STEAM TURBINE

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An Introduction to
Steam Turbine at Shuweihat S1 through An Overview of the Steam Turbine and its subsystems Basic logics of some of the systems made easy

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What will we do?

Take a look at Technical Data, pictures and section drawings - MAA Lube Oil System - MAV Control Oil System - MAX Gland Steam System - MAW Turbine Drain System MAL Go around the ST
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What we will cover in a session sometime later

TSE

and Margins STG Start Up and Shut Down STG controller Detailed discussion on Protections Lub Oil Purification Unit

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Simple Rankine Cycle

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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 Details

Type- M30-40

Order No - 10445 Steam Press. 76.5 Bar Speed 50 rps

Year of Manufacture -2003 Steam Temp. 560 C Rated Capacity 251.35 MW

Exhaust Steam Pressure 2.8 Bar

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Steam Parameter Limits

Steam

Flow 325.44 kg/s Steam Pressures in Bar Absolute

Nominal Main Steam Before 1st Stage Exhaust Steam 76.5 75.5 2.23 Long Term 85.7 81.5 5.0 Short Term 99.5* 81.5 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 Specs

Mineral

or Synthetic oil of viscosity class ISO VG 32 or ISO VG 46 (DIN 51 519) Capable of withstanding 120 C in bearings and 80 C in the oil tank without physical or chemical degradation. Hydraulic Oil ISO-L-HM46 (DIN 51524-HLP46) capable of withstanding 70 C.
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Hydro 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 minimize environmental impact and have low environmental persistance. Hydro Safe ISO VG 32 offers excellent antiwear performance in a wide array of hydraulic components, and can be used as a superior replacement for conventional petroleum oil. It exhibits good thermal and oxidative properties when compared to other vegetable-derived products. Formulated from canola oil, and containing biodegradable, non-toxic chemical additives. Its high vicosity index (VI) allows outdoor operations in winter and summer without the need for fluid changes or equipment modifications. Viscosity Index ASTM D-567, ASA Z11.45 is an empirical number indicating the rate of change in viscosity of an oil within a given temperature range. A low viscosity index signifies a relatively large change in viscosity with temperature change, while a high viscosity index shows a relatively small change 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 an attribute of products that have a natural ability to biodgrade quickly and completely. Once the fluid is leaked into the ground, it has the ability of substance to be digested or consumed by naturally occurring microorganisms present in water, air, and soil systems. Complete biodegradability is the conversion of a substance to carbon dioxide and water.

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Steam Purity Why ?

Impurities

can cause damage to turbine components by - corrosion, stress corrosion, corrosion fatigue, erosioncorrosion. Deposition can cause - thermodynamic losses, lower efficiency, upsetting of pressure distributions, clogging of seals and clearances
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Values recommended for continuous operation

Parameter ACC @ 25 C Na Silica Total Iron Total Copper Unit S/cm g/kg g/kg g/kg g/kg Normal Value < 0.2 <5 < 10 < 20 <2 Achievable Value 0.1 2 5 5 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 of deviation from values recommended for continuous operation.
Parameter Unit ACC @ 25 C Na Silica Total Iron Total Copper Hours per event allowable Cumulative time per year S/cm g/kg g/kg g/kg g/kg h h/a 0.2 < 0.35 5 < 10 10 < 20 20 < 30 2<5 100 2000 0.35 < 0. 5 10 < 15 20 < 40 30 < 40 5<8 24 500 0.5 < 1.0 15 < 20 40 < 50 40 < 50 8 < 10 4 80 1.0 20 50 50 10 0 0

Action Level Action Level 2 Action Level 3 Action Level 4 1

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Output Limit During Valve Testing

While

testing the Main Steam Stop and Control Valves with Automatic Turbine Tester, the Turbine output should be limited to 80%

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HP Steam from 2 Inlet Pipes ESV 1 Safety Valve ESV & CV Drain Valves CV 1 Gland steam exhauster

Butterfly Flap

CV 2

ESV 2 Turbine Drain 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 Valves

2

Stop and Control Valves each Stop and CV combined in a common body with stems arranged at right angles Stop Valve Single seat valve with integral pilot disk. Hydraulic actuation against spring force will close in case of power failure to solenoid CV Tubular disk with relieving holes. Hydraulic actuation against spring force.
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Function ESV MAA11/12AA051

Rapid

and reliable interruption of Steam Supply 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 MAA12/22AA151
Rapid

interruption of Steam Supply to the turbine in case of activation of protection Allow admission of steam into turbine for warm up during start. Control the speed gradient during run up to Nominal speed Control the load of the steam turbine when synchronised
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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 EXHAUST AND SAFETY VALVES

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HP Steam from 2 Inlet Pipes

Start up / Safety Valve

3 pressure switches 1 of 3 actuation 2 of 3 for turbine trip through TTS ESV Cyclic self test - If test1not OK, test stop and 1of 2 mode. ESV & CV Drain Manual check of device allowed Valves during turbine load operation but CV 1 load < 80%

Steam Press Check Device

Gland steam exhauster

ST Exhaust Valve NAA50 AA001 ST Exhaust Valve NAA50 AA001 STButterfly Valve NAA50 AA001 Exhaust valve Hydraulic actuator with closing Operation Start Test spring Automatic > 100 by SGC Open dp Start mbar and SLC on 2 trip solenoid valves NAA50 ST, XS51 trip or Safety Close ST Functions AA013/014 power supply from Manual test by start Valve open Safety Valve Protects ST exhaust from too high pressure (4.0 bar) CV 2 Turbine trip system OM command fromactuated Fire Protection Dump Valve Opens when ST trips, to limit blading stress Pilot valve NAA50AA011 switched hydraulic system is in part (recommended oncefor6 Start-up valve Protects blading from too high temperature caused by Globe valve 10% rated MS flow lift testweeks) off. Hydraulic windage operated Safety Valve with ESV 2 During 2s, Opening time Closing time ST maintenance can Pilot valve On Valve steame.g. start up (Unit CB Off and speed > 47.5 Hz and Exhaust pressure check device be locked in close 150s closes slowly, 82%position limit Turbine Drain and seal air can Valve with 2 Control fluidtemp Prot high) steam supply from MAX01 Control fluid by extra be provided unitpilot switch, switches off between the 2 ring seats Vent Valve Opens during all starts at SGC ST step 21 and closes at system pumpsvalve (80% second limit + a manual pump for Opening speed > step 22 (&time 2s 9 Hz) commissioning modification to vent out air emergency switch) Closing time section. in the exhaust 15s Task - To separate ST exhaust 36 Has 4 functions from Process steam header 07/24/12
Butterfly Flap

Lube Oil System - MAV

Safe

Oil Supply to Bearings Jacking up shaft at low speeds Driving the hydraulic turning device Avoid escape of oil vapours from the bearings and the oil tank Oil cooling Oil Purification Special Op mode during Fire Protn
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Main Components
Lub
2

Oil Tank MAV10BB001

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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10MAV
10CT001 Should be > 10 Deg C to enable SGC Oil Supply SGC Oil Supply maintains Oil Temperature between 42CT001 High Warning Shutdown 25-35 Deg C in at > 57 Deg C Temp >30 Deg C Steps by Starting &SGC ST stoppingat step 21 Release Pre-selected LO Pump

2v3=42FP016 If 1v3 < 2.5 Bar Warning If 2v3 < 2.3 Bar & Speed>0.25 Hz-Turbine Trip

If DP>0.9 Bar -Alarm Auto Pump Changeover If 42CP019<2.5 OR 21CP001<4.8 Bar then Auto Changeover Electrical fault of Running Pump ACO EOP will start in any Change over command 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

1. 2. 3.

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35CP001 If Press < 125 Bar and Running Pump Discharge Press < 125 Bar - Press Low Alarm Also Command for AUTO CHANGEOVER

If Oil Supply Emergency Operation is triggered by following reasons

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 Manual 4)SGC Turbine OiL Supply OFF 5)Main LO Pumps35CT001 & SLC -OFF Prot OFF RESET is required Temp > 65 Warning before Oil Supply Deg C RESTARTED Temp > 70 can be & Speed < 0.15 Hz & TM HPS < 100 Deg C then Temp TOO If DP>4.2 Bar High Alarm & Lift Oil -Alarm Pump OFF 6)EOP OFF Enabled 7)SGC Check Oil Pumps-OFF 8)Lift Oil Pumps OFF & SLC OFF 9)Oil Maint System OFF 10)Eop Protection ON 11)Turning Gear OFF 82CP001 Press> -5 mBar Auto Changeover

10MAV

31CP001 If Press> 180 Bar High Warning If < 125 Bar Low Alarm

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HP side Bearing & HydroMotor

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Thrust Pads

Journal Bearing

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Outer Wheel is connected to HYDRO Motor Inner Wheel is connected to ST shaft ST Shaft

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HYDRO Motor Working Principle

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CLUTCH Hydro motor & ST Shaft

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Manual Turning Gear Mechanism

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Control Fluid System MAX

Supply

the ST ESVs, CVs and Safety Valve actuators with high pressure control fluid (160 Bar) Fast closing/opening of valves when Trip signal actuated. Transmission of electrical signals from turbine controller into hydraulic signals for fast and accurate positioning of CVs
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Main 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
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CT901-2v3 LowLevel < 5 Deg C - Both Pumps Low Switches 2v3 Protection OFF 1) Low Temp >Low 2) Low 15 Deg C Enables SGC Turbine Valves Operation 3) Low Low Any 2v3 activates ST Protection and SGC High > 70 Deg Auto Shutdown and Turbine Valves Pumps Prot OFF High High > 85 Deg C then ST Auto Shutdown by SGC Turbine Valves SD and Start Device- Set Point LOWERING If any two Transmitters deviation > 5 then FAULT is Generated

If CF Supply Emergency Operation is triggered Changeover reasons Auto by following

1) Fire Protection Manual Switch is activated orIf Press < 150 for 100 Secs then OR detected < 115 Bar then 2) Oil Supply Emg Operaion is triggered AUTOCHANGEOVER Command If Discharge Header Press > 150 Bar & 01CP003 any one Pump then Then following will be executed If Press < 150 Bar for 110secsin service If Both Pumps Discharge < 105 Bar 1)CF Supply Protection OFF OR then ST Prot TRIP 2)Turbine Trip If Press < 110 Bar then Low Press 3)CF Circulation Pump OFF Alarm 4)SGC Turbine Valves Auto Shutdown 5)CF Pumps Prot OFF & SLC OFF 6)Both ESVs Prot OFF

CONTROL FLUID SYSTEM (MAX )

If DP>Max -Alarm

SGC Turbine Valves

Alarm Only

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10MAD11 /12 CY021 / 22(mm/s) Bearing > 9.3 Casing MAD &Alarm 11.8 Vibrations MKD Alarm >Trip > 9.4 If Trip > 14.9Deviation between two Transmitters > If Deviation between two Transmitters > 1 then FAULT 1 then FAULT Relative Shaft-Brg Vib. Shaft Axial Position 2v3 + 0.5 mm ALRAM + 1 mm ST Prot TRIP Fault If Deviation between 2 transmitters > 0.09 mm 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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TURBINE JOURNAL / THRUST BRGS

GENERATOR BRGS

1v3 > 90 Deg C -ALARM 2v3 > 130 Deg C TRIP

If all channels of any measurement become faulty then ST TRIP

1v3 > 100 Deg C -ALARM 2v3 > 110 Deg C TRIP

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DRAIN Valve before ESV MAL09/10AA011 Open-OR condition 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 condition 1)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-OR condition 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 DRAIN Valve after CV 1)SGC ST Step 14/26/55 DRAIN Valve MAL15AA011 Turbine casing 2)Speed > 47.5 Hz & ESV Opened & Open-ORMAL11AA011 condition CV Position Not Closed Open-OR condition 1) SH HPS Steam - Inner casing OK 1) Level & < 20 K drain LPS Turb Mon > Max1 2) HPS or 2 Opened SH Load 2) TMESV 1Groove < 440 & C & MS ahead < 8 MW Turbine 10 K Close-OR condition Close-OR condition 1) SGC Step 55 1) SGC ST ST Step 55 2) HPS drain - Inner casing > Max1 OR 2) SH(LevelSteamLPS Turb Mon OK & > 50 (ESV 1 or 2 Opened & SH MS ahead K 3) TM HPS Turbine 10 K))C & Load + 30 sec Groove > 450 Negated > 8 MW

GSE System If > Max Both the exhausters Prot OFF GSE SLC Auto ON in SGC ST Step 17 & Auto OFF in Step 55

IF Level drain LPS Turb Mon 10MAL22FL001 > Max2 DRAIN Valve Turbine casing MAL11AA011 will Protection 53 Open and Block AP

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Gland Steam Extraction Points

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GLAND STEAM EXHAUSTER

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Thank You!

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