15 MW turbine Safety sensors

Through Interlocks, we are ensuring the safety of Steam turbine and its
accessories. Therefore, to have interlocks we have supervisory sensors to make sure the
turbine parameters should not jump the safe limits. Moreover, if they act, they either trip the
machine or shutdown it.

Speed Sensors
Six Magnetic pickup transducers are used to measure the speed of the turbine units, A
magnetic pickup is a coil wound around a permanently magnet.  When discrete ferromagnetic
objects—such as bearing teeth, turbine rotor blades, are passed through the permanent
magnet’s magnetic field, the flux density is changed.  This induces AC voltages in the coil. 
One complete cycle of voltage is generated for each object passed. If the objects are evenly
spaced on a rotating shaft, the total number of cycles will be a measure of the total rotation,
and the frequency of the AC voltage will be directly proportional to the rotational speed of
the shaft.

Speed Sensor type Input Unit Module

Magnetic pickup transducer Over speed protect 203 Unit A, Pin 11-12 (Operational)

Magnetic pickup transducer Over speed protect 203 Unit B, Pin 11-12 (Faulty sensor )

Magnetic pickup transducer Over speed protect 203 Unit C, Pin 11-12 (Operational)

Magnetic pickup transducer 505 Woodward Pin 82-83 of the governor. Sensor
Governor is functional but the input port of
governor is faulty

Magnetic pickup transducer 505 Woodward Pin 94-95, and Functional

Governor

Pulse generator Pulse Indicator Local Terminal

 Chinese vibration sensor module
Module Channel Sensor Input signal Alarm Trip signal
Signal
N1.1 Channel A Axial Pin 0,1,2 X0.7 X0.8
Operational Displacement
N1.2 Channel A Front Axial x- Pin 0,1 X0.9 X0.A
Operational vibration
N1.2 Channel B Front Axial y- Pin 0,1 X0.B X0.C
Operational vibration
N1.3 Channel A Rear Axial x- Pin 0,1 X0.D X0.E
Operational vibration
N1.3 Channel B Rear Axial y- Pin 0,1 X0.F X1.0
Operational vibration

Sensors
1. Axial displacement (Operational):

Three-wire magnetic pickup unit sensor model ZT127-0, Convertor Pretage WT-D0-A2-B2-
C2-D2 is installed and currently operational.

-24
Convertor
0

Signal

Signal:

-10 volts = zero displacement

-10 volts to zero volts= Rotor is far from axial displacement sensor

-10 volts to -20 V= Rotor is near to axial displacement sensor

2. Front Axial x-vibration sensor (Operational):

Two-wire vibration sensor, model ST-A3-B installed at Thrust bearing to measure the radial
x-vibration of turbine rotor. Sensor is operational and is installed at Chinese vibration module
sensor.
 3. Front Axial y-vibration sensor (Operational):

Two-wire vibration sensor, model ST-A3-B installed at Thrust bearing to measure the radial
y-vibration of turbine rotor. Sensor is operational and is installed at Chinese vibration module
sensor.

4. Rear Axial x-vibration sensor (Operational):

Two-wire vibration sensor, model ST-A3-B installed at rear Journal bearing to measure the
radial x-vibration of turbine rotor. Sensor is operational and is installed at Chinese vibration
module sensor.

5. Rear Axial y-vibration sensor (Operational):

Two-wire vibration sensor, model ST-A3-B installed at rear Journal bearing to measure the
radial y-vibration of turbine rotor. Sensor is operational and is installed at Chinese vibration
module sensor.

6. Front thrust bearing temperature (Operational):

K –type thermocouple is installed at front Thrust bearing to measure the temperature of the
bearing. Omron PLC Thermocouple input unit is used to process the voltage developed due
to temperature. There is no intermediate junction and special thermocouple wire is connected
from the hot junction (Bearing) to cold junction (PLC input unit).

Three-wire RTD is also installed to measure the temperature of front thrust bearing.
Yokogawa temperature transmitter is used to convert the thermal resistant to 4-20mA
Analogue signal and is processed be Analogue input unit of Omron PLC.

Only thermocouple’s temperature is displayed at HMI

7. Rear thrust bearing temperature (Operational):

K –type thermocouple is installed at rear Thrust bearing to measure the temperature of the
bearing.

Three-wire RTD is also installed to measure the temperature of front thrust bearing.
Yokogawa temperature transmitter is used to convert the thermal resistant to 4-20mA
Analogue signal and is processed be Analogue input unit of Omron PLC.

Only RTD’s temperature is displayed at HMI

8. Front Journal bearing temperature (Operational):

K –type thermocouple is installed at front Journal bearing to measure the temperature of the
bearing.
Three-wire RTD is also installed to measure the temperature of front thrust bearing.
Yokogawa temperature transmitter is used to convert the thermal resistant to 4-20mA
Analogue signal and is processed be Analogue input unit of Omron PLC.

Only RTD’s temperature is displayed at HMI

9. Rear Journal bearing temperature (Operational)::

K –type thermocouple is installed at rear Journal bearing to measure the temperature of the
bearing.

Three-wire RTD is also installed to measure the temperature of front thrust bearing.
Yokogawa temperature transmitter is used to convert the thermal resistant to 4-20mA
Analogue signal and is processed be Analogue input unit of Omron PLC.

Only RTD’s temperature is displayed at HMI.

Controller (Omron PLC)

Digital Input modules
Four Digital Input Modules, each have a 16-channel input,

4*16=64 channels, 5 spare channels

Module Channel Purpose

X0 8 Axial Alarm
X0 9 Axial Trip
X0 10 Front X-Vibration
Alarm
X0 11 Front X-Vibration
Trip
X0 12 Front Y-Vibration
Alarm
X0 13 Front Y-Vibration
Trip
X0 14 Rear X-Vibration
Alarm
X0 15 Rear X-Vibration
Trip
X0 16 Rear Y-Vibration
Alarm
X1 1 Rear Y-vibration
 Trip

Analogue Input module:

Three analogue input module, each have 8 channels, Only one channel is spare

Module Channel Purpose

Analogue card 1 AI2.1-AI2.2 Front Thrust Bearing
Temperature
Analogue card 1 AI1.1-AI1.2 Rear Thrust Bearing
Temperature
Analogue card 1 AI3.1-AI3.2 Front Journal
Bearing Temperature
Analogue card 1 AI4.1-AI4.2 Rear Journal Bearing
Temperature

Thermocouple input unit

Three Thermocouple modules, each have a 4 input channels, two thermocouples channels are
free

Module Channel Purpose

Thermocouple input T2- T2+ Front Thrust Bearing
unit 1 Temperature
Thermocouple input T3- T3+ Rear Thrust Bearing
unit 1 Temperature
Thermocouple input T1- T1+ Front Journal
unit 1 Bearing Temperature
Thermocouple input T4- T4+ Rear Journal Bearing
unit 1 Temperature

Spare Channels
Digital Input
Module Channel
X0 3
X1 16
X2 16
X3 15
X3 16
Digital Output
Module Channel
Y0 12
Y0 13
Y0 14
 Y0 15
Y0 16
Y1 13
Y1 14
Y1 15
Y1 16
Y2 7
Y2 8
Y2 9
Y2 10
Y2 11
Y2 12
Y2 13
Y2 14
Y2 15
Y2 16
Analogue output
Analogue card 1 5
Analogue card 1 6
Analogue card 1 7
Analogue card 1 8
Analogue Input
Analogue input card 1 8
Analogue input card 3 8
Thermocouple input card
Module 3 T12-,T12+
Module 3 T11-,T11+