ATRS SYSTEMS FOR TURBINE

TURBINE STARTUP
Startup is a phase of the turbine operation where all the operating conditions are subject to change and monitoring these transient conditions by instrumentation and operator are needed ATRS are start up schematics made to start the unit from control room by operation and monitoring Some tests are to be preformed during turbine start up and some instructions are to be followed.

IMPORTANCE OF TEMPERATURE ON TURBINE ELEMENTS

When the turbine rotor is getting heated up as in cold start the surface of the rotor is getting heated ,but the core is cold. It tries to resist heating by developing compressive stress at the surface. The compressive stress reaches a maximum which should be less than yield stress of the material. So the rotor surface has to be slowly heated. Similarly in case of cooling of the rotor the surface is getting cooled but the inner core is hot and resists it by developing tensile stress at the surface..

IMPORTANCE OF FATT
Present FATT value of rotors not known (Fracture appearance transition temperature). This is the temperature when transition from brittle to ductile fracture takes place This is a method for finding the residual life of turbines. As the turbines become old the FATT value increases. It also indicates that the critical crack size decreases. To overcome such situation sufficient soaking of rotor upto the centre line is required. No RLA service provider is doing this test even when the test is included in the RLA. In ATRS rolling the minimum HP shaft temperature is included for speeding up to rated speed and minimum IP shaft temperature is included is a criteria for loading. These criteria take care of FATT

What are startup curves

These are curves drawn for turbine They give safe rolling criteria from steam at any condition. Steam pressure and temperature for rolling. Following these curves the turbine can be safely rolled without crossing the yield stress of the turbine material. ATRS x-y curves are built up on the above curves

Prechecks for TG on barring gear

LPT gland clearances around 0.7mm. Lifts at bearings are as per manual. The turbine should rotate by the weight of the manual rod put for turning. Check for return oil flow (lifts) at all the bearings with JOP ,DCEOP and AOP,they should be same for the machine unless rotors are changed. Check for jacking oil hoses leakages before box up of bearings. Check the jacking oil pockets are as per design when the bearing is opened if the lift is not coming at a bearing. Normally half turn is sufficient to lift the turbine shaft at a bearing. Open equally both the jacking oil hoses at Bearing 3 & 4 (LPT).other wise the resistance for rotation may increase.

TG on turning gear
Check for rubbing sound at all bearings during turning gear. Observe for changes in jacking oil header pressure during turbine on TG. Note for changes in jacking oil pressure at bearings in TG and also in running condition. If jacking oil pressure is dropping change the JOP filter. Observe for any abnormal sound from exciter and generator in barring gear.

TSE IN KWU MACHINES

The TSE is built up on signals from HP shaft temperature HP casing temperature IP shaft temperature HP stop valve temp HP CV temperature These temperatures are compared with MS/HRH temperatures and when we come into the recommended margin the turbine is allowed to roll.

Turbine Reset Criteria

This criteria is to be satisfied for opening of stop valves. Both pressure and stop valves temperature are combined in this curves.

>msat
Initially the steam temperature drop across HPCVs & nozzlebox st or 1 stage is great when the steam flow is small. this leads to high cooling of HP rotor. Hence steam should be 50 C above saturated temperature at that pressure

msat

Turbine reset Criteria

1) ms >msv mid

HP control valve mid temp mcv mid

ms >mcv mid
UPPER LIMIT It is the temperature margin below which the metal temperature if goes down the turbine is not permitted to roll. Suppose the MCV mid temp is 200 0C for a MS temperature of 3500C ,the upper margin is 60 0C. LOWER LIMIT:Lower margins are to be seen for when the machine is cooling down.

STARTUP CRITERIA

1)ENSURES MINIMUM MS TEMPERATURES.

ms >msat
&

ms > 50%OHT ( HP casing /simulated HP shaft)

STARTUP CRITERIA Reheat temperature

rh >50%rh ips

SPEED UP/ROLLING CRITERIA IN CASE OF CONSTANT PRESSURE OPERATION

1) ms >mcv midhpc,hps
For example the HP casing is 1800C and ms temperature is 3500C there will be 500C margin in case of fast mode of rolling.But for normal mode of rolling there will be 10C margin.

SPEED UP/ROLLING CRITERIA IN CASE OF SLIDING PR OPERATION

2) ms >mcv midhpc,hps

LOADING CRITERIA

rh >50%ips
MODES OF ROLLING
So it is clear that in case of fast mode of rolling we stress the turbine components to higher stress cycles.(compressive and tensile). We can tell that we use more turbine residual life on fast mode.

 Rolling parameters in KWU M/C Cold start

Different starts for KWU turbine

Warm start
Hot start

MS PR=50KSC MS TEMP=350C HRH PR = 9-10KSC HRH TEMP= 350C MS PR=90KSC MS TEMP=440C HRH PR = 12KSC HRH TEMP= 415C

MS PR= 90KSC MS TEMP=480C HRH PR = 12KSC HRH TEMP= 470C

ROLLING PHILOSOPHY
500MW KW UNITS Preheating of turbine casings is done with main steam. warm up lines heat the stop valve body. Turbine rolling is through HPT After synchronization IPT is loaded up to 100MW until it is opened full. After wards the load increases by opening HPCV and holding/raising the MS pressure

ROLLING PHILOSOPHY
500MW KW UNITS Barring gear speed is 80-100 rpm In cold start soaking at 360 rpm is done until the TSE curves are satisfied. In warm start soaking at 360 rpm is done until the TSE curves are satisfied. In hot start if the machine permits the machine may roll by itself to 3000rpm

Observations during rolling-control room

Observe for changes in vacuum while rolling.this happens due to changes in seal steam pressure and temperature Observe for DE of HP/IP/LP turbines.At some sites one of the casings have not expanded leading to vibration While rolling have an eye on drop in steam pressure and HRH pressure if they drop considerably then dn/dt can act Before synchronisation check whether the exciter /hydrogen and primary water temperatures are ok. Have a watch on bearing temperatures and if any temperature is abnormal find reasons and cross check. Before synchronisation wait for 20 minutes so that the turbine parameters will stabilize. Keep LP Bypass until your IPT steam and casing DT has come down below 100C

Checks at local during and just after rolling

During rolling observe for sound of rubbing of rotor at seals. Find whether there is any steam coming out of HP/IP/LP seals Check whether oil vapour is coming out of any bearings. Check for any abnormal sound from bearings. Check for any chattering/hunting sound from control ,stop valves and CRH NRV Check for any hunting of governing oil at turbine rack Cross check the speed if the unit is coming after overhaul. Keep a watch on CFT and MOT oil levels after the unit has reached 3000rpm.the level should not change more than 30mm.otherwise investigate.

Control system changeover

Speed control to load control Load control to speed control Load control to pressure control Tracking device problems

SOME TIPS
How to get HP shaft temperature fast while soaking the turbine for curves. Some times reduction of temperatures will get the permissives for rolling.(churning) How much block load should we take Why is the ms/hrh pressure ratio important for a turbine. When should we close steam drain valves

ATRS Systems
SGC OIL SYSTEM SGC EVACUATION SLC CF SYSTEM SLC DRAINS SGC ATT

SGC OIL SYSTEM

PERMISSIVES Cooling water systems charged. Oil system available for operation SLC oil pumps ON OVE on and GEN OVEF ON SLC oil temp control ON Oil level normal GEN CONDITIONS Gas and Air SOP ON SLC SOP on No alarm on SOS System (incl LLD)

OIL SYSTEM START

All oil pumps OFF/SLC OFF and TG valve close AOP 1 ON Discharge pr(>5ksc) ,oil level,filter DP lub oil pr(1.2ksc) all ok TGV open SLC TGV ON 210<N<240rpm and oil level ok ALL SLC OIL PUMPS ON ON PR INTERLOCKS THE OIL PUMPS START(4.8/4.5/1.1KSC)

CONTD
SLC seal oil gets activated and the seal oil pumps are started as per oil and H2 pressure JOP SWITCH ON SLC JOP ON PRESSURE AND SPEED ARE CHECKED for auto start of jacking oil pumps

SGC Control Fluid

SYSTEM CHECKS Water and oil side lined up CF recirculation system pump started and SLC made ON Oil level normal and filter/heater in service CF temperature 55+5 0 C set

TURBINE PROTECTIONS
BASIC PROTECTIONS (have mechanical and electrical back up) Lub oil pr low Low vacuum Turbine over speed EPB and hard wired trip Axial shift

Other protections
HP casing/IP casing DT high HP exhaust temp high Bearing vibration Bearing temperature Generator protection Reheat protection Control oil pressure low

OPERATION PHILOSOPHY
Check the validity of alarms Always roll with ATRS Any normal problem wait for assistance Emergency and blackout instruction practice Follow chemical regime Do all testings for turbine Keep all P&I of turbine healthy.

EFFECTS OF FREQUENT START UPS

Area of passage decreases due to salt deposition Jump in steam pressure leads to invasion on turbineby solid particles. Increase in steam leakages through stage ,diaphragm& end seals due to brushing and rubbing During load raise from zero to nominal value wilson line engulfs the HP/IP turbine stages which run on S/H steam normally Startup leads to leakages of steam shutoff valves along their steam and wear of gland seals, A BAD START UP WILL DAMAGE ALL THE TURBINE SEALS AND MONEY INVESTED FOR REFURBISHMENT.ALL MAINTENANCE WORK IS UNDONE WITH A BAD START.

Idea to ponder!!!
Why are we doing large scrapping in HP casing parting planes? Why are we changing/refurbishing diaphragms frequently? Why are our control valves getting jammed in the cone and bush area frequently/

How do we manitain seal steam header temperature

Line up one source Always some steam is to be drained through the fixed orifice to flash tank Line up HT PRDS Pulling vacuum when maching is hot Where should we measure the seal steam temperature

Setting of Jacking oil pressures

Setting of relief valves Setting of header pressure Setting pressure and lift at bearings Maintenance of gages

Some more tips

How should we check fire protection fault
when should we lock the spring deck during overhaul. After release what are the checks should we do? Regeneration of fuller earth procedure? Pegging of deaerator?tips for avoiding hammering

TDBFP -discussions
Mcv/acv changeover problem & provision of i-h converter Checks before TDBFP steam rolling How to reduce main pump thrust bearing temperature in mechanical seal TDBFP model.

Any suggestions please