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A PRESENTATION ON 660MW TURBO-GENERATOR ,ITS AUXILIARIES AND ASSOCIATED SYSTEMS By

A PRESENTATION ON 660MW TURBO-GENERATOR ,ITS AUXILIARIES AND ASSOCIATED SYSTEMS By Ashvani Shukla C&I BGR energy. STEAM TURBINE K-660-247. GENERAL INFORMATION. TG DECK IS VIS SUPPORTED AND HAS 26 CONCRETE COLUMNS (T1 – T26).

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A PRESENTATION ON 660MW TURBO-GENERATOR ,ITS AUXILIARIES AND ASSOCIATED SYSTEMS By

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  1. A PRESENTATION ON 660MW TURBO-GENERATOR ,ITS AUXILIARIES AND ASSOCIATED SYSTEMS By Ashvani Shukla C&I BGR energy

  2. STEAM TURBINE K-660-247

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

  4. RATED CONDITIONS • LOAD : 660MW • BEFORE HP STOP VALVE • STEAM PRESSURE : 247KSC • STEAM TEMPERATURE : 5370C • STEAM FLOW : 2023.75T/HR • AFTER HPC • STEAM PRESSURE : 48KSC • STEAM PRESSURE : 298.710C • BEFORE IP STOP VALVE • STEAM PRESSURE : 43.2KSC • STEAM TEMPERATURE : 5650C • STEAM FLOW TO REHEATER : 1681.12T/HR. • DESIGN CONDENSER PRESSURE : 0.105KSC (abs.) • COOLING WATER FLOW : 64000M3/HR • FINAL FEED WATER TEMP. : 286.350C • FREQUENCY RANGE : 47.5 – 51.5 Hz

  5. STEAM TURBINE Generator rated speed 3000 rpm Generator manufacturer - Electrosila No. of bleedings 8 Length of the turbine 36.362 m No. of stages HPT 17 IPT 11x2 LPT-1 5x2 LPT-2 5x2 Total 59

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

  7. STEAM TURBINE Turbine Governing system Mode of Governing Nozzle Type E/H Control fluid Firequel-L make Supresta-USA Normal Operating Pr. 50 Ksc Capacity 600 lpm Fluid pump motor rating 200 KW Filter material Ultipor Mesh size 25 µ

  8. STEAM TURBINE Lube oil system Lube oil Tn-22C Russia Mobil DTE Oil light Teresso 32 In accordance with ISO VG 32 Absolute viscosity 16.7 Centipoise Kinematic viscosity -32 Centistokes Specific gravity 0.89 Flash point 180 0C Fire point 240 0C Oil requirement per bearing N1 200 lpm N2 200 lpm N3 450 lpm N4 280 lpm N5 350 lpm N6 350 lpm N7 350 lpm N8 350 lpm N9 600 lpm N10 600 lpm

  9. STEAM TURBINE Lube oil system Total oil system capacity 52000 lit Full volume of oil tank 58000 lit Material of tank SS Normal lube oil pressure 1.2 Ksc Oil temp at inlet of bearings Normal 55 0C Maximum 59 0C Piping SS Seal steam system Source of gland sealing system During normal operation End glands of HPC & IPC During low load operation End glands of HPC & IPC + AS Quantity of seal steam required 3.54 TPH Seal steam pressure at turbine glands 1.1-1.2 Ksc Seal steam temperature at turbine glands 160 0C

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

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

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

  13. STEAM TURBINE • Fixed blades • HPT first stage 18Cr11MoNiVNb (1-5) • HPT other stages 15Cr11MoV (6-17) • IPT first stage 18Cr11MoNiVNb • IPT other stages 15Cr11MoV • LPT first stage 12Cr13 (1-4) • LPT Other stages 08 Cr13 (5) • Number of stages • HPT • Impulse stages 1 • Reaction stages 16 • IPT • Impulse stages 22 • Reaction stages 0 • LPT • Impulse stages 20 • Reaction stages 0 • All rows of blades are integrally shrouded

  14. STEAM TURBINE No. of HP Stop valves 2 No. of HP Control valves 4 Type of control valve unit Block united No. of IP Stop valves 2 No. of IP Control valves 4 Type of control valves Separate No. of Journal bearings for turbine 8 No. of Journal bearings for Gen 4 No. of thrust cum journal bearing 1 Type of thrust bearing Tilting Type of journal bearing 6-Fixed & 2-Tilting pad Material of bearing shell Alloy steel Type of lining Babbit LPT diaphrams 4

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

  16. TG SEAL STEAM SYSTEM

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

  18. IPT SEAL STEAM CONNECTION IPT TO COLD SEAL STEAM HEADER TO GSC

  19. LPT SEAL STEAM CONNECTION LPT FROM COLD SEAL STEAM HEADER TO GSC

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

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

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

  23. MAXIMUM ALLOWALABLE UPPER LIMIT (WITH CF PUMPS IN STOPPED CONDITION) IS 150mm FROM THE UPPER COVER (85 GRADUATION OF L.G.) AND MINIMUM OPERATING LEVEL IS 800mm (20 GRADUATON OF L.G.) FROM THE UPPER COVER. • CF PUMP STOPS AUTOMATICALLY INCASE OF RESERVOIR OIL LEVEL LOW-LOW. • FOR VISUAL OVSERVATION OF OIL LEVEL ,LEVELGLASSES HAVE BEEN PROVIDED IN THE BOTH SIDES (DIRTY AS WELL AS CLEAN). • DIFFERENTIAL PRESSURE SWITCH (10MAX10CP001) HAS BEEN PROVIDED TO WARN ABOUT INCREASE IN PRESSURE DIFFERENCE IN SIDE THE MESH FILTER. ALLOWABLE DIFFERENCE IN MESHES DOESNOT EXCEED 150mm. • THE STANDBY CF PUMP STARTS WHEN THE RUNNING ONE TRIPS OR SYSTEM PRESSURE DROPS TO 36KSC. • IT TAKES 2 MINS FOR THE SYSTEM TO GET PRESSURIZED. • IF SYSTEM PRESSURE DROPS TO 20KSC (10MAX14CP001) AND STOP VALVES START CLOSING ,THE OPEARTING PUMP WILL STOP AND NO SIGNAL WILL BE GENERATED TO START THE STAND BY PUMP (SENSING OIL LEAKAGE). • CF PUMP ALSO TRIPS ON FIRE PROTECTION. • DUPLEX FULL PASSAGE FILTER WITH FILTERING DEGREE 20-25MICRONS IS INSTALLED IN GENERAL PRESSURE COLLECTOR OF CONTROL SYSTEM.IF PRESSURE DIFFERENCE (10MAX14CP301,10MAX15CP301) ACROSS THE RUNNING FILTER REACHES 0.8KSC,THE STANDBY FILTER HAS TO BE TAKEN INTO SERVICE.

  24. 2NOS.OF CF COOLERS (A&B) ARE INSTALLED IN THE CF SUPPLY LINE BEHIND THE DUPLEX FILTER. THESE COOLERS ARE DOUBLE PASS (BY WATER) SURFACE HEAT EXCHANGERS WITH TUBULAR DESIGN ,WATER STREAM FLOWS INSIDE THE TUBES AND CONSIST OF 148 TUBES OF SIZE 16X1500mm AND HEAT EXCHANGE AREA 25m2.CF FLOWS FROM TO DOWNARD. • COOLERS ARE DESIGNED FOR A MAXIMUM COOLING WATER PRESSURE OF 10 ± 0.5KSC AND CF PRESSURE OF 68.7 ± 0.5KSC.CFFLOW RATE TO EACH COOLER IS 50m3/hr AND PRESSURE DROP IS 0.2KSC. CWFLOW RATE TO EACH COOLER IS 80m3/hr AND PRESSURE DROP IS 0.194KSC. • FOR HYDRODYNAMIC FLUSHING OF PIPELINES DURING MAINTENANCE,THERE IS A BYPASS VALVE (10MAX14AA501)TO THE COOLERS WHICH SHOULD BE CLOSED AND SEALED DURING ROUTINE OPERATION. • IN THE INPUT AND OUTPUT TO THE COOLERS CF LINE IS PROVIDED WITH TRIPLE-PASS SWITCHING OVER VALVES WHICH PREVENT FALSE ACTIVATION OF BOTH COOLERS. • CF TEMPERATURE IS MAINTAINED (48-52OC)BY COOLING WATER FLOW VARIATION WITH THE HELP OF A FLOW CONTROL STATION CONSISTING OF A PNEUMATIC CONTROL VALVE (10PGM20AA001) AND A BYPASS MOTORIZED CONTROL VALVE(10PGM20AA002).IN CASE TEMPERATURE RISES TO 55OC (10MAX14CT001,10MAX14CT002),MOTORIZED BYPASS VALVE OPENS TO MAINTAIN THE CF TEMPERATURE. THE MAXIMUM LIMIT OF CW TEMPERATURE AT COOLER INLET IS 37OC.IF CW TEMPERATURE IS BELOW 36OC ONE COOLER CAN BE PUT OUT OF OPERATION.

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