Chapter 5

KWU TURBINE TECHNICAL DATA

5.1

Turbine Specification

1.
2.

Make
Type

:
:

3.
4.
5.
6.
7.
8.

Number of Cylinders
Rated output
Peaking Capacity with time duration
Most economical continuous rating
Rated Speed
Type of governing

:
:
:
:
:
:

5.2
a)

Constructional Data
Sr.No.
1.
2.
3.
4.
5.

HPT
H30-25-2
Single
43 mm
99mm
643 mm

IPT
M30-20
Double
66 mm
100 mm
756 mm

LPT
N30-2x5
Double
73 mm
676 mm
1471mm

695 mm

1041 mm

2132 mm

7.

Particulars
Type
No. of flows
Height of first stage moving blades
Height of last stage moving blades
Mean diameter of first stage moving
blades
Mean diameter of last stage moving
blades
Type of blade roots

T & Hook

T & Hook

8.
9.

Total exhaust area of LP turbine

Overall length of rotor

3905 mm

4145 mm

T & Axial Fir

Tree
2x5 m2
6300 mm

6.

b)

Rotor Weights Complete with blading

c)

HP Turbine
IP Turbine
LP Turbine

:
:
:

7t
13.3 t
43 t

:
:
:

3905 mm
4145 mm
6300 mm

:
:
:
:
:
:

25 t
7.9 t
24.8 t
15.4 t
9.85 t
16.16 t

Rotor Lengths

d)

BHEL Haridwar
Reaction, 3 cylinder, Tandem Compounded,
Reheat, Condensing type
3 (HP, IP& LP)
210 MW
221 MW
210 MW
3000 rpm
Throttle Control

HP Turbine
IP Turbine
LP Turbine

Casing Weights

HP Outer Casing
HP Inner Casing
IP Outer Casing
IP Inner Casing
LP Inner Casing
LP Inner-outer casing
LP Outer casing

Steam Turbines for Power Generation 102

i)
ii)
iii)
e)
f)
g)
h)
i)
j)

k)

l)

m)

Upper half
End walls
Longitudinal beam

:
:
:

Total weight of turbine

:
Overall length of turbine
:
Width of turbine(with cross around pipes):
LP exhaust dimensions at condenser :
Heaviest part of turbine for erection
:
Journal Bearings
Number
:
Size of HPT front bearing
:
Size of IPT rear bearing
:
Size of LPT rear bearing
:
Lining material
:

17 t
2 x 8.4 t
2 x 8.1 t
490 t
16850mm
10000 mm
6300 x 4750 mm
60 t (HP turbine)
Three, Elliptical type
280 mm x140mm
400 mm x 320 mm
500 x 400 mm
Babbit

Combined Journal cum thrust bearing

Number
Size of thrust bearing
Size of journal bearing
Lining material

:
:
:
:

One, tilting pad type

280 mm x 240mm
280 mm
Babbit

Bearing Shaft Span

HP Turbine
IP Turbine
LP Turbine

:
:
:

3350 mm
4050 mm
6325 mm

Coupling
HP IP
IP LP
LP Generator

:
:
:

Rigid
Rigid
Rigid

n)

Control Valves (Combined with stop Valves)

Number
:
Size
:
Stroke
:
Type
:

HPT
IPT
2
2
125 mm
280 mm
50mm
95 mm
Single spherical seat stop cum control valve

o)

Moments of Inertia
HPT rotor
IPT rotor
LPT rotor

:
:
:

316.94 kg m2
1155.59 kg m2
9794.13 kg m2

:
:
:

3000 rpm
3090rpm (51.5 Hz)
2850rpm (47.5 Hz)

:
:

2 hours
1545,2126 rpm

5.3

Speed Data

103

Rated Speed
Maximum speed no time limitation
Minimum speed no time limitation
Permissible below 47.5 Hz and
above 51.5 Hz in life time (total)
Critical speeds

Steam Turbines for Power Generation

5.4

Speed exclusion range at

operation without load
Overspeed trip
Turning gear speed
Maximum speed rise in the event
of tripping at MCR

:
:
:

700 2850 rpm

3330 rpm
160 rpm (at normal vacuum in condenser)

8% from full to house load

150 kg/cm2 (abs) [100% & 80% load]

:
:

34.35 Kg/cm2 (abs)

27.0 kg/cm2 (abs)

At HPT exhaust

100% load

80% load

:
:

38.1 Kg/cm2 (abs)

31.0 kg/cm2 (abs)

At IPT exhaust

100% load

80% load
At LPT exhaust

:
:
:

7.05 Kg/cm2 (abs)

6 kg/cm2 (abs)
0.0911 Kg/cm2 (abs)

:
:

535oC
535oC

:
:

334.8oC
328.1oC

:
:
:

314.5oC
316oC
45oC (approx.)

Steam Parameters
a) Steam Pressures
At inlet of ESV
At inlet of IV

100% load

80% load

b) Steam Temperatures
At inlet of ESV
At inlet of IV
At HPT exhaust

100% load

80% load
At IPT exhaust

100% load

80% load
At LPT Exhaust

c) Steam Flow Rates

Main Steam flow through ESV of HPT

100% load
:

80% load
:

Reheat steam flow IV of IPT

(all heaters in service)

100% load

80% load

627 t/hr
504t/hr

:
:

564 t/hr
463t/hr

:
:
:
:

Pressure
Kg/cm2
150
150
40
8

d) Design pressure and temperature of

Valve Chest (HP)

HPT casing
IPT Casing
LPT Casing

Chapter-5: KWU Turbine Technical Data

Temperature
o
C
535
535
535
350

104

e) Extraction steam parameters at 100% load

Extraction No. Location

25th stage at HPT
(exhaust stage)
36th stage at IPT
45th stage at IPT
(exhaust stage)
48th stage at LPT
50th stage at LPT
52nd stage at LPT

6
5
4
3
2
1

5.5

Temperature
o
C

Flow
t/hr.

39.15
15.98

336
432

56
39.25

6.52
2.23
0.84
0.214

314
198.8
106.6
62

34.18
27.41
29.8
4.76

Limiting Values of Turbovisory Parameters

Axial shift of rotor

Differential expansion
HPT
IPT
LPT

- 0.5 to + 0.5 mm

:
:
:

- 3.5 to + 5.5 mm
- 3.0 to + 6.0 mm
- 7.0 to + 30 mm

:
:
:

Bearing
35 m
45 m

:
:

90oC
120oC

Vibration

5.6

Pressure
Kg/cm2

Nominal value for alarm

Maximum value alarm
Limit value for machine shutdown

Bearing temperatures
Alarm at
Machine must be shutdown at

Casing temperatures
HPT exhaust temperature alarm at
:
Machine must be tripped at HPT exhaust temp:
LPT outer casing temperature alarm at
:
Machine must be tripped at LPT exhaust temp :
Difference between upper & lower casing
sections at HPT middle
:
Difference between upper & lower casing
sections at IPT front & rear
:

Shaft
90 m
120 m
200m

480oC
500oC
90oC
110oC
+ 30oC
+ 30oC

Material for Turbine Components

a) Turbine Casings
i) HP inner and outer casing
ii) IP casings
iii) IP exhaust end
iv) LP casing

:
:
:
:

GS-17 Cr Mo V 511
GS-17 Cr Mo V 511
GS-22 Mo 4
St 37.2

b) Blades
i)
ii)

105

Turbine Area
HP Moving blades
HP stationary blades

First Stage
X 22 Cr Mo V 121
X 22 Cr Mo V 121

Last Stage
X 20 Cr 13
X 20 Cr 13/

Steam Turbines for Power Generation

5.7

iii) IP moving blades

iv) IP Stationary blades

X 22 Cr Mo V 121
X 22Cr Mo V 121

v) LP moving blades
vi) LP Stationary blades

X 20 Cr 13
20 Cr 13/
X 20 Cr Mo 13

Turbine Governing Specifications

a) Type of Governing System

b) Steady State speed regulation

c) Dead band
d) Emergency governor
(Eccentric strikers in HP Shaft)
i) Speed Setting
ii) Range of adjustment of emergency
trip setting
e) Motor operated speeder gear
i) Type of motor
ii) Adjustable no-load speed change
iii) Speed droop adjustment

:
:

Electro-hydraulic backed-up by hydromechanical system.

5%(adjustable between 2.5 to 8%)
0.06% of rated speed

111% of rated speed

110 to 112% of rated speed

:
:
:

A.C.
Approx. 92 to 108%
Approx. 2.5 to 8%

5.8

Emergency Main Stop Valves (ESV), Strainers & Control Valves

a)
b)
c)
d)

Number off
Nominal diameter of ESV
Type
Maximum pressure drop across the
Valve assembly
e) Material for construction
i) Valve body
ii) Valve trim
iii) Seats
f) Mesh screen material for strainer
g) Maximum particles size, which will
Pass the screen
h) Nominal diameter of HP control valve
and type
i) Sequence of opening control valves
j)

5.9

X 20 Cr Mo 13
X 20 Cr 13
X 20 Cr 13/
X 20 Cr Mo13
X 20 Cr 13
20 Mn 5/
X 7 Cr AL 13

Material of HPCV
i) Valve body
ii) Trip
iii) Stem

:
:
:

2
: 160 mm
Single seated
Approx. 8 kg/cm2 (including
strainer, stop and control valve)

:
:
:
:

GS-17 Cr Mo V 511
Stellited
Stellited
X 8 Cr Ni Nb 16 13

:
:

1600 microns
125 mm
Single Rated
Both control valves open together before
IP control valves.

:
:
:
:

GS-17 Cr Mo V511
Stelliited
X 22 Cr Mo V 121 (Stellited)

Intercepter Valves, Strainers & IP Control Valves

a) Number off
b) Nominal diameter of IV & Type
c) Material of IV
i) Valve body
ii) Valve trip
iii) Seats
d) Mesh material for strainer

Chapter-5: KWU Turbine Technical Data

:
:

2
320 mm, Single seated

:
:
:
:

GS-17 Cr Mo V 511
GS-17 Cr Mo V 511
Stellited
X8 Cr Ni Nb 1613

106

e) Maximum particle size which will

Pass screen
f) Nominal diameter of IPCV, and type
g) Material of IPCV
i) Valve body
ii) Trim & seats
iii) Stem

5.10

a)
b)
c)
d)
e)
f)
g)

107

:
:
:

GS-17 Cr Mo V 511
Stellited
X 22 Cr Mo V 121 (Stellited)

Surface type, two pass,

single or double shell
9655 m2
19,208
25.4 x 1.254 mm thick
Length = 7500 m
Cu-Ni-10 Fe
(Both condensing & air-cooling zone)
1.9 m/s

Type

Cooling Surface area

No. of tubes
Tube size

:
:
:

Tube material

Water velocity in tubes

C.W. flow rate with inlet
Temperature of 36oC
Assumed fouling factor
Tube plate material
Tube plate thickness
Condenser supported on
Condenser pressure at 36oC
C.W. inlet temp.
Tube & plate joint
Water box and shell material
Water box test pressure
Shell test pressure

:
:
:
:

Temperature rise of cooling water

:
:
:
:
:

27000 m3/hr
0.85
Carbon Steel
40 mm
Helical springs
0.0911 kg/cm2 (abs)
(0.91 kg/cm2 vacuum)
By roller expansion
Carbon steel
6 kg/cm2 (g)
Static water pressure column upto 1 m
above top row of tubes
8.8oC

Limits of Casing temperatures

Wall temperature
HP Turbine exhaust
Outer casing of LP turbine

5.12

1600 microns
280 mm, Single seated

Main Condenser

5.11

:
:

Alarm at
480oC
90oC
(Spray water to LPT comes
in to service at90oC)

Machine must be tripped at

500oC
110oC

Performance Parameters
Gross Turbogenerator heat rate
Gross unit heat rate
Gross Turbo generator cycle efficiency
Gross Unit efficiency
HP Cylinder efficiency
IP Cylinder efficiency
LP Cylinder efficiency

:
:
:
:
:
:
:

1980 Kcal/KWhr
2284 Kcal/KWhr
43.43%
37.64%
83-85%
90-91%
88-90%

Steam Turbines for Power Generation

-o0o-

Chapter-5: KWU Turbine Technical Data

108