MAIN TURBINE SPECIFICATION: MAKE DESIGN TYPE : BHEL :KWU, GERMANY :THREE CYLINDER REHEAT CONDENSING,SINGLE FLOW BARREL

TYPE CASING,IP&LP DOUBLE FLOW WITH 2&3AXIAL SPLIT CASING RESPECTIVELY

STAGES

:HPT 1x17 REACTION STAGES IPT 2X12 REACTION STAGES LPT2X6 REACTION STAGES

VALVES

LOAD SHARING

:HPT 2 MAIN STOP&CONTROL VALVES IPT 2 RH STOP& CONTROL VALVES CRH LINE-1 SWING CHECK VALVE LP BYPASS 2 STOP &CONTROL VALVE :HP 26%, IP 34%, LP 40%

IPSV1 IPCV 1 FROM RH

From boiler

ESV1 CV1

HP BYPASS

CRH

GENERATOR 1 HPT 1X17 TO LP HEATERS CONDEN LPBYPASS 2 IPT 2X12 3 4 LPT 2X6 5 6

EXCI TER 7

TURBINE LAYOUT

HP TURBINE
The HP turbine has 2 main stop valves and 2 control valves located symmetrically to the right and left of the casing . The main steam is admitted through the main steam inlet passing first the main stop valves and then the control valves. From the control valves the steam passes to the turbine casing. The HP outer casing is designed as a barrel-type casing without axial joint . Because of its symmetrical construction, the barrel-type casing retains its cylindrical shape and remains leak proof during quick changes in temperature (e.g. on start-up and shut down, on load changes and under high pressures. The inner casing, too, is almost cylindrical in shape and axially split. The inner using is attached in the horizontal and vertical planes in the barrel-type using so that it can freely expand radially in all directions and axially from a fixed point when heating up while maintaining concentricity relative to the turbine rotor. On the admission side, four projections of the inner casing and on the exhaust side three projections into corresponding grooves in the barrel.

TURBINE BLADES
MOST COSTLY ELEMENT OF TURBINE BLADES FIXED IN STATIONARY PART ARE CALLED GUIDE BLADES/NOZZLES AND THOSE FITTED IN MOVING PART ARE CALLED ROTATING/WORKING BLADES. BLADES HAVE THREE MAIN PARTS 1. AEROFOIL: WORKING PART 2. ROOT 3. SHROUDS SHROUD ARE USED TO PREVENT STEAM LEAKAGE & TO GUIDE STEAM TO NEXT SET OF MOVING BLADES.

HP TURBINE
The HP turbine balding consists of 17 drum stages. All stages are reaction stages with 50% reaction. The stationary and moving blades of all stages are provided with inverted T-roots, which also determine the distance, between the blades. The shrouds are machined integral with the blades and forms a continuous shrouding after insertion.

The moving and stationary blades are inserted into corresponding grooves in the shaft and inner casing and are caulked at bottom with caulking material. The insertion slot in the shaft is closed by a locking blade ,which is fixed by grub screws.

Shaft Seals and Balance Piston FUNCTION:The H P turbine has shaft seals in front and rear. The front shaft seal is labyrinth type,while the rear shaft seal is see through type. The function of these shaft seals is to seal the interior of the casing from the atmosphere at the ends of the shaft on the admission and exhaust sides. The difference in pressure before and after the raised part of the shaft seal on the admission side serves to counteract the axial thrust caused by steam forces. The effective seal diameter is suited to the requirements for balancing the axial thrust. GAP SEALS: Sealing between the rotating and stationary parts of the turbine is achieved by means of seal strip caulked into seal rings and into the rotor. SEAL RING: The seal rings the number of which depends on the pressure gradient to be scaled are divided into several segments, mounted in T-shaped annular grooves in the inner casing and shaft seal cover. In the region subjected to the low relative expansion in the vicinity of the combined journal and thrust bearing, the seal strips are caulked alternately into the shaft and into spring-supported segmented seal rings in the casing, forming a labyrinth to impede the outflow of steam. In the region subject to greater relative expansion at the exhaust end, see through seals are used. in which the seal strips are located opposite each other, caulked into the Shaft and into seal rings cantered in the outer casing. STEAM SPACES: Steam spaces are provided within the shaft seals.For HP turbine connection is given to IP/LP crossover, seal steam supply header and gland steam condensor.

Front Bearing Pedestal

Arrangement: The front bearing pedestal Is located at the turbine-side end of the turbine generator unit. Its function is to support the turbine casing and bear the turbine rotor. It houses the following components and instruments: Journal bearing Hydraulic turning gear Main oil pump with hydraulic speed transducer Electric speed transducer Over speed trip Shaft vibration pick-up Bearing pedestal vibration pick-up.
The bearing pedestal is anchored to the foundation by means of anchor bolts. The anchor bolt holes are filled with gravel, which gives a considerable vibration damping effect. Lubricating oil is admitted to the bearing shells from one side and flows to oil spaces that are milled into the upper shell at the horizontal joint and are open to the rotor. The rotor picks up oil from oil pockets machined into the babbitting.

Rear Bearing Pedestal

Arrangement:The bearing pedestal is located between the HP and IP turbines. Its function is to support the turbine casing and bear the HP and IP turbine rotors. The bearing pedestal houses the following turbine components: Combined journal and thrust bearing Shaft vibration pick-up Bearing pedestal vibration pick-up Thrust bearing trip (electrical). Oil Supply: Lubricating oil is admitted to the bearing shell, fro, one side via oil line from where it flows to the oil spaces milled into the upper and lower bearing shells at the hi joint. Oil leaving the journal bearing flows to the two annular grooves adjacent to the bearing surface and then to the thrust pads. Through the two return cowlings, is discharged into the drain area in the pedestal. Passages are located at the lowest point in the lower bearing shell through which high pressure jacking oil is supplied ' ed under the journal at low speed of the. turbine reef (on start-up or shutdown)

CASING SUPPORT& FIXED POINT

The turbine casing Is supported on the support horns such as to make allowance for thermal expansion. It is essential for the casing to retain concentric alignment with the rotor, which is supported independently. The turbine casing is supported With its two front and two rear support horns on the horn supports of the bearing pedestals. Fixed Point: The fixed point for the turbine casing is located at the rear horn support on HP-IP pedestal at the turbine centreline level and is formed by the parallel keys.

IP Turbine
Casing: The casing of the IP turbine is split horizontally and is of double-shell construction. Inner casing is supported in the outer casing.

Steam from the HP turbine after reheating enters the inner casing from top and bottom through two admission branches which are integral with the mid section of the outer casing.
This arrangement provides opposed double flow in the two blade sections and compensates axial thrust. The provision of an inner casing confines the steam inlet conditions to the admission section of this casing, while the joint flange of the outer casing is subjected only to the lower pressure and temperature effective at the exhaust from the inner casing. In this way, difficulties arising from deformation of a casing with flange joint due to nonuniform temperature rise, e.g. on start-up and shut-down, are avoided.

IP TURBINE
INNER CASING ATTACHMENT Due to the different temperatures 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 fixed point and radially in all directions, while maintaining the concentricity of the inner casing relative to the shaft. In the horizontal plane, the four support horns of the top half inner casing rest on plates. which are supported by the joint surface of the bottom half outer casing. The shoulder screws are provided with sufficient clearance to permit the inner casing to expand freely in all directions in the horizontal plane. The support horns provided at the bottom half inner casing, project into the recesses in bottom half outer casing with clearance on all sides.

IP TURBINE
MOVING & STATIONARY BLADES

The IP turbine balding consists of 12 drum stages in each steam flow direction. All stages are reaction stages with 50% reaction. The stationary and moving blades of all stages are provided with inverted T-roots, which also determine the distance between the blades. All these blades are provided with integral shrouds, which after Installation form a continuous shroud.

The moving am stationery blades are inserted grooves in the rotor and in the inner casing and are bottom caulked with caulking material . The insertion slot in the rotor is sealed by a locking blade, which is fixed by grub screws.

IP TURBINE
GAP & SHAFT SEAL: The function of the shaft seals is to seal the interior of the turbine casing against the atmosphere at the front (thrust bearing end) and rear shaft penetrations of the IP turbine.

In the region subject to low relative expansion in the vicinity of the combined journal and thrust bearing, the seal strips are caulked alternatively into the shaft and into spring-supported segmented rings in the casing, forming a labyrinth to impede the outflow of steam. In the region subject to greater relative expansion at the exhaust end, see-through seals are used, in which the seal strips are located opposite each other, caulked into the shaft and into seal rings cantered in the Outer, casing.
Sealing between the rotating and stationary elements of the turbine is achieved by means of seal strip caulked into seal rings and into the rotor. Steam Spaces Steam spaces are provided within the shaft seals. One connection is drawn off to the steam seal header. The slight amount of leakage steam which are still able to pass the seal ring are conducted from the space into the seal steam condenser.

IP TURBINE
REAR BEARING PEDESTAL ARRANGEMENT The bearing pedestal is located between the IP and LP turbines. Its function is to support the turbine casing and bear the weight of IP and LP rotors. The bearing pedestal houses the following turbine components: Journal bearing Shaft vibration pick-up Bearing pedestal vibration pick-up Hand barring arrangement Differential expansion measurement device The bearing pedestal is aligned on the foundation by means of hexagon head screws that are screwed into it at several points. On completion of alignment, the space beneath the bearing pedestal is filled in with special non-shrinking grout. The bearing pedestal is anchored to the foundation by means of anchor bolts. The anchor bolt holes are filled with gravel, which gives a considerable vibration damping effect.

IP TURBINE
CASING SUPPORTS & FIXED POINTS The turbine casing is supported on the support horns such as to make allowance for thermal expansion. It is essential for the casing to retain concentric alignment with the

rotor, which is supported independently.

The turbine casing is supported with its two front and two rear support horns on the horn supports of the bearing pedestals at the turbine centreline level. This arrangement determines the height of the casing and also allows thermal expansion to take place in the horizontal plane by the support horns sliding on the sliding pieces of the bearing pedestals. The fixed point f or the turbine casing is located at the front horn support at the turbine centreline level and is formed by the parallel keys . Axial expansion of turbine casing originates from this point.

LP TURBINE
The LP turbine casing consists of a double flow unit and has a triple shell welded casing. Steam admitted to the LP turbine from the IP turbine flows into the inner casing from both sides. The LP casing has a double-flow inner casing. This inner casing is a double shell construction and consists of the outer part and the inner part. The inner shell is suspended in the outer shell to allow thermal movement and carries the front guide blade rows. The rear guide blade rows of the LP stage are bolted to the outer shell of -the inner casing. The complete inner casing is supported in the LP outer casing in a manner permitting free radial expansion, concentric with the shaft, and axial expansion from a fixed point.

LP TURBINE
The drum blading stages 1 to 3 of the double flow LP turbine are of the reaction type with 50 % reaction. They are located in the inner shell of the inner casing and thus form the front part of the LP blading. All guide and moving blades have integral shrouds which, after insertion, provide continuous shrouding. The moving blades of the last stages aretwisted and have thinned tips. All guide and moving blades have T-roots. which also determine the distance between the blades. They are inserted into grooves of corresponding design in the turbine shaft and inner casing and secured by caulking material.

The last three stages of the LP turbine are designed as reaction stages.

The stationary blade rows are made into segments by welding the inner rings, blades and outer rings together and bolting them to the inner casing. The blades of rows are made of steel sheet and are hollow. Drainage slots are provided in the blades of row. Through these slots, any water on the surface of the blades may be drawn away to the condenser. The moving blades have curved fir-tree roots which are inserted in axial grooves in the turbine shaft and :secured by means of caulking pieces.

LP TURBINE Shaft Seals: The function of the shaft seals, arranged between the bearing pedestals and the LP turbine, is to seal the interior of the LP turbine casing against the atmosphere at the shaft penetrations. Sealing between the rotating and stationary elements of the turbine is achieved by means of seal strip caulked into seal rings. The pressure gradient across the seal is reduced by conversion of pressure energy into velocity energy which is then dissipated as turbulence as the steam passes through the numerous compartments. Seal Rings: The seal rings are divided into several segments and mounted in grooves in the shaft seal casing such that they are free to move radially. Each segment is held in position against a shoulder by 3 helical springs. Steam Spaces Steam spaces are provided within the shaft seals. During start-up and on-line turbine operation, seal steam is fed into space to prevent the penetration of air into the vacuum region of the system. The slight amounts of leakage steam which are still able to pass the middle seal rings are conducted from the space into the seal steam condenser.

LP TURBINE
Rear Bearing Pedestal: The bearing pedestal is situated between the LP turbine and generator. Its function is to bear the LP rotor. The bearing pedestal contains the following turbine components: Journal bearing Shaft vibration pick-up Bearing pedestal vibration pick-up

COUPLING & BARRING GEAR There is limit to the length of turbine shaft that can be economically made. So there is need for coupling to join the individual rotors together to transmit the driving torque to each other and generator rotor. Due to high torque flexible coupling can not be used ,otherwise thrust bearing is required for each loosely connected shaft. So rigid coupling is used between turbine shafts so that entire shaft behaves as one continuous rotor. Turning gear is provided to rotate turbine shafts slowly during the pre run up operation and after shut down, to prevent uneven heating or cooling of shafts. That lead to bending between the fixed and moving with possible fouling between fixed and moving parts. Another advantage of turning gear is that the necessity for suddenly admitting a large flow of steam, in order start turbine from rest is avoided and therefore prevents sever temperature gradients occurring in turbine metal. During turning gear operation, the shaft system is rotated by double row blade wheel which is driven by oil provided by AOP. This oil passes into nozzle box to nozzle which conduct the oil jet in front of the blading. After passing the blading oil drains into bearing pedestal and flows with the bearing oil into return flow piping.

TURNING GEAR
A manual turning gear is provided in addition to hydraulic turning gear which enables the combined shaft system to be rotated manually in the event of a failure of normal hydraulic turning gear.

Steps to operate manual turning gear

1. Remove cover 2. Then latch and attach a bar to lever 3. Barring lever will rotate the combined turbine shaft.

TECHINICAL DATA
Three cylinders reheat condensing turbine

Single flow HP turbine with 17 reaction stages Type: Double-flow IP turbine with 12 reaction stages per flow Double-flow LP turbine with 6 reaction stages per flow 2 main stop and control valves 2-reheat stop and control valves 1 swing check valve in cold reheats line

H30-100-2 Type:M30-63 Type: N30-2X10 Type:EV320-1 Type:IV560 DN-800 make BHEL Tiruchy

2 bypass stop and control valves

Extraction swing check valves: Extraction 2 and 1 swing check valve without actuator 1 swing check valve with actuator Extraction 3: 1 swing check valve with actuator and 1 swing check valve without actuator Extraction 4.12 swing check valves with actuator Extraction 4.2 2 swing check valves with actuator Extraction 5 1 swing check valve with actuator

DN-400
Extraction 1: No valve DN 800 make BHEL Tiruchy DN 500 make BHEL Tiruchy DN 500 make BHEL Tiruchy DN 500 make - BHEL Tiruchy DN 400 make BHEL Tiruchy

and 1 swing check valve without actuator Extraction 6 no valve

Speed

Rated speed Speed limitation in load and station auxiliary load operation Max. Speed, no time limitation Min. Speed, no time limitation

50.0 /s

51.5 /s 47.5 /s

Permissible for a maximum of 2 hours during the life of LP blading

Speed below Speed above Speed exclusion range at operation without load Standard over speed trip setting 47.5 /s 51.5 to 60 /s 6.7 to 47.5/s

max. 55.5/s

This speed range should be passed through in one smooth operation to avoid endangering the blades due to resonance

Steam Pressures

Steam Pressures

Rated Operation

Long time Operation

Short time

Initial Steam Bar Before1 st HP drum stage HP cylinder exhaust IP cylinder stop valve inlet Extraction 6 Extraction 5 Extraction 4 Extraction 3 Extraction 2 Extraction 1 LP cylinder exhaust

166.7 154.0 44.1 39.7 44.1 17.3 7.2 2.56 1.33 0.256 0.1013

171.7 167.9 51.1 46.1 51.1 22.4 8.7 3.23 1.66 0.41 0.3

213.2 184.8 56.5 * * 54.4 * * 56.5 22.4 8.7 3.23 1.66 0.41 0.3

Low vacuum trip, standard setting

Hydraulic low vacuum trip Electrical low vacuum trip Hydraulic low vacuum trip bypass operation

0.3 bar 0.3 bar 0.6 bar

Seal Steam Supply System Pressure in seal steam header (above atmospheric) 35 mbar

Axial Shift Alarm: Trip: 0.5 mm 1 mm

Direction of rotation Anti clock wise when viewed from Front Pedestal towards the Generator

Casing Temperatures
Wall Temperatures HP turbine casing exhaust Outer casing of LP Casing Temperatures cylinder 90 Alarm at Machine must be shut down at 500 110 C C

480 90

Permissible differential temperature between parallel steam supply lines: No time limitation 17C Short time period (1 5 min) 28C In the honest line the limitations indicated for initial steam and reheat temperature must not be exceeded. Spray water to LP turbine must be switched on at 90C.
Temperature Difference Difference between upper and lower casing halves HP turbine, middle IP turbine, front IP turbine, rear Alarm at 90 30 30 Machine must be shut down at 100 45 45
C C

Motoring Motoring is the condition in which the turbine is driven by the generator at rated speed with the stop and control valves closed, in this operating mode, certain turbine components are heated up by windage power in the blading. To prevent heat-up beyond permissible temperatures, motoring must not be allowed to continue for longer than one minute. If the condenser low vacuum limit of 0.3 bars is exceeded, motoring must not be allowed to continue for more than 4 seconds.

Bearing Metal Temperatures vibration weights Alarm at 90 C 100 C 110 C 115 C Machine must be shut down at 120 C 120 C 120 C 120 C

Bearing Temperatures Operation temperature below 75 6C Operation temperature 75 to 85 OC Operation temperature 85 to 90 OC Operation temperature above 90 Vibration OC

Absolute bearing housing vibration Standard alarm setting Maximum alarm setting Limit value for tripping 30 M above normal level 35 m 45 m

Absolute Shaft Vibration

120 m 200 m

* The normal level is the reproducible vibration behaviour typical for the machine

Weights

HP turbine, completely assembled IP turbine, top half outer casing IP turbine, top half inner casing, complete with blading LP turbine, top half outer casing complete LP cylinder, top half outer shell of inner casing, complete with blading stationary blade carriers & diffuser

94.6 T 125.7 T 15.5 T 42.6 T 38.5 T

HP turbine rotor, complete with blading

IP turbine rotor, complete with blading LP turbine rotor, complete with blading Main stop and control valve, complete with Servo motors, without bend & pipe section Reheat stop and control valve, complete servo motors, without bend & pipe section

16.3 T
23.1 T 85.8 T 20.9 T 32.2T

All weights have been calculated with safety

Estimated oil requirements of bearings: 0.8 dM3/S 15.4 4.1 8.6

Bearing 1 (HP turbine, front pedestal) Bearing 2 Bearing 3 Bearing 4

Generator front bearing

Generator rear bearing Exciter bearing 1 Duplex Oil filter for bearing oil (Full Flow) Duplex oil filter, Type - 2.68.2, Size 355/750, Make Boll & Kirch Filtration particle size of Duplex filter element Filtration particle size of main oil tank filter element Safety valve in jacking oil system, setting Max 200 bar Pressure limiting valve in jacking oil system, setting 1 Duplex Oil Filter for Jacking Oil Filtration Particle size of Jacking Oil Filter 37 micro M

7.92
7.92 0.70 150 mm 37 micro M 250 micro M

180 bar 25 mm

Jacking oil pump, cut-in and out speeds

Jacking oil pump must be in operation at turbine speeds below approx. 51 0 rpm to avoid damage Oil PUMPS to bearings. Jacking oil pump should be cut out at speeds above approx. 540 rpm

Main Oil pump Quantity Maker Type Capacity (rated) Discharge pressure Speed Drive 1 BHEL 97.22 dm3/s 75 dm3/s 8.6 Bar 50 Turbine

Auxiliary oil pump 2 KSB ETA- 1 5050VL 89.25 6.2 Bar 24.75 AC Motor

DC Emergency Oil pump 1 KSB ETA-100-33VL SDF80 30 dm3/s 2.3 24.3 DC Motor

Jacking oil pump AC2 Sdf80 1.53 178 49.42 AC Mot or DC Motor dm3/s bar /S DC-1 Tushako

Steam Purity Required values for main steam condensate The deposits which occur in turbines due to impurities in the steam can lead to thermodynamic and mechanical inefficiencies and, with the presence of salts, especially chlorides, and sodium hydroxide also cause damage to turbine parts. The corrosion stressing caused by active deposits, f or example, has an adverse effect on the fatigue strength of the blade material when the steam is in the transition zone between the superheated and the saturated state. Compliance with the target values is mandatory in continuous operation, with the values in the normal operation column preferable. With the commissioning of a new plant and starting-up operation, however, these values ran not be attained with an economical outlay. The values listed in the column "starting-up operation" are then valid. It should be pointed out that adherence to the target values does not rule out deposition in the turbine with absolute certainty. Wherever possible every effort should be made to achieve the values in the normal operation column. A recording instrument may be used to continuously monitor the electrical conductivity of the main steam and turbine condensate following a strongly acid cation exchange unit. In order to determine slight impurities, the sodium concentration should be measured in addition to this. Should saline contamination occur, the turbine is to be immediately washed with saturated steam to remove salt deposits. Whether an alkaline, neutral or combined method is used for conditioning, the water-steam circulation is for the customer to decide. If an alkaline method is used, the oxygen content in the main steam condensate can be max. 0.02 mg/kg and the pH value in the turbine condensate max. 9.3 with brass condenser piping. When the condenser piping is of coopernickel alloys, the pH value must not exceed 9.5. There is no limitation f or the pH value with non-corroding steel or titanium.

QUANTITYTARGET VALUENORMAL OPERATION START UP Conductivity at 2,5'C, down stream of highly acidic sampling cation exchanger, continuous measurement. at sampling pointS/cm< 0.20.1< 0.50Silica(sio2)mg/kg<,0.0200.005< 0.050Total iron(Fe)mg/kg< 0,0200.005< 0.050Total copper(Cu)mg/kg< 0.0030.001< 0.010Sodium(Na)mg/kg< 0.0100.002< 0.020To avoid any drop in efficiency, it is recommended that values be kept below the target values and into the range of the values for normal operation. The target values must show a noticeable downward trend. On initial startup of new plants the values given for normal operation must be achieved within 2 to 3 days and within 2 to 3 hours for other start-ups

HP INNER CASING

HP SEAL FINS

HYDRAULIC BARRING GEAR

LP ROTOR

MOP IMPLLER

THRUST UPPER HALF