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TURBINE AND GENERATOR SYSTEM

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Title: TURBINE AND GENERATOR SYSTEM


1
A PRESENTATION ON 660MW TURBO-GENERATOR ,ITS
AUXILIARIES AND ASSOCIATED SYSTEMS
By Ashvani Shukla CI BGR energy
2
STEAM TURBINE K-660-247
3
GENERAL INFORMATION
  • TG DECK IS VIS SUPPORTED AND HAS 26 CONCRETE
    COLUMNS (T1 T26).
  • TG HALL IS CONSTITUTED OF 3 MAINS ROWS OF COLUMNS
    A,B ,C ROW AND TWO BAYS AB BAY AND BC BAY.
    THE WIDTH OF AB BAY IS 36m AND BC BAY IS 12m
  • CONDENSER TUBE BANKS (CW PATH) HAS AN INCLINATION
    OF 40.
  • THERE ARE TWO MAIN EOT CRANES FOR TG HALL.EACH
    EOT CRANE IS HAVING A CAPACITY OF 200t FOR MAIN
    HOIST AND 20t FOR AUXILIARY HOIST. 35.5m IS THE
    MAXIMUM VERTCAL DISTANCE A HOIST CAN
    TRAVEL.TANDEM OPERATION OF TWO EOT CRANES ARE
    ALLOWED.

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9
RATED CONDITIONS
  • LOAD 660MW
  • BEFORE HP STOP VALVE
  • STEAM PRESSURE 247KSC
  • STEAM TEMPERATURE 5370C
  • STEAM FLOW 2023.75T/HR
  • AFTER HPC
  • STEAM PRESSURE 48KSC
  • STEAM PRESSURE 298.710C
  • BEFORE IP STOP VALVE
  • STEAM PRESSURE 43.2KSC
  • STEAM TEMPERATURE 5650C
  • STEAM FLOW TO REHEATER 1681.12T/HR.
  • DESIGN CONDENSER PRESSURE 0.105KSC (abs.)
  • COOLING WATER FLOW 64000M3/HR

10
STEAM TURBINE
  • Generator rated speed 3000 rpm
  • Generator manufacturer - Electrosila
  • No. of bleedings 8
  • Length of the turbine 36.362 m
  • No. of stages
  • HPT 17
  • IPT 11x2
  • LPT-1 5x2
  • LPT-2 5x2
  • Total 59

11
STEAM TURBINE
  • Parameters
  • Pr. Before HPC SV 247.0 Ksc
  • Temp. before HPC SV 537.0 0C
  • Steam flow 2023.75 TPH
  • Pr. After HPC 48.0 Ksc
  • Temp. after HPC 298.71 0C
  • Pr. Before IP SV 43.2 Ksc
  • Temp. before IP SV 565.0 0C
  • Steam flow to reheat 1681.12 TPH
  • Design Cond pr. 0.105 Ksc
  • CW flow 64000 TPH
  • Final FW Temp. 286.35 0C

12
STEAM TURBINE
  • Turbine Governing system
  • Mode of Governing Nozzle
  • Type E/H
  • Control fluid Firequel-L make
  • Supresta-USA
  • Normal Operating Pr. 50 Ksc
  • Capacity 600 lpm
  • Fluid pump motor rating 200 KW
  • Filter material Ultipor
  • Mesh size 25 µ

13
STEAM TURBINE
  • Lube oil system
  • Lube oil Tn-22C Russia Mobil DTE Oil light
    Teresso 32
  • In accordance with ISO VG 32
  • Absolute viscosity 16.7 Centipoise
  • Kinematic viscosity -32 Centistokes
  • Specific gravity 0.89
  • Flash point 180 0C
  • Fire point 240 0C
  • Oil requirement per bearing
  • N1 200 lpm
  • N2 200 lpm
  • N3 450 lpm
  • N4 280 lpm
  • N5 350 lpm
  • N6 350 lpm
  • N7 350 lpm
  • N8 350 lpm
  • N9 600 lpm
  • N10 600 lpm

14
STEAM TURBINE
  • Lube oil system
  • Total oil system capacity 52000 lit
  • Full volume of oil tank 58000 lit
  • Material of tank SS
  • Normal lube oil pressure 1.2 Ksc
  • Oil temp at inlet of bearings
  • Normal 55 0C
  • Maximum 59 0C
  • Piping SS
  • Seal steam system
  • Source of gland sealing system
  • During normal operation End glands of HPC IPC
  • During low load operation End glands of HPC
    IPC AS
  • Quantity of seal steam required 3.54 TPH
  • Seal steam pressure at turbine glands 1.1-1.2 Ksc
  • Seal steam temperature at turbine glands 160 0C

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

16
STEAM TURBINE
  • Turbine Protection
  • Over speed trip 110-112
  • Low lube oi pressure 0.3 (g) Ksc
  • Low vacuum trip 0.3 (abs) Ksc
  • Thrust bearing excessive wear trip 1.2/-2.0 mm
  • Pressure relief diaphragm setting 1.2 (abs) Ksc

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

18
STEAM TURBINE
  • Fixed blades
  • HPT first stage 18Cr11MoNiVNb (1-5)
  • HPT other stages 15Cr11MoV (6-17)
  • IPT first stage 18Cr11MoNiVNb
  • IPT other stages 15Cr11MoV
  • LPT first stage 12Cr13 (1-4)
  • LPT Other stages 08 Cr13 (5)
  • Number of stages
  • HPT
  • Impulse stages 1
  • Reaction stages 16
  • IPT
  • Impulse stages 22
  • Reaction stages 0
  • LPT
  • Impulse stages 20
  • Reaction stages 0
  • All rows of blades are integrally shrouded

19
STEAM TURBINE
  • No. of HP Stop valves 2
  • No. of HP Control valves 4
  • Type of control valve unit Block united
  • No. of IP Stop valves 2
  • No. of IP Control valves 4
  • Type of control valves Separate
  • No. of Journal bearings for turbine 8
  • No. of Journal bearings for Gen 4
  • No. of thrust cum journal bearing 1
  • Type of thrust bearing Tilting
  • Type of journal bearing 6-Fixed 2-Tilting pad
  • Material of bearing shell Alloy steel
  • Type of lining Babbit
  • LPT diaphrams 4

20
STEAM TURBINE
  • Turbine model No K-660-247
  • Generator model No TBB-660-2T3
  • Strainers are installed in the steam chests of
    the stop valves
  • In HPT, having passed the control stage and 8
    stages which generate left jet of steam (from
    generator towards front bearing) steam changes
    its direction 180 and flows between internal and
    external cylinders to 8 stages of right jet
    (towards generator)
  • In CRH lines, NRV has a bypass with electric
    valve and control valve to enable counter flow
    mode of HPT with the aim of warming up of
    cylinder and high pressure cross over pipes at
    turbine start up and cold condition
  • HPT has nozzle steam distribution system
  • IPT has throttle steam distribution system
  • On each upper half (cover) of low pressure
    cylinder four membrane type relief valves are
    installed which are activated when the absolute
    pressure in exhaust nozzles rises up to 1.35 1.4
    Ksc absolute

21
TG SEAL STEAM SYSTEM
22
HPT SEAL STEAM CONNECTION
TO BLED STEAM TO LPH 4
1ST CHAMBER
2ND CHAMBER
HPT
TO 2nd CHAMBER EXHAUST
TO BLED STEAM TO D/A
TO HOT SEAL STEAM HEADER
TO GSC
23
IPT SEAL STEAM CONNECTION
IPT
TO COLD SEAL STEAM HEADER
TO GSC
24
LPT SEAL STEAM CONNECTION
LPT
FROM COLD SEAL STEAM HEADER
TO GSC
25
  • IN HIGH PRESSURE DRAINAGE EXPANSION TANK A VALVES
    IN DRAINAGE COLLECTORS FROM EXTRACTION STEAM
    PIPES TO HPHs (10MAL20AA110, 10MAL20AA120,
    10MAL20AA140) AND IN LOW PRESSURE DRAINAGE
    EXPANSION TANK VALVES IN DRAINAGE COLLECTORS FROM
    EXTRACTION STEAM PIPES TO LPHs(10MAL30AA110,
    10MAL30AA120) CLOSE AUTOMATICALLY IF TURBINE LOAD
    INCREASES OVER 200MW AND AT THE SAME TIME ALL
    VALVES ARE OPEN IN THE CORRESPONDING STEAM
    EXTRACTION FROM THE TURBINE TO HPHs AND LPHs.
  • VALVES IN DRAINAGE PIPES OF HPBP AND LPBP
    (10MAL30AA107, 10MAL30AA108) CLOSE AUTOMATICALLY
    IF TURBINE LOAD INCREASES OVER 30MW.

26
CONTROL FLUID SYSTEM
  • FIRE RESISTANT SYNTHETIC HYDRAULIC FLUID FYRQUEL
    L MANUFACTURED BY SUPRESTA IS USED AS
    OPERATING FLUID.ITS SELF IGNITION TEMPERATURE IS
    ABOUT 740OC.
  • OPERATING PRESSURE IS APPROXIMATELY 50KSC.
  • OPERATING TEMPERATURE IS 45-55OC.
  • CONTROL OIL SUPPLY UNIT CNSISTS OF A RESERVOIR
    (10MAX10BB001)OF CAPACITY 7.0m3 ,2NOS.OIL
    COOLERS(10MAX10AC001,10MAX10AC002),DE-AERATOR,MESH
    FILTER,FINE FILTER(10MAX18AT001),DUPLEX
    FILTER(10MAX14AT001) AND 2 NOS. OF VERTICALLY
    MOUNTED CENTRIFUGAL PUMPS(10MAX11AP001,10MAX12AP00
    1) DRIVEN BY AC MOTOR (1W1S).EACH PUMP IS HAVING
    A CAPACITY OF 36m3/h AND DISCHARGE PRESSURE IS
    50KSC.
  • CONTROL FLUID RESERVOIR IS SEPERATED BY TWO
    NUMBERS OF TANDEM MESHES OF CELL SIZE 0.25mm INTO
    TWO SECTIONS ,DIRTY AND CLEAN. DE- AERATOR IS
    INSTALLED INSIDE THE RESERVOIR INFRONT OF MESHES
    AND IT CONSISTS OF SLOPING PLATE ASSEMBLY.
  • CF FINE FILTER FOR REMOVING MECHANICAL IMPURITIES
    IS INSTALLED IN RESERVOIR. DURING NORMAL
    OPERATION CF IS SUPPLIED TO THE FINE FILTER
    THROUGH AN ORIFICE OF DIAMETER 4mm FROM
    UNSTABILIZED PRESSURE LINE VIA VALVE 10MAX18AA501
    . AFTER THAT IT IS DISCHARGED IN THE DIRTY
    CHAMBER OF THE RESERVOIR. WHEN TURBINE IS STOPPED
    CF IS SUPPLIED TO THE FINE FILTER WITH THE HELP
    OF ANOTHER PUMP (CF TRANSFER PUMP,10MAX19AP001,CAP
    ACITY 4m3/hr, AND DISCHARGE PRESSURE 25KSC) VIA
    VALVES 10MAX19AA503 AND10MAX19AA504 FOR FILTERING
    PURPOSE KEEPING MAIN PUMPS IN OFF CONDITION.

27
  • OIL PURIFICATION IS CONTINUOUS DUE TO FILTERING
    OF ITS PART VIA CONCURRENTLY MOUNTED WORKING
    FILTER CARTRIDGES INSTALLED INSIDE THE FINE
    FILTER HOUSING.
  • FILTER CARTRIDGES DESIGN ALLOWS USAGE OF
    DIFFERENT FILTERING MATERIAL.
  • METAL SEMI-PINCEBECK MESH WITH FILTERING DEGREE
    OF 70 MICRONS TO FLUSH SYSTEM AFTER INSTALLATION
    OR MAINTENANCE.
  • FILTER BELTING FABRIC WITH FILTERING DEGREE 30
    40 MICRONS FOR PRIMARY REFINING DURING TURBINE
    OPERATION.
  • FILTERING ELEMENTS MANUFACTURED BY PALL WITH
    FILTERING DEGREE 12 MICRONS FOR CONTINUOUS OIL
    FILTERING DURING TURBINE OPERATION.
  • OCCURRENCE OF PRESSURE OF 0.1 TO 0.3KSC IN FILTER
    HOUSING WITHIN 1-3 HOURS SHOWS CORRECT ASSEMBLY
    OF FILTER AND ITS PROPER OPERATION.
  • IT IS NECESSARY TO SWITCH OFF THE FINE FILTER AND
    REPLACE FILTERING ELEMENTS IF PRESSURE IN FILTER
    HOUSING RISES UPTO 2KSC.WHICH SHOWS CONTAMINATION
    OF FILTER FABRIC.
  • INSIDE FILTER HOUSING THERE IS A RELIEF VALVE
    BYPASSING FLUID BESIDES FILTER CARTRIDGES WHEN
    THEY ARE CONTAMINATED AND PRESSURE RISES UPTO
    5KSC.
  • AN OIL LEVEL GAUGE WITH ALARM SYSTEM WHISKERS
    (10MAX10CL001,10MAX 10CL002) IS PROVIDED IN THE
    CLEAN SIDE OF THE RESERVOIR.
  • NORMAL OPERATING LEVEL IS 700mm FROM THE UPPER
    COVER (30 GRADUATION OF L.G.) AND THE AMOUNT OF
    CF IS 2.5m3

28
  • MAXIMUM ALLOWALABLE UPPER LIMIT (WITH CF PUMPS IN
    STOPPED CONDITION) IS 150mm FROM THE UPPER COVER
    (85 GRADUATION OF L.G.) AND MINIMUM OPERATING
    LEVEL IS 800mm (20 GRADUATON OF L.G.) FROM THE
    UPPER COVER.
  • CF PUMP STOPS AUTOMATICALLY INCASE OF RESERVOIR
    OIL LEVEL LOW-LOW.
  • FOR VISUAL OVSERVATION OF OIL LEVEL ,LEVELGLASSES
    HAVE BEEN PROVIDED IN THE BOTH SIDES (DIRTY AS
    WELL AS CLEAN).
  • DIFFERENTIAL PRESSURE SWITCH (10MAX10CP001) HAS
    BEEN PROVIDED TO WARN ABOUT INCREASE IN PRESSURE
    DIFFERENCE IN SIDE THE MESH FILTER. ALLOWABLE
    DIFFERENCE IN MESHES DOESNOT EXCEED 150mm.
  • THE STANDBY CF PUMP STARTS WHEN THE RUNNING ONE
    TRIPS OR SYSTEM PRESSURE DROPS TO 36KSC.
  • IT TAKES 2 MINS FOR THE SYSTEM TO GET
    PRESSURIZED.
  • IF SYSTEM PRESSURE DROPS TO 20KSC (10MAX14CP001)
    AND STOP VALVES START CLOSING ,THE OPEARTING PUMP
    WILL STOP AND NO SIGNAL WILL BE GENERATED TO
    START THE STAND BY PUMP (SENSING OIL LEAKAGE).
  • CF PUMP ALSO TRIPS ON FIRE PROTECTION.
  • DUPLEX FULL PASSAGE FILTER WITH FILTERING DEGREE
    20-25MICRONS IS INSTALLED IN GENERAL PRESSURE
    COLLECTOR OF CONTROL SYSTEM.IF PRESSURE
    DIFFERENCE (10MAX14CP301,10MAX15CP301) ACROSS THE
    RUNNING FILTER REACHES 0.8KSC,THE STANDBY FILTER
    HAS TO BE TAKEN INTO SERVICE.

29
  • 2 NOS.OF CF COOLERS (AB) ARE INSTALLED IN THE CF
    SUPPLY LINE BEHIND THE DUPLEX FILTER. THESE
    COOLERS ARE DOUBLE PASS (BY WATER) SURFACE HEAT
    EXCHANGERS WITH TUBULAR DESIGN ,WATER STREAM
    FLOWS INSIDE THE TUBES AND CONSIST OF 148 TUBES
    OF SIZE 16X1500mm AND HEAT EXCHANGE AREA 25m2.CF
    FLOWS FROM TO DOWNARD.
  • COOLERS ARE DESIGNED FOR A MAXIMUM COOLING WATER
    PRESSURE OF 10 0.5KSC AND CF PRESSURE OF 68.7
    0.5KSC.CF FLOW RATE TO EACH COOLER IS 50m3/hr AND
    PRESSURE DROP IS 0.2KSC. CW FLOW RATE TO EACH
    COOLER IS 80m3/hr AND PRESSURE DROP IS 0.194KSC.
  • FOR HYDRODYNAMIC FLUSHING OF PIPELINES DURING
    MAINTENANCE,THERE IS A BYPASS VALVE
    (10MAX14AA501)TO THE COOLERS WHICH SHOULD BE
    CLOSED AND SEALED DURING ROUTINE OPERATION.
  • IN THE INPUT AND OUTPUT TO THE COOLERS CF LINE IS
    PROVIDED WITH TRIPLE-PASS SWITCHING OVER VALVES
    WHICH PREVENT FALSE ACTIVATION OF BOTH COOLERS.
  • CF TEMPERATURE IS MAINTAINED (48-52OC)BY COOLING
    WATER FLOW VARIATION WITH THE HELP OF A FLOW
    CONTROL STATION CONSISTING OF A PNEUMATIC CONTROL
    VALVE (10PGM20AA001) AND A BYPASS MOTORIZED
    CONTROL VALVE(10PGM20AA002).IN CASE TEMPERATURE
    RISES TO 55OC (10MAX14CT001,10MAX14CT002),MOTORIZE
    D BYPASS VALVE OPENS TO MAINTAIN THE CF
    TEMPERATURE. THE MAXIMUM LIMIT OF CW TEMPERATURE
    AT COOLER INLET IS 37OC.IF CW TEMPERATURE IS
    BELOW 36OC ONE COOLER CAN BE PUT OUT OF
    OPERATION.

30
  • CF SUPPLY TO CONTROL UNITS IS CARRIED OUT BY TWO
    PRESSURE COLLECTORS OF STABILIZED AND
    UNSTABILIZED PRESSURE.
  • CF IS SUPPLIED TO UNSTABILIZED PRESSURE COLLECTOR
    THROUGH AN ORIFICE OF SIZE 22mm. STOP AND CONTROL
    VALVE ACTUATORS ARE FED FROM THIS COLLECTOR.
  • INTO STABILIZED PRESSURE COLLECTOR WHICH FEEDS
    OIL TO ALL CONTROL DEVICES,CF IS SUPPLIED FROM
    THE SECTION BETWEEN PUMPS AND THE ORIFICE.
  • DUE TO THE ARRANGEMENT MENTIONED ABOVE ,THE
    PRESSURE VARIATION IN UNSTABILIZED PRESSURE
    COLLEECTOR CAUSED BY INCREASE IN CF CONSUMPTION
    WITH OPEN ACTUATORS AFFECTS IN A LESS DEGREE
    PRESSURE VARIATION IN STABILIZED PRESSURE
    COLLECTOR.
  • SPRING-WEIGHT ACCUMULATOR (10MAX20BB001) IS
    CONNECTED TO UNSTABILIZED PRESSURE COLLECTOR TO
    PREVENT DECREASE IN FORWARD PRESSURE IN CASE OF
    LOSS AC SUPPLY TO THE PUMPS FOR 5-7SECS OR
    DURING PUMP CHANGE-OVER.
  • THE SETTING OF FLUID PRESSURE LEVEL (45KSC) TO BE
    ENSURED BY THE ACCUMULATOR IS DETERMINED BY A
    WEIGHT WHICH IS CONCRETE FILLED IN THE SITE.
  • ONE NRV IS INSTALLED IN THE LINE CONNECTING THE
    ACCUMULATOR TO THE UNSTABILIZED PRESSURE
    COLLECTOR. ACCUMULATOR IS FILLED WITH THE CF
    THROUGH AN ORIFICE OF SIZE 5mm INSTALLED IN THE
    BYPASS LINE OF THE NRV.
  • TWO EXHAUST FANS (1W1S) ,10MAX21AN001,10MAX21AN00
    2 (CAPACITY OF 3200m3/hr AT A HEAD OF 5-20mm OF
    WATER COLUMN) ARE ALSO INSTALLED TO REMOVE CF
    VAPOUR FROM CF RESERVOIR AND SYSTEM.
  • THE EXHAUSTER SWITCHES ON AUTOMATICALLY WHEN CF
    PUMP STARTS AND SWITCHES OFF AUTOMATICALLY WITH
    15mins TIME DELAY AFTER THE STOPPING OF CF PUMP
    AND CF SYSTEM PRESSURE DROPS BELOW 2.0KSC.

31
  • HYDRAULIC TEST OF PIPE LINES CARRIED OUT AT A
    PRESSURE OF 90KSC.HYDRAULIC TEST SHOULD BE
    CARRIED OUT AFTER ASSEMBLING,OVERHAUL AND
    INSPECTION.

32
CONTROL FLUID SYSTEM
33
CONTROL FLUID SYSTEM
  • Isolation valves on pump suction discharge side
  • Pump discharge pressure 50 Ksc
  • Capacity 41 TPH
  • Stabilized pressure header supply oil to servo
    motors of SV CV
  • Un stabilized pressure header with 22 mm orifice
  • Accumulator in unstabilized pressure header
  • CF tank capacity 6.9 m3
  • Duplex filter
  • Control fluid transfer pump to empty the CF tank
  • CF Temperature control by control station in the
    ECW line

34
COMPONENT OF GOVERNING SYSTEM
  1. ELECTRO-HYDRAULIC CONVERTER SUMMER 8 NOS.
  2. SUMMER 8NOS.
  3. ELECTRO-MECHANICAL CONVERTER 8NOS.
  4. GOVERNING BLOCK
  5. CONTROLGEAR(AE001) 1NO.
  6. EMERGENCY GOVERNOR OR OVERSPEED GOVERNOR 1NO.
  7. TRIP SOLENOID (AA213,AA214)-2NOS.
  8. TEST ELECTROMAGNETS(AA211,AA212) 2NOS.
  9. ROTATIONAL SPEED DETECTOR -3 NOS.
  10. LIMITER OF PRESSURE (AA502) 1NO.
  11. SPEED TRANSDUCER 1NO.
  12. LEVER OF OVER SPEED GOVERNOR (AX201) 1NO.
  13. PILOT VALVE FOR SUPPLY (AX202) 1NO.
  14. ACCUMULATOR 1NO.
  15. OIL SUPPLY AND PURIFIER UNIT
  16. SERVOMOTOR OF HPSV 2NOS.
  17. SERVOMOTOR OF HPCV 4NOS.

35
DIFFERENT TYPES OF OIL
  1. HEAD PRESSURE LINE (STABILIZED,50KSC,10MAX15)
  2. HEAD PRESSURE LINE ( NON-STABILIZED,50KSC,10MAX15)
  3. LINE OF PROTECTION (50KSC,10MAX51)
  4. LINE TO COCK THE OVERSPEED GOVERNOR SLIDE VALVE
    (50KSC)
  5. CONTROL OIL LINE TO STOP VALVE SERVOMOTORS
    (50KSC,10MAX16)
  6. CONTROL LNE TO SUMMATORS (35KSC,10MAX17)

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TURBINE PROTRCTIONS
  • OUT OF TOLERANCE ROTOR OVERSPEED ALARM AT
    3300RPM AND TRIPPING AT 3360RPM
  • OUT OF TOLERANCE AXIAL DISPLACEMENT OF ROTOR
  • TOWARDS FRONT BEARING BY 0.6mm (-0.6mm) -ALARM.
  • TOWARDS FRONT BEARING BY 1.2mm (-1.2mm) -
    TRIPPING.
  • TOWARDS GENERATOR BY 1.4mm (1.4mm)A- ALARM.
  • TOWARDS GENERATOR BY 2.0mm (2.0mm) - TRIPPING.
  • LUBRICATING OIL PRESSURE DROP ALARM AT 0.70KSC
    AND TRIPPING AT 0.30KSC WITH 3SECS TIME DELAY.
  • PRESSURE RISE IN CONDENSERALARM AT 0.15KSC abs.
    AND TRIPPING AT 0.20KSC abs. PROTECTION IS
    INTRODUCED AUTOMETICALLY AT UNIT START-UP AFTER
    PRESSURE DROP IN CONDENSER LOWER THAN 0.15KSC
    abs. OR AT TURBINE SPEED INCREASE OVER 1500RPM.
    PROTECTION IS IN OPERATION UNTIL STOP VALVES ARE
    OPEN
  • INCREASE OF BEARING VIBRATION ALARM SOUNDS AT
    INCREASE OF VERTICAL OR TRANSVERSE OR AXIAL
    COMPONENT OF VIBRATION ON ANY BEARING OF TG SET
    REACHES 4.5mm/s .TRIPPING OCCURS WITH 2 SECS TIME
    DELAY AT INCREASE OF VERTICAL OR TRANSVERSE
    COMPONENT OF VIBRATION OVER 11.2mm/s ON ANY TWO
    BEARINGS OF TG SET.

38
  • RISE IN STEAM TEMPERATURE AT HPT OUTLET
  • LIVE STEAM TEMPERATURE BEFORE TURBINE FALLS BELOW
    470OC
  • LIVE STEAM TEMPERATURE BEFORE TURBINE RISES ABOVE
    565OC
  • STEAM TEMPERATURE BEFORE IV FALLS BELOW 500OC
  • STEAM TEMPERATURE BEFORE IV RISES ABOVE 593OC
  • MOT LEVEL LOW-LOW
  • DRIP LEVEL HIGH-HIGH IN ANY HPH
  • ANY FAILURE IN TURBNE CONTROL SYSTEM
    ELECTRONICS
  • GENETERATOR PROTECTION
  • FIRE PROTECTION OPERATED
  • EPB PRESED.

39
TURBINE LUBE OILSYSTEM
  • LUBRICATION OIL SYSTEM IS DESIGNED TO SUPPLY OIL
    TO TURBINE AND GENERATOR BEARINGS IN ALL TURBINE
    PLANT OPERATION MODES AND ALSO TO PROVIDE ROTOR
    JACKING OIL SYSTEM AND GENERATOR SEAL OIL SYSTEM
    WITH OIL.
  • LUBRICATION OIL IS ISO VG 32 TYPE WITH FOLLOWING
    PROPERTIES
  • ABSOLUTE VISCOCITY 16.7CENTIPOISE
  • KINEMATIC VISCOSITY 32CENTISTOKE
  • SPECIFIC GRAVITY 0.89
  • SPECIFIC HEAT 0.459Kcal/Kg Deg.C
  • FLASH POINT 180OC
  • FIRE POINT 240OC
  • DEGREE OF CLEANLINESS 16/13 ISO 4406
  • PERMISSIBLE SUSPENDED PARTICLE SIZE 25 MICRON
  • WATER CONTENT lt10PPM
  • LUBE OILTANK IS MADE OF STAINLESS STEEL AND
    HAVING A CAPACITY OF 58m3 . PROVISION IS MADE FOR
    OIL TREATMENT INSIDE THE TANK BY PROVIDING TWO
    ROWS OF FLAT GRIDS WITH MESH DIMENSIONS 0.25mm
    LOCATED INSIDE THE TANK WHICH DIVIDES THE TANK
    INTO DIRTY AND CEAN COMPARTMENTS. THE AIR
    SEPARATOR CONSISTING OF TILTED METAL PLATES SET
    IS INSTALLED TO SEPARATE THE AIR DISSOLVED IN
    OIL.
  • THE OIL TANK HAS ATTACHMENTS FOR OIL DRAINING TO
    OIL TREATMENT PLANT FOR SLUDGE DRAIN AND TO
    EMERGENCY TANK INCASE OF FIRE.

40
  • NORMAL OPERATING LEVEL IS 600mm FROM TANK TOP
    COVER.ALARM IS AT 500mm AND TURBINE TRIP IS THERE
    AT 400mm.
  • 4 NOS OF LUBE OIL PUMPS (SINGLE STAGE
    CENTRIFUGAL) ARE INSTALLED VERTICALLY ABOVE THE
    TANK .2 PUMPS (AUXILLIARY OIL PUMP) ARE ac MOTOR
    DRIVEN AND 2 PUMPS ARE dc (EMERGENCY OIL PUMP)
    MOTOR DRIVEN.
  • ONE PUMP WITH ac MOTOR IS CONTINUOUS RUNNING AND
    OTHER IS KEPT STANDBY.
  • EACH ac PUMP IS HAVING A DISCHARGE CAPACITY OF
    300m3/hr A DISCHARGE PRESSURE OF 4.3KSC.
  • EOP WLL START IN CASE OF LOSS OF AC.EACH EOP IS
    HAVING A DISCHARGE CAPACITY OF 250m3/hr AND A
    DISCHARGE PRESSURE OF 2 KSC.FOR HIGHIER
    RELIABILITY EOP DELIVERS OIL DIRECTLY TO THE
    BEARING BYPASSING COOLER AND THROTTLE VALVE.

41
TG LUBE OIL SUPPLY SYSTEM
42
TG LUBE OIL SYSTEM
43
TG LUBE OIL SYSTEM
  • Turbine oil is ISO VG 32
  • KV 20-23 CST at 500C
  • Acidity Number lt 0.05 mg KOH/r
  • Viscosity index gt 90
  • Bearings
  • HPT Front N1
  • HPT Rear N2
  • IPT Front (TB) N3
  • IPT Rear N4
  • LPT-1 Front N5
  • LPT-1 Rear N6
  • LPT-2 Front N7
  • LPT-2 Rear N8
  • Generator Front N9
  • Generator Rear N10
  • Exciter Front N11
  • Exciter Rear N12

44
TG LUBE OIL SYSTEM
  • DC Lube oil pump 1 No.

Equipment Capacity (m3/hr) Head (Ksc)
AC Lube oil pump 300 4.3
DC Lube oil pump 250 2.0
  • NRV Isolation valve in each Lube oil pump
    discharge line
  • Oil first goes to duplex filter instead of
    cooler
  • Coolers Bypass line with isolating valve
  • Hydraulic Pressure control valve maintains the
    pressure at the center shaft level at 1.2 Ksc
  • PCV Bypass with throttling orifice which
    provides lubrication even at fully closed control
    valve

45
TG LUBE OIL SYSTEM
  • Oil is first delivered to bearing brasses through
    emergency tanks located on bearing cap
  • Emergency tanks capacity in m3
  • N1 0.43
  • N2 0.35
  • N3 0.75
  • N4 0.44
  • N5 0.44
  • N6 0.44
  • N7 0.44
  • N8 0.44
  • N9 0.5
  • N10 0.44
  • N11 0.1
  • N12 0.1

46
TG LUBE OIL SYSTEM
  • Lube oil temperature control by control station
    in the ECW inlet line to Lube oil coolers
  • View glasses in the oil return line from each
    bearing
  • MOT Capacity 58 m3
  • Duplex filters fineness 25 µm
  • Provision is made for oil cleaning by delivering
    a portion of oil from the oil pressure pipe to
    the oil tank through the fine cleaning filter
    with fineness of 12-15 µm
  • Fresh oil is filled through the above filter only
  • Oil recirculation pump to purify the oil
  • Electrical oil heater of 152 KW capacity is
    provided for the preliminary oil warming in the
    lubrication oil tank before turbine start up by
    running the oil recirculation pump
  • Oil draining to Emergency lube oil tank in case
    of emergency with MOV

47
TG LUBE OIL SYSTEM
  • Oil trap at the suction of the vapor extractor
    fans
  • Oil trap drain to lubrication oil tank
  • Jacking oil pumps suction also given from lube
    oil discharge header after coolers before
    control valve

48
TG JACKING OIL AND BARRING GEAR SYSTEM
49
Barring gear Jacking oil system
  • Automatic barring gear engagement at the rotor
    stop and barring gear disengaging at the start-up
  • High pressure oil supply for bearing inserts oil
    jacking
  • Barring speed 1.05 rpm
  • Motorized barring gear
  • Torque transfer from the barring gear motor to
    the turbine shaft is carried out via three stage
    reducer and free wheel clutch
  • Reduction gear first stage shaft end mounts
    special handle for hand barring
  • Normal source for jacking oil pumps suction is
    from lube oil pumps discharge header after
    coolers
  • JOP discharge pressure 120 Ksc

50
Barring Gear Jacking oil system
  • Dozing devices at each bearing of the Turbine
    Generator which contain strainer, NRV, orifice
    isolation valve
  • Bearing jacking oil is supplied via separate
    lines for oil jacking of inserts of bearing no
    4-9
  • Stand-by bearing insert oil jacking pump is not
    provided as the system is designed to realize
    auxiliary functions at turbine start-up. If this
    pump does not start when it is required then also
    the turbine can be operated normally without any
    bearing damage and disturbance of turbine
    operation
  • Each bearing insert jacking oil line is equipped
    with orifice only
  • Both pumps cut in/cut out is 1500/1500
  • Barring gear cut in/cut out is 1500/1500

51
Barring Gear Jacking oil system
  • Bearing Insert Oil Jacking Pump is started
    automatically, if the rotor neck displacement
    becomes more than 0.1 mm relative to the insert
    of any of bearings No. 4,9 provided that the oil
    pressure to rotor jacking is higher than 45
    kg/cm2 or the turbine rotor rotational speed is
    higher than 1500 rpm
  • Pump is stopped automatically, with time delay of
    30 seconds, if the rotor neck displacement is
    less than 0.1 mm relative to the insert of
    bearings No. 4-9

52
GENERATOR SEAL OIL SYSTEM
53
GENERATOR SEAL OIL SYSTEM
  • Seal oil pumps suction from MOT
  • No Hydrogen side seal oil pump
  • Pumps re-circulation line directly to MOT
  • Coolers bypass valve
  • Magnetic filters 2 No. (1W1SB)
  • NRV in the seal oil line after filters
  • DPR
  • DPR bypass manual control valve

54
GENERATOR SEAL OIL SYSTEM
  • Damper tanks 2 No. 1 for TE 2 for EE, designed
    for oil supply to front and back generator shaft
    seals with drop, specified by the height of
    damper tank installation, and also to seal at
    short-time interruption in oil supply, at the
    moment of automatic transfer from working pump to
    standby and at generator runback with generator
    shaft seal pumps switched off
  • View glasses in return oil lines
  • Float hydraulic seal functions as SOT
  • Hydraulic seal overflows in to return oil header
  • No SOST
  • Provision of trap upstream of fans
  • Fans suction is from return oil header

55
GENERATOR STATOR WATER COOLING SYSTEM
56
STATOR WATER COOLING SYSTEM
  • Water tank not on the generator
  • Ejector to make vacuum over the water tank to
    prevent air ingress
  • Ejector cooling by auxiliary cooling water
  • Air venting of Generator through Gas trap
    connected from winding inlet and outlet headers
  • Gas trap to determine hydrogen present which will
    be extracted from trap cap to gas analyzer
  • Coolers bypass valve
  • Ion exchanger-1 contains anion cat ion in H-OH
    form to maintain conductivity
  • Ion exchanger-2 contains anion cat ion in Na-OH
    form to maintain Ph if it decreases below 8
  • Ion exchanger-1 first will be put in to service
    for reducing dissolved oxygen below 5.0 µs/cm and
    then it will be put out of service. Then Ion
    exchanger-2 will be put in to service to increase
    the Ph value. If conductivity increases above
    12.5 µs/cm, Ion exchanger-2 to be stopped

57
STATOR WATER COOLING SYSTEM
  • Control valves at the inlet of individual Ion
    exchanger circuits
  • DM water flow through ion exchanger is 1.5 to 2.0
    m
  • No NAOH dozing system
  • Ion exchangers separate bypass lines
  • Mechanical filter at the inlet of Ion exchanger
    circuit
  • Dissolved oxygen analyzer Ph analyzer
  • Winding inlet valve for flow adjustment
  • Winding outlet valve for pressure adjustment
  • Normal make up from DM make up line emergency
    make up line from CST
  • Filter in the common make up line
  • Control station in the common make up line

58
GENERATOR GAS SUPPLY SYSTEM
59
GENERATOR GAS SUPPLY SYSTEM
  • Two Hydrogen manifolds to connect 16 cylinders
    each
  • Direct acting Pressure regulator installed on
    cylinder connecting line to Manifold header to
    reduce the Hydrogen pressure from 175 Ksc to 10
    Ksc
  • Total Pressure regulators 32
  • Safety valve on each manifold header which
    operates when the Hydrogen pressure in the
    manifold exceeds 10.5 Ksc
  • MOV NRV in each manifold header
  • Three CO2 manifolds to connect 17 cylinders each
  • Each manifold header contains MOV, NRV
    Isolation valve
  • MOV with manual bypass valve at the inlet of CO2
    heater
  • CO2 heater is steam heated
  • Steam source is from auxiliary steam system
  • Steam parameters 15 Ksc 210 0C
  • MOV in the steam inlet line
  • Steam exhaust will go to FWSV Dish flash tank
  • Manifold header pressure is 175-20 Ksc
  • Control station with Pressure regulator provided
    D/S of heater to maintain a pressure of 2.0-2.2
    Ksc with manual bypass valve
  • SV installed D/S of pressure regulator operates
    if the pr gt 5.0 Ksc
  • Capacity of one cylinder 50 lit

60
GENERATOR GAS SUPPLY SYSTEM
  • One Hydrogen manifold is in operation under
    normal operating conditions
  • If the pr decreases below lt 10 Ksc, an alarm will
    come and operator connects the standby manifold
    and disconnects the first manifold
  • Two CO2 manifolds are in operation under normal
    operating conditions
  • If the pr decreases below lt 20 Ksc, an alarm will
    come and operator connects the standby manifold
    and disconnects the first manifold
  • Provision is given for emergency removal of
    hydrogen from generator itself by providing a
    line with one manual isolating valve 2 No. MOV

61
FLASH TANKS
  • DRAINS FROM THE TURBINE AND STEAM LINES ARE
    REMOVED TO TWO HP DRAIN FLASH TANKS - A
    (10MAL10BB001) AND B (10MAL20BB001) AND ONE LP
    DRAIN FLASH TANK (10MAL30BB001)
  • BOTH THE HP FLASH TANKS ARE HAVING A CAPACITY OF
    2.6m3. LP DRAIN FLASH TANK IS ALSO HAVING A
    CAPACITY OF 2.6m3.

62
CONDENSER
  • Design LMZ
  • Design CW Flow 64000 m3/hr
  • Vacuum 77 mm Hg (abs) at 33 0C
  • 89 mm Hg (abs) at 36 0C
  • No. of passes 1
  • Total no. of tubes 22.225 (OD)x0.71 (t) - 29920
  • 22.225 (OD)x1.00 (t) - 2080
  • Tube material ASTM A-249 TP 304
  • Rated TTD 3.40C
  • DT of CW 100C

63
CONDENSATE EXTRACTION PUMP
  • Design flow rate 238.75 Kg/s
  • Discharge pressure 32.15 Ksc
  • Shut off head 395 m
  • Pump speed 1480 rpm
  • Power input 972.3 KW
  • No. of stages 6
  • Type of first stage impeller double entry
  • Depth 7.43 m

64
DE-AERATOR
  • Design Pressure 13 Ksc
  • No. of trays 896
  • Spray valves 132
  • Design temp for D/A 395 0C
  • Design temp for FST 250 0C

65
DRIP PUMP
  • Design flow rate 324.509 TPH
  • Discharge pressure 43 ata
  • Shut off head 306.7 m
  • Pump speed 1486 rpm
  • Power input 310.1 KW
  • No. of stages 5
  • Type of first stage impeller centrifugal, single
    entry
  • Depth 1090 mm

66
MDBFP
  • Pump flow 769.950 TPH
  • Suction temp 186.2 0C
  • BP Suction pr. 14.05 ata
  • BFP Suction pr. 21.01 ata
  • BFP Discharge pr. 335.78 ata
  • BFP Discharge temp. 187.9 0C
  • BP Discharge pr. 22.01 ata
  • Shut off head 4830 m
  • BFP Speed 6275 rpm
  • BP Speed 1490 rpm
  • Normal R/C flow 220 TPH
  • HC Rated O/P Speed 6505 rpm
  • Outer casing type barrel
  • No. of stages 7
  • BFP warm up flow 15 TPH

67
TDBFP
  • Pump flow 1283.14 TPH
  • Suction temp 186.2 0C
  • BP Suction pr. 14.10 ata
  • BFP Suction pr. 28.24 ata
  • BFP Discharge pr. 335.83 ata
  • BFP Discharge temp. 187.8 0C
  • BP Discharge pr. 29.06 ata
  • Shut off head 4580 m
  • BFP Speed 4678 rpm
  • BP Speed 2098 rpm
  • Normal R/C flow 365 TPH
  • HC Rated O/P Speed 6505 rpm
  • Outer casing type barrel
  • No. of stages 7
  • BFP warm up flow 20 TPH

68
TDBFP GOVERNING SYSTEM
69
GOVERNING SYSTEM
  • PARTS OF GOVERNING SYSTEM
  • Hydraulic Accumulator (HA)
  • Remote switch (RS)
  • Lubrication system pressure relay (LSPR)
  • Trip Gear (TG)
  • Stop valve (SV)
  • Governor valve 1 (GV1)
  • Governor valve 2 (GV2)
  • Cut off pilot valve (COPV)
  • Electro mechanical converter (EMC)
  • Electro mechanical converter position transducer
    (ECPT)
  • Electronic control part (ECP)
  • Servo motor (S)
  • Governor valves position transducer (GVPT)

70
TDBFP TURBINE
  • Number of stages 9
  • Casing Split
  • Steam admission Dual
  • Steam pressure at inlet 20.82 ata
  • Steam temperature at inlet 469 0C
  • Turbine operating speed 4678 rpm
  • Steam consumption 61.4 TPH
  • Steam pressure at exhaust 0.128 ata
  • Turning gear speed 15 rpm
  • Type of governing system Electro-Hydraulic
  • Over speed type trip Centrifugal electrical
  • JOP Not required
  • Lube oil tank capacity 10.97 m3
  • Lube oil Same as main turbine

71
TDBFP CONDENSER
  • CW flow 3000 TPH
  • Vacuum in the condenser 0.128 Ksc (abs)
  • Total no. of tubes 3312
  • Tube OD and thickness 22.225x1.06 mm
  • No. of water passes 2
  • Tube material ASTM A-249 TP321

72
TDBFP LUBE OIL SYSTEM
73
TDBFP EXTRACTION SYSTEM
74
TDBFP CONDENSATE SYSTEM
75
ACW SYSTEM
76
ACW SYSTEM
  • Suction header is from all the 4 CW inlet lines
    to condensers
  • MOV at Suction header from CW line
  • MOV at SCS inlet
  • MOV at PHE inlet outlet
  • Supply to
  • Ejector of Stator water cooling system
  • TDBFP vacuum pumps (4 No.)
  • Main turbine vacuum pumps (1 No. extra)
  • MOV at return header to CW line

77
TURBINE VACUUM SYSTEM
78
TURBINE HEATING FLANGES SYSTEM
79
AUXILIARY STEAM SYSTEM
80
CONDENSATE SUPPLY SYSTEM TO EXT NRVS
81
EXHAUST HOOD SPRAY
82
FEED WATER SYSTEM
83
TDBFP-A FEED WATER SYSTEM
84
MDBFP FEED WATER SYSTEM
85
LP DOZING OXY TREATMENT SYSTEM
86
HP BYPASS SYSTEM
87
LP BYPASS SYSTEM
88
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