Professional Documents
Culture Documents
Sagar Sahu
Submitted by
Reg. No.-A13MB2020012
Of
MBA
IN
Operations Management
1
STUDENTS DECLARATION PAGE
2
EXAMINERS CERTIFICATION
3
BONAFIDE CERTIFICATE
SIGNATURE
Designation
Dept.
4
ACKNOWLEDGEMENT
I am also grateful to Mr. Sagar Sahu and providing me useful information. I am also
indebted to all the employees of the organization for their sincere help and cooperation.
This project is a satisfactory outcome of several days hard work. We are thankful to
the respondent who has given us sample feedback and co-operation during the preparation of
this project.
Finally, I take this opportunity to thank the entire senior executives team and every
associate of this organization, who have helped me directly and indirectly during this period
of project preparation.
5
UNIVERSITY STUDY CENTRE CERTIFICATE
This is to certify that the project report entitled Production and Operation
Management in JSPL (6*135MW) submitted in partial fulfillment of the requirement for
the degree of Masters of Business Administration of GITAM UNIVERSITY,
VISAKHAPATNAM.
Regd. No.-A13MB2020012
Certified
(Director Creative)
6
COMPANY CERTIFICATE
During the above period we found his to be sincere and hardworking. She followed
the rules and regulations of the organization and was punctual in his attendance. His
performance and conduct was good. He possesses the ability to transform conceptual
knowledge to practical situations.
(Signature)
7
BACKGROUND PROFILE OF JINDAL STEEL & POWER LIMITED
After consolidating its position as a leading player in the steel, power, mining and
infrastructure sectors domestically, JSPL has now diversified into the oil & gas sector and
internationally with operations in Africa, Oman, Australia, Madagascar, Indonesia and
Georgia.
Mr. Naveen Jindal is the Chairman of Jindal Steel & Power Limited (JSPL) which is one
of the most efficiently managed steel companies in the world. The company is a part of the
about US$ 18 Billion O.P Jindal Group. The company has the worlds largest coal-based
sponge iron capacity and has established a Rail & Universal Beam Mill, which is
manufacturing the worlds longest 121 meter rails and parallel flange beams & columns in
large sizes for the first time in India.
The company produces economical and efficient steel and power through backward
integration from its captive coal and iron-ore mines. rom the widest flat products to a whole
range of long products, JSPL today sports a product portfolio that caters to varied needs in the
steel market. The company also has the distinction of producing the world's longest 121
metre rails and introducing large size parallel flange beams in India. The company's segments
include iron and steel; power, and others.
The company's manufacturing plants are located at Raigarh in Chhattisgarh, Angul in Orissa
and Patratu in Jharkhand. Its machinery division is located in Raipur. Its coal mines are
located at Dongamahua and Tamnar, Chhattisgarh, iron ore mine at Tensa, Orissa and iron ore
pelletisation plant at Barbil, Orissa. Jindal Steel and Power Ltd was incorporated in the year
1979. In the year 1995, the company forayed into power sector and started a company
namely, Jindal Power Ltd to engage the power sector. In May 1998, the Steel Melting Shop of
the company was shut down due to the explosion. In the year 1999, as per the scheme of
8
arrangement, the Raigarh and Raipur Divisions of Jindal Strips Ltd were hived off the
company. In October 2009, they reopened the Steel Melting Shop and commenced
operations.
In May 2000, the company commissioned Round Caster Unit set up in Raigarh and started
producing Rounds, which import substitution product. Also, the company entered into an
agreement with Maharashtra Seamless Ltd for selling 50,000 MT of Rounds annually. Also,
they forayed into the Infotech sector and launched Infovergix Technologies. In the year 2001,
the company introduced a new value added product namely, Alloy Steel Rounds, which is
used for manufacture of seamless tubes. The company signed an MoU with the Chattisgarh
government to invest Rs 6, 400 crore in various projects in the state over the seven years.
During the year 2003-04, the company started manufacturing Universal beams and structures,
in addition to manufacturing of value added steel products, such as, rounds, billets, blooms
and slabs. In January 7, 2005, the company signed an MoU with Government of
Chhattisgarh. In July 5, 2005, they signed an MoUn with Jharkand Government. Also, they
inked an agreement with S. African, German Company for coal gasification facility at their
proposed six-million-tonne steel plant in Orissa. In November 3, 2005, they signed a revised
MoU was signed with the state Government of Orissa to increase production capacity of
proposed steel plant from 2.00 million TPA to 6.0 million TPA. In the year 2006, the
company inked a joint venture deal with Bolivia for El Mutun development. In March 30,
2007, the company signed an MoU with the Government of Chhattisgarh for setting up 2
million TPA Cement plant and 30 MW Power Plant in Raigarh at an estimated cost of Rs720
crore. In April 2007, the company's Plate Mill of 1.0 million TPA capacity was commissioned
successfully and commenced commercial production.
The company signed an MoU with the Government of Orissa for setting up a 6 Million TPA
Integrated Steel Plant near Kerajang Railway Station in Angul District of State of Orissa at an
estimated cost of Rs 16, 560 rore. During the year 2010-11, the company commenced
production in 0.6 MTPA capacity wire rod mill and 1.0 MTPA capacity bar mill, at Patratu,
Jharkhand. The company through their 100% subsidiary Jindal Steel & Power (Mauritius)
Limited, Mauritius (JSPLM), has acquired Shadeed Iron & Steel Co. LLC (SISCO), a
Company incorporated under the laws of the Sultanate of Oman, in June 2010. The plant has
been commissioned in record time and commercial operations started in December 2010,
three months ahead of its schedule. In May 2010, the company completed the modification in
mini blast Furnace and commissioned the steel melting shop (SMS - III). The company
synchronized the two units of 135 MW each under Phase - I in May and September 2010
respectively. In May 2010, the company completed the A 0.5 MTPA capacity slag grinding
unit at Raigarh, Chhattisgarh. This plant is utilising the slag produced by blast furnace I and
II and clinker, purchased from outside, is mixed with slag to produce cement.
In January 2011, the company completed the 0.6 MTPA medium and light section mill at
Raigarh, Chhattisgarh and commenced production. In March 2011, the company
commissioned the first unit of 135 MW captive power plant in steel plant proposed to be set
up at Angul, Orissa. As of March 31, 2011, the company's installed capacity at its Raigarh
9
Unit include: 13,70,000 metric tons of sponge Iron; 30,00,000 metric tons of mild steel; 36,
000 metric tons of ferro alloys; 623 megawatts of power; 16,70,000 metric tons of hot
metal/pig iron; 7,50,000 metric tons of rail and universal beam mill; 10,00,000 metric tons of
plate mill, 60,000 metric tons of fabricated structures; 5,00,000 metric tons of cement plant
and 6,00,000 metric tons of medium & light section mill. In January 2012, the company
commissioned the fourth unit of 135MW plant at Dongamahua, Raigarh, Chhattisgarh and
second unit of 135 MW power plant at Angul, Orissa, with this total 6 units are
commissioned in series of 10 units of 135 MW. Jindal Steel Bolivia S.A (JSB), a subsidiary
of the company, was allotted land for setting up of an integrated 1.7 MTPA steel plant, a 6
MTPA sponge iron plant, a 10 MTPA iron ore pellet plant and a 450 MW power plant. The
company is in the advanced stage of implementation of Steel Plant in Angul, Orissa. Also, the
Captive Power Plant in Raigarh, Chhattisgarh is under implementation.
The company is setting up an integrated steel plant in Patratu in the state of Jharkhand. The
steel plant is expected to be commissioned in second half of 2013. The company is expanding
production capacity of Machinery Division, Raipur, Chhattisgarh from 5,100 to 10,000 metric
tons per annum. During the year, two sheds were completed and the CNC machines have
been commissioned enhancing the production capacity to 9,000 metric tons per annum.
During the financial year 2011-12, two more sheds will be constructed in which cranes will
be installed thereby increasing the production capacity to 10,000 metric tons per annum.
Mr. Jindal has also been ranked among the top ten of India Incs Most Powerful CEOS
2011 list by a survey conducted by IMRB for Economic Times-Corporate Dossier.
Mr. Jindal won the Ernst and Young Entrepreneur of the Year award in the field of Energy
and Infrastructure.
JSPL has been ranked the Second Highest Value Creator in the World by the prestigious
Boston Consulting Group and first in the Mining and Materials industry category.
Jindal Steel & Power Limited was awarded the Forbes Asias Fabulous 50 international
award in 2009 & 2010.
Jindal Steel & Power Limited was awarded the CNBCs Most Promising Entrant into the
Big League at IBLA (Indian business Leaders Award) 2009.
Under the able leadership of Mr. Naveen Jindal, JSPL was rated as the highest wealth
creator in the country for the period 2005-09 and was also rated among Indias 50 best Blue
Chip companies by Dalal Street journal.
10
Content
1. Introduction
2. Turbine proper
2.1 Introduction
3.1Introduction
4. References
1. Introduction
11
Steam turbine is a rotating prime motor to change the heat energy into
mechanical power. There are a lot of advantages of large power, high
speed, high efficiency, smooth operating and longer life. It is used
comprehensively in fossil fuel power plant, nuclear plant and geothermy
power plant. It appeared in 18 century, a 5 horse power steam turbine
was produced by Sweden engineer Laval in 1890, up to now more than
100 years had passed, and 1300MW capacity of single steam turbine had
put into operation in United States.
Fig1-1Thermocycle
12
Fig1-2 Fossil single re-generating heating cycle scheme, T-S drawing
13
Back The exhausting steam is directly used as heat
pressure supply, no condenser is provided, when the
turbine exhausting steam being used as other IP/LP
Thermal turbines work steam, it will be called pre-
feature position turbine.
14
Industrial Driving fans, pumps, variable speed
turbine
15
Number
steam para
parameter
Rated outputMW
Turbine type
Type Type
Symbol Symbol
N Condensing CB Back
pressure with
extraction
CC Two stages
regulating
extraction
16
Two stages Main steam pressure/HP CC25-
regulating extraction steam 8.82/0.98/0.118
extraction pressure/LP steam
extraction pressure
Super-heated steam generated from boiler enters into turbine then pass
thru annular nozzle (Stationary blades block) and moving blades changing
the heat energy into mechanical power of turbine rotor rotation. The
different work mode turbine has different steam energy changing mode.
Work theory
17
Figure 1-4 Steam flow acting on barrow
18
1.3.2 Reacting turbine
Wok theory
According to the Newtons third law, when a body makes an acting force
to another body, it will receive a reactive force which is equal to the acting
force and with an opposite direction. For example, a flight rocket (Figure
1-6) utilizes the reactive force of high velocity gas by burned fuel, jet out
from its end part, this reactive force is called as reacting force. This
theory of making work by reactive force is called reacting theory. An
Egyptian Hero made a reactive steam ball in 120 B.C. (refer to Figure 1-
7), it worked with reacting theory.
Fig. 1-6 Rocket work theory Fig. 1-7 Hero reactive ball theory
19
Impulse multi-stage turbine scheme Reacting multi-stage turbine
scheme
10-balance hole
2. Turbine proper
2.1 Introduction
20
are arranged on the middle area of H/IP casing to decrease the operating
temperature of front and back bearings and decrease the heat stress of
rotor and casing, the steam flow in LP casing is in a double flow and radial
expansion mode, it will decrease the shaft axial dimension and exhaust
loss.
There are three bearing supports for this turbine set, HIP rotor and LP
rotor connected rigidly with rigid coupling, this configuration is benefit for
bearings load share, LP rotor is connected with generator rotor by semi-
flexible coupling. The thrust bearing in middle pedestal is the anchor point
of the turbine shaft which expands forward and backward according to
this anchor point. HIP casing expands forward based on the anchor point
of longitudinal and transverse keys. There is an absolute expansion
indicator fitted on front pedestal, total casing expansion is 20-22 mm, LP
outer casing expands backward based on the anchor point of front end of
LP outer casing.
HP nozzle block includes four. arc nozzle blocks, the entering steam of
each block is controlled by related regulating valves, when in rated load
operation, three valves wide open needed only, the 4th valve will be used
in summer and low main steam condition operation.
HIP casing is a single casing, there are one regulating stage and 13
pressure stages provided in HP turbine, 1st extraction is led after 10th
stage for No.1HP heater. Steam discharged from HP part thru two opens
under the casing and check valve flows to boiler reheater, a part of cold
reheating steam used for No.2 HP heater.
Hot steam from reheater flows thru two pipes connected with reheat stop
valves and interceptor valves driving by hydraulic actuator then enter into
21
intermediate part connected with rigid pipes. There are 13 pressure
stages in IP part, 3rd extraction is led to deaerator after 7th stage, 4th
extraction is led to No.4 LP heater after 10th stage. Steam flows out from
IP part thru two opens at the IP upper casing connected to LP casing by
two flexible connecting pipes, there is a No.5 extracting open on the lower
part of IP casing for connecting No.5 extracting piping.
Two reheat stop valves and interceptor valves are located on both side of
turbine, it is able to be free moving following the turbine expansion, the
reheat stop valves and interceptor valves act only when load is less than
30%, when load is more than 30%, it is kept in full open position.
22
Type: Super high pressure, reheating, double
casing, double flow, single shaft condensing
First critical speed: HIP rotor 1849 rpm, LP rotor 2350 rpm,
generator rotor 809 rpm, exciter rotor
2660 rpm
23
HP part and IP part are in a common casing (refer to Fig. 2-10),the steam
inlet end of both parts are located at casing central area, one HP retainer
and three IP retainers are installed directly on the HIP outer casing, LP
casing is a double flow construction. There is a IP heat shield installed at
IP steam inlet area to decrease the temperature difference of casing wall.
Opposite arrangement of HP and IP flow pass has an advantage of high
temperature area at the casing middle part decreasing its heat stress. The
two ends of HIP casing are HP steam outlet and IP steam outlet, pressure
is rather lower, leakage will be smaller and the heat influence to bearing is
less. The balance drum decreases the thrust force and makes a good
balance of axial displacement. HIP common casing configuration
decreases turbine length and bearing number.
HIP cylinder is a horizontal split casing, divided upper and lower parts, its
material is Cr-Mo steel. There are four HP steam inlet nozzles, two of
them are on each part, four flexible pipes link them to regulating valves
outlet, steam supplied from chest into HP casing. Two HP steam outlet
opens located at the lower part near the GV end of HIP casing, two IP
steam inlet opens located at the middle lower part, IP steam outlet opens
located at the upper part near by generator end, some extracting opens
are located at lower part.
24
There are HP and IP retainers installed in the HIP casing, gland sealing
are provided at the end, opens are provided at both end of casing for
adjusting balance screws.
HIP casing is supported by four flukes casted together with lower casing.
At generator end, these flukes supported by keys which located between
flukes and the pedestal of lower casing, fluke moving on the keys freely.
At the Governor valve (GV) end, the fluke supported also by keys of front
pedestal. At each end, outer casing connected to cylinder and pedestal
with H beam and bolts, pins. These beams keep the casing in a correct
position. The GV end pedestal fabricated together with LP casing to keep
the HIP casing and LP casing in a correct position at axial direction.
GV end front pedestal can freely moving on its frame. Longitudinal key is
provided to prevent it from transverse moving. Enough clearance is kept
between bolts and pedestal to allow axial moving freely.
25
Fig 2-2 Casing support type
(a) upper fluke support; (b) lower fluke support; (c) bed plate
support
Turbine diaphragms are fixed in retainer ring which are fixed in casing. For
extracting regenerating steam to heat feed water, some steam extracting
opens are provided, extracting chamber are separated by retainer rings.
This retainer ring construction possesses benefit of simpler casing, easier
manufacturing and decreasing temperature difference and thermal stress
during start up/shut down and low load condition, but a larger casing in
axial and larger flange.
For reactive turbine, the axial force of moving blade is larger, so force
acting to the rotor is also larger, some bosses is designed on the rotor to
balance the axial force. There are three balance drum sealing provided in
HIP casing to seal the related bosses.
2.3.3 LP casing
26
LP casing is double flow type, divided inner and outer casing, outer casing
is fabricated by steel plate and composes three sections for being easy
transportation and manufacture then assembled at site, three sections
connected with bolts, after aligned the connecting flange will be welded
for sealing, LP outer casing is designed based on radial diffusion idea,
steam passes special guide device into condenser.
Gland sealing boxes of both side welded directly on the outer casing,
extracting pipe and sealing steam pipe with their shield tube of both side
route along with the inner wall downward go out at condenser neck
connecting to gland sealing balance chamber and cooler. In site erection,
welding of double skin pipe (inner pipe with another outer shield pipe) will
be careful especially when it penetrate wall, all inner and outer pipe welds
will be complete.
Supporting stand of outer casing sit on casing frame, the center of outer
casing and two pedestals will be fixed by lower vertical key, anchor point
of outer casing is fixed with lateral key.
For decreasing steam leakage, 12-M42 bolts are provided at split face
inside inner casing nearby first stage diaphragm. When lifting upper outer
casing, this 12 bolts should be removed first then remove other 36-M42
bolts.
27
For improving inner casing heat stress, stainless cover sheet is provided
on outer wall of inner casing.
There are exhaust guide plates arranged at both end of inner casing, it
combines with outer casing end plate forming a radial diffusion pass, the
velocity energy will be recovered after diffusion to get higher efficiency.
Exhaust hood water spray device is provided outside of exhaust guide
ring, (refer to figure 2-3).
1-water inlet pipe; 2- spray tube; 3-last stage moving blade; 4-de-
moisture ring; 5-guide plate
I/LP casing connecting piping led steam from IP casing to LP casing thru
two pipes (refer to Fig, 2-4).
Due to both H/IP casing and LP casing are with itself anchor point, so this
piping will be a flexible one to absorb heat expansion.
28
Due to the large volume flow, two pipes are provided, it is a balanced
bellow type, four axial bars are provided on each pipe for bearing the
huge vacuum force to prevent this force acting directly to the casing.
29
HP nozzle group (Refer to Fig.2-5, Fig.2-6) is divided to four groups, two
groups in each inner casing and outer casing, each nozzle chest contains
one group meridian plane nozzle. There are 29 nozzles in each group.
Each nozzle group fastened with 31 piece of M27 bolts preventing from
leakage.
30
Fig2-7 HP retainer ring
31
Fig. 2-8 Steam leakage in turbine
Gland sealing (Fig 2-9) is provided for preventing HP steam leakage out
to decrease heat loss and protecting lubricating oil pollution. LP gland
sealing is provided for preventing air leaking in casing to keep condenser
vacuum in specified value.
Gland sealing divided H/IP end sealing (governor valve end), H/IP end
sealing (generator end) and LP casing sealing.
These gland sealing are composed of sealing body, sealing ring which
installed in sealing body, fixed with leaf spring, sealing body includes
upper and lower part linked with bolts at split face, lower part positioned
with key and axial position adjusted by shim, sealing ring is tooth
labyrinth type.
32
2.3.7 Slide pin
The lateral pin is located under front and rear flukes, between pedestal
and casing fluke, support key (lateral pin) arranged. At the middle area
of HIP lower part both ends, there are alignment H beam arranged to link
with front pedestal, LP outer casing (governor valve end) and connected
by bolts and pin. It guarantees the center of front pedestal, HIP casing
33
and LP casing is not changed. The longitudinal key between front pedestal
and frame will guarantee the expansion center of turbine stationary parts
is not changed when it moving forward governor valve end, based on the
anchor point of LP casing center.
LP casing is supported on bed plate thru its skirt (support leg) integrated
with lower part, the leg positioned by four keys, its position is as follows:
two axial keys of each end are local at shaft center line to fix casing
lateral position but axial moving freely; two lateral keys of both side to fix
casing axial position but lateral moving freely. LP casing can expanse any
direction freely based on the anchor point of exhaust open, the front
bearing box on LP outer casing contains not only its own bearing but also
the No.2 bearing of HIP casing.
2.3.8 Valve
2.3.8.1 Throttle valve
Throttle valve is casted by Cr, Mo, V steel alloy with enough strength in
higher temperature, it located at both side of turbine vertically.
34
Its valve is shaped a good profile with less pressure loss, higher efficiency.
When valve is in full open position, self sealing structure will prevent HP,
high temperature steam from leakage, steam leaking from stem flows to
gland sealing cooler.
Interceptor valve set includes reheat stop valves and interceptor valves,
its bodies are casted together by Cr, Mo, V steel alloy with enough
strength in higher temperature.
35
temporary filter screen arranged out side of governor valve, for
preventing debris entered, it will be changed with a permanent one after
trial run.
36
Fig. 2-12 HIP rotor
Extended shaft connected on rotor regulating valve end, main oil pump
impeller mounted on it and linked with trip device spindle. The generator
end connected with LP rotor by rigid coupling using fitted bolts, this
coupling will transmit moment, axial thrust force, lateral shear load and
bend torque. Spacer is arranged between two rotors, it will adjust the
relative position of two rotors to guarantee the clearance between moving
and stationery parts. Rotor is able to be moved axially for take out the
spacer, jack bolts are provided on two couplings.
2.4.2 LP rotor
37
Fig.2-13 LP rotor
2.4.3 Coupling
This turbine shaft system is a three bearing support type, HIP rotor and
LP rotor connected by its own integrated coupling ( Refer to Fig 2-14),
this three bearing support system is benefit for load balance of each
bearing, LP rotor and generator rotor connected by semi-flexible coupling(
Refer to Fig 2-15), turbine rotor expansion backward based on anchor
point( thrust bearing in HIP front pedestal), HIP casing based on anchor
point( the crossing point of longitudinal key and lateral key in middle
pedestal) expansion forward. The advantage of rigid coupling for HIP and
LP rotor connection is: simple construction, reliability, large torque being
transmitted, the possibility to transmit axial and radial force, use one
thrust bearing, but the disadvantage is rotors vibration will be
transmitted and influence together, when resonance vibration happening,
difficult to find the cause.
38
In middle pedestal, journal bearing and thrust bearing are provided, a
temporary, installing used bearing is provided near by oil catch (LP casing
end), and will be removed after installation.
The anchor point of H/IP casing is essentially based on the lateral key and
axial key of middle pedestal, so, middle pedestal does not move in
operation as like front pedestal.
39
2.4.4 Blades
Blades is divided to moving blades and stationery blades according to its
effect, moving blades are assembled on rotor when it is impinged by high
velocity steam, the steam kinetic energy is transmitted to mechanical
energy to push rotor rotation. Stationery blades are assembled on
retainer, in reacting turbine, it play a role of nozzle and in velocity stage,
it is a guide blade to change the steam flow direction then flow to next
moving blade. Blade consists of blade profile, root and blade tip, refer to
Fig 2-16.
1-shrouding; 2-blade;3-spacer;4-impeller
2.4.5 Bearing
There are two kind of bearing in this turbine: journals and thrust bearing.
40
shaft axial position to guarantee the clearance of moving part and
stationery parts.
Block bearing
Block bearing (refer to fig 2-17) also called main bearing, according to the
different construction, are divided: round journal, elliptical journal, multi-
wedge bearing and tilt bearing. Round journal and elliptical journal are
mainly used in middle and small turbine. Turbine is a high speed machine,
the larger the rotor heavier. Bearing burn out and high vibration are the
main accident.
10-thermometer hole;11- lower bush right pad;12- lower bush left pad
18-oil outlet
41
stuck on journal surface rotates with shaft in same speed, this layer
causes lower layer moving together then the oil in bearing moving layer
by layer, oil moves following shaft from the wide section of wedge to
bottom and accumulated in the narrow wedge clearance forming
pressure, the turbine speed higher, more oil bringing in the wedge, the
pressure higher, when the lifting force is more than its load, journal lifted,
it does not contact the bush directly but separated by oil film called liquid
friction ( refer to fig 2-18)
(a) form wedge clearance in bearing (b) distribution of oil pressure (c)
axial distribution of oil pressure
Thrust bearing
Thrust bearing is combined with front block bearing (Refer to Fig 2-19), it
consist of thrust disk, flexible balance ring, thrust pad (Refer to Fig 2-20),
pedestal and ancillaries: oil inlet pipe, oil outlet pipe, measure device etc.,
it separates horizontally in upper part and lower part. Oil forms film
between thrust disk and pad , changing dry friction to liquid friction and
bring out quantity of heat, cooling the bearing. Thrust disk forged rigidly
with shaft and machined simultaneously.
42
Fig 2-19 Block and thrust bearing
43
The rotor turning gear (Refer to Fig 2-21,22), is used to rotate the rotor at a low
speed while the turbine is shut down, so as to reduce to a minimum the distortion
of the rotor due to uneven cooling of the turbine parts. Turning gear uses two
stage reduction gear box, installed on upper cover of rear pedestal. It uses low
speed, variable frequency motor driving device, speed is variable from 3 to 62.5
rpm, 7-8 rpm is suggested when in initial period. Jacking oil should be supplied
before starting this device.
1- pinion;2-gear;3-moving-gear;4-turning-gear;5-motor;6-spindle;7-
hand lever;8-safety pin;9-motor position switch;10-boss;11-turbine
shaft;12-screw shaft;13-coupling;14-cable;15-slide valve;16-piston
44
Fig 2-22 Turning gear scheme
Function:
45
Fig 2-23 Schematic drawing
When oil pressure and air pressure are normal, as soon as DCS received
the signal of turbine speed low than 600 rpm, an on/off signal sent to
auto control cabinet, then the cabinet send out command to initiate
cooling air fan and pneumatic oil valve, other systems are in waiting
condition. When DCS receiving a signal of turbine speed lower than 7-8
rpm set point, it sends again a zero speed on/off signal to auto control
cabinet then the cabinet send out pull pout pin signal, pneumatic
actuator pull out the pin of turning gear and feed back to control cabinet,
after it confirming the pin has pull out then orders engage motor moving
step by step and control the engage actuator to perform engage
46
operation, this operation can avoid gear strike and engaging smoothly,
after engage completed, feed back signal to control cabinet, after 5
seconds delay, 7-8 rpm turning gear started, and after another 5 seconds
delay , stop air supply to engage actuator, waiting for turbine rolling.
When turbine rolling after speed higher than turning speed, the gear is
forced de-clutched, signal feedback to control cabinet, it commands
actuator to pull gear off and pin reset automatically locking the engage
device, signal feedback to control cabinet, after 10 seconds delay, turning
gear finished.
Warning:
3.1 Introduction
The basic reason is input comes only from speed, now, for large capacity
unit, turbine governing system will based both speed (frequency) and
load to control the system.
47
Fig 3-1 DEH system schematic drawing
For India jindal power plant, DEH (Digital Electric Hydraulic) system (Fig
3-1) is provided. Fire resistant oil will be used in EH system, its work
pressure is 13.8 MPa, having its own independent Fire resistant oil supply
system. Each governor valve provided with a actuator, among them,
actuator of reheat stop valves are on/off type, actuator of throttle valves,
governor valves and interceptor valves are fire resistant oil servo-
actuator, it receive valve position signals (+/- 40mA) from DEH to control
the valve opening, all these actuators using fire resistant oil, single action,
open valve hydraulically, close valve by spring force.
During start up, reset emergency trip pilot valve by turn on solenoid valve
20/RS, then open throttle valve by DEH, after fully open, governor valves
and interceptor valves open by DEH to perform start-up, raise speed and
synchronize.
48
In over speed protection system, two solenoid valves (20/OPC-1,2) are
provided, when speed higher than 103% rated speed or turbine trip out,
this solenoid valves energized open, fast closing all governor valves to
confine speed raising rapidly.
In Emergency Trip System one fly-ball governor and emergency trip pilot
valve are provided, the work pressure of pilot valve and actuator is
0.7MPa, turbine oil. When speed higher than 108-112 % rated speed, fly-
ball fly out to attack emergency trip lever, act emergency trip pilot valve
to release the protection oil in upper chamber of diaphragm of this valve
then release the oil in header of emergency trip system (AST) oil closing
all throttle valves and reheat stop valves, turbine shut down. There are
another four auto stop solenoid valves, two and one or each, (20/AST-
1,2,3,4) provided, it will receive all protection signals to trip turbine.
Oil supply part includes: oil supply device, cooling system, filter and
regenerating system and oil piping and fittings (oil pipes, accumulator,
rack, etc.).
Actuator part includes: Two sets of actuators of throttle valve, Two sets of
actuators of reheat stop valve, two sets of actuators of interceptor valve
and four sets of actuators of governor valve.
49
The main function of oil supply system (Fig 3-2) is supplying work oil for
actuator and keeping its normal physical and chemical properties.
It composes oil tank, motor pump set, control block, oil filter, magnetic
filter, over flow valve, accumulator, cooling system, fire resistant oil
regenerating and filling system, oil tank heater, ER terminal box and
instruments for oil pressure, temperature, level indication, control and
alarm.
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Motor HP plug pump extracts fire resistant oil thru filter from oil tank
discharges thru filter, check valve to HP oil header which connected
accumulator then sends oil to actuators and emergency trip system.
Warning: Plug pump needs high quality oil and specified oil
viscosity, before starting oil temperature must me higher than 20
.
Pump discharge pressure can be set in 0-21 MPa range, for this unit, it
will be 13.8 0.5 MPa.
After starting pump, it operates in 100 l/min full capacity, supplying oil to
system and filling oil to accumulator, when oil pressure reaching set-point
13.80.5 MPa, oil pressure control valve operates variable displacement
mechanism of pump decreasing its flow as soon as the output flow
equaling the consumption, variable displacement mechanism kept on one
position, if system consumption changed, pump flow will follow this
change automatically to keep 13.80.5 MPa oil pressure, when oil
consumption increased instantly, accumulator will supply oil.
There are two independent pumps provided, one operation, one stand-by,
when system needing more oil supply or oil pressure too low due to some
reasons, in this condition, another pump can put into operation
automatically, two pumps can operate same time to supply double flow
oil.
Pilot over flow valve is provided as safety valve of oil supply device,
initiate pressure 16.2 MPa.
All return oil from actuator flow to pressure return oil piping (DP) then
thru a filter back oil tank. A self- contained oil treatment system is
provided, Special pump discharges oil from tank through filter, cooler
return back to tank.
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There is over pressure by-pass device provided for return filter, when
return oil flow fluctuated (such as system closing suddenly) and return
pressure is more than 0.35MPa, over pressure by-pass device initiated to
protect filter from damage.
Main components of oil supply device includes: oil tank, pumps, filter,
accumulator, return oil filter, oil cooler, heater, circulating pump, re-
generating pump and instrument.
Manual drain valve is arranged under tank. Two float type level switches
(alarm and trip) are provided. Control block, over flow valve, hydraulic
parts are mounted at lateral side. A group of heaters inserted into tank on
side for heating when ambient temperature is low than 21 .
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There are two plug and variable displacement pumps provided, one
operation, one stand-by, two pumps operated together is also permitted,
pumps arranged under oil tank for keeping positive suction head.
Filter
element Check
valve
Over flow valve
To filter
pressure
Stop valve
differential To oil tank electric
box
To system Stop valve
HP filter
Two HP filters installs on the outlet piping of pump to filter out the oil into
system.
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closed, only this train is isolated, but not influence the another one for
normal operation, this isolated train will be maintenance or change
equipment.
3.2.1.3.4 Accumulator
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When oil pumps loss power, the accumulator will supply oil to EH system.
There are one set of three permanent magnetic rod on tank top to absorb
the ferritic particulate in oil, it can be moved out for cleaning and
maintenance during unit shut down.
Fluid level alarm components are mounted on the reservoir top plate.
When fluid level changes, it moves the switch mechanism and causes an
alarm for high, low fluid level. It actuates trip switch at low-low limit fluid
level.
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abnormal condition to keep the tank oil temperature in normal value and
the specified oil quality. When in normal operation, the main filter effect is
not enough, after a period operation, oil is changed worse, for keeping the
specified oil quality, shut down and oil re-circulating is needed. For
guaranteeing the oil quality and not shut down the unit, this self
contained oil circulating cooling and filtering system is provided.
It can perform on-line oil circulation to purify and cool the oil, even the
servo actuator system is not in work. Oil pump will be started or stop at
ER control cabinet, pump capacity is 40 l/min.
Self contained oil circulating cooling and filtering system includes one
motor pump, two 3 filters, two coolers and solenoid valve for cooling
water control.
There are two EH oil coolers provided, tube type, installed in self
contained oil circulating cooling and filtering system to keep oil
temperature in specified range.
When the purity, water content and acidity of oil do not fulfill the specific
value, re-generation device will be put into service to improve its quality
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Pressure
gauge
One 3return oil filter is arranged in return oil piping beside tank, Movable
Bergmeal
filter
cover is designed for easy changing filter cartridge. To oil
tank
3.2.1.3.10 Electric
Stop
heater Orifice
valve
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introduced, its normal working temperature is 20-60, its specification,
please refer to related document.
3.2.2 Actuator
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Electro-hydraulic servomotor (actuator) (Fig 3-6) is a important
component in DEH. In spite of turbine capacity 600NW, 300MW, 200MW,
125MW, its work theory is the same.
Fire resistant oil acts to open valve, but closing valve is by spring force.
Oil cylinder of the actuator is single side in type, it connects with a control
block, on which isolating valve, quick release valve and check valve are
installed, , There are two kind of basic actuators, when adding different
devices, that is, on/off actuator and control actuator.
In order to decrease the impingement force between valve disc and seat
when actuator closed quickly, hydraulic cushion device is designed to
change the accumulated kinetic energy to fluid energy.
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Fig 3-8 LVDT work principal
The output circuit of LVDT is designed with a cam effect, when actuator
raising to a specified point, after this point steam flow almost not
increasing again and no proportional feed back signal. When the position
required signal increased over this point, position feedback signal no
longer increasing, position D-value will no reach zero, therefore, after
actuator enters the cam effect range, smaller D-value input potential can
still quickly move the actuator to fully open, the cam effect point is
adjustable.
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3.2.2.3 Dump valve
There is a slide valve in dump valve which lower chamber connected with
actuators lower chamber, at slide valve bottom there is a small orifice to
let a few pressurized oil flow to its upper part, on the upper oil chamber
of slide valve, two mouths are existed: one connected to emergency trip
oil thru a check valve; another connected to actuator piston upper
chamber thru a needle valve, adjusting the opening of needle valve can
change the pressure upon slide valve, at normal operating condition, the
oil force adding spring force is larger than the slide valve upward HP oil
force, slide valve pressed on seat, and close the mouth to return piping.
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For stabilizing the HP oil pressure to increase the stability of control
system, HP dump valve is provided, includes: adjusting lever, spring,
small slide valve, piston, big slide valve, plate spring etc.
Fig 3-10
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For preventing the turbine operation from critical accident caused by
some equipment abnormal operation, Emergency Trip System (ETS) is
provided (Fig 3-10). It trips out turbine to guarantee turbine safety.
During abnormal condition, ETS supervises some operation parameters of
turbine, when it excesses its limits, this system closes all steam inlet
valves.
System function
Trip function
When speed is more than 110% emergency trip acts, turbine emergency
shut down (mechanical over speed Fig 3-11)
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When any one of following monitored parameters excesses operating
limits, ETS acts (failure open) turbine trip solenoid valve (20/AST), safety
oil drained thru solenoid valve, closing reheat stop valve and emergency
control block is initiated, control oil pressure is lost, throttle valve,
governor valve, interceptor valve are closed, turbine emergency shut
down(Fig 3-12):
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If another accident occurred, operator confirms tripping is necessary, or
needed shut down in normal condition, trip out can be performed to pull
the local crank on the front pedestal or push the trip button in central
control room dumping the safety oil and control oil, tripping the turbine.
Electric over speed emergency trip out: in load rejection condition, when
turbine speed is more than 103 %, over speed solenoid valve acts after
receiving the signal from electric over speed emergency trip device to cut
off control oil supply of governor valves and interceptor valves, and
connecting the control oil to oil return piping (the control oil pressure in
this time is called OPC pressure), over speed solenoid valve closed quickly
to increase the kinematic stability of turbine set. Extracting check valves
are closed when OPC pressure is lower by sequential control system. After
turbine speed decreased to a specified value, electric over speed solenoid
valve resets, opening the governor valves and interceptor valves.
AST-OPC solenoid valve component consists of: two parallel over speed
protecting solenoid valves (20/OPC-1,2), two check valves ,four parallel
and serial Auto Stop emergency Trip solenoid valves (20/AST-1,2,3,4) and
one control block, this component arranged in HP fire resistant oil system.
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It is controlled by OPC and AST of DCS, in normal operation, the two OPC
solenoid valves are de-energized closed (FC), isolating the oil releasing
piping, oil pressure in actuator piston lower chamber of governor valve is
established, when speed is higher than 103% rated speed, OPC signal
send out, this two OPC solenoid valves are energized open, the oil in OPC
oil header return back to EH oil tank and the related dump valves open
quickly, governor valves closed quickly.
Four parallel and serial arranged AST solenoid valves (20/AST-1,2,3,4) are
controlled by Emergency Trip System (ETS), in normal operation , these
valves are energized close, isolated the oil drain pass, there is oil pressure
established under actuator piston of throttle valve and governor valve, in
emergency condition, Signal send out , these four solenoid valves are de-
energized open, the oil in AST oil header return back to EH oil tank and
the related dump valves open quickly, throttle valve and governor valves
closed quickly.
Four AST solenoid valves are arranged parallel and serially to guarantee
turbine operating safely and reliably. AST/1 and AST/3 arranged parallel,
AST/2 and AST/4 arranged parallel also then two sets arranged serially,
any solenoid valve acts will release the pressurized oil of AST header
guarantee turbine safety. When reset needed, any solenoid valve set of
these two sets closed, the oil pressure in AST header will be established,
turbine will be in a waiting start condition.
AST oil piping and OPC oil piping are connected with two check valves, it
is designed that when OPC solenoid valve acting, AST header pressure is
not influenced, and when AST solenoid valve acting, OPC header pressure
will be released also.
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Diaphragm valve
Diaphragm valve links with LP turbine oil system and HP fire resistant oil
system, when turbine over speed, the emergency trip device take action
or emergency trip device sends out trip signal, the oil pressure in the
mechanical over speed manual trip header released, diaphragm valve
opens, AST oil header pressure released, throttle valve, governor valve,
reheat stop valve and interceptor valve closed, turbine shut down,
guarantee its safety.
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When turbine in normal condition, the safety oil in turbine LP oil system
filled on upper chamber of diaphragm, against the force of the spring,
keeping the valves in close position, isolating AST system from the
drain piping, ordering the HP/LP auto closer and the actuator of HP/LP
governor valves put into operation.
The action of both the mechanical over speed trip device and manual trip
slide valve or any independent one will release or decrease the safety oil
pressure in turbine oil system, the compression spring open the
diaphragm valve, AST oil returns to EH oil tank, all valves closed.
3.3.1 Introduction
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Another protection required as follows:
The main auxiliaries feed water pump is provided with protection device,
such as: axial displacement protection, lube oil pressure low protection
and shaft vibration protection.
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. Low lube oil pressure protection
Low lube oil pressure protection is also a critical protection function. When
turbine rotor rotes with high speed, it is supported by bearing using lube
oil, if oil pressure is low, dry friction will happen between shaft and bush,
the babbit alloy will be burned, vibration increased, even moving parts
tough with stationery parts, it is not permitted absolutely. As soon as lube
oil pressure decreased to a safety value, AC motor emergency oil pump
will be started immediately, if failure of this starting, DC pump will be
started.
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3.3.2 Periodically testing of turbine protection system
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3.3.3.1 Turbine major protection
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HP/LP bypass valve position and temperature.
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Load command can not be more than the maximum permitted unit load,
so, in load command handing device, a calculating circuit which calculates
the maximum permitted unit load based on the related auxiliaries
operating condition will be provided.
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4.Refrances
1) www.jspl.com
2)www.sanghaielectric.com
3)www.google.com
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