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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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11

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12

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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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 recommendeddeviation from values recommended

for continuous operation.for continuous operation.Parameter Unit Action Level1

Action Level 2Action 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 with integral

pilot disk. Hydraulic actuation against springforce will close in case of power failure tosolenoid

CV 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 EXHAUSTAND SAFETYAND SAFETY

VALVESVALVES

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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!