GENERAL DESCRIPTION

Technical Description
of the Steam Turbine

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 GENERAL DESCRIPTION

Revision History
Revision Content of Change Document Pages
total :
- - 42

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 GENERAL DESCRIPTION

Contents

1 GENERAL .............................................................................................................................. 7
1.1 Foundation ................................................................................................................ 7
1.2 Rotor line ................................................................................................................... 7
1.3 Expansion and fixation .............................................................................................. 7

2 EXPANSION SLEEVE COUPLINGS ..................................................................................... 8

3 HIGH PRESSURE TURBINE................................................................................................. 9

3.1 Outer casing .............................................................................................................. 9
3.2 HP inner casing ....................................................................................................... 10
3.3 HP blade carrier ...................................................................................................... 10
3.4 Shaft seals............................................................................................................... 11
3.5 Turbine rotor............................................................................................................ 11
3.6 Blading .................................................................................................................... 11

4 LIVE STEAM VALVES ......................................................................................................... 12

4.1 Live steam stop valve.............................................................................................. 13
4.1.1 Stop valve actuator...................................................................................... 14
4.1.2 Stroke tests ................................................................................................. 15
4.2 Live steam control valve.......................................................................................... 15
4.2.1 Control valve actuator ................................................................................. 16
4.2.2 Stroke tests ................................................................................................. 17

5 THIRD STEAM VALVES ...................................................................................................... 17

5.1 Third steam stop valve ............................................................................................ 18
5.1.1 Third steam stop valve actuator .................................................................. 19
5.1.2 Stop valve pilot control system.................................................................... 19
5.1.3 Stroke test ................................................................................................... 19
5.2 Third steam control valve ........................................................................................ 19
5.2.1 Third steam control valve actuator .............................................................. 19
5.2.2 Control valve pilot control system................................................................ 20
5.2.3 Stroke test ................................................................................................... 20
5.3 Steam strainer ......................................................................................................... 20

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 GENERAL DESCRIPTION

6 LOW PRESSURE TURBINE ............................................................................................... 21

6.1 Outer casing............................................................................................................ 22
6.2 Inner casing............................................................................................................. 22
6.3 Shaft seals .............................................................................................................. 22
6.4 Turbine rotor............................................................................................................ 23
6.5 Blading .................................................................................................................... 24
6.6 Water injection ........................................................................................................ 24
6.7 Rupture diaphragm ................................................................................................. 24
6.8 Vacuum breaking valve........................................................................................... 24

7 BEARING PEDESTALS....................................................................................................... 25
7.1 Thrust bearing pedestal .......................................................................................... 25
7.1.1 Combined thrust and journal bearing .......................................................... 26
7.2 Intermediate bearing pedestal................................................................................. 28
7.2.1 Pocket-type journal bearing ........................................................................ 30
7.3 LP turbine bearing pedestal .................................................................................... 32
7.3.1 Pocket-type journal bearing ........................................................................ 33

8 ROTOR TURNING GEAR.................................................................................................... 33

8.1 General ................................................................................................................... 33
8.2 Tasks....................................................................................................................... 33
8.3 Design ..................................................................................................................... 34

9 TURBINE INSULATION....................................................................................................... 34

10 TURBINE INSTRUMENTS .................................................................................................. 35

10.1 Temperature sensors at turbines ............................................................................ 35
10.1.1 Startup probes............................................................................................. 35
10.1.2 Thermocouples ........................................................................................... 35
10.2 Bearing temperature measurement ........................................................................ 35
10.3 Speed sensor .......................................................................................................... 36
10.4 Vibration pick-up ..................................................................................................... 36
10.5 Expansion transmitter ............................................................................................. 36
10.5.1 Differential expansion transmitter................................................................ 36

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 GENERAL DESCRIPTION

10.5.2 Absolute expansion transmitter ................................................................... 36

10.5.3 Shaft position monitor.................................................................................. 36
10.6 Pressure transmitter ................................................................................................ 37
10.7 Grounding equipment.............................................................................................. 37
10.7.1 Grounding strip............................................................................................ 37

11 EXPLANATORY DESIGNATIONS....................................................................................... 38
11.1 Turbine subassemblies ........................................................................................... 38
11.2 Designation of the external connections ................................................................. 39
11.3 Designation of code letters...................................................................................... 39

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 GENERAL DESCRIPTION

Figures

Fig. 2-1 Expansion sleeve coupling............................................................................................... 8

Fig. 3-1 HP turbine ........................................................................................................................ 9
Fig. 4-1 Live steam valve housing ............................................................................................... 12
Fig. 4-2 Live steam stop valve..................................................................................................... 13
Fig. 4-3 Live steam stop valve actuator....................................................................................... 14
Fig. 4-4 Live steam control valve................................................................................................. 15
Fig. 4-5 Live steam control valve actuator................................................................................... 16
Fig. 5-1 Third steam valve ........................................................................................................... 18
Fig. 8-1 LP turbine ....................................................................................................................... 21
Fig. 8-2 LP turbine internals ........................................................................................................ 23
Fig. 7-1 Thrust bearing pedestal.................................................................................................. 25
Fig. 7-2 Combined thrust and journal bearing ............................................................................. 27
Fig. 7-3 Intermediate bearing pedestal........................................................................................ 29
Fig. 7-4 Pocket-type journal bearing............................................................................................ 31
Fig. 7-5 LP turbine bearing pedestal ........................................................................................... 32
Fig. 8-1 Rotor turning gear .......................................................................................................... 33
Fig. 11-1 Turbine views ............................................................................................................... 41

Additional Documents
„

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 GENERAL DESCRIPTION

1 GENERAL

1.1 Foundation
The foundation considerably influences the smooth running of a turboset. When de-
termining the foundation components which largely define the natural frequency of
the foundation, ALSTOM selects the design that is most advantageous for the oper-
ating behaviour of the turboset.
A simple, operationally reliable and cost-effective configuration of the foundation is
therefore already taken into account when designing a turboset.

1.2 Rotor line

The various steam turbine rotors are coupled in such a way that they are without
bending moments in operation. The couplings are supported via a journal bearing on
a bearing pedestal, located between the different subassemblies. This single-bearing
concept ensures clear bearing loads, even in the case of foundation deformations.
The rigid cast design of the bearing pedestals positively influences the running
smoothness and operational reliability of the turboset.

1.3 Expansion and fixation

The steam turbine train is fixed axially by a two-collar thrust bearing in the thrust
bearing pedestal. The relative and absolute fixed points of the turbine are at the LP
exhaust casing.
To permit thermal expansion of the turbine casings the free-standing bearing pedes-
tals can slide in axial direction. The turbine casings expand and move the front bear-
ing pedestal towards the turbine-end of the train.
This expansion concept has the advantage of minimising differential expansion be-
tween stationary and rotating turbine components, resulting in a higher efficiency due
to small seal clearances.

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 GENERAL DESCRIPTION

2 EXPANSION SLEEVE COUPLINGS

The expansion sleeve couplings are easy to assemble and maintain they connect
rigidly and positively the HP/IP turbine, LP turbine and the generator.
The conical coupling bolts and expansion sleeves are inserted in the honed bores of
the coupling flanges.
The coupling bolts are tightened hydraulically so that the expansion sleeves expand
elastically and compensate the assembly clearances.

Pos Designation Pos Designation

1 Coupling halves 2 Coupling bolt
3 Expansion sleeve 4 Coupling nut
5 Locking ring

Fig. 2-1 Expansion sleeve coupling

The torque is transmitted in operation by the shear stress of the coupling bolts and
expansion sleeves.
The coupling flanges are not twisted in the case of electric faults with step changes
in the torsional moments of the rotor line occurs the coupling can be dismantled
without damage.
To minimise ventilation loss the nuts of the coupling bolts are countersunk in the
coupling flanges. The centring recesses of both coupling flanges serve as assembly
aid.

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 GENERAL DESCRIPTION

3 HIGH PRESSURE TURBINE

The main components of the single-flow HP turbine of the cast double-shell type are
the outer casing, the bladed HP inner casing with integral balance piston first stage
and inlet part, the HP blade carrier, the shaft seals and the bladed rotor.
The distribution of the pressure and temperature gradients in the two casings en-
sures wall thicknesses and flange geometry in the outer casing which are favoured in
loading and casting practices.
The internals, especially the blading, can be inspected with an endoscope through
designed openings, avoiding dismantling the casing.
5 4 6 1 2 7 3 10 18

9
9

17
17

CDAB0105_
16 15 11 12 14
A2983

Pos Designation Pos Designation

1 Outer casing 10 Turbine rotor
2 HP inner casing 11 Start-up probe
3 HP blade carrier 12 Temperature sensor
4 Balance piston, first stage 14 Third steam admission
5 Balance piston, second stage 15 Piston relief steam
6 Inlet scrolls 16 Piston return steam
7 HP blading 17 Gland steam leak-off
9 Shaft seal 18 Cross-over pipe connection

Fig. 3-1 HP turbine

3.1 Outer casing

The outer casing is split horizontally along the turbine axis and held together by hy-
draulically tightened elongation studs. The flanges are equipped with sealing and
support strips to ensure optimum sealing.

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 GENERAL DESCRIPTION

The live steam flows through flanged-on valve housings with integral diffusers to the
HP inner casing inlet part and from there it flows into the HP blade carrier. The HP
exhaust then flows together with the third steam via a cross-over pipe into the LP
turbine.
The gland steam and leak-off connections for the shaft seals and the relief and re-
turn steam connections for the balance piston are located at the casing lower half.
Claws with integral adjusting elements, cast on the casing upper part, support the
turbine on the bearing pedestals. Adjustable fixing elements connect the turbine axi-
ally with the bearing pedestals.

3.2 HP inner casing

The horizontically split inner casing is fixed together by hydraulically tightened elon-
gation studs. The steam inlet part is designed as two 180° scrolls.
The inner casing houses the stationary blades and the pertinent sealing strips which
are fitted in radial grooves. The first stationary blade row is located in the inlet scrolls
to ensure uniform steam distribution.
The two-stage balance piston is a labyrinth seal and compensates the axial rotor
thrust. The sealing elements yield radially to prevent dangerous rubbing, the sealing
strips are caulked in the rotor.
The relief and return steam system for the balance piston is connected to the third
steam system.
Sliding keys that can be adjusted in height are fitted below the parting plane and
support the casing. In the inlet region the inner casing is fixed and supported in an
axial direction by adjustable keys. Lateral keys are fitted in the outer casing lower
part, which provide lateral guiding. All support and fixing systems are designed and
located so that the casings can expand freely in all directions without the position of
their centre axes being changed.

3.3 HP blade carrier

The horizontically split HP blade carrier is fixed together by hydraulically tightened
elongation studs.
The blade carrier houses the stationary blades and the pertinent sealing strips which
are fitted in radial grooves.
Sliding keys that can be adjusted in height are fitted below the parting plane and
support the blade carrier. In the inlet region the blade carrier is fixed to the outer cas-
ing. A lateral key is fitted in the outer casing lower part, which provide lateral guiding.
All support and fixing systems are designed and located so that the casings can ex-
pand freely in all directions without the position of their centre axes being changed.

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 GENERAL DESCRIPTION

3.4 Shaft seals

The shaft seals, designed as labyrinth seals, seal the turbine outer casing under
steam pressure and against the atmosphere at the rotor penetrations prevents the
steam from escaping from the turbine.
The sealing elements yield radially to prevent dangerous rubbing, the sealing strips
are caulked in the rotor. The shaft seal housings and the turbine outer casing form
annular ducts for the gland steam and leak-off system.
The gland steam system is operated with slight gauge pressure; the leak-off system,
having a slight vacuum, is routed with the sucked-in air to the gland steam con-
denser.

3.5 Turbine rotor

The turbine rotor is a monoblock rotor, forged from the solid, with rotating blades fit-
ted in radial grooves.
The sealing strips are inserted in grooves and fastened with caulking wire and their
alternate arrangement minimise the gap losses in the entire blading. This ensures
optimum utilisation of the steam and a high efficiency.
The rotor ends are provided with balancing holes distributed radially on the circum-
ference and permit rebalancing within a closed casing. The coupling flange is inte-
gral part of the rotor.

3.6 Blading
The stationary and rotating blades are milled from one piece so that blade root, airfoil
and shroud form a homogeneous unit. This robust design is easy to assemble.
The milled, rhombic rotating blades have slighty oversized shrouds compared with
the blade root. When assembled, the rhombic shrouds are fitted tightly against one
another so that the airfoils twist elastically.
The resultant torsional prestress ensures adequate shroud pressure under all oper-
ating conditions and a stable, closed shroud ring.
The shroud ring provides rigidity which makes the blades insensitive to resonance
with low excitation frequencies.

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 GENERAL DESCRIPTION

4 LIVE STEAM VALVES

The live steam passes through the live steam pipes into the valve housing, flanged
to the HP turbine and comprising a stop and a control valve with actuators. Acting as
a safety valve, the stop valve is located upstream of the control valve, looking in di-
rection of the flow.
3

BVAA0801_
A2779

Pos Designation Pos Designation

1 Stop valve actuator 4 Control valve
2 Stop valve 5 Spring support
3 Control valve actuator 6 Valve Housing

Fig. 4-1 Live steam valve housing

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 GENERAL DESCRIPTION

4.1 Live steam stop valve

The stop valve is a balanced single-seat valve with pilot stroke. Its steam strainer
protects the internals of valve and turbine against damage due to solid particles. The
valve seat is pressed into the valve housing.
1 2 3 4 5 6 7 8

CVAB0701_
A2756

Pos Designation Pos Designation

1 Valve seat 6 Steam strainer
2 Segment Ring 7 Valve Head
3 Clamping ring 8 Diffuser
4 Seal ring 9 Spindle
5 Lock

Fig. 4-2 Live steam stop valve

The stop valve can assume two stationary positions, fully open or fully closed. The
pilot stroke of the stop valve initiates the opening movement. If the valve is open, the
valve head is pressed against the backseat in the lock. The valve is then insensitive
to vibration excitation and sealed towards the outside.
The closing movement is also initiated by the pilot stroke.
With closed valve, the spindle leakage is minimised by a multi-part sealing element.

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 GENERAL DESCRIPTION

4.1.1 Stop valve actuator

The stop valve actuator is a hydraulic actuator for directly actuating the stop valve. In
the case of inadmissible operating conditions or a shutdown the actuator and the
coupled valve shuts off the steam supply to the turbine. The actuator operates ac-
cording to the "fail-safe" principle, i.e. the actuator closes the stop valve with spring
force in the case of a pressure drop in the safety system.

2 3
1

5 4 CTAA0201_
7 6 A2895

Pos Designation Pos Designation

1 Proximity sensors 5 Bellville spring asssembly
2 Actuator housing 6 Piston rod
3 Discharge amplifier valve plate 7 Cover
4 Actuator piston

Fig. 4-3 Live steam stop valve actuator

The main parts of the actuator are the housing, the actuator piston with Belleville
spring assembly, the discharge amplifier and the control elements for the stroke test.
Inductive proximity switches indicate the open or closed position of the stop valve.
To open the valve, pressure is built up in the safety system and pressure fluid flows
via a check valve and an orifice in the valve plate of the discharge amplifier into the
space below the actuator piston. With increasing pressure the Belleville spring as-
sembly is compressed and the actuator piston and the valve move in opening direc-
tion. The stroke of the coupled valve limits the end position.
The closing movement is initiated by the pressure collapse in the safety system. The
pressure before the valve plate of the discharge amplifier drops.

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 GENERAL DESCRIPTION

The backpressure generated by the Belleville spring assembly opens the valve plate.
The stroke volume of the actuator piston is directly discharged into the drain via
bores in the valve body. As a consequence, the stop valve closes.

4.1.2 Stroke tests

The stop valve must be subjected periodically to a stroke test in normal operation.
The steam supply to the turbine must, however, be ensured. The stroke test must
also be compatible with the operating concept of the turbine.

4.2 Live steam control valve

The control valve controls the steam flow rate to the HP turbine and blocks the
steam supply, together with the stop valve, in the case of a disturbance. The valve is
a balanced single-seat valve with flow equaliser; its diffuser is led directly into the HP
inner casing where it is sealed off with a thermally flexible steam seal ring.
2 1

CVAC0701_
A2784

Pos Designation Pos Designation

1 Diffuser 2 Sealing element

Fig. 4-4 Live steam control valve

The control valve can assume any position between fully open and closed.
The opening movement of the control valve is initiated with open stop valve. A multi-
part sealing element seals the spindle towards the atmosphere.

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 GENERAL DESCRIPTION

4.2.1 Control valve actuator

The control valve actuator is a hydraulic actuator with end position dampening for di-
rectly actuating the control valve. It can assume any position as stationary position
over the entire stroke range. The actuator operates according to the "fail-safe" prin-
ciple, i.e. the actuator closes the valve with spring force in the event of a pressure
drop in the safety system.
In the case of inadmissible operating conditions or a shutdown the actuator and the
coupled valve shut off the steam supply to the turbine.

Pos Designation Pos Designation

1 Actuator piston 2 Proportional valve
3 Discharge amplifier 4 Linear transducer

Fig. 4-5 Live steam control valve actuator

The main parts of the actuator are the housing, the actuator piston with Belleville
spring assembly, a proportional valve with power amplifier, the discharge amplifier
and a position feedback.
The pilot control system, comprising discharge amplifier, proportional valve with
power amplifier and integral stroke transmitter, is flanged directly to the actuator. Via
the pressure below the actuator piston the proportional valve controls the position of
the actuator in accordance with the electrical input signal that corresponds to the

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 GENERAL DESCRIPTION

control valve position, required by the turbine controller. This control can be config-
ured at the power amplifier.
When the valve opens, pressure fluid flows from the proportional valve into the
space below the actuator piston via orifices in the valve plate of the discharge ampli-
fier. The orifices limit the maximum opening speed; the valve plate of the discharge
amplifier remains always closed.
The control mode and control variables can be set at the power amplifier and are
preadjusted for optimum operation. The stroke transmitter of the actuator transmits
the position signal of the control valve actuator, and thus of the control valve, to the
turbine controller.
The closing movement is initiated by the pressure collapse in the safety system. The
pressure before the valve plate of the discharge amplifier drops.
The backpressure generated by the Belleville spring assembly opens the valve plate.
The stroke volume of the actuator piston is directly discharged to the drain via bores
in the valve body. As a consequence, the control valve closes.

4.2.2 Stroke tests

The control valve must be subjected periodically to a stroke test in normal operation.
The steam supply to the turbine must, however, be ensured. The stroke test must
also be compatible with the operating concept of the turbine.

5 THIRD STEAM VALVES

The third steam from the steam generator flows through a steam pipe to the third
steam valve and then through an inlet pipe to the exhaust end of the HP / IP turbine,
from where the LP turbine is fed via a cross-over pipe.
The valve consists of the following subassemblies, arranged one behind the other in
the direction of the flow: a stop valve with actuator and control elements, a control
valve with actuator and control elements and a steam strainer.

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 GENERAL DESCRIPTION

Pos Designation Pos Designation

1 LP steam stop valve 2 LP steam stop valve actuator
3 LP steam control valve 4 LP steam control valve act.
5 Steam strainer

Fig. 5-1 Third steam valve

The stop valve and the control valve are identical, double-eccentrically supported
and unilaterally sealing butterfly valves. The steam force acts on the valve disk in
any position in closing direction due to the eccentric arrangement. The closed posi-
tion of the valves is defined by a stop in the actuator. For safety reasons, additional
stops are provided for the valve disk in the valve housing. The valve disk is sealed in
the closed position by metallic seals into which the cone-shaped valve disk edges
penetrate during closing. The disk edges are hard-faced.
Due to its size, overhang and weight, the valve housing is supported on the founda-
tion by an adjustable, thermally flexible swing arm support.

5.1 Third steam stop valve

The stop valve is a butterfly valve that is controlled by the turbine safety system and
can assume two positions, fully open or closed. In the case of inadmissible operating
conditions or a shutdown the valve shuts off the steam supply to the LP turbine. The

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 GENERAL DESCRIPTION

main parts of the valve are the housing with integral valve seat, the eccentrically
supported valve disk, the actuator with pilot control and the proximity switches for
position indication.

5.1.1 Third steam stop valve actuator

The stop valve actuator is a hydraulic actuator with end position dampening for di-
rectly actuating the stop valve. In the case of inadmissible operating conditions or a
shutdown the actuator and the coupled valve shut off the steam supply to the tur-
bine. The actuator operates according to the "fail-safe" principle, i.e. the actuator
closes the stop valve with spring force when their is pressure drop in the safety sys-
tem.
In the actuator housing, a gear rack, fastened to the piston rod, and pinion transmits
the stroke of the actuator piston to the valve disk shaft and converts it in a rotational
movement.

5.1.2 Stop valve pilot control system

The pilot control system with a discharge amplifier for activating the actuator and so-
lenoid valve for the stroke test are flanged to the actuator. With adequate pressure in
the safety system the stop valve is opened by the actuator.
If the pressure in the safety system is discharged, the pressure before the discharge
amplifier drops and the backpressure, generated by the Belleville spring assembly of
the actuator opens the valve plate of the discharge amplifier. The stroke volume in
the actuator piston is discharged into the drain and the stop valve closes.

5.1.3 Stroke test

The stop valve must be subjected periodically to a stroke test in normal operation.
The steam supply to the turbine must, however, be ensured. The stroke test must
also be compatible with the operating concept of the turbine.

5.2 Third steam control valve

The control valve is a butterfly valve that controls the steam flow to the turbine in ac-
cordance with the flow rate required by the turbine controller. The control valve as-
sumes a position corresponding to the relevant actuating signal.
In the case of inadmissible operating conditions or a shutdown the valve shuts off the
steam supply to the LP turbine, together with the stop valve.
The main parts of the valve are the housing with integral valve seat, the eccentrically
supported valve disk, the actuator with pilot control and the angular position trans-
ducer for position indication and adjustment.

5.2.1 Third steam control valve actuator

The control valve actuator is a hydraulic actuator with end position dampening for di-
rectly actuating the control valve. It can assume any position as stationary position
over the entire stroke range. The actuator operates according to the "fail-safe" prin-

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 GENERAL DESCRIPTION

ciple, i.e. the actuator closes the stop valve with spring force when their is a pressure
drop in the safety system.
In the case of inadmissible operating conditions or a shutdown the actuator and the
coupled valve shuts off the steam supply to the turbine.
In the actuator housing, a gear rack, fastened to the piston rod, and pinion transmits
the stroke of the actuator piston to the valve disk shaft and converts it in a rotational
movement.

5.2.2 Control valve pilot control system

The pilot control system, comprising of, a discharge amplifier and a propor-tional
valve with power amplifier and integral stroke transmitter, is flanged di-rectly to the
actuator. Via the pressure below the actuator piston the propor-tional valve with
power amplifier controls the position of the actuator in accor-dance with the electrical
input signal which corresponds to the control valve position, required by the turbine
controller. This control can be configured at the power amplifier.
If the pressure in the safety system is discharged, the pressure before the discharge
amplifier decreases and the backpressure generated by the Belleville spring assem-
bly in the actuator opens the valve plate of the discharge amplifier. The stroke vol-
ume in the actuator piston is discharged to the drain and the control valve closes.
A feed and a discharge orifice are installed in the pilot control system. The feed ori-
fice prevents emptying of the pilot control system and the control valve actuator
when the control valve is closed. The discharge orifice causes the slow closing of the
control valve in the case of proportional valve failure.

5.2.3 Stroke test

The control valve must be subjected periodically to a stroke test in normal operation.
The steam supply to the turbine must, however, be ensured. The stroke test must
also be compatible with the operating concept of the turbine.

5.3 Steam strainer

The steam strainer is a strainer basket, arranged eccentrically in a housing and de-
signed as a cylindrical perforated plate with a welded-on fine screen. The strainer
basket acts as a flow equaliser, ensuring a uniform, twist-free steam supply to the
turbine. The fine screen protects the turbine against solid particles.
As the steam flows from the inside to the outside, the solid particles are collected in
the strainer and can be easily removed.

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 GENERAL DESCRIPTION

6 LOW PRESSURE TURBINE

Two identical LP turbines are installed between the HP turbine and the Generator.
The main components of the double-flow type LP turbine, are the welded outer cas-
ing, the cast and bladed inner casing, the bladed turbine rotor and the shaft seals.
Openings provided in the outer casing allow for inspection of the turbine internals,
especially the blading and inlet scroll, with the outer casing assembled.

Pos Designation Pos Designation

1 Outer casing, lower part 6 Shaft seal
2 Outer casing, upper part 7 Water injection valve
3 Inner casing 8 Heat shield
4 Turbine rotor 9 Rupture diaphragm
5 Blading 10 Shaft covering

Fig. 8-1 LP turbine

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 GENERAL DESCRIPTION

6.1 Outer casing

The LP outer casing is a two-part solid weldment whose lower part is supported di-
rectly to the foundation forming the axial fixpoint of the steam turbine shaft.
The turbine exhaust is downward and connects to the condenser neck.

6.2 Inner casing

The cast inner casing is split along the turbine axis and held together by hydraulically
tightened elongation studs. The steam inlet part is designed as a 360° scroll. The in-
ner casing houses the stationary blades and the pertinent sealing strips, mounted in
radial grooves. The first stationary blade row is located in the inlet scroll to ensure
uniform steam distribution to the two flows of the blading. Each flow has symmetri-
cally arranged extractions to prevent thrust problems.
In the parting plane, the inner casing is supported vertically at four points on the
outer casing lower part via cast-on supports. With the two support points in direction
to HP / IP turbine the inner casing is adjusted axially to the outer casing. Radial
guidance of the inner casing is provided by guide elements fitted at the bottom in the
longitudinal rib of the outer casing lower part.
All support and fixing systems are so designed and located that the outer and inner
casing can expand freely in all directions without the position of their centre axes be-
ing changed.

6.3 Shaft seals

The LP exhaust chamber operates below atmospheric pressure and to prevent air
entering though the rotor penetrations labyrinth shaft seals are fitted. The adjustable
arrangement of the shaft seal at the bearing pedestals permits minimal labyrinth
clearances so that only a very small quantity of gland steam is required. Piston rings
provide sealing between the LP outer casing and the shaft seal casings.
This arrangement permits thermal movement of the LP outer casing relative to the
shaft seal casing without affecting the labyrinth clearances. The sealing elements
yield radially to prevent dangerous rubbing.
The shaft seal casings contains annular ducts for connection to the gland steam and
leak-off system each. The gland steam system is operated with slight gauge pres-
sure; the leak-off system, having a slight vacuum, is routed with the sucked-in air to
the gland steam condenser.

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 GENERAL DESCRIPTION

CCAB0110_
A2986

Pos Designation Pos Designation

1 Outer casing, lower part 5 Inlet scroll
2 Inner casing, lower part 6 Water injection valve
3 Vertical support 7 LP turbine bearing pedestal
4 Intermediate bearing pedestal 8 Vacuum breaking valve

Fig. 8-2 LP turbine internals

6.4 Turbine rotor

The LP turbine rotor is welded from shaft disks and shaft ends in accordance with a
proven ALSTOM practice. The rotating blades are mounted in radial grooves. Seal-
ing strips, inserted in grooves and fastened with caulking wire, and their alternate ar-
rangement minimise the gap losses. This ensures optimum utilisation of the steam
and a high efficiency.

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 GENERAL DESCRIPTION

The rotor ends are provided with balancing holes that are distributed radially and
permit rebalancing with closed casing. The coupling flanges are integral parts of the
rotor.

6.5 Blading
The stationary and rotating blades of the first rows are milled from one piece so that
blade root, airfoil and shroud form a homogeneous unit. This robust design is there-
fore easy to assemble.
The milled, rhombic rotating blades have a shroud that has a slight oversize com-
pared with the blade root. When assembled in rows, the rhombic shrouds are
strongly pressed against one another so strongly that the airfoils twist elastically.
The resultant torsional prestress ensures adequate shroud pressure under all oper-
ating conditions and a stable, closed shroud ring.
The gap- and clearance-free shroud ring provides a stiffness that makes the blades
insensitive to resonance with low excitation frequencies.
The blades of the last two rows are also made from one piece, but their size requires
a different manufacturing procedure. The stationary blades are ferro- castings, the
rotating blades are of forged alloy steel. The airfoils are tapered towards the end to
reduce the stresses in the blade. The twisted shape of the airfoil ensures adaptation
to the flow conditions.

6.6 Water injection

A water injection system, provides cooling during no-load and low-load operation via
a water injection valve. Its supply depends on the steam mass flow in the turbine.
The water injection system which has pipes with water spray nozzles is installed in
the exhaust casing and protects against overheating due to ventilation of the LP end
stage.

6.7 Rupture diaphragm

Rupture diaphragms are mounted on the outer casing upper part to protect the con-
denser and prevent overpressure in the turbine. The rupture diaphragms consist
mainly of a special lead plate and are planned weak points that burst at a defined re-
sponse pressure in the case of inadmissible operating conditions. In normal opera-
tion the lead plates lies steam-tight on the vacuum supports of the rupture dia-
phragms.

6.8 Vacuum breaking valve

A vacuum breaking valve is attached to the LP outer casing to permit quick passing
of the critical speed ranges during turbine rundown. In certain speed ranges the con-
denser vacuum must be broken partially or completely in order to achieve certain
condenser pressures.
Under certain operating conditions a full vacuum break is not permitted, in order to
protect, for example, the LP last-stage blades.

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7 BEARING PEDESTALS

7.1 Thrust bearing pedestal

The thrust bearing pedestal with installed combined axial thrust and journal bearing
is mounted on a base plate, permitting displacement in axial direc-tion, and houses
the main lube oil pump. The rotor turning gear is mounted on the top of the bearing
pedestal. Various instruments are installed in- and outside of the bearing pedestal.
The base plate is secured on the foundation by foundation bolts via adjustable sup-
ports and is fixed laterally and axially by retaining blocks cast into the foundation.
Maintenance-free sliding elements with low friction coefficients are inserted between
the bearing pedestal support surface and the base plate. The sliding elements can
be exchanged without requiring disassembly of the bearing pedestal. Permanently
lubricated, adjustable keys guide the bearing pedestal axially on the base plate.

Pos Designation Pos Designation

1 Bearing pedestal 2 Foundation support
3 Comb. thrust/journal bearing 4 Turning gear
5 Base plate 6 Oil shield
7 Expansion transmitter 8 Main lube oil pump
9 Jacking oil connection

Fig. 7-1 Thrust bearing pedestal

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The HP/IP turbine casing is supported in the parting plane via claws on permanently
lubricated, adjustable spherical seats and support keys with integral hold-down bars
that prevent the turbine casing from lifting off due to reaction forces.
The turbine casing forces acting in a vertical direction, are transmitted through the
bearing pedestal and base plate and are absorbed by the adjust-able supports and
the foundation bolts. The retaining and friction surfaces of the retaining claws are fit-
ted with maintenance-free sliding elements.
Bolted joints, which can be adjusted axially with spacer sleeves, connect the turbine
casing and the bearing pedestal and permit free thermal expansion of the turbine
and bearing pedestal. An adjustable guide is mounted at the faceside to the turbine
for lateral guidance.
The lube oil supply and drain are of the tube-in-tube design. A pump, mounted ex-
ternally on the lube oil supply unit, delivers the jacking oil to the journal bearing
through a flow control valve, a check valve and internal jacking oil pipes. The flow
control valve maintains constant the adjusted volume flow in order to ensure rotor
elevation during turning gear operation, startup and rundown.
At the rotor penetration an oil shield is fitted radially.

7.1.1 Combined thrust and journal bearing

Combined thrust and journal bearings are designed according to hydrody-namic
principles which ensures that the sliding machine parts do not come into contact and
results in low friction losses and low space requirements. The bearings transmits ax-
ial thrust forces from both sides and part of the shaft weight to the bearing pedestal.
The bearing is centred with cylindrical pins and slightly clamped in the bear-ing ped-
estal by fitted plates. Shims under the fitted plates, allows bearing adjustment. A cy-
lindrical pin is inserted in the upper part of the fitted plate to prevent the bearing turn-
ing.
The thrust bearing consist of a two-part bearing housing, fixed together by hexagon
head bolts and thrust pads, backed for damping with spring rings.
The fully enclosed journal bearing consists of two bearing shells, lined with white
metal, centred with cylindrical pins and held together by socket head screws. The
bearing is slightly clamped in the thrust bearing housing. A cylindrical pin is inserted
in the upper fitted plate to protect the bearing turning.

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Pos Designation Pos Designation

1 Journal bearing, lower part 2 Journal bearing, upper part
3 Bearing housing, lower part 4 Bearing housing, upper part
5 Spring ring 6 Set of pads
7 Sealing ring 8 Fitted plate

Fig. 7-2 Combined thrust and journal bearing

The lube oil for the bearing is supplied through a bore in the bearing housing and the
lateral oil inlet, where the oil passes into the inlet pocket of the bear-ing shells.
The oil exits the bearing at both face sides along the entire shaft circumfer-ence.
Discharge orifices and sealing rings keep the internal chamber of each thrust bearing
side permanently filled with lubricating oil. This assures the lu-brication and cooling
of all thrust bearing parts.

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The higher-loaded journal bearings have a jacking oil system which prevents metallic
contact between the bearing metal and the bearing journal during turning gear op-
eration, startup and rundown, when a hydrodynamic film is not available. The friction
coefficient in the bearings and the torque produced by the turning gear is reduced
significantly.

7.2 Intermediate bearing pedestal

The bearing pedestal with installed pocket-type journal bearing is mounted directly to
the foundation and houses an expansion sleeve coupling. The bearing pedestal is
bolted to the foundation by foundation bolts via adjustable supports and fixed later-
ally and axially by retaining blocks, cast into the foundation.
Various instruments are installed in- and outside of the bearing pedestal.
A shaft seal of the LP turbine is bolted directly to the face of the bearing pedestal.
The HP/IP turbine casings is supported in the parting plane via claws on perma-
nently lubricated, adjustable spherical seats and support keys of the bearing pedes-
tal with integral hold-down bars which prevent the turbine casing from lifting off due
to reaction forces.
The turbine casing forces, acting in a vertical direction are transmitted through the
bearing pedestal and are sbsorbed by the adjustable supports and the foundation
bolts. The retaining and friction surfaces of the retaining claws are fitted with mainte-
nance-free sliding elements.
Bolted joints, which can be adjusted axially with spacer sleeves, connect the turbine
casing and the bearing pedestal and permit free thermal expansion of the turbine
and the bearing pedestal. Adjustable guides are fitted at the facesides for lateral
guidance.

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A1211

Pos Designation Pos Designation

1 Bearing pedestal 2 Foundation support
3 Journal bearing 4 Expansion sleeve coupling
5 Jacking oil connection 6 Oil shield

Fig. 7-3 Intermediate bearing pedestal

The lube oil supply and drain are of a tube-in-tube design. A pump, mounted exter-
nally on the lube oil supply unit, delivers the jacking oil to the journal bearing through
a flow control valve, a check valve and internal jacking oil pipes. The flow control
valve maintains constant the adjusted volume flow in order to ensure rotor elevation
during turning gear operation, startup and rundown. The rotor penetrations have ra-
dially arranged oil shields.

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7.2.1 Pocket-type journal bearing

The journal bearing is designed according to hydrodynamic principles which ensures
that the sliding machine parts do not come into contact and results in low friction
losses and low space requirements. The bearing transmits part of the shaft weight to
the bearing casing.
The fully enclosed bearing consists of two bearing shells, lined with white metal, cen-
tred with cylindrical pins and held together by socket head screws. The bearing is
slightly clamped in the bearing casing by fitted plates. Shims under the fitted plates,
allows bearing adjustment. A cylindrical pin is inserted in the upper fitted plate to
prevent the bearing turning.

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Pos Designation Pos Designation

1 Protection against turning 2 Fitted plate
3 Shim 4 Upper bearing shell
5 Lower bearing shell

Fig. 7-4 Pocket-type journal bearing

The lube oil for the bearing is supplied through a bore in the bearing casing and the
lateral oil inlet, where the oil passes into the inlet pocket of the bear-ing shells. The
oil exits the bearing at both facesides along the entire shaft circumference.
The higher-loaded journal bearings have a jacking oil connection that pre-vents me-
tallic contact between the bearing metal and the bearing journal during turning gear
operation, startup and rundown when a hydrodynamic film is not available. The fric-
tion coefficient in the bearings and the torque pro-duced by the turning gear is re-
duced significantly.

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7.3 LP turbine bearing pedestal

The bearing pedestal with installed pocket-type journal bearing is mounted di-rectly
on to the foundation. The bearing pedestal is bolted to the foundation by foundation
bolts via adjustable supports and fixed laterally and axially by retaining blocks, cast
into the foundation.
Inside of the coupling enclosure runs an expansion sleeve coupling which connects
the steam turbine shaft and the generator rotor. Various instru-ments are installed in-
and outside the bearing pedestal. An LP turbine shaft seal is bolted directly to the
face of the bearing pedestal.
The forces and weight of the rotors, acts in a vertical direction, are transmit-ted
through the bearing pedestal and absorbed by the adjustable supports and the foun-
dation bolts.

A2984

Pos Designation Pos Designation

1 Bearing pedestal 2 Foundation support
3 Journal bearing 4 Expansion sleeve coupling
5 Coupling enclosure 6 Oil shield
7 Flow control valve 8 Diff. expansion transmitter

Fig. 7-5 LP turbine bearing pedestal

The lube oil supply and drain are of a tube-in-tube design. A pump, mounted exter-
nally on the lube oil supply unit, delivers the jacking oil to the journal bearing through
a flow control valve, a check valve and internal jacking oil pipes.

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The flow control valve maintains constant the adjusted volume flow in order to en-
sure rotor elevation during turning gear operation, startup and rundown.
The rotor penetrations have radially arranged oil shields.

7.3.1 Pocket-type journal bearing

The journal bearing in the LP turbine bearing pedestal is of the same design as the
journal bearing in the intermediate bearing pedestal.

8 ROTOR TURNING GEAR

8.1 General
The rotor turning gear, designed for automatic operation is driven by an electric mo-
tor.
3
2

CJAD0101_
A2446_
4

Pos Designation Pos Designation

1 Drive casing 3 Reduction gearbox
2 Motor 4 Drive pinion

Fig. 8-1 Rotor turning gear

It is also possible to operate the turning gear by hand. This is done in the event of a
failure of the power supply, or if only sporadic turning is necessary during mainte-
nance work. The turning gear, and all functional elements are mounted on or fas-
tened to the thrust bearing pedestal.

8.2 Tasks
The turning gear has mainly the following tasks:

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• Turning gear operation after rundown of the steam turbine

• Turning gear operation before re-starting the turbine
• Turning gear operation during maintenance work
The ventilation of the blading, caused by turning the rotor line after rundown or dur-
ing preheating before commissioning, results in a temperature equalisation while
maintaining the shaft axis in the casings. This prevents temperature layers and de-
formation of the casings and turbine rotors, ensuring safe startup without rubbing.
The turning gear is disengaged automatically after starting the steam turbine and the
motor shutdown. Incorrect operation is excluded.

8.3 Design
The rotor turning gear consists of functional elements, grouped in a control block, for
direct fastening to the drive casing and comprises the following:
• Motor with attached, bevel wheels and displaceable drive pinion
• Swivel arm at the drive pinion for engaging process
• Impulse pick-up (rotor speed)

9 TURBINE INSULATION
The turbine insulation restricts the heat flow that results from temperature differences
due to convection and radiation of the heat-conducting media and materials. It also
prevents heat loss of all plant components that carry steam or hot condensate and
serves simultaneously as a protection against radiation and contact.
It also prevents inadmissible thermal stresses during cooling down of the casings
and resultant asymmetric deformations by reducing the wall temperature gradients of
the insulated parts.
To achieve a good contact of insulation and casings and prevent sagging of the insu-
lating material, the insulation is secured on the casings. Reinforcements are pro-
vided additionally at exposed points. To avoid air circulation, the insulation must con-
tact the hot casings all over.
A hard-shell is applied to protect the surface against oil or impurities.

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10 TURBINE INSTRUMENTS
Various instruments are required for protect the turbine, transmitting selected pa-
rameters to the measured value processing system under different operating condi-
tions and monitoring and switching certain devices during operation.
The values measured by the instruments are transmitted to the control room and
serve as a basis for the automatic operation of the plant. Selected variables are
processed in the display units and recorders for long-term monitoring.
The incoming values are evaluated in the different processing systems and com-
pared with the values determined during commissioning and with specified operation
values. For example, limit values for alarms, shutdowns, admissible or inadmissible
operating conditions, and also measured values that indicate certain conditions such
as whether commissioning can be started.
Continually measured and correctly interpreted measured values are the basis for a
long service life and can prevent damage to the turbine.

10.1 Temperature sensors at turbines

10.1.1 Startup probes
Transient operation, such as startup, rundown and load changes, causes thermal
stresses as well as the existing stationary stresses due to pressure, temperature and
centrifugal force. These additional thermal stresses must be limited so not to reduce
the useful life of the machine.
This is achieved by adhering to the permitted temperature gradients. The resultant
admissible load gradients for the machine are determined as a function of the steam
conditions and geometry.
To meet these requirements, special temperature sensors are installed in the inlet
parts of the HP turbine.

10.1.2 Thermocouples
Temperature sensors or thermocouples that measure the temperature are installed
in the bladings of all turbines.
Temperature measurement is of particular importance in low-load operation in order
to counteract the risks of ventilation and resultant inadmissible temperature increase
in the blading.

10.2 Bearing temperature measurement

The bearing metal temperature and the oil drain temperature are measured in all
bearing pedestals. The bearing metal temperature measurement is the most suitable
criterion for monitoring the proper functionality of a bearing. The bearing metal tem-
perature is measured with double-thermocouples in the lower bearing shells of jour-
nal bearings or load-bearing pads and at the top, bottom and both sides of the thrust
bearing in the thrust pads.

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The oil drain temperature measurement is the suitable means for monitoring the lube
oil supply to the turbine bearings. Excessive temperatures indicate inadmissible con-
ditions in the bearings or excessive oil supply temperatures.
Defined excessive temperatures trigger an alarm or a turbine trip.

10.3 Speed sensor

Electrical speed sensors are installed in the thrust bearing pedestal and pulsed via a
gear ring. The speed of the rotor line is measured by these sen-sors which protects
against overspeed. When reaching inadmissible speeds, the turbine is automatically
shut down. The proper functionality of the safety system can be tested during opera-
tion with the help of these speed sensors and certain safety elements.

10.4 Vibration pick-up

Smooth running of the machine depends largely on vibration-free operation of the ro-
tor line. To measure the relative vibration of rotors and the bearing casings, two in-
ductive vibration pick-ups are installed in each bearing casing. Equipped with an ad-
ditional device, these pick-ups also allow rebalancing of the turbine rotors.
Defined excessive vibration values trigger an alarm or a turbine trip. A transmitter for
measuring the phase angle is additionally installed in the thrust bearing pedestal.

10.5 Expansion transmitter

10.5.1 Differential expansion transmitter
The differential expansion of the bearings and turbine casings is measured and the
transmitter signals are compared. The differential expansion is caused by the differ-
ence in mass and surface of the relevant components and does not usually give ab-
normal values because it was taken into consid-eration in the design. The differential
values must, however, be observed during quick loading or unloading of the ma-
chine.

10.5.2 Absolute expansion transmitter

The absolute expansion of every turbine casing, referred to the absolute fixed point
of the turbine, is measured with these transmitters, fastened to the bearing pedes-
tals. These values indicate the free thermal expansion and, in contrast to the differ-
ential expansions, show the co-action of load and temperature gradients.

10.5.3 Shaft position monitor

The positive or negative displacement of the turbine rotor, referred to the relative
fixed point of the turbine, is measured with the shaft position monitor, fitted at the
thrust bearing pedestal. The measured values must be thor-oughly observed, par-
ticularly during load surges and indicate the pressure behaviour in the turbine.

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10.6 Pressure transmitter

Pressure transmitters are mounted on the LP outer casing for monitoring the con-
denser pressure.

10.7 Grounding equipment

10.7.1 Grounding strip
The grounding strip, fastened at the LP bearing pedestal at the generator, is an elec-
trically conductive connection of the rotating rotor line and the power plant grounding
system.
The grounding strip discharges possibly occurring shaft voltages and prevents dam-
age to bearings, seal rings, shields and similar devices.

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11 EXPLANATORY DESIGNATIONS

11.1 Turbine subassemblies

MAA10 HP turbine
MAA10CT005 Startup probe, HP turbine
MAA10CT010 Ventilation monitoring, HP turbine
MAA10HA400 Stationary blading, HP turbine
MAA10HB400 Rotating blading, HP turbine
MAA11AA001 Live steam stop valve
MAA11AA011 Live steam control valve
MAA12AA001 Live steam stop valve
MAA12AA011 Live steam control valve
MAC01 Cross-over pipe
MAC10 LP turbine
MAC10-20AA021 Vacuum breaking valve
MAC10-20BP010 Rupture diaphragm
MAC10-20HA410 Stationary blading, LP turbine left flow
MAC10-20HA420 Stationary blading, LP turbine right flow
MAC10-20HB410 Rotating blading, LP turbine left flow
MAC10-20HB420 Rotating blading, LP turbine right flow
MAC32AA001 Third steam stop valve
MAC32AA011 Third steam control valve
MAC80AA001/2 Water injection valve
MAD20 Thrust bearing pedestal
MAD21 Thrust/journal bearing
MAD40 Intermediate bearing pedestal
MAD41 Pocket-type journal bearing
MAD50 LP bearing pedestal
MAD51 Pocket-type journal bearing
MKD10 LP bearing pedestal
MKD11 Pocket-type journal bearing
MAK21 Expansion sleeve coupling
MAK22 Expansion sleeve coupling
MAK23 Expansion sleeve coupling
MAK80 Rotor turning gear
MAV21AP011 Main lube oil pump

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11.2 Designation of the external connections

MAA10/20 Gland steam system, HP turbine part
MAA10/25 Leak-off system, HP turbine part
MAA10/21 Gland steam system, HP turbine (IP part)
MAA10/26 Leak-off system, HP turbine (IP part)
MAC32/01 Third steam supply
MAC10-20/20 Gland steam system, LP turbine
MAC10-20/21 Gland steam system, LP turbine
MAC10-20/25 Leak-off system, LP turbine
MAC10-20/26 Leak-off system, LP turbine
MAD20/50 Lube oil supply, thrust bearing pedestal
MAD40/50 Lube oil supply, intermediate bearing pedestal
MAD50/50 Lube oil supply, LP intermediate bearing pedestal
MKD10/50 Lube oil supply, LP bearing pedestal

11.3 Designation of code letters

A Endoscope opening
B Balancing opening
C Balance piston feed back
D Balance piston relieve

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Blank Page

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C D

A2982

Fig. 11-1 Turbine views

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Blank Page

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