TURBINE &

AUXILIARIES
COMMISSIONING/OPER
ATION
STEAM TURBINE(270 MW)
BY
SWAPNIL JAIN

COMMISSIONING
Project commissioning is the process of assuring that
all systems and components of a industrial plant are
designed, installed, tested, operated, and maintained
according to the operational requirements of the owner.
A commissioning process may be applied not only to
new projects but also to existing units and systems
subject to expansion, renovation.
In practice, the commissioning process comprises the
integrated application of a set of engineering
techniques and procedures to check, inspect and test
every operational component of the project, from
individual functions, such as instruments and
equipment, up to complex amalgamations such as
modules, subsystems and systems.

COMMISSIONING
Commissioning activities, in the broader sense,
are applicable to all phases of the project, from
the basic and detailed design, procurement,
construction and assembly, until the final
handover of the unit to the owner, including
sometimes an assisted operation phase.

TURBINE COMMISSIONING
1.
2.
3.
4.
5.
6.
7.
8.

DM MAKE UP SYSTEM
DMCW SYSTEM
TURBINE LUBE OIL SYSTEM
JACKING OIL SYSTEM
BFP LUBE OIL SYSTEM
CONDENSATE WATER SYSTEM
FEED WATER SYSTEM
SEAL OIL SYSTEM

TURBINE COMMISSIONING
9. GENERATOR GAS SYSTEM
10. CONDENSER FLOOD TEST
11. AIR EXTRACTION SYSTEM
12. LP BYPASS SYSTEM
13. HP BYPASS SYSTEM
14. SEAL STEAM OPERATION
15. TURBINE ROLLING OPERATION
16. EXTRACTION SYSTEM CHARGING

1. DM MAKE UP SYSTEM

CST

HOT WELL MAKE UP

PUMP

BOILER FILL
PUMP

1. EMERGENCY/
NORMAL MAKE
UP TO HOT
WELL
2. CEP SEALING
3. EMERGENCY
MAKE UP TO
DMCW O/H
TANK
4. VALVE GLAND
SEALING
1. DEARATOR
FILLING
2. BOILER FILLING

DM MAKE UP SYSTEM
1.
2.
3.
4.
5.

CST INSPECTION
WATER FLUSHING- WHY ?
LINE UP
INTERLOCK PROTECTION
TRIAL RUN- RECIRCULATION LINE

2. DM COOLING WATER SYSTEM

O/H
TANK

DMCW PUMP

PHE

RETURN
FROM
AUX.

SG BOOSTER
PUMP

TO BOILER SIDE
AUX. COOLING

1. TURBINE OIL
COOLER
2. BFP AIR MOTOR
COOLER,
WORKING OIL
COOLER, LUBE OIL
COOLER,
MECHANICAL
SEAL
3. CEP THRUST
BEARING COOLER
4. SEAL OIL COOLER
5. HYDROGEN
COOLER
6. EXCITER AIR
COOLER

DM COOLING WATER SYSTEM

1. SYSTEM INSPECTION- DRAIN, VENT
2. FLUSHING- LOOPS, PROBLEM, SUCTION
STRAINER
3. LINE UP
4. INTERLOCKS & PROTECTIONS
5. TRIAL RUN

3. TURBINE LUBE OIL SYSTEM

TURBINE LUBE OIL SYSTEM

1.CARD BOARD BURSTING
2. TURBINE LUBE OIL FLUSHING
3. HYDRAULIC TEST
3. INTERLOCKS & PROTECTIONS

4.JACKING OIL SYSTEM

1.
2.
3.
4.
5.
6.
7.

FLUSHING
TRIAL RUN
HYDRAULIC TEST
PRV OPERATION
ROTOR LIFTING
TURBINE BARRING GEAR
INTRLOCK & PROTECTIONS

5. BFP LUBE OIL SYSTEM

BFP LUBE OIL SYSTEM

1. ACID PICKLING
.RINSING WITH DM WATER
.5% HCL + 0.2 RODINE 213 SPECIAL + DM
WATER 4 HRS SOAKING
.5-6 TIMES RINSING WITH DM WATER
.2 % SODIUM NITRATE + 5% LIQUOR AMMONIA
+ DM WATER - 30 MINNUTES
. DRY THE TUBES
.OIL FILM

BFP LUBE OIL SYSTEM

2. LUBE OIL FLUSHING
AOP
HC
TANK

LUBE
OIL
COOLE
R

WORKIN
G OIL
COOLER

FILTER
BEARI
NG

PROBLEMS

6. CONDENSATE WATER SYSTEM

CONDENSATE WATER SYSTEM

CONDENSATE WATER SYSTEM

1.
2.
.
.
.

HOT WELL INSPECTION

CEP TRIAL RUN
LINE UP
INTERLOCKS & PROTECTIONS
PROBLEMS

CONDENSATE WATER SYSTEM

3. DETERGENT FLUSHING OF PRE BOILER SYSTEM
SCHEME
CLOSED CIRCUIT FLUSHING WITH COLD WATER
DRAINING USING SUSTITUTION
DETERGENT FLUSHING USING RINOPOL-JET 100 % (0.1 %
CONC.)
DRAINING
PASSIVATION USING HYDRAZINE & AMMONIA
DRAINING THE SYSTEM

7.FEED WATER SYSTEM

FEED WATER SYSTEM

1. BFP TRIAL RUN
. LINE UP
. INTERLOCK & PROTECTIONS
. TRIAL RUN

8. SEAL OIL SYSTEM

8. SEAL OIL SYSTEM

1.
2.
3.
4.
5.
6.

SEAL OIL FLUSHING

HYDRAULIC TEST
LINE UP
INTERLOCK & PROTECTIONS
TRIAL RUN
PROBLEMS

9. GENERATOR GAS SYSTEM

GENERATOR GAS SYSTEM

1.
2.
3.
4.

GENERATOR AIR TIGHTNESS TEST

AIR PURGING USING CO2
HYDROGEN FILLING
HYDROGEN DRIER

10. CONDENSER FLOOD TEST

1. FILL THE CONDENSER UPTO 14.5 M
2. CHECK LEAKAGES

11. AIR EXTRACTION SYSTEM

AIR EXTRACTION SYSTEM

1.
2.
3.
4.

FLUSHING
LINE UP
INTERLOCK & PROTECTIONS
TRIAL RUN

12. LP BYPASS SYSTEM

FA
N

CIRC
.
PUM
P

CF
PUMP

TANK

PR
V

VALVES

LP BYPASS SYSTEM
1. FLUSHING
2. INTERLOCK & PROTECTIONS
3. TRIAL RUN

13. HP BYPASS SYSTEM

1.
2.
3.
4.

FLUSHING
INTERLOCK & PROTECTION
TRIAL RUN
REHEATER PROTECTION

14. SEAL STEAM SYSTEM

SEAL STEAM SYSTEM

1. OPERATION
2. PROBLEMS

15. TURBINE ROLLING

1.
2.
3.
4.
5.
6.

TURBINE OIL SYSTEM

COOLING WATER SYSTEM
SEAL STEAM
BYPASS OPERATION
WARMING UP
ROLLING

16. EXTRACTION SYSTEM

1. LPH 1,2,3
. LINE UP
. FLUSHING
. INTERLOCK & PROTECTION

THANK YOU !