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

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Presentation on theme: "A PRESENTATION ON 660MW TURBO- GENERATOR,ITS AUXILIARIES AND ASSOCIATED SYSTEMS OF STAGE – I OF SIPAT SUPER THERMAL PROJECT."— Presentation transcript:

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

2 STEAM TURBINE K

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

4  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 4 0.  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.

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10  LOAD :660MW  BEFORE HP STOP VALVE  STEAM PRESSURE:247KSC  STEAM TEMPERATURE:537 0 C  STEAM FLOW: T/HR  AFTER HPC  STEAM PRESSURE:48KSC  STEAM PRESSURE: C  BEFORE IP STOP VALVE  STEAM PRESSURE:43.2KSC  STEAM TEMPERATURE:565 0 C  STEAM FLOW TO REHEATER: T/HR.  DESIGN CONDENSER PRESSURE:0.105KSC (abs.)  COOLING WATER FLOW:64000M 3 /HR  FINAL FEED WATER TEMP.: C  FREQUENCY RANGE:47.5 – 51.5 Hz

11 STEAM TURBINE  Generator rated speed3000rpm  Generator manufacturerElectrosila  No. of bleedings8  Length of the turbine36.362m  No. of stages  HPT17  IPT11x2  LPT-15x2  LPT-25x2  Total59

12 STEAM TURBINE  Parameters  Pr. Before HPC SV247.0Ksc  Temp. before HPC SV C  Steam flow TPH  Pr. After HPC48.0Ksc  Temp. after HPC C  Pr. Before IP SV43.2Ksc  Temp. before IP SV C  Steam flow to reheat TPH  Design Cond pr.0.105Ksc  CW flow64000TPH  Final FW Temp C

13 STEAM TURBINE  Turbine Governing system  Mode of Governing Nozzle  TypeE/H  Control fluidFirequel-L make Supresta-USA  Normal Operating Pr.50 Ksc  Capacity600 lpm  Fluid pump motor rating200 KW  Filter materialUltipor  Mesh size25 µ

14 STEAM TURBINE  Lube oil system  Lube oilTn-22C Russia Mobil DTE Oil light Teresso 32 In accordance with ISO VG 32  Absolute viscosity16.7Centipoise  Kinematic viscosity-32Centistokes  Specific gravity0.89  Flash point180 0 C  Fire point240 0 C  Oil requirement per bearing  N1200lpm  N2200lpm  N3450lpm  N4280lpm  N5350lpm  N6350lpm  N7350lpm  N8350lpm  N9600lpm  N10600lpm

15 STEAM TURBINE  Lube oil system  Total oil system capacity52000lit  Full volume of oil tank58000lit  Material of tankSS  Normal lube oil pressure1.2Ksc  Oil temp at inlet of bearings  Normal55 0 C  Maximum59 0 C  PipingSS  Seal steam system  Source of gland sealing system  During normal operationEnd glands of HPC & IPC  During low load operationEnd glands of HPC & IPC + AS  Quantity of seal steam required3.54TPH  Seal steam pressure at turbine glands Ksc  Seal steam temperature at turbine glands160 0 C

16 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,310 O C). PRESSURE AND TEMPERATURE OF COLD HEADER OR COLLERTOR ARE 1.1TO1.15 KSC ABSOLUTE AND 140TO 180 O C RESPECTIVELY. PRESSURE AND TEMPERATURE OF HOT HEADER OR COLLERTOR ARE 1.1TO1.15 KSC ABSOLUTE AND RESPECTIVELY.

17 STEAM TURBINE  Turbine Protection  Over speed trip %  Low lube oi pressure0.3 (g)Ksc  Low vacuum trip0.3 (abs)Ksc  Thrust bearing excessive wear trip+1.2/-2.0mm  Pressure relief diaphragm setting1.2 (abs)Ksc

18 STEAM TURBINE  Materials of construction  HP Outer casing15Cr1Mo1V  HP blade/carrier casings15Cr1Mo1V  IP Outer casing15Cr1Mo1V  LP inner casingSteel 3  LP Outer casingSteel 3  HP Shaft25Cr1Mo1V  IP Shaft25Cr1Mo1V  LP Shaft26CrNi3Mo2V  Moving blades  HPT first stage blades18Cr11MoNiVNb (1-5)  HPT other stages15Cr11MoV (6-17)  IPT first stage 18Cr11MoNiVNb (1-3)  IPT other stages15Cr11MoV (4-11)  LPT last stage13Cr11Ni2W2MoV  LPT other stages20Cr13 (1-2)  LPT other stages15Cr11MoV (3-4)

19 STEAM TURBINE  Fixed blades  HPT first stage18Cr11MoNiVNb (1-5)  HPT other stages15Cr11MoV (6-17)  IPT first stage18Cr11MoNiVNb  IPT other stages15Cr11MoV  LPT first stage12Cr13 (1-4)  LPT Other stages08 Cr13 (5)  Number of stages  HPT  Impulse stages1  Reaction stages16  IPT  Impulse stages22  Reaction stages0  LPT  Impulse stages20  Reaction stages0  All rows of blades are integrally shrouded

20 STEAM TURBINE  No. of HP Stop valves2  No. of HP Control valves4  Type of control valve unitBlock united  No. of IP Stop valves2  No. of IP Control valves4  Type of control valvesSeparate  No. of Journal bearings for turbine8  No. of Journal bearings for Gen4  No. of thrust cum journal bearing1  Type of thrust bearingTilting  Type of journal bearing6-Fixed & 2-Tilting pad  Material of bearing shellAlloy steel  Type of liningBabbit  LPT diaphrams4 

21  Turbine model NoK  Generator model NoTBB-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

22 TG SEAL STEAM SYSTEM

23 TO 2 nd CHAMBER EXHAUST TO BLED STEAM TO D/A TO BLED STEAM TO LPH # 4 TO HOT SEAL STEAM HEADER TO GSC HPT HPT SEAL STEAM CONNECTION 1 ST CHAMBER2 ND CHAMBER

24 TO COLD SEAL STEAM HEADER TO GSC IPT IPT SEAL STEAM CONNECTION

25 FROM COLD SEAL STEAM HEADER TO GSC LPT LPT SEAL STEAM CONNECTION

26  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.

27  FIRE RESISTANT SYNTHETIC HYDRAULIC FLUID FYRQUEL – L MANUFACTURED BY “SUPRESTA” IS USED AS OPERATING FLUID.ITS SELF IGNITION TEMPERATURE IS ABOUT 740 O C.  OPERATING PRESSURE IS APPROXIMATELY 50KSC.  OPERATING TEMPERATURE IS O C.  CONTROL OIL SUPPLY UNIT CNSISTS OF A RESERVOIR (10MAX10BB001)OF CAPACITY 7.0m 3,2NOS.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 36m 3 /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 4m 3 /hr, AND DISCHARGE PRESSURE 25KSC) VIA VALVES 10MAX19AA503 AND10MAX19AA504 FOR FILTERING PURPOSE KEEPING MAIN PUMPS IN OFF CONDITION.

28  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 2.5m 3

29  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.

30  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 25m 2.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 50m 3 /hr AND PRESSURE DROP IS 0.2KSC. CW FLOW RATE TO EACH COOLER IS 80m 3 /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 (48-52 O C)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 55 O C (10MAX14CT001,10MAX14CT002),MOTORIZED BYPASS VALVE OPENS TO MAINTAIN THE CF TEMPERATURE. THE MAXIMUM LIMIT OF CW TEMPERATURE AT COOLER INLET IS 37 O C.IF CW TEMPERATURE IS BELOW 36 O C ONE COOLER CAN BE PUT OUT OF OPERATION.

31  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 3200m 3 /hr AT A HEAD OF 5- 20mm OF WATER COLUMN) ARE ALSO INSTALLED TO REMOVE CF VAPOUR FROM CF RESERVOIR AND SYSTEM.  THE EXHAUSTER SWITCHES ON AUTOMATICALLY WHEN CF PUMP STARTS AND SWITCHES OFF AUTOMATICALLY WITH 15mins TIME DELAY AFTER THE STOPPING OF CF PUMP AND CF SYSTEM PRESSURE DROPS BELOW 2.0KSC.

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

33 CONTROL FLUID SYSTEM

34  Isolation valves on pump suction & discharge side  Pump discharge pressure 50 Ksc  Capacity41TPH  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 capacity6.9 m 3  Duplex filter  Control fluid transfer pump to empty the CF tank  CF Temperature control by control station in the ECW line

35 1. ELECTRO-HYDRAULIC CONVERTER – SUMMER – 8 NOS. 2. SUMMER – 8NOS. 3. ELECTRO-MECHANICAL CONVERTER – 8NOS. 4. GOVERNING BLOCK 1.CONTROLGEAR(AE001) – 1NO. 2.EMERGENCY GOVERNOR OR OVERSPEED GOVERNOR– 1NO. 3.TRIP SOLENOID (AA213,AA214)-2NOS. 4.TEST ELECTROMAGNETS(AA211,AA212) – 2NOS. 5.ROTATIONAL SPEED DETECTOR -3 NOS. 6.LIMITER OF PRESSURE (AA502) – 1NO. 7.SPEED TRANSDUCER – 1NO. 8.LEVER OF OVER SPEED GOVERNOR (AX201)– 1NO. 9.PILOT VALVE FOR SUPPLY (AX202) – 1NO. 5. ACCUMULATOR – 1NO. 6. OIL SUPPLY AND PURIFIER UNIT 7. SERVOMOTOR OF HPSV – 2NOS. 8. SERVOMOTOR OF HPCV – 4NOS. 9. SERVOMOTOR OF IPSV – 2NOS. 10. SERVOMOTOR OF IPCV – 4NOS. 11. SERVOMOTOR OF CRH NRV – 2NOS. 12. LOCKING PILOT VALVE (AA001,AA002,AB001,AB002)- 4NOS. 13. EX.STOP VALVE SERVOMOTOR OR ESV (10LBQ10AA101)– 1NO.

36 1. HEAD PRESSURE LINE (STABILIZED,50KSC,10MAX15) 2. HEAD PRESSURE LINE ( NON-STABILIZED,50KSC,10MAX15) 3. LINE OF PROTECTION (50KSC,10MAX51) 4. LINE TO COCK THE OVERSPEED GOVERNOR SLIDE VALVE (50KSC) 5. CONTROL OIL LINE TO STOP VALVE SERVOMOTORS (50KSC,10MAX16) 6. CONTROL LNE TO SUMMATORS (35KSC,10MAX17)

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38 1. OUT OF TOLERANCE ROTOR OVERSPEED : ALARM AT 3300RPM AND TRIPPING AT 3360RPM 2. 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. LUBRICATING OIL PRESSURE DROP: ALARM AT 0.70KSC AND TRIPPING AT 0.30KSC WITH 3SECS TIME DELAY. 4. 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 5. 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.

39 6. RISE IN STEAM TEMPERATURE AT HPT OUTLET: 7. LIVE STEAM TEMPERATURE BEFORE TURBINE FALLS BELOW 470 O C: 8. LIVE STEAM TEMPERATURE BEFORE TURBINE RISES ABOVE 565 O C: 9. STEAM TEMPERATURE BEFORE IV FALLS BELOW 500 O C: 10. STEAM TEMPERATURE BEFORE IV RISES ABOVE 593 O C: 11. MOT LEVEL LOW-LOW: 12. DRIP LEVEL HIGH-HIGH IN ANY HPH: 13. ANY FAILURE IN TURBNE CONTROL SYSTEM ELECTRONICS: 14. GENETERATOR PROTECTION: 15. FIRE PROTECTION OPERATED: 16. EPB PRESED.

40  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:16.7CENTIPOISE  KINEMATIC VISCOSITY:32CENTISTOKE  SPECIFIC GRAVITY:0.89  SPECIFIC HEAT:0.459Kcal/Kg Deg.C  FLASH POINT:180 O C  FIRE POINT:240 O C  DEGREE OF CLEANLINESS:16/13 ISO 4406  PERMISSIBLE SUSPENDED PARTICLE SIZE:25 MICRON  WATER CONTENT:<10PPM  LUBE OILTANK IS MADE OF STAINLESS STEEL AND HAVING A CAPACITY OF 58m 3. 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.

41  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 300m 3 /hr A DISCHARGE PRESSURE OF 4.3KSC.  EOP WLL START IN CASE OF LOSS OF AC.EACH EOP IS HAVING A DISCHARGE CAPACITY OF 250m 3 /hr AND A DISCHARGE PRESSURE OF 2 KSC.FOR HIGHIER RELIABILITY EOP DELIVERS OIL DIRECTLY TO THE BEARING BYPASSING COOLER AND THROTTLE VALVE.

42 TG LUBE OIL SUPPLY SYSTEM

43 TG LUBE OIL SYSTEM

44  Turbine oil is ISO VG 32  KV20-23 CST at 50 0 C  Acidity Number< 0.05 mg KOH/r  Viscosity index> 90  Bearings  HPT FrontN1  HPT RearN2  IPT Front (TB)N3  IPT RearN4  LPT-1 FrontN5  LPT-1 RearN6  LPT-2 FrontN7  LPT-2 RearN8  Generator FrontN9  Generator RearN10  Exciter FrontN11  Exciter RearN12

45 TG LUBE OIL SYSTEM DC Lube oil pump 1 No. EquipmentCapacity (m 3 /hr)Head (Ksc) AC Lube oil pump DC Lube oil pump 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

46 TG LUBE OIL SYSTEM  Oil is first delivered to bearing brasses through emergency tanks located on bearing cap  Emergency tanks capacity in m 3  N10.43  N20.35  N30.75  N40.44  N50.44  N60.44  N70.44  N80.44  N90.5  N  N110.1  N120.1

47 TG LUBE OIL SYSTEM  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 m 3  Duplex filters fineness25 µm  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 µm  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

48 TG LUBE OIL SYSTEM  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

49 TG JACKING OIL AND BARRING GEAR SYSTEM

50 Barring gear & Jacking oil 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

51 Barring Gear & Jacking oil system  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

52 Barring Gear & Jacking oil system  Bearing Insert Oil Jacking Pump is started automatically, if the rotor neck displacement becomes more than 0.1 mm relative to the insert of any of bearings No. 4,…9 provided that the oil pressure to rotor jacking is higher than 45 kg/cm2 or the turbine rotor rotational speed is higher than 1500 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

53 GENERATOR SEAL OIL SYSTEM

54  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

55 GENERATOR SEAL OIL SYSTEM  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

56 GENERATOR STATOR WATER COOLING SYSTEM

57 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 µs/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 µs/cm, Ion exchanger-2 to be stopped

58 STATOR WATER COOLING SYSTEM  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

59 GENERATOR GAS SUPPLY SYSTEM

60  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 regulators32  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 CO 2 manifolds to connect 17 cylinders each  Each manifold header contains MOV, NRV & Isolation valve  MOV with manual bypass valve at the inlet of CO 2 heater  CO 2 heater is steam heated  Steam source is from auxiliary steam system  Steam parameters: 15 Ksc & C  MOV in the steam inlet line  Steam exhaust will go to FWSV Dish flash tank  Manifold header pressure is Ksc  Control station with Pressure regulator provided D/S of heater to maintain a pressure of 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

61  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 CO 2 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

62  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 2.6m 3. LP DRAIN FLASH TANK IS ALSO HAVING A CAPACITY OF 2.6m 3.

63 CONDENSER  DesignLMZ  Design CW Flow64000 m 3 /hr  Vacuum 77 mm Hg (abs) at 33 0 C 89 mm Hg (abs) at 36 0 C  No. of passes1  Total no. of tubes (OD)x0.71 (t) (OD)x1.00 (t)  Tube materialASTM A-249 TP 304  Rated TTD3.4 0 C  DT of CW10 0 C

64 CONDENSATE EXTRACTION PUMP  Design flow rate Kg/s  Discharge pressure32.15 Ksc  Shut off head395 m  Pump speed 1480 rpm  Power input972.3 KW  No. of stages6  Type of first stage impellerdouble entry  Depth7.43 m

65 DE-AERATOR  Design Pressure13 Ksc  No. of trays896  Spray valves132  Design temp for D/A395 0 C  Design temp for FST250 0 C

66 DRIP PUMP  Design flow rate TPH  Discharge pressure43 ata  Shut off head306.7m  Pump speed1486rpm  Power input310.1KW  No. of stages5  Type of first stage impellercentrifugal, single entry  Depth1090 mm

67 MDBFP  Pump flow TPH  Suction temp C  BP Suction pr.14.05ata  BFP Suction pr.21.01ata  BFP Discharge pr ata  BFP Discharge temp C  BP Discharge pr.22.01ata  Shut off head4830m  BFP Speed6275 rpm  BP Speed1490rpm  Normal R/C flow220TPH  HC Rated O/P Speed6505rpm  Outer casing typebarrel  No. of stages7  BFP warm up flow15TPH

68 TDBFP  Pump flow TPH  Suction temp186.20C  BP Suction pr.14.10ata  BFP Suction pr.28.24ata  BFP Discharge pr ata  BFP Discharge temp C  BP Discharge pr.29.06ata  Shut off head4580m  BFP Speed4678 rpm  BP Speed2098rpm  Normal R/C flow365TPH  HC Rated O/P Speed6505rpm  Outer casing typebarrel  No. of stages7  BFP warm up flow20TPH

69 TDBFP GOVERNING SYSTEM

70  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)

71 TDBFP TURBINE  Number of stages9  CasingSplit  Steam admissionDual  Steam pressure at inlet20.82ata  Steam temperature at inlet469 0 C  Turbine operating speed4678rpm  Steam consumption61.4TPH  Steam pressure at exhaust0.128ata  Turning gear speed15rpm  Type of governing systemElectro-Hydraulic  Over speed type tripCentrifugal + electrical  JOPNot required  Lube oil tank capacity10.97 m 3  Lube oilSame as main turbine

72 TDBFP CONDENSER  CW flow3000 TPH  Vacuum in the condenser0.128Ksc (abs)  Total no. of tubes3312  Tube OD and thickness22.225x1.06mm  No. of water passes2  Tube materialASTM A-249 TP321

73 TDBFP LUBE OIL SYSTEM

74 TDBFP EXTRACTION SYSTEM

75 TDBFP CONDENSATE SYSTEM

76 ACW SYSTEM

77  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

78 TURBINE VACUUM SYSTEM

79 TURBINE HEATING FLANGES SYSTEM

80 AUXILIARY STEAM SYSTEM

81 CONDENSATE SUPPLY SYSTEM TO EXT NRVS

82 EXHAUST HOOD SPRAY

83 FEED WATER SYSTEM

84 TDBFP-A FEED WATER SYSTEM

85 MDBFP FEED WATER SYSTEM

86 LP DOZING & OXY TREATMENT SYSTEM

87 HP BYPASS SYSTEM

88 LP BYPASS SYSTEM

89


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