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POWER DIVISION
DHARMAVARAM
PREPARED BY
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Standard Operating Procedure
Steam turbine is a machine, which converts the heat energy available from Boiler
main steam into mechanical energy in an economical way. Turbine is associated with
Reduction gearbox and Generator, to convert this mechanical energy into electrical
energy.
One number 0f 32 MW, single cylinder, horizontal, impulse, multistage, multtivalve,
axial flow, condensing, one controlled and one uncontrolled extractions with
reduction gear and down exhaust type turbo generator supplied by SNM Co Ltd.,
Japan is installed in our plant.
Principle of Operation:
The steam with 86 Kg/Sq.cm pressure and 515 Deg.C temperatures will enter into
turbine through one ESV and 4 numbers Governing control valves. The steam entered
into the turbine expands over the moving and fixed blades of turbine releasing the
mechanical energy and rotates the turbine rotor at 6194 rpm. The turbine is coupled
with the generator rotor through reduction gearbox (6194/1500 rpm) and rotates the
generator rotor to convert mechanical energy into Electrical energy.
Steam after doing its work in turbine, gets collected into Condenser and forms as
condensate by giving its latent heat to CW water flowing in the tubes of condenser.
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From condenser the condensate is pumped with Condensate Extraction Pumps (CEP)
through ejectors and gland steam cooler upto Deareator. From Deareator, feed water
is pumped to boiler Economizer using BFPs through HP heater. Deaerator & HP
heaters draw the steam from the turbine to heat the condensate flowing through them.
This is known as Regenerative feed heating system.
OPERATION - PROCEDURES
1. Cold, warm and hot start up of TG
2. Loading of Turbine
3. Planned and Emergency shutdown.
4. Emergency conditions during Turbine Operation.
5. Important DOs and DONTs
6. Operating parameters and alarm trip values as Annexure I.
7. Possible troubles, causes and remedies
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multistage, multi valve, axial flow, condensing, nozzle governing, extraction and
geared type. The turbine is provided with 16 stages of blades.
Steam flow to the HP part is regulated by 4nos steam control valves constituted as a
single assembly as HP governor valve. Steam Turbine consists of Casing, fixed
blades, moving blades, rotor (on which moving blades are fixed) bearings (journal
and thrust), steam flow control valves.
The casing or cylinder of turbine is a pressure vessel, which is capable of with
-standing the working pressure and temperature. It provides support to the fixed
blades and rotor bearings. The turbine HP part is made up of Cast alloy and LP part is
made up of carbon steel and rotor is made up of Chromium, molybdenum, and
vanadium steels. The moving blades are fixed on rotor and rotate between the
stationary (fixed) blades. The rotor is mounted on two journal bearings. The front side
of the rotor is mounted with thrust bearing to take the axial thrust coming on rotor.
Lube oil to the bearings is provided from lubrication system.
To reduce the speed of the turbine rotor from 6194 to 1500 rpm, which is required for
generator, reduction gearbox was incorporated between turbine and generator rotors.
The turbine shaft is coupled with pinion shaft of gearbox and where as generator shaft
is coupled with wheel shaft of gearbox. Reduction gearbox assembly also consists of
Turning gear motor arrangement and Main oil Pump in it.
The full load parameters of turbine are 86 kg/Sq.cm g main steam pressure, 515
Deg.C MS temperature, 6194 rpm, 0.1 Kg/Sq.cm (abs) exhaust steam pressure and
127.61 TPH steam flow through it. The two extraction steam quantities are 14.114
TPH for HP heater, 7.68 TPH for Deareator, and 12.05 TPH for LP heater. And
remaining 93.37 TPH gets collected in condenser where it is condensed by using
Circulating water. To supply the cooling water for the above condensation process,
TWO numbers of CW pumps each of 6900 Cu.M/Hr capacities are installed here.
The circulating water gets heated by approx 9 Deg.C in the condenser during
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condensation process. In order to cool this water by 10 Deg.C, two nos of cooling
towers with induced draught fans are installed.
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23. Reduction gear wheel front shaft vibration high high 180 microns
24. Reduction gear wheel rear shaft vibration high high 180 microns
25. Generator front shaft vibration high high 160 microns
26. Generator rear shaft vibration high high 160 microns
27. Turbine thrust bearing temperature high high (inactive) 120 Deg.C
28. Turbine thrust bearing temperature high high (active) 120 Deg.C
29. Turbine front shaft bearing temperature high high 120 degC
30. Turbine rear shaft bearing temperature high high 120 degC
31. Reduction Gear pinion front bearing temperature high high 120 degC
32. Reduction Gear pinion rear bearing temperature high high 120 degC
33. Reduction Gear wheel front bearing temperature high high 120 degC
34. Reduction Gear wheel rear bearing temperature high high 120 degC
35. Generator front bearing temperature high high 85 degC
36. Generator rear bearing temperature high high 85 degC
37. HP heater level high high 290mm. (Protection should be bypassed during
charging of HP heater.) not incorporated.
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system. Two numbers of vapor fans (one working and one standby) are provided to
extract oil vapors from MOT and vent them out to atmosphere.
Startup Sequence:
01. Ensure the following
COP1&2 are ready from Mechanical, Electrical and Instrumentation sides and NO
Line Clearance is pending on COP- 1&2, governing and lube oil systems.
Power supply and control supply are available.
Pressure switches and interlocks are properly checked and incorporated.
Discharge valves are opened.
Level of oil in MOT is normal (550mm).
Valves in oil system supply mains are properly lined up.
Ensure oil vapor fan is ready to start (at least one).
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Before changing the filter, open air vent & Equalizing valve and ensure that both the
filters are equalized with oil. After change over, close the air vent.
Shutdown Sequence:
As these pumps are intended for continuous supply of governing oil to the turbine,
they are to be switched off only when the turbine is not in service. Before switching
off these pumps, ensure that the standby pump is in MAN mode (if pump is in
AUTO mode, it will come in to service on interlock).
Important Note:
When one COP is in service with the turbine running, the standby COP should be in
AUTO selection. Otherwise, auto-change over will not take place when running COP
trips and this results n trip of Turbine.
Interlocks on COPs:
Auto Start: COP discharge pressure low (PSL 510) or running COP off, and pump is
selected in auto, the AUTO selected pump will come into service in AUTO.
Auto Stop: No Auto Stop incorporated.
Pump can be switched ON and OFF at any time if it is selected in MAN in DCS.
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in auto. This pump comes into service in AUTO if lube oil header pressure is less
than 0.87+/-0.2 Kg/Sq.Cm and pump is selected in AUTO.
In the event of turbine trip due to any reason, AOP comes into service into operation
by interlock when oil header pressure drops to 0.87+/-0.2 Kg/Sq.Cm to supply lube
oil to all bearings for its safe coasting down and subsequent Turning gear operation.
This pump also supplies suction to the Jacking oil pumps. The discharge of AOP
passes through the Lube Oil Coolers.
Start up Sequence:
01.Ensure the following
AOP is ready from Mechanical, Electrical and Instrumentation sides and NO Line
Clearance is pending on AOP, governing and oil systems.
Power supply and control supply are available.
Pressure switches and interlocks are properly checked and incorporated.
Discharge valve is opened.
Level of oil in MOT is normal.
Valves in oil system supply mains are properly lined up.
Ensure oil vapor fan is in service (at least one).
02. Start the pump by pressing the start button on DCS.
03. Check the discharge pressure of pump and motor current.
04. Keep the pump in auto, in order to come in to service in auto as per the interlock.
05. Observe the lube oil filter DP (< than 0.8) from local gauge. If necessary change
the filter.
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NOTE:
Before changing the filter, open air vent & Equalizing valve and ensure that both the
filters are equalized with oil. After change over, close the air vent.
Shutdown Sequence:
As this pump is intended for initial run up of Turbine, this will be switched off in auto
when turbine speed is above 4650 rpm (>95% of rated speed). Before switching off
AOP manually, keep the pump in MAN selection and ensure that Turbine speed is
>95%( MOP has taken over the job of AOP) and Turning gear motor is not in service.
Interlocks on AOP:
Auto Start: Lube oil header pressure low (PSL504 ) alarm and pump is selected in
AUTO, AOP comes in to service in AUTO.
Auto Stop: When Turbine speed is greater than 95% of rated speed, AOP will be
switched off in AUTO.
Pump can always be switched on and off manually at any time.
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EMERGENCY OIL PUMP
The EOP comes into service in the event of an Emergency. A DC motor drives this. It
has rated capacity of 260LPM against a 1.5 Kg/Sq.cm head and is driven
by 2.2 KW, 1500-rpm 110V DC motor. In the event of total power
failure or if AOP fails to start on its interlock due to any reason, EOP
comes into operation when lube oil header pressure drops to
0.62Kg/Sq.cm to supply the lube oil to the TG bearings for its safe
coasting down. EOP supplies oil only to the bearings. The discharge of
this pump will not go through oil coolers.
Startup sequence:
01.Ensure the following.
EOP is ready from Mechanical, Electrical and Instrumentation sides and NO Line
Clearance is pending on EOP, governing and oil systems.
DC Power supply and control supply are available.
Pressure switches and interlocks are properly checked and incorporated.
Discharge valve is opened.
Level of oil in MOT is normal
Valves in oil system supply mains are properly lined up.
2. When the above are satisfied, the DC EOP will start by inter lock, if lube oil
header pressure drops to 0.62 Kg/Sq.Cm
3. If the interlock does not work, the pump can be started by pressing the start push
button on Turbine governor panel (TGP).
04. After starting the pump check the discharge pressure, motor current.
Shutdown sequence:
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The DC EOP can be stopped from TGP when it is no longer required to run, say,
when AC power is restored and AOP has taken into service. To stop the pump, press
stop button on TGP. The pump can only be stopped whenever lube oil header pressure
is > 0.62Kg/Sq.Cm, otherwise EOP will come into service in auto.
Important Note:
During normal running of turbine, EOP should be ready in all respects to come into
service with out fail. Trail run may be taken in every shift to check the availability
of EOP. While TG is in service or in TGM operation, EOP should be in Auto
Standby mode on TGP.
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Inter locks on EOP:
Auto Start: Lube oil header pressure low low (PSLL 504-1) and EOP auto selected
on TGP then EOP come into service in AUTO.
Auto Stop: Auto stop isnt incorporated.
Manual start and manual stop can be done at any time from TGP.
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TURNING GEAR
Before starting of the turbine and as well as after trip, turbine and generator shafts
are to be rotated at certain speed to avoid deflection of rotor due to self
weight in high temperature atmosphere. Turning Gear is incorporated in
the system to facilitate this operation. In our case, turbine rotates at 40
rpm in turning gear operation. 11 kW, 415V, 1450-rpm motor, drives the
turning Gear.
Interlocks on TGM:
Auto Start: TGM comes in to service in AUTO 200 seconds, after the start
permissives were satisfied and if it is selected in AUTO. The start
permissives for TGM are
Turbine speed <10%(490 rpm)
Lube oil header pressure is not low (PSL 504).
Auto Stop: If any one of the above conditions is not present the TGM will trip and
turns to MAN selection. Manual start can be possible if all the start
permissives are satisfied. Manual stop can be done at any time.
During turbine rolling, TGM automatically disengages at 100 rpm (approx) of turbine
rotor, and TGM trip at 490rpm of Turbine.
Whenever the unit trips barring gear will engage automatically, during the barring
gear operation if power fails after restoration power barring gear
should be manually engaged before starting. If it is not so which will
lead ton damage the gears of barring gear.
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Proper functioning of instruments indicating:
Axial displacement
All turbine, reduction gear box, generator bearing vibrations
All bearing metal temperatures
Lube oil temperature and pressure
Jacking oil pressure
Turbine speed
Ensure DC EOP is healthy and in standby mode on the Governor panel.
Start AOP as per the procedure and check the Lube oil pressure and parameters
mentioned in point 1.c.
Throttle the cooling water outlet from oil coolers and maintain oil temperature around
45 Deg.C +/- 5 Deg.C
Engage turning gear pinion by rotating the motor shaft with the lever from local.
Start the turning gear motor (TPBSSBGMT) and check the following:
TGM current
Axial displacement
All bearing vibrations
Turbine speed
Lube oil pressure
It needs approx. 10 hours to cool down the turbine casing and bearings. After turbine
cooling period, the TGM may be stopped. AOP & JOP should be continued in service
for another 2 hours.
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III.CONDENSER and AIR EVACUATION SYSTEM:
CONDENSER:
Condenser is a tubular, non-contact type heat exchanger, which receives the steam
from turbine after doing work, and condenses it to form condensate
using CW system. Condensate Extraction pumps are connected to
condenser, and they will pump the main condensate to Deareator through
Ejector and Gland Steam Cooler. To increase the work done by the
turbine and to avoid backpressure on Turbine rotor, pressure inside the
condenser is maintained below atmosphere pressure (vacuum). To obtain
vacuum in condenser, air and non-condensable gases are to be removed.
For this purpose, air evacuation system with Main ejector has been
provided. The makeup DM water needed for the system is added in the
condenser from UCFT through Normal and Emergency makeup control
valve lines.
Heat transfer area in condenser : 2435 Sq.M
Number of Tubes : 5016
Dia/Thickness of tubes : 22.225/0.71mm
Rated CW flow : 5800 Cu.m/hr
DP across condenser at rated flow: <5300 mmwc
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Condenser is charged from CW side.
Hot well level is normal.
CEP is running on re-circulation through Main Ejector, Gland steam cooler.
PRDS steam is available at rated pressure and temperature.
Ensure water sealing is provided for all valves connected to condenser and vacuum
break valve.
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After attaining 0.70Kg/Sq.Cm (g) of vacuum, isolate the startup ejector by Closing
air valve first and steam valve next. With the main ejector in service we can attain
0.9 to 0.95 Kg/ Sq.Cm (g).
Important Note:
a. Before charging the main ejector, ensure flow of main condensate (CEP
discharge) through ejector.
b. While charging the ejector, open steam valve and air valve next gradually.
c. During cut off of the ejector, close air valve first and steam valve next and
discharge valve next.
d. Ensure tightness of vacuum break valve manually. Provide water sealing.
e. Do not open any drain valve connected to condenser when there is no
sufficient vacuum (>0.5Kg/Sq.Cm (abs)).
f. Ensure that the drain line isolation valves of condensate trap & casing drain of
the running exhaust fan are in open position.
g. While charging the main ejectors, ensure that Rotameter isolation valves drain
line isolation valves of Condensate Trap are in open position.
h. Ensure that the suction valve& casing drain valves of the standby exhaust fan
on Gland steam condenser are in closed position.
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After condensing of Exhaust steam in condenser, condensate forms. This condensate
is pumped to Deareator using Condensate Extraction pumps through Main ejectors,
GSC. The discharge of CEP is also used for 1. Flash box attemperation,2. Valve
sealing. From CEP discharge header one line is connected to UCFT with Motor
Operated Valve, to drain the excess condensate from the hot well.
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SHUT DOWN SEQUENCE:
When there is no vacuum in Condenser, the pump can be stopped by keeping the
Pump in re-circulation.
Interlocks on CEP:
1. When hot well level Hi switch (TLT300A1) is acted (cond. Level >1000 mm)
auto stand by pump comes into service in Auto.
2. When hot well level Low switch (TLT302A) is acted (cond. Level < 550 mm)
auto stand by pump trips in Auto.
3. When hot well level Low Low switch (TLT303A) is acted (cond. Level < 300
mm) both pumps will trip. (Turbine trip)
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from the turbine at high pressure and temperature and heats the feed water flows
through them. The condensed steam from HP heater are connected to condenser and
deareator respectively.
The presence of certain gases like oxygen, carbon monoxide and ammonia, dissolved
in water is harmful because of their corrosive attack on metals. Hence these gases are
removed in deareator unit. Spraying the water and heating the same by steam achieve
the same. The Deaerator consists of two chambers, the deareating column and feed
storage tank.
Note: 1. Do not charge the heater with out water flowing through them
1. During cut out of heater, close steam valve first.
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Open HPH extraction check valve
Open HPH extraction bypass to Deareator MOV
Maintain the Deaerator pressure at 4.9 to 5.0 kg/sq.cm by operating the Deareator
pressure control valve.
After charging of Deaerator close the drains before and after check valve.
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During turbine rolling and up to 10MW load the aux. Steam with 8Kg/sq.cm; 180 0C
is being used for sealing. After 10MW load, the turbine HP gland leak off steam is
being used for turbine LP gland sealing. To collect and condense the gland leak off
steam from turbine front and rear glands, gland steam piping and gland steam cooler
are provided. Turbine glands are to be sealed with gland steam during vacuum pulling
after attaining () 0.70Kg/sq.cm (g) vacuum in condenser.
After trip of turbine, to kill the vacuum stop the glands sealing by closing the hand
operated valve before 3 way pneumatic control valve.
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Boiler is steaming and steam is available.
All TG interlocks and protections are checked and checking of all motor operated
valves, Pneumatic
Operated control valves closing and opening is completed.
TG instrumentation / annunciation system is OK. Root valves to transmitter lines are
in open
Position.
DC supply is healthy for EOP and trail run was taken.
MOT level is normal.
Overhead tank level is normal.
Auto start of EOP, COP - 1&2, AOP, are checked.
II. Carry out related operations and ensure the following
AOP&JOP are running as per the procedure.
COP is running as per the procedure.
EOP is selected in standby mode on the Governor panel.
Oil flow is normal through the bearings (observe from sight glass).
Circulating water is charged in condenser and ACW pump and CW pumps are in
service.
TG is on Turning Gear Operation as per the procedure. During cold start up, Turbine
should be kept
in TGM operation 2 hours prior to turbine rolling.
Oil cooler is charged from cooling waterside to maintain oil temperature 45 +/- 5 deg
C.
Ensure ACW to Generator air coolers line valves are in open position.
Condenser hot well level is normal and CEP is running through Main Ejector and
GSC.
Main steam line is charged up to MSV (T).
Start vacuum pulling as per the procedure.
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Check the set pressure of sealing steam (PIC 107) is 0.1 to 0.2Kg/Sq.Cm (g) then
open the sealing
Steam HOV.
After attaining 0.5 Kg/Sq.Cm (a) pressure in condenser, open the drains in extraction
lines to
remove the Condensate in the pipelines.
Ensure the following drains are open
Drain before MSV (T).
Drain valves in extraction before check valves lines.
Isolate the Steam traps of ESV, Turbine Casing and Turbine Chest.
Turbine casing drain (Wheel chamber) through Steam trap bypass.
ESV drain through Steam trap bypass.
HP governor chest drain through Steam trap bypass.
Ensure all extraction check valves and MOVs are in closed position.
Meanwhile, attain condenser vacuum to -0.9 Kg/Sq.cm (g).
Check and record the following Turbovisory readings:
Rotor axial displacement
Thermal expansion (Local measurement)
Turbine, Reduction Gear and Generator rotor vibrations
Turbine speed
MOT level
Lube oil pressure and temperature
All bearing temperatures
Casing metal temperature
MS pressure and temperature
Gland steam pressure and temperature
Condenser vacuum
PRDS pressure and temperature
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Ensure main steam line is warmed upto MSV (T), then open MSV (T) bypass valve
(H.O.V) and open the drains in MS line and ESV body slowly. (Ensure ESV is in
closed condition before doing the above).
After warming up ESV body, ensure that no Turbine protection is active (from
Turbine Protection graphic) and then give RESET ON command from DCS. This
will reset all the protections.
Reset fault signals by pressing Governor Clear button on TGP.
Check lube oil pressure, trip oil pressure, control oil pressure and lube oil
temperatures.
Check the auto-standby position of COP, & EOP.
Open the ESV by pressing the Turbine Reset button on TGP. Check the open feed
back on TGP and warm up the chest at least 20 min. This is tentative, ensure the chest
drain temp. is equal to the MS metal temp.
Ensure the Hotness of ESV and Turbine Chest drains.
Check AOP & Turning Gear are in service and selected in auto.
Open the MSV (T) before going to roll the turbine.
Start the Turbine rolling by pressing the START button on TGP. The governor will
accelerate the speed of the turbo generator and hold it at idle speed 750 rpm. During
the speed rise, check for Turning gear motor stop at the set rpm (> 10% of rated rpm).
Ensure the Hotness of Turbine Casing drain.
Observe the exhaust hood temperature .
Observe all the Turbovisory readings. (Mentioned earlier).
Feel and listen for any rubbing and abnormal noises during warm up.
Check and record the shaft vibrations and axial displacement monitor on TGP.
Check whether the turbine casing expansion has started and its pointer is moving on
local scale, near turbine front bearing.
After ensuring expansion by 1.0 to 1.5mm, Press the RATED SPEED button on
TGP. The governor will accelerate the speed of the turbine generator automatically to
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4897 rpm. Observe for the bearing vibrations in the Critical speed range from 1650
2050 rpm.
Check AOP are stopped at > 95%(4650 rpm) respectively.
Start the CT fans before synchronizing the generator as for the procedure.
Synchronize the generator with the GRID as per the procedure.
Increase the load on generator to 3 MW.
Close all the MS drains.
Gradually increase the load (not more than 1.0mw/min) by means of SPEED/LOAD
SETTING lever on TGP or Generator control panel.
At 6.0 MW load, operator can select for load control when connected with grid.
Steam traps of ESV, Turbine Casing, Turbine Chest drains should be kept in service
and close the bypass valves.
Ensure the Steam traps are working or not. If they are not working open the bypass
valve slightly.
Gradually increase the load as per the loading procedure.
After paralleling with both the boilers gradually increase the load to 30MW as per the
procedure.
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Warm start up and Hot start up
Turbine start up is termed as Warm startup if it is being started 3 to 4 hours after
trip of turbine. Turbine start up is termed as Hot Startup if it is being started with
in 2 hours after trip of the turbine. Follow the procedure for the cold startup upto
speed up to idle speed (i.e 750 rpm). After reaching 750 rpm, allow the machine for
soaking at the idle speed. Ensure that casing expansion has started from local scale
during soaking than previous condition. After ensuring that casing expansion has
started, then give command for Rated Speed. MS temperature should be maintained
50 0C more than MS skin / MS temp.at Turbine inlet. (Subjected to operating
temperature 530 0C at Turbine inlet.)
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Raise the load at 0.5MW increment (1.0mw/min) by observing MS pressure and
temperature at turbine inlet.
At above 6 MW load take Generator Automatic Power control in to service.
At 8MW stable load charge the Deareator as per the procedure.
At 12 MW stable load charge the HP heater as per the procedure.
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Observe AOP to start in auto when lube oil header pressure drops to 0.87+/-0.2
Kg/Sq.Cm. If it is not started, start the pump manually and observe discharge
pressure.
Ensure TGM starts in auto at <10% speed with time delay of 150 seconds. If it is not
started, engage the turning gear manually at 0 rpm of the turbine and start TGM
from DCS.
When the shut down period is less than 1.0 hour, maintain the vacuum in condenser.
During this period, ensure that gland seal exhaust fans are in continuous service and
the PRDS parameters should be reduced to 7.0kg/sq.cm & 150deg.c gradually i.e
5deg.c/min.
When the shut down period is more than 1.0 hour, kill the vacuum in condenser by
opening the vacuum break valve. Before opening the vacuum break valve, make sure
that hand operated valve in gland sealing steam supply line is closed and isolate the
Main ejector as per procedure.
Before killing the vacuum close all the Before QCVs drains.
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8. After ensuring the bearing Babbitt, oil inlet and drain oil temperature becomes
near equal. Stop AOP, When AOP is stopped EOP will start in auto. Stop EOP
from TGP.
9. Stop (OVEF) oil vapour fan.
WORK INSTRUCTIONS
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X. Emergency conditions during Turbine Operation:
The following emergency conditions may occur during Turbine operation. The
turbine operator should always be ready to take correct decision and act as per the
operating procedures. It is also necessary that he should know about the boilers
loading status, Tie- feeders positions, import and export power details in his shift.
a. Total power failure
b. Island mode operation
c. Any one boiler trip
d. DCS failure
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Close the Isolation valves in PRDS Pressure CV and Temperature CV. Close HOVs in
air and steam lines of Ejector from local.
Close HO isolation valve in Gland sealing line.
Close all drain valves connected to condenser. And open Vacuum break valve.
After restoring the Emergency DG set power, close the following valves:
All three extraction MOVs
Main steam stop valve (Turbine)
Discharge valve of BFP
Start AOP after informing to Switchgear operator.
Start JOP as per the procedure.
After turbine reaches to <10% of rated RPM start TGM as per the procedure.
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The following procedure is to be followed:
Load drops / rises as per the FAP demand. The turbine rotor speed and MS pressure at
turbine inlet will change.
Maintain the Generator Frequency at 50HZ by changing the turbine speed from
load/speed change lever from TGP.
Ensure the steam being supplied from the Boiler is sufficient to generate the load on
the turbine. If steam flow is less, MS pressure will drop. Ask shift engineer to
decrease the load on FAP to the suitable limits.
Observe the turbovisory readings like axial shift, all bearing vibrations, all bearing
temperature and casing expansion for any change. Do not allow MS temp to fall
sharply.
LP heater levels, HP heater levels and Deareator pressure may disturb due to load
fluctuations. Control the above parameters in manual mode.
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Observe HP, LP, Deareator extraction pressures from local pressure transmitters.
LP, HP heater levels to be monitored from local gauge glass and level transmeter
analog indication.
Observe lube oil pressure, governing oil pressure, trip oil pressure, MOT level,
vacuum and Gland steam pressure local gauges/transmitters.
Maintain the same load.
Observe BFP parameters from local. Inform to Boiler operator to maintain constant
feed water flow
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XI. Important Dos and DONTs during Turbine Operation:
DOs:
1. The turbine has to be shutdown immediately in the following cases.
When the turbine rotor speed increases higher than 5200 rpm.
Whenever oil pipes, steam pipes, main condensate pipes, feed water pipes are
broken or some cracks / leaks are found in them.
Whenever some hydraulic shocks are occurred in the piping or in the turbine
casings.
Some metallic noise is heard clearly in the turbine
When the mechanical over speed lever is defective
2. The turbine is to be tripped emergently with breaking vacuum manually in the
following cases:
When the lube oil header pressure drops to <0.45Kg/Sq.cm
When the oil catches fire and fire could not be extinguished immediately.
When the turbine tripped on Rotor Axial Displacement protection
3. DO in every shift:
Check Main oil tank level is normal.
Check oil vapour fan and GSC exhaust fan are in service.
Check the availability of DG set.
Check the availability of AOP, Stand by COP and DC EOP.
Check the open position of Discharge valves of AOP, EOP, standby COP.
Ensure the Steam traps of ESV, Turbine Casing and Turbine Chest drains
are working normal.
Ensure condensate system and feed water systems are running normal
Ensure CW system is running normal
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Ensure Glands sealing steam control valve is functioning normally
Ensure the parameters of turbine and its auxiliaries are within the limits
Check the sealing water to Condenser connected valves are given
Check starting ejector air valve and vacuum break valve are tightly closed
Ensure that all instruments functioning properly
Ensure that standby ACW and stand by CEP discharge valves are in open
position.
DONTs
1. Do not operate the turbine, any equipment bypassing the interlocks
2. Do not operate the turbine with high vibration values and high bearing
temperatures conditions
3. Do not allow sudden drop or rise in MS temperature and MS pressures.
4. Do not start the vacuum pulling with out turbine on Turning Gear operation
5. Do not start the Glands charging with out turbine on Turning Gear operation
6. Do not continue turbine on TGM operation if unusual sound / vibration comes
from gland seal, bearings etc.
7. Do not operate the turbine with LOW main oil tank levels.
8. Do not start the TGM with out Over head oil tank level normal
9. Do not start the Turbine with out Over head oil tank level normal
10.Do not start the TGM with out running the AOP&JOP.
11.Do not run Lube oil system with out running the oil vapor exhaust fan.
12.Dont run Oil vapor Exhaust Fan when MOT level is high.
13.Do not allow hot rotor to stand with out rolling (with out TGM operation)
14.Do not overlook abnormality in any important reading
15.Do not forget to check stand by position and healthiness of DC EOP
16.Do not allow any leakage in the suction side of the CEPs.
17.Do not start the CEP with out opening of Air removal and Gland sealing.
37
18.Do not open any valve, fitting, flange in the suction side of CEPs in normal
working condition. When condenser is in vacuum this will cause vacuum to
drop and pump (CEP) to loose its suction.
19.While cleaning suction strainer of stand by CEP, ensure closure of suction
valve.
20.Do not keep the steam valve of main ejector open for long time if condensate
flow is not there through main ejector.
21.Do not run the turbine with open or un tightened flanges on oil tank, oil piping,
steam piping. etc.
22.Dont charge the PRDS line without closing the Turbine Glands Isolation
Valve.
23.Do not open the Vacuum break valve with out Isolating the Glands Isolation
valve and Steam lines connected to Condenser.
*/Technical Data/*
Type of pump : Diffuser
Feed water temperature : 158 Deg.C
Flow rate : 166 TPH
Developed head : 1285 Mlc
Speed : 2980 rpm
Net positive suction head : 5.8mlc
Recirculation flow : 40 TPH
Direction of Rotation : CCW from Motor DE.
38
STARTING OF BFP:
Ensure no line clearance is pending on BFP, its auxiliaries and its connecting piping
and valves. Ensure supply to the Motor is available.
Ensure Deaerator level is normal and CEP is in service to maintain its level.
Check the lube oil levels of pump DE & NDE bearings.
Ensure ACW pump is in service.
The inlet and outlet valves of ACW water to BFP should be in open position and
check the ACW pressure at BFP is 2.5 Kg/ Sq.cm
NOTE*
1. Dont close the valves in re-circulation and balancing leak off lines
2. Dont allow the BFP to run when the bearing temperatures exceeds>80 deg.
3. Dont run the Pump without ACW pump is in service.
4. Dont allow the Pump to run when the seal water temp. Exceeds the limit.
(>80 deg)
5. Dont switch on the pump during discharge valve is in open position.
STARTING PERMISSIVES:
CW PUMPS
2 CW pumps (both working) are installed to supply cooling water to condenser. It is
rated to deliver 6900 TPH, at 2.10Kg/Sq.cm and is driven by 415V, 550 KW, 740-rpm
motor. The cooling water pump receives its suction from CT Sump and discharge is
returned to CT sump through Condenser and riser pipes.
STARTING OF CW PUMPS:
1. Check no line clearance is pending on CW system.
2. Ensure LT supply to the Motor is available.
3. Ensure Sump level is normal. If low, make it normal with CT Sump Make up
Pump. (Sump level is > 2800 mm)
4. Ensure CW to Condenser I/L and O/L valves and CT raiser valves are opened. (For
one pump one CT riser valve, and for two pumps in operation two riser valves)
5. Open all the 4 air vents of Condenser Water box during initial starting of pump.
Close them after air vented out
6. Open Air release cocks located above the Pump to ensure that the Pump is full of
water.
7. Ensure Gland cooling water valves are open.
8. Ensure suction valve is opened and discharge valve is in closed position.
9. Release Local Push Button.
10. Start the Pump from DCS.
11. After speed pick up and restoration of normal currents, slowly open the discharge
valve.
12. Observe the discharge pressure should be > 1.5 kg/sq.cm at pump.
13. Check the bearing & Glands temperatures Physically.
14. Observe the gland leakage water from Pump DE and NDE.
41
SHUT DOWN SEQUENCE:
1. Close the discharge valve.
2. Switch off the Motor.
STARTING PERMISSIVES:
1. CW Sump level is > 2800 mm.
PROTECTIONS:
1. Sump level low low. (Value not incorporated.)
IMPORTANT NOTE:
1. Dont start the Pump keeping Discharge valve in open position.
2. Maintain sump level between 2800 and 3000 mm.
3. When both the pumps are in service, ensure that at least two riser valves must be
in open position.
4. Discharge valve of the stand by pump should be in closed position.
5. Dont allow the pump to start or run with protection interlock bypass.
42
DESK OPERATORS GUIDE:
The following are the Protections (Trip values) of the Turbine:
1. Steam temperature at turbine inlet high high > 543 Deg.C
2. Steam temp. at turbine inlet low low < 460degC, this protection comes in to
service only when MS temperature reaches to 495 deg C and then falls to 460.
3. Steam pressure at turbine inlet low low < 60 kg/sq.cm (may be bypassed initially
for Cold and Warm start ups if required.)
4.Steam pressure at turbine inlet high high >103kg/sq.cm (not incorporated).
5. Control oil pressure low low 8.0+/-0.5 Kg/sq.cm
6. Lube oil pressure low low < 0.62 Kg/Sq.cm
7. Generator heavy fault (Generator trip).
8. Turbine mechanical over speed trip >/= 5632 rpm
9. Turbine electrical over speed trip >/= 5583 rpm
10. Governor heavy fault.
11. Remote trip from turbine governor panel.
12. Turbine trip from desk push button.
13. Exhaust steam pressure high high > 1.3 Kg/Sq.cm (abs)
14. Exhaust steam Temperature high high > 150 degC
15. Lube oil reservoir level (MOT) low low < 350 mm.
16. Hot well level low low < 300mm
17. Hot well high high 1400 mm
18. Turbine Rotor axial shift high high +0.65, -0.65 mm.
19. Turbine front shaft vibration high high 90 microns
20. Turbine rear shaft vibration high high 90 microns
21. Reduction gear pinion front shaft vibration high high 140 microns
22. Reduction gear pinion rear shaft vibration high high 140 microns
23. Reduction gear wheel front shaft vibration high high 180 microns
43
24. Reduction gear wheel rear shaft vibration high high 180 microns
25. Generator front shaft vibration high high 160 microns
26. Generator rear shaft vibration high high 160 microns
27. Turbine thrust bearing temperature high high (inactive) 120 Deg.C
28. Turbine thrust bearing temperature high high (active) 120 Deg.C
29. Turbine front shaft bearing temperature high high 120 degC
30. Turbine rear shaft bearing temperature high high 120 degC
31. Reduction Gear pinion front bearing temperature high high 120 degC
32. Reduction Gear pinion rear bearing temperature high high 120 degC
33. Reduction Gear wheel front bearing temperature high high 120 degC
34. Reduction Gear wheel rear bearing temperature high high 120 degC
35. Generator front bearing temperature high high 85 degC
36. Generator rear bearing temperature high high 85 degC
37. HP heater level high high 290mm. (Protection should be bypassed during
charging of HP heater.) not incorporated.
44
06 TTI106 Exhaust steam temperature 44 120 150/15
Deg.c 0
07 TLT300A Condenser Level mm 800 600 100 300/30 1400/1
0 0 400
08 TLT440 UCFT Level mm 16501900
09 TDPT40 DP across Cond. Left 5300 4500 60003500 7000
0A mmwc
10 TDPT40 DP across Cond. Right 5300 4500 60003500 7000
0B mmwc
11 TCV440 Emergency Makeup CV
AFB Feed back
12 TCV440 Normal Makeup CV Feed
BFB back
13 TCV300 CEP Recirculation CV Feed
AFB back
14 TLCV430 Deareator level CV Feed
FB back
15 TPT321 CEP Discharge Pressure 9.0 7.0 11 6.0 14.0
Kg/Sq.cm
16 Hot well Temperature Deg.c 44 40 52 35 55
45
Disch Deg.c
04 TTI471B FW temperature at BFP-2 158 140 160 120 160
Disch Deg.c
05 TPT460 BFP-1 Discharge Pressure 120.5 110 135 105/10 140
Kg/Sq.cm 5
06 TPT470 BFP-2 Discharge Pressure 120.5 110 135 105/10 140
Kg/Sq.cm 5
07 TTI468A BFP-1 DE Bearing 60 70 80/80
Temperature Deg.c
08 TTI468B BFP-2 DE Bearing 60 70 80/80
Temperature Deg.c
09 TTI469A BFP-1 NDE Bearing 60 70 80/80
Temperature Deg.c
10 TTI469B BFP-2 NDE Bearing 60 70 80/80
Temperature Deg.c
11 TTI466A BFP-1 Motor DE Bearing 70 90 80/95
Temp Deg.c
12 TTI466B BFP-2 Motor DE Bearing 70 90 80/95
Temp Deg.c
13 TTI467A BFP-1 Motor NDE Bearing 70 90 80/95
Temp Deg.c
14 TTI467B BFP-2 Motor NDE Bearing 70 90 80/95
Temp Deg.c
15 TPT103 HPH Ext. Steam pressure 20.5 18 22 15 25
Kg/Sq.cm
16 TTI103 HPH Ext. Steam 337 300 350 280 360
temperature Deg.c
17 TTI702A HPH Drain temperature 154 140 165 120 180
Deg.c
S.N Tag No Description of Tag Nor Lo Hi LL HH/Trip
18 TTI704A FW temp at HPH I/L Deg.c 158 135 155 120 160
19 TTI703A FW temp at HPH O/L Deg.c 220 190 225 180 235
20 TLT420A HPH level 1 mm 180 170 220 160 240/29
0
21 TLT420B HPH level 2 mm 180 170 220 160 240/29
0
22 TCV420F HPH drain to Deareator CV
B Feed Back
23 TCV420 HPH drain to Condenser CV
46
BFB Feed Back
24 TPT104 Deareator Extr Steam 5.00 5.51 6
Pressure Kg/Sq.cm
25 TTI104 Deareator Extraction Steam 219 240 300
Temp Deg.c
26 TPT430 Deareator Pressure 5.0 5.5 6.0
Kg/Sq.cm
27 TLT430A Deareator Level 1 mm 1150 650 146 500/40 1665
5 0
28 TLT430B Deaerator Level 2 mm 1150 650 146 500/40 1665
5 0
29 TLT430S Deareator Level Selection 1350 650 166 500/401865
EL mm 5 0
47
Turbovisory
01 TLT500A Lube oil tank level mm 550 400 800 350/35 870
0
02 TPT531ALube oil pressure to 1.5 1.17 1.7 0.62/0. 2.0
Bearings Kg/Sq.cm 62
03 TTI510A Lube oil temp at cooler I/L 65 40 70 30 75
Deg.c
04 TTI511A Lube oil temp at cooler O/L 45 40 50 30 55
Deg.c
05 TPT530 Control oil Pressure 14 12 10 17
Kg/Sq.cm
06 TTI804 ACW temp at I/L of oil 30 25 34 20 36
cooler Deg.c
07 TTI805 ACW temp at O/L of oil 35 27 39 25 42
cooler-1 Deg.c
08 TTI806 ACW temp at O/L of oil 35 27 39 25 42
cooler-2 Deg.c
09 TTI807 ACW temp at I/L of Gen 30 25 34 20 36
cooler Deg.c
10 TTI807A ACW temp at O/L of Gen 35 30 39 25 41
cooler-1 Deg.c
11 TTI807B ACW temp at O/L of Gen 35 30 39 25 41
cooler-1 Deg.c
12 TTI807C ACW temp at O/L of Gen 35 30 39 25 41
cooler-1 Deg.c
13 TTI807D ACW temp at O/L of Gen 35 30 39 25 41
cooler-1 Deg.c
14 TSE2011Turbine Seed rated rpm 4900 4700 533 4652 5632
8
Turbine Seed 16% rpm 816
Turbine Seed 95% rpm 4650
S.N Tag No Description of Tag Nor Lo Hi LL/Tri HH/Trip
15 TZE2011Axial shift mm 0 -0.45 0.45 -0.65 -
0.65/0.
65
16 TZE2012Axial shift mm 0 -0.45 0.45 -0.65 -
0.65/0.
65
48
17 TTI201 Turbine bearing 60 110 120/12
temperature 1 Deg.c 0
18 TTI202 Turbine bearing 60 110 120/12
temperature 2 Deg.c 0
19 TTI203 Turbine bearing 60 110 120/12
temperature 3 Deg.c 0
20 TTI204 Turbine bearing 60 110 120/12
temperature 4 Deg.c 0
21 TTI205 R/G pinion front bearing 100 120/12
temp-1 Deg.c 0
22 TTI206 R/G pinion rear bearing 100 120/12
temp-2 Deg.c 0
23 TTI207 R/G wheel front bearing 100 120/12
temp-3 Deg.c 0
24 TTI208 R/G wheel rear bearing 100 120/12
temp-4 Deg.c 0
25 TTI209 Generator front bearing 75 85/85
temp-1 Deg.c
26 TTI210 Generator rear bearing 75 85/85
temp-2 Deg.c
27 TVXT201Turbine front shaft vib, 45 90/90
Horizontal microns
28 TVYT201Turbine front shaft vibr, 45 90/90
Vertical microns
29 TVXT202Turbine rear shaft vibr, Hor 45 90/90
microns
30 TVYT202Turbine rear shaft vibr, 45 90/90
Vertical microns
31 TVXT203RG pinion front shaft vibr, 96 140/14
Hor microns 0
32 TVYT203RG pinion frt shaft vibr, 96 140/14
Vertical microns 0
33 TVXT204RG pinion rear shaft vibr, 96 140/14
Hor microns 0
34 TVYT204RG pinion rear shaft vibr, 96 140/14
Vert microns 0
35 TVXT205RG wheel front shaft vibr, 120 180/18
Hor microns 0
36 TVYT205RG wheel front shaft vibr, 120 180/18
Vert microns 0
49
37 TVXT206RG wheel rear shaft vibr, 120 180/18
Hori microns 0
38 TVYT206RG wheel rear shaft vibr, 120 180/18
Vert microns 0
39 TVXT207Generator front shaft vibr 100 160/16
hor microns 0
40 TVYT207Generator front shaft vibr 100 160/16
Vert microns 0
41 TVXT208Generator Rear shaft vibr 100 160/16
hor microns 0
42 TVYT208Generator Rear shaft vibr 100 160/16
vert microns 0
43 TTI254 Gen cold air temp 50
44 TTI255 Gen cold air temp 50
45 TTI256 Gen hot air temp 77
46 TTI251 Gen Winding temp-1 100 80 110 70 120
47 TTI252 Gen Winding temp-2 100 80 110 70 120
48 TTI253 Gen Winding temp-3 100 80 110 70 120
Currents / Winding
Temperatures
50
S.N Tag No Description of Tag Nor Lo Hi LL/Tri HH/Trip
16 OVEF motor current, Amp
17 GSCEF motor current Amp
18 TGM motor current Amp
19 TTI460A BFP-1 Winding 95 140 110
temperature-1 Deg.c
20 TTI460B BFP-2 Winding 95 140 110
temperature-1 Deg.c
21 TTI461A BFP-1 Winding 95 140 110
temperature-2 Deg.c
22 TTI461B BFP-2 Winding 95 140 110
temperature-2 Deg.c
23 TTI462A BFP-1 Winding 95 140 110
temperature-3 Deg.c
24 TTI462B BFP-2 Winding 95 140 110
temperature-3 Deg.c
25 TTI463A BFP-1 Winding 95 140 110
temperature-4 Deg.c
26 TTI463B BFP-2 Winding 95 140 110
temperature-4 Deg.c
27 TTI464A BFP-1 Winding 95 140 110
temperature-5 Deg.c
28 TTI464B BFP-2 Winding 95 140 110
temperature-5 Deg.c
29 TTI465A BFP-1 Winding 95 140 110
temperature-6 Deg.c
30 TTI465B BFP-2 Winding 95 140 110
temperature-6 Deg.c
51
COMMUNICATION
To avoid communication gap among all the power plant staff the following
stationary to be maintained in addition to the walke talkies and phanes.
1. Line Clearance form for safety.
2. complaint register to enter abnormalities.
3. Instructions register.
4. Log sheets for each field.
5. Log books for each field.
6. Running hours log book.
7. Coal & bagasse stock log book.
8. Coal & ash analysis log sheets.
9. Daily Generation & consumption log sheets & log books.
10. Water and steam analysis log sheets.
52
form. After ensuring the line /equipment isolated the shift in charge/engineer con give
Line Clearence to carryout the work to concerned maintenance department.
Before starting the work the maintenance person should ensure that the
field operator & shift in charge/ engineer signed on the L.C form and the
equipment is isolated.
After completion of the work the maintenance persons has to return the L.C.
The concerned operator should keep the equipment ready for operation. The
same is to be ensured by shift in charge/engineer.
If needed the trail run of the equipment/line to be carried out in presence of
shift in charge/engineer & maintenance person.
Instructions register:
If any special instructions in operations of any equipment/system the same is to
be entered in the Instruction register by the maintenance depart and the instruction
to be duly signed by the C.M(O&M). The instruction should contain the reasons
for the specialty and the valid period.
53
Each field operator and desk operator should enter the parameters
periodically in the log sheet. The log sheet should be duly signed by the shift in
charge in each shift.
54
The DM plant chemist should enter the periodical water and steam analysis in
the log sheets and the duly signed log sheets to be sent to shift in charge for reference
and recording.
55