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- 1. Power Plant Fundamentals TrainingProgram Click to Start Program Industrial Resources, Inc. A Training Services Company
- 2. Power Plant Fundamentals TrainingProgram Module 10 Turbines INDUSTRIAL RESOURCES, INC. © 2009 - Industrial Resources, Inc.
- 3. Demonstrate Basic Knowledgeof the Steam Cycle and Turbine Operation Knowledge of Turbine Construction and Principles of Operation Knowledge of Turbine Valves and Support Systems Knowledge of Turbine Control, Instrumentation and Protection Systems Knowledge of Turbine Operation MODULE OBJECTIVES 3
- 4. Steam Cycle andTurbine Operation Review the purpose of the Steam Turbine Look at general arrangement of Steam Turbines Look inside a Steam Turbine to see what is happening to the Steam passing through it 4
- 5.
- 6.
- 7. There are manyaccessories necessary for commercial operation of a steam turbine – Governing systems – Bearing lubrication system – Piping systems for steam supply and exhaust – Steam condensing system are a few of the auxiliary systems required Turbine Principles of Operation Accessories 7
- 8. Simple Impulse &Reaction Turbines 8
- 9. Power Plant –Energy Converter Boiler Turbine Generator Fuel (Chemical Energy) Air (Oxygen) Steam (Thermal Energy) Torque (Mechanical Energy) 9
- 10. Function of theSteam Turbine 10
- 11.
- 12.
- 13.
- 14. Some Turbine Basics Shaft Turbine SteamGenerator Electricity Mechanical Energy (Torque) Heat Energy Electrical Energy Energy Conversion in a Turbine-Generator 14
- 15.
- 16.
- 17. Comparing Types ofBlades High Pressure Low Pressure 17
- 18.
- 19.
- 20.
- 21. Shell and StationaryBlades 21
- 22.
- 23.
- 24.
- 25. Question 1 What isthe purpose of the Steam Turbine? – Convert mechanical energy into thermal energy – Convert thermal energy into mechanical energy – Convert electrical energy into mechanical energy – Act as a heat sink for the Boiler 25
- 26. Question 1 Answer Ifyou said convert thermal energy into mechanical energy, you were right. We want to change the heat in steam into torque on the shaft connected to the Generator. 26
- 27. Question 2 In aSteam Turbine, a set of Fixed Blades followed by a set of Rotating Blades is called a _____________. – turbine – rotor – stage – steam chest 27
- 28. Question 2 Answer Ifyou said stage, you were right. 28
- 29. Turbine Construction Have abasic idea of how a simple turbine works But want to look at a more complicated, and common, turbine Steam passes through stages, dropping in pressure and expanding Steam gives up thermal energy Will look at one made up of several simple turbines. 29
- 30. Multistage turbines useboth impulse and reaction blading to provide the most efficient means of energy conversion Turbine classifications – Pressure velocity compounded – Impulse reaction – Straight reaction staging, are terms describing ways in which manufacturers incorporate the principles of blade design. Multistage Turbines 30
- 31.
- 32.
- 33. All turbines mayalso be classified as either single casing or compound As the name implies, a single casing type has only a single steam path from throttle to exhaust The term compound signifies a construction in which the steam leaves the high pressure casing before expansion is complete and then goes through one or more low pressure casings Compound Turbine 33
- 34. LP Turbine A IP Turbine HPTurbine LP Turbine B Tandem Compound Turbine 34
- 35.
- 36.
- 37.
- 38.
- 39. Reheat turbines havebeen provided to meet the demand for greater economy in the operation of a modern power plant In the reheat turbine – High pressure steam is expanded through the highest pressure section – Then withdrawn and returned to the reheat section of the boiler to increase its energy level before expansion through the lower pressure sections of the turbine Reheat Turbine 39
- 40. Steam Flows –HP Turbine Main Steam SV-1 SV-2 SV-3 Warm-Up Line Condenser Drains Flash Tank T T P P Sample CV Chest HP Turbine P T To Steam Air Heaters To Reheater T P To Soot Blowers To Reheater 40
- 41. Steam Flows –IP Turbine IP Turbine CRV-1 South Hot Reheat Line T Main Stop Leakoff From Ventilator Valve CRV-2 North Hot Reheat Line T Crossover to LP Turbines 41
- 42.
- 43.
- 44.
- 45.
- 46.
- 47.
- 48. Bearings Shaft Packing Bearing Thrust 1 N 1 N 2 2 HP Turbine 3 N 3 IP Turbine N 4 4 N 5 LP Turbine AN 6 6 5 N 7 LP Turbine B N 8 8 7 1 N1 N2 2 HP Turbine 3 N3 IP Turbine N4 4 N5 LP Turbine A N6 6 5 N7 LP Turbine B N8 8 7 Packing 48
- 49. Question 3 In alarge Steam Turbine, Cold Reheat Steam leaves the _______ Turbine section, goes to the Reheater in the Boiler, and then returns as Hot Reheat Steam to the ______ Turbine section. – IP, HP – HP, IP – IP, LP – LP, HP 49
- 50. Question 3 Answer Ifyou said HP, IP, you were right. 50
- 51. Question 4 In alarge Steam Turbine, Crossover Steam is the steam that leaves the _____ Turbine section and goes to the _____ Turbine section. – IP, HP – HP, IP – IP, LP – LP, HP 51
- 52. Question 4 Answer Ifyou said IP, LP, you were right. 52
- 53. Turbine Valves Main ControlValves Main Stop Valves Combined Reheat Stop Valves (CRVs) Turbine Drains Valve Drains Blowdown Valve Ventilator Valve 53
- 54. Control Valve Steam Inlet Poppet Valves Poppet Valve Stems FirstStage Diaphragm 54
- 55. Full & PartialArc Admission 55
- 56.
- 57.
- 58. Main Stop Valve Valve Body AboveSeat Drain Below Seat Drain Hydraulic Operator Stem Leak-Off 58
- 59. Main Stop ValveBypass 59
- 60.
- 61.
- 62. Turbine Drain Valves MainSteam Leads – manual Turbine Bypass Valves – pneumatic Stop Valves Before Seat – MOVs Stop Valves After Seat – MOVs Cold Reheat – manual CRVs Before Seat – manual CRVs After Seat – manual Extraction Lines - manual 62
- 63.
- 64.
- 65. Stop Valve Drains SV-2 After Seat Drain SV-2 Before SeatDrain SV-1 Before Seat Drain SV-1 After Seat Drain 65
- 66. Blowdown Valve Releases Steamfrom N2 Packing on Turbine Goes to Condenser Ventilator Valve Releases Steam from Extraction Line on HP Turbine Protects last few stages from windage on load rejection Goes to Condenser 66
- 67.
- 68.
- 69. Question 5 Which TurbineValve acts as a stop valve for Hot Reheat Steam going to the IP Turbine? – Main Stop Valve – Main Control Valve – Combined Reheat Valve (CRV) – Main Poppet Valve 69
- 70. Question 5 Answer Ifyou said Combined Reheat Valve (CRV), you were right. 70
- 71. Question 6 Which TurbineValve controls the exact flowrate of Main Steam to the HP Turbine? – Main Stop – Main Control Valve – Combined Reheat Valve (CRV) – Above Seat Drain Valve 71
- 72. Question 6 Answer Ifyou said Main Control Valve, you were right. 72
- 73. Turbine Support Systems TurningGear Turbine Lube Oil System – Turbine Oil Reservoir – Turbine Oil Pumps – Turbine Oil Conditioner Turbine Steam Seal System 73
- 74. Clean lubricating oilat the proper pressure, temperature and flow must be provided at all times that the turbine- generator shafts are rotating Lubricating oil provides a necessary cooling affect on the bearings, even when the rotors are at rest Because of the critical nature of a continuous supply, back up AC and DC pumps are provided for off-line or emergency situations Turbine Lube Oil System 74
- 75. The normal sourcefor lube oil is the shaft driven oil pump A few units use a small turbine driven pump as a backup Cleanliness is very important in the lube oil system Contaminant's can affect lubricating properties and foreign material can plug lines or score bearing surfaces. Turbine Lube Oil System (cont.) 75
- 76. Oil temperature isvery important for operation. – Too low a temperature at speed will cause vibration problems (oil whip) – Too high a temperature will decrease the viscosity and increase wear of bearing surfaces The lube oil also acts to cool the bearing Turbine Lube Oil (cont.) 76
- 77. Main Oil Pumps P P MainOil Pump Booster Pump (Pri.) Bearing Oil Header Lube Oil Coolers P Turning Gear Oil Pump Emergency Oil Pump Motor Suction Pump Oil Reservoir L LO Filter Pump LO Cond. 77
- 78.
- 79. Motor Suction Pump P P MainOil Pump Booster Pump (Pri.) Bearing Oil Header Lube Oil Coolers P Turning Gear Oil Pump Emergency Oil Pump Motor Suction Pump Oil Reservoir L LO Filter Pump LO Cond. 79
- 80. Emergency Bearing andTurning Gear Oil Pumps P P Main Oil Pump Booster Pump (Pri.) Bearing Oil Header Lube Oil Coolers P Turning Gear Oil Pump Emergency Oil Pump Motor Suction Pump Oil Reservoir L LO Filter Pump LO Cond. 80
- 81.
- 82. Turbine Oil Coolers P P MainOil Pump Booster Pump (Pri.) Bearing Oil Header Lube Oil Coolers P Turning Gear Oil Pump Emergency Oil Pump Motor Suction Pump Oil Reservoir L LO Filter Pump LO Cond. 82
- 83.
- 84. Turbine Oil Conditioner P P MainOil Pump Booster Pump (Pri.) Bearing Oil Header Lube Oil Coolers P Turning Gear Oil Pump Emergency Oil Pump Motor Suction Pump Oil Reservoir L LO Filter Pump LO Cond. 84
- 85.
- 86. Lube Oil VaporExtractor 86
- 87. GE Turbine LubeOil System 87
- 88. Westinghouse Lube OilSystem 88
- 89.
- 90.
- 91. Journal and ThrustBearings 91
- 92.
- 93.
- 94.
- 95.
- 96.
- 97.
- 98.
- 99.
- 100.
- 101.
- 102.
- 103. Steam Seal System Turbine Packing N5 N1N2 N3 N4 N6 N7 N8 Main Steam Aux. Steam M SSAFV MOV MOV7021 M MOV SSFV M To Heater To Condenser A Diverting Valve M SSUV MOV MSV Below Seat Drains CV Valve Stem Leak-off To/From BFPT Gland Steam Drains F Ventilator Valve Hot Reheat Blowdown Valve 103
- 104. Steam to Packing Turbine Packing N5 N1N2 N3 N4 N6 N7 N8 Main Steam Aux. Steam M SSAFV MOV MOV7021 M MOV SSFV M To Heater To Condenser A Diverting Valve M SSUV MOV MSV Below Seat Drains CV Valve Stem Leak-off To/From BFPT Gland Steam Drains F Ventilator Valve Hot Reheat Blowdown Valve 104
- 105. Unloading and Diverting Valves Turbine Packing N5 N1N2 N3 N4 N6 N7 N8 Main Steam Aux. Steam M SSAFV MOV7025 MOV7021 M MOV7020 SSFV M To Heater 3B To Condenser A Diverting Valve M SSUV MOV7 308 MSV Below Seat Drains CV Valve Stem Leak-off To/From BFPT Gland Steam Drains F Ventilator Valve Hot Reheat Blowdown Valve 105
- 106. Packing Exhaust Turbine Packing N1 Seal Steam N3 Seal Steam N2 Seal Steam Steam Air Heater ExtractionLine N4 Seal Steam N6 Seal Steam N5 Seal Steam N8 Seal Steam N7 Seal Steam From BFPTs Gland Steam Condenser 106
- 107. High Pressure Packing SteamSeal Lands Steam Air Steam Packing Sealing Steam In During Start Up & Low Load, Out at Load Sealing Steam Exhaust Steam Packing Steam Packing 107
- 108. Low Pressure Packing SlantCut Seal Grooves Sealing Steam In Sealing Steam Exhaust Air 108
- 109.
- 110.
- 111.
- 112.
- 113.
- 114. Question 7 What componentseals steam inside the HP Turbine casing? – Thrust bearing – Journal bearings – Packing glands – Turning gear 114
- 115. Question 7 Answer Ifyou said packing glands, you were right. They seal air out of the LP turbine. 115
- 116. Question 8 Why isthe Turbine shaft rotated at slow speed while it cools down? – Prevent sagging of the shaft of the Turbine – Prevent it from cooling down too rapidly – Keep adequate flow of oil – To reduce the steam flow to the turbine 116
- 117. Question 8 Answer Ifyou said prevent sagging of the shaft, you were right. 117
- 118. Turbine Control &Instrumentation Extraction Control Speed Control Instrumentation (Supervisory) Electro-Hydraulic Control (EHC) Turbine Protective System Turbine Trips 118
- 119.
- 120.
- 121. Pilot Valve andActuator 121
- 122.
- 123.
- 124.
- 125.
- 126.
- 127.
- 128.
- 129.
- 130. Turbine Protective System Turbines,even though massive, can be damaged rather easily. Several operating parameters must be maintained to prevent damage When a turbine rotor is allowed to run at overspeed conditions, there may be enough speed to cause complete destruction of the turbine 130
- 131. Turbine Protective System 1stLine of Protection – Main Speed Governor (GE, West.) – Pre-Emergency Governor (GE) – Auxiliary Governor (Westinghouse) – Cut Out Pre-Emergency Governor (GE) – HP Speed Governor – RH Speed Governor (ABB) 2nd Line of Protection – Emergency Governor (Mechanical) (GE,West.,ABB) – Backup Emergency Governor (Electrical) (GE, WEST, ABB) 131
- 132.
- 133.
- 134.
- 135. Generator Motoring Turbines drivegenerators which deliver power to the system under normal operating conditions If the steam input to the turbine is less than the power required to maintain the turbine at rated speed while the generator is synchronized to the system, the power required to maintain the generator and turbine at synchronous speed will come from the system 135
- 136. Generator Motoring (cont.) Turbineshave limits to their ability to operate under motoring conditions The last stages of the low pressure rotors have very long blades which can be overheated by reduced steam flow or degraded back pressure The increased density of the blade environment will result in the overheating of the blades and exhaust hood 136
- 137.
- 138. Turbine Supervisory Instrumentation Local EHC Panel FrontStandard Control Room Bench Boards Control Room Vertical Boards DCS 138
- 139.
- 140. Load Set Load Selector LoadingRate Limit Circuit Breaker Emerg. Trip System Vacuum Trip Mechanical Trip Trip Reset Load 140
- 141. Control Room Instruments& Controls Throttle Pressure Before Seat (Narrow Range) Throttle Pressure Before Seat (Wide Range) Throttle Pressure After Seat First Stage Pressure 141
- 142.
- 143.
- 144. Turbine Supervisory Instruments (cont.) Becausethe rotating parts of a turbine are in close proximity to the stationary parts, it is necessary to measure the expansion of each and compare these measurements to ensure that the parts do not touch. The three measurements of importance are shell expansion, rotor expansion, and differential expansion. 144
- 145. Diff and RotorExpansion Detectors 145
- 146. Relationship Between Rotorand Shell Expansion 146
- 147.
- 148.
- 149. Hot Turbine RotorBow 149
- 150. 150 This section isabout Turbine Vibration
- 151.
- 152.
- 153.
- 154.
- 155.
- 156.
- 157.
- 158. Thrust Bearing WearDetector 158
- 159.
- 160.
- 161. 8 psi decreasing GE ThrustBearing Wear Detector 161
- 162. 30 psi alarm 80psi trip Westinghouse Thrust Bearing Wear Detector 162
- 163. Turbine Control -EHC Hydraulic Power Unit EHC Cabinets EHC Operating Panel Valve Operators Emergency Trip System 163
- 164. EHC Power Unit EHCFluid Tank Primary Pump Filter Pump Instrumentation Fluid Cooler 164
- 165. Valve Position Warming Rate Pre-Warming AuxiliaryValves Chest Pressure Speed Set - RPM Starting Rate Trip Servo Valve Current Stop Valves Control Valves Comb. Reheat Valves Test Valves Test Valves Test Valves Mech. Trip Test Master Trip Solenoid Test Load Limit Initial Pressure Limit Alarms Trip Anticipator Load Limit Set Limiting Pressure 165
- 166. Load Set Load Selector LoadingRate Limit Circuit Breaker Emerg. Trip System Vacuum Trip Mechanical Trip Trip Reset Load 166
- 167. Load Set Load Selector LoadingRate Limit Circuit Breaker Emerg. Trip System Vacuum Trip Mechanical Trip Trip Reset Load 167
- 168. Causes of TurbineTrip Thrust Bearing Wear Low Hydraulic Pressure Loss of Stator Cooling to Generator Low Main Oil Pump Discharge Pressure Loss of both BFPs Loss of EHC pressure Manual Trip Loss of all speed signals High Exhaust Hood temperature Low vacuum in Condenser Loss of Hydraulic Trip pressure 168
- 169. Master Trip Solenoid Closes: –Main Stop Valves – Main Control Valves – Combined Reheat Valves – Extraction line trip Valves Opens: – Packing Blowdown Valve – Ventilator Valve 169
- 170. Question 9 One purposeof extracting steam from a Steam Turbine, other than removing moisture, is to save _________. – water – heat – pressure – temperature 170
- 171. Question 9 Answer Ifyou said heat, you were right. 171
- 172. Question 10 Which ofthe following will likely be the first indication of mechanical problems or damage in a Steam Turbine? – High exhaust hood temperature – High vibration – Speed slightly low – Reheat Steam temperature high 172
- 173. Question 10 Answer Ifyou said high vibration, you were right. 173
- 174.
- 175. Starting and LoadingInstructions (SALI) 175
- 176. Turbine Startup Verify allnecessary systems are operating Electrical Power System, Instrument Air System, Turbine Lube Oil System, Turbine Steam Seal System, Closed Cooling Water System, Hydrogen Seal Oil System, Generator Stator Cooling System, Circulating Water System, Auxiliary Boilers and CRASS, Condensate System, Feedwater System. 176
- 177. Verify that thefollowing conditions exist: At least one Circulating Water Pump is operating with the other Pump in hot standby, Closed Cooling Water Header pressure is at least 75 psig, Condenser Hotwell level is at least 12 inches but less than 36 inches, 177
- 178. Condensate Pump dischargetemperature is less than 125 degrees Fahrenheit and discharge pressure is greater than 75 psig, Deaerator level is at least 5 feet but less than 9 feet, with pressure greater than 75 psig. Condenser vacuum has been established of at least 25 inches of Hg, Generators are full of hydrogen, Turbine Gear Oil Pump is in operation, Motor Suction Oil Pump is running, 178
- 179. Main Turbine ison Turning Gear for the required amount of time, EHC System is operating properly, the Turbine Lube Oil Pump trip and the EHC Fluid Pump has been tested, Main Turbine is tripped, Exhaust Hood Spray is ready for operation, Steam seals are established on the Turbine, 179
- 180. Vacuum hasbeen drawn in the Condensers, The Boiler Trip is reset, The Turbine Master Trip is reset, The EHC First Hit and the Generator-Main Transformer Trip Relays are reset, All Turbine valves are in the proper position for starting the Turbine. Position all Turbine drain valves for Turbine start to make sure that no moisture in the Turbine or Steam lines could damage the Turbine blades. 180
- 181. Shaft Pre-Warming Warming Rate Pre-Warming Auxiliary Valves ChestPressure Speed Set - RPM Starting Rate Trip Valve Position Servo Valve Current Stop Valves Control Valves Comb. Reheat Valves Test Valves Test Valves Test Valves Mech. Trip Test Master Trip Solenoid Test Load Limit Initial Pressure Limit Alarms Trip Anticipator Load Limit Set Limiting Pressure 181
- 182.
- 183. Roll Up theTurbine Warming Rate Pre-Warming Auxiliary Valves Chest Pressure Speed Set - RPM Starting Rate Trip Valve Position Servo Valve Current Stop Valves Control Valves Comb. Reheat Valves Test Valves Test Valves Test Valves Mech. Trip Test Master Trip Solenoid Test Load Limit Initial Pressure Limit Alarms Trip Anticipator Load Limit Set Limiting Pressure 183
- 184. Synchronize and Load LoadSet Load Selector Loading Rate Limit Circuit Breaker Emerg. Trip System Vacuum Trip Mechanical Trip Trip Reset Load 184
- 185.
- 186. Turbine Shutdown Load Set LoadSelector Loading Rate Limit Circuit Breaker Emerg. Trip System Vacuum Trip Mechanical Trip Trip Reset Load 186
- 187. Question 11 The mainpurpose of Turbine Starting and Loading instructions is to reduce Turbine stress and maintain the Turbine ___________. – design – warranty – speed – vibration 187
- 188. Question 11 Answer Ifyou said warranty, you were right. 188
- 189. Question 12 As aSteam Turbine is being started up, the most important instrumentation to check as speed increases is the _______________. – pressure – temperature – vibration – thrust 189
- 190. Question 12 Answer Ifyou said vibration, you were right. 190
- 191. 191 This concludes thistraining presentation. If you have further questions about Power Plant Fundamentals, consult with your supervisor or training manager.