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1.0 INTRODUCTION :

TSC is realised a part of TG control system.

During start up, load changes and shut down, the internals of the
turbine are subjected to temperature fluctuations, resulting in
thermal stresses, which in turn cause material fatigue. To achieve
safe operation during the total lifetime of the turbine and to prevent
premature failure of turbine or parts of it, these thermal Stresses
must be kept within permissible limits. The main task of the
Turbine Stress Controller (TSC) is the on line monitoring and
evaluation of turbine components in respect of their
material fatigue and life expectancy. TSC monitors the operational
non steady-state thermal stresses affecting the steam admission
area and the turbine. Dedicated computing channels perform on
calculations of material fatigue. For fatigue calculation & long term
storage a dedicated PC will be provided. This allows turbine
operation within a set envelope against various permitted stress
types or loading combinations.

2.0 COMPONENT FATIGUE:

Changes in the steam temperature inside the turbine cause non

steady-state changes in the metal temperature of the individual
components, giving rise to both free and constrained thermal
expansions. Whereas free thermal expansion shows itself as a
change in length and distortion and is allowed for in the design for
normal operation, constrained thermal expansion causes thermal
stressing which leads to material fatigue. These stresses occur
cyclically during operation, i.e. they are alternating in nature
(compressive and tensile stresses developed during start-up and
shut down respectively). Depending on the location of stress
development and the resultant fatigue mechanism, a distinction is
made.

a) Low Cycle Fatigue: The thermal stresses, acting at component

surfaces, which are exposed to steam, leads to what is termed
as " Low Cycle Fatigue (LCF) “.
b) Stress Cycle Fatigue: For the thermal stresses acting at the
shaft centerlines the resulting fatigue is termed as " Stress Cycle
Fatigue (SCF) “.

The magnitude of temperature differences within the components

and thus the degree of thermal stressing are governed by the time
profiles of steam temperature changes, heat transfer between
steam and metal, and the geometry and material properties of the
component concerned.

In addition to the above, creep fatigue is also considered in the

calculation of total material fatigue.

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3.0 FUNCTIONS OF THE TSC:

 The microprocessor-based system of the TSC is capable of performing

a large number of tasks.

 It compares thermal stresses in monitored components with the limits

for the operating modes to generate the reference variables (guidance
signals) which correspond to the smallest of the upper and lower
temperature margins respectively of all the monitored components.

 The reference variables (guidance signal) for speed or load increase /

reduction, are supplied to the set point control of the turbine
controller. Thus the TSC acts directly on the turbine control system.

 With the TSC it is possible to monitor turbine operation against three

temperature limits associated with different fatigue rates: one for fast
operation with high fatigue rates (F mode), one for normal operation
(N mode) and one for slow operation with correspondingly low fatigue
rates (S mode).

 On line fatigue rate calculations to evaluate the actual life expectancy

of the monitored components or component cross sections.

 The TSC provides long-term storages of parameters, necessary for

fatigue analysis.

 The smallest temperature margin in the TSC serves as the set point for
the warm-up controller.

 TSC derives the start-up criteria’s for ATRS.

4.0 MEASURED VALUE ACQUISITION:

For stress evaluation it is necessary to have information on the

surface temperature and the wall center temperature of the
component as well as the shaft centerline temperatures. The
components, which are found most critical from thermal stress
point of view, are monitored. They are Emergency Stop Valve
(ESV), HP Turbine Control valve (HPCV), HP Turbine Casing (HPC),
HP Turbine Shaft (HPS) & IP Turbine Shaft (IPS).

The monitoring scope depends on turbine design, the design of

main steam piping and the configuration of the steam admission
area. Temperature measurements are carried out by Ni-cr-Ni
thermocouples.

The temperatures measured by thermocouples are acquired in TSC

RPU. For Surface temperature of valve & casing components and
likewise the mean wall center component temperatures of ESV,
HPCV & HPC are measured However it is not possible to
measure material temperatures in the turbine shafts by
thermocouples. Instead the shaft surface temperatures are

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measured with sufficient accuracy at suitable parts of the casings,

where the thermal behavior is similar to that of an imaginary
measuring point on the shaft surface. It is then possible to use this
value to derive the mean integral shaft temperature Tm and the
temperature at the shaft centerline Tax (Ref. Appendix - 2).

Steam pressure measurement, required for creep fatigue

calculation, is carried out by pressure measuring transducers at
relevant measuring points.

The actual load of the turbine generator set (pact) and

instantaneous speed
(nact) are measured separately.

5.0 CALCULATION OF FATIGUE COMPONENTS:

5.1 LOW CYCLE FATIGUE (LCF):

The criterion for analysis of low cycle fatigue is the occurrence of a

temperature difference ∆T = Ti – Tm, where Ti represents the
surface temperature and Tm the wall center temperature of the
component. Maximum values of compressive and tensile stresses
(highest values of T in positive and negative directions
respectively) in each stress cycle are added together to assess the
fatigue increment of that cycle.

Successive different values for T of like sign are termed as

intermediate fluctuations and are calculated within a full stress
cycle and stored in a buffer memory, if such fluctuations exceed a
certain magnitude. When a full stress cycle is completed, the
fatigue increment of the full stress cycle along with the fatigue
increment due to intermediate fluctuations for that stress cycle are
added to the prevailing low cycle fatigue status of the component,
to evaluate cumulative total low cycle fatigue.

5.2 STRESS CYCLE FATIGUE (SCF):

Parallels to the cyclic stresses at the shaft surface, the inner part of
the shaft are subjected to cyclic stress changes, particularly near
the centerline of the shaft (shaft axis). For the analysis it is
assumed that there is an incipient crack at the shaft centerline,
which is growing as a result of internal stresses and cyclical,
stresses resulting from centrifugal force and restrained thermal
expansion. The criterion for analysis is the range of stress
evaluated for the stress cycles, i.e. the total stress sustained from
thermal stresses and centrifugal stresses.

It is evaluated from the difference, ∆T= Tm - Tax, where Tm is the

mean integral shaft temperature and Tax is the shaft centerline
temperature. The fatigue increment of the last full stress cycle is
derived from the summation of the highest values of T in the
positive and negative direction and from the intermediate

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fluctuations during the cycle, and is added to the cumulative fatigue

status.

5.3 CREEP FATIGUE (CF):

Creep fatigue depends on the pressure and temperature. As

the operating temperature and loading normally vary during
operation, therefore the creep fatigue is expressed as the sum of
individual periods at constant load and temperature. The average
pressure pm and temperature tm of the component over a set
period of time is used for evaluating the value of creep fatigue
increment. Creep fatigue is evaluated only at high temperatures
e.g. above 460oC. The fatigue increment is added to the cumulative
fatigue status.

6.0 WARNING POINT:

If for a component, the sum of the cumulated component fatigues

reaches to its allowable value (i.e. 100 % for casings and rotor
surface [LCF] & 50 % for shaft centerline [CF + SCF]), it does not
yet signify the "end of life" of this component, but it means that the
component has to be rigorously checked for having cracks and
creep deformation. It is an instant of warning. If cracks are
detected in a component, these must be assessed for crack growth
possibilities and suitable measures must be initiated to remove
them.

7.0 LONG TERM DATA STORAGE :

During the accumulated fatigue computation, the surface

temperature, the wall center temperature, shaft center line
temperature, average pressure and temperature (ti ,tm ,tax ,pm
etc )for the representative assembly components is saved on hard
disk and periodically on compact disk for long term storage .

8.0 OPERATING MODE INTERLOCKS:

Depending on operational requirements, three stress limits for the

turbine (i.e. three modes of operation, namely S, N & F modes)
may be selected from the operation interface, to cover the entire
range of monitored components. The increased fatigue rate
associated with the F mode can be compensated by more frequent
low stress operation (S mode). If either the "N" or the "F" mode is
selected on start up, the associated limits apply for the casings
right from the beginning. However, the limits for the "S” operating
mode apply for the turbine shafts until the relevant shaft
centerline temperature exceeds 100oC, even if the "N" or "F"
mode is selected. The signal lamp in the color monitor (ref.
Appendix 1) remains illuminated until both shaft axes have reached
to the temperature of 100oC. Beyond this point it is possible to
switch from "S" to "N" mode or from "N” to "F" mode at any time.

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Before switching over from the "F" mode back to the “N” mode or
from "N” to the "S” mode, it is automatically checked whether
there will still be a positive temperature margin of 15oK in the new
mode. If the "F” mode was selected, TSC will automatically
switch back to the normal mode if the following conditions are
satisfied:

- Tm HPS greater than 500oC

- Pact greater than 30%
- Set point control matched
- Changeover to slow mode possible

9.0 STRUCTURE OF THE TSC:

Structure and interfacing of TSC with the superheated steam

turbine is shown in Appendix 1.

10.0 DISPLAYS :

The following parameters are available to the operation .

 Actual speed and actual load both parameters are displayed
digitally also

 Reference variable for raising / reducing temperature or output

.

 Temperature margins for ESV, HPCV, HPC, and HPS & IPS are
continuously displayed on the monitor .
 Display of selected operating mode "S”, "N" or "F"

 Alarm window (e.g. to display "measuring point failure" or to

display which channel is faulty)

OUTPUT REPORT

The following data can be printed on the request of the operator:

 TSC current data
 Creep fatigue matrix
 Epsilon Temp matrix
 -Sigma temp matrix

Appendix 2 shows the points which are recorded for historical

storage (HSS) in MMI (Man Machine Interface ) system of MAX
DNA.

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11.0 CALCULATION OF MARGINS:

For any component, the difference Ti - Tm represents the actual

thermal stress acting on the component at that moment. Depending
on the value of the mean temperature Tm and the operating mode
selected, the permissible value of thermal stress is determined. The
difference between the permissible stress and the prevailing actual
stress gives rise to the "margins". With the permissible differential
temperature ‘dt permu’ or ‘dt’ perml’. This comparison yields the
temp margin ‘ddtu’ and ‘ddti’. The margin with the subscript
‘u’(upper) is used for raising the turbine’s temperature( increasing
speed or power) and the margin with the subscript ‘l’(lower) for
reduction of temp,(speed or load)

The scheme for margin calculation is given in Appendix 3.

11.1 MEANING OF MARGINS:

The available margins (both upper & lower) for each component as
well as for the reference variables are indicated by color bars (ref.
Appendix 3). A margin is the allowable step change at that
moment. As long as the margins exist, it implies that the
components are within allowable stress limits. For any component,
if margin becomes zero. It implies that one should wait for
sometime till sufficient margin becomes available.

If the margin of a particular channel is less then the other channel.

It indicates that the margin of this component influences the warm-
up & the start-up controller at that time.

11.2 TSC FAULT:-

TSC fault is generated on following condition -:

(i) TEMP. signal acquisition fault .
(ii) JB thermostate monitoring fault .
On detector the fault, the margin signal (ddTu /ddTl )are switched
to a fixed valve of 15k . Also annunciation of fault signal is made.

11.3 ACTION ON TURBINE CONTROL SYSTEM:

The reference variables derived from the minimum temperature

margins, act directly on the turbine control (guided signal) system
via the set point controllers for "Speed" and "Load" (Appendix 3).

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HISTORICAL STORAGE OF TEMPERATURES/MARGINS IN MMI

SYSTEM.

Following parameters are stored in MMI system for retrieval, whenever

required.

MEASURING PARAMETER SCALE

POINT
01 TMS -- Main steam temp. 0-600oC
02 TRH -- Hot reheat temp. 0-600oC
03 Ti ESV -- Measured value 0-600oC
04 Tm ESV – Measured value 0-600oC
05 Ti HPCV -- Measured value 0-600oC
06 Tm HPCV -- Measured value 0-600oC
07 Ti HPC -- Measured value 0-600oC
08 Tm HPC – Measured value 0-600oC
09 Ti HPS -- Representative value 0-600oC
10 Ti IPS -- Representative value 0-600oC
11 Tm HPS -- Calculated value 0-600oC
11 Tax HPS -- Calculated value 0-600oC
12 Tm IPS -- Calculated value 0-600oC
12 Tax IPS – Calculated value 0-600oC
13 TU ESV -- Temp. Margin -150oK...0...+150oK
14 TL ESV -- Temp. Margin +150oK...0...-150oK
15 TU HPCV -- Temp. Margin -150oK...0...+150oK
16 TL HPCV -- Temp. Margin +150oK...0...-150oK
17 TU HPC -- Temp. Margin -150oK...0...+150oK
18 TL HPC -- Temp. Margin +150oK...0...-150oK
19 TU HPS -- Temp. Margin -150oK...0...+150oK
20 TL HPS -- Temp. Margin +150oK...0...-150oK
21 TU IPS -- Temp. Margin -150oK...0...+150oK
22 TL IPS -- Temp. Margin +150oK...0...-150oK
23 -- Free -- -- Free --
24 NACT – Speed (before synchronization) 0-3600 RPM = 0 to 120%
25 PACT – Load (after synchronization) 0-600mw = 0 to 120%
-----------------------------------------------------------------------------
--
Ti: Surface temp. Of Casing /Stop valve ESV: Emergency Shaft
(Steam side)
Tm: mean temp. Of Casing /Control valve HPCV: HP Turbine Shaft
Tax: Shaft centerline temp. HPC: HP turbine casing
Too: Upper temp. Margin HPS: HP turbine shaft
To: Lower temp. Margin IPS: IP turbine shaft
∆∆Tu : Temp margin upper ∆∆Tl : Temp margin lower
∆T: differential temp.

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