Dr NTTPS, Stage-2,3, & Iv are linked to Talcher coal Fields in Orissa to

meet the increased demand. The average distance of Talcher Coal Fields
by train in 950 KMs.

1.1 SPECIAL DESIGN FEATURES OF V T P S:

STAGE-1:
The Coal bunkers and Mills are located in between the Boiler
house and ESPs unlike usual arrangement elsewhere in the country, of
placing the bunkers and mills in between the Turbine House and Boiler.
Thus, the Turbine House is completely isolated from the Mils to ensure
dust free atmosphere in the Turbine House and also to ensure easy
accessibility of Mils of maintenance. Multiple Flue Chimney is also a
new feature at this Power Station.

STAGE Il & III:

The Second and Third stage Boilers, Turbines and Generators
are of a completely new design:
Tower Type Boilers of single pass design manufactured by Ms
B.H.E.L. under collaboration with M/s. Stein Industries (France), KWU
Turbines and Generators of West Germany design are installed in the
second and Third stages.

1) TOWER TYPE BOILERS:

Among the advantages: Drainable beat exchangers and their
edge over Two Pass Boilers when using high ash content coals, lesser
erosion of the heating surfaces compared to Two Pass Boilers etc. The
spacing of the tubes and velocity of gases can be suitably adjusted at the
Design stage to achieve better result. Maintenance of Boiler could be this
faster as there is no need for scaffolding or sky climber for maintenance
of super Heaters and Economizer.
2) DIRECT FIRED TUBEMILLS:
The Tube Mills can nun for a very long time(several thousand
hours) without stopping as the forged balls are fed into the running mill
while a vertical Bowl Mills is prone to frequent shut downs due to its
design consisting of several moving and wear parts wide in system.
Moreover the mill rejects system is completely dispensed with.

3) 6,6 KV vacuum Circuit Breaker- Free from oils and Maintaince.

4) DINTRIBUTED DIGITAL CONTROL SYSTEM(DCS):

Several advantages are there with Distributed Digital Control system as

compared conventional Hardwired system. The performance of the plant right
from its commissioning has been highly satisfactory.

STAGE IV(1 300 MW):

The 7th Unit of Dr.N.T.T.P.S with an installed capacity of 500 MW was

synchronized with grid on 06-04-2009. The commercial operation of the above
unit was commenced from 28.01.2010.

1.2 General Design Features of KWU Turbine:

In the reaction turbine, condensing type tandem compound with

throttle governing and regenerative system of feed water heating It is coupled
directly to generator.

The turbine is suitable for eliding pressure operation to avoid throttling

losses at part loads. The turbine has one single now HP one double now IP and
one double now LP cylinders, steam(150kg/cm2 5350c) is admitted to the HP
turbine through two combined main steam stop and control valves. The lines
leading from two 11P exhaust(40kg/cm2,3430c) branches to the reheated are
provided with check valves, which provided combined stop and control valves
and the exhaust from LP turbine is taken to the LP turbine by two cross around
pipes a the operating floor level. The steam from LPT is exhausted to condenser
at a backpressure of 0.1187 bar(490c).
Technical data:

Type : 210 MW, KWU turbine

Rated output : 210MW

Rated speed : 3000 rpm

Inlet steam pressure of HPT after strainer : 150kg/cm2

HPT exhaust pressure : 40Kg/cm2

Inlet pressure of IPT after, V valves : 35Kg/cm2

LPT exhaust pressure : 0.1187bar

MS inlet of HPT : 5350c

Exhaust : 3430c

Inlet of IPT : 5350c

Weight of approximately : 475 tones

Length approximately : 16.975m

No.of extractions : 6

No.of stages HPT : 1x12

IPT : 1x11

LPT : 2x4

Frequency band : 47.5Hz to 51.5Hz

The major elements of coal fired steam power plant are:

1. Boiler

2. Super heater

3. Turbine

4. Alternator

5. Condenser

6. Cooling tower

7. Hot well

8. Feed pump

9. Economizer(feed water heater)

10. Air preheater

11. Chimney

12. Ash disposal equipment.

 BOILERS

This is a common practice to use high pressure and temperatures of

steam in power plants to increase the efficiency of the plant and to reduce the
cost of electricity production.
The modern high pressure boilers used for power generation are having
steam capacities 30 to 650 tons/ hr, and above with a pressure up to 160 bar and
maximum steam temperature of about 5400c. One of the large boiler plants in
the word is in U.K used in the central electricity generation board. This boiler
was designed for 1700 tons of steam generation per hour at a pressure of 169bar
and a temperature of 560c with one reheat to 5600c burning 220 tons of coal
per hour.

The commonly used boilers are:

1. Water tube boiler
2. Fire tube boiler
2.1 Water tube boiler:
In this boiler the water circulate through tubes while fire surrounds it in
this boiler the formation of steam is high pressure. In this boiler high overall
efficiency up to 90% is possible

.
The water tube boiler are classified in to
1. Babcock and Wilcox boiler
2. Lamont boiler (high pressure boiler)
3. Benson boiler (high pressure boiler)
 Fig.2.1.Diagram of Boiler Plant

2.2 Fire tube boiler:

The fire passes through tubes while water surrounding it, The formation of
steam is at low pressure. In this low overall efficiency is up to 75%.

These types of boiler are

1. Cochran boiler
2. Cornish boiler
3. Locomotive boiler
4. Lancashire boiler
The mostly used in power plant station is
1. Babcock and Wilcoxand
2. Bensonboiler

Babcock and Wilcox boiler:

The boilers used here are water tube type, with a straight tube and are
stationary type. It consists of steam and water drum. It is connected by a short
tube with up take header or raiser at the back end.
The water tubes are inclined to the horizontal and connect the uptake
header to down take header. Each row of tubes are connected to two headers
with number of rows. A mud box is provided with each down take header and
mud that settles down is removed. Dampers are operated by chain which passes
over a pulley to front of a boiler to regulate the draught. The doors are provided
for the man to enter the boiler for repairing and cleaning. Water circulates till
its evaporation. The steam super heater consists of a large number of tubes and
contains two boxes one is superheated steam box and the other is saturated
steam box steam generated in the drum flows in to dry pipe through the inlet
tubes into superheated steam box. Now the steam is taken to the out let pipe to
stop valve.

Advantages:
1. Generates steam at high pressure and rate steam generation is high
2. For given out it occupies less space.
3. Parts are accessible for cleaning inspection and erected easily.
4. The fuel is completely burn due to large heating surface. Hence
efficiency of the boiler is high.
Disadvantages:
1. Required pure feed water to avoid scale formation.
2. Cost of boiler is high.
3. Not suitable for mobile purpose
Benson boiler:
It is a high pressure boiler drum less water tube steam boiler using forced
circulation. In this boiler the feed water enters at one end and discharges at
superheated steam at the other end. The feed pump increases the pressure of
water to super critical pressure, thus the water transforms into steam without
boiling. The feed water passes through the economizer to the water cooled
walls of the furnace. The water receives heat by radiation and temperature
raises to almost critical temperature. Then it enters the evaporator, gets
superheated to some degree, then it passes through the super heater to obtain
desired superheated steam.

Benson boiler is also known as light weight boiler as there is no large

water and steam drum. 90% of thermal efficiency may be achieved by this
boiler. It's operating capacity is 135 tons/ hour at 250 bar.
Advantages:

1. High in weight and occupies smaller floor area.

2. Can be started very quickly.
3. Elimination of drum reduces the cost of boiler.
4. steam at super critical pressure can be generated.
5. Explosion hazards are not occur

Disadvantages:
1. Water treatment is necessary.
2. Difficult to clean the tubes it requires sensitive control
2.3 Boiler Accessories:
Integral parts for the boiler and helps in These are the devices which are used
for efficient running. Some of the boiler accessories are mentioned below

1.Super heater
2.Economizer
3.Air preheater
Super heater:
It is an integral part of the boiler. Its purpose is to increase the
temperature of the steam without raising its pressure. It is placed in the path of
hot flue gases from the furnace, the heat given up by the flue gases is used in
super heating of steam. Steam heaters which are installed with in the boiler are
known as integral super heaters.

Economizer:
An economizer is a feed water device which is used to heat the feed
water by utilizing the heat in the exhaust flue gases before leaving through the
chimney. Economizer improves the economy of steam boiler. Efficiency of
steam generator increases about 1% for each 10of raises in feed water
temperature.

Air preheaters:
Air pre heater is used to recover the heat from the exhaust flue gases. It
is installed between economizer and chimney, Air required for the purpose of
combustion is drawn through the air pre heater is to raise the temperature. It is
then passed through the ducts to furnace. The air is passed through the tubes of
internal heater while hot flue gases are passed over outside of tubes.
 Fig. 3.1. Turbine House

The main function of turbine is to produce power. We can use many

sources to run a turbine like water, gas, steam, etc., while we use steam then
they are called as steam turbines. First the water is sent onto boilers when
steam is generated and this steam is sent through the turbine to generate power.

steam turbine is a prime mover in which heat energy in the steam is

converted into kinetic energy is absorbed by the turbine blades to rotate the
shaft while steam flowing through the turbine. Thus in steam turbines two
energy conversations are required.
 Fig.3.3. T-S Diagram for Rankine Cycle

3.1 Working principle of steam turbine

The steam turbine is essentially a flow machine in which heat energy in

the steam is transferred into kinetic energy and this kinetic energy is utilized to
rotate rotor when steam flows through turbine. During flow of steam through
nozzle the heat converted into kinetic energy. The steam impinges (or) strikes
the blades. Blade is curved so that jet gets dejected. Due to change in direction
the accelerated is produces in the jet of steam has certain mass which is
accelerated produces force due to change of momentum. This force tangentially
on the wheel and locates it. Thus producing mechanical work. The steam jet
while moving over the curved blade exerts some centrifugal force. The pressure
acts normal to blade surface all along its whole length This centrifugal force
result in the change in velocity and it is motive force on the blade
3.2 Classification of steam turbine:
steam turtines are classified as

1)According to action of steam

a Impulseturbine
b Reactionturbine
c Impulse reactiomfurbine

2) According to direction ofsteam

a. Axial flow turbine Steam nowa in a peapendicular direction to axis of
turbine.
b Radial flow turbine:- Steam nows in a direction perpendicular to axis
of turbine.

3) According to the exhaust conditions ofsteam

a.Condensing turbine: Steam flows in at a pressure less than

atmospheric pressure
b Non condensing turbine: Pressure of exhaust steam greater than
atmospheriepressure

4.)According to initial condition

a. Low pressure turbine-1.2 to 2bar

b Medium pressure turbine-up to40bar
c. High pressure turbine-above 40bar

5) According to number ofstages

a. Single stageturbine
b. Multi stageturbine

6) According touse

a. stationary turbine used in power plants, and for driving turbo blowers
and pumps
b. Non stationary turbine- used to drive andsteamers
3.3 Impulse turbine:

In a impulse turbine the potential energy in the steam due to pressure super heat
is converted to kinematic energy in fonu of velowity by expanding it in suitably
shaped nozzles The whole expansion takes place in fixed nozzle passages. As
there is not expansion in the passage between rotor blades, the steam Iressure is
the same at inlet and outlet of these blades. The steam impinges on the blades
causing the wheel to rotate The expansion is carried out in stages ray rofemed to
as pressure stage each stage being separated from the next by a diaphragm with
nozzles openings through which the steam passages on its way through the
turbine.

Impulse turbine is again subdivided into

1. Simple impulse

2. Compoundimpulse

3. Combined impulse
 Fig Turbine Blade Profile
I.Simple impulse turbine:
It consists of a Met of nozzle and blade ring mounted on a rotor, steam
plied from the boiler expands through the nozzle to the exit pressure, aner the
expansion it enters the blades at high velocity and the blades are shaped auch
that steam glides over the blades with out shock. Due to charge in the
momentum steam exert an impulsive force on the blades. This provides driving
torque on die rotor of therurbine
 Fig.3.6. Section through upper half of turbine

3.4 Comparison between impulse and reactionturbines:

4. The blades of impulse turbine are symmetrically shaped around the

centerline, While the blades ofreaction turbine are usually aero foilsection
5. Heat energy of steam could be effective on the impulse turbine only when
the blade is in front ofnozzle.
6. In impulse turbine pressure drops only in the nozzle and remains constant
over the movingblades.
3.6 Reaction turbine:
Reaction turbine consists of ring of fixed blades followed by a ring
moving blades. The fixed blades acts as nozzles and allows a relatively small
expansion of steam. Turbine expansion takes place in the moving blades. Thus
in reaction turbine steam expands continuously and, consequently there is an
increase in specific volume as the expansion proceeds, which is accommodated
by an increase in the size of blades. As the steam expands through blades,
relatively velocity increase and this increase ofrelatively achieved from the
enthalpy drop velocity. Due to increase in relative velocity a thrust or reaction
force acts on blades. This reaction force constitutes the driving force.
Example of reaction turbine is Parson Turbine.
The following figure shows the working principle of reaction turbine

Fig 3.11. Reaction Turbine

Reaction turbines are sub divided into

a. Axial flow
b. Radial flow
c. Combination of impulse and reaction Turbine
Axial flow:
In a pure reaction turbine expansion takes place only as the steam posses
through moving blades. This effect is due to reaction consequent on the
increase in the velocity which accompanies expansion. The reaction turbine has
a ring of stationary blades instead of diaphragm with nozzle passages between
the blades of each pair ofadjacent wheels. The steam expands in fixed blades,
increasing velocity which is imparted to the moving on theprinciple.

Radial Flow:
The steam turbine is really a combined radial and axial flow machine the
flow of steam is radial being admitted at the Centre of the blades disc and
flowing outwards, the steam then being inverted of the axial flow in the last
stages. The turbine may constructed for the single or double motion. With the
double motion design the disc rotates in the opposite direction at the equal
speeds and the relative speed of the blades is the therefore equal to the twice the
running speed. Each steam rotor is couples to an alternator which carries half
totaloutput.

Combination of Impulse& ReactionTurbines:

This type consists of a machine employing the'impulse and reaction'
principles. The high pressures turbine being the'impulse section' and the
intermediate and low pressure turbine being the"reaction turbine' where the
term reaction is used is understood that this refers the"impulse reaction' turbine.
The practice in large output speed sets in the include reaction balding at the low
pressure end. The blade areas are large and the therefore the leakage areas are
proportionately small and as a double flow exhaust is used the end thrust is
balanced. These arrangements enable the length of the turbine to there duced
Chapter 4
 TURBINE OIL SYSTEM

4.1 General:
Mineral oil powessing the properties given below is recommended to be
used as the nad for actuating the governing system The same oil is used for the
purpose of labrication The oil loc-14 of Indian oil company or Mobile DTE
modium generally meets the specification of the oil required for both the
system.

Specification of oil:

1. Specific gravity at500c 0.852

0
2. Kinematic viscosity at 50 cincentistokes 28
3. Neutralization number 0.2
0
4. Flab point in c 201(min)
0
5. Pour point in c 0.01
6. Ash percentage by weight 0.01
7. Mechanical impurities Nil
4.2 Different Governing oil and their Purpose:
In the 210MW KWU turbine single oil used for lubrication of bearings
control oil for governing and hydraulic turbine hiring gear During start-ups aux
oil pump(2nos) wpplies the control oil once the turbine speed is more than 90%
of rated The main oil pump(M.O.P) takes over. It draws oil from man oil tank
The lubricating oil passes through oil cooler

o Control oil: Trapped from Mor discharge header through

emeriency shut off valve and is used for turbine control.

o Start up oil: This was developed from control oil at SXLL device
The purpose is to press the piston or test valve to downward
position there by permitting trip oil now to the space above the
piston of stop valve servomotors resetting the stop valve
servomotor.

o Auxiliary start up oil: Which is developed from control od at

sxLL device, the purpose is to lin piston of main trip valve There
by trip ol now win establish in the main trip valves.

 o Trip oil: Which is developed from control oil by main trip valves-
1&21s for opening and closing of stop valves servomotors and the
Nourue for auxiliary secondary oil and secondaryoils
4.3 oil Circuit:
It indicates the schematie arrangement of important element of oil
syitem and their interconnection.
Main oil pump delivers 3 Lumin oil at 20atm which is directly used for
governing system as well as for lubrication system through injectors 1640 L'min
oil at 20 aug enters de various element of the governing system. Some part of
this oil retums to the suction of main oil pump from governing system(control
valves servomotor and remaining goes lo the oil tank. The balance 2300 L'min
oil at 20atm flows to the injectors.
1360L/ min oil flows to injector I. the oil passing through injector
Isucks 4340Lmin oil from oil tank and thus 5700 Lmin oil is delivered by
injector 1 at latg out of this, 3940 Umin oil flows to suction of main oil pump
and balance 1760 Umin oil flows to suction of injector 2 further raises the
pressure ofoil from latg to 3 atg. The energy for this purpose is provided by the
940 min oil entering the injector 2 at pressure of 20 atg In this manner 2700
Lmin ofoil is delivered by injector 2 at pressure 3 atg
This oil is cooled in oil coolers. Five oil coolers have been foreseen, out
of which four would be normally in service. To maintain the oil temperature
afer this oil cooler at 5050c. valve on the lubrication line maintains the oil
pressure of I atg at bearings under all operating conditions. Remaining oil from
the bearings retums to the oil tank.
When the turbine is at standstill or the speed is less than 3000 rpm,
desired quantity of oil at satm to the governing as well as lubrication system is
supplied by the auxiliary oil pump driven by Ac motor oil the suction of Ao P
nows under gravity from the oil tank
 AC Driven lube oil pump has been foreseen for providing lubrication oil
to the bearings during the boring operation of the turbine. This pump cannot
meet the governing system requirement.
DC Driven lube oil pump has been foreseen as a backup protection to AC
driven lube oil pump. It cuts in under interlock action whenever the oil pressure
in the lubrication line falls to 0.5atm

4.4 Main Elements:

Main oil pump(MOP)

This is a centrifugal oil pump, directly turbine shaft and is the prime
source of supply of oil to the governing and lubrication system when the turbine
is in service, The main technical data are given below:
Technical Data:
l. Pressure corresponding todischarge 4000 Lmin20atg
2. Pressure correspondingtodischarge latg7000 Lmin16atg
3. 3, Suctionpressure 250KW 4 Powerconsumed Auxiliary oil Pump: This
is multi-stage centrifugal oil pump with horizontal arrangement. It is
driven by an alternating cument motor. As a unique feature the pump as
been designed to develop a pressure of 18atg at 1000rpm and 4latg at
1500rpm In this manner the same pump with two different motor can be
used to develop the pressure of 18atg required for normal service and
41atg required for hydraulic testing. The foundation frame of pumping
set is designed to facilitate mounting ofeither motor with the pump.
Technical data Service pump Normal pump Testing Pressure 18atg 4latg
Discharge 3330 LUmin 5000 L/min MotorRating 2000KW 630KW
Speed 1000 rpm 1500 rpm
6.6 KV Supply 6,6KV Frequency 50Hz 50 Hz Lubrication Oil Pump: This is a
centrifugal oil pump, driven an AC motor. The technical data are given below
Technical data: Pumppressure 1.2atg Discharge 2500L min Motorpower 25KW
Speed 1000rpm Supply 415V Phase Lubrication Oil Pump(Emergency): This is
a centrifugal oil pump, driven by a DC motor. This pump feeds lubrication
system when there is failure of AC supply at power station and or the pressure
in the lubricating lines falls to 0.5atg. 4.5 Oil Tank: General: The oil is stored
in the oil tank, which has got holding capacity of 28,000 lit. At opening level
in the tank 4000lit/min oil remains in circulation. Liberally sized tank holds the
inside the tank for a period long enough to ensure liberation of the air from the
oil. Different mesh sized filters, which are located inside the tank, filter the oil
during its normal course. The filters are easily accessible and removable for
cleaning even when turbine is in service.
4.6 OilGauge: The oil gauge is mounted in the oil tank having display
instrument at the turbine floor. The gauge is also provided with limit switches
for annunciation of low and high level in the oil tank. 4.7 Self Regulating
Drainvalve: mounted on the oil tank and it maintains latm pressure in the
lubrication The valve is lie at the bearings. If the pressure falls below latm it
does not act. 4.8 Injectors: The injectors are located in the oil tank and they are
inlet connected with each other in the manner shown in sketch. Each injector
comprises of three parts: a) Nozzle b) Suctionchamber c) Diffuser Injector-1
oil at 20 atg enters in the nozzle of the injectors where the potential energy is
converted into kinetic energy, thereby creating a very low pressure at the
nozzle's outlet. The oil from tank at o atg gets sucked into the suction chamber.
In the diffuser kinetic energy is converted back into potential energy
developing 1 atg ofpressure at delivery. Injector-2 In this injector oil is sucked
from delivery of injector 1 and the potential energy of 940 Lmin oil at 20 atg is
utilized to raise the pressure of oil from 1 atg to 3 atg.
4.9 Pressures witch: The lubrication oil pumps came in service automatically
under interlock action. The impulse for brining the pumps into service is
provided by the pressure switch. It is possible to over-ride the interlock
manually to bring lube oil pumps in service. Pressure switch is mounted on the
oil tank. The relay is provided with a value for testing the reliability of its
operation even when the turbine is inservice. 4.10 Oil Coolers: oil cooler are
used for cooling the oil required for the lubrication of turbine and generator
bearings. The soft raw water can be used as cooling medium. The operation
pressure of cooling water should be lower than the pressure of the oil. Five oil
cooler have been foreseen out of which four are for continuous operation and
one remain as stand by. The important technical data will give over leaf.
Technical data for each cooler: 63m? CoolingSurfacearea 1500 L/min
Quantity ofoilcooled 130 m3/hr Waterconsumption 5 Kg/cm2
Shelldesignpressure 5K g/cm Water boxdesignpressure No. ofwaterpaths 4
Diameteroftubes 19/17mm. 2280mm Lengthoftubes Hydraulic resistanceon
Waterside 1.75 mwc
METHODS OFGOVERNING The methods of steam turbine governing as
follows 5.1 ThrottleGoverningi Throttle governing is most widely used in small
turbines, because of its initial cost and simple mechanism. The throttling is
achieved with the help of double beat balanced valve, which is operated by a
centrifugal governor through servo mechanisun. The effort of the governor may
not be sufficient to move the valve against the piston in big units Therefore an
oil operated relay is incorporated in the circuit to magnify the small force
produced by the governor to operate thevalve, Let the position of the governor
correspond to the full load on the turbine will start to rotate at speed greater than
full load speed as the energy supplied is same An increased speed of the turbine
shaf causes the governor sleeve to move upward and this cause move piston to
move upwards. This upward motion of pilot position allows the higher pressure
oil to enter topside of the relay through upper part and the oil from the relay
cylinder to come out through the point cylinder. The downward motion of the
relay piston partly closes the throttle valve causing the reduction in steam
supply, The reverse opera ration takes place when the load on the turbine
increases, Its mechanism is simple and be capacity(50 to 60kw) in a throttle
governed turbine The relation between steam consumption and load(Kwh is
linear by a straight line called William'sline 5.2 Nozzle Governing: The
efficiency of a steam turbine is considerably reduced when throttle- governing
is carried at low loads. An alternative and more efficient form of governing is
by means of nozzle control. In this method of governing, the nozzles are
grouped into three or more groups and the regulating valves control the supply
of steam to each group, Under full load conditions the valves remain fully
open. When the load on the turbine becomes more or less the desired valve.
The supply of steam to the group of nozzles may be accordingly so as to restore
the originalspeed.
Nozzle control can only be apylind tn the first stage ofturbine it is impulse
turtine and large units have an impulse staze felko wod by an turbine. nonule
set 2 monte set Fig 5.1, Nozzle Governing 5.3 By PassGoverning: The steam is
turbines which are designed to worn at oconomic load. is desirable to have full
admission of steam in the high- pressure stages. At the maximum load which is
greater than economic load. The additional nozzles are not le. By pass
regulation allows for this in a turbines which is throttle governed valve has
opened a definite amount steam is bypassed through the bypass valve to storage
in theturbine.
ss Types of Goven gsystem The governing system can be one of the following
types Mechanical govemingsystem 2. Hydro echanical governingsystem 3. lly
draulic governing 4, Electro-hydraulic governing Mechanical Now a days
purely mechanical governing systems are not used for utility turbines. In this
speed transducer is mechanical centrifugal type specd 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 the hydraulic system this signal is amplified
so that control valves 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 a signal, which is proportional to valve
opening/closure required. Before applying it to control valves servomotors this
signal is suitably amplified Electro-hydraulic: The Electro-hydraulic goveming
offers certain advantages o above three types of governing systems and is
becoming popular for units rating larger than 200 Mw Due to large
interconnected systems and growing automation of turbine generator sets,
governing system has to meet many additional requirements. The combined
advantages of electrical measuring and signal processing(flexibility, dynamic
quality, and simple representation of complicated functional relationships)
and hydraulic controls(continuous controlof large positioning forces provide a
very good combination. In electro-hydraulic governing all transducers are
electricaVelectronic components. The acquisitioned signals are processed
electronically and processed electrical signal is given to electro-hydraulic
converter, which convert electrical signal to hydraulic signal. Hydraulic signal
before application to control valves servomotors is suitably amplified.
GOVERNING AND PROTECTION SYSTEM The following elements are
involved in the normal governing mechanism: 1. Speed governor 2. Follow-up
pilotvalve 3. Speeder gear 4. speed load control pilotvalve 5. Summation
pilotvalve 6. Intermediate pilotvalve 7. Servo motor pilotvalve 8. Servomotor
9. Feedback pilotvalve 10. Control valve 6.1 Specdgovernor: It senses the
variations in the speed of the turbine rotor and converts it into a proportional
movement of the sleeve. This acts on force balance principle. The centrifugal
force of the fly weights being balanced by the tension spring 6.2 Follow-up
pilotvalve: This transmits the movement of governor sleeve to the summation
valve through the lever. The linkages between the sleeve and Pv is hydraulic
and there is no mechanical linkage. The back pressure of the nozzle(5 atg acts
on the right face of the piston. A constant oil pressure(13 atg acts on smaller
area of the left face of the piston and keeps the piston in equilibrium. The
movement of follow-up pilot valve is transmitted through lever to summation
pilot valves. 6.3 Speedergear: This can be actuated either by a hand wheel
provided on turbine front pedestal or by a control switch provided on turbine
desk. This determines the position of speed
oad control pilot valve. This also positions the summation pilot valve through
the lever
6.4 speed load control pilot valve:

The position of this controls the hydraulic impulses to emergency governor pilot
valves of ESVs& IVs through EGPvs

6.5 Summation pilotvalve

This converts mechanical impulses received from follow-up pilot valve and
speed load control. PV into hydraulic signals to intermediate Pv and
differentiator. This in lact controls the drain orifices in the primary sensitive oil
line and differentiator oil line

6,6 Intermediate PV:

This controls inlet orifice of primary sensitive oil and drain orifice of secondary
sensitive oil line. This is under equilibrium due lo the primary sensitive oil
pressure C..7 atg acting at the bottom and a constant oil pressure acting from
above. This is primarily intended to amplify the sensitive oil pressure to 10.3
atg, To be used to position the PV of CV servomotor. The higher sensitive oil
pressure lessens the effect ofreactionary forces of power relay oil flowing to the
servomotor, on the position of pilot valve spool. This causes true reflection of
the secondary sensitive oil pressure on the position ofthe pilot valve.

6,7 Servomotor Pilot Valve:

This receives the secondary sensitive oil pressure impulses and position of the
servomotor accordingly. This is in equilibrium due to the force exerted by
sensitive oil pressure(103 atg on the bottom of the spool and control oil pressure
acting on top of the PV The position of the servomotor PV decides the amount
of oil admitted to the bottom of the servomotor piston and the oil drained from
the top of the piston and vice versa. This regulates the position of the
servomotorpiston

6.8 Servo motor:

This is a double acting piston. The piston is positioned due to the regulation
ofrelay oil admission/dnining by the PV. The piston rod is connected through
horizontal lever to the two racks operating the CVs ofHPT and IPT. Care is
taken to avoid bangingofthepistonatthebottomofthecylinder,
whenasuddendrainingof oil takes place during large load drop by restricting the
oil drain during the end travel of the piston
6.9 Feedback pilot valve:

This receives mechanical impulses from the movement of the servomotor

piston and converts them into hydraulic impulses to servomotor Pv. This in fact
controls the inlet orifice of secondary sensitive oil system, the drain orifice of
which is located in the intermediate Pv as already statedearlier.

6.10 Controlvalves:

There are 4 Nos. CVs for HPT and 4 Nos, CVs for IPT. All the control valves
are operated by a single servomotor as explained earlier. As throttle governing
is adopted for 210 Mw of turbine, the cvs open in a pre-arranged sequence.
This is achieved by suitably shaping the individual cams, which operate the
corresponding CVs.

6.11 BRIEF DESCRIPTIONOF PROTECTIONSYSTEM:

Protection system functions similar to governing system a combination of

mechanical and hydraulic signals on various elements stated below
1. Emergencygovernor

2. Emergency governorlevers
3, Emergency governorindicators
4. Emergency governor testingcock
5. Emergency governor pilotwalve
6. Emergency stop valveservomotor
7. Interceptor valvesenvomotor
8. Turbine shut downswitch

Protection system operates and trips the set(complete closure of emergency stop
valves, inceptors valves and control valves) in the unlikely event of the
following hazards

1. Speed rise upto 111 to 112%

2. speed rise upto 114 to 114%
3. Thrust and wear beyond impermissiblevalves
4. vacuum below 540 mmHge
5. Lube oil pressure below o3atg
6, Main steam temperaturelow,
7. HP heater level extrahigh s.
8.Manual tripping orthe set may be done by pressing the knob oshutdown 9.
Automatic closure of emergency stop valves occurs. If control oil pr drops
below 10atg.
10. Automatie closure of intereeptor valves occurs oil pressure drops below
Satg

PROTECTION AGAINST ovERSPEEDING BY 11 To 12 ABOVE

NOMINALSPEED:

l. Emergency governor strikers, which are eccentric to the to the rotation, ny

out against spring force at a specd 11% to 12 more than ratespeed

2 Strikers strike one end of the emergency govemor evers. The other end of
levers presses impulse pilot spoolsdownwards.

3 The impulse pilot spool converts the mechanical signal into hydraulic signal
and actuates the emergency governor pilot valve to trip theset.

The emergency govemor pilot valve receives hydraulic signal fallow pilot valve
when the speed of the set rises by 14 to 15% above rated speed. The
emergency governor pilot valve receives hydraulic i from the turbine shut down
switch also Emergency governor pilot valve, in turn actuates to close the
servomotor for the emergency stopvalves,

PROTECTION AGAINST OVERSPEEDING 14% TO 15% ABOVE

NOMINALSPEED:
1.In case protection system for 11% to 12 5 speed rise fails to trp the sct.
Speed may go even higher to dangerous valves. For this purpose backup
protection to trip the set a speed 14% to 15% above nominal isprovided.

2. At speed 14% to 15% above rated, follow pilot spool moves towards
extreme right position and gives hydraulic signal to emergency governor
pilotvalve

MANUALAUTOMATIC TRIPPING BY TURBINE SHUT DOWN

SWITCH:

By pressing the knob or by energizing the solenoid, a hydraulic impulse to

emergency governor pilot valve is transferred. EGD valves, in turn actuates to
close the servomotors of emergency stop valve, interceptor valve and
controlvalves.