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Vacuum System Improvement

TNEB had recently replaced the full set of HP, IP, and LP Steam Turbine rotors with new ones. During the shutdown several modifications were initiated outside the main STG rotor system, with a view to improve STG performance. At earlier times, when the unit was running at 70-90 MW after R&M, the vacuum was always poor and affecting the unit output.

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Charu Chhabra
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63 views

Vacuum System Improvement

TNEB had recently replaced the full set of HP, IP, and LP Steam Turbine rotors with new ones. During the shutdown several modifications were initiated outside the main STG rotor system, with a view to improve STG performance. At earlier times, when the unit was running at 70-90 MW after R&M, the vacuum was always poor and affecting the unit output.

Uploaded by

Charu Chhabra
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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PROJECT:

Ennore TPS Unit 3 - 110 MW

PROBLEM: 110 MW Vacuum System improvement In Unit 3 - 110 MW of Ennore Thermal Power Station M/s. TNEB had recently replaced the full set of HP, IP, and LP Steam Turbine rotors with new ones. During the shutdown several modifications were initiated outside the main STG rotor system, with a view to improve STG performance. At earlier times, when the unit was running at 70-90 MW after R&M, the vacuum was always poor and affecting the unit output. A comprehensive effort was made with all round focus on the vacuum and related systems. Listed below are the important measures taken: 1. LP Casing parting plane modification: Grooves were cut in the in LP Casing parting plane and a silicone cord was introduced for sealing against air ingress. 2. LP Casing metal stitching Metal stitching was done in cracked sections of the LP Casing to seal the steam space from air ingress. 3. Polymer cladding of condenser Polymer cladding of condenser CW water boxes and parting planes was done to reduce the seawater corrosion of water box material. CW parting plane corrosion has resulted in poor condenser heat transfer because of CW short circuit.

4. Introduction of priming ejector in CW lines A Priming ejector was introduced for air removal in condenser CW lines and water boxes for achieving full CW flow. 5. Rerouting of LPHs 1&2 drains: LPHs 1&2 drains were modified in consultation with BHEL (HYD) to route them to condensate pump suction as per original scheme. 6. Segregation of turbine extraction and pipeline drains: The steam from high pressure MS, CRH and HRH drains, and most other low pressure drains, were earlier connected to Service Condensate tank ( SCT) with a provision to be connected to condenser or to atmosphere. This resulted in additional thermal loading of the condenser, and was an undetectable source of air ingress. The SCT was isolated from the condenser by blanking its vent and drain connections to vacuum system, and converting it to a purely atmospheric pressure vessel for startups. Thus high temperature steam has been diverted away from the condenser to reduce thermal loading on it. At the same time the extraction line drains were removed from SCT and connected to HPH Flash Tank. 7. Rerouting of LPH and HPH e xtraction drains HPH 7,8 and LPHs 3,4,5 extraction drains from pipelines, downstream of NRVs were routed to HPH Flash tank in consultation with BHEL (HYD). This was required to ensure the drains in the vacuum system were segregated from the SCT. 8. Replacement of Ejectors New Ejectors were installed with enhanced air handling capacity, considering the age and corrosive atmosphere in these old units at Ennore.

9. LP Gland Steam pressure tapping modification LP Gland Steam pressure tapping was relocated at the LP front gland seal with NB 65 impulse pipe header for accurate measurement for auto control. 10. HP Gland steam line introduced HP Gland steam line for HP gland packing was introduced from 11 ata PRDS header since it was not envisaged in earlier SKODA design. It was one of the major reasons for air ingress from HP Gland seals in this steam turbine, that prevented achieving of full vacuum, when there was no self sealing steam while STG on barring gear. 11. Condenser water tightness test The Condenser tightness test was conducted by filling water upto TG floor (7.9 meters). Water was retained in the condenser for 36 hours and zero drops in level was achieved for this period after attending all the leaks. 12. LP Gland Steam header drain modified. A drain was introduced in the LP Gland Steam header, with a steam trap and trap bypass to condenser, since it caused hammering in the sealing steam lines every time these lines were charged during vacuum pulling. With this, most of the air ingress to condenser, and its thermal loading points have been taken care of. The drain modifications were undertaken by TNEB on the request of PSSR, on the original SKODA system, with the support of BHEL Hyderabad T & C Engineering for attaining full load and improved steady state behavior of the machine at higher loads.

The unit was restarted recently in March 2006. During the restart when vacuum was pulled in this modified system, 0.95 ksc (approx 720 mm Hg of mercury) vacuum was achieved with STG on barring gear. 715 mm Hg of vacuum was found to be maintaining stably under steam dumping, rolling, synchronization, and load conditions.

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