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Over Frequency Tripping of a 12 MW Steam Turbine Generator

07/18/2016 7:58 PM

Hello Everyone. i need some help, Our steam turbine driven generator that is connected to the grid with 60 Hz, 13.8kV, 15MVA tripped because of over frequency. the generator breaker (13.8kV) and sf6 breaker (69kV) tripped at the same time. indication at the GPR (sr489) is over frequency while at the 69kV side (siprotec 7sj62 relay) indicates 32 and 55 which is reverse power and power factor respectively. my question is, what is the possible cause of this event and does it indicate a future failure of the generator or at the power transformer (13.8kV/69kV)? voltage of the grid is fluctuating and humming sound comes from the generator before tripping. we restarted the plant immediately and until now all is running smoothly. your help will be much appreciated.

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#1

Re: Over Frequency Tripping of a 12 MW Steam Turbine Generator

07/19/2016 1:41 AM

The combination of over frequency and reverse power seems odd. Do you have any indication of how the load varied just before the trips?

A rapid drop in load would of course cause all generating sources on the grid to speed up, but then they should restabilize to nominal frequency. However, the various governors could have different response rates. What is odd is that if your generator is over frequency, it should be feeding excess power into the grid, rather than absorbing reverse power from the grid.

One of the best CR4 guys on issues like this is RAMConsult, from whom we can hope to hear.

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#6
In reply to #1

Re: Over Frequency Tripping of a 12 MW Steam Turbine Generator

07/20/2016 4:20 AM

Well put. I find it also very strange too.

I tend to think that possibly some part of the equipment has a fault, as an alternator connected to the grid, cannot overspeed, it just takes more "load" from the grid, maybe too much load!!

But the frequency remains "held" by the grid....

I feel that possibly the over frequency is just an indication that actually happens AFTER the alternator has dropped off and the speed control, cannot reduce the speed/frequency to the no load situation fast enough.

So I feel that the problem lies a short time before the incident.

This could even be something like a very large local motor being suddenly being shut off, combined with a rise in voltage from the grid.

I tend to assume, maybe wrongly here, that the grid is inherently very stable, voltage changes are relatively slow and frequency is held to being exact over 24 hours average......

Naturally, the alternator will "follow" the frequency of the grid if it changes, so theoretically if the grid frequency rises, it may even rise about the level at which will cause the alternator to simply drop off, though I personally have never ever heard of such a situation.....the grid is usually totally stable...

Maybe a proper mains monitor needs to be attached (permanently!), it might give a better indication of where the problem lies......

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#7
In reply to #6

Re: Over Frequency Tripping of a 12 MW Steam Turbine Generator

07/20/2016 5:40 AM

Grid frequency is almost always changing by usually small amounts. If some big load is started somewhere, all of the rotating generators on the grid slow down by a little bit, until their governors bring them back up to speed. Conversely, if some big load drops off, everything speeds up until the governors bring the speed back down to nominal frequency.

It is possible to use this effect to shed loads when grid frequency drops, and then restore them when grid frequency recovers. One of my former workplaces has done a lot of work in this area. (Pacific Northwest National Laboratory = Battelle.)

These deviations are periodically adjusted over time to keep the average grid frequency (nearly) constant, which keeps your clocks on time.

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#2

Re: Over Frequency Tripping of a 12 MW Steam Turbine Generator

07/19/2016 1:54 AM

Interesting. Was there anything else happening out on the grid? I assume that your machine is small relative to the rest of the grid, that would mean that it would follow any external transient event, and the grid voltage fluctuating and abnormal humming sound point in that direction.

It's hard to know exactly what happened without seeing any TDR (Transient Data Recorder) playback from the grid and your machine, so I'll take a WAG (Wild A$$ed Guess) at what took place. There was a frequency/voltage excursion out on the grid due to the loss of a large chunk of load, possibly a dropped transmission or tieline while your system was a net exporter. The remaining generation had no place to go and the grid frequency rose rapidly enough to trigger the GPR Over Frequency Trip, but not quite quickly enough to immediately dump your machine.

While the frequency was climbing, but before the GPR would operate, your relatively small machine responded to the first swing by having it's Power Angle (not Power Factor angle) driven from positive (generator mode) to negative (motor mode), which in turn set the RPR (Reverse Power Relay) into action. Now it's simply a race between relays to see who acts first, in this case it looks like they timed out simultaneously. The Power Factor Relay saw both the swinging voltage and the initial change in the direction of the current, and joined in the race.

The fact that you had a successful restart indicates that you probably suffered no damage, but a look at the vibration monitors would be wise. You would also be wise to check the settings on your relays to make sure they're not set so tight that they act too quickly the next time.

Please let us know what the Root Cause Analysis revealed.

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#3
In reply to #2

Re: Over Frequency Tripping of a 12 MW Steam Turbine Generator

07/19/2016 2:12 AM

I don't believe in prayer, but damn, that was uncanny!

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#4
In reply to #2

Re: Over Frequency Tripping of a 12 MW Steam Turbine Generator

07/19/2016 4:30 AM

thank you for your input sir. before restarting the generator, we checked winding temperatures and vibrations both on the turbine and generator and find that all were in normal condition. as for the data recorder, on our side there is no trending for the measured values. problem here is that the grid to which we are connected is not transparent to what is happening to the system so it left us hanging elsewhere. gpr setting for over frequency is 62.5 for 5 sec, and 63.0 for 3 sec. reverse power is set at .02 x rated for 2 sec.

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#5

Re: Over Frequency Tripping of a 12 MW Steam Turbine Generator

07/19/2016 10:45 PM

Dear Mr.jimmy23,

Over Speeding indicates, the load n the Generator is cutoff instantly or the governor has developed some problem or too sensitive.

Pl.check the Turbine Governor Sensitivity and Over-Speed Setting. The governor Speed Droop Character should be checked and adjusted as referred in the Instuction/Operation Manual.

Pl. report back - how the problem was sorted out - as we are eager to know it.

DHAYANANDHAN.S

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#8

Re: Over Frequency Tripping of a 12 MW Steam Turbine Generator

07/20/2016 12:31 PM

Over-frequency is load rejection, external to your equipment. Loss of generator excitation would normally be covered by other protective equipment, voltage sensing equipment, and protective devices directly on the field supply.

Your reverse power 32 indicates that you were motoring your generator for a short time (assuming no powerhouse loads on the 13.8kV side). This may have happened when your turbine governor reacted to the over speed caused by the load rejection, but before the 13.8kV breaker had a chance to open.

Your settings may have overlapped a little, but erred on the side of caution.

12MW is very small for pretty much any utility, so it is unlikely you could survive a large sectionalization of the external load, and perhaps the automatic controls to switch to isochronous mode for the governor are not enabled.

How is your powerhouse fed, electrically?

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