Steam Turbine Seminar -17 Lund University
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1 Steam Tubine Semina -17 Lund Univesity
2 Something on hydaulics N.B. This is an old setup with 1 of 2 the stateof-the-at is 2 out of 3 tip edundancy (both the potection system and the hydaulics) The safety system woks like a thee-way valve The tip system will simply de-pessuize the hydaulics system Most diect tips such as speed and condense pessue have been eplaced by 2/3 measuing devices (and tips) The 2/3 philosophy makes it possible to test the tip all the way to the hydaulics ESV movability test Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 2
3 Bus Lube oil pes Tip logic non exhaustive pinciple 1oo2 PLC 2oo3 Had-wied Vibations N.N. High exh temp High bg temp N.N. Speed < max Speed < max Speed < max P cond < max P cond < max P cond <max Ch Ch Ch.3 1 Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 3 Tip block 2oo3
4 Tip block two out of thee logic Channel A Channel B Channel C ESV Manual tip valve ) ( Hydaulic supply unit PI Pessue switch Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 4
5 Tip block test Tipped channel ESV Manual tip valve ) ( Hydaulic supply unit PI Pessue switch Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 5
6 Tip block tip Tipped channel Tipped channel No pessue! ESV Manual tip valve ) ( Hydaulic supply unit PI Pessue switch Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 6
7 The Duck-Cuve Sweden Califonia 4.3 GW/h Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 7
8 Flexibility Load Coutesy of Siemens LF Stat Steady state Active geneation contol Spinning eseve off-peak tundown SS Shutdown Load Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 8
9 Stat-up tansient stess Coutesy of John Gülen, Gas Tubine Combined Cycle Fast Stat: The Physics Behind the Concept Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 9
10 Tubine pessues vs. flow (load) Nomalised pessue [ ] Linea CV Ext #5 Ext #4 Ext #3 Ext #2 Ext #1 Cond Q U ALMTD Q m c T Q m hsteam m Steam h Cond CW Steam m p,cw h m CW, c p,cw Cond Steam m CW,in h Steam T Cond CW,out Nomalised flow [ ] Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 10
11 Condense pessue vs. flow (load) 1 16 Relative pessue [-] Condense pessue Linea Extaction #1 pessue Pessue atio Relative flow [-] Tubine load Section pessue atio[-] Q U ALMTD Q m c T Q m hsteam m Steam h Cond CW Steam m p,cw h m CW, c p,cw Cond Steam m CW,in h Steam T Cond CW,out Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 11
12 The poof Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 12
13 Gid codes Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 13
14 Gid stability The inetia constant: The inetia constant is typically within the ange of 5 and 10 seconds: Nominal powe = 500 MW 5 s MJ 10 s MJ Enegy equied duing a 5000 MJ, as 48 MJ/kg natual gas: This is equivalent of some cups of tea! Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 14
15 Gid stability 10 units á 500 MW unning at 90 % load 4500 MW Gid demand (4500 MW) Fequency Speed/fequency vs. s Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 15
16 Gid Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 16
17 Inceased flexibility stating Stess contolle State-of-the Blankets Since the 80s matue if OEM involved Hot ai High initial cost Vey effective High-speed baing Risky Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 17
18 Heating blankets Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 18
19 Hot-ai ST waming Used by Kalshamnsveket (KKAB) since 1980s Lage 340MW HP-IP-LP Alstom (BBC) utility tubines Flanges fo blowe/heate Open vacuum beake About 15 minutes fo hogging/vacuum pull No coosion isk since RH<<60 pecent Hot ai Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 19
20 Backgound Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 20
21 High-speed baing Both ventilation and disk fiction feed enegy into the tapped steam. Scales with speed cubed and density Nomal baing speed is appox. 200 pm Potential isk of uneven tempeatue Moe wok with longe blades and stage diamete LSB spay cooling Pipe and valve fom HP-extaction to condense Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 21
22 Shaft glands Coutesy to Siemens Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 22
23 Gland system Inceased pessue No o low load Contolling Low P. Low P ba(a) Spay Sep. The mass flow of seal steam into the tubine(s) follow a Fanno line Steaming seals should be avoided Steam into the HPT though seal off-load pipe(s) Steam supply must be available No had-wae modifications 0.98 ba(a) Closed FAN Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 23
24 Inceased flexibility in opeation Capacity bypass Loss one in use Exta ac Small loss when not used Top-heate shut-down Thust foce Condensate pump shut-down sliding pessue mode Caveat! Dum- and hot well levels Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 24
25 FW7pasEnhanced flexibility Capacity by-pass HP G LP m m by. HP-FV by-pass0fwt/deae HP-FWH bypass Capacity bypass Top-heate fo constant FW-temp Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 25
26 Roto stess tempeatue gadients T Steam T T Suface T Aveage T Cente ΔT Tempeatue induced stesses (adial and hoop): σ σ θ 2 2 y α E i T d T d μ y i i 2 2 y α E i 2 T d T d T μ y i i Simplified equations fo a case without a boe: i i Example α = C -1 E = MPa ΔT = 55 C = 46 MPa σ σ θ 1 im α E T d T d im im 1 1 α E ΔT im α E T d T d T im im 1 α E ΔT Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 26
27 Roto stess tempeatue gadients 3 C Enthalpy 46 C 94 C 18 C 28 C The HPT-example shows a load change fom full to 1/3 load IPT swallowing capacity and e-heate tempeatue contols the HPT backpessue Contol mode ΔT fist stage ΔT exhaust Patial ac 94 C 61 C Thottle 46 C 28 C Sliding 3 C 18 C 61 C Entopy Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 27
28 Fatigue low o high? Wöhle- o σ,n cuve Based on Tanuma & Tadashi, Advances in Steam Tubines fo Moden Powe Plants Stess amplitude, [σ a ] Failue Stess Fatigue limit No failue no cack initiation Low-cycle fatigue High-cycle fatigue Life cycles, [n] σ Time σ a σ a Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 28
29 Casing wall tempeatue pobe Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 29
30 Avancead tubinegulato T Steam T T Suface T Aveage T Cente ΔT Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 30
31 Aged deteioation failues Type of deteioation Mode of deteioation Damage o incidence Typical damaged potion Based on Tanuma & Tadashi, Advances in Steam Tubines fo Moden Powe Plants Mateial Pefomance Ceep Embittlement Fatigue Envionment assisted cack Softening Ceep Wea/ubbing Eosion/FAC Scale deposition Themal fatigue Low-cycle fatigue Fetting Dynamic SCC* Static SCC* Coosion fatigue *Stess coosion cacking Cack Bittle factue Cack Cack Cack Cack Cack Cack Loosening Defomation Efficiency decease Efficiency decease Efficiency decease, stick, ubbing HP/IP shoud, blade goove, HP/IP casing, main pipes, main valves HP/IP oto HP/IP heat goove, bottom of blade oot goove LP last blades goove of LP oto, HP/IP casings HP/IP blade goove of oto Blade goove of LP oto Blade goove of LP oto Blade oot and goove, shoud and pofile Casing bolts (high tempeatue) HP/IP diaphagm nozzle plate (impulse), HP/IP oto and inne casings (leak) Seals, beaings, valve shafts Contol stage nozzle and LP last stages HP/IP nozzles and blades, main valves Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 31
32 Envionment assisted cack Based on Tanuma & Tadashi, Advances in Steam Tubines fo Moden Powe Plants Static stess Repetitive stess Vibation stess Mateials Stength high is moe suspicious fo SCC Impuities etc. Stess Envionment SCC Dynamic SCC Coosion fatigue Tempeatue Wetness* Dissolved oxygen Coosive envionment Impuities in steam Stat-up and shutdown *Wilson zone Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 32
33 Tubine damage eosion Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 33
34 Solid paticle eosion (SPE) N.B. This is a vey design specific poblem!!! Ken Cotton, Evaluating and Impoving Steam Tubine Pefomance, 2 nd ed. Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 34
35 Tubine damage ubbing Lund Univesity / LTH / Enegy Sciences / TPE / Magnus Genup / Page 35
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