TURBINE AND GENERATOR SYSTEM

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A PRESENTATION ON 660MW TURBO-GENERATOR ,ITS
AUXILIARIES AND ASSOCIATED SYSTEMS
By Ashvani Shukla CI BGR energy
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STEAM TURBINE K-660-247
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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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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

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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

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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

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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

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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

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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

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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.

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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

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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)

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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

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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

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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

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TG SEAL STEAM SYSTEM
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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
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IPT SEAL STEAM CONNECTION
IPT
TO COLD SEAL STEAM HEADER
TO GSC
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LPT SEAL STEAM CONNECTION
LPT
FROM COLD SEAL STEAM HEADER
TO GSC
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• 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.

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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.

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• 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

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• 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.

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• 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.

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• 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.

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

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CONTROL FLUID SYSTEM
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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

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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.

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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.

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• 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.

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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.

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• 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.

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TG LUBE OIL SUPPLY SYSTEM
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TG LUBE OIL SYSTEM
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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

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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
Thank you