ERECTION OF 210 MW CAPACITY STEAM TURBINE AND ACCESSORIES r A DISSERTATION Submitted in partial fu!lment of the requirements for the award of the Degree of MASTER OF ENGINEERING in MECHANICAL ENGINEERING (Applied Thermoscience) 0 by SURENDRA KUMAR GUPTA LAM ~n1rV - - CJs-I.- DEPARTMENT OF MECHANICAL & INDUSTRIAL ENGG. UNIVERSITY OF ROORKEE ROORKEE-247672 (INDIA) August, 1981 0ERT.IFICATE a` ~ w rr w r w ww w rw Certified that the dissertation entitled "ERECTION OF 210 NW CAPACITY STEAM TURBINE AND ACCESSORIES" which is being submitted by Shri Surendra Kumar Gupta in partial fulfilment for the award of the Degree of I TER 0' E INE IMING in MEC RAN IC , ENGINEERING (APPLIED THERMO - SCIENCE) of University of Roorkee, Roorkee is a record of candidate' o own work carried out by him under my supervision and guidance. The matter embodied in this dissertation has not been submitted for the award of any other degree or diploma. This is to certify, further, that be has worked for a period of about Seven months from January 1981 to 10th August 1981, for preparing this dissertation for Nas ter of Engineer Degree as a part time student of this University: Dated: Aug./y, 19814 (RAJENDRA tA&&8R` `~ Professoarn d Read Department of fec hanical and Industrial Engineering University of RQorkeo ROORKEE ACKNOWLEDGE ENT S The author* with deep sense of gratitude, wishes to express his sincere thanks to Dr. Ra jendra Prakash, Professor and Bead, Mechanical zkd Industrial Engineering Department for suggesting this topic, for his valuable guidance and encouragement during the preperation of this dissertation. The author expresses his sincere thanks to the Engineers of E.. .E .L. , Hardwar for providing various data required for the dissertat .on. The author is very thankful to Sbri P.I.Baranwal, S .R .P , University of Roorkee for his cooperation during I preparation of this dissertation* strxExnRn uMatt GUPTA ii XIa jor Portion of C cuntryt a Power Demand is being met by thermal power neceeeiat ng more and more instal.. latione of Thermal Power Plants to augment the grid capacity,, Large size turbo sets (210 14W) are forming the back bone of the Po rer Generation programme, now- ai d ays An attempt has been made to stud r the Thermal Power InstallatiOns in India and to depict the recent developments in the field of Steam Turbines. Piwther, various aspects of the erection of a 210 1 W Steam Turbine have been dealt in this report. The details of the Turbine components and its auxiliaries have been studied in the context of their erection Lay out of the Turbine House, aa pertinent to the erection has been described An exact eequenee of operations, needed during erection process, has been discussed in detail. iii LIST OF FIG RES Figure Description page Ro. 1.1 Growth of installed capacity in the ... 4 country in 1 1.2 Addition to Installed capacity in 6 the country. 211 Turbine cycle diagram. ... 30A 2,2 Sketch of lower halt of E,cy1inder. ... 32 2.3 Sketch of lower half of ZP.cylinder. ... 33 3.1 Turbine oil. pipe line system. ' ... 48 3.2 Surface condenser. ... 49A 4.1 View of Turbine Rouse from turbine side, ,.. 61 4.2 Turbine view from oil system side. ... 69A 4.3 Turbine view from ,heater side. ... 71 5.1 In3tallation of cylinders and pedestals • .. 84 as per support reactions. 5.2 Making position of cylinder's by pianowire. . 87 513 Turbine ke positions. .. r go 5.4 Clearances in Journal and Radial ,•. 93 thrust bearings. 5,5 Alignment of lower halves of end seal s .. 97 and diaphragms of Z.P. cylinder. 5.6 Alignment of lower halves c ' end sealings .. 90 and diaphragms of H.P. cylinder 5.7 C entering of Rotors by coupling. ... 104 5.8 Slop of Rotor Journals. • .. 105 iv LIST OF TAB S Table Description Page No# 1.1. Growth of ,nata1led capaci ty in India. 1.2 Additions to capacity in power 5 e ector uptO fourth five year plan. 1.3 Addition 't o capacity inparer 5 ector beyond fourth five year plan. 1.4 Load in India.* .. 8 1 « Location of platform . , . , 13 1.6 operation a equenc a for turbine ,•, erection. CONTENT S PAGE AO NO DGEMsNTS ••, j ABSTRACT ... ij LIST OF ¶PIGU jji LIST OF 'TAB ... is CHAPTER 1 POWER DBVELCPMENT IN INDIA .. I 1.1 Introduction 1 .iR 9 1.2 Pture Growth of Power in India .1. 1.3 ... Thezal. Power Ian!•tallations in India 12 MW 1,4 210 Installations, In India • .. 20 1.5 Proposed 210 Vii` Installations in India . 21 •.. 1.6 Choice of Unit-Size 24 1.7 Installation of Largest Single ... 25 Shaft Turbine O PTER2 DESCRIPTION OP TU IN AND VARIOUS SYSTEMS 27 2.1 Basic Technical a ..e of Turbine i * 2 7 M 2.2 Turbine Power Oyo'ie ... 29 2.3 Constructional Peat'ureo of Turbine ... 31 .. 2„ 4 Turbine Governin System • 37 2.5 Turbine Protection System ... 40 2.6 Turbine Stzpez'viaory Instrument System .. 43 CHAPTER 3 TURBX1 ' AUXILIARIESS .. 46 34 Oil System ... 46 3.2 Condensing System ••• 49 303 Air Evacuation System .,. 50 3.4 8egene v System ... 52 3.5 H.P.L.:P,, BYPSSa Stations ... 54 CHAPTER 4 TURBINE LAYOUT «+. 56 •.. 4.1 General 56 rrangement 4.2 A of St in Power Station ... 58 4,3 Des o.1. T M+ btne ou8 e ... 60 4.4 Selection of MachjneRafl Width i . « 64 4 5 Machine Hall Height . » 66 4.66 Operating Floor Level * w 66 4.7 Capacity of Overhead Crane . » 67 4*8 Location of Condensing Plant .4.. 4.9 Lootion of Oil System Equipment ... 69 4.10 Location of Regenerative Feed 69 Heating Equipment 4.11 Floors and Platforms . ► 72 CHAPTER 5 TURBXN RECTION AT SITE . «; '74 Sol Turbine Poundations . . 74 5.2 Preparatory work . . 75" 5,3 Preperation of turbine Parts and a . 78 Auxiliaries 5,4 Pre eration of Mating Surfaces 79 •1I Of Foundation Frames and Bearing Pedest3p. 5.5 Znsta11aton of Lower Pressure Cylinder. and Checking Loading and Levelling . » » $2 »6 Erection of Middle Bearing Pedestal and X.P.Cylirdor 5.7 installation of Front Bearing Pedestal and R,P.Oyii4der as Preperation of Bearing Bushes and S e& the Rotor 91 5.9 Fixation of Permanent Spacers and. Welding of Condenser with Exhaust Part 9 2 5.l0 Pouring of Concrete in Pow dation 94 5,11 Final Checking of Centertng of Turbine 95 5.12 Installation and Centering of L ,ere, Diaphragis and Seating Chambers in Cylinders 95 4.. 5.13 Checking of Steam Path Clearance, 99 5,14 Closing of Cy].ire3 » .. 100: I 545 Centering of Rotors 103. 5.36 Installation of Governing and Protection Systems 106 5.17 Coupling of turbine with Generator » . 106 5 018 Preservation and Handling of Turbine Parts During Erection 107 5.19 List of 'Tools Used DuringBreotiou w . 108 «.. CHAPTER 6 ERECTION OF AUXILIARIES n2 Condor .• ,. 6.1 Erection of er 12 , , . .6.2 z'eotion -of ©il System 114 4 6.3 i i • Brection of Conde ate Pump 17 6,4 Erection of Connecting Steam . , Pipe Lines x19 6,65 Erection of Connecting Oil , pipe Iinea 119 k CHAPTER 7 0©NCLt$ION. ... 121 'RBPB•RENCE a .. x.23 C H A P T E R- ..-.W..__.._ POWER DvgLopMBNT IN INDIA Li INTRODtTIOi Power developmfnt was initiated in India as early as with the commissioning of hydroelectric power station 1900 at Shiva8amudran in Karnataka, Ins pite of this early beginning the progress was not Impressive till 1947. The then was as low as total ino tslle d capacity of the country 1900 MW and the development was mainly concentrated around urban areas . The growth, of inta1led capacity in power sector can be aeon in table-1.1 and figure 1.1. Power generation ogramrnsp , however, made phenomenal. progress with the advent of Five Year Plans • During the First Plan (1951-56) construction of a numbr of major river valley projects like Bhakra-Nangai, Damodar valley, Hirakud and Chambal valley was taken up and resulted in the stepping up of food production and also power generation. At the and of the First Plan the generation capacity stood at 3,4,20 MW which got increased to 5,700 MV at the end of 1966. During the Third Plan the emphasis was laid on extend i . power o upply to rural areas A significant development in this phase was the emergence of inter-etate grid ayotem. The country was divided into five regions to promote power develop- ment on a regional basis. A regional Electricity Board was established in each region to promote integrated operation of the constituent power systems.