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Rev. 01

WRITE UP

ON

TURBINE PROTECTION SYSTEM

PROJECT: BHUSAWAL TPS EXPANSION

PROJECT 2X 500 MW
CONSULTANTS: DCPL NAVI MUMBAI

00 10.07.07 MS Sd./- BSR Sd./- BSR Sd./-

Rev. REMARKS DATE WORKED CHKD APPD

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1.0 GENERAL :
The turbine protection system can be actuated by any of the following trip
systems :
-- Hydraulic trip system
-- Electrical trip system
Both the trip systems, when initiated, act on the hydraulic control system
and cause trip oil pressure to collapse which in turn closes the Emergency
stop valves, Interceptor valves and control valves.

2.0 HYDRAULIC TRIP SYSTEM:

The hydraulic trip system comprises of the following trip devices and actuation
of any one of these devices trips
the turbine.
-- Overspeed trip device 1
-- Overspeed trip device 2
-- Vacuum trip device
-- Hand trip lever 1 (local)
-- Hand trip lever 2 (local)
The mode of operation of these devices is separately covered in the
description of hydraulic control (governing) system.

3.1.1 Configuration :

Two trip solenoids MAX51AA001 & MAX51AA002 are provided in the hydraulic
circuit, which get trip signals from the electrical system. Actuation of any
one solenoid is sufficient to trip the turbine.
The electrical system is configured as a 2-channel system. Each channel is
realized in a Processing Unit . Both the processor units are completely
independent of each other and input modules, processor module and output
modules reside on each.
Each channel having two processors Unit with one processor in hot standby
mode .Trip signals from sensors/field instruments are conditioned &
distributed to both the channels (processor unit ) via hardwired modules.
Realisation of 2 out of 3 trip logic is carried out in the processor. On detection
of a fault in any one of the input signals to a channel, the configuration for
that channel changes from 2 out of 3 to 1 out of 2 and is annunciated .
Further failure in a channel changes the configuration to 1 out of 1. Trip
signal from each of the local buses acts on 3 relays in 2 out of 3
combination. Configuration of the system is shown in Fig. 1 on sheet7.

Both the channels are tested periodically even while the turbine is
running. Cyclic testing is done automatically at preset intervals and can be
blocked from the protection cabinet, if desired. The testing can also be
initiated manually from the cabinet. Only one channel can be tested at a
time. Online testing is done by simulating the trip signals and it determines

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faults in the input modules, processor modules, output modules or the

trip relays. These faults can be acknowledged from the cabinet. Next cycle
test can only be carried out after acknowledging of the fault.

3.1.2 Once initiated, the trip signal keeps the trip solenoids energised unless and
until the following conditions are fulfilled :

i) Command signal from the individual trip initiating circuit ceases.

ii) Both the ESVs are closed and trip oil pressure (sensed by any of the two
pressure switches tagged as MAX51CP011 & MAX51CP012) is less than 2
Kg/Cm² : ( Disconnection relay 1 ) OR
( Disconnection relay 2 ) is made ON from reset program of ATT , SG : Safety
devices .

The protection system conforms to the following

requirements :

3.1.3 The command signal appearing due to a fault sustains till

i) the deviated parameter causing the fault returns to normal operating value or

ii) all the related safety measures are successfully implemented.

The specific safety measures means for once trip is initiated , during the trip
initiation if some fault occurs, the trip command to trip solenoid valve will be
maintained and ESV will be completely closed with help of safety devices.

3.1.4 The affected equipment should be reinstated by the operating personnel

only after ascertaining the cause of the fault and its elimination.

3.1.5 Once initiated, the fault command signal cannot be interrupted or

reversed till all the related safety measures are successfully implemented.

3.1.6 Suitable signals are provided for annunciation of fault conditions in the
control room.

All fault conditions shall be annunciated independently and action of

protection system and trip-out shall not hold annunciations for any
subsequent faults. Under such conditions annunciation system must ensure
positive identification of the first cause which initiated action of the protection
system.

3.1.7 Hydraulic trip devices including the trip solenoids MAX51AA001 and
MAX51AA002 can be tested even during on- load with the help of Automatic
Turbine Tester (ATT).

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During such testing both the trip channels are transferred to two separate trip
solenoids (test) MAX51AA201 & 202 which serve to trip the turbine if any
actual trip condition arises during testing.

3.2 TRIPPING CRITERIA :

The turbine trips automatically under any of the following conditions. The
initiating signal in each case actuates both the channels.

Turbine trip system , drg. no. 41800039112 may be referred for generation of
trip criteria.
3.2.1 Condenser Pressure protection :

Two types of condenser pressure protection , one with fixed set point (FSP)
and one with variable set point (VSP), are provided. The task of condenser
pressure protection is to protect the condenser against a non permissible
pressure increase and the deterioration of vacuum.

3.2.1(a) Condenser pressure protection (fixed set point ) :

This is a back up protection to the hydraulic low vacuum trip device mentioned
in clause 2.0.
To prevent operation of trip circuit during start-up, an interlock is provided.
This interlock ensures that the trip circuit is enabled only, if the turbine speed
is more than 540 RPM. The trip signal is initiated by three pressure
transmitters in 2-out of -3 logic configurations.

3.2.1(b) Condenser pressure protection (variable set point)

For the protection with variable set point , the permissible condenser pressure
is specified through a set point characteristic curve in each channel depending
upon the LP inlet pressure . The setpoint is derived such that it is lower for
lower mass flow through LP turbine. Difference of the actual pressure value
minus pressure set point is continuously compared with a limit signal in each
of the channels. If the differential pressure (Δp) exceeds the set limit a trip
signal is formed in each channel. The 3 trip signals are gated in 2V3 logic
configuration, The trip signal is enabled with a release (> 540 RPM)

3.2.2 Lube oil pressure low :

The protection acts if the lube oil pressure before thrust bearing decreases
to 1.2Kg/Cm² . The trip signal is initiated by three pressure
transmitters in 2-out-of-3-logic.

3.2.3 Fire protection :

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The protection acts in the event of any of the following conditions :

i) Fire protection switch either in control room or in machine hall operated.
ii) Level in main oil tank falls to a very low value indicating substantial
leakage of oil from the system.

The command signal under condition (ii) is initiated from three level
transmitters in 2-out-of-3 logic configuration . The trip circuit shall switch on
automatically if the oil level rises above
'low level' after turning gear operation. The command signal remains
blocked till the turning gear oil supply valve is not closed.

3.2.4 HP Exhaust Temp. High :

The HP exhaust steam temp. protection ckt. protects the exhaust section of
the Turbine, the blading & extraction points against overheating.
During startup/shutdown or load rejections, there can be long period during
which steam turbines are operated at very low volumetric flows and relatively
high back pressure i.e. the mech. Energy transmitted by the turbine shaft is
converted to thermal energy, which in turn result in an increase in the temp.
of both the exhaust steam and turbine components. This temp. is required to
be monitored to avoid any deformation in the casing or blades. The temp. is
measured by means of three Thermocouples and protection criteria is derived
in 2 out of 3 logics."

3.2.5 Axial Shift Very High :

A too low axial displacement of the turbine shaft may cause damage to the
turbine blades. This protection trips the turbine in case the axial shift of the
shaft exceeds the limits set during erection . The axial shift is
measured in both directions (±) using three proximity probes. These
measured signals are fed to a protection ckt. designed in 2-out-of -3 logic
for further realization.

3.2.6 HPT/IPT Top Bottom Temp. High

Excessive large temp. differentials within turbine components cause heat

stresses. The temp. differential between upper & lower parts of the turbine
casing (HP and IP sections) is a measure of casing distortion. The casing
temperatures of HP turbine are measured using three thermocouples are
configured in 2 out of 3 logic. The casing temperatures of IP turbine are
measured using three thermocouples also configured in 2 out of 3 logic.

3.2.7 TG Bearing Metal Temp. Very High :

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The excessive temperature rise of bearings during operation can cause wear to
bearing shells.
Bearing temperature high trip protects the thrust and journal bearings of the
Turbine and Generator against excessive temperatures rise. The temperature
of the Babbitt metal temp is measured by means of four thermocouples in the
bearing for each bearing at HP front and HP rear Journal bearings and Thrust
bearing. In other journal bearings , temperature is measured by means of
thermocouples at front and rear end of generator and exciter. Protection
criteria are derived in 2 out of 4 logics configurations of each bearings to safe
guard the TG set.

3.2.8 Turbine overspeed trip

Turbine overspeed protection (elctronic) is provided to prevent the TG set
from overspeeeding in addition to existing mechanical overspeed trip device
1&2. The speed signal is taken from speed probes and criteria are derived in 2
out of 3 logic configuration. If the actual turbine speed exceeds above 3300
RPM then turbine is tripped.

3.2.9 Write up on wet steam protection shall be included

3.2.10 Turbine trip switch operated :

i) The protection acts when the turbine trip switch 1 & 2 in CRT is
operated manually.
ii) The protection acts when the turbine trip switch 1 & 2 on Desk to be
provided by BHEL operated manually.

3.2.11 Trip command initiated from ATRS

Trip command signal initiated from 'Shut-down' program of Turbine Sub-

Group Control in ATRS.

3.2.12 Trip command from Gen. mechanical protection

Trip command signal is initiated to trip the turbine from 2 out of 3 logic of
gen. mechanical protection processed in Generator Auxiliary Monitoring
Panel .
(Refer doc. titled logic diagram on Gen. mechanical Protection and document
titled w/p on logic for Generator Auxiliary Control & Instrumentation).

3.2.13 Generator Protection OR Master fuel trip relay energised:

In the event of generator faults under Class-B trip both the turbine trip
channels are actuated to trip the turbine. In such a case the generator
protection acts as mentioned at clause 4.0.

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In the event of generator faults under Class-A trip or in the event of boiler
Master fuel trip relay energised, the command signal for turbine trip shall
act simultaneously and independent of other equipment trip out sequence.
Three contacts for each of these conditions are taken from respective areas
and processed in 2 out of 3 logic.

4.0 Isolation of Generator from grid :

4.1 It is recommended to provide two identical and independent channels and

each channel with separate reverse power relay for isolation of generator
from grid. The generator breaker shall open if one or both the channels
operate. Each channel shall be operated under any of the following conditions:

i) Turbine has tripped and reverse power relay has operated. The
command signal shall be initiated with a delay of 3 Seconds OR

ii) Reverse power relay has operated. The command signal shall be
initiated with a time delay of 10 seconds.

4.2 In addition gen. Breaker opening scheme identical to 4.1 but with Low
Forward Power Relay may be parallely used as shown in Turbine Trip System.

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