 2
Design capacity : 2 x 100%
Suction pressure : 25 mm Hg
Suction temperature : 22
0
C
Dry air leakage : 20.4 kg/hr
Associated saturated vapor : 45.5 kg/hr.
Total gas vapour mixture : 66 kg/hr.
Motive steam pressure : 10 kg/cm
2
(g)
Motive steam temperature : 240
0
C
Steam consumption : 400 kg/hr.
Surface area of inter condenser : 8 m
2
Size of tubes : 0 15 mm x 1 thk
Length of tube : 1000 mm
Method of fastening tubes : Roller expanding
Cooling water : condensate
Cooling water quantity at
100% capacity : 160 m
3
/hr
Water side design
Pressure (max) : 0.5 kg/cm
2
.
Materials of Construction
shell, water chamber
Difuser, tube sheets : Carbon steel
Steam nozzles : Stainless steel
Tubes : Admiralty brass
Suction chambers : Carbon steel
Weights
Ejector assembly dry : 4855 kg
Ejector assembly operating : 6200 kg
Ejector assembly fooded : 700 kg
4.0 Technical Data of Condenser
4.1 Condenser
Efective surface area : 4700 m
2
No. of water passes : 2
Duty: 8.05 x 10
2
kcal/hr
Circulating water quantity : 13500 m
3
/hr.
Cooling water inlet temperature : 33
0
C
Condenser vacuum : 0.866 ata (716 mm/Hg)
Resistance on water side : 6 MWC
No. of tubes in condensing zone : 8512
Size of tube : 25.4 X 1 mm
Efective length of tube : 6440 mm
Tube material in condensing : a1 Brass
No. of tubes in air cooling zone : 698
Air cooling zone material : 90/10 Cu. No
No. of tubes at impingement section : 90
Impingement section tube material : Stainless steel
Water box cover material : Carbon steel
Shell material : Carbon steel
Water chamber design pressure : 4.5 atg
Water chamber test pressure : 6.7 atg
Size of nozzles inlet/outlet : NB 1000
Shell thickness : 16 mm
Number of shell section : 2 (two)
Hotwell capacity : 9.6 m
3
.
Material for hotwell shell : Carbon steel
Weight
- condenser dry : 185,000 kg
- condenser during operation : 265,000 kg
- Condenser fooded : 300,000 kg
4.2 Condensate Extraction Pump
Type: 150 CJAV/6, centrifugal, vertical
No. of pumps : 2 x 100%
Number of stages : 6 (six)
Pump design capacity : 276 m
3
/hr. (4600 1/m)
Discharge head : 160 MWC
Temperature of liquid : 47
0
C, condensate
Speed : 1480 rpm
Min. NPSH required : 2.7 MWC
Main Motor
Rating : 225 KW
RPM: 1500
Voltage : 6600 volts
Electrical protections : Motor protection relay
Winding temp. Trip/Alarm
Bearing temp Trip/Alarm
Guaranteed Performance
KW required at operating point : 203 KW
Efciency : 59.5%
Construction Features
Casing type : Stage bodies radially split
Thrust bearing type : Roller bearing 29326
Coupling type : fexible
Construction Material
Stage bodies : Cast iron
Impellers : 1-11 14% Cr steel other Bronze
Difuser : Cast iron
Wearing ring : Cast iron
Shaft: Cr.steel
Coupling : forged carbon steel
Stufng box elbow : Cast steel
Tests
Casing hydrotest pressure : 24 kg/cm
2
.
Cooling water (Thrust bearing) quantity : 10 ltrs./min
Sealing water requirement : 2 ltrs./min. at 2 kg/cm
2
.
Sealing water requirement : 2 ltrs./min at 2 kg/cm
2
Lube Oil
Grade : Turbine Oil 14
Quantity : 1 (One) litre
Period of change : After every 100 hours run
Temperature of oil at inlet : 35
0
C
Weights
Pump and coupling : 3150 kg
Bed plate : 111 kg
Motor stool : 440 kg
Rotor: 241 kg
total weight assembled : 7150 kg
4.3 DEAERATOR
4.3.1Heater Assembly
Inside diameter thickness : 1400 x 10 mm
Total height : 2614 mm
Design pressure : 5 atg and full vacuum
Design temperature : 200
0
C
Operating pressure : 4.12 ata
Operating temperature : 144.69
0
C
Condensate inlet quantity : 210766 kg/hr.
Number of trays : 5 (fve)
Vent condenser shell drain quantity : 6922 kg/hr.
4.3.2.Feed Water Storage Tank
Design pressure : 5 atg and full vacuum
Design temperature : 200
0
C
Operating pressure : 4.12 atg
Operating temperature : 144.69
0
C
Inside diameter x thickness : 3500 x 16 mm
Total length : 23000 mm
Total volume : 215 m
3
.
Volume at operating level : 150 m
3
.
Number of initial heating nozzles : 1 (one)
Steam inlet quantity : 7902 kg/hr.
Inlet steam pressure : 4.12 ata
Inlet steam temperature : 194.3
0
C
HPH shell drains : 962 kg/hr.
4.3.3 Vent Condenser
Shell side design pressure : 5 atg and full vacuum
Shell side design temperature : 200
0
C
Tube side design pressure : 200
0
C
Tube side design pressure : 8atg
Tube side design temperature : 150
0
C
Condensate inlet quantity : 2,10,766 kg/hr.
Condensate inlet temperature : 122.57
0
C
Inlet steam quantity : 9,222 kg/hr.
Number of tubes : 301
Size of tubes : 15 x 1 mm
Length of tube : 5670 mm
Surface area : 72 m
2
.
Number of air vents : 2 (two)
4.4 Boiler Feed Pump
Type: 150 KHI/9 Multistage horizontal barrel
type
No. of pumps : 2 (1 + 1) x 100%
No. of stages : 9 (nine)
Capacity : 315 t/hr.
Head: 1375 MWC
Speed : 2980 rpm
consumption of cooling water : 280 lt/min.
Consumption of oil : 60 lt/min.
Feed water temperature : 144.7
0
C
Min. NPSH required : 11.7 MWC
Recirculation fow : 60 t/hr
Quantity of water for heating the pump : 6 t/hr over the balancing device.
Motor rating : 2000 KW
Voltage : 6.6 KV
Efciency : 71%
Critical speed : 1640 rpm
Type of coupling : Space coupling
Shaft: Forged chrome steel
Casing : Barrel
Impeller, guide vanes & shaft sleeves,
wearing ring : Stainless steel
Balancing disc : chrome steel
Gland packing : Mechanical seal
Max. leak-of quantity : 600 1/min.
Lube Oil Pump Type : Gear pump, OH-63
Capacity : 63 lt/min,
Head: 25 MWC
Speed : 1420 rpm
Nos.: 2 (1 + 1)
Motor rating : 0.37 KW AC
Voltage : 415 V
Lube Oil Tank Capacity : 1 m
3
Oil Filter
Type: Duplex
Capacity : 80 1/mt.
Oil Cooler
Tube: Shell & Tube
Capacity : 631/mt.
Shell material : MS
Tube material : Brass
5.0.Technical Data of HeaterS
5.1 Low Pressure Heaters
LP1 LP2
Type: Vertical U-tube Vertical U-
tube
Number of Passes shell : 1 (one) 1 (one)
Number of passes tube side : 4 (four) 4 (four)
Pressure drop through tube : 0.6 kg/cm
2
. 0.6 kg/cm
2
Design pressure (shell) : 4 kg/cm
2
4 kg/cm
2
Design pressure (tube) : 22 kg/cm
2
22 kg/cm
2
Tube material : 460 460
Design temperature : 200
0
C 270
0
C
Tube material : Admiralty Brass Admiralty
Brass
No. of tubes : 460 460
Design temperature : 200
0
C 270
0
C
Inlet temperature of steam : 89.2
0
C 244.9
0
C
Outlet temperature of
Feed water : 87.88
0
C 120.7
0
C
Outlet temperature of
Feed water : 49.13
0
C 84.88
0
C
Operating pressure of shell : > 0.64 kg/cm
2
2.18
kg/cm
2
5.2 HP Heater-4
Nos.: 1 (one)
Type: U-tube
Position : Vertical
Parameters Shell Side Tube Side
Fluid circulated Steam Drains Feedwater
Inlet temperature 278
0
C (188 sat) 232.8
0
C 147
0
C
Outlet temperature - 154.7
0
C 187.4
0
C
Operating pressure 12.4 kg/cm
2
- 147
Number of passes - - 2
Pressure drop 0.06 kg/cm
2
0.08 kg/cm
2
1.0 kg/cm
2
.
Design pressure 20 kg/cm
2
- 185 kg/cm
2
Test pressure 30 kg/cm
2
. - 280 kg/cm
2
Design temperature 300
0
C - 300
0
C
Material Steel - Steel
5.3 HP Heater-5
Nos.: 1
Type: U-tube
Position : Vertical
Parameters Shell Side Tube Sides
Fluid circulated Steam Drain Feed
water
Inlet temperature 389.1
0
C (232 sat) - 187.4
0
C
Outlet temperature - 232.8
0
C 230.32
0
C
Operating pressure 29.45 kg/cm
2
- 146
Number of passes - - 2
Pressure drop 0.23 kg/cm
2
- 0.9 kg/cm
2
Design pressure 45 kg/cm
2
- 185 kg/cm
2
Test pressure 67.5 kg/cm
2
- 280 kg/cm
2
Design temperature 300
0
C (shell) - 300
0
C
Material Steel - Monel-SB-
1
Turbine Details of Bokaro CAPTIVE POWER PLANT
The steam turbine generator was manufactured and supplied by M/s. Elektrim Magadex,
Poland.
A.0 Description and Functions (UNIT #6, #7 & #8)
A.1 General Description
The steam turbine-generator set has a maximum continuous rating of 66,000 KW operating
at rated speed of 3000 RPM with steam conditions at turbine inlet at entry to emergency stop
valves as 90 ata and 525
0
C and the exhaust pressure of 0.090 ata. The steam turbine is a
single cylinder impulse reaction condensing type of machine with four (4) uncontrolled
extractions and two (2) controlled extraction to supply steam to two (2) high pressure feed
water heaters, three (3) low pressure feed water heaters and a 6 ata steam header. The
turbine is equipped with an electrohydraulic speed governing system. The steam turbine is a
single cylinder turbine with disc type rotor design. The fxed point of the turbine is located on
the axis of LP casing exhaust. The turbine rotor is supported in the front section by a
combined thrust and journal bearing installed on the front pedestal. In the rear section of the
turbine, the rotor shaft is connected by a rigid coupling to the shaft of the generator rotor and
is supported on the front end generator bearing. All bearings are provided with a hydraulic
rotor jacking system. In order to safeguard the rotor against bending during start-up and
shutdown, the turbine is equipped with a mechanical rotor turning gear built into the front
pedestal and is driven by an AC motor. The rotor speed when turned by the turning gear is 5
rpm and also provision is available for manual rotation of the rotor. Rotation of direction of
steam fow is CLOCKWISE.
1.0 Technical Data of Bokaro TurbineS
(UNITS #6, #7 & #8)
1.1 Turbine
Type: 9K66 (Elektrim, Poland make) impulse
type, axial fow, single cylinder, condensing
Nominal Rating
Live steam temperature : 535
0
C
Live steam pressure : 90 ata
Cooling water inlet temperature : 32
0
C
Maximum continuous rating : 66 MW
Nominal speed : 3000 RPM
Critical Speed of Turbine : 1377 RPM
Critical Speed of Generator : 1647 RPM
Fly-wheel efect of turbine rotor G x D
2
: 12,932 Mgm
2
1.2 Live steam conditions at Turbine Inlet at Entry to Emergency Stop Valve
i) Nominal pressure : 90 ata (8.83 MPA)
ii) Nominal Temperature : 535
0
C
Steam Consumption
i) At nominal rating (60 MW) : 227.5 t/hr. (63.19 kg/sec.)
ii) At maximum rating (66 MW) : 256.5 t/hr. (71.52 kg/sec.)
Exhaust steam pressure : 0.085 ata
1.3 Materials of Important Parts
1.3.1Turbine
Inner casing : L17 HMF/N
Outer casing : L17 MHF/N
Exhaust part casing : St 41K
Diaphragm liner : L20 HM L120
Rotor: 23 H2 MFA
Rotor blades : 15 H11MF/1H13/2H13
Diaphragms : 13 HMF/15HM/st3S
Diaphragm blades : 1H13
Casing closing bolts : 21 HMF
1.3.2Condenser
Type: KPG- 5000 1/6
Tubes : Aluminium,. Brass
Tube plates : St3s plated with 1H18N9T
Shell: St3s
1.4 Dimensions and Weight of Large Elements
1.4.1Dimensions
Total turbine length : 6600 mm (approx.)
Rotor length : 5814 mm (approx.)
Maximum diameter of bladed rotor : 2474 mm (approx.)
Assembled casing Hp and IP outlet, top part
(height x width x length) : 4600 x 6000 x 6000 mm
IP outlet casing transportation
dimension of bottom part
(height x width / length) : 2950 x 6000 x 2250 mm
Condenser
(height x width x length) : 7450 x 5250 x 12600 mm
1.4.2Weights
Biggest weight for turbine erection
- IP outlet casing bottom part : Approximately 20,000 kgs
Biggest weight for turbine inspection-
HP/LP casing top part : Approximately 17,000 kgs.
Technical Date of Turbine Auxl (Lub Oil Sys)
Oil grade : TU 20 according to polish PN-
76/0-96059 Mobile DTE of viscosity 28 cst at 50
0
C
Turbo shell 27
Turbo shell 29
Servo prime 46
Oil Tank
Operational volume : 14 m
3
Volume at maximum level : 18 m
3
Maximum level : 100 mm
Maximum operational level
(from the top) after flling the system : 685 mm
Minimum operational level
(from the top) after flling the system : 835 mm
Volume in the tank between the
maximum and minimum opertional level : 6 m
3
(approx.)
Oil Coolers
Type: Horizontal
No. of oil coolers : 2 (two)
No. of oil coolers in operation : 1 (one)
Heat exchange surface : 215 m
2
Cooling water fow per cooler at 32
0
C : 115 m
3
Description of item Discharge Capacity Drive
pressure m
3
/hr. rating
KW
Relay oil pumps 2 nos. 20 50.4 AC
(one no. as reserve) Motor
Lubricating oil pump Turbine
Shaft
Auxiliary oil pump 2.5 72.0 AC
Motor
Emergency oil pump 0.95 57.6 DC
Motor
Jacking oil pump 35-140 0.648 AC
Motor
2.4 Relay Oil Filter
Capacity : 1000 l/min
Filteration accuracy : 25 microns
Nominal pressure : 25 atg
2.5 Lubricating Oil Filter
Capacity : 1100 1/min.
Filteration accuracy : 32 microns
Nominal pressure : 2.5 atg
2.6 Air Filter
Capacity : 32 m
3
/hr.
Filter area : 0.19 m
2
Mesh size of flter change : 0.1 mm x 0.1 mm
2.7 Hydraulic Accumulator
Nominal volume size : 4 x 25 liters
Nitrogen flling pressure : 14 atg
Maximum useful working pressure : 20 atg
Nominal pressure to which the pressure
falls upon discharging : 17 atg
2.8 Vapour Fan
Capacity : 0.12 m
3
/s
Numbers : 2
Motor rating : 0.37 KW
3.0 TECHNICAL DATA OF GSC & STEAM COOLER
3.1 Gland Steam Condenser
Type: KP-55-101
Numbers : 1 (one)
Heat exchange surface : 55 m
2
Quantity of steam/air : 1.2/0.6 t/hr.
normal/maximum : 300/380
0
C
Steam inlet pressure : 0.97 ata
Cooling water inlet/outlet temperature : 50
0
C/54.5
0
C
Cooling water consumption at 45
0
C : 170 m
3
/hr. (47.2 kg.sec.)
Rating of the exhauster fan motor : 5.5 KW
3.2 Steam Cooler
Cooling water temperature : 50
0
C
Cooling water pressure : 16 atg
Cooling water quantity : 0.04 kg/sec.
Steam temperature after cooler : 150
0
C
3.3 Operational Steam Ejector
Number : 2 (two)
Working steam pressure : 12 ata
Working steam temperature : 240
0
C
Dry air quantity : 0.432 t/hr.
Suction pressure : 0.07 kg/cm
2
Quantity of cooling condensate : 108 t/hr.
Inlet. Outlet temperature of condensate : 38/41
0
C
Inlet/outlet pressure condensate : 15.5 kg/cm2 / 14.9 kg/cm
2
Condenser surface area : 44 m
2
Condenser pressure : 1.2 kg/cm
2
3.4 Start-up Ejector
Number : 1 (One)
Quantity of extracted steam air mixture : 12 ata
Working steam pressure : 6 ata
Working steam temperature : 240
0
C
Working steam quantity : 0.27 t/hr.n
Extraction ability : 0.85 ata
Inlet/Outlet pressure of condensate : 15.5/14.9 kg/cm
2
4.0 Technical Data of Condenser
4.1 Condenser
Type: Two-run; two-way with steam
dumping arrangement
Efective surface area : 5000 m
2
Dury: 8.07 x 10
2
kcal/hr
Circulating water quantity : 9000 m
3
/hr. (2500 kg/s)
Cooling water inlet temperature : 32
0
C
Cooling water outlet temperature : 41
0
C
Condenser vacuum : 0.0851 ata (716 mm Hg)
Cooling water velocity in tubes : 1.97 m/s.
Terminal temperature diference : 1.7
0
C
Quantity of condensed steam : 158.1 t/hr.
Steam enthalpy : 551.1 kcal/kg
Permissible pressure for the
Water space of the condenser : 0.39 Mpa
No. of water passes : 2
No. of banks : 4
No. of tubes in the condenser : 6680
Tubes dimensions : 24 dia x 1mm/24 dia. x 1.5 mm
Total tube cross area of one pass : 2.52 m
2
Water Chamber
- Design pressure : 4.2 ata
- Design temperature : 100
0
C
Hotwell capacity - steam chamber : 24m
3
Steam box and exhaust neck volume : 176m
3
Steam Chamber
- Design pressure : 1.5 atg and full vacuum
- Design temperature : 160
0
C
Material of the cooling tubes : Brass MA-77C
Material of the air cooling tubes : MNZ 101
Condenser dimension :
Height X width X length : 7450 x 5250 x 12600 mm
4.2 Condensate Extraction Pump
Type: 15K34X%
Condensate extraction pump nos. : 2 X 100%
No. of stages : 5
Pump capacity : 200 m
3
/hr
Discharge head : 160 MWC
Speed : 1485 rpm
Pump weight : 1960 kg
Motor
Motor type : SZDVc 174t
Rating : 200 KW
Speed : 1485 rpm
Voltage : 6600 volts
Motor weight : 2550 kg
4.3 Feed Water Deaerator
4.3.1Heater Assembly
Design pressure : 7 ata
Design temperature : 2000
0
C
Operating pressure : 6 ata
Operating temperature : 158
0
C
Capacity
- Maximum : 310 t/hr.
- Minimum : 100 t/hr.
Deaeration degree : 0.007 mg/litre
Nominal output : 225 t/hr.
No. of heating arrangements : 2
4.2.2Feed Water Storage Tank
Working volume : 130m
3
Total volume : 170m
3
Water reserve in the tank at maximum
Plant capacity will be sufcient for : 25 min.
4.4 Make-up Water deaerator
Rated capacity : 15/50 t/hr.
Working pressure : 1.23 ata
Working temperature : 105
0
C
Deaeration degree : 0.05 mg/litre
4.4.1Make-up Water Tank
Working volume : 30 m
3
Total volume : 39 m
3
Water reserve in the tank at maximum
plant capacity will sufcient for : 36 min.
4.5 Boiler Feed Pump
Type: 15Z33 X&V1 multi-stage horizontal
No. of stages : 270 t/hr.
Head at rated capacity : 1650 MWC
Temperature of pumped feed water : 158
0
C
Speed : 3724 rpm
Motor rating : 1597 KW
Voltage : 6.6 kV
No. of pumps : 2 (1+1) X 100%
Efciency : 76%
4.5.1Gear with the Hydro kinetic Coupling
Power transferred : 2500 KW
Slow running shaft speed : 2980 rpm
Fast running shaft speed : 4034 rpm
Rated slip of hydro-kinetic coupling : 2.8%
Hydrokinetic coupling slip control range : 2.8 - 70%
4.52Driving Motor
Type: SZJE - 132t
Rating : 2300 KW
Speed : 2980 rpm
Voltage : 6.6 kV
5.0 TECHNICAL DATA OF FEED HEATING SYSTEM
5.1 Feed Heating System
Number of heating stages : 6 (six)
Quantity of feed water fowing through
the Hp heaters at nominal load : 234.6 t/hr. (65.1 kg/sec.)
Final feed water temperature : 230
0
C
Type of HP heater : Vertical, surface type, single and
two zones
Type of LP heater : Horizontal, surface type, single
and two zones.
5.2 LP Heaters
LPH-1 LPH-2 LPH-3
Steam pressure ata 0.45 1.3
Steam temperature
0
C 78.5 106.6
Steam fow kg/sec. 2.18 2.50
Condensate inlet temperature
0
C 52.7 75.5
Condensate fow Kg/sec 48.88 48.88
Condensate pressure ata 16 16
Heat exchange surface m
2
202 181
Steam side maximum
Working pressure ata 0.5 1.48
Water side maximum
Working pressure atg 16 16
Hydraulic pressure
Drop of LPHs MWC 3.7 3.2
(without pipings and fttings)
Deaerator constant pressure 6 ata
5.3 HP Heater HPH-1
Steam pressure ata 14.2
Steam temperature
0
C 304.6
Steam fow t/hr. 13.72
Feed water outlet temp
0
C 192.6
Feed water fow t/hr. 235.0
Feed water pressure ata 160
Condensate temperature
0
C 195.0
Water velocity in tubes m/s 2.04
Water pressure loss across tubes ata 0.75
Heat exchange surface m
2
196
Steam side maximum working
pressure ata 16.2
Water side maximum working
Pressure atg 180.0
Hydraulic pressure drop of HPHs MWC 4.6
(without pipings and fttings).
5.4 Extraction Steam Lines
No. of Bleeding points Exhaust
Symbol of 1 2 3 4 5 6
Equipment HPH-2 HPH-1 Deaerator LPH-3 LHP-2 LPH1
Condenser
Pressure ata 29.47 14.56 8.06 3.23 1.32 0.4560
0.085
Temperature
0
C
or dryness 392.9 305.1 240.5 153.9 0.9752 0.9336
0.8871
Steam fow t/hr 18.22 13.81 5.46 10.62 9.119 9.097
258.1
6.0 Technical Data of Governor
Type: Hydraulic with mechanical speed
governor
Operation range of speed governor : 600-3600 rpm
Response speed of safety governor : 3345 + 15 rpm
Adjustable range of static : 3.5 < 4.5 - 6.0 % of nominal
speed, Nn
characteristic of speed governor
Intensitivity of speed governor : < 0.10% Nn
Regular speed change between idle run and nominal load:3 to 5 % Nn
Maximum speed increase after load rejection : < 10% Nn
Relay oil pressure, P : 20 atg
Safety oil pressure, Ps : 1.5 atg
Safety governor trip setting : 1.5 atg
Safety governor no. 1 at : 111% Nn
Safety governor no. 2 at : 112% Nn
Turbine Data of Durgapur Steel Plant, (Captive Power Plant)
The steam turbine generator was manufactured and supplied by M/S. ELEKTRIM
MEGADEX, Poland. NO OF UNITS INSTALLED - TWO
A.0.DESCRIPTION AND FUNCTIONS
A.1 General Description
The steam-turbine-generator set has a maximum continuous rating of 63,000 KW operating
at rated speed of 3000 rpm with steam conditions at turbine inlet at entry to emergency stop
valves at 90 ata and 525
0
C and the exhaust pressure of 0.090 ata. The steam turbine is a
single cylinder impulse reaction condensing type of machine with six (6) uncontrolled
extractions to supply steam to two (2) high pressure feed water heaters, three (3) low
pressure feed water heaters and a 6 ata steam header. The turbine is equipped with an
electrohydraulic speed governing system. The steam turbine is a single cylinder turbine with
disc type rotor design. The fxed point of the turbine is located on the axis of LP casing
exhaust. The turbine rotor is supported in the front section by a combined thrust and journal
bearing installed on the front pedestal. In the rear section of the turbine, the rotor shaft is
connected by a rigid coupling to the shaft of the generator rotor and is supported on the front
end generator bearing. All bearings are provided with a hydraulic rotor jacking system. In
order to safeguard the rotor against bending during start-up and shutdown, the turbine is
equipped with a mechanical rotor turning gear built into the front pedestal and is driven by an
AC motor. The rotor speed when turned by the turning gear is 5 rpm and also provision is
available for manual rotation of the rotor.
Starting of the turbine may be carried out with two alternative kinds of boiler operation viz. (i)
boiler operating with varying pressure (ii) boiler operating with constant line steam pressure.
However, as per the recommendations of the manufacturer, the turbine operation must be
carried out under boiler operating with constant steam pressure conditions.
1.0 Technical Data of Turbine
TURBINE
Type: 9K66 (Elektrim, Poland make) impulse
type, axial fow, single cylinder, condensing
Nominal rating : 60 MW
Live steam temperature : 525
0
C
Live steam pressure : 90 ata
Max. pressure at Curits wheel (limiting) : 71.5 ata
Cooling water inlet temperature : 33
0
C
Maximum continuous rating : 63 MW
Nominal speed : 3000 RPM
Combined Critical Speeds of TG
First: 1820 RPM
Second : 3870 RPM
Fly wheel efect of turbine rotor G x D
2
: 12,932 Mgm
2
Live Steam Conditions at Turbine Inlet
at Entry to Emergency Stop Valve
i) Nominal pressure : 90 ata (8.83 Mpa)
ii) Nominal temperature : 525
0
C
Steam Consumption
i) At nominal rating (60 MW) : 232.01 t/hr.
ii) At maximum rating (63 MW) : 245.0 t/hr.
Exhaust steam pressure : 0.090 ata
MATERIAL OF IMPORTANT PARTS
Turbine
Inner casing : L17 HMF/N
Outer casing : L17 HMF/N
Exhaust part casing : St 41K
Diaphragm liner : L20 HM L120
Rotor: 23H2 MFA
Rotor blades : 15 H11MF/1H13/2H13
Diaphragms : 13 HMF/15HM/St3S
Diaphragm blades : 1H13
Casing closing bolts : 21 HMF
Condenser
Type: KPG
Tubes : Aluminium, Brass
Tube plates :St3s plated with 1H18N9T
Shell:St3s
Dimensions and Weight of Large Elements
Dimensions
Total turbine length : 6600 mm (approx.)
Rotor length : 5814 mm (approx.)
Maximum diameter of bladed rotor : 2474 mm (approx.)
Assembled casing Hp and Ip outlet,
top part (height x width x length) : 4600 x 6000 x 6000 mm
IP outlet casing transportation dimension
of bottom part (height x width x length) : 2950 x 6000 x 2250 mm
Condenser (height x width x length) : 7450 x 5250 x 12600 mm
Weights
Biggest weight for turbine erection -
IP outlet casing bottom part : approximately 20,000 kgs
Biggest weight for turbine inspection -
HP/LP casing top part : Approximately 17,000 kgs
Technical Data of Turbine Lub System
Oil grade : TU 20 according to POLISH PN-
76/0-96059 Mobile DTE of vis-cosity 28 cst at 50
0
C
Turbo shell 27
Turbo shell 29
Servo prime 46
Oil Tank
Operational volume : 14 m
3
Volume at maximum level : 20 m
3
Maximum level : 100 mm
Maximum operational level
(from the top) after flling the system : 685 mm
Minimum operational level
(from the top) after flling the system : 835 mm
Volume in the tank between the maximum
and minimum operational level : 6 m
3
(approx.)
Oil Coolers
Type: Horizontal
No. of oil coolers : 2 (two)
No. of oil coolers in operation : 1 (one)
Heat exchange surface : 215 m
2
Cooling water fow per cooler at 32
0
C : 115 m
3
3.3 Oil Pumps
Description of item Discharge Capacity Drive
Motor
pressure m
3
/hr.
rating
atg
KW
Relay oil pumps 2 nos 20.00 50.40 Ac
55.00
(one no. as reserve) motor
Lubricating oil pump 1.50 61.20 Turbine -
shaft
Auxiliary oil pump 2.50 72.00 AC
15.50
motor
Emergency oil pump 0.95 57.60 DC
4.60
motor
Jackcing oil pump 35-140 0.648 AC
1.64
motor
Relay Oil Filter
Capacity : 1000 1/min
Filtration accuracy : 25 microns
Nominal pressure : 25 atg
Lubricating Oil Filter
Capacity : 1100 1/min.
Filtration accuracy : 32 microns
Nominal pressure : 2.5 atg
Air Filter
Capacity : 32 m
3
/hr.
Filter area : 0.19 m
2
Mesh size of flter : 0.1 mm x 0.1 mm
Hydraulic Accumulator
Nominal volume size : 4 x 24 liters
Nitrogen flling pressure : 14 atg
Maximum useful working pressure : 20 atg
Nominal pressure to which the pressure
falls upon discharging) : 17 atg
Vapour Fan
Capacity : 0.12 m
3
/s
Numbers : 2
Motor rating : 0.37KW
Technical Data of Gland Steam & Steam Cooler
Gland Steam Condenser
Type: KP-55-010
Numbers : 1 (one)
Heat exchange surface : 55 m
2
Quantity of
Steam : 1.2 t/hr
Air : 0.6 t/hr
Steam inlet temperature
Normal : 300
0
C
Maximum : 380
0
C
Steam inlet pressure : 0.97 ata
Cooling water temperature
Inlet: 54.5
0
C
Outlet : 54.5
0
C
Cooling water temperature : 50
0
C
Cooling water pressure : 16 atg
Cooling water quantity : 0.04 kg/sec.
Steam temperature after cooler : 150
0
C
TECHNICAL DATA OF STEAM EJECTORS
Operational Steam Ejector
Type: SP-3-1000-1
Number : 2
Working steam pressure : 6 kg/cm
2
Working steam temperature : 240
0
C
Working steam quantity : 0.432 t/hr.
Dry air quantity : 0.07 t/hr.
Suction pressure : 0.07 kg/cm
2
Quantity of cooling condensate : 108 t/hr.
Inlet/Outlet temperature of condensate : 38/41
0
C
Inlet/Outlet pressure of condensate : 15.5 kg/cm
2
/14.9 kg/cm
2
Condenser surface area : 44 m
2
Condenser pressure : 1.2 kg/cm
2
Start-up Ejector
Number : 1(One)
Quantity of extracted steam air mixture : 225 kg/hr.
Working steam pressure : 6 ata
Working steam temperature : 240
0
C
Working steam quantity : 0.27 t/hr.
Extraction ability : 0.85 ata
Inlet/Outlet pressure of condensate : 15.5/14/9 kg/cm
2
Technical Data of Condenser
Condenser
Type: Two-run; two-way with steam dumping
arrangement.
Efective surface area : 5000m
2
Duty: 8.07 x 10
2
kcal/hr.
Circulating water quantity : 9000 m
3
/hr. (2500 kg/s)
Cooling water inlet temperature : 32
0
C
Cooling water outlet temperature : 41
0
C
Condenser vacuum : 0.0851 ata (716 mm Hg)
Cooling water pressure drop across
condenser : 4.6 mm wc
Cooling water velocity in tubes : 1.97 m/s
Terminal temperature diference : 1.7
0
C
Quantity of condensed steam : 158.1 t/hr.
Steam enthalpy : 551.1 kcal/kg
Permissible pressure for the water space
of the condenser : 0.39 Mpa
No. of water passes : 2
No. of banks : 4
No. of tubes in a bank : 1670
No. of tubes in the condenser : 6680
Tubes dimensions : 24 dia. x 1 mm/24 dia. x 1.5 mm
Total tube cross area of one pass : 2.52 m
2
Water chamber
Design pressure : 4.2 ata
Design temperature : 100
0
C
Hotwell capacity - steam chamber : 24 m
3
Steam box and exhaust neck volume : 176 m
3
Steam chamber
Design pressure : 1.5 atg and full vacuum
Design temperature : 160
0
C
Material of the cooling tubes : Brass MA-77C
Material of the air cooling tubes : MnZ 101
Condenser dimension :
Height x width x length : 7450 x 5250 x 12600 mm
Condensate Extraction Pump
Type: 15 K34X5
Condensate extraction pump nos. : 2 x 100%
No. of stages : 5
Pump capacity : 200 m
3
/hr.
Discharge head : 160 MWC
Speed : 1485 rpm
Pump weight : 1960 kg
Motor
Motor type : SZDVc 174t
Rating : 200 KW
Speed : 1485 rpm
Voltage : 6600 volts
Motor weights : 2250 kg
DEAERATOR
Heater Assembly
Design pressure : 7 ata
Design temperature : 200
0
C
Operating pressure : 6 ata
Operating temperature : 158
0
C
Capacity
Maximum : 310 t/hr.
Minimum : 100 t/hr.
Deaeration degree : 0.007 mg/litre
Nominal output : 225 t/hr.
No. of heating arrangements : 2
Feed Water Storage Tank
Working volume : 130 m
3
Total volume : 170 m
3
Water reserve in the tank at maximum
Plant capacity will be sufcient for : 25 min
Boiler Feed Pump
Type: 15Z33 X7V1 multi-stage horizontal
No. of stages : 7
Capacity : 270 t/hr.
Head: 1650 MWC
Temperature of pumped feed water : 158
0
C
Min NPSH required : 16 MWC
Speed : 3724 rpm
Input power : 1629 KW
Voltage : 6.6 kV
No. of pumps : 2 (1 + 1) x 100%
Efciency : 77%
Weight of complete pump : 3380 kg.
Weight of base plate : 445 kg.
Gear with the Hydrokinetic Coupling
Power transferred : 2500 KW
Slow running shaft speed : 2980 rpm
Fast running shaft speed : 4034 rpm
Rated slip of hydrokinetic coupling : 2.8%
Hydrokinetic coupling slip control range : 2.8 - 70%
Driving Motor
Type: SZJE - 132t
Rating : 2300 KW
Speed : 2980 rpm
Voltage : 6.6 kV
Boiler Filling Pump
Capacity : 2.5 m
3
/hr.
Discharge pressure : 5.5 kg/cm
2
TECHNICAL DATA OF FEED HEATERS
Feed Heating System
Number of heating stages : 6 (six)
Quantity of feed water fowing through the
HP heaters at nominal load : 234.6 t/hr. (65.1 kg/sec.)
Final feed water temperature : 230
0
C
Type of HP heater : Vertical, surface type, single and
two zones
Type of LP heater : Horizontal, surface type, single
and two zones.
LP Heaters.
Steam pressure ata 0.45 1.30
Steam temperature
0
C 78.50 106.60
153.40
Steam fow kg/sec 2.18 2.50
Condensate inlet temperature
0
C 52.70 74.50
103.90
Condensate outlet temperature
0
C 75.50 103.90
131.70
Condensate fow kg/sec 48.88 48.88
54.33
Condensate pressure ata 16.00 16.00
16.00
Hat exchange surface m
2
202.00 181.00
181.00
Steam side maximum working pressure ata 0.50 1.48
Hydraulic pressure drop of LPHs
(without pipings and fttings) MWC 3.70 3.20
Deaerator constant pressure : 6 ata
HP Heaters
Particulars HPH-1
Steam pressure ata 14.30
Steam temperature
0
C 304.60
Steam fow t/hr 13.72
Feed water outlet temperature
0
C 192.60
Feed water fow t/hr 235.00
Condensate temperature
0
C 195.00
Water velocity in tubes m/s 2.04
Water pressure loss across tubes ata 0.75
Heat exchange surface m
2
196.00
Steam side maximum working pressure ata 16.20
Water side maximum working pressure atg 180.00
Hydraulic pressure drop of HPHs
(without pipings and fttings) MWC 4.60
Extraction Steam Lines
No. of bleeding points
1 2 3 4 5 6 -
Symbol of
equipment HPH-2 HPH-1 Deaerator LPH-3 LPH-2 LPH-1
Condenser
Extraction stage 7 12 15 18 20 22
Pressure ata 29.6 14.4 6.4 3.6 1.4 0.44
0.085
Temperature
0
C
or dryness 392.90 305.10 240.50 153.90 0.9752 0.9336
0.887
Steam fow t/hr. 18.22 13.81 5.46 10.62 9.119 9.097
158.
Technical Data of Turbine Governor
Type: Hydraulic with mechanical speed
governor
Operation range of speed governor : (3345 + 15) RPM
Response speed of safety governor : (3345 + 15) RPM
Adjustable range of static characteristic
of speed governor : 3.5 < 4.5 - 6.0% of nominal
speed, N
n
Intensitivity of speed governor : < 0.10% Nn
Regular speed change between idle run
and nominal load : 3 to 5 N
n
Maximum speed increase after
load rejection : 10% N
n
Relay oil pressure, Pr : 20 atg
Safety oil pressure, Ps : 1.5 atg
Safety governor trip setting : 1.5 atg
Safety governor no. 1 at : 111% N
n
Safety governor no 2 at : 112% N
n
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