LP TURBINE CONSTRUCTION

LP TURBINE CONSTRUCTION:
8.1 Design Features:
The LP turbine is of double flow design. The casings of LP turbine has three casings with fabricated
construction.
The outer casing consisting of the front and rear end walls, two longitudinal girders and a top cover
encloses two inner casings. The twin shell inner casing is supported kinematically at each end by two
support arms resting on the longitudinal girder of the outer casing.
The inner shell of inner casing acts as a guide blade carrier for the initial stages. Together with the
welded structure of the inner casing, these carriers form the ducts required for steam admission and
extraction.
Fig.8.1 Triple Shell, Double Flow LP Turbine
A diffuser bolted to the vertical flanges of inner outer casing acts as a guide and deflects the exhaust
steam thereby outlet steam velocity is partly recovered and reconverted into pressure in the diffuser,
reducing the leaving losses correspondingly.
In addition the condenser vacuum monitoring, which act on to trip the Turbine and the LP bypass control
station, so that the condenser & LP outer casing are protected against excessive pressure & temperature
by bursting diaphragms (4 Nos.) located at the top LP turbine.
The shaft is forged form solid ingot and is supported on only one bearing at the rear of the casing (front
side bearing is shared by IPT & LPT). The last three stages of the LP rotor have twisted blades. 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 fixed blades of 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. Also the trailing edges of the blades are very thin in order to avoid any
stall patches and the formation of streams of water. Another important design feature of final stages is
that the distance between them is kept at optimum value to facilitate the break-up of any water droplets,
which may still remain.
Above blade design features reduces the relative velocity between the droplets and the leading edges of
the moving blades resulting into less wear and tear. However, 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.
8.2 Construction:
8.2.1. Steam Admission
The vertical sectional view of LP Turbine is shown in Fig. 8.2. The exhaust steam from IP Turbine
(7kg/cm2, 314oC) is admitted into LP turbine inner casing (3,4) from both sides through steam inlet
nozzles at the center section before the LP blading. Expansion joints are installed in the steam piping to
prevent any undesirable deformation of the casing due to thermal expansion of the steam piping. The
steam flows through the blading in two opposite streams and finally exhausted to condenser from the
diffuser sections (6) attached at the ends of last stages.
8.2.2. Casing Arrangements
8.2.2.1 Fabricated Construction
The LP turbine casing consists of a double flow unit and has a triple shell welded casing. The outer
casing consists of the front and rear walls, the two lateral longitudinal support beams and the upper part.
The front and rear walls, as well as the connection areas of the upper part are reinforced by means of
circular box beams. The outer casing is supported by the ends of the longitudinal beams on the base
plates of the foundation.
8.2.2.2 Inner Casing

The double flow inner casing, which is of double shell construction, consists of the outer shell (2,5) and
the inner shell (3,4) as shown in Fig. 8.3, Section D-D. The inner shell is attached in the outer shell with
provision of free thermal movement. The inner shell carries stationary blading. The stationary blade row
segments of the LP stages are bolted to the outer shell of the inner casing. The complete inner casing is
supported by the longitudinal support members of the outer casing.
8.2.2.3 Support and Centering of Outer Casing
The outer casing of the turbine is carried on the side members, which rest on plates grouted into the
foundation alongside the turbine. Two guides are attached to the longitudinal beams of the outer
180 Steam Turbines for Power Generation
casing lower part (7) below the center inlet as shown in detailF (Ref. Fig. 8.3, 8.4) to prevent axial
displacement of the outer casing. The outer casing (1,7) expands axially in both directions from this
point with the longitudinal beams. The keys (12) in the casing guides allow radial expansion.
The vertical center plane guides for the casing are at the lowest point of circular box beam which stiffen
the front and rear end walls (see Detail A, Fig. 8.2, 8.5). This location allows for radial and axial
expansion of the casing.
Two rectangular plates (16) are welded at right angles to the inner surface of each box beam. A guide
block (15) rigidly attached to foundation, fits between these plates to locate the casing. Keys (14) are
provided between the block (15) and the plates (16) to facilitate accurate vertical alignment of the
casing.
8.2.2.4 Attachment of Inner Casing in L.P.
In the horizontal plane, the four brackets of the complete inner casing are supported by shims (19)
placed in the plates (22) bolted to the longitudinal support beam of the outer casing. The two brackets
(Fig. 8.7(a)) towards the IP turbine end are fixed in the axial direction by fitted keys (20) as compared to
the brackets at the generator end (Fig. 8.7(b)), which are free to move due to thermal expansion.
The spacer bolts (23) prevent lifting of the inner casing. Spacer bolt hole clearance is provided to permit
the inner casing to expand horizontally on shims (19) of the fixed support in the transverse direction
relative to the axis of the machine and on the shims of the non-fixed support in the transverse and
longitudinal direction relative to the machine axis. Since vertical thermal expansion originates at the
level of the horizontal joint, concentricity of the inner casing with the shaft is ensured in this plane.
As shown in Fig. 8.6, two casing guides are located at the lower half (5) of the outer shell to prevent any
transverse displacement of the inner casing from the centerline of the turbine. Radial and axial
expansion is permitted by fitted keys (18) in these casing guides (Also refer Fig.8.2 & 8.3).
8.2.2.5 Attachment of Inner Shell
The inner shell (3,4) is attached to the outer shell (2,5) in the horizontal plane and guided axially in the
vertical plane ( Fig. 8.8, 8.9). The upper half of the inner shell is supported in the horizontal plane by
four brackets resting on support plates (26,27) located at N & O of the joint face (Fig. 8.9) of the lower
half of the outer shell (Fig. 8.10, 8.11). Four brackets of the inner shell lower half that are covered by the
joint face of the outer shell prevent lifting of the inner shell. Small clearance between cover plates
(25,28) and joint face of the outer shell permits the inner shell to freely expand in the horizontal
direction at the support points. Thermal expansion in the vertical plane originates at the joint face. This
ensures concentricity of the inner shell with the shaft in the vertical plane.
The brackets of the inner shell (Fig. 8.8), lower half (4) project into recesses of the outer shell, lower
half (5). These brackets are provided with clearance on all sides and serve to align the inner shell, lower
half in the outer shell, and lower half by the use of lifting bolts during erection. Fitted keys (24) are
located on each side of the brackets at the IP turbine end of the LP casing. As shown in Fig. 8.10, these
keys locate the inner shell in the axial direction as thermal expansion in the axial direction originates
from these two points.
In the vertical plane, there are four centering pins (31) (Ref. Fig. 8.12), which are guided in bushings
(30). The ends of the centering pins are fitted in Keys (32), which slide in axial grooves of the inner
shell. This arrangement permits axial displacement along the axis of the centering pins (31). However,
the keys prevent transverse displacement relative to the axis of the turbine. Transverse thermal

expansion relative to the axis of the turbine originates from these keys, so that concentricity of the inner
shell with the shaft is also maintained in this plane. Bushings (30) have an eccentric bore and by turning
them during erection, transverse alignment of the inner casing is adjusted. After the alignment is
completed, the bushings are locked in place by grub screws.
8.2.3 Atmospheric Relief Diaphragms
Atmospheric Relief Diaphragms (Fig. 8.14) (4 Nos.) are provided in the upper half of each LP exhaust
end section to protect the turbine against excessive pressure. In the event of failure of the low vacuum
trips, the pressure in the LP turbines exhaust rises to an excessively high level until the force acting on
the rupturing disc (1) ruptures the breakable diaphragm (2), thus providing a discharge path for the
steam.
The diaphragm consists of a thin rolled lead plate. To ensure that the blow-off steam does not carry the
remnants of the diaphragm and rupturing disc along, a cage with brackets (5) is provided. As long as
there is a vacuum in the condenser, the atmospheric pressure forces the breakable diaphragm and the
rupturing disc against the supporting flange (3).
8.2.4 Drum Blading
8.2.4.1 Initial stages
The drum blading stages 1 to 5 of the double flow LP turbine (Fig. 8.15) are of the reaction type with
50% degree of reaction. The stationary blades are located in the inner shell of the inner casing, and form
the inlet group of blading of the LP turbine. The LP exhaust (3 stages) following these blades are located
in the outer casing.
The stationary blades (6) of the first stage have T-roots. They are fitted in the inner casing (1) in grooves
of corresponding design where they are secured by caulking material. The remaining stationary blades
(5) have hook-type roots and are secured in their grooves by means of filler pieces (2). Special locking
blades are used at the horizontal joint, secured by means of grub screws.
The moving blades (4) have T-roots, which are inserted into grooves of corresponding design in the LP
turbine shaft (8) and secured by caulking material (9). The insertion slot is closed by means of a locking
blade, which is attached to the adjacent blade by means of taper pins.
All T-root blades have integral shrouds, which, upon installation, form a continuous shroud. The blades
with hook-type roots have riveted shrouds. In order to kip the blade tip losses low, replaceable sealing
strips (3) are caulked into the inner casing (1) and the turbine shaft (8).
8.2.4.2. Exhaust Stages
The last three stages of the LP turbine blading are designed as reaction stages. The stationary blade rows
are made into semicircular segment by welding the inner rings, blades and outer ring together and
bolting them to the inner casing (12). The last two stationary rows consist of hollow blades. Slots are
provided in the blade surface of the last stationary row. Through these slots any water passing over the
surface of the blades may be drawn away into condenser. The inner rings form a continuous shrouding
strip after assembly with stationary blade segment. Moving blades (3,5) with curved fir-tree roots (viewx Fig. 8.16) are fixed in the axial grooves of the turbine shaft (10) by means of spring keys (6). These
blades are secured against axial movement by retaining strips (7), which are inserted into a circular
groove milled in the shaft and segments are spot welded at each joint. Moving blades (9) have inverted
T-roots placed in grooves of corresponding design in the shaft and fixed in position by caulking material.
In order to minimise blade-tip losses at the stationary blades (4,8,11), sealing strips (1) are caulked into
the turbine shaft (10). Opposite the sealing strips, shroud rings of the stationary blades have cylindrically
turned surfaces. This arrangement permits favourable radial clearances to be attained.
8.2.5 Shaft Seals
8.2.5.1 Function
The function of the axial shaft seals situated between the bearing casings and the LP exhaust casing is to
seal the inner space of the LP exhaust casing against atmospheric pressure at the passages through the
shaft. Thus it prevents air ingress into the turbine, which is under vacuum.
8.2.5.2 Gap Sealing
Fig. 8.18(a) & (b) show the LP front and rear seals. The sealing effect between the moving and

stationary parts of the turbine is achieved by means of sealing strips (4), which are caulked into the
individual seal rings (2). The prevailing pressure is reduced according to the labyrinth principle by
conversion into velocity with subsequent turbulence in many sections. The chamber "R" is connected to
gland seal steam supply header whereas "Q" is connected to gland steam cooler header.
8.2.5.3 Sealing Rings
The sealing ring (2), the number of which depends on the pressure existing in the turbine, is split into
several segments as shown in section A-A (Fig. 8.18). Segments are arranged in T-shaped annular
grooves in the steam seal casing (1) so that they can move radially several helical springs (3) force each
segment against a shoulder and hold in this position. This permits the correct clearance in the sealing
gaps. Should rubbing occur, the segments contained retreat. The frictional heat developed by the thin
sealing strips (4) due to this light pressure is so small that it cannot cause deformation of the rotor (5).
When the turbine is started from the cold or semi-warm state, the sealing rings naturally heat-up more
quickly that the steam seal casings. They can then expand radially without hindrance against the
centering force of the helical springs.
8.2.6 Rear Bearing Pedestal
8.2.6.1 Arrangement
The bearing pedestal is situated between LP turbine and generator. Its function is to support LP turbine
and generator rotors. The bearing pedestal contains the following turbine components:
a) Bearing pedestal vibration pick-up
b) Journal bearing
c) Shaft position measuring device (for differential expansion)
d) Shaft vibration pick-up
8.2.6.2 Connection of Bearing Pedestal & Foundation (Fig. 8.19)
The bearing pedestal is aligned on the foundation by hexagonal screws that are bolted into the bearing
pedestal. To overcome friction resistance, balls are arranged under the heads of these hexagonal screws.
After alignment, the space under the bearing pedestal is fitted in with special grout, resistance to
expansion and contraction. The bearing pedestal is firmly connected to the foundation by means of
anchor bolts.
8.2.7 Journal Bearing (Fig. 8.20)
The function of journal bearing is to support the turbine rotor. Essentially, the journal bearing (Fig. 8.20)
consists of the upper and lower shell (3,6), bearing cap (1), spherical block (7), cylindrical shell (14) and
the keys (10). The bearing shells are provided with a babbit lining on inside face. The sliding surfaces of
this bearing are machined and additional scraping is not required. Both bearing shells are fixed by means
of taper pins and bolted together.
In order to prevent the bearing from exerting a bending moment on the rotor (5), it is pivot-mounted in
the cylindrical shell (14). For this purpose, the spherical block (7) with shims (12,13) is firmly bolted to
the bearing shell (6). A projection in Cap (1) with shims (9) fits into a corresponding groove in the
bearing shell (3) and prevents vertical movement of the bearing shells. Centering of the bearing shells in
the vertical plane is thus maintained.
The bearing shells are fixed laterally by the keys (10), which are bolted to each other. Each key is held in
position in the bearing pedestal (1) by two lateral collars. The temperature of the bearing babbit metal is
monitored by the thermocouples (15) as shown in Section C-C (Fig. 8.20).
Lubrication oil is admitted to the bearing shells from both sides, from where it flows to the oil spaces
milled into the upper and lower shells at the horizontal joint that are open to the rotor end. Oil from the
oil space machined in the Babbitting is carried through the rotor (5) and emerges from the bearing shell
from where it is collected in the oil return cowling (4) and drained into the bearing pedestal (11).
As shown in Section B-B (Fig. 8.20), two threaded nozzles (17) are arranged at the bottom side of the
lower bearing shell (6) through which high pressure oil is supplied during start-up. The high-pressure oil
relieves the bearing to overcome breakaway torque and prevent dry friction, thus reducing the torque
requirement of the hydraulic turning gear.
The jacking oil flows into the above mentioned threaded nozzles (17) through passages in the lower

bearing shell (6). A seal (18) prevents high-pressure oil from penetrating the space between threaded
nozzle and the ring (16) and thus from lifting the babbit. Any leakage oil can drain though passages in
the bearing shell below the ring.
8.3 LP Turbine Assembly
8.3.1 Supports and Centralizing Keys
The LP turbine is completely assembled at site only. However, the matching of internal parts and
clearance checking is performed at factory only.
As discussed earlier, the outer casing of the turbine is carried on the side members, which rest on plates
grouted into the foundation alongside the turbine. These end supports are provided with sliding
arrangement. The LP turbine is anchored below the center steam inlet as shown in Fig. 8.21, (also refer
Fig.8.3 & 8.4). The outer casing expands axial in both directions (IPT side and Generator side) from this
point with the longitudinal beams. The casing is guided at the bottom most centerline of the casing by
the fitting keys, which allow free radial expansion.
The supports of longitudinal beams are matched to ensure specified clearances in non-fixed supports at
the ends. Similarly fitted keys of center guide are matched. Then the outer casing is placed in position.
8.3.2 Installation of Shaft
The LPT shafts of HMN series turbines are forged single block shafts with forged on coupling and
having slot for moving blades. The turbine shaft is treated with a protective agent and micro-finished
areas are protected with denso binding prior to dispatch as shown in Fig. 8.22. The rotor is transported to
site after removing the final blade rows (Fig. 8.23).
Before installation of the turbine shaft, the matching spigots and recesses must be measured and
compared to ensure that the coupling heads can be connected up (Fig. 8.24). Then the turbine shaft is
installed in the inner casing.
The bottom half outer shell of inner casing with the complete bottom half inner casing has been adjusted
axially and aligned radially. By mounting the top halves, the clearances achieved during alignment using
the alignment shaft are to be checked with the actual shaft installed. When the prescribed checks have
been performed, the top halves are assumed ready for operation and the casing
joints are drawn together by tightening the bolts to the prescribed torque. The steps for clearance
checking are as follows.
Before proceeding for assembly, remove all traces of protective agents from the casing joints of the
inner casing.
Screw in the guide bolts required for mounting the top half at the prescribed locations (Fig. 8.25).
To determine the various radial clearances between the individual blade rows and the top half of the
shell, it is necessary to make a lead impression. For this, attach the fine lead wires of diameter
approximately 1mm larger than the anticipated radial clearance to the upper regions of the moving and
stationary blade rows (Fig. 8.28).
Hook up the top-half of the inner shell of the inner casing to perfectly horizontal position using ropes
and shackles. Clean the blading and casing joint of all traces of protective agents. Carefully lower the
top half inner shell of the inner casing (Fig. 8.29).
When the top half has been lowered until the casing joint is limited on all sides by the screwed-in guide
bolts, align the top half in both planes using a spirit level. While lowering when the gap between the
casings joint approaches 10 mm, insert the taper pins smeared with a corrosion inhibiting paste
(Molykote paste G) into the holes and install the support plates for the brackets. Then lower the top half
to close the casing joint and hammer in the taper pins.
The casing joints may now be bolted together. Smear the threads of the stud bolts and the contact
surfaces of the cap tighten up on both sides in parallel proceeding from the center (Fig.8.30).
Tighten the casing joint with the aid of a bolt heater (Fig. 8.31). Finally remove the guide bolts and
alignment screws from the bottom half.
Attach fine lead wires of the required thickness to the last stages moving blades and to the seal strips on
the stationary blades (Fig. 8.32).
Mount the top-half outer shell of the inner casing (Fig. 8.33) in the same manner.

Observing the measures already discussed, tighten the bolts from the center outwards. Check using
feeder gauges to ensure that the casing joint surfaces make contact (Fig. 8.34).
Remove the taper pins and casing joint bolts. Lift the outer casing by leveling with sprit level. Measure
the thickness of lead wires attached on the moving blades and scaling strips to ascertain the radial
clearances as specified.
Apart from the above lead wire procedure, the axial (Fig. 8.27) and radial clearances (Fig. 8.26) can be
measured in the bottom half casing by using appropriate feeler gauges.
The turbine shaft must be axially aligned as specified in drawing prior to measurement of the radial
clearances. The feeler gauge blades shall be long enough to be able to enable measurement at all points
of the lower half between the individual moving and guide blade stages.
After the clearance check, the top inner casings are mounted again and bolts are hot tightened as
described before (Fig. 8.34).
8.4 Expansion joints at the Shaft Seals
The expansion joints are arranged between the shaft seals attached to the bearing pedestals and outer
casing of the LP turbine. They seal-off the space inside the LP turbine casing from the atmosphere and
have the function of compensating the pull on the end wall due to the vacuum within the casing,
thermal expansion and any possible vertical deformation and displacement of the foundation transverse
girders.
The expansion joint is delivered to the site as a complete unit pre-tensioned to insertion length. The
inner and outer surfaces of the thin-walled corrugated tube bellows are protected by sheet metal sleeves
backed with laminated paper. The installation of expansion joint is shown in Fig. 8.35 (a, b).
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