TRIVENI TURBINE OPERATION

AND MAINTENANCE MANUAL

16.5 MW- BACK PRESSURE
TURBINE
Contents
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TRIVENI 16.5 MW TURBINE SUMMARY

CLIENT: SATANDER SUGAR LIMITED

TRIBEMI W.O. NO. : C 3-60
TURBINE POWER: 16.5 MW
TURBINE TYPE: BACK PRESSURE TURBINE
QUANTITY: 1
DRIVEN EQUIPMENT: ALTERNATORWHILST EVERY EFFORE HAS BEEN MADE
TP ENSURE THAT THE INFROMATION CONTAINED IN THIS MANUAL IS
CORRECT AND FULLY UPDATED, THE MANUFACTURER M/S TRIVENI TURBINE
LIMITED CANNOD BE HELD RESPONSIBLE FOR ANY ERRORS OR OMISSIONS.
ANY QUERIES REGARDING THIS HANDBOOK SHOULD BE REFERRED TO
TRIVENI TURBINE LIMIRED QUOTING ORDER REFERENCE NO. C- 3060
IMPORTANT
WHEN ORDERING SPARE PARTS, QUOTE THE ABOVE TRIVENI WORK ORDER
NUMBER C-3060 AND TURBINE SERIAL NUMBER.
GENERAL DESCRIPTION
The turbine is single cylinder, multistage impulse type.
The high-speed turbine drives an alternator through hardened ground helical
gearing. The turbine and gearbox are mounted on a composite steel plate while the
alternator is mounted on it soleplate.
Flexible couplings- are placed between the turbine rotor shaft and the gearbox
high speed input shaft and the gearbox output shaft to the generator. This is to
ensure the correct meshing of the gear teeth under all conditions.
ESSENTIAL Equipment For THE FUNCTIONING OF THE TURBINE
a) Control system- (actuator and throttle valves) controlled by the governor
b) Safety and protection devices- trips and trip valves
c) Lubrication system- oil tank control and lubricating oil filter, pressure
regulating valves, accumulator, main, auxiliary and emergency oil pumps.
d) Gland and oil seal system- prevents oil and steam leakage into the turbine
room.
e) Instrumentation- including all sensors such as: pressure transmitters,
temperature sensors, vibrator probes etc. to provide local and remote
indications of all operating data.
f) Barring gear system- to keep the shaft turning during warming up and cooling
down.
Description of turbine components
Inlet stop and emergency trip valve-
Hydraulically operated- is flanged and bolted to the throttle valve chest.
it has a pilot valve for running. It is spring loaded and supplied with control oil from
the control oil circuit. When control oil pressure is lost, the valve is rapidly closed by
steam pressure and spring load. Loss of control oil pressure is initiated by operation
of the low-pressure oil trip valve in the supply line to the control oil circuit.
It can also be done electrically by activating 3-way solenoid low pressure LP trip
For addition protection, a separate 3-way valve is provided to initiate quick closing
of SEV
SEV (STOP AND EMERGENCY VALVE)
On/off type valve which can be remotely operated via the 3-way solenoid in the
control oil system

To test this valve, press the valve connected under the oil cylinder which opens a
drain, reducing the pressure which results in a spring load reaction.
THROTTLE VALVE CHEST
Mounted on top of the steam end casing. The chest houses 3 control valves that
feed the inlet nozzles housed in nozzle belts integral with the valve chest (a
rectangular opening at the top of the steam end casing) the entire assembly bolted
horizontally
Operate single beat with valve head and spindle guides. Valve and guides are
houses in separate columns, bolted on the top face of the valve chest.
They are opened by lift arms from a rocker shaft.
The rocker shaft is mechanically linked to the servo actuator and mounted with
bracket support from nozzle chest body. Follows what the governor dictates to
position valves to maintain pressure or set speed required.

CYLINDER/ CASING
Divides at horizontal joint and is arranged with centerline support. (support points
are on the same horizontal plane as turbine center line. It has two integral
horizontal extended palm pieces that is bolted on top of the pedestal equispaced
about the pedestal center line.
The exhaust end is anchored to the baseplate. The steam end pedestal gives
support to the casing and provides rigidity in vertical and lateral planes, but allows
sliding in axial (horizontal) movement of casing due to thermal expansion.
There is a link support between the casing and the pedestal to allow the free radial
expansion of the casing and at the same time restrain transverse movement.
The cylinder supported moves axially away from the fixed exhaust end.

ROTOR
Has a number of integral straight sided discs that are formed with inverted T root
grooves to accept the blading.
These gates are slotted radially into the discs and are arranged diametrically to
minimize the out of balance effects
The special closing blades are pinned in position. These close the blading gates
giving a uniform arc of blades with no gaps. Such gaps give rise to increased and
non-uniform bending stresses and could cause vibrations.
Balancing strips are formed integrally on all stage discs. These strips permit matal
to be removed fir dynamic purposes without encroachment on the stressed disc
profile.
Steam balance holes are drilled axially through the discs.
The shaft end and interstage gland seals have common stepped diameter on the
rotor and match high low tooth, stepped, spring loaded labyrinth packing.
The rotor has a flange as part of the forging at the driving end to accept the high
speed coupling.

COUPLINGS
Between the turbine rotor and gearbox input shaft is of the flexible steel membrane
type requiring no lubrication. Its contained with a coupling guard.
Same for coupling between gear shaft and generator.

OVERSPEED TRIP
Pedestal end of the rotor shaft, an extension shaft is bolted to the shaft. This
extension houses the overspeed trip unit and carries a spur gear for the governor
magnetic pickups.

NOZZLE AND DIAPRAGMS

1st stage nozzle is provided by profile milling the center of the segments leaving top
and bottom shrouds. The shrouds are provided with peripheral tenons which are
straight radially, to fit into matching circular grooves turned in the nozzle chest.

SHROUDS (SHEETING)
Profile milling is the removing of at least part of a surface. Milling removes just
enough thickness to level and smooth the surface to a full depth removal

MOVING BLADES
Machined from solid bar material. Circular or elongated tenons are employed
according to the blade section and circumferential pitch of the blading material
used in the individual stages. Blade material are chosen to be suitable for the
operating conditions as is the compatible shroud band.

LABYRINTH GLANDS
-non contact glands provided to restrict leakage where the turbine rotor shaft
passes through the casing.
Stepped labyrinth high low tooth type which consists of a number of metal rings cut
into segments on the inside of the rings.
The fins are positioned to match high low steps turned on the rotor shaft. Which
presents a tortuous labyrinth path against leakage.
At the steam end, the wheel case pressure increases progressively with load on the
turbine. To break the pressure down and to reduce steam leakage outward from the
wheel case, the high pressure gland provided with additional inner labyrinth rings
and leak off pocket.
The outer pocket is connect the gland drain manifold and to gland vent condenser
or to atmosphere.
OIL SEALS-
Similar construction to the steam labyrinth glands but have a thrower and
catcher on the inner side of the pedestal housing. A large diameter
thrower of the pedestal housing. A large diameter thrower is on both
steam and exhaust end pedestals between the steam and oil seals.
End oil discharge is stopped by splash guards as to guide leakage oil down the
pedestal oil drains.

JOURNAL AND TRUST BEARING

Journal bearing white metal line tilting pads type. Axial thrust is taken by a tilting
offset pivot type thrust bearing. The separate pads having white metal thrust faces
on steel backing.
The rotor shaft bearing and the thrust bearing are located in steam end pedestal.

STEAM STRAINER
Cylindrical shape with punched holes, filter beneath the cover, surrounding the
main valve. This prevents debris from reaching the main valve or seat.

SPEED GOVERNING AND CONTROL

THE GOVERNING AND CONTROL SYSTEM CONSISTS OF:
1) ELECTRONIC TYPE GOVERNOR MOUNTED TO THE CONTROL PANEL AND A
SERVO ACTUATOR MOUNTED TO THE NOZZLE CHEST.
2) The servo actuator receives signals from the governor and with its inbuilt
servo valves controls the throttle valve movement for steam admission.
3) Three single beat throttle valves inside the chest nozzle chest are operated in
sequence by levers controlled by the servo valves. This controls the steam
admission to the three separate banks of first stage nozzles.

Rapid response to speed variations changes the position of the profiled throttle
valves via the servo mechanism
The following faults will result in automatic shutdown of the turbine via mechanical
trip units.

Overpseed
Lowlubricating oil pressure (l.p trip)
High exhaust pressure
High control oil pressure
Low control pressure
In addition to these solenoid trip is incorporated to provide a remote shut down
facility.
OPERATION
Oil reservoir- integral part of the turbine baseplate supplies both control
oil and lubricating oil.
warming up, start up, operating and shutdown procedures

Standby state
It is good to practice to prevent as much leakage from getting through to a standby
machine.
1. Isolation and turbine stop valve should be closed. Steam line fitted with a
drain to atmosphere.
2. Turbine stop valve closed (stop and emergency stop valves)
3. Turbine should be let at trip and shoudnt reset
4. Open all drains, (dirty water drain is always open so is has no valve)
5. Oil reservoir maintained at appropriate level and any water drained off
6. Oil filter should be clean
7. Cool water isolating valves closed
8. With boiler stop valve closed, check the freedom of all other valves by
opening/ closing once a week.

Starting.
Check points before starting
i. Two way solenoid remote trip is not in trip state (energized)
ii. Turn hand trip on steam end pedestal to run position
iii. Check oil level through level glass
iv. Admit cooling water to the oil cooler and auxiliaries.
v. Reset low pressure trip valve
vi. Start aop and acop
vii. Start ejector system
viii. Check that the control oil accumulator is charged at the right
pressure with oxygen.
ix. Check for operating of throttle valve. The governor in service
mode opens and closes the throttle valve, this is because the
servo actuator can be governed even with turbine at 0 rpm with
control oil available.
x. Check for operation of SEV a three way solenoid valve in the
control oil pipeline deactivated ti open or activated to close. This
can be done 2-3 times.
 xi. Dont operate turbine if throttle valve or SEV stick/operate jerkily

If the turbine is stopped for long periods, the barring gear should
run for at least one hour every two- three days to prevent the
rotor maintaining the same position.

Warming from cold start

i. Ensure that all the drains on the turbine are opened
(throttle valve drain, stop valve drain, wheel case drain)
ii. Ensure all the checkpoints are done
iii. Start the motor barring gear. An interlock prevents the
barring gear from starting before bearing oil pressure is
established.
iv. To start open the isolating valve in steam line after boiler
and open vent line v2 and v3. Crack open the main valve
in the main valve in the main header. This would warm up
the steam pipe to the turbine and upstream of turbine
stop valve.
v. At this moment the SEV calve is closed. The excess
steam is vented through v2 an v3
vi. When steam temperature is consistent and in range of 50
C of rated design, reset 3way solenoid valve to allow
contro oil into the hydraulic system to open the stop and
emergenvy hydraulic system to open the stop and
emergency valve, which in turn admits steam into the
SEV and nozzle chest for the warming up process.
vii. Open valves v4,v5 and v6 to vent excess steam to the
header and close valves v2 and v3
viii. Observe nozzle chest body.
ix. Open throttle valve to allow steam to pass to the steam
casing for waming. The differential temperature between
top and bot steam casing should not exceed 50c.

Start after warming

i. Ensure governor is set like start up curve
ii. When steam casing is at desired temperature start to
close valves in venting line (v4-v6) and open main inlet
valve fully.
iii. Reset governor in run mode
iv. Check turbine readings (oil pressure, vibration,
temperature)
v. During run up, check the barring gear has stopped
vi. Any speed other than critical rotor speed can be
changed. If it starts to vibrate causing a temporary bend,
 drop the speed to 1000 rpm and soak for half an hour
before retrying.
vii. Once running appropriately at reated speed test
electrical and mechanical overtrip peed devices
viii. Test overspeed trip by goin over the rated speed but not
over trip speed

GOVERNING SYSTEM
WOODWARD 505 ELECTRONIC GOVERNOR TAKES READING from the speed
sensor mounted on the steam end pedestal. The governing system is electronic
type which transmits an electrical signal to the actuator which controls the lift of the
throttle valve which controls the steam flow to the turbine.
Servo actuator is a high performance cylinder, servovalve and transducer specially
designed for closed loop application to move in both directions the system uses an
external hydraulic supply (24-25 bar g)
Double rod linear actuator
Position transducer
Servo electro-hydraulic servo valve.

THROTTLE VALVE GEAR

The throttle valve chest (nozzle) has 3 separate nozzle banks. Each group of
nozzles has steam flow controlled by uts respective throttle valve.
Type: single beat, seat obturated type with spindle guide.
CMR- continuous max rating
MER- max economic rating
#3 VALVE OPERATES TO PROVIDE cmr CAPACITY FOR THE TURBINE. UNDER mer
LOAD remains shut.
Loaded throttle valve spring resist valve opening.
The upper end of each valve spindle is screwed and connected with a spring carrier,
which also houses a spherical bearing.
A separate throttle valve lifting spindle is retained within the spring carrier by a
flange turned on its lower end. Screwed bearing retainer prevents withdrawal of the
bearing and 23.
All 3 valves has a second spherical bearing trapped at the extremity through which
the upper portion of spindle 23 will slide.
The outer end of spindle (23) is threaded, with adjusting nut 40 positioned at some
fixed point to provide to correct valve phasing.
The valve life against spring load when sleeve (25) contacts the adjusting nut (40).
Cross shafts 29 provides the necessary upward motion to the lever, spherical
bearing 47 and sleeve 25 rotating anticlockwise in bearing block 30.
Operation
The nozzle governed turbine has three nozzle banks with respective throttle valves.
These open in sequence relative to the load carried reducing throttling losses at
MER and CMR setpoints. It follows that the valves must be arranged to operate in
correct sequence.
Valve pick up points can be determined statically but final settings can only be
achieved by plotting the droop line on site.
All three valves are phased sequentially by means of lift arms from a common
rocker shaft. The latter located in the spherical bearings rotated by direct
mechanical linkage from movement of the power piston of actuator system to
pvercome combined spring and steam loads.

Throttle valve gland leakage setting

1. Nut 18 will not be fully tightened in initial stage.
2. After admitting steam and witnessing some fumes of leakage of steam
3. Fine tuning of nut 18 can be done again if its a leak

EMERGENCY TRIP GEAR

Purpose- to stop the turbine as quickly as possible should any running fault
occurs.

the system comprises of

a) Stop and emergency valve with hydraulic servos, providing steam isolation
for the turbine
b) Low pressure trip valve to provide control oil. SEV servosystem
GENEREAL DESCRIPTION
The unit combines 2 functions, a remote operated steam stop valve and an
emergency shut down facility.
- Horizontally mounted on one end of the inlet flange of the nozzle chest.
 - The front houses the main steam valve while the rear has the hydraulic oil
cylinder sub assembly.
Valve body:
i. Valve seat
ii. Steam strainer
iii. Main steam valve
iv. Spindle
v. SEV column and oil cylinder
vi. Oil piston
vii. Oil spindle
viii. Main spindle
ix. Indicated half coupling
x. Plunger
xi. Plunger housing
xii. Plunger housing cover
xiii. Limit switch spindle guide bush
xiv. Limit switch indicator plate
xv. End cover
xvi. Helical spring
The valve body contains the value seat, steam strainer and operating parts such as
the spindle, SEV column and oil cylinder house the oil piston that is bolted to the oil
spindle, coupled to the main spindle with an indicator half coupling.
Operation
The pilot valve and the main spindle are integral parts use to provide pressure
balance to the main steam valve. On start up the inlet steam pressure exceed the
force of the control oil but the hydraulic pressure to the pilot valve is strong enough
to fully open it, allowing sufficient steam to diminish the unbalanced pressure.
Having reduced pressure drop across the main valve, ample force can be exerted
from the servo to lift the main valve.
The valve operating mechanism works as follows:
Control oil flows through the main oil inlet to the servo assemble moving the
plunger towards the oil piston which in turn pressurizes the oil in the oil cylinder
which enter through the main oil inlet. Making enough pressure to initially lift pilot
valve.
The pilot valve movement helps in pressure balancing of the emergency stop valve.
Steam enters main steam inlet, to the pilot valve up to the throttle valve, the flow
through the pilot valve reduces the pressure drop allowing continuous travel to
spindle 5 which keeps main valve in full open position.
When operating, the movement of the spindle can be checked with check valve
assembly.
For manual testing of spindle 5 movement remove valve cap and push in screw
valve for a few second, this opens a small port that drains the oil causing a pressure
decrease under the piston and moves it to a closing position. Remove hand and it
returns to open position.
Note* this manual testing can be done while the turbine is running and must be
done weekly.
This function ensures the spindles 5 and 18 free movement and avoids sticking of
the stop valve due to any progressive silicate deposit on the spindle surface in
operation.
The operation of any security trip in this section causes a collapse of the control oil
pressure under the plunger. This drop-in pressure spawn a reaction from the LP trip
block and the dump spool valve. In addition to the LP trip valve, another 3-way
solenoid valve is connected in the trip oil inlet line of the servo system. The second
3-way valve quickly drains the control oil by upsetting the plunger and helps
tripping the SEV by collapsing COP, oil piston, oil spindle, coupling, pilot valve and
main steam valve all close under the action of steam pressure and compression of
spring.
The turbine can only be started again after resetting the trip signal of the valve.

LOW PRESSURE OIL TRIP

Has 2 functions, low lubricating oil trip, master control oil trip.
It provides bearing protection when lubricating oil pressured is below recommended
value. It also takes signal from the valve spring.
If the oil pressure is greater that .6-.8 bar it remains lifted and permits continuous
flow of control oil to the servo-mechanism. If lube oil pressure falls, the plunger
drops down and control oil it cut off from the servo mechanism.
After restoring the lube oil pressure, the system can be brought into operation. For
this, give signal reset the lp trip which would full the knob. The plunger moves up
and admit oil to main SEV power piston.

SECURITY TRIPS
A) Overspeed
B) Low lubricating oil pressure
C) High relay oil pressure
D) Hand trip/ manual trip
E) Solenoid trip
F) High exhaust pressure
G) Through elec governor.

Overspeed trip
MECHANICAL OVERSPEED TRIP- IN ORDER TO PREVENT THE TURBINE UNIT
ACCELERATING TO A DANGEROUS SPEED, AN OVERSPEED TRIP IS FITTED.
OVERSPEEDCAN BU CAUSE BY
SEIZURE OF THETHROTTLE VALVES
RAPID Changes in exhaust condition
Sudden loss of load or too late resetting governing system
Dirt in the oil, sticking, lost motion can result in the steam flow through the
throttle valve being greatly in excess of requirements will rapidly accelerate the
turbine.
The overspeed trip is of the unbalanced valve type.
An unbalances steel valve, located in the rotor shaft extension is held into the
valve seat by means of a helical spring, while the speed of the rotor shaft
remains below tripping speed.
If the speed exceeds 10/15% rated turbine speed, the centrifugal force exerted
by the trip valve at his higher speed, overcomes the spring force and moves
rapidly away from the valve seat.
This allows the low-pressure oil which is fed into the center of the shat extension
downstream from the orifice to escape, creating and instant pressure drop which
operates the low pressure trip.

ELECTRONIC OVERSPEED TRIP

Consists of a Woodward protective device completely dedicated to sensing
overspeed of the turbine for additional safety. For this purpose, 3 speed sensing
probes are mounted on steam end pedestal
HAND TRIP
A means of manually tripping the machine, this means in case of excessive
bearing temperature, vibrations and for testing LP trip and SEV.
The body of the valve is bolted to the front of the steam end pedestal over the
overspeed trip valve inlet oil fitting.
Low pressure oil is supplied to the underside of the valve via the control orifice
from the oil trip circuit.
SOLENOID TRIP
Is a normally closed block and dump type valve. It opens to drain when the
solenoid coil is de energized.
Under normal running conditions the valve is energized and closed. Should
remote shutdown be required the valve is deenergized, oil in the trip circuit then
flows to the drain, cause oil pressure loss and lp-trip initiation.
OIL SYSTEM
When opening part of the turbine that contains oil subject to running
temperature, dont smoke or use naked light

The oil system incorporates the following components.

1. The oil tank carries the total oil capacity
2. The main lube oil pump driven from the low speed line of the gearbox
3. The main oil pump driven by an electrical motor
4. Motor driven aux lube oil pump and a standby motor driven control oil pump
also provided.
5. Duplex lubricating oil filters
6. Duplex control oil filter
7. Duplex shell and tube type water cooled, oil cooled
8.