MAIN TURBINE

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General Layout:
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Technical Details:

The Turbine is a reaction, two cylinder, single reheat, Regenerative and condensing type.

The HP-IP Cylinder of double casing houses the HP turbine of single flow cylinder with 22
reaction stages and IP turbine of opposed single flow with 20 stages of reaction blades.The LP
Turbine casing of double flow is of three shell design with 2x9 stages of reaction blades.

The HP-IP tubine has throttle control governing. Two numbers of combined Stop and
Control valves for Main steam line and two combined Stop and Control valves for HRH Steam are
connected to both sides of the HP-IP outer casing. HP exhaust (Cold reheat) to the reheater is
provided with Two Swing Check valves which prevent the hot steam from reheater flowing back
into the HP turbine during turbine trips. Cross around pipes connect the IP turbine exhaust to
the LP Turbine. Over load Control valve is connected to HP turbine after sixth stage of
HP blading. Six Extraction are taken for Regenerative Feed Water Heating as mentioned below.

 Extraction-6 for HP heater-6 is taken from Cold Reheat line.

 Extraction-5 for HP heater-5 is taken from IP turbine after 12 th Stage.

 Extraction-4 for Deaerater is taken from IP turbine exhaust.

 Extraction-3 for LP Heater-3 is taken from LP Turbine after 3rd Stage.

 Extraction-2 for LP Heater-2 is taken from LP Turbine after 5th Stage.

 Extraction-1 for LP Heater-1 is taken from LP Turbine after 8th Stage.

Rated Steam parameters: ( ata/degC )

Initial Steam 126 535

HP first stage 124 535
HP Exhaust 33 350
Extraction : 6 33 350
Extraction : 5 13 400
Extraction : 4 5.5 300
Extraction : 3 2.5 200
Extraction : 2 0.95 120
Extraction : 1 0.36 73
LP Turbine Exhuast 0.1 47.6
Trip Settings:

HP Exhaust temperature 480 o C ( See Curve )

LP Exhaust temperature 90 / 130 o C ( Curve )
Over Speed 3300 rpm
Bearing temperature 90 / 130 o C
Shaft vibration (Turbine) 120 / 160 microns

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 Shaft vibration (Generator) 160 / 240 microns
Bearing vibration 7 / 11 mm/s
Axial displacement: +/- 1.0 mm

TURBINE OIL SYSTEM:

A main oil tank (MOT) of 11-m3 capacity is located at ground level. All oil pumps are
mounted on the top of the oil tank. Two AC motor driven Main oil pumps (MOP) provides lube oil
for the turbine bearings A DC Emergency Oil pump is available for the lube oil system during
power failure or unavailability of AC pumps. MOP discharges through a Lube Oil Cooler and Filter
(25 ) before going to the Turbine bearings. DMCW is used as coolant in LOC (one in service,
one standby). The oil temperature is controlled by a preset thermostatic temperature controller
(3-way valve), which bypasses part of the oil going to the cooler. Duplex filters (one in service,
one standby) are inspected for cleanliness and should be changed above a P of 2.5 Ksc

A Lifting oil pump (LOP) provides high-pressure filtered (10 ) oil for TG shaft jacking & turning
gear. A DC standby LOP is available for use during power failure or unavailability of AC pump.

Two Oil Vapour Extraction Fans (OVEF), mounted on the MOT, are employed for extracting oil
vapors from the turbine bearing pedestals and from the Main Oil tank. (One in service, one in
standby).

Two Control Oil Pumps with a separate control oil tank are provided for Hydraulic control of
Turbine Stop and Control Valves & the LP BP Valves. A separate control oil Recirculation pump is
provided to cool and filter the control oil in the system. The Control oil Coolers use DMCW as the
cooling medium. Accumulators are provided in lube oil as well as control oil circuits to take care
of sudden pressure variations.

OIL PUMP DETAILS:

MOP EOP LOP DCLOP COP CO R/C

Qty (nos) 2 1 1 1 2 1
Flow (m3/hr) 80 80 5.1 5.1 40 (lpm) 23 (lpm)
Head (bar) 7 3 150 150 160 5
Speed (rpm) 2900 2900 2900 2900 1450 1450
Drive (AC/DC) AC DC AC DC AC AC
Voltage (HT/LT) 415 220 415 220 415 415
Power (kW) 37 15 37 37 15 0.75
Current (Amps) 63 166 63 197 - -

Electro Hydraulic Turbine Controller (EHTC)

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EHTC consists of three loops namely Speed Control Loop, Load Control Loop and Pressure
Control Loop. Speed Control Loop is used for Rolling and Synchronizing. Thereafter Load
Controller is used to raise the unit load from 12 MW onwards. In Pressure Control mode, MS
pressure is maintained according to the Throttle pressure set point by the Turbine Control
Valves, and therefore the Load output will be proportional to the firing in the Boiler.

Speed Controller: The Speed Reference (NR) is set from the OWS. The increase in NR from zero
is decided by the available Turbine Stress Evaluator (TSE) Margin, depending on the Turbine
Metal temperatures. The time delayed Speed set point (NRTD) after applying the TSE gradient is
compared with the actual TG Speed (N act ) and the error signal is fed to the Speed controller (A
Pressure correction is also applied here to take care of the pressure ranges). The Speed
Controller or the Load Controller output gets selected at a MAX Gate, and the MAX Gate output
is fed to a MIN Gate along with Pressure Controller output. The final output of these two gates
will decide the Control valve opening.

Load Controller: The Load Reference (PR) is set from the OWS. The increase in PR from the
minimum set point of 12 MW is decided by the TSE Gradient or Load Gradient set point, which
ever is minimum. The time delayed Load set point (PRTD) after applying a pressure and frequency
correction is compared with the Absolute Load Limiter (Prmax) at a MIN gate. The output of this
MIN gate and the actual Load (Pact) goes to the Load Controller.

Pressure Controller: The pressure control loop is capable of controlling the turbine on two
operating modes. It can operate on any one of the following two modes on selection.

 Limit Pressure Mode (LP Mode/ Boiler Follows Turbine ).

 Initial Pressure Mode (IP Mode / Turbine Follows Boiler ).

On selection of ‘Initial pressure mode’, this control loop takes control of the turbine directly. In
‘Limit Pressure mode’, it acts as a back up loop for the load control loop and takes control, in
case of drop in pressure by threshold value of 10 Ksc.

In ‘Boiler Follows Turbine’ mode (Limit Pressure Mode), the combustion controller of
Boiler automatically adjusts the combustion rate (The fuel and air flow rate) according to the
level of power generation demanded by the load control loop. When the load set point is
altered, the load controller changes the steam flow rate and the consequent variation in the
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steam pressure will effect changes in the fuel and air flow rate. The pressure control loop, in this
mode acts as a back up loop. It comes into action only when the steam pressure gets reduced
below set pressure by 10 Ksc and cannot be restored by the combustion controller.

In ‘Turbine follows Boiler’ mode (Initial Pressure Mode), the combustion controller of
Boiler is in manual mode and the changes in the rate of combustion will be reflected as changes
in the steam pressure. In this mode, the pressure control loop takes control of the turbine
directly and main steam pressure is maintained at the set value by effecting changes in the
steam flow rate and hence the level of power generation. This is achieved by closing/opening the
governing valves.

Pre rolling activities

1. Before charging APRDS Keep following valves in open condition

 Pilot Ejector before Atmospheric drain at 5m level.

 Gland steam atmospheric drain (partially open) before MAW 10 valve at 5m level.

 APRDS to Ejector main isolation valve (Full open) at HT APRDS header.

 Keep open AS-9 partially from DCS

 MS strainer drains to atmospheric flash tank MS-101 and MS-104 and it’s before
gate valve.

 HP B/P line drain to atmospheric flash tank (AFT) BP-102, BP-104 and HRH-
122, HRH-123.

2. Before Opening the Bypass valve of Boiler Stop valve, Keep the following valves in
partially open condition

 HP B/P warm-up valve BP-2 and BP-4 connected to CRH line

 CRH Swing valve drain to AFT CRH-123 and CRH-124.

 Check HP B/P OSU (oil supply unit) are in service.

3. When Drum pressure reaches 15 ksc

 Open BP-5 & 6 more than 2%. Check BD valve opening and gradually open HP
B/P depending on drum pressure rise.(Initially put the valves in auto and again
take back to manual for opening)

 Open LP B/P warm up drain to AFT HRH-103 and HRH-104.

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 4. When APRDS is 11 ksc and > 200o C

 Ensure one CEP is running

 Start one Control Oil Pump (COP) and COP recirculation pump. check discharge
pressure is more than 150 ksc

 Start vacuum pulling. Open LPBP valve drains and line drains. Once vacuum
reaches less than 0.2 ata, manually open LP B/P valves slowly observing vacuum.
Check water injection valves and LP B/P stop valves opening.

 As LP BP valves are Opened, choke the Re heater Start up vents MS-85 & MS 86
to maintain HRH pressure. Finally, Close the HRH Vents fully.

 Once RH pressure more than 1.5 ksc, close BP-102 , BP-104 ,CRH-123, CRH-124,
HRH-122, HRH- 123, HRH-103 and HRH-104.

 Open CRH-101, CRH-120, HRH-101, HRH-102, HRH-113 and HRH-118 and it’s
before gate valve to HP FT

 Open HP B/P and LP B/P gradually depending on drum pressure raise.

 Once the drum pressure is stabilized, put the HP B/P BP-5 and BP-6 into auto one
by one observing drum level. (Keep the HP B/P Pressure set point slightly lower
than actual pressure. Don’t put pressure set point into auto.)

 Once reheater pressure is above fixed set point select LP B/P Pressure controller
in auto. (For cold start fixed set is 3.0 ksc and for hot start fixed set is 6.0 ksc.)

Pre Rolling Checks & Rolling

Ensure all Turbine auxiliaries are running normal.

Ensure HP & LP Bypass systems are working normal.

Keep all turbine MAL drains and it’s before hand operated gate valves in open condition,
otherwise open all.

Check all Main steam, Cold and hot reheat line drains are in partial open condition.

BP-5&6 are in auto with tracking Set Point at 40 Ksc (manual), maintaining pressure and
temperatures (290 oC).

Check any one Control oil pump (COP) and the CO recirculation pump are in service. LP B/P
controller in auto with Fixed set point at 2-3 Ksc for cold startup and the same may be
gradually raised to 6.0 ksc. For Hot start up set point can be 6.0 ksc

Check Lube Oil temperature (cooler outlet <50 o C) and Control oil temperature (< 45 o C) and
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Pressure are normal.

Check MOT Duplex filter DP is less than 1.0 ksc and Lube oil header pressure is above 4.8 ksc.
Otherwise change the filter.

Check Vacuum is normal (<0.10ata).

Check Turbine shaft sealing system is normal and controller in auto. Check shaft seal
temperature is more than 190 o
C. otherwise check APRDS temperature and MAW 10
atmospheric drain.

Make sure Turbine Supervisory Instrument Panel readings are normal.

Observe the raise in the turbine stop valve Ti (Inner wall temp.) and Tm (Mid wall Temp.) in
Turbine TSE metal temperature/Margin page.

Check for Criteria X1/X2, X3 are in FULFILLED condition.

Watch that the Rolling parameters are maintained steadily.

Keep Speed Reference set point Zero, Load reference set point 12 MW, Load Gradient 12.5
MW/min, Load Control Off, LP On, TSLLE (Turbine Start-up Lift Limiter Equipment) is zero.

Check for EHTC TMR (Electro hydraulic Turbine Controller) diagnostic page for any EHTC fault
(all the 3 EHTC s should be healthy) and for variation in data between EHTC-1, EHTC-2 and
EHTC-3. If so reset the fault by pressing EHTC RESET button in EHTC TMR pages (Triple
Monitoring Relay) Reset TSE Fault, if any. Check Criteria X1/X2/X3 are fulfilled. Acknowledge
PTRIP at EHTC page.

Check TP TMR1, 2 & 3 (Turbine Protection) for any alarm or trip Indication, Except TSLLE.
(Generator trip is reset)

Check SLC (Sub Loop Control) of SV’s & CV’s status to be ‘ON’ in EHA Overview (Electro
Hydraulic Actuator) page. Control Oil Pump SLC is ‘ON’.

For Cold start up Rolling parameters are 35 ksc / 350 oC. Start stop valve warming up at 30 ksc /
350 oC

Reset Turbine by raising the TSLLE to 100 %.( In TP TMR page TSSLE Trip will get reset)

Initially Pilot valve is ‘ON’ and all Trip Solenoid valves are in ‘OFF’ condition. Observe the trip
solenoid and pilot valve change over at the appropriate times: At 22% SV trip Solenoid valves
will be ‘ON’, at 33 % CV trip Solenoid valves will be ‘ON’, at 44% Pilot valves will ‘OFF’ and all
Stop valves will open fully. TSLLE continue to go to 100 % with CV position zero (since Speed set

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point is zero).

Observe Ti (Inner wall temp.) and Tm (Mid wall Temp.) of HP Stop Valves in Turbine TSE metal
temperature/Margin Page. Ensure Margin is adequate.

Ensure DMCW valves for Generator Air Cooler and Turbine LOC are Open.

Allow for Stop Valve warm up, till Criteria X4/X5/X6 are FULFILLED for Opening the Control
Valves.

Record all Turbine Supervisory Instrument Parameters (SIP) and TSE (Turbine Stress Evaluator)
readings.

Raise speed set to 600 rpm in speed reference setter and confirm the ramp.

Observe the turbine bearing metal temperature and shaft / housing vibration.

Allow for Soaking till Criteria X7 are fulfilled. Watch LOP (Lift oil pump) tripping at the speed of
540.rpm. Wait till Casing expansion is > 3.5 mm

Record all SIP and TSE readings. Record all bearing temperatures and lube Oil temperature.

Ensure a minimum opening of 15 % for both HPBP valves at 40 Ksc / 350 oC

Raise the Speed set point to 3000 rpm and confirm the ramp. Record the maximum vibrations in
bearing/shaft and the speeds. Ensure all SIP are within the limits.

Ensure there is no fast change in Speed reference value. If vibration goes high or any
abnormalities are observed at local, trip the turbine immediately.

After reaching 3000rpm check all SIP, Vibration, bearing metal temperatures, Turbine Margins,
and oil temperature. Check CRH NRV opening. Check Criteria X8 is fulfilled. If all are ok give
clearance for Synchronizing.

In manual synchronizing, adjust speed to match the frequency. Synchronize only when the
synchronoscope is rotating clockwise.

After synchronizing, manually give a single speed rise impulse for getting a minimum block load.

Put Load Controller ‘ON’ and observe the SC and LC outputs. Wait till the LC output builds up
and takes over through the maximum gate. Observe the SC output to fall to 7.5% (apprx.) due
to speed tracking. Verify Load Controller has taken over in the display.

Further raise load through LC, and observe HP/LP Bypass closing according to the available fire
in Boiler. At 16 MW Close all MAL (Except MAL 13) and steam Line Drains.

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At 22 MW charge all the LP Heaters. At 60 MW charge HPH-5. and At 100 MW charge HPH-6.

Turbine Tripping:

During planned tripping, reduce load and parameters upto minimum permissible firing in the
boiler, and thereafter hand trip the turbine. (Emergency Trip button in DCS / Control Desk /
Annunciation panel window)

Observe HPBP/LPBP Openings and watch for drop in Condenser vacuum.

Observe reduction in speed and record maximum vibrations of bearing/shaft during coasting
down.

HP Heaters / LP Heaters / Deaerator Extraction valves are to be closed and their drains opened,
if they are still in open condition.

Record the speed at which LOP comes into service (510 rpm) and turning gear SOV Open
indication (210 rpm). Ensure turning gear comes into service and shaft speed is maintained
between 60 to 80 rpm.

Observe the Lube Oil Cooler inlet/outlet temperature (45 to 50 o

C) and TCV is functioning
properly. Otherwise throttle the Lube Oil Cooler Cooling Water (DMCW) Outlet valve and control
the Oil temperature

Load Vs Steam Flow and wheel chamber pressure

The Inlet pressure before stop valve : 126.0 ksc

Exhaust Pressure : 0.1033 ata
HP Turbine Wheel Chamber pressure at
Maximum load Condition : 123.7.0 ksc

MW 10 20 30 40 50 60 70 80 90 100 110 120 125

Main
30 60 90 120 150 180 210 240 270 300 330 360 375
Steam Flow
Wheel
chamber 13 20 30 40 50 60 70 80 90 100 108 119 123
Pressure

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TURBINE PROTECTIONS

1. ATRS Trip From ATRS Step

2. Boiler MFT BP1 after a delay of 10 sec
3. Control Oil Supply Off Protection/Emergency Off
4. Fire Protection Ch -1 Operated. From Local / UCB Desk
5. Fire Protection Ch -2 Operated. From Local / UCB Desk
6. TSLLE < 7.5 %
7. Axial Shift +/- 1.0 mm
8. Control Oil Emergency Push Button Operated. From Local / DCS
9. Emergency Push Button Operated. From UCB Desk
10.HP /IP Shaft vibration Front Journal Bearing. 160 microns
11.HP /IP Shaft Vibration Rear Journal Bearing 160 microns
12.LP Shaft Vibration Rear Journal Bearing. 160 microns
13.Generator Bearing Vibration Front Journal Bearing 240 microns
14.Generator Bearing Vibration Rear Journal Bearing 240 microns
15.Generator Electrical Protection. 1&2
16.Condenser Pressure (VAR) High 0.2 ata (based on Curve)
17.Condenser Pressure (FXD) High 0.3 ata
18.DP Across HP Turbine ***
19.Drum Level High +225 mm
20.HP Top–Bottom Casing Temperature. -55 upto 30 % load
(thereafter based on Curve)
21.HP Exhaust Temperature Based on TM 380/480 deg C (Curve)
22.IP Steam Temperature Low 320/430 deg C (Curve)
23.IP Steam Temperature High 380/565 deg C (Curve)
24.Live Steam Temperature Low 320/450 deg C (Curve)
25.Live Steam Temperature High 380/565 deg C (Curve)
26.LP Exhaust Temperature High 120 deg C
27.Lub Oil Level Low 440 (From Top of tank)
28.Lub oil Pressure Low <3.2 KSc 3.2 Ksc
29.Over Speed Trip Ch- A 3300 rpm
30.Over Speed Trip Ch- B 3300 rpm

SUB GROUP CONTROL

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SGC: OIL SYSTEM

Start Up:

Start One MOP and one OVEF. Check the healthiness of Standby drives and Switch ON the SLC’s
of MOP and OVEF.

Check EOP availability. Keep SLC ON and put OFF STG solenoid for rotating the Turbine Shaft.

Start the A/C LOP. Observe shaft rotation. Check the healthiness of DC LOP and Switch ON SLC
for the DC LOP.

Shut Down:

When HP Shaft mean temperature and HP Inner Casing temperature are< 90o C, STG Solenoid is
switched ON. After shaft came to rest stop LOP and switch OFF SLC ‘s of LOPs. After 30 minutes
stop MOP and switch OFF SLC’s of MOPs and EOP.

SGC: EVACUATION SYSTEM

Start Up:

Check for normal Hot well level. Put ON CEP SLC. Open ME Air valves.

Check CEP Header pressure, and Close the Vacuum Breaker valve.

When HT AST header pressure & temperature are normal, open PE steam valve.

Open PE Air valve. (Bypassed if Cond. Pressure is <= 0.26 ksc)

Put GPSC in auto when condenser pressure < 0.85 ksc. Start a GSEF

Open ME Steam valves (at 0.3 ksc)

Close PE air valve at 0.25 ksc cond pr. Close PE steam valve also.

When Cond.Pr < 0.12 ksc and Load > 5 %, cut off one ME

Shut Down:

Verify if TG Shaft speed < 240 rpm and LPBP is close

Close ME Steam valves\

Open Vacuum Breaker valve and PE Air valve

Isolate Gland Steam system and stop GSEF

Stop CEP and switch off SLC

SGC: TURBINE SYSTEM

Start Up:
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CO System is ready

Condenser pressure is <0.4 ksc, LPBP is ready, Main condensate is OK and DMCW system is OK

Switch ON ASM (automatic set point matching) or ACI for LPBP

Switch ON Drains SLC. Put ON HP Exhaust temp control and switch to auto

Check for CLOSE condition of all Turbine Stop and Control Valves, CRH NRVs and all Extraction
NRVs.

Check NO Turbine Trip is existing, Oil system is OK and LO temp > 35 oC and Drain SLC are OK

Ensure minimum live steam flow (HPBP opening > 20 % on both sides), Minimum Super Heat
(rolling parameters), Criteria X1, 2 &3, Condenser pressure < 0.5 and Speed > 15 rpm

Raise TSLLE from 0 to 100 %. (TSLLE Holds & Triggers turbine trips, Limits the Control Valve lift
and Blocks the Open/Close of Stop valve Actuators

Check Full Open of all the Turbine Stop Valves.

Speed set point is raised to 600 rpm after checking:-Minimum steam flow, Criteria X4, 5 & 6,
Drains SLC, Condenser vacuum, TG Shaft Speed, HP Casing T and Load set point > 10 %.

Raise speed to 3000 rpm after 5 minutes, after checking Criteria X7, Upper Margin > 30 K, HPC
flange temperature > 60 oC, DT (HP  i,m) < 12 K

Close all HP Control Valve Drains

Ensure Criteria X8 is fulfilled & TSSLE > 100 %. Switch ON Auto Synchronizer.

Shut Down:

Put ON SLC Drains

Reduce Load to minimum

Trip the Turbine. Check TSLLE is 0 %. Check SGC Oil System.

SLC DRAINS

HPCV1&2 After Drains: (MAL 15, 16)

OPEN: If T (HPCV~MS) is < 20 K & HPCV CLOSED

CLOSE: If T (HPCV~MS) is > 50 K & HPCV NOT CLOSE

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IPSV1&2 Before Drains: (MAL 26, 27)

OPEN: If T (IPCV ~ HRH) is < 20 K & IPSV CLOSED

CLOSE: If T (IPCV ~ HRH) is > 50 K & IPSV NOT CLOSE

CRH NRV DRAIN:

OPEN: If Any NRV not Full Open Condition.

CLOSE:If Both NRV Full Open Condition.

GS Header Drain MOV: (MAW 10 AA 011)

OPEN: If GS Temp 1 Or 2 is < 120 oC

CLOSE:If GS Temp 1 Or 2 is > 150 oC

EXTRACTION A5/A3: (MAL 47 / 54)

OPEN: If LOAD is < 2 % & EXTN OPEN is < 5 %

CLOSE: If LOAD is > 10 % & EXTN OPEN is > 15 %

EXTRACTION A4: (MAL 51)

OPEN: If EXTN OPEN is < 5 % & P is < 10 mbar

CLOSE: If EXTN OPEN is > 15 % & P is > 32 mbar

HP Exhaust :(MAL 30 AA011)/IP Extraction Insert :(MAL 35 AA011)

OPEN: IF T (Temp ~ Sat Temp) < 20 K

CLOSE: If T (Temp ~ Sat Temp) > 50 K

HP-IP CASING: (MAL 24 AA 011)

OPEN: If TOP OR BOTTOM Temp < 300 oC

CLOSE:If TOP OR BOTTOM Temp > 320 oC

Vacuum Breaker Control:

VB Valve Opens during: Shaft vibration very high, Bearing temperature very high, Axial Shift very
high and Fire Protection responded.

FC NRV s:

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Close command goes to FCNRV s during: Level very high in Heaters, P high across the NRV,
Depending on Control Valve position (MCV for HPH & IPCV for LPH), Turbine trip Or Manual
Close command.

EXHAUST HOOD SPRAY (MAC01)

OPEN: LP Wall Temperature > 90 oC

CLOSE:TG Speed < 2850 rpm Or Load > 10 %

CRH NRV

OPEN: HPCV opening is < 17 %

CLOSE:HPCV opening is > 22 %

FP 1&2:

Fire Protection initiates: Turbine trip, SLC OFF for MOP/LOP, Control Oil system OFF, DC EOP &
DC LOP and STG ON and VB Open.

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