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STUDY OF WORKING OF

STEAM TURBINE AND ITS AUXILIARIES

WORKING OF STEAM TURBINE AND ITS AUXILIARIES

INDEX

Abstract
CHAPTER 1
Introduction to Steam Turbine
1.1 Definitions of Steam turbine
1.2 Principle of Operation
1.3 Classification of Steam Turbines
1.4 Basic types of turbine
1.4.1 The Impulse Turbine
1.4.2 The Reaction Turbine
1.5 Steam Turbine Applications
CHAPTER 2
Steam Turbine Parts
CHAPTER 3
Construction and Steam Flow
CHAPTER 4
Normal Working Condition
CHAPTER 5
Specifications of Steam Turbine
CHAPTER 6
Turbine Auxiliaries
6.1 Turbine Governing System
6.2 Vacuum System
6.3 Condensate System
6.4 Feed Water System
6.5 Cooling Water System
6.6 Lubrication Oil System
Conclusion
Bibilography

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STUDY OF WORKING OF
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List of Figures

Page No.

Fig(a)
Diagram of a typical coal-fired thermal power station.
Fig.1.4.1 Diagram of a Impulse Turbine
Fig.1.4.2 Diagram of a Reaction Turbine
Fig.2.1
Diagram showing Parts of Steam Turbine
Fig:2.2
Outer & Inner casing of Steam turbine
Fig:2.3
Oil system
Fig.2.4
Pipes
Fig.3.1
HP Turbine
Fig.3.2
Sectional view of HP Turbine
Fig.3.3
IP Turbine
Fig.3.4
LP Turbine with Shaft
Fig.3.5
Turbine & Generator System in Steam Power Plant
Fig.3.6
Main and Thrust Bearings:(a)main bearing;(b)section of thrust bearing and
housing;(c)thrust bearing cage in place
Fig:4.1
Diagram showing Working of Steam turbine
Fig:6.2
Condenser
Fig:6.2.1 Ejector
Fig:6.3
Condensate Extraction Pump
Fig:6.3.1 Deareator
Fig:6.3.2 Circuit diagram of Condenser Connections
Fig:6.3.3 Circuit diagram of Condensate System Connections
Fig:6.4
Turbine Driven Boiler Feed Pump
Fig:6.4.1 HP Heater
Fig:6.4.2 Circuit Diagram of Turbine Driven Boiler Feed Pump
Fig:6.5
Cooling towers
Fig:6.6
Turbine Lube Oil System
Fig:6.6.1 Steam Turbine flow Diagram Showing Auxiliaries

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DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

ABSTRACT

A power plant can be roughly divided into 3 parts. Furnace boiler, Turbine which
includes condenser pump, feed water heater, and rejection system and the electric
generator. Steam from furnace is supplied in which K.E of steam is used to drive
the turbine to obtain Mechanical Energy. Study of Steam turbine which is capable
of generating power with its auxiliaries is studied in this project.

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INTRODUCTION TO THE FUNCTIONING OF A POWER


PLANT

(a)Diagram of a typical coal-fired thermal power station

Key
1. Cooling tower

10. Steam governor valve


4

19. Superheater

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2. Cooling water pump


3. Transmission line (3-phase)
4. Unit transformer (3-phase)
5. Electric generator (3-phase)
6. Low pressure turbine
7. Boiler feed pump
8. Condensor
9. Intermediate pressure turbine

11. High pressure turbine


12. Deaerator
13. Feed heater
14. Coal conveyor
15. Coal hopper
16. Pulverised fuel mill
17. Boiler drum
18. Ash hopper

20. Forced draught fan


21. Reheater
22. Air intake
23. Economiser
24. Air preheater
25. Precipitator
26. Induced draught fan
27. Chimney Stack

Description:.
1. Coal is conveyed (14) from an external stack and ground to a very fine powder by large metal
spheres in the pulverized fuel mill (16).
2. There it is mixed with preheated air (24) driven by the forced draught fan (20).
3. The hot air-fuel mixture is forced at high pressure into the boiler where it rapidly ignites.
4. Water of a high purity flows vertically up the tube-lined walls of the boiler, where it turns into
steam, and is passed to the boiler drum, where steam is separated from any remaining water.
5. The steam passes through a manifold in the roof of the drum into the pendant superheater (19)
where its temperature and pressure increase rapidly to around 200 bar and 570C, sufficient to
make the tube walls glow a dull red.
6. The steam is piped to the high-pressure turbine (11), the first of a three-stage turbine process.
7. A steam governor valve (10) allows for both manual control of the turbine and automatic set
point following.
8. The steam is exhausted from the high-pressure turbine, and reduced in both pressure and
temperature, is returned to the boiler reheater (21).
9. The reheated steam is then passed to the intermediate pressure turbine (9), and from there
passed directly to the low pressure turbine set (6).
10. The exiting steam, now a little above its boiling point, is brought into thermal contact with
cold water (pumped in from the cooling tower) in the condensor (8), where it condenses rapidly
back into water, creating near vacuum-like conditions inside the condensor chest.
11. The condensed water is then passed by a feed pump (7) through a deaerator (12), and
prewarmed, first in a feed heater (13) powered by steam drawn from the high pressure set, and
then in the economiser (23), before being returned to the boiler drum.
12. The cooling water from the condensor is sprayed inside a cooling tower (1), creating a highly
visible plume of water vapor, before being pumped back to the condensor (8) in cooling water
cycle.
13. The three turbine sets are coupled on the same shaft as the three-phase electrical generator (5)
which generates an intermediate level voltage (typically 20-25 kV).
14. This is stepped up by the unit transformer (4) to a voltage more suitable for transmission
(typically 250-500 kV) and is sent out onto the three-phase transmission system (3).
15. Exhaust gas from the boiler is drawn by the induced draft fan (26) through an electrostatic
precipitator (25) and is then vented through the chimney stack (27).

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1. INTRODUCTION TO STEAM TURBINE


A steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and
converts it into rotary motion. Its modern manifestation was invented by Sir Charles Parsons in
1884.

1.1 Definitions of Steam turbine:

Turbine in which steam strikes blades and makes them turn.

A system of angled and shaped blades arranged on a rotor through which steam is passed
to generate rotational energy. Today, normally used in power stations

A device for converting energy of high-pressure steam (produced in a boiler) into


mechanical power which can then be used to generate electricity.

Equipment unit flown through by steam, used to convert the energy of the steam into
rotational energy.

1.2 Principle of Operation:


In reciprocating steam engine, the pressure of energy of steam is used to overcome
external resistance and dynamic action of the steam is negligibly small. Steam engine may be
return by using the full pressure without any expansion or drop of pressure in the cylinder.
The steam energy is converted mechanical work by expansion through the turbine. The
expansion takes place through a series of fixed blades (nozzles) and moving blades each row of
fixed blades and moving blades is called a stage. The moving blades rotate on the central turbine

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rotor and the fixed blades are concentrically arranged within the circular turbine casing which is
substantially designed to withstand the steam pressure.

1.3 Classification of Steam Turbines


The first steam turbine, at its time indeed did spark off the industrial revolution through
out the west. However, the turbine at that time was still an inefficient piece of heavy weighing
high maintenance machine. The power to weight ratio of the first reciprocating steam turbine was
extremely low, and this led to a great focus improving the design, efficiency and usability of the
basic steam turbine, the result of which are the power horses that currently produce more than
80% of todays electricity at power plants!

Steam Turbines are Classified as:Steam Turbines can be classified on the basis of a number of factors. Some of the important
methods of steam turbine classification are enunciated below:

On the basis of Stage Design:

Steam turbines use different stages to achieve their ultimate power conversion goal. Depending
on the stages used by a particular turbine, it is classified as Impulse Turbine, or Reaction type.

On the Basis of the Arrangement of its Main Shaft:

Depending on the shaft arrangement of the steam turbine, they may be classified as Single
housing (casing), tandem compound (two or more housings, with shafts that are coupled in line
with each other) and Cross compound turbines (the shafts here are not in line).

On the Basis of Supply of Steam and Steam Exhaust Condition:

They may be classified as Condensing, Non Condensing, Controlled or Automatic extraction


type, Reheat (the steam is bypassed at an intermediate level, reheated and sent again) and Mixed
pressure steam turbines (they have more than one source of steam at different pressures).

On the basis of Direction of Steam Flow:

They may be axial, radial or tangential flow steam turbines.

On the Basis of Steam Supply:

Superheated steam turbine or saturated steam turbine.

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1.4 Basic types of turbine


The two most basic and fundamental types of steam turbines are the impulse turbine and the
impulse reaction turbine.

1.4.1 The Impulse Turbine:


The impulse turbine consists of a set of stationary blades followed by a set of rotor blades which
rotate to produce the rotary power. The high pressure steam flows through the fixed blades,
which are nothing but nozzles, and undergo a decrease in pressure energy, which is converted to
kinetic energy to give the steam high velocity levels. This high velocity steam strikes the moving
blades or rotor and causes them to rotate. The fixed blades do not completely convert all the
pressure energy of the steam to kinetic energy, hence there is some residual pressure energy
associated with the steam on exit. Therefore the efficiency of this turbine is very limited as
compared to the next turbine we are going to review- the reaction turbine or impulse reaction
turbine.

Fig.1.4.1 Diagram of a Impulse Turbine

Working of Impulse Turbine:-

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The impulse turbine was one of the basic steam turbines. It involved striking of the blades
by a stream or a jet of high pressure steam, which caused the blades of the turbine to
rotate. The direction of the jet was perpendicular to the axis of the blade. It was realized
that the impulse turbine was not very efficient and required high pressures, which is also
quite difficult to maintain. The impulse turbine has nozzles that are fixed to convert the
steam to high pressure steam before letting it strike the blades.

Impulse turbine mechanism:


Impulse turbine Mechanism deals with the Impulse force action-reaction.
As we all know the Newton 3rd law of motion," Every action has equal and opposite
reaction", the same is work on this.
As the water fall on the blade of the rotor it generate the impact force on the blade
surface, The blade tends to give the same reaction to the fluid, but the rotor is attached to
the rotating assembly, it absorb the force impact and give the reaction in the direction of
the fluid flow. Thus the whole turbine rotates.
The rotation speed of the turbine depends on the fluid velocity, more the fluid velocity,
greater the rotation speed, and greater the speed means more power generation.

1.4.2 The Reaction Turbine


The reaction turbine is a turbine that makes use of both the impulse and the reaction of
the steam to produce the rotary effect on the rotors. The moving blades or the rotors here
are also nozzle shaped (They are aerodynamically designed for this) and hence there is a
drop in pressure while moving through the rotor as well. Therefore in this turbine the
pressure drops occur not only in the fixed blades, but a further pressure drop occurs in the
rotor stage as well. This is the reason why this turbine is more efficient as the exit
pressure of the steam is lesser, and the conversion is more. The velocity drop between the
fixed blades and moving blades is almost zero, and the main velocity drop occurs only in
the rotor stage.

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Fig.1.4.2 Diagram of a Reaction Turbine

WORKING OF REACTION TURBINE:


In the reaction turbine, the rotor blades themselves are arranged to form convergent
nozzle Reaction Turbines.
In the reaction turbine, the rotor blades themselves are arranged to form convergent
nozzles. This type of turbine makes use of the reaction force produced as the steam
accelerates through the nozzles formed by the rotor. Steam is directed onto the rotor by
the fixed vanes of the stator. It leaves the stator as a jet that fills the entire circumference
of the rotor. The steam then changes direction and increases its speed relative to the speed
of the blades. A pressure drop occurs across both the stator and the rotor, with steam
accelerating through the stator and decelerating through the rotor, with no net change in
steam velocity across the stage but with a decrease in both pressure and temperature,
reflecting the work performed in the driving of the rotor.
This type of turbine makes use of the reaction force produced as the steam accelerates
through the nozzles formed by the rotor. Steam is directed onto the rotor by the fixed
vanes of the stator. It leaves the stator as a jet that fills the entire circumference of the
rotor. The steam then changes direction and increases its speed relative to the speed of the
blades. A pressure drop occurs across both the stator and the rotor, with steam
accelerating through the stator and decelerating through the rotor, with no net change in
steam velocity across the stage but with a decrease in both pressure and temperature,
reflecting the work performed in the driving of the rotor.

1.5 Steam Turbine Applications

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The Steam turbines of today are mostly used in the power production field. Steam
turbines are used to efficiently produce electricity from solar, coal and nuclear power
plants owing to the harmlessness of its working fluid, water/steam, and its wide
availability. Modern steam turbines have come a long way in increasing efficiency in
performance and more and more efforts are being made to try and reach the ideal steam
turbine conditions, though this is physically impossible! Almost every power plant in the
world, other than hydro electric power plants, that use turbines that run on water (the
Francis, Pelton turbines also have the influence of steam turbines) , use steam turbines for
power conversion. With all the scientific advancement in power generation being
attributed to them, steam turbines really have changed the way the world moves!
Steam turbines are devices which convert the energy stored in steam into rotational
mechanical energy. These machines are widely used for the generation of electricity

Utility Steam Turbine Applications:


Applications for utility Steam Turbines are applied for control of straight condensing,
reheat and non-reheat steam turbines up to 300MW. These upgrades may include
integrated generator control for generator protection and excitation/ AVR upgrades,
utilizing the latest commonly available industry-standard digital equipment.

Industrial application of steam turbine:


Applications of Industrial Steam Turbines cover all straight condensing, non-condensing,
and automatic extraction steam turbines. Specific design features are incorporated to
address control issues often unique to process plants including paper mills, oil refineries,
chemical plants, and other industrial applications, generator and mechanical drive.
Some of the worlds largest turbines manufacturing companies that are seeing the rewards
of research and steam turbine advances are coming together to develop highly efficient
turbines. The collaboration of Mitsubishi Heavy Machinery and General Electric Energy
(GE Energy) for the conceptualization and design of a highly efficient next- generation
steam turbine for its inception in combined cycle gas turbine power plants recently has
further proved that there is still a lot to be achieved in steam turbine related research and
development, and that the scope for improvement can be much higher.

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CHAPTER 2
Steam Turbine Parts
Steam turbines are machines that are used to generate mechanical (rotational motion)
power from the pressure energy of steam. Steam turbines are the most popular power
generating devices used in the power plant industry primarily because of the high
availability of water, moderate boiling point, cheap nature and mild reacting properties.
The most widely used and powerful turbines of today are those that run on steam. From
nuclear reactors to thermal power plants, the role of the steam turbine is both pivotal and
result determining.
A steam turbine basically has a mechanical side, and an electrical side to it. The
mechanical components include the moving parts (mechanical), such as the rotor, the
moving blades, the fixed blades, and stop valves, while the electrical side consists of the
generator and other electrical components to actually convert the energy into a usable,
easily transferable form.

Blades:
For starters, a simple turbine works just like a windmill. Only, in the steam turbines of
today, rather than striking the blades directly, the blades are designed in such a way as to
produce maximum rotational energy by directing the flow of the steam along its surface.
So the primary component that goes into a steam turbine is its blades. The blades of a
steam turbine are designed to behave like nozzles, thus effectively tapping both the
impulse and reaction force of the steam for higher efficiency. Nozzle design itself is a
complex process, and the nozzle shaped blade of the turbine is probably one of the most
important parts in its construction. The blades are made at specific angles in order to
incorporate the net flow of steam over it in its favor. The blades may be of stationary or
fixed and rotary or moving or types.

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Fig.2.1 Diagram showing Parts of Steam Turbine

Shafts:
The shaft is a power transmitting device and is used to transmit the rotational movement
of the blades connected to it at one end via the rotor to the coupling, speed reducer or
gear at the other end.

Outer Casing:
The steam turbine is surrounded by housing or an outer casing which contains the turbine
and protects the device components from external influence and damage. It may also
support the bearings on which the shafts rest to provide rigidity to the shaft. Usually split
at the center horizontally, the casing parts are often bolted together for easy opening,
checking and steam turbine maintenance, and are extremely sturdy and strong.

Fig:2.2 Outer & Inner casing of Steam turbine.

Governor:
The governor is a device used to regulate and control or govern the output of the steam
turbine. This is done by means of control valves which control the steam flow into the
turbine in the first place.

Oil System:
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A steam turbine has thousands of moving parts and all these parts not only have to move
in high velocities, but also need to be protected from wear and tear over the years. This is
done by effective lubrication by the oil system, which governs the pressure, flow and
temperature of the turbine oil, the bearing oil and lubrication of other moving parts.

Fig:2.3 Oil system

Pipes:
The pipe is an all important steam turbine component that brings the steam from the
boiler to the turbine. This has to be done without an appreciable loss in pressure, and at
the same time, must be able to withstand all these pressures safely. The pipes should be
easy to clean and are prone to deposits on their inner surfaces. Deposits on the inner
surface of the steam pipe reduce the net steam flow area, throwing forth a negative effect
on the efficiency.

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Fig.2.4 Pipes

CHAPTER 3
CONSTRUCTION & STEAM FLOW
The turbine is a single shaft machine with separate HP and LP parts, the HP part being a single
flow, the IP and IP parts double flow cylinders. Ring couplings connect the individual turbine
rotors and the generator rotor.
The HP cylinder has a throttle control. The initial steam admitted before the blading by four
combined main steam stop and control valves. The lines leading from the two HP exhaust
branches to the reheated are provided with swing check valves which prevent hot steam from the
reheater flowing back into the HP turbine.
The steam coming from the reheater is passed to the IP part via four combined reheats stop and
control valves. Crossover pipes connect the IP and LP cylinders.

HP TURBINE, BARREL TYPE CASING:


The outer casing of the HP turbine is of the barrel type and has neither an axial nor a radial
flange. This prevents mass accumulation with high thermal stresses. The almost perfect
rotational symmetry permits moderate wall thickness of nearly equal strength at all sections. The
guide blade carrier is axially split and kinematically supported. As only slight pressure
differences are effective, the horizontal flange and connection bolts can be kept small. The barrel
type casing permits flexibility of operation in the form of short startup times and a high rate of
change of load even at high initial steam conditions.

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Fig.3.1 HP TURBINE

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Fig.3.2 SECTIONAL VIEW OF HP TURBINE

IP TURBINE:

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STUDY OF WORKING OF
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The IP turbine part is double flow construction. Attached in the axially split casing is an inner
casing supported kinematically and taking the guide blades. The reheated steam is admitted to
the inner casing through the top and bottom center of the casing. The arrangement of an inner
casing confines the high steam inlet conditions to the admission branch of the casing, while the
joint of the outer casing is only subjected to the lower pressure and lower temperature at the
exhaust of the inner casing.

Fig.3.3 IP TURBINE
LP TURBINE:
The casing of the double flow IP cylinder is of three shell design. The shells are axially split and
have rigid welded construction. The inner shell taking the first rows of the guide blades is
attached kinematically in the middle shelf. Independent of the outer shell, the middle shell is
supported at four points on longitudinal beams. Two rings carrying them last guide blade rows
are also attached to the middle shelf.

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Fig.3.4 LP TURBINE WITH SHAFT

Fig.3.5 TURBINE & GENERATOR SYSTEM IN STEAM POWER PLANT

BLADING:
The entire turbine is provided with reaction blading. The guide blades of the LP parts with
inverted T-roots and shrouding are milled from one piece. The last stages of the IP part consists
of twisted drop forged moving blades with fir-tree roots inserted in corresponding grooves of the
rotor and guide blade rows made of sheet steel.
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BEARINGS:

Fig.3.6 Main and Thrust Bearings:(a)main bearing;(b)section of thrust bearing and housing;
(c)thrust bearing cage in place
The HP rotor is supported by two bearings, the journal bearing at the front end of the turbine and
a combined journal and thrust bearing directly adjacent to the coupling with the IP rotor. The IP
and LP rotors having journal and thrust bearing incorporates a journal hearing and thrust bearing
which takes up residual thrust from both directions. The bearing temperatures are measured by
thermocouples in the lower shell directly under the white metal lining. The temperature of the
thrust bearing is measured in two opposite thrust pads. The front rear bearing pedestals of the HP
turbine is placed on base plates. The pedestals of the LP part are fixed in position, the front
pedestals of the LP part are fixed in position, the front pedestal and the pedestal between HP and
IP part are able to move in axial direction.
The brackets at the sides of the HP and IP parts are supported by the pedestals at the level of the
machine axial. In the axial direction of the HP and IP parts are firmly connected with the pedestal
by means of casing guided without restricting radial expansion. Since the casing guide do not
yield response to axial displacement, the HP and IP casings as well as associated bearings
pedestals move forward from the front LP bearing pedestal on thermal expansion.

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Journal bearings are manufactured in two halves and usually consist bearing body faced with
anti-friction tin based babbling to decrease coefficient of friction. Bearing body match with
adjustable seating assembly in the pedestal. Bearings are usually forced lubricated and have
provision for admission of jacking oil.
The thrust bearing is normally Mitchel type and is usually combined with a journal bearing,
horsed in spherically machined steel shell. The bearing between the HP and IP rotors is of this
type; while the rest are journal bearings.
Earlier each rotor used to have its own set of bearings. Not with the popularity of rigid coupling
between rotors, it is possible to use only on bearings between two rotors. This arrangement will
lead to more flexible rotors (lower critical speed), for the same rotor design because span
between bearings increases. With reduction in number of bearings, length of turbine gets reduced
resulting in consideration saving in capital cost.

SHAFT GLANDS AND BLADE SEALING STRIPS:


All shaft glands sealing the steam in the cylinders against atmosphere are axial flow labyrinths.
They consist of a large number of thin sealing strips which in the HP and IP parts are alternate
caulked into grooves in the shafts and surrounding sealing rings. The sealing strips of the LP
parts are only caulked into the sealing rings. These rings are split into segments, which are forced
radially against a projection by helical springs and are able to yield in the event of rubbing.
Sealing strips of similar design are also used to seal the radial blade strip clearances.

VALVES:
The HP turbine is fitted with four initial steam stop and control valves. A stop and control valve
with steams arranged at right angles to each other are combined in a common body. The stop
valves are spring operated single seal valves; the control valves, also of single seat design, have
diffuser to reduce pressure losses.
IP turbine has four-combined reheat stop and control valves. The reheat stop valves are spring
loaded single sealed valves. The control valves operate in parallel and fully opened in the upper
load range in the load range, they control the steam flow to the IP turbine and ensure stable
operation even when the turbo set is supplying only the station load.

Emergency Stop Valves and Control Valves: (ESVs)


Turbine is equipped with emergency stop valves to cut off steam supply and with control valves
to regulate steam supply. Emergency stop valves (ESV) are provided in the mainstream line and
interceptor valves (IV) are provided in the hot reheat line.
Emergency stop valves are actuated by servomotor controlled by the protection system. ESV
remains either fully open or fully close.
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Control valves are actuated by the governing system through servomotors to regulate steam
supply as required by the load.
Valves are either single seat type or double seat type. Single seat type valves are preferred
through these require higher force for opening or closing.

Couplings:
Since the shaft (rotor) is made in small parts due to forging limitations and other technological
and economic reasons, the couplings are required between any two rotors. This coupling permits
angular misalignment, transmits axial thrust and ensures axial location. The couplings are either
rigid or semi flexible. The former neither permits angular nor lateral defection while the later
permits only angular defection. Number of critical speeds depends upon the modes of vibrations
and hence the type of coupling provided between rotors. Generally in 200/210MW
turbine,coupling between HPT and IPT is of rigid type and between IPT and LPT is of semiflexible lens type.

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CHAPTER 4
NORMAL WORKING CONDITION

Fig:4.1 Diagram showing Working of Steam turbine

The super heated steam from the boiler super heater is bleed into high pressure turbine where the
expansion takes place upto an intermediate pressure.

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STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

This intermediate steam is next further bleed into intermediate pressure turbine after reheating
expansion occurs. This expanded steam further sent into low pressure turbine.
The kinetic head of the steam is used to rotate or drive the turbine rotor due to expanding on the
turbine blades. This rotor of the turbine is coupled to generator shaft.
Due to revolution of generator shaft produces the electricity (based on the faradays law). The
power generated is 14KV is connected to the step up transformer producing 400 KV and further
connected to switchyard for distribution.

Working under abnormal conditions:


The super heated steam from the boiler super heater is bleed into high pressure turbine is cut off
by a control valve then the by pass system is used because due to the continuous flow of super
heated steam from the boiler super heater lead to the damage of steam pipe line due to excessive
increase in pressure.
Then the steam from the by pass valve, I made to pass through the intermediate pressure turbine
or high pressure reheater.
Similarly if the steam entering the intermediate pressure turbine is cut off then the steam is made
by passed to pass through the control valves and sent to cold reheater.
Similarly if the steam entering the low pressure turbine is cut off then the steam is made by
passed to pass through boiler feed pump.
The expanded steam from the low pressure turbine is sent to the condenser.
The condensate is pumped to Low preheater 1,2 and further to low preheater 3 by condensate
extraction pump.
The water from lph3 is sent to deareator. The water from deareator is sent to high pre-heater 5,6
and then to economizer and then to the boiler furnace. The heat absorbed by the cooling water by
condensing the steam in the condenser is sent to the cooling towers for cooling by I.D. fan.

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DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

CHAPTER 5
Specifications of Steam Turbine

Make

BHEL, KWU

Type

Three cylinder reheat Condensing reaction turbine

Nominal rating

500 MW

Peak loading

545 MW

Rated speed

3000rpm

Max/Min speed

3090/2850rpm

400 to 2850rpm

(no time limitation)


Speed exclusion range

Steam Pressure & Temperature (Rated Values)


Pressure (ata) Temp. (0C)
Initial Steam

170

25

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DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

First stage pressure

151.79
537.0

HP cylinder exhaust

45

342.5

IP stop valve inlet

40.5

537

Extraction-6

45.0

342.5

Extraction-5

19.52
428.3

Extraction-4

7.57

302.0

Extraction-3

2.76

197.8

Extraction-2

1.42

138.8

Extraction-1

0.286
67.6

LP cylinder exhaust

0.0884
43.1

Weight(Tonnes)

HP

IP

LP

Rotor(complete with
Blading)

11.6

21.8

84.6

Reheat stop and control


Valve(complete without
Bend & pipe section)

17.0

Moments of Inertia(Kg-M2)
Rotor of HP cylinder
Rotor of IP cylinder

713.0
2145.6
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DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

Rotor of LP cylinder

22981.0

Limiting Values
Casing temperature(0C)
Alarm at M/c must be shut down at
HP turbine exhaust

480.0

Outlet casing of LPcylinder

500.0

90.0

110.0

Alarm at M/c must be shut down at


HP turbine middle

+55

+70

IP turbine front

+30

+45

IP turbine rear

+30

+45

(Spray water to LP cylinder must be switched on at 900C)


Temperature Difference (K)
(Between Upper and Lower Casing Section)
Steam Purity(KWU Recommended Values) During Operation
Conductivity at 250C
Alkaline method

<0.10 us/Cm

Silica acid(SiO2)

<0.010 mg/Kg

Total iron(Fe)

<0.005 mg/Kg

Total copper

<0.0010 mg/Kg

Sodium(Na)

<0.005 mg/Kg
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DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

Bearing Temperature(0C)
Alarm M/c must be shut down at Vibration(Absolute Vibration)
Bearing

Shaft

Housing
Nominal value for alarm

30 microns above
normal level

Max. value for alarm

35microns

120 microns

45microns

200 microns

Limit value for


tripping(manual)

Differential Expansions
HP turbine

+5mm to -3mm

IP turbine

+8mm to -2mm

LP turbine

+30mm to -3mm

Material Of Construction
Casings
HP outer casing
Barrel casing

GS 17 cr. MOV 511

HP blade carrier

GS 17 cr. MO 511

IP casing

GS 22 MO 4

LP casing

Outer ST 37-2N
Inner-I GS 22,MO4,H II,15 MO 3

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DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

Inner-II ST 37-2N
Shafts
HP shaft

28 Cr.MO Ni 59

IP shaft

30 Cr.MO Ni V 511

LP shaft

26 Ni Cr MO V 145

Moving Blades
HP turbine first stage
HP turbine other stages

x22 Cr MOV 121


x20 Cr 13/x22 CrMOV 121

IP turbine stage

x20 Cr MO 13/x 20 Cr.30

LP turbine stage

x20 Cr 13

CHAPTER 6

TURBINE AUXILIARIES
6.1 TURBINE GOVERNING SYSTEM
Power station turbines are constant sped machines and they are rotated at a speed of 3000rpm to
enable the coupled generator to produce electricity at 50 Hz frequency.
The main purpose of the governor is to maintain the desired speed of turbine during fluctuation
of load on generator by varying steam input into the turbine as required.
The governing system is addition to ensuring the following load speed characteristics of the
turbine also ensure the following functions.

The run up of the turbine from the rest to the rated speed and synchronizing with
the grid.

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DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

Meeting the steam load variation in the predetermined manner, when running in
parallel with the other machines.

Protecting the machine by reducing the load or shutting of completely in a


abnormal and emergency situation.

TYPES OF GOVERNING SYSTEMS:


1. Throttle Governing.
2. Nozzle Governing.
3. Bypass Governing.

THROTTLE GOVERNING:
In Throttle Governing system the governing attachment is attached directly to the Turbine shaft
itself and rotates at the same speed of the turbine. According to the turbine speed the attachment
linked with the rotor will run. The balls attached to the arrangement will run by the centrifugal
force and the valve will operate and allow the steam to flow into the turbine. When the load on
the generator will get through off and due to this effect the speed of the turbine will rise
tremendously which will damage the equipment. The fulcrum attached to the governing system
will pull the valve position.

NOZZLE GOVERNING:
In this method the Nozzles are grouped and the supply of steam is controlled by a special system
called as ELECTRO HYDRAULIC CONTROL system. The controlling of the intercept valves
will supply the steam to the curtesvey stage of the high pr turbine through intercept valves. There
will be a rack and pinion attachment arrangement to operate the intercept valves. The valves will
operate radially in a sequence by maintaining the input supply under balancing. At full load the
valves will be in fully open condition. The operation of the valves totally carried out by the
hydraulic oil supply only thus the nozzle governing system is called as ELECTRO
HYDRAULIC CONTROL GOVERNING system. In Ramagundam this system was adopted to
have better control on valve operation. It is most effective one and is suitable for control the high
capacity turbines.

BYPASS GOVERNING:
In this system the steam is supplied through a primary valve and is adequate to meet a major
function of the maximum, load, which is called the economic load. At loads less than this
throttling steam through this valve does the regulations. When the load on the turbine exceeds
this economic load which can be develop by the UN throttled, full flow through the primary
valve. This steam joins the partially spent steam admitting through the primary valve, developing
additional blade torque to meet the increased load.

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DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

6.2 VACUUM SYSTEM


As we begin the recirculating processes, the first system, which comes into focus, is the vacuum
system. The equipments under this system, as described in this chapter, strive to maximize the
work done of turbine by maintaining the rated vacuum limits.

Condenser:
There are two condensers entered to the two exhausters of the LP turbine. These are surface type
condensers with two-pass arrangement. Cooling water pumped into each condenser by a vertical
C.W. Pump thru the inlet pipe. Water enters the inlet chamber of the front water box, passes
horizontally thru the brass troes to the water box at the other end, takes a turn, passes thru the
upper cluster to tubes and reaches the outlet chamber in the front water box. From these, cooling
water leaves the condenser thru the outlet pipe and discharges into the discharge duct.
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DEPARTMENT OF MECHANICAL ENGINEERING

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Steam exhausted from the LP turbine washing the outside of the condenser tubes loses it latent
heat to the cooling water and is connected with water in the steam side of the condenser. This
condensate collects in the hot well.

Fig:6.2 Condenser

Ejectors:
There are two 100% capacity ejectors of the steam eject type. The purpose of the ejector is to
evacuate air and other non-condensing gases from the condensers and thus maintain the vacuum
in the condensers.
This is a 3 stage ejector using steam from the deaerator with 11 ATM header as the working
medium. The ejector has three compartments. Steam is supplied generally at a pressure of 4.5 to
5 kg/Cm2 to the three nozzles in the three compartments. Steam expands in the nozzles thus
giving a high velocity eject which creates a low pressure zone in the throat of the eject. Since the
nozzle box of the ejector is connected to the air pipe from the condenser, the air and pressure
zone. The working steam which has expanded in volume comes into contact with the cluster of
tube bundles thru which condensate in flowing and gets condensed thus further aiding the
formulation of vacuum. The non consuming gases of air are further sucked with the next stage of
the ejector by the action of the second nozzle. The process repeats itself in the third stage also
and finally the steam air mixture is exhausted into the atmosphere thru the outlet.
In addition to the main ejectors there is a single stage starting ejectors which is used for initial of
vacuum upto 500mm of Hg. It consists of nozzle is connection to the air pipe from the
condenser.

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DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

Fig:7.2.1 Ejector

Gland Steam Cooler:


Steam from deaerator or from Auxillary steam header is supplied to the end seals of the HP rotor
and LP rotor generally at a pressure of 0.01 to 1.03 ata. So as to prevent ingress of atmosphere
air into the turbine thru the end clearances. This steam supplied to the end seals is extracted by
the gland steam cooler by the auction of single stage steam ejector.

6.3 CONDENSATE SYSTEM


The steam after condensing in the condensing in the condenser known as condensate, is extracted
out of the condenser hot well by condensate pump and taken to the deaerator through ejectors,
gland steam cooler and series of LP heaters
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DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

Condensate Pumps:
The function of these pumps is to pump out the condensate to the deaerator through injector,
gland steam cooler and LP heaters. These pumps have four stages and since the suction is at a
negative pressure, special arrangements have been made for providing sealing.
The level indicator for visual level indication of heating steam condensate pressure vacuum
gauges for measurement of steam pressure etc, it is a direct contact type heater combined with
feed storage tank of adequate capacity. The heating steam is normally supplied from turbine
extractions but during starting and low load operation the steam is supplied from auxiliary
source.

Fig:6.3 Condensate Extraction Pump

Deaerator:
The Deaerator comprises of two chambers:
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DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

A) Deaerating column.
B) Feed storage tank.
Deaerating column is a spray cum tray type cylindrical vessel of horizontal construction with
dished ends weided to it. The tray stack is designed to ensure maximum contact time as well as
optimum scrubbing of condensate to achieve efficient deaeration. The deaeration column in
mounted on the feed storage tank which in turn is supported on rollers at the two ends and a
fixed support at the center. The feed storage tank is fabricated from boiler quality steel plates.
Man holes are provided on deaerating column as well as on feed storage tank for inspection and
maintenance.
The condensate is admitted at the top of the deaerating column and flows downwards through the
spray valves and trays. The trays and designed to expose though the maximum water surfaces for
efficient scrubbing to effect the liberation of the associated gases-steam enters from the
underneath of the trays and flows in counter direction of condensate. While flowing upwards
through the trays, scrubbing and heating is done. Thus the liberated gases move upwards along
with the steam. Steam gets condensed above the trays and in turn heats the condensate. Liberated
gases escapes to atmosphere from the office opening eant for it. This opening is provided with a
number of deflectors to minimize the loss of steam.
Deaerators main components are given below:
1.
2.
3.
4.
5.
6.
7.

Tubular type gauge glass.


High level alarm switch.
Low level alarm switch.
Pressure gauge.
Straight thermometers with pockets.
Safety valve.
Isolating valves for stand pipes.

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DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

Fig:6.3.1 Deareator

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DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

Fig:6.3.2 Circuit diagram of Condenser Connections

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DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

Fig:6.3.3 Circuit diagram of Condensate System Connections

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DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

6.4 FEED WATER SYSTEM


This system plays an important role in the supply of feed water to the boiler at requisite pressure
and steam water ratio. This chapter describes the various auxiliaries under this system starting
from Boiler Feed Pump to Feed regulating station via HP heaters.

Boiler Feed Pump:


This pump is horizontal and of barrel design driven by an Electric motor through a hydraulic
coupling. All the bearings of pump and motor are forced lubricated by a suitable oil lubricating
system with adequate protection to trip the pump if the lubrication oil pressure fails below a
preset valve.
The high-pressure boiler feed pump is very expensive machine which calls for a very careful
operation and skilled maintenance. The safety in operation and efficiency of the feed pump
depends largely on the reliable operation and maintenance. Operation staff must be able to find
out the causes of defect at the very beginning which can be easily removed without the
endangering the operator of the power plant and also without the expensive dismantling of the
high pressure feed pump.
The feed pump consists of the pump barrel, into which is mounted the inside stator together with
rotor. The hydraulic part is enclosed by the high pressure cover along with the balancing device.
The suction side of the barrel and the space in the high pressure cover behind the balancing
device are enclosed by the low pressure covers along with the stuffing box casings. The brackets
of the radial bearing of the suction side and radial and thrust bearing of the discharge side are
fixed to the low pressure covers. The entire pumps is mounted on a foundation frame. The
hydraulic coupling and two claw couplings with coupling guards are also delivered along with
the pump. Water cooling and oil lubricating connections are provided with their accessories.

39

DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

Fig: 6.4 Turbine Driven Boiler Feed Pump

High Pressure Heaters:


These are regenerative feed water heaters operating at high pressure and located by the side of
turbine. These are generally vertical type and turbine bled steam pipes are connected to them.
HP heaters are connected in series on feed water side and by such arrangement, the fed water,
after feed pump enters the HP Heaters. The steam is supplied to these heaters from the bled point
of the turbine through motor operated valves. These heaters have a group bypass protection on
the feed water side. In the event of tube rupture in any of the HPH and the level of the
condensate rising to dangerous level, the group protection device diverts automatically the feed
water directly to boiler, thus bypassing all the 3 HP heaters.
As shown in fig.V-8, feed water flows through the tube spirals and is heated by seam around the
tubes in the shell of the heaters. These heaters are cylindrical vessels with welded dished ends an
with integrated, de-superheating, condensing and sub cooling sections. The internal tube system
of spirals is welded to the inlet and outlet headers. In order to facilitate assembly and
disassembly, rollers at the side of the header have been provided. Both feed water and steam
entries and exists are from the bottom end of the heaters. This design offers the advantage to
optimize the arrangement of piping and the location of the heaters at power station.
Following fittings are generally provided on the HP heaters:
a)
b)
c)
d)
e)

Gauge glass for indicating the drain level.


Pressure gauge with three way cock.
Air vent cock.
Safety valve shell side.
Seal pot.
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DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

f) Isolating valves.
g) High level alarm switch.
Group protection device of HP Heaters: In the event of rising of the drain condensate level in any
one of the HP heater, to the emergency high level, the feed water flowing through the coils of the
heaters, is diverted automatically directly to the boiler, thereby all the groups of three HP heaters
is by passed.

Turbine Driven Boiler Feed Pump:


The single cylinder turbine is of the axial flow type.The live steam flows through emergency
stop valve and then through the main control valves.The valves regulate the steam supply
through the turbine.There are 14 stages of reaction blading.The turbine is provided with the
electro hydraulic governing system.The steam exhausted from the BFP turbine is directly
connected to the main condenser and the turbine glands are gland steam.There are 2 TDBFPs for
each 500MW unit at ramagundam of capacity 1080.3m3/hr at 204.32 bar.

Fig: 6.4.1 HP Heater

Drip/Drain System:

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DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
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The steam, bled from the turbine, after condensation is termed as drip/ drain. The drain is
cascaded from HP 7 to IPs and further to LP 2 all the condensate due to the bled steam of the
heaters is collected to in deaerator (during normal load) and in LP 2, from where the drain is
pumped back into the feed system. The drain from LP.1 is only connected to the condenser by Utube water seal. The drain from HP.5 will go to deaerator or LP.4 depending on the shell pressure
and load on the machine. All the LP heater drains are having manual bypass, which can be
operated in case of any individual regulators, fail. The drain from LP.2 can be regulated to
condenser in case the level in LP.2 rises to a predetermined level.

Drip Pumps:
Two numbers of sectional multistage centrifugal horizontal pumps per unit are provided. One
will be running and the other is standby (100% standby). These are especially suited for the
purpose of pumping from the space of high vacuum. Condensate drip from LP heater No.2
(which is under vacuum) is pumped again to main condensate line in between LP heaters.

Fig:6.4.2 Circuit Diagram of Turbine Driven Boiler Feed Pump

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DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

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DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
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6.5 COOLING WATER SYSTEM

Equipment cooling water (ECW) system: This water is used to cool the heated lubricating
oil coming from the lube oil coolers of boiler and turbine side. This is demineralised
water and is supplied through ECW pumps.
Auxiliary cooling water (ACW) system: This is raw water, taken a taping from CW
pumps discharge side, pressurized and circulated in a Plate Heat Exchanger to cool the
heated ECW water.

COOLING TOWERS (CTs):

A closed circuit cooling system is used for heat rejection that consists of cooling pond
and two cooling towers, ponds and towers are connected in a parallel arrangement to
study the behavior of the cooling system.

The cooling tower models based on the analogy approach of a cooling tower and an heat
exchanger. An effectiveness-NTU method is employed to predict the cooling tower
performance with respect to ambient and load conditions.

For the circulation of cooling capacity of the cooling pond surface, a semi empirical
approach is selected that is based on the combination of free and forced convection. The
water flow in the pond is a approximated by a plug flow model.

From the energy transfer and flow model a stimulation program is developed that is
capable of predicating of cooling pond temperatures dependent on meteorological
conditions and head load on the pond.
A simple model of an atmospheric cooling spray is employed.

Fig: 6.5 Cooling towers


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DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

6.6 LUBRICATION OIL SYSTEM


Introduction: same oil is used for governing & lubrication. The oil is kept in the main oil
tank. The governing is designed for operation at the oil pressure of 14kg/cmsq while lubrication
of bearings is designed to work at 2kg/cmsq.The following equipment is available in the
lubricating system.
1.
2.
3.
4.
5.
6.
7.
8.

Auxiliary oil pump


A.C lube oil pump
D.C emergency oil pump
main oil pump
booster pump
oil tank
oil coolers
vent fans

Lubrication oil system lubricates both turbine and generator bearings. Moreover it supplies
oil to seal oil system.
During normal operation of turbine shaft directly drives pump (centrifugal type) at 3000
rpm and supplies oil to the lubrication system. Auxiliary oil pump is incorporated in the oil
system to deliver oil to governing system and bearings at the time of starting of turbine
with back up protection. D.C. stands by oil pumps are used for bearing oil supply only.

AUXILARY OIL PUMP:


It is centrifugal pump driven by A.C electric motor. Auxiliary oil pump is provided for
meeting the requirement of oil for the turbine governing system and bearing lubrication system
during and stopping. It is mounted on the main oil tank.

DC LUB OIL PUMP:


The bearing are protected from possible lubrication failure by the provision of two
automatically starting oil pumps-i.e. AC lubrication oil pump and DC emergency oil pump AC
lube oil pump automatically start when lubrication oil pressure drops to 1.2kg/cmsq. The
emergency lubrication oil pump (DC driven) is provided as a backup protection against the
failure of AC lubrication oil pump or AC supply. DC lubrication oil pump cuts in automatically
when lubrication pressure drops down to 0.8kg/cmsq. Both AC lubrication oil pump and DC
lubrication oil pump are mounted on main oil tank.

MAIN OIL PUMP:


45

DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

During normal operation of turbine, main lubrication oil pump is mounted on turbine shaft
and driven by turbine shaft at 3000rpm. It supplies oil to the governing and lube oil system.
Pump is designed for continues operation at 3000rpm and installed inside the front pedestal of
turbine. The MOP is capable to supply oil to the system at full capacity when the turbine reaches
to 2800rpm. Then the AOP, which is in service, will be separated from the system automatically.

BOOSTER PUMP:
The oil pressure developed by auxiliary oil pump discharge during staring and stopping of
turbine operates booster pump. During normal running of turbine (at 3000rpm) it is operated by
main oil pump discharge. It supplies oil to lubricating.

OIL TANK:
Oil is stored in main oil tank (MOT) whose capacity is 16cum. Two numbers of vapour fans
are mounted on MOT to extract oil vapour and dissolved gases also to the atmosphere from
MOT. Auxiliary oil pump, AC lubrication oil pump, DC lubrication booster pump and oil coolers
are mounted on MOT.
Oil level indicators and instruments such as oil pressure and temperature gauges and
pressure switches for pump interlocks and annunciations are mounted on MOT. Local starting
and stopping of pumps and local pressure indicators are also available on MOT. The oil cooler
changing system and magnetic duplex system selection also mounted on MOT. The line to oil
purification system is connected to MOT.

OIL COOLERS:
Oil coolers are of surface type. Usually one cooler will be in service while the other is
standby. It consists of tubes through which cooling medium flows. The cooling medium used is
raw water. The oil cooler consist of the following.
1.
2.
3.
4.
5.

shell
upper water chamber
lower water chamber
tube system
cooler change over mechanism

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DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

Fig:6.6 Turbine Lube Oil System

47

DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

48

DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

Fig:6.6.1 Steam Turbine flow Diagram Showing Auxiliaries

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DEPARTMENT OF MECHANICAL ENGINEERING

STUDY OF WORKING OF
STEAM TURBINE AND ITS AUXILIARIES

CONCLUSION

The working of Steam Turbine 500MW was studied, the process of Conversion of
Kinetic head of Steam into Mechanical Energy was observed. The Auxiliaries of
Steam Turbine and their importance in power generation were studied and
observed the various components involved in the working of Steam Turbine.

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DEPARTMENT OF MECHANICAL ENGINEERING

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STEAM TURBINE AND ITS AUXILIARIES

BIBILOGRAPHY

http://www.brighthub.com/engineering/mechanical/articles/60844.aspx#ixzz1UAY
phNuz
http://www.scribd.com/doc/46740256/Power-Plant-Familiar-is-at-Ion-v-III
http://www.seminarprojects.com/Thread-steam-turbine
en.wikipedia.org/wiki/Thermal_power_station
www.indiamart.com ... Industrial Plants & Machines

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DEPARTMENT OF MECHANICAL ENGINEERING

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