A PRESENTATION ON 660MW TURBOGENERATOR ,ITS AUXILIARIES
AND ASSOCIATED SYSTEMS OF
STAGE – I OF SIPAT SUPER THERMAL
PROJECT
STEAM TURBINE K-660-247


LMZ (LENINGRADSKY METALLICHESKY ZAVOD)
K STANDS FOR KLAPAN LTD.,BULGARIA WHICH SUPPLIES
TURBINE,NOZZLES,DIAPHRAGMS, SEALS,BLADES ETC.




TG DECK IS VIS SUPPORTED AND HAS 26 CONCRETE COLUMNS (T1 – T26).
TG HALL IS CONSTITUTED OF 3 MAINS ROWS OF COLUMNS – A,B ,C ROW AND TWO BAYS – AB BAY AND BC BAY.
THE WIDTH OF AB BAY IS 36m AND BC BAY IS 12m
CONDENSER TUBE BANKS (CW PATH) HAS AN INCLINATION OF 40.
THERE ARE TWO MAIN EOT CRANES FOR TG HALL.EACH EOT CRANE IS HAVING A CAPACITY OF 200t FOR MAIN
HOIST AND 20t FOR AUXILIARY HOIST. 35.5m IS THE MAXIMUM VERTCAL DISTANCE A HOIST CAN
TRAVEL.TANDEM OPERATION OF TWO EOT CRANES ARE ALLOWED.


LOAD
BEFORE HP STOP VALVE




660MW
5370C
:
247KSC
:
2023.75T/HR
:
:
48KSC
298.710C
:
43.2KSC
:
:
AFTER HPC



STEAM PRESSURE
STEAM TEMPERATURE
STEAM FLOW
:
STEAM PRESSURE
STEAM PRESSURE
BEFORE IP STOP VALVE


STEAM PRESSURE
STEAM TEMPERATURE
STEAM FLOW TO REHEATER
DESIGN CONDENSER PRESSURE
COOLING WATER FLOW
:
:

FINAL FEED WATER TEMP.
:

FREQUENCY RANGE
:



5650C
1681.12T/HR.
0.105KSC (abs.)
:
64000M3/HR
286.350C
47.5 – 51.5 Hz





Generator rated speed
3000
Generator manufacturerElectrosila
No. of bleedings
8
Length of the turbine
36.362
No. of stages





HPT
IPT
LPT-1
LPT-2
Total
17
11x2
5x2
5x2
59
rpm
m

Parameters











Pr. Before HPC SV
Temp. before HPC SV
Steam flow
Pr. After HPC
Temp. after HPC
Pr. Before IP SV
Temp. before IP SV
Steam flow to reheat
Design Cond pr.
CW flow
Final FW Temp.
537.0
48.0
247.0
0C
2023.75
Ksc
298.71
43.2
565.0
1681.12
0.105
64000
286.35
Ksc
TPH
0C
Ksc
0C
TPH
Ksc
TPH
0C

Turbine Governing system
 Mode of Governing
 Type
 Control fluid
Nozzle
E/H
Firequel-L make
Supresta-USA
 Normal Operating Pr. 50 Ksc
 Capacity
600 lpm
 Fluid pump motor rating
200 KW
 Filter material
Ultipor
 Mesh size
25 µ

Lube oil system
 Lube oil






Absolute viscosity
Kinematic viscosity
Specific gravity
0.89
Flash point
Fire point
Oil requirement per bearing










N1
N2
N3
N4
N5
N6
N7
N8
N9
N10
Tn-22C Russia Mobil DTE Oil light Teresso 32
In accordance with ISO VG 32
16.7
Centipoise
-32
Centistokes
180
240
0C
200
200
450
280
350
350
350
350
600
600
lpm
lpm
lpm
lpm
lpm
lpm
lpm
lpm
lpm
lpm
0C

Lube oil system





Total oil system capacity
Full volume of oil tank
Material of tank
Normal lube oil pressure
Oil temp at inlet of bearings
52000
58000
SS
1.2
lit
lit
 Normal
 Maximum
55
0C
0C
 Piping

59
Ksc
SS
Seal steam system
 Source of gland sealing system
 During normal operation
 During low load operation
 Quantity of seal steam required
 Seal steam pressure at turbine glands
 Seal steam temperature at turbine glands
End glands of HPC & IPC
End glands of HPC & IPC + AS
3.54
1.1-1.2
160
TPH
Ksc
0C
TURBINE SEAL STEAM
•TWO HEADERS OR COLLECTORS ARE THERE i.e. HOT
COLLECTOR AND COLD COLLECTOR.
•INITIAL SOURCE OF STEAM SUPPLY IS APRDS (UNIT
HT,16KSC,310OC).
•PRESSURE AND TEMPERATURE OF COLD HEADER OR
COLLERTOR ARE 1.1TO1.15 KSC ABSOLUTE AND 140TO
180OC RESPECTIVELY.
•PRESSURE AND TEMPERATURE OF HOT HEADER OR
COLLERTOR ARE 1.1TO1.15 KSC ABSOLUTE AND
RESPECTIVELY.

Turbine Protection





Over speed trip
110-112 %
Low lube oi pressure
0.3 (g)
Ksc
Low vacuum trip
0.3 (abs) Ksc
Thrust bearing excessive wear trip +1.2/-2.0mm
Pressure relief diaphragm setting 1.2 (abs) Ksc

Materials of construction









HP Outer casing
15Cr1Mo1V
HP blade/carrier casings15Cr1Mo1V
IP Outer casing
15Cr1Mo1V
LP inner casing
Steel 3
LP Outer casing
Steel 3
HP Shaft
25Cr1Mo1V
IP Shaft
25Cr1Mo1V
LP Shaft
26CrNi3Mo2V
Moving blades







HPT first stage blades 18Cr11MoNiVNb (1-5)
HPT other stages
15Cr11MoV (6-17)
IPT first stage
18Cr11MoNiVNb (1-3)
IPT other stages
15Cr11MoV (4-11)
LPT last stage
13Cr11Ni2W2MoV
LPT other stages
20Cr13 (1-2)
LPT other stages
15Cr11MoV (3-4)
 Fixed blades







HPT first stage
HPT other stages
IPT first stage
IPT other stages
LPT first stage
LPT Other stages
18Cr11MoNiVNb (1-5)
15Cr11MoV (6-17)
18Cr11MoNiVNb
15Cr11MoV
12Cr13 (1-4)
08 Cr13 (5)
Number of stages
 HPT
 Impulse stages
 Reaction stages
1
16
 IPT
 Impulse stages
 Reaction stages
22
0
 LPT
 Impulse stages
 Reaction stages

20
0
All rows of blades are integrally shrouded




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
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No. of HP Stop valves
No. of HP Control valves
Type of control valve unit
No. of IP Stop valves
No. of IP Control valves
Type of control valves
No. of Journal bearings for turbine
No. of Journal bearings for Gen
No. of thrust cum journal bearing
Type of thrust bearing
Type of journal bearing
Material of bearing shell
Type of lining
LPT diaphrams
2
4
Block united
2
4
Separate
8
4
1
Tilting
6-Fixed & 2-Tilting pad
Alloy steel
Babbit
4
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

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

Turbine model No
K-660-247
Generator model No
TBB-660-2T3
Strainers are installed in the steam chests of the stop valves
In HPT, having passed the control stage and 8 stages which
generate left jet of steam (from generator towards front bearing)
steam changes its direction 180° and flows between internal and
external cylinders to 8 stages of right jet (towards generator)
In CRH lines, NRV has a bypass with electric valve and control
valve to enable counter flow mode of HPT with the aim of
warming up of cylinder and high pressure cross over pipes at
turbine start up and cold condition
HPT has nozzle steam distribution system
IPT has throttle steam distribution system
On each upper half (cover) of low pressure cylinder four
membrane type relief valves are installed which are activated
when the absolute pressure in exhaust nozzles rises up to 1.35 –
1.4 Ksc absolute
TG SEAL STEAM SYSTEM
HPT SEAL STEAM CONNECTION
TO BLED STEAM TO LPH # 4
1ST CHAMBER
2ND CHAMBER
HPT
TO 2nd CHAMBER EXHAUST
TO HOT SEAL STEAM HEADER
TO GSC
TO BLED STEAM TO D/A
IPT SEAL STEAM CONNECTION
IPT
TO COLD SEAL STEAM HEADER
TO GSC
LPT SEAL STEAM CONNECTION
LPT
FROM COLD SEAL STEAM HEADER
TO GSC


IN HIGH PRESSURE DRAINAGE EXPANSION TANK A VALVES IN DRAINAGE COLLECTORS FROM EXTRACTION STEAM
PIPES TO HPHs (10MAL20AA110, 10MAL20AA120, 10MAL20AA140) AND IN LOW PRESSURE DRAINAGE
EXPANSION TANK VALVES IN DRAINAGE COLLECTORS FROM EXTRACTION STEAM PIPES TO LPHs(10MAL30AA110,
10MAL30AA120) CLOSE AUTOMATICALLY IF TURBINE LOAD INCREASES OVER 200MW AND AT THE SAME TIME
ALL VALVES ARE OPEN IN THE CORRESPONDING STEAM EXTRACTION FROM THE TURBINE TO HPHs AND LPHs.
VALVES IN DRAINAGE PIPES OF HPBP AND LPBP (10MAL30AA107, 10MAL30AA108) CLOSE AUTOMATICALLY IF
TURBINE LOAD INCREASES OVER 30MW.






FIRE RESISTANT SYNTHETIC HYDRAULIC FLUID FYRQUEL – L MANUFACTURED BY “SUPRESTA” IS USED AS
OPERATING FLUID.ITS SELF IGNITION TEMPERATURE IS ABOUT 740OC.
OPERATING PRESSURE IS APPROXIMATELY 50KSC.
OPERATING TEMPERATURE IS 45-55OC.
CONTROL OIL SUPPLY UNIT CNSISTS OF A RESERVOIR (10MAX10BB001)OF CAPACITY 7.0m3 ,2NOS.OIL
COOLERS(10MAX10AC001,10MAX10AC002),DE-AERATOR,MESH FILTER,FINE FILTER(10MAX18AT001),DUPLEX
FILTER(10MAX14AT001) AND 2 NOS. OF VERTICALLY MOUNTED CENTRIFUGAL
PUMPS(10MAX11AP001,10MAX12AP001) DRIVEN BY AC MOTOR (1W+1S).EACH PUMP IS HAVING A CAPACITY OF
36m3/h AND DISCHARGE PRESSURE IS 50KSC.
CONTROL FLUID RESERVOIR IS SEPERATED BY TWO NUMBERS OF TANDEM MESHES OF CELL SIZE 0.25mm INTO
TWO SECTIONS ,DIRTY AND CLEAN. DE- AERATOR IS INSTALLED INSIDE THE RESERVOIR INFRONT OF MESHES
AND IT CONSISTS OF SLOPING PLATE ASSEMBLY.
CF FINE FILTER FOR REMOVING MECHANICAL IMPURITIES IS INSTALLED IN RESERVOIR. DURING NORMAL
OPERATION CF IS SUPPLIED TO THE FINE FILTER THROUGH AN ORIFICE OF DIAMETER 4mm FROM UNSTABILIZED
PRESSURE LINE VIA VALVE 10MAX18AA501 . AFTER THAT IT IS DISCHARGED IN THE DIRTY CHAMBER OF THE
RESERVOIR. WHEN TURBINE IS STOPPED CF IS SUPPLIED TO THE FINE FILTER WITH THE HELP OF ANOTHER PUMP
(CF TRANSFER PUMP,10MAX19AP001,CAPACITY 4m3/hr, AND DISCHARGE PRESSURE 25KSC) VIA VALVES
10MAX19AA503 AND10MAX19AA504 FOR FILTERING PURPOSE KEEPING MAIN PUMPS IN OFF CONDITION.


OIL PURIFICATION IS CONTINUOUS DUE TO FILTERING OF ITS PART VIA CONCURRENTLY MOUNTED WORKING
FILTER CARTRIDGES INSTALLED INSIDE THE FINE FILTER HOUSING.
FILTER CARTRIDGES DESIGN ALLOWS USAGE OF DIFFERENT FILTERING MATERIAL.
 METAL SEMI-PINCEBECK MESH WITH FILTERING DEGREE OF 70 MICRONS TO FLUSH SYSTEM AFTER
INSTALLATION OR MAINTENANCE.
 FILTER BELTING FABRIC WITH FILTERING DEGREE 30 – 40 MICRONS FOR PRIMARY REFINING DURING
TURBINE OPERATION.
 FILTERING ELEMENTS MANUFACTURED BY ”PALL” WITH FILTERING DEGREE 12 MICRONS FOR CONTINUOUS
OIL FILTERING DURING TURBINE OPERATION.





OCCURRENCE OF PRESSURE OF 0.1 TO 0.3KSC IN FILTER HOUSING WITHIN 1-3 HOURS SHOWS CORRECT
ASSEMBLY OF FILTER AND ITS PROPER OPERATION.
IT IS NECESSARY TO SWITCH OFF THE FINE FILTER AND REPLACE FILTERING ELEMENTS IF PRESSURE IN FILTER
HOUSING RISES UPTO 2KSC.WHICH SHOWS CONTAMINATION OF FILTER FABRIC.
INSIDE FILTER HOUSING THERE IS A RELIEF VALVE BYPASSING FLUID BESIDES FILTER CARTRIDGES WHEN THEY ARE
CONTAMINATED AND PRESSURE RISES UPTO 5KSC.
AN OIL LEVEL GAUGE WITH ALARM SYSTEM WHISKERS (10MAX10CL001,10MAX 10CL002) IS PROVIDED IN THE
CLEAN SIDE OF THE RESERVOIR.
NORMAL OPERATING LEVEL IS 700mm FROM THE UPPER COVER (30 GRADUATION OF L.G.) AND THE AMOUNT OF
CF IS 2.5m3




MAXIMUM ALLOWALABLE UPPER LIMIT (WITH CF PUMPS IN STOPPED CONDITION) IS 150mm FROM THE UPPER
COVER (85 GRADUATION OF L.G.) AND MINIMUM OPERATING LEVEL IS 800mm (20 GRADUATON OF L.G.) FROM
THE UPPER COVER.
CF PUMP STOPS AUTOMATICALLY INCASE OF RESERVOIR OIL LEVEL LOW-LOW.
FOR VISUAL OVSERVATION OF OIL LEVEL ,LEVELGLASSES HAVE BEEN PROVIDED IN THE BOTH SIDES (DIRTY AS
WELL AS CLEAN).
DIFFERENTIAL PRESSURE SWITCH (10MAX10CP001) HAS BEEN PROVIDED TO WARN ABOUT INCREASE IN PRESSURE
DIFFERENCE IN SIDE THE MESH FILTER. ALLOWABLE DIFFERENCE IN MESHES DOESNOT EXCEED 150mm.

THE STANDBY CF PUMP STARTS WHEN THE RUNNING ONE TRIPS OR SYSTEM PRESSURE DROPS TO 36KSC.

IT TAKES 2 MINS FOR THE SYSTEM TO GET PRESSURIZED.



IF SYSTEM PRESSURE DROPS TO 20KSC (10MAX14CP001) AND STOP VALVES START CLOSING ,THE OPEARTING
PUMP WILL STOP AND NO SIGNAL WILL BE GENERATED TO START THE STAND BY PUMP (SENSING OIL LEAKAGE).
CF PUMP ALSO TRIPS ON FIRE PROTECTION.
DUPLEX FULL PASSAGE FILTER WITH FILTERING DEGREE 20-25MICRONS IS INSTALLED IN GENERAL PRESSURE
COLLECTOR OF CONTROL SYSTEM.IF PRESSURE DIFFERENCE (10MAX14CP301,10MAX15CP301) ACROSS THE
RUNNING FILTER REACHES 0.8KSC,THE STANDBY FILTER HAS TO BE TAKEN INTO SERVICE.





2 NOS.OF CF COOLERS (A&B) ARE INSTALLED IN THE CF SUPPLY LINE BEHIND THE DUPLEX FILTER. THESE
COOLERS ARE DOUBLE PASS (BY WATER) SURFACE HEAT EXCHANGERS WITH TUBULAR DESIGN ,WATER STREAM
FLOWS INSIDE THE TUBES AND CONSIST OF 148 TUBES OF SIZE 16X1500mm AND HEAT EXCHANGE AREA
25m2.CF FLOWS FROM TO DOWNARD.
COOLERS ARE DESIGNED FOR A MAXIMUM COOLING WATER PRESSURE OF 10 ± 0.5KSC AND CF PRESSURE OF 68.7
± 0.5KSC.CF FLOW RATE TO EACH COOLER IS 50m3/hr AND PRESSURE DROP IS 0.2KSC. CW FLOW RATE TO EACH
COOLER IS 80m3/hr AND PRESSURE DROP IS 0.194KSC.
FOR HYDRODYNAMIC FLUSHING OF PIPELINES DURING MAINTENANCE,THERE IS A BYPASS VALVE
(10MAX14AA501)TO THE COOLERS WHICH SHOULD BE CLOSED AND SEALED DURING ROUTINE OPERATION.
IN THE INPUT AND OUTPUT TO THE COOLERS CF LINE IS PROVIDED WITH TRIPLE-PASS SWITCHING OVER VALVES
WHICH PREVENT FALSE ACTIVATION OF BOTH COOLERS.
CF TEMPERATURE IS MAINTAINED (48-52OC)BY COOLING WATER FLOW VARIATION WITH THE HELP OF A FLOW
CONTROL STATION CONSISTING OF A PNEUMATIC CONTROL VALVE (10PGM20AA001) AND A BYPASS
MOTORIZED CONTROL VALVE(10PGM20AA002).IN CASE TEMPERATURE RISES TO 55OC
(10MAX14CT001,10MAX14CT002),MOTORIZED BYPASS VALVE OPENS TO MAINTAIN THE CF TEMPERATURE. THE
MAXIMUM LIMIT OF CW TEMPERATURE AT COOLER INLET IS 37OC.IF CW TEMPERATURE IS BELOW 36OC ONE
COOLER CAN BE PUT OUT OF OPERATION.

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






CF SUPPLY TO CONTROL UNITS IS CARRIED OUT BY TWO PRESSURE COLLECTORS OF STABILIZED AND
UNSTABILIZED PRESSURE.
CF IS SUPPLIED TO UNSTABILIZED PRESSURE COLLECTOR THROUGH AN ORIFICE OF SIZE 22mm. STOP AND
CONTROL VALVE ACTUATORS ARE FED FROM THIS COLLECTOR.
INTO STABILIZED PRESSURE COLLECTOR WHICH FEEDS OIL TO ALL CONTROL DEVICES,CF IS SUPPLIED FROM THE
SECTION BETWEEN PUMPS AND THE ORIFICE.
DUE TO THE ARRANGEMENT MENTIONED ABOVE ,THE PRESSURE VARIATION IN UNSTABILIZED PRESSURE
COLLEECTOR CAUSED BY INCREASE IN CF CONSUMPTION WITH OPEN ACTUATORS AFFECTS IN A LESS DEGREE
PRESSURE VARIATION IN STABILIZED PRESSURE COLLECTOR.
SPRING-WEIGHT ACCUMULATOR (10MAX20BB001) IS CONNECTED TO UNSTABILIZED PRESSURE COLLECTOR TO
PREVENT DECREASE IN FORWARD PRESSURE IN CASE OF LOSS AC SUPPLY TO THE PUMPS FOR 5-7SECS OR
DURING PUMP CHANGE-OVER.
THE SETTING OF FLUID PRESSURE LEVEL (45KSC) TO BE ENSURED BY THE ACCUMULATOR IS DETERMINED BY A
WEIGHT WHICH IS CONCRETE FILLED IN THE SITE.
ONE NRV IS INSTALLED IN THE LINE CONNECTING THE ACCUMULATOR TO THE UNSTABILIZED PRESSURE
COLLECTOR. ACCUMULATOR IS FILLED WITH THE CF THROUGH AN ORIFICE OF SIZE 5mm INSTALLED IN THE
BYPASS LINE OF THE NRV.
TWO EXHAUST FANS (1W+1S) ,10MAX21AN001,10MAX21AN002 (CAPACITY OF 3200m3/hr AT A HEAD OF 520mm OF WATER COLUMN) ARE ALSO INSTALLED TO REMOVE CF VAPOUR FROM CF RESERVOIR AND SYSTEM.
THE EXHAUSTER SWITCHES ON AUTOMATICALLY WHEN CF PUMP STARTS AND SWITCHES OFF AUTOMATICALLY
WITH 15mins TIME DELAY AFTER THE STOPPING OF CF PUMP AND CF SYSTEM PRESSURE DROPS BELOW 2.0KSC.

HYDRAULIC TEST OF PIPE LINES CARRIED OUT AT A PRESSURE OF 90KSC.HYDRAULIC TEST SHOULD BE CARRIED
OUT AFTER ASSEMBLING,OVERHAUL AND INSPECTION.
CONTROL FLUID SYSTEM



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
Isolation valves on pump suction & discharge side
Pump discharge pressure
50
Ksc
Capacity
41
TPH
Stabilized pressure header supply oil to servo motors of SV & CV
Un stabilized pressure header with 22 mm orifice
Accumulator in unstabilized pressure header
CF tank capacity
6.9
m3
Duplex filter
Control fluid transfer pump to empty the CF tank
CF Temperature control by control station in the ECW line
ELECTRO-HYDRAULIC CONVERTER – SUMMER – 8 NOS.
SUMMER – 8NOS.
ELECTRO-MECHANICAL CONVERTER – 8NOS.
GOVERNING BLOCK
1.
2.
3.
4.
1.
2.
3.
4.
5.
6.
7.
8.
9.
5.
6.
7.
8.
9.
10.
11.
12.
13.
CONTROLGEAR(AE001) – 1NO.
EMERGENCY GOVERNOR OR OVERSPEED GOVERNOR– 1NO.
TRIP SOLENOID (AA213,AA214)-2NOS.
TEST ELECTROMAGNETS(AA211,AA212) – 2NOS.
ROTATIONAL SPEED DETECTOR -3 NOS.
LIMITER OF PRESSURE (AA502) – 1NO.
SPEED TRANSDUCER – 1NO.
LEVER OF OVER SPEED GOVERNOR (AX201)– 1NO.
PILOT VALVE FOR SUPPLY (AX202) – 1NO.
ACCUMULATOR – 1NO.
OIL SUPPLY AND PURIFIER UNIT
SERVOMOTOR OF HPSV – 2NOS.
SERVOMOTOR OF HPCV – 4NOS.
SERVOMOTOR OF IPSV – 2NOS.
SERVOMOTOR OF IPCV – 4NOS.
SERVOMOTOR OF CRH NRV – 2NOS.
LOCKING PILOT VALVE (AA001,AA002,AB001,AB002)- 4NOS.
EX.STOP VALVE SERVOMOTOR OR ESV (10LBQ10AA101)– 1NO.
1.
HEAD PRESSURE LINE (STABILIZED,50KSC,10MAX15)
2.
HEAD PRESSURE LINE ( NON-STABILIZED,50KSC,10MAX15)
3.
LINE OF PROTECTION (50KSC,10MAX51)
4.
LINE TO COCK THE OVERSPEED GOVERNOR SLIDE VALVE (50KSC)
5.
CONTROL OIL LINE TO STOP VALVE SERVOMOTORS (50KSC,10MAX16)
6.
CONTROL LNE TO SUMMATORS (35KSC,10MAX17)
1.
OUT OF TOLERANCE ROTOR OVERSPEED : ALARM AT 3300RPM AND TRIPPING AT 3360RPM
2.
OUT OF TOLERANCE AXIAL DISPLACEMENT OF ROTOR:
3.
4.
5.

TOWARDS FRONT BEARING BY 0.6mm (-0.6mm) -ALARM.

TOWARDS FRONT BEARING BY 1.2mm (-1.2mm) - TRIPPING.

TOWARDS GENERATOR BY 1.4mm (+1.4mm)A- ALARM.

TOWARDS GENERATOR BY 2.0mm (+2.0mm) - TRIPPING.
LUBRICATING OIL PRESSURE DROP: ALARM AT 0.70KSC AND TRIPPING AT 0.30KSC WITH 3SECS TIME DELAY.
PRESSURE RISE IN CONDENSER:ALARM AT 0.15KSC abs. AND TRIPPING AT 0.20KSC abs. PROTECTION IS
INTRODUCED AUTOMETICALLY AT UNIT START-UP AFTER PRESSURE DROP IN CONDENSER LOWER THAN
0.15KSC abs. OR AT TURBINE SPEED INCREASE OVER 1500RPM. PROTECTION IS IN OPERATION UNTIL STOP
VALVES ARE OPEN
INCREASE OF BEARING VIBRATION: ALARM SOUNDS AT INCREASE OF VERTICAL OR TRANSVERSE OR AXIAL
COMPONENT OF VIBRATION ON ANY BEARING OF TG SET REACHES 4.5mm/s .TRIPPING OCCURS WITH 2 SECS
TIME DELAY AT INCREASE OF VERTICAL OR TRANSVERSE COMPONENT OF VIBRATION OVER 11.2mm/s ON
ANY TWO BEARINGS OF TG SET.
6.
RISE IN STEAM TEMPERATURE AT HPT OUTLET:
7.
LIVE STEAM TEMPERATURE BEFORE TURBINE FALLS BELOW 470OC:
8.
LIVE STEAM TEMPERATURE BEFORE TURBINE RISES ABOVE 565OC:
9.
STEAM TEMPERATURE BEFORE IV FALLS BELOW 500OC:
10.
STEAM TEMPERATURE BEFORE IV RISES ABOVE 593OC:
11.
MOT LEVEL LOW-LOW:
12.
DRIP LEVEL HIGH-HIGH IN ANY HPH:
13.
ANY FAILURE IN TURBNE CONTROL SYSTEM ELECTRONICS:
14.
GENETERATOR PROTECTION:
15.
FIRE PROTECTION OPERATED:
16.
EPB PRESED.




LUBRICATION OIL SYSTEM IS DESIGNED TO SUPPLY OIL TO TURBINE AND GENERATOR BEARINGS IN ALL TURBINE
PLANT OPERATION MODES AND ALSO TO PROVIDE ROTOR JACKING OIL SYSTEM AND GENERATOR SEAL OIL
SYSTEM WITH OIL.
LUBRICATION OIL IS ISO VG 32 TYPE WITH FOLLOWING PROPERTIES:

ABSOLUTE VISCOCITY
:
16.7CENTIPOISE

KINEMATIC VISCOSITY
:
32CENTISTOKE

SPECIFIC GRAVITY
:
0.89

SPECIFIC HEAT
:
0.459Kcal/Kg Deg.C

FLASH POINT
:
180OC

FIRE POINT
:
240OC

DEGREE OF CLEANLINESS
:
16/13 ISO 4406

PERMISSIBLE SUSPENDED PARTICLE SIZE
:
25 MICRON

WATER CONTENT
:
<10PPM
LUBE OILTANK IS MADE OF STAINLESS STEEL AND HAVING A CAPACITY OF 58m3 . PROVISION IS MADE FOR OIL
TREATMENT INSIDE THE TANK BY PROVIDING TWO ROWS OF FLAT GRIDS WITH MESH DIMENSIONS 0.25mm
LOCATED INSIDE THE TANK WHICH DIVIDES THE TANK INTO DIRTY AND CEAN COMPARTMENTS. THE AIR
SEPARATOR CONSISTING OF TILTED METAL PLATES SET IS INSTALLED TO SEPARATE THE AIR DISSOLVED IN OIL.
THE OIL TANK HAS ATTACHMENTS FOR OIL DRAINING TO OIL TREATMENT PLANT FOR SLUDGE DRAIN AND TO
EMERGENCY TANK INCASE OF FIRE.
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NORMAL OPERATING LEVEL IS 600mm FROM TANK TOP COVER.ALARM IS AT 500mm AND TURBINE TRIP IS
THERE AT 400mm.
4 NOS OF LUBE OIL PUMPS (SINGLE STAGE CENTRIFUGAL) ARE INSTALLED VERTICALLY ABOVE THE TANK .2
PUMPS (AUXILLIARY OIL PUMP) ARE ac MOTOR DRIVEN AND 2 PUMPS ARE dc (EMERGENCY OIL PUMP) MOTOR
DRIVEN.
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ONE PUMP WITH ac MOTOR IS CONTINUOUS RUNNING AND OTHER IS KEPT STANDBY.
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EACH ac PUMP IS HAVING A DISCHARGE CAPACITY OF 300m3/hr A DISCHARGE PRESSURE OF 4.3KSC.
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EOP WLL START IN CASE OF LOSS OF AC.EACH EOP IS HAVING A DISCHARGE CAPACITY OF 250m3/hr AND A
DISCHARGE PRESSURE OF 2 KSC.FOR HIGHIER RELIABILITY EOP DELIVERS OIL DIRECTLY TO THE BEARING
BYPASSING COOLER AND THROTTLE VALVE.
TG LUBE OIL SUPPLY SYSTEM
TG LUBE OIL SYSTEM
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Turbine oil is ISO VG 32
 KV
20-23 CST at 500C
 Acidity Number < 0.05 mg KOH/r
 Viscosity index > 90
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Bearings
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HPT Front
HPT Rear
IPT Front (TB)
IPT Rear
LPT-1 Front
LPT-1 Rear
LPT-2 Front
LPT-2 Rear
Generator Front
Generator Rear
Exciter Front
Exciter Rear
N1
N2
N3
N4
N5
N6
N7
N8
N9
N10
N11
N12
TG LUBE OIL SYSTEM
• DC Lube oil pump 1 No.
Equipment
Capacity (m3/hr)
Head (Ksc)
AC Lube oil pump
300
4.3
DC Lube oil pump
250
2.0
• NRV & Isolation valve in each Lube oil pump
discharge line
• Oil first goes to duplex filter instead of cooler
• Coolers Bypass line with isolating valve
• Hydraulic Pressure control valve maintains the
pressure at the center shaft level at 1.2 Ksc
• PCV Bypass with throttling orifice which provides
lubrication even at fully closed control valve
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Oil is first delivered to bearing brasses through
emergency tanks located on bearing cap
Emergency tanks capacity in m3
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N1
N2
N3
N4
N5
N6
N7
N8
N9
N10
N11
N12
0.43
0.35
0.75
0.44
0.44
0.44
0.44
0.44
0.5
0.44
0.1
0.1
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Lube oil temperature control by control station in the ECW inlet
line to Lube oil coolers
View glasses in the oil return line from each bearing
MOT Capacity
58 m3
Duplex filters fineness
25 µm
Provision is made for oil cleaning by delivering a portion of oil
from the oil pressure pipe to the oil tank through the fine
cleaning filter with fineness of 12-15 µm
Fresh oil is filled through the above filter only
Oil recirculation pump to purify the oil
Electrical oil heater of 152 KW capacity is provided for the
preliminary oil warming in the lubrication oil tank before
turbine start up by running the oil recirculation pump
Oil draining to Emergency lube oil tank in case of emergency
with MOV
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Oil trap at the suction of the vapor extractor fans
Oil trap drain to lubrication oil tank
Jacking oil pumps suction also given from lube oil discharge header after
coolers & before control valve
TG JACKING OIL AND BARRING GEAR SYSTEM
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Automatic barring gear engagement at the rotor stop
and barring gear disengaging at the start-up
High pressure oil supply for bearing inserts oil jacking
Barring speed 1.05 rpm
Motorized barring gear
Torque transfer from the barring gear motor to the
turbine shaft is carried out via three stage reducer and
free wheel clutch
Reduction gear first stage shaft end mounts special
handle for hand barring
Normal source for jacking oil pumps suction is from
lube oil pumps discharge header after coolers
JOP discharge pressure: 120 Ksc
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Dozing devices at each bearing of the Turbine & Generator which
contain strainer, NRV, orifice & isolation valve
Bearing jacking oil is supplied via separate lines for oil jacking of
inserts of bearing no: 4-9
Stand-by bearing insert oil jacking pump is not provided
as the system is designed to realize auxiliary functions at
turbine start-up. If this pump does not start when it is
required then also the turbine can be operated normally
without any bearing damage and disturbance of turbine
operation
Each bearing insert jacking oil line is equipped with orifice
only
Both pumps cut in/cut out is 1500/1500
Barring gear cut in/cut out is 1500/1500
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Bearing Insert Oil Jacking Pump is started automatically, if the rotor
neck displacement becomes more than 0.1 mm relative to the insert
of any of bearings No. 4,…9 provided that the oil pressure to rotor
jacking is higher than 45 kg/cm2 or the turbine rotor rotational
speed is higher than 1500 rpm
Pump is stopped automatically, with time delay of 30 seconds, if the rotor
neck displacement is less than 0.1 mm relative to the insert of bearings No.
4-9
GENERATOR SEAL OIL SYSTEM
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Seal oil pumps suction from MOT
No Hydrogen side seal oil pump
Pumps re-circulation line directly to MOT
Coolers bypass valve
Magnetic filters 2 No. (1W+1SB)
NRV in the seal oil line after filters
DPR
DPR bypass manual control valve
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Damper tanks 2 No.: 1 for TE & 2 for EE, designed
for oil supply to front and back generator shaft
seals with drop, specified by the height of damper
tank installation, and also to seal at short-time
interruption in oil supply, at the moment of
automatic transfer from working pump to standby
and at generator runback with generator shaft
seal pumps switched off
View glasses in return oil lines
Float hydraulic seal functions as SOT
Hydraulic seal overflows in to return oil header
No SOST
Provision of trap upstream of fans
Fans suction is from return oil header
GENERATOR STATOR WATER COOLING SYSTEM
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Water tank not on the generator
Ejector to make vacuum over the water tank to prevent air
ingress
Ejector cooling by auxiliary cooling water
Air venting of Generator through Gas trap connected from
winding inlet and outlet headers
Gas trap to determine hydrogen present which will be extracted
from trap cap to gas analyzer
Coolers bypass valve
Ion exchanger-1 contains anion & cat ion in H-OH form to
maintain conductivity
Ion exchanger-2 contains anion & cat ion in Na-OH form to
maintain Ph if it decreases below 8
Ion exchanger-1 first will be put in to service for reducing
dissolved oxygen below 5.0 µs/cm and then it will be put out of
service. Then Ion exchanger-2 will be put in to service to
increase the Ph value. If conductivity increases above 12.5
µs/cm, Ion exchanger-2 to be stopped
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Control valves at the inlet of individual Ion
exchanger circuits
DM water flow through ion exchanger is 1.5 to 2.0 m
No NAOH dozing system
Ion exchangers separate bypass lines
Mechanical filter at the inlet of Ion exchanger circuit
Dissolved oxygen analyzer & Ph analyzer
Winding inlet valve for flow adjustment
Winding outlet valve for pressure adjustment
Normal make up from DM make up line & emergency
make up line from CST
Filter in the common make up line
Control station in the common make up line
GENERATOR GAS SUPPLY SYSTEM
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Two Hydrogen manifolds to connect 16 cylinders each
Direct acting Pressure regulator installed on cylinder connecting line to Manifold
header to reduce the Hydrogen pressure from 175 Ksc to 10 Ksc
Total Pressure regulators
32
Safety valve on each manifold header which operates when the Hydrogen pressure
in the manifold exceeds 10.5 Ksc
MOV & NRV in each manifold header
Three CO2 manifolds to connect 17 cylinders each
Each manifold header contains MOV, NRV & Isolation valve
MOV with manual bypass valve at the inlet of CO2 heater
CO2 heater is steam heated
Steam source is from auxiliary steam system
Steam parameters: 15 Ksc & 210 0C
MOV in the steam inlet line
Steam exhaust will go to FWSV Dish flash tank
Manifold header pressure is 175-20 Ksc
Control station with Pressure regulator provided D/S of heater to maintain a
pressure of 2.0-2.2 Ksc with manual bypass valve
SV installed D/S of pressure regulator operates if the pr > 5.0 Ksc
Capacity of one cylinder 50 lit
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One Hydrogen manifold is in operation under normal operating conditions
If the pr decreases below < 10 Ksc, an alarm will come and operator
connects the standby manifold and disconnects the first manifold
Two CO2 manifolds are in operation under normal operating conditions
If the pr decreases below < 20 Ksc, an alarm will come and operator
connects the standby manifold and disconnects the first manifold
Provision is given for emergency removal of hydrogen from generator itself
by providing a line with one manual isolating valve & 2 No. MOV
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DRAINS FROM THE TURBINE AND STEAM LINES ARE REMOVED TO TWO HP DRAIN FLASH TANKS - A
(10MAL10BB001) AND B (10MAL20BB001) AND ONE LP DRAIN FLASH TANK (10MAL30BB001)
BOTH THE HP FLASH TANKS ARE HAVING A CAPACITY OF 2.6m3. LP DRAIN FLASH TANK IS ALSO HAVING A
CAPACITY OF 2.6m3.
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Design
Design CW Flow
Vacuum
No. of passes
Total no. of tubes
Tube material
Rated TTD
DT of CW
LMZ
64000 m3/hr
77 mm Hg (abs) at 33 0C
89 mm Hg (abs) at 36 0C
1
22.225 (OD)x0.71 (t) - 29920
22.225 (OD)x1.00 (t) - 2080
ASTM A-249 TP 304
3.40C
100C
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Design flow rate
Discharge pressure
Shut off head
Pump speed
Power input
No. of stages
Type of first stage impeller
Depth
238.75 Kg/s
32.15 Ksc
395
m
1480 rpm
972.3 KW
6
double entry
7.43
m
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Design Pressure
No. of trays
Spray valves
Design temp for D/A
Design temp for FST
13 Ksc
896
132
395 0C
250 0C
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Design flow rate
Discharge pressure
Shut off head
Pump speed
Power input
No. of stages
Type of first stage impeller
Depth
324.509 TPH
43
ata
306.7
m
1486
rpm
310.1
KW
5
centrifugal, single entry
1090
mm
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Pump flow
Suction temp
BP Suction pr.
BFP Suction pr. 21.01
BFP Discharge pr.
BFP Discharge temp.
BP Discharge pr. 22.01
Shut off head
BFP Speed
BP Speed
Normal R/C flow 220
HC Rated O/P Speed
Outer casing type
No. of stages
BFP warm up flow
769.950
186.2
14.05
ata
335.78
187.9
ata
4830
6275
1490
TPH
6505
barrel
7
15
TPH
0C
ata
ata
0C
m
rpm
rpm
rpm
TPH
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Pump flow
Suction temp
BP Suction pr.
BFP Suction pr.
BFP Discharge pr.
BFP Discharge temp.
BP Discharge pr.
Shut off head
BFP Speed
BP Speed
Normal R/C flow
HC Rated O/P Speed
Outer casing type
No. of stages
BFP warm up flow
1283.14
186.2
14.10
28.24
335.83
187.8
29.06
4580
4678
2098
365
6505
barrel
7
20
TPH
0C
ata
ata
ata
0C
ata
m
rpm
rpm
TPH
rpm
TPH
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PARTS OF GOVERNING SYSTEM
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Hydraulic Accumulator (HA)
Remote switch (RS)
Lubrication system pressure relay (LSPR)
Trip Gear (TG)
Stop valve (SV)
Governor valve 1 (GV1)
Governor valve 2 (GV2)
Cut off pilot valve (COPV)
Electro mechanical converter (EMC)
Electro mechanical converter position transducer (ECPT)
Electronic control part (ECP)
Servo motor (S)
Governor valves position transducer (GVPT)
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Number of stages
Casing
Steam admission
Dual
Steam pressure at inlet
Steam temperature at inlet
Turbine operating speed
Steam consumption
Steam pressure at exhaust 0.128
Turning gear speed
Type of governing system
Over speed type trip
JOP
Lube oil tank capacity
Lube oil
9
Split
20.82
ata
0C
469
4678
rpm
61.4
TPH
ata
15
rpm
Electro-Hydraulic
Centrifugal + electrical
Not required
10.97
m3
Same as main turbine
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CW flow
Vacuum in the condenser
Total no. of tubes
Tube OD and thickness
No. of water passes
Tube material
3000
TPH
0.128
Ksc (abs)
3312
22.225x1.06
mm
2
ASTM A-249 TP321
TDBFP LUBE OIL SYSTEM
TDBFP EXTRACTION SYSTEM
TDBFP CONDENSATE SYSTEM
ACW SYSTEM
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Suction header is from all the 4 CW inlet lines to
condensers
MOV at Suction header from CW line
MOV at SCS inlet
MOV at PHE inlet & outlet
Supply to
 Ejector of Stator water cooling system
 TDBFP vacuum pumps (4 No.)
 Main turbine vacuum pumps (1 No. extra)
MOV at return header to CW line
TURBINE VACUUM SYSTEM
TURBINE HEATING FLANGES SYSTEM
AUXILIARY STEAM SYSTEM
CONDENSATE SUPPLY SYSTEM TO EXT NRVS
EXHAUST HOOD SPRAY
FEED WATER SYSTEM
TDBFP-A FEED WATER SYSTEM
MDBFP FEED WATER SYSTEM
LP DOZING & OXY TREATMENT SYSTEM
HP BYPASS SYSTEM
LP BYPASS SYSTEM