SUBJECT : TRIPPING OF TURBINE ON HIGH DIFFERENTIAL TEMPERATURE PROJECT : NALCO / ANGUL UNIT 7 Unit 7 of Nalco CPP was commissioned

on 6th Dec., 2002. During the cold start up of the Unit, the problem of HP/IP outer casing top bottom differential temperature very high tripping was

reported. Problem: KN-Series turbines supplied by BHEL/Hyderabad are provided with tripping at high top bottom differential temperature of HP/IP outer casing. increases to During every cold start up of Nalco Unit-7, DT the tripping level of 50 Deg.C. and Unit trips.

After trip out, DT reduces below alarm level over a period of 3 to 4 hours. During restart of Unit, DT could be contained within

tripping limit. Analysis: The construction of HP/IP module of KN Series turbines is similar to the Turbines supplied to other Sites (Jindal, Mangrol and

Jojobera). All the steam entry and exit are in the bottom half of the module. Due to this, the DT normally remains around

15 Deg.C. at full load. During cold start up, at low loads the DT remains high around 30 to 35 Deg.C. and improves during further loading. Main steam temperature to be maintained during cold Main steam

start up is between 330 Deg.C. and 370Deg.C. temperature to be increased gradually

as per the HP shaft This phenomena

temperature increase and outer casing heats up.

is generally observed in the other KN Series machines. The only difference in the machine supplied to Nalco Site is the addition of over load bypass control valve in top half of outer casing. The HP control valves are designed for 100 MW load with wide open condition. For further loading, steam is injected at the sixth stage through this over load bypass control valve (OLCV). The problem of high DT was referred to BHEL/Hyderabad. The heating phenomena of outer casing studied by BHEL/Hyderabad. The sixth stage of HP turbine provided with annular steam space enabling steam entry from over load control valve. The bottom of inner casing is provided with 6 mm drain hole to avoid condensate collection in this chamber. As the machine rolled, high

temperature steam from this drain flows between inner and out casing.

BHEL/Hyderabad made calculations/ modeling

including this drain

flow in the bottom half of casing. This indicated localised heating in the drain zone at low load as this drain becomes predominant flow in the annular space. Also the temperature measurement point is close to this drain area. BHEL/Hyderabad decided to give correction for this localized heating phenomena. The trip value is increased from 50 Deg.C. to 60 Deg.C. As the load increases the effect of drain flow in the annular space becomes negligible. Conclusion: The DT trip value increased as per BHEL/Hyderabad

recommendation.

In the subsequent cold start up, it was observed

that the DT stabilizing around 53 to 54 Deg.C. with controlled main steam parameters. During cold start up, the MS temperature After synchronizing,

maintained around 330 Deg.C. to 370 Deg.C.

the MS temperature maintained around 400 410 Deg.C. with lower elevation mill in service and careful spray control. Load maintained around 30 35 MW for two hour period. After ensuring decreasing trend in DT, further load on the machine increased. With this

measures taken, the behaviour of DT is under control and the machine could be operated satisfactorily.