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The document discusses replacing old mechanical actuators on steam turbines with new electraulic actuators to improve reliability and performance. Specifically:
1) Mechanical actuators can cause issues like speed instability, reduced efficiency, and unplanned shutdowns on steam turbines.
2) A refinery replaced a sticking mechanical actuator with a REXA Electraulic actuator, which stabilized turbine speed control and avoided process trips.
3) Electraulic actuators provide more precise speed control and eliminate maintenance needs of mechanical hydraulic systems, improving turbine operation.
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CCC White Paper Avoiding Speed Instability in Steam Turbines Sep 2016
The document discusses replacing old mechanical actuators on steam turbines with new electraulic actuators to improve reliability and performance. Specifically:
1) Mechanical actuators can cause issues like speed instability, reduced efficiency, and unplanned shutdowns on steam turbines.
2) A refinery replaced a sticking mechanical actuator with a REXA Electraulic actuator, which stabilized turbine speed control and avoided process trips.
3) Electraulic actuators provide more precise speed control and eliminate maintenance needs of mechanical hydraulic systems, improving turbine operation.
The document discusses replacing old mechanical actuators on steam turbines with new electraulic actuators to improve reliability and performance. Specifically:
1) Mechanical actuators can cause issues like speed instability, reduced efficiency, and unplanned shutdowns on steam turbines.
2) A refinery replaced a sticking mechanical actuator with a REXA Electraulic actuator, which stabilized turbine speed control and avoided process trips.
3) Electraulic actuators provide more precise speed control and eliminate maintenance needs of mechanical hydraulic systems, improving turbine operation.
REPLACING MECHANICAL ACTUATORS CAN IMPROVE RELIABILITY AND PERFORMANCE DAVE NELSEN AND MIKE MURPHY
ecades-old low-tech mechanical and
D hydro-mechanical governor equip-
ment continues to operate with many turbines in refineries and process plants. This equipment can present mainte- nance and operational challenges. It can lead to reduced efficiency and reliability in the production process. The job of the turbine speed governor is to provide accurate speed control, thus pre- venting process oscillations and unplanned shutdowns, and improving process through- A mechanical actuator was changed to a REXA electraulic actuator in order to put. To achieve this goal precisely and improve steam turbine reliability and performance dependably, it is advisable to perform a gov- ernor valve actuation retrofit. Advantages include stabilization of equip- Controlling compressor efficiency high resolution control performance ment speed with tighter rpm control, and starts with precision control of the ST dri- required for the application. avoiding nuisance process and equipment ver in order to regulate the speed of the Since the system is open to atmosphere trips. This enables the turbine to operate at its compressor. Actuator upgrades depend on at the reservoir, the oil is subject to break- maximum potential without interruption. turbine design. down. Exposure to the atmosphere adds Compressor Controls Corporation For turbines with shell-mounted control moisture that causes degradation to the oil (CCC) recently implemented a mechanical valves, the actuators may individually drive system due to moisture ingress, oxidation retrofit for a U.S. refinery experiencing large multiple control valves, or there may be a and corresponding acid build-up. The con- swings (100-200 rpm) in the speed control of single power piston arrangement that drives tinuous circulation of hydraulic fluid adds a steam turbine (ST). Speed instability was a bar or rack allowing multiple steam valves heat to the oil, which accelerates breakdown caused by a subpar governor valve actuation that are mechanically coupled together to be of the hydraulic fluid. system. The sticking actuator could not opened sequentially. To combat the effects of oil breakdown, maintain the setpoint target and had recently For turbines with chest-mounted control system owners are required to perform main- caused a process trip of the main air blower. valves, it may be a globe-style valve external to tenance, use filtration systems, and replace the turbine that is providing the control. In some hydraulic fluid, which degrades, causing Sticky actuators configurations, a pilot valve assembly with a sticking in servo and proportional valves. Difficulties with speed control meant the ST small stroke and a low thrust requirement may Electraulic actuators are designed for con- had to be operated manually and at a higher be used to port lube oil to the power piston. tinuous modulating service with an adjustable target speed than desired. In addition, load Typical ST control requirements include dead-band that is .05% of stroke. This pro- sharing with a secondary air blower could not 0.1% repeatability, 100% duty cycle, <100 vides repeatable, stiff and accurate control be implemented, and the operator had to use m/sec dead time, fail-safe capability, the performance, and eliminates filtration and oil the blow-off valve to adjust the air flow. ability to withstand high ambient tempera- maintenance. Additionally, the ST could not use the existing tures and a fast stroking speed (less than 1-2 CCC automatic start-up sequence because of seconds for full stroke). Dave Nelsen is the sticking actuator. Steam turbine designs at this refinery used Turbomachinery The actuation system specified was a a system comprised of a hydraulic power unit Controls Engineer at REXA Electraulic self-contained unit. It (HPU) and servo or proportional valves for Compressor Controls uses a position-controlled power module dri- control. These hydraulic systems were proven Corp. (CCC), which ven by a 4-20 ma signal to turn an internal oil to meet and exceed turbine control require- offers consultation on gear pump that displaces hydraulic fluid ments when operating in design conditions. advanced controls. For from one side of cylinder piston to the other. But after time, the system required extensive more information, visit www.cccglobal.net A rod extending from the cylinder is oil maintenance for proper operation. mechanically connected to the steam valve Many traditional hydraulic systems are rack and able to position the rack from the open-loop, using an HPU, a gravity fed reser- Mike Murphy is Marketing closed to open position. The system has no voir, and a series of servo or proportional Manager at REXA, which need for an external oil supply source. valves for control. These systems need a lot of manufactures a complete The actuation retrofit was executed dur- oil and all use the same principal of operation. line of industrial grade lin- ing an unscheduled outage. As a result, the Hydraulic fluid is drawn from the reser- ear and rotary self-con- turbomachinery train could more accurately voir by motors and pumps to facilitate move- tained electro-hydraulic match its performance with the desired ment of the actuator cylinder and is drained actuators and damper dri- process set point. This also allowed use of back to the reservoir when the cylinder ves. For more information, the automatic startup sequencing and load moves to position. The oil is continually cir- visit www.rexa.com sharing features of the CCC control system. culated at high frequency to accomplish the
40 Turbomachinery International • September/October 2016 www.turbomachinerymag.com