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Master controllers automatically engage when required to ensure the appropriate rates of change match the mode of operation of the turbine. Setpoint controls, open and closed-loop control functions, as well as continuous monitoring functions associa with the TCS system prevent the turbine generator from assuming inadmissible operating conditions, thus avoiding the necessary response of the turbine protection equipment and possible damage to the machine. This is the predominant operating philosophy surrounding the high availability criteria of the turbine generator.
The vendor should provide each of these functions within their standard turbine control packages. Each of these functions can be inhibited as necessary to facilitate proper integration within the existing Distributed Control System (DCS) as required. The principle features of the TCS system are summarized as follows: •
•
•
Speed Control Inlet/Admission Pressure Control-two channel selection which facilitates initial pressure (boiler follow mode) and limit pressure (turbine follow mode) functions
Load Control-via either a load setpoint command from a DCS, or can be configur to receive MW input for utilization of the load control function developed within the system, or can be configured stand-alone as a MW or Speed Droop function.
•
Turbine Stress Influence
•
Frequency Influence
•
ADS (Automatic Dispatch System) Influence
•
Valve Lift Control Sign up to vote on this title
The TCS system ensures stable operation throughout all operational Useful Not usefulphases, i.e. during unit start up, shutdown, parallel operation, Island mode, etc. In generation applications, full load rejections created by a sudden separation from the grid (lightni
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from it’s associated algorithm. An alarm is issued, alerting the operator of the device malfunction, and the control algorithm automatically transfers to the next assigned device redundancy level. Upon correction of the malfunction, the control system will automatically transfer to the next device redundancy level to ensure the maximum availability and protection of the system.
The TCS should provide automatic and manual shutdown. In automatic shutdown, the system must lower the load until the generator breaker opens on reve current. On manual shutdown, the operator will open the generator breaker manually once the turbine is at minimum load. The TCS Software System Comprises the Following Standard Master Controllers: 1. Speed Control
The speed control function provides the operational control involving the speed limiting and acceleration functions of the unit over the entire operating speed range. The speed control system is fully integrated with the load rejection and load anticipat functions as required, as well as the turbine trip system. The speed control function i designed to receive up to three speed inputs. These inputs feed a 1 of 2, 2 of 3, and 2 of 4 voting algorithm which issue an overspeed trip command. If one of the chann fail, that channel is automatically deselected, an alarm is issued alerting the operator the malfunction, and the unit shifts to the next available comparison algorithm. In the event the speed channel is repaired (the operator found a loose wire connection in th junction box on the ST), then the unit automatically detects the correction, and shifts back automatically into the pre-configured algorithm.
In generation applications, when the generator is on the grid and the turbine controller is in the “load” control mode, the speed control function continues to provid speed error (influence) input for use in frequency regulation. Comparing the speed detec reference with the actual speed derives the speed error signal. The frequency Sign up to vote on this title accuracy is within 10 mHz, with tunable variables controlling deadband and droop Useful Not useful characteristics.
The desired speed reference is selectable manually from the client Operating Sta
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password protection) to the desired setpoint and holds at the selected value until another command is issued.
The operator manually raises and lowers the speed via a soft-key selector (up or down gradient key). In this function, if the operator selects a “stop” function during a transient condition through the predetermined critical bands, the unit will continue to either increase or decrease to the next available threshold. What this means is that the operator is telling the unit to ramp up, and then “stops” the command during a critical state, the unit will not stop until after achieving the “high” end of the critical ran The same occurs during a downward gradient change.
Depending on the particulars of the steam turbine itself and it’s application use, th unit can be configured to open the governor valve(s), and modulate the stop valve in order to “warm” the unit without breaking turning gear speed. After the unit has gone through it’s initial thermal soak period (which can be configured via either thermal inputs-RTD’s/Thermocouples or via a time-based sequence), the stop valve will continue to open, bringing the unit up to the minimum governor speed (typically 95% rated speed/synchronous speed). This function is completely programmable and generally depends on specific unit requirements. At this point in time, the unit will br the Governor Valve down below the Stop Valve (in order to shift the control from the stop valve- full arc, to the governor valves-partial arc control), and issues a synch command enable, facilitating generator breaker closure.
Another standard function utilized by many customers to facilitate automatic startis the configuration of the system according to the unit’s Standard Operating Procedu Each unit is issued with a Standard Operating Procedure (SOP), which typically is modified in writing and issued by the customer as the operations guide governing the machine. The vendor provides for configuration of the unit to operate based on the time- based sequence issued under the SOP. In other words, the unit would be ram to a pre-determined setpoint, held at that point on a timer, and then ramped to the ne the point and so and so forth. At no point would the unit Sign be “allowed” to stop within up to vote on this title critical bandwidths.
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The TCS employs a configurable, operator controllable, proportional regulation controller to ensure a bumpless transfer from full arc and partial arc admission.
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2. Inlet/Admission Pressure Controller Sheet Music
The inlet/admission pressure control provides two channel selection which facilita initial pressure (boiler follow mode) and limit pressure (turbine follow mode) functions This automatic control function is activated when the inlet-steam pressure drops to a pre-determined configurable setpoint. This gives the operator the ability to perform sliding pressure control for lower MW minimums.
3. Load Control Once the turbine is on the grid, the TCS can either be transferred automatically o manually into the load control mode of operation. The load control function produces produce steam flow demand signals via the position controller of the associated servo valve actuators. Logic signals derived from the units load control system (ULCS) indicate operating conditions, such as power load imbalance.
The load reference (setpoint) value corresponds to the current desired load as compared to the rated main main steam pressure. To initiate a change in desired load, th operator dials in the selected desired setpoint and hits “go”, and the unit ramps at a p determined ramp rate (which is configurable via password protection) to the desired setpoint and holds at the selected value until another command is issued. The load reference (setpoint) may be changed by either raising or lowering the desired target load at the operator control panel, or from the increase or decrease signals generate by the Generator synchronization functions.
Turbine runback control functions reside within the load control logic. This functio exists as designed to provide a controlling medium during abnormal conditions wher an engagement of automatic ramp rates bring the unit down to predetermined values These predetermined runback ramp rates and setpoint limits are configurable via password protection. Standard turbine runback features designed withinSign theupsystem are: to vote on this title •
Loss of boiler feed water pump Loss of condenser vacuum
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is designed to provide an indication of deviation percentage from the load limit and issue an indication when the load limit is activated.
A load rejection occurs when the generator breaker opens at load. This situation should be handled by the TCS by rapidly shutting the governor valves thereby minimizing the pending overshoot. This is an anticipatory function triggered by the generator breaker position indication. The governor valves then reopen to achieve pr configured load rejection speed.
A megawatt (MW) feedback loop embedded within the TCS load control function which automatically adjusts the megawatt reference setting to correspond with the actual real load (MW). Through selection of this control loop function through the cli OS, the MW error value developed between the relationship of the corrected referen MW and the actual MW is applied to a PI controller, which will automatically adjust th control valve signal to reduce any MW deviation.
An initial load pickup (Min-load) function embedded within the TCS load control function provides a configurable (typically 3-5%) step increase that occurs each time generator is initially synchronized to the grid. This Min-load function is used during initial loading of the machine in order to prevent reverse power conditions upon sync enable and is configurable through password protection at the Engineering Station (E
An impulse pressure feedback loop is embedded within the TCS load control function to correct the megawatt reference versus the actual megawatt value based actual Impulse pressure. The impulse pressure error derived from the corrected reference impulse pressure (in MW units) and the actual impulse pressure is applied the controller, which will trim the control valve signal to reduce any impulse pressure error. 4. Turbine Stress Influence Sign up to vote on this title
The TCS system is designed to accept influencing from a turbine stress evaluatio Not useful Useful (TSE) system thereby limiting the acceleration and load ramp gradients. During star and shutdown, a TSE would provide an input generated from the algorithm delta created between two thermocouples embedded within the main stop valve (MSV or
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5. Frequency Influence Sheet Music
When the generator is on the grid and the turbine controller is in the “load” contro mode, the speed control function continues to provide a speed error (influence) input use in frequency regulation. Comparing the speed reference with the actual speed derives the speed error signal. The frequency detection accuracy is within 10 mHz, tunable variables controlling deadband and droop characteristics. 6. ADS (Automatic Dispatch System) Influence
The TCS system is designed to accept influencing from an ADS controller, facilita the remote dispatch loading and unloading of the machine along predetermined ram gradients. The load limit gradients are configurable through the entire range of opera via password protection. 7. Valve Lift Control
The valve lift controller integrates the min-gated valve demand reference versus valve actual (setpoint) functions. Some vendors have standard applications oversampling rates of greater than 20 samples per cyclic event throughout the stroke of t valve to achieve the fastest possible response time. The Turbine Control System (TCS) Processor
The brain of the steam turbine controller should be a high-speed digital processor One example is the S7 Programmable Logic Controller. The S7-416 is a high availab processor with the performance required for applications such as steam turbine cont It acquires measured values and status signals from the I/O, carries out open- and closed-loop control functions, transfers the resulting commands to the I/O and perfor all the functions of the group and individual device levels. Clearly structured and Sign up to vote on this title vigorously tested control concepts should be available for various configurations of p Useful Not useful control tasks. One example of a specific application would provide a modular-based fan-free, cost-effective solution with a high degree of expansion and communication options. This user-friendly system provides for the easy implementation of distribute
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The Turbine Protection System (TPS) Processor
A critical part of the steam turbine control system upgrade is the protection system The protection system must have a robust controller to safely shutdown the turbine in the case of emergency. One such controller is the S7-314C-2DP. This is a high availability processor with the performance required for applications such as steam turbine protection systems. It acquires measured values and status signals from the board I/O, carries out open- and closed-loop control functions, transfers the resulting commands to the I/O and performs all the functions of the group and individual devic levels. Clearly structured and vigorously tested control concepts are available for various configurations of plant control tasks. This user-friendly system provides for th easy implementation within a distributed architecture that is capable of handling the most sophisticated tasks in the high-end performance range. In the TPS application these processors will automate the turbine trip system (TPS) package within a triplemodular, 2 out-of-3 voting architecture.
Mechanical / Hydraulic Engineering And Modifications
The vendor should manage the coordination between the mechanical and hydrau modifications and the electronic control system requirements, so that the complete control system retrofit is a successful project. Mechanical/Hydraulic Trip Subsystem
All new steam turbines are being supplied with electronic trip systems without mechanical bolts for overspeed protection. Many customers have requestedupgrad Sign up to vote on this title to the existing “Mystery Box” and mechanical bolt style systems. The mechanical Useful Not useful upgrade completely replaces the original equipment within a 2-out-of-3, 2-out-of-4 algorithm voting architecture. A prefabricated panel incorporating triple redundant devices for each of the associated parameters facilitates on-line testing and calibratio
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A trip-reset input is necessary to clear any latched trips. The trip output of the TPS consists of six- (6) discrete outputs, two- (2) from each processor. This matches the six- (6) emergency trip oil dump solenoids configured in a ‘2-out-of-3 to trip’ arrangement. Field Device Parameter Sensing Assemblies
This instrumentation upgrade is a 2-out-of-3, 2-out-of-4 voting design. Each transm has a local LED readout, and is plumbed with an isolation valve and calibration port. The transmitters are pre-wired to an on-board junction box with ring lug terminal strip This proposal includes 2-out-of-3 sensing assemblies for the following functions:
The following items are installed in place of the trip block assembly and provide inpu to the TPS. •
•
•
Vacuum Pressure. The new panel has three- (3) vacuum pressure measuremen devices that provide discrete contacts and analog 4-20mA signals. They may connected to the TPS as either. Upon sensing a high exhaust pressure (low vacuum) the TPS will issue a trip command.
Bearing Lube Oil Pressure. The new panel has three- (3) pressure measuremen devices that provide discrete contacts or analog 4-20mA signals. They may be connected to the TPS as either. Upon sensing a low bearing oil pressure the TP will issue a trip command.
Turbine Thrust Pressure Sensing. While retaining and monitoring the existing pressure based thrust-sensing system, this modification incorporates four- (4) independent, pressure measurement devices that provide discrete contacts or analog 4-20mA signals. Two- (2) of the transmitters facilitate monitoring of the active thrust position, and two- (2) of the transmitters facilitate monitoring of the inactive thrust position. The transmitter outputs may be connected to the TPS either discrete contacts or as 4-20mA signals. Upon sensing turbine Sign up to vote on this titlethrust the T will issue a trip command.
•
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Turbine Trip Solenoids. This modification incorporates the installation of three- (3
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Trip Solenoid Testing Sheet Music
The six- (6) solenoids (typically) are piped to the throttle valve emergency trip fluid header. They are organized in sets of three- (3) pairs. Each pair is comprised of tw (2) solenoids plumbed in series, with the three- (3) pairs plumbed in a parallel configuration. The three- (3) TPS processors actuate the solenoids to generate a 2of-3 algorithm. Each solenoid may be independently tested. Pressure switches loca between each pair of solenoids indicate when a solenoid has been tripped. Similarly these pressure switches indicate when a failure of a particular solenoid has occurred The following permissive conditions must be met prior to testing of any solenoid: •
All TPS processors are operating normally.
•
All solenoid panel pressure switches indicate a normal status.
•
No TPS processor is sensing a trip and or fault condition.
Tests are conducted from the DCS via a communication link or locally via the HMI. Speed Sensing
The Magnetic Pick Up (MPU) bracket provides for primary speed control and electro overspeed protection will be designed to incorporate multiple new speed probes. the confines of a base scope of supply, the vendor should provide four- (4) new activ magnetic speed probes for “software” based zero speed detection, measurement, an overspeed protection. •
Three- (3) of these probe slots are dedicated for “software” overspeed measurem and protection. Sign up to vote on this title
•
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Three- (3) of these probe slots are dedicated for “hardware” overspeed protection
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Mechanical Overspeed Trip Assembly Sheet Music
The mechanical overspeed trip assembly is not very high tech. These systems us bushing, adjustment nut, plunger, and spring arrangement. As the spring is compressed, the force to overcome the spring force is increased. The weight of the plunger, spring force, speed, and the distance from the plunger to the trip lever defin the trip speed. Since the desired trip speed, the weight of the plunger, and the distan the plunger must travel to strike the trip lever are fixed, the only adjustment that can made is the spring force. Adding or removing shims, or repositioning the spring compression adjustment nut, changes the trip speed. The only way to change the tri speed is to shutdown the turbine to make the mechanical adjustments. Multiple runu are not unusual. This is time consuming and introduces a potential for human or mechanical error. Owner / Operators have experienced many problems over the yea with the setting of mechanical governors. A list of some actual issues follows here: •
•
Trip plunger improperly machined, a grooved finish on the bore of the plunger gu bushing
The end of the plunger was flared out preventing the trip plunger from moving. Th was the result of a millwright physically pushing on the end of the plunger with a center punch.
•
The plunger and guide bushing had a buildup of varnish.
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The installed spring was too strong.
•
•
The installed spring was too weak from either an old spring that had lost some of force or a spring with too low a spring constant. The millwright turned the adjustment nut in the wrong direction. Sign up to vote on this title
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Table: Comparison of Mechanical Overspeed Trip System versus Electronic Oversp Trip System
Mechanical Overspeed Trip System General trip speed range, +/- 50 rpm Trip speed will change over time Does not interface with anything Does not provide any trip indication Must have mechanical trip lever interface Oil varnish buildup will keep the mechanical trip plunger from functioning Not fault tolerant Cannot be tested except when uncoupled from the driven equipment, which requires a shutdown Must be initially set in a spin test pit Requires multiple runs of the turbine to adjust the trip set point in the field
Electronic Overspeed Trip System Precise trip speed, digital set point Trip speed will not change over time Provides DCS interface Provides first out trip indication No physical contact with shaft or mechanical trip lever is required Oil varnish does not affect the trip func
Fault tolerant System can be tested periodically with signal generator with minimal or no risk the operation of the turbine Set by a signal generator Does not require any extra runs of the turbine in the field
Redundant Interface to Valve Positioners
The vendor should provide drivers for redundant servomotor coils, expecting the existing servomotors to have dual coils. They should also provide redundant LVDTs the LVDT represents a single point of failure in a system that has redundancy built in nearly every other area. This design provides redundancy all the way to the valve. Failure of any module, power supply, servomotor coil,Sign LVDT up to or votewiring on thiswill title not interrup operation in any way, and will only result in an alarm forUseful the operator. Not useful
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For the purpose of vibration monitoring, a system to monitor the status of the bearings should be made available. It should provide highly reliable turbomachinery information for improved protection. The system should continuously measure and monitor a variety of parameters, which are vital to turbine protection. When any of these parameters begin to indicate weakness in the turbine components, such as imbalance, bearing failures, misalignment, and shaft crack conditions, the operator should be alerted. Engineering information should be provided that includes mechan modification instructions to install probes in the turbine.
The communications to the existing DCS should be a non-proprietary open protoc Many plant sites have multiple protocols that increase maintenance. The ability to communicate with one common protocol to devices such as generator protective rela automatic voltage regulators, Turbine Stress Evaluator, vibration monitoring, etc will operations and maintenance capabilities. It would be prudent for a customer to chose a vendor that can provide all of the basics plus auxiliaries utilizing a common control platform. This includes generator protective relay and automatic voltage / excitation systems. Having systems that communicate with the same protocol and contain similar hardware will reduce operating, training, and maintenance costs. Conclusion
Because of their age, design, and lack of maintenance, today’s steam turbine governor control systems are operating in a manner far different than the original manufacturers designed them. They are also operating in an order of magnitude less efficient in performance than that of similar sized turbines operating with the latest digital controls. Typically these older steam turbines drift, control has a sluggish response caused by multiple individual servo motors connected by antiquated linkag and connectors, or does not operate in a coordinated fashion. These problems are costing your operation and maintenance teams time Sign andup money better spenton to vote on this title improving the operation rather than just keeping it running. Find a vendor that can Useful Not useful steam implement an innovative solution for modernizing your turbine controls and tha can integrate this upgrade into your current or future plant systems using a scalable, standardized, proven platform. Upgrading to a state-of-the-art turbine control system
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References API Standard 612, 1995, “Special – Purpose Steam Turbines for Petroleum, Chemic and Gas Industry Service,” Fourth Edition, American Petroleum Institute, Washington D.C.
API Standard 670, 2000, “Vibration, Axial-Position, and Bearing Temperature Monitoring Systems,” Fourth Edition, American Petroleum Institute, Washington, D.C
Clark, E. E., 2002, “Steam Turbine Overspeed Incidents,” The Hartford Steam Boiler Inspection and Insurance Company.
Rutan, C.R., 2003, “Turbine Overspeed Trip Protection,” Lyondell/Equistar Chemical LP, Proceedings of the Thirty-Second Turbomachinery Symposium. Clark, B.E., 1992, “Steam Turbine Generator Equipment” Westinghouse Electric Corporation. Simatic Catalog ST 70, 2000, “Components for Totally Integrated Automation,” Siemens.
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