WORKING OF STEAM TURBINE AND ITS AUXILIARIES

INDEX

Abstract CHAPTER 1 Introduction to Steam Turbine 1.1 Definitions of Steam turbine 1.2 Principle of Operation 1.3 Classification of Steam Turbines 1.4 Basic types of turbine 1.4.1 The Impulse Turbine 1.4.2 The eaction Turbine 1.5 Steam Turbine Applications CHAPTER 2 Steam Turbine Parts CHAPTER 3 Construction and Steam #lo$ CHAPTER 4 &ormal 'or(in) Condition CHAPTER 5 Specifications of Steam Turbine CHAPTER 6 Turbine Au,iliaries 6.1 Turbine -o.ernin) System 6.2 0acuum System 6.3 Condensate System 6.4 #eed 'ater System 6.5 Coolin) 'ater System 6.6 1ubrication Oil System Conclusion Bibilo)raphy

1 5 5 5 5 6 6 ! " 11 1% *1 *+ */ *" +1 +6 %1 %* %/ %!

DEPARTMENT OF MECHANICAL ENGINEERING

1ist of #i)ures

Pa)e &o2
+ / ! 11 1* 1+ 1+ 15 15 16 1/ 1/ 1! *1 *" += +1 ++ +% +5 +6 +! +" %1 %%
%6

#i)3a) Dia)ram of a typical coal4fired thermal po$er station2 #i)212%21 Dia)ram of a Impulse Turbine #i)212%2* Dia)ram of a eaction Turbine #i)2*21 Dia)ram sho$in) Parts of Steam Turbine #i):*2* Outer 5 Inner casin) of Steam turbine #i)6*2+ Oil system #i)2*2% Pipes #i)2+21 7P Turbine #i)2+2* Sectional .ie$ of 7P Turbine #i)2+2+ IP Turbine #i)2+2% 1P Turbine $ith Shaft #i)2+25 Turbine 5 -enerator System in Steam Po$er Plant #i)2+26 8ain and Thrust Bearin)s63a9main bearin):3b9section of thrust bearin) and housin):3c9thrust bearin) ca)e in place #i)6%21 Dia)ram sho$in) 'or(in) of Steam turbine #i)662* Condenser #i)662*21 ;<ector #i)662+ Condensate ;,traction Pump #i)662+21 Deareator #i)662+2* Circuit dia)ram of Condenser Connections #i)662+2+ Circuit dia)ram of Condensate System Connections #i)662% Turbine Dri.en Boiler #eed Pump #i)662%21 7P 7eater #i)662%2* Circuit Dia)ram of Turbine Dri.en Boiler #eed Pump #i)6625 Coolin) to$ers #i)6626 Turbine 1ube Oil System #i)662621 Steam Turbine flo$ Dia)ram Sho$in) Au,iliaries

DEPARTMENT OF MECHANICAL ENGINEERING

ABSTRACT

A po$er plant can be rou)hly di.ided into + parts2 #urnace boiler> Turbine $hich includes condenser pump> feed $ater heater> and re<ection system and the electric )enerator2 Steam from furnace is supplied in $hich ?2; of steam is used to dri.e the turbine to obtain 8echanical ;ner)y2 Study of Steam turbine $hich is capable of )eneratin) po$er $ith its au,iliaries is studied in this pro<ect2

DEPARTMENT OF MECHANICAL ENGINEERING

INTRODUCTION TO THE FUNCTIONING OF A POWER PLANT

(a)Diagram of a typical coal-fired thermal power station

K !
12 Coolin) to$er *2 Coolin) $ater pump +2 Transmission line 3+4phase9 %2 @nit transformer 3+4phase9 52 ;lectric )enerator 3+4phase9 62 1o$ pressure turbine /2 Boiler feed pump !2 Condensor "2 Intermediate pressure turbine 1=2 Steam )o.ernor .al.e 112 7i)h pressure turbine 1*2 Deaerator 1+2 #eed heater 1%2 Coal con.eyor 152 Coal hopper 162 Pul.erised fuel mill 1/2 Boiler drum 1!2 Ash hopper 1"2 Superheater *=2 #orced drau)ht fan *12 eheater **2 Air inta(e *+2 ;conomiser *%2 Air preheater *52 Precipitator *62 Induced drau)ht fan */2 Chimney Stac(

DEPARTMENT OF MECHANICAL ENGINEERING

D "#$%&'%():12 Coal is con.eyed 31%9 from an e,ternal stac( and )round to a .ery fine po$der by lar)e metal spheres in the pul.eriAed fuel mill 31692 *2 There it is mi,ed $ith preheated air 3*%9 dri.en by the forced drau)ht fan 3*=92 +2 The hot air4fuel mi,ture is forced at hi)h pressure into the boiler $here it rapidly i)nites2 %2 'ater of a hi)h purity flo$s .ertically up the tube4lined $alls of the boiler> $here it turns into steam> and is passed to the boiler drum> $here steam is separated from any remainin) $ater2 52 The steam passes throu)h a manifold in the roof of the drum into the pendant superheater 31"9 $here its temperature and pressure increase rapidly to around *== bar and 5/=BC> sufficient to ma(e the tube $alls )lo$ a dull red2 62 The steam is piped to the hi)h4pressure turbine 3119> the first of a three4sta)e turbine process2 /2 A steam )o.ernor .al.e 31=9 allo$s for both manual control of the turbine and automatic set point follo$in)2 !2 The steam is e,hausted from the hi)h4pressure turbine> and reduced in both pressure and temperature> is returned to the boiler reheater 3*192 "2 The reheated steam is then passed to the intermediate pressure turbine 3"9> and from there passed directly to the lo$ pressure turbine set 3692 1=2 The e,itin) steam> no$ a little abo.e its boilin) point> is brou)ht into thermal contact $ith cold $ater 3pumped in from the coolin) to$er9 in the condensor 3!9> $here it condenses rapidly bac( into $ater> creatin) near .acuum4li(e conditions inside the condensor chest2 112 The condensed $ater is then passed by a feed pump 3/9 throu)h a deaerator 31*9> and pre$armed> first in a feed heater 31+9 po$ered by steam dra$n from the hi)h pressure set> and then in the economiser 3*+9> before bein) returned to the boiler drum2 1*2 The coolin) $ater from the condensor is sprayed inside a coolin) to$er 319> creatin) a hi)hly .isible plume of $ater .apor> before bein) pumped bac( to the condensor 3!9 in coolin) $ater cycle2 1+2 The three turbine sets are coupled on the same shaft as the three4phase electrical )enerator 359 $hich )enerates an intermediate le.el .olta)e 3typically *=4*5 (092 1%2 This is stepped up by the unit transformer 3%9 to a .olta)e more suitable for transmission 3typically *5=45== (09 and is sent out onto the three4phase transmission system 3+92 152 ;,haust )as from the boiler is dra$n by the induced draft fan 3*69 throu)h an electrostatic precipitator 3*59 and is then .ented throu)h the chimney stac( 3*/92

DEPARTMENT OF MECHANICAL ENGINEERING

1. INTRODUCTION TO STEAM TURBINE

A steam turbine is a mechanical de.ice that e,tracts thermal ener)y from pressuriAed steam> and con.erts it into rotary motion2 Its modern manifestation $as in.ented by Sir Charles Parsons in 1!!%2

1.1 Definitions of S' *+ ',$-%) :

Turbine in $hich steam stri(es blades and ma(es them turn2 A system of an)led and shaped blades arran)ed on a rotor throu)h $hich steam is passed to )enerate rotational ener)y2 Today> normally used in po$er stations A de.ice for con.ertin) ener)y of hi)h4pressure steam 3produced in a boiler9 into mechanical po$er $hich can then be used to )enerate electricity2 ;Cuipment unit flo$n throu)h by steam> used to con.ert the ener)y of the steam into rotational ener)y2

1.2 P$%)#%&. (/ O& $*'%():

In reciprocatin) steam en)ine> the pressure of ener)y of steam is used to o.ercome e,ternal resistance and dynamic action of the steam is ne)li)ibly small2 Steam en)ine may be return by usin) the full pressure $ithout any e,pansion or drop of pressure in the cylinder2 The steam ener)y is con.erted mechanical $or( by e,pansion throu)h the turbine2 The e,pansion ta(es place throu)h a series of fi,ed blades 3noAAles9 and mo.in) blades each ro$ of fi,ed blades and mo.in) blades is called a sta)e2 The mo.in) blades rotate on the central turbine rotor and the fi,ed blades are concentrically arran)ed $ithin the circular turbine casin) $hich is substantially desi)ned to $ithstand the steam pressure2

1.3 C.*""%/%#*'%() (/ S' *+ T,$-%) "

The first steam turbine> at its time indeed did spar( off the industrial re.olution throu)h out the $est2 7o$e.er> the turbine at that time $as still an inefficient piece of hea.y $ei)hin) hi)h maintenance machine2 The po$er to $ei)ht ratio of the first reciprocatin) steam turbine $as e,tremely lo$> and this led to a )reat focus impro.in) the desi)n> efficiency and usability of the basic steam turbine> the result of $hich are the po$er horses that currently produce more than !=D of todayEs electricity at po$er plantsF

S' *+ T,$-%) " *$ C.*""%/% 0 *":Steam Turbines can be classified on the basis of a number of factors2 Some of the important methods of steam turbine classification are enunciated belo$6

O) '1 -*"%" (/ S'*2 D "%2):

DEPARTMENT OF MECHANICAL ENGINEERING

Steam turbines use different sta)es to achie.e their ultimate po$er con.ersion )oal2 Dependin) on the sta)es used by a particular turbine> it is classified as Impulse Turbine> or eaction type2

O) '1 B*"%" (/ '1 A$$*)2 + )' (/ %'" M*%) S1*/':

Dependin) on the shaft arran)ement of the steam turbine> they may be classified as Sin)le housin) 3casin)9> tandem compound 3t$o or more housin)s> $ith shafts that are coupled in line $ith each other9 and Cross compound turbines 3the shafts here are not in line92

O) '1 B*"%" (/ S,&&.! (/ S' *+ *)0 S' *+ E31*,"' C()0%'%():

They may be classified as Condensin)> &on Condensin)> Controlled or Automatic e,traction type> eheat 3the steam is bypassed at an intermediate le.el> reheated and sent a)ain9 and 8i,ed pressure steam turbines 3they ha.e more than one source of steam at different pressures92

O) '1 -*"%" (/ D%$ #'%() (/ S' *+ F.(4:

They may be a,ial> radial or tan)ential flo$ steam turbines2

O) '1 B*"%" (/ S' *+ S,&&.!:

Superheated steam turbine or saturated steam turbine2

1.4 B*"%# '!& " (/ ',$-%)

The t$o most basic and fundamental types of steam turbines are the impulse turbine and the impulse reaction turbine2

1.4.1 T1 I+&,." T,$-%) :

The impulse turbine consists of a set of stationary blades follo$ed by a set of rotor blades $hich rotate to produce the rotary po$er2 The hi)h pressure steam flo$s throu)h the fi,ed blades> $hich are nothin) but noAAles> and under)o a decrease in pressure ener)y> $hich is con.erted to (inetic ener)y to )i.e the steam hi)h .elocity le.els2 This hi)h .elocity steam stri(es the mo.in) blades or rotor and causes them to rotate2 The fi,ed blades do not completely con.ert all the pressure ener)y of the steam to (inetic ener)y> hence there is some residual pressure ener)y associated $ith the steam on e,it2 Therefore the efficiency of this turbine is .ery limited as compared to the ne,t turbine $e are )oin) to re.ie$4 the reaction turbine or impulse reaction turbine2

DEPARTMENT OF MECHANICAL ENGINEERING

#i)212%21 Dia)ram of a Impulse Turbine

W($5%)2 (/ I+&,." T,$-%) :The impulse turbine $as one of the basic steam turbines2 It in.ol.ed stri(in) of the blades by a stream or a <et of hi)h pressure steam> $hich caused the blades of the turbine to rotate2 The direction of the <et $as perpendicular to the a,is of the blade2 It $as realiAed that the impulse turbine $as not .ery efficient and reCuired hi)h pressures> $hich is also Cuite difficult to maintain2 The impulse turbine has noAAles that are fi,ed to con.ert the steam to hi)h pressure steam before lettin) it stri(e the blades2

I+&,." ',$-%) + #1*)%"+:

Impulse turbine 8echanism deals $ith the Impulse force action4reaction2 As $e all (no$ the &e$ton +rd la$ of motion>G ;.ery action has eCual and opposite reactionG> the same is $or( on this2 As the $ater fall on the blade of the rotor it )enerate the impact force on the blade surface> The blade tends to )i.e the same reaction to the fluid> but the rotor is attached to the rotatin) assembly> it absorb the force impact and )i.e the reaction in the direction of the fluid flo$2 Thus the $hole turbine rotates2 The rotation speed of the turbine depends on the fluid .elocity> more the fluid .elocity> )reater the rotation speed> and )reater the speed means more po$er )eneration2

1.4.2 T1 R *#'%() T,$-%)

8
DEPARTMENT OF MECHANICAL ENGINEERING

The reaction turbine is a turbine that ma(es use of both the impulse and the reaction of the steam to produce the rotary effect on the rotors2 The mo.in) blades or the rotors here are also noAAle shaped 3They are aerodynamically desi)ned for this9 and hence there is a drop in pressure $hile mo.in) throu)h the rotor as $ell2 Therefore in this turbine the pressure drops occur not only in the fi,ed blades> but a further pressure drop occurs in the rotor sta)e as $ell2 This is the reason $hy this turbine is more efficient as the e,it pressure of the steam is lesser> and the con.ersion is more2 The .elocity drop bet$een the fi,ed blades and mo.in) blades is almost Aero> and the main .elocity drop occurs only in the rotor sta)e2

#i)212%2* Dia)ram of a eaction Turbine

WORKING OF REACTION TURBINE:

In the reaction turbine> the rotor blades themsel.es are arran)ed to form con.er)ent noAAle eaction Turbines2 In the reaction turbine> the rotor blades themsel.es are arran)ed to form con.er)ent noAAles2 This type of turbine ma(es use of the reaction force produced as the steam accelerates throu)h the noAAles formed by the rotor2 Steam is directed onto the rotor by the fi,ed .anes of the stator2 It lea.es the stator as a <et that fills the entire circumference of the rotor2 The steam then chan)es direction and increases its speed relati.e to the speed of the blades2 A pressure drop occurs across both the stator and the rotor> $ith steam acceleratin) throu)h the stator and deceleratin) throu)h the rotor> $ith no net chan)e in steam .elocity across the sta)e but $ith a decrease in both pressure and temperature> reflectin) the $or( performed in the dri.in) of the rotor2 This type of turbine ma(es use of the reaction force produced as the steam accelerates throu)h the noAAles formed by the rotor2 Steam is directed onto the rotor by the fi,ed .anes of the stator2 It lea.es the stator as a <et that fills the entire circumference of the rotor2 The steam then chan)es direction and increases its speed relati.e to the speed of the blades2 A pressure drop occurs across both the stator and the rotor> $ith steam acceleratin) throu)h the stator and deceleratin) throu)h the rotor> $ith no net chan)e in steam .elocity across the sta)e but $ith a decrease in both pressure and temperature> reflectin) the $or( performed in the dri.in) of the rotor2

1.5 S' *+ T,$-%) A&&.%#*'%()"

9
DEPARTMENT OF MECHANICAL ENGINEERING

The Steam turbines of today are mostly used in the po$er production field2 Steam turbines are used to efficiently produce electricity from solar> coal and nuclear po$er plants o$in) to the harmlessness of its $or(in) fluid> $aterHsteam> and its $ide a.ailability2 8odern steam turbines ha.e come a lon) $ay in increasin) efficiency in performance and more and more efforts are bein) made to try and reach the ideal steam turbine conditions> thou)h this is physically impossibleF Almost e.ery po$er plant in the $orld> other than hydro electric po$er plants> that use turbines that run on $ater 3the #rancis> Pelton turbines also ha.e the influence of steam turbines9 > use steam turbines for po$er con.ersion2 'ith all the scientific ad.ancement in po$er )eneration bein) attributed to them> steam turbines really ha.e chan)ed the $ay the $orld mo.esF Steam turbines are de.ices $hich con.ert the ener)y stored in steam into rotational mechanical ener)y2 These machines are $idely used for the )eneration of electricity

U'%.%'! S' *+ T,$-%) A&&.%#*'%()":

Applications for utility Steam Turbines are applied for control of strai)ht condensin)> reheat and non4reheat steam turbines up to +==8'2 These up)rades may include inte)rated )enerator control for )enerator protection and e,citationH A0 up)rades> utiliAin) the latest commonly a.ailable industry4standard di)ital eCuipment2

I)0,"'$%*. *&&.%#*'%() (/ "' *+ ',$-%) :

Applications of Industrial Steam Turbines co.er all strai)ht condensin)> non4condensin)> and automatic e,traction steam turbines2 Specific desi)n features are incorporated to address control issues often uniCue to process plants includin) paper mills> oil refineries> chemical plants> and other industrial applications> )enerator and mechanical dri.e2 Some of the $orldEs lar)est turbines manufacturin) companies that are seein) the re$ards of research and steam turbine ad.ances are comin) to)ether to de.elop hi)hly efficient turbines2 The collaboration of 8itsubishi 7ea.y 8achinery and -eneral ;lectric ;ner)y 3-; ;ner)y9 for the conceptualiAation and desi)n of a hi)hly efficient Ine,t4 )enerationJ steam turbine for its inception in combined cycle )as turbine po$er plants recently has further pro.ed that there is still a lot to be achie.ed in steam turbine related research and de.elopment> and that the scope for impro.ement can be much hi)her2

10

DEPARTMENT OF MECHANICAL ENGINEERING

CHAPTER 2 S' *+ T,$-%) P*$'"

Steam turbines are machines that are used to )enerate mechanical 3rotational motion9 po$er from the pressure ener)y of steam2 Steam turbines are the most popular po$er )eneratin) de.ices used in the po$er plant industry primarily because of the hi)h a.ailability of $ater> moderate boilin) point> cheap nature and mild reactin) properties2 The most $idely used and po$erful turbines of today are those that run on steam2 #rom nuclear reactors to thermal po$er plants> the role of the steam turbine is both pi.otal and result determinin)2 A steam turbine basically has a mechanical side> and an electrical side to it2 The mechanical components include the mo.in) parts 3mechanical9> such as the rotor> the mo.in) blades> the fi,ed blades> and stop .al.es> $hile the electrical side consists of the )enerator and other electrical components to actually con.ert the ener)y into a usable> easily transferable form2

B.*0 ":
#or starters> a simple turbine $or(s <ust li(e a $indmill2 Only> in the steam turbines of today> rather than stri(in) the blades directly> the blades are desi)ned in such a $ay as to produce ma,imum rotational ener)y by directin) the flo$ of the steam alon) its surface2 So the primary component that )oes into a steam turbine is its blades2 The blades of a steam turbine are desi)ned to beha.e li(e noAAles> thus effecti.ely tappin) both the impulse and reaction force of the steam for hi)her efficiency2 &oAAle desi)n itself is a comple, process> and the noAAle shaped blade of the turbine is probably one of the most important parts in its construction2 The blades are made at specific an)les in order to incorporate the net flo$ of steam o.er it in its fa.or2 The blades may be of stationary or fi,ed and rotary or mo.in) or types2

#i)2*21 Dia)ram sho$in) Parts of Steam Turbine

11

DEPARTMENT OF MECHANICAL ENGINEERING

S1*/'":
The shaft is a po$er transmittin) de.ice and is used to transmit the rotational mo.ement of the blades connected to it at one end .ia the rotor to the couplin)> speed reducer or )ear at the other end2

O,' $ C*"%)2:
The steam turbine is surrounded by housin) or an outer casin) $hich contains the turbine and protects the de.ice components from e,ternal influence and dama)e2 It may also support the bearin)s on $hich the shafts rest to pro.ide ri)idity to the shaft2 @sually split at the center horiAontally> the casin) parts are often bolted to)ether for easy openin)> chec(in) and steam turbine maintenance> and are e,tremely sturdy and stron)2

F%2:*2* Outer 5 Inner casin) of Steam turbine2

G(6 $)($:
The )o.ernor is a de.ice used to re)ulate and control or )o.ern the output of the steam turbine2 This is done by means of control .al.es $hich control the steam flo$ into the turbine in the first place2

O%. S!"' +:
A steam turbine has thousands of mo.in) parts and all these parts not only ha.e to mo.e in hi)h .elocities> but also need to be protected from $ear and tear o.er the years2 This is
12

DEPARTMENT OF MECHANICAL ENGINEERING

done by effecti.e lubrication by the oil system> $hich )o.erns the pressure> flo$ and temperature of the turbine oil> the bearin) oil and lubrication of other mo.in) parts2

#i)6*2+ Oil system

P%& ":
The pipe is an all important steam turbine component that brin)s the steam from the boiler to the turbine2 This has to be done $ithout an appreciable loss in pressure> and at the same time> must be able to $ithstand all these pressures safely2 The pipes should be easy to clean and are prone to deposits on their inner surfaces2 Deposits on the inner surface of the steam pipe reduce the net steam flo$ area> thro$in) forth a ne)ati.e effect on the efficiency2

#i)2*2% Pipes

13

DEPARTMENT OF MECHANICAL ENGINEERING

CHAPTER 3 CONSTRUCTION 7 STEAM FLOW

The turbine is a sin)le shaft machine $ith separate 7P and 1P parts> the 7P part bein) a sin)le flo$> the IP and IP parts double flo$ cylinders2 in) couplin)s connect the indi.idual turbine rotors and the )enerator rotor2 The 7P cylinder has a throttle control2 The initial steam admitted before the bladin) by four combined main steam stop and control .al.es2 The lines leadin) from the t$o 7P e,haust branches to the reheated are pro.ided $ith s$in) chec( .al.es $hich pre.ent hot steam from the reheater flo$in) bac( into the 7P turbine2 The steam comin) from the reheater is passed to the IP part .ia four combined reheats stop and control .al.es2 Crosso.er pipes connect the IP and 1P cylinders2

HP TURBINE8 BARREL T9PE CASING:

The outer casin) of the 7P turbine is of the barrel type and has neither an a,ial nor a radial flan)e2 This pre.ents mass accumulation $ith hi)h thermal stresses2 The almost perfect rotational symmetry permits moderate $all thic(ness of nearly eCual stren)th at all sections2 The )uide blade carrier is a,ially split and (inematically supported2 As only sli)ht pressure differences are effecti.e> the horiAontal flan)e and connection bolts can be (ept small2 The barrel type casin) permits fle,ibility of operation in the form of short startup times and a hi)h rate of chan)e of load e.en at hi)h initial steam conditions2

14

DEPARTMENT OF MECHANICAL ENGINEERING

#i)2+21 7P T@ BI&;

#i)2+2* S;CTIO&A1 0I;' O# 7P T@ BI&;

15

DEPARTMENT OF MECHANICAL ENGINEERING

IP TURBINE:
The IP turbine part is double flo$ construction2 Attached in the a,ially split casin) is an inner casin) supported (inematically and ta(in) the )uide blades2 The reheated steam is admitted to the inner casin) throu)h the top and bottom center of the casin)2 The arran)ement of an inner casin) confines the hi)h steam inlet conditions to the admission branch of the casin)> $hile the <oint of the outer casin) is only sub<ected to the lo$er pressure and lo$er temperature at the e,haust of the inner casin)2

#i)2+2+ IP T@ BI&; LP TURBINE: The casin) of the double flo$ IP cylinder is of three shell desi)n2 The shells are a,ially split and ha.e ri)id $elded construction2 The inner shell ta(in) the first ro$s of the )uide blades is attached (inematically in the middle shelf2 Independent of the outer shell> the middle shell is supported at four points on lon)itudinal beams2 T$o rin)s carryin) them last )uide blade ro$s are also attached to the middle shelf2

16

DEPARTMENT OF MECHANICAL ENGINEERING

#i)2+2% 1P T@ BI&; 'IT7 S7A#T

#i)2+25 T@ BI&; 5 -;&; ATO SKST;8 I& ST;A8 PO'; P1A&T

BLADING:
The entire turbine is pro.ided $ith reaction bladin)2 The )uide blades of the 1P parts $ith in.erted T4roots and shroudin) are milled from one piece2 The last sta)es of the IP part consists of t$isted drop for)ed mo.in) blades $ith fir4tree roots inserted in correspondin) )roo.es of the rotor and )uide blade ro$s made of sheet steel2

17

DEPARTMENT OF MECHANICAL ENGINEERING

BEARINGS:

#i)2+26 8ain and Thrust Bearin)s63a9main bearin):3b9section of thrust bearin) and housin): 3c9thrust bearin) ca)e in place The 7P rotor is supported by t$o bearin)s> the <ournal bearin) at the front end of the turbine and a combined <ournal and thrust bearin) directly ad<acent to the couplin) $ith the IP rotor2 The IP and 1P rotors ha.in) <ournal and thrust bearin) incorporates a <ournal hearin) and thrust bearin) $hich ta(es up residual thrust from both directions2 The bearin) temperatures are measured by thermocouples in the lo$er shell directly under the $hite metal linin)2 The temperature of the thrust bearin) is measured in t$o opposite thrust pads2 The front rear bearin) pedestals of the 7P turbine is placed on base plates2 The pedestals of the 1P part are fi,ed in position> the front pedestals of the 1P part are fi,ed in position> the front pedestal and the pedestal bet$een 7P and IP part are able to mo.e in a,ial direction2 The brac(ets at the sides of the 7P and IP parts are supported by the pedestals at the le.el of the machine a,ial2 In the a,ial direction of the 7P and IP parts are firmly connected $ith the pedestal by means of casin) )uided $ithout restrictin) radial e,pansion2 Since the casin) )uide do not yield response to a,ial displacement> the 7P and IP casin)s as $ell as associated bearin)s pedestals mo.e for$ard from the front 1P bearin) pedestal on thermal e,pansion2 Lournal bearin)s are manufactured in t$o hal.es and usually consist bearin) body faced $ith anti4friction tin based babblin) to decrease coefficient of friction2 Bearin) body match $ith ad<ustable seatin) assembly in the pedestal2 Bearin)s are usually forced lubricated and ha.e pro.ision for admission of <ac(in) oil2
18

DEPARTMENT OF MECHANICAL ENGINEERING

The thrust bearin) is normally 8itchel type and is usually combined $ith a <ournal bearin)> horsed in spherically machined steel shell2 The bearin) bet$een the 7P and IP rotors is of this type: $hile the rest are <ournal bearin)s2 ;arlier each rotor used to ha.e its o$n set of bearin)s2 &ot $ith the popularity of ri)id couplin) bet$een rotors> it is possible to use only on bearin)s bet$een t$o rotors2 This arran)ement $ill lead to more fle,ible rotors 3lo$er critical speed9> for the same rotor desi)n because span bet$een bearin)s increases2 'ith reduction in number of bearin)s> len)th of turbine )ets reduced resultin) in consideration sa.in) in capital cost2

SHAFT GLANDS AND BLADE SEALING STRIPS:

All shaft )lands sealin) the steam in the cylinders a)ainst atmosphere are a,ial flo$ labyrinths2 They consist of a lar)e number of thin sealin) strips $hich in the 7P and IP parts are alternate caul(ed into )roo.es in the shafts and surroundin) sealin) rin)s2 The sealin) strips of the 1P parts are only caul(ed into the sealin) rin)s2 These rin)s are split into se)ments> $hich are forced radially a)ainst a pro<ection by helical sprin)s and are able to yield in the e.ent of rubbin)2 Sealin) strips of similar desi)n are also used to seal the radial blade strip clearances2

:AL:ES:
The 7P turbine is fitted $ith four initial steam stop and control .al.es2 A stop and control .al.e $ith steams arran)ed at ri)ht an)les to each other are combined in a common body2 The stop .al.es are sprin) operated sin)le seal .al.es: the control .al.es> also of sin)le seat desi)n> ha.e diffuser to reduce pressure losses2 IP turbine has four4combined reheat stop and control .al.es2 The reheat stop .al.es are sprin) loaded sin)le sealed .al.es2 The control .al.es operate in parallel and fully opened in the upper load ran)e in the load ran)e> they control the steam flo$ to the IP turbine and ensure stable operation e.en $hen the turbo set is supplyin) only the station load2

E+ $2 )#! S'(& :*.6 " *)0 C()'$(. :*.6 ": ;ES:"<

Turbine is eCuipped $ith emer)ency stop .al.es to cut off steam supply and $ith control .al.es to re)ulate steam supply2 ;mer)ency stop .al.es 3;S09 are pro.ided in the mainstream line and interceptor .al.es 3I09 are pro.ided in the hot reheat line2 ;mer)ency stop .al.es are actuated by ser.omotor controlled by the protection system2 ;S0 remains either fully open or fully close2 Control .al.es are actuated by the )o.ernin) system throu)h ser.omotors to re)ulate steam supply as reCuired by the load2 0al.es are either sin)le seat type or double seat type2 Sin)le seat type .al.es are preferred throu)h these reCuire hi)her force for openin) or closin)2

19

DEPARTMENT OF MECHANICAL ENGINEERING

C(,&.%)2":
Since the shaft 3rotor9 is made in small parts due to for)in) limitations and other technolo)ical and economic reasons> the couplin)s are reCuired bet$een any t$o rotors2 This couplin) permits an)ular misali)nment> transmits a,ial thrust and ensures a,ial location2 The couplin)s are either ri)id or semi fle,ible2 The former neither permits an)ular nor lateral defection $hile the later permits only an)ular defection2 &umber of critical speeds depends upon the modes of .ibrations and hence the type of couplin) pro.ided bet$een rotors2 -enerally in *==H*1=8' turbine>couplin) bet$een 7PT and IPT is of ri)id type and bet$een IPT and 1PT is of semi4 fle,ible lens type2

20

DEPARTMENT OF MECHANICAL ENGINEERING

CHAPTER 4 NORMAL WORKING CONDITION

#i)6%21 Dia)ram sho$in) 'or(in) of Steam turbine

The super heated steam from the boiler super heater is bleed into hi)h pressure turbine $here the e,pansion ta(es place upto an intermediate pressure2 This intermediate steam is ne,t further bleed into intermediate pressure turbine after reheatin) e,pansion occurs2 This e,panded steam further sent into lo$ pressure turbine2 The (inetic head of the steam is used to rotate or dri.e the turbine rotor due to e,pandin) on the turbine blades2 This rotor of the turbine is coupled to )enerator shaft2 Due to re.olution of )enerator shaft produces the electricity 3based on the faradayEs la$92 The po$er )enerated is 1%?0 is connected to the step up transformer producin) %== ?0 and further connected to s$itchyard for distribution2

21

DEPARTMENT OF MECHANICAL ENGINEERING

W($5%)2 ,)0 $ *-)($+*. #()0%'%()":

The super heated steam from the boiler super heater is bleed into hi)h pressure turbine is cut off by a control .al.e then the by pass system is used because due to the continuous flo$ of super heated steam from the boiler super heater lead to the dama)e of steam pipe line due to e,cessi.e increase in pressure2 Then the steam from the by pass .al.e> I made to pass throu)h the intermediate pressure turbine or hi)h pressure reheater2 Similarly if the steam enterin) the intermediate pressure turbine is cut off then the steam is made by passed to pass throu)h the control .al.es and sent to cold reheater2 Similarly if the steam enterin) the lo$ pressure turbine is cut off then the steam is made by passed to pass throu)h boiler feed pump2 The e,panded steam from the lo$ pressure turbine is sent to the condenser2 The condensate is pumped to 1o$ preheater 1>* and further to lo$ preheater + by condensate e,traction pump2 The $ater from lph+ is sent to deareator2 The $ater from deareator is sent to hi)h pre4heater 5>6 and then to economiAer and then to the boiler furnace2 The heat absorbed by the coolin) $ater by condensin) the steam in the condenser is sent to the coolin) to$ers for coolin) by I2D2 fan2

22

DEPARTMENT OF MECHANICAL ENGINEERING

CHAPTER 5 S& #%/%#*'%()" (/ S' *+ T,$-%)

8a(e Type

6 6

B7;1> ?'@ Three cylinder reheat Condensin) reaction turbine

&ominal ratin) Pea( loadin) ated speed 8a,H8in speed 3no time limitation9 Speed e,clusion ran)e

6 6 6 6

5== 8' 5%5 8' +===rpm +="=H*!5=rpm

%== to *!5=rpm

S' *+ P$ "",$ 7 T +& $*',$ ;R*' 0 :*., "< P$ "",$ ;*'*< T +&. ;=C<
Initial Steam #irst sta)e pressure 5+/2= 7P cylinder e,haust IP stop .al.e inlet ;,traction46 ;,traction45 %*!2+ %5 %=25 %52= +%*25 5+/ +%*25 1"25* 1/= 5+/2= 1512/"

23

DEPARTMENT OF MECHANICAL ENGINEERING

;,traction4% ;,traction4+ ;,traction4* ;,traction41

/25/ *2/6 12%* 6/26

+=*2= 1"/2! 1+!2! =2*!6 =2=!!% %+21

1P cylinder e,haust

W %21';T()) "< R('($;#(+&. ' 4%'1 B.*0%)2<

eheat stop and control 0al.e3complete $ithout Bend 5 pipe section9

HP

IP

LP

11.6

21.8

84.6

17.0

M(+ )'" (/ I) $'%*;K2-M2<

otor of 7P cylinder otor of IP cylinder otor of 1P cylinder /1+2= *1%526 **"!12=

L%+%'%)2 :*., " C*"%)2 ' +& $*',$ ;=C< A.*$+ *' M># +,"' - "1,' 0(4) *'
7P turbine e,haust Outlet casin) of 1Pcylinder %!=2= "=2= 5==2= 11=2=

24

DEPARTMENT OF MECHANICAL ENGINEERING

A.*$+ *' M># +,"' - "1,' 0(4) *'

7P turbine middle IP turbine front IP turbine rear M55 M+= +30 M/= M%5 +45

3Spray $ater to 1P cylinder must be s$itched on at "==C9 T +& $*',$ D%// $ )# ;K< ;B '4 ) U&& $ *)0 L(4 $ C*"%)2 S #'%()< S' *+ P,$%'!;KWU R #(++ )0 0 :*., "< D,$%)2 O& $*'%()
Conducti.ity at *5=C Al(aline method Silica acid3SiO*9 Total iron3#e9 Total copper Sodium3&a9 N=21= usHCm N=2=1= m)H?) N=2==5 m)H?) N=2==1= m)H?) N=2==5 m)H?)

B *$%)2 T +& $*',$ ;=C< A.*$+ M># +,"' - "1,' 0(4) *' :%-$*'%();A-"(.,' :%-$*'%()< B *$%)2 H(,"%)2
&ominal .alue for alarm += microns abo.e normal le.el 8a,2 .alue for alarm 1imit .alue for +5microns 1*= microns

S1*/'

25

DEPARTMENT OF MECHANICAL ENGINEERING

trippin)3manual9

%5microns

*== microns

D%// $ )'%*. E3&*)"%()"

7P turbine IP turbine 1P turbine 6 6 6 M5mm to 4+mm M!mm to 4*mm M+=mm to 4+mm

M*' $%*. O/ C()"'$,#'%() C*"%)2"

7P outer casin) Barrel casin) 7P blade carrier IP casin) 1P casin) -S 1/ cr2 8O0 511 -S 1/ cr2 8O 511 -S ** 8O % Outer ST +/4*& Inner4I -S **>8O%>7 II>15 8O + Inner4II ST +/4*& S1*/'" 7P shaft IP shaft 1P shaft M(6%)2 B.*0 " 7P turbine first sta)e 7P turbine other sta)es IP turbine sta)e ,** Cr 8O0 1*1 ,*= Cr 1+H,** Cr8O0 1*1 ,*= Cr 8O 1+H, *= Cr2+= *! Cr28O &i 5" += Cr28O &i 0 511 *6 &i Cr 8O 0 1%5

26

DEPARTMENT OF MECHANICAL ENGINEERING

1P turbine sta)e

,*= Cr 1+

CHAPTER 6

TURBINE AUXILIARIES
6.1 TURBINE GO:ERNING S9STEM
Po$er station turbines are constant sped machines and they are rotated at a speed of +===rpm to enable the coupled )enerator to produce electricity at 5= 7A freCuency2 The main purpose of the )o.ernor is to maintain the desired speed of turbine durin) fluctuation of load on )enerator by .aryin) steam input into the turbine as reCuired2 The )o.ernin) system is addition to ensurin) the follo$in) load speed characteristics of the turbine also ensure the follo$in) functions2 The run up of the turbine from the rest to the rated speed and synchroniAin) $ith the )rid2 8eetin) the steam load .ariation in the predetermined manner> $hen runnin) in parallel $ith the other machines2 Protectin) the machine by reducin) the load or shuttin) of completely in a abnormal and emer)ency situation2

T9PES OF GO:ERNING S9STEMS:

12 Throttle -o.ernin)2 *2 &oAAle -o.ernin)2 +2 Bypass -o.ernin)2

THROTTLE GO:ERNING:
In Throttle -o.ernin) system the )o.ernin) attachment is attached directly to the Turbine shaft itself and rotates at the same speed of the turbine2 Accordin) to the turbine speed the attachment lin(ed $ith the rotor $ill run2 The balls attached to the arran)ement $ill run by the centrifu)al force and the .al.e $ill operate and allo$ the steam to flo$ into the turbine2 'hen the load on the )enerator $ill )et throu)h off and due to this effect the speed of the turbine $ill rise

27

DEPARTMENT OF MECHANICAL ENGINEERING

tremendously $hich $ill dama)e the eCuipment2 The fulcrum attached to the )o.ernin) system $ill pull the .al.e position2

NO??LE GO:ERNING6
In this method the &oAAles are )rouped and the supply of steam is controlled by a special system called as ;1;CT O 7KD A@1IC CO&T O1 system2 The controllin) of the intercept .al.es $ill supply the steam to the curtes.ey sta)e of the hi)h pr turbine throu)h intercept .al.es2 There $ill be a rac( and pinion attachment arran)ement to operate the intercept .al.es2 The .al.es $ill operate radially in a seCuence by maintainin) the input supply under balancin)2 At full load the .al.es $ill be in fully open condition2 The operation of the .al.es totally carried out by the hydraulic oil supply only thus the noAAle )o.ernin) system is called as ;1;CT O 7KD A@1IC CO&T O1 -O0; &I&- system2 In ama)undam this system $as adopted to ha.e better control on .al.e operation2 It is most effecti.e one and is suitable for control the hi)h capacity turbines2

B9PASS GO:ERNING:
In this system the steam is supplied throu)h a primary .al.e and is adeCuate to meet a ma<or function of the ma,imum> load> $hich is called the Ieconomic loadJ2 At loads less than this throttlin) steam throu)h this .al.e does the re)ulations2 'hen the load on the turbine e,ceeds this economic load $hich can be de.elop by the @& throttled> full flo$ throu)h the primary .al.e2 This steam <oins the partially spent steam admittin) throu)h the primary .al.e> de.elopin) additional blade torCue to meet the increased load2

28

DEPARTMENT OF MECHANICAL ENGINEERING

6.2 :ACUUM S9STEM

As $e be)in the recirculatin) processes> the first system> $hich comes into focus> is the .acuum system2 The eCuipments under this system> as described in this chapter> stri.e to ma,imiAe the $or( done of turbine by maintainin) the rated .acuum limits2

C()0 )" $:
There are t$o condensers entered to the t$o e,hausters of the 1P turbine2 These are surface type condensers $ith t$o4pass arran)ement2 Coolin) $ater pumped into each condenser by a .ertical C2'2 Pump thruE the inlet pipe2 'ater enters the inlet chamber of the front $ater bo,> passes horiAontally thruE the brass troes to the $ater bo, at the other end> ta(es a turn> passes thruE the upper cluster to tubes and reaches the outlet chamber in the front $ater bo,2 #rom these> coolin) $ater lea.es the condenser thruE the outlet pipe and dischar)es into the dischar)e duct2 Steam e,hausted from the 1P turbine $ashin) the outside of the condenser tubes loses it latent heat to the coolin) $ater and is connected $ith $ater in the steam side of the condenser2 This condensate collects in the hot $ell2

#i)662* Condenser

E@ #'($":

29

DEPARTMENT OF MECHANICAL ENGINEERING

There are t$o 1==D capacity e<ectors of the steam e<ect type2 The purpose of the e<ector is to e.acuate air and other non4condensin) )ases from the condensers and thus maintain the .acuum in the condensers2 This is a + sta)e e<ector usin) steam from the deaerator $ith 11 AT8 header as the $or(in) medium2 The e<ector has three compartments2 Steam is supplied )enerally at a pressure of %25 to 5 ()HCm* to the three noAAles in the three compartments2 Steam e,pands in the noAAles thus )i.in) a hi)h .elocity e<ect $hich creates a lo$ pressure Aone in the throat of the e<ect2 Since the noAAle bo, of the e<ector is connected to the air pipe from the condenser> the air and pressure Aone2 The $or(in) steam $hich has e,panded in .olume comes into contact $ith the cluster of tube bundles thruE $hich condensate in flo$in) and )ets condensed thus further aidin) the formulation of .acuum2 The non consumin) )ases of air are further suc(ed $ith the ne,t sta)e of the e<ector by the action of the second noAAle2 The process repeats itself in the third sta)e also and finally the steam air mi,ture is e,hausted into the atmosphere thru the outlet2 In addition to the main e<ectors there is a sin)le sta)e startin) e<ectors $hich is used for initial of .acuum upto 5==mm of 7)2 It consists of noAAle is connection to the air pipe from the condenser2

#i)6/2*21 ;<ector

G.*)0 S' *+ C((. $:

Steam from deaerator or from Au,illary steam header is supplied to the end seals of the 7P rotor and 1P rotor )enerally at a pressure of =2=1 to 12=+ ata2 So as to pre.ent in)ress of atmosphere air into the turbine thruE the end clearances2 This steam supplied to the end seals is e,tracted by the )land steam cooler by the auction of sin)le sta)e steam e<ector2

30

DEPARTMENT OF MECHANICAL ENGINEERING

6.3 CONDENSATE S9STEM

The steam after condensin) in the condensin) in the condenser (no$n as condensate> is e,tracted out of the condenser hot $ell by condensate pump and ta(en to the deaerator throu)h e<ectors> )land steam cooler and series of 1P heaters

C()0 )"*' P,+&":

The function of these pumps is to pump out the condensate to the deaerator throu)hE in<ector> )land steam cooler and 1P heaters2 These pumps ha.e four sta)es and since the suction is at a ne)ati.e pressure> special arran)ements ha.e been made for pro.idin) sealin)2 The le.el indicator for .isual le.el indication of heatin) steam condensate pressure .acuum )au)es for measurement of steam pressure etc> it is a direct contact type heater combined $ith feed stora)e tan( of adeCuate capacity2 The heatin) steam is normally supplied from turbine e,tractions but durin) startin) and lo$ load operation the steam is supplied from au,iliary source2

31

DEPARTMENT OF MECHANICAL ENGINEERING

#i)662+ Condensate ;,traction Pump

D * $*'($:
The Deaerator comprises of t$o chambers6 A9 Deaeratin) column2 B9 #eed stora)e tan(2 Deaeratin) column is a spray cum tray type cylindrical .essel of horiAontal construction $ith dished ends $eided to it2 The tray stac( is desi)ned to ensure ma,imum contact time as $ell as optimum scrubbin) of condensate to achie.e efficient deaeration2 The deaeration column in mounted on the feed stora)e tan( $hich in turn is supported on rollers at the t$o ends and a fi,ed support at the center2 The feed stora)e tan( is fabricated from boiler Cuality steel plates2 8an holes are pro.ided on deaeratin) column as $ell as on feed stora)e tan( for inspection and maintenance2 The condensate is admitted at the top of the deaeratin) column and flo$s do$n$ards throu)h the spray .al.es and trays2 The trays and desi)ned to e,pose thou)h the ma,imum $ater surfaces for

32

DEPARTMENT OF MECHANICAL ENGINEERING

efficient scrubbin) to effect the liberation of the associated )ases4steam enters from the underneath of the trays and flo$s in counter direction of condensate2 'hile flo$in) up$ards throu)h the trays> scrubbin) and heatin) is done2 Thus the liberated )ases mo.e up$ards alon) $ith the steam2 Steam )ets condensed abo.e the trays and in turn heats the condensate2 1iberated )ases escapes to atmosphere from the office openin) eant for it2 This openin) is pro.ided $ith a number of deflectors to minimiAe the loss of steam2 DeaeratorEs main components are )i.en belo$6 12 *2 +2 %2 52 62 /2 Tubular type )au)e )lass2 7i)h le.el alarm s$itch2 1o$ le.el alarm s$itch2 Pressure )au)e2 Strai)ht thermometers $ith poc(ets2 Safety .al.e2 Isolatin) .al.es for stand pipes2

#i)662+21 Deareator

33

DEPARTMENT OF MECHANICAL ENGINEERING

#i)662+2* Circuit dia)ram of Condenser Connections

34

DEPARTMENT OF MECHANICAL ENGINEERING

#i)662+2+ Circuit dia)ram of Condensate System Connections

35

DEPARTMENT OF MECHANICAL ENGINEERING

6.4 FEED WATER S9STEM

This system plays an important role in the supply of feed $ater to the boiler at reCuisite pressure and steam $ater ratio2 This chapter describes the .arious au,iliaries under this system startin) from Boiler #eed Pump to #eed re)ulatin) station .ia 7P heaters2

B(%. $ F 0 P,+&:
This pump is horiAontal and of barrel desi)n dri.en by an ;lectric motor throu)h a hydraulic couplin)2 All the bearin)s of pump and motor are forced lubricated by a suitable oil lubricatin) system $ith adeCuate protection to trip the pump if the lubrication oil pressure fails belo$ a preset .al.e2 The hi)h4pressure boiler feed pump is .ery e,pensi.e machine $hich calls for a .ery careful operation and s(illed maintenance2 The safety in operation and efficiency of the feed pump depends lar)ely on the reliable operation and maintenance2 Operation staff must be able to find out the causes of defect at the .ery be)innin) $hich can be easily remo.ed $ithout the endan)erin) the operator of the po$er plant and also $ithout the e,pensi.e dismantlin) of the hi)h pressure feed pump2 The feed pump consists of the pump barrel> into $hich is mounted the inside stator to)ether $ith rotor2 The hydraulic part is enclosed by the hi)h pressure co.er alon) $ith the balancin) de.ice2 The suction side of the barrel and the space in the hi)h pressure co.er behind the balancin) de.ice are enclosed by the lo$ pressure co.ers alon) $ith the stuffin) bo, casin)s2 The brac(ets of the radial bearin) of the suction side and radial and thrust bearin) of the dischar)e side are fi,ed to the lo$ pressure co.ers2 The entire pumps is mounted on a foundation frame2 The hydraulic couplin) and t$o cla$ couplin)s $ith couplin) )uards are also deli.ered alon) $ith the pump2 'ater coolin) and oil lubricatin) connections are pro.ided $ith their accessories2

#i)6 62% Turbine Dri.en Boiler #eed Pump

36

DEPARTMENT OF MECHANICAL ENGINEERING

H%21 P$ "",$ H *' $":

These are re)enerati.e feed $ater heaters operatin) at hi)h pressure and located by the side of turbine2 These are )enerally .ertical type and turbine bled steam pipes are connected to them2 7P heaters are connected in series on feed $ater side and by such arran)ement> the fed $ater> after feed pump enters the 7P 7eaters2 The steam is supplied to these heaters from the bled point of the turbine throu)h motor operated .al.es2 These heaters ha.e a )roup bypass protection on the feed $ater side2 In the e.ent of tube rupture in any of the 7P7 and the le.el of the condensate risin) to dan)erous le.el> the )roup protection de.ice di.erts automatically the feed $ater directly to boiler> thus bypassin) all the + 7P heaters2 As sho$n in fi)204!> feed $ater flo$s throu)h the tube spirals and is heated by seam around the tubes in the shell of the heaters2 These heaters are cylindrical .essels $ith $elded dished ends an $ith inte)rated> de4superheatin)> condensin) and sub coolin) sections2 The internal tube system of spirals is $elded to the inlet and outlet headers2 In order to facilitate assembly and disassembly> rollers at the side of the header ha.e been pro.ided2 Both feed $ater and steam entries and e,ists are from the bottom end of the heaters2 This desi)n offers the ad.anta)e to optimiAe the arran)ement of pipin) and the location of the heaters at po$er station2 #ollo$in) fittin)s are )enerally pro.ided on the 7P heaters6 a9 b9 c9 d9 e9 f9 )9 -au)e )lass for indicatin) the drain le.el2 Pressure )au)e $ith three $ay coc(2 Air .ent coc(2 Safety .al.e shell side2 Seal pot2 Isolatin) .al.es2 7i)h le.el alarm s$itch2

-roup protection de.ice of 7P 7eaters6 In the e.ent of risin) of the drain condensate le.el in any one of the 7P heater> to the emer)ency hi)h le.el> the feed $ater flo$in) throu)h the coils of the heaters> is di.erted automatically directly to the boiler> thereby all the )roups of three 7P heaters is by passed2

T,$-%) D$%6 ) B(%. $ F 0 P,+&:

The sin)le cylinder turbine is of the a,ial flo$ type2The li.e steam flo$s throu)h emer)ency stop .al.e and then throu)h the main control .al.es2The .al.es re)ulate the steam supply throu)h the turbine2There are 1% sta)es of reaction bladin)2The turbine is pro.ided $ith the electro hydraulic )o.ernin) system2The steam e,hausted from the B#P turbine is directly connected to the main condenser and the turbine )lands are )land steam2There are * TDB#PEs for each 5==8' unit at rama)undam of capacity 1=A=.3+3>1$ *' 2=4.32 -*$.

37

DEPARTMENT OF MECHANICAL ENGINEERING

#i)6 62%21 7P 7eater

D$%&>D$*%) S!"' +:
The steam> bled from the turbine> after condensation is termed as dripH drain2 The drain is cascaded from 7P / to IPs and further to 1P * all the condensate due to the bled steam of the heaters is collected to in deaerator 3durin) normal load9 and in 1P *> from $here the drain is pumped bac( into the feed system2 The drain from 1P21 is only connected to the condenser by @4 tube $ater seal2 The drain from 7P25 $ill )o to deaerator or 1P2% dependin) on the shell pressure and load on the machine2 All the 1P heater drains are ha.in) manual bypass> $hich can be operated in case of any indi.idual re)ulators> fail2 The drain from 1P2* can be re)ulated to condenser in case the le.el in 1P2* rises to a predetermined le.el2

D$%& P,+&":
T$o numbers of sectional multista)e centrifu)al horiAontal pumps per unit are pro.ided2 One $ill be runnin) and the other is standby 31==D standby92 These are especially suited for the purpose of pumpin) from the space of hi)h .acuum2 Condensate drip from 1P heater &o2* 3$hich is under .acuum9 is pumped a)ain to main condensate line in bet$een 1P heaters2

38

DEPARTMENT OF MECHANICAL ENGINEERING

#i)662%2* Circuit Dia)ram of Turbine Dri.en Boiler #eed Pump

39

DEPARTMENT OF MECHANICAL ENGINEERING

40

DEPARTMENT OF MECHANICAL ENGINEERING

6.5 COOLING WATER S9STEM

;Cuipment coolin) $ater 3;C'9 system6 This $ater is used to cool the heated lubricatin) oil comin) from the lube oil coolers of boiler and turbine side2 This is demineralised $ater and is supplied throu)h ;C' pumps2 Au,iliary coolin) $ater 3AC'9 system6 This is ra$ $ater> ta(en a tapin) from C' pumps dischar)e side> pressuriAed and circulated in a Plate 7eat ;,chan)er to cool the heated ;C' $ater2

COOLING TOWERS ;CT"<:

A closed circuit coolin) system is used for heat re<ection that consists of coolin) pond and t$o coolin) to$ers> ponds and to$ers are connected in a parallel arran)ement to study the beha.ior of the coolin) system2 The coolin) to$er models based on the analo)y approach of a coolin) to$er and an heat e,chan)er2 An effecti.eness4&T@ method is employed to predict the coolin) to$er performance $ith respect to ambient and load conditions2 #or the circulation of coolin) capacity of the coolin) pond surface> a semi empirical approach is selected that is based on the combination of free and forced con.ection2 The $ater flo$ in the pond is a appro,imated by a plu) flo$ model2 #rom the ener)y transfer and flo$ model a stimulation pro)ram is de.eloped that is capable of predicatin) of coolin) pond temperatures dependent on meteorolo)ical conditions and head load on the pond2 A simple model of an atmospheric coolin) spray is employed2

#i)6 625 Coolin) to$ers

41

DEPARTMENT OF MECHANICAL ENGINEERING

6.6 LUBRICATION OIL S9STEM

Introduction6 same oil is used for )o.ernin) 5 lubrication2 The oil is (ept in the main oil tan(2 The )o.ernin) is desi)ned for operation at the oil pressure of 1%()HcmsC $hile lubrication of bearin)s is desi)ned to $or( at *()HcmsC2The follo$in) eCuipment is a.ailable in the lubricatin) system2 12 *2 +2 %2 52 62 /2 !2 Au,iliary oil pump A2C lube oil pump D2C emer)ency oil pump main oil pump booster pump oil tan( oil coolers .ent fans

1ubrication oil system lubricates both turbine and )enerator bearin)s2 8oreo.er it supplies oil to seal oil system2 Durin) normal operation of turbine shaft directly dri.es pump 3centrifu)al type9 at +=== rpm and supplies oil to the lubrication system2 Au,iliary oil pump is incorporated in the oil system to deli.er oil to )o.ernin) system and bearin)s at the time of startin) of turbine $ith bac( up protection2 D2C2 stands by oil pumps are used for bearin) oil supply only2

AUXILAR9 OIL PUMP:

It is centrifu)al pump dri.en by A2C electric motor2 Au,iliary oil pump is pro.ided for meetin) the reCuirement of oil for the turbine )o.ernin) system and bearin) lubrication system durin) and stoppin)2 It is mounted on the main oil tan(2

DC LUB OIL PUMP:

The bearin) are protected from possible lubrication failure by the pro.ision of t$o automatically startin) oil pumps4i2e2 AC lubrication oil pump and DC emer)ency oil pump AC lube oil pump automatically start $hen lubrication oil pressure drops to 12*()HcmsC2 The emer)ency lubrication oil pump 3DC dri.en9 is pro.ided as a bac(up protection a)ainst the failure of AC lubrication oil pump or AC supply2 DC lubrication oil pump cuts in automatically $hen lubrication pressure drops do$n to =2!()HcmsC2 Both AC lubrication oil pump and DC lubrication oil pump are mounted on main oil tan(2

MAIN OIL PUMP:

Durin) normal operation of turbine> main lubrication oil pump is mounted on turbine shaft and dri.en by turbine shaft at +===rpm2 It supplies oil to the )o.ernin) and lube oil system2

42

DEPARTMENT OF MECHANICAL ENGINEERING

Pump is desi)ned for continues operation at +===rpm and installed inside the front pedestal of turbine2 The 8OP is capable to supply oil to the system at full capacity $hen the turbine reaches to *!==rpm2 Then the AOP> $hich is in ser.ice> $ill be separated from the system automatically2

BOOSTER PUMP:
The oil pressure de.eloped by au,iliary oil pump dischar)e durin) starin) and stoppin) of turbine operates booster pump2 Durin) normal runnin) of turbine 3at +===rpm9 it is operated by main oil pump dischar)e2 It supplies oil to lubricatin)2

OIL TANK:
Oil is stored in main oil tan( 38OT9 $hose capacity is 16cum2 T$o numbers of .apour fans are mounted on 8OT to e,tract oil .apour and dissol.ed )ases also to the atmosphere from 8OT2 Au,iliary oil pump> AC lubrication oil pump> DC lubrication booster pump and oil coolers are mounted on 8OT2 Oil le.el indicators and instruments such as oil pressure and temperature )au)es and pressure s$itches for pump interloc(s and annunciationEs are mounted on 8OT2 1ocal startin) and stoppin) of pumps and local pressure indicators are also a.ailable on 8OT2 The oil cooler chan)in) system and ma)netic duple, system selection also mounted on 8OT2 The line to oil purification system is connected to 8OT2

OIL COOLERS:
Oil coolers are of surface type2 @sually one cooler $ill be in ser.ice $hile the other is standby2 It consists of tubes throu)h $hich coolin) medium flo$s2 The coolin) medium used is ra$ $ater2 The oil cooler consist of the follo$in)2 12 *2 +2 %2 52 shell upper $ater chamber lo$er $ater chamber tube system cooler chan)e o.er mechanism

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DEPARTMENT OF MECHANICAL ENGINEERING

#i)6626 Turbine 1ube Oil System

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DEPARTMENT OF MECHANICAL ENGINEERING

45

DEPARTMENT OF MECHANICAL ENGINEERING

#i)662621 Steam Turbine flo$ Dia)ram Sho$in) Au,iliaries

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DEPARTMENT OF MECHANICAL ENGINEERING

CONCLUSION

The $or(in) of Steam Turbine 5==8' $as studied> the process of Con.ersion of ?inetic head of Steam into 8echanical ;ner)y $as obser.ed2 The Au,iliaries of Steam Turbine and their importance in po$er )eneration $ere studied and obser.ed the .arious components in.ol.ed in the $or(in) of Steam Turbine2

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DEPARTMENT OF MECHANICAL ENGINEERING

BIBILOGRAPH9

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DEPARTMENT OF MECHANICAL ENGINEERING