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TURBINE

STAGE II
OPERATION MANUAL










CONTENTS:
CHAPTER I : Technical Details Of Turbine Equipments


CHAPTER II : General Description Of Turbine & Its
Auxiliaries.

CHAPTER III : Constructional Details Of Turbine And Its
Auxiliaries.
CHAPTER IV : Operation Of Turbine And Its Auxiliaries.

CHAPTER V : Modifications.

CHAPTER VI : List Of Drawings.
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Chapter I
Technical Details Of Turbine & Its Auxiliaries.

1.1 Turbine 2
1.1.1 Construction 2
1.1.2 Speed 3
1.1.3 Bearing Temperature, Vibration, Moments, Weights 3
1.1.4 Oil Supply, Oil Pumps 4
1.2 Thermal Cycle Data 7
1.3 Condenser Constructional Features 8
1.4 Condenser Thermal Cycle Data (At 100 % MCR) 10
1.5 LP Heaters 10
1.6 HP Heaters 11
1.7 Deaerator Design Data 12
1.8 Deaerator Thermal Data 14
1.9 Boiler Feed Pump Technical Data 15
1.10 Circulating Water Pump - Technical Data: 19
1.11 Auxiliary Oil Pump 22
1.12 Jacking Oil Pump 23
1.13 DC Emergency Oil Pump 23
1.13.a Oil Vapour Exhaust Fan 24
1.14 Turbine Lube Oil Coolers 24
1.15 Lub Oil Filter 25
1.16 Main Oil Tank 25
1.17 Central Lub Oil System 26
1.18 Main Oil Pump 27
1.19 Condensate Extraction Pump Technical Data 28
1.20 Condensate Transfer Pump 29
1.21 Auxiliary Cooling Water Pump 30
1.22 Auxiliary Cooling Water Booster Pump 30
1.23 Plate Type Heat Exchanger 31
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1.24 Centrifuge 31
1.25 Gland Steam Condenser 32
1.26 Gland Steam Condenser Air Extracting Fans 33
1.27 Main Ejectors 33
1.28 Cooling Tower 34
1.29 HP Bypass System 35
1.30 Condensate Storage Tank 38
Chapter II
General Description Of Turbine & Its Auxiliaries.

2.1 Introduction Of Stage II Turbine
& Its Associated Systems 41
2.2 Main Turbine 42
2.3 Condenser 43
2.3.1 Condenser On Load Tube Cleaning System 43
2.4 Water Treatment Plant/ Stage-II 44
2.5 Make-Up Water System 45
2.6 Main Condensate System 46
2.7 Circulating Water System 47
2.7.1 Chlorination 48
2.7.2 Dozing Of Organo Phosphate 49
2.8 Cooling Towers 49
2.9 Fire Protection System 50
2.10 Deaerator 51
2.11 Boiler Feed Pumps 52
2.12 Ejectors 53
2.13 Gland Sealing Steam System And Leak Off Steam 54
2.14 Gland Steam Condenser 55
2.15 HP And LP Bypass Systems 56
2.16 Auxiliary Steam System 57
2.17 Regenerative And FW Heating System 57
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2.18 Auxiliary Cooling Water System 59
2.19 Turbine Oil System 61
2.20 Hydraulic Turning Gear And Hydraulic Lifting 62
2.21 Turbine Stress Evaluator 63
2.22 Turbo Supervisory System 64
2.23 Turbine-Governing-System 64
2.24 Centrifuge 65
2.25 Air Conditioning 65
2.26 Salient Thermal Cycle Data (At 100 % MCR) 66

CHAPTER III
CONSTRUCTIONAL DETAILS OF TURBINE AND ITS AUXILIARIES

3.1 Turbine 68
3.1.a. Turbine oil system 79
3.1.b. Turbine Stop and Control valves 88
3.1.c. Turbine Protective Devices 95
3.2 HP & LP B/P valves 103
3.3 Electro Hydraulic Governing System 119
3.4 Turbine Stress Evaluator 143
3.5 Turbine Supervisory System 164
3.6 Hydraulic Turning Gear 184
3.7 Centrifuge 193
3.8 Condenser 196
3.9 Condensate Extraction Pump 204
3.10 Ejectors, Gland Steam Condenser and Drain cooler 210
3.11 Deaerator 219
3.12 Boiler Feed Pump 225
3.13 Circulating Water Pump 242
3.14 Natural Draught Cooling Tower 247
3.15 CTP, ACWP, ACWBP 255
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3.16 Fire Protection System 260
3.17 LP Heaters & HP Heaters 267
CHAPTER IV
OPERATION OF TURBINE AND ITS AUXILIARIES
4.1 Start-up of Turbine
4.1.0. Preparation prior to rolling 270
4.1.1. Cold 288
4.1.2. Hot 291
4.2 Shut-down procedures 294
4.3 HP & LP B/P control system
4.3.1. HP B/P system 296
4.3.2. LP B/P system 315
4.4 Turbine logics and protections 322
4.5 Turbine governing system operation MHG, EHC 327
4.6 Operation of High capacity pumps
4.6.1. Boiler Feed Pump 340
4.6.2. Condensate Extraction Pump 345
4.6.3. Circulating Water Pump 349
4.7 Operation of Regenerative Feed Heaters 351
4.8 Fire protection System 357
4.9 Special operation procedures
4.9.1. Boiler Hydro test 360
4.9.2. Condenser Air Tightness Test 361
4.9.3. Deaerator Safety Valve Floating 362
4.9.4. Turbine Over speed Test
Turbine Over Speed Oil Injection Test. 363
Turbine Over Speed Test (Actual) 364
4.9.5. Boiler passivation Turbine readiness. 365
4.9.6. Condenser vacuum Drop Test. 367
4.9.7. System Make-Up Test. 367
4.9.8. Turbine oil flushing. 368
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4.9.9. Governing Characteristics. 369
4.9.10. EHC Calibration. 370
4.9.11. LP B/P Valve characteristics. 370
4.9.12. Check List For Isolating And Draining CST-6. 371
4.10 Emergencies. 372
CHAPTER V
5.0 Modifications. 382
CHAPTER VI
6.0 List Of Drawings. 390


Turbine Stage II
Operation Manual
Chapter I
Technical details of turbine & its auxiliaries.
1.1 TURBINE
TECHNICAL DATA FOR CONSTRUCTION AND SPEED :
1.1.1 CONSTRUCTION:
Three cylinder reheat condensing turbine
Single flow HP turbine with 25 reaction stages Type H 30 25 2
Double flow IP turbine with 20 reaction Type M 30 20
stages per flow

Double flow LP turbine with 8 reaction Type N 30 2 * 5
stages per flow

2 Main stop and control valves Type EV 160
2 Reheat stop and control valves Type IV 320
2 Swing check valves in cold reheat line DN 450
2 Bypass stop and control valves DN 200
Extraction Swing Check valves:
Extraction 1 : no valve.

Extraction 2 : 1 swing check valve with auxiliary actuator ,
1 swing check valve.
7

Extraction 3 : 1 swing check valve with auxiliary actuator ,
1 swing check valve.

Extraction 4 : 1 swing check valve with auxiliary actuator ,
1 swing check valve.

Extraction 5 : 1 swing check valve with auxiliary actuator ,
1 swing check valve.

Extraction 6 : no valve.


1.1.2 SPEED:

Rated speed : 50.0 S
-1
Speed limitation in load and
station auxiliary load operation
Max. speed , no time limitation : 51.5 S
-1

Min. speed , no time limitation : 47.5 S
-1
Permissible for a maximum of 2 hours
during the life of LP blading : speeds below 47.5 S
-1
: speeds above 51.5 S
-1
Speed exclusion range at operation
without load * : 11.67 S
-1
to 47.5 S
-1

Standard over speed trip setting : max. 55.5 S
-1
- This speed range should be passed through in one smooth
operation to avoid endangering the blades due to resonance.

1.1.3 BEARING TEMPERATURE, VIBRATION , MOMENTS, WEIGHTS:
1.1.3.a BEARING TEMPERATURE:

Alarm at
Machine must be
shutdown at

Normal operating
temperature
below 75 C
90 120 C
Normal operating
temperature
above 75 C
100 120 C
8

1.1.3.b VIBRATION:
Absolute
bearing
housing vibration
Absolute Shaft
vibration
Nominal value for alarm 35 m
30 m above
normal level *
Maximum value for
alarm
120 m
Limit value for tripping 45 m 200 m




1.1.3.c MOMENTS OF INERTIA:
Rotor of HP cylinder 316.94 kg m
2

Rotor of IP cylinder 1155.59 kg m
2

Rotor of LP cylinder 9794.13 kg m
2

1.1.3.d WEIGHTS
1. HP cylinder, assembled complete with steam inserts. 56.0 T
2. IP cylinder, upper outer casing, complete 13.2 T
with out Steam inserts.

3. IP cylinder, upper inner casing, complete with blading. 8.0 T
4. LP cylinder, upper outer casing, complete. 17.7 T
5. LP cylinder, upper outer shell of inner casing complete 15.5 T
With blading, carriers and diffuser.

6. Rotor of HP cylinder, complete with blading. 7.5 T
7. Rotor of IP cylinder, complete with blading. 15.8 T
8. Rotor of LP cylinder, complete with blading. 48.0 T
9. Main stop and control valve, complete without 7.0 T
Bend and pipe section.

10. Reheat stop and control valve, complete without 11.5 T
Bend and pipe section.

Weights have been calculated with addition.
Slings chosen must provide sufficient security.
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1.1.4 OIL SUPPLY, OIL PUMPS:

1.1.4.a OIL SUPPLY
Oil tank, rated capacity 20 / 32 m
3

Highest oil level from the top of tank (at rated speed) 800 mm
Lowest oil level from the top of tank (at rated speed) 850 mm
First oil filling (estimated) 30 m
3
Flushing oil quantity (estimated) 20 m
3



Oil cooler operation, number 1
Oil cooler for reserve 1
Cooling surface per cooler 280 m
2

Oil temp at cooler outlet, in operation min 38 C
Normal 45 C
Max 47 C
Oil temp at cooler outlet, when shutdown max. 75 C
Temperature rise of oil in bearings Normal 20 C
Max. 25 C

ESTIMATED OIL REQUIREMENTS OF BEARINGS
Bearing 1 0.8 dm
3
/ s
Bearing 2 9.1 dm
3
/ s
Bearing 3 4.0 dm
3
/ s
Bearing 4 3.5 dm
3
/ s
Front generator bearing 3.5 dm
3
/ s
Rear generator bearing 5.0 dm
3
/ s

1 Duplex Oil filter for thrust bearing oil DN 100

Filtration particle size 37 m
Safety valve in Jacking Max 200 bar
Oil system, setting. Min. 10 %
10

Pressure limiting valve in Jacking 120 bar
Oil system, setting

Jacking oil pump, speeds when switching on and off.
Jacking oil pump must be switched on at turbine speeds below
approx. 8.5 S
-1
to avoid damage to bearing.
Jacking oil pump should be switched off at speeds above
approx. 9.0 S
-1



1.1.4.b OIL PUMPS

MOP AOP DCEOP JOP
Quantity 1 2 1 2
Make BHEL KSB KSB Allweiler
Type
ETA 150
50 VL
ETA 100 33
VL
SDF 40 R 54
Capacity
(rated)
139 78.31 30 1.26 dm
3
/ s
Discharge
pressure
(gauge)
8.2 6.8 2.3 120 Bar
Speed 50 24.66 24.3 49.16 S
-1

Drive Turbine E motor E motor E motor
Make
Enclosure IP 44 IP 44 IP 44
Voltage 415 220 415 V
Frequency 50 50 Hz
Motor power 90 13.6 30 KW
11
Rated
current
168 57 A
Starting
current
1075 365 A

12
1.2.1 Salient Thermal Cycle Data (at 100 % MCR):

S.No Subject Pressure Temp Flow
Ata deg C t/hr

1. Saturated steam from boiler drum. 167 350 607
2. Superheated steam after super heater. 152 540 657
3. Superheated steam before HPSVs. 150 535 639.82
4. Cold reheat steam to re-heater. 38.1 341.4 573
5. Hot reheat steam to IP cylinder. 34.3 535 573
6. Steam to LP cylinder. 7.17 318.8 504
7. Exhaust steam to condenser. 0.1033 46.1 441
8. Main condensate after CEPs. 19.8 46.3 529
9. Main condensate after LPH-3. 8.46 120.3 529
10. Feed water at Deaerator. 6.4 161 660
11. Feed water after Boiler Feed Pumps. 188 164.3 660
12. Feed water after HP Heater-6. 186.3 243 660
13. Feed water after Economizer. 170.3 329 611

1.2.2 Turbine efficiency:

Turbine efficiency at 0.1033 ata back pressure 3 % make up
including 2.5% non-recoverable auxiliary steam for 100 % MCR condition at
cooling water inlet temperature 34 C and deminetalised water inlet
temperature at 38 C = 42.8116 %.

1.2.3. Protection from pitting & erosion:

Special protection against erosion due to moisture impingement is
provided by flame hardening of leading edges of the blades of last stage of
the LP cylinder.


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1.2.4. Tip velocity of LP cylinder last row blades:

1. Tip diameter : 2.794m.
2. Tip velocity :438.880 m/sec.
1.2.5. Last stage annulus area:

Total : 2 * 5.0 Square meters.
1.3 CONDENSER CONSTRUCTIONAL FEATURES :
Design Features:
1. Number of condenser per unit : One
2. Type : Rectangular down flow
type surface Condenser -
Divided water box with
two water passes in each
section
3. Overall length of the condenser : 14000 mm
4. Method of support for condenser : Floated over the
springs
5. Number spring elements : 24 Nos. (in 2 rows)
6. Loading data:
a. Dry weight of condenser : 361 Tones
b. Operating weight of Condenser : 555 Tones
c. Weight transferred to LP cylinder : 190 Tones
from stability consideration

d. Operating weight on springs : 365 Tones
e. Hydraulic Test weight : 693 Tones
f. Water to be filled in the
Hot well during spring adjustment : 4 Tones
7. Hot well Storage capacity : 3 minutes of
pumping by CEP
8. Number of end tube plates : 4 (2 on each side)
9. Length between end tube plates : 10,000 mm
14
10. C. W. Tubes:
a. Length of the tube : 10,1 0 mm
b. Tube OD and thickness : 25.4 x 0.7112 mm
c. Tube material : Stainless steel (SS TP 316)
d. Percentage tube thinning : 7.5 % (average)
e. Number of tubes:
i) Condensing zone : 16148 nos.
ii) Air cooling zone : 1240 nos.
TOTAL : 17658
f. Total heat transfer : 14090 m
2
surface area
11. Number of support tube plates : 2 x 12
12. Design Data:
Water side Steam side
i) Condenser pressure : 5.0 KSC full
vacuum
ii) Condenser temperature : 50 deg C 100 deg C
13. Hydraulic test pressure
i) Water box : 6.5 ksc
ii) Steam space : By filling water up to
1m above the top row
of the tubes.
14. Number of air take off pipes : Two
(with holes on their
bottom surface )

15. Circulating water Data:
i) Design inlet temperature : 34 deg C.
ii) Temperature rise in tubes : 8.6 deg C.
iii) Flow quantity : 29000 m
3
/ hr
iv) Pressure drop across : 5.5 m W.C.
the tubes
15

1.4 Condenser Thermal Cycle Data (at 100 % MCR):

- Rate of steam flow from main turbine : 441.96 T/Hr.
- Enthalpy of steam from turbine : 579.5 Kcal / kg.
- Temperature of exhaust steam from turbine : 46.1 deg C
- (* = 0.9335)
- Condenser pressure : 0.1033 ata.

1.5 LP Heaters
1.5.1 LP HEATERS DESIGN FEATURES AND THERMAL DATA:
LP-DC LPH-1 LPH-2 LPH-3
1. Type shell &tube shell &tube shell &tube shell &tube
2. Tube side pressure 28 ksc 28 ksc 28 ksc 28 ksc
3. Shell side pressure vacuum vacuum vacuum vacuum
& 3.5 ksc & 3.5 ksc & 3.5 ksc & 3.5ksc

4. Tube side temperature 150 C 150 C 150C 150 C
5. Shell side temperature 100 C 100 C 150 C 210 C
6. Tube surface area 35 m2 317 m2 500 m2 426 m2
7. No of water passes 1 2 2 2
8. Tube outer diameter 16mm 16 mm 16 mm 16 mm
9. Tube material TP 316 SS TP 304 SS TP 304 SS TP 304SS
10. Tube thickness 0.889 mm 0.889 mm 0.889 mm 0.889mm
11. Total number of tubes 501
12. Tube length 1540

16

1.5.2 LPH - Shell Side Safety Valve
LPH-1 LPH-2 LPH-3
1. Type P 33 E
2. Capacity 72.83 m3 /hr 72.83 m3 /hr 72.83 m3 /hr
3. Set pressure 3.5 ksc 3.5 ksc 3.5 ksc
4. Service temperature 400 C 400 C 400C

1.6 HP HEATERS
1.6.1 HP HEATERS DESIGN FEATURES AND THERMAL DATA

HPH 5 HPH 6

1. Type Surface- V type Surface- V type
2. Tube side pressure 275 ksc 275 ksc
3. Shell side pressure 19 ksc 48 ksc
4. Tube side temperature 230 C 281 C
5. Shell side temperature 210 C 4581 C
6. Heat exchange surface area 703 m2 810 m2
7. No of tube passes 2 2
8. Design flow [tube side] 660.37 t/hr 660.37 t/hr
9. Shell side flow:
i. Steam 33.77 t/hr 60.608 t/hr
ii. Drain 60.86 t/hr ----
Total 94.65 t/hr. 60.608 t/hr
10. Enthalpy:
a. Tube inlet side 168.6 kcal/kg 203.8 kcal/kg
b. Tube Outlet side 203.82 kcal/kg 252 kcal/kg
c. Shell inlet side 791.5 kcal/kg 736 kcal/kg
d. Shell Outlet side 172.4 kcal/kg 209.6 kcal/kg
11. Pressure drop [tube side 0.66 ksc 0.72 ksc
without plugging]
12. Terminal temp. Diff. 0 0
17
13. Tube size 15.875 mm 15.875 mm
14. No of tubes 952 952
15. Wall thickness 13/14 BWG 13/14 BWG
16. Shell material BQCS SA 516/ 60 BQCS SA 516/ 60
17. Water box material CS CS
18. Tube material SA 688 TP 304 SA 688 TP 304
19. Tube sheet material CS CS
1.6.2 HP Heater Safety Valve [Shell Side):

HPH 5 HPH 6

1. Make BHEL BHEL
2. Material CS 216 WCB CS 216 WCB
3. Capacity 55224.9 Nm3/hr air 65263.8 Nm3/hr air
4. Set pressure 20 ksc [gauge] 48 ksc [gauge]
5. Temperature 182 C 222 C

1.7 DEAERATOR
1.7.1 Deaerator Design Data:

1. Type : Spray and Tray
2 Layout :
Deaerating Header : Horizontal (Top ).
Deaerator storage tank : Horizontal (Bottom ).
3. Code followed in the design : ASME Sec VIII Division I (1986).
and fabrication

4. Design and Test parameters for header and storage tank :
Design pressure : 7.4 Kg / cm
2
and full vacuum.
Design temperature : 250
o
C.
Test pressure : 11.1 Kg / cm
2
(1.5 design pressure)
Test temperature : Room temperature.


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5. Weight of the deaerator :
Dry weight : 65 tones
Operating weight : 197 tones.
Flooded weight : 262 tones.
6. Deaerator support:
Distance between the : 7500 mm.
centre and the roller support.

Expansion rollers : provided at both ends.
7. Elevation:
Deaerator floor : 27.0 M.
Deaerator centre line : 29.22 M.
1.7.2 Deaerating Header:

1. Dimensions :
Diameter : 2400 mm.
Length : 5800 mm.
2. Spray nozzles:
Material : Stainless steel.
Number : 40
3. Number of vertical stacks : 2.
4. Number of trays in each stack : 5.
5. Main condensate pipes : 2 Nos. (Left and Right ).
connecting header and
storage tank
6. Steam pipe connecting : 1 No. ( at the Centre ).
header and storage tank

1.7.3 Storage Tank:
1. Capacity : 130 m
3
.
2. Overall dimensions ( OD x Length ) mm : 3500 x 21400.



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3. Safety valve :
(i) Set pressure : 7 Kg / cm
2
(g).
(ii) Relieving Capacity : 40,000 Kg / hr . of
saturated steam.
(iii) Number : 2.

1.8.1 Deaerator Thermal Data:

1. Mode of operation of deaerator : Variable Pressure
2. Limit down to which oxygen : 0.005 cc / liter.
is removed

3. Operating pressure : 6.6 ata (at 100% MCR).
4. Minimum pegging pressure : 1.5 ata.
5. Operating temperature : 161.9
o
C (at 100% MCR)
6. Normal source of steam for Deaeration : IV
th
Extraction steam of
Turbine.

1.8.2 Parameter at the point of extraction:

I) Pressure : 7.2 ata.
Temperature : 319.4
o
C.
Saturation temperature : 165.3
o
C


Degree of superheat : 154
o
C.
ii) Enthalphy of steam : 740.5 Kcal / Kg.
iii) Steam flow : 35.18 T/ hr.
iv) Tapping point of extraction : IP cylinder outlet (from
cross around pipes)
(after 45 stages).
20
1.8.3 Water Parameters:
Main condensate Feed water
(at inlet) (at outlet)
1. Enthalpy (Kcal / Kg) : 121.3 162.8
2. Temperature (
o
C) : 120.8 161.9
3. Pressure : 8.5 ata 6.5 ata
4. Flow : 530 T / hr 660 T / hr.

1.8.4 Terminal Temperature Difference
o
C (TTD) :

(Saturation Temperature of extracted steam Out going feed water
temperature) = 3.9 deg C.
1.8.5 IV
th
Extraction steam parameters at lower loads:
Pressure (ata) Flow (T / hr)
1. 80 % load : 5.86 27.64
2. 60 % load : 4.54 19.55

1.9 Boiler Feed Pump Technical Data:

1.9.1 Main Pump:

1. Make : BHEL
2. Discharge quantity : 420 m
3
/hr
3. Speed : 5300 rpm
4. Temperature : 162.5 C
5. No of stages : 6
6. Efficiency : 81 %
7. Specific weight at suction : 905 kg /m
3

8. Minimum re-circulation flow : 100 m
3
/hr
9. Power : 2840 kw
21
1.9.2 Thrust Bearing:
1. Type : double thrust
2. Size : 8159/2KP-2KP
1.9.3 Coupling Between Hydro coupling & Pump, Motor

: flexible coupling
1.9.4 Motor Of BFP:

1. Type : squirrel cage induction
motor

2. Speed : 1485 rpm
3. Power : 4000 kw
4. Ambient temperature : 50 C
5. Weight : 13300 kg
6. Drive end bearing : dia 160 140
7. Non drive end bearing : dia 125 115
1.9.5 Booster Pump:
1. Type : single stage double
suction

2. Flow quantity : 395 m
3
/hr
3. Speed : 1485 rpm
4. Suction temperature : 162.5 c
5. Power : 140 KW
1.9.6 Thrust Bearing:
1. Make : GLACIER metal Co. Ltd
2. Size : 811/2KP-2KP
3. Type : double thrust
1.9.7 Mechanical Seal:
1. Make : Durametallic
2. Size : 4-250 PTO/type 503
3. Type : sedol
22
1.9.8 Coupling Between Motor &Pump:
1. Type : flexible coupling
2. Make : TORSIFLEX Ltd
3. Size : HB 4-140
1.9.9 Hydro Coupling:
1. Type : variable speed geared
Coupling

2. Make : VOITH TURBO GMDH &CO,
GERMANY.

3. Power : 2840 KW
4. Gear ratio : 131/136
5. Primary speed : 5404 rpm
6. Full load slip : 1.8%
7. Capacity of oil tank : 700 liters
8. Oil type : servo torque- 10
9. Gear type : herring bone
1.9.10 Working Oil Pump:

1. Type : centrifugal
2. Quantity of working oil : 421 LPM

1.9.11 Lub Oil Pump & Auxiliary Lub Oil Pump:

1. Type : gear pump

1.9.12 Motor Of Auxiliary Lub Oil Pump:

1. Power : 5.5 kw
2. Speed : 1445 rpm
3. Volt : 415 volts
4. Ampere : 11.2 amps
23
1.9.13 Working Oil Cooler:

1. Type : L1 N1 09 16 04
2. No of coolers : 2
3. Capacity : 3 liters [oil], 47 liters [water]
4. Cooling water flow : 41 m
3
/hr
5. Cooling water inlet temperature : 38 C
6. Cooling water outlet temperature : 48 C
7. Oil flow : 25.26 m
3
/hr
8. Oil inlet temperature : 95 C
9. Oil side [shell side] operating pressure : 16 bar
10. Water side [tube side] operating pr : 10 bar
11. Oil outlet temperature : 55 C
12. Shell side volume [oil] : 71 liters
13. Water side volume [tube] : 51 liters
14. Shell design temperature : 120 C
15. Water design temperature : 50 C
1.9.14 Lub Oil Cooler:

1. Type : L1 N1 07 16 04
2. No of coolers : 2
3. Cooling water flow : 26.6 m
3
/hr
4. Cooling water inlet temperature : 38 C
5. Cooling water outlet temperature : 41 C
6. Oil flow : 13.2 m
3
/hr
7. Oil inlet temperature : 60 C
8. Oil side [shell side] operating pressure : 16 bar
9. Water side [tube side] operating pr : 10 bar
10. Oil outlet temperature : 45 C
11. Shell side volume [oil] : 47 liters
12. Water side volume [tube] : 31 liters
13. Shell design temperature : 120 C
14. Water design temperature : 50 C
24

1.10 Circulating Water Pump - Technical Data:

1. Type of the pump : 1400-50-MFD Vertical , Mixed
flow Diffuser , Non pull out type
2. Number of stages : One
3. Make : M/S Mather and Platt.
4. Rated capacity : 16500 m
3
/hr.
5. Pump efficiency at design : 86 %
Parameters
6. Effective head at rated capacity : 27.5 m of liquid column.
7. Power input to Motor at design : 1496.7 KW
capacity

8. Water levels ( from the pump sump floor level )
a) Minimum water level : 7.59 m
b) Maximum water level : 9.65 m
c) Normal water level : 8059 m
d) Minimum submergence : 4.2 m if liquid column for
Required operation at any
point within the range of
operation.
9. Pump bearings:
a) Thrust bearing : Tilting pad type bearing ( oil
lubrication)
b) Impeller shaft bearing : FINOSTOS B
c) Line and head shaft Bearing : FINOSTOS B
10. Coupling:
a) Line shaft coupling : Split Muff type rigid coupling
b) Coupling between Motor : Flexible pin and Bush type
shaft and Pump shaft
coupling.
11. Suction bell diameter : 1480 mm of I.D.
(To limit flow velocity at the
maximum flow within 2.977
m/second through column
pipe)
12. Discharge pipe diameter : 1600 mm of I.D.
25
1.10.1 Guaranteed Performance Details Of Pump:

1. Flow capacity : 16500 m
3
/ hr.
2. Head developed at the rated : 27.5 m of water column.
capacity(excluding losses in the
pump assembly)
3. Power input : 1496 KW.
4. Shut off head : 40 m of liquid column.
5. Rated speed ; 496 rpm.
6. Range of operation : 30 % to 140 % of rated capacity.
7. Noise level : 85 dB at 1.86 meter distance.
8. Availability over the warranty period : 91 %.
1.10.2 Motor Of Circulating Water Pump:
1. Type of motor : CACA ( closed air circuit air
cooled ) SCR IM Three
phase induction motor.
2. Service : Continuous.
3. Rated continuous output at 40 C : 1760 KW.
ambient condition

4. Rated speed : 496 rpm.
5. Rated voltage and its variation : 6600 V + 10 %
6. Rated frequency and its variation : 50 Hz + 5 %.
7. Duty cycle / Designation : S1.
8. Full load current : 193 A.
9. No load current : 85 A ( indicative ).
10. Rated power factor : 0.78.
11. Efficiency at rated voltage and frequency
a) Full load : 96.3 %.
b) Three quarter load : 95.5 %.
c) Half load : 94.0 %.
12. Method of starting : Direct on line starting.
13. Starting current : 600 % of full load current.



26
14. Starting time ( seconds ) at 100% at80%
voltage voltage

a) with load(from cold and hot 4.2 12.6
conditions )
b) without load ( from cold and 0.8 1.3
hot conditions )
15. Make : M/s. Crompton greaves ltd.
16. Insulation : Class F
17. Space heaters : 4 Nos. 250 w , 240 V.
1.10.3 Motor Bearings:

Bearing details NDE bearing DE bearing

a) Type Tilting pad type thrust bearig Cylindrical
+ white metal lined journal roller bearing
bearing

b) Make Crompton SKF
c) Lubrication Oil bath Grease
d) Lubricant Turbine oil grade ISO VG 56 Lithium base
Greese
e) Recommended SERVO PRIME 57 (or ) SERVO GEM 2
equivalent
f) initial quantity 150 litres 2100 gm
g) Re lubrication
interval & One year 5 months
quantity 150 litres 250 gm.
h) Cooling method Water cooled Naturally cooled
i) Cooling water 20 to 30 litres per min
flow rate
1.10.4 Lubrication chart:

a) Pump Tilting pad type thrust bearing
Manufacturer Recommended grade
(i) M/s Indian oil corporation Servo system 46
(ii) M/s Hindustan petroleum ENCLO 46
(iii) M/s Bharat petroleum Hydral 46
27
b) Motor Top bearing Tilting pad thrust type + journal bearing
(i) Oil used Servo prime 57 or equivalent
(ii) Quantity 150 litres
(iii) Interval of change One year
c) Motor Bottom bearing:
(i) Grease lubricant Servo Gem 2 or equivalent
(ii) Initial filling quantity 2500 gm.
(iii) Replacement quantity 250 gm ( 5 months interval)
1.10.5 Butterfly Valves In Circulating Water System:

S.No Location Size Nos. Operation

1. Cooling tower inlet lines 1600 mm 8 manual
2. Condenser inlet lines 1600 mm 8 Electric motor driven
3. Condenser outlet lines 1600 mm 8 Electric motor driven
4. CWP discharge lines 1600 mm 14 Electric motor driven
5. Make up water lines 1200 mm 4 manual
6. Make up water line
for fore bay 900 mm 3 manual
900 mm 1 Electric motor driven
7. Water supply lines to ADPH 300 mm 4 manual
900 mm 1 manual
1.11 Auxiliary Oil Pump:

1. Make : KSB Pumps LTD.
2. Type : ETA 150-50 vl
3. Discharge : 152.64 m
3
/hr
4. Head : 84.2 m
5. Speed : 1485 rpm
6. Capacity : 2544 lpm
7. Differential pressure : 7 bar


28
1.11.1 Motor Of Auxiliary Oil Pump:

1. Make : AEI Works, Calcutta
2. Kw : 100
3. Amps : 175
4. Volts : 415
5. Rpm : 1485
1.12 Jacking Oil Pump:

1. Make : ALLWEILER
2. Type : SDF 40 R54
3. Capacity : 1.26 d m
3
/sec
4. Discharge pressure : 120 bar
5. Speed : 2949.6 rpm
1.12.1 Motor Of Jacking Oil Pump:

1. Make : SIEMENS
2. Volts : 415
3. Speed : 2945 rpm
4. Full load current : 47.5 Amps

1.13 DC EMERGENCY OIL PUMP:
1. Make : KSB pumps Ltd
2. Type : ETA 100-33 VL
3. Capacity : 108.0 m
3
/hr
4. Discharge pressure : 2.3 bar ( gauge )
5. Speed : 1425 rpm

1.13.1 Motor Of DC Emergency Oil Pump:
1. Make : Crompton Greaves
2. Volts : 220-v dc
3. KW : 15
4. Speed : 1425 rpm
29
1.13.a Oil Vapour Exhaust Fan:
1. Make : SKS PVT Ltd
2. Type : SHSH
3. Capacity : 396 m
3
/hr
4. Speed : 2840 rpm
1.13.a.1 Motor Of Oil Vapour Exhaust Fan:
1. Make : REMI Ltd, Mumbai
2. Volts : 415
3. Speed : 2840 rpm
4. Full load current : 1.8 Amps
5. KW : 0.75
1.14 TURBINE LUBE OIL COOLERS :
No. of oil coolers per unit : Two.
No. of oil coolers in service : One.
No. of oil coolers in reserve : One.
Type : Vertical, single shell with
two water passes in tubes.
1.14.a SHELL SIDE:
Oil inlet temperature (max) - when shut down : 75 C.
Oil outlet temperature in operation
(maximum) : 47 C.
Normal : 45 C.
Minimum : 38 C.
Type of baffles : Disc & dough nut.
Cooling surface area : 280 m
2.

1.14.b TUBE SIDE:

Circulating water flow : 360 m
3
/hr.
Total no tubes : 1250.
Tube side velocity : 1.04 m/sec.
Tube size : dia 16 * 1 mm.
Material of the tube : Admiralty brass.
30
1.15 LUB OIL FILTER:
1.15.A Old BOLL &KIRCH filter (In service in Units 6&7).
Type No : 2-69-9-220-500-10NW-100
Fab No : 233884/1B
Filteration size : 37 microns
1.15.B New BOLL & KIRCH filter (Installed in Unit 4& 5).
Drg No : Z100827
Type : BFD 180-580-80-08 GS-LUB
Flow rate : 33 cubic meter/hr
Filteration size : 37 microns
Operating pr : 8.5 bar
Allowable operating pr : 16 bar
Operating temperature : 45 deg C
Allowable operating temp : min. TS : -10 deg C,
max. TS : 80 deg C
Initial pr. drop : 0.2 bar at 48 cst (Clean
condition)
1.16 MAIN OIL TANK :

Location : Turbine intermediate
floor level 3.5 mts.
elevation.
Number of tanks per unit : One.
Number of filters mounted inside the tank: I) One no basket filter to
filter the drain oil from
the turbine oil system.



31
Number of filters mounted outside the tank ii) 10 self cleaning filters to
filter control oil before
admission to governing
system.
iii) two nos of Y type
strainers in the LP B/P
rack.
Total oil in the system with the tank level : to allow a retention time of
normal during normal
operation approx. 7 to 8
minutes from entry into the
tank to suction by the pumps.
1.17 CENTRAL LUB OIL SYSTEM.
1.17.a CLEAN OIL TANK:

Location : 0 ML outside power
house - Unit - 5.
Total Nos. : One for 4 units.
Capacity : 70 m
3
.
1.17.b CLEAN OIL TRANSFER PUMP:

Total Nos. : One for all the four
units of St-II.
Make : PRAKASH INDUSTRIES.
Output : 100 LPM.
Pressure : 50 psi.
1.17.c Clean oil transfer pump MOTOR

Make : CROMPTON GREAVES.
Type : 3 phase, 50 Hz
induction motor
Voltage : 415.
Amps. : 7.9 A.
RPM : 1430.
32
KW : 3.7.
HP : 5.0
1.17.d DIRTY OIL TANK:

Location : 0 ML outside power
house.U5.
Total Nos. : One for 4 units.
Capacity : 70 m
3
.
1.17.e DIRTY OIL TRANSFER PUMP:

Total Nos. : One for each unit of St-II.
Make : PRAKASH INDUSTRIES.
Output : 100 LPM.
Pressure : 50 psi.
1.17.f Dirty oil transfer pump MOTOR:

Make : CROMPTON GREAVES.
Type : 3 phase, 50 Hz
induction motor
Voltage : 415.
Amps. : 7.9 A.
RPM : 1430.
KW : 3.7.
HP : 5.0
1.18 Main Oil Pump:

1. Make : BHEL.
2. Capacity : 139 dm
3
/hr.
3. Discharge pressure : 8.2 [gauge].
4. Speed : 3000 rpm.
5. Drive : Turbine .






33
1.19 Condensate Extraction Pump: Technical Data

Number of Pumps for one Unit : Two
Number of Pumps in Service : One
Number of Pumps in reserve : One
Type of the pump : Vertical Multistage
Centrifugal Canister Type
Specification : En 6J 40D
Number of Stages : 6
Type of Stage (i) First Stage : Double Suction Type
(ii) Other Stages : End Suction Type
Differential head : 225 m of Wcl.
Capacity : 678m
3
/Hr.
Rated Speed : 1482 rpm
Power absorbed : 507 KW
Efficiency : 81%
Suction bore diameter : 400mm
Discharge bore diameter : 300mm
1.19.a Motor Of Condensate Extraction Pump:

Voltage : 6600 V
Rated Speed : 1482 rpm
Rated Power : 600 KW
1.19.b Thermal Cycle Data (AT 100% MCR)

The temperature of main condensate : 46.1
-
C
in the hot well of condenser

The absolute pressure in the Condenser : 0.1033 ata
Flow of Main Condensate towards
Deaerator : 529.2 T/Hr.
The temperature of main condensate
After gland steam condenser : 48.0 C
After drain cooler : 48.7 C
After LP Heater (1) : 56.4 C
34
After LP Heater (2) : 89.9 C
After LP Heater (3) : 120.3 C
The main condensate pressure at : 19.84 Kg/Cm
2
(a)
CEP discharge
1.20 Condensate Transfer Pump A :
a) Motor:
1. Type : induction motor
2. Make : G.E.C
3. Power : 110 KW
4. Supply : 415 v, 3 phase
5. Speed : 2980 rpm
6. Ampere : 190 amps
b) Pump:
1. Make : BEACON WEIR Ltd, Madras
2. Capacity : 180 m
3
/hr
3. Head : 140 m
4. Speed : 2930 rpm
1.20.a Condensate Transfer Pumps B & C:
a) Motor:
1. Type : induction motor.
2. Make : ABB or Kirloskar.
3. Power : 47 KW.
4. Supply : 415 v, 3 phase.
5. Speed : 1475 rpm.
6. Ampere : 110 amps.
b) Pump:
1. Make : Kirloskar.
2. Capacity : 200 m
3
/hr.
3. Head : 55 m.
4. Speed : 1470 rpm.
35

1.21 Auxiliary Cooling Water Pump:
a) Motor:
1. Type : induction motor
2. Ambient temperature : 50 C
3. Speed : 985 rpm
4. Power : 100 kw
5. Supply : 415 v ,3 phase
6. Ampere : 180 amps
7. Synchronous speed : 1000 rpm
b) Pump:
1. Type : centrifugal
2. Make : BEACON WEIR Ltd,
Madras
3. Total head : 20 m
4. Capacity : 347.2 LPS
5. Power : 79.17 KW
6. Efficiency : 86%
7. Speed : 985 rpm
1.22 Auxiliary Cooling Water Booster Pump:
a) Motor:
1. Make : G.E.C
2. Power : 22 kw
3. Supply : 415 v,3 phase
4. Ampere : 41 amps
5. Speed : 1470 rpm
b) Pump:
1. Type : centrifugal
2. Make : BEACON WEIR Ltd,
Madras
3. Total head : 20 m
4. Capacity : 69.4 lps
36
5. Power : 16 kw
6. Efficiency : 84.7%
7. Speed : 1470 rpm

1.23 Plate Type Heat Exchanger:

1. Make : ALFA LAVEL
2. Type : AX30 BFM
3. Maximum working temperature : 50 C
4. Maximum working pressure : 6 bar
5. No of plates : 130 140.
6. No. of heat exchangers per unit : Three.
1.24 Centrifuge:

1. Make : ALFA Level
2. Type : MAB 206
3. Capacity : 6000 liters/hr
4. Speed : 8425 rpm
1.24.a Motor Of Centrifuge:
1. Make : Bharat Bijlee
2. Volts : 415
3. Speed : 1440 rpm
4. Full load current : 14.7Amps
5. KW : 7.5
1.24.b Centrifuge Booster Pump Motor:

1. Make : Bharat Bijlee
2. Type : IMI 31324
3. Volts : 415
4. Speed : 1450 rpm
5. Full load current : 8.15 Amps
6. KW : 3.7

37
1.24.c Centrifuge Heaters

1. Type : Indirect type heaters .
immersed in water.
2. No of Heaters : 3
3. Total power : 72 Kw
i. Heater I : 36 Kw
ii. Heater II : 18 Kw
iii. Heater III : 18 Kw
4. Voltage : 415 V
5. Phase : 3
6. Cap. Of water tank : 450 liters
7. Area Heat Transfer : 11 Sq. meters
1.25 GLAND STEAM CONDENSER:

Number per unit : One.
Type : Horizontal, Single Pass
Surface Condenser.
Hydraulic test pressure
i) Shell side : 36.0 Kg/cm
2

Design pressure/Temperature.
i) Shell side : 24.0 Kg/cm
2
/150C
ii) Tube side : 24.0 Kg/cm
2
/150C.
No. of tubes : .
Surface area : 20 m
2
.
Drain condensate temperature leaving the : 99.9 C.
gland steam condenser at full load.
Main condensate flow through gland : 529.276 T/hr..
steam condenser at full load.
Main condensate temperature at Gland : 48 C.
Steam Condenser outlet at full load.
Weight ; 808 kg.

38
1.26 GLAND STEAM CONDENSER AIR EXTRACTING FANS:

No. of fans per unit : Two.
No. of fans in service : One.
No. of fans is reserve : One.
Manufactured by : SK system pvt limited.
Type : Single stage,
Centrifugal radial fan.
Static pressure : 310 mm of WG.
Rate of flow : 1080 m
3
/hr.
Speed : 2840 rpm.
Fan input power : 3.0 HP.
1.26.a MOTOR:

Manufactured by :
Voltage : 240 / 415.
Amps. : 26/15
KW : 7.5
Speed : 2900 rpm.
1.27 MAIN EJECTORS:

No. of ejectors per unit : Two.
No. of ejectors in service : One.
No. of ejectors in reserve : One.
Manufactured by : M/S BHEL Ltd.
Type : Steam Ejector.
Weight : 3000 kg.
No. of stages : Three.
Source of steam supply for ejectors : Aux steam from AST Hdr
at 6.5 ksc & 210 C.
Tube side test pressure : 24 ksc.
Tube side test pressure : 36 ksc.
Shell side test pressure : 2.5 ksc.
39
Steam consumption (about) : Kg/hr.
Main condensate flow : T/hr.
through (Min./Max.) ejectors.
Temperature of main condensate : C at inlet
min./max.
Main Condensate Flow/Through : 529.276 T/HR.
Ejectors at 100% mcr.
Main Condensate Inlet Temperature To Ejectors : 46.3 / 47.6 C.
Steam Consumption For Ejector (Both Stages) : Kg/HR.
1.28 COOLING TOWER
1.28.1 Operation Data:

a. Design capacity of the tower : 30,000 m
3
/hr
b. Design cold water temperature : 33.19 deg C
c. Hot water inlet temperature : 42.73 deg C
d. Design approach : 5.19 deg C
e. Design atm. Wet bulb temperature : 28 deg C
f. Wind velocity for performance : calm
g. Design atm relative humidity : 50 %
h. Pumping head at the entry of the tower : 12 M of water column
1.28.2 Design Parameters:

1. Sprinkling density (L) or cooling
Water flow in Kg/Hr M2 fill area : 5364 Kg/M
2
/Hr.
2. Dry air flow (G) Kg/M2/Hr. : 2823.7 kg/m
3
/hr
3. Effective fill volume (inclusive of air gap) : 31,700 m
3.

4. Ratio of water to air weight (L/G) : 1.8998.
5. Temperature of leaving air
(i) Dry bulb temperature : 40.04 deg C.
(ii) Wet bulb temperature : 39.91 deg C.
6. Total dry air flow per tower : 17,370 X 10
3
kg/hr.
7. Inlet air enthalpy above 0 deg C : 21.18608 kcal/kg.
8. Total wet air flow per tower : 17,719 X 10
3
kg/hr.
40
9. Sensible heat gain by dry air thro tower : 0.73264 kcal/kg
10. Latent heat gain by dry air : 17.3686 kcal/kg
11. Exit air enthalpy above 0 C : 39.28732 kcal/kg
12. Total heat exchanged per Kg of inlet air : 18.10124 kcal/kg
13. Total heat exchanged per hour : 314.82 X 10
6
kcal
14. Evaporation loss (maximum) : 519.36 m
3
/hr
15. Drift loss (maximum) : 9.9 m
3
/hr
16. Wetted packing surface per sq.m of tower area : 19 m
2
/m
2
(laths only)
1.29 HP BYPASS SYSTEM

1.29.1 HP B/P Oil Supply Unit:

1. Type : OV 32 B-30-201
2. Oil used : Servoconval 46
3. No of OSUs per unit : 2
4. Operating oil pressure : 100 bar
5. Set pressure for opening of
Safety relief valve : 180 bar
6. Volume of oil tank : 70 litres
1.29.2 Pump Of Oil Supply Unit:

1. Make : BOSCH
2. Type : Axial piston type
3. Speed : 1500 rpm
4. KW : 7.5
5. Discharge rate : 24 litres /min
6. Discharge pressure : 170 ata
1.29.3 Motor Of Oil Supply Unit:

1. Make : BBC Brown Beweri
2. Type : Intermittent duty
3. Speed : 1440 rpm
4. KW : 7.5
5. Volt : 415
41
1.29.4 Filters Of Oil Supply Unit:
1.29.4.A. Suction filter:
1. Filtration rating : 100 micron
2. Filter material : Phosphor bronze wire
mesh
3. Max press drop rating : 2 Mpa
1.29.4.B. Pressure filter [coarse]:

1. Filtration rating : 10 micron
2. Filter material : Super micronic type .
852.127
1.29.4.C. Pressure filter [fine]:

1. Filtration rating : 3 micron
2. Maximum operating pressure : 350 bar
3. Allowable differential press [max] : 7 bar
1.29.5 Steam Valves BP1 & BP2:

1. Design pressure : 170/50 ata
2. Design temperature : 540/ 485 C
3. Body material : 10CV Mo 910
4. Nozzle material : 10CV Mo 910
5. Maximum flow : 236.05 T/hr
6. Seat diameter : 100 mm
7. Maximum valve stroke : 46 mm
1.29.6 Actuator Of BP1 & BP2:

1. Type : hydraulic
2. Design : ASM 210-10-KSK
3. Hydraulic system pressure : 100 bar
1.29.7 Spray Control Valves BPE1 & BPE2:

1. Valve design : E32 S
2. Maximum valve stroke : 40 mm
3. Design pressure : 280 ata
42
4. Design temperature : 175 C
5. Body material : 15 Mo 3
6. Nozzle material : 15 Mo 3
7. Maximum flow : 32.22 T/hr
8. Seat diameter : 30mm
1.29.8 Actuator Of BPE1 & BPE2:

1. Type : hydraulic
2. Design : ASM 100-10-KSK
3. Hydraulic system pressure : 100 bar
4. Type of operation : control
5. Positioning time : 10 sec
1.29.9 Spray Water Pressure Reducing Valve- BD:

1. Valve design : E 32 S
2. Maximum valve stroke : 35 mm
3. Design pressure : 280 ata
4. Design temperature : 175 C
5. Body material : 15 Mo3
6. Nozzle material : 15 Mo3
7. Maximum flow : 64.44 t/hr
8. Seat diameter : 30mm
9. Pressure drop : 41.53 ata [max]
1.29.10 Actuator Of BD:

1. Type : hydraulic [solenoid
valve]
2. Design : ASM 100-10-KCS
3. Type of operation : open-close
4. Positioning time : 10 sec



43
1.29.11 Hydraulic Accumulator In Oil Supply Unit:

1. Nominal volume : 30 litres
2. Pressure rating : 200 bar
3. Ambient temperature Min : 15 C
1. Max : 65 C
4. Operating gas : nitrogen only
5. Bladder material : synthetic rubber
6. Make : BOSCH

1.30 CONDENSATE STORAGE TANK:

No. for each unit : One.
Capacity : 500 m
3
.
Dimension of the tank : Dia. 8 mts.
Height 10.5 mts.


45



1.31 SAFETY VALES
TECHNICAL DETAILS


1 Location
Over Dea tank
east / west
Steam To
Ejector
Line
Deaerator
Extraction
Line
CEP Suction
line
Valve
Gland
Sealing
Header
Steam To
Ejectors
Line
LP drain cooler
2 Size 8" * 10 " 4" * 6" 6" * 8" 1.5" * 2" 4" * 6"
LPHs -Water
Expansion
3 Set pr 7.0 ksc 8.5 ksc 6.8 ksc 1.5 ksc 3.5 ksc 8.5 ksc 28 ksc
4 Type 1910 T/p2
905 M
/P3
19100 / P3 1905/ 30 E 1/2"-1970 1905 M/P3 S 15030
5 Temp 300 C 250 C 342 /360 C 44 /60 C 45/60 C 250 C 200 C
6 Material
C S SA 216
wcb
CS
7 Capacity
4000 kg/hr of
dry sat. Steam

30782.7
kg /hr
220.6
litres /min
3.95
8 Open pr 6.8 ksc / 6.9 ksc 28.25 ksc
9 Closing pr 5.4 ksc / 5.3 ksc












25 ksc

46
TURBINE
STAGE II
OPERATION MANUAL











CHAPTER II



GENERAL DESCRIPTION
OF
TURBINE & ITS AUXILIARIES.

47

STAGE II TURBINE OPERATION MANUAL
CHAPTER II
GENERAL DESCRIPTION OF TURBINE & ITS ASSOCIATED SYSTEMS:

2.1 Introduction OF Stage II Turbine & ITS Associated Systems
Turbines, condensers, regenerative heaters and other associated
equipments were supplied and erected by M/s. BHEL. M/s. BHEL. supplied
the Boiler Feed pumps. The Turbine is a three cylinders, tandem compound,
double exhaust, condensing, single reheat type designed for high
operating efficiency and maximum reliability. The motive force of rotating
the turbine rotor is obtained from the expansion of high pressure and high
temperature steam that is supplied by the boiler. The steam works on the
modified Rankine cycle. Whenever steam flow varies the torque on turbine
rotor changes, which in turn effects change in generator stator current,
ultimately leading to changes in active power output. The condenser is of
surface type. It is of single shell and rectangular in construction and has
divided water box. In the condenser the steam is condensed by means of
circulating water supplied by circulating water pump. M/s Mather and Platt
supplied the circulating water pumps. The hot circulating water from the
condenser is sent to Natural draught cooling tower where hot water is
cooled by the natural flow of air. The main condensate collected at the
condenser hotwell is pumped by condensate extraction pump and sent to
Deaerator via LP heaters. At Deaerator, the oxygen present in the main
condensate is removed by means of thermal deaeration. The deaerated
water is pumped by Boiler feed pump and sent to boiler drum via HP
heaters.



48
2.2. Main Turbine:
The turbine of the second stage Units IV to VII is three cylinders,
double exhaust, condensing, single reheat, regenerative axial flow, tandem
compound reaction type. It has High pressure (HP), Intermediate pressure
(IP) and Low pressure (LP) cylinders. The HP cylinder is of single flow pattern.
Both IP and LP cylinders are of double flow type.
HP cylinder consists of 25 reaction stages and IP cylinder 20 double
flow reaction stages. LP cylinder consists of 8 double flow reaction stages.
Superheated steam is received from the boiler through two main
steam lines. Each main steam line has a combined HP stop valve and HP
control valve. Two transfer lines take the steam from the HP control valves to
the HP cylinder on left and right. The steam flow in the HP cylinder is from
Generator end to HP cylinder pedestal end.
The exhaust steam of HP cylinder reaches reheaters arranged in two
stages located in the boiler through two cold reheat lines. These cold
reheat lines are provided with swing check valves to prevent the steam
from the reheaters flowing back into the HP turbine in case of turbine trip.
The steam coming from the reheater is taken to IP cylinder through
two hot reheat lines through two combined reheat stop and control valves.
The exhaust from the IP cylinder is taken from eight points, which join
together to form two cross-around pipes leading to LP cylinder.
Six extractions are taken from the turbine, three for low-pressure
heaters, and one for the Deaerator and two for the high-pressure heaters.
The individual turbine rotors and the generator rotor are connected
by rigid couplings. The rotor as a coupled system rotates in six journal
bearings out of which the bearing between HP and IP cylinder is a
combined journal cum thrust bearing with tilting pads on both sides.




49
2.3. Condenser:
The condenser, which is surface type, is of single shell and rectangular
in construction. It is rated to operate at a pressure of 0.1033 ata. The pattern
of exhaust steam flow is downward with an upward flow in air-cooling
section. The number of flow passes of circulating water is two.
It has a divided water bow to enable part load operation (50%) of the
unit. The circulating water coming through two cold water pipes at a
temperature of 34 deg C enters the two water boxes at their bottom. The
water flows in two passes and leaves the water box at the topside through
two hot water pipes at 42.6 deg C. The condenser contains 17,668 numbers
of stainless steel tubes (SSTP 316) of 25.4 mm outside diameter and
0.7112mm thickness. 1,240 numbers of tubes are provided at the Air-cooling
zone. The condenser is supported on 24 numbers of springs at its bottom
and its neck is connected to the bottom of the LP cylinder. The exhaust
steam flows downward to envelop all the bundles and then flows upward
towards air suction pipe in the air-cooling zone. Air and non-condensing
gases are extracted by one of the 2 ejectors normally in service, through
the holes provided in air suction pipe.
The system water losses for thermal cycle are made up at the hot
well.
2.3.1 Condenser On Load Tube Cleaning System:
The performance of a Steam Power plant depends upon the
condenser vacuum. Condenser vacuum depends on the cleanliness of the
condenser tubes. Fouling and scaling in the condenser tubes reduce the
heat transfer rate and hence the vacuum in the condenser tends to be
poor. To keep the condenser tubes clean, Condenser on load tube
cleaning system is installed. It consists of a ball vessel into which the balls to
be kept in circulation are introduced initially. The ball recirculation pumps
circulate these pumps through the condenser tubes on both sides. The balls
after passing through the respective monitors are injected into the inlet
water pipes of the condenser. They are carried by the circulating water to
50
the condenser tubes from the inlet water boxes and then the balls reach
the reversing chamber. Later they pass through the second pass of the
condenser tubes and reach the outlet water boxes. These balls are carried
into the outlet water pipes. Two ball separators are located in the
condenser outlet water pipes and the balls which get trapped in the ball
separator are then collected in a transverse channel, these balls are
extracted along with the circulating water to form suction for the
recirculating pump.
Normal cleaning balls used are of type soft-NTO-S and of diameter 27
mm. Abrasive cleaning balls used are of type NTO-A and of diameter 26
mm.
Separate system is provided for A and B side of the condenser.
2.4. Water Treatment Plant/ Stage-II
Raw water for the stage-II water treatment plant is obtained from
three bore wells named as E, F and G each of capacity 270 cubic m/hr all
connected in parallel. There is an interconnection in the common supply
line so that the raw water can be exchanged between stage-I and stage-II
water treatment plants. Two raw water pumps each of capacity 150 m
3
,
one in service and other as reserve serve as suction points for the three
numbers of raw water pumps. They are of 200-m3/hr capacity and are
capable of developing 4.5-ksc pressure. Out of the three, two will be in
service and the third will be standby. The first treatment stage encountered
is pressure sand filter and they are in 3 number. Pebbles, sand and crushed
gravel serve as filtering mediums here and suspended matter is removed.
The water after this stage is known as clarified water. It is followed by 3 nos.
of weak acid cationic filter and the resin is CCXO-9. Potassium and sodium
metallic radicals are removed here. The third treatment stage is strong acid
cationic filter in which the resin T42H
+
is used. Metallic radicals of calcium
and magnesium are removed and this stage also has 3 vessels. Fourth stage
treatment is the removal of carbon-di-oxide in two numbers of degasser
towers,, each equipped with to air blowers of capacity 4,400m
3
/hr and
51
capable of developing 100 mm of water column pressure, one in service
and other as standby. The degassed water is let into two numbers of
storage tanks, each of capacity 100m
3
. The pressure which was provided by
the raw water pump is sufficient for bringing the water up to this point. For
passing the water through further treatment stages, the necessary pressure
is provided by three numbers of degassed water pumps, two in service and
one as reserve each of capacity 110 m
3
/hr and a pressure rating of 5 ksc.
Three nos. strong base anion (primary) with A36MP resin in which all acidic
radicals except silica are removed forms the fifth stage treatment. Three
vessels containing A27MP resin in which silica removal is done is the
penultimate stage. Final treatment is given in 3 numbers of mixed bed
exchangers, which contain both the resins A27MP and T42H
+
. The treated
water is stored in 3 nos. of DM water tanks each of capacity 500 m
3
and the
treated water can also be exchanged between the two plants. 3 nos of DM
water pumps each of capacity 80m
3
/hr and 10 Ksc rating, two in service,
one as reserve, pump the water through 2 mains. One main is going to the
condensate storage tanks of Units 4 and 5 and the other main to the
condensate storage tanks of Units 6 and 7. Each CST is also of capacity 500
m
3
. The water treatment plant of stage-II has facilities for receiving, storing,
diluting and supplying Hydrochloric acid and sodium hydroxide used for the
regeneration of cationic and anionic resins respectively. It has an effluent
treatment facility as well. The plant has flexibility of operation as all other
streams are interconnected. DM water has a quality of 0.1 ppm total
dissolved salts. Capacity of the plant is 160 tonnes of treated water per
hour.
2.5 Make-Up Water System:
The system water losses in the thermal cycle are made up at the
condenser through a surge tank of capacity 50 m
3
. DM water supplied by
the water treatment plant is stored at 2 Condensate storage tanks (CST) of
each capacity 500 m
3
. The DM water stored in these tanks are also used for
the following purposes:
52
- Make-up water for Auxiliary Cooling water (ACW) overhead tank of
capacity 15 m
3
.
-
Make-up water for Stator water tank of capacity 5 m
3.
- Initial filling up of Deaerator.
- Initial filling up of Boiler.
- Make-up water for Surge Tank.
These tanks are provided with 3 pumps called as condensate
transfer pumps. Pump-C will be normally in service and others (A and B) are
reserve. This is a single stage end suction centrifugal pump. Pump A and B
are of same capacity (180 m
3
/hr, dis press: 14 ksc, 2970 rpm, 110 KW) and
Pump-C has the capacity of 200 m
3
/hr (dis press: 5.5 ksc, 1475 rpm, 45 KW)
2.6. Main Condensate System:
The main condensate collected at the hot well of the condenser is
pumped to deaerator by means of Condensate Extraction Pump (CEP).
There are 2 CEPs each of 100 % capacity. One pump is to be kept in service
and the other is intended to be standby. This is a 6 stage, vertical,
centrifugal pump of canister type. The rated capacity of the CEP is 678
m
3
/hr at a design differential pressure of 22.5 ksc. The pump is provided with
an airline connected to the steam space of the condenser. It is also
provided with a gland sealing line for avoiding air entry into the condenser.
The water for the gland sealing is supplied from the discharge header of
CEPs and a surge tank provides the reserve facility. The CEP drive motor
rated at 600 KW, runs at 1482 rpm and is provided with 6.6 KV power supply.
The main condensate delivered by the CEP flows through the Main
Ejectors, Gland Steam Condenser, LP drain cooler and regenerative Low
Press Heaters 1,2 and 3 to reach the top of the Deaerator heater finally. The
main condensate which is leaving the Gland Steam Condenser at 48 degC
is heated to 120 degC in LP heaters. Necessary bypass lines are also
provided for the Main Ejectors, Gland Steam Condenser and all the 3 LP
heaters. A condenser recirculation line is also provided after Gland Steam
53
Condenser to maintain a minimum flow through CEP, Main Ejectors and
Gland Steam Condensers.
This system also supplies condensate for the following auxiliary
purposes.
1. Spray water for the LP B/P system.
2. Exhaust hood spray water system.
3. Chemical feeding
4. Quenching the vapours of the flash boxes.
5. Vacuum breaker line sealing.
6. Gland sealing of valves, which are connected with the condenser.
7. Condenser constant level vessel filling.
8. Main Ejectors syphons initial filling.
9. Gland sealing water for condensate exhaust pumps.
2.7. Circulating Water System:
A common circulating water pump house is located in the western
end of the power station and there are 11 single stage vertical mixed flow
pumps. Each pump is of capacity 16,500m
3
/hr at a delivery head of 27.5 m
of water column and is coupled to a motor of capacity 1760 KW and
running at 496 rpm.
Two circulating water pumps can meet the needs of the condenser
of one unit while three pumps are kept as standby for all the four units. Each
one of the standby pumps is located in between the pairs of pumps. The
cold circulating water stored in Forebay is made available to the circulating
water pumps through suction pits. The delivery of each pump is supplied
through a steel pipe with a butterfly discharge valve. The pair of the
discharge pipes from the two pumps of a unit join a cold water pipe and
this pipe can also be fed from the concerned standby pump. This cold
water pipe takes the cold circulating water to the condenser and supplies it
in two intake pipes just before entry to the condenser. These two intake
pipes join the front water boxes at their bottom.
54
The circulating water entering the water box flows in two passes inside
the condenser. The reversing chamber at the rear connects both water
passes. Two outlet pipes from the topside of the front water boxes join a
common hot water pipe for taking hot circulating water to the cooling
tower.
Makeup to the circulating water system is from an artificial lake of
capacity 1,708,605 m3 located in the North West of the power station,
which in turn gets its water supply from Mines-II through four pipe lines. Major
water losses in the circulating water system are
i. Blow down to Ash disposal pump house,
ii. Evaporation loss in the cooling tower,
iii. Drift loss in the cooling tower.
The make up water is drawn from the lake to the forebay through a
line with level control valve. This line can also receive water directly from the
two make up water lines from Mines-II.Normal storage at the lake is sufficient
for a period of 6 days for all the seven units.
2.7.1. Chlorination:
The circulating water flowing through the condenser contains various
vegetable and animal microorganisms. Some of them will get accumulated
and reproduce themselves inside the tube walls. Due to this accumulation,
the flow of circulating water inside the condenser will be reduced which in
turn results in reduction in the rate of heat transfer and hence the vacuum
in the condenser. Chlorination of this water kills the microorganisms and
hence they lose their ability to stick to the inner tube walls.
The chlorination plant located nearer to the circulating water pump
house has three units each of 120 kg/hr. dosing capacity. Liquid chlorine
drawn from the chlorine Tonners is piped to an evaporator cylinder, which is
immersed in a controlled temperature hot water bath. Liquid chlorine is
evaporated into gas and then supplied to an Ejector through a chlorine
metering device called as Chlorinator.
55
Raw water is supplied by a booster pump and the water flow through
the ejector mixed with the raw water is dosed through diffuser pipes at the
forebay just at the entry of cold circulating water from the open channel.
Chlorination is carried out periodically to maintain an optimum level of
chlorine in the water so that it is effective.
2.7.2. Dozing of Organo Phosphate:
Calcium Carbonate (Ca CO3) is the most common scale found in the
circulating water system. It is normally results from the break down of
calcium bi carbonate, a naturally occurring soluble salt in water. The rate of
calcium carbonate break down increases with P
H
and temperature. In the
condenser, formation of scale is severe at high temperature regions.
Treatment of water with organo phosphate is done to minimize the scaling
by avoiding precipitation of salts. HEDP (1 hydroxy ethylidine, 1
diphosphonic acid) is dosed along with zinc hydroxide and Benxe tirazole
as copper corrosion inhibitors. Additional benefit due to this dosing is the
reduction in the circulating water blow down.
2.8. Cooling Towers:
Four natural draught cooling towers are located at the South West of
the power station. The shape of the tower is circular in plan and hyperbolic
in profile. The empty shell does the function of evolving draught, i.e., flow of
air. The entire shell of the tower is supported by 72 diagonal columns of
diameter 900mm.the inner diameter of the tower is reduced from 94.42m at
sill level to 53.9 m at its neck at an elevation of 89 m. Then it is increased to
59.4 m at the top elevation of 124 m. eighteen layers of R.C.C louvers
constitute the internal fill in the cooling tower. They are supported by
precast columns and beams.
Hot circulating water leaving the condenser flows in a single hot
water pipe towards the cooling tower. From the hot water pipes, hot water
flows up to the middle of the basin through two hot water ducts. From the
basin floor, the hot water rises through risers and the hot water enters
distribution network at 10 metres elevation. The hot water from each riser is
56
distributed with a main duct and a branch duct and thereafter through
A.C.pipes. These pipes are fitted with nozzles and sprayers. Total number of
sprayers in the tower is 8752.
The basin for collecting cold water has a partition wall for isolating
50% of the tower in service for maintenance work. Wind baffles are
provided in the space between the top of the basin and the bottom of the
fill in order to avoid a break through of air during strong winds. The cooling
capacity of the cooling tower is 30000 m
3
/hr and the range of cooling is 8.5
deg C.
2.9. Fire protection system:
The Fire Protection System comprises of a Fire Hydrant System and a
High Velocity Water System (HVW) with their related pump sets. The hydrant
system provides a convenient source of water supply for fire fighting
purpose inside the Thermal Power Station premises in the event of a fire out
break. HVW system sprays water on to the risk it protects when it is actuated
manually in case of outbreak of a localized fire. These two systems are
interconnected.
The fire hydrant system id provided with three hydrant pumps out of
which two are electrically driven while the third is diesel engine driven.
These pumps feed a common header, which feeds the hydrant lines
leading to various hydrant circuits in the Thermal Power Station. In the event
of a fire outbreak the water under pressure can be tapped from the outlets
called as hydrant points and directed on the to seat of the fire manually by
means of the hoses and nozzles provided, the water for the fire hydrant
system is drawn from the forebay of the circulating water pump house.
The HVW spray system consists of an electric motor driven pump and
a diesel engine driven pump and these two pumps feed the HVW system.
The system pressure is maintained at 9.8 ksc by a hydro pneumatic
tank. This tank is pressurized vessel. The top of the tank is connected to an
air compressor while the jockey pump feeds the tank with pressurized water
from the bottom. In the event of a minor system leakage in either the
57
hydrant system or in the HVW system, the make up water under pressure will
be fed from this tank so as to sustain the system pressure. The water level in
the tank is maintained by the jockey pump and the pressure in the tank is
maintained by means of the compressor.
The HVW system protects the Main Oil Tank, Lub oil Canal I and Lub
Oil canal- II. Each hazard is protected by a spray system provided with a
network of piping all around. Spray nozzles are located to cover the
complete surface area of the hazard by a uniform spray. The high velocity
water is tapped off from the HVW spray mains and is supplied through
Deluge Valve. The hazards are provided with smoke detectors and Heat
detectors. These detectors and Manual call points are in parallel to send
signal to the fire alarm panel in the event of a fire. On seeing the alarms, the
release system of the respective Deluge valve can be initiated manually to
provide the HVW spray on the hazard.
2.10. Deaerator:
In order to avoid corrosion of internal surfaces all the heat transfer
elements and pipelines in the feed water path boiler water wall tubes and
drum, the gases dissolved in the feedwater, are removed in the deaerator.
Operation of the Deaerator is based upon the fact that the gas solubility in
the water decreases as the temperature rises. If the water is heated up to
the saturation temperature and kept at this temperature for a sufficient
time, all gases can be removed and vented to atmosphere. In order to
increase the deaerating efficiency, the water is broken up into small
droplets through a system of spray nozzles and perforated trays.
The deaerator is of combined spray and tray type and is erected at
27.0 m elevation. It consists of a horizontal deaerating header and a
horizontal deaerated water storage tank. The header is connected to the
storage tank through 3 numbers of pipes. The deaerator is operated on a
variable pressure mode.
There are five perforated trays in each of the two stacks in the
deaerating header. The main condensate enters the header at the top and
58
is divided into small droplets by means of spray nozzles. Then it is distributed
uniformly over the trays. Fourth extraction steam of turbine is used for
deaeration. Cold reheat steam and auxiliary steam bus provide necessary
reserve supply of steam for the deaerator. Two safety valves are provided
on the top of deaerator storage tank in addition to the four safety valves in
the steam supply line.
The operating parameters of deaerator are 6.6 ata and 161.9C.
Normal water level of deaerator is 585 mm above the geometric center line
of the storage tank. The deaerating steam at initial start up periods is
received from the auxiliary steam bus.
2.11. Boiler Feed Pumps:
Each unit is provided with three boiler feed pumps of 50% capacity
each. Two pumps are in normal service and the other is intended to be at
standby. These pumps are located at 4.5 metres elevation inside the turbine
hall.
The feed pump is a 6 stage centrifugal pump. The capacity of the
pump is 423m
3
/hr. Its differential pressure is 222.2 kg/cm
2
at a speed of 5300
rpm. An inter-stage tap off after the third stage is taken to feed the two de-
super-heaters of the reheater meant for the reheated steam temperature
control.
Feed pump itself is fed by the booster pump, this is a single stage
double centrifugal pump and is also driven by the feed pump moor,
coupled to the other end shaft of the motor the booster pump has its
suction from the Deaerator and delivers the water at a higher pressure
thereby providing the net positive suction head (NPSH) for the feed pump.
The differential pressure of the booster pump is 10.4 ksc.
The 6.6kv feed pump drive motor is of capacity 4000kw with a rated
speed of 1485 rpm. The power is transmitted from the motor to the feed
pump through a variable speed hydro coupling. It consists of a step up
herring bone gear of gear ration 131/36 followed by the hydro-coupling.
The variable speed for the feed pump is achieved by positioning of a
59
pneumatically operated scoop tube. The necessary working oil for the
hydro coupling is supplied by a working oil pump. Requirement of lub oil for
the bearings of the motor, the feed pump and the bearings of the hydro
coupling is met by a lub oil pump. Both the working oil pump and the lub oil
pump are mounted on a single shaft and are driven by the input shaft of
the hydro coupling through a spur and bevel gear train. These two pumps
draw oil from a common sump at the bottom of the hydro coupling and
supply oil for the hydro coupling and lubrication of various bearings
separately. Another motor driven lub oil pump is also provided to supply lub
oil during start- up, tripping and break down periods.
A pneumatically operated recirculation valve is provided on the
recirculation line to ensure a minimum flow of 100 m
3
/hr through the feed
pump. The feed pump is provided with mechanical seals at both the ends
and a seal water cooler is provided to cool the seal water with the help of
the auxiliary cooling water.
In order to keep the reserve / idle feed pump in warmed up condition
so as to avoid thermal shock, a small quantity of feed water is continuously
allowed to flow to the flash box (and then to the condenser). This line is
provided with a pneumatic, valve and it is called the warming up line . By
this line, the temperature of the casing and the internal assembly is
maintained at the operating value.
The feed pumps discharge the feed water to the boiler drum through
two high pressure heaters, feed water regulating station and two stages of
the economizer.
2.12. Ejectors:
The function of the steam air ejector is to create vacuum inside the
condenser and further maintain it by continuously extracting air and non-
condensing gases. There are two main ejectors and one starting or pilot
ejector.
Pilot ejector is used exclusively for initial building up of vacuum in the
condenser. Main ejectors take up the work of raising the vacuum further.
60
After normal vacuum is achieved out of the two main ejectors, one will be
in normal in service and the other will be a stand by.
Ejectors operate based on the principle of Nozzles cum diffuser. When
flow of steam at design pressure is effected through a nozzle cum diffuser,
high vacuum is created in the chamber in between the nozzle and the
diffuser due to increased velocity of the steam. Since this chamber is kept in
communication with the air line from the condenser, extraction of air and
non-condensing gases from the condenser takes place.
Pilot ejector is dingle stage type and the main ejectors are of three
stage type, the operating steam fro these ejectors is supplied from the
Auxiliary steam bus at 16 kg/cm
2
.in the case of pilot ejector, the exhaust of
the one stage becomes suction for the next stage. The cooling medium
used to condense the operating steam in the condensing chambers of all
the stages of the main ejectors is the main condensate flowing through
inverted U tubes. The drain condensate collected in each stage is
cascaded so as to reach the condenser hotwell finally through the flash
box.
2.13. Gland Sealing Steam System And Leak Off Steam:
During the normal service of the unit, the operating steam admitted
into HP and IP cylinders of the turbine tries to leak off through the small
clearances between the rotor and casing at both ends. Labyrinth glands
are provided for the purpose of minimizing the steam leakage through the
spindle, long and short packing seal strips laid alternatively over the grooves
of the rotor give the improved performance of minimizing the steam
leakage. In the case of the LP cylinder leakage of air into the condenser
through both ends of the rotor takes place since the steam leaving the last
stage of LP cylinder is having a sun atmospheric pressure of 0.1033 ata.
Hence a rotor gland sealing steam system is warranted it supplies steam for
sealing at a pressure just above the atmospheric and this acts as a seal
against the entry of air at both ends of LP rotor. During the period of initial
vacuum raising in the condenser, the sealing steam becomes necessary for
61
the ends of the HP and Ip cylinders also as there will not be any operating
steam inside HP and Ip cylinders.
During normal service of the unit, the spindle leak off steam from the
HP cylinder, admission end is collected in four phases. The steam collected
after I phase of pressure reduction is diverted to cold reheat steam. The
steam collected after II phase of pressure reduction is diverted to IP cylinder
exhaust. The steam leaking through after III phase of pressure reduction
becomes self-source of steam for sealing of LP cylinder ends. The steam
leaking past after IV phase of pressure reduction is collected by Gland
steam condenser.
Similarly the spindle leak off steam from HP cylinder Exhaust end is
collected in 3 phases. The steam leaking after I phase of pressure reduction
is diverted to IP cylinder exhaust and the steam leaking after II phases of
pressure reduction also becomes the self source steam supply for sealing of
LP cylinder ends. The steam leaking after III phase of pressure reduction is
collected by Gland steam condenser.
In the case of LP cylinder, the sealing steam is supplied at both ends
to avoid air entry. After serving the sealing function in the LP cylinder a part
of the sealing steam enters the condenser and the remaining part comes
out to atmosphere and it is collected by Gland steam condenser.
2.14. Gland Steam Condenser:
Gland steam condenser is provided to collect and then condense
the turbine Gland steam and the leak off steam from turbine valves. It is
located in the thermal cycle after the main ejectors and the main
condensate flowing through the tubes of Gland steam condenser
condenses the steam collected, the Gland steam condenser operated
under vacuum so as to draw the following and then condense.
1. Leak off steam from both ends of HP cylinder.
2. Leak off steam from both ends of IP cylinder.
3. Low pressure leak off steam from Turbine valves viz., HP Stop
valves, HP control valves, IP stop valves and IP control valves. The
62
condensate collected in the gland steam condenser is diverted to the
condenser hotwell through flash box.
To maintain a slight vacuum in the gland steam condenser and in the
leak off system, two air extractors are provided. One extractor is normally in
service and the other one as standby.
2.15. HP and LP Bypass systems:
As can be seen in the thermal flow diagram, the reheater in the boiler
is supplied with steam from HP cylinder of the turbine. Naturally when the
boiler is in service and the turbine is not in service, there is no steam flow
through the reheater. This situation will occur during start-up and turbine trip.
During the above situations, the tubes of reheater are to be safeguarded
by preventing starvation. This is done by connection the main steam lines
with the cold reheat steam lines through HP bypass system.
To create necessary steam flow through reheater tubes, the reheated
steam can either be vented out or dumped into the condenser. The latter
will be advantageous as it is conserving Demineralised water. This can be
cone by connecting the hot reheat line to the condenser through LP bypass
system. The HP and LP bypass systems help in handling the steam, which the
turbine cannot handle.
The pressure and temperature are to be reduced for the bypassed
steam in the above systems. While the pressure is reduced by throttling of
the valves, the temperature is reduced by the injection of spray water. The
spray water for HP and LP bypass systems are feed water (from the
discharge header of boiler feed pumps) and main condensate (from the
discharge header of condensate extraction pumps) respectively.
The HP and LP bypass systems are capable of handling a maximum of
60% of the steam quantity at full load.




63
2.16. Auxiliary Steam System:
Whenever the boiler is not in service, the steam requirements of the
unit will be met by an Auxiliary Steam System. The parameter of the steam
in the auxiliary steam header are 16.0 kg/cm2 and 230C.This steam is used
for the following.
1. Heating of oil in fuel oil heaters and floor coil heaters,
2. Tracing steam line,
3. Atomizing oil in oil burners,
4. Steam coil air preheater (SCAPH) in the boiler,
5. Soot blowing for regenerative air preheater,
6. Reserve steam supply line for deaerator,
7. Preheating steam line for deaerator,
8. Reserve steam for Gland sealing steam of turbine,
9. Operating steam for Pilot ejector.
The auxiliary steam header of a unit can receive the steam supply
from the following sources.
1. Packaged boilers,
2. Auxiliary steam headers of the other units,
3. Auxiliary steam system pressure reducing station (AST PRDS)
Source of steam for AST PRDS is main steam lline. Pressure of steam is
reduced by throttling at the control valve and the temperature is reduced
by mixing of spray water. Feed water tapped from the discharge header of
Boiler feed pumps is used as spray water.
2.17. Regenerative Feed Water Heating System:
In the regenerative feed water heating system, there are totally six
steam extractions of uncontrolled type. First three steam extractions are
taken from LP cylinder for preheating the main condensate in LP heaters.
Fourth extraction from IP cylinder is meant for feeding the steam to
deaerator. Fifth extraction from IP cylinder and sixth extraction from cold
reheat steam line are meant for preheating the feed water in HP heaters. All
the steam extractions are provided with motor operated isolating valves.
64
Hydraulically operated forced closing non return valve (FCNRV) are also
provided in all the steam extraction lines except the first extraction. These
valves isolate the heaters from the turbine in case of a trip and al so in case
of a very high shell water level. The feed water is heated up to 243C in HP
Heaters and the main condensate is heated up to 120C in LP Heaters.
Two vertical HP Heaters similar in construction are installed with a
water chamber at the bottom. The shell is a cylinder with one end closed by
a dished head and the other end connected to a tube sheet. The water
chamber is provided with a partition wall to provide two water passes. The
tube bundle consists of tubes of hair pin shape. Drain condensate of HP
Heaters is sent to deaerator. The heaters are provided with individual
bypassing facility with the help of motor operated isolating valves. Group
protection bypassing facility for both the heaters together is made
available to guard against the pressurization of the shell in case of a tube
puncture. Hydraulically operated inlet and outlet valves along with
emergency bypass line are provided for this purpose. More over, safety
valves on both water side and shell side are provided to guard against
excessive pressure.
Three LP Heaters are of vertical type similar in construction. The heater
is a cylindrical shell with its one end closed by a dished head and the other
end connected to the tube sheet. The water box is at the bottom of the
shell and divided into two chambers to double pass of main condensate.
The tubes are of hair pin shape. The drain condensate of LP Heaters is
cascaded to the hot well through a drain cooler and a flash box. All the LP
Heaters are provided individual bypassing facility with the help of motor
operated isolating valves. All the LP Heaters are provided with safety valves
on both water and shell side.




65
2.18. Auxiliary Cooling Water System:
An exclusively closed cycle with demineralised water as cooling
water is used in this ACW system. This system meets the cooling water
requirements of auxiliary equipments. It is used for the following purposes.
(A) Boiler Zone:
1. Sample coolers,
2. Lub oil coolers of ID and FD fans,
3. Bearing coolers of Regenerative Air preheaters,
4. Shaft cooling of After Burning Gates,
5. Bearing coolers of Mills.
(B) Compressors:
For instrument air compressors and service air compressors, it is used
for the following.
1. Inter cooler,
2. After cooler,
3. Jacket cooling of HP cylinder,
4. Jacket cooling of IP cylinder.
(C) Turbine Zone:
1. Cooling of oil in thrust bearing of Condensate Extraction Pump,
2. For Boiler feed pump, it is used for the following.
a) Lub oil cooler,
b) Working oil cooler,
c) Motor air cooler,
d) Mechanical seal cooler,
e) Boiler feed pump seal box cooling,
f) Booster pump
i. Seal box cooling,
ii. Gland cooling.
(D) Generator Zone:
1. It is used for cooling the hydrogen gas in the Generator,
2. Cooling of Stator cooling water.
66
In this closed cycle, two auxiliary cooling water pumps are provided.
One pump is normally in service and the other pump is a standby. These
pumps are single stage double suction centrifugal type driven by 415 V,
3 phase, 100 KW motors. The total dynamic head of the pump is 20 m and
its capacity is 1250 m
3
/hr.
These pumps draw water from a common suction header and pump
it through plate type water to water heat exchangers to different coolers
and cooling points. Warm water returns to this common suction header for
circulation, three heat exchangers are provided out of which two can meet
the requirements. The auxiliary cooling water is cooled by a part of
circulating water drawn from the cold water intake pipe of the circulating
water system. The hot circulating water returns to the cooling tower.
A part of cooled auxiliary cooling water from the heat exchangers is
distributed to Boiler Auxiliaries by means of Auxiliary cooling water booster
pumps. There are two ACW Booster pumps. One pump is normally in service
and the other is standby. These pumps are of single stage double suction
centrifuge type driven by 415 V, 3 phase, 22 KW motor. The total dynamic
head of the pump is 20 m and its capacity is 250m
3
/hr.
For providing make up water to this system, a tank known as Auxiliary
cooling water over head tank of capacity 15 m3 is provided at 27 metres
elevation and it feeds the make up water by gravity to the ACW system. This
tank itself is periodically made up with water from Condensate storage tank
(CST) through Condensate Transfer pumps.
In order to cool the lubricating oil of the turbine in the Turbine Lub oil
coolers and the seal oil in the seal oil coolers the circulating water itself is
used by tapping the water from the CW supply line to heat exchangers. The
hot circulating water from these coolers return to cooling tower along with
outgoing circulating water from the heat exchangers.



67
2.19. Turbine Oil System:
A main oil tank with a capacity of 20/32 m
3
serves to contain the oil
for the oil system of the turbo generator. This supplies the oil for the
following systems.
1. To supply lubricating oil for the lub oil system of turbo generator,
2. To supply control oil for the LP Bypass system,
3. To supply control oil for the governing system of the turbine,
4. To provide oil for driving the hydraulic turning gear during start
up and shut down of the turbine,
5. To provide jacking oil for hydraulic lifting of the turbo generator
rotor.
A main oil pump is provided to supply the oil when the Turbine is in
service. It is driven by the TG rotor itself and the other pumps provided in the
oil system are standby pumps. The main oil pump is single stage double
suction centrifugal pump developing a discharge pressure of 8.2 bar.
To meet the requirements of the oil system during start up and
shutdown, two pumps called as Auxiliary oil pumps are provided inside the
main oil tanks. One pump will be in service during start-up and shutdown,
the other is standby. Those pumps are single stage, vertical, end suction
centrifugal type. These pumps are kept in parallel with the main oil pump
and they are driven by 415 V, 90 KW motors. The discharge pressure is 6.8
bar.
From the discharge header of these pumps (via MOP and AOPs) oil is
supplied for the following.
(a) Oil for driving the hydraulic turning gear through a motor operated
valve known as Gate valve Gearing ,
(b) Control oil supply for the Turbine Governing system and LP Bypass
system through the Emergency Shut off valves.
(c) Oil for providing positive suction for the main oil pump through two
oil injectors connected in series. The oil ejectors serve the purpose of sucking
68
more oil from the main oil tank, supplying it to the main oil pump at a
positive pressure,
(d) Oil for lubrication of the Turbo generator bearings after reducing
the pressure of oil through a line throttle device.
Lub oil for TG bearings at a pressure of 3.1 Ksc is cooled to 45 to 47 C
in the lub oil coolers by the circulating water. A D.C. emergency oil pump
driven by 220 V D.C. motor is provided to meet the emergency lub oil
requirements only. This pump is also a single stage, vertical, centrifugal type
and its discharge pressure is 2.3 bar. It supplies lub oil to the lub oil header
after the lub oil coolers.
2.20. Hydraulic Turning Gear And Hydraulic Lifting:
The function of hydraulic turning gear is to rotate the Turbo generator
shaft system at a slow speed during the period before start up and the
period after shut down. Before cold or hot rolling of turbine, it is necessary to
monitor the eccentricity of the rotor in order to ensure that no vibration is
caused and no rubbing between the moving and the stationary parts takes
place. The eccentricity of the rotor is caused when it becomes unstraight
due to bending.
Before cold rolling of the turbine, a natural deflection of rotor is there
due to the non-uniform distribution of its own weight. This is an initial
condition of eccentricity. Moreover uniform heating of rotor is necessitated
while admitting steam for sealing at glands on raising vacuum. Due to the
above, slow rotation of the turbine rotor is needed.
When the turbine is tripped, the rotor comes to rest from its rated
speed. The turbine starts cooling very slowly. Due to the difference in areas
exposed to atmosphere between cylinder top and cylinder bottom, the
rate of cooling varies, leading to uneven cooling. In such conditions, if the
rotor is kept idle, it is exposed to high and low temperature zones resulting in
thermal stressing, bending and eventually eccentricity in the rotor. Hence
the rotor is to be given a slow rotation.
69
The hydraulic turning gear is located in the bearing pedestal
between IP an LP cylinders. The turbine generator is equipped with a
mechanical bearing gear, which enables the combined shaft system to be
rotated manually in the event of failure of the hydraulic turning gear.
During turning gear operation, the turbo-generator shaft system is
rotated by a double row blade wheel, which is driven by oil. The oil is
supplied by the auxiliary oil pump and it flows through a gate valve gearing
and a nozzle box. Gate valve gearing is an electrically operated valve
through which the high pressure oil is supplied to turning gear thro Nozzle
box. Nozzles guide the jet of oil towards the moving blades. Nozzles increase
the velocity of oil and guide the jet of oil towards the moving blades. This
flow of high velocity jet of oil through the two rows of moving blades result in
slow rotation of the Turbo generator rotor system. Speed of rotation of TG
rotor during the turning gear operation is 120 rpm without condenser
vacuum and 160 rpm with condenser vacuum.
To overcome the initial breakaway torque on start-up and to prevent
dry friction, the bearings are supplied with jacking oil from below the shafts.
The shafts are thus lifted slightly. To supply the high pressure jacking oil, two
jacking oil pumps of 100 % capacity each are provided in the main oil tank.
One pump is intended to be in service, the other is standby. The jacking oil
pumps are screw type immersion pumps, the discharge pressure of the
pump being 120 bar.
2.21. Turbine Stress Evaluator:
The operating engineer of the turbine has to have a monitoring
facility to know how quickly he can start-up a turbine and the changes in
load he can make without fear of overstressing the turbine components
and thereby causing excessive fatigue. When the turbine is in service in a
steady state condition, there is little chance that major changes in the
turbine metal temperatures occur. But during start-up, loading, shut down
etc, changes in the steam temperature cause changes in the metal
temperature of the turbine equipments such as valve bodies, high pressure
70
and intermediate pressure (HP and IP) cylinders and rotors. This results in free
or constrained thermal expansion or contraction. Constrained thermal
expansion or contraction causes thermal stressing which must not exceed
the permissible limits for the material.
The turbine stress evaluator, a turbo-visory instrument, provides the
basis for long life operation of the turbine in that it is continuously computing
the stress margins during changes in the operating conditions of the turbine.
The optimum operation of turbine is achieved if the range of the permissible
material stress can be utilized to the full. The turbine stress evaluator
computes the permissible values of the rate of change of load/speed
based on the existing operating conditions of turbine and also influences
the turbine governor.
2.22. Turbo Supervisory System:
The ever-growing demand for electricity is forcing the power industry
to look for new technologies. This is essential to make plant availability as
high as possible under a safe operating environment. Certain critical
parameters such as Casing Expansion, Differential Expansion, Vibration
(shaft as well as bearing) etc., are to be necessarily monitored for high
speed rotating equipment. Accurate measurement and on line monitoring
of Critical parameters of Turbine and initiating the necessary alarms and
trips are done by the Turbo Supervisory System in modern steam turbines.
The equipments for the above system for the Turbines of Units 4 to 7/Stage-
II/TPS-II were supplied by M/S BHEL.
2.23. Turbine-Governing-System:
The turbine has an electro hydraulic governing system backed up
with a hydraulic governing system.
An electro hydraulic governing measures and controls the speed and
output, and operates the control valves hydraulically in conjunction with an
electro-hydraulic converter. The electro-hydraulic governing system permits
run-up control of the turbine up to rated speed and keeps low the speed
71
swings following sudden load shedding. The linear output frequency
characteristics can be very closely set even during operation.
2.24. Centrifuge:
In Power Stations, Centrifuges are mainly used to separate moisture
particles from lubrication oil. They are connected with turbine main oil tanks.
Two separation processes viz. Purification and Clarification can be done in
centrifuge.
Purification is the process of separation of two immiscible liquids
having different specific gravities and is useful for the removal of the solid
particles with specific gravity higher than those of the liquids.
Clarification is the process of separation of solid particles from oil
or any other liquid.
2.25. Air Conditioning:
In TS-II/Stage II, each UCB is provided with a direct expansion
type air conditioning system. The air conditioning system is as follows: -
There are three Accel make reciprocating compressors; of these
one is normally in service while the other is a standby and another one is
idle. Each compressor consists of four cylinders. Two cylinders get loaded
directly when the compressor is started while the other two cylinders can be
loaded / unloaded as per the system requirements through a solenoid valve
ULSV 1.
The refrigerant vapor returning from the coils of the Air Handling
Units flows through the freon suction header and is compressed in the
compressor. The compressed vapour flows into the shell of the condenser
and is condensed into liquid at high pressure giving up latent heat to the
circulating water flowing through the tubes of the condenser, the high
pressure liquid freon then flows through the liquid freon header to the
expansion valves of the AHUs where it is throttled. This enables it to start
boiling in the coils of the AHU causing the refrigerating effect.
In the AHU, three double suction blowers draw the warm return air
from the air-conditioned area across two banks of coils. The air is thus
72
cooled and the cooled air is blown into a common air supply duct in which
are fitted 24 micro vee filters and 3 sets of strip heaters. The micro vee filters
remove all the dust particles in the air and the strip heaters / dehumidifiers
help to maintain the relative humidity and temperature of the conditioned
air close to the design value.
An induced draught cooling tower having two cells, cools the warm
circulating water from the condenser. This cooled circulating water is again
circulated by the circulating water pumps through the tubes of condenser.

2.26. Salient Thermal Cycle Data (at 100 % MCR):

S.No. Subject Pressure Temp Flow
Ata deg C t/hr

1. Saturated steam from boiler drum. 167 350 607
2. Superheated steam after SH3 hdr 152 540 657
3. Superheated steam before HPSVs. 150 535 639.8
4. Cold reheat steam to reheater. 38.1 341.4 573
5. Hot reheat steam to IP cylinder. 34.3 535 573
6. Steam to LP cylinder. 7.17 318.8 504
7. Exhaust steam to condenser. 0.1033 46.1 441
8. Main condensate after CEPs. 19.8 46.3 529
9. Main condensate after LPH-3. 8.46 120.3 529
10. Feed water at Deaerator. 6.4 161 660
11. Feed water after Boiler Feed Pumps. 188 164.3 660
12. Feed water after HP Heater-6. 186.3 243 660
13. Feed water after Economiser. 170.3 329 611

73
TURBINE
STAGE II
OPERATION MANUAL












CHAPTER III


CONSTRUCTIONAL DETAILS

OF

TURBINE AND ITS AUXILIARIES

74
CHAPTER III
GENERAL CONSTRUCTION OF TURBINE AND ITS AUXILIARIES
3.1 TURBINE
3.1.1 HP CYLINDER:
The outer cylinder of the HP cylinder (Ref Fig. 5) is of barrel type and
has neither an axial nor a radial flange. This prevents mass accumulations
with high thermal stresses. The inner casing is axially split. As the pressure
difference across the wall of inner casing is low, the horizontal flange and
connection bolts are small. The barrel type casing permits flexibility of
operation in the form of short startup times and a high rate of change of
load even at high initial steam conditions.
The inner casing serves as the guide blade carrier. The barrel type
casing also remains constant in shape and leak proof during quick changes
in temperature (e.g., on start up and shut down, on load change and
under high pressure). The guide blade carrier is almost cylindrical in shape
as the horizontal joint flanges are relived by the higher pressure arising
outside and thus are small. For this reason, turbines with barrel type casings
are especially suitable for quick start up and loading.
3.1.2 Seals Between Inner And Outer Casings:
The pretensioned U shaped seal ring on the inlet side and the I
shaped seal ring that allows axial displacement of the guide blade carrier
on the outlet side seal the space between the guide blade carrier and the
barrel type casing from the adjacent spaces.
3.1.3 Attachment of the inner casing:
The guide blade carrier is attached to the barrel type casing in such
a way that it can freely expand radially in all directions and axially towards
the outlet when heating up while maintaining concentricity relative to the
turbine rotor.


75
3.1.4 Connection to the control valves:
The steam lines from the control valves are connected to the inlet of
HP cylinder by threaded sleeves.
3.1.5 Shaft Steam Seals:
The shaft seals are axial steam flow labyrinths, the sealing strips of
which are caulked alternately into the shaft and into the radial rings that
are divided into segments which in turn are fixed in the inner and outer
casings on the inlet side and in the outer casing on the outlet side.
3.1.6 HP Rotor Supports:
The front bearing pedestal (Ref. Fig. 6) has a journal bearing and the
main oil pump. The rear-bearing pedestal (Ref. Fig. 7 & 8) has a combined
journal and thrust bearing and is located between HP and IP cylinders. The
magnitude and direction of axial thrust to be carried by the bearing
depends on the load conditions of the turbine. The thrust bearing maintains
desired axial clearances for the combined turbine generator shaft system.
The thrust bearing has tilting type pads on the both sides.
3.1.7 Stages & Extractions:
The HP cylinder has 25 reaction stages (drum stages). No extraction is
taken from the HP cylinder. Extractions No: 6 for HP heater No: 6 taken from
the two cold reheat lines, one pipe from each. They join together and go as
a single pipe. As latent heat utilization is the prime concern of the
regenerative feed water heating system (which is the single major
improvement done to the cycle) high-pressure steam in the HP cylinder,
which has low latent heat content, cannot serve the purpose well and can
better perform work in the HP cylinder. This is the reason for why no
extraction has been taken from the HP cylinder.




76
3.1.8. IP Cylinder:
The casing of the IP cylinder (Ref. Fig. 9) is split horizontally and is of
double shell construction. A double flow inner casing is supported in the
outer casing. Steam from the two hot reheat lines enters the inner casing
from above and below after passing through the two reheat stop and
control valves. The inlet has two nozzles one above and the other below
flanged to the mid sections of the outer casing.
This arrangement provides opposed double flow in the two blade
sections and compensates axial thrust. The centre flow prevents the steam
inlet temperature from affecting the support brackets and bearing sections.
In this arrangement the steam inlet conditions are limited to the inlet section
of the inner casing where as the joint of the outer casing is only subjected to
the lower pressure and lower temperature prevailing at the outlet of the
inner casing. The joint flange is this kept small and material accumulations
reduced to the minimum in the area of the flange. In this way, difficulties
arising from deformation of the casing with flange joint due to non-uniform
temperature rises e.g. on start-up and shut-down are avoided.
The joint of the inner casing is relieved by the pressure in the outer
casing so that this joint has to be sealed only against the resulting
differential pressure.
3.1.9. Attachment of the inner casing:
Angle sealing rings form the connections of the inlet and extraction
nozzles with inner casing. One leg of the ring fits into the circular groove of
the inlet nozzle where as the other leg is held in position by a threaded ring,
which is screwed inside the inner casing. The angle rings are flexibly
expanded by the pressure on the inside and their outer areas forced
against the annular groove to provide the desired sealing effect.
While providing a tight seal, this arrangement permits the inner casing
to more freely in all directions. The inlet nozzles and the extraction nozzles
are bolted to the outer casing.

77
3.1.10. Attachment of the inner casing:
Due to the different temperatures of the inner casing relative to the
outer casing, the inner casing is attached to the outer casing in such a
manner as to be free to expand axially from a fixed point (Ref. Fig. 4) and
radially in all directions, while maintaining the concentricity of the inner
casing relative to the shaft. The steam inlet connections and the extraction
connections are designed to avoid any restrictions due to thermal
expansion. The inner casing is attached to the outer casing in the horizontal
and vertical planes.
3.1.11 Blading And Sealing Arrangements:
The IP cylinder consists of 20 double flow reaction stages (drum
stages). All the moving and stationary blades are provided with T roots
except for the rear stationery blades which are equipped with hook type
roots with filler pieces. Sealing strips are caulked into the inner casing and
the shaft to reduce leakage losses at the blade tips.
The function of the shaft seals is to seal the interior of the turbine
casing against the atmosphere at the front (thrust bearing end) and rear of
the IP cylinder. The sealing between the rotating and stationary elements is
achieved by means of seal strips, which are caulked into the individual
sealing rings and in to the shaft.
There are steam spaces within the shaft seals. Leakage steam arising
is conducted into the steam seal header. Any small amounts of leakage
steam that still pass the neighboring sealing ring is drawn into the seal steam
condenser from another space.
3.1.12. Arrangement Of IP Rear Bearing Pedestal:
This bearing pedestal (Ref. Fig. 10) is situated between IP and LP
cylinders. Its function is to support the turbine casing and bear the IP and LP
rotors.
The bearing pedestal contains a journal bearing, the hydraulic shaft
turning gear and the manual barring gear.
78
The exhaust from the IP cylinder is taken from eight points, four in the
top and four in the bottom. In the top, the pipeline from left rear is coming
to the front and joins as a T with the pipeline from the left front. A similar
arrangement exists for the left bottom. The left top and bottom pipelines join
together as a Y piece arrangement and the common pipeline goes to the
left middle of the LP cylinder. Same type of arrangement is there for the
right side. Since these pipelines embrance the IP and LP cylinders, they are
called as cross around pipes.
Extraction no: 5 meant for High pressure Heater no: 5 is taken after the
11
th
stage of the IP cylinder (after 36
th
stage of the turbine) at 4 points, 2 in
the top and 2 in the bottom which join together and go as a single pipeline.
Extraction no: 4 meant for Deaerator (Heater no: 4) is taken from the
cross around pipes i.e., after 45 stages of the turbine. As such out of the
three extractions seen so far, only one has been taken from the IP cylinder,
the other two are taken from the exhausts of the HP and IP cylinders. This
makes the turbine arrangement less complicated.
Extraction no: 4 to Deaerator is taken from the two pipe lines which
start from the bottom rear left and right exhaust points of the IP cylinder but
before they join with the pipelines taken from the bottom front left and right
exhaust points. The two lines join together and go as a single line to the
Deaerator.
3.1.13 LP Cylinder:
The LP cylinder (Ref Fig. 11) is of double flow pattern, which serves the
purpose of axial thrust compensation similar to that of the IP cylinder. Apart
from that the double flow pattern reduces the tip diameter of the last stage
moving blades and consequently the tip velocity by reducing the area of
flow. This prevents the flying off of last stage blades due the large
centrifugal force created. It has eight double flow stages.
It has a triple shell welded casing consisting of inner shell, outer shell
and outer casing. The outer casing consists of the front and rear walls, the
two lateral longitudinal support beams in the bottom and the upper part.
79
The front and rear walls, as well as the connection areas of the upper part
are reinforced by means of two circular box beams. The outer casing is
supported by the ends of the longitudinal beams on the base plates of the
foundation.
3.1.14 Steam Admission:
Steam admitted to the LP cylinder from the IP cylinder flows into the
inner casing from both sides through steam inlet nozzles before the LP
blading. Expansion joints are installed in the steam piping to prevent any
undesirable deformation of the casings due to thermal expansion of the
steam piping.
3.1.15 Inner Casing:
The double flow inner casing, which is of double shell construction,
consists of the outer shell and the inner shell. The inner shell is attached to
the outer shell with provision for free thermal movements. The inner casing
carries stationary blading. The stationary blade holding semi-circular
segments of the last three stages are bolted to the outer shell of the inner
casing. The inner shell carries the stationary blading of the first five stages.
The complete inner casing is supported by the longitudinal support
members pf the outer casing, lower half, in a manner permitting free radial
expansion concentric with the shaft and axially from a fixed point.
3.1.16 Support And Centering Of The Outer Casing:
The outer casing of the LP cylinder is carried on the side members
which rest on plates grouted to the foundation along side the turbine.
3.1.17 Atmospheric Relief Diaphragms:
Two atmospheric relief diaphragms are provided one in the left front
and the other in the right rear of the upper part of the LP cylinder outer
casing to protect the LP cylinder against excessive pressure. In the event of
failure of the low vacuum trips, the pressure n the LP cylinder exhaust rises to
an excessively high level until the force acting on the disc ruptures the
breakable diaphragm thus providing a discharge path for the steam. The
80
diaphragm is made of a thing rolled lead plate. To ensure that the rupturing
disc and diaphragm are not carried away by the blow off steam, a cage
with brackets is provided. As long as there is vacuum in the condenser, the
atmospheric pressure forces the breakable diaphragm and the rupturing
against the supporting flange. The breakable diaphragm is placed over the
rupturing disc. Bursting pressure is 1.2 ata.
3.1.18 LP Cylinder: First Five Stages:
The stationary blades are located in the inner shell of the inner casing.
They have T-roots fitted in the inner casing in grooves meant for them by
caulking material. The moving +blades are secured in the same way, and
also have T-roots. Extraction No.3 meant for LP heater No.3 is taken after the
3
rd
stage of the LP cylinder. i.e. after 48 stages of the turbine. A single pipe
goes to LP heater No.3. Extraction No.2 meant for LP heater No.2 is taken
after 5
th
stage of LP turbine i.e. after 50 stages of the turbine, which after the
inner shell, and is also a single pipe.
3.1.19 LP Cylinder Last Three Stages:
The stationary blade rows of the last three stages (Ref. Fig. 12) are
made into two semicircular segments by welding the inner rings blades and
outer rings together and bolting them to the inner casing. The last two
stationary rows consist of hollow blades. Slots are provided in the surfaces of
the last stage stationary blades and through these slots any water passing
over the surface of the blades may be drawn away to the condenser. In
this way, erosion and pitting of the last stage moving blades due to moisture
is reduced considerably. Moving blades with curved fir-tree roots are fixed
in the axial grooves of the turbine shaft by means of spring keys. In order to
reduce blade tip losses at the stationary blades, sealing strips are caulked
into the turbine shaft.
Extraction No.1 meant for LP heater No.1 is taken off after the 7
th

stage of the LP cylinder i.e. after 52 stages of the turbine via 4 pipes, which
join together and go as a single pipe. Three extractions are taken in total
81
from LP cylinder for the better utilization of latent heat of low-pressure
steam, which promotes cycle efficiency.
3.1.20 Shaft Seals:
The function of the axial shaft seals situated between the bearing
casings and the LP exhaust casing is to seal the inner space of the LP
exhaust casing against atmospheric pressure at the passages through the
shaft. The seals are of labyrinth type.
3.1.21 LP Rear Bearing Pedestal: (Ref. Fig. 13)
The bearing pedestal is situated between LP cylinder and generator.
Its function is to bear the LP and generator rotors. It has a journal bearing.
3.1.22 Provisions For Thermal Expansions:
In designing the supports for the turbine on the foundation, attention
is given to the expansion and contraction of the machine during thermal
cycling. Excessive stresses would be caused in the components if the
thermal expansion or contraction were restricted in any way. The method of
attachment of the machine components and their coupling together are
also decisive factors in determining the magnitude of the relative axial
expansion between the rotor system and turbine casings, which are given
careful attention when determining the internal clearances in the design.
3.1.23 Fixed Points Of The Turbine: (Ref. Fig. 4)
i) The bearing housing between IP and LP cylinders.
ii) The rear bearing housing of the LP cylinder
iii) The longitudinal beam of the LP cylinder
iv) The thrust bearing in rear bearing housing of the HP cylinder
3.1.24 Casing Expansion:
The front and rear bearing housings of the HP cylinder can slide on
their base plates in an axial direction. Any lateral movement perpendicular
to the machine axis is prevented by fitted keys. The bearing housings are
connected to the HP and IP cylinder casings by guides which ensure that
the cylinder casings maintain their central position while at the same time
82
allowing axial movement. Thus the origin of the cumulative expansion of the
casings is at the front bearing housing of the LP cylinder.
The casing of the LP cylinder is located axially in the centre area of
the longitudinal beam by fitted keys cast in the foundation. Free lateral
expansion is allowed. The centre guides for this casing are recessed in the
foundation cross beams. There is no restriction on axial movement of the
casings.
Hence, when there is a temperature rise, the outer casing of the LP
cylinder expands from its fixed point. Differences in expansion between the
outer casing and the fixed bearing housings to which the housings for the
shaft glands are attached are taken up by the bellows expansion joints.
3.1.25 Rotor Expansion:
The thrust bearing is incorporated in the rear bearing housing of the
HP cylinder. Since this bearing housing is free to slide on the base plate, the
shafting system moves with it. Seen from this point, both the rotor and
casing of the HP cylinder expand towards the front bearing housing of the
HP cylinder. The rotor and the casing of the IP cylinder expand towards the
generator in a similar manner.
The LP cylinder rotor is displaced towards the generator by the
expansion of the shafting system from the thrust bearing. The magnitude of
this displacement however is reduced by the amount by which the thrust
bearing is moved in the opposite direction by the casing expansion of the IP
cylinder.
3.1.26 Differential Expansion:
Differential expansion between the rotors and casings results from the
difference between the casing expansion originating from the bearing
housing behind the IP cylinder and that of the rotor from the thrust bearing.
This means that the maximum differential expansion of the HP and IP
cylinders occurs at the end, farthest from the thrust bearing.
Differential expansion between the rotor and casing of the LP cylinder
results from the difference between the expansion of the shafting system,
83
originating from the thrust bearing and the casing expansion originating
from the fixed point of the LP casing on the longitudinal girder.
3.1.27 Technical Data:
I. Thermal Data (AT 100% MCR): Data From The Heat Balance Diagram Of
BHEL:
S.No Description
Pressure
ata
Temp.
Deg C
Enthalpy
Kcal/kg
Flow
T/hr
1 Saturated steam from Boiler
drum
167.2 343.7
(water)
378.6
(water)
637.759
2 Superheated steam after
SH3
158 540 815.2 637.759
3 Superheated steam before
MS stop
cum control valves
150 535 814.7 637.759
4 Cold reheat steam to
reheater
38.135 341.6 735.7 572.472
5 Reheater inlet 37.95 339 732.4 572.472
6 Reheater outlet 36.35 540 845.8 572.472
7 HRH steam before reheat
stop cum
Control valve
34.228 535 843.3 572.472
8 Steam to LP turbine 7.2058 319.4 740.5 506.136
9 Exhaust steam to
condenser
(y = 0.0664)
0.1033 46.1 579.5 445.331
10 Main condensate after CEP 20.232 46.3 46.7 511.142
11 Main condensate after
LPH: 3
8.5349 120.6 121.3 511.142
12 Feed water at Deaerator 6.5349 161.4 162.8 637.969
13 Feed water after BFP 186.348 164.7 168.6 637.969
14 Feed water after HPH: 6 184.632 243.6 252.4 637.759
84
15 Feed water before
Economiser
171.85 241 249.4 637.759
16 Feed water after
Economiser
168.35 310 332 637.759
17 a. TG heat rate at 0.1033 ata back pressure, 3% make up including
2.5 % non-recoverable auxiliary steam for 100% MCR condition at
cooling water inlet temp at 34 deg and DM water inlet temperature
38 degC = 2008.8 kcal/kw-hr
b. TG heat rate with 0% make up at 100% MCR and 0.1033 ata
condenser pressure = 1998.9 kcal/kw-hr
Note: 1. Super heater desuperheaters spray = 43.02 t/hr
2. Reheater desuperheaters spray = 4.6 t/hr
3. Auxiliary steam requirement = 23 t/hr
These are not included in the data.
If auxiliary steam is included, steam flow is = 650 t/hr
18 No of stages in each cylinder HP 25
IP 20 (double flow)
LP 8 (double flow)
Total - 53



85
3.1.A OIL SUPPLY SYSTEM: (Ref. Fig.15)
The oil system fulfills the following functions:
a) Lubricating and cooling the bearings.
b) Driving the hydraulic turning gear during interruptions to
operation, on start-up and shut-down (1).
c) Jacking up the shaft at low speeds (turning gear operation,
start-up and shut-down).
3.1.A.1 Oil System:
Under normal operating conditions, the main oil pump (1) situated in
Front bearing pedestal and coupled directly to the turbine shaft draws oil
from the main oil tank (22) and supplied it to the pressure oil system.
The suction of the main oil pump is aided by two injectors. The
injectors produce pressure at the suction connection to the main oil pump.
This guarantees that the main oil pump takes over the supply of oil and
cavitations that could occur due to greater suction heads are avoided.
The amount of oil required for driving is extracted from the pressure oil
circuit and adjusted by means of the throttles. (31, 32).
The oil for the turning gear (6) is also extracted from the pressure oil
system. Oil is admitted to the nozzles by opening the shut-off valve (16).
The pressure oil is cooled in the oil coolers (30) and reduced to
lubricating oil pressure in the throttle (28). The throttle is adjusted on initial
start-up.
The amount of oil required for each bearing is adjusted on start-up by
means of the oil throttles (13).
3.1.A.2 Full-Load Auxiliary Oil Pumps :
During turning gear operation and start-up and run-down operation,
one of the two three-phase a.c. full-load auxiliary oil pumps (24, 25) supplies
the pressure oil system and takes over the function of the main oil pump
when it is not in operation because the turbine is running too slowly.
The full-load submersible auxiliary oil pumps are situated on the main
oil tank (22) and draw in oil directly. Check valves behind the auxiliary oil
86
pumps and in the suction line of the main oil pump prevent oil from flowing
back via pumps that are not in operation.
3.1.A.3 Emergency Oil Pump :
When main and full-load auxiliary oil pumps fail, the lubrication oil
supply is maintained by a D.C. driven emergency oil pump (26). This pump
supplies oil directly to the lubricating oil line, bypassing the oil cooler and
thus preventing damage to the bearing shells.
3.1.A.4 Control of the Auxiliary Oil Pumps :
The full-load auxiliary oil pumps and the emergency oil pump are
automatically started control as soon as the pressure switch limit has been
reached. The pressure switches are set in sequence so that the pumps can
be started in succession if necessary.
3.1.A.5 Turbine Trip:
The function of the pressure switches arranged in the lube oil circuit is
to operate the main trip valve when the lube oil pressure drops below a set
value.
3.1.A.6 Oil Return System:
The lubricating oil from the bearings is returned to the main oil tank
via a header. A loop in the return oil piping behind the seal oil reserve tank
(15) prevents H2 Gas reaching the main oil tank (22) when there is a
disturbance in the seal oil system.
3.1.A.7 Extraction Of Oil Vapour :
The main oil tank is designed to be airtight. The extractors (18)
produce a slight vacuum in the main oil tank and the bearing pedestals to
draw off any oil vapour.
3.1.A.8 Duplex Filter:
Oil for the combined journal and thrust bearing is passed through the
duplex oil filter (17), which can be switched over and cleaned during
operation.

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3.1.A.9 MAIN OIL TANK (Ref. Fig. 16)
A) Function:
The main oil tank contains the oil required for lubricating and control
systems of the turbine. It not only serves as a storage tank but also for de-
aerating the oil.
The capacity of the tank is such that the full quantity of oil is
circulated not more than 8 times per hour. This results in a retention time of
approx. 7 to 8 minutes from entry in to the tank to suction by the pumps.
This time allows sedimentation and detrainment of the oil.
B) Flow In Tank :
Oil returning to the tank from the oil supply system first flows through a
submerged inlet (9) in to the riser section of the tank where the first stage of
de-aeration takes place as the oil rises to the top of the tank. Oil overflows
from the riser section through the oil strainer (6) in to the adjacent section of
the tank where it is then drawn off on the opposite side by the suction pipe
or the oil pumps.
C) Oil Pumps:
The main oil pump draws the oil through a suction pipe (1) situated at
the flow end of the tank (1). This suction pipe is constructed as an injector
to aid the suction of the main oil pump, which has to overcome a certain
suction head. Pressure oil is conducted to the injector via an injection pipe.
This injection pipe also fills the suction pipe of the main oil pump with oil
when the plant is being started up.
The auxiliary oil pumps (2, 3) and emergency oil pump (4) arranged
on the tank are electrically driven rotary oil pumps (2). The lifting oil
pumps (5) also situated on the tank are electrically driven jack-screw
immersion pumps (3). All pumps immerse in the oil contained in the tank
and draw oil from the deepest point in order to obtain oil as free of air as
possible driving elements of the pumps are fixed to the base plates of the
tank cover.
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D) Oil Strainer:
The basket type oil strainer (6) is mounted in the tank. It is of stainless
steel wire mesh of 0.25mm filtration particle size and can be exchanged by
opening the tank cover (12).
E) Oil Vapour Exhaust:
The whole tank is made as airtight as possible. Oil vapour exhausters
(13) produce a slight negative pressure in the tank, in the return drain lines
and in the spaces in the bearing pedestals so that oil vapour arising is
drawn off (4).
F) Oil Level Indicator:
The main oil tank has a direct reading fluid level indicator (5) and a
fluid limit switch (6). This permits signals to be transmitted when maximum
and minimum levels have been reached. Extra tank volume is provided
between the normal operating level and the tank cover to accept oil from
the entire oil supply system when the turbine is shut down. The tank is
constructed with a sloping bottom with drain connections at the lowest
point (7, 8).
3.1.A.10. AUXILIARY OIL PUMP (Ref. Fig.17)
A. Description:
The auxiliary oil pump is a vertical one-stage rotary pump with a radial
impeller and spiral casing. It is fixed to the cover of the oil tank and
submerges in to the oil with the pump body. It is driven by an electric motor
that is bolted to the cover plate (1). The oil enters the suction connection
from underneath and is supplied to the oil system via the pressure pipe (18).
The pump shaft has a sleeve bearing (12) in the pump casing and a
grooved ball bearing (7) in the bearing yoke. The bearings are lubricated
from the pressure chamber of the pump; the sleeve bearing via a bore in
the casing; the grooved ball bearing via a lube line.


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3.1.A.11. JACKING OIL PUMP (Ref. Fig.18)
A. Function:
The jacking oil pump is a self-priming screw-spindle pump with three
spindles and internal bearings. The pump supplies the jacking oil that is
needed for lifting the shafting at low speeds.
B. Construction, Mode Of Operation:
The screw-spindle pump is connected vertically to the cover plate (2)
of the main oil tank via a support (5) and immerses with the suction
casing (15) in to the oil. The drive is an electric motor that is bolted to the
cover plate (2). The oil flows in to the suction branch of the suction casing
(15) from underneath and is supplied to the lifting oil system by the pump
via the pressure pipe (3).
The driving spindle (16) and the two moving spindles (20) run in the
inner casing (13). The fluid pressure to which the spindle thread is subjected
on the pressure side is compensated by the driving spindle by means of the
balancing (11). With the hollow moving spindles, the axial thrust is
compensated by the balancing pistons arranged on the suction side, which
run in the balancing bushings (21).
The throttle bushing (11) and the driving spindle (16) form a throttling
gap that separates the pressure area from the following area. The oil that
leaves the throttle gap, flows via the grooved ball bearing (7) in to the
support and from there back in to the main oil tank. The grooved ball
bearing is lubricated with this oil. The driving spindle is fixed by means of the
grooved ball bearing in the bearing carrier (9) that is bolted to the pressure
casing (12) of the pump.
Due to the special profile given by the sides of the threads the three
spindles form sealed chambers, the contents of which are continuously
being moved axially from the suction side to the pressure side of the pump
as the spindles rotate.

90
3.1.A.12. D.C. EMERGENCY OIL PUMP (Ref. Fig.19)
A. Function:
The emergency oil pump is of the vertical, centrifugal, submerged
type and serves for lubrication and cooling of the bearings during
emergency conditions.
B. Location:
The unit is located on top of the main oil tank and driven by a D.C.
motor. The complete pump motor assembly is attached to mounting
plate (1), which is bolted to the top of the main oil tank.
C. Construction:
Oil is delivered by impeller (15) via the intake (140 to volute (13) from
where the oil flows through discharge pipe (18) to the oil supply system.
The vertical pump shaft (9) is connected to the motor shaft by a
flexible coupling equipped with rubber sleeved coupled studs. The radial
ball bearing (7) carries the downward thrust load of the pump and with the
lower babbited sleeve bearing (12) guides the shaft. The lower sleeve
bearing is mounted in volute (13). Pressure lubrication is provided to both
bearings. The lower bearing is supplied with oil through a drilled oil passage
from the discharge side of the pump. The upper bearing is oil fed by pipe
(10), which connects to the pump discharge. Seal rings. (17) form a seal
between the impeller suction and the pump discharge.
3.1.A.13. MAIN OIL PUMP (Ref. Fig.20)
A. Function:
The main oil pump is situated in the front bearing pedestal and
supplies the entire turbine with oil that is used for bearing lubrication,
cooling the shaft journals and as control oil for the hydraulic governing
system. The main oil pump is driven direct from the turbine shaft (16) via the
coupling (17). If the turbo set is out of operation or the main oil pump fails,
the auxiliary oil pumps take over the necessary oil supply. These pumps also
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supply oil in the suction branches of the main oil pump until the main oil
pump takes over.
B. Construction:
The double flow impeller (7) is mounted on the pump shaft (20) by
means of the feather key (8) and fixed axially by the bearing busing (5) and
the spacer sleeve (21). The pressure and suction chambers are sealed off
from each other by sealing rings, which are split and secured against
turning at the joint. The pump shaft (20) runs in the journal bearing (3) and
the combined journal and thrust bearing (10). Both bearings are lubricated
from the pressure chamber of the main oil pump via the oil lines (4, 15). If
the over speed trip test device, which is described separately, is actuated,
over speed trip test oil a flows to the over speed trip device via the oil
tube (23) installed in the pump shaft (20).
C. Hydraulic Speed Transmitter:
The pump shaft (20) also carries the hydraulic speed transmitter (14),
which runs, in the bearing (10) and in rings (11). The hydraulic speed
transmitter operates on the same principle as a centrifugal pump impeller.
The variation of the pressure in the primary oil circuit a1, due to a speed
variation, serves as a control impulse for the hydraulic speed governor. The
hydraulic speed transmitter (14) is supplied with control oil supplied from the
hydraulic control equipment rack via the oil supply reservoir (13). An
annular groove in the speed transmitter ensures that its inside is always
covered with a thin layer of oil to maintain a uniform initial pressure. Excess
oil drains in to the bearing pedestal.
D. Electrical Speed Pick-Up :
A non-magnetic disc of the electrical speed transmitter (18), in which
small magnets are inserted around the circumference, gives impulses to the
electrical speed pick-up. When the disc rotates with the pump running, an
electrical current arises due to the alternating effect between the magnets
and the Hail generators, which are not visible here. This current is forwarded
as a signal to the electrical speed pick-up.
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3.1.A.14. TURBINE OIL COOLER (Ref. Fig.21)
A. Function:
The Oil Coolers (2 X 100%) have been provided in the lube oil system
for cooling the oil used for lubrication and cooling of turbine bearings.
B. Design And Mode Of Operation:
Essentially, the oil cooler consists of a tube nest 6, inner and outer
shells 7, 10, lower water box and upper water box. The tube nest through
which cooling water flows is surrounded by the oil space formed by the
outer shall 10. The oil to be cooled enters the outer shell at inlet nozzle 16
and flows in to the inner shell 7. The shell supports the large baffles 8 which
are provided with an opening in the center. Between every two large
baffles there is a small baffle plate 9 held and supported by short tubes 12
placed in steel rods 11. The intermediate plates are smaller in diameter
than the inner shell 7 and thus leave an annular gap. This arrangement
serves to achieve a cross flow pattern forcing the oil flowing towards outlet
to flow through the middle of large baffles and over the edge of the smaller
baffles and increases the heat transfer rate. The inner shell and the large
baffles are supported on the lower tube plate 14; in to which admiralty
brass tubes (16x1) 17 are expanded.
The cooling water enters and leaves through the lower water box
which is divided by a partition plate so as to force water through one half of
the tube system to the upper water box 1 and from the there through
other half back to lower water box. Closed end tubes are arranged in tube
system in line with the partition plate to avoid oil bypassing.
C. Monitoring:
Inlet and outlet branches of water box are provided with
thermometers. When filling in oil, open the vent valve 2. For draining the
shell, drain valve 19 is provided. The cooling water flow is adjusted
throughout to get the desired oil outlet temperature. If the oil outlet
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temperature is high even with maximum CW flow, the oil cooler should be
cleaned.
3.1.A.15. THREE-WAY CONTROL VALVE (Ref. Fig.22)
A. Function:
The three-way control valve is electrically driven and has the function
of regulating the lubricating oil temperature at 45
0
C.
Possible oil flow paths for regulating the oil temperature:
All lubricating oil flows through oil cooler.
Lubricating oil flows through oil cooler and by-pass piping.
All lubricating oil flows through the by-pass piping.
B. Construction Of Valve:
The casing (17) is sealed by the cover (14) by means of a bolted
connection. The cover bears the lower part of the valve cover (9). The
bearing (5) of the threaded nut (3) is approx. at the level of the joint
between lower and upper (2) valve support.
At this point the torque caused by the actuator is converted in to an
axial thrust by the buttress thread. The actuator itself can be easily
assembled and this can thus be carried out in the works or one site: the
end shaft with fitted key is carefully inserted in the insertion bore on the
valve flange tightened. The valve stem (6) is protected against rotation by
the pointer (8). With full valve lift, the limiting disc (7) runs against the lower
part of the valve support and sets off the actuator switch, which is
dependent on the torque. The opposite limit position (closing end position)
is reached when the throttle body (16) comes against the seat (18).
The cup spring (4) inserted above the upper ball bearing causes the
throttle body to rest lightly against the seat and also provides a balance to
the axial thermal stresses.
The valve stem is sealed with a gland packing (12). The throttle is
guided from one side and has a linear characteristic.

94
3.1.B.0 TURBINE STOP AND CONTROL VALVES:
3.1.B.1 Main Stop And Control Valve: (Ref. Fig.23)
A. Function, Arrangement:
The main stop and control valve are combined in a common body.
The main stop valve is provided as the main check valve between the
steam circuit and the turbine and can interrupt the supply of steam to the
turbine extremely quickly. The function of the control valve is to control the
amount of steam admitted to the turbine in accordance with the load
requirement of the unit.
B. Main Stop Valves :
Steam enters the valve casing (14) via the inlet connections above
the main stop valve disc (2). A pilot valve, integral with the valve s tem
(10), operates inside the main stop valve disc. Packing rings (6) seal the
valve stem where it passes through the valve body. The valve disc has a
back seating arrangement, which is forced against the base bushing (3)
and when the valve is fully opened forms the seat at this point. This also
provides additional sealing for the passage of the stem. Stem and valve
disc are prevented from rotating. The valve body (4) is secured in the valve
casing (14) by means of the threaded ring (8). The sealing gasket is U-
section ring (5), the legs of which are flexibly expanded by steam pressure
and forced against the associated sealing faces of the casing. The main
stop valve is opened hydraulically by servomotor (13) and closed by spring
force (1).
C. Testing The Stop Valves :
Each main stop valve must be checked for correct operation at
regular intervals. A test valve is provided for this purpose (2).
D. Control Valve :
The control valve disc is integral with the stem (17). The effort
required to open the valve is reduced by relief holes in the valve disc.
Valve disc and stem (17) are guided by bushings in the valve body (18), the
95
stem being sealed by packing rings (21). Additional sealing is provided by
the back seating arrangement of the valve disc which lies against the base
bushing (20) when the valve is wide open. As with the stop valve, the valve
body (18) is secured in the valve casing (14) by a threaded ring (23) and
sealed by the U-shaped seal ring (22). The control valve is operated by the
piston of the actuator (29), which is opened hydraulically and closed by
spring force (3).
3.1.B.2 COMBINED REHEAT STOP AND CONTROL VALVES :
(Ref. Fig.24)
A. Function and Construction :
One stop and one control valve are combined in a common body
with their stems arranged at right angles to each other. The stop valve can
interrupt the supply of steam from the reheater to the IP and LP turbines
extremely quickly. The control valve controls the steam flow to the IP and LP
turbines on load rejection, start-up and shut-down and remains fully open in
the upper load range to eliminate any throttling losses.
B. Reheat Stop Valve :
The stop valve is a single seat valve with integral pilot valve. Steam
enters via the inlet of the valve body (1) and remains above the valve disc
(4) when the stop valve is closed. A pilot valve, integral with the valve stem
(6) is provided for relieving, thereby reducing the force necessary for
opening. The valve disc (4) slides in the bushing of the valve cover (5)
and has a bead on the back which lies against the base bushing (7) and
provides additional sealing at this point. Metal packing rings (8) seal the
valve stem. Both stem and valve disc are prevented from rotating. The
stop valve is opened hydraulically and closed by spring force (1).
C. Testing Stop Valves:
Each stop valve must be checked for correct operation at regular
intervals. A test valve is provided for this purpose (2).

96
D. Control Valve :
The control valve has a pipe-shaped valve disc (14) that is bolted to
the valve stem (16) and slides in the bushing in the valve cover (18). The
valve disc is provided with relieving holes to reduce the necessary
controlling forces. A ring fixed in the bushing of the valve cover prevents
the valve disc from rotating. This valve disc also has a back sealing that
operates when the valve is fully open. Packing rings (17) seal the valve
stem (16) in the valve cover (18). The control valve is operated by the
piston of the servomotor (20) ie. it is opened hydraulically and closed by
cup springs (30.
In the event of a disturbance in the system or on trip out, both stop
valve and control valve close rapidly.
3.1.B.3 SERVOMOTOR FOR MAIN STOP VALVES AND REHEAT STOP
VALVES
The operative part of the servomotor consists of a two part piston the
lower disc-shaped part of which is connected via piston rod to the vale
stem. The other part of the piston is bell-shaped and moves within the
housing which is in the form of a cylinder. Two spiral springs are placed
between the two halves of the piston; at the lower end a spring plate is
interposed between the springs and the piston disc. When trip fluid is
admitted to the space above the bell-shaped part of the piston, it moves
this half of the piston downwards, compressing the springs, until it seats
against the piston disc.
After the main stop valves have been opened, the turbine is started
by the control valves. Before the main stop valves can be opened,
however, they must be pressurized, i.e., prepared for opening, by
admitting trip fluid from the trip fluid circuit to the space above the piston to
press it down against the piston disc after overcoming the resistance of the
springs. The edge of the bell-shaped half of the piston is designed to
produce a fluid-tight seal with the piston disc.
97
To open the valve, fluid from the trio circuit is admitted to the space
below the piston disc and, simultaneously, the space above the bell-
shaped half of the piston is opened to drain. This causes both halves of the
piston to move together in the direction, which opens the valve. In order to
reduce fluid leakage past the bell-shaped part of the piston when the valve
is open, a back seat is provided in the housing against which the collar of
the piston can seat.
When the valve is tripped, the pressure in the trip fluid circuit, and
hence in the space below the piston disc, falls, with the result that the
springs separate the two halves of the piston and the piston disc connected
to the valve stem moves to close the valve. Just before the valve disc
seats, the piston disc enters a part of the cylinder where the diametric
clearance is reduced. This arrangement restricts the flow of fluid past the
piston disc and so produces a braking action, which cause the valve disc to
seat gently.
All fluid connections are routed through a test valve. All operations
can be controlled by means of the test valve and the starting and main trip
valve.
3.1.B.4 HP CONTROL VALVE SERVOMOTOR (Ref. Fig.25)
The flow of steam to the turbine is regulated by varying the lift of the
control valve by means of its servomotor.
The control valve is actually moved by the piston (2), which is loaded,
on one side by the disc springs (3) and on the other side by hydraulic
pressure. The position of the valve is determined by the secondary fluid
pressure, which is controlled by the governor. The supply of secondary fluid
(connection b) controls the pilot valve (8) so that when the valve is being
opened, oil at approximately 9 bar from connection a is directed to the
underside of piston (2). When the valve is being closed, fluid drains through
the pilot valve.


98
A. Opening Procedure:
When the turbine is running and the valve is steady at any particular
value of lift, the pilot valve (8) will be in the center position shown in the
drawing. In this position the force exerted by the spring (5) and the
secondary fluid pressure action on the pilot valve are in equilibrium.
When the governor raises the secondary fluid pressure to open the
control valve, the pilot valve (8) is lifted. Control fluid from connection a
can flow in to the upper annulus e of the valve bushing (9) and though a
duct in the casing on the underside of the piston (2), causing the valve to
open. The movement of the piston thus directs the depressurized fluid on
the spring side of the piston into the annulus d of the valve bushing (9)
and further in to the drain above it. The straight feed back cam (7)
mounted at the end of the servomotor piston rod (1) returns the pilot valve
(8) to its center position by means of a lever system (4) and spring (5) and
checks the flow of control fluid from connection a.
B. Closing Procedure :
On a reduction in the secondary fluid pressure, the pilot valve is
forced downwards by the spring (5), thus connecting the space on the
underside of the piston with the intermediate flow back of the valve
bushing (9) via the upper annulus (e). The spring (3) can now close the
valve. On a greater reduction in secondary fluid pressure, the pilot vale
moves so far downwards that the fluid can flow back via the lower annulus
e - which is connected to the upper space e thus accelerating the
closing the closing of the valve.
On a sharp drop in the secondary fluid pressure (e.g. load decrease
or tripping) the pilot valve goes to its lowest position. This separates annulus
d from the flow back and at the same time allows control fluid to flow
from connection a through the annulus on the spring side of the piston.
This additional closing force aids the spring force and ensures a proper
closing of the control valve even if abnormal frictional forces arise in the
valve system.
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C. Rotation And Oscillation Of The Pilot Valve :
The pilot valve (8) is continuously rotated by the action of fluid issuing
from tangential drillings in a disc mounted on its spindle in order to ensure
that the valve moves freely.
In addition, a little secondary fluid flows through a small bore in the
lower part of the valve with each revolution. The slight control impulses thus
caused keep the pilot valve constantly oscillating; thus increasing still further
the sensitivity.
3.1.B.5 IP CONTROL VALVE SERVOMOTOR : (Ref. Fig.26)
A. Function:
The purpose of the control valve servomotor is to adjust the lift of the
control valve so the main steam flow corresponds to the desired generator
output.
B. Construction, Mode Of Operation :
The control valve servomotor consists essentially of the pilot valve (26),
piston (3), and the fed back mechanism (15, 19, 37 & 21).
The control valve lift is determined by the position of piston (3), which
is controlled by pilot valve (26). Secondary oil is supplied through
connection b to the pilot valve at a pressure, which is adjusted by the
governor in proportion to the desired steam flow. This oil pressure acts on
the bottom side of the pilot valve (26), which slides in valve sleeve (25). If,
when the turbine is running, the control valve has assumed any amount of
opening under steady-state conditions, pilot valve (26) is in the central
position as shown. The secondary oil pressure below the piston is opposed
by the weight of the pilot valve and the force of spring (39). When the
governor, by increasing the secondary oil pressure, gives a control pulse to
increase the amount of opening of the control valve, the pilot valve (26) is
forced upwards. Through connection a, control oil will then flow via
connection e to the space below piston (3) resulting in the piston moving
in the opening direction against the force of springs (11) and the valve
100
opening force. The oil on the reverse side (spring side) of piston (3) is
discharged through the uncovered outlet port in the top annulus of the
valve sleeve (25) to drain c in cover (41).
The piston rod (2) is guided in bushings (8, 18) and is coupled with the
control valve stem. At one end, the follow-up cam (13) is attached to the
outer end of the piston rod by means of a hexagonal nut and locked to
prevent rotation. The follower (15) is pivoted in the bearing (16) and slides
on the follow-up cam (13). The outer end of follower (15) engages tappet
(19) and supports, through the floating lever (37), tappet (21), spring disc
(20) and spring (39). Under steady-state conditions, this mechanism returns
the pilot valve to its central position. Steady-state conditions are attained
when the piston position corresponds to a specific secondary oil pressure.
If the secondary oil pressure rises, pilot valve (26) is forced upwards
and spring (39) is compressed. Therefore, the piston is moved in the
opening direction, moving the follower (15) on the follow-up cam (13) in
such a way that the pilot valve (26) is restored to its central position via the
feedback mechanism. The initial tension of the spring (39) is therefore a
function of the secondary oil pressure.
If the secondary oil pressure is reduced, which corresponds to a
closing pulse for the control valve, the pilot valve is forced downwards by
spring (39), thus connecting the space below piston (3) via connection e
to the middle drain of valve sleeve (25). The pressure below piston (3)
moves in the closing direction due to the force of springs (11). The follower
(15) slides downwards, thereby reducing momentarily the initial tension of
spring (39) to such a degree that the secondary oil pressure restores the
pilot valve (26) to its central position.





101
3.1.c TURBINE PROTECTIVE DEVICES
3.1.c.A MAIN TRIP VALVES (Ref. fig.36)
3.1.c.A.1 FUNCTION
The function of the main trip valve is to open the trip oil circuit in
event of abnormal conditions, thereby closing the main and reheat stop
valves and thus shutting off the admission of steam to the turbine.
3.1.c.A.2 CONSTRUCTION
The assembly consists of the bodies (11,16,20), valve (14), rod (7) with
spring (18), and levers (3,4) with switches (1,21).
During normal operation, valve (14) is in the position illustrated. Its
lower section is designed as a differential piston and the resulting oil
pressure forces the crowned rim of the valve tightly against the body (16)
overcoming its own weight and the force of spring (18).
Pressure oil enters the body (11) through connection a. From there it
flows up through the annular passage to trip oil connection x and on to
the main and reheat stop valves. Via passages drilled in body (11), pressure
oil flows to auxiliary trip oil connection x1, which leads to the over speed
trip valve, the thrust bearing trip, and the vacuum trip.
3.1.c.A.3 OPERATION
If for any reason the oil pressure in the connected lines drops below a
specific value (by opening of the auxiliary trip oil circuit) valve (14) moves
downwards due to its own weight and the adjustable force of spring (18).
This connects x and x1 with drain connection c, thus depressurizing the
trip oil circuit which results in closing the main and reheat stop valves. Also,
the oil supply to the follow up pistons of the hydraulic speed governor is shut
off, therefore causing the main and reheat control valves to close.
The valve (14) can be depressed manually by means of lever (3), thus
opening the trip oil circuit.
When starting the unit, the auxiliary start up oil (connection u)
returns valve (14) to its upper operating position.
102
Limit switches (1,21) are provided to initiate electrical trip out signals
to the control room. Limit switch (1) operated upon a manual trip out and
switch (21) on a trip out caused by a collapse in pressure in the trip oil
circuit.
3.1.c.B SOLENOID VALVE FOR REMOTE OPERATION OF
MAIN TRIP VALVE (Ref. fig.37)
3.1.c.B.1 FUNCTION
The solenoid valve is installed in the pressure oil pipe to the main
trip valve and, when operated, interrupts the oil flow. This causes the
tripping oil circuit to be opened and the turbine to be stopped. The
solenoid valve is remote controlled electrically. E.g. from the control room
or from a protective device.
3.1.c.B.2 CONSTRUCTION
The valve body (15) has three connections:
Pressure oil inlet (20)
Oil to the main trip valve (13)
Oil drain (17)
The directions of flow are indicated by arrows on the body.
The valve seat (6) is inserted in three-way valve (7). A filter (24) for
the control oil is provided laterally. The complete valve element is inserted
in the body (15) from below and retained by the plug (16). The two valve
discs of the stem (12) seal the valve seats (14) alternately. The plug (16) also
serves as the lower guide of the stem.
3.1.c.B.3 OPERATION
When the solenoid (1) is not energized, the armature (30) is held
down by the spring (3), and the stem (8) seals the lower valve seat in the
three-way valve (7). When the valve seat (6)is open, the space between
the piston of stem (12) and the bushing (9) is linked with the oil drain via
pipe (11). The piston is forced upwards by the incoming pressure oil,
whereby the lower valve disc of the stem (12) comes in contact with the
103
lower valve seat (14) and closes the oil drain (17). The pressure oil can flow
to the main trip valve through connection (13).
The solenoid valve is operated by energizing the solenoid (1). The
armature (30) is attracted against the forced of the spring (3), and the valve
disc of the stem 980 is forced against the valve seat (6). Pressure oil can
now flow through the filter (24) into the space between the piston on the
stem (12) and the busing (9). The stem (12) is forced downwards, the upper
valve disc bearing down upon the upper valve seat. The connection (13) is
thus linked with the oil outlet, and the pressure in the pipe to the main trip
valve collapses.
3.1.c.C OVERSPEED TRIP (Ref. Fig.38)
3.1.c.C.2 FUNCTION AND CONSTRUCTION
The function of the over speed trip is tip stop the turbine when the
permissible speed is exceeded. It is fitted in the turbine rotor (7) and consists
of the eccentric bolt (4), the adjusting screw (6), the spring (5) and the
screw plug (4).
3.1.c.C.3 MODE OF OPERATION
The over speed trip mechanism is set by the adjusting screw (6). By
appropriate adjustment of the screw, the center of gravity of bolt (4) is
positioned eccentrically to the turbine shaft so that below the tripping
speed the bolt is held in the position shown, by the spring (5) against the
centrifugal force. In this position, the bolt bears against the screw plug (1). If
the turbine rotational speed exceeds the over speed setting, the centrifugal
force overcomes the force of the spring (5) and forces the bolt (4) out of
the turbine rotor. This activates the turbine trip mechanism.
3.1.c.D OVER SPEED TRIP DEVICE (Ref. Fig.39)
3.1.c.D.1 FUNCTION
The function of the over speed trip device is to open the auxiliary trip
oil circuit and thereby shutdown the turbine when an over speed is reached
which would subject the rotor to a dangerously high centrifugal force.

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3.1.c.D.2 CONSTRUCTION
The trip device situated in the front bearing pedestal (1) consists of a
valve body (5), pistons (4) and pawls (7). The spindles (2) resting against the
pistons (4) actuate the limit switches (10).
3.1.c.D.3 SHUTDOWN BY OVER SPEED TRIP
When the over speed trip operates the eccentric bolts fly out of the
shaft (9) thereby striking the pawls (7) and turning these against the force of
the springs (6). The latches of the pawls release the two pistons (4), which, in
turn, move towards the shaft (9) due to force of the auxiliary trip oil pressure
x and the spring-loaded spindles (2). This process opens the oil return line
c to the auxiliary trip oil x thus causing the turbine to be shut down
due to the drop in pressure.
3.1.c.D.4 ELECTRIC TRIP OUT SIGNAL
The spring-loaded spindles (2) rest against the pistons. On trip out
these spindles assist in moving the pistons inwards and actuate the limit
switches (10), which transmit an electric trip out signal to the control desk.
3.1.c.D.5 START UP
After the turbine has been tripped out, the trip device must be
latched in before the turbine is restarted. This is done by admitting auxiliary
start up oil u to the valve body (5) thereby forcing the respective piston
(4) outwards until it engages the latch of the pawl. The supply of oil is then
interrupted and the oil in the body drained via a bore into the bearing
pedestal (1).
3.1.c.D.6 TESTING OF OVER SPEED TRIPS
The proper functioning of the over speed trips is of the utmost
importance as severe damage may result from excessive speeds. The over
speed trip testing device, serves for checking the over speed trip bolts (8),
pistons (4) and spindles (2) and permits the over speed trip to be tested
without the turbine having to be shutdown.


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3.1.c.E THRUST BEARING TRIP DEVICE (Ref. Fig.40)
3.1.c.E.1 FUNCTION
In the event of axial displacement of the shaft due to excessive
wear of the thrust bearing pads, the function of the thrust bearing trip
device is to open the auxiliary trip oil circuit, thus shutting down the unit to
avoid damages (1).
3.1.c.E.2 CONSTRUCTION
The main parts of the trip device, situated in the bearing pedestal
(2), are the valve body (4), piston (3), pawl (6) and limit switch (10). On
start-up, the auxiliary start-up oil u moves the piston and pawl into the
latched position.
3.1.c.E.3 THRUST BEARING TRIP
When the shaft (5) becomes axially displaced, the pawl (6), which
is between the two cams on the turbine shaft, engages one of these cams.
The pawl (60, which is suspended to allow rotation, releases the piston (3)
which moves in the direction of the shaft (5) due to the force of the spring
(1) and the unbalanced auxiliary trip oil pressure. The auxiliary trip oil x is
thus connected to the oil drain c via bores in the valve body (4). The
resulting drop in pressure in the auxiliary trip oil circuit closes the turbine stop
valves and shuts down the unit. An electrical signal indicating trip-out due
to the action of the thrust bearing trip is transmitted to the control room by
the limit switch (10).
3.1.c.E.4 TEST DEVICE
It is of utmost importance for safe operation of the turbine-generator
that the thrust bearing trip is in proper working order at all times. It is
therefore essential that the device be tested at regular intervals. This is
done by admitting test oil to the space above piston (8) thru connection
a whereby pawl (6) is made to deflect against the force of spring (7). The
response of the thrust-bearing trip is thereby tested.


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3.1.c.F LOW VACUUM TRIP DEVICE (Ref. fig.41)
3.1.c.F.1 FUNCTION
The purpose of the low vacuum trip is to operate the main trip
valve when a failure of vacuum occurs in the condenser, thus tripping out
the main and reheat stop and control valves and shutting off the supply of
steam to the turbine within the shortest possible time (1).
3.1.c.F.2 OPERATION
The condenser vacuum is connected via. 1 (connection to
condenser) to the topside of the diaphragm (7). The space below the
diaphragm is at atmospheric pressure. Upon failure of the condenser to
maintain proper vacuum, diaphragm (7) is forced downwards by the
increase in pressure and the force of the spring (6) against the force of
spring (9), thus moving valve (8) downwards. This establishes a connection
between X1 (control fluid) and drain c so that the auxiliary trip fluid circuit is
depressurized and the main trip valve operates. Concurrently, valve (14)
actuates the limit switches (10), which initiates and alarm contact.
The range in which the vacuum safety device operates can be
varied by adjusting the initial tension of the spring (6) by means of the
adjusting screw (5).
In order to isolate the auxiliary trip fluid circuit during starting,
auxiliary pilot valve (8) is lifted by means of the spring (90 so that drain c is
shut off, thereby establishing pressure in the auxiliary trip fluid circuit when
no vacuum exists.
As primary oil pressure builds up with the increase in turbine speed,
piston (2) is forced into the lower position. This lower position is reached
when the speed is still far below the rated valve at which time the low
vacuum trip safety device is ready to operate.



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3.1.c.G Low Vacuum Condenser Protection (Ref. fig.42)
3.1.c.G.1 FUNCTION
The function of the condenser safety device situated in the control
fluid circuit of the bypass control system is to protect the condenser, when
there is an excessive increase in pressure in the condenser, by opening the
control fluid lines so that the resulting drop in pressure causes the bypass
valves to close (1).
3.1.c.G.2 MODE OF OPERATION
The steam space in the condenser is connected with the spring
space above the diaphragm (5) via connection l. The space below the
diaphragm is at atmospheric pressure. If the pressure in the condenser
increases excessively, the diaphragm (5), and thus the valve (6), is forced
downwards out of the upper end position by the increasing pressure and
the force of the spring (4). This shuts off the connection a1 to the bypass
valve from the connection a from the converter and connects it to
drain c.
The pressure range in which the vacuum safety device operates can
be varied by adjusting the initial tension of the spring (4) by means of the
adjusting screw (2).
During commissioning the valve (6) is automatically moved into the
upper end position, where it keeps the control fluid circuit closed, as soon as
the negative pressure in the condenser falls below the preset value. In order
to be able to close the control fluid circuit when there is still insufficient
vacuum in the condenser, the valve is lifted via the lever (10) and cam (9)
but is not yet brought into its upper end position. As already mentioned, this
end position is not reached until there is sufficient vacuum.
After this, the lever (10) and the cam (9) drop down and do not
impair the functioning of the vacuum safety device. Any leakage fluid can
drain off through passages in the valve sleeve (7) and the casing (8).


108
3.1.c.H PRESSURE SWITCH FOR INJECTION WATER (Ref. fig.43)
3.1.c.H.1 FUNCTION
The pressure switch monitors the injection water, when the injection
water pressure drops below the set rated value, the control fluid is
interrupted and thus the LP bypass valves closed (1)
3.1.c.H.2 CONSTRUCTION
The pressure switch consists of a casing in which a measuring system,
a counter-connected system for adjusting the rated value, a knife-edged
lever (4), a nozzle (11) and a slide valve (12), are installed.
The measuring system consists of bellows (2) upon which the injection
water pressure l acts and these influence the knife-edged lever (4) via a
pushrod (3). The cylindrical pin (10) is the picot point of knife-edge lever (4).
The compression spring (6), the tension of which is set to the appropriate
rated value, is provided as a counter force.
3.1.c.H.3 MODE OF OPERATION
The lever (4) diverts the fluid jet leaving the nozzle (11) so that there is
no fluid pressure above the piston surface of the slide valve (12). If the
pressure drops below the rated value, the lever allows the jet of fluid to
enter the bushing (13), which subjects the piston surface of the slide valve
(12) to fluid pressure. The slide valve is thus pushed downwards against the
force of the spring (14) into the shut-off position in which control fluid a2 is
connected to the return flow c. This process causes the signal fluid to be
cut off and thus the bypass valves to be closed.
If necessary, the knife-edged lever (4) can be fixed in its end position
by means of the lever (7).




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3.2 HP & LP B/P VALVES:
3.2.1 HP B/P VALVES:
1.0 Introduction:
When the demand for electricity has continued to rise by
phenomenal magnitudes, leading to the design and adoption of units of
very high capacity year after year. Flexibility in the operation of different
equipment of the unit ensuring maximum reliability, with reduction of
downtime on shut down or tripping, has been the focal point in the
evolution of new technology in all facets of Thermal Power Generation. HP
and LP Bypass systems were introduced for achieving flexibility and reliability
in operation. For the four 210 MW units of Thermal Power Station II (Stage II),
the HP and LP Bypass systems were supplied by M/S.BHEL Ltd.
2.0 Necessity Of HP/LP Bypass Systems:
The occasions during which the HP and LP Bypass systems have to be
effective operation are as given below:
1) Cold Start Up
2) Hot Start Up
3) Load Rejection
4) Load Throw off
5) Quick Shutdown of Turbine
6) Tripping of Turbo generator
In addition, HP Bypass System will come into service whenever there is
an impermissible rise in the main steam pressure and LP bypass system will
come into service whenever there is an impermissible rise in Hot Reheat
Steam Pressure.
3.0 Capacity Of HP/LP Bypass Systems:
During earlier stages of development, these systems were designed
for 30% by pass capacity. But the advantages of such bypass systems were
limited. In case of 210 MW units, HP/LP bypass systems with 60% bypass
capacity were introduced. The bypass capacity of 60% is maximum at
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present, the restricting factor being the size of Condenser. In the 210 MW
units of Neyveli Thermal PowerStation II (stage II), HP/LP Bypass systems of
60% bypass capacity are installed.
4.0 HP Bypass System Arrangement:
For a 210 MW unit/Stage II of the thermal power station II, two sets of
HP bypass systems are provided as the steam for the turbine is supplied
through two lines.
The HP bypass system bypasses the steam from the main steam line to
the cold reheat line thus bypassing the HP turbine. When the steam is to be
bypassed, its pressure and temperature are to be sufficiently reduced.
The HP bypass system comprises mainly five valves. Two HP bypass
valves, left and right, designated as BP-1 and BP-2, two HP bypass spray
water flow control valves designated as BPE1 and BPE2 and a spray water
pressure control valve designated as BD are provided.
HP bypass valve is a pressure-reducing valve with built in spray
nozzles. The pressure is reduced by throttling and the temperature is
reduced by the injection of spray water.
The spray water for HP bypass system is drawn from the discharge
header of the Boiler Feed Pumps. The Feed Water is supplied through a
spray water pressure-reducing valve, BD. This valve is provided to reduce
and then maintain the down stream pressure. This is intended for having
finer operation of the spray water flow to control valves. The feed water,
supplied through the valve BD, is admitted to HP bypass valves BP1 and BP2
through two spray water control valves BPE1 and BPE2. These BPE1 and BPE2
valves are provided to regulate the quantity of feed water so as to control
the downstream temperature of the bypassed steam.
The schematic arrangement of the HP B/P system is shown in the
Fig.93.



111
5.0 Valves:
Since all the control valves in the HP bypass system are normally kept
closed and are required to come in to operation quickly, the valve body is
designed to keep the thermal stresses low. The valve body is of welded
body with its welded seat.
The body of HP bypass valve is made of alloy steel suitable for the
high working pressure and temperature. The spray water is injected inside
the valve through the inclined holes. A jet cage provided prevents direct
impingement of the spray water to the valve body and also creates
turbulence in the steam water mixture for rapid evaporation.
The spray water pressure control valve BD and the spray water flow
control valves BPE1 and BPE2 are similar in construction. Since the flow
medium, the water, is erosive in nature, the valve seat and the valve are
deigned in such a way that the pressure drops in three stages. The cross
sectional views of BP, BD, and BPE valves are shown in Fig.34 and Fig.35.
6.0. Control System : Electro Hydraulic Servo System: (Ref. Fig. 33)
Because of the requirements of high forces to operate, quick
positioning and finer control, Electro hydraulic servo system is provided for
the operation of valves in the bypass systems. Two servo systems control the
operation of HP Bypass valves.
The electro hydraulic servo system comprises,
- Control cubicle
- Console insert in the control desk with all push button and
indicators for operations.
- Field mounted pressure; temperature and the feed back valve
position transmitters.
- Oil supply units with its controls.
- Final Actuating elements for the control valves.
1. Servo valve
2. Blocking unit
3. Hydraulic Actuator
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6.1. The Oil Supply Unit:
The oil supply unit shown in Fig.32 provides the hydraulic actuation
energy for the actuators. Two separate oil supply units are provided for HP
bypass valves at 10.5 M level. Both the oil supply units are similar in
construction and operation.
Each unit consists of an oil tank with an oil pump. An electric motor
driven axial piston pump sucks the oil through a suction strainer and
discharges the oil at high pressure to an accumulator through a pressure
filter and a non-return valve NRV. Any abnormal rise in the oil pressure is
limited by safety relief valve.
The accumulator is intended for storing the hydraulic energy and
meeting all the peak demands of the actuators supplying the pressurized
oil. The oil pump is therefore sized only for the mean supply requirements
and it is switched off when the accumulator is fully charged. The
accumulator is of bladder type and consists of a steel pressure vessel
containing a nitrogen filled rubber bladder, which separates oil from the
gas.
From the accumulator, the oil is delivered to the supply manifold
through a pressure a switch and a pressure-reducing valve. The Pressure
switch monitors the oil pressure in the accumulator and provides the signals
for the operation of the oil pump and the alarms. The pressure reducing
valve keeps the system oil pressure at a constant value (100 Bar) so that the
oil can be supplied to the servo valves of the actuators within narrow limits
of variation in pressure.
The oil from the supply manifold is supplied to the servo valves
through the pipe work designated as P line.
6.2. Actuator:
Hydraulic actuators are to be used as drives because the valves are
to be accurately set with considerable setting force and speed. The
actuator consists of a double acting cylinder honed inside surface. A piston
inside the cylinder makes the movement according to the
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admission/withdrawal of oil taking place at both the spaces, above and
below piston. The piston through a solid coupling between the valve stem
and the piston rod actuates the valve. The piston and the piston rod are
sealed with sets of packing rings.
The actuator is connected with the valve through a yoke (or lantern).
A feed back position transmitter is fixed to the yoke to transmit the valve
opening electrically to the controller.
The admission /withdrawal of oil to the spaces of the actuator is
controlled by the servo valve and it takes place through the blocking unit.
6.3. Servo Valve: (Ref. Fig. 57)
Servo valve is an electro hydraulic converter intended for
transforming the control signals coming from the control cubicle into
corresponding hydraulic pressure for the operation of the actuator. It is
mounted at the actuator.
The oil is supplied to the servo valves through three-micron high-
pressure filters and line throttling devices (P line). The high-pressure filter
prevents any minute foreign particle from going to the servo valve, which
has very small control holes. The line-throttling device provides the facility for
adjusting the actuating speed of the actuator by varying the rate of flow of
oil.
The servo valve is made up of Electrical and Hydraulic parts. The
upper electrical part is a torque motor and the lower part is a hydraulic
amplifier.
6.3.1. Torque Motor:
It is an arrangement to operate on the principle of Electro-Magnetism
and to convert the control signals into proportional torque. This torque is
applied on a control fork of the hydraulic part so as to result in its
movement.
The torque motor shown in Fig.56 consists of two permanent magnets
of equal strength mounted on a base plate. An armature supported on a
ball bearing can have angular movement in the space formed by the
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specially shaped shoed. This arrangement is shown in Fig.56. Two coils are
wound over these magnets and they are connected as shown in the Fig.56
The control signal can be introduced via these coils at the terminals 1 and 2.
These two magnets create a magnetic circuit through the base plate
and the armature in which two separate parallel paths of same strength are
formed. Hence the armature is at its equilibrium position as shown in fig (A).
Whenever the valve needs to be operated, a control current (initiated by
the controller) flows through the two coils so as to generate magnetic lines
as shown in fig (B). The resultant magnetic field is as shown fig (C) and
hence an angular movement of the armature towards the stronger field
results. This movement, which is against the spring force, is transmitted to the
control fork through a distance piece and a coupling plate.
The torque induced is approximately proportional to the magnetic
flux and hence to the control current. To reduce the effects of friction and
residual magnetism, an A.C Voltage is superimposed on to the DC control
signal in the control amplifier when it is functioning on automatic mode.
Manual operation is possible from the control desk.
6.3.2. Hydraulic Amplifier:
The lower hydraulic part of the servo valve transforms the movement
of the control fork (operated by the torque motor) into an equivalent
pressure of the oil. This principally consists of a central spool which is
movable in its housing. This spool is designed to act as an amplifier with an
internal feed back.
The details of the servo valve are shown in the Fig. 57. There are
totally three oil lines connected with the servo valve as explained
hereunder.
- Supply Oil Line: designated as P line
- Return Oil Line: designated as T line
- Leakage Oil Line: designated as L line
Through T and L lines the oil returns to the oil supply unit. Both the
admission of the pressure oil to the actuator and the withdrawal of the oil
115
from the actuator (either to the top or bottom space of the piston
according to the action required) are routed through the servo valve. The
oil withdrawn from the actuator returns through T line. The position of the
central spool decides about the above oil routing.
The central spool gets located at its central equilibrium position due
to the equal pressure exerted at its both ends by the pilot control oil. This
pilot control oil is nothing but the oil originating from the same supply oil (P
line) through a filter and an orifice. The variation in the pressure of the pilot
control oil at the ends result in the movement of the spool to a new position.
The spool has a central hole along its length as shown in the figure.
This hole is not completely through and the oil flowing from one end of the
spool cannot mix with the oil from the other end. However the oil can flow
out through the control orifices. These two control orifices are covered by
the lower portion of the control fork. Any movement of the control fork (on
either side) leads to uncovering of the control orifices concerned.
Suppose when the lower portion of the control fork moves to left (in
the figure), the left control orifice of the spool is uncovered. More pilot
control oil passes out from the left end of the spool into the leakage space.
Since the pilot control is originating through an orifice (from P line), the oil
pressure in the left end space gets decreased. Because of the resulting
pressure difference, the spool moves to the left until both control orifices
throttle equally again. Thus the spool follows the movement of the control
fork continuously.
When the spool is moved from its middle position, it allows the
hydraulic oil to flow to one side of the piston and the return oil to flow back
from the other side.
The power needed to move the spool is very small since the hydraulic
forces act at right angles to the direction of the movement. By this way the
servo valve acts as an amplifier with a high amplification factor.
The oil from the leakage space returns to the oil supply unit through
the L line along with the leakage oil from the blocking unit
116
(explained in sec. 6.4). The pressure oil for the blocking unit is also supplied
through the servo valve.
The servo valve can be operated by local manual operation
overriding the electrical signals.
6.4. Blocking Unit:
The blocking unit has the function of freezing the actuator and the
valve in their last held position when the condition in the system warrant. This
electro-hydraulic pilot operated unit is mounted between the servo valve
and the actuator.
The admission /withdrawal of the oil to/from the actuator takes place
through this blocking unit. It blocks the above oil flow during the following
conditions.
- Electric blocking: This is the result of any of the following:
a. Failure of Electrical Supply
b. Selecting the controller into manual
c. Very low oil pressure signal from the pressure switch.
- Hydraulic Blocking: The reduction in the pressure of oil will also
result in blocking.
The blocking unit is shown in the Fig. 58. The main constituents of the
blocking unit are the main blocking spool, the spool housing, the
spool-guiding bush, the centering disc, the springs and the pilot valve with
solenoid.
6.4.1. Release Function:
When the solenoid is energized the spool of the pilot valve moves up
so as:
1. To admit the pressure oil (P Line) through the servo valve into the
pressure chamber at the end of the blocking spool.
2. To prevent the draining of the oil from the above pressure
chamber to the leakage line (L)
The above action of the solenoid hence results in the movement of
the blocking spool to the normal position compressing the spring at the
117
same time. The above normal position of the blocking spool allows the free
movement of the oil to and from the actuator. The blocking unit is in
released condition.
6.4.2. Blocking Function:
When the solenoid is de-energized due to the reasons for electrical
blocking or the oil pressure itself gets dropped, the returning of the blocking
spool to its original position by the action of the springs takes place. The
above movement of the blocking spool leads to interruption of the oil flow
to and from the actuator, thereby freezing the actuator at its last held
position. When the solenoid is de-energized the spool of the pilot valve cuts
off the supply from the P line to pressure chamber and also drains the oil
from it by opening the leakage line.
By moving the lever provided at the side of the blocking unit, the
blocking spool can be moved into its operational position and the oil
connections can be established between the actuator and the servo valve.
The above operation is known as Manual De-blocking.
6.5. Quick Opening Device:
This device is useful for the following purposes:
1. To operate an actuator in a quick way faster than the normal
control path, and
2. To facilitate the operation of the actuator (independent of the
control system) during the emergency conditions leading to the failure of
closing and opening of the valve.
This device receives its emergency oil from an additional
accumulator, which provides a safe function of at least one stroke even
after the failure of the oil supply unit.
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3.2.2 LP B/P VALVES:
3.2.2.A Combined Bypass Stop And Control Valve:
(Ref. Fig.27)
7.0. Function:
Bypass stop and control valves are combined in common valve
body. This valve combination dumps the steam not accepted by the
turbine to the condenser. The valves are controlled by the LP bypass
controller and the LP bypass limit controller. For details, see section
Governing system.
7.1. Bypass Stop Valve:
The bypass stop valve is arranged in the inlet branch of the valve
body (25) and is either closed or fully opened. The bypass steam enters the
valve body through the inlet branch and is admitted to the valve cone (45).
A relief cone forming a part of the valve spindle (49) is incorporated in the
cone of the stop valve to reduce the forces required to open the valve.
The valve cone (45) slides in the guide bush (48) of the lantern (31). The
packing rings (32) provided as a seal along the valve spindle may be
tightened by means of the gland nut (35). The valve spindle (49) and the
valve cone (45) are secured against rotation.
7.2. Actuator Of Bypass Stop Valve :
The bypass stop valve is opened hydraulically and closed
hydraulically with the assistance of the three springs (38; 39; 40) in the piston
(37). These are arranged in the cylinder (36), which is bolted to the lantern
(31). The piston (37) is connected to the rod (58), which in turn is connected
to the valve spindle (49). To open the valve, control oil is admitted to the
space below the piston (37) via connection a3. The oil pressure forces the
piston (37) to the outer end position against the action of the springs (38; 39;
40), opening the valve. A reversal of the oil flow in the pilot valve closes the
valve again. While the oil at connection a3 is de-pressurized control oil is
admitted to the space above the piston (37) via connection a4. This
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control oil combines with the force of the springs to move the piston to the
inner end position, which corresponds to the closed position of the valve.
7.3. Bypass Control Valve :
The bypass control valve, which follows the signals of the bypass
controller to dump necessary flow of bypass steam, is arranged in the
exhaust branch of the valve body (25). The actuator controlled by the pilot
vale holds the control valve in the corresponding position.
The spring (42), which connects the control valve cone (44) to spindle
(26), provides a sufficiently flexible attachment to produce a tight seal for
the cone (44) when it bears against the valve seat in the body (25). The
closing force of the valve spindle (26) is transmitted to the cone (44) via the
pressure elements (43). The valve spindle (26) slides in the guide bushes (24;
27) of the lantern (19). In contrast to the lantern (31), no special packing is
required to seal the spindle (26) in the lantern (19), since most of the
pressure constantly acting on the bypass stop valve has been spent at the
bypass control valve during bypass operation. In addition, the bush (27)
guiding the spindle (26) has the sealing effect of a labyrinth, resulting in a
pressure acting on the guide bush (24) via connection l which is so
minimal as to permit only an insignificant amount of leakage steam to
escape. The valve spindle (26) is connected to the piston rod (9) and
secured against rotation.
7.4. Actuator Of Bypass Control Valve :
The bypass control valve is actuated hydraulically by the piston (11)
arranged in the cylinder (10). In accordance with the signals of the bypass
controller, this piston is acted up on by control oil alternately admitted via
connection a1 (closes) and a2 (opens). The position of the valve cone
(44) depends on the amount of control oil, which is in the cylinder (10). This
particular amount of oil is determined by a pilot valve controlled by the
bypass controller and described in detail in another section.
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3.2.2.B Feedback For Pilot Valve Of Bypass Control Valve :
(Ref. Fig.28)
8.0. Arrangement:
The feed back unit is flanged to the actuator (13) of the bypass
control valve. Depending on the valve lift, the unit counteracts the signal
oil of the bypass station in the pilot valve.
8.1. Construction:
Essentially, the feedback unit consists of the cam bush (10) fitted onto
the spindle (9), feedback linkage system (11; 24; 30; 20), the proportional
range setting elements (34; 35; 36) and the follow-up piston (41) with sleeve
(39). The follow-up piston is guided in the bush (44). The setscrews (40; 45),
the spring end pieces (43) and the spring (42) connect the bush and the
follow-up piston. The sleeve (39) operated by the feedback linkage slides
on the lower end of the follow-up piston (41). The follow-up piston and the
sleeve have drain ports through which oil emerges from the follow-up piston
depending on the amount of port overlap. The function of the follow-up
piston is to return the pilot valve connected with the feedback system via
connection b, to the center position from the upper or lower end position.
The proportional range of the feedback is set by means of the nut
(35). A change in the position of the spindle (34) results in a ratio change
and hence in a change in the relationship of piston lift and resetting
movement of the pilot valve.
8.2. Mode Of Operation:
If the bypass control valve is in a steady-state condition at any given
opening position when the turbine is running, the pilot valve will be at its
center position. When the signal oil pressure of the bypass station increases,
the pilot valve is lifted, moving the spindle (9) of the bypass control valve
upwards in the opening direction. The bell crank (11) sliding on the cam
bush (10) as well as the levers (24; 30; 20) and the sleeve (39) of the follow-
up piston (41) follow this movement. The resulting change in the relative
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position of the drain ports in the sleeve and follow-up piston produces an oil
pressure in the spring (42). This newly established feedback oil pressure is
communicated via connection b and returns the pilot valve to its center
position.
On a drop in signal oil pressure corresponding to a closing signal for
the bypass control valve, the pilot valve is moved downwards and with it
the spindle (9) in the closing direction, the feedback linkage (11; 24; 30; 20)
moving the sleeve (39) on the follow-up piston (41). This changes the
relative position of the drain ports in the sleeve and follow-up piston so as to
reduce the oil pressure in the follow-up piston and also in the space above
the pilot valve. The greater signal oil pressure acting in the space below the
pilot valve then returns this valve to its center position at which equilibrium is
established between the signal oil pressure and the valve weight and spring
tension, causing the movement of the piston to stop.
3.2.2.C Pilot Valve Of Bypass Control Valve : (Ref. Fig.29)
9.0. Function:
The pilot valve controlling the actuator of the bypass control valve
opens or closes the bypass control valve by admitting pressure oil in
accordance with the signals of the bypass controller. For details on the
arrangement of the pilot valve in the overall bypass system, see section
Governing System.
9.1. Construction :
The pilot valve admitting control oil at a is in circuit with actuator of
the bypass control valve via the control oil connections a1 and a2.
Depending on the pulses from the bypass controller, the signal of l from
the bypass controller moves the valve (5) from the center position shown.
The valve (5) slides in the bush (19) of the body (6) provided with two return
ducts at the side. The ball (8) in the guide bush (7) screws to the valve bush
(19) limits the downward travel of the valve. The inner collar of the hood
(15) against which the spring disc (1) of the compression spring (14) bears,
limits the upward travel of the valve (5).
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9.2. Mode Of Operation:
The pilot valve operates as follows: signal oil from the bypass control
circuit is passed to the space below the valve (5) via connection l. The
weight of the valve and the force of the spring (14) hold the valve at its
lower end position until connection l becomes pressurized when the
bypass controller gives an opening signal for the bypass control valves. The
control oil at connection a then flows to the space above the piston of
the bypass control valve via connection a2 forcing the piston downwards
together with the compression spring arranged there. The bypass control
valve remains closed. On an opening signal given by the bypass controllers
in the form of a pressure increase in the control oil, the valve is lifted to the
center position shown and the flow of control oil a2 to the space above
the piston is shut off. On further upward movement of the valve, control oil
is passed to the space below the piston of the bypass control valve via
connection a1, while the oil above the piston flows out. The control oil
a1 lifts the piston to open the bypass control valve. The newly established
feedback oil pressure in the feedback system is admitted to the space
above the valve (5) via connection d forcing the valve back to the
center position show.
A decrease in control oil pressure following a closing signal given from
the bypass controller to the bypass control valve is accompanied by a
downward movement of the valve (5). The oil in the space below the
piston of the bypass control valve is allowed to flow out, while the control oil
admitted at a2 forces the piston downwards, thus closing the bypass
control valve. At the same time, there is a drop in feedback oil pressure in
the space above the valve, as a result of which the valve returns to its
centre position. The bypass control valve now remains at its new position.
Satisfactory operation of the valve (5) is of utmost importance for the
bypass control valve. To prevent the valve from seizing, it is made to rotate
by pressure oil supplied through the centre bore of the valve which imparts
a rotating movement to the valve as it leaves the tangential bores of the
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wheel disc. To reduce friction, a thrust ball bearing (2) is fitted between the
spring disc (1) and the valve (5).
3.2.2.D Pilot Valve Of Bypass Stop Valve: (Ref. Fig.30)
10.0. Function:
The pilot valve controlling the actuator of the bypass stop valve
opens or closes this valve by admitting control oil in accordance with the
signal of the LP bypass controller.
10.1. Construction :
The pilot valve is in circuit with the actuator of the bypass stop valve
via the control oil connections a1 and a2. Depending on the signal oil
l of the bypass control system, the valve (9) sliding in the bush (11) is
moved from the center position shown. Opposing the effect of the signal oil
l, the tensioning oil l1 at the upper end of the valve (9) determines the
opening point of the bypass stop valve and is held constant by a pressure
converter. To prevent the valve from seizing in its sleeve during operation,
pressure oil is passed through the center bore and out through tangential
bores in the wheel disc (8) to make the valve rotate. For this reason, a thrust
ball bearing (2) and the ball (15) are fitted at opposite ends of the valve. In
the p lane not shown, two oil return ducts are arranged at the side of the
valve body (10).
10.2. Mode Of Operation :
The weight of the valve (9) and the tensioning oil pressure keep the
valve at its lower end position until the LP bypass controller passes an
opening signal to the bypass stop valve. The control oil at connection a
then flows on through connection a1 to the space above the piston of the
bypass stop valve, forcing it inwards together with the compression spring
arranged there. The valve remains closed.
If the bypass controller gives an opening signal in the form of an
increase in the pressure of signal oil l, the valve is lifted against the force of
the tensioning oil pressure l1 to the center position shown, at which the
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flow of control oil at a1 to the space above the piston is shut off. On
further upward movement of the valve, the control oil is passed to the
space below the piston of the bypass stop valve via connection a2, while
at the same time the oil above the piston flows out to the oil return c. This
reversed oil flow lifts the piston, thus opening the bypass stop valve.
Conversely a drop in signal oil pressure indicating a closing signal
given by the LP bypass controller to the bypass stop valve, as a result of
which the tensioning oil pressure in the valve body (10) begins to build up,
causes the valve (9) to move downwards. The control oil now admitted to
the piston will make the bypass stop valve close.

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3.3 ELECTRO HYDRAULIC GOVERNING SYSTEM :
Introduction:
The Large size of power distribution systems, Power Plant Units
including turbine generators make the use of Electro-hydraulic Control
Systems mandatory and essential.
Electro hydraulic control systems feature the following advantages:
1. High Flexibility
2. Excellent dynamic response
3. Convenient and easy materialization of complex functional
interrelation
4. Continuous and precise control of large actuating forces of
hydraulic control systems.
5. Accomplishment of safety operation of TG units with maximum
available capacities.
Turbine Control System:
The standard configuration provides a MHC and an EHC for the
control of the turbine generator. For the interface to the hydraulics,
1. A hydraulic /hydraulic converter for the MHC
2. An electro hydraulic converter for the EHC
Though these two converters, both the EHC and the MHC are
connected to a hydraulic MIN-Gate. The lesser of the two control signals is
subsequently transmitted to the hydraulic actuation system to control the
positions of the main and Reheat control valves (MCV/RCV). While EHC can
be isolated at local by two isolation valves on the HP & IP Secondary oil
lines, MHC will always be available and cannot completely be isolated. This
description is not intended to explain the details of the MHC and of the
hydraulic actuation system. These two systems are therefore described to
the extent required to understand the operation of the EHC only.

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Electro Hydraulic Controller :
Functional Requirements For The EHC:
The EHC has the task to control the steam flow through the
HPCV/IPCVs and accordingly the speed, as well as load of the turbine
generator for any operating condition (start up, loading, operation under
load, shut down, load reduction).
The EHC meets the following requirements
1. High operational safety and reliability by utilizing control modules
with integrated circuits, as well as multiple channel speed and load
measurements.
2. Reliable and dependable control of load rejection, caused for
instance by separation of generator from the distribution system, and safe
control of the resulting speed excursion in a quick and decisive intervention
of EHC.
3. Material stress consistent operation of turbine generator by
acceptance of the respective GUIDANCE SIGNAL issued by TURBINE STRESS
EVALUATOR (TSE) or the Turbine Stress Control System (TSC) ie the rate of
speed and load changes are executed at an optimum rate while the
maximum allowable thermal stresses in the turbine materials are not
exceeded.
4. Support of frequency control of the distribution system through a
precise frequency /load characteristic with a high response sensitivity and
provisions for detailed adjustment of the slope of the characteristic in small
increments during operation of the turbine generator.
5. Provisions to start and shutdown the turbine generator
automatically by providing the components within the EHC to accept
signals from an automatic start up programme.



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Basic Arrangement Of The EHC: (Ref Fig.61)
The EHC consists of the following basic control loops namely,
1. Speed Control Loop
2. Load Control Loop and
3. Pressure Control Loop.
By means of a selection circuit, consisting mainly of a MAX and two
MIN gates, these controllers are meaningfully connected to position
controller.
CONTROL LOOPS OF EHC: (Ref Fig.60)
SPEED CONTROL LOOP:
The speed control loop is primarily intended to perform control of the
turbine generator during startup and during synchronization with the
distribution system.
While the turbine generator is operating under load the speed
controller serves as an over speed limit controller to keep speed increases,
which result from separation from the grid (e.g. Turbo generator full load
rejections) below the response threshold of the hydraulic over speed trip
device set to approx 110% rated speed.
In case of faults in the load control loop, the speed control loop may
also be used for loading and unloading the turbine generator.
Speed Reference Setter (SRS)
The speed reference NR is determined by adjusting the SRS. The set
point can be changed manually from the turbine control panel. The speed
reference can also be changed in the control cabinet of the EHC at the
respective control module.
For the entire speed range of 0-3600 rpm the electrical output signal
of the SRS(0-10.8V) is proportional to the speed reference to facilitate fine
adjustment of the speed reference at synchronous speed, the rate of
change of the SRS is kept lower by a factor of 20 at settings above 2850
RPM.
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Provisions to accept signals from the automatic synchronizer and the
automatic turbine run up system are available. Manual commands to
change the set point of the SRS are executed with priority.
For the display of the speed reference, two instruments are provided
in the turbine control panel one for the entire speed range of 0-3600 RPM
and the second one for the speed range of 2700-3300 RPM to facilitate
fine adjustment. In case of turbine trip the speed set point would be
automatically brought down by a factor ( Nact- 120 RPM).
Speed Reference Limiter (SRL):
The speed reference NR is subsequently entered into the SRL, which
determines the acceleration rate. The maximum permissive speed
acceleration rate is set during initial start up of the turbine generator. It can
be adjusted in the control cabinet only.
Another controlling influence to the acceleration rate is from the TSE,
which may limit the acceleration rate further (TSE acquires and evaluates
the thermal stresses evaluated at representative locations of the turbine
casings and shafts. Based on the results obtained, the TSE prevents
excessive thermal stressing of the turbine, but at the same time allows
starting of the turbine with the maximum allowable acceleration rate,
contributing towards optimized operation of the turbine generator).
Depending on the thermal conditions of the turbine casings and
shafts, the TSE may cause the acceleration rate to be reduced to zero or
become even negative. This feature accordingly would call for maintaining
a particular speed or even call for a reduction of the speed of the turbine
generator, requiring a temporary closing of the control valves.
The maximum acceleration allowed is limited to 0-600 rpm
2
for the TSE
margin of 0-30 deg K .In case of faults or failures in the TSE, the momentary
speed output signal of the SRL is frozen automatically until the fault has
been cleared or the input signal supplied by the TSE is switched off in the
control cabinet. However if the speed is below 2850 rpm it will run up to
2850 rpm and when it is above that speed, it freezes at that speed.
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Speed Controller
The speed controller is designed to meet the requirements of the
turbine control system during start up, shut down, and incase of load
rejections to avoid excessive speed excursions.
The input for speed controller is the deviation resulting between SRL
output and (NR lim) and the actual speed Nact . The speed controller has
a proportional characteristic and hence requires a difference between the
set point (NR lim) and actual speed Nact always.
If the set point and actual speed becomes equal the controller
output becomes zero. Moreover since the turbine is started at different
throttle pressures the valve opening would also be different. Hence a
corrective signal n=f (p) which depends upon the throttle pressure of the
boiler is provided as a positive bias to the speed controller during start up
process assuring that the actual speed could be held as per the required
speed. This bias becomes zero when rated pr and actual pressure are
same.
Based upon the difference between the corrected speed signal and
the actual speed the speed controller gives an output as per its droop
characteristics. The SC is characterized by 5% droop i.e. if the turbine is to
be loaded with speed controller the speed set point should be set at 3150
RPM when the actual speed of the turbine is 3000 rpm to open the control
valves fully and vice versa.
The output of the speed controller goes to the selection circuit CKT
and if selected goes as an input signal for the admission controller.
As explained earlier due to the proportional characteristics of speed
controller if the difference between NRlim and the Nact is more it will give a
maximum output. In order to avoid rapid acceleration and over speeding
of turbine during rolling process, speed controller output is limited to 40%.
For this action to take place the following conditions should be
satisfied:
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1. The difference between speed set point and the speed act is
more than 60 RPM.
2. Generator Breaker should be in OFF condition.
Block Loading
To give a positive loading of the turbo generator when the unit is
synchronized an automatic command is give to raise the speed set point
when the generator breaker is closed for 2 sec. This may be approximately
12 to 15 RPM.
Acceleration Rate Monitoring (DN/dt monitoring)
To avoid the speed of the turbine generator being maintained below
2800 rpm which might coincide with one of the critical speeds, the
acceleration rate of the turbine is monitored in the range from approx
warm up speed (i.e. 700 RPM) to approx 2850 rpm. If DN/dt drops less than
108 rpm/min the SRS automatically runs back to warm up speed i.e. 600 rpm
thereby reducing the actual turbine speed. Subsequently the SRS has to be
set up manually again. Hence for DN/dt monitoring the following conditions
should be satisfied.
1. Generator breaker is in OFF condition
2. Speed set point > 700 rpm and actual speed < 2850 RPM.
LOAD CONTROL LOOP
Immediately after synchronization of the Turbine generator to the
grid, the load controller is made to take across the entire load range of the
turbine generator. The main components of the load controller are the load
reference setter, the load reference limiter and the load controller.
Load Reference Setter:
The load reference PR is determined by adjusting the LRS from the
turbine control desk. The load reference can also be changed in the
control cabinet of the EHC at the respective control module.
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For alternate changing of the LRS, provisions are available to accept
lower/raise signals from an Automatic dispatch system and analog signal
from the Boiler Control System (Combustion Master Control)
Load Reference Limiter (LRL)
The load reference PR is subsequently entered into the LRL, which
determines the loading rate. The following functions are performed by the
LRL. The LRL is influenced by a minimum selection between two signals.
1. A load rate limit as required by the evaluation of the desired
loading rate (load gradient) dp/dt in MW/min as set at the Turbine control
desk (2.5 MW/min to 25 MW/min). ON/OFF facility is available at the
TCP/Desk for load gradient.
2. The load gradient influenced by the TSE as explained in SRL
(Speed Reference Limiter) TSE influence on load gradient can be switched
ON/OFF at the cabinet. The output signal PR LIM of the LRL is displayed on
an instrument on the turbine control desk.
Prior to the use of the output signal of LRL PR LIM as the input signal for
the load controller, additional influence is entered into the signal flow.
1. A pressure influence signal PR P supporting pressure control of
the boiler during operation of the turbine generator in limit pressure mode.
Whenever there is a deviation from the set MS pressure load controller will
load/unload the M/C to maintain the set value of throttle pressure upto a
deviation of +/- 10KSc. P, the load variation is limited to +/- 12.5 MW. This
facility is available at control cabinet and not yet connected for
operational use.
2. A frequency control signal PR F is another signal added to the
output of the LRL. This signal supports frequency control of the grid.
The magnitude of frequency deviation from rated to that existing in
the grid represents a measure for the ratio of load delivered VS load
demanded.
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This relationship is used to counteract frequency excursions within a
system through opposing corrections of the load delivered by the turbine
generators.
To perform these corrections, a device with suitable droop
characteristics is used. The output of this device is used as a correction
signal. To this signal a frequency correction signal is added. (This is a linear
function of the frequency deviation from rated frequency vs. load, as
expressed by the frequency/load characteristic). If the frequency drops,
the load reference signal is increased, if the frequency rises above the
rated frequency, the load reference signal is decreased. However the load
variation is limited to 15% of the rated load.
Frequency Control (DROOP) UNIT : (Ref. Fig.62)
Characteristics Of The Frequency Influence:
This frequency correction can be switched ON/OFF for the instrument
cabinet. The droop unit compares a quartz stabilized set point frequency
with the actual frequency of the system. The quartz-generated frequency is
highly accurate, detecting frequency deviation of < 5MHz.
By means of a selection switch provided inside the control cabinet,
the droop can be changed even during operation in steps of 0.5% each
with in a range from 2.5% to 8%. For coal fired boilers this is kept as 5%.
A monitoring circuit inside the droop unit disconnects the droop unit
automatically incase of failure of the set point frequency generated by the
quartz oscillation. Faults are indicated on the respective control module
inside the EHC cabinet with an LED and will initiate also the common alarm
EHC fault. Due to high disturbance in grid condition this facility is not used
at present.
The output signal of LRL, PR LIM, and the two additive signals are fed
to the load controller through a MIN gate through which the absolute load
limit PR ABS may limit the max output of the turbine generator.
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The absolute load limit PR ABS can be adjusted by the operator from
the TCP/and may be used for fast load reductions, for instance if a BFP is not
available or any other disturbance in the boiler requires.
If the generator is not synchronized to the grid (or) the load controller
is switched off, the output of the LRL will be kept at ZERO. This permits the
LRL to increase its output PRLIM only after synchronization of the generator
to the grid.
Load Controller LC
The control deviation forms the input signal for the LC. This deviation
is derived from the output signal of the LRL (PRLIM) (after entering additional
influences in the signal flow) and the actual load signal (pack)
LC exhibits a proportional integral response characteristic.
The advantage of this configuration is that events requiring quick
response, such as signals issued by the boiler control are transmitted without
delay, while disturbances originating in the grid (e.g. the frequency control
signal PRLIM) are controlled by the LC.
When the LC comes into service, the speed set point will follow grid
speed between 48.5 HZ and 50.5 HZ. Beyond these limits, the set point is
frozen at extreme ends. However if needed for operational purpose it can
be raised/lowered manually.
Beyond 8% of the load LC comes into service after
synchronization.
Inbuilt Frequency Influence
When the grid frequency is > 50.8 HZ, the M/C will start unloading.
The unloading rate is such that the load reaches OMW corresponding to
the grid frequency of 54.0 HZ. This facilitates that speed excursions will be
limited to below the set point of over speed trip device. This is an inbuilt
feature.
Whenever the deviation between load set point and actual load is
greater than 10% and the grid frequency is greater than 51 HZ there will be
no indication available at the desk to identify which loop is in service. This
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shows that the M/C is on ISOLATED grid condition and the indication
ISOLATED GRID would appear.
On such occasion, the load set point should be matched quickly with
the actual load, after matching the load, when isolated grid condition is
reset at the desk, LOAD CTRL ACTIVE indication will appears at the EHC
desk. This will take about 8 to 10 seconds for changing to load controller
mode. The term ISOLATED GRID is explained in detail later in this write up.
When the load controller is in service and when the throttle Pr.drops
to a value less than 10 KSC from the set pressure control loop will change
over to pressure control. Pressure controller will unload the M/C there by it
will maintain the set throttle pressure minus 10 KSC. This can be understood
clearly while going through pressure control loop and selection circuit.
PRESSURE CONTROL LOOP:
Pressure Reference Signal:
To make sure that PC of the EHC uses the same pressure reference as
the pressure controller of the boiler the EHC is designed to accept the
pressure reference signal from the boiler control. The throttle pressure
reference signal should therefore be generated for the EHC and the boiler
with the Boiler control system.
The pressure reference signal, branched off to the EHC, has to be an
isolated signal, is through a buffer amplifier.
Actual Throttle Pressure:
Again to assure the use of same signal for boiler and turbine controls
of actual throttle pressure, an input is provided within the EHC to accept the
actual throttle pressure as required by boiler control.
The actual throttle pressure signal has to be an isolated signal too.




135
Pressure Controller:
The EHC Pressure control has got two optional operating modes
1. The initial pressure mode and
2. The limit pressure mode.
The modes can be changed by at the TCP/instrument cabinet the set
throttle pressure, the limit pressure mode serves as a back up for load
control loop when the AP between set and actual falls below 10 KSC.
For a set throttle pressure of 150 KSC the IP mode will be maintaining
150 KSC irrespective of the load. Thus depending upon the Boiler conditions
the generated load will be varying where as the pressure remains constant.
This is also called as turbine follow mode is Turbine follows boiler. Normally IP
mode is selected after a load of 120 MW or after attaining 120 KSC (MSP).
If for the same set pressure LP mode is selected the EHC will be in load
control (i.e.) one load will be constant as set by the LRS and pressure would
be varying. Now if the throttle pressure drops to 140 KSC, Pressure control
loop will take over the EH control and maintain the pressure of 140 KSC at
the expense of load.
The input of the pressure controller is the deviation derived from the
throttle set pressure and actual pressure. The PC exhibits a proportional
integral action of selected in the selection CKT the PC controls the position
of the turbine control valves in accordance with the operational mode
selected.
It may so happen that PC demands full close of control valves to
maintain throttle pressure. To avoid such occurrence the output of the PC if
fed thro a MAX gate where in another bias voltage corresponding to 40%
EHC controller position is applied thereby freezing the EHC controller at that
position.
To avoid frequent change over from pressure to load and vice versa
a small bias is added to load controller whenever IP mode is selected so
that the LC output will be slightly more than the pressure controller output.
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Selection Circuit: (Ref. Fig.63)
The selection CKT represents a logic network containing a Max
selection MAX gate and two minimum selection MIN gates. This logic
determines depending upon the operational conditions which control loop
(speed, load or pressure) is controlling the opening of Turbine control valves.
The max of the outputs of speed and load controller is selected in
the MAX gate which becomes one of the input of the I main gate. This
output plus a +ve bias voltage of 10.5 which is used for controlling the
turbine speeds during sudden grid disturbances becomes the second input
for the MIN gate 1.
The minimum of these two inputs then becomes the input to the MIN
gate 2 the other input being the PC output. The output of the MIN gate 2
then goes to the admission or position controller, which energises the
plunger coil of the electro hydraulic converter.
To understand the operation of control loops the diff-operating
conditions are dealt one by one.
(a) SPEED RAISING/BEFORE SYNCHRONISATION
During start up or at 3000 rpm (i.e.) before synchronization to the grid
the load controller output is zero. Hence the speed controller output gets
selected in MAX gate. As can be visualized the same is selected in the
MIN 1 gate also.
At the MIN 2 gate since the pressure controller is restricted to 40$% the
speed controller gets selected and hence takes control of the turbine
control valves.
(b) AFTER SYNCHRONIZATION
Immediately after synchronization the load controller starts to
integrate depending upon the load set point and when LC output
becomes greater than SC outputs, load control loop takes control of
governing valves if the set pressure and the actual pressure deviation are
below 10 KSC (LP mode) and the load on T.G. is more than 8% of rated
load.
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If the EHC controller position goes beyond 40% and at this juncture if
the pressure deviation is more than 10 KSC (10 KSC less than set pressure)
the pressure control loop due to its negative signal is selected in the MIN 2
gate and takes control of the control valves.
(C) DURING LOAD THROW OFF
If at any stage full load is thrown off due to disturbance in the grid
and the unit is in station load (GB open) the output in the LC becomes zero
where as the speed of the turbo generator increases. Since the unit was
under load before load throw off the pressure controller output would be
maximum and hence the SC takes the control of the control valves thro
MAX and MIN gates. The actual speed of the T.G. rotor will then depend
upon the speed set point.
(d) OVER SPEED CORRECTION
This is incorporated to control the turbine speeds during partial load
throw off in the distribution system for (e.g.) Tripping of the feeders
decreases the Generator load, which increases the T.G. rotor speed.
For (e.g.) if the unit is running at 3000 rpm at full load and load control
is in service let the
SC output be 1 V
LC output be 8.5 V
The voltage of the summing junction before MIN gate would be
1+10.5 = 11.5 V.Now due to one of the feeders tripping the speed of the
turbo generator increases instantly. When the speed raises above 3000 rpm
the SC output becomes negative.
If the speed raises to 3045 rpm the SC output would be -3V
Now even though the LC output is selected in MAX gate the Voltages
at the MIN gate would be
Load control : 8.5V
Summing Junction : -3 + 10.5 = 7.5V
As a result speed controller takes control even though load controller
is ON thro MIN 1 & MIN 2 gates.
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The example given is just for explanation and as it could be seen the
SC thro summing junction takes control when the voltage is just below 8.5 V.
The actual speed of the Turbine at that instant depends upon the drop
characteristics.
Tracking And Control Transfer:
Whenever load control or pressure control is in service the speed
set point would be tracked 15 rpm more than the actual speed so as to
ensure station load and control speed excursions in case of breaker
opening, However this becomes effective only when the grid frequency is
between 48.5HZ and 50.5HZ.
Whenever speed control is active the load controller will be tracked
just below MINI output to have a fast bump less control transfer.
Whenever pressure controller is in service load controller will be
tracked just above the pressure controller output.
CONTROL TRANSFER
(a) From Speed to load:
As it is obvious load control becomes effective only when GB is
closed. To changeover from speed to load after synchronization raise the
load set point than the actual load load control active lamp status
appears at the EHC desk insert which implies load control has taken over.
(b) From load to Speed
Whenever load/pressure control has taken over and if the grid
frequency is between 48.5 HZ speed set point cannot be varied due to
tracking mentioned earlier.
Hence for change over from load to speed the load control ON/OFF
push button at the desk is to be given OFF command. The OFF lamp blinks
which is now the release for raising the speed set point. The speed set point
is to be raised till the speed control takes over through Max gate. Once
speed control active appears L.C. OFF lamp will be steady which indicates
that the LC output is now zero.

139
(c) From load to pressure on IP mode:
The deviation IP between the boiler throttle pressure and actual
pressure is to be made zero. Once the deviation is zero the IP mode is to be
selected by switching on the IP/LP selection push button. Pressure control
active appears. To avoid frequent change over from pressure to load and
from load to pressure raise the load set point to the max load that can be
generated depending upon the operating loads.
(d) From pressure to load (From IP mode to LP mode)
Match the load set point and the load actual and see whether Load
control active appears. Select LP mode by pressing the IP/LP push button.
POSITION CONTROLLER
As the name implies the form of the position controller is to position
the control valve opening indirectly thro the actuator piston of the DH
converter.
The output of the selection CKT forms the position control input signal.
The positional controller has got a proportional derivative PD response.
The input signal for this controller is formed by the control deviation
between the output signal of the selection circuit and the actual position of
turbine control valves as required indirectly at the actuator piston of the EH
converter.
The output signal of the position or Admission controller controls the
secondary control fluid pressure of the hydraulic control system thro the
plunger coil of the EH converter, the actuator piston and the mechanically
linked follow up piston battery. Accordingly the EH-converter determines
the position of main and reheat control valves in a sequence determined
by the setting of follow up piston battery.
By means of a switch located inside the EHC-Cabinet, the output
signal of the AC can be disabled during servicing of EHC and also during
normal operation. Due to an interlocking logic provided for protective
reasons disabling of the AC output signal is however feasible only after
140
control of the turbine generator has effectively been transferred to the
MHG.
A monitoring circuit within the AC monitors the plunger coil in the EH-
converter for short ckts. A failure is indicated in the EHC cabinet with an LED
and is also connected to the common alarm EHC fault.
In case of an open wire inside the plunger coil or the cable from the
EHC control of the TG is immediately transferred to MHC which will assume
control, since by design, the plunger coil will move to a position which
would cause the control valves to move to the fully open condition and
because of the fault in the plunger coil Tracking device will be switched
off and hence the MHC will assume control thro hydraulic minimum gate.
Combined Operation Of EHC And MHG
The EHC and the MHC constitute both individual controllers, each of
which may assume control of the turbo generator within the conditions and
limits described before. For positioning the control valves both use the
same hydraulic actuation system. An EH converter for the EHC and a
Hydraulic-hydraulic converter for the MHC serve as interface between the
respective controllers and the hydraulic actuation system.
The hydraulic MINGATE always places the controller calling for a
lower control valve position in control of the turbine generator. By
appropriate setting of the set points of the individual controllers, control of
the turbo-generator may be assigned to either of the two controllers, EHC or
MHC.
Incase the EHC is to be selected for control of the turbo generator; it
is necessary to set the setpoint of the hydraulic speed governor within the
MHC to its 100% position. This will allow the EHC to cover the entire control
range of the valves.
For transfer of control from the EHC to the MHC the set point for the
speed governor has to be set lower than the load reference of the EHC.
The load reference of the EHC must then be raised to full load so as to
enable the speed governor to cover the entire control range. However
141
care must be taken to maintain main steam pressure since drop in main
steam pressure by 10KSC less than the set pressure would make the pressure
control loop of the EHC to become active.
To avoid interference of the EHC due to some fault when MHC is in
service two isolation valves (hand operated) are provided in the secondary
oil lines to HP & LP Control valves which isolates the complete control of the
EHC.
Tracking Device
When EHC is in service if the speed governor is at 100% if any EHC
fault occurs causing the amplifier piston of EHC to drift to 100% valve
opening position the control valves would open 100%. To avoid such
occurrences a tracking device is provided which maintains the position of
the starting and load limiting device just above the EHC output (10%
higher). Once the plunger coil is off the Tracking device is automatically
switched off. The Tracking device can also be switched ON or OFF from the
TCP/Cabinet.
Since the starting device is just over EHC a drift in EHC to 100% valve
opening switches off T.D. and the control valves assume position
corresponding to the hydraulic set point depending upon that position of
the startup device.
Normally 0-100% EHC range is equivalent to 60-100% of starting and
load limiting device.
The tracking device is automatically switched off due to
1. In case of any EHC fault as explained earlier
2. In case of a Turbine trip
Subsequently the Tracking device has to be switched on manually.




142
Alarms
For Anns. A common alarm EHC fault and the following individual
alarms are available.
PLUNGER COIL OFF
SPEED SLOPE VALUE LOW
DN/DT MONITORING OPERATED
LIMIT PRESSURE ENGAGED
TSE INFLUENCE OFF
The common alarm EHC fault will be initiated by any one of the
following individual alarms indicated with LEDs in the EHC control cabinet.
EHC Protective Breaker Trip
EHC Power supply Fault
EHC alarm voltage Fault
Valve Position measurement Fault
Actual Speed measurement Fault
Actual Load measurement Fault
Pressure controller (Pact. Or Pr.
are disturbed Fault
TSE/TSC System Fault
Quartz-Oscillator for droop Unit Fault
Plunger Coil Fault
Power Supply
For dependable supply of power, the EHC is designed to be supplied
from the two independent, redundant sourced of + 24 VDC.
The two power sources are mutually decoupled by means of diodes
inside the cabinet for the EHC. Following the diodes, DC power is supplied
to the power supply buses inside the EHC cabinet thro protective breakers.
Individual forms of the EHC are supplied with + 24V DC power
required for the electronics are generated on individual control modules by
means of solid state DC converters
143
Both power sources and the individual power supply modules within
the EHC are monitored for failures. Faults are indicated selectively inside
the EHC cabinet by means of LEDs and will also initiate the common alarm
EHC fault.
If one of the power supply should fail power continues to be supplied
without interruption by the other power source.
Isolated Grid Condition : (Ref. Fig. No.43)
Isolated grid condition has been dealt earlier. However the term
isolated grid must be clearly understood. If it is assumed that the EHC is in
control of the Turbo generator with its load control loop and is generating
power at a frequency of 50 HZ, if at some juncture the generation becomes
more than the actual demand the frequency of the grid raises. If the
generation becomes much more than the demand raising the load set
point does not raise the generated load but the grid speed (frequency)
raises. In other words the LC is no longer acting as a load controller but acts
as a speed controller. This phenomena is called the Isolated grid
condition. This process could be well understood if the unit is assumed to
feed radial feeders only.
The figure shows the conditions for isolated grid indication to appear
in the control desk.
As can be seen the isolated grid condition occurs only after a grid
frequency of 51HZ. As the load controller would be unloading the turbine if
the grid frequency raises beyond 51 HZ due to its inbuilt frequency influence
the ISOLATED GRID indn. would appear when the load controller deviation
is more than 10%. As can be analysed this condition is different from the
actual Isolated grid condition explained earlier. To distinguish between
these two reduce the load set point signal to the LC by 5 MW with the help
of the load limiter when the ISOLATED GRID indn. is available at the desk
(or no indn. is available to show which control loop is active). Change in
load may be watched. For example if the load set point is 180 MW the
144
frequency is 51 HZ, the actual load has dropped to 150 MW ISOLATED
GRID indn. would appear and there would not be any status in the desk to
show which control loop is active. Now reduce the load limiter to make
PR to 175 MW and watch out for any load change. If there is any
corresponding redn. in the generated load the L.C. is still in service thro its
frequency influence. The system can be run as such.
If there is no change in the generated load then the system is said to
be in actual ISOLATED GRID condition. Reduce the load limited to
another 5 MW to confirm the same.
To get out this isolated grid condition reduce the load set point to the
actual load (Load limiter may be used for fast change over) and press the
RESET ISOLATED GRID push button provided at the control desk. After a
few sec. LOAD CONTROL ACTIVE indn. will appear. Under these
circumstances it is better to run the machine in speed control loop thereby
having the effective control over speed.
However owing to our grid conditions this phenomena of actual
isolated grid conditions are seldom encountered.
Load Rejection Relay : (Ref. Fig.64)
The load rejection relay (LRR) constitutes a supplement to MHC to
ensure that the speed of the Turbo generator is kept below the response
value of mechanical/hydraulic over speed trip device during load
rejections. Though this provision is necessary only when MHC is in service
(since EHC takes care by its own speed control loop) it is also provided for
EHC. Upon load rejections this relay is energised which closes the control
valves fully for a short internal supporting the hydraulic system.
The LRR measures the electrical load rejections of the generator. Any
load rejections (i.e.) a large negative load change of the turbo generator is
acquired instantaneously by the LRR and is transformed into an electric
pulse the duration of which depends upon the load rejection.
This pulse energises two solenoid valves
145
1. One solenoid valve connects the aux secondary fluid supply
line to drain thereby dropping the secondary oil pressure and hence closing
the control valves.
2. The second solenoid valve connects the IP secondary oil line to
drain causing the IPCVS to close faster than only be the action of the first
solenoid valves.
The fast response of the LRR is causes by measuring the change of
generator load, which precedes the later speed increase. The LRR thus acts
before MHC takes action due to speed increase.
The duration of electric pulse is kept at 1.8 Sec (max) (i.e.) for a
complete load throw (100%) the LRR will be energised for 1.8 Sec. For 40%
to 100% load throw this pulse duration varies linearly.
After the electrical pulse has ended secondary oil pressure builds up
again. The MHC will resume control of the turbine control valves to a
position corresponding to the new generator load (It is assumed that EHC is
out of service and the machine in MHC)
To prevent any response of the LRR at frequencies below rated
frequency a frequency lock out is employed. If without this lockout if the
transmission system is operating at a frequency lesser than the rated grid
frequency while a load rejection occurs the LRR will close the valves fully.
After this signal disappears the MHC will find a big mismatch between the
actual speed and the hydraulic speed point causing the control valves to
open rapidly and in turn accelerate the turbine that is most likely to cause
over speed trip.
Speed/Power Set Pt Block And Stop Ref Limiter
As the name implies these two provisions are for blocking or freezing
the input to the speed/load controller if certain faults (which are dealt later)
are encountered. When these conditions occur the Nrtd & Lrtd are freezes
as such. Though the set point could be varied there wont be any change
in the Nrtd/Lrtd output. However pressure controller will be active even in
146
these conditions. Lamp status (indication) are provided in the control desk
to indicate the said conditions.
Speed/Power Set Pt Block
This condition occurs only when the turbine speed is > 285 0 rpm and
the following conditions are satisfied.
1. I. When the steam temperature before HPSV1 & HPSV2 is less than
that of the curve generated designated by X4.15
2. When the steam temp. before LPBP <15
0
K that of saturation temp
3. When turbine stress margin is < 0
0
K
4. When the HPSV1 remains closed for more than 180 Sec.
However the conditions said before are valid only if
a) EHC position is more than 0%
b) Turbine Speed set point >650 rpm.
c) SGC Turbine check back (operation) is completed.
II. When the speed slope value (dn/dt < min) is low.
III. When the monitoring time is exceeded during SGC TURBINE
operation is step 5, 9 & 16.
IV. When EHC fault occurs.
V. When TSE influence is switched off.
As explained at the beginning SPEED/POWER SET POINT block occurs
only when the turbine speed is > 2850 rpm.
Resetting Of Speed/Power Set Pt.Block
The signal for speed/power set point block, which occurs due to the
said reasons, will stay only for 1 sec even if the said conditions are persisting.
Resetting of this block can be done in two ways
1. By pressing the Master SET POINT RELEASE push button at the
control desk.
2. Thro SGC shut down Programme (STEP 54)
Since SGC shut down Programme is for Shut down of the unit the first
point is usually adopted.

147
Stop Reference Limiter
This condition occurs
1. When Speed/Power set point block occurs
2. When Pressure control loop has taken control in LP mode and if
load set point is raised.
3. When pressure control loop has taken control is LP mode and if
speed set point is raised.
4. If TSE influence is ON and if TSE fault occurs.
For faults other than TSE this condition resets by itself if the conditions
get normalized.
For TSE faults it has to be properly accepted from the control cabinet.
The TSE faults could be
(a) TSE margin 10
0
K
(b) Reference: Temperature variation in the junction box thermostats.
(c) Computing channels faulty.
(d) Other TSE faults like thermocouple open etc.
Mostly the fault in TSE switches off the TSE influence. Switching off TSE
influence causes SPEED/POWER SET POINT block, which in turn produces
STOP REF LIMITER. The same condition occurs when the TSE influence is
switched off manually (optionally).
First the faults are to be accepted by means of an accepting/are
dynamic in nature (Dynamic faults are these which come and go all of a
sudden for (e.g.) junction box temperature monitoring set point is 60
0
C and
if JB Temperature drops below 59 or raises above 61 this fault occurs.
Similarly due to any loose contact if temperature measurement fails and
again becomes normal the faults get reset. Otherwise the fault persists.
The following action may be taken in ease of a STOP REF LIMITER.
(a) Accept the fault in the TSE control cabinet see whether in the control
cabinet. If the faults the fault vanishes.
148
(b) Switch off and Switch on TSE influence (after checking for any
abnormalities in the TSE margin) by means of push button provided in
the desk.
(c) Due to switching off of TSE influence SPEED/POWER set point block
would appear. Press Master set point release from the desk.
Since the dynamic faults are encountered often the faults are
permanently accepted at the control cabinet by inserting the pin. In this
case the actions B & C as described above may be done from the board.
In case the fault persists TSE influence cannot be switched on. Hence
operate only the Master set release. See whether STOP REF LIMITER
Vanishes. Instrument staff to be informed to analyse the fault cause.
Switching Off TSE Influence Manually
If TSE influence is switched off SPEED/POWER SET POINT BLOCK and
hence STOP REF LIMITER would appear. To switch off the following
procedure may be adopted.
1. Switch off TSE influence by operating the push button from the board.
2. SPEED/POWER SET POINT BLOCK & STOP REF LIMITER would appear.
Operate Master set point release by operating the push button at the
desk.The set conditions will normalize but TSE influence will be switched off.
To switch ON the TSE influences again press the TSE INFLUENCE
ON/OFF push button at the desk once more. TSE influence will be switched
ON.
149
3.4 TURBINE STRESS EVALUATOR
3.4.1 Introduction :
It is important for the operator of a Power station to know how quickly
his turbine can be started up and what changes in load he may make
without fear of overstressing the components and thereby causing
excessive fatigue.
It is a well known fact that the steam temperatures inside the turbine
vary when there are changes to the operating conditions such as start up,
loading and shut down etc., It is the resulting non steady state temperature
differences which give rise to thermal stressing of the materials.
If a turbine is to be operated so that there is no undesirably high
material fatigue these thermal stresses must be kept within certain limits. The
optimum balance between longevity on the one hand and maximum
flexibility of operation on the other hand is achieved if the range of
permissible material stress can be utilized to the full.
The turbine stress evaluator provides the basis for long life operation in
that it continuously computing permissible values for changes in operating
conditions and displaying the data for the operators use.
3.4.2 Thermal Stressing Of Turbine :
The steam temperatures inside the turbine vary, when there are
changes in the operating conditions. Changes in the steam temperature
cause changes in the metal temperatures of turbine components such as
valve bodies, high pressure and intermediate pressure turbine cylinders and
the inlet areas of HP and IP turbine rotors. This results in free or constrained
thermal expansion.
Free thermal expansion effects in change in length and hence
distortion takes place. Constrained thermal expansion causes thermal
stressing of the components.
The components of turbine cylinder are designed to have higher
thickness of metal depending on the pressure difference experienced
between the inner layer and the outer layer. Since the inner layer of
150
component is directly exposed to the incoming steam, the variation in the
parameters of incoming steam will have greater influence on the
temperature of the inner layer of component. Since the bulk of the material
is behind the inner layer, there is a transient lag in transmission of the effect
of changes in temperature from inner layer to outer layer of component.
This results in thermal stressing of inner and outer layers of material, when it is
heated or cooled.
Since the inner layer of turbine cylinder metal is exposed to the
incoming steam directly, it experiences the effect of increase in steam
temperature quickly during cold start-up. But the other layers of metal
underlying the inner layer will lag behind due to the reason that the
conduction of heat takes place with a time lag. Due to this, the outer layers
are still cold while the inner layer is hot. The inner layer is thus subjected to
compressive stresses as they are constrained from expanding and the outer
layer is subjected to tensile stresses. The magnitude of compressive stress
will be high and is proportional to the difference between the temperature
at the inner layer and the mean integral wall temperature (the average
temperature in the rest of the material). The mean wall temperature is
measured approximately at the layer, which is at 50% of the thickness of the
material.
During unloading of turbine, the inner layer is experiencing quickly the
effect of cooling and the other layers underlying will lag behind. In
attempting to contract, the inner layer is subjected to tensile stresses. The
outer layers will be subjected to compressive stresses. The magnitude of
tensile stress will be high and proportional to the difference between the
temperature at the inner layer and that at the mean integral wall.
Thus the inner layer of turbine component is subjected to high
magnitude of compressive stress during loading and tensile stress during
unloading. When the turbine component is subjected to both compressive
stresses (during loading) and the tensile stresses (during unloading) once, it
is said to have experienced a LOAD CYCLE.
151
When the magnitude of thermal stress is low and does not exceed
the elastic limit, the material is not damaged by repeated load cycles. But
if the thermal stress gets increased to plastic region, material fatigue occurs
with additional strain. The number of load cycles, the total stress
experienced and the strain amplitude are deciding factors for assessing the
material fatigue. The pattern of thermal stressing for start up and shut down
of a turbine is shown in Fig.69.
3.4.3 Permissible Thermal Stress Levels :
The permissible stress level, which is a measure of the temperature
difference between the temperature at the inner layer of the component
and the mean integral wall temperature.
In Fig.67. the mean integral wall temperature Tm is shown in the x-axis
and the thermal stress (0i-0m) in the Y-axis while 0i is the inner surface layer
temperature. The permissible stress level curves for starting up and
shutdown are shown. The difference in temperature (0i-0m) is positive
during start-up and negative during shutdown accordingly. These curves
indicate the permissible temperature difference (0i-0m) for different mean
integral wall temperatures 0m.
3.4.4 Need Of TSE:
The stress evaluator generally monitors the following components of
turbine.
Main steam stop valves and control valves where the stress occurs
during start-up.
High-pressure turbine casing and the rotor where high stresses can
occur after start-up, and also during loading and load changes.
Intermediate pressure turbine rotor where high stresses can occur,
during start-up, mostly in the low load range after synchronizing the
turbo generator with the grid.


152
3.4.5 Measurement Of Stress And Importance Of Margins.
(Ref. Fig. 68)
The point A is taken as an example for starting up/loading. The
point A refers to the present actual stress level expressed as the
temperature difference (0i-0m) i.e. AC for the mid wall temperature of 0m
at C. The points B & D refer to the corresponding permissible stress
levels for starting up/loading and shutdown/unloading respectively. The
upper margin AB is the limit available for loading. By evaluating the value
of upper margin AB the rate of loading is decided. Turbine stress evaluator
calculates the upper margin and then evaluates the desirable rate of
loading. For the same point A the lower margin
AD is the limit available for unloading of turbine. By calculating the
lower margin, the rate of unloading is evaluated for the same condition A.
The point E indicates the situation arising due to unloading of turbine
when the shutdown is being carried out. Here, the calculation of lower
margin is useful to evaluate the desirable rate of unloading. (Here, 0i-0m is
negative since 0i the surface temperature always follows the steam
temperature and 0m the mid wall temperature lags behind). For the
same condition E, the upper margin EH is useful for evaluating the
desirable rate of loading.
3.4.6 Upper Margin:
The temperature margin is a measure of the degree to which the
turbine can be subjected to thermal stresses during changes in operating
conditions.
The upper margin is an indication of the highest possible change in
speed/load based on the instantaneous stress conditions, which the turbine
can withstand without being overstressed. If the turbine condition is such
that the available upper margin is minimum, it means that the component is
being stressed to its permissible limit. Further increase in the speed/load
should be made at a rate, which will maintain the same stress conditions.
153
By this way, the optimum start-up/loading is achieved without overstressing
the component.
If the turbine is started up such that the permissible stress limit is
exceeded and the upper margin does not exist at all, it means that the
material of component is being overstressed. Turbine Stress Evaluator
comes into action (In case of EHC Speed / Load loop) to unload the
turbine till the upper margin is improved to zero. During unloading, the
reduction in steam flow and its pressure decreases the temperature
differential (0i-0m) and hence the thermal stresses. For having adequate
upper margin, it is desirable to maintain the same steam parameters for
some time or to reduce the rate of loading.
3.4.7 Lower Margin:
The lower margin is an indication of the extent to which the rate of
unloading of turbine can be done, during the shutdown of turbine. If the
turbine is unloaded such that the permissible stress limit is exceeded and the
lower margin does not exist at all, it means that the material is being
overstressed. To keep the stress within the limits, the steam input to the
turbine is to be increased or the turbine should be loaded.
3.4.8 TURBINE STRESS EVALUATER: (STAGE II) :
The turbine stress evaluator (stage II units) monitors five turbine
components in five channels. Two channels in the Admission Zone and
three channels in the turbine zone are monitored. An analog computer is
entrusted with the task of evaluating the stresses in the five components,
determining the smallest of the upper and the lower margins and displaying
them in an indicator and also a recorder. The monitored components are
HP stop valve & HP Control valve in the Admission Zone and HP Shaft, HP
Casing and IP Shaft in the Turbine Zone.



154
3.4.9 Input Signals To Evaluator :
The input temperature signals for the turbine stress evaluator are
supplied by wall temperature sensors (thermo couples). These sensors,
shown in Fig.78, measure the temperature at the inner surface exposed to
steam (Ti) and the mean integral wall temperature (0
m
) (i.e. 100% and 50%
deep respectively).
Since at present there is no reliable way of measuring temperatures in
rotating components, indirect methods are used for ascertaining the
temperatures. The surface temperature of the shaft is determined by
measuring the temperature at a point of the casing whose behaviour is
similar to that of an imaginary point on the surface of the shaft. The point of
measurement in the casing is located after taking the following conditions
in to consideration.
1) Identical steam temperature and identical changes in steam
temperature.
2) Identical heat transfer characteristics.
3) Identical magnitude of mass distribution.
4) Identical cooling down behaviour.

From this measured value, the mean integral wall temperature of the
shaft is computed. The details of thermocouples useful for Turbine stress
Evaluator are given in TABLE below:









155

Sl. No. Ref. No. Legend Location of Thermo Couple for TSE.
1. LBA 10 CT 001 A Main steam temp before strainer.
2. LBB 10 CT 001 A HRH steam temp before strainer.
3. MAA 10 CT 001 A 0
I
MSV

HPSV (L) Metal temp at 100%
depth.
4. MAA 10 CT 001 B 0
m
MSV HPSV (L) Metal temp at 50% depth.
5. MAA 10 CT 011 A 0
I
MCV HPCV (L) Metal temp at 100%
depth.
6. MAA 10 CT 011 B 0
m
MCV HPCV (L) Metal temp at 50% depth.
7. MAA 50 CT 006 A 0
I
HPS HP Outer casing I/L section metal.
temp at 100% depth.
8. 0
m
HPS Calculated value.
9. MAA 50 CT 001 A 0
I
HPC HP OC metal temp at 100 % depth.

10. MAA 50 CT 001 B 0
m
HPC HP OC metal temp at 50 % depth.

11. MAB 50 CT 011 0
I
IPS IP innercasing metal temp at 100 %.
depth.
12. 0
m
IPS Calculated value.

In addition to the metal temperature, the actual load and the actual
speed signals are also used as input signals. These input signals are
received from Electro Hydraulic Controller.
The actual load signal is acquired for calculation of load margins and
also for display. The actual speed signal is useful for display as well for
calculation of speed margins.


156
3.4.10 Functioning Of Turbine Stress Evaluator :
Five different computing channels for monitoring the turbine
components, viz. HP stop valve & HP Control valve in the Admission Zone
and HP Shaft, HP Casing and IP Shaft in the Turbine Zone are provided in the
system. These five channels function independently.
In each computing channel, the metal temperature values at the
inner wall of turbine component and the mean integral wall (at 50% of
metal thickness) are [measured or computed]. The inner wall temperatures
(( 0I MSV, 0I MCV), (0I HPS 0I HPC & 0I IPS)) and the mean integral wall
temperatures ((0m MSV, 0m MCV),(0m HPS 0m, HPC 0m IPS)) are measured /
computed for five channels. The difference between the inner wall
temperature 0I and the mean integral wall temperature 0m is calculated
and this temperature difference is a representation of current actual
thermal stress induced in the monitored component. The difference in
temperature calculated for five channels are shown as A (0i-0m) MSV, A
(0i-0m) MCV, A (0i-0m) HPS, A (0i-0m) HPS and A (0i-0m) IPS.
The permissible stresses in terms of temperature difference for five
channels are shown as A (0i-0m) MSV (P), A (0i-0m) MCV (P), A (0i-0m) HPS
(P), A (0i-0m) HPS (P) and A (0i-0m) IPS (P). The permissible stress values for
HP Shaft, HP Casing and IP Shaft against the mean integral wall
temperature are shown in figures. These permissible temperature difference
values are already stored and they are pre-determined values based on
the turbine metal and the number of load cycles for which the turbine
component was designed.
Comparison of current actual stress with permissible stress will give the
current upper temperature margin (useful for speed raising and loading)
and the current lower margin (useful for unloading) for each computing
channel. The smallest margin of the three upper margins and the smallest
margin of the three lower margins will be selected finally for further
processing and display.
157
The smallest upper and lower margins are displayed, in TSE indicator.
The actual speed n act measured for Electro Hydraulic Controller is also
used here for display and for calculating the speed margins. During
loading of turbine, the actual load measured for Electro Hydraulic
Controller is also used here for display and for calculating the load margins.
The upper load margin is added to and the lower load margin is subtracted
from the actual load. The load range, thus obtained, is useful for display as
the maximum and the minimum permissible load.
The turbine stress evaluator is logically integrated with Electro
Hydraulic Controller. The change in speed / load are carried out by Electro
Hydraulic Controller after receiving the guidance from turbine stress
evaluator in order to achieve the optimum power generation for the unit.
The influence of turbine stress evaluator is effected up on the speed
and the load control loops of Electro Hydraulic Controller. When the speed
loop of EHC is in service, the turbine stress evaluator, passed on upper
margin, influences the rate of change of speed set point through speed
reference limiter.
When the load control loop is in service, the turbine stress evaluator
changes the rate of loading / unloading according to available upper and
lower margins. If the upper margin is completely utilized and exceeded, the
load set point is even reduced by stress Evaluator to make the margin zero
again.
When the Mechanical Hydraulic Controller is in service, the influence
of stress Evaluator can not be had and hence TSE guides the operating
Engineer through its display of indicator.






158

3.4.11 TSE Indicator :
The Turbine stress evaluator indicator is divided vertically in to two
semicircular sections as shown in the Fig.66. The speed and the temperature
margins are displayed on the left hand section during warming up and
speed raising operations (before the generator in synchronized). The actual
load and the load margins are displayed on the right hand section during
loading and normal operations (after the generator has been
synchronized). The section which is in use at a particular instant is
illuminated.
Two independently rotating discs are provided in the indicator. In
each disc, a semicircular area is red coloured and the other semicircular
area is transparent. Both the discs can form a sector for indicating the
margins. Another moving white coloured circular scale is also provided
behind the above two discs. The left hand section of this disc indicates the
scale of speed while the right hand section the scale of load. This disc
rotates accordingly in such a way that the arrow provided indicates the
actual speed (left side) / the actual load (right side). A static temperature
scale is also provided at the area inside the above white coloured disc as
shown in Fig.66.
During the operation of speed rising, two circulator discs rotate in
such a way that they form a transparent sector of a circle at left hand
section of the indicator. The remaining area of the circular discs in opaque.
Inside this transparent sector, the actual speed of turbine is indicated by left
hand side arrow on the moving white coloured disc as shown in the figure
(10). The upper boundary of the transparent sector is formed by two discs
such that it indicates the speed obtained after adding the upper margin to
actual speed. The lower boundary of the transparent sector is formed by
two discs such that it indicates the speed obtained after subtracting the
lower margin from the actual speed. Thus the speed range is actually
displayed. The discs also display temperature margins on the static scale
159
provided. The opaque sections of the discs cover the temperature scale,
which is not to be displayed.
When the turbo-generator is synchronized and loaded, the display
automatically gets changed over to right hand section of the indicator.
During on-load operation the discs display the actual load and the load
margins similar to the left hand side display explained earlier.
At the top of the indicator, two green rectangular indications with the
following inscriptions are provided.
ADMISSION & TURBINE
and is also a red coloured fault alarm indicator between these two
indications.
In the TURBINE rectangle, there are LEDs loaded above and below
the letters HP & IP (for HP and IP. Illumination of appropriate LED will
indicate the channel from which the upper margin / the lower margin is
selected for display and process.
Push buttons are provided for Turbine Stress Evaluator at Electro
Hydraulic Control Desk Insert for the following:
LED Light Emitting Diodes.
i) To display Admission Zone when right hand section Turbine Zone
is illuminated and vice versa.
ii) To display temperature margins (upper and lower margins) for a
particular channel (i.e. MSV, MCV, HP Shaft, HP Casing & IP Shaft) selected.









160
3.4.12 TSE Margin Recorder :
The individual margin upper & lower can be inferred from the TSE
Margin Recorder. The details are as follows.
S.No Description.
1. uu MSV Upper margin.
2. uL MSV Lower margin.
3. uu MCV Upper margin.
4. uL MCV Lower margin.
5. uu HPS Upper margin.
6. uL HPS Lower margin.
7. uu HPC Upper margin.
8. uL HPC Lower margin.
9. uu IPS Upper margin.
10. uL IPS Lower margin.
11. uu / uL Load margin.
12. q act / P act Speed / Load.

161
Channel - I MSV Permissible Margin Generation
-4.0
-2.0
0.0
2.0
4.0
6.0
8.0
10.0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 10
0m MSV

M
S
V

(
P
)
Heating up
Cooling down
S
t
a
r
t

u
p
S
h
u
t

d
o
w
n

Channel - II MCV Permissible Margin Generation
-4.0
-2.0
0.0
2.0
4.0
6.0
8.0
10.0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 10
0m MCV
A
(
0
i
-
0
m
)
M
C
V

(
P
)
Heating up
Cooling down
S
t
a
r
t

u
p
S
h
u
t

d
o
w
n


162
Channel - III HPS Permissible Margin Generation
-6.0
-4.0
-2.0
0.0
2.0
4.0
6.0
8.0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 8 9 10
0m HPS
A
(
0
i
-
0
m
)
H
P
S

(
P
)
Heating up
Cooling down
S
t
a
r
t

u
p
S
h
u
t

d
o
w
n
Channel - IV HPC Permissible Margin Generation
-4.0
-3.0
-2.0
-1.0
0.0
1.0
2.0
3.0
4.0
5.0
6.0
0 1 2 3 4 5 6 7 8 9 10
0m HPC
A
(
0
i
-
0
m
)
H
P
C

(
P
)
Heating up
Cooling down
S
t
a
r
t

u
p
S
h
u
t

d
o
w
n

163



Load Margin - HP Turbine
-4
-2
0
2
4
6
8
10
12
5 6 7 8 9
0 m MT min
L
o
a
d

M
a
r
g
i
n

164


Load Margin - IP Turbine
-6
-4
-2
0
2
4
6
8
10
12
4 4.5 5 5.5 6 6.5
0 m MT min
L
o
a
d

M
a
r
g
i
n
165
3.4.13 LIMIT CURVES FOR FIVE TURBINE COMPONENTS BEING MONITORED
BY TURBINE STRESS EVALUATOR.

1. Permissible temperature difference A0 in the wall of HP main stop valve
and control valve casing.
2. Permissible temperature difference A0 in the wall of HP casing.
3. Permissible temperature difference A0 in the wall of HP turbine shaft.
4. Permissible temperature difference A0 in the wall of IP turbine shaft.























166































167































168































169































170
3.5.0 TURBO SUPERVISORY SYSTEM :
3.5.1 Critical Parameters Of Turbine:
The monitors of Turbo Supervisory System perform the following
functions:
a. They convert the output of the transducers into usable signals
depending upon the purpose for which they are required.
b. They actuate alarms and trips, when some preset operating limit is
exceeded
The following critical parameters of Turbine are measured and
monitored:
- Turbine bearing metal temperature
- Vibrations in one or more points of support of Turbo generator
- Valve positions (Stop Valves & Control Valves)
- Rotational Speed of Turbine
- Thermal Expansion of Turbine casing related to a fixed point.
(Casing Expansion)
- Differential Expansion between the rotor and the casing of the
Turbine
- Axial Displacement of Turbine rotor relative to Thrust bearing (Axial
shift)
The points of measurements of turbo supervisory system are as
detailed in Table-I.

S.No
Parameter
measured
Type of Pick-up
Location of the
Pick-up
I
CASING
EXPANSION


1
HP casing
expansion
Inductance (Rope and
Cam arrangement)
HPT front bearing
Pedestal

2
IP casing
expansion
Inductance (Rope and Cam
arrangement)
HPT rear bearing
Pedestal
171

II
DIFFERENTIAL
EXPANSION


1

HP differential
expansion

Inductance
(non contact type)
Adjacent to HPT
Front bearing

2

IP differential
expansion

Inductance
(non-contact type)
On coupling
between IP and LP
rotor

3

LP differential
expansion

Inductance
(non-contact type)
On coupling
between
LP & Gen rotor
III

AXIAL SHIFT

Inductance
(non-contact type)


On coupling
between HP & IP
rotor

IV

SPEED OF TURBINE Halls effect
Adjacent to gear
coupling of MOP
V

VALVE POSITION


1 HP control valves
Inductance (Rope and
cam arrangement)
Respective valves

2 IP control Valves


3
LP bypass control
valves

VI

RELATIVE VIBRATION
OF TG SHAFT


1 HP turbine front
Eddy current
(non-contact type)
Adjacent to HPT front
bearing

2 HPT rear
Adjacent to Thrust
bearing

3 IPT rear
Adjacent to IPT rear
bearing

4 LPT rear
Adjacent to LPT rear
bearing
172

VII
ABSOLUTE VIBRATION
OF BEARING PEDESTAL


1 HPT front
Seismic
Mass
(Contact
type)
Pickups are provided just
above the respective shaft
vibration pick-ups

2 HPT rear


3 IPT rear


4 LPT rear


5 Generator Front


6 Generator Rear

VIII

TURBINE BEARING METAL
TEMPERATURE
Ni Cr Ni
Thermo
couples


1 HP front Top L, Top-R Bot-L, Bot-R (4 nos)

2 HPT rear
Top L, Top-R Bot-L, Bot-R (8 nos)
Front & Rear

3 IPT rear Bot-L, Bot-R (2 nos)

4 LPT rear
Front-Bot Right, Rear Bot Right
(2nos)

5 Generator Front
Front-Bot Right, Rear Bot Right
(2nos)

6 Generator Rear Bearing Liner (2nos)

3.5.2 Inductive Transducers:
Inductive transducers are those in which the self-inductance of a coil
or the mutual inductance of a pair of coils is altered in value due to
variations in the value of the quantity under measurement.
The measuring principle is based on the fact that the impedance of a
coil with iron core depends on the size of air gaps in the magnetic circuit.
The curve of the characteristic ie., Impedance as a function of the air gap
is shown in Fig: 71(a). The characteristic almost has the shape of hyperbola.
It has its maximum value when the air gap is zero and approaches a value
called Basic Impedance Zero as the air gap becomes larger. This strongly
173
bent characteristic is very steep when the air gaps are small. When the air
gap becomes larger, no measuring effect can be observed.
A measuring set up comprising 2 coils are shown in Fig: 71(b). If there
is a relative displacement of the shaft with respect to the housing (in a
turbine), the air gaps d1 and d2 between measuring disc at the shaft and
the 2-coil cores change and the inductances L1 and L2 thus change as well
but inversely. If the displacements are small, the change in inductance is
approximately proportional to the change in the air gap.
These 2 coils L1 and L2 are connected to form a measuring bridge as
shown in Fig: 71(c). A fixed a.c voltage is fed to the bridge across the
terminals (2) and (4).
For a particular position of the collar of the turbine shaft, the air gaps
d1 and d2 are identical. Hence the bridge is in balanced/equilibrium. When
the bridge is in balanced state, there is no potential difference across the
terminals (1) and (3).
When the turbine shaft changes its position, the air gaps between the
coils L1 and L2 and the collar will vary. This varies the inductance of the coils
L1 and L2 resulting in unbalancing of the bridge. Hence a potential
difference exists between the terminals (1) and (3) and this output voltage is
processed as measured quantity. The characteristic of this measuring set up
i.e., the output voltage as a function of air gap is shown in Fig: 71(d). The
characteristic is almost linear in the area of passage through zero and this
area is used for measuring the quantity.
This type of inductance transducers i.e., non-contact type is used for
HP, IP, LP differential expansions and axial shift of Turbine. Inductance type
transducers (contact type) are used for measuring HP, IP casing expansions,
HP, IP control valve positions and LP bypass control valve positions.




174
3.5.3 Casing Expansion:
Whenever any metal is heated up, it tends to expand in all directions.
In the same way, when the steam is being admitted into turbine, both the
rotor and the cylinder expand. The cylinder and the rotor of the turbine are
supported in such a way that they are free to expand thermally.
Absolute thermal expansion of the turbine cylinder with reference to
its fixed point is referred to as Casing Expansion.
The fixed points of 210 MW turbine casing are as shown in the Fig: 4.
Supports for the turbine casing are as detailed below.
IP rear pedestal and LP rear pedestal are anchored rigidly over the
concrete foundation. Since IP casing and LP casing are supported on these
pedestals, they act as absolute fixed points for the respective casings.
Moreover the middle of the LP turbine outer casing is supported on the
concrete foundation through key and key-ways (Left & Right). Thus the
middle point of LP turbine outer casing acts as absolute fixed point for
thermal expansion. This facilitates thermal expansion of one half of LP outer
casing towards IP turbine end and the other half towards the generator
end. Since IP rear pedestal and LP rear pedestal are fixed points the
thermal expansion of both halves of LP turbine outer casing (with reference
to middle fixed point) towards both the ends is accommodated by stainless
steel bellows provided for this purposes.
HP front and rear pedestals are located on the concrete foundation
with a sliding support. HP outer casing is seated over these two pedestals.
IP outer casing is seated over HP rear pedestal (sliding support) and IP
rear pedestal (fixed support).
3.5.4 IP Turbine Casing Expansion:
IP turbine outer casing, on heating, will expand towards HP turbine
end with reference to IP rear pedestal as fixed point. IP turbine casing
thermal expansion hence results in physical movement of HP rear pedestal.
Hence, the pick up of IP turbine casing expansion is located on the
bedplate of HP rear pedestal.
175
3.5.5 HP Turbine Casing Expansion:
HP turbine outer casing, on heating, will expand towards HP front
pedestal with reference to IP rear pedestal as fixed point. But the effect of
IP turbine casing expansion will be super imposed on HP turbine casing
expansion. The pick up of HP turbine casing expansion is located on the
bedplate of HP front pedestal. Hence the value measured by this pick up
will be a total of HP turbine and IP turbine casing expansions and it is not an
absolute thermal expansion of HP casing alone.
The transducer used for measuring HP/IP turbine casing expansion is
of inductance type (contact type). The part which is subject to a linear
movement and whose movement is to be measured i.e.: HP front pedestal
for HP casing expansion / HP rear pedestal for IP casing expansion is
connected by a rope to a rotatable measuring device called as CAM as
shown in Fig. 72. This measuring device (cam) forms the magnetic return
path for the two sensor coils. The linear movement of the HP front/rear
pedestal will be transmitted as a rotary movement of the cam through the
rope. The air gaps between the cam and the coils depend on the angle of
rotation. As the air gaps vary due to the rotation of the cam, the output
voltage of the bridge will also vary.
3.5.6 Differential Expansion:
Differential expansion is the difference in the thermal expansions of
the rotor and the casing. Differential expansion = Rotor expansion Casing
expansion
The phenomenon of differential expansion is encountered during start
up and initial pick up of load and differential contraction on occasions of
sudden load throw off.
Differential expansion is said to be positive, when the total expansion
exceeds that of the casing and vice versa.
The rate of expansion / contraction of the rotor is faster than of the
casing because of the following reasons:
176
(i) The mass of the rotor is less, compared to the mass of the casing,
which is heavy.
(ii) The rotor is rotating in full jacket of steam while the inner portion of
the casing alone is exposed to the steam.
(iii) The shell thickness of the casing is more and this accounts for the
slow rate of expansion / contraction of the casing.
The value of the differential expansion tends to increase while starting
and loading and also during unloading and tripping of the turbine. Since
the rotor is revolving with very close clearances with stationary components
of the casing, an uncontrolled differential expansion would prove to be
unsafe for the turbine. This is because; such a condition may lead to
rubbing, vibration and consequent damage to the equipment. Hence
continuous monitoring of the values of the differential expansion of all the
turbine cylinders becomes necessary.
Differential expansion is measured at three points viz HP differential
expansion, IP differential expansion and LP differential expansion.
The turbo-generator rotor is supported by a double collar combined
journal and thrust bearing located in HP rear pedestal and 5 journal
bearings in total. The thrust bearing acts as a fixed point for the rotor and
with reference to that point the rotor can expand thermally on both
directions (towards generator end and HP front pedestal end). Since the HP
rear pedestal itself is located with a sliding support, the fixed point for the
rotor is relative only.
The fixed points for the casing and the rotor shown in Fig.4. It may be
observed that the inner casings of HP, IP and LP turbines are supported in
their respective outer casings in such direction in all three cylinders.





177
3.5.7 HP Turbine Differential Expansion
Transducer of the HP differential expansion is located in the HP front
pedestal adjacent to the journal bearing in such a way that it measures the
linear movement of a measuring disc / collar which is provided in the HP
rotor. The linear movement of the measuring disc is due to the following
thermal expansions.
(i) Since the IP casing expansion leads to physical movement of the
HP rear pedestal, the thrust bearing itself is subjected to a movement
towards the HP front pedestal end and hence the entire rotor itself. Hence
the measuring disc is also subjected to an equivalent physical movement
towards the HP front pedestal end.
(ii) Direction of HP rotor expansion with reference to the thrust bearing
(fixed point) of the rotor is towards the HP front pedestal end and the
measuring disc hence moves towards HP front pedestal end due to HP rotor
expansion
(iii) Since the transducer is mounted on HP front pedestal, the effect of
HP and IP casing expansions together will result the movement of the
transducer towards the HP front pedestal end.
The nett liner movement of the measuring disc due to the above 3
effects is measured by the transducer as HP Differential Expansion.
The transducer is of Inductance type (non-contact type). A
measuring set up comprising 2 coils as shown in Fig. 73 is provided. If there is
a relative displacement of the rotor with respect to the casing i.e., due the
differential expansion, the air gaps d1 and d2 between the measuring disc
(in the rotor) and the two coils will change. Thus the inductances L1 and L2
change as well but inversely.
The coils are connected to form a measuring bridge as shown in
Fig.73. Alternating current is fed to this bridge, which is in equilibrium when
the air gaps are the same. The output voltage of the measuring set-up
depends on the changes of the air gaps and this will be measured as HP
differential expansion.
178
3.5.8 IP Turbine Differential Expansion:
Transducer for the IP Turbine differential expansion is located in the IP
rear pedestal adjacent to Hydraulic turning gear in such a way that it
measures the linear movement of a measuring disc/collar which is provided
in the IP/LP rotors coupling itself. The linear movement of the measuring
disc is due to the following thermal expansions:
1. Since the IP casing expansion leads to physical movement of the
HP rear pedestal, the thrust bearing itself is subjected to a movement
towards the HP front pedestal end and hence the entire rotor itself. Hence
the measuring disc is also subjected to an equivalent physical movement
towards the HP front pedestal end.
2. Direction of IP rotor expansion with reference to the thrust bearing
(fixed point) of the TG rotor is towards the Generator end and the
measuring disc hence moves towards the Generator end due to IP rotor
expansion.
3. The transducer is mounted on IP rear pedestal and it is not
subjected to any physical movement, as IP rear pedestal is the absolute
fixed point for the casing.
The net linear movement of the measuring disc due to the above 3
effects is measured by the transducer as IP Differential Expansion. The
transducer is of Inductance type (non-contact type), which is explained in
sec: 3.5.7 for HP Differential Expansion.
3.5.9 LP Turbine Differential Expansion:
Transducer for measuring the LP turbine differential expansion is
located in the LP rear pedestal at the coupling between the Generator
rotor and the LP rotor. The face of the coupling itself is of a double cone
shape and the transducer measures the linear movement of the double
cone. The linear movement of the double cone is due to the following
thermal expansions:


179
1. Since the IP casing expansion leads to physical movement of the
HP rear pedestal, the thrust bearing itself is subjected to a movement
towards the HP front pedestal and hence the entire rotor itself. So the
measuring double cone is also subjected to equivalent physical movement
towards the HP front pedestal end.
2. Direction of LP rotor expansion with reference to the thrust bearing
(fixed point) of the rotor is towards the Generator end. The effect of IP rotor
expansion will be superimposed on LP rotor expansion since both the rotors
are coupled together. So the measuring cone moves towards the
Generator end due to LP rotor expansion as well as IP rotor expansion.
3. The transducer is mounted on LP rear pedestal and it is not
subjected to any physical movement, as the LP rear pedestal is the
absolute fixed point for the LP turbine casing.
The net linear movement of the measuring cone due to the above 3
effects is measured by the transducer as LP Differential Expansion.
The transducer is of Inductance type (non contact type). A
measuring set up comprising of 2 coils arranged obliquely is shown in Fig. 73.
Generally the transducers meant for differential expansion measurements
are positioned parallel to the rotor collar, but in the double cone
arrangement adopted here, the measuring cone makes an angle of 15
deg with the horizontal line.
The transducer is positioned parallel to this angled face at a distance
a. Now let Ab be the actual displacement to be measured.
Then Aa = Ab sin | = Ab sin 15
= 0.25 Ab
For a cone angle of | = 15 , an axial displacement of b results in
an air gap change of Aa, which is equal to 0.25 Ab. Thus the large
changes in displacement can thus be reduced to relatively small changes
in the air gaps.


180
3.5.10 Axial Shift Of Turbine:
The axial shift of turbine rotor is the physical shift of rotor due to the
action of any unbalanced axial thrust on it.
The axial thrust experienced by the multistage rotor in the direction of
steam flow depends on the rate of steam flow and pressure drop in the
moving blades in various stages of the Turbine. When the steam passes
through the moving blades of a reaction stage, the rotor experiences an
axial thrust due to pressure drop across the moving blades.
The cumulative axial thrust on the rotor needs to be balance exactly
so that the rotor acquires a correct and fixed position in its dynamic
condition. The shift of the rotor takes place when an unbalanced condition
sets in. The rotor spins at a very high speed; the moving blades and the fixed
blades are in very close proximity to each other and the clearances at the
labyrinth glands are also very small. Such conditions naturally warrant that
the rotor position should be very much exact. A shift of the rotor to an
impermissible extent leads to, rubbing at the labyrinth glands and blades,
vibrations and finally failure. Hence a close watch on the axial shift is
warranted.
The IP and LP turbine stages are of double flow type. Hence the axial
thrust gets balanced automatically since the rate of steam flow and the
amount of pressure drop across the stages are opposite and equal. In HP
cylinder, which is of single flow type, the rotor would experience cumulative
axial thrust due to the pressure drop in all the stages of the moving blades.
This cumulative axial thrust is balanced by the provision of a Balance Piston.
To maintain proper axial position and to take up any unbalanced
axial thrust, the turbo-generator rotor is positioned and supported by a
double collar thrust bearing located in the HP rear pedestal. In the thrust
bearing, 2 collars, which are integral with the rotor, rotate between the
thrust shoes made up of segments and thus they are supported. The
clearance between the collar and the shoes is small and the bearing is
lubricated by forced circulation of lub oil. If the rotor starts to move in either
181
direction (due to unbalanced condition), the axial thrust is transmitted to
the shoes through the lub oil film.
Transducer for measuring the axial shift of the turbine rotor is located
in the HPT rear pedestal adjacent to the thrust bearing in such a way that it
measures the linear movement of a measuring disc provided in the
coupling outer surface between HP and IP rotors. Since the thrust bearing
acts as a fixed point for the rotor, the thermal expansion of the rotor here is
zero. Hence the effect of thermal expansion of the rotor will not affect the
position of the measuring disc. Movement of this measuring disc is only due
to physical shift of the rotor (due to unbalanced axial thrust). The transducer
thus measures true physical axial shift of the rotor.
The transducer is of Inductance type (non contact type), which is
similar to the one, explained in sec: 3.5.7 for HP differential expansion.
3.5.11 Turbine Speed:
The speed of a turbine is a measure of revolutions in unit time and it is
measured as revolutions per minute. The operating speed of turbine is 3000
rpm.
Measurement and monitoring of the speed of turbine will be
necessary for the following:
i. For automatic control of the turbine control valves for speed
raising during start-up
ii. During normal operation, the optimum speed of the turbine is to
be maintained.
iii. To help the operator to run the turbine at an optimum speed
during emergencies such as load shedding, grid disturbances etc.,
iv. To achieve accurate speed control when the generator feeding
only to its unit auxiliaries (house load condition).
v. For conducting the over-speed test.



182
Transducer for the measurement of turbine speed works on the
principle of Hall Effect and it is called Hall probe. This Hall probe is located
in the HPT front pedestal at the coupling end of main oil pump adjacent to
Hydraulic speed transducer (Governor impeller)
3.5.12 HALL Effect:
In this principle, a semiconductor plate is placed as a probe and
supplied with a constant current I as shown in Fig. 74 when a transverse
magnetic field is applied, it produces an output voltage VH is proportional
to the flux density B of the transverse magnetic field. If a permanent
magnet is attached to a moving object, the reluctance of internal
magnetic circuit gets changed with the changes in the distance between
the object and the probe. This leads to changes in the flux density. As this
probe converts the magnetic flux density into a proportional voltage, all the
characteristic parameters of flux densities changing in time can also be
measured.
3.5.13 Measurement Of Speed:
In this arrangement, a non-magnetic disc is fitted with 120 small
magnets of alternating polarity around its circumference. The disc is
mounted on the shaft by means of the hub ring at the coupling end side of
main oil pump. Four Hall effect generators (Hall probes) are placed
opposite at a small distance from the pole surface of the disc as shown in
Fig: 59. These probes are of contact less type and three out of four probes
are used here. When the turbine rotor is in rotation, the reluctance of the
magnetic circuit gets changed alternately and hence the flux density. This
leads to the generation of an alternating voltage whose frequency is
proportional to the speed of the turbine rotor.
3.5.14 Generation Of Actual Speed Signal:
The output signal of each Hall-effect generator is approximately
sinusoidal and its frequency is proportional to the speed of the turbine. The
output signal of each Hall probe is passed to a separate pulse converter.
Each of these pulse converters amplifies the Hall effect voltage and
183
multiplies to form 3 square wave signals. One of the 3 signals of each pulse
converter is routed to pulse amplifiers.
A pulse monitor continuously monitors the 3 output signals of the pulse
amplifiers for failures. This is implemented by cyclical scanning of the input
pulses. The second signal in the chronological order is selected in the
channel selection circuit as the actual speed signal and supplied to a
frequency/voltage converter. In this frequency/voltage converter, the
square wave signals are converted into analog signals.
The above arrangement is needed for reliable and accurate
measurement of speed. Fixed control current is supplied to the Hall probes
from the pulse converter.
3.5.15.1 Valve Position:
Superheated steam from the boiler is supplied to the HP turbine
through 2 main steam lines. Each main steam line is having a set of HP Stop
Valves (HPSV) and HP Control valve (HPCV) just before HP turbine. The HP
turbine exhaust steam (Cold Reheat Steam) is taken to the reheater
through 2 Cold Reheat Lines. The reheated steam is sent to the IP turbine
through 2 hot reheat lines. A set of IP stop valve (IPSV) and IP Control Valve
(IPCV) is available in each hot reheat line. The exhaust steam of IP turbine is
flowing to the LP turbine through 2 cross around pipes. Finally the exhaust
steam of the LP turbine is sent to the condenser.
HPSVs and IPSVs are meant for instantaneous isolation of the turbine
from the boiler in case of turbine tripping. HPCVs and IPCVs are used to
regulate the steam flow into the turbine.
Indications about the position of the above mentioned turbine valves
are helpful for the turbine operation Engineer to understand the existing
condition of the turbine. Valve positions need to be monitored due to the
following reasons:
a. To verify whether the turbine generators execute their controlling
functions effectively.
b. To supervise the healthiness of each valve.
184
c. To observe and record the positions thereby knowing the
operating status of turbine.
d. To raise the speed of the turbine and also to control it while
starting up
e. To check whether all the turbine valves have got closed during
tripping of turbine.
f. To monitor behaviour of these whenever sudden grid disturbances
occur.
The transducer for measuring the valve position is of Inductance type
(contact type). The part which is subject to a linear movement, whose
movement is to be measured, i.e., valve stem is connected by a rope to a
rotatable measuring disc called as CAM as shown in Fig: 55. This measuring
device is similar to that explained in sec: 4.2 for the measurement of HP/IP
casing expansions.
With the above type of transducer, the positions of the following
valves are measured:
i. HP control valve (Left)
ii. HP control valve (Right)
iii. IP control valve (Left)
iv. IP control valve (Right)
v. LP bypass control valve (Left)
vi. LP bypass control valve (Right)
3.5.15.2 Vibrations:
All bodies possessing mass and elasticity are subjected to vibration.
The rotating machines are to be designed in such a way that the vibration
levels are acceptable. Reliability of Turbo-Generators performance
depends greatly upon the level of vibration. Higher level of vibration results
in fast wear out of components such as rotor, bearings, couplings etc. Since
the vibration is an application of alternating forces, it will result in
catastrophic failure of the components due to fatigue and the failure of
stationary structures such as bearing supports, bolts, foundation, pipings etc.
185
3.5.16 Causes Of Vibration:
Vibration in a rotating turbo-machine is mainly due to the
unbalance. The Rotor unbalance is the result of unequal radial weight
distribution and it is due to the geometric centre line not coinciding with the
mass centre line. Such an unbalance creates a centrifugal force that
deflects the rotor. It results in radial displacement of the rotor. A rotor is said
to be perfectly balanced when its mass distribution is such that the
summation of all the centrifugal forces is zero and the summation of the
moments of these forces about the centre of gravity is also zero.
Turbine rotors are manufactured with a high degree of precision. Still
some residual unbalance, it unavoidable. Main causes of Unbalance in a
new rotor are usually due to the factors such as machining tolerances,
assembly procedures etc. During operation, this unbalance results in
vibrations, which are transmitted through the bearing and the bearing
pedestal on to the foundation.
For the rotors, which are in service, Bow or Deflection is the cause of
unbalance. Some of the causes of shaft Bow are hereunder:
1. Lengthy horizontal turbine rotors, which are supported in one
position, for a long period after shut down, may develop bow. This is due to
non-uniform distribution of its weight along the rotor.
2. During shut down, a bow may develop in the rotor because of
non-uniform distribution of heat.
3. Rubbing in glands and seals will cause hot spots, which can bow
the rotor.
4. The weight shifts on rotor.
5. The loss of rotating elements.
6. Unequal building of silica deposits on the rotor.
Hence the perfect balance of the rotor is warranted to avoid high
level of vibrations.

186
Some other causes of vibration for new as well as old rotors are as
follows:
1. Misalignment of rotors due to improperly seated bearings.
2. Mechanical looseness at the supports.
3. Oil whirl in the fluid film bearings (oil whirl is caused by the instability
of the rotor supported in the fluid film)
3.5.17 Critical Speed:
All rotating machine components have more than one natural
frequencies of oscillation; the frequencies at which they will vibrate
enormously. When the speed of rotation is nearing its natural frequency,
even a small amount of unbalance in rotor causes unacceptable vibration
leading to resonance. The speed of the rotor is known as CRITICAL SPEED.
At these critical speeds only, all the unbalanced forces in the rotor resonate
and create maximum amplitude of vibration. Above or below each critical
speed, resonant effects diminish. Hence the turbo machines are designed
such that the natural frequencies do not coincide with the operating
speed.
3.5.18 Need Of Measurement:
Vibration measurement and monitoring are warranted due to the
following reasons:
1. It is useful to diagnose the healthiness of the turbine to avoid
failure. Any change in quiet running means a deterioration of the balanced
state of the rotor.
2. It is useful to assess the units operating time between major
overhauls.
3. It is useful to locate the failing component in the machine. A blade
rupture may cause a sudden change in quiet running.
4. It is useful to correlate with probable failures by having history of
vibration data as a function of changes in the process parameters such as
load, temperature etc.
187
5. It is useful to estimate how much longer a machine can be safely
run by observing the trend in vibration level
When the normal operating speed of the turbine rotor is less than its
first critical speed, the rotor is said to be a rigid rotor. When its normal
operating speed lies above its first critical speed, the turbine rotor is said to
be a flexible rotor. The critical speed values of 210 MW turbine rotors (Units 4
to 7 / TPS-II) are indicated below:

3.5.19 Critical Speed (in rpm):

HP rotor IP rotor LP rotor Gen. Rotor
Combine
d
1
1

First critical
speed
4230 3858 1818 1370 1544
2
2

Second
critical
speed
>3600 >3600 >3600 3400 2126
3.5.20 Absolute Vibration Of Bearing Pedestal:
Pick-up used for measuring absolute vibration of bearing pedestal is
of SEISMIC MASS TYPE (contact type). This type is a velocity transducer. In
this, the mechanical vibration is converted to an electric signal, which is
proportional to the velocity of the vibration.
The Fig.75 shows the schematic diagram of absolute vibration
measurement by means of a seismic device. In this device, a plunger coil is
suspended in an air gap. A permanent magnet is firmly connected to the
sensor housing and to the magnetic return path and it provides a strong
magnetic field around the coil. The magnetic flux in the air gap is constant.
The plunger coil is suspended from the housing by a spring. The
inherent frequency of the spring/mass is
e = 2tf = (c/m)

where m is mass of the plunger coil with spring and
C is the spring constant.
When the vibrating frequency is above the inherent frequency, the
plunger coil is steady in space due to its mass inertia. Thus a fixed point in
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space is created and the vibrations can be measured with reference to this
point.
Whenever this transducer (seismic device) is firmly connected to the
surface of the vibrating item to be measured, a relative motion is generated
between the permanent magnet and the plunger coil. When the
permanent magnet vibrates and the spring-suspended coil is stationary in
space, the coil cuts magnetic lines of force resulting in generation of
voltage.
The voltage is proportional to the vibration velocity (the rate of
vibration); the strength of the magnetic field, and the number of turns of
wire in the coil.
e = B.l.v
where e is Induced voltage, B is magnetic induction of the
permanent magnet, l is length of the conductor in the coil and v is rate
of vibration velocity.
A seismic velocity transducer responds directly to the velocity of
vibration. The voltage generated in a seismic velocity transducer is normally
expressed in terms of millivolts per mm per second. This is the sensitivity
specification for the pick up. The sensor, provided here, generates 20mV for
a vibration velocity of 1 mm/sec.
The amplitude of vibration is usually indicated rather than the rate of
vibrations. This is achieved by integrating the sensor output voltage, which is
proportional to the rate of vibrations.
3.5.21 Relative Vibration Of Shaft:
Relative shaft vibration is the radial periodic motion of the shaft with
respect to the bearing or casing. Radial shaft position is the position of the
shaft with respect to the bearing or casing and depends on the operating
state of the turbine and on the condition of the bearings. The range within
which the radial shaft position may change is very much greater than the
vibration travel amplitude of the shaft. The relative vibration is thus
superimposed over the change of the radial shaft position.
189
The measurement is carried out in a contact less manner according
to the eddy current method. A non-contact sensor requires external
electronic circuitry to generate a very high frequency a.c signal and detect
vibrations in the a.c signal caused by the vibration of the shaft.
The electronic circuit, called a signal sensor, generates a very high
frequency electrical signal. This signal is applied to a small coil of wire in the
tip of the non-contact pick-up. The high frequency electric signal applied to
the coil generates a magnetic field. This electro magnetic alternating field
generated induces eddy currents in any metallic object in the vicinity of the
coil, namely the turbine shaft (whose vibration is to be measured). The
smaller the distance between the sensor coil and the turbine shaft, these
eddy currents are larger. Due to this, the turbine shaft absorbs some of this
magnetic energy. This absorption effect places an electrical load on the
electrical signal, thereby reducing its strength. The amount of loading-
reduction in strength-is inversely proportional to the distance the coil and
the shaft. The closer the coil to the shaft, the greater the loading effect and
the smaller the amount of electrical signal.
As the shaft moves relative to the tip of the pick up, the strength of
the electrical signal changes proportional to the movement. The variation in
the strength of the electrical signal is thus proportional to the amount of
vibration and is further processed.
Schematic diagram of non-contact pick-ups is shown in the Fig. 77.
The signal sensor consists of a high frequency oscillator, an amplitude
detector (Demodulator) and an amplifier.
When the incoming supply is ON, the transducer starts working. The
oscillator generates a very high frequency electrical signal, which is applied
through a cable to a small coil of wire in tip of the pick up. The variation in
the strength of this electric signal occurs as explained earlier and it is
proportional to the amount of vibration.
The amplitude modulated high frequency electric signal of the
transducer is demodulated by the amplitude detector to give a d.c voltage
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signal proportional to the gap (the distance between the tip of the
transducer and the shaft is called Gap) and an a.c. signal voltage
proportional to vibration. These signals are then amplified to a high level to
give usable output voltages.
3.5.22 Measurement Of Temperature - Thermocouple
(Ref Fig. 78)
Thermocouple is the temperature-sensing device widely employed
for industrial applications. In steam turbines, they are used for measuring
metal and steam temperatures in addition to bearing temperature.
A thermocouple is composed of 2 dissimilar metal wires joined
together at their ends. It is a device that converts temperature difference
directly into an electric voltage when a temperature gradient exists
between the two end junctions of the pair of dissimilar metal wires. One end
is fused together to for a measuring junction called as the hot junction and
the other end, the cold junction or the reference junction and are
connected to a measuring device. The temperature at the hot junction is
determined by measuring the voltage appearing at the cold junction. The
voltage developed is a function of the difference in temperature between
the hot and the cold junctions. Hence the temperature of the cold end
junction must be accurately known.
3.6.0 HYDRAULIC TURNING GEAR:
3.6.1 Introduction:
The function of hydraulic turning gear is to rotate the Turbo-Generator
shaft system at a sufficient speed during the period before start-up and the
period after shut down. During cold or hot rolling of turbine, it is necessary to
measure and monitor the eccentricity of the rotor even before the
admission of steam into the turbine in order to ensure that no vibration is
caused and no rubbing between the moving and the stationary parts takes
place. The eccentricity of the rotor is caused when it becomes unstraight
due to bending. Hydraulic Turning gear is useful to rotate the Turbo
generator shaft system at a sufficient speed during the period before start
191
up and the period after shut down. Mechanical Barring gear is also
available as a back up.
3.6.2 Hydraulic Turning Gear: (Ref Fig. 14)
Hydraulic turning gear is located in the bearing pedestal between IP
turbine and the HP turbine. Mechanical barring gear is available as a back
up to this.
During turning gear operation, the turbo-generator shaft system is
rotated by a double row blade wheel, which is driven by oil. The oil is
supplied by the auxiliary oil pump and it flows through a gate valve gearing
and a nozzle box. Gate valve gearing is an electrically operated valve
through which the high pressure oil is supplied to turning gear thro Nozzle
box. Nozzles guide the jet of oil towards the moving blades. Nozzles increase
the velocity of oil and guide the jet of oil towards the moving blades. This
flow of high velocity jet of oil through the two rows of moving blades result in
slow rotation of the Turbo generator rotor system. (Ref Fig. 14)
Speed of rotation of TG rotor during the turning gear operation is 120
rpm without condenser vacuum and 160 rpm with condenser vacuum.
In order to reduce the gap losses at the moving blades, sealing strips
are caulked into the nozzle boxes. After passing through the moving blades,
the oil drains into the bearing pedestal and flows along with the bearing
drain oil into the return flow piping.
To overcome the initial breakaway torque on startup and to prevent
dry friction, the bearings are relieved for a short time by jacking oil supplied
below the shaft. The shafts are thus slightly.
3.6.3 Mechanical Bearing Gear
The turbo generator is also equipped with a mechanical barring
gear, which enables the combined shaft system to be rotated manually in
the event of failure of the normal hydraulic turning gear.



192
3.6.3.1 Construction
The mechanical barring gear (Ref.Fig.14) consists of a gear
machined on the rim of the turning gear wheel and a pawl. The pawl
engages with the ring gear and turns the shaft system when operated by
means of a bar attached to a lever. The pawl can be engaged or
disengaged by using a lever. The lever is held in position by means of a
latch.
3.6.3.2 Operation of STG
The following steps of operation are to be made
- Remove the cover and unlatch,
- Attach a bar to the lever,
- Barring of lever will rotate the combined turbo-generator shaft
system.
- After the barring has been completed return the lever and the
pawl to disengaged position.
- Secure the lever by means of latch and replace the cover.
The barring gear shall be operated only after the turbo-generator
shaft system has been lifted with jacking oil. If it is hard to start turning by
means of the mechanical barring gear, this may be due to incorrect
adjustment of the jacking oil system or due to rubbing of the shaft.
Corrective action must be taken before the steam is admitted into turbine.
After shut down of turbine, turning gear should be in operation till the
maximum metal temperature reaches 120 Deg.C
3.6.4 Hydraulic Lifting Device:
When the turbine is started up or shut down, the hydraulic lifting
device is used to maintain the oil film between rotor and bearings. The
necessary torque for rotation is reduced in this way when the hydraulic
device or manual turning device is in service.
The turbo-generator bearings are supplied with high-pressure oil
delivered by a jacking oil pump. The high pressure oil lifts the rotor when it is
forced under the journal of the bearings. To avoid damage to the bearings,
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the jacking oil pump must be switched ON at turbine speed below 510 RPM.
(approximately) during shut down and it should be switched OFF at turbine
speed above 540 RPM. (approximately) during start-up.
3.6.4.1 Need of the jacking oil for lifting:
The way in which liquids lubricate can be explained by considering
the example of a plain journal bearing as shown in Fig.81.
As the shaft (journal) rotates in the bearing, lubricating oil is dragged
into the loaded zone. Since the loaded zone will be the point at which the
shaft and the bearing surfaces are closet together, the entry into this zone is
tapered, like a curved wedge. As the oil is forced to move into the narrower
part of the wedge, its pressure increases, and it is this hydrodynamic
pressure, which supports the shaft load.
Increasing load reduces the oil film thickness while increasing
hydrodynamic pressure increases the oil film thickness. The hydrodynamic
pressure, in turn, is determined by the viscosity of the oil and the speed at
which it is squeezed into the wedge shaped entry zone. Thus the rise in
hydrodynamic pressure and therefore the thickness of the film will depend
on the shaft speed and the lubricant viscosity.
The relationship between speed, viscosity, load, film thickness and
friction can be understood by considering a graph shown in Fig.82. In this
graph, the co-efficient of friction is plotted against expression V/P where,
V/P = (Oil viscosity * Shaft speed)/ Bearing pressure.
There are three different zones in the graph, separated by the points
A & B.
At B, the co-efficient friction is at its minimum, and this is the point at
which the oil film is just thick enough to ensure that there is no contact
between the shaft and the bearing surfaces. The zone 3, to the right of B,
the oil film thickness is increasing and the co-efficient of friction also
increases (as the film thickness increases). This increase in the oil film
thickness is because of increasing viscosity or increasing shaft speed or
194
reducing the bearing load. Zone 3 is the zone of hydrodynamic lubrication
or Full film lubrication.
As the conditions change from B towards A, the oil film thickness
reduces and hence the shaft and the bearing rub against each other, the
amount of rubbing, and the friction increases as the oil film thickness
decreases, zone 2, between A & B, is known as the zone of mixed
lubrication or partial lubrication. The shaft load was supported by a mixture
of oil pressure and surface contacts,
At A, the oil film thickness has been reduced to nil and the load
between shaft and bearing is carried entirely on surface contact. In zone1,
the co-efficient of friction is almost independent of load, viscosity and shaft
speed. Zone1 is the zone of boundary lubrication.
The different lubrication zones also have an influence on wear, the
amount of wear which takes place depends on the severity with which two
surfaces rub against each other. In zone 3, there is no contact between the
surfaces and therefore the wear is minimum. As the oil film thickness
becomes thinner in zones 2 and 1, there is a greater tendency to wear.
When the turbine is on Turning Gear during start-up or shut down,
the shaft speed is much less compared to its normal operating speed.
Hence the shaft rotates in the region of boundary lubrication. Since the oil
film thickness is minimum during low shaft speed, there is increasingly severe
contact between the shaft and the bearing surface resulting in increased
wear and reduction in life of the bearing. To avoid this, a jacking oil system
also known as hydraulic lifting device is necessitated to supply high pressure
oil called as jacking oil under the journal of the bearing thereby slightly
lifting the journal. Slow rotation of turbine rotor during turning operation is
thus done in slightly lifted condition so as to avoid damage to the bearings.
Hence the shaft rotates now in the region of Hydrodynamic lubrication.



195
3.6.4.2 Jacking Oil System
To supply the high pressure oil for the lifting device, two jacking oil
pumps of each 100% capacity are provided on the main oil tank. When
one pump is intended to be in service, the other one is stand by.
3.6.4.2.1 Jacking Oil Pump: (Ref.Fig.18)
The jacking oil pump is a self-priming screw spindle pump with three
spindles and internal bearings. The screw spindle pump is connected
vertically to the cover plate (2) of the Main oil tank via a support (5) and
immerses with the suction casing (15) into the oil. The drive is an electric
motor that is bolted to the cover plate. The oil flows into the suction branch
of the suction casing from underneath and is supplied to the jacking oil
system by the pump via the pressure pipe (3).
The driving spindle (16) and the two moving spindles (20) run in the
inner casing (13). Due to the special profile given by the sides of the
threads, the three spindles form-sealed chambers, the contents of which
are continuously being moved axially from the suction side to the pressure
side of the pump as the spindles rotate.
There is a balancing piston in the form of a shrunk on sleeve in the
main drive spindle just above the screwed portion of the main drive spindle
and this runs inside the throttle bushing (11). Pressure oil of a small quantity
flows in a very small gap between the throttle bushing (11) and the driving
spindle (16) in an upward direction. This gap is known as throttling gap since
the pressure of oil which is coming out of this gap is very much reduced. The
oil that leaves the throttle gap flows via the grooved ball bearing (7) and
lubricates it. This bearing serves as both support and thrust bearing. There
after the oil flows through the support to the main oil tank itself via an
opening in the support. The driving spindle is fixed by means of the grooved
ball bearing in the bearing carrier (9) that is bolted to the pressure casing
(12) of the pump. The drive main spindle is a solid one. The cumulative axial
thrust generated by the main drive spindle screw is countered by the
balancing piston in the form of the shrunk on sleeve. The Ap across the
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balance piston and the annular area of it are so designed to match with
the cumulative axial thrust generated by the main drive spindle.
There are two idler screw spindles, which are hollow and are driven
by the main drive spindle whose continuous helical screw is in mesh with the
continuous helical screws of them. Pressure oil in a very small quantity flows
via gaps in the top of the screwed portion of the main drive spindle though
the hollow spaces of the two idler screw spindles in a downward direction.
The two idler screw spindles also exert a cumulative axial thrust in a
downward direction, which are to be balanced, to perform this task, each
idler screw spindle is having a balancing bushing (21) in its bottom. These
are fixed to the support plate (18), which also supports the inner casing (13)
by means of distance pipes (17) attached to it. The balancing bushing has
a small piston with a guide pin in its bottom and can move only in a vertical
direction in a small cylinder, which is open in its top. The piston is located just
below the ending point of the continuous helical screw of the idler spindle.
Pressure oil is supplied in the bottom of the piston via hollow space of the
idler spindle through a small opening. The top of the piston is exposed to
pressure less oil in the tank. The upward counter thrust provided by the
balance piston in the balancing bushing encounters the cumulative axial
thrust exerted by the continuous helical screw of each one of the idler
spindle screws in the downward direction. There is provision for leakage oil
to escape to the main oil tank from the balancing bushing on the pressure
side.
3.6.4.2.2 Jacking Oil Supply: (Ref.Fig.80).
The discharge pressure oil piping of both the jacking oil pumps is
connected in parallel to supply high pressure oil to the common jacking
header. In each discharge line, a check valve is provided to prevent the
jacking oil returning from the header to the oil tank, if the pump concerned
is not in operation. A spring loaded safety relief valve is provided between
the jacking oil pump and the check valve. This is to prevent any damage to
the jacking oil pumps discharge piping in case that the concerned jacking
197
oil pump is in operation and the check valve continues to remain in closed
position.
The pressure in the common jacking oil header is maintained at a
constant value (approximately 120 bar) by means of a pressure limiting
valve. The pressure limiting valve can be relieved by a bypass valve. The
superfluous flow from the pump is conducted into the main oil tank.
The jacking oil required for each bearing is supplied from the
common header as detailed below.
Bearing No of lines
Hp front One
Hp Rear journal cum thrust One
IP Rear Two
LP Rear Two
Generator Front Two
Generator Rear One
In each supply line, a fine control valve and a check valve are
provided. The necessary jacking oil pressure sufficient to lift the shaft varies
with respect to bearing load. The lift will be of 0.03 to 0.05 mm. The required
jacking oil pressure is set for each bearing by means of a finer control valve.
The pressure gauges mounted in the downstream pipes of these finer
control valves indicate the jacking oil pressure required for lifting. A check
valve provided in the jacking oil supply pipings prevent the lub oil from
flowing out of the bearings into the header during the normal operation of
turbine since the jacking oil pumps are out of service.
The finer control valve, the check valve and the pressure gauge for
each line are arranged in boxes, which are connected laterally to the
bearings. At the generator free end bearing alone, they are arranged in the
hacking oil piping outside the bearing housing.



198
The lift in mm of the shaft at the bearings is about 0.04 to 0.08 mm.
Bearing Jack oil pressure (in ksc) where the shaft lifts.
(When JO header pressure is 120ksc)
Hp front 40
Hp Rear journal cum thrust 60
IP Rear a) 62 b) 82
LP Rear a) 50 b) 36
Generator Front a) 80 b) 70
Generator Rear 40
The values are given above for the purpose of indication only.
During turning gear operation, the turbo-generator shaft system is
rotated by a double row blade wheel, which is driven by oil. The oil is
supplied by the auxiliary oil pump and it flows through a gate valve gearing
and a nozzle box. Gate valve gearing is an electrically operated valve
through which the high-pressure oil is supplied to turning gear. Nozzles guide
the jet of oil towards the moving blades. In order to reduce the gap losses
at the moving blades, sealing strips are caulked into the nozzle boxes.
After passing through the moving blades, the oil drains into the
bearing pedestal and flows along with the bearing drain oil into the return
flow piping.
To overcome the initial break-away torque on startup and to prevent
dry friction, the bearings are relieved for a short time by jacking oil supplied
below the shaft. The shafts are thus slightly lifted and the necessary torque
for rotation from hydraulic turning gear or manual turning gear is reduced.
Thus the bearings are relieved and the damage is avoided.
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3.7.0 CENTRIFUGE:
3.7.1 Description Of The Centrifuge: (Ref.Fig.87)
This unit consists of a centrifugal separator of type MAB-206. The
separator has a bowl, which can be assembled as a purifier or a clarifier.
The speed of rotation of the bowl is about 8425 rpm.
The process liquid enters the centrifuge through the distributor C
and flows through the space between the bowl discs D. The water particles
and solid particles experience high centrifugal force and hence move
towards the bowl periphery. The solid particles settle on the bowl wall B. The
centrifuge bowl has two outlets. The water leaves the bowl through the
outlet (4). The oil flows towards the centre of the bowl and gets discharged
through the outlet (3).
To prevent the oil from crossing the outer edge of the top disc (E)
and escaping with water, a liquid seal (5) must be provided in the bowl.
Before the process liquid is supplied the bowl must be filled with water
through the inlet (2). When the process liquid is supplied, it will then force
the water towards the periphery of the bowl. An interface (6) gets formed
between the water and the oil. Its position can be adjusted by altering the
diameter of the water outlet i.e. by exchanging the gravity disc.
3.7.2 Description Of The Oil Scheme: (Ref.Fig.88)
The dirty oil from the main oil tank is supplied to the centrifuge
through an inlet pipe. This inlet line is provided with a manual gate valve (1)
for adjusting the capacity of centrifuge, a Y type strainer (2) for pump
protection and a solenoid valve (3). The solenoid valve is of normally closed
type and it is energized to open whenever the centrifuge motor is started.
The solenoid valve will close automatically and stop the oil supply to
prevent any further wastage of oil, if any of the following faults occurs:
a) Breaking of liquid seal
b) Motor over load
c) Choking up of filter.
200
The inlet line supplies the oil to the suction of a feed pump. A view
glass provided before the pump enables the visual inspection of the oil flow.
The feed pump is built in with the centrifuge and is a gear pump. It is
provided with an integral pressure relief valve to prevent building up of
excessive pressure in the discharge side due to closure of any gate valve.
When the pressure exceeds a preset value, the relief valve opens and
discharges the oil to the pump suction itself. The suction and discharge
pressure can be read from the pressure gauge (C) and P1 respectively and
these gauges are mounted on the local panel.
The pump delivers oil to a heater tank through a check valve. The
oil is heated in this tank by means of hot water .The water is in turn heated
by electric heaters. The tank is provided with connections for water inlet,
overflow, and drain. A vent provided on top of the tank is useful to let out
water vapor and to fill up the tank quickly with water. A sight glass is also
provided for checking the water level.
Three sections of immersion type electric heaters are used for
heating the water. The required number of heaters to be in service can be
selected by means of a selector switch provided in the control panel. In
case of low water levels in the tank, a level switch is useful to trip the heater.
In case of high water temperature at 90 deg. C, a temperature switch RT
101 will trip the heaters. Two numbers of thermostats RT 101 provided the
outlet of heater tank maintain the oil temperature by tripping the heaters
through relay R2.
The heated oil is then fed to the centrifuge through a rotameter of
range 900 9000 liters per hour (lph). The oil flow through centrifuge can be
observed and maintained with the use of rotameter. The pressure and
temperature indicators provided at the oil entry point to centrifuge indicate
the pressure and temp of the incoming oil to centrifuge.
The oil is purified in the centrifuge and the water gets separated.
The water is discharged to an Antiflood tank and then drained through the
tank drain. In case of breakage of water seal inside the bowl, a high level
201
switch provided in the Anti flood tank gives an audible alarm and shuts off
the oil supply by closing the solenoid valve in the inlet oil line.
The purified oil from the centrifuge is fed to a booster pump for
raising the pressure. The booster pump delivers the oil through a polishing
unit ball filter and a check valve to the main oil tank. A pressure gauge and
a pressure switch (IPS 100) are also mounted in the pumps discharge line. If
the polishing filter gets choked up leading to an increase in the discharge
pressure of the booster pump, this pressure switch (IPS 100) trips the
centrifuge motor, and heaters II and III. The pressure switch is set to operate
at a pressure of 3 to 4 Ksc. The polishing filter is provided with an inlet valve,
an outlet valve and a bypass valve. This arrangement facilitates the
operation of centrifuge with the filter in bypassed condition.
3.7.3 Power Transmission:
The motor rotates the bowl through a friction coupling and a
worm gear. The friction coupling ensures a gentle start and acceleration
and prevents overloading of worm gear and motor. The worm gear steps
up the motor speed. To decrease the bearing wears and prevent
transmission of bowl vibration to frame and foundation, the top bearing of
the bowl spindle is isolated.
For safety of the equipment and for achieving the best separating
results, it is essential to operate the machine at the correct speed. A
revolution counter has been fitted for checking the speed. When the
centrifuge has been started, the number of revolutions of counter per
minute can be counted. It should be in the range of 118- 125 rpm.
Provision of a brake enables to bring the centrifuge shaft to rest
quickly while stopping the centrifuge. The brake reduce the retardation
time of bowl thus quickly crossing the critical speed.
202
3.8.0 CONDENSER:
The condenser of 210 MW units 4 to 7/Stage-II/TPS-II is a rectangular
shell of surface type. The exhaust steam flow pattern in the condenser is
down flow. The circulating water flow is of double pass type and the lower
tubes are in series with the upper tubes. The condenser is with divided water
boxes to have the tube nest in two parts in order to have 50% operation
during on load leak testing and maintenance. The circulating water system
is of closed circuit type with a cooling tower.
The condenser primarily comprises of
1. Condenser supports
2. Hotwell
3. Condensing chamber
4. Condenser neck
5. End tube plates
6. Tube nest
7. Water boxes
8. Air removal system
9. Steam dumping device.
The condenser is rated to handle 442 t/hr of exhaust steam at the
parameters of 0.1033 ata and 46.1 deg C.
3.8.1 Condenser Supports. (Ref.Fig. 83)
The condenser is supported on 24 springs in the two rows (2 x 12) in
order to have flexible connection with the turbine. It is rigidly connected to
the base (Bottom half) of the LP cylinder of the turbine. This kind of support
for condenser ensures effective dampening of vibration and shock and also
gives provision for thermal expansion of the LP cylinder of the turbine,
condenser neck and condenser itself.
Since the condenser has been floated over the springs, empty weight
of the condenser is taken by the springs along with partial operating weight.
The remaining operating weight is taken by the turbine foundation. While
conducting hydraulic test in the shell side of the condenser water is to be
203
filled up into steam space upto one meter above the top tube row. Prior to
filling water into condenser steam space for testing, jacking screws
provided with spring support should be used for ensuring water weight
being passed on to them, to avoid over stressing of springs. Prior to putting
the system back in operation, condenser must be floated over springs to
avoid excessive upward thrust being passed on to the turbine foundation.
3.8.2 Hotwell:
The Hotwell is in the lower part of the condenser to form a storage
tank for main condensate. It also collects the drains entering through flash
boxes. It is a water reserve in the thermal cycle along with Deaerator and
boiler drum. Hotwell is divided in the middle through a partition. The purpose
is to separate the condensate condensed in each half of the condenser
nest for better identification of tube leaking zone. Conductivity
measurements are to be done in each condensate outlet from the Hotwell
to give a warning of any leakage of circulating water into the condenser.
Two lines from the bottom of the Hotwell will take the main
condensate to the suction of the condensate extraction pumps. The
Hotwell is provided with 2 level columns having level glasses, level switches
and level transmitters. It is also provided with 3 nos of drains at its bottom.
Normal water level in the Hotwell is 750mm and its capacity is
designed to be for 3 minutes of pumping by a CEP.
3.8.3 Condensing Chamber:
The condensing chamber is a shell where the exhaust steam of
turbine comes into contact with the tube nest and gets condensed. It is
floated on spring supports and welded to the condenser neck and its top.
The end tube plates secured to the shell provide support for the tube nest.





204
3.8.4 Condenser Neck:
This is the part of the condenser to form an interconnection between
the condensing chamber and LP turbine. It is designed such that the
exhaust steam of turbine reaches the condensing chamber with a relatively
low velocity and very low-pressure drop. The make-up water line and LP
bypass steam lines join the condenser at the neck.
3.8.5 End Tube Plates (Ref Fig.84).
The end tube plates are perforated plates, which separate the water
boxes from the condensing chamber. There are 4 end tube plates, two on
each side of the condenser, to have divided water box construction. The
circulating water tubes have been roller expanded into end tube plates.
These tube plates ensure a perfect sealing so that the purity of the main
condensate is not affected. They are also designed for withstanding against
the difference in pressure between the condensing chamber and the water
box. The end tubes are cladded with stainless steel plates on C.W side for
corrosion protection.
3.8.6 Tube Nest:
The thickness of the tubes should be as small as possible to have high
rate of heat transfer. The tubes are of outer diameter 25.4 mm and thickness
of 0.7112 mm.16418 Nos. of tubes are provided in the condensing zone and
1240 Nos. of tubes in air cooling zone.
Method for making tube to end plate expansion joint on at both ends
of the tube is by roller expansion. (Ref Fig.85). Quality of expansion joints
determine whether there is any seepage of cooling water into steam space
which has a bearing on the scaling of the water wall tubes of the boiler,
steam purity and silica deposition on last stage turbine blades. To ensure
very high quality of the expansion joints the expansion is carried out by
torque controlled expander tools. The holes should have good finish and
minimum ovality. The expanders should be set to achieve 7 to 10 % wall
thinning.
205
The intermediate tube plates at twelve places on each side provide
the support for the tubes. These intermediate support plates serve the
following purposes:
To support the weight of the tubes thereby preventing sagging of
these tubes
To provide increased strength to withstand the force of direct
impingement of the exhaust steam.
To curb flow induced vibration.
The tubes are placed horizontally with an inclination of 0.5 degree
towards the front water box side for self draining during circulating water
pump tripping or plant shutdown.
The principal factors to be taken into consideration when determining
the tube spacing are low steam velocity between condenser tubes, uniform
distribution of the steam over the whole condensing surface and equal
pressure at the top and bottom rows of tubes. A computerized design is
used to optimize tube spacing, tube cross section and condensing surface
of the condenser. The tube spacing is broken up to a large extent by the
arrangement of the condenser tubes in bundles. Wide lanes from top to
bottom are left between the tube bundles so that the steam can also reach
the lower rows of the tubes without incurring appreciable pressure loss. The
steam then flows side ways from these lanes into the tubes.
The selection of material for the condenser tubes is playing a greater
role in designing a condenser and it depends on the following aspects:
Impact strength (to withstand the impact of the exhaust steam).
Thermal conductivity (for better heat transfer).
High resistance for corrosion.
Cooling water analysis.
Techno Economic aspects.



206
Depending upon the water conditions, the selection of the major
tube materials is made.
S.No Tube Material Composition Remarks
1 Stainless steel
a. SA 249 TP 304


b. SA 249 TP 316

Ni: 8-11%
Cr: 18-20%

Ni: 10-14%
Cr: 16-18%
Mo: 2-3%
Suitable for highly
corrosive dirty
water

Stainless steel (SS TP 316) tubes had been provided in the tube nest of
condenser of Units 4 to 7 /Stage-II/TS-II.
The pattern of exhaust steam flow is down flow and the exhaust
steam gets condensed before reaching the bottom. The condensate then
settles down at the Hotwell in the bottom.
3.8.7 Water Boxes:
Since the condenser is constructed with divided water boxes, there
are totally 4 water boxes. Two front water boxes are divided horizontally to
have 2 passes of the circulating water. The water makes its entry at the
bottom and leaves at the top of the front water box. The reversing chamber
at the rear acts as an interconnecting chamber for bottom and top passes.
All the water boxes are provided with vents and drains. The inlet and outlet
circulating water pipes join the front water boxes through expansion joints.
Water box inside surfaces have been protected against corrosion by
application of protective coating over the surfaces in contact with the
circulating water. Water boxes incorporate hinge arrangement to facilitate
the removal of cover for enabling leak detection, retubing and cleaning of
tubes etc.


207
3.8.8 Air Off Take System:
Although the condenser is theoretically expected to condense the
entire quantity of exhaust steam, practically a small quantity of steam will
remain in the vapour state along with the air ingressed into the system and
non-condensing gases. This uncondensed vapour and the air will have to
be removed by means of ejectors in order to sustain the vacuum inside the
condenser. The system, which collects the uncondensed vapour and the air
from the condenser, so as to enable ejection is known as AIR OFF TAKE
SYSTEM.
As explained earlier, the pattern of exhaust steam flow is Down Flow
and the exhaust steam gets condensed before reaching the bottom.
Hence the air and the uncondensed vapour will reach the bottom space of
the tube nest in each side.
At the bottom space of the tube nest of each side, a horizontal pipe
with perforations at its bottom surface only is provided for collecting the air
and the uncondensed vapour. A zone called as air cooling zone is formed
below these 2 pipes. The air and the uncondensed vapours existing at the
bottom space (above the Hotwell water level) gets sucked (through the air
cooling zone) into these horizontal pipes are in communication with the
ejectors through two vertical pipes, there is vacuum inside these pipes.
Since the air and uncondensed vapour flow over the surfaces of 1240
Nos. of circulating water tubes separately provided in air cooling zone, the
reduction in specific volume of the air and the uncondensed vapour takes
place (due to temperature reduction) resulting in reduction of the
volumetric load on the ejectors.
3.8.9 Steam Dumping Device. (Ref. Fig. 86)
Two numbers of Steam Dumping devices are provided for the
condenser for dumping bypassed steam (from LP bypass system) directly
into the condenser during start-up, load throw-off etc., Each device is
provided with an orifice plate which reduces the bypassed steam pressure
to approximately condenser pressure. The pressure of bypassed steam has
208
already been reduced partially due to throttling in LP bypass control valve.
More over, injection of main condensate into the bypassed steam is done
here to reduce the temperature.
100% steam dumping can be carried out in condenser for a
maximum duration of 10 minutes, and within this time, Unit operation is
required to be brought down to 60% and then the Unit may be operated
continuously.
3.8.10 Condenser Connections:
The lines, which are in communication with the steam spaces of
condenser, are detailed here under:
3.8.10.1 Western Side (Ref. Fig.90)
Steam space lines (2 nos.) of Flash Box-2
Steam space lines of Turbine flash boxes-1,2
Steam to seal header to condenser steam space through the valve
MAW-50
Level Instruments
3.8.10.2 Eastern Side (Ref. Fig. 89)
Steam space lines of Flash Boxes 1,2
Level Instruments
3.10.3.1 Northern Side (Switch Yard Side) (Ref. Fig.92)
LP bypass steam lines (2nos)
Vacuum Breaker Line
3.10.3.2 Southern Side. (Ref. Fig. 91):
Shell vents of LP heaters 1,2 & 3
CEP air lines (2 Nos)
Make-up water line
Main condensate Recirculation line
Air line to ejectors (2 Nos)



209
3.10.3.3 Bottom Hotwell:
Drain from LP bypass system
Suction lines of CEP (2 Nos.)
Hotwell drains (3 Nos.)
Water space lines of Flash boxes 1,2 and 3
Water space lines of Turbine Flash boxes 1 and 2
Hotwell-vertical storage tank drain.
3.10.3.4 Vacuum Breaker.
A line communicating directly the condenser steam space with
atmosphere is provided for the condenser. A hydraulically operated valve is
provided in this line and it is known as Vacuum Breaker. During normal
operation of the Unit, this vacuum breaker valve is kept in closed position. In
order to avoid air ingress into the condenser through this line, a water
sealing arrangement is provided and the main condensate drawn from the
discharge header of CEP is used as sealing water.
Purpose of providing this vacuum breaker is to safe guard the Turbo
Generator rotor against any possible damage during any emergency. For
the causes/emergencies related to TG rotor, the turbine has to be tripped
and the rotor has to brought to rest as quick as possible. During these
situations, the vacuum breaker need to be opened to admit the
atmospheric air into the condenser in the reverse direction thereby
retarding the speed of turbine rotor after tripping.









210
3.9.0 CONDENSATE EXTRACTION PUMPS:
There are two condensate extraction pumps each of 100% capacity.
Out of the two, one pump is normally in service and the other pump is
intended to be in reserve. They are of vertical, centrifugal and canister type
with six stages. Capacity of the pump is 678m
3
/hr. (670T/Hr.) and it is driven
by a 600 KW electric motor.
The driving motor is supported on a fabricated motor stool, which is in
turn resting on a Head piece. The head piece is secured to the canister
which is suspended and Secured to a foundation ring as shown in Fig. 46.
The six stages of the pump are contained within the canister. The pumps
discharge branch is formed on the head piece and the suction line is
connected to the canister. Temperature of the main condensate increases
from 46.1 to 46.3 C in CEP.
The condensate extraction pump is shown in Fig. 46.
3.9.1 Canister:
The canister is a fabricated tubular chamber formed with a dished
bottom end. The bottom end is closed by a snubber, which is secured to
the canister with nuts and washers on studs. The entire pump assembly is
held inside the canister and the canister acts as a suction chamber for the
pump. The snubber provides guide support at the first stage end of the
pump rotor.
A flange provided with tapered holes and clearance holes is welded
to the top of the canister. The flange is secured to the foundation ring and
provides the means for locating and supporting the headpiece.
The canister in-corporates means for connecting the suction piping.
3.9.2 Head Piece And Motor Stool:
The head piece is secured to the canister and it incorporates
connection for the discharge piping. Motor stool is supported on the head
piece and it in turn supports the motor. The pumps thrust bearing housing is
located in the motor stool.
211
The pump shaft comes out of the head piece through a stuffing box.
The stuffing box is provided with pipings for seal water entry and stuffing box
drain (explained in Sec.2.3.6). An airline is also provided for connecting the
head piece with the condenser (explained in Sec.2.3.9.).
Auxiliary cooling water line connection is provided for thrust bearing
oil cooling.
3.9.3 Foundation Ring:
The structure of the foundation ring comprises top and bottom
flanges, ribs and a wrapper. The bottom flange is provided with plain-
machined holes for locating on to foundation studs, which are grounded to
the floor. The top flange is provided with tapered holes, which facilitate the
fixing canister securing screws.
3.9.4 First Stage Pump Assembly:
The first stage pump assembly comprises of a pump casting, a double
entry impeller keyed to the shaft and a suction bell mouth.
The suction bell mouth is spigot located on the pump casing and is
secured in position by studs and nuts. The pump casing is spigot located to
the second stage casing.
The suction bell mouth is closed by the snubber, which is secured to
the canister. The snubber projects into the bell mouth. The suction bell
mouth is provided with an internal passage way fitted with a flow control
orifice, which restricts the condensate pressure prior to lubricating the
bottom bearing.
The pump casing and suction bell mouths are machined internally for
fitting the casing wear rings which are secured in position by socket set
screws.
The double entry impeller is keyed to the shaft and located axially by
a shaft sleeve on each side of the impeller.
Each shaft sleeve is keyed to the shaft and the assembly is secured in
position by a shaft nut.

212
3.9.5 Second To Sixth Stage Pump Assemblies:
The second, third, fourth, fifth and sixth stage pump assemblies are
secured together and the assembly is connected to the headpiece
through the sixth stage. The sixth stage casing is located by a spigot formed
on the headpiece and secured by bolts, nuts and lock washers.
Each of these stages is similar in construction and each one
comprises of a pump casing and a single entry impeller. Each pump casing
is spigot located on its respective housing. Each casing is machined
internally for fitting the casing wear rings. The impeller provided with wear
rings is keyed to the shaft and located axially by the shaft sleeves.
The pump shaft is radially located by seven cutless rubber bearings,
one being fitted in the bell mouth and one in the first stage casing. The
remaining cutless rubber bearings are located one in each of the second,
third, fourth, fifth and sixth stage casings. The bearings are lubricated by the
condensate handled by the pump.
3.9.6 Stuffing Box Assembly:
The stuffing box within the headpiece is provided with a restriction
bust, two top rings of packing, a lantern ring and three bottom rings of
packing. This assembly is retained by a gland which is secured by nuts on
studs, Shaft protection, within the area of the stuffing box, is provided by a
sleeve which is secured to the shaft by loctite adhesive.
A water thrower, which is secured to the shaft, provides protection for
the thrust bearing and prevents any excessive gland leakage from entering
into the underside of the thrust bearing.
Since the pump is operating under vacuum at its suction and the
standby condensate extraction pump remains under vacuum, an air entry
into the pump casing and thereby into the condenser results in. Hence the
glands are to be necessarily sealed against air entry by the injection of high
pressure water into it. The main condensate, tapped from the discharge
header of Condensate Extraction pumps, is used for sealing. Surge tank
213
provides necessary reserve water supply for sealing. The seal water, after
sealing, returns to the canister through a small return line.
3.9.7 Thrust Bearing & Journal Bearing Assembly:
The water-cooled type 8-SNT Combined thrust and journal bearing
assembly is mounted in the head piece and absorbs the pump hydraulic
thrust and the weight of the pump rotating assembly.
The bearing casing base plate is spigot located on a fitting plate. The
bearing casing plate and the fitting plate are together secured to the head
piece by nuts and studs.
The thrust collar is keyed on the shaft and retained in position by a
thrust collar nut and lock washer. The axial thrust is absorbed by the tilting
white metal faced thrust pads fitted to the base plate under the collar.
White metal lined journal pads are fitted in the casing and locate the shaft
radically.
The bearing casing is provided with auxiliary cooling water inlet and
outlet connections, an oil level gauge a combined air vent and oil filler, and
oil drain plug.
3.9.8 Coupling
Drive from the motor to the pump shaft is transmitted via a spacer
type flexible coupling. Each half of the coupling is keyed to its respective
shaft the halves being connected by means of a spacer which
incorporates flexible membranes at each end.
The coupling is designed to accommodate a certain amount of
offset, angular misalignment free and float or vertical movement of the two
shafts.
3.9.9 Drive Motor
The vertical drive motor is of 600 KW rating and runs at 1482 rpm. The
motor is air cooled and mounted on the motor stool, its correct location
being ensured by a spigot face provided on the head piece.


214
3.9.10 Air Line (Or) Balancing Line:
Condensate Extraction Pumps operate under a very high vacuum in
their suction lines and they have to extract the main condensate from the
hot well for pumping. In order to ensure that the pump is operating without
failure of flow in its suction, a line from the head piece of the pump is
connected to the steam space of the condenser. This line is known as Air
line or Balancing line and it is necessary to execute the following
functions.
(a) The hot well of the condenser is located just above the canister of
the pump. The main condensate stored in the hotwell can flow smoothly to
the canister without any difficulty by gravity. To have this flow by gravity in
the suction line, the pressure in the suction chamber (canister) of the pump
needs to be equated with the pressure in the condenser. Thus by
balancing only, the suction flow to the pump can be ensured. The
balancing line serves for this purpose.
(b) Since the pressure of main condensate in the hotwell is close to its
saturation pressure, vapours will form at the points of lower pressure. The
absolute pressure inside the condenser is the sum of the partial pressure of
air and that of uncondensed steam (out of exhaust Steam of LP Turbine) in
the condenser. The quantity of uncondensed steam in the condenser
depends on the effectiveness of condensation by the circulating water.
Whenever there is a sudden drop in the Power Generation, the rate of
exhaust steam flow to the condenser from LP Turbine gets reduced. Since
the rate of flow of Circulating water and its inlet temperature do not vary
during this occasion, the condensation is more effective resulting in
reduced quantity of uncondensed steam. This leads to an improvement in
vacuum or a reduction in absolute pressure inside the condenser. During
the above situation, the rate of drop in absolute pressure will be greater
than the rate of fall of main condensate temperature. It leads to vapour
formation (flashing) due to the reason that the temperature of main
condensate is now higher than the saturation temperature corresponding
215
to that reduced pressure. The above condition necessitates continuous
venting of vapour from the suction chamber (canister) of the pump so that
the performance of the pump is unaffected from cavitation. The airlines
serve this purpose of venting for both the running and the standby pumps.
This air line is to be kept in open position for the pump in service and also
for the pump in standby to enable venting.
3.9.11 Discharge Lines:
Discharge lines of both CEPs join together to form a discharge
header. Each discharge line is provided with a non return valve and a
motor operated discharge valve. While CD 002 is the discharge valve for
CEP, CD 004 is the discharge valve for CEP B. Non return valve in each
discharge line prevents the back flow of main condensate from the
discharge header whenever one pump is kept in standby position with its
discharge valve in open position and the other pump is running.














216
3.10.0 MAIN & STARTING EJECTOR
GLAND STEAM CONDENSER
DRAIN COOLER
3.10.1 Starting Ejector: (Ref. Fig. 49).
For the evacuation of 210 MW system, starting ejector provided.
Starting Ejector evacuates the complete system.
The unit consists of a nozzle, a suction chamber and a diffuser. The
suction chamber is connected with the condenser. The working steam
expands in the nozzle and its pressure energy is converted in to kinetic
energy thereby producing supersonic velocity jet. This jet, discharging from
the nozzle entrains the surrounding air, which finally comes from the
condenser. The air and steam mixture is then compressed in the diffuser to
a pressure slightly above atmospheric pressure and then exhausted in to the
atmosphere.
Starting ejector is recommended to be used for accelerating the
initial pulling of vacuum. The working medium for this ejector is steam of low
parameters, which can be taken from auxiliary steam source.
The pressure of this steam is to be kept 8.5 kg/cm
2
(g) and
temperature 240
0
C.
This ejector is switched off when main ejectors are taken in to service
and stabilized after vacuum reaches 500 600 of Hg.
3.10.2 Main Ejector (Ref. Fig.48).
Description
Main Ejectors used for extracting non-condensable gases from the
coldest zone of the condenser. The working medium for these ejectors is
steam of low parameters, which can be taken from the auxiliary source.
The pressure of this steam is to be kept 8.5 kg/cm
2
(g) and temperature
240
0
C. The energy of steam is retrieved to the fullest possible extent as the
ejectors are interposed in the feed heating cycle thereby improving the
overall efficiency of the cycle.
217

These ejectors consist of three compression stages with inter coolers
and after cooler. The first stage of the suction chamber is connected to the
condenser. The main assemblies of the ejector are:
i) Suction chamber.
ii) Shell.
iii) Water chamber.
iv) Tube system.
v) Air measuring device.
The suction chamber has been divided in to three parts and all the
compression stages consisting of nozzle and diffuser are mounted inside this
chamber.
The water box has also been divided in to different zones in such a
manner that cold condensate first flows through the 1
st
stage inter cooler
and thereafter through the 2
nd
& 3
rd
stages simultaneously.
The air-measuring device, for measurement of dry air discharge from
condenser, has been fitted at the air exit of the ejector. The sign of this
device is such that it enables the measurement of dry air discharge while
the condenser and ejector are in operation.
The convergent divergent nozzle has been designed to accelerate
the steam flow and thereby reduce the pressure of steam to
0.03-kg/cm
2
abs., in the 1
st
stage of suction chamber. This low pressure in
suction chamber sucks the non-condensable gases from the condenser.
The steam and gas mixture enters the diffuser inlet and while
passing through the diffuser, the kinetic head is converted to pressure head.
The steam and gas mixture flows over the tube nest and steam gets
condensed while non-condensable gases flow to suction chamber of 2nd
stage. The same phenomenon happens in 2
nd
stage during which all the
steam gets condensed and gases are exhausted to atmosphere through air
measuring device.
218
Main condensate is used as the cooling mediums for inter coolers
and the after coolers. Each ejector is capable of passing maximum 253
T/hr. of condensate and minimum quantity required is 103 T/hr.
2 Nos. ejectors have been supplied along with the T. G. sets. One is
expected to be in operation to maintain vacuum in the condenser, when
rate of air ingress in to the system does not exceed 20 kg/hr. The other one
has been supplied to take care of the excess air ingress in to the system
during low load operation when quite a few equipments / pipe line go
under vacuum which are otherwise normally under pressure or system is not
adequately tight.
The following fittings have been provided on the ejectors:
i) Gauge glass for indicating the condensate level. (in 1
st
stage
only).
ii) Pressure relief valve (water side).
iii) Dial type thermometers with pockets.
iv) Pressure gauge with three-way cock.
v) Vacuum gauge with three-way cock.
vi) Stop valve.
vii) Non-return valves.
3.10.3 Gland Steam Condenser (Ref. Fig. 50).
Gland steam condenser along with the air exhauster has been
provided for condensing the gland seal leak steam, thereby retrieving the
heat energy by heating the condensate and to maintain the desired steam
pressure in the gland seals.
Gland steam condenser has been provided with two nos. of
exhausters. One of the exhausters is meant for normal operation and the
other as stand-by. When the Gland steam condenser or both the
exhausters need isolation, the seal steam is directly lead outside turbine hall
through chimney line. During such an operation, the heat of the seal steam
is wasted to the atmosphere. Isolation and putting in of the exhauster,
gland steam condenser and chimney is done manually. Syphon has been
219
provided in the air steam mixture pipeline from gland steam condenser to
condenser to ensure draining of condensate in the event of tube failure.
This prevents entry of water in to turbine.
Exhauster removes the non condensable gases along with the left out
vapour of seal steam in to heat exchanger (GSC) where heat energy is
taken-up by the main condensate. By cooling the non condensable and
condensation of steam, duty of the air exhauster gets reduced.
Gland steam condenser is a shell and tube type heat exchange
having water boxes on either sides and stainless steel tubes for heat
exchanger surface. Tubes have been fixed on either end in the main tube
plates by roller expansion. Condensate and seal steam are kept on tube
and shell side respectively. Shell is connected with the exhauster for
discharging non-condensable gases along with left out vapour in to the
atmosphere.
Exhauster is a centrifugal fan directly mounted on the motor. The
assembly of exhauster and motor is mounted on the foundation.
3.10.3.1 Function Of The Gland Steam Pressure Control System:
This system ensures the sealing of glands in HP, IP and LP turbine under
various Load conditions. The Turbine glands are self-seal type. Up to
approximately 40% load steam from auxiliary source (CRH/Aux. steam
header) through gland steam valve is taken to seal all the HP, IP and LP
glands. During this period the steam leakage valve connecting this header
to condenser is kept closed. After approx. 40% of load, gland steam valve is
closed and steam leakage valve is opened. Pipings are so sized that the
leak-off steam from Front and Rear end of HP turbine goes to the condenser
through steam leakage valve while leak-off steam from the IP front and rear
glands is utilized for sealing the LP glands, thus ensuring proper temperature
of sealing steam. The leak-off steam and air from the last chambers of
each rotor is sucked into a gland cooler. Building up of vacuum in the
condenser is the first step during start-up. For building up vacuum it is
necessary to seal the turbine gland by supplying steam to the shaft through
220
gland steam valve. The control system opens the gland steam supply valve
until the pressure in the header acquires a preset value. Subsequently when
the set picks up Load, the pressure of steam inside HP and IP turbine builds
up resulting in the leakage of steam from the Turbine into gland steam
supply header, which in turn would result in increase of pressure. The
controller gradually closes the gland steam supply valve and opens gland
leak-off valve, if required.
3.10.3.2 Electro-Hydraulic valve actuators:
The actuators of the two control valves are continuously under the
control commands from the electric controller through 2 Electro hydraulic
converters. The +ve voltage output opens the gland steam supply valve
while the -ve voltage output opens the gland leak-off valve.
Each hydraulic actuator has its own motor driven oil pump supplied
from station AC system. In the event of pump failure, the valve remains in
stay put position. Subsequent operation of the valve can be carried out
locally though hand pump.
3.10.3.3 Description of the hydraulic actuator and its
operation: (Ref. Fig. 79).
The function of the position controller is to position the valves rapidly,
accurately and proportionally according to the vale position value issued
by the pressure controller. The output voltage of the pressure controller
serves as the position set value; a contact-less and wear-free magneto
resistive potentiometer is fitted to each actuator 1.11 to act as a position
transmitter. Its output signal varies proportionally with the vale position and
is transmitted to the position controller as the actual value of position as well
as being using for valve position indication in the control room. In its output
the position controller has a transistorized power amplifier for 10V and 20
mA. load current connected to the two control coils 1.11.7 of the
actuators. The D.C. control current from the controller flows through the coil
1.11.7 of the electro magnetic control system, entering at terminals 1.11.12.
The system exerts a force on the pivoted arm 1.11.8 and deflects if from the
221
mid position the deflection being proportional to the control current in
magnitude and direction. The impingement plate 1.11.9 attached to the
arm them covers the two nozzles 1.11.10 and 1.11.10a unevenly. The control
oil is supplied to the nozzles through two restrictors 1.11.13 and 1.11.13a. The
uneven covering of the nozzles resulting from the deflection of the arm and
impingement plate produces a different pressure at each end of the pilot
valve 1.11.14 causing it to be moved from its mid position and allowing oil to
flow to the working piston 1.11.5. The movement of the working piston is
transmitted directly to the final control element 1.3 or 1.4 mounted below
the actuator. Simultaneously the movements of the working piston are
transmitted to the control system by a feedback linkage 1.11.11. This varies
the tension of the return spring 1.11.14 and exerts a force on the arm
opposite to the force produced by the control current. When both forces
are in equilibrium, the working piston ceases moving and hence the
actuating element maintains its position. A positive output voltage or
positive control current opens the seal steam control valve 1.4, whereas
negative values open the leak-off control valve 1.3.
In order to achieve continuous control characteristics at the transition
from one valve to the other, the valve ranges are overlapped slightly at this
point. The output voltage of the pressure controller, the output voltage of
the position controller and valve position are all proportional to each other.
The oil pump 1.11.2 driven by the motor 1.11.1 supplied control oil to
the working cylinder 1.11.5 via filter 1.11.3, pilot valve 1.11.4 and blocking
valve 1.11.15. Surplus control oil returns to the tank via the adjustable
pressure limiting valve 1.11.6.
The double blocking valve 1.11.15 prevents any creeping of the
working piston, and hence the final control element, if there is a failure of oil
pressure. One valve cone 1.11.16 is opened directly by pressure oil and the
other by plunger 1.11.17 so that oil can flow to and from the working
cylinder 1.11.5. If the supply of pressure oil fails, the cones of the blocking
valve are closed springs.
222
3.10.3.3.1 Manual Operation:
Pressure oil is pumped in to the power cylinder by means of the hand
pump (1.11.18) and the direction of movement is pre-selected by means of
the manual operation control (1.11.19). The knob is turned to the required
direction; this should be done carefully to avoid forcing it against the stop.
When released it will return to the zero position automatically. The check
valve (1.11.20) prevents oil running back through the pump (1.11.2). It is also
possible to use the manual control (1.11.19) for overriding during normal
operation.
3.10.3.3.2 Pressure Measurement:
The pressure in the header is measured by means of a pressure
transducer. This measurement is used for control as well as display purposes.
The measurement range is 100 to +300mmWC
3.10.3.3.3 Control System Equipment:
The control system is comprised of solid-state control system. The
modules, including power supply, operating and monitoring modules are
arranged in a 3-tier group frame and housed in a cubicle. The pressure
controller has PI characteristics. Its output is fed to electro-hydraulic
actuators via a PID position controller. The function of this controller is to set
the position of the valve as determined by the pressure controller as quickly
and accurately as possible.
The actuators incorporate magneto-resistor potentiometer to give
contact less non-wearing position indication. The output voltage of the
potentiometer varies proportionally with the valve position. The voltage is
used to give an actual value signal to the position controller as well as for
valve position indication in the control room. In order to ensure stable
control characteristics during the transition period of Gland steam supply
valve closure to Leakage steam supply valve opening or vice-versa, the
valve travel of both the valves have got slight overlap. The reference value
for the steam pressure in the header can be set between 0-220mmWC by
means of potentiometer on the controller.
223
The pressure reference value is compared with the actual value
supplied by the transducer at the input to control of the deviation amplifier.
The press controller is given the progressive static characteristics so that its
action is increased in the event of large disturbance to the press control
system e.g., Load Trip. For small deviation up to +10mmWC, the
characteristics are chosen to ensure stable control under all operating
conditions. The controller action is increased for larger deviations.
Progressive characteristics of the press controller indicates that it is possible
to adjust the amplifications between the press controller and position
controller independently for each valve. This feature enables to take care
of any inaccuracies in the sizing of the supply and leakage valves and the
pipelines.
3.10.4 DRAIN COOLER (Ref. Fig. 51).
Description :
This is a shell and tube type heat exchanger. Condensate flows
through the tubes, which gets heated up while cooling the drip, which is on
the shell side. Condensate passes through the tubes only once. The
following are the main sub-assemblies.
i) Shell And Tube Bundle Assembly:
Shell is carbon steel fabricated cylindrical vessel, assembled with the
tube system by welding with the tube plates. Tubes are straight and fixed at
both ends by roller expanding in to the holes of the main tube plates.
Baffles have been provided for ensuring drip velocity on shell side in line
with the design requirements.
ii) Water Box:
Drain cooler has been provided with one number water box each at
inlet and outlet ends. These are fabricated from carbon steel plates and
have been provided with flanges on both ends. On one end, these flanges
have to match with the main condensate pipe line flanges and one the
224
other end, these have to match with the fixing holes provided on the tube
plates.
iii) Fittings:
i) Condensate side relief valve.
ii) Dial type thermometer for measuring condensate inlet and
outlet temperatures.
Data Sheet:
Type Shell & Tube Type
Design
Pressure
1. Shell - Full vaccum/3.5cm
2
(g)
2. Tube side - kg cm
2
(g)
Design
Temperature
1. Shell - 100 deg C.
2. Tube side - 150 deg C.
Tube surface area 35 m
2

Total No. of tubes. 501
Tube size OD x t x L 19 x 0.889 x 1540 mm.
Tube material TP 316 SS.

225
3.11.0 DEAERATOR :
The Deaerator of units IV to VII of Thermal Power Station II / Stage II
is of combined spray and tray type. It consists of two elements viz a feed
water storage tank and a deaerating header.
The feed water storage tank is a horizontal cylindrical vessel with
dished ends at either end. The horizontal deaerating header is connected
at the upper part of the feed water storage tank. The details shown in
Fig.94.
3.11.1 Storage Tank:
The feed water storage tank is fabricated from boiler quality steel
plates. There are three supports in the bottom of the storage tank. The
central support is a fixed one. The end supports are of sliding nature to
accommodate the thermal expansion of the storage tank. The end
supports are rollers supports with two rollers in each. Movement of roller
support from cold to hot condition is about 8 mm. The storage tank is
provided with two numbers of safety relief valves. The capacity of the
storage tank is 130 m
3
. Man- holes are provided for internal inspection of the
storage tank.
While the main condensate is led into the deaerating header, the
heating cum the deaerating steam entry pipe is connected at one end of
the storage tank. Initially the feed water in the storage tank is reheated to
saturation temperature corresponding to the operating pressure of the
Deaerator. This is done with the help of auxiliary steam system. This
preheating steam can be admitted at one end of the storage tank and
distributed along the length of the tank through many vertical perforated
pipes. Another connection is also provided with deaerating header from
this preheating steam line.
The BFPs take the suction from the bottom of the tank. A vortex
breaker is provided in the feed water outlet pipe to prevent vortices, which
would damage Boiler Feed Pumps due to entry of steam bubbles. The
storage tank has also other connections for HPHs drain condensate, BFP
226
recirculation lines etc., as detailed later. Pressure, Level and Temperature
instruments are also provided for the storage tank.
3.11.2 Deaerating Header:
The deaerating header is a steel shell mounted on the feed water
storage tank. It comprises of a water distributor with spray nozzles and also
trays. In order to increase the efficiency of deaeration, the area of contact
and also the duration of contact between the main condensate and
deaerating steam are increased by breaking the main condensate into fine
particles (in the form of spray) and also making the condensate flow down
through perforated trays.
The main condensate, which is pre-heated in 3 nos. of LPHs, is making
its entry into the Deaerator at the top of the deaerating header. Then the
condensate is sprayed with the help of 40 nos. of spray nozzles provided at
the distributor. (Ref.Fig.94). The condensate is sprayed over 2 stacks of
perforated trays. Each stack has 5 nos. of trays in it. The duration of contact
gets increased as the water flows down through the trays. The deaerating
steam admitted at the storage tank rises up in a counter flow direction to
the main condensate flow. The process of deaeration takes place at the
header. Most of the steam quantity is recovered as feed water on
condensation. The remaining quantity of steam along with air removed
leaves the deaerating header through Deaerator vents. By this, the main
condensate is also pre-heated before it reaches the storage tank.
Tray removal doors are provided on both sides of the deaerating
header
3.11.3 Deaerator Connections: (Ref. Fig. 95 and 96)
The following inflow and outflow connections of steam and water
provided for the Deaerator.
3.11.3.1. Steam Inlets:
The deaerating steam for Deaerator enters at one end of the storage
tank from a common junction formed by the following 3 sources of steam
227
Normal source of steam: The normal source of deaerating steam is
made available from the 4
th
Extraction steam of Turbine. It is tapped from IP
cylinder exhaust steam, is from cross around pipes, after 20 stages of IP
casing. It is admitted through an electric motor driven isolation valve EX-014.
1
ST
standby source of steam (CRH Steam): In order to feed the
Deaerator during the occasions in which 4th extraction steam of Turbine is
not sufficient, a stand by source of steam is warranted. The steam drawn
from CRH lines is used as 1
ST
standby source of steam for the Deaerator. The
supply of CRH steam is made available through a pressure control station
comprising of an electric motor driven inlet isolation valve (EX-001), and a
pneumatic control valve (PCV-2) as shown in Fig. 95. The Deaerator can
also be fed from CRH lines during the occasions in which the Turbine is not in
service and the Boiler is in service with HP and LP bypass systems
2
nd
standby source of steam (Pegging/Auxiliary steam): In order to
feed the Deaerator during initial start-up periods and also during the period
after shut-down, where both 4
th
extraction steam and CRH steam may not
be sufficient; another source of steam is made available from Auxiliary
steam bus. This steam also admitted through a pressure control station
PCV-1.All the above 3 sources of steam are made available to the junction
with provision of NRVs in order to prevent any back flow. Four numbers of
line Safety valves are also provided to relieve the increase in pressure in
case that any pressure control valve malfunctions.
3.11.3.2 Preheating Steam From The Auxiliary Steam System:
Initial preheating of feed water in the storage tank can be done with
the help of steam drawn from the auxiliary steam bus.
3.11.3.3 CBD (continuous Blow Down) tank steam to the
storage tank:
Continuous blow-down from boiler drum is resorted to keep the salt
concentration of boiler water not only within limits i.e., not to cross the
critical value which will result in salt carry over along with steam but also to
maintain a steady salt concentration irrespective of time. This is achieved
228
by making the salt input to the cycle through the make up water supplied in
the condenser equal to the salt output from the cycle through the
continuous blow-down.
Since practically there is no salt carry over along with steam from the
boiler drum, all the salts remain trapped in the boiler drum water. This highly
salt concentrated water from the boiler drum is taken, thereby reducing
considerably the need of make up water.
The CBD water is at high pressure and temperature and consequently
has a high enthalpy. Roughly, one third of this water is flashed into steam in
the CBD flash tank located near the Deaerator. Pressure maintained in this
tank is slightly above that of the Deaerator. The quantity of water wasted is
roughly two thirds of the water taken from the boiler drum. This cannot be
used as it is highly contaminated. Further reduction in make up water need
is achieved by this.
Water from CBD flash tank goes to the intermittent blow-down flash
tank where further flashing takes place. Steam is let out to atmosphere and
the water to the drainage.Thus, the CBD flash tank arrangement not only
reduces the make up water requirement to the cycle considerably but also
results in the utilization to the maximum possible extent of the heat energy
of the CBD water.The CBD flash tank steam is admitted to the storage tank
through a gate valve and a NRV.
3.11.3.4 Shell Vents of HPHs (5) & (6) (2 Nos.) to the Deaerator
header:
Heat transfer between the extraction stream and the feed water
takes place in HP heater. Non-condensing gases coming along with the
extraction steam also enter the heaters. If they are allowed to remain, they
get accumulated in the heaters. These gases blanket the surface of the
heater coils and the performance of the heaters will get affected. If the
oxygen is also present in these non-condensing gases, it will promote
corrosion of the tubes since the stream is getting condensed there. Hence
continues venting of non- condensing gases is warranted. The shell vent of
229
HP heaters (5) and (6) are connected to the deaerating header for
evacuating the non- condensing gases along with a small part of the
extraction steam. Thus, these gases are finally driven out to atmosphere
through the Deaerator vent. These vent lines are provided with isolation
valves and non return valves.
3.11.4 Water Inlets To Deaerator:
3.11.4.1 Main Condensate After LP Heater (3):
The main condensate, which is preheated in the three numbers of
LP heaters, is admitted at the top of the deaerating heater. Thereafter it is
sprayed and it is flowing down through perforated trays kept in stakes. It
reaches the storage tank after the process of deaeration and heating.
3.11.4.2 Initial Filling Line From The Condensate Storage Tank
When the unit is to be started up, the initial filling of Deaerator can
be done directly by supplying the DM water delivered by condensate
transfer pump. The DM water from the condensate storage tank is admitted
through an electrical motor driven isolation valve DM 20 in the initial filling
line.
3.11.4.3 Boiler Feed Pumps Recirculation Lines (3 nos.):
Boiler feed pump is provided with a recirculation line in order to
maintain a minimum water flow through the pump. This line connects the
discharge of boiler feed pump with the Deaerator through a recirculation
valve. The recirculation line is provided with (nearer to Deaerator) a non-
return valve, a manually operated gate valve and an orifice. All the three
lines join the storage tank.
3.11.4.4 Drain condensate from HP heaters (5) & (6) to the
Deaerator Storage Tank:
The drain condensate collected in the HP heaters (5) & (6) is sent
to the Deaerator through the respective heater level control stations. For
HPH - 5 level control station, a pneumatic level control valve DR 11 and a
motor driven bypass valve DR 43 are provided. Similarly for HPH 6, the
230
valves DR 6 and DR 42 are provided as shown in the fig- (3). The drain
condensate from the HPHs is also preheating the feed water in the
Deaerator.
3.11.5 Water Outlets From The Deareator:
3.11.5.1 Feed Water Suction Bus For The Boiler Feed Pumps:
The suction for the boiler feed pumps is taken at the bottom of the
storage tank at its one end. Dozing of Hydrazine Hydrate is done at the
suction bus of the boiler feed pumps.
3.11.5.2 Deaerator Over Flow Line:
Deaerator overflow water line is at one end of the Deaerator
storage tank and is connected to Blow down Tank. This line is provided with
a pneumatic Open/Close (ON/OFF) valve DR 33. The valve DR 33 gets
opened/closed automatically according to the Deaerator water level.
3.11.5.3 Deaerator Drain:
Two drain line connections are provided at the bottom of the
Deaerator storage tank on both ends. These two drain lines join together
before finally joining with Deaerator overflow line, which is connected to
blow down tank.
3.11.6 Steam Outlets From Deaerator:
Deaerator vents are provided for the deaerating header as
detailed below. They are useful for venting the air removed along with a
part of deaerating steam.
1. One vent with provision of motor operated valve SM 20.
2. One vent with provision of hand operated isolation valve.
3. Two nos. of vents provided with an orifice in each line and without
any valve.
231
3.12.0 BOILER FEED PUMP (Ref.Fig.44)
3.12.1 Pump Casing:
The pump casing consists of a forged steel barrel with welded suction,
discharge branches, interstage tapping and mounting feet. The drive end
of the casing is closed by a suction guide, which is entered from the non-
drive end of the casing and is located by a spigot against the inner face of
the casing. A mild steel gasket is located between the suction guide spigot
and the casing inner face to prevent leakage between the barrel casing
and suction annulus. An O ring with backup ring is also fitted in a groove in
the periphery of the suction guide to prevent leakage. Leakage between
suction-annulus and the drive end of the pump casing is prevented by an
O ring and gasket located on an insert ring which is secured to the pump
casing by a ring of studs and nuts. The non-drive end of the casing is closed
by a discharge cover secured to the casing by a ring of studs, washers and
nuts, sealing being effected by an O ring located in a machined recess in
the pump casing. On each side of the casing, on its horizontal centerline,
are two support feet which are secured to the base plate pedestals by
spacer pieces, washers and holding down bolts, thus allowing for
expansion. Transverse keys in the drive end pump feet and longitudinal keys
under the casing transfer moments and thrust to the base plate, while
allowing the casing freedom to expand. Provision is there in the pump
casing for drain connection and temperature probes.
3.12.2 Discharge Cover:
The discharge cover closes the non-drive end of the pump casing
and also forms the balance chamber that, inturn, is closed by the non-drive
and water jacket and mechanical seal housing. The discharge cover is a
close fit in the casing bore and is held in place by a ring of studs and nuts. A
spring disc is located between the last stage diffuser and the discharge
cover balance drum bush to provide the force required to hold the ring
section assembly in place against the drive end of the barrel before startup.
Once running, the discharge assists the spring disc in holding the ring
232
section in place. The last stage diffuser is free to slide over the balance
drum bush, which is shrunk, into the discharge cover bore to minimize the
flow of liquid to the balance chamber.
Two holes are drilled radially through the periphery of the discharge
cover to provide outlet connections through which the liquid from the
balance chamber is returned to the pump suction piping and two similarly
drilled holes are also provided in the discharge cover for cooling water
connections to the water jacket. The non-drive end bearing housing is
attached to a hearing bracket secured to the outer face of the discharge
cover by studs, nuts and dowel pins.
To assist in removing the cover, two tapped holes are provided on the
flange for the use of starting screws and a tapped hole is provided on top
of the cover for an eyebolt.
3.12.3 Suction Guide:
The suction guide closes the drive end of the pump casing and forms
the suction annulus. As a section of the pump cartridge, the suction guide is
not secured to the pump casing but is held against an internal shoulder in
the casing by the ring section assembly, the discharge cover and the spring
disc. Like the discharge cover, the suction guide is closed by the drive end
water jacket and mechanical seal housing.
Two tapped holes are provided in the suction guide for cooling water
connections to the water jacket. The drive-end bearing housing is attached
to a bearing bracket secured to the outer face of the suction guide by
studs, nuts and dowel pins.
3.12.4 Ring Section Assembly:
The ring section assembly consists of ring sections which locate one to
another by spigots and are secured to each other by socket head screws in
counter bored holes, sealing being effected by metal-to-metal joint faces
and O rings with backup rings located in grooves in the ring section
spigots. Diffusers are dowel and spigot located to the ring sections and to
the suction guide, and the last stage diffuser is secured to the last stage ring
233
section with socket head screws in counter bored holes, the screws being
locked in position by locking strips. Packing rings are shrunk into the bores of
the ring sections and diffusers and are secured by grub screws, the purpose
of the packing rings being to restrict the recirculation of the pumped liquid
between the stages.
The ring sections and diffusers form the transfer passage from the
impeller outlet of one stage of the pump to the impeller inlet of the next
stage, and the diffusers are designed to convert some of the kinetic energy
of the product into pressure energy.
The first stage ring section is spigot and dowel located to the suction
guide and is secured in position by socket head screws in counter bored
holes. At the non-drive end a dowel pin fitted to the discharge cover is
located in a hole in the last stage diffuser and thus keeps the ring section
assembly in its correct position relative to the casing. A circular spring disc is
located in the last stage diffuser and over the inner end of the balance
drum bush. A shoulder on the balance drum bush bears against the spring
disc and clamps the ring section assembly and suction guide in position.
3.12.5 Rotating Assembly:
The dynamically balanced rotating assembly consists of the shaft,
impellers, abutment rings, keys, the rotating parts of the mechanical seals,
shaft nuts, balance drum, thrust collar and the pump half coupling.
The shaft is chromium plated at each end where it is supported by
the journal bearings and its diameter increases in increments from the non-
drive end towards the drive-end to facilitate the fitting and removal of the
impellers.
The impellers are of the single entry shrouded inlet type and are
keyed and shrunk on to the shaft, the keys, one per impeller, being
alternately fitted on diametrically opposite sides of the shaft to maintain
rotational balance. The hub of the each impeller butts against a split
abutment ring fitted in a groove in the shaft. The split ring is retained by an
extension on the impeller hub.
234
The balanced drum is keyed and shrunk on to the shaft and held in
place against the shaft locating shoulder by the balance drum nut and
lock-washer. The inner end of the balance drum is recessed and the bore of
the recess is a close fit over the last stage impeller hub. The face of the
balance drum incorporates a connection for oil injection to assist in the
removal of the drum and tapped holes are provided for withdrawal
purposes.
The rotating parts of the mechanical seals are fitted to the shaft
where it passes through the seal housings. The seal sleeves are keyed to the
shaft and are clamped in position by seal sleeve nuts and lock nuts.
The thrust collar is keyed to the non-drive end of the shaft and is
secured against a shoulder on the shaft by a thrust collar nut locked by a
lock washer.
The pump half coupling is located on the tapered end of the shaft by
keys and it is secured by a coupling nut locked by a grub screw.
3.12.6 Mechnical Seals:
The mechanical seals are fitted at each end of the pump and each
seal comprises a seal body assembly secured to a seal housing which
contains the rotating components of the seal.
Each seal consists of rotating tungsten carbide seat, mounted in a
carrier, running against a stationary carbon face. Contact between the
face and seat is maintained by hydraulic pressure on startup. Any other
possible leakage paths, within the seal unit, are sealed with O rings and
the stationary components are prevented from rotating by keys or anti-
rotation pins.
The seal is designed to recirculate the pumped product through a
seal cooler, to maintain an acceptable temperature in the region of the
seal face.



235
3.12.7 Journal And Thrust Bearing:
The rotating assembly is supported at each end of the shaft by a
white metal lined journal bearing and the residual thrust is carried by a tilting
pad double thrust bearing mounted at the non-drive end of the pump.
The journal bearing shells are of mild steel, white metal lined, thin wall
type and are split on the horizontal plane through the shaft axis. Each
bearing is secured in a bearing housing and prevented from rotating by
lugs located in recesses in the housing.
The thrust bearing is fitted in the non-drive end bearing housing and
has light white metal lined tilting pads held in a split carrier ring positioned
on each side of the thrust collar. The carrier rings are prevented from
rotating with the shaft by dowel pins in each ring, which engage in sl ots in
the bearing housing top half. The thrust pads are retained on the carrier
rings by special pad stops screwed into the rings.
A split floating oil sealing ring is located in a groove in the thrust
bearing housing to restrict the escape of lubricating oil from the thrust-
bearing chamber. To ensure that the thrust bearing remains flooded, an
orifice is fitted at the oil outlet.
Machined spacers are fitted behind the carrier rings to effect the
axial position setting of the rotating assembly on the original build. The
bearings are supplied with lubricating oil from the forced lubrication oil
system.
3.12.8 Bearing Housings:
The bearing housings are in the form of cylindrical casings split on the
horizontal shaft axis.
The drive end bearing housing is secured to the bearing housing
bracket by bolts, nuts and washers and is radially located by dowel pins
fitted in the flange of the housing bracket. The journal bearing is located by
lugs in recesses in the bearing housing, and held by the top half bearing
housing, which is secured to the bottom half by studs and nuts and located
by dowel pins. Oil guards fitted in a groove at each end of the bearing
236
housing are dowel located and serve to prevent oil escaping from the
housing.
An air breather is screwed into a tapped hole in the top half bearing
housing and a tapped hole is provided for a temperature gauge.
Connections for an oil inlet and an oil outlet are provided in the bottom half
bearing housing.
The non-drive end bearing housing, which contains both the journal
and thrust bearings, is secured to the bearing housing bracket by studs and
nuts. The top and bottom halves of the bearing housing are secured
together by studs and nuts and located by dowel pins. Leakage of
lubricating oil from the non-drive end bearing housing is prevented by an oil
guard in the inboard side of the housing and by bearing housing end cover
with O ring secured to the outboard side of the housing by socket head
screws.
3.12.9 Hydraulic Balance:
The rotating assembly is subject to varying forces due to the
differential pressure forces acting on the impellers. The pump has therefore
been designed so that the shaft is kept in tension by the location of a
balance drum at the non-drive end, and is hydraulically balanced to that
only a small residual thrust remains, which is carried by the thrust bearings.
3.12.9.1 Hydraulic Balance Arrangement operates as follows:
The pump product passes from the last stage of the pump between
the balance drum and the bush and enters the balance chamber at a
pressure approximately equal to the suction pressure. Two parts in the
discharge cover allow the product to be pumped back to the pump
suction side. The pressure differential across the balance drum is therefore
equal to that across the impellers. The cross sectional area of the balance
drum is sized to give a small residual thrust towards the drive end of the
pump.


237
3.12.10 BFP Warm Up System:
The pump must be started with its inhand and onhand parts at
enertially the same temperature (hot or cold). It should never be started in
an unevenly heated condition, where differences in thermal expansion
resulting from temperature difference may cause binding or rubbing of
informed parts.
When a hot water pump is on standby duty it is held ready for starting
with suction and discharge valves open, the discharge check valve
preventing the back flow, and hence reverse rotation of the pump. To
maintain the casing and internal assembly of the idle pump at
approximately operating temperature, a small flow of feed water passes
through the pump to avoid thermal shock during start-up of the pump.
Hence a war,-up system is provided to warm the pump accordingly.
In Boiler Feed Pumps, (BHEL supply) from the balancing led-off line,
which is connected to the suction pipe, a tapping is taken and it is
connected to condenser flash box-2. This line serves as warming up line for
the feed pump. When the pump is idle, due to the suction head feed water
flows through the warm-up line, after passing through the feed pump and
the balancing leak-off line, thus warming up the feed pump and booster
pump.
A pneumatically operated valve, a pressure relief valve, a check
valve and an isolating valve are installed in the warming up line. Before
starting the pump the pneumatic valve must be closed. It can be kept
open when the pump is standby.
Since the warming water is passed to the condenser through flash
box-2, vacuum must be present in the condenser, so as to keep the exhaust
head temp, within limits. The warm up valve will get closed at a condenser
vacuum of 520 mmHg, for condenser protection. Hence any one of the
ejectors, and at least one CEP must be kept in service, in order to keep the
warm up system in operation.
238
The main components of the hydraulic balancing arrangement are
the balance chamber in the discharge cover, the balance drum, which is
secured to the shaft and the balance drum bush, fitted in the bore of the
discharge cover. The thrust caused by the discharge pressure acting on the
area outside each impeller wear ring on the inlet side of the impeller is
balanced by the same pressure acting on an equal area on the outlet side
of each impeller. The thrust caused by the suction pressure acting on the
area inside the wear ring on the inlet side of each impeller is overcome by
the much greater thrust caused by the discharge pressure acting on an
equivalent area on the outlet side of each impeller. The resultant thrust
force due to the different pressures acting on these equal areas tends to
move the rotating assembly towards the drive end of the pump.
The thrust force will vary with the Load on the pump but the hydraulic
balance arrangement will reduce this effect, enabling the residual thrust to
be taken by the tilting pad thrust bearing. This bearing has a double face so
that the surges in opposite directions, which occur during the start up
period and during transient conditions, will be accommodated.
3.12.11 Flexible Coupling:
The flexible coupling between the hydraulic coupling and the pump
shaft consists of 2 hubs flexibly connected through laminated stainless steel
elements to a tubular spacer.
The element assemblies are secured to the flanges of the spacer and
the hubs by bolts and Nyloc nuts. The flanges of the hubs are drilled to clear
the overload washers fitted to the bolts, which secure the flexible element
to the spacer. Similarly the flanges of the spacer are drilled to clear the
overload washers fitted to the bolts, which secure the flexible elements to
the hubs. The coupling is thus able to accommodate a certain amount of
misalignment between the turbo couplings and pump shafts, to which the
hubs are fitted.


239
3.12.12 Booster Pump (Ref.Fig.45)
The drive for the pump is transmitted through a spacer type coupling
from the motor. The coupling is enclosed in a split, fabricated guard.
The bearings of the booster pump, feed pump and motor are
lubricated in the turbo coupling. The pump has a suction strainer, a non
return valve in the feed pump discharge and a modulating, minimum flow
recirculation system comprising a Masoneilan pneumatic actuator leak off
regulating valve, leak off isolating valve and a non return valve.
The booster pump is a single stage double suction, horizontal, axial
split type casing having the suction and the discharge branches in the
casing bottom half, thus allowing the pump internals to be removed without
disturbing the suction and the discharge pipes or the alignment between
the pump and the drive motor.
The pump shaft is sealed at the coupling and free ends by
mechanical seals which are flushed by a supply of clarified water. The
rotating assembly is supported by plain white metal lined journal bearings
and axially located by a Glacier double tilting pad thrust bearings.
3.12.12.1 Pump Casing:
The cast steel pump casing is of the double volute type split on the
horizontal centerline. The top and bottom half casings are located to each
other by dowel pins and secured by studs and nuts, sealing at the axial split
being effected by an asbestos fibre joint.
The bottom half pump casing has the suction and discharge
branches and support feet cast integrally. Cast extensions at each end of
the bottom half casing provide supports for the bearing housings and also
from gland wells. A tapped hole is provided in each gland well for drainage
purpose.
The pump casing is machined internally to accept, the casing rings
and deep stuffing boxes are also formed at each end of the casing to
accommodate the water jackets and the mechanical seals thus preventing
water leakage along the pump shaft.
240
A flanged air vent connection is provided on the top half of the
casing. Connections are also provided on the suction and the discharge
branches for pressure gauges and a drain.
3.12.12.2 Rotating Assembly:
The dynamically balanced rotating assembly consists of the shaft,
impeller, nuts, keys, seal sleeves, thrust collar, the rotating parts of the
mechanical seals and pump coupling.
The double entry impeller is keyed to the shaft and is located axially
by an impeller nut on each side of the impeller hub. The impeller is fitted
with a wear ring on each shroud, the rings being retained by grub screws.
The seal sleeves are keyed to the shaft and are located and secured
by grub screws, leakage between the shaft and sleeve is prevented by an
O ring fitted in a groove machined in the bore of the sleeve. The thrust
collar is keyed to the shaft and is secured against a shoulder on the shaft by
the thrust collar nut. The pump half coupling is keyed to the tapered end of
the shaft and is secured by a coupling nut, locked by a lock screw.
3.12.12.3 Journal And Thrust Bearings:
The rotating assembly is supported at each end of the shaft by a
white metal lined journal bearing and the residual axial thrust is taken up by
a tilting pad double thrust bearing mounted on the free end of the pump.
The journal bearing shells are of mild steel and are split on a horizontal
plane through the shaft axis, the halves of each bearing shell being
provided with lugs which are located in the recesses in the bearing housing
which prevent the bearing shell turning with the shaft.
The thrust bearing is fitted in the free end of the pump and has eight
tilting pads held in a split carrier ring on each side of a thrust collar, which is
keyed to the pump shaft and secured by a nut and lock washer. The carrier
rings are held in the free end bearing housing and are prevented from
turning with the thrust collar by dowels located in slots in the top half of the
housing .the thrust pads are retained on the carrier rings by special pad
stops screwed into the rings. Machined spacers are fitted behind each
241
barrier ring during manufacture to effect the axial running position of the
rotating assembly .The thrust bearing is provided with four resistance
temperature detectors.
A split floating oil seal is fitted in a groove in the housing to maintain a
level of lubricating oil within the housing, around the thrust bearing, when
the pump is stopped. The floating seal is prevented from turning by an
antirotation pin fitted in a slot in the bottom half of the housing. An orifice
plug fitted at the thrust bearing lubricating oil outlet ensures a flooded
bearing housing when the pump is stationary. The bearings are supplied
with lubricating oil from the forced lubricating oil system.
3.12.12.4 Bearing Housings:
The bearing housings are in the form of cylindrical castings, split
horizontally, secured to each bracket by set screws and bowel. Each
housing is provided with lubricating oil inlet and outlet connections, vent
connections and instrument points.
The top and bottom halves of the drive end bearing housing s are
secured together by studs and nuts, and the housing is closed at the drive
end by a cover plate. An oil-retaining shield at each end of the housing
prevents oil leakage from the housing when the pump is running.
The top and bottom halves of the free end bearing housings are
secured together by studs and nuts and are located by dowel pins,
leakage of lubricating oil from the free end bearing housing is prevented by
an oil retaining shield in the inboard side of the housing and by a bearing
housing end cover and joint secured to the outboard side of the housing by
hexagonal head screws.
3.12.12.5 Mechanical Seals:
The drive and free end stuffing boxes are fitted with mechanical seals
mounted on seal sleeves and located within seal cooling jackets to prevent
feed water escaping along the shaft. Tapped holes are provided on each
seal plate and cooling jacket for demineralised cooling water inlet and
outlet connections.
242
3.12.12.6 Motor / Pump Coupling:
The drive from the motor to the pump shaft is transmitted through a
diaphragm type spacer flexible coupling.
3.12.13 Hydro coupling: (Ref. Fig.98)
The hydrodynamic geared variable speed coupling is used for infinite
speed control of high speed feed pump. The turbo coupling and step up
gear are incorporated in the same housing, while the lower section of the
housing serves as an oil tank.
Flexible couplings are used for transmitting power from the motor to
the variable speed hydrodynamic geared speed coupling and from there
to the feed pump. Speed transmission between the input shaft and primary
shaft is by way of herring bone gears. Torque is transmitted from the primary
wheel to the secondary wheel hydro dynamically by the working oil.
The primary wheel (impeller) accelerates the working oil. This is
delayed in the secondary wheel (turbine) to produce an equal torque. The
oil can only circulate by dropping the pressure between the primary and
secondary wheels. This requires that the secondary wheel speed is lower
than that of the primary wheel.
The coupling size is selected to have a minimum slip of (2 to 3.5%)at
full load, when the coupling is completely filled. the output speed can be
regulated infinitely by changing the volume of the oil in the working
chamber, between the primary and secondary wheels. this is accomplished
by positioning the scoop tube accordingly, which will determine the oil
volume of the working chamber.
The power loss caused by the slip will heat up the working oil. To carry
off this heat, the oil has to be cooled.
3.11.3.2. Advantages of Hydrocoupling:
1.power savings when driving centrifugal machinery like feed pump
operating at part load compared with throttle control.
2.longer life of driven machine as a result of stepless speed control.
3.no wear problems as throttle valves are not required,
243
4.precise speed adjustment and fast response times,
5.wear free power transmission,
6.damping of torsional vibration.
3.12.15 Design Details:
The geared variable speed turbo coupling is connected to the
driving and driven machines through torsionally flexible couplings. All
rotating parts are housed in an oil tight casing. a mechanical gear stage on
the input side of the variable speed turbo coupling matching the speed of
the high driven machine (feed pump) to that of a standard 4 pole squirrel
cage motor. The compact space saving design is a characteristic feature
of this gear stage and turbo coupling combination.
The rotating parts of the variable speed turbo coupling i.e. primary
wheel, secondary wheel and casing are made of steel.
The variable speed turbo coupling has plain bearings. The highly
loaded radial and thrust bearings are white metal lined. Remote
thermometers monitor the temperature of the bearings.
The housing is split along the shaft centerline giving ready access to
the bearings, gears and minimum dismantling and reassembly is required for
maintenance.
3.12.16 Working And Lube Oil Circuits:
The same oil is used as working and lube oil. The working oil pump
(centrifugal pump) and the main lub oil pump (gear pump) are combined
to form a pump set and are driven off the input shaft.
The main oil pump which is driven mechanically from the gear input
shaft draws the working fluid from the oil reservoir in the lower part of the
housing and delivers it through the flow control valve into the couplings
working chamber. This chamber formed by the primary and secondary
wheels connects with the space inside the coupling casing surrounding the
secondary wheel. Due to the centrifugal force, the fluid inside the casing
forms a ring round the periphery. The inside diameter of this ring is
determined by the radial position of the adjustable scoop tube.
244
The oil picked up by the scoop tube passes thro a heat exchanger to
the flow control valve and from there back to the working chamber or the
oil reservoir. The flow control valve whose function is dependent upon the
position of the scoop tube regulates the oil flow rate relative to the heat
due to slip generated in the coupling .The excess oil flows back to the oil
reservoir.
As a result, the response time to a control signal is very fast. On the
signal increase speed the full flow of the oil pump passes into the working
chamber; on the signal reduce speed oil flow to the working chamber is
cut off.
3.12.17 Working Oil Circuit:
The working oil circuit consists of a closed circuit on which an open
circuit is superposed so that the filling can be changed.
In the closed circuit, the oil, which flows into the coupling via, the
control valve for power transmission and heat dissipation, is removed by the
displaceable scoop tube. Under the action of the dynamic pressure, the oil
flows through the scoop tube housing, working oil cooler and control valve
back into the coupling.
The open circuit is made up of the working oil pump, orifice plate and
pressure relief valve. The coupling is filled by oil flowing from the open to the
closed circuit.
Excess oil supplied by the working oil pump flows through the relief
valve back into the sump. The same applies when the coupling filling is
reduced.
The pressure relief valve holds the pressure of the working oil at 1.5 to
2.8 bar.
Factory setting of working oil pressure is approximately 2 bar. If the
closed circuit is broken and the hydrodynamic geared variable speed
coupling oil temperature rises to 160 C, the fusible plug blow. Bores in the
plugs are thereby released and the coupling drains.
245
If the fusible plugs blow due to temporary thermal overloading of the
oil circuit, the control behaviour of the coupling changes only slightly and
the sump temperature rises a little.
The fusible plugs in the shell can be easily replaced by removing the
inspection hole cover on the housing cover.
3.12.18 Lub Oil Circuit:
The lubricating system is separate from the working oil circuit although
the same oil is used for both. The main lubricating pump is fitted to the main
working oil pump drive shaft. Lube oil is pumped from the oil reservoir
through oil cooler and a double filter to the bearings and the gears. A
motor driven auxiliary pump is switched on before start up to ensure that all
bearings are lubricated before the turbo coupling runs. The auxiliary pump
operates until the turbo coupling reaches its rated speed when the
mechanically driven main lube oil pump takes over. The auxiliary pump is
stopped automatically on a signal from the instruments monitoring the lube
oil circuit. If the pressure in the lube oil circuit drops e.g. if the drive unit is
shut down, the auxiliary pump is switched on again.
A double filter is fitted in the lubricating system to allow for continuous
operation. Only one of these two filters is in use at one time and if this
becomes choked, a differential pressure gauge with alarm contacts
provides a visual and / or audible alarm to indicate the need to change
filters. The dirty filter must be them be isolated and cleaned.
The main lube oil pumps oil out of the sump through the check valve,
pressure relief valve, lube oil cooler and the reversible double filter to the
bearing points and the gear wheels.
The lube oil pressure is set approximately 2.5 bar on pressure relief
valve.
To ensure that the bearings are coated with oil during coupling
startup , run down and failure , they are supplied with oil by the auxiliary
lube oil pump.
246
The ALOP, which is driven by the electric motor, draws lube oil out of
the sump and pumps it through a check valve into the lube oil circuit.
3.12.19 External Oil Supply:
Lube oil for the drive motor and feed pump is taken from the
couplings lube oil circuit and returned to the oil sump.
The oil quantity taken for lubrication of the bearing units must not
exceed 120 liters at a pressure of 2.0 to 2.5 bar. Pilot bored orifice plates are
fitted at the flange connections of the external lube oil supply system. These
orifice plates can be modified during the trial run.
3.12.20 Scoop Tube Control:
The scoop tube which regulates the amount of oil in the coupling is
controlled by the actuator turning the cam disc, positioning the scoop tube
accordingly.
3.12.20.1 Step Up Speed Control:
The scoop tube moves away form the oil ring in the coupling the
amount of oil scooped up decreases, the pressure in the recirculation
control valve (nodal pressure), drops, the pressure relief valve closes, the
filling pump flow rate is used to fill the working chamber.
3.12.20.2 Step Down Speed Control:
The scoop tube moves into the oil ring in the coupling the scoop tube
delivery increases, the pressure in the recirculation control valve (nodal
pressure), rises. The pressure relief valve opens and discharges the scooped
oil plus the filling pump delivery into the sump.
3.12.20.3 Operation Of Hydro Dynamic Geared Variable
Speed Coupling:
A continuous monitoring of hydrodynamic geared variable speed
coupling under maintaining admissible temperatures, lube oil pressure and
oil level means a trouble free operation and low maintenance.The viscosity
of operating oil for start up must not exceed 250 mm2/s (cst). For this,
according to the oil selection the oil temperature should be at least +5.0 C.
247
The hydrodynamic geared variable speed coupling can be started
and stopped with the scoop tube at minimum position; the main motor can
run up under virtually no load.
To keep good air separation, the sump temperature must not fall
below 45 C.
3.12.20.4 Oil Coolers:
There are tow oil coolers for working oil and two for lube oil. They are
placed at O meter elevation just below the oil tank. One working oil
cooler and one lube oil cooler will be in service normally; the other for each
purpose is a standby. The coolers are placed side by side in each category.
The working oil coolers are located on the western side and are big where
as lube oil coolers are small and are to be found on the eastern side. The
coolers are identical in construction except for their size. Water inlet is in the
bottom and outlet is in the top. Oil inlet is in the head side and outlet is in
the free side. Oil flow can be quickly changed over one cooler to the other
by operating the change over lever.







248
3.13.0 CIRCULATING WATER PUMP
3.13.1 Pump Assembly: (Ref. Fig.47)
3.13.1.1 Suction Bell:
The suction bell forms the inlet to the pump assembly and it is secured
to the impeller bowl through taper connecting piece by fasteners. This is
designed specifically to stabilize the flow of incoming water into the eye of
the impeller.
3.13.1.2 Impeller Bowl:
The impeller bowl and diffuser are integrally cast to form a single unit
of semi-spheroidal shape. The delivery guide vanes and impeller bearing
are also incorporated in this unit. The guide vanes structure is centrally
disposed within the casting. A spigotted flange is provided on the casting
for the purpose of connecting it to taper column pipe.
3.13.1.3 Taper Column Pipe:
A taper column pipe is located between the impeller bowl and the
column pipe. Flanges of taper column pipe are drilled to allow passage for
fasteners, which secure these flanges with O seal ring between them.
3.13.1.4 Rotating Elements:
The impeller, the impeller shaft and the impeller-bearing sleeve form
the rotating elements. The line and head shafts coupled through shaft
coupling are also part of rotating elements.
Impeller is keyed to the impeller shaft and axially located against
impeller bearing sleeve. The complete impeller and sleeve assembly is end
tightened against a shoulder on the shaft by an impeller nose cap, which is
held in position by means of a locking screw. The impeller is of open mixed
flow type.
3.13.1.5 Impeller Baring, Shaft And Gland:
Renewable sleeves are fitted to the shaft in the places where the
shaft passes through the bearings. This is intended to prevent scouring of the
impeller shaft and line shafts by abrasive materials, which may get lodged
249
in the line bearings. These sleeves are shrunk fitted on the respective shafts
and additionally secured by a grub screw.
3.13.2 Intermediate Assembly:
3.13.2.1 Column Pipe:
The impeller bowl, suction bell and taper column pipe assembly is
connected to the motor stool through three column pipes and a discharge
head. The top most column pipe is provided with an integral flange to
accommodate the pump thrust bearing assembly. Apertures provided in
the motor stool provide access to the thrust bearing and auxiliary pipings.
3.13.2.2 Line Shaft Bearing Carrier And Bearing:
The line shaft bearing carrier is centrally located in the taper column
pipe and the column pipe with the help of integral radial support ribs. The
ribs are designed to offer minimum resistance to the pumped water as it
flows through them. The bearing carrier supports the line shaft bearing.
3.13.2.3 Discharge Head:
Discharge head, which forms the discharge branch of the pump, is a
fabricated structure and located below the motor floor level. The top
flange of this is connected with bottom flange of the top column pipe. The
bottom flange of the discharge head supports column pipe and impeller
bowl assembly. Tappings are provided in the outlet branch of the discharge
head for pressure gauge mountings and cooling water requirements.
Provision is also made for mounting the thrust pipe. The top flange
accommodates the stuffing box and spit gland assembly for sealing the first
line shaft with packings.
3.13.3 Motor Stool:
Motor stool is a fabricated structure. Bottom flange of motor stool
rests on the top of sole plates. Top flange of column pipe is bolted to the
motor stool. Top flange of motor stool supports the drive motor.Apertures
provide access to the thrust bearing housing and auxiliary piping. Aperture
is also provided to gain access to the pump and motor half couplings.
250
3.13.4 Motor Winding Cooling Arrangement:
The stator frame is of fabricated type. Two heat exchangers are fitted
on the side of the stator frame and shields and they are of shell and tube
type. An external fan draws the external cooling air through a wire mesh
screen and forces it through the steel tubes of heat exchanger. An internal
fan creates a cross flow of the air inside the motor around the tubes of heat
exchanger. Heat transfer takes place through the tubes and this also
ensures non-contamination of internal air with external cooling air.
3.13.5 Thrust And Guide Bearing Of Pump:
The bearing is of oil bath lubricated type. The lub oil is held within the
confines of bearing housing and is cooled by water supplied to a cooler
immersed in the oil bath.
The bearing is mounted on integral flange provided in top column
pipe and it is designed to support and prevent lateral movement of the
rotating element. The inherent design of the bearing internals ensures the
circulation of oil through the bearing within the confines of the bearing
housing when the shaft is in rotation.
3.13.4.1 Construction Details:
The bearing comprises of a housing, a top cover and a bottom plate.
The bottom plate and the housing support the load transmitted by the
bearing elements. The bottom plate provides the seating for the thrust pads
and housing. The spigot on the bottom plate locates the bearing in position
on the supporting flange and it is held in position by means of fasteners.
The housing is secured to the bottom plate by studs and nuts. The nuts
are secured into the supporting stool through the bottom plate. A gasket
provided between the mating faces of the bottom plate and housing
prevents the leakage of oil.
A cover bolted to the housing encloses the top end of the bearing. A
gasket provided between the mating surfaces prevents the leakage of oil.
An air vent fitted to the cover can be removed for filling the oil
251
Bearing support is achieved on the principle that the lubricating oil
carries the bearing load apart from reducing friction between the moving
metallic surfaces. When the shaft is in rotation, the bearing components viz
thrust collar and thrust pads/journal pads never come into contact. They
are forcibly separated and kept apart by automatic self generated
tapered oil films drawn from the normal oil supply. The thrust pads and the
journal pads are so designed and positioned that they tilt and float the load
on their own films.
Down thrust of the pump shaft is transmitted from the collar on to the
white metal faces of thrust pads. These pads are located on the bottom
plate and retained in position by the housing bore. These pads are
prevented from rotation with the collar by a stopper, which is permanently
locked in position on the bottom plate.
Lateral movement of the shaft is restricted by the journal pads, which
are located in the bore of the housing. These pads encircle the collar
journal. These pads are also of tilting type and are prevented from rotating
with the collar by a pad stopped permanently locked in position in the
housing bore. The pads are supported on a wedge machined in the
housing bore and are retained in position by an anti-vortex ring which is
bolted to the casing.
Oil is retained in the bearing by an oil retainer bush. This bush is bolted
to the bottom plate and projects into the thrust collar bore above the
standing oil level. A gasket provided between the sleeve and the bottom
plate prevents oil leakage. An annular projection in the bore of the collar
and the vent holes drilled through the collar above the standing oil level
prevent the spillage over the top of the sleeve.
The oil level indicator, which is connected to the housing through an
adopter, gives a direct visual indication of the standing and running oil
levels.


252
3.13.4.2 Cooling Arrangement: (Ref. Fig.99)
A tapping of cooling water is taken from the pumps discharge
column pipe and the cooling water flows to the pumps thrust bearing oil
cooler. In this line, a gate valve, a strainer, a flow switch and a pressure
switch are provided. Whenever the flow of cooling water to the thrust
bearing is less than 12 litres per minute an alarm is initiated at local control
panel/UCB. A local pressure indicator is also available for checking the
cooling water pressure to thrust bearing.

253
3.14.0 NATURAL DRAUGHT COOLING TOWERS
3.14.1 Introduction
The efficient operation of a steam turbine depends on the vacuum in
the condenser and the effective functioning of the circulating water
system. The absorption of latent heat of the turbine exhaust steam result in
effective condensation and maintaining optimum vacuum in the
condenser warrant that the performance of cooling towers should be kept
high. Four hyperbolic natural draught cooling towers located in the west of
Thermal Power Station-II serve to cool the enormous quantity of hot
circulating water flowing out of the condensers of four units of the station
(Station-II).
If a natural supply of water is available from a river, a mine or from the
sea, it is best to employ this natural source rather than cool the cooling
water by exposing it to an air stream.
However, circumstances often arise where the water is unsuitable, or
the supply very limited, in which case the cooling water must be cooled by
spraying it down a tower, through which air circulates, or by spraying it
directly into the atmosphere over the surface of a spray pond.
3.14.2 Description: (Ref. Fig. 54)
A natural draught cooling tower is s semi-enclosed heat exchanger
consisting of an empty reinforced concrete shell forming a chimney, which
has the principal function of forming a draught. The shape of the tower is
circular in plan and hyperbolic in profile. At the lower portion of the tower,
there is fill packing or distribution network through which the hot water from
the condenser sprayed and drops in a pre-determined manner so as to
give up a portion of its heat to the air stream flowing past.
The hyperbolic profile is chosen for the construction of the tower as it
directs the air that enters to have a smooth flow towards the center.
Moreover upper rim aids to produce a strong upward draught.
The advantages of natural draught tower over a mechanical draught
tower are
254
1. A single natural draught cooling tower has a capacity equivalent
to a number of cells of induced draught cooling tower. Thereby ground
space required is saved considerably.
2. As the fans are eliminated, the operating costs, maintenance
costs and down time are reduced and reliability in operation service is
ensured.
3. Hyperbolic shaped towers have superior strength, since a thinner
shell thickness can be used in comparison with other designs; the
quantitative need for materials of construction is reduced.
4. Warm air recirculation is an adulteration of the atmospheric air
entering the tower by a portion of warm air leaving the tower. The above
problem is non-existent in natural draught.
5. Due to higher elevation of natural draught cooling towers. Drift
losses are minimized.
3.14.1 Principle Of Operation:
The draught in a natural tower is created mainly by the levitation of
air itself; resulting from its being heated and mixed with the steam, steam
being lighter than air. The draught is due to the difference in densities
between the air leaving the tower and that entering the tower and also
due to the aerodynamic lift of the wind passing over the top of tower. The
shell of the tower is supported on legs so as to allow free ingress of air at the
base.
The hot water from the condenser is distributed at the level just above
the fill packings by nozzle and sprayer and the resulting spray makes a
considerable contribution to increase the exposed surface of the hot water
by subdividing into fine droplets. Exchange of heat takes place between
the ascending air and the falling water. The purpose of fill packing is to
increase the period (retention time) and area of contact.
The evaporative cooling is the process that takes place in the tower
and in this, 3 processes go on simultaneously.
255
(a) The first is the transfer of sensible heat by convection from hot
water to cold air.
(b) Since the atmospheric air has definite capacity to absorb
water vapour at given temperature, a part of moisture is transferred to air in
the form of vapours when it is exposed to air in the form of droplets or sheet.
(c) The heat required for vapourisation of a part of water is taken
from the remaining part of it. There is a transfer of heat from the bulk of the
water to the surface and thus the water gets cooled.
The rate of evaporation of water in cooling tower and subsequent
reduction in water temperature depends on many factors, which are
indicated below:
1. The area of water surface exposed
2. The time of exposure
3. The relative velocity of air passing over the water droplets formed
in cooling water
4. The direction of airflow relative to the water
5. The ambient temperature
6. Relative humidity of air
7. The difference between the hot water and the wet bulb
temperature.
3.14.4.0 Description Of Natural Draught Towers
The entire shell of the hyperbolic cooling tower is supported by 72
diagonal columns on a foundation rim beam. Precast columns and beams
support the internal fill. The diameter of the tower is progressively reduced
from 94.42 metres at sill level to 53.9 metres at neck (Elevation 89.0 metre).
Then it is increased progressively to 59.4 metre at top (Elevation 124.0 metre
3.14.4.1 Hot Water Distribution Arrangement
The hot circulating water leaving from both water boxes of the
condenser flows in a single pipe (called hot water tunnel) towards cooling
tower. From the hot water pipe, the hot water flows up to middle of the
basin through two hot water ducts, (R.C.C.). From basin floor, the hot water
256
rises through risers (R.C.C.) and the hot water enters the distribution network
at 10 metre elevation. The hot water from each riser is distributed with a R.C.
main distribution duct and a branch R.C.duct. From these ducts, the water
is distributed through A.C pipes which are fitted with nozzles and sprayers
(Poly Urethane).
3.14.4.2 Internal Fill:
The internal fill is of precast prestressed concrete splash bar (Laths).
They are arranged in 18 layers. The vertical spacing of layers is 300 mm and
horizontal spacing is 150 mm to 200 mm.
3.14.4.3 Basin:
R.C. Basin of the tower has a partition wall for independent operation.
The cold water collected at each half of the basin is led through C.I Screen
to a common channel. This channel takes the cold water to fore bay of
circulating water pump house. The basin can be isolated from the channel
by wooden stop logs and intermediate clay filling arrangement.
Wind baffles are provided to avoid a break through of air during
strong wings, the wind baffles are form the top of the basin to the bottom of
the fill. The length of the wind baffle is equal to the half of the radius from
the outer end of basin, due to this arrangement; carryover of water by wind
is reduced,
3.14.5 Terminology:
1. Cooling range The extent by which the hot water is cooled in
the tower is known as cooling range
2. Approach The difference between the cold water leaving the
tower and the wet bulb temperature of air entering is called Approach.
Presumably the wet bulb temperature is the minimum temperature
3. Heat Load It is the amount of heat exchanged in a cooling tower
between the hot water and the cold air in calories/minute
4. Drift The windage loss or carry over is otherwise known as drift
and this indicates the amount of water that is carried from cooling towers in
the form of fine droplets entrained in the circulation air.
257
5. Evaporation rate The rate at which the water is being
evaporated to cool the hot water is called evaporation rate and circulating
air carries this evaporated water vapour away
6. Capacity The average volume of circulating water that is
cooled in the tower at any time is the capacity of the tower.
7. Sprinkling density The rate at which the water is falling through
unit fill area of the tower is known as sprinkling density
8. Draught factor = P / 1.64(10-8 h)
where P is the density difference in air at inlet and exit of the tower in
lbs/cu.ft and h is the total enthalpy difference of air at inlet and exit of the
tower in Btu.
9. Performance Coefficient C = L X / (L/GN
1/3
)
where L is the cooling water flow or sprinkling density
X is Markels factor
N is the resistance of tower to air flow through it in velocity head
G is the Dry airflow
10. Duty coefficient D = AH/C .C
1/2

A is the Pond area at sill level
H is the height of tower above sill
3.14.6 Operation Data:
a. Design capacity of the tower : 30,000 m
3
/hr
b. Design cold water temperature : 33.19 deg C
c. Hot water inlet temperature : 42.73 deg C
d. Design approach : 5.19 deg C
e. Design atm. Wet bulb temperature : 28 deg C
f. Wind velocity for performance : calm
g. Design atm relative humidity : 50 %
h. Pumping head at the entry of the tower: 12 M of water column
3.14.7 Design Parameters:
1. Sprinkling density (L) or cooling
Water flow in Kg/Hr M2 fill area : 5364 Kg/M
2
/Hr.
258
2. Dry air flow (G) Kg/M2/Hr. : 2823.7 kg/m
3
/hr
3. Effective fill volume (inclusive of air gap) : 31,700 m3
4. Ratio of water to air weight (L/G) : 1.8998
5. Temperature of leaving air
(i) Dry bulb temperature : 40.04 degC
(ii) Wet bulb temperature : 39.91 deg C
6. Total dry air flow per tower :17,370 X 10
3
Kg/hr
7. Inlet air enthalpy above 0 deg C : 21.18608 kcal/kg
8. Total wet air flow per tower :17,719 X 10
3
kg/hr
9. Sensible heat gain by dry air thro tower : 0.73264 kcal/kg
10. Latent heat gain by dry air : 17.3686 kcal/kg
11. Exit air enthalpy above 0 C : 39.28732 kcal/kg
12. Total heat exchanged per Kg of inlet air : 18.10124 kcal/kg
13. Total heat exchanged per hour : 314.82 X 10
6
kcal
14. Evaporation loss (maximum) : 519.36 m
3
/hr
15. Drift loss (maximum) : 9.9 m
3
/hr
16. Wetted packing surface per sq.m of : 19 m
2
/m
2
(laths .
tower area only)

3.14.8 Other Technical Data:
3.14.8.1 Levels
(a) Level of Basin bottom below sill at the periphery : 3 metre
(b) Nominal working level of water :2.49
metre
3.14.8.2 Heights:
(a) Height of top of tower above sill : 124 m
(b) Height of throat of tower above sill : 89.0 m
(c) Height of top of air inlet above sill : 8.2 m
(d) Height of top of fill above sill at the
periphery and center : 9.29 m
(e) Height of bottom of fill above sill at the
259
periphery and center : 4.13 m
3.14.8.3 Diameters:
(a) Internal diameter of tower at sill level : 94.42 m
(b) Internal diameter of tower at the top of air opening : 88.90 m
(c) Internal diameter of tower at sill level : 54.10 m
(d) Internal diameter of tower at sill level : 59.40 m
3.14.8.4 Thickness:
(a) Thickness of the top of tower : 200 mm
(b) Thickness of bottom of tower : 1000 mm
3.14.8.5 Shell Supports:
(a) Number of supporting diagonal columns : 72
(b )Diameter of shell support piers : 900 mm
3.14.8.6 Basin:
(a) Area of basin : 7986 m
2
(b) working volume

of basin : 19300 m
3
3.14.8.7 Fill:
(a) Shape : Pear shape
(b) Material of fill : R.C.C.
(c) Total height : 5.16 m
(d) Number of flaths per tower : 2.2 lakhs
(e) Number of fill support elements : 24000
3.14.8.8 Sprayers:
(a) Material : Poly Urethene
(b) Type of spray : Upward spray
(c) Number of sprayers/tower : 8752
(d) Nozzles (i) Diameter : 18 mm
(ii) Thickness : 2 mm
(iii) Capacity : 3.6 m
3
/hr


260
3.14.8.9 General:
(a) Total approximate quantity of
cement used per tower : 7500 MT
(b) Treatment of concrete internal surfaces :
Inside shell surface was painted with three coatings of anti
corrosive water resistant bitumastic paint.
(c) Number of lightning arresters : 7
(d) Number of aviation warning lights per tower : 12 (each 100 Lux )
(e) Rebar quantity per tower : 2200 MT
(f) Period of construction per tower : 32 months.
261

3.15.0 CT PUMP, ACW PUMP & ACWB PUMP:
3.15.1 CT PUMP:
3.15.1.1 General:
The system water losses in the thermal cycle are made up at the
condenser through a surge tank of capacity 50 m
3
. DM water supplied by
the water treatment plant is stored at 2 Condensate storage tanks (CST) of
each capacity 500 m
3
. The DM water stored in these tanks are also used for
the following purposes:
- Make-up water for Auxiliary Cooling water (ACW) overhead tank of
capacity 15 m
3
.
-
Make-up water for Stator water tank of capacity 5 m
3
- Initial filling up of Deaerator
- Initial filling up of Boiler
- Make-up water for Surge Tank.
The above purposes are met by the use of CT Pumps namely
condensate transfer pumps. At the time of commissioning there were
frequent failures of CT Pumps. There were many occasions in which both the
CT Pumps were out of service. In such cases, the running units received the
system make up thro the gravity make up lines via the valve DM 6.
However the ACW Over head tank and SW make up tanks located at 27 ml
needed the source of water for filling up the tank. To sort out the above
recurring problems faced an alternate pump of same capacity but with
lower discharge head was tried. Various experiments were conducted at
the site for identifying the pump. Finally the Kirloskar pump of type KPD-125 /
40 was selected after the successful field trial. As a trial basis, a third pump
was installed and after ascertaining the suitability of the pump for the
running units in the long run another pump was also installed in the place of
the existing CTP B.


262
3.15.1.2 CT Pump A, B & C.
Now the condensate storage tanks are provided with three pumps
called as condensate transfer pumps. Pump B or C will be normally in
service and others (A and B or C) are reserve. This is a single stage end
suction centrifugal pump.
Pump-C has the capacity of 200 m
3
/hr (dis press: 5.5 ksc, 1475 rpm, 45 KW)
CTP A was supplied by the Beecon Weir.
CTP B & C were supplied by the Kirloskar Brothers Ltd.
The technical features of CTP A, B & C are

CTP A CTP B CTP C
Type IG 125-100-315 KPD 125/40 KPD .
125/40
BKW KW 95.58 45 45
Speed rpm 2970 1475 1475
Make Beecon weir Kirloskar Kirloskar

Capacity m
3
/hr 180 200 200
Head m 140 55 55
Efficiency % 71.8 -- --
3.15.1.3 CTP B & C has the following features.
KPD KPD pump with enclosed impeller
Spacer type flexible coupling.
Has a constant level oiler. It has a plastic container and aluminium
body. Its capacity is 70 ml approx.
Maximum allowable temperature of bearings 80 C.
Lubrication
Bearing should be lubricated with lubricating oil as noted below.
The oil should be a highly refined straight mineral product of
high demulsibility, free from running and acid forming tendencies,
detergent oil may cause foaming and emulsion difficulties and should not
263
be used. The lubrication oil should be conformed to following grades of oil
available in the market.
1. Indian Oil Servo System 81
2. Hindustan Petroleum ENKLO 57.
3.15.1.4 CTP A has the following features.
The Beacon Weir Isoglide pump is a horizontal, back pullout, single
stage, end suction centrifugal pump fitted with closed impeller. The pump
casing and bearing bracket are secured together on the vertical axis with
suction and discharge connections incorporated in the pump casing. This
arrangement allows easy removal of the rotating assembly without
disturbing the pipe work and motor alignment. The pumps are designed to
ISO standard and the drive from the electric motor is transmitted to the
pump through a spacer type flexible couple.
The pump may be supplied as follows: -
a) Standard packed gland.
b) Standard mechanical seal.
c) Jacketed stuffing box.
d) Oil lubricated bearing.
e) Wearing rings.
With an electric motor and spacer type flexible coupling mounted on
a base-plate, extended for driving motor and coupling guard.
3.15.1.5 Lubrication of CTP A bearing:
For lubrication of the bearings Oil of Grade SAE 30 or Equivalent is
used.
3.15.2 ACW & ACWB Pumps:
An exclusively closed cycle with demineralised water as cooling
water is used in this ACW system. This system meets the cooling water
requirements of auxiliary equipments. It is used in the following zones for
cooling purposes.


264
(A) Boiler Zone:
(B) Compressors:
(C) Turbine Zone:
(D) Generator Zone:
In this closed cycle, two auxiliary cooling water pumps are provided.
One pump is normally in service and the other pump is a standby. These
pumps are single stage double suction centrifugal type driven by 415 V, 3
phase, 100 KW motors. The total dynamic head of the pump is 20 m and its
capacity is 1250 m
3
/hr.
These pumps draw water from a common suction header and pump
it through plate type water to water heat exchangers to different coolers
and cooling points. Warm water returns to this common suction header for
circulation, three heat exchangers are provided out of which two can meet
the requirements. The auxiliary cooling water is cooled by a part of
circulating water drawn from the cold water intake pipe of the circulating
water system.
A part of cooled auxiliary cooling water from the heat exchangers is
distributed to Boiler Auxiliaries by means of Auxiliary Cooling Water Booster
Pumps. There are two ACW Booster pumps. One pump is normally in service
and the other is standby. These pumps are of single stage double suction
centrifuge type driven by 415 V, 3 phase, 22 KW motor. The total dynamic
head of the pump is 20 m and its capacity is 250m
3
/hr.
The ACW Pumps & ACWB Pumps were supplied by the Beacon
Weir.







265

The technical particulars of the ACW Pumps & ACWB Pumps are
tabulated below.

S.No ACWP ACWBP

Design parameters:
1. Capacity in m
3
/hr 1250 250
2. Head in m 20 20
3. NPSH reqd at design capacity
3 % Head break in m 3.9 4.0
4. Efficiency in % 84.7 86
Max capacity parameter:
5. Capacity in m3/hr 1500 300
6. Head in m 16.9 14.5
7. NPSH in m 4.9 6.0
8. Efficiency in % 78 70
9. Pump speed in rpm 985 1470
10. Type SDA 350/450 SDB 125/150
RD
11. Direction of rotation CW CW
When viewed from Drive end.
12. Shut off head in m 25 26
Motor specifications:
13. Motor efficiency in % 93 90.5
14. Rated continuous output 100 KW 22 KW
at 50 C amb
15. Full load current in amps 180 41
16. No load current in amps 80 18.


266
3.16.0 FIRE PROTECTION SYSTEMS:
3.16.1 Introduction:
The Fire Production System installed by M/s. Technofab Private
limited comprises of a Fire Hydrant System and a High Velocity Water (HVW)
system with their related pump sets. The hydrant system provides a
convenient source of water supply for fire fighting purposes inside the
Thermal Power Station premises in the event of a fire out break. HVW
system sprays water on to the risk it protects when it is actuated manually in
case of outbreak of localized fire. Pump sets have been provided in the
circulating water pump house to ensure instant water supply to the above
system at the required pressure and flow. Visible and audible warnings and
annunciations have been provided in unit control room to alert the
operation personnel.
3.16.2 System Description: (Ref: Fig 100)
The fire protection system consists of two interconnected circuits
namely the hydrant system and HVW (High Velocity Water) system. The
hydrant circuit has got three hydrant pumps of which two are electrically
driven pumps while the third is a diesel engine driven pump. These pumps
feed a common header, which feeds the hydrant lines leading to various
hydrant circuits in the Power Station (Units IV to Vii). The HVW system
consists of one electrically driven pump M3and a diesel engine driven
pump M4. These two pumps feed the HVW spray system through two filters
(one filter in service and the other stand by) under normal conditions, the
system pressure is maintained at 9.8 KSC by the hydro pneumatic tank.
3.16.3 Hydro Pneumatic Tank:
The hydro pneumatic tank is a pressurized vessel having a total
capacity of 3m
3
and a make up capacity of 1.5 m
3
(Volume between low
level and high level switches). The top of the tank is connected to an air
compressor while the jockey pump feeds the tank with pressurized water
from the bottom. Under normal conditions, the level in the hydro
267
pneumatic tank will be maintained at constant and the tank pressure will
be 9.8 KSC. In the event of minor system leakage in either the hydrant
system or in HVW system, the make up water under pressure will be fed from
the hydro pneumatic tank so as to sustain the system pressure. The level in
the tank will gradually decrease, resulting in slow drop of pressure in the
hydro pneumatic tank. When the tank pressure drops to 9.45 KSC, the air
compressor starts on Auto and increases the pressure to 9.8 KSC and then
stops. If the system leakage is more, then the compressor will be in
continuous service. When the level in hydro pneumatic tank reaches low
level, the jockey pump will start and the compressor will stop simultaneously.
The level in the hydro pneumatic tank will begin to rise and the tank
pressure will also increase. When the tank pressure increases to 10.5 KSC,
the solenoid valve on the top of the tank will open and vent out some air
and it will close when the tank pressure reduces to 10.2 KSC. The solenoid
valve will operate number of times before the high level is attained in the
tank. When the high level is attained, the jockey pump will stop. The hydro
pneumatic tank is provided with a safety valve set at 12.5 KSC for ultimate
safety of the tank.
3.16.4 Description Of Sprinkler Unit :
Each hazard Main Oil Tank (MOT), Lub oil canal (1) Lub oil canal (2)
protected by the spray system is provided with a network of piping all
around spray nozzles are strategically located to cover the complete
surface area of the hazard by a uniform spray. The high velocity water
required for the spray system is tapped off from the HVW spray mains.
The MOT & Lub oil canals are provided with the following types of
detectors.
3.16.6.1 Ionisation Type Smoke Detectors:
These smoke detector are dual chamber detectors with a small amount of
radioactive material (Americium 241, 0.5 micro curies) that ionizes the air in
the sensing chamber thus rendering it conductive and permitting a current
flow through the air between the two charged electrodes.
268
When the smoke particles enter the ionizing area, they decrease the
conductance of the air by attaching themselves to the ions, causing a
reduction in mobility. When the conductance is less than a predetermined
level, the detector picks up and responds. Ionization detectors are
responsive to invisible particles produced by most flaming fires.
3.16.6.2 Rate Of Rise Of Temperature Type Heat Detectors:
These heat detectors consists of bimetallic strips placed directly in the
alarm circuit. When the temperature increases, the strip gets heated and
deforms in the direction of its contacts point. The width of the gap between
the contacts determines the operating temperature. The wider the gap,
the higher the operating point.
Smoke detectors and rate of rise of temperature type heat detectors are
placed alternatively around the MOT / Lub oil canal. Each smoke / heat
detector is provided with an integral response indicator. In lub oil canals,
for each detector an additional external response indicator is also
provided.
All the heat / smoke detectors and MCP (Metal Call Point) of the MOT
and lub oil canals of one unit are wired on to a single circuit in parallel.
Whenever there is a fire in MOT / lub oil canal area, a signal will be sent from
the detectors to the fire alarm panel (in UCB) and ON FIRE annunciation
will appear in fire alarm panel (Ref. fig. 3) for the corresponding zone. On
seeing the annunciation the Turbine Board Staff, will have to move to the
local and initiate the release system of the respective deluge valve.
3.16.5 Fire Hydrant Installation:
Manual fire fighting can be extremely hazardous in any Thermal
Power Station unless fixed equipment has been carefully provided for Fire
Fighting. This equipment has been provided in the form of the Hydrant
installation, and is a reliable means of fighting a fire out break.
The fire Hydrant Installation is basically made up of water mains,
which run through the premises in areas, which are to be protected. In the
event of a fire out break, water under pressure can be tapped from one or
269
several of the outlets called hydrant points and directed on to the seat of
the fire manually by means of the hoses and nozzles provided. Water for
the fire hydrant system is drawn from the fore bay of circulating water pump
house water is pumped in to the installation by the pump sets provided.
Both the Fire hydrant system of Stage I and Stage II are interconnected
at several points. A Jockey pump J3 has been provided to make up minor
losses in the mains pressure and prevents unnecessary & frequent start ups
of the main pumps.
The mains are always kept pressurized at 8.0 ksc and any reduction in
the pressure as & when a landing valve is opened to fight a fire
automatically brings the pumps in to operation and a continuous flow of
water at the required pressure is ensured.
Pump P4, the electric motor driven pump is set to come in to
automatic operation when the mains pressure drops to 8.0 ksc. Pump P
5
,
the electric motor driven pump is set to come in to automatic operation
when the mains pressure drops to 7.0 ksc. The Diesel engine driven standby
pump P6 is set to come in to operation at 6.0 ksc. All these pumps have to
be stopped manually. Pump J3, the Jockey pump comes in to operation
when the water level in the hydrodynamic tank came to low level and
makes up the level. It comes in to operation at low tank level and cuts out
at high level.
3.16.6 Mulsifyre Installation:
3.16.6.1 General Description:
The Automatic Mulsifyre system installed at the Second Thermal Power
Station protects the Generator transformers, Station transformers, and Main
oil tanks. The mulsifyre protection of each risk (or group of risks) is controlled
by a deluge valve. The operation of the deluge valve brings the mulsifyre
installation of that particular risk in to operation.



270
3.16.6.2 Principles Of The Mulsifyre System:
The mulsifyre system applies water in the form of a conical spray
consisting of droplets of water traveling at high velocity. Three principles of
extinguishment are employed in the system, viz. Emulsification, Cooling and
Smothering. The result of applying these principles is to extinguish the fire
with in a few seconds.
3.16.6.3 Emulsification:
Droplets of water, traveling at high velocity, bombard the surface of
the oil to form an emulsion of oil and water that will not support combustion.
The effect of this emulsion is to convey a flammable liquid in to one that will
not burn. The emulsion thus formed is not of stable character so that a few
minutes after the water is shut off the oil has started to separate from the
water, which can be drained away, bearing the oil unimpaired so far as the
action of the water is concerned.
3.16.6.4 Cooling & Smothering:
The rate of burning of a flammable liquid depends on the rate at
which vapour is given off from the surface of the liquid, and the supply of air
or oxygen to support combustion. When a flammable liquid burns, the rate
of vaporization increases until the fire reaches a maximum rate of burning
with the surface of the liquid near to boiling point.
The mulsifyre system when forming an emulsion, intersperses cold
water with the oil, thus cooling it and reducing the rate of vaporization. In
addition, it prevents further escape of the flammable vapours. While the
water droplets are passing through the flame zone, some parts of the water
get formed in to steam. This dilutes the air or oxygen feeding the fire and
creates a smothering effect.
3.16.6.5 Advantages Of Mulsifyre System:
Speed: The Mulsifyre System extinguished oil fires within a few
seconds by emulsification, cooling and smothering.
271
Economy: The Mulsifyre System uses water only as the
extinguishing agent.
Reliability: Automatic operation of the mulsifyre equipment is free
from the human element and is almost always recommended. The
equipment is designed for simplicity and is proved for reliable operation in
all types of industrial locations and in any climate.
Minimum Fire Damage: The Mulsifyre System with automatic
detection and economical use of water ensures that after fire damage is
kept to a minimum and that of the plant affected is in operation again with
minimum delay.
3.16.6.6 The Mulsifyre System:
The salient features of the Mulsifyre System are
a. Arrangement of projectors.
b. Arrangement of Detectors.
c. Compressed Air supply.
d. The deluge valve.
e. Water Mains.
f. Manual operation of the system.
g. Annunciation panel/alarm motor and Gang.
(a) Arrangement Of Projectors.
The basic design of the Mulsifyre System consists of two ring mains,
one above and one below the transformers so that the whole
transformer is covered.
(b) Arrangement Of Detectors.
Grinnell Quartzoid Bulb Detectors from the heat-sensing element
for the Mulsifyre System. They are spaced over the entire area of the
transformer in a manner where they could detect a fire, which develops
in any part of the transformer. The heat sensitive detector bulb shatters
at 155F (68.3C) in case of a fire, creating a drop in the air pressure in
the detector pipe work.

272
(c) Compressed Air Supply:
Compressed air supply of the detector pipe work at 3.0 ksc
pressure forms the actuating element of the deluge valve. There are
two mulsifyre compressors available to supply the compressed air; they
are kept in auto mode. Supply source for the mulsifyre compressors is as
follows.
Mulsifyre compressor A: U6 EMCC 2 P2A.
Mulsifyre compressor B: U5 EMCC 1 P 7B.
The mulsifyre compressors and their control panel are located
near A row columns Nos. A 53. When the compressed air supply
header is > 3.0 ksc, the mulsifyre compressor stops on auto. When the
compressed air supply header is < 2.5 ksc, the mulsifyre compressor A
starts on auto. When the compressed air supply header is < 2.0 ksc, the
mulsifyre compressor B starts on auto. When the compressed air supply
header further drops below 1.5 ksc, an alarm Low pressure in
Detector Network is initiated in the Fire Alarm Panel in the UCB 4.
(Ref: Fig 102) When the compressed air supply header pressure is < 0.8
ksc, the deluge valve opens.
(d) The Deluge Valve: (Ref: Fig 101)
This is basically a pneumatic operated water valve. It is actuated
by release of compressed air in the detector pipe work. Normally the
water pipe work below the deluge valve is charged with water under
pressure. The clack of the deluge valve is kept closed by compressed air
of the detector pipe work. In case of fire, the compressed air in the
detector pipe work is released to the atmosphere and the clack swings
open due to the hydraulic thrust & the pressurized water is sprayed on to
the risk through the deluge valve and mulsifyre projectors.
e) Water Mains:
Cast Iron Tyton Joint pipes have been used to connect the pumps
to the deluge valves. A common underground main connects the
pumps to all the deluge valves.
273
3.17. LP HEATERS & HP HEATERS:
3.17.a LP Heaters: (Ref: Fig. 52)
3.17.1 Description:
The L.P. Heaters are of shell and tube type heat exchangers with
steam on shell side and condensate on tube side. These have been
provided with connections for shell and tube side vent and shell side drain.
Shell side vent is connected with condenser in the steam space. Shell side
drip is cascaded, during normal operation, to lower heater and through
drain cooler and flash tank it is finally connected to condenser. Provision is
also there to divert the drip of L.P. Heaters 2 & 3 to condenser through
flash tank bypassing the L.P. heater 1 and Drain Cooler, to take care of
the abnormal conditions of shell side flooding of heaters due to tube failure
etc.
Following are the main sub assemblies of the L.P. Heaters:
3.17.2 Shell:
Shell is of cylindrical construction with dished end welded at one
end and the other end welded to tube plate through shell skirt. The shell is
provided with suitable steam inlet, drain and other nozzle connections for
mounting various fittings.
3.17.3 Tube System:
Tube system consists of stainless steel U tubes fixed in the carbon
steel tube plate holes at both ends by roller expansion. Tube system has
been provided with skid bars to facilitate its withdrawal from shell.
To protect the tubes from impingement of high temperature and
high velocity steam, impingement plates have been provided at steam
inlet nozzles. Suitably spaced baffles have been provided for ensuring
uniform distribution of steam and proper support to the tubes.



274
3.17.4 Water Box:
Water box is welded with the tube plate. Cover of the water-box
is of flanged type, which acts as a manhole also. Suitably sized nozzles
have been provided for the condensate inlet and outlet.
3.17.b Hp Heaters: (Ref: Fig. 53)
3.17.5 Description:
The H.P. Heaters are of shell and tube type heat exchangers with
steam on shell side and feed water on tube side. These have been
provided with connections for shell and tube side vent and shell side drain.
Shell side vent is connected with Deaerator in the top of storage tank. Shell
side drip is cascaded, during normal operation, to lower heater and it is
finally connected to Deaerator. Provision is also there to divert the drip of
H.P. Heaters 5 & 6 to condenser through flash tank by-passing the H.P.
heater 5 in the case of HPH 6, and Deaerator in the case of HPH 5, to
take care of the abnormal conditions of shell side flooding of heaters due to
tube failure etc.
The HP Heaters are provided with a safety valve on the shell side
to safeguard it in the event of pressure rise in the heater shell side.
275
TURBINE
STAGE II
OPERATION MANUAL










CHAPTER IV

OPERATION

OF

TURBINE AND ITS AUXILIARIES.










276
4.1 Start up of Turbine:
4.1.0 Preparation prior to rolling:

After Boiler light up it is essential to fix the rolling parameter. The
following points have to be borne in mind while fixing the rolling
parameters.
A.Steam temperature should have a minimum super heat of 50 C.
B.Steam temperature should be more than the turbine maximum
metal temperature.
In order to help the board engineer to fix the correct rolling
parameters the following charts are given by the manufacturer for
a ready guidance tool for Warming up and the Starting the turbine
& speeding up and loading criteria.

Fig. 4.1. Steam with super heat.
Fig. 4.2. Recommended minimum (Curve A) and Maximum (Curve B) main
steam temperature ahead of turbine when opening the main stop
valves.
Fig. 4.3. Allowable maximum main steam pressure ahead of turbine when
opening the main steam stop valves.
Fig.4.4. Recommended minimum main steam temperature ahead of
turbine before opening the main steam control valves.
Fig.4.5. Recommended minimum reheat steam temperature ahead of IP
turbine before opening the reheat control valves.
Fig.4.6. Recommended maximum main steam temperature ahead of
turbine before the turbine is brought to rated speed.
Fig.4.7. Recommended maximum re heat steam temperature before the
turbine is loaded.
Fig.4.8. Start up curves after 250 Hours shut down (Absolute Cold start)
Fig.4.9. Start up curves after 160 Hours shut down (Cold start)
Fig.4.10. Start up curves after 36 Hours shut down (Warm start)
277
Fig.4.11. Start up curves after 8 Hours shut down (Hot start)

Warming up and the Starting the turbine
Temperature criteria.
The admission steam temperatures should meet the metal
temperatures as shown in the diagrams below in order to start and load the
turbine in the shortest possible time.
Criteria for the opening of stop valves
When opening the main stop valves the main steam parameters
should meet the following recommended values.
Minimum MS temperature.
0MS > 0s + 50 C. Ref Fig. 4.1.
0MS = Main Steam temperature at Steam Generator outlet.
0
s
= temperature of saturated steam (depending on main steam pr)
and
0MS > f(0MCV 50% ) Ref Fig. 4.2. Curve A
0MS = Main Steam temperature at Steam Generator outlet.
0s = temperature of saturated steam (depending on main steam pr)
0MCV 50% = Middle wall temperature of HP Control valve casing.
Maximum MS temperature.
0MS < f(0MCV 50% ) Ref Fig. 4.2 .Curve B
0MS = Main Steam temperature at Steam Generator outlet.
0s = temperature of saturated steam (depending on main steam pr)
0MCV 50% = Middle wall temperature of HP Control valve casing.
Maximum MS pressure ahead of the turbine.
Pmax. = f (0MCV 50% ) Ref Fig. 4.3.
Pmax. = Maximum main steam pressure ahead of turbine.
0MCV 50% = Middle wall temperature of HP Control valve.
If the control valve temperatures 0MCV 50% exceed the temperature of
the saturated steam belonging to the main steam pressure the pressure
criteria must not be observed.
278

Starting criteria.
When the main control valves are opened the main steam and reheat
temperatures should fulfill the following criteria.
0MS > 0s + 50 C. Ref Fig. 4.1.
0MS = Main Steam temperature ahead of the Turbine.
0s = temperature of saturated steam (depending on main steam pr)
and
0MS > f(0HT 50% ) Ref Fig. 4.4.
0MS = Main Steam temperature ahead of the Turbine.
0HT 50% = Middle wall temperature of HP Casing or simulated middle phase
shaft temperature.
Minimum Reheat temperature.
0Reh > f(0IT 50% ) Ref Fig. 4.5.
0Reh = Steam temperature in the hot reheat line.
0IT 50% = Simulated middle phase temperature of the IP shaft.
Speeding up criteria.
Before the turbine is brought to rated speed the main steam
temperature ahead of the turbine should fulfill the following criteria.
0MS > f(0HT 50% ) Ref Fig. 4.6.
0MS = Main Steam temperature ahead of the Turbine.
0HT 50% = Middle wall temperature of HP turbine Casing or simulated middle
phase shaft temperature.
Loading criteria.
Before the turbine is loaded the reheat temperature ahead of the
turbine should fulfill the following criteria.
0Reh < f(0IT 50%) Ref Fig. 4.7.
0Reh = Steam temperature in the hot reheat line.
0IT 50% = Simulated middle phase temperature of the IP turbine shaft.
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291

Stage - II UNITS Turbine start up Steam Parameters / Rolling / Hold time / Turbine Loading Chart
HP Shaft Turbine Minimum Hold Total
mean temp Rolling load time time
TSE Rec Boiler O/L Turbine I/L Duration Hold at after at Min from
TR 3230 at the start at the end 600 rpm synchro- load start
8th point SH3 O/L pr & MS pr & temp nising of
temp in TSE rec Phase - I Phase - II rolling
1 2 3 4 5 6 7 8 9 10
450 C 120 ksc 120 ksc 15 min 15 min 40 MW 10 min 520 C 535 C 1 Hr
and 500 C 520 C 140 ksc 150 ksc
above 100 MW 210 MW
15 min 20 min
350 C 80 ksc 100 ksc 30 min 30 min 30 MW 15 min 520 C 535 C 2 Hrs
to 400 C 475 C 140 ksc 150 ksc
450 C 100 MW 100 MW
30 min 45 min
250 C 60 ksc 80 ksc 30 min 45 min 30 MW 15 min 500 C 535 C 3 Hrs
to 375 C 400 C 120 ksc 150 ksc
350 C 100 MW 210 MW
60 min 60 min
150 C 30 ksc 50 ksc 45 min 45 min 20 MW 30 min 500 C 535 C 3 3/4
to 325 C 400 C 120 ksc 150 ksc Hrs
250 C 100 MW 210 MW
60 min 90 min
Below 30 ksc 50 ksc 45 min 45 min 20 MW 30 min 500 C 535 C 4 1/4
150 C 300 C 375 C 120 ksc 150 ksc Hrs
100 MW 210 MW
90 min 90 min
HPSV and IPSV warming up
Steam parameters at
Further Loading
292
Steam purity.
Required values for main steam condensate.
The deposits which occur in turbines due to impurities in the steam
can lead to thermodynamic and mechanical inefficiencies and, with the
presence of salts, especially chlorides, and sodium hydroxide also cause
damage to turbine parts. The corrosion stressing caused by active deposits,
for example, has an adverse effect on the fatigue strength of the blade
material when the steam is in the transition zone between the superheated
and the saturated state.
The required values (Fig.1) must be adhered to for continuous
operation, with the commissioning of a new plant and starting up
operation however, these values can not be attained with an economical
outlay. The values listed in the column starting up operation are then
valid.
To avoid any misunderstanding, it should be noted that even if the
required values are adhered to, deposits in the turbine can not be
eliminated with absolute certainty.
A recording instrument may be used to continuously monitor the
electrical conductivity of the main stem and turbine condensate following a
strongly acid cation exchange unit. In order to determine slight impurities, the
sodium concentration should be measured in addition to this. Should saline
contamination occur, the turbine is to be immediately washed with saturated
steam to remove salt deposits.
If an alkaline method is used, the oxygen content in the main steam
condensate can be max.0.02 mg/kg and the pH value in the turbine
condensate max. 9.3 with brass condenser piping. When the condenser
piping is of copper-nickel alloys, the pH value must not exceed 9.5. There is
no limitation for the pH value with non corroding steel or titania.

293
"RECOMMENDED VALUES OF STEAM PURITY FOR TURBINES"

Quantity Continuous Starting Up Unit
Operation **

Conductivity at 25 C Continuous
Measurement at the sampling point
"1. Direct Measurement " Alkaline Method. Not Specified Not Specified s / cm
Neutral Method. < 0 .15 < 0 .50 s / cm
"2. Strongly acid
cation - exchange unit " Alkaline Method. < 0 .10 < 0 .50 s / cm
Neutral Method. < 0 .10 < 0 .50 s / cm
Silicic Acid (SiO2) < 0 .010 < 0 .050 mg / kg
Total Iron (Fe) < 0 .005 < 0 .050 mg / kg
Total Copper (Cu) < 0 .001 < 0 .010 mg / kg
Sodium (Na) < 0 .005 < 0 .020 mg / kg

* Recommended values.
** There should be a discernable tendency for this value to fall. When commissioning a new plant the
recommended values for continuous operation should be reached after 2 to 3 days and with starting up
operations after 2 to 3 hours.
294
4.0 OPERATION OF TURBINE AND ITS AUXILIARIES:
4.1 Start-up of Turbine:
4.1.1 Cold Start-Up Procedure:
TIME ACTIVITIES OPERATION REMARKS
Preparation of Boiler for cold light up.
Thorough inspection of furnace for complete closing of
peep holes and manholes.
After filling the slag bath, ensure running of slag conveyor
and ABG's

-04.30
Hrs
Start preheating of feed water in Deaerator and raise the
water temperature to 70
o
C to 80
o
C.
Close waterside drain valves.
Open SH1 I/L Air vent, other air vents, startup vents and
drains of SH & RH.
Start warm-up of BFPs,
keeping casing drains,
vent in crack open condition.
-02.00
Hrs
Start one BFP.
Start boiler feeding.
Pegging steam to Deaerator can be made through and
pre-heating steam may be isolated.
Keep the oil in circulation.
Charge trace-heating system in Boiler.
Check the possible leaks in each oil burners.
Ensure the healthiness of oil burner system.
After Boiler contour filling,
Check whether all air vents, startup vents
and SH, RH drains are in open condition.
Ensure that LSHS Oil temperature is more than 90

C.
General interlocking for oil fire existing' is available now.
BOILER IS READY FOR LIGHT UP.
Start ID & FD fans.
Charge SCAPH.
Start purging.
00.00
Hrs
Light up Boiler by cutting in
2 OBs with LDO.
Change over to HFO after 10
mins one by one.
Oil pr is 6 Ksc.
Keep drum level at 300 mm.
Note down the Drum Metal Temperature (DMT),
Oil flow and oil pressure.
Condenser vacuum raising can be started.
While cutting in OB raise oil pressure to 12 Ksc.
Then reduce pressure to 6 Ksc.
01.00
Hrs
Watch the DMT.
When it reaches 90

C, surging of drum level may start.


When surging of drum level is observed, open EBD.
Cut out one burner and if necessary open CBD also to
contain drum level.
Dozing pumps are to be started.
Oil pressure to be raised to 12 Ksc.
295
01.30
Hrs
Cut in 3
rd
OB with HFO 4
th
OB
afterwards.
After normalizing drum level close CBD & EBD, cut in 3
rd
OB.
When SH1 -I/l temperature is more than 110

C, close SH1
inlet vent & all vents at 44 ML.
Close the SH drains in order, when steam temp SH shows
rising trend and steam temperature at O/L header is
greater than I/L header.
When SH3 O/L pressure is 1Ksc start closing start up vent
gradually within 10 minutes.
When SH3 O/L pressure is 5Ksc open HP bypass and charge
re heaters.
Open MS25&26;MAL-11&12;HR-47&48.
Reduce oil pressure to 10 Ksc.
Before opening HP Bypass valves check for
1) Safe drum level.
2) Full open condition of MS-001 & 002.
3) Closing of startup vent valves.
4) Vacuum is stable.
02.00
Hrs
Raise oil pressure to
8 Ksc.
Open HP Bypass according to the SH3 O/L pressure rise.
When the RH pressure is 2Ksc open LP Bypass without
affecting vacuum.
(At this stage HP Bypass opening shall be around 30%.)
Rate of pressure is
MST : 1Ksc / 2 minutes
HRH : 1Ksc / 4 minutes
Rate of temp rise is 2.5

C /min upto 350

C
02.30
Hrs
Raise oil pressure to
10 Ksc.
Prepare injection scheme for temperature control.
HP Bypass shall be operated manually so as to maintain MS
pressure at 23 Ksc.
Select LP Bypass in auto at HRH pr of 7 Ksc.
S-92 bypass valve is to be used for injection to have fine
control.
At MS Pressure 23 Ksc & MS Temperature 300

C start
warming up of stop & control valves.
Maintain MS temperature not more than 350

C.
Check injection station drains and vents for closed condition.
Hand operated isolation valves in open condition.
For 23 Ksc Sat. temperature is 225

C.
In TSE recorder and confirm rise in temperature.
03.00
Hrs
Raise oil pressure to
12 Ksc.
Raise MS Pressure at a rate of 1Ksc/min up to 40Ksc and
when the pressure is steady at 40 ksc select HP Bypass in
auto.
During warming up MS & HRH temperature should not drop
below 320

C.
03.30
Hrs
START ROLLING
MS Pr : 40 Ksc
MS Temp. : 350

C
HRH Pr : 7 Ksc
HRH Temp : 350

C
HP B/P open >50 %
Rolling can be started after confirming
5th & 6th points to reach its saturation value.
Reach 600 RPM.

296

04.00
Hrs
After watching HP shaft & HP casing (pts.7th & 9th and 8th
& 10th) for its warming up and cross checking with HP shaft
& HP casing stress margin (not less than 30

K) further speed
raising to 3000 RPM can be started.

04.05
Hrs
SYNCHRONISATION Synchronize the unit with the grid and keep the
temperature steady at 350

C for 20 minutes and observe


for the stress margins.
Accordingly loading can be done and HP B/P closed.
Watch Drum level.
Wait till HP casing & IP shaft margin (7th & 9th point) saturates.
Prepare the mill & feeder system.
04.35
Hrs
Raise oil pressure slowly such
that flow rises to 16 T/Hr.
Raise the load to 50 MW
MS Pressure : 60 Ksc
MS Temperature : 400

C
LP heaters may be taken into service.
For further load raising HP casing margin must be more than
10

K
05.00
Hrs
Start 1st Mill. Raise the load to 70 MW (Rate 2 MW/minute)
MS Pressure : 80 Ksc
MS Temperature : 440

C (Rate 4

C/minute)
Open S-92 valve & close its bypass valve for more injection flow.
Commission ESP.
SH1 inlet temp. shall be > 450

C
05.15
Hrs
Start 2nd Mill. Raise the load to 90 MW
MS Pressure : 100 Ksc
MS Temperature : 440

C
Reduce oil Pr. 10 to 12 Ksc.
Start warm-up of HP heaters on steam side at 70 MW.
Warm-up HPHs at least for 20 minutes.
05.30
Hrs
Start 3rd Mill. Reduce oil flow to
7 T/Hr.
Raise the load to 110 MW
MS Pressure : 120 Ksc
MS Temperature : 490

C
05.45
Hrs
Start 4th Mill & cut out oil
burners one by one.
Raise the load to 125 MW
MS Pressure : 130 Ksc
MS Temperature : 490

C
Before taking out oil burners, stable condition of firing should be
ensured with IR scanners.
Take EHC into IP mode.
06.00
Hrs
Start 5th Mill. Raise the load to 150 MW
MS Pressure : 140 Ksc
MS Temperature : 500

C
Take CMC in Auto.
06.30
Hrs
Raise firing to full load. Raise the load to 210 MW
MS Pressure : 150 Ksc
MS Temperature : 540

C


297
4.1.2 Hot Start-Up Procedure:
1. Turbine is in hot condition and it is on STG.
2. Hp shaft / HP Casing metal temperature i.e. 7
th
, 8th, 9th & 10th of
TSE Recorder is greater than 450
0
C.
3. AOP, JOP and oil vapour extractor are in service.
4. One CWP is in service with one half of condenser through.
5. One ACW &ACW booster pump is in service with two heat
exchangers in service.
6. CD64, 66 &DM 6 tobe made through.
7. CEP is in service on recirculation.
8. All BFPs are in charged condition with their warm up valve in open
condition
9. HP Bypass- oil systems are ready.
10. Open MS 25,26 & HR 15,16 & CR 11,12 valves
11. Open Hp B/P atm. drain.
12. CST level 75 %. Deaerator O/L temperature 90
0
C.
Instructions received to start-up the unit.
13. Check initial HP shaft/casing metal temperature of turbine and
inform boiler board the required steam parameters for turbine hot
rolling.
14. Also fix up rolling time and hold at minimum load from the start-up
guidelines tabulation.
15. Make the feed line scheme ready up to boiler feed control valves.
16. Start one BFP &put in recirculation. Put the other BFPs in standby
condition.
17. Charge the feed line.
18. Open pegging steam to Deaerator.
19. Start warming up the pilot ejector line. Start warming up the
steam to seals line. Commission pilot ejector and start the Gland
seam vapour extractor fan at 100 mm and put the other fan in
standby condition. Admit steam to seals at 200 mm of Hg.
298
20. Open the following drains fully.
21. All MAL drains.
22. Extraction drain pot drains.
23. Full vacuum reached. .
24. Boiler is lit up.
25. Open HP B/P by 30 %
26. LP B/P opens on auto when HRH pr is 2 ksc when auto control
interface is put on auto. Till then reheater drain to be in open
condition.
27. Pegging steam to Deaerator PCV is set to maintain Deaerator
pressure at 3 Ksc.
28. Start second BFP.when MS pressure is 40 ksc
29. Start second CWP and make through the other side of the
condenser.
30. Gradually increase the opening of HP B/P and LP B/P to 60 %
depending on the boiler firing.
Commence pre-rolling checks and operations.
31. Ensure that Turbine protection relays K 101 & K 201 are in ON
condition.
32. Physically ensure that EHC is made through. Stop valve test valves
tobe made through.
33. Check lube oil temp control valve is maintaining in auto at 45
0
C.
34. Commission one main ejector. Cut out pilot ejector. Put HP B/P
valves on auto.
35. Change over steam to seals source to CRH when H/P d/s temp is
>280
0
C and HRH pr is 12 ksc
36. Change over steam source to Deaerator from AST to CRH
37. Reset the turbine. CVs warming up at appropriate temp.
38. Rolling parameter is attained.
39. Inform boiler board and Generator board about commencement
of turbine rolling.
299
40. Rolling through EHC to 600 rpm. TG rotor starts rolling.
41. Check whether STG has properly disengaged at 240 rpm.
42. Check Jop stops at 540 rpm.
43. Check the conditions at turbine local for abnormal noise, oil leaks
etc.
44. Check vibrations in TG bearing shafts at different turbine speeds.
45. At 2800 RPM AOP stops on auto. Switch on TD at 2900 rpm.
46. Turbine is ready for synchronizing.
47. Synchronize the Unit. Take block load of 10 MW.
48. Take load control at 25 MW.
49. Hold this load for 10 minutes.
50. Close all MAL drains and manually tighten them.
51. Observe the warming up pattern of turbine from Turbine metal
temperature recorder and TSE recorder.
52. Also observe Turbine Expansion, Differential Expansion and Axial
Shift.
53. Start raising load and pressure at the rate given, considering also
the warming up pattern of turbine from Turbine metal temperature
recorder and TSE recorder.
54. Also observe Turbine Expansion, Differential Expansion and Axial
Shift.
55. At the load of 40 MW, charge LP heaters on steam side.
56. Slowly raise the load so that HP & LP B/P closes on auto.
57. At 120 MW extraction to dea to be made through.
58. Put EHC - IP mode at about 125 MW.
300

4.2 Shutdown procedures:
1. Unit Load is at 210 MW and M.S parameters are 150 Ksc / 540
0
C.
Turbine is running normal with all HP heaters and LP heaters.
Turbine governing is on EHC I.P mode.
2. Ball collection in OLTCS is tobe carried out.
3. Reduce the boiler firing gradually and reduce the load set point.
4. At 140 MW, reduce the pressure set point in HP Bypass desk insert
and reduce MS pressure at the rate of 3 Ksc / minute.
5. At 120 MW, cutout HPHs on steam side & Extraction to Dea to be
cut, CRH to Dea to be made through.
6. Take load control at 110 MW.
7. When the load drops to110 MW and at the M.S pressure of 120 Ksc
(with 3 Mills), watch for opening of LP Bypass as the HRH pressure
rises.
8. At the Load of 40 MW (with 1 Mill and 4 Oil burners), open MAL
drains.
Start AOP. Trip the turbine from the desk using manual trip button.
Watch for Trip oil pressure zero and turbine stop valves closing.
Also ensure that fast opening of HP B/P.
9. Observe the coasting down vibrations.
If vibration exceeds open partial vac. breaker valve.
10. Stop one CWP & one BFP.
11. Close HP Bypass and LP Bypass as the boiler is tripped.
12. Observe the Turbine speed. Check for auto starting of JOP at 510
rpm.
13. Check for gate valve gearing opening at 210 rpm.
14. Stop second BFP after consulting boiler staff.
15. Open the vacuum breaker valve and kill the condenser vacuum.
16. Isolate the condenser on steam side.
301
17. Cut out the steam to seals at the condenser vacuum of 200 mm of
Hg and stop the gland steam vapour extractor fan at 100 mm of
Hg. Close the gate valve in the steam to seals line at 8.5ML
18. Observe the exhaust hood temperature. If it rises, further tighten
the valves through which the steam can enter the condenser.
19. Close the butterfly valve at inlet to the condenser on one side by
90%.
20. Stop the CEP when exhaust hood temp is 45
0
C.
21. Stop ACW & ACW BP after confirming that no equipments on
Boiler, Turbine & Generator sides require Auxiliary cooling water.
22. Isolate hot well makeup system.
23. AOP, JOP, Oil Vapour extractor fan and STG alone are in service.
302

4.3 HP & LP B/P CONTROL SYSTEM:
4.3.a. HP B/P System. (Ref. Fig. 55)
The HP bypass system comprises mainly five valves. Two HP bypass
valves, left and right, designated as BP-1 and BP-2, two HP bypass spray
water flow control valves designated as BPE1 and BPE2 and a spray water
pressure control valve designated as BD are provided.
HP bypass valve is a pressure-reducing valve with built in spray
nozzles. The pressure is reduced by throttling and the temperature is
reduced by the injection of spray water.
The spray water for HP bypass system is drawn from the discharge
header of the Boiler Feed Pumps. The Feed Water is supplied through a
spray water pressure-reducing valve, BD. This valve is provided to reduce
and then maintain the down stream pressure. This is intended for having
finer operation of the spray water flow to control valves. The feed water,
supplied through the valve BD, is admitted to HP bypass valves BP1 and BP2
through two spray water control valves BPE1 and BPE2. These BPE1 and BPE2
valves are provided to regulate the quantity of feed water so as to control
the downstream temperature of the bypassed steam.
4.3.a.1 Servo Valve:
There are totally three oil lines connected with the servo valve as
explained hereunder.
1. Supply Oil Line: designated as P line
2. Return Oil Line: designated as T line
3. Leakage Oil Line: designated as L line
Through T and L lines the oil returns to the oil supply unit. Both the
admission of the pressure oil to the actuator and the withdrawal of the oil
from the actuator (either to the top or bottom space of the piston
according to the action required) are routed through the servo valve. The
oil withdrawn from the actuator returns through T line.
303
The oil from the leakage space returns to the oil supply unit through
the L line along with the leakage oil from the blocking unit. The pressure oil
for the blocking unit is also supplied through the servo valve.
The servo valve can be operated by local manual operation
overriding the electrical signals.
4.3.a.2 The Oil Supply Unit (OSU):
`The oil supply unit provides the hydraulic actuation energy for the
actuators. Two separate oil supply units are provided for HP bypass valves at
10.5 M level. Both the oil supply units are similar in construction and
operation.
Each unit consists of an oil tank with an oil pump. An electric motor
driven axial piston pump sucks the oil through a suction strainer and
discharges the oil at high pressure to an accumulator through a pressure
filter and a non-return valve NRV. Any abnormal rise in the oil pressure is
limited by safety relief valve.
The accumulator is intended for storing the hydraulic energy and
meeting all the peak demands of the actuators supplying the pressurized
oil. The oil pump is therefore sized only for the mean supply requirements
and it is switched off when the accumulator is fully charged. The
accumulator is of bladder type and consists of a steel pressure vessel
containing a nitrogen filled rubber bladder, which separates oil from the
gas.
From the accumulator, the oil is delivered to the supply manifold
through a pressure a switch and a pressure-reducing valve. The Pressure
switch monitors the oil pressure in the accumulator and provides the signals
for the operation of the oil pump and the alarms. The pressure reducing
valve keeps the system oil pressure at a constant value (100 Bar) so that the
oil can be supplied to the servo valves of the actuators within narrow limits
of variation in pressure.
The oil from the supply manifold is supplied to the servo valves
through the pipe work designated as P line.
304
4.3.a.3 Oil Pump: Operation
4.3.a.4 Tripping Of Oil Pump:
The pump will trip automatically if any of the following conditions
persists:
1. The oil level in the OSU is very low (from a level switch)
2. The motor is continuously running for more than 90 seconds.
3. The oil temperature is high (i.e. greater than 60 C)
4.3.a.5 A pressure switch with 4 contacts is provided for the following
actions:
1. 90 bar Alarm Oil Pressure too low initiated at control desk.
2. 120 bar The oil pump gets switched ON.
3. 160 bar The oil pump gets switched OFF.
4. 170 bar Alarm Oil Pressure too High is initiated at control
desk.
4.3.a.6 Routine Check Up For Oil System:
o The oil level in HP bypass oil outlet is to be checked with the help
of dipstick. It should be above the MIN mark.
o All the ball valves in P line and T line at oil supply unit and at all
servo valves are to be checked for their OPEN condition.
o Any oil leak in the system is to be checked.
o If any choking of 3 micron filters occurs, the differential pressure
optical Micro switch (Red in color) would be in lifted up condition.
The internal element of the filter is to be changed if the pressure
switch could not be pressed back.
o Trip latch for oil supply units should be checked for their released
condition.
o Nitrogen pressure in the bladder of oil accumulator is to be
checked periodically.



305

o Entry of moisture into the oil due to gland steam leak of the valve
should be avoided as this leads to rusting and filter choking.
o The efficient operation of the valves is possible only when the
cleanliness of the oil is ensured.
4.3.a.7 Pressure And Temperature Control Of Hp Bypass
System:
The purpose of HP Bypass station is to allow the steam pressure at the
HP turbine inlet to be controlled by the BP Valves before and during turbine
start-up as well as during trip and shut down conditions. In addition, the
dumped steam is attemparated to the temperature in accordance with
the cold reheat line with the help of BPE Valves.
The console insert of HP Bypass system is shown in Fig. 59. The control
loops of HP Bypass system are shown in Fig. 4.12. These control loops are
namely.
a. Pressure master controller
b. Temperature controller
c. Spray water isolating valve (and)
d. Fast opening system.
The mosaic tile console insert for HP bypass system is shown in figure-9.
Normal operation is defined as 100% MCR Operation of the main
turbo alternator set during which all valves of the bypass station are tightly
closed with their controllers on Automatic mode and are ready to control
the steam to the preset pressure and temperature.
The three control loops are all to be left on auto continuously and
the only manipulation needed is at the desk mounted pressure set point
(02.08, 02.11 and 02.12) stations during start-up and shutdown. The pressure
controller also receives set point from throttle pressure (4-20 MA Signal from
customer) and the motorised memory card gives the set point according to
the throttle pressure if it is selected on auto.

306

4.3.a.8 Main Pressure Controller, BP Valves:
4.3.a.8.a Operating Mode: -
The HP Bypass receives set point either from throttle pressure with a
positive bias, when the motorised memory unit (02.08) is on auto or from
manual set point when 02.08 is selected for manual using the 3 PB module
02.12 and SIS (02.11).
The motorised memory unit (02.08) tracks the output so that when the
throttle pr. Signal fails the output set point remains at the earlier value.
When the deviation between the measured pressure signal and the set-
point value is more than preset value, alarms will be given. The deviation
will be comprehended as a positive as well as a negative difference.
If the deviation raises too much, an over ride is given to the fast
opening device to open the BP valves quickly. After synchronisation and
taking over of the steam by turbine, the bypass station only serves for
keeping the live steam pressure of the system. Therefore the pressure set
point should be adjusted approximately 5.8 Ata, higher than the
desired operating pressure value. This acting mode prevents slight and fast
movements of the bypass valve actuators caused by small pressure
variations.
4.3.a.8.b Loop Description:
A PI Action controller drives the hydraulic actuators to move the BP
Valves in order to maintain the live-steam pressure at the pre-selected
value. The loop is supplied via circuit breaker module.
The pressure signal is compared at the input of the controller RPV 10
(02 02) with the 0-10V set value signal coming from the motorised memory
unit RNM (02.08). The throttle pr. Signal after the bias and the set point at
the output of motorised memory RNM (02.08) are indicated by a double
indicator (02.13). The resultant control deviation is shown on the desk
indicator (02.05).
307
This deviation, following P & I modification via integrator RIV 10 (02.04)
produces a valve position demand signal, 0-10V, indicated by the desk
indicator (02.05) which drives the summing amplifiers RVE 10 (01.05) in both
positioning loops, until they are balanced by the BP Valve position
feedback signals coming from the SG 10 position transmitters (01.03) fitted
on the actuators (01.02).
The RVE 10 Outputs are fed to the analogue power amplifiers RKL 10
(01.07) which drive the actuator servo valves (0..100%) and the deviations
of the positioning loops are shown on the desk indicators (01.10).
Auto Manual selection is done on the desk by the push button
unit (01.09) and relay memories SIS 10 (01.08). The 24 V.D.C. desk lamps are
switched on by relay SA of the SIS (01.08) and SSS 10 modules.
The actual pressure is measured in the two transmitters 02.23/M and
02.23/R. The output signals (420mA) of both transmitters are monitored for
deviation, by the 1 out of 2 selector MAM 20 (02.25). In the case of a fault, it
is necessary to switch off the defective transmitter (via. Selector M/R on the
supplies to all signal receiver.
Normally the pressure signal from the transmitter 02.23/R is taken for
the controller.
4.3.a.8.c Over Rides and Interlocks:-
The PI output and the BP valve position signals are also fed to the
monitors RUM 20.02.06 and 01.11 respectively, which initiate the following
important functions.
4.3.a.8.c.i BP Closing over Ride
As soon as the BP valve position is less than 2% open, the monitor
(01.11) will give a signal. This has the effect of closing the BP Valve fully, if it
is on Manual control and below 2% open, via SIS 10 (FC). This over Ride is
to prevent the BP Valve from drifting open.



308
4.3.a.8.c.ii BD Closing Over Ride
When the BP Valves are closed (below 2%) and the PI output is less
than 2%, a closing signal to the BD Valve for tightly closing to prevent any
spray water entering the system is given.
4.3.a.8.c.iii BD Opening interlock
When the BP Valve opens more than 2% or the PI output is more than
2%, an opening command is given to BD Valve for full open in order to
ensure correct attemparation.
4.3.a.8.c.iv BPE Auto Interlock
When the BP Valve opens more than 2% or P1 output is more than 2%,
a command is given to the positioning loop of the BPE Valves (SIS 4.08) on
auto,
4.3.a.8.c.v Fast Opening
Besides the normally control channels additional elements are
mounted on the actuators of the BP valves for a quick opening.
When the channels are activated, the valves will open quickly. The
signals which activate the fast opening devices are the following.
Generator circuit breaker open
Turbine load shedding relay operated
Turbine trip
Other fast opening criteria (4 Creteria)
Pressure deviation too high (Monitor 02.16)
Fast opening p.b. (03.02)
The fast opening signals select the positioning loop of the BP Valves to
Auto and block the control signals from the RKL. Once the valve is fully
opened in about 3 secs., the fast opening signal will be cut off by the timer.
4.3.a.8.c.i Protection over Rides:-
Any one of the following protection signals will select the BP
positioning loops to Manual and close the BP Valves fully, SIS (FSH) and
RKL (Cp), whereby the Open push-button of the desk and the fast
opening signals are inoperative.
309
These signals are
Steam temperature downstream of BP too high (Monitor 04.16)
Condenser Vacuum low.
Other closing Criteria (4 Criteria)
4.3.a.9 SPRAY SYSTEM:
The spray system consists of two nos. spray water flow control valves
(temp. control) and one no spray water isolating valve.
By injecting water into the HP Valves, the HP Steam is cooled to the
temperature required at the reheater inlet.
The spray water system does the following major requirements.
a. The spray flow has to be correspond statically as well as
dynamically under all operating conditions to the Steam flow as closely as
possible.
b. An absolute stable flow has to be maintained even at very low
steam flow rates.
c. The anticipatory control must not lead in any way to a transient
over travel of the spray control. The anticipatory control action has to be
adopted to the actual operating conditions.
4.3.a.10 TEMPERATURE CONTROLLER, BPE VALVE:
4.3.a.10.a
The PI action controllers drive the hydro valve actuators to move
the valves to maintain the down Stream steam temperature of the BP Valve
at the preset value.
i) The loops are supplied via MCB modules and SSS 10.
ii) The temperature signals are compared at the input of the
controllers RPV 10 (04.11) WITH THE 0-10V desired value signal
coming from the motorised desired valve setter RMS 10 (05.02). This
setter is driven by Raise-lower push buttons (05.04) on the desk and
the set value is shown on the desk by indicator (05.03). The
resultant control deviations are shown on the desk indicator
(04.10).
310
iii) The controlled process shows considerable time lag originating
from the temperature measurement, particularly because of the
reduced steam velocity at low flow rates. To compensate this
delay, a PD action controller is provided at the output signal from
temp. Transmitter.
iv) The control deviation, following P&I modifications, via integrator
RIV 10 (04.12) produces the valve position demand signals 0-10V,
which drive the summing amplifier RVE 10 (04.05) of the positioning
loops, until they are balanced by the BPE Valve position feed back
signals coming from the position transmitter SG 10 fitted on the
actuators.
v) A variable gain controller is provided at the output of the PI
controller to regulate the spray water flow according to the steam
flow through the bypass valves. This is achieved by adopting the
amplification of the PI controller by means of multiplying the
controller output signal with the steam flow signal. This signal has
the simultaneous effect of generating an anticipatory positioning
signal for the spray valve. The gain between steam flow rate and
position of the spray valve (controller output signal) is
automatically adjusted to the actual operating conditions.
vi) The steam flow signal is the product of steam pressure multiplied
boy the actual bypass valve area whereby the valve area is
represented by a non-linear function of the valve stroke.
vii) The valve positions are shown 0-100% on the desk indicators
(04-10). Auto, manual selection and open/close movement are
done from the desk through three push button unit (04.09) and
relay memories SIS 10 (04.08).
The actual temperature is measured by the thermocouples
04.18. The transmitter output signals (4-20mA) are monitored by
the 1 of 2 selector MAM. In case of one transmitter faulty, it is
necessary to switch off the defective transmitter (via selector M/R
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on the front of the MAM module) so that the healthy one supplies
to all signal receiver. The process values are indicated in the
console insert.
Normally temperature signal from the transmitters 04.19/R is
taken for the controller.
4.3.a.10.b OVER RIDES AND INTERLOCKS :
i) As described under BP control loop, 2 signals are given to the BPE
control.
ii) Auto interlock
As the BP Valves open more than 2% or PI demand is more than
2% an auto command is given to BPE control to change it to auto.
iii) Opening signal
As the BP Valve opens more than 2%, the BPE Valves opens to a
minimum value as set by MIN set to ensure that certain amount
of water is immediately injected into the steam flowing through BP
Valves. This is to give an advance opening of spray valve, before
a meaningful signal reaches from the temperature measuring
systems.
iv) Closing interlock
1) When the HP Bypass temp. raises above a preset limit, an
alarm will be given.
2) If the temperature rises still above the temperature of very
high set value, a closing signal will be given to bypass valve
followed by an alarm.
v) SPRAY WATER ISOLATION VALVE
The spray water line ahead of BPE is provided with an electro
hydraulically operated isolation valve.
a) Interlocks and Over Rides
i) When any one of the Bypass valve opens more than 2% or
the position demand is more than 2%, an opening signal is
given to the isolation valve for full open.
312
ii) When both HP Bypass valves close less than 2%, position
demand is less than 2 %, a closing signal is given to the
isolation valve to close it fully.
vi) REHEATER PROTECTION LOGIC
Boiler will trip after 10 seconds time delay when any one or more of
the following conditions occur.

1. a) Turbine tripped or Generator CB opened.
b) HP Bypass or LP bypass valve is in less than 2% position.
(and)
c) HP Bypass and LP bypass valves do not start opening within
5 seconds.
2. a) Turbine is working
b) Load Shedding relay acted-memory got stored for 11
seconds.
c) HP Bypass or LP Bypass valve closed less than 2%
3. a) Boiler is working
b) Turbine is not working
(and)
c) HP Bypass or LP Bypass Valve closed less than 2%
The above third condition is to trip the boiler during starting and when
the HPBP or LPBP closes due to safety interlocks in HP/LP bypass system such
as down stream temp. very high, Vacuum low etc.




313

HP B/P 'B' < 2% OPENED
NO FIRE IN BOILER EXISTING

o t
TURBINE NO TRIP
FUEL FLOW < 60 %
o t
5 Sec.
o t
45 sec.
KEY SWITCH IN BYPASS POSITION
HP B/P 'A' > 2% OPENED
HP B/P 'B' > 2% OPENED
HP B/P 'A'< 2% OPENED
CRH TEMP. 'A' < 370 C
30 Sec HP B/P 'B' < 2% OPENED
o t
CRH TEMP. 'B' < 370 C
o t
5 Sec
SH + RH CONDITIONS EXISTING
>
>
&
FUNCTION DIAGRAM OF SH & RH CONDITIONS (EXISTING LOGIC)
>
&
>
&
HP B/P 'A' < 2% OPENED
&
>
>
&
&
>
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315































316































318































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4.3.a.11 LIST OF ALARMS IN UCB FOR HP BYPASS SYSTEM
Sl. No.
Module
Alarm No.
Description Set value
1. AL.10.0 HP B/P Temp. High 350
0
C
2. AL.11.0 HP B/P Temp. very High 370
0
C
3.
AL.03.1 &
03.2
HP B/P Main supply failure
4.
HP B/P System process
trouble *
Group Alarm
5.
AL.08.1 &
08.2
HP B/P Valves trip/close
6. AL.17,18 HP B/P malfunctioning
7. AL.13.1, 13.2 HP B/P valves open >2%
8. HP B/P controls trouble ** Group Alarm

4.3.a.12 HP B/P SYSTEM PROCESS TROUBLE Group Alarms List
1. AL.04 HP B/P pressure transmitter failure
2. AL.05.1 Temp. down stream BP-1 transmitter failure
3. AL.05.2 Temp. down stream BP-2 transmitter failure
4. AL.09.1 DP-1 Fast opening system activated
5. AL.09.2 DP-2 Fast opening system activated
6. AL.12.1 Bypass valve closed (DP-1<2%)
7. AL.12.2 Bypass valve closed (DP-2<2%)
8. AL.14 BD Valve closed
9. AL.15 BD Valve opened
10. DL.1 Pressure Valve exceeded
11. DL.10 HP B/P Control on Auto
12. DL.11 BPE-1 Control on Auto
13. DL.12 BPE-1 Control on Auto

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4.3.a.13 HP B/P CONTROLLER TROUBLE Group Alarm List
1. AL.01 Controller failure
2. AL.02 Oil pressure too low
3. AL.03.2 Fan supply failure
4. AL.07 Pressure deviation exceeded
5. AL.17 BP-1 Valve malfunctioning
6. AL.18 BP-2 Valve malfunctioning
7. AL.19 Loss of turbine throttle pressure set point




321

4.3.b. LP B/P SYSTEM:
4.3.b.1 General:
LP Bypass Stop and Control valves are combined in a common body.
This valve combination dumps the steam not accepted by the turbine to
the condenser. Each unit is supplied with 2 nos of LP Bypass Stop and
Control valves. The valves are controlled by the LP Bypass controller and the
LP Bypass limit controller. The condenser protection device continues to be
operative via the hydraulic LP Bypass governor.
4.3.b.2 Function:
The turbine is equipped with an electro hydraulic LP Bypass system.
The function of the LP Bypass control system is to monitor the pressure in the
reheat system and to control it under certain operating conditions. During
start up and shut down, and at operation below minimum boiler load, the
volume of steam not utilized by the IP and LP cylinders of the turbine must
be passed to the condenser via the LP Bypass valves. This requires the
bypass control system to maintain the pressure in the reheater constant in
accordance with the pre set value. In the event of disturbances, e.g. load
shedding or trip out, the amount of excess reheat steam passed to the
condenser depends on the capacity of the condenser.
4.3.b.3 Mode Of Operation:
In the electro hydraulic LP Bypass control system, the electric
controller governs a number of hydraulic actuators. The link between the
electric controller and the hydraulic part of the control system is provided
by the electro hydraulic converter in the form of a jet pipe amplifier
controlled by a plunger coil.
In order to monitor the flow dependent reheat pressure, irrespective
of whether fixed or variable pressure operation is used, the pressure before
the HP drum blading which is also flow dependent, is used as the reference
input for the electric controller. The variable reference value is replaced by
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a fixed reference value for certain operating sequences, such as start up
and shutdown; the controlled variable is the reheat pressure after the boiler
outlet.
If the reheat pressure exceeds the reference value, the electric
controller will initiate LP Bypass operation. The LP Bypass control system
operates the combined LP Bypass emergency Stop and Control valves. This
double shut off arrangements separates the condenser from the reheater
both during normal operation and when it cannot accept any more bypass
steam.
The hydraulic part of the control system includes the necessary
protective and safety devices for the condenser as well as interlocks for the
water side.
Electro hydraulic LP Bypass control uses the reheat pressure and the
pressure upstream of the HP blading for control purposes.
4.3.b.4 Set Point Formation:
Two set points, the fixed set point and the reference variable, are
formed for the LP Bypass controller, the effective set point under any set of
operating conditions being the greater of the two, as selected by the
auctioneer.
The fixed set point can be set in the control room to any point
between 0 and approximately 120 % of the maximum LP Bypass pressure
with the aid of a motorized set point adjuster. It is normally used to set the
lower limit for the pressure set point.
The pressure upstream of the HP Blading, required for reference
variable formation, is measured by the pressure transducer and transmitted
to a matching amplifier, which sets the characteristic for the reference
variable as a function of the pressure upstream of the HP Blading. This way
the reference variable is formed.
When both set points, fixed and reference variable, have been
applied, they are compared in the auctioneer, the greater of the two being
selected and taking effect in the controller.
323
4.3.b.5 Manual and Auto mode of the LP Bypass controller:
The LP Bypass controller can be changed over to the manual from
the automatic control mode using the controller ON /OFF push button. It is
thus possible to actuate the valves directly using the Open and Close push
buttons at the manual controller. This may be necessary in the event of
defects in parts of the automatic system and is essential for testing valve
actuator travel.
In order to facilitate switching on and off of the automatic controller
during operation of the control variable not taking effect in the controller is
made to continuously follow up that effective in the controller. This function
is performed by the tracking controller.
When the automatic controller is effective, the manual controller is
automatically made to follow up the automatic controller output voltage,
the manual controller itself being inoperative. This permits the automatic
controller to be switched off and manual controller to take operation at
any time.
When on the other hand, the system is under the manual control, the
output voltage of the inoperative automatic controller is made to
automatically follow up the manual control voltage.
4.3.b.6 Monitoring:
The electrical section of the electro hydraulic LP Bypass control is
monitored for the following faults, which are annunciated at the control
desk by means of the group alarms Fault in controller, Fault in automatic
interface, Fault in reheat safety valve actuation circuit and Fault in
condenser temperature protection system.
I) Fault in controller:
1. Fault in power supply to controller
2. Insertion fault
3. Fault in power supply to pressure transducer for measuring pressure
upstream of HP Blading.
324
4. Fault in power supply to pressure transducer for measuring reheat
pressure.
5. Fault in power supply to Collins transmitters.
6. Fault in power supply to binary signal conditioning section for
solenoid valve for 2
nd
spray water stage.
II) Fault in automatic interface
1. Fault in power supply to automatic interface.
2. Insertion fault.
III) Fault in condenser temperature protection system 1
1. Module fault
4.3.b.7 Automatic Change Over From Automatic To Manual
Mode Of Operation
To increase operating reliability, automatic change over to manual
operation is performed in the event of any of the faults listed under the
group alarm Fault in controller.
This automatic change over to manual operation ensures, thanks to
the tracking feature, that the valve position at the moment at which the
above faults occur is retained, this prevents spurious automatic control
actions and provides the operating personnel with sufficient time to
intervene manually to avert operating disturbances.
4.3.b.8 Automatic Control Interface
The electro hydraulic LP bypass controller incorporated an automatic
interface feature. This allows the power plant automatic control system to
switch the controller on and off, to adjust the set point and to switch the
automatic start up unit on and off.
At the beginning of start up the fixed set point of the LP B/P controller
is matched to the actual value by means of the signal IGNITION IS ON.
When the reheat pressure exceeds the fixed set point the bypass control
valves open. As a result of the positive control deviation the control valves
rapidly reach a minimum opening of approx. 25% which is required to
provide adequate cooling of the reheater. The valves are held in this
325
position as a result of limiting the controller output in order to permit rapid
pressure built up. Simultaneously during holding the fixed set point is
matched to the actual value. When the reheat pressure reaches to the
value for turbine start up (approx 12 bar) holding is relinquished, the fixed ser
point is no longer influenced and reheater pressure (sliding, set point) soon
supersedes the fixed set point via, the auctioneering circuit. As soon as the
by pass valve position 50% is reached the automatic control interface is
automatically switched off.
4.3.b.9 LP Bypass Limiting Regulator:
LP Bypass limiting regulator has priority over converter. As soon as
injection water is available at the required pressure and there is also a
sufficiently high condenser vacuum in condenser, the jet pipe is swung to
the right and piston KA 07 of the actuator of the bypass limiting regulator
moves into its upper end position. This increases the pressure in follow up
piston KA 02 so that LP Bypass valves are released for opening.
If the condenser vacuum in condenser drops or the pressure
downstream of the LP Bypass valves rises above the permissible value, or
the pressure of the injection water is too low, the jet pipe of LP Bypass
limiting regulator is moved to the left and piston KA 07 of the actuator of the
bypass limiting regulator moves down wards, when piston KA 07 is in its lower
position, the spring in follow piston KA 02 is de tensioned to such an extent
that the LP Bypass valves are unable to open.
4.3.b.10 LP Bypass Valves Operation:
At the beginning of the control operation, the rising pressure in follow
up piston KA 03, acting by way of slide valve and water injection valve
actuators KA01 causes water injection valves to open. The injection water
reaches the expansion orifice and is available for cooling down the bypass
steam flowing into the condenser.
Electro hydraulic LP Bypass governor actuates the moving coil
arranged on the left hand side of the converter. When the signal voltage
increases, jet pipe KA 01 swings to the right and differential pressure
326
amplifier piston KA 08 of converter moves downwards. Because of the
proportional feedback, this piston assumes a position proportional to the
voltage change. Sleeves KA 04 of follow up pistons KA 02 and KA 03, being
connected to the piston, are moved downwards and the oil pressure in the
follow up piston rises.
With a slight delay compared to the water injection valves, LP Bypass
Stop valves are fully opened as the oil pressure in follow up piston KA 02 rises
and then LP Bypass Control valves are opened via hydraulic feedback
between actuator pistons and pilot valves until they are in a defined
position corresponding to the instantaneous oil pressure.
4.3.b.11 Protection For The Condenser During Bypass
Operation.
During the LP Bypass operation, the three protective devices installed
in the signal oil line to LP B/P Stop and Control valves protect the
condenser.
4.3.b.12 Condenser Vacuum Protection:
A condenser safety device is installed in the signal line from follow up
piston KA 02 to pilot valves of the LP Bypass valves to provide back up
protection for the condenser during bypass operation. If the condenser
vacuum sinks below 265 mm of Hg, the valve of condenser safety device is
moved downwards from its upper end position by the force of the spring.
The valve thus blocks off the signal line and simultaneously opens the drain
so that signal oil in the lines between condenser safety device and pilot
valves is depressurized and LP Bypass valves close.
4.3.b.13 Injection Water Protection
A pressure switch is installed in the signal line from follow up piston KA
02 to pilot valves of the LP Bypass valves to protect the condenser in the
event of water injection failing. If the injection pressure drops below 8.3 ksc,
the valve of pressure switch is moved downwards from its upper end
position. The valve thus blocks off the signal line and simultaneously opens
327
the drain so that signal oil in the lines between pressure switch and pilot
valves is depressurized and LP Bypass valves close.
4.3.b.14 Temperature Protection:
Thermocouples that transmit a switching pulse to associated solenoid
valves when a specified temperature (greater then 90C) is exceeded are
installed in the steam dome opposite the LP Bypass steam inlet to protect
condenser.
If the temperature measured by the thermocouple exceeds 90C, a
memory is latched and the solenoid valve blocks off the signal line and
simultaneously opens the drain so that signal oil in the lines between
pressure switch and pilot valves is depressurized and LP Bypass valves close.
The solenoid valve can be brought to the open position from the
control room only when the temperature is less than 90C.
4.3.b.15 Two Stage Water Injection:
When the pressure sensed by the pressure switch MAN 01 CP 001
installed in the downstream of LP Bypass valves is > 5.8 ksc, a second set of
injection valves are opened via the solenoid valve and pilot valve.
By this arrangement the CEPs do not have to supply the injection
water flow required for the full boiler capacity and to prevent the amount
of excess water flow becoming too high, under normal start up and
shutdown conditions.










328
4.4 TURBINE LOGICS AND PROTECTIONS.
a) Turbine Protections [Electrical]:







Condenser press > 0.8 ksc-MAG 10 CP 013-XG01
Condenser press > 0.3 ksc-MAG 10 CP 012-XG01 To trip the turbine
Emergency Trip From Control Room To trip the turbine
MVA 01 EZ 001
FIRE PROTECTION - I Ch:1 (Desk) MAY 00 EY 010-XG 01
FIRE PROTECTION - I Ch:1 (MBLD) MAY 00 EY 011-XG01
FIRE PROTECTION - I Ch:1 (MBLD) MAY 00 EY 012-XG 01
FIRE PROTECTION - II Ch:1 (Desk) MAY 00 EY 020-XG 01
FIRE PROTECTION - II Ch:1 (MBLD) MAY 00 EY 021-XG 01 To trip the turbine
FIRE PROTECTION - II Ch:1 (MBLD) MAY 00 EY 022-XG 01
OIL TANK LEVEL > 900 mm MAV 10 CL 006 XG 52
OIL TANK LEVEL > 900 mm MAV 10 CL 007 XG 52 2 Sec
OIL TANK LEVEL > 900 mm MAV 10 CL 008 XG 52
OIL TANK LEVEL > 850 mm MAV 10 CL 001 XG 02
To trip the turbine
BOILER FIRE-OFF
To trip the turbine
DRUM LEVEL VERY HIGH - BAC 01 CL 001 XG 01
To trip the turbine
GENERATOR CKT. BREAKER OFF
SGC TURBINE / STEP : 53
100 Sec
MAIN STEAM BEF ESV > 520 Deg C LBA 10 CT 001 B
MAIN STEAM BEF ESV > 520 Deg C LBA 20 CT 001 B
TRIP OIL PRESS < 5 KSC MAX 51 CP 013 To trip the turbine

MAIN STEAM BEF ESV < 480 Deg C LBA 10 CT 001 B
MAIN STEAM BEF ESV < 480 Deg C LBA 20 CT 001 B
LUB OIL PRESSURE < 1.2 KSC MAV 43 CP 016 XG 51 To trip the turbine
LUB OIL PRESSURE < 1.2 KSC MAV 43 CP 017 XG 51
LUB OIL PRESSURE < 1.2 KSC MAV 43 CP 018 XG 51
2
/
3 &

1

1
1
S
R
&
2/3
OR
& &
329



b) Turbine Protections: [Hydraulic]

1. Over Speed Trip - 1 MAY 10 CG 001C > 3300 RPM
2. Over Speed Trip - 2 MAY 10 CG 002C > 3300 RPM
3. Thrust Wear Excess Trip MAY 10 CG 011C + 0.5 MM
4. Low Vacuum Trip (Mech) MAG 01 CG 011 < 518 mm Of Hg
5. Hand Lever (1) [Main Trip Valve] MAX 51 CG 005
6. Hand Lever (2) [Main Trip Valve] MAX 51 CG 006
GENERATOR CLASS-B PROTECTIONS
LOSS OF EXCITATION 40 G
STATOR WATER FLOW VERY LOW CV2-1
STATOR WATER CONDUCTIVITY VERY HIGH CV2-1
GT WINDING (WT-2)/OIL (OT-2) TEMP HIGH CV2-5 To trip the turbine
UAT A/B WINDING TEMP HIGH CV2-3
UAT A/B OIL TEMP HIGH CV2-4
SES REGULATION SUPPLY FAIL CV2-2
SES EXCITATION TR. TEMP VERY HIGH CV2-2
SES MANUAL CHANNEL SUPPLY CV2-2
3 SEC
CHANGE OVER VALVE IN TEST POSITION TO TRIP CHANNEL :1
WAITING TIME / MAY 01 EC 101.1 L.2.1
TRIP FLUID PRESS > 5 KSC To trip the turbine
AUX. START UP OIL PRESS > 2 KSC
STEP 5 CHANGE OVER VALVE TEST To trip the turbine
REMOTE TRIP DEVICE 1 - ON
REMOTE TRIP DEVICE 2 - ON TO TRIP CHANNEL :2
REMOTE TRIP DEVICE 1 - ON
REMOTE TRIP DEVICE 2 - ON
GENERATOR CLASS-A PROTECTIONS
MAX 51 AA 001 (MAY D1 EX 110/A2
MAX 51 AA 002 (MAY D1 EX 210/A2
STEP 51 SHUT DOWN RESETTING ATT
To trip the turbine
TURBINE SOLENOID VALVE TRIPPED
TRIP OIL PRESS < 2 KSC (MAX 51 CP 011-XG 52)
TRIP OIL PRESS < 2 KSC (MAX 51 CP 012-XG 52)
POSITION OF ESV-1 (LEFT) (MAA 10 CG 001E-XG 02)
POSITION OF ESV-2 (RIGHT) (MAA 20 CG 001E-XG 02)
1
&
&
1
1
&
&
&
330

When the following conditions occur, the Turbine has to be tripped manually
by the Board Engineer as NO DIRECT TURBINE TRIP has been incorporated.
S.No. Conditions Values

1. Speed:
a) Maximum speed for continuous operation. :51.5Hz
b) Minimum speed for continuous operation : 47.5 Hz
2. STEAM TEMPERATURE:
(Main Steam and HRH Steam at Turbine Inlet)
a) Normal operating value (Annual Mean Value) : 535 C
b) Operating Value limited to 400Hours per Annum : 549 C
c) Maximum operating value limited to 80 Hrs per Annum
and 15 Min in individual cases. : 563 C
d) The Turbine should be Tripped immediately at
Temperatures exceeding. : 563C
3. Permissible Differential Temperature Between Parallel
Steam supply Lines (Main Steam and HRH Steam).
a) Maximum permissible for continuous operation : 17 C
b) Maximum permissible for short time period (15 Min) : 28 C
4. Casing Temperature: Alarm Value "Trip Value"
a) HP Turbine casing Exhaust 480C 500C
b) LP Turbine Outer Casing 90C 110 C
5. Casing Temperature Differences: Alarm Value "Trip Value"
a) HP Turbine outer casing Middle
top & bottom temperature difference
(Points 3 & 4 in TR 2401) 30C 45C
b) IP Turbine outer Front
top & bottom temperature difference
(Points 1 & 2 in TR 2402) 30C 45C

331
c) IP Turbine outer Rear
top & bottom temperature difference
(Points 3 & 4 in TR 2402) 30C 45C
6. Turbo Generator Bearing Metal Temperature:
Alarm Value Trip Value
a) Bearing Number 1 HPT Front 90C 100C
b) Bearing Number 2 HPT Rear 90C 100C
c) Thrust Bearings 90C 100C
d) Bearing Number 3 IPT Rear 100C 110C
e) Bearing Number 4 LPT Rear 100C 110C
f) Bearing Number 5 Generator Front 100C 110C
g) Bearing Number 6 Generator Rear 80C 90C

IMPORTANT: Watch the response of Lub oil temperature control
valve on Auto especially during ROLLING as there is no protection Trip of
Turbine on Bearing metal temperature as in stage I Units.

7. Turbine Bearing Vibrations: Alarm Value "Trip Value"
a) Absolute Brg Vibration in (0 Peak) 35 45
b) Absolute Shaft Vibration in (0 Peak) 120 200
8. Differential Expansion: Upper Limit Lower Limit
a) HP Differential Expansion. + 5 - 3.5
b) IP Differential Expansion. + 6.5 - 2.0
c) LP Differential Expansion. + 30 - 9
9. STEAM PRESSURE:
a) Main Steam Pressure:
Rated Main Steam Pressure before ESV Inlet 149.0 KSC
1. Maximum Main Steam Pressure before ESV Inlet # 178.0 KSC
# Permissible momentarily. The aggregate duration
of such swings must not exceed 12 Hours in anyone year.

332
b) HP Blading Pressure:
Rated Steam Pressure before HP Blading 134.0KSC
1. Maximum Permissible for long time operation 139.5 KSC
2. Maximum Permissible for short time operation ## 147.6 KSC
## Permissible momentarily. The aggregate duration
of such swings must not exceed 12 Hours in anyone year.
c) HRH Pressure:
Rated HRH Pressure Before IPSV 33.7 KSC
4.4 Maximum HRH pressure allowed for long time operation 39.3
KSC
4.5 Maximum permissible allowed for short time operation
40.7 KSC*
* Permissible momentarily. The aggregate duration
of such swings must not exceed 12 Hours in anyone year.
10. Steam Extractions:
Rated Long time 80hrs/year in special case
Value operation max 15min at No load in
Individual case
a) HP Cylinder exhaust 343 359 425 500 #
b) Extraction 6 343 359 425 500 #
c) Extraction 5 433 433 473 -
d) Extraction 4 316 326 366 -
e) Extraction 3 200 211 255 -
f) Extraction 2 107 127 167 -
g) Extraction 1 62 82 127 -
h) LP Cylinder exhaust 49 70 70 100 #

# Only valid for the no-load period with high reheat pressure after
trip out from full load operation. For the individual case approx. 15 min. the
turbine is immediately re-loaded, or the boiler load is reduced to minimum, if
no load operation is maintained.
333
4.5.0 TURBINE GOVERNING SYSTEM OPERATION MHG, EHG,
FREE GOVERNING
4.5.1 MHG:
1. Ensure EHC is isolated in the governing rack.
2. Bring Starting Device to minimum to reset the turbine.
3. Ensure Speeder Gear is at 0%.
4. Raise Starting Device and open the stop valves.
5. Switch OFF Tracking Device.
6. Ensure no fault on EHC & TSE.
7. Raise the speed to 600 rpm by ensuring the margin using SD.
8. Raise the speed further to 3000 rpm with Starting Device up to
around 2100 rpm.
9. Further speed raise up to 3000 rpm thro Speeder Gear and
withdraw. Starting Device to 100%.
10. Upon synchronization raise the Speeder Gear to take block load.
11. Take the machine control to Starting Device and withdraw Speeder
Gear to 100%.
12. Ensure that Gen Class C protection is clubbed to Gen Class A
protection for keeping the unit in mechanical governing mode for
longer duration.
4.5.2 EHC:
1. Ensure EHC is not isolated in the governing rack.
2. Raise Starting Device and open the stop valves.
3. Switch on Tracking Device by ensuring no fault on EHC & TSE.
4. Raise the speed set point to 600 rpm by ensuring the margin.
5. Ensure Speeder Gear is at 100%.
6. Adjust the machine speed to approx 15 rpm more than the grid speed
and switch on load controller and keep load set point at 35 MW.
7. Switch on auto synchronizer and check the actual speed adjusted to
match the grid speed.
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8. Check the synchronizing (if not manually)
9. Ensure speed set point is raising by 10 to 20 rpm in speed indicator on
desk when the Generator breaker just closes.
10. Ensure load ser point PR is raised to 35MW. Machine control changes
to load control.
11. Raise the load of the machine by load control ensuring TSE margin
and load limiter position.
12. Once load is > 125 MW stable, change over to IP mode when DP is
just zero. Raise the load set point around 10% more than actual load.
13. Ensure the load set point is always kept 10% more than the actual
load.
14. Ensure load set point is always kept 10% more than the actual during
IP operation.
15. Ensure load ser point is not more than 205MW in IP mode to avoid
over loading of the machine.
4.5.3 To transfer from one control to other control (pressure
load speed):
1. When AP is 0 change over to LP mode and match the load limiter to
actual load.
2. Match the load set point to actual load and control changes to load
control.
3. Switch off load control (on lamp will be steady off lamp blinks). Now
Speed control set point can be raised slowly (tracking set point + EHC
% 150 rpm) till load control off lamp is steady. Machine will change
over to speed control.
4. Ensure speed set point tracks grid speed by 15 rpm more than when
machine is either on load or on pressure control (when the grid speed is
between 48.5 to 50.5hz).
5. Whenever grid speed is greater than 51.0 Hz & the deviation
betweenset point and actual load is greater than 20 MW, machine will
change over to isolated grid operation on load control.
335
6. To reset isolated grid operation match actual load and load set point
by operating load limiter. Isolated grid operation can be reset. The time
delay will be around 6 seconds. Machine will change over to load
control active.
4.5.4 Free Governing In CMC Mode:
In CMC mode, frequency correction signal with 10% droop and a
load limitation of +/- 20 MW is incorporated in the load set point for Boiler
Master Control. The facility to switch on/off the CMC frequency influence is
available in the CMC desk. In CMC mode, CMC frequency influence
correction module receives the input from EHC frequency influence
correction module. EHC frequency influence correction signal is available
only when it is in ON condition. Hence prior to switch on the CMC
frequency influence, EHC frequency influence must have been switched
on.
To avoid the double effect of load variation (i.e., frequency
influence in both CMC and EHC), the effect of EHC frequency influence
correction signal is nullified by providing an equal and opposite effect of
freq. influence in CMC Load signal flow to EHC.
In CMC mode, when CMC frequency influence is switched on,
frequency corrected signal immediately goes to Boiler Master Control
whereas it goes to EHC cabinet after a time delay to cope up with the
process delay of the Boiler Master.
4.5.4.1 Example:
- Unit Load 200 MW in CMC mode with CMC frequency influence
ON
- Unit Master set point : 200 MW.
- CMC set point to EHC (PCMC) : 200 MW.
- Boiler Load set point : 200 MW.
- Frequency : 50 Hz.
When frequency rises to 50.1 Hz,
1. Boiler Load set point changes by 5 MW (at SJ1, i.e. 195 MW)
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2. PCMC changes by +5 MW (at SJ2, i.e. 205 MW)
3. EHC Frequency corrected Load set point changes by 5 MW (at
SJ3, i.e., 200 MW)
PCMC changes immediately due to f signal at SJ2 at the rate of +/- 5
MW for the frequency variation of +/- 0.1 Hz. EHC Frequency corrected
Load set point changes due to Pr f signal at SJ3 at the rate of -/+ 5 MW,
effecting no change in the existing Load of 200 MW. As the load signal for
SJ2 passes through a delay circuit, Pcmc gradually changes to the Unit
Master set point of 200 MW. As a result, EHC Frequency Corrected Load set
point changes gradually to 195 MW effecting a change in Actual Load by 5
MW.
4.5.4.2 Guidelines to switch-off Frequency influence in CMC
mode:
1. Boiler Master to be taken to Manual mode.
2. CMC Frequency influence to be switched off.
3. EHC Frequency influence should not be switched off.
4.5.4.3 Guidelines for change over to Turbine follow mode
from CMC:
1. Boiler Master to be taken to Manual mode.
2. CMC Frequency influence to be switched off.
3. Throttle pressure set point should be matched with the actual
pressure.
4. Turbine Follow Mode to be selected.
5. EHC Frequency influence should be switched off.





337
4.5.4.4 Guidelines to select CMC mode from Turbine follow
mode:
In EHC, absolute load limiter Pr MAX is to be matched with the actual
Load.
a) Condition-I (Grid Frequency = 50 Hz)
1. EHC Frequency influence should be switched ON.
2. CMC mode should be selected.
3. CMC Frequency influence can be switched ON.
4. EHC Absolute load limiter should be set higher than the Boiler
Max load limit set point.
5. Boiler Max load limit set point should be matched with the
declared load
b) Condition-II: (Grid Frequency < 50 Hz)
1. EHC Frequency influence should be switched ON.
2. CMC mode should be selected.
3. CMC Frequency influence can be switched ON.
4. EHC Absolute load limiter should be set higher than the Boiler
Max load limit set point.
5. Boiler Max load limit set point should be matched with the
declared load.
c) Condition-III: (Grid Frequency > 50 Hz)
1. Raise Load Reference Setter (Pr)
a. by 5 MW, if freq is 50.1 Hz.
b. by 10 MW, if freq is 50.2 Hz.
c. by 15 MW, if freq is 50.3 Hz.
d. by 20 MW, if freq is 50.4 Hz.
2. After confirming the matching of Pr and Pr lim,
EHC Frequency influence should be switched on.
3. CMC mode should be selected.
4. CMC Frequency influence can be switched ON.
338
5. EHC Absolute load limiter should be set higher than the Boiler
Max load limit set point.
6. Boiler Max load limit set point should be matched with the
declared load.


CMC freq.
correction
AF(LOAD)
Unit Master
Load set pt on/off
SJ1
AF
CCS /CMC
To Boiler SJ2
Master
PCMC o f
PR on/off

Prlim PRAF desk
indicator
SJ3
PR MAX
E PR
Boiler Load set pt
Max Load Limit set pt.
+ +
+ -
Delay circuit
LRS
LRL
+ +
Abs.Load
Limiter
MIN
LC
MIN


CIRCUIT
DIAGRAM
339
4.5.5 GOVERNING SYSTEM:
4.5.5.1 Governing system:
The turbine has a hydraulic speed governor and an electro hydraulic
turbine controller. The hydraulic speed governor adjusts main control valves
by way of hydraulic converter whilst electro hydraulic turbine controller
adjusts these control valves by way of electro hydraulic converter.
The electro hydraulic converter is the connecting element between
the electrical and hydraulic parts of the turbine control system. It converts
the signals from the EHC into hydraulic signals and amplifies them before
transmitting them to the actuating devices.
Hydraulic converter and electro hydraulic converter are switched in
parallel to form a minimum value gate. The system not exercising control at
any given time is at its maximum position.
The turbine is started and brought up to speed with the help of main
control valves and reheat control valves. Speeder gear is set to minimum
speed at this point if the hydraulic governor is to be used. In this case, the
speed reference of the electro hydraulic controller is set to maximum. The
stop and control valves are in the closed position as the trip oil circuit is not
yet pressurized. By turning the hand wheel or by operating the motor of the
Starting Device in the close direction, spring in auxiliary follow up piston is
relieved by the linkage action, thereby preventing a build up of auxiliary
secondary oil pressure. Hydraulic converter with follow pistons is now in the
control valves closed position. As a result, no pressure can build up in the
secondary oil circuit when main trip valves are latched in.
By further moving the hand wheel of the Starting Device control oil is
admitted first into the start up oil circuit and then into the auxiliary start up oil
circuit. The auxiliary start up oil resets the main trip valves, thrust wear excess
& over speed protection devices. The start up oil flows to the space above
the pistons of test valves forcing them down against the action of the return
springs. The auxiliary start up oil raises the pistons of main trip valves, thereby
permitting trip oil to flow to test valves of the main and reheat stop valves.
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Trip oil now flows to the space above piston of main and reheat stop
valves and forces it down against piston discs. Operation of the Starting
Device is continued until piston discs reach their lower end position. Now
Speeder Gear and Starting Device are kept in minimum position. This causes
the bellows in the speeder Gear to be compressed thro the lever and pin
below the bellow until the Speeder Gear assumes the position control
valves closed.
When the hand wheel of the Starting Device is turned in the open
direction, the control oil is allowed to drain first from the auxiliary start up oil
circuit and then from the start up oil circuit. The pistons of test valves are
forced upwards by restoring springs whereby the trip oil flows to the space
below piston disc and slowly drains from the space above piston. The
pressure difference thus occurring lifts both pistons together into their upper
end positions, thus causing main and reheat stop valves to open. Main trip
valves are now held in their upper position by the oil pressure of the trip oil
under their stepped differential pistons.
After the stop valves have opened, further turning the hand wheel or
operation of motor of the Starting Device in the open direction will after
passing through a certain dead range, cause increase in secondary oil
pressure above the hydraulic converter with follow up pistons and will
gradually open control valves. This will run the turbine up to approximately
85 to 90 % of rated speed. Starting Device is then set at the maximum
position.
Hydraulic speed converter is mounted on Main oil pump shaft and
runs at the same speed of turbine generator. It converts the speed signal to
hydraulic signal, namely primary oil pressure. This oil pressure can also be
read directly form the speed indicator pressure gauge.
This primary oil pressure acts on the diaphragm of Hydraulic speed
governor against the force of the speed setting spring, which is tensioned
by the Speeder Gear. The travel of diaphragm, which can be limited by
Starting Device, is transmitted by linkage to sleeves of auxiliary follow up
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pistons. During running, if the turbine speed increases due to external
reasons, then the primary oil pressure increase will lift the bellow and drain
the auxiliary secondary oil and thus closing the control valves to a required
amount. If the speed drops the reverse phenomena occurs.
The Hydraulic amplifier amplifies the hydraulic pressure signal namely
the auxiliary secondary oil pressure from the Hydraulic Governor. The
increase in auxiliary secondary oil pressure will cause the pilot valve to
move down which cause the control oil admission on the top of the main
piston and as a result the piston moves down. This results in reduction in
secondary oil draining in the follow up pistons and hence the secondary oil
pressure builds up.
Further speed increase, synchronizing and loading of the turbine are
accomplished by adjusting Speeder Gear. Turning the hand wheel or
operating motor of Speeder Gear applies additional tension applied to
Speed setting spring, which results in an increase in speed. Since in
interconnected system operation, turbine speed is determined by the grid,
operation of the Speeder Gear amounts to a load change for the turbine.
4.5.5.2 : PROTECTIVE DEVICES:
A. General:
The turbine is equipped with the protective devices. During the
normal operation, the protective devices act via, main trip valves 1 & 2 on
the stop and control valves and extraction swing check valves. The remote
trip solenoids, over speed trips, low vacuum trip and thrust bearing trip
actuate the main trip valves and by opening the auxiliary trip oil circuit.
B. Turbine Trip Gear:
The trip oil is taken from the control oil circuit via turbine trip devices
and flows to both the secondary oil circuits and main stop valves and
reheat stop valves. The turbine trip devices serve to rapidly reduce the oil
pressure in the trip oil circuit. If the pressure below the differential piston of
turbine trip devices drops below a pre-set adjustable value, the piston in
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each device is forced downwards by the spring, opening the drain passage
for the trip oil and closing the control oil inlet.
If the pressure in the trip oil circuit drops below a pre-determined
value, spring loading separates the upper and lower pistons of main stop
valves and reheat stop valves and all the main and reheat stop valves
close very rapidly. At the same time, the control valves and the extraction
check valves also close as the secondary oil circuits are fed form the trip oil
circuit. Thus on trip initiation, all turbine stop and control valves close.
C. Manual Initiation:
Possibilities of initiating turbine trip operation of lever KA01 at local.
D. Over Speed Trip Initiation:
Two over speed trip devices are provided to shut down the turbine in
the event of over speed. Each trip device consists of an eccentric bolt
fitted in the turbine shaft with its centre of gravity displaced from the axis of
rotation and held in position against centrifugal force by a spring up to an
adjustable pre-set speed of 10 to 12% of the normal speed in the non-
operating position. If the speed exceeds the pre-set percentage,
centrifugal force overcomes the spring force and the eccentric bolt flies
outwards to the outer limit position. In doing so, it strikes the pawls of the
over speed releasing device which releases the spool valve of tripping
device. Through combined spring force and oil pressure, the spool valve
opens the auxiliary trip oil circuit to turbine trip device.
E. Thrust-Bearing Trip;
The lever and differential piston movement described above is also
initiated by thrust-bearing trip (tripping cams) on axial displacement of the
turbine shaft above the permissible value.
F. Trip oil Pressure Switch:
Installed in the trip oil circuit are two pressure switches, which bridge
the slow speed relay of the reverse power protection system in such a way
that the generator is shut down by response of the high speed relay as soon
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as it continues to run as a motor taking current. The annunciation Turbine
trip initiated is transmitted simultaneously to the control room.
G. Remote Solenoid Trip:
Remote solenoid trip is activated via two solenoid valves. The remote
solenoid trip may be operated manually from the control room by means of
contact transmitters, by the electrical low vacuum trip or other similar
devices.
H. Low Vacuum Trip For Turbine Protection:
In the event of pressure increase in the condenser, the spool valve of
low vacuum trip device is moved from the upper limit position in the
downward direction by the pre-loaded spring. The area below the right
hand spool valve is thus depressurized. The right hand spool valve is
brought in to the lower limit position by a spring and thus opens the auxiliary
trip oil circuit. As a result of opening the auxiliary trip oil circuit, the oil below
the differential pistons of trip devices is depressurized and the differential
pistons are activated by a spring. The trip oil circuit is opened, the trip oil
pressure drops and all main and reheat stop and control valves of the
turbine close.
Limit switch MAG01 CG011B signals to the control room that the low
vacuum trip is not operational. Limit switch MAG01 CG011C indicates in the
control room that turbine trip was initiated by the low vacuum trip.
The low vacuum trio is fitted with an additional piston arranged
above the adjustable spring and is supplied with primary oil pressure so that
with shut down turbine and lack of vacuum it is possible to latch the trip
devices and thus build up trio oil pressure for adjusting and testing the
control loop and similar purposes. When the turbine is shut down there is no
primary oil pressure, which causes the additional piston to unload the
adjustable spring, which is arranged above the diaphragm system. The
spool valve is raised so high by the spring installed below the diaphragm
system that the auxiliary trip oil circuit is closed and the trip devices may be
latched in.
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As soon as the turbine is started up and brought up to speed, primary
oil enters above the additional piston and forces it in to the lower limit
position even at a speed far below rated speed. Thus the normally set
response value of the low vacuum trip for initiation of the turbine trip is the
governing factor again the turbine has reached rated speed.
I. Solenoid Valves for Load Shedding Relay:
Two Solenoid valves are provided to prevent the turbine from
reaching trip out speed in the event of a sudden load rejection. These
valves are actuated by the load shedding relay if the rate of load drop
relative to time exceeds a pre-determined value. Solenoid valve MAX45
AA001 then directly opens the IP auxiliary secondary oil circuit. Solenoid
valve MAX46 AA011 opens the auxiliary secondary oil circuit. Pilot valve
KA07 of hydraulic converter moves upwards and allows the control oil to
flow to the area below piston KA08 of hydraulic amplifier. Piston KA08
moves to its upper limit position and all secondary oil circuits are
depressurized.
Since the IP secondary oil circuit opens directly, the reheat stop and
intercept valves (which control the major portion of the power output) close
without any appreciable delay.A slight delay is involved in closing all control
valves by op0ening the auxiliary secondary oil circuit before an increase in
speed causes the speed governor to respond. At the same time extraction
check valves LBQ50, LBS21, LBS31, LBS40 AA which are dependent on
secondary oil via auxiliary spool valve close. After an adjustable interval, the
solenoid valves are re-closed and the new secondary oil pressures
corresponding to the reduced load may build up.
J. Trimming Device:
When the turbine runs at low loads i.e., 20 % load and with higher CRH
pressure, the HP cylinder does not develop any power; instead it gives heat
to steam. It will heat the steam up to 600 C and more. Only the first 3 or 4
stages develop power under such conditions.
345
To avoid such conditions, the trimming device solenoid valve
deenergises and drains the control oil below the trimming device when the
load is less than 20 % and CRH pressure is greater than 32 bars. Draining the
control oil below the trimming devices of Hydraulic converter and electro
hydraulic governor to slacken the springs of follow up pistons and drain the
IP Secondary oil in such a way that the IPCVs are closed partly to enable HP
Turbine to share the load.Once the trimming device solenoid valve is
energized, the IPCVs will slowly open back due to damping device effect.
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4.5 OPERATION OF HIGH CAPACITY PUMPS:
4.6.1. BOILER FEED PUMP.
4.6.1.1 Operating Instructions:
The 50% boiler feed pump is an integral part of the boiler feed system
and hence the instructions are to be followed in conjunction with the
operation of the associated equipment of the system.
4.6.1.2 Preparation For Starting:
1. Check that the Deaerator is filled to normal working level
2. Check that instrument air and electrical supplies are available for the
instrumentation and valves
3. Check that the booster pump and feed pump drain valves are
closed.
4. Check that the recirculation valve and isolating valves near BFP and
at deaerator are open.
5. Check that all the instrument tapping points and isolating valves are
open and that all drain and equalizing valves are closed
6. Check that the pump discharge valve is closed.
7. Check open the suction valve, for charging the feed pump.
8. Open the strainer, air vent and booster pump air vent valves and
vent any trapped air. When water comes out freely, close the valves.
9. Similarly open the interconnecting pipe air vent and the boiler feed
pump discharge pipe air vent in the recirculation line and prime the
lines. After venting out air, close the air vents.
10. Fully open the pump suction isolating valve.
11. Ensure that auxiliary cooling water pump is running, the water is
available for the pump.
12. Open the Auxiliary cooling water inlet and outlet isolating valves for
the feed pump mechanical seal cooler.
13. Prepare the drive motor for starting.
347
14. Prepare the hydraulic coupling and lubricating oil system for starting.
Check the oil level is adequate.
15. Ensure that all instruments and coolers have been primed and
vented.
16. Check that the lubricating oil is flowing freely through the following
flow indicators.
a. Booster pump drive end and free end bearings drain flow
b. Booster pump side and hydraulic coupling side drive motor
bearings drain flow
c. Feed pump drive end and free end bearings drain flow.
17) Check that the Auxiliary cooling water from the booster pump
mechanical seals is flowing freely through the flow indicators.
18) Check that the cooling water from the feed pump mechanical seal
coolers is flowing freely through the flow indicators..
19) Charge the feed water line & HP heaters, if they are not already
charged, by opening the discharge valve. After charging the line,
close the discharge valve.
4.6.1.3 Start Up:
1) Ensure that the hydraulic coupling auxiliary lubricating oil pump is
running.
2) The following conditions must be fulfilled before the pump drive motor
can be started.
a. Pump suction valve is fully open,
b. Recirculation valve is open,
c. Lubricating oil pressure is at a minimum of 2.0 bar,
d. Deaerator level is not low,
e. Discharge valve is closed,
f. Cooling water pressure to pump is normal,
g. Cooling water to Motor & working oil cooler valve in open,
h. Differential temperature across top and bottom casings should
not be more than 15
o
C.
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3) Close the warm up valve,
4) Start the feed pump drive motor.
4.6.1.4 Running Condition:
1) When the pump is running normally the recirculating valve will
modulate to ensure a minimum flow of 100 tonnes/hour through the
pump.
2) The Auxiliary lubricating oil pump should be stopped.
4.6.1.5 Routing Checks:
1) Check that the drive motor ammeter reading is normal,
2) Check that all pressure and temperature readings are normal,
3) Check that the lubricating oil is flowing freely through the following
flow indicators,
a. Booster pump drive end and free end bearings drains flow,
b. Booster pump side and hydraulic coupling side drive motor
bearings drain flow,
c. Feed pump drive end and free end bearings drains flow,
4) Check that the cooling water from the booster pump mechanicals
seals is flowing freely through the flow indicators,
5) Check that the cooling water from the feed pump mechanical seal
coolers is flowing freely through the flow indicators,
6) Check for any undue noise or vibration,
7) Check all joints and valve glands for leakage,
8) Check the security of all fastenings, paying particular attention to the
holding down bolts.
4.6.1.6 Standby Condition:
When a pump is required for standby duty, it should be prepared as
follows:
1) Set the selector switch to auto condition,
2) Open the discharge valve,
3) Start the auxiliary lubricating oil pump,
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4) Keep the pump under warm up condition, by opening warm up
valve.
NOTE: The scoop tube of the standby pump will follow the scoop tube
of the running pump, when the pump is put in Auto-Reserve.
4.6.1.7 Shut Down:
1) Stop the drive motor and position the circuit breaker in the OFF
position,
2) Close the discharge valve,
3) Close the cooling water valves to the drive motor air cooler and the
working oil cooler of the Hydraulic coupling.
4.6.1.8 Lubrication System Of Boiler Feed Pump:
The hydraulic coupling has an auxiliary lubricating oil pump ALOP. In
addition the hydraulic coupling has a shaft driven lub oil pump (SP). The
ALOP shall be initially started to pre lubricate the step up gear and bearings
of the coupling, pump and motor. When the HM starts, the lub oil pressure
increases due to the AOP and also the Shaft drive lub oil pump (SP). When
the lub oil pressure is approximately 4.0 Kg/ Cm
2
another pressure switch
makes the AOP cut off. (No.150). If the lub oil pressure drops down to 1.5
KSC, the ALOP will be started automatically with impulse from pressure
switch (No.150). If the pressure falls to 1.0 Kg/ Cm
2,
the BFP Motor shall be
immediately tripped by the minimum contact in pressure switch. (No.149)
4.6.1.9 Tripping And Run Down Of BFP:
Whenever the BFP motor (HM) is tripped, the AOP will start on AUTO,
or when the lub oil pressure is less than or equal to 1.5 Kg/Cm
2
to supply lub
oil during the running down of the BFP including hydraulic coupling.
4.6.1.10 Annunciations For Each BFP And Auxiliaries:
1) Journal bearings temperature of booster pump high : 75
0
C
in temperature switches 107 & 110.
2) Motor journal bearings temperature high : 75
o
C
in temperature switches 116 &119.
350
3) Motor cold air temperature high : 45
o
C
in temperature indicator120.
4) Motor hot air temperature high : 65
o
C
in temperature indicator124.
5) Hydraulic coupling bearings temperature high : 75
o
C
in temp indicator alarm nos.128,130,132,134,136 &138.
6) Hydraulic coupling lub oil temperature after cooler high : 50
o
C
in temperature switch 146.
7) Hydraulic coupling working oil temperature high :120
o
C
in temperature switch 140.
8) Hydraulic coupling tank oil level low
minimum oil level set in level switch 152.
9) Feed pump bearing temperature high : 75
o
C
in temperature switch Nos.164 &167.
10) Mechanical seal water inlet temperature high : 80
o
C
in temperature switch nos.175 & 178.
11) High AT of feed water between suction and discharge : 8
o
C
in temperature switch 173.
12) Oil filter choked AP across filter high : 0.3 Ksc
in differential pressure switch 151.
13) Suction filter before booster pump choked : 0.5 Ksc
in differential pressure switch 161.
14) Motor winding temperature high : 70
o
C
over ambient temperature No.126.
15) Discharge pressure low :132 Ksc
in differential pressure switch 159.
16) Suction flow high No.183. : 460t/hr.
17) AT of top and bottom casing high : 15
o
C.
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4.6.2. CONDENSATE EXTRACTION PUMP:
4.6.2.0 Operation Of Condensate Extraction Pumps:
4.6.2.1 Starting Of Condensate Extraction Pump:
During start-up of unit, one of the two condensate extraction pumps
is to be started with main condensate in recirculation.
4.6.2.2 Initial conditions:
1. CST is full and condensate Transfer pump is in service
2. ACW System is in service.
3. Circulating water is available for Heat Exchangers.
4. Instrument Air Compressor is in service.
4.6.2.3 Preparation Of The Scheme:
1. Check the water level in the hotwell. (Normal Level-750mm of wcl.).
If the water level is low, it has to be made up from surge tank by
opening Deaerator Normal Level control valves CD 64 & CD 66.
2. Check that the hotwell drains (3 Nos.) are in Closed position.
(Total = 6 valves)
3. Check that the following lines are also in closed position
4. CEP suction bus drain.
5. Hotwell bottom storage tank drain.
6. Suction filter drain.
7. Check that the gate valve after suction pressure relief valve is in
Open position (for both pumps).
8. Check that the inlet isolation valve for LP bypass spray water is in
Open position.
9. Check that all the four LP bypass injection valves (V1 to V4) are in
closed position. Close indications are to be available in LP bypass
control console in the desk.
10. For valve sealing header, the following positions are to be checked.
11. Root valve at CEP discharge header should be in Open position.
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12. Inlet and outlet isolation valves for the control valve CD 50 should be
in Open position with its bypass valve in Close position.
13. The control valve CD 50 maintains the valve sealing header pressure
at 2.5 Kg/Cm
2
.
14. Reserve water supply line valve from surge tank to valve sealing
header (13.5m level) should be in Open position.
15. Inlet and Outlet valves for both the main ejectors should be in Open
position with their bypass valve in Closed position.
16. Line drains in inlet bus, inlet line, outlet line and outlet bus should be
checked for CLOSE position.
17. Inlet and Outlet valves for Gland steam condenser should be in
Open position with its bypass valve in Close position.
18. Line drain before hotwell level control station should be in Closed
position.
19. Hotwell level control valve CD 14 should be kept in Close position
with its inlet and outlet valves in OPEN position. Its bypass valve CD
16 should be in Close position. Since the hotwell level control valve
CD 14 is in full close position, the recirculation control valve CD 19
will be in full open position.
20. Keep the hotwell level control in manual.
21. Check that the inlet and the outlet valves for CD 19 are in Open
position with its bypass valve CD 21 in Close position.
4.6.2.4 Preparation Of The Pump:
1. Check that the Suction valve is in Open position.
2. Check that the discharge valve is in Closed position.
3. Open the charging valve of the discharge valve.
4. Check that the pair line valve to condenser is in Open position.
5. Check that the Gland sealing water line valves from the CEP
discharge header and also from the surge tank are in Open
position.
6. Check the Oil level in the level gauge for pumps thrust bearing.
353
7. Check that the inlet and outlet ACW line valves for pumps thrust
bearing cooling are in Open position.
4.6.2.5 Starting The Pump:
1. Avail power supply for the CEP motor and the discharge valve.
2. Keep SLC of CEPs in Off position.
3. Start the pump from control desk.
4. Check the pump for its normal operation.
4.6.2.6 Charging PHASE-I CEP Running In Recirculation:
1. Charging of the system with the main condensate will take place
upto the hotwell level control valve CD 14. During this occasion the
quenching water line to Turbine Flash Boxes 1 & 2 tapped from LP
bypass spray water valve station will act as air vent.
2. After complete charging, the discharge valve is to be opened from
the desk and the charging valve is to be manually closed.
3. Select the other CEP as standby pump (at the desk).
4. Make SLC of CEPs ON.
5. Now CEP is in service in recirculation and the main condensate is
available up to valve CD 14.
4.6.2.7 Charging Phase-II Upto Deaerator;
1. Check that both inlet and Outlet valves of LP heaters 1,2 & 3 are in
open position with their bypass valves in CLOSE position.
2. Check that the Outlet water box drains of LPH 1,2 & 3 and also drain
cooler drains are in CLOSE position.
3. All the line air vents in the main condensate system (after the valve
CD 14) need to be opened for charging if no locked-up water is
available initially (i.e. the air vents in water boxes and lines).
4. Check that the isolation valve just before Deaerator is in Open
position.
5. Open the valve CD 14 for charging.
6. Hot well level control shall be later brought to auto mode after
adjusting the hot well level set point.
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4.6.2.8 Stopping Of Condensate Extraction Pump:
1. Close the hot well level control valve CD 14 completely / check that
the Hot well level control valve CD 14 is in full close position.
2. Make SLC of CEPs OFF.
3. Stop the pump from local/control desk.
4. Close the discharge valve of the pump, which was stopped.
5. Check that the CEP rotor has come to rest.
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4.6.3. CIRCULATING WATER PUMP:
4.6.3.1 3.6.3.a. First Starting Of CWP After Long S/D Guidelines:
1. Check for any LC on CWPs, butterfly valves, discharge valves,
condenser water box, condenser water box inlet and outlet valves,
cooling tower etc.,
2. Keep open blow down to ADPH valve by 25% and its air vent is to be
opened fully.
3. Condenser water boxes air vents & drains are to be opened.
4. Check the pressure gauges in CWPs for their healthiness.
5. Check the pressure gauges in condenser water boxes for their
healthiness.
6. Isolate CW to oil cooler filter, PHEs, Turbine Lub oil coolers and seal oil
coolers.
7. All the pressure gauges & switches impulse lines must be made thro.
8. Check all the pressure gauges, temp gauges, pressure indicators, and
temperature indicators for their healthiness.
9. Start one CWP with its discharge valve 10% open following the normal
starting procedure.
10. After complete charging, close all the drains & vents.
11. Check for any leak in filter, Lub oil coolers, PHEs, and check for any
abnormalities.
12. Open the CW pump discharge valve fully & close ADPH Blow down
valve and its air vent.
4.6.3.2 Starting Of The CW Pump:
01. Ensure that no LC is pending.
01.a. Check the oil level in the bearings and cooling water was made
through.
02. Ensure the gate valves before automatic air releasing valves in Hot
& Cold tunnels in open condition.
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03. Ensure that Hot & Cold tunnel drains at minus level in the condenser
sump pit closed.
04. Open the water box air vents (Front & Rear) & Close the water box
drains.
05. Open the air vent sin Lub oil cooler & Plate Heat Exchanger & Seal
oil system.
06. Choke the O/L water box valves to 10%.
07. Open the CWP discharge valve to 10% and isolate the valve supply
when 10% contact is appeared in the control desk.
08. Start one CWP & check that pump is running normal and air is
properly released in the system.
09. After air is released close all air vents and ensure that cooling water
flow in cooling tower. After that give supply to discharge valve and
it will open fully.
4.6.3.3 Stopping the CW Pump:
1. Close the discharge valve.
2. After discharge valve 10% contact vanishes, stop the pump.
3. Confirm the discharge valve has closed fully and there is no reverse
rotation of the pump.
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4.7 OPERATION OF REGENERATIVE FEED HEATERS:
4.7.1. Charging of LP Heater:
Conditions:
1) Main condensate inlet & outlet valves are in closed condition.
2) The main condensate bypass valve of LP heater is in open condition.
3) The drains and the vents are in open condition.
Charging the LP Heater:
1) Close both the drains.
2) Open manually the inlet valve (2 or 3 turns).
3) Close the air vent, when the air is completely released.
4) Check the pressure inside the LP heater (tube side).
5) Open electrically the inlet and outlet main condensate valves, when
the main condensate pressure in the heater and outside are same.
6) Close electrically the bypass valve and tighten it manually.
7) Observe for any level rise on the shell side of the LP heater due to
tube leak.
4.7.2. Isolation Of HP Heater:
1) Close the extraction valve and open the extraction line drain valve.
2) Isolate the cascaded drain condensate from the higher heater as
well as the drain condensate to the lower heater.
3) Open the bypass valve and then close the FW inlet & outlet valves.
4) Manually tighten these valves.
5) Crack open the air vent on tube side and observe for drop in
pressure.
6) When the pressure has been released, open the drains.
4.7.3. Charging Of HP Heaters On Tube Side:
CONDITIONS:
1) Inlet and outlet valves are in closed condition.
2) The vent and drains are in open condition.
3) The charging valve is in closed condition.
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Charging Procedure:
1) Avail power supply for heater protection solenoid valve and check
whether its airline is made through.
2) Open fully the gate valve before the Sempell valve.
3) Check whether the reversing chamber valve is in closed conditions.
(Above piston drain line valve).
4) Completely withdraw the wheels closing the GPV inlet and outlet
valve.
5) Close the drains of HP Heaters.
6) Crack open the charging valve and observe for the rise in the
temperature of feed water. When the temperature rise is steadied,
further open the charging valve.
7) Close the water box air vent after releasing the air.
8) Observe for pressure rise in tube side and further open the charging
valve.
9) Check whether the GPV inlet and outlet valves open automatically.
After that close the charging valve fully.
10) Observe for any level rise on the shell side of the HP heater due to
tube leak.
4.7.4. Operation Of Feed Water System Description
The HP Heaters have been provided with individual isolation and
bypass as well as with a group bypass facility. The group bypass system is
designed to quickly shut off feed water flow in heaters when there is level
rise in any of the HP Heaters to very high level due to heater tube failure or
mal-operation of level controls.
The system consists of a quick closing three way valve GPV I/L with an
integral hand operated reversing valve, a quick closing three way check
valve GPV O/L, two control valves FD-26 & FD-27 connected in parallel
along with GPVs, and charging valves to refill pipe line. It also has a
motorized dump valve FD-24 to dump feed water from the system.

359
Operation
During normal operation the discs of the quick closing valves GPV I/L
& O/L remain open allowing the flow of feed water through HP heaters. The
out of balance forces acting on the discs caused by a combination of
differential area between bottom & top of the disc and pressure drop
across the heaters bank will hold these valves in position.
In case water in any of the two HP Heaters rises to very high level, the
very high level switch initiates a signal to open the motorized feed water
bypass valves and after opening of the B/P valve to close the motorized
feed water isolating valves and also energize the solenoid valves of Sempell
valves to close both the GP Valves.
After ensuring physically that motorized feed water isolating valves
of the affected heater are closed and bypass valve is open, healthy heater
is brought into service by opening charging valves. As soon as the pressure
on the heater bank approaches more than 90% of BFP discharge pressure,
the GPVs automatically reopen, thus allowing feed water to pass through
the heaters, with low operating pressure in the range of 15 to 40 ata, the
integral hand operated reversing valve FD-25 is also to be opened to relieve
pressure in above piston of GPV I/L valve for allowing the disc to move into
open position.
4.7.5. Maintaining Levels In The Heater.
1. The normal level in HP heater 6 is maintained by cascading the drain
to HP heater 5 or Deaerator through two separate control valves.
Normally HP heater 6 drain is cascaded to HP heater 5, but in case
drain from HP heater - 6 to HP heater 5 is blocked due to outage of
HP heater 5, the HP heater 6 drain is cascaded to Deaerator.
2. When the high level controller of HPH 6 comes in to operation i.e.
alternate drain to condenser, the normal drain control valve DR 2 will
remain open unless it has been closed from the HPH 5 interlocks.
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3. In case of turbine load reduction to 40% or below, observe that the
pressure switch located in the extraction line to HP heater-5 closes the
drain control valve DR-2 in drain line from HP heater-6 to HP Heater-5
and HP Heater 6 drain should be diverted to Deaerator / condenser.
4. The normal level in HP heater 5 is maintained by cascading the drain
to Deaerator through the control valve DR 11 which is operated by
normal level controller.
5. When the HP Heater 5 continues to drain to condenser, HP Heater 6
drain control valve to HP Heater 5, i.e., DR 2, if in operation, should
be closed manually and HP Heater 6 drain should be diverted to
Deaerator through control valve DR 6
6. Normal level in LP heater 3 & 2 is controlled by cascading the drain to
LP heater 2 through control valve DR 16 and by cascading the drain
to LP heater 1 through control valve DR 21 by the level controllers at
normal level of LP heater 3 and 2 respectively.
7. There is no controller in the LP Heater 1. The drain is taken to
condenser flash box through a siphon and the drain cooler.
8. After heater gets isolated on steam side by the closure of extraction
valve, isolate the heater on condensate side by first opening the
bypass valve and then closing the isolating valves.
4.7.6. Three Zones In A Heater:
Each feed water heater bundle will contain from one to three
separate head transfer areas or zones. These are the condensing, de-
superheating and sub-cooling zones.
1. A condensing zone is present in all feed water heaters. Large volumes
of steam are condensed in this zone and most of the heat is transferred
here.
2. The de-superheating zone is a separate counter-flow heat exchanger
contained within the heater shell. This zones purpose is to remove
superheat present in the steam. Because of the high steam velocities
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employed, condensation within the de-superheating zone is
undesirable. The sub-cooling zone, like the de-superheating zone, is
another separate counter flow heat exchanger whose purpose is to
sub-cool incoming drains and steam condensate.
4.7.7. HPHs Operation:
The following are precautions that should be reviewed and
recognized when operating these feed water heaters.
1. Feed water heater operation should not be undertaken if any of the
protective devices are known to be faulty.
2. Feed water heaters must not be subjected to abrupt temperature
fluctuations. Hot fluid must not be introduced rapidly when the heater
is cold, nor cold fluid when the heater is hot.
3. Continuous venting of air and other non-condensable is assured by
keeping the shell operating vent valves open.
4. During initial start up phases, the drains approach temperature
(difference between drain cooler outlet and feed water inlet
temperatures) should be monitored. Approach temperatures in excess
of 8
0
C indicate the probability of flashing at the sub-cooler inlet. In this
case, the liquid level should be raised until the drain approach
temperature approached the specification sheet value.
4.7.8. General Performance:
The failure of a feed water heater to perform satisfactorily may be
caused by one or more factors, such as:
1) Air or non-condensable gas blanketing resulting from improper piping
installation or lack of suitable venting.
2) Flooding resulting from inadequate drainage of condensate.
3) Operating conditions differing from design conditions.
4) Tubing failure.
5) Mal-distribution of flow.
Abrupt flooding, unusual noise or loss of feed water temperature rise
can indicate tubing failure. If such a condition occurs, the heater must be
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removed from service as quickly as possible. Tube failures tend to have a
chain reaction effect; impingement on adjacent tubes can cause
additional failures.
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4.8 FIRE PROTECTION SYSTEM:
4.8.1. System Description:
The fire protection system consists of two interconnected circuits
namely the hydrant system and HVW (High Velocity Water) system. The
hydrant circuit has got three hydrant pumps of which two are electrically
driven pumps while the third is a diesel engine driven pump. These pumps
feed a common header, which feeds the hydrant lines leading to various
hydrant circuits in the Power Station (Units IV to VII). The HVW system
consists of one electrically driven pump and a diesel engine driven pump.
These two pumps feed the HVW spray system through two filters (one filter in
service and the other stand by) under normal conditions, the system
pressure is maintained at 9.8 KSC by the hydro pneumatic tank.
4.8.2. Deluge Valve:
The deluge valve is used in the high velocity water spray system for
MOT and lub oil canals. The water spray network has got a number of
nozzles which discharge water over the hazard in a cone shaped pattern in
the event of fire.
4.8.3. Release System :
In the event of fire at the main oil tank or the lub oil canals of the
turbine, a signal will be sent from the local sensors to initiate the alarm in the
Fire alarm panel, located in the UPS room. When the fire alarm flashes in
the control room (for MOT & Lub oil canals) release system can be initiated
at local by,
a) Breaking the glass of the deluge valve Local control panel and
pressing the start push button, which initiates the opening of the solenoid
valve in the deluge valve release line.
b) By opening the manual release ball valve provided in the release
line at the deluge valve.
c) By pressing manual release button on the solenoid valve.

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Area Panel location Deluge valve.
Location
1. Lub oil canal 13.5 ml at Static Excitation 8.5 ml near LP B/P
- Zone 1. Room wall. Valves
2. Lub oil canal adjacent to LP B/P Governing 8.5 ml near LP B/P
- Zone 2. Rack in A row column. Valves
3. Main Oil Tank. At the entry of the oil room 0 ml near OLTC.Sys

When the release system is operated, the water in the priming
chamber gets released, thus the pressure above the clapper reduces
resulting in the opening of the clapper plate and flowing of water in to the
outlet chamber towards the hazard on fire for quenching of the fire. As
soon as the water flows in to the outlet chamber the pressure operated
relief valve (PORV) opens and provides continuous venting of water from
the priming (top) chamber. This continuous draining of water from the top
chamber provides a foolproof means of ensuring that the deluge valve
does not close due to pressure balance being restored before the fire has
been quenched. Some high pressure water also flows from the outlet
chamber through the water gong impulse line for initiating the water gong
audible alarm and then it flows out through the drain.
The strainer orifice check valve provided in the priming line
facilitates .
a) Charging of the priming chamber through the priming valve (there
will be no flow to the inlet chamber during this period).
b) Flow of make up water for minor losses from inlet chamber to
priming chamber under normal conditions.
c) Reduced flow to the priming chamber in the event of opening of
the deluge valve due to release of water in the priming chamber through
the release line.


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4.8.4. Resetting Of Deluge Valve :
For charging the deluge valve after extinguishing the fire (resetting of
deluge valve), the following operations should be carried out.
a) Check for the closing of the gate valve before the deluge valve.
b) Open the inlet and outlet chamber drain valves partially to drain the
water in the piping network and body of the deluge valve.
c) Check for the closing of the manual release ball valve and solenoid
operated valve.
d) Open the ball valve in the priming line and charge the priming
chamber of the deluge valve and check the pressure in the priming
chamber (8 to 10 KSC).
e) Check whether the flow of water through the pressure operated relief
valve drain line has stopped.
f) After completion of charging, close the outlet chamber drain valve.
g) Open the deluge valve inlet gate valve and after releasing air from
the inlet chamber. Close the inlet chamber drain valve. Check the
inlet chamber pressure.
h) In order to check whether the clapper has got seated properly on
the valve seat, press the drip check valve No water should flow out
if the clapper has got seated properly.
i) Close the priming line ball valve.

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4.9 SPECIAL OPERATION PROCEDURES:
4.9.1 Boiler Hydro Test.
a) Ensure that there is no LC, pertaining to Hydro test scheme
b) Required Condition:
1. Ensure that CT pump, ACW pump and one CWP are in service.
2. Ensure the availability of two BFPs.
3. Ensure that Boiler Stop valves and their bypass valves are closed.
4. Ensure that after Boiler Stop valves drains are open.
5. Ensure that Boiler contour and Super heater is filled.
c) Activities:
1. Close isolation valve of HP BYPASS BD VALVE.
2. Open MS25 and MS26.
3. Close HP heaters GPVs and lock their wheels.
4. Open MAL drain valves.
5. Open HP B/P atmospheric drains.
d) Procedure:
1. Start one BFP.
2. Raise the Boiler drum pressure by operating Super heater injection
valves.
3. While raising the drum pressure check for any abnormal drop in
Turbine metal temperature.
4. When the Boiler drum pressure reaches 60 Ksc gradually raise the
scoop such that the rate of pressure rise is 2Ksc/min upto 100 Ksc.
5. Start second BFP and keep its scoop in minimum position.
6. After Boiler drum pressure reaches 100 Ksc, ensure that the pressure
rise is 1Ksc/min.
7. Ensure that both BFPs are loaded at regular intervals.
8. After confirming the completion of Hydro test, reduce the drum pressure
at the rate of 1Ksc/min upto 100 Ksc and 2Ksc/min below 100 Ksc.
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9. Stop one BFP at 100 Ksc and the other pump after getting
concurrence from Boiler staff.
10. Normalise the scheme.
4.9.2 Condenser Air Tightness Test:
Condenser Neck Filling (Air Leak Test)
a) Ensure that there is no LC, pertaining to Hotwell.
b) Required Conditions:
1. Ensure that Unit is in shut down condition.
2. Ensure that Turbine MMT is less than 120C.
3. Jack the Condenser.
4. Ensure one CT pump is in service.
5. Ensure that Surge Tank level is full.
6. No CWPs shall be in service.
7. Open Condenser water box drains.
8. Ensure availability of the sump pump.
c) Activities To Be Done:
1. Isolate the power supply of the both CEPs.
2. Close the suction valves of CEPs.
3. Open the drain valves of the CEPs suction filters.
4. Close the suction safety valves of both CEPs.
5. Close the air lines of both CEPs.
6. Close CEPs Discharge lines to Flash Box.3.
7. Close the suction valves of Gland Steam Exhausters A and B.
8. Close the overflow drain of Gland Steam Condenser.
9. Open all the MAL drain valves.
10. Ensure that Flash Box connections are through.
11. Close HR 47,48, CR 51,52, and their isolation valves.
12. Open Condenser Neck air vents, 2 nos (UCB side)
13. Ensure that HP and LP heater level columns are through.
14. Close the Hotwell drain valves.
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d) Procedure:
1. Open Hotwell make up line valves CD 64 and CD 66, Observe
increase in Hotwell level in the UCB recorder.
2. After some time observe for increase in the level of LP heaters 2 and
3, and HP heaters 5 and 6.
3. Once water comes out of Condenser neck vents, close the vents and
the CD 64 and CD 66.
4. Check for leaks, if any, in the system.
5. Open the Condenser W/B drains and check for tube side leak.
6. Check for action of level switches of HP and LP heaters meant for
annunciation and protection purposes.
7. After the inspection drain the Hot well up to normal working level.
8. Release the condenser jack.
9. Normalise the scheme.
4.9.3 Deaerator Safety Valve Floating:
a) Ensure that there is no LC. on Deaerator and other connected system
b) Required Conditions:
1. Fill Deaerator to normal working level.
2. Ensure that AST is in charged condition.
3. Preheat Deaerator water to 75 deg C.
c) Activities To Be Carried Out:
1. Close recirculation gate valves of all BFPs at Deaerator level.
2. Isolate power supply of all BFPs, and close their suction valves.
3. Close main condensate line valve at Deaerator.
4. Close gate valves before and after Deaerator over flow valve DR 33.
5. Close CRH to Deaerator extraction valve EX 001, and its bypass valve.
6. Close Deaerator Filling valve DM 20 and its isolation gate valve.
7. Close Operating vents of HP heaters 5 and 6 at Deaerator level.
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8. Close HP heater 5 and 6 drain condensate to Deaerator PCVs and
their isolation gate valves (before and after). Open Drain valve after
the PCV.
9. Isolate both Deaerator level columns.
10. Close Deaerator Vent SM 20 and check its operation.
d) Procedure:
1. Gag all the line and dome safety valves, except the one to be
floated.
2. Open gradually the AST to Deaerator, pegging line bypass valve and
slowly raise the Deaerator pressure.
3. Ensure the opening of concerned safety valve at the set pressure,
otherwise reduce the Deaerator pressure and adjust the spring
tension accordingly.
4. Again raise the Deaerator pressure gradually and ensure the blowing
of safety valve at the set pressure.
5. Once safety valve is lifted, close the pegging bypass valve and open
immediately the SM 20.
6. Repeat the above procedure for the remaining safety valves, one by
one.
4.9.4 Turbine Over Speed Test:
4.9.4.A. Turbine Over Speed Oil Injection Test:
1. Record Unit Load, Speed, Frequency and Primary oil pressure
reading.
2. Close Aux.Trip oil port of over speed trip test device (Depress the lever
and lock the same with a special tool).
3. Admit Test oil gradually (By operating the center knob).
4. Check for the action of any one of over speed pawls at local and
corresponding alarm at UCB. Record Test oil pressure reading.
5. Also ensure the killing of Aux.Trip oil circuit between over speed trip
device and test device.
6. Increase further the Test oil pressure, gradually.
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7. Check for action of other over speed pawl at local and
corresponding alarm at UCB. Record Test oil pressure reading.
8. Kill the Test oil pressure, by operating the center knob in the reverse
direction.
9. Reset the Over speed trip test device (Depress the Reset lever).
10. Ensure building up of Aux.Trip oil circuit pressure up to over speed trip
device.
11. Release Aux.Trip Oil port lever.
4.9.4.B. Turbine Over Speed Test (Actual):
1. Reduce Unit load to 120 MW gradually.
2. Bypass the Main Steam Temperature Very Low protection to
prevent the possibility of Turbine trip during load reduction.
3. Maintain minimum Pressure and Load with 4 Mills, keeping the main
steam and reheat temperature, to maximum possible values.
4. Avail the tie for 6.6 KV buses from station bus.
5. Open GB by operating upon Class- C protection.
6. Maintain machine speed at 3000 rpm in EHC speed loop.
7. Change governing control from EHC to MHG speeder gear.
8. Conduct over speed Oil Injection test to check the healthiness of
over speed trip pawls at 3000 rpm. Record the test oil pressure.
9. Raise the machine speed by operating speeder gear and check for
the turbine trip at over speed trip level.
10. Record the speed at which the turbine trip is initiated.
11. Trip the turbine manually if the over speed trip fails to act.







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4.9.5 Boiler Passivation Turbine Readiness:
a) Boiler Passivation:-

During the idle periods if boiler is not preserved, oxide of iron (Fe2O3) is
formed on the surfaces due to the presence of moisture and oxygen. During
the subsequent start up even with the use of deaerated water, corrosion
continues to take place on account of the already formed Fe2O3, which
decomposes into Fe3O4 and free oxygen.
12 Fe2O3 8 Fe3O4 + 2 O2
The free oxygen released will readily react with the metal.
3 Fe + 2 O2 Fe3O4
Such corrosion is evidenced by the formation pf pitting on the surface,
which would eventually lead to failures of tubes.
If it is a very long shut down, care must be taken to see that sufficient
quantity of hydrazine is dozed.
After ensuring that passivation scheme is made ready, start hydrazine-
dosing pump. After the unit is shut down, allow the boiler to cool naturally and
when the pressure drops to 25 Ksc, light up the boiler and maintain the pressure
at 25-30 Ksc, and temperature at 250
0
C with HP B/P valves. Passivation starts
when N2H4 concentration reaches 200 ppm at drum. N2H4 concentration of
200 ppm should be maintained for 24 hours. During Passivation process, N2H4
concentration in condensate is to be carefully monitored. The P
H
value of
water must be maintained above 10. If this is not achieved with hydrazine
alone, ammonia may be added to raise the P
H
. However the ammonia
concentration in superheated steam should be less than 2 ppm to prevent
failures in the condenser and heaters.
The parameters are maintained such that the pressure and temperature
are not exceeding 25-30 Ksc and 250 C and N2H4 concentration in drum is
220 ppm. During the next 24 hours of Passivation, rotate the oil burners once in
4 hours. After 24 hours i.e., after declaring completion of Passivation, stop N2H4
pumps, shut down the Boiler and allow it to cool naturally.
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On tripping of turbo- generator, Boiler is to be kept in service with HP & LP
bypass system. Reduce Boiler drum pressure to 15 Ksc with HP &LP bypass
system.
At 15 Ksc, adjust HP& LP bypass opening so as to keep 2 to 5 Ksc pressure
in reheater and feed Flow of about 50 T/hr.
Keep LP B/P valves in Trip closed condition and open Reheater start up
vents.
After ensuring that scheme is made ready, start dosing pump and
increase the pressure to 25 - 30 Ksc, temperature to 250
0
C with HP B/P valves.
Passivation starts when N2H4 concentration reaches 200 ppm at the drum.
During Passivation process N2H4 concentration in condensate may be carefully
monitored.
During the next 24 hours of Passivation, rotate the oil burners once in 4
hours. After 24 hours i.e., after declaring completion of Passivation, stop N
2
H
4

pumps, shut down the Boiler and allow it to cool naturally.
b) Turbine Schemes Preparation:
1. Condenser vacuum is to be maintained till the end of passivation.
2. All LP / HP heaters are to be bypassed on waterside & I / L and O / L
valves should be further hand tightened.
3. Adequate level should be built in CST.
4. At 30 ksc of boiler drum pressure, MS- 25 & MS 26 should be kept 50%
open & their bef iso valves to be kept fully open.
5. HR 47, HR 48, CR 51, CR 52 drains are to be opened & their bef
iso valves.
6. All MAL drains (including their Bef gate valves) to Flash Box are to be
opened fully.
7. Drain before EX 12 (EX-112) should be closed fully.
8. LP B/P valves and warm up line valves are to be kept opened.
9. HPHs emergency drain to Flash Box is to be kept open fully. AST to
Dea should be made thro to maintain FW temp as per Boiler
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requirement. This is to be done to avoid hammering in Economiser
zone.
4.9.6 Condenser Vacuum Drop Test:
1. Ensure that unit load is steady.
2. Close Air valves of reserve and running Main ejectors.
3. Observe vacuum drop for 5 minutes. If vacuum drops to 640 mm of
Hg. stop the test immediately.
4. Record the change in parameters pertaining to vacuum. (Ex. Hood
temp, Circulating Water O/L temp)
5. Open the Air valves and observe for the vacuum rise, back to original
values.
4.9.7 System Make-Up Test:
1. Ensure that unit load is steady.
2. Ensure that Steam soot and RAPH soot blowers are not in service.
3. Ensure that AST is fed by self-source steam (AST header inter-
connection valve in closed condition).
4. Ensure that Surge tank level is high.
5. Close make-up valves of Surge tank, DM 23 and its isolation gate
valve.
6. Observe drop in Surge tank level for one hour.
7. Calculate make-up value and compare with integral make-up
Reading.
8. Open the make-up valves DM 23 and its isolation gate valve, and
observe for the increase in the surge tank level.







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4.9.8 Turbine Oil Flushing:
a) Ensure that there is no LC, pertaining to oil system.
b) Required Condition:
1. Ensure the availability of AOP, DCEOP.
2. Ensure that MOT level is sufficient.
c) Activities:
1. Isolate the oil coolers on raw waterside.
2. Close the shut-off valve.
3. Close the isolation valve of self-cleaning filter before Fire-Protection 1
gate valve.
4. Close the GATE VALVE GEARING and isolate its power supply.
5. Cover the MOT BASKET FILTER with white cloth to collect foreign
particles.
6. Ensure the closed status of the following drain valves:
a) Oil cooler.
b) Duplex filter.
c) MOT drain to central lub oil system.
7. Ensure that the isolation valve in oil line to MOT from Central Lub Oil
System is closed.
8. Isolate the Control oil and Secondary oil lines to all HP and IP control
valves.
9. Close all test valves.
10. Isolate the control oil supply line to Governing rack and LP B/P rack.
11. Ensure the closed status of the following valves in LP B/P oil canal:
12. Signal oil line valves (4 nos.).
13. Isolation valve before self-cleaning filter
14. Remove oil throttles in lub oil supply line to bearings, instead provide
line filters.

375
d) Procedure:
1. Charge the lub oil system by intermittent starting of DCEOP and
check for any leak.
2. If there is no leak start AOP and stop DCEOP.
3. Slowly charge reserve lub oil cooler and monitor the oil level.
4. Continuously monitor choke across duplex filter both at local. If Ap
exceeds 0.5 Ksc change the filter and clean the choked one. Ap can
also be monitored from UCB.
5. Start Centrifuge and cut in heaters.
6. Observe for choke in MOT basket filter. If choke is found to be more,
stop AOP and clean the basket filter and the line filters.
7. After cleaning the filters resume oil flushing and repeat the above
procedures.
8. If the frequency of choking of duplex filters is considerably reduced,
slowly include the GATE VALVE GEARING supply line.
9. Declare the completion of oil flushing on attaining satisfactory results
after inspection of line filters.
10. Normalise the system.

4.9.9 Governing Characteristics:
a) Activities:
1. Reset the turbine after switching off Turbine Protection supply K101 &
K201.
2. Charge the governing rack, control oil lines to all valves one by one
and check for any leaks.
b) Procedure:
1. Open all stop valves (HP, IP) by operating on starting device and
record the start up oil pressure at which each (4Nos) stop valve
opens.
2. Close governing rack isolation valves slowly and note down the trip oil
pressure at which Main trip valves close.
376
3. Close governing rack isolation valves slowly and note down the trip oil
pressure at which stop valves close.
4. Normalise the governing rack and close the test valves of stop valves.
5. Isolate HP, IP secondary oil lines to EHC.
6. Keep the starting device at 60% and adjust its follow up piston to set
the auxiliary secondary oil pressure at 2.3Ksc.
7. At the same pressure adjust the follow pistons of HP&IP to get the
required Secondary oil pressures.
8. Now adjust the valve strokes of HP/IP control valves to the required
values as per the protocol.

4.9.10 EHC Calibration:
1. Keep the Starting device to maximum position.
2. Open HP, IP secondary oil lines to EHC.
3. Inject the voltage at EHC Terminal box.
4. Adjust the follow pistons of HP/IP to get the required oil pressure as per
protocol.
5. After completion of Governing characteristics, normalise the power
supply of K101, K201 and open the test valves.

4.9.11 LP B/P Valve Characteristics:
1. Simulate spray water and condenser vacuum at limiting regulator
and bypass protection switches, if spray water pressure and vacuum
are not available.
2. Adjust the follow pistons of spray water to set the signal oil pressure for
water injection valves as per the protocol.
3. Adjust the slide valves of water injection to set the opening w.r.t signal
oil pressure as per the protocol.
4. Adjust the follow pistons of spray water to set the signal oil pressure for
water injection valves as per the protocol.
377
5. Adjust the slide valves of water injection to set the opening w.r.t signal
oil pressure as per the protocol.
6. Adjust the follow pistons of stop/control valves to set the signal oil
pressure as per the protocol.
7. Adjust the slide valves of stop/control valves to set the opening w.r.t
signal oil pressure as per the protocol.
8. Record signal oil pressure versus valves opening.
9. Normalise the simulations/protections.
4.9.12 Check List For Isolating And Draining CST-6:
1. Check make up valve from WCTP to CST-4 & CST-7 in open condition.
2. Close the make up valve to CST-6.
3. Close the interconnection valve between CST-4 & CST-6.
4. Check CST-6 O/L valve to CT pumps in full open condition.
5. Close CT pump recirculation line isolation valve to CST-6 after
confirming the R/C line isolation valve to CST-7 is in full open
condition.
6. Close CST-7 O/L valve to CT pumps.
7. Check level drop in CST-6 as unit 6 & 7 make up is from CST 6 only.
8. Also monitor CST- 7 level closely. When its level is about 10 m close the
make up valve.
9. When CST 6 level is about 1 m stop the running CT pump and close
the CST 6 O/L valve.
10. Then open CST 7 O/L valve and start CT pump. Open CST 7 make
up valve.
11. Drain the CST 6 completely & issue LC.
12. CST 7 level must be carefully monitored as no interconnection
between CST 5 and CST 7. Also unit 6 & 7 make up is from CST 7
only.



378
4.10 EMERGENCIES IN STAGE II TURBINE SIDE:
4.10.1 Procedure To Be Followed During Station Pullout
1. Start DCEOP immediately if AOP not comes on N/E bus.
2. Give trip command to all 6.6 KV equipment in board and latch it.
3. Isolate all steam sources to condenser.
4. MAW 10 before gate valve to be closed. Ejector steam source to be
isolated.
5. Seals to be diverted to atmosphere.
6. Drain all BFPs if ALOP not comes in to service and bearing
temperature rises.
7. If AOP could not be started. Start hand barring for every 15 minutes
and rotate the shaft to 180
0
with JOP in service.
After normalizing the supply:
i) Start A/C plant equipments.
ii) Start one CT pump.
iii) Release the air in ACW system and start ACWP & ACW BP.
iv) Start one CWP & release the air in condenser water box, lub oil
cooler, hot & cold tunnels.
v) Start one CEP and release the air in condensate system and put in
re-circulation.
vi) Before starting BFP, FW line to be properly vented & drained to avoid
hammering.
vii) Raise the vacuum after proper warming up the system and admit
pegging steam to Deaerator.





379
4.10.2 : Procedure To Be Followed During House Load Operation
When ever the unit comes under house load,
1. Check whether the speed loop is selected in EHC, and raise the
speed set point to 3000 rpm.
2. Check for opening of HP & LP Bypass on auto (otherwise opens
manually).
3. Due to heavy dumping in Hotwell, Hotwell level may raise. Hence
Hotwell level control may be taken in to manual to avoid dumping at
Deaerator and hence tripping of BFPs on suction pressure very low
protection.
4. Without waiting for CRH to Deaerator PCV to come into service on
auto, it may be opened manually to avoid fast decay of Deaerator
pressure.
5. Confirm that CT pump is running or make up the system through DM 6.
6. Check the A/C plant is running or starts immediately as the supply
source is station bus.
Watch the HPT exhaust temperature rise if any and monitor the other
parameters.
4.10.3 Motoring Action Of Unit VI On 24-05-1999:
Turbine got tripped on boiler fire off (Air & flue path way free not
existing).
Generator breaker did not open due to failure of 220 VDC.
Turbine was running at 2950 rpm.
DC supply was restored and generator breaker got opened. Turbine
speed started reducing.
Both AOPs could not be started due to supply failure. Hence DCEOP
was started.
As ACWP 6B got tripped and ACWP 6A did not come into service,
both BFPs got tripped on W. O. temperature very high protection.
380
AOP 6A was started and STG was put in to service. System was
normalized one by one.
As motoring of Generator had taken place for nearly 23 minutes
following guidelines were issued for future reference.
Guidelines:
a) In the event of confirmation of Steam less regime operation of turbine,
the following guidelines are to be followed in Stage-II Units.
1. Confirm whether Trip oil press is zero and HP/IP stop valves and control
valves are closed
2. Ensure AOP availability. In case, AOP doesnt start from desk, Start
AOP from annex.
3. Keep HP and LP bypass system in service
4. Open all MAL drains
b) Observe and monitor the following parameters:
1. HPT exhaust temperature
2. LPT exhaust-hood temperature
3. Turbine metal temperatures in Recorders TR-2401, 2402
4. Condenser Vacuum
5. Differential Expansion of HP, IP and LP Turbine
c) Prepare the Governing System for admitting steam into the Turbine
1. Isolate EHC at local
2. Switch off K101 and K201
3. Reset the Turbine through Start-up Device and Open Stop valves
4. On observing Exhaust/metal temperature rise, open HP & IP control
valves a little to admit steam into Turbine and regulate the steam flow
such that temp rise is contained
+ Closely monitor the Exhaust and Turbine temperature till Generator
breaker is opened.
+ Immediately after opening the Generator breaker TRIP the Turbine
either from local or by Switching on K101 and K201.
Carryout the normal shutdown operations.
381
4.10.4 MOP coupling key failure on 14-11-96.
Unit 4 running normal in EHC / IP mode.
Turbine got tripped due to lub oil pressure very low.
Boiler was in service.
Condenser pressure mechanical trip ann. Appeared. Vacuum was
normal.
Both AOP & EOP came in to service.
Jop A started and tripped. Jop B came on auto.
All speed indications failed.
Lub oil pressure 3.7 KSC.
MOP discharge pressure had a sudden dip from 9.5 KSC to 6.8 KSC.
During barring gear operation, Speed indication was normal.
Turbine rolling was done to check the problem.
At a speed of 2350 rpm, suddenly speed indication failed and Turbine
was hand tripped. Jop & GVG came in to service.
Boiler was boxed up.
It was confirmed by local inspection that MOP coupling had failed.
Vacuum was killed. Turbine was on barring gear. Speed indication
became available.
15-11-2006;
At MMT 380
0
C, AOP was stopped after closing the GVG. EOP was
kept in service. Shaft came to rest. Continuous hand barring was
done. MOP shaft was inspected. MOP coupling key got sheared.
4.10.5 Bearing 2 Failure On 25-12-1999 In Unit 6:
Unit was running normal.
Thrust bearing duplex filter choked ann. appeared. (Oil is passing via
this filter to the Bearing No.2)
Filter SB

was in service. At local choke indication was only 5 % and
ann. was persisting in UCB. Hence SA filter was taken into service.
While tightening the change over wheel, in SA filter, choke indicator
rose to 100%.
382
Turbine got tripped on lub oil pressure very low protection while
changing the duplex filter from SB to SA. As the choke indication was
at 100% in SA filter, the duplex filter SB was taken back into service.
Turbine Speed gradually reduced and TG Shaft came to rest.
Speed got reduced from 148 rpm to 0 rpm with in 2 minutes.
Shaft could not be rotated even with hand barring there after. (Aop,
Jop in service GVG open).
There was steep raise in the bearing metal temperature and the
same was noted as below ( in deg C ).
HPT Rear bearing top left - 140.7
HPT Rear bearing top right - 80
HPT Rear bearing bottom left - 90.8
HPT Rear bearing bottom right - 173.5
Thrust bearing front left - 133
Thrust bearing front right - 70.38
Thrust bearing rear left - 82.06
Thrust bearing rear right - 73.31
Axial shift also shoot up to
+
0.345 from
+
0.003.
Maximum Coasting Down vibration was also higher in all the Bearings
and the values are as follows.
HPT (F) HPT IPT(R) LPT
Shaft 336 286 67 104
Bearing 57 35 23 22
On inspection, when Turbine thrust bearing duplex filter SA was kept in
service, no oil flow was observed in the Bearing pedestal No.2.It was
suspected that there was some mechanical blockage, which
prevented the oil flow to the thrust cum journal bearing.
Frequent choking of SB filter was noticed due to damage of Babbit
lining in Bearing No.2.


383
Findings:
1. On 26/12/1999 in between 20:50 to 01:35 hours when MMT was 334
0
C,
keeping JOP alone in service, duplex filter housing was replaced.
2. On dismantling the duplex filter housing assembly, it was noticed that
the locking pin that keeps the valve seats intact against the spring
came out resulted in blocking the inlet port of SA filter.
3. On inspection of thrust cum journal bearing after stopping AOP when
MMT was 118
0
C, it was observed that Babbitt liners were found in
completely damaged condition and some scourings were noticed in
thrust pads. Hence the same bearing was refixed with new liner and
also the same thrust pads were refixed after rectifying the scourings.
4.10.6 BFP Failure In Unit-Vii On 21-07-2001 :
Load 201 MW IP mode HPHs were in service. BFP 7A, 7B & CEP 7A
in service.
Instrument air header pressure low alarm appeared.
Instrument air pressure got reduced from 7 KSC to 3.9 KSC.It was due
to a puncture in instrument header in Unit 5 Boiler area.
HPHs got bypassed. Load raised to 214 MW. CEP flow got reduced to
161 T/hr from 520 T/hr within 2 minutes as CD14 valve got closed and
R/C valve slowly opened on failure of air pressure.
Load was reduced to 167 MW and CEP flow raised to 733 T/hr (both
CEPS in service and CD16 motor operated valve was opened.
BFP 7A got tripped on suction pressure very low protection. BFP 7C
came in to service on auto and got tripped on suction pressure very
low protection.
BFP 7B tripped on suction pressure very low protection.
BFP 7A was started and got tripped on suction pressure very low.
Unit got tripped on drum level very low, as feed flow was 379 t/hr.
BFP 7A was started again and got tripped immediately without any
alarm.
384
BFP 7B was started again and got tripped immediately without any
alarm.
The Deaerator level dropped below 640 mm and raised to 2267 mm
within a short span of 15 minutes.
As both CEPs were in service, condensate was dumped to Deaerator
through CD16 MOV, Deaerator pressure dropped to 0:248 KSC from
6.0 KSC.
BFP 7A & 7B were started one by one to check the healthiness of the
pump. As they did not develop any pressure / flow and they were
tripped immediately. Working oil temperature got raised above
130
0
C. On inspection, main pump shaft could not be rotated and
suspected seizure of pump.
Analysis:
2) After Unit tripping, there was no steam flow through A
4
Extraction line.
Steam source from AST header Deaerator was also not fully available
due to instrument air failure. As a result, Deaerator pressure dropped
to 0.248 KSC. In this situation, BFP A & B were started and had
caused a severe vapour block in BFP with the higher feed water
temperature between 158
0
C to 131
0
C at booster pump suction
pressure of 3.4 KSC to 1.8 KSC (Deaerator pressure 2 KSC to 0.866
KSC).
3) While starting BFP 7C the water temperature had come down to
118
0
C and booster pump suction pressure also found to be 2.268 KSC,
which saved the pump from damage.




385
4.10.7 Non availability of BP2 in Unit 4
( from 14-11-1997 to 06-09-1998)
Initially there was bottom flange leak in BP2 valve and also passing in
the valve due to which d/s temperature rise was there. Spray valve BPE2
was opened frequently to quench the HP B/P downstream temperature to
avoid the trip closing of BP valves. As the frequency of opening of BPE2 was
more due to heavy passing in BP2, BP2 was kept 2% open permanently to
avoid the d/s temperature rise.
During the s/d period, on inspection, it was observed that there was a
crack in the valve on the down streamside. While grinding and clearing this
crack, another crack was observed on the main body of the valve. Also
spray nozzle was found broken. It was decided to dummy this valve and
valve plug was welded with the valve seat area and a support was
provided for the bottom. Similarly CRH side was welded with a dummy
plate.
As only one HP B/P valve namely BP1 was available for service, unit
maximum load was restricted to 180 MW, till the problem was attended. BP2
& BPE2 controls were defeated at local and cables were disconnected at
local. Also the protection was modified to trip the Boiler immediately
whenever turbine tripped.

4.10.8 BFP 6A Dry Run On 04 - 01-1993:
o Unit came to house load operation. Boiler was hand tripped
subsequently. Total grid failed.
o All BFPs were latched, isolated and drained due to non-availability of
ALOPs.
o While resuming 6.6 KV bus power supply BFP 6A started on its own.
BFP 6A could not be stopped from UCB desk. It was stopped at
annex.

386
4.10.9 Condenser Tube Puncture In Unit VII :
1. After synchronizing the Unit-VII on 05/10/2004 @ 01:53 hrs. Silica value
was found to have increased in condensate & FW (condensate 0.1
FW 0.1).
2. Initially Ejector air vents kept opened & subsequently CBD 6 turns kept
opened when MS pressure was 150 KSC.
3. As the value was not coming down on 06/10/2004, LPH WB air vent
was opened in addition.
4. On 07/10/2004, HPH 5 shell drain was also opened.
5. But there was no improvement in condensate & FW silica values but
silica value came down to 0.024 (Earlier it was 0.068) in superheated
steam due to heavy blow down.
6. On 10/10/2004, Unit was hand tripped @ 12:12 hours to attend SH2 coil
puncture.
7. On 12/10/2004, Condenser was jacked and filled up to neck. One of
the condenser tubes at A side Outlet found punctured. The same
was plugged.
4.10.10 HIGH CONDUCTIVITY IN DM WATER

On 09/07/2001 due to high conductivity in DM water all the CSTs were
drained & filled.
387
TURBINE
STAGE II
OPERATION MANUAL












CHAPTER V


MODIFICATIONS.






388

CHAPTER - V
Modifications Carried Out After Commissioning
In Stage-II Turbines:
26-05-1993
1. For running BFP the suction pressure very low Trip protection will act
after a time delay of 2 seconds.
05-07-1994
2. Gate valve gearing valve operation was made inching type. It was
done to regulate the STG speed.
05-07-1994
3. Drain cooler, Drain condensate bypass line was provided to avoid
bypassing of LP heater 1 on level very high contacts at low loads.
27-09-1994
4. In EHC DN/DT will act at 2800 rpm instead of 2850 rpm.
19-09-1995
5. BFP C C2 breaker will close after a time delay of 2 Seconds from the
time of giving start command.
21-08-1995
6. CWP motor winding temperature very high protection was bypassed.
23-01-1996
7. EHC cutout valves can be operated from control desk also.
06-02-1996
8. Standby CWPs discharge valve power supply is available from Unit
Bus.
14-08-1996
9. Turbine oil purification system trouble alarm window was
commissioned. Annunciation will appear when the main motor
tripped or power supply is switched off.
17-08-1996
10. Load restriction on Condenser vacuum is set at 665mmHg.
389
30-08-1996
11. On drum level very high contact all BFP scoops will come to minimum
in both auto and manual mode.
07-08-1997
12. In EHC UNLOADING of turbine will start at a frequency of 50.8 Hz and
Turbine will unload fully at 55 Hz.
16-04-1998
13. MOT level monitoring fault ann. was commissioned. The alarm will
come if any of the MOT level switch is fault.
21-05-1998
14. TSE influence will get switched OFF at 150 MW during load rising, and
gets switched ON at 120 MW while load reduction.
25-06-1998
15. Whenever scoop/FCV come to forced manual, BFP scoop control
forced manual alarm will come.
17-10-1998
16. HP B/P atmospheric drains were provided.
26-12-1998
17. OLTCS independent stream of operation was commissioned.
17-02-1999 CTP 6C; 13-01-2000 CTP 6B
18. Two numbers of Additional CT Pumps with a capacity of 200 t/hr and
total head of 55 m were commissioned.
17-03-1999
19. DM water make-up line at 27 ML between Unit 5 and Unit 6 was
interconnected.
07-01-2000
20. JOP will come into service whenever Lub oil Pressure very low
protection acts.



390
Oct - 2000
21. DCEOP will come into service even if SLC DCEOP is in OFF mode when
i. HP Outer casing middle top/bottom 50% temperature is
> 120*C and Lub oil press < 1.1 ksc.
22. MOT duplex filter bypass valve was commissioned.
Unit-4: One number of hand-operated ball valve is available.
Unit-5: 24 V DC Solenoid valve is available Whenever Lub oil
pressure downstream of duplex filter drops to 1.5 ksc SOV will
open on Auto. CLOSE command is to be given manually
from desk.
Oct - 2000
Unit-6: Two numbers of hand-operated ball valves are available
Unit-7: One number of hand-operated ball valve is available.
Oct - 2000
23. When Unit is in service (contact is from trip oil pressure very low) pilot
ejector air valve can be opened only after opening the pilot ejector
steam valve.
02-05-2001
24. HPH FW inlet and outlet valves can be closed only if its B/P valve is in
open condition.
04-09-2001
25. Hot well level low alarm on LVM contact is set to act at 655 mm Wcl.
04-09-2001
26. Hot well level high alarm on LVM contact is set to act at 855 mm Wcl.
01-10-2001
27. In HP bypass, the downstream lines from BP to CRH were replaced
with alloy steel pipes P11.
01-10 - 2001
28. Turbine bearing metal temperature indicator was provided in the UCB
desk.

391
06-10-2001
29. GSC exhauster tripped window ann. was commissioned. Alarm will
appear when both GSEF are not in service.
14-02-2002
30. For EHC monitoring Group No.287 was earmarked with the following
analog points in IS.
A 162 Speed controller output. (Over speed).
A 151 EHC Collins feed back.
A 152 Speed set point time delayed n
RTD.

A 153 Speed controller output.
A 154 Speed set point. NR.
A 155 Pressure set point. P ref.
A 156 Pressure actual. Pact.
A 157 Pressure controller output. hrpc.
A 158 Load set point. P ref.
A 159 Sigma Pr.
A 160 Starting device position feed back.
A 161 Load controller out put. hrlc.
A 163 Load reference absolute limiter.

14-02-2002
31. For EHC monitoring Group No.94 was earmarked with the following
digital points in IS.
D 796 Speed set point. nr < 2700 RPM.
D 797 Speed set point. nr < 2800 RPM.
D 798 Speed set point. nrtd < 2700 RPM.
D 799 Speed set point. nrtd < 2800 RPM.
D 800 Load control active.
D 801 Isolated grid in action.
D 802 Pressure control active.
D 803 Speed control active.
392
D 804 hr > 0%.
D 805 Followup < 120 RPM, > 15 RPM.
D 806 Followup > 15 RPM.
D 811 Generator breaker (EHC) ON.
D 812 SC active through MIN.
D 813 SC active through MAX.
07-03-2002
32. HP bypass trip open on LSR operated contact was bypassed.
28-03-2002
33. In BFPs the following protections will act a time delay of 15 seconds.
i. Working oil temperature very high (>130*C).
ii. Feed water suction & discharge DT very high (>10*C).
07-03-2002
34. HP B/P Trip open on Load shedding relay operated was bypassed.
08-04-2002
35. BFP suction pressure indicator in UCB will read its Booster pump
discharge pressure.
24-05-2002
36. HPHs GPV open, HPHs GPV closed & HPHs bypassed anns. were
commissioned.
18-07-2002
37. CD 64 & CD 66 can be closed from UCB desk defeating the CD 64
& CD 66 protection open, by giving reset command at desk to the
deaerator normal level controller.
01-09- 2002
38. Vacuum Breaker Valve: Open indication is from Limit Switch and
close indication is from breaker.
07-10-2002
39. CWP 5C & CWP 6C discharge valves to Unit 6 latches were
provided in UCB.

393
24-10- 2002
40. CTP 6C supply source is now available from Unit 7 Annex Unit-7
ACDB MCC P 8E.
20-06-2003
41. CEPs & CWPs motor winding temperature high alarm setting was
changed to 105C from 95C.
01-08-2003
42. Free governing mode was commissioned in Boiler Follow mode. A
push button was provided near TSE indicator to switch on / off
frequency influence.
27-08-2003
43. Free governing mode was commissioned in CMC mode.
01-09-2003
44. MOT inspection door height above MOT top floor was raised to
prevent water entry during MOT mulsifier system operation.
01-10-2003
45. For BFPs minimum scope additional permissive was given.
25-11-2003
46. MS temperature before HP bypass (R) was given in IS. A 60.
20-01-2005
47. Deaerator / Hotwell level controller forced manual alarm was
commissioned.
11-03-2005
48. HP B/P OSU A/B cubicle fault alarm was included in the window ann.
2.05 C2 (HP B/P malfunctioning).
HP B/P OSU A/B cubicle fault alarm will come for the following
conditions.
i. Oil pressure too low.
ii. Oil pressure too high.
iii. Switch gear fault.
iv. Switch gear trouble.
394
v. Motor running time too long.
vi. On applying local latch.
18-08-2005
49. BFP start command was used to open motor cooling water valve and
to close warm up valve.
18-08-2005
50. Deaerator pressure tracking set point difference of 1 KSC with the
actual pressure was reduced to 0.5 KSC for the fast action of PCVs.
01-09-2005
51. Continuous drain line with an orifice of dia 4mm bypassing the DR 119
drain valve was introduced.
24-09-2005
52. Restriction imposed to prohibit auto starting of BFP 6A with BFP 6C
running in 6.6 KV A Bus & BFP 6B with BFP 6C running in 6.6 KV B Bus
was removed.
53. MS/HRH temperature high alarm was given on Turbine Annunciation
window in addition to the boiler side alarm indication.
54. Turbine Digital speed indicator was provided.
55. A/C plant Cooling Tower make up water is taken from the Service
water booster pump located at Unit 2.
56. Compressor ACW buses were interconnected between Unit 6 & Unit 7.
57. Additional line is provided from CT Pump discharge header for ESP
water washing during Major overhaul.
58. BFP inter-stage tap off line is used for AST PRDS attemperation.
59. In HPHs, the Normal and High-level controllers were isolated. Level
transmitter signal is used for Control purpose.



Note: The date of modification is with respect to Unit 6.


395
TURBINE
STAGE II
OPERATION MANUAL












CHAPTER VI


LIST OF DRAWINGS.






396
CHAPTER VI LIST OF DRAWINGS

Fig. 1 Thermal cycle diagram.
Fig. 2 Heat balance diagram.
Fig. 2a Heat balance diagram.
Fig. 3 Steam Turbine Sectional arrangement.
Fig. 4 Turbine fixed points.
Fig. 5 HP Turbine casing.
Fig. 6 Longitudinal section of HPT Front bearing pedestal.
Fig. 7 Longitudinal section of HPT Rear bearing pedestal.
Fig. 8 Combined Journal and Thrust bearing.
Fig. 9 IP Turbine Longitudinal section.
Fig.10 IP Turbine rear bearing pedestal.
Fig. 11 LP Turbine casing.
Fig. 12 LP Cylinder Blades of last three stages.
Fig. 13 LP Turbine rear bearing pedestal.
Fig. 14 Hydraulic Turning Gear & Manual Barring Gear.
Fig. 15 Oil supply system.
Fig. 16 Main oil tank.
Fig. 17 Auxiliary oil pump.
Fig. 18 Jacking oil pump.
Fig. 19 D. C. Emergency oil pump.
Fig. 20 Main oil pump with Hydraulic speed transmitter.
Fig. 21 Turbine Lub oil cooler.
Fig. 22 Three way temperature control valve for lub oil.
Fig. 23 Main stop and control valve.
Fig. 24 Combined reheat stop and control valve.
Fig. 24.1 Serovomotor for main stop valves and reheat stop valves.
Fig. 25 HP Control valve Servomotor.
Fig. 26 IP Control valve Servomotor.
Fig. 27 Combined LP B/P stop and control valve.
397
Fig. 28 Feed back for pilot valve of LP B/P Control valve.
Fig. 29 Pilot valve of LP B/P Control valve.
Fig. 30 Pilot valve of LP B/P Stop valve.
Fig. 31 LP B/P Water injection valve.
Fig. 32 HP B/P System Oil supply unit.
Fig. 33 HP B/P System Electro hydraulic servo system.
Fig. 34 Sectional view of BP valve.
Fig. 35 Sectional view of BD and BPE valve.
Fig. 36 Main trip valve.
Fig. 37 Solenoid valve for remote operation of Main Trip valve.
Fig. 38 Arrangement of over speed trip in turbine rotor.
Fig. 39 over speed trip device.
Fig. 40 Thrust bearing trip device.
Fig. 41 Low vacuum trip device.
Fig. 42 Low vacuum condenser protection for LP B/P.
Fig. 43 Pressure switch for injection water (LP B/P).
Fig. 44 Boiler feed pump assembly.
Fig. 45 Booster pump assembly.
Fig. 46 Condensate Extraction pump
Fig. 47 Circulating water pump
Fig. 48 Main ejector.
Fig. 49 Starting ejector.
Fig. 50 Gland steam condenser.
Fig. 51 Drain cooler.
Fig. 52 LP Heater 1, 2 & 3.
Fig. 53 HP Heater 5 & 6.
Fig. 54 Natural draught cooling tower.
Fig. 55 HP B/P oil system.
Fig. 56 Torque motor.
Fig. 57 Servo valve.
Fig. 58 Blocking unit.
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Fig. 59 Console insert of HP B/P System.
Fig. 60 EHC.
Fig. 61 Structure of EHC.
Fig. 62 Frequency control (Droop) Unit.
Fig. 63 Selection circuit.
Fig. 64 Load rejection relay.
Fig. 65 Isolated grid condition.
Fig. 66 Display instrument of TSE.
Fig. 67 Permissible thermal stress level (TSE).
Fig. 68 Upper and Lower margin of TSE.
Fig. 69 A load cycle produced by temperature change.
Fig. 70 TSE Basic System Diagram 5 Channel (2A/3T).
Fig. 71 Inductive transducers.
Fig. 72 Schematic set up for valve position, HPCE / IPCE.
Fig. 73 Measuring disk for HPDE / IPDE, Measuring double cone for LPDE.
Fig. 74 Hall effect.
Fig. 75 Schematic diagram of absolute vibration measurement by
means of a permanently dynamic plunger coil system (seismic
device).
Fig. 76 Electrical speed pick up : Halls probe.
Fig. 77 Non contact pick up operation.
Fig. 78 Thermo couple.
Fig. 79 Electro hydraulic actuator for Seal steam control valve
(MAW 10 & MAW 50).
Fig. 80 Jacking oil system.
Fig. 81 Stribeck curve.
Fig. 82 Lubrication of a plain journal bearing.
Fig. 83 Spring element (Condenser).
Fig. 84 End tube plates.
Fig. 85 Tube expansion joints.
Fig. 86 Steam dumping device.
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Fig. 87 Centrifuge purification process.
Fig. 88 Centrifuge flow diagram.
Fig. 89 Condenser and its connections (East side).
Fig. 90 Condenser and its connections (West side).
Fig. 91 Condenser and its connections (UCB side).
Fig. 92 Condenser and its connections (Switch yard side).
Fig. 93 HP B/P System.
Fig. 94 Deaerator.
Fig. 95 Deaerator and its connections (View from Turbine Hall).
Fig. 96 Deaerator and its connections (View from Boiler Hall).
Fig. 97 Make up water system.
Fig. 98 BFP Hydro coupling unit.
Fig. 99 Circulating water pump - Cooling water arrangement.
Fig. 100 Fire protection system.
Fig. 101 Deluge valve assembly.
Fig. 102 Fire alarm panel.
Fig. 103 Plant water system 1.
Fig. 104 Plant water system 2.
Fig. 105 A/C Plant Freon flow scheme.
Fig. 106 A/C Plant Circulating water scheme.

Fig. A Turbine Governing Scheme.
Fig. A.1 Legend - Turbine Governing Scheme.
Fig. B Adjustment of Governing System. (Sheet 1 of 2)
Fig. C Adjustment of Governing System. (Sheet 2 of 2)
Fig. D Adjustment of LP Bypass Converter.
Fig. E P & I Diagram Steam
Fig. F P & I Diagram Condensate & Feed water

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