23660053 steam turbinesteam turbine
TRANSCRIPT
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STEAM TURBINESTEAM TURBINE
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An Introduction toAn Introduction to
Steam Turbine at Shuweihat S1 through
An Overview of the Steam Turbine and its
subsystemsBasic logics of some of the systems
made easy
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What will we do?What will we do?
Take a look at -Technical Data, pictures and section
drawings - MAALube Oil System - MAVControl Oil System - MAXGland Steam System - MAWTurbine Drain System MAL
Go around the ST
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What we will cover in a sessionWhat we will cover in a session
sometime latersometime laterTSE and Margins
STG Start Up and Shut Down
STG controllerDetailed discussion on Protections
Lub Oil Purification Unit
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Simple Rankine Cycle
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2 to 3: Isobaric heat rejection(Condenser)
3 to 4: Isentropic compression (Pump)4 to 1: Isobaric heat supply (Boiler)1 to 2: Isentropic expansion (Steam
turbine )
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Name Plate DetailsName Plate Details
Order No - 10445 Year of Manufacture -2003
Steam Press. 76.5 Bar Steam Temp. 560 C
Speed 50 rps Rated Capacity 251.35 MW
Exhaust Steam Pressure 2.8 Bar
Type- M30-40
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Steam Parameter LimitsSteam Parameter Limits
Steam Flow 325.44 kg/s
Steam Pressures in Bar Absolute
Nominal Long Term Short Term
Main Steam 76.5 85.7 99.5*
Before 1st Stage 75.5 81.5 81.5
Exhaust Steam 2.23 5.0 7.0
Long Term Upper limit with no time restriction
Short Term Permissible instantaneous value with cumulative
duration not more than 12 hours in a year.
* - Set the safety valve so as not to exceed this value
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ST Speed Sensors
-Total 6
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Turbine Oil SpecsTurbine Oil Specs
Mineral or Synthetic oil of viscosity classISO VG 32 or ISO VG 46 (DIN 51 519)
Capable of withstanding 120 C inbearings and 80 C in the oil tank withoutphysical or chemical degradation.
Hydraulic Oil ISO-L-HM46 (DIN51524-HLP46) capable of withstanding 70C.
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Hydro Safe ISO VG 32Hydro Safe ISO VG 32 Non-Toxic - Biodegradable - Environmentally Friendly
Antiwear - Hydraulic Oil Hydro Safe ISO VG 32 is a vegetable based hydraulic fluid formulated to
meet the demand for biodegradable hydraulic oils. It is designed to minimizeenvironmental impact and have low environmental persistance. Hydro SafeISO VG 32 offers excellent antiwear performance in a wide array of hydrauliccomponents, and can be used as a superior replacement for conventionalpetroleum oil. It exhibits good thermal and oxidative properties whencompared to other vegetable-derived products. Formulated from canola oil,and containing biodegradable, non-toxic chemical additives. Its highvicosity index (VI) allows outdoor operations in winter and summer withoutthe need for fluid changes or equipment modifications.
Viscosity Index ASTM D-567, ASA Z11.45 is an empirical number indicatingthe rate of change in viscosity of an oil within a given temperature range. Alow viscosity index signifies a relatively large change in viscosity withtemperature change, while a high viscosity index shows a relatively smallchange in vicosity with temperature change. Viscosity Index cannot be used
to measure any other quality of an oil. The fluid is totally biodegradable, and exceeds the government criteria of
being "readily biodegradable." Readily biodegradable is defined as anattribute of products that have a natural ability to biodgrade quickly andcompletely. Once the fluid is leaked into the ground, it has the ability ofsubstance to be digested or consumed by naturally occurringmicroorganisms present in water, air, and soil systems. Completebiodegradability is the conversion of a substance to carbon dioxide andwater.
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Steam Purity Why ?Steam Purity Why ?
Impurities can cause damage to turbinecomponents by - corrosion, stress
corrosion, corrosion fatigue, erosion-corrosion.
Deposition can cause - thermodynamiclosses, lower efficiency, upsetting ofpressure distributions, clogging of sealsand clearances
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Values recommended for continuousValues recommended for continuous
operationoperation
Parameter Unit Normal Value AchievableValue
ACC @ 25 C S/cm < 0.2 0.1
Na g/kg < 5 2
Silica g/kg < 10 5
Total Iron g/kg < 20 5
Total Copper g/kg < 2 1
Mass weighted averaging for multiple sources. i.e. if A conductivity
A = Mi * Ai / Mi
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Limit Values for Start Up and cases ofLimit Values for Start Up and cases of
deviation from values recommended fordeviation from values recommended for
continuous operation.continuous operation.Parameter Unit Action Level1
Action Level 2 Action Level 3 Action Level 4
ACC @ 25 C S/cm 0.2 < 0.35 0.35 < 0. 5 0.5 < 1.0 1.0
Na g/kg 5 < 10 10 < 15 15 < 20 20
Silica g/kg 10 < 20 20 < 40 40 < 50 50
Total Iron g/kg 20 < 30 30 < 40 40 < 50 50
Total Copper g/kg 2 < 5 5 < 8 8 < 10 10
Hours per eventallowable
h 100 24 4 0
Cumulative timeper year
h/a 2000 500 80 0
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Output Limit During Valve TestingOutput Limit During Valve Testing
While testing the Main Steam Stop andControl Valves with Automatic Turbine
Tester, the Turbine output should belimited to 80%
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HP Steam from
2 Inlet Pipes
Butterfly Flap
Turbine Drain Valve
ESV 1
ESV & CV Drain
Valves
Gland steam
exhauster
ESV 2
CV 1
CV 2
Safety Valve
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TLRI 115/52
16.5 + 5% KV, 10462 A
299 MVA, COS 0.85
COLD AIR 41 C
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Turbine Stop & Control ValvesTurbine Stop & Control Valves
2 Stop and Control Valves eachStop and CV combined in a common body
with stems arranged at right anglesStop Valve Single seat valve withintegral pilot disk. Hydraulic actuationagainst spring force will close in case of
power failure to solenoidCV Tubular disk with relieving holes.
Hydraulic actuation against spring force.
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FunctionFunction ESV MAA11/12AA051 ESV MAA11/12AA051
Rapid and reliable interruption of SteamSupply to the turbine in case of activation
of protection.To allow admission of steam for warm up
of the CV during cold start
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Function CV MAA12/22AA151Function CV MAA12/22AA151
Rapid interruption of Steam Supply to theturbine in case of activation of protection
Allow admission of steam into turbine forwarm up during start.
Control the speed gradient during run up toNominal speed
Control the load of the steam turbine whensynchronised
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Example
(Not at
S1)
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ST ESV
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ST CV
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TURBINE EXHAUSTTURBINE EXHAUST
AND SAFETY VALVESAND SAFETY VALVES
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FunctionsSafety Valve Protects ST exhaust from too high pressure (4.0 bar)
Dump Valve Opens when ST trips, to limit blading stressStart-up valve Protects blading from too high temperature caused by
windagee.g. start up (Unit CB Off and speed > 47.5 Hz and Exhaust
steam temp Prot high)Vent Valve Opens during all starts at SGC ST step 21 and closes at
step 22 (& speed > 9 Hz) commissioning modification to vent out air
in the exhaust section.
Globe valve 10% rated MS flowHydraulic operated Safety Valve with
steam pressure check deviceControl fluid supply from MAX01
systemOpening time 2sClosing time 15sHas 4 functions
HP Steam from 2
Inlet Pipes
Butterfly Flap
Turbine Drain Valve
ESV 1
ESV & CV Drain
Valves
Gland steam
exhauster
ESV 2
CV 1
CV 2
Start up / SafetyValve
Steam Press Check DeviceSteam Press Check Device 3 pressure switches 1 of 3
actuation 2 of 3 for turbine trip through TTS Cyclic self test - If test not OK, test
stop and 1of 2 mode. Manual check of device allowed
during turbine load operation but
load < 80%
ST Exhaust Valve NAA50 AA001ST Exhaust Valve NAA50 AA001 Butterfly valve Hydraulic actuator with closing
spring 2 trip solenoid valves NAA50
AA013/014 power supply from
Turbine trip system
Pilot valve NAA50AA011 for partlift test
Closing time 2s, Opening time
150s Control fluid by extra unit with 2
pumps + a manual pump for
emergency
Task - To separate ST exhaustfrom Process steam header
ST Exhaust Valve NAA50 AA001ST Exhaust Valve NAA50 AA001 OperationOperation
Open dp > 100 mbar and
SLC on Close ST trip or Safety
Valve open
Fire Protection actuated hydraulic system is switched
off. During ST maintenance can
be locked in close position
and seal air can be provided
between the 2 ring seats
ST Exhaust Valve NAA50 AA001ST Exhaust Valve NAA50 AA001
Start TestStart Test Automatic Start by SGC
ST, XS51 Manual test by start
command from OM(recommended once in 6
weeks) Pilot valve On Valve
closes slowly, 82% limit
switch, switches off pilot
valve (80% second limit
switch)
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Lube Oil System - MAVLube Oil System - MAV
Safe Oil Supply to BearingsJacking up shaft at low speeds
Driving the hydraulic turning deviceAvoid escape of oil vapours from the
bearings and the oil tankOil coolingOil PurificationSpecial Op mode during Fire Protn
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Main ComponentsMain ComponentsLub Oil Tank MAV10BB001 2 x 100% LOPs (~ 5.5 Bar) MAV21AP021/022 1 x 100% EOP (~ 2.5 Bar) MAV24AP001 2 x 100% Lift Oil Pps (~ 160 Bar) MAV24AP001
2 x 100% Vapour Extractor fans MAV82AN001/2 2 x 100% Lub Oil Coolers 2 x 100% Lub Oil Filters Thermostatic Temperature CV
Oil Purification Unit
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10CT001Should be > 10 Deg C to
enable SGC Oil SupplySGC Oil Supply maintains
Oil Temperature between
25-35 Deg C in ShutdownSteps by Starting &
stopping Pre-selected LO
Pump
2v3-10FL021
L = 1v3 < 1050 Alarm
LL= 2v3 < 1000 ST Trip &
Emg Operation/Fire
Protection Activated
H= 1v3 >1150 Alarm
HH=2v3 >1200 ST Trip
SGC Turbine Oil supply Start
Enable Condition
Oil Level 1170 1260 mm
2v3=42FP016
If 1v3 < 2.5 Bar Warning
If 2v3 < 2.3 Bar & Speed>0.25 Hz-Turbine
Trip
10MAV
If DP>0.9 Bar
-Alarm
Auto Pump Changeover
1. If 42CP01930 Deg C - SGC ST
Release at step 21
35CP001
10MAV
If Oil Supply Emergency Operation is triggered by following reasons
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35CT001Temp > 65 WarningTemp > 70 Deg C & Speed
< 0.15 Hz & TM HPS < 100
Deg C then Temp TOO
High Alarm & Lift Oil
Pump OFF
31CP001
If Press> 180 Bar
High Warning
If < 125 Bar Low
Alarm
If Press < 125 Bar and
Running Pump
Discharge Press < 125
Bar - Press Low Alarm
Also Command for
AUTO CHANGEOVER
10MAV
82CP001
Press> -5 mBar Auto
Changeover
If DP>4.2 Bar
-Alarm
1) Fire Protection Manual Switch is activated or detected OR CCR Push Button
2 Tank LOW LOW Level
Then following will be executed
1)CF Supply Protection OFF
2)Turbine Trip
3)GC Oil Supply Manual4)SGC Turbine OiL Supply OFF
5)Main LO Pumps Prot OFF & SLC -OFF
6)EOP OFF Enabled
7)SGC Check Oil Pumps-OFF
8)Lift Oil Pumps OFF & SLC OFF
9)Oil Maint System OFF10)Eop Protection ON
11)Turning Gear OFFRESET is required before Oil
Supply can be RESTARTED
HP side Bearing & Hydro-
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g y
Motor
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Thrust Pads
Journal Bearing
Outer Wheel is
connected to
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ST Shaft
Inner Wheel is
connected to
ST shaft
connected to
HYDRO Motor
HYDRO Motor
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Working Principle
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CLUTCH
Hydro motor & ST Shaft
Manual Turning Gear MechanismManual Turning Gear Mechanism
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Manual Turning Gear MechanismManual Turning Gear Mechanism
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Control Fluid System MAXControl Fluid System MAX
Supply the ST ESVs, CVs and SafetyValve actuators with high pressure control
fluid (160 Bar)Fast closing/opening of valves when Trip
signal actuated.
Transmission of electrical signals fromturbine controller into hydraulic signals forfast and accurate positioning of CVs
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Main ComponentsMain Components
Control fluid tank MAX01BB001
2 x 100% control fluid pps MAX01AP001/002
2 Hydraulic accumulators MAX01BB011/012 2 filters downstream of each pump
MAX01AT011/012
1 Circulating oil pump MAX01AP011
1 Control fluid cooler MAX01AC011 Fine mesh filter d/s of cooler MAX01AT013
CT901-2v3
L L < 5 D C B th P
Auto Changeover
If Press < 150 for 100 Secs then OR
If CF Supply Emergency Operation is triggered by following reasons
1) Fi P i M l S i h i i d d d
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CONTROL FLUID SYSTEM
(MAX )
If DP>Max
-Alarm
SGC TurbineValves
01CP003If Press < 150 Bar for 110secs then
ORIf Press < 110 Bar then Low Press
Alarm
Low Low < 5 Deg C - Both Pumps
Protection OFF
Temp > 15 Deg C Enables SGC Turbine
Valves Operation
High > 70 Deg
High High > 85 Deg C then ST AutoShutdown by SGC Turbine Valves SD
and Start Device- Set Point LOWERING
If any two Transmitters deviation > 5
then FAULT is Generated
If Press < 150 for 100 Secs then OR
< 115 Bar then
AUTOCHANGEOVER Command
If Both Pumps Discharge < 105 Bar
then ST Prot TRIP
Alarm Only
If Discharge Header Press > 150 Bar &
any one Pump in service
2v3 Level Switches
1) Low
2) Low Low
3) Low Low
Any 2v3 activates ST Protection and SGC
Turbine Valves Auto Shutdown and
Pumps Prot OFF
1) Fire Protection Manual Switch is activated or detected
2) Oil Supply Emg Operaion is triggered
Then following will be executed
1)CF Supply Protection OFF
2)Turbine Trip
3)CF Circulation Pump OFF
4)SGC Turbine Valves Auto Shutdown
5)CF Pumps Prot OFF & SLC OFF
6)Both ESVs Prot OFF
MAD & MKD
Bearing Casing Vibrations
10MAD11 /12 CY021 / 22(mm/s)Alarm > 9.3
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MAD & MKD
Shaft Axial Position 2v3
+ 0.5 mm ALRAM+ 1 mm ST Prot TRIP
Fault If Deviation
between 2 transmitters >
0.09 mm
Bearing Casing VibrationsAlarm > 9.4Trip > 14.9If Deviation between two Transmitters >
1 then FAULT
Alarm 9.3Trip > 11.8If Deviation between two Transmitters >
1 then FAULT
Relative Shaft-Brg Vib.
If Speed > 45 Hz and Value > 83 m =Alarm
And Value > 130m =High
If all channels of any measurement become faulty then ST TRIP
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If all channels of any measurement
become faulty then ST TRIP
TURBINE JOURNAL / THRUST BRGS
1v3 > 90 Deg C -ALARM
2v3 > 130 Deg C TRIP
GENERATOR BRGS
1v3 > 100 Deg C -ALARM
2v3 > 110 Deg C TRIP
DRAIN Valve before ESV
MAL09/10AA011
GSE System
If > Max Both the exhausters Prot OFF
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MAL09/10AA011
Open-ORcondition
1)SGC ST Step 7
2)Speed > 47.5 Hz & Steam
Superheat Value < 20 o K
3)Superheat Value Fault & Load
< 8 MW
Close- OR condition1)SGC ST Step 19 or Step 55
2)Speed > 47.5 Hz & SH > 50 o K
3) SH Fault & load > 40 MW
DRAIN Valve before CV
MAL11/12AA011
Open-ORcondition
1)SGC ST Step 5
2)SGC ST Step 18 & Upper Temp
Margin Value > 5 K
3)ESV & CV are Close & Speed >
47.5 Hz for 5 Hrs
Close-OR condition
1)SGC ST Step 14/26/55
2)Speed > 47.5 Hz & ESV Opened &
CV Position Not Closed
DRAIN Valve after CV
MAL15AA011
Open-ORcondition
1) SH HPS Steam - Inner casing OK
& < 20 K2) TM HPS Groove < 440 C & Load
< 8 MW
Close-OR condition
1) SGC ST Step 55
2) SH HPS Steam - Inner casing OK
& > 50 K
3) TM HPS Groove > 450 C & Load
> 8 MW
DRAIN Valve Turbine casing
MAL11AA011
Open-ORcondition
1) Level drain LPS Turb Mon > Max12) ESV 1 or 2 Opened & SH MS ahead
Turbine 10 K
Close-OR condition
1) SGC ST Step 55
2) (Level drain LPS Turb Mon > Max1 OR
(ESV 1 or 2 Opened & SH MS ahead
Turbine 10 K)) Negated + 30 sec
IF Level drain LPS Turb Mon
10MAL22FL001 > Max2
DRAIN Valve Turbine casing
MAL11AA011 will Protection
Open and Block AP
GSE SLC
Auto ON in SGC ST Step 17 & Auto OFF in Step 55
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Gland Steam
Extraction Points
GLAND STEAM EXHAUSTER
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Thank You!Thank You!