Beruflich Dokumente
Kultur Dokumente
|Sx A +xFh xn
STEAM TURBINE
0PERATION & MAINTENANCE
INSTRUCTIONS
NO.STENO.STE-TFTF-266-MS
KHAPERKHEDA, 1X500 MW
1x500
i c <BD]BE ]b
x{, cu
BHARAT HEAVY ELECTRICALS LIMITED
RANIPUR, HARIDWAR 249403 (INDIA)
Steam Turbine
General
Preface
Issued by
BHEL Haridwar
SM
VS
Checked
by
SRP
PCK
Approved
by
Issue
Date
19.08.09
5.0-0001-66
Steam Turbine
Description
Subject
Contents
Document No
GENERAL
Preface
Contents
DESCRIPTION
5.0-0001-66/1
5.0-0002-66/3
Brief Description
Sectional arrangement
General description
Fixed points
Technical Data
5.1-0001-04/1
5.1-0002-04/2
5.1-0003-02/2
5.1-0100-66/3
5.1-0103-66/2
5.1-0104-66/4
Casing
Blading
Shaft seals
Rear bearing pedestal
5.1-0310-01/3
5.1-0320-02/1
5.1-0330-01/2
5.1-0340-02/1
BHEL Haridwar
Document No
5.1-0345-01/2
5.1-0350-01/2
5.1-0510-01/1
5.1-0520-01/1
5.1-0530-66/2
General description
Start-up procedure
Speed control
Electrical speed measuring
Protective devices
Over speed trip test
Testing of stop valves
LP bypass System (General)
Extraction check valve
Swing check valve (CRH)
Testing of check valves in
cold reheat line
Automatic turbine tester
general
Automatic turbine tester
for protective devices
Automatic turbine tester
stop and control valves
HP actuator
Electro hydraulic seal steam
pressure control
Governing scheme
Control system diagram
legend
Lubrication chart
Control System Parts
5.1-0600-01/2
5.1-0610-01/2
5.1-0620-01/2
5.1-0621-02/1
5.1-0630-01/2
5.1-0631-01/1
5.1-0632-02/1
5.1-0640-01/1
5.1-0650-01/1
5.1-0651-01/1
5.1-0652-02/1
Subject
5.1-0101-66/2
5.1-0102-66/1
5.1-0110-01/1
5.1-0111-01/2
5.1-0112-01/2
5.1-0113-01/1
5.1-0120-01/1
5.1-0130-04/2
5.1-0140-04/2
5.1-0205-00/1
5.1-0210-01/3
5.1-0220-02/1
5.1-0230-01/2
5.1-0240-01/2
5.1-0250-02/2
5.1-0260-01/2
5.1-0270-01/2
5.1-0280-01/2
5.1-0410-00/4
5.1-0420-00/1
5.1-0430-01/1
5.1-0440-01/2
5.1-0450-01/1
5.1-0460-02/1
5.1-0470-00/2
5.1-0660-00/1
5.1-0661-00/7
5.1-0662-01/4
5.1-0665-00/1
5.1-0670-01/4
5.1-0680-01/1
5.1-0681-01/5
5.1-0690-01/3
5.0-0002-66/1
Subject
Document No
Adjusting gear
Electro hydraulic converter
for turbine control system
Hydraulic amplifier for
turbine control system
Electrical speed pick-up
Pressure converter
Steam valves and
accessories
Combined main stop and
control valve
Servomotor for main &
reheat stop valves
Hydraulic servomotor for
main & reheat control valves
Test valve for emergency
stop valve
Combined reheat stop &
control valves
Hangers for reheat stop &
control valves
Steam strainer
Changeover valve for
bleeder check valve
Auxiliary valve of extraction
check valve
Rotary vane actuator for
reheat swing check valve
Pilot valve for rotary vane
actuator of swing check valve
Auxiliary pilot valve for
rotary vane actuator of
reheat swing check valve
Gland steam control valve
Leakage steam control valve
Protective Devices
Main trip valve
Emergency trip valve for
manual trip out
Solenoid valve for remote
trip out
Over speed trip
Over speed trip releasing
device
Over speed trip test device
Low vacuum trip
Condenser safety device
5.1-0720-00/1
5.1-0730-02/3
5.1-0740-02/3
5.0-0002-66/2
5.1-0760-01/1
5.1-0761-00/1
5.1-0810-01/2
5.1-0811-00/1
5.1-0812-00/2
5.1-0813-00/1
5.1-0814-00/2
5.1-0815-01/1
5.1-0816-00/1
5.1-0840-00/1
5.1-0841-00/2
5.1-0853-01/1
5.1-0854-00/1
5.1-0855-00/1
5.1-0860-02/1
5.1-0870-02/1
5.1-0910-00/2
5.1-0911-00/1
5.1-0912-00/1
5.1-0920-00/1
5.1-0921-00/2
5.1-0922-00/2
5.1-0935-00/1
5.1-0940-00/1
Subject
Document No
5.1-0950-00/1
5.1-0960-02/2
5.1-0980-00/1
5.1-1000-66/4
5.1-1001-66/2
5.1-1002-66/2
5.1-1003-66/1
5.1-1010-01/2
5.1-1020-01/2
5.1-1030-01/1
5.1-1040-01/1
5.1-1050-00/2
5.1-1080-00/1
5.1-1081-00/1
5.1-1090-01/1
5.1-1110-00/1
5.1-1120-00/1
5.1-1130-00/3
5.1-1140-00/3
5.1-1210-66/2
5.1-1220-66/3
5.1-1230-66/11
5.1-1240-66/5
5.2-0001-01/1
5.2-0002-00/1
5.2-0020-00/1
5.2-0021-01/1
5.2-0022-01/1
5.2-0023-01/1
5.2-0024-01/1
5.2-0025-01/1
5.2-0026-01/1
5.2-0027-01/1
5.2-0028-01/1
Subject
Start-up
Starting the turbine
Startup & shutdown
diagrams, symbols
Startup diagram
General
Preparation for startup
Operating position of
manually operated valves
Oil System & Turning Gear
Control fluid system
start-up diagram
Condensing Plant
Bypass System
Warm-up & startup of turbine
Temperature criteria
Controllers
On-load Running
Load operation, Introduction
Synchronization and loading
Power operation, controllers
Actions to prevent
unallowable heat-up
through blade wind age
Shut-down
Introduction
Shutdown diagram
General
Turbine-generator
Condensing plant
Oil system
Fast cooling down of turbine
Preventing corrosion in
idle turbine
Fault Tracing
Introduction
Serious faults
Vibration
Bearing temperature
Casing temperatures
Turbine stress controller:
measures to avoid
impermissible operation
Stop & control valves
Protective devices
Automatic turbine tester
Document No
5.2-0110-01/1
5.2-0111-00/1
5.2-0112-00/2
5.2-0113-00/1
5.2-0120-00/1
5.2-0130-02/5
5.2-0135-02/4
5.2-0140-02/4
5.2-0150-00/3
5.2-0160-02/6
5.2-0170-01/4
5.2-0180-00/4
5.2-0200-00/1
5.2-0210-00/5
5.2-0220-00/9
5.2-0230-00/4
5.2-0300-00/1
5.2-0310-01/1
5.2-0320-02/5
5.2-0330-01/2
5.2-0340-01/2
5.2-0350-01/1
5.2-0360-00/2
5.2-0400-00/1
5.2-0410-00/8
5.2-0420-00/5
5.2-0421-01/1
5.2-0423-02/2
5.2-0430-01/5
Subject
Document No
Oil system
Control fluid system
Gland steam system
Bypass System
MAINTENANCE
Introduction
Inspection schedule
Maintenance schedule
Turbine
Oil system, seal steam
system, drains
FRF system
Testing during start-up
Testing during power
operation
Acquisition & archiving of
operating data
Remedial actions for offnormal operating conditions
Measurement of internal
efficiency
Testing during shut down
Testing during standstill
Testing of safety valves
Testing of signaling devices
Testing of TSC
Steam washing of turbine
Turbine Oil care
Grease and Oil lubrication
Care of control fluid
Determination of FRF purity
Vibration dampers
Instructions for overhaul
Turbine restart after boiler
repairs
Turbine restart after major
inspections or repairs
Environmental protection
Fluorelastomer products
safety notice
Safe disposal of turbine oil
Ordering of spares
5.2-0460-00/6
5.2-0470-00/3
5.2-0480-01/1
5.2-0490-00/3
5.3-0001-01/1
5.3-0010-04/3
5.3-0021-02/1
5.3-0022-01/3
5.3-0023-01/2
5.3-0030-02/7
5.3-0035-02/5
5.3-0037-03/3
5.3-0040-01/6
5.3-0050-02/3
5.3-0060-01/5
5.3-0061-02/6
5.3-0062-01/1
5.3-0063-00/2
5.3-0064-01/4
5.3-0070-02/3
5.3-0080-03/11
5.3-0081-00/1
5.3-0082-02/9
5.3-0083-01/2
5.3-0100-00/2
5.3-0200-05/8
5.3-0210-00/1
5.3-0220-00/3
5.3-0250-00/1
5.3-0251-00/1
5.3-0252-00/1
5.3-0300-00/1
5.2-0440-01/2
5.2-0450-01/7
5.2-0455-00/9
5.0-0002-66/3
Steam Turbine
Description
BHEL Haridwar
5.1-0001-04
Steam turbine
Description
General Description
LP Turbine
IP Turbine
The IP turbine section is of double 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.
BHEL Haridwar
Blading
The entire turbine is provided with reaction
blading. The stationary and moving blades of the
HP and IP sections and the front rows of the LP
turbine are designed with integrally milled
inverted T -roots and shrouds. The last stages of
the LP turbine are fitted with twisted drop -forged
moving blades with fir-tree roots engaging in
grooves in the shaft with last stage stationary
blades made from sheet steel.
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
babbit 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.
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.
5.1-0002-04/1
Valves
The HP turbine is fitted with two main stop and
control valves. One main stop valve and one
control valve with stems arranged at right angles
to each other are combined in a common body.
The main stop valves are spring-action singleseat valves; the control valves, also of singleseat design, have diffusers to reduce pressure
losses.
These valve combinations are located at both
sides of the turbine with their stems horizontal.
The HP valves are connected to the turbine by
easily separable collar couplings, which contain
self-sealing U-rings as sealing elements.
The IP turbine has two reheat stop and control
valves. The reheat stop valves are spring-action
single-seat valves. The control valves, also
spring-loaded, 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 turbinegenerator unit is supplying only the station load.
The reheat stop and control valves are
supported free to move in response to thermal
expansion on the foundation cover plate below
the operating floor and in front of the turbinegenerator unit. All valves are actuated by
individual hydraulic servomotors.
5.1-0002-04/2
Steam Turbine
Description
Design of the supports for the turbine has to
allow for the expansion of the turbine during
thermal cycling. Constrained thermal expansion
would cause overstressing of the components.
The method of attachment of the turbine
components is also critical to the magnitude of
the differential expansion between the rotor and
turbine casings which is given careful attention
in the determination of internal clearances.
BHEL, HARIDWAR
Fixed Points
Centering of LP outer casing is provided by
guides which run in recesses in the foundation
cross beam. Axial movement of the casings is
unrestrained.
Hence, when there is a temperature rise, the
outer casings of the HP turbine expand from
their fixed points towards Front pedestal. Casing
of IP Turbine expand from its fixed point towards
the generator.
LP Casing expands from its fixed point at front
end, towards the generator.
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.
Differential 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.
5.1-0003-02/1
5.1-0003-02/2
Steam Turbine
Description
Technical Data
Construction, Speed
& Steam Pressure
Load
Rated Load
500 MW
524.2 MW
Construction
Three cylinder reheat condensing turbine
Single flow HP Turbine with 17 reaction stages
Type : H30-100-2
Type : M30-63
Type : N30-2x10-2
Type : EV 320-1
Type : IV 560
DN-800
Make : BHEL, Trichy
M/s Bomafa
: No valve
Extraction 2
DN 800
Make : BHEL, Trichy
Extraction 3
DN 500
Make : BHEL, Trichy
DN 500
Make : BHEL, Trichy
DN 500
Make : BHEL, Trichy
Extraction 5
DN 400
Make : BHEL, Trichy
Extraction 6
: No valve
BHEL Haridwar
5.1-0100-66/1
Speed
Rated speed
50.0 c/s
51.5 c/s
47.5 c/s
47.5 c/s
51.5 to 60 c/s
7 to 47.5 c/s
* This speed range should be passed through in one smooth operation to avoid endangering the
blades due to resonance
Steam Pressures
Rated
Initial Steam
Unit
166.7
175.0
200.0
bar
154.4
169.8
169.8
bar
HP cylinder exhaust
44.03
50.64
52.84
39.63
45.97
47.55
Extraction 6
44.03
50.64
52.84
bar
Extraction 5
16.84
19.87
19.87
bar
Extraction 4
6.94
8.33
8.33
bar
Extraction 3
2.744
3.35
3.35
bar
Extraction 2
1.469
1.81
1.81
bar
Extraction 1
0.342
0.42
0.42
bar
LP cylinder exhaust
0.1013
0.3
0.3
bar
st
bar
bar
These values correspond to 500 MW load with 3 % make-up and 0.1013 bar condenser back
pressure with all heaters in service and rated steam conditions.
The safety valves must be set so that short time values are not exceeded.
Long time operation: Upper limit value, permissible without time limit.
Short time operation: Permissible momentary value. The aggregate duration of such swings
must not exceed 12 hours in any one year
All pressures are absolute pressures
5.1-0100-66/2
0.3 bar
0.3 bar
0.6 bar
35 mbar
Axial shift
Alarm
0.5 mm
Trip
1.0 mm
Direction of rotation
Anti clock wise when viewed from Front Pedestal towards the Generator
5.1-0100-66/3
Steam Turbine
Description
Technical Data
Steam & Casing Temperatures
Steam Temperatures
Rated value,
Annual
average
Long-term
value, subject to
annual average
400 hrs.
per year
Unit
Main steam at HP
stop valve inlet
537.0
545.3
551.0
565.0
HRH steam at IP
Stop valve inlet
565.0
573.3
579.0
593.0
Steam Temperatures
Rated value
Long term
operation
In special
cases at no
load
HP turbine exhaust
336.1
338.1
428.1
500.0
Extraction 6
336.1
338.1
428.1
500.0
Extraction 5
444.8
449.8
484.8
Extraction 4
309.4
319.4
359.4
Extraction 3
208.2
221.2
268.2
Extraction 2
147.3
167.3
212.3
Extraction 1
72.0
92.2
142.0
LP turbine exhaust
46.4
70.0
70.0
Unit
Alarm at
Unit
485
500
90
110
BHEL Haridwar
5.1-0101-68/1
Alarm at
Unit
90
100
30
45
* For IP turbine during cooling down, casing top bottom temperature difference can exceed
these limits. However, during restart once steam is admitted to the turbine the temperature
difference will come down.
Permissible differential temperature between parallel steam supply lines
No time limitation
17
28
In the hottest line the limitations indicated for main and reheat steam temperature must not be exceeded
Load,
MW
369
500
< 300
MW
300
MW
Motoring
Motoring is the condition in which the turbine is driven by the generator at rated speed with the
stop and control valves closed. In this operating mode, certain turbine components are heated up
by windage power of the blading.
To prevent heat-up beyond permissible temperatures, motoring must not be allowed to continue
for longer than one minute. If the condenser low vacuum limit of 0.3 bar is exceeded, motoring
must not be allowed to continue for more than 4 seconds.
5.1-0101-68/2
Steam Turbine
Description
Technical Data
Bearing Metal Temperatures
Vibration, Weights
90 C
130 C
Operation temperature 75 to 85 C
100 C
130 C
Operation temperature 85 to 90 C
110 C
130 C
115 C
130 C
Vibration
Absolute bearing housing vibration
84 m
200 m
106 m
320 m
The normal level is the reproducible vibrational behaviour typical for the machine &
dependent on the operating conditions.
Vibration readings indicated in control room are peak to peak. The above values are also
given in peak to peak.
Weights
HP turbine, completely assembled
95 T
26 T
16 T
43 T
LP turbine, top half inner outer casing, complete with blading, guide blade carriers &
diffusers
37 T
16 T
23 T
100 T
Main stop and control valve, complete with servo motors, without bend & pipe section
22 T
Reheat stop and control valve, complete with servo motors, without bend & pipe
section
32 T
All weights have been calculated with safety allowances. Slings chosen must provide sufficient
security.
BHEL Haridwar
5.1-0102-66
Steam Turbine
Description
Technical Data
Oil Supply, Oil Pumps
OIL supply
3
25/40
53
32
No.
No.
Min.
Normal
Max.
38
45
47
Max.
75
Normal
Max.
20
25
0.8
dm /s
15.4
dm /s
4.55
dm /s
9.29
dm /s
7.92
dm /s
7.92
dm /s
0.70
dm /s
57.4
dm /s
Duplex oil filter- full flow, Type: 2.68.2, size 355/750, Nb 150
Make: MS HYDAC FILTER TECHNIK GMBH.
No.
37
250
200
bar
178
bar
BHEL Haridwar
5.1-0103-66/1
Duplex oil filter for jacking oil, Type: DFDK 330 D40 W/HC/-V-So212
Make: K&H Eppensteiner, Germany
No
37
Jacking oil pump must be in operation at turbine speeds below approx. 510 rpm to avoid
damage to bearings.
Jacking oil pump should be cut-out at speeds above approx. 540 rpm.
Oil pumps
Main oil
pump
Auxiliary oil
pump
DC emergency
oil pump
Quantity
AC: 1
Make
BHEL
KBL
M&P
Tushaco
Type
350m3/hr
KPDS/125/26L
4/5 SR 12KL
Model 70
T 38/46
100
30
1.85
dm /s
Discharge
pressure
8.4
6.3
2.3
178
bar
gauge
Speed
3000
2970
1500
2900
rpm
Drive
Turbine
AC motor
DC motor
5.1-0103-66/2
DC: 1
AC motor
DC motor
Steam Turbine
Description
Technical Data
Control Fluid System &
Control Fluid Pumps
10/16
15
12
No.
No.
Make: Tushaco
Fluid flow
0.25
dm /s
Gauge pressure
bar
speed
1405
rpm
Motor power
0.55
KW
BHEL, HARIDWAR
5.1-0104-66-1
Manufacturer
Speed
2982
Drive
Enclosure
IP 55
Voltage
415
Frequency
50
Hz
121
KW
132
KW
Rated current
224
Starting current
1614
Nos.
rpm
Fluid flow
3
(dm /s)
Discharge
Pressure (bar)
7.60
11.5
6.16
38.5
20.60
10.8
6.16
37.8
7.60
10.0
16.16
31.0
5.1-0104-66-2
Steam Turbine
Operation
Technical Data
Limit Curves
120
Heating up
100
F
80
N
60
40
OPERATION MODE
F=Fast
N=Normal
S=Slow
[K]
20
0
-20
-40
Cooling down
-60
-80
100
200
300
400
500
600
m [C]
BHEL Haridwar
5.1-0110-01
Steam Turbine
Operation
Technical Data
Limit Curves
140
= f(m)
120
Heating up
100
80
60
N
40
OPERATION MODE
F=Fast
N=Normal
S=Slow
[K]
20
0
-20
-40
Cooling down
-60
-80
100
300
400
m =
BHEL Haridwar
200
500
600
m [C]
5.1-0111-01/1
140
= f(m )
120
100
Heating up
80
60
40
OPERATION MODE
F=Fast
N=Normal
S=Slow
20
[K]
0
-20
-40
Cooling down
-60
-80
0
100
200
300
400
500
m [C]
5.1-0111-01/2
600
Steam Turbine
Operation
Technical Data
Limit Curves
160
f (m)
Heating up
140
120
100
[K]
80
60
40
OPERATION MODE
F = Fast
N = Normal
S = Slow
20
0
-20
-40
Cooling down
-60
-80
0
200
100
300
400
500
600
m [C]
220
200
180
160
[K]
140
120
100
80
60
0
o
m
ax
BHEL Haridwar
=
=
=
=
20
40
60
80
100
120
ax [ C]
5.1-0112-01/1
140
f (m)
Heating up
120
100
80
[K]
60
40
20
OPERATION MODE
F = Fast
N = Normal
S = Slow
0
-20
-40
-60
Cooling down
-80
-100
0
100
200
300
400
500
600
m [C]
200
180
160
140
[K]
120
100
80
60
40
0
o
m
ax
5.1-0112-01/2
=
=
=
=
20
40
60
80
100
120
ax [ C]
Steam Turbine
Operation
Technical Data
Limit Curves
160
f (m )
Heating up
140
120
100
N
80
[K]
60
40
OPERATION MODE
F = Fast
N = Normal
S = Slow
20
0
-20
-40
Cooling down
-60
-80
0
100
200
300
400
500
m [C]
600
220
200
180
160
140
[K]
120
100
80
60
0
o
m
ax
BHEL Haridwar
=
=
=
=
20
40
60
80
100
120
ax [C]
5.1-0113-01
Steam Turbine
Description
The deposits which occur in turbines due to
impurities in the steam can lead to
thermodynamic and mechanical inefficiencies
and, with the presence of salts, especially
chlorides, and sodium hydroxide also cause
damage to turbine parts. The corrosion
stressing caused by active deposits, for
example, has an adverse effect on the fatigue
strength of the blade material when the steam
is in the transition zone between the
superheated and the saturated state.
Compliance with the target values is
mandatory in continuous operation, with the
values in the normal operation column
preferable. With the commissioning of a new
plant and starting-up operation, however,
these values cannot be attained with an
economical outlay. The values listed in the
column starting-up operation are then valid.
It should be pointed out that adherence to the
target values does not rule out deposition in
the turbine with absolute certainty. Wherever
possible every effort should be made to
Target Value
*
Normal
Operation
Start Up
**
S/cm
< 0.2
0.1
< 0.50
Silica
(SiO2)
mg/kg
< 0.020
0.005
< 0.050
Total iron
(Fe)
mg/kg
< 0.020
0.005
< 0.050
Total copper
(Cu)
mg/kg
< 0.003
0.001
< 0.010
Sodium
(Na)
mg/kg
< 0.010
0.002
< 0.020
* To avoid any drop in efficiency, it is recommended that values be kept below the target values
and into the range of the values for normal operation.
** The target values must show a noticeable downward trend. On initial start-up of new plants the
values given for normal operation must be achieved within 2 to 3 days and within 2 to 3 hours
for other start-ups.
BHEL Haridwar
5.1-0120-01
Steam Turbine
Description
Oil Specification
Standard
Introduction
This standard specifies the turbine oil
recommended for use in governing and
lubrication systems of BHEL make steam
turboset.
Description
Oil of viscosity class ISO VG 46 shall be
used. The oil shall be a petroleum product
with or without additives to meet the
requirement of this standard. The finished oil
shall be clear and free from water,
suspended matter, dust, sediment and other
impurities.
The turbine oil shall not contain additives
having any negative effect on the materials
of the oil system. The turbine oil must be
capable of withstanding bearing temperature
of max. 130C and oil tank temperature of
max. 80C without physical and chemical
degradation.
The properties of the oil shall not be affected
by centrifuging, water washing or filtering.
Compatibility
For topping up of the oil system, it is
preferable if the oil used is of the same
brand and quality as that already in the
system. However, if the same brand of oil is
not available and where it is intended to mix
in different products that individually conform
to this standard, a compatibility test should
be conducted before actually mixing the oils.
Samples of both the oils in equal volume
should be mixed and centrifuged for about
40 hrs. and then mixture must comply fully
with the requirements of this standard.
Properties
The oil should comply with the
requirements given in table below when
tested according to the test methods given
in the respective standards mentioned
against each property. For obvious
reasons, we do not give any special
recommendation to a particular brand of oil
to be used in the oil system of our turbo
sets. Any brand of the oil complying with
the above standards may be used.
Properties
Value
Unit
1.
41.4 50.6
cst
28
cst
2.
Viscosity Index
98
3.
Neutralization No.
acidity)
4.
Colour
5.
Test Method
IS: 1448, P-25
ASTM D445
Min.
-----
mg
KOH/g
ASTM D974
Max.
ASTM D1500
Specific gravity at 50 C
Specific gravity at 15 C
0.85
---
ASTM D1298
0.90
---
6.
> 200
ASTM D92
7.
---
-----
8.
Pour point
-6
ASTM D97
9.
Rust preventing
characteristics
0-B
---
DIN: 51585
ASTM D665
BHEL Haridwar
(Total
0.20
5.1-0130-04/1
Properties contd.
Sl. No.
Properties
Value
Unit
Test Method
10.
Emulsion characteristics
20
minute
DIN: 51599
ASTM D1401
11.
0.2
mg
KOH/g
DIN: 51587
ASTM D943
12.
Foaming characteristics at
25C
- Foaming tendency
-----
ASTM: D892
- Foaming stability
400
cm
450 s
s
minutes
DIN: 51381
ASTM: D3427
13.
14.
0.01
IS:1448, P-4
-----
15.
0.01
DIN: 51777-1
ASTM: D1744
16.
0.05
DIN: 51592
-----
17.
Particle distribution
-/17/14
Minimum
ISO: 4406
(Class-8)
18.
Water release
(NAS: 1638)
300
DIN: 51589-1
Brand
Supplier
Brand
lOC
Servo Prime 46
Gulf Crest 46
Bharat Petroleum
Turbol 46
Apar Ltd.
Power Turbo-46
Caltex
Regal R&O 46
Savita Chemicals
HPCL
Turbinol 46
TOTALFINAELF
Total Preslia 46
5.1-0130-04/2
Steam Turbine
Description
This specification is valid for Fire Resistant
Fluids (FRF) recommended for BHEL
make steam turbine control system.
According to ISO 6743/4, FRF is a fluid
based on triarylphosphate ester marked
ISO-L-HFDR.
General Requirements
Limit values
Disposal
BHEL Haridwar
5.1-0140-04/1
Numerical
Value
Unit
2
Test method
DIN / ISO
ASTM
Kinematic Viscosity at 40 C
(ISO VG 46)
41.4 - 50.6
mm /s
DIN 51 562-1
D 445
Air release at 50 C
minutes
DIN 51 381
D 3427
Neutralisation number
0.1
mg KOH/g
DIN 51 558-1
D 974
Water content
1000
mg/kg
DIN 51 777-3
Tendency
100
ml
Stability
450
sec
Water separability
300
sec
Demulsification
20
minutes
Foaming at 25 C
D 892
(Seq. 1)
DIN 51 589-1
DIN 51 599
D 1401
DIN 51 757
D 1298
D 92
Density at 15 C
1250
kg/m
> 235
DIN/ISO 2592
Ignition temperature
> 550
DIN 51 794
sec
DIN/ISO 14935
Pour point
18
DIN/ISO 3016
Particle distribution *
15/12
Code
ISO 4406
Chlorine content
50
mg/kg
DIN 51 577-3
Oxidation stability
2.0
mg KOH/g
DIN 51 373
Hydrolytic stability
Change of neutralisation number
2.0
mg KOH/g
DIN 51 348
Electrical resistivity
> 50
Mm
IEC 247
D 97
* The required system cleanliness is dependent upon the system design. Suitable measures (e.g.
filtration, separation) have to be taken to achieve this cleanliness level.
5.1-0140-04/2
Steam Turbine
Description
HP Turbine
Valve Arrangement
General Arrangement
The HP turbine has 2 main stop valves and 2
control valves located symmetrically to the right
and left of the casing. The valves are arranged
in pairs with one main stop valve and one
control valve in a common body.
Valve Actuation
Steam flow
The main steam is admitted
steam inlet passing first the
and then the control valves.
valves the steam passes
casing(1).
BHEL Haridwar
5.1-0205-00
Steam Turbine
Description
HP Turbine
Casing
Seals
The pretensioned U-shaped seal ring(12),
that is forced against the axial sealing surfaces
by the steam pressure and the I shaped seal
ring (16), that allows axial displacement of the
inner casing (4), seal the space between the
inner casing (4) and the barrel type outer casing
(3) from the adjacent spaces.
Fig. 1 HP Turbine
BHEL Haridwar
5.1-0210-01/1
Outer casing
Inner casing
U seal ring
Cylindrical pin
Breech nut
Inlet pipe from main stop and control valve
3 Outer casing
4 Inner casing
11 Fitted Key
3 Outer casing
4 Inner casing
10 Fitted Key
Fig.
4 Centering
and support
of
Fig.
4 Centering
and support
inner casing (Exhaust side)
of
Outlet Connections
The exhaust end of HPT has single outlet
connection from bottom. At the flange
connection a U-seal ring (19) is provided to
prevent any leakage (Fig.1)
3 Outer casing
4 Inner casing
12 U- seal ring
3
4
16
17
18
Outer casing
Inner casing
I-seal ring
Holding ring
Hexagon head screw
13 Thrust pads
14 Thrust pads
15 Support ring
Fig. 6 Axial Retention ofInner casing and Centering in vertical plane (Detail E from Fig.1)
5.1-0210-01/3
HP Turbine
Blading
Steam Turbine
Description
Moving and Stationary Blades
The HP turbine with advance blading consists of
17drum stages. All stages are reaction stages
with 50% reaction. The stationary and moving
blades of all stages (Fig.1) are provided with
inverted T-roots which
2
3
.
B
4
Gap sealing
Fig. 1 Drum Stages
1 Inner casing
2 Guide blade
3 Moving blade
4 Turbine shaft
5 Caulking piece
BHEL Haridwar
5.1-0220-02
Steam turbine
Description
Function
HP Turbine
Shaft seals and Balance Piston
Seal Rings
1
3
4
5
6
Gap Seals
5.1-0230-01/1
5.1-0230-01/2
Steam Spaces
Steam spaces are provided within the shaft
seals. From spaces Q and R leakage is drawn
off to another part of the turbine for further use.
The steam seal header is connected to space
S. The slight amount of leakage steam which
are still able to pass the seal ring are conducted
from the space T into the seal steam
condenser.
Steam Turbine
Description
Arrangement
The front bearing pedestal is located at the
turbineside end of the turbine generator unit. Its
function is to support the turbine casing and
bear the turbine rotor. It houses the following
components and instruments.
HP Turbine
Front Bearing Pedestal
Connection
Foundation
of
Bearing
Pedestal
and
1 Bearing pedestal
2 Main oil pump
3 Hydraulic speed transducer
4 Electric speed transducer
5 Gear coupling
6 Over speed trip
7 Hydraulic
turning
gear
7 Hydraulic
turning
gear
8 Bearing
8 Bearing
pedestal
pedestal
vibration
vibration
pick-up
pick-up
9 Shaft
vibration
pick-up
9 Shaft
vibration
pick-up
10 10
Journal
bearing
Journal
bearing
11 11
HPHP
turbine
rotor
turbine
rotor
12 12
Foundation
Foundation
BHEL Haridwar
5.1-0240-01/1
10 Journal bearing
Also refer to the following information
12 Foundation
13 Anchor bolts
14 Hex head screw
5.1-0240-01/2
Staem Turbine
Description
HP Turbine
Rear bearing Pedestal
Arrangement
The bearing pedestal is located between the
HP and IP turbines. Its function is to support the
turbine casing and bear the HP and IP turbine
rotors.
The bearing pedestal houses the following
turbine
components:
Combined journal and thrust bearing
Shaft vibration pick-up
Bearing pedestal vibration pick-up
Thrust bearing trip (electrical)
Details of casing supports and casing guides
are given in descriptions 5.1-0280 and 5.1-0350.
Connection
Foundation
of
Bearing
Pedestal
and
1
2
3
4
5
6
7
8
HP turbine rotor
Combined journal and thrust bearing
Bearing pedestal vibration pick-up
Shaft vibration pick-up
Thrust bearing trip (electrical)
Coupling bolts
IP turbine rotor
Foundation
BHEL Haridwar
5.1-0250-02/1
10
11
12
13
14
15
Straight pin
Anchor bolt
Plate
Round nut
Hex nut
Guard cap
5.1-0250-02/2
Steam turbine
Description
Combined
Bearing
Function
The function of the combined journal and
thrust bearing is to support the turbine rotor and
to take the residual axial thrust. The magnitude
and direction of axial thrust to be carried by the
bearing depends on the load conditions of the
turbine. This bearing is located in the bearing
pedestal between HPT & IPT. The thrust bearing
maintains desired axial clearances for the
combined turbine generator shaft system.
BHEL Haridwar
8 Turbine shaft
9 Brg. pedestal
lower
10 Key
11 Oil line
Journal
and
Thrust
12 Bearing shell,lower
13 Shim
14 Spherical block
15 Shim
16 Spherical support
25 Key
a Shaft jacking oil
5.1-0260-01/1
19 Thermocouple
20 Thermocouple
Oil Supply
Lubricating oil is admitted to the bearing
shells from one side via oil line (11) from where
it flows to the oil spaces milled into the upper
and lower bearing shells at the horizontal joint.
5.1-0260-01/2
21 Spring
22 Key
23 Dowel pin
Steam Turbine
Description
Construction
The function of the journal bearing is to
support the turbine rotor. Essentially the journal
bearing consists of the upper and lower shells
(3,6), bearing cap (1), spherical block (7),
spherical support (14) and the key (11) .The
bearing shells are provided with a babbit face.
The babbit surface of the bearing is precision
machined and additional scraping is neither
necessary nor permissible. 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 pivotmounted in the spherical support (14). For this
purpose the spherical block (7) with shims
(12,13) is bolted to the bearing shell (6) . A
projection in cap (1) with shims (9) fits into a
Journal Bearing
HP front
bearing shells. Keys (8) are fitted on both
sides of the projection.
The bearing shells are fixed laterally by key (11)
which are bolted to each other. Each key is held
in position in the bearing pedestal (10) by two
lateral collars. The temperature of the bearing
bodies is monitored by thermocouples (19) as
shown in section c-c.
Oil Supply
Lubricating oil is admitted to the bearing shells
from one side and flows to oil spaces that are
milled into the upper shell at the horizontal joint
and are open to the rotor. The rotor (5) picks up
oil from oil pocket machined into the babbitting
.The oil emerges from the bearing shell where it
is collected in the oil return cowling (4) and
drained into the bearing pedestal(10).
1
2
3
4
5
Cap
6 Lower baering shell
Tab Washer
7 Spherical block
Upper bearing shell 8 Key
Oil return Cowling
9 Shim
Turbine Rotor
10 Bearing pedestal
BHEL Haridwar
11
12
13
14
15
Key
Shim
Shim
Spherical support
Shim
5.1-0270-01/1
Jacking oil
As shown in Detail B, a threaded nozzle( 17)
is arranged at the lowest point of the lower
bearing shell (6) through which high pressure lift
oil is supplied to the space below the journals
when the rotor is turning at low speed (on startup and shutdown).This high pressure oil floats
the shaft to prevent dry friction and overcome
breakway torque during start-up on the hydraulic
turning gear.
A seal (18) prevent high pressure oil from
penetrating the space between threaded nozzle
and ring (16) and thus from lifting the babbit.
Any leakage oil can drain through passages in
the bearing shell below the ring.
5.1-0270-01/2
16 Ring
17 Threaded nozzle
18 Sealing ring
19 Thermocouple
Steam Turbine
Description
Supports
The turbine casing is supported on the support
horns such as to make allowance for the thermal
expansion. It is essential for the casing to retain
concentric alignment with the rotor, which is
supported independently.
1
2
3
HP Turbine
Casing Supports and Guides
The turbine casing (2) is supported with its two
front and two rear support horns on the horn
supports of the bearing pedestal (1,3) at the
turbine centerline level. This arrangement
determines the height of the casing and also
allows thermal expansion to take place in the
horizontal plane by the support horns
BHEL Haridwar
5.1-0280-01/1
Fixed Point
The fixed point for the turbine casing (2) is
located at the horn support on HP-IP pedestal at
the turbine centerline level and is formed by the
parrallel keys (16). Axial expansion of the
turbine casing (2) originates from this point.
10
11
12
13
14
15
16
Sliding piece
Plate
Parallel key
Scale indicating casing expansion
Sliding piece
Plate
Parallel key
5.1-0280-01/2
Steam Turbine
Description
Double Shell Construction
The casing of the IP turbine is split
horizontally and is of double shell construction.
A double-flow inner casing (3,4) is supported
in the outer casing (2,5) (Fig.1) Steam from
the HP turbine after reheating enters the inner
casing from top and bottom through two
admission branches which are integral with the
mid section of the outer casing. This
arrangement provides opposed double flow in
the two blade sections and compensates axial
thrust. The centre flow prevents the steam
inlet temperature from affecting the support
horns and bearing sections.
IP Turbine
Casing
The provision of an inner casing confines
the 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 temprature effective at the
exhaust from the inner casing. This means
that the joint flange can be kept small and
material concentrations in the area of the
flange reduced to a minimum. In this way,
difficulties arising from deformation of a casing
with flange joint due to non uniform
temperature rise e.g. on start-up and shut
down, are avoided. The joint of the inner
casing is relieved by the pressure in the outer
casing so that this joint has to be sealed only
against the resulting differential pressure.
BHEL Haridwar
5.1-0310-01/1
5.1-0310-01/2
5.1-0310-01/3
IP Turbine
Blading
Steam Turbine
Description
Gap SealIng
Sealing strips (7) are caulked into the inner
casing (1) and the rotor (4) to reduce leakage
losses at the blade tips. Cylindrically machined
surfaces on the blade shrouds are opposite the
sealing strips. These surfaces have stepped
diameters in order to increase the turbulence of
the steam and thus the sealing effect. In case of
an operation disturbance, causing the sealing
strips to come into contact with opposite surfaces,
they are rubbed away without any considerable
amount of heat being generated. They can then
easily be renewed at a later date to provide the
specified clearances.
1 Inner Casing
2 Guide Blade
3 Moving Blade
4 Turbine Shaft
5 Caulking piece
6 Sealing strip
7 Caulking wire
7
5
BHEL Haridwar
5.1-0320-02
Steam Turbine
Description
Function
The function of the shaft seals is to seal the
interior of the turbine casing against the
atmosphere at the front (thrust bearing end) and
rear shaft penetrations of the IP turbine.
The shaft seals are axial-steam-flow noncontacting seals.
In the region subject to low relative
expansion in the vicinity of the combined journal
and thrust bearing, the seal strips are caulked
alternatively into the shaft and into springsupported segmented rings in the casing,
forming a labyrinth to impede the outflow of
steam.
In the region subject to greater relative
expansion at the exhaust end, see-through seals
are used, in which the seal strips are located
opposite each other,
BHEL Haridwar
IP Turbine
Shaft Seals
5.1-0330-01/1
Seal Rings
The seal rings (3), the number of which
depends on the pressure gradient to be sealed
are divided into several segments as shown in
Section BB and mounted in grooves in the rings
such that they are free to move radially. Each
segment is held in position against a shoulder by
helical springs (6) and by the steam pressure
above the seal rings (3). This provides the
proper clearance for the seal gaps. Should
rubbing occur the segments concerned can
retreat. The heat developed by light rubbing of
the thin seal strips (9) is so slight that it cannot
cause deformation of the rotor (4).
5.1-0330-01/2
IP Turbine
Steam Turbine
Description
RearBearing Pedestal
Arrangement
The bearing pedestal is located between the
IP and LP turbines. Its function is to support the
turbine casing and bear the weight of IP and LP
rotors.
The bearing pedestal houses the following
turbine components:
Journal bearing
Shaft vibration pick-up
Bearing pedestal vibration pick-up
Hand barring arrangement
Connection
Foundation
of
Bearing
Pedestal
and
BHEL Haridwar
5.1-0340-02
Steam Turbine
Description
Construction
The function of the journal bearing is to support
the turbine rotor. Essentially, the journal bearing
consists of the upper and lower shells (3, 6),
bearing cap (1), torus piece (7), cylindrical
support (14) and the keys (10). The bearing
shells are provided with a babbit face which is
precision machined. Additional scraping is
neither necessary nor permissible. 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 pivotmounted in the cylindrical support (14). For this
purpose, the torus piece (7) with shims (12, 13)
is bolted to the bearing shell (6). A projection in
cap (1) with key (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 achieved by means of keys (8).
BHEL Haridwar
Oil Supply
Lubricating oil is admitted to the bearing shells
from both sides, from where it flows to 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).
5.1-0345-01/1
Jacking Oil
As shown in section B-B, two threaded
nozzles (17) are arranged at the lowest point of
the lower bearing shell (6) through which high
pressure oil is supplied to the space below the
journal when the rotor is turning at low speed
(on start-up and shutdown). This high pressure
oil floats the shaft to prevent dry friction and
overcome breakaway torque during startup, thus
reducing torque requirements of the hydraulic
turning gear.
A seal (18) prevents high pressure oil from
penetrating the space between threaded nozzle
and ring (16) and thus from lifting the babbit.
Any leakage oil can drain through passages in
the bearing shell below the ring.
Removal of Bearing Shells
Not only the upper shell (3) but also the lower
bearing shell (6) can be removed without the
removal of rotor (5). To enable this to be done,
the shaft is lifted slightly by means of jacking
device but with in the clearance of the shaft
seals. The lower bearing shell can then be
turned upwards to the top position and removed.
5.1-0345-01/2
Steam Turbine
Description
IP Turbine
Casing Supports and Guides
BHEL Haridwar
5.1-0350-01/1
5.1-0350-01/2
Fixed Point
The fixed point for the turbine casing (2) is
located at the front horn support at the turbine
centerline level and is formed by the parallel
keys ((7;10). Axial expansion of turbine casing
(2) originates from this point
Steam Turbine
Description
LP Turbine
Casing
Construction
The LP turbine casing consists of a doubleflow 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.
1
2
3
4
Inlet Connections
Steam admitted to the LP turbine from the IP
turbine flows into the inner casing (4,5) from
both sides through steam inlet nozzles before
the LP blading Expansion bellows are
provided in the steam piping to prevent any
undesirable deformation of the casings due to
thermal expansion of the steam piping.
5
6
7
8
5.1-0410-00/1
5.1-0410-00/2
5.1-0410-00/3
5.1-0410-00/4
Steam Turbine
Description
BHEL Haridwar
5.1-0420-00
Steam Turbine
Description
LP Turbine
Blading, Drum Blading
Arrangement
The drum blading stages 1 to 3 of the double
flow LP turbine are of reaction type with 50%
reaction. They are Located in the inner-Inner
casing and form the initial stages of the LP
blading. The LP stages following these drum
stages are described in detail in next chapter.
Guide and moving blades
All guide and moving blades of drum stages
have integral shrouds, which after installation
form a continuous shrouding. The moving
blades (7) of the last drum stage are tapered
and twisted. All stationary and moving blades
have T -roots which also determine the
distance between the blades. They are
inserted into the matching grooves in the
turbine shaft (5) and inner casing (1) and are
caulked in place with
caulking material (6). The insertion slot in the
rotor is closed by means of a locking blade
which is secured in its position by means of
grub screws between shaft and lock blade .In
casing, blades at joint planes are fixed by
means of grub screws.
Inter stage Sealing
In order to reduce blade tip losses, tip to tip
sealings are provided in these stages. Thin
sealing strips (9) are caulked in inner casing
(1) and turbine rotor (5). The sealing fins are
machined on the shrouds of moving and
stationary blades opposite to the sealing strips
in inner casing or rotor (Detail A). In the event
of rubbing due to a fault , little heat will be
generated due to rubbing of thin sealing strips.
These can be renewed at a later date to
provide the correct radial clearances.
BHEL Haridwar
5.1-0430-01
Steam Turbine
Description
BHEL Haridwar
LP Turbine
Blading, Low Pressure Stages
5.1-0440-01/1
5.1-0440-01/2
Steam Turbine
Description
LP Turbine
Shaft Seals
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.
Gap Sealing
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.
Sealing Rings
The sealing rings (2), the number of which
depends on the pressure existing in the
turbine, are split into several segments as
shown in section A-A and arranged in Tshaped annullar grooves in the steam seal
casing (1) so that they can move radially.
Several helical sprir1gs (3) force each
segment against a shoulder and hold it in this
position. This permits the correct clearance in
the sealing gaps. Should rubbing occur, the
segments concerned retreat. The frictional
heat developed by the thin
BHEL Haridwar
5.1-0450-01
Steam Turbine
Description
LP Turbine
Rear Bearing Pedestal
Arrangement
The bearing pedestal is situated between
the LP turbine and generator. Its function is to
bear the weight of LP rotor.
The bearing pedestal
following turbine components:
contains
the
Journal bearing
of
Bearing
Pedestal
and
BHEL Haridwar
5.1-0460-02
Steam Turbine
Description
Journal Bearing
Construction
The function of the journal bearing is to
support the turbine rotor. Essentially, the
journal bearing consists of the upper and lower
shells (3, 6), bearing cap (1), torus piece (7),
cylindrical support (14) and the keys (10). The
bearing shells are provided with a babbit face.
The bearing bore is precision machined and
additional scraping is neither necessary nor
permissible. 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 support (14).
For this purpose, the torus piece (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 achieved by
means of keys (8).
1
2
3
4
Cap
Tab washer
Upper bearing shell
Oil return cowling
BHEL Haridwar
5
6
7
8
Rotor
Lower bearing shell
Torus piece
Key
9 Shim
10 Key
13 Shim
14 Cylindrical support
11 Bearing Pedestal
12 Shim
5.1-0470-00/1
15
16
17
18
Termocouple
Ring
Threaded nozzle
Sealing ring
5.1-0470-00/2
Steam Turbine
Description
Arrangement
The hydraulic turning gear is situated
between the main oil pump and the journal
bearing in the HP turbine front bearing pedestal.
Function
The function of the hydraulic turning gear is
to rotate the shaft system at sufficient speed
before start-up and after shut-down in order to
avoid irregular heating up or cooling down and
thus avoid any distortion of the turbine rotors.
The air flow set up by the blades along the inner
wall of the casing during turning operation
provides good heat transfer conducive to
temperature equalization between upper and
lower casing halves.
Operation
During turning gear operation, the shaft
system is rotated by a blade wheel which is
driven by oil supplied by the auxiliary oil pump.
This oil passes via a check valve into the nozzle
box (1) and from there into the nozzles (2) which
direct the oil jet in front of the blading.
Return Oil Flow
After passing the blading, the oil drains into
the bearing pedestal and flows with the bearing
oil into the return flow line.
Manual Turning Gear
A manual turning gear is provided in addition
to the hydraulic turning gear to enable the
combined shaft system to be rotated manually.
Lifting of Shaft
To overcome the initial break-away torque on
start-up and to prevent dry friction, the bearings
are relieved during turning gear operation by
lifting oil supplied from below i.e. the shafts are
lifted slightly.
BHEL Haridwar
5.1-0510-01
Steam Turbine
Description
Function
The turbine generator is equipped with a
mechanical barring gear, which enables the
combined shaft system to be rotated manually
in the event of a failure of the normal hydraulic
turning gear.
It is located at IP - LP pedestal
Construction
The barring gear consists of a gear
machined on the rim of the turning gear wheel
(10) and pawl (6). This pawl engages the ring
gear and turns the shaft system when
operated by means of a bar attached to laver
(1). The pawl (6) is shown disengaged and the
lever (1) resting against a stop. The lever (1) is
held in position by latch (7).
BHEL Haridwar
Operation
Take the following steps to make the
barring gear ready for operation: Remove
cover (2) unlatches at (7) and attach a bar to
lever (1).
Barring of lever (1) will rotate the
combined turbine generator shaft system.
After barring has been completed, return
lever (1) and pawl (6) to the position shown in
figure and secure lever (1) by means of latch
(7) Replace cover (2).
The barring gear may only be operated
after the shaft system has been lifted with
high-pressure lift oil. If it is hard to start turning
by means of the mechanical barring gear, this
may be due to incorrect adjustment of the
jacking oil system or due to a rubbing shaft.
Before steam is admitted to the turbine.
corrective action must be taken
5.1-0520-01
Steam Turbine
Description
Function
When the turbine is started up or shut
down, the hydraulic jacking device is used to
maintain the oil film between rotor and
bearings. The high-pressure oil is forced under
the individual bearing, thus raising the rotor.
The necessary torque from the hydraulic
turning device or from the manual turning
device is reduced in this way. The highpressure oil also provides motive force to
hydraulic turning gear motor installed in front
bearing pedestal.
Speed Limit Values
In order to avoid damage to the bearings,
the jacking oil pump must be switched on
below a certain speed. The exact speeds for
switching on and off can be seen in the
Technical data 2-0103.
Jacking Oil Pump
The jacking oil pumps, one number AC
(13) and one number DC(14) are jack-screw
immersion pumps situated on the tank (10)
supply the high pressure oil for the lifting
device. The oil is drawn off directly by one of
the two pumps. The pressure oil piping of the
jacking oil pump that is not in operation is
closed by the check valve (12). In order
1 HP turblne
2 IP turblne
3 LP turblne
4 Generator
5 Exciter
6 Check Valve
7 Fine control valve
8 Pressure Limiting Device
9 Bypass Valve
10 Main Oil Tank
BHEL Haridwar
11
12
13
14
15
Steam Turbine
Description
The turbine control system description for
500 MW steam turbine comprises the
following:
General Description
Start-up Procedure
Speed Control
Electrical Speed Measuring
Protective Devices
Overspeed Trip Test
Testing of Stop Valves
LP Bypass System (General)
Extraction Check Valve
Swing Check Valve in CRH line
Testing of Swing Check Valves in the Cold
Reheat Line
Automatic Turbine Tester, General
Automatic Turbine Tester, Protective
Devices
Automatic Turbine Tester, Stop Valves
HP Actuator
Electro-hydraulic Gland Steam Pressure
Control
Control System Diagram
List of Parts
Lubrication Chart
Lubrication Chart, Index
Turbine generator unit MAA50HA001
MAB50HA001and MAC10HA001 comprises
three-cylinder reheat condensing turbine
with condenser MAG10BC001 and a directdriven three-phase a.c. generator.
The turbine has a hydraulic speed governor
MAX46BY001 and an electric turbine
controller. The hydraulic speed governor
adjusts control valves MAA10+20AA002 and
MAB10+20AA002 by way of hydraulic
amplifier MAX45BY011 whilst the electric
turbine controller acts on these control
valves by way of electro-hydraulic converter
MAX45BY001.
Hydraulic amplifier MAX45BY011 and
electro-hydraulic converter MAX45BY001
are switched in parallel to form a minimum
gate. The system not exercising control is in
its maximum position.
The special operating conditions existing in
reheat condensing turbines necessitate
additional control elements. On start-up of
the high-pressure boiler it is necessary to
BHEL Hardwar
General Description
5.1-0600-01/1
Steam Turbine
Description
Mode of Operation
The turbine is started up and brought up to
speed with the assistance of the control
valves MAA10+20AA002 and MAB10+20
AA002. If the hydraulic controller is to
govern start-up, the reference speed setter
MAX46BY001 must be set to minimum
speed during this process. In this case the
speed reference from the electric controller
is at maximum. If conversely, start-up is to
be governed by the electric controller,
reference speed setter MAX46 BY001 is set
to maximum and the speed reference from
the electric controller to minimum. The
combined stop and control valves are closed
because the trip fluid circuit is not yet
pressurized. Turning hand-wheel KA01
clockwise
or
operating
motor
MAX47BY001M of start-up and load limiting
device MAX47BY001 in the close direction
releases spring KA06 in auxiliary follow up
piston KA08 via the linkage, thereby
preventing a buildup of auxiliary secondary
fluid pressure. The hydraulic amplifier
MAX45BY011 with follow-up pistons KA01
and KA02 is now in the control valves closed
position so that a buildup of secondary fluid
pressure is prevented when main trip valves
MAX51AA005 and MAX51M006 are latched
in.
Further turning of hand-wheel KA01 moves
pilot valve KA02 of start-up and load limiting
device MAX47BY001 further downwards,
admitting control fluid first into the start-up
fluid circuit and then into the auxiliary start
up fluid circuit. The start-up fluid flows to the
space above the pilot valve of test valves
MAX47AA011+012 and MAX47AA021+
022, forcing them down against the action of
the springs. The auxiliary start-up fluid
raises the pilot valves of main trip valves
MAX51AA005 and MAX51AA006, thereby
moving them into their normal operating
position and permitting trip fluid to flow to
test
valves
MAX47AA011+012
and
MAX47AA021+022 of the main stop valves
and reheat stop valves. At the same time,
overspeed
trip
release
devices
MAY10AA001 and 002 are latched in if they
have been tripped. The function of non
return valve MAX42AA011 is to interrupt
BHEL Hardwar
Start-up Procedure
5.1-0610-01/1
5.1-0610-01/2
Steam Turbine
Description
BHEL Hardwar
Speed Control
5.1-0620-01/1
5.1-0620-01/2
Steam Turbine
Description
BHEL Hardwar
Control System
Electrical Speed Measuring
5.1-0621-02
Steam Turbine
Description
Overspeed Trip
Two overspeed trips MAY10 AA001 and 002
are provided to trip/shut down the turbine in
the event of overspeed. Each trip device
consists of an eccentric bolt/striker fitted in
the emergency governor shaft with its center
of gravity displaced from the axis of rotation
and held In position against centrifugal force
by a spring up to an adjustable preset speed
of 10 to 12 % above the normal turbine
operating speed. At the preset overspeed,
centrifugal force overcomes the spring force
and the eccentric bolt/striker flies outwards
into its extended position. In doing so it
strikes the pawl which releases the piston of
the overspeed trip release device KA01.
Through combined spring force and fluid
pressure, the piston opens the auxiliary trip
fluid circuit to the main trip valves MAX51
AA005 and MAX51AA006.
Thrust-Bearing Trip
Thrust bearing trips MAD12CY011/012/013
are tripped electrically in the event of
excessive axial displacement of the turbine
shaft.
Pressure Switch
Installed in the trip fluid circuit are two
pressure switches MAX51CP011 and
MAX51CP012 which bridge the longtime
delayed relays of the reverse-power
protection system in such a way that the
generator is shut down by response of the
short-time delayed relays as soon as it
begins to motor. The annunciation Turbine
trip initiated is transmitted simultaneously to
the control room.
Remote Solenoid Trip
Remote solenoid trip is activated via
solenoid valves MAX52 AA001 and MAX52
AA002. The remote solenoid trip may be
initiated manually from the control room by
push button, by the electrical low-vacuum
trip or the thrust bearing trip or other
protective devices.
BHEL Hardwar
Protective Devices
5.1-0630-01/1
5.1-0630-01/2
Steam Turbine
Description
BHEL Hardwar
The buildup of pressure in the auxiliary startup medium circuit between the overseed trip
test device and the overspeed trip release
device can be followed at pressure gauge
MAX48CP501. When pilot valve KA02 is
then released, the auxiliary start-up medium
pressure returns to 0 pressure. The auxiliary
trip medium pressure must then remain at its
full value (readable at pressure gauge
MAX52CP501). If this is the case, pilot valve
KA03 may be released. The test is
completed. If, when valve KA02 is released,
the auxiliary trip medium pressure collapses,
pilot valve KA02 must be pushed
downwards again and must be held in this
position a little longer. It is essential that the
auxiliary trip medium pressure must remain
steady before valve KA03 is released.
5.1-0631-01
Steam Turbine
Description
Main Steam Stop Valves
The stop valves can be tested for freedom of
movement independently of each other even
during operation with the aid of the test
valves MAX47AA011 to 012 attached to
each of them. The main stop valves MAA10
and 20AA001 may only be tested at a load
that is less than 80% of the maximum
output.
If the test is conducted with the initial
pressure controller out of operation, the
main stop valves may only travel out of the
open position to about 50% closed at the
most and are to be reopened immediately. If
the initial pressure controller is in operation
complete closure of a main stop valve may
be performed. This, however, is conditional
upon the response time of the initial
pressure controller being high enough to
keep the initial pressure constant even
during the testing procedure.
First the main control valve concerned
MAA10 or 20AA002, is to be closed by
pressing of pushbutton in the supply unit. If
in operation, the initial pressure controller
opens the other main control valve
accordingly. Once the control valve has
been closed the stop valve can be closed. It
is to be reopened immediately.
BHEL Hardwar
5.1-0632-01
Steam Turbine
Description
Function
The function of the LP bypass control
system (EHA Type) is to monitor the
pressure in the reheat system and to control
it under certain operating conditions. During
start-up and shutdown, and at operation
below minimum boiler load, the volume of
steam not utilized by the IP and LP cylinders
of the turbine must be bypassed to the
condenser via the LP bypass valves. This
requires the bypass control system to
maintain the pressure in the reheater
constant in accordance with the preset
reference value. In
the event of
disturbances, e.g. load shedding or trip out,
the amount of excess reheat steam
bypassed to the condenser.
Hydraulic Power Supply Unit (HPSU)
The hydraulic unit serves to supply the
necessary pressurized fluid to the actuators.
The hydraulic power unit has two pumps.
One pump is always in operation and the
other is stand-by.
Two nos. filtration circuits are provided in
order to maintain the cleanliness of system
for proper functioning of hydraulic system.
Hydraulic fluid, a phosphate ester is chosen
for high pressure hydraulic system, which
ensures good fire protection. The fluid has
good lubricating properties and allows a
comparatively easy maintenance.
A regeneration unit for hydraulic fluid is
provided to maintain its properties/quality.
Electro-hydraulic Actuator for LP Bypass
Stop Valve
LP Bypass System
(General)
Electro-hydraulic Actuator for LP Bypass
Control Valve
The LP bypass control valve actuator is an
electro-hydraulic actuator with an external
control fluid supply from centralized
Hydraulic Power Unit (HPSU). The control
block converts the electrical signal from the
controller into flow of hydraulic fluid. It
controls the intake and discharge of
hydraulic fluid to and from the piston
chambers of the actuator in a continuous
mode, thus permitting very precise
positioning of the actuator. The control block
will position the valve as well as block the
cylinder in case of hydraulic fluid failure.
Water Injection System
During LP Bypass operation a part or entire
steam flow produced by boiler is routed to
the condenser. In order that the condensate
pumps do not have to supply the injection
water flow required for the full boiler capacity
and to prevent the amount of excess water
flow becoming too high, under normal startup and shut down conditions, a regulating
type water injection system to optimize the
water quantity to be mixed with LP Bypass
steam is provided.
Actuator for water injection valve may be
hydraulic or pneumatic type.
A separate flow controller is provided to
regulate the spray water valve.
BHEL Haridwar
5.1-0640-01-1
Steam Turbine
Description
BHEL Hardwar
5.1-0650-01
Steam Turbine
Description
In order that the turbine may be completely
separated from the steam when it is
stationary, an additional check valve
LBC10 AA001 is fitted in the line between
the HP cylinder and the reheater and
operating through pilot valve MAX42AA001
+002 and the rotary actuator KA01
depending on the pressure in the
associated secondary medium circuit. The
swing check valve opens fully when the
control valves reached approx. 5 to 10% of
their full-power travel. Only when the
control valves reach this point again as
they are being closed, the swing check
valve brought into steam flow again by the
hydraulic actuator. Thus when the steam
flow in the normal direction ceases, the
BHEL Hardwar
5.1-0651-01
Steam Turbine
Description
BHEL Hardwar
5.1-0652-01
Steam Turbine
Description
Function
Healthiness of the protective devices and the
stop and control valves is vitally important for
the operational reliability and availability of
the turbine. Hence, it is essential that these
equipments are always kept in a fully
serviceable condition. Economy has dictated
longer intervals between turbine overhauls,
with the result that testing of the equipments
and devices is now necessary at regular
intervals during normal operation.
There are manually operated devices for
testing the free operation of the stop and
control valves. However, these tests do not
cover all components involved in an
automatic trip with the result that the
conditions only party corresponds to those
prevailing during a real trip.
The system
Any possible mal-operation associated with
manually operated devices are avoided with
fully automatic tests by means of the
automatic turbine tester. Full protection for
the turbine during testing is also assured by
suitable circuit arrangements. This increases
the operational reliability and availability of
the plant.
The automatic turbine tester is realised in
digital technology.
System adaptation
The system is subdivided into functional
groups for each device. Each group contains
the device itself and all necessary
transmission elements for initiation of a
normal trip.
The automatic turbine tester is divided into
the following 2 subgroups:
BHEL Hardwar
1. Protective devices
Description:
Automatic
Turbine
Tester, Protective device.
2. Main stop and control valves
Description: Automatic Turbine tester,
stop and control valves.
The complete testing of all components
which must operate when an automatic trip
becomes necessary is assured, despite the
subdivision into two testing groups
(protective devices, stop and control
valves), because the main trip valves which
store the trip signal by mechanical hydraulic
means are operated together with each
protective
device
and
subsequent
satisfactory reduction of the trip oil pressure
after the valves are monitored.
Nature of the description
The descriptions mentioned above contain
the practical sequence of the tests on the
individual devices and gives details of
possible irregularities. The description of
equipment contained in the automatic
control cubicle (stepping switches, interlock
modules, etc), the control panel in the
control room and schematic circuit diagrams
are contained in the separate electrical
section of the Operating Manual for the
automatic turbine tester.
For the understanding of the automatic
turbine tester from these descriptions it is
assumed that the reader is fully conversant
with the functioning of the individual
protective devices and valves within the
overall turbine governing and protection
system.
5.1-0660-00
Steam Turbine
Description
Scope of Testing
The Automatic turbine tester (ATT)
subgroup for the protective devices is
divided into a preliminary test and the
following four individual testing systems.
Remote trip solenoid MAX52AA001
Remote trip solenoid MAX52AA002
Over speed trips MAY10AA001/MAY10
AA002
Low vacuum trip MAG01AA011
One or more systems can be selected for
testing at the control panel and the selection
is stored. The start of the test program
automatically causes a preliminary test to be
carried out on the protective channels which
are to be effective during actual testing and
then establishes the test circuit. Once the
first test selected has been completed and
the protective device has latched in again,
the test circuit is restored to its normal
operational configuration. Further selected
tests must be started individually by
pressing the Test push-button to start the
program.
General
During normal operation, the protective
devices act via main trip valves MAX51
AA005 and MAX 51AA006 on the stop and
control valves and extraction swing check
valves. The remote trip solenoids MAX52
AA001 and MAX52 AA002, over speed trips
MAY10AA001/MAY10AA002
and
low
vacuum trip MAG01AA011 actuate main trip
valves MAX51AA005 and MAX51AA006 by
opening the auxiliary trip fluid circuit.
For the duration of testing of the protective
devices, a test circuit is established .In order
to keep the trip fluid circuit effective, it is
isolated from main trip valves MAX51 AA005
and MAX51AA006 by means of change-over
valve MAX51AA211 and supplied with fluid
via solenoid valves MAX51AA201 and
MAX51AA202 (remote trip during testing).
BHEL Hardwar
of
each
turbine
5.1-0661-00/1
Setting Data
The setting data for the pressure switches
are listed in the setting record Measuring
Point List. The actually set values are
logged in the Commissioning Test
Record.The test running times, etc. are
entered in the functional diagrams.
Test Sequence
Start of Testing
The test begins with the selection of the
protective devices subgroup. This is
performed by pressing the subgroup On/Off
push button.
The subgroup remains on until switched off
when the program has been completed.
While the protective devices subgroup
program is running, the other subgroups are
blocked.
The On/Off push-button is also used to
acknowledge alarms.
Selection
After the subgroup has been switched on,
the protective device to be tested is selected
by pressing the selection push button for the
individual device.
A separate selection push-button is provided
for each protective device. Only one
selection may be made at a time. Selection
of a further test is possible only once all
other programs have ended
Test Push-Button
The automatic test program is started by
pressing the Test push-button
Cancel Push-Button
This push-button can be used to terminate
the test program running at any time and to
initiate the reset program. The reset
program has priority over the test program.
Lamp Test Push-Button
All the signal lamps on the control panel can
be tested by pressing the Lamp Test PushButton.
5.1-0661-00/2
Individual Tests
The individual test is performed after
completion of the preliminary test and after
the test circuit has been established.
Successful completion of each individual
test is annunciated by the limit switches on
main trip valves MAX51AA005 and MAX51
AA006, pressure switch MAX52CP211 in
the auxiliary trip fluid circuit and pressure
switch MAX 51CP209 in the trip fluid circuit
between change-over valve MAX51AA211
and the main trip valve MAX51AA006. The
associated limit switch also annunciates
when a protective device (except for the
remote trip solenoids) has been activated.
On completion of each individual test, all
activated protective devices are returned to
their normal operating position by reset
solenoid valves MAX48AA201 and MAX48
AA202 and the test circuit is deactivated.
Whenever several of the same types of
protective device are provided, only one will
be described in the following, as the test
procedure is the same for all.
Preliminary Test
Pressing the Test push-button automatically
initiates a test of the protective circuits to be
effective during testing.
Function
The function of the preliminary test is to
detect any faults in the protective circuits to
be used during testing, and, if any are
detected, to inhibit testing of the protective
device, as this would leave the turbine
without protection.
Test Sequence
In the course of the preliminary test,
solenoid valves MAX51AA201 and MAX51
AA202 (remote trip during testing) are
automatically tested before the test circuit is
established. These valves (MAX51AA201
and MAX51AA202) are first energized,
resulting in a buildup of control fluid
upstream of changeover valve MAX51AA
211.lnitiation of Schmitt triggers (in the
speed
measuring
unit)
de-energizes
solenoid valve MAX51AA201 and the control
5.1-0661-00/3
Function
The function of the main trip valve is to
amplify and store the hydraulic or
mechanical (manually initiated local) trip
signal. It must respond in the course of
every successful protective device test.
Operation
Each main trip valve is kept in its position by
auxiliary trip fluid pressure. If a protective
device is actuated, the auxiliary trip fluid
circuit is depressurized and the main trip
valve is activated. This connects the trip fluid
and auxiliary trip circuits to drain and shuts
5.1-0661-00/4
Overspeed Trips
MAY10AA001/MAY10AA002
Function
The two over speed trips are provided to
protect the turbine against over speeding in
the event of load rejection coincident with
failure of the speed controller. As they are
particularly important to the protection of the
turbine, they can also be locally tested by
manually with the aid of the over speed trip
test device MAX62AA001 (hydraulic test
signal transmitter) during turbine operation
at rated speed. (For description see Over
Speed Trip Test).
Operation
When the preset over speed is reached, the
eccentric flybolt/striker (2) of each over
speed trip activates piston (5) and limit
switch (6) annunciate via pawl (4). This
connects the auxiliary trip fluid circuit to
5.1-0661-00/5
5.1-0661-00/6
Test sequence
After energizing of test signal transmitter
(solenoid valve) MAG01AA201, fitted in the
signal line to the condenser, this signal line
is blocked off and simultaneously the space
above diaphragm (4) is connected to
atmosphere. The air flow via orifice causes a
slow increase of pressure by which the
pistons (6) and (7) move to their trip position
connecting the auxiliary trip fluid circuit to
the drain.
Reset Solenoids
MAX48 AA201 and MAX48 AA202
Function
The function of the reset solenoids is to
restore the tripped protective devices to their
normal operating positions during the ATT
reset program.
Operation
The reset solenoids are two 2/3-way
solenoid valves, fitted in the auxiliary startup fluid line. Both solenoid valves are
energized in the course of the reset program
conducted after each subtest, so that
auxiliary start-up fluid II is supplied with
control fluid III. The control fluid pressure
forces all protective devices back into their
normal operating positions and the trip fluid
and auxiliary trip fluid pressure can build up
again.
When the protective devices have latched-in
again, reset solenoid MAX48AA021 is deenergized first to shut oft the control fluid
supply through this value.
1 Compression
spring
2 Coil
3 Valve disc
5.1-0661-00/7
Steam Turbine
Description
BHEL Hardwar
5.1-0662-01/1
time
Setting Data
The setting data for the pressure switches
used to monitor the individual valve
movements are listed in the setting record
Pressure Switch settings. The actual set
values are logged in the Commissioning
Test Record. The test running times, etc.,
are entered in the functional diagram.
Test Selection Units
There are two nos. of combined main
steam and control valves and two nos.
of combined reheat stop and control
valves, each of which is tested as a
separate unit and has a separate selection
push-button on the ATT control panel.
They are as follows:
Selection1:
Main stop and control valve (LHS)
Selection 2:
Main stop and control valve (RHS)
Selection 3:
Reheat stop and control valve (LHS)
Selection 4:
Reheat stop and control valve (RHS)
Test Procedure
Start of Test
The test starts with the selection of
subgroups by pressing the On/Off pushbutton.
The subgroup remains on until it is
switched off after the programme is
5.1-0662-01/2
5.1-0662-01/3
5.1-0662-01/4
Steam Turbine
Description
The actuator is of the two-stage
amplification type, i.e. it incorporates pilot
and main control mechanisms. The
actuating forces for movement of the HP
control valve are generated, in the opening
direction, by main actuator piston KA02
under the force of the control fluid and, in
the closing direction, by the disc spring
column. During actuation main pilot valve
KA07 acts as a 3-way valve to allow the
control fluid to flow to the space behind main
actuator piston KA02. Main pilot valve KA07
is actuated via the resetting linkage by
means of auxiliary pilot piston KA06 which is
subject to control fluid pressure on both
sides.
The actuating signal given by the signal fluid
pressure acts on the face of pilot valve KA05
pressing it against the resetting spring on
the opposite side. Acting as a 4-way valve,
the pilot valve allows fluid to flow to both
sides of auxiliary pilot piston KA06. When
BHEL Hardwar
HP Actuator
5.1-0665-00
Steam Turbine
Description
Function
With all shaft seals subject to a positive
pressure difference, the escaping steam is
throttled to a low pressure and fed into a
header 1.1, which is common to all shaft
seals. Those seals, which are under
vacuum, must be supplied with seal steam
to prevent the ingress of air. The supply of
steam is taken from the header 1.1. The
amount of leakage steam and seal steam
required depends on the pressure at the
seals, which, in turn, is primarily
dependent on the turbine load.
The function of the control system is to
maintain the pressure at the bleed-off
points of all seals at the same preset
pressure. This is effected by exhausting
steam from the header (e.g. to the
condenser) or supplying extra steam to the
header 1.1, according to operating
conditions.
Arrangement
Leak-off control valve 1.3 is used for
discharging surplus steam from the header
1.1 and seal steam supply control valve
1.4 for admitting extra steam to it. All
valves are actuated by type HSA-1-K
electro hydraulic actuators. The actuators
1.11 are under the continuous control of
an electric controller 1.9 each via an
electro hydraulic converter. The electro
BHEL Hardwar
Electro-hydraulic Seal
Steam Pressure Control
hydraulic converter comprises a control
coil, which adjusts the position of the
impingement plate of the hydraulic
preamplifier.
Controller
The function of the electric controller 1.9 in
conjunction with the transducer 1.6 and
the actuating elements (control valves) is
to maintain a controlled variable at a
preset valve by adjusting the final
controlling elements. The actual valve of
the
control
system
is
acquired
continuously by the transducer 1.6 and
compared against the set value in the
electric controller 1.9. If the actual value
deviates from the set value, one of the
final controlling elements (either the leakoff or steam supply control valve) is
adjusted until the actual value again
agrees with the set value. Only if there is a
large control deviation, e.g. during a fullload trip, are all valves operated
simultaneously. The electric controller is
realised in digital technology.
Mode of Operation
The input signal coming from the controller
flows through the solenoid (31). The
magnetic field of the solenoid together with
the magnetic field of the permanent
magnet system (42) exercises a force on
the freely pivoted armature (30). This force
reacts against the force generated by the
5.1-0670-01/1
5.1-0670-01/2
5.1-0670-01/3
5.1-0670-01/4
5.1-0680-01/1
Steam Turbine
Description
Control System
Diagram Legend
Title
Coordinete
LBB01 CP511
E8
LBC10 AA001
KA01
LBC10 CG001 B
C
D
E
E7
E7
E7
E7
E7
E7
LBS21 AA001
KA01
LBS21 CG001A
E12,13
E12,13
E12,13
LBS31 AA001
KA01
LBS31 CG001A
E13
E13
E13
LBS31 AA002
LBS31 CG002 A
E13
E13
LBS41 AA001
KA01
LBS41 CG00 1A
C10
C10
C10
LBS41 AA002
KA01
LBS41 CG002A
C10
C10
C10
LBS42 AA001
KA01
LBS42 CG001A
AB11
A 11
B 11
LBS42 AA002
KA01
LBS41 CG002A
AB1 1,12
A12
B12
LBQ50AA001
KA01
LBQ50CG001 A
E9
E9
E9
LBQ5OAA002
LBQ50 CG002A
E9
E9
MAA10 + 20
CG001 B,F,H
C,G,J
D
E
MAA10+ 20
AA002
KA01
KA02
KA05
ABC7
AB7
B7
BHEL Hardwar
BC7,8
C7,8
C7
C7
Coordinete
KA06
KA07
KA09
M
AA002 MS61
MAA10 + 20
CG002 A
C
MAB10 +20
AA001
KA01
KA02
MAB10 + 20
CG001 B,F,H,
C,G,J
D
E
MAB10+ 20
AA002
KA01
KA02
KA05
KA06
KA07
KA09
M
MS61
MS62
MS72
MAA10 + 20
AA001
KA01
KA02
Title
MS73
MAB10 + 20
CG002
A
C
MAD12
CY011,012,013
MAG01 AA011
MAG01CG01 B
C
E
MAG01AA016
ABC9
A9
A9
BC9,10
Servomotor
C10
Piston
C10
Pre Control Pilot Valve
C10
Relay Piston for Precontrol Pilot ValveC10
Main Pilot Valve
C10
Hand wheel for Testing Device
B10
Electrical Motor for Testing Device B10
Torque Limit Switch,
Testing Device 100% ATT
B10
Travel Limit Switch,
Testing Device 100% ATT
B10
Torque Limit Switch,
Testing Device 0% ATT
B10
Travel Limit Switch,
B10
Testing Device 0% ATT
D8
B5
B5
B5
B5
G9
5.1-0681-01/1
Title
Coordinete
MAN01AA001
MAN AA011
MAN01CP511
MAN01DP001
KA01
MAN11 + 12
AA001
KA01
KA02
MAN11 +12
CG001 B, D
C, E
D12
F11
E12
MAN11 +12
AA002
KA01
KA02
KA05
KA06
KA07
MAN 11 + 1 2
CG002
A
B
MAN11 +12
AA003
KA01
MAN11 + 12
CG003
B
C
MAN11 + 12
AA004
KA01
MAN11 + 12
CG004
B
C
MAN11 + 12
CP501
C12
A13
A13
MAX32BT021
MAX32BT081
G9
MAV21 AP001
E1
MAV21BT001
Oil Filter
(Hydraulic Control Equipment Rack)
D4
D8
MAX42AA011
Non-Return Valve
B1
MAX42BT001
Fluid Filter
(Hydraulic Control Equipment Rack)
C1
Fluid Filter
(Hydraulic Control Equipment Rack)
C2
Fluid Filter
(Hydraulic Control Equipment Rack)
B4
G6
MAX42BT002
MAX42BT003
MAX42BT022
MAX42CP501
MAX42CP512
MAX44AP001
E1
MAX44CP501
A5
MAX45BB001
E4
MAX31
BB21, 26
B9
KA02
MAX31 BB021
BB041,049
5.1-0681-01/2
A7
F6
MAX42CP511
MAX45BY001
KA01
C11
MAX42AA002
B7
MAX32
BT011 +012
D7
C11
A10
A13
A13
A 14
MAX42AA001
Coordinete
MAX42BT021
Title
MAX41 CP50l
D11
MAX31
BB011, 016
KA04
KA05
KA06
KA07
KA08
KA10
KA11
Electro-Hydraulic Converter
Follow-Up Piston for Main
Control Valves
Follow Up Piston for Reheat
Control Valv8S
Sleeve
Piston
Helical Spring
Pilot Valve
Piston
Adjusting Device Control Valves
Manual Adjusting Device
F4
F5
F5
F4
F4
F4
G4
F4
F5
F5
A
K
T
B
C
Title
Coordinete
MAX45BY011
KA01
KA02
Hydraulic Converter
F2
Follow-up Piston for Main Control Valves F3
Follow-Up Piston for Reheat Control F3
valve
KA04
Sleeve
G3
KA05
Piston
G3
KA06
Helical Spring
F3
KA07
Pilot Valve
G2
KA08
Piston
G3
KA09
Proportional Band Adjustment
G2
KA10
Adjusting Device Control Valves
F4
KA11
Manual Adjusting Device
F4
MAX45CG011 B
Limit Switch, Operation without Bypass
Valves and Adjusting Device Blocked F3
C
Limit Switch, Displacement of control
valves
F4
MAX45CP501
MAX45CP511
F2
Title
Coordinete
G1
G1
MAX51
AA005 +006
B2
MAX 51
CG005+006 C
E
B2
B2
MAX51 AA011
KA01
KA02
D5
D5
D5
MAX51AA041
MAX51 AA044
E3
E12
C12
A 11
C12
A11
E9
MAX51AA211
Changeover Valve
B3
MAX51 CG211B
C
MAX51CP501
MAX51 CP522
527
MAX51 AA047
MAX51 AA048
MAX 51 AA 050
E13
E2
MAX46BY001
KA01
KA02
KA03
KA04
KA05
KA06
KA07
KA08
KA09
M
G1
F2
F1
F1
F2
F2
F2
F2
F2
G1
F1
MAX46CG001 A
B
F2
F2
MAX 51 CP523
528
Pressure Gauge.
Auxiliary Secondary Fluid
F2
MAX51 CP542
547
MAX47
AA011 +012
B6
MAX51 CP543
548
MAX47
AA021 +022
A9
MAX52AA005
MAX52 CG005 C
E
B2
B2
B2
MAX47BY001
KA01
KA02
M
F1
F1
F1
F1
MAX 52 CP501
D3
MAX53 AA021
MAX46CP501
MAX47CG001 A
B
C
D
F1
G1
G1
G1
MAX 51 AA051
MAX 51 AA056
A
B
A3
F11
F11
F11
5.1-0681-01/3
Title
MAX53CG021B
C
F11
F11
MAX53 AA022
F11
F11
F11
MAX53CG022B
C
F11
F11
MAX53AA031
MAX53 AA041
A
B
MAX 53BY001
KA01
KA02
KA03
KA04
KA05
KA06
KA07
KA08
KA09
Coordinate
G6
F6
F7
F7
G7
G7
G7
G7
G7
F7
MAX42AA001
MAX47
AA211 +212
MAX 47
AA221 +222
MAX48
AA201 +202
MAX51AA021
MAX53 BY 011
KA01
F8
F8
MAX51AA027
MAX51 AA028
F5
B5
B8
B1,2
E12
E13
C 12
A10
C12
A11
E9
B3
B4
C12
MAX51AA031
F11
MAX51 AA030
MAX61
AA011 +012
B4
MAX51AA024
MAX46AA011
F7
G6
MAX 53CP511
E1
MAX45AA001
MAX53CG001 A
T
MAX53
CP501 +502
Coordinate
B6
MAX51 AA036
MAX61
AA021 +022
B8
MAX62AA001
KA01
KA02
KA03
KA001M
C4
C4
C4
C4
C4
MAX52AA001
C2
MAX62CG001 B
C
MAX52AA002
C2
MAX62CP501
MAX53AA051
MAX51 AA201
MAY10
AA001 +002
KA01
Overspeed Trip
Releasing Device
E2
E2
MAY10
CG001 +002 C
E
E3
E3
5.1-0681-01/4
MAX51AA202
MAX61AA201
C13
MAX61
AA221 +222
LBB001 CP011
LBS42 CP002
MAA50CP006
MAG01CP201
MAG01CP202
MAG01CP203
MAG01CP204
MAG10CP011
MAG 10CP012
Title
Coordinete
MAX48 CP202
Solenoid Valve for Testing of
Main Stop Valves
C5,6
MAX51
CP011 +012
C8
E8
B11
B4
B4
B5
B5
E13
E13
MAG10CP016
MAN01CP001
MAX45 CP211
MAX51
CP013
MAX51
CP205 +206
MAG10CP013
MAX48 CP201
E13
MAX51
CP207 +208
MAX51
CP209 +210
Coordinete
B1
A1
A1
MAX51CP 221
+226
MAX51CP222
+227
B7
MAX51 CP223
+228
A7
MAX51CP242
+247
A9
MAX51 CP243
+248
B9
MAX52CP211
B3
D1
D1
D2
MAX62 CP 211
G8
MAX62 CP 212
E2
Title
MAX62 CP 213
C2
MAX45 AA031
E4
5.1-0681-01/5
Steam Turbine
Description
No.
1
2
3
4
5
6
10
11
12
13
14
15
16
17
Lubrication
Point
Overspeed test
device
Reduction gear of
overspeed trip
test device
Bearing of low
vacuum trip
Main control valve
stem
Main stop valve
stem
Limit Switch
attachment on
main stop valve
Limit Switch
attachment on
main control valve
Hinge of main
control valve
position indicator
LAWA actuator
VR 16 of main
control valve
Reheat control
valve stem
Reheat stop valve
stem
Limit switch
attachment on
reheat stop valve
LAWA actuator
VR 16 of reheat
control valve
Hinge of reheat
control valve
position indicator
Limit switch
attachment on
reheat control
valve
Hinge of
extraction swing
check valve
Adjusting gear of
starting and load
limit device
BHEL Hardwar
Filling
Quantity
Lubrication Chart
Lubricant
Turbine oil*
200g
Grease
Servogem-2
Turbine oil*
10g
Molykote
M30
Molykote
M30
Every 1 to 2
months
Use no oil
or grease
Molykote
M30
Every 1 to 2
months
Use no oil
or grease
Calypsol
SF7-026
Every 104
Operating
hours
After every
dismantling
After every
dismantling
Every 1 to 2
months
0.4 kg
0.4 kg
Molykote
M30
Every 104
Operating
hours
Every 1 to 2
months
Molykote
M30
Every 1 to 2
months
Molykote U
Molykote U
Molykote
M30
Calypsol
SF7-026
Molykote U
200g
Remarks
Use no oil
or grease
Use no oil
or grease
Use no oil
or grease
Molykote U
0.4 kg
Every 1 to 2
months
Every 1 to 2
months
Top-up
Quantity
Every 1 to 2
months
After every
dismantling
After every
dismantling
Every 1 to 2
months
Molykote U
0.4 kg
Lubrication
Interval
Grease
Servogem-2
Use no oil
or grease
Use no oil
or grease
Use no oil
or grease
Use no oil
or grease
Use no oil
or grease
After every
dismantling
Every 1 to 2
months
Use no oil
or grease
10g
5.1-0690-01/1
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
*
**
Lubrication
Point
Journal for
hydraulic speed
governor
Adjusting gear of
reference speed
setter
Bearing of
trimming device
Hinge of cold
reheat swing
check valve
Journal of
Converter for
bypass governor
Bearing of
condenser safety
device for bypass
operation
Hinge of bypass
control valve
position indicator
Limit switch
attachment on
bypass control
valve
Bypass control
valve stem
Limit switch
attachment on
bypass stop valve
Bypass stop valve
stem
Stem guides of
shaft seal steam
valve
Filling
Quantity
Lubricant
Turbine oil*
200g
Grease
Servogem-2
Turbine oil*
Molykote U
Top-up
Quantity
Every 1 to 2
months
Every 1 to 2
months
10g
Every 1 to 2
months
After every
dismantling
Use no oil
or grease
Every 1 to 2
months
Turbine oil*
Every 1 to 2
months
Molykote
M30
Every 1 to 2
months
Use no oil
or grease
Molykote
M30
Every 1 to 2
months
Use no oil
or grease
After every
dismantling
Every 1 to 2
months
Use no oil
or grease
Use no oil
or grease
After every
dismantling
After every
dismantling
Use no oil
or grease
Use no oil
or grease.
Lubrication
point not
shown
Lubrication
point not
shown
Molykote
M30
Molykote U
Molykote U
Hydraulic oil
to DIN 51517
and VDMA
24318 H-LP
oils**
1stoil change
after 6
months,
thereafter
every12
months.
7 to 9 kg
5.1-0690-01/2
Remarks
Turbine oil*
Molykote U
7 to 9 kg
Lubrication
Interval
5.1-0690-01/3
Steam Turbine
Description
Function
The function of the hydraulic speed governor
is to operate the control valves to give the
appropriate turbine steam throughput for the
particular load condition. The arrangement
and functioning of the governor within the
overall governing system is described in the
section on governing.
Construction
The principal components of the speed
governor are the bellows (8), the link (11),
the speed setting spring (13), the sleeve (5)
and the follow-up piston (4). The primary oil
supply from the hydraulic speed transmitter
is available at connection a1. A fire
resistant fluid is used as the hydraulic fluid in
the governing system. An additional bellows
(9) prevents primary oil getting into the
control fluid circuit if there be a leakage in
the governor bellows (8). In this case, the
leakage oil can be drained off via connection
c1 . In case a leak in the bellows (9) occur,
the control fluid that has leaked in will also
be drained off via connection c1.
The primary oil pressure (connection a1) is
dependent on the speed and determines the
position of the link (11) via the bellows (8)
and the push rod (10). The speed setting
spring (13) opposes the primary oil
pressure. Its pre-compression can be varied
either by hand or remotely by the motor (16).
The sleeve (5) which can slide on the
bottom end of the follow-up piston (4) is
attached to the link (11). The follow-up
piston is held against the auxiliary
secondary fluid pressure (connection b) by
the tension spring (3). The follow-up piston
and the sleeve have ports, which at normal
overlap allow sufficient fluid to escape to
produce equilibrium between the auxiliary
secondary fluid pressure and the force of the
tension spring (3).
Each steady-state position of the link (11)
and hence of the sleeve (5) corresponds to
a specific force from the tension spring (3)
and hence to a specific secondary fluid
pressure which in turn determines the
position of the control valves.
BHEL Haridwar
Mode of Operation
If the primary oil pressure falls (as a result of
increasing load and the resulting drop in
speed), the link (11) and the sleeve (5)
sliding on the follow-up piston (4) are moved
downwards by the speed setting spring (13)
so that the overlap of the ports in the sleeve
and the follow-up piston is reduced. This
causes the pressure in the auxiliary
secondary fluid circuit to rise and the followup piston follows the movement of the
sleeve against the increasing force of the
tension spring (3) until normal overlap of the
ports and equilibrium are restored. The lift of
the control valves is increased in this
manner by the increased secondary fluid
pressure.
Conversely, a rise in primary oil pressure
causes the lift of the control valves to be
reduced.
When the pre-compression of the speed
setting spring (13) is varied with the
reference speed setter it changes the
relationship between the primary oil
pressure and the secondary fluid pressure
and hence the relationship between speed
and power output.
Lever (12) allows the link (11) to be
depressed by hand to give a lift signal to the
governor, e.g. to provide a second means of
overspeeding the machine for testing the
overspeed trips in addition to the overspeed
trip tester.
Starting and load limiting device
Before start-up, the pilot valve (21) is
brought to its bottom limit position either by
hand or remotely by the motor (20). This
causes the bellows to be compressed via
the lever (6) and the pin (7) until the
governor assumes the position Control
valves closed. With the pilot valve (21) in
the bottom limit position, control fluid from
connection a can flow simultaneously to the
auxiliary start-up fluid circuit (connection
u1) and as start-up fluid via connection u
5.1-0710-00/1
5.1-0710-00/2
Steam Turbine
Description
Function
The adjusting gear is used for manual or
motor operation of the reference speed
setter and the starting and load limiting
device.
Mode of Operation
The speed/load adjusting gear is operated
either manually or by means of motor (28).
The rotary movement of the motor shaft is
transmitted to worm wheel (15) via worm
wheel (9) and the worm attached to it.
Wormwheel (15) is located axially on the
threaded portion of the hand wheel spindle
(16) by insert (5) and the gear casing (11).
The spindle (16) is connected with bushing
(4) by a feather key so as to permit the
BHEL Haridwar
Adjusting Gear
5.1-0720-00
Steam Turbine
Description
Electro-hydraulic Converter
for Turbine Control System
Function
The electro-hydraulic converter is the
connecting element between the electrical
and hydraulic parts of the turbine control
system. It converts the signals from the
electric controller into the hydraulic signals
and amplifies them before transmitting them
to the actuating devices.
Construction
The principal components of the converter
are moving coil system (12), sleeve (10),
pilot valve (6), amplifier piston (3), follow-up
pistons (21), differential transformer (1) and
actuator (17). Bushings and follow-up
pistons A are connected to each other via
the adjusting screws (24), spring end pieces
and the springs (22). The control signals
from the electro-hydraulic controller operate
the sleeve (10) via the moving coil system
(12). This sleeve slides up and down on the
top end of the pilot valve (6) and determines
the position of the valve in the manner of a
follow-up piston. The pilot valve and sleeve
have ports which depending on the overlap,
control the amount of trip fluid flowing from
connection x. In the steady-state condition,
the pilot valve is in its center position and
the trip fluid pressure acting on the face of
the pilot valve is in equilibrium with the force
of compression spring (9). The pilot valve is
kept in rotation by control fluid flowing from
tangential holes in an integral collar to give
greater freedom of reciprocal motion and
achieve high response sensitivity.
When the pilot valve is deflected from its
center position, control fluid from connection
a is admitted to the space above or below
the amplifier piston (3) with the opposite side
of the piston opened to the fluid drain. The
resulting motion of the amplifier piston is
transmitted via lever (13) to the sleeves (20)
which in turn can slide on the following-up
pistons (21). The secondary fluid circuits,
which are fed from the trip fluid circuit via
throttles and supply the various actuating
devices, are connected at point b. The
secondary fluid pressures are determined by
the tension of springs (22) which
BHEL Haridwar
5.1-0730-02/1
5.1-0730-02/2
5.1-0730-02/3
Steam Turbine
Description
Function
The function of the hydraulic amplifier is to
amplify the signals from the hydraulic speed
governor (connection b1) so that they are
sufficient for the actuating devices.
Construction
The principal components of the amplifier
are amplifier piston (1), pilot valve (7),
follow-up piston (2) with sleeves (3),
mechanical feedback system (6) and
actuator (21). Bushings and follow-up
pistons A are connected to each other via
the setscrews (10), spring end pieces and
springs (11). Auxiliary secondary fluid flows
BHEL Haridwar
Hydraulic Amplifier
for Turbine Control System
5.1-0740-02/1
5.1-0740-02/2
5.1-0740-02/3
Steam Turbine
Description
BHEL Haridwar
5.1-0760-01
Steam Turbine
Description
Pressure Converter
Function
The pressure converter is installed in the IP
secondary oil circuit. It does not permit to
raise the IP secondary oil pressure beyond
certain value.
Construction
The pressure converter is provided with a
follow up piston (3), which slides in the
bushing (6) at the top, and in the sleeve (2)
at the bottom. The bushing and follow up
piston are connected to each other via the
set screw (9, 10) and the spring (4). There
are drainage slots in the follow up piston (3)
and sleeve (2), through which a larger or
smaller amount of fluid can flow into the fluid
return line c depending on how much they
overlap. The fluid pressure prevailing in the
follow up piston (3) is connected to the
reheat control valves for speed control via
connection x.
Mode of Operation
When the setscrew (9) of the pressure
converter has been appropriately set, IP
secondary fluid pressure is permitted to
increase to certain value.
1 Ring
2 Sleeve
3 Follow up piston
4 Spring
5 Casing
6 Bushing
7Cover
BHEL Haridwar
8 Cap
9 Set Screw
10 Set Screw
c Return flow
x IP secondary fluid
5.1-0761-00
Steam Turbine
Description
BHEL Haridwar
Stop Valve
The steam enters the valve casing (13) via
the Inlet connection and remains above the
stop disc (1). The main valve disc
incorporates a pilot disc formed from the end
of the valve steam (3). The valve stem is
sealed by packing rings (6). On the back of
the valve disc is a raised seat which comes
into contact with a neck bush (4) when the
5.1-0810-01/1
5.1-0810-01/2
Control Valves
The stem and disc (16) of the control valve
are in one piece. Balancing holes in the
valve disc reduce the operating force
required. The valve stem and disc (16) are
guided in the cover (17) and the stem is
sealed by packing rings (20). When the
valve is fully opened, the raised seat of the
valve disc rests against the neck bushing
(18) and provides additional sealing. As with
the stop valve, the valve body cover (17) is
held in the casing by a threaded ring (21)
and is sealed by U-shaped gasket (19). The
control valve is actuated by the piston of the
servomotor (26) that is operated by a cup
spring in the closing direction and
hydraulically in the opening direction.
Steam Turbine
Description
BHEL Haridwar
5.1-0811-00
Steam Turbine
Description
BHEL Haridwar
5.1-0812-00/1
5.1-0812-00/2
Steam Turbine
Description
Test Valve
for Emergency Stop Valve
Function
The function of the test valve is to open and
close the emergency stop valve, either by
start-up fluid circuit or manual operation
especially when the emergency stop valve is
being checked for easy movement.
Arrangement
Each test vale (6) and auxiliary valve (5) is
arranged in series behind a solenoid valve
(1, 2).
BHEL Haridwar
5.1-0813-00
Steam Turbine
Description
Function and Construction
One stop and one control valve are
combined in a common body with their
stems arranged at right angles to each
other. The stop valve can interrupt the
supply of steam from the reheater to the
IP and LP turbines extremely quickly. The
control valve controls the steam flow to
the IP and LP turbines on load rejection,
start-up & shutdown and remains fully
open in the upper load range to eliminate
any throttling losses. Further details of the
arrangement of the valve combination in
the control system can be seen under
section Governing system.
Reheat Stop Valve
The stop valve is a single seat valve with
integral pilot valve. Steam enters via the
BHEL Haridwar
5.1-0814-00/1
Control Valve
The control valve has a pipe-shaped
valve disc (14) that is bolted to the valve
stem (13) and slides in the bushing in the
valve cover (11) The valve disc is
provided with relieving holes to reduce the
necessary controlling force. A ring fixed in
the bushing of the valve cover prevents
the valve disc from rotating. This valve
disc also has a back sealing that operates
5.1-0814-00/2
when
the
valve
is
fully
open.
Asbestos/graphite packing rings (10) seal
the valve stem (13) in the valve cover (11).
The control valve is operated by the piston
of the servomotor (9) i.e. is opened
hydraulically and closed by disc springs.
In the event of a disturbance in the system
or on trip-out, both stop valve and control
valve close rapidly.
Steam Turbine
Description
BHEL Haridwar
5.1-0815-01
Steam Turbine
Description
Function
Steam Strainers are installed in the main
steam lines and in the hot reheat lines from
the boiler. They protect the admission
elements of the HP and IP turbines from
foreign objects, which could be picked up in
the boiler or associated piping.
Construction
The strainer screen (2) is made of
corrugated strip wound on a frame. This
BHEL Haridwar
Steam Strainer
5.1-0816-00
Steam Turbine
Description
Changeover Valve
for Bleeder Check Valve
Function
The function of the changeover valve is to
manually operate the actuator of the
bleeder check valve.
Mode of Operation
The trip fluid (connection x) holds the valve
(10) in the upper end position (illustrated)
against the force of the spring (8). The trip
fluid flows via the holes in the valve to
connection x 1 and then on to the actuator
of the bleeder check valve. The valve can
be moved downwards by means of hand
wheel (1). In this way connection x1 is
connected to the fluid drain c and the fluid
drains away from the actuator of the bleeder
check valve. The spring of the actuator can
then initiate the closing of the check valve. If
the pressure drops at the trip fluid
connection x, the spring (8) pushes the
valve (10) downwards. In this way the fluid
drain of the actuator is also freed.
1 Hand wheel
2 Spindle
3 Cap nut
4 Bush
5 Lip ring
6 Cover
7 Bush
8 Spring
9 Ball
10 Valve
11 Cover
c Drain fluid
x Trip fluid
x1 Trip fluid to actuator
BHEL Haridwar
5.1-0840-00
Steam Turbine
Description
Function
The auxiliary valve controls the fluid supply
to the extraction check valve actuators and
its function is to give the check valves a
signal to close in the case of a drop in load
or trip-out so that steam can not flow out of
bleeder lines back to the turbine. The
auxiliary valve serves several check valves.
Mode of Operation
Trip fluid is admitted through connection x
on the body (10) (section A-B). Secondary
fluid from follow-up pistons of main control
valves is admitted to the spaces above and
below the valve (11) through connection b2
As the pressure above and below the valve
(11) are equal under normal conditions, the
valve is held in the lowest position by the
force of the spring (7).
BHEL Haridwar
Auxiliary Valve
of Extraction Check Valve
5.1-0841-00/1
5.1-0841-00/2
Steam Turbine
Description
Function
The function of the rotary vane actuator
flanged to the swing-check valve is to
open or close the swing-check valve fitted
in the cold reheat line.
Operation
When the pilot valve operated by the
transformer of the speed controller
passes control fluid via connections d to
the interior of the actuator, the adjacent
connection d1 is depressurized. The
control fluid then flows through bores in
the body into the two diametrically
opposite chambers turning rotary vane (2)
on actuator shaft (8) into contact with the
BHEL Haridwar
5.1-0853-01
Steam Turbine
Description
Function
The function of the pilot valve is to control
the admission of control fluid to the moving
vane actuator in such a way that the swingcheck valve is operated in accordance with
the pressure in the secondary fluid circuit.
Mode of operation
The swing-check valve is kept open as long
as the pressure in the secondary fluid circuit
does not drop below a definite limit value. If
signal fluid enters the body via connection
b, the valve (10) is lifted against the action
of the spring (5). The initial tension of this
spring and thus the point at which the swingcheck valve opens can be adjusted. If the
valve (10) is lifted beyond the center position
illustrated, the control fluid entering at
connection a flows on to a chamber of the
actuator via connection a2 to open the
swing-check valve. Connection a1 then
communicates with the fluid return c via
passages in the body, permitting the fluid to
drain away from the actuator chambers not
supplied with control fluid. If the valve (10)
drops below the center position illustrated,
the control fluid will then be conversely
admitted to the actuator chambers in such a
way that the swing-check valve closes.
To prevent the valve (10) from seizing in its
sleeve (9) during operation control fluid is
passed through the center bore and out
through the tangential bores at the wheel
disc (8) to impart rotary movement to the
valve (10). For this reason, a thrust ball
bearing (7) and a ball (13) is fitted for this
purpose.
1 Throttle capillary tube 12 Slotted nut
2 Cap nut
13 Ball
3 Setscrew
4 Hood
5 Compression spring
6 Spring disc
7 Thrust ball bearing
8 Wheel disc
9 Valve bush
10 Valve
11 Bush
c Return
a Control fluid
b Signal fluid
a1 Control fluid(closes swing check valve)
a2 Control fluid(opens swing check valve)
BHEL Haridwar
5.1-0854-00
Steam Turbine
Description
Function
The function of the auxiliary pilot valve for
the pilot valve for the reheat check valve
actuator is to control the admission of
control fluid to the pilot valve in such a way
that the swing-check valve is actuated in
accordance with the pressure in the
secondary fluid circuit.
Operation
The swing-check valve is kept open as long
as the pressure in the secondary fluid circuit
does not drop below a definite limit value.
Secondary fluid entering body (9) via
connection b lifts spool (7) against the
action of the spring (3). The initial tension of
this spring and thus the point at which the
swing-check valve opens can be adjusted. If
spool (7) is lifted beyond its central position
as illustrated, the control fluid entering at
connection a flows on via connection a1 to
connection b of the pilot valve to open the
swing- check valve via the rotary actuator. If
spool (7) drops below its central position as
illustrated, control fluid is admitted to the
opposite chambers of the rotary actuator, so
that the swing-check valve closes.
To prevent spool (7) from seizing in its
sleeve (6) control fluid is passed through the
center bore in the spool during turbine
operation and out through tangential bores
in the upper part of spool (7) to impart rotary
motion to the spool. A deep-groove ball
bearing (5) between spool (7) and spring
retainer (4) reduces friction from the rotary
motion.
BHEL Haridwar
5.1-0855-00
Steam Turbine
Description
Function
One function of the gland steam control
valve, which is situated in the grand steam
pipe of the seal steam system, is to supply
the shaft seals with seal steam during startup and in the lower load range. A further
function is to keep the set pressure in the
header constant in order to prevent air
penetrating the vacuum of the shaft seals.
BHEL Haridwar
5.1-0860-02
Steam Turbine
Description
Function
The function of the leakage steam control
valve, which is situated in the leakage steam
pipe of the seal steam system, is to drain
excessive steam from the header in order to
keep the set pressure in the seal steam
header.
Construction and Mode of Operation
The leakage steam control valve is operated
by the pneumatic actuator. Valve is moved
in the open direction by the air pressure and
moved in closed direction by spring force.
The gland steam pressure controller feeds 4
to 20 mA control signal to the positioner
which in turn gives the corresponding air
pressure to the actuator for the operation of
leakage steam control valve.
The cross sectional view of leakage steam
control valve alongwith actuator of gland
steam system is given here.
1-Body
2-Seat
3-Plug
4-Bush
5-Packing
6-Plug stem
7-Lock Nut
8-Threaded bush
9-Retainer Ring
10-Body Gasket
11-Adaptor
12-Ext. Bonnet
13-Yoke
14-Travel Indicator
15-Coupling (Clamp)
16-Diaphragm plate
17-Diaphragm
18-Actuator casing
19-Spring
20-Actuator nut
21-1 6UNC-2B Nut
22-1 6UNC-2A Stud
BHEL HarIdwar
5.1-0870-02
Steam
Steam Turbine
Description
Function
The Function of the main trip valve is to
open the trip fluid circuit in the event of
abnormal conditions, thereby closing the
valves and thus shutting off admission of
steam to the turbine.
Construction
The main trip valve consists of mainly two
valves (12) that slide in the casing (11) and
are loaded by the springs (5,6). The valves
BHEL Haridwar
5.1-0910-00/1
Operation
When starting the unit, the valves (12) are
lifted by the aux. start up fluid (connection
u1 ) against the force of the springs (5,6)
and forced tightly against the assemblies
(10). In this way pressure is build up in the
trip fluid circuit (x) and the auxiliary trip fluid
circuit (x1). The pressure in the auxiliary trip
fluid circuit keeps the valve in the position
shown while the aux. start up fluid drains
through the start up device.
Should the fluid in the pressure in the
auxiliary trip fluid circuit drop below a
specific value for any reason (e.g. by
tripping of a protection device) the valves
5.1-0910-00/2
Steam Turbine
Description
Ball head
Limit switch
Cover
Spindle
spring
Bushing
Spring
Valve cone
Bushing
Casing
Cover
BHEL Haridwar
5.1-0911-00
Steam Turbine
Description
Function
The solenoid valve is installed in the
auxiliary trip fluid line to the automatic trip
gear and, when operated, causes the
auxiliary trip fluid circuit to be opened and
the turbine stopped, The solenoid valve is
remote-controlled electrically, e.g. from the
control room or from a protective device.
Construction
The directions of flow are indicated by
arrows on the body. The solenoid sleeve (4)
is bolted to the casing (6) and is inserted in
the magnet casing (1) with the armature (3).
The complete valve element is placed in the
body (6) and held by the plug (11). The two
valve discs (8) seal the valve seats (9). The
solenoid valve and the line to the automatic
trip gear are ventilated by means of the
screw (12).
Mode of Operation
When the solenoid (1) is not energized, the
armature (3) is moved downwards by the
spring (2) so that the valve disc (8) is
pressed against the valves seats (9) to
provide sealing. The solenoid valve is
operated by energizing the solenoid (1). The
armature and the valve discs are drawn
upwards against the force of the spring (2)
so that the auxiliary trip fluid a is linked with
the drain c and the pressure in the line to
the automatic trip gear collapses.
1
2
3
4
5
6
7
8
9
10
11
12
a
c
Magnet casing
Spring
Armature
Solenoid sleeve
Hexagonal nut
Casing
Ring
Stem with two valve discs
Valve seat
O-ring
Plug
Ventilation screw
Auxiliary trip fluid to automatic trip gear
Drain
BHEL Haridwar
5.1-0912-00
Steam Turbine
Description
1
2
3
4
Screw plug
Guide bushing
Guiding foil
Bolt/striker
5 Spring
6 Adjusting screw
7 Turbine rotor
8 Guide ring
BHEL Haridwar
5.1-0920-00
Steam Turbine
Description
Function
The function of the overspeed trip releasing
device is to open the auxiliary trip fluid circuit
and thereby shut down the turbine when an
overspeed is reached which would subject
the rotor to high centrifugal force.
Construction
The overspeed trip releasing device located
in the bearing pedestal consists of valve
bodies (4,10), pilot valve and rods (3,5,7,8),
pawls (12) and limit switch (1). The bellows
16) on the pilot valves and rods prevent
hydraulic control fluid from entering bearing
pedestals and lubrication system. When the
turbine is started up, the pilot valve, rods
and pawls are latched by auxiliary start-up
fluid u1 .
BHEL Haridwar
5.1-0921-00/1
5.1-0921-00/2
Start-up
Before restarting the turbine following a trip,
latch in the overspeed trip. This is done by
admitting auxiliary startup fluid u1 into pilot
valve body (4) and forcing the respective
pilot valve (3) outwards until rod (8) engages
the latch of the pawl. The auxiliary start-up
fluid flow is interrupted and auxiliary start-up
fluid flows via a hole to fluid drain c.
Steam Turbine
Description
Function
The function of the overspeed trip test
device is to test and exercise the overspeed
trip. The overspeed trip consists of
bolts/strikers which protrude against the
force of a spring under the effect of
centrifugal force during an overspeed
condition. The bolt/striker strikes a pawl and
thus opens the auxiliary trip fluid circuit and
in turn trip fluid circuit so that the stop and
control valves immediately interrupt the
admission of steam to the turbine. Perfect
BHEL Haridwar
5.1-0922-00/1
5.1-0922-00/2
Steam Turbine
Description
Function
The purpose of the low vacuum trip is to
operate the main trip valve when a failure
of vacuum occurs in the condenser, thus
tripping out the main and reheat stop and
control valves and shutting off the supply
of steam to the turbine within the shortest
possible time.
Operation
The condenser vacuum is connected via I
(connection to condenser) to the top side
of the diaphragm (8). The space below the
diaphragm is at atmospheric pressure.
Upon failure of the condenser to maintain
proper vacuum, diaphragm (8) is forced
downwards by the increase in pressure
and the force of the spring (7) against the
force of spring (10), thus moving valve (9)
downwards. This establishes a connection
between x1 (control fluid) and drain c so
that the auxiliary trip fluid circuit is
BHEL Haridwar
5.1-0935-00
Steam Turbine
Description
Function
The function of the condenser safety device
situated in the control fluid circuit of the
bypass control system is to protect the
condenser, when there is an excessive
increase in pressure in the condenser, by
opening the control fluid lines so that the
resulting drop in pressure causes the
bypass valves to close.
Mode of Operation
The steam space in the condenser is
connected with the spring space above the
diaphragm (5) via connection I. The space
below the diaphragm is at atmospheric
pressure. If the pressure in the condenser
increases excessively, the diaphragm (5),
and thus the valve (6), is forced downwards
out of the upper end position by the
increasing pressure and the force of the
spring (4). This shuts off the connection a1
to the bypass valve from connection. a
which is from the converter and connects it
to drain c.
The pressure range in which the vacuum
safety device operates can be varied by
adjusting the initial tension of the spring (4)
by means of the adjusting screw (2).
During commissioning the valve (6) is
automatically moved into the upper end
position, where it keeps the control fluid
circuit closed, as soon as the negative
pressure in the condenser falls below the
preset value. In order to be able to close the
control fluid circuit when there is still
insufficient vacuum in the condenser, the
valve is lifted via the lever (10) and cam (9)
but is not yet brought into its upper end
position. As already mentioned, this end
position is not reached until there is
sufficient vacuum.
After this, the lever (10) and cam (9) drop
down and do not impair the functioning of
the vacuum safety device. Any leakage fluid
can drain off through passages in the valve
sleeve (7) and the casing (8).
BHEL Hardwar
5.1-0940-00
Steam Turbine
Description
Function
When there is an unallowable rise in
condenser temperature due to lack of
injection water a temperature sensor
situated in the condenser dome sends
electric signals to the solenoid valve which
open the signal fluid circuit of the bypass
valve actuators, thereby closing the bypass
valves so that the steam flow to the
condenser is interrupted.
Mode of Operation
During normal operation, the control fluid a
holds the main control valve (7) against the
force of the compression spring (8) in the
center position as shown here, This provides
the connection between the signal fluid from
pressure switch for injection water b and
the stop and control valve operator of the
bypass stop valve b1 , If the temperature in
the condenser rises to an unallowable value,
the solenoid valve (3) is moved downwards
against the force of the compression spring
(4) so that the control fluid a arising before
the main control valve (7) is connected with
the drain c.
Simultaneously, the control fluid a can flow
behind the main valve (7) so that the main
valve moves forwards against the force of
the compression spring (6) and the signal
fluid circuit b1 is opened and connected to
the drain c and the bypass stop and control
valve closed.
BHEL Hardwar
5.1-0950-00
Steam Turbine
Description
Function
With normal shut down or tripping of the
machine, the function of the vacuum breaker
is to cause an increase in condenser
pressure by conducting atmospheric air into
the condenser together with bypass steam
flowing into the condenser from the bypass
station. When the pressure in the condenser
increases, the ventilation of the turbine
blading is increased, which causes the turbo
set to slow down so that the running down
time of the turbo set and the time needed for
passing through critical speeds are
shortened?
Partial and Total Vacuum Breakers
The partial vacuum breaker is used when
the running down time is to be shortened
with normal shut down and plant conditions
are free of disturbance. Taking blade stress
into
consideration,
the
permissible
operational condenser pressure of 0.3 bar
should not be exceeded. For this reason the
limiting value for the condenser pressure
has been set at 0.2 bar.
In special cases requiring a rapid shut down
of the turbo set, the total vacuum breaking is
employed.
Electrical Control of Partial Vacuum Breaker
BHEL Haridwar
1234567-
LP Turbine
Pressure Transmitter
Solenoid Valve
Vacuum Breaker Valve with actuator
Condenser
Condensate Pump
Water Injection Valve
5.1-0960-02-1
5.1-0960-02-2
Steam Turbine
Description
Changeover Valve
for Testing Device
Function
The function of the changeover valve is to
shut off the flow of trip fluid into the trip
fluid circuit while the protective devices
are being tested for proper operation by
means of the Automatic Turbine Tester
(ATT) and to allow control fluid a to flow
in so that the stop valves do not close
when the safety devices respond.
Mode of Operation
During normal operation, the control fluid
a1 in the space under the lower piston
(8) of the changeover valve keeps the
valve in the upper end position shown
here. In this way, connection x is
connected with connection x1 and trip
fluid can flow into the trip fluid circuit. The
space above the piston (6) (connection
a) remains depressurized during normal
operation.
When safety devices are checked for
proper operation, the space below the
lower piston (8) is depressurized by
means of a solenoid valve and control
fluid a enters the space above the upper
piston, which moves the valve into the
lower position. Due to the connection now
made between connections a and x1,
control fluid a can flow freely into the trip
fluid circuit, which keeps the stop valves
open for the duration of the test. Two limit
switches (1) transmit the position of the
valve to the control room.
1
2
3
4
5
6
7
8
Limit switch
Piston rod
Seal
Bushing
Inset
Upper piston
Sliding bushing
Lower piston
BHEL Haridwar
9 Body
10 Cover
a Control fluid
a1 Control fluid
c Fluid drain
x Trip fluid from
tripping device
x1 Trip fluid to trip
fluid circuit
5.1-0980-00
Steam Turbine
Description
MAV51 AA001
MAV41 BC001
MAV41 BC002
MAV41 AA521
MAV41 AA001
MAV42 BT001
MAV42
MAV22 AP001
MAV23 AP001
see below
see below
BHEL,HARDWAR
5.1-1000-66/1
Oil coolers
oil cooler 1
oil cooler 2
MAV41 BC001
MAV41 BC002
Technical Data
The Technical
information:
Data
contain
the
following
5.1-1000-66/2
-
The
INJECTOR
(MAV21BN001
/
MAV21BN002) ensure a positive pressure of
approx. 0.2 bar in the suction line immediately
upstream of the main oil pump.
5.1-1000-66/3
Oil vapour extractors and oil separator
oil vapour extractor1
MAV82 AN001
oil vapour extractor2
MAV82 AN002
throttle valve upstream of
MAV82 AA511
oil vapour extractor1
throttle valve upstream of
MAV82 AA512
oil vapour extractor2
check valve of
MAV82 AA001
oil vapour extractor1
check valve of
MAV82 AA002
oil vapour extractor2
oil separator
MAV82 BT001
Throttle valves downstream of bearing
pedestals
bearing pedestal 1
MAV81 AA501
bearing pedestal 2
MAV81 AA503
bearing pedestal 3
MAV81 AA505
gen. brg. pedestal
MAV81 AA507
exciter bearing pedestal
MAV81 AA511
Throttle valves of oil return lines
throttle valve
MAV81 AA521
throttle valve
MAV81 AA522
Description and function of components of the oil
vapour extraction system
The components of the oil vapour extraction system
and their function are described in the following :
BHEL, Hardwar
5.1-1001-66/1
Steam Turbine
Description
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
BHEL,HARDWAR
Information
for
operation
and
maintenance
Incorrect
valve
positions,
inadequate
protection of valves against unauthorized
actuation, incorrect turbine oil fill and discharge
procedures, and failure to isolate valves can
result
in
faulty
operation,
damage,
contamination of waste water or buildings, and
loss of turbine oil. For this reason, all
information on this subject in this system
description must be observed. In particular, the
following information must also be complied with:
5.1-1002-66-1
Steam Turbine
Description
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
5.1-1002-66/2
Steam Turbine
Description
Accompanying system diagram:
(Drawing No. 2-13100-N1103 On sheet 5.1-1001-66/2)
BHEL, Hardwar
5.1-1003-66
Steam Turbine
Description
Function
The main oil tank contains the oil necessary for
the lubrication and cooling of the bearings, for the
jacking system and for the hydraulic turning gear. It
BHEL Hardwar
8
9
Oil inlet
Riser section inlet
3
4
5
6
7
10
11
12
13
Inspection port
Oil vapour Ehauster
Level switch
Oil strainer
5.1-1010-01/1
Oil pumps
Oil Strainer
5.1-1010-01/2
Steam Turbine
Description
Function
The main oil pump is situated in the font bearing
pedestal and supplies the entire turbine with oil that is
used for bearing lubrication, cooling the shaft journals
and as primary and test oil. The main oil pump is
driven direct from the turbine shaft via the coupling
(11). If the turbo-set is out of operation or the main oil
pump fails, auxiliary oil pumps take over the
necessary oil supply. These pumps also convey oil
into the suction branch of the main oil pump until the
main oil pump has started to draw from the main oil
tank which is situated at a lower level [1].
Construction
the double flow impeller (5) is an integral part of
the pump shaft. The pressure and suction chambers
are sealed off from each other by seal rings (4) which
are split and secured against turning at the joint. The
BHEL Hardwar
pump shaft (5) runs in the journal bearing (1) and the
combined journal and thrust bearing (7). Both
bearings are lubricated with filtered 011. If the
overspeed trip test device, which is described
separately [2] is actuated, overspeed trip test oil a
flows to the overspeed trip devices via the oil tube
(16) built into the pump shaft (5).
Hydraulic Speed Transmitter
The pump shaft (5) also carries the hydraulic
speed transmitter (14) which runs in the bearing (7)
and in rings (13). The hydraulic speed transmitter
operates on the same principle as a centrifugal pump
impeller. Any change in speed gives rise to a
pressure change in primary oil circuit a1 which
serves as a control impulse for the hydraulic speed
controller. The hydraulic speed transmitter (14) is
supplied with control oil from the hydraulic control
5.1-1020-01/1
Fig. 2
5.1-1020-01/2
Steam Turbine
Description
Description
The auxiliary oil pump is a vertical one-stage
rotary pump with a radial impeller and spiral casing. It
is fixed to the cover of the oil tank and submerges
into the oil with the pump body. It is driven by an
electric motor that is bolted to the cover plate (1). The
oil enters the suction connection from underneath and
is supplied to the oil system via the pressure pipe
(18). The pump shaft has: a sleeve bearing (12) in the
pump casing and a grooved ball bearing (7) in the
bearing yoke. The bearings are lubricated from the
pressure chamber of the pump; the sleeve bearing
via a bore in the casing; the grooved ball bearing ,ia
a lube line.
Assembly
The pump is assembled before dispatch and can
be mounted on and bolted to the oil tank as a
complete unit. When connecting, care must be taken
the piping is not stressed when bolted.
Dismounting
Exchanging the Impeller
After the motor has been disassembled and the
pressure pipe disconnected. the pump must be
BHEL Hardwar
5.1-1030-01
Steam Turbine
Description
Function
The emergency oil pump is of the vertical,
centrifugal, submerged type and serves for lubrication
and cooling of the bearings during emergency
conditions.
Location
The unit is located on top of the main oil tank and
driven by a D.C. motor. The complete pump -motor
assembly is attached to mounting plate (1) which is
bolted to the top of the main oil tank.
Construction
Oil is delivered by impeller (15) via the intake (141
to volute (13) from where the oil flows through
discharge pipe (18) to the oil supply system.
BHEL Hardwar
5.1-1040-01
Steam Turbine
Description
Function
The jacking oil pump is a self-priming screwspindle pump with three spindles and internal
bearings The pump supplies the jacking oil that is
needed for lifting the shafting at low speeds [1].
Construction, Mode of Operation
The screw-spindle pump is connected vertically to
the cover plate (2) of the main oil tank via a support
(5) and immerses with the suction casing (15) into the
oil, The drive is an electric motor that is bolted to the
cover plate (2). The oil now into the suction branch of
the suction casing (15) from underneath and is
supplied to the lifting oil system by the pump via the
BHEL Hardwar
5.1-1050-00/1
throttle gap. flows via the grooved ball bearing (7) into
the support and from there back into the main oil tank.
The grooved ball bearing is lubricated with this oil.
The driving spindle is fixed by means of the grooved
ball bearing in the bearing carrier (9) that is bolted to
the pressure casing (12) of the pump.
5.1-1050-00/2
Steam Turbine
Oil Throttle
Description
Arrangement
The oil throttles arranged immediately before
the bearing in the lubricating lines serve for
adjusting the necessary amount of oil for the
bearings. While the left half of the sectional view
represents the oil throttle during oil flushing, the
right half shows the oil throttle in normal operation.
Construction
The main parts of the oil throttle are the body
(8), in which either the oil strainer (7) which is held
in place by the screw plug (6), for the flushing
process or the adjustable throttle piece (5) with
parts (1, 2, 3) for normal operation are inserted.
Operation
The flushing process is carried out before the
turbine is taken into service. After the flushing, the
oil strainer (7) as well as the screw plug (6) are to
be exchanged with the throttle piece (5) and the
screw plug (3) with the capped nut (11. By means
of the adjustable throttle piece, the cross section
of the passage is then adjusted for normal
operation, according to the necessary amount of
the lubricating oil and consequently the lubricating
oil flow adapted to the required oil exit temperature
of the bearing.
BHEL Hardwar
5.1-1080-00
Steam Turbine
Oil Throttle
Description
Arrangement
The oil throttles arranged immediately before
the bearings in the lubricating lines inside the
bearing pedestals serve for adjusting the
necessary amount of oil for the bearings. While
the Fig. 1 represents the oil throttle during normal
operation, Fig. 2 shows the oil throttle during final
stage of oil flushing.
Operation
The flushing process is carried out before the
turbine is taken into service. The strainer (7) is
BHEL Hardwar
5.1-1081-00
Steam Turbine
Description
Description
The three way temperature control valve has the
function of regulating the lubricating oil temperature
at 45 C. Possible oil flow paths for regulating the oil
temperature are:
All lubricating oil flows through oil cooler.
Lubricating oil flows through oil cooler and
bypass piping.
All lubricating oil flows through bypass piping.
Valve Type
Three way Angle Valve with Electric Actuator.
BHEL Hardwar
5.1-1090-01
Steam Turbine
Description
Description
The extraction or dual pressure pump is a
vertical rotary pump in multiple stages. It is attached
to the cover of the fluid tank and submerges in the
control fluid. Drive is provided by an electric motor
located on the cover plate (1). Control fluid enters
the suction casing (10) from below and is conducted
into the LP control fluid circuit via the pressure pipe
(19) and into the HP control fluid circuit via pressure
pipe (23). The pump shaft is guided by a sleeve
bearing (11) in the suction casing and by ball
bearings (25) in the bearing support (4). The ball
bearings and the bevel gear coupling are lubricated
by oil from the 1st stage pressure chamber via
lubricating pipe (22).The sleeve bearing is lubricated
via a passage in the casing.
Assembly
The pump is delivered in assembled state and
can be placed as a unit on the tank and bolted to it.
When connecting the pressure pipe care must be
taken that the piping is not stressed when bolted.
Exchanging the Rotors
When the motor has been dismantled and the
pressure piping removed. the pump must be
extracted as a unit from the tank. After the suction
casing has been removed and the rotating wheel nut
loosened, the 1 st stage rotating wheel can be
extracted. In order to dismantle the other stages, the
baffle ring and then the stage casing are removed. It
is expedient to renew the seal rings when
exchanging the rotating wheels. The new clearance
between seal ring and the neck of the rotating wheel
is 0.3 mm in diameter. The pump is assembled in
the reversed sequence.
Exchanging the Bearings (11 and 25)
The pump is first taken apart; loosen pump
casing from pressure piping and bearing support
from the cover plate; remove coupling half from the
shaft by means of special device; remove bearing
securing device; loosen nut (2) and ball bearings
(25). The pump is assembled in the reversed
sequence.
Adjusting Pump Rotor
During assembly the shaft is supported by the
sealing ring of the suction casing. The shaft is lifted
by means of the nut (2) until the rotor with shaft
shoulder and distance ring (24) sits firmly on the
inner ring of the ball bearing. Bearing nut is then
secured with threaded pin.
BHEL Hardwar
5.1-1110-00
Steam Turbine
Description
Plate-type Filter
BHEL Haridwar
5.1-1120-00
Steam Turbine
Description
Function
Duplex filters permit the dirty fiter elements to be
cleaned during operation.
Construction
The Duplex filter consists of two filter bodies and
is fitted with a change-over device which enables the
filter to be switched as desired. The filter bodies are
designed according to the pressure stage and the
relevant codes and the filter itself is designed to
provide safety taking into account the differential
Duplex Filter
for Pilot Control of Control Valves
pressures.
BHEL Hardwar
5.1-1130-00/1
5.1-1130-00/2
2.2
2.3
3.
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
4.
Cleaning Agents
Suitable cleaning agents are e.g. air,
water,
steam,
Tri-Perchlorethylene,
petrol, benzene, diesel oil, etc.
The application depends on their cleaning
capacity and their compatibility with the
media to be filtered.
5.1-1130-00/3
Steam Turbine
Description
General
Of the various types of fire resistant fluid, the
only ones suitable for use with our turbines are
phosphoric esters of the group HS-D which have
a low water and chlorine content.
Their chemical composition and structure
necessitate certain measures and alterations
compared with an oil system.
Fire resistant fluid systems for our turbines
are provided with a bypass regenerating plant.
The design of this plant is made to the
specifications of the fluid manufacturer. Any
acids and ageing products are removed during
operation by continuous filtering through
Fullers-earth and mechanical filters.
The mode of operation of this natural earth
treatment is based on a ion-exchange reaction.
In addition to the precautions against acidifying
of the fluid, continuous care is taken that any
solid particles are separated by the fine filter so
that they can not speed up the reaction. The fine
filter of this plant retains particles of Fullers
earth as well as providing the essential
cleanliness of the whole system and increasing
the life of the filters.
BHEL Haridwar
Regenerating Plant
5.1-1140-00/1
5.1-1140-00/2
5.1-1140-00/3
Steam Turbine
Description
System Diagram
MAL
MAG
BHEL, Hardwar
5.1-1210-66/1
Steam Turbine
Description
System Diagram
Index
System Diagram
MAN
LCE
MAA
MAB
MAC
HP-IP-LP Scheme
HP-IP-LP Scheme
HP-IP-LP Scheme
BHEL, Hardwar
5.1-1220-66/1
Steam Turbine
Description
Component Diagram
Index
Component Diagram
MAA
on sheet 5.1-1230-66/3
MAB
on sheet 5.1-1230-66/4
MAN
on sheet 5.1-1230-66/5
MAW
on sheet 5.1-1230-66/6
on sheet 5.1-1230-66/7
MAD
BHEL, HARDWAR
5.1-1230-66-1
Steam Turbine
Description
ACOMPANYING SYSTEM DIAGRAMS
Drg nos. 1-13100-91121 & 3-13100-N1122 on Sheet nos.
5.1-1240-66/4 & 5.1-1240-66/5
Process engineering function of the shaft seal steam
system
The process engineering function of the shaft seal
steam system is to prevent the escape of shaft seal
steam from the turbine to the atmosphere and the ingress
of air into the turbine and the condenser. The provision is
also made for drawing the leak off steam from U-Ring, in
case of failure, the spindles of Main Steam Stop & Control
valves, HRH Steam Stop & Control Valves and LPBP
Stop & Control Valves under leak off steam system.
The subsystems of the shaft seal steam system have
the following functions:
Seal and leakoff steam system
exhausting of leakoff steam from shaft seals
having a positive internal pressure and from valve
stem seals.
supplying the shaft seals having a subatmospheric internal pressure with seal steam.
admission of excess leakoff steam to the
condenser.
Leakage steam system
exhausting of leakage steam from the leakage
steam chambers of the shaft seals.
condensing of leakage steam in the seal steam
condenser.
exhausting of leakage steam to atmosphere
during faulted seal steam condenser operation.
extraction of air from the seal steam condenser
using one of the leakoff steam condenser
exhausters.
Leakage steam condensate system
exhausting of leakage steam condensate to the
waste water system.
Components of the shaft seal steam system
In addition to piping, monitoring equipment and
manually operated valves, the following equipment and
valves are necessary for operation of the shaft seal steam
system:
Seal steam supply System
Seal steam control valve
MAW10AA001
Motor-operated bypass valve
MAW15AA001
Valve upstream/downstream of seal steam control
valve
-upstream of seal steam
MAW10AA010
control valve
-downstream of seal steam
MAW10AA512
control valve
Leakoff steam discharge system
Leakoff steam control valve
MAW50AA001
Motor-operated bypass valve
MAW55AA001
Valve upstream/downstream of leakoff control valve
- upstream of leakoff steam
MAW50AA010
of control valve
- downstream of leakoff steam
MAW50 AA512
control valve
BHEL,HARDWAR
5.1-1240-66/1
5.1-1240-66/2
5.1-1240-66/3
Steam Turbine
Description
Introduction
BHEL Hardwar
5.2-0001-01
Steam Turbine
Operation Control
Fluid
Steam Purity
The steam purity must comply with the guideline
on Steam Purity (1) before startup and power
operation is begun.
Blade deposits reduce the efficiency. Deposits
can only be removed by time-consuming processes
[2] and occur during power operation when normal
values are exceeded.
Immediate corrective action must be taken to
restore the required steam Quality specified in the
guideline [1].
Turbine Oil
Oil Specifications guideline [3] lists the
requirements for the operating fluid. Also
Control Fluid
The guideline Control Fluid [5] has the
requirements for this operating fluid. The
maintenance instruction Care of Control Fluid [6]
should also be followed. Regular sampling and
laboratory checks will indicate that the control fluid
complies with the specifications.
The purity (freedom from liquid and solid
impurities),
neutralization
coefficient
as a
characteristic for aging, air-release properties and
foaming characteristics of the fluid are important to
the functioning of the turbine generator units
components.
[1] 5.1-0120
[2] 5.3-0070
[3] 5.1-0310
[4] 5.3-0080
[5] 5.1-0140
[6] 5.3-0082
BHEL Hardwar
5.2-0002-00
Steam Turbine
Operation
General
Introduction
The operational reliability and availability of a
turbine is assured only if all the vital components and
monitoring equipment for operation are in the specified
condition at all times.
This applies particularly to :
controllers
protective devices
safety devices
stop and control valves and other important turbine
valves
monitoring equipment
Testing Intervals
The following recommendations, for time Intervals
between tests have been compiled, on the basis of
experience gained by the turbine manufacturer and the
operators.
BHEL Hardiwar
Performance of Tests
Tests are generally performed by the operators
properly qualified plant personnel.
As a rule the performance testing should be
executed immediately after maintenance or overhaul
activities, such as major inspection, in the presence of
concerned
qualified
personnel
form
BHEL.
5.2-0020-00
Turbine Governor
- function
- setting
Plant Status
Running
yearly
monthly
Test Cycle
After start-up
weekly
COMPONENT
- Type of test
shutdown
Steam Turbine
Operation
X
X
X
X
X
X
X
X
X
X
Fluid Temperature
Controller
- function
Oil Temperature
Controller
- function
BHEL Hardwar
5.2-0021-01
Steam Turbine
Operation
Automatic
Tester for
Devices
-
Running
shutdown
Plant Status
yearly
monthly
Test Cycle
After start-up
weekly
COMPONENT
- Type of test
Turbine
Protective
functioning of remote
trip solenoid
functioning & setting of
overspeed trips
functioning & setting of
hydraulic
low
vacuum trip
BHEL Hardwar
5.2-0022-01
Steam Turbine
Operation
Automatic
Turbine
Tester for Stop & Control
valves
- free movement of stop
valves
- free
movement
of
control valves
BHEL Hardwar
Running
shutdown
Plant Status
yearly
monthly
Test Cycle
After start-up
weekly
COMPONENT
- Type of test
5.2-0023-01
Steam Turbine
shutdown
running
Plant
Status
After shutdown>1
month
During or after overhaul
Test Cycle
After start -Up
Yearly
Component
Type of test
Weekly
Monthly
Operation
Turbine Systems-Testing
x
x
1
1
BHEL Hardwar
x
x
x
x
x
x
x
x
x
x
5.2-0024-01
Safety Valves
- functioning and set pressure
Shutdown
Running
Plant
Status
During or after overhaul
Test Cycle
After start Up
After shutdown>1 month
Component
Type of test
Weekly
Yearly
Operation
Turbine Systems-Testing
Monthly
Steam Turbine
x
x
x
x
x
x
x
x
x
x
x
x
BHEL Hardwar
5.2-0025-01
Operation
Control Valve
- free movement
using starting and load limiting device.
test gear or trip actuation
- leak tightness
(in conjunction with test of reverse power protection at
each shutdown)
- free movement
(observe control valves lift at each load change)
Extraction Valves
- free movement
by observation of position indicators
BHEL Hardwar
x
x
x
x
2-4
Shutdown
Running
Vacuum Breaker
- functioning at each shutdown
CRH NRV
- free movement
by operating pushbutton on desk
Stop Valve
- free movement
using starting and load limiting device.
test valve or trip actuation
- breakaway pressure
- leak tightness at each startup
Plant
Status
After shutdown>1month
Yearly
Test Cycle
After start -Up
Monthly
Component
Type of test
Weekly
Steam Turbine
5.2-0026-01
Plant Status
Alarms
- functioning
Binary
Signal
Transmitters
- functioning and setting
Speed Indicators
Temperature Gauges
Expansion
Measuring
Devices
Vibration
Measuring
Devices
liquid Level Measuring
Devices
Valve lift Transducers
- accuracy of indication
BHEL Hardwar
Running
yearly
monthly
Test Cycle
After start-up
weekly
COMPONENT
- Type of test
shutdown
Steam Turbine
Operation
5.2-0027-01
BHEL Hardwar
Shutdown
Running
Steam Pressures
Steam Temperatures
Steam Mass Flow Rates
Casing Temperatures
Bearing Metal Temperatures
Expansion
Vibration
liquid Levels
Oil Pressures
Oil Temperatures
Control Fluid Pressures
Control Fluid Temperatures
- recording of operating values for long term monitoring
purposes
Plant
Status
After shutdown>1 month
Test Cycle
After start -Up
Yearly
Component
Type of test
Weekly
Turbine Systems-Testing
Testing Intervals- Operating Parameters
Monthly
Steam Turbine
Operation
5.2-0028-01
Steam Turbine
Operation
Introduction
Startup of the turbine and auxiliary systems
must always be performed to ensure
operational reliability and economy.
Startup is a phase where almost all
operating values are subject to change.
Monitoring of these transient operating
state by the monitoring instrumentation
demands close attention.
It is very important that all control
operations are always performed in the
recommended sequence.
To fulfill these requirements, startup
schematics are prepared to show all control
operations and monitoring criteria for the
turbine and its auxiliary systems.
The startup schematics of the turbine
manual are compiled so that with their help
BHEL Hardwar
5.2-0110-01
Steam Turbine
Operation
Symbols
BHEL Hardwar
5.2-0111-00
(01)
(02)
(03)
(04)
(05)
Steam Turbine
Start of Turbine/Generator
Operation
+ TURBINE/GENERATOR START UP
PREPARE
+ PREPARATION FOR START UP
COMPLETED
+ EXTERNAL SYSTEMS READY FOR OPERATION
CHECK
CIRCULATING WATER FOR CONDENSER
AVAILABLE
COOLING WATER FOR COOLERS
AVAILABLE
AUXILIARY STEAM
AVAILABLE
DEMINERALIZED WATER SUPPLY
AVAILABLE
CONDENSATE SYSTEM
READY FOR OPRN.
VACUUM PUMP
READY FOR OPRN.
THE EXTERNAL SYSTEMS DO NOT BELONG TO
THE SCOPE OF SUPPLY (TURBINE/GENERATOR).
POSITION OF VALVES ACCORDING TO SINGLE
LINE DIAGRAMS OF SYSTEMS.
INSTRUCTIONS OF EXTERNAL SYSTEMS MUST
COMPLY WITH TURBINE OPERATION.
+ EXTERNAL SYSTEMS
READY FOR OPRN.
+ OIL SYSTEM AND TURNING GEAR
START
START OF OIL SYSTEM APPROX.6 HOURS
PRIOR TO TURBINE START.EXTEND
TIME IN ADVANCE OF TURBINE START IF
OIL TEMPERATURES ARE EXTREMELY LOW.
WITH FGA (OIL SUPPLY)
OR
MANUAL OPERATION AT OPER. CONSOLE
FGA=FUNCTIONAL GROUP AUTOMATIC
+ SHAFT
TURNS
CF-RECONDITIONING-PLANT AND HEATERS
IN OPERATION
PRIOR TO CONTROL FL PUMP OPERATION THE
CONTROL FLUID TEMPERATURE SHOULD BE
> 20C
TEMP. RATE DURING HEATER OPERATION
1-2 K / HOUR
START OF OPERATION OF RECONDITIONING
AND HEATERS IN ACCORDANCE WITH INITIAL
TEMPERATURE AND HEATING RATE.
OPERATE RECONDITIONING PLANT CONTINUOUSLY
IF NEUTRALISATION NUMBER TENDS TO INCREASE
+ TEMPERATURE IN CONTROL FLUID TANK
> 20C
+ CONTROL FLUID SYSTEM
START
WITH FGA (CONTROL FLUID SYSTEM)
OR
MANUAL OPER.AT OPER.CONSQLE
+ CONTROL FLUID SYSTEM
IN OPERATION
+ CONDENSING PLANT
START
TIMING OF CONDESING-PLANT START MUST
AGREE WITH TIMING OF FIRST STEAM ENTERING
THE CONDENSING PLANT
THE CONDENSING PLANT DOES NOT BELONG TO
THE SCOPE OF SUPPLY (TURBINE/GENERATOR).
POSITION OF VALVES ACCORDING TO SINGLE
LINE DIAGRAM OF SYSTEMS.
INSTRUCTIONS OF THE MANUFACTURER OF THE
CONDENSING PLANT MUST AGREE WITH TURBINE
OPERATION.
+ CONDENSATE PUMPS
ON
WITH FGA (CONDENSING PLANT)
OR
MANUAL OPER.AT OPER.CONSOLE
BHEL Hardwar
REF. TO 5.2-0133
REF. TO 5.2-0130
REF. TO 5.2-0135
REF.TO 5.2-0140
5.2-0112-00/1
(06)
(07)
(08)
(09)
(10)
(11)
(12)
(13)
VACUUM PUMPS
WITH FGA (CONDENSING PLANT) :
OR
WITH SLC(AIR REMOVAL)
OR
MANUAL OPER, AT OPER, CONSOLE
ON
ON
< P AMB
> P AMB
CHECK
IN OPERATION
FULFILLED
OBSERVE
WARM UP
WARMED UP
CHECK
WARM UP
SPEED UP
REF. TO 5.2-0160
3000 RPM
FULFILLED
SYNCHRONISED
+ LOADING CRITERIA
FULFILLED
5.2-0112-00/2
REF. TO 5.2-0160
WARMED UP
FULFILLED
+ GENERATOR BREAKER
WITH FGA (TURBINE CONTROL)
OR
AUTOMATIC SYNCHRONISER
+ GENARATOR
+ TURBINE/GENERATOR
REF. TO 5.2-0150
REF. TO 5.2-0160
ON
LOAD
REF. TO 5.2-0210
REF. TO 5.2-0210
Steam Turbine
Operation
Startup Diagram
(01)
PRESERVATION DEVICES
AIR DRYER
CONNECTING FLANGES
AIR OUTLET SOCKETS
REMOVE
REMOVED
CLOSED
CLOSED
(02)
INSPECTION OPENINGS
MAN-OR HANDHOLES IN
- LP TURBINE
- CROSS AROUND PIPES
- CONDENSER
CLOSE
(03)
+
+
+
+
+
+
+
+
+
VOLTAGE SUPPLY
DRIVES
REMOTE CONTROLS
CONTROLS
MEASURING DEVICES
ALARM DEVICES
SUPERVISORY EQUIPMENT
PROTECTIVE DEVICES
TESTING DEVICES
(04)
(05)
+
+
+
+
(06)
+
+
+
+
+
LIQUID LEVELS
LEVEL OF CONDENSER
LEVEL. IN U-LOOPS
LEVEL OF OIL TANK
LEVEL OF CONTROL FIUID TANK
(07)
FILTERS
(08)
(09)
(10)
+
+
+
+
+
+
+
+
BHEL Hardwar
SWITCH ON
ENERGISED
ENERGISED
ENERGISED
ENERGISED
ENERGISED
ENERGISED
ENERGISED
ENERGISED
CHECK
REPLACED
CHECK
CARRIED OUT
SWITCHED ON
TIME ADJUSTED
CHECK
NORMAL
NORMAL
NORMAL
NORMAL
CLEAN
CHECK
FILLED
IN OPERATION
IN OPERATION
IN OPERATION
ON
NO ALARM
NO ALARM
5.2-0113-00
Steam Turbine
Operating Position of
Operation
Introduction
BHEL Hardwar
Operating positions
Open
Closed
Mode-Dep.
Permset
Operational
=
=
/FG
Mode-dependent
(position varies with
mode of operation,
cannot be classed as
Open or Closed) .
permanently set
ready to opetate (e,g,
control valves)
Position cannot be
controlled
manually
(controlled
by
automatic
functional
group controls or by
medium carried)
5.2-0120-00
Steam Turbine
Operation
(01)
+
-
CHECK
CHECKED
AND IN POSITION
OPEN
OPEN
OPEN
OPEN
OPEN
OPEN
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
IN SERVICE
IN SERVICE
ADJUSTED
BHEL Hardwar
CHECKED
AND IN POSITION
ADJUSTED
ADJUSTED
CLOSED
OPEN
OPEN
ADJUSTED
MAV22 APOO1
MAV23 APOO1
MAV24 APOO1
MAV31 AP 0 01
MAV32 APOO1
MAV33 APOO1
SWITCH ON
SWITCH ON
NORMAL
ON
OR
OR READY FOR OPRN
OR
ON
OR
OR READY FOR OPRN
OR
ON
MAV82 ANOO1
MAV82 AN002
MAV82 ANOO2
MAV82AN-OO1
MKO31 ANOO1
MKO32 ANOO1
MKO32 ANOO1
MKO31 ANOO1
----------------------
5.2-0130-02/1
IN SERVICE
AVAILABLE
FILLED
MAV41 BCOO1
AND VENTED OR MAV41 BCOO2
VENTED
DRAINED
MAV41 BCOO1
AND DRIED OR MAV41 BCOO2
(02)
5.2-0130-02/2
MAV41 BCOO1
OR MAV41 BC002
ON
NORMAL
MAV10 CL521
CHECK
ADJUSTED
FILLED
> 95%
MKG25 CQO01
ON
MKW11 APOO1
OR MKW21 APOO1
OFF
MKW21 APOO1
OR MKW11 APOO1
AND MKW31 APOO1
ON
MKW13 APOO1
ON
-------------------AND -------------------
(O3)
NO ALARM
NO ALARM
CHECK
OFF
(04)
.
(05)
OFF
MAV22 APOO1
AND MAV23 APOO1
MAV24 APOO1
CLOSED
MAV51 AAO01
OFF
OFF
MAV51 EEO01
MAV22 EEOO1
OFF
OFF
MAV24 EEO01
MAV31APOO1
AND MAV32 APOO1
AND MAV33 APO01
AND
+ SBULOOP CONTROL JACKING OIL PUMPS
OFF
MA V30 EEOO 1
AND MAV33 EEO01
START
ON
MAV22 APO01
OR MAV23 APO01
ON
MAV22 APO01
OR MAV23 APO01
(06)
+
+
+
+
+
ON
FAULTED
ON
> 5 KG/CM2
>1.2 KG/CM2
NOALARM
NO ALARM
NOT HIGH
NOT LOW
NOT INITIATED
MAV22 APO01
MAV22 APO01
MAV23 APO01
MAV21 CPO01
MAV42 CPO01
MAV1O CLOO1
MAV42 CP013
MAV42 CPO14
MAV42 B1001
OPEN
OPEN
MAV51 AAO01
MAV51 AAOOl
SWITCH ON
ON
MA V 51 EEOO1
MAV 51 EEO01
5.2-0130-02/3
(06/S) +
(7)
ON
MAV51 EEO01
ON
< 210 RPM
> 240 RPM
+
+
SWITCH ON
+
+
+
(07/S) *+
(08)
SWITCH ON
ON
ON
ON
+
+
+
+
+
=
CHECK
> P MIN MKW71 CP511
> P MIN MKW71 CP521
> P MIN MKW73 CP511
< P MIN MKW73 CP521
ON
ON
ON
5.2-0130-02/4
MAV31 APO01,
OR MAV32 APO01
MAV31 APOOl
OR MAV32 APO01
AND
SUBLOOP CONTROL STARTS THE JACKING OIL
PUMP 2 DEPENDING ON JACKING OIL PRESSURE
5.2-0130-02/5
Steam Turbine
Operation
(01)
+
-
CHECK
CHECKED
AND IN POSITION
OPEN
OPEN
OPEN
OPEN
OPEN
OPEN
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
IN SERVICE
IN SERVICE
ADJUSTED
BHEL Hardwar
CHECKED
AND IN POSITION
ADJUSTED
ADJUSTED
CLOSED
OPEN
OPEN
ADJUSTED
MAV22 APOO1
MAV23 APOO1
MAV24 APOO1
MAV31 AP 0 01
MAV33 APOO1
SWITCH ON
SWITCH ON
NORMAL
ON
OR
OR READY FOR OPRN
OR
ON
OR
OR READY FOR OPRN
OR
ON
MAV82 ANOO1
MAV82 AN002
MAV82 ANOO2
MAV82AN-OO1
MKO31 ANOO1
MKO32 ANOO1
MKO32 ANOO1
MKO31 ANOO1
----------------------
5.2-0130-51/1
IN SERVICE
AVAILABLE
FILLED
MAV41 BCOO1
AND VENTED OR MAV41 BCOO2
VENTED
DRAINED
MAV41 BCOO1
AND DRIED OR MAV41 BCOO2
(02)
5.2-0130-51/2
MAV41 BCOO1
OR MAV41 BC002
ON
NORMAL
MAV10 CL521
CHECK
ADJUSTED
FILLED
> 95%
MKG25 CQO01
ON
MKW11 APOO1
OR MKW21 APOO1
OFF
MKW21 APOO1
OR MKW11 APOO1
AND MKW31 APOO1
ON
MKW13 APOO1
ON
-------------------AND -------------------
(O3)
NO ALARM
NO ALARM
CHECK
OFF
(04)
.
(05)
OFF
MAV22 APOO1
AND MAV23 APOO1
MAV24 APOO1
CLOSED
MAV51 AAO01
OFF
OFF
MAV51 EEO01
MAV22 EEOO1
OFF
OFF
MAV24 EEO01
MAV31APOO1
AND MAV33 APO01
AND
+ SBULOOP CONTROL JACKING OIL PUMPS
OFF
MA V30 EEOO 1
AND MAV33 EEO01
START
ON
MAV22 APO01
OR MAV23 APO01
ON
MAV22 APO01
OR MAV23 APO01
(06)
+
+
+
+
+
ON
FAULTED
ON
> 5 KG/CM2
>1.2 KG/CM2
NOALARM
NO ALARM
NOT HIGH
NOT LOW
NOT INITIATED
MAV22 APO01
MAV22 APO01
MAV23 APO01
MAV21 CP901
MAV42 CP901
MAV1O CLOO1
MAV42 CP013
MAV42 CPO14
MAV42 B1001
OPEN
OPEN
MAV51 AAO01
MAV51 AAOOl
SWITCH ON
ON
MA V 51 EEOO1
MAV 51 EEO01
5.2-0130-51/3
(06/S) +
(7)
ON
MAV51 EEO01
ON
< 210 RPM
> 240 RPM
+
+
SWITCH ON
+
+
+
(07/S) *+
(08)
SWITCH ON
ON
ON
ON
+
+
+
+
+
=
CHECK
> P MIN MKW71 CP511
> P MIN MKW71 CP521
> P MIN MKW73 CP511
< P MIN MKW73 CP521
ON
5.2-0130-51/4
ON
ON
MAV31 APO01
MAV31 APO01
SWITCH ON
AND
ON
MA V31 EEOO1
MAV33 EEOO1
MAV33 EEOO1
ON
AND
ON
FAULTED
ON
MAV30 EEO01
MAV33EEOO1
MAV31 APOO1
MAV31 APO01
MAV33 APO01
AND
SUBLOOP CONTROL STARTS THE JACKING OIL
PUMP 2 DEPENDING ON JACKING OIL PRESSURE
5.2-0130-51/5
(01)
Steam Turbine
Condensing Plant
Operation
Startup Diagram
CHECK
CHECKED
AND IN POSITION
OPEN
OPEN
OPEN
OPEN
OPEN
CLOSED
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CHECKED
AND IN POSITION
VALVE AHEAD OF SEAL-STEAM CONDENSER
OPEN
VALVE IN SEAL STEAM LINE TO ATMOSPHERE
CLOSED
ISOLATING VALVES BEF/BEH SEAL STEAM SUPPLY LINE
OPEN
BYPASS VALVE OF SEAL STEAM SUPPLY LINE
CLOSED
BYPASS VALVE OF SEAL STEAM LEAK-OFF VALVE
CLOSED
THROTTLE VALVES IN VAPOUR LINES
ADJUSTED
VALVES IN AIR SUCTION LINES
OPEN
ISOLATING VALVES IN AIR SUCTION LINES
CLOSED
VALVES IN AIR SUCTION LINES
OPEN
FROM AIRCOOLER OF CONDENSER
VALVES IN SEALING WATER-LINES
OPEN
FOR VACUUM VALVES
VALVES IN SEALING WATER-LINES
OPEN
FOR VACUUM BREAKER
VALVES IN SPRAY-WATER-LINES
OPEN
FOR STAND- PIPES
OPEN
VALVES BEHIND VACUUM BREAKER
OPEN
LEVEL OF CONDENSER
NORMAL
LEVEL IN U-LOOPS
NORMAL
U-LOOPS FILLED BY MEANS OF
FILLING VALVES
SET-POINT SEAL STEAM CONTROLLER
>P AMB
FIX SETTING
BHEL Haridwar
5.2-0140-02/1
(02)
+
+
(03)
VACUUM PUMPS
THE VACUUM PUMPS
DO NOT BELONG TO THE SCOPE OF
SUPPLY<TURBINE/GENERATOR>
OPERATIONAL READINESS ACC.
TO SPECIAL INSTRUCTIONS
+
+
+
+
+
+
+
5.2-0140-02/2
CHECK
AVAILABLE
IN OPERATION
AVAILABLE
CHECK
IN OPERATION
IN OPERATION
CLOSED
OFF
CLOSED
CLOSED
OFF
AND OFF
CLOSED
REF TO S.2.0130
REF TO S.2.0135
MAL81AA001
MAW11AA001
MAW10AA001
MAW80AN002
(04)
(05)
(06)
OPEN
OPEN
MALe-1AA011
MAL81AA011
SWITCH ON
OPEN
SWITCH ON
ON
AND
+ SEAL-STEAM CONTROL
+ SEAL-STEAM CONTROL
AND
+ WARM-UP VALVE SEAL STEAM
+ WARM-UP VALVE SEAL STEAM
+ WARM-UP CONTR. <SEAL-STEAM>
+ WARM-UP CONTR. <SEAL-STEAM>
SLC <SEAL-STEAM
SLC=SUBLOOP CONTROL
(06/S)*+ SEAL STEAM EXHAUST FAN
MALOOEEO01
MAL81AA011
MAW80ANO01
OR MAW80AN001
MAW80ANO01
OR MAW80ANO02
SWITCH ON
ON
OPEN
OPEN
SWITCH ON
ON
ON
OR
MAW11AA011
MAW11AA011
MAW80ANO01
MAW80ANO02
AND
(06/S)*+ SEAL-STEAM CONTROL
AND
(06/S)*+ WARM-UP CONTR. <SEAL-STEAM>
BY STEAM FLOW THROUGH THE
WARM-UP VALVE THE STEAMTEMPERATURE UPSTREAM OFTHE
SEAL-STEAM SUPPLY VALVE
WILL BE INCREASED UNTIL THE
REQUIRED TEMPERATURE WILL
BE REACHED.
THE SEAL STEAM SUPPLY VALVE
MUST NOT BE OPENED UNTIL
THE TEMPERATURE CRITERIA
IS FULFILLED AND A MINIMUM
VACUUM IS REACHED IN THE
CONDENSER.
CRITERIA FOR OPENING THE
SEAL STEAM SUPPLY VALVE
STEAM-TEMPERATURE
VACUUM
ON
ON
5.2-0140-02/3
(07)
+ VACUUM-PUMPS
THE VACUUM PUMPS DO NOT BELONG
TO THE SCOPE OF SUPPLY OF THE
<TURBINE/GENERA TOR>.
OPERATION OF PUMPS AND VALVES .
FOR AIR REMOVAL PRIOR TO AND
DURING OPERATION ,\CCORDING
TO SPECIAL INSTRUCTIONS. .
IOPERATION OF PUMPS AND VALVES
FOR AIR REMOVAL PRIOR TO AND
DURING OPERATION REFER
TO PLANT-MANUAL
+ VACUUM-PUMPS
SWITCH ON
ON
AND
(08)
(08/S)*+
+ VACUUM
MAJ60ANO01
MAJ70ANO01
MAG10CPO01
MAW10CTO01
OPENINGOFSEAL-STEAMSUPPLYVLV
(10)
OPEN
OPEN
ON
AND
< 0.7 BAR
(09) * +
VACUUM PUMP
MAJ60ANO01
MAJ70ANO01
VACUUM
OBSERVE
>P AMB
< 0.15 BAR
CHANGEOVER
GENERAL OUTLINE:
+ SERVICE VACUUM PUMP
AND
+ STARTUP A. STANDBY VACUUM PUMPS
5.2-0140-02/4
ON
CFF
MAW11AAO01
MAW20CPO01
Steam Turbine
Description
(01)
Bypass-System
Start of Operation
CHECK
CHECKED
AND IN POSITION
+ BYPASS-CONTROLLER ON
+ BYPASS-CONTROLLER
+ FIXPRESSUREREFERENCEVALUE
THE SETTING OF THE FIX
PRESSURE REFERENCE VALUE
DEPENDS ON THE REQUIREMENTS
OF THE STEAM-GENERATOR
F.E. THE SYSTEM FLOW THROUGH
THEREHEATER.
THE SETPOINT HAS TO BE
RAISED DURING STARTUP TO
MEETTHE DESIGN-VALUE FOR
MINIMUM LOAD OF THE STEAMGENERATOR.
FIX PRESSURE REFERENCE
VALUE AS DESIGNED.
+ HYDRAULIC PRESSURE SWITCH
THE H(DRAULIC PRESSURE
SWITCH MUST ONLY BE
BLOCKED FOR THE PURPOSE
OF TESTING.
(02)
KG/CM2
...KG/CM2
DELOCKED
CHECK
AVAILABLE
+ CONDENSATE PUMPS
IN OPERATION
+ VACUUM-PUMPS
IN OPERATION
+ VACUUM
(03)
NOT FAULTED
BHEL Hardwar
5.2-0150-00/1
+ Oil SYSTEM
IN OPERATION
+ TURNING GEAR
IN OPERATION
IN OPERATION
+ VACUUM-PUMPS
IN OPERATION
+ VACUUM
(04)
(05)
(06)
CHECK
+ STEAM-GENERATOR
IN OPERATION
RELATION < 1
CHECK
CLOSED MAN11AAO01
AND MAN12AAO01
CLOSED
AND
+ REHEATPRESSURE/FIXPRESS.
REF. VALUE
RELATION = 1
+ START OF BYPASS-OPERATION
BYPASS OPERATION STARTS IF
THE STEAM PRESSURE UPSTREAM
OF THE BYPASS VALVE MEETS
THE PRESS-REFERENCE VALUE.
* + BYPASS STOP VALVE
OBSERVE
OPENS
AND
OPEN
OPENS
AND
+ INTERLOCKS OF BYPASS-CONTROLS
THE BYPASS-CONTROL AND
STOP VALVES CLOSE IF THE
FOLLOWING CRITERIAARE
FULFILLED:
VACUUM
SPRAYWATERPRESSURE
5.2-0150-00/2
MAN11AAO02
MAN12AAO02
MAN11AAO01
MAN12AAO01
MAN11AAO02
MAN12AAO02
NOT INITIATED
(07)
+ LIFT OF BYPASS-CONTROL-VALVES
100%
SETHIGHER
HIGHER
+ LIFT OF BYPASS-CONTROL-VALVES
THIS CASE CAN OCCUR IF
THE FIXPRESSURE REFERENCE
VALUE HAS BEEN REDUCED
BELOW THE DESIGN VALUE
DURING STARTUP.
< 100%
5.2-0150-00/3
(01)
Steam Turbine
Operation
Startup Diagram
CHECK
CHECK
OPEN.
OPEN
OPEN
ON
NOT FAULTED
< N TURN GEAR
0%
100 %
ON
NOT FAULTED
MAX47 BYOO1
MAX46 BYOO1
ON
REFER TO 5.2-0430
REFER TO 5.1-011.
NO ALARM
MAY10 AAO01
AND MAY10 AAO02
> 20 %
NO ALARM
NO ALARM
< 90C
< 30C
< 30C
MAA50 CT051
AND MAA50 CT052
MAB50 CT0 43
AND MAB50 CT044
MAB50 CT06 1
AND MAB50 CT062
BHEL Hardwar
CHECK
OFF
OFF
IN OPERATION
P DESIGN
> 95%
ON
MKG25 CPO03
MKG25 CQO01
5.2-0160-02/1
+ H2 TEMPERATURE CONTROL
+ PRIMARY WATER PUMP
+ STANDBY PRIMARY WATER PUMP
+
+
+
+
+
NOT FAULTED
ON
OFF
MKF12 APO01
OR MKF22 APO01
MKF22 APO01
OR MKF12 APO01
> P MIN
ON
< 1,5 MYS/CM
ON
NOT FAULTED
MKF12 CPOOl
MKF35 COOOl
OPEN
AND
OPEN
< 300 C
MAL22 AAOll
> 320 C
OPEN
CLOSED
OPEN
MAL65 AAOll
AND
+ DRAIN DOWN STREAM IP CONTROL VALVE
OPEN
AND
MAL11AA011
MAL AA011
MAL22 AAOll
MAL26 AAOll
MAL27 AAOll
MAL31 AAOll
MAL32 AAOll
<-20 C
CLOSED
MAL26 AA011
MAL27 AAOll
MAL31 AAO 11
AND MAL32 AAOll
AND
+ DRAIN DOWN STREAM IP CONTROL VALVE
MINUS SATURATION TEMPERATURE OF STEAM
CRITERION: EXTRACTION VALVE
(05)
CLOSED
> 50 C
CLOSED
CHECK
IN OPERATION
CLOSED
CLOSED
CLOSED
+ HP CONTROL VALVES
CLOSED
+ IP CONTROL VALVES
CLOSED
CLOSED
+ EXTRACTION VALVE
CLOSED
(06)
CHECK
(07.)
+ PREWARMING OF TURBINE
OR WITH FGA (TURBINE CONTROL)
PROGRAMME (STARTUP)
START
5.2-0160-02/2
START
MAA10 AAOOl
AND MAA20 AAOO 1
MAB10 AAOOl
AND MAB20 AAOOl
MAA 10 AAO02
AND MAA20 AAO02
MAB 10 AAO02
AND MAB20 AAO02
LBC10 AAOOl
SWITCH OFF.
OFF
OFF
CLOSED
MAL11 AA011
MAL AA011
MAL11 AA011
AND MAL12 AA01 1
AND
CLOSED
CLOSED
(09/S)*+
(10)
(11)
(12)
(13)
REFER TO 5.2-0170
REFER TO 5.2.0170
< 100 C
CHECK
SET HIGHER
MAX47 BYO01
SET HIGHER
> 42%
OPEN
MAX47 BYO01
MAX47 BYO01
MAA10 AAO01
MAA20 AAO01
(14)
(16)
CHECK
FULFILLED
FULFILLED
MAL11 AA011
AND MAL12 AA01 1.
CHECK
FULFILLED
SWITCH ON.
SWITCHED ON
SWITCHED ,ON
SET HIGHER
RAISE
> 56 %
OPEN
MAX4B.YO01
MAX47 BYO01
MAX47 BYOO 1
MAB10 AAO01
WAIT
WARM UP PROCEDURE WILL BE GUlDED BY THE
WARM.UP CONTROL. LEADING PARAMETER IS THE
TEMPERATURE ALLOWANCE OF THE TSE/TSC CHANNEL
(ADMISSION). THE DRAINS OF THE CONTROL
VAL VES WILL BE OPENED AND CLOSED DEPENDING
ON THE MAGNITUDE OF TSC ALLOWANCE. IF THE
WARM.UP CONTROL IS DISTURBED OR NOT IN
5.2-0160-02/3
CLOSE
CLOSED
(18)
CHECK
FULFILLED
FULFILLED
(19)
(20)
22)
+ SPEED OF TURBINE/GENERATOR
+ JACKING OIL PUMP
+ JACKING OIL PUMP
5.2-0160-02/4
CHECK
> 10 %
MYA01 DUO01
MYAOL DUOOL
SET HIGHER
> 650 RPM
SET HIGHER
MAV51 AAOOL
CLOSED
MAV51 AAOOL
MAV31 APOOL
OR MAV32 APO01
MAV31 APOO1
AND MAV32 APOO1
OFF
MAV31 APO01
AND MAV32 APOO1
(23)
+
+
+
+
+
AND
OPERATIONAL VALUES OF TURBINE
CHECK
STEAM TEMPERATURE CRITERIA
FULFILLED
TURBINE STRESS MARGIN
> 30 OK
BEARING VIBRATION
NORMAL
SHAFT VIBRATION
NORMAL
DEFINITION OF NORMAL VALUES OF VIBRATION:
VIBRATION PREVIOUSLY OBSERVED WHEN OPERATING
WITH SAME SPEED AND OTHER PARAMETERS
(24)
(24)
(25)
+
+
(25/S)* +
(26)
CHECK
WARM-UP CONTROL
WARM-UP CONTROL
OR WITH FGA (TURBINE CONTROL)
WARM-UP CONTROL
SWITCH OFF
OFF
SET HIGHER
> 3000 RPM
OFF
(28)
MYAO1 DUO01
MYA01 DUOO1
WAIT
THE LIMITED SPEED REFERENCE VALUE FOLLOWS
THE SPEED REFERENCE VALUE WITH THE PRESET
GRADIENT. DO NOT HOLD THE TURBINE IN THE
CRITICAL SPEED ZONE. THE SPEED GRADIENT
WILL BE REDUCED IF REDUCTION OF THE TSE/TSC
ALLOWANCE OCCUR. THE TSE/TSC INFLUENCE WILL
BE EFFECTIVE VIA THE REFERENCE LIMITER.
IF A SIGNIFICANT REDUCTION OF THE TSE/TSC .
ALLOWANCE OCCURS, THE TURBINE SPEED WILL BE
REDUCED TO WARM UP SPEED. IF THE TSE/TSC IS
FAULTED THE DIFFERENTIAL TEMPERATURES AT
THE MEASURING POINTS WHICH REPRESENT THE
THERMAL STRESSES OF CASING AND ROTOR MUST
BE EVALUATED
REDUCE SPEED REFERENCE VALUE TO WARMUP
SPEED WHEN OPERATING WITHOUT TSE/TSC
INFLUENCE AND THE TSE/TSC ALLOWANCE
REDUCED TO ZERO.
(27)
+
+
+
+
+
REFER TO 5.1-011..
3000 RPM
CHECK
NORMAL
NORMAL
NORMAL
CLOSE
MAL 11 AAO11
5.2-0160-02/5
CLOSED
MAL 11 AA011
AND MAL 12 AA011
(28/S)* +
CLOSED
MAL 11 AA011
AND MAL 12 AAO1 1
(29)
SWITCH OFF
MAV22 APO01
5.2-0160-02/6
CHECK
SYNCHRONIZE REFER TO 5.2-0210
Steam Turbine
Description
Fig.1
ms
steam
Temperature of saturated
steam (depending on main
steam pressure)
and
ms>f(mcv50%)
ms
Fig.2
mcv50% =
BHEL Hardwar
5.2-0170-01/1
Des
Maximum
main
steam
saturation
temperature ahead of the turbine
s>f(mcv50%)
Fig.3
mcv 50% =
Starting Cretaria
When the main control valves are opened
the main steam
and reheat steam
temperatures should fulfill the following criteria:
Fig.1
ms
Main
steam
temperature
ahead of the turbine
Temperature
of
saturated
steam (depending on main
steam pressure)
and
ms>f(HT50%)
ms
HT 50% =
5.2-0170-01/2
Fig.4
Main
steam
ahead of turbine
temperature
Fig. 5
9Roh
9IT 50%
Speeding up criteria
Before the turbine is brought to rated speed
the main steam temperature 9MS ahead of the
turbine should fulfill the following criteria:
9MS < f ( 9HT 50% )
9MS
Main
steam
temperature
ahead of the turbine
9HT 50%
5.2-0170-01/3
Loading criteria
Before the turbine is loaded the reheat
temperature, ahead of the turbine should fulfill
the following criteria
9Reh > f (9IT 50%)
9Reh
9IT 50%
Fig. 7
5.2-0170-01/4
Steam Turbine
Operation
Controller
Warm-up operation
Warm up operation
BHEL Hardwar
5.2-0180-00/1
Operation
- Operating elements and monitoring
instruments
-
Limitation by higher-level or
alternative controllers or other device
- Minimum Value selection
Electrohydraulic controller
<100% value selection
starting and IQad limit device
Operation
- Operating elements and monitoring
instruments
- Operating logic sequences for
changing operating mode
5.2-0180-00/2
+
+
+
+
+
+
+
(1) +
+
raise
= 100%
(2) +
+
Plunger coil
Plunger coil
deenergize
deenergized
(3) +
+
+
lower
=0%
in operating configuration
(4) +
+
+
+
raise
>40%
= 100%
fulfilled
(A) +
+
+
warm-Up
fulfilled
adequate
(5) +
+
+
raise
= warm-up speed
(6) +
(B) +
+
+
Turbine
Run-up criteria
Steam generator output
Warm-up
fulfilled
adequate
(7) +
+
+
+
raise
open
> warm-up speed
= 75% rated speed
(8) +
+
raise
= 100% open
(9) +
+
raise
= rated speed
5.2-0180-00/3
+
+
= 56 to 100%
(1) +
+
lower
effective
(2) +
+
raise
= 100%
(3) +
+
Plunger coil
Plunger coil deenergized
deenergize
(4) +
(5) +
+
lower
= 0%
+
+
+
+
(1) +
+
Plunger coil
Plunger coil
energize
energized
(2) +
+
lower
= electrical speed reference
(3) +
+
raise
56 to 100 %
(4) +
+
raise
= 100%
5.2-0180-00/4
Steam Turbine
Operation
Power
operation
begins
Load Operation
Introduction
by
in
correct them.
Regular checking of protection equipment,
long-term monitoring of operating variables
and operational maintenance are very
important for early detection and elimination
of system faults.
BHEL Hardwar
5.2-0200-00
(01)
Steam Turbine
Operation
Startup Diagram
GENERATR READY TO BE
CHECK
SYNCHRONIZED
(02)
SPEED OF TURBINE/GENERATOR
3000 RPM
NORMAL
H2-SUPPL Y SYSTEM
NO ALARM
SEAL-OIL PLANT
NO ALARM
NO ALARM
LIQUID IN GENERATOR
NO ALARM
FULFILLED
EXCITATION BREAKER
SWITCH ON
SWITCHED ON
EXCITATION BREAKER
SWITCHED ON
(03)
HIGHER
GENERATOR VOLTAGE
HIGHER
AUTOMATIC SYNCHRONIZER
ON
(04)
CLOSED
SWITCHED ON
SWITCHED ON
(05)
SYNCHRONOSCOPE
SWITCHED ON
SYNCHRONOSCOPE
BHEL Hardwar
SWITCHED ON
5.2-0210-00/1
(07)
GENERATOR VOATAGE
BY MEANS OF REFERENCE
VALUE OF VOLTAGE CONTROL
ADJUSTED
GENERATOR/LINE-VOLTAGE
OR WITH (AUTOMATIC SYNCHRONIZER)
MET
(07/5)* +
GENERATOR/LINE-VOLTAGE
MET
(08)
GENERATOR FREQUENCY
BY MEANS OF REFERENCE
VALUE OF SPEED CONTROL
GENERATOR/LINE-FREQUENCY
ADJUSTED
MET
GENERATOR / LINE-FREQUENCY
GENERATOR FREQUENCY MUST
BE ADJUSTED IN SUCH A WAY
THAT THE NEEDLE OF THE
SYNCHRONOSCOPE TURNS
SLOWLY IN THE DIRECTION
GENERATOR FREQUENCY HIGHER
THAN LINE FREQUENCY =
FAST SYNCHRONIZING.
FAST SYNCHRONIZING ENSURES
THAT THE GENERATOR Will
BE LOADED IMMEDIATELY
AFTER SYNCHRONIZING
THUS PREVENTING REVERSE
POWER RELAY TO BE ACTUATED.
(09)
SYNCHRONIZING DEVICE
GENERATOR BREAKER
IF THE BREAKER WILL BE
SWITCHED ON MANUALLY
ADJUSTED PHASE ANGLE TO
NEEDLE OF SYNCHRONOSCOPE
MUST METT THE ZERO-ANGLE
MARK ON THE SCALE WHEN
SWITCHING IN BREAKER.
MET
START
SWITCHED ON
GENERATOR BREAKER
(10)
GENERATOR LOAD
5.2-0210-00/2
SWITCHED ON
SET HIGHER
> 10%
MYA01DU001
(11)
SET HIGHER
MAX47BYO01
100%
MAX47BYO01
100%
MAX47BYO01
CHECK
CHANGED OVER
GENERATOR LOAD
LOAD CONTROLLER
THE LOAD CONTROL WILL BE
SWITCHED ON AT A PRESET
MINIMUM LOAD.
(12)
(13)
> 10%
SWITCHED ON
SET HIGHER
MYA01 DUO01
TARGET LOAD
MYA01 DUO01
(13/S)* +
WAIT
LIMITED LOAD REFERENCE VALUE
THE LIMITED LOAD REFERENCE
VALUE FOLLOWS THE TARGET
LOAD REFERENCE VALUE
WITH THE ADJUSTED
LOAD GRADIENT.
THE LOAD GRADIENT WILL
BE REDUCED, IF REDUCTION
OF THE TSE ALLOWANCE OCCUR.
THE TSE INFLUENCE WILL BE
EFFECTIVE VIA THE REFERENCE
LIMITER.
HIGHER
MYA01DUO01
5.2-0210-00/3
(14)
CLOSE
CRITERIUM:
VALVE CASING TEMPERATURE
MINUS SATURATION
TEMPERATURE OF STEAM
+
(15)
+
+
+
HEATER OPERATION
HEATERS
EXTRACTION VALVE
(16)
DRAINS OF EXTRACTIONS
5.2-0210-00/4
CLOSED
MAL 15AAO01
AND MAL 16AAO01
> 50 CEL
CLOSED
MAL 22AA011
>320 CEL
CLOSED
MAL65AA011
LBC10AAO01
OPEN
CLOSED
MAL26AA011
AND MAL27 AA 11
> 50 CEL
CLOSED
MAL31AA011
AND MAL32AA011
> 50 CEL
CHECK
IN OPERATION
> 0%
LBO50AAO01
AND LBS41AAO01
AND LBS42AAO01
AND LBS31AAO01
AND LBS21AAO01
CLOSE
MAL47AA011
AND MAL51AA011
AND MAL54AA015
AND MAL55AA011
DRAINS OF EXTRACTIONS
CLOSED
MAL47AAO11
AND MAL51AAO11
AND MAL54AAO15
AND MAL 55AAO11
(17)
CHECK
CLOSED MAN11AAOO2
AND MAN12AAOO2
CLOSED MAN11AAOO1
AND MAN12AAOO1
5.2-0210-00/5
Steam Turbine
Operation
1 Control System Operating Modes
Electrical speed control
- During synchronization of generator
-
Hydraulic control
(operation if electrical control system defective)
- During synchronization of generator
-
Power Operation
Controllers
Maintenance of constant load;{steam generator control system takes over control when max. control
valve lift reached).
Maintenance of constant load;
Turbine generator assists in grid frequency stabilization
when frequency changes.
BHEL Hardwar
5.2-0220-00/1
Valve lift
load at design pressure.
Reference limiter
- Target reference value/actual
reference value
- Limitation of reference limiter by TSE
(turbine stress evaluator) component
-
Operation
- Control and monitoring devices
-
Hydraulic Governor
Control range
- Speed
- Valve travel at rated speed
- load at design pressure
Reference limiter
- Target reference value/actual
reference value
0-170%
(limited by hydraulic governor)
100%
100%
80-107%
100%
100%
Actual reference value tracks target reference
value directly (no TSE component).
During operation with the hydraulic governor in
control, the thermal stresses in the turbine components must be assessed by referring to the TSE
display or, if the TSE is faulted, by comparing
the actual temperatures and their differences with
the curves for permissible temperature margins as
give in Technical Data 5.1-011.
Operation
- Control and monitoring devices
- Control logic for changing operating
mode
Instructions for control and operational
monitoring
- Actual speed after load shedding
5.2-0220-00/3
Operation
- Control and monitoring devices
-
5.2-0220-00/4
APPENDIX
+
+
+
+
+
+
+
+
= rated speed
= Zero MW
on
in operation
not in operation
= rated speed
= 100%
= 100%
(1) +
+
Speed changer
Speed changer reference value
lower
< electrical speed reference value
(2) +
+
+
raise
= max. speed
> 100%
(3) +
+
+
Plunger coil
Plunger coil
Required speed
switch off
off
reference value higher or lower
(4) +
Speed changer
raise or lower
Control logics 1: Changeover from electrical to hydraulic speed control in idling mode, e.g. for exercising overspeed trips.
+
+
+
+
+
+
+
+
=rated speed
= Zero MW
off
not in operation
not in operation
= max. speed
= % position for rated speed
= 100%
(1) +
+
Plunger coil
Plunger coil
Switch on
on
(2) +
+
lower
< speed setter reference value
(3) +
+
+
Speed changer
Speed changer
Required speed
raise
= 100%
higher or lower
(4) +
raise or lower
Contrl logics 2: Changeover from hydraulic speed control in idling mode e.g. after exercising overspeed trips.
5.2-0220-00/5
+
+
+
+
+
+
+
+
>0MW
in operation
on
in operation
in operation
= rated speed + load component
= 100%
= 100%
(1) +
+
Speed changer
Speed changer reference valve
lower
< electrical speed reference value
(2) +
+
+
raise
= max. speed
> 100%
(3) +
+
+
Plunger coil
Plunger coil
Load
switch off
off
reference value higher or lower
(4) +
+
Speed changer
Hydraulic frequency control
raise or lower
not required
(5) +
+
lower
in effect
(6) +
+
+
Speed changer
Speed changer
Load
raise
= 1 00%
higher or lower
(7) +
raise or lower
Control logic 3: Changeover from electrical to hydraulic speed control during speed controlled Power operation
(procedure (5) onwards: Switching off hydraulic frequency influence)
5.2-0220-00/6
+
+
+
+
+
+
+
> OMW
off
not in operation
not in operation
= max. speed
= 100%
= in effect
(1) +
+
Speed changer
Speed changer
lower
in effect
(2) +
+
raise
= 100%
(3) +
+
Plunger coil
Plunger coil
switch on
on
(4) +
(5) +
+
+
= 100%
reference value higher or lower
(6) +
raise or lower
Control logics 4: Changeover from hydraulic to electrical speed control in power operation
(up to procedure (2): switching on hydraulic frequency component)
5.2-0220-00/7
+
+
+
+
+
+
+
+
+
> a MW
on
in operation
on
in operation
= actual # pressure component
= approx 1.005 x rated speed
= 100%
= 100%
(1) +
+
+
switch off
off
on
(2) +
+
switch off
off
(3) +
+
Speed changer
Speed changer reference valve
lower
< electrical load reference value
(4) +
+
+
raise
= max. speed
= max. load
(5) +
+
+
Plunger coil
Plunger coil
Turbine generator load
switch off
off
reference value higher or lower
(6) +
+
Speed changer
Hydraulic frequency control
raise or lower
off
(7) +
+
lower
in effect
(8) +
+
+
Speed changer
Speed changer
Turbine generator load
raise
= 100%
reference value higher or lower
(9) +
raise or lower
Control logics 5:
5.2-0220-00/8
+
+
+
+
+
+
+
> 0 MW
off
not in operation
= max. load
= max. speed
= 100%
in effect
(1) +
+
Speed changer
Speed changer
lower
in effect
(2) +
+
raise
= 100%
(3) +
+
Plunger coil
Plunger coil
switch on
on
(4) +
+
switch on
(5) +
+
lower
= approx. 1.005 x rated speed
(6) +
+
lower
< speed setter reference value
(7) +
+
+
Speed changer
Speed changer
Load
raise
= 100%
higher or lower
(8) +
+
+
+
raise or lower
actual load higher or lower
reference value on
required
(9) +
switch on
(10) +
+
+
balance
(11) +
+
+
switch on
(12) +
raise or lower
balanced
higher or lower
Control logics 6: Changeover from hydraulic to electrical load control in power operation
Procedure (1) + (2) Switch off hydraulic frequency cornball
Procedure (9) + (10) Switching on pressure condoner
5.2-0220-00/9
Steam Turbine
Operation
Introduction
During startup and shut-downs, there can be iong
period during which Steam turbines are operated at very
low volumetic flows. This operating mode can result in
blade windage in individual stages of multi-stage
turbines.
The direction of the energy conversion cycle at the
affected blade stages is reversed. The mechanical
energy transmitted by the turbine shaft is converted to
thermal energy, which in turn result in an increase in the
temperature of both the steam and the turbine
components.
Unallowably high temperatures can occur as a result
of blade windage, leading to loosening of the blade
assembly of drum stages through plastic deformation.
Turbine casings can undergo deformation due to the
effects of high temperatures.
During steam turbine operation, the operating mode
and limiters and protective devices must be used to keep
heatup due to blade windage within the prescribed Imits.
Thermodynamic and operating factors affecting
blade windage
The following factors can lead to blade windage:
Volumetric flow Blade windage can occur as a result
of insufficient volumetric flow through a multistage
expansion section of the steam turbine.
The lower the volumetric flow through a blade stage,
the lower the turbine efficiency will be in the case of
very low volumetric flows, steam flow through the
stage is not directed and the steam has to be
accelerated up to the average speed of the rotating
blades, which creates a deceleration effect.
As the volumetric flow decreases, and the turbine
starts to operates at zero load, blade windage result
in transition from power transfer from the blades to
power transfer to the blades.
Blade windage starts in the final blade stages of an
expansion section, and extends towards the first
stages as flow decreases.
Steam density, steam pressure and turbine generator
speed.
The degree of windage-induced heatup Which occurs
as a result of low volumetric flow through an
expansion section of the steam turbine depends on
the windage power.
The higher the steam density and the turbine speed
to the third power, the greater will be windage power,
and therefore the heatup, in one blade stage.
BHEL Hardwar
5.2-0230-00/1
5.2-0230-00/2
5.2-0230-00/3
5.2-0230-00/4
Steam Turbine
Operation
Introduction
BHEL Hardwar
5.2-0300-00
Steam Turbine
Operation
(01)
TURBINE/GENERATOR
UNLOAD
REF. TO 5.2-0320
OR
+
(02)
OBSERVE
REF. TO 5.2-0320
(03)
OBSERVE
REF. TO 5.2-0320
INITIATED
(04)
(05)
TURBINE TRIP
START
CARRY OUT
REF. TO 5.3.0060
INITIATE
REF. TO 5.2-0320
TURBINE TRIP
INITIATED
REF. TO 5.2-0320
OBSERVE
REF. TO 5.2-0320
START
REF. TO 5.2-0320
(07)
IN OPERATION
IN OPERATION
(08)
*+
ON
*+
STEAM -GENERATOR
NOT IN SERVICE
BYPASS -OPERATION
COMPLETED
CONDENSING PLANT
SHUT DOWN
VACUUM PUMPS
SHUT -DOWN
CONDENSATE PUMPS
OFF
OPEN
REF. TO 5.2-0330
OFF
NOT IN SERVICE
OBSERVE
(09)
SHUT -DOWN
REF. TO 5.2-0320
(10)
SHUT -DOWN
REF. TO 5.2-0340
OR
MANUAL OPERATION AT OPER. CONSOLE
+
SHAFT
OIL SYSTEM
BHEL Hardwar
STANDSTILL
NOT IN SERVICE
5.2-0310-01
(01)
(02)
Operation
Turbine/Generator
Shut-Down Diagram
OPERATIONAL CONDITIONS
LOAD CONTROLLER
LOAD GRADIENT
ADJUSTMENT ACCORDING TO
- REQUIREMENT OF LOAD DESPATCHER
- STEAM GENERATOR CONTROL
- THERMAL INFLUENCE ON TURBINE
+
BYPASS CONTROL
+ FIXED PRESSURE SET POINT BYPASS CONTROL
ADJUSTMENT IN AGREEMENT WITH
PRESSURE REQUIREMENTS - REHEAT PRESSURE DURING START-UP
AND SHUTDOWN
+
ELECTRO HYDRAULIC TURBINE CONTROL
+
BYPASS CONTROL
+
TSC -INFLUENCE
+
TURBINE STRESS CONTROLLER (TSC)
IF THE TSC IS FAULTED THE DIFFERENTIAL
TEMPERATURES AT THE MEASURING POINTS WHICH
REPRESENT THE ADDITIONAL THERMAL STRESSES
OF CASING AND ROTOR MUST BE EVALUATED.
REFER 5.2-0430 IF TSC ALLOWANCE IS REDUCED
+
SUBLOOP CONTROL OF AUXILIARY OIL PUMPS
+
SUBLOOP CONTROL OF EMERGENCY OIL PUMPS
+
SUBLOOP CONTROL OF JACKING OIL PUMPS
+
SUBLOOP CONTROL TURNING GEAR OIL VALVE
+
SUBLOOP CONTROL DRAINS
THE SUBLOOP CONTROLS MUST ALWAYS BE
SWITCHED ON DURING OPERATION
+
TURBINE/GENERATOR LOAD
IT IS ASSUMED THAT THE TURBINE/GENERATOR
WILL BE UNLOADED FROM ANY LOAD TO 0 LOAD
WITHOUT DELAY
+
+
(02/S) * +
(04) *
+
+
+
(03)
Steam Turbine
+
*+
+
+
*+
*+
BHEL Hardwar
CHECK
ON
ADJUSTED
ON
...KG/CM2
NOT FAULTED
NOT FAULTED
ON
NOT FAULTED
ON
ON
ON
ON
ON
> 0 MW
LOWER
0 MW
START
0 MW
WAIT
LOWER
<1
OBSERVE
OPEN
OPEN
MAN41 AAO01
AND MAN51 AAO01
MAN42 AAOO2
AND MAN 52 AAOO2
5.2-0320-02/1
(05)
+
*+
+
*+
*+
WAIT
LIMITED LOAD REFERENCE VALUE
AUXILIARY POWER SUPPLY SECURED
CRITERION:
AFTER THE GENERATOR CIRCUIT BREAKER IS OPEN
THE UNIT AUX. POWER SUPPLY IS SECURED
OPERATION OF SWITCH GEARS MUST AGREE
WITH AUXILIARY POWER SUPPLY FACILITIES
TURBINE LOAD CONTROLLER
TURBINE SPEED CONTROLLER
AFTER A FIX SET MINIMUM LOAD IS REACHED
THE TURBINE CONTROLLER CHANGES OVER FROM
LOAD TO SPEED CONTROL
LOWER
LOWER
(06)
(06/S)
*+
+
*+
*+
*+
*+
OFF
ON
LOWER
< RATED SPEED
CLOSED
MAA 10 AAO02
AND MAA20 AAO02
CLOSED
MAB 10 AAOO2
AND MAB20 AAO02
INITIATED
OPEN
REF. TO 5.2-0410
(07)
(08)
(08/S)
*+
+
*+
*+
TURBINE TRIP
OR WITH FGA
TURBINE TRIP
BEGIN OF COASTING DOWN TIME
TRIP FLUID PRESSURE
MAIN STEAM STOP VALVES
*+
CLOSED
*+
CLOSED
*+
CLOSED
*+
*+
*+
*+
(09)
+
+
(09/s)
5.2-0320-02/2
CARRY OUT
OBSERVE
INTERRUPT
REF, TO 5.3-0060
REF. TO 5.2-0020
INITIATE
INITIATED
NOTE
0 KG/CM2
CLOSED
MAX51 CPO 13
MAA10 AAO01
AND MAA20 AAO01
MAB10 AAOO1
AND MAB20 AAO01
MAA 10 AAO02
AND MAA20 AAO02
MAB 1 0 AAO02
AND MAB20 AAO02
LBC10 AAO01
MAG10 AAO01
LOWER
0%
MAX47BYO01
MAX47BYO01
0%
MAX47BYO01
(10)
+
+
DE-EXCITATION BREAKER
DE-EXCIT A TION BREAKER
(11)
+
+
+
VACUUM BREAKER
VACUUM
VACUUM BREAKER
(12)
+
+
(13)
+
+
(14)
(15)
*+
+
+
+
+
SPEED OF TURBINE/GENERATOR
JACKING OIL PUMP
*+
+
+
+
+
+
*+
+
(16)
*+
*+
+
OPEN
OPEN
CHECK
> 0.2 KG/CM2 ABS
CLOSED
LOWER
0%
SWITCH CONTROL
OFF
OPEN
OPEN
MAL11 AA011
AND MAL12 AAO 11
MAL 11 AA011
AND MAL12 AA011
OBSERVE
MAV22 APO01
OBSERVE
< 4.8 KG/CM2
ON
MAV24 APO01
MAV21 CPO01
MAV22 APO01
MAV21 CPO01
NOT ON
ON
MAV22 APO01
MAV23 APO01
MA V42 CPO 14
MAV22 APO01
AND MAV23 APO01
MAV24 APO01
MAV41 AAO01
MAV41 AAO01
MAV31 AP001
ON
MAV31 AP001
ON
MAV31 AP001
MAV35 CP012
MAV35 CP012
MAV33 AP001
5.2-0320-02/3
(17)
+
+
+
*+
(18)
+
+
+
+
+
*+
(19)
+
+
+
+
+
SPEED OF TURBINE/GENERATOR
TURNING GEAR OIL VALVE
TURNING GEAR OIL VALVE
OR BY SUBLOOP CONTROL TURNING GEAR
TURNING GEAR OIL VALVE
DRAIN VALVES
DRAIN HP OUTER CASING
CRITERION:
TEMPERATURE HP OUTER CASING MIDDLE TOP
OR TURBINE LOAD
DRAIN AHEAD OF CRH SWING CHECK VALVE
CRITERION: CRH NRV CLOSED
DRAIN UPSTREAM OF EXTRACTION VALVES
DESIGNATION OF DRAIN VALVES ACCORDING
TO SINGLE LINE DIAGRAM.
CRITERION: EXTRACTION CHECK VALVES
DRAIN SEAL STEAM HEADER
CRITERION: TEMPERATURE IN SEAL STEAM HEADER
OR WITH SUBLOOP CONTROL
SUBLOOP CONTROL OF DRAINS
DRAIN VALVES BY SUBLOOP CONTROL
CRJTERION : REFER TO MANUAL OPERATION
5.2-0320-02/4
MAV51 AAOO1
MAV51 AAOO1
OPEN
MAV51 AAO01
OPEN
OPEN
MAL22 AA011
< 300 C
<2%
OPEN
MAL65 AA011
OPEN
CLOSED
OPEN
< 120 C
MAL81 AA011
NOT FAULTED
OPEN
CHECK
CHECK
CHECK
NOT IN SERVICE
COMPLETED
CLOSED
CLOSED
ON
OR OFF
P AMB
OFF
CLOSED
OFF
REF. TO 5.2-0330
MAW11 AAO01
MAW80 ANOO1
AND MA W80 ANOO2
(20)
+
+
+
COMPLETED
NOT IN SERVICE
SHUTDOWN
+
+
+
SWITCH OFF
OFF
OFF
*+
*+
OFF
OFF
(21)
(21/S)
(21/S)
START
(22)
+
+
(22/S)
*+
CF -RECONDITIONING PUMP
(23)
+
+
MAX16 AP001
OR MAX16 AP002
MAX 16 AP001
AND MAX 16 AP002
SWITCH OFF
OFF
MAX91 APOO1
MAX 91 APOO1
OFF
MAX91 APOO1
MAX11 CTO01
5.2-0320-02/5
Steam Turbine
Condensing Plant
Operation
Shutdown Diagram
(1)
(2)
CHECK
NOT IN SERVICE
COMPLETED
CLOSED
OPEN
+
+
+
+
+
+
CONDENSATE SYSTEM
CIRCULATING WATER OF CONDENSER
VACUUM BREAKER
WARM-UP CONTROL (SEAL STEAM)
+
+
(4)
+
+
(5)
+
+
VACUUM PUMPS
VACUUM PUMPS
THE VACUUM PUMPS DO NOT BELONG TO THE
SCOPE OF SUPPLY OF THE TURBINE/GENERATOR
OPERATION OF VACUUM PUMPS AND VALVES
ACCORDING TO SPECIAL INSTRUCTION.
SWITCH OFF
OFF
(6)
+
+
VACUUM BREAKER
VACUUM BREAKER
OR WITH FGA, SUBGROUPS (SEAL STEAM SUPPLY
STANDSTILL)
OPEN
OPEN
MAG10 AAO01
MAG10 AAO01
(06/S)
*+
VACUUM BREAKER
OPEN
MAG10 AAO01
+
+
+
+
(3)
BHEL Hardwar
CHECK
OPEN
ON
CLOSED
ON
OPEN
ON
MAW11 AAO01
MAW80 ANO01
ORMAW80 AN02
IN OPERATION
AVALABLE
OPEN
ON
SHUT DOWN
START
CLOSE
CLOSED
5.2-0330-01/1
+
+
(07/S)
*+
(07/S)
*+
VACUUM
SEAL STEAM CONTROL
AND
SEAL STEAM SUPPLY VALVE
SEAL STEAM CONTROL
AND
SEAL STEAM SUPPLY VALVE
OR WITH FGA, SUBGROUP (SEAL STEAM SUPPLY
STANDSTILL)
SEAL STEAM CONTROL
AND
SEAL STEAM SUPPLY VALVE
(08)
SWITCH OFF
OFF
(08/S)
*+
(9)
+
+
CONDENSATE SYSTEM
CONDENSTATE SYSTEM
THE CONDENSATE SYSTEM DOES NOT
BELONG TO THE SCOPE OF SUPPLY (TURBINEGENERATOR). SPECIAL INSTRUCTIONS FOR
-CONDENSATE PUMPS
-CONDENSER LEVEL CONTROL
-MINIMUM FLOW CONTROL
-HEATERS
MUST AGREE WITH TURBINE OPERATION AND
HAVE TO BE FOLLOWED.
THE CONDENSATE SYSTEM CAN ALSO BE
SHUT DOWN AFTER STEP (12) IS CARRIED OUT.
SHUT DOWN
NOT IN SERVICE
(10)
+
+
SHUT DOWN
NOT IN SERVICE
(11)
+
+
(11/S)
*+
VACUUM BREAKER
VACUUM BREAKER
OR WITH FGA (SEAL STEAM SUPPLY STANDSTILL)
VACUUM BREAKER
(12)
+
+
(12/S)
+*
+
+
+
5.2-0330-01/2
> 0.8KG/CM2
SWITCH OFF
CLOSE
OFF
MAW11AAO01
CLOSED
MAW11 AAO01
OFF
CLOSED
MAW11 AAO01
MAW80 ANO01
ORMAW80 AN02
MAW80 ANO01
AND MAW80 ANOO2
OFF
AND
MAW80 ANO01
MAW80 ANOO2
CLOSE
CLOSED
MAG10 AAOO1
MAG10 AAO01
CLOSED
MAG10 AAO01
SWITCH OFF
OFF
OFF
(01)
(02)
Operation
Shutdown Diagram
CHECK
< 100 C
CHECK
+
+
+
+
+
+
(04)
Oil System
+
+
(03)
Steam Turbine
+
+
+
+
(04/S)
*+
(05)
MAA50 CT053A
AND MAA50 CT054A
ON
ON
ON
ON
MAV22 APOOl
OR MAV23 APOOl
EXPIRED
ON
ON
MAV31 APOOl
OR MAV32 APO01
SHUTDOWN
SWITCH OFF
CLOSE
OFF
MAV51 AAO01
CLOSED
MAV51 AAOO1
OFF
MAV51AA012
WAIT
THE WAITING TIME IS EXPIRED WHEN THE
SHAFT COMES TO A COMPLETE STOP.
SHAFT
BHEL Hardwar
STAND STILL
5.2-0340-01/1
06)
+
+
+
+
+
+
*+
*+
AND
EMERCJENCY OIL PUMP
*+
*+
(07)
+
(06/S)
SWITCH OFF
SWITCH OFF
SWITCH OFF
MAV22 APO01
OR MAV23 APOOl
OFF
OFF
OFF
MAV22 APO01
AND MAV23 APO01
OFF
MAV24 APO01
OFF
OFF
OFF
MAV22 APOOl
AND MAV23 APO01
OFF
MAV24 APO01
WAIT
WAIT FOR SHUTDOWN OF JACKING OIL PUMP UNTIL
THE RELATIVE EXPANSIONS ARE REDUCED AND NO
FURTHER MAJOR AXIAL SHIFTING OF THE JOURNALS
IN THE BEARINGS IS EXPECTED.
(08)
+
+
+
+
(08/S)
*+
*+
5.2-0340-01/2
SWITCH OFF
SWITCH OFF
MAV31 APOOl
OR MAV32 APO01
OFF
OFF
MAV31 APO01
AND MAV32 APO01
OFF
OFF
MAV31 APO01
AND MAV32 APO01
Steam Turbine
Operation
Introduction
If service activities or repairs have to be carried out
very soon or immediately after shut down of the
turbine, it is advisable to reduce the cooling down time.
Fast cooling down is necessary especially if activities
are to be executed at turbine parts, which are exposed
to high operational temperatures.
load.
Slowly reduce admission temperatures to values,
BHEL Hardwar
5.2-0350-01
Steam Turbine
Maintenance
Introduction
If a turbine stands idle for a long period it is liable to
corrosion attack which if not prevented by appropriate
means, will cause deterioration of the components.
During long idle periods when the turbine has
cooled to the ambient temperatures, all components
which come into contact with steam vapour, water or
damp air are liable to corrosion attack.
The Effect of Corrosion
Preventing Corrosion
in Idle Turbines
the condensation produced when the temperature
within the turbine falls below point ( this is the
principal source of the water).
Fig.1 shows the effect of relative humidity on rusting
loss (VA) for a sample of carbon steel.
The rusting loss increase sharply when the relative
humidity is high therefore, to inhabit corrosion attack in
an idle turbine, the relative humidity of the enclosed air
should be maintain below 50% as far as possible.
FIg. 1 Enect of Relative Humidity on Hustling Loss
Vr
BHEL Hardwar
5.2-0360-00/1
5.2-0360-00/2
of BHEL.
Steam Turbine
Operation
Fault Tracing
Introduction
BHEL Haridwar
5.2-0400-00
Steam Turbine
Operation
Serious Faults
Fault Tracing
Introduction
Many operating faults require the monitoring
staff to take immediate appropriate action if
serious reductions in the availability,
operating reliability and service life of the
turbine are to be averted.
The following criteria and instruction must be
included in the intensive schooling and
training program for the monitoring staff.
Fault
Other symptoms
Cause
Remedy
Load rejection
Prolonged operation at
rated speed with or without
residual load.
Normal procedure
may
continue
BHEL Haridwar
5.2-0410-00/1
Fault
Other symptoms
Cause
Remedy
Control malfunction
Check control
malfunction.
and
attend
Turbine trip
Turbine-generator unit in
imminent danger
5.2-0410-00/2
Fault
Other symptoms
Cause
Remedy
Allow
air
to
condenser plant
enter
power
Vibration high
5.2-0410-00/3
Fault
Other symptoms
Cause
Remedy
Casing
differential
temperatures high
See 5.2-0423
Bearing
temperatures high
See 5.2-0421
Temperature differences
between parallel steam
supply lines high
Condensate
level
condenser very high
metal
in
Reduce
steam
generator
output or increase turbine load
Change
steam
generator
operation, eliminate fault if
necessary.
HP exhaust temperature
high during no-load or low
load operation.
steam
increase
LP
turbine
exhaust
temperature high during no
load or low load operation.
Ventilation
blading.
Bypass
stream
temperature high during
bypass operation
5.2-0410-00/4
heating
through
Fault
Other symptoms
Cause
Remedy
All
measures
as
prescribed in 5.2-0455 fail.
Check
bearing
metal
temperatures, if impermissibly
high, inspect bearings.
Fault
in
pump(s).
oil
jacking
Press
fire
pushbutton 1
protection
or
Switch off sub-loop control for
the
control
fluid
pumps
immediately and shut-down
(operating)
pump
(result:
turbine generator unit trips).
Press
fire
protection
pushbutton 2 (pressing fire
protection
pushbutton
2
automatically
initiate
fire
protection 1 measures), result:
turbine generator unit trips.
5.2-0410-00/5
Fault
Other symptoms
Cause
Remedy
or
Shut down turbine generator
unit. Depressurize control fluid
system (measures as above).
Switch off sub loop control for
jacking oil pumps.
Start up jacking oil pumps.
Switch off subloop control for
auxiliary
oil
pump.
If
necessary, shut down auxiliary
oil pump(s). Check to ensure
that subloop control cuts-in
emergency oil pump as oil
pressure drops. Close turning
gear
oil
valve.
Reduce
condenser vacuum to shorten
coast down.
Allow
air
to
condenser plant
enter
turning
gear
5.2-0410-00/6
Fault
Other symptoms
Cause
Remedy
Set off fire alarm.
Follow fire protection rules.
If necessary, initiate
fighting measures.
fire
Separate
control
fluid
system
Alarm: fluid level low or very
low (2-out-of-3)
Oil system
Alarm: oil level low
Oil system
Turbine trip due to oil level
very low (2-out-of-3)
Fire
protection
measures
initiated automatically.
Note: The trip system is
inoperative during turning gear
operation.
5.2-0410-00/7
Fault
Other symptoms
Cause
Remedy
Escape of steam
Earthquake
5.2-0410-00/8
Steam Turbine
Operation
Vibration
Fault Tracing
The following
data
refers
to
the
characteristics, causes and remedial actions
pertaining to some typical type of vibration.
Fault
Other symptoms
Cause
Remedy
Suspected
damage,
e.g.
broken blades or metal to
metal rubbing
Caution:
stop
turbine
immediately
even
when
accuracy
of
reading
is
doubtful.
Casing
wall
temperature,
because of rapid temperature
changes.
Clearances
eliminated
casing distortion.
by
Check
whether
increased
vibration is maintained after
load is reduce and when
coasting down.
Clearance
eliminated
casing distortion.
by
Bearing damage
Reduce
turbine
load
immediately until vibration
decreases; examine vibration;
load turbine slowly to stability
limit.
Rapid
or
instantaneous
increase in vibration over
the permissible limits or the
range of the measuring
system (alarm or instrument
display)
Low-frequency vibration.
Vibration frequency less
than rotational frequency.
Irregular point trace from
recording Instrument.
BHEL Haridwar
5.2-0420-00/1
Fault
Other symptoms
Cause
Remedy
Determine main frequency of
vibration.
Measure vibration at
bearings in three plans:
all
h - Horizontal
v - Vertical
a - Axial
Measure shaft vibration in two
directions at right angles, if
possible.
Measure the phase relation
ship of the bearings and shaft
vibration.
Measure
vibration.
foundation
the
Changes in shaft
balance due to:
system
Examine
magnitude
direction of vibrations.
and
fit
of
5.2-0420-00/2
Fault
Other symptoms
Cause
Remedy
Final corrective action: Stress
relieving, thermal stabilisation
and
balancing
at
manufactures works, if runout
is more.
Blade damage
Inspect blading.
If blades in the final LP stages
are damaged, a temporary
corrective measure is to
shorten the blade in the 180
opposite position to damaged
blade or to attach a balancing
weight in the plane of damage
to compensate for the missing
piece (consult manufacturer).
if the blade damage is
suspected
elsewhere
the
appropriate turbine casing
must be opened.
Temporary increase in
vibration during non steady
state operating conditions
(startup,
loading
and
unloading, main steam
temperature changes etc.)
Constant
relationship
between vibration and
specific
changes
in
operating parameters.
Remove
restriction
to
expansion by improving sliding
of bearing housings and
casing guides.
Determine relationships by
measuring magnitude and
direction of vibration under
varied operating conditions.
5.2-0420-00/3
Fault
Other symptoms
Cause
Remedy
After, each variation there
must be a delay for steady
state conditions.
Check the following operating
parameters and conditions:
- Speed
- Active load
- Reactive load
- Valve lift
- Steam temperatures
- Casing temperatures
- Steam pressure
- Oil temperatures
- Bearing metal temperatures
- Casing expansion
- Thrust bearing position
- Shaft eccentricity
Check turbine casing
bearing housing for:
- Freedom
washers
of
and
spacing
Increased
vibration
passing critical speeds.
while
5.2-0420-00/4
Fault
Other symptoms
Cause
Remedy
Balancing
pressure
of
generator axial seal ring not
correctly set.
Adjust seal
pressure.
Increased vibration in LP
turbine
and
generator
area.
ring
balancing
- Oil temperature
- Load
- Control valve lift
- Expansion
- Shaft displacement
- Bearing metal temperatures
Vibration
related
to
lubricating oil temperature
changes.
Changes
properties
viscosity.
in
damping
due changes in
5.2-0420-00/5
Steam Turbine
Operation
Fault
Other symptoms
Bearing Temperatures High
Rapid rise of one or more
bearing metal temperatures
to the preset alarm level;
similar temperature rise not
observed before under
comparable conditions
Bearing Temperature
Fault Tracing
Cause
Remedy
Shut
down
turbine
immediately
to
prevent
consequential damage.
Check
bearing,
analyse
cause of bearing damage
and take corrective action.
Dirt in oil
Tilting of bearing
Excessive
thrust
thrust bearings)
Fault in oil
control system
(in
temperature
Check
oil
temperature
downstream of cooler.
Switch off controller.
Establish
normal
temperature.
oil
Establish
manually
oil
temperature
BHEL Haridwar
water
Misalignment
Check alignment
5.2-0421-01
Steam Turbine
Operation
Fault
Other symptoms
Casing Temperatures
Fault Tracing
Cause
Remedy
Annunciation: Casing
temperature differentials
top/bottom high
+
(positive)
=
higher
temperature in top half casing
(negative)
=
lower
temperature in top half casing
During start-up, + / -
After
load
reductions,
during
low
power
operation, + / -
As above
As above
During power
+ / -
operation,
During start-up, -
During start-up, +
BHEL Haridwar
5.2-0423-02/1
Fault
Other symptoms
Cause
Remedy
Repair lagging
Casing temperature
differentials excessive
Coast
down
turbine
immediately
by
tripping;
observe coast down; record
coast down time.
5.2-0423-02/2
Steam Turbine
Operation
Fault
Other symptoms
Remedy
Limitation
by
TSC
admission
monitoring
channel by TSC detector in
stop valve and/or TSC
detector in control valve
during warm-up of the
main steam line and the
stop and control valves.
stop valves open.
or
Hold warm-up valve position
until a sufficient margin has
developed.
or
Continue to close warm-up
valve(s) until a sufficient
margin has developed.
by
TSC
Limitation
admission
monitoring
channel by TSC detector in
control valve during warmup of the main steam line
and the main steam valves
immediately after opening
of the stop valves.
Check
whether
warm-up
valves (drains) between stop
and control valves are closed;
if not, close-warm up valves;
wait for sufficient margin
before re-opening warm-up
valves. If margin is negative,
repeatedly open and close the
main steam stop valves.
General rule: If main stem
temperature can be reduced
when margins narrow, this
should be done in order to
avoid prolonging warm-up.
BHEL Haridwar
5.2-0430-01/1
Fault
Other symptoms
Cause
Remedy
Reduce
main
steam
temperature, if possible.
5.2-0430-01/2
Automatic
and/or
measures as above.
manual
Fault
Other symptoms
Cause
Remedy
Automatic
and/or
measures as above.
manual
Limitation by TSC
monitoring channel
power operation.
turbine
during
5.2-0430-01/3
Fault
Other symptoms
Cause
Remedy
Limitation
by
TSC
admission
monitoring
channel during warm-up of
the main steam line and
the main steam stop and
control valves.
Check
steam
conditions
upstream of the turbine; raise
steam temperature before
warming and/or starting up the
turbine.
Limitation
by
TSC
admission and turbine
monitoring
channels
during
disturbances in
steam
generator
operation.
Rapid,
pronounced
temperature reduction due to
fault in steam generator.
Normal occurrence as a
consequence of the reduction
in throttle temperature; will
reduce turbine life only if
repeated frequently.
No
particular
measures
required in the event of
isolated load rejections.
5.2-0430-01/4
Fault
Other symptoms
Fault in
controller
Alarm
turbine
Cause
Remedy
stress
5.2-0430-01/5
Steam Turbine
Operation
Fault
Other symptoms
Cause
Remedy
Secondary
present
oil
pressure
Slight
changes
secondary pressure
valve
in
and
in
Control
valve
fails
to
respond to control signals
Starting and
device
not
position
load limit
in
100%
BHEL Haridwar
5.2-0440-01/1
Fault
Other symptoms
Cause
Remedy
Change
in
relationship
between secondary pressure
and control valves
Steady-state operation
Travel of converter
Secondary
pressure
Secondary pressure
auxiliary
Steady-state operation
As above
Restriction in movement of
valve stem
5.2-0440-01/2
Steam Turbine
Operation
Fault
Other symptoms
Protective Devices
Fault Tracing
Cause
Remedy
Turbine trip
Manual trip-out
Automatic trip-out
BHEL Haridwar
5.2-0450-01/1
Fault
Other symptoms
Cause
Remedy
Control valves
Converter
of
turbine
5.2-0450-01/2
Fault
Other symptoms
Cause
Remedy
Check
temperature
extraction lines.
in
Thrust
bearing
responded
trip
Excessive
bearing
play
in
thrust
Check
bearing
temperature.
metal
Identify
the
cause
condenser vacuum loss.
Fault in
supply
Check
circulating
water
pumps.
Check
flow
of
circulating
water
through
condenser.
circulating
water
Check position
valves.
of
of
control
Check controller.
If fault in controller or if control
valves malfunction, switch of
controller and maintain gland
seal steam pressure manually
or by local operation of valves.
Fault in vacuum pumps
rupture
disks
for
5.2-0450-01/3
Fault
Other symptoms
Cause
Remedy
As stated earlier
Reduce
main
temperature
See 5.2-0410
Jammed
steam
Locate
and
immediately.
Trip solenoids
repair
fault
Do
not
operate
turbine
generator unit if trip solenoids
are not functioning perfectly.
Fault in solenoids
Overspeed
fouled
trip
jammed
5.2-0450-01/4
or
Locate
and
immediately.
repair
fault
Fault
Other symptoms
Cause
Remedy
Check
speed
indicator
(compare frequency of excited
generator
with
system
frequency
by means
of
synchronizing device).
Adjust speed indicator.
Jammed or fouled
Check
speed
indicator.
(Compare frequency of excited
generator system frequency by
means
of
synchronizing
device).
Correct speed
Adjust speed indicator.
5.2-0450-01/5
Fault
Other symptoms
Cause
Remedy
5.2-0450-01/6
Correct setting
Diaphragm damaged
Fault
Other symptoms
Cause
Remedy
or
Fault in signal path
or
Fault in protective devices
Check
signal
devices.
or
Device malfunction
path
and
5.2-0450-01/7
Steam Turbine
Operation
Fault
Other symptoms
Fault after selecting
starting program
Group
alarms
turbine
panel.
Cause
Remedy
and
and
individual
on
automatic
tester
control
perform nonprograms as
Alarm:
condition
No
starting
BHEL Haridwar
5.2-0455-00/1
Fault
Other symptoms
Cause
Remedy
Reset
program
automatically.
started
Reset
program
automatically.
started
5.2-0455-00/2
Reset
program
automatically.
Observe
program.
running
started
of
reset
Fault
Other symptoms
Cause
Remedy
Running
of
protective
devices
test
program
interrupted,
program
stopped in faulted program
step
5.2-0455-00/3
Fault
Other symptoms
Cause
Remedy
Program
stopped,
changeover valve in test
position
Actuate
contactor
for
approximately 10s to return
main trip valve or trip device
to normal operating position.
If normal operating position
cannot be restored, there is a
mechanical or hydraulic fault
(e.g. jamming of solenoid
valves, worn latching edges,
oil pressure too low for
latch-in)
that
must
be
corrected.
Incorrect
operation
of
protective device during
testing
Trip solenoid valves for
protecting
the
turbine
testing are not actuated.
5.2-0455-00/4
Fault
Other symptoms
Cause
Remedy
Incorrect
operation
monitoring equipment
of
Operating fault
Check operation.
Check power supply.
Check solenoid.
Check freedom
movement.
Fault
in
equipment
monitoring
of
valve
path
of
Failure of
solenoids
remote
trip
Incorrect
operation
monitoring equipment
Fault in operation
of
Check
signal
path
formation of trip signal.
for
Check operation.
Check power supply.
Fault
in
equipment
monitoring
path
of
5.2-0455-00/5
Fault
Other symptoms
Cause
Remedy
See
trouble
instructions
for
devices.
Fault may
immediately.
Fault in monitoring equipment
be
shooting
protective
corrected
Take
action
if
incorrect
operation of the overspeed
trips occur.
See instruction: Protective
Devices.
Troubleshooting:
5.2-0450.
Check if
transmitter
test.
the test
operates
signal
during
Mechanical
blockage
overspeed trips
of
5.2-0455-00/6
Fault
Other symptoms
Cause
Remedy
Check overspeed trip setting
by precise oil pressure testing
or actual overspeed test.
Check setting.
Check
auxiliary
pressure.
start-up
Trip
mechanism
of
overspeed trips fails to
latch-in.
trip
Fault in
solenoid
test
Check operation.
operation
of
Check solenoid.
Clear air
probe.
Incorrect operation
vacuum trip device
of
low
inlet
duct
using
Incorrect operation
vacuum trip device
of
low
fault
or
fault
or
5.2-0455-00/7
Fault
Other symptoms
Cause
Incorrect
operation
valves during testing
Remedy
of
Control valve not closed
Fault
in
valve
test
positioner or its actuation
Check
operation
solenoid.
of
trip
Test solenoid;
Check freedom of movement
of valve.
Stop valve
slowly
closed
too
Incorrect
mechanical
operation of stop valve
Repeat test.
Measure time taken for valve
to close.
Repair valve if no other cause.
Malfunction of monitoring
equipment
(pressure
switches, position transmitters
etc.)
Check
valves.
operation
solenoid
5.2-0455-00/8
Fault
Other symptoms
Cause
Remedy
5.2-0455-00/9
Steam Turbine
Operation
Fault
Other symptoms
Oil System
Fault Tracing
Cause
Remedy
Oil contamination
Remove water
Improper sealants
Water content
too
much
Introduce
waiting
period
between closure of turning
gear oil valve and run-up of the
turbine.
in
During
rated
operation
speed
BHEL Haridwar
5.2-0460-00/1
Fault
Other symptoms
During
turning
operation
Cause
gear
Remedy
or
Normal procedure
See incorrect
main oil pump.
of
5.2-0460-00/2
Fault
Other symptoms
In pressure oil
during
rated
operation
system
speed
Cause
Remedy
Check
bearing
temperatures.
metal
Check
bearings
temperature increase.
after
Differential
pressure
across filter high
Filter choked
See faults:
inadequate
Oil
properties
Turbine
sped
may
be
temporarily raised to force
main oil pump to take over.
Oil temperature high
During
rated
speed
operation after startup
5.2-0460-00/3
Fault
Other symptoms
Cause
Remedy
Check vents.
Cooling
water
temperature too high.
inlet
changeover
During
shut-down
turbine generator unit
During
rated
speed
operation after startup
of
Oil
temperature
faulty.
controller
not
or
5.2-0460-00/4
Fault
Other symptoms
Cause
Remedy
During
startup
(acceleration to warm-up
or rated speed)
After initiation of
protection system
When
shutting
turning gear
fire
down
Drive
Control or
AC-power supply
Turning
gear
interlocked.
oil
valve
Acknowledge
measures.
fire-protection
On start up
or
Drive
Control
On shut down
turbine generator
Main oil
failure
pump
of
bearing
the
Replace
damaged
components.
Rotor earthing
not healthy
Attend
rotor
arrangement.
arrangement
MOP
earthing
Improve insulation.
from
5.2-0460-00/5
Fault
Other symptoms
Seal steam
glands
leaking
Seal
steam
normal
Cause
Remedy
Discharge seal
atmosphere.
Check
pressure,
pressurizer valve.
from
pressure
steam
to
Both
control
valve
operating in a sequence
faulted
Mechanical fault in
steam control valve
seal
reset
Electrical fault
Valves
Control system
5.2-0460-00/6
Steam Turbine
Operation
Fault
Other symptoms
Cause
Remedy
Control
fluid
inadequate
properties
Rise
in
neutralization
number (Observed on the
basis of constant values
measured
continuously
under
the
same
conditions).
or
Check its operational status.
Examine control fluid for water
content, (take sample from
surface).
Change over to other control
fluid cooler.
Air
release
diminished
property
Excessive loss
Caution:
Stop
turbine
generator immediately. Stop
control fluid pumps and initiate
fire protection measures.
Pump faulty
BHEL Haridwar
5.2-0470-00/1
Fault
Other symptoms
Cause
Remedy
Control
fluid
differential
pressure
across
interchangeable filter high
Filter chocked
Control
low
fluid
temperature
Control
high
fluid
temperature
Inadequate cooling
Heater switched on
(fault in open loop control)
Temperature
at
protective tube high
heater
5.2-0470-00/2
Diaphragm damaged:
Repair leak
Fault
Other symptoms
Cause
Remedy
Repair leak
Leakage of water at
hydraulic pressure alarm
Repair leak
5.2-0470-00/3
Steam Turbine
Operation
Fault
Other symptoms
Seal steam
glands
escaping
Cause
Remedy
Start
one
seal
exhauster fan.
from
steam
Discharge seal
atmosphere.
steam
to
Both
control
valves
operating in sequence are
faulty
Electrical fault
Valves
Control system
BHEL Haridwar
5.2-0480-01
Steam Turbine
Operation
Fault
Other symptoms
Bypass System
Fault Tracing
Cause
Remedy
control
Check condensate pressure,
condenser
vacuum
and
bypass steam temperature.
Reheat
pressure
>
constant
or
variable
pressure setpoint.
Injection
water
pressure
downstream of injection water
control valves < interlock
pressure
Condensate
failed.
Pressure downstream of
Condensate pump(s) too
low.
pump(s)
Bypass
high.
steam
temperature
Reheat
pressure
<
constant pressure setpoint
but > variable pressure
setpoint.
Reheat
pressure
>
constant
or
variable
pressure
setpoint.
Interlocks ineffective
Fault in control
Lower
constant
setpoint.
pressure
BHEL Hardwar
Injection
effective.
water
interlock
5.2-0490-00/1
Fault
Other symptoms
Cause
Remedy
operating
Steam flow
effective.
Reduce
output.
Reheat
pressure
>
constant pressure setpoint
rate
limitation
generator
control
Reheat
pressure
>
constant pressure set point
Signal
pressure
not
present: Fault in regulator
or hydraulic control gear.
Condensate
pressure
upstream of injection water
control valves normal.
Condensate
pressure
downstream of injection water
control valves < interlock
pressure.
5.2-0490-00/2
steam
Fault
Other symptoms
Cause
Remedy
Reheat
pressure
>
constant pressure setpoint.
Condensate
pressure
normal.
as
soon
as
Diaphragm
of
pressure
control
damaged.
limit
gear
Replace diaphragm;
Diaphragm
of
bypass
condenser safety device
damaged.
Replace diaphragm.
Close cutoff valve upstream of
measuring element.
Insert lever and lock.
Replace diaphragm.
In this case bypass operation
may be continued for the
duration of the repair.
Reheat
pressure
>
constant pressure setpoint.
Bypass steam temperature
normal.
5.2-0490-00/3
Steam Turbine
Maintenance
In-Service Maintenance
Introduction
BHEL Haridwar
5.3-0001-01
Steam Turbine
Maintenance
Activity
No.
Work to be performed
1.0
1.1
Testing of
Controllers
1.2
1.3
Protective devices
1.4
Safety devices
1.5
Valves
1.6
Monitoring devices
2.0
Recording
and
documentation
of
operational
parameters
and conditions
Steady state operation
Non-steady state operation
Faults
Analysis of steam
Measurement of internal
efficiency
2.1
2.2
2.3
2.4
2.5
3.0
3.1
3.2
3.3
3.4
Inspection of LP turbine
free standing blades
Visual inspection
Blade profile and root
crack examination
Cleanliness of blade root
and groove
Blade natural frequency
test
BHEL Haridwar
Inspection Schedule
Parameter
measured
or tested
Functioning
& setting
Functioning
Functioning
& setting
Functioning
& setting
Functioning
free movement
leak tightness
Functioning
setting and
accuracy
Comparison
of specified and
actual data
Purity
Internal
condition of
turbine
Erosion,
looseness
Crack
Cleanliness
h
d
w
m
y
Frequency
= hourly
= daily
= weekly
= monthly
= yearly
Ref. 5.2-0021
Ref. 5.2-0022
& 5.2-0023
Ref. 5.2-0024
Ref. 5.2-0025
Remarks
Ref. 5.2-0026
Ref. 5.2-0027
Ref. 5.2-0028
for long term
monitoring
h
every start-up
every occurrence
Ref. 5.3-0050
d
3m
During
intermediate
and major
inspections,
every 50,000
hrs. of
operation
Natural freq.
5.3-0010-04/1
Activity
No.
Work to be performed
4.0
Inspection of accessible
expansion joints in cross
around and extraction lines
Visual inspection
Surface crack examination
4.1
4.2
5.0
5.1
5.2
5.3
5.4
6.0
Inspection
of
casing
guides and supports
Seating of casing on
support elements
Cleanliness
Integrity of keys & packers
Thermal clearances as per
drawing
Parameter
measured
or tested
Damages
Crack
Frequency
h = hourly
d = daily
w = weekly
m = monthly
y = yearly
During minor,
intermediate
and major
inspections
w
w
During
intermediate
and major
inspections
Damage
Clearances
Leakage
noise
6.1
6.2
6.3
6.4
6.5
Visual
inspection
for
steam-tightness
Casing joints
Flanges
Shaft seals
Valve stems
Instrument connections
7.0
7.1
7.2
Inspection of drains
Internal leak-tightness
External leak-tightness
w
w
8.0
8.1
8.2
8.3
8.4
8.5
Inspection
of
pumps,
motors and other drives in
continuous operation
Vibration behaviour
Head
Bearing temperatures
Thrust
Leak-tightness
d
d
d
d
d
9.0
9.1
9.2
9.3
9.4
9.5
d
d
w
w
3m
5.3-0010-04/2
Remarks
Activity
No.
Work to be performed
10.0
Inspection of hydraulic
accumulator
Check charge pressure
10.1
11.0
11.1
11.2
11.3
11.4
11.5
11.6
11.7
12.0
12.1
12.2
12.3
12.4
13.0
13.1
13.2
14.0
14.1
14.2
14.3
Parameter
measured
or tested
Frequency
h = hourly
d = daily
w = weekly
m = monthly
y = yearly
Remarks
2w
d
w
2w
w
Ref. 5.1-0130
d
d
Ref. 5.3-0080
d
w
w
Ref. 5.1-0140
Ref. 5.3-0082
d
d
Ref. Technical
After first year
circular No. X-85 of operation
5.3-0010-04/3
Steam Turbine
Maintenance
Activity
No.
Work to be performed
Maintenance Schedule
Turbine
Parameter
measured
or tested
Frequency
= hourly
= daily
= weekly
= monthly
= yearly
Remarks
1.
Cleaning
of
sliding
surfaces
casing supports
spacer bolts and discs
for bearing pedestals and
turbine casings
2.
measurement
of i
as indicated by
criteria
The
criteria
indicating
stage
pressure
when
saturated
steam
flushing
is
necessary are the
internal efficiency
i and the stage
pressures
3.
Preservation of turbine
using air drying equipment
as prescribed in 5.2-0360
relative
humidity
in
turbine < 50%
continuous
During shutdowns
lasting longer than
1 week
4.
Lubrication of components
of the turbine control and
turbine protection systems
as prescribed in
5.1-0690
5.
Tightening
of
turbine
control valve packings
1m
6.
3m or in the
event
of
leakages
7.
as prescribed
5.1-0690
BHEL Haridwar
Visual
inspection
h
d
w
m
y
1m
5.3-0021-02
Steam Turbine
Maintenance
Maintenance Schedule
Oil system, Seal Steam system, Drains
Oil System
Activity
No.
1.
Work to be performed
Cleaning of
centrifuge
3.
using
p across
filter
Frequency
= hourly
= daily
= weekly
= monthly
= yearly
Remarks
as indicated by
criteria, max 6m
6m -1y
p across
filter
oil level in
bucket
strainers
as indicated by
criteria, max 6 m
as indicated by
criteria,
max. 6m - 1y
during
appropriate
shut-downs and
overhauls
during
appropriate
shut-downs and
overhauls
6m
solid or liquid
foreign matter
in oil
continuous, as
indicated by
criteria
Cleaning of centrifuge as
specified
by
the
manufacturer
deposits in
centrifuge
1m
indicated by
criteria
4.
deposits in oil
tank
3 -4 y
5.
1 d (check),
topping up as
indicated by
criteria
6.
water collecting
on oil tank
bottom
as indicated by
criteria
BHEL Haridwar
oil
Parameter
measured
or tested
h
d
w
m
y
as
during overhauls
establish cause
of water
accumulation
5.3-0022-01/1
Activity
No.
Work to be performed
Parameter
measured
or tested
Frequency
h = hourly
d = daily
w = weekly
m = monthly
y = yearly
7.
as specified by
actuator
manufacturer
8.
as specified by
motor
manufacturer
9.
as prescribed by
fan manufacturer
10.
as prescribed in
5.3-0081
11.
3m or in the
event of leakages
12.
13.
14.
Charging
of
accumulators
5.3-0022-01/2
hydraulic
oil leakages
continuous
1y
charge
pressure
1m
Remarks
Activity
No.
Work to be performed
Parameter
measured
or tested
Frequency
h = hourly
d = daily
w = weekly
m = monthly
y = yearly
1.
1y
2.
1y
3.
Lubrication
of
vapour
exhaust fan motors
as specified by
motor
manufacturer
4.
Lubrication
of
vapour
exhaust fan bearings
as prescribed by
fan manufacturer
5.
3m
6.
3m or in the
event of leakages
Remarks
Drains
Activity
No.
Work to be performed
Parameter
measured
or tested
Frequency
h = hourly
d = daily
w = weekly
m = monthly
y = yearly
1.
as specified by
actuator
manufacturer
2.
3m
3.
3m or in the
event of leakages
4.
1 -2y
Remarks
5.3-0022-01/3
Steam Turbine
Maintenance
Activity
No.
Work to be performed
Maintenance Schedule
FRF system
Parameter
measured
or tested
h
d
w
m
y
Frequency
= hourly
= daily
= weekly
= monthly
= yearly
Cleaning of filters
and strainers
Switch
over
duplex
filters; and clean fouled
filter cartridges
as
prescribed in 5.1-1130
Turn plate-type filters
through
two
three
revolutions
Clean plate-type filters
p across filter
p across filter
as indicated by
criteria, max 6 m
Neutralization
number
6m or as
indicated by
criterion
FRF level in
strainers
as indicated by
criteria
Discoloration of
filter filling
3m, or as
indicated by
criterion
2.
deposits in FRF
tank
3-4y
3.
Level in FRF
tank
1 d check; Top
up as indicated
by criterion
1.
4.
Lubrication of motors of
pumps and fans
FRF pumps
FRF circulating pump
FRF vapour extraction
fan
BHEL Haridwar
Remarks
6m -1y
during appropriate
shut-downs and
overhauls
during appropriate
shut-downs and
overhauls
during overhauls
as specified by
the motor
manufacturer
5.3-0023-01/1
Activity
No.
Work to be performed
Parameter
measured
or tested
Frequency
h = hourly
d = daily
w = weekly
m = monthly
y = yearly
5.
as specified by
fan manufacturer
6.
3m
7.
3m of if leakage
detected
8.
Elimination of leaks by
retightening flanges and
unions
9.
10.
Charging
of
accumulators
5.3-0023-01/2
hydraulic
leakage
regularly, as
indicated by
criterion
1 -2 Y
Filling
pressure
1m
Remarks
Steam Turbine
Maintenance
Introduction
Tests demonstrate the readiness for
operation and the proper functioning of
important components. They must be
performed before and during start-up of the
turbine generator unit, irrespective of the
time of the preceding shutdown.
Test Performance
Take care to avoid any risks to people or
machines while performing tests.
BHEL Haridwar
5.3-0030-02/1
Equipment tested
Type of test
Preconditions
Test Step
Result
o
()
(1)
(2)
(3)
(1)
(2)
o Shaft at standstill
o Oil system depressurised
o Auxiliaries and emergency oil pumps off
o Subloop controls on Manual
(1)
(2)
5.3-0030-02/2
Date
Result
Tested by
Equipment tested
Type of test
o
()
Preconditions
Test Step
Result
Date
Result
Tested by
(3)
(4)
Pressure-dependent
on command from
subloop control before
starting turning gear
operation
(1)
(2)
(3)
(4)
(5)
Auxiliary and
Emergency oil pumps
o
Operational readiness
before starting turning
gear
operation
(testing not required if
sobloop
controls
have already been
successfully tested)
(1)
Auxiliary and
Emergency oil pumps
o
Operational readiness
after starting turning
gear operational
(1)
(2)
(3)
(4)
5.3-0030-02/3
Equipment tested
Type of test
Preconditions
Test Step
Result
o
()
Speed-dependent
cutout when rated
speed is reached
(1)
Speed-dependent on
command
of
AC
jacking oil pump from
subloop control before
starting
turning
gear operation
Shaft at standstill
(1)
(2)
(3)
Manual on of AC
jacking
oil
pump
before starting turning
gear operation
(1)
(2)
System depressurised
Speed-dependent on
command
of
DC
Jacking oil pump from
subloop control before
turning gear operation
5.3-0030-02/4
(1)
Date
Result
Tested by
Equipment tested
Type of test
o
()
Preconditions
Test Step
Result
Date
Result
Tested by
(2)
(3)
Operational readiness
of
Jacking oil
pumps
(1)
Pressure-dependent
on command from
subloop control
(1)
(2)
(3)
(4)
(5)
(6)
Operational readiness
(Testing not required
if subloop controls
have already been
successfully tested)
(1)
5.3-0030-02/5
Equipment tested
Type of test
Preconditions
Test Step
Result
o
()
(1)
Trip annunciated
Stop valves
o
Leak test
(1)
(2)
No speed increase
Bring back test valves to operating position
Control valves
o
Leak test
(1)
(2)
Overspeed trip
o
(1)
(2)
(3)
(4)
5.3-0030-02/6
Date
Result
Tested by
Equipment tested
Type of test
o
()
Date
Result
Tested by
Preconditions
Test Step
Result
(5)
(6)
(7)
5.3-0030-02/7
Steam Turbine
Maintenance
Equipment tested
Type of test
Test performance
Test performance must be recorded. If
incorrect operation of the equipment tested
occurs, take action establishing full
operational reliability of the turbine generator
unit immediately.
Pay attention to fault tracing instructions. [2]
Preconditions
Test Step
Result
o
()
Date
Result
Tested by
Turbine controllers
o
Functional test
(1)
Bypass control
o
Functional test
(1)
(2)
BHEL Haridwar
5.3-0035-02/1
Equipment tested
Type of test
Preconditions
Test Step
Result
o
()
Functional test
(1)
(2)
(3)
(4)
Oil temperature
controller
o
Functional test
(1)
(2)
(3)
(4)
Auxiliary and
emergency oil pumps
o
Operational readiness
test
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Operational readiness
test
o
(1)
(2)
5.3-0035-02/2
Date
Result
Tested by
Equipment tested
Type of test
Preconditions
Test Step
Result
o
()
Date
Result
Tested by
Ease
test
of
movement
(1)
Functional test
(1)
Overspeed trips
o
Functional test
testing of setting
and
(1)
Overspeed trips
o
(2)
(1)
(2)
(3)
(4)
(5)
(6)
respond(s)
handwheel
of
(7)
(8)
5.3-0035-02/3
Equipment tested
Type of test
o
()
(9)
Preconditions
Test Step
Result
Hydraulic low-vacuum
trip
o
Functional test
testing of setting
and
o
(1)
Differential pressure
switch in extraction
lines
o
Functional test
(1)
Exercising
(1)
(2)
Exercising
5.3-0035-02/4
Date
Result
Tested by
Equipment tested
Type of test
o
()
Preconditions
Test Step
Result
Date
Result
Tested by
Alarms
o
Functional test
Speed indicator
o Alarms generated
(1)
(1)
(1)
(1)
Important operating
values
o
Recording
Drains
o
Leak test
5.3-0035-02/5
Steam Turbine
Maintenance
Introduction
It is in the interest of both the plant operator
and the supplier that the causes of faults,
severe damage and unfavourable inspection
findings be determined, and actions taken to
prevent a recurrence of such incidents.
In order to determine the cause of such
faults, it is essential that information be
available, in the form of operating
documentation, on the operating history of
the turbine generator unit both in the past
and immediately before and during the fault
or damage.
This instruction contains recommendations
on the acquisition and archiving of operating
data.
Scope
of
measurement
and
instrumentation
The scope of measurements and also,
therefore, the instrumentation of the turbine
generator unit are dictated by the
agreements between plant operators and
suppliers.
The data are of importance for operations
management.
The
scope
of
data
recommended in Table-1 should therefore
be available to permit post-event analysis.
Scope of operating documentation
Operating documentation comprises the
following documents:
Printouts from continuous-line printer
Operating data logs or curves based on
the data archived in the electronic data
acquisition system
Alarm and switching logs ; such logs
document the histories of faults or
damage and should be archived
Logs with handwritten entries are
required in cases where certain data are
not recorded or archived
Logs used to document the long-term
behavior of the turbine generator unit
BHEL Haridwar
showing
the
availability
5.3-0037-03/1
decide
on
implemented.
countermeasures
to
be
5.3-0037-03/2
Table 1
Data acquisition recommended for post event analysis
ID Code
Measuring point
Retention
Period
Power/Speed
MKA
CE Active Power
MKA
CE Reactive Power
MYA
FS Turbine generator speed
Steam pressure
30 s
30 s
5s
0.002 Pnom
0.002 Pnom
0.05 to 0.1 s-1
service life
service life
inspection cycle
LBA
CP Upstream MS stop valves
MAA
CP Upstream HP blading
LBC/MAA CP Downstream HP blading
LBB
CP Upstream reheat stop valves
MAB
CP Upstream IP blading
LBQ
CP HP extractions
LBS
CP LP extractions
MAG
CP Condenser
Steam temperatures
30 s
30 s
30 s
30 s
30 s
30 s
30 s
30 s
0.01 Pnom
0.01 Pnom
1 bar
0.01 Pnom
0.01 Pnom
0.005 to 0.01 Pnom
0.02 Pnom
0.01 bar
service life
service life
inspection cycle
service life
service life
inspection cycle
inspection cycle
inspection cycle
LBA
CT Upstream MS-stop valves
LBC/MAA CT Downstream HP turbine
LBB
CT Upstream reheat stop valves
MAB
CT Downstream IP turbine
LBO
CT HP extractions
LBS
CT LP extractions
MAW
CT Seal steam header
Casing temperatures
30 s
30 s
30 s
30 s
30 s
30 s
30 s
2K
2K
2K
2K
2K
1K
1K
service life
inspection cycle
service life
inspection cycle
inspection cycle
inspection cycle
inspection cycle
MAA
CT MS-SV/CV 100/50%
MAA/MAB CT Turbine casing 100/90/50%
MAA/MAB CT Turbine casing top/bottom
MAC
CT Turbine casing front/rear
Bearing temperatures
30 s
30 s
30 s
30 s
2K
2K
2K
1K
service life
service life
inspection cycle
inspection cycle
MAD
CT
MKD
CT
Vibrations
5s
5s
1K
1K
inspection cycle
inspection cycle
5s
1 m
inspection cycle
5s
5s
5 m
inspection cycle
inspection cycle
5 m
5.3-0037-03/3
Steam Turbine
Maintenance
Turbine
Off-Normal Condition
Action
Classification of action
In-service correction
Main/reheat
steam
temperature > max (longterm)
steam
In-service correction
Main
/
reheat
temperature < design
Raise main
temperature
steam
In-service correction
In-service correction
Take i measurements
In-service check
Maintenance (saturated
steam washing) during
short shut-down
steam
reheat
(long-term)
Clean blading
Maintenance
(cleaning)
during overhaul
Seal
steam
pressure
deviates from setpoint or
fluctuates
Check
control
system;
if
necessary
correct
setpoint
adjuster
In-service
correction
check
and
Replace filters
control valves
at seal
steam
In-service check
In-service check
Check shaft
if necessary
Inspection and
during overhaul
seal
and
repair
repair
In-service check
In-service
repair
Discrepancies at TSC
- TSC test
correct
function
not
- High
wall
temperature
differentials during steadystate operation
BHEL Haridwar
check
and
5.3-0040-01/1
Off-Normal Condition
Spacer plates at casing
supports not free to move
Action
Classification of action
In-service check
In-service
check
and
maintenance
(cleaning)
only if casing does
not lift when fixture
elements are removed;
inspection
and
maintenance (cleaning) or
repair during overhaul
In-service
correction
down
In-service check
Actions
as
finding e.g.
appropriate
during
check;
shut-
to
In-service check
Check alignment,
shaft seals
In
service
correction
Check during overhaul
or after turbine shut-down
bearings,
In-service check
Inspection and
during overhaul
In-service correction
In-service maintenance
In-service check
Perform
inspection
necessary repair
5.3-0040-01/2
and
if
repair
Oil system
Off-Normal Condition
Action
Classification of action
Check
and
remedial
actions may
in many
cases
be
performed
during
operation;
otherwise
shut down
plant and perform repairs
Lubricating
oil
pressure
downstream of filter < Pnormal
In-service maintenance
Control
< Pnormal
pressure
In-service maintenance
In-service checks
maintenance
and
In-service
check
maintenance
and
In-service
check
remedial action
and
Maintenance
during
service or shut-down
In-service maintenance
In-service
correction
fluid
Check
oil
cooler
vents;
check
that
no
water
is
being admitted to standby oil
cooler; check oil cooler for
chocking,
where
necessary
change over and clean
Oil level in oil tank < normal
- Slow change
- Rapid change
check
and
Perform
additional
oil
examinations;
consult
on
appropriate actions with
oil
supplier and turbine manufacturer
In-service maintenance
5.3-0040-01/3
Action
Classification of action
In-service
check
maintenance
and
- Rapid change
In-service
check
remedial actions
and
Maintenance
during
service or shut-down
Operate
regeneration
plant
continuously; shorten sampling
intervals;
replace
Fullers
earth in filter
In-service maintenance
In-service checks
maintenance
and
5.3-0040-01/4
of
Recharge accumulators
In-service maintenance
Action
Control
synchronisation
valve
Control
changed
travel
as function
pressures
valve
of
Classification of action
Check
control
system,
if
necessary reset or correct,
establish cause of discrepancy
and eliminate
In-service check
secondary
Primary
oil
pressure
fluctuates or < Pnormal
valve
opening
Control
valve
leaking
(internal steam leak)
Load
shedding
defective
In-service repair
In-service repair
In-service repair
relay
5.3-0040-01/5
Action
Classification of action
Inspect
bearing,
renew
replenish grease or oil charge
Tighten
and
if
repack shaft seals
Performance degraded
In-service correction
In-service correction
Perform
system
check,
if
necessary
correct
system
operation
In-service correction
Pipes vibrating
Inspect dampers
In-service maintenance
In-service repair
Piping
and/or
connections leaky
or
In-service maintenance
necessary
In-service maintenance
piping
- Large-scale escape
flammable media
of
- Small-scale escape
flammable media
of
Establish
eliminate
5.3-0040-01/6
cause
of
leak
and
In-service maintenance,
repair during stoppages
and overhauls
Steam Turbine
Maintenance
Measurement of
internal Efficiency
Test Instructions
recommendations given in Table-1 or as
specified by the operator on the basis of
practical experience with the particular plant,
which also includes the trend of any
changes in efficiency.
Introduction
This test instruction describes the procedure
used for measuring the internal efficiency of
turbines whose expansion line lies within the
superheated steam region.
Principle of measurement
Prerequisites and limitations
The steam conditions in the reference plane
at the inlet and exhaust of the turbine,
whose internal efficiency is to be measured,
must lie within the superheated steam
region.
Boundary conditions
Test interval
Measuring
the internal
efficiency
6-months
BHEL Haridwar
5.3-0050-02/1
P1
h1
hs
T1
S1
h2
P2
T2
hs
Figure-1 : Steam conditions and enthalpies for calculating the internal efficiency of a
turbine cylinder
Notations:
h
h1 - h2
Internal Efficiency in % = -------- x 100 = ----------- x 100
hs
h1 - hs
Where,
P1 : Pressure of inlet steam before group stage section
T1 : Temperature of inlet steam before group stage section
P 2 : Pressure of exit steam after group stage section
T2 : Temperature of exit steam after group stage section
h1 : Enthalpy of inlet steam corresponding to P1 & T1
S1 : Entropy of inlet steam corresponding to P1 & T 1
h2 : Enthalpy of exit steam corresponding to P2 & T2
hs : Adiabatic steam Enthalpy corresponding to P2 & S1
Note: Values of h1, S1, h2 and hs are to be worked out from steam table.
5.3-0050-02/2
5.3-0050-02/3
Steam Turbine
Maintenance
Introduction
Tests that demonstrate the proper
functioning of important components, must
be performed during shut down of the
turbine generator unit.
The scope of the tests performed is listed in
the Test interval instruction [1].
Test Procedures
Test prerequisites, test activities and criteria
in tabular form are intended to simplify
testing.
Test performance
Take care to avoid any risks to people or
machines while performing tests.
Any simulated condition necessary for the
tests must be cancelled after completion of
tests.
Steam inlet valves may only be opened for
test purposes if the piping system upstream
of those valves is not under pressure and
the system concerned have been cleared for
testing.
Test performance must be recorded.
Equipment tested
o Type of test
o
()
Preconditions
Test Step
Result
Date
Result
Tested by
(1)
(2)
(3)
BHEL Haridwar
5.3-0060-01/1
Equipment tested
o Type of test
()
o Preconditions
Test Step
Result
Main trip valves in operating position
and ready to trip
Stop valves closed
(2)
Overspeed trip
o
(2)
(3)
(4)
o Generator synchronised
and
o Load > 0 %
5.3-0060-01/2
(1)
Date
Result
Tested by
Equipment tested
o Type of test
o
()
Preconditions
Test Step
Result
Date
Result
Tested by
opening
Control valves 0%
(2)
power
protection
relay
Pressure dependent on
command
Speed-dependent open
command
Response of electrical
condenser safety device
5.3-0060-01/3
Equipment tested
o Type of test
o
()
Preconditions
Test Step
Result
Date
Result
Tested by
(2)
(3)
device
test
(2)
(3)
(4)
(5)
(6)
o Condensate
operating
extraction
pumps
5.3-0060-01/4
Equipment tested
o Type of test
o
()
Preconditions
Test Step
Result
Date
Result
Tested by
Press push-button
governor
of
LP
bypass
(3)
(4)
bypass
5.3-0060-01/5
Steam Turbine
Maintenance
Introduction
Tests that demonstrate the proper
functioning of important components, must
be performed during stand still of the turbine
generator unit.
Test performance
Take care to avoid any risks to people or
machines while performing tests.
Test Procedures
Test prerequisites, test activities and criteria
in tabular form are intended to simplify
testing.
Equipment tested
o Type of test
()
o Preconditions
Test Step
Result
Date
Result
Tested by
(2)
(3)
BHEL Haridwar
5.3-0061-02/1
Equipment tested
o Type of test
()
o Preconditions
Test Step
Result
Main trip valves in operating position and
ready to trip
Stop valves closed
o Starting and load limit device not in 0%
position
(2)
Turbine control
o Testing of setting
Hydraulic amplifier
5.3-0061-02/2
Secondary pressures
(2)
(3)
Date
Result
Tested by
Equipment tested
o Type of test
()
o Testing of setting
Electro hydraulic converter
o Preconditions
Test Step
Result
Date
Result
Tested by
Travel of converter
Secondary pressures
(2)
(3)
o Functional test
Bypass control
o As per vendors recommendation
o Testing of setting
Main trip valves
(2)
of
5.3-0061-02/3
Equipment tested
o Type of test
()
o Preconditions
Test Step
Result
Date
Result
Tested by
Trip initiated
(2)
o Functional test
(2)
5.3-0061-02/4
in
Equipment tested
o Type of test
()
o Preconditions
Test Step
Result
Date
Result
Tested by
o Functional test
Trip started
Stop valve
o Exercising
o Cut-off pressure
(2)
5.3-0061-02/5
Equipment tested
o Type of test
Vacuum breakers
o Functional test
o Preconditions
()
Test Step
Result
(1)
Alarms
o Functional test 4-1190
Binary signal transmitters
o Functional testing of
pressure switches
General measuring
instrumentation
o Functional and annunciation
test
5.3-0061-02/6
(1)
Date
Result
Tested by
Steam Turbine
Maintenance
Introduction
The set pressure of the safety valves of
turbine integral system (e.g. oil or other
control media) are checked during
commissioning.
The scope of instruction in the turbine
manual is, apart from certain exceptions,
strictly limited to the scope of supply of the
turbine factory. Safety valves of the steam
and water systems are not normally a part of
the turbine factorys scope of supply. Thus
the following instructions may only be
regarded as recommendations.
If the pressure in a system increases
impermissibly from the operating pressure, it
is the function of the safety valve to reduce
this pressure to the normal value thus
protecting the system concerned from
damage.
Therefore,
the
turbine
manufacturer must approve the valve
settings to be used [1].
Performance of Testing
Shut-down can be avoided if the testing is
carried out during operation of the turbine.
From the point of view of the turbine
manufacturer, however, they can only be
performed if the turbine generator unit is not
endangered.
Operation of the turbine with elevated
reheater pressure may lead to impermissible
temperatures or the control and thrust
characteristics of the turbine being
disturbed.
Furthermore, faults in the safety valves may
cause impermissible load changes or
instability of the steam generator. In this
case, it is best to carry out testing when the
turbine is not operating.
BHEL Haridwar
5.3-0062-01
Steam Turbine
Maintenance
Introduction
Signaling devices in their various forms are
important aids to operational supervision.
However, they are of value only if they are
completely reliable in operation.
Therefore, the signaling devices must be
tested at regular intervals.
These
instructions
deal
with
the
fundamentals of testing and maintenance of
signaling devices.
the
Test procedures
There are various ways to
functioning of signaling devices.
BHEL Haridwar
test
5.3-0063-00/1
Other tests
The lamps of visual signaling devices have
only a limited life. Therefore, they must be
tested regularly by means of the lamp test
facility to ensure that they are operative and
be replaced if they are blown. When
replacing coloured lamps in operating
5.3-0063-00/2
Malfunctions
Any malfunctioning of signaling devices
must be rectified Immediately upon
discovery.
Steam Turbine
Maintenance
Testing of
Turbine Stress Controller (TSC)
Introduction
This test instruction describes the plausibility
checks to be carried out on the measured
values acquired by the temperature sensors
for turbine stress monitoring, as well as the
recording of measured and calculated
values
for
long-term
evaluation
of
temperature acquisition and of calculation
circuitry.
Using the stress monitoring function of the
turbine stress controller (TSC), the nonsteady-state thermal stresses to which the
steam turbine is exposed during startup and
shut-down and as a result of changes in
heat input to components during power
operation are acquired and compared with
the permitted limits.
The margins obtained from this comparison
define the stress and set the limits for
permitted temperature load.
Evaluation of measured temperatures
recording and action of the calculated
margins on the setpoint control for the
turbine controller allow an optimum
operating mode as regards both degree of
component
fatigue
and
economical
operation.
Test recommendations
A pre-requisite for the proper functioning of
turbine stress monitoring as described in the
introduction is fault-free operation of the
Boundary conditions
Test interval
Plausibility
checks
measured values
Non-steady-state and
steady-state operation
Steady-state operation
on
BHEL Haridwar
5.3-0064-01/1
During
steady-state
operation,
temperature
differences
of
approximately 15 K maximum develop
between the measuring points on the
heated surfaces and at the mid-wall of
valve bodies or the steam admission
area.
5.3-0064-01/2
5.3-0064-01/3
5.3-0064-01/4
Terms
Unit
peff
preact
MW
MVA
mms
pms
ms
kg/s
bar
C
pHPexh
HPexh
bar
C
pRS
RS
bar
C
pIPexh
bar
IPexh
i-adm
m-adm
C
C
i-HPC
m-HPC
C
C
i-HPS
m-HPS
C
C
i-IPS
m-IPS
C
C
adm-u
K
K
K
K
HPC-u
HPS-u
IPS-u
adm-l
HPC-l
HPS-l
IPS-l
K
K
K
K
Steam Turbine
Maintenance
Introduction
During operation, deposits occur on the
turbine blading to a greater or lesser degree
depending on the steam purity [1] and the
pressures and temperatures of the operating
steam. These deposits cause a reduction of
the turbine generator units efficiency due to:
BHEL Haridwar
5.3-0070-02/1
5.3-0070-02/2
5.3-0070-02/3
Steam Turbine
Maintenance
Introduction
Function of the turbine oil is to lubricate and
cool the bearings of the turbine generator
and
to
actuate
governing
system
components. Turbine oil is subjected to high
physical loads, should have a long service
life and must not have any adverse effect on
the proper functioning of the bearings and
other turbine oil consumers
The physical and chemical properties of new
turbine oil must comply with the
requirements of the Turbine Oil Specification
[1]. The aim of turbine oil care is to maintain
the properties and the useful service life of
the turbine oil for as long as possible.
This general maintenance instruction
discusses the necessity for, and the
procedures involved in turbine oil care.
The program for the care of turbine oil
includes regular inspection and analysis of
turbine oil samples. In this way changes in
turbine oil properties can be determined and
the necessary actions can be taken to
remedy the situation.
The filters and strainers in the operating oil
systems retain solid contaminants which can
cause damage and/or impair functioning if
they ingress into turbine oil consumers.
By centrifuge (i.e. oil conditioning station)
which is independent of the oil operating
systems, contaminants and aging and
corrosion products which are not soluble in
oil are removed from the turbine oil.
Thorough cleaning of the oil system during
initial startup and after inspections and
overhauls is one of the prerequisites for
successful turbine oil care. In addition, the
ingress of contaminants into the oil system
must be prevented.
Turbine oil properties
As a rule, turbine oils are paraffin-based
mineral oils which contain additives to
improve their resistance to corrosion and
their oxidation stability.
BHEL Haridwar
Total-acid number
Foaming characteristics
5.3-0080-03/1
5.3-0080-03/2
5.3-0080-03/3
5.3-0080-03/4
Fine-mesh filter
The turbine oil can be conditioned in an
oil filter with filter elements made of finepored cloth or filter paper. Since the finemesh filter has a high separation
efficiency, a high degree of turbine oil
purity can be achieved. Contaminants
insoluble in oil which ingress into the oil
system from outside, as well as products
of system-internal aging and corrosion
mechanisms are almost completely
removed from turbine oil.
Dynamic separator
The dynamic separator uses centrifugal
force to remove either solid or liquid
contaminants as required from the
turbine oil. The dynamic separator must
be set to operate in either solid
contaminant or water separation mode
in accordance with the manufacturers
instructions.
Static separator
A static separator is used to remove
water from the turbine oil. Since the
efficiency of the filter elements
deteriorates due to deposits of solid
contaminants, and in view of the
expense of filter elements, it is
recommended that the static separator
be used in conjunction with an upstream
fine mesh filter.
Multipurpose oil purification unit
The multipurpose oil purification unit is
used to remove solid and liquid
contaminants from the turbine oil.
Hydraulic oil
Hydraulic oil or control fluid containing
phosphoric esters, if in use, must not be
allowed to ingress into the oil system.
Oil coolers
If the water content of the turbine oil
increases, the leak tightness of the
operating oil cooler must be checked.
Dirty fluid
Fluid from the dirty-fluid tank must not
be refilled into the main oil tank without
thorough inspection and treatment.
Small amounts of turbine oil which
accumulate in the dirty-fluid tank are to
be disposed properly.
Turbine oil
Problems can arise as a result of the
incompatibility of turbine oils from
different manufacturers and containing
5.3-0080-03/5
Material
The compatibility of materials with the
turbine oil has been taken into account
by the turbine manufacturer during
materials selection. During inspections
and overhauls, care must be taken to
ensure that no incompatible materials
are used. This applies particularly to
gaskets
and
silicone-based
seal
materials.
5.3-0080-03/6
Table1 :
Fault
Cause
Actions
Boundary conditions
Total-acid number
> mg KOH/g
Purity
Water content
Foaming
5.3-0080-03/7
in
Fault
Cause
Actions
Boundary conditions
-
Investigate
the
origin
of
contaminants
and
prevent
contaminant ingress into oil
system.
Take
turbine
oil
samples
upstream and downstream of
the oil centrifuge and determine
the
separation
efficiency.
Implement
measures
in
accordance with the operating
unit manufacturer, in order to
improve contaminant separation
efficiency.
Check oil filter cartridges or
elements, replace damaged oil
filter cartridges or elements.
If necessary, vent the oil filters.
Solid contaminants
into the oil system
ingress
5.3-0080-03/8
Fault
Boundary conditions
Cause
Actions
There is no permanently
installed dynamic or static
separator for removing water
from the turbine oil
5.3-0080-03/9
Fault
Boundary conditions
Cause
Actions
Turbine
oil
foaming
characteristics
do
not
comply
with
the
Specification
5.3-0080-03/10
Fault
Cause
Actions
The
differential
pressure
across one oil filter is high
Boundary conditions
The
oil
centrifuge
is
defective or the operating
conditions for the oil do not
comply
with
the
requirements
Oil filters
Unit-specific or additional
dynamic separator
Unit-specific or additional
static separator
Turbine
oil
temperature
upstream of static separator
too low
5.3-0080-03/11
Steam Turbine
Maintenance
Introduction
To ensure satisfactory functioning and to
limit wear, a small number of components
on the turbine must be lubricated at regular
intervals.
Over-greasing
avoided.
Actuators
for
remote-controlled
governing, control and similar devices
Spindles
devices
Lubrication Intervals
Scope
of
hand-operated
or
overfilling
must
be
shut-off
BHEL Haridwar
5.3-0081-00
Steam Turbine
Maintenance
Introduction
The use of fire resistant control fluid for
turbine control and protection systems
reduces the risk of fire. This is due to the
higher ignition temperature (compared to
mineral oil) in case of leaks.
Phosphoric esters with a low water and
chlorine content (HS-D series) are used and
must be carefully maintained to preserve
their properties.
BHEL Haridwar
The system must be refilled from leadsealed barrels; precautions must be taken to
prevent filling with a control fluid that is not
identical to the one specified for use or with
mineral oil from similar casks.
Changing Control Fluid
The entire system must be drained when
changing the fluid. New filter elements must
be installed or those present thoroughly
cleaned.
If unavoidable, old control fluid residue (up
to 3%) may be tolerated.
The system must be refilled and samples
taken for comparison with the initial filling.
The amount of residue of control fluid within
the system and the neutralisation number
must be checked by analysing and
comparing the samples taken before filling
and after the system has been put into
operation. If this shows an increase in the
neutralisation number, it must be reduced by
passing the control fluid through the bypass
regenerating system.
Treatment of waste control fluid
Biological decomposition of control fluid is
difficult; control fluid is heavier than water
and affects it adversely and therefore must
5.3-0082-02/1
5.3-0082-02/2
FKM
IIR
PTFE
PE
PA
Viton
Butyl IIR-40
Teflon
Hostalene
Nylon
Metallic materials
Phosphoric esters have a negligible effect
on steel, copper alloys, zinc, tin and
aluminum alloys provided the neutralisation
number is within the admissible limits. The
solid outer oxide layer of aluminum alloys
must not be destroyed due to friction.
Pure copper cannot be used due to its
catalytic effect on the decomposition of the
phosphoric ester. Sealing material made of
5.3-0082-02/3
- Stability
Acid and aging products may cause a loss
of stability; the speed of aging increase in
the manner of a chain reaction, drastically
reducing the service life of the control fluid
(resulting from chemical reactions of the
control fluid with water, air and other
impurities).
+ Removal of acids and aging products
5.3-0082-02/4
5.3-0082-02/5
- Purity
Particles / 100 ml
Magnitude
5 10 m
10 25 m
25 50 m
50 100 m
> 100 m
2700
670
93
16
1
4600
1340
210
28
3
9700
2680
380
56
5
24000
5360
780
110
11
32000
10700
2510
225
21
87000
21400
3130
430
41
128000
42000
6500
1000
92
Class-3:
5.3-0082-02/6
5.3-0082-02/7
Time of Sampling
Degree of purity
Discol
oration
test
Particle
count
NZ
KOH
mg/g
ASC
min
Water
content
%
by
vol.
x
x
x
x
24h after
commencing hot
operation
Before commencing
flushing for record of
as-delivered condition
PNB
Continuous sampling
during flushing
PNR
Kinem.
Visco
Anticorro.
2
Props.
V mm /s
(2)
x
x
(3)
PNB
PNU
PNBF
PNMF
Before commencing
hot operation (Last
sample taken more
than 2 weeks earlier)
Density
3
g/cm
PNR
5.3-0082-02/8
PNU
PNBF
PNMF
Parameter and
dimensions
Inspection
method
Water content
% by vol.
Permissible
limit
Inspection
interval
Measures to be taken if
limits exceeded
No free water
visible to
naked eye
0.5
weekly
Evaporate, suction-extract,
ladle-off, centrifuge using
special device
Check regeneration plant,
Replace fullers earth, Check
effects
by
frequent
measurement of NZ
Replace filling
Neutralisation
number
NZ (mg KOH/g)
DIN 51 558-1
ASTM D974
Monthly,
weekly if
negative
trend
monthly
Kinematic
viscosity at
2
40C (mm /s)
Solid impurities
DIN 51562-1
ASTM D445
26-50
Particle count
and
discolouration
test
SAE purity
grade class 6
monthly
Air separation
capability
(min. at 50C)
DIN 51381
Proper
functioning of
system must
be assured
every 4
month
Density at 15C
3
(g/cm )
DIN 51757
ASTM D1298
Fire resistance
test
DIN/ISO 14935
5 sec
Anti-corrosion
properties
DIN 51585
ASTM D665-60
no corrosion
permissible
after
determining
oil content
th
every 4
month
Oil content
% by vol.
nuclear
resonance test,
density
3% max.
see note
th
th
every 4
month
5.3-0082-02/9
Steam Turbine
Maintenance
Introduction
A fire-resistant control fluid (FRF) is used in
control and governing systems. The purity of
the fire-resistant fluid is of vital importance to
the reliable operation of the plant and must
be monitored continuously.
Sampling
Always perform sampling at the same
location directly from the system.
BHEL Haridwar
Determination Procedure
Measure 20 ml (about 23 g) of fireresistant fluid into an Erlenmeyer flask
previously
cleaned
with
purified
n-heptane, p.a., and dissolve in 80 ml of
purified n-heptane, p.a.
Use a clean hair brush to remove any
dust from the membrane filter and clamp
the filter into the filtering device.
Connect up the water jet pump to the
aspirator and filter the fire-resistant fluid /
n-heptane
mixture
through
the
membrane filter.
5.3-0083-01/1
5.3-0083-01/2
Steam Turbine
Maintenance
Introduction
If the piping of the lubricating and control
fluid system is excited to vibration, the
deflections
involved
could
cause
inadmissible stressing of the piping material.
Dampers are used to attenuate piping
vibration. These consist essentially of a
cylindrical casing enclosing a plunger
embedded in a viscous bitumen mass that
performs the actual damping function. The
upper part of the damper is sealed by a
fabric-base plastic guard sleeve.
This damper design is not subject to wear,
but the damping medium properties may be
impaired by temperature influences or, if the
guard sleeve is damaged, by contamination
Vibration Dampers
Scope of Inspection
- Criteria
1y
Damper Attachment
- firm seating of damper components on pipe and support sides (and at
thermal insulation plates, if applicable)
Motion reserve
- cold condition: position of plunger as in support drawing
Guard sleeve
- correct and firm seating
- tension of the clamps
- damage (cracking or perforations)*
External influences
- effects of water, oil or similar *
5y
As for 1 y
Condition of the damper medium
- surface appearance
- elasticity
* If found, perform 5-year inspection immediately
BHEL Haridwar
5.3-0100-00/1
Points to Note
If welding work is to be performed close to
the piping dampers, take care to protect the
dampers (and particularly the guard sleeves)
from weld spatter and other potential
damage.
To preclude any deterioration due to ingress
of foreign matter such as water, oil, etc.,
replace guard sleeves as soon as any
damage is discovered. In that event, also
check the condition of the damper medium
immediately.
5.3-0100-00/2
Steam Turbine
Maintenance
Types of Overhaul
17,000
Medium
Overhaul
(Inspection,
servicing, repair)
A Medium Overhaul is a planned shutdown,
if possible, simultaneously with other plant
components during which a casing may be
opened. It covers all work which has a
bearing on the availability of the turbinegenerator unit.
BHEL Haridwar
To =
5.3-0200-05/1
TURBINE OVERHAUL
02
25800
LP turbine
IP turbine
HP turbine
Turbine valves
Turbine bearings
Coupling check
LP turbine
IP turbine
Coupling check
Turbine valves
Turbine bearings
Coupling check
*
*
05
06
60200
Medium Overhaul
03
04
43000
Major Overhaul
HP turbine
01
Variant-2
Turbine valves
Operating years
8600
Minor
Overhaul
Turbine bearings
Variant-1
07
08
77400
09
10
94600
11
12
111800
13
14
129000
15
16
146200
17
18
-Mandatory,
5.3-0200-05/2
-Optional,
*
*
Major Overhaul
Medium Overhaul
For units with spring mounted TG deck, check reference readings of deck
spring units, carryout alignment and catenary check and readjust spring
units after first year of operation.
Minor Overhaul
Check guides of inner casing for freedom of movement and wear. Overhaul.
Check shaft seals and labyrinth glands for abrasion and scaling. Check
springs of spring-mounted ring segments. Replace springs of high
temperature zone.
Check shaft for cracks. Perform run out check, eliminate score-marks in
shaft journals. Inspect coupling.
Clean rotors and casings and examine for damage. Pay particular attention
to blades and seal strips.
Open main oil pump, check bearings, seal rings, shaft, impeller etc.
*
Check casing guides for deposit, if guides are jammed, remove, clean and
overhaul keys. Ensure design key clearances.
- If necessary, if applicable,
- Mandatory,
5.3-0200-05/3
Minor Overhaul
Medium Overhaul
Major Overhaul
Check drains for foreign material, open and clean sludge traps.
Measure casing distortion, check casing joints for erosion, check for cracks.
Drain main oil / control fluid tank, separate impurities, change oil / control
fluid if necessary. Inspect tank. Clean strainers.
Remove and check steam strainers for deposits and damage, clean/replace
if necessary.
Check oil / control fluid filters for leaks, remove and clean the inserts, pay
attention to damage.
Examine oil / control fluid lines for damage, eliminate leaks. Retighten
flange joints. Change gaskets, if applicable.
Check pipe supports and hangers and readjust if necessary. Check casing
horn drop and eliminate pipe pull by adjusting hangers & supports
= If necessary, if applicable,
5.3-0200-05/4
= Mandatory,
MINOR OVERHAUL
Casings are not opened. Bearing check,
coupling check if necessary, mandatory for
spring mounted TG deck after first year of
operation, checks of controls, safety and
protective equipment on steam and oil sides.
Components to be inspected
st
TG deck springs (if applicable) after 1
year of operation, alignment & catenary
Casing roll check (if rotors realigned)
Bearings
Oil guard rings of bearing pedestals
Sliding pieces in casing guides and
supports
Control valves, bypass valves
Emergency stop valves and extraction
non-return valves
Control and safety equipment
Piping supports and hangers
Steam strainers
Drains
Oil lines
Pumps (main oil pump, jacking-oil pump,
auxiliary oil pumps and emergency oil
pumps, if necessary)
Oil / control fluid tanks
Oil / control fluid filters
Last stage of LP Turbine
Monitoring equipment
Scope of activities
TG deck springs (where applicable)
For units with spring mounted TG deck, the
deck springs are to be inspected and
reference dimensions compared and
adjusted after first year of operation. This
will also call for alignment, catenary and roll
check.
Couplings
If couplings are to be opened, carry out
swing check & coupled runout measurement
before loosening the coupling bolts,
measure the pretension of the coupling bolts
while loosing and tightening. Check the
alignment radially and axially. If deviations
exceed
the
permissible
tolerance,
realignment is required.
5.3-0200-05/5
Crack
Monitoring equipment
Check that mechanical, electrical and
hydraulic monitoring equipment function
properly and repair or recalibrate as
necessary.
MEDIUM OVERHAUL
At least one casing is to be opened and the
rotor lifted out. Otherwise as for minor
overhaul.
Components to be inspected
As for minor overhaul but augmented by the
following:
Scope of activities
Inlet and outlet connections
Inspect for scale and freedom of movement
at I-and L-seal rings. Inspect U-seal rings
and measure precompression.
Casing
Measure for deformation, crack examination.
Rework according to findings. Inspect casing
joint plane for erosion
Inner casing guides
Check for freedom of movement and wear.
Blading
Clean entire blading with casing open and
inspect for damage and incipient cracks,
Check shrouds for scale according to
temperature. Check for blade looseness and
lock blade lift.
The fir-tree root free standing blades of LP
rotor need special attention. After every
50,000 hours of operation, take out the
blades from groove, clean root and groove,
carry out crack detection of the entire blade
including root, check natural frequency in
position with technological pieces.
Glands and labyrinths
Check for abrasion and scale (dependent on
temperature). Check condition of springs.
Rotor
Check for cracks in fillets. Perform run out
check. Eliminate scoring on the journals.
Check coupling.
TSC thermocouples
Replace TSC thermocouples fitted in IP
inner casing, whenever IP Turbine in
opened for overhaul. Take advance action
for procurement of the TSC thermocouples
and associated fittings.
5.3-0200-05/6
5.3-0200-05/7
MAJOR OVERHAUL
All casings are to be opened and the rotors
lifted out. Otherwise as for medium
overhaul, but instruction if necessary is
inapplicable.
Components to be inspected
As for medium overhaul but instruction if
necessary is inapplicable, and augmented
by the following:
Oil / Control fluid tanks
Steam lines
Casing center guides
Scope of Activities
Oil / Control fluid tanks
Drain and clean tank. Purify oil / Control
fluid, change if necessary.
Steam lines
Check steam lines exposed to main or
reheat steam for expansion, deformation
and crack.
Casing centre guide
Disassemble and overhaul. Ensure design
clearances
SUGGESTED INSPECTION & TESTING
PROCEDURES
During inspection of steam turbine generator
units, certain components are required to be
inspected in-depth to achieve more accurate
evaluation of their condition. The findings
are to be documented (descriptions, check
calculations, drawings and photographs).
INTEGRITY ASSESSMENT
During integrity assessment, following
examination / inspection / testing of steam
turbine parts may be done.
Visual Inspection
5.3-0200-05/7
Eddy-current examination
Ultrasonic examination
Hardness test
Manual spectroscope
X-Ray examination
Expansion
measurements
(measurement of diameter, length,
circumference).
5.3-0200-05/8
Material testing
Chemical composition
Metallographic microstructure
evaluation
Steam Turbine
Maintenance
Introduction
Following extensive boiler repairs, measures
must be taken to protect the turbine against
erosion by solid particles.
Bypass Operation
When extensive repairs have been carried
out on the boiler, it is not possible to prevent
solid particles remaining in the system in
spite of chemical cleaning. For this reason,
provision must be made for a lengthy period
of bypass operation with the highest
possible bypass steam mass flow rate at the
time of unit restart. During this bypass
BHEL Haridwar
Turbine Restart
After Boiler Repairs
operation, all solid particles remaining in the
system are blown down into the condenser,
which prevents them from causing particle
erosion on the turbine blades Particles
blown down into the condenser must be
removed from the hot well before
commencement of process operation. The
bypass steam mass flow rate must comply
with the limits (mass flow rate and duration
of operation) defined in the specifications.
The bypass stop and control valves may
suffer slight damage to their seats and discs
as a result of steam dumping and must,
where necessary, be checked by sampling.
5.3-0210-00
Steam Turbine
Maintenance
Introduction
Pre-service Inspections
and
upgrading
measures
retrofitting
and
BHEL Haridwar
In-Service Inspections
Documents
modifications
Protective devices
Service phase testing applies mainly to
those devices which protect the turbine
against over speed. The test programs of
the automatic turbine tester may also be
executed if required.
Controllers
The performance of the controllers must
be observed throughout the restart
phase.
5.3-0220-00/1
Output
Evaluation of Tests
Parameter Records
and
Operating
+ Extraction steam
+ Exhaust steam
Casing temperatures
Expansions
Vibrations
Condensate temperatures
5.3-0220-00/2
Automatic testers
Summary
of
results
inspections and repairs
from
major
open
(actions,
implementation
5.3-0220-00/3
Steam Turbine
Maintenance
Environmental protection
BHEL Haridwar
5.3-0250-00
Steam Turbine
Maintenance
BHEL Haridwar
Fluorelastomer Products
Safety Notice
Decontamination
procedures
for
decomposed Fluorelastomer products
Decontamination of equipment exposed
to decomposed Fluorelastomer products
If decomposed fluorelastomer products are
suspected, great care must be taken when
removing the residues from equipment.
Protective equipment and clothing must be
used and worn, including heavy duty rubber
gloves and full face protection, to prevent
accidental skin contact with the Hydrofluoric
acid (H-F).
The residues should be disposed of with
great care, such as very high temperature
incineration. All containers or bags used to
transport the residues must be clearly
marked to ensure careful handling to the
point of disposal.
H-F residues may be washed away using
sufficient quantities of water to dilute them to
harmless concentrations.
5.3-0251-00
Steam Turbine
Maintenance
Safe disposal of
Turbine Oil
BHEL Haridwar
5.3-0252-00
Steam Turbine
Maintenance
Ordering of Spares
Assembly
Drawing
No.
Item No.
Qty.
Description
Part Drg.No. /
Code No. /
KKS tag No.
Application
1.
2.
3.
4.
5.
Description as above
Installed Quantity
Required Quantity
1.
2.
3.
BHEL Haridwar
5.3-0300-00