MARC Steam Turbines The Modular Steam Turbine Generation

Engineering the Future since 1758.

MAN Turbo

Originating from the Blohm+Voss shipyard, MAN Turbo AG Hamburg today combines the experience of a traditional company with state-of-the-art technology.

The first steam turbines under the name of Blohm+Voss were manufactured in 1907, initially for ships built in the shipyard and subsequently for electric power generation. Since 1952 the company concentrated on developing and manufacturing industrial steam turbines. The list of worldwide references encompasses more than 2,000 turbo generators.

A wide range of renowned companies and utilities use our turbines, mainly in Industrial power plants Cogeneration plants Waste incineration plants Biomass power plants Combined Cycle plants

Our modern manufacturing facilities in Hamburg are equipped with machine tools of high performance and cover a floor area of more than 10,000 m2. The quality management system is certified to DIN EN ISO 9001. Centrally situated in the free-port of Hamburg, MAN Turbo offers ideal transport links, enabling even large components to be transported with ease.

The concept

The customers demand on durability, efficiency and economy has always had top priority for the development of BVI steam turbines. The result of our permanent development is a solution that sets new standards: The MARC (Modular ARrangement Concept) turbine series has proven its high quality throughout more than 100 installations since its market introduction in 1998. This modular turbine concept allows a flexible arrangement of the auxiliary components and enables the overall assembly to be set up in line with individual requirements.

MARC Turbines
Modular ARangement Concept

MARC 1
Electric power up to 3 MW

MARC 2
Electric power up to 12 MW

MARC 4
Electric power up to 22 MW

MARC 6
Electric power up to 35 MW

MARC 8
Electric power up to 50 MW

Max. flange diameter Live steam: 125 Exhaust: 700

Max. flange diameter Live steam: 200 Exhaust: 1,200

Max. flange diameter Live steam: 250 Exhaust: 1,500

Max. flange diameter Live steam: 300 Exhaust: 2,200

Max. flange diameter Live steam: 350 Exhaust: 2,600

Max. live steam conditions 30 bar(a) / 480C

Max. live steam conditions 90 bar(a) / 520C

Max. live steam conditions 120 bar(a) / 520C

Max. live steam conditions 120 bar(a) / 530C

Max. live steam conditions 120 bar(a) / 530C

up to 15,000 1/min

up to 12,000 1/min

up to 10,000 1/min

up to 8,000 1/min

up to 6,000 1/min

The turbo generator unit comprises the following modules: Steam turbine Gearbox/generator unit LP lubricating oil system HP control oil system Control cabinet The lubricating oil module, control oil module and the control cabinet can be individually arranged around the unit.

Benefits of the modular concept: Proven turbine design with robust technology and high availability Space-saving, low-noise epicyclic gear generator unit (up to 25 MW) High level of efficiency thanks to optimised turbine design and use of epicyclic gearing Use of proven system modules for lubricating oil and control oil Compact control cabinet as blackbox for connection via bus system to the central control system Low investment costs

Five different turbine sizes cover a performance range from 1.5 MW to 50 MW. The MARC production programme includes backpressure, heating and condensing turbines that can also be fitted with extraction and bleed ports. Explanation of type codes: MARC x - A B C x Code for turbine size A Code for turbine type C: Condensing B: Backpressure H: Heating B Number of controlled extractions C Number of bleed ports

Turbine type B: Backpressure Backpressure turbines are used as generator drive units in combined heat and power plants and for on-site electricity generation of industrial facilities. They are also used in cogeneration applications.

Turbine type C: Condensing The areas of application for condensation turbines range from turbo generators for industrial power plants and waste incineration systems through to biomass facilities. The extraction steam is typically used for heating, production purposes and feed water prewarming. To achieve optimum part-load efficiency, the LP part can also provided with a nozzle group control.

Turbine type H: Heating The typical application is electricity and heat generation. The special feature of this turbine type is the double-flow exhaust for connect-ing a two stage heating system. This design provides the most efficient way of electricity and heat production throughout the year.

The new MARC 1

The success formula of the MARC 2 has been transferred to a new MARC model in the power range of 1.5 - 3 MW. Built on the design principles of proven turbines and the positive operational experience gained, the new MARC 1 turbo generator has been developed specifically for use in the smaller segment of biomass applications.

With the MARC concept developed in the mid-1990s, MAN Turbo has successfully established itself in the biomass power plant market sector from 4 - 20 MW electrical output. MAN Turbos operational experience with steam tur-

bines previously supplied for biomass power plants provides compelling evidence of the economic efficiency and operational reliability of this concept.

Turbine module

In industrial turbines, part of the steam often is extracted for production purposes, heating steam systems or generative feed water heating. In that case, in addition to several bleedings, two controlled extractions can also be provided. The MARC concept allows an individual and optimized design of the different turbine elements, according to specific requirements, such as the pressure level and the extraction steam quantity. Depending on the live steam conditions and the specified operation mode, either a nozzle group control with or without bypass or a throttle control may be se-

lected. The control stage, either single or two-row type, and the number of reaction stages are especially adapted to the specific requirements. For all reaction stages the low-loss round-head profile is used.

pulse wheel is only necessary in the upper casing half, how-ever, the lower half can also be utilized, if required. In that case, a bypass leads to the lower nozzle group. The exhaust casing is a welded con-

The HP blades are provided with milled shrouds, whereas the last blade rows are mostly designed with conically twisted blades, the blade ends of which being tip-thinned on one side.The rotor blades of the last rows are grouped by means of damping and bind-ing wires in conformity with the results of vibration calculations. Due to the small flow volume, steam admission of the im-

struction and may either be fitted facing upward or downward, depending on the site conditions. MARC steam turbines have been designed for highest operating security and utmost reliability. As the highest thermal impact on the steam carrying parts occurs at load changes, the casing, guide blade carrier and inner casing have been developed for a high thermal elasticity.

The following design features apply for all turbine types: multi-stage reaction design maximum symmetry of the upper and lower casings symmetrical temperature distribution at the circumference in all crosssections under all load conditions single-piece forged rotor labyrinth sealing glands between rotor and casing split tilting pad sleeve bearings self-aligning axial bearing, for doublesided loading nozzle group control guide blade carrier

Turbine rotors The reaction turbines are supplied with a drum-type rotor. The turbine rotors, the balance piston and the impulse wheel disc as well as the subsequent drum parts are solid forging of high temperature material.The rotor design is based on modern calculation methods to meet the highest demands regarding smooth and resonant-free operation. The bladed rotors are statically and dynamically bal-anced at operating speed in a modern high-speed vacuum balancing plant, in a way that the shaft vibrations over the whole speed range are considerably below ISO10816 permitted values.

Bearings The radial bearings are of multiface sleeve or tilting pad type. A stable rotor position is maintained by hydrodynamical oil wedges, equally spaced on the circumference.The axial forces resulting from pressure differences in the blading are mainly absorbed by the balance piston. A double-sided segmental axial bearing absorbs the residual thrust and the coupling forces.

Bearing Pedestals The bearings are located in two bearing pedestals on which the turbine casing rests by means of brackets on the level of the horizontal joint. The exhaust connection of condensing turbines rests on lateral supports on the level of the horizontal joint. Due to this form of arrangement, the position of the rotor to the casing and thus, the radial blade clearance remain virtually constant under all load and temperature conditions.

Labyrinth Sealing Glands The steam sealing between the turbine rotor and the casing located at the casings ends as well as at the balance piston is a labyrinth sealing type. The sealing strips of high-temperature material are caulked into the rotor. Blading In the blading, consisting of control stage and reaction part, the potential energy of the high-pressure steam is converted into mechanical energy.

Control Stage Due to partial admission, a high degree of dynamical tension occurs in the blades of the control stage. This tension is reduced by grouping the blades in the shrouding.Highly loaded control stages are designed with blade triplets, meaning that three blades having one root together are machined from one workpiece.

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Reaction Part The multi-stage reaction blading ensures utmost reliability and economy due to high mechanical and thermal strengthen both guide blades and rotor blades to withstand operating stress a large sectional modulus to avoid vibrations. low flow losses in the blading covering a wide operating range.

The guide and rotor blades have the same profile. It was theoretically and experimentally tested during its development. Hereby, the characteristics of the profile, depending on the cascade arrangement and the entry angles, were determined by measurements in a plane wind tunnel. A characteristic feature of partload operation is the entry angle deviating from the normal line of flow. The impact-free entry angle range is very large and ensures a high part load efficiency at operating conditions different from those of rated load.

The clearance and rim losses of backpressure turbines and high-pressure parts of condensing turbines are reduced to a minimum by using shrouds. The blade with root and shroud is machined from one piece. After blading the rotor, the shrouding is machined to its form. Regarding stages with a low clearance loss factor, the blade tips are provided with a one-sided thinning.

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Control mechanism The steam control valves of MARC turbines are of a diffuser type. Small valve dimensions allow a vast number of valves and nozzle groups. Consequently, the throttling losses are kept low also at part load. The cone form of the valve has been optimized regarding the flow. Valve spindles, valve cone and valve bar consist of heat-resistant steel with hardened, wear-resistant surface. The hardening is effected via a plasmahardening process.

Due to the small valve dimensions, the steam control valves can be actuated directly. This so-called group drive is a compact and reliable solution. The actuator is a single acting hydraulic cylinder which is fed by the control oil system at an oil pressure of 160 bar. On turbine tripping or full-load disconnection the valves are closed by the pre-loaded spring, thus, protecting the turbine plant at malfunctions. If the pressure in the control oil system decreases, both the control valves and the tripping devices will be closed automa-

tically, as they act on the same principle (single-acting hydraulic piston against pre-loaded spring). This means double security for the turbine and the steam system. A lever system for parallel motion of both valve spindles precisely transmits changes of the controller output onto the valve bar and depending on the valve lift on one or more valve cones. The moving parts are made of non-corrosive and maintenance-free self-lubricating material. The valve spindles are sealed by maintenancefree, pre-compressed graphite laminated glands, and reinforced carbon guide bushes.

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Gearbox/Generator module

Gearbox and generator are installed as one compact unit. For the MARC 2 and the MARC 4, generally an epicyclic gearbox is used which is flanged directly to the generator. For the types MARC 6 and MARC 8 either an epicyclic or a helical gearbox is used, depending on power and speed. The application of epicyclic gearboxes bear the following advantages: The offset usually caused by a helical gearbox is avoided, which greatly facilitates the alignment. Moreover, one coupling and the high-speed gear bearing are omitted which improves the total efficiency.

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Lubrication oil module

Lubrication oil system Turbine Gearbox and generator Diagram of the lubrication oil system 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Turbine Turning gear Extraction Exhaust steam LP control valvel HP control valve Trip valve Gearbox Generator Oil tank Main oil pump 1 Main oil pump 2 Emergency oil pump Oil cooler with cooling water connections 15 Oil filter 16 Oil mist fan

The lubrication oil system* is a compact module designed as a low-pressure oil system for turbine, gearbox and generator, consisting of: complete set of 2 main oil pumps emergency oil pump with DC motor oil cooler redundant oil filter oil mist fan temperature control valve pressure control valve * For MARC1: Combined lubrication and control oil system.

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Control oil module

Control oil system Turbine Gearbox and generator Diagram of the control oil system 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Turbine Gearbox Turning gear Generator LP control valve HP control valve HP trip valve Extraction non-return flap Turbine governor Generator cooler Extraction Exhaust steam Oil tank Circulation pump Control oil pump Control oil cooler Pressure tank

The control oil system is a compact module. The main components are: oil tank designed as base frame main oil pump with AC motor pressure tank redundant oil filter bypass pump oil cooler measuring and control system Apart from the control valves, the system also feeds the live steam trip valve and, if necessary, the extraction-trip valves and control devices in the extraction with a system pressure of 160 bar, commonly used for hydraulic systems.

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Measuring and Control System

Hardware Data storage Ethernet or Profibus Central Processing Unit (CPU) Vibration monitoring Overspeed protection Generator protection Voltage controller cos controller

Function

Turbine open-loop controller Turbine closed-loop controller Turbine protection and monitoring Generator protection Generator controller

Control cabinet The turbo set control cabinet is a compact unit that can be arranged flexibly around the turbine unit. All control functions and protection of the turbine and generator are integrated in a single control box with a user interface on the front. This saves space and ensures minimal installation and commissioning time. All desired signals can be sent via a databus (e.g. Ethernet or Profibus) to a host control system, and operational commands and setpoint values can be received from there.

Control system In order to maintain flexibility when meeting the varied process requirements, the turbine control system is implemented in the modern programmable logic control (PLC) system S7-400. The comprehensive range of modules enables flexible and user-friendly handling of a wide range of communication options to other systems and problem-free expansion, should additional tasks be required. Startup, shutdown and operation of the entire turbine unit are completely automated in the control system, with ease of use being one of its key features.

Based on many years of experience in the field of turbo generator operation, we have developed a digital steam turbine controller. The inte-gration of this controller in the existing control system hardware enables a contin-uous control concept and optimal integration of the controller without additional interfaces. The steam turbine controller is a powerful and flexible device. Speed, output, pressure and temperature are optimally controlled and critical variables are limited. All control modes are seamlessly integrated.

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Control room PC
Ethernet or Profibus

Control cabinet MP270-B SIMATIC CPU 414 - DP

Hardwired Profibus

I/O Rack
Hardwired

ISDN Router

Data Logger PC

Measurement transducer

Generator protection

Overspeed protection

Voltage controller

Emergency switch-off

Hardwired

Field Turbine trip valve

Pressure Limit switch Temperature Control Oil Lubrication Oil Condenser Low voltage switchgear Mean voltage switchgear

External Trips
Turbine

Vibrations
Control box

Operation The turbo generator can be operated either via a central control system or locally, directly via the operator interface on the control panel. In automatic mode only the turbine start/stop commands and specification of the setpoint values are required. All operating modes and fault messages are displayed locally and supplied to the control system via a bus system. In manual mode, local control of the auxiliary modules and components is possible.

Safety All turbine units are provided with extensive safety equipment that safely shuts down the steam turbine and generator when critical conditions are reached. The classification of safety criteria is in accordance with IEC 61508. Measurement systems, trip and alarm criteria are specified in such a way that an optimal balance between machinery protection and availability is achieved. If desired, the design also enables unattended 24-hr operation.

Remote access A datalogger with ISDN interface enables remote support for your operating personnel: Important operating data is saved to a datalogger and can be analysed by our Service Team, while our service engineers have direct access to the control system and control panel. This enables us to provide you with quick and cost-effective support.

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Quality Assurance

The most important principle of turbine manufacture is to ensure high quality standards for all components. The turbines are subjected to the following checks during the manufacturing process. Material inspections Castings inspection Production inspection Assembly inspection

Continuous quality control is ensured by the ISO 9001 quality management system.The turbine and baseframe are erected and the internal piping is installed on the assembly bed. The gearing/generator modular unit is assembled at the generator manufacturer and subjected to a functional check. As with the other modules, both oil modules are tested at the manufacturer prior to their installation adjacent to the turbine on site.

In order to meet the requirements for quiet running, operational safety and high availability of the steam turbines, each turbine rotor is subjected to highspeed dynamic balancing and spin testing in a vacuum spin test facility. After this acceptance test the rotor can be installed.

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Service

Our

experienced

Turbine

Service

MAN Turbo provides person-al consultancy and optimum support for service and repair work as well as for retrofitting. Maintenance and revisions are coordinated between our service department and the customer. Our experienced service staff is available night and day to assure the recommissioning of the plant.
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Department ensures the professional installation of the supplied turbine unit, including commissioning and trial operation. The operating personnel concurrently receive training as required.

MAN Turbo AG Steinbrinkstrasse 1 46145 Oberhausen/Germany Phone +49. 208. 6 92-01 Fax +49. 208. 6 92-20 19 www.manturbo.com MAN Turbo a member of the MAN Group Turbo 1002 e 1208 1.5 ba In the interests of technical progress, subject to change without notice. Printed in Germany. December 2008