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

STEAM TURBINE K-660-247

LMZ (LENINGRADSKY METALLICHESKY ZAVOD) K STANDS FOR KLAPAN LTD.,BULGARIA WHICH SUPPLIES TURBINE,NOZZLES,DIAPHRAGMS, SEALS,BLADES ETC.

TG DECK IS VIS SUPPORTED AND HAS 26 CONCRETE COLUMNS (T1 T26). TG HALL IS CONSTITUTED OF 3 MAINS ROWS OF COLUMNS A,B ,C ROW AND TWO BAYS AB BAY AND BC BAY. THE WIDTH OF AB BAY IS 36m AND BC BAY IS 12m CONDENSER TUBE BANKS (CW PATH) HAS AN INCLINATION OF 40. THERE ARE TWO MAIN EOT CRANES FOR TG HALL.EACH EOT CRANE IS HAVING A CAPACITY OF 200t FOR MAIN HOIST AND 20t FOR AUXILIARY HOIST. 35.5m IS THE MAXIMUM VERTCAL DISTANCE A HOIST CAN TRAVEL.TANDEM OPERATION OF TWO EOT CRANES ARE ALLOWED.

LOAD BEFORE HP STOP VALVE

STEAM PRESSURE STEAM TEMPERATURE STEAM FLOW : :

:
247KSC : 2023.75T/HR

660MW

5370C

AFTER HPC
STEAM PRESSURE STEAM PRESSURE : : 48KSC 298.710C

BEFORE IP STOP VALVE

STEAM PRESSURE STEAM TEMPERATURE : 43.2KSC : 5650C

STEAM FLOW TO REHEATER DESIGN CONDENSER PRESSURE COOLING WATER FLOW FREQUENCY RANGE

: :

FINAL FEED WATER TEMP.

:
:

1681.12T/HR. 0.105KSC (abs.) : 64000M3/HR

286.350C

47.5 51.5 Hz

Generator rated speed 3000 Generator manufacturer Electrosila No. of bleedings 8 Length of the turbine 36.362 No. of stages
HPT IPT LPT-1 LPT-2 Total 17 11x2

rpm

5x2 5x2 59

Parameters
Pr. Before HPC SV Temp. before HPC SV Steam flow Pr. After HPC Temp. after HPC Pr. Before IP SV Temp. before IP SV Steam flow to reheat Design Cond pr. CW flow Final FW Temp. 537.0 48.0 247.0 0C 2023.75 Ksc 298.71 43.2 565.0 1681.12 0.105 64000 286.35 Ksc TPH
0C

Ksc 0C TPH Ksc TPH 0C

Turbine Governing system

Mode of Governing Type Control fluid Nozzle E/H Firequel-L make

Supresta-USA Normal Operating Pr. 50 Ksc Capacity 600 lpm Fluid pump motor rating 200 KW Filter material Ultipor Mesh size 25

Lube oil system

Lube oil Absolute viscosity Kinematic viscosity Specific gravity 0.89 Flash point Fire point Oil requirement per bearing
N1 N2 N3 N4 N5 N6 N7 N8 N9 N10

Tn-22C Russia Mobil DTE Oil light Teresso 32 In accordance with ISO VG 32 16.7 Centipoise -32 Centistokes 180 240
200 200 450 280 350 350 350 350 600 600
0C 0C

lpm lpm lpm lpm lpm lpm lpm lpm lpm lpm

Lube oil system

Total oil system capacity Full volume of oil tank Material of tank Normal lube oil pressure Oil temp at inlet of bearings
Normal Maximum 59

52000 58000 SS 1.2

55 0C

lit lit Ksc

0C

Piping

SS

Seal steam system

Source of gland sealing system
During normal operation During low load operation End glands of HPC & IPC End glands of HPC & IPC + AS

Quantity of seal steam required Seal steam pressure at turbine glands Seal steam temperature at turbine glands

3.54 1.1-1.2 160

TPH Ksc 0C

TURBINE SEAL STEAM

TWO HEADERS OR COLLECTORS ARE THERE i.e. HOT COLLECTOR AND COLD COLLECTOR. INITIAL SOURCE OF STEAM SUPPLY IS APRDS (UNIT HT,16KSC,310OC). PRESSURE AND TEMPERATURE OF COLD HEADER OR COLLERTOR ARE 1.1TO1.15 KSC ABSOLUTE AND 140TO 180OC RESPECTIVELY. PRESSURE AND TEMPERATURE OF HOT HEADER OR COLLERTOR ARE 1.1TO1.15 KSC ABSOLUTE AND RESPECTIVELY.

Turbine Protection
Over speed trip 110-112 % Low lube oi pressure 0.3 (g) Ksc Low vacuum trip 0.3 (abs) Ksc Thrust bearing excessive wear trip +1.2/-2.0 mm Pressure relief diaphragm setting 1.2 (abs) Ksc

Materials of construction
HP Outer casing 15Cr1Mo1V HP blade/carrier casings 15Cr1Mo1V IP Outer casing 15Cr1Mo1V LP inner casing Steel 3 LP Outer casing Steel 3 HP Shaft 25Cr1Mo1V IP Shaft 25Cr1Mo1V LP Shaft 26CrNi3Mo2V Moving blades
HPT first stage blades 18Cr11MoNiVNb (1-5) HPT other stages 15Cr11MoV (6-17) IPT first stage 18Cr11MoNiVNb (1-3) IPT other stages 15Cr11MoV (4-11) LPT last stage 13Cr11Ni2W2MoV LPT other stages 20Cr13 (1-2) LPT other stages 15Cr11MoV (3-4)

 Fixed blades

HPT first stage HPT other stages IPT first stage IPT other stages LPT first stage LPT Other stages

18Cr11MoNiVNb (1-5) 15Cr11MoV (6-17) 18Cr11MoNiVNb 15Cr11MoV 12Cr13 (1-4) 08 Cr13 (5)

Number of stages HPT

Impulse stages Reaction stages

IPT

1 16 22 0 20 0

Impulse stages Reaction stages

LPT

Impulse stages Reaction stages

All rows of blades are integrally shrouded

No. of HP Stop valves No. of HP Control valves Type of control valve unit No. of IP Stop valves No. of IP Control valves Type of control valves No. of Journal bearings for turbine No. of Journal bearings for Gen No. of thrust cum journal bearing Type of thrust bearing Type of journal bearing Material of bearing shell Type of lining LPT diaphrams

2 4 Block united 2 4 Separate 8 4 1 Tilting 6-Fixed & 2-Tilting pad Alloy steel Babbit 4

Turbine model No K-660-247 Generator model No TBB-660-2T3 Strainers are installed in the steam chests of the stop valves In HPT, having passed the control stage and 8 stages which generate left jet of steam (from generator towards front bearing) steam changes its direction 180 and flows between internal and external cylinders to 8 stages of right jet (towards generator) In CRH lines, NRV has a bypass with electric valve and control valve to enable counter flow mode of HPT with the aim of warming up of cylinder and high pressure cross over pipes at turbine start up and cold condition HPT has nozzle steam distribution system IPT has throttle steam distribution system On each upper half (cover) of low pressure cylinder four membrane type relief valves are installed which are activated when the absolute pressure in exhaust nozzles rises up to 1.35 1.4 Ksc absolute

TG SEAL STEAM SYSTEM

HPT SEAL STEAM CONNECTION

TO BLED STEAM TO LPH # 4

1ST CHAMBER

2ND CHAMBER

HPT

TO 2nd CHAMBER EXHAUST

TO HOT SEAL STEAM HEADER

TO BLED STEAM TO D/A

TO GSC

IPT SEAL STEAM CONNECTION

IPT

TO COLD SEAL STEAM HEADER

TO GSC

LPT SEAL STEAM CONNECTION

LPT

FROM COLD SEAL STEAM HEADER

TO GSC

IN HIGH PRESSURE DRAINAGE EXPANSION TANK A VALVES IN DRAINAGE COLLECTORS FROM EXTRACTION STEAM PIPES TO HPHs (10MAL20AA110, 10MAL20AA120, 10MAL20AA140) AND IN LOW PRESSURE DRAINAGE EXPANSION TANK VALVES IN DRAINAGE COLLECTORS FROM EXTRACTION STEAM PIPES TO LPHs(10MAL30AA110, 10MAL30AA120) CLOSE AUTOMATICALLY IF TURBINE LOAD INCREASES OVER 200MW AND AT THE SAME TIME ALL VALVES ARE OPEN IN THE CORRESPONDING STEAM EXTRACTION FROM THE TURBINE TO HPHs AND LPHs. VALVES IN DRAINAGE PIPES OF HPBP AND LPBP (10MAL30AA107, 10MAL30AA108) CLOSE AUTOMATICALLY IF TURBINE LOAD INCREASES OVER 30MW.

FIRE RESISTANT SYNTHETIC HYDRAULIC FLUID FYRQUEL L MANUFACTURED BY SUPRESTA IS USED AS OPERATING FLUID.ITS SELF IGNITION TEMPERATURE IS ABOUT 740OC. OPERATING PRESSURE IS APPROXIMATELY 50KSC. OPERATING TEMPERATURE IS 45-55OC. CONTROL OIL SUPPLY UNIT CNSISTS OF A RESERVOIR (10MAX10BB001)OF CAPACITY 7.0m3 ,2NOS.OIL COOLERS(10MAX10AC001,10MAX10AC002),DE-AERATOR,MESH FILTER,FINE FILTER(10MAX18AT001),DUPLEX FILTER(10MAX14AT001) AND 2 NOS. OF VERTICALLY MOUNTED CENTRIFUGAL PUMPS(10MAX11AP001,10MAX12AP001) DRIVEN BY AC MOTOR (1W+1S).EACH PUMP IS HAVING A CAPACITY OF 36m3/h AND DISCHARGE PRESSURE IS 50KSC. CONTROL FLUID RESERVOIR IS SEPERATED BY TWO NUMBERS OF TANDEM MESHES OF CELL SIZE 0.25mm INTO TWO SECTIONS ,DIRTY AND CLEAN. DE- AERATOR IS INSTALLED INSIDE THE RESERVOIR INFRONT OF MESHES AND IT CONSISTS OF SLOPING PLATE ASSEMBLY. CF FINE FILTER FOR REMOVING MECHANICAL IMPURITIES IS INSTALLED IN RESERVOIR. DURING NORMAL OPERATION CF IS SUPPLIED TO THE FINE FILTER THROUGH AN ORIFICE OF DIAMETER 4mm FROM UNSTABILIZED PRESSURE LINE VIA VALVE 10MAX18AA501 . AFTER THAT IT IS DISCHARGED IN THE DIRTY CHAMBER OF THE RESERVOIR. WHEN TURBINE IS STOPPED CF IS SUPPLIED TO THE FINE FILTER WITH THE HELP OF ANOTHER PUMP (CF TRANSFER PUMP,10MAX19AP001,CAPACITY 4m3/hr, AND DISCHARGE PRESSURE 25KSC) VIA VALVES 10MAX19AA503 AND10MAX19AA504 FOR FILTERING PURPOSE KEEPING MAIN PUMPS IN OFF CONDITION.

OIL PURIFICATION IS CONTINUOUS DUE TO FILTERING OF ITS PART VIA CONCURRENTLY MOUNTED WORKING FILTER CARTRIDGES INSTALLED INSIDE THE FINE FILTER HOUSING. FILTER CARTRIDGES DESIGN ALLOWS USAGE OF DIFFERENT FILTERING MATERIAL.

METAL SEMI-PINCEBECK MESH WITH FILTERING DEGREE OF 70 MICRONS TO FLUSH SYSTEM AFTER INSTALLATION OR MAINTENANCE. FILTER BELTING FABRIC WITH FILTERING DEGREE 30 40 MICRONS FOR PRIMARY REFINING DURING TURBINE OPERATION. FILTERING ELEMENTS MANUFACTURED BY PALL WITH FILTERING DEGREE 12 MICRONS FOR CONTINUOUS OIL FILTERING DURING TURBINE OPERATION. OCCURRENCE OF PRESSURE OF 0.1 TO 0.3KSC IN FILTER HOUSING WITHIN 1-3 HOURS SHOWS CORRECT ASSEMBLY OF FILTER AND ITS PROPER OPERATION. IT IS NECESSARY TO SWITCH OFF THE FINE FILTER AND REPLACE FILTERING ELEMENTS IF PRESSURE IN FILTER HOUSING RISES UPTO 2KSC.WHICH SHOWS CONTAMINATION OF FILTER FABRIC. INSIDE FILTER HOUSING THERE IS A RELIEF VALVE BYPASSING FLUID BESIDES FILTER CARTRIDGES WHEN THEY ARE CONTAMINATED AND PRESSURE RISES UPTO 5KSC. AN OIL LEVEL GAUGE WITH ALARM SYSTEM WHISKERS (10MAX10CL001,10MAX 10CL002) IS PROVIDED IN THE CLEAN SIDE OF THE RESERVOIR. NORMAL OPERATING LEVEL IS 700mm FROM THE UPPER COVER (30 GRADUATION OF L.G.) AND THE AMOUNT OF CF IS 2.5m3

MAXIMUM ALLOWALABLE UPPER LIMIT (WITH CF PUMPS IN STOPPED CONDITION) IS 150mm FROM THE UPPER COVER (85 GRADUATION OF L.G.) AND MINIMUM OPERATING LEVEL IS 800mm (20 GRADUATON OF L.G.) FROM THE UPPER COVER. CF PUMP STOPS AUTOMATICALLY INCASE OF RESERVOIR OIL LEVEL LOW-LOW. FOR VISUAL OVSERVATION OF OIL LEVEL ,LEVELGLASSES HAVE BEEN PROVIDED IN THE BOTH SIDES (DIRTY AS WELL AS CLEAN).

DIFFERENTIAL PRESSURE SWITCH (10MAX10CP001) HAS BEEN PROVIDED TO WARN ABOUT INCREASE IN PRESSURE DIFFERENCE IN SIDE THE MESH FILTER. ALLOWABLE DIFFERENCE IN MESHES DOESNOT EXCEED 150mm.
THE STANDBY CF PUMP STARTS WHEN THE RUNNING ONE TRIPS OR SYSTEM PRESSURE DROPS TO 36KSC. IT TAKES 2 MINS FOR THE SYSTEM TO GET PRESSURIZED. IF SYSTEM PRESSURE DROPS TO 20KSC (10MAX14CP001) AND STOP VALVES START CLOSING ,THE OPEARTING PUMP WILL STOP AND NO SIGNAL WILL BE GENERATED TO START THE STAND BY PUMP (SENSING OIL LEAKAGE). CF PUMP ALSO TRIPS ON FIRE PROTECTION. DUPLEX FULL PASSAGE FILTER WITH FILTERING DEGREE 20-25MICRONS IS INSTALLED IN GENERAL PRESSURE COLLECTOR OF CONTROL SYSTEM.IF PRESSURE DIFFERENCE (10MAX14CP301,10MAX15CP301) ACROSS THE RUNNING FILTER REACHES 0.8KSC,THE STANDBY FILTER HAS TO BE TAKEN INTO SERVICE.

2 NOS.OF CF COOLERS (A&B) ARE INSTALLED IN THE CF SUPPLY LINE BEHIND THE DUPLEX FILTER. THESE COOLERS ARE DOUBLE PASS (BY WATER) SURFACE HEAT EXCHANGERS WITH TUBULAR DESIGN ,WATER STREAM FLOWS INSIDE THE TUBES AND CONSIST OF 148 TUBES OF SIZE 16X1500mm AND HEAT EXCHANGE AREA 25m2.CF FLOWS FROM TO DOWNARD.
COOLERS ARE DESIGNED FOR A MAXIMUM COOLING WATER PRESSURE OF 10 0.5KSC AND CF PRESSURE OF 68.7 0.5KSC.CF FLOW RATE TO EACH COOLER IS 50m3/hr AND PRESSURE DROP IS 0.2KSC. CW FLOW RATE TO EACH COOLER IS 80m3/hr AND PRESSURE DROP IS 0.194KSC. FOR HYDRODYNAMIC FLUSHING OF PIPELINES DURING MAINTENANCE,THERE IS A BYPASS VALVE (10MAX14AA501)TO THE COOLERS WHICH SHOULD BE CLOSED AND SEALED DURING ROUTINE OPERATION. IN THE INPUT AND OUTPUT TO THE COOLERS CF LINE IS PROVIDED WITH TRIPLE-PASS SWITCHING OVER VALVES WHICH PREVENT FALSE ACTIVATION OF BOTH COOLERS. CF TEMPERATURE IS MAINTAINED (48-52OC)BY COOLING WATER FLOW VARIATION WITH THE HELP OF A FLOW CONTROL STATION CONSISTING OF A PNEUMATIC CONTROL VALVE (10PGM20AA001) AND A BYPASS MOTORIZED CONTROL VALVE(10PGM20AA002).IN CASE TEMPERATURE RISES TO 55OC (10MAX14CT001,10MAX14CT002),MOTORIZED BYPASS VALVE OPENS TO MAINTAIN THE CF TEMPERATURE. THE MAXIMUM LIMIT OF CW TEMPERATURE AT COOLER INLET IS 37OC.IF CW TEMPERATURE IS BELOW 36OC ONE COOLER CAN BE PUT OUT OF OPERATION.

CF SUPPLY TO CONTROL UNITS IS CARRIED OUT BY TWO PRESSURE COLLECTORS OF STABILIZED AND UNSTABILIZED PRESSURE. CF IS SUPPLIED TO UNSTABILIZED PRESSURE COLLECTOR THROUGH AN ORIFICE OF SIZE 22mm. STOP AND CONTROL VALVE ACTUATORS ARE FED FROM THIS COLLECTOR. INTO STABILIZED PRESSURE COLLECTOR WHICH FEEDS OIL TO ALL CONTROL DEVICES,CF IS SUPPLIED FROM THE SECTION BETWEEN PUMPS AND THE ORIFICE. DUE TO THE ARRANGEMENT MENTIONED ABOVE ,THE PRESSURE VARIATION IN UNSTABILIZED PRESSURE COLLEECTOR CAUSED BY INCREASE IN CF CONSUMPTION WITH OPEN ACTUATORS AFFECTS IN A LESS DEGREE PRESSURE VARIATION IN STABILIZED PRESSURE COLLECTOR. SPRING-WEIGHT ACCUMULATOR (10MAX20BB001) IS CONNECTED TO UNSTABILIZED PRESSURE COLLECTOR TO PREVENT DECREASE IN FORWARD PRESSURE IN CASE OF LOSS AC SUPPLY TO THE PUMPS FOR 5-7SECS OR DURING PUMP CHANGE-OVER. THE SETTING OF FLUID PRESSURE LEVEL (45KSC) TO BE ENSURED BY THE ACCUMULATOR IS DETERMINED BY A WEIGHT WHICH IS CONCRETE FILLED IN THE SITE. ONE NRV IS INSTALLED IN THE LINE CONNECTING THE ACCUMULATOR TO THE UNSTABILIZED PRESSURE COLLECTOR. ACCUMULATOR IS FILLED WITH THE CF THROUGH AN ORIFICE OF SIZE 5mm INSTALLED IN THE BYPASS LINE OF THE NRV. TWO EXHAUST FANS (1W+1S) ,10MAX21AN001,10MAX21AN002 (CAPACITY OF 3200m3/hr AT A HEAD OF 520mm OF WATER COLUMN) ARE ALSO INSTALLED TO REMOVE CF VAPOUR FROM CF RESERVOIR AND SYSTEM. THE EXHAUSTER SWITCHES ON AUTOMATICALLY WHEN CF PUMP STARTS AND SWITCHES OFF AUTOMATICALLY WITH 15mins TIME DELAY AFTER THE STOPPING OF CF PUMP AND CF SYSTEM PRESSURE DROPS BELOW 2.0KSC.

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

CONTROL FLUID SYSTEM

Isolation valves on pump suction & discharge side Pump discharge pressure 50 Ksc Capacity 41 TPH Stabilized pressure header supply oil to servo motors of SV & CV Un stabilized pressure header with 22 mm orifice Accumulator in unstabilized pressure header CF tank capacity 6.9 m3 Duplex filter Control fluid transfer pump to empty the CF tank CF Temperature control by control station in the ECW line

1. 2. 3. 4.

ELECTRO-HYDRAULIC CONVERTER SUMMER 8 NOS. SUMMER 8NOS. ELECTRO-MECHANICAL CONVERTER 8NOS. GOVERNING BLOCK
1. 2. 3. 4. 5. 6. 7. 8. 9. CONTROLGEAR(AE001) 1NO. EMERGENCY GOVERNOR OR OVERSPEED GOVERNOR 1NO. TRIP SOLENOID (AA213,AA214)-2NOS. TEST ELECTROMAGNETS(AA211,AA212) 2NOS. ROTATIONAL SPEED DETECTOR -3 NOS. LIMITER OF PRESSURE (AA502) 1NO. SPEED TRANSDUCER 1NO. LEVER OF OVER SPEED GOVERNOR (AX201) 1NO. PILOT VALVE FOR SUPPLY (AX202) 1NO.

5.
6. 7. 8. 9. 10. 11. 12.

13.

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

1. 2. 3. 4. 5. 6.

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

1. 2.

OUT OF TOLERANCE ROTOR OVERSPEED : ALARM AT 3300RPM AND TRIPPING AT 3360RPM OUT OF TOLERANCE AXIAL DISPLACEMENT OF ROTOR:
TOWARDS FRONT BEARING BY 0.6mm (-0.6mm) -ALARM. TOWARDS FRONT BEARING BY 1.2mm (-1.2mm) - TRIPPING. TOWARDS GENERATOR BY 1.4mm (+1.4mm)A- ALARM. TOWARDS GENERATOR BY 2.0mm (+2.0mm) - TRIPPING.

3. 4.

LUBRICATING OIL PRESSURE DROP: ALARM AT 0.70KSC AND TRIPPING AT 0.30KSC WITH 3SECS TIME DELAY. PRESSURE RISE IN CONDENSER:ALARM AT 0.15KSC abs. AND TRIPPING AT 0.20KSC abs. PROTECTION IS INTRODUCED AUTOMETICALLY AT UNIT START-UP AFTER PRESSURE DROP IN CONDENSER LOWER THAN 0.15KSC abs. OR AT TURBINE SPEED INCREASE OVER 1500RPM. PROTECTION IS IN OPERATION UNTIL STOP VALVES ARE OPEN INCREASE OF BEARING VIBRATION: ALARM SOUNDS AT INCREASE OF VERTICAL OR TRANSVERSE OR AXIAL COMPONENT OF VIBRATION ON ANY BEARING OF TG SET REACHES 4.5mm/s .TRIPPING OCCURS WITH 2 SECS TIME DELAY AT INCREASE OF VERTICAL OR TRANSVERSE COMPONENT OF VIBRATION OVER 11.2mm/s ON ANY TWO BEARINGS OF TG SET.

5.

6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

RISE IN STEAM TEMPERATURE AT HPT OUTLET: LIVE STEAM TEMPERATURE BEFORE TURBINE FALLS BELOW 470OC: LIVE STEAM TEMPERATURE BEFORE TURBINE RISES ABOVE 565OC: STEAM TEMPERATURE BEFORE IV FALLS BELOW 500OC: STEAM TEMPERATURE BEFORE IV RISES ABOVE 593OC: MOT LEVEL LOW-LOW: DRIP LEVEL HIGH-HIGH IN ANY HPH: ANY FAILURE IN TURBNE CONTROL SYSTEM ELECTRONICS: GENETERATOR PROTECTION: FIRE PROTECTION OPERATED: EPB PRESED.

LUBRICATION OIL SYSTEM IS DESIGNED TO SUPPLY OIL TO TURBINE AND GENERATOR BEARINGS IN ALL TURBINE PLANT OPERATION MODES AND ALSO TO PROVIDE ROTOR JACKING OIL SYSTEM AND GENERATOR SEAL OIL SYSTEM WITH OIL. LUBRICATION OIL IS ISO VG 32 TYPE WITH FOLLOWING PROPERTIES:
ABSOLUTE VISCOCITY KINEMATIC VISCOSITY SPECIFIC GRAVITY SPECIFIC HEAT FLASH POINT FIRE POINT DEGREE OF CLEANLINESS PERMISSIBLE SUSPENDED PARTICLE SIZE : : : : : : : : 180OC 240OC 16/13 ISO 4406 25 MICRON 16.7CENTIPOISE 32CENTISTOKE 0.89

0.459Kcal/Kg Deg.C

WATER CONTENT

<10PPM

LUBE OILTANK IS MADE OF STAINLESS STEEL AND HAVING A CAPACITY OF 58m3 . PROVISION IS MADE FOR OIL TREATMENT INSIDE THE TANK BY PROVIDING TWO ROWS OF FLAT GRIDS WITH MESH DIMENSIONS 0.25mm LOCATED INSIDE THE TANK WHICH DIVIDES THE TANK INTO DIRTY AND CEAN COMPARTMENTS. THE AIR SEPARATOR CONSISTING OF TILTED METAL PLATES SET IS INSTALLED TO SEPARATE THE AIR DISSOLVED IN OIL. THE OIL TANK HAS ATTACHMENTS FOR OIL DRAINING TO OIL TREATMENT PLANT FOR SLUDGE DRAIN AND TO EMERGENCY TANK INCASE OF FIRE.

NORMAL OPERATING LEVEL IS 600mm FROM TANK TOP COVER.ALARM IS AT 500mm AND TURBINE TRIP IS THERE AT 400mm.
4 NOS OF LUBE OIL PUMPS (SINGLE STAGE CENTRIFUGAL) ARE INSTALLED VERTICALLY ABOVE THE TANK .2 PUMPS (AUXILLIARY OIL PUMP) ARE ac MOTOR DRIVEN AND 2 PUMPS ARE dc (EMERGENCY OIL PUMP) MOTOR DRIVEN. ONE PUMP WITH ac MOTOR IS CONTINUOUS RUNNING AND OTHER IS KEPT STANDBY. EACH ac PUMP IS HAVING A DISCHARGE CAPACITY OF 300m3/hr A DISCHARGE PRESSURE OF 4.3KSC. EOP WLL START IN CASE OF LOSS OF AC.EACH EOP IS HAVING A DISCHARGE CAPACITY OF 250m3/hr AND A DISCHARGE PRESSURE OF 2 KSC.FOR HIGHIER RELIABILITY EOP DELIVERS OIL DIRECTLY TO THE BEARING BYPASSING COOLER AND THROTTLE VALVE.

TG LUBE OIL SUPPLY SYSTEM

TG LUBE OIL SYSTEM

Turbine oil is ISO VG 32

KV 20-23 CST at 500C Acidity Number < 0.05 mg KOH/r Viscosity index > 90

Bearings
HPT Front HPT Rear IPT Front (TB) IPT Rear LPT-1 Front LPT-1 Rear LPT-2 Front LPT-2 Rear Generator Front Generator Rear Exciter Front Exciter Rear N1 N2 N3 N4 N5 N6 N7 N8

N9 N10
N11 N12

TG LUBE OIL SYSTEM

DC Lube oil pump 1 No.
Equipment AC Lube oil pump DC Lube oil pump Capacity (m3/hr) 300 250 Head (Ksc) 4.3 2.0

NRV & Isolation valve in each Lube oil pump discharge line Oil first goes to duplex filter instead of cooler Coolers Bypass line with isolating valve Hydraulic Pressure control valve maintains the pressure at the center shaft level at 1.2 Ksc PCV Bypass with throttling orifice which provides lubrication even at fully closed control valve

Oil is first delivered to bearing brasses through emergency tanks located on bearing cap Emergency tanks capacity in m3
N1 N2 N3 N4 N5 N6 N7 N8 N9 N10 N11 N12 0.43 0.35 0.75 0.44 0.44 0.44 0.44 0.44 0.5 0.44 0.1 0.1

Lube oil temperature control by control station in the ECW inlet line to Lube oil coolers View glasses in the oil return line from each bearing MOT Capacity 58 m3 Duplex filters fineness 25 m Provision is made for oil cleaning by delivering a portion of oil from the oil pressure pipe to the oil tank through the fine cleaning filter with fineness of 12-15 m Fresh oil is filled through the above filter only Oil recirculation pump to purify the oil Electrical oil heater of 152 KW capacity is provided for the preliminary oil warming in the lubrication oil tank before turbine start up by running the oil recirculation pump Oil draining to Emergency lube oil tank in case of emergency with MOV

Oil trap at the suction of the vapor extractor fans Oil trap drain to lubrication oil tank Jacking oil pumps suction also given from lube oil discharge header after coolers & before control valve

TG JACKING OIL AND BARRING GEAR SYSTEM

Automatic barring gear engagement at the rotor stop and barring gear disengaging at the start-up High pressure oil supply for bearing inserts oil jacking Barring speed 1.05 rpm Motorized barring gear Torque transfer from the barring gear motor to the turbine shaft is carried out via three stage reducer and free wheel clutch Reduction gear first stage shaft end mounts special handle for hand barring Normal source for jacking oil pumps suction is from lube oil pumps discharge header after coolers JOP discharge pressure: 120 Ksc

Dozing devices at each bearing of the Turbine & Generator which contain strainer, NRV, orifice & isolation valve Bearing jacking oil is supplied via separate lines for oil jacking of inserts of bearing no: 4-9

Stand-by bearing insert oil jacking pump is not provided as the system is designed to realize auxiliary functions at turbine start-up. If this pump does not start when it is required then also the turbine can be operated normally without any bearing damage and disturbance of turbine operation Each bearing insert jacking oil line is equipped with orifice only Both pumps cut in/cut out is 1500/1500 Barring gear cut in/cut out is 1500/1500

Bearing Insert Oil Jacking Pump is started automatically, if the rotor

neck displacement becomes more than 0.1 mm relative to the insert of any of bearings No. 4,9 provided that the oil pressure to rotor jacking is higher than 45 kg/cm2 or the turbine rotor rotational speed is higher than 1500 rpm
Pump is stopped automatically, with time delay of 30 seconds, if the rotor neck displacement is less than 0.1 mm relative to the insert of bearings No. 4-9

GENERATOR SEAL OIL SYSTEM

Seal oil pumps suction from MOT No Hydrogen side seal oil pump Pumps re-circulation line directly to MOT Coolers bypass valve Magnetic filters 2 No. (1W+1SB) NRV in the seal oil line after filters DPR DPR bypass manual control valve

Damper tanks 2 No.: 1 for TE & 2 for EE, designed for oil supply to front and back generator shaft seals with drop, specified by the height of damper tank installation, and also to seal at short-time interruption in oil supply, at the moment of automatic transfer from working pump to standby and at generator runback with generator shaft seal pumps switched off View glasses in return oil lines Float hydraulic seal functions as SOT Hydraulic seal overflows in to return oil header No SOST Provision of trap upstream of fans Fans suction is from return oil header

GENERATOR STATOR WATER COOLING SYSTEM

Water tank not on the generator Ejector to make vacuum over the water tank to prevent air ingress Ejector cooling by auxiliary cooling water Air venting of Generator through Gas trap connected from winding inlet and outlet headers Gas trap to determine hydrogen present which will be extracted from trap cap to gas analyzer Coolers bypass valve Ion exchanger-1 contains anion & cat ion in H-OH form to maintain conductivity Ion exchanger-2 contains anion & cat ion in Na-OH form to maintain Ph if it decreases below 8 Ion exchanger-1 first will be put in to service for reducing dissolved oxygen below 5.0 s/cm and then it will be put out of service. Then Ion exchanger-2 will be put in to service to increase the Ph value. If conductivity increases above 12.5 s/cm, Ion exchanger-2 to be stopped

Control valves at the inlet of individual Ion exchanger circuits DM water flow through ion exchanger is 1.5 to 2.0 m No NAOH dozing system Ion exchangers separate bypass lines Mechanical filter at the inlet of Ion exchanger circuit Dissolved oxygen analyzer & Ph analyzer Winding inlet valve for flow adjustment Winding outlet valve for pressure adjustment Normal make up from DM make up line & emergency make up line from CST Filter in the common make up line Control station in the common make up line

GENERATOR GAS SUPPLY SYSTEM

Two Hydrogen manifolds to connect 16 cylinders each Direct acting Pressure regulator installed on cylinder connecting line to Manifold header to reduce the Hydrogen pressure from 175 Ksc to 10 Ksc Total Pressure regulators 32 Safety valve on each manifold header which operates when the Hydrogen pressure in the manifold exceeds 10.5 Ksc MOV & NRV in each manifold header Three CO2 manifolds to connect 17 cylinders each Each manifold header contains MOV, NRV & Isolation valve MOV with manual bypass valve at the inlet of CO2 heater CO2 heater is steam heated Steam source is from auxiliary steam system Steam parameters: 15 Ksc & 210 0C MOV in the steam inlet line Steam exhaust will go to FWSV Dish flash tank Manifold header pressure is 175-20 Ksc Control station with Pressure regulator provided D/S of heater to maintain a pressure of 2.0-2.2 Ksc with manual bypass valve SV installed D/S of pressure regulator operates if the pr > 5.0 Ksc Capacity of one cylinder 50 lit

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

DRAINS FROM THE TURBINE AND STEAM LINES ARE REMOVED TO TWO HP DRAIN FLASH TANKS - A (10MAL10BB001) AND B (10MAL20BB001) AND ONE LP DRAIN FLASH TANK (10MAL30BB001) BOTH THE HP FLASH TANKS ARE HAVING A CAPACITY OF 2.6m3. LP DRAIN FLASH TANK IS ALSO HAVING A CAPACITY OF 2.6m3.

Design Design CW Flow Vacuum No. of passes Total no. of tubes Tube material Rated TTD DT of CW

LMZ 64000 m3/hr 77 mm Hg (abs) at 33 0C 89 mm Hg (abs) at 36 0C 1 22.225 (OD)x0.71 (t) - 29920 22.225 (OD)x1.00 (t) - 2080 ASTM A-249 TP 304 3.40C 100C

Design flow rate Discharge pressure Shut off head Pump speed Power input No. of stages Type of first stage impeller Depth

238.75 Kg/s 32.15 Ksc 395 m 1480 rpm 972.3 KW 6 double entry 7.43 m

Design Pressure No. of trays Spray valves Design temp for D/A Design temp for FST

13 Ksc 896 132 395 0C 250 0C

Design flow rate Discharge pressure Shut off head Pump speed Power input No. of stages Type of first stage impeller Depth

324.509 TPH 43 ata 306.7 m 1486 rpm 310.1 KW 5 centrifugal, single entry 1090 mm

Pump flow Suction temp BP Suction pr. BFP Suction pr. 21.01 BFP Discharge pr. BFP Discharge temp. BP Discharge pr. 22.01 Shut off head BFP Speed BP Speed Normal R/C flow 220 HC Rated O/P Speed Outer casing type No. of stages BFP warm up flow

769.950 186.2 14.05 ata 335.78 187.9 ata 4830 6275 1490 TPH 6505 barrel 7 15

TPH 0C ata
ata 0C m rpm rpm rpm

TPH

Pump flow Suction temp BP Suction pr. BFP Suction pr. BFP Discharge pr. BFP Discharge temp. BP Discharge pr. Shut off head BFP Speed BP Speed Normal R/C flow HC Rated O/P Speed Outer casing type No. of stages BFP warm up flow

1283.14 186.2 14.10 28.24 335.83 187.8 29.06 4580 4678 2098 365 6505 barrel 7 20

TPH 0C ata ata ata 0C ata m rpm rpm TPH rpm

TPH

PARTS OF GOVERNING SYSTEM

Hydraulic Accumulator (HA) Remote switch (RS) Lubrication system pressure relay (LSPR) Trip Gear (TG) Stop valve (SV) Governor valve 1 (GV1) Governor valve 2 (GV2) Cut off pilot valve (COPV) Electro mechanical converter (EMC) Electro mechanical converter position transducer (ECPT) Electronic control part (ECP) Servo motor (S) Governor valves position transducer (GVPT)

Number of stages Casing Steam admission Dual Steam pressure at inlet Steam temperature at inlet Turbine operating speed Steam consumption Steam pressure at exhaust 0.128 Turning gear speed Type of governing system Over speed type trip JOP Lube oil tank capacity Lube oil

9 Split 20.82 ata 0C 469 4678 rpm 61.4 TPH ata 15 rpm Electro-Hydraulic Centrifugal + electrical Not required 10.97 m3 Same as main turbine

CW flow Vacuum in the condenser Total no. of tubes Tube OD and thickness No. of water passes Tube material

3000 TPH 0.128 Ksc (abs) 3312 22.225x1.06 mm 2 ASTM A-249 TP321

TDBFP LUBE OIL SYSTEM

TDBFP EXTRACTION SYSTEM

TDBFP CONDENSATE SYSTEM

ACW SYSTEM

Suction header is from all the 4 CW inlet lines to condensers MOV at Suction header from CW line MOV at SCS inlet MOV at PHE inlet & outlet Supply to Ejector of Stator water cooling system TDBFP vacuum pumps (4 No.) Main turbine vacuum pumps (1 No. extra) MOV at return header to CW line

TURBINE VACUUM SYSTEM

TURBINE HEATING FLANGES SYSTEM

AUXILIARY STEAM SYSTEM

CONDENSATE SUPPLY SYSTEM TO EXT NRVS

EXHAUST HOOD SPRAY

FEED WATER SYSTEM

TDBFP-A FEED WATER SYSTEM

MDBFP FEED WATER SYSTEM

LP DOZING & OXY TREATMENT SYSTEM

HP BYPASS SYSTEM

LP BYPASS SYSTEM