JINDAL POWER LIMITED.

JINDAL POWER LIMITED

DESIGN & FEATURE OF 600 MW STEAM TURBINE

 DEFINATION OF TURBINE

What is steam turbine?

 Turbine is a machine in which the kinetic energy of a
moving fluid is converted into mechanical energy by
causing a blade rotor to rotate. The moving fluid may
be water, steam, air or combustion product of a fuel.
 Rotary machine that converts the thermal energy of
steam into mechanical energy(rotary motion).
 It is a machine witch thermal energy of fluid converts
in to kinetic energy by means of expansion of steam.
 HOW TURBINE WORKS

How turbine works?

 High pressure any high temperature steam/fluids
passed through the fixed blades witch are fixed with
turbine casing and than passing through the moving
blades fixed with rotor. The fixed and moving blades
are design such a way that the velocity/pressure of
steam forced to rotate the moving blades. The Pressure
energy converted into velocity energy in fixed blades
and same velocity energy force to rotate the moving
blade and mechanical/kinetic energy generated.
 TYPES OF TURBINE

1. Impulse Turbine:
2. Reaction Turbine:
 Impulse Turbine:
Pressure drop occur only fixed blades(Nozzle).
Maximum steam velocity (Impulse) is created at the inlet
of moving blades. This energy is utilised for rotation of
blades. The steam velocity can be maximised by having
maximum pressure drop in the fixed blades or nozzles.
Hence in 100% impulse steam turbine, whole pressure
drop will be in stationary blades or nozzle.
 Reaction Turbine: Pressure drops occurs both fixed and
moving blades.
 Technical Specification of TG SET 600MW

Load
Rated Load 600MW
Maximum Load Under valve wide open 630.2MW

Construction

Single Flow HP Turbine with 15 Reaction Stage Type: H30-100-2

Double Flow IP Turbine With 10 Reaction Stage Per Flow Type:M30-63
Double Flow LP Turbine(2 no's) with (5 drum+3 module) stage per Flow. Type:N30-4x6.3(2LPT)

2 Main stop & Control Valves(HP Casing Mounted) Type:EV320-1

2 Reheat stop & Control Valves (Floating) Type:IV560
1 Swing Check Valve in Cold Reheat Line DN-800 (BHEL Trichy)

2LP Bypass Stop & Control Valve(EHA Based) Make: CCI, Switzerland
 Technical Specification of TG SET 600MW
Speed
Rated Speed 50.0 c/s (3000 rpm)
Max. Speed no time limitation 51.5 c/s (3090 rpm)
Min. Speed No time Limitation 47.5 c/s (2850 rpm)
Permissible for maximum 2 hours during the Speed Below 47.5 c/s
life of LP Blading Speed above 51.5 to 60 c/s
Speed Exclusion range at operation without 7 to 47.5 c/s
load
Standard Over Speed Trip Setting Max.55.5 c/s (3300 rpm)
Generator Technical Specification
Type THDF115/67
Rating 705.9MVA/600MW
Voltage/Current 21KV/19407A
Rated Speed/Frequency 3000 rpm/50 Hz
Power factor 0.85
DESIGN & FEATURE OF 600MW TAMNAR UNITS

600 MW capacity turbines at our station are design

by Kraft Werk Union (KWU-Germany)
,manufacturing and supplied by BHEL. The turbine
is condensing, tandem compounded, horizontal,
reheat type machine. In has got separate high
pressure, Intermediate and low-pressure parts. The
HP part is a single flow and IP, LP parts are double
flow cylinders. The turbine rotors are rigidly coupled
with each other and with generator rotor and exciter
also.
600MW Turbine schematic diagram
 STEAM TURBINE:GENERAL

HP turbine has throttle control. The steam is

admitted through two combined stop and control
valves. The lines leading from HPT exhaust to re
heater have got cold reheat swing check NRVs. The
steam from re heater has got two cold reheat swing
check NRVs. The steam from re heater is admitted to
IP turbine through two combined stop and control
valves. Two crossover pipes connect IP and LP
cylinder.
Cross sectional Arrangement of HP-IP-LP
turbine
Arrangement drawing
 Bladding

The entire turbine is provided with reaction blading.

The moving blades of HPT, IPT and front rows of
LPT have inverted T roots and are shrouded. The last
stages of LPT are twisted; drop forged moving blades
with fir-tree roots. Highly stressed guide blades of
HPT and IPT have inverted T roots. The other guide
blades have inverted L roots with riveted shrouding.
 Bearings

The HP rotor is supported on two bearings, a journal

bearing at its front end, and a combined journal and thrust
bearing immediately next to the coupling to the IP rotor.
The IP and LP rotors have a journal bearing each at rear
end. The combined journal and thrust bearing incorporates
a journal bearing and a thrust bearing which takes up
residual thrust from both directions. The bearing metal
temperatures are measured by thermocouples directly
under the Babbitt lining. The temperature of the thrust
bearing is measured in two opposite thrust pads. The
bearing pedestals are anchored to the foundation by means
of anchor bolts and are fixed in position.
 Bearings

The HP and IP turbines rest with their lateral support

horns on the bearing pedestals at the turbine centerline
level. The HP and IP casings are connected with the
bearing pedestals by casing guides, which establish the
centerline alignment of the turbine casing. The axial
position of the HP and IP casings is fixed at the support
brackets on HP-IP bearing pedestal.
The fixed point for the LP casing is at the front point of
support on the longitudinal girder. Thermal expansion
of the casings originates from the fixed points.
Journal Bearing
Thrust Bearing Cum journal Bearing
Cross-Sectional blade of HPT
 HPT Construction

The outer casing of the HP turbine is of the barrel type and

has neither an axial nor a radial flange. his prevents mass
concentration which would have caused high thermal
stresses. The almost perfect asymmetric design of the casing
permits moderate and nearly uniform wall thickness at all
sections. The inner casing is axially split and supported so
as to be free to move in response to thermal expansion. As
only slight pressure differences are effective, the horizontal
flange and joint bolts of the inner casing can be kept small.
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.
Cross-sectional view of IPT
 IPT Construction

The IP turbine section is of single flow construction

with horizontally split casings. Allowance is made for
thermal movement of the inner casing within the outer
casing. The inner casing carries the stationary blading.
The reheated steam enters the inner casing from top
and bottom. The provision of an inner casing confines
high steam inlet conditions to the admission section of
this casing, while the joint
flange of the outer casing is subjected only to the lower
pressure and temperature effective at the exhaust from
the inner casing.
Inner & outer casing assembly
Inner & outer casing assembly
Cross- Sectional view of LPT
 LPT Construction

The casing of the double-flow LP cylinder is of three-

shell design. The shells are horizontally split and are
of rigid welded construction. The inner most shell,
which carries the first rows of stationary blades, is
supported so as to allow thermal expansion within
the intermediate shell. The intermediate shell rests
at four points on longitudinal girders, independent
of the outer shell. Guide blade carriers, carrying the
last stationary blade rows are also attached to the
intermediate shell.
Low Pressure Turbine(LPT)
Low Pressure Turbine(LPT)
Steam flow Diagram
 Turbine Controlling system

The turbine has an electro hydraulic control system.

An electric system measures speed and output and
controls them by operating the control valves
hydraulically via an electro hydraulic converter. The
electro hydraulic controller ensures controlled
acceleration of the turbine-generator up to rated
speed and limits speed overshoot in the event of
sudden load rejection. The linear power frequency
droop characteristic can be adjusted in fine steps
even when the turbine is running.
 Turbine Monitoring System

In addition to measuring and display instruments for

pressure, temperatures, valve lifts and speed, the
monitoring system also includes instruments for
measuring and indicating the following parameters:
 Rotor expansion measured at the rear bearing
pedestal of the LP turbine
 Axial shift measured at the HP-IP pedestal
 Bearing pedestal vibration, measured at all turbine
bearings
 Shaft vibration measured at all turbine bearings
 Oil Supply System

A common oil supply system lubricates and cools the bearings .

The main oil pump is driven by the turbine shaft and draws oil
from the main oil tank. Auxiliary oil pumps maintain the oil
supply on start-up and shutdown, during turning gear operation
and when the main oil pump is faulted. DC Emergency oil pump
supplies oil to the bearings during AC power failures.
A Jacking oil pump forces high-pressure oil under the shaft
journals to prevent boundary lubrication during turning gear
operation. The Jacking oil pump also supplies the high pressure
oil to the Hydraulic Turning gear motor. The lubricating and
cooling oil is passed through oil coolers before entering the
bearings.
 FUNCTION OF LUBE OIL SYSTEM

Provides a supply of oil to the journal bearings to give

an oil wedge as the shaft rotates.
Maintains the temperature of the turbine bearings
constant at the required level. The oil does this by
removing the heat which is produced by the shaft
conduction, the surface friction and the turbulence
set up in the oil.
Provides a medium for hydraulically operating the
governor gear and controlling the steam admission
valves.
Provides for hydrogen cooled generators a sealing
medium to prevent hydrogen leaking out along the
shaft.
 INTRODUCTION OF LUBE OIL SYSTEM

 A common oil supply system lubricates and cools the bearings . The
main oil pump is driven by the turbine shaft and draws oil from the
main oil tank.
 Auxiliary oil pumps maintain the oil supply on start-up and
shutdown, during turning gear operation.
 DC Emergency oil pump supplies oil to the bearings during AC
power failures.
 A Jacking oil pump forces high-pressure oil under the shaft journals
to prevent boundary lubrication during turning gear operation.
 The Jacking oil pump also supplies the high pressure oil to the
Hydraulic Turning gear motor.
 The lubricating and cooling oil is passed through oil coolers before
entering the bearings.
 MOP
TURBINE OIL SYSTEM
HPT IPT LPT Gen

FROM
EXC. BRG.

INJECTOR
3 NO.S 6 NO.S SOST
II
TI OIL COOLER TI TT PS PT

OVE-1
TT PI OTCV OIL FILTER
OVE-2
DMCW

PI PI PI PI PI PI
PI
AC AC DC AC AC DC

INJECTOR
I
AOP - 1 AOP - 2 EOP - 1 EOP - 2 JOP - 1 JOP - 2

MAIN OIL TANK

TG lube oil &jacking Oil System
TG lube oil &jacking Oil System
TG lube oil &jacking Oil System
TG lube oil &jacking Oil System
TG lube oil &jacking Oil System
 Main Oil Pump(MOP)

LOCATION: This pump is mounted in the front bearing

pedestal. It is coupled with turbine rotor through a gear
coupling.
Oil suction from MOT Through two number of injectors
connected in series.
Takes over when turbine speed > 2800 rpm.
Supplies oil for turbine bearing lubrication as well as for
the turbine governing system.
Main Oil Pump(MOP)
Main Oil Pump(MOP)
 Main Oil Tank(MOT)

The oil necessary for operation is stored in the main

oil tank. The oil pumps draw the turbine oil from the
main oil tank and forward it to where it is needed.
Large solid contaminants in the returning oil are
removed by the strainers in the main oil tank before the
oil reaches the suction section of the main oil tank.
The capacity of the tank is such that the full quantity of oil is
circulated not more than 8 times per hour. This results in a
retention time of approx. 7 to 8 minutes from entry into the tank
to suction by the pumps. This time allows sedimentation &
deaeration of the oil
 Main Oil Tank(MOT)

Extra tank volume is provided between the normal

operating level & the tank cover to accept oil from the
entire oil supply system when the turbine is shut down.
Main oil tank, rated capacity : 25/40 m3
First Oil filling (estimated) : 38 m3
Flushing Oil quantity (estimated) : 25 m3
 Lube Oil System

INJECTOR:
Injector is located upstream of the main oil pump.
The injector produce adequate pressure for all operating conditions at the suction of the main
oil pump.
THREE WAY TEMP. CONTROL VALVE:
The oil temp. control valve is a multiport valve in which hot & cold turbine oil is mixed to
obtain the desired lubricating oil temp of approx. 45 Deg C downstream of the control valve.
COOLER:
To cool the lubricating oil
Consists of tube nest, inner & outer shell & water boxes
The cooling medium for these coolers is circulating water.
The pressure of the cooling water is kept lower than that of oil to avoid its mixing with oil in
the event of tube rupture.
OIL TEMP. CONTROLLER for maintaining the lub oil temp at rated value by controlling
the flow through the coolers.
 Governing System

“A SYSTEM WHOSE PURPOSE IS TO

CONTROL A PRIME MOVER”
 The characteristics of an ungoverned turbine is unsuitable
for electric power generation.
 The turbine output is controlled by varying the steam flow
by means of throttling valves of the turbine .The valves are
controlled by the governor.
 Governing system is required to ensure that the system
demand is followed automatically without large deviation
in the nominal electric frequency
 Function of Governing System

To control the initial run up and synchronization of the

machine
To control the turbine load when running in parallel with
other generating sets.
To control the speed rise within acceptable limits in case of
the unit getting disconnected from the load
To provide protective gears to ensure the safe operation of
the turbine
Thus the individual TG governing system imply a need to
 withstand a full load rejection safely
 provide appropriate contributions to system frequency control.
Governing System Scheme
Control oil system
Control oil system
 GLAND SEAL STEAM SYSTEM

A high pressure steam turbine having a sealing gland where the

turbine rotor penetrates in to the casing of the turbine. Under no load
conditions the gland is sealed by an auxiliary steam supply, and
under load conditions the gland is self sealed by turbine inlet steam.
The turbine have two main parts one is rotating parts(Rotor) and
another is stationary parts(casing) so that minimum clearance sell be
required to avoid friction between rotating and stationary parts and
for thermal expansion. The high pressure steam inside the turbine try
to exits through the clearance between rotor and casing. And in
vacuum condition atmospheric air try to enter into the
turbine/condenser through the clearance. To avoid the steam exits &
air entering, gland is provided in turbine and steam is used for
sealing.
Functions of Gland Sealing System

To prevent the atmospheric air entering in to the

condenser during vacuum pulling and during normal
operation maintaining vacuum in
condenser( approx. -0.9bar) by sealing the gland
with seal steam.
 To prevent the steam leakage from the turbine gland
seals by leak-off steam control system
Benefits of Gland sealing system

Maximized the efficiency of back pressure steam

turbine by sealing the LPT gland to maintaining the
vacuums in condenser.
Minimized the wastage of leak-off gland steam from
the turbine by controlling leak-off steam pressure
equal to seal steam pressure by dumping excess
steam to condenser.
Schematic Diagram of Seal steam system
Seal Steam PID Drawing
 Seal Steam Control System

Seal steam control system is combined control system of

auxiliary supply seal steam and gland leak-off steam with a
common header maintaining 1.048bar (absolute) pressure
equivalent to 350mmwc.
Auxiliary supply seal steam control station:
During vacuum pulling in condenser, auxiliary steam is
required for sealing the turbine gland to prevent the
entering of out side air to the condenser. It maintains the
seal steam pressure approx. .035bar. Gland seal steam
control station consists of one pneumatic control valve with
two numbers manual isolation valve and a bypass motorized
valve.
 Seal Steam Control System

Leak-off steam control system:

After loading the turbine, the leak-off steam of HP &
IP turbine tries to exits from to atmosphere. To
prevent the exits of leak-off steam coming out from
turbine is draw back in to the leak-off steam control
station maintaining pressure equal to supply steam
pressure by dumping the excess steam to condenser
and also same steam supply to LPT for sealing. Leak-
off steam control station consists of one pneumatic
control valve with two numbers manual isolation valve
and a bypass motorized valve.
 Seal Oil System

 The generator requires cooling to dissipate the heat that it

generates. Seal oil Provide a seal between the generator housings
and rotor shaft to maintain the pressurized hydrogen gas inside
the generator and prevent the hydrogen gas from escaping from
the generator to the atmosphere.
 Because Hydrogen gas is highly flammable and will burn in air at a
very wide range of concentrations between 4% and 75% by
volume. The mixtures spontaneously detonate by spark. The
hydrogen auto ignition at the temperature of spontaneous ignition
in air, is 500 °C.
 Hydrogen gas is used for cooling because it has the highest known
heat transfer rate of any gas and Light in weight, which reduces
windage losses and its dew point is-259.14 °C.
Seal Oil System P&ID Drawing
 SEAL OIL

B.C. EXHAUST FAN-1 RING RELIEF OIL

TO
ATMOSPHERE

B.C. EXHAUST FAN-2

GENERATOR
DPR DPR

OIL TRAP

SOST
DRAIN
LUB OIL RETURN HEADER

W FILTERS
IOT
O
T
SOVP-A
VACUUM
TANK

SOVP-B COOLERS

DC SOP
SOP-1 SOP-2

. . .
 Seal Oil Storage Tank

 The bearing oil which flows through the seal oil storage tank
mixes with the seal oil and contains small amounts of hydrogen
gas escaping from the generator. The oil settles in the seal oil
storage tank and degases due to the sub atmospheric pressure
conditions. The seal oil storage tank is connected to the bearing
vapour exhausters to continuous venting.
 Seal Oil Pump

 Seal oil pumps are used to draw the oil from seal oil vacuum tank
and supply to the shaft seals via coolers and filters in a closed
circuit.
 The seal oil pumps are three-screw pumps. One double-
thread driving rotor and two driven idler screws are closely,
meshed and run with a close clearance in the casing insert.
The pump casing accommodates the casing insert and is
closed off by covers at the drive end and non drive end.
 Seal Oil Tank

INTERMEDIATE TANK
 In this tank the seal oil drained from hydrogen side of the shaft seal via
generator pre-chambers where escape of entrained gas bubbles and de-
foaming of the oil. The function of this tank to prevents the ingress of
hydrogen in to the vacuum tank. A float valve keeps the oil level in this
tank a predetermine level.
VACUUM TANK:
The oil from the intermediate tank is flow into the vacuum tank together
with the seal oil drained from the air side of the shaft seal via a float
valve. In this tank vacuum establishes by vacuum pump which removes
entrained air bubbles from the seal oil. The seal oil supplied to the shaft
seals by the seal oil pumps in thus largely free of gas which prevents a
deterioration of the hydrogen purity in the generator.
 Thermal Expansion

Casing Expansion:
The bearing pedestals are anchored to the foundation by
means of anchor bolts and are fixed in position. The HP and
IP turbines rest with their lateral support horns on the
bearing pedestals at the turbine centerline level. The HP and
IP casings are connected with the bearing pedestals by casing
guides which establish the centerline alignment of the turbine
casings. The axial position of HP and IP casings is fixed at the
HP-IP pedestal. Thermal expansion of the casings originates
from the fixed points. The LP Turbine outer casing is held in
place axially, at centre area of longitudinal girder by means of
fitted key. Free lateral expansion is allowed.
 Thermal Expansion

Rotor Expansion:
The thrust bearing is housed in the rear bearing
pedestal of the HP turbine. The HP turbine rotor
expands from the thrust bearing towards the front
bearing pedestal of the HP turbine and the IP
turbine rotor from the thrust bearing towards the
generator.
The LP turbine rotor is displaced towards the
generator by the expansion of the shaft assembly,
originating from the thrust bearing.
 Thermal Expansion

Deferential Expansion:
Differential expansion between the rotors and casings
results from the difference between the expansion of rotor
and casing originating from the HP-IP pedestal. The largest
differential expansions of the HP and IP turbines thus occur
at the ends farthest from the thrust bearing. Differential
expansion between the rotor and casing of the LP turbine
results from the difference between the expansion of the
shaft assembly, originating from the thrust bearing and the
casing expansion, which originates from the fixed points on
the LP turbine longitudinal beams.
Thermal Expansion Graphs
Construction
Steam Temperature
Speed
Thank You