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POSITIONAL TRAINING
COURSE CONTENTS
1. Turbo - generator
1.1. Turbine
1.2. Alternator
1.3. Turbine Details
1.4. Condensing Plant
1.4.1. Surface Condenser 1.4.2. Condenser Details
1.5. Governing Sste!
1.". #P $eater
1.%. Air &'ector
1.%.1. $ogging &'ector
1.(. Gland Sealing Sste!
1.). Condensate &*traction Pu!+
2. ,il Sste!
2.1. ain ,il Pu!+ ,P/
2.2. Au*iliar ,il Pu!+ A,P/
2.3. &!ergenc ,il Pu!+ &,P/
2.4. 0ac ,il Pu!+ 0,P/
2.5. ,il Centrifuge
3. Circulating ater Sste!
4. Stea! Distribution Sste! at P$ 3
4.1. $P Stea! etor
4.2. Au*iliar P6DS
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OBJECTIVES
At the end of the course, the participants will be able to
KNOW
1. Various aspects of Turbine Operation
DO
1. Start various auxiliaries in connection with Turbine operation.
2. Start up and shut down the Turbine.
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POSITIONAL TRAINING DOCUMENT
DOCUMENT NO. : PED/PH 3#PTD/3011
DEPARTMENT : POWER ENGINEERING
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TURBO GENERATORS
There are two Turbo generators each having a generating capacity of ! "w and
e#uipped with hydraulic governing syste" $S% &V' and details of which are given
below.
TURBINE
(a)e * +..-.
Type * /ouble casing, 0ondensing type,reaction turbine.
o. of stages * 2
1st
stage * &"pulse stage $0urtis wheel'.
/OPT/SCRIBD/CONVERSION/TMP/SCRATCH1!12/"3!!20!".DOC
PREPARED BY : APPROVED BY :
N$% : A%'()'$ *+%$' N$% : A,$(+ S$-
D. : M$($' D. : S' M$($'
S($,+' : S($,+' :
D$, : 20/0/2011 D$, : 20/0/2011
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2nd to 2nd stage * %eaction stage.
3ressure * 41 )g5c"2
6or)ing Te"p. * 78 *72O
0.
%3( * !!!
0ooling water te"p. * 9O0 $(ax'
:ov. Syste" * O;;- governing, hydraulic $S%&V'
3 Stea" 0onsu"ption * . 79
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CONDENSING PLANT
Surface C!"e!#er $ The surface condenser is a shell and tube arrange"ent with
water boxes at either end. The sleeve side of the surface condenser isconnected to the exhaust hood of the turbine.
(ain function of condenser are
To condense the stea" exhausted fro" the turbine.
To "aintain vacuu".
To "aintain the te"perature of condense always at the saturation te"p.
To for" a convenient point for introducing "a)e up.
To facilitate extraction of air and other gases.
C!"e!#er "e%a&'#
(a)e * +-
Type * S0/52524!!
Shape * 0ircular
0ondenser vacuu"s * !.1!9 Ata
uantity of slain *
Total no. of tubes * 4!!! os.
Tubes si?e * 22 "" /ia * 4!! "" length
0ooling surface area * 24!! "2
ty of cooling water * 4!! "
5hr
0ooling water inlet te"p * 9 to 7o0
0ooling water outlet te"p * 2B4.o0
os. of passes * 2
Shell "aterial * 0arbon steel
Tubes "aterial * +rass
GOVERNING S(STEM
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The T: is provided with hydraulic governing syste". The governing syste" wor)s
on hydrodyna"ic principles and is si"ple and easy to operate and "aintain.
The hydraulic speed governor "aintains the speed of the T: set constant
according to the droop characteristics. Above all, governing syste" incorporates
protective devices to protect the turbine during adverse operating condition such
as over speed, axial shift, low lube oil pressure etc.
An e"ergency stop valve provided at the entrance of the turbine gives the initial
stea" access to the ad"ission chest. /uring nor"al operation the stop valve is
held open by oil pressure against counter acting forces of co"pression spring.
&n an e"ergency, pressure in the trip oil circuit is suddenly relieved and -.S.V.
as well as the control valves closes i""ediately.
The control valves of the turbine regulate the stea" through the re#uired channel for
obtaining the desired out put or speed. They are hydraulically actuated by oil.
The control valves are suspended fro" a valve bea" by "eans of two spindles
and a lever syste". The bea" can be "oved by the actuator which is "ounted
on the stea" chest.
The control i"pulse of the governing syste" is the pri"ary oil pressure generated
by the governing i"peller coupled with turbine shaft. The pri"ary oil act on a
bellow which is countered balance by the spring force of a speeder gear. The
changes in oil pressure results in change in the position of the balancing lever.
The travel of the bellow is trans"itted to the lever which is pivoted at one end.
At its free end the pivoted lever is connected to control sleeve of the hydraulic
a"plifier. The trip oil co"ing out of the a"plifier is )nown as secondary oil.
0hanges in the pri"ary oil and speeder gear setting results in changes in
secondary oil. The secondary oil pressure is trans"itted to control valve
actuator asse"bly such as pilot valve and servo"otor. igh secondary oil
pressure "eans high valve lift and high load.
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L. P. )EATER
A feed water heater is a shell and tube exchanger designed for the application of
recovering the heat fro" the turbine extraction stea" by preheating the boiler
feed water.
ow pressure feed water heaters are located upstrea" fro" the condensate pu"p.
Typically low pressure feed water heaters are designed for feed water pressure
between 28 to 94.! )g5c"2. +ut the actual design pressure depends upon the
cycle location relative to feed water pu"ps. -ach feed water heater bundle will
contain fro" one to three separate that transfer areas. These are condensing,
deBsuperheating and sub cooling area. A condensing area is present in all
heaters. arge volu"e of stea" is condensed in these areas. The sub cooling
area $drain cooler' is another separate counter flow heat exchanger whose
purpose is to sub cool inco"ing drains and stea" condensate fro" .3. heater.
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6or)ing stea" te"p * !!o0
Stea" 0onsu"ption * 92! )g5hr
Section pressure * !.9 )g5c"2
GLAND SEALING S(STEM
:land sealing pac)ing boxes are provided at both ends of the casing where the
turbine shaft co"es out. Sealing is necessary to prevent ingress of air in the
exhaust end and prevention of 3 stea" lea)age at the high pressure end.
On no load condition extra sealing stea" is necessary to seal the pac)ing
boxes. +ut on full load the lea)age stea" fro" the 3 side is sufficient to seal
the gland sealing syste" at 3 end.
T: and T: D 9 are provided with "anual gland sealing syste".
CONDENSATE E*TRACTION PUMP +CEP,
+oth the Turbo :enerators are provided with two nu"bers of "ultistage vertical
condensate extraction pu"ps. These pu"ps are extracting condensate fro" hot
well and sending it to /eaerator through eCector, drain cooler and .3. heater.
(a)e * GS+
or"al wor)ing for * 4 to 1! )g5c"2
0apacity * 19! T5hr "ax.
All these pu"ps are located in the base"ent area. 3u"ps bearings are oil cooled.
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POSITIONAL TRAINING DOCUMENT
DOCUMENT NO. : PED/PH 3#PTD/3014
DEPARTMENT : POWER ENGINEERING
PREPARED BY : APPROVED BY :
N$% : A%'()'$ *+%$' N$% : A,$(+ S$-
D. : M$($' D. : S' M$($'
S($,+' : S($,+' :
D$, : 20/0/2011 D$, : 20/0/2011
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2. OIL SYSTEM
A satisfactory and continuous oil supply is necessary for the safe and reliable
running of a turbo generator. The oil supply syste" should ensure the
operational safety of bearings. The syste" is of closed circuit type. A part fro"
this oil supply syste" has to ensure the oil re#uired fro" the governing syste"
and other safety devices. Sa"e pu"p is giving oil to governing syste" as well
as for lubricating syste" with the help of orifice adCust"ent. The oil syste"
includes the following e#uip"ent.
i' (O3 H (ain oil 3u"p
ii' AO3 H Aux oil pu"p
iii' -O3 H -"ergency oil pu"p
Oil coolers
/uplex filters
(ain oil tan)
2.1. Ma&! O&' Pu- +MOP,
The centrifugal type of pu"p is driven by turbine shaft through pinion and gear
wheel arrange"ent. 6hen the turbine is at full speed "ain oil pu"p delivers the
total oil re#uired for the total syste". &t is nor"ally "ounted on the front of the
turbine.
2.2. AU*ILIAR( OIL PUMP +AOP,
This pu"p enables oil supply during period of stand still, starting and stopping of the
T:. This pu"p builds up necessary suction head to the "ain oil pu"p by
inCecting oil into the suction piping. A chec) valve ensures safety of AO3 against
reverse rotation. (ain duties of these pu"ps are B
To supply oil for governing syste" and lubricating syste" during turbine start up till
"ain oil pu"p has ta)en over.
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To supply lubricating oil and governing oil when discharge pressure of (O3 falls
below 8.2 )g5c"2.
There are 2 nu"bers of AO3>s in each "5c B one electrically driven and other turbo
driver. These are screw pu"ps and located in the base"ent. %elief valves are
provided for the safe wor)ing of the pu"ps. or"al wor)ing pressure is around
1! )g5c"2.
2.3. E-er/e!c0 O&' Pu- +EOP,
6hen all sources of oil supply fails, the -O3 ensure oil supply to all bearings. These
pu"ps are designed for a "odest output of li"ited capacity. This is the reasonwhy these pu"p are connected to the bearing oil circuit directly bypassing oil
cooler and filters.
There are three -O3>s for each T:>s B one /0 "otor driven, one A0 "otor
driven and other turbo driven. /0 E A0 -O3>s are located in the base"ent and
Turbo -O3 located on the top of the oil tan). /0 E A0 driven -O3 are sa"e,
only the "otors are different. /05A0 -O3 is hori?ontal pu"p and Turbo -O3 is
vertical pu"p.
Setting of the 3u"ps is adCusted such as that Turbo -O3 first co"e in action
when any of the lubricating oil syste" fails and then co"es /0 -O3. or"ally
these pu"ps develop a pressure between 1.9 to 2.9 )g5c"2.
2.4. JAC* OIL PUMP JOP
This pu"p is used during starting and stopping of turbo generator. These pu"ps
supply high pressure oil around 1!! )g5c"2 to lift the rotor slightly fro" its
bearing Cournal. This reduces the tor#ue and increase the life of these Cournal
bearings. At present this arrange"ent is provided only in T: 9.
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2.. OIL CENTRIUGE
Oil centrifuge is used to purify oil by separating "oisture. &t clarifies, purifies the oil in
service. Since a turbid li#uid in a stationary vessels will clear slowly as the heavy
particles in the li#uid "ixture are sin)ing to the botto" under the influence of
gravity. The lighter li#uid phase will rise while the heavier sin)s.
This can be achieved by centrifugal separation also. &n this, in rapidly rotating
vessels the gravity is replaced by the centrifugal force, which can be thousand
ti"es greater. Sedi"entation and separation are continuous and are very fast.
The bowl is running at a very high rp" of 9!!! to
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1"
POSITIONAL TRAINING DOCUMENT
DOCUMENT NO. : PED/PH 3#PTD/3013
DEPARTMENT : POWER ENGINEERING
PREPARED BY : APPROVED BY :
N$% : A%'()'$ *+%$' N$% : A,$(+ S$-
D. : M$($' D. : S'. M$($'
S($,+' : S($,+' :
D$, : 20/0/2011 D$, : 20/0/2011
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POSITIONAL TRAINING DOCUMENT
DOCUMENT NO. : PED/PH 3#PTD/301DEPARTMENT : POWER ENGINEERING
STEAM DISTRIBUTION SYSTEM AT PH 5 3
PREPARED BY : APPROVED BY :
N$% : A%'()'$ *+%$' N$% : A,$(+ S$-
D. : M$($' D. : S'. M$($'
S($,+' : S($,+' :
D$, : 20/0/2011 D$, : 20/0/2011
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4. STEAM DISTRIBUTION SYSTEM AT PH 5 3
4.1. HP STEAM NETWOR*
There are four nu"bers of identical +oilers and two ! "w T: sets of condensing
type in two phases. 3hase * 1 is having +oilerB D 9 E 4, T: B D whereas 3hase
* 2 is having +oiler D 8 E 7, T: B D 9.
3hase B 1 and 3hase B 2 is interBconnected with two identical isolating valves having
byBpass arrange"ent as shown in the figure below.
All strea" headers are having sufficient no. of drains, stea" trap drains and vents.
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.2. AU*ILIAR( PRDS +PRESSURE REDUCING DESUPER)EATING,
There are three nu"bers of auxiliary 3%/S at 3 D. The purpose of Aux 3%/S is
to produce 3 stea" fro" 3 stea" which is suitable for so"e auxiliaries li)e
Air -Cectors, Turbo AO3 E Turbo -O3, /eaerator E gland seal etc.
$P ST&A #P ST&A
Pressure 3 6/7%2 1 6/7%2
Te!+erature 4! 8 9C 319C
A tapping fro" (ain Stea" header is ta)en to a control valve where pressure is
reduced by passing 3 stea" through no??le and te"p is reduced by spray
water.
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UESTIONNAIRE
6hat is type, no. stages and rp" of Turbine at 3DI
6hat is the rated capacity and generating voltage of alternator at 3
D I
6hat are the "ain function of surface condenserI
6hat type of :overning syste" is deployed with the T: setI
6hat is the wor)ing principle of :overnorI
6hat are the "ain functions of the :overnorI
6hat are the "ain functions of .3. eaterI
6hat are the functions of condensate -xtraction 3u"ps and where they are
locatedI
6hat are the functions of air -CectorI
6hat are the neccesities for gland sealing of turbineI ow the gland sealing
is achievedI
6hat are the various oil pu"ps installed for T: setsI
6hat are the "ain purpose of various oil pu"ps at 3DI
6hat are the functions of Jac) oil pu"pI 6hen it is usedI
6hat are the functions of a oil centrifugeI
-xplain, in se#uence, how to operate the oil centrifugeI
6hat are the "ain purpose of /eareatorI
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-xplain the principle of operation of /eareator.
6hat are the functions of 3%/S in a boilerI 6here does 3%/S supplies
stea"I
6hat are the various para"eters to be "onitored prior to startBup of Turbine.
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1. 3rior to starting 06 pu"p what are various chec)s are to be doneI
6hat are the functions of vacuu" syste"I
6hat are the chec)s to done before starting the oil pu"p for T: setI
6hat do you understand by %olling and synchronisation of T: SetI
-xplain, how rolling and synchronisation is done for TurboBgenerator set at
3D .
+efore allowing stea" to enter 3 eater, what are the various valves to be
operatedI
6hat are the two various operating pera"eters are to be "onitored before
starting the turbine.
6hat are the pri"ary chec)s to be done before starting the e"ergency oil
pu"psI
-xplain, the steps to be followed in starting a turboB-O3F
At what pressure an AO3 should runI
ist the chec)s re#uired before starting the condensate exteraction pu"ps.
6hat are the steps $in se#uence' re#uire to follow in shut down of turbineI
6hat are the vaccu" brea)ingI ow is it doneI