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Other important parameter like speed is measured electrically by Hall Probe & signals are
provided to Electro-hydraulic governor & for display in unit control room after conditioning.
12.1.2 Absolute Bearing Vibration
Turbine rotors are manufactured and balanced with high degree of precision. Some residual
unbalance is unavoidable. It results during operation in vibrations, which transmitted through the bearing
on to the casing. Hence bearings should provide proper damping of vibrations.
For measurement of absolute shaft vibrations, the seismic mass type pick-ups are mounted on
the pedestal cover. The bearing vibrations are transmitted directly to the seismic device.
The device operates on the plunger coil principle. The mechanical vibrations are converted to an
electrical signal, which is proportional to velocity of vibration. In seismic device (Fig. 12.1), a coil is
suspended in an air gap in a resilient way by a spring. The magnetic flux in an air gap is constant. The
permanent magnet is firmly connected to the housing and to the magnetic return path. Above the natural
frequency, the plunger coil is steady in space due to its mass inertia. Thus a fixed point in space is
created and vibrations can be referred to this point. The relative motion between the coil and magnet
generates a voltage, which is proportional to the rate of vibration.
The measurement system is designed to operate satisfactorily over a frequency range of 16 Hz to
200 Hz and measures the amplitude of the vibrational displacement. The output voltage of the sensor is
amplified in a differential amplifier, which suppresses any interference voltages picked up by the cable.
Then the signal is integrated in an active integrator to form signal proportional to the vibrational
displacement. It is then rectified and displayed.
The functioning of the amplifier can be checked with the help of a standard oscillator built in the
system. Failure of sensor and field cable will be annunciated. Similarly, supply voltage is also monitored.
The range of measurement is 0- 160 microns peak-to-peak.
facility of the measuring attachment is provided. The range of measurement is 0.5 to +0.5 mm.
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Fig.12.3 Inductive Type Axial Shaft Position & Differential Expansion Pick-up
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Fig.12.5 (b) Location of Differential Expansion Sensors for HP, IP & LP Turbines
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12.2
12.2.1 Function
The turbine is equipped with Turbine Stress Evaluator to assist in attaining optimized start-up,
operation and shutdown without impairing the expected operating life. As such during start-up and
loading operations of steam turbine, time is of prime importance as also reaching full load keeping the
stresses of the turbine components within permissible limits. Turbine wall stress evaluator is specifically
designed for achieving the above objectives. During changes in operation of the turbine, the internals of
turbine are subjected to temperature fluctuations resulting in thermal stresses. The maximum thermal
stress is proportional to the difference in temperature at the surface on the steam side and the mid wall
temperature. This difference is compared with the permissible temperature difference, which is
determined on the basis of -
The difference between permissible temperature difference and the actual difference between
surface & middle wall temperatures is known as available temperature margin. The margins are
evaluated in an analogue computing circuit and displayed in the instruments as upper and lower
temperature margins upto the stage of synchronization and as load margins during subsequent loading.
The display also indicates the component, which is critical at any given time.
12.2.2 Arrangement
The scheme of TSE consists of following five computing channels as shown in Fig. 12.7 :
1.
2.
3.
4.
5.
Channels 1 & 5 (ESV & HPCV) form the steam admission area and channels 2, 3 & 4 form the
turbine area. The indicator (TSE Display) is shown in Fig. 12.8.
The input to turbine stress evaluator is supplied by thermo-couples mounted on stop valve, high
pressure turbine and intermediate pressure turbine. Ni Cr-Ni thermocouples (WT Sensors), as shown in
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Fig.12.9, are used for measuring the surface temperature near steam (i) and mean temperature (midwall
temperature) (m) for the above five channels mentioned. But for channels 2 & 4 (HP & IP shaft), the
mean shaft temperature m is derived by computation from i. The output of thermocouple is fed to
analog signal conditioning cabinet CJJ05 where it is converted into 4 20 mA signal and fed to TSE
cabinet CJJ01.
The actual load of the turbine generator set Pact is measured separately and a current signal of
4-20 mA is available for load indication and computation of load margins. The speed is also measured
separately and 4 20 mA signal is available for display in TSE indicator.
12.2.3 Computation
The permissible temperature margins are converted into permissible load margins with the help of
mechanical stress calculations for on load operation of the TG set. The available temperature margins are
converted into corresponding load margins by TSE circuitry with the help of mathematical algorithms.
These load margins are the guiding factors to further load or unload the TG set on both manual and
automatic mode.
12.2.4 Principle of Operation
In each computing channel, the difference between m and i is calculated as and this is
compared with the permissible upper and lower temperature difference u per. and L per. which are
dependent on the midwall temperature and are derived from function generators. The difference between
u per. and gives the upper temperature margin whereas difference between L per and gives
the lower temperature margin. These margins are called available temperature margins and are
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represented by u and L. the lower temperature margins of admission area and turbine area are
selected for display and for further processing.
During no load and start-up and shutdown operations the temperature margins are indicated for
admission (or for the turbine area whichever is lower or as selected), together with the instantaneous
speed. During on load operation the upper and lower load margins Pu and PL are computed from
available minimum temperature margins and are displayed together with instantaneous load value.
12.2.5 TSE Display
The TSE indicator (Fig.12.8) has two separate sections one for starting upto synchronization sage
and the other for on load conditions. The sections are illuminated according to the operating mode. The
sector shaped aperture formed by two semicircular discs display margins. The top rectangles get
illuminated & indicate the component, which is the cause for imposing the minimum margin. The upper
boundary of the transparent sector indicates the upper margin for start-up/increasing load and the lower
boundary indicates lower margin for decreasing load/lowering of speed.
During speeding up and upto synchronization, the markings on the white scale indicate the actual
speed of the set. The operature formed by the red discs indicates the safe temperature margin (in degree
Kelvin) in which components remain stressed within the permissible level only.
These indicated margins along with the actual metal temperature help to assess the matching
steam temperature requirement prior to rolling. Correcting action has to be taken when the margin
narrows down or become zero.
During the loading operation the display indicates the load range in which the output can be
altered without any restriction on rate offload load change. The margin is a step change in load permitted
on the turbine at that moment. The actual load is indicated in the white scale. It is possible to switch back
to the variable speed range in order to check the instantaneous temperature margins at admission area or
turbine area.
Two 12-point recorders of Kompensograph model are provided for recording of absolute
temperature, temperature margins actual speed, actual load and load margins.
For checking the proper functioning of the computing circuit from the input section upto display, a
known input can be applied to get a predetermined reading in the indicator for each channel. It is
advisable to test the circuits periodically. If there are deviations the TSE should not be used till the fault is
cleared.
12.2.6 Significance of TSE Margins
The difference between permissible temperature difference and actual difference in temperature
is known as temperature margin. Fig. 12.10 gives the maximum permissible temperature difference
allowed Vs m (midwall temperature). These curves depend upon the thickness of the material at the
point where the margins are calculated, and as well as on material composition. Hence all the five
channels of TSE (as described earlier) have different curves.
The basic philosophy for computing the margin remains the same. For example, as shown in Fig.
12.10, the margins with respect to m of 250oC are computed as follows :
Steam Temperature i = 280oC
Midwall temperature m = 250oC
act
= (i - m)
= (280 250) = 30oC
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