Review of the coal-fired,over-supercritical and ultra-supercritical steam power plants

The article presents a review of developments of modern high-capacity coal-fired over-supercritical (OSC) and ultra-supercritical (USC) steam power plants and their implementation. The basic engineering solutions are reported that ensure the reliability, economic performance, and low atmospheric pollution levels. The net efficiency of the power plants is increased by optimizing the heat balance, improving the primary and auxiliary equipment, and, which is the main thing, by increasing the throttle conditions. As a result of the enhanced efficiency, emissions of hazardous substances into the atmosphere, including carbon dioxide, the “greenhouse” gas, are reduced. To date, the exhaust steam conditions in the world power industry are p ₀ ≈ 30 MPa and t ₀ = 610/620°C. The efficiency of such power plants reaches 47%. The OSC plants are being operated in Germany, Denmark, Japan, China, and Korea; pilot plants are being developed in Russia. Currently, a project of a power plant for the ultra-supercritical steam conditions p ₀ ≈ 35 MPa and t ₀ = 700/720°C with efficiency of approximately 50% is being studied in the EU within the framework of the Thermie AD700 program, project AD 700PF. Investigations in this field have also been launched in the United States, Japan, and China. Engineering solutions are also being sought in Russia by the All-Russia Thermal Engineering Research Institute (VTI) and the Moscow Power Engineering Institute. The stated steam parameter level necessitates application of new materials, namely, nickel-base alloys. Taking into consideration high costs of nickel-base alloys and the absence in Russia of technologies for their production and manufacture of products from these materials for steam-turbine power plants, the development of power plants for steam parameters of 32 MPa and 650/650°C should be considered to be the first stage in creating the USC plants as, to achieve the above parameters, no expensive alloys are require. To develop and construct OSC and USC head power plants, joint efforts of the government, experts in power industry and metallurgy, scientific institutions, and equipment manufacturers are required.     

Specific features of the control systems of new-modification 310–330-MW steam turbines manufactured by PAO turboatom

Principal engineering solutions taken by PAO Turboatom when developing the control systems of the 310–325-MW turbines for thermal power stations are set forth. A schematic diagram of the control system is presented and the designs of the retrofitted basic mechanisms, viz., high-pressure steam-distribution unit and the cutoff valve, are described. It is noted that the accepted principles of designing the control systems allow retaining the following advantages of the latter: use of the condensate as a cheap nonflammable working fluid, valveless switches to control the locking servomotors, a mechanical ring-type turbine trip mechanism (TTM) in combination with an actuator fitted with two double-seated actuator valves to control the pressure in the pulse security lines, and a rotary valve to block the triggering of the actuator valves during successive testing of the TTM rings by filling the oil during the operation of the turbine and the subsequent raising of the above valves. The control systems of the new-modification turbines are based on microprocessor hardware using electromechanical converters to drive every cutoff valve as a universal solution that is not oriented towards a particular manufacturer of the control system electronics. Application of a mechanical turbine trip mechanism is acknowledged as indispensable for unconditional guarantee of the safe operation of the turbines irrespective of the presence of the electronic turbine trip mechanism.     

Development of elements of the condition monitoring system of turbo generators of thermal power stations and nuclear power plants

The rationale is given for the improvement of the regulatory framework for the use of shaft sensors for the in-service condition monitoring of turbo generators and the development of control systems of shaft surfacing and misalignments of supports. A modern concept and a set of methods are proposed for the condition monitoring of the “shaft line–thrust bearing oil film–turbo generator supports” system elements based on the domestic COMPACS® technology. The system raw data are design, technology, installation, and operating parameters of the turbo generator as well as measured parameters of the absolute vibration of supports and mechanical quantities, relative displacements and relative vibration of the rotor teeth in accordance with GOST R 55263-2012. The precalculated shaft line assembly line in the cold state, the nominal parameters of rotor teeth positions on the dynamic equilibrium curve, the static and dynamic characteristics of the oil film of thrust bearings, and the shaft line stiffness matrix of unit support displacements have been introduced into the system. Using the COMPACS-T system, it is planned to measure positions and oscillations of rotor teeth, to count corresponding static and dynamic characteristics of the oil film, and the static and dynamic loads in the supports in real time. Using the obtained data, the system must determine the misalignments of supports and corrective alignments of rotors of coupling halves, voltages in rotor teeth, welds, and bolts of the coupling halves, and provide automatic conclusion if condition monitoring parameters correspond to standard values. A part of the methodological support for the proposed system is presented, including methods for determining static reactions of supports under load, the method for determining shaft line stiffness matrices, and the method for solving the inverse problem, i.e., the determination of the misalignments of the supports by measurements of rotor teeth relative positions in bearing housings. The procedure for calculating misalignments of turbo generator shaft line supports is set out.     

Application of Artificial Thunderstorm Cells for the Investigation of Lightning Initiation Problems between a Thundercloud and the Ground

The results of the experimental application of artificial thunderstorm cells of negative and positive polarities for the investigation of the lightning initiation problems between the thundercloud and the ground using model hydrometeor arrays are presented. Possible options of the initiation and development of a discharge between the charged cloud and the ground in the presence of model hydrometeors are established. It is experimentally shown that groups of large hydrometeors of various shapes significantly increase the probability of channel discharge initiation between the artificial thunderstorm cell and the ground, especially in the case of positive polarity of the cloud. The authors assume that large hail arrays in the thundercloud can initiate the preliminary breakdown stage in the lower part of the thundercloud or initiate and stimulate the propagation of positive lightning from its upper part. A significant effect of the shape of model hydrometeors and the way they are grouped on the processes of initiation and stimulation of the channel discharge propagation in the artificial thunderstorm cell of negative or positive polarity–ground gap is experimentally established. It is found that, in the case of negative polarity of a charged cloud, the group of conductive cylindrical hydrometeors connected by a dielectric string more effectively initiates the channel discharge between the artificial thunderstorm cell and the ground. In the case of positive polarity of the artificial thunderstorm cell, the best effect of the channel discharge initiation is achieved for model hydrometeors grouped together by the dielectric tape. The obtained results can be used in the development of the method for the directed artificial lightning initiation between the thundercloud and the ground.     

Probable causes of damage of heat-exchange tubes of low-pressure-exchanges of PND-3 type and repair methods

The structures of low-pressure heaters (LPH), which are installed at nuclear power plants with the K-1000-60/1500 type turbine plants are considered. It was revealed that only the PND-3 type low-pressure heaters have the damages of the heat exchange tubes. For a short operation life, the number of the damaged heat-exchange tubes of PND-3 is approximately 50 pcs for Kalinin NPP and 100–150 pcs for Balakovo NPP. The low-pressure heaters were manufactured at AO Ural Plant of Chemical Machine-Building “Uralkhimmash,” OAO Taganrog Boiler-Making Works “Krasny Kotelshchik,” and Vitkovice Machinery Group, but the damage nature of the heat-exchange tubes is identical for all PND-3. The damages occur in the place of passage of the heat exchange tubes through the first, the second, and the third partitions over the lower tube plate (the first path of the turbine condensate). Hydraulic shocks can be one of the possible causes of the damage of the heat-exchange tubes of PND-3. The analysis of the average thermal and dynamic loads of the tube systems of PND-1–PND-4 revealed that PND-3 by the thermal power are loaded 1.4–1.6 times and by the dynamic effects are loaded 1.8–2.0 times more than the remaining LPHs. Another possible cause of damage can be the cascaded drain of the separate into PND-4 and then through the drainage heat exchange into PND-3. An additional factor can be the structure of the condensate drainage unit. The advanced system of the heating steam flow and pumping scheme of the separate drain using the existing drainage pumps of PND-3 for K-1000-60/1500 turbine plants for Balakovo and Kalinin NPPs were proposed. The considered decisions make it possible to reduce the flow rate of the heating steam condensate from PND-3 into PND-4 and the speed of the heating steam in the tube space of PND-3 and eliminate the occurrence of hydraulic shocks and damages of the heat exchanger tubes.     

Test facility for investigation of heat transfer of promising coolants for the nuclear power industry

The results are presented of experimental investigations into liquid metal heat transfer performed by the joint research group consisting of specialist in heat transfer and hydrodynamics from NIU MPEI and JIHT RAS. The program of experiments has been prepared considering the concept of development of the nuclear power industry in Russia. This concept calls for, in addition to extensive application of water-cooled, water-moderated (VVER-type) power reactors and BN-type sodium cooled fast reactors, development of the new generation of BREST-type reactors, fusion power reactors, and thermonuclear neutron sources. The basic coolants for these nuclear power installations will be heavy liquid metals, such as lead and lithium-lead alloy. The team of specialists from NRU MPEI and JIHT RAS commissioned a new RK-3 mercury MHD-test facility. The major components of this test facility are a unique electrical magnet constructed at Budker Nuclear Physics Institute and a pressurized liquid metal circuit. The test facility is designed for investigating upward and downward liquid metal flows in channels of various cross-sections in a transverse magnetic field. A probe procedure will be used for experimental investigation into heat transfer and hydrodynamics as well as for measuring temperature, velocity, and flow parameter fluctuations. It is generally adopted that liquid metals are the best coolants for the Tokamak reactors. However, alternative coolants should be sought for. As an alternative to liquid metal coolants, molten salts, such as fluorides of lithium and beryllium (so-called FLiBes) or fluorides of alkali metals (so-called FLiNaK) doped with uranium fluoride, can be used. That is why the team of specialists from NRU MPEI and JIHT RAS, in parallel with development of a mercury MHD test facility, is designing a test facility for simulating molten salt heat transfer and hydrodynamics. Since development of this test facility requires numerical predictions and verification of numerical codes, all examined configurations of the MHD flow are also investigated numerically.     

Using the sensors of shaft position for simulation of misalignments of shafting supports of turbounits

Examples of using the method developed for the earlier proposed concept of the monitoring system of the technical condition of a turbounit are presented. The solution methods of the inverse problem—the calculation of misalignments of supports based on the measurement results of positions of rotor pins in the borings of bearings during the operation of a turbounit—are demonstrated. The results of determination of static responses of supports at operation misalignments are presented. The examples of simulation and calculation of misalignments of supports are made for the three-bearing “high-pressure rotor–middle-pressure rotor” (HPR–MPR) system of a turbounit with 250 MW capacity and for 14-supporting shafting of a turbounit with 1000 MW capacity. The calculation results of coefficients of the stiffness matrix of shaftings and testing of methods for solving the inverse problem by modeling are presented. The high accuracy of the solution of the inverse problem at the inversion of the stiffness matrix of shafting used for determining the correcting centerings of rotors of multisupporting shafting is revealed. The stiffness matrix can be recommended to analyze the influence of displacements of one or several supports on changing the support responses of shafting of the turbounit during adjustment after assembling or repair. It is proposed to use the considered methods of evaluation of misalignments in the monitoring systems of changing the mutual position of supports and centerings of rotors by half-couplings of turbounits, especially for seismically dangerous regions and regions with increased sagging of foundations due to watering of soils.     

Predicting the energy-supply parameters for a transportation process based on multifactor models

Results are presented for the construction of a model of an energy-supply parameter characteristic for the transportation process, “electric-energy consumption for traction (plan),” based on the identification thereof with actual production and economic parameters by the example of one of the branches of JSC Russian Railways. The research was carried out based on a database created for monthly actual values over a long period, from 2007 to 2016. A methodology and results are presented for statistical studies of the parameter “electric-energy consumption for traction (plan)” in conjunction with 20 parameters, including “sectoral speed,” “average weight of the train,” “transportation costs.” The methodology involves choosing the factors for a multifactorial model and elimination of the consequences of multicollinearity based on the results of cluster analysis and constructed dendrograms. Variants are presented for the construction of multifactorial models to predict and manage the parameter of “electric-energy consumption for traction (plan)” for control and risk-management tasks. A variant of construction of a multifactorial model for predicting and control of the parameter “electric-energy consumption for traction (plan)” for control tasks and risk-management is given. As a mathematical tool for constructing the multifactorial models, a technique of linear regression equations has been used. The construction of dendrograms and obtaining the regression equation coefficients have been carried out using the Statistica software package. Using the multifactorial model results in improvement in the predictive accuracy of the “electric-energy consumption for traction (plan)” parameter measured with a MAPE estimate, from a 15% level to a level better than 6%.     

Adaptive noise abatement in automatic cab signaling receivers

Under conditions of a priori noise uncertainty, it is effective to use adaptive noise-abatement techniques to improve noise protection of continuous automatic cab signaling (CACS) receivers. The purpose of this article is to study the possibilities of an adaptive signal-processing technique, adaptive noise filtration (AF), providing better noise resistance of the CACS signals. To achieve this goal, the following problems are solved: a mathematical model of the CACS receivers' input signals is developed, a functional circuit and adaptation algorithm of a basic and a modified multichannel CACS receivers' adaptive filters is substantiated, and a computer simulation of adaptive filters is performed, confirming the accuracy of the obtained results and effectiveness of such filters for noise reduction. A distinctive feature of the proposed filters, which significantly expands their functionality, is a priori information on the presence of breaks in the CACS signals used in the adaptive algorithms.     

An analytical model of the emission of magnetizing-current harmonics by a power transformer under the action of quasi-direct currents

This article validates the possibility of a piecewise linear approximation with one breakpoint of the magnetizing characteristic of a power transformer for studying the processes of unilateral saturation of a magnetic system during periods of a high geomagnetic activity, which is caused by space-weather disturbances. An integral quantitative characteristic of a piecewise linear approximation is proposed that takes the features of the main magnetization curve of electric steel and the structural features of the power-transformer magnetic system into account. An analytical model is developed that allows determination of the instantaneous values and the harmonic structure of the magnetizing current at different intensities of quasi-direct currents. Two specific levels of the geomagnetic activity are determined. At one of them, the even harmonics of the magnetizing current are maximized, while at the second level the fundamental harmonic of the magnetizing current reaches a maximum that exceeds the certified value of the open-circuit current of the power transformer by several times.