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STEAM TURBINE STRESS

EVALUATOR & CONTROL


SYSTEM

1
FOR TRAINING ONLY
INTRODUCTION
Turbine Stress Evaluator (TSE) and Turbine Stress Control System (TSC)

• Acquires the Thermal Stresses in the Most Stressed Turbine Components During Non-
steady-state Operation
– Start-up
– Shutdown
– Load Changes

• Compares These With Specified Limits Set to Match the Scheduled Mode of Operation

• TSC Permits Low-stress, Optimally Timed Turbine Operation Without Exceeding Permissible
Limits

• Performs the Formation of the Start-up Criteria, and Determination of the Optimum Steam
Temperatures.

2
FOR TRAINING ONLY
Turbine Stress Evaluator (TSE)
Turbine Stress Control System (TSC)

3
FOR TRAINING ONLY
Determining Total Stress
Total stress,total , is the summation of all stresses acting upon the thick wall of the component
including temperature, pressure and loading stresses.
 
total = temp + press + loading
 
The total stress required to cause component failure is determined by various testing methods to
obtain the design total stress, design.
 
Since the design stress will cause component failure, a safety margin is incorporated to the design
stress that results in a permissible stress. DF is the design factor.
 
permissive = design/DF
 
permissive is a summation of all allowable stresses acting upon the thick wall of the component
including temperature, pressure and loading stresses. By rearranging the equation and knowing
the amount of stress from pressure and loading, the stress allowed due to temperature differences
in the metal can be determined.
 
permissive = temp + press + loading or
temp = permissive - press - loading
 
Changes in the steam temperatures inside the turbine bring about delayed changes in the metal
temperatures of the individual components, giving rise to both unrestrained and restrained thermal
expansion. Restrained thermal expansion results in material stresses or thermal loadings that lead
to corresponding material fatigue. These stresses occur cyclically during operation and comprise
alternating stresses (compressive and tensile stress) caused by warm-up and cool down of the
4
components. FOR TRAINING ONLY
Thermal Stress
• Changes in Temperature Result in Delayed Changes in the Metal Temperatures of
the Individual Components
• Unrestrained and Restrained Thermal Expansion
– Restrained Thermal Expansion Results in Material Stresses or Thermal Loading That Lead
to Material Fatigue
– These Stresses Occur Cyclically During Operation
– They are Alternating Stresses (Compressive and Tensile Stress) Caused by Warm-up and
Cool Down of the Components.

Com pre s s ion


Stre s s
He a t In p ut

Te n s ile
S tre s s
Bar, He a te d fro m o n e s id e . If b a r w e re not m ad e of s te e l Ste e l b a r is o n ly m arg inally d e form e d ,
it w ould b e d e form e d . how e ve r the m ate ria l is s tre s s e d due
to re s traine d th e rm al e xp ans io n.

5
FOR TRAINING ONLY
Determining Maximum Permissible Differential Temperature
Knowing the component material and temperature, a permissive differential temperature can be calculated as a
function of allowable stress due to temperature differential. Since the permissive differential temperature varies
with component temperature, a permissive differential temperature graph is created.
 
dTpermissive = f(temp)

The actual temperature differences are then compared with the actual permissible maximum temperature
differences.
6
FOR TRAINING ONLY
Determining Actual Permissible Differential Temperature
Measurement of Wall Temperatures
• Used to Acquire the Casing and Valve Body Temperatures
• Comprises Two Temperature Measuring Points
– Inner Wall Surface
– Middle Wall

7
FOR TRAINING ONLY
Determining Actual Permissible Differential Temperature
By measuring the deep or mean temperature (T50%) and shallow (T100%), the actual differential temperature can
be determined.
 
dTactual = T100% - T50%

The difference between the actual and permissible stress forms the temperature margin (ddT).

8
FOR TRAINING ONLY
Determining Temperature Margin
Difference between the differential temperature that is allowed and what is actually measured
Turbine Stress Evaluator calculates how close the component is to reaching the maximum allowed differential
temperature, or determines the margin.
 
ddTmargin = dTperm – Tactual

That temperature margin (ddT) directly influences the turbine control system. If the stress is too high by reducing
the permissible gradients for speed and load.
9
FOR TRAINING ONLY
Determining Temperature Margin
During a Load Decrease or Steam Temperature Decrease
This same methodology can be used to determine a permissive lower dt and dt margin lower for a cooldown
where the steam temperature is lower than the metal temperature.
 
ddTmargin = dTperm – Tactual

1
0 FOR TRAINING ONLY
Calculation of Shaft Surface Temperatures
Measurement of Shaft Surface Temperature
• Measure Temperatures on Parts of the Inner Casing to Give a Measurement That Is
Representative of Shaft Surface Temperatures (Ta shaft)
• From the measured shaft surface temperature, the associated “mean shaft temperature, Tm“ and
“shaft center-line temperature Tax are calculated

1
1 FOR TRAINING ONLY
Calculation of Shaft Surface Temperatures
Magnitude of the Temperature Differences (Degree of Thermal Stressing)
• Governed by
– How Long (Time) the Temperature Change Takes,
– The Heat Transfer Between Steam and Metal
– The Geometry and Material
Properties of the Component
• The temperature differences
(T1 - Tm) are determined for the
most stressed turbine components.
• The actual temp differences are
compared with the maximum
permissible temperature
differences.

1
2 FOR TRAINING ONLY
Turbine Stress Evaluator Channel Block Diagram

1
3 FOR TRAINING ONLY
1
4 FOR TRAINING ONLY
Permissible temperature difference Δ in the wall of the main steam stop valve

EXAMPLE ONLY
REFERENCE TAHADDART STEAM
TURBINE MANUAL WHEN RELEASED

1
5 FOR TRAINING ONLY
Permissible temperature difference Δ in the wall of the main steam control valve

EXAMPLE ONLY
REFERENCE TAHADDART STEAM
TURBINE MANUAL WHEN RELEASED

1
6 FOR TRAINING ONLY
Permissible temperature difference Δ in the wall of the high pressure casing

EXAMPLE ONLY
REFERENCE TAHADDART STEAM
TURBINE MANUAL WHEN RELEASED

1
7 FOR TRAINING ONLY
Permissible temperature difference Δ in the HP Shaft

Δ = o - m
o = inner layer temperature of the
inner casing ≈ surface temperature
of the shaft
m = mean temperature of the shaft
(calculated)
ax = axis temperature of the shaft
(calculated)

For axis temperatures below 100°C,


the permissible temperature
difference Δ is the minimum value
between Δ as function the mean
temperature (right diagram) and Δ
as function of the axis temperature
(left diagram).

EXAMPLE ONLY
REFERENCE TAHADDART STEAM
TURBINE MANUAL WHEN RELEASED

1
8 FOR TRAINING ONLY
Permissible temperature difference Δ in the IP Shaft

Δ = o - m
o = inner layer temperature of the
inner casing ≈ surface temperature
of the shaft
m = mean temperature of the shaft
(calculated)
ax = axis temperature of the shaft
(calculated)

For axis temperatures below 100°C,


the permissible temperature
difference Δ is the minimum value
between Δ as function the mean
temperature (right diagram) and Δ
as function of the axis temperature
(left diagram).

EXAMPLE ONLY
REFERENCE TAHADDART STEAM
TURBINE MANUAL WHEN RELEASED

1
9 FOR TRAINING ONLY
TSC Influence on the Steam Turbine Controller
• If one of the margins from dTperm and dTact drops to 0, the appropriate setpoint control acts
on the speed or load setpoint
– by reducing the rate of change for speed or load, by inhibiting changes, or by reversing the direction of
change (lower instead of higher)
• The component supplying the lowest TS margin ddTu or ddTl will be used for control purposes.
• If action is to reduce speed while in the barred speed range,
– A dn/dt monitoring function (differential acceleration) is activated to reduce the tracked speed setpoint to
prewarming speed.

2
0 FOR TRAINING ONLY
• All the measured and calculated temperatures are displayed as numeric
values on the operation and monitoring system. The calculated margins
are displayed as green bars and also as numeric values. If a margin falls
below 15 K, the color of the bar changes to yellow. Negative margins
are indicated by red bars.
• An active cold start criterion is signaled by a binary status indicator.
• A fault in a turbine stress evaluation channel is displayed, as is the group
fault alarm. The group fault alarm requires acknowledgement.

2
1 FOR TRAINING ONLY
Significance of Temperature Margins
• A Temperature Margin Is The Permitted Step Change In Temperature Or Load From The Present Load Which The Turbine Can
Accommodate Without Exceeding Permissible Limits.
• If The Total Temperature Margin Is Used, This Means That The Component Is Stressed Up To The Permissible Limit.
• If the Bar on the Display Falls Below the Zero Mark, the Material Is Then Overstressed. Depending on the Frequency and Extent With
Which the Limit Is Exceeded, Incipient Cracking Must Be Expected.
• This Means That the Design Limits Have Been Violated.
• If Excessive Stresses Are to Be Reduced, the Steam Temperatures Must Be Changed in the Opposite Direction to the Turbine
Temperatures. This Means That If the Upper Bar on the Display Falls Below the Zero Mark During Heating, the Steam Temperatures or
Load Must Be Reduced.
• If the differences are slight it is frequently sufficient to wait or to reduce the rate of change for the steam temperature or load (transient).
• The permitted temperature differences are specified in the form of limit curves for the operating modes SLOW, NORMAL, and FAST

2
2 FOR TRAINING ONLY
Variable Temperature Criteria (X-Criteria)

Matching Steam Temperature to Component Temperature

• Turbine operation, including startup times, can be optimized by matching steam parameters to the temperatures of casings and shafts in so far as conditions in the steam
generating system allow.

• If the temperature of steam entering a turbine is considerably higher than the temperature of the turbine components, it will be impossible to observe the stress limits unless
the steam supply is regulated to offset the high steam temperature. In certain cases, this can lengthen the overall startup time.

• If the steam temperature is lower than the temperature of the turbine components, the turbine will first of all be cooled before starting to warm up again as the steam
temperature rises. This process also lengthens startup time.

• If steam and component temperatures are largely matched, the turbine can be run up from warm-up speed to rated speed and synchronized without significant hold times.

• For this reason, before each stage in the turbine startup sequence (rolloff with steam, runup, synchronization and loading) is enabled, either using the function group control or
manually, certain steam temperature criteria which vary as a function of the respective component temperature, so called X-criteria, must be satisfied.

2
3 FOR TRAINING ONLY
Variable Temperature Criteria (X-Criteria)

Derivation of X-Criteria
• Specific requirements in terms of steam condition must be fulfilled to allow the individual steps in start-
up of a turbine-generator to be performed. These criteria indicate whether the reheat or steam
temperatures are adequate to permit the START-UP program to be continued without the set limits
being exceeded.

• The steam and metal temperatures are measured to generate the limit curves for the variable
temperature criteria (X criteria).

• In the case of redundant measuring points for pressure and temperature, two measured values are
scanned, with the maximum, minimum or arithmetic mean then selected from these as appropriate. In
the event that one of the measured values is faulted, the valid value is then used on its own. This fault
condition does not result in issue of an alarm to the functional group control.

• If both measured values are faulted or in the case of a fault in a measured value scanned on a single
channel only, the fault alarm "X criteria faulted" is then issued to the functional group control.

2
4 FOR TRAINING ONLY
Variable Temperature Criteria (X-Criteria)

The variable temperature criteria define the steam conditions required to allow the switching actions
below to be performed:
 
• Opening of high pressure steam emergency stop valves at start of warmup for main steam line
and for valve bodies
• Opening of control valves for roll off of turbine-generator under steam
• Acceleration of turbine-generator to rated speed
• Loading of turbine-generator
 
The variable temperature criteria are divided into three different groups on the basis of function:
• Minimum steam temperature limits to avoid inadmissible cooling of warm components
• Minimum casing temperature limits to avoid inadmissible transient thermal loadings at a given
steam temperature
• Set degree of superheat to be effective prior to roll off of the steam turbine under steam
 

2
5 FOR TRAINING ONLY
Variable Temperature Criteria (X-Criteria)
Measuring Point Requirements
Measuring point X criteria Z criteria

X X X X X X X X X Z Z Z Z Z
1 2 3 4 5 6 7 7 8 1 2 3 4 5
A B
T 00LBA10CT002 Tempeature upstream of branch to X   X   X   X X   X        
1 high pressure bypass station

T 00LBA20CT007 Temperature upstream of high X   X X X   X X       X    


2 pressure steam emergency stop valve

T 00LBB40CT002 Temperature upstream of branch to           X     X   X      


3 intermediate bypass station

T 00LBB50CT007 Temperature upstream of intermediate           X     X       X  


4 pressure steam emergency stop valve

T 00LBA90CT001 Temperature of low pressure induction                           X


5 steam

P 00LBA10CP001 Pressure upstream branch to high                   X        


1 pressure bypass station

P 00LBA20CP901 Pressure upstream of high pressure   X   X               X    


2 steam emergency stop valve

P 00LBB55CP001 Pressure upstream of branch to                     X      


3 intermediate pressure bypass station

P 00LBB50CP901 Pressure upstream of intermediate                         X  


4 pressure steam emergency stop valve

P 00LBA90CP901 Pressure of low pressure induction                           X


5 steam
2
6 FOR TRAINING ONLY
Superheat Criteria (Z-Criteria)

Criterion KKS Measuring point Signal   Signal  

Z1 MAY10FT011 Main steam upstream of branch to high XH02 >30C    


pressure bypass station

Z2 MAY10FT012 Reheat steam upstream of branch to XH02 >30C    


intermediate pressure bypass station

Z3 MAY10FT013 Main steam upstream of turbine XH02 >30C XH52 <15C

Z4 MAY10FT014 Reheat steam upstream of turbine XH02 >30C XH52 <15C

Z5 MAY10FT015 Low pressure (induction) steam upstream XH02 >30C XH52 <15C
of turbine

2
7 FOR TRAINING ONLY
X1, X2- Criterion (Starting Warm-up of Steam Turbine)
• Before opening the emergency stop valve, the steam at the branch line off
of the main steam line to the bypass valves must be superheated.

Interrogation: Prior to opening of high pressure steam emergency stop valves


Background: To avoid inadmissible cooling of the high pressure steam valve bodies
Criterion: Main steam temperature above temperature of high pressure steam control valve
Formula: main steam >  high pressure steam emergency stop valve 50% + X1

LBA10CT002
main steam temperature upstream of HP B/PS
LBA20CT007
main steam temperature upstream of turbine
MS
MAA12CT022A
CTRL-V CTRL-V body temperature
at 50% depth
ESV

to
HP B/PS HP

to
cold reheat

2
8 FOR TRAINING ONLY
X1-Criteria

Interrogation: Prior to opening of high pressure steam emergency stop valves


Background: To avoid inadmissible cooling of the high pressure steam valve bodies
Criterion: Main steam temperature above temperature of high pressure steam control valve
Formula: main steam >  high pressure steam emergency stop valve 50% + X1

LBA10CT002
main steam temperature upstream of HP B/PS
LBA20CT007
main steam temperature upstream of turbine
MS
MAA12CT022A
CTRL-V CTRL-V body temperature
at 50% depth
ESV

to
HP B/PS HP

to
cold reheat

2
9 FOR TRAINING ONLY
X1-Criteria – Avoidance of Cooling Down a Hot CV
X-1: the steam temperature (MS) should be higher than the initial temperature of the valve bodies
(mESV/CV), to prevent undesired cooldown.
Criterion MS > mCV + X1
Inquiry Before opening Emergency Stop Valve

LBA10CT002
main steam temperature upstream of HP B/PS
LBA20CT007
main steam temperature upstream of turbine
MS
MAA12CT022A
CTRL-V CTRL-V body temperature
at 50% depth
ESV

to
HP B/PS HP

to
cold reheat

EXAMPLE ONLY
REFERENCE TAHADDART STEAM TURBINE
MANUAL WHEN RELEASED
X2-Criteria – Avoidance of Over-Excessive Temperature Swing in the HP CV
X-2: the saturated temperature of the main steam (satSt) has to be lower than a limit curve calculated
from the control valve (mCV). During the condensation phase, this prevents an over-excessive increase
in temperature in the HP CV.
Criterion SatSt < mCV + X2
Inquiry Before opening Emergency Stop Valve

LBA20CP901
main steam pressure upstream of turbine
MS (header)
MAA12CT022A
CTRL-V CTRL-V body temperature
at 50% depth
ESV

to
HP B/PS HP

to
cold reheat

EXAMPLE ONLY
REFERENCE TAHADDART STEAM TURBINE
MANUAL WHEN RELEASED
X4, X5, X6- Criterion (Roll-off Criteria)
• Before opening the control valve:

3
2 FOR TRAINING ONLY
X4-Criteria – Avoidance of Wet Steam Admission
X-4: the main steam temperature (MS) upstream of the ESV should be higher than the saturated steam
temperature (satSt) for the associated main steam pressure, avoidance of wet steam admission.
Criterion MS > satSt + X4 Inquiry Before opening control valve
LBA20CP901
main steam pressure upstream
of turbine (header)
LBA20CT007
MS main steam temperature
upstream of turbine
CTRL-V

ESV

to HP
HP B/PS

to
cold reheat

EXAMPLE ONLY
REFERENCE TAHADDART STEAM TURBINE
MANUAL WHEN RELEASED
X5-Criteria – Avoidance of Cooling Down HPS
X-5: the main steam temperature (MS) upstream of the ESV should be higher than the temperature of the
turbine components (mHPS; HP-Shaft), to prevent undesired cool down of the HP turbine.
Criterion MS > mHPS + X5 Inquiry Before opening control valve
LBA10CT002
main steam temperature upstream of HP B/PS
LBA20CT007
main steam temperature upstream of turbine
MS

CTRL-V
MAY01EP154
mean integral shaft temperature
ESV
MAA50CT032A
HP HP casing temperature at 50%
to
depth
HP B/PS

to
cold reheat

EXAMPLE ONLY
REFERENCE TAHADDART STEAM TURBINE
MANUAL WHEN RELEASED
X6-Criteria – Avoidance of Cooling Down IPS
X-6: the reheat steam temperature upstream of the
IP-Bypass (RS) should be higher than the IP Shaft
temperature (mIPS), to prevent undesired cool down
of the IP turbine.
Criterion RS > mIPS + X6
Inquiry Before opening control valve

EXAMPLE ONLY
REFERENCE TAHADDART STEAM TURBINE
MANUAL WHEN RELEASED
X7A-Criteria (Run-up Criteria) – Avoidance of Too Fast Warm up HP Shaft
X-7: the steam temperature upstream of the HP-
Bypass (MS) has to be lower than a limit curve
calculated from the HP-Shaft temperature (mHPS), the
aim is not exceeding the margin from the turbine
stress evaluator during run up.
Criterion MS < mHPS + X7A
Inquiry Before runup to rated speed, coupling
and loading

EXAMPLE ONLY
REFERENCE TAHADDART STEAM TURBINE
MANUAL WHEN RELEASED
X7B-Criteria (Run-up Criteria) – Avoidance of Too Fast Warm up HP Case
X-7: the steam temperature upstream of the HP-Bypass
(MS) has to be lower than a limit curve calculated from the
HP-Case temperature (mHPC), the aim is not exceeding the
margin from the turbine stress evaluator during run up.
Criterion MS < mHPC + X7B
Inquiry Before runup to rated speed, coupling and
loading

EXAMPLE ONLY
REFERENCE TAHADDART STEAM TURBINE
MANUAL WHEN RELEASED
X8-Criteria – (Loading Criteria)-Avoidance of Too Fast Warm up IP Shaft
X-8: the reheat steam temperature upstream of
the IP-Bypass (RS) has to be lower than a limit
curve calculated from the IP-Shaft temperature
(mIPS).
Criterion RS < mIPS + X8
Inquiry Before loading steam turbine

EXAMPLE ONLY
REFERENCE TAHADDART STEAM
TURBINE MANUAL WHEN RELEASED
Optimum MS/Hot Reheat Temperatures
• Calculates the optimum steam and hot reheat temperatures from the turbine stress signals - the actual
temperature margin (ddT)

• Determines the optimum main steam temperature setpoint to get a rapid startup.

Gra di e nt Note :
HP st e am All valu e s for inf orma tio n
30 K te m p . only - s e t during
10K/m in
(K/m in ) 10 co mm is s ioning
DD THP Su
Up pe r te m p. m a rg in
HP sha ft 5 10 20 30
(M AY01EP 154XQ0 6) 2 .5 K/min -5
ST loa d < 10%

Tra nsie nt
<0 K IN CREAS E / DECREAS E
1.7
DDTpe rm u
Pe rmis sible up pe r
te m p. diff. HP sh aft 45 0o C 545 o C
(M AY01EP 154XQ0 4)

Gra die nt
M M
+ A I
Tm HPS HP ste am te m p.
+ X N co ntrolle r
Me an te m pe ra ture LAE10DT0 01
HP sha ft -
(Tm groove HPS, S TO P
&
MAY01EP 1 54XQ01 )
+ < 10 k S e tpoint guidanc e

3
9 FOR TRAINING ONLY
Optimized Turbine Startup

• The subgroup control (SGC) enables turbine startup/shutdown to be as bumplessly and as economically as possible.
• The SGC issues the steps of the turbine startup/shutdown:
– Turbine rolloff with steam and preheating at warm-up speed
– turbine runup to rated speed
– synchronization of generator

• Before the next step can be enabled, the variable temperature criteria must be satisfied.
• The TSC system
– performs the comparisons
– Ensures the Criteria is Satisfied and
– Issues the next step enable criterion.

• On manual turbine startup, these criteria should also be taken into consideration as far as possible.

4
0 FOR TRAINING ONLY
Startup Profiles (Startup Curves)

• steam pressure and steam temperature profiles for steam turbine start-ups.
• the initial point of time is set to the first opening of HP/IP control valves.
• They do not show heat soaking times of steam lines or valves.
• They are based on several assumptions:
– Temperature, pressure and load changes are exclusively restricted by the designed
allowable thermal stress limits of the steam turbine.
– The HRSG provides the given steam conditions at all times during the start-up.
– Critical speed ranges will be passed through quickly.

4
1 FOR TRAINING ONLY
Table 1: Start-up categories Table 2: Turbine Stress Controller operation modes

EXAMPLE ONLY
REFERENCE TAHADDART STEAM TURBINE MANUAL WHEN RELEASED

initial
Temperature
preceding fatigue per
Start-up of high Op.- start-up
standstill start-up
category pressure mode times
time event
/intermediate
pressure Rotor

Cold-     fatigue
50°C description
start I fraction `

Cold- high
15C"C / 180°C > 72 hrs FAST 1/1500
start II fatigue

Warm medium
310°C /190°C 48 hrs. NORMAL 1/4400
start fatigue

Hot-start 490°C /400°C 8 hrs. SLOW 1/12000 low fatigue

  the given fatigue fraction reflects the consumed portion of the designed life time with each start-up executed in the
corresponding op-mode.

4
2 FOR TRAINING ONLY
Start Up Profile Sheets

Sheet Start-up Category Operation Mode

2 -3 - M – 431/1 Cold Start I FAST

2 -3 - M – 431/2 Cold Start II FAST

2 -3 - M – 431/3 Warm-start FAST

2 -3 - M – 431/4 Hot-start FAST

2 -3 - M – 432/1 Cold Start I NORMAL

2 -3 - M – 432/2 Cold Start II NORMAL

2 -3 - M – 432/3 Warm-start NORMAL

2 -3 - M - 432 /4 Hot-start NORMAL

2 -3 - M – 433/1 Cold Start I SLOW

2 -3 - M – 433/2 Cold Start II SLOW

2 -3 - M – 433/3 Warm-start SLOW

2 -3 - M – 433/4 Hot-start SLOW

4
3 FOR TRAINING ONLY
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STEAM TURBINE MANUAL
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STEAM TURBINE MANUAL
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STEAM TURBINE MANUAL
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STEAM TURBINE MANUAL
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STEAM TURBINE MANUAL
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