THERMAL STRESS HOW IT IS GENERATED IN TURBINE?
During operational changes of the Turbine say Start-up, Loading &
unloading the surface of the Turbine components gets heated
or cooled immediately as it comes in contact with the steam.
Whereas internals of the turbine components are not able to
response that fast.
The result is a differential temperature between Surface (Ts) &
Mid metal (Tm)which generates Thermal stress.
Because Thermal Stress Ts – Tm (T)
The more the value of T the more will be the
thermal stress.
TSE WHAT IS THE NEED ?
• The Turbine is equipped with TSE to assist in optimized
Start-up,operation & Shutdown without impairing the expected
operating life.
• Time is a prime importance while start-up,loading operation of
Turbine.
• At the same time it also very necessary to keep the thermal
stress in turbine components under control.
TSE is specifically designed for achieving both
the above mentioned objectives at the same
time.
The components of TSE
TSE basically consists of three sections.
1. INPUT SECTION
2. COMPUTING DEVICES
3. OUTOUT DEVICES
INPUT SECTION
Input section needs
• Temperature inputs from Turbine components.
• ACTUAL LOAD
• ACTUAL SPEED
Temperature Inputs
• TSE takes temperature inputs from five Turbine
components.
They are
1. Emergency Stop Valve.
2. HP Control Valve.
3. HP Turbine casing.
4. HP Turbine Shaft.
5. IP Turbine Shaft.
WALL TEMPERATURE SENSORS
• The Temperature inputs are supplied by Ni Cr-Ni thermocouples known as
WT SENSORS
• Temperature inputs for stationery parts are obtained from WT Sensors having
Two legs.
• One leg is inserted at 95% of the metal depth nearing surface measure
surface temperature (TS) & another leg is inserted at 55% of material
thickness (Tm).
• For TS & Tm for rotating parts TS is taken from a place where the Radial
clearance between Casing & Rotor is minimum.
• The Tm is calculated with fair degree of accuracy by means of following
equation.
• Tm = Ts [ 1- (0.692 e -t/T1 + 0.131 e -t/T2 + 0.177 e
-t/Tk ) ]
Where, Ts : Surface Temperature T1 : 2408.31
Tm : Mid metal Temperature T2 : 457.08
t : Time in minutes Tk : 56.62
Computation
• The five turbine components has got five computing channels in
computing devices.
• Each Computing channel calculates the difference Ta from Ts
& Tm.
Ta = Ts-Tm
• The calculated temperature difference Ta is compared with
the permissible temperature difference Tp.
Tp is derived from limit curve of that particular component
already fed into TSE hardware.
• These Limit Curves are nothing but maximum permissible
temperature difference allowed w.r.t. Tm while heating &
cooling.
• The difference between Tp & Ta is
called margin.
• Comparing Ta against Tp on the +ve side,
we get UPPER MARGIN & the same on the
–ve side we get LOWER MARGIN.
Suppose at any particular condition
Ts of HP Casing = 300 deg c
Tm of HP Casing = 240 deg c
∆ Ta= Ts-Tm= 300-240=60 deg c
From upper limit curve when Tm = 240 deg c
Then Max upper permissible temp diff (∆ Tpu) = 100 deg
c
Max lower permissible temp diff (∆ Tpl) = -60 deg c
So the Upper margin = (∆ Tpu-∆ Ta) =100-60=+40 deg c
& the Lower margin = (∆ Tpl-∆ Ta) =-60-60 =-120 deg c
• The inference of the above computation of upper &
lower temperature is that Surface temp Ts can be
increased by 40 deg c (to the level of 340 deg c) is
known as Upper margin.
• Similarly Ts can be decreased by 120 deg c is known
as Lower margin.
• Thus the upper & lower margin for all the five turbine
components calculated in similar fashion.
• The minimum upper margin & minimum lower margin
among them is selected separately for display purpose
& as well fed to EHC for controlling speed rate & load
rate.
• TSE OUTPUT SIGNAL GOES TO
• TSE DISPLAY
• TSE MARGIN RECORDER
• ATRS
• CMC
• EHC
SPEED CONTROLLER
LOAD CONTROLLER
TSE DISPLAY
• TSE DISPLY
TSE DISPLAY has two separate sections
1. One is up to synchronisation stage.
2. Another for Load condition.
The sections are illuminated according to
operating mode
• TSE OUTPUT SIGNAL GOES TO
• TSE DISPLAY
• TSE MARGIN RECORDER
• ATRS
• CMC
• EHC
SPEED CONTROLLER
LOAD CONTROLLER
• Speed controller output ( EHC OUTPUT)
gets blocked if
Turbine speed >2850 r.p.m.
and
TSE GETS FAULTED
• LOWER MARGIN IS NOT USED IN SPEED
CONTROLLER AS TURBINE COASTING DOWN
IS NATURAL.
• NEGATIVE LOAD MARGIN CAN UNLOAD
THE MACHINE WHEREAS REDUCRD
LOWER MARGIN CAN PREVENT
TURBINE FROM UNLOADING.
TSE INFLUENCE TO ATRS
• SGC Turbine can not be made ON if TSE is N/A.
• TSE upper margin is one of criteria needed for
the next step (No. 15) and subsequently speed
raise to 3000 r.p.m.
• Speed raise is held up till upper margin is not
more than 30 deg c.
• SGC Turbine start up programme gets switched
off while Rolling (600-2850 r.p.m.)if TSE Upper
Margin <0 deg c.
• TSE FAULT does not make SGC TURBINE start up
programme off while in operation.
USE OF MARGIN IN CMC
• Minimum of TSE lower margin & Unit Load Rate
(in CMC Console) is considered as allowable load
rate at which the unit would be unloaded.
• Minimum of TSE upper margin & Unit Load Rate
is considered as allowable load rate at which the
unit would be loaded.
Procedure adopted in case of lost upper Margin
• The turbine should not be loaded further.
• Reduction of steam temperature by cutting
down firing.
• Soaking the turbine for sufficient time period.
Procedure adopted in case of lost lower Margin
• Avoidance of further unloading.
• Increase firing to increase steam temperature.
• Soaking the machine.