Types and Working Principles Steam Turbines

TYPES AND WORKING PRINCIPLES STEAM TURBINES
TYPES AND WORKING PRINCIPLES STEAM TURBINES

1.0 INTRODUCTION
Steam turbine is a rotating machine which- CONVERTS HEAT ENERGY OF
STEAM TOMECHANICAL ENERGY.
In India, steam turbines of different capacities, varying from 15 MW to 500
MW, are employed in the field 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, with reference to the
specific features of 21 0 MW steam turbines (both L.M.W. Soviet & KWU German
Designs)'and 500 MW (KWU) turbines which form the backbone of the thermal
power sector in India.
1.1 DEVELOPMENT OF STEAMTURBINE
Historically, first steam turbine was produced by Hero, a Greek Philosopher, in 120
B.C. (Fig. 1. l.). As the fig. shows, k was a pure reaction turbine (explained at 1.4).
In 1629, an Mlian. named Branc actually anticipated the boiler-steamturbine
combination that is a major source of power today. The concept, is illustrated in
(Fig. 1.2).
First practical steam turbine was introduced by Charles Parsons in 1884
which was also of the reaction type. Just after five years, in 1889, Gustav De Lava]
produced the first practical impulse turbine.
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Active development of steam turbine made ft the principal prime mover of
generating stations by 1920. Most units used 14 kg/cm2 and 276oc steam and
capacity ranged from 5,000 'La 30,000 KW. By 1930 steam M2 conditions rose to
48 kg/c and 398oc and by 1940 steam condition of 81 kg/cm' and 509oc was
achieved.
After second world war (1 945), reheat. cycle was adopted widely and
capacity increased gradually. While turbines of 900 MW are in use in USSR, in
India the largest capacity is 50&MW with steam condition of 179
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1.2 WORKING PRINCIPLES
When steam is allowed to expand through a narrow orifice, ft assumes kinetic
energy at the expense of its enthalpy (heat emrgy). This kinetic energy of steam is
changed to mechanical (rotational) energy through the impact (impulse) 6r reaction
of steam against the blades.
It should be realized 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 steamwill glide on and off the blade without
any tendenc to 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 forces plus the change of momentum. (Fig. 1.3). This causes the
rotational motion of the blades.
FIG. 1.4 SIMPLE IMPULSE TURBINE
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1.3 TURBINE TYPES
Basically there are two broad classifications of steam turbines:
i) Impulse: In Impulse turbine(Fig.1.4),the steam is expanded (i.e. pressure is
reduced) in fixed 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 fixed and moving
blades. Both fixed and moving blades act like nozzles and are of same shape. Work is
done by the impulse affect due to the reversal of direction of the high velocity steam plus
a reaction effect due to the expansion of steam through the moving blades. This turbine
is commonly called a reaction turbine and is shown below in (Fig.1.5).
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(H1-H2) m/s.
K=constant, H, 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 R in several steps and thus reducing the velocity of steam and
rotor speed to practical levels. This is termed compounding.
Following are the various types of compounding.
1.4.1 Velocity Compounded Impulse Turbine (Fig. 1.6)
Like simple impulse turbine this has also only one set of nozzles and entire steam
pressure drop takes place there. The kinetic energy of high velocity steam issuing
from nozzles is utilised in a number of moving row of blades with fixed blades in
between them (instead of a single row of moving blades in simple impulse turbine).
The role of the fixed 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.
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1.4.2 Pressure Compounded Impulse Turbine (Fig.1.7)
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 first nozzle ring, but is
divided equally between all of them. Steam is passed through the first nozzle ring
in which it is only partially expanded. It then passes over the first moving blades
wheel 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 of 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.
1.4.3 Pressure-Velocity Compounded Impulse Turbine (Fig. 1.8)
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
increasing volume of steam. This type was once very popular. But it is rarely,
used as efficiency is quite low.
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1.4.4 Multistage Reaction Turbine
(Fig. 1.9) shows such a multisage reaction turbine consisting of a number of rows
of moving blades attached to the rotor and an equal number of rows of fixed
blades attached to the casing. Each stage txilises 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.
FIG. 1.8 COMPOUDING FOR PRESSURE FIG.1.9 REACTION TURBINE PRESSURE AND
AND VELOCITY VELOCITY CURVES
The fixed blades compare to the nozzle used in the impulse turbine. Steam is
admitted over the whole circumference, and in passing through the first row of fixed
blades, undergoes a small drop in pressure and its velocity is increased. It then
enters the first row of moving blades and, as in the impulse turtiine, suffers a
change in direction and hence momentum giving an impulse on the blades. During
the steam passage through the moving blades, k undergoes a further small drop in
pressure resulting in an increase in velocity which gives riseto areaction inthe
direction opposite tothat of the added velocity. It is in thisthat the impulsereaction
turbine differs 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.
(Fig. 1.9) also shows how the blade heights increase as the specific volume of
the steam increases with reduction in pressure. Note, how the pressure falls
gradually as the steampasses through the groups of blades. There is a pressure drop
across each row of blades both fixed and moving. This is of considerable practical i
, especially atthe high pressure end of the turbine where the pressure drops are
greatest. Because this diftererwe of pressure tends to force some steam through the
clearance spaces between the nxmng b~s and the casing and between the fixed
blades and the rotor. These dearances have to be carefully controkd by using axial
and 1 or radial seals at the blade tips, otherwise the leakage would be so large that
the turbine would be ineffi~t. The pressure drop across the moving blades gives
rise to a large axiaj thrust on #m rotor, towards the low pressure end of the turbine,
and special balance pistons / thrust
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bearings have to be fitted 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 flow, balances out the force on the rotor blades in the direction of steamflow.
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 off point down the cylinder. This pipe-maintains the steam
pressure on the out board side of the dummy pistonto correspond with pressure at
the stage down the turbine cylinder to which the balance pipe is connected. Under
steady load conditions the steam leakage through the dunvny piston "rinth packings
flows, from out board side of dummy piston, through the balance pipe and does
workin the lower stages of turbine. This arangement is shown in (Fig.1.10).
The steam velocities in this type of turbines are moderate. The velocity of
steam for maximum blade efficiency being roughly equal to the blade velocity. The
leaving loss is normally about the same as for the muffi@age 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 Parson's 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 provedthat efficienc@of reaction stage is
greaterthan efficiency of impulse stage. A pressure difference 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 efficiency is off set
by the inter stage leakage of steam which flows without doing useful work. Hence
a reaction stage should be located in the low pressure region of turbine.
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There is a general rule to use a greater percentage of impulse on the HP end
and greater percentage of reaction on the L.P. end. The percentage of reaction
progressively increases as we go towards L.P. end.
In actual turbines it is common for the best feature of various types to be
incorporated in one machine. Forexample, a turbine may have avelocity
compounded (curtis) firststagefollowed by pressure compounded impulse (Rateau)
stages and, at the low pressure end of the machine, reaction blading.
1.6 CLASSIFICATION OF STEAMTURBINES
Steam turbines may be classified into different categories depending on their
construction, the progress by which heat drop is achieved, the initial and final
conditions of steam used and their industrial usage etc.
1.6.1 According to the Directon of SteamFlow
a) Axial turbines:in which the steam flows in a direction parallel to the axis of the
turbine.
b) Radial turbines: in which the steam flows in a direction perpendicular to the
axis of the turbine.
1.6.2 According to the Number of Cylinders
a) Single - cylinder turbines
b) Double - cylinder turbines
c) Three - cylinder turbines and
d) Four - cylinder turbines etc.
1.6.3 According to the Method of Governing
a) Turbines with throttle governing in which fresh steamenters through one or
more (depending on the power developed) simultaneously operated throttle valves.
b) Turbines with nozzle governing which fresh steam enters through two or
more consecutively opening regulators.
c) Turbines with by-pass governing in which steam besides being fed to the
first stage is also directly led to one, tow or even three intermediate stages of
turbine.
1.6.4 According to the Principle of Action of Steam
a) Impulse Turbine
b) Reaction Turbine
1.6.5 According to the Heat Balance Arrangements
a) Condesnsing turbines with regeneration; in these turbines steam ad 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 wfthoneortwoin termediate stage extractions at
sp'opific pressures for in dustrialand 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
difference that the exhaust steam from these turbines is furtherutilised in
mechum and fow-Kessure condensing turbines. These turbines, in general,
operate at high initial conditions of steampressure and temperature, and are
mostly used during extension of power station capacities, with a view to
obtain better effidencies.
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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, del~ng steam to the already existing
medium-pressure turbines from the exhaust of topping turbines.
e) Back pressure turbines with steam extraction from in terme diate stagesat
specific pressures ;turbines of this type are meant for supplying the
consumer with steam of various pressure and temperature conditions.
f) Low-pressure (exhaust-pressure)turbine sin which the (exhaust-steam) from
reciprocating steam engines, power hammers, presses etc. is utilised for
power generation purposes. g) MLxed pressure turbines with two or three
pressure stages, with supply of exhaust steam to its intermediate stages.
1.6.6 According to the SteamConditions 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 steamat 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 550oc and higher.
e) Turbines of superc~i pressures, using steam at pressures of 225 ata and
above.
1.6.7 According 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 cylinders are arranged to drive two or
more shafts with separate generators with every shaft.
1.6.8 Automatic 1 Non-Autoniatic Extraction Turbines
Automatic-extraction unit bleeds off part of main steam flow at one, two or three
points. Valved partitions between selected turbine stages control extracted steam
pressure at the desired level.
Non autom@-extraction turbines bleed steam at as many as nine different
stages. Pressure of extracted steam at each state varies with the turbine shaft load;
extracted steam is used for feed heating.
(Fig. 1. 1 1) & (Fig. 1. 1 2) show various types of turbines.
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 fluid is a condensable vapour which is in liquid phase during
part of the cycle and
ii) the cycle consists of a succession of steady flow processes, with each process
carded 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 fluid
circulates through the power plant each fluid element passes through a cycle
of mechanical and thermodynamic stages.
1.7.1 Temperature Entropy Diagram(Discussed in Detail in Vol.1)
The teniperature-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
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(Fig. 1. 1 3). The unit uses steam at a pressure of 1 00 bar absolute, temp. 540'c
(813'K) and rejects it to the condenser at 30 m bar (saturation temp. 24.1 "c).
At point'A'the condensate is at boiling temperature corresponding to the back
(condenser) pressure. Its pressure is raised to 1 00 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 1 00 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 ft, 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. AtG steam is at 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 GA. At point A the steam has all been condensed and
condensate is at boiling temperature ready to begin another cycle.
To summarise the above:
AB pressure Rise in BFpp.
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.
FIG. 1.13 SENSIBLE LATENT AND SUPERHEAT, 100 BAR, 540OC CYCLE ON T-S DIAGRAM
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1.7.2 Velocity Diagrams
Let us consider an axial-flow turbine consisting of one or more stages, each stage
comprising one annulus of fixed nozzles and one annulus of moving blades as in
(Fig. 1.14) (a). Usually the total pressure drop across the stage is divided between
the nozzle and blades as illustrated, (Fig. 1.14) (b). The division is usually
expressed, not in terms of pressure drops, but in terms of the corresponding
enthalpy drops. The criterion used is the degree of reaction A, defined as
A = Enthalpy drop in moving blades (h1-h2)
Enthalpy drop in stage (h0-h2)
In Impulse Turbine, A < 0.5
In Reaction Turbine, A >0.5
The mode of action of the turbine can best be studied by following the path of
fluid through a single stage at the mean radius of the annulus, as in (Fig. 1.15)
(a). The fluid enters the nozzles with velocity C0 at pressure Po and is expanded
to pressure P0 . It leaves the nozzles with a velocity C1, in a direction making an
angle α1 with the tangential direction, i.e. the plane of rotation, It must satisfy
the energy equation.
½ (C1
2 – C0
2) = h0 – h1
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The velocity of the fluid 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,,
V, makes an angle P, with the tangential direction, and if the fluid is to flow
smoothly into the blade passages without undue disturbance, the inlet angle of
the blades must be made approximately equal to P, If the outlet angle of the rotor
blades is P2'the direction of the relative velocity at outlet, V2 will also be
approximately 02. Applying the energy equation to the flow relative to the rotor
blades it follows that
1/2 (V2
2 - V1
2) = h1 - h2
Since no work is done relative to the blades, i.e. in the frame of reference of the
blades, V2 must satisfy this equation. Vectorial addition of the blade speed then
givesthe absolutevelocity C2 andthe direction CL2; Usually, if this is one stage
of a multistage turbine, C2 will be made equal to Cl and ct 2 equal to a.; the fluid
can then pass on to another similar stage.
1.7.3 Work done in a stage
Equation below gives the work done i.e.
W = mU. (C1w - C2w) = mU Cw
Where Cw denotes the tangential component of fluid velocity or commonly
called the 'whirl velocity'.
An alternative expression for the work done in terms of the fluid velocities is
given by:-
W = m/2 (C1
2 _ C2
2) + (V2
2 _ V1
2)
WORK DONE IS THE KINETIC ENERGY AT INLET TO THE ROTOR
BLADES mC,212, PLUS THE ENERGY M(V22 _ V,2) MADE AVAILABLE BY
EXPANSION IN THE ROTOR MINUS THE REJECTED KINETIC ENERGY
mC2
2 / 2. Since in an impulse stage turbineV2 = V1
W= 1 / 2m (C1 - C2 ) 2
1.7.4 Turbine Losses
The losses in a turbine may be divided conveniently into two groups external
and internal.
There will be external losses due to bearing friction and the power required to
drive auxiliaries. These losses will be similar for all types of turbine and will not
be considered here.
The second and major group, the internal losses, are basically of three types;
a) Friction losses: The fluid friction in the nozzle and rotor blade passages
results in the actual enthalpy drop being less than the isentropic enthalpy
drop. The losses due to this are friction losses.
b) Leakage losses : Because clearance is needed between the moving and
stationary parts, some fluid passes through the turbine without doing its full
complement of work on the blading. Losses incurred in this way are called
leakage losses.
On modern turbines inter-stage leakage accounts for 0.5 to 1.0% loss if the
seals are in good condition.
c) Leavingloss: The considerable kinetic energy of steam when ftieaves the last
row of moving biadesdoes not do further useful work. This loss of energy is
known as 'Leaving Loss' or "residual loss";
Thus, Leaving loss = MVO2 1 2 where M = Mass steam flow, V. = absolute
velocity of steam at the outlet of last row of moving blades.
This loss varies as square of the velocity of steam. To minimize this loss R is
important to keep the velocity of steam leaving the last wheel as low as possible.
To achieve this the annular area (i.e., blade height x mean diameter) of last row of
blading is made as large as practicable. This is done by increasing the height of last
stage blades.
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TURBINE DESCRIPTION
2.1 GENERAL DESCRIPTION OF A 210 MW(LMW) STEAMTURBINE
Before discussing in details about various features of the steam turbine and its
auxiliaries let us have an over view of the system as a whole. (Fig.2.1) shows the
schematicofa21OMW steam turbine (BHEL/LMW).
Superheated steam (130KglcM2,535'c) from the boiler enters in to the High
pressure turbine through two emergency stop valves (ESVS) and four control valves
(CVs).
The high pressure turbine (HPI) comprises of 12 stages, the first stage being
governing stage. The stean flow in High pressure turbine (HPT) being in reverse
direction, the blades in high pressure turbine HPT are designed for anticlockwise
rotation, when viewed in the direction of steam flow.
After passing through High pressure turbine (HP]) steam (27 Kg/cm 327'C)
flows to boiler for reheating and reheated steam (24.5 Kglcm2, 535oC) comes to the
intermediate pressure turbine (IP'T) through two interceptor valves (IVs) and four
control valves (CVs) mounted on the IPT it self.
The intermediate pressure turbine has 1 1 stages. High pressure turbine
(HPT) and intermediate pressure turbine (I PT) rotors are connected by rigid
coupling and have a common bearing.
After flowing through intermediate pressure turbine (IPT), steam enters the
middle part of low pressure turbine (LP]) through two crossover pipes. In low
pressure turbine, steam flows in the opposite paths having four stages in each path.
After leaving the low pressure turbine the exhaust steam (0.09 KgIcm2 abs)
condenses in the condensers welded directly to the exhaust part of the low pressure
turbine.
Rotors of intermediate and low pressure turbiners are connected by a semi
flexible coupling.
The direction of rotation of the rotors is clock wise when viewed from the
front bearing end towards the generator. The three rotors are supported in five
bearings. The common bearing of High pressure and Intermediate pressure rotors is
a combined journal and radial thrust bearing. .
Turbine is equipped with a turming (barring) gear which rotates the rotor of
the turbine at a speed of nearly 3.4 rpm for providing uniform heating during
starting and uniform coiling during shut down. Seven steam extractions for feed
water heating have been taken from gth, 12th, 1 Sth, 18th, 21 st, 23rd & 25th
stage.Condensate from the hot well of condenser is pumped by the condensate
pumps, and supplied to the deaerator through ejectors, gland steam cooler and four
number low pressure heaters. Steam is extracted from the various points of the
turbine to heat the condensate in these heat exchangers. From deaeratc)r the feed
water is supplied to boiler by boiler feed pumps through three number High
pressure heaters.
PAGE15
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2.2 200 / 210 MW(KWU) STEAM TURBINE
(Fig.2.2) shows the sectional arrangement of a 21O MW steam turbine of BHEL /
KWU make.21OMW KWU turbine is a Tandem compounded, three cylinder,
single reheat, condensing turbine provided entirely with reaction blading.
Superheated steam (1 47 Kg/ cM2 abs, 535OC) enters the HP turbine through two
initial steam stop and control valves. HP cylinder has a throttle control. HP turbine
comprises of 25 single flow stages. HPTexhauststeam (39.2 kg/cm', 343'c)
goesforreheating and reheated steam (34 kg /CM2 535'c) comes to
intermediate pressure turbine through two combined reheat stop and control valves.
The lines, leading fromthe two HP exhaust branches to Reheater, are provided with
swing check valves which prevent hot steam from the reheater flowing back into the
HP turbine. IPT is a double flow turbine with 20 reaction stages per flow. From 1
PT, steam goes to double flow LP turbine with eight reaction stages per flow
through cross around pipes. The steam from LPT is exhausted to condenser at a
back pressure of 0.1 187 bar (49'c). Extraction steam is bled from six bleeding
points (3-LP Heaters, 2-HP heaters, one deaerator). The individual turbine rotors
and the generator rotor are connected by rigid couplings.
2.3 500MW(KMU) UNIT
Like 200 MW KWU design, 500 mw turbine is a Tandem compounded, three
cylinder, single reheat condensing turbine provided entirely with reaction blading.
Superheated steam (1 70 Kg / CM2 , 537'C) enters the H.P turbine through four
combined main stop & control valves. HP turbine comprises of 18 single flow
stages. HP turbine exhaust steam (45 kg / CM2 , 342.5'c) goes for reheating and
reheated steam (40.5 kg cm2, 5370c) comes to I P turbine through four combined
reheat stop and control valves.
I.P. turbine is a double flow turbine with 14 stages per flow. The LP turbine is
a double flow turbine with 6 stages per flow. Condenser is maintained at a preasure
of 0. 09 kg / CM2 (abs). Extraction steam is bled from six bleeding points.
The turbine shaft layout is similar to that of 21 0 MW KWU design. As in 21
0 MW unit, the HP rotor is supported by two bearings, a journa[Dearing at the front
end of the turbine and a combined journal and thrust bearing directly adjacent to the
coupling with the ]P rotor. The iP & LP rotors have a journal bearing each at the
end of the shaft. The bearing temperatures are measured by thermocouples in the
lower shell directly under the white metal lining. The temperature of the thrust
bearing is measured in two opposite thrust pads.
PAGE 19
TURBINE COMPONENTS
3.1 CASINGS OR CYLINDERS
A casing is essentially a pressure vessel which must be capable of withstanding the
maximum working pressure and temperature that can be produced within it. The
cylinder is supported at each end. The cylinder has to be extremely stiff in a
longitudinal direction in order to prevent bending and to allow accurate clearances
to be maintained between the fixed and moving parts of the turbine. This
determines the length between bearing centres which in turn determines the number
of stages which can be accommodated within the cylinder.
The working pressure aspects demand thicker and thicker casing and the
temperature aspects demand thinner and thinner casings. Design developments
took place to take care of both pressure and temperature considerations and resulted
in the following three types of casing design.
i) Single shell casing
ii) Multiple(double)shell.easing
iii) Barrel type casing
3.1.1 H.P. Turbine Casing
a) Single Shell Split Casing : Barlier design turbines including the 21O MW
BHEL / L.M.W. varieties are of single shell split casing for H.P. cylinders.
In this type the casing thickness would be of the order of about20 cms for
the 21 0 MW turbine which will make the flange to about 40cms and the
jointing bolts to about 23 crm size. This ' leads to concentration of mass
where high temperature and sharp fluctuation in temperature h expected.
This poses several problems during machine start ups and load changes.
b) Double Sheli Casinci: With the rise of steam conditions there fore single
shell casings are of no more use for H igh Pressure (H P) and 1 ntermediate
Pressure (1 P) casings. By using a double shell casing , the casing
thickness has been reduced to 9 cms and bolt size to 1 1 cms. in 21 0 MW
turbine H.P. cylinder. (Fig. 3. 1) shows how a double shell reduces
temperature difference through metal casing.
FIG. 3.1 SHOWING HOW A DOUBLEWALL CYLINDER REDUCES
TEMPERATURE DIFFERENCE THROUGH METAL CASING
PAGE 20
In turbines where steam temperature are veryhigh, the HP cylinder is
generally of the double shell design, the inner shell carries the stationary blading
and diaphragms and is subject to full steam pressure, whilst the space between the
two shells is subjected to the exhaust steam pressure of the particular H.P.
cylinder. The advantage of this arrangement is that each shell need only be
designed for a relatively small pressure difference. This permits reduced shell
thickness and allows quicker warming up without undue stress when starting up .
Special expansion joints are provided for the main steam inlet pipes to pass
through the outer shell and connect on to inner shell. (Fig.3.2) illustrates,a typical
double shell H.P. cylinder. (Fig.3.3) shows longitudinal section of a H.P. turbine
with double shell casing.
BHEL 21 0 mw Turbines of Soviet Design have single casing type HP
cylinders, while 21 0 MW BHEL KWU Turbines have barrel type for HP cylinder.
PAGE 21
c) Barrel Type Casing : The barrel type of cylinder construction ensures
symmetry of the wall thickness around the aixs of rotation and hence the wall
thickness itself is relatively less than that used in other type of constructions.
Barrel Design has also been used successfully for other turbo machines working at
high pressure, e.g. Feed Pump. Because of its rotational symmetry, the barrel type
casing also remains constant in shape and leak proof during quick changes in
temperature (e.g. on start-up and shutdown, on load change and under high
pressures).
The principal parts of the HP Turbine casing are an axially split inner shell
enclosing the rotor and an outer shell of barrel type casing (Fig.3.4). (Fig. 3.5)
shows how the inner shell is accommodated into the barrel.
The space between inner shell and the barrel type casing is sealed from the
neighboring spaces by a sealing with U &1 cross-section. The axially splitinner
shell is constructed as a guide blade carrier. The location of guide blade carrier
within outer casing enables, independent expansion of each other, i.e., it is radial
in all directions and axial from a fixed point.
PAGE 22
The guide blade carrier is kinematrically supported and located and this is
guaranted by 4 projections on e,@s the inlet side and 2 projections on the exhaust
side of the guide blade carrier, which match with corresponding e ofslotsand
havesliding contacts. Thesliding contacts make it possibleforthe blade carrierto be
exactly guided igh into the vertical and horizontal planes. A ring with a buttress
thread holds the guide blade carrier in the barrel-ant type casing. As the
combined journal and thrust bearing on the inlet side of the turbine forms the fixed
pointge of the turbine shaft, the guide blade carrier and turbine shaft expand in the
same direction. This means that only small aaxial clearances between the two parts
are necessary.
(Fig. 3.5) shows the 500 MW (KWU Design) HP Turbine with barrel type
casing assembly.
PAGE 23
FIG. 3.5 ASSEMBLY SEQUENCE FOR AN HMN – RANGE H.P. TURBINE
Steam Admission
Steam is admitted to HP turbine either through two or four branches as per
designers choice.
In 210 MWBHEL_LMW design steamis admitted through four branches, each having a
control valve (CV) in it.
PAGE 24
In 210 MW BHEL-KWU Design, steam is admitted through two branches each having a
combined stop valve and control valve in it.
The following (Fig.3.6) shows different versions of steam admision to HP turbines.
FIG. 3.6 DIFFERNT VERSIONS OF THE h.p. TURBINES
3.1.2 I.P. Turbine Casing
In modern large capacity turbines the casing of the IP turbine is split horizontally
and is of double-shell construction. (Fig. 2.2) shows a double-flow type I.P.
turbine casing (KWU-210 MW). Steam from the HP turbine enters the inner
casing from above and below through two inlet nozzles flanged to the mid section
of the outer casing. This arrangement provides oppesed doublke flow in two blade
section and compensates axial thrust.
In BHEL / LMW 210 MW set the IP turbine is of single flow type (see Fig.
2.1). The casing here is made of two parts, The two parts are connected by a
vertical joint. Each part consist of two halves having a horizontal joint. The
horizontal joint is secured with the help of studs and nuts.
From I.P. turbine steam is carried through two cross-over pipes to the
double flow L. P. cylinder. Each cross-over pipe is provided with a compensator
for taking care of thermal expansion and to ensure that no
PAGE 25
FIG. 3.7 I.P. TURBINE OF 500 MWTURBINE
heavy thrust or turning moments are thrown on to the I.P. cylinder. (Fig. 3.7)
shows cut away section of 500 MW Unit I.P. turbine.
3.1.3 L.P. Turbine Casing
The LP turbine casing shown in Fig. 2.2 consists of a double-flow unit and has a
triple shell welded casing, The outer casing consists of the front and rear walls, the
two lateral longitudinal support beams and the upper part. The front and rear
walls, as well as the connection areas of the upper part are reinforced by means of
circular box beams. The outer casing is supported by the ends of the longitudinal
beams on the base plates 3.2 of the foundation.
The double-flow inner casing, which is of double-shell construction,
consists of the outer shell and the inner shell. The inner shell is attached in the
outer shell with provision forfree thermal movement. Stationary blading is carried
bythe innershell. The stationary blade rowsegments of the LP stages are bolted
tothe outer shell of the inner casing. The complete inner casing is supported.
The design of low pressure cylinders has changed a lot in recent years.
Before the advent of the 500 MW machines, condensers were invariably situated
beneath the low pressure turbine and the condenser tubes were at right angles to
the.axis of the machine. With the development of the 500 MW machines several
variations of the above turbine / condenser arrangement have been adopted (Fig.
3.8) shows one such variation with condensers mounted on each side of the I P.
casings. These are called pannier condensers.
PAGE 26
FIG. 3.8 L.P. CYLINDERWITH PANNIER CONDENSERS
Atmospheric relief valve 1 diaphragms (Fig. 3.9)
In the event of failure of low vacuum trips the pressure in LP turbine exhaust rises
to an excessively high level. This results in increase of exhaust hood temperature.
The radiation heat due to this can result in loosening of LP rotor blades thus
increasing vibration levels. To protect against excessive internal pressure,
atmospheric relief valves / rupture diaphragms are provided in the exhaust hoods.
Each valve assembly has approximately 1 mm thick gasket clamped between
valve seat and valve disc. In case of high pr. (say 1.2 bar abs.) the valve disc tries
to lift and thereby ruptures the gasket ring, thus allowing the steam to exhaust into
the atmosphere.
3.2 FIXED POINTS, CASING AND ROTOR EXPANSION (500 MWKWU UNIT)
In designing the supports for the turbine on the foundation, provisions are kept for
the expansion and contractiion of the machine during thermal cycling.
The fixed points of the turbine easing on the foundation are as follows:
i) The bearing pedestals between the IP and LP turbines. From this point the
IP and HP easing expand towards the front bearing housing of the HP
turbines
ii) LP - Generator bearing housing.
iii) The middle portion of each longitudinal girders of LP turbine. From these
points longitudinal girders expands in both the directions (TS & GS).
PAGE 27
Casing Expansion
The front bearing housings of the HP and IP turbines can slide on their base plates in an
axial direction. Any lateral movement perpendicular to the machine axis is prevented by
fitted keys. The bearing pedestals are connected to the HP & ]P turbine casings by
guides which ensurethattheturbine casing maintain their central position while at the
same time allowing axial movement. Thus the origin of the cumulative expansion of the
casings is at the front bearing pedestals of the LP turbine.
The outer casing of the LP turbine is located axially by fitted keys at the middle of
their longitudinal beam members. Free lateral expansion is allowed. The centre guides f
or these longitudinal beams are recessed in the foundation. There is no restriction
on'axial movement of the casings. At the front and rear supports of the longitudinal beam
members the casing is free to expand horizontally in any direction.
Hence, when there is a temperature rise, the outer casing of the LP turbine expands
from its fixed points towards the generator. Differences in expansion between the outer
casing and the fixed bearing pedestals to which the housings for the shaft glands are
attached are taken by shaft seal compensators.
Rotor Expansion
The thrust bearing is incorporated in the front bearing pedestals of the 1 P turbine. Since
this bearing pedestal is free to slide on the baseplate the shafting system moves with it.
Seen from this point both the rotor and casing of the HP turbine expand towards the front
bearing of the HP turbine.
PAGE 28
3.3 MATERIAL FOR CASING AND DIAPHRAGMS
H.P. & I.P. turbine casings and diaphragms are normally Cr, Mo, V creep
resistance steel castings. L.P. casings and diaphragms where the temperature
never exceeds 230'C (e.g. L.P. cylinder on non-reheat machines) are sometimes
made of cast iron. On large reheat turbines, however the temperature of steam
entering the L..P. cylinder may be more than 230'C and because of this and the
large over all dimensions of L.P. cylinders, these are usually fabricated from
carbon steel castings or M.S. Plates, This construction also provides greater
protection in the event of blading failures and speeds manufactures.
3.4 STEAM CHESTS AND STRAINERS
3.4.1 HP SteamChest
Steam is admitted to a turbine from the steam main pipework via a steam chest,
which normally houses a steam strainer, an emergency stop valve and one or more
governing valves. In some designs a combined emerency stop and control valve is
provided. There may be one or two steam chests provided, depending on the size
of the turbine. The chest consists of a steel casting or, in the case of very high
steam conditions, of a solid forging. Where nozzle govering is used, it is often
convenient to include the governing valve in the high pressure cylinder castings.
Usually the steam chest is firmly anchored to the supporting steel work and
connected to the turbine by loop pipes which are long and flexible enough to allow
the turbine to expand freely. Some manufacturers prefer the chest to move with
the turbine when ft expands; in such cases the movement has to be taken up by the
flexibility of the high pressure steammains. This has the disadvantage that thrusts
from the steam mains may be transmitted to the turbine. It does, however, permit
shorter loop pipes so that during load rejections. less steam is trapped by the
governing valves and the tendancy to overspeed is lessened.
PAGE 29
A better way of controlling over speed, which becomes even more important as
the size of the machine and steamconditions rise, is to mount single governing chests
on the cylinder. The length of the loop pipes is then of less,consequence, but the
relay gear becomes slightly more difficult to accommodate satisfactorily.
To prevent small lumps of dirt being carried into the turbine by incoming
steam, and causing damage tq. the blading, the steam passes through acylindricai
strainer (which surrounds the stop valve) having holes i about 5 mm diameter. The
danger is particularly prevalent on newplant where pieces of weld metal@and oth(
debris may be swept through the steam mains. When first commissioned, therefore,
extra fine strainer having holes of about 1.5 mm diameterr are fitted. Even particiesd
of this size can cause serious blad damage and thorough blowing out of all pipework
is essential when commissioning new plant.
One of a pair of steam chests fitted to a 500 MWturbine is shown in (Fig. 3.1 0
and 3.1 1). One steam che is fitted to each side of the high pressure cylinder, each
chest containing two emergency stop valves controlling the supply of steam to the
high pressure turbine.
3.4.2 IP Steam Chest
On reheat units it is necessary to provide valve gear to control the flow of steam
from the-reheater into the intermediate pressure cylinder. This valve gear is
housed in a reheat steam chest situated adjacent to the intermediate pressure
cylinder. Large units have two of these steam chests, one mounted on each side of
the, machine.
The reheat steam chest houses an intercept valve which, under certain
conditions, controls the flow of steam, and an emergency stop valve which shuts
off the steam in the event of the turbine valve gear tripping. A diagram of the
reheat steam chest of a 500 MW machine is shown in (Fig.3.12).
PAGE 30
Like some H.P. steam chest the I.P steam chests may also have a combined stop and
control valve.
A reheat strainer is fitted immediately before the steam chest to protect the valve & IP
bladign from damage by debris. A typical strainer is shown in (Fig. 3.13).
PAGE 31
3.5 STEAM VALVES
A turbine is equipped with one or more emergency stop valves, in order to cut off
the steam supply dun'rn pe~of shut down and to provide prompt interruption of the
steam flow in emergency. In addition govemirl valves are used to provide
accurate control of steam flow entering the turbine. Reheat turbines require add~
ermrgency and interceptor valves . in the return path from the reheater and dual
pressure turbines require two @ of emergency and governing valves. (Fig.3.14)
shows some basic schematic designs ol valves in modem use.
a) Shows a “ double--beat" valve having two seatings, the object being to balance the
forces due to steam pressure. It is suitable for most pressures, but not for high
temperatures as differential expansion between the valve and cage would cause
one or other sealing to owrapm.
b) Shows another double-beat valve of the hollow type in which the steam from one
sealing is led through the centre of the valve. The thinner walls promote even
heating and lesser differential expansion.
c) Shows a modern sphedcal valve used for control linghigh temperature steam.
Beinga' sing@beatvalve with one seating, the pressure forces are not balanced and
a large operating force is required.
d) Shows a similar valve fitted with an internal pilot valve which, by opening first,
equalises the pressures and provides initial fine control.
e) Shows a cylindrical valve in which steam pressure is prevented from acting on the
back of the valve by fine annular clearance.
f) Shows a flap valve, used for reheat emergency valves, where the steam pressures
are moderate and the specific volumes (and hence the valve diameters) are large.
g) Shows a governing valve of the *mushroom' type, with a profiled skirt to give a
more linear area 1 lift relationship.
Other types of valves, such as piston and grid valves are used in pass-out turbines.
The diameters of valves opening are generally calculated to dive maximum steam
veloc~ of about 60 m / sec for. ermrgency valves, and about 120 m 1 sec for
governing valves.
The seating upon which any such valves closes is invariably part of a
removable sleeve which is replaceable when worn. -rhe mating annular faces of
valves and their seats are nitrided or faced with Stelide to resist wear. Such wear
is due more to erosion by the steam than to mechanical impact and is particulars
lipme to taker place when the valve is cracked open and a jet of steam is propelled
at high velocity through the n arrow port opening by the large pressure differential,
impact damage can occur as a result of frequent test ck)sures, and cushioning
devices or slow motion testing may be adopted to avoid this.
PAGE 32
3.5.1 Valves in the SteamChests
Depending on the size and design the number of types of valves in steam chests
will vary. For example the valves where as the HP turbine of same rating from
BHEL / KWU design has only two combined ESV and control valves.
Similarly the type and number of valves in IP steam chest will also vary
according to designers choice. All these valves are quite massive in size and are
operated by lever and hydraulic relays which inturn are guided by the governing
system. (Fig. 3.15 to 3.18) shows the lever arrangement for these valves.
PAGE 33
PAGE 34
3.6 LOOP PIPES
Steam passes from the steam chest to the turbine via loop pipes which are normally
U-shaped to give them sufficient flexibility (ft is important that these loops be
provided with drain rocks for use when starting up). With the use of high pressures,
the pipe walls have to be thick, making the pipes stiff. To achieve the required
flexibility and to avoid the imposition of large forces or bending moments on the
turbine very long loops are required.
Where pipes enter a double shell cylinder, it is preferable that they enter
radially, passing through asliding joint in the outer cylinder; in this way the two
sheli scan expand radially without losing concentricity. The sliding joint usually
contains piston rings made of nimonic alloy or special steel which will retain its
springiness at the prevailing steam temperature. See (Fig. 3.19 (a).
Cross-over pipes between cylinder must also be flexible, as they expand more
than the bearing pedestal and cylinders over which they pass. Pipes with long loops
are used for transmitting very hot steam. Where possible, crossover pipes pass under
or alongside cylinders rather than overhead, to improve cylinder access.
Expansion of LP cross over pipes is taken up by two or more hinge-linked
bellows which allow bending but no axial movement (Fig. 3.19 (b) in this way the
pressure force in the pipe is transmitted through the links, thus protecting the
convolutions from the tenency to open out. Afternatively, straight linked bellows may
be used in pairs, as shown in (Fig. 3.19 (c).,
PAGE 35
3.6 ROTORS
3.7.1 There are two types of turbine rotor used in large turbines which have impulse type
blading :
a) The built up rotor also called Disc Rotor consisting of a forged steel shaft on
which separate forged steel discs are shrunk and keyed. (Fig. 3.20).
b) The integral rotor in which the wheels and shaft are formed from one solid
forging. (Fig. 3.21).
The built up rotor is made up of a number of separately forged discs or
wheels and the hubs of these wheels are shrunk and keyed on to the central shaft.
The outer rims of the wheels have suitable grooves machined to allow for fixing
the blades. The shaft is sometimes stepped so that the wheel hubs can be threaded
along to their correct positions. Suitable clearances are left between the hubs to
allow for expansion axially along the line of the shaft.
PAGE 36
Integral rotors as said before have discs and shaft machined from one solid
forging, the whole rotor being one complete' icce of metal. This results in a rigid
construction and troubles due to lobse wheels of the shrunk on type are eliminated.
Grooves are machined in the wheel rims to take the necessary blading. These are
also called solid forged rotors.
FIG. 3.21 INTEGRAL ROTOR
The built-up rotor tends to be the cheaper of the two since the discs and
shaft are relatively easy to forge and inspect for flaws; also, the machining of these
components can be carried out concurrently. On the other hand, integral rotors are
expensive and difficult to forge and there is a high incidence of rejects; there is
also a large amount of machinery time and waste material involved.
In spite of the expenses involved, the advantages of integral rotors are such
that they are invariably used for the high pressure rotors on high temperature
plant; on reheatmachines in particular they are often used for intermediate pressure
and low pressure rotors as well. This is because of the difficulty of ensuring that
the shrunk-on discs on intermediate and low pressure rotors cannot become loose,
particularly at the high temperature end during start up when the shafts may be
relatively cool and the discs are hot. Another source of trouble under conditions
of high temperature and stress is the phenomenon of creep which could also cause
the shrink-fft to disappear after a large number of running hours.
With regard to low pressure rotors, the main problem is one of centrifugal
stress, the last stage being the most heavily stressed part of the turbine. The last
row wheels on the standard 500 MW turbine are the largest cap able of operating
at 1 000 rev 1 min; the blades are 900 mm in length and are mounted on the disc
so as to have a mean diameter of 2.5 m, the overall diameter is therefore 3.45 m.
On large turbines using 50 per cent reaction, four types of rotor are used:
a) The hollow drum rotor which promotes even temperature distribution because it is
designed with the same thickness of material as the casing.
(Fig. 3.22) illustrates the construction of the hollow drum type rotor.
b) The solid drum rotor suitable for cylinders where there are lower temperatures but
large diameters, as in intermediate pressure cylinders without reheat.
c) The built up rotor previously described.
d) Welded Rotors which are built up. From a number of discs and two shaft ends.
These are joined together by welding at the circumferences and because, there are
no central holes in the discs the whole structure has considerable strength. Small
holes are drilled in the discs to allow steam to enter inside the rotor body to give
uniform heating when coming on load. Grooves are machined in the discs to carry
the blades and (Fig. 3.23) shows this type of rotor construction.
PAGE 37
PAGE 38
3.7.2 Balancing
When assembled complete with blades the rotor is balanced both statistically and
dynamically.
In the case of built-up rotors, each bladed disc is balanced individually
before assembly. The aim of balancing is to reduce vibration to a tolerable level,
usually accepted to be about 35μm at the bearing pedestal of a 3000 rev / min.
machine.
A stationary shaft supported between bearings has a natural frequency of
vibration depending upon its diameter and the distance between the bearings. If its
speed of rotation corresponds to its natural vibration frequency, the residual out –
of-balance forces can build up to a dangerous extent. This speed is known as the
Critical Speed. Sometimes it is above the running speed and sometimes it is
below. If above, the shaft is said to be stiff, if below, the shaft is said to be flexible
and the critical speed should be passed as quickly as possible when running the
turbine up to speed.
The critical speed should not be within 20 per cent of the running speed.
PAGE 39
3.7.3 Materials
High and intermediate pressure rotors are usually made from chromium-moly
bdenum-vanadium steel ferritic materiao which is suitableforwheeicase steam
temperatures up to 540'C. Austenitic materials are no favoured because of the cost
of their manufacture and their high coefficient of expansion.
Low pressure rotors are made of 3 per cent chromium-molybdenum steel or
2 114 per cent nickd chromium-molybdenum steel. The first of these is not used
in modern designs because of the tendenq towards scuffing in the bearings during
the early life of the rotor.
Low pressure discs are made of 3 per cent chromium-molybdenumvanadium
steel, or more recentn 0 3 112 per cent nickel-chromium-molybdenumvanadium
steel.
3.8 BLADES
These are most important (and co" too) components of the turbine as these are
respcinsible for the ma:i@ function of the turbine, i.ib. conveting heat energy to
mechanical energy.
A blade has three main parts:
- AEROFOIL - It is the working part of the blade
- ROOT - It is the portion of the blade which is fixed with the
rotor or casing.
- SHROUD - It can be rivetted to the main blade or can be integrally
machined with the blade
(Note: Blades maybe without shroud also).
PAGE 40
3.8.1 Type of Blades
Most modern turbines use reaction type blading throughout the machine.
Some designs have impulse in the H.P. and I.P.cylinders and reaction in the L.P.
cylinder.
But use of impulse or reaction cannot always be dearly defined because
both principles may be combined in the same blade. For example large L. P.
blades are generally of twisted and tapered design (see fig. 3.24). These blades
produce varying conditions of impulse or reaction between root and tip and are
called vortex blades. The object of this design is to prevent uneven steam flow
caused by centrifugal forces forcing the steam towards blade tips. This is done
by changing the throat opening from root to tip. A 915 mrn (36m) blade with
zero reaction at the root has approximately 70 per cent reaction at the tip. Also
the inlet angle of the blade afters along its length giving smooth and efficient
steam entry.
3.8.2 Impulse Type Moving Blades
lmpluse type moving blades (for H.P.. Turbine) are machined from solid
bar and the roots and spa@rsformed with the blade (Fig. 3.25). Tangs are left at
the tips of the blades so that when fitted in position in the wheel, shrouding can be
attached.
The shrouding is made up from sections of metal strip punched with holes
to correspond with the tangs. As there is no pressure drop across the moving
blade, the seating arrangements are not of such great importance, as in the reaction
type. The shrouding on the impluse blading helps to guide the steam through the
moving blades, allowing larger radial clearance, as well as strengthening the
assembly.
PAGE 41
3.8.3 Impulse Type Fixed Blading (Fig. 3.26).
The fixed blading in an ampluse turbine takes the form of nozzles mounted in
diaphragms. The diaphragm is made in two halves, one half being fixed to the
upper half of the cylinder casings by means of keys so that when expansion
occurs fouling of the shaft seals is avoided. Special carrier rinfs are generally used
to support the diaphragms in H.P. cylinders.
Because of the steam pressure difference on each side of the diaphragm,
seals are provided at the bore where the shaft passes through the diaphragm, to
prevent steam leakage along the shaft.
FIG. 3.26 IMPULSE TYPE FIXED BLADING
In reaction type blading pressure drop occurs across both the fixed and
moving blades. So, very effective seal between fixed and moving blading is
essential to prevent steam leakage which would make the turbine inefficient. The
leakage of steam controlled by axial clearance is shown in (Fig. 3.27). This type
of sealing is called end tightening. Following is the details of Reaction type
blading of the H.P. Turbine of 210 Mw Set (KWU / BHEL).
PAGE 42
FIG. 3.27 REACTION TYPE BLADING-SHOWING END TIGHTENING
Moving and Stationary Blades
The HP turbine blading consists of several drum strages. All stages are reaction
stages with 50 per cent. The stationary and moving blades of the front stages (Fig.
3.28) are provided with T-roots which also determine the distance between the
blades. Their cover plates are machined intergral with the blades and provide a
continuous shroud after insertion.
PAGE 43
The moving stationary blades are inserted into appropriately shaped grooves
closed casing (1) and are bottom caulked with caulking material (9). The insertion
slot in the shaft (8) i a locking blade which is fixed either by taper pins or grub
screws. Special end blades which lock with t horizontal joint are used at the
horizontal joints of the inner casing. Graub screws which are inserted from t joint
into the material secure the stationary blades in the grooves.
Gap Sealing
Sealing strips (3,7) are caulked into the inner casing (1) and the shaft (8) to reduce
leakage and losses at th blade tips (4,5). Cylindrically machined surfaces on the
blade shrouds are opposite the sealing strips. Thesf surfaces have stepped
diameters in orderto increase the turbulence of the steam and thus the sealing
effec@ Should an operation disturbance cause the sealing strips to come into
contact with opposite surfaces they ar@ rubbed away without any considerable
amount of heat being generated.
3.9 SPECIAL FEATURES OF LP TURBINE BLADING
The blades used in LP Turbine have to be very long to cater for increasing specific
volume of steam at the lower pressures. In the final stages of LP turbine the prime
importance is of ensuring uniform steam flo@ around the circumference. To
achieve this twisted and ta@ered blades are generally used (function ofwhic@area
already explained) to dampen vibration, the long blades may be laced together (Fig.
3.29). But as facing holes are a source of weakness and wires upset the steam path,
the trend now a days is to avoid lacing b@ designing blades whose natural
frequency is well clear of the rate of impingement at running speed.
In the LP turbine stages the steam becomes wet. Maximum wetness normally
tolerated is about 12 pe@ cent. In wet region some steam condenses to tiny
droplets of water and water quantity increases as stean continues its expansion.
Water droplets, being heavier, flying outwards by centrifugal force. Part of it is
conducted away by steam extraction with water catch channels and part collected in
special draining grooves built into the turbine casing (Fig.3.30).
PAGE 44
Condensing droplets impinge on the moving blades and cause erosion on
the leading edges of the (mainly) last few stages. So, generally, physical damage
to moving blades of last two stages are minimized by fitting “Stellite” shields on
the inlet edges (stellite is the proprietary name for a series of extremely hard alloys
of cobalt, chromium, tungsten and carbon). (Fig. 3.30) also shows the stellite
protection provided to the last two blades of 210 MW BHEL / LMW Turbine.
In other design (Fig. 3.31 of 210 MW BHEL / KWU set) the fixed blades
of last two stages are hollow. Slits are provided in the blade surface of last
stationary row through which any water passing over the blade can up of any
droplets which may still remain. The leading edges of the final stage rotors are
flame hardened to give protection against erosion.
PAGE 45
3.9.1 Baumann Exhaust 3.1
A special type of exhaust blading, invented by Dr. Baumann, is used by some
manufacturers to achieve 3.1 greater exhaust area wmmtd undue lengthening of
the last row blades. I ncrerased exhaust area is favoured to reduce 'leaving loss'.
Also known as multi exhaust, it uses two-tier blades for the penultimate stage.
(Fig. 3.32) shows the fast but one stage of a turbine fitted with a Bauniann
exhaust. As the steam passes through the turbine to the exhaust, the blading is
conventional until it reaches the fixed blade A. This blade has a circular di~on ring
B which spins the steam into two paths. The outer path of steam is expanded to
back pressure and passed to the condenser via the moving blades C. Meanwhile
the other steam is discharged from A at a pressure higher than the exhaust
pressure. It p through the penultimate moving row of blades, after which R passes
to a further rcww of fixed blades D contained within a shroud E. Here the pressure
is reduced to that of the exhaust before. being discharged to the condenser via the
last row of blades F.
PAGE 46
3.10 METHODS OF FITTING BLADES
3.10.1 Root Fixings
Many types of root fixing shapes exist for turbine blading to suit both the
conditions u nder which the blade must operate and the preference of the particular
designer concerned. In general there are the types which either fit
intheirappropriate groove or straddle ft, whilst otherdesigns are fixed by rivets
through the blade root. Some examples of these blade root fixings are shown in
(Fig. 3.33).
In the case of reaction type turbines the H.P. blading is built up in packets
of up to ten blades and held in the rotorgroovewith serrated looking stripsas shown
earlier in (Figure 3.27). A gap is left in the rotorgroove to allow the last serrated
locking strip to be inserted. This gap is then closed with a plate fixed by screws to
the rotor body. In these turbines, the last L.P. rotor blades are subjected to a
centrifugal force of about 250 Tons / blade. Here fir tree fixing has proved most
effective. This is also shown at (Fig. 3.31).
For some impulse type blading a gap or "gate" is left in the rotor groove
and the blades.,are fed in and located by the particular shape of serrations used for
the blade root and groove. The last blade, which has a plain root with no
serrations, fits over the "gate" and is secured by riveting.
In other methods of fitting a soft metal distance piece or wedge is driven in
the groove to locate the last blade.
Where the blades are all attached to the rotor wheels by riveting or are of
the side entry type any blade can be last one and each must be separately secured
by riveting or with locking plates.
PAGE 47
3.11 SHAFT TURNING (BARRING) GEAR
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 the shafts.
The uneven heating or cooling would lead to bending and misalignment of shafts
with possible fouling of stationary and moving parts.
Use of turning gear during starting eliminates the necessity of admitting
suddenly a large flow of steam to rotate the turbine from the rest.
The turning gear speed is chosen to ensure satisfactory lubrication of the
bearing and, at the same time, provide some circulation of air within the casing
(particularly at the low pressure end) after shut down. The speed of turning gear
varies considerably from one design to another. For example while BHEL 1
LMW 210 MW turbine is rotated by the turning gear atthe speed of 3.4 rpm, in
500 MW KWU turbines, the T/ G rotates the turbineshaft at 270 R.P.M. / or 240
R.P.M. depending on whether the condenser is under vacuum or not.
The turbine must remain on turning gear units metal temperature has
dropped below 150"c with normall cooling, this will take approximately 72
hours.
Before putting the turbine on turning gear a few conditions like-adequate
bearing oil pressure, jacking oil pump running etc. must be satisfied.
JACKING OIL PUMPS (JOPS) are positive dispi - acement pumps that
provide high pressure (1 20 bar for KWU turbines) supply of oil under strategic
journals @~turbo generator and the oil lifts the shaft slightly, This ensures that
there is no metal contact between a journal and the bearing. This greatly reduces
the static friction and bearing wear, also the starting torque headed by the turning
gear drive. The JOP can be stopped after the lubricating oil film is established
between the shaft and bearings.
On early turbogenerators, turning of TG was done by hand withthe help of
long barfitted with rachetworm and pinion mechanism. (Fig. 3.34). This gave the
name "barring gear" or "barring" to this operation. Now, the driving force is
provided by either electric motors or hydraulic pressure.
Hand barring gear is used, nowadays, in emergency, when T.G. motor is
non-operational, and for
PAGE 48
maintenance purposes, to rotate the turbine shaft manually. An auxiliary source of
power from U.P.S. (Uninterrupted Power Supply) or Diesel Generating set is also
provided in some cases for reliability of T /G operation.
Fig.3.35 shows the functional arrangement of a turning gear.
In BHEL 1 21 0 MW LMW turbine, the T./ G is mounted on LP rotor rear
coupling. It consists of a worm,,
worm wheel spur gear and pinion, spiral shaft and sliding shaft with lever. The
system comes into operation when the shaft comes to stand still. When T / G is
engaged, the turbine shaft rotates at 3.4 R. P.M.
In KWU turbines, the turning gear is hydraulic. It is engaged when shaft
speed comes down to 545 R.P.M The T 1 G rotates the shaft at 120 RPM or 80
R.P.M. depending on whether the condenser is under vacuum or not. The T / G
assembly is located in the front bearing pedestal of LP cylinder and consists of two
rows of moving blades mounted on coupling flange of I.P. rotor, an inlet nozzle
box with stationary nozzles and .,guideblades (Fig. 3.36). The TG shaft system is
rotated by the double row wheel which is driven by prerssurised oil supplied by
auxiliary oil pump. After passing through the blading the oil drains to the bearing
pedestal and combines with the bearing lube oil returning to the iube oil tank.
In addition, the system is equipped with facility for manual barring in the even
of failure of hydraulic turning gear.
PAGE 49
3.12 COUPLING
3.12.1 Introduction
The need for couplings arises fromthe limiting length of shaft which it tis possible
to forge in one piece and from the frequent need to use different materials for the
various rotors, in view of the various conditions of temperature and stress.
Couplings are essentially devices fir transmitting torque, but they may also have to
allow relative angular misalignment: transmit axial thrust, and ensure axial
location or allow relative axial movement. They may be classified as flexible,
semi-flexible or rigid.
Type of coupling used may vary from manufacturer to manufacturer. For
example, the BHEL / LMW 210 MW units employs a rigid coupling to connect
HP and IP Turbine and a semi flexible one for connecting IP and LP turbine;
whereas, both the couplings of 210 MW BHEL /KWU set are of rigid type.
Following are the brief descriptions of basic three types of couplings;
PAGE 50
3.12.2 Flexible Coupling
Flexible couplings are capable of absorbing small amounts of angular misalignment
as well as axial movement. Double flexible couplings can also accommodate
eccentricity. Semi-flexible couplings will allow angular bending only.
(Fig. 3.37) shows some designs in common use. The claw coupling, which
may be single or double, is robust and slides easily when transmitting light load; on
heavy load, however, friction causes ft to become axially rigid. The Bibby
coupling is satisfactory up to medium sizes and provides, in addition to the other
features, torsional resilience' The mutti tooth coupling transmits torque by internal
and external gear teeth of involute form, which are curved to accommodate angular
misalignment,
All these couplings require continuous lubrication, normally obtained from
a jet of oil feeding into an annual recess, from which k is led centrifugally to the
coupling teeth through drilled passage_ways.
PAGE 51
3.12.3 Semi flexible Coupling
The semi-flexible type of coupling requires no lubrication and is normally
interposed between the turbine and generator. It consists of a hollow piece having
one or more convolutions (Fig. 3.38. (a)
3.12.4 Rigid Couplings
On large turbines the high torque to be transmitted renders the use of flexible
couplings impracticable. Consequently rigid couplings are employed between the
turbine cylinders so that the turbine shaft behaves as one continuous rotor A spigot
locates the two half-couplings and numbered fitted bolts join the flanges (Fig. 3.38
(b).
PAGE 52
GLANDS AND GLAND SEALING SYSTEMS
4.1 GLANDS
Glands are used on turbine to prevent or reduce the leakage of steam or air
between rotating and stationary components which have a pressure difference
across them; this applies particularly where the turbine shaft passes through the
cylinder. If the cylinder pressure is higher than atmospheric pressure there will be
a general steam leakage outwards; d the cylinder is below atmospheric pressure
there Mil be a leakage of air inwards, and some sort of sealing system must be
used to prevent the air from entering the cylinder and the condenser.
4.1.1 Water-sealed glands
Some turbine designs incorporate a shaft gland which depends on a water seal to
prevent steam or air leakage. A typical seal arrangement (Fig. 4.1) consists of a
shaft - mounted impeller with a series of vanes or pockets machined on both faces.
The impeller is contained within an annular chamber, and, when water is admitted
to the chamber, the impeller vanes force the water to rotate, at a speed
approximately equal to the impeller speed. The seal is relatively inefficient at low
speeds and air-sealed auxiliary labyrinth glands must be used, in conjunction with
high capacity air pumps, to raise vacuum when starting. Water is usually injected
into the seal at approximately hag of the full operating speed.
FIG. 4.1 A TYPICAL WATER-SEALED GLAN FIG. 4.2 (A, B & C) LABYRINTH GLAND DESIGN
PAGE 53
The side clearances between the impeller and seal chamber must be fairly
small, and so the use of this seal is restricted to positions on a turbine where the
axial differential expansions are within the effective limits of impeller and seal
chamber clearance. When this type of seal is used on a high pressure turbine, the
seal cannot absorb the full differential pressure so air-sealed labyrinth glands are
used to breakthe pressure down to a figure which the water seal can handle.
Since a water seal absorbs and generates heat, the water contained in the
annular chamber of the water - sealed gland is continuously evaporated; the water
losses are made up from a header tank.
4.1.2 Labyrinth glands
In modern turbines the labyrinth gland are used because it can withstand high
pressures and temperatures and yet requires little maintenance.
The labyrinth gland provides a series of very fine annualar clearances, in
the gap between the cylin@, wall and the shaft. The steam isthrottled through this
gap and its pressure reduced step by step. In expandii@,, through each clearance,
the steam develops kinetic energy at the expense of its pressure energy; idealism
the kinetic energy is converted by turbulence into heat with no recovery of
pressure energy. In this way, t@@e pressure is progressively broken down as the
steam is throttled at successive restrictions. By keeping t,@,,, clearance area
sufficiently small, the quantity of energy lost may be kept low, and as increase in
turbine outr@l occur the gland leakage loss becomes proportionately less.
To reduce the clearance area, glands are made with a diameter as small as
possible, and clearances . @s fine as possible. The diameter is limited by
considerations of shaft strength and radial clearance, by t clearance within the
bearing, and by the possibility of shaft distortion.
Glands must allow for axial expansion of the shaft and casing to take place
without causing a rub. On t' other hand, if a rub does take place because of shaft
vibration, ft is desirable that the heat generated minimized to prevent serious
frictional heating of the shaft and possible distortion. A typical modern giants,.
comprises stationary fins on spring-loaded sectors, white the shaft is either smooth
or castellated. If a should occur, the sectors receive the generated heat and can be
replaced readily if they are damaged.
Designs of labyrinth gland at present in use are shown in (Fig. 4.2).
In (Fig. 4.2(a) the clearances are staggered to ensurethat no kinetic energy is
carried overfrom one genius to the next. The stationary fins are axial, so that if a
rub occurs, the heat causes them to expand relative their fixing, and they move out
to increase the clearance.
(Fig. 4.2 (b) shows a resilient gland, the stationary part being divided into
sectors, each of which is sprir@,' loaded in an annular groove. If a rub occurs, the
sectorwould'give', andthe low contac that only a little heat is generated.
The gland shown in (Fig. 4.2 (c) is of the vernier type, the fins being much
finer than in the previo,,@,designs. By making the pitch of the fins on one side 1
0 per cent greater than the pitch of the mating fins, oi-@one fin in nine or ten will
be opposite another fin. If a rub occu rs, then only exactly opposing fins make
conta so the amount of heat generated is small.
Each of these glands can accommodate a certain amount of axial movement of
the rotor without dama or loss of effectiveness.
The arrangement of glands and gland sealing system vary between different
makes and sizes. Though purpose of the system is same. Following is the
description of the gland sealing system of a 21 0 MW (LMW 1 BHEL) turbine.
Gland sealing system(21 0 MWLMW1 BHEL Turbine) (Fig.4.4)
The 210 MW turbine has got 6 sets of gland seal one for each side of HP and LP.
Each set of gland seal consists of no. of sectionalised gland. HP turbine front
gland is sectionalised in to five section. HP rear and IP front into four sections, IP
rear into three sections and LP glands into two sections. Each gland sealing
consists of number of sealing rings divided into segment, each segment is backed
by two flat springs. The no. of sealing rings depended on pressur e against which
it is working. The sealing rings are housed in grooves machined in gland bodies
which in turn are housed in the turbine casing or bolted to the casing at ends.
The glands are sealed by steam. Penultimate section of each gland is
supplied with steam from gland
PAGE 54
FIG.4.3 HIGH PRESSURE CYLINDER LABYRINTH GLAND (PARCON TURBINE)
Steam header maintained at a pressure of 1.03Kg/cmlabsto 1.05Kg/CM2absand
between 130'>cto 1500c. The header receives steam from de.3erator steam space
through a pressure control valve. Provision is also there to supply the steam from
TAS (Turbine Aux steam) system during non availability of deaerator steam.
Steam is suppliedto last but one seal of each gland at a pressure of 0.1 Oto
0.20 Kg/ CM2 and temperature 130'cto 1 50'c from sealing steam header. Leak
off steam from the turbine istapped off from different section in the gland seal and
is either cooled in the gland steam cooler or fed to lower pressure stages of
turbine. The leakage from the last stage i.e. air side leakage is cooled in gland
cooler No. 1. The cooler is maintained under vacuum with help of a special steam
ejector provided inside the Gland Cooler No.l.
Steam from fourth sealing chamber (from air side) of HP front, rear and IP
front is connected with turbine 4th Extraction before the NRV. Steam from the
third chamber of HP front, rear and I P front rear is connected with the Gland
steam cooler No,2 for regenerative feed heating cycle. The third gland chamber
and gland cooler No.2 are always maintained at condenser vacuum as the
condensate drain side of gland cooler No. 2 is connected with the condenser. The
lead off steamfrom thefirstchamber of the HP front gland is connected to HP
turbine last stage. Steam / air mixture from the spindle seals of ESVS. IVs, and
control valves of HP and IP is exhausted into the gland steam cooler No.l.
In addition to the above mentioned gland steam supply system, an another
source of supplying gland air from the live steam is there.
All the gland seals of turbine are normally fed with steam from deaerator at
controlled pressure. Following a turbine trip-out, this gland steam shall be sucked
into the cylinders which would be under vacuum at that condition. Sincethe
temperature of gland steam fed from deaerator is much lowerthanthe
steamtemperature at ini6ts to HPT and IPT, differential expansion of HPT and IPT
are likely to increase at a faster rate under such conditions. In view of the above a
provision has been made to inject main steam to the front gland seals of HPT and
IPT. This system is called Rotor heating system.
PAGE 55
PAGE 56
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
5.1 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 types:
i) Direct contact
ii) Surface contact
5.1.1 Direct 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 qualityshould be equal to condensate quality (Fig.
5.1).
5.1.2 Surface 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 flowing inside them (Fig.5.2).
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 outietwater boxes, there may be two or more
pair of separate inlet-outietwater 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.
5.1.3 Description of Condenser for 210 MW(BHEL) Turbines (Fig. 5.3)
The condenser group consists of two condensers, each connected with exhaust part
of low pressure casing. These two condensers have been interconnected by a bypass
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
waterforthe boilers. The tube layout of condenser has been arranged to ensure
efficient heat transfer from steam to cooling water passing through the tubes, and
at the same time the resistance to flow of steam has been reduced to the barest
minimum.
350% capacity condensate pumping sets are installed for pumping the
condensate from condenser to the deaerator through low pressure heaters. Two
pumps are for normal operation and one works as stand by pump.
PAGE 57
PAGE 58
Constructional feature
Each condenser has been sub-divided into upper and lower parts. Front water box,
shell and rear water box constitute the lowerpart. 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. Manholes have been provided for routine
maintenance and visual inspection along with venting and draining arrangement
for individual water boxes. Condensertubes are secured to the end tube plates by
expanding and flanging 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 flow. 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.
FIG. 5.3 CONDENSER
Upper part of condenser has been designed to allow smooth flow of steam
over tube nest. It consists of mild steal flat walls, strengthened from inside by
gratings of longitudinal and transverse rods and from outside by channels. These
rigid bars help the condenser to ratain its shape against atmospheric pressure.
Two sections of low pressure heater No, l have also been located inside the
upper parts of condenser. In orderto allow expansion along the height, the
condenser is supported on springs specially designed to take up load (Fig,5.9).
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 alon~h the thrust of springs during expansion is transfered to
turbine foundation.
PAGE 59
Special care has been taken for removal of condensate formed as a result of
condensation of steam. Baffle p"es have been provided to guide the steamflow on
the tube nest and for collecting the condensate h~ from upper rows of tubes and
directing it towards the intermediate support plates for flowing down in na~ layers,
leaving the passage free from steam flow.
Asteam throw off device has been incorporated in each condenser for
dumping the steam into the condenser during start up and sudden load throw off
from the set.
5.1.4 Materials for Condenser Tubes
Selection of tube material depends mainly on the quality of cooling water and the
cost. Copper bearing alloys are prefered as copper has very high beat transfer
coefficient. But as copper has very little mechanical strength; d has to be
reinforced by alloying with other metals. Copper alloys are basically of three
categories. Br (h) C-upro-nickel and (iii) Bronzes.
Stainless steel tubes has also been used and has good corrosion resistance
though heat transfer coeffi~t is quite lower than the copper alloys. Because of
high cost, stainless steel is used only where water is highly corrosive. So~ sea
side power plants are also using Titanium despite high cost, because of highly
corrosive environment.
5.1.5 Tube Packing
The ~hod otattachmentof thetubestothe tube plate is very important. These tubes
being brass will expand more ffim the steel shed 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 @ids through the tube plate as it
expends. This means that the holes must be bigger ~ the tube and, to prevent
leakage, the gap between tube and tube plate must be sealed. Linen or metallic
paddngs are used for sealing purposes.
The pacidngs 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, bin matailic packing is often prefered. Metallic
packing gives a firm metal contact from tube to tube plate. This, ft is claimed,
prevents corrosion of the tube ends by ~~c action, which is corrosion due to the
passage of very small electric currents.
When using ferrules, A is important that sufficient 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 thal flush ferrules be used at the inlet end to cause least i~rwence wM ~er
flow. (Fig.5.4)
5.1.6 Expand Tubes
Afternatively, 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.
With double tube places, the tubes are fixed to the tube plates by rolling
into form the required expansion as ~wn in (Fig .5.5).
PAGE 60
5.1.7 Tube Nest Arrangement
In addition to designing the condenser to give a low back pressure while
using as little pumping power as possible, it also necessary to ensure that the
condensate is nor under cooled and tat the pressure drop of the steampath through
the condenser is a small a possible.
In early condensers the tube bundles were tightly packed tigether. 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.
PAGE 61
The first step in improving the tube nest arrangement was to provide considerable
space around the tube bundles and to incorporate wide stearb lanes to allow steam
to,circulate freely (Fig.S.6 ). 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 steam to condense in the lower
parts of the condenser with the advantage that those condensate droplets did not
have far to travel; those droplets which fell from the upper parts of the condenser
also had to pass through the warn steam., so helping to reduce under coo ing .
A further improvement was the introduction of condensate deflectors.
These plates or'trays collect the condensate droplets and direct themaway fromthe
lower tubes so that they fall directly into the hotwell again reducing under colling.
In modem condensers particular care is gives to channelling part of the
exhaust steam directly to the space immediately above the hotwelf; the object of
this is to recover as much as possible of its velocity-head 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 (see
fig.S.7) by the conden sate droplets failing 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 understung condensers, the necessity to pass the top hag
of the exhaust steam across the horizontal joint imposes a limit on the degree of
pressure recovery that can be obtained economically.
This difficulty 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 flows directly into the condensing surfaces, with the result that the
length and complexity of the steam path is greatly reduced. (Fig.S.8) and (Fig.3.8)
show two variations of this development. (Fig.5.8) illustrates the principle of the
radial condenser, and (Fig.3.8) the pannier condenser. In case 'of pannier
condensers which are recently gaining popularity, the savings from increase in
efficiency, and savings from a reduction in the basement depth far exceed any
increase in building costs caused by the extra width of the turbine.
FIG. 5.6 IMPROVED TUBE NEST ARRANGEMENT FIG. 5.7 STEAM AND CONDENSATE
FLOWS THROUGH CONDENSER
PAGE 62
5.1.8 Condenser leaks
Air leakage into the condenser is one of the main cause of poor vacuum.
5.1.8.1 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
flame of the taper is drawn towards the place where the air is being drawn into
the condenser.
This is a time-consuming technique as the taper has to be passed slowly
over every area where a leak is suspected, and the presense of draughts
cantnake 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 lighed blow lamp is placed with its flame above
the air discharge port on the air extraction equipment the normally blue flame
will change to orange when the halogen is emitted.
A more modern development of this method is the use of halogen gas
detectors. These are. inserted into the air discharge line from the air extraction
equipment and a meter registers wh'e"n a halogen gas passes the detector. A
suitable gas (such as, freon) is sprayedround the suspected area until the
detector registers.
The disadvantages of these systems are:
a) The operation needs two men: one, mans praying, and the other watching the
blow lamp or indicator.
b) Time must be allowed to elapse aftere ach spray so that, if there is an
indication, the operator knows which area that has been sprayed contains the
leak.
Off-load leak searches are carried out by filling the condensate system and
stearb space with water to a level below the turbine blades.. Care must be taken to
ensure that the condenser supports have first been set in the correct position to cater
for the extra load in the condenser. (Fig.S.9) shows how the condenser supports are
arranged.
Fluorescene is added to the water, and if any leakage takes place the
fluorescene can be detected by the use of an uftra-violet lamp. Leakage is detected by
this method, not only at the condenser mountings, but also on the low pressure feed
heater train.
PAGE 63
FIG. 5.9 CONDENSER SUPPORT SPRING ARRANGEMENT
5.1.8.2 Circualting (Cooling)Water Leakage
There are two kinds of CW leakage, internal and external. Internal leakage into
the steam and condensate space is the most important of these two.
5.1.8.3 Internal Leakage
Leakage of cooling water into the condensate can be caused by several faults, but
the main ones are:
a) Tube to tube plate fixings leakage.
b) lnternalcorrosionanderosionofthetubes.
c) External erosion of the tubes.
d) Fatigue and stress cracking of the tubes.
The Effects of CWLeakage 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 deterimental are those containing chlorides, such as sodium chloride (NaCI).
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 CWleakage should be detected., the source of leakage located,
and the leak rectified.
PAGE 64
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 betterthan the pure condensate and is said to have a
higher conductuvity. If the conductivity of the condensate is monitored a change will
be detected when a leakage of CW occurs.
The practical advantage of condensate conductivity measurement is that ft
indicates changes, not only in the actual value but also it increases above the normal
running value. To a plant operator, this often gives the first indication of condenser
leakage.
Location the Leaking Tube
There are several methods of locating the leaking tube, and new methods are
continually being tried. The principal methods of leak location are as follows:
a) The Simple Manometer. (Fig.5.10) shows a simple manometer, which can be
manufactured by the station chemist. One end of the condenser tube is plugged and
the manometer is inserted into the other end. The leaking tube will suck the liquid out
of glass because of the vacuum in the condenser. This method is ver ,y effective, but
can be time consuming.
b) The Blanket Effect. In this method the tube plate is covered by thin plastic
sheeting or by foam. The leaking tube will tend to pul! the foam or sheet into R.
c) Sonic Detection. As air is drawn into the leaking tube it creates a supersonic
whistle. This whistle is detected by a microphone placed in the entrance to the tube,
and the resulting signal is amplified. d) Bubbler Leak Detectors. (Fig.5.1 1) shows a
conventional bubbler. This can be used for on-load detection and its method of
operation is similar to the simple manometer.
If one end of the tube is blocked with a bung, the vacuum of the condenser pulls
air through the bubbler when it is inserted in the other end of the tube.
Amore advanced type of bubbler called MEL bubbler can be used both f or onload
and off-load detection and is very suitable for use with pannier and integral
condensers.
(Fig.5.12) illustrates the principle of the MEL bubbler, The tube to be tested is
plugged, connected to a reference vessel and vacuum pump, and there the system is
evacuated. The pump is then isolated from the system and, after a short time, to
ensure that the pressure in the tube being tested and the reference vessel have
equalized, the balance valve is closed. From then on any air leaking into the tube
under test will be indicated by a stream of bubbles issuing from the end of the tube in
the jar or water.
PAGE 65
FIG. 5.14 (A) SACRIFICIAL ANODE TYPE OF FIG. 5.14 (B) IMPRESSED CIRCUIT SYSTEM OF
CATHODIC PROTECTION CATHODIC PROTECTION
If on-load location is not successful it may be necessary to take the turbine
off load to locate the leak. On some older turbines it is possible;to enter the steam
space and locate the leak directly as the CW sprays into the steam space, but
usually this is not possible on a modern turbine.
Whereundersiungcondensersarefittedftispossibletofilithesteamspacewithcon
densate.contain'ing fluorescene and examine the tube plate with an uftra-violet
lamp to find the leaking tube.
As we mentioned previously, the condenser support springs must be jacked
up be forelhe steam space is filled with condensate.
Where pannier or integral condensers have been fitted this method cannot
be used if the steam space is filled with water the low pressure cylinder could be
under water.
The Double-Tube Plate
On modern turbine, plant extensive use is being made of the double-tube plate in
an attempt ot reduce the effect of leakage at tube fixings. ( Fig. 5.13) illustrates
the priciple of the double-tube plate.
The interspace A can either be under vacuum (@,n which case leakage will
be into space) or ft can be fed with condensate under pressure a leakage from the
system. Alternatively, the conductivity of the drainage from the interspace A can
be monkored; an increase indicating a leaking tube fixing.
PAGE 66
5.1.8.4 External 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 turbui >entwater (particularly when it contains air bubbles), or by
water carrying grit or other suspended solids. This makes particularly susceptible
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 impetier eye and casing of large C.W pumps may
necessitate the use of wearing rings at this point. An external leakage source may
also @ a broken anode in a cathodic protection system.
Corrosion is the result of electro-chemical action, which can be reduced but
cannot be entirely eliminated. Cast iron condenser waterboxes are particularly
affected 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 difficult to achieve, severe localised corrosion may
occur where there is a defect in point film. 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 waterboxes 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 Oubes) from
the cathodes. If a 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. This system is known as the sacrificial anode type of cathodic protection
(Fig.5.14) (a)), as the third electrode is sacrificed to save the original (iron)
electrodeimproved cathodic protection, requiring less maintenance (replacement of
sacrificial anodes) and able to protect a larger area, is provided by an impressed
circuit type system. It uses the sarm principle, but an inert or semi-inert material
(e.g. platinum coated titanium) is deliberately made anodic to existing material by
passing low voltage direct current through it into the electrolyte (Fig.5.14) (b)
5.2 CONDENSATE EXTRACTION PUMPS
Condensate extraction pumps are normally multistage, vertical,,
contrifugal,pumps (Fig.5.15). They are to 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 hotwelf, 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 re uired
for the condensaite cycle.
In 21 0 MW unit, three condensate pumps, each having SO%- 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) Operation of group protection device for bypassing H.P. heaters.
vi) For cooling steam dumped through.steam throw off device.
PAGE 67
LEGEND
1. DISCHARGE HEAD
2. OUTER SHELL
3. IMPELLER SHFT
4. IMPELLER FIRST STAGE
5. BELL MOUTH
6. STUFFING BOX HOUSING
7. THRUST BEARING HOUSING
8. UPPER PUMP BEARING
9. LOWER PUMP BRARING
10. GLAND IN TWO HALVES
11. ST. BOX PACKING
PAGE 68
Major specification of a typical BHRC 28 type condensate extraction pump (for 210 MW)
PUMP :
3 Nos. per unit
Multistage, vertical turbine centrifugal pump.
Low specific speed, medium head
Medium Capacity
Discharge - 281 T / hr.
Manometric - 201 Metres.
Head
NPSH - 3.5 MTRS
r.p.m. - 1489
No. of stages - 8
hp - 256
MOTOR
Power - 220 kW (300 hp), Voltage - 6.6 kV
5.3 AIR EXTRACTION SYSTEM
Air extraction systemis needed to extract air and other non condensable gases from
the condenser for ma~kn 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 rkwmal operating conditions quantity of air to be extracted is lower. It
consists of air ieakage into the condenser via flanges 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 baffles 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.
5.3.1 Air Ejectors
The oprerating medium of the air ejector can be either high pressur gas or liquid.
In thermal power stations steam of low parameter (Approx. 4.5 kg 1 cm', 250'c) is
used for the air e@or. The operating principle is simple - steam is passed through
a nozzle and the pressure energy converted into velocity energy. High velocity
fkjid aspirates air and other non condensable gases from the condenser and moves
into diffuser which re-converts the velocity energy into pressure energy@r The
pressu~ 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 e@or is recommended to be used for accelerating the initial pulling of
vacuum. During this period starting e@or operates in parallel with main ejector.
When the vacuum in the condenser reaches 500-600 mm of Hq column, the
starting ejector is switched off.
(Fig. 5. 1 6) shows the construction of a starting ejector. It may be noted
that the steam alongwith the mbdure of air and other gases is exhausted to the
atmosphere. Gener ally starting ejector is single stage and has high steam
consumption.
PAGE 69
FIG. 5.16 AIR EJECTOR
Main Elector
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 passed through a
converging-diverging nozzle and the pressure energy of steam is converted into
velocity energy. This high velocity steam jet entre fins air and in condensable
gases and then enters a diffuser steam lair mixture is ihen cooled in the first stage
shell by condensate. Steam is thus condensed, heat in the operating system is
partly recovered, and the steam 1 air mixture volume is reduced, allowing the
second stage nozzle and its steam consumption to be reduced. The second stage
cooler can be followed by a third stage nozzle, and its after cooler (as done in
BHEL 21 0 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. (Fig. 5.17) shows the arrangement of typical two-stage main ejector.
PAGE 70
FIG. 5.17 MAIN EJECTOR
An air measuring device for measurement of air discharge from condenser may
be fitted at the air exit of the ejector. It measures dry air discharge while the
condenser and ejectors are in operation.
5.3.2 Air Pumps
In the ejector system high quality steam from the boiler is used by reducing both
pressur and temperature. For example, for running the ejection the main steam
from boiler having 140 kg cm2 and pressure 540 c temp. is reduced to 4.5 kg / cm
2and 250'c. Due to this reason the steam operated air ejector, which in other
circumstances is prefectly satisfactory, is not idealfor use inthe high pressure, high
temperature units. Hence, now-a-days air pumps are being used in the condensers
of the 500 MW units.
Air pumps allows greater flexibility 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 un condensabie gases in the condensate. Air
pump can deal with either starting and normal conditions and there fore@a
separate starting equipment is unnecessary.
Air pumps are basically of 3 types : rotary, liquid ring and hydraulic.
a) Rotary Air Pumps (Fig. 5.18)
It has two impeliers 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 in to the compartments
PAGE 71
formed by the blanking plate and the ends of pump casing.
When the pump rotates, water is drawn through the guide nozzle and is
broken into slugs by the impeller blades. These slugs of water pass the discharge
nozzle, aspirates the air and effectively seal the pockets of air asthey passthrough
the diffuser. Fromthe diffuser, the air, non-condensable gases and sealing water
tank. The swirling motion imparted to the mixture.by the tangential entry, assists
the separation of water and gases. The gases are released to atmosphere through a
vent in the top of the tank. The sealingwater is re-circulated to the pump.
b) Liquid Ring Type Air Pump (Nash VacuumPump) (Fig. 5.19).
There are several varieties of this type which is essentially a centrifugal
displacement type pump. A mufti blade rotor / impeller revolves within an
elliptical or offset casing which is partially filled with water. The rotating impeller
throws the liquid out wards resulting in a solid ring of liquid revolving in the
casing at the same speed as the rotor but following the shape of the casing. This a
alternatively causes the liquid to enter and recede from the inter blade spaces on
the impeller. The provision of inlet and outlet parts enables this pumping section
to be used for sucking in and out of the gases from the condenser.
Thesepumpsaresimpleandreliable.Therearelargeclearanceonrotatingpartsandnovalv
esorpistons,
c) Hydraulic Air Pumps : (Fig. 5.20)
Hydraulic air pump is a water operated ejector using a motor driven recirculating
lift pump and a simple spill over system. The sealing water is pressurised by a
piping pump and fed into a series of nozzles. Streams ol water leaving the nozzles
pass over the blades of spinner which is mounted on the end of a shaft and free to
rotate. The blades are formed so that the sealing water propels the spinner and is
broken into slugs. These slugs, like rotary air pump, pass to discharge nozzle,
aspirate air and seal the pockets of air in the diffuser and thus pressurises them and
discharges the mixture (of air and water) into a tank.
The tank is ven'ted and sealing water is recirculated to the lift pump.
PAGE 72
PAGE 73
B01LER FEED PUMP
Boiler Feed Pump (BFP) is a multistage pump provided for pumping feed water to
economiser. Generally three pumps each of 50% Of total capacity are provided,
For rated capacity two Pumps Will be working in parallel and the third will be in
reserve.
6.1 Description of Feed Pump (BHEL - 2oo KHI, provided for 200 / 21 0 MW Unit).
Feed pump consists of the following major parts:
1) Pump Barrel
2) Rotor
3) Stator
4) Mechanical Seal
5) Balanc7ing Device.
6.1.1 Pump 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 press cover behind the
balancing device are closed by the low pressure covers alongwith the stuffing box
casings. The brackets of the radial bearing of the suction side and the bracket of
the radial and thrust bearings of the discharge side are fixed to the low pressure
covers. The entire pump is mounted on a foundation frame. As the pump handles
hot water, sometimes, arrangements are made for cooling the foundation frame to
prevent unequal expansion of the frame.
6.1.2 Rotor
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 two the two parts
supporting rings which are mounted in the grooves in the shaft. The rotor is
supported on two part bearing shells. The bearing brackets are connected to the
low pressure cover.
6.1.3 Stator
The stator consists of stage bodies. The diffusers with the diffusing wheels and
guide wheels are assembled to the stage bodies. . The end diffuser is connected to
the outlet stage outside the stage body. Stage bodies are fitted with wearing rings
at the place where it is likely to come into contact with the wearing rings of
impellers, and the wearings rings are secured to the stage bodies woth the help of
screws.
6.1.4 Mechanical Seal
Sealing of the pump is achieved by a specially designed mechanical seal. It
minimises the loss of the feed water in the stuffing 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 stuffing box space and the cooler. The feed
water is circulated in the cooling circuit through the cooler and back bymeans of a
pumping ring. The coolers are so designed that water temperature in the stuffing
box remains below 80o C..
6.1.5 Balancing Device
As in other multi stage pumps, all the six irnpellers are arranged on the shaft with
inlets in the same direction. This causes a thrust of about 34 Tons in the direction
of suction end of the pump while running. This axial thrust is taken up by the
balancing device. About 1 0% of feed water which is not calculated to the
guaranteed delivery
PAGE 74
PAGE 75
capacity is taken off from the space behind the last impeller for operation of the
automatic balancing device. The bakime disc is fixed to the shaft and rotates
between a ren~ie seating and the balance disc cover. The thrust generated by the
impeders tends to force the disc against its seating, but the high pressure water,
bled off the delivery stage of the pump, flows along an annular 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 R exerts sufficients pressure on
the balance disc to overcome the end thrust of the impeller. Waterthen escapes
between the face of the disc and its seating. The balance disc thus runs on a film
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 kingsbe" bearing toes over the function of the balancing device when feed
pump is started. The & dngs berry shell is forced against the direction of action of
balancing disc on the disc by means of springs kwaed in the kings berry 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 kings berry 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 Mil move to the suction side and
balancing disc comes into contact with bearing disc" reducing the a)dal gap and due to
the increased pressure on the balancing disc, the rotor move to the middle position
creating the gap between the balancing disc and the bearing ring.
Fig.62 DIAGRAMOF BALANCE PISTON ((DISC)
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 the
thrust, a certain amour* of water flows through the axial gap between the
balancing disc and the bearing ring and there is no danger of balancing device
getting seized.
PAGE 76
It is evident that behind the balancing disc the pressure must not rise.
Otherwise the hydraulic equalizing piping must have a sufficent flow 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 necessury to trip the pump in order to
find out the cause of defect and to rectify it.
6.2 WORKING OF BIOLER FEED PUMP
the water with the given operating temperature should flow 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 first impeller. After leaving through the
impeller it passes through the distributing passages of the diffuser where it get certain
pressure rise and flows over to guide vances 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 diffusers. Thus the feed water arriving into the discharge space
develops the necessary operating pressure, a small part of feed water i.e. about 10% is
taken off from the space behind the last impeller for the operating of the automatic
balancing device to balance the hydraulic axial thryst of the pump rotor.
TYPICAL SPECIFICATIONS OF BOILER FEED PUMP (200 KHI TYPE)
No. of stages 6
Suction Pressure 12.3 ata
Quantity of water for 100 Tons / hr.
Minimum take off
Discharge capacity / head 430 T / hr. / 1830MWC
Quantity of water for 8 Tons / hr
Warming up
Feed water temperature 164.2oC
Consumption of cooling 280 LPM
Water
Speed 4320 rpm
Lubrication Forces
Stuffing box Mech. Seal
Net weight of pump 5850 Kg.
Axial Thrust at Designed 34 Tonnes
Speed.
MOTOR
Output 4000 kW
Rated voltage 6.6 kV
Current 421 Amps.
Speed 1483 rpm
Frequency / Powe factor 50 c / s / 0.914
6.3 RECIRCULATION SYSTEM
To maintain a reasonable efficiency in the pump, running clearances between
stationary and rotating parts must be fairly narrow. Liquid flow through these
clearances acts as a lubricant to prevent seizure. The power input to the pump is
partly conveted into hydraulic energy due to the increase in pressure of the liquid.
The
PAGE 77
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 flashes into steam. Flashing breaks down the thin
film 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 sufficient water must be kept moving through the
pump to prevent its temperature from reaching the flash 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 off system is provided between the pump discharge and the
deaerator to establish a minimum flow through the pump. A solenoid operated
diaphragm valve or a motorised valve is installed in the leak off line which opens
when the pump runs at a lower capacity.
The recirculation valve (of BHEL 21 0 MW unit BFpp) opens when the flow at
pump suction is below 1 00 T 1 hr & closes when k increases to 220 T 1 hr. The
flow through recirculation line is 125 T / hr.
6.4 WARMING UP
Centrifugal pumps handling hot water should always be maintained nearly at
operating temperature when idle, If suddenly hotwater is admitted intothe 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, asmall quantity of the medium is always
passed through the steam pump for warm up. Various methods are used for this
purpose. In some, the flow is from the suction, through the pump and out through
the balancing chamberto the flash tank. 1 n others, a by pass across the main
discharge non-retum valve is provided with a pressure reducing orifice. The flow
is from the discharge and, through the pump and back to the deaertor. Larger the
pump the longer is the time and the larger is the quantity of hot water required for
warming up.
In orderto avoid pump seizure in case of 200 KHI model while starting,
warming up valve should be open and temperature of pumps casing should not be
less by more than 150c than that of feed tank temperature.
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 definite delivery
head add delivered quantity of the feed water as per requirement of the boiler.
This reduces the power consumption particularly at part load operation.
6.5.1 Basic Principle and Operation
A fluid coupling is basically a combination of pump and turbine connected in
series. (Fig.6.3) shows avertable speed fluid coupling blading and the arrangement
of the impellers in the working area.
The rotating impeffer energy to the operating fluid. The resultant centrif
ugal force causes the fluid to flow outwards whereby the velocity is increased by
the impeller. The flow of the fluid into the runner takes place at the outer
diameter, where the energy is transmitted from the fluid. The fluid contained in
the runner blade chambers then flows inwards to the centre and back into the
impeller blade chambers. This circuit is maintained by the centrifugal force
difference resulting from the speed difference between the impetter and runner.
This speed difference is cabled slip, which nominally is in the order 1.5 to 3.5%.
In contrast to the constant-filled type turbo-coupling, the oil filling of the variablespeed
turbo coupling can be varied between fully filled and drained while in
operation. Ln this way stepiessspeed regulation of the driven machine over a large
range is achieved when the coupling operates against the load characteristics. This
regulating range is 4:1.
PAGE 78
The working circuit is governed by a system which can continuously extract or
supply the working compartment fluid. This enables precise adjustment of the
driven machine speed to be achieved.
The working circuit is charged by continuously running pump which delivers oil
from the int egral sump below the coupling into he working compartment. The
working compartment is the chamber between the primary (impeller) and
secondary (runner) wheels which is a connected to a rotating scoop chamber
consisting
FIG. : 6.3 VARIABLE SPEED FLUID COUPLING
PAGE 79
of an inner and an outer shell. The,oil level in the working compartment
deterrpines the speed at the output side of the coupling and depends upon the
radial position of ascoop tube located in the scoop chamber. The flow capacity of
the; scoop tube far exceeds the purnp delivery; thus, with respect to control and
regulation, reaction times are at a minimum.
6.6 BOOSTER PUMP (FIG. 6.4)
Booster pump is provided before feed pp. to maintain required NPSH and lower
Deaerator height. KHI type boiler feed pump is provided with a booster pump in
its suction line which is driven by the main motor of the boiler feed pump. One of
the major daimages which may occur to a B.F. pump is from cavaation or vapour
bounding at the pump suction 1due to suction failure. Cavitation will occur when
the suction pressure of the pump atthe pump suction is equal orvery
neartothevapour pressure of the liquidto be pumped at aparticular feed water
temperature. By the use oj-.booster pump in the main pump suction line, always
there will be positive suction pressure which will remove the possibility of
cavitation.
Typical Specification of Booster Pump Provide with 200 KHI Type BFPP.
Delivery quantity 460 T / hr.
Delivery head 31 MWC.
Speed 1475 rpm.
6.7 F.K. RANGE BOILER FEED PUMP
These pumps are barrel casing, multistage cart-ridge pumps. The cartridge
(Pump-Barrel) includes all - pump internals with shaft, impellers, Diffusers, shaft
seals, bearing housings and pump half coupling.. The cartridge design enables
easy removal of pump internals.
(Fig. 6.5) shows sectional arrangement of F.K. Type Boiler Feed Pump. lh
500 MW units in India, F3 4E K6 feed pump is used. Its specifications are given
below:
TYPICAL SPECIFICATIONS OF FK 4E 36 FEED PUMP
No. of stages 4 + 1 Kicker stage
Suction Flow 1080 M3 / HR
Head 2100 MTR
Speed 5690 RPM
Efficiency 81.75%
Power 6752 KW
Typical Arrangement 2 * 50 % Turbine Driven
1 * 50% Motor Driven
Interstage Tapping to supply water for Reheat Steam Desuperheating.
Kicker Stage Tapping to supply water for superheater Desuperheating.
Axial Thrust Balancing: Balancing Drum and Tilting Pad Thrust Bearing.
Axial Thrust at design speed: 72.5 Tonnes
Balancing Force at design speed: 66 Tonnes
Residual Axial thrust at de@igr4 speed : 6.5 Tonnes
Thrust Bearing Capacity : 14.5 Tonnes.
6.8 BFP DRIVE
For units of capacity upto 200 1 21 0 MW the drives for b ' oiler feed pumps are
electric motors. For units of capacity 500 MW and above the general practice is
to.employ steam turbines for driving the pumps. (An
PAGE 80
PAGE 82
electric motor driven feed Pump of 50% capacity is also provided for start up and
stand by). Number of steam turbines driven feed pumps per unit also vary. Some of
500 MW Units provide only one steam turbine driven feed pump of 1 00% capacity
and some provide two steam turbine driven feed pumps of 50% capacity each). It
normally takes steam from either CRH or lst Extraction and the exhaust normally
goes to one of the low pressure heaters.
One of the major gains in using steam turbine as the primemover for BFPs is
an increase in overall efficiency. The power consumed by feed pump is transfered to
feed water. But when the power consumed is electricity, ft has been generated at
around 33% efficiency only. So loss of power at feed pump drive is (in terms of %
of boiler heat input).
Pump Power (1 - n.)
Generator Load
Where nc = Cycle efficiency = nb x nt x ng
= 0.85 X 0.4 x 0.98 = 0.33 or 33%
nb = boiler efficiency = 0.85
nt = turbine efficiency = 0.4
ng = generator efficiency = 0.98
So if the power consumption of feed pump of a 500 MW Unit is 14 MW, then the
pump motor will consume 141 500 of the alternator output at an efficiency of 0.33
so, pump loss (% of boiler heat input)
= 14 - (100-0.33) / 500
= 1.88%
Now in case of turbine driven feed pump, the loss will be 14 / 500 (1 00 - n b) =
0.42% of boiler heat input. In addition, the steam turbine driven feed pump has
the foliowing other advantages:
1) Compared with the system using electrically driven pumps there is again in
therrnal and overall efficiency since thermally, the extraction of steam from the
feed pump turbine requires an increased steamflow through the early stages of
the turbine. This allows the use of longer blades resulting in higher stage
efficiency.
2) As the bled steam is normally taken from the cold reheat line the steam flow
through the reheater is reduced. This permits reduction of cost of reheater
steam pipe works because of the reduction of size. The main turbine
construction is simplified as there is no bled steam tapping points for HP
heaters.
3) Thermodynamically, it is advantageous to use the low temperature steam bled
from the feed pump steam turbine for feed heating in HP heaters as it helps
avoiding degradation of high super-heat steam tapped from H.P. and ].P.
turbine.
4) The feed pump speed is infinitely variable and it has been demonstrated that
the bled steam turbine will run the pump with the main turbine producing only
25% of full load.
5) There is no need for gearing between the turbine and pump.
6) The lower stage efficiency of the bled steam turbine is more than off set by the
higher transmission efficiency. The alternator shaft hydraulic coupling must
be designed such that the b.f.p. will give 1 00% output under frequency
reduction. Therefore under normal 50 Hz conditions the coupling will be
operating at less than its maximum range point with an increase in its losses.
7) A higher speed pump results in a smaller and cheaper pump. Also the b.f.p.
turbine operates at higher intenal efficiency at higher speeds. In order that high
pump-speed scan be obtained with an alternator shaft drive, a step-up gearbox
will be required, which increases the transmission losses.
8) Lt does not interfere with at ternator rotor with drawal and does not complicate
an are a already used for other auaxiliaries such as exciter and alternator
cooling fan.
9) Lt often allows a reduction in building costs as the over aillength of the T/A
unit is not increased.
PAGE 83
PAGE 84
10) The turbine driven feed pump may be sited in the basement instead of at
engine room floor level, so that for a given N.P.S.H. the deaerator height may
be lowerd.
(Fig. 6.6) shows a K 1401 type B.F.P. turbine used in 500 MW (KWU) Unit.
PAGE 85
REGENERATIVE FEED HEATING SYSTEM
7.1 Economics of feed heating
lf steam is bled from a turbine and is made to give up its latent and any supe.-heat it
may possess, to a heater, this system is called regenerative, because the fluid (steam)
gives up heat, which would be otherwise wasted, to the fluid whilst in another state
(water) to raise its temperature. The highest A heorectical temperature to which the
feed water may be raised in the heater is the saturation temperature of the bled steam.
There is an optimum point at which the steam is bled from the turbine once a feed
temperature is selected, a tappling point near the stop valve produces no gain in
efficiency as practically live steam is used for heating. An intermediate point, if
carefully chosen, gives maximum feed temperature rise with minimum loss of
mechanical power at the turbine. The steam, having given up a proportion of lits work
to the turbine, then gives up all its latent heat which would otherwise be lost to the
condenser C.W.The heat gained in this way outweighs the loss ofmechanical power and
a gain in efficiency follows. Other advantages of this cycle are that less C.W. is
required with a decrease in pumping power, a smaller condenser can be used and the
turbine exhaust annulus is smaller.
The thermal gain resulting from feed water heating can be illustrated by
considering an example with approximate figures as follows (Single Feed
Heater).
Without Feed Heating With Feed Heating
Turbine steam consumption 4.5 kg / kWh 4.5 x 1.05 = 4.725 kg 1 kWh
Boiler feed temperature 31oC 93oc
Total heat in steam 314 x 4.5= 3140 x.725=
14130 kJ kwh 14836.5 kJ / kwh
Heat already in water 4.5 x 4.19 x 31 4.725 x 4.19 x 93
= 584.5 kJ / kwh = 1840 kJ / kwh
Heat used by turbine (4.5 x 3140) - 584.5 (4.725 x 3140) - 1840
Heat in mass of steam = 14130 - 584.5 = 14836-1841
- Heat to raise water (1 3545 kJ / Kwh) = 12995 kJ / kwh
The difference between these values is 4.23% which can result in a considerable
yearly saving in fuel consumption.
7.2 Types of feed water heaters
A feed water is simply a heat exchanger which is arranged so that the water leaving
a condenser is pre-heated before it is fed to a boiler. The feed heater is supplied by
steam which has already performed some useful work. This steam, which is taken
from suitable stages along a turbine, transfers its latent heat to the boiler feed water
and accordingly increases the water temperature.
It is now universal practice to use feed heaters to heat the feed water from the
temperature at which it leaves a condenser to a temperature approaching the
saturation temperature of the boiler steam pressure.
When a feed heater is in operation, it requires no regulation because the bled
steam consumption responds automatically to the temperature and quantity of feed
water passing through the heater.
Low pressure feed heaters are positioned after an extraction pump, while high
pressure feed heaters are positioned after a boiler feed pump and, therefore, have to
be constructed to withstand the full discharge pressure of a boiler feed pump.
Two types of feed heaters are used; the surface type, in which the feed water is
passed through tubes, with the bled steam surrounding them; and the direct contact
type, in which the steam and water mix together.
PAGE 86
7.2.1 The surface – Feed Heater
A surface type heater consists basically of three parts;
a) A shell with a steam connection
b) A nest of tubes
c) A water box, with water connections on the inlet and outlet headers.
A low pressure surface heater (Fig. 7.1) may consist of a cylindrical body
fabricated from mild steel and sealed at its upper end by a cast steel water box. Which
houses a nest of solid brass U-tubes. The ends of the tubes are expanded into a mild steel
tube plate trapped between a flange on the body and a corresponding flange on the water
box. Baffles are provided to ensure that the steam is directed across the tubes. The upper
section of the quadrant of the tube nest, which carries the condensate in its last pass
through the heater, is totally enclosed by vertical baffles, so forming a flashed-steam
drain cooler section of the heater.
FIG. 7.1 L.P. HEATER
PAGE 87
high pressure surface heater (FIg. 7.2) consists of a mild steel cylindrical
body and some secured together to form a vessel, which houses a tube nest of
carbon steel tubes suspended from a condensate inlet and outlet heater.
A typical modern high-pressure heater has integral desuper heating and
drain cooling zones in addition to condensing surfaces in the one shell. (Fig. 7.3)
shows a temperature / heat transferred diagram for this heater. The outlet
terminal difference is –0.56oC(-1oF) and the drain cooling terminal difference is
5.56oC
FIG. 7.2 H.P. HEATER
PAGE 88
7.2.2 Heat Transfer in FeedWater Heaters
There are three (3) heel transfer zones in a typical H.P. surface feed heater.
(a) esuperheating Zone
This zone is the @ feed header zone through which the feed-water passes
before leaving the heater. When the feed-weder enters the zone it has been heated
in the condensing, zone to within a few degrees of the saturation temperature,
corresponding to the bled steam pressure at the entry to the feed heater. Although
the desuperheating zone adds only a small percentage of the total heat transfered
in the heater, this small rise in feed-water temperature is very valuable in terms of
thermal economy. The heat in the zone is transferred by convection - the
superheater steam can be considered to behave as a normal gas.
The steam normally leaves the desuperheating zone with a residual
superheat of about 27.8'c. The temperature gradient between the bulk steam and
feed water temperature is shown in the top right hand inset of (Fig. 7.3). The tube
wall temperature is above the saturation temperature of the bled steam and no
condesnsation takes places on the tube wall under normal conditions. There is,
therefore, no problem of condensed steam forming droplets and being carried into
the condemning zone by the relatively high velocity steam which could cause
impingement attack @the exit from the zone.
(b) Condensing Zone
In the condensing zone the overall coefficient of heat transfer is high. The
main problem in larger heaters is to obtain good steam distribution tothe
condensing surface with the minimum pressure loss. Under normal load running
conditions the ingress of non-condensabie gases is unlikely. However, continuous
venting is necessary to help the steam distribution and to clear any non
condensable gases which are likely to accumulate after shut down during two shift
operation. The diaphragm plates serve a dual purpose, not only do they support
the tube nest, but they also prevent the accumulation of condensate from running
down the outsiders of the tubes and forming a thick film with a consequent
reduction in heat transfer.
(c) Drain Cooling Zone
It is possible to obtain a fairly high beat transfer rate in the drain cooling
zone provided the drains are not reheated by head transfered through the shrouds
around the drain cooler convection zone. If there were. no desuperheating by a
steamy atmosphere which would tend to condense on the shrouds and reheat the
drain In the heater shown in Fig.7.3 the desuperheating zone is larger than the drain
cooling zone and it is possible to have the heater shell flooded with condensate to
above the drain cooler inlet . This condensate forms a stagnant pool around the
drain cooler shrouds causing them to follow the temperature gradient in the drain
cooler. Under this condition the problem of drain reheat is eliminated provided the
shell drain valves are kept closed.
7.3 REGENERATIVE SYSTEM OF 210 MW(BHEL LMW) UNIT
The regenerative system of the turbine consists of four low pressure (LP) heaters,
two gland coo ers, one deaerator and three high pressure (HP) heaters. The
condensate is drawn by condensate pumps from the hot well of condenser and is
pumped to the deaerator through gland cooler and low pressure heaters where it is
progressively headed up by steam extracted from sems and bled points of the
turbine. The drain of condensed steamon LP heaters No.2,3 and 4 flows in cascade
and is ultimately pumped into the main condensate line after heater No.2 orflowsto
condenser. The feed water after being deaerated in the deaerator is drawn by the
boiler feed pump and pun~ to boiler through high pressure heaters where it is heated
up by the bled steam from the turbine. The drain of condensed steam of HP heaters
flows in cascade and under normal load conditions flows to the deaerator.
PAGE 89
FIG. 7.3 TEMPERATURE / HEAT TRANSFERRED HIGH-PRESSURE HEATER
7.3.1 Low Pressure Heater No. 1
The heater is of horizontal surface type consisting of two halves, each half has
been located inside the upper part of each condenser. The two halves have been
installed.in parallel. The steam to both is supplied from the same extraction point.
The housing forthe heaterisfabricated from M.S. Plates with suitable steam
inlet and drain connections. The tube plate is of mild steel and is secured to the
water box and housing by means of studs and nuts. U. shaped tubes have been
used to ensure independent expansion of tubes and the shell. They are of solid
drawn admirality brass, 19 mm external dia, 1 mm and 0.75 nwn thick and are
expanded by rolling into the tube plate at facilitate drawal for tube replacement,
and maintenance. Partitions mild steel plates have been provided for supporting
the tubes at intermediate points and effective distribution of heat load in all the
zones of the heater.
The water box is of mild steel with suitable water inlet and outlet branches.
It is of rectangular shapes and has been provided with suiitable air vent and drain
connections.
7.3.2 Low Pressure Heater Nos. 2,3 & 4 (Fig. 7.4).
a) Construction
These heaters-identical in construction are of vertical surface type and are
designed for the steam to pass over the tubes and the condensate to flow
through them. Following are main elements of these heaters.
i) shell
ii) tube system
iii) removable water box.
PAGE 90
FIG. 7.4 L.P. HEATER 2,3 & 4 (210 MW1 LMW UNIT)
Shell is a cylindrical construction with dished end welded at bottom and
having a flange at the upper end for assembly of tube system and water box. The
shell is provided with suitable steam inlet and drain connections alongwith other
nozzle connections to accommodate various fittings. M.S. baffles are provided to
ensure effective distribution of steam in the condensing zone of the heater.
Tube system consists of U-shaped admirality brass tube, 16 mm external
dia, 1 mm thick and are expanded by rolling into tube plate at both the ends.
Tube system has been provided with rollers to facilitate drawal for tube
replacement. Tube plate is of mild steel and is secured to the water box and shell
flange by means of studs and nuts.
Water box consists of thick walled cylindrical shell having a flange at the
lower end and a dished end welded at top. It has been provided with suitable
water inlet and out let branches. Partitions have been provided in the water box to
make it four path design.
PAGE 91
b)Working Principle
The main condensate f . lows through the tubes in four Paths before leaving
t he heater. The heating steam enters the shell through a pipe and flows over theU
shaped tube nest. The partition walls installed in the tube system ensures zig-zag
flow of steam over tube nest. Condensate of heating steam referred as drain,
trickles down the tubes and it taken out from the lower portion of the shell by
automatic level control valve installed on the drain line.
7.3.3 Gland Steam Cooler No. 1
It cools the air-steam mixture sucked from turbine end seals. It is of vertical type
and has two sections. An ejector mounted on the cooler, maintains constant
vacuum in the first section. It also sucks the remaining air steam mixture from ist
section to second, where air is let off and steam condensed., A part of main
condensate, after main ejector, flows through the cooler tubes consisting of Ushaped
brass tubes rolled in steel tube plate. Drain from cooler is led to
condenser.
7.3.4 Gland Cooler NO.2
Gland cooler has been designed to condensate the leak-off steam from
intermediate chambers of end sealings of HP& IP turbines.
The construction of this cooler is identical with low pressure heaters No.
2,3 & 4.
The main condensate flows through the tubes in four paths before leaving
the cooler. The leak off steam enters the shell through a pipe and flow over the
tube nest . The participation walls installed in the tube system lead to zig-zag flow
of steam over the tube nest. Condensate ofleak off steam referred as drain trickles
down the tubes and is taken out from the lower portion of the shell by automatic
level control valve, installed on the drain fine.
7.4 DEAERATOR
7.4.1 Functions
The pressure of certain gases like Oxygen, carbon dioxide and amonia,
dissolved in water is harmful because of their corrosive attack on metals,
particularly at elevated, temperatures. Thus in modern high pressure boiler, to
prevent in ternal corrosion, the feed water should be free, as far as practicable, of
aildissolvedgases, especially oxygen. This is achieved by embodying into the
freed system a deaeratifig unit. Apart from this, a deaerator also serves the
following functions:
1) Heating incoming feed water.
2) To act as a reservior to provide a sudden or instantaneous demand.
7.4.2 Principle of Deaeration
a) The solublity of any gas dissolved in a liquid is direct typroportional to the
part ial pressure of the gas.This holds within close limits for any gas which
does not react chemically with the solvent.
b) Solubility of gases decrease with increase in solution temperature and or
decrease in pressure.
7.4.3 210MWLMWUnit Deaerator (Fig. 7.5a)
A constant pressure deaerator, pegged at 7 kg/ cM2 (abs) is provided in turbine
regenerative cycle to provide properly deaerated feed water for boiler, limiting
gases (mainly oxygen) to 0.005 cc/ Litre. It is a direct contact
PAGE 92
PAGE 93
type heater combined with feed storage tank of adequate capacity. The heating
steam is normally supplied from turbine extractions but during starting and low
load operation the steam is supplied from auxiliary source.
The deaerator comprises of two chambers:
i) Deaerating column
ii) Feed storage tank
Deaerating column is a spray cum tray type cylinderical vessel of horizontal
c ' onstruction with dished ends welded to it. The tray stack is designed to ensure
maximum contact time as well as optimum scrubbing of condensateto achieve
efficient deaeration. The deaerating column is mounted on thefeed
storagetankwhich in turn is supported on rollers at the two ends and a fixed
support at the centre. The feed storage tank is fabricated from boiler quality steel
plates. Manholes are provided on dearating column as well as on feed storage
tank for inspection and maintenance.
The feed water is admitted at the top of the deaerating column and flows
downwards through the spray valves and trays, The trays are designed to expose to
the maximum water surface for efficient scrubbing to effect the liberation of the
associated gases. Steam enters from the underneath of the tray and flows in
counter direction of condensate. While flowing upwards through the trays,
scrubbing and heating is done. Thus the liberated gases move upwards alongwith
the steam. Steam gets condensed above the trays and in turn heat the condensate.
Liberated gases escape to atmosphere from the orifice opening meant for ft. This
opening is provided with a number of deflectors to minimise the loss of steam.
In some deaerator designs, a vent condenser (Fig.7.5b) is also located above
the Deaerator. A portion of feed water is first passed through the vent condenser
before it enters the Deaerator. This water is heated by remaining steam after
steam has passed through the Deaerator. Thus only gases escape to atmosphere.
7.4.4 Location of Deaerator
A deaerator is placed at a height of about 20 Mts above B. F.P suction to avoid
flashing and cavitation during a rapid load drop.
PAGE 94
During a rapid load drop pressure in the heaters and deaerator tends to drop. This
causes flashing in the deaerator as the water is stored at boiling point,
corresponding to the pressure at full-load. The rate at ic head as it descends must
be greater than the rate of the water in the feed pump suction pipe gains stat'
pressure decay in the deaerator, if flashing in the pump is to be avoided. The
suction pipe should be as near vertical as possible to avoid unnecessary head loss
duetofriction.(Fig.7.6) illustratesthe variation in pressure in a deaerator and at a
feed pump positioned beneath it follomng a load rejection. The curve of pump
suction pressure is greater, by a constant figure than the curve of deaerator
pressure; this constant difference is equal to the static head of the deaerator on the
pump. If the saturation pressure corresponding to the ternperadure of the water
arriving ad the pump is greaterthan the total pressure atthe pump inlet, in other
words static head plus deaerator pressure at that time less friction loss, then
flashing will take place in the pump. because of static head, this situation is
avoided. In Modern units, a booster pp-is located before the Main feed pump to?
further increase the feed pp-suction pressure above saturation pressure at feed
pump suction.
FIG. 7.6 PRESSURE CHANGES AT A DEAERATOR AND FEED PUMP
FOLLOWING LOAD REJECTION
7.5 HIGH PRESSURE HEATERS (Fig. 7.7)
The feed water flows through the tube spirals and is heated by bied steam around
the tubes in the shell of the heaters. These heaters are cylindrical vessels with
welded dished ends and with integrated, desuperheating, condensing and
subcooling sections. The internal tube system of spirals is welded to the inlet and
outlet headers. As there are no flange ends the chances of tube leakages are less in
this type of heaters. In order to facillitate assembly and disassembly, rollers at the
side of the heater have been provided. Both feed water and steamentries and exits
are from the bottom end of the heater.
In 21 0 MWILMW units, the feed water, after feed pump enters the HPHs
5,6 & 7. The steam is supplied to these heaters from the bleed point Nos.3,2 & 1
of turbine through motor operated valves. These heaters have a group bypass
protectionon the feed water side, in the event of tube rupture in any of MPHs and
the level of the condensate rising to dangerous level, the group protection device
diverts automatically the feed water directly to boiler, thus by passing all the 3
H.P. heaters.
The condensate of the bled steam formed in the heater is thrown either to
the next lower stage heater in cascade or to the deaerator through a set of interlocked
valves depending upon the pressure condition inside the heaters. There is
also an arrangement to take out;dir steam mixture from each heater in cascade and
air steam mbdure is thrown to the condenser through the LP heaters.
PAGE 95
PAGE 96
TURBINE OIL SYSTEM
8.1 PURPOSE OF OIL SYSTEM
The turbine oil system fulfils four fuctions. It:
a) Provides a supply of oil to the journal bearings to give an oil wedge at the shaft
rotates.
b) Maintains the temperature of the turbine bearings constant at the required level.
The oil does this by removing the heat which is produced by the shaft
conduction, the surface friction and the turbulence set up in the oil.
c) Provides a mediumfor hydraulically operating the governor gear and controlling
the steam admission valves.
d) Provides for hydrogen-cooled generators a sealing medium to prevent hydrogen
leaking out along the shaft.
It is worth noting that for 500 MW unites and above, h is becoming the
practice to use fire resistant fluids in place of lubricating oil for the control of
governer gear and steam admission valves. These eliminate the risk of fire
caused by leakage which is particularly likely when higher fluid pressures are
used.
(Fig.8. 1) shows the schematic of the lubricating oil system for 21 0 MW
(BHEL/ LMW) turbine. Lubricating oil systems for power station steam turbines
of other make or ratings also are a more or less simillar.
OIL SPECIFICATION (210 MWJLMWTurbine 011)
1 . Recommended Oil
a) Turbine oil 14
b) Mobil DTE medium
2. a) Specific gravity at 50'c 0.852
b) Kinematic viscosity at 50'c 28 CS
c) Neutralisation number 0.2
d) Flash point 201'c (min)
e) Pour point -6.60c (max)
f) Ash percentage by weight 0.01%
g) Mechanical impurities Nil
8.2 SYSTEM
The turbine oil system consists of the following:
1.Main oil pump
2. Starting oil pump
3. A.C. Lub oil pump
4.. D.C. emergency oil pump
5. Oil tank
6. Drain valve
7. Oil pressure drop relay (OPDR)
8. Oil Coolers
Lubricating oil is supplied from oil tank (capacity 28,000 lftres) to bearings
and governing system with the help of pumps.
During period of normal operation the required oil is supplied through the
main oil pump mounted on the turbine shaft. A portion of discharge of the main
oil pump is used as the working oil for the injectors. In fact there are two injectors
located in the oil tank. The first injector supplies oil to the suction of the main oil
pump and the discharged oil is further pressurised through the second injector
which supplies oil to the bearings through coolers.
PAGE 97
PAGE 98
During initial starting a A.C. driven starting oil pump meets the requirement of
both the bearing oil and governing oil.
Two standby oil pumps are incorporated in the system to supply bearing oil in
emergency. One of these is A.C. driven and the other is D.C. driven.
8.2.1 Main Oil Pump
This pump is mounted in the front bearing pedestal 'It is coupled with turbine rotor
through a gear coupling. When the turbine is running at normal speed i.e. 3000
rpm or the turbine speed is more than 2800 rpm, then the desired quantity of oil to
the governing system at 20 Kg 1 cm' (gauge) and to the lubrication system at 1 Kg
1 CM2 (gauge) is supplied by this oil pump. The oil to the lubrication system at
the level of turbine axis is supplied through two injectors arranged in series. First
injector develops a pressure of 3 Kg 1 CM2 (gauge) before oil coolers. After the
oil coolers, the oil pressure is 1 Kg 1 CM2 (gauge) which goes to lubrication
system. (Fig. 8.2) shows main oil pump of a 500 MW unit. It is similar to main oil
pump of 21 0 MW unit.
8.2.2 Starting Oil Pump (Auxiliary Oil Pump)
It is a multi-stage centrifugal oil pump driven by A.C. electric motor. Starting oil
pump is provided for meeting the requirement of oil of the turbo set during
starting. During starting or when the turbine is running at a speed lower than 2800
rpm ft supplies oil to governing system as well as to the lubrication system.
PAGE 99
8.2.3 A.C. Lub Oil Pump
This is a centrifugal pump, driven by an A.C. electric motor. This runs for about 1
0 minutes in the beginning to remove air from the governing system and to fill the
oil system with the oil. This pump automati over under inter lock action whenever
the oil pressure in lubrication system fails to 0.6 kg 1 CM2s (guage). Thus
8.2.4 D.C. Emergency Oil Pump
This is a centrifugal pump, driven by D.C. electric motor. This pump has been
provided as a back-up protection to A. C. driven lub. oil pump. This automatically
cuts in whenever there is failure of A.C. supply at power station and or the
pressure in the lubrication system fails to 0.5 kg 1 cm, (gauge).
8.2.5 Oil Tank
The oil is stored in oil tank of 28000 litres capacity upto operating level of the
tank. About 4000 lit / min. oil remains in circulation. Liberally sized tank holds
the oil inside the tank for a period long enough to ensure liberation of air from the
oil. Different mesh sized fitters are located inside the tank to filter the oil during
its no~ course. The filters are easily accessible and removable for cleaning even
when turbine is in service. This oil tank is supported on the framed structure just
below the turbine floor at the left side of the turbine.
8.2.6 Relief 1 Drain Valve
This valve is mounted on the oil pipe fine to maintain 1 kg / CM2 (gauge)
pressure at bearing axis in the lubrication system. So, whenever the pressure in
lubrication system differs from the above value, the drain valve increases or
decreases the oil drain to the tank and thereby maintain the required oil pressure in
the bearing lubrication system.
8.2.7 Oil Pressure Drop Relay (OPDR)
The A.C. lub. oil pump and emergency oil pump come in service automatically
under interlock action. The impulse for bringing the pumps into service is
provided by oil pressure drop relay. It is possible to over ride the interlock
manually to bring both pumps in service.
This OPDR comes into action under following conditions:
a) lt switches on the A.C. lub. Oil pump when the pressure in the lubricating
line drop stoO.6k91CM2(gauge).
b) It switches on the emergency oil pump when the pressure in the lubricating
jine drops to 0.5 kg / cm (gauge).
c) It trips the turbine and prevents the operation of barringge arwhen lubricating
oil pressured ropstoo.3 kg 1 cm' (gauge).
The relay is provided with a drain valve and an isolating valve for testing the
reliability of as operation, even when the turbine is running.
8.3 TURBINE OIL PURIFIER (CENTRIFUGE)
The purifier is used for purification of turbine oil. It draws oil from the turbine oil tank
(or impure oil. It draws oil from the turbine oil tank (or impure oil tank located outside
turbine building) through a oil pump. After removing any water and entrained solid
matter, the clean oil is returned to the oil tank (or pure oil tank).PAGE 100
The Centrifuge can perform the following Functions
1. Clarification : A liquid (oil) – Slude separation in which the machine is used for
separating off particles normally solids.
2. Purification : Liquid (oil) – Liquid (water) separation in which the machine is
used for separating two intermixed liquids which are insoluble in each other and a
have different specific gravities solids with specific gravites higher than those of
the liquids that can be separated off at the same time.
FIG. 8.3 CENTRIFUGE
PAGE 101
8.3.1 Centrifuge
The centrifuge (Fig.8.3) consists of a bowl which rotates on a vertical axis in
an,outer casing. A 415 V induction] motor, mounted on the side of the casing
drives the bowl through a. centrifugal clutch and a worm gear; a manually
operated brake is included on the worm shaft. The outer casing has a hinged lid
which incorporates the oil inlet and outlet connections, indications forflow and
temperature and a priming water supply, The base, which has an oil sump in which
the worm gear runs, is mounted on the purifier.
The bowl, rotated by a vertical shaft, consists of a body and hood joined
with a locking ring. The body contains a stack of conical discs on a distributor,
the top disc has a level ring which bridges the hub of the distributor, immediately
above the level ring is fitted a paring disc. The dirty oil inlet passes through the
bowl hood gravity ring and paring disc to the hollow distributor.
8.3.2 Principle of Operation
The mixture of,dirty oil, water and solid impurities, flowsthrough ducts in the inlet
connection on the centrifuge hood and through ports in the walls of the inlet pipe
into the spa 1 ce between the hub of the bowl and the bore of the distributor. The
mixture flows through holes in the conical base of the distributor and the discs to
the inter spaces between the revolving discs where the water and solids are thrown
outwards by the centrifugal force and so are separated from the oil. The water and
solids pass along the undersurface of the discs towards the edge of the bowlwhere
the solids are deposited and so can be removed later when the bowl is dismantled
for maintenance.The water rises above the top disc and is discharged through the
annular space between the gravity disc and the inlet connection into the outer
casing and then out through the inspection box.
The clean oil goes along the upper surface of the discs towards the centre of
the bowl and is discharged through the bore of the level ring tothe paring disc.
The oil is kept in the centre of the bowl by the water forming a rotating seal: This
prevents the oil from flowing over the rimof the top disc and escaping through the
gravity disc. There is, however, a small region where the oil and water meet
known as the inter-face. The position of this interface can be varied by altering
the size of the bore of the gravity disc and so altering the flow of the sealing water
out of the bowl. The position of the interface also determines the purity of the
water and the oil, A smaller bore in the disc will move the interface towards the
centre of the bowl so that the water will contain less oil and vice versa. It should
be noted that if the specific gravity of the turbine lubricating oil changes it will
also affect the interface and the gravity disc will have to be changed. The water
seal has to be established on start-up by filling the bowl with hot water; this can be
supplied from the pump through the inlet connection on the hood.
The clean oil leaving the bowl rotates in the form of a ring around the
paring disc which is fitted with internal radial scoops. These scoops dip into the
liquid ring converting its kinetic energy into pressure to pump the oil through the
annular space, between the oil inlet tube and the housing, to the outlet connection.
8.3.3 Anti-flood Arrangements and Drains
The water seal is essential for the centrifuge to be operated correctly; if the seal is
broken (because of a low water contant in the oil and evaporation or faulty
operation), oil will be discharged through the.,water drain. The water sump in the
centrifuge mounting platform is divided into two sections by a low weir plate ane
section is occupied by the floats of two mercurys witches mounted on the
platform, When operated normally, the water separated from the oil is discharged
into the other section of the sump and drains through a discharge valve which is
set to pass the expected flow.
If oil is discharged with the water, the sump will overflow into the section
containing the floats; these rise and operate the switches. This automatically stops
the centrifuge motor.
PAGE 102
HP-LP BYPASS SYSTEM
9.1 INTRODUCTION
This bypass system has been provided to allow the steam generator to build up,
during start up, matching steam parameter with the turbine. The steam generated
is dumped into the condenser, thus avoiding loss of boiler water. This system
enables starting of the unit of sliding parameters and also facilitates hot restarting
of the unit. In the event of loss of load on the turbine, the bypass system disposes
the steam produced by the boiler automatically to the condenser without affecting
the boiler operation.
The bypass system has two section: HP & LP. The HP-Bypass system
diverts the steam before main steam valve (MSV) to the cold reheat CRH line. HP
Bypass system also reduces the rated steam parameters of the incoming steam
from the superheater (SH) to the steam conditions expected in the CRH line (i.e.
steam temp. and pressure after HP Turbine exhaust).
The LP Bypass system diverts the incoming steam f rom hot reheat (HRH)
line before intercepting valves (]V) to the condenser after reducing the HRHsteam
parameters to the condition approximately to that of LP steam turbine exhaust
steam (Fig. 9.1).
HP Bypass station is utilised for the following tasks.
i) To establish flow at the outlet of superheater (SH) for raising boiler
parameters during start up.
ii) To maintain or control steam pressure at preset value in main steam line
during start up.
iii) To warm up the steam lines.
iv) To control steam temperature down stream of HP bypass at the preset value.
v) To dump steam from boiler into condenser, via LP-Bypass system, in case the
generator circuit breaker opens.
LP Bypass station is utilised for the following tasks.
i) Control of steam pressure after reheater.
ii) Establish flow of steam from reheat lines to condenser by its opening,
proportional to the opening of HP bypass valves.
iii) Release of steam entrapped in HPT and reheater circuit in case generator
circuit breaker opens.
Feed water is used for cooling H.P. bypass station and condensate water is
used for cooling of L.P. bypass station, condensate is also used for steam
cooling of H.P. 1 L.P. Bypass valves.
9.2 DESIGN CAPACITY OF H.P. BYPASS STATION 210 MW(LMW) UNIT
Total capacity of both bypass valves = 2x100= 200T/hr.
Max. M.S. Temp. = 5400c
Max. M.S. Pressure = 140 ata.
Down stream temperature = 380'c (Max.)
In KWU design, the capacity of HP & LP Bypass valves varies from 30% to 1
00% as per requirements of different customers. Higher capacity bypass valves
involve high cost.
9.3 CONTROL
a) The control components are located in a control cabinet in unit control board
(UCB). Each positioning loop may be controlled separately from the central
control desk. For supervision of the control loops, the position and control
deviation are indicated on mosaic insert of the control desk.
b) 0i1 Supply Unit : The oil supply units for the high pressure bypass and the
low pressure bypass are connected in parallel. Monostats control the oil
pressure. in the accumulators and signal alarm "PRESSURE TOO HIGH" or
"PRESSURE TOO LOW" appear in UCB if the pressure is not in order. If the
oil pressure should fall below the minimum in both accumulators, positioning
actuators will be blocked, and thereon the signal "ACTUATOR BLOCKED"
shall appear in UCB which simultaneously changes the operation of
positioning loops from automatic to manual.
PAGE 103
PAGE 104
9.4 INTERLOCKS
1. The HP-bypass system are influenced by the following interlocks:
a) Generator circuit - breaker
b) Condenser vacuum too low
c) HP valve position
d) Temperature too high at down stream of LP bypass station.
Following interlocks are produced by the bypass system and given to the other
positioning loops.
e) HP valve position more than 2%
f) “Close" - signal for spray water pressure control valve.
2. Generator Circuit Breaker: The HP bypass station shall come in to operation at
the moment the logic signal "GENERATOR CIRCUITBREAKER CLOSED"
disappears. However, this does not implythatthe HP bypass station shall be
out of service if the logic signal "GENERATOR CIRCUIT BREAKER
CLOSED".
3. Condenser Vacuum Too Low : The HP bypass station shall close immediately
in case of too low condenser vacuum (500 mm Hg Cot.) This interlock holds a
first priority for the controller.
4. HP Bypass valve position less than 2%:
a) When turbine is running or not running and the control of HP bypass valve is
on manual, the memory will get closing signal through AND logic, 9 the valve
position is less than 2%.
b) When turbine is running and control of HP bypass valve is on auto, the memory
will get closing signal through AND logic, if valve position is less than 2%.
c) When turbine is not running and control of HP bypass valve are on auto, there
is no closing signal to memory whatever is the position of the valve and thus
pressure control loop will actuate the valve.
5. Temperature too high: if the temperature after the outlet of the HP or LP bypass
station becomes "TOO HIGH" the closing signal to HP bypass valve is
forwarded and simultaneously positioning loops changes from automatic to
manual mode. The inter lock for this case will be provided by the temperature
supervising monitor.
6. HP bypass valve position more than 2%: if any of the HP bypass valves are
opened more than 2% (which is initiated by a part of voltage monitor) or if the
position demand signal is equivalent to more than 2%, valve opening (which is
initiated by a part of voltage monitor) a signal is available through or logic to
indicate the valve is open and the same signal is used to change the control of
valves from manual to auto if their control was on manual.
9.5 DESIGN CAPACITY OF L.P BYPASS STATION : (210 MW, LMW UNIT)
Total capacity of both bypass valves = 2x112=224 T / hr Steam flow.
Design Temperature = 540oC
Steam temperature after desuperheater = 200oC (Max. desuperheater).
Steam pressure at upstream of by = 6 ata (Max).
Pass valve
PAGE 105
TURBINE GOVERNING SYSTEM
10.1 INTRODUCTION
Power Station Turbines are constant speed machines. In our country these are
supposed to rotate always at a speed of 3000 revolution per minute (within a small
band of fluctuations on either side) to enable the coupled generator to produce
electricity at 50 Hz frequency.
The main purpose of governor is to maintain this desired speed of turbine
during fluctuations of load on the generator by varying steam Input to the
turbine.
The governing system in addition to ensuring the failing load-speed
characteristics of the turbine (i.e. a characteristic of failing output powerwith
raising shaftspeed 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 off 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.
10.2 METHODS OF GOVERNING
Basically there are three methods of varying the steamadmission which are
briefly explained below (Fig. 1.12).
10.2.1 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 flow to turbine is reduced and the power
developed by the turbine is regulated.
10.2.2 By-pass Governing
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 throwing
steam through this valve. When the load on the turbine exceeds this economic
load which can be developed by the unthrottled, fuliflow through the primary
valve, a secondary valve, is opened and throttled steamis supplied downstream,
bypassing the first 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 increased load.
10.2.3 Nozzle Control Governing
Here the first 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
numberofvalvesopenedisvariedaccordingtotheloadontheturbine.insuchcases,ifsa
y,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.
PAGE 106
10.3 SPEED SEN SING DEVICE
As mentioned, the job of governor is to vary the steam admission according to
variation of it is imperative that some form of s~ sensors (also ca#ed speed
governors) are required. Speed sensors sense the changes in magnitude of s~ from
the desired value and generate corresponding correcting ~s to control steam flow.
(Fig. 1 0.1 (a) shows a typical speed governing loop in block diagram form.
The system is in s~ equilibrium till the turbine torque T, is equal to the generator
torque T,. If there is a sudden fall in load demand, the excess torque developed by
turbine AT will accelerate the machine ad a rate.
α= ΔT/1
Where 1 is the machine inertia. As a machine s~ rises, the speed governor acting
through the control system will throttle the steam valves unite the turbine torque is
equal to the new power demand. (Fig. 1 0.1 (b) shows the response of turbine to a
sudden change in load and the resultant change in s~.
The percentage charbge in rated s~ corresponding to 100% change in load is
termed the "speed regulation" or the mdroopm of the turbine. It is nomially
around 4%. The regulations of the turbines operating in parallel Influence the load
sharing amongst them.
FIG. 10.1 (B)
PAGE 107
10.4 TYPES OF SPEED SENSORS 1 GOVERNORS
10.4.1 Mechanical
The earliest known automatic turbine speed governor was a mechanical
governor of centrifugal fly 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 different radius for each speed and produce a proportional displacement
of the sleeve linked to the fly balls through hinges (Fig. 10.2).
FIG. 10.2 FLYWEIGHT GOVERNOR BALANCES THE FORCE
OF SPRING ANDWEIGHTS, MOVES SPEEDER ROD
10.4.2 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 amplification, is fed to a
torque motor which in turn produces a proportional displacement.
10.4.3 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.
10.4.4 Hydro-Mechanical (Used in 21 0 MW BHEL (LMW) Turbine)
Here speed transducer is usually mechanical centrifugal type speed governor,
controlling through a combination of hy drautic 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.
PAGE 108
10.4.5 Electro Hydraulic (Used in 21 0 MW 500 MW BHEL (KWU) Turbines, 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 (flexibility,
dynamic quality, and simple representation of complicated functional
relationships) and hydraulic controls (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 fine 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-hydraulic 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
amplified.
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 flyball governor, which is a
function of the shaft speed, is used to control the throttle valve of the turbine
through hydraulic relay action or mechanical linkages or a combination of both.
The arrangement of the various devices varies for different types and makes of
the turbines but their basic functions are similar.
10.5 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 Low vacuum run back / unloading unit
g) Initial pressure regulator/ low initial pressure unloading unit (Gear).
10.6 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 called "Protection Oil / "Trip Oil" either directly or
through hydraulic relays. This "Protection Oil" is the same high pressure oil
butsuppliedthrough an EmergencyTripValve". This EmergencyTrip 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 shuits off 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.
PAGE 109
The protection oil being fed to the HP control valve servomotor piloit 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, LowVac. Pay off unit, 1
nitiai Pressure Regulator are hooked up into this control valve governing system
through hydraulic relays and linkages. Two different arrangements of control
system of HP control valve are shown in (Fig. 10.3 (a) and (b).
10.7 GOVERNING OF REHEAT TURBINES
In reheat turbines in cases of partial or full load thro woff even after the HP
control valves are fully closed, the entrained steam in the reheaters and hot reheat
line is more than enough to speed up the turbine above over speed limits. Hence
itis necessary to provide stop valves and intercoptor valves on hot reheat line
before IP turbine. While the stop valve is operated controlled similar to HP
control valve but at a higher speed range by a secondary or pre-emergency
governor as it is called. The valve remains full open at rated speed and starts
closing at about 3% over speed and is fully closed at about 5% over speed.
10.8 GOVERNING DEVICES
10.8.1 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
flyball 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 actuating relay is regulated by the relative
displacement 1 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.
10.8.2 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.
10.8.3 Load Limiting Gear (LLG)
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 off or draining the oil
as in the case of a system shown in (Fig. 10.3 (a) and by acting similar to a relief
valve, not allowing the control oil pressure to raise more than the preset value in a
system as shown in (Fig. 10.3 (b). It is to be noted that LLG provides only an
upper limit. A small motor is provided usually for remote operation of the gear.
PAGE 110
PAGE 111
PAGE 112
10.9 PROTECTION DEVICES
10.9.1 Emergency Trip Valve
The function of the valve has already been explained. (Fig. 10.4) shows a typical
trip valve in "Reset" position with provision for manual and oil injection tripping
and resetting. Remote tripping by Emergency Push Button also can be

incorporated to trip the trip valve position through a solenoid.
10.9.2 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 spring. There are two sets
of contacts in series. One is operated by a Wattmetric relay and the other by a
relay under steam pressure in a selected range of the turbine. For example, the
contact operated by steam pressure may be set to remain closed over the range
60% to 1 00% load and that operated by the load at Oto 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-energies and open the valve when the Steam pressure drops and
the contact opens.
10.9.3 Acceleration Sensing Device
To cope with the rapid rise in speed that would occur in the event of a sudden
loss of load, san acceleration sensitive governor is fitted. This causes the rapid
closure of HP throttle and IP interceptor valves and when the acceleration of
theturbine cases the speedwould have come down generally to such avaluethatthe
main governor will keep these valves closed.
If for any reason the speed should continue to rise the over sp;eed 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
outer 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
valves. (Fig. 10.5)
10.9.4 Pre-Emergency Governor
The IP control valves / Interceptor valves independently or along with the HP
control valves are operatged either by another centrifugal governor or the same
main speed governor by an acceleration sensing differentiator and pilot valve. The
operation is similar to that of HP control valve governing. The interceptor 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 final speed rise due to time delay in relay operation and the effect 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.
PAGE 113
PAGE 114
10.9.5 Over Speed Governor 1 Emergency Governor

ln the un likely event of speed increasing to lll% to ll2% emergency or over speed
governors are provided to trip the machine. The emergency governor is normally
mounted on the front end of HP rotor. It consists of two strikers for reliability.
Centre of gravity of the striker is away from the centre line of rotation and they are
held in place by springs. As soon as the speed rises to lll% -112%of the nominal,
centrifugal forceon the strikers overcomes force of the springs and the strikers fly
out: once the strikers begin to move out, distance between the centre of gravity of
the strikers and centre line of rotation increases, causing further increase in
centrifugal force. Thus strikers, once dislodged from stable position would
continue to move out till checked by the stop of the body. One or more of the
strikers flying out will hit trip levers placed close the the tip which on being hit
will instantaneously trip emergency trip valve causing the complete shut off of all
steam input to the machine (both HP and I P).
10.9.6 Testing of Strikers by Oil Injection
It is necessary to test these strikers for their free movement periodically. This is
done by oil injection, without actually raising the speed of the machine. Actual
over speed test can be done in some turbines during start up or shutting down by
tripping the machine. Provisions are also made in some turbines to test during
operation when the Emergency trip valve is kept gagged in "Reset" position or the
over speed trip level made out of action during the test period. A tell tale
indication is normally provided to show that the striker has flown out.
10.9.7 Low Vacuum Unloading Gear
In addition to normal control of the turbine a Low Vacuum unloading gear may
also be provided. The purpose is to gradually close the turbine CVs when the
pressure in condenser rises above a preset value. This is achieved by different
arrangements. The displacement of a bellow connected to the condenser vacuum
space is utilised to reduce the control oil pressure directly or by changing the
position of pilot valve thus reducing the control valve opening or closing a contact
which will undown the LIG motor.
If required, a provision is made on the device by means of which automatic
reloading of the turbine with restoration of condenser vacuum is lirevented and
reloading will be manual. The stroke of the unloading gear is so limited that ft can
only close the valves down to no load position. This is to prevent the machine
from motoring (Fig. 10.6).
PAGE 115
PAGE 116
10.9.8 Initial Pressure Regulator (IPR)
The device is similar to low vacuum unloading gear. If the throttle pressure
should fali to more than 10% below normal, the device comes into operation and
starts closing the CVs until a balance is reached. It is provided with a stop to
avoid motoring and also equipped with a cutout device to block the regulator
completely to permit starting with lower boiler pressure. Reloading is automatic

with restoration of throttle pressure. If required it is provided with a manual
resetting device to prevent automatic reloading of the machine.
10.9.9 On Load Testing Device
The risk of serious damage to a large turbine due to sticking of one of the steam
valve in the event of sudden loss of load is so great that provision is normally
made for testing at suitable intervals of time, the freeness of movement of each
valve steam while the turbine is running on load. In general, this is done by a
device which releases the power oil from under the servomotor / relay piston of
the valve being tested. Provision is made such that only one set of valve can be
tested at a time with machine load limited to the capability of the other set.
10.10 GOVERNING & PROTECTION SYSTEM OF 210 MW(LMW) TURBINE
10.10.1 Introduction
High response hydro-mechanical governing system has been for the steam turbine
to maintain the speed at the desired set points during startup and normal operation.
It also serves to prevent undesired overspeeds following sudden loss of export
load. The control action is of the proportional type with a steady state overall
speed regulation (i.e. proportional band) of 4 ± 1 %. This proportional band is
necessary in order to realise:
a) Stable speed control in isolated operation of the set: and
b) the desired degree of load distribution between sets running in parallel.
All the operations of starting and loading of the set can be performed by
manually operating the speeder gear hand wheel located at front standard or by
operating speeder gear motor remotely from unit control panel.
10.10.2 Special Features
a) In the event of generator breaker opening, following a full load loss, governing
system prevents the over speeding of the set to a dangerous level and quickly
stabilises the set on house load or on no load. This feature enables the quick
reloading in case of surplus loss of export load. This is achieved by electrohydraulic
transducer which closes the control valves when generator circuitbreaker
opens. However, the electro hydraulic transducer receives the signal
only for two seconds.
b) The governing systemenvisages anticipatory over speed control gear termed as

"Differentiator". The differentiator causes anticipatory closure of the turbine
control valves depending on the magnitude of the acceleration being
experienced by the turbine. This action prevents the transient speed rise to
dangerously high levels.
c) Transient speed rise is anticipated to be not more than 7 to 8% over the normal
speed, even in case of total loss of export load.
d) Speed governor can control speed in the range of approx. 300- 345O rpm
when set is not synchronised.
e) Load limiter has been foreseen to avoid accidental overloading of the set. The
set point of load limiter can be chosen over entire range from no load to full
load.
f) Governing gear operates on constant oil pressure principle.
g) Lnitial steam pressure unloading gear (ISPUG) has been foreseen to unload the
set in case initial steam pressure drops by more than 1 0% of the rated value.
PAGE 117
10.10.3 BRIEF DESCRIPTION OF GOVERNING REGULATION SYSTEM
10.10.3.1The governing or regulation process is achieved by a combination of
mechanical and / or hydraulic signals causing interaction of elements listed
below:
SI.NO. Description Tag No.
a) Speed governor 01
b) Follow-pilot valve 02
c) Summation-pilot valve 03
d) I ntermediate-pilot valve 04
e) Control valves servomotor 05
f) Load 1 speed control pilot valve 06
g) Load Limiter 07
h) Differentiator (Anticipatory gear) 08
i) Electro-hydraulic transducer (E.H.T) 09
j) Speedergear 10
k) Initial steam pressure unloading gear (ISPUG) 11
l) Lever 12
10.10.3.2 The block diagram of the regulation process is given in (Fig. 10.7). The salient
features are explained below:
Governing 1 Regulation Process (Fig. 10.7) & (10.8)
a) Any difference between the power generated by the turbine and the load on
it, would cause change in the speed of the set. This change is sensed by speed
governor (01). The governor sleeve moves proportional to speed change.
b) The pilot spool of follow-pilot valve (02) follows the governor sleeve. This
movement is caused hydraulically and there is no mechanical linkage between
the governor sleeve and the pilot spool.
c) The follow pilot spool actuates the summation pilot valve(O3)through lever
(12).The summation pilot valve converts the mechanical signal into hydraulic
signal which actuates the intermediate pilot valve(O4). The intermediate pilot
valve also receives hydraulic signals from:
i) Differentiator (08)
ii) Electro-hydraulic transducer (09)
iii) Protection system
d) The intermediate pilot valve amplifies the hydraulic impulses.
e) The amplified hydraulic signal from intermediate pilot valve actuates the
control valves servomotor (05).
f) The control valves servomotor actuates the control valves of HPT and iPT
through rack, pinion, cams and other linkages.
10.10.3.3 Operation of Differentiator (Anticipatory Gear)
The purpose of this device is to prevent transient speed rise to dangerously high
level due to sudden rejection of a major chunk of load. Ditferentiator receives
hydraulic impulse from summation pilot valve and it senses the acceleration of
turbine. The differentiator cuts in only if the acceleration of the set is equal to or
more than the value corresponding to load dump of more than 50% of the rated
load.
The cutting in of the differentiator results in anticipatory closure of control valves
through intermediate pilot valve (04) and control valves servomotor (05).
PAGE 118
10.10.3.4 Operation of Electro-Hydraulic Transducer
Electro-hydraulic transducer cuts in, when electrical signal due to generator circuit
breaker opening is given to energise the operating coil of the transducer. This
would lead to anticipatory closure of control valves. The electrical signal tothe
electro-hydraulic transducer is applied onlyfortwo seconds so thatthis anticipatory
action exists onlyfortwo seconds. This has been done with the objective to
enablethe normal governing system to bring the set to no load position and not to
shut down the set due to dangerous overspeed.
10.10.3.5 Operation of Load Limiter
The load-limiter physically checks the movement of summation pilot spool in load
increase direction. As soon as the summation pilot spool presses the limiter rod,
an annunciation signal "Reduce Load" would flash in unit control panel. A
continuous operation of set on load at which load limiter is set, is not
recommended.
10.10.3.6 Operation of Initial SteamPressure Unloading Gear
Initial steam pressure unloading gear (ISPUG) starts unloading the set in case
steam pressure ahead of emergency stop valves fails below 90% + 2% of the rated
valve i.e. below 1 17 + 2 ata. The actuation of, ISPUG causes a pressure drop in
secondary sensitive oil line and thus closing the control valves. ISPUG would
completely unload the set if initial steam pressure falls to 91 ata and maintains the
set at no load condition. In between 1 1 7 + 2 ata and 91 ata unloading is
proportional to pressure drop, In case steam pressure is restored, it reloads the set.
10.10.4 BRIEF DESCRIPTION OF PROTECTION SYSTEM
10.10.4.1 Protection system functions similarto governing system by a combination of
mechanical and hydraulic signals on various elements described below:
SI. No. Description Tag No.
a) Emergency governor 21,
b) Emergencyh governor levers 22
c) Emergency governor indicators 23
d) Emergency governor testing cock 24
e) Emergency governor pilot valve 25
f) Emergency stop valve servomotor 26
g) Interceptor valve servomotor 27
h) Turbine shut down switch 28
10.10.4.2 Protection systemoperates and trips the set (complete closure of emergency
stop valves, interceptor valves and control valves) in the unlikely event of the
following hazards.
a. Speed rise upto 1 1 1 to 1 1 2%
b. Speed rise upto 114 to 11 5%
c. Thrust pad wear beyond impermissible value
d. Vacuum below 540 mm Hgcol.
e. Lube oil pressure below 0.3 atg. Main steam temperature low.
f. H.P. heater level extra high.
PAGE 121
10.10.4.3 Manual tripping of the set may be done by pressing the knob of shut down
switch.
10.10.4.4 Automatic closure of emergency stop valves occurs,d control oil pressure
drops below 10 atg.
10.10.4.5 Automatic closufre of interceptor valves occurs, if control oil drops below 5
atg.
10.10.4.6 Protection Against Overspeeding By 11% to 12% Above Nominal
Speed
a) Emergency governor strikers, which are eccentric to the axis of rotation,
flyout against spring force at a speed 1 1 % to 12% more than rated speed.
b) Stikers strike one end of the emergency governor levers. The other end of
lever presses impulse pilot spools downwards.
c) The impulse pilot spool converts the mechanical signal into hydraulic
signal and actuates the emergency governor pilot valve to trip the set.
The emergency governor pilot valve receives hydraulic signal from
follow pilot valve when the speed of the set rises by 14% to 15% above rated
speed. The emergency governor pilot valve receives hydraulic impulse from
the turbine shut down switch also. Emergency governor pilot valve, in turn,
actuates to close the servomotors for the emergency stop valves, interceptor
valves and control valves.
10.10.4.7 Protection Against Over-Speeding by 14% to 15% Above Nominal
Speed
a) In case protection system for 1 1 % to 12% speed rise fails to trip the set,
speed may go even higher to dangerous vlalves. For this purpose, back up
protection to trip the setata speed l4%tolS%above nominal is provided.
b) At speed 14% to 15% above rated, follow pilot spool moves towards
extreme right position and gives hydraulic signal to emergency governor
pilot valve (25).
10.10.4.8 Manual / Automatic Tripping By Turbine Shut Down Switch (28)
By pressing the knob or by energizing the solenoid, a hydraulic impulse to
emergency governor pilot valve is transferred. EGP valves, in turn, actuates to
close the servomotors of emergency stop valves, interceptor valves and control
valves.
10.11 210 MW / 500 MW (KWU) TURBINE GOVERNING SYSTEM (FIG.
10.9)
10.11.1 Introduction
The speed of turbine generator set can be controlled either by hydraulic governing
system or by electro hydraulic governing system. Changeover fromone governing
system to the other is possible during operation. When electro-hydraulic
governing is controlling the speed of the set, hydraulic speed governing acts as
back up and comes into operation automatically in case the former fails.
10.11.2 HYDRAULIC SPEED CONTROL
On the shaft of main oil pump, the "Hydraulic Speed Transmitter" has been
provided, which provides primary oil pressure. The change in absolute pressure
can be taken as proportional to small changes in speed (within limits of steady
state characteristics). This primary oil pressure acts on diaphragm of "Hydraulic
speed governor" against the force of speed setting spring, which is compressed by
speed changer. Travel of diaphragm is limited by start up and load limiting
device. The movement of diaphragm is transmitted by link mechanism to
"Auxilliary Follow up Pistons". The piston of "Auxilliary Follow up Pistons" is

held in balance by a spring against oil pressure.
PAGE 123
The oil is essentially trip oil fed from trip circuit and drained from a port formed
between the piston and the sleeve. Depending upon Port opening, oil pressure gets
stabilised corresponding to initial displacement of the piston and initial spring
tension. The necessary auxilliary oil pressure provides asignal to "Hydraulic
amplifier" through its pilot.
The piston of the hydraulic amplifier assumes a position corresponding to
secondary auxilliary oil pressure and actuates the sleeve of follow up pistons,
through a linkage system. A feed back system has been foreseen for quickly
stabilising the position of the pilot valve and the piston of "Hydraulic Amplifier".
With a view to avoiding stricking of pilot spool and increase sensitivity, pilot
spool is kept rotating due to reaction of oil leakage through tangential holes by
means of control oil.
Asecondary oil pressure corresponding to the position of the sleeve and related
spring tensions is built up in the "Follow-up Pistons" of thej'Hydraulic Amplifier"
in a similar fashion to "Auxilliary Follow-u Pistons'. Any change in the position
of,Iink results in proportional change of secondary oil pressure in the "Follow-up-
Pistons" of "Hydraulic Amplifier". The secondary oil circuit is also fed oil from
trip oil circuit through reducing valves.
The varying secondary oil pressure'in the "Follow-up Pistons"..' of "Hydraulic
Amplifier: operates the control valves.
10.11.3 Electro-HydraulicControl
(Fig.10.10) is a typical principle diagram of Electro-Hydraulic Governing. The
turbine speed control loop employs electronic means of speed measurement. This
provides a ,faster,. speed of response than the mechanical method.
The unit power output control present in the scheme deals with the non linearities
of the Governor illustrated in (Fig. 1 0. 1 1). The, desired value setting of power
controllers forms the means of establishing the generated output at a particular
frequency value. Its operation must of course be relatively slower than that of the
governor control loop in@ order that the latter may be effective in dealing with
emergency conditions.
With the ability to apply an adjustab!e load / frequency characteristic to each unit
of a part of the grid system it is possible to vary the overall response of the units to
frequency change and also vary the distribution of load changes thus involved
between the units.
The turbine speed is measured digitally by an Electrical speed transducer mounted
at the HP end of turbine rotor. An electrical controller consisting of electrohydraulic
converter and a moving coil system link electrical and hydraulic parts of
governing system. A control sleeve is coupled to the moving coil (position of
which is controlled by electric controller)., The control sleeve determines the
position of pilot ,valve and this determines the secondary oil pressure th 11 rough
"Follow-up-Pistons".
10.11.4 Changeover from Hydraulic to Electro-Hydrautic Control
As earlier pointed out, changeover from one control system to the other one is
possible during normal operation of turbine, since the two systemare brought into
parallel connection after associated follow up pistons which represent a minimum
value selection, meaning that the system with the lower reference value is always
the controlling one.
If the turbine is to be run under hydraulic control,, the reference speed set point of
the electrical controller is t "Max. Speed", which prevents the efectro-hydrauiic
system from coming into action. When bringing in, the efectro-hydraulic control
system, the reference speed set point of the electrical controller should be reduced
slowly until the secondary oil pressure drops slightly. When this occurs, the
electrohydraulic converter has taken over. The speed changer of the hydraulic
speed governor is then set at maximum speed. The electro-hydrautic converter is
now fully effective and can operate over the entire output range. The hydraulic
speed governor also acts as a speed limiter in the event of electrical controller
developing a fault. In this case, operation of turbine may immediately be
continued by means of hydraulic speed governor.
PAGE 124
10.11.5 Changeover fromElectro Hydraulic to Hydraulic Control

PAGE 125
FIG. 10.11 LOAD LOOP CHARACTERISTICS OF GOVERNOR

PAGE 126
10.11.5 Changeover from Electro Hydraulic to Hydraulic Control
This changeover is done in the reverse sequence mentioned above. First, speed
change is actuated in the 'decrease" direction until secondary oil pressure drops
slightly. This is an indication that hydraulic speed governor has taken over the
control. Then reference speed limit of electric controller is set at ..maximum".
Now the hydraulic speed governor is fully effective, and can operate over the
entire load range.
The secondary oil pressure is transmitted to the actuators of the HP and IP
control and controls their opening.
10.11.6 Advantages
The integrated electronic and hydraulic control systems offer significant
advantages. These are given below:
a) Exact load frequency drop with high sensitivity.
b) Reliable operation in case of isolated power grids.
c) Dependable control during load rejection.
d) Low transient and low steady state speed deviations under all operational
conditions.
e) Excellent operational reliability and dependability.
Safe operation of the Turbo set in conjunction with the turbine stress
evaluation (TSE).
The other features are:
i) A sequence timing device which adjusts the relative opening of HP and I P
control valves and thus avoids heating of HP exhaust at reduced loads.
ii) Two load shedding relays which act for anticipatory closure of control
valves in the even to flarge load dump.
iii) An extraction valve relay which actuates NRVs in extraction lines as
demanded by load situation.
10.11.7 Protection System
The protection system has been designed to protect the turboset fromany mishaps
by closing the fast acting stop and control valves and thus tripping the set. The
hydraulic trips are:
a) Overspeed trips 1 and 2
b) Low vacuum trip
c) Thrust bearing trip
d) Local manual trip
The Electrical trips are:
i) Manual remote trip
ii) Low vacuum trip
iii) Low lube oil trip
iv) Fire Protection trip
v) Trips due to other causes e.g. generator protection.
The electrical trips act through remote trip solenoids for tripping the set.
All the protections act for closing of EVSS, IVs, HPCVs and IPCVs through
Main trip valves.
10.11.8 Automatic Turbine Tester
The turbine operates uninterruptedly for long slots of time and none of the
protection device may be operating for years at a stretch. During this healthy
period of turbine operation, it is necessary to check the availability and efficiency
of the protection devices. The scheme envisages an automatic turbine tester which
carries out the functional tests of various devices even when turbine is carrying
load without
PAGE 127
jeopardizing the safety of the turbine.
Automatic Turbine Tester consists Of two sub groups, one sub group is for safety
devices e.g. Remote trip device, overspeed trip, thrust bearing trip and hydraulic
low vacuum trip. The other sub-group is for in testing main stop valves, main
control valves, reheat stop valves and reheat control valves. Testing of ic valves is
done at reduced load.
10.11.9 L.P. Bypass System
An additional control to dump the excess steam of the reheater in the event of
violent load excurison is desirable. This is achieved by incorporating a 1 00% LP
Bypass System. The LP System when operating in conjunction with HP Bypass
keeps in matching of steam parameter during start-up. The control of L.P. Bypass
are integrated with EHG controls. It dumps the steam from the reheater to the
condenser in case the reheater pressure is more than the desired value being
demanded by the load considerations.
10.11.10 Special Features
i. The system is equipped with the electro hydraulic control of gland steam
pressure which maintains at all gland bleed points a uniform pressure as
determined by preset value.
ii. Damping Devices are envisaged in the control oil circuit (secondary oil) to
damp out any pulsation which may ocur in the flow to the control valves.
Thus it ensure the smooth operation of the system.
iii. The system is provided On-Load testing facility for all extraction fine nonreturn
valve.
iv. The emergency stop valve HP control valve, Interceptor valve IP control
valve and LP Bypass stop;
valve and control valve are housed in their single combined casing'
v The pilot valves in the control circuits have rotational and oscillatory
motion.
Through rotation, minimum friction is created between pilot valve and sleeve.
Oscillation prevents seizing of pilot valve in the guides and other sliding surface.
vi LP Bypass cuts into operation when the water is charged and vacuum is
healthy.
PAGE 131
AUTOMATIC TURBINE RUN UP SYSTEM
11.1 INTRODUCTION
With increase in unit capacity associated with increased capital costs and the steep
rise in fuel cost, it necessary to maintain the availability of thermal power sets at
as high a level as possible. To achieve th it is, essential to reduce the extent of
damage, to provide facility for tracking down the faults and th causes by m good
an over view of the process, and shortest possible start up and shut downs.
For start up, acquisition and analysis of a wide variety of information pertaining to
various paramete of steam turbine demand, quick decisions and numerous
operations from the operating personnel. orderto reducethe arduoustask of
monitoring various parameters and effect sequential start up, minimi the possible
human errors and to achieve start up in minimum time in optimum way Automatic
Turbi Run up System (A.T.R.S.) is introduced.
11.2 PHILOSOPHY
The ARTS is based on functional group philosophy i.e. the main plant is divided
into clearly defin sections called functional groups such as oil system, vacuum
system, turbine system. (Fig. 1 1.1). Ea functional group is organised and arranged
in sub group control (SGC), sub loop control (SLC) and contr interface (Cl). Each
functional group continues to function automatically all the time demanding enab
criteria based on process requirements and from neighbouring functional groups if
required. In t absence of desired criteria, the system will act in such a manner as
to ensure the safety of the ma equipment.
PAGE 132
11.3 FUNCTION OF THE SUB-GROUP CONTROL (OIL)
The main task of the sub-group control "Oil" during a start up programme are
(a) establishing lubricating oil, control oil, and jacking oil supply
(b) putting the turbine on barring gear
(c) taking off the jacking oil pump when-appropriate turbine speed is
achieved
(d) taking off the AOP when turbine main oil pump has taken over
(e) leaving the various sub loop control of oil systems in automatic regime so
that the logics built up in this sub-loop control will take care of the
requirement of the individual systems.
The sub loop control of any system essentially serves to provide an auto
start / stop command when certain preset conditions are fulfilled. The feature
can be included or excluded by manual push botton commond or by sub-group
control. During a shut down programme this sub group control essentially
serves to bring the turbine to a standstill and switch off the oil system.
11.4 FUNCTION OF SGC TURBINE
The main tasks of the sub group control (SGC) "turbine" during a start up programme are
(a) Warming of the admission pipe lines and stop and control valves (carried
out by the warm up controller in conjunction with the turbine stress
evaluator)
(b) Warming up of the turbine at 64ORPM (carried out by electro hydraulic
speed controller, in conjunction with the turbine stress evaluation)
(c) Acceleration of the turbine to synchronous speed carried out by the
turbine stress evaluator,
(d) Synchronise the machine to the grid (carried out by the auto synchroniser)
and
(e) block loading of the machine.
In addition, the sub-group control also switches on the sub-loop control
drains during the course of its programme forWarming up of casing pipe
lines and other valve bodies.
During a shut down programme the sub-group control "Turbine" essentially
does the task of
(a) re-loading the machine and switching on sub-loop control drains
(b) Setting the load controller to its minimum value and lowering the speed
reference valve of the speed controller
(c) Tripping of the machine.
FIG. 11.2 OPERATOR INTERFACE TO SUBGROUP

PAGE 133
11.5 FUNCTION OF SGC CONDENSATE AND EVALUATION
The sub-group control for condensate and evacuation system accomplised its task
which comprises of keeping at least one of the two CEPs in operation / evacuating
the condensate gases from the system, maintaining the desired level of condenser
pressure when turbine in operation and breaking the vacuumas and when required
byMechanical process.
The combination of the three sub-group control will provide a turbine start
up in the ollowing sequence :
1) Prepare turbine for start-up
2) Start oil supply system and turbine gear
3) Start up condensing plant
4) Start seal steam system
5) Warm up main steam line
6) Warm up turbine
7) Accelerate turbine to rated speed
8) Synchronize and block generator

FIG. 11.3 HIERARCHY OF CONTROL
11.6 SHUT-DOWN OPERATION
The shut-down is carried out in the following sequences :
f. Reduce turbine load
g. Ensure bypass operation
h. Reduce turbine load to less than 5 % of rated capacity
i. Switch off generator
j. Trip turbine and check if AOP is in operation
PAGE 134
k. Shut down steam generator
l. Close Main Steam Valve of Boiler
m. Depressurise main steam line
n. Close drains of main steam line
o. Shut down condensing plant
p. Start turning gear
11.7 SUB-GROUP CONTROL (S.G.C.) (FIG. 11.4)
A sub group control executes commands, to bring the equipment upto a particular
defined state and contains the start up and shutdown programme of there spective
group S.G.C. issues commands efther to control interface level on switches on
S.L.C. Desired number of criteria act as preconditions before the S.G.C. can take
off to execute its defined programme. The programme comprises of steps. For
each step there is provision form on during time and waiting time. Waiting time
implies that the subsequent step could not be executed unless the specified time
elapsed. The time between command signal and appearance of check back signal
is known as monitoring time and when it is executed alarm is initiated and the
programme is not proceeding further. In addition execution of any step is also
permitted only if the conditions specified for that particular step are completely
fulfilled. By-pass conditions are included to enable switching on after S.G.C. at
any stage after completing certain task manually d so desired.
FIG. 11.4 SUBGROUP CONTROL STRUCTURE
11.8 MODES OF OPERATION
ATRS can be operated in the following three modes:
a) Automatic : In this mode all the specified operations are
carried out in appropriate sequence automatically.
PAGE 135
b) Step Mode : This mode has been envisaged to allow the operator to by
pass anychte had the operator finds that a criteria is not being obtained
because of the, malfunctioning of any instrument or transducer.
c) Operator Guide Mode : in this mode the ATRS does not issue any
commands. The command outputs are blocked and have to be issued
only by hand. This mode allows correct fulfilment of the criteria and
satisfactory progress of the sub-group control systemto be tested during
commissioning and at other times. This mode can also be used as a
training aid for the operators.
11.9 CONTROL INTERFACE (Cl)
The control interface module forms the link between the individual commands and
the power plant (Fig. 11.5 & 11.6). Each remote controlled drive has a control
interface module. The module consists of command section, monitoring section,
power supply and alarm section. The command section proves the control
actuation signals to the interposing relays in the switch gear. Soienoid valves can
be actuated directly up to certain capacity (36 W). The, monitoring section
normally checks the command functions namely the position of the drive check
back signals, protection logic and FGC.
The control interface module type AS 1 1 is used mainly for ON /OFF motor
drives. AS 12 for motor operated regulating valves, and AS 13 for solenoids. The
Cl modules monitors status discrepancies, running time between command output
and check back actuation of the torque switches, check back for non contincidence
+ 24 V supply voltage for module control circuit MCB in the switch gear and
blocking of command by protective logic. Protection commands are given
priority.
FIG. 11.5 DRIVE CHARGEOVER AUTOMATIC

PAGE 136
11.10 SUB LOOP CONTROL (SLC)
When SLC is switched ON, it actuates the connected mechanical equipment to the
required operating condition as per the process condition. No sequence logic is
involved. SLC can be switched ON / OFF manually or through SGC.
11.11 CONTROLS AND DISPLAYS
S.G.C. Switching ON/OFF can bedonefrom desktile (Fig. 11.2). Display of step
and criteriaare available at the control desk. PB-2 is for switching ON and OFF.
The programme can be executed manually at the Cl level when the SGC is OFF.
PB-1 is for start up and 3 for shut down in auto mode. Rapid flickering (8 Hz)
light in lamp 4 or 8 indicates that programme is running towards desired status,
"Steady" on completion of programme and also flashing light indicates that the
programme is in the desired mode but a programme fault has appeared.
FIG.11.6
PAGE 137
FIRE RESISTANT FLUID
12.1 INTRODUCTION
Mineral lubricating oils used in hydraulic systems situated adjacent to equipments
maintained at high temperatures have always constituted a considerable fire risk.
Fires have in fact occurred in the past in power stations, when oils and hydraulic
fluid leaking on to hot surfaces, have ignited. Even at ambient temperatures, fires
have occassionally resulted from such leaks owing to sparking from commutators
of adjacent electric motors. Since 1957, mineral oils used for hydraulic purposes,
have generally been replaced with fire resisting fluids. Typical power station
hydraulic system applications include circulating water valve operation, boiler
controls, boiler damper and soot blowing equipment and window operating gear.
Fire-resisting lubricating oils are now being introduced for use in air compressors
and also, for use in turbine control gearwhere the turbine lubrication system is
quite separate from the control system. Fire resistant fluid are used in the
governor control system (32 bar system) of 500 MW steam turbine of KWU
Design.
12.2 SPECIFICATION
This specification is valid for fire resistant fluids, hereafter referred to as FR F,
used as electro hydraulic control fluids in turbine governor systems.
12.2.1 Chemical Composition
Triaryphosphate esters are reaction products of phosphorous oxychloride and
phenol and phenol derivates, which are obtained either from natural raw materials
(Natural FR F) or synthetic raw materials ('synthetic'FRF). The final product must
be free of ortho-cresol-compounds. In order to improve certain properties, e.g.
corrosion protection, oxidation stability, additives may be admixed provided that
they have no negative effects on the materials of the FRF-system of its operation.
12.2.2 Requirements
a) CorrosionProtection:The FRF shall not cause corrosion to the following
materials: steel, copper, copper alloys, zinc, tin, aluminium. The FRF must
grant sufficient corrosion protection to the materials used in the FRF system.
The FRF will be continuously regenerated with a fuller's earth filtration
system.
The FRF must not cause any erosion or corrosion on the edges of the control
elements.
b) Viscosity Range : FRF of viscosity class ISO VG 32 and ISO VG 46 shall be
used
c) Shear Stability : The FRF must be shear-stable. It should not contain any
Vi-improver. (Viscosity index improvcfr).
d) FireResistance: FRF leaking from the system must not ignite or burn in
contact with hot surfaces (up to 550'c).
e) Thermal Stability: The FRF must be capable of with standing continuous
operating temperatures of 7500c without physical or chemical
degradation.
f) Compatability: The FRF must be miscible with traces of triaryphosphate
esters of another kind but of the same base ('natural'or'synthetic'). There
should be no deterioration of the FRF in the presence, ofsuch race quantities.
g) Physiological Consideration: The FRF must not represent a safety or health
hazard to the persons working with it providing that normal good industrial
hygience practices are following:
PAGE 138
12.2.3 Factors Affecting the Quality of Fire Resistant Fluids
During operation hydraulic fluide on the base of phosphate esters are undergoing
degradation in a more or less progressive manner. Degradation will be caused
mainly by OXIDATION AND HYDROLYSIS.
The loss of oxidation and hydraulic stability will be indicated by the
increase of the NEUTRALISATION NUMBER. Other indicators are :
- Increasing air release value
- Foaming and high from stability
- Increasing conductivity
a) Oxidation Stability : Oxidation stability will be affected by :
- High temperatures including local overheating
- Catalytic effect of dissolved metals
- High air content
b) Hydrolytic Stability : Hydrolytic Stability will be affected by :
- water content
- Presence of degradation products mainly of acidic nature which can
catalyse further hydrolysis.
c) Viscosity : The Viscosity can be altered by progressing oxidation or by

mixture of fluid and other non compatible liquids e.g, oil.
d) Auto-lgnition Temperature : The autoignition temp. will mainly be
affected by oil content in the control fluid.
e) Water content :Water content starts hydrolysis and must be avoided by all
means.
f) Neutralisation Number : Increasing neutralisation number indicates
oxidation and / or loss of hydraulic stability.
g) Air Release Properties : The air release properties are mainly affected by
materials non-compatible to the fluid among other oil is badly affecting the
air release properties. Air release properties must also be seen in
conjunction with the system.
h) Foaming : Factors affecting foaming can be :
- High air content
- Reduction of anti foam activities by filtering
- Contamination e.g. by oil.
i) Chlorine Content : Chlorine content starts acidic reaction. Chlorine finds
access if environmental conditions are not adequate. Also, cleaning liquids
can affect the fluid.
j) Purity : Purity can be affected by :
- Access of solid particles from external sources.
- Build-up of solid particles by degradation
k) Conductivity : Conductivity will be affected by :
- Degradation products
- Water
- Chloride
- Contamination from other sources
12.2.4 Fluid Testing Programme
a) Sampling Frequency : The effectiveness of the program is greatly
increased if a regular sampling interval is set up. Experience has shown the
following sampling frequency to be the most effective:
Turbine start up - Sample before and after start up
1st Month of operation - Weekly

1st Year of operation - Every month
2nd Year of operation - Every 2 months
3rd Year of operation - Every 4 months
Samples can be taken from the sampling value in the auxiliary filter system
Two separate samples are required due to the particle count testing.
PAGE 139
b) Test Limits :
Viscosity Minimum 200
Maximum 240
This is a test of the fluidity at 100 F and is important to pump life and system
response time. Experience has shown that fluid out of this range has probably been
contaminated with a mineral oil or fuel.
Mineral Oil Content 4% Maximum
Recordings of below 1% in this category are generally the results of hydrocarbon
extraction from pipe dopes, seals or packings contamination above 1% may
indicate contamination from an external source. A connection above 4% is
potentially harmful to the system due to the lowering of fire-resistance and
incompatibility with some materials of construction.
Water Content Maximum 0.15%
New Hydraulic fluid may contain as high as 0.10% moisture. A reading above
0.15% indicated that water is entering the system from an external source, such as
an intercooler. Corrective measures should be taken to remove the excess water
and to eliminate the source of the leak. High water content can lead to increased
pump wear and hydrolysis of FRF to form corrosive acids.
Neutralisation No. Maximum 0.50 MGKOH /G
An operational maximum of 0.30 MGKOH / G should be set on neutralisation
numbere with an understanding that 0.50 MGKOH / GM can be tolerated. Fullers
earth filtration may be used to control and reduce this value. A high neutralisation
number could increase valve erosion.
Chlorine Content Maximum 150PPM
A maximum of 150 PPM chlorine, by X-Ray emission method, can be tolerated in

operational systems. Higher chlorine values have been associated with servo-valve
erosion.
Particle Count Maximum Class 3 SAE A-6D
5 to 10 microns 24,000 particles / 100 ML.
10 to 25 microns 5,360 particles / 100 ML.
25 to 50 microns 780 particles / 100 ML.
50 to 100 microns 110 particles / 100 ML.
Over 100 microns 11 particles / 100 ML.
Fluid cleanliness, in terms of particle distribution, has been shown to be of
utmost importance when operation servo-valves.
Resistivity Minimum 5.0 x 109 OHM / CM
Restivity is a test of the fluid’s resistance to conduct electrical potentials and thus
protect the valves from electrical erosion.
12.2.5 Fluid Conditioning
It cannot be emphasised too strongly that the key to a long fluid life is to keep the
fluid clean and dry and to maintain a low level of acidity. This is normally
achieved in situ by using solids treatment and / or vacuum dehydration to remove
acid degradation products and water. The equipment should preferably be a fixed
part of the system, but portable units can be used to conditin the fluid on a batch
basis. The solids treatment system should be of the correct size for the volume of
fluid if the system a 1.5-3% w/w ratio of absorbant solids: fluid is usually
adequate where 5-10% of the fluid volume is circulated every hour. If the
treatment system is too small, it will obviously be diffcult to maintain the
necessary low levels of acidity. All solids treatment systems should contain a 0.5
pm (nominal) fine filter immediately downstream of the solids filter in order to
remove fine particles which might otherwise spread throughout the system.
Although fullers earth has been used successfully for many years to treat
natural or coal tar phosphates, some depositin problems have arisen when this type
of sold has been used in conjunction
PAGE 140
with synthetic phosphates based on alkylated phenols. The deposists have
invariably been associated with high fluid acidities and high carbonate levels in
the fullers earth. The high acid levels can result in the production of insoluble
polymeric phosphates and leads to the formation of soluble and insoluble calcium
and magenesium salts through interaction with the carbonate content of the fuller's
earth. Since the fullers' earth is a naturally occring product, it has a cariable
composition, and on occasion high carbonate levels cannot be avoided. The
problem can be virtually eliminated by using activated alumina, a synthetic
product of constant composition.
In the presence of acid, hydrolysis of the fluid is autocatalytic, so it is
important to keep the acidity level as low as possible. It is recommended that the
acidity is not allowed to increase by more than 0.1 mg KOH / g above the limit
on the fresh fluid specified by the turbine manufacturer. Usually this means a
maximum service acidity of 0.2 mg KOH / g. The absorbant solid cartridges
should be replaced when the limit is exceeded and the acidity is showing a steady
increase. Alternatively, the solid can be replaced at regular intervals (for example
every 6 months) assuming that the acidity is monitored between filter changes, so
the reason for abnormal values should be investigated as soon as possible.
Absorbant solid filters can also become clogged by small particles and the
filter cartridges should be changed if the pressure drop across the filter exceeds the
manufactures recommendations (normally about 2 bar).
Since the fullers earth or activated alumina will rapidly absorb moisture
when exposed to the atmosphere, the replacement elements should preferably be
supplied and stored in air-tight plastic bags. Immediately before use, the solids
should be dried at 110oc for at least 12 hours. As moisture is quickly reabsorbed, if
the dried solids are left at ambient temperature for morre one hour after drying, the
filter element should be cooled to 20-30oc in the drying oven and immediately
transferred to the filter. A wet solid will not only be less effective in removing
degradation products, but it may also release water into the fluid and thus promote
hydrolysis.
When the turbine is shut down and the fluid allowed to cool, condensation
may occur in the tank, with the resulting hydrolysis of the tester. For outage
periods of longer than 1 week it is recommended that if possible the fluid be
conditioned each week for a sufficient time to ensure at least one passof the fluid
charge through the absorbant solid and the tank exhauster be operated during this
period.
Samples of fluid should be checked for acidity and water content at
intervals of (say) two weeks in order to ensure that the recommended limits are not
exceeded. If it is not possible to circulate the fluid through tje absorbant solid,
samples should still be taken at similar intervals for analysis, and if the acidity
rises to 0.3-0.5 mg KOH / g, conditioning should be started as soon as possible in
order to reduce the acidity to below the recommended limits before turbine
operatin resumes. If the acidity exceed 0.6 mg KOH / g it may be difficult or even
impossible to recondition the fluid charge and it may have to be replaced.
In view of the possible formation of metal salts by chemical reaction
between acidic degradation products and the fullers' earth or, much less likely,
alumina, their presence should be monitored at regular intervals.
Some solids can remove certain additives, e.g. the antifoam, from the
fluids, in the event of unsatisfactory fluid performance users are advised to check
with the fluid sppliers as to whether the additive levels should be restored.
PAGE 141
COMPARISON OF 500 MW AND 200 / 210 MW TURBINES
(A) CONSTRUCTION 500 MW (KWU) 200 / 210 MW (KWU) 200 / 210 (LMW)
1. 3 cylinder reheat condensing
turbine
3 cylinder reheat condensing
turbine.
3 cylinder reheat
condensing
turbine.
2. Single flow HP turbine with 18
reaction stages
Single flow HP turbine with
25 reaction stages
Single flow HP turbine with
12 impulse stages
3. Double flow IP turbine with 14
reaction stages per flow
Double flow IP turbine with
20 reaction stages each flow
Single flow IP turbine with
11 impulse stages
4. Double flow LP turbine with 6
reaction stages each flow
Double flow LP turbine with
8 reaction stages each flow
Double flow LP turbine with
4 impulse Reaction stages
(45% Reaction in last stage)
each flow.
5. 4 Main stop and control valves
(combined)
2 Main stop and control
valves (combined)
2 Main stop valves(ESVs) &
4 control valves
6. 4 Reheat stop and control valves
(combined)
2 Reheat stop and control
(combined)
2 Interceptor valves and 4
control valves (CVs).
7. 2 Swing check NRVs in cold
reheat line
2 Swing check NRVs in cold
reheat line
2 Lift check NRVs in cold
reheat line.
8. 2 Bypass stop and control valves 2 Bypass stop and control
valves
2 Bypass stop and control
valves
500 MW (KWU) 200 MW (KWU) 200 MW (LMW)
9. Rated steam flow 1568 T / hr. 670 T/hr. 670 T/hr.
10. Circulating water 54,000 m3 / hr 28,570 M3/hr 27,000 M3/hr
11. Type of Governing Hydraulic Hydraulic Hydraulic
Electro-hydraulic Electro-hydraulic Electro-hydraulic
(throttle) (throttle) (throttle)
12. No. of bearings 4 4 5
(Turbine only)
13. Rated speed 3000 r.p.m. 3000 r.p.m. 3000 r.p.m.
14. Max. Speed notime 3090 r.p.m. 3090 r.p.m. 3030 r.p.m.
limitation (51.5 Hz) (51.5 Hz) (50.5 Hz)
15. Min. speed no time 2850 r.p.m. 2850 r.p.m. 2940 r.p.m.
limitation (47.5 Hz) (47.5 Hz) (49 Hz)
(B) * BHEL is considering to lower it to 2910 r.p.m. (48.5 Hz)
16. Permissible below
47.5 Hz and 51.5
Hz in life time (Total)
2 Hrs. 2 Hrs. BHEL is considering to
allow 5 minutes continuous
operation between 48 Hz
and 48.5 Hz not exceeding
3 hrs. in total life.
PAGE 142
17. Critical Speed r.p.m. 900, 1548, 1896
2700, 3858
1200, 1600, 1900 1585, 1881, 2015
18. Speed exclusion range at
operation without load
400-2850 r.p.m. 700-2850 r.p.m. 1100-2600 r.p.m.
19. Overspeed trip 3350 r.p.m. 3330 r.p.m. 3330 r.p.m.
20. Barring Gear Speed (r.p.m.) 240 / 210 (r.p.m.)
cut-in / cut-out
(Hydralic)
540 / 500
cut-in / cut-out
(Hydralic)
3.4 r.p.m. (motorised)
(C) STEAM PARAMETERS
21. Initial steam Pressure 170 Kg / cm2 147 Kg / cm2 130 Kg / cm2
(abs) (abs) (abs)
22. Initial steam temperature 537oc 535oc 535oc
23. Before HP 1st stage
pressure
151.8 Kg / cm2 132.6 Kg / cm2 91 Kg / cm2
(abs) (abs) after CURTIS WHEEL
(I.e. after regulating stage)
24. HP cylinder exhaust
pressure
45 Kg / cm2 39.2 Kg / cm2 27 Kg / cm2
(abs) (abs) (abs)
25. HP cylinder exhaust temp. 342.5oc 343oc 327oc
26. IP cylinder stop valve 40.5 Kg / cm2 34 Kg / cm2 35 Kg / cm2
intel pressure. (abs) (abs) (abs)
27. IP cylinder stop valve 537oc 535oc 535oc
intel temp.
28. Bleed Steam point
(stages of turbine)
1 Nos. -CRH
2 Nos. - IPT
1 Nos. Cross around
pipe between IPT
& LPT, 2 Nos. LPT
25,36,45,48,
50,52
9,12,15,18,21,23,25
29. Extraction valves 500 MW (KWU) 200 MW (KWU) 200 MW (LMW)
a. Extraction 1- No Valve 1 swing No Valve 1 swing No Valve 1 NRV
b. Extraction 2- check valve with
Aux. Actuator
check valve with
Aux. Actuator
(lift check type) with Aux.
actuator
c. Extraction 3- 1 swing check valve
with Aux.actuator
1 swing check
valve with Aux.
Actuator
1 NRV (lift check type)
with Aux. Actuator
d. Extraction 4,1- 2 swing check valves
with
Aux. Actuator
Extraction-4
1 swing check
valve with Aux.
Actuator
with Aux. Actuator
4,2
e. Extraction 5- 1 swing check valve
with
Aux.actuator
1 swing check
valve with Aux.
Actuator
with Aux. Actuator
f. Extraction 6- No valve No valve 2 NRVs (lift check type)
with Aux. Actuator
g. Extraction 7- 1 NRV (lift check type)
with Aux. Actuator
PAGE 143
30. a.Extraction 7 - 39 Kg / cm2
Pressure / temp. (abc) 377oc
b.Extraction 6 - 45 Kg / cm2 (abs) 39 Kg / cm2 (abs) 26 Kg / cm2 (abs)
Pressure / temp. 537oc 537oc 537oc
c.Extraction 5 - 19.5 Kg / cm2 (abs) 16.7 Kg / cm2 (abs) 12 Kg / cm2 (abs)
d.Extraction 4 - 7.57 Kg / cm2 (abs) 7.06 Kg / cm2 (abs) 6.5 Kg / cm2 (abs)
e.Extraction 3 - 2.76 Kg / cm2 (abs) 2.37 Kg / cm2 (abs) 2.8 Kg / cm2 (abs)
Pressure / temp. 197.8oc 200oc 252oc
f.Extraction 2- 1.42 Kg / cm2 (abs) 0.86 Kg / cm2 (abs) 1.3 Kg / cm2 (abs)
Pressure / temp. 197oc 138.8oc 172oc
g.Extraction 1- 0.286 Kg / cm2 (abs) 2.216 Kg / cm2 (abs) 0.3 Kg / cm2 (abs)
31. LP cylinder exhaust 0.884 Kg / cm2 (abs) 0.118 Kg / cm2 (abs) 0.09 Kg / cm2 (abs)
32. Low vacuum trip 0.31 Kg / cm2 (abs) 0.3 Kg / cm2 (abs) 0.3 Kg / cm2 (abs)
(Hyd. & Electical) (540 mm vac)
33. Bypass trip 0.61 Kg / cm2 (abs) 0.6 Kg / cm2 (abs) 0.41 Kg / cm2 (abs)
(450 mm vac.)
Posted 8th April 2016 by powerplanta2

Types and Working Principles Steam Turbines

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TYPES AND WORKING PRINCIPLES STEAM TURBINES

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