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44
STEAM POWER PLANT TURBINE
A steam power plant continuously converts the energy stored in fossil fuels ( Coal, Oil or natural gas ) or fissile fuel ( uranium, thorium ) into shaft work and ultimately into electricity. The working fluid is water, which sometimes in the form of liquid and sometimes in the state of vapour phase during its cycle of operation. Energy released by burning of fuel is transferred to water to generate steam at high pressure & temperature, and then it expands in turbine to a low pressure to produce shaft work. The steam leaving the turbine is condensed in a condenser. Thus it follows the cycle -
Steam Turbines are of two types : 1. Impulse Turbine 2. Reaction Turbine. 1. Impulse Turbine : In impulse turbine fixed nozzles are used for expanding steam to convert steam pressure into kinetic energy of steam. The high velocity steam impulse acts on the moving blades to rotate the turbine shaft.
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Sl.No. 1. 2. 3. 4.
Location of Steam H.P. Turbine inlet I.P. Turbine inlet I.P. Turbine exhaust L.P. Turbine exhaust
From above it is seen that steam expansion in L.P. Turbine is 58 times. 210 MW LPT and 210 MW KWU IPT & LPT are of double flow turbines. 3. Reverse Flow Turbine :
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Dummy Piston: High pressure & temperature steam when expands in a single flow HP turbine along the axis of the shaft, it develops a huge amount of axial thrust acting on the shaft in the direction of steam flow. To reduce / minimize this axial thrust a dummy piston is provided at the inlet of turbine .A force opposite to the axial thrust is generated in dummy piston. The value of axial thrust is more in a reaction turbine than in an impulse turbine. Thrust Bearing: Thrust bearing is provided to absorb unbalance axial thrust generated in turbine. It is located in between HP & IP turbine at central pedestal. The bearing is called as Michel type tilting pad bearing. The wedge shaped cavity between thrust pad & shaft collar is filled with oil. Diaphragms : Diaphragms are located inside inner casing of turbine to house stationary blades. The fixed blades in an impulse turbine have the form of nozzles mounted in diaphragms. Diaphragms are fixed in both upper & lower halves of the cylinder casing by means of keys so that during expansion of the cylinder fouling with the shaft seal is avoided. LP turbine diaphragms are cast type. The cast type diaphragms are made of iron castings with steel nozzle plates embedded in them. To avoid leakage of steam across the diaphragms seals are provided in between shaft and diaphragms. TURNING GEAR / BARRING GEAR : Turning gear motor drives the TG shaft at a slow speed before steam rolling to avoid the need of large quantity of steam flow to get the rotor moving from rest. This avoids unwanted thermal stress on the rotor shaft. After shutdown of turbine, various parts of it remain at high temperature and uneven cooling of the same takes place, which in turn may cause shaft bending and misalignment. To avoid this TG shaft is rotated at slow speed through barring gear for uniform cooling. In LMW turbine Turning Gear is mounted on LP Generator coupling. It rotates TG shaft at 3-4 rpm. by a turning gear motor. In KWU turbine the shaft is rotated by a hydraulic turbine at around 120 rpm. Before putting the TG on barring gear the following must be ensured : Generator seal oil is established. ( to avoid rubbing of seal block). Turbine lub oil system is established. Jacking oil pump is running properly. There is a provision of hand barring to rotate turbine shaft by engaging hand barring manually in case of failure of barring gear driving mechanism. Metallurgy of Turbine : Turbine operates at high temperature & pressure. Hence Creep & fatigue failure of the shaft may occur. Considering these factors the metallurgy of turbine shaft is selected. When any component is under thermal stress at high temperature for a considerable period creep stress occurs. The material may fail due to this creep stress. It varies directly with the duration of time. Creep failure occurs at the blade attachment with the rotor shaft. Thermal fatigue develops after repeated cyclic reversal of thermal stresses. This happens due to repeated heating & cooling of turbine. If steam temperature is fluctuated repeatedly at the inlet of HP & IP turbine fatigue failure may occur. Considering the above the metallurgy of the turbine should be : Good creep resistance at high temperature. High fracture toughness. Good mechanical toughness. Good proof strength. HP & IP rotors are made from Cr Mo V ferritic steel.
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LP rotors requirement is low temperature high tensile strength and high toughness. For this it is made of 3.5Ni Cr M0 V material. Expansion of Turbine: The turbine casing and rotor expands and contract due to heating and cooling. Due to difference of metal mass of rotor and casing the rate of expansion and contraction are different. The casing may expand both in radial and axial directions. Radial expansion is controlled by radial fixing points. The maximum expansion in axial direction at full load is called the absolute expansion. The casing may expand over the sliding support. The bearing pedestal is allowed to slide axially on keyways fitted between bedplates / soleplates and pedestal. Some cases pedestal bearings are fixed with the foundation and the casings are allowed to expand to one end by means of supporting feet. Axial Expansion of Rotor: For KWU 210 MW turbine the anchor point is at central pedestal i.e. at bearing no. 2. HP turbine rotor expands towards bearing no. 1, whereas IP & LP turbine rotors are expanded towards bearing no. 5. In LMW turbine HP-IP coupling is rigid one and IP-LP coupling is semi-flexible. The axial expansion of rotor is difference between HP & IP rotor expansion since IP for LMW turbine is single flow type. In 210 MW KWU turbines HP-IP & IP-LP both couplings are rigid. Permissible axial shift is 1.7 mm towards front end pedestal and 1.2 mm towards LP turbine. Axial Expansion of Casing: HP cylinder casing is anchored at bearing no. 2, so its casing expansion takes place towards bearing no. 1. IP cylinder casing is anchored at bearing no. 3, so it expands towards bearing no. 2. LP cylinder is anchored at middle of casing, so it expands towards bearing no. 4 & 5. Expansion bellows are provided I LP turbine to accommodate LP casing expansion.
Differential Expansion of Rotor: Both rotor & casing of turbine expands due to increase of temperature. Due to difference of geometry and mass of metals the expansions are different. The difference of expansion of rotor & casing is called differential expansion. Its value may be (+) ve or (-) ve. Positive expansion indicates Rotor is expanded more than casing and opposite in case of (-) ve expansion. The TURBINE BEARINGS : LMW 210 MW TG Bearing No. 1, 3, 4 & 5 are journal bearings, whereas bearing no. 2 is a combined journal cum thrust bearing. KWU 210 MW TG bearing No.1, 3, & 4 are journal bearings, whereas bearing no. 2 is a combined journal cum thrust bearing.
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Journal Bearings : Turbine Rotor is supported on journal bearings. The bearing is splitted into two halves. White metal is used as bearing metal. The bearings are spherical in shape to take over small deflection of shaft. Combine journal cum Tilting Pad Thrust Bearing : Michel type bearings are universally used to withstand heavy axial thrust of turbine shaft. It is accomplished by using oil film. Function of thrust bearing is to bear thrust load and to keep the shaft in position to maintain stator & rotor blade clearance. This bearing has a provision with a step on the back to tilt. Due to this tilting ability an oil film is formed in between shaft collar and white metal lining of thrust pad. Pads are usually fitted on both sides of the collar. This thrust bearing is combined with a journal bearing for supporting the shaft.
45
THERMAL POWER STATION TURBINE PLANT LAYOUT DESIGN & ITS LOCATION
Introduction Power station layout is concerned with the logical and economic use of space and the relationship of one piece of plant with another. The design & layout of Steam Turbine station building, which contain Main Turbine, Generator and Turbine auxiliary equipment and its system like condensing system and equipments, regenerative system & equipments, cooling system & equipments, lube oil system & equipments, feed system & equipments, compressed air system & equipments, etc are very much important for the erection cost control & easiness of operation and maintenance, good and safe working condition. An efficient turbine plant and system layout minimizes losses and running cost. Ideally, plant items should be located as close as practical considering adequate access for operation and maintenance. The best layout design of turbine plant & its system involves the correct balance between lowest cost and best arrangement from both constructional and operation point of view. The basic layout of a standard 210 MW capacity Turbine Station has already been standarised considering above stated aspects. However, the Turbine plant arrangements within the building envelope vary due to the design and manufacture of main plant items particularly Turbine, Generator, Condenser and its auxiliary equipments. The basic pattern consists of an integral building structure with Boiler and Turbine houses arranged in parallel but separated by annexe containing mechanical, electrical auxiliary plant items and its systems including instrumentation.
1. Main Turbine Plant Orientation With fossil fired plant, the important determination and
consideration for T.G. Plant layout design are a) The overall dimensions of Turbine Generator with the condensing, feed heating and general Turbine auxiliary plant with walkway and passages. b) Provision for adequate access, unloading bay, lay down area for machine parts. c) Turbine hall dimension & space for lifting generator and turbine with casing. d) E.O.T. crane for lifting and installation of equipments. e) Regenerative heaters position and location. f) Type and design of B.F. Pump, C.E. Pump, etc. g) Piping layout from Boiler to Turbine & Turbine to Boiler. Beside this, one of the most important decisions, which influences overall station layout, is the choice of the relationship between T.G. and Boiler, since both the Boiler center line spacing and dimensions of the Turbine hall can be significantly influenced by this decision. The final out come depends on
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3.
4.1 Feed Heating System It forms an integral plant of the generating process by raising the temperature and pressure of the condensate returning from the Turbine to Boiler end. In this system, a number of pumps (Boiler Feed Pumps, C.E.Pumps, Drip Pumps, etc.) and heaters (H.P. & L.P. Heaters) arranged in saris and which are linked by pipe work system. The location of each of the components in the system follow logical and defined sequence and it is important in terms of overall system economics and hydraulic performance. Each elements of this system should be correctly located in relation to the other and to the Turbine in particular. 4.2 Condenser & Condensate System The condenser is an integral part of the Turbine as it serves as heat sink & creates vacuum. Recently more conventional under-slung arrangement is preferred. In this arrangement condenser, it self located directly beneath the L.P. Turbine. The main advantages of this location are: a) Easy condenser box erection facility. b) Access for tube insertion & withdrawal. c) Convenient C.W. pipe, condensate pipe connection & optimized C.W. pipe length. d) Good water distribution and uniform flow through condenser. e) Convenient efficient air extractions system related to condenser. 4.3 Circulating Water System It serves to transform L.P.Turbine exhaust steam to water. The system-piping network located below ground and connected to condenser and Cooling Tower through C.W.Pumps.
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THEORY OF STEAM TURBINE, SPECIAL FEATURES AND CONSTRUCTION DETAILS OF TURBINE
1.
Introduction: The Steam Turbine is a most popular prime mover of generator, which requires steam as
a working fluid, a source of high-grade energy and a sink for low-grade energy. When the steam flows through the Turbine, part of the energy content continuously extracted and converted into useful mechanical work. The main objective of the Turbine designer are to ensure that this process of conversion of heat energy of steam to mechanical work is carried out with maximum efficiency, maximum reliability and minimum cost. Second objectives are that the plant should require minimum supervision and minimum starting time. Steam Turbine offers many advantages a) From thermodynamic point of view, the Steam Turbine occupies a favourable position as it can translate into mechanical work from the expansion of steam in the Turbine. Its thermal economy also good especially in Turbine of large output and operating at high pressure. From mechanical point of view, the Turbine is ideal because propelling force applied directly to the rotating element of machine.
b)
2.
2.1
Theory of Steam Turbine : Modern Steam Cycle Thermal Power Station operates by using steam in closed power cycle, where water undergoes various thermodynamic processes in a cycle process. One-half of the cycle consists of the boiler cycle (heat source) and the other half is turbine cycle, consists of turbine, condenser, feed pump and feed water heaters. Feed water supplied to the boiler drum where water is boiled and converted into saturated steam and that steam further superheated to the super heaters and then fed to the turbine where the steam expands and give-up heat energy, a high proportion of which is transferred into work energy on the turbine shaft due to change of momentum in the moving blade and increment of velocity in the nozzles and/or moving blades. The exhaust steam from turbine, which is termed as carry over loss, passes to the condenser where it condense by transferring its latent heat of vapourisation to the cooling water. This condensed water enters into hotwell and the same is pumped by condensate extraction pump through L.P. Heaters, coolers to the Deaerator and Feed Storage Tank. Boiler Feed Pumps, in turn, takes feed water from Feed Storage Tank and pumps the feed water to the boiler drum routing through regenerative heaters. In this way water cycle and steam cycle is completed. This cycle follows modified Rankin Cycle. In this cycle steam after HP Turbine outlet sends for reheating to the boiler again. The reheated steam further expanded in the IP & LP cylinder for increasing the thermal cycle efficiency. Development of various types of Turbine and their theory of operation a) Simple Impulse Steam Turbine Here steam expansion takes place in the set of nozzle and the pressure drops to about condenser pressure after expansion in nozzle. The expansion of steam results very high velocity and due to this high velocity steam jet blade/rotor velocity reaches maximum. In this Turbine carry over/exhaust loss also high and efficiency is poor. This type of Turbine is not economical and can be employed for small power generation. b) Pressure Compounded Impulse Turbine This type of Turbine construction is arrangement of number of simple impulse Turbine in series on the same shaft, allowing the exhaust steam from one Turbine to enter the next Turbine nozzle. Each simple impulse machine is termed as a stage of Turbine. Each stage comprising of a set of nozzles and blades. Here total pressure drop in the Turbine is the summation of pressure drop in each stage nozzle & for that reason the Turbine is termed as pressure compounded. Here nozzles are fitted into partition, termed as diaphragm. It separates one
2.2
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2.3
Factors of Turbine performance and sizing Turbine performance and sizing is affected by followings i) Initial Steam Pressure. ii) Initial Steam Temperature. iii) Whether reheat is used or not, and if used reheat pressure and temperature. iv) Condenser Pressure. v) Regenerative Feed Water Heating. i) Initial Steam Pressure: With increase in the initial steam pressure at constant temperature & constant condenser pressure, wetness of steam in the last stages of turbine increases, thereby reducing internal efficiency of these stages. Usually 1% moisture in steam in a particular stage results in 0.9 to 1.2% reduction, erosion becomes so severe that life of turbine in endangered. With increase in initial steam pressure, blade heights of initial stages get reduced. If blade heights of initial stage blades are less than 25 mm, this stage becomes very inefficient due to three dimensional flow and vortex formation etc. Sometimes this problem is overcome by partial admission in first or first few stages. With increase in pressure, shell thickness of casings and size of flange and flange bolts increase. Bigger and thicker flanges and flange bolts implies non-symmetric casing resulting in higher incremental stress, thereby restricting rate of speeding loading of Turbine. This problem to certain extent can be solved by using multi (double) shell design for casings or by flange and flange bolt heating arrangement.
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v) Regenerative Feed Water Heating: In modern power thermal power station, usually feed water is heated to 0.65 to 0.75 times saturation temperature in 5 to 9 heaters by regenerative heating for achieving optimum efficiency. As a consequence of steam extraction for feed water heating, increased steam flow through Turbine is required to generate the same power. Usually thermal cycle employing regenerative feed water heating will have 30% higher flow at stop valves and 30% lower flow at Turbine exhaust as compared to thermal cycle without regenerative feed water heating. This makes regenerative feed water heating even move attractive due to following reasons: a) Increased steam flow in initial stages results in increased blades heights resulting in improving internal efficiency of Turbine. b) Reduced flow at Turbine exhaust demands lesser exhaust area, resulting in smaller blades in last stages blades, which limiting factor in Turbine design. c) The decrease in steam flow at Turbine exhaust also reduces flow of working fluid through auxiliary equipment (like condenser, condensate pumps, ejectors and low-pressure heaters), thereby reducing their sizes and saving in capital investment. Construction of Steam Turbine: Main components of a Steam Turbine are i) Rotors, ii) Cylinders or casings, iii) Emergency Stop Valves and Control Valves, iv) Liners and Diaphragms, v) Blades, vi) Bearings, vii) Sealings, Viii) Barring Gear, ix) Governing and Protection System, x) Turbine Supervisory System.
3.
i)
Rotor: If the Turbine is impulse type the rotor is disc type, i.e. blades are carried in the discs, which may be integral forged with shaft or shrunk on the shaft. If the Turbine is reaction type, the rotor is drum type, i.e. blades are directly carried on the rotor. In the integral forged rotors discs and shaft are machined from one single forging. The main advantage of integral rotor is that there is no disc loosening problem and as such are commonly used in high temperature zones (H.P. & I.P.) integral rotors are expensive and difficult to forge and there is relatively high incidence of rejections. Also more material is to be removed by machining. Now a days, it is becoming more and more popular for fossil fuel Turbines. Build-up type rotors can be of two types (a) Shrunk-on disc rotor - It is used when rotor is too heavy to be forged in single piece. Shaft and disc are forged separately and are assembled after machining is shrinking of discs on shaft. (b) Welded (Hollow drum) rotors In this case discs are separately forged, rough machined and welded together at periphery to make the complete rotor. Radial holes are drilled in the rotor so that steam can go inside the voids of rotor and help in uniform heating of the rotor. Welding and subsequent heat treatment has to be performed with extreme care. Rotors are coupled by means of coupling. Earlier semi flexible coupling were used because these allowed a limited amount of misalignment and required original rigidity. In this case, each rotor required its own set of bearing. Now-a-days trend is to use rigid coupling, because in this case only one bearing is required between two rotors (because whole rotor system behaves as a single rotor).
ii)
Casings:
Turbine casings are essentially pressure vessels, their weight being supported at each end. These are therefore, designed to withstand and hoop stresses in transverse plane and to be very stiff in longitudinal direction to maintain accurate clearance between stationary and rotating components.
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iii)
Emergency Stop Valves and Control Valves: Turbines are equipped with emergency stop valves to cut off steam supply and with control valves to regulate steam supply. In case of reheat Turbines emergency stop valves are also provided in the hot reheat line. Emergency stop valves are actuated by servomotor controlled by the protection system. ESV remains either fully open or fully close. Control valves are actuated by the governing system through servomotors to regulate steam supply as required by the load.
iv)
Liners and Diaphragms: In reaction Turbines, guide blades are directly carried in the casings and hence liners and diaphragms are not generally used. In impulse Turbines, most of the pressure drop of a stage takes in guide blades resulting in higher deflection guide blades. Additional bending strength to guide blades is provided by diaphragms. Welded diaphragms are used in higher temperature zones while cast diaphragms are used in low temperature zones.
v)
Blades: Blades are single most costly element of Turbine. Blades fitted in the stationary part are called guide blades or nozzles and fitted in the rotor are called moving or working blades: Blades are of three types: a) Cylindrical (or constant profile) blade. b) Tapered cylindrical (tapered but similar profile) blades. c) Twisted (twisted and varying profile) blades. This type of blade is used for very long blades. Blades have three main parts (a) Aerofoil: it is working part of blade and is one of the types described above. (b) Root: It is portion of the blade which is held with disc, drum or casing. Three type of root arrangement are commonly used; (b1) T-Roots: from small blades; (b2) Firtree or Serrated Roots: for longer blades; (b3) Fork and Pin Root: for longer blades but it can be used with shrunk on disc type rotors only.
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vi)
Bearings: Journal bearings are manufactured in two halves and usually consist bearing body faced with antifriction tin-based babbiting to decrease coefficient of friction. Bearing body match with adjustable seating assembly in the pedestal. Bearings are usually forced lubricated and have provision for admission of jacking oil.
The thrust bearing is usually Mitchell type and is usually combined with a journal bearing, housed in spherically machined steel shell. vii) Sealings: Sealings in Turbine casings are provided to check steam leakage from H.P. and I.P. Turbines and air leakage into L.P. Turbine. Sealing of Turbines are usually Multi-labyrinth type, which provide maximum amount of throttling in a given axial length. viii) Barring Gear: Barring gear rotates the Turbine as high speed when Turbine is being started or shutdown, thus allowing uniform heating or cooling of the rotors to avoid any distortion of rotors. .
ix)
Governing and Protection System: Governing system is provided on utility steam Turbines to maintain rated speed (within steady state regulation) at all the loads and to provide predetermined load sharing among the Turbines operating in the grid. Governing system has speed control in parallel to speed governing to maintain constant speed at all the loads when set is running is isolation and change load share of Turbine when running in parallel.
x)
4. 1.
Instrumentation is provided for indication/recording of important parameters like vibrations, eccentricity, differential expansion, overall expansion, valve position and stresses in major components. Hooked up with indicators are suitable alarms and tripping mechanisms for cautioning the operating men and tripping the Turbine, if these values reach alarmingly inadmissible values. Special features of Bk.T.P.P. Turbine (Similar to KWU design): Fuji Electric Company, Japan make, Tandem compound condensing type, three-cylinder reaction turbine with reheat cycle and regenerative feed water heating system. No. of stages in H.P. = 23, in I.P. = 17 and in L.P.T = 8 x 2. Individual rotors of H.P., I.P. and L.P. cylinder are rigidly coupled. All rotors are machined from single forging. H.P. cylinder Barrel type design and permit flexible operation, rapid start-up and high load change. The casing has no flanges and hence thermal stress is minimized. The inner casing is vertically split. H.P. Turbine employed with throttle governing without a control stage.
2. 3. 4. 5.
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6.
H.P. Turbine main steam pipe connection after valve designed by easy detachable breech nut and Useal ring elements. Cold reheat pipe designed as single pipe construction tapped from H.P. Turbine exhaust for materials saving and erection advantage. The pipe divided into two sections at boiler area. I.P. Turbine is single flow double shell construction fitted with two nos. combine reheat stop valves and intercept valves to control steam flow from reheater to turbine (I.P.) and to prevent acceleration during trip-out of turbine by the remaining steam of reheater pipe and flow back to H.P. Turbine. I.P. inlet steam pipe fixed at outer casing vertically is provision of expansion in all direction fixing special type L-ring. Double flow, three casing L.P. Turbine is connected with I.P. Turbine through cross around pipe and Turbine exhaust is multi exhaust type and extraction (L.P.) tapped at difference stages for moisture control and sizing control. The L.P. exhaust directly connected to the twin condensers. L.P. Turbine gland packing with connected through bellows for keeping turbine rotor centre unaffected. H.P. & I.P. rotors, exposed to high temperature, are designed as integrally forged reaction blades with shroud and formed as rigid shaft. Therefore, blade vibration chance can be avoided. The entire turbine blading is provided with reaction blading for achieving highest efficiency. The stationary blades are inverted T or L and shrouds are machined from solid. Last three stages of L.P. Turbine blades are designed without shroud ring and of taper twisted type. Critical speed of H.P. and I.P. rotors are designed to be above normal rated speed. Critical speed of this Turbine is 3700 and 1739 rpm. The bearing pedestals of the L.P. Turbine are mounted on the foundation. L.P. cylinder carries shaft seal housing are joined with outer casing by diaphragm. Here the flexibility factor of each bearing is greater than double point bearing and the bearing type is dynamically stable. The journal bearing is double wedge type. At the bottom of bearing centre oil hole with nozzles provided for jacking of shaft. The turning gear, positioned between I.P. & L.P. rotor and at bearing no.-3, is provided with oil hydraulic type turbine for high-speed turning (80 120 rpm) by oil pressure. Turbine is provided with two nos. oil coolers of each capacity 100%. The Turbine oil pumps for lubrication and governing is directly mounted on main oil tank and oil pipe connections are welded type routed through oil canal. Turbine equipped with Electro-hydraulic governor with provision of a standard hydraulic governor as a back up. Governor impeller serves as speed detector and generates primary oil pressure corresponding to speed, which in turn regulates speed governor bellows. High pressure jacking oil system for Turbine rotor jacking during coasting down of speed or rising of speed or during turning operation is provided to eliminate chance of bearing Babbitt material rubbing.
7.
8. 9.
13. 14.
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WBPDCL
The axial shift of each Turbine is about to zero irrespective of loading. The differential expansion/contraction problem is avoided in this design for multi casing construction of Turbine cylinder. Large load dumping of Turbine, islanding and house operation, quick start-up and shutdown facilities are provided with incorporation of 60% capacity H.P. & L.P. bypass system. Important parameters: Main Steam Inlet RSV Inlet Exhaust Pressure No. of Extraction -149 Kg/Cm2, 5370 C. - 33.9 Kg/Cm2, 5370C. - 0.103 Kg/Cm2. - 6 nos.
Special features of Turbine (LMW design): 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 210 MW capacity, BHEL make, Tandem compound condensing, three cylinder, horizontal, disc and diaphragm type with nozzle governing. High pressure Turbine comprises 12 stages, 1st stage is governing stage. After H.P. Turbine steam flows for reheating and fed to I.P. Turbine of 11 stages. I.P. Turbine coupled with L.P. Turbine by semi-flexible coupling. L.P. Turbine is double flow with a multi exhaust is each flow. No. of stages is 4x2 and in penultimate stage is Baumanian exhaust provided for large moisture separation. L.P. Turbine handles 88% dry saturated steam. Three Turbine rotors are supported on five bearings. Turning gear with motor is mounted on L.P. rear bearing cover to mesh with spur gear & to rotate rotor at 3.4 rpm during start-up and shutdown. High response hydro-mechanical governing is provided for speed/load control. 30% H.P. & L.P. bypass system provided for start-up. Initial steam unloading gear is provided for unloading Turbine when main steam press drops more than 10% of rated steam pressure. Flange & stud heating system is provided for casing heating during cold start-up and rotor heating is provided for hot start-up. Main steam parameters at inlet at rated load 130 kg/Cm2, 5350C. Rated steam flow 670 T/hr, CW flow 27000 T/hr, Turbine exhaust pressure 0.08 Kg/Cm2.
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TURBINE START UP FROM COLD, WARM, HOT, VERY HOT CONDITION ALONG WITH ITS AUXILIAIRES.
TURBINE START UP 1). PREPARATION FOR TURBINE START UP.
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(a) At least one CW pump and ACW pump are running (b) Turbine lub. Oil system is healthy i.e. Auxiliary oil pump is running and AC EOP & D.C. EOP are in auto. AC JOP is running and D.C. JOP is in auto. (c) Generator seal oil system is healthy with normal H2 pressure (2Kg/cm) and normal H2 purity (> 99.5%). (d) Turbine is running at barring speed (80-120 rpm) with turning oil supply valve full open. (e) Turbine interlock system is healthy. (f) MOT oil level normal. MOT vapour extractor running and lub. Oil temp. at oil cooler outlet is more than 35C, Lub. Oil temp. control in auto & set point 40C. (g) DMSW pump is running and DMCW make up tank level is normal (h) DMCW (T) pumps running (at least one). (i) Service Air and instrument air compressors running. (j) C.T fans are running (k) At least one condensate pump (CEP) and boiler feed Pump (BFP) running on recirculation and also condensate path and feed water path are through. Check the quality of Hot well and deaerator water, if necessary take fresh DM water. (l) Hot well level and deaerator level are normal and respective controllers are on auto. 2). MAIN TURBINE PRE-WARNING: (a) Check that M.S line and H.P. bypass drain valves to unit flash tank is open. All the drains connected to HP. Flash tank should be closed and alternate drains to unit flash tank will be opened till condenser vacuum min. 320 mm Hg is achieved. HPBP warm up line valves are closed till condenser vacuum pulling. (b) Charge M.S. lines at boiler outlet pressure 10 kg / cm and temperature 200C (c) Warm up M.S. lines for 30 minutes. (d) Raise M.S. pressure to 35Kg/cm and temp. 280C (e) Put the TAS system in service and maintain its normal pressure & temp. In auto (>9kg/cm & 270C) (a) (b) (c) (d) (e) (f) (g) 4). VACUUM UP OPERATION: Gland steam exhauster is running. Put starting ejector in service after achieving gland steam header temp. more than 21C and steam pr at starting ejector >7Kg/cm. At condenser vacuum. 135mm of Hg, put gland steam controller in service and set G.S. header pressure at 0.068 kg in auto At condenser vacuum 200 mm of Hg, close vacuum breaker and put on auto. Close all atmospheric drains (connected to UFT) and open their drains to HP flash tank. Watch continuously LPT exhaust temp. Check drip line loops and ejector loops are sealed with normal water level and established. When vacuum reaches 680mm of Hg withdraw starting ejector. HP-LP BYPASS SYSTEM OPERATION: (a) After achieving vacuum (>670mm of Hg) set the HP bypass downstream temp. at 320C. (b) Ensure water supply before spray control v/vs of HPLP BP (c) After warning HP-LP bypass lines through warm up lines gradually open HP-LP bypass valves up to 5% and allow steam to flow through these lines. (d) Set the HP BP and LPBP down stream pressure at 25 kg/cm respectively and put them on auto. If required increase boiler firing rate. 5). CHECK THE FOLLOWING CONDITION OF DRAIN VALVES: (a) All the drain valves of M.S. lines are open to UFT. (b) Open all the drain of CRH and HRH lines to flash tanks (i.e. CRH 101, HRH
3).
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(c) (d) (e) (f) (g) (h) (i) (j) (k) (l) 6).
CHECK THE METAL MATCHING CONDITION : (a) Check the boiler outlet temp. and R.H. outlet temp. superheat is more than 50C (b) Check the steam purity PH - 9.0 to 9.3 ; conductivity < 1.0 mho/cm. Silica < 0.05 ppm ; total iron < 0.05 ppm It required sufficient steam dumping may be done to achieve above steam purity. (c) Raise the M.S. parameters for metal matching condition of MSV, HPC and IPS according to the following graphs. (SEE FIGURE 1 TO 5 ATTACHED AT THE END). TURBINE STEAM ROLLING: Depending upon the HP turbine outer casing metal temp. at 50% metal thickness, the type of turbine start up can be chosen: Cold start up : < 250C Warm start up : 250 -410C Hot start up : 410 -460C Very hot start up : > 460C Cold start up (HP casing temp. <250C ) Manual rolling : Select EHG Governor All the trip devices and generator relays are in reset condition Speeder gear (65M) : 100% EHG speed setter (65F) : 0% EHG power setter (65P) : 0% Slowly bring the starting device (77M) to 0% and reset the turbine (TLR). Slowly increase 77M from 0 to 42%. At 77M 0% auxiliary starts up oil will reset the trip devices and start up oil will reset stop (MSV, RSV) valves. At 42% starting device position start up oil and aux. start up oil pr. will be reduced to zero. As trip oil pr. develops at the bottom portion of stop valves, pistons, stop valves (MSV, RSV) start opening. Thus heating of MSV & RSV starts as MAL drain valves are previously opened. Full open MSV (L& R) warming drains valves (MAL-11, MAL-12). Checking the warming of MSV and RSV casing Check the MSV (L) casing metal diff. temp. < limit value (30C) Check the HP turbine casing neutral diff. temp. < limit value (30C) Check the IP rotor metal diff. temp. < limit value (30C) Check the diff. temp. of turbine casing between top & bottom HPT < 55C IPT < 65C Close the MSV (L&R) warming drain valve from 100% to 25%. Check the shaft eccentricity < 75 M. Check the LPT exhaust temp. Within limit and put spray valve on auto.
7).
(A) 1)
2) 3) 4) 5) 6)
7) 8) 9)
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Now increase the starting device (77M) position to 100% Confirm the condition for speed up from curve and metal matching condition for MSV, HPT, and IPS. Select TSC influence: ON and turbine speed raise mode selected slow (200 rpm/ min.). Selection of speed raise mode is given below:Speed change rate Start up mode Zero to heat soak (1080RPM) Heat soak to rated (3000RPM) Cold (<250C) 200 rpm/ min. 500 rpm/min. Warm (250-410C) 500 rpm/min. 500 rpm/min. Hot (410-460C) 500 rpm/min. 500 rpm/min. V. Hot (460C above) 500 rpm/min. 500 rpm/min. Set the EHG speed setter (65F) : 1080 RPM (soaking speed). This increases EHG output and thus develops secondary oil pressure to open CVs proportionately. Dont hold the turbine between 400 to 1050 rpm . In case of any trouble, decrease the speed to turning speed. Confirm that at turbine speed more than 400 rpm, turning oil supply valves closes automatically. At speed more than 500 rpm AC JOP stops on auto. Hold the turbine at soaking speed 1080 30 rpm for 30 min. for heat soaking. Check turbovisory readings are within limit HPT diff. Exp. + 4.5 to -3.0 LPT DE + 7.5 to - 2.0 LPT DE +18.5 to - 2.0 Check the following : (a) Turbine Bearing metal temp. <90C (b) Lub. Oil temp. maintaining at 40C (c ) HPT exhaust steam temp. < 480C (d) LPT exhaust steam temp. < 90C (e) Shaft vibration < 125 M (f) Bring pedestal vibration < 62 M (g) Steam purity < limiting value (h) HPT top bottom diff. temp. < 55C (i) IBT top bottom diff. temp. <65C (j) Check HPT casing, HPT rotor metal diff. temp. <30C (k) IPT rotor metal diff. temp. < 30C (l) MSV (L) casing metal diff. temp. <30C Confirm the condition for turbine speed up as per the curve for turbine speed up. Set the EHG speed setter (65F) to 3000 RPM (rated). Speed rise rate will be 500 rpm/min. Dont hold the turbine between 1110-2850 rpm. Turbine critical speeds are at 2439 rpm and 3700 rpm. In case of any abnormality such as vibration, brg. Temp. etc. crosses limit, decrease the speed to heat soak speed (1080 rpm). At rated speed (3000rpm) hold the turbine for 5 min. Close the MSV (L&R) warming drain valves and ICV(L&R) warming drain valves. At 2950 rpm AOP stops automatically. Control oil pr. > 8.5 kg/cm . Charge DM water to generator H2 gas cooler and exciter air cooler. Check all the turbine parameters similar to the checking done after soaking (1080 RPM) speed. Now synchronize the turbo-generator with grid as per the synchronizing procedure. Keep the load at 10.5 MW (5%) for 55 min. observe M.S. pr. and temp. as 70 kg/cm and 370C . Close HP connection pipe (L&R), MS line & HPC drain valves. Refer to the start up diagram, confirm the condition for load increase and check the following limiting values.
13)
17)
18) 19)
20)
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28)
1) 2) 3) 4) 5) 6)
After that load can be increased up to 24% (50MW) at rate of 1.9 % / min (4MW/min) and then increased up to 100% load at 0.95% / min. (2MW/min.). Hence at least 100 min. is required to achieve full load. 7) LPHS, HPHS, UAT, TAS LC, deaerator pegging etc are taken in to service similar to cold start up.
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It is obvious that during load increase, dt will be positive and during load decrease dt will be negative. If we plot a curve between tm & dt, then the instantaneous point can be defined on it. The point must be within allowable limit defined in the curve. Say for tm being same as that for the current point, the max. allowable dt for positive side is dtu and for negative side is dtl. Then upper temp. margin a dtu dti and lower temp. margin =dti dtl which should not fall below 15C . TURBINE INTERLOCKS AND PROTECTIONS : 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) AOP auto starts at 2280 RPM and pr.< 5.1 ksc. AOP auto stops at 2850 RPM and pr. > 8.0 kg/cm AC EOP auto starts at 1.1 kg /cm AC EOP auto starts at 1.1 kg /cm with time delay AC JOP auto starts at 400 RPM Similar for DC JOP AC JOP auto stops at 500 RPM Turning oil stop valve auto open at 300 RPM Turning oil stop v/v auto close at 400 RPM MOT oil capacity -20m, type of oil ISOVG32 Turbine over speed 3330 RPM (Mech.) 3360 RPM (Elect.) (Trip) Cond. Vac very low - 542 mm of Hg(T) - 608 mm (A) Control oil pr. low < 5.0 k Sc. (A), < 2.0 Ksc (T) Lub. Oil pr. low < 1.0 Ksc (A), trip 0.3KSc(T) Shaft vibration high 125 M (A) , trip 250 (T) LPT exhaust temp. high 90C (A), 117C (T/S),115C(G/S) trip. M.S. temp. high - 545C (A), 565C (T), M.S. temp. low - 440C (A), 430.8C (T) Turbine I/L pr. low - 63.5 KSC (A), 60 KSC (T) , when Turbine load > 40% HPT diff. Exp. + 4.75 - 3.02 (A) + 5.69 - 3.96 (T) IPT DE + 7.6 - 2.0 (A) + 8.4 - 2.9 (T) LPT DE + 18.5 - 3.0 (A) + 19.2 - 3.8 (T) Axial Thrust + 0.51 - 0.53 (A) + 0.98 - 1.03 (T) Tur electricity high> 76 M (A) Very high> 200 M (T)
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ROUTINE CHECK UP OF TURBINE AND EMERGENCY OPERATION.
The following routine check-up should be done (for turbine area) from time to time at CRT and at least once local checking must be done in a shift. TURBINE LUB OIL AREA: At CRT checkings I. MOP disch pr ii. Turbine lub oil pr iii. Control oil pr Normal value 9.0 Kg/cm(i.e ksc 2.8 ksc 8.5 ksc Alarm value 1.1 ksc(low alarm) 2.0 ksc (low alarm) Trip value 0.8ksc(V.Lo-Tur Trip) 2.0ksc(V.lo-tur trip
Check Secondary oil pr at HPCVs and IPCVs. Check AC AOP, AC EOP, DC EOP, AC JOP, DC JOP, Turning oil supply V/V, MOT Vapour extractor (stand-by), turbine drain v/v Master are in AUTO mode. Lub oil temp before & after cooler 62C/45C & 55C (Hi at cooler O/L) iv) Lub oil temp control v/v position. v) Brg drain oil temp 65C 75C (High) vi) Brg metal temp : brg-1:100C (high) 120C(v.hi- Tur trip manually) brg-2: 90C ,, --- do--brg-3,4 : 105C ,, ----do--At LOCAL checkings-
1. Look for any leakage of oil, air, steam, water etc and hear for any abnormal sound and also check approach, cleanliness of equipments.
2. Check lock out switches of AC AOP, AC EOP, AC JOP, Turning oil supply v/v, stand-by equipments, drain v/vs are in released condition. All available equipments must be in lined-up 3. Condition. 4. check turbine lub oil local pr gauge ,DP across lub oil filter (normal value below0.5ksc& high at 0.9ksc) 5. check MOT level(Normal: 0.0cm,high/low value :+7.5cm/-7.5cm),MOT oil temp,MOP disch pr,tur lub oil temp &cooling water temp before /after tur lub oil cooler,cooling wtr control v/v position,stand-by cooler status(whether back charged or not etc ) 6. Check all brg drain oil temp gauges. 7. DP across control oil filter (Normal: 0.2ksc,high:1.0ksc). 8. both JOPs are lined up from MOT & tur lub oil disch hdr,DP across jacking oil filter (normal: 0.2ksc, high:0.5ksc) TURBO-VISORY PARAMETERS: At CRT checkingsSl.No. 1. 2. 3. 4. 5. Description Axial Shift Differential expansion of HPT Differential expansion of IPT Differential expansion of LPT Diff temp bet top& bottom of HPT Normal value -0.30mm -1.1mm +3.7 mm +11.0 mm High value 0.5mm(high) +4.5mm/-3.0 mm +7.5 mm/ -2.0mm +18.5 mm / -2.0 mm 55c(high) V. High & (Trip) value 1.0mm(tur-trip) +5.5mm/-4.0mm +8.5 mm / - 3.0 mm +19.5 mm / -3.0mm 70c (trip- manual)
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80c (trip- manual
viii) check HPT,IPT,LPT I/L & O/L steam parameters, condenser vacuum, LP turbine exhaust hood temp, HP Casing temp, HP Rotor metal temp, casing inner(50% & 100%) temp, and same parameters for IP Turbine. ix) Check upper and lower temp margins of MSV, HP Casing, HP Rotor, IP Rotor, casing expansion. x) Check LP Turbine exhaust hood temp control spray v/v is in AUTO. At LOCAL Checking: i) Check all local temp, pr gauges and other meters. Check for any type of leakage. ii) Check local condenser vacuum gauges. iii) Check the position of isolation v/v (before & after) of LPT exhaust hood temp controller. TURBINE GOVERNING SYSTEM At CRT Checking: i) Check mode of operation (i.e. CMC, Turbine Follow, Boiler Follow, Manual mode) ii) IF M/C on CMC mode check load set-point, actual load, maximum /minimum load set point, effect of frequency influence, MS pr set point and actual MS pr, coal flow, load rate set point. iii) Check TSC is ON and ALFC is ON. iv) Check MSVs and RSVs opening feed-back are persisting. v) Check position of MCVs, ICVs, position reference, 77M, 65M, 77E. At LOCAL Checking: i) Check for any leakage etc. ii) Check control oil pr, secondary oil pr, aux. sec oil pr, trip oil pr, primary oil pr (in terms of rpm) iii) Check sec. Oil pr and aux. sec oil pr at MCVs and ICVs. iv) Check all pr gauges at MSVs & RSVs are showing trip oil pr. All pr and temp gauges at different areas are showing correct values. GLAND STEAM SUPPLY SYSTEM: At CRT Checking: i) Check gland steam pr set point and actual pr, gland steam temp, gland steam supply v/v and exhaust v/v position. ii) Check the v/v position of AS-9, CRH-7, and CRH-105. iii) Check gland steam exhauster status and that of stand-by gland steam exhauster. At LOCAL Checking; i) Check locally gland steam supply v/v and exhaust v/v position. ii) Check lock out switch of stand-by gland steam exhauster in released condition with duly lined up. iii) Check vacuum created by gland steam exhauster on compound gauge mounted on gland steam condenser. GENERATOR SEAL OIL & COOLING SYSTEM: At CRT Checking: i) Check hydrogen pr, purity at generator casing. ii) Check seal oil pr at turbine end and exciter end, vacuum at vacuum tank. iii) Check stand-by AC Seal Oil P/P, DC Seal Oil P/P, vacuum p/p are in auto mode. iv) check cold gas temp set point & actual temp, check hot gas temp, cold & hot air temp of exciter, cold gas temp control position, cooling water I/L & O/L temp.
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At LOCAL checking: i) Check for any leakage. ii) Check stand-by seal oil p/p , vacuum at vacuum tank, vacuum tank level, IOT level, seal oil temp before and after seal oil cooler, seal oil pr and flow at turbine end / exciter end, hydrogen gas pr. iii) Check hydrogen cooler I /L, O/L water pr/temp, position of cold gas temp control v/v. HP-BP & LP-BP AND OIL SUPPLY UNIT: At CRT checking: i) Check HP Bypass pr set point, actual pr, temp set point, BP-1, BP-2, BPE-1, BPE-2 and BD Valve position. ii) Check BP-3, BP-4 and HP Bypass drain v/vs are in closed condition. iii) Check HP Bypass oil supply unit p/ps status; ensure both oil p/ps are getting started alternately. iv) Check LP Bypass stop v/vs, control v/vs position, open feed-back & AUTO position, spray v/vs are on AUTO. At LOCAL checkings : i. ii. iii. iv. v. Check locally BP-3, BP-4 & drain v/vs lock out switches are in released condition, BD v/v isolation in open condition. Check oil supply p/ps LOS position, both oil tank oil level, p/p disch pr, supply manifold pr, auto cut in & auto cut out of both p/p. Check all filters/strainers are O.K.(whether chocked ) Check oil level of LP BP oil tank, p/p selection, p/p disch pr, filter p/p status, cooling fan status auto cut in & cut out of selected p/p ,p/p disch pr supply manifold pr. Check attemperation lines lined-up.
TURBINE EXTRACTION CYCLE: At CRT checkings: i. Check all extraction steam pr and temp parameters. Check allforce closing NRVs (FCNRV) are in open condition and OPEN feed-back is coming at CRT. ii. Check condensate/feed water pr and temp rise in each heater. iii. Check drip level set point and actual level ; position of controller to cascading, condenser and deaerator as the case may be. At LOCAL checking : i. Check locally all extraction steam pr and temp. ii. Check position of each drip controller and check their isolation v/v status. iii. Check for any leakage, hammering sound etc. iv. Check vent v/v to deaerator of running HP heaters are in open condition at both end. v. Check lock out switches of condensate/feed water I/L, O/L & by-pass v/vs are in released condition and check all drain v/vs of running heaters are in closed condition. TURBINE AUXILIARIES STEAM AND OTHER CYCLE : At CRT checking : i. Check TAS pressure set point, temperature set point and their actual values. ii. Check position of controllers (of High consumption / Low consumption hdr) of steam and attemperation. iii. Check condensate cycle, feed cycle parameters, parameters of running BFPs, CEPs and line up of stand-by equipments. At LOCAL checking: i. Check all isolation v/vs of TAS header (HC/LC) are in open condition (if available). ii. Check for any leakage, hammering sound. Also check the drain v/vs are in closed condition. iii. Check all local parameters of condensate cycle, feed cycle, for running BFPs, CEPs are normal and stand-by equipments are in lined up condition.
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EMERGENCY OPERATIONS
A) Total Power Failure:
The following prompt actions are to be taken during total power failure i.e. at blackout: 1. Check Turbine has tripped and its speed is decreasing. DC Seal Oil Pump took start on AUTO, if not taken start on auto then starts it MANUALLY. On speed reduction (at about 2200 rpm) DC EOP will take start. Confirm that Vacuum Breaker has opened; if not then open it manually. 2. Close isolation valve before gland steam supply control v/v. Isolate TAS. Close MS-1 & MS-2 at Boiler end manually if not closed by DC power. 3. Give ' OFF ' command to all running equipments, close oil v/v of all running burners. 4. Took all control valves to MAN mode from AUTO. 5. Start Diesel Generator set in the mean time, restore power of emergency bus. Start AC AOP, AC Seal Oil P/P and stop DC EOP, DC Seal Oil P/P. Start AC JOP and stop DC JOP (if turbine speed has fallen below 400rpm then DC JOP will come into service). On further reduction of speed turning oil supply v/v will open, otherwise open it manually, Turbine will be in turning. Close all extraction v/vs. Start lub oil p/ps of Mills, ID fans, FD Fans, PA Fans, BFPs. 6. If it was not possible to restore power from DG set and in the mean time auxiliary power is not restored, then turbine is to be rotated by HAND BARRING operation at small intervals. (During this time both DC EOP and DC JOP must be in service) 7. After restoration of auxiliary power and normalization of Bus, start one ACW P/P, one CW P/P. Then start air compressors and DMCW (Turbine), DMCW (Boiler), and then start one CEP on recirculation. Start CT Fans one by one as per requirement. 8. Start one set ID / FD Fan and one BFP. Start Furnace purge. Bring the Drum level to light-up level. 9. After getting clearance, lit-up Boiler and follow normal start up procedures. B) TURNING GEAR IS NOT ENGAGING AFTER DEAD STOP OF TURBINE Possible Cause: The rotor has taken Bow shaped due to temperature difference between upper and lower part. Remedy/Action: Do not try to rotate the turbine by force. Wait until the temp distribution becomes uniform. When temp falls, then rotor will come back to its original position. Then start barring gear.
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CONDENSER
1. INTRODUCTION :
The closed vessel in which steam is condensed by abstraction of heat and in which vacuum is maintained is called Condenser. Condensation of steam enables expansion of steam to a lower back pressure. The available enthalpy drop increases. Consequently more work is done and the plant efficiency improves. In our plant Surface type condenser is used to condense the exhausted steam from L.P. Cylinder and to produce vacuum in order to increase the heat drop and the turbine output beside making it possible to reuse condensate thus obtained. Optimum utilization of steam space by providing rectangular cross-section of tube nest is an added feature of this condenser. For ensuring equitable loading of condenser tubes without incurring appreciable steam side pressure drop, tubes have been segregated in small bunches leaving wide lanes between
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4. INSTALLATION :
Condenser has been floated over the springs, which take empty weight of condenser while operating weight is taken by the turbine foundation. Tube installation is tested by filling water into the condenser steam space up to one metre above the top tube row. Prior to filling water for above testing, screws provided with spring support should be used for ensuring that water weight is being passed on to them., to avoid over stressing of turbine foundation. Prior to putting the system back into operation, condenser should again be floated over springs to avoid excessive upward thrust being passed on to the turbine foundation. 5. SOME IMPORTANT INSTRUCTION : While isolating one part of condenser on CW side close the isolating valve provided in the pipe line connecting condenser with air evacuating equipment. During above operation turbine load should be reduced to 50 to 60%. Locate and plug the leaking tube by observing higher conductivity of condensate. Use copper for plugging tube ends. Attend / Replace the instruments and fitting found not functioning properly. Attend to the cause if excessive rise in CW temperature is noticed. Attend to the cause if appreciable variation in CW side pressure drop across condenser tube system is noticed.
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Investigate the reason for condenser vacuum not commensurate with turbine loading, CW inlet temperature, site barometric pressure etc. and attend to the possible causes. The best possible obtainable condenser vacuum at particular CW inlet temperature is the difference of barometric pressure minus condenser back pressure at that particular CW inlet temperature. The condenser back pressure is the pressure corresponding to saturation temperature obtained by adding 3 to 40C for terminal temperature difference to the condenser CW outlet temperature. Excessive air leakage (more than 20-30 kg/hr) into vacuum system which includes condenser, lowest LP heater, drain cooler, LP flash tank, inter connecting steam/drain side piping, fittings etc. cause deterioration in condenser vacuum. To ensure that air leakage is not excessive, conduct vacuum drop test by shutting off ejector and noting down the vacuum drop test. An acceptable vacuum system shall have the vacuum drop rate within 1 to 2 mm/min. CW side should be charged only after ensuring priming of CW system. Periodically check the vacuum system tightness.
6. TUBE LEAKAGE DETECTION : A. When Turbine Is In Operation : Condenser has been provided with the divided water chambers thus making it possible to locate the leaking tube and plug its ends, even when turbine is in operation For locating the leaked tube, concerned portion of water chambers should be isolated on CW side and tube plate should be dried commencing from top to bottom by the application of dry air. For attending above job individual can enter into the water box through the water box cover man-hole opening. Tube opening should be covered with a thin polythene sheet, which will get sucked into the failed tube end, alternatively tube ends should be scanned through with a lighted candle tick/smoke generator. The flame/smoke will get attracted in the leaky tube end. Leaky tube can also be detected by the use of U-tube manometer. Plug one end of the tube with soft rubber plug and connect the other end of the tube with U-tube manometer having colored water. Colored water will get sucked into the tube in case of leaky tube, otherwise water level will remain unchanged. B. When Turbine Is Under Shut Down : Drain the water boxes and fill condenser steam space with DM water only up to 10 M from bottom plate. Prior to DM water filling in steam space, condenser should be supported as described in Article No.4. 7. INITIAL CHARGING PROCEDURE OF CONDENSER CW SIDE : Before charging of condenser the followings should be checked : Condenser is floated over springs. At least one CEP is running on recirculation. Only ACW pump is running. CW inlet valves (CW13 & CW14) and CW outlet valves (CW15 & CW16) are closed. Condenser Water Box drain valves are closed and Water Box Vent valves are fully OPENED condition. CW/ACW Cooling Tower inlet valves are Opened position. After confirming the above conditions, Back Charge the condenser water box side by slowly crack opening of CW outlet valves CW15 & CW16. Trapped air from water box will come out from W/B vents. When sufficient water is coming out from these vents, it is confirmed that condenser W/B is fully charged. After that fully open the CW15 & CW16 and close the W/B vent valves.Then run one CW pump as per operating procedure of CW pump. After sufficient CW discharge header pressure is developed, open the CW inlet valves of condenser (CW13 & CW14). After that check the water is flowing through Cooling Tower cells. 8. CONDENSER HOTWELL LEVEL CONTROL SYSTEM : The steam from LP turbine exhaust is condensed in the condenser and this condensate is collected in the Hotwell. Condenser hotwell level is an important parameter during operation of the plant. This level is to be maintained as a controlled manner for the safe operation of LP turbine and CEP. Two electronic level transmitters (MAG11CL101 & MAG12CL101) in 1 out of 2 logic is used for hotwell level control. Normal level in hotwell is maintained by hotwell level controller (CD19) which is positioned in
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Ball Transport Piping : Ball transport pipes are installed between the ball separator extraction nozzle to the injection nozzle. These pipes are used to transport the cleaning balls from the ball extraction nozzle to injection nozzle. Control Panel : The control panel (S01) is a common control panel for tube cleaning system and debris filter, which is a programmable logic controller type which enables automatic and manual operation of the system. The control panel is fitted with a mimic diagram which explains the system functioning. Necessary audio and visual annunciations in the MIMIC for easy operation and fault tracing. Ball Oversize Cum Recirculating Monitor : The ball oversize cum recirculating monitor is to monitor the condition of cleaning balls in a tube cleaning system. Since, the cleaning balls are subjected to wear while being used , their diameter must be measured regularly. A plexiglass pipe integrally installed in the tubes system, allows to continually count the number of balls passing by and to compare their diameters with the desired size. A cleaning ball, the size of which is not less than desired value in an effective ball. If the proportion of the effective ball is less than a specified percentage or if the total number of the measured balls is less than required, the cleaning balls must be replaced. Counting and measuring the balls is made free from any mechanical contact with the use of three light barriers the signals of which are assessed by microprocessors. The course of beams of the three light barriers being perpendicular to the flow direction of the balls is set to the centerline of the plexible pipe. The course of beam of the two exterior light barriers is set so that an effective ball would interrupt both light beams for a short moment. A ball will, however, not be detected unless the light barrier ion the centre is also darkened. This allows to identify balls or dirt particles. Hence, an effective ball would interrupt all three light beams for a short moment, whereas only two light beams would be interrupted by an effective ball. Prior to the operation of program the user may define the following parameters : - measuring time of test cycle - minimum number of all measured balls per test cycle - minimum number of effective balls per test cycle During the preset period of time the unit determines the total number of balls and the number of effective balls. On termination of test cycle verification is made whether the minimum number of all measured and effective balls was reached. If not, the related alarm signals are initiated. The test cycle is repeated automatically. The alarm signals are maintained and will not be stopped or reset until the next test cycle is completed. Cleaning Balls : The cleaning balls are used for preventing formation of hard deposits and scales inside the condenser tubes. The composition of balls is based on a natural rubber mixture containing inert filler material. To ensure that all the condenser tubes are cleaned, the cleaning balls should have a specific gravity close to that of cooling water. The cleaning balls should be squeezed under water in the ball vessel about 3 times to expel air. The ball diameter should always exceed the internal diameter of the tube to be cleaned. The maximum permissible oversize is dictated by the available pressure drop across the condenser and need to avoid balls sticking in the tubes. Ball life is strongly dependent on the cleaning frequency and the surface condition of the tubes to be cleaned. 9.3. OPERATION PROCEDURE OF COLTC SYSTEM : (A) PRE-REQUISITE OR CHARGING OF CLEANING BALLS : Check all manual isolation valves [N41, N42, N21, N22, N23, N25, N31, N32] are opened , except bypass valve of Ball Vessel [N05]. Check motorized 3-way reversing valve [M01] of DP flushing system is closed. Check the Ball Recirculation Pump [F01] & DP Flushing Pump[F32] are OFF. Check the inlet & outlet motorized valves [N01 & N02] of Ball Vessel are closed. Manual bypass valve [N05] of Ball Vessel should be closed. Open the vent valve [N91] of Ball Vessel. Open the drain valve [N92] of Ball Vessel for short time. Water level in Ball Vessel falls. When water level in Ball Vessel is up to half of its capacity, close the drain valve [N92]. Open hand hole [G01] of Ball Vessel. Charging the cleaning balls and squeeze in water to remove air. Close the hand hole [G01] of Ball Vessel. Open a little bit the bypass valve [N05] of Ball Vessel. Ball Vessel will slowly filled with water. When water flows out from the vent valve [N91] of Ball Vessel, close this valve.
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Open the Ball Vessel bypass valve [N05] fully. (B) MANUAL OPERATION OF COLTC SYSTEM : Check the Control Panel is in energized condition and there is no Fail Indication persisting. Check the Ball Separator Screens [A01] are in OPERATION position. Turn the control cabinet mode of operation function Selector Switch to Manual mode. Start the Ball Recirculation Pump [F01/T91] by pressing ON PB. Open the Ball Vessel inlet valve [N01] by pressing OPEN PB. Observe the cleaning balls are circulating in Ball Vessel. After 5 minutes of Ball Recirculation Pump starting, open the Ball Vessel outlet valve [N02] by pressing OPEN PB. Now the system is under operation. Balls are circulated. Ball movement can be observed when viewed through the sight glass of Ball Vessel & V-Piece. Start Ball Oversize Cum Recirculating Monitor by pressing ON PB (if required). This monitor starts counting the effective and total number of balls in circulation. Check the DP across the Ball Separator Screens in DP indicating controller. Stop the Ball Oversize Cum Recirculating Monitor by pressing OFF PB. After certain time of manual operation (1 hr) , close the Ball Vessel outlet valve [N02] by pressing CLOSE PB. 30 minutes later close the Ball Vessel inlet valve [N01] by pressing CLOSE PB. Stop the Ball Recirculation Pump [F01/T91] by pressing OFF PB. Manual Operation Of DP Flushing System : When DP measuring system is in operation, lamp indication for Backwash & Emergency Backwash will be available when DP exceeds the set limit (30 mbar & 50 mbar respectively). DP flushing system will have to be initiated manually when the system is in Manual mode. Start DP Flushing Pump [F32/T92] by pressing ON PB. Open 3-way reversing valve [M01] by pressing OPEN PB. After a certain time close 3-way reversing valve [M01] by pressing CLOSE PB. Stop DP Flushing Pump [F32/T92] by pressing OFF PB. (C) AUTO OPERATION OF COLTC SYSTEM : Check the Ball Separator [A01] Screens are in Backwash position. Confirm balls are available in Ball Vessel. Check Ball Vessel vent valve [N91] & drain valve [N92] are fully closed. Check Ball Vessel bypass valve [N05] is fully opened. Setting the timer of ball collection time [Tb : ball collection time = 1 hr] and flushing operation time [Tf : flushing time = 30 min.]. Operation time of tube cleaning is 1 hr. Turn the control cabinet mode of operation function Selector Switch to AUTO. Check Ready To Start lamp is ON. Start the system by pressing Automatic Start PB Now observe the following operation steps in auto mode : Ball Separator Screens turn to OPERATION position. Ball Recirculation Pump [F01] starts. Ball Vessel inlet valve [N01] opens. Cleaning balls circulate in Ball Vessel. 5 minutes later Ball Vessel outlet valve [N02] opens. After completion of operation time [1 hr] Ball Vessel outlet valve [N02] closes. After completion of ball collection time [30 min] Ball Vessel inlet valve [N01] closes. Ball Recirculation Pump [F01] stops. (D) AUTO OPERATION OF COLTC SYSTEM BY DP CONTROLLER : When Differential Pressure Is Greater Than 30 mbar & Less Than 50 mbar : When the DP across the Ball Separator Screens is greater than 30 mbar and less than 50 mbar during auto operation of COLTC system, the following steps will take place automatically :-
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Indication lamp of Screen Backwash is ON. Ball Vessel outlet valve [N02] closes. Cleaning balls are being collected in Ball Vessel. 30 minutes later i.e. after completion of ball collection time Ball Vessel inlet valve N01] closes. Ball Recirculation Pump [F01] stops. Ball Separator Screens turn to Backwash position. Screens are backwashed and cleaned for 30 min. (screen backwash time is adjusted by timer). DP will display 0 mbar. DP Flushing operation is ON. DP Flushing Pump [F32] starts. 3-way reversing valve [M01] opens. Immediately 3-way reversing valve [M01] closes. DP Flushing Pump [F32] stops. After completion of backwashing (i.e. after the timing of 30 min. is elapsed), Ball Separator Screens turn to Operation position. Ball Recirculation Pump [F01] starts. Ball vessel inlet valve [N01] opens and cleaning balls circulate in Ball Vessel. After 5 minutes Ball Vessel outlet valve [N02] opens and cleaning balls distributethemselves through the system. Now unit is again in operation.
When Differential Pressure Is Greater Than 50 mbar : When the DP across the Ball Separator Screens is greater than 50 mbar during auto operation of COLTC system, the following steps will take place automatically : DP Indicator on control panel displays Failure indication and lamp of Emergency Backwash is ON with alarm. Ball Separator Screens turn to Backwash position. Ball Vessel outlet valve [N02] closes. Ball Vessel inlet valve [N01] closes. Ball Recirculation Pump [F01] stops. Ball Oversize Cum Recirculating Monitor OFF. Screens are in Backwash position for 30 min. DP flushing is ON. DP Flushing Pump [F32] starts. 3-way reversing valve [M01] opens. 3-way reversing valve [M01] closes. DP Flushing Pump [F32] stops. After flushing is over, DP value comes down and then do the following operations: Turn the function Selector Switch from Auto to Manual. Press fault accept and reset push button. Turn the function Selector Switch from Manual to Auto. Press the Automatic Start PB for starting the COLTC operation with Auto mode. NOTE : After each Emergency Backwash operation, cleaning balls are counted and the number of balls lost are replaced with new cleaning balls to maintain the basic charge. (E) AUTO SHUTDOWN PROCEDURE OF COLTC FOR CHARGING OF CLEANING BALLS : For charging of new cleaning balls during auto mode operation of COLTC, press the control cabinet illuminated Automatic Stop PB. Then the following operations will take place automatically : Ball Vessel outlet valve [N02] closes. Cleaning balls are being collected in Ball Vessel. 30 minutes later (adjusted by timer) Ball Vessel inlet valve [N01] closes. Ball Recirculation Pump [F01] stops. Automatic Stop PB glows steadily i.e. OFF program is completed.
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Turn the Function Selector Switch to Manual. After completion of the above automatic operation, follow the procedure for charging of cleaning balls as discussed in Art. No. 9.3.A.
10. DEBRIS FILTER SYSTEM : 10.1. INTRODUCTION : Debris such as shells, sticks stones and plastics are common cause of failure in condenser tubes by localized attack (erosion-corrosion). When water flows through the condenser tubes, a shear stress is developed in the tube surface which is dependent on the C.W. velocity. Every alloy has a critical shear stress corresponding to a critical CW velocity, above which erosion-corrosion will occur. The free cross-sectional area at a lodged obstruction is reduced and this leads to a corresponding increase in the CW velocity to maintain volume flow rate. This increase may then be sufficient for the critical shear stress to be exceeded and for erosion-corrosion to take place. Erosion-corrosion is particularly a rapid form of attack. The protective oxide film is removed and attack of the tube material can therefore proceed virtually unimpeded. Tube penetration in a few thousand hours is common. Where an extremely large number of tubes are blocked by debris, it is possible that the CW velocity in the remaining tubes will be sufficiently high to cause film breakdown and subsequent erosion-corrosion. The source of lodged obstructions originate from within the CW system. This could typically be pieces of concrete or stones from the CW basin / culverts, packing material from within the cooling tower or bio-species which have grown to maturity in the CW system. Mussels, barnacles etc. can easily penetrate the primary screening in the larval state and grow rapidly under the very favourable conditions (warmth, ready supply of nutrients and oxygen) pertaining in the CW intake system. Sooner or later the mussels etc. get detached an the shells enter the condenser tubes causing blockages. Improvements in the primary screening would only lead to a partial solution. It would not solve the problem of debris from within the CW system itself. Similarly chlorination can be used to kill mussels etc. but will not prevent the shells entering the condenser. Recognition of these problems
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TURBINE GOVERNING SYSTEM
In order to maintain the synchronous speed under changing load/grid or steam conditions, the FUJI steam turbine. is equipped with electro-hydraulic governor fully backed-up by a hydraulic governor. The measuring and processing of electrical signal offer the advantages such as flexibility, dynamic stability and simple representation of complicated functional systems. The integration of electrical and hydraulic system is an excellent combination with following advantages :i) Exact load-frequency droop with high sensitivity. ii) Avoids over speeding of turbine during load throw-offs. iii) Adjusting of power frequency droop in fine steps even during on-load operation. In this chapter the following discussions will be made step by step :(a) Governing oil system. (b) Main elements of the governing system. (c) Electro- Hydraulic Governing (EHG). (d) Mechanical Hydraulic governing (MHG). (e) Turbine protection devices. (A) GOVERNING OIL SYSTEM Introduction :Please refer to the Turbine Hydraulic Governing Diagram in which the turbine control devices and turbine protective devices are shown with its line. Items Nos. of equipment used in this explanation are same as those in
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9. TEST VALVE [Item No. 5.2 & 7.2] :Each of the HP & IP stop valves servo motors receive trip oil through their associated test valves. The function of the test valve is to open or close the MSSV and RHSV. The test valves have got port openings for trip oil as well as start- up oil. The test valves facilitate the supply of trip oil pressure beneath the servo motor disc under normal condition (i.e. stop valve open condition). For the purpose of resetting MS Stop valves and RH stop valves after turbine tripping, start - up oil pressure is supplied to the associated test valves which moves their spool downwards against the spring force. In their bottom most position, the trip oil pressure starts building up above the stop valve servo motor piston while the trip oil beneath the disc gets connected to drain. When start- up oil pressure is reduced, the test valve moves up draining trip oil above the servo motor piston and building the trip oil pressure below the disc, thus opening the stop valves. A hand wheel is also provided for manual operation of test valves.
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10. EMERGENCY GOVERNOR [Item No. 1.3.1 & 1.3.2.] : The emergency governor is provided to trip the turbine when its speed exceeds the allowable limit. Refer Fig.5. The centrifugal bolt (6) is so positioned that its centre of gravity is apart from the turbine rotor centre by means of the specially designed adjusting bolt (7). At the rated speed, the centrifugal bolt is held in the position shown on the figure by the force of the spring (5). The spring force under this condition
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Speed setter generates required set points which are fed to the speed secondary setter which determines the rate of change of speed set points according to the selected rate of change of speed. 3. INTERFACING OF GOVERNING WITH AUTOSYNCHRONISER : The EHG system is interfaced with the autosynchroniser. The autosynchroniser gives speed raise or lower command to the speed setter according to the beat frequency sensed by the autosynchroniser. The speed of the turbine increases or decreases according to the command. 4. MAIN ELEMENTS OF SPEED CONTROL : 4.1. Speed Setter (65F) : Turbine speed can be set by the following ways : Turbine speed setting from the ATS system. Manual turbine speed setting. Turbine speed setting by automatic synchronization system (ASS). Automatic setting operation according to the other conditions. Turbine Speed Setting From The ATS System : This setting is done by supplying a heat soak turbine speed command and a rated turbine speed command and target speed commands (pulses) at automatic start up of the turbine. When one of these commands is applied, the speed setting increases the speed up-to the target value according to the predetermined stroke time (refer to Table.1). but the actual turbine speed is increased at a change rate based on the starting mode by a secondary speed setter.
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Manual Speed Change Rate Setting : The turbine speed change rate is set by selecting one of the predetermined change rates in manual mode. 4.3. Secondary Speed Setter : A buffering action is performed so that the setting change of speed setter (65F) is kept within the allowable change rate of the turbine. Speed Change Rate Limiting : The secondary setter is activated by the speed change rate setter to determine the change rate. In the secondary setter, raise command from the primary speed setter (65F) is limited by the change rate from 65Fd and then the turbine speed is up to the speed given by 65F with the change rate given by 65Fd. The mutual relation between the speed setting (65F) and the speed change rate setting (65Fd) is shown in the following Fig.
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Quick Balance (not in use of change rate limiting) : The quick balance is a function for automatically removing the change rate limiting circuit. The integral time constant of the speed setter (65F) & speed secondary setter is decreased, practically this circuit is excluded. The condition is as follows : Turbine trip (Emergency trip circuit switch off ). Turbine Speed Setting Hold : The turbine speed is held on the following condition, but not within the critical speed. Either ON or OFF of HOLD function is selected, are used in order to block or release the speed secondary setter. This function is used just in testing of turbine and also used for power secondary setter. 4.4. Turbine Speed Increase Rate Monitoring Circuit (65F rundown circuit) : In order to avoid interference with the turbine speed in the critical speed range, where a critical speed exists in the process of turbine speed increase, the turbine speed increase rate is monitored, and when the increase rate is below a defined rate, the turbine speed setting goes to heat soak speed automatically and then the turbine speed is rundown to the heat soak speed accordingly. This function is considered for the trouble of boiler pressure control fault, the bypass valve control fault etc. 4.5. Over Speed Test : Over speed test is done by raising the speed setter manually (7-65F) after the over speed test ON is selected by key switch in the unit control room. C.2. POWER CONTROL : 1. OPERATION : The power controller ensures smooth loading of the turbine. It is active when the Generator Circuit Breaker (GCB) closes. Various features are incorporated in this controller which includes : Initial Load Concept. Governor Free operation. Limiting Pressure Control (LPC). Frequency Influence. Interfacing With Coordinated Master Control. 1.1. Initial Load Concept : When Generator is synchronized the power set point automatically becomes 5% of the rated load i.e. 10.5 MW. Since the turbine goes on power control with an initial load of 10.5 MW, this ensures that generator never goes on motoring which was one of the synchronization problems. It should be noted that this set point goes directly to secondary setter, hence no influence of rate is present. 1.2. Governor Free Operation : In the Governor Free operation turbine responds directly with speed even though the turbine is on power control mode. In Bk.T.P.P. the Governor Free has a droop of 4.5%. The present dead band of this circuit is 0%, i.e. loading and unloading of machine starts just as it crosses 50 Hz. However this is a variable quantity and can be changed as desired. The droop and the maximum load change can also be changed as desired. Presently the maximum load change from Governor Free operation is 50% i.e. 105 MW. The response of the load change can be controlled by proper setting of time constant for an integrator circuit.
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When the grid frequency variation is large, the Governor Free operation is very difficult because of large variation of load changes. 1.3. Limiting Pressure Control : If due to certain abnormal condition the pressure of the system falls, a control system reduces the load to a certain extent to control the pressure. This type of pressure control within the power control is known as Limiting Pressure Control. Here it should be mentioned that LPC can be switched on only if the turbine is on power control. In Bk.T.P.P. load rejection starts if pressure falls below 10% of the limiting pressure setting and total 21 MW load rejection take place when the pressure deviation becomes more than 20% of the set point.
1.4. Frequency Influence : There is a proportional controller whose value depends on the speed deviation and which directly influences the power controller. The purpose of this controller is to decrease the load at high frequency. Here it must be mentioned that Governor Free operation does not have dead band and it is mainly a frequency controller. But the Frequency Influence circuit within the power controller restricts turbine loading at high frequency. Unlike the governor free operation this circuit always remains active when power controller is ON. Initially a dead band of 1.5 Hz was present but now this dead band has been increased to 3.5 Hz.
1.5. Interfacing With Coordinated Master Control : Under CMC mode of operation the power controller becomes active and load set point is given by the unit load set point of the CMC circuit. The secondary power setter tracks the unit load demand set point. In this mode of
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3. MAIN ELEMENTS OF POWER CONTROL : 3.1. Power Setter (65P) : Turbine output power is set in the following ways : Power setting from the ATS Manual power setting via 7-65P (Raise or Lower P.B.) Power setting from the unit coordinator control Automatic setting operation according to other conditions The set value is indicated on the power setting indicator in the Unit Control Room, and the actual load is indicated on the output power indicator in the UCR. Power Setting From The ATS : This setting is done by supplying the initial setting (0%) command, and the 20% power command at ATS. When these commands are applied, the power setter increases or decreases to the target value according to the stroke time. The actual power under ATS is controlled at a change rate based on the starting mode by a secondary setter. Manual Power Setting : It is accomplished by use of the 7-65P (PB) installed in the UCR in case of not using the ATS system or voluntary setting by operator. Power Setting From The Unit Coordinator : On the coordinated mode (ALR mode) the demand signal from the unit coordinator is applied to the power setter. Automatic Setting Operation According To Other Conditions : The power setter is returned to the lower limit value (0%) for restart when the turbine is tripped. Automatic follow up of 65P. Power setter (65P) is automatically following the actual load during the initial pressure mode operation or Run Back ON. 3.2. Power Change Rate Setter (65Pd) : When the power controller is on operation, the excessive load variation is set by the power change rate setter (65Pd). The power change rate setting is done in the following ways : Power change rate setting from the ATS. Manual power change rate setting. The set value is indicated on the indicator in the Unit Control Room.
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Power Change Rate Setting From The ATS : This setting is done via the selected start mode at the automatic start up of the turbine.
When the starting mode is selected, the change rate setter is automatically set at the predetermined change rate for each mode. Power change rate of load down is also set automatically to 3% /min by ASD. Manual Power Change Rate Setting : This setting is done by 7 65Pd (raise or lower PB) in case of not using the ATS/ASD system or normal operation. 3.3. Limiting Circuit According To Wall Temperature Monitoring (WT) : This system affects the secondary speed setter and the secondary power setter to limit the speed change rate and power change rate for keeping the temperature difference (the wall stress) within allowable limits. This wall temperature monitoring system (TSC) is installed in DCS supplied by BHEL, is capable of switching ON or OFF in the UCR. 3.4. Secondary Power Setter : A buffering action is performed so that the setting change of the power setter (65P) is kept within the allowable change rate of the turbine. Power Change Rate Limiting : The power secondary setter is activated by the power change rate setter (65Pd) to determine the change rate. The signal of the limiting circuit via the wall temperature monitoring (WT) also activates the secondary power setter to limit the change rate as necessary. The secondary power setter has a step component. When the wall temperature monitoring (WT) is not limited, the power variation ratio is as follows : Sustained component : MW/min. Step component : Approx. MW (two different setting values are applicable, one for loading and one for unloading). The mutual relation between the power setter (65P) and the secondary power setter (65Pd) and via the wall temperature monitoring circuit (WT) is shown in the following Fig.
Quick Balance (not in use of the change rate limiting) : The quick balance is a function for automatically excluding the change rate limiting circuit. The integral time constant of the power change rate setter (65Pd) is decreased, practically this circuit is excluded. The conditions are as follows : Turbine trip Pressure control ON.
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3.5. Electrical Load Limiter (77E) & ALFC : Electrical Load Limiter can be used for sudden decrease of load during emergency conditions. Electrical Load Limiter works in association with ALFC or Automatic Load Limiter Follow Up Control which is activated above 82 MW. If ALFC is ON then the Electrical Load Limiter tracks the controller outputs (valve position) with a 10% higher value. This tracking is done at a certain rate controlled by the Load Limit 2ndry setter. During ALFC this rate is 33%/min. Thus this also ensures that no sudden increase or decrease of load changes take place under any abnormal conditions.
4. AUTO FOLLOW UP OF MECHANICAL GOVERNING : This circuit makes the Speeder Gear to follow the Electro-hydraulic Governor at a value above 5% of the valve position of the E/H Converter. A function generator makes the 65M position with the EHC valve position.
Due to large variation of grid frequency at the commissioning period the auto follow up circuit was not functioning properly at Bakeswar and hence the normal practice here is to keep 65M at 100% . MHG droop curve changes as 65M is lowered and if there is a fluctuation in frequency it may so happen that MHG sometimes come into action which is undesirable. The disadvantage of this that if due to certain reason the EHG fails, the control valves will suddenly go to 100% causing accidents and damage in certain conditions.
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C.3. PRESSURE CONTROL : There is a pressure controller within the EHG system which maintains constant pressure at HP turbine inlet. The pressure setting value is given from the CMC desk. This controller becomes active only in the Turbine Follow Mode (TFM). In this mode the EHG is in AUTO and no set point for load can be given. The power controller tracks at 5% higher value i.e. 10.5 MW higher than the original load. If due to certain reason the pressure controller output reaches a value below 50% , then the output is limited to 50%. In this condition the pressure controller will not work properly. This is done to ensure that boiler has sufficient energy to give desired load.
C.4. VALVE POSITION CONTROLLER : 1. OPERATION : All controller output is finally fed to the valve position controller which controls the opening of the control valves. This is a PI Controller.
If Generator Circuit Breaker is opened then speed controller is always active. The output of the speed and power controller is fed to an adder circuit. When GCB is closed output of the speed controller becomes zero and power becomes active. The output of this and pressure controller output is fed to a Low Value Selector. When pressure control is not selected the output of this controller is 100%, thus the power controller becomes active. If we select the pressure control then the power control output tracks the load at a value 5% higher than the actual load thus pressure controller output is selected for the control. A logical diagram above describes the operation. 2. HARDWARE : The valve position controller gives command to the EHC. The output card generates a voltage of 0-10V which is used for lifting the pistons within the EHC. If 0 voltage is applied to the EHC the piston is lifted and the auxiliary secondary oil pressure is maximum leading to
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Thus for EHG starting device is used as the resetting device. Speeder gear or 65M is the mechanical governor and we can control the load when MHG is selected. If auto follow up feature is selected then this follows the E/H valve position with a 5% higher value. Otherwise the normal practice is to keep it at 100% so that Mechanical Governor does not influence the EHG system. One thing must be mentioned here that 65M has certain droop characteristics and this droop depends on frequency.
Above figure shows the droop characteristics of 65M. Presently MHG droop is set at 7.5% and turbine can generate 210 MW without the influence of 65M droop up to a frequency of 51.75 Hz. This should be noted that this is the case when 65M is 100%. If 65M position is decreased, the droop characteristics will also fall parallely i.e. at 75% 65M position we can supply 210 MW at relatively lower frequency. If there is a frequency fluctuation and auto follow up of 65M is made ON then there may be a position where 65M falls below EHG command and Starting Device 0% comes into action which may be undesirable. So for smooth running of 65M we should maintain a constant grid frequency. (D) MECHANICAL HYDRAULIC GOVERNING (MHG) 1. INTRODUCTION : The turbine generator is equipped with an electro-hydraulic governing system (EHG) backed-up mechanical hydraulic governing system (MHG). Under normal operation mode EHG is used, however, in case of any fault with EHG, transfer of control to MHG will be done seamless. And then the MHG will continue to operate the turbine unit, but manually, that is, automatic operation such as automatic turbine start-up and shutdown system (ATS) is not available for the MHG system. The MHG system operates the EHC with oil pressure. When the electrical system is not used, this oil pressure is directly fed to the oil servo system for controlling the control valves. For the EHG system, the oil pressure from the MHG system is adjusted in the EHC by using electrical signals from the valve position controller, then the oil pressure is fed to the oil servo system. Therefore, the output oil pressure of EHC can never exceed the control oil pressure from the MHG system. In other words, the
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(E) TURBINE PROTECTION DEVICES The turbine is equipped with following protection devices in order to stop the turbine immediately when it is subjected to a failure. The following protection devices can be tested when the turbine is on loading operation. (Refer to the Turbine hydraulic governing diagram). 1. EMERGENCY TRIP DEVICE : The emergency trip device (2.1) is automatically actuated in an emergency by the operation of releasing device for emergency governor (1.3.1) and the thrust failure protection device (1.5), and can be manually actuated by operating of the emergency trip lever (2.2). As a result, the main stop valves (5.1), the main steam control valves (6.1), the reheat stop valves (7.1) and the intercept valves (8.1) are closed immediately and the turbine is stopped. The control oil from the main oil pump (1.1) is supplied as trip oil for stop valves and secondary oil for the control (intercept) valves through the emergency trip device (2.1). The emergency trip device cuts off the trip oil circuit in an emergency and the trip oil drains into the oil tank. Then, the main stop valves (5.1), the main steam control valves (6.1), the reheat stop valves (7.1) and the intercept valves (8.1) are closed immediately and shut off the steam supply into the turbine. The changeover valve of the emergency trip device (2.1) is of the differential piston type in which its position is determined to balance the spring force and predetermined aux. trip oil pressure. When the aux. trip oil pressure is lowered by operation of protection devices that are connected to aux. trip oil circuit, the emergency trip device is actuated automatically. 2. SOLENOID TRIP DEVICE : Two solenoid trip devices (43.1.1 & 43.1.2) are provided for the turbine auto stop or manually from control center, and are installed on the control oil circuit to the emergency trip device (2.1) and cut off the control oil circuit. 3. EMERGENCY GOVERNOR : Two emergency governors (1.3) actuate the emergency trip device (2.1) via the releasing device (1.3.1). The operation test of the emergency governor can be performed by mans of the oil trip test device (1.6) even when the turbine is on loading operation. This turbine has two emergency governors to protect the turbine from over speeding. 4. THRUST FAILURE PROTECTION DEVICE : The thrust failure protection device (1.4) is actuated when the turbine rotor has been displaced axially beyond the allowable limit. Operation of thrust failure protection device actuates the emergency trip device (2.1) via the releasing device (1.5). 5. VACUUM TRIPPING DEVICE : The vacuum tripping device (2.3) is actuated when the pressure in condenser exceed its allowable limit. Operation of vacuum tripping device actuates the solenoid trip devices (41.3). STOP VALVES ACUTATORS: (fig-5) The stop valves are opened hydraulically and closed by spring force. The mechanism consists of a plunger (44), springs (45, 46), spring seat (42), and piston (38), which is contained within the cylinder (43). The piston (38) is mounted on the connecting rod (37) that is connected to the valve stem (8). To open the valve, pressure oil from the trip oil circuit is admitted through connection W to the space above plunger (44). The plunger (44) is forced against the piston (38), compressing the springs (45, 46). The contained in the plunger can now escape through connections X & C. By reversing the oil flow, trip oil is admitted through connection X to the space below the piston (38) against which the plunger (44) is bearing. The plunger and piston are then lifted together and the valve is moved to its open position. When the trip oil pressure drops below a predetermined value for any reason (such as tripping the turbine) the spring force separates the piston from the plunger. As the area below the piston (38) is depressurised, the springs (45, 46) cause the valve to close rapidly. Any oil under the piston that does not escape through connection X flows into the open area occupied by the springs. During this action the plunger (44) remains in the upper end position. Actuator arrangements for all the stop valves are almost same. From the above discussion it is clear that the ultimate target to trip the Turbine is to drain trip. TURBINE RESETTING, START UP AND LOADING:
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Fig-5
STOP VALVE ACTUATOR
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AUTOMATIC TURBINE RUN-UP SYSTEM
INTRODUCTION
A successful start-up of the turbine normally requires collection and analysis of wide variety of information pertaining to various parameters like speed, temperature, and pressure and warm-up condition of turbine. Apart from this, it is important to see whether vital auxiliary equipments are in automatic control loop or not. It is an enormous task for the operation-engineer to collect and handle so many information correctly and swiftly. ATRS performs this task swiftly, accurately and at the appropriate time reducing chances of mal-operation due to error and improper judgment.
MODE OF OPERATION
ATRS is based on Sequential Group Control philosophy, which means the entire logical steps are arranged in a proper sequence. Prior to the commencement of any step, it is necessary that certain conditions regarding status of plant get fulfilled and the relevant parameters acquire the desired value. All these preconditions are meticulously planned for each next step and demanded from the system to move ahead stepwise. The entire run up can be handled in basic 3 modes, namely manual, semi-auto and auto mode. As the name suggests in manual mode each step is advanced only when the operator wants and issues a command for it. In the semi auto mode the sequential logic runs automatically when the start command is issued, however in between the steps operator intervention is required when speed is to be raised, unit to be synchronized and load to be raised. Because the system runs with little help from operation desk it is called semi-auto mode. In auto mode no external help is required and the turbine can be rolled, synchronized and load of 40 MW can be raised automatically. However the system being in auto or semi-auto mode if there happens to be any problem and the operator decides to hold on the rolling procedure there is provision for ATRS LOCK. If ATRS LOCK is selected then the rolling stops at the sequence in operation and advances further only if lock is removed. Listed below are the pre requisite for the start up and the stepwise procedure for ATRS
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Speed raise permission Speed raise on Speed change rate selected ATS temp mode selected. Speed raise-1 ( heat soak) Speed setter heat soak ATS waiting at 1080 rpm
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Speed setter generates required set points, which are fed to speed 2ndry setter, which determines the rate of change of the speed set points according to the selected rate of change of speed. Interfacing of Governing with auto synchroniser
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In normal generating conditions it is very difficult to have governor free operation owing to the large variations in grid frequency, which leads to large load changes resulting in fluctuations of other important parameters in the system. Limiting Pressure Control (LPC)
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The E/H Converter is the connecting link b/w electrical and hydraulic parts. It consists mainly of a moving coil system, sleeve and pilot valve assembly. The sleeve slides up and down on spool, changing the relative overlap b/w them. The conversion is achieved by electro-magnetically operating the plunger valve because of current flowing through the coil. Movements of plunger valve cause change in the control oil pressure either on the top or bottom of amplifier piston. The motion of the amplifier piston actuates the sleeves of follow up piston valves, causing secondary oil pressure to change. Actually the valve position controller gives command to the E/H converter in voltage. The output card generates a voltage of 0 to -10V, which is used for lifting the pistons within the E/H converter. If 0V is applied to the E/H converter the piston is lifted and the auxiliary secondary oil pressure is maximum leading to opening
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IMPORTANCE OF MARGINS
The margins are a measure of the degree of thermal stresses which turbo set can be subjected to. If the margin is consumed, this means that the component is being stressed to its permissible limit. DATA ACQUISITION AND PROCESSING The input parameters for TSC are provided by wall temperature sensors (T/C). This can measure temperature of the surface, which is in contact with steam, and mean wall temperature in the middle section of component. The wall temperature sensors have two legs and a screwed sleeve containing a measuring insert. The screwed sleeve is inserted through the wall of casing and wielded outside. The material is similar to that of casing to have good thermal contact and have similar thermal gradient. At Bk.T.P.P. the use of TSE is optional to the operation-engineer. TSC generates a hold function i.e. doesnt allow increase or decrease of load or speed during synchronization if metal matching conditions are not satisfied. If margins fall below 10% it generates a trigger to EHG and blocks any further changes in load. Hold function is active/generated only if TSE influence is active. During start up the following parameters need to be satisfied: Metal matching conditions for parameters in calculation 1. MSV open-1 (temp) 2. MSV open-2 (press.) 3.Stm. admission . HPT 4.Stm. admission IPT 5. Speed up 6.Load raise temp. MSV-50%, boiler outlet temp. press. MSV-50% [f (temp.)], boiler outlet pressure. temp. HPC-50%, HPT inlet stm. temp. temp. IPS-50%, HRH stm. temp. temp. HPC-50%, HPT inlet stm. temp temp. IPS-50%, HRH stm. temp.
The metal matching conditions changes with different types of start-ups and the mid wall temps are also processed for different mode of start-ups. The temperature margins that are monitored include MSV, HPC, and HPS & IPS. For this calculation purpose the surface temperatures and the midwall temperatures need to measure. However the midwall temp. for the shafts cannot be measured directly. They are derived from the surface temperatures.
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TURBINE PROTECTION & INTERLOCK
M/s FUJI ELECTRIC, Japan has supplied the Turbine at BkTPP. It is like KWU turbine and designed by SIEMENS. . All KtPS Turbines & BTPS 210 MW Turbine are of LMW design. Turbine Interlock & Protections are provided to run the turbine safely. General description: The turbine consists of three parts HP, IP, and LP. The steam supplied to the HP (high pressure) turbine through 2 nos. of stop valves (one from left & the other from right side) & 4 nos. of control valves (two from left &two from right side). The steam to the IP Turbine is through two nos. RSV (reheat stop valves, one from left & other from right side) & then through two nos. of ICV (intermediate control valves, one from left & other from right side). The exhaust from the IP Turbine is directly fed to LP Turbine. The exhaust of the LP Turbine is feed to condenser, which is physically located below the LP Turbine. The functions of the stop valves are to cut of the steam supply to turbine as quickly as possible. The control valves are primarily used for controlling action (by EHG or by MHG) of the turbine. To change the load (MW) we have to change the position of control valves thus allowing change in the steam flow. OIL CIRCUIT: Here, the philosophy is to run the turbine in normal condition by keeping a protection oil line (named TRIP OIL) in pressurised condition (>6 kg/cm2). If by any mean this oil line pressure drops down (< 2 kg/cm2) the turbine will trip. Some protection devices are directly fed with this oil & the electrical tripping through TLR (i.e. from outside) is directly connected to this line. This TRIP OIL inside the valves keeps the stop valves open against pressing a spring. As soon as the pressure drops the spring force comes pushes back the piston, thus closing of stop valves. The CONTROL OIL is produced by the turbine main oil pump (MOP) during running at speed > 2800 rpm. Before that it is produced by running AOP (aux oil pump). The resetting of turbine generates the TRIP OIL. As soon as the TURBINE RESET PB is pressed, it moves the starting & load-limiting device (77M) to 0 (minimum) positions. At this position, of 77M, the START UP OIL & the AUX START UP OIL is generated. The START UP OIL is used for resetting of all the STOP VALVES. The AUX START UP OIL is used for resetting of all trip devices. The CONTROL OIL is send through SV1 & SV2 (turbine trip solenoids, reset by electrical signal) & the ETD (emergency trip device, reset by AUX START UP OIL) to generate the TRIP OIL provided all these devices are in reset condition.
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OIL CIRCUIT
TRIPPING OF TURBINE: It can be classified into two major categories, viz a) Tripping from inside the turbine & b) tripping by TLR (TURBINE LOCKOUT RELAY), i. e. from outside of turbine i.e. electrical tripping. a) Tripping from inside the turbine:
1. Operation of Solenoid valve (TLR SOLENOID): - TLR (Turbine Lockout Relay) is the electrical
command to trip the turbine from TPR (turbine protection panel). There are two nos. of solenoids for the tripping; if at least one will operate it will trip the turbine by draining the trip oil. Two nos. are provided for better reliability of protection.
2. Tripping by ETD: - The function of the emergency trip device is to open the trip oil line in the event of abnormal condition, thereby closing the stop valves & control valves and thus shutting off the steam admission to the turbine. A hand trip device is also fitted in ETD for manual hand tripping. 3. Tripping by EMERGENCY GOVERNOR: - The emergency governor is provided to trip the turbine when its speed exceeds the allowable limit (setting 111%). By centrifugal principle, if the speed exceeds the set speed the centrifugal bolt came out overcoming a spring tension & push a projected lever which in turn drains the aux trip oil. The setting value can be changed by the adjusting bolt. 4. Tripping by Vacuum Trip Device: - A vacuum line is connected in oil ckt. When condenser vacuum drops to very low level, it drains aux. trip oil and thereby trips the turbine. b) Tripping by TLR (TURBINE LOCKOUT RELAY), i.e. electrical tripping: Electrical panel (TPR panel) Normally most of the time turbine is tripped through this panel. As mentioned above, in the field there are two solenoid valves SV1 & SV2. Normally the trip solenoids are kept without power (220V DC). To trip the turbine, we have to power the coil. As turbine trip is very vital, so here all the inputs are multiplexed into three signals (or three inputs are taken from field, where possible) for processing in three different CPU. The output is taken in duplex mode, and if at least one output mode is active it trips the turbine. The power source to this panel is also dual. One is taken from the Unit UPS & the other from Unit 220v DC. In power stations, both sources are considered extremely stable. However, in extreme emergency case, if both sources are down, one capacitor bank is entrusted to supply energy to trip solenoid to trip the turbine to ensure positive tripping.
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Electrical trip can be categorised into three major types : Turbine itself protection tripping (turbine supervisory) Tripping from unstable process parameters Tripping from other sources. Turbine Supervisory 1a. Control oil pr. Very low: Taken from three nos. pr switches mounted in the control oil line. Normally in running condition the oil pr => 8 kg/cm2. If this pr drops down to < 2 kg/cm2, it is processed & trip signal is send to SVs through TLR. 1b. Trip oil pr very low: - Taken from three nos. pr switches mounted in the control oil line. Normally in running condition the oil pr => 6 kg/cm2. If this pr drops down to < 2 kg/cm2, it is processed & trip signal is send to SVs through TLR. 1c. Lub oil pr very low: - Taken from three nos. pr switches mounted in the control oil line. Normally in running condition the oil pr => 3 kg/cm2. If this pr drops down to < 0.8 kg/cm2, it is processed for 2/3 logic directly & trip signal is send to SVs through TLR. 1d. Turbine over speed: - Mechanical arrangement is illustrated before in the emergency governor caption (setting 111%). Electrical part is done by sensing the actual rpm in rpm monitor. For this two nos. of sensors are mounted in the non-rotating part of turbine & one slotted disk is rotated with the turbine rotor. The pulses from the sensors are fed to two nos. of overspeed monitors for monitoring of the speed by counting the pulses. Each monitor displays the actual rpm. If any monitor detects turbine overspeed (here setting 112%) it operates a relay, which in turn trips the TLR. A third sensor is also provided which is used to display the actual speed of turbine in control room & in screen (VPC). 1e. Axial Shift (Thrust Failure): - Done in TFPD (mechanically, by draining the AUX TRIP OIL) as described earlier. There is one thrust collar meant for measuring the axial thrust of the total turbine at brig no. 2 near the thrust bearing. The measurement represents the position of the thrust collar relative to the thrust bearing clearance. Two nos. of probes are mounted on the bearing cover looking for the gap between the collar & the stationary parts. Each probe is sensing the gap (in mm) & convert it in electrical signal (dc, varying voltage) by the proximitor (transducer) fixed at the outside of turbine. This electrical signal is processed in the AXIAL SHIFT monitor situated at the control room. The alarm values are +0.50 mm & -0.50 mm. and the trip values are +1.00 mm & -1.00 mm. The value indicates the axial shaft position relative to the axial clearance within the turbine. 1f. Shaft Vibration:This is measured in both horizontal & vertical axis. The value is 125 micron for ALARM & 250 micron for TRIP. The logic for tripping is one value should be very high ( 250 micron) & any adjacent channel to this brg. Must be high (> 125 micron). 1g. Differential Expansion:- By differential expansion of turbine means the relative movement of stator part & rotor part in running condition. It is measured in HP, IP & LP turbine differently. The trip values HP Turbine :- +5.69 mm, -3.02 mm.
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WBPDCL
1h. TPR system Heavy Fault:- This is mainly the health of CPU & power supply of TPR system checked. If any major deviation found, it trips the turbine (hardware logic).
2 TRIPPING FROM UNSTABLE PROCESS PARAMETERS The turbine is used to generate the rated parameter (210 MW) with steam parameter 149Kg/cm2 & Temp 537 C. But in the start up, or due to some process error, the steam parameters may not match the pressure/ temp bands. For this during start up steam parameters are checked & if is in the safe zone, the permission have to be obtained from ATRS to allow the steam entry to turbine. In running condition the following parameters have to be checked:-
TRIPPING FROM ANALOG PROCESS PARAMETERSFor a single parameter three field signals are taken to all three TPR processors. Processor selects the middle value input for processing. It compares this with a set point and gives a binary output for alarm or trip. One binary output (high/low) from each processor is sent to two SECONDARY CPU cards. This card processes 2/3logic for processors output and energises two pair of relays (r1, r2 and s1, s2) for a single signal. These two pairs of relays energise 94Tx1 and 94Tx2.
2a. STEAM TEMP VERY HIGH/ VERY LOW: - The value of steam temp is measured in the before the steam entry to the STOP valves for processing. Three thermocouple probes are fitted for measuring & each input is multiplexed to 3 times for processing in three nos. of CPU of TPR panel. In each CPU, three inputs are processed for checking the validity, and the average values of the valid signal are taken as reference signal. It is then compared with the very high value (564 c) & very low value (428 c) and initiates the corresponding trip signal. The very low value signal is again checked for passing whether the MW load is passed more than 40% (i.e. 82 MW) once. If that is true, then the trip signal is passed. 2b. STEAM PRESS. VERY LOW:- The value of steam press is measured by press transmitters before the steam entry to the STOP valves for processing. Three transmitters (left- one no., right two nos.) are fitted for measuring & each input is multiplexed to 3 times for processing in three nos. of CPU of TPR panel.
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AUTO CLOSE by turbine speed > 400 rpm. Manual START/STOP also possible. Drain valves:- There are a no. of drain valves in the turbine, the stop valves & the steam carrying pipes. The general logic is to keep the drains open during start up, and after synchronizing gradually close them in a grouped manner. Extraction check valves:- The extracted steam from turbine is used as heat source in the heaters for heating the condensate flowing from CEP to boiler DRUM. There are total 6 nos. of extractions going to HPH (2 nos.), Dearator (1 no.) & LPH (3 nos.). In each of the extraction lines one check valve is provided to pass the steam in the heaters in normal running condition. But in abnormal condition, it prevents the steam/water ingress into the turbine. When the steam press is adequate inside the turbine or lift of the control valves (i.e. secondary oil press) is adequate & corresponding heater level is adequate the check valves are open to supply the steam to the corresponding heater. If the conditions are not true & in case of turbine trip all the extraction lines are closed. SPECIAL FEATURE OF THE TURBINE Load shedding relay (LSR) ;- The LSR is a control device to prevent the acceleration of the turbine speed by the sudden load rejection (load shedding). In case of sudden load rejection from near about full load, turbine speed may reach high value, which is dangerous for the machine. The mechanical speed governor takes some time to adjust with the new speed feedback & lower the speed by lowering the oil press. To prevent this one device, named LSR is fitted inside TPR panel. It senses the load change rate & if the rate is higher than a pre-defined value it operates a relay (LSR). The relay in turn power two nos. of solenoid valves, the first of which drains the oil from the aux secondary oil, thus closing the HP control valves through secondary oil to HP CV. The second one drains the secondary oil from the IP control valve, thus closing the IP control valve. The action stands for a max of 1 second, after which the normal action through oil lines as per requirement takes place. In total the transient speed rise (due to load shedding) is kept in a small range by momentary closing the control valves thus reducing the steam intake.
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AUTOMATIC TURBINE TESTING (ATT) :- The unique feature of this type of turbine that in turbine running condition, the oil path of the trip lines can be tested for their healthiness & readiness. The load should be < 80% (i.e. 164 MW) for the testing. The following tests can be done 1 Emergency Governor Test 2 Solenoid trip devices test 3 Thrust failure protection device test 4 Vacuum tripping test AUTOMATIC VALVE TESTING (AVT): - As described earlier, the stop valves & the control valves can also be tested on load in a phased manner for their healthiness & readiness. The stop valves & the control valves are grouped into four categories as under & testing can be done one group at a time. First the control valves are closed & then the stop valves. The load should be within 40% to 80% (i.e. within 84 MW to 168 MW) for the testing. Test of MSV (Left) & MCV 1, MCV 3. Test of MSV (Right) & MCV 2, MCV 4. Test of RSV (Left) & ICV (Left). Test of RSV (Right) & ICV (Right).
a1 & a2 B1 & b2
: Same logic processed & output by CPU 1. : Same logic processed & output by CPU 2.
( i.e if CPU 1 malfunctions CPU-2 ensures the trip & vice-versa. a1 & a2 ( two nos. are used if a1 or a2 relay malfunctions . same true for b1 & b2. )
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53
CYCLE EFFICIENCY
Definition of cycle:
The object of all heat engines is to convert heat into mechanical work. In all such engines we use some substance, termed the working substance or working fluid to which we supply heat, so causing the working substance to expand, and in overcoming some external resistance to perform a certain amount of mechanical work. After the expansion process , we have some cold body or receiver of heat to which the working substance rejects heat before taking in a new supply of heat from the hot body or source of heat. The working substance is said to have undergone a cycle of changes of state when, after starting from some definite initial condition receiving a supply of heat, expanding and performing mechanical work and finally rejecting that quantity of heat which can not be converted into work, it is brought back to its initial state or condition. A single cycle is shown below how it works:
In the above cycle the working fluid is water. The burning of fuel is transferred to water in the Boiler (B) to generate steam at a high pressure and temperature, which then expand s in the turbine (T) to a low pressure to produce shaft work. The steam leaving the turbine is condensed into water in the condenser (C) where cooling water takes the heat released during condensation. The water is then fed back to the boiler by the pump (P) and the cycle goes on repeating itself. The working substance water thus follows along the B-T-C-P path. Since the fluid is undergoing a cyclic process, there will be no net change in its internal energy over the cycle ( d E = O) and subsequently the net energy transfer to work from the fluid. Cycle net = Cycle W net or Q1-Q2 = Wt Wp Where Q1 = heat transferred to the working fluid , KJ/kg. Wt = Work transferred from the working fluid KJ/Kg Wp = Work transferred into the working fluid KJ/Kg. The efficiency of the vapour power cycle would thus be Cycle = (W net / Q1) = (Wt Wp)/ (Q1-Q2) / (Q1) = 1- (Q2 ) / ( Q1) The ideal rankine Cycle : Fig.-1 shows the simplified flow diagram of a Rankine cycle. Fig. -2 & Fig. 3 show ideal Rankine cycles on the PV & T-S diagrams respectively. The curved lines to the left of the critical point (CP) on both diagrams are loci of all saturated liquid lines. The regions to the left of these are the sub-cooled liquid regions. The curved
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Cycle analysis : Consider unit mass of working fluid Heat added (from SFEE of Boiler Q1 = h1 -h4 Turbine work Wt = h1 h2 Heat rejected Q2 = h2-h3 Pump work Wp = h4-h3 Q1 - Q2 Wnet Efficiency = Rankine = = Q1 Q1
= (Wt Wp) / Q1 = (h1-h2) (h4-h3)/(h1-h4) .. (A) Now consider pump work : Since , pump handles incompressible fluid, its specific volume undergoes little change with an increase in pre. For reversible adiabatic compression, if we combine first and second law of thermo dynamics, we will get following result From first law,
dQ = du +pdv (1) dQ = Heat transfer dv= Change in volume du= Change in internal energy P= Pressure From second law, we can define entropy and change in entropy is given by. dQ rev. = Tds . (2) T = Temperature Ds = Change in entropy
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For reversible expansion process, the path will be 1-2s. For an ordinary, Turbine the heat loss is small and actual turbine work is less than the reversible work out put and in that case h2> h2s, that means steam leveling the turbine will have more enthalpy than the ideal case. If heat loss is more, then the end state of steam from the turbine will be h2 . Isentropic efficiency of a turbine is given by T = (h1-h2) (h1-h2s) (c ) Condenser loss : CARNOT CYCLE The carnot cycle is an ideal but non-practical cycle giving the maximum possible thermal efficiency for a cycle operating on selected maximum and minimum.
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But at the same time , if inlet pressure increases from P1 P2, the ideal expansion line shifts to the left and the moisture content at the turbine exhausts increases because (X6< X2 ). If moisture content of steam in the later stages of turbine is high, the water particles along with the vapour coming out with high velocity strike the blade and erode their surfaces as a result of which the longevity of the blade decreases. From this consideration, the moisture content at the turbine exhaust is not allowed to exceed 12%; from this limitation we can get maximum operating steam pressure. Rated pressure at Bk.TPP is 149 KSC. Effect of superheat: If the initial temperature T1 increases (Fig.6) to T1 mean temperature of heat addition Tm will increase. If steam expansion is finished in the two phase region, an increase of the initial steam; temperature will diminish the wetness fraction of the steam in the last stages of turbine. Normal initial temperature, maintained at 540C in thermal power plants. A further increase of the temperature of superheating is restricted by the possibility of modern metallurgy and requires substantially higher expanses on power station construction.
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Effect of Exhaust pressure on Rankine Cycle: Exhaust pressure of turbine is commonly known as back pressure and it is equal to vacuum value maintained in condenser of Thermal Power Plant. A decrease of the pressure of exhaust steam Po at the same initial steam parameters, lower the temperature of heat rejection. A decrease of final pressure results in a higher average temperature difference between the supplied and removed heat, therefore, a higher available heat drop and hence a higher thermal efficiency of the cycle. The theoretical limit of pressure reduction in a cycle is determined by the saturation temperature at the final pressure (Po) which must not be less than the temperature of surroundings otherwise, it would not be possible to transfer heat during condensation, the surroundings. At lower value of pressure , specific volume of steam increases, for that reason to get lower value of exhaust pressure (means higher value of vacuum) in condenser, a greater cross section and dimensions of the last stages of the turbine ,(which makes the turbine more expensive), to accommodate large volume of steam flow . Again maintenance of high vacuum in the condenser is trouble some due to air ingress from outside and noncondensable gasses in feed water. An increase in the exhaust pressure increases the temperature of heat rejection. Here change in mean temperature of heat addition is negligible. From the equation of Rankine Cycle efficiency Rankine = (1(To/Tm), it can be easily decided that Rankine will be less for higher value of exhaust pressure of Turbine (lower value of vacuum). So, efficiency of Rankine cycle will be less for low vacuum of condenser. Practically, it is seen that, lower value of vacuum, increases exhaust temperature. Lower value of vacuum reduces the driving force of steam, which is required for driving out the steam from turbine into condenser. For this reason, steam delays to be driven out from the turbine and last stages of LP turbine are subjected to charning effect. As a result LP turbine blades and glands are subjected to higher temperature than the designed temperature. Effect of Reheat: It has been already seen that initial temperature of Rankine cycle is restricted because of limitation of high temperature metallurgy and related expanses. If very high pressure is used in power plant, keeping initial temperature constant (540C ), then dryness fraction at the turbine exhaust reduces and for that reason to limit the dryness fraction at the LP turbine exhaust to 0.88, reheat has to be adopted. In that case all the steam after partial expansion in the HP turbine is brought back to the boiler, reheated by combustion gases and then fed back to the turbine for further expansions in IP/LP turbine. The flow, T-S & h-s diagrams for the ideal Rankine cycle with reheat are shown in the figure . In the first step, steam expands in the higher pressure (H.P) turbine from initial state to some intermediate pressure (1-2). The steam is reheated at constant pressure in the Boiler (2-3) and the remaining expansion (process-3-4) of steam is carried out in the low pressure (L.P) turbine . For 1Kg of steam . Q1= h1-h6s +h3 -h2s Q2= h4s -hs Q2 = Wt = h1-h2s+h3-h4s, Wp=h6s-h5 = (WT Wp) / Q1= (h1-h2s+h3-h4s) Steam rate =3600 / Wnet kg/kwh Heat rate =3600/ kg/KWH If higher pressure (P1) is used without reheat, the ideal Rankine cycle would have been 1-4-5-6 with the use of reheat , the area 2-3-4-4 has been added to the basic cycle. It is obvious that net work out of plant increases with reheat, because (h3-h4) is greater than (h2-h4 ) and hence the steam rate decreases whether the cycle efficiency improves with reheat depends upon whether the mean temperature of heat addition of reheat cycle is higher than the basic cycle. In practice , reheat gives a marginal increase in cycle efficiency by in increases net work out of the cycle as it makes possible the use of higher pressure, keeping the quality of steam at turbine exhaust within permissible limit. The quality improves from (X- X4 ) by use of reheat. A low reheat pressure may bring down mean temperature of heat addition and hence cycle efficiency. A high reheat pressure increases the moisture content at LP turbine exhaust. Thus the reheat pressure is optimized, and the optimum reheat pressure for most of the power plant is about 0.2 to 2.5 of initial steam pressure. Effect of Regeneration: In order to increase the mean temperature of head addition , attention was so far confined to increasing the amount of heat supplied at high temperatures such as increasing super-heat , using higher pressure and
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Efficiencies in a Steam Power Plant: Boiler efficiency = boiler (rate of energy absorption by water to form steam) rate of energy release by the combustion of fuel). Ws(h1-h4) / (Wf x C.V.). Where Ws = Steam generation rate Wf = Fuel burning rate C.V. = Calorific Value. generator = (Electrical output at generator terminal)/(brake output of the turbine). Aux. = (Net power transmitted by generator) / (gross power produced by the plant). So, boiler x cycle x turbine (mech.) X generator X Aux. = overall For modern power plants typical values are: boiler = 0.92; cycle = 0.44; turbine = 0.95; generator = 0.93; Aux. = 0.95 So overall = 0.92 x 0.44 x 0.95 x 0.93 x 0.95 = 0.34 = 34% TURBINE EFFICIENCY For the steady flow operation of a turbine, neglecting changes in K.E. and P.E. Maximum or ideal work output per unit mass of steam (WT) max = (WT) Ideal = (h1-h2s ) = Reversible and adiabatic enthalpy drop in turbine. This work is however, not obtainable, since no real process is reversible. The expansion process is accompanied by irreversibilities. The actual final state 2 can be defined, since the temperature, pressure and quality can be found by actual measurement. The actual path 1-2 is not known and its nature is immaterial, since the work output is here being expressed in terms of change of a property, enthalpy. Accordingly, the work done by the turbine in irreversible adiabatic expansion from 1 to 2 is (WT ) actual = h1-h2 This work is known as internal work, since only the irreversibilities within the flow passages of turbine are affecting the state of steam at the turbine exhaust. So, Internal output = Ideal output Friction and other losses within the turbine casing. If Ws is steam flow rate in kg/h. Internal output =Ws (h1-h2) KJ/h. The internal efficiency of turbine is defined as
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internal = (Internal output) / Ideal output) = (h1-h2) / (h1-h2s) . Work output available at the shaft is less than the internal output because of the external losses in the bearings etc. So, break output or shaft output. = Internal output Internal and external losses. The brake efficiency of turbine is defined as mech = (brake output)/ (Internal output) = (KW x 3600) / Ws (h1-h2s). The mechanical efficiency of turbine is defined as mech = (brake output)/ (Internal output) = (KW x 3600) / Ws (h1-h2). Work output available at the shaft is less than the internal output because of the external losses in the bearings etc. So, Brake output or shaft output. = Internal output External losses. = Ideal output Internal and External losses. The brake efficiency of turbine is refined as brake = (brake output)/ (Ideal output) = (KW x 3600) / Ws (h1-h2s). The Mechanical efficiency of turbine is defined as mech = (brake output)/ (Internal output) = (KW x 3600) / Ws (h1-h2). So, brake = internal X mech
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WBPDCL
Correction for Turbine Heat Rate When the actual operating conditions are deviated from those specified for the guarantee values or expected values at the tests, the measured turbine heat rate shall be corrected according to the following formula. HRT/GM x (1-1 + 2+ 3 + 4+ 5+ 6+ 7+ 8+ 9+ 10) HRT/GC= 100 Where , HRT /GC HRT/GM Correction factor : : : Corrected Turbine heat rate at test load Measured turbine heat rate at test load
1 : MS pressure (%) 2 : MS temperature( % ) 3 : HRH Temperature (%) 4 : Condenser Vacuum (%) 5 : Reheater Pressure drop (%) 6 : Make up water flow (%) 7 : Power factor (%) 8 : Auxiliary Steam flow (%) 9 : Reheater spray water flow (%) 10 : Final feed water Temperature (%) All the above calculations are done according to the test code ASME PTC 6 Steam turbine HP turbine efficiency IP turbine efficiency LP turbine efficiency Unit Heat rate Net turbine heat rate : 84.71% 92% 88.8% 2551 K cal/KWH 2289 K cal/KWH ONE LINE VALVES OF UNIT # 1 AT 210MW.
: : : :
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WBPDCL
Parameter
Main Steam Temp. Main Steam Pr. Reheat Temp. Reheat Spray Back Pressure Excess O2 Flue Gas Temp. Excess Make up Auxiliary Power TABLE - 2
Deviation
-5C -1Kg/cm -5C + 1% (Throttle flow) + 1mm HgA +1% O2 +5C + 1% + 1%
VALUE OF TURBINE EFFICIENCY LEVEL IMPROVEMENT ON A UNIT HEAT RATE OR 2500 K CAL/KWH One % improvement in Effect on Turbine cycle heat Effect on Heat Rate efficiency On rate HP turbine 0.2% Heat Rate 5 kcal KWH IP turbine 0.2% Heat Rate 5 kcal KWH LP turbine 0.5% Heat Rate 12.55 kcal KWH Calculation formula for the heat Rate (Heat Rate = (( Main Steam flow X Main steam enthalpy ) -(Final feedwater flow X final feedwater enthalpy) + (Hot heat steam flow x hot reheat steam enthalpy) - (Cold reheat steam flow x cold reheat steam enthalpy)) / Generator output Ex. 100% load no.FE GN-179-100-001-1/50 PARAMETER Unit MAIN STEAM FLOW T/H MAIN STEAM ENTHALPY K cal /Kg FINAL FEED WATER FLOW T/H FINAL FEED WATER ENTHALPY K cal /Kg HRH STM FLOW T/H HRH STM ENTHALPY K cal /Kg CRH STM FLOW T/H CRH STM ENTHALPY K cal /Kg GENERATOR OUTPUT LW TURBINE HEAT RATE K CAL/kwh
Data 623.798 816.03 623.798 253.82 559.367 844.25 559.367 735.73 210 1959.1
Calculation procedure of turbine heat rate A. CLACULATION FLOW: Measured flow Deaerator inlet condensate water flow (QDEA) Deaerator inlet condensate water flow is measured by the flow element for the test (F540) HP turbine leak off steam flow (QGL1) HP turbine leak off steam flow is measured by the flow orifice for the test (F150)
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G2 = QDEA (1Qfw Where : QDEA hfw hfw1 hfw2 Hfw3 HE6 HE5 HE4 hh6d hh5d hDEA : : : : : : : : : : :
=
G2 G1
Deaerator I/L condensate water flow HP Heater No.6 O/L (feed water enthalpy) HP Heater No.6 L/L (feed water enthalpy) HP Heater No.5 I/L (feed water enthalpy) Deaerator O/L feed water enthalpy HP Heater No.6 I/L extraction steam enthalpy HP Heater No.5 I/L extraction steam enthalpy Deaerator I/L extraction steam enthalpy HP heater no.6 O/L drain enthalpy HP heater no.5 drain enthalpy Deaerator I/L condensate water enthalpy
t/h (Kcal/kg) (Kcal/kg) (Kcal/kg) (Kcal/kg) (Kcal/kg) (Kcal/kg) (Kcal/kg) (Kcal/kg) (Kcal/kg) (Kcal/kg)
Cold reheat steam flow to the boiler (QCRS) QCRS = QMS-QGL-QE6 Where QMS : Main Steam flow QGL: HP turbine leak off steam flow QE6: HP heater no.6 I/L extraction steam flow Hot reheat steam flow (QHRS)
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QHRS = QCRS + QRSP Where; QCRS: Cold reheat steam flow to the boiler QRSP : Reheater attemperator spray water flow HP heater No. 6 I/L extraction steam flow (QE6) QE6 = Qfw x (hfw-hfw1)/HE6-hH6d) Where : Qfw : HP Heater No.6 O/L feed water flow HP Heater No.6 O/L feed water enthalpy hfw : Hfw1 : HP Heater No.6 O/L feed water enthalpy HE6 : HP Heater No.6 I/L extraction stream enthalpy HP Heater No.6 O/L drain enthalpy hH6d HP Turbine leak off flow (QGL) QGL = QGL1 + QGL2 + QVLL Where : QGL1 : Gland leak off flow measured by test orifice (t/h) QGL2 : Other gland leak off flow (t/h) QVLL : HP turbine control valve leak off flow (t/h) HP Turbine other gland leak off flow (QGL2)
(t/h) (t/h)
HP turbine other gland leak of flow (QGL2) HP turbine other gland leak off flow for which the following design value is taken At 100% load : 0.811 (t/h) At 75% load : 0.61 (t/h) HP turbine control valve leak off flow (QVLL) HP turbine control valve leak off flow, for which the following design value is taken At 100% load : 0.53 At 75% load : 0.53 C. Calculation of Enthalpy Enthalpy of HP turbine inlet steam (HMS ) (Kcal/kg) This enthalpy is calculated from HP turbine inlet steam pressure (P100, P102) and temperature (T100,T102,T103). Enthalpy HP turbine outlet steam (HCRH ) (Kcal/kg) This enthalpy is calculated from HP turbine outlet steam pressure (P110) and temperature (T110,T111). Enthalpy of Hot reheat turbine inlet steam (HCRH ) (Kcal/kg) This enthalpy is calculated for LP turbine inlet steam pressure (P206,P207) and temperature (T200, T201,T202,T203). Enthalpy final feedwater (hfw) (Kcal/kg) This enthalpy is calculated from HP heater no.5 O/L feed water temp.(T612), HP heater No.6 I/L feed water pressure (P620) and temp. (T610,611). Enthalpy deaerator O/L feedwater (hfw3) Kcal/kg) This enthalpy is calculated from deaerator outlet feed water pressure (P600, P602, P603, P604) and temp. (T600, T601,T602,T604,T605) Enthalpy of deaerator I/L condensate water (hDEA) ( kcal/kg) (t/h) (t.h)
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