Professional Documents
Culture Documents
A
REPORT ON
STEAM TURBINE
MAINTENANCE
AT
RAMAGUNDAM SUPER
THERMAL
POWER
STATION
CERTIFICATE
THIS IS TO CERTIFY THAT Mr. M.RAJ KIRAN, M.RAJ KUMAR,
E.BUCHANNA AND Mr. G.SAI SHARATH
BEARING ROLL NO.
11E35A0305, 11E35A0301, 11E35A0303, 10E31A0312 OF MAHAVEER
INSTITUTE OF SCIENCE AND TECHNOLOGY AFFILIATED TO JNTU
HYDERABAD, MECHANICAL [B.TECH, 4TH YEAR]
HAVE DONE A
PROJECT ON MAINTAINENCE OF STEAM TURBINE UNDER MY
GUIDENCE AND SUPERVISION AT RSTPS NTPC RAMAGUNDAM FROM
16-01-2014 TO 15-02-2014 . PERFORMANCE OF THE PROJECT TRAINEE IS
SATISFACTORY.
PROJECT GUIDE:
Mr. S.SATYANARAYAN A
ASST MANAGER (TMD) ,
ACKNOWLEDGEMENT
The successful completion of my project is indeed practically incomplete without
mentioning of all those encouraging people who genuinely supported me throughout the
project.
I would like to express my sincere gratitude to Shri NAMDEV S UPPAR(AGMTM(I/C)) who extended his support and accepted the proposal of carrying out the project
work on STEAM TURBINE MAINTAINANCE.
I am indebted to my project guide Shri S Satyanarayana (ASST MANAGER-TMD)
who spared his valuable time and energy to guide me patience fully and interactively
throughout the training.
I in deep sense of gratitude to record my thanks to Shri T.ASHOK who had forwarded
me to do my project work at NTPC-Ramagundam.
I express my profound gratitude to Sri SHANMUKH DEV (H.O.D-Mechanical
Department) and K.S.S.S.N REDDY(Principal) of MAHAVEER INSTITUTE OF
SCIENCE & TECHNOLOGY, Bandlaguda , Hyd Dist, for their support.
I extend my thanks to Shri E. Nandakishore (AGM-HR EDC), Shri P.M.G.V Srinivas
(DGM HR EDC), Smt. AshwiniRajkumar (ASST MANAGER HR EDC) and Shri C.
Keshavulu (SUB OFFICER HR EDC) also for their valuable advices and guidance to the
project work.
Finally, I thank one and all who have given their assistance directly or indirectly.
Abstract
Power plants are the main source for large-scale production of electrical energy. Raw
materials used in thermal power plant are coal, water, oil and air. Thermal power plant
uses a dual phase cycle to enable the working fluid (water) to be used repeatedly. The
cycle used is Modified Rankine cycle which includes super heated steam, regenerating
feed water and reheated steam.
The main objective behind my project is to study about the thermal plant, how power is
generated, what are its sources, working of boilers, turbines, generators etc.
This work concentrates much about turbines, their maintenance and various equipments
installed to ensure the safe, reliable and efficient performance of the turbine. This deals
with the controls of a turbine to regulate the speed to required and tripping devices and
their working at emergencies.
Contents
Sl no.:
Particulars
Page no.:
Introduction
About RSTPS
16
Steam Turbines
20
25
Turbine lubrication
28
Turbine governors
31
Trip valves
35
Other devices
37
10
41
11
Maintenance of turbines
42
12
44
13
47
14
49
15
50
INTRODUCTION
NTPC-National Thermal Power Corporation, Indias largest power company was set up in the
year 1975 to accelerate power development in India. Today it has emerged as an Integrated
Power Major with a significant presence in the entire value chain of power generation business.
NTPC was ranked 317th in 2009, Forbes Global 2000 ranking of the Worlds biggest companies.
ORGANISATION:
The total installed capacity of the company is 30,644MW (including JVs) with 22 stations,
located across the country as of financial year 2009. The generation growth trend is shown
below.
In addition under JVs, 4 stations are there. By 2017, the power generation portfolio is expected
to have a diversified fuel mix with coal based capacity of around 53000MW, 10000MW through
gas, 9000MW through Hydro generation, about 2000MW from nuclear sources and around
1000MW from Renewable Energy Sources (RES). NTPC has adopted a multi-pronged growth
strategy which includes capacity addition through green field projects, expansion of existing
stations, joint ventures, subsidiaries and takeover of stations.
NTPC has been operating its plant at higher efficiency levels. Although the company has 18.79%
of the total national capacity it contributes 28.60% of total power generation due to its focus on
higher efficiency.
Fuel
NTPC Owned:
Coal
Gas/Liquid fuel
Total
Owned by JVs:
Coal
Gas
Total
No.: of Plants
Capacity(MW)
15
7
22
24,395
3,955
28,350
3
1
26
814
1480
30,644
Region
Northern
Western
Southern
Eastern
JVs
Total
Coal
7,035
6,360
3,600
7,400
814
25,209
Gas
2,312
1,293
350
1,480
5,435
Total(MW)
9,437
7,653
3,950
7,400
2,294
30,644
The TG Hall:
The TG Hall or the Turbo-Generator hall or the Turbine-Generator Hall is the hall or space where
the turbine-generator sets are present.
NTPC Ltd., Ramagundam has two TG Halls one for STAGE - I and the other common for
STAGE-II and STAGE-III. These TG halls are equipped with heavy overhead cranes that assist
in transportation of material to, from and within the TG hall. These cranes find their use greatly
during overhauls.
STAGE 1 (3 * 200MW):
This stage consists of three units (Unit-1, Unit-2, Unit-3) each with a generation capacity of
200MW. The turbines for these three units were manufactured by The Ansaldo Energia Ltd. The
construction began in the late 1970s and these units have performed well over a long period
setting many records regarding maintenance and generation over the other two stages.
STAGE 2 (3 * 500MW):
This stage again consists of three units (Unit-4, Unit-5, Unit-6) each with a generation capacity
of 500MW. The turbines for these three units were manufactured by Bharat Heavy Electricals
Limited (BHEL). These Units have shown a relatively lower performance. Especially Unit-6 has
imposed many problems on the maintenance departments.
STAGE 3 (1 * 500MW):
This stage comprises only one unit (Unit - 7). This is a first of its kind in South India being a
computer operated unit. A wide disparity may be seen between the control rooms of the other
two stages and this computerized unit. To this day, many Power plant engineers train in this unit
to upgrade themselves to this new mode of operation. This unit also has the tallest chimney in
Asia.
OVERHAULS:
Once in two years, these units are stopped and overhauled, one unit at a time. The overhauls are
usually taken up during the months June to September as the monsoons activate hydel power
generation which substitute the power generation lost due to the overhaul of the unit. The same
practice is followed all through the country. The overhauls usually take 15 to 20 days per unit
provided there is no major repair involved. Major repairs include turbine casing, turbine rotor
damage and other damages that require transporting the equipment to another location (usually
the manufacturer). The overhauls are the dissipaters of the annual PLF of any power plant.
Generation Distribution:
States:
As NTPC Ltd. is a Public Sector Undertaking (PSU), the generation is almost uniformly
distributed to 4-5 states all of them sharing about 20-25 percent of the Generation. The States
include:
Andhra Pradesh
Tamil Nadu
Kerala
Karnataka
Maharashtra
The Switchyard:
The switchyard is the place where the station last takes care of the power it produces. The
switchyard links the power generated to the southern Power grid. The major transmission points
are:
Nagarjunasagar
Chandrapur
Hyderabad
Khammam
Inputs:
Water:
The power station gets it water periodically released from the SRSP- Sriram Sagar project. This
water is stored in the balance reservoir. The water level in the balance reservoir is monitored dayto-day, at POCHAMPADU DAM.
Coal:
NTPC Ramagundam is a Thermal Power Station and hence uses coal. This coal is available at a
large scale from the Singareni Coal mining company nearby and is transported using the
MGR(Merry-go-round) system wherein, a train comes on one railroute, delivers coal and returns
on another route. The wagons arriving by this route are taken for coal collection wherein a
mechanism provided underneath the wagons opens on application of air pressure and drops the
coal it is carrying. A separate department (MGR Dept.) handles this process.
Coal also arrives by the Indian Railways. The wagons are routed via Ramagundam railway
station to the separate plant line and these coaches arrive at the wagon tippler. The wagons
arriving in this manner must be tilted at the wagon tippler to obtain the coal as they do not have
the drop mechanism underneath.
These are periodically purchased as per requirement from the Indian oil corporation IOCL
establishment nearby.
Departments:
The plant classifies its departments as O&M and Non-O&M.
Operation:
The operation department has the maximum number of employees. It takes care of operation of
the various equipments and controls in the plant. The operation department takes care of the unit
control rooms(UCBs).A power plant operates 24 X 7 so, the operation department works in shifts
to take care of the units at all times.
Electrical Maintenance:
This is the largest department under the Maintenance section. This department takes care of all
the electrical aspects of the plant. It takes care of the following sections.
Switchyard
Generator
Generator Transformer
Civil Maintenance:
Civil Maintenance takes care of all the civil activities in the plant such as non-mechanical
constructions, maintenance of locations, scrap removal and ensuring a proper working condition
of minor equipments.
This dept. takes care of the coal transport to the plant. The coal dig out at singareni mines is
transported to plant with separate wagons.
Coal collection
Coal crushing
consequent milling
Mechanical Maintenance:
This dept. has the following sections
Boiler Maintenance:
Boiler feeders
Primary and secondary air pumps
Boiler feed pumps
Boiler core parts
Turbine Maintenance:
Turbine core parts
Turbine governing system
HR
Finance
IT...etc...
Staff:
The plant is headed by the General Manager (GM) to whom the AGM's report. The O&M group
being reported by the Additional General Manager (O&M) again to whom the AGMs of
concerned departments report.
The AGM's are again reported to by the Heads of various departments (DGM cadre) and so on
following the order below
GM
AGM
DGM
Senior Superintendent
Manager
Deputy Manager
Senior Engineer
Engineer
ET (Executive trainee)
Assistant Engineer
Township:
NTPC, Ramagundam has a very beautiful and a serene township. The TTS is the temporary
township constructed during the early stages of the plant .It is now resided by the secondary
employees of the organization (Contractors, Allied organization employees, service organizations
to the township like Dooradarshan...etc...)
The PTS is the permanent township where most of the employees reside with their families. It is
known for its serenity, cleanliness, Greenery and its parks.
Schools:
The township has three schools. Kendriya Vidyalaya NTPC Ramagundam, Saint Claire High
school and the Sachdeva school of excellence (formerly Chinmaya Vidyalaya).
Shopping:
The township has a main shopping centre and four small shopping centers where the residents
may shop for groceries and other regular needs.
Facilities:
The township is well facilitated with banking( The State Bank of Hyderabad with an on-site
ATM), postal services,telephone and internet services(BSNL),Adequate water supply, 24*7
electricity right from the plant, Civil services and its own security.
Parks:
The township has beautiful parks namely the Ambedkar Park, the Chacha Nehru Park, the
Priyadarshini Park and other small parks and in it theaters are also there.
Installed capacity:
2600MW
Coal consumption:
13Million tons/year
10,000Acres
Total investment:
Rs.10,000Crores
Reservoir capacity:
Daily production:
62.4Mu
Efficiency of the cycle can be increased by using reheat and regeneration techniques. Reheating
means using multiple turbines for expansion of steam and Regeneration constitutes drawing
steam at different stages and using feed water pumps.
Efficiency () = net work done/heat input.
Bleed steam extraction: for regenerative system, numbers of non-regulated extractions are
taken from HP, IP turbine.
Regenerative heating of the boiler feed water is widely used in modern power plants, the effect
being to increase the average temperature at which heat is added to the cycle, Thus improving the
cycle efficiency.
COAL TO STEAM:
Coal from the coal wagons is unloaded in the coal handling plant using wagon tippler. After
unloading, coal is transferred to crusher house using conveyor belts, where it is crushed down to
small size. The speed of conveyor belts is around 450-500 feet per minute. The conveyor belts
are driven with the help of roller bearing. This coal is transported up to the raw bunkers with the
help of belt conveyors. Coal is transported to bowl mills by coal feeders. The coal is pulverized
in the bowl mill, where it is ground to a powder form. This crushed coal is taken away to the
furnace through coal pipes with the help of hot and cold air mixture from primary air (PA) fan.
PA fan takes atmospheric air, a part of which is sent to air pre-heaters for heating while a part
goes directly to the mill for temperature control. Atmospheric air from FD fan is heated in the air
heaters and sent to the furnace for combustion.
Water from the boiler feed pump passes through economizer and reaches the boiler drum. Water
from the drum passes through down corners and goes to bottom ring header. From bottom ring
header is divided to all four sides of furnace. Due to heat and the density difference the water
rises up in the water wall tubes. It is partly converted to steam as it rises up in the furnace. This
steam and water mixture is again taken to the boiler drum where the steam is separated from
water. It follows the same path while the steam is sent to super heaters for superheating. The
super heaters are located inside the furnace and the steam is superheated to 540C and finally it
goes to turbine. Flue gases from the furnace are extracted by induced draft fan which maintains
balance various super heaters in the pent house and finally pass through air pre heaters and goes
to Electro static precipitator(ESP), where the ash particles are extracted. ESP consists of metal
plates which are electrically charged. Ash particles are attracted on to these plates, so that they do
not pass through the chimney to pollute the atmosphere. Regular mechanical hammer blows
cause the accumulated ash to fall to the bottom of the precipitator where they are collected in a
hopper for disposal. This ash is mixed with water to form slurry and is pumped to ash pond.
cylinder CRH goes back to the boiler for reheating and returns by a further pipe HRH to the IP
cylinder. Here it passes through another series of stationary and moving blades. Finally, the
steam is taken to the LP cylinders, each of which it enters at the center flowing outwards in
opposite direction through the rows of turbine blades, an arrangement known as double flow to
the extremes of cylinder. As the steam gets up its heat energy to drive the turbine, its
temperature & pressure fall and it expands. Because of this expansion the blades are much larger
and longer towards the LP end of the turbine.
The turbine shaft usually rotates at 3000rpm. This speed is determined by the frequency of the
electrical system used and is the speed at which a 2-pole generator must be driven to generate
Alternating Current at a frequency of 50Hz in India. The speed is 3600rpm at a frequency of
60Hz for American systems.
When much possible has been extracted from the steam it is exhausted directly to the condenser.
This runs the length of the LP part of the turbine or may be beneath or on either side of it. The
condenser consists of a large vessel enclosing 20,000 tubes, each about 25mm in diameter. Cold
water from cooling tower is circulated through these tubes and as the steam from the turbine
passes round them it is rapidly condensed into water (condensate). Because water has much
smaller comparative volume than steam, a vacuum is created in the condenser. This allows the
steam to reduce down to pressure below that of the normal atmosphere and more energy can be
utilized.
From the condenser, the condensate is pumped through Condensate Polishing Unit (CPU), Gland
Steam Condenser (GSC), Low Pressure Heaters (LPH) and drain cooler by the Condensate
Extraction Pump (CEP) after which it is passed through Deaerator for removing the dissolved
gases. Then its pressure is raised to the boiler pressure by the Boiler Feed Pump (BFP). It is
passed through further feed water heaters, High Pressure Heaters (HPH) to the Economizer and
then the boiler for reconversion into the steam.
STEAM TURBINES
Steam turbines are the devices which convert Heat energy of the steam into Mechanical energy.
HISTORY:
The first device that may be classified as a reaction steam turbine was little more than a toy, the
classic Aeolipile, described in the1st century by Hero of Alexandria Roman Egypt. More than a
thousand years later, in 1543 Spanish naval officer Blasco De Garay used a primitive steam
machine to move a ship in the port of Barcelona. In1551, Taqi al-Din in ottoman Egypt described
a steam turbine with the practical application of rotating a spit. Steam turbines were also
described by Italian Giovanni Branca in 1629 and John Wilkins from England in 1648. The
devices described by al-Din and Wilkins are today known as steam jacks.
The modern steam turbine was invented in 1884 by the Englishman Sir Charles Parsons, whose
first model was connected to a dynamo that generated 7.5KW (10Hp) of electricity. The
invention of Parsons steam turbine made cheap and plentiful electricity possible and
revolutionized marine transport and naval warfare. His patent was licensed and the turbine
scaled-up shortly after by an American, George Westinghouse. The parsons turbine also turned
out to be easy to scale up. Parsons had the satisfaction of seeing his invention adopted for all
major world power stations and the size of generators had increased from his first 7.5KW to
50,000KW capacity.
CLASSIFICATION:
Turbines are broadly classified into two main types. They are
Impulse turbines and
Reaction turbines.
Impulse turbine:
An impulse turbine has fixed nozzles that orient the steam flow into high speed jets. These jets
contain significant kinetic energy, which the rotor blades shaped like buckets convert into shaft
rotation as the steam jet changes the direction. A pressure drop occurs across only at the
stationary blades, with a net increase in steam velocity across the stage.
As the steam flows through the nozzle, its pressure falls from inlet pressure to exit pressure
(atmospheric pressure, or more often the condenser vacuum). Due to this high ratio of expansion
of steam in nozzle, it leaves with a very high velocity. Steam leaves the moving blades with
larger portion of maximum velocity. The loss energy due to this higher exit velocity is commonly
called the carry over velocity or leaving loss.
Reaction turbine:
In the reaction turbine, the rotor blades are arranged to form convergent nozzles. This type of
turbine makes use of reaction force produced as steam accelerates through the nozzle formed by
the rotor. Steam is directed into the rotor by the fived vanes of the stator. It leaves stator as a jet
that fills the entire circumference of the rotor. The steam then changes the direction and increase
the speed relative to the speed of the blades. A pressure drop occurs across both the stator and the
rotor, with a steam accelerating through the stator and decelerating through the rotor, with no jet
change in the steam velocity across stage. But with a decrease in both temperature and pressure,
reflecting the work performed in the driving of the rotor.
Hp turbine:
HP turbine is of double cylinder construction. Outer casing is barrel type without any axial/radial
flanges. This kind of design prevents any mass accumulation and thermal stresses. Also perfect
rotational symmetry permits moderate wall thickness of nearly equal strength at all sections. The
inner casing is axially split and kinematic ally supported by outer casing. It carries the guide
blades. The space between casings is filled with the main steam. Because of low differential
pressure, flanges and connecting bolts are smaller in size. Barrel design facilitates flexibility of
operation in the form of short start-up times and higher rate load changes even at high steam
temperature conditions. For a typical 500MW, at HPT the temperature of steam would be around
540C and pressure 170kg/sq.cm
Ip turbine:
IP turbine is of double flow construction. Attached to axially split out casing is an inner casing
axially split, kinematic ally supported and carrying the guide blades. The hot reheat steam enters
the inner casing through top and bottom center. Arrangement of inner casing confines high inlet
steam condition to admission breach of the casing. The joint of outer casing is subjected to lower
pressure and temperature at the exhaust. For a typical 500MW, at IPT the temperature of steam
would be around 540C and pressure 170kg/sq.cm
LP turbine:
Double flow LP turbine is of three-shell design. All shells are axially split and are of rigid
welded construction. The inner shell taking the first rows of guide blades is attached kinematic
ally in the middle shell. Independent of outer shell, middle shell is supported at four points on
longitudinal beams. Two rings carrying the last guide blade rows are also attached to the middle
shell. For a typical 500MW, at LPT the temperature of steam would be around 136C and
pressure -0.86kg/sq.cm
Condensing turbines are most commonly found in electrical power plant. These turbines
exhaust steam in a partially condensed state, typically of a quality near 90%, at a pressure well
below atmospheric to a condenser.
Non-Condensing are back pressure turbines are most widely used for process steam
applications. The exhaust pressure is controlled by regulating valve to suit the needs of the
process steam pressure. These are commonly found at refineries, distinct heating units, pulp and
paper plants and de-salination facilities where large amount of low pressure process steams are
available.
Reheat turbines are also used almost exclusively in electrical power plants. In a re-heat
turbine, steam flow exits from high pressure section of the turbine and is returned to the boiler
where additional super heat is added. The steam then goes back into an intermediate pressure
section of the turbine and continues its expansion.
Extracting type turbines are common in all applications. In an extracting turbine, steam is
released from various stages of the turbine, and used for industrial process needs or sent to boiler
feed water heaters to improve cycle efficiency. Extraction flows may be controlled with a valve
or left uncontrolled.
Induction turbines introduce low pressure steam at an intermediate stage to produce
additional power.
HP & IP Cylinder:
alloy steel. Outer shell is supported to the front pedestal (standard) at one end and exhaust
hood at the other end. Outer shell is common for HP and IP cylinders. The HP inner shell
is supported in the outer shell on four pads. The inner shell is keyed to outer shell on
upper and lower vertical center lines to locate it transversely. The horizontal joint
between cylinders is secured with the help of studs and nuts of alloy steel.
The HP turbine comprises of 14 stages including first stage, which is a Curtis wheel
stage. Each turbine stage consists of a diaphragm and set of moving blades connected to
a disc on the rotor.
LP Cylinder:
is keyed to outer hood by four supporting pads for axial and transverse location. It is free
to expand for thermal differences.
The cross over pipe which carries steam from IP turbine to LP turbine is provided with an
expansion joint which absorbs the thermal expansion of the pipe without putting undue
stresses on turbine components. Exhaust hood spray will be done from condensate to
control the exhaust steam temperature through nozzles. Two expansion diaphragms are
provided on the top of LP turbine exhaust hood to rupture in case of condenser
pressurization.
rotor. Both are coupled rigidly. These rotors are supported on three journal bearings.
Bearing-I is of combined radial and thrust type. Others are journal bearings. Rotor bodies
are made of solid alloy steel forgings, which are machined. Rotor consists of shafts,
wheels, bearings, journals and coupling flanges.
Dove and tail grooves are machined on wheels to fix the moving blades.
Control Valves:
to the turbine. Three control valves mounted on the top of HP cylinder and three mounted
at the bottom. These control valves are of puppet type with venturi seat. The valve discs
have spherical seat to ensure tight seating. These valves are operated by double action
hydraulic oil servomotor. Sequential opening of control valves is effected by means of
cams and levers.
Combined Reheat
combined reheat valves through which steam enters into IP turbine. It consists of an
intercept valve and reheat stop valve. Intercept valve of control type and stop valve is of
full open/full close type. A strainer is provided in valve to prevent foreign material entry
in to the IP turbine. These valve also operated by oil pressure.
bearings. Bearings No.1 is a combined radial and thrust type housed in Front Pedestal and
other bearings are journal type. HP IP rotor is coupled to LP rotor by rigid coupling and
LP is coupled to Generator also by rigid coupling with gear wheel for turning gear
arrangement.
The thrust bearing absorbs axial thrust of turbine and generator; rotor consists of a
rotating thrust collar on the turbine shaft and two stationary Babbitt plates supported in
housing.
an automatic barring gear capable of continuously rotating the turbine shaft at 5.4rpm to
affect uniform cooling and warming up during shutdown and start up respectively. It is
meshed with AC motor and rotates Turbine rotor through gear train. It is provided in
between BP turbine and generator.
Thrust bearing.
Front/rear housing of HPT can slide on base plates. Any lateral movements perpendicular to
machine axis are prevented by fitted keys. Bearing housings are connected to HP-IP casings by
guides, which ensure central position of casings while axially expanding and moving.
The LPT casing is located in center area of longitudinal beam by fitted keys cast in the
foundation cross beams. Axial movements are not restricted. The outer casing of LP turbine
expands from its fixed points towards generator. Bellows expansion couplings take the
differences in expansion between the outer casing and fixed bearing housing. Hence HPT rotor &
casing expands towards bearing-I while IPT rotor expands towards generator. The LPT rotor
expands towards generator. The magnitude of this expansion is reduced by the amount by which
the thrust bearing is moved in the opposite direction due to IPT casing expansion.
The oil systems and related sub-loop controls (SLCs) can be started or stopped automatically be
means of SGC oil sub-group of automatic control system. The various logics and SLCs under
SGC oil age given in the ATRS section.
Injector 1 and 2 takes oil from Main Oil Tank and provide suction of MOP. The MOP Discharges
Oil at 9.5kg/cm2 through Oil Coolers, temperature control valves and form the lubricating oil
header and uniformly flow through all turbine bearing with the help of throttle valve. Here for
the thrust bearing oil is only filtered with help of duplex of filter.
The oil temperature is maintained by temperature control valve, which is located after outlet of
oil cooler in MOT Room. The temperature of oil always maintained at 45 degrees.
of all shaft seals is sent to the gland steam cooler for regenerative feed heating. Refer the below
Figure.
in the pilot valve, allows oil to drain from the bottom (J) of the power piston. Due to this
operation, the steam valve will move towards the closed position, thus admitting less steam to
the machine. During installation and also afterwards, the governor springs are adjusted
periodically, so as to keep the range at which the governor operates between limits.
Loading on the machine is done/carried out by operating the hand wheel (K) thus opening the
steam valve. The hand wheel (K) is normally on remote operation from the control panel by
means of a reversible motor known as the speeder motor. Such governors do not use the
elector-hydraulic governors, which control the operation by electrical interfacing units i.e. the
electro-hydraulic converter. For detailed working of Governor, the drawing as shown below
should be referred.
The percentage of control valve opening on each turbine depends upon the electrical output from
that individual T.G, and in turn the entire system at the same speed (frequency). The system
frequency decreases, as more electrical load is required. To regain the previous frequency/speed,
the amount of fuel fed to the steam generator is increased adequately. Since with more customer
load on the system, the frequency tends to decrease then the governors on all the system turbine
need to operate (to open) the control valves to admit more steam to Turbine and allow the system
to supply the extra load.
The bolt or the ring flies out of the normal position. In doing so, it operates a trip and releases the
relay oil pressure, which is holding the emergency, valve open. The emergency valve then shuts
off the steam supply.
The emergency governor is tested at periods by deliberately over-speeding the machine when the
load has been taken off. Each of the twin bolts or rings is operated in turn. The one not being
tested is made inoperative by a selector lever.
TURBINE EFFICIENCY:
To maximize turbine efficiency the steam is expanded, generating work, in a no of stages. These
stages are characterized by how the energy is extracted from them and are known as either
impulse or reaction turbine. The most steam turbines use a mixture of reaction and impulses
designs: each stage behaves as either one other, but the overall turbine use both. Typically, higher
pressure sections are impulse type and lower pressure stages are reaction type.
auxiliary trip oil flows in a closed loop formed by main trip valves and turbine hydraulic
protective devices.
The construction of main trip valves is such that when auxiliary trip oil pressure is adequate, it
holds the valve spools in open condition against the spring force. Whenever control oil pressure
drops or any of the hydraulic protective devices are actuated, the main trip valves are tripped.
Under tripped condition, trip oil pressure is drained rapidly through the main valves, closing
turbine stop and control valves.
Test valve:
Each of the HP and IP stop valves servomotors receives trip oil through their associated test
valves. The test valves have got port openings for trip oil as well as start-up oil. The test valves
facilitate supply of trip oil pressure beneath the servomotor disc. For the purpose of resetting stop
valves after a tripping, start up oil pressure is supplied to the associated test valves, which moves
their spool downwards against the spring force. In their bottom most position the trip oil pressure
starts building up the above the stop valve servomotor piston while the trip oil beneath the disc
gets connected to drain. When start-up oil pressure is reduced the test valve moves up draining
trip oil above the servomotor piston and building the trip oil pressure below the disc, thus
opening the stop valve. A hand wheel is also provided for manual operation of test valves.
`
Starting and load limit device:
The starting and load limit device is used for resetting the turbine after tripping, for opening the
stop valves and releasing the control valves for opening. The starting device consists of a pilot
valve that can be operated either manually by means of hand wheel or by means of a motor from
remote. It has got port connections with the control oil; start up oil and auxiliary start up circuits.
The starting device can mechanically act upon the hydraulic governor bellows by means of a
lever and link arrangement.
Before start-up, the pilot valve is brought to its bottom limit position by reducing the starting
device to 0% position. This causes the hydraulic governor bellows to be compressed, thus
blocking the build-up of secondary oil pressure. This is known as control valve close position.
With the pilot valve in the bottom limit position (starting 0%) control oil flows into the auxiliary
start-up circuit (to reset trip gear and protective devices) and into the start up oil circuit (to reset
turbine stop valves).
A build-up of oil pressure in these circuits can be observed, while bringing the starting device to
zero position. When the pilot valve i.e., the starting device position is raised, the start-up oil and
auxiliary start-up oil circuits are drained. This opens the stop valves: ESVs open at 42% and IVs
open at 56% positions of the starting device. Further raising of the starting device release
hydraulic governor bellows which is in equilibrium with hydraulic governors spring tension and
primary oil pressure (turbine speed) and raises the auxiliary secondary oil pressure; closing the
auxiliary follow-up drains of hydraulic governor.
VACUUM BREAKER:
The function of a Vacuum breaker is to cause an increase in condenser pressure by conducting
atmospheric air into the condenser together with the steam flowing from the LP bypass. When
the pressure in the condenser increases, the ventilation of the turbine balding is increased. This
causes the turbo set to slow down so that the running down time of the turbo set and the time
needed for passing through critical speeds are shortened.
BEARINGs:
The HP rotor is supported by two bearings, a Journal bearing at the front end of the turbine of the
combined journal and Thrust bearing adjacent to the coupling with the IP and LP rotor have a
journal bearing at the end of the shaft. The combined journal and bearing incorporates a journal
bearing and the thrust bearing which takes up a residual thrust from both the directions. The
bearing temperatures are measured in two opposite thrust pads.
The front and rear bearing pedestals of the HP turbine are placed on base plates. The pedestals of
the LP part are fixed in position. The front pedestal and the pedestal between the HP and the IP
parts are able to move in axial direction.
The brackets at the sides of the HP and IP parts are supported by pedestals at the level of the
machine axis. In the axial direction the HP and IP parts are firmly connected with the pedestal by
means of casing guides without restricting radial expansion. Since the casing guides do not yield
in response to axial displacement, the HP and LP casings as well as the associated bearing
pedestals move forward from the front LP bearing pedestal on thermal expansion.
The two rows of tripping cams, which are arranged on opposite sides of turbine shaft, have a
specific clearance, equivalent to the permissible shaft relative to pawl of the thrust-bearing trip.
If the axial displacement the shaft exceeds the permissible limit, the cams engage pawl, which
releases a piston to de pressurize the auxiliary trip oil and at the same time to actuate limit
switch.
Maintenance of Turbines
Maintenance of turbines includes the inspection of the working of turbines and ensuring that they
are working with the maximum efficiency.
This is done at two different times:
Over hauling and
Intermediate maintenance.
OVERHAULING:
Overhauling means regular inspection of the different components which includes turbines,
bearings valves etc., and their working.
Overhauling is done for every 20,000 to 25,000 working hours (2-3years).
INTERMEDIATE MAINTENANCE:
This is done if there is a problem at present working condition i.e., more heat generation, less
turbine output etc.
For bearings:
1. DTP (Dye-Penetration Test)
As accumulation of mass over the turbine blades causes loss of energy and decreases the
efficiency of the turbine and requires more energy for same work output.
To avoid this abrasive jet cleaning is used to remove the accumulated mass.
ABRASIVE JET CLEANING: the removal of dirt from a solid by a gas or liquid jet carrying
abrasives to ablate the surface.
In this process high speed abrasive jet is sprayed over the blades which removes the
accumulated mass over the turbine and improves the efficiency of the turbine. Abrasives used are
generally Aluminum Oxide (Al2O3) and Silicon Carbide (SiC).
Turbine oil system consists of two nos injectors, main oil pump, oil coolers, duplex filter for
thrust bearing, two nos of AOPS, one EOP, three nos of JOPS and temperature control valve.
The main oil pump directly coupled with turbine shaft in bearing pedestal at bearing I. After
2850rpm of turbine speed the pump starts discharging oil pressure and running AOP
automatically gets tripped at 540rpm of turbine speed running JOP will get tripped.
Injector 1 and 2 oil from main oil tank and provide suction of MOP. The MOP discharges oil at
9.5Kg/cm^2 through oil coolers, temperature control valves and from the lubricating oil header
and uniformly flow through the entire turbine bearing with the help of throttle valve. Here for the
thrust bearing oil is only filtered with the help of duplex of filter. The all bearings return oil is
cooled to main oil tank.
The oil temperature is maintained by temperature control valve which is located after outlet of
oil cooler in MOT room. The temperature of oil is always maintained at 45C.
The testing system or automatic turbine testing is sub-divided into two functional sub-groups.
ATT
STOP/CONTROL VALVES
PROTECTIVE DEVICES
Over speed trip device: Trip consists of two eccentric bolts on the shaft with
centre of gravity displaced from the shaft axis. They are held in position against centrifugal force
by springs whose tensions can be adjusted corresponding to 110%-111% over speed. When over
speed occurs, the fly weights (bolts) fly out due to centrifugal force and strike against the pawl
and valves, draining auxiliary trip oil pressure and tripping turbine.
Hydraulic over speed trip device: two hydraulically operated over speed
trips are provided to protect the turbine against over speeding in the event of load coincident with
failure of speed governor.
When the preset over speed is reached, the eccentric fly bolt activates the piston and limit switch
via a pawl. This connects the auxiliary trip oil to drain, thereby depressurizing it. The loss of
auxiliary trip medium pressure causes the main trip valve to drop, which in turn causes the trip
oil pressure to collapse.
TASK OF TSE:
If the turbine is to be operated so that there is no undesirable material fatigue, these thermal
stresses must be kept within acceptable limits. The optimum balance between longevity on one
hand and material flexibility of operation on the other is achieved when the permissible range of
material stress can be utilized to the fullest extent.
The turbine stress evaluator provides the basis of continuously calculating permissible values for
desired changes in operating conditions at all times and under all operating states and by
displacing temperature margins, within which the speed/load can be changed during
loading/unloading of the machine. Signals from the TSE are also fed to the speed and reference
limiter of the turbine controller for use in set point and gradient (speed and load) control.
The mean internal (mid metal) shaft temperature can be calculated with an adequate degree of
accuracy by means of the following mathematical equation.
TM = Ts [1-(0.692e-t/T1+0.131e-t/T2+0.177e-t/TK)]
Where, TS: Surface Temperature T1: 2408.31
Tm: Mid metal Temperature T2: 457.O8
t: Time in minutes
TK: 56.62
Various constants used in the above equation are derived from the shaft diameter and thermal
diffusivity of the rotor material. The solution of this equation is realized by means of three
integrators and one summing amplifier.
Normally 5 measuring points feed the TSE. First two measuring points are located in the body of
combined Stop/Control valves are called ADMISSION sensors. The next two are located in the
HPT cylinder adjacent to the first drum stage and are called HPT wall temperature sensors. The
last measuring point is in the flange of IPT cylinder inner casing, before the last drum stage to
represent the surface temperature of the shaft.
Conclusion:
In the steam turbine, the kinetic energy of the steam is directly utilized to rotate the rotor.
Steam turbines can be directly coupled to high speed machines and generate power
ranging from a few MW to 1000MW.
Exhaust steam is free from oil; hence condensate can be reused as feed water.
Governing of steam turbines is easy.
Bibliography:
A. Turbine. Encyclopedia Britannica online.
B. A new loo at Herons STEAM ENGINE (1992-06-25). Archive for History of Exact
Sciences 44(2):107-124.
C. http://www.birrcastle.com/steamturbine.asp
D. Parsons Sir Charles A. THE STEAM TURBINES.
http:/www.history.rochester.edu/steam/parsons/part1.html.
E. www.wikipedia.org.