Turbine Stress Evaluator

TURBINE STRESS EVALUATOR
By
SUMIT CHAURASIA
EE , TMD-III
2X250 MW, PTPP, Parichha
Turbine Stress Evaluator (TSE)
Function:
The turbine is equipped with Turbine Stress
Evaluator to assist in attaining optimized start-up,
operation and shutdown without impairing the
expected operating life. During changes in operation
of the turbine, the internals of turbine are subjected to
temperature fluctuations resulting in thermal stresses.
The maximum thermal stress is proportional to the
difference in temperature at the surface on the steam
side and the mid wall temperature. This difference is
compared with the permissible temperature
difference, which is determined on the basis of -
Estimated load cycle on turbine
Thermal fatigue strength of material.
The geometry of the components.
The difference between permissible temperature
difference and the actual difference between surface &
middle wall temperatures is known as available
temperature margin.
The margins are evaluated in an analogue computing
circuit and displayed in the instruments as upper and lower
temperature margins up to the stage of synchronization
and as load margins during subsequent loading. The
display also indicates the component, which is critical at
any given time.
The scheme of TSE consists of following five computing

channels
1. Emergency Stop Valve
2. IP turbine shaft
3. HP turbine casing
4. HP turbine shaft
5. HP Control Valve
Channels 1& 5 (ESV & HPCV) form the steam

admission area and channels 2, 3 & 4 form the turbine
area.
The input to turbine stress evaluator is supplied by thermo-
couples mounted on stop valve, high pressure turbine and
intermediate pressure turbine. Ni Cr-Ni thermocouples (WT
Sensors) are used for measuring the surface temperature near
steam (Θi) and mean temperature (mid wall temperature)
(Θm) for the five channels. But for channels 2 & 4 (HP & IP
shaft), the mean shaft temperature (Θm) is derived by
computation from (Θi) .
The output of thermocouple is fed to analog signal
conditioning cabinet where it is converted into 4 - 20 mA
signal and fed to TSE cabinet .
The actual load of the turbine generator set Pact is
measured separately and a current signal of 4-20 mA
is available for load indication and computation of
load margins. The speed is also measured separately
and 4 - 20 mA signal is available for display in TSE
indicator.
Computation
The permissible temperature margins are converted into
permissible load margins with the help of mechanical
stress calculations for on load operation of the TG set.
The available temperature margins are converted into
corresponding load margins by TSE circuitry with
the help of mathematical algorithms. These load
margins are the guiding factors to further load or
unload the TG set on both manual and automatic
mode
Principle of Operation
In each computing channel, the difference between
(Θm) and (Θi) is calculated as (ΔΘ) and this is
compared with the permissible upper and lower
temperature difference (ΔΘu) per. and (ΔΘL) per. which
are dependent on the mid wall temperature and are
derived from function generators.
The difference between (ΔΘu) per. and (ΔΘ) gives the
upper temperature margin whereas difference between
(ΔΘL) per and (ΔΘ) gives the lower temperature
margin. These margins are called available temperature
margins and are represented by (ΔΘu) and (ΔΘL) the
lower temperature margins of admission area and
turbine area.
During no load and start-up and shutdown operations the
temperature margins are indicated for admission (or for
the turbine area whichever is lower or as selected),
together with the instantaneous speed. During on load
operation the upper and lower load margins ΔPu and ΔPL
are computed from available minimum temperature
margins and are displayed together with instantaneous
load value.
Significance of TSE Margins
The difference between permissible temperature difference
and actual difference in temperature is known as temperature
margin.
The maximum permissible temperature difference allowed
Vs Θm (mid wall temperature). These curves depend upon
the thickness of the material at the point where the
margins are calculated, and as well as on material
composition. Hence all the five channels of TSE have
different curves.
Calculation of margins with respect to Θm of 250°C
Steam Temp Θi = 280° C
Mid Wall Temp Θm = 250° C
 Θ act = Θi - Θm
= 280 -250 = 30° C
Maximum Upper Permissible Difference = 60 ° K
Maximum lower Permissible Difference = 30 ° K
The Maximum Upper Margin = Θ Permissible -  Θ act
= 60°K- 30°K
Similarly from Lower curve,
The maximum lower margin = -80-30 = -110 ° K
Hence
Θi maximum = 280+30 = 310 ° C
Θi minimum = 280-110 = 170 ° C
The inference of the above computation of upper and lower temperature
margins is that the steam temperature Θi can be increased by 30°C (to the
level of 310°C) safely. This is known as upper margin. Similarly Θi can be
decreased by 110°C safely and this is known as lower margins.
Effect of TSE Influence
 The influence of margin during rolling is such that the rate
of rise of speed is directly proportional to TSE margins
between 0 - 30°K rpm/ min.
 If margin is more than 30°K, then the speed
increases at a constant maximum rate of 600 rpm/min.
During loaded condition, the rate of rise of load depends
upon upper margin and rate of decrease of load depends
upon lower margin as follows:
 TSE Margin 0- 30°K =0 - 25 MW/min. If the margin
is more than 30°K load will increase/decrease at a
constant maximum rate of 25 MW/min. Between 0- 30°K
of margin, the rate of rise of load is directly proportional
to margin.
 Hence operator should maintain TSE margins well above
30°K while rolling & loading the set by proper control of
MS & HRH steam temperatures.

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TURBINE STRESS EVALUATOR

The scheme of TSE consists of following five computing

Channels 1& 5 (ESV & HPCV) form the steam

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