New features of 660 MW Units

Turbine Maintenance
Sipat Super thermal power project
 New features of 660 MW units

• Constructional features

• Operational features

• Lube oil system

• Governing system

• Feed water system

• Turbine Auxiliaries
 Specifications
• Make
• Design
• Type
• Stages
• No of HP Control Valve
• No of IP Intercept valves
• No of IP Governing valves
• Over all length of turbine
• Direction of Rotation
OJSC Power machines, Russia
LMZ, Russia
K-660-247
Four Cylinder, tandem
compound, Reheat, Condensing Turbine
Spring deck foundation
HPT, reverse flow, 17 (1-control
stage,16 Reaction stages)
IPT 11 X 2 impulse stages.
LPT 2 nos. - 5 X 2 impulse stages.
4
2
4
35.8 Mtr
Clockwise (Viewed from front
pedestal towards Generator)
 Main features
• Turbine: HPT, IPT, LPT1 and LPT2
• Two condensers for Main Turbine
• TG Bearings: 12
• Turbine Stop Valves: 04 (HPSV-1&2, IPSV-1&2)
• Turbine Control Valves: 08 (4 HPCV & 4 IPCV)
• CRH Check Valves: 02 ( With Bypass lines for warm up)
• IP Turbine has throttle governing – all four control valves open
simultaneously
• HP Turbine has nozzle governing – all four control valves open in preset
sequence
• LP heaters – 1a, 1b, 2, 3 & 4
• HP heaters – 6A, 6B, 7A, 7B, 8A & 8B
• Steam coolers – one each for HPH 6A & 6B
• 2 MDBFP (2 X 30%)
• 2 TDBFP (2 X 50%)
• Separate condensers and vacuum pumps for TDBFPs
 HP Turbine IP Turbine LP Turbine # 1 LP Turbine # 2
540ºC 247 KSc 298ºC 47.9 KSc 565ºC 43.1 KSc

Governing MS CRH HRH

Box

349ºC 68.8 KSc

LPH#1
LPH#1a LPH#1
LPH#1b
CRH

HPH#8A
Deareator
HPH#7A LPH#4
HPH#8B

HPH#7B
LPH#3

Steam cooler

LPH#2

HPH#6A HPH#6B
 Main parameters
Parameters Units Value
Live steam consumption, HPT inlet t/h 2023.7
Rated total pressure of live steam, HPT inlet MPa (kgf/cm 2 abs) 24.2 (247)
Live steam rated temperature °С 537
T after HPT exhaust °С 297.8
4.8 (47.9
P after HPT exhaust MPa (kgf/cm 2 abs)
kgf/cm2)
4.3 (43.1
Steam absolute pressure before IP SV MPa (kgf/cm 2 abs)
kgf/cm2)
Live steam consumption , IPT inlet t/h 1678.5
steam temperature before IPSV °С 565

steam absolute pressure in condenser MPa (kgf/cm 2 abs) 0.105

Inlet condenser CW temp °С 33
cooling-water consumption m3/h 64000
 Extraction Steam parameters
Locations Pressure (bar) – Temperatures (oC)
Absolute
Initial steam HPT inlet 247 537
HP cylinder exhaust 48 298.50
IP cylinder stop valve Inlet 43.20 565
Extraction 8 (HPT 13th stage to HPH 8) 68.8 349
Extraction 7 (CRH to HPH 7) 45.6 295.62
Extraction 6 (IPT 3rd stage to HPH 6 & 21.7 470
TDBFP)
Extraction 5 (IPT 6rd stage to Deareator) 11.34 374.28
Extraction 4 (IPT 8th stage to LPH 4) 6.25 301
Extraction 3 (IPT 11th stage to LPH 3) 2.97 214
Extraction 2 (LPT 2nd stage to LPH 2) 0.624 0.79% / 89
Extraction 1 (LPT 4th stage to LPH 1) 0.264 4.38% / 68
LP cylinder exhaust 0.105 7.84%
 Operational features

• Turbine rolling by IPT

• HPC & IPC flange heating system
• IP Turbine rotor cooling system
• Turbine motorized barring gear
• Jacking oil for bearing shell & rotor
• No Main oil pump
• Separate governing box in front pedestal
• High pressure governing system
• Pressurized damper tanks with no separate air / h2 seal oil pumps
• HP / LP Bypass control system similar to 500 MW unit HP Bypass
system
 HP Turbine
• Reverse flow turbine (1 – 9 stages: left flow, 10 -17
stages: right flow)
• 17 stages (1 control stage + 16 reaction stages.
• Type of Casing: Horizontally split inner & outer casing
• Four main steam inlet and two cold reheat outlet
• No balance drum / balance piston arrangement
• Extraction steam from HP Casing in 13th stage to HP
Heater # 8.
• Stationary blades are fixed in casing. No diaphragms in
HPT
• Flange heating system from HRH source.
HP Turbine
 HP Turbine
Material:
– HP outer casing: 15Cr1Mo1V
– HP blade carrier/casings: 15Cr1Mo1V
– HP shaft: 25Cr1Mo1V
– HP Turbine Moving Blades first stage (1-5): 18Cr11MoNiVNb
– HP Turbine Moving Blades stages (6-17): 15Cr11MoV
– HP Turbine Fixed Blades first stage (1-5): 18Cr11MoNiVNb
– HP Turbine Fixed Blades stages (6-17): 15Cr11MoV
– HPT Casing Joint Bolts: 20Cr1Mo1V1TiB, 25Cr1MoV,
18Cr12WMoNbVB
– Shaft Couplings: 25Cr1MoV
– HP Labyrinth Seals: 20CrMo, 15CrMo
 IP Turbine
• Double flow turbine (2 X 11 impulse type)
• Type of Casing: Horizontally split inner & outer casing
• All four HRH steam inlet from bottom side
• IP Turbine stationary blades (1st & 2nd stages) cooling
system from CRH & HRH source.
• Flange heating system from HRH source.
• Stationary blades are fixed in diaphragms
• Balance holes: 10 holes / ST (2nd stage to 11th stage)
IP Turbine
IP Turbine
 IP Turbine
Material:
– IP outer casing: 15Cr1Mo1V
– IP Inner casing: G-X 12CrMoVNbN9-1
– IP shaft: 26CrNi3Mo2V
– IP Turbine Moving Blades first stage (1-3): 18Cr11MoNiVNb
– IP Turbine Moving Blades stages (4-11): 15Cr11MoV
– IP Turbine Fixed Blades first stage (Ist ST): 18Cr11MoNiVNb
– IP Turbine Fixed Blades stages (2-11): 15Cr11MoV
– IPT Casing Joint Bolts: 20Cr1Mo1V1TiB, 25Cr1MoV,
– 18Cr12WMoNbVB
– Shaft Couplings: 25Cr1MoV
– IP Labyrinth Seals: 20MnSi
 LP Turbine # 1 & 2
No of LP Turbine: 2

Type of turbine cylinders: Double flow

Type of Casing: Horizontally split inner & outer casing

No of Stages: 2 X 5 (impulse)

Last Stage Blade height: 1000 mm

Extraction Steam at 2nd stage & 4th Stage

Last stage – locking shrouded blades with lacing wire

LP Turbine 1 & 2
LP Turbine
 LP Turbine
Material:
– LP inner & outer casing: Steel 3
– LP shaft: 26CrNi3Mo2V
– LP Turbine Moving Blades first stage (1-2, 3-4): 20Cr13,
– 15Cr11MoV
– LP Turbine last stage moving blades: 13Cr11Ni2W2MoV
– LP Turbine Fixed Blades first stage (1-4): 12Cr13
– LP Turbine Fixed Blades stages (5): 08 Cr13
– LPT Casing Joint Bolts: Steel 25
– Shaft Couplings: 25Cr1MoV
– LP Labyrinth Seals: 26CrNi
From HRH
Flange heating system
From HRH

To condenser

1. Put into operation by operator during cold and warm start-ups of the
turbine

2. To decrease differential temperature of HPC and IPC flanges, and to

prevent inadmissible relative extensions of HPC and IPC rotors

3. Without flange heating system turbine can be started up but the start up
time shall be increased by 30-60 minutes
 HPC Flange heating
• HPC flange heating is put into operation when relative expansion of
rotor > +3.0 mm or differential temperature across the width of any
HPC flanges > 40 ºC.

• Conditions for putting in operation:

– Steam pressure in hot reheat pipeline is above 6.0 kg/cm2
– Steam temperature in hot reheat pipeline is above 150 ºC
– Pressure in main turbine condensers is below 0.5 kg/cm2 (abs).
• Supply header temperature > 150 ºC and 35 ºC above outer surface
temperature of any flange.
• In auto mode initial 15 min the pressure is maintained at 0.5 Ksc
• After 15 mins, pressure is increased to 5 Ksc and drain valve is
closed.
 HPC Flange heating
• HPC flange heating is put out from operation when
– Relative expansion of rotor < - 1.0 mm or
– Temperature difference between outer surface temperature of any
HPC and HPC top or bottom > 80 ºC or
– if the HPC top metal temperature exceeds 350 ºC

• HPC flange heating is put out from operation by

– The gate valve closes on the HPC flange heating steam supply
line.
– Control valve closes and drain opens
 IPC Flange heating
• IPC flange heating is put into operation when relative expansion of
rotor > +1.0 mm or differential temperature across the width of any
HPC flanges > 40 ºC.

• Conditions for putting in operation:

– Steam pressure in hot reheat pipeline is above 6.0 kg/cm2
– Steam temperature in hot reheat pipeline is above 150 ºC
– Pressure in main turbine condensers is below 0.5 kg/cm2 (abs).
• Supply header temperature > 150 ºC and 35 ºC above outer surface
temperature of any flange.
• In auto mode initial 15 min the pressure is maintained at 0.5 Ksc
• After 15 mins, pressure is increased to 5 Ksc and drain valve is
closed.
 IPC Flange heating
• IPC flange heating is put out from operation when
– Relative expansion of rotor < - 1.0 mm or
– Temperature difference between outer surface temperature of any
IPC and IPC top or bottom > 80 ºC or
– if the IPC top metal temperature exceeds 350 ºC

• IPC flange heating is put out from operation by

– The gate valve closes on the IPC flange heating steam supply line.
– Control valve closes and drain opens
 IP Rotor cooling system
• IP Turbine rotor cooling system is provided from HRH and
CRH source.
 HRH Strainer

Screw Jacks
660 MW Turbine casings

Bearing No 2

Bearing No 3
 LUBE OIL SYSTEM

• Turbine oil is ISO VG 32 Equipment Capacity Head

(m3/hr) (Ksc)
• MOT Capacity : 58 m3
AC Lube oil pump 300 4.3
• 2 AC Lube oil pumps DC Lube oil pump 250 2.0
• 1 DC lube oil pump
• Deaeration screen + fine mesh screen
• Duplex filters fineness: 25 µm
• fine cleaning filter with fineness of 12-15 µm
• Oil draining to Emergency lube oil tank in case
of emergency
• PCV Bypass with throttling orifice which
provides lubrication even at fully closed control
valve
 TG LUBE OIL SYSTEM

GENERATOR
ECT
LPC2 LPC1 IPC HPC

LUBE OIL SUPPLY HEADER

LUBE OIL RETURN HEADER VAP.EX.FAN

M M

VAPOUR LINE
OIL TRAP

PCV

COOLER B
COOLER A
FROM TOP UP OIL TANK

FROM PURIFIER UNIT

FROM SEAL OIL SYSTEM

FILTRATION
UNIT
M M M M
HEATER

DUPLEX
FILTER A
M

MOP A MOP B EOP A EOP B

R/C PUMP

M
TO JACKING OIL SYSTEM

MAIN OIL TANK

TO PURIFIER UNIT
TO SEAL OIL SYSTEM

DUPLEX
FILTER B

TO TRANSFER PUMP
DMCW
INLET DMCW O/L
TO EOT
 Turbine Bearings
• Bearings
 HPT Front N1 (Multi wedge Tilting type JB)
 HPT Rear N2 (Multi wedge Tilting type JB)
 IPT Front (TB) N3
 IPT Rear N4
 LPT-1 Front N5
 LPT-1 Rear N6
 LPT-2 Front N7
 LPT-2 Rear N8
 Generator Front N9
 Generator Rear N10
 Exciter Front N11
 Exciter Rear N12
Lube oil supply HPC FRONT BRG

Lube oil return

Vapor
exhauster
line
Bearing & Pedestals
BEARING PEDESTAL CONNECTIONS

Lube oil
supply

Vapour
exhauster

Lube oil
return line
 Oil inlet to Bearing chamber

Shell N Dia of orifice to Dia of orifice Pressure at

standby tank to shell stand by tank
N1 39 20 0.9 Ksc
N2 39 20 0.9
N3 39 39 0.4
N3 Shell holder ---- ---- ----
N4 39 29 1.0
N5 39 29 1.05
N6 30 29 0.95
N7 30 29 0.95
N8 33 29 0.95
N9 29 29 0.75
 Barring gear
 Barring speed 1.05 rpm
 Installed in the bearing between
Brg No.4 & Brg No.5
 Cut in 800 rpm / cut out 1200 rpm
 Components:
 Barring gear motor
 3-stage reducer and free
wheel clutch (on turbine rotor)
 For Hand barring special
handle is provided at first
stage of Reduction gear. (15-
20 min by 180 deg manually)
 Reduction gear & Free wheel clutch system

Hand drive for hand barring

Barring gear motor
(30 KW, 735 rpm,)

1
Reduction gears
(3 stages)
2
Free wheel clutches

3
Rotor shaft, 1.05 rpm
 TG ROTOR JACKING OIL SYSTEM

GENERATOR LPC 2 LPC 1 IPC HPC

BRG10 BRG2 BRG1

BRG9 BRG6 BRG4 BRG3
BRG8 BRG7 BRG5

H= 120 ksc

FROM MOT
M M
AC ROTOR DC ROTOR
JOP JOP

LUBE OIL COOLER OUT LET

 TG ROTOR JACKING OIL SYSTEM

Oil outlet
points

Rotor Jacking oil

Rotor
r

Oil inlet from JOP discharge header

ROTOR JOP(AC) PROTECTIONS & INTERLOCKS
 Rotor oil jacking pump (AC) starts automatically if
o Speed becomes lower than 800 rpm(but not zero i.e >3 rpm) &
o Vacuum breaking valves are closed

 Rotor oil jacking pump (AC) stops automatically if

o Speed becomes higher than 1200 rpm (OR)
o Oil Pr at p/p suction decreases down to L=0.8 ksc (OR)
o After pump start oil pressure in the discharge header < LL=20 ksc
(Td=60 sec).
o Any Fire Key activated.
 Remotely from CCB motor can be started if
 Pump suction is higher than 0.8 ksc
 Fire key not activated.
 ROTOR JOP(DC) PROTECTIONS & INTERLOCKS
Rotor oil jacking pump (DC) starts automatically with Time delay 10sec ,
if
o Oil pressure in the rotor discharge jacking oil header < 45 ksc.&
o Speed becomes lower than 800 rpm(but not zero) &
o Vacuum breaking valves are closed &
o Turbine stop valves are closed

Rotor oil jacking pump (DC) stops automatically if

o Oil Pr at p/p suction decreases down to L=0.8 ksc (OR)
o After pump start oil pressure in the discharge header is lower than
LL=20 ksc (Td=60 sec).
o Any fire key activated.
 Remotely from CCB motor can be started if
 Pump suction is higher than 0.8 ksc
 Fire key not activated.
 TG BEARING JACKING OIL SYSTEM
GENERATOR

LPC 2 LPC 1 IPC HPC

BRG10 BRG2 BRG1

BRG9 BRG6 BRG4 BRG3
BRG8 BRG7 BRG5
ORIFICE
BEARING
HOUSING

Jop Discharge header

FROM MOT
M

AC BRG.
JOP

JOP suction Header FROM OUT LET OF COOLER

 Bearing jacking oil
 During turbine start-up and unit load
variation conditions the rotor neck
displacement occurs in the bearing
inserts.
 To level the position relative to the
rotor necks the bearing jacking oil
pump starts.
 The rotor neck displacement(X-Y) in
the inserts < 0.1mm Bearing JOP
stops.
 No Standby Bearing JOP.
Bearing jacking oil
 BEARING INSERT JOP PROTECTIONS &
INTERLOCKS
Bearing insert JOP starts automatically if
 Rotor neck displacement > 0.1 mm relative to the inserts of any of
bearings 4-9.
 provided – 1. Rotor JOP Header Pr >45 ksc.(OR)
2. Speed is higher than 1200 rpm.

Bearing insert JOP stops automatically with time delay of 30 sec if

 Rotor neck displacement < 0.1 mm relative to the inserts of any of

bearings 4…9
 Oil Pr at p/p suction decreases down to L=0.8 ksc (OR)
 After pump start oil pressure in the discharge header is lower than LL=20
ksc (Td=60 sec).
 Any fire key activated
 GOVERNING SYSTEM
• High pressure governing & a very compact governing & a
concealed governing.
• High pressure governing : Advantages: Faster response of
systems & smaller sizes of the systems
• Disadvantages: leakages from seals & failure of devices.
• Governing block located at turbine bearing pedestal no. 1
• Electro Hydraulic governing only
• 4 Nos HP control valves , 4 Nos IP control valves with individual
EHCs ie 8NOS. of EHC
• HPT – Nozzle governing , IPT – Throttle Governing
 COMPONENTS OF 660 GOVERNING SYSTEM
• Oil supply
• Spring loaded Accumulator
• Governing block
• EHC (Electro hydraulic converter)
• Stop valve servomotors
• Control valve servomotors
• Pilot valves
• Extraction stop v/v
• CRH FCNRVs.
• CF regeneration system – Resin based Vacuum dehydrator
cum filtration units
 FROM GOV BOX

VAP.EX.FAN ACCUMULATOR

M M

FROM CF PURIFIER
CF SEPARATOR

FROM CLEAN CF TANK

FROM GOV
SYSTEM
M

CF PUMP A

DUPLEX FILTER

MAIN CF TANK
V= 6.9 M3

CF PUMP B

TO CF PURIFIER

CF TRANSFER PUMP
M
M CF COOLER TO
DRAIN
HEADER
TO CF DRAIN TANK

TO CF DRAIN TANK

TO CLEAN CF TANK
NON-STABILIZED
STABILIZED PR. LINE PR. LINE
 OIL SUPPLY UNIT
• Two motor driven centrifugal pumps (2 x 100%) are of 30.5
T/hr. design capacity and 50ksc head with one in standby
located at 0m height.
• Discharge of oil to system via two headers :
– Stabilized pressure header (50ksc).
– Unstabilized pressure header (50 ksc).
– Stabilized header (50NB) provides control oil to all SVs &
EHCs through governing block.
• Non stabilized header (125NB) feeds oil to servomotor of all
SV & CV.
• Spring loaded mechanical type having working vol :40L
connected to Non stabilized pressure header
SCHEME OF 660
MW Governing
System
 GOVERNING BOX
• Location : Bearing pedestal 1.
• Components in governing box
– Control gear
– Over speed governor
– Trip solenoids
– Test electromagnets
– Manual trip buttons.
– Intermediate shaft.
– Intermediate shaft lever.
– Pressure limiting device.
– Test valve.
 Control gear

Intermediate
shaft lever

Test valve

GOVERNING BOX
GOVERNING BOX

To SV

To EHC

Stabilized oil (50 ksc)

 CONTROL GEAR
• Acts like a starting device.
• Inlet supply : 50 ksc stabilized oil from pump.
• It generates oil for
1. Resetting (cocking) of overspeed
governor(OG) slide valve(50 ksc).
2. Line of protection (50 ksc) to OG & trip
solenoids
3. Signal oil for stop valve (50 ksc) via OG.
4. Control line to EHC through pressure limiter
(35 ksc).
• The generation of oil carried out while rotating
Control gear from its position 00 to 900 either
by operator command or hand wheel.
 OVERSPEED GOVERNOR
• Heart of governing system.
• Main purpose to cut in & cutoff
signal oil supply to all S.V.
• Ensures draining of S.V signal oil
OG2 OG1
and EHC signal oil at the time
turbine protection action.
• Signal oil enters in 111% OG and
comes out from 110% OG.
• In case of protection oil is drained,
results pressure drop in protection
line and due to pressure in 110% OVERSPEEDING
cocking line & Inlet SV line OG
pilot valve moves down which cuts
the oil supplying to S.V & EHC 111% OVERSPEEDING
and connects it to drain.
 TEST VALVE
• Ensure 50ksc oil supply to fly
bolts under oil injection testing.
• Oil supply done under two INTERMEDIATE SHAFT
conditions: LEVER

1. Load condition.
2. Idle running condition

TEST VALVE
LEVER
 INTERMEDIATE SHAFT
• A device which links fly bolts to OG pilot valves.

• Three position linking mechanism

– 1. when pressed : OG1(110%) switched out.

– 2. when pulled : OG2(111%) switched out.

– 3. At mid position : OG1 & OG2 are in service.

• Play role in :

– Overspeeding (110% & 111%).

– Oil injection testing.

 Turbine main shaft

O.G
INTERMEDIATE SHAFT

Fly bolts @ 1800

 OG 1 IN SWITCHED OUT CONDITION

OG2

OG1
 OG 2 IN SWITCHED OUT CONDITION

OG2

OG1
Trip Solenoid 1
With manual trip button

Trip Solenoid 2
With manual trip button

Test electromagnets
box
 ONE SET OF MS STOP & CONTROL V/V

STABILISED
OIL(50ksc)

CONTROL OIL
FOR EHC(35ksc)

CONTROL OIL
FOR STOP V/V
UNSTABLISED CONTROL
OIL STREAM OIL FOR
CRH NRVS
 HP STOP VALVE IP STOP VALVE

Tie rods Drain Pilot v/v

oil above
piston

Drain oil
above piston

Head oil I/L

Head oil I/L to
servomotor
 HP CONTROL VALVE

FEED BACK
CAM LEVERS
ATT
LEVER

Control
oil I/L

TIE
RODS

Head oil I/L Drain port

Head oil
I/L
 EHC (ELECTRO HYDRAULIC CONVERTER)

• It consist of EMC and summator

• EHC’s are used for controlling Control
valve for HPT & IPT.
• Control oil for EHC(35ksc) and
stabilized oil(50ksc) are used for the
operation of EHC.
HEAD OIL/
• For ‘0’ signal from Turbine controller
STABILISED
output pressure is equal to 0, because OIL I/L (50
of draining. KSc) O/L CONTROL
OIL /
• Output pressure signal also goes for I/L CONTROL SECONDARY OIL
opening CRH FCNRV. OIL PR FROM
GOV BLOCK
• Loss of control oil pressure(35ksc) (35 KSc)
results zero output pressure from EHC
to CONTROL V/VS.
 CRH FCNRV
Head oil/un Control oil/secondary oil from
stablised oil EHC : 1&2 for CRH NRVS
 ATT
• TESTING OF STOP VALVE
– Testing of SVs is carried with a drive of AC motor
mounted on SVs.
– Load range for testing of full closing SV : 30%-75%.
– Load range for testing of partial closing SV : 30%-
100%.
– Test of full or partial closing is carried out separately
for each SV.
– As per OJSC’s guidelines:
• Full closing test carried out once in a month
• Partial closing test carried out once in a week.
 ATT
• TESTING OF CONTROL VALVE
– Test for partial closing and opening of the CV is performed
from the turbine controller i.e. EHC signal.
– Test only carried out on fully open CV.
– Turbine load range during testing : 40%-100%.
– During testing EHCs are controlled by test program.
– As per OJSC’s guideline testing of partial closing of CV is
carried out once in a week.
– Test of partial closing is carried out separately for each CV.
 ATT
• TRIP SOLENOID TESTING
– The test program for trip solenoid is used to monitor
operation of solenoid protection valves during turbine
operation.
– Trip solenoid gets isolated from main circuit by the help of
corresponding test electromagnet for testing.
– As per guideline testing of trip solenoids carried out once
in a month.
– In case of any protection acts during testing ; testing
program is stopped and testing mechanism set into initial
position.
 Governing System
• HPT control valves open only after achieving preset load
(12% of 660 MW)
• Opening time of control valve is 1.5 sec
• Closing time of Stop valve in case of operation of
protection is 0.3 sec
• Turbine maximum speed is restricted to 108% in case of
generator disconnected from grid
• Over speed protection system stops steam supply in
HPC in < 0.5s
• Speed Controller Droop is adjustable from 2.5% to 8%
(with dead band of 0.04%)
 Rolling Speed Gradient Curve
Speed gradients as per Manufacturer’s start up curve are as follows:

Rolling Condition Target Speed Preset Time Min. Halt Time

3 - 500 rpm 150 sec 300 sec

Cold Startup 1200 rpm* 550 sec 300 sec
( > 72 H )
3000 rpm 630 sec --------

3 - 500 rpm 75 sec 120 sec

Between 36H –
72H 3000 rpm 240 sec --------

Between 8H – 36H 3 - 3000 rpm 360 sec --------

3 - 3000 rpm 300 sec --------
Between 2H – 8H
Control Valve Opening Curve
 Turbine Start Up Sequence
• Start Turbine rolling with Speed Control on from barring speed
to 500 rpm
• After achieving desired criteria, raise speed set point to 1200
rpm* and subsequently to 3000 rpm
• After synchronization Load Controller gets switched On – raise
load > 80MW when “HPC ON” signal is generated
• Turbine Pressure Control will be automatically switched On
• After HPCV demand crosses 80%, switch ON Position
controller to hold 80% as the o/p to control valves for raising
pressure to rated value
• Switch ON Pres. Controller to raise load to rated value
• Switch ON Load Control after load reaches the rated value
START UP CURVES OF TURBINE AFTER SHUTDOWN OF THE UNIT
 Start Up Curves Nomenclature
• To – S.H Live steam temperature.
• Trh – R.H steam temperature
• Po – S.H outlet steam pressure
• Prh – R.H. steam pressure
• Go – Electrical Load of TG
• Ne – Live steam flow from boiler
• N – Turbine rotor speed
• A – Steam Admission
• B – Synchronization
• C – HPC switch on
• D – HPCV open with 20% Throttle reserve & Loading with constant
HPCV position & HP heaters charged
• E – HPCV no-3 opening. Throttle pressure reduced
• F – Full Load
START UP CURVES OF TURBINE AFTER SHUTDOWN OF THE UNIT
START UP CURVES OF TURBINE AFTER SHUTDOWN OF THE UNIT
 Turbine Protection System
Hydraulic Protection: Apart from the Electrical Trip,
Turbine is equipped with the following Hydraulic
Protections:

1. Local Manual Trip (1V2)

2. Over speed Trip #1 at 110% of rated speed
3. Over speed Trip #2 at 111% of rated speed
4. Governing oil pressure < 20 Ksc
CONDITIONS OF TRIPPING THROUGH TRIP SOLENOID
CONDENSATE SYSTEM

HOTWELL 1 HOTWELL 2
DEAERATOR

Recirculatio

Condenser
LPH 4 LPH 3 LPH 2

n to
CEP-A CEP-B CEP-C

LPH1.2
DRIP P/P-A

LPH1.1
DRIP P/P-B

CPU

GSC
 Feed water system
• 2 X 50 % TDBFP
– Separate Condenser, CEP, Vacuum pump system
• 2 X 30 % MDBFP
• HP Heaters 6A/6B, 7A,7B, 8A/8B and two steam coolers
for 6A/6B.
• 3 way quick closing bypass valves system for HP Heater
feed water isolation.
 Boiler feed pump’s
• MDBFP’s ( 2 x 30 % )
• TDBFP’s ( 2 x 60 %)

BFP combintaion LOAD

02 TDBFP 100 %
01 TDBFP & 02 MDBFP 100%

01 TDBFP & 01 MDBFP 95%

01 TDBFP 65%
02 MDBFP 60%

01 MDBFP 30%
 MDBFP
 No of stages -07
 Tapping stage for RH spray -02
 Capacity- 769.95 T/hr
 Head- 3654.47 m
 Tapping flow & press – 48.12 T/hr , 112.2 ksc
 BP inlet/outlet- 14/21 ksc , 186.2 ºC
 Shut off head- 4830m
 Rated motor power -11.5 MW
 Full travel time of scoop tube- 8 sec
 Critical speeds – 8548/10122
 operating speeds-BP/MP- 1490/6275
 Min R/C flow -220 T/hr
 Double piston balancing device with segmental tilting pad
thrust bearing
 FST RH spray Hdr BFP Dish Hdr
Ammonia.
hydraine s
Oxygen
Boiler fill
pump

2nd 7th
stage stage
BP Strainer
cooling MAIN PUMP
system

From BFP warm

other up scheme
BP’s

Warm up line
 TDBFP
 No of stages-7
 Capacity- 1283.14 T/Hr
 Tapping flow & press – 80.12 T/hr , 113.7 ksc
 BP inlet/outlet- 14/28 ksc , 186.2 ºc
 Total head- 3654 m
 Rated speed MP/BP- 4678/2098
 Rated power -13.5 MW
 Min R/C flow -365 T/hr
 Critical speed of MP- 6086/7621
 TDBFP turbine
 No of stages -09
 Split casing design
 Dual steam admission
 Steam inlet – IPT-6th stage/ 21 ksc, 469 ºc.
 Steam flow -61.4 T/hr
 Operating speed- 4678 rpm
 Critical speeds – 1899/6196 rpm
 Throttle governing
 01 stop valve & 02 control valves
 HP HEATERS
HPH-6 HPH-7 HPH-8
Source of steam IPT- 3rd CRH HPT – 13th
stage stage
Inlet Press (ksc) & 21 45.65 69.85
temp (ºC) 309 296 351
Quantity (T/HR) 41 93.18 79
Drip outlet temp (ºC) 200 223.64 265.42
Fw inlet /outlet temp 190/213 213/255 255/285

No of passes 03 03 03
 HPH-6 & Its Desuperheater
TO HPH-8
OUTLET
22.7/470/41.78

FROM IPT- 373.6/316/100

3rd STAGE

373.6/287.3/100

22.7/308/41.78 FROM HPH-8 TO HPH-7A

OUTLET 373.6/215/1135

HPH-6

373.6/196/1135
TO DEA
22.7/224.5/231.3
FROM BFP’s (Ksc/ºc/T/hrr)
CASCADE
DRIP & VENT DEAERATOR
SYSTEM

HPH-7 HPH-6
HPH-8

CONDENSOR
ECO To TDBFP AUX
INLET PRDS SPRAY

HPH-8A HPH-7A HPH-6A

TO SH
SPRAY

100 % 3-WAY
BYPASS VALVE

50% BYPASS

BFP dish
HPH-8A HPH-7A HPH-6A
header

HP bypass
spray
 BYPASS

Change over line

HP
HEATERS
FROM TO
BFP BOILER
close
DRAIN
INITIAL LINE
FILL
LINE TO DRAIN
close
 HPH LEVEL HI-HI

BYPASS

Change over line

HP
HEATERS
FROM TO
BFP BOILER
open
DRAIN
INITIAL LINE
FILL
LINE
close
 MOT Centrifuge
Self cleaning type

Model: S 871
Make: Alfa laval
 Unit # 4 Overhauling

Completed in 21 days and saved 3 days of original schedule

Overhaul was carried out by 5S

- Individual almirah for individual bearings
- Racks
- Aluminium Boxes and trays
- Tilting Drums for metallic and non metallic Scraps

Which saved valuable time in retrieval of spares and materials during box up
and avoided un necessary mess up due to intermixing and loss of materials
Thank you