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STEAM TURBINE
0PERATION & MAINTENANCE
INSTRUCTIONS
NO.STENO.STE-TFTF-263-MS
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BHARAT HEAVY ELECTRICALS LIMITED
RANIPUR, HARIDWAR 249403 (INDIA)
Steam Turbine
General
Preface
Issued by
BHEL Haridwar
VS
SRP
Checked
by
PCK
SB
Approved
by
Issue
Date
19.08.2009
5.0-0001-63
Steam Turbine
Description
Subject
Document No
GENERAL
Preface
Contents
DESCRIPTION
5.0-0001-63/1
5.0-0002-63/4
Brief Description
Sectional arrangement
General description
Fixed points
Technical Data
5.1-0001-04/1
5.1-0002-04/2
5.1-0003-02/2
5.1-0100-63/3
Casing
Blading
Shaft seals
Rear bearing pedestal
5.1-0310-01/3
5.1-0320-02/1
5.1-0330-01/2
5.1-0340-02/1
BHEL Haridwar
Subject
Document No
5.1-0345-01/2
5.1-0350-01/2
5.1-0510-01/1
5.1-0520-01/1
5.1-0530-63/2
General description
5.1-0600-01/2
Start-up procedure
5.1-0610-01/2
Speed control
5.1-0620-01/2
Electrical speed measuring
5.1-0621-02/1
Protective devices
5.1-0630-01/2
Over speed trip test
5.1-0631-01/1
Testing of stop valves
5.1-0632-02/1
Electro hydraulic LP bypass 5.1-0640-00/1
control system (general)
Electro hydraulic LP bypass 5.1-0641-00/2
Control (electrical system)
Electro hydraulic LP bypass 5.1-0642-00/2
Control (hydraulic system)
Extraction check valve
5.1-0650-01/1
Swing check valve (CRH)
5.1-0651-01/1
Testing of check valves in
5.1-0652-02/1
cold reheat line
Automatic turbine tester
5.1-0660-00/1
general
Automatic turbine tester
5.1-0661-00/7
for protective devices
Automatic turbine tester
5.1-0662-01/4
stop and control valves
HP actuator
5.1-0665-00/1
Electro hydraulic seal steam 5.1-0670-01/4
pressure control
Governing scheme
5.1-0680-05/1
Control system diagram
5.1-0681-01/5
5.1-0681-05/5
legend
Contents
5.1-0101-63/2
5.1-0102-63/1
5.1-0103-63/2
5.1-0104-63/4
5.1-0110-01/1
5.1-0111-01/2
5.1-0112-01/2
5.1-0113-01/1
5.1-0120-01/1
5.1-0130-04/2
5.1-0140-04/2
5.1-0205-00/1
5.1-0210-01/3
5.1-0220-02/1
5.1-0230-01/2
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5.1-0410-00/4
5.1-0420-00/1
5.1-0430-01/1
5.1-0440-01/2
5.1-0450-01/1
5.1-0460-02/1
5.1-0470-00/2
5.0-0002-63/1
Subject
Document No
Lubrication chart
Control System Parts
5.1-0690-05/3
5.1-0710-00/2
5.0-0002-63/2
5.1-0720-00/1
5.1-0730-02/3
5.1-0740-02/3
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5.1-0860-01/1
5.1-0870-01/1
5.1-0910-00/2
5.1-0911-00/1
5.1-0912-00/1
5.1-0920-00/1
Subject
Document No
5.1-0921-00/2
5.1-0922-00/2
5.1-0935-00/1
5.1-0940-00/1
5.1-0950-00/1
5.1-0960-02/2
5.1-0970-00/2
5.1-0980-00/1
5.1-1000-63/4
5.1-1001-63/2
5.1-1002-63/2
5.1-1003-63/1
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5.1-1220-63/3
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5.1-1240-63/5
5.2-0001-01/1
5.2-0002-00/1
5.2-0020-00/1
5.2-0021-01/1
5.2-0022-01/1
Subject
Document No
5.2-0023-01/1
5.2-0024-01/1
5.2-0025-01/1
5.2-0026-01/1
5.2-0027-01/1
5.2-0028-01/1
5.2-0110-01/1
5.2-0111-00/1
5.2-0112-00/2
5.2-0113-00/1
5.2-0120-00/1
5.2-0130-02/5
5.2-0135-02/4
5.2-0140-02/4
5.2-0150-00/3
5.2-0160-02/6
5.2-0170-01/4
5.2-0180-00/4
5.2-0200-00/1
5.2-0210-00/5
5.2-0220-00/9
5.2-0230-00/4
5.2-0300-00/1
5.2-0310-01/1
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5.2-0400-00/1
5.2-0410-00/8
5.2-0420-00/5
5.2-0421-01/1
5.2-0423-02/2
5.0-0002-63/4
Subject
Document No
5.2-0430-01/5
5.2-0440-01/2
5.2-0450-01/7
5.2-0455-00/9
5.2-0460-00/6
5.2-0470-00/3
5.2-0480-01/1
5.3-0001-01/1
5.3-0010-04/3
5.3-0021-02/1
5.3-0022-01/3
5.3-0023-01/2
5.3-0030-02/7
5.3-0035-02/5
5.3-0037-03/3
5.3-0040-01/6
5.3-0050-02/3
5.3-0060-01/5
5.3-0061-02/6
5.3-0062-01/1
5.3-0063-00/2
5.3-0064-01/4
5.3-0070-02/3
5.3-0080-03/11
5.3-0081-00/1
5.3-0082-02/9
5.3-0083-01/2
5.3-0100-00/2
5.3-0200-05/8
5.3-0210-00/1
5.3-0220-00/3
5.3-0250-00/1
5.3-0251-00/1
5.3-0252-00/1
5.3-0300-00/1
Steam Turbine
Description
BHEL Haridwar
5.1-0001-04
Steam Turbine
General
Preface
Issued by
BHEL Haridwar
VS
SRP
Checked
by
PCK
SB
Approved
by
Issue
Date
19.08.2009
5.0-0001-63
Steam turbine
Description
General Description
LP Turbine
IP Turbine
The IP turbine section is of double flow
construction with horizontally split casings.
Allowance is made for thermal movement of the
inner casing within the outer casing. The inner
casing carries the stationary blading. The
reheated steam enters the inner casing from top
and bottom. The provision of an inner casing
confines high steam inlet conditions to the
admission section of this casing, while the joint
flange of the outer casing is subjected only to
the lower pressure and temperature effective at
the exhaust from the inner casing.
BHEL Haridwar
Blading
The entire turbine is provided with reaction
blading. The stationary and moving blades of the
HP and IP sections and the front rows of the LP
turbine are designed with integrally milled
inverted T -roots and shrouds. The last stages of
the LP turbine are fitted with twisted drop -forged
moving blades with fir-tree roots engaging in
grooves in the shaft with last stage stationary
blades made from sheet steel.
Bearings
The HP rotor is supported on two bearings, a
journal bearing at its front end, and a combined
journal and thrust bearing immediately next to
the coupling to the IP rotor. The IP and LP rotors
have a journal bearing each at rear end. The
combined
journal
and
thrust
bearing
incorporates a journal bearing and a thrust
bearing which takes up residual thrust from both
directions. The bearing metal temperatures are
measured by thermocouples directly under the
babbit lining. The temperature of the thrust
bearing is measured in two opposite thrust pads.
The bearing pedestals are anchored to the
foundation by means of anchor bolts and are
fixed in position.
The HP and IP turbines rest with their lateral
support horns on the bearing pedestals at the
turbine centerline level. The HP and IP casings
are connected with the bearing pedestals by
casing guides, which
establish the centerline alignment of the turbine
casing.
The axial position of the HP and IP casings is
fixed at the support brackets on HP-IP bearing
pedestal.
5.1-0002-04/1
Valves
The HP turbine is fitted with two main stop and
control valves. One main stop valve and one
control valve with stems arranged at right angles
to each other are combined in a common body.
The main stop valves are spring-action singleseat valves; the control valves, also of singleseat design, have diffusers to reduce pressure
losses.
These valve combinations are located at both
sides of the turbine with their stems horizontal.
The HP valves are connected to the turbine by
easily separable collar couplings, which contain
self-sealing U-rings as sealing elements.
The IP turbine has two reheat stop and control
valves. The reheat stop valves are spring-action
single-seat valves. The control valves, also
spring-loaded, have diffusers. The control valves
operate in parallel and are fully open in the
upper load range. In the lower load range, they
control the steam flow to the IP turbine and
ensure stable operation even when the turbinegenerator unit is supplying only the station load.
The reheat stop and control valves are
supported free to move in response to thermal
expansion on the foundation cover plate below
the operating floor and in front of the turbinegenerator unit. All valves are actuated by
individual hydraulic servomotors.
5.1-0002-04/2
Steam Turbine
Description
Design of the supports for the turbine has to
allow for the expansion of the turbine during
thermal cycling. Constrained thermal expansion
would cause overstressing of the components.
The method of attachment of the turbine
components is also critical to the magnitude of
the differential expansion between the rotor and
turbine casings which is given careful attention
in the determination of internal clearances.
BHEL, HARIDWAR
Fixed Points
Centering of LP outer casing is provided by
guides which run in recesses in the foundation
cross beam. Axial movement of the casings is
unrestrained.
Hence, when there is a temperature rise, the
outer casings of the HP turbine expand from
their fixed points towards Front pedestal. Casing
of IP Turbine expand from its fixed point towards
the generator.
LP Casing expands from its fixed point at front
end, towards the generator.
Rotor Expansion
The thrust bearing is housed in the rear bearing
pedestal of the HP turbine. The HP turbine rotor
expands from the thrust bearing
towards the front bearing pedestal of the HP
turbine and the IP turbine rotor from the thrust
bearing towards the generator.
The LP turbine rotor is displaced towards the
generator by the expansion of the shaft
assembly, originating from the thrust bearing.
Differential Expansion
Differential expansion between the rotors and
casings results from the difference between the
expansion of rotor and casing originating from
the HP-IP pedestal. The largest differential
expansions of the HP and IP turbines thus occur
at the ends farthest from the thrust bearing.
Differential expansion between the rotor and
casing of the LP turbine results from the
difference between the expansion of the shaft
assembly, originating from the thrust bearing
and the casing expansion, which originates from
the fixed points on the LP turbine longitudinal
beams.
5.1-0003-02/1
Overspeed Trips
MAY10AA001/MAY10AA002
Function
The two over speed trips are provided to
protect the turbine against over speeding in
the event of load rejection coincident with
failure of the speed controller. As they are
particularly important to the protection of the
turbine, they can also be locally tested by
manually with the aid of the over speed trip
test device MAX62AA001 (hydraulic test
signal transmitter) during turbine operation
at rated speed. (For description see Over
Speed Trip Test).
Operation
When the preset over speed is reached, the
eccentric flybolt/striker (2) of each over
speed trip activates piston (5) and limit
switch (6) annunciate via pawl (4). This
connects the auxiliary trip fluid circuit to
5.1-0661-00/5
5.1-0661-00/6
Test sequence
After energizing of test signal transmitter
(solenoid valve) MAG01AA201, fitted in the
signal line to the condenser, this signal line
is blocked off and simultaneously the space
above diaphragm (4) is connected to
atmosphere. The air flow via orifice causes a
slow increase of pressure by which the
pistons (6) and (7) move to their trip position
connecting the auxiliary trip fluid circuit to
the drain.
Reset Solenoids
MAX48 AA201 and MAX48 AA202
Function
The function of the reset solenoids is to
restore the tripped protective devices to their
normal operating positions during the ATT
reset program.
Operation
The reset solenoids are two 2/3-way
solenoid valves, fitted in the auxiliary startup fluid line. Both solenoid valves are
energized in the course of the reset program
conducted after each subtest, so that
auxiliary start-up fluid II is supplied with
control fluid III. The control fluid pressure
forces all protective devices back into their
normal operating positions and the trip fluid
and auxiliary trip fluid pressure can build up
again.
When the protective devices have latched-in
again, reset solenoid MAX48AA021 is deenergized first to shut oft the control fluid
supply through this value.
1 Compression
spring
2 Coil
3 Valve disc
5.1-0661-00/7
Steam Turbine
Description
BHEL Hardwar
5.1-0662-01/1
time
Setting Data
The setting data for the pressure switches
used to monitor the individual valve
movements are listed in the setting record
Pressure Switch settings. The actual set
values are logged in the Commissioning
Test Record. The test running times, etc.,
are entered in the functional diagram.
Test Selection Units
There are two nos. of combined main
steam and control valves and two nos.
of combined reheat stop and control
valves, each of which is tested as a
separate unit and has a separate selection
push-button on the ATT control panel.
They are as follows:
Selection1:
Main stop and control valve (LHS)
Selection 2:
Main stop and control valve (RHS)
Selection 3:
Reheat stop and control valve (LHS)
Selection 4:
Reheat stop and control valve (RHS)
Test Procedure
Start of Test
The test starts with the selection of
subgroups by pressing the On/Off pushbutton.
The subgroup remains on until it is
switched off after the programme is
5.1-0662-01/2
5.1-0662-01/3
5.1-0662-01/4
Steam Turbine
Description
The actuator is of the two-stage
amplification type, i.e. it incorporates pilot
and main control mechanisms. The
actuating forces for movement of the HP
control valve are generated, in the opening
direction, by main actuator piston KA02
under the force of the control fluid and, in
the closing direction, by the disc spring
column. During actuation main pilot valve
KA07 acts as a 3-way valve to allow the
control fluid to flow to the space behind main
actuator piston KA02. Main pilot valve KA07
is actuated via the resetting linkage by
means of auxiliary pilot piston KA06 which is
subject to control fluid pressure on both
sides.
The actuating signal given by the signal fluid
pressure acts on the face of pilot valve KA05
pressing it against the resetting spring on
the opposite side. Acting as a 4-way valve,
the pilot valve allows fluid to flow to both
sides of auxiliary pilot piston KA06. When
BHEL Hardwar
HP Actuator
5.1-0665-00
Steam Turbine
Description
Function
With all shaft seals subject to a positive
pressure difference, the escaping steam is
throttled to a low pressure and fed into a
header 1.1, which is common to all shaft
seals. Those seals, which are under
vacuum, must be supplied with seal steam
to prevent the ingress of air. The supply of
steam is taken from the header 1.1. The
amount of leakage steam and seal steam
required depends on the pressure at the
seals, which, in turn, is primarily
dependent on the turbine load.
The function of the control system is to
maintain the pressure at the bleed-off
points of all seals at the same preset
pressure. This is effected by exhausting
steam from the header (e.g. to the
condenser) or supplying extra steam to the
header 1.1, according to operating
conditions.
Arrangement
Leak-off control valve 1.3 is used for
discharging surplus steam from the header
1.1 and seal steam supply control valve
1.4 for admitting extra steam to it. All
valves are actuated by type HSA-1-K
electro hydraulic actuators. The actuators
1.11 are under the continuous control of
an electric controller 1.9 each via an
electro hydraulic converter. The electro
BHEL Hardwar
Electro-hydraulic Seal
Steam Pressure Control
hydraulic converter comprises a control
coil, which adjusts the position of the
impingement plate of the hydraulic
preamplifier.
Controller
The function of the electric controller 1.9 in
conjunction with the transducer 1.6 and
the actuating elements (control valves) is
to maintain a controlled variable at a
preset valve by adjusting the final
controlling elements. The actual valve of
the
control
system
is
acquired
continuously by the transducer 1.6 and
compared against the set value in the
electric controller 1.9. If the actual value
deviates from the set value, one of the
final controlling elements (either the leakoff or steam supply control valve) is
adjusted until the actual value again
agrees with the set value. Only if there is a
large control deviation, e.g. during a fullload trip, are all valves operated
simultaneously. The electric controller is
realised in digital technology.
Mode of Operation
The input signal coming from the controller
flows through the solenoid (31). The
magnetic field of the solenoid together with
the magnetic field of the permanent
magnet system (42) exercises a force on
the freely pivoted armature (30). This force
reacts against the force generated by the
5.1-0670-01/1
5.1-0670-01/2
5.1-0003-02/2
5.1-0670-01/3
5.1-0670-01/4
Steam Turbine
Description
Power Plant identification System
Title
Control System
Diagram Legend
Coordinete
LBC10 AA001
KA01
LBC10 CG001 B
C
D
E
E7
E7
E7
E7
E7
E7
LBS21 AA001
KA01
LBS21 CG001A
E12,13
E12,13
E12,13
LBS31 AA001
KA01
LBS31 CG001A
E13
E13
E13
LBS31 AA002
LBS31 CG002 A
E13
E13
LBS41 AA001
KA01
LBS41 CG00 1A
C10
C10
C10
LBS41 AA002
KA01
LBS41 CG002A
C10
C10
C10
LBS42 AA001
KA01
LBS42 CG001A
AB11
A 11
B 11
LBS42 AA002
KA01
LBS41 CG002A
AB1 1,12
A12
B12
LBQ50AA001
KA01
LBQ50CG001 A
E9
E9
E9
LBQ5OAA002
LBQ50 CG002A
E9
E9
MAA10 + 20
CG001 B,F,H
C,G,J
D
E
MAA10+ 20
AA002
KA01
KA02
KA05
ABC7
AB7
B7
BHEL Haridwar
BC7,8
C7,8
C7
C7
Coordinete
KA06
KA07
KA09
M
AA002 MS61
MAA10 + 20
CG002 A
C
MAB10 +20
AA001
KA01
KA02
MAB10 + 20
CG001 B,F,H,
C,G,J
D
E
MAB10+ 20
AA002
KA01
KA02
KA05
KA06
KA07
KA09
M
MS61
MS62
MS72
MAA10 + 20
AA001
KA01
KA02
Title
MS73
MAB10 + 20
CG002
A
C
MAD12
CY011,012,013
MAG01 AA011
MAG01CG01 B
C
E
MAG01AA016
ABC9
A9
A9
BC9,10
Servomotor
C10
Piston
C10
Pre Control Pilot Valve
C10
Relay Piston for Precontrol Pilot ValveC10
Main Pilot Valve
C10
Hand wheel for Testing Device
B10
Electrical Motor for Testing Device B10
Torque Limit Switch,
Testing Device 100% ATT
B10
Travel Limit Switch,
Testing Device 100% ATT
B10
Torque Limit Switch,
Testing Device 0% ATT
B10
Travel Limit Switch,
B10
Testing Device 0% ATT
D8
B5
B5
B5
B5
G9
5.1-0681-05/1
Title
Coordinete
MAV21 AP001
E1
MAV21BT001
Oil Filter
(Hydraulic Control Equipment Rack)
D4
B7
MAX31
BB21, 26
B9
MAX31 BB021
BB041,049
C11
MAX31
BB011, 016
MAX32
BT011 +012
MAX32BT081
A10
C11
MAX42AA001
D7
D8
MAX42AA011
Non-Return Valve
B1
MAX42BT001
Fluid Filter
(Hydraulic Control Equipment Rack)
C1
Fluid Filter
(Hydraulic Control Equipment Rack)
C2
Fluid Filter
(Hydraulic Control Equipment Rack)
B4
G6
MAX42BT002
MAX42BT003
MAX42BT021
MAX42BT022
MAX42CP501
F6
MAX42CP511
MAX42CP512
MAX44AP001
E1
MAX44CP501
A5
MAX45BB001
E4
MAX45BY001
KA01
KA02
KA04
KA05
KA06
KA08
KA10
KA11
5.1-0681-05/2
Coordinete
MAX41 CP50l
MAX42AA002
A7
Title
Electro-Hydraulic Converter
Follow-Up Piston for Main
Control Valves
Follow Up Piston for Reheat
Control Valv8S
Sleeve
Piston
Helical Spring
Piston
Adjusting Device Control Valves
Manual Adjusting Device
F4
F5
F5
F4
F4
F4
F4
F5
F5
A
K
T
B
C
Title
Coordinete
MAX45BY011
KA01
KA02
Hydraulic Converter
F2
Follow-up Piston for Main Control Valves F3
Follow-Up Piston for Reheat Control F3
valve
KA04
Sleeve
G3
KA05
Piston
G3
KA06
Helical Spring
F3
KA07
Pilot Valve
G2
KA08
Piston
G3
KA09
Proportional Band Adjustment
G2
KA10
Adjusting Device Control Valves
F4
KA11
Manual Adjusting Device
F4
MAX45CG011 B
Limit Switch, Operation without Bypass
Valves and Adjusting Device Blocked F3
C
Limit Switch, Displacement of control
valves
F4
MAX45CP501
MAX45CP511
F2
Title
Coordinete
G1
G1
MAX51
AA005 +006
B2
MAX 51
CG005+006 C
E
B2
B2
MAX51 AA011
KA01
KA02
D5
D5
D5
MAX51AA041
MAX51 AA044
E3
E12
C12
A 11
C12
A11
E9
MAX51AA211
Changeover Valve
B3
MAX51 CG211B
C
MAX51CP501
MAX51 CP522
527
MAX51 AA047
MAX51 AA048
MAX 51 AA 050
E13
E2
MAX46BY001
KA01
KA02
KA03
KA04
KA05
KA06
KA07
KA08
KA09
M
G1
F2
F1
F1
F2
F2
F2
F2
F2
G1
F1
MAX46CG001 A
B
F2
F2
MAX 51 CP523
528
Pressure Gauge.
Auxiliary Secondary Fluid
F2
MAX51 CP542
547
MAX47
AA011 +012
B6
MAX51 CP543
548
MAX47
AA021 +022
A9
MAX52AA005
MAX52 CG005 C
E
B2
B2
B2
MAX47BY001
KA01
KA02
M
F1
F1
F1
F1
MAX 52 CP501
D3
MAX47CG001 A
B
C
D
F1
G1
G1
G1
MAX46CP501
MAX 51 AA051
MAX 51 AA056
A3
5.1-0681-05/3
MAX45AA001
Title
Coordinate
E1
B4
F5
MAX47
AA211 +212
MAX 47
AA221 +222
MAX48
AA201 +202
MAX51AA021
MAX51AA024
MAX51AA027
MAX51 AA028
MAX51 AA030
MAX51AA031
MAX61
AA011 +012
Coordinate
B5
B8
B1,2
E12
E13
C 12
A10
C12
A11
E9
B3
B4
B6
MAX51 AA036
MAX61
AA021 +022
B8
MAX62AA001
KA01
KA02
KA03
KA001M
C4
C4
C4
C4
C4
MAX52AA001
C2
MAX62CG001 B
C
MAX52AA002
C2
MAX62CP501
MAX53AA051
MAX51 AA201
MAY10
AA001 +002
KA01
Overspeed Trip
Releasing Device
E2
E2
MAY10
CG001 +002 C
E
E3
E3
5.1-0681-05/4
MAX51AA202
MAX61AA201
C13
MAX61
AA221 +222
LBS42 CP002
MAG01CP201
MAG01CP202
MAG01CP203
MAG01CP204
MAG10CP011
MAG 10CP012
Title
Coordinete
MAX48 CP202
Solenoid Valve for Testing of
Main Stop Valves
C5,6
MAX51
CP001 +002
C8
B11
B4
B4
B5
B5
E13
E13
MAG10CP016
MAX48 CP201
MAX51
CP205 +206
MAX51
CP207 +208
MAX51
CP209 +210
MAG10CP013
MAX45 CP211
E13
E2
Title
Coordinete
B1
A1
MAX51CP 221
+226
MAX51CP222
+227
B7
MAX51 CP223
+228
A7
MAX51CP242
+247
A9
MAX51 CP243
+248
B9
MAX52CP211
B3
D1
D1
D2
MAX62 CP 211
MAX62 CP 212
MAX62 CP 213
C2
MAX45 AA031
E4
5.1-0681-05/5
Steam Turbine
Description
No.
1
2
3
4
5
6
10
11
12
13
14
15
16
17
Lubrication
Point
Overspeed test
device
Reduction gear of
overspeed trip
test device
Bearing of low
vacuum trip
Main control valve
stem
Main stop valve
stem
Limit Switch
attachment on
main stop valve
Limit Switch
attachment on
main control valve
Hinge of main
control valve
position indicator
LAWA actuator
VR 16 of main
control valve
Reheat control
valve stem
Reheat stop valve
stem
Limit switch
attachment on
reheat stop valve
LAWA actuator
VR 16 of reheat
control valve
Hinge of reheat
control valve
position indicator
Limit switch
attachment on
reheat control
valve
Hinge of
extraction swing
check valve
Adjusting gear of
starting and load
limit device
BHEL Haridwar
Filling
Quantity
Lubrication Chart
Lubricant
Turbine oil*
200g
Grease
Servogem-2
Turbine oil*
10g
Molykote
M30
Molykote
M30
Every 1 to 2
months
Use no oil
or grease
Molykote
M30
Every 1 to 2
months
Use no oil
or grease
Calypsol
SF7-026
Every 104
Operating
hours
After every
dismantling
After every
dismantling
Every 1 to 2
months
0.4 kg
0.4 kg
Molykote
M30
Every 104
Operating
hours
Every 1 to 2
months
Molykote
M30
Every 1 to 2
months
Molykote U
Molykote U
Molykote
M30
Calypsol
SF7-026
Molykote U
200g
Remarks
Use no oil
or grease
Use no oil
or grease
Use no oil
or grease
Molykote U
0.4 kg
Every 1 to 2
months
Every 1 to 2
months
Top-up
Quantity
Every 1 to 2
months
After every
dismantling
After every
dismantling
Every 1 to 2
months
Molykote U
0.4 kg
Lubrication
Interval
Grease
Servogem-2
Use no oil
or grease
Use no oil
or grease
Use no oil
or grease
Use no oil
or grease
Use no oil
or grease
After every
dismantling
Every 1 to 2
months
Use no oil
or grease
10g
5.1-0690-05/1
No.
18
19
20
21
22
23
*
**
Lubrication
Point
Journal for
hydraulic speed
governor
Adjusting gear of
reference speed
setter
Bearing of
trimming device
Hinge of cold
reheat swing
check valve
Stem guides of
shaft seal steam
valve
Filling
Quantity
Lubricant
Turbine oil*
200g
Grease
Servogem-2
Turbine oil*
Molykote U
7 to 9 kg
Lubrication
Interval
Top-up
Quantity
Every 1 to 2
months
Every 1 to 2
months
10g
Every 1 to 2
months
After every
dismantling
Molykote U
After every
dismantling
Hydraulic oil
to DIN 51517
and VDMA
24318 H-LP
oils**
1stoil change
after 6
months,
thereafter
every12
months.
Use no oil
or grease
7 to 9 kg
5.1-0690-05/2
Remarks
Use no oil
or grease.
Lubrication
point not
shown
Lubrication
point not
shown
Steam Turbine
Description
Technical Data
Construction, Speed
& Steam Pressure
Load
Rated Load
500 MW
524.9 MW
Construction
Three cylinder reheat condensing turbine
Single flow HP Turbine with 17 reaction stages
Type : H30-100-2
Type : M30-63
Type : N30-2x10-2
Type : EV 320-1
Type : IV 560
DN-800
Make : BHEL, Trichy
: No valve
Extraction 2
DN 800
Make : BHEL, Trichy
Extraction 3
DN 500
Make : BHEL, Trichy
DN 500
Make : BHEL, Trichy
DN 500
Make : BHEL, Trichy
Extraction 5
DN 400
Make : BHEL, Trichy
Extraction 6
: No valve
BHEL Haridwar
5.1-0100-63/1
5.1-0690-05/3
Steam Turbine
Description
Function
The function of the hydraulic speed governor
is to operate the control valves to give the
appropriate turbine steam throughput for the
particular load condition. The arrangement
and functioning of the governor within the
overall governing system is described in the
section on governing.
Construction
The principal components of the speed
governor are the bellows (8), the link (11),
the speed setting spring (13), the sleeve (5)
and the follow-up piston (4). The primary oil
supply from the hydraulic speed transmitter
is available at connection a1. A fire
resistant fluid is used as the hydraulic fluid in
the governing system. An additional bellows
(9) prevents primary oil getting into the
control fluid circuit if there be a leakage in
the governor bellows (8). In this case, the
leakage oil can be drained off via connection
c1 . In case a leak in the bellows (9) occur,
the control fluid that has leaked in will also
be drained off via connection c1.
The primary oil pressure (connection a1) is
dependent on the speed and determines the
position of the link (11) via the bellows (8)
and the push rod (10). The speed setting
spring (13) opposes the primary oil
pressure. Its pre-compression can be varied
either by hand or remotely by the motor (16).
The sleeve (5) which can slide on the
bottom end of the follow-up piston (4) is
attached to the link (11). The follow-up
piston is held against the auxiliary
secondary fluid pressure (connection b) by
the tension spring (3). The follow-up piston
and the sleeve have ports, which at normal
overlap allow sufficient fluid to escape to
produce equilibrium between the auxiliary
secondary fluid pressure and the force of the
tension spring (3).
Each steady-state position of the link (11)
and hence of the sleeve (5) corresponds to
a specific force from the tension spring (3)
and hence to a specific secondary fluid
pressure which in turn determines the
position of the control valves.
BHEL Haridwar
Mode of Operation
If the primary oil pressure falls (as a result of
increasing load and the resulting drop in
speed), the link (11) and the sleeve (5)
sliding on the follow-up piston (4) are moved
downwards by the speed setting spring (13)
so that the overlap of the ports in the sleeve
and the follow-up piston is reduced. This
causes the pressure in the auxiliary
secondary fluid circuit to rise and the followup piston follows the movement of the
sleeve against the increasing force of the
tension spring (3) until normal overlap of the
ports and equilibrium are restored. The lift of
the control valves is increased in this
manner by the increased secondary fluid
pressure.
Conversely, a rise in primary oil pressure
causes the lift of the control valves to be
reduced.
When the pre-compression of the speed
setting spring (13) is varied with the
reference speed setter it changes the
relationship between the primary oil
pressure and the secondary fluid pressure
and hence the relationship between speed
and power output.
Lever (12) allows the link (11) to be
depressed by hand to give a lift signal to the
governor, e.g. to provide a second means of
overspeeding the machine for testing the
overspeed trips in addition to the overspeed
trip tester.
Starting and load limiting device
Before start-up, the pilot valve (21) is
brought to its bottom limit position either by
hand or remotely by the motor (20). This
causes the bellows to be compressed via
the lever (6) and the pin (7) until the
governor assumes the position Control
valves closed. With the pilot valve (21) in
the bottom limit position, control fluid from
connection a can flow simultaneously to the
auxiliary start-up fluid circuit (connection
u1) and as start-up fluid via connection u
5.1-0710-00/1
5.1-0710-00/2
Steam Turbine
Description
Function
The adjusting gear is used for manual or
motor operation of the reference speed
setter and the starting and load limiting
device.
Mode of Operation
The speed/load adjusting gear is operated
either manually or by means of motor (28).
The rotary movement of the motor shaft is
transmitted to worm wheel (15) via worm
wheel (9) and the worm attached to it.
Wormwheel (15) is located axially on the
threaded portion of the hand wheel spindle
(16) by insert (5) and the gear casing (11).
The spindle (16) is connected with bushing
(4) by a feather key so as to permit the
BHEL Haridwar
Adjusting Gear
5.1-0720-00
Steam Turbine
Description
Electro-hydraulic Converter
for Turbine Control System
Function
The electro-hydraulic converter is the
connecting element between the electrical
and hydraulic parts of the turbine control
system. It converts the signals from the
electric controller into the hydraulic signals
and amplifies them before transmitting them
to the actuating devices.
Construction
The principal components of the converter
are moving coil system (12), sleeve (10),
pilot valve (6), amplifier piston (3), follow-up
pistons (21), differential transformer (1) and
actuator (17). Bushings and follow-up
pistons A are connected to each other via
the adjusting screws (24), spring end pieces
and the springs (22). The control signals
from the electro-hydraulic controller operate
the sleeve (10) via the moving coil system
(12). This sleeve slides up and down on the
top end of the pilot valve (6) and determines
the position of the valve in the manner of a
follow-up piston. The pilot valve and sleeve
have ports which depending on the overlap,
control the amount of trip fluid flowing from
connection x. In the steady-state condition,
the pilot valve is in its center position and
the trip fluid pressure acting on the face of
the pilot valve is in equilibrium with the force
of compression spring (9). The pilot valve is
kept in rotation by control fluid flowing from
tangential holes in an integral collar to give
greater freedom of reciprocal motion and
achieve high response sensitivity.
When the pilot valve is deflected from its
center position, control fluid from connection
a is admitted to the space above or below
the amplifier piston (3) with the opposite side
of the piston opened to the fluid drain. The
resulting motion of the amplifier piston is
transmitted via lever (13) to the sleeves (20)
which in turn can slide on the following-up
pistons (21). The secondary fluid circuits,
which are fed from the trip fluid circuit via
throttles and supply the various actuating
devices, are connected at point b. The
secondary fluid pressures are determined by
the tension of springs (22) which
BHEL Haridwar
5.1-0730-02/1
5.1-0730-02/2
5.1-0730-02/3
Steam Turbine
Description
Function
The function of the hydraulic amplifier is to
amplify the signals from the hydraulic speed
governor (connection b1) so that they are
sufficient for the actuating devices.
Construction
The principal components of the amplifier
are amplifier piston (1), pilot valve (7),
follow-up piston (2) with sleeves (3),
mechanical feedback system (6) and
actuator (21). Bushings and follow-up
pistons A are connected to each other via
the setscrews (10), spring end pieces and
springs (11). Auxiliary secondary fluid flows
BHEL Haridwar
Hydraulic Amplifier
for Turbine Control System
5.1-0740-02/1
5.1-0740-02/2
5.1-0740-02/3
Speed
Rated speed
50.0 c/s
51.5 c/s
47.5 c/s
47.5 c/s
51.5 to 60 c/s
7 to 47.5 c/s
* This speed range should be passed through in one smooth operation to avoid endangering the
blades due to resonance
Steam Pressures
Unit
166.7
166.7
200
bar
154.4
169.8
169.8
bar
HP cylinder exhaust
44.0
50.63
52.84
39.6
45.97
47.56
Extraction 6
44.0
50.63
52.84
bar
Extraction 5
16.8
20.08
20.08
bar
Extraction 4
6.94
8.36
8.36
bar
Extraction 3
2.744
3.36
3.36
bar
Extraction 2
1.469
1.81
1.81
bar
Extraction 1
0.342
0.42
0.42
bar
LP cylinder exhaust
0.1013
0.3
0.3
bar
Rated
Initial Steam
st
bar
bar
These values correspond to 500 MW load with 3 % make-up and 0.1013 bar back pressure
with all heaters in service and rated steam conditions.
The safety valves must be set so that short time values are not exceeded.
Long time operation: Upper limit value, permissible without time limit.
Short time operation: Permissible momentary value. The aggregate duration of such swings
must not exceed 12 hours in any one year
All pressures are absolute pressures
5.1-0100-63/2
Steam Turbine
Description
BHEL Haridwar
5.1-0760-01
Steam Turbine
Description
Pressure Converter
Function
The pressure converter is installed in the IP
secondary oil circuit. It does not permit to
raise the IP secondary oil pressure beyond
certain value.
Construction
The pressure converter is provided with a
follow up piston (3), which slides in the
bushing (6) at the top, and in the sleeve (2)
at the bottom. The bushing and follow up
piston are connected to each other via the
set screw (9, 10) and the spring (4). There
are drainage slots in the follow up piston (3)
and sleeve (2), through which a larger or
smaller amount of fluid can flow into the fluid
return line c depending on how much they
overlap. The fluid pressure prevailing in the
follow up piston (3) is connected to the
reheat control valves for speed control via
connection x.
Mode of Operation
When the setscrew (9) of the pressure
converter has been appropriately set, IP
secondary fluid pressure is permitted to
increase to certain value.
1 Ring
2 Sleeve
3 Follow up piston
4 Spring
5 Casing
6 Bushing
7Cover
BHEL Haridwar
8 Cap
9 Set Screw
10 Set Screw
c Return flow
x IP secondary fluid
5.1-0761-00
Steam Turbine
Description
BHEL Haridwar
Stop Valve
The steam enters the valve casing (13) via
the Inlet connection and remains above the
stop disc (1). The main valve disc
incorporates a pilot disc formed from the end
of the valve steam (3). The valve stem is
sealed by packing rings (6). On the back of
the valve disc is a raised seat which comes
into contact with a neck bush (4) when the
5.1-0810-01/1
5.1-0810-01/2
Control Valves
The stem and disc (16) of the control valve
are in one piece. Balancing holes in the
valve disc reduce the operating force
required. The valve stem and disc (16) are
guided in the cover (17) and the stem is
sealed by packing rings (20). When the
valve is fully opened, the raised seat of the
valve disc rests against the neck bushing
(18) and provides additional sealing. As with
the stop valve, the valve body cover (17) is
held in the casing by a threaded ring (21)
and is sealed by U-shaped gasket (19). The
control valve is actuated by the piston of the
servomotor (26) that is operated by a cup
spring in the closing direction and
hydraulically in the opening direction.
Steam Turbine
Description
BHEL Haridwar
5.1-0811-00
Steam Turbine
Description
BHEL Haridwar
5.1-0812-00/1
5.1-0812-00/2
Steam Turbine
Description
Test Valve
for Emergency Stop Valve
Function
The function of the test valve is to open and
close the emergency stop valve, either by
start-up fluid circuit or manual operation
especially when the emergency stop valve is
being checked for easy movement.
Arrangement
Each test vale (6) and auxiliary valve (5) is
arranged in series behind a solenoid valve
(1, 2).
BHEL Haridwar
5.1-0813-00
Steam Turbine
Description
Function and Construction
One stop and one control valve are
combined in a common body with their
stems arranged at right angles to each
other. The stop valve can interrupt the
supply of steam from the reheater to the
IP and LP turbines extremely quickly. The
control valve controls the steam flow to
the IP and LP turbines on load rejection,
start-up & shutdown and remains fully
open in the upper load range to eliminate
any throttling losses. Further details of the
arrangement of the valve combination in
the control system can be seen under
section Governing system.
Reheat Stop Valve
The stop valve is a single seat valve with
integral pilot valve. Steam enters via the
BHEL Haridwar
5.1-0814-00/1
Control Valve
The control valve has a pipe-shaped
valve disc (14) that is bolted to the valve
stem (13) and slides in the bushing in the
valve cover (11) The valve disc is
provided with relieving holes to reduce the
necessary controlling force. A ring fixed in
the bushing of the valve cover prevents
the valve disc from rotating. This valve
disc also has a back sealing that operates
5.1-0814-00/2
when
the
valve
is
fully
open.
Asbestos/graphite packing rings (10) seal
the valve stem (13) in the valve cover (11).
The control valve is operated by the piston
of the servomotor (9) i.e. is opened
hydraulically and closed by disc springs.
In the event of a disturbance in the system
or on trip-out, both stop valve and control
valve close rapidly.
0.3 bar
0.3 bar
0.6 bar
35 mbar
Axial shift
Alarm
0.5 mm
Trip
1.0 mm
Direction of rotation
Anti clock wise when viewed from Front Pedestal towards the Generator
5.1-0100-63/3
Steam Turbine
Description
BHEL Haridwar
5.1-0815-01
Steam Turbine
Description
Function
Steam Strainers are installed in the main
steam lines and in the hot reheat lines from
the boiler. They protect the admission
elements of the HP and IP turbines from
foreign objects, which could be picked up in
the boiler or associated piping.
Construction
The strainer screen (2) is made of
corrugated strip wound on a frame. This
BHEL Haridwar
Steam Strainer
5.1-0816-00
Steam Turbine
Description
Changeover Valve
for Bleeder Check Valve
Function
The function of the changeover valve is to
manually operate the actuator of the
bleeder check valve.
Mode of Operation
The trip fluid (connection x) holds the valve
(10) in the upper end position (illustrated)
against the force of the spring (8). The trip
fluid flows via the holes in the valve to
connection x 1 and then on to the actuator
of the bleeder check valve. The valve can
be moved downwards by means of hand
wheel (1). In this way connection x1 is
connected to the fluid drain c and the fluid
drains away from the actuator of the bleeder
check valve. The spring of the actuator can
then initiate the closing of the check valve. If
the pressure drops at the trip fluid
connection x, the spring (8) pushes the
valve (10) downwards. In this way the fluid
drain of the actuator is also freed.
1 Hand wheel
2 Spindle
3 Cap nut
4 Bush
5 Lip ring
6 Cover
7 Bush
8 Spring
9 Ball
10 Valve
11 Cover
c Drain fluid
x Trip fluid
x1 Trip fluid to actuator
BHEL Haridwar
5.1-0840-00
Steam Turbine
Description
Function
The auxiliary valve controls the fluid supply
to the extraction check valve actuators and
its function is to give the check valves a
signal to close in the case of a drop in load
or trip-out so that steam can not flow out of
bleeder lines back to the turbine. The
auxiliary valve serves several check valves.
Mode of Operation
Trip fluid is admitted through connection x
on the body (10) (section A-B). Secondary
fluid from follow-up pistons of main control
valves is admitted to the spaces above and
below the valve (11) through connection b2
As the pressure above and below the valve
(11) are equal under normal conditions, the
valve is held in the lowest position by the
force of the spring (7).
BHEL Haridwar
Auxiliary Valve
of Extraction Check Valve
5.1-0841-00/1
5.1-0841-00/2
Steam Turbine
Description
Function
The function of the rotary vane actuator
flanged to the swing-check valve is to
open or close the swing-check valve fitted
in the cold reheat line.
Operation
When the pilot valve operated by the
transformer of the speed controller
passes control fluid via connections d to
the interior of the actuator, the adjacent
connection d1 is depressurized. The
control fluid then flows through bores in
the body into the two diametrically
opposite chambers turning rotary vane (2)
on actuator shaft (8) into contact with the
BHEL Haridwar
5.1-0853-01
Steam Turbine
Description
Function
The function of the pilot valve is to control
the admission of control fluid to the moving
vane actuator in such a way that the swingcheck valve is operated in accordance with
the pressure in the secondary fluid circuit.
Mode of operation
The swing-check valve is kept open as long
as the pressure in the secondary fluid circuit
does not drop below a definite limit value. If
signal fluid enters the body via connection
b, the valve (10) is lifted against the action
of the spring (5). The initial tension of this
spring and thus the point at which the swingcheck valve opens can be adjusted. If the
valve (10) is lifted beyond the center position
illustrated, the control fluid entering at
connection a flows on to a chamber of the
actuator via connection a2 to open the
swing-check valve. Connection a1 then
communicates with the fluid return c via
passages in the body, permitting the fluid to
drain away from the actuator chambers not
supplied with control fluid. If the valve (10)
drops below the center position illustrated,
the control fluid will then be conversely
admitted to the actuator chambers in such a
way that the swing-check valve closes.
To prevent the valve (10) from seizing in its
sleeve (9) during operation control fluid is
passed through the center bore and out
through the tangential bores at the wheel
disc (8) to impart rotary movement to the
valve (10). For this reason, a thrust ball
bearing (7) and a ball (13) is fitted for this
purpose.
1 Throttle capillary tube 12 Slotted nut
2 Cap nut
13 Ball
3 Setscrew
4 Hood
5 Compression spring
6 Spring disc
7 Thrust ball bearing
8 Wheel disc
9 Valve bush
10 Valve
11 Bush
c Return
a Control fluid
b Signal fluid
a1 Control fluid(closes swing check valve)
a2 Control fluid(opens swing check valve)
BHEL Haridwar
5.1-0854-00
Steam Turbine
Description
Function
The function of the auxiliary pilot valve for
the pilot valve for the reheat check valve
actuator is to control the admission of
control fluid to the pilot valve in such a way
that the swing-check valve is actuated in
accordance with the pressure in the
secondary fluid circuit.
Operation
The swing-check valve is kept open as long
as the pressure in the secondary fluid circuit
does not drop below a definite limit value.
Secondary fluid entering body (9) via
connection b lifts spool (7) against the
action of the spring (3). The initial tension of
this spring and thus the point at which the
swing-check valve opens can be adjusted. If
spool (7) is lifted beyond its central position
as illustrated, the control fluid entering at
connection a flows on via connection a1 to
connection b of the pilot valve to open the
swing- check valve via the rotary actuator. If
spool (7) drops below its central position as
illustrated, control fluid is admitted to the
opposite chambers of the rotary actuator, so
that the swing-check valve closes.
To prevent spool (7) from seizing in its
sleeve (6) control fluid is passed through the
center bore in the spool during turbine
operation and out through tangential bores
in the upper part of spool (7) to impart rotary
motion to the spool. A deep-groove ball
bearing (5) between spool (7) and spring
retainer (4) reduces friction from the rotary
motion.
BHEL Haridwar
5.1-0855-00
Steam Turbine
Description
Function
One function of the gland steam control
valve, which is situated in the gland steam
pipe of the seal steam system, is to supply
the shaft seals with seal steam during startup and in the lower load range. A further
function is to keep the set pressure in the
header constant in order to prevent air
penetrating the vacuum of the shaft seals.
Construction and Mode of Operation
The control valve is operated by the piston
of the electro-hydraulic actuator, which is
moved in the open and closed direction by
the pressure of the control fluid. The piston
rod (2) is connected to the valve stem (7) via
the coupling (4), the threaded cap (5) and
cover (6).
The steam flow is regulated by the internal
pilot valve, which is integral with the valve
stem, and the main cone (13). The position
of the valve is shown on the lift scale (3).
The valve stem (7) and valve cone (1 3) are
guided in the bushing (11).
Any leakage steam arising in the upper part
of the bushing (11) is conducted to the
header.
1 Electr-hydraulic actuator
2 Piston rod
3 Lift scale
4 Coupling
5 Threaded cap
6 Cover
7 Valve stem with pilot valve
8 Packed stuffing box
9 Valve yoke
10 Base ring with packing rings
11 Bushing
12 Valve cover
13 Valve cone
14 Valve casing
c Leakage steam
BHEL Haridwar
5.1-0860-01
Steam Turbine
Description
Function
The function of the leakage steam control
valve, which is situated in the leakage steam
pipe of the seal steam system, is to drain
excessive steam from the header.
Construction and Mode of Operation
The control valve is operated by the piston
of the electro-hydraulic actuator, which is
moved in the open and close direction by
the pressure of the control fluid.
The piston rod (3) is connected to the valve
stem (8) via the coupling (4). The packing
rings (10) and the bushing (12) seal the
passage of the rod to the outside and guide
the valve stem (8) during the opening and
closing movement.
1 Electrohydraulic actuator
2 Valve yoke
3 Piston rod
4 Coupling
5 Threaded piece
6 Cover
7 Lift indicator
8 Valve stem
9 Stuffing box
10 Base ring with packing rings
11 Valve cover
12 Bushing
13 Valve casing
BHEL Haridwar
5.1-0870-01
Steam Turbine
Description
Technical Data
Steam & Casing Temperatures
Steam Temperatures
Rated value,
Annual
average
Long-term
value, subject to
annual average
400 hrs.
per year
Unit
Main steam at HP
stop valve inlet
537.0
545.3
551.0
565.0
HRH steam at IP
Stop valve inlet
537.0
545.3
551.0
565.0
Steam Temperatures
Rated value
Long term
operation
In special
cases at no
load
HP turbine exhaust
336.2
338.2
428.2
500.0
Extraction 6
336.2
338.2
428.2
500.0
Extraction 5
410.6
415.6
450.6
Extraction 4
288.2
298.2
338.2
Extraction 3
189.9
202.9
249.9
Extraction 2
132.5
152.5
197.5
Extraction 1
72.2
92.2
142.2
LP turbine exhaust
46.1
70.0
70.0
Unit
Alarm at
Unit
485
500
90
110
BHEL Haridwar
5.1-0101-63/1
Steam
Steam Turbine
Description
Function
The Function of the main trip valve is to
open the trip fluid circuit in the event of
abnormal conditions, thereby closing the
valves and thus shutting off admission of
steam to the turbine.
Construction
The main trip valve consists of mainly two
valves (12) that slide in the casing (11) and
are loaded by the springs (5,6). The valves
BHEL Haridwar
5.1-0910-00/1
Operation
When starting the unit, the valves (12) are
lifted by the aux. start up fluid (connection
u1 ) against the force of the springs (5,6)
and forced tightly against the assemblies
(10). In this way pressure is build up in the
trip fluid circuit (x) and the auxiliary trip fluid
circuit (x1). The pressure in the auxiliary trip
fluid circuit keeps the valve in the position
shown while the aux. start up fluid drains
through the start up device.
Should the fluid in the pressure in the
auxiliary trip fluid circuit drop below a
specific value for any reason (e.g. by
tripping of a protection device) the valves
5.1-0910-00/2
Steam Turbine
Description
Ball head
Limit switch
Cover
Spindle
spring
Bushing
Spring
Valve cone
Bushing
Casing
Cover
BHEL Haridwar
5.1-0911-00
Steam Turbine
Description
Function
The solenoid valve is installed in the
auxiliary trip fluid line to the automatic trip
gear and, when operated, causes the
auxiliary trip fluid circuit to be opened and
the turbine stopped, The solenoid valve is
remote-controlled electrically, e.g. from the
control room or from a protective device.
Construction
The directions of flow are indicated by
arrows on the body. The solenoid sleeve (4)
is bolted to the casing (6) and is inserted in
the magnet casing (1) with the armature (3).
The complete valve element is placed in the
body (6) and held by the plug (11). The two
valve discs (8) seal the valve seats (9). The
solenoid valve and the line to the automatic
trip gear are ventilated by means of the
screw (12).
Mode of Operation
When the solenoid (1) is not energized, the
armature (3) is moved downwards by the
spring (2) so that the valve disc (8) is
pressed against the valves seats (9) to
provide sealing. The solenoid valve is
operated by energizing the solenoid (1). The
armature and the valve discs are drawn
upwards against the force of the spring (2)
so that the auxiliary trip fluid a is linked with
the drain c and the pressure in the line to
the automatic trip gear collapses.
1
2
3
4
5
6
7
8
9
10
11
12
a
c
Magnet casing
Spring
Armature
Solenoid sleeve
Hexagonal nut
Casing
Ring
Stem with two valve discs
Valve seat
O-ring
Plug
Ventilation screw
Auxiliary trip fluid to automatic trip gear
Drain
BHEL Haridwar
5.1-0912-00
Steam Turbine
Description
1
2
3
4
Screw plug
Guide bushing
Guiding foil
Bolt/striker
5 Spring
6 Adjusting screw
7 Turbine rotor
8 Guide ring
BHEL Haridwar
5.1-0920-00
Steam Turbine
Description
Function
The function of the overspeed trip releasing
device is to open the auxiliary trip fluid circuit
and thereby shut down the turbine when an
overspeed is reached which would subject
the rotor to high centrifugal force.
Construction
The overspeed trip releasing device located
in the bearing pedestal consists of valve
bodies (4,10), pilot valve and rods (3,5,7,8),
pawls (12) and limit switch (1). The bellows
16) on the pilot valves and rods prevent
hydraulic control fluid from entering bearing
pedestals and lubrication system. When the
turbine is started up, the pilot valve, rods
and pawls are latched by auxiliary start-up
fluid u1 .
BHEL Haridwar
5.1-0921-00/1
5.1-0921-00/2
Start-up
Before restarting the turbine following a trip,
latch in the overspeed trip. This is done by
admitting auxiliary startup fluid u1 into pilot
valve body (4) and forcing the respective
pilot valve (3) outwards until rod (8) engages
the latch of the pawl. The auxiliary start-up
fluid flow is interrupted and auxiliary start-up
fluid flows via a hole to fluid drain c.
Steam Turbine
Description
Function
The function of the overspeed trip test
device is to test and exercise the overspeed
trip. The overspeed trip consists of
bolts/strikers which protrude against the
force of a spring under the effect of
centrifugal force during an overspeed
condition. The bolt/striker strikes a pawl and
thus opens the auxiliary trip fluid circuit and
in turn trip fluid circuit so that the stop and
control valves immediately interrupt the
admission of steam to the turbine. Perfect
BHEL Haridwar
5.1-0922-00/1
5.1-0922-00/2
Steam Turbine
Description
Function
The purpose of the low vacuum trip is to
operate the main trip valve when a failure
of vacuum occurs in the condenser, thus
tripping out the main and reheat stop and
control valves and shutting off the supply
of steam to the turbine within the shortest
possible time.
Operation
The condenser vacuum is connected via I
(connection to condenser) to the top side
of the diaphragm (8). The space below the
diaphragm is at atmospheric pressure.
Upon failure of the condenser to maintain
proper vacuum, diaphragm (8) is forced
downwards by the increase in pressure
and the force of the spring (7) against the
force of spring (10), thus moving valve (9)
downwards. This establishes a connection
between x1 (control fluid) and drain c so
that the auxiliary trip fluid circuit is
BHEL Haridwar
5.1-0935-00
Steam Turbine
Description
Technical Data
Bearing Metal Temperatures
Vibration, Weights
90 C
130 C
Operation temperature 75 to 85 C
100 C
130 C
Operation temperature 85 to 90 C
110 C
130 C
115 C
130 C
Vibration
Absolute bearing housing vibration
84 m
200 m
106 m
320 m
The normal level is the reproducible vibrational behaviour typical for the machine &
dependent on the operating conditions.
Vibration readings indicated in control room are peak to peak. The above values are also
given in peak to peak.
Weights
HP turbine, completely assembled
95 T
26 T
16 T
43 T
LP turbine, top half inner outer casing, complete with blading, guide blade carriers &
diffusers
37 T
16 T
23 T
100 T
Main stop and control valve, complete with servo motors, without bend & pipe section
22 T
Reheat stop and control valve, complete with servo motors, without bend & pipe
section
32 T
All weights have been calculated with safety allowances. Slings chosen must provide sufficient
security.
BHEL Haridwar
5.1-0102-63
Steam Turbine
Description
Function
The function of the condenser safety device
situated in the control fluid circuit of the
bypass control system is to protect the
condenser, when there is an excessive
increase in pressure in the condenser, by
opening the control fluid lines so that the
resulting drop in pressure causes the
bypass valves to close.
Mode of Operation
The steam space in the condenser is
connected with the spring space above the
diaphragm (5) via connection I. The space
below the diaphragm is at atmospheric
pressure. If the pressure in the condenser
increases excessively, the diaphragm (5),
and thus the valve (6), is forced downwards
out of the upper end position by the
increasing pressure and the force of the
spring (4). This shuts off the connection a1
to the bypass valve from connection. a
which is from the converter and connects it
to drain c.
The pressure range in which the vacuum
safety device operates can be varied by
adjusting the initial tension of the spring (4)
by means of the adjusting screw (2).
During commissioning the valve (6) is
automatically moved into the upper end
position, where it keeps the control fluid
circuit closed, as soon as the negative
pressure in the condenser falls below the
preset value. In order to be able to close the
control fluid circuit when there is still
insufficient vacuum in the condenser, the
valve is lifted via the lever (10) and cam (9)
but is not yet brought into its upper end
position. As already mentioned, this end
position is not reached until there is
sufficient vacuum.
After this, the lever (10) and cam (9) drop
down and do not impair the functioning of
the vacuum safety device. Any leakage fluid
can drain off through passages in the valve
sleeve (7) and the casing (8).
BHEL Hardwar
5.1-0940-00
Steam Turbine
Description
Function
When there is an unallowable rise in
condenser temperature due to lack of
injection water a temperature sensor
situated in the condenser dome sends
electric signals to the solenoid valve which
open the signal fluid circuit of the bypass
valve actuators, thereby closing the bypass
valves so that the steam flow to the
condenser is interrupted.
Mode of Operation
During normal operation, the control fluid a
holds the main control valve (7) against the
force of the compression spring (8) in the
center position as shown here, This provides
the connection between the signal fluid from
pressure switch for injection water b and
the stop and control valve operator of the
bypass stop valve b1 , If the temperature in
the condenser rises to an unallowable value,
the solenoid valve (3) is moved downwards
against the force of the compression spring
(4) so that the control fluid a arising before
the main control valve (7) is connected with
the drain c.
Simultaneously, the control fluid a can flow
behind the main valve (7) so that the main
valve moves forwards against the force of
the compression spring (6) and the signal
fluid circuit b1 is opened and connected to
the drain c and the bypass stop and control
valve closed.
BHEL Hardwar
5.1-0950-00
Steam Turbine
Description
Function
With normal shut down or tripping of the
machine, the function of the vacuum
breakers is to cause an increase in
condenser
pressure
by
conducting
atmospheric air into the condenser together
with bypass steam flowing into the
condenser from the bypass station. When
the pressure in the condenser increases, the
ventilation of the turbine blading is
increased, which 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.
Total Vacuum Breakers
In special cases requiring a rapid shut down
of the turbo set, the total vacuum breaker is
employed.
Electrical Control of Total Vacuum
Breaker
So that the vacuum can also be broken
without limitation due to condenser
pressure, a manual key is provided. This key
opens the vacuum breaker valve. However,
it can not go into the closing position until
the close key provided for closing is used.
This control enables a complete equalization
of condenser and ambient pressure.
Automatic Control
The vacuum breaker is also actuated
automatically by the turbine fire protection
system to shut the turbo set down more
quickly. It is switched back manually using
the close key in this case.
Mode of Operation of Vacuum Breaker
When the magnet is not excited, the
solenoid valve is switched to open. The
control medium arising holds the vacuum
breaker valve in the closed position by
means of the power piston. When the
pressure drops the vacuum breaker is
opened by spring force.
BHEL Haridwar
5.1-0960-00/1
Opening Process
When the magnet is excited the control
medium is without pressure so that the
control medium in front of the solenoid valve
is connected with the drain c. The piston (3)
and thus the valve disc (19) are moved
upwards by the force of the spring (5) (Fig.
2).
Closing Process
When the magnet is not excited the valve is
closed by the control medium arising. The
pressure of the control medium a via the
piston (3) presses seal ring (17) arranged in
the valve disc (19) on to the valve seat (20)
against the force of the compression spring
(5).
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Piston cover
Stop
Piston
Valve stem
Compression spring
Piston bottom
Limit switch
Spacer column
Cap nut
Gland seal
Pecking
Valve cover
Bushing
Valve calling
Screw coupling
Divided ring
Seal ring
Disc guide
Valve disc
Valve seat
a Control medium
I Inlet for atmospheric air
I1 Atmospheric air flowing into condenser
5.1-0960-00/2
Steam Turbine
Description
Function
The pressure switch monitors the injection
water pressure. When the injection water
pressure drops below the set rated value,
the control fluid is interrupted and thus the
LP bypass valve closed.
Construction
The pressure switch consists of a casing in
which a measuring system, a counterconnected system for adjusting the rated
value, a knife-edged lever (4), a nozzle (11)
and a slide valve (12) are installed.
The measuring system consists of bellows
(2) upon which the injection water pressure
I acts and these influence the knife-edged
lever (4) via a pushrod (3). The cylindrical
pin (10) is the pivot point of knife-edge lever
(4). The compression spring (6), the tension
BHEL Hardwar
Pressure Switch
for Injection Water
5.1-0970-00
Steam Turbine
Description
Changeover Valve
for Testing Device
Function
The function of the changeover valve is to
shut off the flow of trip fluid into the trip
fluid circuit while the protective devices
are being tested for proper operation by
means of the Automatic Turbine Tester
(ATT) and to allow control fluid a to flow
in so that the stop valves do not close
when the safety devices respond.
Mode of Operation
During normal operation, the control fluid
a1 in the space under the lower piston
(8) of the changeover valve keeps the
valve in the upper end position shown
here. In this way, connection x is
connected with connection x1 and trip
fluid can flow into the trip fluid circuit. The
space above the piston (6) (connection
a) remains depressurized during normal
operation.
When safety devices are checked for
proper operation, the space below the
lower piston (8) is depressurized by
means of a solenoid valve and control
fluid a enters the space above the upper
piston, which moves the valve into the
lower position. Due to the connection now
made between connections a and x1,
control fluid a can flow freely into the trip
fluid circuit, which keeps the stop valves
open for the duration of the test. Two limit
switches (1) transmit the position of the
valve to the control room.
1
2
3
4
5
6
7
8
Limit switch
Piston rod
Seal
Bushing
Inset
Upper piston
Sliding bushing
Lower piston
BHEL Haridwar
9 Body
10 Cover
a Control fluid
a1 Control fluid
c Fluid drain
x Trip fluid from
tripping device
x1 Trip fluid to trip
fluid circuit
5.1-0980-00
Steam Turbine
Description
MAV51 AA001
MAV41 BC001
MAV41 BC002
MAV41 AA521
MAV41 AA001
MAV42 BT001
MAV42
MAV22 AP001
MAV23 AP001
see below
see below
BHEL,HARDWAR
5.1-1000-63/1
Oil coolers
oil cooler 1
oil cooler 2
MAV41 BC001
MAV41 BC002
Technical Data
The Technical
information:
Data
contain
the
following
5.1-1000-63/2
-
The
INJECTOR
(MAV21BN001
/
MAV21BN002) ensure a positive pressure of
approx. 0.2 bar in the suction line immediately
upstream of the main oil pump.
5.1-1000-63/3
5.1-1000-63-4
Steam Turbine
Description
Technical Data
Oil Supply, Oil Pumps
OIL supply
3
25/40
53
32
No.
No.
Min.
Normal
Max.
38
45
47
Max.
75
Normal
Max.
20
25
0.8
dm /s
15.4
dm /s
4.55
dm /s
9.29
dm /s
7.92
dm /s
7.92
dm /s
0.70
dm /s
57.4
dm /s
No.
37
250
200
bar
178
bar
BHEL Haridwar
5.1-0103-63/1
Oil vapour extractors and oil separator
oil vapour extractor1
MAV82 AN001
oil vapour extractor2
MAV82 AN002
throttle valve upstream of
MAV82 AA511
oil vapour extractor1
throttle valve upstream of
MAV82 AA512
oil vapour extractor2
check valve of
MAV82 AA001
oil vapour extractor1
check valve of
MAV82 AA002
oil vapour extractor2
oil separator
MAV82 BT001
Throttle valves downstream of bearing
pedestals
bearing pedestal 1
MAV81 AA501
bearing pedestal 2
MAV81 AA503
bearing pedestal 3
MAV81 AA505
gen. brg. pedestal
MAV81 AA507
exciter bearing pedestal
MAV81 AA511
Throttle valves of oil return lines
throttle valve
MAV81 AA521
throttle valve
MAV81 AA522
Description and function of components of the oil
vapour extraction system
The components of the oil vapour extraction system
and their function are described in the following :
BHEL, Hardwar
5.1-1001-63/1
No
37
Jacking oil pump must be in operation at turbine speeds below approx. 510 rpm to avoid
damage to bearings.
Jacking oil pump should be cut-out at speeds above approx. 540 rpm.
Oil pumps
Main oil
pump
Auxiliary oil
pump
DC emergency
oil pump
Quantity
AC: 1
Make
BHEL
KBL
M&P
Tushaco
Type
350m3/hr
KPDS 125/26L
4/5 SR 12KL
Model 70
T 38/46
100
30
1.85
dm /s
Discharge
pressure
8.4
6.3
2.3
178
bar
gauge
Speed
3000
2970
1500
2900
rpm
Drive
Turbine
AC motor
DC motor
5.1-0103-63/2
DC: 1
AC motor
DC motor
Steam Turbine
Description
Technical Data
Control Fluid System &
Control Fluid Pumps
10/16
15
12
No.
No.
Make: Tushaco
Fluid flow
0.25
dm /s
Gauge pressure
bar
speed
23.42
rpm
Motor power
0.55
KW
BHEL, HARIDWAR
5.1-0104-63-1
Manufacturer
Speed
2982
Drive
Enclosure
IP 55
Voltage
415
Frequency
50
Hz
132
KW
148
KW
Rated current
217
Starting current
1614
Nos.
rpm
Fluid flow
3
(dm /s)
Discharge
Pressure (bar)
7.6
11.5
6.16
38.5
20.60
10.8
6.16
37.8
7.60
10.6
16.16
31.6
5.1-0104-63-2
Steam Turbine
Operation
Technical Data
Limit Curves
120
Heating up
100
F
80
N
60
40
OPERATION MODE
F=Fast
N=Normal
S=Slow
[K]
20
0
-20
-40
Cooling down
-60
-80
100
200
300
400
500
600
m [C]
BHEL Haridwar
5.1-0110-01
Steam Turbine
Operation
Technical Data
Limit Curves
140
= f(m)
120
Heating up
100
80
60
N
40
OPERATION MODE
F=Fast
N=Normal
S=Slow
[K]
20
0
-20
-40
Cooling down
-60
-80
100
300
400
m =
BHEL Haridwar
200
500
600
m [C]
5.1-0111-01/1
140
= f( m )
120
100
Heating up
80
60
40
OPERATION MODE
F=Fast
N=Normal
S=Slow
20
[K]
0
-20
-40
Cooling down
-60
-80
0
100
200
300
400
500
m [C]
5.1-0111-01/2
600
Steam Turbine
Operation
Technical Data
Limit Curves
160
f (m)
Heating up
140
120
100
[K]
80
60
40
OPERATION MODE
F = Fast
N = Normal
S = Slow
20
0
-20
-40
Cooling down
-60
-80
0
100
200
300
400
500
600
m [C]
220
200
180
160
[K]
140
120
100
80
60
0
o
m
ax
BHEL Haridwar
=
=
=
=
20
40
60
80
100
120
ax [ C]
5.1-0112-01/1
140
f (m)
Heating up
120
100
80
[K]
60
40
20
OPERATION MODE
F = Fast
N = Normal
S = Slow
0
-20
-40
-60
Cooling down
-80
-100
0
100
200
300
400
500
600
m [C]
200
180
160
140
[K]
120
100
80
60
40
0
o
m
ax
5.1-0112-01/2
=
=
=
=
20
40
60
80
100
120
ax [ C]
Steam Turbine
Operation
Technical Data
Limit Curves
160
f (m )
Heating up
140
120
100
N
80
[K]
60
40
OPERATION MODE
F = Fast
N = Normal
S = Slow
20
0
-20
-40
Cooling down
-60
-80
0
100
200
300
400
500
m [C]
600
220
200
180
160
140
[K]
120
100
80
60
0
o
m
ax
BHEL Haridwar
=
=
=
=
20
40
60
80
100
120
ax [C]
5.1-0113-01
Steam Turbine
Description
The deposits which occur in turbines due to
impurities in the steam can lead to
thermodynamic and mechanical inefficiencies
and, with the presence of salts, especially
chlorides, and sodium hydroxide also cause
damage to turbine parts. The corrosion
stressing caused by active deposits, for
example, has an adverse effect on the fatigue
strength of the blade material when the steam
is in the transition zone between the
superheated and the saturated state.
Compliance with the target values is
mandatory in continuous operation, with the
values in the normal operation column
preferable. With the commissioning of a new
plant and starting-up operation, however,
these values cannot be attained with an
economical outlay. The values listed in the
column starting-up operation are then valid.
It should be pointed out that adherence to the
target values does not rule out deposition in
the turbine with absolute certainty. Wherever
possible every effort should be made to
Target Value
*
Normal
Operation
Start Up
**
S/cm
< 0.2
0.1
< 0.50
Silica
(SiO2)
mg/kg
< 0.020
0.005
< 0.050
Total iron
(Fe)
mg/kg
< 0.020
0.005
< 0.050
Total copper
(Cu)
mg/kg
< 0.003
0.001
< 0.010
Sodium
(Na)
mg/kg
< 0.010
0.002
< 0.020
* To avoid any drop in efficiency, it is recommended that values be kept below the target values
and into the range of the values for normal operation.
** The target values must show a noticeable downward trend. On initial start-up of new plants the
values given for normal operation must be achieved within 2 to 3 days and within 2 to 3 hours
for other start-ups.
BHEL Haridwar
5.1-0120-01
Steam Turbine
Description
Oil Specification
Standard
Introduction
This standard specifies the turbine oil
recommended for use in governing and
lubrication systems of BHEL make steam
turboset.
Description
Oil of viscosity class ISO VG 46 shall be
used. The oil shall be a petroleum product
with or without additives to meet the
requirement of this standard. The finished oil
shall be clear and free from water,
suspended matter, dust, sediment and other
impurities.
The turbine oil shall not contain additives
having any negative effect on the materials
of the oil system. The turbine oil must be
capable of withstanding bearing temperature
of max. 130C and oil tank temperature of
max. 80C without physical and chemical
degradation.
The properties of the oil shall not be affected
by centrifuging, water washing or filtering.
Compatibility
For topping up of the oil system, it is
preferable if the oil used is of the same
brand and quality as that already in the
system. However, if the same brand of oil is
not available and where it is intended to mix
in different products that individually conform
to this standard, a compatibility test should
be conducted before actually mixing the oils.
Samples of both the oils in equal volume
should be mixed and centrifuged for about
40 hrs. and then mixture must comply fully
with the requirements of this standard.
Properties
The oil should comply with the
requirements given in table below when
tested according to the test methods given
in the respective standards mentioned
against each property. For obvious
reasons, we do not give any special
recommendation to a particular brand of oil
to be used in the oil system of our turbo
sets. Any brand of the oil complying with
the above standards may be used.
Properties
Value
Unit
1.
41.4 50.6
cst
28
cst
2.
Viscosity Index
98
3.
Neutralization No.
acidity)
4.
Colour
5.
Test Method
IS: 1448, P-25
ASTM D445
Min.
-----
mg
KOH/g
ASTM D974
Max.
ASTM D1500
Specific gravity at 50 C
Specific gravity at 15 C
0.85
---
ASTM D1298
0.90
---
6.
> 200
ASTM D92
7.
---
-----
8.
Pour point
-6
ASTM D97
9.
Rust preventing
characteristics
0-B
---
DIN: 51585
ASTM D665
BHEL Haridwar
(Total
0.20
5.1-0130-04/1
Properties contd.
Sl. No.
Properties
Value
Unit
Test Method
10.
Emulsion characteristics
20
minute
DIN: 51599
ASTM D1401
11.
0.2
mg
KOH/g
DIN: 51587
ASTM D943
12.
Foaming characteristics at
25C
- Foaming tendency
-----
ASTM: D892
- Foaming stability
400
cm
450 s
s
minutes
DIN: 51381
ASTM: D3427
13.
14.
0.01
IS:1448, P-4
-----
15.
0.01
DIN: 51777-1
ASTM: D1744
16.
0.05
DIN: 51592
-----
17.
Particle distribution
-/17/14
Minimum
ISO: 4406
(Class-8)
18.
Water release
(NAS: 1638)
300
DIN: 51589-1
Brand
Supplier
Brand
lOC
Servo Prime 46
Gulf Crest 46
Bharat Petroleum
Turbol 46
Apar Ltd.
Power Turbo-46
Caltex
Regal R&O 46
Savita Chemicals
HPCL
Turbinol 46
TOTALFINAELF
Total Preslia 46
5.1-0130-04/2
Steam Turbine
Description
This specification is valid for Fire Resistant
Fluids (FRF) recommended for BHEL
make steam turbine control system.
According to ISO 6743/4, FRF is a fluid
based on triarylphosphate ester marked
ISO-L-HFDR.
General Requirements
Limit values
Disposal
BHEL Haridwar
5.1-0140-04/1
Numerical
Value
Unit
2
Test method
DIN / ISO
ASTM
Kinematic Viscosity at 40 C
(ISO VG 46)
41.4 - 50.6
mm /s
DIN 51 562-1
D 445
Air release at 50 C
minutes
DIN 51 381
D 3427
Neutralisation number
0.1
mg KOH/g
DIN 51 558-1
D 974
Water content
1000
mg/kg
DIN 51 777-3
Tendency
100
ml
Stability
450
sec
Water separability
300
sec
Demulsification
20
minutes
Foaming at 25 C
D 892
(Seq. 1)
DIN 51 589-1
DIN 51 599
D 1401
DIN 51 757
D 1298
D 92
Density at 15 C
1250
kg/m
> 235
DIN/ISO 2592
Ignition temperature
> 550
DIN 51 794
sec
DIN/ISO 14935
Pour point
18
DIN/ISO 3016
Particle distribution *
15/12
Code
ISO 4406
Chlorine content
50
mg/kg
DIN 51 577-3
Oxidation stability
2.0
mg KOH/g
DIN 51 373
Hydrolytic stability
Change of neutralisation number
2.0
mg KOH/g
DIN 51 348
Electrical resistivity
> 50
Mm
IEC 247
D 97
* The required system cleanliness is dependent upon the system design. Suitable measures (e.g.
filtration, separation) have to be taken to achieve this cleanliness level.
5.1-0140-04/2
Steam Turbine
Description
HP Turbine
Valve Arrangement
General Arrangement
The HP turbine has 2 main stop valves and 2
control valves located symmetrically to the right
and left of the casing. The valves are arranged
in pairs with one main stop valve and one
control valve in a common body.
Valve Actuation
Steam flow
The main steam is admitted
steam inlet passing first the
and then the control valves.
valves the steam passes
casing(1).
BHEL Haridwar
5.1-0205-00
Steam Turbine
Description
HP Turbine
Casing
Seals
The pretensioned U-shaped seal ring(12),
that is forced against the axial sealing surfaces
by the steam pressure and the I shaped seal
ring (16), that allows axial displacement of the
inner casing (4), seal the space between the
inner casing (4) and the barrel type outer casing
(3) from the adjacent spaces.
Fig. 1 HP Turbine
BHEL Haridwar
5.1-0210-01/1
Outer casing
Inner casing
U seal ring
Cylindrical pin
Breech nut
Inlet pipe from main stop and control valve
3 Outer casing
4 Inner casing
11 Fitted Key
3 Outer casing
4 Inner casing
10 Fitted Key
Fig.
4 Centering
and support
of
Fig.
4 Centering
and support
inner casing (Exhaust side)
of
Outlet Connections
The exhaust end of HPT has single outlet
connection from bottom. At the flange
connection a U-seal ring (19) is provided to
prevent any leakage (Fig.1)
3 Outer casing
4 Inner casing
12 U- seal ring
3
4
16
17
18
Outer casing
Inner casing
I-seal ring
Holding ring
Hexagon head screw
13 Thrust pads
14 Thrust pads
15 Support ring
Fig. 6 Axial Retention ofInner casing and Centering in vertical plane (Detail E from Fig.1)
5.1-0210-01/3
HP Turbine
Blading
Steam Turbine
Description
Moving and Stationary Blades
The HP turbine with advance blading consists of
17drum stages. All stages are reaction stages
with 50% reaction. The stationary and moving
blades of all stages (Fig.1) are provided with
inverted T-roots which
2
3
.
B
4
Gap sealing
Fig. 1 Drum Stages
1 Inner casing
2 Guide blade
3 Moving blade
4 Turbine shaft
5 Caulking piece
BHEL Haridwar
5.1-0220-02
Steam turbine
Description
Function
HP Turbine
Shaft seals and Balance Piston
Seal Rings
1
3
4
5
6
Gap Seals
5.1-0230-01/1
5.1-0230-01/2
Steam Spaces
Steam spaces are provided within the shaft
seals. From spaces Q and R leakage is drawn
off to another part of the turbine for further use.
The steam seal header is connected to space
S. The slight amount of leakage steam which
are still able to pass the seal ring are conducted
from the space T into the seal steam
condenser.
Steam Turbine
Description
Arrangement
The front bearing pedestal is located at the
turbineside end of the turbine generator unit. Its
function is to support the turbine casing and
bear the turbine rotor. It houses the following
components and instruments.
HP Turbine
Front Bearing Pedestal
Connection
Foundation
of
Bearing
Pedestal
and
1 Bearing pedestal
2 Main oil pump
3 Hydraulic speed transducer
4 Electric speed transducer
5 Gear coupling
6 Over speed trip
7 Hydraulic
turning
gear
7 Hydraulic
turning
gear
8 Bearing
8 Bearing
pedestal
pedestal
vibration
vibration
pick-up
pick-up
9 Shaft
vibration
pick-up
9 Shaft
vibration
pick-up
10 10
Journal
bearing
Journal
bearing
11 11
HPHP
turbine
rotor
turbine
rotor
12 12
Foundation
Foundation
BHEL Haridwar
5.1-0240-01/1
10 Journal bearing
Also refer to the following information
12 Foundation
13 Anchor bolts
14 Hex head screw
5.1-0240-01/2
Staem Turbine
Description
HP Turbine
Rear bearing Pedestal
Arrangement
The bearing pedestal is located between the
HP and IP turbines. Its function is to support the
turbine casing and bear the HP and IP turbine
rotors.
The bearing pedestal houses the following
turbine
components:
Combined journal and thrust bearing
Shaft vibration pick-up
Bearing pedestal vibration pick-up
Thrust bearing trip (electrical)
Details of casing supports and casing guides
are given in descriptions 5.1-0280 and 5.1-0350.
Connection
Foundation
of
Bearing
Pedestal
and
1
2
3
4
5
6
7
8
HP turbine rotor
Combined journal and thrust bearing
Bearing pedestal vibration pick-up
Shaft vibration pick-up
Thrust bearing trip (electrical)
Coupling bolts
IP turbine rotor
Foundation
BHEL Haridwar
5.1-0250-02/1
10
11
12
13
14
15
Straight pin
Anchor bolt
Plate
Round nut
Hex nut
Guard cap
5.1-0250-02/2
Steam turbine
Description
Combined
Bearing
Function
The function of the combined journal and
thrust bearing is to support the turbine rotor and
to take the residual axial thrust. The magnitude
and direction of axial thrust to be carried by the
bearing depends on the load conditions of the
turbine. This bearing is located in the bearing
pedestal between HPT & IPT. The thrust bearing
maintains desired axial clearances for the
combined turbine generator shaft system.
BHEL Haridwar
8 Turbine shaft
9 Brg. pedestal
lower
10 Key
11 Oil line
Journal
and
Thrust
12 Bearing shell,lower
13 Shim
14 Spherical block
15 Shim
16 Spherical support
25 Key
a Shaft jacking oil
5.1-0260-01/1
19 Thermocouple
20 Thermocouple
Oil Supply
Lubricating oil is admitted to the bearing
shells from one side via oil line (11) from where
it flows to the oil spaces milled into the upper
and lower bearing shells at the horizontal joint.
5.1-0260-01/2
21 Spring
22 Key
23 Dowel pin
Steam Turbine
Description
Construction
The function of the journal bearing is to
support the turbine rotor. Essentially the journal
bearing consists of the upper and lower shells
(3,6), bearing cap (1), spherical block (7),
spherical support (14) and the key (11) .The
bearing shells are provided with a babbit face.
The babbit surface of the bearing is precision
machined and additional scraping is neither
necessary nor permissible. Both bearing shells
are fixed by means of taper pins and bolted
together.
In order to prevent the bearing from exerting a
bending moment on the rotor (5), it is pivotmounted in the spherical support (14). For this
purpose the spherical block (7) with shims
(12,13) is bolted to the bearing shell (6) . A
projection in cap (1) with shims (9) fits into a
Journal Bearing
HP front
bearing shells. Keys (8) are fitted on both
sides of the projection.
The bearing shells are fixed laterally by key (11)
which are bolted to each other. Each key is held
in position in the bearing pedestal (10) by two
lateral collars. The temperature of the bearing
bodies is monitored by thermocouples (19) as
shown in section c-c.
Oil Supply
Lubricating oil is admitted to the bearing shells
from one side and flows to oil spaces that are
milled into the upper shell at the horizontal joint
and are open to the rotor. The rotor (5) picks up
oil from oil pocket machined into the babbitting
.The oil emerges from the bearing shell where it
is collected in the oil return cowling (4) and
drained into the bearing pedestal(10).
1
2
3
4
5
Cap
6 Lower baering shell
Tab Washer
7 Spherical block
Upper bearing shell 8 Key
Oil return Cowling
9 Shim
Turbine Rotor
10 Bearing pedestal
BHEL Haridwar
11
12
13
14
15
Key
Shim
Shim
Spherical support
Shim
5.1-0270-01/1
Jacking oil
As shown in Detail B, a threaded nozzle( 17)
is arranged at the lowest point of the lower
bearing shell (6) through which high pressure lift
oil is supplied to the space below the journals
when the rotor is turning at low speed (on startup and shutdown).This high pressure oil floats
the shaft to prevent dry friction and overcome
breakway torque during start-up on the hydraulic
turning gear.
A seal (18) prevent high pressure oil from
penetrating the space between threaded nozzle
and ring (16) and thus from lifting the babbit.
Any leakage oil can drain through passages in
the bearing shell below the ring.
5.1-0270-01/2
16 Ring
17 Threaded nozzle
18 Sealing ring
19 Thermocouple
Steam Turbine
Description
Supports
The turbine casing is supported on the support
horns such as to make allowance for the thermal
expansion. It is essential for the casing to retain
concentric alignment with the rotor, which is
supported independently.
1
2
3
HP Turbine
Casing Supports and Guides
The turbine casing (2) is supported with its two
front and two rear support horns on the horn
supports of the bearing pedestal (1,3) at the
turbine centerline level. This arrangement
determines the height of the casing and also
allows thermal expansion to take place in the
horizontal plane by the support horns
BHEL Haridwar
5.1-0280-01/1
Fixed Point
The fixed point for the turbine casing (2) is
located at the horn support on HP-IP pedestal at
the turbine centerline level and is formed by the
parrallel keys (16). Axial expansion of the
turbine casing (2) originates from this point.
10
11
12
13
14
15
16
Sliding piece
Plate
Parallel key
Scale indicating casing expansion
Sliding piece
Plate
Parallel key
5.1-0280-01/2
Steam Turbine
Description
Double Shell Construction
The casing of the IP turbine is split
horizontally and is of double shell construction.
A double-flow inner casing (3,4) is supported
in the outer casing (2,5) (Fig.1) Steam from
the HP turbine after reheating enters the inner
casing from top and bottom through two
admission branches which are integral with the
mid section of the outer casing. This
arrangement provides opposed double flow in
the two blade sections and compensates axial
thrust. The centre flow prevents the steam
inlet temperature from affecting the support
horns and bearing sections.
IP Turbine
Casing
The provision of an inner casing confines
the steam inlet conditions to the admission
section of this casing. While the joint flange
of the outer casing is subjected only to the
lower pressure and temprature effective at the
exhaust from the inner casing. This means
that the joint flange can be kept small and
material concentrations in the area of the
flange reduced to a minimum. In this way,
difficulties arising from deformation of a casing
with flange joint due to non uniform
temperature rise e.g. on start-up and shut
down, are avoided. The joint of the inner
casing is relieved by the pressure in the outer
casing so that this joint has to be sealed only
against the resulting differential pressure.
BHEL Haridwar
5.1-0310-01/1
5.1-0310-01/2
5.1-0310-01/3
IP Turbine
Blading
Steam Turbine
Description
Gap SealIng
Sealing strips (7) are caulked into the inner
casing (1) and the rotor (4) to reduce leakage
losses at the blade tips. Cylindrically machined
surfaces on the blade shrouds are opposite the
sealing strips. These surfaces have stepped
diameters in order to increase the turbulence of
the steam and thus the sealing effect. In case of
an operation disturbance, causing the sealing
strips to come into contact with opposite surfaces,
they are rubbed away without any considerable
amount of heat being generated. They can then
easily be renewed at a later date to provide the
specified clearances.
1 Inner Casing
2 Guide Blade
3 Moving Blade
4 Turbine Shaft
5 Caulking piece
6 Sealing strip
7 Caulking wire
7
5
BHEL Haridwar
5.1-0320-02
Steam Turbine
Description
Function
The function of the shaft seals is to seal the
interior of the turbine casing against the
atmosphere at the front (thrust bearing end) and
rear shaft penetrations of the IP turbine.
The shaft seals are axial-steam-flow noncontacting seals.
In the region subject to low relative
expansion in the vicinity of the combined journal
and thrust bearing, the seal strips are caulked
alternatively into the shaft and into springsupported segmented rings in the casing,
forming a labyrinth to impede the outflow of
steam.
In the region subject to greater relative
expansion at the exhaust end, see-through seals
are used, in which the seal strips are located
opposite each other,
BHEL Haridwar
IP Turbine
Shaft Seals
5.1-0330-01/1
Seal Rings
The seal rings (3), the number of which
depends on the pressure gradient to be sealed
are divided into several segments as shown in
Section BB and mounted in grooves in the rings
such that they are free to move radially. Each
segment is held in position against a shoulder by
helical springs (6) and by the steam pressure
above the seal rings (3). This provides the
proper clearance for the seal gaps. Should
rubbing occur the segments concerned can
retreat. The heat developed by light rubbing of
the thin seal strips (9) is so slight that it cannot
cause deformation of the rotor (4).
5.1-0330-01/2
IP Turbine
Steam Turbine
Description
RearBearing Pedestal
Arrangement
The bearing pedestal is located between the
IP and LP turbines. Its function is to support the
turbine casing and bear the weight of IP and LP
rotors.
The bearing pedestal houses the following
turbine components:
Journal bearing
Shaft vibration pick-up
Bearing pedestal vibration pick-up
Hand barring arrangement
Connection
Foundation
of
Bearing
Pedestal
and
BHEL Haridwar
5.1-0340-02
Steam Turbine
Description
Construction
The function of the journal bearing is to support
the turbine rotor. Essentially, the journal bearing
consists of the upper and lower shells (3, 6),
bearing cap (1), torus piece (7), cylindrical
support (14) and the keys (10). The bearing
shells are provided with a babbit face which is
precision machined. Additional scraping is
neither necessary nor permissible. Both bearing
shells are fixed by means of taper pins and
bolted together.
In order to prevent the bearing from exerting a
bending moment on the rotor (5), it is pivotmounted in the cylindrical support (14). For this
purpose, the torus piece (7) with shims (12, 13)
is bolted to the bearing shell (6). A projection in
cap (1) with key (9) fits into a corresponding
groove in the bearing shell (3) and prevents
vertical movement of the bearing shells.
Centering of the bearing shells in the vertical
plane is achieved by means of keys (8).
BHEL Haridwar
Oil Supply
Lubricating oil is admitted to the bearing shells
from both sides, from where it flows to oil spaces
milled into the upper and lower shells at the
horizontal joint that are open to the rotor end. Oil
from the oil space machined in the babbitting is
carried through the rotor (5) and emerges from
the bearing shell from where it is collected in the
oil return cowling (4) and drained into the
bearing pedestal (11).
5.1-0345-01/1
Jacking Oil
As shown in section B-B, two threaded
nozzles (17) are arranged at the lowest point of
the lower bearing shell (6) through which high
pressure oil is supplied to the space below the
journal when the rotor is turning at low speed
(on start-up and shutdown). This high pressure
oil floats the shaft to prevent dry friction and
overcome breakaway torque during startup, thus
reducing torque requirements of the hydraulic
turning gear.
A seal (18) prevents high pressure oil from
penetrating the space between threaded nozzle
and ring (16) and thus from lifting the babbit.
Any leakage oil can drain through passages in
the bearing shell below the ring.
Removal of Bearing Shells
Not only the upper shell (3) but also the lower
bearing shell (6) can be removed without the
removal of rotor (5). To enable this to be done,
the shaft is lifted slightly by means of jacking
device but with in the clearance of the shaft
seals. The lower bearing shell can then be
turned upwards to the top position and removed.
5.1-0345-01/2
Steam Turbine
Description
IP Turbine
Casing Supports and Guides
BHEL Haridwar
5.1-0350-01/1
5.1-0350-01/2
Fixed Point
The fixed point for the turbine casing (2) is
located at the front horn support at the turbine
centerline level and is formed by the parallel
keys ((7;10). Axial expansion of turbine casing
(2) originates from this point
Steam Turbine
Description
LP Turbine
Casing
Construction
The LP turbine casing consists of a doubleflow unit and has a triple shell welded casing.
The outer casing consists of the front and rear
walls, the two lateral longitudinal support
beams and the upper part. The front and rear
walls as well as the connection areas of the
upper part are reinforced by means of circular
box beams. The outer casing is supported by
the ends of the longitudinal beams on the base
plates of the foundation.
1
2
3
4
Inlet Connections
Steam admitted to the LP turbine from the IP
turbine flows into the inner casing (4,5) from
both sides through steam inlet nozzles before
the LP blading Expansion bellows are
provided in the steam piping to prevent any
undesirable deformation of the casings due to
thermal expansion of the steam piping.
5
6
7
8
5.1-0410-00/1
5.1-0410-00/2
5.1-0410-00/3
5.1-0410-00/4
Steam Turbine
Description
BHEL Haridwar
5.1-0420-00
Steam Turbine
Description
LP Turbine
Blading, Drum Blading
Arrangement
The drum blading stages 1 to 3 of the double
flow LP turbine are of reaction type with 50%
reaction. They are Located in the inner-Inner
casing and form the initial stages of the LP
blading. The LP stages following these drum
stages are described in detail in next chapter.
Guide and moving blades
All guide and moving blades of drum stages
have integral shrouds, which after installation
form a continuous shrouding. The moving
blades (7) of the last drum stage are tapered
and twisted. All stationary and moving blades
have T -roots which also determine the
distance between the blades. They are
inserted into the matching grooves in the
turbine shaft (5) and inner casing (1) and are
caulked in place with
caulking material (6). The insertion slot in the
rotor is closed by means of a locking blade
which is secured in its position by means of
grub screws between shaft and lock blade .In
casing, blades at joint planes are fixed by
means of grub screws.
Inter stage Sealing
In order to reduce blade tip losses, tip to tip
sealings are provided in these stages. Thin
sealing strips (9) are caulked in inner casing
(1) and turbine rotor (5). The sealing fins are
machined on the shrouds of moving and
stationary blades opposite to the sealing strips
in inner casing or rotor (Detail A). In the event
of rubbing due to a fault , little heat will be
generated due to rubbing of thin sealing strips.
These can be renewed at a later date to
provide the correct radial clearances.
BHEL Haridwar
5.1-0430-01
Steam Turbine
Description
BHEL Haridwar
LP Turbine
Blading, Low Pressure Stages
5.1-0440-01/1
5.1-0440-01/2
Steam Turbine
Description
LP Turbine
Shaft Seals
Function
The function of the axial shaft seals situated
between the bearing casings and the LP
exhaust casing is to seal the inner space of
the LP exhaust casing against atmospheric
pressure at the passages through the shaft.
Gap Sealing
The sealing effect between the moving and
stationary parts of the turbine is achieved by
means of sealing strips (4) which are caulked
into the individual seal rings (2), The prevailing
pressure is reduced according to the labyrinth
principle by conversion into velocity with
subsequent turbulence in many sections.
Sealing Rings
The sealing rings (2), the number of which
depends on the pressure existing in the
turbine, are split into several segments as
shown in section A-A and arranged in Tshaped annullar grooves in the steam seal
casing (1) so that they can move radially.
Several helical sprir1gs (3) force each
segment against a shoulder and hold it in this
position. This permits the correct clearance in
the sealing gaps. Should rubbing occur, the
segments concerned retreat. The frictional
heat developed by the thin
BHEL Haridwar
5.1-0450-01
Steam Turbine
Description
LP Turbine
Rear Bearing Pedestal
Arrangement
The bearing pedestal is situated between
the LP turbine and generator. Its function is to
bear the weight of LP rotor.
The bearing pedestal
following turbine components:
contains
the
Journal bearing
of
Bearing
Pedestal
and
BHEL Haridwar
5.1-0460-02
Steam Turbine
Description
Journal Bearing
Construction
The function of the journal bearing is to
support the turbine rotor. Essentially, the
journal bearing consists of the upper and lower
shells (3, 6), bearing cap (1), torus piece (7),
cylindrical support (14) and the keys (10). The
bearing shells are provided with a babbit face.
The bearing bore is precision machined and
additional scraping is neither necessary nor
permissible. Both bearing shells are fixed by
means of taper pins and bolted together.
In order to prevent the bearing from
exerting a bending moment on the rotor (5), it
is pivot-mounted in the cylindrical support (14).
For this purpose, the torus piece (7) with
shims (12, 13) is firmly bolted to the bearing
shell (6). A projection in cap (1) with shims (9)
fits into a corresponding groove in the bearing
shell (3) and prevents vertical movement of
the bearing shells.. Centering of the bearing
shells in the vertical plane is achieved by
means of keys (8).
1
2
3
4
Cap
Tab washer
Upper bearing shell
Oil return cowling
BHEL Haridwar
5
6
7
8
Rotor
Lower bearing shell
Torus piece
Key
9 Shim
10 Key
13 Shim
14 Cylindrical support
11 Bearing Pedestal
12 Shim
5.1-0470-00/1
15
16
17
18
Termocouple
Ring
Threaded nozzle
Sealing ring
5.1-0470-00/2
Steam Turbine
Description
Arrangement
The hydraulic turning gear is situated
between the main oil pump and the journal
bearing in the HP turbine front bearing pedestal.
Function
The function of the hydraulic turning gear is
to rotate the shaft system at sufficient speed
before start-up and after shut-down in order to
avoid irregular heating up or cooling down and
thus avoid any distortion of the turbine rotors.
The air flow set up by the blades along the inner
wall of the casing during turning operation
provides good heat transfer conducive to
temperature equalization between upper and
lower casing halves.
Operation
During turning gear operation, the shaft
system is rotated by a blade wheel which is
driven by oil supplied by the auxiliary oil pump.
This oil passes via a check valve into the nozzle
box (1) and from there into the nozzles (2) which
direct the oil jet in front of the blading.
Return Oil Flow
After passing the blading, the oil drains into
the bearing pedestal and flows with the bearing
oil into the return flow line.
Manual Turning Gear
A manual turning gear is provided in addition
to the hydraulic turning gear to enable the
combined shaft system to be rotated manually.
Lifting of Shaft
To overcome the initial break-away torque on
start-up and to prevent dry friction, the bearings
are relieved during turning gear operation by
lifting oil supplied from below i.e. the shafts are
lifted slightly.
BHEL Haridwar
5.1-0510-01
Steam Turbine
Description
Function
The turbine generator is equipped with a
mechanical barring gear, which enables the
combined shaft system to be rotated manually
in the event of a failure of the normal hydraulic
turning gear.
It is located at IP - LP pedestal
Construction
The barring gear consists of a gear
machined on the rim of the turning gear wheel
(10) and pawl (6). This pawl engages the ring
gear and turns the shaft system when
operated by means of a bar attached to laver
(1). The pawl (6) is shown disengaged and the
lever (1) resting against a stop. The lever (1) is
held in position by latch (7).
BHEL Haridwar
Operation
Take the following steps to make the
barring gear ready for operation: Remove
cover (2) unlatches at (7) and attach a bar to
lever (1).
Barring of lever (1) will rotate the
combined turbine generator shaft system.
After barring has been completed, return
lever (1) and pawl (6) to the position shown in
figure and secure lever (1) by means of latch
(7) Replace cover (2).
The barring gear may only be operated
after the shaft system has been lifted with
high-pressure lift oil. If it is hard to start turning
by means of the mechanical barring gear, this
may be due to incorrect adjustment of the
jacking oil system or due to a rubbing shaft.
Before steam is admitted to the turbine.
corrective action must be taken
5.1-0520-01
Steam Turbine
Description
Function
When the turbine is started up or shut
down, the hydraulic jacking device is used to
maintain the oil film between rotor and
bearings. The high-pressure oil is forced under
the individual bearing, thus raising the rotor.
The necessary torque from the hydraulic
turning device or from the manual turning
device is reduced in this way. The highpressure oil also provides motive force to
hydraulic turning gear motor installed in front
bearing pedestal.
Speed Limit Values
In order to avoid damage to the bearings,
the jacking oil pump must be switched on
below a certain speed. The exact speeds for
switching on and off can be seen in the
Technical data 2-0103.
Jacking Oil Pump
The jacking oil pumps, one number AC
(13) and one number DC(14) are jack-screw
immersion pumps situated on the tank (10)
supply the high pressure oil for the lifting
device. The oil is drawn off directly by one of
the two pumps. The pressure oil piping of the
jacking oil pump that is not in operation is
closed by the check valve (12). In order
1 HP turblne
2 IP turblne
3 LP turblne
4 Generator
5 Exciter
6 Check Valve
7 Fine control valve
8 Pressure Limiting Device
9 Bypass Valve
10 Main Oil Tank
BHEL Haridwar
11
12
13
14
15
5.1-0530-63-02
Steam Turbine
Description
The turbine control system description for
500 MW steam turbine comprises the
following:
General Description
Start-up Procedure
Speed Control
Electrical Speed Measuring
Protective Devices
Overspeed Trip Test
Testing of Stop Valves
Bypass Control System (General)
Electro-hydraulic Bypass Control (Electrical
System)
Electro-hydraulic Bypass Control (Hydraulic
System)
Extraction Check Valve
Swing Check Valve in CRH line
Testing of Swing Check Valves in the Cold
Reheat Line
Automatic Turbine Tester, General
Automatic Turbine Tester, Protective
Devices
Automatic Turbine Tester, Stop Valves
HP Actuator
Electro-hydraulic Gland Steam Pressure
Control
Control System Diagram
List of Parts
Lubrication Chart
Lubrication Chart, Index
Turbine generator unit MAA50HA001
MAB50HA001and MAC10HA001 comprises
three-cylinder reheat condensing turbine
with condenser MAG10BC001 and a directdriven three-phase a.c. generator.
The turbine has a hydraulic speed governor
MAX46BY001 and an electric turbine
controller. The hydraulic speed governor
adjusts control valves MAA10+20AA002 and
MAB10+20AA002 by way of hydraulic
amplifier MAX45BY011 whilst the electric
turbine controller acts on these control
valves by way of electro-hydraulic converter
MAX45BY001.
Hydraulic amplifier MAX45BY011 and
electro-hydraulic converter MAX45BY001
are switched in parallel to form a minimum
gate. The system not exercising control is in
its maximum position.
BHEL Hardwar
General Description
5.1-0600-01/1
5.1-0600-01/2
Steam Turbine
Description
Mode of Operation
The turbine is started up and brought up to
speed with the assistance of the control
valves MAA10+20AA002 and MAB10+20
AA002. If the hydraulic controller is to
govern start-up, the reference speed setter
MAX46BY001 must be set to minimum
speed during this process. In this case the
speed reference from the electric controller
is at maximum. If conversely, start-up is to
be governed by the electric controller,
reference speed setter MAX46 BY001 is set
to maximum and the speed reference from
the electric controller to minimum. The
combined stop and control valves are closed
because the trip fluid circuit is not yet
pressurized. Turning hand-wheel KA01
clockwise
or
operating
motor
MAX47BY001M of start-up and load limiting
device MAX47BY001 in the close direction
releases spring KA06 in auxiliary follow up
piston KA08 via the linkage, thereby
preventing a buildup of auxiliary secondary
fluid pressure. The hydraulic amplifier
MAX45BY011 with follow-up pistons KA01
and KA02 is now in the control valves closed
position so that a buildup of secondary fluid
pressure is prevented when main trip valves
MAX51AA005 and MAX51M006 are latched
in.
Further turning of hand-wheel KA01 moves
pilot valve KA02 of start-up and load limiting
device MAX47BY001 further downwards,
admitting control fluid first into the start-up
fluid circuit and then into the auxiliary start
up fluid circuit. The start-up fluid flows to the
space above the pilot valve of test valves
MAX47AA011+012 and MAX47AA021+
022, forcing them down against the action of
the springs. The auxiliary start-up fluid
raises the pilot valves of main trip valves
MAX51AA005 and MAX51AA006, thereby
moving them into their normal operating
position and permitting trip fluid to flow to
test
valves
MAX47AA011+012
and
MAX47AA021+022 of the main stop valves
and reheat stop valves. At the same time,
overspeed
trip
release
devices
MAY10AA001 and 002 are latched in if they
have been tripped. The function of non
return valve MAX42AA011 is to interrupt
BHEL Hardwar
Start-up Procedure
5.1-0610-01/1
5.1-0610-01/2
Steam Turbine
Description
BHEL Hardwar
Speed Control
5.1-0620-01/1
5.1-0620-01/2
Steam Turbine
Description
BHEL Hardwar
Control System
Electrical Speed Measuring
5.1-0621-02
Steam Turbine
Description
Overspeed Trip
Two overspeed trips MAY10 AA001 and 002
are provided to trip/shut down the turbine in
the event of overspeed. Each trip device
consists of an eccentric bolt/striker fitted in
the emergency governor shaft with its center
of gravity displaced from the axis of rotation
and held In position against centrifugal force
by a spring up to an adjustable preset speed
of 10 to 12 % above the normal turbine
operating speed. At the preset overspeed,
centrifugal force overcomes the spring force
and the eccentric bolt/striker flies outwards
into its extended position. In doing so it
strikes the pawl which releases the piston of
the overspeed trip release device KA01.
Through combined spring force and fluid
pressure, the piston opens the auxiliary trip
fluid circuit to the main trip valves MAX51
AA005 and MAX51AA006.
Thrust-Bearing Trip
Thrust bearing trips MAD12CY011/012/013
are tripped electrically in the event of
excessive axial displacement of the turbine
shaft.
Pressure Switch
Installed in the trip fluid circuit are two
pressure switches MAX51CP011 and
MAX51CP012 which bridge the longtime
delayed relays of the reverse-power
protection system in such a way that the
generator is shut down by response of the
short-time delayed relays as soon as it
begins to motor. The annunciation Turbine
trip initiated is transmitted simultaneously to
the control room.
Remote Solenoid Trip
Remote solenoid trip is activated via
solenoid valves MAX52 AA001 and MAX52
AA002. The remote solenoid trip may be
initiated manually from the control room by
push button, by the electrical low-vacuum
trip or the thrust bearing trip or other
protective devices.
BHEL Hardwar
Protective Devices
5.1-0630-01/1
5.1-0630-01/2
Steam Turbine
Description
BHEL Hardwar
The buildup of pressure in the auxiliary startup medium circuit between the overseed trip
test device and the overspeed trip release
device can be followed at pressure gauge
MAX48CP501. When pilot valve KA02 is
then released, the auxiliary start-up medium
pressure returns to 0 pressure. The auxiliary
trip medium pressure must then remain at its
full value (readable at pressure gauge
MAX52CP501). If this is the case, pilot valve
KA03 may be released. The test is
completed. If, when valve KA02 is released,
the auxiliary trip medium pressure collapses,
pilot valve KA02 must be pushed
downwards again and must be held in this
position a little longer. It is essential that the
auxiliary trip medium pressure must remain
steady before valve KA03 is released.
5.1-0631-01
Steam Turbine
Description
Main Steam Stop Valves
The stop valves can be tested for freedom of
movement independently of each other even
during operation with the aid of the test
valves MAX47AA011 to 012 attached to
each of them. The main stop valves MAA10
and 20AA001 may only be tested at a load
that is less than 80% of the maximum
output.
If the test is conducted with the initial
pressure controller out of operation, the
main stop valves may only travel out of the
open position to about 50% closed at the
most and are to be reopened immediately. If
the initial pressure controller is in operation
complete closure of a main stop valve may
be performed. This, however, is conditional
upon the response time of the initial
pressure controller being high enough to
keep the initial pressure constant even
during the testing procedure.
First the main control valve concerned
MAA10 or 20AA002, is to be closed by
pressing of pushbutton in the supply unit. If
in operation, the initial pressure controller
opens the other main control valve
accordingly. Once the control valve has
been closed the stop valve can be closed. It
is to be reopened immediately.
BHEL Hardwar
5.1-0632-01
Steam Turbine
Description
Function
The function of the LP bypass control
system is to monitor the pressure in the
reheat system and to control it under certain
operating conditions. During start-up and
shutdown, and at operation below minimum
boiler load, the volume of steam not utilized
by the IP and LP cylinders of the turbine
must be bypassed to the condenser via the
LP bypass valves. This requires the bypass
control system to maintain the pressure in
the reheater constant in accordance with the
preset reference value. In the event of
disturbances, e.g. load shedding or trip out,
the amount of excess reheat steam
bypassed to the condenser depends on the
capacity of the condenser.
Mode of operation
In the electro-hydraulic LP bypass control
system, the electric controller governs a
number of hydraulic actuators. The link
between the electric controller and the
hydraulic part of the control system is
provided by the electro-hydraulic converter
in the form of a jet pipe amplifier controlled
by a plunger coil.
In order to monitor the flow-dependent
reheat pressure, irrespective of whether
fixed-pressure
or
variable-pressure
operation is used, the pressure before the
HP drum blading, which is also flow
BHEL Hardwar
Electro-hydraulic LP Bypass
Control System (General)
dependent, is used as the reference input
for the electric controller. This variable
reference value is replaced by a fixed
reference value for certain operating
sequences, such as start-up and shutdown.
The controlled variable is the reheat
pressure after the boiler outlet.
The electric controller has a characteristic
tailored to the pressure distribution within
the turbine and monitors the reheat
pressure. Monitoring is either a function of
the reference input Pressure before HP
reaction blading or a function of the fixed
reference value under certain operating
conditions. If the reheat pressure exceeds
the reference value, the electric controller
will act on the plunger coil of the electrohydraulic converter and initiate bypass
operation.
The bypass control system operates the
combined LP bypass stop and control valves
via various intermediate elements. This
double shut-off arrangement separates the
condenser from the reheater both during
normal operation and when it can not accept
any more bypass steam.
The hydraulic part of the control system
includes the necessary protective and safety
devices for the condenser as well as the
interlocks for the water side. See section: LP
bypass control (hydraulic).
5.1-0640-00
Steam Turbine
Description
Set-point Formation
Two set points, the fixed set point and the
reference variable, are formed for the LP
bypass controller, the effective set point
under any set of operating conditions being
the greater of the two, as selected by an
auctioneer.
The fixed set point can be set in the control
room to any point between 0 and
approximately 120% of the maximum LP
bypass pressure with the aid of a motorized
set point adjuster. It is normally used to set
the lower limit for the pressure set point.
The pressure upstream of the HP blading,
required for reference variable formation, is
measured by the dedicated pressure
transducer and transmitted to a matching
amplifier which sets the characteristic for the
reference variable as a function of the
pressure upstream of the HP blading.
When both set points, fixed set point and
reference variable, have been applied, they
are compared in the auctioneer, the greater
of the two being selected and taking effect in
the controller.
Provision is also made for limiting the
reference variable to an adjustable level
below the set pressure of the reheat safety
valves. The actual value for reheat pressure
is supplied by the pressure transducer as a
proportion (between 0 and 120%) of the
maximum LP bypass pressure.
Pressure Controller
The continuously acting electronic pressure
controller consists of a DC amplifier and a
power amplifier.
The deviation is formed at the input to the
DC amplifier by comparing the effective set
point with the actual value. The pressure
BHEL Hardwar
5.1-0641-00/1
Monitoring
The electrical section of the electro-hydraulic
LP bypass control is monitored for the
following faults, which are annunciated at
the control desk by means of the group
alarms Fault in controller, Fault in
automatic interface, Fault in reheat safety
valve actuation circuit and Fault in
condenser
temperature
protection
system 1:
Fault in controller
1 Fault in power supply to controller
2 Insertion fault
3 Fault in power supply to pressure
transducer for measuring pressure
upstream of HP blading
4 Fault in power supply to pressure
transducer for measuring reheat pressure
5 Fault in power supply to Collins
transmitters
6 Fault in power supply to binary signal
conditioning section for solenoid valve for
2nd stage spray water.
Fault in automatic interface
1 Fault in power supply to automatic
interface
2 Insertion fault
Fault in reheat safety valve actuation
circuit
1 Fault in power supply to reheat safety
valve actuator
2 Module fault
Fault
in
condenser
temperature
protection system 1
1 Module fault
Automatic Change-over from Automatic
to Manual Mode of Operation
To increase operating reliability, automatic
changeover to manual operation is
5.1-0641-00/2
Steam Turbine
Description
Operation
Electrical LP bypass controller MAN01
DP001 activities the plunger coil arranged
on the left-hand side of transducer MAX53
BY001. In the event of voltage increases, jet
pipe KA01 is swung to the right and piston
KA08 of transducer MAX53BY001 is moved
in the downward direction. This takes up a
position proportional to the downward
direction. This takes up a position
proportional to the voltage change due to
the rigid feedback. Sleeves KA04 of followup piston KA02 and KA03 connected to the
piston are move in the downward direction
and the fluid pressure in the follow-up
pistons rises.
At the beginning of the control process,
injection valves MAN11and12AA003 and
004 by way of pilot valve MAX53
AA031+AA041 and the actuators to injection
valve KA01 are opened first due to the rising
pressure in follow-up piston KA03. The
injection water reaches the pressure
reducing orifice and is available for cooling
down the bypass steam flowing into the
condenser, with a slight delay compared to
the injection valves, LP bypass stop valves
MAN11and12 AA001 are fully opened as the
fluid pressure in follow-up piston KA02 rises
(assuming that the piston of the actuator to
bypass limit controller KA07 is in the upper
limit position) and following this, LP bypass
control valves MAN11and12AA002 are
opened taking up a defined position due to
the feedback caused by the respective fluid
pressure (proportional control action).
LP bypass limit controller MAX53BY011 has
priority over transducer MAX53 BY001. As
soon as injection water is available at the
required pressure and there is also a
sufficiently high vacuum in condenser
MAG10BC001, the jet pipe is swung to the
right and the piston of the actuator to bypass
limit controller KA07 moves into the upper
limit position. As a result the pressure in
follow-up piston KA02 is increased so that
LP bypass stop and control valves
MAN11and12AA001 and MAN11and12
AA002 are released for opening.
BHEL Hardwar
Electro-hydraulic LP Bypass
Control(Hydraulic System)
5.1-0642-00/1
5.1-0642-00/2
Steam Turbine
Description
BHEL Hardwar
5.1-0650-01
Steam Turbine
Description
In order that the turbine may be completely
separated from the steam when it is
stationary, an additional check valve
LBC10 AA001 is fitted in the line between
the HP cylinder and the reheater and
operating through pilot valve MAX42AA001
+002 and the rotary actuator KA01
depending on the pressure in the
associated secondary medium circuit. The
swing check valve opens fully when the
control valves reached approx. 5 to 10% of
their full-power travel. Only when the
control valves reach this point again as
they are being closed, the swing check
valve brought into steam flow again by the
hydraulic actuator. Thus when the steam
flow in the normal direction ceases, the
BHEL Hardwar
5.1-0651-01
Steam Turbine
Description
BHEL Hardwar
5.1-0652-01
Steam Turbine
Description
Function
Healthiness of the protective devices and the
stop and control valves is vitally important for
the operational reliability and availability of
the turbine. Hence, it is essential that these
equipments are always kept in a fully
serviceable condition. Economy has dictated
longer intervals between turbine overhauls,
with the result that testing of the equipments
and devices is now necessary at regular
intervals during normal operation.
There are manually operated devices for
testing the free operation of the stop and
control valves. However, these tests do not
cover all components involved in an
automatic trip with the result that the
conditions only party corresponds to those
prevailing during a real trip.
The system
Any possible mal-operation associated with
manually operated devices are avoided with
fully automatic tests by means of the
automatic turbine tester. Full protection for
the turbine during testing is also assured by
suitable circuit arrangements. This increases
the operational reliability and availability of
the plant.
The automatic turbine tester is realised in
digital technology.
System adaptation
The system is subdivided into functional
groups for each device. Each group contains
the device itself and all necessary
transmission elements for initiation of a
normal trip.
The automatic turbine tester is divided into
the following 2 subgroups:
BHEL Hardwar
1. Protective devices
Description:
Automatic
Turbine
Tester, Protective device.
2. Main stop and control valves
Description: Automatic Turbine tester,
stop and control valves.
The complete testing of all components
which must operate when an automatic trip
becomes necessary is assured, despite the
subdivision into two testing groups
(protective devices, stop and control
valves), because the main trip valves which
store the trip signal by mechanical hydraulic
means are operated together with each
protective
device
and
subsequent
satisfactory reduction of the trip oil pressure
after the valves are monitored.
Nature of the description
The descriptions mentioned above contain
the practical sequence of the tests on the
individual devices and gives details of
possible irregularities. The description of
equipment contained in the automatic
control cubicle (stepping switches, interlock
modules, etc), the control panel in the
control room and schematic circuit diagrams
are contained in the separate electrical
section of the Operating Manual for the
automatic turbine tester.
For the understanding of the automatic
turbine tester from these descriptions it is
assumed that the reader is fully conversant
with the functioning of the individual
protective devices and valves within the
overall turbine governing and protection
system.
5.1-0660-00
Steam Turbine
Description
Scope of Testing
The Automatic turbine tester (ATT)
subgroup for the protective devices is
divided into a preliminary test and the
following four individual testing systems.
Remote trip solenoid MAX52AA001
Remote trip solenoid MAX52AA002
Over speed trips MAY10AA001/MAY10
AA002
Low vacuum trip MAG01AA011
One or more systems can be selected for
testing at the control panel and the selection
is stored. The start of the test program
automatically causes a preliminary test to be
carried out on the protective channels which
are to be effective during actual testing and
then establishes the test circuit. Once the
first test selected has been completed and
the protective device has latched in again,
the test circuit is restored to its normal
operational configuration. Further selected
tests must be started individually by
pressing the Test push-button to start the
program.
General
During normal operation, the protective
devices act via main trip valves MAX51
AA005 and MAX 51AA006 on the stop and
control valves and extraction swing check
valves. The remote trip solenoids MAX52
AA001 and MAX52 AA002, over speed trips
MAY10AA001/MAY10AA002
and
low
vacuum trip MAG01AA011 actuate main trip
valves MAX51AA005 and MAX51AA006 by
opening the auxiliary trip fluid circuit.
For the duration of testing of the protective
devices, a test circuit is established .In order
to keep the trip fluid circuit effective, it is
isolated from main trip valves MAX51 AA005
and MAX51AA006 by means of change-over
valve MAX51AA211 and supplied with fluid
via solenoid valves MAX51AA201 and
MAX51AA202 (remote trip during testing).
BHEL Hardwar
of
each
turbine
5.1-0661-00/1
Setting Data
The setting data for the pressure switches
are listed in the setting record Measuring
Point List. The actually set values are
logged in the Commissioning Test
Record.The test running times, etc. are
entered in the functional diagrams.
Test Sequence
Start of Testing
The test begins with the selection of the
protective devices subgroup. This is
performed by pressing the subgroup On/Off
push button.
The subgroup remains on until switched off
when the program has been completed.
While the protective devices subgroup
program is running, the other subgroups are
blocked.
The On/Off push-button is also used to
acknowledge alarms.
Selection
After the subgroup has been switched on,
the protective device to be tested is selected
by pressing the selection push button for the
individual device.
A separate selection push-button is provided
for each protective device. Only one
selection may be made at a time. Selection
of a further test is possible only once all
other programs have ended
Test Push-Button
The automatic test program is started by
pressing the Test push-button
Cancel Push-Button
This push-button can be used to terminate
the test program running at any time and to
initiate the reset program. The reset
program has priority over the test program.
Lamp Test Push-Button
All the signal lamps on the control panel can
be tested by pressing the Lamp Test PushButton.
5.1-0661-00/2
Individual Tests
The individual test is performed after
completion of the preliminary test and after
the test circuit has been established.
Successful completion of each individual
test is annunciated by the limit switches on
main trip valves MAX51AA005 and MAX51
AA006, pressure switch MAX52CP211 in
the auxiliary trip fluid circuit and pressure
switch MAX 51CP209 in the trip fluid circuit
between change-over valve MAX51AA211
and the main trip valve MAX51AA006. The
associated limit switch also annunciates
when a protective device (except for the
remote trip solenoids) has been activated.
On completion of each individual test, all
activated protective devices are returned to
their normal operating position by reset
solenoid valves MAX48AA201 and MAX48
AA202 and the test circuit is deactivated.
Whenever several of the same types of
protective device are provided, only one will
be described in the following, as the test
procedure is the same for all.
Preliminary Test
Pressing the Test push-button automatically
initiates a test of the protective circuits to be
effective during testing.
Function
The function of the preliminary test is to
detect any faults in the protective circuits to
be used during testing, and, if any are
detected, to inhibit testing of the protective
device, as this would leave the turbine
without protection.
Test Sequence
In the course of the preliminary test,
solenoid valves MAX51AA201 and MAX51
AA202 (remote trip during testing) are
automatically tested before the test circuit is
established. These valves (MAX51AA201
and MAX51AA202) are first energized,
resulting in a buildup of control fluid
upstream of changeover valve MAX51AA
211.lnitiation of Schmitt triggers (in the
speed
measuring
unit)
de-energizes
solenoid valve MAX51AA201 and the control
5.1-0661-00/3
Function
The function of the main trip valve is to
amplify and store the hydraulic or
mechanical (manually initiated local) trip
signal. It must respond in the course of
every successful protective device test.
Operation
Each main trip valve is kept in its position by
auxiliary trip fluid pressure. If a protective
device is actuated, the auxiliary trip fluid
circuit is depressurized and the main trip
valve is activated. This connects the trip fluid
and auxiliary trip circuits to drain and shuts
5.1-0661-00/4