A PRESENTATION ON 660MW TURBO-GENERATOR ,ITS AUXILIARIES AND ASSOCIATED SYSTEMS OF STAGE I OF SIPAT SUPER THERMAL PROJECT

STEAM TURBINE K-660-247

LMZ (LENINGRADSKY METALLICHESKY ZAVOD)

K STANDS FOR KLAPAN LTD.,BULGARIA WHICH SUPPLIES TURBINE,NOZZLES,DIAPHRAGMS, SEALS,BLADES ETC.

GENERAL INFORMATIONTG 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 12mCONDENSER 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.

RATED CONDITIONSLOAD :660MWBEFORE HP STOP VALVESTEAM PRESSURE:247KSCSTEAM TEMPERATURE:5370CSTEAM FLOW:2023.75T/HR

AFTER HPCSTEAM PRESSURE:48KSCSTEAM PRESSURE:298.710C

BEFORE IP STOP VALVESTEAM PRESSURE:43.2KSCSTEAM TEMPERATURE:5650C

STEAM FLOW TO REHEATER:1681.12T/HR.DESIGN CONDENSER PRESSURE:0.105KSC (abs.)COOLING WATER FLOW:64000M3/HRFINAL FEED WATER TEMP.:286.350CFREQUENCY RANGE:47.5 51.5 Hz

STEAM TURBINEGenerator rated speed3000rpmGenerator manufacturerElectrosilaNo. of bleedings8Length of the turbine36.362mNo. of stagesHPT17IPT11x2LPT-15x2LPT-25x2Total59

STEAM TURBINEParametersPr. Before HPC SV247.0KscTemp. before HPC SV537.00CSteam flow2023.75TPHPr. After HPC48.0KscTemp. after HPC298.710CPr. Before IP SV43.2KscTemp. before IP SV565.00CSteam flow to reheat1681.12TPHDesign Cond pr.0.105KscCW flow64000TPHFinal FW Temp.286.350C

STEAM TURBINETurbine Governing systemMode of Governing NozzleTypeE/HControl fluidFirequel-L makeSupresta-USANormal Operating Pr.50 KscCapacity600 lpmFluid pump motor rating200 KWFilter materialUltiporMesh size25

STEAM TURBINELube oil systemLube oilTn-22C Russia Mobil DTE Oil light Teresso 32In accordance with ISO VG 32Absolute viscosity16.7CentipoiseKinematic viscosity-32CentistokesSpecific gravity0.89Flash point1800CFire point2400COil requirement per bearingN1200lpmN2200lpmN3450lpmN4280lpmN5350lpmN6350lpmN7350lpmN8350lpmN9600lpmN10600lpm

STEAM TURBINELube oil systemTotal oil system capacity52000litFull volume of oil tank58000litMaterial of tankSSNormal lube oil pressure1.2KscOil temp at inlet of bearingsNormal550CMaximum590C PipingSSSeal steam systemSource of gland sealing systemDuring normal operationEnd glands of HPC & IPCDuring low load operationEnd glands of HPC & IPC + ASQuantity of seal steam required3.54TPHSeal steam pressure at turbine glands1.1-1.2KscSeal steam temperature at turbine glands1600C

TURBINE SEAL STEAMTWO 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.

STEAM TURBINETurbine ProtectionOver speed trip110-112%Low lube oi pressure0.3 (g)KscLow vacuum trip0.3 (abs)KscThrust bearing excessive wear trip+1.2/-2.0mmPressure relief diaphragm setting1.2 (abs)Ksc

STEAM TURBINEMaterials of constructionHP Outer casing15Cr1Mo1VHP blade/carrier casings15Cr1Mo1VIP Outer casing15Cr1Mo1VLP inner casingSteel 3LP Outer casingSteel 3HP Shaft25Cr1Mo1VIP Shaft25Cr1Mo1VLP Shaft26CrNi3Mo2VMoving bladesHPT first stage blades18Cr11MoNiVNb (1-5)HPT other stages15Cr11MoV (6-17)IPT first stage 18Cr11MoNiVNb (1-3)IPT other stages15Cr11MoV (4-11)LPT last stage13Cr11Ni2W2MoVLPT other stages20Cr13 (1-2)LPT other stages15Cr11MoV (3-4)

STEAM TURBINEFixed bladesHPT first stage18Cr11MoNiVNb (1-5)HPT other stages15Cr11MoV (6-17)IPT first stage18Cr11MoNiVNbIPT other stages15Cr11MoVLPT first stage12Cr13 (1-4)LPT Other stages08 Cr13 (5)Number of stagesHPTImpulse stages1Reaction stages16IPTImpulse stages22Reaction stages0LPTImpulse stages20Reaction stages0All rows of blades are integrally shrouded

STEAM TURBINENo. of HP Stop valves2No. of HP Control valves4Type of control valve unitBlock unitedNo. of IP Stop valves2No. of IP Control valves4Type of control valvesSeparateNo. of Journal bearings for turbine8No. of Journal bearings for Gen4No. of thrust cum journal bearing1Type of thrust bearingTiltingType of journal bearing6-Fixed & 2-Tilting padMaterial of bearing shellAlloy steelType of liningBabbitLPT diaphrams4

STEAM TURBINETurbine model NoK-660-247Generator model NoTBB-660-2T3Strainers are installed in the steam chests of the stop valvesIn 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 conditionHPT has nozzle steam distribution systemIPT has throttle steam distribution systemOn 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

TG SEAL STEAM SYSTEM

TO 2nd CHAMBER EXHAUSTTO BLED STEAM TO D/ATO BLED STEAM TO LPH # 4TO HOT SEAL STEAM HEADERTO GSCHPTHPT SEAL STEAM CONNECTION1ST CHAMBER2ND CHAMBER

TO COLD SEAL STEAM HEADERTO GSCIPTIPT SEAL STEAM CONNECTION

FROM COLD SEAL STEAM HEADERTO GSCLPTLPT SEAL STEAM CONNECTION

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.

CONTROL FLUID SYSTEMFIRE 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(10MAX11AP001,10MAX12AP001) DRIVEN BY AC MOTOR (1W+1S).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,CAPACITY 4m3/hr, AND DISCHARGE PRESSURE 25KSC) VIA VALVES 10MAX19AA503 AND10MAX19AA504 FOR FILTERING PURPOSE KEEPING MAIN PUMPS IN OFF CONDITION.

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

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.

2 NOS.OF CF COOLERS (A&B) 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),MOTORIZED 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.

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 (1W+1S) ,10MAX21AN001,10MAX21AN002 (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.

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

CONTROL FLUID SYSTEM

CONTROL FLUID SYSTEMIsolation valves on pump suction & discharge sidePump discharge pressure 50 KscCapacity41TPHStabilized pressure header supply oil to servo motors of SV & CVUn stabilized pressure header with 22 mm orificeAccumulator in unstabilized pressure headerCF tank capacity6.9 m3Duplex filterControl fluid transfer pump to empty the CF tankCF Temperature control by control station in the ECW line

COMPONENT OF GOVERNING SYSTEMELECTRO-HYDRAULIC CONVERTER SUMMER 8 NOS.SUMMER 8NOS.ELECTRO-MECHANICAL CONVERTER 8NOS.GOVERNING BLOCK

CONTROLGEAR(AE001) 1NO.EMERGENCY GOVERNOR OR OVERSPEED GOVERNOR 1NO.TRIP SOLENOID (AA213,AA214)-2NOS.TEST ELECTROMAGNETS(AA211,AA212) 2NOS.ROTATIONAL SPEED DETECTOR -3 NOS.LIMITER OF PRESSURE (AA502) 1NO.SPEED TRANSDUCER 1NO.LEVER OF OVER SPEED GOVERNOR (AX201) 1NO.PILOT VALVE FOR SUPPLY (AX202) 1NO.

ACCUMULATOR 1NO.OIL SUPPLY AND PURIFIER UNITSERVOMOTOR OF HPSV 2NOS.SERVOMOTOR OF HPCV 4NOS.SERVOMOTOR OF IPSV 2NOS.SERVOMOTOR OF IPCV 4NOS.SERVOMOTOR OF CRH NRV 2NOS.LOCKING PILOT VALVE (AA001,AA002,AB001,AB002)- 4NOS.EX.STOP VALVE SERVOMOTOR OR ESV (10LBQ10AA101) 1NO.

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

TURBINE PROTRCTIONSOUT OF TOLERANCE ROTOR OVERSPEED : ALARM AT 3300RPM AND TRIPPING AT 3360RPMOUT 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 CONDENSER:ALARM 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 OPENINCREASE 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.

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.

TURBINE LUBE OILSYSTEMLUBRICATION 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:16.7CENTIPOISEKINEMATIC VISCOSITY:32CENTISTOKESPECIFIC GRAVITY:0.89SPECIFIC HEAT:0.459Kcal/Kg Deg.CFLASH POINT:180OCFIRE POINT:240OCDEGREE OF CLEANLINESS:16/13 ISO 4406PERMISSIBLE SUSPENDED PARTICLE SIZE:25 MICRONWATER CONTENT:

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.

TG LUBE OIL SUPPLY SYSTEM

TG LUBE OIL SYSTEM

TG LUBE OIL SYSTEMTurbine oil is ISO VG 32KV20-23 CST at 500CAcidity Number< 0.05 mg KOH/rViscosity index> 90BearingsHPT FrontN1HPT RearN2IPT Front (TB)N3IPT RearN4LPT-1 FrontN5LPT-1 RearN6LPT-2 FrontN7LPT-2 RearN8Generator FrontN9Generator RearN10Exciter FrontN11Exciter RearN12

TG LUBE OIL SYSTEM DC Lube oil pump 1 No. 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

EquipmentCapacity (m3/hr)Head (Ksc)AC Lube oil pump3004.3DC Lube oil pump2502.0

TG LUBE OIL SYSTEMOil is first delivered to bearing brasses through emergency tanks located on bearing capEmergency tanks capacity in m3N10.43N20.35N30.75N40.44N50.44N60.44N70.44N80.44N90.5N100.44N110.1N120.1

TG LUBE OIL SYSTEMLube oil temperature control by control station in the ECW inlet line to Lube oil coolersView glasses in the oil return line from each bearingMOT Capacity 58 m3Duplex filters fineness25 mProvision 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 mFresh oil is filled through the above filter onlyOil recirculation pump to purify the oilElectrical 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 pumpOil draining to Emergency lube oil tank in case of emergency with MOV

TG LUBE OIL SYSTEMOil trap at the suction of the vapor extractor fansOil trap drain to lubrication oil tankJacking oil pumps suction also given from lube oil discharge header after coolers & before control valve

TG JACKING OIL AND BARRING GEAR SYSTEM

Barring gear & Jacking oil systemAutomatic barring gear engagement at the rotor stop and barring gear disengaging at the start-upHigh pressure oil supply for bearing inserts oil jackingBarring speed 1.05 rpmMotorized barring gear Torque transfer from the barring gear motor to the turbine shaft is carried out via three stage reducer and free wheel clutchReduction gear first stage shaft end mounts special handle for hand barringNormal source for jacking oil pumps suction is from lube oil pumps discharge header after coolersJOP discharge pressure: 120 Ksc

Barring Gear & Jacking oil systemDozing devices at each bearing of the Turbine & Generator which contain strainer, NRV, orifice & isolation valveBearing 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 operationEach bearing insert jacking oil line is equipped with orifice onlyBoth pumps cut in/cut out is 1500/1500Barring gear cut in/cut out is 1500/1500

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 rpmPump 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

GENERATOR SEAL OIL SYSTEM

GENERATOR SEAL OIL SYSTEMSeal oil pumps suction from MOTNo Hydrogen side seal oil pumpPumps re-circulation line directly to MOTCoolers bypass valveMagnetic filters 2 No. (1W+1SB)NRV in the seal oil line after filtersDPR DPR bypass manual control valve

GENERATOR SEAL OIL SYSTEMDamper 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 offView glasses in return oil linesFloat hydraulic seal functions as SOTHydraulic seal overflows in to return oil headerNo SOSTProvision of trap upstream of fansFans suction is from return oil header

GENERATOR STATOR WATER COOLING SYSTEM

STATOR WATER COOLING SYSTEMWater tank not on the generatorEjector to make vacuum over the water tank to prevent air ingressEjector cooling by auxiliary cooling waterAir venting of Generator through Gas trap connected from winding inlet and outlet headersGas trap to determine hydrogen present which will be extracted from trap cap to gas analyzerCoolers bypass valveIon exchanger-1 contains anion & cat ion in H-OH form to maintain conductivityIon exchanger-2 contains anion & cat ion in Na-OH form to maintain Ph if it decreases below 8Ion exchanger-1 first will be put in to service for reducing dissolved oxygen below 5.0 s/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 s/cm, Ion exchanger-2 to be stopped

STATOR WATER COOLING SYSTEMControl valves at the inlet of individual Ion exchanger circuitsDM water flow through ion exchanger is 1.5 to 2.0 mNo NAOH dozing systemIon exchangers separate bypass linesMechanical filter at the inlet of Ion exchanger circuitDissolved oxygen analyzer & Ph analyzer Winding inlet valve for flow adjustmentWinding outlet valve for pressure adjustmentNormal make up from DM make up line & emergency make up line from CSTFilter in the common make up lineControl station in the common make up line

GENERATOR GAS SUPPLY SYSTEM

GENERATOR GAS SUPPLY SYSTEMTwo Hydrogen manifolds to connect 16 cylinders eachDirect acting Pressure regulator installed on cylinder connecting line to Manifold header to reduce the Hydrogen pressure from 175 Ksc to 10 KscTotal Pressure regulators32Safety valve on each manifold header which operates when the Hydrogen pressure in the manifold exceeds 10.5 KscMOV & NRV in each manifold headerThree CO2 manifolds to connect 17 cylinders eachEach manifold header contains MOV, NRV & Isolation valveMOV with manual bypass valve at the inlet of CO2 heaterCO2 heater is steam heatedSteam source is from auxiliary steam systemSteam parameters: 15 Ksc & 210 0CMOV in the steam inlet lineSteam exhaust will go to FWSV Dish flash tankManifold header pressure is 175-20 KscControl station with Pressure regulator provided D/S of heater to maintain a pressure of 2.0-2.2 Ksc with manual bypass valveSV installed D/S of pressure regulator operates if the pr > 5.0 KscCapacity of one cylinder 50 lit

GENERATOR GAS SUPPLY SYSTEMOne Hydrogen manifold is in operation under normal operating conditionsIf the pr decreases below < 10 Ksc, an alarm will come and operator connects the standby manifold and disconnects the first manifoldTwo CO2 manifolds are in operation under normal operating conditionsIf the pr decreases below < 20 Ksc, an alarm will come and operator connects the standby manifold and disconnects the first manifoldProvision is given for emergency removal of hydrogen from generator itself by providing a line with one manual isolating valve & 2 No. MOV

FLASH TANKSDRAINS 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.

CONDENSERDesignLMZDesign CW Flow64000 m3/hrVacuum 77 mm Hg (abs) at 33 0C89 mm Hg (abs) at 36 0CNo. of passes1Total no. of tubes22.225 (OD)x0.71 (t) - 2992022.225 (OD)x1.00 (t) - 2080 Tube materialASTM A-249 TP 304Rated TTD3.40CDT of CW100C

CONDENSATE EXTRACTION PUMPDesign flow rate238.75 Kg/sDischarge pressure32.15 KscShut off head395 mPump speed 1480 rpmPower input972.3 KWNo. of stages6Type of first stage impellerdouble entryDepth7.43 m

DE-AERATORDesign Pressure13 KscNo. of trays896Spray valves132Design temp for D/A395 0CDesign temp for FST250 0C

DRIP PUMPDesign flow rate324.509 TPHDischarge pressure43 ataShut off head306.7mPump speed1486rpmPower input310.1KWNo. of stages5Type of first stage impellercentrifugal, single entryDepth1090 mm

MDBFPPump flow769.950TPHSuction temp186.20CBP Suction pr.14.05ataBFP Suction pr.21.01ataBFP Discharge pr.335.78ataBFP Discharge temp.187.90CBP Discharge pr.22.01ataShut off head4830mBFP Speed6275 rpmBP Speed1490rpmNormal R/C flow220TPHHC Rated O/P Speed6505rpmOuter casing typebarrelNo. of stages7BFP warm up flow15TPH

TDBFPPump flow1283.14TPHSuction temp186.20CBP Suction pr.14.10ataBFP Suction pr.28.24ataBFP Discharge pr.335.83ataBFP Discharge temp.187.80CBP Discharge pr.29.06ataShut off head4580mBFP Speed4678 rpmBP Speed2098rpmNormal R/C flow365TPHHC Rated O/P Speed6505rpmOuter casing typebarrelNo. of stages7BFP warm up flow20TPH

TDBFP GOVERNING SYSTEM

GOVERNING SYSTEMPARTS OF GOVERNING SYSTEMHydraulic 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)

TDBFP TURBINENumber of stages9CasingSplitSteam admissionDualSteam pressure at inlet20.82ataSteam temperature at inlet4690CTurbine operating speed4678rpmSteam consumption61.4TPHSteam pressure at exhaust0.128ataTurning gear speed15rpmType of governing systemElectro-HydraulicOver speed type tripCentrifugal + electricalJOPNot requiredLube oil tank capacity10.97 m3Lube oilSame as main turbine

TDBFP CONDENSERCW flow3000 TPHVacuum in the condenser0.128Ksc (abs)Total no. of tubes3312Tube OD and thickness22.225x1.06mmNo. of water passes2Tube materialASTM A-249 TP321

TDBFP LUBE OIL SYSTEM

TDBFP EXTRACTION SYSTEM

TDBFP CONDENSATE SYSTEM

ACW SYSTEM

ACW SYSTEMSuction header is from all the 4 CW inlet lines to condensersMOV at Suction header from CW lineMOV at SCS inletMOV at PHE inlet & outletSupply toEjector of Stator water cooling systemTDBFP vacuum pumps (4 No.)Main turbine vacuum pumps (1 No. extra)MOV at return header to CW line

TURBINE VACUUM SYSTEM

TURBINE HEATING FLANGES SYSTEM

AUXILIARY STEAM SYSTEM

CONDENSATE SUPPLY SYSTEM TO EXT NRVS

EXHAUST HOOD SPRAY

FEED WATER SYSTEM

TDBFP-A FEED WATER SYSTEM

MDBFP FEED WATER SYSTEM

LP DOZING & OXY TREATMENT SYSTEM

HP BYPASS SYSTEM

LP BYPASS SYSTEM