Training On Steam Turbine RBP

Bilfinger Mauell ESG AG
Training on Generator
Yambu
Kingdom of Saudi Arabia
25/11/2015 Turbine Engineering Department
Bilfinger Power Systems Group
CONTENT
Operating principle
Group 1
Mechanical components
Group 2
Regulation system
Group 3
Protection system
Group 4
Maintenance
Group 5
page 2
OPERATING PRINCIPLE : Fundamentals Overview
There are two fundamental forms of steam

turbines.
-
One form is the impulse turbine, deriving its

name from the fact that the rotating member is
pushed around by the force of steam impacting
on blades or diaphragms.
The second form is the reaction turbine, so
called because it is the reactive kick from steam
in the rotating element which causes it to rotate.
page 3
Exhaust steam conditions, extractions and

admission.
-
The name "Condensing turbine" and "Back pressure turbine"

expressed about steam condition exit the turbines. If steam condition
exit the turbine in wet steam or where steam condition at bellow
saturated line of Mollier diagram, named condensing turbine. If steam
condition exit the turbine in dry or still in superheated condition or at
upper of saturated line of Mollier diagram, named back pressure
turbine.
In applications, when required, steam can be extracted from turbine
before steam flowing through the last stage, named extraction turbine.
In the other case, if required, steam also can be admitted to turbine
before last stage, named admission turbine.
page 4
Backpressure and Condensing turbines.

- Each class may be subdivided according to
whether full throttle flow continues through the
machine to exhaust or whether part of the steam is
withdrawn from the unit after some expansion. Units
of the latter types are referred to as extraction
turbines. These may be further classified as simple
extraction turbines or automaticextraction units. In
the latter, a regulating valve gear is introduced to
control the pressure at the extraction flange. In the
simple extraction turbine, sometimes known as a
bleeder turbine, one or more stages have openings
of fixed size through which steam may be
withdrawn.
page 5
First Law of Thermodynamics

-
The first law of thermodynamics or the law of conservation of energy states that energy can neither be created nor destroyed. It
describes the change of energy between forms (heat to work and work to heat) and allows for accounting for the transfer of
energy to and from a system and changes of energy within a system. One typical form of the first law is
Where =heat added to the system. =work done by the system to the surroundings. =increase in energy storage within the system.
-
A useful property for flow processes, such as in steam turbines, is the concept of enthalpy. Enthalpy per unit mass is defined as.
H*u + Pv
Where H* =enthalpy. u=internal energy per unit of mass. P=pressure. v=volume per unit mass.
In the case of an ideal flow system with no heat exchange with the
surroundings or change in potential or kinetic energy, the work done by the
system is the change in enthalpy between two states:
page 6
Second Law of Thermodynamics
- Simply stated, the second law of thermodynamics is that not all of a given quantity of heat can be converted to useful work. The
second law of thermodynamics places strict limits on the available performance of any heat engine, including a steam turbine. For
example, one of the implications of the second law is that all real cycles must reject heat. The second law is typically discussed by
considering the entropy of a thermodynamic system. Entropy is defined as the quantity of heat added during a reversible process
divided by the absolute temperature at which the addition takes place:
(Reversible)
- The second law of thermodynamics is the postulate that the entropy of an isolated system cannot decrease:
0
- Processes that would decrease entropy are therefore not possible; processes that increase entropy are possible.
page 7
Process Representations
Process representations provide information
about key thermodynamic variables during a cycle.
Two valuable process representations for the
analysis of thermodynamic cycles in steam turbines
are the temperature entropy diagram and the
enthalpyentropy (Mollier) diagram
page 8
COMPOSITION : Main components
Steam turbine main components:

1.
2.
3.
4.
5.
6.
5
Stator
Rotor
Front and rear pedestals
Control Valves
Governor
Gland sealing
6
page 9
COMPOSITION : Stator overview
The stator is composed of:
page 10
COMPOSITION : Stator overview
The magnetic core is built from

staked insulated steel plate. The
plate form is depending of the
generator design.
The stator coils are built with

Roebel copper bars. The bars are
installed in the stator core slots
with specific slot feeling and lock
in place by the slot packing and
wedges.
page 11
COMPOSITION : Stator core
1.
2.
3.
4.
6.
7.
8.
9.
10.
11.
Stacked plate block

Cooling vent
Stacked plate block in steps
External support
Clamping plate
Clamping finger
Damper winding plate
Bottom bar
Top bar
Hot air output
page 12
COMPOSITION : Stator end winding
1.
2.
3.
4.
6.
7.
8.
9.
10.
Bottom bar
Top bar
Insulated caps
Bar connection
Radial support
Outer support ring
Plans wedge
Support ring wedge
Inner support ring
page 13
COMPOSITION : Stator winding
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Bottom bar
Top bar
Magnetic core
Bottom bar spacer
Inter-bars insulated wedge
Radial / closing wedge (dovetail)
Adjustment shims
Radial wedging
Ripple spring
Side wedging
page 14
COMPOSITION : Rotor overview
The rotor is coupled to the turbine

through a gear box or directly ;
depending the type and speed of
turbine.
The rotor winding is connected to

an excitation system through two
copper bore connection, localized
in the centre of the shaft.
page 15
1.
2.
3.
4.
5.
6.
7.
8.
Coupling (to turbine or gear-box)

Journal from shaft
Central connection
Fan blades
Coil retaining ring
CRR support and fan hub
CRR locking ring
Spacer of windings overhang
page 16
9.
10.
11.
12.
13.
14.
15.
Axial rotor slot

Inertia compensation slot
Balancing masse area
Field lead
Radial stalk
Coupling (to exciter shaft)
Rotor winding
page 17
COMPOSITION : Rotor winding
1.
2.
3.
4.
5.
6.
9.
10.
11.
Shaft
Winding overhang
Axial rotor winding
Curved rotor winding
Radial jumper
Inter-turns connection
Tangential wedging
Axial wedging
Overhang wedge
page 18
COMPOSITION : Rotor slot
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Rotor shaft (tooth)

Slot wedge
Insulated spacers
Rotor winding coil
Copper conductor
Axial vent
Radial vent
Wedge vent
Slot channel
Inter-turns insulated spacer
Lateral insulated spacer
Bottom slot support insulated
page 19
COMPOSITION : Excitation system overview
There is two different excitation

systems :
The static exciter ; composed of
two slip rings and a brush system
The brushless exciter ; composed
of a rotating exciter with diodes
page 20
COMPOSITION : Static excitation system
The static exciter is composed of :
Two slip rings, each ones

connected to one rotor polarity
One brush-holder with carbon
brushes
One cooling system done mainly
by air ventilation
The system is simple and very

reactive but required strong AVR
and strong preventive
maintenance
page 21
COMPOSITION : Static excitation system
1.
2.
3.
4.
5.
6.
7.
Collector ring (or slip ring)

Insulated bushing
Shaft
Connection bloc
Fan blades
Central connection
Rotor shaft
page 22
COMPOSITION : Brushless excitation system
A brushless exciter has :
One exciter rotor

One exciter stator
One rectifier system (fixe or
rotating diodes)
This system required less

maintenance but more complicate
to implement
The excitation current is amplified
by the exciter, then required a
smaller AVR
page 23
COMPOSITION : Brushless excitation system
A.
B.
C.
D.
E.
F.
G.
H.
J.
K.
Casing
Inductor support
Inductor core (stacked plates)
Inductor winding
Inducer support
Inducer core
Inducer winding
Diodes
Connection to rotor winding
Air seals
page 24
COMPOSITION : Bearing overview
Bearing on frame 6 generator are

mainly circular full bearings
Alstom made a system with only

one bearing on exciter side, but
usually a generator has two
bearings.
A special anti-friction metal wear

the bearing. It is called as white
metal or Babbitt as the name of
his inventor.
page 25
1
2
Deflectors or oil seals avoid oil

leaks on shaft area
The bearing (on exciter side) is

insulated to avoid shaft voltage
Bearings are monitored, mainly, by

temperature and vibration sensors
page 26
1
2
5
6
1.
2.
3.
4.
5.
6.
7.
Journal bearing
Gaskets
Cover
Diaphragms
Oil seals
Jacking oil inlet
Lube oil inlet
page 27
COMPOSITION : Instrumentation overview
Operation of unit requires material

information on this unit. This
information is coming from
instrumentation
Instrumentation are installed for

protection, regarding potential
issue, but also for analysis
page 28
COMPOSITION : Instrumentation overview
There is two different type of

instrumentation
Monitoring instrumentation
Physical measurement
Electrical measurement
Operational instrumentation
On line
At standstill
page 29
COMPOSITION : Instrumentation / monitoring
The physical measurement are

done directly on the unit through
different sensors as :
Vibration sensors on bearing

Temperature sensors on bearing
Temperature sensors on winding
Temperature sensors of air
Pressure sensors of lube oil
page 30
1.
2.
3.
4.
5.
6.
7.
8.
9.
Resistance (RTD)
Sensor frame
Wiring
Measurement line
Compensation line
Connection
Grounding resistance
Discharge
Ground
page 31
Conversion table from

temperature (C) to resistance
(), according to European norm
DIN43760
page 32
1.
2.
3.
4.
5.
6.
7.
Thermocouple
Measurement line
Measurement line
Connection
Grounding
Grounding resistance
Discharge
page 33
Conversion table from

temperature (C) to F.E.M. (mV),
reference junction 0C
page 34
The electrical measurements are

done through different components
Current transformer
Voltage transformer
Power transformer
Neutral transformer
Shunt
page 35
The electrical measurements are

done through different components
Current transformer
Voltage transformer
Power transformer
Neutral transformer
Shunt
page 36
COMPOSITION : Instrumentation / operational
The on line instrumentation are

designed to prevent or avoid
problems
Rotor earth fault detection
(prevent from rotor winding fault)
Shaft grounding brush (avoid and
control shaft voltage propagation)
page 37
COMPOSITION : Instrumentation / operational
The at standstill instrumentation

are designed as preservation
function
On generator the space heater

avoid accumulation of moisture
during all shut-down phase
page 38
REGULATION SYSTEM : Generality
The generator regulation system is design to supply a variable

direct current to a rotor.
The nominal current of an excitation system will depend on
generator characteristics and the type of exciter
The exciter power needs are provided, in operation, by a PMG or a
transformer, rectified and regulated by thyristor bridge(s)
page 39
The regulation system includes or AVR has automatic channel(s)

and manual channel(s)
The automatic regulation is regulating usually, stator voltage, reactive
power and power factor ; normal operation regulation
The manual regulation is regulating the excitation current ; emergency
operation regulation
page 40
page 41
REGULATION SYSTEM : Alstom eurorec regulation
Alstom Eurorec regulation is an

analogic generator regulation
system.
There is two channel per

regulation system, an automatic
channel for normal operation and a
manual channel in case of fault on
automatic channel
page 42
The automatic channel has several

electric cards
The main electric cards are:
CMS1, automatic set point

RS1, voltage regulator
GIMS, pulse generator
LSES, under excitation limitation
LUF2, U/f limitation
page 43
The manual channel has several

electric cards
The main electric cards are:

CMS1, manual set point
RIEX, field current loop
GIMS, pulse generator
page 44
REGULATION SYSTEM : Alstom microrec K regulation
Alstom microrec K is a digital

regulation
The regulation usually found on
generator is the K4.1
The regulation include different
regulation mode, set up in the
software
In complement of the regulation,
several limitation function are
available
page 45
The AVR K4.1 has several cards
The main cards are :

RDSP : regulation processor card
CPRM : pulse generation card
ESVI : voltage/current
input/output card
IRVI : regulation interface
AMS : power supply card
page 46
page 47
PROTECTION SYSTEM : Generality
Purpose
Avoid any generator improper operation coming from internal or
external fault
Definitions
External faults are generator problem caused by turbine or network
side malfunctioning
Internal faults are generator problem caused by internal problem as
stator earth fault
Protection equipment includes several relays/function specially

design for surveillance of parameters (voltage, current, power )
page 48
PROTECTION SYSTEM : LGPG
Digital integrated generator

protection relay
Application for wide range of

generator
Display measurement value
Remote serial communication
Self monitoring
page 49
MAINTENANCE : Introduction
SATISFY THE
REQUIREMENT OF THE
PRODUCTION
Target
INSURE A GOOD
MAINTENANCE OF THE
PRODUCTION TOOLS
II
III
SATISFY THE
REQUIREMENT OF THE
MANAGEMENT
SATISFY THE
REQUIREMENT OF THE
MAINTENANCE CREW
page 50
MAINTENANCE : Introduction
There is different kind of maintenances

The routine maintenance
regularly check/inspection done by operator
The planned maintenance
regularly inspection done by specialists
The curative maintenance
repair activities following failure or problem
page 51
MAINTENANCE : Routine checks
The routine checks are done to detect any abnormal operation or

problem as soon as possible
The routine checks are done by the operation or the maintenance
team of the power station
The routine checks allow to increase the availability of the unit and
optimize the planned maintenances
The routine checks list is normally provided on operation manual
supply by the Original Equipment Manufacturer
page 52
MAINTENANCE : Routine checks
Typical list of routine checks for air cooled generator :
Checking of oil leaks on the bearing and/or gear box (ones per day)
Checking of abnormal noise in generator frame (ones per day)
Checking the shaft grounding brush/braid (ones per week)
If static exciter (brush system)
Brushes inspection (ones per week)

Reverse the polarity (every year)
page 53
MAINTENANCE : Planned maintenance
Typical Minor Inspection :

Inspection of the end-winding by removal frame covers or with
endoscope through man-holes
Simple electrical tests on rotor and stator :
Insulation and polarization index of stator
Winding resistance measurement on stator
Insulation and polarization index of rotor
Winding resistance measurement of rotor
page 54
Typical Minor Overhaul :

Inspection of the end-winding by removal frame covers or with
endoscope through man-holes
Inspection of generator bearing(s)
Simple electrical tests on rotor and stator :
Insulation and polarization index of stator
Winding resistance measurement on stator
Insulation and polarization index of rotor
Winding resistance measurement of rotor
Inter-turns short circuit detection on rotor by RSO
page 55
Typical Major Overhaul :

Minor overhaul +
Dismantling of the generator
Rotor extraction
Complete inspection of generator package
High voltage DC test (current leakage ramp)
Checking of stator radial wedges tightness
Reassembly of generator
Alignment check (correction if necessary)
Support for commissioning
page 56
MAINTENANCE : Assessment
Standard Electrical test :

Insulation measurement (IR)
U(test) = ( 2 x Un ) / 10 (by theory)
usual voltage to test the stator insulation
resistance
From IEEE 43-2000 (by experience)
U(test) = 2500V / 5000V
if Un = 5000V /
12000V
U(test) = 5000V / 10000V
if Un > 12000V
Acceptance criteria
IR(M) > Un(kV) +1
page 57

Polarization Index (PI)
Polarization index give indication on contamination and moisture on

stator winding
PI = IR(10min) / IR(1min)
Recommended minimum values by IEEE 43-2000
Class A insulation > 1,5
Class B, F, H insulation > 2,0
Winding resistance
Required very precise instruments as the resistance value is low

On stator, three phases value should be balanced within 0,5%
page 58

Winding impedance
Impedance test is done on rotor winding at different step of voltage

Impedance test can be done at different speed
Impedance test can detect short-circuit in rotor winding
Recurrent Surge Oscillograph (RSO)
Detection of inter-turns short-circuit in rotor winding

Comparison of two waves with an oscilloscope. Waves obtained by
injecting pulse into each rotor poles, reflecting each rotor turns.
page 59
High voltage test :

Two main types of test
Destructive test, by applying a high potential to windings

Qualitative test, with partial discharge detection, power factor
calculation or leakage current record
Test can be performed in alternative (AC) or direct current (DC)

Allows to evaluate the winding insulation condition and reduce the
risk of winding failure by planning predictive action, in case of bad
results
page 60
High voltage test in AC:

Destructive tests
High Potential test ( 2 x Un +1000 ) x Kr

Un : Nominal voltage
Kr : Coefficient chosen according with unit
age
Qualitative test, with partial discharge detection, power factor
calculation or leakage current record
Qualitative tests
Partial discharge performed at Un

Power factor performed at Un
page 61
High voltage test in DC:

Destructive tests
High Potential test ( 2 x Un +1000 ) x Kr x 1,7

Un : Nominal voltage
Kr : Coefficient chosen according with unit
age
1,7 : Coefficient of stress given between AC
test and DC test
Qualitative tests
Leakage current ramp test, with monitoring allowing to stop the test
in case of instability
Dielectric absorption test ( 2 x Un +1000) / 10
page 62
Lamination core test:

The test consist of checking the integrity of insulation between
lamination in stator core
Two possible tests on core lamination
Rated flux test
The test consist to induce a near rated flux in the stator core.
This flux induce circulating currents and excessive heating in areas
where the stator iron is damaged.
This method requires a large power source and certain time and
manpower to execute
page 63
Lamination core test:

Two possible tests on core lamination
Low flux test
Electromagnetic Core Imperfection Detector (El CID)
The process is based on the detection of core faults by measuring the
magnetic flux resulting from the current flowing in the fault area.
The core is magnetized to 3 - 4% of rated core flux.
The test requires light equipment, short resource and time to perform
with latest equipment generation.
page 64
Non Destructive Test (NDT):

The following tests are the usual NDT performed on generator
Visual inspection
This inspection allows to detect several problems and is the main inspection
used to schedule maintenance action
Liquid penetrant
Liquid penetrant inspection is done to detect microscopic surface cracks or
pitting
Ultra sonic
Ultra-sonic inspection is done to detect microscopic surface and subsurface
cracks
page 65
Alignment check and correction:

Alignment are a very important topic for the dynamic behavior of
the unit
Alignment has to be checked regularly and corrected when the
measurement are out of OEM tolerances
Misalignment will have a direct impact on the mechanical behavior
and will produce vibration
Alignment must be checked on two position
Concentricity of the shaft axis (define by OEM tolerances)

Parallelism of the shaft axis (define by OEM tolerances)
page 66
Alignment check and correction
Concentric misalignment
Angular misalignment
page 67
Alignment check and correction
Opening value of 0,07 to 0,11mm
Parallelism should be equal with a

maximum difference of 0.02mm
page 68
MAINTENANCE : Example of findings
Digital integrated generator

protection relay
Application for wide range of

generator
Display measurement value
Remote serial communication
Self monitoring
page 69

Training On Steam Turbine RBP

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Bilfinger Mauell ESG AG

Bilfinger Power Systems Group

OPERATING PRINCIPLE : Fundamentals Overview

There are two fundamental forms of steam

Bilfinger Power Systems Group

One form is the impulse turbine, deriving its

OPERATING PRINCIPLE : Fundamentals Overview

Exhaust steam conditions, extractions and

Bilfinger Power Systems Group

The name "Condensing turbine" and "Back pressure turbine"

OPERATING PRINCIPLE : Fundamentals Overview

Backpressure and Condensing turbines.

Bilfinger Power Systems Group

OPERATING PRINCIPLE : Fundamentals Overview

First Law of Thermodynamics

Bilfinger Power Systems Group

OPERATING PRINCIPLE : Fundamentals Overview

Second Law of Thermodynamics

Bilfinger Power Systems Group

OPERATING PRINCIPLE : Fundamentals Overview

Bilfinger Power Systems Group

COMPOSITION : Main components

Steam turbine main components:

COMPOSITION : Stator overview

The stator is composed of:

Bilfinger Power Systems Group

COMPOSITION : Stator overview

Bilfinger Power Systems Group

The magnetic core is built from

The stator coils are built with

COMPOSITION : Stator core

Bilfinger Power Systems Group

Stacked plate block

COMPOSITION : Stator end winding

Bilfinger Power Systems Group

COMPOSITION : Stator winding

Bilfinger Power Systems Group

COMPOSITION : Rotor overview

Bilfinger Power Systems Group

The rotor is coupled to the turbine

The rotor winding is connected to

COMPOSITION : Rotor overview

Bilfinger Power Systems Group

Coupling (to turbine or gear-box)

COMPOSITION : Rotor overview

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Axial rotor slot

COMPOSITION : Rotor winding

Bilfinger Power Systems Group

COMPOSITION : Rotor slot

Rotor shaft (tooth)

COMPOSITION : Excitation system overview

There is two different excitation

Bilfinger Power Systems Group

COMPOSITION : Static excitation system

The static exciter is composed of :

Bilfinger Power Systems Group

Two slip rings, each ones

The system is simple and very

COMPOSITION : Static excitation system

Bilfinger Power Systems Group

Collector ring (or slip ring)