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STEAM TURBINE
0PERATION & MAINTENANCE
INSTRUCTIONS

NO.STE-
NO.STE-TF-
TF-263-MS

MEJIA - DVC 2X500 MW

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BHARAT HEAVY ELECTRICALS LIMITED
RANIPUR, HARIDWAR – 249403 (INDIA)
 Steam Turbine
General
This manual contains information on the
operation and maintenance of steam turbine.
The information has been prepared with the
assumption that the O&M personnel have
basic knowledge of power plant engineering
and operation.
It is an essential prerequisite for satisfactory
operation and maintenance of the steam
turbine that the operating and maintenance
personnel are fully familiar with the design of
the steam turbine plant and receive thorough
training in operating and maintaining the
unit.
Extensive operation beyond rated design
values will eventually result in increased
maintenance expenses or a corresponding
reduction in the useful life of the steam
Mejia-DVC,Unit-1,2 500 MW: Document No. STE-TF-263-MS
SM VS
Prepared
Checked
by
by
Issued by STE (FES), BHEL, Haridwar
BHEL Haridwar
Preface
turbine. Bharat Heavy Electricals Limited
can not be responsible for any malfunction
occurring as a result of operation beyond
rated limits and such operation, if
undertaken by utilities, must be at their own
risk.
The part numbers of components, indicated
in the Description section of the manual
should not be used for ordering spare parts.
Please refer the chapter on Ordering of
spares for that purpose.
Effort has been made to include adequate
information in this manual. For any further
information or clarification please contact:
Field Engineering Services, Steam Turbine
Engineering, BHEL, Haridwar– 249403,
Uttarakhand, India.
SRP PCK SB
Approved
by
Issue 19.08.2009
Date
5.0-0001-63
0 Steam Turbine Contents
Description

Subject Document No Subject Document No

GENERAL ■ Journal bearing IP rear 5.1-0345-01/2
■ Preface 5.0-0001-63/1 ■ Casing supports and guides 5.1-0350-01/2
■ Contents 5.0-0002-63/4 LP Turbine
DESCRIPTION ■ Casing 5.1-0410-00/4
Brief Description ■ Atmospheric relief 5.1-0420-00/1
■ Sectional arrangement 5.1-0001-04/1 diaphragm
■ General description 5.1-0002-04/2 ■ Blading, drum stages 5.1-0430-01/1
■ Fixed points 5.1-0003-02/2 ■ Blading, LP stages 5.1-0440-01/2
Technical Data ■ Shaft seals 5.1-0450-01/1
■ Construction, speed & 5.1-0100-63/3 ■ Rear bearing pedestal 5.1-0460-02/1
Steam pressure ■ Journal bearing 5.1-0470-00/2
■ Steam and casing 5.1-0101-63/2 Turning Gear
temperatures ■ Hydraulic turning gear 5.1-0510-01/1
■ Bearing metal 5.1-0102-63/1 ■ Manual turning gear 5.1-0520-01/1
temperatures, vibration, ■ Hydraulic lifting device 5.1-0530-63/2
weights Control System
■ Oil supply, oil pumps 5.1-0103-63/2 ■ General description 5.1-0600-01/2
■ Control fluid system and 5.1-0104-63/4 ■ Start-up procedure 5.1-0610-01/2
control fluid pumps ■ Speed control 5.1-0620-01/2
■ Limit curves: HP stop & 5.1-0110-01/1 ■ Electrical speed measuring 5.1-0621-02/1
control valve casing ■ Protective devices 5.1-0630-01/2
■ Limit curves: HP casing 5.1-0111-01/2 ■ Over speed trip test 5.1-0631-01/1
■ Limit curves: HP shaft 5.1-0112-01/2 ■ Testing of stop valves 5.1-0632-02/1
■ Limit curves: IP shaft 5.1-0113-01/1 ■ Electro hydraulic LP bypass 5.1-0640-00/1
■ Steam purity values 5.1-0120-01/1 control system (general)
■ Oil specification standard 5.1-0130-04/2 ■ Electro hydraulic LP bypass 5.1-0641-00/2
■ Fire resistant fluid (FRF) for 5.1-0140-04/2 Control (electrical system)
turbine control system ■ Electro hydraulic LP bypass 5.1-0642-00/2
HP Turbine Control (hydraulic system)
■ Valve arrangement 5.1-0205-00/1 ■ Extraction check valve 5.1-0650-01/1
■ Casing 5.1-0210-01/3 ■ Swing check valve (CRH) 5.1-0651-01/1
■ Blading 5.1-0220-02/1 ■ Testing of check valves in 5.1-0652-02/1
■ Shaft seals and balance 5.1-0230-01/2 cold reheat line
piston ■ Automatic turbine tester 5.1-0660-00/1
■ Front bearing pedestal 5.1-0240-01/2 general
■ Rear bearing pedestal 5.1-0250-02/2 ■ Automatic turbine tester 5.1-0661-00/7
■ Combined journal and thrust 5.1-0260-01/2 for protective devices
bearing ■ Automatic turbine tester 5.1-0662-01/4
■ Journal bearing, HP front 5.1-0270-01/2 stop and control valves
■ Casing supports and guides 5.1-0280-01/2 ■ HP actuator 5.1-0665-00/1
IP Turbine ■ Electro hydraulic seal steam 5.1-0670-01/4
■ Casing 5.1-0310-01/3 pressure control
■ Blading 5.1-0320-02/1 ■ Governing scheme 5.1-0680-05/1
■ Shaft seals 5.1-0330-01/2 ■ Control system diagram 5.1-0681-05/5
5.1-0681-01/5
■ Rear bearing pedestal 5.1-0340-02/1 legend

BHEL Haridwar 5.0-0002-63/1

 Subject Document No Subject Document No
■ Lubrication chart 5.1-0690-05/3 ■ Over speed trip releasing device 5.1-0921-00/2
Control System Parts ■ Over speed trip test device 5.1-0922-00/2
■ Hydraulic speed governor with 5.1-0710-00/2 ■ Low vacuum trip 5.1-0935-00/1
starting and load limiting device ■ Condenser safety device 5.1-0940-00/1
■ Adjusting gear 5.1-0720-00/1 ■ Solenoid valve for tempera- 5.1-0950-00/1
■ Electro hydraulic converter 5.1-0730-02/3 ture controlled interlock
for turbine control system ■ Vacuum breaker 5.1-0960-02/2
■ Hydraulic amplifier for 5.1-0740-02/3 ■ Pressure switch for injection 5.1-0970-00/2
turbine control system water
■ Electrical speed pick-up 5.1-0760-01/1 ■ Changeover valve for 5.1-0980-00/1
■ Pressure converter 5.1-0761-00/1 testing device
Steam valves and Oil Supply
accessories ■ Oil supply system 5.1-1000-63/4
■ Combined main stop and 5.1-0810-01/2 ■ Oil vapor extraction system 5.1-1001-63/2
control valve ■ Oil discharge & vent system 5.1-1002-63/2
■ Servomotor for main & 5.1-0811-00/1 ■ Oil purification system 5.1-1003-63/1
reheat stop valves ■ Main oil tank 5.1-1010-01/2
■ Hydraulic servomotor for 5.1-0812-00/2 ■ Main oil pump with hydraulic 5.1-1020-01/2
main & reheat control valves speed transmitter
■ Test valve for emergency 5.1-0813-00/1 ■ Auxiliary oil pump 5.1-1030-01/1
stop valve ■ DC emergency oil pump 5.1-1040-01/1
■ Combined reheat stop & 5.1-0814-00/2 ■ Jacking oil pump 5.1-1050-00/2
control valves ■ Oil throttle 5.1-1080-00/1
■ Hangers for reheat stop & 5.1-0815-01/1 ■ Oil throttle 5.1-1081-00/1
control valves ■ Three way control valve for 5.1-1090-01/1
■ Steam strainer 5.1-0816-00/1 Lubricating oil temp. control
valve Control Fluid Supply
■ Changeover valve for 5.1-0840-00/1 ■ HP control fluid pump with 5.1-1110-00/1
bleeder check valve LP extraction
■ Auxiliary valve of extraction 5.1-0841-00/2 ■ Plate-type filter 5.1-1120-00/1
check valve ■ Duplex filter for pilot control 5.1-1130-00/3
■ Rotary vane actuator for 5.1-0853-01/1 of control valves
reheat swing check valve ■ Regenerating plant 5.1-1140-00/3
■ Pilot valve for rotary vane 5.1-0854-00/1 Other Systems
actuator of swing check valve ■ Drain system (MAL) 5.1-1210-63/2
■ Auxiliary pilot valve for 5.1-0855-00/1 ■ System diagram index 5.1-1220-63/3
rotary vane actuator of ■ Component diagram index 5.1-1230-63/11
reheat swing check valve ■ Shaft seal system 5.1-1240-63/5
■ Gland steam control valve 5.1-0860-01/1 Operation
■ Leakage steam control valve 5.1-0870-01/1 ■ Introduction 5.2-0001-01/1
Protective Devices ■ Specification of steam, oil & 5.2-0002-00/1
■ Main trip valve 5.1-0910-00/2 control fluid
■ Emergency trip valve for 5.1-0911-00/1 ■ Testing of turbine 5.2-0020-00/1
manual trip out Components - General
■ Solenoid valve for remote 5.1-0912-00/1 ■ Turbine systems testing
trip out testing intervals
■ Over speed trip 5.1-0920-00/1 □ Controllers 5.2-0021-01/1
□ Automatic turbine tester 5.2-0022-01/1

5.0-0002-63/2
 Subject Document No Subject Document No
□ Automatic turbine tester 5.2-0023-01/1 ■ Turbine stress controller: 5.2-0430-01/5
□ Protective devices 5.2-0024-01/1 measures to avoid
□ Safety devices 5.2-0025-01/1 impermissible operation
□ Valves 5.2-0026-01/1 ■ Stop & control valves 5.2-0440-01/2
□ Monitoring devices 5.2-0027-01/1 ■ Protective devices 5.2-0450-01/7
□ Operating parameters 5.2-0028-01/1 ■ Automatic turbine tester 5.2-0455-00/9
Start-up ■ Oil system 5.2-0460-00/6
■ Starting the turbine 5.2-0110-01/1 ■ Control fluid system 5.2-0470-00/3
■ Startup & shutdown 5.2-0111-00/1 ■ Gland steam system 5.2-0480-01/1
diagrams, symbols MAINTENANCE
■ Startup diagram ■ Introduction 5.3-0001-01/1
□ General 5.2-0112-00/2 ■ Inspection schedule 5.3-0010-04/3
□ Preparation for startup 5.2-0113-00/1 ■ Maintenance schedule
□ Operating position of 5.2-0120-00/1 □ Turbine 5.3-0021-02/1
manually operated valves □ Oil system, seal steam 5.3-0022-01/3
□ Oil System & Turning Gear 5.2-0130-02/5 system, drains
□ Control fluid system 5.2-0135-02/4 □ FRF system 5.3-0023-01/2
start-up diagram ■ Testing during start-up 5.3-0030-02/7
□ Condensing Plant 5.2-0140-02/4 ■ Testing during power 5.3-0035-02/5
□ Bypass System 5.2-0150-00/3 operation
□ Warm-up & startup of turbine 5.2-0160-02/6 ■ Acquisition & archiving of 5.3-0037-03/3
□ Temperature criteria 5.2-0170-01/4 operating data
□ Controllers 5.2-0180-00/4 ■ Remedial actions for off- 5.3-0040-01/6
On-load Running normal operating conditions
■ Load operation, Introduction 5.2-0200-00/1 ■ Measurement of internal 5.3-0050-02/3
■ Synchronization and loading 5.2-0210-00/5 efficiency
■ Power operation, controllers 5.2-0220-00/9 ■ Testing during shut down 5.3-0060-01/5
■ Actions to prevent 5.2-0230-00/4 ■ Testing during standstill 5.3-0061-02/6
unallowable heat-up ■ Testing of safety valves 5.3-0062-01/1
through blade wind age ■ Testing of signaling devices 5.3-0063-00/2
Shut-down ■ Testing of TSC 5.3-0064-01/4
■ Introduction 5.2-0300-00/1 ■ Steam washing of turbine 5.3-0070-02/3
■ Shutdown diagram ■ Turbine Oil care 5.3-0080-03/11
□ General 5.2-0310-01/1 ■ Grease and Oil lubrication 5.3-0081-00/1
□ Turbine-generator 5.2-0320-02/5 ■ Care of control fluid 5.3-0082-02/9
□ Condensing plant 5.2-0330-01/2 ■ Determination of FRF purity 5.3-0083-01/2
□ Oil system 5.2-0340-01/2 ■ Vibration dampers 5.3-0100-00/2
■ Fast cooling down of turbine 5.2-0350-01/1 ■ Instructions for overhaul 5.3-0200-05/8
■ Preventing corrosion in 5.2-0360-00/2 ■ Turbine restart after boiler 5.3-0210-00/1
idle turbine repairs
Fault Tracing ■ Turbine restart after major 5.3-0220-00/3
■ Introduction 5.2-0400-00/1 inspections or repairs
■ Serious faults 5.2-0410-00/8 ■ Environmental protection 5.3-0250-00/1
■ Vibration 5.2-0420-00/5 □ Fluorelastomer products 5.3-0251-00/1
■ Bearing temperature 5.2-0421-01/1 safety notice
■ Casing temperatures 5.2-0423-02/2 □ Safe disposal of turbine oil 5.3-0252-00/1
■ Ordering of spares 5.3-0300-00/1

5.0-0002-63/4
 Steam Turbine
Description Cross Sectional Arrangement

BHEL Haridwar 5.1-0001-04

 Steam Turbine
General
This manual contains information on the
operation and maintenance of steam turbine.
The information has been prepared with the
assumption that the O&M personnel have
basic knowledge of power plant engineering
and operation.
It is an essential prerequisite for satisfactory
operation and maintenance of the steam
turbine that the operating and maintenance
personnel are fully familiar with the design of
the steam turbine plant and receive thorough
training in operating and maintaining the
unit.
Extensive operation beyond rated design
values will eventually result in increased
maintenance expenses or a corresponding
reduction in the useful life of the steam
Mejia-DVC,Unit-1,2 500 MW: Document No. STE-TF-263-MS
SM VS
Prepared
Checked
by
by
Issued by STE (FES), BHEL, Haridwar
BHEL Haridwar
Preface
turbine. Bharat Heavy Electricals Limited
can not be responsible for any malfunction
occurring as a result of operation beyond
rated limits and such operation, if
undertaken by utilities, must be at their own
risk.
The part numbers of components, indicated
in the Description section of the manual
should not be used for ordering spare parts.
Please refer the chapter on Ordering of
spares for that purpose.
Effort has been made to include adequate
information in this manual. For any further
information or clarification please contact:
Field Engineering Services, Steam Turbine
Engineering, BHEL, Haridwar– 249403,
Uttarakhand, India.
SRP PCK SB
Approved
by
Issue 19.08.2009
Date
5.0-0001-63
 Steam turbine
Description
Construction, Steam Flow
The turbine is a tandem compound machine with
separate HP,IP and LP sections. The HP section
being a single-flow cylinder and the IP and LP
sections double-flow cylinders. The turbine
rotors and the generator rotor are connected by
rigid couplings.
The HP turbine is throttle controlled. The initial
steam is admitted ahead of the blading via two
main stop and control valve combinations. A
swing check valve is installed in the line leading
from HP turbine exhaust to the Reheater to
prevent hot steam from the reheater flowing
back into the HP turbine.
The steam coming from the Reheater is passed
to the IP turbine via two reheat stop and control
valve combinations. Cross around pipes connect
the IP and LP cylinders. Connections are
provided at several points of the turbine for
feedwater extraction purpose.
HP Turbine, Barrel Type Casing
The outer casing of the HP turbine is of the
barrel type and has neither an axial nor a radial
flange. his prevents mass concentration which
would have caused high thermal stresses. The
almost perfect asymmetric design of the casing
permits moderate and nearly uniform wall
thickness at all sections. The inner casing is
axially split and supported so as to be free to
move in response to thermal expansion. As only
slight pressure differences are effective, the
horizontal flange and joint bolts of the inner
casing can be kept small. The barrel type casing
permits flexibility of operation in the form of short
start-up times and a high rate of change of load
even at high initial steam conditions.
IP Turbine
The IP turbine section is of double flow
construction with horizontally split casings.
Allowance is made for thermal movement of the
inner casing within the outer casing. The inner
casing carries the stationary blading. The
reheated steam enters the inner casing from top
and bottom. The provision of an inner casing
confines high steam inlet conditions to the
admission section of this casing, while the joint
flange of the outer casing is subjected only to
the lower pressure and temperature effective at
the exhaust from the inner casing.
BHEL Haridwar
General Description
LP Turbine
The casing of the double-flow LP cylinder is of
three-shell design. The shells are horizontally
split and are of rigid welded construction. The
innermost shell, which carries the first rows of
stationary blades, is supported so as to allow
thermal expansion within the intermediate shell.
The intermediate shell rests at four points on
longitudinal girders, independent of the outer
shell. Guide blade carriers, carrying the last
stationary blade rows are also attached to the
intermediate shell.
Blading
The entire turbine is provided with reaction
blading. The stationary and moving blades of the
HP and IP sections and the front rows of the LP
turbine are designed with integrally milled
inverted T -roots and shrouds. The last stages of
the LP turbine are fitted with twisted drop -forged
moving blades with fir-tree roots engaging in
grooves in the shaft with last stage stationary
blades made from sheet steel.
Bearings
The HP rotor is supported on two bearings, a
journal bearing at its front end, and a combined
journal and thrust bearing immediately next to
the coupling to the IP rotor. The IP and LP rotors
have a journal bearing each at rear end. The
combined journal and thrust bearing
incorporates a journal bearing and a thrust
bearing which takes up residual thrust from both
directions. The bearing metal temperatures are
measured by thermocouples directly under the
babbit lining. The temperature of the thrust
bearing is measured in two opposite thrust pads.
The bearing pedestals are anchored to the
foundation by means of anchor bolts and are
fixed in position.
The HP and IP turbines rest with their lateral
support horns on the bearing pedestals at the
turbine centerline level. The HP and IP casings
are connected with the bearing pedestals by
casing guides, which
establish the centerline alignment of the turbine
casing.
The axial position of the HP and IP casings is
fixed at the support brackets on HP-IP bearing
pedestal.
5.1-0002-04/1
The fixed point for the LP casing is at the front
point of support on the longitudinal girder.
Thermal expansion of the casings originates
from the fixed points.
Shaft Seal and Blade Tip Sealing
All shaft seals, which seal the steam in the
casings against atmosphere, are axial-flow
type. They consist of a large number of thin seal
strips which, in the HP and IP turbines are
caulked alternately into grooves in the shafts
and the surrounding seal rings. In the LP
turbine, the seal strips are caulked only into the
seal rings. Seal strips of similar design are also
used to seal the radial blade tip clearances.
Valves
The HP turbine is fitted with two main stop and
control valves. One main stop valve and one
control valve with stems arranged at right angles
to each other are combined in a common body.
The main stop valves are spring-action single-
seat valves; the control valves, also of single-
seat design, have diffusers to reduce pressure
losses.
These valve combinations are located at both
sides of the turbine with their stems horizontal.
The HP valves are connected to the turbine by
easily separable collar couplings, which contain
self-sealing U-rings as sealing elements.
The IP turbine has two reheat stop and control
valves. The reheat stop valves are spring-action
single-seat valves. The control valves, also
spring-loaded, have diffusers. The control valves
operate in parallel and are fully open in the
upper load range. In the lower load range, they
control the steam flow to the IP turbine and
ensure stable operation even when the turbine-
generator unit is supplying only the station load.
The reheat stop and control valves are
supported free to move in response to thermal
expansion on the foundation cover plate below
the operating floor and in front of the turbine-
generator unit. All valves are actuated by
individual hydraulic servomotors.
5.1-0002-04/2
Turbine Control System
The turbine has an electrohydraulic control
system. An electric system measures speed and
output and controls them by operating the
control valves hydraulically via an
electrohydraulic converter. The electrohydraulic
controller ensures controlled acceleration of the
turbine-generator up to rated speed and limits
speed overshoot in the event of sudden load
rejection. The linear power frequency
droopcharacteristic can be adjusted in fine steps
even
when the turbine is running.
Turbine Monitoring System
In addition to measuring and display instruments
for pressure, temperatures, valve lifts and
speed, the monitoring system also includes
instruments for measuring and indicating the
following parameters:
 Rotor expansion measured at the rear-
bearing pedestal of the LP turbine
 Axial shift measured at the HP-IP pedestal
 Bearing pedestal vibration, measured at all
turbine bearings
 Shaft vibration measured at all turbine
bearings
Oil Supply System
A common oil supply system lubricates and
cools the bearings . The main oil pump is driven
by the turbine shaft and draws oil from the main
oil tank. Auxiliary oil pumps maintain the oil
supply on start-up and shutdown, during turning
gear operation and when the main oil pump is
faulted. DC Emergency oil pump supplies oil to
the bearings during AC power failures.
A Jacking oil pump forces high-pressure oil
under the shaft journals to prevent boundary
lubrication during turning gear operation. The
Jacking oil pump also supplies the high pressure
oil to the Hydraulic Turning gear motor. The
lubricating and cooling oil is passed through oil
coolers before entering the bearings.
The control fluid pumps situated on a control
fluid tank supply the hydraulic turbine and
bypass control system and the protective
devices and valve actuators with HP and LP
control fluid.
 Steam Turbine
Description
Design of the supports for the turbine has to
allow for the expansion of the turbine during
thermal cycling. Constrained thermal expansion
would cause overstressing of the components.
The method of attachment of the turbine
components is also critical to the magnitude of
the differential expansion between the rotor and
turbine casings which is given careful attention
in the determination of internal clearances.
The following components form the fixed
points for the turbine:

The HP, IP and LP turbine bearing pedestals

The horn supports of the HP and IP
turbine at
HP- IP Pedestal

At turbine end of longitudinal girder of the
LP Turbine

The thrust bearing in the HP turbine rear
bearing pedestal
Casing Expansion
The bearing pedestals are anchored to the
foundation by means of anchor bolts and are
fixed in position. The HP and IP turbines rest
with their lateral support horns on the bearing
pedestals at the turbine centerline level. The HP
and IP casings are connected with the bearing
pedestals by casing guides which establish the
centerline alignment of the turbine casings. The
axial position of HP and IP casings is fixed at the
HP-IP pedestal. Thermal expansion of the
casings originates from the fixed points. The LP
Turbine outer casing is held in place axially, at
turbine end of longitudinal girder by means of
fitted keys. Free lateral expansion is allowed.
BHEL, HARIDWAR
Fixed Points
Centering of LP outer casing is provided by
guides which run in recesses in the foundation
cross beam. Axial movement of the casings is
unrestrained.
Hence, when there is a temperature rise, the
outer casings of the HP turbine expand from
their fixed points towards Front pedestal. Casing
of IP Turbine expand from its fixed point towards
the generator.
LP Casing expands from its fixed point at front
end, towards the generator.
Rotor Expansion
The thrust bearing is housed in the rear bearing
pedestal of the HP turbine. The HP turbine rotor
expands from the thrust bearing
towards the front bearing pedestal of the HP
turbine and the IP turbine rotor from the thrust
bearing towards the generator.
The LP turbine rotor is displaced towards the
generator by the expansion of the shaft
assembly, originating from the thrust bearing.
Differential Expansion
Differential expansion between the rotors and
casings results from the difference between the
expansion of rotor and casing originating from
the HP-IP pedestal. The largest differential
expansions of the HP and IP turbines thus occur
at the ends farthest from the thrust bearing.
Differential expansion between the rotor and
casing of the LP turbine results from the
difference between the expansion of the shaft
assembly, originating from the thrust bearing
and the casing expansion, which originates from
the fixed points on the LP turbine longitudinal
beams.
5.1-0003-02/1
solenoid valve so that the auxiliary trip fluid
circuit is connected to drain. Trip initiation is
monitored downstream of the main trip
valves by pressure switches MAX51CP209
and MAX52CP211 in the auxiliary trip fluid
circuit. In addition, the limit switch of each
main trip valve must annunciate successful
completion of the test.
Latching -in
On successful completion of testing, remote
trip solenoids MAX52AA001 and MAX52
AA002 are de-energized. The reset program
is then started.
Overspeed Trips
MAY10AA001/MAY10AA002
Function
The two over speed trips are provided to
protect the turbine against over speeding in
the event of load rejection coincident with
failure of the speed controller. As they are
particularly important to the protection of the
turbine, they can also be locally tested by
manually with the aid of the over speed trip
test device MAX62AA001 (hydraulic test
signal transmitter) during turbine operation
at rated speed. (For description see Over
Speed Trip Test).
Operation
When the preset over speed is reached, the
eccentric flybolt/striker (2) of each over
speed trip activates piston (5) and limit
switch (6) annunciate via pawl (4). This
connects the auxiliary trip fluid circuit to
drain, thereby depressurizing it. The loss of
auxiliary trip fluid pressure causes the main
trip valve to drop which in turn causes the
trip fluid pressure to collapse.
To activate the over speed trip at rated
speed, as the test routine performed by the
automatic turbine tester requires, a specific
force, equivalent to the increase in
centrifugal force between rated speed and
preset trip over speed, is needed .For
testing, this force is exerted by the test oil
pressure, acting on the flybolt /striker (2) .On
the basic of the existing defined geometry,
the test oil is reproducible measure for the
trip speed, and can therefore be used to
check whether the over speed trip responds
at the desired setting.
Test Sequence
The test oil pressure is produced using the
hydraulic test signal transmitter, which is
also used for manual testing. First the
command is given to the actuator motor to
go into the trip position (down). After a
certain idling time, the test oil pressure
builds up to act on the two over speed trip
flybolts/strikers (2).
If the two bolts are functioning correctly, they
will fly outwards into the trip position when
the defined pressure is reached, thereby
activating the main trip valve via pawl (4),
piston (5) and the auxiliary trip fluid circuit.
The two over speed trips are monitored for
activation at the given test oil pressure by
the two pressure switches MAX62CP211
and MAX62CP212 in the test oil line, and
the limit switch (6). Pressure switches MAX
62CP211 and MAX62CP212 are preset to
respond at a certain level (approx.O.15 bar)
below and above the test oil reference
5.1-0661-00/5
pressure respectively. This test oil reference operation, the pressure in the turbine
pressure is determined during condenser exceed a preset valve.
commissioning and entered in the
commissioning test record. Limit switch (6) Operation
must respond within the pressure range
When the condenser pressure exceeds the
between the settings of pressure switches
adjusted limit, the piston (6) is moved
MAX62CP211 and MAX62CP212. A slow
downwards by this pressure, which acts
buildup of pressure is required for this
against diaphragm {4), and the spring force
operation, that is why a relatively long
(3). Thereby pressure below piston (7) drops
monitoring period equivalent to the running
and this piston moves in its lower end
time of the actuator, has to be selected.
position by spring force connecting the
Premature response of the over speed trips
auxiliary trip fluid circuit to the drain. The
is annunciated.
resultant depressurization of the auxiliary
trip fluid circuit actuates main trip valves
Latching-in MAX51AA005 and MAX51AA006, thereby
closing all turbine valves.
Once the trip has been initiated, the actuator
of the hydraulic test signal transmitter is
driven back until the limit switch annunciates
that normal position has been reached.
Monitoring must be continued until the test
oil pressure at pressure switch MAX62
CP213 is less than 0.1 bar.
This double check-back of the hydraulic test
signal transmitter having returned to normal
position ensures that, after completion of
testing, the over speed at which the turbine
will trip is not reduced due to test oil
pressure remaining effective and that the
over speed trip will not be set off
prematurely in the event of load reduction.
While test oil pressure is decreased, the two
over speed flybolts/strikers spring back into
their normal positions at a pressure well
above 0.5 bar.
Subsequently, piston (5) is brought back into
its normal position by the pressure of
auxiliary start-up fluid II and latched-in with
pawl (4). At the same time, piston (5) shuts
off drain channel IV, so auxiliary trip fluid III
can build up pressure. Once this has been
done, the auxiliary start-up fluid can be
Test sequence
depressurized.
After energizing of test signal transmitter
(solenoid valve) MAG01AA201, fitted in the
signal line to the condenser, this signal line
Low Vacuum Trip is blocked off and simultaneously the space
MAGO1 AAO11 above diaphragm (4) is connected to
Function atmosphere. The air flow via orifice causes a
slow increase of pressure by which the
The function of the low vacuum trip is to pistons (6) and (7) move to their trip position
operate the main trip valve if, during normal
connecting the auxiliary trip fluid circuit to
the drain.

5.1-0661-00/6
The low vacuum trip is monitored for Dispersion of the auxiliary start-up fluid
operation within the specified vacuum range pressure is monitored by pressure switch
by observing pressure switches MAG01 MAX48CP201. The second reset solenoid
CP202 and MAG01CP204. MAX48 AA202 is then de-energized to
disperse the pressure between the two-
solenoid valves. This is monitored by
Latching-in pressure switch MAX48 CP202. The use of
When test signal transmitter (solenoid valve) two reset solenoids ensures that main trip
MAG01AA201 has been de-energized and valve MAX51AA005 and MAX51AA006 and
the connection between low vacuum trip and over speed trip will always be sure to be
the condenser re-established, condenser actuated if either one of the two reset
pressure builds up again above diaphragm solenoids is de-energized.
(4). Piston (6) moves into its upper end
position thereby opening the passage for the
control fluid flow to piston (7). When piston
(7) is in its upper end position, the auxiliary
trip fluid circuit is closed again. Restoration
of normal operating configuration is
annunciated by the limit switch of the low
vacuum trip and by pressure switches
MAG01CP201

Reset Solenoids
MAX48 AA201 and MAX48 AA202

Function
The function of the reset solenoids is to
restore the tripped protective devices to their
normal operating positions during the ATT
reset program.

Operation
The reset solenoids are two 2/3-way 1 Compression I Aux. start-up fluid
solenoid valves, fitted in the auxiliary start- spring II Aux. start-up fluid
2 Coil to protective devices
up fluid line. Both solenoid valves are
3 Valve disc III Control fluid
energized in the course of the reset program
conducted after each subtest, so that Fig. 7 –Reset Solenoid
auxiliary start-up fluid II is supplied with
control fluid III. The control fluid pressure
forces all protective devices back into their
normal operating positions and the trip fluid
and auxiliary trip fluid pressure can build up
again.
When the protective devices have latched-in
again, reset solenoid MAX48AA021 is de-
energized first to shut oft the control fluid
supply through this value.

5.1-0661-00/7
 Steam Turbine
Description
The following description refers to a
standard stop and control valve assembly.
The same text applies analogously to both
the main stop and control valves and the
reheat stop and control valves. The valve
assembly described is drawn in the closed
position (ready for start-up).
General
The stop and control valves of the turbine
are the final control elements actuated by
the protective devices arid it is, therefore,
equally important that these, as well as the
protective devices, should function
reliably. The testing of these valves in
conjunction with testing of the protective
devices, as already described in
Automatic Turbine Tester, General
ensures that all elements which must
respond on turbine trip are tested for their
ability to function reliably.
Each stop valve is tested together with its
associated control valve. The automatic
turbine tester is designed so that only one
valve assembly may be selected and
tested at any time.
Test Requirements
To avoid turbine output changes and initial
pressure variations due to the closing of
the control valve under test during ATT,
the electro-hydraulic turbine controller
must be in operation prior to testing. To
facilitate compensation by the controller,
the closing time of the control valves is
relatively long, and to enable initial
pressure to be maintained constant,
testing is only permissible when the
turbine output is below a certain value.
Special Conditions during Testing
The main stop and control valves may only
be tested if no other ATT subgroup is
running.
During testing the selected control valve
(MAA10+20AA002) is closed completely
BHEL Hardwar
Automatic Turbine Tester
Stop and Control Valves
by means of a motor operated actuator
(-AA002M) acting on pilot piston (KA06)
parallel to pilot value (KA05). This result in
a closing movement simulating that which
occurs when the associated secondary
fluid pressure drops. The resultant,
constant slow closing movement is
necessary in order to keep the output
constant. Thus the conditions for actuation
of the valve are the same during testing as
during normal actuation by the controller.
The stop valves, which are held in the
open position by trip fluid pressure during
normal operation, are subjected to exactly
the same hydraulic conditions during
testing as would be the case in the event
of actual turbine trip, as the action of the
protective devices is simulated by the
solenoid valve (MAX61AA211 and 212).
The steam side conditions during testing
are somewhat more severe than during
actual trip, as the pressure downstream of
the stop valve can not drop off during
closure because the control valve is
closed. This means that the steam
pressure acting against the spring closure
force is greater than in the event of normal
trip.
The automatic turbine tester intervenes
only in the fluid circuits normally used to
control the valves and uses only trip fluid
to actuate the test valves (MAX47AA011
and 012) and to reset and open the stop
valves. Thus closure of the valves cannot
be impeded in the event of a genuine trip
during testing, regardless of the stage,
which the test has reached. This also
applies to the control valves, as the ATT
does not interrupt the secondary fluid
circuit and secondary fluid can thus be
depressurized in the normal manner in the
event of a trip.
Features of Automatic Turbine Tester
The ATT has the following features:

Separate part-testing of each valve
assembly.
5.1-0662-01/1

Time-related monitoring of all program
steps, and their implementation.

Interruption due to running time
exceeded or turbine trip.

Automatic reset of test program after a
fault.

Protection of the turbine during testing
provided by special test protective
circuits.
Setting Data
The setting data for the pressure switches
used to monitor the individual valve
movements are listed in the setting record
Pressure Switch settings. The actual set
values are logged in the Commissioning
Test Record. The test running times, etc.,
are entered in the functional diagram.
Test Selection Units
There are two nos. of combined main
steam and control valves” and two nos.
of combined reheat stop and control
valves, each of which is tested as a
separate unit and has a separate selection
push-button on the ATT control panel.
They are as follows:
Selection1:
Main stop and control valve (LHS)
Selection 2:
Main stop and control valve (RHS)
Selection 3:
Reheat stop and control valve (LHS)
Selection 4:
Reheat stop and control valve (RHS)
Test Procedure
Start of Test
The test starts with the selection of
subgroups by pressing the On/Off push-
button.
The subgroup remains on until it is
switched off after the programme is
5.1-0662-01/2
concluded. When one subgroup program
is running, the other subgroup is blocked.
The On/Off push button also
acknowledges signals:
Selection
If the test requirements have been fulfilled,
the valve, assembly (e.g. main stop and
control valve (LHS)) to be tested is
selected by switching in the subgroup by
pressing title selection push-button.
A separate selection push-button is
provided for each combination of stop and
control valve assembly. Only one selection
may be made at a time. Selection of a
further test is not possible until the
programme already selected has ended.
Operation Push-button
The test run is started by pressing the
Operation push- button in the Stop and
Control valves tile.
Shutdown Push-button
This push-button can abort the current unit
test and introduce the reset program,
which has priority over the test
programme.
Lamp Test Push-button
All lamps on the panel are tested by
pressing the Test push-button.
Closure of Control Valve
If all the test requirements have been
fulfilled and the selection and operation
push buttons pressed, the control valve
(MAA10 and 20AA002) is closed by
means of the associated actuator (test
motor –AA002M). Operation of the
actuator (KA01) is continued until limit
switch (-CG002C) and limit switch (-
AA002M S72, S73) on the actuator is
tripped to annunciate that the control valve
being tested is in closed position.
During this time, the turbine output
controller compensates for the effects of
closure of the valve being tested on the
turbine output by opening the remaining
control valves.
The running time for closure of the control
valve is monitored. If the control valve is
functioning properly, it will close within the
preset running time.
Closure of Stop Valve
Then the solenoid valve (MAX61AA211
and 212) energized. This allows trip fluid
to flow to the space below changeover
slide valve (MAX61AA011 and 012), which
moves into its upper end position and
connects the space below piston disc
(KA02) with the drain. The pressure in this
space drops rapidly and is monitored by
pressure switch (MAX51CP223,228).
When the pressure at this pressure switch
has dropped slightly below the breakaway
pressure of piston disc (KA02), monitoring
of the stop valve closure time starts. The
associated limit switch (-CG001E)
annunciates entry of the valve into its
closed position, thus making it possible to
monitor the valve closing action for
completion within the maximum
permissible running time.
Opening of Stop Valve
Next, solenoid valve MAX47AA211 and
212 is energized (test position) and trip
medium is admitted to the control surface
of the piston in the test valve MAX47
AA011 and 012. The pilot moves into its
lower end position against the spring
force, thus permitting trip medium to flow
to the space above piston KA01 of the
stop valve. This piston is forced
downwards by pressure of the medium,
thereby tensioning the spring between
piston KA01 and piston disc KA02 and
finally pressing against piston disc KA02.
Up to this point the medium pressure
above piston KA01 is relatively low, being
equal to the spring force acting against it.
The spontaneous pressure rise when
piston KA01 has made contact with piston
disc KA02, and thus on completion of the
spring tensioning action, is detected by
pressure switch MAX51CP222, 227. If all
conditions are fulfilled within this relatively
long monitoring period, solenoid valve
MAX61AA211 and 212 is de-energized
(operating position), so that trip medium is
once again able to flow to test valve
MAX47AA011 and 012 and the drain is
blocked off again. The buildup of trip
medium pressure is monitored by pressure
switch MAX51CP221, 226.
When the pressure is sufficiently high, the
stop valve is opened by de-energizing
solenoid valve MAX47AA211 and 212
(operating position). Test valve MAX47
AA011 and 012 switches over, admitting
trip medium to the underside of the piston
disc KA02 and after a certain amount of
further travel, slowly connects the space
above piston KA01 with the drain. The
resultant pressure difference causes the
tensioned piston relay to open the stop
valve. As soon as the open position is
reached, the full trip medium pressure
builds up. This is monitored by pressure
switch MAX51CP221, 228 and by limit
switch –CG001D. Testing of the stop valve
is now completed.
Re-Opening of Control Valve
If the conditions are fulfilled within the
specified monitoring period, the control
valve is reopened. The motor of positioner
–AA002M is operated in the opening
direction. Positioner –AA002M moves the
control valve into its original position in the
reverse sequence to the closing action.
Again the initial pressure and output are
kept constant by the appropriate controller.
Operation of positioned -AA002M is
continued until, after a certain amount of
over travel, it has positively ceased to
influence the controller. This position is
detected by limit switch –AA002 MS61 or
–AA002 MS62. If the control valve is
functioning properly, it will open within the
preset running time.
Cancellation of Selection
On conclusion of testing of each
combination of valve assembly, the
selection is automatically cancelled and
the programme is shut down.
5.1-0662-01/3
Interruption due to Running Time
Exceeded
The reset program is automatically
initiated if the running time for any step in
the test program is exceeded. If any
running time is exceeded during the reset
program, the program halts. In either case,
the alarms Fails signal and Time overrun
generated. If the Faults in ATT alarm is
displayed, the fault lies in the automatic
tester itself.
5.1-0662-01/4
Interruption due to Turbine Trip
If electrical turbine trip is initiated during
testing, all solenoid valves are de-
energized and positioner –AA002M is
returned to its extreme position and the
programme cancelled. All equipments
associated with the automatic turbine
tester are automatically returned to their
normal position.
 Steam Turbine
Description
The actuator is of the two-stage
amplification type, i.e. it incorporates pilot
and main control mechanisms. The
actuating forces for movement of the HP
control valve are generated, in the opening
direction, by main actuator piston KA02
under the force of the control fluid and, in
the closing direction, by the disc spring
column. During actuation main pilot valve
KA07 acts as a 3-way valve to allow the
control fluid to flow to the space behind main
actuator piston KA02. Main pilot valve KA07
is actuated via the resetting linkage by
means of auxiliary pilot piston KA06 which is
subject to control fluid pressure on both
sides.
The actuating signal given by the signal fluid
pressure acts on the face of pilot valve KA05
pressing it against the resetting spring on
the opposite side. Acting as a 4-way valve,
the pilot valve allows fluid to flow to both
sides of auxiliary pilot piston KA06. When
BHEL Hardwar
HP Actuator
the signal fluid pressure changes, pilot valve
KA05 is displaced which results in
movement of auxiliary pilot piston KA06. The
movement of piston KA06 is transmitted via
the resetting linkage of the pilot mechanism
to the resetting spring, causing spool valve
KA05 to return to the central position which
establishes proportionality between the
signal fluid pressure and the travel of
auxiliary pilot piston KA06.
At the same time, main pilot valve KA07
displaced via the resetting linkage system by
auxiliary pilot piston KA06, effects
displacement of main actuator piston KA02
whose movement returns main pilot valve
KA07 to the central position via the resetting
mechanism. Consequently the position of
the pilot and main actuator pistons are
proportional to the secondary fluid pressure
in the steady state (on completion of the
control action).
5.1-0665-00
 Steam Turbine
Description
Function
With all shaft seals subject to a positive
pressure difference, the escaping steam is
throttled to a low pressure and fed into a
header 1.1, which is common to all shaft
seals. Those seals, which are under
vacuum, must be supplied with seal steam
to prevent the ingress of air. The supply of
steam is taken from the header 1.1. The
amount of leakage steam and seal steam
required depends on the pressure at the
seals, which, in turn, is primarily
dependent on the turbine load.
The function of the control system is to
maintain the pressure at the bleed-off
points of all seals at the same preset
pressure. This is effected by exhausting
steam from the header (e.g. to the
condenser) or supplying extra steam to the
header 1.1, according to operating
conditions.
Arrangement
Leak-off control valve 1.3 is used for
discharging surplus steam from the header
1.1 and seal steam supply control valve
1.4 for admitting extra steam to it. All
valves are actuated by type HSA-1-K
electro hydraulic actuators. The actuators
1.11 are under the continuous control of
an electric controller 1.9 each via an
electro hydraulic converter. The electro
BHEL Hardwar
Electro-hydraulic Seal
Steam Pressure Control
hydraulic converter comprises a control
coil, which adjusts the position of the
impingement plate of the hydraulic
preamplifier.
Controller
The function of the electric controller 1.9 in
conjunction with the transducer 1.6 and
the actuating elements (control valves) is
to maintain a controlled variable at a
preset valve by adjusting the final
controlling elements. The actual valve of
the control system is acquired
continuously by the transducer 1.6 and
compared against the set value in the
electric controller 1.9. If the actual value
deviates from the set value, one of the
final controlling elements (either the leak-
off or steam supply control valve) is
adjusted until the actual value again
agrees with the set value. Only if there is a
large control deviation, e.g. during a full-
load trip, are all valves operated
simultaneously. The electric controller is
realised in digital technology.
Mode of Operation
The input signal coming from the controller
flows through the solenoid (31). The
magnetic field of the solenoid together with
the magnetic field of the permanent
magnet system (42) exercises a force on
the freely pivoted armature (30). This force
reacts against the force generated by the
5.1-0670-01/1
tension of the return spring. If the input
signal is changed, the equilibrium will be
disturbed and, therefore, there will be a
deflection of the armature retained by the
spring (32) and return spring (36). The
baffle plate (29) then covers the two-
rebound nozzle tips (15) to an unequal
extent. In the oil flow that flows through
two-choke valves (21) to the rebound
nozzles (16), a pressure differential is
created. The oil pressure existing in the
rebound nozzles is applied to the face of
the slide gate (1a). The slide gate is
deflected and releases the oil flow to or
from the hydraulic cylinder (5.1). The
deflection of the slide gate is dependent
5.1-0670-01/2
upon the magnitude of an input signal
change. The greatest amount of deflection
and, therefore, the fastest change in the
Hydraulic cylinder’s position is already
achieved with an input signal change of
delta I ≥ 3 mA.
Following smaller changes in signal, the
hydraulic cylinder operation is
correspondingly slower. The servo-valve
enables an extremely sensitive control by
virtue of its special construction. The main
cylinder piston moves and in so doing
changes the position of the coupled
actuator. At the same time, the tension in
the return spring (36) changes via the
return rod (44) and the adjustment lever
5.1-0003-02/2
(39), until the tension of the springs and
magnetic forces reach a state of
equilibrium. The armature returns to its
mid position, the pressures on the faces of
the slide gates (1a) are of equal
magnitude. The slide gate moves to its
mid position, the oil flow to the cylinder is
initially reduced and, when the slide gate
(1a) reaches its middle setting it is
completely shut off, and the main piston of
the hydraulic cylinder is in its set position.
The position of the main piston or rather
the actuator is directly proportional to the
input signal on the servo valve.
Double Blocking Valve
A double blocking valve is connected to
the outlet side of the servo-valve. The
pump pressure opens the hydraulically
operated check valve (8). the connections
to the hydraulic cylinder (5.1) are free. If
the oil supply fails, both hydraulically
operated check valve close. The hydraulic
cylinder’s piston will be retained in its last
position.
Display of control deviation /Adjusting
the set value
The control deviation is displayed on each
of the two desk tiles for the valves. The
two instruments are connected in parallel.
The set value for steam pressure in the
header can be adjusted between 0 and 22
mbar at the controller by means of the set
value push-button.
Electric manual control
The controller can be switched off by the
push button “Controller on/off”. Then the
valves can be controlled directly by hand
by means of the push-button
“Higher/Lower” below the valve position
display with the aid of the remote-control
manual control setter of the electrical
equipment. The inscription “Higher/Lower”
refers to the change in pressure when the
push-button is operated, e.g. “Higher”
means increasing the pressure (the leak-
off steam control valve closes or the seal
steam control valve opens). Manual
control is disconnected during automatic
control; the manual control setter is then
automatically tracked to the controller
output voltage by the equalizing controller
so that when changing over from
automatic control to manual control the
manual control setter is already in the
correct position. Under manual control the
equalizing controller automatically tracks
the output voltage of the disconnected
controller 1.9 to the manual control
voltage. If the control deviation has been
reduced to zero by positioning the valves
before the controller is switched on, the
change-over from manual control to
automatic control will be bump less;
otherwise the controller regulates the
pressure to the preset value after it has
been switched on. Thus, it is quite easy to
switch the controller on and off during
operation.
5.1-0670-01/3
5.1-0670-01/4
 Steam Turbine Control System
Description Diagram Legend

Power Plant iden- Title Coor- Power Plant iden- Title Coor-
tification System dinete tification System dinete

KA06 Relay Piston for Pre Control Pilot ValveC7

KA07 Main Pilot Valve C7
KA09 Hand wheel for Testing Device B7
LBC10 AA001 Swing Check Valve of CRH E7 M Electrical Motor for Testing Device B7
KA01 Rotary Servomotor E7 AA002 MS61 Torque limit Switch,
LBC10 CG001 B Limit Switch, Open Position E7 Testing Device 100% ATT B7
C Limit Switch, Closed Position E7 MS62 Travel Limit Switch,
D Limit Switch, Open Position E7 Testing Device 100% ATT B7
E Limit Switch, Closed Position E7 MS72 Torque Limit Switch,
Testing Device 0% A TT B7
LBS21 AA001 Extraction Check Valve A2 E12,13 MS73 Travel Limit Switch, B7
KA01 Servomotor E12,13 Testing Device 0% ATT
LBS21 CG001A Remote Position Indicator E12,13
MAA10 + 20
LBS31 AA001 Extraction Check Valve A3 E13 CG002 A Remote Position Indicator C7
KA01 Servomotor E13 C Limit Switch, Closed Valve Position ATT C7
LBS31 CG001A Remote Position Indicator E13
MAB10 +20
LBS31 AA002 Extraction Check Valve A3 E13 AA001 Reheat Stop Valve ABC9
LBS31 CG002 A Remote Position indicator E13 KA01 Piston A9
KA02 Piston Disc A9
LBS41 AA001 Extraction Check Valve A4 C10
KA01 Servomotor C10 MAB10 + 20
LBS41 CG00 1A Remote Position Indicator C10 CG001 B,F,H, Limit Switch, Open Valve Position A9
C,G,J Limit Switch, Closed Valve Position A9
LBS41 AA002 Extraction Check Valve A4 C10 D Limit Switch, Open Valve Position ATT A9
KA01 Servomotor C10 E Unlit Switch,Closed Valve Position ATT A9
LBS41 CG002A Remote Position Indicator C10

LBS42 AA001 Extraction Check Valve A4 AB11 MAB10+ 20 Main Control Valve BC9,10
KA01 Servomotor A 11 AA002
LBS42 CG001A Remote Position Indicator B 11
KA01 Servomotor C10
LBS42 AA002 Extraction Check Valve A4 AB1 1,12 KA02 Piston C10
KA01 Servomotor A12 KA05 Pre Control Pilot Valve C10
LBS41 CG002A Remote Position Indicator B12 KA06 Relay Piston for Precontrol Pilot ValveC10
KA07 Main Pilot Valve C10
LBQ50AA001 Extraction Check Valve A5 E9 KA09 Hand wheel for Testing Device B10
KA01 Servomotor E9 M Electrical Motor for Testing Device B10
LBQ50CG001 A Remote Position Indicator E9 MS61 Torque Limit Switch,
Testing Device 100% ATT B10
LBQ5OAA002 Extraction Check Valve A5 E9 MS62 Travel Limit Switch,
LBQ50 CG002A Remote Position Indicator E9 Testing Device 100% ATT B10
MS72 Torque Limit Switch,
MAA10 + 20 Testing Device 0% ATT B10
AA001 Main Stop Valve ABC7 MS73 Travel Limit Switch, B10
KA01 Piston AB7 Testing Device 0% ATT
KA02 Piston Disc B7
MAB10 + 20
MAA10 + 20 CG002 A Remote Position Indicator C10
CG001 B,F,H Limit Switch, Open Valve Position B7 C Limit Switch, Closed Valve Position C10
C,G,J Limit Switch, Closed Valve Position B7 ATT
D Limit Switch, Open Valve PositionATT B7 MAD12
E Limit Switch, Closed Valve PositionATTB7 CY011,012,013 Electrical Thrust Bearing Trip D8

MAA10+ 20 MAG01 AA011 Low Vacuum Trip. B5

AA002 Main Control Valve BC7,8 MAG01CG01 B Limit Switch, Not Reset B5
KA01 Servomotor C7,8 C Limit Switch, Alarm B5
KA02 Piston C7 E Limit Switch, Alarm ATT B5
KA05 Pre Control Pilot Valve C7 MAG01AA016 Condenser Safety Device
(Bypass Control) G9

BHEL Haridwar 5.1-0681-05/1

 Power Plant iden- Title Coor-
Power Plant iden- Title Coor-
tification System dinete
tification System dinete
MAX32BT021 Fluid Filter for Pre Control,
MAV21 AP001 Main Oil Pump E1 Reheat Control Valves A10

MAV21BT001 Oil Filter MAX32BT081 Fluid Filter for Pre Control,

(Hydraulic Control Equipment Rack) D4 Bypass Control Valves C11

MAX31
MAX41 CP50l Pressure Gauge. Control Fluid
BB011, 016 Accumulator for HP Servomotor,
Main Control Valves B7 (Hydraulic Control Equipment Rack) C2

MAX31 Accumulator for HP Servomotor, MAX42AA001 Slide Valve for Swing Check Valve
BB21, 26 Reheat Control Valves B9 Cold Reheat D7

MAX31 BB021 Accumulator for HP Servomotor, MAX42AA002 Slide Valve for Swing Check Valve
BB041,049 Bypass Control Valves C11 Cold Reheat D8
MAX32
MAX42AA011 Non-Return Valve B1
BT011 +012 Fluid Filter for Pre Control.
Main Control Valves A7
MAX42BT001 Fluid Filter
(Hydraulic Control Equipment Rack) C1

MAX42BT002 Fluid Filter

(Hydraulic Control Equipment Rack) C2

MAX42BT003 Fluid Filter

(Hydraulic Control Equipment Rack) B4

MAX42BT021 Fluid Filter (Hydraulic

Bypass Control Equipment Rack) G6

MAX42BT022 Fluid Filter for Water Injection Valves

(Hydraulic Bypass Control
Equipment Rack) A12

MAX42CP501 Pressure Gauge, Control Fluid

(Hydraulic Bypass Control
Equipment Rack) F6

MAX42CP511 Pressure Gauge, Control Fluid Water

Injection Valve Open B12

MAX42CP512 Pressure Gauge. Control Fluid Water

Injection Valve for Sequential Water
Injection Open B13

MAX44AP001 Hydraulic Speed Transmitter E1

MAX44CP501 Pressure Gauge, Primary Oil A5

MAX45BB001 Accumulator for Extraction Valve

Relay E4

MAX45BY001 Electro-Hydraulic Converter F4

KA01 Follow-Up Piston for Main
Control Valves F5
KA02 Follow Up Piston for Reheat
Control Valv8S F5
KA04 Sleeve F4
KA05 Piston F4
KA06 Helical Spring F4
KA08 Piston F4
KA10 Adjusting Device Control Valves F5
KA11 Manual Adjusting Device F5

5.1-0681-05/2
Power Plant iden- Title Coor- Power Plant iden- Title Coor-
tification System dinete tification System dinete
MAX45 MAX47CG001F Limit Switch, 56% G1
CG001 A Remote Position Indicator F4 MAX47CP501 Pressure Gauge, Start-up Fluid G1
K Remote Position Indicator F4 MAX48 CP501 Pressure Gauge,
T Solenoid F4 Auxiliary start-up fluid E3
B Limit Switch Operating Without Bypass
Valves and Adjusting Device Blocked F5
C Limit Switch, Displacement of MAX51
Control Valves F5 AA005 +006 Main Trip Valve B2

MAX45BY011 Hydraulic Converter F2 MAX 51

KA01 Follow-up Piston for Main Control Valves F3 CG005+006 C Limit Switch, Alarm B2
KA02 Follow-Up Piston for Reheat Control F3 E Limit Switch, Alarm, ATT B2
valve
KA04 Sleeve G3 MAX51 AA011 Extraction Valve Relay D5
KA01 Valve D5
KA05 Piston G3
KA02 Valve D5
KA06 Helical Spring F3
KA07 Pilot Valve G2 MAX51AA041 Slide Valve for Extraction
KA08 Piston G3 Check Valve A2 E12
KA09 Proportional Band Adjustment G2
KA10 Adjusting Device Control Valves F4 MAX51 AA044 Slide Valve for Extraction
KA11 Manual Adjusting Device F4 Check Valve A3 E13
MAX45CG011 B Limit Switch, Operation without Bypass MAX51 AA047 Slide Valve for Extraction
Valves and Adjusting Device Blocked F3 Check Valve A4 C12
C Limit Switch, Displacement of control
valves F4 MAX51 AA048 Slide Valve for Extraction
Check Valve A4 A 11
MAX45CP501 Pressure Gauge Secondary Fluid
Main Control valves F2 MAX 51 AA 050 Slide Valve for Extraction
Check Valve A4 C12
MAX45CP511 Pressure Gauge, Secondary Fluid
Reheat Control Valves E2 MAX 51 AA051 Slide Valve for Extraction
Check Valve A4 A11
MAX46BY001 Hydraulic Speed Governor G1
MAX 51 AA056 Slide Valve for Extraction
KA01 Hand wheel F2
Check Valve A5 E9
KA02 Speed Setting Spring F1
KA03 Link F1 MAX51AA211 Changeover Valve B3
KA04 Sleeve F2
KA05 Piston F2 MAX51 CG211B Limit Switch, up Normal Position ATT B3
KA06 Helical Spring F2 C Limit Switch, Down- Test Position ATT B3
KA07 Overspeed Tester Lever F2
KA08 Auxiliary Follow-up Piston F2 MAX51CP501 Pressure Gauge, Trip Fluid A3
KA09 Governor Bellows G1
M Electrical Motor F1 MAX51 CP522 Pressure Gauge, Trip Fluid above piston
527 Main Stop Valve A6
MAX46CG001 A Remote Position Indicator F2
B Limit Switch 100% MAX 51 CP523 Pressure Gauge, Trip Fluid below piston
(Start-Up Automatic) F2 528 Disc Main Stop Valve B6

MAX46CP501 Pressure Gauge. MAX51 CP542 Pressure Gauge, Trip Fluid above Piston
Auxiliary Secondary Fluid F2 547 Reheat Stop Valve A9

MAX51 CP543 Pressure Gauge, Trip Fluid below Piston

MAX47
548 Disc Reheat Stop valve B9
AA011 +012 Test Valve for Main Stop Valves B6
MAX52AA005 Local/Manual Trip Valve B2
MAX47 MAX52 CG005 C Limit Switch, Alarm B2
AA021 +022 Test Valve for Reheat Stop Valves A9 E Limit Switch, Alarm ATT B2

MAX47BY001 Starting and Load Limit Device F1 MAX 52 CP501 Pressure Gauge, Aux, Trip Fluid D3
KA01 Hand wheel F1
KA02 Valve F1
M Electrical Motor F1

MAX47CG001 A Remote Position Indicator F1

B Limit Switch, 100% G1
C Limit Switch, 0% G1
D Limit Switch, 42% G1

5.1-0681-05/3
Power Plant Iden- Title Coor- Power Plant Iden- Title Coor-
tification System dinate tification System dinate

MYA01
CS011-013 Electrical Speed Transmitter E1
MAG01 AA201 Solenoid Valve for Testing
Low Vacuum Trip B4
MAX42AA001 Solenoid Valve, Adjustment of
Control Valves F5

MAX45AA001 Solenoid Valve for Load Shedding Relay

in Secondary Fluid to Reheat
Control Valves E5

MAX46AA011 Solenoid Valve for Load Shedding Relay

in Auxiliary Secondary Fluid G2

MAX47
AA211 +212 Solenoid Valve for start -up Fluid,
Main Stop Valve B5
MAX 47
AA221 +222 Solenoid Valve for Start-up Fluid,
Reheat Stop Valves B8

MAX48
AA201 +202 Solenoid Valve for Auxiliary
Start-Up Fluid B1,2

MAX51AA021 Solenoid Valve for Extraction

Check Valve E12

MAX51AA024 Solenoid Valve for Extraction

Check Valve E13

MAX51AA027 Solenoid Valve for Extraction

Check Valve A4.1 C 12

MAX51 AA028 Solenoid Valve for Extraction

Check Valve A4.2 A10

MAX51 AA030 Solenoid Valve for Extraction

Check Valve A4.1 C12

MAX51AA031 Solenoid Valve For Extraction

MAX61 Check Valve A4.2 A11
AA011 +012 Test Valve for Main Stop Valves B6
MAX51 AA036 Solenoid Valve for Extraction
MAX61 Check Valve A5 E9
AA021 +022 Test Valve for Reheat Stop Valves B8
MAX51 AA201 Solenoid Valve for Control Fluid
MAX62AA001 Overspeed Trip Test Device C4 Supply during Test B3
KA01 Valve for Test oil C4
KA02 Valve for Auxiliary Start-up Fluid C4 MAX51AA202 Solenoid Valve for Control Fluid
KA03 Valve For Auxiliary Trip Fluid C4 Supply During Test B4
KA001M Electrical Motor C4
MAX52AA001 Remote Trip Solenoid C2
MAX62CG001 B Limit Switch, up-Normal position ATT C4
C Limit Switch, Down- Test Position ATT C4 MAX52AA002 Remote Trip Solenoid C2

MAX62CP501 Pressure Gauge, Test Oil Overspeed D1 MAX53AA051 Solenoid Valve for Sequential
Trip Water Injection C13
MAY10
AA001 +002 Overspeed Trip E2 MAX61AA201 Solenoid Valve for Changeover from
KA01 Releasing Device E2 Trip Fluid to Control Fluid C3

MAY10
CG001 +002 C Limit Switch, Alarm E3
E Limit Switch Alarm ATT E3

5.1-0681-05/4
 Power Plant iden- Title Coor-
Power Plant iden- Title Coor-
tification System dinete
tification System dinete
MAX48 CP202 Pressure Switch for Auxiliary
MAX61 Start-up Fluid Between Solenoid
AA211 +212 Solenoid Valve for Testing of
Valves MAX48AA201 and202 B1
Main Stop Valves C5,6
MAX51
MAX61
CP001 +002 Pressure transmitter for Trip fluid A1
AA221 +222 Solenoid Valve for Testing of
Reheat Stop Valves C8 MAX51
CP205 +206 Pressure Switch for Trip Fluid Between
Solenoid Valves MAX51 AA201
and 202 B3
LBS42 CP002 Differential Pressure Monitor for
Extraction Check Valve-A4
MAX51
(Batron -Cell) B11
CP207 +208 Pressure Switch for Trip Fluid Ahead of
Changeover Valve MAX51 A211 B3

MAX51
CP209 +210 Pressure Switch for Trip Fluid Ahead of
MAG01CP201 Pressure Switch, low-Vacuum Trip,
Changeover Valve MAX51 AA211 B2,3
Vacuum min. B4
MAX51CP 221 Pressure Switch for Trip Fluid ahead of
MAG01CP202 Pressure Switch, low-Vacuum Trip,
+226 Main Stop Valve, Test Valve B6
Vacuum max. B4
MAX51CP222 Pressure Switch for Pressure above
MAG01CP203 Pressure Switch, low-Vacuum Trip,
+227 Piston of Main Stop Vale B7
Vacuum min. B5
MAX51 CP223 Pressure Switch for Pressure below
MAG01CP204 Pressure Switch, low-Vacuum Trip
+228 Piston Disc of Main Stop Vale A7
Vacuum max. B5
MAX51CP242 Pressure Switch for Trip Fluid above
MAG10CP011 Pressure Switch, Electrical Low
+247 Piston of Reheat Stop Valve A9
Vacuum Trip.
Signal Pressure to high E13 MAX51 CP243 Pressure Switch for Trip Fluid Below
+248 Piston Disc of Reheat Stop Valve B9
MAG 10CP012 Pressure Switch, Electrical low
Vacuum Trip, Alarm E13 MAX52CP211 Pressure Switch for Auxiliary
Trip Fluid B3
MAG10CP013 Pressure Switch Electrical low Vacuum
Trip Interlocking MAG10CPO12 E14 MAX62 CP 211 Pressure Switch for Test oil of
overspeed Trip max D1
MAG10CP016 Pressure Switch for Energizing of
Vacuum Breaker E13
MAX62 CP 212 Pressure Switch for Test oil of
overspeed Trip max. D1
MAX45 CP211 Pressure Switch For Reheat Control
Valves Secondary Fluid E2
MAX62 CP 213 Pressure Switch for Test oil of
overspeed Trip Pressure Collapsed D2
MAX48 CP201 Pressure Switch For Auxiliary C2
Start-up Fluid
MAX45 AA031 Pressure Converter for IP secondary
Oil E4

5.1-0681-05/5
 Steam Turbine Lubrication Chart
Description

No. Lubrication Filling Lubricant Lubrication Top-up Remarks

Point Quantity Interval Quantity

1 Overspeed test Turbine oil* Every 1 to 2

device months
2 Reduction gear of 200g Grease Every 1 to 2 ≈ 10g
overspeed trip Servogem-2 months
test device
3 Bearing of low Turbine oil* Every 1 to 2
vacuum trip months
4 Main control valve Molykote U After every Use no oil
stem dismantling or grease
5 Main stop valve Molykote U After every Use no oil
stem dismantling or grease
6 Limit Switch Molykote Every 1 to 2 Use no oil
attachment on M30 months or grease
main stop valve
7 Limit Switch Molykote Every 1 to 2 Use no oil
attachment on M30 months or grease
main control valve
8 Hinge of main Molykote Every 1 to 2 Use no oil
control valve M30 months or grease
position indicator
9 LAWA actuator 0.4 kg Calypsol Every 104 0.4 kg
VR 16 of main SF7-026 Operating
control valve hours
10 Reheat control Molykote U After every Use no oil
valve stem dismantling or grease
11 Reheat stop valve Molykote U After every Use no oil
stem dismantling or grease
12 Limit switch Molykote Every 1 to 2 Use no oil
attachment on M30 months or grease
reheat stop valve
13 LAWA actuator 0.4 kg Calypsol Every 104 0.4 kg
VR 16 of reheat SF7-026 Operating
control valve hours
14 Hinge of reheat Molykote Every 1 to 2 Use no oil
control valve M30 months or grease
position indicator
15 Limit switch Molykote Every 1 to 2 Use no oil
attachment on M30 months or grease
reheat control
valve
16 Hinge of Molykote U After every Use no oil
extraction swing dismantling or grease
check valve
17 Adjusting gear of 200g Grease Every 1 to 2 ≈ 10g
starting and load Servogem-2 months
limit device

BHEL Haridwar 5.1-0690-05/1

No. Lubrication Filling Lubricant Lubrication Top-up Remarks
Point Quantity Interval Quantity

18 Journal for Turbine oil* Every 1 to 2

hydraulic speed months
governor
19 Adjusting gear of 200g Grease Every 1 to 2 ≈ 10g
reference speed Servogem-2 months
setter
20 Bearing of Turbine oil* Every 1 to 2
trimming device months
21 Hinge of cold Molykote U After every Use no oil
reheat swing dismantling or grease
check valve
22 Stem guides of Molykote U After every Use no oil
shaft seal steam dismantling or grease.
valve Lubrication
point not
shown
23 Shaft seal steam 7 to 9 kg Hydraulic oil 1stoil change 7 to 9 kg Lubrication
valve actuators to DIN 51517 after 6 point not
and VDMA months, shown
24318 H-LP thereafter
oils** every12
months.

* Turbine oil 46/Servoprime 46 of IOC, Turbinol 47 of HPCL or equivalent

** HLP 46 (VG) ISO of IOC

5.1-0690-05/2
 Steam Turbine Technical Data
Description Construction, Speed
& Steam Pressure

Load

Rated Load 500 MW

Maximum Load under valve wide open (VWO) condition 524.9 MW

Construction

Three cylinder reheat condensing turbine

Single flow HP Turbine with 17 reaction stages Type : H30-100-2

Double flow IP Turbine with 12 reaction stages per flow Type : M30-63

Double flow LP Turbine with 6 reaction stages per flow Type : N30-2x10-2

2 Main Stop and Control valves (HP casing mounted) Type : EV 320-1

2 Reheat Stop and Control Valves (Floating) Type : IV 560

1 Swing Check Valve in cold reheat line DN-800

Make : BHEL, Trichy

2 LP Bypass Stop and Control Valves (EHA Based) Make : CCI, Switzerland

Extraction Swing Check Valves

Extraction 1 : No valve

Extraction 2 : 1 Swing Check Valve with actuator and DN 800

1 Swing Check Valve without actuator Make : BHEL, Trichy

Extraction 3 : 1 Swing Check Valve with actuator and DN 500

1 Swing Check Valve without actuator Make : BHEL, Trichy

Extraction 4.1 : 2 Swing Check Valves with actuator DN 500

Make : BHEL, Trichy

Extraction 4.2 : 2 Swing Check Valves with actuator DN 500

Make : BHEL, Trichy

Extraction 5 : 1 Swing Check Valve with actuator and 1 Swing DN 400

Check Valve without actuator Make : BHEL, Trichy

Extraction 6 : No valve

BHEL Haridwar 5.1-0100-63/1

5.1-0690-05/3
 Steam Turbine
Description
Function
The function of the hydraulic speed governor
is to operate the control valves to give the
appropriate turbine steam throughput for the
particular load condition. The arrangement
and functioning of the governor within the
overall governing system is described in the
section on governing.
Construction
The principal components of the speed
governor are the bellows (8), the link (11),
the speed setting spring (13), the sleeve (5)
and the follow-up piston (4). The primary oil
supply from the hydraulic speed transmitter
is available at connection ‘a1‘. A fire
resistant fluid is used as the hydraulic fluid in
the governing system. An additional bellows
(9) prevents primary oil getting into the
control fluid circuit if there be a leakage in
the governor bellows (8). In this case, the
leakage oil can be drained off via connection
‘c1 ‘. In case a leak in the bellows (9) occur,
the control fluid that has leaked in will also
be drained off via connection ‘c1’.
The primary oil pressure (connection ‘a1‘) is
dependent on the speed and determines the
position of the link (11) via the bellows (8)
and the push rod (10). The speed setting
spring (13) opposes the primary oil
pressure. Its pre-compression can be varied
either by hand or remotely by the motor (16).
The sleeve (5) which can slide on the
bottom end of the follow-up piston (4) is
attached to the link (11). The follow-up
piston is held against the auxiliary
secondary fluid pressure (connection ‘b’) by
the tension spring (3). The follow-up piston
and the sleeve have ports, which at normal
overlap allow sufficient fluid to escape to
produce equilibrium between the auxiliary
secondary fluid pressure and the force of the
tension spring (3).
Each steady-state position of the link (11)
and hence of the sleeve (5) corresponds to
a specific force from the tension spring (3)
and hence to a specific secondary fluid
pressure which in turn determines the
position of the control valves.
BHEL Haridwar
Hydraulic Speed Governor
with Starting and Load
Limiting Device
Mode of Operation
If the primary oil pressure falls (as a result of
increasing load and the resulting drop in
speed), the link (11) and the sleeve (5)
sliding on the follow-up piston (4) are moved
downwards by the speed setting spring (13)
so that the overlap of the ports in the sleeve
and the follow-up piston is reduced. This
causes the pressure in the auxiliary
secondary fluid circuit to rise and the follow-
up piston follows the movement of the
sleeve against the increasing force of the
tension spring (3) until normal overlap of the
ports and equilibrium are restored. The lift of
the control valves is increased in this
manner by the increased secondary fluid
pressure.
Conversely, a rise in primary oil pressure
causes the lift of the control valves to be
reduced.
When the pre-compression of the speed
setting spring (13) is varied with the
reference speed setter it changes the
relationship between the primary oil
pressure and the secondary fluid pressure
and hence the relationship between speed
and power output.
Lever (12) allows the link (11) to be
depressed by hand to give a lift signal to the
governor, e.g. to provide a second means of
overspeeding the machine for testing the
overspeed trips in addition to the overspeed
trip tester.
Starting and load limiting device
Before start-up, the pilot valve (21) is
brought to its bottom limit position either by
hand or remotely by the motor (20). This
causes the bellows to be compressed via
the lever (6) and the pin (7) until the
governor assumes the position “Control
valves closed”. With the pilot valve (21) in
the bottom limit position, control fluid from
connection ‘a’ can flow simultaneously to the
auxiliary start-up fluid circuit (connection
‘u1‘) and as start-up fluid via connection ‘u’
5.1-0710-00/1
 to the stop valve to prepare these for
opening. When the pilot valve (21) is moved
back the auxiliary start-up fluid circuit is
depressurized and subsequently the start-up
fluid connection ‘u’ is opened to the return
‘c’. This opens the stop valves. Further
upward movement of the pilot valve (21)
5.1-0710-00/2
causes the pin (7) to release the bellows as
with falling primary oil pressure and the
control valves are opened. The release of
the bellows can be limited by the pin (7) so
that the control valves do not open any
further despite a further reduction in primary
oil pressure.
 Steam Turbine
Description
Function
The adjusting gear is used for manual or
motor operation of the reference speed
setter and the starting and load limiting
device.
Mode of Operation
The speed/load adjusting gear is operated
either manually or by means of motor (28).
The rotary movement of the motor shaft is
transmitted to worm wheel (15) via worm
wheel (9) and the worm attached to it.
Wormwheel (15) is located axially on the
threaded portion of the hand wheel spindle
(16) by insert (5) and the gear casing (11).
The spindle (16) is connected with bushing
(4) by a feather key so as to permit the
BHEL Haridwar
Adjusting Gear
spindle to slide axially in the bushing (4),
which can rotate in cover (19). Spring (6)
forces the thrust rings (18) against bushing
(4) which prevents bushing (4) and spindle
(16) from turning. Spindle (16) however, can
be moved axially by turning the worm wheel
(15).
Spindle (16) can be moved up or down
depending on which direction worm- wheel
(15) turns. The limit of travel is set by limit
rings (14 and 17). If either stop has been
reached the thrust rings operates as a slip
coupling. The thrust rings also protect the
motor (28) from overload in the event of
restrictive movement within the adjusting
gear.
5.1-0720-00
 Steam Turbine Electro-hydraulic Converter
Description for Turbine Control System

Function
The electro-hydraulic converter is the
connecting element between the electrical
and hydraulic parts of the turbine control
system. It converts the signals from the
electric controller into the hydraulic signals
and amplifies them before transmitting them
to the actuating devices.

Construction
The principal components of the converter
are moving coil system (12), sleeve (10),
pilot valve (6), amplifier piston (3), follow-up
pistons (21), differential transformer (1) and
actuator (17). Bushings and follow-up
pistons ‘A’ are connected to each other via
the adjusting screws (24), spring end pieces
and the springs (22). The control signals
from the electro-hydraulic controller operate
the sleeve (10) via the moving coil system
(12). This sleeve slides up and down on the
top end of the pilot valve (6) and determines
the position of the valve in the manner of a
follow-up piston. The pilot valve and sleeve
have ports which depending on the overlap,
control the amount of trip fluid flowing from
connection ‘x’. In the steady-state condition,
the pilot valve is in its center position and
the trip fluid pressure acting on the face of
the pilot valve is in equilibrium with the force
of compression spring (9). The pilot valve is
kept in rotation by control fluid flowing from
tangential holes in an integral collar to give
greater freedom of reciprocal motion and
achieve high response sensitivity. counter balance the fluid pressure acting on
the follow-up pistons (21). Each follow-up
When the pilot valve is deflected from its piston and sleeve (20) has ports, which
center position, control fluid from connection control the secondary fluid flow according to
‘a’ is admitted to the space above or below their overlap. When the throttling area is
the amplifier piston (3) with the opposite side changed by the movement of the sleeve
of the piston opened to the fluid drain. The (20), it also changes the pressure in the
resulting motion of the amplifier piston is follow-up piston causing it to follow the
transmitted via lever (13) to the sleeves (20) movement of the sleeve. This varies the
which in turn can slide on the following-up tension of springs (22) until equilibrium is
pistons (21). The secondary fluid circuits, regained between the spring force and the
which are fed from the trip fluid circuit via new secondary fluid pressure. Each position
throttles and supply the various actuating of the amplifier piston (3) thus corresponds
devices, are connected at point ‘b’. The to a specific position of the sleeves (20) and,
secondary fluid pressures are determined by
the tension of springs (22) which

BHEL Haridwar 5.1-0730-02/1


therefore, the follow-up pistons (21). The
position of the follow-up piston is the
determining factor for the secondary fluid
pressure at point ‘b’.
The initial tension of the follow-up piston
springs can be varied by means of the
setscrews (24).
5.1-0730-02/2
Controlling action with the Elctro-
hydraulic Converter
When the electric controller gives a
command to open the control valves, the
sleeve (10) is moved upwards by the moving
coil system (12), thus decreasing the fluid
drain area. This causes the pressure below
the pilot valve (6) to increase and the pilot
valve moves upwards and opens the way for
control fluid from connection ‘a’ to flow to the
space below the amplifier piston (3).
The following movement of the amplifier
piston (3) then slides the sleeves (20)
downwards over the levers (13,19) reducing
the drain area between the sleeves and the
follow-up pistons, causing the pressure in
the follow-up pistons and secondary fluid
circuits to rise.
The motion of the amplifier piston (3)
produces a simultaneous feedback action on
the pilot valve (6) via the differential
transformers (1). The sleeve (10) is moved
back until the new position of the amplifier
piston causes the pilot valve (6) to assume
its center position and equilibrium is restored
between the fluid pressure below the pilot
valve and the compression spring force (9).
When a command is given to close the
control valves, the controlling action is
similar but in the reverse sequence.
Adjusting Device for Valves
The follow-up pistons ‘B’ and the lever (14)
of the rotary shaft (15) situated above it are Setting Device for start-up without
connected by the springs (22) of follow-up Bypass Valves
pistons ‘B’, the guide pin (16) and the If the plant is started up without bypass
setscrews (30). During normal operation an system, the IP/reheat stop and control
energized solenoid valve allows control fluid valves must open before the main steam
‘a1’ to flow under the piston (25) of the stop and control valves. For this purpose,
actuator (17). The piston (25) is moved the hand wheel (32) is set in the upper end
upwards against the forces of the spring position. Signal from limit switch (33):
(26). Stop (34) locked in normal position by Setting device in operation without
pin and the initial tension of the tension bypass system position.
springs (22) of the follow-up pistons ‘B’ is
adjusted by means of the lever (28, 14)
which results in the IP control valves
opening in relation to the HP control valves
as intended for this operation.
If the condition turbine load less than a set
minimum load and the ratio of HP
exhaust steam pressure to main steam
pressure greater than the set pressure
ratio is fulfilled, for example after load
shedding, the solenoid valve will be de-
energized. This blocks the flow of control
fluid to the actuator (17) and allows control
fluid under the piston (25) to flow into the
return pipe. The force of the spring (26)
moves the piston into the lower end position
and the tension springs (22) of the follow-up
pistons ‘B’ are adjusted so that the IP control
valves do not begin to open until the HP
control valves are wider open. The lever (28)
then rests on the precisely set stop (34).
Limit switch (29) indicates: Setting device
engaged.

5.1-0730-02/3
 Steam Turbine
Description
Function
The function of the hydraulic amplifier is to
amplify the signals from the hydraulic speed
governor (connection ‘b1’) so that they are
sufficient for the actuating devices.
Construction
The principal components of the amplifier
are amplifier piston (1), pilot valve (7),
follow-up piston (2) with sleeves (3),
mechanical feedback system (6) and
actuator (21). Bushings and follow-up
pistons ‘A’ are connected to each other via
the setscrews (10), spring end pieces and
springs (11). Auxiliary secondary fluid flows
over the pilot valve (7) via connection ‘b1’. In
the steady-state condition, the pilot valve is
in its center position and the pressure in the
BHEL Haridwar
Hydraulic Amplifier
for Turbine Control System
auxiliary secondary circuit and the force of
spring (8) are in equilibrium. The pilot valve
is kept in rotation by control fluid flowing
from tangential holes in an integral collar to
give greater freedom of reciprocal motion
and high response sensitivity.
When the pilot valve is deflected from its
center position control fluid from connection
‘a’ is, admitted to the space above or below
the amplifier piston (1) with the opposite side
of the piston opened to the fluid drain. The
resulting motion of the amplifier piston is
transmitted via lever (5) to the sleeves (3)
which in turn, slide on the follow-up piston
(2). The secondary fluid circuits, which are
fed from the trip fluid circuit via throttles and
supply the various actuating devices, are
5.1-0740-02/1
connected at point ‘b’. The secondary fluid
pressures are determined by the tension of
springs (11), which counterbalance the fluid
pressures acting upon the follow-up pistons.
Each follow-up piston (2) and sleeve (3) has
ports, which control the secondary fluid flow
according to their overlap. When the
throttling area is changed by movement of
the sleeve (3), it also changes the pressure
in the follow-up piston causing it to follow the
movement of the sleeve, This varies the
tension of spring until equilibrium is regained
between the spring force and the new
secondary fluid pressure. Each position of
the amplifier piston (1) corresponds to a
specific position of the sleeve (3) and the
follow-up piston (2). The position of the
follow-up piston is the determining factor for
the secondary fluid pressure at point ‘b’.
5.1-0740-02/2
The initial tension of the follow-up piston
springs can be varied by means of the
adjusting screws (10, 14), and the levers
(15, 16).
Controlling action with the Hydraulic
Governor
The pressure above the pilot valve (7) is
varied by the hydraulic governor via varying
the auxiliary secondary fluid pressure
connected at ‘b1’. An increasing auxiliary
secondary fluid pressure causes the
secondary fluid pressure at the connection
‘b’ to rise and open the actuating devices; a
reduction in the secondary fluid pressure
causes the actuating device to close. The
motion of the amplifier piston produces a
simultaneous feedback via lever (6) and
causes the pilot valve to assume its center
position when the new position of the
amplifier piston is reached. Each auxiliary
secondary fluid pressure corresponds to a
certain position of the piston (1) which, in
turn, results in a certain secondary fluid
pressure at connection ‘b’ with each
auxiliary fluid pressure. The degree of
proportionality of the hydraulic governor can
be adjusted by varying the position of lever
pivot (6) with the setscrew (9).
The follow-up piston ‘B’ and the lever (15) of
the rotary shaft (12) situated above it are
connected by the springs (11) of follow-up
pistons ‘B’, the guide bolts (13) and the
setscrews (14).
During normal operation, an energized
solenoid valve allows control fluid ‘a1’ to flow
under the piston (20) of the actuator (21).
The piston (20) is moved upwards against
the force of the spring (19). Stop (25) locked
in normal position by pin and the initial
tension of the tension spring (11) of the
follow-up piston ‘B’ is adjusted by means of
the lever (15, 16) which result in the IP
control valves opening in relation to the HP
control valves as intended for this operation.
If the condition Turbine load less than a
set minimum load and the ratio of HP
exhaust steam pressure to main steam
pressure greater than the set pressure
ratio is fulfilled, for example after load
shedding, the solenoid valve will be de de-
energized. This blocks the flow of control
fluid to the actuator (21) and allows control
fluid under the piston (20) to flow into the
return pipe. The force of the spring (19)
moves the piston into the lower end position
and the tension springs (11) of the follow-up
pistons ‘B’ are adjusted so that the IP control
valves do not begin to open until the HP
control valves are wider open.
The lever (16) then rests on the precisely set
stop (25). Limit switch (17) indicates:
Setting device engaged.
Setting Device for Start-up without
bypass valves
If the plant is started up without bypass
system, the IP/reheat control valves must
open before the main steam control valves.
For this purpose, the hand wheel (24) is set
in the upper end position.
Signal from limit switch (23): Setting device
in operation without bypass system
position.
5.1-0740-02/3
Speed

Rated speed 50.0 c/s

Speed limitation in load and station operation

Max. Speed, no time limitation 51.5 c/s
Min. Speed, no time limitation 47.5 c/s
Permissible for maximum 2 hours during the life of LP blading
Speed below 47.5 c/s
Speed above 51.5 to 60 c/s

Speed exclusion range at operation without load * 7 to 47.5 c/s

Standard over speed trip setting Max. 55.5 c/s

* This speed range should be passed through in one smooth operation to avoid endangering the
blades due to resonance

Steam Pressures
♦ ♣ ♥ Unit
Rated Long time operation Short time operation

Initial Steam 166.7 166.7 200 bar

st
Before 1 HP drum stage 154.4 169.8 169.8 bar
HP cylinder exhaust 44.0 50.63 ♠ bar
52.84
IP cylinder stop valve inlet 39.6 45.97 ♠ bar
47.56
Extraction 6 44.0 50.63 52.84 bar
Extraction 5 16.8 20.08 20.08 bar
Extraction 4 6.94 8.36 8.36 bar
Extraction 3 2.744 3.36 3.36 bar
Extraction 2 1.469 1.81 1.81 bar
Extraction 1 0.342 0.42 0.42 bar
LP cylinder exhaust 0.1013 0.3 0.3 bar
♦ These values correspond to 500 MW load with 3 % make-up and 0.1013 bar back pressure
with all heaters in service and rated steam conditions.
♠ The safety valves must be set so that short time values are not exceeded.
♣ Long time operation: Upper limit value, permissible without time limit.
♥ Short time operation: Permissible momentary value. The aggregate duration of such swings
must not exceed 12 hours in any one year
All pressures are absolute pressures

5.1-0100-63/2
 Steam Turbine
Description
Construction and Mode of Operation
The electrical speed pick-up located in the
front bearing pedestal indicates the exact
speed through all speed ranges of the
turbine. The measuring procedure
functions as follows: -
A toothed wheel (1) is mounted on shaft
(2) of main oil pump. The speed probes
are installed around the periphery of the
BHEL Haridwar
Electrical Speed Pick-Up
toothed wheel, which rotates, with the
rotation of the turbine shaft. On rotation of
the toothed wheel (1), electrical impulses
are generated as a result of alternating
effect between the speed probe (3) and
the toothed wheel (1). The output
frequency is conducted to the speed-
measuring unit.
5.1-0760-01
 Steam Turbine Pressure Converter
Description

Function
The pressure converter is installed in the IP
secondary oil circuit. It does not permit to
raise the IP secondary oil pressure beyond
certain value.

Construction
The pressure converter is provided with a
follow up piston (3), which slides in the
bushing (6) at the top, and in the sleeve (2)
at the bottom. The bushing and follow up
piston are connected to each other via the
set screw (9, 10) and the spring (4). There
are drainage slots in the follow up piston (3)
and sleeve (2), through which a larger or
smaller amount of fluid can flow into the fluid
return line ‘c’ depending on how much they
overlap. The fluid pressure prevailing in the
follow up piston (3) is connected to the
reheat control valves for speed control via
connection ‘x’.

Mode of Operation
When the setscrew (9) of the pressure
converter has been appropriately set, IP
secondary fluid pressure is permitted to
increase to certain value.

1 Ring 8 Cap
2 Sleeve 9 Set Screw
3 Follow up piston 10 Set Screw
4 Spring
5 Casing
6 Bushing c Return flow
7Cover x IP secondary fluid

BHEL Haridwar 5.1-0761-00

 Steam Turbine
Description
Function and Arrangement
One stop and one control valve are
combined in a common body. The main stop
valve provides a means of isolating the
turbine from the main steam line and can
rapidly interrupt the supply of steam to the
turbine. The function of the control valve is
to regulate the flow of steam to the turbine
according to the prevailing load.
BHEL Haridwar
Combined Main Stop
and Control Valves
Stop Valve
The steam enters the valve casing (13) via
the Inlet connection and remains above the
stop disc (1). The main valve disc
incorporates a pilot disc formed from the end
of the valve steam (3). The valve stem is
sealed by packing rings (6). On the back of
the valve disc is a raised seat which comes
into contact with a neck bush (4) when the
5.1-0810-01/1
valve is fully open and so provides extra
sealing at this point for the stem. Both stem
and disc are secured against torsion. The
valve body cover (2) is held in the valve
casing (13) by a threaded ring (8). There is a
U-shaped gasket (5) between cover and
casing. The two legs of the gasket are
pressed against the sealing face to give a
tight joint .The stop valve is opened
hydraulically and closed by spring force.
Testing Main Stop Valve
Each stop valve must be tested at regular
intervals to ensure proper functioning. A
testing valve is provided for this purpose.
5.1-0810-01/2
Control Valves
The stem and disc (16) of the control valve
are in one piece. Balancing holes in the
valve disc reduce the operating force
required. The valve stem and disc (16) are
guided in the cover (17) and the stem is
sealed by packing rings (20). When the
valve is fully opened, the raised seat of the
valve disc rests against the neck bushing
(18) and provides additional sealing. As with
the stop valve, the valve body cover (17) is
held in the casing by a threaded ring (21)
and is sealed by U-shaped gasket (19). The
control valve is actuated by the piston of the
servomotor (26) that is operated by a cup
spring in the closing direction and
hydraulically in the opening direction.
 Steam Turbine Servomotor for Main
Description and Reheat Stop Valves

The operative part of the servomotor the piston and the piston disc connected to
consists of a two-part piston, the lower disc- the valve stem moves to close the valve.
shaped part of which is connected via piston Just before the valve disc seats, the piston
rod to the valve stem. The other part of the disc enters a part of the cylinder where the
piston is bell-shaped and moves within the diametral clearance is reduced. This
housing, which is in the form of a cylinder. arrangement restricts the flow of fluid past
Two spiral springs are placed between the the piston disc and so produces a braking
two halves of the piston at the lower end a action, which causes the valve disc to seat
spring plate is interposed between the gently.
springs and the piston disc. When trip fluid
All fluid connections are routed through a
is admitted to the space above the bell-
test valve. All operations can be controlled
shaped part of the piston, it moves this half
by means of the test valve and the starting &
of the piston downwards, compressing the
load limiting device and main trip valve.
springs, until it seats against the piston disc.
After the main stop valves have been
opened, the turbine is started by the control
valves. Before the main stop valves can be
opened, however, they must be
“pressurized”, i.e. prepared for opening, by
admitting trip fluid from the trip fluid circuit to
the space above the piston to press it down
against the piston disc after overcoming the
resistance of the springs. The edge of the
bell-shaped half of the piston is designed to
produce an fluid tight seal with the piston
disc.
To open the valve, fluid from the trip fluid
circuit is admitted to the space below the
piston disc and, simultaneously, the space
above the bell-shaped half of the piston is
opened to drain. This causes both halves of
the piston to move together in the direction,
which opens the valve. In order to reduce
fluid leakage past the bell-shaped part of the
piston when the valve is open, a back seat is
provided in the housing against which the
collar of the piston can seat.
When the valve is tripped, the pressure in
the trip fluid circuit, and hence in the space
below the piston disc, falls, with the result
that the springs separate the two halves of

BHEL Haridwar 5.1-0811-00

 Steam Turbine
Description
The flow of steam to the turbine is regulated
by varying the lift of the control vale by
means of its servomotor.
The control valve is actually moved by the
piston (9), which is loaded, on one side by
the disc springs (10) and on the other side
by hydraulic pressure. The position of the
valve is determined by the secondary fluid
pressure, which is controlled by the
governor. Since large operating forces are
required, the servomotor is of the high-
pressure type (approx. 32 bar) and has a
pilot control system. The supply of
secondary fluid (connection ‘b’) controls the
auxiliary pilot valve (14) which directs control
fluid from connection ‘a1’ to the appropriate
side of the pilot piston (4). The pilot piston
operates the main pilot valve (3) through
lever (5) so that when the valve is being
opened, control fluid from connection ‘a’ is
directed to the underside of piston (9). When
the valve is being closed, fluid drains
through the main pilot valve.
Pilot Control System
When the turbine is running and the valve is
steady at any particular value of lift, the
auxiliary pilot valve (14) will be in the center
position shown in the drawing. In this
position the force exerted by the spring (13)
and the secondary fluid pressure acting on
the auxiliary pilot valve are in equilibrium.
When the governor varies the secondary
fluid pressure to open or close the control
valve, the auxiliary pilot valve is deflected
from this center position. This allows control
fluid (connection’ a1 ‘) to flow to one side of
the pilot piston (4) while the other side of the
piston is opened to drain. The movement of
the pilot piston returns the auxiliary pilot
valve to its center position by means of the
feedback linkage (12) thus giving
proportionality between secondary fluid
pressure and pilot piston travel. The degree
of proportionality of the pilot control system
can be adjusted by varying the position of
the feedback lever pivot (12). The auxiliary
pilot valve is continuously rotated by the
action of fluid issuing from tangential
drillings in a disc mounted on its spindle in
BHEL Haridwar
Hydraulic Servomotor for
Main and Reheat Control Valves
order to ensure that the valve moves freely
at all times.
Main Control System
The movement of the pilot piston (4) deflects
the main pilot valve (3) from its center
position by means of lever (5) so that either,
control fluid from connection ‘a’ is directed to
the underside of piston (9) and the control
valve opens, or the underside of piston is
opened to drain so that the disc springs can
close the control vale. Shortly before the
main valve disc actually comes into contact
with the seat, the servomotor piston (9)
enters a recess turned in the body and
throttles the flow of fluid draining from the
underside of the piston. This slows down the
valve closing motion and the disc seats
gently. The spring (1) pre-loads the linkage
and prevents any slackness or lost motion at
the pivots. The straight feedback cam (7)
mounted on the end of the servomotor
piston rod (8) returns the main pilot vale (3)
to its center position by means of a lever
system. The slope of the feedback cam is in
two stages to give two degrees of
proportionality, which produce good linearity
of the steam flow characteristics.
Testing Device
The control valve can be operated either by
hand or under power independently of the
governor by means of the testing device (11)
in order to check the free movement of the
valve. The testing device acts on the lever
(5) in the same manner as the pilot piston
(4); the system demanding the smaller valve
lift being in control,
Damping Device
Fig.2 illustrates the auxiliary pilot valve (14)
and the damping device in the secondary
fluid circuit. Any signals in the secondary
fluid circuit are damped out by passing the
secondary fluid through capillary tube (16)
before it enters the auxiliary pilot vale (14).
Any air carried by the secondary fluid is
conducted to the free space in the actuator
via the screw plug (18) and holes in the
casing of the damping device and pilot
valve.
5.1-0812-00/1
5.1-0812-00/2
 Steam Turbine
Description
Function
The function of the test valve is to open and
close the emergency stop valve, either by
start-up fluid circuit or manual operation
especially when the emergency stop valve is
being checked for easy movement.
Arrangement
Each test vale (6) and auxiliary valve (5) is
arranged in series behind a solenoid valve
(1, 2).
Each emergency stop valve is served by
one test valve, whereby a test valve (6) is
combined with an auxiliary valve (5) in a
common casing. These blocks of test valves
are arranged in frames immediately next to
the relative emergency valve groups.
Opening of the Emergency Stop Valve
In order to open the emergency stop valve,
the valve (6) must first be forced downwards
against the force of the spring (7). This can
either be done by start-up fluid (connection
‘u’) or manually with the hand wheel (3). Trip
fluid (connection ‘x’) can then flow to
connection ‘x1’ and on over the piston in the
emergency stop valve. The valve must then
be returned to the upper position, either by
BHEL Haridwar
Test Valve
for Emergency Stop Valve
lowering the pressure in the start-up fluid
circuit or by manually turning the hand wheel
(3). The trip fluid can now flow from
connection ‘x’ to connection ‘x2’ via the
auxiliary valve (5) and ducts in the casing,
and thus under the piston disc.
Testing the Emergency Stop Valves
For testing the emergency stop valve, the
valve (6) is moved slowly downwards by
means of the hand wheel (3). In this way,
trip fluid is admitted to connection x1, and
then connection x2 Iinked to drain c, which
closes the emergency stop valve. After this,
the hand wheel (3) is slowly turned back and
the emergency stop valve opens again. This
procedure is accordingly the reverse of the
closing procedure.
Closing the Emergency Stop Valve by
Automatic Testing Device
When trip fluid is admitted under the
auxiliary valve (5) via connection v, this will
be forced upwards against the force of the
spring (4). This links connection x2 with
drain ‘c’ via valve (5). Fluid thus drains
under the piston disc in the emergency stop
valve and the valve closes suddenly.
5.1-0813-00
 Steam Turbine
Description
Function and Construction
One stop and one control valve are
combined in a common body with their
stems arranged at right angles to each
other. The stop valve can interrupt the
supply of steam from the reheater to the
IP and LP turbines extremely quickly. The
control valve controls the steam flow to
the IP and LP turbines on load rejection,
start-up & shutdown and remains fully
open in the upper load range to eliminate
any throttling losses. Further details of the
arrangement of the valve combination in
the control system can be seen under
section “Governing system”.
Reheat Stop Valve
The stop valve is a single seat valve with
integral pilot valve. Steam enters via the
BHEL Haridwar
Combined Reheat Stop
and Control Valves
inlet of the valve body (2) and remains
above the valve disc (7) when the stop
valve is closed. A pilot valve, integral with
the valve stem (6) is provided for relieving,
thereby reducing the force necessary for
opening. The valve disc (7) slides in the
bushing of the valve cover (4) and has a
bead on the back which lies against the
base bushing (5) and provides additional
sealing at this point. Metal packing rings (3)
seal the valve stem. The stop valve is
opened hydraulically and closed by spring
force.
Testing Stop Valves
Each stop valve must be checked for
correct operation at regular intervals. A test
valve is provided for this purpose. The
checking procedure is described in section
“Test valve”.
5.1-0814-00/1
Control Valve
The control valve has a pipe-shaped
valve disc (14) that is bolted to the valve
stem (13) and slides in the bushing in the
valve cover (11) The valve disc is
provided with relieving holes to reduce the
necessary controlling force. A ring fixed in
the bushing of the valve cover prevents
the valve disc from rotating. This valve
disc also has a back sealing that operates
5.1-0814-00/2
when the valve is fully open.
Asbestos/graphite packing rings (10) seal
the valve stem (13) in the valve cover (11).
The control valve is operated by the piston
of the servomotor (9) i.e. is opened
hydraulically and closed by disc springs.
In the event of a disturbance in the system
or on trip-out, both stop valve and control
valve close rapidly.
Low vacuum trip, standard setting

Hydraulic low vacuum trip 0.3 bar

Electrical low vacuum trip 0.3 bar

Electrical low vacuum trip bypass operation 0.6 bar

Seal steam supply system

Pressure in seal steam header (above atmospheric) 35 mbar

Axial shift

Alarm ± 0.5 mm

Trip ± 1.0 mm

Direction of rotation

Anti clock wise when viewed from Front Pedestal towards the Generator

5.1-0100-63/3
 Steam Turbine
Description
The reheat stop and control valves arranged
beneath the turbine operating floor in front of
the turbine-generator unit are suspended at
three points from girders in the upper
foundation plate in such a way that they can
follow thermal expansion of the steam lines.
The ball-and-socket design of the tie caps
(5) and spring body (9) and the disk spring
stack (8) arrangement permit free movement
of the reheat stop and control valve (3) in all
BHEL Haridwar
Hangers for Reheat Stop
and Control Valves
directions. Tensile forces are taken up via
the disk spring (8) and tie rod (6) by girders
(1) that rest horizontally on shims in a
recess in the foundation and are connected
to the foundation via clamping plates.
Tie rod (6) is screwed into rod cap (5) and
when the correct elevation of the reheat stop
and control valve (3) has been established,
is secured to prevent turning.
5.1-0815-01
 Steam Turbine Steam Strainer
Description

Function parts. The end turns of the corrugated strip

are then tacked to the T -section
Steam Strainers are installed in the main
intermediate rings (3). The maximum mesh
steam lines and in the hot reheat lines from
size of the strainer, which inner diameter
the boiler. They protect the admission
determined by the height of the
elements of the HP and IP turbines from
corrugations, is 1.6 mm. The effective area
foreign objects, which could be picked up in
is made atleast three times the cross-
the boiler or associated piping.
sectional area of the pipe. The strainer is
used for both initial commissioning of the
Construction turbine and for regular operation.
The strainer screen (2) is made of
corrugated strip wound on a frame. This

design offers a high degree of resistance,

even to particles impinging at high velocity. Fig. 3 Corrugated metallic` strip
The frame consists of two rings (1, 6) and a
number of rods (5) welded between the
rings. The rods are additionally held by
reinforcing rings (4) welded inside them. The
strainer is designed for a single direction of
flow from the outside inwards. For longer
strainers, the screen is made up of several

BHEL Haridwar 5.1-0816-00

 Steam Turbine Changeover Valve
Description for Bleeder Check Valve

Function
The function of the changeover valve is to
manually operate the actuator of the
bleeder check valve.

Mode of Operation
The trip fluid (connection x) holds the valve
(10) in the upper end position (illustrated)
against the force of the spring (8). The trip
fluid flows via the holes in the valve to
connection x 1 and then on to the actuator
of the bleeder check valve. The valve can
be moved downwards by means of hand
wheel (1). In this way connection x1 is
connected to the fluid drain ‘c’ and the fluid
drains away from the actuator of the bleeder
check valve. The spring of the actuator can
then initiate the closing of the check valve. If
the pressure drops at the trip fluid
connection x, the spring (8) pushes the
valve (10) downwards. In this way the fluid
drain of the actuator is also freed.

1 Hand wheel 6 Cover

2 Spindle 7 Bush
3 Cap nut 8 Spring
4 Bush 9 Ball
5 Lip ring 10 Valve
11 Cover
c Drain fluid
x Trip fluid
x1 Trip fluid to actuator

BHEL Haridwar 5.1-0840-00

 Steam Turbine
Description
Function
The auxiliary valve controls the fluid supply
to the extraction check valve actuators and
its function is to give the check valves a
signal to close in the case of a drop in load
or trip-out so that steam can not flow out of
bleeder lines back to the turbine. The
auxiliary valve serves several check valves.
Mode of Operation
Trip fluid is admitted through connection ‘x’
on the body (10) (section A-B). Secondary
fluid from follow-up pistons of main control
valves is admitted to the spaces above and
below the valve (11) through connection ‘b2’
As the pressure above and below the valve
(11) are equal under normal conditions, the
valve is held in the lowest position by the
force of the spring (7).
BHEL Haridwar
Auxiliary Valve
of Extraction Check Valve
With this position of the valve, the trip oil
‘x’ can flow to the other valves and as
soon as these valves have been
switched to the upper position by
secondary fluid from follow-up piston of
reheat control valves-on to the change-
over valves of the extraction check
valves (connection ‘x1‘). The check
valves are then free to open. On a
reduction in load, as mentioned above,
the pressure above the valve (11) is
reduced accordingly while the Pressure
below the valve is retained for a while.
This is made possible by the fact that the
pressure reduction below the valve is
retarded by the ball (15) and the
pressure in the accumulator (connection
‘b’) until the equilibrium is re-established
5.1-0841-00/1
between the pressure in the accumulator
and the new pulse fluid pressure
(connection ‘b2’) via the equalizing passage
in the cover (12). Owing to the brief
differential surge, the valve (11) is forced
upwards against the action of the spring (7),
thus cutting off the trip fluid supply to the
check valves and opening the fluid return.
As a result of this, the check valves receive
a closing impulse and close at reduced or
reversed differential steam pressure.
The valves (16), (section C-D) are acted
upon from below (connection ‘b1’) by the
load -dependent secondary fluid pressure of
the control valves. If the secondary fluid
pressure exceeds the value set by adjusting
the springs, these valves are forced
5.1-0841-00/2
upwards against the action of the springs
and open the path for the trip fluid to the
changeover valves of the extraction check
valves. The lift of the valves is limited by a
collar at their lower end. By appropriately
setting the springs (14) to the valves, it can
be ascertained at which secondary fluid
pressure i.e, at which turbine load, the check
valves open or receive an impulse to close.
If the pressure in the secondary fluid circuit
drops, the valves are pushed downwards by
the force of the springs and the inlet ports
from the trip fluid circuit are cut off, the bleed
valves thus receiving an impulse to close.
The fluid in the line to the changeover valves
can drain off through the opened fluid return
‘c’.
 Steam Turbine
Description
Function
The function of the rotary vane actuator
flanged to the swing-check valve is to
open or close the swing-check valve fitted
in the cold reheat line.
Operation
When the pilot valve operated by the
transformer of the speed controller
passes control fluid via connections ‘d’ to
the interior of the actuator, the adjacent
connection ‘d1’ is depressurized. The
control fluid then flows through bores in
the body into the two diametrically
opposite chambers turning rotary vane (2)
on actuator shaft (8) into contact with the
BHEL Haridwar
Rotary Vane Actuator
for Reheat Swing-Check Valve
segments (1). This rotary movement,
transmitted by actuator shaft (8) to shaft (3)
of the swing-check valve via coupling (5;6)
closes the swing-check valve. Conversely,
the swing-check valve is opened when
control fluid is admitted through
connections ‘d1’
Seals, Fixing
Actuator shaft (8) is guided in bushings
(11) at both ends of the segments (1) and
is sealed off by seal ring (10). The
segments (1) are fixed in body (12) and in
cover (13) by means of fitted pins. Leaking
fluid ‘c’ is drained to the header.
5.1-0853-01
 Steam Turbine Pilot Valve for Rotary Vane
Description Actuator of Swing-Check Valve

Function
The function of the pilot valve is to control
the admission of control fluid to the moving
vane actuator in such a way that the swing-
check valve is operated in accordance with
the pressure in the secondary fluid circuit.

Mode of operation
The swing-check valve is kept open as long
as the pressure in the secondary fluid circuit
does not drop below a definite limit value. If
signal fluid enters the body via connection
‘b’, the valve (10) is lifted against the action
of the spring (5). The initial tension of this
spring and thus the point at which the swing-
check valve opens can be adjusted. If the
valve (10) is lifted beyond the center position
illustrated, the control fluid entering at
connection ‘a’ flows on to a chamber of the
actuator via connection ‘a2’ to open the
swing-check valve. Connection ‘a1’ then
communicates with the fluid return ‘c’ via
passages in the body, permitting the fluid to
drain away from the actuator chambers not
supplied with control fluid. If the valve (10)
drops below the center position illustrated,
the control fluid will then be conversely
admitted to the actuator chambers in such a
way that the swing-check valve closes.
To prevent the valve (10) from seizing in its
sleeve (9) during operation control fluid is
passed through the center bore and out
through the tangential bores at the wheel
disc (8) to impart rotary movement to the
valve (10). For this reason, a thrust ball
bearing (7) and a ball (13) is fitted for this
purpose.
1 Throttle capillary tube 12 Slotted nut
2 Cap nut 13 Ball
3 Setscrew
4 Hood
5 Compression spring
6 Spring disc
7 Thrust ball bearing
8 Wheel disc
9 Valve bush
10 Valve
11 Bush c Return
a Control fluid b Signal fluid
a1 Control fluid(closes swing check valve)
a2 Control fluid(opens swing check valve)

BHEL Haridwar 5.1-0854-00

 Steam Turbine Auxiliary Pilot Valve
Description for Rotary Vane Actuator
For Reheat Swing-Check Valve

Function
The function of the auxiliary pilot valve for
the pilot valve for the reheat check valve
actuator is to control the admission of
control fluid to the pilot valve in such a way
that the swing-check valve is actuated in
accordance with the pressure in the
secondary fluid circuit.

Operation
The swing-check valve is kept open as long
as the pressure in the secondary fluid circuit
does not drop below a definite limit value.
Secondary fluid entering body (9) via
connection ‘b’ lifts spool (7) against the
action of the spring (3). The initial tension of
this spring and thus the point at which the
swing-check valve opens can be adjusted. If
spool (7) is lifted beyond its central position
as illustrated, the control fluid entering at
connection ‘a’ flows on via connection ‘a1” to
connection ‘b’ of the pilot valve to open the
swing- check valve via the rotary actuator. If
spool (7) drops below its central position as
illustrated, control fluid is admitted to the
opposite chambers of the rotary actuator, so
that the swing-check valve closes.
To prevent spool (7) from seizing in its
sleeve (6) control fluid is passed through the
center bore in the spool during turbine
operation and out through tangential bores
in the upper part of spool (7) to impart rotary
motion to the spool. A deep-groove ball
bearing (5) between spool (7) and spring
retainer (4) reduces friction from the rotary
motion.

BHEL Haridwar 5.1-0855-00

 Steam Turbine Gland Steam Control Valve
Description

Function
One function of the gland steam control
valve, which is situated in the gland steam
pipe of the seal steam system, is to supply
the shaft seals with seal steam during start-
up and in the lower load range. A further
function is to keep the set pressure in the
header constant in order to prevent air
penetrating the vacuum of the shaft seals.

Construction and Mode of Operation

The control valve is operated by the piston
of the electro-hydraulic actuator, which is
moved in the open and closed direction by
the pressure of the control fluid. The piston
rod (2) is connected to the valve stem (7) via
the coupling (4), the threaded cap (5) and
cover (6).
The steam flow is regulated by the internal
pilot valve, which is integral with the valve
stem, and the main cone (13). The position
of the valve is shown on the lift scale (3).
The valve stem (7) and valve cone (1 3) are
guided in the bushing (11).
Any leakage steam arising in the upper part
of the bushing (11) is conducted to the
header.

1 Electr-hydraulic actuator
2 Piston rod
3 Lift scale
4 Coupling
5 Threaded cap
6 Cover
7 Valve stem with pilot valve
8 Packed stuffing box
9 Valve yoke
10 Base ring with packing rings
11 Bushing
12 Valve cover
13 Valve cone
14 Valve casing

c Leakage steam

BHEL Haridwar 5.1-0860-01

 Steam Turbine Leakage Steam Control Valve
Description

Function
The function of the leakage steam control
valve, which is situated in the leakage steam
pipe of the seal steam system, is to drain
excessive steam from the header.

Construction and Mode of Operation

The control valve is operated by the piston
of the electro-hydraulic actuator, which is
moved in the open and close direction by
the pressure of the control fluid.
The piston rod (3) is connected to the valve
stem (8) via the coupling (4). The packing
rings (10) and the bushing (12) seal the
passage of the rod to the outside and guide
the valve stem (8) during the opening and
closing movement.

1 Electrohydraulic actuator
2 Valve yoke
3 Piston rod
4 Coupling
5 Threaded piece
6 Cover
7 Lift indicator
8 Valve stem
9 Stuffing box
10 Base ring with packing rings
11 Valve cover
12 Bushing
13 Valve casing

BHEL Haridwar 5.1-0870-01

 Steam Turbine Technical Data
Description Steam & Casing Temperatures

Steam Temperatures

Rated value, Long-term 400 hrs. 80 hrs. per year

Annual value, subject to per year Max. 15 min in
average annual average individual case Unit

Main steam at HP 537.0 545.3 551.0 565.0 °C

stop valve inlet

HRH steam at IP 537.0 545.3 551.0 565.0 °C

Stop valve inlet

Steam Temperatures
Rated value Long term 80 hrs. per year, In special
♦ operation Max. 15 min. in cases at no
Unit
individual case load

HP turbine exhaust 336.2 338.2 428.2 ♥ °C

500.0
Extraction 6 336.2 338.2 428.2 ♥ °C
500.0
Extraction 5 410.6 415.6 450.6 °C
Extraction 4 288.2 298.2 338.2 °C
Extraction 3 189.9 202.9 249.9 °C
Extraction 2 132.5 152.5 197.5 °C
Extraction 1 72.2 92.2 142.2 °C
LP turbine exhaust 46.1 70.0 70.0 °C
Long-term operation: upper limit value permissible without time limit.
♦ These values correspond to 500 MW Load with 3% makeup and 0.1013 bar back pressure
with all heaters in service and rated steam conditions.
♥ Only valid for the no load period with high reheat pressure after trip-out from full load
operation. For individual case approx. 15 minutes.
The turbine is immediately re-loaded or the boiler immediately reduced to minimum load if no
load operation is maintained.

Casing Metal Temperatures

Wall Temperatures Alarm at Machine must be shut down at Unit

HP turbine casing exhaust 485 500 °C

Outer casing of LP cylinder 90 110 °C

0
Spray water to LP turbine must be switched on at 90 C

BHEL Haridwar 5.1-0101-63/1

 Steam Turbine
Steam Description
Function
The Function of the main trip valve is to
open the trip fluid circuit in the event of
abnormal conditions, thereby closing the
valves and thus shutting off admission of
steam to the turbine.
Construction
The main trip valve consists of mainly two
valves (12) that slide in the casing (11) and
are loaded by the springs (5,6). The valves
BHEL Haridwar
Main Trip Valve
(12) are designed as differential pistons
being forced tightly against the body
assemblies (10) by the rising pressure of the
fluid. Control fluid flows into the casing (11)
via connection ‘a’ and with a tripping device
latched in (in the position shown), into the
trip fluid circuit via connection ‘x’. The trip
fluid circuit leads to the stop valves and the
secondary fluid circuits. Via passage drilled
in the body (11) (Section A-A) fluid flows to
the auxiliary trip fluid circuit, which leads to
the hydraulic protection devices.
5.1-0910-00/1
Operation
When starting the unit, the valves (12) are
lifted by the aux. start up fluid (connection
‘u1 ‘) against the force of the springs (5,6)
and forced tightly against the assemblies
(10). In this way pressure is build up in the
trip fluid circuit (x) and the auxiliary trip fluid
circuit (x1). The pressure in the auxiliary trip
fluid circuit keeps the valve in the position
shown while the aux. start up fluid drains
through the start up device.
Should the fluid in the pressure in the
auxiliary trip fluid circuit drop below a
specific value for any reason (e.g. by
tripping of a protection device) the valves
5.1-0910-00/2
(12) move downwards due to the spring
force and their own weight, thus connecting
connections ‘x’ and ‘x1’ with the fluid back
flow ‘c’. This depressurizes the trip fluid
circuit which causes the main and reheat
stop valves to close. The fluid supply to the
secondary fluid circuits is also shut off, thus
causing the control valves to close.
The two valves (12) work independently of
each other so that even if one valve fails the
function of the tripping device is not
impaired. The limit switches (1) transmit
electrical signals to the control room.
 Steam Turbine Emergency Trip Valve
Description for Manual trip out

The emergency trip valve enables the

machine to be manually tripped out.
The valve consists of the valve cone (8),
which slides in the bushing (9) and is
loaded by the spring (7), and the ball head
(1) with the spindle (4).
During normal operation the valve (8) is
forced tightly against the bushing (6) by
the pressure of the auxiliary trip fluid
arising at connection ‘x1 ‘. To actuate the
trip, the ball head (1) is pushed
downwards. This opens the valve and
connects the auxiliary trip fluid circuit
(connection ‘x1 ‘) with the fluid back flow
‘c’, The drop in pressure in the auxiliary
trip fluid circuit actuates the emergency
tripping device. The limit switch (2) shows
the tripping of the valve.
On start-up, before the auxiliary trip fluid is
pressurized, the valve (8) is forced
upwards against the bushing by the
auxiliary start-up fluid (connection ‘u1‘).
1 Ball head
2 Limit switch
3 Cover
4 Spindle
5 spring
6 Bushing
7 Spring
8 Valve cone
9 Bushing
10 Casing
11 Cover

x1 Auxiliary trip fluid

u1 Auxiliary start-up fluid
c Return fluid

BHEL Haridwar 5.1-0911-00

 Steam Turbine Solenoid Valve for
Description Remote Trip-out

Function
The solenoid valve is installed in the
auxiliary trip fluid line to the automatic trip
gear and, when operated, causes the
auxiliary trip fluid circuit to be opened and
the turbine stopped, The solenoid valve is
remote-controlled electrically, e.g. from the
control room or from a protective device.

Construction
The directions of flow are indicated by
arrows on the body. The solenoid sleeve (4)
is bolted to the casing (6) and is inserted in
the magnet casing (1) with the armature (3).
The complete valve element is placed in the
body (6) and held by the plug (11). The two
valve discs (8) seal the valve seats (9). The
solenoid valve and the line to the automatic
trip gear are ventilated by means of the
screw (12).

Mode of Operation
When the solenoid (1) is not energized, the
armature (3) is moved downwards by the
spring (2) so that the valve disc (8) is
pressed against the valves seats (9) to
provide sealing. The solenoid valve is
operated by energizing the solenoid (1). The
armature and the valve discs are drawn
upwards against the force of the spring (2)
so that the auxiliary trip fluid ‘a’ is linked with
the drain ‘c’ and the pressure in the line to
the automatic trip gear collapses.

1 Magnet casing
2 Spring
3 Armature
4 Solenoid sleeve
5 Hexagonal nut
6 Casing
7 Ring
8 Stem with two valve discs
9 Valve seat
10 O-ring
11 Plug
12 Ventilation screw
a Auxiliary trip fluid to automatic trip gear
c Drain

BHEL Haridwar 5.1-0912-00

 Steam Turbine Over speed Trip
Description

Function and Construction

The function of the overspeed trip is to stop
the turbine when the permissible speed is
exceeded. It is fitted in the turbine rotor (7)
and consists of the eccentric bolt/striker (4),
adjusting screw (6), spring (5) and the screw
plug (1).

Mode of Operation
The overspeed trip mechanism is set by the
adjusting screw (6). By appropriate
adjustment of the screw, the center of
gravity of bolt/striker (4) is positioned
eccentrically to the turbine shaft so that
below the tripping speed the bolt is held in
the position shown by the spring (5) against
the centrifugal force. In this position, the bolt
bears against the screw plug (1). If the
turbine rotational speed exceeds the
overspeed setting, the centrifugal force
overcomes the force of the spring (5) and
forces the bolt/striker (4) out of the turbine
rotor (7). This activates the turbine 1 Screw plug 5 Spring
2 Guide bushing 6 Adjusting screw
automatic stop mechanism.
3 Guiding foil 7 Turbine rotor
4 Bolt/striker 8 Guide ring

Fig. 1 Arrangement of overspeed trip in

turbine rotor

BHEL Haridwar 5.1-0920-00

 Steam Turbine
Description
Function
The function of the overspeed trip releasing
device is to open the auxiliary trip fluid circuit
and thereby shut down the turbine when an
overspeed is reached which would subject
the rotor to high centrifugal force.
Construction
The overspeed trip releasing device located
in the bearing pedestal consists of valve
bodies (4,10), pilot valve and rods (3,5,7,8),
pawls (12) and limit switch (1). The bellows
16) on the pilot valves and rods prevent
hydraulic control fluid from entering bearing
pedestals and lubrication system. When the
turbine is started up, the pilot valve, rods
and pawls are latched by auxiliary start-up
fluid ‘u1 ‘.
BHEL Haridwar
Overspeed Trip Releasing Device
Turbine Trip by Overspeed Trip Device
When the overspeed trip operates, the
eccentric bolts/striker fly out radially and
strike pawls (12). The impact of the
bolt/striker rotates the pawls outwards
against the force of torsion springs (11). The
latches of the pawls release rod (8) which, in
turn, moves towards the shaft (13) due to
the force of spring-loaded pilot valve (3) and
force of the auxiliary trip fluid ‘x1’. This
movement opens fluid drain ‘c’ to the
auxiliary trip fluid and the resulting loss in
pressure and trips the turbine. The electrical
trip signal is transmitted to the control room
by the limit switches (1).
5.1-0921-00/1
Testing the Overspeed Trips for Free
Movement
Proper functioning of the overspeed trips is
important since severe damage may result
from excessive over speeds. The overspeed
trip test device makes it possible to check
the bolts/strikers as well as pilot valves and
rods (3, 5, 7, 8) without interrupting
operation of the turbine.
5.1-0921-00/2
Start-up
Before restarting the turbine following a trip,
latch in the overspeed trip. This is done by
admitting auxiliary startup fluid ‘u1’ into pilot
valve body (4) and forcing the respective
pilot valve (3) outwards until rod (8) engages
the latch of the pawl. The auxiliary start-up
fluid flow is interrupted and auxiliary start-up
fluid flows via a hole to fluid drain ‘c’.
 Steam Turbine Overspeed Trip Test Device
Description

Function functioning of the overspeed trip is of the

The function of the overspeed trip test utmost importance.
device is to test and exercise the overspeed Construction
trip. The overspeed trip consists of
The overspeed trip test device consists of
bolts/strikers which protrude against the
three pilot valves (4,10, 11) combined in
force of a spring under the effect of
valve block (12). Pilot valve (11) is held in
centrifugal force during an overspeed
the position by spring (9), which bears
condition. The bolt/striker strikes a pawl and
against guide piece (15) and rod (7). In this
thus opens the auxiliary trip fluid circuit and
position auxiliary trip fluid can pass to the
in turn trip fluid circuit so that the stop and
overspeed trip release device via connection
control valves immediately interrupt the
‘x’ and ‘x1‘. If the pilot valve (11) is pushed
admission of steam to the turbine. Perfect

BHEL Haridwar 5.1-0922-00/1

inwards and held by means of the knob (6),
the auxiliary trip fluid circuit (connection ‘x’
and ‘x1’) is separated from the overspeed
trip release apart from a small quantity of
fluid which is permitted to pass to fill up the
empty pipe after the test operation. This
prevents the emergency trip from being
actuated by the overspeed trip.
Pilot valve (10) performs the function of
admitting test oil to the eccentric
bolts/strikers of the overspeed trips, causing
them to protrude from the turbine shaft
during the overspeed trip test operation.
Pilot valve (10) is guided in guide bushings
(13,14). A center bore with radial openings
is provided in the pilot valve. An annular
chamber in the bushing (13) is connected to
test oil connection ‘a1’. In the position
shown oil is prevented from entering the
5.1-0922-00/2
bore of the pilot valve. By means of
handwheel (5), the pilot valve (10) can be
moved inwards so that the passage from
connection ‘a2’ is blocked from drain ‘c1’.
Control oil can now flow from connection ‘a1’
via the bushing (13) and the pilot valve (10)
to connection ‘a2’ and the bolts/strikers of
the overspeed trip.
Pilot valve (4) is used for resetting the
overspeed trip release device after the test
operation. When pilot valve (4) is pushed
inwards against the force of spring (3),
control fluid can flow from connection ‘a’ to
‘u1, thus latching in the overspeed trip
device. During start-up, connections ‘u’ and
‘u1’ provide a passage for auxiliary start-up
fluid for latching in the overspeed trip release
device. After the test operation, the pilot
valves (4,11) are blocked.
 Steam Turbine
Description
Function
The purpose of the low vacuum trip is to
operate the main trip valve when a failure
of vacuum occurs in the condenser, thus
tripping out the main and reheat stop and
control valves and shutting off the supply
of steam to the turbine within the shortest
possible time.
Operation
The condenser vacuum is connected via ‘I’
(connection to condenser) to the top side
of the diaphragm (8). The space below the
diaphragm is at atmospheric pressure.
Upon failure of the condenser to maintain
proper vacuum, diaphragm (8) is forced
downwards by the increase in pressure
and the force of the spring (7) against the
force of spring (10), thus moving valve (9)
downwards. This establishes a connection
between ‘x1’ (control fluid) and drain ‘c’ so
that the auxiliary trip fluid circuit is
BHEL Haridwar
Low Vacuum Trip
depressurized and the main trip valve
operates. Concurrently, valve (11)
actuates the limit switches (15), which
initiates an alarm contact.
The range in which the vacuum safety
device operates can be varied by adjusting
the initial tension of the spring (7) by
means of the adjusting screw (5).
In order to isolate the auxiliary trip fluid
circuit during starting, auxiliary pilot valve
(9) is lifted by means of the spring (10) so
that drain ‘c’ is shut off, thereby
establishing pressure in the auxiliary trip
fluid circuit when no vacuum exists.
As primary oil pressure builds up with the
increase in turbine speed, piston (2) is
forced into the lower position. This lower
position is reached when the speed is still
far below the rated value at which time the
low vacuum trip safety device is ready to
operate.
5.1-0935-00
 Steam Turbine Technical Data
Description Bearing Metal Temperatures
Vibration, Weights

Bearing babbit metal temperatures

Alarm at Machine must be shut down at

Operation temperature below 75 °C 90 °C 130 °C

Operation temperature 75 to 85 °C 100 °C 130 °C

Operation temperature 85 to 90 °C 110 °C 130 °C

Operation temperature above 90 °C 115 °C 130 °C

Vibration
Absolute bearing housing vibration Absolute shaft vibration

Standard alarm setting 50 µm above normal level

Maximum alarm setting 84 µm 200 µm

Limit value for tripping 106 µm 320 µm

The normal level is the reproducible vibrational behaviour typical for the machine &
dependent on the operating conditions.

Vibration readings indicated in control room are peak to peak. The above values are also
given in peak to peak.

Weights
HP turbine, completely assembled 95 T

IP turbine, top half outer casing 26 T

IP turbine, top half inner casing, complete with blading 16 T

LP turbine, top half outer casing complete 43 T

LP turbine, top half inner outer casing, complete with blading, guide blade carriers & 37 T
diffusers
HP turbine rotor, complete with blading 16 T

IP turbine rotor, complete with blading 23 T

LP turbine rotor, complete with blading 100 T

Main stop and control valve, complete with servo motors, without bend & pipe section 22 T

Reheat stop and control valve, complete with servo motors, without bend & pipe 32 T
section
All weights have been calculated with safety allowances. Slings chosen must provide sufficient
security.

BHEL Haridwar 5.1-0102-63

 Steam Turbine Condenser Safety Device
Description

Function
The function of the condenser safety device
situated in the control fluid circuit of the
bypass control system is to protect the
condenser, when there is an excessive
increase in pressure in the condenser, by
opening the control fluid lines so that the
resulting drop in pressure causes the
bypass valves to close.

Mode of Operation
The steam space in the condenser is
connected with the spring space above the
diaphragm (5) via connection ‘I’. The space
below the diaphragm is at atmospheric
pressure. If the pressure in the condenser
increases excessively, the diaphragm (5),
and thus the valve (6), is forced downwards
out of the upper end position by the
increasing pressure and the force of the
spring (4). This shuts off the connection ‘a1”
to the bypass valve from connection. ‘a’
which is from the converter and connects it
to drain ’c’.
The pressure range in which the vacuum
safety device operates can be varied by
adjusting the initial tension of the spring (4)
by means of the adjusting screw (2).
During commissioning the valve (6) is
automatically moved into the upper end
position, where it keeps the control fluid
circuit closed, as soon as the negative
pressure in the condenser falls below the
preset value. In order to be able to close the
control fluid circuit when there is still
insufficient vacuum in the condenser, the
valve is lifted via the lever (10) and cam (9)
but is not yet brought into its upper end
position. As already mentioned, this end
position is not reached until there is
sufficient vacuum.
After this, the lever (10) and cam (9) drop
down and do not impair the functioning of
the vacuum safety device. Any leakage fluid
can drain off through passages in the valve
sleeve (7) and the casing (8).

BHEL Hardwar 5.1-0940-00

 Steam Turbine Solenoid Valve for Temperature
Description Controlled Interlock

Function
When there is an unallowable rise in
condenser temperature due to lack of
injection water a temperature sensor
situated in the condenser dome sends
electric signals to the solenoid valve which
open the signal fluid circuit of the bypass
valve actuators, thereby closing the bypass
valves so that the steam flow to the
condenser is interrupted.

Mode of Operation
During normal operation, the control fluid ‘a’
holds the main control valve (7) against the
force of the compression spring (8) in the
center position as shown here, This provides
the connection between the signal fluid from
pressure switch for injection water ‘b’ and
the stop and control valve operator of the
bypass stop valve ‘b1 “, If the temperature in
the condenser rises to an unallowable value,
the solenoid valve (3) is moved downwards
against the force of the compression spring
(4) so that the control fluid ‘a’ arising before
the main control valve (7) is connected with
the drain ‘c’.
Simultaneously, the control fluid ‘a’ can flow
behind the main valve (7) so that the main
valve moves forwards against the force of
the compression spring (6) and the signal
fluid circuit ‘b1’ is opened and connected to
the drain ‘c’ and the bypass stop and control
valve closed’.

BHEL Hardwar 5.1-0950-00

 Steam Turbine Vacuum Breaker for
Description Reducing the Running Down
Time of the Turbine

Function
With normal shut down or tripping of the
machine, the function of the vacuum
breakers is to cause an increase in
condenser pressure by conducting
atmospheric air into the condenser together
with bypass steam flowing into the
condenser from the bypass station. When
the pressure in the condenser increases, the
ventilation of the turbine blading is
increased, which causes the turbo set to
slow down so that the running down time of
the turbo set and the time needed for
passing through critical speeds are
shortened.

Total Vacuum Breakers

In special cases requiring a rapid shut down
of the turbo set, the total vacuum breaker is
employed.

Electrical Control of Total Vacuum

Breaker
So that the vacuum can also be broken
without limitation due to condenser
pressure, a manual key is provided. This key
opens the vacuum breaker valve. However,
it can not go into the closing position until
the close key provided for closing is used.
This control enables a complete equalization
of condenser and ambient pressure.

Automatic Control
The vacuum breaker is also actuated
automatically by the turbine fire protection
system to shut the turbo set down more
quickly. It is switched back manually using
the close key in this case.

Mode of Operation of Vacuum Breaker

When the magnet is not excited, the
solenoid valve is switched to open. The
control medium arising holds the vacuum
breaker valve in the closed position by
means of the power piston. When the
pressure drops the vacuum breaker is
opened by spring force.

BHEL Haridwar 5.1-0960-00/1

Opening Process
When the magnet is excited the control
medium is without pressure so that the
control medium in front of the solenoid valve
is connected with the drain ‘c’. The piston (3)
and thus the valve disc (19) are moved
upwards by the force of the spring (5) (Fig.
2).

Closing Process
When the magnet is not excited the valve is
closed by the control medium arising. The
pressure of the control medium ‘a’ via the
piston (3) presses seal ring (17) arranged in
the valve disc (19) on to the valve seat (20)
against the force of the compression spring
(5).

1 Piston cover
2 Stop
3 Piston
4 Valve stem
5 Compression spring
6 Piston bottom
7 Limit switch
8 Spacer column
9 Cap nut
10 Gland seal
11 Pecking
12 Valve cover
13 Bushing
14 Valve calling
15 Screw coupling
16 Divided ring
17 Seal ring
18 Disc guide
19 Valve disc
20 Valve seat

a Control medium
I Inlet for atmospheric air
I1 Atmospheric air flowing into condenser Fig. 2 Drawing Showing Function of Vacuum
Breaker

5.1-0960-00/2
 Steam Turbine
Description
Function
The pressure switch monitors the injection
water pressure. When the injection water
pressure drops below the set rated value,
the control fluid is interrupted and thus the
LP bypass valve closed.
Construction
The pressure switch consists of a casing in
which a measuring system, a counter-
connected system for adjusting the rated
value, a knife-edged lever (4), a nozzle (11)
and a slide valve (12) are installed.
The measuring system consists of bellows
(2) upon which the injection water pressure
‘I’ acts and these influence the knife-edged
lever (4) via a pushrod (3). The cylindrical
pin (10) is the pivot point of knife-edge lever
(4). The compression spring (6), the tension
BHEL Hardwar
Pressure Switch
for Injection Water
of which is set to the appropriate rated
value, is provided as a counter force.
Mode of Operation
The lever (4) diverts the fluid jet leaving the
nozzle (11) so that there is no fluid pressure
above the piston surface of the slide valve
(12). If the pressure drops below the rated
value, however., the lever allows the jet of
fluid to enter the bushing (13) which subjects
the piston surface of the slide valve (12) to
fluid pressure, The slide valve is thus
pushed downwards against the force of the
spring (14) into the shut-off position in which
control fluid ‘a2’ is connected to the return
flow ‘c’, This process causes the signal fluid
to be cut off and thus the bypass valves to
be closed.
If necessary, the knife-edged lever (4) can
be fixed in its end position by means of the
lever (17).
5.1-0970-00
 Steam Turbine Changeover Valve
Description for Testing Device

Function
The function of the changeover valve is to
shut off the flow of trip fluid into the trip
fluid circuit while the protective devices
are being tested for proper operation by
means of the Automatic Turbine Tester
(ATT) and to allow control fluid ‘a’ to flow
in so that the stop valves do not close
when the safety devices respond.

Mode of Operation
During normal operation, the control fluid
‘a1’ in the space under the lower piston
(8) of the changeover valve keeps the
valve in the upper end position shown
here. In this way, connection ‘x’ is
connected with connection ‘x1’ and trip
fluid can flow into the trip fluid circuit. The
space above the piston (6) (connection
‘a’) remains depressurized during normal
operation.
When safety devices are checked for
proper operation, the space below the
lower piston (8) is depressurized by
means of a solenoid valve and control
fluid ‘a’ enters the space above the upper
piston, which moves the valve into the
lower position. Due to the connection now
made between connections ‘a’ and ‘x1’,
control fluid ‘a’ can flow freely into the trip
fluid circuit, which keeps the stop valves
open for the duration of the test. Two limit
switches (1) transmit the position of the
valve to the control room.

1 Limit switch 9 Body

2 Piston rod 10 Cover
3 Seal
4 Bushing a Control fluid
5 Inset a1 Control fluid
6 Upper piston c Fluid drain
7 Sliding bushing x Trip fluid from
8 Lower piston tripping device
x1 Trip fluid to trip
fluid circuit

BHEL Haridwar 5.1-0980-00

 Steam Turbine Oil Supply System MAV
Description System Description

Accompanying system diagram

Description and function of components of the
(Drawing No. 2-13100-91101 on Sheet No. hydraulic and lubricating oil system
On Sheet No.5.1-1000-63/4)
Process engineering functions of the The components of the hydraulic and lubricating oil
hydraulic and lubricating oil system system and their function are described below:
The hydraulic and lubricating oil system has
Main oil tank
the following process engineering functions: The oil necessary for operation is stored in the
• Lubrication and cooling of the turbine and main oil tank. The oil pumps draw the turbine oil
generator bearings with turbine oil drawn from the main oil tank and forward it to where it is
from the main oil tank by the oil pumps and needed. Large solid contaminants in the returning
forwarded via cooler and filter to the oil are removed by the strainers in the main oil tank
bearings; pressures and flow rates are set before the oil reaches the suction section of the
with throttle valves. main oil tank.
Air and oil vapour are drawn out of the main oil tank

Supplying motive oil to turning gear. by the oil vapour extractor.

Backflow of the turbine oil to main oil tank. The main oil tank level is monitored.
The turbine oil can be drained from the main oil
Components of the hydraulic and tank.
lubricating oil system • Injector MAV21 BN001
MAV21 BN002
Injector is located upstream of the main oil pump,
In addition to piping, manually operated which is driven by the turbine shaft. The injector is a
valves, and monitoring equipment, the submersible pump, which draws the turbine oil
following tanks, pumps, drives, coolers, filters directly from the main oil tank using turbine oil and
and valves are necessary for operation of the forwards it to the main oil pump under positive
hydraulic and lubricating oil system: pressure.
• Main oil pump MAV21 AP00I
• Main oil tank and oil pumps The main oil pump is driven by the turbine shaft
Main oil tank and assumes the function of oil supply just before
Injector feeder pump MAV 21 BN001 the turbine generator unit reaches rated speed.
Injector feeder pump MAV 21 BN002 • Auxiliary oil pumps
Main oil pump driven by MAV 21 AP001 auxiliary oil pump 1 MAV22 AP001
the turbine shaft auxiliary oil pump 2 MAV23 AP001
Auxiliary oil pump 1 MAV22 AP001 The auxiliary oil pumps are submersible pumps,
Auxiliary oil pump 2 MAV23 AP001 which draw oil directly from the main oil tank.
Emergency oil pump MAV24 AP001 One of the two auxiliary oil pumps supplies the
hydraulic and lubricating oil system with turbine
• Turning gear oil supply valve MAV51 AA001 oil as long as the main oil pump is unavailable
when turbine generator speed is too low for

Oil coolers and oil filters supplying oil, e.g., during start-up or shutdown of
.Oil cooler 1 MAV41 BC001 the turbine. generator or during turning gear
Oil cooler 2 MAV41 BC002 operation
Double multiport butterfly MAV41 AA521
Emergency oil pump MAV24 AP001
valve The emergency oil pump is a submersible
Oil temperature control valve MAV41 AA001 pump, which draws oil directly from the main 'oil
Lubricating oil filter MAV42 BT001 tank. The turbine oil is forwarded by the
emergency oil pump while bypassing the oil
cooler and oil filter in the lubricating oil system

Lubricating oil supply to bearings when the auxiliary oil pumps are unavailable for
lubricating oil valve MAV42 turbine oil supply due to a fault in three-phase
AA502 power supply.
upstream of turbine bearing 1
lubricating oil valve see below
upstream of turbine bearing n
lubricating oil valve see below
upstream of generator bearing n
There is a lubricating oil throttle valve (coded
according to the system diagram) in the
lubricating oil line upstream of every turbine or
generator bearing.

BHEL,HARDWAR 5.1-1000-63/1
• Motive oil valve of the MAV51 AA001
turning gear
The motive oil valve of the turning gear is actuated
by the associated motor.
• Oil coolers
oil cooler 1 MAV41 BC001
oil cooler 2 MAV41 BC002
One oil cooler is always in operation to remove
the heat generated by the turbine and generator
bearings from the turbine oil. The second oil
cooler is on standby. Changeover to the standby
oil cooler must be made when the oil cooler in
operation clogs or leaks.,
The maximum flow rate of the cooling water
.through the oil cooler in operation must be
maintained for good heat transfer and preventing
deposits in the cooler tubes.

Double multiport butterfly MAV41 AA521
valve
The double multiport butterfly valve is the
changeover valve for the oil coolers.

Oil temperature control MAV41 AA001
valve
The lubricating oil temperature upstream of the
turbine and generator bearings is maintained by
the oil temperature control valve.
The oil temperature control valve is a multiport
valve in which hot and cold turbine oil is mixed to
obtain the desired lubricating oil temperature of
approx. 45-degree C downstream of the control
valve.

Duplex lubricating oil filters
lubricating oil filter MAV42 BT001
One element of the switchable duplex lubricating
oil filter is always in operation to protect the
turbine and generator bearings against solid
contaminants.
The differential pressure across the lubricating oil
filter in operation is a measure of filter clogging.

Double multiport butterfly valve
The double multiport butterfly valve is the
changeover valve for the lubricating oil filters.

Lubricating oil throttle valves upstream of
turbine and generator bearings
5.1-1000-63/2
The bearing-specific oil flow rates are set with
the throttle valves in the lubricating oil lines
upstream of the turbine and generator bearings.

Piping and valves
The turbine oil is supplied to where it is needed
through piping. The dimensions of the oil lines are a
function of oil velocity and the oil pressure during
operation.
Piping, oil coolers, and oil filters are equipped with
drain valves. Oil coolers and oil filters can be filled
and vented.
Air and oil vapour is extracted from the return lines.
Sampling valves are provided for taking oil samples.
Passive turbine fire protection
The main oil tanks, oil pumps, oil coolers, oil
filters, and important oil system valves are
installed in separate compartment of the turbine
building. This compartment is designed with a
sump for catching leak oil. The sump volume is
the same as that of the main oil tank.
The oil lines are laid in ducts, which can collect
leak oil and prevent it from contacting machine
parts on which it can ignite.
Information for operation and maintenance

Technical Data
The Technical Data contain the following
information:
- nominal capacity of the main oil tank
- reference values for the capacity of the
lubricating oil system including the oil-side
volume of the system tanks, coolers, filters, and
piping, which are filled during operation
- highest and lowest oil level in the main oil tank
during turbine generator operation at rated ,s-
.peed
- reference values for the amount of oil which
must be filled into the main oil tank for operation
of the hydraulic and lubricating oil system and
for the amount of oil necessary for flushing the
oil system during commissioning or inspection
and overhaul
- manufacturer, type designation, and design data
of oil pump motors
- setpoint and limit values of the lubricating oil
temperature for operation and shutdown of
the turbine generator unit
-
 - manufacturer, type designation , and fineness
of the lubricating oil system filter
- reference values for oil heatup in the bearings
and bearing-specific oil requirement

Dimensioning of the main oil tank
auxiliary oil pump must be switched off.
Extended parallel operation of the main and auxiliary
oil pumps shall be avoided.

Sub-loop controls of the hydraulic and
lubricating oil system.

The main oil tank is dimensioned so that the total oil
in the tank is not recirculated more than 8-10 times
per hour. The turbine oil in the system takes up air
during every recirculation. This air is released from
the turbine oil in the course of the dwell time in the
main oil tank. Large amounts of air in the turbine oil
are either due to an excessive turbine oil recirculation
rate or due to an inadequate air release property of
the turbine oil.

Setting of the throttle valves of the hydraulic
and lubricating oil system
The throttle valve settings for the hydraulic and
lubricating system are optimised during initial start-
up when the turbine generator unit is running at
rated speed:
- The INJECTOR (MAV21BN001 /

MAV21BN002) ensure a positive pressure of
approx. 0.2 bar in the suction line immediately
upstream of the main oil pump.
- Lubricating oil throttle valves upstream of the
turbine and generator bearings, e.g.,
lubricating oil throttle valve upstream of the
first turbine bearing MAV42 AA501.
- Sub-loop controls for the oil Pumps
All oil pumps of the hydraulic and lubricating oil
system driven by electric motors are controlled
by the switching commands of the associated
sub-loop controls. The oil pumps should always
be switched on in a certain sequence to ensure
the lubricating oil supply to the turbine and
generator bearings in the event of a drop in oil
pressure in the hydraulic or lubricating oil
system. The sub-loop controls of the oil pumps
must be in AUTO mode as long as the line of
shafting is driven by steam or the turning gear.

Changeover of oil coolers and filters
Standby oil coolers and standby lubricating oil
filters must be filled and vented before
changeover.
Venting of the oil coolers
The oil-side vent of the oil cooler in operation
must be open.

The mass flows of the oil necessary for

lubricating and cooling are set using the
lubricating oil throttle valves upstream of the
turbine and generator bearings in accordance
with the reference values given in the Technical
data. The lubricating oil throttle valve upstream
of every bearing should be adjusted so that the
turbine oil in the bearing heats up to approx. 20
K.

Characteristics of the main and auxiliary oil

pumps are designed with respect to one another
so that the main oil pump assumes the oil supply
just before the turbine generator unit reaches
rated speed. If the auxiliary oil pump is still in
operation when the takeover criteria of the main
oil pump are fulfilled, the

5.1-1000-63/3
5.1-1000-63-4
 Steam Turbine Technical Data
Description Oil Supply, Oil Pumps

OIL supply
3
Main oil tank, rated capacity 25/40 M
3
First oil filling (estimated) 53 M
3
Flushing oil quantity (estimated) 32 M

Oil cooler for operation, number 1 No.

Oil cooler for reserve, number 1 No.

Min. 38 °C
Oil temperature at cooler outlet, unit in operation Normal 45
Max. 47

Oil temperature at cooler outlet, unit shut down Max. 75 °C

Temperature rise of oil in bearings Normal 20 °C

Max. 25
3
Estimated oil requirement for Bearing 1 0.8 dm /s
3
Estimated oil requirement for Bearing 2 15.4 dm /s
3
Estimated oil requirement for Bearing 3 4.55 dm /s
3
Estimated oil requirement for Bearing 4 9.29 dm /s
3
Estimated oil requirement for Generator front bearing 7.92 dm /s
3
Estimated oil requirement for Generator rear bearing 7.92 dm /s
3
Estimated oil requirement for Exciter bearing 0.70 dm /s
3
Estimated oil requirement for Hydraulic Barring at 4.5 – 5.0 bar 57.4 dm /s

Duplex oil filter- full flow, Type: RFLD W 4020ZAV 25 VZ 1.0 1 No.
Make: MS HYDAC FILTER TECHNIK GMBH.

Filtration particle size of duplex filter element 37 µm

Filtration particle size of main oil tank filter element 250 µm

Safety valve in jacking oil system, setting 200 bar

Pressure limiting valve in jacking oil system, setting 178 bar

BHEL Haridwar 5.1-0103-63/1

Steam Steam Turbine Oil System MAY
Description Oil Vapour Extraction System
System Description

Accompanying system diagram Oil vapour extractors

(Drawing No. 2-13100-91103 on Sheet No. 5.1- oil vapour extractor 1 MAV82 AN001
1001-63/2 oil vapour extractor 2 MAV82 AN002
check valve of MAV82 AA001
Process engineering function of the oil vapour
oil vapour extractor 1
extraction system
Oil vapour forming, for example, due to turbulent flow check valve of MAV82 AA002
of turbine oil in the bearing pedestals and due to release oil vapour extractor 2
of entrained air in the oil return lines and main oil tank is One of the two single-stage oil extractors, whose
removed by one of the two extractors of the oil vapour characteristic is matched to volumetric flow of oil-
extraction system. enriched air, must be in operation as long as the
The negative pressures above the oil surface in the generator is filled with hydrogen.
bearing pedestals, oil return lines, and main oil tank The check valves downstream of the oil vapour
prevent turbine oil or vapour from escaping into the extractors prevent the extractor in operation from
atmosphere. drawing in air tough the standby extractor.
Turbine oil and oil vapour are separated in the oil
Oil separator MAV82 BT001
separator of the oil vapour extractors so that the air Virtually all of the turbine oil in the vapour phase is
released into the atmosphere is virtually free of oil. removed by the oil separator. Inadequate oil
separation is usually caused by excessive
Components of the oil vapour extraction system volumetric flow of oil vapour. Consequently, the
In addition to piping the following equipment is necessary throttle valves in the oil vapour extraction lines
for operation of the oil vapour extraction system : must not be opened too far and the lid of the main
oil tank must be airtight.

Adjustable throttle valves in the oil vapour

Oil vapour extractors and oil separator extraction lines
oil vapour extractor1 MAV82 AN001 Volumetric flow in the oil vapour extraction lines is
oil vapour extractor2 MAV82 AN002 adjusted with throttle valves so that negative
throttle valve upstream of MAV82 AA511 pressures in the bearing pedestals equal the
oil vapour extractor1 reference value of approx. 5-10 mm of water column.
throttle valve upstream of MAV82 AA512 The negative pressures in the oil return lines and
oil vapour extractor2 main oil tank must be matched to this reference value
check valve of MAV82 AA001 without degrading oil separation in the oil separator
oil vapour extractor1 due to excessive volumetric flow.
check valve of MAV82 AA002 If the pressure in one bearing pedestal or in the main
oil vapour extractor2 oil tank is considerably lower than the reference
oil separator MAV82 BT001 value, there is a risk of dust, moisture, or leak off

Throttle valves downstream of bearing steam from the immediate atmosphere being drawn
pedestals into the oil system.
bearing pedestal 1 MAV81 AA501
bearing pedestal 2 MAV81 AA503 Notes on operation of the
bearing pedestal 3 MAV81 AA505 oil vapour extraction system
gen. brg. pedestal MAV81 AA507 During extended shutdowns the oil system fills with
exciter bearing pedestal MAV81 AA511 air as the oil slowly flows back into the main tank. When

Throttle valves of oil return lines the system is started up again by activating the pump,
throttle valve MAV81 AA521 resuming oil flow, the air is driven out and accumulates in
throttle valve MAV81 AA522 the bearing pedestals. Pressure build-up in the bearing
pedestals and discharge of oil through the seal rings can
Description and function of components of the oil be prevented by filling the system using the emergency
vapour extraction system oil pump.
The components of the oil vapour extraction system
and their function are described in the following :

BHEL, Hardwar 5.1-1001-63/1

Duplex oil filter for jacking oil, Type: DFDK 330 1 No

Make: M/s HYDAC

Filtration particle size of jacking oil filter 37 µm

Jacking oil pump, cut-in and cut-out speeds

Jacking oil pump must be in operation at turbine speeds below approx. 510 rpm to avoid
damage to bearings.

Jacking oil pump should be cut-out at speeds above approx. 540 rpm.

Oil pumps

Main oil Auxiliary oil DC emergency Jacking oil pump

pump pump oil pump

Quantity 1 2 1 AC: 1 DC: 1

Make BHEL KBL M&P Tushaco

Type 350m3/hr KPDS 125/26L 4/5 SR 12KL T 38/46

Model 70
3
Rated Capacity 87.48 100 30 1.85 dm /s

Discharge 8.4 6.3 2.3 178 bar

pressure gauge

Speed 3000 2970 1500 2900 rpm

Drive Turbine AC motor DC motor AC motor DC motor

5.1-0103-63/2
 Steam Turbine Technical Data
Description Control Fluid System &
Control Fluid Pumps

CONTROL FLUID SYSTEM

A Fire Resistant Fluid (FRF) is used for the control system

3
Control fluid tank, rated capacity 10/16 M
3
First fill quantity (estimated) 15 M
3
Flushing fluid quantity (estimated) 12 M

Control fluid cooler for operation 1 No.

Control fluid cooler for reserve 1 No.

Control fluid regeneration system

Gear pump Make: Tushaco

3
Fluid flow 0.25 dm /s

Gauge pressure 3 bar

speed 23.42 rpm

Motor power 0.55 KW

Control fluid purification system Make: M/s Hilliard corporation, Type:82119-

550973001
1 No. Drying filter
2 Nos. Fuller’s earth filter
1 No. Fine filter

BHEL, HARIDWAR 5.1-0104-63-1

Control Fluid Pumps

Control fluid pumps 2 Nos.

Manufacturer KSB, Type: WKVM80/1+3

Speed 2982 rpm

Drive A.C. motor, Manufacturer – Siemens AG Type: ILG4313-2AB94-Z

Enclosure IP 55

Voltage 415 V

Frequency 50 Hz

Motor rating (at 50ºC) 132 KW

Motor rating (at 40ºC) 148 KW

Rated current 217 A

Starting current 1614 A

Control fluid pumps operating characteristics Fluid flow Discharge

3
(dm /s) Pressure (bar)

Operating point I (normal operation)

Low pressure leakage fluid 7.6 11.5

High pressure leakage fluid 6.16 38.5

Operating point II (during start & opening of stop valve servomotors)

Low pressure leakage fluid & low pressure control fluid 20.60 10.8

High pressure leakage fluid 6.16 37.8

Operating point III (during opening of CV servomotors)

Low pressure leakage fluid 7.60 10.6

High pressure leakage fluid & high pressure control fluid 16.16 31.6

All pressures are gauge pressures.

5.1-0104-63-2
 Steam Turbine Technical Data
Operation Limit Curves

Permissible temperature difference ∆θ in the wall of HP stop and control valve

casing during Sliding Pressure Operation Mode

140

120 ∆θ = f(θm )
Heating up
100
F
80

N
60

40 S
∆θ[K] OPERATION MODE
F=Fast
20 N=Normal
S=Slow

-20

-40
Cooling down
-60

-80
0 100 200 300 400 500 600
θm [°C]

∆θ = (θi - θm) on the wall temperature sensor

θi = temperature of inner layer
θm = temperature of middle layer

BHEL Haridwar 5.1-0110-01

 Steam Turbine Technical Data
Operation Limit Curves

Permissible temperature difference ∆θ in the wall of HP casing during

Sliding Pressure Operation Mode

140

120 ∆θ = f(θm)

100 Heating up

80 F

60

N
40
OPERATION MODE
∆θ[K] F=Fast S
N=Normal
20 S=Slow

-20

-40
Cooling down

-60

-80
0 100 200 300 400 500 600
θm [°C]
∆θ = (θi - θm) on the wall temperature sensor
θi = temperature of inner layer
θm = temperature of middle layer

BHEL Haridwar 5.1-0111-01/1

 Permissible temperature difference ∆θ in the wall of the HP casing during
Constant Pressure Operation Mode

140

120 ∆θ = f( θm )

100
Heating up

80 F

60
N

40
OPERATION MODE
S
F=Fast
20 N=Normal
S=Slow
∆θ[K]
0

-20

-40
Cooling down
-60

-80
0 100 200 300 400 500 600
θm [°C]

∆θ = (θi - θm) on the wall temperature sensor

θi = temperature of inner layer
θm = temperature of middle layer

5.1-0111-01/2
 Steam Turbine Technical Data
Operation Limit Curves

Permissible temperature difference ∆θ in the HP turbine shaft during

Sliding Pressure Operation Mode
200
180
∆θ = f (θm)
160
Heating up
140
120 F
100
80 N
∆θ[K]
60
S
40 OPERATION MODE
20 F = Fast
N = Normal
0 S = Slow
-20
-40
Cooling down
-60
-80
θm [°C]
0 100 200 300 400 500 600

220

200

180

160

∆θ[K]
140

120

100

80

60
θax [° C]
0 20 40 60 80 100 120

∆θ = (θo - θm) on the wall temperature sensor

θo = outer layer temperature of the shaft
θm = temperature of middle layer in the shaft (calculated)
θax = temperature of axis in the shaft (calculated)

BHEL Haridwar 5.1-0112-01/1

 Permissible temperature difference ∆θ in the HP turbine shaft during
Constant Pressure Operation Mode

180
160
∆θ = f (θm)
140
Heating up
120
100 F
80
60 N
∆θ[K]
40
S
20 OPERATION MODE
0 F = Fast
N = Normal
-20 S = Slow
-40
-60
Cooling down
-80
-100
θm [°C]
0 100 200 300 400 500 600

200

180

160

140

120
∆θ[K]

100

80

60

40
θax [° C]
0 20 40 60 80 100 120

∆θ = (θo - θm) on the wall temperature sensor

θo = outer layer temperature of the shaft
θm = temperature of middle layer in the shaft (calculated)
θax = temperature of axis in the shaft (calculated)

5.1-0112-01/2
 Steam Turbine Technical Data
Operation Limit Curves

Permissible temperature difference ∆θ in the IP turbine shaft during

Sliding Pressure Operation Mode
200
180
∆θ = f (θm )
160
Heating up
140
120 F
100
80 N
∆θ[K]
60
S
40 OPERATION MODE
20 F = Fast
N = Normal
0 S = Slow
-20
-40
Cooling down
-60
-80
θm [°C]
0 100 200 300 400 500 600

220

200

180

160

140

∆θ[K] 120

100

80

60
θax [°C]
0 20 40 60 80 100 120

∆θ = (θo - θm) on the wall temperature sensor

θo = outer layer temperature of the shaft
θm = temperature of middle layer in the shaft (calculated)
θax = temperature of axis in the shaft (calculated)

BHEL Haridwar 5.1-0113-01

 Steam Turbine Steam Purity values
Description for main steam condensate

The deposits which occur in turbines due to
impurities in the steam can lead to
thermodynamic and mechanical inefficiencies
and, with the presence of salts, especially
chlorides, and sodium hydroxide also cause
damage to turbine parts. The corrosion
stressing caused by active deposits, for
example, has an adverse effect on the fatigue
strength of the blade material when the steam
is in the transition zone between the
superheated and the saturated state.
Compliance with the target values is
mandatory in continuous operation, with the
values in the normal operation column
preferable. With the commissioning of a new
plant and starting-up operation, however,
these values cannot be attained with an
economical outlay. The values listed in the
column “starting-up operation “are then valid.
It should be pointed out that adherence to the
target values does not rule out deposition in
the turbine with absolute certainty. Wherever
possible every effort should be made to
achieve the values in the normal operation
column.
A recording instrument may be used to
continuously monitor the electrical
conductivity of the main steam and turbine
condensate following a strongly acid cation
exchange unit. In order to determine slight
impurities, the sodium concentration should
be measured in addition to this. Should
saline contamination occur, the turbine is to
be immediately washed with saturated
steam to remove salt deposits.
Whether an alkaline, neutral or combined
method is used for conditioning, the water
steam circulation is for the customer to
decide. If an alkaline method is used, the
oxygen content in the main steam
condensate can be max. 0.02 mg/kg and the
pH value in the turbine condensate max.9.3
with brass condenser piping. When the
condenser piping is of copper-nickel alloys,
the pH value must not exceed 9.5. There is
no limitation for the pH value with non-
corroding steel or titanium.

Recommended values for main steam condensate

Quantity Target Value Normal Start Up
* Operation **
Conductivity at 25°C, down stream of highly µS/cm < 0.2 0.1 < 0.50
acidic sampling cation exchanger,
continuous measurement at sampling point
Silica (SiO2) mg/kg < 0.020 0.005 < 0.050

Total iron (Fe) mg/kg < 0.020 0.005 < 0.050

Total copper (Cu) mg/kg < 0.003 0.001 < 0.010
Sodium (Na) mg/kg < 0.010 0.002 < 0.020
* To avoid any drop in efficiency, it is recommended that values be kept below the target values
and into the range of the values for normal operation.
** The target values must show a noticeable downward trend. On initial start-up of new plants the
values given for normal operation must be achieved within 2 to 3 days and within 2 to 3 hours
for other start-ups.

BHEL Haridwar 5.1-0120-01

 Steam Turbine Oil Specification
Description Standard

Introduction
This standard specifies the turbine oil
recommended for use in governing and
lubrication systems of BHEL make steam
turboset.
Description
Oil of viscosity class ISO VG 46 shall be
used. The oil shall be a petroleum product
with or without additives to meet the
requirement of this standard. The finished oil
shall be clear and free from water,
suspended matter, dust, sediment and other
impurities.
The turbine oil shall not contain additives
having any negative effect on the materials
of the oil system. The turbine oil must be
capable of withstanding bearing temperature
of max. 130°C and oil tank temperature of
max. 80°C without physical and chemical
degradation.
The properties of the oil shall not be affected
by centrifuging, water washing or filtering.
Compatibility
For topping up of the oil system, it is
preferable if the oil used is of the same
brand and quality as that already in the
system. However, if the same brand of oil is
not available and where it is intended to mix
in different products that individually conform
to this standard, a compatibility test should
be conducted before actually mixing the oils.
Samples of both the oils in equal volume
should be mixed and centrifuged for about
40 hrs. and then mixture must comply fully
with the requirements of this standard.
Properties
The oil should comply with the
requirements given in table below when
tested according to the test methods given
in the respective standards mentioned
against each property. For obvious
reasons, we do not give any special
recommendation to a particular brand of oil
to be used in the oil system of our turbo
sets. Any brand of the oil complying with
the above standards may be used.

Properties of turbine oil ISO VG 46 shall be as follows:

Sl. No. Properties Value Unit Test Method
1. Kinematic Viscosity at 40ºC 41.4 – 50.6 cst IS: 1448, P-25 ASTM D445
Kinematic Viscosity at 50ºC 28 cst
2. Viscosity Index 98 Min. IS: 1448, P-56 -----

3. Neutralization No. (Total ≤ 0.20 mg IS: 1448, P-1 ASTM D974

acidity) KOH/g
4. Colour ≤2 Max. IS: 1448, P-12 ASTM D1500

5. Specific gravity at 50 ºC 0.85 --- IS: 1448, P-32 ASTM D1298

Specific gravity at 15 ºC 0.90 ---
6. Flash point (Cleveland > 200 °C IS: 1448, P-69 ASTM D92
open cup)
7. Copper strip corrosion test at Not worse --- IS: 1448, P-15 -----
100 ºC for 3 hrs. than No.1

8. Pour point ≤-6 °C IS: 1448, P-10 ASTM D97

9. Rust preventing ≤ 0-B --- DIN: 51585 ASTM D665

characteristics

BHEL Haridwar 5.1-0130-04/1

Properties contd.
Sl. No. Properties Value Unit Test Method
10. Emulsion characteristics ≤ 20 minute DIN: 51599 ASTM D1401

11. Total acidity after 2500 ≤ 0.2 mg DIN: 51587 ASTM D943
hrs oxidation KOH/g
12. Foaming characteristics at ----- ASTM: D892
25°C
3
- Foaming tendency ≤ 400 cm
- Foaming stability ≤ 450 s s
13. Deaeration capacity at 50°C ≤4 minutes DIN: 51381 ASTM: D3427

14. Ash (by weight) ≤ 0.01 % IS:1448, P-4 -----

15. Water content by weight ≤ 0.01 % DIN: 51777-1 ASTM: D1744

16. Solid particles by weight ≤ 0.05 % DIN: 51592 -----

17. Particle distribution -/17/14 Minimum ISO: 4406

(Class-8) (NAS: 1638)
18. Water release ≤ 300 s DIN: 51589-1

Following brands of oil are acceptable

Supplier Brand Supplier Brand

lOC Servo Prime 46 Castrol lndia Ltd. Castrol Perfecto T-46-Superclean

Gulf Oil India Ltd Gulf Crest 46 Bharat Petroleum Turbol 46
Apar Ltd. Power Turbo-46 Indo Mobil Ltd. Mobil DTE Medium / DTE798
Caltex Regal R&O 46 Savita Chemicals Daphne Super Turbine oil 46
HPCL Turbinol 46 Bharat Shell Ltd. Shell Turbo oil T46
TOTALFINAELF Total Preslia 46

Also refer to the following sections:

[1] 5.3-0080: Turbine oil Care

5.1-0130-04/2
 Steam Turbine
Description
This specification is valid for Fire Resistant
Fluids (FRF) recommended for BHEL
make steam turbine control system.
According to ISO 6743/4, FRF is a fluid
based on triarylphosphate ester marked
ISO-L-HFDR.
General Requirements
The FRF shall not cause corrosion to Steel,
Copper and its alloys, Zinc, Tin or
Aluminum.
The FRF must provide sufficient corrosion
protection to the materials used in the FRF
system.
The FRF shall be continuously regenerated
with Fuller’s earth or an equivalent
regeneration agent.
Note: Before using regeneration agents
other than Fuller’s earth (e.g. ion
exchangers) BHEL and FRF manufacturer
or supplier shall be contacted.
The FRF must not cause any erosion or
corrosion on the edges of the control
elements.
The FRF must be shear-stable. It should not
contain any viscosity index improver.
FRF leaking from the system, if any, must
not ignite or burn in contact with hot
surfaces (up to 550 ºC).
The FRF must be capable of withstanding
continuous operating temperatures of 75 °C
without physical or chemical degradation.
The FRF must be miscible with traces (max.
3 % by vol.) of TXP of another brand. There
BHEL Haridwar
Fire Resistant Fluid (FRF)
for Turbine Control System
should be no deterioration of the FRF in
presence of such trace quantities.
The air release of the FRF should not
deteriorate in presence of fluoroelastomer
seals and packing used in the FRF system.
The FRF must be free of ortho-cresol
compounds.
The FRF must not pose a safety or health
hazard to the persons working with it,
provided that the requisite hygiene
regulations are observed.
Limit values
The following limit values are not to be
exceeded during the life time :
Kinematic viscosity - maximum variation
± 5% with reference to delivery condition.
Neutralisation number - maximum increase
0.20 mg KOH/g with reference to delivery
condition.
Air release -maximum 12 minutes.
Foaming at 25 °C -Tendency maximum 200
ml, Stability maximum 450 sec.
Disposal
Supplier to be contacted for ‘Buy Back’ of
used fire resistant fluid.
In consultation with supplier, liquid material
should be incinerated and material absorbed
on sand should be disposed off as
hazardous solid waste.
5.1-0140-04/1
Recommended Properties of new batches of FRF
Property Numerical Unit Test method
Value
DIN / ISO ASTM
2
Kinematic Viscosity at 40 °C 41.4 - 50.6 mm /s DIN 51 562-1 D 445
(ISO VG 46)
Air release at 50 °C ≤3 minutes DIN 51 381 D 3427
Neutralisation number ≤ 0.1 mg KOH/g DIN 51 558-1 D 974
Water content ≤ 1000 mg/kg DIN 51 777-3
Foaming at 25 °C Tendency ≤ 100 ml D 892
(Seq. 1)
Stability ≤ 450 sec
Water separability ≤ 300 sec DIN 51 589-1
Demulsification ≤ 20 minutes DIN 51 599 D 1401
3
Density at 15 °C ≤ 1250 kg/m DIN 51 757 D 1298
Flash point (Cleveland open cup) > 235 °C DIN/ISO 2592 D 92
Ignition temperature > 550 °C DIN 51 794
Wick flame persistance time ≤5 sec DIN/ISO 14935
Pour point ≤ −18 °C DIN/ISO 3016 D 97
Particle distribution * ≤ 15/12 Code ISO 4406
Chlorine content ≤ 50 mg/kg DIN 51 577-3
Oxidation stability ≤ 2.0 mg KOH/g DIN 51 373
Hydrolytic stability ≤ 2.0 mg KOH/g DIN 51 348
Change of neutralisation number
Electrical resistivity > 50 MΩm IEC 247
* The required system cleanliness is dependent upon the system design. Suitable measures (e.g.
filtration, separation) have to be taken to achieve this cleanliness level.

Following fire Resistant Fluids are approved:

Brand Supplier
1. Reolube Turbofluid 46XC M/s. Chemtura, UK
2. Fyrquel EHC-N M/s. Supresta, USA

Also refer to the following sections:

[1] 5.3-0082 : Care of control fluid

5.1-0140-04/2
 Steam Turbine HP Turbine
Description Valve Arrangement

General Arrangement
The HP turbine has 2 main stop valves and 2
control valves located symmetrically to the right
and left of the casing. The valves are arranged
in pairs with one main stop valve and one
control valve in a common body.
The short length of the admission section
between the control valves and the casing
results in a very low steam volume in this
section, which has a beneficial effect on the
shutdown characteristics of the turbine-
generator unit.

Steam flow
The main steam is admitted
steam inlet passing first the
and then the control valves.
valves the steam passes
casing(1).
Valve Actuation
Each main stop valve and control valve has a
through the main dedicated hydraulic servomotor(3;5). The
main stop valves servomotors are mounted above floor level so
From the control that they are accessible and can be easily
to the turbine maintained.

5.1-0205-00
BHEL Haridwar
 Steam Turbine
Description
Barrel type Casing
The HP outer casing is designed as a barrel-
type casing without axial joint. An axially split
inner casing (4) is arranged in the barrel-type
casing(3)
Because of its symmetrical construction, the
barrel - type casing retains its cylindrical shape
and remains leakproof during quick changes in
temperature (e.g. on start-up and shut down, on
load changes and under high pressures). The
inner casing too is almost cylindrical in shape as
the joint flanges
BHEL Haridwar
HP Turbine
Casing
are relieved by the high pressure acting from the
outside and can thus be kept small. For this
reason, turbines with barrel type casing are
especially suitable for quick start-up and loading.
Seals
The pretensioned U-shaped seal ring(12),
that is forced against the axial sealing surfaces
by the steam pressure and the I shaped seal
ring (16), that allows axial displacement of the
inner casing (4), seal the space between the
inner casing (4) and the barrel type outer casing
(3) from the adjacent spaces.
Fig. 1 HP Turbine
5.1-0210-01/1
 Fig.2 Inlet Connection

3 Outer casing
4 Inner casing
valves are connected to the inlet connections
6 U seal ring of the outer casing by Breech Nuts(8) (Fig.2)
7 Cylindrical pin through buttress threading. Sealing is achieved
8 Breech nut by U-seal rings(6) which is forced against the
9 Inlet pipe from main stop and control valve outer sealing surface by inlet steam pressure.
The annular space around the sealing ring is
connected to the condenser through a steam
Connection to Main Stop and Control Valves leak-off line. Cylindrical pins(7) located at the
joint flange prevent rotation of the inlet pipe with
The steam lines from the main stop and control respect to the outer casing.

3 Outer casing 3 Outer casing

4 Inner casing 4 Inner casing
11 Fitted Key 10 Fitted Key

Fig. 3 Centering and support of Fig.

Fig.4 Centering and support
4 Centering of
and support of
inner casing (Exhaust side)
Inner casing (Admission side) Inner casing (Exhaust side)

5.1-0210-01/2
 Attachment of Inner Casing

The inner casing (4) is attached in the

horizontal and vertical planes in the barrel-type
casing(3) so that it can freely expand radially in
all directions and axially from a fixed point when
heating up while maintaining concentricity
relative to the turbine rotor.
On the admission side, four projections of the
inner casing (4) and on the exhaust side three
projections fit into corresponding grooves in the
barrel-type casing (3). In the horizontal plane
these projections rest on fitted keys (10) and in
the vertical plane they are guided by the fitted
keys (11) (Fig.3&4). Radial expansion is
therefore not restricted by this suspension.

As shown in fig.6 the axial fixed point of the

inner casing is provided by a shoulder in the
3 Outer casing
barrel-type casing (3) against which a collar of
4 Inner casing
the inner casing(4) rests. The axial thrust to
16 I-seal ring
which the inner casing is subjected is
17 Holding ring
transmitted to and absorbed by the thrust ring
18 Hexagon head screw
(14) via thrust pads(13). The thrust ring is held
in position by support ring (15).

Outlet Connections
The exhaust end of HPT has single outlet
Fig. 5 I-Ring seal (Detail A from Fig. 1)
connection from bottom. At the flange
connection a U-seal ring (19) is provided to
prevent any leakage (Fig.1)

3 Outer casing 13 Thrust pads

4 Inner casing 14 Thrust pads
12 U- seal ring 15 Support ring

Fig. 6 Axial Retention ofInner casing and Centering in vertical plane (Detail E from Fig.1)

5.1-0210-01/3
 HP Turbine
Steam Turbine Blading
Description

Moving and Stationary Blades

The HP turbine with advance blading consists of

17drum stages. All stages are reaction stages
with 50% reaction. The stationary and moving
blades of all stages (Fig.1) are provided with
inverted T-roots which

A 2
3

B .

The moving and stationary blades are

inserted into corresponding grooves in the
shaft( 4) and inner casing (1) and are caulked
5 at bottom with caulking piece (5) .The
insertion slot in the shaft is closed by a
locking blade which is fixed by taper pins or
grub screws. End blades are used at the joint
plane in L/H & U/H of inner casing along with
predetermined interference.

Gap sealing
Fig. 1 Drum Stages
Sealing strips(6) are caulked into the inner
casing(1) and the shaft (4) to reduce leakage
1 Inner casing 4 Turbine shaft losses at the blade tips. Cylindrically
2 Guide blade 5 Caulking piece machined surface on the blade shrouds are
3 Moving blade
opposite the sealing strips. The surfaces have
stepped diameters in order to increase the
also determine the distance between the
turbulence of the steam and thus the sealing
blades. The shrouds are machined integral with
effect. Should an operational disturbance
the blades and forms a continuous shrouding
cause the sealing strips to come into contact
after insertion.
st th with opposite surfaces, they are rubbed away
From 1 . to 8 . stages are provided with ‘3DS’
th th without any considerable amount of heat
blades, 9 . to 13 . stages with ‘TX’ blades and
th being generated. They can easily be renewed
14 . to 17 th. stages with ‘F’ blades.
at a later date to provide the specified
clearance.

BHEL Haridwar 5.1-0220-02

 Steam turbine
Description
Function
The function of shaft seals is to seal the interior
of the casing from the atmosphere at the ends of
the shaft on the admission and exhaust
sides.The HP Turbine has shaft seals in front
and rear. The front shaft seal is of labyrinth type,
while the rear shaft seal is of ‘see through’ type.
The difference in pressure before and after the
raised part of the shaft seal on the admission
side serves to counteract the axial thrust caused
by steam forces.The raised part is called
Balance piston. The effective seal
Fig. 1 Shaft Seal Admission side
1 Inner casing 2 Seal ring
3 Turbine rotor
4 Shaft seal cover
5 Caulking wire
6 Seal strip
Fig. 2 Shaft seal Exhaust side
BHEL Haridwar
HP Turbine
Shaft seals and Balance Piston
diameter is suited to the requirements for
balancing the axial thrust.
Gap Seals
Sealing between the rotating and stationary
parts of the turbine is achieved by means of seal
strip(6) caulked into seal rings (2,7,9) and into
the rotor (3) (details D and E). The pressure
gradient across the seal is reduced by
conversion of pressure energy into velocity
energy which is then dissipated as turbulence as
the steam passes through the numerous
compartments according to the labyrinth
principles.
Seal Rings
The seal rings (2), the number of which
depends on the pressure gradient to be sealed
are divided into several segments as shown in
Section A-A, B-B and C-C and mounted in
T -shaped annular grooves in the inner casing
(1 ) and shaft seal cover (4) such that they are
free to move radially. Each segment is held in
position against a shoulder by helical springs
(11). This provides the proper clearance for the
seal gaps. Should rubbing occur, the segment
concerned can retreat. The heat developed by
light rubbing of the thin seal strip (6)
5.1-0230-01/1
 is so slight that it cannot cause deformation of
the rotor (3). When the turbine is started from
the cold or warm state, the seal rings naturally
heat up faster than the casing. However, they
can expand freely In the radial direction against
the centering force of the helical spring (11).
The shaft seals are axial-steam flow non-
contacting seals.
In the region subjected to the low relative
expansion in the vicinity of the combined
journal and thrust bearing, the seal strips are
caulked alternately into the shaft and into
spring-supported segmented sealrings in the
casing, forming a labyrinth to impede the
outflow of steam (Detail D).
In the region subject to greater relative
5.1-0230-01/2
expansion at the exhaust end, see through
seals are used in which the seal strips are
located opposite each other, caulked into the
shaft and into seal rings centered in the outer
casing (Detail E).
The outer seal rings can be removed for
inspection and if necessary, seal strips can be
replaced during short turbine shut down.
Steam Spaces
Steam spaces are provided within the shaft
seals. From spaces ‘Q’ and ‘R’ leakage is drawn
off to another part of the turbine for further use.
The steam seal header is connected to space
’S’. The slight amount of leakage steam which
are still able to pass the seal ring are conducted
from the space ‘T’ into the seal steam
condenser.
 Steam Turbine HP Turbine
Description Front Bearing Pedestal

Arrangement Connection of Bearing Pedestal and

The front bearing pedestal is located at the
turbine-
side end of the turbine generator unit. Its
function is to support the turbine casing and
bear the turbine rotor. It houses the following
components and instruments.

Journal bearing [1]

Hydraulic turning gear [2]

Main oil pump with hydraulic speed
transducer [3]

Electric speed transducer [4]

Overspeed trip [5]

Shaft vibration pick-up

Bearing pedestal vibration pick-up
Details of casing supports and casing guides are
given in description 5.1-0280.
Foundation
The bearing pedestal (1) is aligned to the
foundation
by means of hexagon head screws that are
screwed into it at several points. On completion
of alignment, the space beneath the bearing
pedestal is filled with special non-shrinking
grout. The bearing pedestal is anchored to the
foundation by means of anchor bolts (13). The
anchor bolt holes are filled with gravel, which
gives a considerable vibration damping effect.
The defined position of the bearing pedestal on
the foundation is established by a projection in
the middle of the bearing pedestal base
engaging in a recess in the Foundation. On
completion of alignment, the remaining space
in this recess is likewise filled with grout .

1 Bearing pedestal 7 Hydraulic turning

7 Hydraulic gear
turning gear
2 Main oil pump 8 Bearing
8 Bearing
pedestal
pedestalvibration
vibration
pick-up
pick-up
3 Hydraulic speed transducer 9 Shaft vibration
9 Shaft pick-up
vibration pick-up
4 Electric speed transducer 10 10
Journal bearing
Journal bearing
5 Gear coupling 11 11
HPHPturbine rotor
turbine rotor
6 Over speed trip 12 12
Foundation
Foundation

Fig.1 Axial Section through HP Turbine Front

Bearing Pedestal
5.1-0240-01/1
BHEL Haridwar
 Fig. 2 Cross section of main oil pump

Fig. 3 Cross Section of Journal Bearing

[4] 5.1-0760 Electric Speed Transducer

Also refer to the following information
10 Journal bearing [1] 5.1-0270 Journal Bearing
Also refer to the following information [2] 5.1-0510 Hydraulic Turning Gear
12 Foundation [3] 5.1-1020 Main Oil Pump with Hydraulic
13 Anchor bolts Speed Transducer
[1] 5.1-0270 Journal Bearing
14 Hex head screw [4]
[2]5.1-0760
5.1-0510Electric Speed
Hydraulic Transducer
Turning Gear
[5]
[3]5.1-0920
5.1-1020Overspeed
MainOilPumptrip with Hydraulic Speed Transducer
5.1-0240-01/2 [5] 5.1-0920 Overspeed trip
 Staem Turbine
Description HP Turbine
Rear bearing Pedestal

Arrangement
The bearing pedestal is located between the
HP and IP turbines. Its function is to support the
turbine casing and bear the HP and IP turbine
rotors.

The bearing pedestal houses the following

turbine
components:

 Combined journal and thrust bearing

 Shaft vibration pick-up
 Bearing pedestal vibration pick-up
 Thrust bearing trip (electrical)
Details of casing supports and casing guides
are given in descriptions 5.1-0280 and 5.1-0350.

Connection of Bearing Pedestal and

Foundation

The bearing pedestal is aligned on the

foundation by means of hexagon head screws
that are screwed into it. On completion of
alignment, the space beneath the bearing
pedestal is filled-in with special non-shrinking
grout. The bearing pedestal is anchored to the
foundation by means of anchor bolts. The
anchor bolt holes are filled with gravel, which
gives a considerable vibration damping effect.
The defined position of the bearing pedestal on
the foundation is established by a projection in
the middle of the bearing pedestal base
engaging a recess in the foundation. On 1 HP turbine rotor
2 Combined journal and thrust bearing
8
completion of alignment, the remaining space in
the recess is likewise filled with grout. 3 Bearing pedestal vibration pick-up
4 Shaft vibration pick-up
5 Thrust bearing trip (electrical)
6 Coupling bolts
7 IP turbine rotor
8 Foundation

Fig. 1 Axial Section through the HP Turbine

Rear Bearing pedestal

BHEL Haridwar
5.1-0250-02/1
2 Combined journal and thrust bearing 9 8
8 Foundation
9 Hex head screw

Fig. 2 Cross Section through Combined

Journal and Thrust Bearing
10 Straight pin
11 Anchor bolt
12 Plate
13 Round nut
14 Hex nut
15 Guard cap

Fig. 3 Connection between Bearing Pedestal

and foundation

5.1-0250-02/2
 Steam turbine
Description
Function
The function of the combined journal and
thrust bearing is to support the turbine rotor and
to take the residual axial thrust. The magnitude
and direction of axial thrust to be carried by the
bearing depends on the load conditions of the
turbine. This bearing is located in the bearing
pedestal between HPT & IPT. The thrust bearing
maintains desired axial clearances for the
combined turbine generator shaft system.
Construction and Mode of Operation
The combined journal and thrust bearing
consists of the upper and lower bearing shells
(4, 12), thrust pads (6), cap (2), spherical blocks
(14, 16) and keys (10, 17). The upper and lower
halves (4, 12) of the bearing shell are bolted and
doweled at the horizontal joint by means of 4
taper pins and 4 stocket-head screws.
Section A-A
1 Bearing pedestal, upper 7 Bearing liner
2 Cap 8 Turbine shaft
3 Key 9 Brg. pedestal
4 Bearing shell upper lower
5 Cowling with all baffle 10 Key
6 Thrust pad 11 Oil line
BHEL Haridwar
Combined Journal and Thrust
Bearing
The journal bearing is constructed as
elliptical sleeve bearing. The bearing liners are
provided with a machined babbit face; additional
scraping is neither necessary nor allowable.
In order to prevent the bearing from exerting
a bending moment on the shaft, it is pivot-
mounted on spherical support (16). The
spherical block (14) with shims (13,15), is bolted
to the lower bearing shell (12). A transverse
projection in the upper part of the cap (2) and
the fitted key (3) prevent the bearing shells from
rising.
The bearing shells are located laterally by
keys (10). The bearing is supported axillay
against the bearing pedestal (1,9) by means of
keys (17, 18) (Section H-H). This fixing is of
great importance for axial clearance in the whole
turbine.
Located at each end of the bearing shell,
babbitted thrust pads (6) form two annular
surfaces on which the integralily machined shaft
collars run.
Section B-B
12 Bearing shell,lower
13 Shim
14 Spherical block
15 Shim
16 Spherical support
25 Key
“a” Shaft jacking oil
5.1-0260-01/1
These collars and thrust pads permit equal
19 Thermocouple
loading of the thrust bearing in either direction.
20 Thermocouple
As shown in section N-N, the thrust pads are of
the tilting type, secured in place by pins (23) and
Oil Supply
flexible mounted on split spring element (21).
Lubricating oil is admitted to the bearing
shells from one side via oil line (11) from where
Temperature Measurement
it flows to the oil spaces milled into the upper
Metal temperature of the journal bearing and
and lower bearing shells at the horizontal joint.
thrust pads is monitored by the thermocouples
(19,20) (Section E-E and G-G).

Oil leaving the journal bearing flows to the two

annular grooves adjacent to the bearing surface
and then to the thrust pads (6). Through the two
oil return cowlings (5), oil is discharged into the
drain area in the pedestal (9)

JackingOil

Passages are located at the lowest point in the

lower bearing shell through which high pressure
jacking oil is supplied under the journal at low
speed of the turbine rotor (on start up or
shutdown). Thus dry friction is prevented and
the breakaway torque on start-up with turning
gear is reduced.

High pressure oil “a” flows under the journals

via
the oil line and via openings in the lower bearing
shell (12). O-ring (24) located between the
bearing liner (7) and the lower bearing shell (12)
prevents any oil from penetrating between the
4 Bearing shell upper 21 Spring two elements (Detail “C”).
element
Any leakage passing the seal will drain off to
6 Thrust pad 22 Key
the
12 Bearing shell, lower 23 Dowel pin
bearing pedestal through a groove in the lower
bearing shell. This arrangement ensures that no
oil penetrates between the bearing liner and the
bearing shell.
5.1-0260-01/2
 Steam Turbine Journal Bearing
Description HP front

Construction bearing shells. Keys (8) are fitted on both

The function of the journal bearing is to
support the turbine rotor. Essentially the journal
bearing consists of the upper and lower shells
(3,6), bearing cap (1), spherical block (7),
spherical support (14) and the key (11) .The
bearing shells are provided with a babbit face.
The babbit surface of the bearing is precision
machined and additional scraping is neither
necessary nor permissible. Both bearing shells
are fixed by means of taper pins and bolted
together.
In order to prevent the bearing from exerting a
bending moment on the rotor (5), it is pivot-
mounted in the spherical support (14). For this
purpose the spherical block (7) with shims
(12,13) is bolted to the bearing shell (6) . A
projection in cap (1) with shims (9) fits into a
sides of the projection.
The bearing shells are fixed laterally by key (11)
which are bolted to each other. Each key is held
in position in the bearing pedestal (10) by two
lateral collars. The temperature of the bearing
bodies is monitored by thermocouples (19) as
shown in section c-c.
Oil Supply
Lubricating oil is admitted to the bearing shells
from one side and flows to oil spaces that are
milled into the upper shell at the horizontal joint
and are open to the rotor. The rotor (5) picks up
oil from oil pocket machined into the babbitting
.The oil emerges from the bearing shell where it
is collected in the oil return cowling (4) and
drained into the bearing pedestal(10).

corresponding groove in the bearing shell (3)

and prevents vertical movement of the

1 Cap 6 Lower baering shell 11 Key

2 Tab Washer 7 Spherical block 12 Shim
3 Upper bearing shell 8 Key 13 Shim
4 Oil return Cowling 9 Shim 14 Spherical support
5 Turbine Rotor 10 Bearing pedestal 15 Shim

BHEL Haridwar 5.1-0270-01/1

Jacking oil

As shown in Detail B, a threaded nozzle( 17)

is arranged at the lowest point of the lower
bearing shell (6) through which high pressure lift
oil is supplied to the space below the journals
when the rotor is turning at low speed (on start-
up and shutdown).This high pressure oil floats
the shaft to prevent dry friction and overcome
breakway torque during start-up on the hydraulic
turning gear.

A seal (18) prevent high pressure oil from

penetrating the space between threaded nozzle
and ring (16) and thus from lifting the babbit.
Any leakage oil can drain through passages in
the bearing shell below the ring.
16 Ring
17 Threaded nozzle
Removal of Bearing Shells 18 Sealing ring
19 Thermocouple
Not only the upper shell(3) but also the lower
bearing shell(6) can be removed without the
removal of rotor (5). To enable this to be done
the shaft is lifted slightly by means of jacking
device but within the clearance of the shaft
seals. The lower bearing shell can then be
turned upwards to the top position and removed.

5.1-0270-01/2
 Steam Turbine HP Turbine
Description Casing Supports and Guides

Supports The turbine casing (2) is supported with its two

The turbine casing is supported on the support
horns such as to make allowance for the thermal
expansion. It is essential for the casing to retain
concentric alignment with the rotor, which is
supported independently.
front and two rear support horns on the horn
supports of the bearing pedestal (1,3) at the
turbine centerline level. This arrangement
determines the height of the casing and also
allows thermal expansion to take place in the
horizontal plane by the support horns

1 Front bearing pedestal

2 HP turbine
3 Rear bearing pedestal

Fig.1 Connection between Turbine Casing

and Bearing Pedestals

BHEL Haridwar 5.1-0280-01/1

sliding on the sliding pieces (6) of the bearing
pedestals (1 ;3). To prevent lift-off of the turbine
casing (2), holders (4) hold down projections of
the support horns which engage in mating
recesses in the bearing pedestal.
When the turbine is being erected, a clearance
’s’ is maintained between the thrust bar(5) and
the turbine casing support horn projection.
Guides
to the turbine centerline is provided by the
guides shown in section B-B and E-E. These
guides allow the turbine casing to expand freely.
Fixed Point
The fixed point for the turbine casing (2) is
located at the horn support on HP-IP pedestal at
the turbine centerline level and is formed by the
parrallel keys (16). Axial expansion of the
turbine casing (2) originates from this point.

The central location of the turbine casing at right

angle

1 Front bearing pedestal

2 HP turbine 10 Sliding piece
4 Holder 11 Plate
5 thrust bar 12 Parallel key
6 sliding piece 13 Scale indicating casing expansion
7 Plate 14 Sliding piece
8 parallel key 15 Plate
9 plate 16 Parallel key

Fig. 2 Details of Casing Supports and guides

5.1-0280-01/2
 Steam Turbine
Description
Double Shell Construction
The casing of the IP turbine is split
horizontally and is of double shell construction.
A double-flow inner casing (3,4) is supported
in the outer casing (2,5) (Fig.1) Steam from
the HP turbine after reheating enters the inner
casing from top and bottom through two
admission branches which are integral with the
mid section of the outer casing. This
arrangement provides opposed double flow in
the two blade sections and compensates axial
thrust. The centre flow prevents the steam
inlet temperature from affecting the support
horns and bearing sections.
BHEL Haridwar
IP Turbine
Casing
The provision of an inner casing confines
the steam inlet conditions to the admission
section of this casing. While the joint flange
of the outer casing is subjected only to the
lower pressure and temprature effective at the
exhaust from the inner casing. This means
that the joint flange can be kept small and
material concentrations in the area of the
flange reduced to a minimum. In this way,
difficulties arising from deformation of a casing
with flange joint due to non uniform
temperature rise e.g. on start-up and shut
down, are avoided. The joint of the inner
casing is relieved by the pressure in the outer
casing so that this joint has to be sealed only
against the resulting differential pressure.
5.1-0310-01/1
Steam Inlet and Extraction Connection
The angle ring (9) are provided at the connection
of admission and extraction branches with the inner
casing (3,4) (Detail ‘D’ Fig. 2 & 3). One leg of the
angle ring (9) at such a connection bears against the
back of the collar of the threaded ring (7) in the outer
casing while the other fits into an annular groove in
the inner casing. The threaded ring (7) is fitted in
such a way that the short leg of the angle ring can
slide freely between the collar of the threaded ring
and the outer casing. The steam pressure prevailing
on the inside, forces the angle ring against the face
of the outer casing. .
The tolerances of the annular grooves in the inner
casing are dimensioned to allow the long legs of the
angle ring (9) to slide in the groove. The angle rings
are flexibly expanded by the pressure on the inside
and their outer areas forced against the annular
grooves to provide the desired sealing effect
5.1-0310-01/2
While providing a tight seal, this arrangement
permits the inner casing to move freely in all
directions.
Attachment of Inner Casing
Due to the different temperatures of the inner
casing relative to the outer casing, the inner casing is
attached to the outer casing in such a manner as to
be free to expand axially from a fixed point and
radially in all directions, while maintaining the
concentricity of the inner casing relative to the shaft.
The steam admission connections and the extraction
connections are designed to avoid any restrictions
due to thermal expansion. The inner casing is
attached to the outer casing in the horizontal and
vertical plane.
 In the horizontal plane, as shown in details E and casing (4) and together with the fitted keys (14)
F (Fig. 4 & 5) the four support horns of the top half provide a centering system for the inner casing (3, 4)
inner casing (3) rest on plates (13) which are in the transverse plane This arrangement allows axial
supported by the joint surface of the bottom half outer and radial expansion of the inner casing relative to
casing (5). The shoulder screws (12) are provided the outer casing while the fitted keys (14) maintain
with sufficient clearance to permit the inner casing to transverse alignment.
expand freely in all directions in the horizontal plane.
Thermal expansion in the vertical direction originates
from the point of support at the joint. This ensures
concentricity of the inner casing relative to the rotor
(1) in this plane.
The support horns provided at the bottom half
inner casing (4), project into the recesses in bottom
half outer casing (5) with clearance on all sides.
Located on top of each support horn is a spacer disc
(11) whose upper surface has a clearance ’s’ to the
flange face of the top half outer casing (2). This
clearance thus determines the lift of the inner casing.
As shown in details E, the inner casing is located
axially by the fitted keys (10) arranged on both sides
of the support horns of the bottom half inner casing
(4). Thermal expansion in the axial direction
originates from these points. Radial expansion is not
prevented by these fitted keys, as they are free to
slide in the recesses of the bottom half outer casing.
Shoulders on the bottom half outer casing (5)
project into corresponding recesses in the bottom
half inner

5.1-0310-01/3
 Steam Turbine
Description
Moving and Stationary Blades
The IP turbine with advance blading consists of
2x12 (double flow) drum stages. All stages are
reaction stages with 50% reaction. The stationary
and moving blades of all stages are provided with
inverted T -roots in moving blade and hook type
roots in Guide blade which also determine the
distance between the blades. All these blades are
provided with integral shrouds, which after
installation form a continuous shroud. The moving
and stationary blades are inserted into
appropriately shaped grooves in the rotor (4) and
in the inner casing (1) and are bottom caulked
with caulking material (5). The insertion slot in the
rotor is closed by a locking blade which is fixed by
grub screws. End blades, which lock with the
horizontal joint are used at the horizontal joint of
the inner casing (1).
1 Inner Casing
2 Guide Blade
3 Moving Blade
4 Turbine Shaft
5 Caulking piece
6 Sealing strip
7 Caulking wire
BHEL Haridwar
IP Turbine
Blading
Gap SealIng
Sealing strips (7) are caulked into the inner
casing (1) and the rotor (4) to reduce leakage
losses at the blade tips. Cylindrically machined
surfaces on the blade shrouds are opposite the
sealing strips. These surfaces have stepped
diameters in order to increase the turbulence of
the steam and thus the sealing effect. In case of
an operation disturbance, causing the sealing
strips to come into contact with opposite surfaces,
they are rubbed away without any considerable
amount of heat being generated. They can then
easily be renewed at a later date to provide the
specified clearances.
5
2
7
5
5.1-0320-02
 Steam Turbine
Description
Function
The function of the shaft seals is to seal the
interior of the turbine casing against the
atmosphere at the front (thrust bearing end) and
rear shaft penetrations of the IP turbine.
The shaft seals are axial-steam-flow non-
contacting seals.
In the region subject to low relative
expansion in the vicinity of the combined journal
and thrust bearing, the seal strips are caulked
alternatively into the shaft and into spring-
supported segmented rings in the casing,
forming a labyrinth to impede the outflow of
steam.
In the region subject to greater relative
expansion at the exhaust end, see-through seals
are used, in which the seal strips are located
opposite each other,
BHEL Haridwar
IP Turbine
Shaft Seals
caulked into the shaft and into seal rings
centered in the outer casing.
The outer seal rings can be removed for
inspection and if necessary seal strips can be
replaced during a short turbine shut down
keeping module in place.
Gap Sealing
Sealing between the rotating and stationary
elements of the turbine is achieved by means of
seal strip (9) ,caulked into seal rings (3;5) and
into the rotor (4) (details A and C). The pressure
gradient across the seal is reduced by
conversion of pressure energy into velocity
energy which is then dissipated as turbulence as
the steam passes through the numerous
compartments according to the labyrinth
principle.
5.1-0330-01/1
Seal Rings
The seal rings (3), the number of which
depends on the pressure gradient to be sealed
are divided into several segments as shown in
Section BB and mounted in grooves in the rings
such that they are free to move radially. Each
segment is held in position against a shoulder by
helical springs (6) and by the steam pressure
above the seal rings (3). This provides the
proper clearance for the seal gaps. Should
rubbing occur the segments concerned can
retreat. The heat developed by light rubbing of
the thin seal strips (9) is so slight that it cannot
cause deformation of the rotor (4).
5.1-0330-01/2
When the turbine is started from the cold or
warm state, the seal rings naturally heat up
faster than the mounting rings. However. they
can expand freely in the radial direction against
the centering force of the helical springs (6).
Steam Spaces
Steam spaces are provided within the shaft
seals. From space ‘P’ leakage is drawn off to the
steam seal header. The slight amount of
leakage steam which are still able to pass the
seal ring are conducted from the space ‘R’ into
the seal steam condenser.
 Steam Turbine IP Turbine
RearBearing Pedestal
Description

Arrangement

The bearing pedestal is located between the

IP and LP turbines. Its function is to support the
turbine casing and bear the weight of IP and LP
rotors.

The bearing pedestal houses the following

turbine components:

• Journal bearing
• Shaft vibration pick-up
• Bearing pedestal vibration pick-up
• Hand barring arrangement

Connection of Bearing Pedestal and

Foundation

The bearing pedestal is aligned on the

foundation by means of hexagon head screws
that are screwed into it at several points. On
completion of alignment the space beneath the
bearing pedestal is filled with special non
shrinking grout. The bearing pedestal is
anchored to the foundation by means of anchor
bolts. The anchor bolt holes are filled with gravel
which gives a considerable vibration damping
effect.

BHEL Haridwar 5.1-0340-02

 Steam Turbine
Description
Construction
The function of the journal bearing is to support
the turbine rotor. Essentially, the journal bearing
consists of the upper and lower shells (3, 6),
bearing cap (1), torus piece (7), cylindrical
support (14) and the keys (10). The bearing
shells are provided with a babbit face which is
precision machined. Additional scraping is
neither necessary nor permissible. Both bearing
shells are fixed by means of taper pins and
bolted together.
In order to prevent the bearing from exerting a
bending moment on the rotor (5), it is pivot-
mounted in the cylindrical support (14). For this
purpose, the torus piece (7) with shims (12, 13)
is bolted to the bearing shell (6). A projection in
cap (1) with key (9) fits into a corresponding
groove in the bearing shell (3) and prevents
vertical movement of the bearing shells.
Centering of the bearing shells in the vertical
plane is achieved by means of keys (8).
BHEL Haridwar
IP Rear Journal Bearing
The bearing shells are fixed laterally by spacers
(10) which are bolted to each other. Each spacer
is held in position in the bearing pedestal (11) by
two laterall collars. The temperature of the
bearing bodies is monitored by thermocouples
(15) as shown in section C-C.
Oil Supply
Lubricating oil is admitted to the bearing shells
from both sides, from where it flows to oil spaces
milled into the upper and lower shells at the
horizontal joint that are open to the rotor end. Oil
from the oil space machined in the babbitting is
carried through the rotor (5) and emerges from
the bearing shell from where it is collected in the
oil return cowling (4) and drained into the
bearing pedestal (11).
5.1-0345-01/1
Jacking Oil

As shown in section B-B, two threaded

nozzles (17) are arranged at the lowest point of
the lower bearing shell (6) through which high
pressure oil is supplied to the space below the
journal when the rotor is turning at low speed
(on start-up and shutdown). This high pressure
oil floats the shaft to prevent dry friction and
overcome breakaway torque during startup, thus
reducing torque requirements of the hydraulic
turning gear.
A seal (18) prevents high pressure oil from
penetrating the space between threaded nozzle
and ring (16) and thus from lifting the babbit.
Any leakage oil can drain through passages in
the bearing shell below the ring.

Removal of Bearing Shells

Not only the upper shell (3) but also the lower
bearing shell (6) can be removed without the
removal of rotor (5). To enable this to be done,
the shaft is lifted slightly by means of jacking
device but with in the clearance of the shaft
seals. The lower bearing shell can then be
turned upwards to the top position and removed.

5.1-0345-01/2
 Steam Turbine
Description IP Turbine
Casing Supports and Guides
The turbine casing is supported on the support It is essential for the casing to retain
horns such as to make allowance for the thermal concentric alignment with the rotor which is
expansion. supported independently

1 HP Turbine rear bearing pedestal Fig.1 Connection between turbine casing and
2 IP turbine bearing pedestal
3 IP turbine rear bearing pedestal

BHEL Haridwar 5.1-0350-01/1

 The turbine casing (2) is supported with its
two front and two rear support horns on the
bearing pedestals(1,3) at the turbine centerline
level. This arrangement determines the height of
the casing and also allows thermal expansion to
take place in the horizontal plane by the support
horns sliding on the sliding pieces (6;16) of the
bearing pedestals (1,3). To prevent lift off the
turbine casing (2), holders (4;15) hold down
projections of the support horns which engage in
mating recesses in the bearing pedestal.
When the turbine is being erected, a
clearance ’s’ is established between the thrust
bars (5;14) and the turbine casing (2) support
horn projection.

Guides Fixed Point

The central location of the turbine casing at right
angles to the turbine centerline is provided by
the guides shown in section B.B .These guides
allow the turbine casing to expand freely.
The fixed point for the turbine casing (2) is
located at the front horn support at the turbine
centerline level and is formed by the parallel
keys ((7;10). Axial expansion of turbine casing
(2) originates from this point

5.1-0350-01/2
 Steam Turbine
Description
Construction
The LP turbine casing consists of a double-
flow unit and has a triple shell welded casing.
The outer casing consists of the front and rear
walls, the two lateral longitudinal support
beams and the upper part. The front and rear
walls as well as the connection areas of the
upper part are reinforced by means of circular
box beams. The outer casing is supported by
the ends of the longitudinal beams on the base
plates of the foundation.
1 Outer casing, upper half
2 Diffuser, upper half
3 Inner outer casing upper half
4 Inner- inner casing, upper half
BHEL Haridwar
LP Turbine
Casing
Inlet Connections
Steam admitted to the LP turbine from the IP
turbine flows into the inner casing (4,5) from
both sides through steam inlet nozzles before
the LP blading Expansion bellows are
provided in the steam piping to prevent any
undesirable deformation of the casings due to
thermal expansion of the steam piping.
5 Inner inner casing, lower half
6 Inner outer casing lower half
7 Diffuser lower half
8 Outer casing lower half
Fig. 1 LP Turbine (Longitudinal
section)
5.1-0410-00/1
Arrangement of Inner Casing in Outer
Casing
The LP casing has a double-flow inner
casing. This inner casing is a double shell
construction and consists of the outer part
(3,6) and the inner part (4,5). The inner shell is
suspended in the outer shell to allow thermal
movement and carries the front guide blade
rows.
The rear guide blade rows of the LP stage
are bolted to the outer shell of the inner
casing. The complete inner casing is
supported in the LP outer casing (1,8) in a
manner permitting free radial expansion
concentric with the shaft and axial expansion
from a fixed point (Fig.2).
Support and Guiding of Outer Casing
The outer casing rests with the brackets at
the end of the longitudinal beam on the base
plates fixed to the foundation crossbeam. The
outer casing of the LP turbine is axially fixed at
the respective front brackets (Fig.2).
In the lower area of the circular beams
which reinforce the front and rear walls of the
outer casing, the casing is guided in the
vertical centre plane (Fig.1, 3) which takes
the radial and axial expansion into account.
5.1-0410-00/2
Two guide plates are welded vertically to
the lower inner bend of each of the beams.
The guiding piece (12) which is rigidly
connected to the foundation crossbar, fits
between these plates. Fitted pieces(11)
inserted between the square guiding piece(12)
and the plates maintain alignment of the
casing in the centre plane and permit
expansion transverse to the axis of the
machine.
Support and Guiding of Inner Casing in
Outer Casing
The complete assembled inner casing rests
in the horizontal plane with 4 brakets on the
sliding piece(15, 18) placed in the plates
bolted to the longitudinal support beam of the
casing. The two brackets (detail C Fig.5) on
the turbine side are fixed in the axial direction
by fitted keys (16) as opposed to the brackets
on the generator side (detail D Fig.6) which
are not fixed. Any thermal expansion in the
axial direction thus originates from here.
The spacer bolts( 17) prevent lifting of the
inner casing. The clearance of these spacer
bolts in the holes of the brackets is
dimensioned to permit the inner casing to
expand horizontally on sliding piece (15) of the
fixed support transverse to the axis of the
machine, and on sliding piece (18) of the non-
fixed support transverse and parallel to the
machine axis. As thermal expansion in the
vertical direction originates at approximately
the level of the horizontal.
Fig.3 Guiding of the Outer Casing

joint, the concentricity of the inner casing with

the shaft is ensured in this plane. As shown in
detail E (Fig.2,4) two casing guides are
located at the lower half (6) of the outer shell
to prevent any transverse displacement of the
inner casing from the centerline of the turbine.
Radial and axial expansions is not prevented
by fitted keys(14) in these casing guides

Suspension of the Inner Shell

The inner shell (4,5) is suspended in the

outer shell (3,6) in the horizontal plane and is serve to align the inner shell, lower half (5) in
guided axially in the vertical plane (Fig.7and the outer shell, lower half (6) by the use of
8). In the horizontal plane, the upper half (4) of jacking bolts during erection. On the IP turbine
the inner shell is supported by four brackets side, 2 fitted keys (19) are inserted between
resting on the support plates (21,22) located at each bracket and recess. As shown in detail L,
L and M of the joint face of the lower half of these fitted keys fix the inner shell in the axial
the outer shell (Fig.9 & 10). The brackets of direction and thermal expansion thus
the upper part (3) of the outer shell which originates from here
project over the cover plates (20) , prevent
lifting of the inner shell. The slight clearance
between these cover plates and the brackets
permits free horizontal expansion of the inner
shell in all directions at the support points.
Thermal expansion in the vertical plane
originates at the joint face. This ensures
concentricity of the inner shell with the shaft in
this plane.

The brackets of the inner shell, lower half (5)

project into recesses of the outer shell, lower
half (6) These brackets are provided with
clearance on all sides and

5.1-0410-00/3
3 Outer shell, upper half
4 Inner shell, upper half
5 Inner shell, lower half
6 Outer shell, lower half
Fig. 7 Inner Casing, Longitudinal Section

In the vertical plane 4 centering pins (26)

which are guided in bushings (25) are
provided for the suspension as shown in detail
A Fig. 11. The lower ends of the centering pins
are fitted into keys (27) which slide in axial
grooves in the inner shell. This arrangement
permits axial displacement of the inner shell
relative to the keys (27) and vertical
displacement along the axis of the centering
pins(26) while displacement transverse to the
axis of the unit prevented by the keys. Thermal
expansion transverse to the axis of the unit
originates from these keys so that
concentricity of the inner shell with the shaft is
also maintained in this plane. The bushings
(25) have an eccentric bore and by turning
them during alignment of the inner casing, the
inner shell can be moved laterally. After the
alignment has been completed, the bushings
are fixed in position by grub screws.

5.1-0410-00/4
 Steam Turbine
Description
Atmospheric relief diaphragms are provided in
the upper half of each LP exhaust end section
to protect the turbine against excessive
pressure. In the event of failure of the low
vacuum trips the pressure in the LP turbine
exhaust rises to an excessively high level until
the force acting on the rupturing disc (1)
ruptures the breakable diaphragm (2) thus
providing a discharge path for the steam. The
diaphragm
BHEL Haridwar
Atmospheric Relief Diaphragm
consists of a thin rolled lead plate. To insure
that the remnants of the diaphragm and
rupturing disc are not carried along by the
blow-off steam a cage with brackets (5) is
provided. As long as there is a vacuum in the
condenser the atmospheric pressure forces
the breakable diaphragm and the rupturing
disc against the supporting flange (3).
5.1-0420-00
 Steam Turbine LP Turbine
Description Blading, Drum Blading

Arrangement

The drum blading stages 1 to 3 of the double

flow LP turbine are of reaction type with 50%
reaction. They are Located in the inner-Inner
casing and form the initial stages of the LP
blading. The LP stages following these drum
stages are described in detail in next chapter.

Guide and moving blades

All guide and moving blades of drum stages

have integral shrouds, which after installation
form a continuous shrouding. The moving
blades (7) of the last drum stage are tapered
and twisted. All stationary and moving blades
have T -roots which also determine the
distance between the blades. They are
inserted into the matching grooves in the
turbine shaft (5) and inner casing (1) and are
caulked in place with
caulking material (6). The insertion slot in the
rotor is closed by means of a locking blade
which is secured in its position by means of
grub screws between shaft and lock blade .In
casing, blades at joint planes are fixed by
means of grub screws.

Inter stage Sealing

In order to reduce blade tip losses, tip to tip

sealings are provided in these stages. Thin
sealing strips (9) are caulked in inner casing
(1) and turbine rotor (5). The sealing fins are
machined on the shrouds of moving and
stationary blades opposite to the sealing strips
in inner casing or rotor (Detail A). In the event
of rubbing due to a fault , little heat will be
generated due to rubbing of thin sealing strips.
These can be renewed at a later date to
provide the correct radial clearances.

BHEL Haridwar 5.1-0430-01

 Steam Turbine
Description
Guide and Moving Blades
The last three stages of the LP turbine are
also reaction stages. Each stage is made up of
guide and moving blades.
The stationary blade rows (2, 5, 7) are made
by welding inner ring, blades and outer ring
together to form Guide Blade Carriers in two
halves, that are bolted to inner outer casing
(1). The blades of rows 2 & 5 are of precision
cast steels and the blades of row 7 are made
BHEL Haridwar
LP Turbine
Blading, Low Pressure Stages
from steel sheets to form hollow blades.
Suction slits are provided in the blades of row
(7). Through these slits water particles on the
surface of these last stage guide blades are
drawn away to the condenser.
The moving blades (3) of first LP stage are
tapered,
twisted and have integral shrouds with T -root.
The last two stages of moving blades (6,8)
have curved fir-tree roots (View-X) which are
inserted in axial grooves in the turbine shaft
(4) and secured by means of clamping pieces
(11). Axial movement of the blades
5.1-0440-01/1
is prevented by segments of locking plate Inter stage sealing
segments (12) and the end segments are spot In order to reduce blade tip
welded at joint. The difference in losses at the stationary blade rows
circumferential speed at the root and tip of the (2,5,7). sealing strips (9) are caulked
moving blades is taken into consideration by into turbine shaft. Opposite to this,
the twisted design of the blades. sealing strips are also caulked on the
inner ring of stationary blade rows as
shown in Detail A. This arrangement
permits favourable radial clearances
to be attained. In case of rubbing, the
thin seal strips are worn away without
generating much heat. They can be
easily replaced at a later date to
restore the required clearances.

5.1-0440-01/2
 Steam Turbine LP Turbine
Description Shaft Seals

Function

The function of the axial shaft seals situated

between the bearing casings and the LP
exhaust casing is to seal the inner space of
the LP exhaust casing against atmospheric
pressure at the passages through the shaft.

Gap Sealing

The sealing effect between the moving and

stationary parts of the turbine is achieved by
means of sealing strips (4) which are caulked
into the individual seal rings (2), The prevailing
pressure is reduced according to the labyrinth
principle by conversion into velocity with
subsequent turbulence in many sections.
strips (4) due to this light pressure are so slight
that it cannot cause deformation of the rotor
(5). When the turbine is started from the cold
or semi-warm state, the sealing rings naturally
heat up more quickly than the steam seal
casings. They can then expand radially without
hindrance against the centering force of the
helical springs.

Steam Spaces
Steam spaces are provided within the shaft
seal. When the plant is started up and in
operation, sealing steam enters space “Q” to
prevent air penetrating the space, which is
under a vacuum. The slight amount of steam
that passes the center seal ring is drawn off
from space “R” into the seal steam condenser.

Sealing Rings

The sealing rings (2), the number of which

depends on the pressure existing in the
turbine, are split into several segments as
shown in section A-A and arranged in T-
shaped annullar grooves in the steam seal
casing (1) so that they can move radially.
Several helical sprir1gs (3) force each
segment against a shoulder and hold it in this
position. This permits the correct clearance in
the sealing gaps. Should rubbing occur, the
segments concerned retreat. The frictional
heat developed by the thin

BHEL Haridwar 5.1-0450-01

 Steam Turbine LP Turbine
Description Rear Bearing Pedestal

Arrangement

The bearing pedestal is situated between

the LP turbine and generator. Its function is to
bear the weight of LP rotor.

The bearing pedestal contains the

following turbine components:

Bearing pedestal vibration pick-up

• Journal bearing
• Shaft position measuring device
• Shaft vibration pick-up

Connection of Bearing Pedestal and

Foundation

The bearing pedestal is aligned on the

foundation by hexagonal screws that are
bolted into the bearing pedestal. To overcome
friction resistance, balls are arranged under
the heads of these hexagonal screws. After
alignment the space under the bearing
pedestal is filled in with special nonshrink
grout, resistant to expansion and contraction.
The bearing pedestal is also connected to the
foundation by means of anchor bolts.

BHEL Haridwar 5.1-0460-02

 Steam Turbine
Description
Construction
The function of the journal bearing is to
support the turbine rotor. Essentially, the
journal bearing consists of the upper and lower
shells (3, 6), bearing cap (1), torus piece (7),
cylindrical support (14) and the keys (10). The
bearing shells are provided with a babbit face.
The bearing bore is precision machined and
additional scraping is neither necessary nor
permissible. Both bearing shells are fixed by
means of taper pins and bolted together.
In order to prevent the bearing from
exerting a bending moment on the rotor (5), it
is pivot-mounted in the cylindrical support (14).
For this purpose, the torus piece (7) with
shims (12, 13) is firmly bolted to the bearing
shell (6). A projection in cap (1) with shims (9)
fits into a corresponding groove in the bearing
shell (3) and prevents vertical movement of
the bearing shells.. Centering of the bearing
shells in the vertical plane is achieved by
means of keys (8).
1 Cap 5 Rotor
2 Tab washer 6 Lower bearing shell
3 Upper bearing shell 7 Torus piece
4 Oil return cowling 8 Key
BHEL Haridwar
Journal Bearing
The bearing shells are fixed laterally by the
keys (10) which are bolted to each other. Each
key is held in position in the bearing pedestal
(11) by two lateral collars. The temperature of
the bearing is monitored by thermocouples
(15) as shown in section C-C.
Oil Supply
Lubricating oil is admitted to the bearing
shells from both sides, from where it flows to
oil spaces milled into the upper and lower
shells at the horizontal joint that are open to
the rotor end. Oil from the oil space machined
in the babbitting is carried through the rotor (5)
and emerges from the bearing shell from
where it is collected in the oil return cowling (4)
and drained into the bearing pedestal (11).
Lift Oil
As shown in section B-B threaded nozzles (17)
are arranged at the lowest point of the lower
bearing
9 Shim 13 Shim
10 Key 14 Cylindrical support
11 Bearing Pedestal
12 Shim
5.1-0470-00/1
shell (6) through which high pressure oil is
supplied during start-up. This high pressure oil
relieves the bearing to overcome breakaway
torque and prevent dry friction, thus reducing
the torque requirements of the hydraulic
turning gear.
The lift oil flows into the above mentioned
threaded nozzles (17) through passages in the
lower bearing shell (6). A seal (18) prevents
high pressure oil from penetrating the space
between threaded nozzle and ring (16) and
thus from lifting the babbit. Any leakage oil can
drain through passages in the bearing shell
below the ring.

Removal of bearing shells

Not only the upper shell (3) but also the
lower bearing shell (6) can be removed without
the removal of the shaft (5). To enable this to
be done, the shaft is lifted slightly by means of
the jacking device but within the clearance of
the shaft seals. The lower bearing shell can
then be rotated to the top position and
removed.

15 Termocouple
16 Ring
17 Threaded nozzle
18 Sealing ring

Also refer to tne following sections

[1] 5.1-0510 Hydraulic Turning Gear

5.1-0470-00/2
 Steam Turbine
Description Hydraulic Turing Gear

Arrangement
The hydraulic turning gear is situated
between the main oil pump and the journal
bearing in the HP turbine front bearing pedestal.
Function
The function of the hydraulic turning gear is
to rotate the shaft system at sufficient speed
before start-up and after shut-down in order to
avoid irregular heating up or cooling down and
thus avoid any distortion of the turbine rotors.
The air flow set up by the blades along the inner
wall of the casing during turning operation
provides good heat transfer conducive to
temperature equalization between upper and
lower casing halves.

Operation
During turning gear operation, the shaft
system is rotated by a blade wheel which is
driven by oil supplied by the auxiliary oil pump.
This oil passes via a check valve into the nozzle
box (1) and from there into the nozzles (2) which
direct the oil jet in front of the blading.

Return Oil Flow

After passing the blading, the oil drains into
the bearing pedestal and flows with the bearing
oil into the return flow line.

Manual Turning Gear

A manual turning gear is provided in addition
to the hydraulic turning gear to enable the
combined shaft system to be rotated manually.

Lifting of Shaft
To overcome the initial break-away torque on
start-up and to prevent dry friction, the bearings
are relieved during turning gear operation by
lifting oil supplied from below i.e. the shafts are
lifted slightly.

BHEL Haridwar 5.1-0510-01

 Steam Turbine
Description
Function
The turbine generator is equipped with a
mechanical barring gear, which enables the
combined shaft system to be rotated manually
in the event of a failure of the normal hydraulic
turning gear.
It is located at IP - LP pedestal
Construction
The barring gear consists of a gear
machined on the rim of the turning gear wheel
(10) and pawl (6). This pawl engages the ring
gear and turns the shaft system when
operated by means of a bar attached to laver
(1). The pawl (6) is shown disengaged and the
lever (1) resting against a stop. The lever (1) is
held in position by latch (7).
BHEL Haridwar
Mechanical Barring Gear
Operation
Take the following steps to make the
barring gear ready for operation: Remove
cover (2) unlatches at (7) and attach a bar to
lever (1).
Barring of lever (1) will rotate the
combined turbine generator shaft system.
After barring has been completed, return
lever (1) and pawl (6) to the position shown in
figure and secure lever (1) by means of latch
(7) Replace cover (2).
The barring gear may only be operated
after the shaft system has been lifted with
high-pressure lift oil. If it is hard to start turning
by means of the mechanical barring gear, this
may be due to incorrect adjustment of the
jacking oil system or due to a rubbing shaft.
Before steam is admitted to the turbine.
corrective action must be taken
5.1-0520-01
 Steam Turbine
Description
Function
When the turbine is started up or shut
down, the hydraulic jacking device is used to
maintain the oil film between rotor and
bearings. The high-pressure oil is forced under
the individual bearing, thus raising the rotor.
The necessary torque from the hydraulic
turning device or from the manual turning
device is reduced in this way. The high-
pressure oil also provides motive force to
hydraulic turning gear motor installed in front
bearing pedestal.
Speed Limit Values
In order to avoid damage to the bearings,
the jacking oil pump must be switched on
below a certain speed. The exact speeds for
switching on and off can be seen in the
Technical data 2-0103.
Jacking Oil Pump
The jacking oil pumps, one number AC
(13) and one number DC(14) are jack-screw
immersion pumps situated on the tank (10)
supply the high pressure oil for the lifting
device. The oil is drawn off directly by one of
the two pumps. The pressure oil piping of the
jacking oil pump that is not in operation is
closed by the check valve (12). In order
1 HP turblne 6 Check Valve
2 IP turblne 7 Fine control valve
3 LP turblne 8 Pressure Limiting Device
4 Generator 9 Bypass Valve
5 Exciter 10 Main Oil Tank
BHEL Haridwar
Hydraulic Jacking Device
to protect the jacking oil system from damage
due to improper switching ON of the jacking oil
pump when the check valve (12) is closed, a
spring-loaded safety valve (11) is situated in
the piping between the jacking oil pump (13)
and the check valve (12). The necessary
pressure in the system is kept constant by
means of the pressure-limiting valve (8). The
pressure-limiting valve can be relieved by the
bypass valve (9). The superfluous flow from
the pump is conducted into the main oil tank.
The necessary jacking oil pressures are
set for each bearing by the fine control valves
(7) in the oil pipes. Check valve (6) in the
jacking oil pipes prevent oil from flowing out of
the bearings into the header during turbine
operation when the jacking oil system is
naturally switched off.
Valve Arrangement
The fine control valve (7) of the turbine
bearings, the check valves (6) and the
pressure gauges are arranged in boxes, which
are connected laterally to the bearing
pedestals.
11 AC Motor driven lifting oil pump 16 Valve
12 DC Motor driven lifting oil pump c Drain
13 Spring loaded safety valve
14 Check valve
15 Duplex filter
5.1-0530-63-1
5.1-0530-63-02
 Steam Turbine
Description
The turbine control system description for
500 MW steam turbine comprises the
following:
General Description
Start-up Procedure
Speed Control
Electrical Speed Measuring
Protective Devices
Overspeed Trip Test
Testing of Stop Valves
Bypass Control System (General)
Electro-hydraulic Bypass Control (Electrical
System)
Electro-hydraulic Bypass Control (Hydraulic
System)
Extraction Check Valve
Swing Check Valve in CRH line
Testing of Swing Check Valves in the Cold
Reheat Line
Automatic Turbine Tester, General
Automatic Turbine Tester, Protective
Devices
Automatic Turbine Tester, Stop Valves
HP Actuator
Electro-hydraulic Gland Steam Pressure
Control
Control System Diagram
List of Parts
Lubrication Chart
Lubrication Chart, Index
Turbine generator unit MAA50HA001
MAB50HA001and MAC10HA001 comprises
three-cylinder reheat condensing turbine
with condenser MAG10BC001 and a direct-
driven three-phase a.c. generator.
The turbine has a hydraulic speed governor
MAX46BY001 and an electric turbine
controller. The hydraulic speed governor
adjusts control valves MAA10+20AA002 and
MAB10+20AA002 by way of hydraulic
amplifier MAX45BY011 whilst the electric
turbine controller acts on these control
valves by way of electro-hydraulic converter
MAX45BY001.
Hydraulic amplifier MAX45BY011 and
electro-hydraulic converter MAX45BY001
are switched in parallel to form a minimum
gate. The system not exercising control is in
its maximum position.
BHEL Hardwar
General Description
The special operating conditions existing in
reheat condensing turbines necessitate
additional control elements. On start-up of
the high-pressure boiler it is necessary to
start up the turbine straight away with a
considerable steam rate and, due to the high
temperature in the reheater to admit steam
to the reheater immediately.
As long as the HP section of the turbine is
unable to accommodate all the steam
supplied by the boiler, the rejected steam is
routed directly to the reheater via HP bypass
valve. The steam from the reheater which
cannot be accommodated by the IP section
with its control valves MAB10+20AA002 and
reheat stop valves MAB10+20AA001 is
routed into condenser MAG10BC001 by way
of LP bypass stop & control valves
MAN11+12AA001 and MAN11+12AA002.
The IP turbine must be fitted with its own
control valves to prevent steam remaining in
the reheater from entering the turbine via the
IP and LP section and causing further
acceleration of the turbine after the main
steam control valves have been closed in
the event of load rejection or trip. In addition,
the steam pressure in the main steam line
would increase after sudden closure of the
main steam control valves, thus causing the
HP by pass valve to open, with the result
that even more steam would flow into the IP
section of the turbine.
It is the function of main oil pump MAV21
AP001, driven directly by the turbine shaft,
to supply oil for bearing lubrication, for the
oil circuit for the overspeed trip test, and for
the primary oil circuit, pressure in which is
generated by hydraulic speed transmitter
MAX44AP001.Two Electrically driven
auxiliary oil pumps are provided for auxiliary
oil supply. The LP control fluid circuit (8 bar)
and the HP actuators of the main steam
control valves, reheat control valves, LP
bypass stop & control valves (32bar) are
supplied by two full-load control fluid pumps
installed in the control fluid tank.
The turbine is equipped with an electro-
hydraulic seal steam control system, an
electro-hydraulic bypass control system, an
5.1-0600-01/1
automatic turbine tester for the protective
devices, main and reheat “Stop & Control
Valves” and an automatic functional group
control.

5.1-0600-01/2
 Steam Turbine
Description
Mode of Operation
The turbine is started up and brought up to
speed with the assistance of the control
valves MAA10+20AA002 and MAB10+20
AA002. If the hydraulic controller is to
govern start-up, the reference speed setter
MAX46BY001 must be set to minimum
speed during this process. In this case the
speed reference from the electric controller
is at maximum. If conversely, start-up is to
be governed by the electric controller,
reference speed setter MAX46 BY001 is set
to maximum and the speed reference from
the electric controller to minimum. The
combined stop and control valves are closed
because the trip fluid circuit is not yet
pressurized. Turning hand-wheel KA01
clockwise or operating motor
MAX47BY001M of start-up and load limiting
device MAX47BY001 in the close direction
releases spring KA06 in auxiliary follow up
piston KA08 via the linkage, thereby
preventing a buildup of auxiliary secondary
fluid pressure. The hydraulic amplifier
MAX45BY011 with follow-up pistons KA01
and KA02 is now in the control valves closed
position so that a buildup of secondary fluid
pressure is prevented when main trip valves
MAX51AA005 and MAX51M006 are latched
in.
Further turning of hand-wheel KA01 moves
pilot valve KA02 of start-up and load limiting
device MAX47BY001 further downwards,
admitting control fluid first into the start-up
fluid circuit and then into the auxiliary start
up fluid circuit. The start-up fluid flows to the
space above the pilot valve of test valves
MAX47AA011+012 and MAX47AA021+
022, forcing them down against the action of
the springs. The auxiliary start-up fluid
raises the pilot valves of main trip valves
MAX51AA005 and MAX51AA006, thereby
moving them into their normal operating
position and permitting trip fluid to flow to
test valves MAX47AA011+012 and
MAX47AA021+022 of the main stop valves
and reheat stop valves. At the same time,
overspeed trip release devices
MAY10AA001 and 002 are latched in if they
have been tripped. The function of non
return valve MAX42AA011 is to interrupt
BHEL Hardwar
Start-up Procedure
transiently the fluid supply to solenoid valve
MAX48AA202 from the connection
downstream of filters MAX42BT001 and
MAX42BT 002 during latching in of main trip
Valves MAX51AA005 and MAX51AA006 by
means of start-up and load limiting device
MAX47BY001, because the pressure drops
in this line considerably for a short time as a
result of the high flow of fluid required to fill
the drained trip fluid system during this
latching in-period. The pressure upstream of
solenoid valve MAX48AA202 is maintained
via orifice MAX42BP022 during this period.
This ensures that the solenoid valve remains
in the position shown. The auxiliary start-up
fluid circuit at the start-up and load-limiting
device MAX47BY001 is fed from the system
down stream of filter MAX42BT003 (fluid
supply during testing), since the pressure in
the system is subject to no significant
change during start-up. It is not possible to
supply the hydraulic fluid connection of
solenoid valve MAX48AA202 from this
system, as this would have an in admissible
effect on the trip fluid system while the
latching operation with the solenoid valves
MAX48AA201 and MAX48AA202 during
testing is taking place.
After latching in, the trip fluid circuit is
closed. The trip fluid now flows to the space
above servomotor piston KA01 of stop
valves MAA10+20AA001 and MAB10+20
AA001 forcing it down against piston discs
KA002. Operation of the start-up and load-
limiting device is continued until their lower
limit position is reached.
When hand-wheel KA01 is turned back or
motor MAX47BY001M of start-up and load
limiting device MAX47BY001 is operated in
the open direction, the control fluid is
allowed to drain first from the auxiliary start-
up fluid circuit and then from the start-up
fluid circuit. The pilot valve of test valves
MAX47AA011+012 and MAX47 AA021+022
are forced upwards by the springs,
whereupon the trip fluid above servomotor
piston KA01 slowly drains off. The pressure
difference thus created lifts both pistons
together into their upper limit position, thus
causing main stop valves MAA10+20 AA001
and reheat stop valves MAB10+20 AA001 to
5.1-0610-01/1
open. Main trip valves MAX51AA005 and
MAX51AA006 are now held in their
operating position by the fluid pressure
beneath the differential piston.
Once the main & reheat stop valves are
open, further turning of hand-wheel KA01 or
operation of motor MAX47BY001M of the
start -up and load limiting device in the open
direction will after passing through a certain
dead range, cause lever KA03 and sleeve
KA04 to move further downwards, as a
result of which the auxiliary secondary fluid
pressure begins to increase and acts via
hydraulic amplifier MAX45 BY011 and follow
up pistons KA01 and KA02 to gradually
open control valves MAA10+20AA002 and
MAB10+20AA002. This brings the turbine
up to about 85 to 90% rated speed. Speed
controller MAX46BY001 now cuts in to
maintain turbine speed. Start-up and load
limiting device MAX47BY001 is then brought
into the fully open position. A pressure
gauge MAX44CP501 and electric speed
transducer MYA001CS011-013 are used to
measure speed.
Reference speed setter MAX46BY001 is
used for further speed run-up for connecting
the turbine-generator unit in parallel and for
bringing it on load. Turning hand-wheel
KA01 of the reference speed setter or
operation of motor MAX46BY001M increase
the tension of speed setting spring KA02 to
increase speed. Since in interconnected
operation speed is determined by grid
conditions, actuation of the reference speed
5.1-0610-01/2
setter has the effect of changing turbine
output.
Load Limitation
Start-up and load limiting device
MAX47BY001 engages mechanically in
controller bellow KA09 of hydraulic speed
governor/controller MAX46BY001 so that it
can serve simultaneously as a load-limiting
device. This means that opening of the
control valves MAA10+20AA002 and
MAB10+20 AA002 is limited to an adjustable
setting. This setting is made manually or
from the control room via motor
MAX47BY001M.
Electro-hydraulic Turbine Controller
If the turbine is to be started up with the
electro-hydraulic turbine controller, the
reference signal from the electric speed
controller must first be set to minimum so
that this takes over running up the turbine -
generator unit from turning speed. Start-up
and load limiting device MAX47BY001 is
brought into its open position once the stop
valves have been opened. Slowly raising the
speed reference from the electric controller
cuts in the electric speed control system,
and the turbine-generator unit is brought up
to rated speed and synchronized.
Further loading is governed by the electric
power controller by increasing the load
reference within the admissible rate of load
change.
 Steam Turbine
Description
Speed control may be exercised either
hydraulically or electro-hydraulically.
Hydraulic Control
Main oil pump MAV21AP001 supplies the
bearing and primary oil circuits with control
oil whilst hydraulic speed transmitter
MAX44AP001 acts as a pulse generator for
the control circuit, providing a primary oil
pressure proportional to the speed. This oil
pressure can also be read directly from
speed indicator pressure gauge
MAX44CP501. This primary oil pressure
acts on diaphragm KA09 of hydraulic speed
governor MAX46BY001 against the force of
speed setting spring KA02 which is
tensioned by reference speed setter
MAX46BY001.The travel of diaphragm
KA09, which can be limited by starting and
load limit device MAX47BY001, is
transmitted by linkage KA03 to sleeves
KA04 of auxiliary follow-up pistons KA08,
the pistons KA05 of which are held against
the medium pressure by spring KA06.
Medium drains off according to the amount
of port overlap between piston and sleeve
and a medium pressure corresponding to
the tension of spring KA06 is built up. This
auxiliary secondary medium pressure acts
as a pulse signal via pilot valve KA07 of
hydraulic amplifier MAX45 BY011.
Piston KA08 of this hydraulic amplifier
assumes a position corresponding to the
auxiliary secondary medium pressure and
operates the sleeves of follow-up piston
KA01and KA02 via a linkage system. A
feedback system stabilizes the position of
pilot valve KA07 and piston KA08 of
hydraulic amplifier MAX45BY011. As
already described for auxiliary follow-up
piston KA08, a secondary medium
pressure corresponding to the position of
the sleeves and to the related spring
tension builds up in the follow up pistons of
hydraulic amplifier MAX45BY011. Any
change in the position of linkage KA03
results in a proportional change of the
BHEL Hardwar
Speed Control
secondary medium pressures in the follow-up
pistons of the hydraulic amplifier.
The secondary medium circuits and the
auxiliary secondary medium circuits are
supplied from the trip medium circuit by way
of orifices.
The varying secondary medium pressure in
the follow-up pistons of the hydraulic amplifier
in turn effects changes in the positions of
their associated control valves or other
control devices.
Electro-hydraulic Control
The speed of the turbine is measured
digitally. For this purpose electrical speed
transducers MYA01CS011 to 013 are
mounted on the high-pressure end of the
turbine shaft.
The electro-hydraulic converter constitutes
the link between the electrical and hydraulic
parts of the governing system. The electro-
hydraulic converter consists of the speed
control converter MAX45BY001 and a
plunger coil system CG001T. The signal from
the electro-hydraulic controller actuates the
control sleeve via the plunger coil system.
The control sleeve determines the position of
pilot valve KA07 in the manner of a follow-up
piston. The further mode of action is the
same as that of the hydraulic speed
governor. Two differential transmitters
CG001A and CG001K are located at piston
KA08 of electro-hydraulic converter MAX45
BY001 as feedback transmitters to the
electro-hydraulic controller. This stabilizes the
control process.
Change-over from Hydraulic to Electro-
hydraulic Control
As already mentioned, Change-over from one
control system to the other is possible even
during operation as the two controllers are
connected in parallel downstream of the
associated follow up piston batteries, which
form a minimum value gate. This means that
5.1-0620-01/1
it is always the controller with the lower set
point, which leads.
If the turbine is operated with the hydraulic
governor, the speed set point of the electro-
hydraulic controller is set at “maximum
speed” which prevents the electro-hydraulic
control system from coming into action. To
bring in the electro-hydraulic control
system, the speed set point of the electro-
hydraulic controller must be reduced slowly
until the secondary medium pressures drop
slightly. When this occurs, the electro-
hydraulic controller has taken over. Then
the reference speed setter of hydraulic
governor speed MAX46BY001 is set to
“maximum speed”. The electro-hydraulic
controller is then fully effective and can
operate over the entire load range. The
hydraulic speed governor also acts as a
speed limiter in the event of failure of the
electro-hydraulic controller. In this case,
operation of the turbine may immediately
be continued by means of the hydraulic
speed governor.
Change-over from Electro-hydraulic to
Hydraulic Control
Change-over is performed in the reverse
sequence. First reduce the set point at
reference speed setter MAX46BY001 until
the secondary medium pressures drop
slightly. This indicates that the hydraulic
speed governor has taken over. Then set
the set point of the electro-hydraulic
controller to maximum. The hydraulic
speed governor is then completely effective
and can operate over the entire load range.
Adjusting Device for Valves
An adjusting device, which makes it
possible to change the setting response of
the HP and IP control valves, is provided
for limiting the HP exhaust steam
temperature.
In normal operation, control medium is
admitted to the space below the pistons of
5.1-0620-01/2
regulating cylinders MAX45BY001 KA10 and
MAX45BY011 KA10 by way of energizing
solenoid valve MAX42AA051, whereby the
pistons move into their upper end positions
against the force of the spring and, via a
linkage, tension the springs of follow-up
pistons KA02 of the control valves in such a
way that this produces the desired setting
response of the IP control valves in relation to
the HP control valves.
If the condition “Turbine load less than set
minimum load and the ratio of HP exhaust
steam pressure to main steam pressure
greater than a set value is fulfilled”, e.g.
after a load rejection, solenoid valve
MAX42AA051 is de-energised, thereby
cutting off the flow of control medium to the
regulating cylinders and allowing the control
medium under the pistons to drain off. The
pistons are moved into their lower end
position by the restoring springs and the
springs of follow-up pistons KA02 are
adjusted so that the IP control valves do not
begin to open until the HP control valves
have opened to a greater extent, with the
result that the HP exhaust steam temperature
is lowered.
For operation of the plant without the HP and
LP bypass stations, a manual adjusting
mechanism KA11 is also provided for
adjusting the relationship between the valves
such that the reheat valves open before the
main steam valves. Under these operating
conditions, solenoid valve MAX42AA051 is
energised and an interlock is provided to
prevent de-energisation.
This adjustment may only be performed
manually and must always be performed on
both follow-up piston batteries MAX45BY001
and MAX45BY011, to ensure that change-
over from hydraulic to electro-hydraulic
control and vice versa is possible at all times.
This manual adjustment must always be
reversed before the HP or LP bypass station
is brought into operation.
 Steam Turbine Control System
Description Electrical Speed Measuring

The electrical speed signals originate from remaining speed probes. The output is then
the electrical speed transducers which fed to the speed measuring unit, electro-
consist of four ferromagnetic type speed hydraulic controller and speed target unit.
probes, MAY01CS011 to 014 (one as spare)
The speed-measuring unit incorporates two
and a toothed wheel with 60 teeth made
speed ranges. The lower range covers 0-
around its circumference located on the
360 rpm and the upper range 0-3600 rpm.
main oil pump shaft.
The changeover from one range to the other
The teeth of the wheel act upon the four is completely automatic.
stationary speed probes. When turbine
A speed indicator mounted on the hydraulic
rotates, square wave signals are generated
control equipment rack provides local
in the probes. The frequency of these
speed-readings. Indicating lights located
voltages is proportional to the rotational
near the speed indicator show which range
speed of the turbine. The output of these
is engaged.
speed probes are fed to the input modules
which provide digital output signals. From the speed-measuring unit, speed
signals are also provided to the turbine
The three values for the rotational speed
stress evaluator/controller, automatic turbine
obtained by this process are continuously
tester and recorders. Output signals are
monitored for failures. If one of the speed
available for purchaser’s remote speed
probes fail, the control circuit continues to
indicators and functional group automatic
operate without interruption, using two
(FGA).

BHEL Hardwar 5.1-0621-02

 Steam Turbine
Description
Overspeed Trip
Two overspeed trips MAY10 AA001 and 002
are provided to trip/shut down the turbine in
the event of overspeed. Each trip device
consists of an eccentric bolt/striker fitted in
the emergency governor shaft with its center
of gravity displaced from the axis of rotation
and held In position against centrifugal force
by a spring up to an adjustable preset speed
of 10 to 12 % above the normal turbine
operating speed. At the preset overspeed,
centrifugal force overcomes the spring force
and the eccentric bolt/striker flies outwards
into its extended position. In doing so it
strikes the pawl which releases the piston of
the overspeed trip release device KA01.
Through combined spring force and fluid
pressure, the piston opens the auxiliary trip
fluid circuit to the main trip valves MAX51
AA005 and MAX51AA006.
Thrust-Bearing Trip
Thrust bearing trips MAD12CY011/012/013
are tripped electrically in the event of
excessive axial displacement of the turbine
shaft.
Pressure Switch
Installed in the trip fluid circuit are two
pressure switches MAX51CP011 and
MAX51CP012 which bridge the longtime
delayed relays of the reverse-power
protection system in such a way that the
generator is shut down by response of the
short-time delayed relays as soon as it
begins to motor. The annunciation Turbine
trip initiated is transmitted simultaneously to
the control room.
Remote Solenoid Trip
Remote solenoid trip is activated via
solenoid valves MAX52 AA001 and MAX52
AA002. The remote solenoid trip may be
initiated manually from the control room by
push button, by the electrical low-vacuum
trip or the thrust bearing trip or other
protective devices.
BHEL Hardwar
Protective Devices
Low-Vacuum Trip for Turbine Protection
An increase of pressure in the condenser
causes the valve of low-vacuum trip MAG01
AA011 to move downwards from its upper
position under the force of the pre-tensioned
spring. This action depressurizes the space
below the right-hand valve. The right-hand
valve is moved into its lower position by a
spring and thus opens the auxiliary trip fluid
circuit. Opening the auxiliary trip fluid circuit
depressurizes the fluid below the differential
pistons of main trip valves MAX51AA005
and MAX51AA006 and the differential
pistons are activated by a spring. This
closes the control fluid inlet to the trip fluid
circuit and at the same time opens the main
trip fluid circuit to drain, causing the trip fluid
pressure to drop and all stop and control
valves of the turbine to close. Limit switch
MAG01CG011B signals to the control room
that the low-vacuum trip is not in its normal
operational position. Limit switch MAG01
CG011C indicates in the control room that
turbine trip has been initiated by the low-
vacuum trip.
To make it possible to latch-in the trip
devices and thus to build up trip fluid
pressure for adjusting and testing the control
loop or similar purposes when the turbine is
shut down and no vacuum exists, the low-
vacuum trip has an auxiliary piston which is
loaded with primary oil pressure above the
adjustable compression spring. When the
turbine is shut down there is no primary oil
pressure and so the auxiliary piston is
unable to tension the adjustable
compression spring arranged above the
diaphragm system. The spring below the
diaphragm system lifts the valve, closing the
auxiliary trip fluid circuit so that the trip
devices can be latched in.
As soon as the turbine is started up and
brought up to speed, primary oil enters the
space above the auxiliary piston, forcing in
into its lower end position at a turbine speed
far below rated speed. Thus the low-vacuum
trip is reset for initiation of turbine trip before
the turbine has reached rated speed.
5.1-0630-01/1
Solenoid Valves for Load Shedding Relay
Solenoid valves MAX45 AA001 and MAX46
AA011 are provided to prevent the turbine
from reaching trip-out speed in the event of
a sudden load rejection. These solenoid
valves are actuated by the load shedding
relay if the rate of load drop relative to time
exceeds a predetermined value. Solenoid
valve MAX45AA001 opens the IP secondary
fluid circuit directly. Solenoid valve MAX46
AA011 opens the auxiliary secondary fluid
circuit. Pilot valve KA07 of hydraulic
converter MAX45BY011 moves upward and
allows the control fluid to flow to the area
below piston KA08 of the converter. Piston
KA08 moves to its upper end position,
thereby depressurizing all secondary fluid
circuits.
Since the reheat IP secondary fluid circuit
opens directly, the IP control valves (which
control the major portion of the power
output) close without any appreciable delay.
A small delay is involved in closing all other
control valves by depressurizing the
auxiliary secondary fluid circuit, but his
action is still performed before an increase
in turbine speed causes the speed controller
to respond. At the same time, the extraction
check valves, which are dependent on
secondary fluid via extraction valve relay
MAX51AA011, close.
After an adjustable interval, the solenoid
valves are reclosed, permitting secondary
fluid pressures corresponding to the reduced
load to build up again.
Turbine Trip Gear
The trip fluid is taken from the control fluid
5.1-0630-01/2
via main trip valve MAX51AA005 and
MAX51AA006 and flows both to the
secondary fluid circuits and to the stop
valves MAA10+20AA001 and
MAB10+20AA001. The main trip valves
serve to rapidly reduce the fluid pressure in
the trip fluid circuit. If the pressure below the
differential piston of main trip valves MAX51
AA005 and MAX51AA006 drops below a
preset adjustable value, the piston in each
valve is forced downwards by the spring,
opening the drain passage for the trip fluid
and closing the control fluid inlet.
If the pressure in the trip fluid circuit drops
below a predetermined value, spring loading
separates the upper and lower pistons of
main stop valves MAA10+20 AA001 and
reheat stop valves MAB10+20 AA001, and
all the stop valves close very rapidly. At the
same time, the control valves and extraction
check valves also close, as the secondary
fluid circuits are fed from the trip fluid circuit.
Thus on trip initiation, all turbine stop and
control valves close.
Manual local Trip Method of Initiating
Turbine Trip
Manual local initiation of turbine trip is
performed by way of local trip valve MAX52
AA005. The valve must be pressed
downwards manually, thus opening the drain
passage for the auxiliary trip fluid. The two
limit switches MAX52CG005C and MAX52
CG005E indicate in the control room that trip
has been initiated locally by hand.
 Steam Turbine
Description
Testing with Turbine under Load
Condition
Overspeed trips MAY10 AA001 and 002 can
be tested using test device MAX62AA001
with the turbine running under load or no-
load conditions. To operate the test device,
pilot valve KA03 is first pushed downwards
and held in this position. This isolates the
auxiliary trip medium circuit from the
overspeed trips and prevents the main trip
being initiated by the overspeed trips.
Subsequent operation of hand-wheel KA01
moves the center pilot valve downwards.
This action blocks the drain and allows the
control oil to flow through the center bore of
the pump shaft into overspeed trips. The
control oil pressure thus builds up and
moves the eccentric bolts/strikers outwards
against the spring force, releasing the pawls
of the overspeed trip releasing device, as a
results of which the pilot valve moves rapidly
inwards. The pressure in the auxiliary rip
medium circuit, up to the over speed trip test
device, then collapses. Operation is followed
by observing the reading at pressure gauge
MAX52CP501.
The trip pressure is read off at pressure
gauge MAX62CP501. If during operation at
rated speed, this pressure should deviate
from the baseline value as recorded in the
test report, a defect in the overspeed trip
may be assumed. If the trip pressure is too
high, the bolt may be made to move freely
by rapidly operating the pilot valve by means
of hand-wheel KA01 several times in
succession. If this measure does not have
the desired result, the turbine must be shut
down and the emergency governor to be
inspected.
As soon as the auxiliary trip medium
pressure drops to 0 at pressure gauge
MAX52CP501, the center pilot valve must
be returned to its original position using
hand-wheel KA01. The pressure in the test
line should then return to 0, as can be read
off at pressure gauge MAX62CP501. The
bolts/strikers of the overspeed trips should
return to their original position.
BHEL Hardwar
Overspeed Trip Test
When this happened, pilot valve KA02 must
be pushed downwards to admit control
medium into the auxiliary start-up medium
circuit to the differential pilot valve of the
overspeed trip device. The pilot valve moves
towards the right and latches the overspeed
trip device in again.
The buildup of pressure in the auxiliary start-
up medium circuit between the overseed trip
test device and the overspeed trip release
device can be followed at pressure gauge
MAX48CP501. When pilot valve KA02 is
then released, the auxiliary start-up medium
pressure returns to 0 pressure. The auxiliary
trip medium pressure must then remain at its
full value (readable at pressure gauge
MAX52CP501). If this is the case, pilot valve
KA03 may be released. The test is
completed. If, when valve KA02 is released,
the auxiliary trip medium pressure collapses,
pilot valve KA02 must be pushed
downwards again and must be held in this
position a little longer. It is essential that the
auxiliary trip medium pressure must remain
steady before valve KA03 is released.
Testing with Turbine under No-Load
Condition
Overspeed trips MAY10AA001 and 002
must be tested at regular intervals by
running the unloaded turbine up to trip
speed. This is done by operating lever KA07
of hydraulic speed governor MAX46BY001,
which presses linkage KA03 downwards,
thus increasing the secondary medium
pressures. This causes the control valves to
open and the turbine starts to overspeed.
The actual speed at which trip occurs can be
read off at pressure gauge MAX44CP501.
Limit switches MAY10CG001&002C of
overspeed trip release device MAY10
AA001 and 002 indicate in the control room
that main trip valves MAX51AA005 and
MAX51AA006 have been actuated by
overspeed protective device.
5.1-0631-01
 Steam Turbine
Description
Main Steam Stop Valves
The stop valves can be tested for freedom of
movement independently of each other even
during operation with the aid of the test
valves MAX47AA011 to 012 attached to
each of them. The main stop valves MAA10
and 20AA001 may only be tested at a load
that is less than 80% of the maximum
output.
If the test is conducted with the initial
pressure controller out of operation, the
main stop valves may only travel out of the
open position to about 50% closed at the
most and are to be reopened immediately. If
the initial pressure controller is in operation
complete closure of a main stop valve may
be performed. This, however, is conditional
upon the response time of the initial
pressure controller being high enough to
keep the initial pressure constant even
during the testing procedure.
First the main control valve concerned
MAA10 or 20AA002, is to be closed by
pressing of pushbutton in the supply unit. If
in operation, the initial pressure controller
opens the other main control valve
accordingly. Once the control valve has
been closed the stop valve can be closed. It
is to be reopened immediately.
BHEL Hardwar
Testing of Stop Valves
The main control valves may be closed for
testing purposes for not longer than 4 to 5
minutes so that the unbalanced steam flow
is only present for a short period to avoid
significant effects on the HP turbine casing.
It is a precondition for testing the main stop
valves that there should be a mixing header
in the steam leads between the boiler and
the stop valves.
Reheat Stop Valves
Testing of a reheat stop valve must be
conducted at a power output at which the
reheat control valves MAB10 and 20 AA002
are fully open. First the associated reheat
control valve is to be closed by pressing of
pushbutton in the supply unit. Then the
reheat stop valve MAB10 or 20 AA001 is
closed by actuating test valve MAX47AA021
and 022 and reopened. On completion of
the test the reheat control valve is to be
reopened.
As for the main steam stop valves it is a
precondition for testing the reheat stop
valves that there should be a mixing header
in the steam leads between the boiler and
the stop valves.
5.1-0632-01
 Steam Turbine
Description
Function
The function of the LP bypass control
system is to monitor the pressure in the
reheat system and to control it under certain
operating conditions. During start-up and
shutdown, and at operation below minimum
boiler load, the volume of steam not utilized
by the IP and LP cylinders of the turbine
must be bypassed to the condenser via the
LP bypass valves. This requires the bypass
control system to maintain the pressure in
the reheater constant in accordance with the
preset reference value. In the event of
disturbances, e.g. load shedding or trip out,
the amount of excess reheat steam
bypassed to the condenser depends on the
capacity of the condenser.
Mode of operation
In the electro-hydraulic LP bypass control
system, the electric controller governs a
number of hydraulic actuators. The link
between the electric controller and the
hydraulic part of the control system is
provided by the electro-hydraulic converter
in the form of a jet pipe amplifier controlled
by a plunger coil.
In order to monitor the flow-dependent
reheat pressure, irrespective of whether
fixed-pressure or variable-pressure
operation is used, the pressure before the
HP drum blading, which is also flow
BHEL Hardwar
Electro-hydraulic LP Bypass
Control System (General)
dependent, is used as the reference input
for the electric controller. This variable
reference value is replaced by a fixed
reference value for certain operating
sequences, such as start-up and shutdown.
The controlled variable is the reheat
pressure after the boiler outlet.
The electric controller has a characteristic
tailored to the pressure distribution within
the turbine and monitors the reheat
pressure. Monitoring is either a function of
the reference input “Pressure before HP
reaction blading” or a function of the fixed
reference value under certain operating
conditions. If the reheat pressure exceeds
the reference value, the electric controller
will act on the plunger coil of the electro-
hydraulic converter and initiate bypass
operation.
The bypass control system operates the
combined LP bypass stop and control valves
via various intermediate elements. This
double shut-off arrangement separates the
condenser from the reheater both during
normal operation and when it can not accept
any more bypass steam.
The hydraulic part of the control system
includes the necessary protective and safety
devices for the condenser as well as the
interlocks for the water side. See section: LP
bypass control (hydraulic).
5.1-0640-00
 Steam Turbine
Description
Measured Valve Acquisition
Pressure transducers with bourdon tube
movements measure the reheat pressure
(controlled variable) and the pressure
upstream of the HP balding (to form the
reference variable).
Set-point Formation
Two set points, the fixed set point and the
reference variable, are formed for the LP
bypass controller, the effective set point
under any set of operating conditions being
the greater of the two, as selected by an
auctioneer.
The fixed set point can be set in the control
room to any point between 0 and
approximately 120% of the maximum LP
bypass pressure with the aid of a motorized
set point adjuster. It is normally used to set
the lower limit for the pressure set point.
The pressure upstream of the HP blading,
required for reference variable formation, is
measured by the dedicated pressure
transducer and transmitted to a matching
amplifier which sets the characteristic for the
reference variable as a function of the
pressure upstream of the HP blading.
When both set points, fixed set point and
reference variable, have been applied, they
are compared in the auctioneer, the greater
of the two being selected and taking effect in
the controller.
Provision is also made for limiting the
reference variable to an adjustable level
below the set pressure of the reheat safety
valves. The actual value for reheat pressure
is supplied by the pressure transducer as a
proportion (between 0 and 120%) of the
maximum LP bypass pressure.
Pressure Controller
The continuously acting electronic pressure
controller consists of a DC amplifier and a
power amplifier.
The deviation is formed at the input to the
DC amplifier by comparing the effective set
point with the actual value. The pressure
BHEL Hardwar
Electro-hydraulic Bypass Control
(Electrical System)
controller has a proportional integral (PI)
characteristic. The power amplifier actuates
the moving coil of the electro-hydraulic
converter directly and through this, the LP
bypass valves. There is a constant
relationship between controller output
voltage and valve position. If there is no
voltage applied to the plunger coil, all LP
bypass valves close.
The LP bypass controller can be changed
over to the manual mode from the automatic
control mode using the controller ON/OFF
push-button. It is then possible to actuate
the valves directly using the open and close
push buttons at the manual controller. This
may be necessary in the event of defects in
parts of the automatic system and is
essential for testing valve actuator travel.
The condenser protection device continues
to be operative via the hydraulic LP bypass
governor.
Tracking Control
In order to facilitate switching on and off of
the automatic controller during operation,
the control variable not taking effect in the
controller (manual control voltage, or
automatic controller output voltage,
depending on the operating mode) is made
to continuously follow up that effective in the
controller. This function is performed by the
tracking controller. When the automatic
controller is effective, the manual controller
is automatically made to follow up the
automatic controller output voltage, the
manual controller itself being inoperative.
This permits the automatic controller to be
switched off and the manual controller to
take over operation at any time. When, on
the other hand, the system is under manual
control, the output voltage of the inoperative
automatic controller is made to automatically
follow up the manual control voltage. As
long as the actual pressure value and the
effective set point are identical, the
changeover will be bumpless, if set point
and actual value are not identical, the
automatic controller will match the actual
value to the set point on being switched on.
5.1-0641-00/1
Monitoring
The electrical section of the electro-hydraulic
LP bypass control is monitored for the
following faults, which are annunciated at
the control desk by means of the group
alarms Fault in controller, Fault in
automatic interface, Fault in reheat safety
valve actuation circuit and Fault in
condenser temperature protection
system 1:
Fault in controller
1 Fault in power supply to controller
2 Insertion fault
3 Fault in power supply to pressure
transducer for measuring pressure
upstream of HP blading
4 Fault in power supply to pressure
transducer for measuring reheat pressure
5 Fault in power supply to Collins
transmitters
6 Fault in power supply to binary signal
conditioning section for solenoid valve for
2nd stage spray water.
Fault in automatic interface
1 Fault in power supply to automatic
interface
2 Insertion fault
Fault in reheat safety valve actuation
circuit
1 Fault in power supply to reheat safety
valve actuator
2 Module fault
Fault in condenser temperature
protection system 1
1 Module fault
Automatic Change-over from Automatic
to Manual Mode of Operation
To increase operating reliability, automatic
changeover to manual operation is
5.1-0641-00/2
performed in the event of any of the faults
listed under the group alarm Fault in
controller, Items 1 to 6 above.
This automatic charge-over to manual
operation ensures, thanks to the tracking
feature, that the valve position at the
moment at which the above faults occur is
retained. This prevents spurious automatic
control actions and provides the operating
personnel with sufficient time to intervene
manually to avert operating disturbances.
Automatic Interface
The electro hydraulic LP bypass controller
incorporates an automatic interface feature.
In case of a cold or warm start-up, when
reheat pressure is low, the fixed set point
value is to be brought down to enable
sufficient flow through reheater. This is done
by switching on the auto control interface
from the control desk. All command and
alarm voltage signals are completely
decoupled from other controller voltages.
Reheat Safety Valve Actuation Circuit.
The auxiliary control circuit for the reheat
safety valves serves to prevent overheating
of the reheater tubes by opening the safety
valves, regardless of the reheat pressure,
when there is insufficient flow through the
reheater. The conditions at the reheater are
reflected in the control deviation while the
reheat flow is determined by the actual valve
lift. Should the control deviation rise above a
preset limit value without all stop valves
being opened and before all control valves
have attained a preset minimum lift, the
reheat safety valves will be actuated to open
after a short dead time of adjustable
duration. The reheat safety valves can also
be opened directly from the control desk.
The limit switches on the stop and control
valves are interrogated via input modules.
 Steam Turbine
Description
Operation
Electrical LP bypass controller MAN01
DP001 activities the plunger coil arranged
on the left-hand side of transducer MAX53
BY001. In the event of voltage increases, jet
pipe KA01 is swung to the right and piston
KA08 of transducer MAX53BY001 is moved
in the downward direction. This takes up a
position proportional to the downward
direction. This takes up a position
proportional to the voltage change due to
the rigid feedback. Sleeves KA04 of follow-
up piston KA02 and KA03 connected to the
piston are move in the downward direction
and the fluid pressure in the follow-up
pistons rises.
At the beginning of the control process,
injection valves MAN11and12AA003 and
004 by way of pilot valve MAX53
AA031+AA041 and the actuators to injection
valve KA01 are opened first due to the rising
pressure in follow-up piston KA03. The
injection water reaches the pressure
reducing orifice and is available for cooling
down the bypass steam flowing into the
condenser, with a slight delay compared to
the injection valves, LP bypass stop valves
MAN11and12 AA001 are fully opened as the
fluid pressure in follow-up piston KA02 rises
(assuming that the piston of the actuator to
bypass limit controller KA07 is in the upper
limit position) and following this, LP bypass
control valves MAN11and12AA002 are
opened taking up a defined position due to
the feedback caused by the respective fluid
pressure (proportional control action).
LP bypass limit controller MAX53BY011 has
priority over transducer MAX53 BY001. As
soon as injection water is available at the
required pressure and there is also a
sufficiently high vacuum in condenser
MAG10BC001, the jet pipe is swung to the
right and the piston of the actuator to bypass
limit controller KA07 moves into the upper
limit position. As a result the pressure in
follow-up piston KA02 is increased so that
LP bypass stop and control valves
MAN11and12AA001 and MAN11and12
AA002 are released for opening.
BHEL Hardwar
Electro-hydraulic LP Bypass
Control(Hydraulic System)
If the vacuum in condenser MAG10BC001
drops or the pressure downstream of the LP
bypass valves rises above the permissible
value, or the pressure of the injection water
is too low, the jet pipe of LP bypass limit
controller MAX53 BY001 is moved to the left
and the piston of the actuator to bypass limit
controller KA07 moves downwards. In the
bottom position of piston KA07, the spring of
follow up piston KA02 is expanded to such
an extent that the LP bypass valves are
unable to open. By means of feedback to
the measuring system “Pressure
downstream of LP bypass valves” a certain
piston setting and thus a certain setting of
the LP bypass valves is allocated the each
pressure deviation if the pressure allocated
to the maximum permissible bypass rate is
exceeded, thus limiting the bypass rate. This
ensures that the volume limitation has a
clear control behavior (Proportional control
action). This feedback is only effective in
volume limitation. It is not necessary for the
other two limit pressures.
To protect the reheater from the thermal
damage as a result of heat accumulation, it
must always have a minimum amount
flowing through it. For this reason the
reheater safety valves are actuated by the
electro hydraulic LP bypass controller at a
preset deviation.
In normal bypass operation this signal is
interlocked via limit switches MAN11and12
CG001D and MAN11and12 CG002B unless
quick-closing LP bypass valves MAN11and
12AA001 are completely open and LP
bypass control valves MAN11and12 AA002
are approx. 60% open. If only one valve fails
to meet these conditions, the signal goes
through and the safety valves open (thus
they open at precisely the existing reheater
pressure (below design pressure)).
So that the safety valves do not respond
unnecessarily as a result of delays present
in the hydraulic control elements, the signal
to them is passed via two parallel time delay
relays which delay contact by approx. 5 sec.
5.1-0642-00/1
Second Low-Vacuum Trip sequence when the preset limit value is
A low-vacuum trip MAG01AA016 is installed reached.
in the signal line from follow-up piston KA02
to pilot valves KA02 and KA05 of the LP Solenoid Valves
Bypass valves for the double protection of
Thermocouples which transmit a switching
condenser MAG10BC001 during bypass
pulse to associated solenoid valves MAX53
operation. If the vacuum sinks below a
AA021and022 when a specified temperature
preset valve during a fault in LP bypass limit
is exceeded are fitted in the steam dome
controller MAX53 BY011, the pilot valve of
opposite the bypass steam inlet to protect
low-vacuum trip MAG01 AA016 is moved in
condenser MAG10BC001. The solenoid
the downward direction from its upper limit
valves shut off the signal fluid and at the
position by the loaded spring. The pilot valve
same time open the drain so that the signal
thus cuts off the signal line and
fluid in the line between solenoid spool
simultaneously opens the drains so that
valves MAX53AA021and 022 and pilot
signal fluid in the line between low-vacuum
valves KA02 and KA05 of the LP bypass
trip MAG01AA016 and pilot valves KA02
valves is depressurized and the LP bypass
and KA05 is depressurized and the LP
valves close. The LP bypass valves may
bypass valves close. As the vacuum
only be opened manually from the control
increases again, bypass operation is
room when the temperature falls short of the
released in the reverse sequence on
limit value again.
attainment of the set limit value.

Staggered Water Injection

Pressure Switch
In the present case, the entire maximum
A spray water pressure switch
boiler steam flow is routed to the condenser.
MAN01AA011 in installed in the signal line
The injection water rate is staggered in two
from follow-up piston KA02 to pilot valves
stages so that under normal start-up and
KA02 and KA05 of the LP bypass valves to
shutdown conditions the condensate pumps
protect condenser MAG10BC001 in the
do not have to supply the entire amount of
event that water injection fails. If the
injection water required for the full boiler flow
injection pressure drops below the
and so that the excess water flow does not
adjustable value during a malfunction in LP
become too high. In this additional device,
bypass limit controller MAX53BY011, the
solenoid valve MAX53 AA051 is opened by
pilot valve of the spray water pressure
way of pressure switch MAN01CP001 and
switch MAN01AA011 is moved from the
injection valves MAN11and12 AA004 via
upper limit position downwards. The pilot
pilot valves MAX53 AA041 when the steam
valve then cuts off the signal line and
pressure upstream of the pressure-reducing
simultaneously opens the drains so that
orifices exceeds a value allocated to an
signal fluid in the line between pressure
amount approx. 45% of the maximum
switch MAN01AA011 and pilot valves KA02
bypass flow. This divides the injection water
and KA05 is depressurized and the LP
volume into two approximately equal
bypass valves close. As the injection
quantities.
pressure increases again. LP bypass
operation is released in the reverse

5.1-0642-00/2
 Steam Turbine
Description
The function of extraction check valves
LBQ50, LBS21, LBS31, LBS41 and LBS42
AA001and 002 is to prevent the backflow of
steam into the turbine from the extraction
lines and the feed water heaters.
Two free-swinging check valves are
installed in each extraction lines A2, A3, A4
and A5. In the event of flow reversal in the
extraction lines, the valves close
automatically, whereby actuator KA01
assists the closing movement of the disc.
The mechanical design of the swing check
valves is such that they are brought into the
free -swinging position by means of trip fluid
pressure via actuator KA01 and the disc is
moved into the steam flow by means of
spring force acting via the lever, shaft and
disc lever and closes if differential pressure
is either lowered or reversed.
The trip supply to actuator KA01 is
controlled by extraction valve relay MAX51
AA011, changeover valves MAX51AA028,
MAX51AA031 etc.
Extraction valve relay MAX51 AA011
actuates the swing check valves in
accordance with the secondary fluid
pressure, suitable adjustment of the spring
in relation to piston KA02 sets the turbine
load at which the swing check valves are
released for opening or assisted in closing.
The release setting for opening cannot be
arbitrarily adjusted towards higher turbine
output, as the swing check valve will open
even without the release action if the steam
pressure difference exerts a greater force
than the closing spring.
In the event of major output drops above
the opening point of the swing check valves,
BHEL Hardwar
Extraction Check Valve
there is a danger that the contents of the
feed water heaters will flash into steam. In
this case, closure of the swing check valves
is assisted for a short time by means of
pistons KA01 of auxiliary slide valve MAX51
AA011. In normal operation pilot valve KA01
passes trip oil to pilot valve KA02. In the
event of an abrupt output drop, the pressure
on the top side of pilot valve KA01 drops,
where as depressurization beneath the
piston is delayed by a check valve and the
pressure in fluid accumulator MAX45BB001.
The resulting differential pressure moves the
piston upward to interrupt the trip fluid supply
to the swing check valves, whose closing
movement is assisted by the spring force of
actuator via a flow restrictor. The pilot valve
moves back into its original position to open
the way for the trip fluid to release the swing
check valves.
Turning the handwheel on the changeover
valves MAX51AA048, MAX51AA051 etc.
close the associated swing check valves
within the bounds of the effectiveness of the
spring.
The swing check valve in extraction lines A4
can also be triggered by differential pressure
switch LBS42CP002. This differential
pressure switches energizes solenoid valves
MAX51AA028 and MAX51AA031 if the
steam flow drops below a preset rate
(differential pressure), thereby further
assisting the closing action of the swing
check valve.
The position of all swing check valves is
indicated via position transmitters-CG001A
and CG002A.
5.1-0650-01
 Steam Turbine
Description
In order that the turbine may be completely
separated from the steam when it is
stationary, an additional check valve
LBC10 AA001 is fitted in the line between
the HP cylinder and the reheater and
operating through pilot valve MAX42AA001
+002 and the rotary actuator KA01
depending on the pressure in the
associated secondary medium circuit. The
swing check valve opens fully when the
control valves reached approx. 5 to 10% of
their full-power travel. Only when the
control valves reach this point again as
they are being closed, the swing check
valve brought into steam flow again by the
hydraulic actuator. Thus when the steam
flow in the normal direction ceases, the
BHEL Hardwar
Swing Check Valve
Cold reheat steam line
check valve is closed by the actuator KA01
and prevent the steam in the cold reheat line
from returning to the turbine. By removing the
valve from the steam flow during operation
above 5 to 10% of maximum power,
additional pressure losses during normal
operation are avoided. If, during start-up, the
steam pressure on the inlet side of the valve
and at the same time the secondary medium
pressure is not yet sufficient to open the
valve, the steam pressure will open the swing
check valve against the medium pressure in
the manner of a safety valve.
The Open and Control position of the swing
check valve are indicated in the control room
via the limit switches.
5.1-0651-01
 Steam Turbine
Description
The check valve LBC10AA001 in cold
reheat line is wide open during normal
operation by its associated rotary
servomotor KA01. For testing the movability,
the check valve can be moved in closing
direction by interrupting the connection
between pilot valve MAX42 AA002 and HP
secondary fluid line with closing of shut-off
valve MAX45AA566 (pilot valve and shut-off
valve are installed in the turbine hydraulic
control rack).
By closing the shut-off valve the pilot valve
MAX42AA002 is reversing and rotary
servomotor is moving the check valves in
closing direction. Because the torque of
these servomotor is limited, the check
valves can not be closed completely. This
BHEL Hardwar
Testing of Check Valves
in Cold Reheat Line
can be brought only in an intermediate
position.
When the check valve starts moving, the
open position limit switch will change
position, which is indicated in the control
room. With this indicator the regular
movement of the check valve can be
checked after closing shut-off valve
MAX45AA566 nearby upto this value. After
this check the shut-off valve has to be
reopened. The check valve is moved then in
its wide-open position. At the position
indicator in the control room it can be
checked if the check valve has reached
again its wide-open position.
5.1-0652-01
 Steam Turbine
Description
Function
Healthiness of the protective devices and the
stop and control valves is vitally important for
the operational reliability and availability of
the turbine. Hence, it is essential that these
equipments are always kept in a fully
serviceable condition. Economy has dictated
longer intervals between turbine overhauls,
with the result that testing of the equipments
and devices is now necessary at regular
intervals during normal operation.
There are manually operated devices for
testing the free operation of the stop and
control valves. However, these tests do not
cover all components involved in an
automatic trip with the result that the
conditions only party corresponds to those
prevailing during a real trip.
The system
Any possible mal-operation associated with
manually operated devices are avoided with
fully automatic tests by means of the
automatic turbine tester. Full protection for
the turbine during testing is also assured by
suitable circuit arrangements. This increases
the operational reliability and availability of
the plant.
The automatic turbine tester is realised in
digital technology.
System adaptation
The system is subdivided into functional
groups for each device. Each group contains
the device itself and all necessary
transmission elements for initiation of a
normal trip.
The automatic turbine tester is divided into
the following 2 subgroups:
BHEL Hardwar
Automatic Turbine Tester
General
1. Protective devices
Description: “Automatic Turbine
Tester, Protective device”.
2. Main stop and control valves
Description: “Automatic Turbine tester,
stop and control valves”.
The complete testing of all components
which must operate when an automatic trip
becomes necessary is assured, despite the
subdivision into two testing groups
(protective devices, stop and control
valves), because the main trip valves which
store the trip signal by mechanical hydraulic
means are operated together with each
protective device and subsequent
satisfactory reduction of the trip oil pressure
after the valves are monitored.
Nature of the description
The descriptions mentioned above contain
the practical sequence of the tests on the
individual devices and gives details of
possible irregularities. The description of
equipment contained in the automatic
control cubicle (stepping switches, interlock
modules, etc), the control panel in the
control room and schematic circuit diagrams
are contained in the separate electrical
section of the “Operating Manual” for the
automatic turbine tester.
For the understanding of the automatic
turbine tester from these descriptions it is
assumed that the reader is fully conversant
with the functioning of the individual
protective devices and valves within the
overall turbine governing and protection
system.
5.1-0660-00
 Steam Turbine
Description
Scope of Testing
The Automatic turbine tester (ATT)
subgroup for the protective devices is
divided into a preliminary test and the
following four individual testing systems.

Remote trip solenoid MAX52AA001

Remote trip solenoid MAX52AA002

Over speed trips MAY10AA001/MAY10
AA002

Low vacuum trip MAG01AA011
One or more systems can be selected for
testing at the control panel and the selection
is stored. The start of the test program
automatically causes a preliminary test to be
carried out on the protective channels which
are to be effective during actual testing and
then establishes the test circuit. Once the
first test selected has been completed and
the protective device has latched in again,
the test circuit is restored to its normal
operational configuration. Further selected
tests must be started individually by
pressing the Test push-button to start the
program.
General
During normal operation, the protective
devices act via main trip valves MAX51
AA005 and MAX 51AA006 on the stop and
control valves and extraction swing check
valves. The remote trip solenoids MAX52
AA001 and MAX52 AA002, over speed trips
MAY10AA001/MAY10AA002 and low
vacuum trip MAG01AA011 actuate main trip
valves MAX51AA005 and MAX51AA006 by
opening the auxiliary trip fluid circuit.
For the duration of testing of the protective
devices, a test circuit is established .In order
to keep the trip fluid circuit effective, it is
isolated from main trip valves MAX51 AA005
and MAX51AA006 by means of change-over
valve MAX51AA211 and supplied with fluid
via solenoid valves MAX51AA201 and
MAX51AA202 (remote trip during testing).
BHEL Hardwar
Automatic Turbine Tester
for Protective Device
Trip Initiation during Testing
To provide normal protection for the turbine
during testing, any trip initiation signals from
the protective devices will de-energize the
solenoid valves for remote trip during testing
and the same time initiate the reset
program. This also applies to all normal
electrical remote trips such as generator
protection, etc. For the duration of testing,
two electrical speed signals are formed to
provide protection against turbine
overspend.
During all electrical testing of the protective
devices, the electric trip action is prevented
however, all annunciations are activated as
for actual trip. The appropriate section of the
alarm annunciation system is thus also
tested.
Features of the Automatic Turbine Tester
The automatic turbine tester is distinguished
by the following features:

Individual testing of each turbine
protective device.

Automatic testing, upon selection of a
test, of the devices that protect the
turbine during that test.
Testing of the protective devices for
normal turbine operation can only be
performed if the preliminary test has run
without fault and the protection of the
turbine during testing is assured.

Monitoring of all program steps for
execution within a certain time.

Interruption if the running time of any
program step is exceeded or if trip is
initiated.

Automatic reset of the test program after
a fault.

Protection of the turbine during testing
provided by special test protective
devices.
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Setting Data
The setting data for the pressure switches
are listed in the setting record Measuring
Point List. The actually set values are
logged in the Commissioning Test
Record.The test running times, etc. are
entered in the functional diagrams.
Test Sequence
Start of Testing
The test begins with the selection of the
protective devices subgroup. This is
performed by pressing the subgroup On/Off
push button.
The subgroup remains on until switched off
when the program has been completed.
While the protective devices subgroup
program is running, the other subgroups are
blocked.
The On/Off push-button is also used to
acknowledge alarms.
Selection
After the subgroup has been switched on,
the protective device to be tested is selected
by pressing the selection push button for the
individual device.
A separate selection push-button is provided
for each protective device. Only one
selection may be made at a time. Selection
of a further test is possible only once all
other programs have ended
Test Push-Button
The automatic test program is started by
pressing the Test push-button
Cancel Push-Button
This push-button can be used to terminate
the test program running at any time and to
initiate the reset program. The reset
program has priority over the test program.
Lamp Test Push-Button
All the signal lamps on the control panel can
be tested by pressing the Lamp Test Push-
Button.
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Individual Tests
The individual test is performed after
completion of the preliminary test and after
the test circuit has been established.
Successful completion of each individual
test is annunciated by the limit switches on
main trip valves MAX51AA005 and MAX51
AA006, pressure switch MAX52CP211 in
the auxiliary trip fluid circuit and pressure
switch MAX 51CP209 in the trip fluid circuit
between change-over valve MAX51AA211
and the main trip valve MAX51AA006. The
associated limit switch also annunciates
when a protective device (except for the
remote trip solenoids) has been activated.
On completion of each individual test, all
activated protective devices are returned to
their normal operating position by reset
solenoid valves MAX48AA201 and MAX48
AA202 and the test circuit is deactivated.
Whenever several of the same types of
protective device are provided, only one will
be described in the following, as the test
procedure is the same for all.
Preliminary Test
Pressing the Test push-button automatically
initiates a test of the protective circuits to be
effective during testing.
Function
The function of the preliminary test is to
detect any faults in the protective circuits to
be used during testing, and, if any are
detected, to inhibit testing of the protective
device, as this would leave the turbine
without protection.
Test Sequence
In the course of the preliminary test,
solenoid valves MAX51AA201 and MAX51
AA202 (remote trip during testing) are
automatically tested before the test circuit is
established. These valves (MAX51AA201
and MAX51AA202) are first energized,
resulting in a buildup of control fluid
upstream of changeover valve MAX51AA
211.lnitiation of Schmitt triggers (in the
speed measuring unit) de-energizes
solenoid valve MAX51AA201 and the control
 fluid up stream of changeover valve MAX51
AA211 is drained. Successful completion of
testing is annunciated by pressure switch
MAX51CP207 between solenoid valve MAX
51AA201 and changeover valve MAX51AA
211. Subsequently, solenoid valve MAX51
AA202 is de-energized via the second
channel of its Schmitt trigger, thereby
depressurizing the control fluid still present
between solenoid valves MAX51AA201 and
MAX51AA202. This process is monitored by
pressure switch MAX51CP205. On
successful completion of the preliminary
test, the test circuit is automatically
established, which permits realistic testing of
the protective devices without initiating
turbine trip.
Solenoid valves MAX51AA201 and MAX51
AA202 (for remote trip during testing) are
again energized whereupon control fluid is
supplied to change over valve MAX51
AA211. Then solenoid valve MAX61AA201
is energized, effecting changeover from trip
fluid to control fluid. The control fluid in this
line drains off, and the pressure difference
drives changeover valve MAX51AA211 into
its test position (lower end position), thereby
actuating limit switch MAX51CG211C which
annunciates this status.
De-activating the Test Circuit
The test circuit is deactivated in the reverse
order on completion of the selected test and
after automatic latching of the protective
device concerned in its normal operating
position.
Hydraulic Test Signal Transmitters
The function of the hydraulic test signal
transmitters is to activate the related
protective device (with the exception of the
remote trip solenoids). Each protective
device has an associated test signal
transmitter. For testing the over speed trip
device, the associated test signal transmitter
builds up a test pressure relatively slowly
and passes it to the overspeed trips, for
testing the low vacuum trip, an air pressure
signal is introduced to the device via an
orifice. The testing signals to remote trip
solenoids MAX52AA001 and MAX52AA002
are formed within the automatic turbine
tester itself and not by a test signal
transmitter.
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Main Trip Valves
MAX 51 AA005 and MAX 51 AA006
Only one of the two main trip valves is
described in the following, as they are
constructional and functionally identical.
Function
The function of the main trip valve is to
amplify and store the hydraulic or
mechanical (manually initiated local) trip
signal. It must respond in the course of
every successful protective device test.
Operation
Each main trip valve is kept in its position by
auxiliary trip fluid pressure. If a protective
device is actuated, the auxiliary trip fluid
circuit is depressurized and the main trip
valve is activated. This connects the trip fluid
and auxiliary trip circuits to drain and shuts
off the control fluid supply to the turbine
valves. At the same time, limit switch 1 is
actuated.
Auxiliary start-up fluid pressure forces
differential piston (3) into its normal
operating position. Control fluid IV is then
free to pass through to buildup the pressure
in the trip fluid and auxiliary trip fluid circuits.
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Pressure switches MAX48CP201 and
MAX48CP202 monitor the orderly pressure
collapse of auxiliary start-up fluid circuit after
latching-in of main trip valves.
Attention: The lever for manual actuation of
the main trip valve must not be test operated
during turbine automatic testing operation,
as the electrical trip action is always initiated
via the manual trip-out limit switch.
Remote Trip Solenoids
MAX52 AA001 and MAX52 AA002
The twin electrical remote trip feature
consists of the two remote trip solenoid
valves MAX52AA001 and MAX52AA002.
0ne trip channel is described here, as the
test procedure is the same for both.
Function
The function of the remote trip solenoids is
to depressurize the auxiliary trip fluid circuit
in the shortest possible time, thereby
bringing main trip valves MAX51AA005 and
MAX51AA006 into their trip positions, in the
event of a malfunction requiring electrical
trip initiation.
During normal operation, the remote trip
solenoid isolates the auxiliary trip fluid circuit
from the drain. For testing, the automatic
turbine tester switches over the