2018 11 Turbine Maintenance Training Kps

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Vietnam EVNEPS 면지.pdf 1 2018-11-21 오후 12:49:22

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Contents Table 1. Steam Turbine General 1-1. Turbine Principle and Classification 1-2. Steam Turbine Structure 1-3. Lubrication Device 1-4. Seal Device 1-5. Turning Device 1-6. Turbine Protection Device

2. Turbine Decomposition maintenance 3. Vibration Analysis of Rotating Machine 4. Turbine Control 4-1. Turbine Control Overview 4-2. Emergency Trip System 4-3. Speed/Load Control

5. Turbine Rotor (Bearing) Alignment 6. Laser Alignment

1. Steam Turbine General

1-1. Turbine Principle and Classification

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1-3. Lubrication Device

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3. Vibration Analysis of Rotating Machine

❚#ᅯ#ખ#ᝂ# VIBRATION ANALYSIS OF ROTATING MACHINE

Equipment Diagnosis Technology?

Check the condition of equipment up to now, Predict cause of failures or abnormalities, and Anticipate potential impacts on the future and find countermeasures •

What is the Condition of Equipment when it comes to Equipment Diagnosis? ௅ Condition of multiple stresses (stress, load, environment) that cause failure ௅ Degradation or Breakdown condition of equipment ௅ Operating condition indicating performance or function of equipment

• Detect condition parameters indicating those above, and evaluate condition of equipment comprehensively

3DJH

Equipment Diagnosis technology? Definition from ISO 13372 :2004 •

Condition Monitoring ? (= Simple Diagnosis) Detect and Collect information and data indicating condition of equipment

•

What is Diagnosis ? (= Precision Diagnosis) Evaluate characteristics or signs indicating abnormal conditions

3DJH

Equipment Diagnosis technology? What is condition Monitoring Parameter? •

Parameters for examining operating condition of equipment, ௅ Method of using primary effect such as function or performance ௅ Method of using secondary effect, which occurs incidentally during operation

•

Primary Effect : Parameter observed when equipment performs its intentional purposes ௅ flow, output pressure, input current of motor, output torque, rotational speed

Condition Monitoring using Primary Effect: Performance / Behavior Monitoring In general, there are advantages of simple analysis and not requiring a special sensor.

3DJH

Equipment Diagnosis technology?

Secondary Effect : Parameters indicating ancillary condition changed by operating equipment - Vibration, Sound, Temperature •

Disadvantages : require sensors for diagnosis only and normally complex signal processing

•

Suitable for early detection of abnormalities, Check causes or places of occurrence and Diagnose

•

Secondary parameters used for Simple & Precision Diagnosis

ISO 18436 defines Equipment Diagnosis as Condition Monitoring (Simple Diagnosis) and Failure Analysis (Precision Diagnosis)

3DJH

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Wireless Vibration Portable Vibration

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Instrumentation

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Causes of Vibration

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Accurate Expressions for Self Cause [abnormal]

Result [Vibration]

Vibration

Easily traceable causes 3DJH

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Unbalance

Blade Faults , Gear Faults Surge, Cavitations

Electrical Faults

Bearing Faults

Bent Shaft

Misalignment

Water Hammering

Mechanical Looseness, Resonance, Crack 3DJH

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Amplitude ¾ Severity of Facility Problems Period ¾ Analysis for a Type of Facility Problems Phase ¾ Calibration Methods of Facility Problems 3DJH

Information earned by Vibration Amplitude

Displacement : ༁

Stress

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Vibration Magnitude (Amplitude)

¾ Vibration Displacement Distance (x) : ༁ (1/1000mm), mil (1/1000 in)

¾ Vibration Velocity Velocity (v=x d/dt) : mm/s, inch/s

¾ Vibration Acceleration Acceleration (a= v d/dt) : m/s2, g, ft/s2

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Determination of Amplitude

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Vibration Frequency (Period)

Period (Analysis for a Type of Facility Problems) ¾ Period : Time required per Cycle sec, T ¾ Vibration Frequency : Cycle per unit time Hz (cps), CPM, (Hz * 60=CPM) Radian= 57¶, ʌ ʌ ¶ Period per 1 cycle (T)= ʌʌ $QJXODUYHORFLW\Ȧ ʌI

Frequency = 1 / Period ( f = 1 / t ) 3DJH

Information obtained by Vibration Frequency

Period and Number of Revolution ¾ CPM (Cycle per Minute) ¾ RPM (Revolution per Minute) (Operating Speed)

Frequency Information ¾ Basic Frequency (1X) ¾ Dominant Frequency (Dominate) ¾ Harmonic Vibration (Harmonic)

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Order Analysis Orders and Frequency generated on Fan (EX: 1800rpm, 30Hz) – – – – – –

Motor Blade Shaft Belt Electrical Structural Bearing (roller) FTF BSF BPFO BPFI

1.0 4.0 0.47 4.07 0.18

1770 rpm 7080 rpm 832 rpm 7200 rpm 319 rpm

29.5 Hz 118 Hz 13.9 Hz 120 Hz 5.3 Hz

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743 rpm 5575 rpm 12638 rpm 17452 rpm

12.4 Hz 92.9 Hz 210.6 Hz 290.9 Hz

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Phase Measurement (LASER or PHOTOCELL)

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Phase Measurement using Key-phasor

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Measurement of Absolute Phase

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Example of Phase Measurement

Tacho Probe

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Phase @ 3DJH

8KDTCVKQP1EEWTTGPEG Vibration arises from an Excitation Force that generates motion.

In other words, a vibration is the result of dynamic forces moving machines Themselves or being generated by structures that are connected to machines • Rotation or Reciprocating motion ซ Generator, Motor, Compressor, Pump, Turbine engine etc . • Friction Vibration between machine parts ซ Gear, Ball Bearing • Vibration caused by shock ซ Press, Forging Machine, Concrete Compactor

Excessive vibrations will cause wear and fatigue, There by destructing machines. 3DJH

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Vibration Measurement [Compare Bearing and Shaft Vibrations] Bearing Vibration

Advantage

Shaft Vibration

͎Abundant Measured Data

͎Better Measurement Sensitivity than Bearing

͎High reliability of Measuring Equipment

Vibration

͎Easy to attach, detach and repair a converter

͎Swift vibration responses (If abnormalities

͎Easy to measure vibrations

occur, it is changed faster than Bearing

͎ Low-priced Instruments

Vibration changes)

͎Easy to determine measurement points,

͎Direct for fundamental quantity (ex:

and Low impacts from places

Unbalanced) to set limits

͎Relatively low of Vibration Measurement Sensitivity

Disadvantage ͎For flexible-shaft casing, insensitive detection to excessive vibration changes or abnormal vibration

͎Reliability of Measuring Equipment (Converter) ͎Limitations of Attachment Methods ͎Difference of Measured Values occurring depending on measured places . Relatively high- priced Instruments

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Learning Objectives 'HVFULEHWKH2SHUDWLRQ&KDUDFWHULVWLFRIWKH9LEUDWLRQ HTXLSPHQW

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Unbalance

Bearing

mass

fault

Gear revolution

FFT Analyzer

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Measurement Tool Classification by Function • Vibration Meter • Monitor : Continuous monitoring for equipment that is permanently installed • Analyzer : Meter + Monitor, tuned filter, Phase Ref signal

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Measurement Tool

Displacement Transducer • Contact, Non-Contact

Speedmeter • Seismic, Piezoelectric

Accelerometer •

Compression-Type piezoelectric,

• Shear-Type piezoelectric

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Measurement Tool Velocity Transducer • Consist of Coils of Fine Wire supported by Soft Spring • A Permanent magnet firmly attached the case of the transducer forms strong magnetic field around the coils. •

Vibrations are transmitted to the permanent magnet when it is fixed or firmly held onto the vibrating source

• The coil of the wire attached to the spring is suspended within the place.

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Vibration Velocity Transducer Operation Principles • When coils of wire and magnet lines are crossed each other, voltage is generated from the wire. • Voltage is proportional to the movement speed, strength of the magnetic field and the number of turns in the coils • Called Velocity Pickup as it is directly responded to vibration velocity

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Vibration Accelerometer Accelerometer •

A self-generating device that produces voltage, charge output proportional to vibration acceleration

•

Measure the Rate of Charge of Velocity ௅ Expressed as “g's generally (980.665 cm/sec2, 386.087 inch/sec2 = 32.17939 ft/sec2)

• Since acceleration equals function of displacement and frequency square, it is very sensitive to high –frequency vibrations

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Vibration Accelerometer Operation Principles •

Mechanical vibrations are transmitted to piezoelectric materials by passing through the frame when the accelerometer is fixed or held on the vibrating area. • The materials respond to vibration force of machines and generate electrical charge. • Mechanical vibrations generate force, and the piezoelectric materials are proportional to vibration acceleration, generating electrical charge. • The charge outputs (pc/g) generated by the piezoelectric material is a little, incorporating a high-gain electronic amplifier.

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Transducer Installation Installation of Transducer • Enlarge contact area • Be careful magnetic field • Be careful radiation dose

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Non Contact Transducer Non Contact Displacement Transducer •

It is difficult to judge the shaft behavior with casing velocity/acceleration vibration monitoring in case of the rotor with a pedestal (including a bearing). (Large facilities such as a turbine) • If the rotor vibrates excessively within the bearing clearance, it is required to measure the actual vibration of shaft for the purpose of monitoring clearance between seal and bearing. • Measure relative shaft in the bearing or housing.

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Non Contact Transducer(NCPU) Operation Principles • RF Signal is transmitted to small wire coils on TIP of Pickup through the coaxial cable. • The high frequency electrical signals transmitted to the coils generate magnetic field. • Any metal bodies close to the coils, in other words, the steel shaft absorbs some of the magnetic force. • Effects resulting from this absorption removes electrical load of the electrical signals and weakens the strength of signals. • The magnitude of the load reducing the strength of signals is inversely proportional to the distance between the coils and the shaft. •

The closer the coils are to the shaft, the larger the loading effect, and the smaller the carrier signals.

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Non Contact Transducer(NCPU)

Proximitor

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Non Contact Transducer(NCPU) Application • Measure Vibration(Circumference, Axial vibration) • Measure Position(location) ௅ Axial Thrust : Measure the location of Thrust Collar in Thrust BRG ௅ Radial Gap : Measure the location of shaft in BRG’ Clearance ௅ Differential Expansion : Measure relative movement between Casing and Rotor ௅ Casing Expansion : Measure relative movement between Casing and Foundation ௅ Eccentricity: Measure bending of the shaft at low speed rotation and degree of Out of Roundness

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Shaft Vibration Measurements Shaft Absolute Vibration • Vibrations of the shaft to a fixed point in space • Shaft Stick ௅ Be careful of supports by two hands, titration, same pressure, being pulled in the direction of a rotation ௅ Be careful of rust, dent, rough surface etc, and use, 1X vibrations. ௅ Check Key, Keyway, Set Screw, lubricant hole etc before measurement ௅ Reduce friction by applying lubricants, and apply it to less than or equal to 12,000 RPM ௅ Detect Out-Of-Round, Shaft Eccentricity, and check them with Dial Gauge

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Shaft Vibration Measurements Shaft Absolute Vibration • Shaft Rider ௅ Consist of Spring-Loaded Probe ௅ Installed in the bearing region, where lubricating Tip is allowed ௅ Abrasion-resistant non-metallic tip is inserted ௅ Installed in Turbine-generator etc, and used for Monitoring and Balancing

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Shaft Vibration Measurements Shaft Relative Vibration •

Shaft vibrations to the casing

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Shaft Vibration Measurements Dual Probe

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Transducer Installation Non-Contact P/U • The quality of the shaft surface to be observed shall be good. • If it is installed on the chrome plated part, errors may occur since the surface of the bottom of the plated part is rough. • The best way to install X-Y Radial Vibration Probe is to install it 90̄apart from each other as shown in Figure 3-36. In the Driver End, the right Probe(X probe) is called Horizontal Probe and the left Probe(Y probe) is called Vertical Probe. (Not related to the direction of shaft rotations) 9HUW

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Transducer Installation Non-Contact P/U • The radial Probe shall be installed within 6” from each Major bearing as shown in the pictures. Outboard 241$'

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Monitoring of Machines Learning Objectives 9LEUDWLRQ0RQLWRULQJ3ORWVFDQEHXVHG

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Shaft Unbalance and Vibration Waveform 3DJH

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Mechanical Looseness and Frequency Waveform 3DJH

Angular Misalignment Axial Direction Vibrations

Rotation Period

Amplitude

Frequency

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Parallel Misalignment Radial Vibrations

Rotation Period

Amplitude

Frequency

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Bearing Vibrations

Radial Vibrations

Rotation Period Amplitude

Frequency

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Ball Pass Frequency

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Upper Vibration Frequency to Acquire Data

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Dynamic Properties of Mechanical Structures Forced Vibration ¾ A vibration generated by an exciting force, such as Unbalance, which machines or structures vibrate at a specific frequency ¾ When the rotator is stationary, no vibrations are generated, but as the rotator rotates, vibrations are generated continuously by unbalance, and defects in bearings etc.

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Dynamic Properties of Mechanical Structures Free Vibration ¾ A vibration generated without

External Exciting Force on machines,

structures ¾ Since the first External Force, internal vibrations have been continuously generated continuously.

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Dynamic Properties of Mechanical Structures Driving Frequency ¾ A frequency (periodicity, forced vibrations) of exciting force applied at this time

when there is an external exciting force that cause the machines to vibrate Natural Frequency ¾ A frequency when machines or structures vibrate freely

¾ Properties inherently possessed ¾ Determined by factors (weight, stiffness, damping) of the structure properties ¾ To see the vibration responses resulting from applying shocks to the mechanical structures to measure natural frequencies, it is necessary to give the same shock to the full frequency domain and then excite. ¾ There exist not only the one natural frequency, but also numerous Natural frequencies

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Resonance & Critical speed Resonance: A phenomenon that vibration amplitude increases when frequency of the force (exciting force) coincides with the natural frequency of the shaft. ೘The frequency with the rotating machine is mostly the rotating frequency, but the electromagnetic exciting force and the impeller passing frequency act as the exciting frequency. ೘ When the rotating frequency acts as the exciting frequency on the rotating machine, it is called Critical speed. ೘ At this time, the vibration amplitude becomes a peak, and the phase angle changes by 90 degrees.

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Dynamic Properties of Mechanical Structures Critical Speed ¾ It is rotating speed when the natural frequency coincides with the driving frequency of machines. ¾ The driving frequency domain of machines is the rotating force of the rotor, which is the rotator. ¾ Since the shaft is bent by a large vibration in the natural frequency domain of the shaft, it is usually designed not to be operated within 20% of the critical speed.

Thermal unbalance vibration at the 1st critical level occur when generator cooling is stopped due to clogging

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Operating Modes 䋸䋸䌫䍌䌽䌹䌼䍑䋸䌫䍌䌹䍌䌽䋸䌛䍇䍆䌼䍁䍌䍁䍇䍆䍋䋸 z Steady State Condition is defined when machines operate at constant speed, direct & indirect data do not change, or very slowly change and the following may be at Steady State Condition. – Load or No-load operation state condition – Network Synchronization or Isolated Operation state condition – Useful Plot at Steady State Conditions: : Time Base Display, Orbit Display, Vertical Position Trend Plot, Spectrum Display

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Comparison of All Types of Plots The Amplitude, Phase vs. Time(APHT) Plot 䋸

- Determine whether mechanical problems have been changed over time - Amplitude, Phase vs. Time are useful for discovering mechanical problems.

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Comparison of All Types of Plots The Shaft Centerline Plot 䋸

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Comparison of All Types of Plots The Shaft Centerline Plot 䋸

- Require Pick up of ‘X’ and ‘Y’ directions to measure the Shaft Centerline. - Used to measure the average position of the shaft for Sleeve BRG clearance using DC Gap Voltage, - The position changes of the shaft centerline during steady state conditions, Slow Roll and stationary state may be caused by the mechanical force or changes of the machine condition. 3DJH

Comparison of All Types of Plots Spectrum Plot 䋸 z Spectrum represents Y axis for amplitude, and X axis for vibration frequency. Since machine vibration generates vibration of unique frequency depending on its component or cause of failures, it is effective date for examining the cause of vibrations.

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Comparison of All Types of Plots 䋸䌯䌹䍌䌽䍊䌾䌹䍄䍄䋸䌨䍄䍇䍌䋸䌳䋸Frequency vs Amplitude vs Time ] [ Spectrum vs Time ]䋸

z Waterfall Plot is to compare Spectrum Plots at the vibration measurement point of the selected machine by certain period of time. The best comparison is made when Spectrum is taken under the same operating conditions. Waterfall Plot indicates a clear trend of Vibration Spectrum. z Analyzing changes in machine responses may help check failure of a specific machine. 3DJH

Comparison of All Types of Plots 䋸䋸䌚䍇䌼䌽䋸䌨䍄䍇䍌䋸䌳䋸Amplitude vs Phase Angle vs RPM ]䋸 z

Bode plots are usually used to show response characteristics of the rotating machines, which represents Vibration Amplitude (1X) of rotating speed for RPM and Phase Delay Angle of Vibration Amplitude Vector for RPM. This is the most useful plot in representing rotating speed of various resonances in the machine.

A. Bode Plot (Uncompensated Bode Plot) Generally, it is not desirable to use Uncompensated Bode Plot except for the case that Slow Roll Speed and Slow Roll Vector for displacement Data are determined. If Run-out has a remarkable large value, the plot can be dented enough to hide the dynamic vibration information.

B. Bode Plot (Compensated Bode Plot) Generally, Compensated Bode Plot shall be used to draw information from the displacement data. This value shall be subtracted because the amplitude and the phase have been modified by the initial Run-out factor in the Slow-roll state. It is the Compensated Bode Plot that was completed by this method. 3DJH

Comparison of All Types of Plots 䋸䌚䍇䌼䌽䋸䌨䍄䍇䍌䋸䌳Amplitude vs Phase Angle vs RPM ]䋸

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Comparison of All Types of Plots 䋸䌨䍇䍄䌹䍊䋸䌨䍄䍇䍌䋸䌳Amplitude vs Phase Angle vs RPM ]䋸 z

Polar Plot is continuous vibration vector (Usually 1X) drawn as function of rpm of the shaft on the polar coordinate.

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Amplitude and Phase Angle of 1X Vibration Vector at each different rpm is directly drawn on the 2 axes. The corresponding rpm of the shaft is also stipulated.

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Polar Plot and Bode Plot have the same information, but what they emphasize is different each other.

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(In other words, slow roll speed, slow roll vector and synchronous amplification factors are normally easy to be obtained from the bode plot, and easy to check heavy spot and structural response with polar plot.

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Comparison of All Types of Plots 䋸䌨䍇䍄䌹䍊䋸䌨䍄䍇䍌䋸䌳Amplitude vs Phase Angle vs RPM ]䋸

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Comparison of All Types of Plots 䋸䌛䌹䍋䌻䌹䌼䌽䋸䌳Amplitude vs Phase Angle vs RPM ]䋸

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Waterfall and Cascade are similar, but Waterfall represents Spectrum on the basis of time-based, which is trend analysis, but Cascade is to show Spectrum represented by speed-based of the rotating machine. Thus, Waterfall is used in a steady state, and Cascade is used in a transient state. Even though it is the transient state, it is capable of using Waterfall by Sampling at specific times not at specific rpm. 3DJH

Comparison of All Types of Plots Waveform : Amplitude vs Time 䋸

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Vibrations damaged by gear and by Unbalance are distinctly distinguished as shown in the figure. Vibrations caused by Unbalance have the shape of the sine curve, while vibrations damaged by gear are spike-like shape. Or it is also doubtful that the actual amplitude may be indicated by the damaged gear teeth. Amplitude is shown when the spike-shaped signal passes through the filter for frequency analysis. An oscilloscope plays a very important role in analyzing short Transient vibrations. 3DJH

Comparison of All Types of Plots Waveform : Amplitude vs Time 䋸

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Although the vibration analysis by amplitude-frequency (spectrum) properties is useful for solving vibration problems of machines, sometimes there is a need for another information to diagnose mechanical faults in service under special conditions and to research dynamic behavior. Thus, it is helpful to watch Time Waveform vibrations that oscilloscope indicates displayed above in the figure. The vertical axis of the waveform r epresents amplitude and the horizontal axis of it represents time. 3DJH

Comparison of All Types of Plots 䋸䌧䍊䌺䍁䍌䋸䌨䍄䍇䍌䋸 z

Shaft Orbit is useful data for vibration analysis apart from Spectrum and Waveform. Two Non-contact Pick-ups shall be installed at each bearing at a 90 angle as shown in the figure. The signal from one Pickup becomes a horizontal axis input of the Oscilloscope, and output from the other Pickup becomes vertical axis input. When installing the Pickup, it is preferable to set up instrumental equipment so that the vertical movement of the axis in the bearings may be shown in the vertical direction on the Oscilloscope, and the lower part of the Oscilloscope be shown in the lower direction. In case that the site conditions are hard, it is often to install by rotating 45, at which there is no difference except that Orbit is rotated by 45 on the Oscilloscope.

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Recently, it is common to install two Non-contact Pickups on the high-speed Turbomachine, which is important for reducing possibilities that machines may stop and for protecting machines more completely in case that the Pickup fails.

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Comparison of All Types of Plots 䋸䌧䍊䌺䍁䍌䋸䌨䍄䍇䍌䋸

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Comparison of All Types of Plots 䋸䌧䍊䌺䍁䍌䋸䌨䍄䍇䍌䋸 It is obtained by simultaneously inputting the signals into 2 Channel FFT analyzer or the oscilloscope using vibration signals orthogonal to the circumferential direction of the axes. ¾ Unbalanced Vibration – Drawing whirling of shaft s a circle or an ellipse. ¾ Axis Alignment Vibration Defect – Forming a distorted ellipse or an eight-figure shape ¾ Nonlinear Vibration – Having intersecting orbits

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4CVKPI'XCNWCVKQP QH8KDTCVKQP&KCIPQUKU Learning Objectives 'HVFULEHWKHSURFHVVGHWHUPLQLQJDQGDFFHSWLQJ 5HIHUHQFH9DOXHV

Objectives of Vibration Evaluation Evaluate dynamic smoothness of machine state Perform Approval testing(evaluation of vibration quality in machinery) on common criteria Indicating limit values and ratings for vibration values of used rotational speed for startup at factory and after installation locally – to make the products useful when a manufacturer delivers them to a user Used for monitoring condition of equipment in operation •

Indicate the degree of departure from a satisfactory operating condition

•

Determine whether to operate machines continually

•

Indication of future operating instructions and Indicator of judgment

•

Indicator for deciding overhaul period

Used as data for determining the condition of machinery by comparing and reviewing the predetermined criteria and measured vibration values

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Methods of Evaluating Vibration

Absolute Judgment Relative Judgment Mutual Judgment

3DJH

Methods of Evaluating Vibration [Absolute Judgment] Compare vibration values and predetermined criteria and determine Equipment condition • Need for Vibration Criteria (ISO, JIS, ANSI, VDI) • Determine whether to repair and discard equipment • Determine whether to ship products, pass or fail import inspection • Determine stability of operation • Determine structural stability, performance and maintainability for the same equipment

3DJH

Methods of Evaluating Vibration [Relative Judgment ] Judged as an Abnormality by the Absolute Judgment since significant high vibration is already indicated during a normal time, but the equipment is actually being operated without problems In contrary, equipment that generates only micro-vibrations during normal operation (less than 1mm/s) Equipment without clear criteria Equipment judged to be normal considering the purchasing time or repairing equipment Methods of determination by examining how many times it would be from the present condition Method of Experience Vibration Values of Abnormalities ;,QLWLDO9DOXHV 3DJH

Methods of Evaluating Vibration [Mutual Judgement] Methods of diagnosing it as an abnormality when a vibration is higher among the equipment of the same types and specification

Equipment that the Absolute Judgment cannot be applied to • Equipment over 4 mm/s during a normal time • Applied to equipment less than 1 mm/s during a normal time

3DJH

Characteristics of Vibration Evaluation Standard The size of vibration varies depending on the specifications, types, modes, and purpose of use of machines The each size of vibration varies despite being manufactured by the same drawing, and processing machine Thus, separate vibration limits are required for an individual machine (ex: steam turbine, compressor, pump etc) Difficulties exist in regulating limits altogether since each limit is different even for the same pump depending on the modes and structure It is necessary to set judging criteria for normality and abnormality of each machine referring to the vibration limits or the reference values of the Standard 3DJH

Recent Trends of Evaluation Standard Vibration The experience evaluated by Shaft Vibration is more abundant in the USA than Europe, and widely adopted in the API standard. ISO established ISO 7919 ,systematic Shaft Vibration Evaluation Standard, for the first time and revised greatly bearing vibration in accordance with the standard, establishing ISO 10816 standards. Since WTO came into effect, efforts has been being made to integrate national standards of each country into International Standards. In the developed countries including South Korea, the trend is to adapt and international standards such as ISO, IEC Standards and to enact the standards into National Standard.

3DJH

ISO 10816 Series The first edition of ISO 10816 was replaced with ISO 2372 and ISO 3945, which were widely used as Evaluation Standard of the existing bearing vibrations, and expanded to be established. This International Standard consists of 6 parts as follows: • Part 1: General Guidelines • Part 2 : Large terrestrial steam turbine exceeding 50MW and generator sets • Part 3 : Industrial machines with rated power of more or than equal to 15kW measured at a field and with a rated speed between 120rpm and 15,000rpm • Part 4 : Gas Turbine Drive Set except aircraft propulsion • Part 5 : Machine Sets of hydraulic and pumping plants • Part 6 : Reciprocating machines with rated output more than or equal to 100kW

3DJH

ISO 10816 Series [Vibration Magnitude]

Two evaluation criteria are used to evaluate Vibration Severity for various types of machines. Evaluation criteria are: Broadband Vibration Magnitude measured and change in Vibration Magnitude

Additionally, operational limits are provided.

If ISO 10816 are ISO 7919 standards are applied, generally, more strict standards are to be applied.

The maximum vibration velocity vrms(mm/s) measured at the bearing housing or bearing support is divided into four evaluation areas established by experience.

•

Area A : Satisfactory

•

Area B : Accept long-hour operation

•

Area C : Accept operation within limited period (Maintenance needed)

•

Area D : Not Acceptable

Recommended values for the boundaries of these areas are differently setup depending on target machines.

3DJH

ISO 7919 Series Mechanical vibrations of non-reciprocating machines – Measurements and Evaluation Criteria of the Rotating Shaft For ISO 10816, which measures and evaluates bearing vibrations of machines, this standard is about the shaft vibration that directly measures vibration displacement on the shaft. It regulates rotating track of the shaft, conditions and methods for measuring the maximum amplitude, indicating methods of measured values, evaluation methods and criteria. This standard consists of 5 parts as follows: • Part 1 : General Guidelines • Part 2 : Large Terrestrial Steam Turbine Generator Set • Part 3 : Connected Industrial machines • Part 4 : Gas Turbine Set • Part 5 : Machine Sets of Hydroelectric and Pumping Plants 3DJH

ऎѭऎЬٔ‫࣌ۮ‬ʟ HRD CENTER z ̛˃߾оଞঋࢵଞૡɼࠪٗ۱ࡶࡢଞࡁ˱‫ی‬ତࡶࢇΏ߭ΰЕ̐ࢇԯࡵ ˃্ࢠ‫ࢂٸ‬୉‫ۘ˕ݥ‬ଢ଼߾ оଞࢶࢸଞ ٗ۱࢕Վձ˱঑ࢶࡳԻ̛ܽଡࡳԻ ‫ٗނ‬۱ࢸ८ձ਺ʯЯܻ୘ଟܹ࢑Ь z ऑѰٗ۱ࡵʠࢂତۘɼएЯ˃ɼ࢑Ь ¾঎धЕ࣏ऐࢶࡳԻଗࡁଞऑѰ࢕Վձ߱Еʨࢇˈ ¾҂धЕ̛˃ࢂઞࢽ‫ࢺࢿח‬Қࡶ୙ࢉଜ̛ࡢଜࠆ࢕ՎձૡɼଜЕʨࢇЬ

3DJH

4. Turbine Control

HRDC

Document Number : Document Name : Turbine Control Document Description : Student Handout Revision Number : 2.0 Printout : November 2018

Trainee: Instructor:

(서명)

Jin Yong Mo

(서명)

Table of Contents Table of Contents Course Objective Module 1 - Turbine Control Overview - Steam Control Valves - Control System & Architecture - Control Sequence Program Module 2 - Emergency Trip System - Hydraulic Circuit in Front Standard - Turbine Protection - Turbine Protection Test Procedures Module 3 - Speed/Load Control - Turbine Operation Mode Selection - TMR Speed(Hz) Control - Load(MW) Control Mode

Course Objectives Upon successful completion of this process, the trainee will be able to : 1. Identify Turbine Control System components. 2. Understand the operation principle of Emergency Trip System and explain Turbine Trip condition. 3. Understand the principles of Speed/Load control and explain turbine operation procedures.

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<<< Rung Number 1 >>> ********************************************************** QG TAEAN CONTROL SEQUENCE QG UNITS #1, #2, #3 & #4 QGGGCreated by : Jorge A. Morel QGGGLast revised: September 15, 1994 ********************************************************** <<< Rung Number 2 >>> ********************************************************** INDEX TO LARGE STEAM CORE "CSP" SEGMENTS LST_Q1: 1.1: PROTECTION 1.2: SPEED CONTROL 1.3: LOAD TARGET/LOAD REFERENCE 1.4: FLOW DEMAND, CONTROL VALVE REFERENCE 1.5: CV CONTROL 1.6: IV CONTROL LST_Q2: 2.1: MODE SELECTION 2.2: ADMISSION MODE CONTROL,AMS 2.3: VALVE POSITION LIMIT (VPL) SEQUENCING

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Hydraulic signal

WULS#FLUFXLWV# Over-speed Trip Device, Emergency Governor

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<<< Rung Number 1 >>> ********************************************************** QG TAEAN CONTROL SEQUENCE QG UNITS #1, #2, #3 & #4 QGGGCreated by : Jorge A. Morel QGGGLast revised: September 15, 1994 ********************************************************** <<< Rung Number 2 >>> ********************************************************** INDEX TO LARGE STEAM CORE "CSP" SEGMENTS LST_Q1: 1.1: PROTECTION 1.2: SPEED CONTROL 1.3: LOAD TARGET/LOAD REFERENCE 1.4: FLOW DEMAND, CONTROL VALVE REFERENCE 1.5: CV CONTROL 1.6: IV CONTROL LST_Q2: 2.1: MODE SELECTION 2.2: ADMISSION MODE CONTROL,AMS 2.3: VALVE POSITION LIMIT (VPL) SEQUENCING

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̰ Emergency Push Button - Pushed PB in the MCR ̰ Manual Mechanical Trip Handle / Manual Trip Valve - Turn left and then pull of the Handle (located in Front Standard) ̰ Mechanical Over-speed Trip Device

- Arrived the actual speed at 110% ̰ MTSV (Mechanical Trip Solenoid Valve) - Energized to Trip (supplied DC 125V power)

̰ ETSV (Electrical Trip Solenoid Valve) - De-energized to Trip (failed DC 24V power)

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Servo CoilG

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TCQC G

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I/O Configuration

TCQC <S>G TCQC Loc 4G

Signal ConditioningG

Voted ValueG

G Control Sequence ProgramG

Control Signal Data BaseG

Digital Control RegulatorG

Stored on EPROM chips on the TCQA cardG

Feedback signal inputs from the steam control valve position (LVDT)G

Servo-valve control reference depend on the output set-point and speed errorG

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Trip Latch L5B

L86TRP

L86TRP

L86TRP

Cross Trip to

L63VTA_V exhaust hood A vacuum trip L63VTB_V exhaust hood B vacuum trip L63VTC_V exhaust hood C vacuum trip L5E input from TCEA, 5E/PB circuit staus, emergency trip L63HLT_V low hhdraulic fluid pr. trip L5TT_HPEM HP exhaust metal temp. trip

L5A2 intermediatr trip 2

trip card relay drive 4

Elect Trip test L4_XTP

L20PTR2

trip card relay drive 3

Mech Trip Piston test 1

L97ETT

L20PTR1

1=TRIP

L86TRP

1=trip

1=run 1=run

2/3

PTR2

PTBA

Elect. Trip SV Energize to Run (normal Energize)

Mech. Trip SV Energize to Trip (normal De-energize)

Operator Trip PB

☞ TCEA includes overspeed protection

2/3

ETR2

24VDC

ETR1 PTR1

2/3

2/3

125VDC

TCTL

☞ ETR1,2 : Energizing Dropping Out

☞ PTR1,2 : De-energizing Dropping Out

TCEA

TCQA

L26HPM_ALM_T trip due to HP temp. alarm during motoring for > 5 minute L26HPM_TRP trip due to HP temp. > 370℃ during motoring L63QBLT_V low BRG oil pressure trip L63MSPT low main steam pr. trip L71MS1H_V MSR #1 high level trip L26LMP_ALM_T trip due to LP temp high motoring for > 5minute

L5A3 intermediatr trip 3

L97MTPT1

Intermediate Trip B

L86MR1_CPB

L86TRP

L63V_MTV

L39BV_T high vibration trip L39TB_T thrust BRG wear trip L26SWC_TP loss of stator coolant trip L26EHTA_V exhaust hood A temp. trip L26EHTB_V exhaust hood B temp. trip L26EHTC_V exhaust hood C temp. trip L63QPLT_V, L14SP

L5A1 intermediatr trip 1

intermediate trip 1 L5A1 intermediate trip 2 L5A2 intermediate trip 3 L5A3 excessive acceleration trip from TCEA L12H_ACC input from TCEA, 4 relay circuit status L4_FB, L86MR1_CPB input from TCEA, overspeed trip signal, cross trip L12XTRP, L97RSTZ

Loss of Speed Signal L14P1 SG Level Hi Trip SG_LVL_HI_T

L63_EMTS1 L63_EMTS2

power up pulse

L83PUP

LARGE STEAM TURBINE PROTECTION

90rpm/min

180rpm/min

3.2rpm/min

MED(0.083%/s)

FAST(0.167%/s)

VARIABLE(0.0035/S)

L3TNR_POS TARGET 증가

감소시 16%/sec

증가시 TNKR_RTE1

-15% min TNKRMN

TNR_TGT1

speed target

TNKRMX 115% max

TNKR_RN 밸브 Close Ramp Rate

60rpm/min

2016rpm

1800rpm

1500rpm

800rpm

100rpm

LOW(0.055%/s)

SPEED RATE

운전원 선택

TNKR_TS VARIABLE TNR_VA_CMD1

OVERSPEED TEST(112%)

CLOSE(-15%) TNKR_CL LOW(5.55%) TNKR_LO MED(44.4%) TNKR_ME HIGH(83.3%) TNKR_HI RATED(100%) TNKR_RT

SPEED TARGET

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360sec

0.0

actual speed (SSPU)

TNH1

TNKERR2

TN_ERR

계통병입전

±0.3% 초과시 Filter

RST C = A

lag(B) 0.8sec

A/1+Bs = C

LOW pass filter ±0.3%

speed error

변동폭 0.3%이상

+

TNR2 speed refer

L83RW (Rotor Warm)

;속도 Target이 1500rpm에서 1500rpm에 도달하면 ±50rpm상하로 움직임

WOBBULATO R active L83WOB SELECT PERMISSIVE TNK2_WOB ± 2.8%

SPEED ERROR OVERVIEW #1

TN_ERR1

L83TN_DB

0.1CNT00

TNK_CVRG1

TNK_CVRGR

0.001CNT00

speed point to change speed droop

TNKR_CVRG 89%속도 도달시 1600rpm

8% DROOP 0.08CNT00

ON 선택시 적용

rate

db

sel

TNK_CVRG

16%/sec K3TN_DB_R

0.833% (15rpmK3TN_DB

"ON"

TN_ERR1

DEAD BAND ; ± 15rpm TN_ERR1X

R A M P

출력운전중

GOV. NON-REGULATOR

B

A

CVTEST시 5%

TN_ERR2

초기값 0%

출력운전중 0.5%

A÷B

DROOP 적용

db

DEAD BAND

SPEED ERROR OVERVIEW #2

speed error, after droop, deadband

TN_ERR3

V

(speed error)

MSPLP_ERR

CVKMSPLP3 (gain, 20.0CNT07)

×

×

L83MSPLP

FPKSPF_G 궤환회로 이득 (6.0CNT07)

+ + ÷ FP_ SPF1X _

TN_ERR3

FP_SPF1

V 1+Ts

L83RW (rotor warm.)

0.0%

DWR (load reference)

FP_MSP_PU (주증기 압력)

FPKSPF_LG (시간지연상수 5sec)

FP_SPF

시간지연

고압터빈 1단압력 PT 46#1

CVKR_MX (high limit)

0.0

L83SPF 밸브시험

HOLD

min

MSPL"ON"

CVR1

DW_NLF +

MAX

CVR2

MIN

CVR_VPL

MIN

CVR4

position limit

CVR3

rate control

CVR_MSPLR

CVR_MSPLP (MSPL proportional)

MIN

proportional control CVR1

max

NO LOAD FLOW LOAD REF.

-20% CVKR_MN

-

+

+

+

+

105%

CONTROL VALVE FLOW REFERENCE CONTROL OVERVIEW #1

MIN

CVR_VPL_CTL (VPL control 설정치)

+

L83CVR_IN

CVKR_BP1 128% (forward flow) -5%

L83VPL_CTL

0.0

VPKL_CTL 2%

CVR4

VPL control

RAMP

CVR5 0.80%

L83SF_CVR split flow bias required on CVR

CVKR_SP

CV REF during turbine bypass

CVR_BP

MIN

CVR6

-10%

CV tightness test active L97CV_TGH

CONTROL VALVE FLOW REFERENCE CONTROL OVERVIEW #2

CVR

×

CVR_SCL

CVKR_TST2 0%

CVKR_TST3 0%

CVKR_TST4 0%

CV#2

CV#3

CV#4

CVKRR4_CR1 10%

CVKRR3_CR1 10%

CVKRR2_CR1 10%

CVKR4_TR1 3.3%

CVKR3_TR1 3.3%

CVKR2_TR1 3.3%

CVKR1_TR1 3.3%

CVR 증가 L3CVR1_PS

the same CV#4

CVKRR1_CR1 10%

CVR 감소시

CVKR_TST1 0%

밸브특성곡선

L97CV1

밸브시험

CVR_XA1

CVKPA4I1 (input_array)

CVKPA3I1 (input_array)

CVKPA2I1 (input_array)

CVKPA1I1 (input_array)

999%/sec

10%/sec

CVKRR1_TR1 CV1 test ramping rate

CV1 VALVE TEST

CVR_EA1

the same CV#3

＋

CVR 증가시 CVKRR1_CR1

+

×

×

Partial Arc 특성

the same CV#2

1.0

CV_AMS

0.0%

CV#1

admission mode refer, CNT01

CVR

CVKR_SCL 1.0CNT01

L97TS_CVF1 CV1 test mode CVKR_TST1

CV'S CONTROL OVERVIEW

71.86%

-0.78%

-0.78%

-0.78%

3.3%/sec

0%

GSADJ

CV1REF

GALIBRATION FUNCTION

JADJ

-25% L3CV_ENA TBN TESET

초기값

CVR_R1

TCQA_REF_2 : servo ref, CV2 position ref TCQA_REF_4 : servo ref, CV3 position ref TCQA_REF_5 : servo ref, CV4 position ref

R A M P

TCQA_REF_1 : servo ref, CV1 position ref

÷

5%

×

1.0

R A M P

IVKG_MOD5 (ramp rate 0.033 pu/s)

1.05 CNT04

L83FFZX IVR>62.5%

L83M_BYP

×

IVR2

TNKIVR5 105%

M A X MIN

IVKRR1_TR1

밸브시험 L97IV1X

IVR

IVR 증가

IVR 감소시

L3IVR1_PS

999%/sec

9.1%/sec

IVR_XA

R A M P

IVR_R1

IV1REF

TCQA_REF_6 : servo ref, IV1 position ref TCQA_REF_7 : servo ref, IV2 position ref TCQA_REF_8 : servo ref, IV3 position ref

밸브특성 곡선

밸브시험시 0%

IV #4,#5,#6은 TEST SOLENOID에 의해 ON/OFF 동작 IV #1-#4, #2-#6, #3-#5가 서로 쌍으로 대응하며, 50% 열림시 개방

IVR 증가시 IVKRR1_CR1 10%/sec

IV gain modifier

LST_Q2 150

IVRG_MOD

CVR5

CVKR_MX 105%

IVKR_CL -5%

for normal control

L3FP_HRSP (RHTR Pr>1%)

64119-PT 45#1/#2/#3

reheat steam pr

IVKG_MOD4

0.8CNT04

IVR1

intermediate steam pr

-10%

1.68 CNT04

÷

5.0CNT04

TNKIVR4

IVKG_MOD3

M A FPKHRSP_MIN X

FP_HRSP1

FP_MSP1_DB

TNKIVR1 0.01CNT00

SPEED ERROR TN_ERR

TNKIVR2 2.5CNT04 CV DROOP/IV DROOP

×

TNKIVR3 (open bias,100%) L83IV_CL LOAD REFERENCE DWR

IV #1,#2,#3 CONTROL OVERVIEW

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