SIEMENS SECTION 8 STEAM TURBINE UNIT Steam Turbine Core Components Steam Turbine Auxiliaries Condensing Plant Algerian Energy Company Projet Skikda CCPP — 2 x 1S.V94.3A, KKS Section at 82 83 Siemens Power Generation Department: W621 / B-075603 Bid Rf. No, ALG296 (1202) W621 ~ Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP — 2 x 1S.V94.3A STEAM TURBINE UNIT Steam Turbine Core Components General Components in today's power stations must be designed to meet stringent requirements regarding: = superior thermal performance - excellent product reliability - operational flexibility characterized by: ~ high efficiency high availability = easy maintenance = low time expenditure for inspections Drawing on a wealth of experience gained in designing, building and the operating ‘experience feedback from more than 1,300 steam turbine-generators, Siemens has developed a modular design approach that divides the steam turbine into three main parts: - high-pressure (HP) section - _ intermediate-pressure (IP) section - low-pressure (LP) section Capacity gradation for each turbine module is based on the laws of similarity. This design le enables Siemens to offer turbine sections with overlapping output ranges, covering ally all application requirements. pract Thus, selection of each turbine section can be performed in accordance with economical and operational considerations. The result Is a group of modules satisfying all diverse requirements in the output range 50 to 1,350 MW. Arrangement The proposed steam turbine-generator set will consist of one barrel type HP cylinder and ‘one reverse flow IP/LP cylinder exhausting axially into the condenser. The generator is located between gas turbine and steam turbine. A synchronous clutch at the front end of the - — & Siemens Power Generation Section: 81 Department: $312 Bg/ B-075603 Page: 1 of 20 Bid Ref, No, ALG296 (1202) W621 ~ Sb / SalSIEMENS Algerian Energy Company Projet Skikda CCPP — 2x 1S.V94.3A steam turbine transmits the torque to the generator shaft. The turbine is of the tandem compound design. The individual shafts of the cylinders are coupled rigidly together. Typical longitudinal Section For information only - no liability for correctness and completeness = a Section: 8.1 Siemens Power Generation Page: 20f 20 Department: S312 Bg/ B-075603 Bid Ref, No. ALG296 (1202) W621 ~ Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S.V94.3A Design of HP Turbine Outer Casing The outer casing is of a barrel-type design which enables almost complete rotational symmetry to be maintained and large asymmetrical deformation and thermal stresses to be avoided, even with high steam parameters. The turbine rests on the bearing pedestals at the level of the machine axis. The casing displacement in the axial direction results from thermal expansion originating from the support brackets at the rear bearing pedestal. At this point cams projecting downwards over the machine axis fit into corresponding recesses in the bearing casing. Displacement transverse to the machine axis originates from the centre guide, situated under the machine axis, which is formed by spurs on the bearing pedestals and forks on the outer casing. Exact alignment of the casing is provided by fitting pieces. In order to keep frictional forces to a minimum, the fitting pieces between the fixed bearing pedestal and the casing bracket supports are provided with a low friction material. Guide Blade Carrier The guide blade carrier is axially split. As steam conditions ahead of the blading and in the outer casing are the same, the bolts of the horizontal joint only have to absorb the forces resulting from thermal stresses. Arrangement of the Guide Blade Carrier The guide blade cartier is centered by alignment pieces which are inserted between projections of the guide blade carrier and corresponding grooves in the outer casing on the admission and exhaust side in the intersection of the axes. There are three guides on the admission end and three on the exhaust end. In axial direction, the guide blade carrier is supported on the thrust bearing side directly on the outer casing. This means that the thermal expansion of the guide blade carrier is in the same direction as that of the rotor and the outer casing. Admission Steam to the HP-turbine is supplied via one combined stop and control valve located laterally. A diffusor type admission nozzle directs the steam from the control valve to the spiral inlet of the HP-turbine. Exhaust One exhaust branch is arranged below the turbine. The exhaust branch is connected to the cold reheat piping by means of a welded connection Rotor The rotor consists of a monoblock forging with integrally forged coupling flanges and inserted blades. - — i Siemens Power Generation Section: 8.1 Department: $312 Bg/ B-075603 Page: 301 20 Bis Re, No. ALG206 (1202) WE21 ~ Sb / SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S.V94.3A Transport Provided the dimension and weight for transport do not exceed the permissible values, the HP turbine is transported fully assembled. IP/LP Turbine Design Outer Casing The outer casing consists of a cast admission casing and a cast exhaust casing connected by a vertically arranged flanged joint. Both these casing sections are horizontally split. The forces which occur as a result of the steam pressure differentials and thermal loadings are accommodated by the casing joint bolts. The upper part of the rear bearing casing is bolted to the exhaust casing and the lower part is integrally cast with the bottom half of the exhaust casing The rear bearing casing is supported by three integrally cast pylons of the exhaust casing bottom half and a pylon bolted to the top half of the exhaust casing. Channels are provided in the pylons for supplying cil and seal steam to the bearing casing resp. seal steam casing, Their cross-section is sufficient to also route through the pylons air, leakage steam, oil vapour, return oil and cabling The front end of the turbine casing rests with its front support brackets at the level of the machine axis on the bearing pedestal. Axial displacement of the casing as a result of thermal expansion originates from these supports and is in the direction of the exhaust end. Axial fixing is accomplished by projections on the support brackets which engage in recesses on the bearing casing. At the exhaust end the casing is supported on the foundation by brackets. Between brackets and foundation sole plates low friction material is provided. Displacements transverse to the turbine axis originate from the casing centering guides located below the turbine centerline. These comprise projections on the bearing pedestal resp. base plate below the exhaust section and forks on the outer casing. Correct alignment of the casing is ensured by fitted keys. To minimize friction, the fitted keys between the bearing pedestals and the casing support brackets are coated with low friction material. Inner Casing The inner casing consists of a cast top and bottom half. The forces resulting from the diffential steam pressure and thermal loadings are accommodated by the casing joint bolts and the centering guides. The inner casing is supported in the horizontal plane such that thermal displacements have no influence on the casing alignment. Transverse to the turbine axis, the inner casing is centered by means of pins. These pins are fitted in eccentric bushes which are installed in the outer casing, The pins engage in grooves of the inner casing. By turning the bushes in the outer casing the inner casing can be aligned with the turbine closed. This results in an optimum alignment of the inner casing relative to the rotor. Relative expansion between outer and inner casing as caused by temperature —_— a4 Siemens Power Generation Section: 8.1 Department: $312 Bg/ B-075603 Page: 4 of 20 Big Ref, No, ALG296 (1202) WE2t ~ Sb / SalSIEMENS. Algerian Energy Company Projet Skikda CCPP - 2x 1S.V94.3A differences are accommodated in vertical and horizontal direction by sliding of the pins in recesses of the inner casing. The support brackets at the front end of the inner casing are aligned by means of fitted keys. Hence axial displacement of the inner casing and the rotor is in the same direction towards the exhaust end. Thus axial clearances between moving and stationary blades can be kept small Internal Steam Flow After leaving the IP-blading the steam passes through the annular space between inner and outer casing. Induction steam is admitted before the steam expands further in the LP blading section. Stationary Blade Carrier and Stationary Blade Rings Stationary blade carriers and rings are arranged in the region of low steam conditions. They are kinematically supported in the outer casing in order to allow for thermal expansion. The first rows of stationary blades are arranged in a cast blade carrier, while the last rows of stationary blades are mounted in welded blade rings. Exhaust The steam leaving the blading passes through an axial diffuser constructed of fabricated steel which in turn is installed in the cast exhaust casing. This ensures that exhaust steam velocity is optimally converted into pressure, reducing exhaust losses. Furthermore the axially arranged condenser with tubing transverse to the turbine axis minimizes the pressure losses between blading and tube banks. Atmospheric Rel Atmospheric relief diaphragms are provided at suitable points as a back-up to the safety devices to protect the turbine against excessive pressure. If pressure rises to an excessively high level a breakable diaphragm is ruptured Diaphragm Rotor The rotor is supported at the front end by the HP turbine rotor which in turn rests in the combined journal and thrust bearing installed between HP and IP turbine. As a result, axial expansion of the rotor is in the exhaust direction. At the exhaust end, the rotor is supported by a journal bearing housed in the rear bearing pedestal of the turbine. The IP/LP Rotor consists of two sections which are joint by an appropriate welding process. Suitable NDT methods assure the quality of the rotor forgings and of the welded area. The IP/LP rotor has no bore, and therefore the need for periodic examinations is eliminated. Shipment Provided the dimensions and weights do not exceed allowable values, these turbine cylinders are shipped fully assembled. Department: S312 Bg/ B-075603 Page: 5 of 20, Bid Ret No, ALG296 (1202) W821 ~ Sb / SalSIEMENS Algerian Energy Company Projet Skikda CCPP — 2x 1S.V94.3A Installation To dismantle the inner casing bottom half, the hot reheat valve has to be withdrawn appropriately. It then rests on a supporting beam mounted on the casing. The journal bearing at the exhaust end can be inspected and, if necessary, replaced via an access ‘opening in the condenser. Blading Configuration General The blading includes all components of a steam turbine which are involved in the conversion of the thermal energy of steam into mechanical energy. This functional description alone is sufficient to indicate the major importance of the blading in terms of turbine efficiency and service reliability. A corresponding amount of design effort goes into achieving the best possible blade profiles and assuring that the blading has the necessary mechanical strength. ‘The same applies to manutacturing precision and surface finish. Elimination of Impermissible Blade Vibrations Particular attention is paid to the elimination of resonances. The natural frequencies of moving blades without shrouding are matched to rotational frequencies as early as the planning and design stage. Once installed, the blades are inspected meticulously and checked carefully for correct seating. Frequency matching is not necessary in the case of moving blades with shrouds. This is because the shrouds are positioned so close together that they generate a high degree of damping which prevents appreciable vibration amplitudes. Drum-Type Blading of Turbine Sections The HP, IP and the first stages of the LP turbine section feature drum type blading. Blading Design The greater part of the blading is designed as drum-type blading consisting of cylindrical reaction stages with approximately 50 % reaction. The stationary and moving blades have integral rhombic roots and integral rhombic shroud plates, Siemens Power Generation Section: at Department: $312 Bg/ B-075603 Page: 6 of 20 Bid Ref. No. ALG296 (1202) WE21 ~ Sb / SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2 x 1S.V94.3A Fixing of Drum Type Blading Caulking pieces are used as fasteners for blade installation. With these it is possible to achieve elastic prestressing in the root and shroud region of all blades. This prestressing factor is determined by measuring root and shroud twist. The shrouds are then finish-turned and their shared shroud profile is machined, Excellent damping characteristics in operation are attributable to prestressing of the blade rings. End blades fastened to the shaft by means of set screws or to the adjacent blades by means of taper pins lock the insertion openings through which the moving blades are insertec the circumferential shaft groove. The ends of the rombic roots and shrouds of the stationary blading protrude beyond the casing joint. Clamping and pre-twist of the end blades and neighbouring blades is ensured by assembling the upper and lower part of the casing using casing joint bolts. LP Turbine Blading The stationary and moving blades of the first stages of the LP turbine correspond to the reaction stages of the drum-type blading. Final LP Stages The final stages of the LP turbine sections are grouped in standardised stages. The twisted design of the moving blades allows for the enormous differences in rotational speed at root and blade tip. The freestanding rotating blades are without lacing wire or shrouding Final Row of Stationary Blades The final row of stationary blading is provided with hollow guide blades of sheet metal. In order to improve the massflow distribution and the efficiency the last stage stationary blades are not only twisted but also curved circumferentially. The trailing edges are tapered finely to prevent dead flow zones and formation of large water droplets. The axial gap of the final stage is large to facilitate the disintegration of water droplets entrained in the flow and to provide a longer acceleration path for remaining water droplets. This reduces relative impingement speeds on the leading edges of the moving blades, Siemens Power Generation Department: $312 Bg/ B-075603 Page: 7 0f 20 Bid Rot, No. ALG296 (1202) WA21 ~ Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP — 2x 1S.V94.3A Droplet Impact Erosion General Droplet impact erosion is a purely mechanical process whereby material is wom away by water droplets that are carried by the steam flow impinging on the moving blades at a high relative velocity. As the water droplets do not have the same absolute velocity as the steam flow, this results in different relative velocity components with the same circumferential velocity. Design Features to Prevent Droplet Impact Erosion INTERSTAGE DRAINAGE Various measures can be taken to avoid droplet impact erosion, for example water separation facilities within the turbine. The water forced outwards by the centrifugal force collects on the casing walls of the LP turbine and is drained off through extraction openings for stage drainage. LEADING EDGE HARDENING Due to the high velocity of the impinging droplets, the leading edges of the last blading row are hardened in the endangered blade region depending on blade material usage. TIPPED TRAILING EDGES A further measure for the prevention of droplet impact erosion are structural precautions to prevent the formation of large water droplets from the start. One such measure is the optimum profile of the guide blades in the end stages with thin blade trailing edges. A sufficiently large axial gap between the guide and moving blades allows a sufficiently large acceleration and atomizing stretch for the large droplets. Siomens Power Generation Section: 8.1 & Department: $312 Bg/ B-075603 Page: 8 of 20 Bid Ret. No, ALG296 (1202) WE2t ~ Sb / SalSIEMENS Algerian Energy Company Projet Skikda CCPP — 2x 1S.V94.3A Synchronous Clutch Coupling General For reasons of flexible operation and start-up procedure of single shaft type combined power plants a synchronous clutch coupling is installed between generator and steam turbine. With the gas turbine driving the generator and the steam turbine at rest, the clutch is disengaged. The pawis are inactive. The steam turbine is accelerated and at the instant the steam turbine speed overtakes the generator, the relay clutch is engaged. When the relay clutch has engaged, the main teeth are stil disengaged but are now aligned for inter-engagement. The relay clutch teeth now move the main sliding assembly along the main helical splines to shift the main teeth smoothly into engagement. During this movement the relay teeth become unloaded when the main teeth are partially engaged, The oil filled dashpot becomes effective whilst the main teeth are shifting the clutch fully into engagement. The clutch is fully engaged and transfers the torque of steam turbine load. When the steam turbine slows down relative to the generator, the torque is reversed on the main helical splines and the main sliding assembly moves to disengage the main teeth. The relay clutch then disengages so the steam turbine is disengaged from the generator. Siemens Power Generation Section: 8.4 Jo Department: $312 Bg/ 8-075603 Page: 9 of 20 Bid Ret. No. ALG296 (1262) W621 ~ Sb / SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S.V94.3A SSS Clutch - Simpliied Operating Principles Ree eee Clutch disengaged cos eave enon be np spsoneing te speed ote cua Tah ae diergeg08. achat pat satan. grove pani rect ure hs pst sped Helical eolines “approaches the ovtput speed. — arta "oon we eae Pawls active : Nw = mY vee lem 9 Coco ig Clutch engaging Furor lpn aae of np, cle opt fant at engegernant wi he cnet at aa Clutch engaged ~~ ouput eg ad ~~ amp te roan aso | wor ota one snore Sere Clutch disengaged fo conan shown ne rt agra sbove oroa2 Siemens Power Generation Section: 8.4 i Department: S312 Bg 8-075603 Page: 100120 Bad Met No. ALE (1282) EZ" ~ S/SSIEMENS Algerian Energy Company Projet Skikda CCPP - 2 x 1S.V94.3A Bearing Configuration Steam turbines of the HE series feature three journal and one combined thrustjournal bearing. Two of the journal bearings are installed in the front bearing pedestal which accommodates the HP turbine front bearing and the rear bearing of the collector shaft and the overrunning clutch. The third journal bearing is located in the exhaust casing of the IP/LP cylinder. The combined thrustjournal bearing is located between the two turbine cylinders at the rear of the HP rotor. Bearing Pedestals The bearing pedestal at the front end of the HP cylinder and the bearing pedestal of the combined axial/radial bearing consist of cast top and bottom halves which are bolted together at the level of the casing joint. Apart from supporting the rotors these bearing pedestals also guide the turbine casings. Forces resulting from friction at the casing supports, earthquakes, vibrations and unbalance are transferred directly to the foundations via a system of anchor bolts and projections underneath the base plate. The rear journal bearing of the IP/LP turbine is located in the diffuser exhaust casing of the IP/LP turbine and is supported by means of three hollow struts which transfer the loads to the lower casing wall. A fourth strut is bolted between upper bearing shell and casing wall. Bearings The journal bearings located in the front bearing casing are designed as tilting pad bearings This type of journal bearing is used in order to achieve the required running characteristics of the shaft. The combined thrustjournal bearing features tilting pads to absorb the axial thrust and a journal bearing to accommodate radial loads. The bearing pads are supported flexibly on the bearing shells and are thus able to transfer axial thrust or radial forces of the rotors to the bearing pedestal via the bearing shells. The bearing at IP/LP exhaust end is a plain cil film bearing with unilateral cil supply; bearings of this type require less lube oil in a well damped system and generate only small friction losses. The journal bearing shells are supported such that they can adjust their position according to the deflection curve. The journal bearing at the IP/LP exhaust can be installed without removal of the upper half of the turbine casing by sliding the bearing shell over the free shaft end. Thermocouples are provided in order to monitor bearing temperatures. Provision is also made for mounting electrical vibration transmitters to monitor vibrations of rotor and bearing pedestals. Siemens Power Generation Section: a O Department: $312 Bg/ 8-075603 Page: 11 of 20 Bic Ref, No, ALG296 (1202) WE21 ~ Sb / SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2 x 18.V94.3A Shaft Turning Gear Main Components The shaft turning gear essentially consists of a hydraulic gear motor, an overrunning clutch, an intermediate shaft and the necessary bearing and fastening parts and is installed in the at the free end of the IP/LP turbine shaft. The hydraulic gear motor is linked to the bearing pedestal via its cover plate and casing. Overruning Clutch The hydraulic motor turns the outer race of the overrunning clutch via @ splined shaft and a flange. The outer race is supported in the casing by means of a retaining ring and two ball bearings; the inner race of the overrunning clutch is fastened straight onto the end of the intermediate shatt. The clamping parts of the overrunning clutch which are enclosed in a cage, are installed in such a way that they swivel inwards during tuming gear operation thus creating a rigid connection between outer and inner race. During turbine run-up to speed, the clamping parts of the clutch swivel outwards and break the connection. To prevent wear at higher speeds, centrifugal force lifts the clamping parts rotating with the inner race clear from the outer race. Oil Supply For oil supply purposes the shaft turning gear is connected to the shaft jacking system; this means that the turning gear starts moving as the shaft jacking system is put into operation. An adjustable throttle valve in the feed pipe of the hydraulic motor is used to make speed changes. By closing the throttle valve it is possible to isolate the shaft turning gear from the shaft jacking system during bearing adjustments. The shaft turning gear is also provided with an electrically actuated valve and it forms part of the turbine generator's automation systems. To prevent stand still corrosion of the bearings during normal turbine operation, a small flow of lube oil is fed to the hydraulic motor which causes the motor to rotate slowly Manual Shaft Turning Gear ‘A manual shaft turning device consisting of a ratchet and a lever is located in the at the front end of the IP/LP turbine section. When the lever is actuated, the ratchet engages in a ring gear on the coupling flange of the rotor, thereby enabling the rotor assembly to be turned slowly, Siemens Power Generation Section: Department: $312 Bg/ B-075603 Page: 12 0f 20 ‘id Rot. No, ALG296 (1202) W621 ~ Sb / SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S.V94.3A eee 12 & 9 Hydraulic Turning Gear 41 Hydromatic gear motor 6 Ball bearing 14 Bearing 2 Specially profiled shaft 8 Casing 12 Turbine Rotor 4 Cover 9 Holding ring 13 Shaft 5 Shaft ange 40 Overrunning clutch 45 Cover Oil Supply for Turning Device For information only - no liability for correctness and completeness Siemens Power Generation Section: 81 # Department: $312 Bg/ 8-075603 Page: 13 0f 20 Bid Ref, No, ALG296 (1262) We2t ~ Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S.V94.3A Electrohydraulically Actuated Steam Valves Gener: The main steam and reheat steam stop valves comprise isolation valves mounted in the main steam and reheat steam lines ahead of the turbine. They have protective functions and are tripped by protective devices on demand to interrupt steam flow. For this reason, they are designed to give the shortest possible closing times with maximum possible reliability. By contrast, the control vaives adjust steam flow to match load conditions. ‘Stop and Control valve are combined in a common body. Integral Strainers Integral strainers are provided in the valve body section of the main and reheat steam stop valves in order to keep foreign particles away from the admission section of the turbine and the blading. Stop Valve With the stop valve in closed condition, steam is present above the valve disk. A pilot disk integral with the valve stem is incorporated in the valve disk to reduce the force required to open the valve. Metallic and graphite rings seal the valve stem off against the atmosphere. In addition a stem leak-off steam connection is provided on the main steam and IP steam stop valves. The valve has a backseat on disk and stem which prevents any leakage of steam from the stem when the valve is open. As a result, relatively large clearances can be set for the seal rings but with only small leakages. This has a positive impact on operating reliability. Control Valve The control valve cone is of balanced design. Relief holes in the valve disk reduce the force required to position the valve. Valve stem sealing and guidance are implemented in the same way as for the stop valve, Actuation The control valves and the stop valves each have dedicated electrohydraulic actuators which move the valves against the force of a spring. The valves are closed by spring force in the event of a power failure. Wear Resistance Treatment The stems and stem and disk bushings of the control and stop valves are specially treated to increase their resistance to corrosion and wear. Siemens Power Generation Section: 8.1 Department: $312 Bg/ B-075603 Page: 14 0f 20 Bid Ret. No, ALG296 (1202) WE21 - $b /Sal feSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S,V94.3A ‘Schattaninab Trip Actuator ‘Sehltschuss vont Sop VaNe 10 or Stotlertab (Contot Actuator au 2 23 Mh WBF Stoned ‘Cano vaive Sectional View S8V Stop Valve STV Control Valve 1 Slop valve actuator 24 Contrel valve actuator A Suppor 2 Support 5 Packing i 2 Pabling ting 4 Gland bushi 24 Gland bushing 6 Vala stem with pt disk 2 Valve stom wih valve disk 8 Valvo cover 26 Vane cover i Base bushing 27 aso bushing 8 Vaio dit 50 Valve saat 10 Valve seat 11 Valva body 42 Siloam strainar Combined Stop- and Control Valve for Main Steam for pressure < 140 bar For information only - no liability for correctness and completeness e Siemens Power Generation Section: 81 Department: $312 Bg/ B-075603 Page: 15 0f 20 Bid Ref, No. ALG296 (1262) WE21 ~ Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP — 2x 1S.V94.3A Induction Steam Butterfly Valves Design Features ‘A metallic seal ring which is installed in the casing, ensures a high degree of leaktightness and offers excellent wear resistance. Casing and disc are castings. The casing material is carbon steel and the material of the disc is stainless steel. The specifically designed seal is arranged in the casing and can be replaced. The axis (double eccentric) of the shaft is arranged off the plane of the disc ensuring that the disc is lifted off the seal in the initial phase of opening with the effect that friction on the sealing surfaces is eliminated. This is essential for control applications. Valve Actuators Rotation of the valve shaft is by means of an actuator. Torque is transmitted to the shaft by splines. A spring assembly for fail safe valve operation, i.e. closing of valves in the event of loss of electric or hydraulic supply, acts directly onto the piston rod. Electrohydraulic Actuators for Steam Valves General The main features of electrohydraulic actuators for steam valves are: = fail safe operation due to closing of the stop- and control valves by spring force - external fluid supply by a packaged supply unit = accurate positioning by a high-grade electrohydraulic servo valve = rapid closing of the stop- and control valves in less than 150 ms (under pressure) Control Valve Actuator Valve Position Control Control valve movement is initiated by the position controller in the event of a control deviation between actual valve position and setpoint by applying a low current to the electrohydraulic converter. This converter, or so called electrohydraulic servo valve, is a continuously operating high- grade directional control valve with particularly good steady state and dynamic characteristics and high amplification. A proportional fluid flow is supplied to the hydraulic cylinder as output variable of the electrical input current, ‘Siemens Power Generation Section: 8.1 & Department: S312 Bg/ B-075603 Page: 16 0f 20 Bid Ret. No, ALG296 (1202) WE2t - Sb / SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2 x 1S,V94.3A Valve Position Transmitter The analog feedback signal for valve travel is transmitted by non-contacting position transmitters to the position controller, thereby closing the control loop. Rapid Closing For rapid closing operations resulting from load rejection or turbine trip hydraulic fast valving is employed. For this, two solenoid-operated 2-way popped valves are rapidly opened and the two piston chambers are interconnected. The short paths between the piston chambers via directional control valves and the generous sizing of the two way popped valves allow short closing times of less than 150 ms and short delay times to be achieved. The two way valves are standard cartridge valves with piston guidance. When pressure is present beneath the control valve piston these valves piston these valves are held closed by the pressure above the disc caused by the solenoid-operated directional control valves. For rapid closure the solenoid is deenergized and the control pressure relieved, so that the two- way valve opens and initiates the valve closing operation. Stop Valve Actuator The stop valve actuator operates the stop valve in response to binary electric signals such that the valve can only adopt the open or closed position. Actuation by pilot operated two- way valves enables short delay and closing times of less than 150 ms to be achieved as with the control valve. The two actuators are therefore identical except for the following - Instead of the electro hydraulic servo valve a solenoid pilot valve is installed, which opens. way for the fluid to the cylinder for valve opening. = The limit position is derived from an analog non-contacting position transmitter. Design Details The actuator has a cast cylinder on which are arranged the cup springs and posi transmitters, as well as the control devices which are operated via plates with internal ports. Power Supply Power is supplied and signals are transmitted to the actuator via flexible cabling with plug ‘connectors. Siemens Power Generation Section: 8.1 & Department: $312 Bg/ B-075603 Page: 17 of 20 Bid Ret, No. ALG296 (1202) WG21 ~ Sb /SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2 x 1S.V94.3A Electrohydraulic Actuator For information only - no liabilty for correctness and completeness Siemens Power Generation Section: 8.1 4 Department: S312 Bg/ B-075603 Page: 18 of 20 Bic Ret. No. ALG296 (1202) WE2t - Sb / SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 18,V94.3A Supply Unit for Electrohydraulic Actuators Compact Unit The complete high-pressure fluid supply unit is housed in a splash proof steel cabinet. Pressure Controlled Pumps Two 100 % pumps are provided, one continuously working and the other on standby. Pump discharge is controlled by system pressure. Continuous pump operation ensures long service life and avoids pressure jerks. Accumulators for Fast Valve Actuation A group of bladder type accumulators allows valve positioning to be implemented during transient conditions. Air Cooling Heat is dissipated via a blast air cooler. The cooler fan is activated as a function of the temperature of the fluid in the reservoir. Fluid Reservoir The fluid reservoir is will be provided with an integral fluid collecting trough. A drain valve and a level switch are provided at the lowest point of the inclined baseplate of fluid collecting trough. Filtering A filter is provided at each pump discharge. Furthermore the required fluid conditions is maintained by a separate filtering loop with micro filter (3 sm absolute). Protection For each pump a pressure limiting valve and for each accumulator a dedicated safety valve is provided. Siemens Power Generation Section, 8.1 0 Department: $312 Bg/ B-075603 Page: 19 of 20 ‘id Rot. No. ALG296 (1202) W621 ~ Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP — 2x 1S.V94.3A 3 ion oseane sf 5 « fig 2 2 s s| 3 sje 3 £ 3] .) 3] 2 olf § 3 z g a) og) 2 aie 3 = 2; § oO ols Seale se 5/8 i | jf ' s 2 é 3 3 = . | Lj} f i- i blast air fluid cooler relief valve accumulator return fluid cooler High Pressure Fluid Supply Unit For information only - no liability for correctness and completeness ‘Siemens Power Generation Seation: 81 a Department: $312 Bg/ B-075603 Page: 20 of 20 Big Ref, No, ALG296 (1202) WE21 ~ Sb / SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S.V94.3A Steam Turbine Auxiliaries Oil System (Lubricant Supply System) Function of the Oil System The turbine generator set requires oil for = lubrication and cooling of bearings = driving the hydraulic turning gear ~ jacking the rotor shaft system at low speeds. The oil supply system, consisting of main oil tank and, oil pumps valves and interconnecting piping, supplies the required volume of oil at the necessary pressure to the points of consumption. = at pump discharge 5.5 bar pressure for bearing lubrication and cooling approx. 2.5 bar for bearing lubrication on emergency rundown pressure. ~ approx. 160 bar jacking Electrically Driven Main Oil Pump By providing electrically driven main oil pumps, the following technical merits have to be considered. = _ better suction conditions (ejector or booster pump not required) - less piping = improved reliability - reduced length of turbine generator set - easier maintenance Oil Supply During Turbine Generator Set Operation During turbine generator set operation one of the electrically driven main oil pumps supplies the required volume of oil to the bearings. The oil is drawn directly from the main oil tank, The oil is filtered through switchable duplex filters, cooled in an oil cooler and supplied to the individual bearings via a flow restrictor. The oil volume required is set by means of these flow restrictors. Oil Temperature Control The necessary oil inlet temperature for the bearings of the turbine generator sot is ensured by the thermostatic oil mixing valve installed in the oil line downstream of the oil cooler. This three-way-valve controls the oil flow which bypasses the oil cooler. Siena Power Goorin rd Department: $312 Bg / B-075603 Page’ 1o0t9 Bid Ft. No. ALG296 (1202) W621 ~ Sb / SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2 x 1S.V94.3A Oil Supply During Start-Up and Shutdown During start-up and shutdown one of the electrically driven main oil pumps supplies lube oil to the bearings of the turbine generator set. A jacking oil system is provided to lift the line of shafting, and to supply the hydraulic turning gear with motive oil. A low volume flow of high pressure oil is forced under each of the rotor journals to lift the rotor off the bearings, in order to prevent metal-to-metal contact at low speeds. dacking Oil Pumps The jacking oll pumps located on the main oil tank are positive displacement pumps driven by a three-phase AC motor. The oil is filtered through switchable duplex filters and supplied to the bearings. The required system pressure is kept constant by means of a pilot operated pressure limiting valve. The pressure limiting valve can be relieved via a bypass of the pilot valve. The required jacking oil pressures are set for each bearing by means of precision control valves upstream of the individual bearings. Check valves prevent backflow of oil into the system while the turbine generator set is running. Oil Supply During Malfunctions The second main oil pump is automatically put into operation by a pressure switch when the oil pressure in the lube oil system drops below a preset valve. The emergency oil pump supplies oil directly into the lube oil line and assures oil supply to the bearings during run down of the turbine generator set. Oil Vapor Extraction All spaces above the oil level in which oil vapor can form (oil tank, return line, bearing pedestals) are exhausted by a common fan. The fan produces a negative pressure approximately 0.5 to 1.0 mbar below atmospheric pressure. An oil separator is installed on the suction side of the fan, air being discharged to atmosphere. If the generator is hydrogen-cooled, the generator bearings have a separate vapor extraction, Main Oil Tank The main oil tank contains the oil necessary for the lubrication and cooling of the bearings, and for jacking the line of shafting at low speeds. It serves not only as a storage tank, but also for deaerating the oi ‘Siemens Power Generation Section: a2 0 t Department: $312 Bg / B-075603 Page: 2019 id Ret, No. ALG296 (1202) W62t ~ Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP — 2x 1S.V94.3A Design of the Tank The capacity of the tank is such that the full oil inventory is circulated not more than 10 times per hour. This results in a retention time of about 6 minutes from entry into the tank to suction by the pumps. This time allows sedimentation and air detrainment of the cil. Reserve capacity is provided between the normal operating level (corresponding to rated capacity) and the tank cover to accept cil from the entire oil supply system when the turbine- generator unit is shutdown. The tank is constructed with a sloping bottom with di connections at the lowest point. Deaers Oil returning to the tank from the oil supply system first flows through a submerged inlet into the tank, where the first stage of deaeration takes place as the oil rises in the tank. Oil flows through an oil strainer into the adjacent section of the tank and then flows lengthwise through the tank until it is drawn off by the oll pumps. n and Filtering of Return Oil Oil Pumps. The following submerged pumps are mounted on the tank: - Two single-stage main oil pumps with three-phase AC motor (centrifugal pump), one for operation and one for standby - Single-stage emergenoy oil pump with DC motor (centrifugal pump) ~ jacking pumps with three-phase AC motor (vane pump) Instrumentation The main oil tank has a local oil level indicator and level switches which signal when maximum and minimum levels have been reached. Oil Cooler Heat transmitted to the lube oil in the bearings is dissipated via a lube oil cooler.SIEMENS Algerian Energy Company Projet Skikda CCPP ~ 2x 1S.V94.3A — 4 ‘yer Sear? HE Series, Typical Lifting Oil System For information only - no liability for correctness and completeness x E u P a Depo iter ts 4 [ Min O1 Pump 1 82. Emergency Ob te Main Oil Tank, eae (Pit Type) HE Series, Typical Lube Oil System For information only - no liability for correctness and completeness ‘Siemens Power Generation ‘Section: 82 & Department: $312 Bg / 8-075603 Page: 40f9 Bid Ret, No. ALG296 (1202) W621 ~ Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP ~ 2x 18.V94.3A Seal Steam System Function The function of the seal steam system is to supply the shaft seals with steam to prevent ingress of air into the turbines or the condenser, irrespective of operating conditions A seal steam header connected to HP and IP shaft seals and a desuperheater connected to the LP shaft seal is provided for this purpose. Pressure in the seal steam lines and thereby in the shaft seals is controlled by either drawing off steam via a seal steam leak-off valve or by supplying additional steam via a seal-steam supply valve, as appropriate for the operating conditions at any given time. Pressure is held at 35 mbar (gauge) in this process. Pressure Control A pressure transducer supplies the actual value for the control and the signal for display in the control room. This pressure transducer measures the differential pressure between the seal steam header and atmosphere, A pressure controller activates the actuators for the seal steam supply valve or leak-off valve on the basis of the result of the comparison between setpoint and actual value for pressure. To increase the availability of the seal steam pressure control provision is made for manual control from the control room. Changeover to this takes place manually from the control room, or automatically in the event of faults in the electrical part of the seal steam pressure control, Warm-Up Valve for Seal Steam Line To prevent the shaft seals from being exposed to steam at too low temperature on a hot start, the seal steam line must be warmed up to the location of the seal steam valve before plant start-up and activation of the seal steam contro! system. Warm-up is also required during operation when the seal steam valve is closed and the steam upstream of this valve stagnates and cools. Likewise, cold steam must not come into contact with the shaft when the seal steam valve opens as a result of a load reduction. The warm-up valve must be closed when the seal steam valve is opened. Siemens Power Generation Section: a2 x Department: $312 Bg / B-075603 Page: Saf 9 Big Ref. No, ALG296 (1202) W621 ~ Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP — 2x 1S.V94.3A Gland Steam System The gland steam system is designed to prevent blowing of shaft seals for the turbines, imespective of operating conditions. The slight negative pressure in the gland steam system is provided by an exhauster installed at the gland steam condenser ski ‘The pressure in the gland steam chambers of the shaft seals can be adjusted by operating the valves at the suction fan or by setting the flap valves in the branch lines from the gland steam chambers. The gland steam condenses in the gland steam condenser. The non-condensable air- fraction of the gland steam is discharged to atmosphere. Gland Steam Condenser The gland steam condenser is designed for surface condensation. Coolant and gland steam condensate are kept entirely separated. The coolant passes through the tube side which consists of plain tubes expanded into the tube sheets. A welded joint connects the tube sheets with the condenser shell and provides the seal between coolant and seal steam system. I Gland Steam Header Uy dy ub Wl Pp Seal Steam Supply Skid [*LAUX. Steam] Gland Steam _! Leakoff Steam Conceneey (Condenser Skid Valve HE Series, Typical Gland and Seal Steam System For information only - no liability for correctness and completeness ‘Siemens Power Generation Section: 82 fe Department: $312 Bg / B-075603 Page: 6 0f9 Bid Ret. No, ALG296 (1202) W621 ~ Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP — 2x 1S.V94.3A ‘Aux. Steam | Gland Steam Supply For information only - no liability for correctness and completeness 4 Ot hem Contaner 2+ exhaner 2 Lovdingesor 4a als) Dean aa) 6 ran (Condens) oom —— i es fe 4 Ary Sao > _Msin Condensate : [ ney ater I Tee oO Gland Steam Condenser For information only - no liability for correctness and completeness ‘Siemens Power Generation Section: aa J Department: $312 Bg / B-075603 Page: 7 of 9 Bid Ref, No, ALG296 (1202) W62! ~ Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S.V94.3A Drain System Function of the Turbine Drain System During turbine start-up the hot steam entering condenses on the cold piping and casing walls. This may cause mechanical damage to the turbine blading where large quantities of condensate are formed. Furthermore, if no provision is made for the draining the condensate produced, temperature differences between the top and bottom halves of the turbine casing can arise which would lead to distortion of the casing. Turbine Drains The condensate produced in the turbine, in the associated valves and internal steam lines passes through drains to the condenser. The drain and warm-up valves are provided with actuators and are operated depending on parameters such as generated power and wall temperatures. Drain of low pressure drain points are equipped with drain traps. IP and LP Bypass Valves Function The bypass valve is a single stem valve and has 3 functions. The bypass valve regulates the flow of steam to the condenser according to the signals from the bypass controller, fast closing for the condenser trip and fast opening for the turbine trip. Bypass Valve The mechanical design of the IP and LP bypass stations are essentially the same. The valve stem and the guide bushings for the stem and valve disc receive a special surface treatment to provide a high degree of resistance to wear and corrosion. The valve sections of the IP and LP valves are fitted with a basket type strainer to prevent debris from passing through the valve. Warm-up and Drain Point IP Bypass ‘The IP bypass valve is fitted with a drain and a warm-up connection at the lowest point of the casing interior of the valve body. This prevents the sudden drop in steam temperature and thereby eliminates damage to the bypass station as a result of high thermal loadings on its sudden opening after a long period on standby during turbine operation. Drain Point LP Bypass LP bypass station is provided with a drain connection at the lowest point on the valve body 0 as to prevent condensate collection within their interior. The LP stations do not contain a warm up connection. Department: $312 Bg / B-075603 Page: 809 Bid Rat, No, ALG296 (1202) WE21 - Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP — 2x 1S.V94.3A Control Fluid Supply The supply of control fluid for the hydraulic actuators is by means of the common hydraulic supply unit for steam and bypass valves. Solenoid valves and servo valves integrated into the hydraulic fluid circuit interface between control system and valve actuator. Bypass Steam Admission into the Condenser ‘A dump line to the condenser is provided for each bypass valve. Due to an orifice provided in this line, a second critical expansion takes place downstream of the bypass valve. The expansion of steam reduces the stresses on the condenser during subsequent supercritical expansion. Water Injection The HP/IP and LP bypass steam is desuperheated by means of condensate injection via a spray valve in order to protect the condenser against excessive temperatures. Siemens Power Generation Section: 82 dé Department: $312 Bg / B-075603 Page: gof9 Bid Ref. No, ALG296 (1202) W621 ~ Sb / SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S.V94.3A Condensing Plant MAG/MAJ Condenser MAG The function of the condenser is to condense the steam exhausted from the LP cylinder and to produce and maintain as high a vacuum as possible in order to increase the heat drop which can be utilized in the turbine. Design Features The condenser is a box-type surface condenser with undivided water boxes on each end. The steam space is of rectangular cross-section to achieve optimum utilization of the enclosed volume for the necessary condensing surface. The condenser is located behind the LP turbine and connected to the condenser neck via an stainless steel expansion joint. The steam dome, shell and hotwell are steel fabrications, as are the water boxes. The condenser is fixed supported on the foundation beneath. Thermal expansion will be accommodated by means of multi-ball bearings. Arrangement The one-flow LP turbine outer casing is connected to the condenser via the steam dome. The steam dome is flanged to the exhaust casing of the turbine via a stainless steel expansion joint with the result that the LP turbine cylinder and the condenser form a unit. The direction of circulation water flow is rectangular with the turbine axis and in two passes, Which allows easy routing of the circulating water inlet and outlet. The condenser tube bundles, on which the exhaust steam from the turbine is condensed, consist of straight tubes, with smooth surfaces and running rectangular with the turbine axis in the steam space of the condenser. The condenser tubes rest in tube support plates at regular intervals along their length. These tube support plates in the steam space prevent impermissible tube vibration when the condenser is in service. Tube sheets on the circulating water inlet and outlet sides act as partitions separating the steam space from the cooling water side. Both ends of the tubes, through which circulating water flows, are roller-expanded and welded into the tube sheets, thus reliably sealing off the joints to prevent the ingress of circulating water into the steam space. The rolled joints provide adequate resistance to avoid impermissible tube sheet deformation. ‘On the cooling water side the water boxes are equipped with an rubber lining to prevent con- tact corrosion. Corrosion and mechanical loading of the tubes by the circulating water impose a need for special care in the choosing of a suitable tubing material, and in this the operating ‘experience available to PG has a decisive influence. The use of flawless materials and of correct procedures and good workmanship in the installation, supporting and securing of the ‘Siemens Power Generation Section: 83 &SIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S.V94.3A tubes is ensured by a quality assurance program which, among other things, provides for quality testing of the tubes before they leave the manufacturer. Appropriate design and QA measures, a suitable mode of operation and, where appropriate, the deployment of ancillary equipment together ensure that the tubing remains in good condition and hence that the availability of the condenser is high. Tube Arrangement The condenser tubes are divided into tube bundles designed to promote uniform flow. Theoretical investigations, as well as laboratory and field tests were performed to improve the tube bundle section design of the rectangular condensers. The following general aspects of possible improvements were closely analyzed: = lowest possible condenser inlet pressure influenced by the pressure drop between the LP-turbine diffusor and condenser tubes, the heat transfer coefficient of the tubes and the activation of the entire heat-exchange surface. smallest possible condenser heat losses. - minimized oxygen content in the condensate Each condenser tube bundle has its own air cooler section, To avoid subcooling in the condensate heating with steam from the turbine is achieved by means of the horizontal tube rows. The function of these rows is to condense the steam and to ensure the heat-up of the condensate to saturated steam conditions. Baffles are used to close off the air lane system from the steam side. The tube arrangement geometry here described is intended for all box-type condensers, and it is optimized with the aid of a computer program covering both the thermodynamics and the fluid mechanics of the condenser design to meet the requirements mentioned above. Siemens Power Generation Section: 83 Department: W711 / B-075603 Page: 203 ‘Bid Rot. No, ALG2G6 (1202) W62! ~ Sb / SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 18.V94.3A Air Extraction MAJ During turbine service, the condenser steam space and the exhaust steam channels connected to it are under steam pressures that are considerably lower than the atmospheric air pressure. In spite of the high degree of leaktightness exhibited by today's units, it is impossible to entirely eliminate the possibility of air ingress into these spaces with’ their substantial dimensions. The exhaust steam itself also entrains small amounts of air and other gases. These gases, including the air in-leakage, are not condensable in the condenser, and so on passing through the condenser tube array they are channeled via the air lane system to the offtake zone and extracted from the condenser by vacuum pumps. Extraction is performed continuously during condenser service in order to maintain the absolute pressure in the condenser at the level demanded by the thermodynamic conditions. Each tube bundle of the condenser has its own gas offtake. The gases, combined with residual water vapour, flow out of the air lanes into the air cooler tube bundles, which acts as the offtake zone. As the vapour/gas mixture flows through the air cooler bundle its temperature drops as a result of the condensation of the steam portion, the partial pressure of the gas rises and the volume to be taken off decreases. This reduces the power required to extract the gases. The gases and any residual water vapour are then compressed to atmospheric pressure by the vacuum pumps and expelled from the steanvwater cycle. ‘Two water ring pumps (elmo Units) are installed for that purpose, one of which serving as a standby unit, During start-up both pumps can be put into operation in order to reduce the ‘evacuation time, ‘Siemens Power Generation Section: 33 F Department: W711 / B-075603 Page: 30f3 ‘Bid Ret. No, ALG296 (1202) W62! ~ Sb / Sal