PLTU Kaltim Teluk Blikpapan

(2×110MW) Power Plant

Emergency Trip System

of Steam Turbine (ETS)
ETS (emergency trip system) is the
abbreviation of emergency trip system of
steam turbine. It is used to monitor some
parameters of steam turbine and when
these parameters exceed their operating
limits, the system will turn on AST
magnetic valve to remove oil of inlet valve
that controls all steam turbines, thus
closing all steam valves, cutting of inlet
steam of steam turbines and realizing
emergency stop of steam turbine.
1. Protection program of ETS system
2. Analysis of protection linked system
3. Reliability design principles of ETS
system
4. Power requirements of ETS system
 Introduction of ETS Related Terms

Pressure oil return: it means oil return has a certain pressure. The generation of
pressure is through check valve with spring at the end of pipeline. Before every
start of machine and in maintenance and operation, its pressure shall be checked
and maintained at about 0.6MPa. Advantage of existence of pressure oil return is
to reduce fluctuation of system and buffer impact on system.
AST oil pressure: it means oil pressure of AST common header. Three pressure
switches are used to represent successful latching of generating units or to
represent the generating units are latched.
ASP oil pressure: in four AST magnetic valves, pair-wise conditions of four
magnetic valves can be judged through changes of ASP oil pressure. For example,
its pressure in normal operation shall be 6 to 7MPa. When there is leakage in first
two magnetic valves and there is increase of ASP pressure, if it is leaked by the
latter two magnetic valves, ASP oil pressure will be decreased. (ASP represents
pressure: >9.30MPa，<4.14MPa)
 Tripping Conditions of ETS
Low oil pressure of EH (Prepared to be canceled)
Low pressure of lubricating oil
Low vacuum of steam condenser
Over speed of 110% electricity
Over speed of DEH 110% electricity
Manual interruption
MFT（hard wiring）
MFT（from DCS）
Protective interruption of generator
Large axial displacement
Swelling dyelot chromatism of high
pressure
Swelling dyelot chromatism of low
pressure
Huge axle vibration
 Low Oil Pressure of EH
Low oil pressure of EH is monitored by 4 pressure switches and the sample
is taken from EH oil header pipe on each control valve. It will be distributed
to 4 pressure switches in two direction through experiment blocks, among
which pressure switch 1 and 3 are the first group and pressure switch 2 and 4
are the second group. Normally open contact in pressure switch is used.
Movement of any pressure switch in the first group and in the second group
will trigger ETS protection.
Set value of EH oil pressure switch is no more than 9.3MPa and adopts
normally open contact to prevent refusing operation. If normally open
contact is adopted, once EH oil pressure switch is damaged and the protection
is not in normal operation, the consequences can not be imagined. Two
groups of switch operation is to prevent maloperation and when one group of
pressure is damaged for fracture of pipeline or jam of experiment blocks, it
can not directly contribute to happening of tripping.
 Because of low oil pressure of EH, AST
magnetic valve is in operation and shed of AST
oil pressure is to close high main gate, medium
main gate, high control valve and medium control
valve; but AST oil is from EH oil, and is used as
power oil of each steam port. AST will close each
steam port without EH protective action and then
trigger signal of tripping.
 Low pressure of Lubricating Oil
Low pressure of lubricating oil and low oil
pressure of EH adopt the same method and their set
value shall be no more than 0.041MPa and the
sampling point is on the lubricating oil header pipe
inside front box of steam turbine.
Problems shall be noticed:
Sampling points of lubricating oil shall be arranged
the remotest place from exit of oil pump.
Diameter of drainage tube shall not be too thin or it
will increase resistance along the tube when the
drainage tube is too long. Drainage tube not draining
oil timely will cause operation lag of the second
protection system.
 Low Vacuum of Steam Condenser

Low vacuum of steam condenser is divided into

A steam condenser, B steam condenser and 8
pressure switches in all. It adopts the same trigger
mode of low oil pressure of EH and low pressure of
lubricating oil. But normally open contact is used
and the set value is no more than 76.0KPa (vacuum).
The sampling point is located inside 6.9-meter steam
condenser.
To prevent water logging in sampling tube and
influence measurement

• There shall be no U-curve in sampling tube

• The sampling tube shall have a certain gradient

What influence does water logging have on measurement?

Precautions in the process of suck-back (tripping caused by
maloperation of anti-vacuum switch)
The drawing above is the internal process drawing of test blocks. If front pipeline of test
blocks leak out pressure, operation of pressure switch at the left of test blocks 63-1/LBO 63-
3/LBO and pressure switch at the right side 63-2/LBO 63-4/LBO at the same time will cause
Internal process drawing of improved experiment block and two groups of pressure
switches at left and right sides use their own pressure tube. It one sampling tube of them
leak pressure, for example the pressure switch at left side （63-1/LBO 、63-3/LBO）
has decompression movement, it will not cause tripping.
Over speed of 110% electricity and over
speed of 114% electricity
Over speed of electricity is measured by 4 rotary probes
(one of them is for standby application) with magnetic
resistance between #5 and #6. Two trigger points are set inside
over speed monitor between rotary signal and ETS cabinet.
Set value of the first trigger point is 3300rpm (namely 110%
over speed) and set value of the second trigger point is
3420rpm (namely 114% over speed) .
There are three over speed monitors inside ETS cabinet
and they adopt 2 of 3 method and use normally closed trigger
point to trigger protection of over speed.
 OPC Over speed
（ Over speed Protection Control ）

• In normal operation, once the rotate speed exceeds 103% and triggers operation of
OPC (>6.89MPa , normally open contact) magnetic valve, AST oil in high control
valve and medium control valve will decompress through OPC magnetic valve,
close control valve of high and medium pressure and keep completely off of
hydraulic servo-motor; when rotate speed of stem turbine falls to rated rotate speed
(3000r/min ), magnetic valve of over speed limit will lose electricity, control valve
will recover to be controlled by servo valve, regulatory valve will start again and
enter automatic control of rotate speed.
• If rotate speed still has no decrease at this time and when it reaches 3300rpm, it will
trigger operation of AST magnetic valve and all valves will be closed and the steam
turbine will trip to prevent more serious accidents from happening.
• Over speed protection is based on operation value including
primary over speed of electricity (it is 109% to 110% of rated
rotate speed in general and it is often set as 3300rpm),
emergency over speed of electricity (it is 113% of rated rotate
speed in general, namely 3390rpm) and mechanical over speed
(it is 111% to 113% of rated rotate speed in general ).
• Mechanical over speed means fly ball flies out when steam
turbine operates to a certain rotate speed under function of
spring force. Leak out controlled oil pressure through
mechanism and close all valves.
• Primary over speed of electricity can be removed
through test button (to ensure correctness of operation,
there is removal confirmation button in general
design to avoid maloperation) to make it convenient
to carry out test of mechanical over speed and test of
emergency over speed. But protective function of
emergency over speed can work all the time, so it is
not allowed to removed to ensure absolute safety of
steam turbine.
• Mechanical over speed test can be finished through
oil injection test or rotate speed of directly rising stem
turbine.
 Manual interruption

Manual interruption is used when

emergency manual tripping is needed under
condition that the generating units go wrong but
the other tripping regulation is not triggered.
Manual tripping button is located before BTG
disc in central control room, adopts triggering of
two buttons (to avoid maloperation) and it will
send signal to ETS control cabinet and start
operation of AST magnetic valve only when two
tripping buttons are pressed at the same time.
MFT
MFT signal is divided into two routes,
among which one is directly sent to ETS
control cabinet through local MFT electric
relay, the other route is provided by DO
blocks of DCS to ensure correct triggering
of MFT tripping conditions.
Protection interruption of generator

Protection interruption signal of

generator is provided by electric and ETS
tripping can correctly triggered when there
is problem in generator.
Large axial displacement

Probe of axial displacement is located nearby thrust pad between

#2 and #3 of steam turbine and adopts reverse installation. The probe
is directly facing front box of steam turbine and there are 4 eddy
current transducer and 2 spindles at left and right side.
Card from probe signal of axial displacement to TSI control
cabinet outputs analog quantity to DCS and TDM after being
processed. At the same time, when numerical value exceeds set value,
it will output switching value to ETS control cabinet. alarm value of
axial displacement is±0.8mm and the operation value is ±1.0mm.
When axial displacement of 1A and1B or 2A and 2B reaches value of
protective operation, AST magnetic valve will be triggered and the
steam turbine will trip.
• Axial displacement means the relative displacement between thrust disc in
axial direction of macroaxis and thrust bearing of axial thrust, namely
moving and motionless horizontal clearance at thrust bearing in axial
direction of steam turbine. Because thrust bearing bears axial thrust that
steam function has on rotor and moving blade and confirms axial location
of rotor, axial displacement represents magnitude of force that thrust
bearing bears and represents attrition rate of coal at the surface of tiles. To
ensure safety of equipment, it shall be controlled within reasonable design
range. In practical applications, zero position of axial displacement is set at
the center of gap of axial thrust and side movement of generator in
macroaxial direction is the positive direction. Therefore alarm and tripping
of axial displacement have positive and negative two values, and it the
alarm value is ±0.8mm , the tripping value will be ±1.0mm .
• Alarm of axial displacement generally adopts logic, namely
give out alarm signal when there is large displacement of any
axial displacement or the signal goes wrong; tripping logic of
large axial displacement can take relevant measures according
to quantity of installed probes, 2/3 logic will be adopted if
three probes are installed, there are two groups 1A and 1B, 2A
and 2B when three probes are installed, the tripping logic
adopts （1A+1B）&（2A+2B）or（1A&1B）+
（2A&2B） , namely or comes first and then comes and (or
parallel connection comes first and then series connection),
namely the system will trip if there is one axial displacement
in two groups reaching the tripping value. Give out alarm
when there is fault in one of axial displacement and trip when
there is 2/3 fault. To avoid maloperation of signal, 1 second
 Probe
Measuring panel
Probe
Macroaxis

Probe
Probe
 Instrumentation Plan of Axial
Displacement

Measured flange
Probe

panel
Pressing
driver

Probe
driver

Support of axial displacement

Transducer
Swelling dyelot chromatism of high pressure
Swelling probe of dyelot chromatism of high
pressure is located in front box of steam turbine and are
2 in all. It adopts reverse installation at left and right
sides and uses eddy current probe. The signal is sent to
TSI control cabinet and protective operation value is ≤-
4.5mm or ≥10.2mm.
When two differential expansion value are higher
than protective operation value at the same time, AST
magnetic valve comes into operation.
 Precautions concerning verification of dyelot
chromatism probe of high pressure
• Specificity of probe of high pressure cylinder （
35mm）
• Size of induction plate
• Texture difference of practical induction plate and
verified induction plate
• Suggestion: conduct linear migration after practical
verification on site
 Swelling dyelot chromatism of low pressure

Differential expansion probe of low pressure cylinder

and are 2 in all. It adopts installation of one forward direction
and one reverse direction and the signal is sent to TSI control
cabinet and the protective operation value is ≤-1.0mm or
≥16mm. When two differential expansion value of low pressure
cylinder are higher than protective operation value at the same
time, AST magnetic valve comes into operation.
• Differential expansion of high pressure cylinder: to ensure
correlativity of two differential expansions in the process of
measurement, two 0-3mm dial indicator is set on site and they
move the same distance at the same time to record change amount
of corresponding voltage value. Fill it in function characteristic
curve of TSI card with differential expansion of high pressure, and
then conduct (-6~14mm) measurement of displacement to ensure
indicators of TSI and DCS system again to make sure one-to –one
correspondence and avoid influence on eddy current because of
texture, area and thickness.
• Differential expansion of low pressure: the measuring
device is LVDT and its measured value is related to practical
displacement amount of LVDT pole. It has less verification
points and 10 points are selected from verification of -10~+40
displacement amount and the space between each verification
point is 5mm and it is easy to cause deviation. Differential
expansion of low pressure is adopted and locally joined to
practical channel. And then conduct commonly used range test
and output voltage test of LVDT in every 2mm space through
micrometer. Input measured value into differential expansion
cards of low pressure as amendment to ensure consistency of
displayed measured value in any differential expansion.
• Axial displacement: after axial displacement is qualified after
verification in test room, input practical function curve of each
displacement probe into corresponding cards of TSI to emend.
And then use portable TSI testing instrument to check whether
transmission on site is normal to ensure displacement probe is
directly sent to site for installation. After acceptance
inspection, displayed value of 4 axial displacement DCS are
respectively:
• All deviations are less than 0.01mm.
Strong axis vibration

There are 2 probes of axis vibration on each tile and 1

probe of tile vibration. The probes of axis vibration are divided
into XY two directions, generator is in the direction of nose and
direction of left hand is direction X and direction of right hand is
direction Y and probe of tile vibration is installed in direction Y.
The alarm value of axis vibration is 128mm and the
operation value is 256mm. The operation method adopts one is to
give out alarm in direction XY of the same bearing bush and one
is to trigger tripping in operation.
 Instrumentation Plan of Axis Vibration
Probe

Plate
driver

Probe
driver
Transducer
Support of axis
vibration

Axis Upper half of

bearing
 Instrumentation Plan of Tile Vibration

Plate

Bearing
box

Upper half of
bearing
Instrumentation Plan of Eccentricity
Probe
Probe
driver
Key phase driver Plate
probe Probe
Eccen driver
tricity
probe
Eccentricity
peak-peak
value

Key phase
signal
 EHA system Close main valve and
control valve

Steam extraction
ETS system

Close extraction valve

Tripping of system
steam turbine
Boiler tripping

Electric The main switch tripping

protection and step-out generator

Open by-pass of high

By-pass
pressure and low pressure
system
 EHA
EHA is the abbreviation of English “Electro-Hydraulic
Valve Actuator ” and it means the actuator of power-driven
hydraulic regulation. The main task of EHA is to receive tripping
order of ETS system and magnetic valve of operation tripping makes
steam turbine trip; it also receives regulating order of DEH system
and the operation servo valve conducts regulation of control valve.
Nowadays, tripping magnetic valves of most generating units adopt
“anti-logic”, namely the generating unit is charged in normal
operation, the main valve and control valve will be closed and steam
turbine will trip once the magnetic valve is discharged. This can
ensure the generating units are in safe operation if coil of tripping
magnetic valve is burnt or the loop is disconnected under condition
of hardware failure.
EHA system of steam turbine: after the EHA system receives
tripping signal of ETS system, main valve of operation and
control valve trip magnetic valve (coil of magnetic valve is
discharged when anti-logic is adopted; coil of magnetic valve
is charged when positive logic is adopted), leak out tripping
oil pressure and rapidly close main valve and control valve.
In general, tripping magnetic valve will adopt 2 of 4
logic. Four tripping magnetic valves adopt method of series-
parallel connection, namely AST1 and AST3 are in parallel
connection, AST2 and AST4 are in parallel connection and
then in series connection. The generating unit will trip only
when there is one operation of AST1 and AST3 and one of
AST2 and AST4.
 Reliability Design Principles of ETS
System
• The system is independent.
• The power supply shall have redundancy configuration.
• Redundancy and logical processing of input signal.
• Redundancy and logical processing of output signal.
• Redundancy control of PLC.
• Generation of the first tripping.
• Power-losing tripping.
• Strict requirements of technology.
• On-line test.
 Independent System

• ETS system shall adopt independent cell controller and it is

not allowed to share one or several controllers with the other
systems. Even though input and output signals of ETS system
is not too much and the tripping logic is very simple, all
controllers commonly adopted at present can realize design
functions and performance of hardware and software can reach
control requirements, but as important protective system of
steam turbine, to avoid protection maloperation or refuse
operation caused by modification of software and hardware of
the other systems and operation and test of the other systems,
it shall be designed different from the other systems and in
independent operation, including power supply system,
processor, input and output cards, relay and the other external
devices.
The power supply shall have redundancy
configuration.
• Redundancy configuration of power supply includes
redundancy of main power supply and redundancy of
distributed power supply. Redundancy of main power
supply is one-road UPS (constant power supply
system) and one-road safety power supply that ETS
system receives from the outside world at the same
time.
• Power supply of processor, power supply of tripping
magnetic valve and power supply of tripping input
signal all have redundancy configuration.
Redundancy and logical processing of input
signal
• To ensure reliability of input signal, many signals adopt
redundancy configuration, such as control oil pressure,
lubrication pressure, vacuum, axial displacement, pressure and
flow of stator cooling water. Input of the same three measure
points even four measure points shall be adopted, however,
logical processing in ETS system is different according to
different redundancy quantity of signals, for example, 1/2 (one
of two) logic, or 2/3 (two of three) logic, or 2/4 (parallel
connection comes first and then series connection) logic. 2/3
(two of three) logic is adopted more frequently because it can
avoid maloperation and refuse operation in logic and it is easy
to design in hardware.
Redundancy Control of PLC
• Namely the main and subsidiary PCL receives the same
tripping input signal at the same time, these tripping signals
can be directly from local place or redundancy tripping signals
from the other system, and they can also be tripping signals
extended through relay of ETS system or processed in the
other forms. Then tripping orders are separately sent according
to the same logical judgment of redundancy PLC and tripping
orders may be sent to local tripping magnetic valve. ETS of
some generating units are even designed to adopt triplex level
redundancy to ensure reliable and stable operation of
protective system.
• When double redundancy is adopted, the same
tripping output signal will adopt 1/2 (one of two)
logic in general, namely output signal or more; when
triplex level redundancy is adopted, 2/3 (two of three)
logic will be adopted, namely the same tripping order
signals output from three controllers firstly go
through 2/3 (two of three) logic and send a real
tripping order and then be sent to local tripping
device together with the other tripping orders.
• ETS system is the device where strong current control coexist
with weak current control. Therefore whether its system
design and wiring technology is reasonable and whether the
wiring is reliable are critical elements of inference elimination
and guarantee of devices’ normal work. It is generally required
that strong current signal and weak current signal go into in
and out ETS equipment cabinet through different cable bridge
and laying shielded wire has a single point grounding.
Especially for rotate speed signal of steam turbine, apart from
requirement that shielded wire shall have a single point
grounding in ETS equipment cabinet, standby core of cable
and negative terminal of signal shall also have single point
grounding in ETS equipment cabinet.
Requirements of power supply
• Allowable voltage range of power supply in control cabinet: 210～240V-
rms（for 220VAC.rms）the allowable frequency range: 45～63Hz
• Power supply of pressure switch and remote control interruption contactors.
 Voltage that closing of normal contactors needs: 115VAC-rms。
 Pressure range: 105～125V-rms。
 Frequency range: 47～63Hz
 Root-mean-square value: RMS---root mean square, which is also named
calibration value
• Equipment connected with channel 1 is powered by alternating current power
supply #1.
• Equipment connected with channel 2 is powered by alternating current power
supply #2.
• Channel 1 and channel 2 have their own fuse and are independent from each
other.
• Power supply of interruption magnetic valve 20/AST and testing magnetic
valve 20/LB，20/LP and20/LV.
• ──normal pressure for magnetic valve: 115VAC
• ──Voltage range: for 115VAC-rms:105～125V-rms
• ──Frequency range: 47～63Hz
• Magnetic valve connected with channel 1 is powered by alternating current
power supply #1.
• Magnetic valve connected with channel 2 is powered by alternating current
power supply #2.