Engineering the Future – since 1758.

MAN Turbo

Industrial Steam Turbines

MAN TURBO offers a highly compre-hensive range of steam turbines with proven performance for industrial applications as well as municipal power utilities.

Our core competence is the delivery of complete turbomachinery trains for industrial processes and electricalpower generation including auxiliary equipment such as:

condensing units oil supply systems thermal and acoustic insulation base frames and steel foundations.

MAN TURBO’s range of steam turbines is based on a modular system thatallows standardised steam turbine com-ponents to be combined in order tomeet a specific customer requirement. Proven steam turbine modules, thathave demonstrated a high level of relia-bility in operation, constitute a funda-mental element of the design.

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The large variety of inlet, admission/extraction and exhaust sections guaran-tee optimum matching to the client’s requirements; condensing turbines can be provided with either a radial (top or bottom) or an axial exhaust. The MAN TURBO steam turbine series can accom-modate powers up to 120 MW and speeds up to 14,000 rpm.

Product Range

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1 40 MW extraction condensing steam

turbine with an axial exhaust

2 Three 38 MW condensing steam turbines for a 300 MWe combined-cycle power plant

3 Range of application

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Power output

Speed

Inlet pressure

Inlet temperature

Exhaust volume

Backpressureturbines

Condensionsteam turbines

MW

rpm

bar

°C

bar

m3/s

5-120

up to 14,000

up to 130

up to 570

up to min. 0.02

up to 1,300

5-120

up to 14,000

up to 130

up to 570

up to 40Exhaust pressure

Innovations introduced by MANTURBO in recent years include:

High temperature inlet casingsTransonic exhaust stagesAxial exhaust casings Variable guide vanes for controlled extraction.

Process control and turbomachineryprotection requirements are handled by the modular MAN TURBO turbolog® control & monitoring system.This digital system continuously guarantees safe and reliable plant operation.

MAN TURBO provides innovative solutions for industrial applications. The following business areas are typicalfor our products:

Chemicals/PetrochemicalsRefineriesOil & GasFertilizersPulp & PaperSteel productionFood processingPharmaceuticalsMunicipal power generation.

Optional supplies and services include:

Foundation calculationsMechanical running tests atMAN TURBO for steam turbinesor complete turbomachinery trainsErection, commisioning and trialplant operationTraining of operational staff.

To maintain our well-developed globalcustomer relationships, MAN TURBO’sservice center is available 24 hours aday with nearly 100 years of soundexperience in the steam turbine industry.

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4 Steam turbine generator set

5 turbolog® DSP control and protection system

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Flexibility:

Modular SolutionsThe modular design of MAN TURBO’ssteam turbines builds the base for optimum efficiency under all operatingconditions.

Standardised modules are available forkey turbine components, such as bear-ing housings, inlet casings, controlstages and exhaust ducts.Furthermore, the modular systemincludes standardised bleed, extractionand admission sections. All this resultsin mature design of the turbine withhigh flexibility regarding the layout ofcasing sizes, number of stages, rotortype and distribution of the nozzlegroups.

Usually each turbine MAN TURBOmanufactures is tailor-made. In order tominimise the risk of unplanned shut-down periods, the modules are derivedfrom thoroughly tested componentsthat have been in operation for thou-sands of hours with proven reliabilityand availability.

Fig. 6 shows the different modulegroups with the options for combiningthese in a line diagram; one possiblecombination from the MAN TURBOmodule system is illustrated in Fig. 7.

R5/A8

7 Example of an extraction condensing turbine derived from the module system

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Inlet casing

Transition pieceExtraction module

Exhaust casing,condensing turbine

Exhaust casing, backpressure turbine

R

VE

A

G

6 Modular design system

R 1

R 2

R 3

R 4

R 5

R 6

V 1

V 2

V 3

V 4

V 5

V 6

E 1

E 2

E 3

E 4

E 5

E 6

A 1 ´

A 2 ´

A 3 ´

A 4 ´

A 5 ´

A 6 ´

A 7 ´

A 8 ´

A 9 ´

A 10 ´

G 1

G 2

G 3

G 4

G 5

G 6

Steam Turbine Types:

Condensing TurbinesThe MAN TURBO condensing steamturbine features a horizontally split maincasing of cast steel; the exhaust casingis a fabricated construction which inturn is welded to the upper and lowerpart of the main casing.

One advantage of this design is thatsealing problems, that may occur withcross partition joints, are completely eliminated, hence power losses are kept to a minimum.

The turbine fixed point is located at theexhaust casing support. The rotor fixedpoint relative to the turbine casing is thetrust bearing housing at the live steamend.

8 Sectional drawing of condensing steamturbine

9 Condensing steam turbine driver foran axial compressor

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Backpressure TurbinesThe turbine features a single horizontallysplit cast casing incorporating the control stage as well as the transitionand exhaust casing modules.

10 12 MW backpressure turbine

11 Sectional drawing of a backpressure turbine

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Extraction TurbinesExtraction steam turbines are designedto operate and control the client’s steamnetworks using defined steam parame-ters.Depending on the mode of operation,quantity of steam and pressure, threedifferent methods of extraction controlare possible:

extraction control stage overflow throttle valvevariable guide vanes.

The valves of an extraction control stageare located in the upper part of the cas-ing. The extraction nozzles can bearranged downwards or towards theside. The minimum cooling steam flowrate for the low-pressure blading is alsoensured at the maximum extraction rate.

12 Variable guide vanesin open position

13 Sectional drawing of a double extractioncondensing steam turbine, the first is a controlled extraction with control stage,the second extraction uses an overflow throttle valve.

Guide vane

Adjustment lever

Guide rollers for adjusting ring

Bearing bush

Guide vane carrier

Adjusting-ring

14 25 MW double-extraction condensingsteam turbine

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Steam Turbines with Central AdmissionCentral admission turbines are used inparticular for large power plant unitswith maximum efficiency requirements.

Machines of this type are distinguishedby their extremely low leakage steamlosses at the balance piston.

15 Central admission turbine during assembly

16 45 MW steam turbine for a CHP plant

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Reliable and Economical:

The Design

Axial ExhaustMAN TURBO steam turbines with anaxial exhaust flow to the condenseroffer an economical alternative to con-ventional turbines which have theexhaust duct in lower casing half andconsequently require a mezzaninearrangement.

The in-line arrangement with an axialexhaust allows significant savings in civil works.

CasingAll steam turbines made by MANTURBO have a horizontally split casing ofcast steel. The guide vane carriers aresupported thermoelastically inside themain casing.

State-of-the-art materials are used forthe casing and the guide vane carrier.

The partition joint bolts are uniformly preloaded by an hydraulic tighteningdevice without the application of any torque. Bolt stresses can be measureddirectly during the assembly and thedevice also allows simultaneous tighten-ing of the bolts. A further advantage is that assemblytimes are shortened.

18 Pre-tensioned partition joint bolts usinghydraulic tensioning device

17 Condensing steam turbine with axial exhauston transport frame

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Bearing housingand bearingsThe modularised design system includesa standard range of bearing housingsfor the live steam and exhaust sides ofthe turbine. The housings are made ofcast iron and located on the centre-lineof the turbine from pedestals on thebaseframe.

Several journal bearing diameters areavailable for each size of bearing housingand are designed either as multi-lobe(lemon shaped) or tilting pad bearings.

The axial bearing assembly is arrangedseparately from the journal bearing in thelive steam side bearing housing. Thethrust bearing is designed as a double-acting segmental bearing for both direc-tions of rotation and thrust.

Self-balancing thrust bearing designscan also be used. In the case of steam turbines featuringan axial exhaust, the rear bearing hous-ing is an integral part of the exhaustcasing.

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19 Assembly of a condensing steam turbine

20 Sectional drawing of bearing housingshowing bearing arrangement

Actuators and ValvesThe actuators used in MAN TURBOsteam turbines are distinguished by theirexcellent control characteristics, shortresponse times and insensitivity to inletpressure fluctuations.

The control valve design is characterised by:

optimum part-load efficiency (minimal throttle losses) due to nozzle group control flow-optimised valve design due to diffuser configuration seizure of the valve stem is avoided due to continuous movement of all four valves during operationactuator spindle leakage minimised as the two spindles supporting the bar-lift beam are provided with graphite packings with leakage steam removal. linear characteristic (valve stroke versus steam throughput) due to optimised plug form and stroke overlap between valveshigh wear resistance due to the use of heat-resistant steels for valve spin-dles, lifting beam, valve cones and diffusers, with additional surface hard- ening of spindles and valve stems.

Fig. 22 shows the arrangement andfunction of the valve control system onMAN TURBO steam turbines; the tripvalve and control valves are opened byoil pressure.

The hydraulic actuator moves the twospindles and thereby the lifting beam;the control valves are attached to thelifting beam and open & close graduallyin line with their individual stem lengths.

The control valve position is determinedby the speed governor.

In the event of an emergency trip, loadshedding or oil pressure failure, thespring force ensures that the entire sys-tem, control valves and trip valve, close,tripping the turbine in the minimum of time.

The trip valve is located to the side ofthe control valve casing and can betested whilst the turbine is in operation.The steam strainer is also integratedinto the trip valve housing and is easy to maintain.

21 Steam turbine upper section with flanged steam chest

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22 Valve chest with control valves and trip valve

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23 Full admission steam chest design forhigh live steam conditions (temperatures up to 570°C)

Inlet casingTwo types of inlet casing are available:

Standard CasingThe standard inlet casing is an economi-cally efficient, proven design for livesteam temperatures up to 500 °C. The complete control valve housingassembly is connected to the main turbine casing using a flanged or weldedjoint. Control stage nozzles are fitted inthe upper section of the wheel chambercasing.

High-temperature casingFor live steam temperatures up to570°C, an internal casing admits steamto the upper and lower sections of thecontrol stage. This thermo-elasticdouble casing design ensures trouble-free operation with demanding livesteam conditions and provides a highlevel of machine flexibility with changesin temperature and load.

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24 Rotor of a steam turbine for a compressor drive application

RotorsAll steam turbine shafts are single pieceforgings and the choice of materialdepends on the requirements of theindividual application. State-of-the-artmaterials guarantee that MAN TURBOturbines are highly reliable.

The shape of the rotor is matched indi-vidually to the steam path and isdesigned to ensure a long machine life.Safety margins relative to lateral & tor-sional critical speeds, take into accountnational and international standards, aswell as MAN TURBO’s own quality criteria.

Our production process and qualityassurance system for steam turbinerotors meets the highest standards.Thermal stability testing follows pre-machining of the rotor. This measure, inconjunction with high-speed balancing of the bladed rotor assembly in our ownbalancing facility, assures maximum availability and smooth running duringoperation.

In order to compensate the axial thrustwhich arises in reaction machines, MANTURBO steam turbines are equippedwith a balancing drum; the residual thrustis compensated by the axial bearing.

Shaft GlandsShaft glands in the turbine casing are sealed by means of contact-freelabyrinth seals; the labyrith strips arecaulked into easily replaceable sealbushings.

BladingSimilar to the modularised casing ele-ments, MAN TURBO has standardisedstator and rotor blades in a variety ofblade series. The profile system, whichis graduated according to chord lengthand stagger angle, is optimally coordi-nated with regard to aerodynamic andstrength factors. The complete bladefamily allows a turbine to be configuredso that over all possible operatingspeed ranges blade vibration resonanceis excluded.All guide vanes and rotor blades aremanufactured from corrosion-resistantchromium steels.

Control StageA single impulse stage or a Curtis wheelis used to control the turbine. The rotorblades are milled complete with integralshrouds from a single piece and in thearea of the shrouds laterally caulkeddamping wires are inserted for optimumvibration damping. The radial gapbetween the rotor blade shrouds andthe guide vane carrier is sealed bymeans of labyrinth sealings strips tominimise losses.

On single impulse control stages theblades are attached to the rotor by apinned root, whereas for Curtis wheelcontrol stages double T-roots are used.

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High-pressure/Intermediate-pressure bladingThe blades used in these sections havea drop-shaped reaction profile with arelatively large radius on the leadingedge. This makes the profil insensitiveto variations in angle of incidence overa wide operating range and ensuresgood profile efficiency, even in the part-load and overload range.

The milled shrouds of the rotor bladesreduce losses at the blade tip, therebyincreasing efficiency. The shroud gap issealed against the guide vane carrier bylabyrinth seals. T-root, double T-root orpinned root fixings are used to attachthe rotor blades, depending upon themechanical load.

Low-pressure bladingIn the low pressure section, above acertain ratio of blade length to hubdiameter, the rotor blades have twistedprofiles.

These blades are designed as free-standing, tapered blades with or with-out damping wires. The modular sys-tem includes T-root, double T-root andpinned root attachment options for thelow-pressure blades. Surface hardeningis also available, depending upon theapplication.

28 Control stage

27 Blade family

25 Low-pressure blading

26 Intermediate-pressure blading

29 Guide vane carrier

Guide vanes and guide vane carriersGuide vane carriers are suspended ther-moelastically in the turbine casing and aresplit horizontally.

Furthermore, the guide vane carriers arelocated axially by a shoulder in the tur-bine casing. In the horizontal plane, theyare supported at the casing split joint byalignable spigot bolts and adjusted verti-cally by eccentric bolts. These fixing elements permit free expan-sion of the vane carrier in the radial direc-tion and enable a centring fit under alloperating conditions. The symmetricaldesign ensures dimensional stability evenin the event of rapid temperature changesto maintain constant radial clearances.

The guide vanes are fitted into the guidevane carrier by means of a hook root andare provided with a riveted shroud.

Grooves in the low-pressure guide vanecarrier remove free water via holes to theexhaust casing and so, directly on to thecondenser. This feature substantiallyreduces the free-water in the wet sectionof our condensing turbines and reducesexhaust stage erosion to a minimum.

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30 Guide vane carriers for high-pressureand low-pressure sections

Applications

The design of steam turbines used formechanical drive applicationsuch as pumps, blowers or compres-sors, must be flexible to adapt to theprocess requirements; flexible designsolutions are therefore particularlyimportant.

The ability to operate over a wide rangeof speeds makes the steam turbine anideal choice to drive a variety of processmachinery.

In addition the steam parametersrequired by the process are providedvia the extraction, admission and bleedconnections on the turbine.

MAN TURBO’s core competenceincludes planning, design, construction,delivery, erection and commissioning ofcomplete turbomachinery sets, com-prising one or more steam turbines,compressors and, where applicable,expanders. Support systems and auxil-iary units required for normal operation usually from part of our supply.

31 Compressor train with condensing steam turbine

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32 Steam turbine with axial exhaustin a combined-cycle power plant

Based on our continoussteam turbine developmentprogram, we are in an excel-lent position to deliver innova-tive and economic solutionsfor our customers worldwide

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Generator drivesWe supply condensing and backpres-sure steam turbines up to power out-puts of 120 MW to drive electrical gen-erators.

These are used for municipal powergeneration as well as for industrialpower plants. MAN TURBO steam tur-bines are distinguished particularly bytheir economic integration into heat &power cogerneration systems.

Steam turbines are also used in com-bined-cycle power generation applica-tions where wast heat of the gas tur-bine exhaust gas is recovered in orderto generate steam for the steam tur-bine. This technology has enormousmarket potential and is environmentallyfriendly, as maximum levels of electricalefficience are achieved.

MAN Turbo AGSteinbrinkstrasse 146145 Oberhausen / GermanyPhone +49. 208. 6 92-01Fax +49. 208. 6 92-20 19www.manturbo.com

MAN Turbo AG SchweizHardstrasse 319 8005 Zürich / SwitzerlandPhone +41. 44. 278-22 11Fax +41. 44. 278-29 89

MAN Turbo AGEgellsstrasse 2113507 Berlin / GermanyPhone +49. 30. 44 04 02-0Fax +49. 30. 44 04 02-20 00

MAN Turbo S.r.l. De PrettoVia A. Fogazzaro 536015 Schio (VI) / ItalyPhone +39. 0445. 6 91-5 11Fax +39. 0445. 5 11-1 38

MAN Turbo AGHermann-Blohm-Strasse 520457 Hamburg / GermanyPhone +49. 40. 3 70 82-0Fax +49. 40. 3 70 82-19 90

In the interests of technical progress, subject to change without notice.Printed in Germany.March 2008Turbo 945 e 0308 2,0 ba