Chapter 4

OVERVIEW OF KWU STEAM TURBINE

4.1 General Description
4.1.1 Modular Concept

The turbine is built on the well-proven design philosophy of "Modular Principle" in steam turbine
engineering field. The readily designed HP, IP & LP turbine modules are combined and sized to required
power output (120 MW, 210 MW, 250 MW and 500 MW capacity), as demanded by the customer. Steam
parameters and cycle configuration are designed to give most economical turbine set. This
maneuverability is achieved without imposing the reliability of the modules, which is governed by the
shape and configuration of rotors, cylinder and distance between the bearings.

For 210 MW design, the turbine comprises of modules H 30-25 for HP turbine, M30-20 for IP
turbine, and N 30- 2x5 for LP turbine. These modules incorporate the design and construction features,
which have proved their reliability in service and ensure trouble free operation over long operating periods
and at the same time ensuring high thermal efficiencies. All the materials used for manufacture of various
parts are most suitable for the duty required and have been selected after exhaustive research and long
experience.

4.1.2 Turbine Arrangement

Fig. 4.1 shows the sectional arrangement of 210 MW KWU Steam Turbine and Fig. 4.2 illustrates
the outline drawing with dimensions.

The turbine is of tandem compound design with separate HP, IP& LP cylinders. The HP turbine is
of single flow type while IP & LP turbines are of double flow type. Rigid couplings connect the individual
turbine rotors and the generator rotor.

The turbine is condensing type with single reheat. It is basically engineered on reaction principle
with throttle governing method. The fixed blade and moving blade stages are arranged in HP, IP & LP
turbines, driving the 210 MW AC generator.

The HP cylinder has throttle control valves. Steam admission circuit is shown in Fig. 4.3. The
main steam is admitted before the blading by two combined main steam stop and control valves. The
lines leading from the two HP exhaust branches to the reheater are provided with swing check non-return
valves (CRH NRVS), which prevent hot steam from the reheater flowing back into the HP turbine when
turbine is tripped.

The steam coming from the reheater is admitted to the IP turbine via two reheat stop and control
valves. The exhaust of IP turbine is connected to LP turbine via two cross-around pipes laid at floor level.

Six bled steam tapings are taken as follows:

- HPT exhaust (25th stage) to HP heater 6
- IPT, 36th stage to HP heater 5
- IPT exhaust, 45th stage to Deaerator (extraction 4)
- LPT, 48th stage to LP heater 3
- LPT, 50th stage to LP heater 2
- LPT, 52nd stage to LP heater 1

Penultimate stages of shaft gland seals are provided with steam at regulated pressure from gland
steam header whereas the last stages are connected to gland steam cooler.

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 Fig.4.1 Sectional Arrangement of Turbine

Chapter-4: Overview of KWU Steam Turbine 89

 Side View

Top View Note: All Dimensions are in mm.

Fig.4.2 Turbine Outline Drawing

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 HP Turbine

LP Turbine

IPTurbine
Sectional Views from Fig.4.2

Fig.4.3 Steam Admission circuit

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4.1.3 Barrel Type HP Turbine
The outer casing of the HP turbine is of barrel type construction without any massive horizontal
flange. This unique construction permits rapid start-up from any thermal state and high rates of load
changes of the turboset. The steam and metal temperature matching requirements are also less stringent
as there is no asymmetry of mass distribution in transverse and longitudinal planes.

Although HP inner casing is with a horizontal split joint, yet it acts like a thin thermal membrane.
As the inner casing is not subjected to large pressure drops across the wall, the horizontal flange joint and
bolts are made of thin sections thus permitting large transverse temperature changes. Inner casing is
kinematically supported within the outer barrel.

The barrel type casing permits flexibility of operation in the form of short start-up times and a high
rate of change of load even at high initial steam conditions.

4.1.4 Double Flow IP Turbine

The IP turbine is double flow and double casing type split horizontally. Double flow design
permits the axial thrust (produced due to reaction stages) balanced by itself and does not impose any
loading on thrust bearing.

IP inner casing is kinematically supported within outer casing. IP inner and outer casings are
suspended from top halves so as to totally eliminate the effect of TG centre line with the heating of
flanges. Although the casings are of horizontal split design yet these do not impose any constraints in
start-up period and rapid load changes.

The reheated steam is admitted to the inner casing through the top and bottom centre of the
casing. The arrangement of an inner casing confines the high steam inlet conditions to the admission
branch of the casing, while the joint of the outer casing is only subjected to the lower pressure and lower
temperature at the exhaust of the inner casing.

4.1.5 Double Flow L P Turbine

LP turbine is also double flow type with exhaust area optimally selected for the expected vacuum
conditions. The casing of LP turbine is connected with IP cylinder by two cross-around pipes, one on
either side of the machine and level with the floor.

The casing of the double flow LP cylinder is of three-shell design. The shells are axially split and
of rigid welded (fabricated) construction. The inner shell taking the first rows of guide blades is attached
kinematically in the middle shell. Independent of the outer shell, the middle shell is supported at four
points on longitudinal beams. Two rings carrying the last guide blade rows are also attached to the
middle shell.

Special design measures have been adopted to remove the moisture from last stages by reducing
the thickness of water film on guide blades. The axial clearances between guide blades. The axial
clearances between guide and moving blades have been so chosen so as to reduce the droplet sizes and
erosion of leading edges. Low-pressure extraction has been optimized not only from thermodynamic
considerations but to effectively drain out moisture also. Free standing blades (without lacing wire) have
been envisaged. The blades are designed to operate in the speed range corresponding to 47.5 to 51.5
Hz grid frequency.

4.1.6 Turbine Blading

In steam turbine, the blades transform the thermal energy into mechanical energy. It is obvious
that blading has got direct impact on the efficiency and reliability of turbine. Appropriate blade profile, with
high aero-thermodynamic efficiency having sufficient mechanical strength to withstand the steam forces,
are determined after excessive research. Utmost care is taken while designing to avoid resonance and to
ensure that the natural frequencies of unshrouded free standing rotor blades are compatible with the

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rotational frequency of the machine. A final accurate check is made when the blades have been fitted into
the rotor. The opportunity is also taken to carefully check the root fastening of the blades.

a) HP & IP Turbine Blades:

These blades have a 50% reaction component and both fixed and moving blades have the same
profile. Each rotor blade is milled from a single piece of material complete with inverted T-root and
integral shroud as shown in Fig. 4.4 (a).

After they have been fitted in the rotor groove, they are caulked into position with brass wire. The
blade roots are made of appropriate size to give the required blade spacing, and hence the designed
width of blade passage, and hence the necessity of spacer-pieces.

Fixed blades are of the same type as the moving blades with an inverted T-root and integral
shroud. In medium and low temperature regions, the fixed blades are made of solid drawn material with
brazed on or loose spacer pieces and have a hook-type root (Fig. 4.4(b)). In this case the shrouding is
separate and riveted in place.

Fig.4.4 HP & IP Turbine Blade Roots

b) LP Turbine Blades :
The fixed and rotor blades of the first few stages of the LP turbine are similar to the IP turbine
blades. However, the last three stages of the LP turbine have twisted blades as shown in Fig. 4.5 (a) &
(b). The difference between the circumferential velocity at the rotor blade root and tip is quite
considerable and is taken into account by twisting the blade along its length. The rotor blade fastening is
of the fir-tree type (Fig. 4.5(c),(d)), which engages in milled axial grooves in the rotor and is then secured.

The fixed blades of the last two stages are hollow. They are fabricated from sheet steel and slots
are provided in the blade surface through which any water passing over the surface of the blades may be
drawn away to the condenser. The trailing edge of the blades is very thin in order to avoid any patches
and the formation of streams of water. The axial distance between the final stages is kept at optimum
value to facilitate the break-up of any water droplets, which may still remain. This will reduce the relative
velocity between the droplets and the leading edges of the moving blades.

The leading edges of the final stage rotor blades are flame hardened to give protection against
erosion.

These blades are free-standing and have neither lacing wire nor shrouding. Great attention is
paid at the design stage to achieve a resonance free operation with long life.

Chapter-4: Overview of KWU Steam Turbine 93

 Fig.4.5 LP Turbine Last Stage Blades

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c) Blade tip Sealing:
In reaction turbine stages, there is a drop in pressure across both the fixed and moving blades.
The pressure differential between the inlet and outlet sides of the blades also causes steam to flow over
the tips of the fixed and moving blades. This amounts to a loss of energy and in order to keep it as small
as possible, it is essential to provide proper sealing at this point. Thus, both fixed and moving blades are
provided with continuous shrouding in which steps have been turned to produce a labyrinth seal. Sealing
strips from the fixed or moving component projects into the steps turned into the shrouding.

The complete rings of shrouding on all rotor blades and on guide blades in high temperature
sections are built-up from the individual sections of shrouding which are machined integrally with each
blade and fitted to butt tightly together. In the case of guide blades for medium and low temperature
sections, the shrouding is riveted onto the blades. When the rotors and guide blade carriers have been
completely bladed, the blading is skinned on a lathe, the steps being machined on integral shrouding or
the rivet heads machined flush on riveted shrouding at the same time.

Various arrangements of tip sealing employing these rows of sealing strips, as shown in Fig. 4.6,
are used. The number of rows of sealing strips chosen depends on the stage pressure and the differential
axial expansion between the rotor and casing at the particular section of blading involved.

The sealing strips, which are caulked into the casing and shaft opposite the blade shrouding, are of
stainless steel. On one hand, they are strong enough to withstand the maximum pressure which will exist
across them on the other hand, the amount of heat generated by them and transmitted to the rotor or
casing in the event of their rubbing shall not be sufficient to cause deformation of the component.

The sealing strips are easy to replace. If the sealing strips wear out due to contact between fixed
and moving components (rubbing) at any time, then the worn out strips could be replaced with new one
within a short time to restore correct clearances at the next overhaul.

4.1.7 Valves
The HP turbine is fitted with two combined emergency stop and control valves. A stop and control
valve fitted in a common body with their spindles arranged at right angles to each other and in the same
plane. The stop valves are spring operated single-seat valves and similarly control valves also of single-
seat design having diffusers to reduce pressure losses. The two valves operate with two separate
servomotors independent of each other.

The IP turbine has also two combined reheat stop (IV) and control valves. The reheat stop valves
are spring-loaded single-seat valves. The control valves, also spring loaded and single seat design, have
diffusers. The control valves operate in parallel and are fully open in the upper load range. In the lower
load range, they control the steam flow to the IP turbine and ensure stable operation even when the
turboset is supplying only the station load.

Throttle governing method is adopted to regulate the turbine load. Both the emergency stop and
reheat stop and their control valves are supported kinematically on the foundation ceiling below the
machine floor before the turboset. Individual oil hydraulic servomotors actuate all valves.

4.1.8 Rotors, Couplings and Bearing

The rotating elements consisting of three monobloc rotors of HP, IP & LP turbines are coupled
together rigidly by means of integrally forged flanges (coupling halves), thus in effect forming a single
shaft system. The critical speeds of the HP and IP rotors are designed to be above the normal rated
speeds. Each rotor is subjected to 20% overspeed test.

The HP rotor is supported by two bearings, a double-wedge journal bearing at the front end of the
turbine and a combined journal and thrust bearing directly adjacent to the coupling with the IP rotor. The
IP and LP rotors have a journal bearing each at the end of the shaft. The combined journal and thrust

Chapter-4: Overview of KWU Steam Turbine 95

 Fig.4.6 Blade Tip Sealing Arrangement

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bearing incorporates a self-adjusting double-wedge journal bearing and a thrust bearing which takes up
residual thrust from both directions. The other journal bearings are self-adjusting elliptical bearings. The
bearing temperatures are measured by thermocouples in the lower shell directly under the white metal
lining. The temperature of the thrust bearing is measured in two thrust pads on each side.

The front and rear bearing pedestals of the HP turbine are placed on base plates. The pedestals
of the LP turbine are fixed in position, whereas the front pedestal and the pedestal between the HP and IP
turbine are able to move in axial direction to permit free longitudinal expansion of HP and IP turbine
casings.

The brackets at the sides of the HP and IP cylinders are supported by the pedestals at the level of
the machine axis. In the axial direction the HP and IP casings are firmly connected with the pedestals by
means of casing guides, without restricting radial expansion. Since the casing guides do not yield in
response to axial displacement, the HP and IP casings as well as the associated bearing pedestals move
forward from the front LP bearing pedestal on thermal expansion.

4.1.9 Shaft Glands

The rotor shafts of HP, IP and LP turbines are sealed at both the ends by employing labyrinth-
type gland seals. In case of HP and IP turbines, there consists of a series of sealing strips alternatively
caulked into the shaft and into stationary rings. In case of LP turbine, gland sealing strips are fitted in the
stationary rings only. The pressure of the steam leaking through the gland is reduced by converting the
pressure energy into velocity energy, which is then dissipated as eddies as the steam passes through
large number of strips.

Fig.4.7 Shaft Gland Sealing Arrangement

Chapter-4: Overview of KWU Steam Turbine 97

 The number of sealing strip rings used depends on the pressure drop required. Each ring consist
of six or eight segments and is carried in grooves in the casing or inner casing to allow radial movement.
Each segment is held in position against a shoulder by two helical springs. In the event of the shaft
coming into contact with the strips in the segments, the affected segments will move away radially. A
possible slight contact between the shaft and the thin strips will generate only a small amount of heat that
cannot lead to a deformation. All the shaft glands, sealing the steam in the cylinder against atmosphere
are axial flow labyrinths. The sections of glands for HP, IP and LP turbines are shown in Fig. 4.7.

4.1.10 Turning Gear

The turbine is equipped with hydraulic turning gear capable to rotate the shaft system at high
speed during start-up and shutdown periods in order to minimize thermal distortion of the turbine casings
and shaft. Due to fanning action of the blades, the steam inside the casing brings about heat transfer
conducive to temperature equalization between the upper and lower parts of the casings.

The turbine gear assembly is located in the front bearing pedestal of LP cylinder and consists of
two rows of moving blades mounted on coupling flange IP turbine rotor, an inlet nozzle box with stationary
nozzles and guide blades. The turbine-generator shaft system is rotated by the double row wheel which
is driven by pressure oil supplied by the auxiliary oil pump. After passing through the blading, the oil
drains to the bearing pedestals and combines with the bearing lube oil returning to the main oil tank.

In addition, shaft system is equipped with facility for manual barring in the event of failure of
hydraulic turning gear.

As discussed above, high speed (160 rpm) hydraulic turning gear is envisaged to ensure uniform
and rapid heating and cooling of the casings and rotors during start-up and trip out respectively. The
turning gear is located on IP coupling flange, between IP and LP turbine coupling. As there is no
mechanical contact between the hydraulic turning gear and shat, the likelihood of a break-down is far less
than mechanical types employing disengaging gears, interlocks and checking devices.

4.2 Turbine Systems Overview

4.2.1 Governing System
The turbine is equipped with electro-hydraulic governing system backed up with hydro-
mechanical system ensuring stable operation under any grid fluctuations and load throw-off conditions.
The electro-hydraulic system has number of advantages, such as high accuracy, fast response and high
sensitivity. The linear power output/frequency characteristic can be adjusted between close limits even
while the machine is in operation.

An electric system measures and controls speed and output, and operates the control valves
hydraulically in conjunction with an electro-hydraulic converter. The electro-hydraulic governing system
permits run-up control of the turbine upto rated speed and keeps speed swings at low level following the
sudden load shedding.

4.2.2 Turbine Stress Evaluator

The turbine stress evaluator continuously scans the critical sections of E.S.V., HP control valves,
HPT casing, HPT shaft and IPT shaft by measuring temperature difference between surfaces in contact
with steam and 50% depth of metal wall. TSE provide instantaneous information regarding safe limits of
load fluctuations based on the fatigue life of the material and state of thermal stresses at that particular
instant. This ensures a stress consistent start-up operation.

4.2.3 Turbine Monitoring System

In addition to the measuring instruments and instruments indicating pressures, temperatures,
valve positions and speed, the monitoring system also includes instruments mounted on turbine to
indicate the following values.
- Absolute expansion, measured at the front and rear bearing pedestals of the HP turbine.
- Differential expansion between the turbine rotor and casing, measured at :
 Front bearing for HPT

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  Bearing No. 3 for IPT
 Bearing No. 4 for LPT
- Axial shift measured at bearing No. 2 (combine thrust and journal bearing)
- Bearing pedestal vibrations measured at all turbine bearings
- Relative shaft vibrations (bearing pedestal shaft) measured at all turbine bearings
- Absolute shaft vibrations, obtained from bearing pedestal vibration and relative shaft vibration by
calculation
- Bearing babbit metal temperatures by RTDs
- Turbine speed by hall probe located in front pedestal on MOP shaft
- Top bottom turbine casing temperatures at 50% and 90% depth by thermocouples.

4.2.4 Oil Supply System

Turbine oil supply system provides oil for –
 Lubrication and cooling of bearings
 Control oil for turbine governing and protection system and hydraulic actuators
 Control oil for LP bypass governor
 Hydraulic turning gear

The main oil pump located in the front pedestal and directly driven by HP turbine shaft draws oil
from the main oil tank via injector, during normal operation of turbine. However, during start-up and
shutdown, Auxiliary Oil Pump (AOP) driven by AC motor maintains the oil supply. Before starting the
turning gear, a jacking oil pump forces high pressure (120 kg/cm 2) oil under the shaft journals to lift the
shaft. This is in order to prevent boundary layer lubrication and metal-to-metal contact. The lubricating
and cooling oil is passed through water-cooled oil coolers before being supplied to the bearings.

Two AOPs, one EOP (DC motor) and two JOPs are mounted on the main oil tank.

4.3 Turbine Anchoring & Expansion

4.3.1 Fixed Points of Turbine
In designing the supports for the turbine on the foundation, attention is given to the expansion and
contraction of the machine during thermal cycling (warming up and cooling). Excessive stresses would be
caused in the components if the thermal expansion or contraction were restricted any way. The method of
attachment of the machine component and their coupling together, are also decisive factors in
determining the magnitude of the relative axial expansion (differential expansion) between the rotor and
turbine casing. The differential expansion aspect is most important factor, which is taken into account
while designing the internal clearances of the machine.

The installation of KWU design 210MW turbine is shown in Fig. 4.8. The fixed points of the
turbine are as follows:

i) The bearing pedestal between the IP and LP turbines. From this point the IP and HP casings
expand towards the front bearing pedestal of the HP turbine.
ii) The rear bearing housing of the LP turbine (LP/Generator bearing pedestal)
iii) The middle portion of each longitudinal girder of LP turbine. From these points the longitudinal
girders expand in both the directions (Turbine side and Generator side).
iv) The thrust bearing in rear bearing casing of HP turbine.

4.3.2 Casing Expansion

The front bearing pedestals of the HP & IP turbines can slide on their base plates in an axial
direction. Any lateral movement perpendicular to the machine axis is prevented by fitted keys. The HP &
IP casings are supported by lugs on bearing pedestals. The guides provided for supporting ensures that
the turbine casings maintain their central position while at the same time allowing axial movement. Thus
the origin of the cumulative expansion of the HP & IP casings is at front bearing pedestal of the LP turbine
(pedestal between IP & LP turbine). The IP expands towards HP turbine by which the middle pedestal
(between HP & IP turbine) also moves in the same direction. Hence the absolute expansion of IP turbine
is registered at middle pedestal.

Chapter-4: Overview of KWU Steam Turbine 99

 Fig.4.8 Fixed Points of Turbine

Fig.4.9 Expansion of Turbine Casings

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 The HP turbine casing, which is supported on middle pedestal and front pedestal expands
towards front pedestals, which also moves on base plate. Hence the cumulative expansion of HP and IP
turbine is recorded at front pedestal as shown in Fig. 4.9.

The outer casing of the LP turbine is located axially by fitted keys at the middle of their
longitudinal beam members. Free lateral expansion is allowed. The centre guides for these longitudinal
beams are recessed in the foundation. There is no restriction on axial movement of the casings. At the
front and rear supports of the longitudinal beam members the casing is free to expand horizontally in any
direction. Hence, when there is a temperature rise, the outer casing of the LP turbine expands from its
fixed point towards IP turbine and generator, as shown in Fig.4.9. Differences in expansion between the
outer casing and the fixed bearing pedestals to which the housings for the shaft glands are attached, are
taken by shaft seal compensators (expansion bellows).

4.3.3 Rotor Expansion

The thrust bearing is incorporated in the rear bearing housing of the HP turbine (middle pedestal).
Since this bearing housing is free to slide on the base plate, the shafting system moves with it (Fig.4.10).
Both the rotor and casing of HP turbine expand towards front bearing housing with respect to rear bearing
housing of HP turbine (middle pedestal). On the other hand, the rotor and casing of IP turbine expand
towards the generator in a similar manner.

Fig.4.10 Expansion of Turbine Rotors

The LP turbine rotor is displaced towards the generator by the expansion of the shafting system
from the thrust bearing. The magnitude of this displacement due to expansion, however, is reduced by
the amount by which the thrust bearing is moved in the opposite direction by the casing expansion of the
IP turbine.

4.3.4 Differential Expansion

Differential expansion between the rotors and casing results from the difference between the rotor
expansion originating from thrust bearing and the casing expansion originating from the rear bearing
housing of IP turbine (Bearing No.3 housing). This means that the maximum differential expansion of the
HP and IP turbines occur at the end furthest from the thrust bearing.

Differential expansion between the rotor and casing of the LP turbine results from the difference
between the expansion of the shafting system originating from the thrust bearing and the casing
expansion originating from the fixed point of the LP turbine casing on the longitudinal girder.

-o0o-

Chapter-4: Overview of KWU Steam Turbine 101