erection of 210 mw capacity steam turbine and accessories

139 Pages·2014·6.83 MB·English

ERECTION OF 210 MW CAPACITY STEAM TURBINE
AND
ACCESSORIES
r
A DISSERTATION
Submitted in partial fu!lment of
the requirements for the award of the Degree
of
MASTER OF ENGINEERING
in
MECHANICAL ENGINEERING
(Applied Thermoscience)
0
by
SURENDRA KUMAR GUPTA
LAM ~n1rV - -
CJs-I.-
DEPARTMENT OF MECHANICAL & INDUSTRIAL ENGG.
UNIVERSITY OF ROORKEE
ROORKEE-247672 (INDIA)
August, 1981
0ERT.IFICATE
a` ~ w rr w r w ww w rw
Certified that the dissertation entitled "ERECTION
OF 210 NW CAPACITY STEAM TURBINE AND ACCESSORIES" which
is being submitted by Shri Surendra Kumar Gupta in partial
fulfilment for the award of the Degree of I TER 0'
E INE IMING in MEC RAN IC , ENGINEERING (APPLIED THERMO -
SCIENCE) of University of Roorkee, Roorkee is a record of
candidate' o own work carried out by him under my supervision
and guidance. The matter embodied in this dissertation has
not been submitted for the award of any other degree or
diploma.
This is to certify, further, that be has worked for
a period of about Seven months from January 1981 to 10th
August 1981, for preparing this dissertation for Nas ter of
Engineer Degree as a part time student of this University:
Dated: Aug./y, 19814 (RAJENDRA tA&&8R` `~
Professoarn d Read
Department of fec hanical and
Industrial Engineering
University of RQorkeo
ROORKEE
ACKNOWLEDGE ENT S
The author* with deep sense of gratitude, wishes
to express his sincere thanks to Dr. Ra jendra Prakash,
Professor and Bead, Mechanical zkd Industrial Engineering
Department for suggesting this topic, for his valuable
guidance and encouragement during the preperation of this
dissertation.
The author expresses his sincere thanks to the
Engineers of E.. .E .L. , Hardwar for providing various data
required for the dissertat .on.
The author is very thankful to Sbri P.I.Baranwal,
S .R .P , University of Roorkee for his cooperation during
I
preparation of this dissertation*
strxExnRn uMatt GUPTA
ii
XIa jor Portion of C cuntryt a Power Demand is being
met by thermal power neceeeiat ng more and more instal..
latione of Thermal Power Plants to augment the grid
capacity,, Large size turbo sets (210 14W) are forming
the back bone of the Po rer Generation programme, now-
ai d ays
An attempt has been made to stud r the Thermal
Power InstallatiOns in India and to depict the recent
developments in the field of Steam Turbines.
Piwther, various aspects of the erection of a
210 1 W Steam Turbine have been dealt in this report.
The details of the Turbine components and its auxiliaries
have been studied in the context of their erection
Lay out of the Turbine House, aa pertinent to the erection
has been described
An exact eequenee of operations, needed during
erection process, has been discussed in detail.
iii
LIST OF FIG RES
Figure
Description page
Ro.
1.1 Growth of installed capacity in the ... 4
country in 1
1.2 Addition to Installed capacity in 6
the country.
211 Turbine cycle diagram. ... 30A
2,2 Sketch of lower halt of E,cy1inder. ... 32
2.3 Sketch of lower half of ZP.cylinder. ... 33
3.1 Turbine oil. pipe line system. ' ... 48
3.2 Surface condenser. ... 49A
4.1 View of Turbine Rouse from turbine side, ,.. 61
4.2 Turbine view from oil system side. ... 69A
4.3 Turbine view from ,heater side. ... 71
5.1 In3tallation of cylinders and pedestals • .. 84
as per support reactions.
5.2 Making position of cylinder's by pianowire. . 87
513 Turbine ke positions. .. r go
5.4 Clearances in Journal and Radial ,•. 93
thrust bearings.
5,5 Alignment of lower halves of end seal s .. 97
and diaphragms of Z.P. cylinder.
5.6 Alignment of lower halves c ' end sealings .. 90
and diaphragms of H.P. cylinder
5.7 C entering of Rotors by coupling. ... 104
5.8 Slop of Rotor Journals. • .. 105
iv
LIST OF TAB S
Table
Description Page
No#
1.1. Growth of ,nata1led capaci ty
in India.
1.2 Additions to capacity in power 5
e ector uptO fourth five year
plan.
1.3 Addition 't o capacity inparer
5
ector beyond fourth five year
plan.

1.4 Load in India.*
.. 8
1 « Location of platform .
, . , 13
1.6 operation a equenc a for turbine ,•,

erection.
CONTENT S
PAGE
AO NO DGEMsNTS ••, j
ABSTRACT ... ij
LIST OF ¶PIGU jji
LIST OF 'TAB ... is
CHAPTER 1 POWER DBVELCPMENT IN INDIA .. I
1.1 Introduction 1
.iR
9
1.2 Pture Growth of Power in India
.1.
1.3 ...
Thezal. Power Ian!•tallations in India 12
MW
1,4 210 Installations, In India • .. 20
1.5 Proposed 210 Vii` Installations in India . 21
•..
1.6 Choice of Unit-Size 24
1.7 Installation of Largest Single ... 25
Shaft Turbine
O PTER2 DESCRIPTION OP TU IN AND VARIOUS SYSTEMS 27
2.1 Basic Technical a ..e of Turbine i * 2 7
M
2.2 Turbine Power Oyo'ie ... 29
2.3 Constructional Peat'ureo of Turbine ... 31
..
2„ 4 Turbine Governin System • 37
2.5 Turbine Protection System ... 40
2.6 Turbine Stzpez'viaory Instrument System .. 43
CHAPTER 3 TURBX1 ' AUXILIARIESS .. 46
34 Oil System ... 46
3.2 Condensing System ••• 49
303 Air Evacuation System .,. 50
3.4 8egene v System ... 52
3.5 H.P.L.:P,, BYPSSa Stations ... 54
CHAPTER 4 TURBINE LAYOUT «+. 56
•..
4.1 General 56
rrangement
4.2 A of St in Power Station ... 58
4,3 Des o.1. T M+ btne ou8 e ... 60
4.4 Selection of MachjneRafl Width i . « 64
4 5 Machine Hall Height . » 66
4.66 Operating Floor Level * w 66
4.7 Capacity of Overhead Crane . » 67
4*8 Location of Condensing Plant
.4..
4.9 Lootion of Oil System Equipment ... 69
4.10 Location of Regenerative Feed
69
Heating Equipment
4.11 Floors and Platforms . ► 72
CHAPTER 5 TURBXN RECTION AT SITE . «; '74
Sol Turbine Poundations . . 74
5.2 Preparatory work . . 75"
5,3 Preperation of turbine Parts and a . 78
Auxiliaries
5,4 Pre eration of Mating Surfaces
79
•1I
Of Foundation Frames and Bearing
Pedest3p.
5.5 Znsta11aton of Lower Pressure Cylinder.
and Checking Loading and Levelling . » » $2
»6 Erection of Middle Bearing Pedestal
and X.P.Cylirdor
5.7 installation of Front Bearing
Pedestal and R,P.Oyii4der as
Preperation of Bearing Bushes and
S e&
the Rotor 91
5.9 Fixation of Permanent Spacers and.
Welding of Condenser with Exhaust Part 9 2
5.l0 Pouring of Concrete in Pow dation
94
5,11 Final Checking of Centertng of Turbine 95
5.12 Installation and Centering of L ,ere,
Diaphragis and Seating Chambers in
Cylinders 95
4..
5.13 Checking of Steam Path Clearance, 99
5,14 Closing of Cy].ire3 » .. 100:
I 545 Centering of Rotors 103.
5.36 Installation of Governing and
Protection Systems 106
5.17 Coupling of turbine with Generator » . 106
5 018 Preservation and Handling of
Turbine Parts During Erection 107
5.19 List of 'Tools Used DuringBreotiou w . 108
«..
CHAPTER 6 ERECTION OF AUXILIARIES n2
Condor .• ,.
6.1 Erection of er 12
, , .
.6.2 z'eotion -of ©il System 114
4
6.3 i i •
Brection of Conde ate Pump 17
6,4 Erection of Connecting Steam
. ,
Pipe Lines x19
6,65 Erection of Connecting Oil
,
pipe Iinea 119
k
CHAPTER 7 0©NCLt$ION. ... 121
'RBPB•RENCE a .. x.23
C H A P T E R-
..-.W..__.._
POWER DvgLopMBNT IN INDIA
Li INTRODtTIOi
Power developmfnt was initiated in India as early as
with the commissioning of hydroelectric power station
1900
at Shiva8amudran in Karnataka, Ins pite of this early
beginning the progress was not Impressive till 1947. The
then was as low as
total ino tslle d capacity of the country
1900 MW and the development was mainly concentrated around
urban areas . The growth, of inta1led capacity in power
sector can be aeon in table-1.1 and figure 1.1.
Power generation ogramrnsp , however, made phenomenal.
progress with the advent of Five Year Plans • During the
First Plan (1951-56) construction of a numbr of major river
valley projects like Bhakra-Nangai, Damodar valley, Hirakud
and Chambal valley was taken up and resulted in the stepping
up of food production and also power generation. At the and
of the First Plan the generation capacity stood at 3,4,20 MW
which got increased to 5,700 MV at the end of 1966.
During the Third Plan the emphasis was laid on extend i
.
power o upply to rural areas A significant development in
this phase was the emergence of inter-etate grid ayotem. The
country was divided into five regions to promote power develop-
ment on a regional basis. A regional Electricity Board was
established in each region to promote integrated operation
of the constituent power systems.