marc steam turbine.pdf
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MARC® Steam TurbinesThe Modular Steam Turbine Generation
MAN TurboEngineering the Future – since 1758.
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Originating from the Blohm+Voss shipyard, MAN Turbo AG Hamburg today combines
the experience of a traditional company with state-of-the-art technology.
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The first steam turbines under the name
of Blohm+Voss were manufactured in
1907, initially for ships built in the ship-
yard and subsequently for electric power
generation. Since 1952 the company
concentrated on developing and manu-
facturing industrial steam turbines. The
list of worldwide references encompasses
more than 2,000 turbo generators.
A wide range of renowned companies
and utilities use our turbines, mainly in
Industrial power plants
Cogeneration plants
Waste incineration plants
Biomass power plants
Combined Cycle plants
Our modern manufacturing facilities in
Hamburg are equipped with machine
tools of high performance and cover a
floor area of more than 10,000 m2. The
quality management system is certified
to DIN EN ISO 9001. Centrally situated
in the free-port of Hamburg, MAN Turbo
offers ideal transport links, enabling
even large components to be trans-
ported with ease.
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The concept
The customers’ demand on durability, efficiency and economy has always had
top priority for the development of BVI steam turbines. The result of our perma-
nent development is a solution that sets new standards: The MARC (Modular
ARrangement Concept) turbine series has proven its high quality throughout
more than 100 installations since its market introduction in 1998. This modular
turbine concept allows a flexible arrangement of the auxiliary components and
enables the overall assembly to be set up in line with individual requirements.
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The turbo generator unit comprises the
following modules:
Steam turbine
Gearbox/generator unit
LP lubricating oil system
HP control oil system
Control cabinet
The lubricating oil module, control oil
module and the control cabinet can be
individually arranged around the unit.
Benefits of the modular concept:
Proven turbine design with robust
technology and high availability
Space-saving, low-noise epicyclic
gear generator unit (up to 25 MW)
High level of efficiency thanks to
optimised turbine design and use of
epicyclic gearing
Use of proven system modules for
lubricating oil and control oil
Compact control cabinet as black-
box for connection via bus system
to the central control system
Low investment costs
Five different turbine sizes cover a per-
formance range from 1.5 MW to 50 MW.
The MARC production programme
includes backpressure, heating and
condensing turbines that can also be
fitted with extraction and bleed ports.
Explanation of type codes:
MARC x - A B C
x – Code for turbine size
A – Code for turbine type
C: Condensing
B: Backpressure
H: Heating
B– Number of controlled extractions
C– Number of bleed ports
MARC TurbinesModular ARangement Concept
Electric power up to 3 MW
Max. flange diameterLive steam: 125
Exhaust: 700
Max. live steam conditions 30 bar(a) / 480°C
up to 15,000 1/min
Electric power up to 12 MW
Max. flange diameter Live steam: 200 Exhaust: 1,200
Max. live steam conditions 90 bar(a) / 520°C
up to 12,000 1/min
Electric power up to 22 MW
Max. flange diameterLive steam: 250Exhaust: 1,500
Max. live steam conditions 120 bar(a) / 520°C
up to 10,000 1/min
Electric power up to 35 MW
Max. flange diameter Live steam: 300 Exhaust: 2,200
Max. live steam conditions 120 bar(a) / 530°C
up to 8,000 1/min
Electric power up to 50 MW
Max. flange diameter Live steam: 350Exhaust: 2,600
Max. live steam conditions 120 bar(a) / 530°C
up to 6,000 1/min
MARC 6MARC 4MARC 2MARC 1 MARC 8
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Turbine type B:
Backpressure
Backpressure turbines are used as gen-
erator drive units in combined heat and
power plants and for on-site electricity
generation of industrial facilities. They
are also used in cogeneration applica-
tions.
Turbine type C:
Condensing
The areas of application for condensa-
tion turbines range from turbo genera-
tors for industrial power plants and
waste incineration systems through to
biomass facilities.
The extraction steam is typically used
for heating, production purposes and
feed water prewarming. To achieve op-
timum part-load efficiency, the LP part
can also provided with a nozzle group
control.
Turbine type H:
Heating
The typical application is electricity
and heat generation. The special feature
of this turbine type is the double-flow
exhaust for connect-ing a two stage
heating system. This design provides
the most efficient way of electricity and
heat production throughout the year.
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With the MARC concept developed in
the mid-1990’s, MAN Turbo has suc-
cessfully established itself in the bio-
mass power plant market sector from
4 - 20 MW electrical output. MAN Turbo’s
operational experience with steam tur-
The new MARC 1
The success formula of the MARC 2 has been transferred to a new MARC model in the power
range of 1.5 - 3 MW. Built on the design principles of proven turbines and the positive opera-
tional experience gained, the new MARC 1 turbo generator has been developed specifically for
use in the smaller segment of biomass applications.
bines previously supplied for biomass
power plants provides compelling evi-
dence of the economic efficiency and
operational reliability of this concept.
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Turbine module
In industrial turbines, part of the steam
often is extracted for production pur-
poses, heating steam systems or gen-
erative feed water heating. In that case,
in addition to several bleedings, two
controlled extractions can also be pro-
vided. The MARC concept allows an
individual and optimized design of the
different turbine elements, according to
specific requirements, such as the pres-
sure level and the extraction steam
quantity.
Depending on the live steam conditions
and the specified operation mode, either
a nozzle group control with or without
bypass or a throttle control may be se-
lected. The control stage, either single
or two-row type, and the number of re-
action stages are especially adapted to
the specific requirements. For all reac-
tion stages the low-loss round-head
profile is used.
The HP blades are provided with milled
shrouds, whereas the last blade rows
are mostly designed with conically twist-
ed blades, the blade ends of which
being tip-thinned on one side.The rotor
blades of the last rows are grouped by
means of damping and bind-ing wires in
conformity with the results of vibration
calculations. Due to the small flow
volume, steam admission of the im-
pulse wheel is only necessary in the
upper casing half, how-ever, the lower
half can also be utilized, if required. In
that case, a bypass leads to the lower
nozzle group.
The exhaust casing is a welded con-
struction and may either be fitted facing
upward or downward, depending on
the site conditions. MARC steam tur-
bines have been designed for highest
operating security and utmost reliability.
As the highest thermal impact on the
steam carrying parts occurs at load
changes, the casing, guide blade carrier
and inner casing have been developed
for a high thermal elasticity.
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The following design features apply
for all turbine types:
multi-stage reaction design
maximum symmetry of the upper
and lower casings
symmetrical temperature distribution
at the circumference in all cross-
sections under all load conditions
single-piece forged rotor
labyrinth sealing glands between
rotor and casing
split tilting pad sleeve bearings
self-aligning axial bearing, for double-
sided loading
nozzle group control
guide blade carrier
Turbine rotors
The reaction turbines are supplied with
a drum-type rotor. The turbine rotors,
the balance piston and the impulse
wheel disc as well as the subsequent
drum parts are solid forging of high tem-
perature material.The rotor design is
based on modern calculation methods
to meet the highest demands regarding
smooth and resonant-free operation.
The bladed rotors are statically and dy-
namically bal-anced at operating speed
in a modern high-speed vacuum balanc-
ing plant, in a way that the shaft vibra-
tions over the whole speed range
are considerably below ISO10816 per-
mitted values.
Bearings
The radial bearings are of multiface
sleeve or tilting pad type. A stable rotor
position is maintained by hydrodynami-
cal oil wedges, equally spaced on the
circumference.The axial forces resulting
from pressure differences in the blading
are mainly absorbed by the balance
piston. A double-sided segmental axial
bearing absorbs the residual thrust and
the coupling forces.
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Bearing Pedestals
The bearings are located in two bearing
pedestals on which the turbine casing
rests by means of brackets on the level
of the horizontal joint. The exhaust con-
nection of condensing turbines rests on
lateral supports on the level of the hori-
zontal joint. Due to this form of arrange-
ment, the position of the rotor to the
casing and thus, the radial blade clear-
ance remain virtually constant under all
load and temperature conditions.
Labyrinth Sealing Glands
The steam sealing between the turbine
rotor and the casing located at the
casing’s ends as well as at the balance
piston is a labyrinth sealing type. The
sealing strips of high-temperature ma-
terial are caulked into the rotor.
Blading
In the blading, consisting of control
stage and reaction part, the potential
energy of the high-pressure steam is
converted into mechanical energy.
Control Stage
Due to partial admission, a high degree
of dynamical tension occurs in the
blades of the control stage. This tension
is reduced by grouping the blades in the
shrouding.Highly loaded control stages
are designed with blade triplets, mean-
ing that three blades having one root
together are machined from one work-
piece.
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Reaction Part
The multi-stage reaction blading ensures
utmost reliability and economy due to
high mechanical and thermal
strengthen both guide blades and
rotor blades to withstand operating
stress
a large sectional modulus to avoid
vibrations.
low flow losses in the blading covering
a wide operating range.
The guide and rotor blades have the
same profile. It was theoretically and
experimentally tested during its devel-
opment. Hereby, the characteristics of
the profile, depending on the cascade
arrangement and the entry angles, were
determined by measurements in a plane
wind tunnel.
A characteristic feature of partload ope-
ration is the entry angle deviating from
the normal line of flow. The impact-free
entry angle range is very large and en-
sures a high part load efficiency at oper-
ating conditions different from those of
rated load.
The clearance and rim losses of back-
pressure turbines and high-pressure
parts of condensing turbines are re-
duced to a minimum by using shrouds.
The blade with root and shroud is
machined from one piece. After blading
the rotor, the shrouding is machined to
its form. Regarding stages with a low
clearance loss factor, the blade tips are
provided with a one-sided thinning.
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Control mechanism
The steam control valves of MARC tur-
bines are of a diffuser type. Small valve
dimensions allow a vast number of val-
ves and nozzle groups. Consequently,
the throttling losses are kept low also at
part load. The cone form of the valve
has been optimized regarding the flow.
Valve spindles, valve cone and valve
bar consist of heat-resistant steel with
hardened, wear-resistant surface. The
hardening is effected via a plasma-
hardening process.
Due to the small valve dimensions, the
steam control valves can be actuated
directly. This so-called group drive is
a compact and reliable solution. The
actuator is a single acting hydraulic
cylinder which is fed by the control oil
system at an oil pressure of 160 bar.
On turbine tripping or full-load dis-
connection the valves are closed by
the pre-loaded spring, thus, protecting
the turbine plant at malfunctions. If the
pressure in the control oil system de-
creases, both the control valves and the
tripping devices will be closed automa-
tically, as they act on the same principle
(single-acting hydraulic piston against
pre-loaded spring). This means double
security for the turbine and the steam
system. A lever system for parallel mo-
tion of both valve spindles precisely
transmits changes of the controller out-
put onto the valve bar and – depending
on the valve lift – on one or more valve
cones. The moving parts are made of
non-corrosive and maintenance-free
self-lubricating material. The valve
spindles are sealed by maintenance-
free, pre-compressed graphite lami-
nated glands, and reinforced carbon
guide bushes.
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Gearbox and generator are installed as
one compact unit. For the MARC 2 and
the MARC 4, generally an epicyclic
gearbox is used which is flanged directly
to the generator. For the types MARC 6
and MARC 8 either an epicyclic or a
helical gearbox is used, depending on
power and speed.
The application of epicyclic gearboxes
bear the following advantages:
The offset usually caused by a helical
gearbox is avoided, which greatly facili-
tates the alignment. Moreover, one
coupling and the high-speed gear
bearing are omitted which improves
the total efficiency.
Gearbox/Generator module
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Lubrication oil module
The lubrication oil system* is a compact
module designed as a low-pressure oil
system for turbine, gearbox and gene-
rator, consisting of:
complete set of 2 main oil pumps
emergency oil pump with DC motor
oil cooler
redundant oil filter
oil mist fan
temperature control valve
pressure control valve
* For MARC1: Combined lubrication
and control oil system.
Diagram of thelubrication oil system
1 Turbine2 Turning gear3 Extraction4 Exhaust steam5 LP control valvel6 HP control valve7 Trip valve8 Gearbox9 Generator
10 Oil tank11 Main oil pump 112 Main oil pump 213 Emergency oil pump14 Oil cooler with cooling
water connections15 Oil filter16 Oil mist fan
Lubrication oil system Turbine Gearbox andgenerator
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Control oil module
The control oil system is a compact
module. The main components are:
oil tank designed as base frame
main oil pump with AC motor
pressure tank
redundant oil filter
bypass pump
oil cooler
measuring and control system
Apart from the control valves, the system
also feeds the live steam trip valve and, if
necessary, the extraction-trip valves and
control devices in the extraction with a
system pressure of 160 bar, commonly
used for hydraulic systems.
Control oil system Turbine Gearbox andgenerator
Diagram of thecontrol oil system
1 Turbine2 Gearbox3 Turning gear4 Generator5 LP control valve6 HP control valve7 HP trip valve8 Extraction non-returnflap
9 Turbine governor10 Generator cooler11 Extraction12 Exhaust steam13 Oil tank14 Circulation pump15 Control oil pump16 Control oil cooler17 Pressure tank
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Ethernet
or
Profibus
Data storage
Central Processing Unit
(CPU)
Vibration monitoring
Turbine open-loop controller
Turbine closed-loop controller
Turbine protectionand monitoring
Generatorprotection
Generatorcontroller
FunctionHardware
Overspeed protection
Generatorprotection
Voltagecontroller
coscontroller
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Measuring and Control System
Control cabinet
The turbo set control cabinet is a com-
pact unit that can be arranged flexibly
around the turbine unit. All control
functions and protection of the turbine
and generator are integrated in a single
control box with a user interface on the
front. This saves space and ensures mi-
nimal installation and commissioning
time.
All desired signals can be sent via a
databus (e.g. Ethernet or Profibus) to a
host control system, and operational
commands and setpoint values can be
received from there.
Control system
In order to maintain flexibility when mee-
ting the varied process requirements,
the turbine control system is implemen-
ted in the modern programmable logic
control (PLC) system S7-400. The com-
prehensive range of modules enables
flexible and user-friendly handling of a
wide range of communication options
to other systems and problem-free
expansion, should additional tasks be
required. Startup, shutdown and opera-
tion of the entire turbine unit are com-
pletely automated in the control system,
with ease of use being one of its key
features.
Based on many years of experience in
the field of turbo generator operation,
we have developed a digital steam tur-
bine controller. The inte-gration of this
controller in the existing control system
hardware enables a contin-uous control
concept and optimal integration of the
controller without additional interfaces.
The steam turbine controller is a power-
ful and flexible device. Speed, output,
pressure and temperature are optimally
controlled and critical variables are
limited. All control modes are seam-
lessly integrated.
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Control room
Control cabinet
Measurementtransducer
Emergencyswitch-off
Har
dwire
d
Low voltageswitchgear
Control box
Limit switchTurbinetrip valve
Field
Mean voltage switchgear
Ethernet or Profibus
MP270-B SIMATIC CPU 414 - DP I/O Rack
ISDNRouter
Data LoggerPC
Generatorprotection
Overspeed protection
Voltagecontroller
Hardwired
ExternalTrips
Turbine
Hardwired
Lubrication Oil
Control Oil
Condenser
Pressure
Temperature
Vibrations
PC
Profibus
Operation
The turbo generator can be operated
either via a central control system or lo-
cally, directly via the operator interface
on the control panel. In automatic mode
only the turbine start/stop commands
and specification of the setpoint values
are required. All operating modes and
fault messages are displayed locally and
supplied to the control system via a bus
system. In manual mode, local control
of the auxiliary modules and compo-
nents is possible.
Safety
All turbine units are provided with ex-
tensive safety equipment that safely shuts
down the steam turbine and generator
when critical conditions are reached.
The classification of safety criteria is in
accordance with IEC 61508. Measure-
ment systems, trip and alarm criteria are
specified in such a way that an optimal
balance between machinery protection
and availability is achieved. If desired,
the design also enables unattended
24-hr operation.
Remote access
A datalogger with ISDN interface enables
remote support for your operating
personnel: Important operating data is
saved to a datalogger and can be ana-
lysed by our Service Team, while our
service engineers have direct access to
the control system and control panel.
This enables us to provide you with
quick and cost-effective support.
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Quality Assurance
The most important principle of turbine
manufacture is to ensure high quality
standards for all components. The
turbines are subjected to the follow-
ing checks during the manufacturing
process.
Material inspections
Castings inspection
Production inspection
Assembly inspection
Continuous quality control is ensured
by the ISO 9001 quality management
system.The turbine and baseframe are
erected and the internal piping is instal-
led on the assembly bed. The gear-
ing/generator modular unit is assembled
at the generator manufacturer and
subjected to a functional check. As with
the other modules, both oil modules are
tested at the manufacturer prior to their
installation adjacent to the turbine on
site.
In order to meet the requirements for
quiet running, operational safety and
high availability of the steam turbines,
each turbine rotor is subjected to high-
speed dynamic balancing and spin
testing in a vacuum spin test facility.
After this acceptance test the rotor can
be installed.
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Service
Our experienced Turbine Service
Department ensures the professional
installation of the supplied turbine unit,
including commissioning and trial ope-
ration. The operating personnel concur-
rently receive training as required.
MAN Turbo provides person-al consul-
tancy and optimum support for service
and repair work as well as for retrofit-
ting. Maintenance and revisions are
coordinated between our service
department and the customer. Our
experienced service staff is available
night and day to assure the recommis-
sioning of the plant.
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In the interests of technical progress,
subject to change without notice.
Printed in Germany. December 2008
Turbo 1002 e 1208 1.5 ba
MAN Turbo AG
Steinbrinkstrasse 1
46145 Oberhausen/Germany
Phone +49. 208. 6 92-01
Fax +49. 208. 6 92-20 19
www.manturbo.com
MAN Turbo – a member of the MAN Group
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