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INQUIRY FOR 3 MW PH STEAM TURBINE WITH ALTERNATOR

We are in need of 3 MW Multi stage Back Pressure steam turbine with complete set with Gear
Box and Alternator combined base frame incorporated oil pumps.

Steam Pressure : 32 Kg/Cm2g
Inlet Steam Temp. : 380 ± 20o C
Exhaust Pressure : 1.5 Kg/Cm2
Output : 3000 KW
Alternater : Rating 3000 KW
Voltage : 415 Volts
Phase : 3 Ph.
Frequency : 50 Hz
No. of Poles : 4
RPM : 1500

The steam consumption of the multi stage steam turbine should be to minimum extend per
KWH with Hydromechanical Governor. UG40 Woodward make package type speed Governer mechanically
linked with steam governing valve. The Governor is driven by a worm and wheel from a lay shaft in the steam
end pedestal. The Governor is provided with speed droop adjustment, local hand speed control knob and electric
motor for remote speed control.

Multistage, centrally balanced, Impulse type, back pressure steam turbine, duly painted capable
of developing necessary power with speed reduction gear box in a common base plate with the following limits of
supply.

 Inlet Steam Flange on Turbine main steam stop valve ;
 Exhaust steam Flange on Turbine casing ;
 Inlet and Outlet flanges for circulating cooling water on oil cooler;
 Turbine drains terminating at base plate level;
 Terminals of AOP motor ;
 Terminals of Alternator ;

1) Combined base-frame for turbine and speed reduction gear unit incorporating oil sump. (Oil level
can be checked through built-in viewing glass).

2) Speed reduction gear box with Hardened and grounded/nitrated internals.

3) High speed Flexible coupling (non-lubricating) between turbine and gearbox and Low speed
coupling (non-lubricating) between output shaft of gear box and Alternator.

4) Emergency over-speed system.

5) UG40 Woodward Make package type speed Governor mechanically linked with steam governing valve.
The Governor is driven by a worm and wheel from a layshaft in the steam end pedestal. The
Governor is provided with speed droop adjustment, local hand speed control knob and electric motor
for remote speed control.

6) Drain connections from emergency valve steam chest, exhaust branch & gland led to two separate
manifolds, one for steam drains & one for drip drains terminating at the base-plate.

7) a) Combined Stop and Emergency valve with steam strainer.
b) Inlet steam stop valve 8” Ø size to be provided.

8) Two Nos. Hand operated overload valve.

9) Electronic tachometer of “BEACON” manufacture, comprising of Magnetic Pick-up, D/A Converter
and speed indicator. This Tachometer is suitable for working on 220 Volts AC Supply. It shall have
two dials one for local display and the other for display on remote panel.

10) Forced lubrication system incorporating the following.

a) Main oil pump driven off the Gear Box slow speed shaft
b) Electric motor driven by auxiliary oil pump with electric motor of suitable capacity duly
mounted on a bracket fitted to turbine and gear box combined base plate.
c) Two Nos. Shell and Tube Type Oil Cooler of equal and adequate capacity to cool pumped
oil with water available at ambient temperature. (Companion flanges for inlet and outlet
branches for water not included). Coolers are inter- connected with changeover facility to
isolate one of the two coolers for cleaning during operation of turbine. (One Cooler will be
operative and other will be stand by).
d) Duplex basket type Oil Filter.
e) Oil pressure relief valve for maintaining desired lubricating oil pressure.
f) Complete piping for the lubricating oil system for turbine and gear box including non-
return valve.
g) Oil strainer.

11) Local mounted Pressure and Temperature gauges:-

a) Two Nos. Dial Thermometer in the oil inlet and outlet of the cooler.
b) Three Nos. Dial type Thermometers for Turbine bearings.
c) Four Nos. Dial type Thermometer for gear box bearings.

12) Safety systems incorporated in the turbine :-

a) Emergency over-speed governor of the unbalanced ring type to automatically shut down the
turbine if speed rises ten percent (10%) above the rated speed.
b) Sentinel valve for warning of exhaust pressure build-up.
c) Manual Trip knob/handle on the Turbine.
d) Remote push button trip through solenoid with audio-visual alarm.
e) Low lubrication oil pressure trip with audio-visual alarm.
f) Axial movement trip with audio-visual alarm.
g) Alternator ACB should trip when Turbine CSEV trips with alarm.
h) Over speed trip with audio-visual alarm.
i) High Back Pressure trip with audio-visual alarm.
j) High Inlet steam temperature alarm.

13) Remote control desk with following instruments :-

a) One No. Dial type Electronic Tachometer ;
b) One No. RPM relay for Tachometer ;
c) One No. DOL starter for AOP motor ;
d) One No. Amp meter for DOL starter ;
e) One No. Indicating lamps for A.O.P. motor “ON”.
f) One No. Indicating lamps for A.O.P. motor “trip”
g) One No. Rotary switch for raising and lowering of turbine speed.
h) One No. Inlet Steam Pressure Gauge.
i) One No. Chest Steam Pressure gauge.
j) One No. Exhaust Pressure Gauge.
k) One No. 1st Cell Pressure gauge.
l) One No. Digital inlet steam Temperature Indicator with alarm output.
m) One No. Digital exhaust steam temperature Indicator.
n) One No. Lube oil Pressure gauge.
o) One No. Digital Tempera ture Indicator for lube oil temperature.

Each gauge will be provided with a tubing of 10 meters length.
14) Lagging and cladding for the turbine.
15) One set of Spanners and Tools for maintenance purposes.
16) One set of Foundation Bolts with nuts, washers & packing plates.
17) Lifting beam of rotor only, with slings.
18) Five Copies of Service and Maintenance Manuals.
19) Five copies of General Arrangement and Foundation Layout Drawings.

EXCLUSIONS :

Inlet and Exhaust steam pipelines, cooling water pipelines, companion flange, steam
separator, relief valve, , exhaust valve, by-pass valves ;
 Any consumables stores and site services;
 Any civil work, foundation, building etc;
 All cables and bus bar trunking between alternator and control panel;
 Expansion bellow for inlet and exhaust ;
 First fill of lubricating or flushing oil ;
 Any other item not specified in scope ;

G. SCOPE OF SUPPLY FOR ALTERNATOR & CONTROL PANEL.
TECHNICAL PARTICULARS OF 3000 KW BRUSHLESS SELF-EXCITED AND SELF-REGULATED,
STEAM TURBINE DRIVEN A.C. GENERATOR
1 Rating A) 3750 KVA
B) 3000 KW
2 Power Factor 0.8 Lagging
3 Speed 1500 r.p.m.
4 Voltage 420 Volts (400 - 440 V)
Voltage variation 420 Volts ± 10%
5 i) No. of phases Three
ii) Rated Current 5155 Amps.
6 Frequency 50 Hz at 1500 r.p.m.
7 No. of poles Four
8 Class of insulataion ‘F’ MICALASTIC,
Temp. rise limited to Class ‘B’
9 Ambient Temperature 45 Deg. C
10 Duty Continuous
11 Applicable standard IS : 4722 - 1992
12 Altitude  1000 M
13 Enclosure Closed Air Circuit Water Cooled
14 Type of protection (Generation Main) IP 54
(Excitor) IP 23
15 Mounting Horizontal Foot Mounted.
16 Bearing arrangement Double, Sleeve Bearing
17 Direction of rotation To suit Turbine’s direction of rotation.
18 Phase sequence R.Y.B. (UVW)
19 Termination 3 main & 3 neutral terminals provided at bottom.
20 Type of excitation Brushless excitation with closed AVR control
21 Vibration with complete assembly  50 Microns
22 Excitor
22.1 Type Brushless
22.2 Enclosure SPDP
22.3 Insulation Class “F”
22.4 Mounting Shaft Mounted
22.5 Excitation Voltage 112 V
22.6 Excitation Current 3.4 A
23 Efficiency
23.1 100% Full Load 96.0
23.2 75% Full Load 95.9
23.3 50% Full Load 95.1
24 Rotating Rectifier Assembly
24.1 Diode Polarity 3 Nos. Forward + 3 Nos. Reverse
24.2 PIV 1000 V
25 Automatic Voltage Regulator
25.1 Quantity 2 Nos.
25.2 Type Analogue
25.3 Model Compact
26 Cooler System
26.1 Type Closed Air Circuit Water Cooled
26.2 No. of Coolers Two
26.3 Water Quantity 362 LPM
26.4 Water Pressure 6 Kg / Cm2 g (max)
26.5 Pressure drop across coolers 0.5 Kg/Cm2g
26.6 Cooling Air Outlet Temp. 40 Deg. C
26.7 Water inlet Temperature 32 Deg. C
26.8 Water outlet Temperature 40 Deg. C
27 Bearings
27.1 Type Pedestal journal sleeve type
27.2 Quantity 2 Nos.
27.3 Grade of Oil ISO VG 46 / 68
27.4 Maximum inlet temperature 50 Deg. C
27.5 Bearing insulation Provided
27.6 Watt loss in bearing 2.5 W each
28 Accessories
28.1 Space Heater
a) Quantity 3 Nos.
b) Wattage 3 x 950 W
c) Voltage 240 V, 1 phase
28.2 Embedded Temperature Detectors
a) Type RTD (For Stator winding)
b) Material PT 100
c) Quantity 6 Nos.
28.3 Bearing temperature Indicator
a) Type Dial
b) Quantity One each for DE & NDE
28.4 Air Temperature Indicator
a) Type Dial
b) Quantity Two for inlet and one for outlet air
28.5 Sole Plate Provided

Specification for 3000 KW Alternator Control Panel

1) CONTROL CUBICLE :-

Generator control panels for 3750 KVA steam turbine driven Generator set consists of

A line up of 3 control cubicles made out of cold/hot rolled steel sheets of 2 mm thick for front and
back and 1.6 mm thick for sides totally enclosed, indoor type, floor mounting with hinged doors at
front and rear, having suitable cut-outs at bottom for in-comer entry and at top for load bus extension, at
both side fitted with louvers and wire mesh for air circulation and suitable for 415 Volts, 3 Phase, 4
wire,50 Hz.,AC supply. The control panel incorporates the following :

AA) BREAKER PANEL :

1) 4000 Amps Electrically operated horizontal draw-out type Air Circuit Breakers Two Nos.
designed as per IS:2516 to be read alongwith Part-I & II having a rupturing capacity
of 50 KA at 415V 50 Hz (Min.) for 1 second, each comprising of :

 Under voltage release 240V, 50 Hz, AC
 Shunt trip coil 24/30 V DC.
 Motor closing mechanism suitable for 240V, 50 Hz, single phase AC supply.
 Test, service, isolation position.
 Thermal and Magnetic releases.
 Manual operating handle.
 Automatic Safety shutters.

a) The above ACBs complete with guide frame receptacle for auxiliary control circuit are housed in
panel 1&3.

b) The shunt trip coils of both the ACBs are connected in parallel and motor closing mechanisms are
separately paralleled to operate the A CBs in parallel.

c) The ACBs are arranged in such a way that when one ACB tripped manually or by a relay, the other
ACB trips automatica lly. Two sets of mechanical castle locks with one key used to interlock the two
ACBs with ACB of Hydel / Diesel supply. One lock is fitted in the above ACB and the other to be
supplied loose for fitting in ACB of hydel / Diesel supply.
2) Electrical grade aluminium bus bars of capacity 6000 Amps for each of the One Set
three phases and 3000 Amps for neutral designed for 45 deg C ambient
and tempera ture rise not exceeding 85 deg C when operating at rated capacity.

3) Metering and Relay Panel :-

a) Misc. Ammeter scaled 0-6000 Amps, Size 144mm x 144mm, AE/IMP Three Nos.
accuracy plus minus 1% as per IS:1248-1968.

b) LTCTs ratio 5300/5A,Cla ss 1 for metering.(not less then 20 VA) Three Nos.

c) Misc. Voltmeter, Range 0-500V, Size: 144mm sq, accuracy plus AE/IMP One No.
minus 1% as per IS:1248-1968.

d) Six way voltmeter selector switch size 75 mm x 75 mm, name Kaycee One No.
plate marked RY/YB/BR/RN/YN/BN.

e) Frequency meter REED type scaled 45-50-55 Hz. Size 144mm x AE/IMP One No.
144mm, accuracy plus minus 1% as per IS:1248-1968.

f) Power factor meter 3-phase, 4 wire, scaled 0.5 lag Unity - 0.5 AE/IMP One No.
lead, size 144mm x 144mm, accuracy plus minus 2%.

g) KW meter 3 phase, 4 wire, unbalanced load suitably scaled, AE/IMP One No.
size: 144mm x 144 mm, Accuracy plus minus 1.5% as per
IS:1248-1968.

h) KWH meter, suitable for 3 phase, 4 wire, unbalanced load GECA One No.

i) DC Voltmeter sca led 0-100V, Size 144mm x 144mm One No.
Accuracy Plus Minus 1% as per IS : 1248-1968 (Supplied with excitation panel).

j) DC A mmeter, scaled 0-10 Amps Size :144mm x 144mm One No.
Accuracy: Plus Minus 1% as per IS:1248-1968.
(Supplied with excitation).

k) KVAR meter 3 phase, 4 wire, unbalanced load, suitably scaled One No.
size 144 mm x 144 mm. Accuracy + 1.5 % as per IS 1248-1968.

l) KVA meter 3 Phase, 4 Wire, unbalanced load suitably scaled size One No.
144 mm x 144 mm. Accuracy + 1.5 % as per IS 1248-1968.

4. Current and Voltage Protection.

a) Triple pole IDMTL Over-current Relay, type, CDG-61, having setting from 50% EE One No.
to 200% and instantenous setting adjustable from 200 to 800%, aux. voltage 24/30V DC.

b) Single pole IDMTL earth fault relay type CDG-21, having setting from 10 to 40% EE One No.
instantaneous setting adjustable from 200 to 800%, Aux. Voltage 24/30V DC.

c) LT CT ratio 5300/5A, Class 10P10, for over current protection EE One No.

d) LT CT ratio 5300/5A, Class 10P10, for earth fault protection EE Three Nos.

e) Triple pole Differential type CAG-34, having setting from 10 to 40% of 5 A One No.
alongwith stablising resistor.

f) LT CTs ratio 5300/5A ,Class PS for differential protection Six Nos.

g) High speed tripping relay type VAJHM -13 / VAJHM – 23 Two Nos.

h) Over voltage relay having setting from 110% to 170% of 110V, and time setting One No.
adjustable between 0 to 7 secs, Aux. Supply 24/30 VDC.

i) Under voltage relay VDG- 13 having setting from 50 to 90% of 110 V, EE One No.
Aux. Supply 24/30V DC.

j) Potential Transformer 25VA, 420/110V for the above two voltage relays One No.

k) Discrepancy Rela y type VTT 11 EE One No.

l) D.C. Monitoring relay One No.

5. Annunciation :-

5.1 Audio visual alarm annunciation having suitable number of windows One Set
for following indication.

i) - Over current trip
ii) - Earth fault trip
- Differential relay trip
iii) - Under voltage trip
- Over voltage trip
iv) - High Generator winding temperature trip
v) - Turbine High back pressure trip
- Turbine high speed trip
vi) - Turbine low lub. Oil pressure trip
- Turbine shutdown
vii) - Turbine Axial movement trip

6.0 Operator Controls :-

6.1 Indicating lamp for following.
i) Generator voltage healthy One No.
ii) DC Supply ON One No.
iii) Generator space heater ON/OFF One Set
iv) Increasing Bus Bar Alive (RYB) One No.
v) Bus Bar alive on load side (RYB) One No.

6.2 Temperature indicator with alarm and trip facility (6 Nos. for windings). One No.

6.3 Control Switches for DC SUPPLY ON / OFF, Space Heater SUPPLY ON/OFF Three Nos.
SUPPLY ON/OFF for DC Failure Relay.

6.4 Neutral isolating switch of suitable capacity mounted in the front side of panel One No.
with handle projecting outside the door.

6.5 Push Botton actuators with elements Eight Nos.

i) Mushroom headed red push button for Turbine Trip
ii) Mushroom headed push button for A CB Trip
iii) Shrouded Blue Push Button for fault reset
iv) Unshrouded yellow push button for Acknowledge (2 Nos)
v) Unshrouded Push Button for lamp test.
vi) Shrouded green push button for ACB/Close.
vii) Unshrouded push button for Diode Failure.

6.6 Door Limit Switches One Set

6.7 Panel illumination la mp suitable for 240V, single phase 50Hz AC Supply One Set
with ON/OFF switch.

7. Accessories :-

i) Panel Space Heaters, 230 V, 50 Hz., AC supply One Set
ii) Hooters Two Nos.
iii) Danger Plates One Set
iv) Contactors with coil energised by 240V, Single phase 50 Hz, for turbine aux. supply One No.
v) Contactors, 240 V AC for acknowledge. One No.
vi) Cable glands for differential CT cables, DC supply cables, exciter field cable One No.
generator spa ce heater cables, Temperature detector cables, Aux. AC supply cables,
turbine aux. AC Supply Cables.

NOTE :-

1) Arrangement is made to trip ACB when turbine trips, Arrangement is also provided to interlock ACB with
client’s ACB.

2) Arrangement is provided to make Generator voltage collapse simultaneously when the ACB trips
due to faults.

3) The control panels duly wired with ferrule markings provided with name plates, dial pla tes,
fuses, lifting eye bolts is painted with light grey shade No. 631 of IS:5 on the outside and oyster
for inside portion.

Secondly to be design, supply, erection and commissioning with IBR test certificates, drawings and
approval of Boiler inspector of all formalities completed the following job which are related to run the
steam turbine on line.

1) High pressure seamless steam pipe line from our Boiler H.P. Header to steam turbine to with stand
pressure 32 Kg/Cm2, temp. 380 ± 20o C with flanges completely approx. 80 mtr. long.

With steam separator in line and expansion below with IBR test certificate with drain valve, traps and
releted pipe line.

2) High pressure Header to be modified for extra connection to be provided to this multi stage turbine of
500 mm diameter size with suitable length. Bhel make High Pressure gate valve to be provided at this
stage of suitable size as per design of pipe line with IBR Test Certificate class 600 to suit for working
pressure 32 Kg/Cm2g and temp. 380 ± 20o C.

3) Exhaust steam pipe line of size 500 to 550 and length 45 mtr. approx. To be fabricated and to be fitted at
position to outlet of multi stage steam turbine upto desuperheat-ing station and valve to be provided to
the same pipe line. Exhaust pipe line to be fabricated and to be fitted with valve towards atmosphere
incorporating 2 Nos. safety valves of size 8” Ø inlet 12” Ø outlet as per existing site condition lengths.
Drain valves and drain pipe line to be take in account.

4) Cooling water pipe line to be provided for oil coolers from our cold water header to cooler approx. 70
mtr. 4” Ø and outlet pipe line of 6” Ø approx. 70 mtr. with valves.

5) Civil foundation drawing and detail to be given.

ELECTRICAL WORK

1) Connection using necessary flexible copper joint, Alluminium busbar, control cable and busduct of
your supplied alternator outgoing terminal to your supplied alternator control panel.

2) Erection of busduct using necessary size Alluminium busbar and connect it to your supplied alter-
nator control panel A.C.B and giving tapping connection to our existing (1) 1500 KW Kirloskar main
panel (2) 1500 KW Jyoti main panel and (2) 2500 KW Kirloskar main panel through installing new
necessary size L & T make A.C.B.

3) Energy meter must be class 1 trivactor type.