12/04/09

1
STEAM TURBINE
STEAM TURBINE
12/04/09
2
An Introduction to
An Introduction to
Steam Turbine at Shuweihat S1 through

An Overview of the Steam Turbine and its

subsystems

Basic ogics of some of the systems !

made easy
12/04/09
3
What will we do?
What will we do?
Ta"e a oo" at #

Technica $ata% &ictures and section

drawings # 'AA

(ube Oi System # 'A)

*ontro Oi System # 'A+

,and Steam System # 'A-

Turbine $rain System ! 'A(

,o around the ST
12/04/09
4
What we will cover in a session
What we will cover in a session
soetie later
soetie later

TS. and 'argins

ST, Start /& and Shut $own

ST, controer

$etaied discussion on 0rotections

(ub Oi 0urification /nit

12/04/09
!
Si"le Ran#ine $%cle
12/04/09
&
12/04/09
'

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 (team

turbine )
12/04/09
(
Nae )late *etails
Nae )late *etails
Order 1o # 10442 3ear of 'anufacture #2004
Steam 0ress5 ! 6752 Bar Steam Tem&5 ! 270 8*
S&eed ! 20 r&s 9ated *a&acity ! 221542 '-
.:haust Steam 0ressure ! 25; Bar
Type- '40#40
12/04/09
+
Stea )araeter ,iits
Stea )araeter ,iits

Steam <ow ! 422544 "g/s

Steam 0ressures in Bar Absoute

1omina (ong Term Short Term
'ain Steam 6752 ;256 9952=
Before 1
st
Stage 6252 ;152 ;152
.:haust Steam 2524 250 650
(ong Term ! /&&er imit with no time restriction
Short Term ! 0ermissibe instantaneous vaue with cumuative
duration not more than 12 hours in a year5
= # Set the safety vave so as not to e:ceed this vaue
12/04/09
-.
12/04/09
--
12/04/09
-2
ST Speed Sensors
-Total 6
12/04/09
-3
12/04/09
-4
12/04/09
-!
12/04/09
-&
Tur/ine 0il S"ecs
Tur/ine 0il S"ecs

'inera or Synthetic oi of viscosity cass

>SO ), 42 or >SO ), 47 ?$>1 21 219@

*a&abe of withstanding 120 8* in

bearings and ;0 8* in the oi tan" without
&hysica or chemica degradation5

Aydrauic Oi ! >SO#(#A'47 ?$>1

21224#A(047@ ca&abe of withstanding 60
8*5
12/04/09
-'
!ydro a"e I# $% 32
!ydro a"e I# $% 32

&on'(oxic ' Biode)radable ' *n+ironmentally ,riendly

-nti.ear ' !ydraulic #il

!ydro a"e I# $% 32 is a +e)etable based hydraulic "luid "ormulated to

meet the demand "or biode)radable hydraulic oils/ It is desi)ned to minimi0e
en+ironmental impact and ha+e lo. en+ironmental persistance/ !ydro a"e
I# $% 32 o""ers excellent anti.ear per"ormance in a .ide array o" hydraulic
components1 and can be used as a superior replacement "or con+entional
petroleum oil/ It exhibits )ood thermal and oxidati+e properties .hen
compared to other +e)etable'deri+ed products/ ,ormulated "rom canola oil1
and containin) biode)radable1 non'toxic chemical additi+es/ Its hi)h
+icosity index ($I) allo.s outdoor operations in .inter and summer .ithout
the need "or "luid chan)es or e2uipment modi"ications/

$iscosity Index -(3 4'5671 -- 811/45 is an empirical number indicatin)

the rate o" chan)e in +iscosity o" an oil .ithin a )i+en temperature ran)e/ -
lo. +iscosity index si)ni"ies a relati+ely lar)e chan)e in +iscosity .ith
temperature chan)e1 .hile a hi)h +iscosity index sho.s a relati+ely small
chan)e in +icosity .ith temperature chan)e/ $iscosity Index cannot be used
to measure any other 2uality o" an oil/

(he "luid is totally biode)radable1 and exceeds the )o+ernment criteria o"
bein) 9readily biode)radable/9 :eadily biode)radable is de"ined as an
attribute o" products that ha+e a natural ability to biod)rade 2uic;ly and
completely/ #nce the "luid is lea;ed into the )round1 it has the ability o"
substance to be di)ested or consumed by naturally occurrin)
microor)anisms present in .ater1 air1 and soil systems/ Complete
biode)radability is the con+ersion o" a substance to carbon dioxide and
.ater/
12/04/09
-(
Stea )urit% 1 Wh% ?
Stea )urit% 1 Wh% ?

>m&urities can cause damage to turbine

com&onents by # corrosion% stress
corrosion% corrosion fatigue% erosion#
corrosion5

$e&osition can cause # thermodynamic

osses% ower efficiency% u&setting of
&ressure distributions% cogging of seas
and cearances
12/04/09
-+
2alues recoended 3or continuous
2alues recoended 3or continuous
o"eration
o"eration
0arameter /nit 1orma )aue Achievabe
)aue
A** B 22 8* CS/cm D 052 051
1a Cg/"g D 2 2
Siica Cg/"g D 10 2
Tota >ron Cg/"g D 20 2
Tota *o&&er Cg/"g D 2 1
'ass weighted averaging for muti&e sources5 i5e5 if A ! conductivity
A E F'i = Ai / F'i
12/04/09
2.
,iit 2alues 3or Start U" and cases o3
,iit 2alues 3or Start U" and cases o3
deviation 3ro values recoended
deviation 3ro values recoended
3or continuous o"eration4
3or continuous o"eration4
0arameter /nit Action (eve
1
Action (eve 2Action (eve 4 Action (eve 4
A** B 22 8* CS/cm G 052 D 0542 G 0542 D 05 2 G 052 D 150 G 150
1a Cg/"g G 2 D 10 G 10 D 12 G 12 D 20 G 20
Siica Cg/"g G 10 D 20 G 20 D 40 G 40 D 20 G 20
Tota >ron Cg/"g G 20 D 40 G 40 D 40 G 40 D 20 G 20
Tota *o&&er Cg/"g G 2 D 2 G 2 D ; G ; D 10 G 10
Aours &er event
aowabe
h H 100 H 24 H 4 0
*umuative time
&er year
h/a H 2000 H 200 H ;0 0
12/04/09
2-
0ut"ut ,iit *urin5 2alve Testin5
0ut"ut ,iit *urin5 2alve Testin5

-hie testing the 'ain Steam Sto& and

*ontro )aves with Automatic Turbine
Tester% the Turbine out&ut shoud be
imited to ;0I
12/04/09
22
12/04/09
23
12/04/09
24
12/04/09
2!
12/04/09
2&
HP Steam from
2 Inlet Pipes
Butterfly Flap
Turbine Drain Valve
ESV
ESV ! "V Drain
Valves
#land steam
e$%auster
ESV 2
"V
"V 2
Safety Valve
12/04/09
2'
T&'I ()(2
6*( + (, -V. /062 1
222 3V1. "4S5 6 /*7(
"4&D 1I' 6 0 8"
12/04/09
2(
Tur/ine Sto" 6 $ontrol 2alves
Tur/ine Sto" 6 $ontrol 2alves

2 Sto& and *ontro )aves each

Sto& and *) combined in a common body

with stems arranged at right anges

Sto& )ave ! Singe seat vave with integra

&iot dis"5 Aydrauic actuation against s&ring
force ! wi cose in case of &ower faiure to
soenoid

*) ! Tubuar dis" with reieving hoes5

Aydrauic actuation against s&ring force5
12/04/09
2+
7unction
7unction
1 ES2 1 MAA--8-2AA.!-
1 ES2 1 MAA--8-2AA.!-

9a&id and reiabe interru&tion of Steam

Su&&y to the turbine in case of activation
of &rotection5

To aow admission of steam for warm u&

of the *) during cod start
12/04/09
3.
7unction 1 $2 1 MAA-2822AA-!-
7unction 1 $2 1 MAA-2822AA-!-

9a&id interru&tion of Steam Su&&y to the

turbine in case of activation of &rotection

Aow admission of steam into turbine for

warm u& during start5

*ontro the s&eed gradient during run u& to

1omina s&eed

*ontro the oad of the steam turbine when

synchronised
12/04/09
3-
E$ample
9:ot at
S;
12/04/09
32
12/04/09
33
ST ESV
12/04/09
34
ST "V
12/04/09
3!
TURBINE E9:AUST
TURBINE E9:AUST
AN* SA7ET;
AN* SA7ET;
2A,2ES
2A,2ES

12/04/09
3&
,unctions
<Sa3et% 2alve 1 )rotects ST e=haust 3ro too hi5h "ressure >44. /ar?
<*u" 2alve 1 0"ens when ST tri"s@ to liit /ladin5 stress
<StartAu" valve 1 )rotects /ladin5 3ro too hi5h te"erature caused
/% winda5e
<e454 start u" >Unit $B 033 and s"eed B 4'4! :C and E=haust
stea te" )rot hi5h?
<2ent 2alve 1 0"ens durin5 all starts at SD$ ST ste" 2- and closes
at ste" 22 >6 s"eed B + :C? 1 coissionin5 odi3ication to vent out
air in the e=haust section4
%lobe +al+e < 1=> rated 3 "lo.
<:%draulic o"erated Sa3et% 2alve with
stea "ressure chec# device
<$ontrol 3luid su""l% 3ro MA9.-
s%ste
<0"enin5 tie 1 2s
<$losin5 tie 1 -!s
<:as 4 3unctions
HP Steam from 2
Inlet Pipes
Butterfly Flap
Turbine Drain Valve
ESV
ESV ! "V Drain
Valves
#land steam
e$%auster
ESV 2
"V
"V 2
Start up ) Safety
Valve
Steam Press "%e<= Devi<e Steam Press "%e<= Devi<e
< 3 pressure s.itches < 1 o" 3
actuation
< 2 o" 3 "or turbine trip throu)h ((
< Cyclic sel" test ' I" test not #?1 test
stop and 1o" 2 mode/
< 3anual chec; o" de+ice allo.ed
durin) turbine load operation but
load @ A=>
ST E$%aust Valve 6 :11(/ 11// ST E$%aust Valve 6 :11(/ 11//
J Butterfly valve
J Hydrauli< a<tuator >it% <losin?
sprin?
J 2 trip solenoid valves :11(/
11/@)/0 6 po>er supply from
Turbine trip system
J Pilot valve :11(/11/ for part
lift test
J "losin? time 6 2s. 4penin? time 6
(/s
J "ontrol fluid by e$tra unit >it% 2
pumps + a manual pump for
emer?en<y
J Tas= - To separate ST e$%aust
from Pro<ess steam %eader
ST E$%aust Valve 6 :11(/ 11// ST E$%aust Valve 6 :11(/ 11//
J
O&eration O&eration
< #pen < dp B 1== mbar and
CC on
< Close < ( trip or a"ety
$al+e open
< ,ire Protection actuated <
hydraulic system is s.itched
o""/
< 4urin) ( maintenance <
can be loc;ed in close
position and seal air can be
pro+ided bet.een the 2 rin)
seats
ST E$%aust Valve 6 :11(/ 11// ST E$%aust Valve 6 :11(/ 11//
J
Start Test Start Test
J Automatic Start by S,*
ST% +S21
J 'anua test by start
command from O'
?recommended once in 7
wee"s@
J 0iot vave On ! )ave
coses sowy% ;2I imit
switch% switches off &iot
vave ?;0I second imit
switch@
12/04/09
3'
,u/e 0il S%ste A MA2
,u/e 0il S%ste A MA2

Safe Oi Su&&y to Bearings

Kac"ing u& shaft at ow s&eeds

$riving the hydrauic turning device

Avoid esca&e of oi va&ours from the

bearings and the oi tan"

Oi cooing

Oi 0urification

S&ecia O& mode during <ire 0rotn

12/04/09
3(
Main $o"onents
Main $o"onents

(ub Oi Tan" 'A)10BB001

2 : 100I (O0s ?L 252 Bar@ 'A)21A0021/022

1 : 100I .O0 ?L 252 Bar@ 'A)24A0001

2 : 100I (ift Oi 0&s ?L 170 Bar@ 'A)24A0001

2 : 100I )a&our .:tractor fans 'A);2A1001/2

2 : 100I (ub Oi *ooers

2 : 100I (ub Oi <iters

Thermostatic Tem&erature *)

Oi 0urification /nit
12/04/09
3+
12/04/09
4.
/"T//
JS%ould be A / De? " to
enable S#" 4il Supply
JS#" 4il Supply maintains
4il Temperature bet>een
2(-@( De? " in S%utdo>n
Steps by Startin? !
stoppin? Pre-sele<ted &4
Pump
2v@-/F&/2
& B v@ C /(/ 1larm
&&B 2v@ C /// ST Trip !
Em? 4peration)Fire
Prote<tion 1<tivated
HB v@ A(/ 1larm
HHB2v@ A2// ST Trip
S#" Turbine 4il supply
Start Enable "ondition
4il &evel D/ 6 26/ mm
2v@B02FP/6
If v@ C 2*( Bar 6 Earnin?
If 2v@ C 2*@ Bar ! SpeedA/*2( HF-Turbine
Trip
/31V
If DPA/*2 Bar
-1larm
1uto Pump "%an?eover
* If 02"P/2C2*( 4' 2"P//C0*7 Bar
t%en 1uto "%an?eover
2* Ele<tri<al fault of 'unnin? Pump 6
1"4
@* E4P >ill start in any "%an?e over
<ommand
02"T//
JHi?% Earnin? at A (D De? "
JTemp A@/ De? " - S#" ST
'elease at step 2
12/04/09
4-
@("T//
JTemp A 6( 6Earnin?
JTemp A D/ De? " ! Speed
C /*( HF ! T3 HPS C //
De? " t%en Temp T44
Hi?% 1larm ! &ift 4il
Pump 4FF
@"P//
If PressA 7/ Bar
Hi?% Earnin?
If C 2( Bar 6 &o>
1larm
@("P//
If Press C 2( Bar and
'unnin? Pump
Dis<%ar?e Press C 2(
Bar - Press &o> 1larm
1lso "ommand for
1GT4 "H1:#E4VE'
/31V
72"P//
PressA -( mBar 6 1uto
"%an?eover
If DPA0*2 Bar
-1larm
If 4il Supply Emer?en<y 4peration is tri??ered by follo>in? reasons
; Fire Prote<tion 3anual S>it<% is a<tivated or dete<ted 4' ""' Pus% Button
2 Tan= &4E &4E &evel
T%en follo>in? >ill be e$e<uted
;"F Supply Prote<tion 4FF
2;Turbine Trip
@;#" 4il Supply 63anual
0;S#" Turbine 4i& Supply 64FF
(;3ain &4 Pumps 6Prot 4FF ! S&" -4FF
6;E4P 4FF Enabled
D;S#" "%e<= 4il Pumps-4FF
7;&ift 4il Pumps 4FF ! S&" 4FF
2;4il 3aint System 4FF
/;Eop Prote<tion 4:
;Turnin? #ear 4FF
'ESET is reHuired before 4il
Supply <an be 'EST1'TED
12/04/09
42
!P side Bearin) D !ydro'
3otor
12/04/09
43
(hrust Pads
Eournal Bearin)
12/04/09
44
ST S%aft
Inner E%eel
is <onne<ted
to ST s%aft
4uter E%eel is
<onne<ted to
HID'4 3otor
12/04/09
4!
HID'4 3otor
Eor=in? Prin<iple
12/04/09
4&
"&GT"H
Hydro motor ! ST S%aft
12/04/09
4'
Manual Turnin5 Dear Mechanis
Manual Turnin5 Dear Mechanis
12/04/09
4(
$ontrol 7luid S%ste MA9
$ontrol 7luid S%ste MA9

Su&&y the ST .S)s% *)s and Safety

)ave actuators with high &ressure contro
fuid ?170 Bar@

<ast cosing/o&ening of vaves when Tri&

signa actuated5

Transmission of eectrica signas from

turbine controer into hydrauic signas for
fast and accurate &ositioning of *)s
12/04/09
4+
Main $o"onents
Main $o"onents

*ontro fuid tan" 'A+01BB001

2 : 100I contro fuid &&s 'A+01A0001/002

2 Aydrauic accumuators 'A+01BB011/012

2 fiters downstream of each &um&

'A+01AT011/012

1 *ircuating oi &um& 'A+01A0011

1 *ontro fuid cooer 'A+01A*011

<ine mesh fiter d/s of cooer 'A+01AT014

12/04/09
!.
"4:T'4& F&GID SISTE3
931J ;
If DPA3a$
-1larm
S#" Turbine
Valves
/"P//@
JIf Press C (/ Bar for /se<s t%en
4'
JIf Press C / Bar t%en &o> Press
1larm
"T2/-2v@
&o> &o> C ( De? " - Bot% Pumps
Prote<tion 4FF
Temp A ( De? " Enables S#" Turbine
Valves 4peration
Hi?% A D/ De?
Hi?% Hi?% A 7( De? " t%en ST 1uto
S%utdo>n by S#" Turbine Valves SD
and Start Devi<e- Set Point &4EE'I:#
If any t>o Transmitters deviation A (
t%en F1G&T is #enerated
1uto "%an?eover
If Press C (/ for // Se<s t%en 4'
C ( Bar t%en
1GT4"H1:#E4VE' "ommand
If Bot% Pumps Dis<%ar?e C /( Bar
t%en ST Prot T'IP
1larm 4nly
If Dis<%ar?e Header Press A (/ Bar !
any one Pump in servi<e
2v@ &evel S>it<%es
; &o>
2; &o> &o>
@; &o> &o>
1ny 2v@ a<tivates ST Prote<tion and S#"
Turbine Valves 1uto S%utdo>n and
Pumps Prot 4FF
If "F Supply Emer?en<y 4peration is tri??ered by follo>in? reasons
; Fire Prote<tion 3anual S>it<% is a<tivated or dete<ted
2; 4il Supply Em? 4peraion is tri??ered
T%en follo>in? >ill be e$e<uted
;"F Supply Prote<tion 4FF
2;Turbine Trip
@;"F "ir<ulation Pump 4FF
0;S#" Turbine Valves 61uto S%utdo>n
(;"F Pumps 6Prot 4FF ! S&" 64FF
6;Bot% ESVs Prot 4FF
12/04/09
!-
31D ! 3-D
S%aft 1$ial Position 2v@

+ /*( mm 1&'13

+ mm ST Prot T'IP
Fault If Deviation
bet>een 2 transmitters A
/*/2 mm
Bearin? "asin? Vibrations
J1larm A 2*0
JTrip A 0*2
JIf Deviation bet>een t>o Transmitters A
t%en F1G&T
/31D )2 "I/2 ) 229mm)s;
J1larm A 2*@
JTrip A *7
JIf Deviation bet>een t>o Transmitters A
t%en F1G&T
'elative S%aft-Br? Vib*
If Speed A 0( HF and Value A 7@ Km B1larm
1nd Value A @/Km BHi?%
If all <%annels of any measurement be<ome faulty t%en ST T'IP
12/04/09
!2
If all <%annels of any measurement
be<ome faulty t%en ST T'IP
TG'BI:E L4G':1& ) TH'GST B'#S
v@ A 2/ De? " -1&1'3
2v@ A @/ De? " 6T'IP
#E:E'1T4' B'#S
v@ A // De? " -1&1'3
2v@ A / De? " 6T'IP
12/04/09
!3
4:-I& $al+e be"ore *$
3-C=FG1=--=11
#pen'#: condition
-?SD$ ST Ste" '
2?S"eed B 4'4! :C 6 Stea
Su"erheat 2alue E 2.
o
F
3?Su"erheat 2alue 1 7ault 6 ,oad
E ( MW
Close' #: condition
-?SD$ ST Ste" -+ or Ste" !!
2?S"eed B 4'4! :C 6 S: B !.
o
F
3? S: 7ault 6 load B 4. MW
4:-I& $al+e be"ore C$
3-C11G12--=11
#pen'#: condition
-?SD$ ST Ste" !
2?SD$ ST Ste" -( D U""er Te"
Mar5in 2alue B ! F
3?ES2 6 $2 are $lose D S"eed B
4'4! :C 3or ! :rs
Close'#: condition
-?SD$ ST Ste" -482&8!!
2?S"eed B 4'4! :C D ES2 0"ened
D $2 )osition Not $losed
4:-I& $al+e a"ter C$
3-C15--=11
#pen'#: condition
-? S: :)S Stea A Inner casin5 0F
D E 2. F
2? TM :)S Droove E 44. G $ D ,oad
E ( MW
Close'#: condition
-? SD$ ST Ste" !!
2? S: :)S Stea A Inner casin5 0F
D B !. F
3? TM :)S Droove B 4!. G $ D ,oad
B ( MW
4:-I& $al+e (urbine casin)
3-C11--=11
#pen'#: condition
-? ,evel drain ,)S Tur/ Mon B Ma=-
2? ES2 - or 2 0"ened 6 S: MS ahead
Tur/ine H -. F
Close'#: condition
-? SD$ ST Ste" !!
2? (,evel drain ,)S Tur/ Mon B Ma=- 0R
>ES2 - or 2 0"ened 6 S: MS ahead
Tur/ine H -. M;; &e)ated H 3. sec
I, Ce+el drain CP (urb 3on
1=3-C22,C==1 B 3ax2
*RAIN 2alve Tur/ine casin5
MA,--AA.-- will )rotection
0"en and Bloc# A)
%* ystem
I3 B Ma= 1 Both the e=hausters )rot 077
%* CC
Auto 0N in SD$ ST Ste" -' 6 Auto 077 in Ste" !!
12/04/09
!4
%land team
*xtraction Points
12/04/09
!!
#&1:D STE13 EJH1GSTE'
12/04/09
!&
Than# ;ouI
Than# ;ouI