1-Lube oil Pump capacity (M3/Hr) of steam turbo generator = 2 X Turbine capacity in MW
For example: 20 MW turbine needs lube oil pump of capacity = 2 X 20 = 40 M3/Hr
2-Capacity of Control oil pump = Lube oil pump capacity X 10%
For example, 20 MW Turbine needs a Control oil pump of capacity = 40 M3/hr X 10% = 4 M3/Hr.
3-Main oil tank capacity of Steam Turbo generator = 225 X Total oil flow to the tank (Lube oil pump + Control oil pump)
For example, 20 MW Turbine needs a MOT of storage capacity = 225 X (40 + 4) = 9900 M3 or Litres
4-Over head oil tank storage capacity of Steam Turbo generator = MOT storage capacity X 35%
For example, 20 MW Turbine needs a Over head tank of storage capacity = 9900 X 35% = 3465 = 3500 appx.Litres
5-Capacity of Emergency oil pump = Main oil pump capacity X 30%
For example, 20 MW Turbine needs a emergency oil pump of capacity = 40 M3/hr X 30% = 12 M3/Hr.
6-Oil cooler Heat load in KW = Lube oil pump flow X 10
For example, 20 MW Turbine needs a oil cooler of heat load = 40 M3/hr X 10 = 400 KW.
7-Heating surface of a Lube oil cooler = Lube oil cooler Heat load in KW X 20%
For example, 20 MW Turbine needs a oil cooler of heating surface = 400 KW X 20% = 80 M2
8-Quantity of lube oil flow to Turbine bearing = Total Lube oil flow X 65%
For example, Lube oil flow to 20 MW Turbine bearings = 40 M3/Hr X 25% = 10 M3/Hr
9-Quantity of lube oil flow to Turbo Gear box bearing = Total Lube oil flow X 65%
For example, Lube oil flow to 20 MW Turbine bearings = 40 M3/Hr X 65% = 26 M3/Hr
10-Quantity of lube oil flow to Alternator bearings = Total Lube oil flow X 10%
For example, Lube oil flow to 20 MW Turbine bearings = 40 M3/Hr X 10% = 4 M3/Hr
11-Reciprocating air compressor Power consumption = Free air delivery (FAD) in M3/min X Discharge Pressure in Kg/cm2
For example, A reciprocating air compressor of FAD 8.75 M3/min and Discharge pressure 8 Kg/cm2 will consume power = 8.75 X 8 = 70 KW
12- A screw compressor Power consumption = Free air delivery (FAD) in M3/min X Discharge Pressure in Kg/cm2 / 1.5
For example, A screw air compressor of FAD 8.75 M3/min and Discharge pressure 8 Kg/cm2 will consume power = 8.75 X 8 / 1.5 = 47 KW (appx)
13-Cooling water flow in M3/hr for a reciprocating air compressor = Free air delivery in M3/min X 140%
For example, Cooling water required for a reciprocating air compressor of FAD 8.75 M3/min and Discharge pressure 8 Kg/cm2 will consume po = 8.75 X 140% = 12.25 M3/hr
15- As a Thumb rule: Capacity of instrumentation air compressor in m3/min = Power plant capacity in MW/4
For example, a 20 MW power plant needs instrument compressor of capacity = 20/4 = 5 M3/min (1-working + 1-Standby)
16- Capacity of Service air compressor = Power plant capacity in MW/4.2
For example, a 20 MW power plant needs instrument compressor of capacity = 20/4.2 = 4.76 M3/min (1-working + 1-Standby)
17-For a condensing cum extraction steam Turbines, maximum extraction steam flow = Inlet steam flow X 70%
And, minimum exhaust steam flow to condenser is Inlet steam flow X 10%
18-For a condensing cum extraction steam Turbines, minimum extraction steam flow = Inlet steam flow X 10%
And, Maximum exhaust steam flow to condenser is Inlet steam flow X 70%
19-Oil vapour extraction fan capacity in m3/sec of a steam Turbine as per thumb rule =Total lube oil flow to the MOT (AOP and COP oil) X 9
For example, a 20 MW steam Turbine will have Oil Vapour extraction fan of capacity = (40 M3/Hr+4 M3/Hr) X 9 =396 M3/sec
20-As a Thumb rule, main cooling water (MCW) flow for surface condenser = Maximum exhaust flow X 70
For, example, as a Thumb rule a 20 MW Turbine of maximum exhaust of 80 TPH, needs circulating cooling water through surface condenser = 80 X 70 = 5600 M3/Hr
21-As a thumb rule auxiliary cooling water (ACW) flow = Main cooling water flow X 8%
For example, a 20 MW Power plant needs total auxiliary cooling water for Generator air cooler, oil cooler, Boiler feed pump, air compressors etc = 5600 X 8% = 448 M3/Hr, 450 M3/Hr appx
So, Total circulating cooling water = MCW + ACW = 5600 + 450 = 6050 M3/Hr
22-As a thumb rule, Cooling tower storage capacity = Total circulating cooling water X 25%
For example, A 20 MW power plant’s cooling tower capacity for total cooling water circulating flow is; 6050 X 25% =1513 M3, 1500 M3 (Appx)
23-Capacity of MCW pump = Main cooling water flow X 60% (For 2 Working & 1 stand by pump)
24-Capacity ACW pump = ACW Water flow i.e 450 M3/hr (1-Working & 1-Standby)
25-Cold start up of Turbine: after a shut-down period exceeding 72 h (metal temperatures below approximately 40 % of their fully-load values in 0C)
25-Warm start: after a shut-down period of between 10 h and 72 h (metal temperatures between approximately 40% and 80 % of their full-load values in 0C)
26-Hot start: after a shut-down period of less than 10 h (metal temperatures above approximately 80 % of their full-load values in 0C)
27-Cold start up– when HP and IP inner casing temperature is lower or equal 170oC
28-Warm start up- when HP and IP inner casing temperature is lower or equal 430oC
29-Hot start up – when HP and IP inner casing temperature is greater than 430oC.
30-During cold start up turbine inlet steam minimum temperature should be saturation temperature at the particular pressure + 50 Deg C.
Example: Turbine operating at 67 kg/cm2 pressure, its inlet steam temperature should be285+50 =335 deg C
31-Turbine bearing normal vibration in microns = 2400 / Sqrt (N), N: Turbine speed
32-Turbine bearing alarm vibration in microns = 4500 / Sqrt (N)
33-Turbine bearing alarm vibration in microns = 6600 / Sqrt (N)
34-Bearing Lube temperature = 45 Deg C
35-Bearing drain oil temperature = Lube oil temperature + 15 deg C
36-Bearing metal normal temperature =Lube oil normal temperature + 25
