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.
Turbine Stress Evaluator (TSE)
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.
 Turbine Stress Evaluator (TSE)

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 (Θ i) and mean
temperature (mid wall temperature) (Θ m) 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.
 
Turbine Stress Evaluator (TSE)
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
Turbine Stress Evaluator (TSE)

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.
 Turbine Stress Evaluator (TSE)
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.
 Turbine Stress Evaluator (TSE)
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 Θ i 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.