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TURBINE
Turbine is a prime mover for the Generator in the power plant. In steam turbine, the potential energy of steam is transformed into kinetic energy and later in its turn is transformed into the mechanical energy of the rotation of the turbine shaft. The common types of turbines are: IMPULSE TURBINE:- In this type of turbine, steam expands in the nozzles REACTION TURBINE:- In this type of turbine, the steam expands and its pressure does not alter as it moves over the blades. continuously as it passes over the blades and thus there is a gradual fall in pressure during expansion.

IMPULSE TURBINE

REACTION TURBINE

Different types of steam turbines are used in Thermal Power Plant but the ones which are used at G.N.D.T.P. are categorized as follows:Sr. No. 1. 2. 3. 4. Type of Turbine Horizontal/Vertical Single/Multi-cylinder Impulse/Reaction Condensing/Non-condensing Turbines at G.N.D.T.P. Horizontal Multi-cylinder (3-cylinder) Impulse Condensing

27 5. 6. 7. Reheat/Non-reheat With bypass/Without bypass Reheat With bypass (ST-1) Without bypass (ST-2)

Regenerative/Non- Regenerative

MAIN TECHNICAL DATA a) The basic parameters: Rated output measured at Terminal of the generator. Economical output. Rated speed. Rated temp. of stearn just before the stop valve. Max Temp. of steam before the stop valve. Rated pressure of steam before the MP casing. Max. pressure of steam before the MP casing Rated temp. of steam before the MP casing. Max. temp. of steam before the MP casing. b) System of turbine: 4 Governing valves +2 interceptor valves HP cylinder- 2 Row Curtis wheel +8 moving wheels. Wt. Of HP rotor approx. 5,500 Kg. MP cylinder - 12 Moving wheels. Wt. Of MP rotor. Approx. 11,000 Kg. LP cylinder - 4 Moving wheels of double flow design. Wt. Of MP rotor approx. 24,000 Kg. Direction of the turbine rotation - To the right, when looking at the turbine from the front bearing pedestal. 110.000KW 95.000KW 3.000RPM 535C 545C 31.63C 35C 535C 545C

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TURBINE ASSEMBLY WITH LOWER CASING TURBINE ACCESSORIES AND AUXILIARIES: The following are turbine accessories and auxiliaries: 1. Surface condensers. 2. 3. 4. 5. 6. 7. 8. 9. Steam jet air ejector LP and HP heaters. Chimney steam condenser. Gland stearn condenser. Oil purifier of centrifuge. Clean oil pumps with clean oil tank. Dirty oil pumps with dirty oil tank. Auxiliary oil pump with aux. Oil tank.

10. Starting oil pumps. 11. Emergency oil pumps (AC and DC). 12. Jacking oil pumping. 13. Bearing or turning gear. 1. SURFACE CONDENSERS Two no. surface condensers are used for condensing the steam which has worked in the turbine. The coolant for condensing the steam is circulating water, which is inside the condenser brass tubes, and steam is outside.

TECHNICAL DATA OF EACH CONDENSER: Cooling area 3330 m2

29 No. of brass tubes Circulating water required for each condenser Circulating water required for both condenser2x7500T/Hr. Allowable difference between inlet & outlet C.W. water Vacuum in the condenser 2. STEAM JET AIR EJECTORS Starting ejector or hogger is used for quick evacuation of the turbo set during starting whereas main steam jet air ejector (Duplex Type) is used to maintain the vacuum in the condenser. Steam Jet Air Ejector works on the principle of venture with steam working media to eject air from the condenser. 3. STEAM HEATERS In regenerative system there is a stream of 5 LP heater, one desecrator and 2 HP heaters. All LP and HP heaters are of surface type i.e. condensate of feed water is inside the heaters tubes and steam extractions are outside the heater tubes in the heater shells. LP heaters are of single flow type whereas HP heaters are of double flow type i.e. feed water is flowing twice through the HP heaters in order to extract total HP latent heat and super heat of steam going into HP heaters, desecrator is a contact type heater in which steam and condensate come in direct contact with each other. Details of Steam Extraction: Steam into HP heater NO. 2 is from cold reheat line. Steam into HP heater NO.1 is from MP turbine, LPH- 4 LPH- 5 is from MP casing at differently steam pressures and temperatures. 6000 7500T/Hr. 15000T/Hr. 10C Temp. 0.90 Kg/cm2

4. CHIMNEY STEAM AND GLAND STEAM CONDENSERS

30 There are the additional two heater stages provided in the regeneration system of the turbine for heating the condensate flowing through it. Steam leak offs from the turbine a gland is used for heating the condensate in these heaters. 5. STARTING OIL PUMPS AND ARRING GEAR S.O.P supply necessary turbine oil during starting of the turbine and up to turbine speed of 2930 RPM till the main oil pump mounted on the turbine rotor at the HP extension.takes manually in order to provide lub. Oil for turbo set. Emergency pumps (AC & DC) are meant to start on auto when turbine trips and lub. Oil pressure falls in order to provide lubrication of turbine and generator bearings. 6. JACKING OIL PUMP AND ARRING GEAR Jacking oil pump is used in order to lift the turbine rotor before it is put on barring gear jacking oil pump takes suction from the turbine lub. Oil system and provide a thin film of oil for lifting the rotor. Barring gear motor used to rotate the turbine rotor at 62 RPM after engaging the rotor with the gear during starting and stopping of the turbine. 7. CIRCULATING WATER PUMPS Two nos. circulating water pumps provide for each unit circulate water @17200 tonnes per hour in a closer cycle comprising of turbine condenser and cooling tower. An additional circulating water pump provide, serves as a stand by for two units. The water requirement for bearingcooling of all plant auxiliaries is also catered by these pumps. SECTION - 1

FUNCTION AND TYPES OF STEAM TURBINE

FUNCTION OF STEAM TURBINE Steam turbine is a from of heat engine in which the available heat energy in from of steam is converted into kinetic energy, to rotate the turbine rotor, by expansion of steam in a suitable shaped nozzle, the pressure on the blades causing rotary motion is purely dynamical

31 and is due solely to the change of momentum of the steam jet during its passage through these blades.

TYPES OF STEAM TURBINE The steam turbines are broadly classified into three groups depending on the conditions of operations of the steam on the rotor blades. 1) Impulse Type This is again subdivided into:a) Simple Impulse b) Compound Impulse (Pressure, Velocity and Pressure & Velocity compounded) c) Combined Impulse 2) Reaction Type This is again grouped into:a) Axial Flow b) Radial flow c) Mixed flow 3) Impulse reaction Type

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IMPULSE TURBINES
In an impulse turbine the potential energy in the steam due to pressure and superheat is converted into kinetic energy in the form of weight and velocity by expanding it in suitably shaped nozzles. The whole of the expansion takes place in the fixed nozzles. The steam pressure at the inlet and outlet edges of the rotor blades are equal as there is no expansion in the rotor bicycles. The steam impinges on the wheel I blades causing the wheels to rotate. The expansion is carried out in stages referred to as Pressure, Stages the commonest type of impulse turbine is the Delaval turbine. REACTION TURBINE In the type of turbines the steam expands in both the stationary and moving blades. So, the steam pressure, at inlet to the moving blades is greater than the exit pressure. The term reactions is strictly not correct as no turbine practice works on pure reaction principle. The action on the balding is both impulse an reaction. The steam turbine installed is a 3 cylinder,(HP r1v1p and LP r condensing, reheat cycle type with 8 non~regulated extractions for regenerative heating pf the boiler feed water. The cross section through a typical 110 MV1 steam turbine. The high-pressure turbine is made of two h Gri20ntally split concentric casings. The inner casing is placed inside the, outer casing so as to permit the expansion of the casing at all directions. The main steam from the boiler is admitted into the HP turbine through t-{O quick clashing~) t09 valves.(HPQCV)and four nos of Governing va1VBs. These v81ves are operated hydraulically and they operate on increase / decrease of secondary oil pressure. In the HP turbine, steam expands in a two row Curtis stage called the impulse stage and further in 8 stages of fixed and moving blades Labyrinth type seals are provided for the HP turbine at both front and II rear ends and CRH steam or 11 at PRDS steam is used for sealing glands.

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The medium pressure part of the turbine is a horizontally divided casing. The guide wheels are partly mounted in the casing in carriers and directly in the casing. The steam after HP turbine enters the reheater, gets heated to 540C and returns to the MP, turbine through MPOCSV and interceptor valves steam entering the MP part flow through 12 fixed and moving blades and taken to the low pressure turbine through the two corrosive pipes. The MPQCSV and IVs are also operated Hydraulically.

MEDIUM PRESSURE TURBINE The low pressure turbine is split horizontally into three parts and all the parts are connected by vertical flanges. The extreme parts of the L.P. turbine are connected rigidly with surface condensers mounted on sturdy spring supports. The steam entering the L.P. casing flows in both directions through 4 stages and finally exhausted into the condenser. The middle part of the L.P. casing houses tube nests of first and second low pressure heaters for heating the condensate. The flanges of H.P., M.P. casings are designed to be heated by steam during the starting up to turbine generator. By heating of the flanges, the differences in temperature between the cylindrical portion of the casing, flanges and the connecting bolts are reduced hence limiting the additional stresses on the bottles. The very important criteria for starting and rate of loading the machine is the difference between the temperature of the steam admitted in and that of the internals of the turbine. For the purpose of measuring the

34 temperature of the casing and the steam transfer piping there monopoles are provided at appropriate points. SECTION - 3

CONDENSATE AND BOILER FEED SYSTEM

The steam after doing the useful work in the turbine is exhausted into the condensers where it is condensed by the cooling water (circulating water) flowing through a network of tubes. After condensation, the condensate is collected in the hot wells of the condensers. From the hot wells, the condensate is handled by the condensate extraction pumps and is taken back to the closed loop system. Condensate pump delivers the condensate into the deaerator through the main ejectors, chimney steam condenser, gland steam condenser and low-pressure heaters. There are three number of condensate extraction pumps of vertical turbine type installed for the above purpose. The pump capacity of 160 T/hr and develops 215 MWC head. Under normal conditions of operation of the unit (including full load condition) two pumps are required to be kept in service while the third is a standby. The condensate tapped off from the condensate extraction pumps discharge header is utilized for the following services:1. Sealing of valves in the vacuum system. Condensate booster pump stuffing box sealing. 2. L.P. gland sealing de-super heaters. 3. de-super heaters in the chimney steam condenser. 4. Cooler in the TG-exhaust. 5. Dilution of phosphate and hydrazine solutions. The make up to the closed cycle is added at the condenser hot well by means of the make up water pumps. There are 5 numbers D.M. transfer pumps installed which take their suction from a D.M. water storage tank. The condensate entering the desecrator under goes desecration process in which all the dissolved gases in the condensate are removed to a greater extent and the desecrated water is collected in the feed water tank which is an integral part of the deaerator. The feed

35 water tank is installed at a sufficiently higher elevation to provide a positive suction to the boiler feed pumps. The flow path of feed water is schematically shown in fig. The boiler feed pumps (locted in the ground floor of the turbine hall) take their suction from the feed water tank and deliver the feed water into the boiler drum through high pressure heater, feed control station and economizer. Two Nos. of boiler feed pump each of capacity- 445 /hr (8180 1 pm) developing 178 atm. head is installed. Out of two pumps, one pump is required to be kept in service while the other one is a standby. The feed control station consists of three branches of feed lines- a low load line meant for up to 20% MCR and other two lines meant for 100% MCR conditions. (Out of the two 100% MCR lines, one will be service while other is a standby). The feed water for the de-super heaters of the SH and RH is tapped off before the feed control station. Provisions are made to use the condensate booster pump for initial filling of the boiler drum.

PROTECTIONS AND INTERLOCKS The main turbine trip relay (TTX) energizes the turbine and trips the turbine under the following conditions:1. Under frequency protection. 2. Generator shut-down energization. 3. Remote trip (P.B). 4. Generator distance relay actuation. 5. Generator negative sequence. 6. Generator transformer ground. 7. Generator loss of excitation. 8. Boiler master trip. 9. L.P.G. heater no.1 level high.(left or right: 775mm). 10. L.P. heater no. 2 level high (left or right: 775mm). 11. Axial shift thrust bearing high: ( 0.65mm).

36 12. Hydro mechanical protection axial shift very high: (0.85mm). 13. Primary governing oil pressure high: (3.05atm.). 14. Bearing oil pressure very low: (0.8atm.). 15. Main oil pump discharge very low: (7 atm.). 16. Exhaust pressure very high: (0.5 atm.). EXPLANATION OF TURBINE SYSTEM :First of all the steam is generated in the steam generator i.e. boiler. From second pass of the boiler the steam is generated at 530C and at a pressure of 110 kg/cm2 enters the high pressure turbine. The steam works i.e. expands along the rows of blades and the prime mover i.e. turbine starts moving. After working in the high pressure turbine the steam again enters the second pass of the boiler for reheat. All the turbines are coupled to a single rotor. The high pressure turbine is of reaction turbine, horizontal type multicylinder. In reaction turbine the steam expands continuously as it passes over the rows of blades and thus there is gradual fall in pressure during expansion. The steam from high pressure turbine enters the second pass of boiler for reheat at 30kg/cm2 at 360C. After reheating the steam again enters the medium pressure turbine at 28 kg/cm2 . The temperature of the steam entering the medium pressure turbine is 530C. After working the steam leaves the medium pressure turbine is of impulse type. In impulse turbines steam expands in the nozzles and its pressure does not alter as it moves over the blades. So the pressure of the steam entering the MP and leaving MP remains 28kg/cm 2. With in the casing of the MP. Number of tappings namely 4,5,6,7 are made for low pressure heaters. Tapping number six is the dummy tapping. Tapping number 5 from the MP turbine goes to the LP turbine goes to the heater NO. 2. The condensate of all the three LPHs goes to the deaerator. Tapping no.7 from MP turbine goes to high pressure heater no.2, HPH no.1 gets connestion from the cold reheat from the high pressure turbine. The condensate of the high pressure heaters goes to the economizer. The outlet temperature of condensate from HPH is 240C. From the deaerator after deaerator the condensate through boiler feed pump goes to HPHs from where this enters to economizer.

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From the MP turbine the steam enters the LP turbine. After working, the steam enters the condenser, four LPHs are also placed within the casing of the LP turbine. The condensate from these heaters through a single pipe enters the ejector, fromwhere the condensate enters the chimney steam condenser and then to the gland steam condenser through which the condensate enters the HPHs and then goes to economizer. The steam leaves the LP turbine at -0.90 kg/cm2 i.e. it works under vacuum. The work of the ejector is to create vacuum. The condensate from the ejector enters the main steam to the condenser. After condensation the condensate entersthe condensate enters the well of the condenser which is at 45C. One tapping from the well goes to the ejector. a level of the water is maintained in the well. The condensate from the gland steam condenser and chimney steam condenser enters the water well. With in the medium pressure turbine a dummy tapping is there. The steam enters this turbine at 530C from two sides. The pressure of steam is 28 kg/cm2. The cold reheat from the HP turbine enters the second pass of the boiler. The turbine speed is controlled by electro-hydraulic governing device, from where governing is done. CONSTRUCTION OF TURBINE :The turbine is a tandem compound machine with HP, IP and LP parts. The HP part is single flow cylinder and IP and LP parts are double flow cylinders. The individual turbine rotors and the governor rotors are connected by rigid couplings. In designing the supports for the turbine on the foundation, attention is given to the expansion and contraction of the machine during thermal cycling. Excessive stresses would be caused in the components if the thermal expansion or contraction were restricted in any way. The method of attachments were restricted in any way. The method of attachments of the machine components and their coupling together are also decisive factors in determining the magnitude of the relative axial expansion between the rotor system and turbine casing. CASING EXPANSION :The front and rear bearing housing of the HP turbine can slide on their base plates in an axial direction. Any lateral movement perpendicular to the machine axis is prevented by fitted keys. The bearing housings are connected to the HP and IP turbine casing by guides which ensures that the turbine casing maintain the central position while at the same time

39 allowing axial movement. Thus the origin of the cumulative expansion of the casing is at the front bearing housing of the IP turbine. ROTOR EXPANSION :The thrust bearing is in corporated in the rear bearing housing of the HP turbine. Since this bearing housing is free to slide on the base plate. The shafting system moves with it. Seen from this point both the rotors and casing of the HP turbine expand towards the front bearing housing of the HP turbine. The rotor and casing of the IP turbine expand towards the generator in a similar manner. DIFFERENTIAL EXPANSION :Differential expansion between the rotor and casing results from the difference between the casing expansion. Originally from the bearing housing behind the IP turbine. CONSTRUCTION OF TURBINE(HP) :Casing :- Barrel type without axial joint. An axially split guide blade carrier is arranged in the barrel type casing suitable for quick start up and loads. Blading :-The HP turbine blading consists of several stages. All the stages are reaction stages with 50%. FOR IP TURBINE :Casing :- The casing of IP turbine is split horizontally and is of double shell construction. Casing :- The LP turbine casing consists of a double flow unit and has a triple shell welded casing. The turbine has a hydraulic speed governor MAX46BY00l and electro-hydraulic turbine controller. The hydraulic speed governor adjusts main control values MAA10 + 20AA002 and MAB10 + 20AA00l by way of hydraulic convertor.