HPT 12 Stages,1st being governing stage

IPT 11 stages
HP & IP rotors are connected by rigid couplings & have a common bearing
LPT Steam flows in opposite paths having four stages in each path
Rotors of IPT & LPT are connected by a semi flexible coupling.
The three rotors are supported on five bearings The common bearing of HP
& IP rotors is a combined Journal & radial thrust bearing
The anchor point of the turbine is located at the middle foundation frame
of the front exhaust part of LP cylinder. The turbine expands towards the
front bearing by nearly 32 mm. & towards generator by 3 mm. in steady
state operation at full load with rated parameter.
In order to heat the FW in the regenerative cycle of the turbine ,
condensate from the HW of condenser is pumped by the CEP & supplied to
D/A through
Ejector ---> GC-1 ---> LPH-1 ---> GC-2 --->LPH-2 ---> LPH-3 ---> LPH-4
From D/A , FW is supplied to boiler by BFP through HPH-5 ---> HPH-6
--->HPH-7.Extracted steam from various points of the turbine is utilized to
heat the condensate.
Atmospheric To protect LP cylinder against excessive internal pressure
Relief Valve four Atmospheric Relief Valves are provided in the exhaust
hoods.
Each assembly has 1 mm. thick ring 525/525, clamped
between valve seat & valve disc. If due to some reason, the
pressure at the exhaust hood rises to 1.2 abs., then the
disc tries to left & thereby rupture the gasket ring , thus
allowing the steam to exhaust into the atmosphere in the
turbine room.
Gland Steam (a) GSC has been provided to suck & cool the air steam
Cooler mixture from turbine gland seals. It employs a small
ejector for which the working medium is steam of low
parameters which can be taken either from D/A or aux.
source. The pressure & temperature of this steam are not
to exceed 4.5 kg/cm2 & 250 0C resp.
The energy of the steam is retrieved to the fullest extent
as this GSC is interposed in the feed heating cycle thereby
increasing the overall efficiency of the cycle.
(b) The nozzle of ejector has been designed to create a
vacuum & there by reduce the pressure to 0.95 kg/cm2 in
the 1st stage of the cooler. The low pressure in the first
stage sucks the air steam mixture from turbine gland seals.
The steam while flowing over the tube nest gets condensed
in the 1st stage 7 then the remaining AS mixture is sucked
by the ejector& is lead to 2nd stage. The diffuser raises
the pressure from 0.95 to 1.05 kg/cm2(abs).The SA

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 mixture flows over the tube nest of 2nd stage where steam
gets condensed& steam is exhausted to atmosphere. The
condensed drain from gland steam cooler is led to the
condenser through a drain expander & siphon.

Steam Supply To Deaerator

To peg the D/A at 7 ata, normally steam is supplied to the deaerater
either from turbine Ext.-III ES-7(counted from the high pr. side)or Ext –
II(ES-6) depending upon the pr. available at these extractions under
various load conditions. If the turbine is under tripped condition or the
steam pr. at Ext-II isn’t adequate to peg the desecrator at specified pr.,
steam shall be supplied from aux. steam source.
Conditions: -
1. If the steam pr. in the Ex. > than set valve (10.8 kg/cm 2) ES-7, first
shall open fully, then ES-6 will close.
2. The steam pr. in the extraction lines for drip diversion from HPH by
HD valves is measured at the heater ends .The preset value of pr.
ensure natural flow of drain from respective heater to D/A.
For forcing the drain from LPH-2 to the main condensate discharge line two
Drip pumps are provided .For level controller in LPH-2, two different
control zones viz. high level control zone & low-level control zone have been
envisaged. The control valve HD-2 shall act as a final control element for
the high level controller (560mm.) and shall maintain the level at high zone
by cascading the drain to condenser. The control valve HD-3 shall act as a
final control element for the low level controller (200mm.) and shall
maintain the level at low zone by controlling the drip pump discharge.

Drip Diversion (Drip always flows from HPH-7 to 6)

HPH PRESSURE VALVE & VALVE POSITION REMARK

6 Pr.adq. (>10.8kg/cm2) HD 21 HD29 HD30 HD31 High load > 170 MW
5 Pr.adq. (>10.8kg/cm2) CLOSE OPEN CLOSE OPEN DRIP WILL DIVERT FROM
HPH-6-->5-->DEARATOR
6 Pr.adq. (>10.8kg/cm2) HD 21 HD29 HD30 HD31 Medium Load ( 120 MW to
5 Pr.inadq. (<9.8kg/cm2) OPEN CLOSE OPEN CLOSE 170 MW)
DRIP WILL DIVERT FROM
HPH-5-->LPH4--> &
FROM HPH6-->D’TOR
6 Pr.inadq. (<9.8kg/cm2) HD 21 HD29 HD30 HD31 Low load ( Below 120 MW)
7 Pr.inadq. (<9.8kg/cm2) OPEN OPEN CLOSE CLOSE at this load withdraw HPH
DRIP WILL DIVERT FROM
HPH-6-->5-->LPH4
(c/o D/A heating from
extraction to aux. PRDS)

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 DRIP DIVERSION
MEDIUM LOAD OPEN
LOW LOAD OPEN HD21 HD29 HIGH LOAD OPEN
HD30 HD31

Main Steam Supply To Gland Seals Of HPT & IPT

1.All the gland seals of turbine are normally fed with steam from D/A at
controlled pr.( ) & temp( ). Following the turbine trip this
gland steam shall be sucked into the cylinders, which would be under
vacuum at that condition. Since the temp. of gland steam fed from D/A
is much lower than the steam temp. at inlet of HPT & IPT, diff expansion
of HPT & IPT are likely to increase at faster rate under such condition.
In view of above a provision has been made to inject main
steam to the front gland seals of HPT & IPT.
The injection of main steam should be carried manually & the
motor operated valves used in the system shall have interlocked opening &
closing sequence as below: -
1. AS-43 for MS injection to HPT front gland seal shall begin to open
after full closing of AS-47 in the leak off line from HPT front gland seal
to Ex.- IV. Also AS-47 shall begin to open after full closing of AS-43.
2. AS-44 for MS injection to IPT front gland seal shall begin to open
after full closing of AS-48 in the leak off line from IPT front gland seal
to Ex.- IV. Also AS-48 shall begin to open after full closing of AS-44.

NRV In Turbine Extraction Lines

Non return valves in turbine extraction lines are basically intended
for stopping reverse flow of steam during turbine trip out or loss of load
& are equipped with power cylinders to ensure +Ve closing under such
conditions. The non-return valves power cylinders are operated by two
solenoid valves MC-53 &MC-54 which when open, would charge the
cylinders with main condensate discharge.
If one or both ESV or one or both IV closes after synchronization
of generator, the valves MC-53 & MC-54 shall open when on ‘Auto’. These
valves shall reclose after closing of MSV & bypass valves when on ‘Auto’
If generator br. opens the valves MC-53 & MC-54 shall open for
one minute & then reclose when on ‘Auto’ If loss of load results in closure
of ESV & IV within one minute, reclosing of MC-53 &54 as explained
above.
Each of these valves MC-53 & 54 shall have remote manual
opening/closing. Remote manual closing of these valves overriding
interlock shall NOT be possible.

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 Charging Of HPH From Steam Side
SN HPH Details HPH-5 HPH-6 HPH-7
1 Quantity of extraction Steam 16649 40391 31844
2 Extraction steam Pressure 13 28 42
3 Quantity of FW (T/hr) 652 652 652
4 Temp. of FW inlet 170 185 222
5 Temp. of FW outlet 185 222 245
High & V/high magnetrol both side isolating valve should be open. & drain
should be closed before charging from steam side. Otherwise heaters may
get bypassed or set may trip.
HPH taking in service from steam side:-
 HPH flushing:- Crack open (i) ES-3 for HPH-7 (ii) ES-4 for HPH-
6(iii) ES-5 for HPH-5 for 8/4 hrs. Max steam pressure should be
2 to 3 kg/cm2.There should not be any hammering, if any reduce
steam pressure.
 During flushing, water sample to be got tested by Chemist for PH
value, which should be 9 to 9.5
 After due flushing, close HPH shell drip, extraction & evacuation
drains & then steam side vents at Turbine Floor.
 Open evacuation valve CA-8 & HD-32, HPH-5 to LPH-4 drip line
isolating valve.
 Load around 165 MW or above.
 Open ES-3,4,5. Load will decrease by @ 20 MW.
 Wait for levels in HPH-7 (10 min), HPH5 (15 min), HPH-6 (20 min)
 HD-29,31à Opens & HD-21,30 àCloses on interlock.
 Put FW-19, 20, 24 on interlock.
If HPH level very high in any HPH appears, HPH get bypassed in enblock.
High level in any HPH will energize FW-8,9 FW-1 & 2 will close &
condensate pressure to FW-1,2 adequate should appear on CD-5. First
FW-20 closes, then FW-19 closes then FW-24 opens.
IMPORTANT INSTRUCTIONS
1. Steam should be turned to the shell side only after FW flow
has been established through the tubes& on shutting down
steam should be cut off before FW flow is stopped.
2. While warming up, special attention should be given to
venting to make sure that all the air originally present has
been displaced by steam.
SN HPH Interlock HPH-5 HPH-6 HPH-7
1 HPH Low level 200 mm 200 mm 200 mm
2 HPH High level 1350 mm 1350 mm 1350 mm
3 HPH Very High Level 2800 mm 2800 mm 2800 mm

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 Heater Isolation In Case Of Tube Leakage Or Otherwise
The following should be the sequence of isolation to prevent
pressurizing of shell up to feed/condensate pr.& likely ingress of water
into turbine.
1. Steam valve.
2. Feed/condensate valves
3. Drip valve
4. Evacuation valve.
During these operations observe that there is no rise in heater shell
pressure & level.
REVERSE should be the procedure for taking the heaters back into the
service.

Isolation of Pump(like CEP,BFP)

Before closing of the suction valve, discharge valve should be closed
first, otherwise due to passing of NRV, the suction joint may be
subjected to high pressure resulting into failure .If discharge NRV is
provided with bypass , then it should also be closed.

Charging Of HP/LP Bypass Station

(During cold/warm start-up, reheater drains & vents on boiler side should
be opened before boiler is lighted up. This will facilitate removal of water/steam
from the reheater coils which will otherwise condense & collect in the cold/hot
reheat lines at the turbine end. Also at the same time turbine side cold/hot
reheat & HP/LP bypass drains to UFT should be opened. Inspection drains will
indicate that draining is completed. After starting BFP confirm that the water
from inspection drain dose not increase in quantity through passing spray valves.
The drains & vents on boiler side should be closed before vacuum pulling &
turbine side drains to be changed over to CFT.
Above precautions will ensure that there will be no hammering when HP/LP
bypass station is charged (slowly)
Charging of HP/LP bypass station:--
CR-3 Non return valve bypass (L), opens on DI when CR-5 or 6 is closed.
CR-4 Non return valve bypass(R) , opens on DI when CR-5 or 6 is closed.
HP evacuation line valve CR-5 , 6 opens on DI when CR-3 & 4 are closed.
Confirm that CR-3,4 are closed & CR-5,6 are open to avoid inadvertent ingress
of water into HPT. Keep HPT/LPT drains open.
First open LP bypass & then HP bypass. Observe temp. rise in downstream of HP
bypass.)

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1. Confirm cooling water to Sulzer valves (for unit 3 from CEP)
2. Drains towards CFT should be open & those towards UFT close (i.e.
drains after HP/LP by pass Sulzer valves)
3. Spray for HP by pass will not be needed hence BD isolating valves with
its by pass should be kept closed.(This is during cold start.)
4. Both isolating valves of LP by pass spray should be open.
5. Charge HP/LP bypass slowly by first opening LP bypass valves & then
HP bypass. Watch condenser level & exhaust temp.
6. Observe temp. rise in downstream of HP bypass. Then only open
injection isolating valve on the common feed line. After opening of
spray valves, keep close watch on the temp. down stream of HP bypass
valves. Close injection valve immediately on closure of the HP bypass
Sulzer valve.
7. Steam conditioning SH & RH temp. upto 280/300oC
8. Boiler pressure should be maintained 25 to 30 kg/cm2
CASE : -
Problem :- During hot start CRH NRV do not open with Δ pr. of 3 kg/cm 2
i.e. 5 kg/cm2 in CRH line & 8 kg/cm2 in HPT exhaust. This causes the
churning of steam & exhaust temp. gets shoot up.
To avoid the churning of steam, HP bypass valve is manually closed to
drop CRH pressure.
The CRH NRV is provided with pneumatic pr. actuator to force
close the valve with HP bypass valve opened. This hits the NRV flap &
comes out after one minute time delay.

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 Checking Of The Governing & Protection System
1 Set the control gear in its ‘ O ‘ position .Start SOP . Open gate valve OL-
6 on its delivery line & raise the pressure to 20 kg/cm 2
Ensure all the SM of ESVs of HPT, IVs of IPT & CV HPT & IPT are
closed.
2 Set the load limiter to ‘O’ position
3 MSV 1 & 2 & its by pass MS 3,4,5,6 are tightly closed
4 By rotating CG hand wheel in anti clockwise direction open ESVs of HPT,
IVs of IPT & CV HPT & IPT
Observe:-
a) ESV SMs begins to open when reading on the CG scale is @ 5.5mm
& its should be fully opened when the reading on CG scale is @ 6.7
mm. So 1.2 mm travel of CG corresponds to the full opening of ESV
SMs
b) IV SMs begin to open when the reading on the CG scale is @ 4.6
mm. SMs should be fully opened when the reading on CG scale is @
6.0 mm. So 1.4 mm travel of CG corresponds to the full opening of
IV SMs
c) CV SM begin to open when the reading on the CG scale is @ 9.6
mm. SMs should be fully opened when the reading on CG scale is @
12.8 mm. So 3.2 mm travel of CG corresponds to the full opening of
CV SMs
5 Bring back the CG to ‘O’ positions as per its scale & ensure closing of SM
& valves.
6 Check that ESVs close when the oil pressure in the governing system
drops to 10 kg/cm2 & when it drops to 6 kg/cm2 IV also close.

Governor Characteristics
S. N. Speeder Gear Position Event
1 2.5 mm Emergency Governor Charging Starts
2 4.5 mm IVs starts Opening
3 5.5 mm ESVs starts Opening
4 5.8 mm IVs Fully Opens
5 6.8 mm ESVs Fully Opens
6 9.6 mm CVSM Starts Opening
7* 12.6 mm CVSM Fully Opens
*When steam is not admitted to TURBINE

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S.N. CVSM EVENT
POSITION HPT IPT
CV-1 CV-2
CV-2 CV-1
Switch Switch
PCR PCR
Yard Yard
CV-3 CV-4
CV-3 CV-4
1 0 mm All CVs closed All CVs closed
2 5-10 mm All CVs closed CV-1,2 Starts opening
3 40-50 mm All CVs closed CV-1,2 opens more
CV-2,4 Starts opening
4 115-117 mm CV-1,2 Starts opening All CVs are opening
CV-3,4 closed
5 220 mm CV-1,2 opens more All CVs fully opened
CV-3,4 closed
6 235 mm CV-1,2 opens more All CVs fully opened
CV-3 Starts opening at cam
angle 720
7 270 mm CV-1,2,3 opens more All CVs fully opened
CV-4 Starts opening at cam
angle 920
8 300 mm All CVs fully opened All CVs fully opened

Speeder Gear Movement

Starts Opening Full Open
Design Actual Design Actual
IV-L 4.6 mm 4.6 mm 5.90 mm 8.2 mm
IV-R 4.6 mm 4.6 mm 5.90 mm 8.2 mm
ESV-L 5.5 mm 5.8 mm 6.65 mm 8.1 mm
ESV-R 5.5 mm 5.8 mm 6.65 mm 8.8 mm
CVSM 9.6 mm 9.0 mm 12.80 mm 12.6 mm

Starts Open
SG Movement Cam Angle CVSM Position Lift in mm.
HPCV-1 10.2 00 115 22
HPCV-2 10.2 20 118 35
HPCV-3 11.6 720 235 29
HPCV-4 12.3 920 272 16

IPCV-1 8.3 50 5 98
IPCV-2 8.3 50 5 98
IPCV-3 9.4 450 50 83
IPCV-4 9.8 780 80 89

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 Group Protection Device Of HP Heaters
a) In the event of rising of the drain condensate level in any of the HPH to
the emergency level, the feed water flowing through the coils of the
heaters is diverted automatically directly to the boiler, thereby all the
group of three HPHs is by passed.
b) By pass inlet valve 01 consists of 4 chambers A,B,C & D. The slide valve ‘S’
has two positions I & II and it occupies any one of it, depending upon the
upward & downward forces acting on the faces of slide valve ’S’ and on
the faces of the servomotor piston ‘K’.
c) In normal working condition the slide valve ’S’ is at position I and is kept
in equilibrium by an upward force equal to (P1 + P2) minus
(P2+P3+W),where
P1 = force acting on the lower face of slide valve due to feed water pressure
in chamber D
P2 = force acting on the upper face of slide valve due to feed water pressure
in chamber C
P3= force acting on the lower face of the servomoter piston due to
atmospheric pressure in chamber A
P4 = force acting on the lower face of the servomoter piston due to
atmospheric pressure in chamber B
W = weight of slide valve, servomotor piston along with spindles.
d) When the level in any of the HPH rises above fixed height, the electronic
device gives signal to solenoid valve (03),which admits condensate at
pressure 12-16 kg/cm2 into chamber A of the servomotor. Thus the
downward force(P2+P3+W) becomes more than the upward force(P1+P4) &
hence slide valve ‘S’ falls down to position II and closes feed water flow to
HPH, diverting it into by pass line.
e) To lift the valve (S) from position II to I, stop valve (05) & (06) are
opened. By the opening stop valve (06) condensate pressure would release &
the opening of stop valve (5) would admit feed water in chamber D. Thus
there would be resultant upward force & the slide valve would be lifted to
position I.
f) The bypass can be tested/operated manually by opening stop valve (04).In
order to keep the impulse lines upto inlet valve(01) always charged with
condensate, the valve (04) is kept as crack open.
Note:- Before testing the group by pass protection device of HPH, it must
be ensured that the motor operated valves on the steam side of these
heaters are CLOSED.

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 TURBINE WRITE UP
Sr. INDEX Page
No. Nos.
1 Turbine General 1
2 Steam Supply To Deaerator 2
3 Drip Diversion 3
4 Main Steam Supply To Gland Seals Of HPT & IPT 3
5 NRV In Turbine Extraction Lines 3
6 Charging Of HPH From Steam Side 4
7 Heater Isolation In Case Of Tube Leakage Or 5
Otherwise
8 Charging Of HP/LP Bypass Station 5
9 Checking Of The Governing & Protection System 7
10 Governor Characteristics 7
11 Group Protection Device Of HP Heaters 9

10