Allen Steam Turbines

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Allen Steam Turbines The Trusted Name In Power Generation

Weir Power & Industrials Allen Steam Turbines was originally part of the world renowned W H Allen Sons & Co. Ltd, which was established at the Queens Engineering Works, Bedford in 1894. The company has a long and illustrious history as manufacturers of steam turbines, pumps and diesel engines. In 1999, during ownership by Rolls-Royce plc, the decision was taken to focus on turbine refurbishment, support and maintenance rather than commercial manufacture, and in 2001 Allen Steam Turbines became part of Weir Power & Industrial. For over 100 years, Allen Steam Turbines has continued to support its installed turbine base throughout Europe and the world. The company is situated in modern premises located in Bedford, and from this site they provide Site Engineering Support, Design and Analysis, Technical Support and Spares Supply to customers in varying industries including Sugar, Waste to Energy, Paper and Pulp and Naval Marine. To complement these support services, Allen Steam Turbines now offers a competitive range of turbines manufactured by their partner NG Metalrgica of Brazil, which has evolved directly from the Allen turbine design. Allen Steam Turbines are accredited to the following international standards: ISO9001:2000, ISO14001:2004 and OHSAS18001:2007.

Allen Steam Turbines Bedford workshop

An original Allen turbine

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Allen Steam Turbines and NG Metalrgica Partners in Power

development centres and a large team of engineering specialists, afforded the most advanced software and equipment to allow continuous improvement and new product development. Along with national approvals from Petrobras and Brazilian Navy certification, NG meets major international standards such as ISO9001:2000.

NG head office

Working Together For over 30 years, Allen Steam Turbines has been working closely with Brazilian company NG Metalrgica. Throughout this time NG and Allen have constantly enhanced the design, efficiency and performance of the Allen design of turbines, culminating in a proven, reliable machine capable of meeting the most exacting demands required in todays applications. As a result of this collaboration, the machines produced by NG have established a significant presence in the South American market. Working in partnership, Allen Steam Turbines and NG now offer the NG Allen range of steam turbines to customers throughout the rest of the world. The turbines are manufactured by NG, with project management, installation, commissioning, technical support and ongoing after-sales support provided by Allen Steam Turbines.

NG Capim Fino workshop

NG Metalrgica an Introduction NG Metalrgica is a family owned Brazilian company established in 1920. It has advanced manufacturing facilities operating from custom-built sites in Piracicaba, So Paulo state. The modern designs of the NG Allen range demand sophisticated manufacturing techniques and a high degree of precision. The constantly updated manufacturing facilities, producing more than 60 turbine designs, are fully equipped to meet these demands. The facilities also contain research and

NG manufacturing complex Capim Fino

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The NG Allen Range A Steam Turbine for Every Application

NG Allen single and multi-stage steam turbines are configured in six distinct series: L Series, a condensing model only, designed for low inlet steam conditions up to 12 bara/350C. M Series, available in back pressure or condensing types, designed for medium inlet steam conditions up to 45 bara/450C. H Series, also available in back pressure or condensing types, designed for high inlet steam conditions up to 86 bara/520C. Each L, M and H models specification is defined by a sequence of letters and numbers - the first letter indicates the turbine type: B for Back Pressure and C for Condensing. The numbers indicate the approximate mean diameter of the wheels. Finally, the suffix E indicates the provision of controlled extraction, available only on the H Series of machines.

HC 1000 E Extraction Condensing 33,300 kW

Ce series

DSE/DME series

H Series - Back Pressure 21,000 kW

DSE Series, available for back-pressure or atmospheric exhaust. Power range from 5 kW to 1200 kW. Suited to small mechanical drive and fully API compliant. Ce Series, available for back-pressure or atmospheric exhaust. Robust single stage machine fully API compliant. DME Series, Multi-stage turbine ideally suited to mechanical drives with up to 35% saving on steam consumption over the DSE series. Fully API compliant.

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L Series
Type
Model Maximum Power Rated Speed Max. Inlet Pressure Max. Inlet Temperature Max. Exhaust Pressure Inlet Flange Exhaust Flange LC 500 6,000 kW 10,250 rpm 12 bara 350C Vacuum 2 x 200 mm 800 mm LC 650 11,000 kW 8,500 rpm 12 bara 350C Vacuum 2 x 250 mm 1020 mm

Condensing
LC 800 20,000 kW 6,500 rpm 12 bara 350C Vacuum 2 x 300 mm 1370 mm LC 1000 25,000 kW 5,400 rpm 12 bara 350C Vacuum 2 x 350 mm 1680 mm LC 1250 32,000 kW 4,750 rpm 12 bara 350C Vacuum 2 x 350 mm 1930 mm

Type
Model Maximum Power Rated Speed Max. Inlet Pressure Max. Inlet Temperature Max. Exhaust Pressure Inlet Flange Exhaust Flange LC 500/500 6,000 kW 10,250 rpm 12 bara 350C Vacuum 2 x 200 mm 2 x 800 mm

Condensing with double ow exhaust

LC 650/650 11,000 kW 8,500 rpm 12 bara 350C Vacuum 2 x 250 mm 2 x 1020 mm LC 800/800 20,000 kW 6,500 rpm 12 bara 350C Vacuum 2 x 300 mm 2 x 1370 mm LC 1000/1000 25,000 kW 5,400 rpm 12 bara 350C Vacuum 2 x 350 mm 2 x 1680 mm LC 1250/1250 32,000 kW 4,750 rpm 12 bara 350C Vacuum 2 x 350 mm 2 x 1930 mm

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M Series
Type
Model Maximum Power Rated Speed Max. Inlet Pressure MB 350 7,000 kW 11,500 rpm 45 bara MB 420 10,000 kW 9,250 rpm 45 bara 450C 22 bara 2 x 200 mm 500 mm MB 510 15,000 kW 8,000 rpm 45 bara 450C 22 bara 2 x 200 mm 600 mm

Back pressure
MB 630 22,000 kW 6,500 rpm 45 bara 450C 22 bara 2 x 250 mm 760 mm MB 750 35,000 kW 5,800 rpm 45 bara 450C 22 bara 2 x 300 mm 900 mm MB 900 42,000 kW 4,750 rpm 45 bara 450C 22 bara 2 x 350 mm 1070 mm

Max. Inlet Temperature 450C Max. Exhaust Pressure Inlet Flange Exhaust Flange 22 bara 2 x 150 mm 400 mm

Type
Model Maximum Power Rated Speed Max. Inlet Pressure Max. Inlet Temperature Max. Exhaust Pressure Inlet Flange Exhaust Flange MC 500 8,000 kW 10,250 rpm 45 bara 450C Vacuum 2 x 150 mm 800 mm MC 650 15,000 kW 8,500 rpm 45 bara 450C Vacuum 2 x 200 mm 1020 mm

Condensing
MC 800 28,000 kW 6,500 rpm 45 bara 450C Vacuum 2 x 200 mm 1370 mm MC 1000 35,000 kW 5,400 rpm 45 bara 450C Vacuum 2 x 250 mm 1680 mm MC 1250 45,000 kW 4,750 rpm 45 bara 450C Vacuum 2 x 300 mm 1930 mm

Type
Model Maximum Power Rated Speed Max. Inlet Pressure Max. Inlet Temperature Max. Exhaust Pressure Inlet Flange Exhaust Flange MC 500/500 8,000 kW 10,250 rpm 45 bara 450C Vacuum 2 x 150 mm 2 x 800 mm

Condensing with double ow exhaust

MC 650/650 15,000 kW 8,500 rpm 45 bara 450C Vacuum 2 x 200 mm 2 x 1020 mm MC 800/800 28,000 kW 6,500 rpm 45 bara 450C Vacuum 2 x 200 mm 2 x 1370 mm MC 1000/1000 35,000 kW 5,400 rpm 45 bara 450C Vacuum 2 x 250 mm 2 x 1680 mm MC 1250/1250 45,000 kW 4,750 rpm 45 bara 450C Vacuum 2 x 300 mm 2 x 1930 mm

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H Series
Type
Model Maximum Power Rated Speed Max. Inlet Pressure Max. Inlet Temperature Max. Exhaust Pressure Inlet Flange Exhaust Flange HB 350 10,000 kW 11,500 rpm 86 bara 520C 22 bara 2 x 100 mm 400 mm HB 420 15,000 kW 9,250 rpm 86 bara 520C 22 bara 2 x 150 mm 500 mm HB 510 22,000 kW 8,000 rpm 86 bara 520C 22 bara 2 x 200 mm 600 mm

Back pressure
HB 630 32,000 kW 6,500 rpm 86 bara 520C 22 bara 2 x 250 mm 760 mm HB 750 50,000 kW 5,800 rpm 86 bara 520C 22 bara 2 x 250 mm 900 mm HB 900 60,000 kW 4,750 rpm 86 bara 520C 22 bara 2 x 300 mm 1070 mm

Type
Model Maximum Power Rated Speed Max. Inlet Pressure Max. Inlet Temperature Max. Exhaust Pressure Inlet Flange Exhaust Flange HC 500 12,000 kW 10,250 rpm 86 bara 520C Vacuum 2 x 100 mm 800 mm HC 650 22,000 kW 8,500 rpm 86 bara 520C Vacuum 2 x 150 mm 1020 mm

Condensing
HC 800 40,000 kW 6,500 rpm 86 bara 520C Vacuum 2 x 200 mm 1370 mm HC 1000 50,000 kW 5,400 rpm 86 bara 520C Vacuum 2 x 250 mm 1680 mm HC 1250 65,000 kW 4,750 rpm 86 bara 520C Vacuum 2 x 300 mm 1930 mm

Type
Model Maximum Power Rated Speed Max. Inlet Pressure Max. Inlet Temperature Max. Exhaust Pressure Inlet Flange Exhaust Flange HC 500/500 12,000 kW 10,250 rpm 86 bara 520C Vacuum 2 x 100 mm 2 x 800 mm

Condensing with double ow exhaust

HC 650/650 22,000 kW 8,500 rpm 86 bara 520C Vacuum 2 x 150 mm 2 x 1020 mm HC 800/800 40,000 kW 6,500 rpm 86 bara 520C Vacuum 2 x 200 mm 2 x 1370 mm HC 1000/1000 50,000 kW 5,400 rpm 86 bara 520C Vacuum 2 x 250 mm 2 x 1680 mm HC 1250/1250 65,000 kW 4,750 rpm 86 bara 520C Vacuum 2 x 300 mm 2 x 1930 mm

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Single Stage Turbine Ratings

DSE Series
DSE 180
Power Inlet P Inlet T Exhaust P 50 kW 22 bara 300C 8 bara

DSE 400
220 kW 43 bara 400C 8 bara

DSE 550
800 kW 43 bara 400C 8 bara

DSE 700
1,200 kW 43 bara 400C 8 bara

Ce Series
Series 300
Power Inlet P Inlet T Exhaust P 3,000 kW 32 bara 350C 8 bara

Series 600
3,000 kW 43 bara 400C 13 bara

Series 1100
1,800 kW 65 bara 450C 13 bara

Multi-Stage Turbine Ratings DME Series

DME 450
Power Inlet P Inlet T Exhaust P 6,000 kW 45 bara 450C 5 bara

DME 500
1,800 kW 43 bara 400C 5 bara

DME 560
15,000 kW 45 bara 450C 5 bara

DME 700
3,200 kW 43 bara 400C 5 bara

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The L,M and H Series Construction Features

The L, M and H Series multi stage steam turbines are NG Allens answer to safe, economical and efficient power generation. The main characteristics of these machines are cost effective investment and high performance in the range 5 to 65 MW. The series offers flexible operation for power and heat generation in co-generation systems, particularly in those using biomass or waste product fuels.

Turbine Casing The turbine HP casing is made in cast steel, split on the horizontal and axial centre lines. The top half has an integrated steam chest, with vertical control valves within the casing. This is a compact arrangement and has the advantage of minimising the thermal stresses experienced during rapid machine start-up. The casing halves are secured with high alloy fasteners, thermally tensioned to provide a perfect seal. Two axial arms on the front of the cylinder provide support via radial keyways on the bearing housing, with alignment controlled by an axial key on the machine centre line. Thermal expansion is controlled by radial keys at the exhaust end of the machine and axial expansion via the bearing housing slideways at the front of the machine. The fixed point of the rotor in relation to the turbine casing is the thrust bearing at the HP end of the rotor, therefore minimising the relative movement between stationary and rotating parts.

Modular Design Concept The combination of standardised modules - front, intermediate and rear - results in machines that precisely meet the specific operating conditions, minimise costs and produce the most efficient machine for the particular application.

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The L,M and H Series Construction Features

Multiple Control Valves Control at all loads is assured by an electrohydraulic actuator, positioned by a digital electronic governor. There are four vertically positioned control valves on the top casing which are operated against individual compression springs to provide failsafe shut down. Each valve controls the steam admission to a first stage nozzle group and can maintain a set pressure at the steam inlet or exhaust. During turbine automatic start, the control valves are partially opened to ensure uniform heating of the casing. This minimises thermal stresses and deformation, to prevent mechanical contact between the rotor and the shaft sealing.

Rotor The rotor is monobloc type with integrally forged discs manufactured from high alloy steel, ultrasonically tested and dynamically balanced. The rotor is balanced at each stage of the blading assembly to achieve smooth operation and extended service life of the machine.

Cross section of emergency valve

Combined stop and emergency valve This valve is of the hydraulically actuated, quick shut off type, with the facility for on line free movement checks in accordance with API 612 requirements. It is mounted in a valve body made from material identical to the main casing and can be removed without disconnecting the steam admission piping. The valve body is fitted internally with a stainless steel steam strainer upstream of the valve to provide protection against foreign particle ingress from the admission steam piping. The opening of the valve is controlled automatically to obtain a speed ramp according to the start-up curve for the machine. The speed ramp is configured in the speed governor so that the start is independent of operators actions. In an emergency situation the valve closes automatically to stop the steam admission and protect the machine. Tip Seals and Advanced Blade Technology The blade profiles are developed through the most modern technology using three dimensional finite element analysis. This ensures the development of machines mechanically optimised for the most efficient thermodynamic energy conversion.

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The L,M and H Series Construction Features

Turbine Bearings Both thrust and journal bearings are of the white metal lined, tilting pad type, thus guaranteeing high dynamic stability of the turbine rotor. The thrust bearings are constructed to withstand the maximum axial thrust loads in both directions. Oil System The oil system is pressure fed type, consisting of a centralised unit supplying common lubrication to the turbine, gearbox and driven unit, and including a supply for the control oil circuit. The system comprises:

Oil reservoir with level gauge, vent and drain Twin oil cooler with change over valve Duplex oil filter for the lubricating oil system Duplex oil filter for the control oil system Gearbox low speed shaft driven main lubrication and control oil pump AC electric motor driven auxiliary lubricating and control oil pump DC electric motor driven or auxiliary steam turbine driven run down emergency oil pump AC electric motor driven barring and lifting device oil pump (if fitted) Oil mist extraction fan Pressure relief control, check and block valves, orifice plates and flow gauges at bearing housing drain piping Oil piping

Shaft Steam Sealing System The system consists of metallic labyrinth rings made in stainless steel and fitted with a steam leakage extraction system. The sealing between stages is by floating type labyrinths assembled on the diaphragms which provide effective sealing while being easily replaced. The external sealing is by floating type labyrinths.

Controlled Extraction Valve The H Series turbines can be fitted with controlled extraction valves for up to 95% of the total admission steam flow. Two types of controlled extraction valves are possible:

vertically mounted balanced valves for high and medium pressures a gate-type rotary valve for low extraction pressures (as shown).

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11

Control Systems

The Control Panel provides complete management of the turbine, gearbox and generator via a comprehensive suite of functions:

Monitoring of axial displacement and relative vibration adjacent to the rotor shaft bearing Programmable Logic Controller - PLC Digital speed governor Digital overspeed trip system Human-Machine Interface (HMI), including alarm and shutdown functions for the control and protection of the turbine and gearbox unit An independent shutdown circuit for total turbine and gearbox protection, even in the event of PLC logic failure Automation of lubricating oil pumps Control switches for oil pumps The ability to test the shutdown circuit during normal turbine operation

Admission steam pressure control Extraction steam pressure control Exhaust steam pressure control Control of the generated power Frequency control Interconnection with digital control systems

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DSE, Ce and DME Series Construction Features

The DSE Series turbines are designed with lubrication by rings for fast start in emergency or stand-by operation, and for working intermittently. They can also have forced lubrication. They comply with NEMA standards and API 611 and API 612.

The Ce Series turbines are some of the most robust single stage machines on the market. Suited to extreme operational conditions and services, they respond efficiently to power variations. They comply with NEMA standards and API 611 and API 612.

The DME Series is a more efficient multi stage steam turbine based on the DSE Series.

Item
Housing Rotor Bearings Speed Regulator (Governor) Number of Control Valves Steam Sealing Oil Seal Electrical and Instrument Panel Test at Factory

DSE

Ce

DME

Cast Steel, Horizontally split at the centre line Twin Supports with shaft and disc made of forged alloy steel Horizontally split bush type NG or Woodward hydraulic, Woodward or Dawson electronic

Three Graphite mechanical seal with metal labyrinth Mechanical seal with metal labyrinth Explosion proof Optional Steam Ejector Metal Labyrinth

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Installation and start up

Allen Steam Turbines team of technicians and engineers have experience in the installation of new turbines and auxiliary systems worldwide. These services include:

Full installation package or supervision only Checking and preparing the base, prior to installation Correct location and installation on the base Levelling and alignment Supervision of steam pipe blowing Full commissioning of oil, steam, water, electrical, regulation and safety systems Start up testing including governor response, load rejections, etc. Performance testing evaluation Training of maintenance and operation personnel
30 MWe Twin Cylinder Condensing Set

Support and service A team of customer-support experts deliver an aftersale service designed to cover every eventuality and need, including:

Technical assistance Fast-response breakdown Problem-solving and repair Replacement parts Equipment monitoring Performance evaluation Retrofit appraisal and delivery Routine and planned maintenance Long-term maintenance and support packages
Re-Blade of 20 MWe Condensing set

Parts As a key function of this service, Allen Steam Turbines provide original turbine spare parts. Parts are supplied worldwide, from labyrinth seals through to complete rotors and diaphragms. Every component is manufactured to the same exacting standards as the original, ensuring that operational integrity is protected. Other products Incorporated in the Allen Steam Turbines business are Allen Gwynnes Pumps (<12), Vickers, Vacseal and Nimbus Pumps, which continue to be manufactured and supported.

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Johannesburg, S. Africa

Allen Steam Turbines Highfield Parc Highfield Road Oakley Bedfordshire MK43 7TA England Tel: +44 (0)1234 826691 Fax: +44 (0)1234 826649 E-mail: steamturbines@weirgroup.com Web: www.weirpowerindustrial.com

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