TURBINE AUXILIARIES

6.1 TURBINE GOVERNING SYSTEM

Power station turbines are constant sped machines and they are rotated at a speed of 3000rpm to
enable the coupled generator to produce electricity at 50 Hz frequency.
The main purpose of the governor is to maintain the desired speed of turbine during fluctuation
of load on generator by varying steam input into the turbine as required.
The governing system is addition to ensuring the following load speed characteristics of the
turbine also ensure the following functions.
The run up of the turbine from the rest to the rated speed and synchronizing with the grid.
Meeting the steam load variation in the predetermined manner, when running in parallel with the
other machines.
Protecting the machine by reducing the load or shutting of completely in a abnormal and
emergency situation.
TYPES OF GOVERNING SYSTEMS:
1. Throttle Governing.
In Throttle Governing system the governing attachment is attached directly to the Turbine
shaft itself and rotates at the same speed of the turbine. According to the turbine speed
the attachment linked with the rotor will run. The balls attached to the arrangement will
run by the centrifugal force and the valve will operate and allow the steam to flow into
the turbine. When the load on the generator will get through off and due to this effect the
speed of the turbine will rise
2. Nozzle Governing.
In this method the Nozzles are grouped and the supply of steam is controlled by a special
system called as ELECTRO HYDRAULIC CONTROL system. The controlling of the
intercept valves will supply the steam to the curtesvey stage of the high pr turbine
through intercept valves. There will be a rack and pinion attachment arrangement to
operate the intercept valves. The valves will operate radially in a sequence by
maintaining the input supply under balancing. At full load the valves will be in fully open
condition. The operation of the valves totally carried out by the hydraulic oil supply only
thus the nozzle governing system is called as ELECTRO HYDRAULIC CONTROL
GOVERNING system. In Ramagundam this system was adopted to have better control
on valve operation. It is most effective one and is suitable for control the high
capacity turbines.
3. Bypass Governing.
In this system the steam is supplied through a primary valve and is adequate to meet a
major function of the maximum, load, which is called the “economic load”. At loads less
than this throttling steam through this valve does the regulations. When the load on the
turbine exceeds this economic load which can be develop by the UN throttled, full flow
through the primary valve. This steam joins the partially spent steam admitting through
the primary valve, developing additional blade torque to meet the increased load.
6.2 VACUUM SYSTEM
As we begin the recirculating processes, the first system, which comes into focus, is the vacuum
system. The equipments under this system, as described in this chapter, strive to maximize the
work done of turbine by maintaining the rated vacuum limits.
Condenser:
 There are two condensers entered to the two exhausters of the LP turbine. These are
surface type condensers with two-pass arrangement. Cooling water pumped into each
condenser by a vertical C.W. Pump thru’ the inlet pipe. Water enters the inlet chamber of
the front water box, passes horizontally thru’ the brass troes to the water box at the other
end, takes a turn, passes thru’ the upper cluster to tubes and reaches the outlet chamber in
the front water box. From these, cooling water leaves the condenser thru’ the outlet pipe
and discharges into the discharge duct. Steam exhausted from the LP turbine washing the
outside of the condenser tubes loses it latent heat to the cooling water and is connected
with water in the steam side of the condenser. This condensate collects in the hot well.
Ejectors:
There are two 100% capacity ejectors of the steam eject type. The purpose of the ejector
is to evacuate air and other non-condensing gases from the condensers and thus maintain
the vacuum in the condensers.
This is a 3 stage ejector using steam from the deaerator with 11 ATM header as the
working medium. The ejector has three compartments. Steam is supplied generally at a
pressure of 4.5 to 5 kg/Cm2 to the three nozzles in the three compartments. Steam expands
in the nozzles thus giving a high velocity eject which creates a low pressure zone in the
throat of the eject. Since the nozzle box of the ejector is connected to the air pipe from the
condenser, the air and pressure zone. The working steam which has expanded in volume
comes into contact with the cluster of tube bundles thru’ which condensate in flowing and
gets condensed thus further aiding the formulation of vacuum. The non consuming gases
of air are further sucked with the next stage of the ejector by the action of the second
nozzle. The process repeats itself in the third stage also and finally the steam air mixture
is exhausted into the atmosphere thru the outlet. In addition to the main ejectors there is a
single stage starting ejectors which is used for initial of vacuum upto 500mm of Hg. It
consists of nozzle is connection to the air pipe from the condenser.
Gland Steam Cooler:
Steam from deaerator or from Auxillary steam header is supplied to the end seals of the
HP rotor and LP rotor generally at a pressure of 0.01 to 1.03 ata. So as to prevent ingress
of atmosphere air into the turbine thru’ the end clearances. This steam supplied to the end
seals is extracted by the gland steam cooler by the auction of single stage steam ejector.
6.3 CONDENSATE SYSTEM
The steam after condensing in the condensing in the condenser known as condensate, is extracted
out of the condenser hot well by condensate pump and taken to the deaerator through ejectors,
gland steam cooler and series of LP heaters
Condensate Pumps:
The function of these pumps is to pump out the condensate to the deaerator through’
injector, gland steam cooler and LP heaters. These pumps have four stages and since the
suction is at a negative pressure, special arrangements have been made for providing
sealing.
The level indicator for visual level indication of heating steam condensate pressure
vacuum gauges for measurement of steam pressure etc, it is a direct contact type heater
combined with feed storage tank of adequate capacity. The heating steam is normally
supplied from turbine extractions but during starting and low load operation the steam is
supplied from auxiliary source.
Deaerator:
The Deaerator comprises of two chambers:
A) Deaerating column.
B) Feed storage tank.
Deaerating column is a spray cum tray type cylindrical vessel of horizontal construction with
dished ends weided to it. The tray stack is designed to ensure maximum contact time as well as
optimum scrubbing of condensate to achieve efficient deaeration. The deaeration column in
mounted on the feed storage tank which in turn is supported on rollers at the two ends and a
fixed support at the center. The feed storage tank is fabricated from boiler quality steel plates.
Man holes are provided on deaerating column as well as on feed storage tank for inspection and
maintenance.
The condensate is admitted at the top of the deaerating column and flows downwards through the
spray valves and trays. The trays and designed to expose though the maximum water surfaces for
efficient scrubbing to effect the liberation of the associated gases-steam enters from the
underneath of the trays and flows in counter direction of condensate. While flowing upwards
through the trays, scrubbing and heating is done. Thus the liberated gases move upwards along
with the steam. Steam gets condensed above the trays and in turn heats the condensate. Liberated
gases escapes to atmosphere from the office opening eant for it. This opening is provided with a
number of deflectors to minimize the loss of steam.
Deaerator’s main components are given below:
1. Tubular type gauge glass.
2. High level alarm switch.
3. Low level alarm switch.
4. Pressure gauge.
5. Straight thermometers with pockets.
6. Safety valve.
7. Isolating valves for stand pipes.
6.4 FEED WATER SYSTEM
This system plays an important role in the supply of feed water to the boiler at requisite pressure
and steam water ratio. This chapter describes the various auxiliaries under this system starting
from Boiler Feed Pump to Feed regulating station via HP heaters.
Boiler Feed Pump:
This pump is horizontal and of barrel design driven by an Electric motor through a hydraulic
coupling. All the bearings of pump and motor are forced lubricated by a suitable oil lubricating
system with adequate protection to trip the pump if the lubrication oil pressure fails below a
preset valve.
The high-pressure boiler feed pump is very expensive machine which calls for a very careful
operation and skilled maintenance. The safety in operation and efficiency of the feed pump
depends largely on the reliable operation and maintenance. Operation staff must be able to find
out the causes of defect at the very beginning which can be easily removed without the
endangering the operator of the power plant and also without the expensive dismantling of the
high pressure feed pump.
The feed pump consists of the pump barrel, into which is mounted the inside stator together with
rotor. The hydraulic part is enclosed by the high pressure cover along with the balancing device.
The suction side of the barrel and the space in the high pressure cover behind the balancing
device are enclosed by the low pressure covers along with the stuffing box casings. The brackets
of the radial bearing of the suction side and radial and thrust bearing of the discharge side are
fixed to the low pressure covers. The entire pumps is mounted on a foundation frame. The
hydraulic coupling and two claw couplings with coupling guards are also delivered along with
the pump. Water cooling and oil lubricating connections are provided with their accessories.
High Pressure Heaters:
These are regenerative feed water heaters operating at high pressure and located by the side of
turbine. These are generally vertical type and turbine bled steam pipes are connected to them.
HP heaters are connected in series on feed water side and by such arrangement, the fed water,
after feed pump enters the HP Heaters. The steam is supplied to these heaters from the bled point
of the turbine through motor operated valves. These heaters have a group bypass protection on
the feed water side. In the event of tube rupture in any of the HPH and the level of the
condensate rising to dangerous level, the group protection device diverts automatically the feed
water directly to boiler, thus bypassing all the 3 HP heaters.
As shown in fig.V-8, feed water flows through the tube spirals and is heated by seam around the
tubes in the shell of the heaters. These heaters are cylindrical vessels with welded dished ends an
with integrated, de-superheating, condensing and sub cooling sections. The internal tube system
of spirals is welded to the inlet and outlet headers. In order to facilitate assembly and
disassembly, rollers at the side of the header have been provided. Both feed water and steam
entries and exists are from the bottom end of the heaters. This design offers the advantage to
optimize the arrangement of piping and the location of the heaters at power station.
Following fittings are generally provided on the HP heaters:
a) Gauge glass for indicating the drain level.
b) Pressure gauge with three way cock.
c) Air vent cock.
d) Safety valve shell side.
e) Seal pot.
f) Isolating valves.
g) High level alarm switch.
Group protection device of HP Heaters: In the event of rising of the drain condensate level in any
one of the HP heater, to the emergency high level, the feed water flowing through the coils of the
heaters, is diverted automatically directly to the boiler, thereby all the groups of three HP heaters
is by passed.
Turbine Driven Boiler Feed Pump:
The single cylinder turbine is of the axial flow type.The live steam flows through emergency
stop valve and then through the main control valves.The valves regulate the steam supply
through the turbine.There are 14 stages of reaction blading.The turbine is provided with the
electro hydraulic governing system.The steam exhausted from the BFP turbine is directly
connected to the main condenser and the turbine glands are gland steam.There are 2 TDBFP’s
for each 500MW unit at ramagundam of capacity 1080.3m3/hr at 204.32 bar.
Drip/Drain System:
The steam, bled from the turbine, after condensation is termed as drip/ drain. The drain is
cascaded from HP 7 to IPs and further to LP 2 all the condensate due to the bled steam of the
heaters is collected to in deaerator (during normal load) and in LP 2, from where the drain is
pumped back into the feed system. The drain from LP.1 is only connected to the condenser by
Utube water seal. The drain from HP.5 will go to deaerator or LP.4 depending on the shell
pressure and load on the machine. All the LP heater drains are having manual bypass, which can
be operated in case of any individual regulators, fail. The drain from LP.2 can be regulated to
condenser in case the level in LP.2 rises to a predetermined level.
Drip Pumps:
Two numbers of sectional multistage centrifugal horizontal pumps per unit are provided. One
will be running and the other is standby (100% standby). These are especially suited for the
purpose of pumping from the space of high vacuum. Condensate drip from LP heater No.2
(which is under vacuum) is pumped again to main condensate line in between LP heaters.
6.5 COOLING WATER SYSTEM
Equipment cooling water (ECW) system: This water is used to cool the heated lubricating oil
coming from the lube oil coolers of boiler and turbine side. This is demineralised water and is
supplied through ECW pumps.
Auxiliary cooling water (ACW) system: This is raw water, taken a taping from CW pumps
discharge side, pressurized and circulated in a Plate Heat Exchanger to cool the heated ECW
water.
COOLING TOWERS (CTs):
A closed circuit cooling system is used for heat rejection that consists of cooling pond and two
cooling towers, ponds and towers are connected in a parallel arrangement to study the behavior
of the cooling system.
The cooling tower models based on the analogy approach of a cooling tower and an heat
exchanger. An effectiveness-NTU method is employed to predict the cooling tower performance
with respect to ambient and load conditions.
For the circulation of cooling capacity of the cooling pond surface, a semi empirical approach
is selected that is based on the combination of free and forced convection. The water flow in the
pond is a approximated by a plug flow model.
From the energy transfer and flow model a stimulation program is developed that is capable of
predicating of cooling pond temperatures dependent on meteorological conditions and head load
on the pond.
A simple model of an atmospheric cooling spray is employed.
6.6 LUBRICATION OIL SYSTEM
Introduction: same oil is used for governing & lubrication. The oil is kept in the main oil tank.
The governing is designed for operation at the oil pressure of 14kg/cmsq while lubrication of
bearings is designed to work at 2kg/cmsq.The following equipment is available in the lubricating
system.
1. Auxiliary oil pump
2. A.C lube oil pump
3. D.C emergency oil pump
4. main oil pump
5. booster pump
6. oil tank
7. oil coolers
8. vent fans
Lubrication oil system lubricates both turbine and generator bearings. Moreover it supplies oil to
seal oil system.
During normal operation of turbine shaft directly drives pump (centrifugal type) at 3000 rpm and
supplies oil to the lubrication system. Auxiliary oil pump is incorporated in the oil system to
deliver oil to governing system and bearings at the time of starting of turbine with back up
protection. D.C. stands by oil pumps are used for bearing oil supply only.
AUXILARY OIL PUMP:
It is centrifugal pump driven by A.C electric motor. Auxiliary oil pump is provided for meeting
the requirement of oil for the turbine governing system and bearing lubrication system during
and stopping. It is mounted on the main oil tank.
DC LUB OIL PUMP:
The bearing are protected from possible lubrication failure by the provision of two automatically
starting oil pumps-i.e. AC lubrication oil pump and DC emergency oil pump AC lube oil pump
automatically start when lubrication oil pressure drops to 1.2kg/cmsq. The emergency lubrication
oil pump (DC driven) is provided as a backup protection against the failure of AC lubrication oil
pump or AC supply. DC lubrication oil pump cuts in automatically when lubrication pressure
drops down to 0.8kg/cmsq. Both AC lubrication oil pump and DC lubrication oil pump are
mounted on main oil tank.
MAIN OIL PUMP:
During normal operation of turbine, main lubrication oil pump is mounted on turbine shaft and
driven by turbine shaft at 3000rpm. It supplies oil to the governing and lube oil system. Pump is
designed for continues operation at 3000rpm and installed inside the front pedestal of turbine.
The MOP is capable to supply oil to the system at full capacity when the turbine reaches to
2800rpm. Then the AOP, which is in service, will be separated from the system automatically.
BOOSTER PUMP:
The oil pressure developed by auxiliary oil pump discharge during staring and stopping of
turbine operates booster pump. During normal running of turbine (at 3000rpm) it is operated by
main oil pump discharge. It supplies oil to lubricating.
OIL TANK:
Oil is stored in main oil tank (MOT) whose capacity is 16cum. Two numbers of vapour fans are
mounted on MOT to extract oil vapour and dissolved gases also to the atmosphere from MOT.
Auxiliary oil pump, AC lubrication oil pump, DC lubrication booster pump and oil coolers are
mounted on MOT.
Oil level indicators and instruments such as oil pressure and temperature gauges and pressure
switches for pump interlocks and annunciation’s are mounted on MOT. Local starting and
stopping of pumps and local pressure indicators are also available on MOT. The oil cooler
changing system and magnetic duplex system selection also mounted on MOT. The line to oil
purification system is connected to MOT.
OIL COOLERS:
Oil coolers are of surface type. Usually one cooler will be in service while the other is standby. It
consists of tubes through which cooling medium flows. The cooling medium used is raw water.
The oil cooler consist of the following.
1. shell
2. upper water chamber
3. lower water chamber
4. tube system
5. cooler change over mechanism