TURNING GEAR AN OPERATION POINT OF VIEW.

WHAT IS A TURNING GEAR?

ITS A PINION AND GEAR ARRANGEMENT TO ROTATE A SHAFT AS A PART OF WARM UP TO PREVENT IT FROM DISTORTION AT ANY STATE. IN THIS PRESENTATION I WILL TRY PROVIDING AN IDEA ABOUT THE ROLE OF TURNING GEAR WITH SCHEMATICS AND PICTORIAL REPRESENTATIONS.

A TURNING GEAR

D11 VERTICAL

A TURNING GEAR (CONTD)

Ge 9fa

PURPOSE IN GENERAL
TURNING GEAR OPERATION DURING TURBINE STARTUP Purposes The major purposes of turning gear operation during turbine startup are: 1. To rollout shaft hogging or sagging before run up is begun.Any attempt to run up the turbine with an extensively deformed shaft is bound to fail because high vibration would sooner or later trip the turbine. Mean while the turbine generator would be exposed to continuous rubbing causing a damage in its bearings.

PURPOSE IN GENERAL(contd)
To Enable PREWARMING of the Turbine Generator. If the turbine generator is prewarmed with rotor held stationary, rotor and casing HOGGING would develop due to thermal stratification of the atmosphere in the machine as outlined in the earlier turbine courses. This would make runup impossible until HOGGING is ruled out.

What is HOGGING and SAGGING?

)
HOGGING : BENDING OF A BEAM OR ROTOR IN UPWARDS DIRECTION TO ITS AXIAL DIRECTION IS KNOWN AS HOGGING. THIS IS OCCURRED DUE TO SUDDEN ENLARGEMENT DUE TO HEAT SUPPLIED

(
SAGGING :

BENDING OF A BEAM OR

ROTOR IN UPWARDS DIRECTION TO ITS AXIAL DIRECTION IS KNOWN AS HOGGING. THIS IS OCCURRED DUE TO SUDDEN ENLARGEMENT DUE TO SUDDEN COOLING OF A BEAM OR SHAFT FROM HIGH TEMPERATURE

GE 9FA TURNING GEAR SYSTEM AND USE OF LIFT OIL.

GE 9FA SHAFT IS SUPPORTED AND MOUNTED ON 4 BEARINGS . TWO ELLIPTICAL JOURNAL BEARINGS FOR GENERATOR COLLECTOR AND TERMINAL END AND TWO ELLIPTICAL JOURNAL BEARINGS FOR THE TURBINE COLECTOR AND TERMINAL END SECTION. LUBE OIL (GRADE 32 ) IS SUPPLIED INTO THE BEARINGS FOR LUBRICATION OF THE SHAFT TO SUPPORT THE SHAFT WHILE ROTATION AND MINIMISE THE FRICTION.

GE 9FA TURNING GEAR SYSTEM AND USE OF LIFT OIL.. (CONTD)

HYDRAULIC OIL FOR GT 9FA IS TAKEN FROM THE LUBE OIL HEADER AND SUPPLIED TO TWO RECIPROCATING PUMPS. THESE RECIPROCATING PUMPS ARE CALLED AS HYDRAULIC PUMPS. THESE HYDRAULIC PUMPS ARE USED FOR TWO PURPOSES
FOR SUPPLYING HYDRAULIC OIL FOR IGV (20TV1 ),FOR ACTUATION OF LIQUID FUEL CONTROL VALVE (20FV1) AND FUEL GAS CONTROL VALV E (20FG1).

GE 9FA TURNING GEAR SYSTEM AND USE OF LIFT OIL.. (CONTD)

IT IS ALSO USED FOR SUPPLYING LIFT OIL TO LIFT THE SHAFT FOR ENGAGING IT WITH TURNING GEAR AND IS (LIFT OIL) IN SERVICE TILL 50 % OF THE SHAFT SPEED. DUAL PRESSURES FROM THE SAME PUMP IS SUPPLIED BY PRESSURE COMPENSATING FLOW DEVICE AT THE PUMP DISCHARGE WHICH IS SOLENOID ACTUATED (20 QB1)

WHAT IS LIFT OIL?

LIFT OIL OR JACK OIL IS THE OIL WHICH IS SUPPLIED TO THE BEARINGS OF THE ROTOR SHAFT AT CERTAIN PRESSURE TO LIFT THE SHAFT TO ENGAGE WITH TURNING GEAR OR FOR ANY TESTS RELATING TO FREE ROTATION OF THE GENERATOR. USING A LIFT OIL MINIMISES THE BREAK AWAY TORQUE REQUIRED FOR ROTATION OF THE SHAFT FROM REST.

WHAT IS BREAK AWAY TORQUE?

BREAK AWAY TORQUE OR BREAKING OF MOMENT OF INERTIA OF A ROTATING DEVICE. AS PER NEWTON S FIRST LAW OF MOTION ANY BODY AT ITS STATE OF REST POSSESSES SOME KIND OF INERTIA WITHIN ITSELF. THERE IS SOME AMOUNT OF ENERGY REQUIRED TO BREAK THIS MOMENT TO FORCE THE BODY TO MOVE ON OR START ITS MOTION. SIMILAR PHENOMENA HAPPENS IN CASE OF GENERATOR ROTOR ALSO

WHAT IS BREAK AWAY TORQUE?...(CONTD)

FROM REST THE GENERATOR ROTOR NEEDS TO BE STARTED TO ATTAIN SOME KIND OF MOTION BEFORE STARTUP AS DISCUSSED EARLIER. SO IN ORDER TO MINIMISE THE ENERGY TO ENGAGE THE SHAFT WITH TURNING GEAR, LIFT OIL IS SUPPLIED FROM THE HYDRAULIC PUMP AT A PRESSURE OF 2800 PSI (GE-9FA) , THE PRESSURE OF WHICH CAN VARY ACCORDING TO ROTOR MASS.

WHAT IS BREAK AWAY TORQUE?...(CONTD)

ALSO NOTE THAT IN GE 9FA THE STARTING DEVICE IS LCI (LOAD COMMUTATED INVERTER) THE SUPPLY OF WHICH IS TAKEN FROM 11 KV AUXILLARY BUS BAR THROUGH A 11 KV ISOLATION TRANSFORMER. SO IF IN ANY CASE OF OVER CURRENT WHICH CAN BE CAUSED DURING THE LIFTING OF SHAFT WITHOUT SUFFICIENT PRESSURE THE LCI MAY TRIP.

WHAT IS BREAK AWAY TORQUE?...(CONTD

SO CONSIDERING ALL THESE FACTORS THE SHAFT IS SUPPLIED WITH A LIFT OIL. I HAVE ATTACHED A SCHEMATIC OF LIFT OIL SYSTEM OF GE 9FA IN THE NEXT PAGE.

WHAT IS BREAK AWAY TORQUE?...(CONTD

TURNING GEAR SYSTEM IN STG D11

FOR STG D11 TURNING GEAR IS A VERTICAL MOUNTED SYSTEM WITH A BULL AND MESH GEAR SYSTEM IN PLACE. THE TURNING GEAR SYSTEM IN STG CONSISTS OF A LOW BOY TURNING GEAR WHICH IS AT THE BOTTOM COUPLED TO TURNING GEAR MOTOR AT THE TOP. THIS LOW BOY TURNING GEAR IS ALSO KNOWN AS PIGGY MOTOR WHICH ENGAGES ITSELF WITH THE SHAFT. THE LOWBOY TURNING GEAR IS ACTUATED WITH ELECTRO PNEUMATIC SIGNAL FORM THE TURNING GEAR MOTOR MOUNTED AT THE TOP OF IT.

WHY LIFT OIL IS NOT REQUIRED FOR STG D11 TURNING GEAR?
D11 TURNING GEAR IS NOT SUPPLIED WITH A LIFT OIL AS THE STG IS ROLLED BY USING STEAM. THERE IS NOT EXTERNAL ELECTRIC POWER USED FOR THE SAME AND HENCE THERE IS NOT TRIPPING IN CASE OF THE MOTION OF THE SHAFT IS CONCERNED. SO PROVIDING A LIFT OIL WILL BE AN ADDITIONAL INPUT TO THE SYSTEM WHICH IS A WASTE OF DESIGN.

WHY LIFT OIL IS NOT REQUIRED FOR STG D11 TURNING GEAR?
ALSO INITIAL ROLLING OF THE STEAM IS SUPPLIED AT AROUND A PRESSURE OF 20 BAR FROM IP REHEAT INTERCEPT VALVE WHICH IS QUITE SUFFICIENT TO COUNTER THE BREAK AWAY TORQUE EFFECT. ALSO THE STEAM TURBINE IS SUPPORTED WITH ELLIPTICAL JOURNAL BEARINGS WHICH ARE WELL CAPABLE OF RETAINING OIL AT SUFFICIENT PRESSURE. NOTE THAT THE OIL USED HERE IS USED FOR LUBRICATION.(GRADE 46 OR 32). NOT THE LIFT OIL WHICH IS AN ETHER (EHC FRYQUEL)

WHY LIFT OIL IS NOT REQUIRED FOR STG D11 TURNING GEAR?

ELLIPTICAL BEARINGS.

 HOPE THE ABOVE PRESENTATION WAS USEFUL FOR U I WILL MAKE ANOTHER PRESENTATION RELATING TO OPERATION AND MAINTENANCE OF TURNING GEAR IN STG AND GT. IN THE NEXT SESSION.