Turbine

 Steam Turbine is a prime mover in which,

 Potential energy of steam is converted into

kinetic energy and

 That kinetic energy is converted to

mechanical energy of the rotating shaft

 Rotating shaft energy is further converted to

electrical energy in generator

 How does the steam turbine work

• Impulse stage –
whole pressure drop
in nozzle (whole
enthalpy drop is
changed into kinetic
energy in the
nozzle)

• Reaction stage –
pressure drop both
in stationary blades
and in rotary blades
(enthalpy drop
changed into kinetic
energy both in
stationary blades
and in the moving
blades in rotor)
Classification of steam turbines

a) Way of energy conversion

o Impulse turbine
o Reaction turbine
o Impulse reaction

b) Steam flow direction

o Axial flow
o Radial flow

c) Number of stages
o Single stage
o Multi stage
d) Inlet steam pressure
o High pressure
o Intermediate pressure
o Low pressure

e) Exhaust condition
o Condensing
o Extraction
o Back-pressure
f) Application
o Power station
o Industrial
o Marine
GVK POWER (GS) TURBINE IS

270 MW turbine installed is

 condensing-tandom-compound,
 Three cylinder(HP,IP&LP)
 Reheat type with throttle governing and
Regenerative system of feed water heating and is
Coupled directly with Generator.
 TECHANICAL DATA SHEET

TYPE
Three cylinder,
reheat, condensing
turbine
Stages
H.P 23 nos. of reaction stages
I.P. 16 nos. of reaction stages
L.P. 8 x2 nos. of reaction stages
Rated load 270 MW
Rated speed 3000 RPM
Inlet pressure 147.1 bar
Inlet temperature 537 ºC
No of extraction
points
COMPONENTS OF TURBINE
 Casing
 Rotor
 Blades
 Sealing glands
 Coupling
 Bearing
 Emergency stop and control valve
 Barring gear
CASING

 Outer most shell of turbine

 Fixed blades and nozzles are attached.
 It facilitates to accommodate moving parts
and provide passage for steam.

MATERIAL OF CONSTRUCTION
HP&IP - GS17CrMoV511
LP - ST42W
HP CASING
Barrel type casing permits flexibility of operation
in the form of short start-up times and a high rate
of change of load even at high initial steam
conditions.
Axially split inner casing
IP CASING
The casing of the IP turbine is split horizontally and is of
double-shell construction. Steam from the HP turbine after
reheating enters the inner casing from top and bottom
through two inlet connections at front section of the outer
casing.
LP CASING
LP turbine casing consists of a double flow unit and has a
triple shell welded casing .
HP TURBINE
IP TURBINE
LP TURBINE
CROSS SECTONAL ARRANGEMENT

1. hydraulic turning
motor 8. Combine Journal & Thrust bearing 14. LP outer casing
2. Front bearing pedestal 9 . IP outer casing 15. LP inner outer casing
3. HP front journal 10 IP Inner casing 16. LP inner inner casing
bearing 11. IP Rotor 17. LP Rotor
4. HP outer casing 12. IP LP Pedestal 18. LP Diffuser
5. HP inner casing 13. IP rear journal bearing 19. LP shaft seal
6. HP Rotor 20. LP Generator pedestal
7. HP IP pedestal 21. LP rear journal bearing
STEAM FLOW CIRCUIT
FROM BOILER TO TURBINE

ESV1
CRH
HPCV1

IPCV1

HPT IPT LPT

BOILER
IPCV2

HPCV2
ESV2

W
W
CONDENSER
HRH - R

.
ROTOR
Moving part of the steam turbine which extracts work from
the steam. It consist of
 Shaft :- A solid body to withstand at high inlet steam
pressure and temperature.
 Moving blade:-Mounted on the shaft and fitted with it.
 Inner stage seal labyrinth

MATERIAL OF CONSTRUCTION
HP - 28CrMoNiV59
IP - 30CrMoNiV511
LP - 26NiCrMoV145
BLADE
Blades fitted in the stationary part are called

stationary blades or nozzles.

Those fitted in the rotating part are called
moving blades.

MATERIAL OF CONSTRUCTION
MOVING/FIXED
HP - X22CrMoV121
IP - X22CrMoV121
LP – X20Cr13
 Gland Steam inlet Gland
steam Casing steam

Sealing

Moving blade Fixed blade

 SEALING GLAND
possibility of steam leakage to atmosphere from the inlet and
exhaust ends of the cylinder.

labyrinth glands of the radial clearance type are provided

which provide a trouble free frictionless sealing.
COUPLINGS
Shaft coupling are needed between various
stages of rotor and generator set. Coupling
should.
Transmit torque.
Allow angular misalignment.
Transmit axial thrust.

Rigid shaft coupling is used for joining of HP,

IP, LP & GENERATOR shaft.
Simpler in design
BEARING

It is kind of mechanical structure which support the shaft or

any rotating part of machine.

REQUIREMENT
Support the shaft ends at front and rear pedestal.

 JOURNAL BEARING are provided to support the rotor.

 THRUST BEARING are provided to take care of axial shift

of the rotor
JOURNAL BEARING
 It is a cylinder which support the rotor and is filled with fluid
lubricant.
Consist of outer shell hard material and inner shell soft
material at cylinder part.
Take radial load of shaft

WORK ON THE FLUID DYNAMIC PRINCIPLE

Hydrodynamic lubrication that the load-carrying surfaces of
the bearing are separated by a relatively thin film of lubricant,
so as to prevent metal to metal contact,
JOURNAL BEARING LUBRICATION

Shaft at Rest Rotation Starts

Thin Pad of Oil Formed Oil Wedge Supports the Shaft

 DIAGRAM

Advantages
 Reduction in the length of rotor.
 Easy alignment of shafts.
Lesser bearing loss.
Define critical speeds.
Lower requirement of lubricants.
Reduce chances of fire.
THRUST BEARING
 function is to take the residual axial thrust.
 The thrust bearing maintains desired axial

clearances for the combined turbine generator

shaft system.
 The magnitude and direction of axial thrust to

be carried by the bearing depends on the load

conditions of the turbine.
 This bearing is located in the bearing pedestal

between HPT & IPT.

 DIAGRAM OF THRUST BEARING

Base Ring
Thrust pad
Arrangement of journal and thrust bearing

Journal
bearing

Thrust
bearing

HP IP LP GENERATOR

Combine journal and thrust

bearing
EMERGENCY STOP VALVE

Turbine is equipped with emergency stop valves to

cut off steam supply .
Emergency stop valves are actuated by servomotor
controlled by the protection system.
ESV remains either fully open or fully close.
Emergency stop valves (ESV) are provided in the
main steam line and Interceptor valves (IV) are
provided in the hot reheat line.
CONTROL VALVE

Control valves regulate steam supply.

Control valves are actuated by the
governing system through servomotors to

regulate steam supply as required by the

load.
BARRING GEAR
Main objective
 When the turbine is stopped after running the steam being

more dense and tries to collect in the lower half of cylinder.

This causes the lower half of rotor to cool more quickly
than upper half CAUSE HOGGING of turbine
 Turbine is started for operation, steam is supplied in gland

for creating vacuum in turbine .if rotor is not moved causes

uneven heating of rotor
 Slowly turning the journals and forcing oil into bearing

damage to bearing can avoided due to heat conduct along

shaft
 HYDRAULIC TURNING GEAR
 It is situated at end of HP turbine.

MANUAL BARRING GEAR

 The turbine generator is equipped with a
mechanical barring gear which enables the shaft
to rotate manually in the event of failure of
normal hydraulic turning gear.
 It is located in between IP and LP pedestal.
 ARRANGEMENT OF BARRING GEAR

Turning gear Mechanical

barring gear

MOP HP IP LP GENERATOR
TURBINE AUXILIARIES
TURBINE AUXILIARIES

 LUBE OIL SYSTEM

 CONDENSATE SYSTEM
 AUXILIARY STEAM SYSTEM
 VACCUM SYSTEM
Turbine Lube Oil System

 Purpose of lubrication system.

 Components of lubrication system.
 Lube Oil circuit
 Specification of oil
Importance of the lubrication system
 To reduce the wear and tear of the rotating elements.
 To maintain the temperature of the bearings.

Purpose of Turbine oil system

Lubrication of turbine.
Cooling of bearings
Sealing medium in Hydrogen cooling system
Turbine barring gear operation.
Working fluid in Governing system
Lubrication system components
 Main oil Pump.
Auxiliary oil pump
Emergency oil pump
Jack oil pump
Main Oil Tank
Oil coolers
Oil Filters
Oil Injectors
Centrifuge
Vapour Extractor
 JACKING
OIL DC DC VEF-
AOP LOP AC JOP
FILTER EOP JOP 1,2O

DMCW IN LUBE
OIL
COOLE MAIN OIL
R
LUBE
OIL
DMCW TANK
FILTER OUT

DMCW
OUT

GENERATOR
AIR
HP IP LP
CO
MOP EXCITER
OL
ER

DMCW
IN

1.LOP- LUBE OIL PUMP- ABOVE MOT

2.AOP-AUX. OIL PUMP

LUBE OIL CIRCUIT 3.EOP- EMG. OIL PUMP

4.JOP-JAKING OIL PUMP
5.OVEF- OIL VAPOUR EXT. FAN
6.MOP- MAIN OIL PUMP- HP REAR
SIDE
 Lubrication Oil Circuit
MOP

HPT IPT LPT Gen

Injector

Vap. Ext
Filter

MOT
Oil cooler
AOP EOP
JOP
 SPECIFICATION OF MAIN OIL TANK

Main oil tank, rated capacity 20/32 m3

Highest oil level from top of tank ( at 800 mm

rated speed)
Lowest oil level from top of tank ( at 850 mm
rated speed)
Specifications of Oil:

 Specific Gravity 0.852 @ 50 0C

Viscosity indes 98 min
 Kinematic Viscosity 28 cs
Colour <2
Flash point 200 0C (Min)
Pour Point - 6.6 0C (Max)
Mechanical Impurities Nil

•The recommended turbine oil Servo prime-46 of IOC.

MAIN OIL PUMP(MOP)
 LOCATION: This pump is mounted in the front bearing
pedestal. It is coupled with turbine rotor through a gear
coupling.
 Oil suction from MOT Through two number of injectors

connected in series.
 Takes over when turbine speed > 2800 rpm.
 Supplies oil for turbine bearing lubrication as well as for

the turbine governing system. .

AUXILIARY OIL PUMPS(AOPS)

 Two in number, AC motor driven

 Supplies oil during turbo-set starting and stopping when

the turbine is running at speed lower than 2800 rpm

supplies oil to governing system as well as to the
lubrication system.
 Submerged pump body
EMERGENCY OIL PUMP(EOP)

 D.C. pump driven by electric motor.

 Vertical and submerged in main oil tank.

This automatically cuts in when ever there is failure of

A.C. supply at power station and or the lube oil pressure
falls below a certain value.
JACKING OIL PUMPS(JOPS)
 JOP1 & JOP2
 One pumps is AC driven and one of the JOP is DC driven .
 To lift the rotor assembly during TG start up and shut

down.
 Suction from MOT.
 delivers pressure for lifting of rotor.
OIL COOLERS
 To cool the lubricating oil
 Consists of tube nest, inner & outer shell & water boxes
 The cooling medium for these coolers is circulating
water.
 The pressure of the cooling water is kept lower than that
of oil to avoid its mixing with oil in the event of tube
rupture.
 OIL TEMP. CONTROLLER for maintaining the lube oil
temp at rated value by controlling the flow through the
coolers.
VAPOUR EXTRACTION SYSTEM

 Two Vapour Extractor fans.

 Maintains negative pressure inside MOT
 Removes oil fumes from the MOT.

OIL FILTER
 Basket type filter inside the oil tank
 Duplex filter
 Filter changeover required after choking.
Main Oil Centrifuge

 Required for removing moisture from the turbine oil.

 A portion of oil is continuously circulated through the

centrifuge to remove the moisture from the oil.
CONDENSATE SYSTEM
 The steam after condensing in the condenser
known as condensate, is extracted out of the
condenser hot well by condensate pump and taken
to the deaerator through drain cooler and series of
LP heaters.
RECOMNDED VALVE FOR MAIN
STEAM CONDENSATE
QUANTITY NORMAL
OPERATION
CONDUCTIVITY μS/cm 0.1

SILICA (SiO2) mg/kg 0.005

IRON (Fe) mg/kg 0.005

COPPER (Cu) mg/kg 0.001

SODIUM (Na) mg/kg 0.002

Line diagram of condensate water system

HOTWELL

CEP
DRAIN
GSC LP HEATER1
COOLER

DEAERATO
LP HEATER2 LP HEATER3
R
CONDENSATE EXTRACTION
PUMP
 The function of these pumps is to pumps out the
condensate to the deaerator through Gsc,Drain cooler,
and L.P. heaters.
 Suction is at a negative pressure, special arrangements

have been made for providing sealing.

QUANTITY 2 × 100%
HEAD 215 MTR
CAPACITY 800 m³/hr
SPEED 1485 rpm
GLAND STEAM CONDENSER (GSC)
 Gland Sealing is provided in the turbine shaft front
and rear end from leakage of steam.
 Gland steam is condensed in the GSC.

DRAIN COOLER
 It is a feed water heater in which is cascade between
LP heater#1 and condenser.
 Differential pressure between LP heater#1 and
condenser is very small , to utilize to heat energy from
steam and increase the efficiency of cycle.
LOW PRESSURE HEATER
• A heater located between the condensate pump and
Deaerator. It normally extracts steam from the low
pressure turbine.
• The function of feed water heaters is to raise the
temperature of the feed water by means of bled steam
before the feed water is supplied to the Deaerator from
the hot well.
DATA SHEET
LP FEED HEATER 1 2 3

1 TYPE SHELL & TUBE SHELL & TUBE SHELL & TUBE

ORIENTATION HORIZONTAL HORIZONTAL HORIZONTAL

DRAIN COOLING ZONE NO YES NO

SHELL DESIGN
2 PRESSURE 3 3 3
SHELL DESIGN
TEMPERATURE 150 150 210
TUBE DESIGN
PRESSURE 3 3
TUBE DESIGN
TEMPERATURE 150 150 150
AMOUNT OF HEAT 14.26 X10⁶ 14.64 *X10⁶ 18.27 X 10⁶
3 EXCHANGED KCAL/M˚ KCAL/HR KCAL/HR
DIAGRAM OF LOW PRESSURE HEATER

Feed
Steam
water
in
outlet

Feed
water
inlet
Condensate
REGENERATIVE CYCLE

Preheats steam entering boiler using a feed water heater, improving

efficiency
Also deaerates the fluid and reduces large volume flow rates at turbine exit.
DEAERATOR
The presence of certain gases, principally oxygen, and carbon-
di-oxide dissolved in water is generally considered harmful
because of their corrosive attack on metals, particularly at
elevated temperatures.

Principle of Deaeration:
The principle of deaeration is based on following two laws.
· Henrys law: The mass of gas with definite mass of liquid will
dissolve at a given temperature and is directly proportional to the
partial pressure of the gas in contact with the liquid. This holds
within close limits for any gas, which does not unite chemically
with the solvent.
· Solubility Law: Solubility of gases decreases with increase m
solution temperature and/or decrease in pressure.
DATA SHEET
DESCRIPTION
MANUFACURER BHEL

GURANTEED OXYGEN
CONTENT AT OUT LET 0.005 CC/LTR
NO OF TRAY ASSEMBLES 280

STORAGE TANK CAPACITY 165 m³

NO OF SPRAY VALVES 52
TEST PRESSURE 11.05 kg/cm²
DIAGRAM OF DEAERATOR
WATER FROM
CEP
BAFFLE PLATES
DEAERATOR DISCHARGE

STEAM
INLET

STORAGE
TANK

TO BOILER FEED
PUMP
HIGH PRESSURE HEATER
• A heater located between the Deaerator and Boiler. It
normally extracts steam from the Intermediate pressure
turbine.
• The function of feed water heaters is to raise the
temperature of the feed water by means of bled steam
before the feed water is supplied to the Boiler from the
Deaerator.
LINE DIAGRAM AUXILIARY STEAM SYSTEM

Auxiliary
steam header

fuel oil
Boiler Turbine
system

HFO
Soot blowing Gland sealing
atomization

Deaerator fuel oil

SCAPH
pegging heating

For FOPH
Mill inerting
unloading
 Line Diagram of auxiliary steam
MAIN STEAM LINE
Auxiliary
Steam
header

TCV
PRV CEP

TCV

High Temperature Unit header” is to

12.5kg/cm2& temp is 320̊C.

Low Temperature Unit header” is to 12.5kg/cm 2& temp

is 220̊C.
 Gland steam system
Steam in

HPT IPT LPT Gen

Steam out To atmosphere

fan

Auxiliary steam header Gland steam

condenser
Turbine Vacuum
System
 Why Vacuum system is required ?
Parts of Vacuum system?
Steam Ejectors

Vacuum Pumps
Why is it required?

 The steam turbine itself is a device to convert

the heat in steam to mechanical power.
 Enthalpy drop across the turbine decides the

work output of the turbine. For increasing this

enthalpy drop across the turbine we need
effective condenser vacuum system.
Parts of Vacuum System
 Condenser
 CW system
 Ejectors/Vacuum pumps
 Gland Sealing System
CONDENSER
 It is a heat exchanger device of tube and shell
arrangement.
Steam from last stage of LPT Exhausts on condenser
tube
 condensation of steam takes place
Water collected in hot well
FUNCTION OF A CONDENSER
• To convert exhaust steam to water so that it can be reused in cycle.
• Minimum undercooling of condensate.
• Minimum pressure drop on steam side.
• Effective removal of non condensable gases carried by steam and air from leakage.
•
Why vacuum is maintained in condenser
 By maintaining a vacuum in the steam condenser, the
efficiency of the steam-power plant can be increased as
greater the vacuum in the system, greater will be the
enthalpy drop of steam. Therefore, more work will be
available per kg of steam condensing.
 non-condensate (air) can be removed from the

condensate-steam circuit by pulling and maintaining a

vacuum in the steam side. Therefore, the condensate
can be used as boiler feed.
SPECIFACTION

Description Data

Manufacture BHEL

Type & No of pass Surface type / 2pass

Cooling water flow 32300m³/hr

Condensing surface area 15468m²

No of tubes 15664

Hotwell capacity 35m³

Shell of the Condenser
 The shell is the outer most body of the condenser
 The shell also gives support to number of intermediate support
plates for the long tubes, depending on the size of the
condenser.

TUBE SHEETS
At each end of the shell, tube sheet of sufficient thickness is
provided, with holes for the tubes to be inserted and rolled
WATER BOXES
 The tube sheet at each end with tube ends rolled, for each end of
the condenser is closed by a fabricated box cover known as a
waterbox, with flanged connection to the tube sheet or condenser
shell. The waterbox is usually provided with man holes on hinged
covers to allow inspection and cleaning.

TUBES
 Tubes are those in which the water will flow from inlet to
outlet Of condenser .
DIAGRAM OF A CONDENSER
TURBINE EXHAUST
STEAM TO CONDENSER
exhaust steam
space for Tube sheets
condensation

Water COOLING WATER

boxes OUT
TO COOLING TOWER

COOLING WATER IN
FRON COOLING
TOWER

HOTWELL
tubes

CONDENSATE
EXTRACTION
PUMP
CW system

CW pumps supply cooling water to condensers

CW maintains vacuum in condensers

CW flows through condensers tubes

VACUUM PUMPS

 The vacuum pump is a specific form of rotary positive-

displacement pump utilizing liquid as the principal
element in gas compression.
 The working parts of the vacuum pump consist of a
impeller mounted in a round casing which is partly
filled with liquid. As the impeller rotates, the liquid is
thrown by centrifugal force to form a liquid ring which
is concentric with the periphery of the casing.
 DIAGRAM OF VACUUM PUMP
Suction port
Discharge port

Casing

Impeller

Gas vapour
mixture Liquid ring
VACUUM PUMP

 Compressing medium, the liquid ring absorbs the

heat generated by compression and friction,
absorbs any liquid slugs or vapor entering with
the gas stream, and condenses water vapor
entering with the gas.
 A closed loop (or total recirculation) seal system is
commonly used. The seal water temperature
warmer than the cooling water to the pump heat
exchanger, which is normally taken from the same
source as the cooling water .
LINE DIAGRAM OF VACUUM PUMP

vent
Non condensible gases and water
vapour from condenser
Separator

Makeup

VP
Cooling
water Seal water
Seal cooler

Liquid ring vacuum pump system

GOVERNING SYSTEM
What is a Governing System

 To govern means to control and regulate certain

parameters to achieve expected results.

Turbine Governing System

Turbine Governing system is meant for regulation of
turbine speed under no load and varying load
condition.
Functions of Governing System

 To control the initial run up and synchronization of the

machine.
 To control the turbine load when running in parallel with
other generating sets.
 To contain the speed rise within acceptable limits in case
of the unit getting disconnected from the load.
TYPES OF GOVERNING SYSTEM

The governing system can be one of the following

types:
 MECHANICAL
 HYDRO-MECHANICAL
 HYDRAULIC
 ELECTRO-HYDRAULIC
MECHANICAL
 In mechanical governing system, speed transducer is mechanical
centrifugal type speed governor, which actuates control valves
through mechanical linkages.

HYDRO-MECHANICAL

In hydro-mechanical governing system , speed

transducer is usually mechanical centrifugal type speed
governor.
It is connected to hydraulic system either hydraulically
or mechanically.
In hydraulic system, signal is amplified so that control
valve servomotors can be actuated.
HYDRAULIC

In hydraulic governing system , speed transducer is a

centrifugal pump , whose discharge pressure is
proportional to square of speed.

This signal is sent to hydraulic converter / transformer

which generates signal proportional to valve opening /
closure required.
 ELECTRO-HYDRAULIC

This system provides very good combination of electrical measuring

& signal processing and hydraulic controls.

SENSING:- To sense speed and power.

PROCESSING:- To evolve the desired valve opening command

signal.

AMPLIFICATION:-Necessary to operate sufficient power to

operate the steam control valve.
ELECTRO HYDRAULIC
GOVERNING SCHEME
 HP & LP
BYPASS SYSTEM
FUNCTION OF HP BYPASS:

 The function of HP bypass is to ensure that the maximum

permissible pressure levels between the turbine and the
boiler are not exceeded and that no abrupt pressure surges
occur during variable pressure operation of the unit.
FUNCTION OF LP BYPASS

The function of LP bypass is to control the pressure in

the reheat system under certain operating conditions
like:
 Start up and shutdown of turbine.
 On partial load below the boiler minimum load.
 In occurrence of fault like load rejection, unit trips out
etc.
 To be used for line blowing particularly initial start up
and commissioning.
 The unit can be started quickly compared to non-
bypass system unit.
Arrangement of hp &lp bypass system

 The Hp Bypass system is arranged between MS line

and CRH steam line, bypassing HP turbine.

 The LP Bypass system is arranged between HRH line

and Condenser, bypassing IP & LP turbines.
Line diagram of hp & lp bypass system

HPT IPT LPT

CRH HRH

Condenser

HP
RH LP
Bypass
Bypass
 To Spray from BFP
HPT D/s Hdr

From
HPT
(CRH)
HPBP Warm-up line

CRH Stm
to RH

HPBP Warm-up line

To HPT
 Drain to HP Flash
Tank
LPB WARM-UP LINE

Spray from CEP D/S Hdr

HRH
Stm
from
RH

IPT
Condenser

Spray from CEP D/S Hdr

LPB WARM-UP LINE

Drain to HPFlash Tank
 TO HPFT
HPFT
HRH - L
MS-
FLASH VESSEL
MS - L
LPBP
TO CONDENSER

BP-1
ESV1
CRH HPCV1

IPCV1

TO HPFT

ATM. HPT IPT LPT

BP-2
MS-110 IPCV2

HPCV2
ESV2

W
W
LPBP
MS - R
FLASH VESSEL
CONDENSER
HRH - R
HPFT
TO HPFT

.
During the large load rejection, the bypass shall open
after initiation of signal from the following:

 Generator Breaker open.

 Turbine trip.
 Turbine load shedding relay operates.
 Control deviation greater than preset value.
 Manual action.
In such event, HP/LP bypass has a capability of
bypassing a large fraction of steam generated in
boiler. This can reduce the impact on the boiler and
need to trip the fire.
THANKS