1.

INTRODUCTION:

4-13300-00-404

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
.'l'o achieve safe
operation
1uring the total
lite
time 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 lite
expectancy
.
TSC monitors
the operational
non steady-stat:e
stresses
affecting
the steam admission
area
turbine.
Dedicated
computilg
channels
perform
calculations
of material
fatigue
.This
allows
operation
within
a set envelope
against
various
ted
2.0

stress

types

or

COMPONENT FATIGUE
Changes

1-11 the

loading

combinatj.ons

thermal
and the
on line
turbile
permit-

'.

:
steam

temperature

j_nside

the

turbine

cause non steady-state

changes in the metal temperatl1re
of the individual
components
, giving
rise
to both free
and constrained
thermal
expansions
whereas
free
thermal
expansion
shows itselfas
a change il length
and
distortion
and is allowed
far in the design
far 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
arid the resultant
fatigue
mechanism
, a
distinction
is made .
(

a)

Low Cycle

Fa,tigue

component
surfaces
what is termed
as
b)

Stress

Cycle

: The thermal

stresses,

which are exposed

..Low CycJ_e Fatigue
Fatj.gue

For

the

to

acting

s.t.eam , leads
(LCF) ..

tlermal

at
to

st,resses

acting 'at the shaft centerlines

the resu~ting
fatigue
is
termed as ..StressCycle
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
, hea~ transfer
the geometry
and material
concerned

In addition
ered in the

between
steam and rnetal
, and
properties
of the component

to the above , creep

calculation
of total

STE, BHEL, HARDWAR

fatigue
material

is also
fatigue.

consid-

SHEET NO 02 OF 13

8.0

OPERATING MODE INTERLOCKS :

4-13300-00-404

Depending
on operational
requi~'ements
, three
stress
Iimits
far
the turbine
( i.e.
three
modes of operation
,
nameIy
8 , N & F modes ) may be seIected
tram the contraI
desk
, ta cover
the
entire
range
of monitored
components
.The
increased
fatigue
rate
associated
with
the F mode can be compensated
by more frequent
Iow
stress
operation
(8 mode) .

lf either
the "N" or the "F" mode is selected
on start
up , the associated
Iimits
apply far the casings
right
tram the beginning
.However
, the limits
far the, "8"
operating
mode apply far t'he turbine
shafts
until
the
relevant
shaft
centerline
temperature
exceeds
100 ?C
, even if the "N" or "F" mode is selected.
The signal
lamp in the colour monitor
( rei.
Appendix 1/3 ) remains
illuminated
until
both shaft
axes have reached
to the
temperature
of 100 ?C .Beyond
this
point
it is possible
to switch
from "8" to "N" mode or tram "N" to "F" mode
at any time .
Before
switching
aver
tram the "F" mode back to the "N"
mode
or
from"
"N"
to
the
"8"
mode,
it
is
automatically
checked
whether
there
will
still
be a
positive
temperature
margin
of 15 ?K in the new mode.

lf

the

switch

tions

9.0

.
9.1

"F"
back

mode was selected

to

'the

normal

mode

, TSC will
if

the

automatically
f9llowi1:1g

condi-

are satisfied
:
-Tm
HPS greater
than 500 ?C
-Pact
greater
than 30%
-' set point
control
matched
-changeover
to slow mode possible

STRUCTURE OF THE TSC :

Structure
and interfacing
of TSC with
steam turbine
is shown in Appendix 1.
provided
far carrying
ouJ: the functions
lations
and data storage.

the superheated
A separ&te
PC is
of liofe
calcu-

PROGRAM SYSTEM :

The functions
implemented
by the TSC are modular
in
structure
and make use of so called
program blocks
(PB).
The PB's are subjected
to tirne controlled
processing
.
The TSC makes lise of 2s and 5s tirne cycles
.The
PB's
used to calculate
low cycle
fatigue
, stress
cycle
fatigue
, creep fatigue
, shaft
axis
temperatures
and
far listings
are called
up with cycle
tirnes of 5s .All
other
PB's are called
up with cycle tirnes of 2s .

STE, BHEL, HARDWAR

SHEETNO 06 OF 13

'.;