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Turbine Cycle
500 MW Turbine is a 3 stage KWU turbine. The salient constructional features
of H.P.T, I.P.T. and L.P.T. are:
H.P. Turbine:
The Turbine consists of single flow Cylinder with barrel type casing. Initial
steam is admitted by 4 main steam Stop and Control valves. In this machine, the
stop valve and control valve are combined and has single body. The exhaust steam
lines, two in numbers, are connected to Reheater and Swing check valves are
provided on these lines to prevent Reheat Steam entry in to the H.P. Casing.
The outer casing is barrel type and has neither axial nor radial flange.
Absence of flanges reduces the mass and high thermal stresses. Due to the perfect
rotational symmetry, the wall thickness is uniform at all sections. The guide blade
carrier is axially split and kinematically supported. In H.P. Turbine, Main steam is
admitted in to the inner casing i.e. guide blade carrier, and it expands on the
number of moving and fixed blades. Exhaust steam is taken to boiler for reheating.
Arrangements are made in the steam supply line to let a part of steam to enter the
outer casing (barrel casing). To prevent leakage of this steam to exhaust, seals are
provided. U shaped seals are also provided to prevent leakage through shaft seals.
There are 2 locations from where Cylinder drains are taken out. This being reaction
turbine, the pressure drop takes place across the moving blades. To avoid inter stage
leakage, due to the difference in pressure between successive blade stages, suitable
sealing is provided. The HPT shaft is provided with balancing dummy piston at inlet
end to balance the thrust. Shaft seals are provided to seal the interior of the turbine
casing against the inrush of ambient air through passage around the shaft at
admission and exhaust side. Main oil pump is coupled to the turbine shaft through
geared coupling.
I.P. Turbine:
I.P. Turbine is of double flow construction. Attached in the axially split casing
is an inner casing supported kinematically, on which fixed blades are fitted. Reheat
steam is admitted to the inner casing from Top and Bottom center of the casing.
Exhaust steam, from inner casing enters in to the outter casing, thus subjecting the
joint of the outter casing to low pressure, low temperature steam.
L. P. Turbine:
The casing is double flow and is of three-shell construction. Shells are axially
split. The inner shell, taking the first rows of guide (i.e. fixed) blades, is attached
kinematically in the middle shell. Middle shell is independent of the outter shell and
is supported on four points no longitudinal beams. Two last rows of the guide blades
are fitted to the middle shell. Atmospheric relief diaphragms, 2 in numbers, are
provided on the casing. In the eventuality of Condenser getting pressurized due to
the failure of evacuation system or failure of Condenser cooling water system, the
diaphragms rupture and steam is released in to atmosphere and thus depressurizes
the condenser. LPT exhaust hood is directly placed on the condenser flanges and
continuously welded to form leak proof joint.
Blading:
The entire turbine is provided with Reaction blading. The guide and rotating
blades of H.P, I. P. and first row of L. P. Turbine, with inverted T roots and shrouding
are milled from one piece. Last stages of L.P. Turbine rotating blades are of twisted
and drop forged construction, and the fixed blades are made of Sheet steel.
Barring Gear:
Turbine is provided with Hydraulic Barring Gear. It consists of the hydraulic
turbine wheel mounted on the shaft between IPT real bearing and LPT. The wheel is
driven with the help of Lubricating oil obtained from A. C. Auxiliary oil pump. This oil
passes via a check valve in to nozzle box and then in to the nozzles. The jet of oil
emerging from the nozzle impacts on the blades thus rotating the shaft at speed
between 90 to 120 rpm. This Oil, after passing over blades, drain in to the bearing
pedestal, from where it returns to M. O. T. In case of non availability of the hydraulic
barring gear, mechanical barring of the turbine can be carried out manually.
Boiler Feed Pump:
There are 4 Nos. of B.F.P’s, 2 of which are Motor driven and 2 Turbine Driven.
MD BFP motor’s rated voltage is 11 KV and it is fed from 11KV station board. For full
load operation, two BFPs are in service. BFP is a 4 stage pump, has integral tapping
for Reheat spray and additional kicker stage, which is the last stage, for very high
pressure Superheat spray water. The pump is of horizontal, barrel type construction.
HPH 5A HPH 6A
HPH 5B HPH 6B
Heater Bypass
valve
(Motor operated)
All feed water heaters are horizontal. HP Heater drip is diverted to Deaerator
in normal operation, in abnormal conditions drip can also be diverted to condenser
flash tank, where as drip of LP Heater is always diverted to Condenser flash tank.
There is no drip pump. HP Heaters are taken in to service when Load is 150 MW and
above. LP Heaters are taken in to service on low loads also. All extraction lines from
Turbine extractions are provided with Hydraulic Swing Check valves. These valves
are hydraulically operated and governing system of the turbines controls the
operation of these valves. The FRF oil is used as hydraulic fluid for actuators of these
valves. In addition, motor operated extraction valves are also provided. There is no
tripping of turbine on Heater level.
Heaters operating data:
Parameter HPH 6 HPH 5 Deaerator LPH 3 LPH 2 LPH 1
Extraction Steam pressure Kg/ cm² 42.7 19.14 6.97 2.59 1.32 0.27
Extraction steam temperature, °C 340.5 430 301 196 137 68
Drain temperature, °C 214 171 163 109 68 66
Steam flow to Heater, T/ H 141 99.2 78.8 44.6 80.8 38.4